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
1) EQUIPPED WITH ONE PIECE BOOM

Battery box Fuel tank Hydraulic oil tank Main pump

Engine

Radiator

Bucket Turning joint Swing motor Main control valve Oil cooler

Arm Arm cylinder Boom Boom cylinder Cab Muffler Counterweight

Bucket rest
Tooth

Dozer blade

Bucket cylinder Connecting rod Front axle Travel motor Transmission Tool box Rear axle

Connecting link Side cutter Front drive shaft Foot step Rear drive shaft

1-9
 2) EQUIPPED WITH TWO PIECE BOOM

Battery box Fuel tank Hydraulic oil tank Main pump

Engine

Radiator

Turning joint Swing motor Main control valve Oil cooler

Arm Arm cylinder Adjust cylinder Boon cylinder Cab Muffler Counterweight
Boom(1st) Boom(2nd)

Outrigger

Rear axle
Dozer blade

Tooth Side cutter Connecting rod Front axle Travel motor Transmission Tool box

Bucket cylinder Connecting link Bucket Front drive shaft Foot step Rear drive shaft

1-10
2. SPECIFICATIONS
1) 5.2m(17' 1") ONE PIECE BOOM, 2.2m(7' 3") ARM AND REAR DOZER BLADE

I(I') D
C

E
G

H
F
K
J L
A B

Description Unit Specification

Operating weight kg(lb) 16480(36330)

Bucket capacity(PCSA heaped), standard m3(yd‫)ރ‬ 0.70(0.92)
Overall length A 8690(28' 6")
Overall width B 2500( 8' 2")
Overall height C 3050(10' 0")
Superstructure width D 2450( 8' 0")
Cab height E 3080(10' 1")
Ground clearance of counterweight F mm(ft-in) 1270( 4' 2")
Engine cover height G 2330( 7' 8")
Minimum ground clearance H 375( 1' 3")
Rear-end distance I 2450( 8' 0")
Rear-end swing radius I' 2530( 8' 4")
Wheel base J 2600( 8' 6")
Tread K 1914( 6' 3")
Dozer blade width L 2490( 8' 2")
Low 6.5(4.1)
Travel speed km/hr(mph)
High 25(15.6)
Swing speed rpm 11.5
Gradeability Degree(%) 30(58)

1-11
2) 5.0m(16' 5") TWO PIECE BOOM(CYL TYPE), 2.2m(7' 3") ARM AND FOUR OUTRIGGER

I(I') D
C

E
G

H
F
K
J B
A 3120
3312

Description Unit Specification

Operating weight kg(lb) 18080(39860)

Bucket capacity(PCSA heaped), standard m3(yd‫)ރ‬ 0.70(0.92)
Overall length A 8510(27' 11")
Overall width B 2500( 8' 2")
Overall height C 2940( 9' 8")
Superstructure width D 2450( 8' 0")
Cab height E mm(ft-in) 3080(10' 1")
Ground clearance of counterweight F 1270( 4' 2")
Engine cover height G 2330( 7' 8")
Minimum ground clearance H 375( 1' 3")
Rear-end distance I 2450( 8' 0")
Rear-end swing radius I' 2530( 8' 4")
Wheel base J 2600( 8' 6")
Tread K 1914( 6' 3")
Low 6.5(4.1)
Travel speed km/hr(mph)
High 25(15.6)
Swing speed rpm 11.5
Gradeability Degree(%) 30(58)

1-12
3. WORKING RANGE
1) 5.2m(17' 1") ONE PIECE BOOM

A
A'
F
D
E
C
B'
B

8ft

Description 1.85m(6' 1") Arm 2.2m(7' 3") Arm 2.6m(8' 6") Arm 3.2m(10' 6") Arm

Max. digging reach A 8410mm(27' 7") 8740mm(28' 8") 9100mm(29' 10") 9690mm(31' 9")
Max. digging reach on ground A' 8200mm(26' 11') 8540mm(28' 0') 8900mm(29' 2") 9510mm(31' 2")
Max. digging depth B 5240mm(17' 2") 5590mm(18' 4") 5990mm(19' 8") 6590mm(21' 7")
Max. digging depth(8ft level) B' 4950mm(16' 3") 5340mm(17' 6") 5760mm(18' 11") 6410mm(21' 0")
Max. vertical wall digging depth C 4380mm(14' 4") 4900mm(16' 1") 5170mm(17' 0") 6120mm(20' 1")
Max. digging height D 8610mm(28' 3") 8820mm(28' 11") 8990mm(29' 6") 9390mm(30' 10")
Max. dumping height E 6020mm(19' 9") 5720mm(18' 9") 6390mm(21' 0") 6750mm(22' 2")
Min. swing radius F 3510mm(11' 6") 3310mm(10' 10") 3310mm(10' 10") 3390mm(11' 1")
105.2 KN 105.2 KN 105.2 KN 105.2 KN
Bucket digging force 10730 kgf 10730 kgf 10730 kgf 10730 kgf
23650 lbf 23650 lbf 23650 lbf 23650 lbf
95.4 KN 78.6 KN 69.6 KN 61.3 KN
Arm crowd force 9730 kgf 8010 kgf 7100 kgf 6250 kgf
21450 lbf 17660 lbf 15650 lbf 13780 lbf

1-13
2) 5.0m(16' 5") TWO PIECE BOOM(CYL TYPE)

A
A'
F
D
E
C
B'
B

8ft

Description 1.85m(6' 1") Arm 2.2m(7' 3") Arm

Max. digging reach A 8370mm(27' 6") 8680mm(28' 6")

Max. digging reach on ground A' 8160mm(26' 9") 8480mm(27' 10")
Max. digging depth B 4820mm(15' 10") 5180mm(17' 0")
Max. digging depth(8ft level) B' 4700mm(15' 5") 5050mm(16' 7")
Max. digging depth of boom open C 3430mm(11' 3") 3780mm(12' 5")
Max. digging height D 9530mm(31' 3") 9720mm(31' 11")
Max. dumping height E 6810mm(22' 4") 7000mm(23' 0")
Min. swing radius F 3180mm(10' 5") 2960mm( 9' 9")
105.2 KN 105.2 KN
Bucket digging force 10730 kgf 10730 kgf
23650 lbf 23650 lbf
95.4 KN 78.6 KN
Arm crowd force 9730 kgf 8010 kgf
21450 lbf 17660 lbf

1-14
4. WEIGHT
R170W-3
Item
kg lb
Upperstructure assembly 4750 10470
Main frame weld assembly 1254 2760
Engine assembly 423 930
Main pump assembly 80 180
Main control valve assembly 135 300
Swing motor assembly 190 420
Hydraulic oil tank assembly 210 460
Fuel tank assembly 115 250
Counterweight 2700 5950
Cab assembly 275 610
Lower frame weld assembly 1622 3580
Swing bearing 260 570
Travel motor assembly 105 230
Turning joint 76 170
Transmission assembly 132 290
Front axle assembly 502 1110
Rear axle assembly 402 890
Dozer blade assembly 831 1830
Front attachment assembly(5.2m boom,2.6m arm, 0.7m
3

3000 6610
PCSA heaped bucket)
5.2m one piece boom assembly 1064 2350
5.0 two piece boom assembly 1534 3380
2.6m arm assembly 540 1190
0.7m PCSA heaped bucket assembly
3
540 1190
Boom cylinder assembly 145 320
Arm cylinder assembly 183 400
Bucket cylinder assembly 135 300
Bucket control linkage assembly 145 320
2.2m arm assembly 469 1030
Oscillating cylinder assembly 30 70
Front outrigger assembly 1015 2240
Rear outrigger assembly 1005 2220
Two piece boom cylinder assembly 130 290
Two piece adjust cylinder assembly 110 240
Outrigger cylinder assembly 78 170
Blade cylinder assembly 62 140
Bucket rest weld assembly 112 250

1-15
5. LIFTING CAPACITIES
1) ROBEX 170W-3
(1) 5.20m(17' 1") boom, 2.20m(7' 3") arm equipped with 0.70m3(PCSA heaped) bucket and rear
dozer blade up.
ş : Rating over-front ş : Rating over-side or 360 degree

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
7.5m kg *3090 2980 6.14
(25ft) lb *6810 6570 (20.1)
6.0m kg *3070 2980 *3090 2100 7.36
(20ft) lb *6770 6570 *6810 4630 (24.1)
4.5m kg *4140 *4140 *3620 2910 2790 1720 8.06
(15ft) lb *9130 *9130 *7980 6420 6150 3790 (26.4)
3.0m kg *8750 8180 *5300 4370 *4110 2760 2550 1550 8.38
(10ft) lb *19290 18030 *11680 9630 *9060 6080 5620 3420 (27.5)
1.5m kg *6370 4030 4260 2600 2510 1510 8.38
(5ft) lb *14040 8880 9390 5730 5530 3330 (27.5)
Ground kg *6690 *6690 6560 3840 4140 2490 2650 1590 8.05
Line lb *14750 *14750 14460 8470 9130 5490 5840 3510 (26.4)
-1.5m kg *6890 *6890 *10030 7350 6510 3800 4100 2460 3070 1860 7.35
(-5ft) lb *15190 *15190 *22110 16200 14350 8380 9040 5420 6770 4100 (24.1)
-3.0m kg *10560 *10560 *8510 7530 *5900 3870 *3340 2570 6.13
(-10ft) lb *23280 *23280 *18760 16600 *13010 8530 *7360 5670 (20.1)
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.

1-16
(2) 5.20m(17' 1") boom, 2.20m(7' 3") arm equipped with 0.70m3(PCSA heaped) bucket and rear dozer
blade down.

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
7.5m kg *3090 *3090 6.14
(25ft) lb *6810 *6810 (20.1)
6.0m kg *3070 *3070 *3090 2390 7.36
(20ft) lb *6770 *6770 *6810 5270 (24.1)
4.5m kg *4140 *4140 *3620 3300 *3150 1970 8.06
(15ft) lb *9130 *9130 *7980 7280 *6940 4340 (26.4)
3.0m kg *8750 *8750 *5300 5000 *4110 3150 *3250 1790 8.38
(10ft) lb *19290 *19290 *11680 11020 *9060 6940 *7170 3950 (27.5)
1.5m kg *6370 4640 *4620 2990 3350 1740 8.38
(5ft) lb *14040 10230 *10190 6590 7390 3840 (27.5)
Ground kg *6690 *6690 *6890 4450 *4930 2870 *3460 1840 8.05
Line lb *14750 *14750 *15190 9810 *10870 6330 *7630 4060 (26.4)
-1.5m kg *6890 *6890 *10030 8730 *6760 4400 *4850 2840 *3510 2150 7.35
(-5ft) lb *15190 *15190 *22110 19250 *14900 9700 *10690 6260 *7740 4740 (24.1)
-3.0m kg *10560 *10560 *8510 *8510 *5900 4480 *3340 2940 6.13
(-10ft) lb *23280 *23280 *18760 *18760 *13010 9880 *7360 6480 (20.1)

(3) 5.20m(17' 1") boom, 2.20m(7' 3") arm equipped with 0.70m3(PCSA heaped) bucket and rear
outrigger down.

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
7.5m kg *3090 *3090 6.14
(25ft) lb *6810 *6810 (20.1)
6.0m kg *3070 *3070 *3090 *3090 7.36
(20ft) lb *6770 *6770 *6810 *6810 (24.1)
4.5m kg *4140 *4140 *3620 *3620 *3150 *3150 8.06
(15ft) lb *9130 *9130 *7980 *7980 *6940 *6940 (26.4)
3.0m kg *8750 *8750 *5300 *5300 *4110 *4110 *3250 2900 8.38
(10ft) lb *19290 *19290 *11680 *11680 *9060 *9060 *7170 6390 (27.5)
1.5m kg *6370 *6370 *4620 *4620 *3350 2860 8.38
(5ft) lb *14040 *14040 *10190 *10190 *7390 6310 (27.5)
Ground kg *6690 *6690 *6890 *6890 *4930 4750 *3460 3020 8.05
Line lb *14750 *14750 *15190 *15190 *10870 10470 *7630 6660 (26.4)
-1.5m kg *6890 *6890 *10030 *10030 *6760 *6760 *4850 4710 *3510 3500 7.35
(-5ft) lb *15190 *15190 *22110 *22110 *14900 *14900 *10690 10380 *7740 7720 (24.1)
-3.0m kg *10560 *10560 *8510 *8510 *5900 *5900 *3340 *3340 6.13
(-10ft) lb *23280 *23280 *18760 *18760 *13010 *13010 *7360 *7360 (20.1)

1-17
(4) 5.20m(17' 1") boom, 2.20m(7' 3") arm equipped with 0.70m3(PCSA heaped) bucket and front
outrigger, rear dozer blade down.

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
7.5m kg *3090 *3090 6.14
(25ft) lb *6810 *6810 (20.1)
6.0m kg *3070 *3070 *3090 *3090 7.36
(20ft) lb *6770 *6770 *6810 *6810 (24.1)
4.5m kg *4140 *4140 *3620 *3620 *3150 *3150 8.06
(15ft) lb *9130 *9130 *7980 *7980 *6940 *6940 (26.4)
3.0m kg *8750 *8750 *5300 *5300 *4110 *4110 *3250 3060 8.38
(10ft) lb *19290 *19290 *11680 *11680 *9060 *9060 *7170 6750 (27.5)
1.5m kg *6370 *6370 *4620 *4620 *3350 3010 8.38
(5ft) lb *14040 *14040 *10190 *10190 *7390 6640 (27.5)
Ground kg *6690 *6690 *6890 *6890 *4930 *4930 *3460 3180 8.05
Line lb *14750 *14750 *15190 *15190 *10870 *10870 *7630 7010 (26.4)
-1.5m kg *6890 *6890 *10030 *10030 *6760 *6760 *4850 *4850 *3510 *3510 7.35
(-5ft) lb *15190 *15190 *22110 *22110 *14900 *14900 *10690 *10690 *7740 *7740 (24.1)
-3.0m kg *10560 *10560 *8510 *8510 *5900 *5900 *3340 *3340 6.13
(-10ft) lb *23280 *23280 *18760 *18760 *13010 *13010 *7360 *7360 (20.1)

(5) 5.20m(17' 1") boom, 2.20m(7' 3") arm equipped with 0.70m3(PCSA heaped) bucket and 4 outrigger
down.

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
7.5m kg *3090 *3090 6.14
(25ft) lb *6810 *6810 (20.1)
6.0m kg *3070 *3070 *3090 *3090 7.36
(20ft) lb *6770 *6770 *6810 *6810 (24.1)
4.5m kg *4140 *4140 *3620 *3620 *3150 *3150 8.06
(15ft) lb *9130 *9130 *7980 *7980 *6940 *6940 (26.4)
3.0m kg *8750 *8750 *5300 *5300 *4110 *4110 *3250 3090 8.38
(10ft) lb *19290 *19290 *11680 *11680 *9060 *9060 *7170 6810 (27.5)
1.5m kg *6370 *6370 *4620 *4620 *3350 3050 8.38
(5ft) lb *14040 *14040 *10190 *10190 *7390 6720 (27.5)
Ground kg *6690 *6690 *6890 *6890 *4930 *4930 *3460 3220 8.05
Line lb *14750 *14750 *15190 *15190 *10870 *10870 *7630 7100 (26.4)
-1.5m kg *6890 *6890 *10030 *10030 *6760 *6760 *4850 *4850 *3510 *3510 7.35
(-5ft) lb *15190 *15190 *22110 *22110 *14900 *14900 *10690 *10690 *7740 *7740 (24.1)
-3.0m kg *10560 *10560 *8510 *8510 *5900 *5900 *3340 *3340 6.13
(-10ft) lb *23280 *23280 *18760 *18760 *13010 *13010 *7360 *7360 (20.1)

1-18
 (6) 5.20m(17' 1") boom, 1.85m(6' 1") arm equipped with 0.70m3(PCSA heaped) bucket and rear
dozer blade up.

Load radius At max. reach

Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
6.0m kg *3280 2290 6.97
(20ft) lb *7230 5050 (22.9)
4.5m kg *4460 *4460 *3830 2850 2980 1840 7.70
(15ft) lb *9830 *9830 *8440 6280 6570 4060 (25.3)
3.0m kg *5590 4270 *4270 2710 2710 1650 8.04
(10ft) lb *12320 9410 *9410 5970 5970 3640 (26.4)
1.5m kg *6550 3950 4210 2560 2660 1600 8.04
(5ft) lb *14440 8710 9280 5640 5860 3530 (26.4)
Ground kg 6510 3800 4110 2470 2830 1710 7.70
Line lb 14350 8380 9060 5450 6240 3770 (25.3)
-1.5m kg *9500 7380 6500 3790 4100 2460 3340 2030 6.96
(-5ft) lb *20940 16270 14330 8360 9040 5420 7360 4480 (22.8)
-3.0m kg *7800 7590 *5500 3900 *3300 2950 5.62
(-10ft) lb *17200 16730 *12130 8600 *7280 6500 (18.4)

(7) 5.20m(17' 1") boom, 1.85m(6' 1") arm equipped with 0.70m3(PCSA heaped) bucket and rear
dozer blade down.

