R320 3 PDF

SECTION 1 GENERAL
GROUP 1 SAFETY
FOLLOW SAFE PROCEDURE

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

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

Unexpected machine movement can cause serious
injury.
Before performing any work on the excavator, attach a
ųDo Not OperateŴtag on the right side control lever.
WARN
DO
NOT
OPERATE
USE HANDHOLDS AND STEPS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Keep sparks, lighted matches, and flame away from the
top of battery. Battery gas can explode.
Never check battery charge by placing a metal object
across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; It may explode. Warm
battery to 16Ş
C(60Ş F).
PREVENT ACID BURNS

Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, eat holes in clothing, and
cause blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling of dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the
acid.
3. Flush your eyes with water for 10-15 minutes. Get
medical attention immediately.
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.
1-7
USE TOOLS PROPERLY
Use tools appropriate to the work. Makeshift tools,
parts, and procedures can create safety hazards.
Use power tools only to loosen threaded tools and
fasteners.
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches.
Use only recommended replacement parts.(See Parts
catalogue.)
DISPOSE OF FLUIDS PROPERLY

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

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

Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.
1-8
GROUP 2 SPECIFICATION
1. MAJOR COMPONENTS
Battery box Fuel tank Oil cooler Radiator
Engine
Bucket Swing motor Hydraulic tank

Tooth Turning joint Main control valve Main pump
Arm Arm cylinder Boom Boom cylinder Cab Muffler Counterweight
Bucket cylinder Connecting link Track roller Carrier roller Travel motor
Side cutter Connecting rod Idler Track Sprocket
1-9
2. SPECIFICATIONS
1) ROBEX 320-3
I(I') D
C
E
G
F
H
J M
K N
A B(L)
Description Unit Specification
Operating weight kg(lb) 30150(66470)

Bucket capacity(PCSA heaped), standard m3(yd ) 1.44(1.89)
Overall length A 10860(35' 8")
Overall width, with 600mm shoe B 3280(10' 9")
Overall height C 3360(11' 0")
Superstructure width D 2920( 9' 7")
Overall height of cab E 3060(10' 0")
Ground clearance of counterweight F 1205(3' 11")
Engine cover height G 2530( 8' 4")
Minimum ground clearance H mm(ft-in) 505( 1' 8")
Rear-end distance I 3250(10' 8")
Rear-end swing radius I' 3250(10' 8")
Distance between tumblers J 3710(12' 2")
Undercarriage length K 4630(15' 2")
Undercarriage width L 3280(10' 9")
Track gauge M 2680(8' 10")
Track shoe width, standard N 600(24")
Travel speed(Low/high) km/hr(mph) 3.1/4.6(1.9/2.8)
Swing speed rpm 9.0
Gradeability Degree(%) 35(70)
Ground pressure(600mm shoe) kg/cm2(psi) 0.62(8.82)
2-2
2) ROBEX 320LC-3
I(I') D
C
E
G
F
H
J M
K N
A B(L)

Bucket capacity(PCSA heaped), standard m3(yd ) 1.44(1.89)
Overall width, with 600mm shoe B 3280(10' 9")
Ground clearance of counterweight F 1205( 3' 11")
Undercarriage width L 3280(10' 9")
Track gauge M 2680( 8' 10")
Swing speed rpm 9.0
Ground pressure(600mm shoe) kg/cm (psi)
2
0.60(8.53)
1-11
3) ROBEX 320NLC-3
I(I') D
C
E
G
F
H
J M
K N
A B(L)

Bucket capacity(PCSA heaped), standard m (yd )
3
1.44(1.89)
Overall width, with 600mm shoe B 2990( 9' 10")
Ground clearance of counterweight F 1205( 3' 11")
Undercarriage width L 2990( 9' 10")
Track gauge M 2390( 7' 10")
Swing speed rpm 9.0
Ground pressure(600mm shoe) kg/cm2(psi) 0.59(8.39)
1-12
3. WORKING RANGE
1) STANDARD BOOM (6.45m, 21' 2")
A
A'
F
D
B' E
C
B
8ft
Description 2.2m(7' 3") Arm 2.5m(8' 2")Arm(A) 2.5m(8' 2")Arm(B) 3.2m(10' 6") Arm 4.05m(13' 3") Arm
Max digging reach A 10340mm (33'11") 10570mm (34' 8") 10740mm (35' 3") 11140mm (36' 7") 11930mm (39' 2")
Max digging reach on ground A' 10130mm (33' 3") 10360mm (34' 0") 10540mm (34' 7") 10950mm (35'11") 11750mm (38' 7")
Max digging depth B 6500mm (21' 4") 6800mm (22' 4") 6870mm (22' 6") 7500mm (24' 7") 8350mm (27' 5")
Max digging depth (8ft level) B' 6300mm (20' 8") 6610mm (21' 8") 6700mm (22' 0") 7330mm (24' 1") 8210mm (26'11")
Max vertical wall digging depth C 5650mm (18' 6") 5950mm (19' 6") 5960mm (19' 7") 6360mm (20'10") 7280mm (23'11")
Max digging height D 10170mm (33' 4") 10170mm (33' 4") 10280mm (33' 9") 10210mm (33' 6") 10580mm (34' 9")
Max dumping height E 7010mm (23' 0") 7020mm (23' 0") 7090mm (23' 3") 7140mm (23' 5") 7490mm (24' 7")
Min swing radius F 4630mm (15' 2") 4550mm (14'11") 4560mm (15' 0") 4460mm (14' 8") 4380mm (14' 4")
174 [190] kN 174 [190] kN 155 [170] kN 174 [190] kN 174 [190] kN
Bucket digging force 17700 [19360] kgf 17700 [19360] kgf 15800 [17280] kgf 17700 [19360] kgf 17700 [19360] kgf
39020 [42680] lbf 39020 [42680] lbf 34830 [38100] lbf 39020 [42680] lbf 39020 [42680] lbf
177 [193] kN 157 [172] kN 156 [171] kN 129 [141] kN 111 [121] kN
Arm digging force 18000 [19690] kgf 16000 [17500] kgf 15900 [17390] kgf 13100 [14300] kgf 11300 [12360] kgf
39680 [43410] lbf 35270 [38580] lbf 35050 [38340] lbf 28880 [31590] lbf 24910 [27250] lbf
[ ] : Power boost
1-13
2) OPTION BOOM (6.15m, 20' 2")
A
A'
F
D
B' E
C
B
8ft
Description 2.2m(7' 3") Arm 2.5m(8' 2") Arm(A) 2.5m(8' 2") Arm(B)
Max digging reach A 10020mm (32'10") 10250mm (33' 8") 10430mm (34' 3")
Max digging reach on ground A' 9810mm (32' 2") 10040mm (32'11") 10220mm (33' 6")
Max digging depth B 6170mm (20' 3") 6470mm (21' 3") 6660mm (21'10")
Max digging depth (8ft level) B' 5970mm (19' 7") 6300mm (20' 8") 6480mm (21' 3")
Max vertical wall digging depth C 5480mm (18' 0") 5630mm (18' 6") 5900mm (19' 4")
Max digging height D 9860mm (32' 4") 9850mm (32' 4") 9960mm (32' 8")
Max dumping height E 6720mm (22' 1") 6930mm (22' 9") 6510mm (21' 4")
Min swing radius F 4420mm (14' 6") 4400mm (14' 5") 4340mm (14' 3")
174 [190] kN 174 [190] kN 155 [170] kN
Bucket digging force 17700 [19360] kgf 17700 [19360] kgf 15800 [17280] kgf
39020 [42680] lbf 39020 [42680] lbf 34830 [38100] lbf
177 [193] kN 157 [172] kN 156 [171] kN
Arm digging force 18000 [19690] kgf 16000 [17500] kgf 15900 [17390] kgf
39680 [43410] lbf 35270 [38580] lbf 35050 [38340] lbf
[ ] : Power boost
1-14
4. WEIGHT
1) R320-3, R320LC-3
R320-3 R320LC-3
Item
kg lb kg lb
Upperstructure assembly 12750 28110
Main frame weld assembly 2720 6000
Engine assembly 610 1340
Main pump assembly 190 420
Main control valve assembly 130 290
Swing motor assembly 320 710
Hydraulic oil tank assembly 280 620
Fuel tank assembly 160 350
Counterweight 5800 12790
Cab assembly 275 610
Lower chassis assembly 11110 24490 12160 26810
Track frame weld assembly 4050 8930 4570 10080
Swing bearing 410 900
Travel motor assembly 410 900
Turning joint 50 110
Track recoil spring and idler 315 690
Idler 205 450
Carrier roller 35 80
Track roller 50 110
Track-chain assembly (600mm standard triple grouser shoe) 1790 3950 1900 4190
Front attachment assembly (6.45m boom, 3.20m arm,
6290 13870
1.44m3 PCSA heaped bucket)
6.45m boom assembly 2935 6470
3.20m arm assembly 1710 3770
1.44m3 PCSA heaped bucket 1055 2330
Boom cylinder assembly 590 1300
Arm cylinder assembly 425 940
Bucket cylinder assembly 270 600
Bucket control link assembly 390 860
1-15
2) ROBEX 320NLC-3
R320NLC-3
Item
kg lb
Upperstructure assembly 12750 28110
Main frame weld assembly 2720 6000
Engine assembly 610 1340
Main pump assembly 190 420
Main control valve assembly 130 290
Swing motor assembly 320 710
Hydraulic oil tank assembly 280 620
Fuel tank assembly 160 350
Counterweight 5800 12790
Cab assembly 275 610
Lower chassis assembly 11960 26370
Track frame weld assembly 4400 9700
Swing bearing 410 900
Travel motor assembly 410 900
Turning joint 50 110
Track recoil spring and idler 315 700
Idler 205 450
Carrier roller 35 80
Track roller 50 110
Track-chain assembly (600mm standard triple grouser shoe) 1900 4190
Front attachment assembly (6.45m boom, 3.20m arm,
6290 13870
1.44m3 PCSA heaped bucket)
6.45m boom assembly 2935 6470
3.20m arm assembly 1710 3770
1.44m3 PCSA heaped bucket 1055 2330
Boom cylinder assembly 590 1300
Arm cylinder assembly 425 940
Bucket cylinder assembly 270 600
Bucket control link assembly 390 860
1-16
5. LIFTING CAPACITIES
1) ROBEX 320-3
(1) 6.15m(20' 2") boom, 2.2m(7' 3") arm equipped with 2.1m3(PCSA heaped) bucket and 600mm
(24") triple grouser shoe.
: Rating over-front : Rating over-side or 360 degree
Load radius At max. reach

Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach
height
m(ft)
7.5m kg *5230 4680 8.02
(25ft) lb *11530 10320 (26.3)
6.0m kg *6200 *6200 *5280 3720 8.91
(20ft) lb *13670 *13670 *11640 8200 (29.2)
4.5m kg *9040 *9040 *7100 *7100 *6210 4390 4920 3240 9.43
(15ft) lb *19930 *19930 *15650 *15650 *13690 10870 10850 7140 (30.9)
3.0m kg *11640 10630 *8280 6810 *6760 4700 4640 3010 9.65
(10ft) lb *25660 23440 *18250 15010 *14900 10360 10230 6640 (31.7)
1.5m kg *13440 9870 *9320 6400 6860 4490 4630 2990 9.58
(5ft) lb *29630 21760 *20550 14110 15120 9900 10210 6590 (31.4)
Ground kg *13940 9620 9560 6150 6700 4350 4900 3170 9.23
Line lb *30730 21210 21080 13560 14770 9590 10800 6990 (30.3)
-1.5m kg *15520 *15520 *13530 9630 9490 6090 6670 4320 5590 3650 8.56
(-5ft) lb *34220 *34220 *29830 21230 20920 13430 14700 9520 12320 8050 (28.1)
-3.0m kg *16880 *16880 *12260 9820 *9040 6190 *5750 4740 7.44
(-10ft) lb *37210 *37210 *27030 21650 *19930 13650 *12680 10450 (24.4)
-4.5m kg *9500 *9500
(-15ft) lb *20940 *20940
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- 17
(2) 6.15m(20' 2") boom, 2.5m(8' 2")-A arm equipped with 2.1m3(PCSA heaped) bucket and 600mm
height
m(ft)
7.5m kg *4960 4460 8.30
(25ft) lb *10930 9830 (27.2)
6.0m kg *5580 5180 *5040 3590 9.16
(20ft) lb *12300 11420 *11110 7910 (30.1)
4.5m kg *6770 *6770 *5960 5020 4760 3130 9.66
(15ft) lb *14930 *14930 *13140 11070 10490 6900 (31.7)
3.0m kg *11070 10900 *8000 6930 *6560 4780 4490 2910 9.87
(10ft) lb *24410 24030 *17640 15280 *14460 10540 9900 6420 (32.4)
1.5m kg *13110 10050 *9130 6490 6920 4550 4470 2880 9.81
(5ft) lb *28900 22160 *20130 14310 15260 10030 9850 6350 (32.2)
Ground kg *13920 9680 9620 6210 6740 4380 4710 3040 9.47
Line lb *30690 21340 21210 13690 14860 9660 10380 6700 (31.1)
-1.5m kg *15340 *15340 *13750 9630 9500 6100 6670 4320 5320 3470 8.81
(-5ft) lb *33820 *33820 *30310 21230 20940 13450 14700 9520 11730 7650 (28.9)
-3.0m kg *18010 *18010 *12720 9770 *9350 6160 *5850 4410 7.74
(-10ft) lb *39710 *39710 *28040 21540 *20610 13580 *12900 9720 (25.4)
-4.5m kg *14410 *14410 *10390 10140
(-15ft) lb *31770 *31770 *22910 22350
(3) 6.15m(20' 2") boom, 2.5m(8' 2")-B arm equipped with 2.1m3(PCSA heaped) bucket and 600mm

height
m(ft)
7.5m kg *4770 4320 8.42
(25ft) lb *10520 9520 (27.6)
6.0m kg *5490 5090 *4860 3460 9.29
(20ft) lb *12100 11220 *10710 7630 (30.5)
4.5m kg *6670 *6670 *5860 4930 4610 3010 9.79
(15ft) lb *14700 *14700 *12920 10870 10160 6640 (32.1)
3.0m kg *10960 10800 *7890 6840 *6460 4690 4340 2790 10.01
(10ft) lb *24160 23810 *17390 15080 *14240 10340 9570 6150 (32.8)
1.5m kg *12990 9930 *9020 6390 6830 4460 4320 2760 9.95
(5ft) lb *28640 21890 *19890 14090 15060 9830 9520 6080 (32.6)
Ground kg *13800 9570 9520 6110 6650 4290 4540 2910 9.61
Line lb *30420 21100 20990 13470 14660 9460 10010 6420 (31.5)
-1.5m kg *15640 *15640 *13630 9520 9400 6000 6580 4230 5130 3320 8.96
(-5ft) lb *34480 *34480 *30050 20990 20720 13230 14510 9330 11310 7320 (29.4)
-3.0m kg *17860 *17860 *12590 9660 *9240 6070 *5670 4230 7.89
(-10ft) lb *39370 *39370 *27760 21300 *20370 13380 *12500 9330 (25.9)
-4.5m kg *14250 *14250 *10260 10030
(-15ft) lb *31420 *31420 *22620 22110
1- 18

height
m(ft)
7.5m kg *5120 4330 8.42
(25ft) lb *11290 9550 (27.6)
6.0m kg *6180 *6180 *5740 5150 *5160 3510 9.27
(20ft) lb *13620 *13620 *12650 11350 *11380 7740 (30.4)
4.5m kg *9350 *9350 *7160 *7160 *6140 4970 4680 3080 9.76
(15ft) lb *20610 *20610 *15790 *15790 *13540 10960 10320 6790 (32.0)
3.0m kg *8350 6760 *6730 4730 4430 2880 9.97
(10ft) lb *18410 14900 *14840 10430 9770 6350 (32.7)
1.5m kg *9360 6340 6860 4500 4420 2860 9.91
(5ft) lb *20640 13980 15120 9920 9740 6310 (32.5)
Ground kg *13870 9510 9500 6110 6700 4350 4660 3020 9.57
Line lb *30580 20970 20940 13470 14770 9590 10270 6660 (31.4)
-1.5m kg *12840 *12840 *13400 9550 9440 6050 6660 4310 5250 3440 8.93
(-5ft) lb *28310 *28310 *29540 21050 20810 13340 14680 9500 11570 7580 (29.3)
-3.0m kg *16470 *16470 *12220 9740 *9160 6150 *5540 4350 7.88
(-10ft) lb *36310 *36310 *26940 21470 *20190 13560 *12210 9590 (25.9)
-4.5m kg *13130 *13130 *9880 *9880
(-15ft) lb *28950 *28950 *21780 *21780
Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) 9.0m(30ft) Capacity Reach
height
m(ft)
7.5m kg *4860 4130 8.70
(25ft) lb *10710 9110 (28.5)
6.0m kg *5480 5230 *4920 3370 9.52
(20ft) lb *12080 11530 *10850 7430 (31.2)
4.5m kg *8800 *8800 *6860 *6860 *5920 5030 4520 2970 10.00
(15ft) lb *19400 *19400 *15120 *15120 *13050 11090 9960 6550 (32.8)
3.0m kg *11440 10600 *8090 6840 *6550 4770 5240 3440 4280 2780 10.20
(10ft) lb *25220 23370 *17840 15080 *14440 10520 11550 7580 9440 6130 (33.5)
1.5m kg *13290 9790 *9170 6390 6890 4520 5120 3320 4260 2750 10.14
(5ft) lb *29300 21580 *20220 14090 15190 9960 11290 7320 9390 6060 (33.3)
Ground kg *13860 9510 9520 6120 6700 4350 4470 2880 9.81
Line lb *30560 20970 20990 13490 14770 9590 9850 6350 (32.2)
-1.5m kg *13340 *13340 *13570 9500 9420 6030 6630 4290 4990 3250 9.19
(-5ft) lb *29410 *29410 *29920 20940 20770 13290 14620 9460 11000 7170 (30.2)
-3.0m kg *17420 *17420 *12560 9660 *9350 6100 *5580 4040 8.18
(-10ft) lb *38400 *38400 *27690 21300 *20610 13450 *12300 8910 (26.8)
-4.5m kg *14260 *14260 *10500 10000 *7670 6370
(-15ft) lb *31440 *31440 *23150 22050 *16910 14040
1- 19
height
m(ft)
7.5m kg *4870 4080 8.76
(25ft) lb *10740 8990 (28.7)
6.0m kg *5430 5310 *4940 3360 9.55
(20ft) lb *11970 11710 *10890 7410 (31.3)
4.5m kg *8650 *8650 *6800 *6800 *5890 5110 4520 2970 10.01
(15ft) lb *19070 *19070 *14990 *14990 *12990 11270 9960 6550 (32.8)
3.0m kg *11280 10740 *8040 6930 *6530 4840 5300 3490 4290 2790 10.19
(10ft) lb *24870 23680 *17730 15280 *14400 10670 11680 7690 9460 6150 (33.4)
1.5m kg *13210 9880 *9150 6470 6950 4590 5170 3370 4290 2770 10.11
(5ft) lb *29120 21730 *20170 14260 15320 10120 11400 7430 9460 6110 (33.2)
Ground kg *13880 9560 9580 6180 6760 4410 4520 2920 9.77
Line lb *30600 21080 21120 13620 14900 9720 9960 6440 (32.1)
-1.5m kg *12780 *12780 *13670 9530 9460 6070 6680 4330 5070 3310 9.12
(-5ft) lb *28180 *28180 *30140 21010 20860 13380 14730 9550 11180 7300 (29.9)
-3.0m kg *17800 *17800 *12730 9680 *9470 6130 6750 4400 *5610 4150 8.07
(-10ft) lb *39240 *39240 *28060 21340 *20880 13510 14880 9700 *12370 9150 (26.5)
-4.5m kg *14730 *14730 *10780 10010 *9720 6380
(-15ft) lb *32470 *32470 *23770 22070 *17460 14070

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) 9.0m(30ft) Capacity Reach
height
m(ft)
7.5m kg *4660 *4660 *4280 3600 9.39
(25ft) lb *10270 *10270 *9440 7940 (30.8)
6.0m kg *4820 *4820 *4370 2990 10.14
(20ft) lb *10630 *10630 *9630 6590 (33.3)
4.5m kg *6050 *6050 *5330 5100 *4970 3590 4080 2650 10.59
(15ft) lb *13340 *13340 *11750 11240 *10960 7910 8990 5840 (34.7)
3.0m kg *10080 *10080 *7330 6960 *6020 4800 52580 3450 3860 2470 10.78
(10ft) lb *22220 *22220 *16160 15340 *13270 10580 11570 7610 8510 5450 (35.4)
1.5m kg *12340 9960 *8560 6440 *6710 4510 5090 3290 3830 2430 10.72
(5ft) lb *27210 21960 *18870 14200 *14790 9940 11220 7250 8440 5360 (35.2)
Ground kg *9160 *9160 *13480 9460 *9430 6080 6650 4290 4960 3170 3980 2520 10.42
Line lb *20190 *20190 *29720 20860 *20790 13400 14660 9460 10930 6990 8770 5560 (34.2)
-1.5m kg *10240 *10240 *13050 *13050 *13650 9310 9290 5910 6520 4170 4380 2800 9.84
(-5ft) lb *22580 *22580 *28770 *28770 *30090 20530 20480 13030 14370 9190 9660 6170 (32.3)
-3.0m kg *13900 *13900 *17650 *17650 *13040 9380 9280 5900 6520 4180 5200 3370 8.92
(-10ft) lb *30640 *30640 *38910 *38910 *28750 20680 20460 13010 14370 9220 11460 7430 (29.3)
-4.5m kg *16370 *16370 *11530 9630 *8490 6060 *5220 4650 7.50
(-15ft) lb *36090 *36090 *25420 21230 *18720 13360 *11510 10250 (24.6)
-6.0m kg *8370 *8370
(-20ft) lb *18450 *18450
1- 20

height
m(ft)
7.5m kg *3680 2980 10.31
(25ft) lb *8110 6570 (33.8)
6.0m kg *4020 3790 *3790 2510 10.99
(20ft) lb *8860 8360 *8360 5530 (36.1)
4.5m kg *4540 *4540 *4290 3660 3530 2230 11.40
(15ft) lb *10010 *10010 *9460 8070 7780 4920 (37.4)
3.0m kg *13520 *13520 *8310 *8310 *6310 *6310 *5290 4890 *4710 3470 3350 2080 11.57
(10ft) lb *29810 *29810 *18320 *18320 *13910 *13910 *11660 10780 *10380 7650 7390 4590 (38.0)
1.5m kg *19530 *9530 *10940 10360 *7710 6590 *6100 4560 5080 3280 3310 2040 11.52
(5ft) lb *21010 *21010 *24120 22840 *17000 14530 *13450 10050 11200 7230 7300 4500 (37.8)
Ground kg *9770 *9770 *12700 9580 *8820 6120 6640 4280 4910 3120 3420 2100 11.24
Line lb *21540 *21540 *28000 21120 *19440 13490 14640 9440 10820 6880 7540 4630 (36.9)
-1.5m kg *8850 *8850 *12110 *12110 *13460 9230 9240 5840 6440 4090 4790 3010 3700 2300 10.71
(-5ft) lb *19510 *19510 *26700 *26700 *29670 20350 20370 12870 14200 9020 10560 6640 8160 5070 (35.1)
-3.0m kg *11770 *11770 *15400 *15400 *13370 9160 9120 5740 6360 4020 4780 2990 4270 2700 9.89
(-10ft) lb *25950 *25950 *33950 *33950 *29480 20190 20110 12650 14020 8860 10540 6590 9410 5950 (32.4)
-4.5m kg *15150 *15150 *18510 *18510 *12450 9300 *9070 5800 6430 4080 *4940 3500 8.67
(-15ft) lb *33400 *33400 *40810 *40810 *27450 20500 *20000 12790 14180 8990 *10890 7720 (28.4)
-6.0m kg *15020 *15020 *10380 9650 *7470 6060
(-20ft) lb *33110 *33110 *22880 21270 *16470 13360
1- 21
2) ROBEX 320LC-3