Load radius At max. reach

Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
6.0m kg *3280 2600 6.97
(20ft) lb *7230 5730 (22.9)
4.5m kg *4460 *4460 *3830 3240 *3330 2110 7.70
(15ft) lb *9830 *9830 *8440 7140 *7340 4650 (25.3)
3.0m kg *5590 4900 *4270 3090 *3420 1900 8.04
(10ft) lb *12320 10800 *9410 6810 *7540 4190 (26.4)
1.5m kg *6550 4560 *4720 2940 *3520 1850 8.04
(5ft) lb *14440 10050 *10410 6480 *7760 4080 (26.4)
Ground kg *6900 4410 *4950 2850 *3610 1970 7.70
Line lb *15210 9720 *10910 6280 *7960 4340 (25.3)
-1.5m kg *9500 8760 *6600 4400 *4720 2840 *3630 2340 6.96
(-5ft) lb *20940 19310 *14550 9700 *10410 6260 *8000 5160 (22.8)
-3.0m kg *7800 *7800 *5500 4510 *3300 *3300 5.62
(-10ft) lb *17200 *17200 *12130 9940 *7280 *7280 (18.4)

1-19
 (8) 5.20m(17' 1") boom,1.85m(6' 1") arm equipped with 0.70m3(PCSA heaped) bucket and rear
outrigger down.

Load radius At max. reach

Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
6.0m kg *3280 *3280 6.97
(20ft) lb *7230 *7230 (22.9)
4.5m kg *4460 *4460 *3830 *3830 *3330 *3330 7.70
(15ft) lb *9830 *9830 *8440 *8440 *7340 *7340 (25.3)
3.0m kg *5590 *5590 *4270 *4270 *3420 *3080 8.04
(10ft) lb *12320 *12320 *9410 *9410 *7540 6790 (26.4)
1.5m kg *6550 *6550 *4720 *4720 *3520 3040 8.04
(5ft) lb *14440 *14440 *10410 *10410 *7760 *6700 (26.4)
Ground kg *6900 *6900 *4950 4720 *3610 3230 7.70
Line lb *15210 *15210 *10910 10410 *7960 7120 (25.3)
-1.5m kg *9500 *9500 *6600 *6600 *4720 4710 *3630 *3630 6.96
(-5ft) lb *20940 *20940 *14550 *14550 *10410 10380 *8000 *8000 (22.8)
-3.0m kg *7800 *7800 *5500 *5500 *3300 *3300 5.62
(-10ft) lb *17200 *17200 *12130 *12130 *7280 *7280 (18.4)

(9) 5.20m(17' 1") boom, 1.85m(6' 1") arm equipped with 0.70m3(PCSA heaped) bucket and front
outrigger, rear dozer blade down.

Load radius At max. reach

Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
6.0m kg *3280 *3280 6.97
(20ft) lb *7230 *7230 (22.9)
4.5m kg *4460 *4460 *3830 *3830 *3330 *3330 7.70
(15ft) lb *9830 *9830 *8440 *8440 *7340 *7340 (25.3)
3.0m kg *5590 *5590 *4270 *4270 *3420 3250 8.04
(10ft) lb *12320 *12320 *9410 *9410 *7540 7170 (26.4)
1.5m kg *6550 *6550 *4720 *4720 *3520 3200 8.04
(5ft) lb *14440 *14440 *10410 *10410 *7760 7050 (26.4)
Ground kg *6900 *6900 *4950 *4950 *3610 3400 7.70
Line lb *15210 *15210 *10910 *10910 *7960 7500 (25.3)
-1.5m kg *9500 *9500 *6600 *6600 *4720 *4720 *3630 *3630 6.96
(-5ft) lb *20940 *20940 *14550 *14550 *10410 *10410 *8000 *8000 (22.8)
-3.0m kg *7800 *7800 *5500 *5500 *3300 *3300 5.62
(-10ft) lb *17200 *17200 *12130 *12130 *7280 *7280 (18.4)

1-20
 (10) 5.20m(17' 1") boom, 1.85m(6' 1") arm equipped with 0.70m3(PCSA heaped) bucket and 4
outrigger down.

Load radius At max. reach

Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
6.0m kg *3280 *3280 6.97
(20ft) lb *7230 *7230 (22.9)
4.5m kg *4460 *4460 *3830 *3830 *3330 *3330 7.70
(15ft) lb *9830 *9830 *8440 *8440 *7340 *7340 (25.3)
3.0m kg *5590 *5590 *4270 *4270 *3420 3280 8.04
(10ft) lb *12320 *12320 *9410 *9410 *7540 7230 (26.4)
1.5m kg *6550 *6550 *4720 *4720 *3520 3240 8.04
(5ft) lb *14440 *14440 *10410 *10410 *7760 7140 (26.4)
Ground kg *6900 *6900 *4950 *4950 *3610 3440 7.70
Line lb *15210 *15210 *10910 *10910 *7960 7580 (25.3)
-1.5m kg *9500 *9500 *6600 *6600 *4720 *4720 *3630 *3630 6.96
(-5ft) lb *20940 *20940 *14550 *14550 *10410 *10410 *8000 *8000 (22.8)
-3.0m kg *7800 *7800 *5500 *5500 *3300 *3300 5.62
(-10ft) lb *17200 *17200 *12130 *12130 *7280 *7280 (18.4)

(11) 5.20m(17' 1") boom, 2.60m(8' 6") arm equipped with 0.70m3(PCSA heaped) bucket and rear dozer
blade up.

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach
height
m(ft)
7.5m kg *2810 2590 6.65
(25ft) lb *6190 5710 (21.8)
6.0m kg *2970 *2970 *2840 1890 7.78
(20ft) lb *6550 *6550 *6260 4170 (25.5)
4.5m kg *3310 2920 2560 1560 8.43
(15ft) lb *7300 6440 5640 3440 (27.7)
3.0m kg *7630 *7630 *4860 4410 *3830 2750 *2890 1840 2350 1400 8.73
(10ft) lb *16820 *16820 *10710 9720 *8440 6060 *6370 4060 5180 3090 (28.6)
1.5m kg *6240 *6240 *6040 4020 4230 2570 2930 1760 2300 1360 8.73
(5ft) lb *13760 *13760 *13320 8860 9330 5670 6460 3380 5070 3000 (28.6)
Ground kg *7020 *7020 6510 3790 4090 2440 2860 1700 2420 1430 8.42
Line lb *15480 *15480 14350 8360 9020 5380 6310 3750 5340 3150 (27.6)
-1.5m kg *6340 *6340 *9720 7200 6420 3710 4020 2380 2760 1640 7.77
(-5ft) lb *13980 *13980 *21430 15870 14150 8180 8860 5250 6080 3620 (25.5)
-3.0m kg *9290 *9290 *9050 7340 *6130 3750 4060 2420 *3270 2180 6.63
(-10ft) lb *20480 *20480 *19950 16180 *13510 8270 8950 5340 *7210 4810 (21.8)
-4.5m kg *6480 *6480
(-15ft) lb *14290 *14290

1-21
(12) 5.20m(17' 1") boom, 2.60m(8' 6") arm equipped with 0.70m3(PCSA heaped) bucket and rear dozer
blade down.

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach
height
m(ft)
7.5m kg *2810 *2810 6.65
(25ft) lb *6190 *6190 (21.8)
6.0m kg *2970 *2970 *2840 2150 7.78
(20ft) lb *6550 *6550 *6260 4740 (25.5)
4.5m kg *3310 3310 *2910 1800 8.43
(15ft) lb *7300 7300 *6420 3970 (27.7)
3.0m kg *7630 *7630 *4860 *4860 *3830 3140 *2890 2120 *3000 1630 8.73
(10ft) lb *16820 *16820 *10710 *10710 *8440 6920 *6370 4670 *6610 3590 (28.6)
1.5m kg *6240 *6240 *6040 4640 *4400 2960 *3590 2040 3090 1580 8.73
(5ft) lb *13760 *13760 *13320 10230 *9700 6530 *7910 4500 6810 3480 (28.6)
Ground kg *7020 *7020 *6720 4400 *4790 2820 *3410 1970 *3230 1660 8.42
Line lb *15480 *15480 *14820 9700 *10560 6220 *7520 4340 *7120 3660 (27.6)
-1.5m kg *6340 *6340 *9720 8570 *6760 4310 *4840 2760 *3320 1910 7.77
(-5ft) lb *13980 *13980 *21430 18890 *14900 9500 *10670 6080 *7320 4210 (25.5)
-3.0m kg *9290 *9290 *9050 8720 *6130 4360 *4280 2800 *3270 2520 6.63
(-10ft) lb *20480 *20480 *19950 19220 *13510 9610 *9440 6170 *7210 5560 (21.8)
-4.5m kg *6480 *6480
(-15ft) lb *14290 *14290

(13) 5.20m(17' 1") boom, 2.60m(8' 6") arm equipped with 0.70m3(PCSA heaped) bucket and rear
outrigger down.

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach
height
m(ft)
7.5m kg *2810 *2810 6.65
(25ft) lb *6190 *6190 (21.8)
6.0m kg *2970 *2970 *2840 *2840 7.78
(20ft) lb *6550 *6550 *6260 *6260 (25.5)
4.5m kg *3310 *3310 *2910 *2910 8.43
(15ft) lb *7300 *7300 *6420 *6420 (27.7)
3.0m kg *7630 *7630 *4860 *4860 *3830 *3830 *2890 *2890 *3000 2680 8.73
(10ft) lb *16820 *16820 *10710 *10710 *8440 *8440 *6370 *6370 *6610 5910 (28.6)
1.5m kg *6240 *6240 *6040 *6040 *4400 *4400 *3590 3350 *3110 2630 8.73
(5ft) lb *13760 *13760 *13320 *13320 *9700 *9700 *7910 7390 *6860 5800 (28.6)
Ground kg *7020 *7020 *6720 *6720 *4790 4700 *3410 3280 *3230 2770 8.42
Line lb *15480 *15480 *14820 *14820 *10560 10360 *7520 7230 *7120 6110 (27.6)
-1.5m kg *6340 *6340 *9720 *9720 *6760 *6760 *4840 4630 *3320 3150 7.77
(-5ft) lb *13980 *13980 *21430 *21430 *14900 *14900 *10670 10210 *7320 6940 (25.5)
-3.0m kg *9290 *9290 *9050 *9050 *6130 *6130 *4280 *4280 *3270 *3270 6.63
(-10ft) lb *20480 *20480 *19950 *19950 *13510 *13510 *9440 *9440 *7210 *7210 (21.8)
-4.5m kg *6480 *6480
(-15ft) lb *14290 *14290

1-22
(14) 5.20m(17' 1") boom, 2.60m(8' 6") arm equipped with 0.70m3(PCSA heaped) bucket and front
outrigger, rear dozer blade down.

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach
height
m(ft)
7.5m kg *3090 *3090 6.65
(25ft) lb *6810 *6810 (21.8)
6.0m kg *3110 *3110 *3130 *3130 7.78
(20ft) lb *6860 *6860 *6900 *6900 (25.5)
4.5m kg *3650 *3650 *3220 *3220 8.43
(15ft) lb *8050 *8050 *7100 *7100 (27.7)
3.0m kg *8200 *8200 *5290 *5290 *4210 *4210 *3050 *3050 *3330 3080 8.73
(10ft) lb *18080 *18080 *11660 *11660 *9280 *9280 *6720 *6720 *7340 6790 (28.6)
1.5m kg *6150 *6150 *6550 *6550 *4820 *4820 *3790 *3790 *3450 3040 8.73
(5ft) lb *13560 *13560 *14440 *14440 *10630 *10630 *8360 *8360 *7610 6700 (28.6)
Ground kg *6910 *6910 *7280 *7280 *5240 *5240 *3590 *3590 *3570 3180 8.42
Line lb *15230 *15230 *16050 *16050 *11550 *11550 *7910 *7910 *7870 7070 (27.6)
-1.5m kg *6210 *6210 *9620 *9620 *7330 *7330 *5300 5260 *3660 3590 7.77
(-5ft) lb *13690 *13690 *21210 *21210 *16160 *16160 *11680 11600 *8070 7910 (25.5)
-3.0m kg *9170 *9170 *9760 *9760 *6670 *6670 *4710 *4710 *3620 *3620 6.63
(-10ft) lb *20220 *20220 *21520 *21520 *14700 *14700 *10380 *10380 *7980 *7980 (21.8)
-4.5m kg *7100 *7100
(-15ft) lb *15650 *15650

(15) 5.20m(17' 1") boom, 2.60m(8' 6") arm equipped with 0.70m3(PCSA heaped) bucket and 4 outrigger
down.

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach
height
m(ft)
7.5m kg *3090 *3090 6.65
(25ft) lb *6810 *6810 (21.8)
6.0m kg *3110 *3110 *3130 *3130 7.78
(20ft) lb *6860 *6860 *6900 *6900 (25.5)
4.5m kg *3650 *3650 *3220 *3220 8.43
(15ft) lb *8050 *8050 *7100 *7100 (27.7)
3.0m kg *8200 *8200 *5290 *5290 *4210 *4210 *3050 *3050 *3330 3110 8.73
(10ft) lb *18080 *18080 *11660 *11660 *9280 *9280 *6720 *6720 *7340 6860 (28.6)
1.5m kg *6150 *6150 *6550 *6550 *4820 *4820 *3790 *3790 *3450 3070 8.73
(5ft) lb *13560 *13560 *14440 *14440 *10630 *10630 *8360 *8360 *7610 6770 (28.6)
Ground kg *6910 *6910 *7280 *7280 *5240 *5240 *3590 *3590 *3570 3220 8.42
Line lb *15230 *15230 *16050 *16050 *11550 *11550 *7910 *7910 *7870 7070 (27.6)
-1.5m kg *6210 *6210 *9620 *9620 *7330 *7330 *5300 *5300 *3660 3630 7.77
(-5ft) lb *13690 *13690 *21210 *21210 *16160 *16160 *11680 11680 *8070 8000 (25.5)
-3.0m kg *9170 *9170 *9760 *9760 *6670 *6670 *4710 *4710 *3620 *3620 6.63
(-10ft) lb *20220 *20220 *21520 *21520 *14700 *14700 *10380 *10380 *7980 *7980 (21.8)
-4.5m kg *7100 *7100
(-15ft) lb *15650 *15650

1-23
(16) 5.20m(17' 1") boom, 3.20m(10' 6") arm equipped with 0.70m3(PCSA heaped) bucket and rear dozer
blade up.

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach
height
m(ft)
6.0m kg *2510 1580 8.45
(20ft) lb *5530 3480 (27.7)
4.5m kg *2830 *2830 *2390 1910 2230 1320 9.04
(15ft) lb *6240 *6240 *5270 4210 4920 2910 (29.7)
3.0m kg *4160 *4160 *3400 2770 *3010 1830 2050 1190 9.33
(10ft) lb *9170 *9170 *7500 6110 *6640 4030 4520 2620 (30.6)
1.5m kg *8800 7740 *5470 4090 *4040 2570 2910 1730 2010 1150 9.32
(5ft) lb *19400 17060 *12060 9020 *8910 5670 6420 3810 4430 2540 (30.6)
Ground kg *7130 *7130 *6390 3780 4060 2410 2820 1650 2100 1200 9.04
Line lb *15720 *15720 *14090 8330 8950 5310 6220 3640 4630 2650 (29.7)
-1.5m kg *5460 *5460 *8770 7060 6350 3640 3950 2310 2770 1600 2350 1360 8.44
(-5ft) lb *12040 *12040 *19330 15560 14000 8020 8710 5090 6110 3530 5180 3000 (27.7)
-3.0m kg *7800 *7800 *9750 7130 6330 3630 3940 2300 2920 1730 7.43
(-10ft) lb *17200 *17200 *21500 15720 13960 8000 8690 5070 6440 3810 (24.4)
-4.5m kg *11000 *11000 *7810 7370 *5210 3750 *2770 2770 5.75
(-15ft) lb *24250 *24250 *17220 16250 *11490 8270 *6110 6110 (18.9)

(17) 5.20m(17' 1") boom, 3.20m(10' 6") arm equipped with 0.70m3(PCSA heaped) bucket and rear dozer
blade down.

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach
height
m(ft)
6.0m kg *2510 1820 8.45
(20ft) lb *5530 4010 (27.7)
4.5m kg *2830 *2830 *2390 2200 *2580 1540 9.04
(15ft) lb *6240 *6240 *5270 4850 *5690 3400 (29.7)
3.0m kg *4160 *4160 *3400 3170 *3010 2110 *2670 1400 9.33
(10ft) lb *9170 *9170 *7500 6990 *6640 4650 *5890 3090 (30.6)
1.5m kg *8800 *8800 *5470 4710 *4040 2960 *3330 2010 2730 1360 9.32
(5ft) lb *19400 *19400 *12060 10380 *8910 6530 *7340 4430 6020 3000 (30.6)
Ground kg *7130 *7130 *6390 4390 *4550 2790 *3580 1920 2840 1410 9.04
Line lb *15720 *15720 *14090 9680 *10030 6150 *7890 4230 6260 3110 (29.7)
-1.5m kg *5460 *5460 *8770 8430 *6720 4240 *4780 2690 *3610 1880 *2990 1590 8.44
(-5ft) lb *12040 *12040 *19330 18580 *14820 9350 *10540 5930 *7960 4140 *6590 3510 (27.7)
-3.0m kg *7800 *7800 *9750 8500 *6400 4230 *4540 2680 *3030 2010 7.43
(-10ft) lb *17200 *17200 *21500 18740 *14110 9330 *10010 5910 *6680 4430 (24.4)
-4.5m kg *11000 *11000 *7810 *7810 *5210 4360 *2770 *2770 5.75
(-15ft) lb *24250 *24250 *17220 *17220 *11490 9610 *6110 *6110 (18.9)

1-24
(18) 5.20m(17' 1") boom, 3.20m(10' 6") arm equipped with 0.70m3(PCSA heaped) bucket and rear
outrigger down.

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach
height
m(ft)
6.0m kg *2510 *2510 8.45
(20ft) lb *5530 *5530 (27.7)
4.5m kg *2830 *2830 *2390 *2390 *2580 2540 9.04
(15ft) lb *6240 *6240 *5270 *5270 *5690 5600 (29.7)
3.0m kg *4160 *4160 *3400 *3400 *3010 *3010 *2670 2360 9.33
(10ft) lb *9170 *9170 *7500 *7500 *6640 *6640 *5890 5200 (30.6)
1.5m kg *8800 *8800 *5470 *5470 *4040 *4040 *3330 *3330 *2780 2310 9.32
(5ft) lb *19400 *19400 *12060 *12060 *8910 *8910 *7340 *7340 *6130 5090 (30.6)
Ground kg *7130 *7130 *6390 *6390 *4550 *4550 *3580 3240 *2890 2410 9.04
Line lb *15720 *15720 *14090 *14090 *10030 *10030 *7890 7140 *6370 5310 (29.7)
-1.5m kg *5460 *5460 *8770 *8770 *6720 *6720 *4780 4560 *3610 3190 *2990 2700 8.44
(-5ft) lb *12040 *12040 *19330 *19330 *14820 *14820 *10540 10050 *7960 7030 *6590 5950 (27.7)
-3.0m kg *7800 *7800 *9750 *9750 *6400 *6400 *4540 *4540 *3030 *3030 7.43
(-10ft) lb *17200 *17200 *21500 *21500 *14110 *14110 *10010 *10010 *6680 *6680 (24.4)
-4.5m kg *11000 *11000 *7810 *7810 *5210 *5210 *2770 *2770 5.75
(-15ft) lb *24250 *24250 *17220 *17220 *11490 *11490 *6110 *6110 (18.9)

(19) 5.20m(17' 1") boom, 3.20m(10' 6") arm equipped with 0.70m3(PCSA heaped) bucket and front
outrigger, rear dozer blade down.

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach
height
m(ft)
6.0m kg *2510 *2510 8.45
(20ft) lb *5530 *5530 (27.7)
4.5m kg *2830 *2830 *2390 *2390 *2580 *2580 9.04
(15ft) lb *6240 *6240 *5270 *5270 *5690 *5690 (29.7)
3.0m kg *4160 *4160 *3400 *3400 *3010 *3010 *2670 2490 9.33
(10ft) lb *9170 *9170 *7500 *7500 *6640 *6640 *5890 5490 (30.6)
1.5m kg *8800 *8800 *5470 *5470 *4040 *4040 *3330 *3330 *2780 2450 9.32
(5ft) lb *19400 *19400 *12060 *12060 *8910 *8910 *7340 *7340 *6130 5400 (30.6)
Ground kg *7130 *7130 *6390 *6390 *4550 *4550 *3580 3410 *2890 2550 9.04
Line lb *15720 *15720 *14090 *14090 *10030 *10030 *7890 7520 *6370 5620 (29.7)
-1.5m kg *5460 *5460 *8770 *8770 *6720 *6720 *4780 *4780 *3610 3360 *2990 2850 8.44
(-5ft) lb *12040 *12040 *19330 *19330 *14820 *14820 *10540 *10540 *7960 7410 *6590 6280 (27.7)
-3.0m kg *7800 *7800 *9750 *9750 *6400 *6400 *4540 *4540 *3030 *3030 7.43
(-10ft) lb *17200 *17200 *21500 *21500 *14110 *14110 *10010 *10010 *6680 *6680 (24.4)
-4.5m kg *11000 *11000 *7810 *7810 *5210 *5210 *2770 *2770 5.75
(-15ft) lb *24250 *24250 *17220 *17220 *11490 *11490 *6110 *6110 (18.9)

1-25
(20) 5.20m(17' 1") boom, 3.20m(10' 6") arm equipped with 0.70m3(PCSA heaped) bucket and 4 outrigger
down.

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach
height
m(ft)
6.0m kg *2510 *2510 8.45
(20ft) lb *5530 *5530 (27.7)
4.5m kg *2830 *2830 *2390 *2390 *2580 *2580 9.04
(15ft) lb *6240 *6240 *5270 *5270 *5690 *5690 (29.7)
3.0m kg *4160 *4160 *3400 *3400 *3010 *3010 *2670 2520 9.33
(10ft) lb *9170 *9170 *7500 *7500 *6640 *6640 *5890 5560 (30.6)
1.5m kg *8800 *8800 *5470 *5470 *4040 *4040 *3330 *3330 *2780 2480 9.32
(5ft) lb *19400 *19400 *12060 *12060 *8910 *8910 *7340 *7340 *6130 2470 (30.6)
Ground kg *7130 *7130 *6390 *6390 *4550 *4550 *3580 3450 *2890 2580 9.04
Line lb *15720 *15720 *14090 *14090 *10030 *10030 *7890 7610 *6370 5690 (29.7)
-1.5m kg *5460 *5460 *8770 *8770 *6720 *6720 *4780 *4780 *3610 3400 *2990 2880 8.44
(-5ft) lb *12040 *12040 *19330 *19330 *14820 *14820 *10540 *10540 *7960 7500 *6590 6350 (27.7)
-3.0m kg *7800 *7800 *9750 *9750 *6400 *6400 *4540 *4540 *3030 *3030 7.43
(-10ft) lb *17200 *17200 *21500 *21500 *14110 *14110 *10010 *10010 *6680 *6680 (24.4)
-4.5m kg *11000 *11000 *7810 *7810 *5210 *5210 *2770 *2770 5.75
(-15ft) lb *24250 *24250 *17220 *17220 *11490 *11490 *6110 *6110 (18.9)

(21) 5.0m(16' 5") two piece boom(cyl type), 2.20m(7' 3") arm equipped with 0.70m3(PCSA heaped)
bucket and rear dozer blade up.

Load radius At max. reach

Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
7.5m kg *3450 *3450 *3100 2990 6.04
(25ft) lb *7610 *7610 *6830 6590 (19.8)
6.0m kg *3290 *3290 *3300 2920 *3050 2090 7.28
(20ft) lb *7250 *7250 *7280 6440 *6720 4610 (23.9)
4.5m kg *3880 *3880 *3460 2870 *2730 1700 7.99
(15ft) lb *8550 *8550 *7630 6330 *6020 3750 (26.2)
3.0m kg *4940 4360 *3780 2730 2570 1540 8.31
(10ft) lb *10890 9610 *8330 6020 5670 3400 (27.3)
1.5m kg *5370 4000 *3830 2570 2540 1500 8.31
(5ft) lb *11840 8820 *8440 5670 5600 3310 (27.3)
Ground kg *6220 *6220 *5460 3800 *3880 2460 2700 1610 7.98
Line lb *13710 *13710 *12040 8380 *8550 5420 5950 3550 (26.2)
-1.5m kg *8890 7320 *5530 3770 *3930 2440
(-5ft) lb *19600 16140 *12190 8310 *8660 5380

1-26
 (22) 5.0m(16' 5") two piece boom(cyl type), 2.20m(7' 3") arm equipped with 0.70m3(PCSA heaped)
bucket and rear dozer blade down.

Load radius At max. reach

Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
10.5m kg *2730 *2730 5.40
(35ft) lb *6020 *6020 (17.7)
7.5m kg *3450 *3450 *3100 *3100 6.04
(25ft) lb *7610 *7610 *6830 *6830 (19.8)
6.0m kg *3290 *3290 *3300 *3300 *3050 2380 7.28
(20ft) lb *7250 *7250 *7280 *7280 *6720 5250 (23.9)
4.5m kg *3880 *3880 *3460 3270 *2730 1960 7.99
(15ft) lb *8550 *8550 *7630 7210 *6020 4320 (26.2)
3.0m kg *4940 *4940 *3780 3120 *2610 1780 8.31
(10ft) lb *10890 *10890 *8330 6880 *5750 3920 (27.3)
1.5m kg *5370 4620 *3830 2960 *2630 1750 8.31
(5ft) lb *11840 10190 *8440 6530 *5800 3860 (27.3)
Ground kg *6220 *6220 *5460 4420 *3880 2850 *2790 1870 7.98
Line lb *13710 *13710 *12040 9740 *8550 6280 *6150 4120 (26.2)
-1.5m kg *8890 8720 *5530 4390 *3930 2830
(-5ft) lb *19600 19220 *12190 9680 *8660 6240

(23) 5.0m(16' 5") two piece boom(cyl type), 2.20m(7' 3") arm equipped with 0.70m3(PCSA heaped)
bucket and rear outrigger down.

Load radius At max. reach

Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
10.5m kg *2730 *2730 5.40
(35ft) lb *6020 *6020 (17.7)
7.5m kg *3450 *3450 *3100 *3100 6.04
(25ft) lb *7610 *7610 *6830 *6830 (19.8)
6.0m kg *3290 *3290 *3300 *3300 *3050 *3050 7.28
(20ft) lb *7250 *7250 *7280 *7280 *6720 *6720 (23.9)
4.5m kg *3880 *3880 *3460 *3460 *2730 *2730 7.99
(15ft) lb *8550 *8550 *7630 *7630 *6020 *6020 (26.2)
3.0m kg *4940 *4940 *3780 *3780 *2610 *2610 8.31
(10ft) lb *10890 *10890 *8330 *8330 *5750 *5750 (27.3)
1.5m kg *5370 *5370 *3830 *3830 *2630 *2630 8.31
(5ft) lb *11840 *11840 *8440 *8440 *5800 *5800 (27.3)
Ground kg *6220 *6220 *5460 *5460 *3880 *3880 *2790 *2790 7.98
Line lb *13710 *13710 *12040 *12040 *8550 *8550 *6150 *6150 (26.2)
-1.5m kg *8890 *8890 *5530 *5530 *3930 *3930
(-5ft) lb *19600 *19600 *12190 *12190 *8660 *8660

1-27
 (24) 5.0m(16' 5") two piece boom(cyl type), 2.20m(7' 3") arm equipped with 0.70m3(PCSA heaped)
bucket and front outrigger, rear dozer blade down.

Load radius At max. reach

Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
10.5m kg *2730 *2730 5.40
(35ft) lb *6020 *6020 (17.7)
7.5m kg *3450 *3450 *3100 *3100 6.04
(25ft) lb *7610 *7610 *6830 *6830 (19.8)
6.0m kg *3290 *3290 *3300 *3300 *3050 *3050 7.28
(20ft) lb *7250 *7250 *7280 *7280 *6720 *6720 (23.9)
4.5m kg *3880 *3880 *3460 *3460 *2730 *2730 7.99
(15ft) lb *8550 *8550 *7630 *7630 *6020 *6020 (26.2)
3.0m kg *4940 *4940 *3780 *3780 *2610 *2610 8.31
(10ft) lb *10890 *10890 *8330 *8330 *5750 *5750 (27.3)
1.5m kg *5370 *5370 *3830 *3830 *2630 *2630 8.31
(5ft) lb *11840 *11840 *8440 *8440 *5800 *5800 (27.3)
Ground kg *6220 *6220 *5460 *5460 *3880 *3880 *2790 *2790 7.98
Line lb *13710 *13710 *12040 *12040 *8550 *8550 *6150 *6150 (26.2)
-1.5m kg *8890 *8890 *5530 *5530 *3930 *3930
(-5ft) lb *19600 *19600 *12190 *12190 *8660 *8660

(25) 5.0m(16' 5") two piece boom(cyl type), 2.20m(7' 3") arm equipped with 0.70m3(PCSA heaped)
bucket and 4 outrigger down.

Load radius At max. reach

Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
7.5m kg *3450 *3450 *3100 *3100 6.04
(25ft) lb *7610 *7610 *6830 *6830 (19.8)
6.0m kg *3290 *3290 *3300 *3300 *3050 *3050 7.28
(20ft) lb *7250 *7250 *7280 *7280 *6720 *6720 (23.9)
4.5m kg *3880 *3880 *3460 *3460 *2730 *2730 7.99
(15ft) lb *8550 *8550 *7630 *7630 *6020 *6020 (26.2)
3.0m kg *4940 *4940 *3780 *3780 *2610 *2610 8.31
(10ft) lb *10890 *10890 *8330 *8330 *5750 *5750 (27.3)
1.5m kg *5370 *5370 *3830 *3830 *2630 *2630 8.31
(5ft) lb *11840 *11840 *8440 *8440 *5800 *5800 (27.3)
Ground kg *6220 *6220 *5460 *5460 *3880 *3880 *2790 *2790 7.98
Line lb *13710 *13710 *12040 *12040 *8550 *8550 *6150 *6150 (26.2)
-1.5m kg *8890 *8890 *5530 *5530 *3930 *3930
(-5ft) lb *19600 *19600 *12190 *12190 *8660 *8660

1-28
 (26) 5.0m(16' 5") two piece boom(cyl type), 1.85m(6' 1") arm equipped with 0.70m3(PCSA heaped)
bucket and rear dozer blade up.

Load radius At max. reach

Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
7.5m kg *3320 *3320 5.52
(25ft) lb *7320 *7320 (18.1)
6.0m kg *3620 *3620 *3230 2290 6.88
(20ft) lb *7980 *7980 *7120 5050 (22.6)
4.5m kg *5510 *5510 *4190 *4190 *3680 2800 *2900 1830 7.62
(15ft) lb *12150 *12150 *9240 *9240 *8110 6170 *6390 4030 (25.0)
3.0m kg *5230 4250 *3790 2670 2740 1640 7.96
(10ft) lb *11530 9370 *8360 5890 6040 3620 (26.1)
1.5m kg *5380 3920 *3840 2530 2700 1600 7.96
(5ft) lb *11860 8640 *8470 5580 5950 3530 (26.1)
Ground kg *5470 3770 *3890 2440 2900 1730 7.62
Line lb *12060 8310 *8580 5380 6390 3810 (25.0)
-1.5m kg *5530 3770 *3940 2450
(-5ft) lb *12190 8310 *8690 5400

(27) 5.0m(16' 5") two piece boom(cyl type), 1.85m(6' 1") arm equipped with 0.70m3(PCSA heaped)
bucket and rear dozer blade down.

Load radius At max. reach

Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
7.5m kg *3320 *3320 5.52
(25ft) lb *7320 *7320 (18.1)
6.0m kg *3620 *3620 *3230 2610 6.88
(20ft) lb *7980 *7980 *7120 5750 (22.6)
4.5m kg *5510 *5510 *4190 *4190 *3680 3200 *2900 2110 7.62
(15ft) lb *12150 *12150 *9240 *9240 *8110 7050 *6390 4650 (25.0)
3.0m kg *5230 4890 *3790 3060 *2750 1900 7.96
(10ft) lb *11530 10780 *8360 6750 *6060 4190 (26.1)
1.5m kg *5380 4540 *3840 2920 *2770 1860 7.96
(5ft) lb *11860 10010 *8470 6440 *6110 4100 (26.1)
Ground kg *5470 4390 *3890 2830 *2970 2000 7.62
Line lb *12060 9680 *8580 6240 *6550 4410 (25.0)
-1.5m kg *5530 4390 *3940 2840
(-5ft) lb *12190 9680 *8690 6260

1-29
 (28) 5.0m(16' 5") two piece boom(cyl type), 1.85m(6' 1") arm equipped with 0.70m3(PCSA heaped)
bucket and front outrigger, rear dozer blade down.