height
m(ft)
7.5m kg *5230 5020 8.02
(25ft) lb *11530 11070 (26.3)
6.0m kg *6200 *6200 *5280 4020 8.91
(20ft) lb *13670 *13670 *11640 8860 (29.2)
4.5m kg *9040 *9040 *7100 *7100 *6210 5300 *5390 3510 9.43
(15ft) lb *19930 *19930 *15650 *15650 *13690 11680 *11880 7740 (30.9)
3.0m kg *11640 11430 *8280 7320 *6760 5070 5410 3270 9.65
(10ft) lb *25660 25200 *18250 16140 *14900 11180 11930 7210 (31.7)
1.5m kg *13440 10670 *9320 6900 *7310 4860 5410 3250 9.58
(5ft) lb *29630 23520 *20550 15210 *16120 10710 11930 7170 (31.4)
Ground kg *13940 10410 *9910 6650 *7640 4710 5720 3450 9.23
Line lb *30730 22950 *21850 14660 *16840 10380 12610 7610 (30.3)
-1.5m kg *15520 *15520 *13530 10420 *9890 6590 *7510 4680 *5960 3960 8.56
(-5ft) lb *34220 *34220 *29830 22970 *21800 14530 *16560 10320 *13140 8730 (28.1)
-3.0m kg *16880 *16880 *12260 10610 *9040 6700 *5750 5110 7.44
(-10ft) lb *37210 *37210 *27030 23390 *19930 14770 *12680 11270 (24.4)
-4.5m kg *9500 *9500
(-15ft) lb *20940 *20940
1- 22

height
m(ft)
7.5m kg *4960 4790 8.30
(25ft) lb *10930 10560 (27.2)
6.0m kg *5580 5550 *5040 3870 9.16
(20ft) lb *12300 12240 *11110 8530 (30.1)
4.5m kg *6770 *6770 *5960 5390 *5180 3390 9.66
(15ft) lb *14930 *14930 *13140 11880 *11420 7470 (31.7)
3.0m kg *11070 *11070 *8000 7440 *6560 5150 5240 3170 9.87
(10ft) lb *24410 *24410 *17640 16400 *14460 11350 11550 6990 (32.4)
1.5m kg *13110 10840 *9130 6990 *7180 4910 5220 3140 9.81
(5ft) lb *28900 23900 *20130 15410 *15830 10820 11510 6920 (32.2)
Ground kg *13920 10480 *9840 6710 *7590 4750 5500 3310 9.47
Line lb *30690 23100 *21690 14790 *16730 10470 12130 7300 (31.1)
-1.5m kg *15340 *15340 *13750 10420 *9970 6600 *7610 4680 *5900 3760 8.81
(-5ft) lb *33820 *33820 *30310 22970 *21980 14550 *16780 10320 *13010 8290 (28.9)
-3.0m kg *18010 *18010 *12720 10570 *9350 6670 *5850 4760 7.74
(-10ft) lb *39710 *39710 *28040 23300 *20610 14700 *12900 10490 (25.4)
-4.5m kg *14410 *14410 *10390 *10390
(-15ft) lb *31770 *31770 *22910 *22910

height
m(ft)
7.5m kg *4770 4640 8.42
(25ft) lb *10520 10230 (27.6)
6.0m kg *5490 5460 *4860 3740 9.29
(20ft) lb *12100 12040 *10710 8250 (30.5)
4.5m kg *6670 *6670 *5860 5300 *5000 3270 9.79
(15ft) lb *14700 *14700 *12920 11680 *11020 7210 (32.1)
3.0m kg *10960 *10960 *7890 7350 *6460 5060 5080 3040 10.01
(10ft) lb *24160 *24160 *17390 16200 *14240 11160 11200 6700 (32.8)
1.5m kg *12990 10730 *9020 6900 *7070 4820 5050 3010 9.95
(5ft) lb *28640 23660 *19890 15210 *15590 10630 11130 6640 (32.6)
Ground kg *13800 10360 *9730 6610 *7490 4650 5320 3170 9.61
Line lb *30420 22840 *21450 14570 *16510 10250 11730 6990 (31.5)
-1.5m kg *15640 *15640 *13630 10310 *9850 6500 *7510 4590 *5720 3610 8.96
(-5ft) lb *34480 *34480 *30050 22730 *21720 14330 *16560 10120 *12610 7960 (29.4)
-3.0m kg *17860 *17860 *12590 10460 *9240 6570 *5670 4570 7.89
(-10ft) lb *39370 *39370 *27760 23060 *20370 14480 *12500 10080 (25.9)
-4.5m kg *14250 *14250 *10260 *10260
(-15ft) lb *31420 *31420 *22620 *22620
1- 23

height
m(ft)
7.5m kg *5120 4650 8.42
(25ft) lb *11290 10250 (27.6)
6.0m kg *6180 *6180 *5740 5520 *5160 3790 9.27
(20ft) lb *13620 *13620 *12650 12170 *11380 8360 (30.4)
4.5m kg *9350 *9350 *7160 *7160 *6140 5340 *5250 3340 9.76
(15ft) lb *20610 *20610 *15790 *15790 *13540 11770 *11570 7360 (32.0)
3.0m kg *8350 7270 *6730 5090 5170 3130 9.97
(10ft) lb *18410 16030 *14840 11220 11400 6900 (32.7)
1.5m kg *9360 6850 *7290 4860 5160 3110 9.91
(5ft) lb *20640 15100 *16070 10710 11380 6860 (32.5)
Ground kg *13870 10300 *9910 6610 *7630 4710 5440 3280 9.57
Line lb *30580 22710 *21850 14570 *16820 10380 11990 7230 (31.4)
-1.5m kg *12840 *12840 *13400 10340 *9880 6550 *7580 4670 *5720 3730 8.93
(-5ft) lb *28310 *28310 *29540 22800 *21780 14440 *16710 10300 *12610 8220 (29.3)
-3.0m kg *16470 *16470 *12220 10540 *9160 6650 *5540 4690 7.88
(-10ft) lb *36310 *36310 *26940 23240 *20190 14660 *12210 10340 (25.9)
-4.5m kg *13130 *13130 *9880 *9880
(-15ft) lb *28950 *28950 *21780 *21780
height
m(ft)
7.5m kg *4880 4440 8.70
(25ft) lb *10760 9790 (28.5)
6.0m kg *5500 *5500 *4940 3660 9.52
(20ft) lb *12130 *12130 *10890 8070 (31.2)
4.5m kg *8830 *8830 *6880 *6880 *5940 5420 *5050 3230 10.00
(15ft) lb *19470 *19470 *15170 *15170 *13100 11950 *11130 7120 (32.8)
3.0m kg *11470 11430 *8110 7370 *6570 5160 *5770 3740 5010 3030 10.20
(10ft) lb *25290 25200 *17880 16250 *14480 11380 *12720 8250 11050 6680 (33.5)
1.5m kg *13330 10610 *9200 6920 *7180 4910 5990 3630 4990 3010 10.14
(5ft) lb *29390 23390 *20280 15260 *15830 10820 13210 8000 11000 6640 (33.3)
Ground kg *13890 10330 *9850 6650 *7590 4740 5230 3160 9.81
Line lb *30620 22770 *21720 14660 *16730 10450 11530 6970 (32.2)
-1.5m kg *13330 *13330 *13610 10320 *9940 6550 *7640 4670 *5650 3550 9.19
(-5ft) lb *29390 *29390 *30000 22750 *21910 14440 *16840 10300 *12460 7830 (30.2)
-3.0m kg *17470 *17470 *12600 10480 *9380 6620 *5600 4380 8.18
(-10ft) lb *38510 *38510 *27780 23100 *20680 14590 *12350 9660 (26.8)
-4.5m kg *14300 *14300 *10530 *10530 *7690 6890
(-15ft) lb *31530 *31530 *23210 *23210 *16950 15190
1- 24
height
m(ft)
7.5m kg *4860 4450 8.69
(25ft) lb *10710 9810 (28.5)
6.0m kg *5480 *5480 *4920 3650 9.51
(20ft) lb *12080 *12080 *10850 8050 (31.2)
4.5m kg *8800 *8800 *6860 *6860 *5920 5400 *5040 3230 9.99
(15ft) lb *19400 *19400 *15120 *15120 *13050 11900 *11110 7120 (32.8)
3.0m kg *11440 11400 *8090 7350 *6550 5140 5000 3030 10.19
(10ft) lb *25220 25130 *17840 16200 *14440 11330 11020 6680 (33.4)
1.5m kg *13290 10580 *9170 6900 *7160 4890 5970 3610 4990 3000 10.13
(5ft) lb *29300 23320 *20220 15210 *15790 10780 13160 7960 11000 6610 (33.2)
Ground kg *13860 10300 *9820 6620 *7570 4720 5230 3150 9.80
Line lb *30560 22710 *21650 14590 *16690 10410 11530 6940 (32.2)
-1.5m kg *13370 *13370 *13570 10290 *9910 6530 *7620 4650 *5650 3540 9.18
(-5ft) lb *29480 *29480 *29920 22690 *21850 14400 *16800 10250 *12460 7800 (30.1)
-3.0m kg *17420 *17420 *12560 10450 *9350 6600 *5610 4380 8.16
(-10ft) lb *38400 *38400 *27690 23040 *20610 14550 *12370 9660 (26.8)
-4.5m kg *14250 *14250 *10500 *10500 *7670 6870
(-15ft) lb *31420 *31420 *23150 *23150 *16910 15150

height
m(ft)
7.5m kg *4660 *4660 *4280 3880 9.39
(25ft) lb *10270 *10270 *9440 8550 (30.8)
6.0m kg *4820 *4820 *4370 3240 10.14
(20ft) lb *10630 *10630 *9630 7140 (33.3)
4.5m kg *6050 *6050 *5330 *5330 *4970 3880 *4510 2880 10.59
(15ft) lb *13340 *13340 *11750 *11750 *10960 8550 *9940 6350 (34.7)
3.0m kg *10080 *10080 *7330 *7330 *6020 5170 *5300 3730 4520 2700 10.78
(10ft) lb *22220 *22220 *16160 *16160 *13270 11400 *11680 8220 9960 5950 (35.4)
1.5m kg *12340 9960 *8560 6940 *6710 4880 *5670 3580 4490 2660 10.72
(5ft) lb *27210 21960 *18870 15300 *14790 10760 *12500 7890 9900 5860 (35.2)
Ground kg *9160 *9160 *13480 10250 *9430 6580 *7260 4660 5810 3460 4670 2760 10.42
Line lb *20190 *20190 *29720 22600 *20790 14510 *16010 10270 12810 7630 10300 6080 (34.2)
-1.5m kg *10240 *10240 *13050 *13050 *13650 10100 *9780 6410 *7500 4540 5130 3050 9.84
(-5ft) lb *22580 *22580 *28770 *28770 *30090 22270 *21560 14130 *16530 10010 11310 6720 (32.3)
-3.0m kg *13900 *13900 *17650 *17650 *13040 10170 *9550 6400 *7280 4540 *5360 3660 8.92
(-10ft) lb *30640 *30640 *38910 *38910 *28750 22420 *21050 14110 *16050 10010 *11820 8070 (29.3)
-4.5m kg *16370 *16370 *11530 10430 *8490 6560 *5220 5020 7.50
(-15ft) lb *36090 *36090 *25420 22990 *18720 14460 *11510 11070 (24.6)
-6.0m kg *8370 *8370
(-20ft) lb *18450 *18450
1- 25

height
m(ft)
7.5m kg *3680 3220 10.31
(25ft) lb *8110 7100 (33.8)
6.0m kg *4020 *4020 *3790 2740 10.99
(20ft) lb *8860 *8860 *8360 6040 (36.1)
4.5m kg *4540 *4540 *4290 3950 *3920 2450 11.40
(15ft) lb *10010 *10010 *9460 8710 *8640 5400 (37.4)
3.0m kg *13520 *13520 *8310 *8310 *6310 *6310 *5290 5260 *4710 3760 3950 2290 11.57
(10ft) lb *29810 *29810 *18320 *18320 *13910 *13910 *11660 11600 *10380 8290 8710 5050 (38.0)
1.5m kg *19530 *9530 *10940 *10940 *7710 7090 *6100 4920 *5180 3570 3920 2250 11.52
(5ft) lb *21010 *21010 *24120 *24120 *17000 15630 *13450 10850 *11420 7870 8640 4960 (37.8)
Ground kg *9770 *9770 *12700 10370 *8820 6620 *6790 4640 *5590 3400 4040 2320 11.24
Line lb *21540 *21540 *28000 22860 *19440 14590 *14970 10230 *12320 7500 8910 5110 (36.9)
-1.5m kg *8850 *8850 *12110 *12110 *13460 10020 *9480 6340 *7240 4460 5650 3290 4370 2530 10.71
(-5ft) lb *19510 *19510 *26700 *26700 *29670 22090 *20900 13980 *15960 9830 12460 7250 9630 5580 (35.1)
-3.0m kg *11770 *11770 *15400 *15400 *13370 9950 *9600 6240 *7320 4380 5630 3280 *4850 2950 9.89
(-10ft) lb *25950 *25950 *33950 *33950 *29480 21940 *21160 13760 *16140 9660 12410 7230 *10690 6500 (32.4)
-4.5m kg *15150 *15150 *18510 *18510 *12450 10090 *9070 6300 *6820 4440 *4940 3800 8.67
(-15ft) lb *33400 *33400 *40810 *40810 *27450 22240 *20000 13890 *15040 9790 *10890 8380 (28.4)
-6.0m kg *15020 *15020 *10380 *10380 *7470 6560
(-20ft) lb *33110 *33110 *22880 *22880 *16470 14460
1- 26
3) ROBEX 320NLC-3

height
m(ft)
7.5m kg *5230 4380 8.02
(25ft) lb *11530 9660 (26.3)
6.0m kg *6200 *6200 *5280 3470 8.91
(20ft) lb *13670 *13670 *11640 7650 (29.2)
4.5m kg *9040 *9040 *7100 6800 *6210 4590 *5390 3000 9.43
(15ft) lb *19930 *19930 *15650 14990 *13690 10120 *11880 6610 (30.9)
3.0m kg *11640 9800 *8280 6330 *6760 4380 5370 2790 9.65
(10ft) lb *25660 21610 *18250 13960 *14900 9660 11840 6150 (31.7)
1.5m kg *13440 9070 *9320 5920 *7310 4160 5360 2760 9.58
(5ft) lb *29630 20000 *20550 13050 *16120 9170 11820 6080 (31.4)
Ground kg *13940 8820 *9910 5690 *7640 4020 5680 2930 9.23
Line lb *30730 19440 *21850 12540 *16840 8860 12520 6460 (30.3)
-1.5m kg *15520 *15520 *13530 8830 *9890 5620 *7510 4000 *5960 3390 8.56
(-5ft) lb *34220 *34220 *29830 19470 *21800 12390 *16560 8820 *13140 7470 (28.1)
-3.0m kg *16880 *16880 *12260 9010 *9040 5730 *5750 4410 7.44
(-10ft) lb *37210 *37210 *27030 19860 *19930 12630 *12680 9720 (24.4)
-4.5m kg *9500 9430
(-15ft) lb *20940 20790
1- 27

height
m(ft)
7.5m kg *4960 4180 8.30
(25ft) lb *10930 9220 (27.2)
6.0m kg *5580 4840 *5040 3340 9.16
(20ft) lb *12300 10670 *11110 7360 (30.1)
4.5m kg *6770 *6770 *5960 4680 *5180 2910 9.66
(15ft) lb *14930 *14930 *13140 10320 *11420 6420 (31.7)
3.0m kg *11070 10060 *8000 6450 *6560 4450 5200 2700 9.87
(10ft) lb *24410 22180 *17640 14220 *14460 9810 11460 5950 (32.4)
1.5m kg *13110 9230 *9130 6020 *7180 4220 5180 2670 9.81
(5ft) lb *28900 20350 *20130 13270 *15830 9300 11420 5890 (32.2)
Ground kg *13920 8880 *9840 5740 *7590 4060 5460 2810 9.47
Line lb *30690 19580 *21690 12650 *16730 8950 12040 6190 (31.1)
-1.5m kg *15340 *15340 *13750 8830 *9970 5640 *7610 4000 *5900 3210 8.81
(-5ft) lb *33820 *33820 *30310 19470 *21980 12430 *16780 8820 *13010 7080 (28.9)
-3.0m kg *18010 *18010 *12720 8970 *9350 5700 *5850 4100 7.74
(-10ft) lb *39710 *39710 *28040 19780 *20610 12570 *12900 9040 (25.4)
-4.5m kg *14410 *14410 *10390 9320
(-15ft) lb *31770 *31770 *22910 20550

height
m(ft)
7.5m kg *4770 4040 8.42
(25ft) lb *10520 8910 (27.6)
6.0m kg *5490 4760 *4860 3220 9.29
(20ft) lb *12100 10490 *10710 7100 (30.5)
4.5m kg *6670 *6670 *5860 4600 *5000 2790 9.79
(15ft) lb *14700 *14700 *12920 10140 *11020 6150 (32.1)
3.0m kg *10960 9960 *7890 6360 *6460 4360 5030 2580 10.01
(10ft) lb *24160 21960 *17390 14020 *14240 9610 11090 5690 (32.8)
1.5m kg *12990 9120 *9020 5920 *7070 4130 5010 2540 9.95
(5ft) lb *23640 20110 *19890 13050 *15590 9110 11050 5600 (32.6)
Ground kg *13800 8770 *9730 5640 *7490 3970 5280 2680 9.61
Line lb *30420 19330 *21450 12430 *16510 8750 11640 5910 (31.5)
-1.5m kg *15640 *15640 *13630 8720 *9850 5540 *7510 3910 *5720 3070 8.96
(-5ft) lb *34480 *34480 *30050 19220 *21720 12210 *16560 8620 *12610 6770 (29.4)
-3.0m kg *17860 *17860 *12590 8860 *9240 5600 *5670 3920 7.89
(-10ft) lb *39370 *39370 *27760 19530 *20370 12350 *12500 8640 (25.9)
-4.5m kg *14250 *14250 *10260 9220
(-15ft) lb *31420 *31420 *22620 20330
1- 28

height
m(ft)
7.5m kg *5120 4050 8.42
(25ft) lb *11290 8930 (27.6)
6.0m kg *6180 *6180 *5740 4820 *5160 3270 9.27
(20ft) lb *13620 *13620 *12650 10630 *11380 7210 (30.4)
4.5m kg *9350 *9350 *7160 6790 *6140 4640 *5250 2860 9.76
(15ft) lb *20610 *20610 *15790 14970 *13540 10230 *11570 6310 (32.0)
3.0m kg *8350 6280 *6730 4400 5130 2670 9.97
(10ft) lb *18410 13850 *14840 9700 11310 5890 (32.7)
1.5m kg *9360 5880 *7290 4170 5120 2640 9.91
(5ft) lb *20640 12960 *16070 9190 11290 5820 (32.5)
Ground kg *13870 8720 *9910 5650 *7630 4030 5400 2790 9.57
Line lb *30580 19220 *21850 12460 *16820 8880 11900 6150 (31.4)
-1.5m kg *12840 *12840 *13400 8760 *9880 5590 *7580 3990 *5720 3190 8.93
(-5ft) lb *28310 *28310 *29540 19310 *21780 12320 *16710 8800 *12610 7030 (29.3)
-3.0m kg *16470 *16470 *12220 8950 *9160 5690 *5540 4040 7.88
(-10ft) lb *36310 *36310 *26940 19730 *20190 12540 *12210 8910 (25.9)
-4.5m kg *13130 *13130 *9880 9320
(-15ft) lb *28950 *28950 *21780 20550
height
m(ft)
7.5m kg *4880 3870 8.70
(25ft) lb *10760 8530 (28.5)
6.0m kg *5500 4910 *4940 3160 9.52
(20ft) lb *12130 10820 *10890 6970 (31.2)
4.5m kg *8830 *8830 *6880 *6880 *5940 4720 *5050 2770 10.00
(15ft) lb *19470 *19470 *15170 *15170 *13100 10410 *11130 6110 (32.8)
3.0m kg *11470 9800 *8110 6380 *6570 4460 *5770 3210 4970 2580 10.20
(10ft) lb *25290 21610 *17880 14070 *14480 9830 *12720 7080 10960 5690 (33.5)
1.5m kg *13330 9020 *9200 5950 *7180 4220 5940 3100 4950 2550 10.14
(5ft) lb *29390 19890 *20280 13120 *15830 9300 13100 6830 10910 5620 (33.3)
Ground kg *13890 8750 *9850 5680 *7590 4050 5190 2680 9.81
Line lb *30620 19290 *21720 12520 *16730 8930 11440 5910 (32.2)
-1.5m kg *13330 *13330 *13610 8740 *9940 5590 *7640 3990 *5650 3030 9.19
(-5ft) lb *29390 *29390 *30000 19270 *21910 12320 *16840 8800 *12460 6680 (30.2)
-3.0m kg *17470 *17470 *12600 8890 *9380 5660 *5600 3770 8.18
(-10ft) lb *38510 *38510 *27780 19600 *20680 12480 *12350 8310 (26.8)
-4.5m kg *14300 *14300 *10530 9220 *7690 5920
(-15ft) lb *31530 *31530 *23210 20330 *16950 13050
1- 29
height
m(ft)
7.5m kg *4860 3880 8.69
(25ft) lb *10710 8550 (28.5)
6.0m kg *5480 4900 *4920 3150 9.51
(20ft) lb *12080 10800 *10850 6940 (31.2)
4.5m kg *8800 *8800 *6860 *6860 *5920 4700 *5040 2770 9.99
(15ft) lb *19400 *19400 *15120 *15120 *13050 10360 *11110 6110 (32.8)
3.0m kg *11440 9770 *8090 6360 *6550 4440 4960 2580 10.19
(10ft) lb *25220 21540 *17840 14020 *14440 9790 10930 5690 (33.4)
1.5m kg *13290 8990 *9170 5920 *7160 4200 5920 3080 4950 2540 10.13
(5ft) lb *29300 19820 *20220 13050 *15790 9260 13050 6790 10910 5600 (33.2)
Ground kg *13860 8720 *9820 5660 *7570 4030 5190 2670 9.80
Line lb *30560 19220 *21650 12480 *16690 8880 11440 5890 (32.2)
-1.5m kg *13370 *13370 *13570 8710 *9910 5570 *7620 3970 *5650 3020 9.18
(-5ft) lb *29480 *29480 *29920 19200 *21850 12280 *16800 8750 *12460 6660 (30.1)
-3.0m kg *17420 *17420 *12560 8860 *9350 5630 *5610 3770 8.16
(-10ft) lb *38400 *38400 *27690 19530 *20610 12410 *12370 8310 (26.8)
-4.5m kg *14250 *14250 *10500 9200 *7670 5900
(-15ft) lb *31420 *31420 *23150 20280 *16910 13010

height
m(ft)
7.5m kg *4660 *4660 *4280 3370 9.39
(25ft) lb *10270 *10270 *9440 7430 (30.8)
6.0m kg *4820 *4820 *4370 2780 10.14
(20ft) lb *10630 *10630 *9630 6130 (33.3)
4.5m kg *6050 *6050 *5330 4770 *4970 3340 *4510 2450 10.59
(15ft) lb *13340 *13340 *11750 10520 *10960 7360 *9940 5400 (34.7)
3.0m kg *10080 *10080 *7330 6470 *6020 4470 *5300 3200 4490 2280 10.78
(10ft) lb *22220 *22220 *16160 14260 *13270 9850 *11680 7050 9900 5030 (35.4)
1.5m kg *12340 9150 *8560 5960 *6710 4190 *5670 3050 4460 2240 10.72
(5ft) lb *27210 20170 *18870 13140 *14790 9240 *12500 6720 9830 4940 (35.2)
Ground kg *9160 *9160 *13480 8670 *9430 5610 *7260 3970 5770 2930 4630 2320 10.42
Line lb *20190 *20190 *29720 19110 *20790 12370 *16010 8750 12720 6460 10210 5110 (34.2)
-1.5m kg *10240 *10240 *13050 *13050 *13650 8520 *9780 5450 *7500 3850 5090 2580 9.84
(-5ft) lb *22580 *22580 *28770 *28770 *30090 18780 *21560 12020 *16530 8490 11220 5690 (32.3)
-3.0m kg *13900 *13900 *17650 17600 *13040 8590 *9550 5440 *7280 3860 *5360 3120 8.92
(-10ft) lb *30640 *30640 *38910 38800 *28750 18940 *21050 11990 *16050 8510 *11820 6880 (29.3)
-4.5m kg *16370 *16370 *11530 8830 *8490 5600 *5220 4320 7.50
(-15ft) lb *36090 *36090 *25420 19470 *18720 12350 *11510 9520 (24.6)
-6.0m kg *8370 *8370
(-20ft) lb *18450 *18450
1- 30

height
m(ft)
7.5m kg *3680 2770 10.31
(25ft) lb *8110 6110 (33.8)
6.0m kg *4020 3530 *3790 2320 10.99
(20ft) lb *8860 7780 *8360 5110 (36.1)
4.5m kg *4540 *4540 *4290 3400 *3920 2050 11.40
(15ft) lb *10010 *10010 *9460 7500 *8640 4520 (37.4)
3.0m kg *13520 *13520 *8310 *8310 *6310 *6310 *5290 4560 *4710 3220 3920 1910 11.57
(10ft) lb *29810 *29810 *18320 *18320 *13910 *13910 *11660 10050 *10380 7100 8640 4210 (38.0)
1.5m kg *19530 *9530 *10940 9530 *7710 6110 *6100 4230 *5180 3030 3880 1870 11.52
(5ft) lb *21010 *21010 *24120 21010 *17000 13470 *13450 9330 *11420 6680 8550 4120 (37.8)
Ground kg *9770 *9770 *12700 8780 *8820 5650 *6790 3950 *5590 2870 4010 1920 11.24
Line lb *21540 *21540 *28000 19360 *19440 12460 *14970 8710 *12320 6330 8840 4230 (36.9)
-1.5m kg *8850 *8850 *12110 *12110 *13460 8440 *9480 5380 *7240 3770 5600 2760 4330 2110 10.71
(-5ft) lb *19510 *19510 *26700 *26700 *29670 18610 *20900 11860 *15960 8310 12350 6080 9550 4650 (35.1)
-3.0m kg *11770 *11770 *15400 *15400 *13370 8370 *9600 5280 *7320 3700 5580 2750 *4850 2480 9.89
(-10ft) lb *25950 *25950 *33950 *33950 *29480 18450 *21160 11640 *16140 8160 12300 6060 *10690 5470 (32.4)
-4.5m kg *15150 *15150 *18510 17460 *12450 8500 *9070 5340 *6820 3760 *4940 3240 8.67
(-15ft) lb *33400 *33400 *40810 38490 *27450 18740 *20000 11770 *15040 8290 *10890 7140 (28.4)
-6.0m kg *15020 *15020 *10380 8850 *7470 5590
(-20ft) lb *33110 *33110 *22880 19510 *16470 12320
1- 31
6. BUCKET SELECTION GUIDE
1) GUIDE 1
0.90m3 PCSA 1.14m3 PCSA 1.38m3 PCSA 1.44m3 PCSA 1.74m3 PCSA
heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket
Recommendation
Capacity Width
6.45m(21' 2") boom 6.15m(20' 2") boom
Weight
PCSA CECE Without With 2.2m arm 2.5m arm 3.2m arm 4.05m arm 2.2m arm 2.5m arm
heaped heaped side cutter side cutter (7' 3") (8' 2") (10' 6") (13' 3") (6' 7") (7' 10")
0.90m3 0.80m3 950mm 1070mm 835kg