Load radius At max. reach

Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
7.5m kg *3320 *3320 5.52
(25ft) lb *7320 *7320 (18.1)
6.0m kg *3620 *3620 *3230 *3230 6.88
(20ft) lb *7980 *7980 *7120 *7120 (22.6)
4.5m kg *5510 *5510 *4190 *4190 *3680 *3680 *2900 *2900 7.62
(15ft) lb *12150 *12150 *9240 *9240 *8110 *8110 *6390 *6390 (25.0)
3.0m kg *5230 *5230 *3790 *3790 *2750 *2750 7.96
(10ft) lb *11530 *11530 *8360 *8360 *6060 *6060 (26.1)
1.5m kg *5380 *5380 *3840 *3840 *2770 *2770 7.96
(5ft) lb *11860 *11860 *8470 *8470 *6110 *6110 (26.1)
Ground kg *5470 *5470 *3890 *3890 *2970 *2970 7.62
Line lb *12060 *12060 *8580 *8580 *6550 *6550 (25.0)
-1.5m kg *5530 *5530 *3940 *3940
(-5ft) lb *12190 *12190 *8690 *8690

(29) 5.0m(16' 5") two piece boom(cyl type), 1.85m(6' 1") arm equipped with 0.70m3(PCSA heaped)
bucket and 4 outrigger down.

Load radius At max. reach

Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
7.5m kg *3320 *3320 5.52
(25ft) lb *7320 *7320 (18.1)
6.0m kg *3620 *3620 *3230 *3230 6.88
(20ft) lb *7980 *7980 *7120 *7120 (22.6)
4.5m kg *5510 *5510 *4190 *4190 *3680 *3680 *2900 *2900 7.62
(15ft) lb *12150 *12150 *9240 *9240 *8110 *8110 *6390 *6390 (25.0)
3.0m kg *5230 *5230 *3790 *3790 *2750 *2750 7.96
(10ft) lb *11530 *11530 *8360 *8360 *6060 *6060 (26.1)
1.5m kg *5380 *5380 *3840 *3840 *2770 *2770 7.96
(5ft) lb *11860 *11860 *8470 *8470 *6110 *6110 (26.1)
Ground kg *5470 *5470 *3890 *3890 *2970 *2970 7.62
Line lb *12060 *12060 *8580 *8580 *6550 *6550 (25.0)
-1.5m kg *5530 *5530 *3940 *3940
(-5ft) lb *12190 *12190 *8690 *8690

1-30
6. BUCKET SELECTION GUIDE

0.45m3 PCSA 0.57m3 PCSA 0.70m3 PCSA 0.80m3 PCSA 1.03m3 PCSA
heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket

Recommendation
Capacity Width ƕ
5.2m (17' 1") one piece boom 5.0m (16' 5") boom
Weight
PCSA CECE Without With 1.85m arm 2.2m arm 2.6m arm 3.2m arm 1.85m arm 2.2m arm
heaped heaped side cutter side cutter (6' 1") (7' 3") (8' 6") (10' 6") (6' 1") (7' 3")

0.45m3 0.35m3 620mm 740mm 410kg

(0.59yd3) (0.46yd3) (24.4") (29.1") (900lb)

0.57m3 0.50m3 840mm 960mm 490kg

(0.75yd3) (0.65yd3) (33.1") (37.8") (1080lb)

Ɠ0.70m3 0.60m3 990mm 1110mm 540kg

(0.92yd3) (0.78yd3) (39.0") (43.7") (1190lb)

0.80m3 0.70m3 1080mm 1200mm 570kg

(1.05yd3) (0.92yd3) (42.5") (47.2") (1260lb)

1.03m3 0.90m3 1400mm 1520mm 650kg

(1.35yd3) (1.18yd3) (55.1") (59.8") (1430lb)
ƕ
Ɠ: Standard bucket : Two piece boom

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

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

1-31
7. SPECIFICATIONS FRO MAJOR COMPONENTS

1) ENGINE

Item Specification

Model Cummins 6BT5.9-C

Type 4-cycle turbocharged 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 boreźstroke 102ź120mm(4.02"ź4.72")
Piston displacement 5880cc(359cu in)
Compression ratio 17.5 : 1
Rated gross horse power 126Hp at 2100rpm(94kw at 2100rpm)
Maximum torque at 1300rpm 53kgfşm(383lbşft)
Engine oil quantity 11ֻ(2.9U.S. gal)
Dry weight 399kg(880lb)
High idling speed 2250*50rpm
Low idling speed 800Ź100rpm
Rated fuel consumption 158g/Hpşhr
Starting motor Delco Remy 37MT(24V)
Alternator DAC HC60(24V-60Amp)
Battery 2ź12Vź160Ah

2) MAIN PUMP

Item Specification

Type Variable displacement bent axis piston pump

Capacity 2ź80cc/rev
Rated 320kg/cm2(4550psi)
Pressure
Maximum(power boost) 350kg/cm2(4978psi)
Rated oil flow 2ź165ֻ/min(43.6U.S. gpm/ 36.3U.K. gpm)
Rated speed 2100rpm(clockwise viewed from shaft end)

1-32
 3) GEAR PUMP

Item Specification

Type Fixed displacement gear pump single stage

Capacity 11.4cc/rev
Maximum pressure 40 +20 kg/cm2(570psi)
Rated oil flow 30ֻ/min(7.93U.S. gpm/6.6U.K. gpm)

4) MAIN CONTROL VALVE

Item Specification

Type 9 spool
Operating method Hydraulic pilot system
Main relief valve pressure ğ350kg/cm2(4980psi)Ġ
320kg/cm2(4550psi)/
Overload relief valve pressure 380kg/cm2(5400psi)
ğĠ
: Power boost

5) SWING MOTOR

Item Specification

Type Fixed displacement axial piston motor

Capacity 151cc/rev
Relief pressure 240kg/cm2(3410psi)
Braking system Automatic, spring applied hydraulic released
Braking torque 27kgşm(195lbşft)
Brake release pressure 20~50kg/cm2(285~710psi)
Reduction gear type 2 - stage planetary
Swing speed 11.5rpm

6) TRAVEL MOTOR

Item Specification

Type Variable displacement bent-axis axial piston motor

Capacity(max/min) 105cc/rev
Relief pressure 420kg/cm2(5977psi)
Counter balance valve Applied

1-33
7) POWER TRAIN

Item Description Specification

Type 2 speed power shift transmission
Transmission 1st 5.35
Gear ratio
2nd 1.39
Type Multi disc brake integrated in transmission
Parking brake
Maximum braking power 168kgfşm(2390lbşft)
Type 4 wheel drive with differential
Axle Gear ratio 19.62
Brake Multi disc brake

8) REMOTE CONTROL VALVE

Item Specification

Type Pressure reducing type

Minimum 5kg/cm2(71psi)
Operating pressure
Maximum 20kg/cm2(284psi)
Single operation stroke Lever 61mm(2.4in)

9) CYLINDER

Item Specification

Bore diaźRod diaźStroke ‫ٻ‬115ź‫ٻ‬80ź1090mm

Boom cylinder
Cushion Extend only
Bore diaźRod diaźStroke ‫ٻ‬120ź‫ٻ‬85ź1320mm
Arm cylinder
Cushion Extend and retract
Bore diaźRod diaźStroke ‫ٻ‬115ź‫ٻ‬80ź950mm
Bucket cylinder
Cushion Extend only
Bore diaźRod diaźStroke ‫ٻ‬110ź‫ٻ‬75ź235mm
Dozer cylinder
Cushion Extend only
Bore diaźRod diaźStroke ‫ٻ‬125ź‫ٻ‬75ź475mm
Outrigger cylinder
Cushion -
Bore diaźRod diaźStroke ‫ٻ‬115ź‫ٻ‬80ź935mm
2 piece boom cylinder
Cushion -
Bore diaźRod diaźStroke ‫ٻ‬115ź‫ٻ‬80ź710mm
2 piece adjust cylinder
Cushion -
Bore diaźRod diaźStroke ‫ٻ‬120ź‫ٻ‬85ź1320mm
2 piece arm cylinder
Cushion Extend and retract

1-34
10) BUCKET
Capacity Tooth Width
Item
PCSA heaped CECE heaped quantity Without side cutter With side cutter
Standard 0.70m3 (0.92yd3) 0.6m3 (0.78yd3) 5 990mm'39.0") 1110mm'43.7")
0.45m (0.59yd )
3 3
0.35m (0.46yd )
3 3
3 620mm'24.4") 740mm'29.1")
0.57m (0.75yd )
3 3
0.5m (0.65yd )
3 3
4 840mm'33.1") 960mm'37.8")
Option
0.80m3 (1.05yd3) 0.7m3 (0.92yd3) 5 1080mm'42.5") 1200mm'47.2")
1.03m (1.35yd )
3 3
0.9m (1.18yd )
3 3
6 1400mm'55.1")

1-35
8. RECOMMENDED OILS
Use only oils listed below or equivalent.
Do not mix different brand oil.

Ambient temperature Ş
C( Ş
F)
Capacity
Service point Kind of fluid
ֻ(U.S. gal) -20 -10 0 10 20 30 40
(-4) (14) (32) (50) (68) (86) (104)

Engine SAE 30
16.4(4.3)
oil pan
SAE 10W
Engine oil
SAE 10W-30
Transmission
3.8(1.0)
case SAE 15W-40

Swing drive 5.0(1.3)

Gear oil SAE 85W-140
Final drive 4.4ź2(1.2ź2)

Front axle 8.5(2.2)

Gear oil SAE 85W-90
Rear axle 10.0(2.6)

Tank: ISO VG 32
200(52.8)
Hydraulic tank Hydraulic oil ISO VG 46
System:
257(68)
ISO VG 68

ASTM D975 NO. 1

Fuel tank Diesel fuel 250(66.1)
ASTM D975 NO. 2

NLGI NO. 1
Fitting
Grease As required
(Grease nipple)
NLGI NO. 2

Mixture of
Radiator antifreeze
35(9.2) Ethylene glycol base permanent type
(Reservoir tank) and water
50 : 50
SAE : Society of Automotive Engineers.
API : American Petroleum Institute.
ISO : International Organization for Standardization.
NLGI : National Lubricating Grease Institute.
ASTM : American Society of Testing and Material.

1-36
 SECTION 2 STRUCTURE AND FUNCTION
GROUP 1 PUMP DEVICE

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

Gear pump

X1 X1 X1 R1 R3

A3
M3

M2 M1
A2 S A1

Regulator R2
Main pump

X1 M3 A1 M1 A2 M2 X1

R3 Port Port name Port size

A3 A1,2 Delivery port SAE6000psi 1"

S Suction port SAE500psi 3 1/2"
R2 Drain port M14ź1.5
R2
A3 Gear pump delivery port M14ź1.5
R1 X1 Negative control port M14ź1.5
M1,2,3 Gauge port M14ź1.5
R1,3 Air bleed port M14ź1.5
S

Hydraulic circuit

2-1
1) MAIN PUMP(1/2)
Variable double pump with two axial tapered piston rotary groups of bent axis design in open circuit.

Gear pump

8 26 7 25 9 24 16 17

22

20
6

21

23

5 14 15 Regulator

2 Rotary group 9 Spacer 21 Shaft seal ring

3 Rotary group 14 Locking screw 22 O-ring
5 Pump housing 15 O-ring 23 Locking screw
6 Cover 16 Seal lock nut 24 Locking screw
7 Gear 17 Threaded pin 25 Ball bearing
8 Stub shaft 20 Retaining ring 26 Shaft key

2-2
MAIN PUMP(2/2)
ϦRotary group(item 2)

2-12 2-11 2-3 2-10 2-2 2-1 2-4

2-1 Hydraulic section 2-4 Control lens 2-11 Tapered roller bearing
2-2 Pinion gear 2-10 Tapered roller bearing 2-12 Ring nut
2-3 Shim

ϦRotary group(item 3)

3-12 3-11 3-3 3-10 3-2 3-1 3-4

3-1 Hydraulic section 3-4 Control lens 3-11 Tapered roller bearing
3-2 Drive shaft 3-10 Tapered roller bearing 3-12 Ring nut
3-3 Shim

2-3
 2) REGULATOR(1/3)

X1 X1

M3

M2 M1
A2 S A1

48

43

42

42 Socket head screw

Port Port name Port size
43 Socket head screw
A1,2 Delivery port SAE6000psi 1" 48 Locking screw
S Suction port SAE500psi 3 1/2"
M1,2,3 Gauge port M14ź1.5
X1 Negative control port M14ź1.5

2-4
 REGULATOR(2/3)

2
10
11
14
15

12

44
A2 A1
13

17

26
37
16
1
A
SECTION A-A

1 Cover assy 13 Positioning trunnion 17 Thread pin

2 Control module assy 14 Spring collar 26 Hexagon screw
10 Control housing 15 Pressure spring 37 Square ring
12 Positioning piston 16 Piston 44 Cylinder pin

2-5
REGULATOR(3/3)
ϦControl module assy(item 2)

2-1

2-6
2-31 2-5
2-30
2-3 2-7
2-4
2-28
X3 M3 2-8
2-25
2-24

2-27
2-10
2-9
2-11

SECTION B-B

2-1 Control module 2-8 Spring collar 2-27 O-ring

2-3 Control housing 2-9 Spring collar 2-28 Locking screw
2-4 Control piston 2-10 Pressure spring 2-29 Locking screw
2-5 Spring bushing 2-11 Pressure spring 2-30 Lock nut
2-6 Pressure spring 2-24 O-ring 2-31 Socket head screw
2-7 Threaded pin 2-25 O-ring 2-32 Double break-off pin

2-6
3) GEAR PUMP

A
19
8
10
17
16 5 14
15
1
18 7
6 4
12
11

A SECTION A-A

1 Pump cover 8 Locking screw 15 Double brake off pin

4 Sandwich plate 10 Cylinder pin 16 Washer
5 Bearing bushing 11 O-ring 17 O-ring
6 Valve piston 12 O-ring 18 Double brake off pin
7 Pressure spring 14 Socket head screw 19 Pressure control valve

2-7
2. FUNCTION

A1

Second rotary group

Suction port

Positioning trunnion
Positioning piston
First rotary group
Cup spring

A2
Center pin
Pump housing Summation horsepower control

Drive shaft pin Qmin stop

Piston/Piston rod

Positioning piston
Control bushing
Control piston
Control bushing
Small control piston
Large control spring

Small control spring

Spring collar
Positioning piston
Control housing
Positioning trunnion
Control lens
Drive pinion

Piston

A Qmax stop

Pinion Cylinder block

2-8
Power curve

P=P1=P2
‫ ڸ‬At pressure P=0, both rotary groups are at
Pmax max. swivel angle.
‫ڼ ڽ‬
‫ ڹ‬This point is the start of the control. Full
Both regulator output flow(Qmax) is available at both rotary
‫ڻ‬ spring groups as long as the sum of pressures
P1=P2 lies below the set value for the start of
control.
‫ ں‬When the sum of P1+P2 rises above point(2),
Designed power the rotary groups swivel against the force of
the large regulator spring.
‫ں‬ Large regulator
‫ ڻ‬Further increase in pressure P1+P2 beyond
spring
point(3) causes a further swivelling of the
rotary groups against the additional force of
‫ڹ‬ the small regulator spring to point(4), where
‫ڸ‬ the fixed stop(Qmin) is reached.
Q=Q1=Q2 ‫ ڼ‬Further pressure increase of P 1 +P 2
0 Qmin Qmax
beyond(4) causes no further swivelling of the
rotary groups, until the set value of the
pressure relief valves is reached.
‫ ڽ‬This point is the set value of the relief valves.

Gear

First rotary group Second rotary group

SECTION A-A

2-9
1) DESCRIPTION
Two rotary groups of bent axis design are built into the pump casing. Mechanically, these two units
are connected by gears, and on the hydraulic side are controlled by a common summation
horsepower control. The output flow of both rotary groups is therefore steplessly variable, and
dependent upon the sum of the two working pressures, so that the drive motor receives an almost
constant torque.

2) FUNCTION
The first rotary group is driven directly by the drive shaft, together with the drive pinion. The second
rotary group rotates in the opposite direction. Because both rotary groups swivel in the same
direction-vertical to the plane of the diagram-the pressure lines are connected to ports A1 and A2.
Both rotary groups are supplied from a common suction port, which is also connected to the inside
of the pump casing.
Seven ball-ended piston rods are connected to each of the geared drive shafts of the rotary group,
such that the piston cause the cylinder block to rotate with the shaft. Each cylinder block rotates on
a spherical control lens, which in turn slides on a cylindrically formed slideway in the regulator
housing. Kidney-shaped slots in the control lens and oil passages in the slideway allow pressure oil
to be fed to pressure ports A1 and A2.
Center hole of control lens holds one end of trunnion. The other end of the trunnion is held to
positioning piston of regulator.
Movement of the positioning piston adjusts the position of the control lenses, and therefore the
swivel angle of the rotary groups.
At zero pressure, the cylinder blocks are pressed against the control lenses by the cup spring on
the center pin. As pressure rises, the forces between the cylinder blocks and control lenses are
balanced by hydraulic forces, so that even at high loads an oil film remains between the control
faces and also on the slideway, while at the same time the leakage oil is held within narrow limits.
The leakage oil is also partly used for lubrication of all moving parts within the rotary group.
The ball ends of the piston rods and the center pin are lubricated within their seats, as are the
bearings, via the center pin seat, which also has a longitudinal drilling at the drive shaft.
When a piston moves within its cylinder bore from the lower to the upper dead point, it will traverse
a stroke dependent on the swivel angle. This will cause a volume of oil proportional to the piston
area and the stroke travelled to be sucked into the cylinder via the control slots in the control lens.
Movement of the piston from the upper to the lower deadpoint will cause this volume of oil to be
moved into the pressure side of the system.
3) SUMMARY
In the pilot operated summation horsepower control, the working pressures of the two circuits are
added and converted into forces. The total force on the regulating spool operates on the
measuring spring system. When the total pressure in both circuits, or the pressure in one circuit
alone, exceeds the set start of control, the two rotary groups are swivelled inwards together. The
distance which the assembly must move in order to balance the hydraulic forces and spring forces
is that distance necessary for the adjustment, in which the output flows of both rotary groups is
separately varied. Increasing the sum of the pressures causes an inward swivelling towards a
smaller swivel angle and lower output flow; falling summed pressure causes the unit to swive out to
a larger angle and higher output flow.

2-10
4) TOTAL HORSEPOWER CONTROL
The regulator decreases the pump tilting
angle(delivery flow) automatically to limit the
input torque within a certain value with a

Delivery flow, Q
rise in the delivery pressure P1 of the self
pump and the delivery pressure P2 of the
companion pump.
(The input horsepower is constant when the
speed is constant.)
Since the regulator is of the simultaneous
Delivery pressure, (P1+P2)
total horsepower type that operates by the
sum of load pressures of the two pumps in
the tandem double-pump system, the prime
mover is automatically prevented from
being overloaded, irrespective of the load
condition of the two pumps, when
horsepower control is under way.
Since this regulator is of the simultaneous
total horsepower type, it controls the tilting
angles(displacement volumes) of the two
pumps to the same value as represented by
the following equation :
Tin = P1źq/2० + P2źq/2०
= (P1+P2)źq/2०
The horsepower control function is the
same as the flow control function and is
summarized in the following.

5) NEGATIVE FLOW CONTROL

By changing the pilot pressure X 1, the
pump tilting angle(delivery flow) is regulated
arbitrarily, as shown in the figure.
This regulator is of the negative flow control
in which the delivery flow Q decreases as
Delivery flow, Q

the pilot pressure X1 rises.

With this mechanism, when the pilot
pressure corresponding to the flow required
for the work is commanded, the pump
discharges the required flow only, and so it
does not consume the power uselessly. Pilot pressure, X1

2-11
 GROUP 2 MAIN CONTROL VALVE
1. STRUCTURE(1/2)

31
8
9
41
42

40 32 16
42 15
33 76
34 64
77
78
58 36 6
35 58
15
15
25

27

26
28
15 25 4
3

67
66
15 576
57 56
6 56 65
74
25 66
39 2 67
38 6 56
26 1 72
71
66
6 67
576
25 75 56
89 44 73
45
13 24 2 43
12 23 29
37
19 30
6 15 11
9
68 8
14 58 29
70 31 10
17 30
18 29
15 69 31
16

1 Cap 14 Cap 26 O-ring

2 O-ring 15 O-ring 27 O-ring
3 Socket bolt 16 Cap 28 Housing
4 Spring washer 17 Spring 29 O-ring
6 O-ring 18 Spring guide 30 Retainer
7 Orifice 19 Spool 31 Socket bolt
8 Cap 20 Cap 32 Plunger assy
9 O-ring 21 Spring 33 Plunger assy(Dozer)
10 Cover 22 Check 34 Plunger assy(SW)
11 Socket bolt 23 Cap 35 Plunger assy(BM2)
12 Piston 24 O-ring 36 Plunger assy(AM1)
13 Sleeve 25 O-ring 37 Cover assy

2-12
STRUCTURE(2/2)

8
9 31

42 16
40 15
81 76
42 51 77
52 78
63
58 80
55 54
56 15 15 62
55 657 53 61
56 66 7 60
6 57 67
59
73 79
56 6 56 6 8
55 57 9
566 67
66 1
5766 2
67

49 50
75
6
48 3
4
47
46
24
23
89 15

80
15 2
1
58
29
30 29
22
21 82 31 30
6 9 31
29 8
2
30
31

38 Spring 53 Plunger assy(BM1) 68 Spacer

39 Poppet 54 Plunger assy(AM2) 69 Cover
40 Cover 55 Cap 70 Piston
41 Retainer 56 Back up ring 71 O-ring
42 O-ring 57 Nylon chip 72 Sleeve
43 Cap 58 Overload assy 73 Cap
44 Spring 59 Spring 74 Cap
45 Spool 60 Check 75 Foot relief assy
46 Spool 61 O-ring 76 Plug
47 O-ring 62 Back up ring 77 Back up ring
48 Cover 63 Cap 78 O-ring
49 Socket bolt 64 Main relief assy 79 Cap
50 Housing 65 Cap 80 Make up assy
51 Plunger assy(OPT) 66 Spring 81 Plunger(TR)
52 Plunger assy(BKT) 67 Check 82 Stopper

2-13
2. FUNCTION
1) HYDRAULIC CIRCUIT

XAk2
Pal Ck1 fl dr1 fr

XAa1
Aa1
XAah XAa2
Ba1
XBa1 ARM1
XBa2 XBa2
XAas ARM2

Ab1
XAb1
Bb1
Op XBb2
XBb2 XBb1
BOOM2 BOOM1
dr4 dr8

Bs Ak1
XAs XAk
As Bk1
XAk2
XBs XBk
SWING BUCKET
Ck2
Bd Ao
XAd XAo
Ad Bo

XBd XBo
DOZER OPTION

At
XAt
Bt

XBt
TRAVEL

Pz P1 Px Py P2 R

Pi

2-14
2) BASIC OPERATION
(1) Bucket flow summation circuit
Oil from pump P2 is fed into cylinder port Ak1 by
adding pressure to bucket plunger pilot port XAk P2
P1
and the oil from actuator flow tank through Pp
cylinder port Bk1.
The center bypass valve is changeover by the
pilot pressure XAk2 and the oil from center P2
bypass passage flows to the bucket summation P1
Fl Fr
port Ck2 via outside piping and some others flow
into foot relief valve.
Then the oil from pump P1 is joins to the flow
from the pump P2 via confluence passage. TR

OPT TL

BKT SW

BM1 BM2

AM2 AM1

XAk2

Ck1
Center bypass
Spool B valve

To tank passage through

foot relief valve

P2 P1

Bk1 Ak1

BKT

XAk

Ck2

2-15
(2) Swing priority circuit
Oil from pump P1 is fed into cylinder port Bs via
center bypass passage by adding pressure to
P1 P2
swing plunger pilot port XBs. Pp
In case of simultaneous operation of swing and
arm, the delivery oil from P1 for swing is also
supplied to arm cylinder port Aa1. P2
P1
Meanwhile the pilot oil from the swing shuttle Fl Fr

valve flows into stroke limiter port XAaS of arm

spool, then the arm1 plunger does not full
stroke.
TR
Consequently, the swing priority is maintained.

OPT TL

BKT SW

BM1 BM2

AM2 AM1

P2 P1

AM2

XAa2

AM1 As Bs
SW

XAa1

XAaS XBs
AM1 Ba1 Aa1 SW
AM2

2-16
3) OPERATIONAL DESCRIPTION OF CONTROL VALVE
(1) Plunger operation
‫ ڸ‬Neutral position of plunger

Parallel feed passage

Cylinder port B Cylinder port A Port relief valve

Port relief valve

Pilot port b Pilot port a

Center bypass passage Low pressure passage Spring

Low pressure passage High pressure feed passage

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

2-17
‫ ڹ‬Operation of plunger

Parallel feed passage

Cylinder port B Cylinder port A Port relief valve

Port relief valve

Pilot port b Pilot port a

Center bypass passage Low pressure passage Spring

Low pressure passage High pressure feed passage

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

2-18
(2) Foot relief valve operation
‫ ڸ‬fp is lower than spring force

Pressure signal
sent out to the pump

Spring
Poppet

From center
bypass valve

fp To tank passage

Oil from the center bypass valve flows into the tank via orifice(A) of poppet.
Pressure fp generated by orifice(A) is led to the pump, to control the pump delivery flow.

‫ ڹ‬fp is higher than spring force

Pressure signal
sent out to the pump

Spring
Poppet

From center
bypass valve

fp To tank passage

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

2-19
(3) Center bypass valve operation
‫ ڸ‬Pilot pressure signal : OFF

From center bypass Spring(B)

Spool(A)

Drain line

Pilot signal
port(XAk2)

To tank passage via foot relief valve

Spring(B) sets spool(A) in position; oil from center bypass flows into the tank passage via the foot
relief valve.

‫ ڹ‬Pilot pressure signal : ON

From center bypass Spring(B)

Spool(A)

Drain line

Pilot signal
port(XAk2)

To tank passage via foot relief valve

To bucket summation port(Ck2)

When pilot pressure reaches a preset spring force, the spool(A) moves left and orificed the flow
to the foot relief valve.
Then the oil from center bypass flow into bucket summation port Ck2 via out side piping.

2-20
(4) Main relief valve operation
‫ ڸ‬High pressure setting pilot signal : OFF

Low pressure Passage Pilot poppet(D)

Main poppet(A) 5 4 Piston(E)

d1
d2
From pump Pilot
port side signal :OFF
(Pz)

1 2 3 Spring(B) Spring(C)

A. This relief valve is built in between the pump port side(1) and low pressure passage.
Piston(E) is seated right end by spring(C).
Hydraulic oil from the pump port side enters chamber(3) via orifice(2) of main poppet(A).
Because d2<d1, main poppet(A) is securely seated.

Pilot poppet(D)

5 4

Spring(C)

B. When hydraulic oil reaches the pressure preset by spring(C), pilot poppet(D) opens; oil flows
around poppet(D) and into the low pressure passage via side hole(4) and passage(5).

2-21
Low pressure passage
Main poppet(A)

d1
d2

1 2 3

C. When the above oil flow is formed, pressure drops before and behind orifice(2); when
pressure of chamber(1) x area d2 is large than pressure of chamber(3) x area d1, main
poppet(A) is opened and hydraulic oil flows into the low pressure passage.

‫ ڹ‬High pressure setting pilot signal : ON

Pilot poppet(E)

Pilot
signal : ON
(Pz)

Spring(C)

Piston(E) move to left by high pressure setting pilot signal; set pressure of spring(C) rises,
making high pressure setting.

2-22
(5) Overload relief valve operation
‫ ڸ‬Overload working operation

Pilot poppet(E) Poppet(C)

6 2 1
d4 d2 d1 d3

Cylinder port

4 5 Piston(A)
Spring(D) Main poppet(B) Low pressure passage

A. Hydraulic oil from cylinder port enters chamber(2) via orifice(3) of piston(A). Because d1<d2
and d3<d4, main poppet(B) and poppet(C) are securely seated.

Pilot poppet(E) Poppet(C)

6 1

Cylinder port

3
4 5 Piston(A)
Spring(D) Main poppet(B) Low pressure passage

B. When hydraulic pressure reaches the preset force of spring(D), pilot poppet(E) opens; oil
flows around pilot poppet(D) and into the low pressure passage via side hole(4) and
passage(5).
C. Oil flow is formed; pressure drops before and behind orifice(3); piston(A) moves to left and
seats at the tip of pilot poppet(E).

2-23
D. Hydraulic oil from chamber(1) enters chamber(2) via throttle(6) at the tip of pilot poppet(E); it
flows into the low pressure passage via side hole(4) and passage(5).

Pilot poppet(E) Poppet(C)

6 1
d4 d2 d1 d3

Cylinder port

4 5 Piston(A)
Spring(D) Main poppet(B) Low pressure passage

E. Pressure drops before and behind throttle(6), making pressure of chamber(1) x area
d1>pressure of chamber(2) x area d2; main poppet(B) is opened and hydraulic oil flows into
the low pressure passage.

2-24
‫ ڹ‬Make up operation

Pilot poppet(E) Poppet(C)

6
d4 d2 d1 d3

Cylinder port

4 5 Piston(A)
Spring(D) Main poppet(B) Low pressure passage

A. Poppet(C) is securely seated because the cylinder port pressure is normally higher than the
tank pressure and d3<d4.
B. When the cylinder port pressure drops(closer to negative pressure) until the cylinder port
pressure is lower than the tank pressure, poppet(C) opens receiving the tank pressure for
the difference in area between d3 and d4; oil flows from the low pressure passage(tank
passage) to the cylinder port in order to prevent cavitation.

2-25
 (6) Arm regeneration operation
‫ ڸ‬Arm operation

Parallel feed passage

(PA) (PB)
Low pressure passage

Aa1 Ba1
Tank passage

C1
C2
Pilot
port

XAa1

High pressure feed passage 2 1 3 4

Center bypass passage Piston(A) Spring(B) Spring(C)

When pressure is applied to pilot port XAa1 of the arm plunger, the plunger moves to right as
shown; the center bypass passage is shut off; oil from the parallel feed passage opens check
valve(C1) and flows into cylinder port Aa1(head side) via the high pressure feed passage.

2-26
 ‫ ڹ‬PB is higher than PA

Parallel feed passage

(PA) (PB)
Low pressure passage

Aa1 Ba1
Tank passage

C1
C2
Pilot
port

XAa1

High pressure feed passage

2 1 3 4

Center bypass passage Piston(A) Spool(B) Spring(C)

PA : Pressure of cylinder head side.

PB : Pressure of cylinder rod side.
Return oil from cylinder rod side opens check valve(C2) in the plunger; it flows into cylinder head
side after returning to the high pressure feed passage via passage(1) and (2) in the plunger.
At this time, the regeneration selector spool(B) is at the shown position; as passage(3) is shut off
from passage(4) return oil from cylinder rod side does not flow into the tank passage.

2-27
 ‫ ں‬PA is higher than PB

Parallel feed passage

(PA) (PB)
Low pressure passage

Aa1 Ba1
Tank passage

C1
C2
Pilot
port

XAa1

High pressure feed passage

2 1 3 4

Center bypass passage Piston(A) Spool(B) Spring(C)

Return oil from cylinder rod side is shut off by check(C2) in the plunger and passage(2) is blocked
from passage(1).
When pressure PA rises higher than the preset pressure of spring(C) and pushes piston(A) in the
regeneration selector to right as shown; spool(B) move to right; passage(3) and passage(4) are
connected; return oil from cylinder rod side flows into tank passage via low pressures passage,
passage(3) and passage(4).

2-28
 (7) Arm holding valve operation
‫ ڸ‬When the plunger is in neutral (Pal pilot signal : OFF)

Tank passage

High pressure
feed passage
Pilot signal port
7
Arm1 plunger (Pal)

To arm
cylinder rod 3(Pv)
(Ba1) d2
2(Pc)
4
Piston(A)
Check(D) d1 1
Poppet(B)
Check(C)
5
6
VIEW Z

Piston(A) and poppet(B) are in the status as shown; passages(5) and (6) are shut off by
poppet(B).
Therefore, the pressure of chamber(1) becomes pressure Pc as it is connected with chamber(2)
via orifice(4). Since d1>d2, check(D) is seated and chambers(2) and (3) are completely blocked.

2-29
 ‫ ڹ‬When the plunger is in operation (Pal pilot signal : ON)
Ϧ If Pv is higher than Pc(in the case of arm out)
When the pressure of pilot signal enters, piston(A) moves to left and poppet(B) opens;
passage(5) and (6) are connected.