(1.18yd3) (1.05yd3) (37.4") (42.1") (1840lb)
1.14m3 1.00m3 1140mm 1260mm 935kg

(1.49yd3) (1.30yd3) (44.9") (49.6") (2060lb)
1.38m3 1.20m3 1330mm 1450mm 1040kg

(1.81yd3) (1.57yd3) (52.4") (57.1") (2290lb)
1.44m3 1.25m3 1380mm 1500mm 1055kg

(1.89yd3) (1.63yd3) (54.3") (59.1") (2330lb)
1.74m3 1.50m3 1610mm 1730mm 1145kg

(2.28yd3) (1.96yd3) (63.4") (68.1") (2520lb)
: Standard backhoe bucket
Applicable for materials with density of 2000kg/m3 (3370lb/yd3) or less

1-32
2) GUIDE 2
1.97m3 PCSA 2.10m3 PCSA

(1)
2.10m3 PCSA
(2) (3)
1.38m3 PCSA (4)
1.38m3 PCSA
heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket
Recommendation
Capacity Width
6.45m(21' 2") boom 6.15m(20' 2") boom
Weight
PCSA CECE Without With 2.2m arm 2.5m arm 3.2m arm 4.05m arm 2.2m arm 2.5m arm
heaped heaped side cutter side cutter (7' 3") (8' 2") (10' 6") (13' 3") (6' 7") (7' 10")
1.97m3 1.70m3 1800mm 1190kg

(2.58yd3) (2.22yd3) (70.9") (2620lb)
2.10m3 1.80m3 1595mm 1715mm 1330kg

(1)
(2.75yd3) (2.35yd3) (62.8") (67.5") (2930lb)
2.10m3 1.80m3 1900mm

(2)
1230kg
(2.75yd3) (2.35yd3) (74.8") (2710lb)
(3)
1.38m3 1.20m3 1405mm 1235kg
(1.80yd3) (1.57yd3) (55.3") (2720lb)
(4)
1.38m3 1.20m3 1430mm 1460kg
(1.80yd3) (1.57yd3) (56.3") (3220lb)
: Rock bucket

1-33
7. UNDERCARRIAGE
1) TRACKS
X-leg type center frame is integrally welded with reinforced box-section track frames. The design
includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock
absorbing springs, and assembled track-type tractor shoes with triple grousers.
2) TYPES OF SHOES
Triple grouser
Model Shapes
Shoe width mm(in) 600(24") 700(28") 750(30") 800(32") 900(36")

Operating weight kg(lb) 30150(66470) 30550(67350) 30700(67680) 30850(68010) 31150(68670)
R320-3
Ground pressure kg/cm2(psi) 0.62(8.82) 0.54(7.68) 0.51(7.25) 0.48(6.82) 0.43(6.11)
Overall width mm(ft-in) 3280(10' 9") 3380(11' 1") 3430(11' 3") 3480(11' 5") 3580(11' 9")
Shoe width mm(in) 600(24") 700(28") 750(29.5") 800(32") 900(36")
Operating weight kg(lb) 31200(68780) 31600(69670) 31750(70000) 31900(70330) 32200(70990)
R320LC-3
Ground pressure kg/cm2(psi) 0.60(8.53) 0.52(7.40) 0.49(6.97) 0.46(6.54) 0.41(5.83)
Overall width mm(ft-in) 3280(10' 9") 3380(11' 1") 3430(11' 3") 3480(11' 5") 3580(11' 9")
Shoe width mm(in) 600(24") 700(28")
Operating weight kg(lb) 31000(68340) 31400(69230)
R320NLC-3
Ground pressure kg/cm2(psi) 0.59(8.39) 0.52(7.40)
Overall width mm(ft-in) 2990(9' 10") 3090(10' 2")
3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE
Quantity
Item
ROBEX 320-3 ROBEX 320LC-3/R320NLC-3
Carrier rollers 2EA 2EA
Track rollers 8EA 9EA
Track shoes 48EA 51EA
1-34
8. SPECIFICATIONS FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Cummins 6CTA8.3-C

Type 4-cycle turbocharged & after cooled diesel engine
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder bore stroke 114 135mm(4.49" 5.32")
Piston displacement 8300cc(504.5cu in)
Compression ratio 16.5 : 1
Rated gross horse power(SAE J1349) 230Hp at 2000rpm(172kW at 2000rpm)
Maximum torque at 1500rpm 99.6kgf m(720lb ft)
Engine oil quantity 21.9 (5.8U.S. gal)
Dry weight 610kg(1340lb)
High idling speed 2275 50rpm
Low idling speed 800 50rpm
Rated fuel consumption 151.5g/Ps hr
Starting motor Nippondenso, 7.5kW
Alternator DAC HC60(24V-60AMP)
Battery 2 12V 160Ah
2) MAIN PUMP
Item Specification
Type Variable displacement tandem axis piston pumps

Capacity 2 130cc/rev
Maximum pressure 320kg/cm2 (4550psi)[350kg/cm2 (4980psi)]
Rated oil flow 2 260 /min (68.7U.S. gpm/ 57.2U.K. gpm)
Rated speed 2000rpm
[ ] : Power boost
1-35
3) GEAR PUMP
Item Specification
Type Fixed displacement gear pump single stage

Capacity 10cc/rev
Maximum pressure 40kg/cm2(570psi)
Rated oil flow 20 /min(5.3U.S. gpm/4.4U.K. gpm)
4) MAIN CONTROL VALVE
Item Specification
Type 7 spools
Operating method Hydraulic pilot system
Main relief valve pressure 320kg/cm2(4551psi)[350kg/cm2(4980psi)]
Overload relief valve pressure 380kg/cm2(5405psi)
[ ] : Power boost
5) SWING MOTOR
Item Specification
Type Two fixed displacement axial piston motor

Capacity 169.4cc/rev
Relief pressure 250kg/cm2(3556psi)
Braking system Automatic, spring applied hydraulic released
Braking torque 70kg m(506lb ft)
Brake release pressure 26kg/cm2(370psi)
Reduction gear type 2 - stage planetary
Swing speed 9rpm
6) TRAVEL MOTOR
Item Specification
Type Variable displacement axial piston motor
Relief pressure 325kg/cm2(4623psi)
Reduction gear type 3-stage planetary
Braking system Automatic, spring applied hydraulic released
Brake release pressure 8.5kg/cm2(121psi)
Braking torque 2700kg m(19530lb ft)
1-36
7) REMOTE CONTROL VALVE
Item Specification
Type Pressure reducing type

Minimum 5.5kg/cm2(78psi)
Operating pressure
Maximum 19.5kg/cm2(277psi)
Lever 61mm(2.4in)
Single operation stroke
Pedal 123mm(4.8in)
8) CYLINDER
Item Specification
Bore dia Rod dia Stroke 140 100 1480mm

Boom cylinder
Cushion Extend only
Arm cylinder
Cushion Extend and retract
Bucket cylinder
Cushion Extend only
9) SHOE
Item Width Ground pressure Link quantity Overall width
Standard 600mm(24") 0.62kg/cm2(8.82psi) 48 3280mm(10' 9")

700mm(28") 0.54kg/cm (7.68psi)
2
48 3380mm(11' 1")
R320-3 750mm(30") 0.51kg/cm2(7.25psi) 48 3430mm(11' 3")
Option
800mm(32") 0.48kg/cm (6.82psi)
2
48 3480mm(11' 5")
900mm(36") 0.43kg/cm2(6.11psi) 48 3580mm(11' 9")
Standard 600mm(24") 0.60kg/cm (8.53psi)
2
51 3280mm(10' 9")
700mm(28") 0.52kg/cm2(7.40psi) 51 3380mm(11' 1")
R320LC-3 750mm(30") 0.49kg/cm (6.67psi)
2
51 3430mm(11' 3")
Option
800mm(32") 0.46kg/cm2(6.54psi) 51 3480mm(11' 5")
900mm(36") 0.41kg/cm (5.83psi)
2
51 3580mm(11' 9")
Standard 600mm(24") 0.59kg/cm2(8.39psi) 51 2990mm( 9' 10")
R320NLC-3
Option 700mm(28") 0.52kg/cm (7.40psi)
2
51 3090mm(10' 2")
1-37
10) BUCKET
Capacity Tooth Width

Item
PCSA heaped CECE heaped quantity Without side cutter With side cutter
Standard 1.44m3(1.89yd3) 1.25m3(1.63yd3) 5 1380mm(54.3") 1500mm(59.1")

0.90m (1.18yd )
3 3
0.80m (1.05yd )
3 3
3 950mm(37.4") 1070mm(42.1")
1.14m3(1.49yd3) 1.00m3(1.30yd3) 4 1140mm(44.9") 1260mm(49.6")
1.38m (1.81yd )
3 3
1.20m (1.57yd )
3 3
5 1330mm(52.4") 1450mm(57.1")
R320-3 1.74m3(2.28yd3) 1.50m3(1.96yd3) 6 1610mm(63.4") 1730mm(68.1")
R320LC-3 Option
R320NLC-3 1.97m (2.58yd )
3 3
1.70m (2.22yd )
3 3
6 1800mm(70.9")
2.10m3(2.75yd3) 1.80m3(2.35yd3) 5 1595mm(62.8") 1715mm(67.5")
2.10m (2.75yd )
3 3
1.80m (2.35yd )
3 3
6 1900mm(74.8")
1.38m3(1.81yd3) 1.20m3(1.57yd3) 5 1405mm(55.3")
1.38m (1.81yd )
3 3
1.20m (1.57yd )
3 3
5 1430mm(56.3")
: Rock bucket
1-38
8. 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 (U.S. gal) -20 -10 0 10 20 30 40
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
Engine SAE 10W

Engine oil 21.9(5.8)
oil pan
SAE 10W-30
SAE 15W-40
Swing drive 11(2.9)

Gear oil SAE 85W-140
7 2
Final drive (1.8 2)
Tank; ISO VG 32
270(71.3)
Hydraulic tank Hydraulic oil ISO VG 46
System;
400(105.7) ISO VG 68
ASTM D975 NO. 1

Fuel tank Diesel fuel 450(118.9)
ASTM D975 NO. 2
NLGI NO. 1
Fitting Grease As required
(Grease nipple)
NLGI NO. 2
Mixture of
Radiator antifreeze
(Reservoir tank) 49.8(13.2) Ethylene glycol base permanent type
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
1-39
SECTION 3 HYDRAULIC SYSTEM
GROUP 1 HYDRAULIC CIRCUIT
1 MAIN PUMP
2 MAIN CONTROL VALVE
3 SWING MOTOR
4 TRAVEL MOTOR
5 RCV PEDAL
6 RCV LEVER
7 RCV LEVER
8 BOOM CYLINDER
9 BUCKET CYLINDER
10 ARM CYLINDER
11 TURNING JOINT
12 SOLENOID VALVE
13 CHECK VALVE
14 CHECK VALVE
15 CHECK VALVE
16 HYDRAULIC TANK
17 OIL COOLER
18 AIR BREATHER
19 BY PASS VALVE
20 RETURN FILTER
21 STRAINER
22 LINE FILTER
23 DRAIN FILTER
24 ACCUMULATOR
25 PRESSURE SWITCH
26 SOLENOID BLOCK
27 SOLENOID VALVE
3-1
GROUP 2 ELECTRICAL CIRCUIT
4-3
ELECTRICAL CIRCUIT FOR HYDRAULIC
4-17
MONITORING CIRCUIT
4-1 8
SECTION 5 MECHATRONICS SYSTEM
GROUP 1 OUTLINE
The CAPO(Computer Aided Power Optimization) system mainly consists of the engine control system
and pump control system. By using the CAPO system, an operator can use the machine power in
optimal condition and in fuel economic state.
It also includes the self-diagnostic system. If any malfunction of short or open circuit happens on the
governor motor part, the error display on cluster let an operator know which error happened to the
governor motor. And if any short circuit occurs in or out of the CPU controller it protects itself from
electric damage.
Engine control system

Mode selection function
Pump control system
Auto deceleration system
Power boost system
CAPO
SYSTEM Hydraulic oil temp warning system
Travel control system Travel speed selection function
Automatic warming up system
Engine overheat prevention system
Governor motor potentiometer signal

Self-diagnostic system
Governor motor driving signal
5-1
SYSTEM DIAGRAM
Travel motor
Pressure Pressure
switch switch
LH travel
Regulator Regulator
Service RH travel
Arm Bucket
Swing Boom
Main relief 2 stage relief
valve solenoid
Travel speed
solenoid
Main control valve
Engine Engine
speed
sensor
Coolant Overheat
temp sensor switch
M
Main pump Pilot pump
P
Fuel injection Governor

pump motor
EPPR valve
Engine speed sensor signal
Power boost
button
potentiometer signal
Motor drive signal
LH control Hyd oil

lever temp switch
Coolant temperature signal
Overheat switch signal
Hyd oil temp signal

Drive signal
CPU controller Drive signal
Pressure switch signal
Hyd oil temp

warning signal
TIME bar
rpm
Tachometer signal
F
Mode lamp signal #1
E C H Mode lamp signal #2 Drive signal
Buzzer signal OFF ON
Mode left switch signal
Prolix Resister Battery
POWER MODE
Mode right switch signal switch
H S L F
AUTO SELECT
Travel speed switch signal
DECEL
H M Auto decel switch signal
TRAVEL SPEED ENGINE SPEED Engine speed up switch signal
Engine speed down switch signal
Warming up signal
5-2
GROUP 6 ENGINE SPEED SENSING FUNCTION
Engine speed sensor
Engine speed signal

TIME bar
rpm
E C H
Tachometer signal Drive signal

POWER MODE
CPU controller EPPR Valve
H S L F
AUTO SELECT
DECEL
H M
TRAVEL SPEED ENGINE SPEED
ş Engine speed sensor mounted on the engine sends AC voltage signals to CPU controller, after
being rectified into rectangular pulse signals by the CPU controller, they are displayed as engine
rpm counter on the 7-segment displays of the cluster.
ş When the engine speed drops below the reference rpm of each mode, the CPU controller reduces
the pump discharge amount through engine speed feedback to match engine output power with
pump absorption power in the optimal condition.
5 - 13
GROUP 7 BATTERY CHARGE WARNING FUNCTION
TIME bar
rpm
E C H
Alternator
Tachometer signal Drive signal
POWER MODE
CPU controller B+
H S L F
AUTO SELECT I
DECEL
H M
GND
1. FUNCTION
When alternator generated voltage drops below 26V DC after engine starts, the CPU controller
sends battery charge warning buzzer drive signal and lamp drive signal to cluster and the warning
buzzer and work in condition of that the generated voltage by alternator is less than 26V DC.
2. LOGIC TABLE
Condition ž26V < 26V Remark
Signal High(5V) Low(0V) CPU Controller
Lamp & buzzer OFF ON Cluster
5 - 14
GROUP 8 TRAVEL CONTROL SYSTEM
Travel motor
Main control valve
LH travel Regulator Regulator

Service RH travel
Arm Bucket
Swing Boom
Main relief 2 stage relief

valve solenoid valve
Travel speed
solenoid valve
Engine
Main pump Pilot pump
EPPR valve
Drive signal
TRAVEL SPEED Drive signal
Travel speed switch signal
CPU controller
1. TRAVEL SPEED SELECTION

Travel speed can be switched manually by pressing the travel speed switch on the cluster.
Speed Travel speed Lamp on Operation

solenoid valve cluster
Lo OFF Turtle Low speed, high driving torque in travel motors
Hi ON Rabbit High speed, low driving torque in travel motors
Ɠ Default : Turtle(Lo)
2. POWER BOOST IN TRAVEL

When operator travels in condition of the power mode H or S, if the power boost switch is pressed,
CPU controller sends control signal to set the pressure of the main relief valve from 320kg/cm2 to
325kg/cm2 to increase travel power.
5 - 15
GROUP 9 HYDRAULIC OIL TEMP WARNING FUNCTION
TIME bar
rpm
Hydraulic oil
E C H temp sensor
Hyd oil temp
warning signal Drive signal
CPU controller
POWER MODE
H S L F
AUTO SELECT
DECEL
H M
1. FUNCTION
When the CPU controller receives hydraulic oil temperature signals(analog voltage signal) from the
hydraulic oil temperature sensor, it converts them into digital signals.
If the temperature increases above 100Ş C, the CPU controller sends hydraulic oil temperature
warning buzzer signal and lamp signal to cluster.
So the warning buzzer and lamp ON the cluster work in condition of that the temperature is above
100Ş C
2. LOGIC TABLE
Condition ž100Ş
C < 100Ş
C Remark
Signal Low(GND) High(5V) CPU Controller
Lamp & buzzer ON OFF Cluster
5 - 16
GROUP 10 AUTOMATIC WARMING UP FUNCTION
Engine
Coolant
temp sensor
Coolant temperature signal
M
P Main pump Pilot pump

pump motor
EPPR valve
Motor drive signal

TIME bar
rpm
E C H
Warming up signal Drive signal

POWER MODE
H S L F
AUTO
DECEL
SELECT CPU controller
H M
1. Cluster reads engine coolant temperature through the temperature sensor, and if the coolant
temperature is less than 30Ɓ
C, it turns the warming-up lamp ON and sends warming-up control signal
to the CPU controller.
2. When the CPU controller receives the warming-up control signal from the cluster, it increases the
engine speed from key start rpm to 1250rpm. At this time the mode is not change.
3. In case of the coolant temperature increases upto 30Ɓ
C, the engine speed is decreased to key start
speed. And if an operator changes mode set among the warming up function, the CPU controller
cancels the automatic warming up function.
4. LOGIC TABLE(1)
Description Condition Function
- Mode : Default(S mode)

- Coolant temperature :
Actuated - Warming up time : at least 10 minutes
less than 30Ɓ
C(after engine run)
- Warming-up lamp : ON
- Coolant temperature : above 30Ɓ C - Default mode
- Warming up time : above 10 minutes - Default mode
- Changed mode set by operator - Changed mode
Canceled
ƕ If any of the above conditions is
applicable, the automatic warming-up
function is canceled
Warming-up
lamp Coolant temperature : above 30Ɓ
C Warming-up lamp : OFF
5 - 17
5. LOGIC TABLE(2)
Description Coolant temp. Ž30Ş

C Coolant temp. >30Ş
C Remark
Signal Low(0V) High(5V)

Cluster
Warming-up lamp ON OFF
Mode Default(S mode) Default(S mode) CPU controller
5 - 18
GROUP 11 ENGINE OVERHEAT PREVENTION FUNCTION
Engine
Overheat
switch
M
Overheat switch signal
P Main pump Pilot pump

pump motor
EPPR valve
Motor drive signal

TIME bar
rpm
E C H
Drive signal
POWER MODE
H S L F
AUTO
DECEL
SELECT CPU controller
H M
1. When the engine coolant boils upto 110Ɓ

C, the overheat switch is ON. and if the temperature drops to
100Ɓ
C, the switch is OFF.
2. When the overheat switch is ON, engine overheat warning buzzer and lamp work and mode set is
changed to F mode automatically on the cluster.
3. If the coolant temperature drops less than 100Ɓ C, at this moment the signal of overheat switch is
detected by the CPU controller, the CPU controller returns the mode to the mode set before. And if
mode set is changed among the function, the CPU controller cancels the function.
Ɠ Even if the overheat prevention function is canceled by mode change, the overheat warning lamp
turns OFF only when the overheat switch is OFF, that is, the coolant temperature is less than 100Ɓ
C
4. LOGIC TABLE(1)
Description Condition Function
Actuated - Coolant temperature : above 110Ɓ

C - Mode : H, S, L ơ F
- Overheat warning lamp & buzzer : ON
- Coolant temperature : less than 100Ɓ
C - Return to the mode set before
- Changed mode by operator - Hold on the changed mode
Canceled Ɠ If any of the above conditions is
applicable, engine overheat prevention
function is canceled
Overheat - Coolant temperature : less than 100Ɓ
C - Lamp OFF
warning lamp
5 - 19
5. LOGIC TABLE(2)
Overheat switch
Description
ON OFF
Condition Coolant temp : above 110Ɓ
C Coolant temp : less than 100Ɓ
C
Signal Low(GND) High(5V)
Lamp & buzzer(cluster) ON OFF
Mode set(CPU controller) F Default
5 - 20
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 the
fuse No. 1(CPU) is not blown out.
After checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
Check voltage
YES
between CN-57
(5) and chassis
Short circuit or poor Repair or replace
NO
Check voltage connection (after clean)
YES
between CN-8(5) between CN-57(5)
and chassis
-CN-8(5)

Check voltage NO
between CN-50 connection (after clean)
(7) and chassis between CN-8(5) -
CN-50(7)
Voltage : 20~30V
Starting switch : ON
YES
Check voltage Defective controller Replace
between CN-50
NO (9) and chassis
NO
connection (after clean)
between CN-36(2)
-CN-50(9)
FUSE
2
NO.1
CN-36
CLUSTER
9
5 5 7
11 11 CN-50
12 12 CPU CONTROLLER
CN-57 CN-8 11
CN-51
Check voltage
YES 20 ~ 30V
NO 0V
6 - 24
2. BATTERY CHARGING LAMP LIGHTS UP(Engine is started)
Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Check voltage
YES
between CN-53
(7) and chassis
Check voltage Defective controller Replace
YES NO
between CN-51
(18) and chassis Disconnection in Repair or replace
NO
Check voltage wiring harness or poor (after clean)
YES
between CN-1 (2) contact between
and chassis CN-51(18)-CN-1(2)
Check voltage Disconnection in Repair or replace

NO
between alternator wiring harness or poor (after clean)
terminal "I" and contact between
chassis
CN-1(2)-alternator
Voltage : 26~30V
Engine : running terminal "I"
Defective alternator Replace

NO
YES
Check voltage
between CN-
7(7) and chassis
Disconnection in Repair or replace
NO
wiring harness or poor (after clean)
contact between
CN-53(7)-CN-7(7)
CLUSTER CPU CONTROLLER

*5V
7 7 7
0V
CN-56 CN-7 CN-53
18
CN-51
ALTERNATOR
Check voltage 2
"I" TERMINAL
YES 20 ~ 30V *5V
CN-1
NO Below 26V 0V
6 - 25
3. WHEN COOLANT OVERHEAT LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Coolant overheat Check engine
(110 2 C) system
Check resistance YES

YES between CN-1(3) -
chassis and CN-
Does display go 51(1) -chassis Disconnection in wiring Repair or replace
off when NO
Starting switch : OFF harness or poor contact (after clean)
disconnect CD-9 Check resistance
and connector? YES between
between CN-9(3)
Starting switch : ON CN-9(3)-CN -51(1) and
Engine : start
and chassis
CN-9(3)-CN -1(3)
Starting switch : OFF
Check resistance Disconnection in wiring Repair or replace
NO
between CN-56 harness or poor contact (after clean)
NO
(15) and chassis
between
Starting switch : OFF CN-56(15)-CN-9(3)
Before checking,
disconnect CN-9
NO
YES
Check resistance Defective sensor Replace
between CD-9 -
chassis and
sensor-chassis Disconnection in wiring Repair or replace
Starting switch : OFF NO
harness or poor contact (after clean)
between
CN-1(3)-CD-9
15 3 1
CN-56 CN-9 CN-51 OVER HEAT SWITCH

T
3
Check resistance CN-1
YES MAX 1
NO MIN 1M
6 - 26
4. WHEN AIR CLEANER LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Check air filter Repair or replace
(after clean)
YES
Defective sensor Replace
Check resistance
Does display go off YES between CD-10-
when disconnect
CD-10 and chassis
connector? Starting switch : OFF
Starting switch : ON Check resistance Disconnection in Repair or replace
NO
Engine : start YES between CN-9(2)- wiring harness or poor (after clean)
chassis and CN-
contact between
1(9)-chassis
CN-9(2)-CD-10
Check resistance Disconnection in Repair or replace

between CN-56 NO
NO wiring harness or poor (after clean)
(14) and chassis
contact between
Starting switch : OFF CN-56(14)-CN-9(2) or
Before checking,
disconnect CD-10 CN-56(14)-CN-1(9)
NO
CLUSTER
AIR CLEANER SWITCH
14 2 9 Pa
CN-56 CN-9 CN-1

CD-10
Check resistance
YES MAX 1
NO MIN 1M
6 - 27
5. WHEN ENGINE OIL PRESSURE LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Engine oil leakage, Check engine oil
or defective switch level or replace
switch
YES Disconnection in wiring

Repair or replace
harness or poor (after clean)
Does display go off Check resistance
YES contact between
when disconnect between CN-1(5)
CD-18 and and chassis CN-1(5)-CD-18
connector?
Starting switch : ON Check resistance Disconnection in wiring Repair or replace
Engine : start YES NO
between CN-9(1) harness or poor (after clean)
and chassis contact between
Check resistance
between CN-56 NO Disconnection in wiring Repair or replace
NO
(13) and chassis harness or poor (after clean)
contact between
Before checking, CN-56(13)-CN-9(1)
disconnect CD-18
NO Defective cluster Replace
ENGINE OIL
CLUSTER PRESSURE SWITCH
13 1 5 Pa
CN-56 CN-9 CN-1 CD-18

Check resistance
YES MAX 1
NO MIN 1M
6 - 28
6. WHEN HYDRAULIC OIL TEMPERATURE LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Hydraulic oil overheart Check hydraulic oil
or defective sender temperature (105 2
C) or replace sender
YES
Check resistance
Does display go YES
between CN-53 (8) Repair or replace
off when and chassis Disconnection in wiring (after clean)
disconnect CD-1 NO
Check resistance harness or poor contact
and connector? YES between CN-7 (12) Starting switch : OFF
between
Engine : start
Starting switch : OFF Repair or replace
Check resistance Disconnection in wiring (after clean)
NO
between CN-56 harness or poor contact
NO
(12) and chassis between
CN-56(12)-CN-7(12)
Before checking, Replace
disconnect CD-1 Defective cluster
NO
Repair or replace
YES
Defective sender (after clean)
Check resistance
between CN-52(21)
and chassis Repair or replace
Starting switch : OFF NO Disconnection in wiring (after clean)
harness or poor contact
between
CN-52(21)-CD-1
HYDRAULIC OIL
Check resistance TEMPERATURE SEN
YES MAX 1
7
NO MIN 1M
CN-4
CD-1
21
CN-52
12 12 8
CN-56 CN-56 CN-53
6 - 29
7. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
(Check coolant temperature lamp ON/OFF)
Cause Remedy
YES
Coolant overheat Check coolant
or Defective sender temperature or
replace
YES Disconnection in wiring

Repair or replace
Does display go off Check resistance contact between
when disconnect YES between CN-1(6)
CD-8 and CN-1(6)-CD-8
and chassis
connector?
Starting switch : ON Starting switch : OFF Disconnection in wiring Repair or replace
Check resistance NO
Engine : start NO
between CN-8(3) harness or poor (after clean)
Check resistance
Disconnection in wiring Repair or replace
between CN-57 NO
NO harness or poor (after clean)
(3) and chassis
contact between
Before checking, CN-57(3)-CN-8(3)
disconnect CD-8
YES Defective cluster Replace
Check table
Temperature
50 C 80 C 100 C 120 C
Item
C H Unit resistance( ) 153.9 51.9 27.4 16.1
Tolerance +25, -20 +4.9, -1.2 +1.9, -1.2 1.2
WATER
TEMPERATURE SENDER
CLUSTER C
C
¡£
3 3 6
CN-57 CN-8 CN-1

CD-8
6 - 30
8. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)
Cause Remedy
YES
NO
Check resistance
between CN-57(4)
CN-57(4)-CN-8(4)
Starting switch : OFF Check resistance
See : TABLE between CN-8(4) NO
NO Disconnection in wiring Repair or replace
and chassis
See : TABLE contact between
Check resistance CN-8(4)-CN-4(6)
between CN-4(6)
YES and chassis NO
See : TABLE harness or poor (after clean)
Check resistance contact between
between CD-2(2)
YES
and chassis CN-4(6)-CD-2(2)
See : TABLE
YES
NO
Check resistance contact between
between CD-2(2)
CD-2(1) and chassis
and CD-2(1)
See : TABLE Defective sender Replace
YES
Check table
F Level
Empty 1/2 Full
Item
Unit resistance( ) 110 32.5 3
E 3 3 2
Tolerance
CLUSTER FUEL SENDER
4 4 6 2
1
CN-57 CN-8 CN-4
CD-2
6 - 31
9. WHEN SAFETY SOLENOID DOES NOT OPERATE
fuse No.8 is not blown out.
Cause Remedy
YES
Check hydraulic
YES Check operation system
of solenoid
Defective solenoid Replace
NO
Check voltage Safety lever : ON-OFF
YES
between CN-68(1) Check chassis Replace
- CN-68(2) contact
Voltage : 20~30V Check voltage YES
Safety state NO between CN-
68(2) with chassis harness or poor
contact between
Safety lever : ON
Check voltage CN-3(6)-CN-68(2)
NO
between CN-3(6)
and chassis YES
Starting switch : ON harness or poor
Voltage : 20~30V
Check operation contact between
NO of safety switch
CS-4(3)-CN-3(6)
Voltage : 20~30V NO
YES
Disconnect in wiring Repair or replace
harness or poor
Check voltage contact between
between CN-36(9)
and chassis CS-4(1)-CN-36(9)
Voltage : 20~30V Replace

Connector(male)
Defective switch
NO
SAFETY SWITCH
FUSE 3 2
9 1
NO.8 2
CN-36
3
1
CS-4
SAFETY SOLENOID
6 2
1
CS-3
CN-68
6 - 32
10. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE
Cause Remedy
NO
Check voltage Recheck fuse Replace
NO
between CN-36(7)
and chassis Disconnection in wiring Repair or replace
YES
Check voltage harness or poor contact
NO between CN-3(4) between
YES
between
CN-70(2)-CN-3(4)
YES
Defective hydraulic Check hydraulic
Check voltage YES
Check operation system system
between CN-70(2)
and chassis of solenoid
Defective solenoid Replace
Starting switch : ON NO
Voltage : 20~30V YES
Check voltage(5V) between
YES
between CN-57
CN-51(5)-CN-57(7)
(7) and chassis
Check voltage Repair or replace
between CN-51 Defective cluster
YES NO
(5) and chassis
Replace
Starting switch : ON Defective controller
NO
FUSE
9
NO.6
CN-36
CONTROLLER TRAVEL SOLENOID
13 5 1
4 2
CN-52
CN-52 CN-70
5
CLUSTER
CN-51
7 7
CN-8 CN-57
6 - 33
11. WHEN ENGINE DOES NOT START
Check supply of the power at fuel stop solenoid while starting switch is ON.
fuse No.2 and No.16 are not blown out.
Cause Remedy
YES
Defective batteryCheck engine START KEY SWITCH
system
1 B+
Charge(after
3 IG
checking specific
5 START
gravity of battery)
or replace CS-2
Check Check voltage YES
Defective magnet Replace
operation of
YES between starter of start motor
start motor magnet coil FUSE
3
Starting switch : start and chassis Defective start Replace NO.2
NO 1
Starting switch : start relay
CN-36
NO
Check operation
harness or poor contact FUSE 24V
NO of start relay 1
between NO.16
Starting switch : start CN-38(1)-CS2(1)
CN-38
Check voltage YES
Defective start Repair or replace
between Check voltage FUEL CUT-OFF
switch
NO CS-2(1) and between CS-2 10 3 E
YES
chassis (5) and chassis 1 2 S
Starting switch : ON Starting switch : START NO 1 I
CN-1
NO CN-79
harness or poor contact STARTER
Check voltage START RY
between B+
between CN-79 M
YES CN-36(3)-CN79(1)
(1) and chassis 1
2
Defective fuel cut- Repair or replace M
YES
off solenoid CR-23 CN-45
YES
Check voltage
between
between CN-1
CN-1(1)-CR23(2)
(1) and chassis
Starting switch : start
Voltage :20~30V
Disconnection in wiring Replace
NO
between
CN-1(1) and CS-2(5)
6 - 34
12. WHEN STARTING SWITCH ON DOES NOT OPERATE
fusible links and fues No.16 are not blown out.
START KEY SWITCH

Cause Remedy
1 B+
YES
Disconnection in wiring Repair or replace 2 BR
harness or poor (after clean) IG
3
Check voltage contact between 5 START
YES between
CN-4(2) and CN-4(2)-CR-1 or
chassis defective battery relay CS-2
Voltage : 20~30V
Check voltage Disconnection in wiring Replace IG POWER
YES between NO 1
harness or poor
CS-2(2) and
chassis contact between CN-36
Check voltage Voltage : 20~30V
CS-2(2)-CN-4(2)
CONTINUOUS POWER
YES between 1
CS-2(1) and Defective start Replace
NO CN-38
key switch
Voltage : 20~30V
2
Check voltage Disconnection in wiring Replace FUSE
NO 1
and specific harness or poor NO.16
gravity of battery contact between CN-40
Specific gravity : MIN 1.28 CS-2(1)-CN-38(1)- BATTERY(12VX2)
Voltage : MIN 24V CN60(1)-CR-1-Battery
Battery capacity Charge or replace

NO
too low (after clean)
FUSIBLE LINK
2 2
1 1
CN-5 CN-60
BATTERY RELAY
M8
M4
2
9
M4
M8 TO STARTER
CN-4 CR-1
6 - 35
13. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
Cause Remedy
WIPER MOTOR
YES
3
Check voltage B
YES 3 4 4
between CN-13 4
2 3 3 S1
(3) and chassis
Disconnection in wiring Repair or replace 7 2 2
NO
Check voltage Voltage : 20~30V harness or poor (after clean) 1 1 1 M E
YES Starting switch : ON 1 2
between CN-6(2) Wiper switch : ON contact between S2
and chassis CN-6 CN-13 CN-21
CN-13(3)-CN-6(2)
Voltage : 20~30V
Wiper switch : ON
NO
Check voltage harness or poor (after clean)
YES
between CS-3(1) contact between
and chassis CN-6(2)-CS-3(1)
Voltage : 20~30V
YES
Starting switch : ON Defective wiper motor Replace
Wiper switch : ON
Check voltage YES
NO between CS-3(6)
and chassis harness or poor (after clean)
Check voltage WASHER SWITCH
contact between
Voltage : 20~30V between CN-36(6) 9 10
Check operation Starting switch : ON NO and chassis CS-3(1)-CN-36(6) 10
of wiper switch Wiper switch : OFF 9 3
Voltage : 20~30V
Recheck fuse Replace 8 8
Starting switch : ON Starting switch : ON NO 1 6
Washer switch : ON-OFF 6
YES
Defective wiper motor Replace 3
YES Check voltage 1
between CN-21(1)
and chassis CS-3
NO
Check voltage Wiper switch : OFF harness or poor (after clean)
between CS-3(6) contact between
NO
and chassis
CN-21(1)-CS-3(6) WASHER TANK
Voltage : 20~30V
Starting switch : ON 1 M
Recheck fuse Replace
NO
2
YES
Defective wiper Replace CN-22
Check voltage motor
between CN-21(3) FUSE
and chassis 6
NO NO.5
harness or poor (after clean) CN-36
Wiper switch : ON-OFF
contact between
CN-21(3)-CN-13(3)
6 - 36
14. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHT UP
Cause Remedy
YES HEAD LIGHT
Check voltage Defective bulb Replace
YES between CL-4(2)- 9 1
chassis and CL-3 7 2
(2)- chassis Disconnection in wiring
NO CN-4 CL-4
Voltage : 20~30V harness or poor Repair or replace
Check voltage
YES Starting switch : ON contact between (after clean)
between CN-4(7) Light switch : ON at 1st 1
and chassis step CN-4(7)-CL-4(2) and 2
CN-4(7)-CL-3(2)
Voltage : 20~30V
Starting switch : ON CL-3
Light switch : ON at 1st Disconnection in wiring Repair or replace
step NO
Check voltage harness or poor (after clean)
YES
between CR-13 contact between
(2) and chassis CR-13(2)-CN-4(7)
Voltage : 20~30V
Starting switch : ON YES
Light switch : ON at 1st
Defective relay Replace
step CLUSTER
Check voltage YES
between CR-13 Disconnection in wiring Repair or replace
NO 9 9
(4) and chassis harness or poor (after clean)
Voltage : 20~30V CN-7 CN-56
between CN-37
Starting switch : ON NO CR-13(4)-CN-37(1)
(1) and chassis
Check operation Voltage : 20~30V
Recheck fuse Replace HEAD LAMP RELAY
of cab lamp relay Starting switch : ON NO LIGHT SWITCH
3 4
4 9 10
Starting switch : ON 4
Light switch: ON-OFF YES 3 10 2
Disconnection in wiring Repair or replace 2 9 7 1
harness or poor (after clean) 1 7 5
Check voltage contact between 1 2
YES 1
between CS-39 CR-13
CR-13(3)-CS-39(7)
(7) and chassis
Light switch : ON at 1st CS-39
step Defective light Replace switch
NO
Check voltage switch
between CS-39(1)
NO
and chassis YES
Voltage : 20~30V harness or poor (after clean) FUSE
Starting switch : ON 1
Check voltage contact between NO.12
between CN-37 CN-37(1)-CS-39(1) CN-37
NO
(1) and chassis
Recheck Replace
NO
6 - 37
15. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
Cause Remedy
YES WORK LIGHT
harness or poor (after clean) 1 1
Check voltage contact between 2 2
YES
between CN-10 CN-10(2)-CL-6(2)-
(2) and chassis CN-10 CL-5
CN-10(2) and CL-5(2)
Voltage : 20~30V
1
Check voltage Disconnection in wiring Repair or replace
YES Light switch : ON at NO 2
9
4
between CN-4(4) 2nd step
and chassis contact between CL-6
CN-4
Voltage : 20~30V CN-10(2)-CN-4(4)
Light switch : ON at
2nd step Disconnection in wiring Repair or replace
NO
Check voltage harness or poor (after clean) TO HEAD LAMP
YES (Refer to page 6-34)
between CR-3 (2) contact between
and chassis CN-4(4)-CR-3(2) CLUSTER
Voltage : 20~30V
Starting switch : ON YES 10 10
Defective relay Replace
Light switch : ON at 2nd
step CN-7 CN-56
Check voltage
YES
NO between CR-3(4) Disconnection in wiring Repair or replace
and chassis harness or poor (after clean) FROM HEAD
Voltage : 20~30V Check voltage contact between WORK LAMP RELAY LAMP RELAY
Check operation NO between CN-37 CN-37(2)-CR-3(4) 3 4 LIGHT SWITCH
(2) and chassis 4 9 10
of work lamp relay 3 10
Voltage : 20~30V Recheck fuse Replace 4
Starting switch : ON NO 2 9 2
Starting switch : ON 7 1
Light switch : ON-OFF YES 1 7 5
Disconnection in wiring Repair or replace 1 2
4
harness or poor (after clean) CR-3
Check voltage 2
YES contact between
between CS-39
CS-39(2)-CR-3(3) CN-36
(2) and chassis
Light switch : ON-OFF
Defective lamp Replace switch
Check voltage NO
switch
between CS-39 FUSE
NO
(4) and chassis YES 2
Disconnection in wiring Repair or replace NO.13
Voltage : 20~30V
harness or poor (after clean) CN-37
between CN-37
NO CS-39(4)-CN-37(2)
(2) and chassis
Recheck fuse Replace

NO
6 - 38
GROUP 4 MECHATRONICS SYSTEM
1. ALL SPEED ARE SLOW

Boom, arm, bucket, swing and travel but engine speed is good.
Spec : H-mode 2250 +50rpm S-mode 2250 +50rpm
L-mode 2050 +50rpm F-mode 1850 +50rpm
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective
YES Check pressure hydraulic system.
at EPPR valve
YES Check electric NO

Defective Replace.
current at EPPR SPEC : 10~16kg/cm2
SEE TEST 4 EPPR valve.
valve
SPEC : 340~400mA
NO
Defective CPU Replace.
Check resistance SEE TEST 3
controller.
between
CN-50(6) - (8) YES
Short circuit or Check & repair
SPEC : 17.5 1 (20 C) poor connection wire harness or
SEE TEST 1
Check resistance between CN-50 - between CN-50 -
NO at EPPR valve CN-75. CN-75.
SPEC : 17.5 1 (20 C) Defective EPPR Replace

SEE TEST 2 NO
valve.
Wiring diagram
RESISTOR
2 Normal :
1 Emergency :
CN-47
CPU
CONTROLLER PLOLIX SWITCH
6 6
5 5
4
4
9 3 3
8 2 2
1
6 1
CN-50 CS-7
EPPR VALVE
11 1 2
2 1
CN-51 CN-2 CN-75
6 - 39
2) TEST PROCEDURE
SPEC : 17.5 1 (20 C)
(1) Test 1 : Check resistance at connector
CN-50(6)-(8).
Starting key OFF. CN-50
Remove CPU controller and disconnect CPU 1 2 3 4 5
connector CN-50. CONTROLLER 6 7 8 9 10
Check resistance between pin and at CN53 CN52 CN51 CN-50
connector CN-50(6)-(8).
Multimeter
(2) Test 2 : Check resistance at connector

CN-75. SPEC : 17.5 1 (20 C)
Starting key OFF.
Disconnect connector CN-75 from
EPPR valve at main hydraulic pump. CN-75
Check resistance between 2 lines as

figure.
Multimeter
(3) Test 3 : Check electric current at EPPR

valve. SPEC : 340~400mA(S mode)
Install multimeter as figure.
Start engine.
Set S-mode and cancel auto decel
mode.
CN-75
If tachometer show approx 2250+50rpm,
Check electric current.
EPPR VALVE
Multimeter
6 - 40
(2) Test 4 : Check pressure at EPPR valve.
SPEC : 10~16kg/cm2(140~230psi)
Remove plug and connect pressure
gauge as figure.
Gauge capacity : 0 to 40~50 kg/cm2
(0 to 570~710 psi)
Start engine.
Supply line, pilot press
Set S-mode and cancel auto decel
mode.
CN-75
If tachometer show approx. 2250+50rpm,
Pressure adjusting
check pressure. screw
locknut
If pressure is not correct, adjust it.
After adjust, test the machine.
6 - 41
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. Check resistance between speed sensor and adjust.
Check resistance between
SEE TEST 6 sensor and fly SEE: 5-25page
YES between No good CN-52(14) -
CN-50(2) - (3) and CN-51(12) wheel
(4) - (5) NO
SPEC : 0.2~0.4K
SPEC : 5~10 SEE TEST 7
Check linkage SEE TEST 5 Defective governor Replace governor
NO
between governor motor or short circuit motor or harness
motor - injection or poor connection assembly.
pump. between CN-50 -
CN-2 and CN-2 -
CN-76
Improper operation Adjust or repair.
NO
by loosening or
interference of
linkage.
YES
Short circuit or poor Check and repair.
connection
Check resistance
between CN-51
between
(12) - CD-17(2) or
CD-17(1) - (2)
CN-52(14) -CD-17(1)
SPEC:0.2~0.4K Defective Replace.
NO
SEE TEST 8 speed sensor.
Wiring diagram
RESISTOR
2 Normal :
1
CN-47 Emergency :
PROLIX SWITCH
CPU
CONTROLLER 6
5
5 6 4
4 5
3 4 3
2 3 2
9 2 1
8 1 EPPR VALVE
6
CS-7 2
CN-50 1
11 1 CN-75 POTENTIOMETER
12 2
10 5 1
4 2
CN-51 3 3
7
6 CN-77 SPEED SENSOR
9
m
24 10 2
rp
23 11 1
14 12
CD-17 GOVERNOR MOTOR
CN-52 CN-2 A
1
2 A' M
3 B
4 B'
CN-76
6 - 42
2) TEST PROCEDURE
SPEC : 5 ~ 10
(1) Test 5 : Check resistance between
CN-50(2)-(3) and CN-50(4)-(5). CPU
Starting key OFF. CONTROLLER
Remove CPU controller and disconnect CN53 CN52 CN51 CN-50
connector CN-50 from CPU controller.

Check resistance as figure.
CN-50 CN-50
1 2 3 4 5 1 2 3 4 5
6 7 8 9 10 6 7 8 9 10
Multimeter Multimeter
unit : rpm
(2) Test 6 : Check tachometer
Spec Remark
(Work properly or not.)
Start engine. H-mode 2250+50rpm
Check tachometer reading. S-mode 2250+50rpm Check rpm after
cancel the auto
L-mode 2050+50rpm decel mode.
F-mode 1850+50rpm

SPEC : 0.2 ~ 0.4K
CN-52(14) and CN-51(12).
Starting key OFF.
Remove CPU controller and disconnect CPU
connector CN-51 and CN-52 from CPU CONTROLLER
controller. CN53 CN52 CN51 CN-50
CN-52 CN-51
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
13 14 15 16 17 18 19 20 21 22 23 24 10 11 12 13 14 15 16 17 18
Multimeter
6 - 43
(4) Test 8 : Check resistance at speed
SPEC : 0.2 - 0.4K
sensor.
Starting key OFF.
Disconnect connector CD-17 of speed Speed sensor
sensor at engine flywheel housing.
CD-17 CD-17
1 2
Engine flywheel
Multimeter
6 - 44
3. ENGINE STALL
Cause Remedy
YES
Not enough engine Contact cummings
YES Check pressure at power. engine dealer.
EPPR valve.
Defective EPPR Replace.
NO
SPEC : 28~34kg/cm2 valve.
Check electric SEE TEST 10
current at EPPR YES
valve. Defective CPU Replace.
controller.
SPEC : 560~620mA
SEE TEST 9 Check resistance
YES
between Short circuit or poor Check and repair.
NO
CN-50(6) - (8) connection
SPEC : 17.5 1 (20 C) between
SEE TEST 1 Check resistance
CN-50 - CN-2 or
NO at EPPR valve.
CN-50 - CN-75
SPEC : 17.5 1 (20 C)
SEE TEST 2 Defective EPPR Replace.
NO
valve.
Wiring diagram
Normal :
RESISTOR Emergency :
2
1
CN-47
CPU
CONTROLLER PLOLIX SWITCH
6 6
5 5
4
4
9 3 3
8 2 2
1
6 1
CN-50 CS-7
EPPR VALVE
11 1 2
2 1
CN-51 CN-2 CN-75
6 - 45
2) TEST PROCEDURE
SPEC : 560~620mA
(1) Test 9 : Check electric current at EPPR
valve at F-mode
Install multimeter as figure. CN-75
Start engine.
Set F-mode with 1850+50rpm
Check electric current.
EPPR VALVE
Multimeter
(2) Test 10 : Check pressure at EPPR valve

SPEC : 28~34kg/cm2(400~480psi)
at F-mode
Connect pressure gauge at EPPR valve.
Start engine.
Set F-mode with 1850+50rpm
Operate bucket lever completely push or Supply line, pilot press
pull. CN-75
Hold arm lever at the end of stroke. Pressure adjusting
screw
locknut
Check pressure at relief position.
6 - 46
4. CLUSTER LAMPS ARE OFF IMMEDIATELY AFTER KEY SWITCH OFF
Before carrying out below procedure, check all the related connector are properly inserted.
Normal condition : Lamps ON approx. 3-12 second after key switch OFF.
Cause Remedy
YES
Defective Replace.
CPU controller.
Check voltage at YES

CN-50(10) Poor connection Check and
or short circuit repair.
SPEC : 24 1 V between
SEE TEST 11
Check CN-50(10) - CN-
NO Fuse No. 18 60(1)
SEE TEST 12
Defective fuse. Replace.
NO
Wiring diagram
CPU
CONTROLLER FUSE BOX
18 BATTERY
10 7 1 1 1
CN-38 CN-40 CN-5 CN-60

CN-50
6 - 47
2) TEST PROCEDURE
SPEC : 24 1V
(1) Test 11 : Check voltage at CN-50(10).
Starting key OFF. CN-50
CPU
Disconnect connector CN-50 from CPU 1 2 3 4 5
CONTROLLER 6 7 8 9 10
controller.
CN53 CN52 CN51 CN-50
Ground
Multimeter
(2) Test 12 : Check fuse at fuse box(18).