Tank passage

High pressure
feed passage
Pilot signal port
7
(Pal)

To arm
cylinder rod 3(Pv)
(Bal1)
2(Pc)
4
Piston(A)
Check(D) 1
Poppet(B)
Check(C)
5
6
VIEW Z

Because check valve(C) is seated by pressure Pv via passage(7), passages(6) and (7) are
shut off. Therefore, the pressure of chamber(1) becomes Pc as it is connected to chamber(2)
via orifice(4); poppet(D) is opened; oil from high pressure feed passage flows into the cylinder
rod side.

2-30
 Ϧ If Pc is higher than Pv(in the case of arm in operation)

Tank passage

High pressure
feed passage
Pilot signal port
7
(Pal)

From arm
cylinder rod 3(Pv)
(Bal1) d2
2(Pc)
4
d1 Piston(A)
Check(D) 1
Poppet(B)

5 Check(C)
6
VIEW Z

When the pressure of pilot signal enters, piston(A) moves to left and poppet(B) opens;
passages(5) and (6) are connected.
If pressure Pc of cylinder port chamber(2) is higher than pressure Pv of chamber(3) (in the
case of arm in operation) oil from chamber(1) pushes up check valve(C) via passages(5) and
(6) and enters chamber(3) through passage(7). Chamber(3) is connected with the tank
passage because the arm plunger is moved to right. Therefore, pressure Pc is applied to(area
d1- area d2), pushing open poppet(D), and return oil from the cylinder rod side flows into the
tank passage.

2-31
GROUP 3 SWING DEVICE

1. STRUCTURE
Swing device consists swing motor, swing reduction gear.
Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve.

Reduction gear Swing motor Relief valve Mu dr3

Air bleed port

R/G drain port

Sh Pg A B
R/G grease fill port Time delay valve

Sh
Port Port name Port size
Pg
A Main port PF 3/4
B Main port PF 3/4
dr3 Drain port PF 3/8
dr3
Mu Make up port PF 1
Sh Brake release port PF 1/4
Pg Stand by port PF 1/4
A Mu B

Hydraulic circuit

2-32
1) SWING MOTOR

4 5 6 7 8 9 10 11 12 13 14 15 17, 18 30 31

3
2
16 31
1 36
35
17,18
37
38

29 28 27 26 25 24 23 22 21 20 19 34 33 32 39 40 41,42 43

1 Inner ring 16 Piston 30 Relief valve assembly

2 Oil seal 17 Cap 31 O-ring
3 Taper roller bearing 18 O-ring 32 Hexagon socket bolt
4 Plug 19 Coned disc spring 33 Time delay valve
5 Backing spring 20 Teflon ring 34 Hexagon socket bolt
6 Cam plate 21 Bushing 35 Cap
7 Return plate 22 Balance plate 36 Back up ring
8 Piston assembly 23 Needle bearing 37 Spring
9 Plate 24 Snap ring 38 Check valve
10 Lining plate 25 Cylinder assembly 39 Cover
11 O-ring 26 Housing 40 O-ring
12 Piston 27 Collar 41 O-ring
13 P-ring 28 Level gauge assembly 42 Back up ring
14 Spring 29 Snap ring 43 Bypass valve assy
15 Parallel pin

2-33
2) REDUCTION GEAR

1 2 3 4 5 6 7 8 9 10 11 12 13 14

23 22 21 20 19 18 17 16 15

24

1 Pinion shaft 9 Roller bearing 17 Shaft 2

2 Collar 10 Pin 18 Bushing
3 Snap ring 11 Planetary gear 4 19 Planetary gear 5
4 Plate 12 Ring gear 20 Thrust plate 2
5 Roller bearing 13 Holder assy 1 21 Spring pin
6 Gear casing 14 Sun gear 22 Holder 2
7 Plug 15 Lock bolt 23 Plug
8 Oil seal 16 Spring washer 24 Holder assy 2

2-34
2. FUNCTION
1) ROTARY PART
When high pressurized oil enters a cylinder through port(a), which is the inlet of balance plate(1),
hydraulic pressure acting on the piston causes axial force F. The pressure force F works via the
piston(2) upon the return plate(3) which acts upon the swash plate(4) via an hydrostatic bearing.
Force F1 perpendicular to swash plate(4) and force F2 perpendicular to cylinder center.
Being transferred to the cylinder block(5) through piston, force F2 causes rotational moment at
surroundings of cylinder.
Since cylinder block has 9 equidistantly arrayed pistons, rotational torque is transmitted to cylinder
shaft in order by several pistons connected to the inlet port of high pressurized oil. When the
direction of oil flow is reversed, rotational direction of cylinder is also reversed. Output torque is
given by the equation.
pźq F
T= , q=ZşAşPCDştanҋ , F1= , F2=F tanҋ, S=PCDźtanҋ
2० COSҋ
Where p : Effective difference of pressure(kgf/cm2)
q : Displacement(cc/rev)
T : Output torque(kgfşcm)
Z : Piston number(9EA)
A : Piston area(cm2)
ҋ: Tilting angle of swash plate(degree)
S : Piston stroke(cm)
PCD

S
ҋ
F2
F1
F

a a
High High Low
pressure oil pressure oil pressure oil

4 3 2 5 1

2-35
2) MAKE UP VALVE
In the system using this type of motor, there is no counter balance functioning valve and there
happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation
caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency.
A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure
feed pressure required when the hydraulic motor makes a pumping action. The boost pressure
acts on the hydraulic motor's feed port via the make up valve.
Pressurized oil into the port B, the motor rotate counterclockwise.
If the plunger of MCV moves neutral position, the oil in the motor is drain via left relief valve, the
drain oil run into motor via right make up valve, which prevent the cavitation of motor.

A B

2-36
3) RELIEF VALVE

1 Body
5 11
2 Seat
3 Plunger
6 10
4 Spring
9 7 5 Adjusting screw
6 Piston
8 7 Bushing
3
8 Spring seat
12
9 Shim
10 O-ring
1 11 Back up ring
12 O-ring
4

(1) Construction of relief valve

The valve casing contains two cartridge type relief valves that stop the regular and reverse
rotations of the hydraulic motor. The relief valves relieve high pressure at start or at stop of swing
motion and can control the relief pressure in two steps, high and low, in order to insure smooth
operation.
(2) Function of relief valve
Figure illustrates how the pressure acting
on the relief valve is related to its rising P P=pressure, T=time
process. Here is given the function, Ps
referring to the figure following page.
4
P2

3
P1

T
1

2-37
‫ ڸ‬Ports (P,R) at tank pressure.

A2 m h n g

A1
P

‫ ڹ‬When hydraulic oil pressure(PźA1) reaches the preset force(FSP) of spring(4), the plunger(3)
moves to the right as shown.
P1źA1=Fsp+PgźA2
Fsp+PgźA2
P1=
A1

4 g

P=P1

2-38
‫ ں‬The oil flow chamber g via orifice m and n. When the pressure of chamber g reaches the preset
force(FSP) of spring(4), the piston(6) moves left and stop the piston(6) hits the bottom of
bushing(7).

4 m n g

P=P2

‫ ڻ‬When piston(6) hits the bottom of bushing(7), it stops moving to the left any further. As the
result, the pressure in chamber(g) equals(Ps).
PsźA1=Fsp+PsźA2
Fsp
Ps=
A1-A2

P=Ps

7 6 g

2-39
4) BRAKE SYSTEM
(1) Control valve swing brake system
This is the brake system to stop the swing motion of the excavator during operation.
In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance
created by this throttling works as a brake force to slow down the swing motion.

Work Deceleration Stop

A B A B A B

MCV MCV MCV

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

(2) Mechanical swing parking brake system

The mechanical swing parking brake system is installed to prevent the upper structure from
swinging downhill because of its own weight when the excavator is parked on a slope since it
completely eliminates the hydraulic drift of swing motion while the excavator is on a slop, work can
be done more easily and safely.
‫ ڸ‬Brake assembly
Circumferential rotation of separate
plate(9) is constrained by the groove
located at housing(26). When housing is
pressed down by brake spring(16)
through lining plate(10), separate 14
plate(9) and brake piston(12), friction 12
force occurs there. 9
Cylinder(25) is constrained by this friction
10
force and brake acts, while brake
releases when hydraulic force exceeds 25
spring force. 26 Groove

9 Separate plate 14 Spring

10 Lining plate 25 Cylinder
12 Brake piston 26 Housing

2-40
‫ ڹ‬Operating principle
a. When the swing control lever(1) is set to the swing position, the pilot oil go to the swing control
valve(2) and to Sh of the time delay valve(3) via the shuttle valve(4), this pressure move
spool(5) to the leftward against the force of the spring(8), so pilot pump charged oil(P3) goes
to the chamber G.
This pressure is applied to move the piston(6) to the upward against the force of the spring(9).
Thus, it releases the brake force.

3 10 7

9 11
G
6
D
8
5

Pg Sh

1 Swing control lever

2 Swing control valve(MCV)
3 Time delay valve
12
4 Shuttle valve
5 Spool P3
6 Piston
7 Poppet
2 2
8 Spring
4
9 Spring
10 Orifice
11 Spring
12 Pilot pump

2-41
 b. Meantime, the oil pressure of port D balance with the preset force of spring(11), the pressure
of chamber G keeps constant pressure.

3 10 7

9 11
G
6
D

8
5

Pg Sh

1 Swing control lever

2 Swing control valve(MCV)
3 Time delay valve 12
4 Shuttle valve
P3
5 Spool
6 Piston
7 Poppet 2 2
8 Spring 4
9 Spring
10 Orifice
11 Spring
12 Pilot pump

2-42
 c. When the swing control(1) lever is set the neutral position, the spool(5) returns right in the time
delay valve(3).
Then, the piston(6) is moved lower by spring force and the return oil from the chamber G
flows back to D-port through orifice(10) of the poppet(7).
At this time, the poppet(7) works to make a time lag for 5 seconds.

3 10 7

9 11
G
6
D
8
5

Pg Sh

1 Swing control lever

2 Swing control valve(MCV)
3 Time delay valve 12
4 Shuttle valve
P3
5 Spool
6 Piston
7 Poppet 2 2
8 Spring 4
9 Spring
10 Orifice
11 Spring
12 Pilot pump

2-43
GROUP 4 TRAVEL MOTOR

1. CONSTRUCTION
Travel motor consists motor unit, regulator and counter balance valve.

Y B'(A') Motor unit U Regulator Counter balance valve

A B

VIEW V

Port Port name Port size

U A Main port SAE 6000psi 1"
Y
B Main port SAE 6000psi 1"
A'(B') S Make up port M22ź1.5
A' Gauge port M14ź1.5
B' Gauge port M14ź1.5
U Drain port M22ź1.5
Y Gauge port M14ź1.5

B A S

Hydraulic circuit

2-44
 1) MOTOR UNIT

1 2 3 5 6 7 10 25 24 11 14 15 29 31

13

12
26 18 20 17 16 28 30 19 28

1 Socket head screw 10 Ring 19 Shim

2 Seal ring 11 Spacer 20 Housing
3 Flange 12 Taper roller bearing 24 Threaded pin
4 Seal ring 13 Drive shaft 25 Threaded pin
5 O-ring 14 Piston 26 Screw plug
6 Shim 15 Retainer ring 28 Retainer ring
7 Retainer ring 16 Thrust washer 29 Cylinder block
8 Nut 17 Socket head screw 30 Pressure spring
9 Taper roller bearing 18 Center pivot 31 Ring

2-45
2) REGULATOR

22,23,24 25,27,28,26,29 16 18
42
30,34,32,31,
15 36,37,38
21 16
41 3
5
2

40
10

8
9
55
56
16
61
60
1 7 6 4 41 58 59

1 Bushing 21 Screw plug 36 O-ring

2 Port plate 22 Pilot 37 Support ring
3 Housing 23 Valve piston 38 Screw plug
4 Pipe 24 Screw plug 40 Seal ring
5 Cylinder pin 25 Shim 41 O-ring
6 Cylinder pin 26 Pressure spring 42 Socket head screw
7 Finger 27 Spring plate 55 O-ring
8 Piston 28 Shim 56 Support ring
9 Ring 29 Screw plug 58 Cover
10 Threaded pin 30 O-ring 59 Threaded pin
15 Housing 31 Valve seat 60 Nut
16 Screw plug 32 Valve sleeve 61 Socket head screw
18 Nozzle 34 Valve seat

2-46
 3) COUNTER BALANCE VALVE

62
80
B' L G A'
4
51 Byp. Byp. 51
52 B' A' 52

B A
41b 41

TN

10

41a B' A'

32
G
41

59

50 50
B A
37 S

2-47
2. FUNCTION
1) HYDRAULIC MOTOR
(1) Regulating motor with high pressure sensing control
In this regulating system the motor is normally fixed in its minimum displacement position. Upon
reaching a pre-selected pressure the motor switches steplessly towards its maximum
displacement.

A B

2 5

L(U)
3

The shuttle valve(1) will always connect the pressure control device(2) with that high pressure port
A or B carrying the higher pressure level(the shuttle valve feed line is equipped with a filter, in
order to protect the entire regulating device against contamination). Therefore, there is always
high pressure in front of the pressure regulator(2) and via channel(3) also on the small face of the
control piston(4). The small area of the control piston being pressurized and the large area
being unloaded via the pressure regulator the motor is always kept in its minimum displacement
position.

The pressure setting of the regulator defines the regulation begin, i.e. that pressure at which the
motor will start to shift towards maximum displacement. As soon as the pressure controller(2)
moves against the spring force, high pressure will be released upon the large area of the control
piston through channel(5). Due to the pressure forces resulting from the area differential the
motor is moved. The adaptation to the required torque is effected steplessly and the motor
maintains positively any position between Vmin and Vmax depending on the high pressure.

2-48
 (2) Control characteristic of the regulating motor

Maximum displacement
100 100
% %
The relevant displacement
self selected to match Output
80 the required torque torque 80

Output torque(Nm)
Displacemant(cm3/rev)

60 Minimum displacement(selected) 60

Required torque
40 40

Selected regulation
begin(RB)
20 Regulation end(RE) 20

ѧp

20 40 60 80 100 %

Maximum working pressure

The motor displacement is varied from Vmin to Vmax within the pressure range of P = PRE-PRB
which is normally about 10 to 15 bar. despite this relatively narrow band the resolution is very
good, because the torque is increased within this by about 2.8 times(depending on the minimum
displacement setting).

2-49
(3) Setting of minimum displacement

Limitation by threaded stud

There is a threaded stud(1) located at the Vmin side of the motor housing secured by the self
sealing nut(2).
In the Vmin position the valve plate(3) of the complete rotating assembly is stopped by this stud.
For changing the minimum displacement the stud(1) has to be turned after loosening nut(2).
Screwing in = Vmin becomes larger
Screwing out = Vmin becomes smaller
Due to the length of the threaded stud the range of adjustment of the minimum displacement is
limited(minimum swash angle 8 to 16Ş ).
Bigger minimum swash angles hence larger minimum displacements are possible upon request
to the factory.

2-50
2) COUNTER BALNCE VALVE

62
80
B' L G A'
4
51 Byp. Byp. 51
52 B' A' 52

B A
41b 41

TN

10
41a B' A'
G 32
41
59

50 50
B A
37 S

(1) Double acting counter-balance valve

The double acting counter balance valve consists of a cast housing(4), control piston(10) with its
check valve(41a) and the low pressure valves(41b) as well as its regulating spring(32). It also
comprises the 3/2 logic devices(51) in their brushes(52). In addition there are the check valves
(50) to separate working line A/B from TN channel, shuttle valve(59) to report load pressure at
port G, the pressure make-up valve(80) with downline orifice(62) to limit flushing oil at port L.

The double acting counter balance valve is mounted onto the hydraulic motor.