Fuse box
Starting key OFF.
Selecting the fuse at fuse box(18). WIPER &
10A
10A
20A 20A
10A 20A
11
SPARE
1
HORN CPU
WASHER
Check if the fuse is defective or not.
20A 10A
10A
FUEL
SPARE SOL. B+
2
12
HEAD LAMP
CUT-OFF SOL
CASSETTE & CIGAR &
20A
20A 10A
10A 30A
3
13
WORK LAMP SPARE
RADIO ETHER SOL.
HORN & &
20A 20A
CASSETTE
10A 20A
AIR-CON
CPU
14
4
HEATER SAFETY
RADIO
FUEL F/PUMP&&
WIPER
20A 20A
10A 30A
15
5
SPARE
XUT-OFF SOL WASHER
T/ALARM
AIR-CON
20A 20A
10A 10A
16
START
SPAREKEY SOL. B+
6
HEATER
CIGAR &
10A 20A
20A 10A
17
CASSETTE
CASSETTEB+B+
7
SPARE SOL.
ETHER
MONITOR
MONITOR&&
20A 10A
20A 20A
SAFETY SOL.
18
HEAD LIGHT
8
CPU
CPUB+
B+
F / PUMP &
10A 10A
20A 10A
ROOM
ROOMLAMP
19
LAMP TWORK LIGHT
9
/ ALARM
20A
10A
SPARE BEACON
10
20
SPARE CABIN LIGHT

20A
21EM-30520
20A
SPARE
SPARE
FUSE
FUSE
20A
SPARE
20A
PULLER
PULLER SPARE
SPEC : 20A
Fuse No. 18 for CPU B+
6 - 48
5. CLUSTER LAMPS ARE STILL ON AFTER STARTING KEY OFF
Cause Remedy
YES
Improper Check and
operation of repair.
governor motor.
Check interference So, governor
YES of connecting rod motor supply
when governor
signal to
motor move to low
rpm side. cluster panel
continuously.
Check voltage at Defective Replace.

CN-50(9). NO
CPU controller.
SPEC : YES
Key ON : 24 1 V Defective battery Replace.
Key OFF : 0 V
SEE TEST 13 Is the voltage 24V relay.
NO
between CN-50(9)
and GND?
NO
TEST :
Repeat key switch controller
ON and OFF
SEE TEST 14
Wiring diagram
FUSE BOX
CPU
CONTROLLER
1
9 2
1
CN-50 CN-36
START KEY SWITCH
B+
3 IGNITION
START
CS-2
6 - 49
2) TEST PROCEDURE
SPEC :
(1) Test 13 : Check voltage at CN-50(9). Key ON : 24 1V
Starting key ON. Key OFF : 0V
Disconnect connector CN-50 from CPU
CN-50
controller. CPU 1 2 3 4 5
Check voltage as figure. CONTROLLER 6 7 8 9 10
Ground
Multimeter
(2) Test 14 : Check operating status of main

SPEC :
power supply at CN-50(9).
Key OFF : 0V
Starting key ON.
Disconnect CN-50 from CPU controller.
Check if the voltage remains at 24 1V CN-50
inspire of operating key switch ON and CPU 1 2 3 4 5
OFF. CONTROLLER 6 7 8 9 10
If there is certain amount of voltage, CN53 CN52 CN51 CN-50
replace CPU controller.

Ground
Multimeter
6 - 50
6. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM
Cause Remedy
YES
Defective lamps or Repair or Replace
Check voltage cluster
YES between CN-50(7)-
chassis and CN-
57(5)-chassis.
SPEC : 24 1V NO
SEE TEST 16 controller.
Check resistance
Poor connection Check and repair.
for switches.
between CN-50 -
SPEC : CN-57.
Switch ON : 0
Switch OFF :
SEE TEST 15 Defective switch at Replace.
NO
cluster.
Wiring diagram
CLUSTER
CPU CONTROLLER
8 8
CN-56 CN-7
4
7 7 5
1 1 6
2 2 7
9 9 8
8 8 9
5 5
CN-57 CN-8 CN-51
CN-51
6 - 51
2) TEST PROCEDURE
(1) Test 15 : Check resistance for switches. CPU
Starting key OFF. CONTROLLER
Disconnect connector CN-51 from CPU CN53 CN52 CN51 CN-50
controller.
CN-51
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
Ground
Multimeter
(2) Test 16 : Check voltage for CN-50, CN-57.

CN-50:Output power(24 1volt) SPEC : 24 1V
CN-57:Input power(24 1volt)
Starting key ON.
CN-50
Remove cluster from panel. CPU 1 2 3 4 5
Don't disconnect connector CN-50 from CONTROLLER 6 7 8 9 10
CPU controller. CN53 CN52 CN51 CN-50
cluster. Ground
Check voltage CN-50,CN-57 with

ground as figure. Multimeter
CN-57
1 2 3 4 5 6
7 8 9 10 11 12
Ground
Multimeter
6 - 52
7. 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 Check voltage
between YES
between CN- Defective CPU Replace.
connecting rod 52(24) - CN-51(10) controller.
and governor YES
and check
resistance between
Check resistance CN-52(23) - Defective Replace.
between CN-51(10). NO
governor motor.
NO CN-50(2) - (3) and SPEC : (24)-(10) : 5 1V
CN-50(4) - (5) (23)-(10) : 0-5K
SEE TEST 18
SPEC : 5~10
SEE TEST 17 Defective Replace.
NO
governor motor.
Wiring diagram
CPU CONTROLLER
5
4
3
2
CN-50
POTENTIOMETER
10 5 1 (-)
4 2 SIG
3 3 (+)
CN-51
CN-77
GOVERNOR MOTOR
24 9 1 A
23 10 2 A' M
11 3 B
12 4 B'
CN-52
CN-2 CN-76
6 - 53
2) TEST PROCEDURE
Test - a
(1) Test 17 : Check resistance.
Starting key OFF.
Disconnect connector CN-50 from CPU CN-50
CPU
controller. 1 2 3 4 5
CONTROLLER
Check resistance between CN-50(2)-(3), 6 7 8 9 10
CN-50(4)-(5) as figure.
Multimeter
Test - b
CN-50
CPU
1 2 3 4 5
CONTROLLER
6 7 8 9 10
Multimeter
6 - 54
(2) Test 18 : Check voltage and resistance.
SPEC : 0 ~ 5K
Check resistance between CN-52(23)
and CN-51(10).
CPU
Starting key OFF.
CONTROLLER
Disconnect connector CN-52 and CN-51
from CPU controller.
Check resistance value with multimeter
as figure.
CN-52 CN-51
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
13 14 1516 17 18 19 20 2122 23 24 10 11 12 13 14 1516 17 18
Multimeter
Check voltage between CN-52(24) and

SPEC : 5 1V
CN-51(10).
CPU
Prepare 2 pieces of thin sharp pin, steel
CONTROLLER
or copper. Pin Pin
Starting key ON.
Insert prepared pins to rear side of
connectors :
One pin to CN-52(24)
Other pin to CN-51(10)
Check voltage.
CN-52 CN-51
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
13 14 15 16 17 18 19 20 21 22 23 24 10 11 12 13 14 15 16 17 18
Multimeter
6 - 55
8. AUTO DECEL SYSTEM DOES NOT WORK
Cause Remedy
YES
Check voltage controller.
YES
between
CN-51(3) - GND.
Short circuit or poor Replace or repair.
SPEC :
NO
Actuator operating : 4.5-5.5V
connection
Check voltage Actuator normal : 0-2V between CN-51(3) -
between SEE TEST 20
pressure switch.
CN-51(4) - GND.
Defective auto Replace.
SPEC : decel press switch.
Switch ON : 0-2V
Switch OFF : 4.5-5.5V
SEE TEST 19
NO
Defective cluster. Replace.
Wiring diagram
AUTO DECEL
PRESSURE SWITCH
Pa
CD-7
8 8 4 Pa
3
CD-6
CN-56 CN-7 CN-51
6 - 56
2) TEST PROCEDURE
SPEC :
(1) Test 19 : Check voltage at CN-51(4) Auto decel switch ON(Light ON) : 0-2V
and ground. Auto decel switch OFF(Light OFF) : 4.5-5.5V
Starting key OFF.
CPU
CONTROLLER
CPU controller. Pin
Turn start key ON.
Check voltage as figure.
CN-51
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
Ground
Multimeter
(2) Test 20 : Check voltage at CN-51(3)

SPEC :
and ground.
Actuator operating : 4.5-5.5V
Prepare 1 piece of thin sharp pin, steel
Actuator normal : 0-2V
or copper.
Staring key ON. CPU
Insert prepared pin to rear side of CONTROLLER
Pin
connectors : One pin to (3) of CN-52.
CN-51
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
Ground
Multimeter
6 - 57
9. MALFUNCTION OF WARMING UP
Cause Remedy
YES
Defective cluster or Repair or
Check resistance CPU controller or Replace.
YES
between CD8(sensor)
CN-57(3) - CD-8
Check resistance SPEC : 0 Poor connection Repair.
NO
between CN - SEE TEST 22 between CN-57(3)
52(20) - CN-56(16) - CD-8.
SPEC : 0
SEE TEST 21
Poor connection Repair.
NO
between CN-
52(20) - CN-56(16).
Wiring diagram
CPU
CONTROLLER
20 4 16
CN-9
WATER TEMP SENSOR

CN-56
C
¡£
CD-8
3 3 6
CN-57 CN-8 CN-1
6 - 58
2) TEST PROCEDURE
SPEC : 0
CN-52(20) and CN-56(16).
Starting key OFF. CPU
CONTROLLER
Remove CPU controller and disconnect
CN53 CN52 CN51 CN50
CN-52 from CPU controller.
Remove cluster and disconnect CN-56
Cluster
from cluster.
CN-56
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
CN-52
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
Multimeter

CN-57(3) and CD-8. SPEC : 0
Starting key OFF.
Remove cluster and disconnect CN-57 CN-57
12 11 10 9 8 7
6 5 4 3 2 1
from cluster.
Disconnect connector CD-8 of water
temp sensor at engine head.
Cluster
WATER TEMPERATURE SENDER
CD-8
Multimeter
6 - 59
10. MALFUNCTION OF OVERHEAT
Cause Remedy
NO
Defective overheat Replace
switch
Check resistance
between YES
CD-9 - GND. Defective CPU Replace
SPEC : Check resistance controller
Region between
(Fig.) 0 YES
CN-51(1) - CD-9
SEE TEST 23 Short circuit or poor Check or Repair
SPEC : 0 NO
SEE TEST 24 connection between
CN-51(1) - CD-9.
Coolant
temperature
110 C
Overheat switch ON : Coolant temperature 110 C 100 C

Overheat switch OFF : Coolant temperature 100 C
Time
Region Region Region
Temperature curve
Wiring diagram
CPU CONTROLLER
OVERHEAT SWITCH
T
1 3
CD-9
CN-51 CN-1
CLUSTER
15 3
CN-9
CN-56
6 - 60
2) TEST PROCEDURE
SPEC : Region , -
(1) Test 23 : Check resistance between Region -0
connector CD-9 - GND.
Starting key OFF. OVER HEAT SWITCH
Disconnect connector CD-9 of overheat
switch at engine head.
CD-9
Ground
Multimeter

connector (1) of CN-51 - CD-9. SPEC : 0
Starting key OFF.
CPU
connector CN-51 from CPU controller. CONTROLLER
Disconnect connector CD-9 of overheat CN53 CN52 CN51 CN-50
switch at engine head.

CN-51
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
Overtheat switch
CD-9
Multimeter
6 - 61
11. MALFUNCTION OF POWER MAX
Cause Remedy
YES
Is only to H,S Defective power Repair or replace
mode resistance max. solenoid valve
YES between CN-
51(15)-CN-88(1)
and CN-51(2)-
GND normal? NO
connection between
Is voltage between SPEC : 0 and power max button ON : 0
power max button OFF : CN-51(15)-CN-
CN-88(2)-GND See test 25
normal? 88(1) and CS-29-
CN-51(2)
SPEC
Switch ON : 24 1V
Switch OFF : 0V
Seet test 24
NO
connection between
CN-88(2)-battery
relay(+)
Wiring diagram
CPU CONTROLLER POWER MAX SOLENOID
15 6 1
2 4 2
CN-51 CN-3 CN-88
FUSE BOX
POWER MAX SWITCH

6
7
CS-29
CN-36
6 - 62
2) TEST PROCEDURE
SPEC : key ON - 24 1V
(1) Test 24 : Check voltage at (2) of connector key OFF - 0V
CN-88 - GND.
Start key ON.
CN-88
Disconnect connector CN-88 from power CN-88
max. solenoid valve.
Power max.
solenoid valve
Ground
Multimeter

connector (15) of CN-51-(1) of SPEC : 0 and power max. button ON - 0
CN-88 and CND-(2) of CN-51. power max. button OFF -
Starting key OFF.
Power max. switch
connector CN-51 from CPU controller.
Disconnect connector CN-88 from power
LH lever
max. solenoid valve.
Check resistance as figure. CN-51
CPU
1 2 3 4 5 6 7 8 9
CONTROLLER
10 11 12 13 14 15 16 17 18
Multimeter
CN-88
Power max.
solenoid valve
CN-88
6 - 63
12. OPEN OR SHORT CIRCUIT OF GOVERNOR MOTOR SYSTEM
Before checking, check all the related connectors are properly inserted.
Before carrying out next procedure, connect the disconnected connectors again immediately
unless otherwise specified.
Cause Remedy
YES Defective Replace
Check the power
mode lamps, H & controller
YES S are glittered
alternately when
change the mode Poor connection Check and repair
NO
Check resistance Reconnect CN-50 of pin
among pins of Starting switch : ON
CN-50 is the
same as table 1 YES
Defect, open or Check and
Check resistance short circuit of replace
among pins of CN-
wiring harness
NO 76 is the same as
table 1
Starting switch : OFF Open or short Repair or replace
NO
circuit inside of
governor motor
Table 1
CN-50(Female) CN-76(Male) Resistance
(5) - (4) (1) - (2) 4~9
(3) - (2) (3) - (4) 4~9
(5) - (3) (1) - (3)
(5) - (2) (1) - (4)
Min 1 M
Pin(2),(3),(4),(5) Pin (1),(2),(3),(4)
- chassis - chassis
CPU CONTROLLER
GOVERNOR MOTOR
5 9 1 A
4 10 2 A' M
3 11 3 A
2 12 4 A'
CN-2 CN-76
CN-51
6 - 64
13. OPEN OR SHORT CIRCUIT OF POTENTIOMETER SYSTEM
Before checking, check all the related connectors are properly inserted.
Before carrying out next procedure, connect the disconnected connectors again immediately unless
otherwise specified.
Cause Remedy
YES Defective Replace
Check the power
mode lamps, F & controller
YES
L are glittered
alternately when
change the mode Poor connection Check and repair
NO
Check resistance Reconnect CN-52 of pin
among pins of Starting switch : ON
CN-51/52 is the
same as table 2 YES
Defect, open or Repair or replace
Check resistance short circuit of
among pins of
wiring harness
NO CN-77 is the same
as table 2
Starting switch : OFF Defect inside of Replace
NO
potentiometer
Table 2
CN51-52(Female) CN-77(Male) Resistance
(23) - (24) (2) - (1) 0.25 ~ 6 K
(23) - (10) (2) - (3) 0.25 ~ 6 K
(24) - (10) (1) - (3) 4~6K
CPU CONTROLLER
POTENTIOMETER
10 5 1 (-)
4 2 SIG
3 3 (+)
CN-51
CN-77
23
24
CN-50 CN-2
6 - 65
SECTION 8 DISASSEMBLY AND ASSEMBLY
GROUP 1 PRECAUTIONS
1. REMOVAL WORK
1) Lower the work equipment completely to the ground.
If the coolant contains antifreeze, dispose of it correctly.
2) After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
3) When draining oil, prepare a container of adequate size to catch the oil.
4) Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
5) To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
6) Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
7) Check the number and thickness of the shims, and keep in a safe place.
8) When raising components, be sure to use lifting equipment of ample strength.
9) When using forcing screws to remove any components, tighten the forcing screws alternately.
10) Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
11) When removing hydraulic equipment, first release the remaining pressure inside the hydraulic tank
and the hydraulic piping.
12) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
number D 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
D d
16 16 13.5 20
18 18 15 22
20 20 17 25
L
22 22 18.5 28
24 24 20 30
27 27 22.5 34
8-1
2. INSTALL WORK
1) Tighten all bolts and nuts(sleeve nuts) to the specified torque.
2) Install the hoses without twisting or interference.
3) Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
4) Bend the cotter pin or lock plate securely.
5) When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2-3 drops of adhesive.
6) When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
7) Clean all parts, and correct any damage, dents, burrs, or rust.
8) Coat rotating parts and sliding parts with engine oil.
9) When press fitting parts, coat the surface with antifriction compound (LM-P).
10) After installing snap rings, check that the snap ring is fitted securely in the ring groove(check that the
snap ring moves in the direction of rotation).
11) When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
12) When using eyebolts, check that there is no deformation or deterioration, and screw them in fully.
13) When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
14) When operating the hydraulic cylinders for the first time after repairing and reassembling the
hydraulic cylinders, pumps, or other hydraulic equipment or piping, always bleed the air from the
hydraulic cylinders as follows:
(1) Start the engine and run at low idling.
(2) Operate the control lever and actuate the hydraulic cylinder 4-5 times, stopping 100mm
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, nut M12 1.75 12.2 1.3 88.2 9.4
2 Radiator mounting bolt M16 2.0 29.6 3.2 214 23
Engine
3 Coupling mounting socket bolt M16 2.0 10.5 0.5 76 3.6
4 Main pump housing mounting bolt M10 1.5 4.8 0.3 34.7 2.2
5 Main pump mounting socket bolt M20 2.5 42 4.5 304 33
6 Main control valve mounting nut M12 1.75 12.2 1.3 88.2 9.4
Hydraulic
7 system Fuel tank mounting bolt M20 2.5 46 5.1 333 37
8 Hydraulic oil tank mounting bolt M20 2.5 46 5.1 333 37
9 Turning joint mounting bolt, nut M16 2.0 29.6 3.2 214 23
10 Swing motor mounting bolt M20 2.5 58.4 6.4 422 46.3
11 Swing bearing upper part mounting bolt M24 2.5 97.8 10 707.4 72.3
Power
12 train Swing bearing lower part mounting bolt M24 2.5 97.8 10 707.4 72.3
system
13 Travel motor mounting bolt M20 2.5 44 2.5 318 18.1
14 Sprocket mounting bolt M20 2.5 51 4.0 369 29
15 Carrier roller mounting bolt, nut M16 2.0 21 2.3 152 16.6
16 Track roller mounting bolt M20 2.5 54.7 6.0 396 43.4
Under
17 Track tension cylinder mounting bolt M16 2.0 29.6 3.2 214 23
carriage
18 Track shoe mounting bolt, nut M20 1.5 78 4.0 586 28.9
19 Track guard mounting bolt M20 2.5 54.7 6.0 395 43
20 Counter weight mounting bolt M36 4.0 297 33 2148 239
21 Others Cab mounting bolt 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 engine maintenance guide and service
manual.
8-4
2. TORQUE CHART
The torques given are standard figures. Any figures specifically described in this manual has priority.
1) METRIC BOLT-coarse thread
8T 10T
Bolt size
kgf m lbf ft kgf m lbf ft
M 6 1.0 0.9 ~ 1.3 6.5 ~ 9.4 1.1 ~ 1.7 A8.0 ~ 12.3
M 8 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7
M10 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60.0
M12 1.75 7.4 ~ 11.2 53.5 ~ 81.0 9.8 ~ 15.8 70.9 ~ 114.3
M14 2.0 12.2 ~ 16.6 88.2 ~ 120.0 16.7 ~ 22.5 120.8 ~ 162.7
M16 2.0 18.6 ~ 25.2 134.5 ~ 182.3 25.2 ~ 34.2 182.3 ~ 247.4
M18 2.0 25.8 ~ 35.0 186.6 ~ 253.2 35.1 ~ 47.5 253.9 ~ 343.6
M20 2.5 36.2 ~ 49.0 261.8 ~ 354.4 49.2 ~ 66.6 355.9 ~ 481.7
M22 2.5 48.3 ~ 63.3 349.4 ~ 457.8 65.8 ~ 98.0 475.9 ~ 708.8
M24 3.0 62.5 ~ 84.5 452.1 ~ 611.2 85.0 ~ 115.0 614.8 ~ 831.8
M30 3.0 124.1 ~ 167.9 897.6 ~ 1214.4 169.1 ~ 228.9 1223.1 ~ 1655.6
M36 4.0 174.3 ~ 235.6 1260.7 ~ 1704.0 250.0 ~ 310.0 1808.3 ~ 2242.2
2) METRIC BOLT-fine thread
8T 10T
Bolt size
kgf m lbf ft kgf m lbf ft
M 8 10 2.2 ~ 3.4 15.9 ~ 24.6 3.0 ~ 4.4 21.7 ~ 31.8
M10 1.2 4.5 ~ 6.7 32.5 ~ 48.5 5.9 ~ 8.9 42.7 ~ 64.4
M12 1.25 7.8 ~ 11.6 56.4 ~ 83.9 10.6 ~ 16.0 76.7 ~ 115.7
M14 1.5 13.3 ~ 18.1 96.2 ~ 130.9 17.9 ~ 21.1 129.5 ~ 174.3
M16 1.5 19.9 ~ 26.9 143.9 ~ 194.6 26.6 ~ 36.0 192.4 ~ 260.4
M18 1.5 28.6 ~ 43.6 206.9 ~ 315.4 38.4 ~ 52.0 277.7 ~ 376.1
M20 1.5 40.0 ~ 54.0 289.3 ~ 390.6 53.4 ~ 72.2 386.2 ~ 522.2
M22 1.5 52.7 ~ 71.3 381.2 ~ 515.7 70.7 ~ 95.7 511.4 ~ 692.2
M24 2.0 67.9 ~ 91.9 491.1 ~ 664.7 90.9 ~ 123.1 657.5 ~ 890.4
M30 2.0 136.9 ~ 185.1 990.2 ~ 1338.8 181.7 ~ 248.3 1314.2 ~ 1796.0
M36 3.0 192.1 ~ 259.9 1389.5 ~ 1879.9 261.8 ~ 354.2 1893.6 ~ 2561.9
8-5
3) PIPE & HOSE
Thread size Width across flat(mm) 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 14 101.3
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 15 108.5
8-6
GROUP 3 PUMP DEVICE
1. REMOVAL AND INSTALL

1) REMOVAL
(1) Lower the work equipment to the ground
and stop the engine.
(2) Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious in
injury.
(3) Loosen the drain plug under the hydraulic
tank and drain the oil from the hydraulic
tank.
Hydraulic tank quantity : 270
(4) Remove bolts(12) and disconnect
pipe(1,2)
(5) Disconnect pilot line hoses(4,5,6,7,8,9,10)
(6) Remove bolts(11) 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.
(7) Sling the pump assembly and remove the
pump mounting bolts.
Weight : 155 kg (342 lb)
Pull out the pump assembly from housing.
When removing the pump assembly,
check that all the hoses have been
disconnected.
8-7
2) INSTALL
(1) Carry out installation in the reverse order
to removal
(2) Remove the suction strainer and clean it.
(3) Replace return filter with new.
(4) Remove breather and clean it.
(5) After adding oil to the hydraulic tank to the
specified level.
(6) Bleed the air from the hydraulic pump.
Remove the air vent plug(2EA)
Tighten plug lightly
Start the engine, run at low idling, and
check oil come out from plug.
Tighten plug.
(7) Start the engine, run at low idling (3~5
minutes) to circulate the oil through the
system.
(8) Confirmed the hydraulic oil level and
check the hydraulic oil leak or not.
8-8
2. MAIN PUMP(1/2)
1) STRUCTURE
A
789 532 548 724 792 954
732 214 531 702 534 901 719
535
808
953
886
717
406
261
824
111
774
127
710
123 251 401 211 156 157 114 312 725 314 012 152 113
490 212 153 158 313 124 466 728 151 271
885 468
012 Cylinder block 313 Valve plate(R) 710 O-ring

111 Drive shaft(F) 314 Valve plate(L) 717 O-ring
113 Drive shaft(R) 325 Valve casing 719 O-ring
114 Spline 401 Hexagon socket bolt 724 O-ring
123 Roller bearing 406 Hexagon socket bolt 725 O-ring
124 Needle bearing 407 Hexagon socket bolt 728 O-ring
127 Bearing spacer 466 VP Plug 732 O-ring
151 Piston 468 VP Plug 774 Oil seal
152 Shoe 490 VP Plug 789 Back up ring
153 Push plate 531 Tilting pin 792 Back up ring
156 Bushing 532 Servo piston 808 Hexagon head nut
157 Cylinder spring 534 Stopper(L) 824 Snap ring
158 Spacer 535 Stopper(S) 885 Pin
211 Shoe plate 541 Seat 886 Spring pin
212 Swash plate 542 Spacer 901 Eye bolt
214 Bushing 543 Stopper 1 953 Hexagon socket screw
251 Support plate 544 Stopper 2 954 Set screw
261 Seal cover(F) 545 Steel ball 981 Name plate
271 Pump casing 548 Pin 983 Pin
312 Valve block 702 O-ring
8-9
MAIN PUMP(2/2)
544
543
080
545 725 325
541
466
725
490 407 725 732

B
VIEW A VIEW B
079 Proportional reducing valve 490 Plug 545 Steel ball

325 Valve casing 541 Seat 725 O-ring
407 Hexagon socket bolt 543 Stopper 1 732 O-ring
466 Plug 544 Stopper 2
8-10
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
Tool name & size Part name
Hexagon socket PT plug PO plug Hexagon socket

Name B
head bolt (PT thread) (PF thread) head set screw
Allen wrench 4 M 5 BP-1/16 M 8
5 M 6 BP-1/ 8 M10
6 M 8 BP-1/ 4 PO-1/4 M12, M14
B
8 M10 BP-3/ 8 PO-3/8 M16, M18
17 M20, M22 BP-1 PO-1, 1 1/4, 1 1/2
Double ring spanner, socket Hexagon Headed VP plug
wrench, double(single) open bolt Hexagon nut (PF thread)
end spanner
19 M12 M12 VP-1/4
B 24 M16 M16
27 M18 M18 VP-1/2
30 M20 M20
36 VP-3/4
Adjustable angle wrench Medium size, 1 set
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-160
Steel bar Steel bar of key material approx. 10x8x200
Torque wrench Capable of tightening with the specified torques.
8-11
(2) Tightening torque
Tightening 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 16.0 115.7 0.47 12
M16 24.0 173.6 0.55 14
M18 34.0 245.9 0.55 14
M20 44.0 318.3 0.67 17
PT plug(Material : S45C) PT 1/16 0.7 5.1 0.16 4
Wind a seal taped 1 1/2 to PT 1/8 1.05 7.59 0.20 5
2 turns round the plug PT 1/4 1.75 12.66 0.24 6
PT 3/8 3.5 25.3 0.31 8
PT 1/2 5.0 36.2 0.39 10
PF plug(Material : S45C) PF 1/4 3.0 21.7 0.24 6
PF 1/2 10.0 72.3 0.39 10
PF 3/4 15.0 108.5 0.55 14
PF 1 19.0 137.4 0.67 17
PF 1 1/4 27.0 195.3 0.67 17
PF 1 1/2 28.0 202.5 0.67 17
8-12
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.
Remove hexagon socket head bolts (416)

and remove gear pump.
(5) Loosen hexagon socket head bolts(401)

which tighten swash plate support(251),
pump casing(271) and valve block(312).
(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.
8-13
(7) Pull cylinder(012) 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.
(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)
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.
(11) Remove shoe plate(211)and swash

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

valve block(312).
These may be removed in work 6.
(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.
8-15
4) ASSEMBLY
(1) For reassembling reverse the
disassembling procedures, paying
attention to the following items.
Do not fail to repair the parts damaged
during disassembling, and prepare
replacement parts in advance.
Clean each part fully with cleaning oil and
dry it with compressed air.
Do not fail to apply clean working oil to
sliding sections, bearings, etc. before
assembling them.
In principle, replace seal parts, such as
O-rings, oil seals, etc.
For fitting bolts, plug, etc., prepare a
torque wrench or so on, and tighten them
with torques shown in Section 2-3.
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
and feedback pin from being damaged.
In addition, apply lock-tight (medium
strength) to their threaded sections.
8-16
(3) Place pump casing with its regulator fitting
surface down, fit tilting bush of swash
plate to tilting pin (531), and fit swash plate
(212) to swash plate support (251)
correctly.
Confirm with fingers of both hands that
swash plate can be removed smoothly.
Apply grease to sliding sections of swash
plate and swash plate support, and drive
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.
(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.
(6) Assemble piston cylinder subassembly

cylinder (012), 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.
8-17
(7) Fit valve plate (313) to valve block (312),
entering pin in to pin hole.
Take care not to mistake suction / delivery
directions of valve plate.
(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 and with
delivery flange left, 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.
(10) Fit drain port plug (468).

This is the end of reassembling procedures.
8-18
3. REGULATOR
1) STRUCTURE(1/2)
412 875 874 755

A 858
897 B 614
612
615
613
A 611
B
A KR3H-9N69
P2
Pf
438
801 Pi
924
641 730 643 708 644 645 646 728
SECTION B-B B
413 438
438
656
735 Pi
722
496 724 725 436
VIEW C
8-19
REGULATOR(2/2)
734 653 654 836 651 652 601 624 629 630 628
655
641 801
925
814
898
631 627
732
C
733
732
622
621 623 625 626 887 763 756
SECTION A-A
412 Hexagon socket screw 629 Cover(C) 730 O-ring

413 Hexagon socket screw 630 Nut 732 O-ring
436 Hexagon socket screw 631 Sleeve 733 O-ring
438 Hexagon socket screw 641 Pilot cover 734 O-ring
496 Plug 643 Pilot piston 735 O-ring
601 Casing 644 Spring seat(Q) 755 O-ring
611 Feed back lever 645 Adjust stem(Q) 756 O-ring
612 Lever(1) 646 Pilot spring 763 O-ring
613 Lever(2) 651 Sleeve 801 Nut
614 Center plug 652 Spool 814 Snap ring
615 Adjust plug 653 Spring seat 836 Snap ring
621 Compensator Piston 654 Return spring 858 Snap ring
622 Piston case 655 Set spring 874 Pin
623 Compensator rod 656 Block cover 875 Pin
624 Spring seat(C) 708 O-ring 887 Pin
625 Outer spring 722 O-ring 897 Pin
626 Inner spring 724 O-ring 898 Pin
627 Adjust stem(C) 725 O-ring 924 Set screw
628 Adjust screw(C) 728 O-ring 925 Adjust screw(QI)
8-20
(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 set screw
Allen wrench 4 M 5 BP-1/16 M 8
B 5 M 6 BP-1/ 8 M10
6 M 8 BP-1/ 4 PO-1/4 M12, M14
socket wrench, Hexagon Headed VP plug
double(single) open end Hexagon nut
bolt (PF thread)
B
6 M8 M8
Adjustable angle wrench Small size, Max 36mm
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-160
Steel bar Steel bar of key material approx. 10x8x200
Pincers
Bolt M4, Length : 50mm
8-21
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 16.0 115.7 0.47 12
PT plug(Material : S45C) PT 1/16 0.7 5.1 0.16 4
Wind a seal taped 1 1/2 to 2
PT 1/ 8 1.05 7.59 0.20 5
turns round the plug
PT 1/ 4 1.75 12.66 0.24 6
PF plug(Material : S45C) PF 1/ 4 3.0 21.7 0.24 6
8-22
3) DISASSEMBLY
Since the regulator consists of small
precision finished parts, disassembly and
assembly are rather complicated.
For this reason, replacement of a regulator
assembly is recommended, unless there is
a special reason, but in case disassembly is
necessary for an unavoidable reason, read
through this manual to the end before
starting disassembly.
(1) Choose a place for disassembly

Choose a clean place.
Spread rubber sheet, cloth, or so on on
top of work-bench to prevent parts from
being damaged.
(2) Remove dust, rust, etc. from surfaces of
regulator with clean oil.
(3) Remove hexagon socket head screw

(412, 413) and remove regulator main
body from pump main body.
Take care not to lose O-ring.
(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.
8-23
(5) After removing cover (C, 629)
subassembly, take out outer spring (625),
inner spring (626) and spring seat (C, 624)
from compensating section.
Then draw out adjusting ring (Q, 645),
pilot spring (646) and spring seat (644)
from pilot section.
Adjusting ring (Q,645) can easily be drawn
out with M4 bolt.
(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.
(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.
(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.
8-24
(9) Remove lever (2,613). Do not draw out
pin (875).
Work will be promoted by using pincers or
so on.
(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).
8-25
(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 operation.
8-26
4) ASSEMBLY
(1) For assembly, reverse disassembly
procedures, but pay attention to the
following items.
Always repair parts that were scored at
disassembly.
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.
Always tighten bolts, plugs, etc. to their
specified torques.
Do not fail to coat sliding surfaces with
clean hydraulic oil before assembly.
Replace seals such as O-ring with new
ones as a rule.
(2) 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
(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
operation. Lever 1 side Lever 2 side
Take care not to mistake direction of (adjust plug fulcrum
feedback lever. plug side)
(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).
(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.
(10) Fit return spring (654) and spring seat

(653) into spool hole and attach snap ring
(814).
8-28
(11) Fit set spring (655) to spool hole and
put compensating piston (621) and piston
case (622) into compensating hole.
Fit pilot cover (641) and tighten it with
hexagonal socket head screws (436, 438).
(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.
(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.
8-29
GROUP 4 MAIN CONTROL VALVE

1) REMOVAL

penetrate the skin causing serious injury.
When pipes and hoses are disconnected,
(3) Remove bolts and disconnect pipe.
(4) Disconnect pilot line hoses.
(5) Disconnect pilot piping.
(6) Sling the control valve assembly.and
remove the control valve mounting bolt.
weight : 130kg(287lb)
(7) 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.
Cylinder (boom, arm, bucket)
Swing motor
Travel motor
See each item removal and install
recheck the hydraulic oil leak or not.
8-30
2. STRUCTURE(1/2)
13
53
54 14
18 17 12 15 79
2 2 67 16
1 1 7 56
66 8
35
36
38
20 25
19
2
135 28
37 27
46 47 36 38
45 27
48 52
45 8
49 29
51
50 5
56 3 6
79 4
30
29
21
26 14
24
29
22 12 27
44 14
23
42
43 64
41
40 65
8 43
25 39
1 O-ring 22 Plunger assy 44 Spool

2 Back up ring 23 Plunger assy 45 O-ring
3 O-ring 24 Cover 46 Cap
4 Cap 25 Socket bolt 47 Piston
5 Check 26 O-ring 48 Cap
6 Spring 27 O-ring 49 Steel ball
7 Cap 28 Retainer 50 Spring
8 O-ring 29 O-ring 51 Spool
12 O-ring 30 O-ring 52 Foot relief assy
13 Cover assy 35 Nylon chip 53 Socket bolt
14 O-ring 36 Spring 54 Spring washer
15 Spring 37 Check 56 O-ring
16 Poppet 38 Check 64 Check
17 Cap 39 Cap 65 Spring
18 Cap 40 Nut 66 O-ring
19 Cap 41 Spacer 67 Cap
20 Housing 42 Washer 79 Overload relief assy
21 Plunger assy 43 Spring
8-31
STRUCTURE(2/2)
11 72
8 1
10 73
9 74
71
69
70
68
34
75 4 8280
3 28 84
8 27 2583
81
31 85 8
76 87
36 86
77 10
9
62
61
60
43 79
56
8
1
78 2
17
33 38 35
32 36 37 1
2
26 18
24
8 19
50 52 351
51 2
90 63 49
89 59 4745
88 58 48
56 45
34 8 55 57 46
23 11 56
79
25
1 O-ring 36 Spring 70 Spring

2 Back up ring 37 Check 71 Sleeve
3 O-ring 38 Check 72 Cap
4 Cap 45 O-ring 73 Piston
8 O-ring 46 Cap 74 Spring
9 Check 47 Piston 75 Cap
10 Spring 48 Cap 76 Back up ring
11 Cap 49 Steel ball 77 Check
17 Cap 50 Spring 78 Main relief assy
18 Cap 51 Spool 79 Overload relief assy
19 Cap 52 Foot relief assy 80 Cap
23 Plunger assy 55 Cap 81 O-ring
24 Cover 56 O-ring 82 Spring
25 Socket bolt 57 Socket bolt 83 Cap
26 O-ring 58 Flange 84 Spring guide
27 O-ring 59 O-ring 85 Spool
28 Retainer 60 Orifice 86 Sleeve
31 Housing 61 Back up ring 87 Piston
32 Plunger assy 62 O-ring 88 Plug
33 Plunger assy 63 Orifice 89 Back up ring
34 Plunger assy 68 Check 90 O-ring
35 Nylon chip 69 Piston
8-32
3. DISASSEMBLY AND ASSEMBLY
1) PRECAUTION
(1) Disassembly
Handle the components carefully not to
drop them or bump them with each other
as they are made with precision.
Do not force the work by hitting or
twisting as burred or damaged
component may not be assembled or
result in oil leakaged or low performance.
When disassembled, tag the
components for identification so that they
can be re-assembled correctly.
Once disassembled, O-rings and backup
rings are usually not to be used again.
(Remove them using a wire with its end
made like a shoehorn. Be careful not to
damaged the slot.)
If the components are left disassembled
or half-disassembled, they may get rust
from moisture or dust. If the work has to
be interrupted, take measures to prevent
rust and dust.
(2) Assembly
Take the same precautions as for
disassembly.
When assembling the components,
remove any metal chips or foreign
objects and check them for any burrs
or dents. Remove burrs and dents with
oil-stone, if any.
O-rings and backup rings are to be
replaced with new ones, as a rule.
When installing O-rings and backup
rings, be careful not to damage them.
(Apply a little amount of grease for
smoothness.)
Tighten the bolts and caps with specified
torque.
8-33
2) MOUNTING AND DISMOUNTING VALVES
(1) Disassembly 1
3-spool valve( ) can be removed by
loosening socket bolts(1) and (2).
4-plunger valve( ) can be removed by
loosening socket bolt(3).
(2) Assembly
In the reverse manner of disassembly,
reassemble 4-spool valve( ).
Reassemble 3-spool valve( ).
Tighten the bolts to the torque of 15kgf m
(108lbf ft)
Valves should be mounted after making 2 3
sure that all O-rings and check assembly
¥ ¥–
are placed on assembling faces of 4-
plunger valve and that check valve and Tools
spring are placed on assembling faces of Hexagon socket : 12mm
Torque wrench
3-plunger valve.
8-34
3) OPERATING SECTION OF HYDRAULIC PACK
(1) Disassembling
Loosen socket bolt(1) to remove cover
(2).
2 1
Pull the plunger out while holding the
spring.
Do not pull it out violently, but draw it out
gently while making sure of its contact
with HG hole.
Place the plunger between holders and
3 4 5
loosen plunger cap(3) by using a vise.
Remove plunger cap(3), guide(4) and
spring(5) in this order. Tools
Hexagon socket : 8mm
Torque wrench
(2) Assembling
Place the plunger between holders and
clamp the holders with the vise.
Mount guide(4), spring(5) and plunger
cap(3) to the plunger.
Tighten plunger cap(3) at the specified
torque.
Tightening torque : 6kgf m (43.4lbf ft)
Restore the plunger to the valve while
holding the spring section.
Insert the plunger into the valve hole
while turning it slowly so that it is well
aligned with the HG hole. In particular,
be careful not to hit it against the first
round corner.
Install cover(2) after making sure that O-
ring is placed on the edge of the valve
hole and tighten socket bolt(1) with the
specified torque.
Tightening torque : 5kgf m (36.2lbf ft)
8-35
4) ORIFICE ASSEMBLY
(1) Disassembling 1
Remove cap(1).
(2) Assembling
Tighten cap(1) with the specified torque.
Be careful for the backup ring not to
protrude.
Tightening torque : 20kgf m(144.7lbf ft)
Tools
Torque wrench
5) CHECK ASSEMBLY
1
(1) Disassembling
Remove cap(1).
Remove spring(2) and check valve(3).
(2) Assembling
Mount check valve(3) and spring(2) to the 2
valve housing.
Be careful for the backup ring not to 3
protrude.
Tools
Torque wrench
8-36
6) LOAD CHECK ASSEMBLY
1
(1) Disassembling
Remove the cap(1).
Remove check valve(2), spring(3) and
check valve(4).
3 2
(2) Assembling
Mount check valve(4), spring(3) and
check valve(2) to the valve housing.
Tighten cap(1) at the specified torque. 4
Be careful for the backup ring not to
protrude.
Tools
Torque wrench
7) MAIN RELIEF ASSEMBLY

Relief assembly is assembled into a single
block as a cartridge. Do not disassemble 1
the relief assembly as a rule.
(1) Disassembling
Remove the cartridge as it is while
holding cap(1).
(2) Assembling
Install the cartridge and tighten cap(1) at Tools
the specified torque. Hexagon socket : 30mm
Torque wrench
8-37
8) FOOT RELIEF ASSEMBLY
Impossible to adjust the foot relief assembly 1 2
as it is installed to the machine.
Remove the cartridge as it is from the valve
housing. Do not disassemble the cartridge.
(1) Disassembling
Remove the cartridge as it is from the
valve housing while holding cartridge
sleeve(1).
(2) Assembling
Install the cartridge to the valve housing Tools
Hexagon spanner : 30mm
and tighten cap(2) at the specified torque. Hexagon socket : 30mm
Torque wrench
9) RELIEF ASSEMBLY
Relief assembly is assembled into a single 1
block as a cartridge. Do not disassemble
the relief assembly as a rule.
(1) Disassembling
Remove the cartridge as it is while
holding cap(1).
(2) Assembling
Install the cartridge and tighten cap(1) at
Tools
the specified torque. Hexagon socket : 32mm
Tightening torque : 6kgf m(43.4lbf ft) Torque wrench
8-38
10) SELECTOR VALVE ASSEMBLY
(1) Disassembling 1 2 3 4 5 6
Remove cap(6).
Pull the spool out while holding the
spring.
Take the spool with a holder and clamp
the latter with a vise.
Remove hexagonal nut(5), washer(4),
spring(3) and washer(2).
Tools
Hexagon socket : 13, 30mm
(2) Assembling Torque wrench
Hold the spool with the holder and clamp
the latter on the vise.
Mount washer(2), spring(3) and
washer(4) to spool(1).
Mount hexagonal nut(5) and tighten the
outer hex. nut at the specified torque.
Tightening torque : 1.5kgf m(10.8lbf ft)
Restore the spool while holding the
spring.
Tighten cap(6) at the specified torque.
11) CENTER BYPASS SPOOL ASSEMBLY

1
(1) Disassembling
Remove cap(1) to take piston(2) off. 2
Remove cap(3) to take spring(4) and 3
spool(5) off.
(2) Assembling
Mount spring(4) and insert spool(5) into
the valve housing. 4
5
Insert piston(2) into cap(3).
Tools
Torque wrench
8-39
12) LOGIC CHECK ASSEMBLY
(1) Disassembling
Remove cap(1). 7 6 5 4 3 2 1
Take off piston(2) and spring(3).
Extract sleeve(4) with a magnet or the
like.
Take off piston(5), spring(6) and check
valve(7).
(2) Assembling
Mount check valve(7), spring(6) and
piston(5) into the valve housing. Tools
Insert spring(3) and piston(2) into Torque wrench
sleeve(4).
Mount sleeve(4) with spring(3) and
piston(2) to the valve housing.
13) ARM REGENERATION

(1) Disassembling
Remove cap(1). 9 8 7 6 5 4 3 2 1
Take off spring retainer(3) and spring(2).
Remove cap(4).
Take off spool(5), piston(6) and sleeve(7).
Take off spring(8) and check valve(9).
(2) Assembling
Tools
Mount check valve(9) and spring(8) into Hexagon socket : 10mm
the valve housing. Socket : 27mm
Torque wrench
Insert piston(6) and spool(5) into
sleeve(7).
Mount sleeve(7) with piston(6) and
spool(5) to the valve housing.
Mount spring(2) and spring retainer(3) to
the assembly.
8-40
14) BUCKET FLOW SUMMATION CHECK
(1) Disassembling 3 1
2
Remove cap(1).
(2) Assembling
Mount check valve(3) and spring(2) to
the valve housing.
Tools
Torque wrench
15) CHECK ASSEMBLY

(1) Disassembling
1
Remove cap(1).
2
(2) Assembling
Mount check valve(3) and spring(2) to
the valve housing.
Tighten cap(1) at the specified torque. 3
Tools
Torque wrench
8-41
16) INTERNAL PARALLEL CIRCUIT
(1) Disassembling 1 2
Remove cap(1) for 4-plunger valve.
Screw M5 thread in the end extracting tap 4-PLUNGER VALVE
of orifice(2) and extract orifice(2).
Remove cap(5) for 3-plunger valve.
(2) Assembling
Mount check valve(3) for 3-plunger valve 3-PLUNGER VALVE
and spring(4).
Tighten cap(5) at the specified torque. 5 4 3
Mount orifice(2) to 4-plunger valve. Tools
Tighten cap(1) at the specified torque. Torque wrench
17) BOOM THROTTLING CAP

1
(1) Disassembling
Remove cap(1).
(2) Assembling
Tools
Torque wrench
18) LOAD HOLDING VALVE(Basic unit)

1
(1) Disassembling
Loosen socket bolt(1) to remove cover
assembly(2). 2
Take off spring(3) and check valve(4)
(2) Assembling 3
Mount check valve(4) and spring(3) to the 4
valve housing.
Mount cover assembly(2) to the valve
housing and tighten socket bolt(1) at the
specified torque.
Tools
Tightening torque : 10kgf m(72.3lbf ft) Hexagon socket : 10mm
Torque wrench
8-42
19) LOAD HOLDING VALVE(Cover assembly)
(1) Disassembling
8 9 5 6 7
Remove cap(5).
Remove cap(8).
10
Take off piston(9).
Remove cap(10). 11
Extract spring(11) and check valve(12).
12
Push sleeve(13) out with a rod or the like
through the hole of cap(8). 13
Be careful not to damage the guideway
of the sleeve.
Tools
(2) Assembling Hexagon socket : 8, 10mm
Torque wrench
Mount sleeve(13) to the cover.
Mount spring(11) with check valve(12) to
the cover.
Insert piston(9) into the cover.
Tightening cap(8) at the specified torque.
Mount check valve(7) and spring(6).
20) HOLDERS
Put the plunger between holders and clamp
them by a vise after decreasing the plunger
and holders as a special tool.
8-43
GROUP 6 TRAVEL DEVICE

1) REMOVAL
(1) Swing the work equipment 90 and lower it
completely to the ground.
injury.
(3) Remove the track shoe assembly.
For details, see removal of track shoe
assembly
(4) Remove the cover.
(5) Remove the hose.
Fit blind plugs to the disconnected hoses.
(6) Remove the bolts and the sprocket.
(7) Sling travel device assembly (1).
(8) Remove the mounting bolts (2), then
remove the travel device assembly.
Weight : 410kg(904lb)
2) INSTALL
to removal
(2) Bleed the air from the travel motor.
Remove the air vent plug.
Pour in hydraulic oil until it over flows from
the port.
Tighten plug lightly.
Start the engine, run at low idling, and
check oil come out from plug.
Tighten plug fully.
8-61
2. TRAVEL MOTOR
1) STRUCTURE(1/2)
111 742 741 709 707 702 708 461 545 547 472 705 461 303
121
568
123
567
122
116
131
202
452 568
113 567
272
107 464
485
101
491 103
304 451
435 507
471
102 506
105 505
506 511
507
504
510
509 461 501 114 201 502 503 508 512 546 509 461 533 531 572 571
101 Drive shaft 304 Seal cover 510 Back up ring