2-51
(2) Traveling under load
The counter balance valve being designed in a symmetric way only one direction of travel is
described here.
The oil flow coming from the main control valve(MCV) and arriving at B moves to port B' via
cone(51). Cone(51) is limited by a back stop and separates connection B/B' from bypass B'. Via
check valve(41a) and make up valve(41b) the working pressure arrives at the front end of the
control piston(10) and shifts the latter to the right towards spring(32). Bypass A' to channel TN is
thus opened(beginning of opening at approx. 8bar-full diameter at approx. 45bar).
Simultaneously travel pressure is built up via shuttle valve(59) at port G to control the regulating
motor.
Draining oil in this case moves to channel TN via port bypass A' and can flow direct to opened
working port A of MCV via check valve(50) on the right.
The oil motor is flushed via make up valve(80) and the subsequent orifice(62) if pressure at port
TN exceeds 5bar.
(3) Functioning of brake
If the oil entering at B is throttled or if the machine is stopped by a slope, pressure at B collapses
and the brake valve closes connection bypass A' to TN. Oil still flowing at first during opening(of
valve) is fed via check valve(50) at port B if pressure at A is higher than that at port B. As the
distance from channel TN via the check valve to port B is very short and as there may be negative
pressure at B When coming to a halt or when braking oil moves from TN to B. The distance from
TN via check valve(50) to A and to rotary oil distributor to the upper carriage being longer a
considerably higher dynamic pressure is built up. The check valve(50) to A remains closed.
(4) Reversing while slowing down the machine
The control piston is fully opened at full speed and at a travel pressure exceeding 40bar and
therefore has to move from open to closed position when travel speed is reduced. The closing
speed depends on the machine concerned and is adjusted by means of a cushioning.
Reversing while the piston moves towards closing position leads to the situation that the main
directional valve shifts the oil flow from B to port A. Pressure is built-up at port A, cone(51) is
moved towards pressure at port A' and closes connection A' to channel bypass A' when pressure
at port A' is exceeded. This means that the driver of the machine can initiate reversing which
overweighs when pressure at port A exceeds the oil pressure at A' still draining to bypass A'.
This set-up enables the construction of very smooth brake valves(long closing time for braking
piston) and at the same time guarantees piloted reversing of the machine. In this case control
piston(10) has locked mid- position to TN. Drifting rates of the machine correspond to only minor
leak oil here.
Via port(37) oil can be added to avoid cavitation if the solution described above proves to be
insufficient.

2-52
GROUP 5 RCV LEVER

1. STRUCTURE
The casing has the oil inlet port P(primary pressure) and the oil outlet port T(tank). In addition the
secondary pressure is taken out through ports 1,2,3 and 4 provided at the bottom face.

1 9Ş

19Ş
25Ş
Simultaneous Single
operation operation
Handle bending direction
(No. 3 push rod direction)
33Ş 33Ş

3 2
45Ş

P T

4 1

VIEW A

A
Port LH RH Port size

P Pilot oil inlet port Pilot oil inlet port

T Pilot oil return port Pilot oil return port
1 Left swing port Bucket out port
PF 1/4
T 2 Arm in port Boom down port
P 3 Right swing port Bucket in port
4 Arm out port Boom up port
1 32 4
Hydraulic circuit

2-53
CROSS SECTION
The construction of the pilot valve is shown in the attached cross section drawing. The casing has
vertical holes in which reducing valves are assembled.
The pressure reducing section is composed of the spool(201), spring(241) for setting secondary
pressure, return spring(221), washer(215), spring seat(216) and washer(217). The spring for setting
the secondary pressure has been generally so preset that the secondary pressure is 5 to 19 kgf/cm2
(depending on the type). The spool is pushed against the push rod(212) by the return spring.
When the push rod is pushed down by tilting the handle, the spring seat comes down simultaneously
and changes setting of the secondary pressure spring.
In case of the two point type electric switch is fitted, as shown in the attached cross section drawing,
the roller(451), switch lever(452) and switch(455) are built in the inside of the handle(401). When the
center of the handle cap(402) provided at the handle head is pushed, the roller is come down, and the
switch lever contacted with the roller tilts to make the switch function. The cord(456), connected to
the switch, is led through the handle section and casing to the outside.

101 Casing 216-1 Spring seat(port 1,3) 413 Plain washer

111 Port plate 216-2 Spring seat(port 2,4) 421 Screw 2
121 Seal washer 217 Washer 2 422 Nut
122 O-ring 221 Spring 431 Screw 3
125 Hex socket screw 241-1 Spring(port 1,3) 451 Roller
126 Spring pin 241-2 Spring(port 2,4) 452 Laever
131 Bushing 301 Universel joint 453 Switch seat 1
151 Plate 302 Plate 454 Switch seat 2
201 Spool 312 Adjust nut 455 Switch
211 Plug 314 Lock nut 456 Cord
212-1 Push rod(port 1,3) 323 Handle bar 457 Bushing
212-2 Push rod(port 2,4) 401 Handle 458 Tube
213 Seal 402 Handle cap 459 Terminal
214 O-ring 411 Screw 1 501 Bellows
215 Washer 1 412 Nut

2-54
CROSS SECTION

451

402
421
422
453
454
452

401
455
458 431

457 411 456

412
413
501
323
301
459 315
302

212-2 312

213
212-1
211
151
214
215
121
125 216-1
241-1
216-2 217
241-2 221
201
126
101
131 122
111

Port 2,4 Port 1,3

2-55
2. FUNCTIONS
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure(=secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port(P) where oil is supplied from hydraulic pump.
(2) Output ports(1,2,3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port(T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port or tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool(201) are to receive the supply oil pressure from the hydraulic pump at
its port P, and to change over oil paths to determine whether the pressure oil of port P is led to
output ports 1,2,3 & 4 or the output port pressure oil to tank port T.
The spring(241) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod(212) is inserted and can slide in the
plug(211).
For the purpose of changing the displacement of the push rod through the plate(302) and
adjusting nut(312) are provided the handle(401) that can be tilted in any direction around the
fulcrum of the universal joint(301) center.
The spring(221) works on the casing(101) and spring seat(216) and tries to return the push
rod(212) to the zero-displacement position irrespective of the output pressure, securing its
resetting to the center position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.

2-56
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram
shown below and the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.

5 6

3
1
3
P T

2 4

1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder

2-57
(1) Case where handle is in neutral position

T
241

221

201
P

1 3

The force of the spring(241) that determines the output pressure of the pilot valve is not applied to
the spool(201). Therefore, the spool is pushed up by the spring(221) to the position of port(1,3) in
the operation explanation drawing. Then, since the output port is connected to tank port T only, the
output port pressure becomes equal to tank pressure.

2-58
(2) Case where handle is tilted

212

201

1 3

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

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

2-59
GROUP 6 ACCELERATOR PEDAL

1. STRUCTURE
The casing has the oil inlet port A(primary pressure), and the oil return port T(tank). In addition the
secondary pressure is taken out through port P.

25

42

T
P

T
A
Port Port name Port size
P
A Pilot oil inlet port
T Pilot oil return port G 1/4

Hydraulic circuit P Pilot oil output port

2-60
GROUP 7 BRAKE PEDAL(VALVE)

1. STRUCTURE
The casing (spacer) has the oil inlet port A(primary pressure), and the oil outlet port T(tank). In
addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face.

15
10 12

14 5
6
37
1
19
36
21
28

51
24 21
11
31
38
52
25 22
12

Leading edge
32 35

1 Base plate 15 Pedal cover 32 Spring

5 Piston 19 Distance washer 35 Plug
6 Bellows 21 Spring set 36 Screw
10 Retainer ring 28 Upper spool 37 Restriction screw
12 Pedal 31 Lower spool 38 Plug
14 Pin

Port Port name Port size

24 11 Port M16ź1.5
51
11 21 12 Port M16ź1.5
21 Brake cylinder port M16ź1.5
22 Brake cylinder port M16ź1.5
24 Pluging M10ź1.0
25
52 25 Pluging M10ź1.0
12 22
51 Drain port M16ź1.5
52 Drain port M16ź1.5

Hydraulic circuit

2-61
2. FUNCTION
1) PURPOSE
The purpose of the brake valve is to sensitively increase and decrease the braking pressure when
the brake pedal is actuated.
2) READY POSITION
When the braking system is ready for operation, its accumulator pressure acts directly on port 11/12
of the brake valve. A connection is established between ports 21/22 and port 51/52 so that the
wheel brakes ports 21/22 are pressureless via the returns ports 51/52.
3) PARTIAL BRAKING
When the brake valve is actuated, an amount of hydraulic pressure is output as a ratio of the foot
force applied.
The spring assembly(21) beneath base plate(1) is designed in such a way that the braking pressure
changes depending on the angle. In the lower braking pressure range, the machine can be slowed
sensitively.
When the braking process is commenced, the upper spool(28) is mechanically actuated via spring
assembly(21), and the lower spool(31) is actuated hydraulically by spool(28). As spools(28 and
31) move downward, they will first close returns 51/52 via the control edges, thus establishing a
connection between accumulator port 11/12 and ports 21/22 for the wheel brake cylinders. The
foot force applied now determines the output braking pressure. The control spools(28 and 31) are
held in the control position by the force applied(spring assembly) above the spools and the
hydraulic pressure below the spool(balance of forces).
After output of the braking pressure, spools(28 and 31) are in a partial braking position, causing
ports 11/12 and 51/52 to close and holding the pressure in ports 21/22.
4) FULL BRAKING POSITION
When pedal(12) is fully actuated, an end position of the brakes is reached and a connection
established between accumulator ports 11/12 and brake cylinder ports 21/22. Returns 51/52 are
closed at this point.
When the braking process ended, a connection is once again established between brake cylinder
ports 21/22 and return ports 51/52, closing accumulator ports 11/12.
The arrangement of spools in the valve ensures that even if one braking circuit fails the other
remains fully operational. This is achieved by means of the mechanical actuation of both spools
and requires slightly more pedal travel.
5) LIMITING THE BRAKING PRESSURE
Pedal restriction screw(37) on base plate(1) below pedal(12) is used to limit the braking pressure.
6) FAILURE OF A CIRCUIT
In the event of the lower circuit failing, the upper circuit will remain operational. Spring assembly
(21) will mechanically actuate spool(28). In the event of the upper circuit failing, the lower circuit will
remain operational since the lower spool(31) is mechanically actuated by spring assembly(21) and
spool(28).
7) INSTALLATION REQUIREMENTS
Return lines 51/52 must be connected directly to the tank.
The connecting lines must be installed in such a way as to permit proper bleeding.

2-62
8) MAINTENANCE OF THE BRAKE VALVE
No special maintenance beyond the legal requirements is necessary.
When using high pressure cleaners on the machined, please make sure that the water jet is not
aimed directly at the brake valve(to prevent damaging the bellows).
Ɠ For safety reasons the whole of the brake valve must be replaced if parts other than those
listed above are damaged.
9) REPAIR WORK
Ɠ When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine is switched off there will be some residual
pressure in the system.
Ɠ When doing repair work, make sure your environment is very clean.
immediately close all open ports on the components and on pipes using plugs.
10) REPLACING THE PEDAL COVER
Pedal cover(15) is simply pulled off by hand. The new pedal covers is pushed over pedal(12) and
tightened manually. Fasten the bellows with the strap retainers.
11) REPLACING THE COMPLETE ACTUATING MECHANISM
Carefully clamp the unit vertically in a fixture. The actuating mechanism can be removed by taking
out the four screws(36) below base plate(1). Make sure that spring assembly(21) does not fall out.
When installing the new actuating mechanism, make sure that spring assembly(21) is fitted in the
right order. Tighten the four screws(36).
12) REPLACING THE BELLOWS
To change bellows(6) it is advisable to remove pedal(12). For this purpose, loosen retaining
ring(10) and knock out pin(14) using a mandrill. When knocking out the pin, make sure that the
mandrill is applied to the side of the pin without a knurl. Remove pedal(12) and bellows(6).
Now fit the new bellows(6) and proceed in reverse order as described above. The upper portion of
bellows(6) is fastened to piston(5), its lower portion to base plate(1) secure the bellows using
clamps.
13) REPLACING THE GROOVED RING
Carefully clamp the unit vertically in a fixture. Unscrew screw plug(35) and pull spools(28 and 31)
out downwards. Check the spools for damage. If they are found to be damaged, the whole brake
valve needs to be replaced(Pairs of spools and housings are matched in manufacturing).
If the spools are not damaged in any way, remove the whole actuating mechanism as described
above. Remove spring assembly(21) and grooved ring(27) and put in a new greased grooved ring
with its lips pointing downwards. Install both the spring assembly as shown in the drawing, and the
pedal. Put in spring(30), followed by spool(31), using a slight turning motion if possible.
Insert spring(32) and close the unit with screw plug(35).
Check return port 51/52 to see if there is a gap of approx. 2mm between the lower edge of the hole
and the control edge of spool(28). If this is not the case, take out screw plug(35) once more and
change the setting by removing or adding distance washers(19) in the upper spring plate. Replace
the screw plug and once again check the distance between the lower edge of the hole at port 51/52
and the control edge of spool(28).

2-63
GROUP 8 TRANSMISSION

1. STRUCTURE

Gauge port(High speed, J)

Gauge port(Low speed, M)
Brake breather E

X
Y

P1

P2

Oil drain

Leakage oil port(E)

Oil filler hole

Oil level check

Shift pressure port(Low speed, P2)

Shift pressure port(High speed, P1)

Disconnection device
(Lever position
when towing machine)

VIEW X VIEW Y

17032TM01

2-64
 2. TRANSMISSION DIAGRAM

From/To power control valve

M J B K P2 P1 L

Throttle Non return valve

check valve
Shift piston
Brake Accumulator Non return
change over valve
Brake Leakage oil
breather non return valve
Clutch Disconnection
device
Pressure
relief valve

E
Oil supply
transmission
Oil supply
transmission Lubricating oil pump
control
Lubricating oil

17032TM02

Port Name Size Port Name Size

P1 Shift pressure, High speed M16×1.5 M Gauge port, Low speed M14×1.5
P2 Shift pressure, Low speed M16×1.5 L Gauge port, Shift interlock M12×1.5
J Gauge port, High speed M14×1.5 E Leakage oil M14×1.5

2-65
3. OPERATION OF TRANSMISSION
1) DESCRIPTION

4 5 6 7

8
9

1 2 3

17032TM03

1 Travel motor 4 Disc clutch 7 Shift interlock

2 Spring cup 5 Planetary gear set 8 Helical gear 1
3 Disc brake 6 Disconnect device 9 Helical gear 2

Coaxially-mounted variable displacement travel motor(1) with specific displacement 105cm3/rev.

The 2-speed powershift transmission comprises a planetary gear set(5), a 2-shaft helical gear
drive(8) with output flanges to front and rear axle.
The powershift mechanism for the planet drive comprises a rotating multi-disc clutch(4) underneath
a multi-disc brake(3) rigidly connected to the housing. Both are closed by spring pressure(2) and
released hydraulically.
Between the planet drive and the helical drive, a disconnect device(6) is provided(Shifting when
machine standstill). It is actuated by means of a lever mounted on the transmission housing, with
firm locking in IN/OUT positions. This disconnect device interrupts the power drive train between
the powershift section and the output and thus allows the machine to be towed up to its maximum
speed and without special restrictions on distance.
When the disconnect device disconnected, the parking brake does not function.

2-66
 The disconnect device should only be used in emergency in order to remove the machine from a
danger zone should power fail or should transmission control pressure not be available.
The shift interlock(7) prevents downshifts at high machine speeds and thus prevents over-rotation of
the travel motor. If the low speed gear is selected while the high speed gear is engaged and input
speed is above approx. 800rpm, the low speed gear shift is inhibited and only performed if input
speed is below this limit. With higher viscosity oil(Cold starting), the downshift is performed at a
lower input speed. Upshifts are always possible.The speed-dependent interlock is effective in both
directions. It does not prevent the possibility of over-rotation when the machine is coasting. For this,
a drive brake valve should be fitted to the travel motor.

2) LOW SPEED(Forward & reverse)

Low speed pilot pressure applied

P2 P1
Ring gear Planetary carrier Helical gear 1

Input

Helical gear 2

Piston
Spring Sun gear
Clutch Output Output
Brake

17032TM04

In low speed operation, the planet drive ring gear is supported on the closed brake fixed to the
housing. In this gear, there is no pressure in the brake piston space so spring force acts on the
multi-disc pack. Therefore, the clutch is opened.

2-67
3) HIGH SPEED(Forward & reverse)

High speed pilot pressure applied

P2 Planetary carrier Helical gear 1

P1

Input

Helical gear 2

Piston
Spring Sun gear
Clutch Output Output
Brake

17032TM05

In high speed operation, the clutch is held closed under spring pressure and the brake is
hydraulically opened.
When a gear shift occurs-for example from high speed to low speed gear- the oil from the brake
piston space is fed back to the tank through a restrictor(Throttle non-return valve) due to the spring
pressure acting on the brake piston. At the same time the clutch is filled with oil and opened.
Required oil flow is necessary for the transmission control to ensure the clutch is open before the
brake begins to transmit torque.
A spring accumulator is also integrated in the transmission. This modulates the pressure sequence
at the brake during a downshift in order to achieve good shift quality.
The gear shift equipment also has the function of a parking brake. When the brake is operated-for
example with high speed gear engaged-the clutch is closed and is statically loaded.