102 Roller bearing 435 Snap ring 511 O-ring
103 Needle bearing 451 Pin 2 512 Back up ring
106 Bearing spacer 452 Pin 1 531 Tilting spool
107 Snap ring 461 Plug 533 Tilting spring
111 Cylinder block 471 O-ring 545 Orifice
113 Spherical bushing 472 O-ring 546 Orifice
114 Cylinder spring 491 Oil seal 547 O-ring
116 Spacer 501 Tilting piston 571 Plug
121 Piston 502 Tilting piston 1 572 O-ring
122 Shoe 503 Stopper 705 Brake piston
123 Set plate 504 Stopper S 707 Piston ring 252
131 Valve plate 505 Tilting rod 708 Piston ring 278
201 Swash plate 506 Hex socket screw 709 Center pin
202 Swash plate support 507 Nut 741 Separator plate
272 Casing A 508 O-ring 742 Friction plate
303 Valve casing 509 O-ring
8-62
STRUCTURE(2/2)
362 022 361 402
366
364
365
711 712
485 713
464
710
350
E
714
702
Section E- E
E
401
567
568
541 543 542 567 568
022 C/B Spool sub assy 402 Hex socket screw 568 O - ring
350 Relief valve 464 VP plug 702 Brake piston
361 Washer 485 O - ring 710 Spring guide
362 C/B spring 541 Seat 711 Spool
364 C/B cover 542 Stopper 712 Bushing
365 O - ring 543 Steel ball 713 Spring
366 Hex socket screw 567 VP plug 714 RO plug
401 Hex socket screw
8-63
(1) Tools
Tool name Remark

Allen wrench 4
6 B
8
10
14
Socket for socket wrench, spanner 24
27
Pliers
( ) Driver 6 100
Plastic and iron hammer Wooden hammer allowed. Nominal 1 or so
Steel rod approx 7 7 200mm
Monkey wrench
Oil seal inserting jig
Bearing pliers
Seal tape
Torque Wrench size

Part name Item Size
kgf m lbf ft in mm
Plug 461 NPTF 1/16 0.7~1.1 5.1~8.0 0.16 4
Socket head bolt 366 M 12 45 10 72.3 0.39 10
VP Plug 464 PF 1/2 11 79.6 1.06 27
Plug 571 PF 3/8 7.5 54.2 0.31 8
Orifice 545, 546 NPTF 1/16 0.7 5.1 0.16 4
Socket head screw 401 M 16 50 24 173.6 0.55 14
RO Plug 567 PF 1/4 3.7 26.8 0.24 6
Socket head screw 402 M16 120 24 173.6 0.55 14
Hexagon nut 507 M 16 16 115.7 0.94 24
RO plug 714 PF 3/8 7.5 54.2 0.31 8
8-64
3. TRAVEL REDUCTION GEAR
1) STRUCTURE
30 6 27 7 1 31
4
26
46
11
5
45
10
24
32
42
9
25
12
21
15
44
19
18
36
32
16
20 41 22 13 20 36 17 14 23 20 37 8 35 33 2 29 34
1 Ring gear 16 Pin 2 31 Hex screw

2 Housing 17 Pin 3 32 Plug
4 Side cover 18 Side plate 33 Angular bearing
5 Carrier 1 19 Side plate 34 Floating seal
6 Carrier 2 20 Side plate 35 Shim
7 Carrier 3 21 Needle case 36 Spring pin
8 Bearing retainer 22 Needle case 37 Spring pin
9 Sun gear 1 23 Needle case 41 Set screw
10 Sun gear 2 24 Thrust ring 42 Shim
11 Sun gear 3 25 Thrust ring 44 Snap ring
12 Planetary gear 1 26 Thrust ring 45 Clip
13 Planetary gear 2 27 Shim 46 W clip
14 Planetary gear 3 29 Hex socket screw
15 Pin 1 30 Hex socket screw
8-65
(1) Tools
Tool name Remark

Allen wrench 5
B
8
10
17
Socket for socket wrench 19
Spanner 27
Pliers For shaft
( ) Driver 6 100, For removing floating seal
Hammer Steel and plastic
Eye bolt M10, M20, For lifting-up
Press(1 ton)
Depth gauge straight edge 100mm depth
Taps M 20, M 12
Oil stone
Seal tape
Screw lock Three bond 1303B
Liquid packing Three bond 1104
Bearing assembling jig
Torque Wrench size

Part name Item Size
kgf m lbf ft in mm
Socket head screw 29 M 20 100 55 397.8 0.67 17
30 M10 35 6.7 48.5 0.31 8
To the exlent their
41 M10 30 0.20 5
bottom is touched.
Hexagon head bolt 31 M12 30 11.5 83.2 0.75 19
8-66
4. DISASSEMBLING
1) GENERAL PRECAUTIONS
(1) Pay attention to not damaging contact surfaces for O-ring, oil seals, etc. and contact/sliding
surfaces for gears, pins, bearings, etc.
(2) This motor can be disassembled even in a state fitted on a machine.
However, in that case, pay full attention to preventing mud, dust, etc. from entering in it.
(3) The numeral in parentheses following each part name indicates its part number shown in the
attached assembly drawings.
(4) The piping side of the motor is referred to as the rear side and the output side, as the front side.
8-67
2) DISASSEMBLY OF REDUCTION GEAR
(1) Select a disassembling place.
Select a clean place.
Spread rubber sheet or cloth on work
bench to prevent parts from being
damaged.
(2) Remove dust, mud, etc. from reduction
gear surfaces with washing oil or so.
(3) Place reduction gear with its gear oil drain
port or level gage at the lowest position,
and drain reduction gear of oil.
Receive gear oil with clean vessel and
check it for abnormalities.
Renew gear oil.
(4) Place reduction gear with its side cover

(004) up, remove hexagon socket head
cap screws(030), and remove cover.
Screw hexagon socket headless set

screws(041) to lift side cover from ring
gear(001), and it can be removed easily.
Screw M10 screws into removing rapped
hole and bring up cover.
8-68
(5) Remove sun gear 1(9).
(6) Remove carrier 1(5) together with

planetary gears 1(12), sun gear 2(10), etc.
fitted.
(7) Disassembling of carrier 1 sub-

assembly
Remove retaining ring(44), and then
remove side plate(19), planetary gear 1
(12), needle bearing(21), and side
plate(18).
Remove circlip(45), and then remove

carrier 1(5) from sun gear 2(10).
Remove thrust ring(24).
If flaking is observed on the surface of pin
1, replace pin 1/carrier 1 as a set. In this
case, replace planetary gear 1 and
needle bearing simultaneously.
8-69
(8) Remove carrier 2(6), with planetary gears
2(13), sun gear 3(11), etc. fitted.
Use M10 eyebolt. In this case, thrust
ring(26) is removed simultaneously.
(9) Disassembling of carrier 2 sub-

assembly
Push in spring pin(36), and remove pin
2(16), from carrier 2.
Remove side plate(20), planetary gear
2(13), and needle bearing(22) from
carrier 2.
Remove thrust ring(26).
Remove retaining ring(46), and remove
carrier 2(6) from sun gear 3(11).
Carry out the following check in advance.
If any abnormality should be found, carry
out disassembling.
Is there any crevice, crack or pitting on
tooth surface of planetary gear?
When turning planetary gear lightly, is
there any abnormal noise or eccentric
clearance?
Carry out check similarly to the above
for carrier 3.
Remove thrust ring(25) from sun gear 3.
8-70
(14) Screw two M10 eyebolts on front side of
ring gear(1), lift up ring gear, housing(2),
angular bearing(33) and floating seal(34)
from casing(272).
When it is difficult to separate them, hung
the whole a little above bench and hit end
face of casing slightly with plastic hammer
or so to separate them.
(15) Place ring gear(1) with its front part down.

Pay attention O-ring and sheet faces.
(16) Remove floating seal(34) from housing

(2), paying attention to not damaging it.
Pay attention to O-ring and sheet races.
(17) Remove floating seal(34) from casing

(272), pay attention to not damaging it.
Pay attention to O-ring and sheet faces.
8-72
(18) Loosen hexagon socket head cap
screws(29) that connect ring gear(1) and
housing(2).
In this case, in order to prevent ring gear
from turning, screw bolt to front side and
lock it to the work bench.
(19) Lift up housing(2) with crane with its ring

gear(1) up, and hit upper face of housing
with steel bar and hammer to separate
them.
(20) Remove angular bearing(33) from

housing(2).
Bearing should be removed once it is
removed.
Remove bearing inner race by pushing it
with press or by hitting it with hammer,
utilizing jig.
8-73
3) DISASSEMBLY OF MOTOR
(1) Disassembling of motor main body
Place hydraulic motor on bench with its
output shaft up.
Don't touch hexagon nut(507) and
hexagon socket headless set screw
(506) with hand, since this may change
adjusted flow valve.
Remove locking nut(435) with pliers.
Screw M4 to seal cover(304) and remove

it.
Fix hydraulic motor with its output shaft
down.
Loosen relief valve, plug, etc. that are

fitted to valve casing(303).
8-74
Loosen hexagon socket head bolts(401,
402) that assemble valve casing(303).
Remove the above hexagon socket head

cap screws, and then separate valve
casing sub-assembly and remove valve
plate(131).
Remove brake springs(705), screw M16

bolt to brake piston(702), and remove it.
Ten pieces of brake springs are provided.
8-75
Pull out cylinder and piston sub-
assembly.
For easy operation, place motor in
horizontal position.
Remove stopper L(503) and piston(501).

Use M5 bolt and they can be removed
easily.
Remove swash plate(201).
Screw M12 bolt to swash plate

supporter(202) and pull it out.
8-76
Pull out piston(501) and stopper S (504).
Hit front side end face of shaft(101) lightly

with plastic hammer or so to remove
casing(272).
Don't remove cylindrical roller bearing
(102) as far as it remains normal.
(2) Disassembling of valve casing sub-

assembly
Remove rod(505), spring(533), and
spool(531).
Don't touch hexagon nut(507) and
hexagon socket headless set screw(506)
with hand, since this may change
adjusted flow valve.
8-77
(3) Disassembling of motor main body
Remove hexagon socket head cap
screw(366) and cover(364), and then
remove counterbalance spool(360) sub-
assembly.
When any abnormality is found in
counterbalance spool, counterbalance
spring, etc. replace counterbalance
spool sub-assembly as a set.
Remove relief valve sub-assembly(350).

Don't remove needle bearing(103) as for
as it remains normal.
Remove ROplug(567) and remove check

valve sub-assembly.
When no abnormality is found in
displacement changeover, it is not
necessary to overhaul it specifically.
8-78
(4) Disassembling of cylinder sub-assembly
Pull out set plate(123), piston(121), and
shoe(122) sub-assembly.
Remove friction plate(742) and separator

plate(741) from cylinder block(111).
Remove spherical bush(113), spacer
(116) and cylinder spring(114).
That is all of the disassembling work.

The pins(451, 452, 709) force-fitted to the
valve casing and casing cannot be
removed.
8-79
5. ASSEMBLING
1) GENERAL CAUTIONS
(1) Clean each part fully with washing oil and dry it by blasting compressed air. It is better not to use
waste cloths as much as possible.
However, if they are to be used, use clean ones, and pay attention to not leaving lint and so on.
Don't clean the friction plate with washing oil without fail.
(2) Use the torque wrench in tightening fitting screws and plugs to their respective torque shown in
Table 6.
(3) When hammering is required, use the plastic hammer and try to hit parts lightly.
(4) Similarly to the disassembling procedures, the numeral in parentheses following each part name
indicates its part number shown in the attached assembly drawings.
8-80
2) ASSEMBLY OF MOTOR
(1) Assembling driving shaft sub-assembly
Put bearing spacer(106) on shaft(101),
and assemble cylindrical roller
bearing(102).
Interference-fit cylindrical roller bearing.
Pay attention to not damaging oil seal
sliding area of driving shaft.
Fit retaining ring(107) with pliers.

Pay attention to not fitting retaining ring
the other way around.
(2) Assembling of valve casing sub-

assembly
Tighten plugs(461) into valve casing(303)
with specified torque.
Tighten them in five positions.
Interference-fit pin(451).
Interference-fit needle bearing(103).
Assemble seat(541), steel ball(543),

stopper(542) and ROplug(567) in the
order named.
Pay attention to not assembling seat and
stopper the other way around.
8-81
Mount relief valve sub-assembly(350).
Assemble counterbalance spool(360),

washer(361), spring(362) and bush(363)
in the order named.
Fit cover(364) by tightening hexagon

socket head cap screws(366).
Confirm that O-ring(365) has been
inserted in cover.
Fit hexagon socket headless set

screw(506) and hexagon nut(507).
When newly assembled, flow should be
adjusted.
8-82
Assemble spool(531), spring(533) and
plug(571).
Assemble rod(505).
Confirm that O ring(511) has been
fitted.
(3)
Assembling of cylinder sub-assembly
Fit cylinder spring(114), spacer(116), and
spherical bush(113) to cylinder(111).
Match spline phase of cylinder to that of
spherical bush.
Fit friction plate(742) and separator

plate(741) into cylinder.
8-83
Put piston(121) / shoe(122) sub-
assembly in seal plate(123) and then
assemble them to cylinder.
(4) Assembling of seal cover sub-assembly

Interference-fit oil seal(491).
Pay attention to not damaging lip of oil
seal.
Assemble O ring(471).
(5) Assembling of motor main body

Tighten plugs(461) into casing(272) to
specified torque.
Tighten them in five positions.
Interference-fit pins(452, 709).
Interference-fit the shaft sub-assembly.

Interference-fit outer race of cylindrical
roller bearing(102) by hitting lightly with
hammer, utilizing key.
8-84
Assembly swash plate supporter (202),
utilizing M12 screws.
Pay attention to not fitting swash plate
supporter the other way around.
Assembling stopper S(504) and piston

(501).
Fit O ring(509) and back-up ring(510) to
stopper.
Pay attention to not fitting stopper the
other way around.
Assemble swash plate(201) onto swash

plate supporter.
Apply grease on sliding area of swash
plate rear surface.
Confirm with finger tips of both hands if
swash plate moves smoothly.
Assemble piston(501) and stopper L

(503).
8-85
Change position of casing(272) from
vertical one to horizontal one.
Pay attention to not dropping swash
plate.
Mount cylinder sub-assembly.

Mate hole of separator plate to pin.
Change position of casing(272) from

horizontal one to vertical one.
Fit piston ring 252(707) and piston ring

278(708) to brake piston(702).
Assemble break piston into casing.

Pay attention to not fitting brake piston
the other way around.
Assemble break spring(705).
8-86
Assemble orifices(545, 546) and tighten
them to specified torque.
They are provided in three positions.
Fit O-rings(547) without fail.
Fit piston ring 252(707) and piston ring

278(708) to brake piston(702).
Fit valve plate(131) to valve casing(303),

assemble them to casing, and then
tighten them with hexagon socket head
cap screws(401, 402).
Apply grease on valve plate rear surface
and pay attention to not dropping valve
plate.
Use crane in assembling valve casing to

casing.
8-87
Tighten to specified torque plugs, relief
valve, etc. fitted to valve casing sub-
assembly.
Mount seal cover sub-assembly.
8-88
3) ASSEMBLY OF REDUCTION GEAR
(1) Place housing(2) with its front side up, and
fit angular bearings(33) with their back
faces mated.
Fit angular bearings one by one with press
or key hammer.
Push outer race side only without fail.
(2) Place ring gear(1) with its rear side up,

degrease and dry mating faces, and then
apply liquid packing to them uniformly.
When ring gear is to be reused, remove
screw lock of its tapped holes with M20
tap.
(3) Screw M20 eyebolt to housing, lift it up

with crane, and place it on ring gear,
mating their respective thread holes.
(4) Apply screw lock to hexagon socket head

cap screws(29) and tighten them to
specified torque with torque wrench.
Degrease and dry tapped hole of ring gear
and screw in advance.
Before tightening screws, lock ring gear.
8-89
(5) Fit O-ring to floating seal(34) with out
twisting it, and then to housing(2).
Apply grease to O-ring thinly.
(6) Similarly, fit floating seal to casing(272) of

hydraulic motor.
(7) Lift up drum sub-assembly assembled in

Items 1 through 5 with its floating seal side
down, and put inner diameter of angular
bearing on outer diameter of casing.
Pay attention to not damaging sliding
faces of floating seal.
(8) Place jig on inner race of angular bearing

and push it down with press until end face
of inner race touches shoulder of casing
firmly.
When press is not available, place drum
assembly jig on inner race and tighten
long M12 screws to push down bearing
until it touches shoulder.
8-90
(9) With bearing pushed down, measure level
difference between bearing end face of
front side and casing mating face with
depth gage.
This dimension is referred to as a
(10) Measure level difference of bearing

retainer(008).
This dimension is referred to as b
(11) Calculate thickness of shim with the

following formula and select shim of this
thickness.
= b - a - (-0.05 to 0.1)
Bearing is to have from pre-compression
of 0.05mm to clearance of 0.1mm axially.
(12) Remove jig and place above-selected

shim(035) on inner race of angular
bearing(033).
8-91
(13) Place bearing retainer(008) on the above,
apply screw lock on hexagon head
bolt(031), and tighten it to specified torque.
Degrease and dry tapped hole of casing
and screw in advance.
(14) Assembling of carrier 3 sub-assembly

Place carrier 3 with its spline side down.
Put needle bearings(23) into inside of
carrier 3, holding them between side
plates(20).
Insert No.3 pin(17) into carrier 3.
Drive spring pins(37) into pin holes of
carrier 3 and pins 3, and punch at two
points as shown in right figure to lock it.
Mate pin hole of carrier with center of
planetary gear.
Mate spring pin holes of them with each
other.
Punching
(15) Screw two M10 eyebolts into carrier 3

sub-assembly and assemble it with crane,
paying attention to its meshing with
planetary gear 3 and ring gear.
Spline-couple carrier 3 and casing(272) so
that their relative position will be as shown
in the following figure.
Pin 3 center
Oil level Motor flange face
8-92
(16) Assembling carrier 2 sub-assembly
Assemble thrust ring(25) to sun gear
3(11).
Assembling carrier 2(6) to sun gear 3(11),
and fit retaining ring.
Place carrier 2 with sun gear 3 up.

planetary gear 2(13), and insert them into
carrier 2, holding them between side
plates(20).
Mate pin hole of carrier with center of

planetary gear.
Insert pins 2(16) into carrier 2.

carrier 2 and pin 2, and punch at two
points as shown in right figure to lock it.
Assemble thrust ring(26) to carrier 2(6).
Turn over carrier 2 and place it with sun
gear 3 down.
other.
(17) Screw two M10 eyebolts into carrier 2

sub-assembly, and assemble it with crane,
paying attention to its meshing with
planetary gear 2 and ring gear.
8-93
(18) Assembling of carrier 1 sub-assembly
Interference-fit pins 1(15) to carrier 1(5).
carrier 1 and pin 1, and punch at two
points similarly to items (14), and (16),
to lock it.
other.
Assemble carrier 1(5) to sun gear 2(10),

and fit retaining ring(45).
Assemble thrust ring(24) to sun gear
2(10).

planetary gear 1(12), and assemble
them, holding them between side plate
50A(18) at rear side and side plate
50B(19) at front side.
Then fit retaining ring(44) on them.
(19) Assemble carrier 1

Sub-assembly, paying attention to its
meshing with planetary gear 2 and sun
gear 2.
8-94
(20) Assemble sun gear 1(9), paying attention
to its meshing with motor shaft spline
planetary gear 1.
(21) Measure height H from side cover(004)

mating face to ring gear(001) mating face
with straight edge and depth gage.
(22) Measure height L from side cover(004)

mating face to center hold bottom with
straight edge and depth gage.
(23) Measure thrust ring(024) thickness t with

vernier calipers, and obtain optimum shim
thickness with the following formula.
H t (1.5 to 2) L
Keep axial clearance between sun gear
and thrust plate 1.5 to 2mm.
(24) Place shim of above-selected thickness to

center of side cover(004), and upon it
force-drive thrust rings(024) with plastic
hammer.
(25) Degrease and dry mating faces of ring

gear, and then apply liquid packing to
them uniformly.
8-95
(26) Degrease and dry also mating faces of
side cover. Then lift it up, utilizing M10
eyebolt, and place it on ring gear.
In this case, mesh side cover ring gear
and planetary gear 1, and also mate their
thread holes with each other.
(27) Tighten hexagon socket head cap

screws(30) to specified torque to fix side
cover.
(28) Wind seal tape round plugs(32) and
tighten them to side cover(4) to specified
torque.
(29) Screw hexagon socket headless set

screws(41) to tapped hole for pulling- out,
until they touch hole bottom.
That is all of the assembling work. After

fitting the motor this reduction gear, supply
oil until overflows from the level gage.
8-96
GROUP 7 RCV LEVER

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

1
(6) Remove the pilot valve assembly(1, 2).
Weight 4.8kg 2EA(11lb)
When removing the pilot valve assembly, 4
check that all the hoses have been
disconnected.
2) INSTALL
3
to removal.
2
8-97
1) STRUCTURE(RH)
451
402
421
422
453
454
452
401
455
431
458
411 456
457 412
413
501
323
301
459 315
302
312
213
212
211
151
214
215
121
125 216
241
217
221
201
126
101
122
111
8-98
101 Casing 216 Spring seat 421 Screw 2
111 Port plate 217 Washer 2 422 Nut
121 Seal washer 221 Spring 431 Screw 3
122 O-ring 241 Spring 451 Roller
125 Hexagon socket bolt 301 Joint 452 Lever
126 Spring pin 302 Plate 453 Switch seat 1
131 Bushing 312 Adjusting nut 454 Switch seat 2
151 Plate 315 Lock nut 455 Switch
201 Spool 323 Handle bar 456 Cord
211 Plug 401 Handle 457 Bushing
212 Push rod 402 Handle cap 458 Tube
213 Seal 411 Screw 1l 459 Terminal
214 O-ring 412 Nut 501 Bellows
215 Washer 1 413 Washer
8-99
2) STRUCTURE(LH)
451
402
421
422
453
454
452
401
455
431
458
411 456
457 412
413
501
323
301
459 315
302
312
213
212
211
151
214
215
216
241
121
217
125
221
201
126
101
122
292
293
294
111 291
8-100
101 Casing 221 Spring 421 Screw 2
111 Port plate 241 Spring 422 Nut
121 Seal washer 291 Seat 431 Screw 3
122 O-ring 292 Steel ball 451 Roller
125 Hexagon socket bolt 293 Plug 452 Lever
126 Spring pin 294 O-ring 453 Switch seat 1
131 Bushing 301 Joint 454 Switch seat 2
151 Plate 302 Plate 455 Switch
201 Spool 312 Adjusting nut 456 Cord
211 Plug 315 Lock nut 457 Bushing
212 Push rod 323 Handle bar 458 Tube
213 Seal 401 Handle 459 Terminal
214 O-ring 402 Handle cap 471 Insulation cap
215 Washer 1 411 Screw 1 472 Rubber tube
216 Spring seat 412 Nut 501 Bellows
217 Washer 2 413 Washer
8-101
(1) Tools
Tool name Remark
Allen wrench 6 B
Spanner 22
27
( + ) Driver Length 150
( - ) Driver width 4 ~ 5
Torque
Part name Item Size
kgf m lbf ft
Port plate 111 PF 1/4 0.37 2.7
Socket head bolt 125 M8 3.0 0.3 21.7 2.2
Joint 301 M 14 3.5 0.25 25.3 1.8
Adjusting nut 312 M 14 5.0 0.35 36.2 2.5
Lock nut 315 M 14 5.2 0.35 36.2 2.5
Screw 1 411 M4 0.05 0.36
Screw 2 421 M4 0.01 0.07
Screw 3 431 M5 0.09 0.01 0.65 0.07
Plug(For LH) 293 M 12 1.1 0.1 7.96 0.7
8-102
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 bellows(501) from casing

(101) and take it out upwards.
For valve with switch, remove cord(456)

also through hole of casing.
(4) Loosen lock nut(315) and adjusting nut

(312) with spanners on them respectively,
and take out handle section as one body.
8-103
(5) Loosen adjusting nut(312) and disk(302)
with spanners on them respectively, and
remove them.
(6) Turn joint anticlockwise to loosen it,

utilizing jig (special tool).
When return spring(221) is strong in
force, plate(151), plug(211) and push
rod(212) will come up on loosening joint.
Pay attention to this.
8-104
(7) Remove plate(151).
(8) When return spring(221) is weak in force,

plug(211) 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(221) force.
Pay attention to this.
(9) Remove reducing valve subassembly

and return spring(221) out of casing.
Record relative position of reducing valve
subassembly and return springs.
(10) Loosen hexagon socket head cap screws

with hexagon socket screw key.
8-105
(11) Remove port plate(111) and O-ring(122)
out of casing.
(12) Take out bushing(131) from casing.
(13) For disassembling reducing valve section,

stand it vertically with spool(201) bottom
placed on flat workbench.
Push down spring seat(216) and remove
two pieces of semicircular washers1(215)
with tip of small minus screwdriver.
Pay attention not to damage spool
surface.
Do not push down spring seat more than
6mm.
(14) Separate spool(201), spring seat(216),

spring(241) and washer 2(217)
individually.
Until being assembled, they should be
handled as one subassembly group.
8-106
(15) Take push rod(212) out of plug(211).
(16) Remove O-ring(214) and seal(213) from

plug(211).
Use small minus screwdriver or so on to
remove this seal.
(17) Remove lock nut(315) and then bellows

(501).
8-107
(18) Remove handle cap(402).
For valve without switch, remove
cap(403), too.
(19) Loosen machine screw 2(421) with plus

screwdriver and remove it together with
nut(422).
For valve with 2-point switch, roller(451)
can be taken out.
(20) Loosen machine screws 3 & 1(431, 411)

with plus screwdriver and remove
machine screw 1, nut(412) and plain
washer(413).
8-108
(21) Disassemble handle(401) into two.
For valve with switch, switch lever (452),
switch(455) and switch seats 1 & 2(453,
454) can be taken out.
(22) Cleaning of parts

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.
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.
(23) 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.
8-109
4) ASSEMBLY
(1) Assemble bushing(131) and O-ring(122)
into casing(101).
(2) Fit port plate to casing(101) with hexagon

socket head cap screws(125) and seal
washers(121).
Keep such assembling position that
spring pin(126) can enter into casing hole.
8-110
(3) Tighten hexagon socket head cap
screws(125) to the specified torque.
Tighten two bolts alternately and slowly.
(4) Put washer 2(217), spring(241) and

spring seat(216) onto spool(201) in this
order.
(5) Stand spool vertically with its bottom

placed on flat workbench, and with
spring seat pushed down, put two pieces
of semicircular washers 1(215) on spring
seat without piling them on.
Assemble washer 1(215) so that its
sharp edge side will be caught by head of
spool.
Do not push down spring seat more than
6mm.
(6) Assemble spring(221) into casing.

Assemble reducing valve subassembly
into casing.
Assemble them to their original positions.
8-111
(7) Assemble O-ring(214) onto plug(211).
(8) Assemble seal(213) to plug(211).

Assemble seal in such lip direction as
shown below.
(9) Assemble push rod(212) to plug(211).

Apply working oil on push-rod surface.
(10) Assemble plug subassembly to casing.

When return spring is weak in force,
subassembly stops due to resistance of
O-ring.
8-112
(11) When return spring is strong in force,
assemble 4 sets at the same time, utilizing
plate(151), and tighten joint(301)
temporarily.
(12) Fit plate(151).
(13) Tighten joint(301) with the specified

torque to casing, utilizing jig.
(14) Assemble disk(302) to joint(301).

Screw it to position that it contacts with 4
push rods evenly.
Do not screw it over.
8-113
(15) Assemble adjusting nut(312), apply
spanner to width across flat of disk(302) to
fix it, and tighten adjusting nut to the
specified torque.
During tightening, do not change position
of disk.
(16) Tighten machine screw 3(431) to the

specified torque to fix handle bar and
handle.
(17) For valve with switch, assemble parts for

switch to handle.
Pay attention to projections/ depression
for assembling on switch seat, switch,
switch lever, etc.
(18) Assemble remaining handle(401).
8-114
(19) Assemble cap(403) and tighten machine
screw 2(421) and nut(422) to their
specified torques.
For valve with switch, assemble roller
(451) in stead of cap and tighten them.
In this time confirm that the clearance
between roller and handle(401) is 0.5 to
1.5mm.
(20) Tighten remaining machine screws 3

(431) to the specified torque.
(21) Tighten machine screws 1(411), plain

washer(413) and nuts(412) to the
241 TITE
specified torque.
LOC
Apply loctite #241 to threaded sections of

machine screws 1, 2 and 3.
(22) Fit handle cap(402).
8-115
(23) Fit bellows(501) and lock nut(315), and
handle subassembly is assembled
completely.
(24) Pull out cord(456) and tube(458) through

adjusting nut hole provided in direction
60 to 120 from casing hole.
(25) Assemble bushing(457) to plate and pass

cord and tube through it.
Provide margin necessary to operation.
8-116
(26) Determine handle direction, tighten lock
nut(315) to specified torque to fix handle.
(27) Apply grease to rotating section of joint

and contacting faces of disk and push rod.
(28) Assemble lower end of bellows to casing.
(29) Inject volatile rust-preventives through all

ports and then put blind plugs in ports.
8-117
GROUP 8 TURNING JOINT

1) REMOVAL
injury.
(3) Disconnect all hoses .
(4) Sling the turning joint assembly (1) and
remove the mounting bolt(2).
Tightening torque : 29.6kgf m(214.1lbf ft)
1
(5) Remove the turning joint assembly.
When removing the turning joint, check
that all the hoses have been
disconnected.
2) INSTALL
1 2
to removal.
Take care of turning joint direction.
Assemble hoses to their original positions.
Confirmed the hydraulic oil level and
8-118
1) STRUCTURE
3 6 10
14
15
13
9
8
12
11
1 Hub 6 Shim 11 PT Plug

2 Shaft assembly 7 Slipper seal 12 PT Plug
3 Cover 8 O-ring 13 Retainer ring
4 Spacer 9 O-ring 14 Hexagon bolt
5 Shim 10 O-ring 15 Spring washer
8-119
2) DISASSEMBLY
Before the disassembly, clean the turning 14
joint. 15
3
(1) Remove bolts(14), washer(15) and cover
(3).
(2) Remove shim(6) and O-ring(10).

6
(3) Remove retainer ring(13), spacer(4) and
10
shim (5). 13
4
5
(4) Place body(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 body(1) or rest it sideway.
V block
Put a fitting mark on body(1) and
shaft(2). Work bench
(5) Remove six slipper seals(7) and O-ring (9)

from body(1).
9
7
8-120
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) Fit six slipper seal(7) and O-ring(9) to

body(1).
9
(2) Fit O-ring(8) to shaft(2).
7
(3) Set shaft(2) on block, tap body(1) with a

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

(13) to shaft(2). 6
10
(5) Fit O-ring(10) to body(1). 13
(6) Fit shim(6) to shaft(2). 4
5
8-121
(7) Install cover(3) to body(1) and tighten
bolts(14). 14
Torque : 10 ~ 12.5 kgf m 15
3
8-122
GROUP 9 BOOM, ARM AND BUCKET CYLINDER

1) BUCKET CYLINDER
(1) Removal
Ɠ Expand the arm and bucket fully, lower the
work equipment to the ground and stop
the engine.
Ɠ Loosen the breather slowly to release the
injury.
Ɠ Fit blind plugs in the hoses after Bucket cylinder
disconnecting them, to prevent dirt or
dust from entering.
‫ ڸ‬Set block between bucket cylinder and

arm. Arm
Wooden block
‫ ڹ‬Remove nut(3), bolt(2) and pull out pin(1).

Ɠ Tie the rod with wire to prevent it from
coming out.
2
1
3
‫ ں‬Disconnect bucket cylinder hoses(4) and

put plugs on cylinder pipe.
8-123
‫ ڻ‬Sling bucket cylinder assembly, and
remove bolt(6), nut(7) then pull out pin(5). 8
Remove bucket cylinder assembly(8)
‫ ڼ‬şWeight : 268kg(591lb)
7
6
(2) Install
‫ ڸ‬Carry 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.
Ɠ Bleed the air from the bucket cylinder.
Ɠ Confirmed the hydraulic oil level and
8-124
2) ARM CYLINDER
(1) Removal
the engine.
injury.
Ɠ Fit blind plugs in the hoses after
dust from entering. Block
‫ ڸ‬Set block between arm cylinder and

boom.
Arm cylinder
‫ ڹ‬Remove bolt(2), nut(3) and pull out pin(1).

Ɠ Tie the rod with wire to prevent it from
coming out.
2
3
‫ ں‬Disconnect arm cylinder hoses(4) and

put plugs on cylinder pipe. 3
‫ ڻ‬Disconnect greasing hoses(5).
4
8-125
‫ ڼ‬Sling bucket arm assembly(9), and
9
remove bolt(7), nut(8) then pull out pin(6).
‫ ڽ‬Remove arm cylinder assembly(9)
şWeight : 485kg(1069lb)
7
8
(2) Install
‫ ڸ‬Carry out installation in the reverse
order to removal.
pin hole.
Ɠ Bleed the air from the arm cylinder.
Ɠ Confirmed the hydraulic oil level and
8-126
3) BOOM CYLINDER
(1) Removal
the engine.
injury.
Ɠ Fit blind plugs in the hoses after
dust from entering.
‫ ڸ‬Disconnect greasing hoses(1).

‫ ڹ‬Sling boom cylinder assembly. 1
‫ ں‬Remove nut(4), spring(3), pin stopper(5)

4
and pull out pin(2).
Ɠ Tie the rod with wire to prevent it from 2 3
coming out. 5
‫ ڻ‬Lower the boom cylinder assembly(6) on

a stand
8-127
‫ ڼ‬Disconnect boom cylinder hoses(7), and
put plugs on cylinder pipe.
‫ ڽ‬Remove bolt(9), plate(10) then pull out

pin(8).
‫ ھ‬Remove boom cylinder assembly(6)
6 9
şWeight : 293kg(646lb) 10
8
(2) Install
‫ ڸ‬Carry out installation in the reverse
order to removal.
pin hole.
Ɠ Bleed the air from the boom cylinder.
Ɠ Conformed the hydraulic oil level and
8-128
1) STRUCTURE
(1) Bucket cylinder
8,9 10 5,6 7 4 22 33 32 3 11,12 1 2 13 14 15,16 17 18 19 20
Internal detail
29 23,24 25 27,28 26,28 30 33,34
1 Tube assembly 13 Cushion ring 26 Spring washer

2 Rod assembly 14 Piston 27 U-bolt
3 Gland 15 O-ring 28 Hexagon nut
4 Du bushing 16 Back up ring 29 Spring washer
5 Rod seal 17 Piston seal 30 Pipe assembly(B)
6 Back up ring 18 Wear ring 31 Pipe assembly(R)
7 Buffer ring 19 Dust ring 32 O-ring
8 Dust wiper 20 Lock nut 33 Hexagon socket head bolt
9 Snap ring 22 Hexagon socket head bolt 34 Pin bushing
10 Wear ring 23 Band assembly 35 Dust seal
11 O-ring 24 Band
12 Back up ring 25 Hexagon bolt
8-129
(2) Arm cylinder
20,21
8,9 10 5,6 7 4 26 39 38 3 11,12 1 2 13 14 15,16 17 18 19 24 22,23,42
Internal detail
33 29 27,28 30,32 31,32 34 36 38 39,40
1 Tube assembly 15 O-ring 30 Band(R)

2 Rod assembly 16 Back up ring 31 Hexagon bolt
3 Gland 17 Piston seal 32 Spring washer
4 Du bushing 18 Wear ring 33 U-bolt
5 Rod seal 19 Dust ring 34 Hexagon nut
6 Back up ring 20 Cushion spear 35 Spring washer
7 Buffer ring 21 Check valve 36 Pipe assembly(B)
8 Dust wiper 22 Spring 37 Pipe assembly(R)
9 Snap ring 23 Steel ball 38 O-ring
10 Wear ring 24 Lock nut 39 Hexagon socket head bolt
11 O-ring 26 Hexagon socket head bolt 40 Pin bushing
12 Back up ring 27 Band assembly(B) 41 Dust seal
13 Cushion ring 28 Band(B) 42 Set screw
14 Piston 29 Band assembly(R)
8-130
(3) Boom cylinder
8,9 10 5,6 7 4 22 33 32 3 11,12 1 2 13 14 15,16 17 18 19 20
Internal detail
26,27
35,37 31 23,24 25 28,29,30 32 36,38
1 Tube assembly 13 Cushion ring 26 Spring washer

2 Rod assembly 14 Piston 27 U-bolt
3 Gland 15 O-ring 28 Hexagon nut
4 Du bushing 16 Back up ring 29 Spring washer
5 Rod seal 17 Piston seal 30 Pipe assembly(B)
6 Back up ring 18 Wear ring 31 Pipe assembly(R)
7 Buffer ring 19 Dust ring 32 O-ring
8 Dust wiper 20 Lock nut 33 Hexagon socket head bolt
9 Snap ring 22 Hexagon socket head bolt 34 Pin bushing(B)
10 Wear ring 23 Band assembly 35 Pin bushing(R)
11 O-ring 24 Band 36 Dust seal
12 Back up ring 25 Hexagon bolt 37 Dust seal
8-131
(1) Tools
Tool name Remark
8 B
Allen wrench 17
19
Spanner 19
( - ) Driver Small and large sizes
Torque
Part name Item Size
kgfşm lbfşft
Bucket cylinder 22 M22 63Ź7 455.7Ź50.6
Socket head bolt Boom cylinder 22 M22 63Ź7 455.7Ź50.6
Arm cylinder 26 M24 78Ź8 564.2Ź57.9
Bucket cylinder 33 M10 6Ź1 43.4Ź7.2
Socket head bolt Boom cylinder 33 M10 6Ź1 43.4Ź7.2
Arm cylinder 39 M10 6Ź1 43.4Ź7.2
Bucket cylinder 25 M12 5.5Ź0.6 39.8Ź4.3
Hexagon bolt Boom cylinder 25 M12 5.5Ź0.6 39.8Ź4.3
Arm cylinder 31 M12 5.5Ź0.6 39.8Ź4.3
Bucket cylinder 27 M10 3.2Ź0.4 23.1Ź2.9
U-bolt Boom cylinder 27 M10 3.2Ź0.4 23.1Ź2.9
Arm cylinder 33 M10 3.2Ź0.4 23.1Ź2.9
Bucket cylinder 20 M70 150Ź15 1085Ź108.5
Lock nut Boom cylinder 20 M70 150Ź15 1085Ź108.5
Arm cylinder 24 M80 150Ź15 1085Ź108.5
Bucket cylinder 14 - 100Ź10 723.3Ź72.3
Piston Boom cylinder 14 - 100Ź10 723.3Ź72.3
Arm cylinder 14 - 100Ź10 723.3Ź72.3
8-132
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
‫ ڸ‬Hold the clevis section of the tube in a
vise.
Ɠ 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.
‫ ڹ‬Pull out piston rod(2) about 200mm

(7.1in). Because the piston rod is rather
200mm
heavy, finish extending it with air pressure
after the oil draining operation.
‫ ں‬Loosen and remove socket bolts(22) of

the cylinder head in sequence. Hexagon 22
Ɠ Cover the extracted piston rod(2) with rag socket wrench
to prevent it from being accidentally
damaged during operation.
Turn counter
clockwise
Cover here
with rag
2
‫ ڻ‬Draw out cylinder head(3) and piston rod

assembly together from cylinder tube(1).
Ɠ Since the piston rod assembly is heavy in Lift
this case, lift the tip of the piston rod(2)
with a crane or some means and draw it
Full straight
out. However, when piston rod(2) has sideways
been drawn out to approximately two
thirds of its length, lift it in its center to
Oil pan
draw it completely.
8-133
Note that the plated surface of piston
rod(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.
‫ ڼ‬Place the removed piston rod assembly

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

‫ ڸ‬Remove lock nut(20). 13 16 15 14 20
Ɠ Since lock nut(20) is tightened to a high
torque, use a hydraulic and power
wrench that utilizers a hydraulic cylinder,
to remove the lock nut(20).
‫ ڹ‬Remove piston assembly(14), back up
ring(16), O-ring(15) and cushion ring
(13).
‫ ں‬Remove the cylinder head assembly

Plastic
from piston rod(2). hammer
Ɠ If it is too heavy to move, move it by Lift with a crane
striking the flanged part of cylinder head
(3) with a plastic hammer. Pull straight
Ɠ 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 (6,7,8,9)
by the threads of piston rod(2).
8-134
(3) Disassemble the piston assembly
‫ ڸ‬Remove wear ring(18). 19 18 17 18 19
‫ ڹ‬Remove dust ring(19) and piston
seal(17).
Ɠ Exercise care in this operation not to
damage the grooves.
(4) Disassemble cylinder head assembly

‫ ڸ‬Remove back up ring(12) and O-ring (11). 9 8 10 6 5 7 4 11 12
Remove snap ring(9), dust wiper(8) and
‫ ڹ‬wear ring (10).
Remove back up ring(6), rod seal(5) and
‫ ں‬buffer ring(7).
Exercise care in this operation not to
Ɠ damage the grooves.
Do not remove seal and ring, if does not
Ɠ damaged.
8-135
4) ASSEMBLY
(1) Assemble cylinder head assembly
Ɠ Check for scratches or rough surfaces if
found smooth with an oil stone.
‫ ڸ‬Coat the inner face of cylinder head(3)
with hydraulic oil.
‫ ڹ‬Coat dust wiper(8) with grease and fit Press here

dust wiper(8) to the bottom of the hole of (Straight down)
dust seal. Metal
8
At this time, press a pad metal to the
metal ring of dust seal.
‫ ں‬Fit snap ring(9) to the stop face.
‫ ڻ‬Fit wear ring(10), back up ring(6), rod

seal(5) and buffer ring(7) to corresponding
grooves, in that order.
Ɠ Coat each packing with hydraulic oil Wrong Right
before fitting it.
Ɠ Insert the backup ring until one side of it
is inserted into groove.
Ɠ Rod seal(5) has its own fitting direction.

Push bar
Therefore, confirm it before fitting them.
Ɠ Fitting rod seal(5) up side down may
damage its lip. Therefore check the
correct direction that is shown in fig.
5
8-136
‫ ڼ‬Fit back up ring(12) to cylinder head (3).
Ɠ Put the backup ring in the warm water of 12
30}50Ɓ C 11
‫ ڽ‬Fit O-ring(11) to cylinder head(3).
(2) Assemble piston assembly

Ɠ Check for scratches or rough surfaces.
If found smooth with an oil stone.
‫ ڸ‬Coat the outer face of piston(14) with
hydraulic oil.
‫ ڹ‬Fit piston seal(17) to piston

Ɠ Put the piston seal in the warm water of 17
60}100Ɓ C for more than 5 minutes.
Ɠ After assembling the piston seal, press its
outer diameter to fit in.
‫ ں‬Fit wear ring(18) and dust ring(19) to

piston(14). 19 18 17 18 19
‫ ڻ‬Fit back up ring(16) and O-ring(15) to
piston(14). 16
15
8-137
(3) Install piston and cylinder head
‫ ڸ‬Fix the piston rod assembly to the work Cylinder head assy
bench.
‫ ڹ‬Apply hydraulic oil to the outer surface of Piston rod
piston rod(2), the inner surface of piston

and cylinder head.
‫ ں‬Insert cylinder head assembly to piston
rod.
‫ ڻ‬Insert cushion ring(13) to piston rod.

Ɠ Note that cushion ring(13) has a 13
direction in which it should be fitted.
Insert
‫ ڼ‬Fit piston assembly to piston rod.

şTightening torque : Piston assy
100Ź10kgfşm(723.3 Ź72.3lbfşft)
‫ ڽ‬Fit lock nut(20) to piston rod.

şTightening torque : 20
Item kgfňm lbfňft
bucket 150Ź15 1085Ź108.5

boom 150Ź15 1085Ź108.5
arm 150Ź15 1085Ź108.5
8-138
(4) Overall assemble
Fix with a bar
‫ ڸ‬Place a V-block on a rigid work bench.
Mount the cylinder tube assembly(1) on it
Lift
and fix the assembly by passing a bar
through the clevis pin hole to lock the
assembly.
‫ ڹ‬Insert the piston rod assembly in to the Straight
cylinder tube assembly, while lifting and
moving the piston rod assembly with a Apply liquid packing
crane.
Ɠ Be careful not to damage piston seal by
thread of cylinder tube.
‫ ں‬Match the bolts holes in the cylinder head Turn clockwise
flange to the tapped holes in the cylinder Apply loctite
tube assembly and tighten socket bolts to
a specified torque.
Ɠ Refer to the table of tightening torque.
Place rag
8-139
GROUP 11 WORK EQUIPMENT
1. STRUCTURE
B
C
SECTION A SECTION B SECTION C
8-152
1) BUCKET ASSEMBLY
(1) Removal
Lower the work equipment completely to
A
ground with back of bucket facing down.
B
Remove nut(1), bolt(2) and draw out the

2
pin(A).
A
1
Remove nut(3), bolt(4) and draw out the

pin(B). 4
B
3
(2) Install
Carry out installation in the reverse
order to removal.
pin hole.
Adjust the bucket clearance.
For detail, see operation manual
8-153
1) ARM ASSEMBLY
(1) Removal
Loosen the breather slowly to release the
penetrated the skin causing serious in
jury.
Remove bucket assembly.
For details, see removal of bucket
assembly.
Disconnect bucket cylinder hose(1).
Fit blind plugs in the piping at the
chassis end securely to prevent oil from
spurting out when the engine is started.
Sling arm cylinder assembly, remove
spring, pin stoper and pull out pin.
Tie the rod with wire to prevent it from
coming out.
1
For details, see removal of arm
cylinder assembly.
Place a wooden block under the cylinder
and bring the cylinder down to it.
Remove bolt(2), plate(3) and pull out the
pin(4) then remove the arm assembly.
Crane
When lifting the arm assembly, always lift
the center of gravity.
2, 3, 4
(2) Install
Carry out installation in the reverse order
to removal.
Bleed the air from the cylinder.
8-154
3) BOOM CYLINDER
(1) Removal
Remove arm and bucket assembly
For details, see removal of arm and
bucket assembly.
Remove boom cylinder assembly from
boom.
For details, see removal of arm cylinder
assembly.
Disconnect head lamp wiring.

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

pin(6) then remove boom assembly. Crane
When lifting the boom assembly always
lift the center of gravity.
4, 5, 6
2
(2) Install
Carry out in stallation in the reverse order
to removal.
Bleed the air from the cylinder.
8-155

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SECTION 1 GENERAL

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

USE HANDHOLDS AND STEPS

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

AVOID POWER LINES

MOVE AND OPERATE MACHINE SAFELY

OPERATE ONLY FORM OPERATOR'S SEAT

PARK MACHINE SAFELY

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

Store flammable fluids away from fire hazards. Do not

REMOVE PAINT BEFORE WELDING OR HEATING

ILLUMINATE WORK AREA SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HIGH PRESSURE FLUIDS

PREVENT BATTERY EXPLOSIONS

PREVENT ACID BURNS

DISPOSE OF FLUIDS PROPERLY

REPLACE SAFETY SIGNS

LIVE WITH SAFETY

Battery box Fuel tank Oil cooler Radiator

Bucket Swing motor Hydraulic tank

Arm Arm cylinder Boom Boom cylinder Cab Muffler Counterweight

Side cutter Connecting rod Idler Track Sprocket

Description Unit Specification

Operating weight kg(lb) 30150(66470)

Description Unit Specification

Operating weight kg(lb) 31200(68780)

Description Unit Specification

Operating weight kg(lb) 31000(68340)

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

Load radius At max. reach

Load radius At max. reach

Load radius At max. reach

Load radius At max. reach

Load radius At max. reach

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

Load radius At max. reach

Load radius At max. reach

Load radius At max. reach

Load radius At max. reach

Load radius At max. reach

Load radius At max. reach

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

Load radius At max. reach

Load radius At max. reach

Load radius At max. reach

Load radius At max. reach

Load radius At max. reach

Load radius At max. reach

0.90m3 0.80m3 950mm 1070mm 835kg

1.14m3 1.00m3 1140mm 1260mm 935kg

1.38m3 1.20m3 1330mm 1450mm 1040kg

1.44m3 1.25m3 1380mm 1500mm 1055kg

1.74m3 1.50m3 1610mm 1730mm 1145kg

: Standard backhoe bucket

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

1.97m3 PCSA 2.10m3 PCSA

1.97m3 1.70m3 1800mm 1190kg

2.10m3 1.80m3 1595mm 1715mm 1330kg