2-68
4) BRAKES

Travel high & low speed

pilot pressure not applied

P2
P1

Output Output

17032TM06

When the travel high/low speed pilot pressure is not applied in the piston space, the piston
compress against the multi disc pack due to the spring force. Thus the parking brake is engaged.

2-69
4. TECHNICAL DATA
1) GENERAL DATA
(1) Max input power : 110kW
(2) Max input torque : 78.5kg·m
(3) Max input speed : 4500rpm
(4) Hydraulic motor : 105cm3/rev
(5) Transmission ratio
Gear step : 3.85
·Low speed gear : 5.35
·High speed gear : 1.39
(6) Shift interlock
Downshift possible at operating temperature with input speed 800rpm(Downshift point lower when
oil temperature cold).
(7) Disconnection device
For towing away machine auxiliary release device for parking brake.
(8) Brake
Parking brake. Necessary brake deceleration by controlled locking of planetary drive. Braking
torque depends on opening pressure set at brake valve(13bar).
(9) Output flange
Bolts for propshaft connection : M10×1.0(Class 10.9)
(10) Transmission weight : 125kg
2) TRANSMISSION CONTROL
Following data are valid for oil temperature 30。
C to 40。
C in hydraulic tank, measured at connections
at powershift transmission(See Structure and Diagram).
(1) Control pressure
① At connection P1 and P2 at Low/High engine speed : 33+1kg/cm2
② Definition of lubricants : API GL-5, SAE 10W-30, 15W-40
(2) Oil flow
① Min oil flow at 24+1kg/cm2 counter pressure(Low engine speed) : 5.5ℓ/min
② Max oil flow : 25ℓ/min
(3) Residual pressure
① Max residual pressure in control line to tank connection P1 respectively P2 : 1.0kg/cm2
(4) Leakage oil transmission control
① Pressure in input housing connection(E) max : 1.0kg/cm2
② Max oil flow(Low speed actuated) : 1ℓ/min

2-70
 GROUP 9 POWER CONTROL VALVE

1. STRUCTURE

P2

T2

Pilot travel P1 AC1 CHOCK T1 BR2a BR2b BR1bGP BR1aGP

BR1a
BR1b

AC4

AC1GP AC3

A BR2

B AC2GP

BR1

AC2

AC2 AC3
AC1 AB GP AC2 AC4
BR1
BR2 Port name Port size
AC1GP
P1, P2, T1, T2, AC1~AC4 3/4-16UNF
Pilot travel, CHOCK, BR1, BR2,
Pilot
travel
BR1aGP 9/16-18UNF
BR1a A, B, BR1a, BR2a, BR1b, BR2b,
BR2a

BR2b
AC1GP, AC2GP, BR1aGP, BR1bGP 7/16-20UNF
BR1b
CHOCK P1 T1 P2 T2 BR1bGP

Hydraulic circuit

2-71
2. FUNCTION

2 5,16

9,16
11
31
31
10
14
13
3
15 32
12 18

1
31 32

4 14
32 13
29 15
2830 12
27
25
23 26 32
34
33 35
32 14
21 32 13
22
19 7,17
15
12
6,17 8,16

1 Body 13 Spring 25 Spring

2 Pressure reducer assy 14 Chrome ball 26 O-ring
3 Relief valve assy 15 O-ring 27 O-ring
4 Relief valve assy 16 Connector 28 Back up ring
5 Solenoid valve 17 Connector 29 O-ring
6 Solenoid valve 18 Orifice plug 30 Back up ring
7 Solenoid valve 19 Unload valve 31 Plug
8 Solenoid valve 20 Honed assy 32 Plug
9 Solenoid valve 21 O-ring 33 Pressure reducer assy
10 Check valve 22 Back up ring 34 Orifice plug
11 Pilot valve 23 Retainer 35 Set screw
12 Check retainer 24 Honed assy

2-72
GROUP 10 STEERING VALVE

1. STRUCTURE

Section A-A

L R
T P
A A

L R

Port Port name Port size

L Left port
R Right port
3/4-16UNF
T Tank port
P Pump port
P T

Hydraulic circuit

2-73
2. COMPONENTS

26

2
26

25 2

1 2
24
27
29
5
2 6
9 7
2 34 8
2
12
2

11

13
14
15 18
16 21
15
16 23
17
18
20
22

1 Dust seal ring 11 Shaft 21 Screw

2 *Housing assy 12 Spring set 22 Name plate
3 Ball 13 O-ring 23 Drive screw
4 Bushing 14 Distributor plate 24 Pressure relief valve
5 O-ring 15 Gear wheel set 25 Wire spring
6 Kin-ring 16 O-ring 26 Shock valve
7 Bearing assy 17 End cover 27 Ball
8 Ring 18 Washer 29 Bushing
9 Cross pin 20 Pin screw

2-74
GROUP 11 AXLE
1. OPERATION
şThe power from the engine passes through main pump, travel motor and transmission and drive
shafts, and is then sent to the front and rear axles.
şInside the axles, the power passes from the bevel pinion to the bevel gear and is sent at right
angles. At the same time, the speed is reduced and passes through the both differentials to the axle
shafts. The power of the axle shafts is further reduced by planetary-gear-type final drives and is
sent to the wheels.
1) FRONT AXLE

Oil filler/level check

Oil drain Oil drain Oil filler/level check

Steering port
Air breather (M18x1.5)
A

A
Final drive Brake port Differential VIEW A
(M14x1.5)

2) REAR AXLE

Oil filler/level check

Oil drain Brake port Oil drain Oil filler/level check

(M14x1.5)

A
VIEW A

Final drive Air breather Differential

2-75
2. SECTION OF DIFFERENTIAL

2.2 9 23.1 3 22 27 21 20.1 17 12 11 10

1.2

25
24
28
26

25

29
30
4
2.1
5

1.1

9 23.2 20.2 7 19 18 16 15 14 13

1.1 Axle 1 11 Hex head nut 22 Allen head screw

1.2 Axle 2 12 Washer 23.1 Differential housing 1
2.1 Shim 13 Drive flange 23.2 Differential housing 2
2.2 Shim 14 Cover 24 Thrust washer
3 Tapered roller bearing 15 Shaft seal ring 25 Tapered gear
4 Tapered roller bearing 16 Tapered roller bearing 26 Differential axle
5 O-ring 17 Bushing 27 Thrust washer
6 Hex head screw 18 Shim 28 Differential axle
7 Screw 19 Tapered roller bearing 29 Roll pin
8 Washer 20.1 Pinion 30 Roll pin
9 Tie rod 20.2 Ring
10 Lock washer 21 Washer

2-76
3. DIFFERENTIAL

Rear axle
Differential

Front axle

The differential is installed on the front and rear axle to transfer the driving torque from the axle to
the wheels. The differential transfers half of the output torque of the transmission via the universal
drive shaft to the planetary gear of the wheel hubs and transfers the rpm and torque from the gear
via the pinion and the ring.
In addition, the differential also servers as an equalizer when going around curves. If the
mechanical connection from the transmission to the universal drive shaft, differential, shaft, and
planetary gears to the wheels would be rigid, every steering movement would strain the axle
construction and would result in increased tire wear.
The equalizing function comes from the special construction of the differential. The power input
from the input flange to the pinion shaft, ring and differential housing to the equalizing axle in the
differential housing meshes the four equalizing tapered gears with the axle gears, which are located
in the equalizing axles. This changes the relative direction of rotation between the shafts meshed
with the side gears. This means that one shaft turns clockwise and the other counterclockwise, and
one shaft turns faster than the other.
This balancing movement has the disadvantage that when traveling off road, traction is reduced on
uneven ground, on loose ground or on snow or ice only wheel per axle is engaged. This
disadvantage can be corrected in part by installing a self locking differential.

2-77
4. FINAL DRIVE
1) FRONT AXLE

3 2

1 Axle shaft 2 Planetary gear 3 Ring gear

4 Sun gear

(1) To gain a large drive force, the final drive uses a planetary gear system to reduce the speed and
send drive force to the tires.
(2) The power transmitted from the differential through axle shaft(1) to sun gear(4) is transmitted to
planetary gear(2). The planetary gear rotates around the inside of a fixed ring gear(3) and in this
way transmits rotation at a reduced speed to the planetary carrier.
This power is then sent to the wheels which are installed to the planetary carriers.

2-78
2) REAR AXLE

1 3 2

1 Axle shaft 2 Planetary gear 3 Ring gear

4 Sun gear

(1) To gain a large drive force, the final drive uses a planetary gear system to reduce the speed and
send drive force to the tires.
(2) The power transmitted from the differential through axle shaft(1) to sun gear(4) is transmitted to
planetary gear(2). The planetary gear rotates around the inside of a fixed ring gear(3) and in this
way transmits rotation at a reduced speed to the planetary carrier.
This power is then sent to the wheels which are installed to the planetary carriers.

2-79
5. TIRE AND WHEEL

1 Wheel rim 3 Flap 5 Stone resister ring

2 Tire 4 Tube 6 Valve assembly

1) The tire acts to absorb the shock from the ground surface to the machine, and at the same time
they must rotate in contact with the ground to gain the power which drives the machine.
2) Various types of tires are available to suit the purpose. Therefore it is very important to select the
correct tires for the type of work and bucket capacity.

2-80
 SECTION 3 HYDRAULIC SYSTEM
GROUP 1 HYDRAULIC CIRCUIT
şMACHINE SERIAL NO : -#0062
1 MAIN PUMP
2 MAIN CONTROL VALVE
22 37 38 35 33 34 36 3 SWING MOTOR
4 TRAVEL MOTOR
13 4
14 15 12 5 RCV LEVER
6 SOLENOID SELECTOR
7 ACCELERATOR PEDAL
8 GEAR PUMP
21 9 POWER CONTROL VALVE
10 STEERING VALVE
10 11 TURNING JOINT
12 OSCILLATING VALVE
11 13 TRANSMISSION
XAk2 14 FRONT AXLE
Pal Ck1 fl dr1 fr
2 15 REAR AXLE
16 BRAKE VALVE
dr2
T2 17 ACCUMULATOR
19
XAa1 18 ACCUMULATOR
18 40 Aa1
XAah XAa2
Ba1 19 ACCUMULATOR
8 XBa1

9 XBa2 XBa2 20 SHUTTLE VALVE

41 16 XAas
21 PILOT CHECK VALVE
Ab1

Op
XAb1
Bb1
22 OSCILLATING CYLINDER
XBb2
XBb2 XBb1 23 CHECK VALVE
dr4 dr8
Bs Ak1
24 CHECK VALVE
XAs XAk
As Bk1 25 OIL COOLER
XAk2
dr5 dr6 XBs XBk 26 STRAINER
45 Ck2
27 BYPASS VALVE
T1 42 Bd
Ao
XAd XAo
Bo
Ad 28 RETURN FILTER
XBd XBo
7 5 3 Sh 29 SPIN FILTER
ACCELERATOR SWING ARM BOOM BUCKET
At
XAt
30 AIR BREATHER
Pg
Bt
31 HYDRAULIC TANK
XBt
dr3
32 LINE FILTER
20 33 BOOM CYLINDER(RH)
XBa1 XAa1 XBb1 XAb1 XBk XAk

XBs XAs 34 BOOM CYLINDER(LH)

Pz P1 Px Py P2 R
Sh XAas
44Pi 35 ARM CYLINDER
39 39
36 BUCKET CYLINDER
fl
6 A Mu B 37 DOZER CYLINDER(RH)
fr
dr9
XBa1 XBd XAa1 XAd 38 DOZER CYLINDER(LH)
dr7 1 39 PRESSURE SWITCH
Pal 23
24 40 PRESSURE SWITCH
17 25
XAt XBt XAa2 Pz
43 30 41 PRESSURE SWITCH
T1 T2 31 42 PRESSURE SWITCH
Pg 32 dr1~dr10 43 SOLENOID VALVE
Pi
46 28 27
44 LAST GUARD FILTER
dr10
26 45 CHECK VALVE
XAah
29
46 LAST GUARD FILTER

3-1
şMACHINE SERIAL NO : #0063- 1 MAIN PUMP
2 MAIN CONTROL VALVE
3 SWING MOTOR
22 37 38 35 33 34 36 4 TRAVEL MOTOR
R 5 RCV LEVER
13 4
14 15 12 6 SOLENOID SELECTOR
L
P2 P1 7 ACCELERATOR PEDAL
8 GEAR PUMP
P 9 TRANSMISSION CONTROL VALVE
21 10 STEERING VALVE
L R
11 TURNING JOINT
10 12 OSCILLATING VALVE
13 TRANSMISSION
11 14 FRONT AXLE
XAk2 15 REAR AXLE
Pal Ck1 fl dr1 fr
2 16 BRAKE VALVE
17 ACCUMULATOR
dr2
P
T2
18 ACCUMULATOR
XAa1
Aa1
19 ACCUMULATOR
18 XAah XAa2
A B Ba1 20 SHUTTLE VALVE
8 40 19 16 XBa1
9 XBa2 XBa2 21 PILOT CHECK VALVE
41 XAas
42 22 OSCILLATING CYLINDER
Ab1
XAb1
Bb1
23 CHECK VALVE
Op
XBb2
XBb2 XBb1 24 CHECK VALVE
48 47 dr4 dr8
Bs Ak1
25 OIL COOLER
XAs XAk
As Bk1 26 STRAINER
XAk2
dr5 dr6 XBs XBk 27 BYPASS VALVE
P1 T1 P T 45 Bd
Ck2
28 RETURN FILTER
Ao
XAd XAo
Bo
Ad 29 SPIN FILTER
XBd XBo
7 5 3 Sh 30 AIR BREATHER
ACCELERATOR SWING ARM BOOM BUCKET
At
XAt
31 HYDRAULIC TANK
Pg
Bt
32 LINE FILTER
XBt
dr3
33 BOOM CYLINDER(RH)
20 (2) (4) (1) (3) (2) (4)
34 BOOM CYLINDER(LH)
XBa1 XAa1 XBb1 XAb1 XBk XAk
(1) (3)
Xbs Xas 35 ARM CYLINDER
Pz P1 Px Py P2 R
Sh XAas
44Pi 36 BUCKET CYLINDER
39 39
P1 P2 37 DOZER CYLINDER(RH)
fl (X1)
6 A Mu B A1 A2 38 DOZER CYLINDER(LH)
fr
dr9
(B1) (A1)
XBa1 XBd
(B2) (A2)
XAa1 XAd
39 PRESSURE SWITCH
dr7 A3
1 40 PRESSURE SWITCH
Pal 23
24 41 PRESSURE SWITCH
17 25
XAt
(A1)
XBt
(A2)
XAa2
(A3) (A4)
Pz
(A5) A6 A7
30 42 PRESSURE SWITCH
43 T1~T2 31 43 SOLENOID VALVE
P1
Pg 32 dr1~dr10 44 LAST GUARD FILTER
(P5)
P2
Pi
46 28 27
P3
P4
45 CHECK VALVE
dr10
26 46 LAST GUARD FILTER
XAah
(P6)
29
47 PRESSURE SWITCH
48 BRAKE SUPPLY VALVE

3-2
GROUP 2 MAIN CIRCUIT

The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit.
The hydraulic system consists of one main pump, one control valve, one swing motor, eight cylinders,
one travel motor, one transmission, one front axle and one rear axle.
The variable displacement bent axis piston pump is used as the main pump and is driven by the
engine at ratio 1.0 of engine speed.

1. SUCTION AND DELIVERY CIRCUIT

To cylinders To motors

Main control valve

To oil cooler To hydraulic oil tank

Main pump Suction filter

The pumps receive oil from the hydraulic tank through a suction filter. The discharged oil from the
pump flows into the control valve and goes out the tank ports.
The oil discharged from the main pump flows to the actuators through the control valve.
The control valve controls the hydraulic functions.
The oil returned from the actuators flows to the hydraulic tank through the control valve and the oil
cooler.

3-3
2. RETURN CIRCUIT

Full flow filter Check valve(2)

1.5kg/cm2

Main control valve Actuators

Check valve(1)
3.0kg/cm2

Bypass relief valve

1.5kg/cm2

All oil from each actuator returns to the hydraulic tank through the control valve.
The bypass check valves are provided in the return circuit.
The setting pressure of bypass check valves are 1.5kg/cm2(21psi) and 3.0kg/cm2(43psi). Usually, oil
returns to the hydraulic tank from the left side of control valve through oil cooler.
When oil temperature is low, viscosity becomes higher and flow resistance increases when passing
through the oil cooler. The oil pressure exceeds 3.0kg/cm2(43psi) the oil returns directly to the hydraulic
tank, resulting in the oil temperature being raised quickly at an appropriate level.
When the oil cooler is clogged, the oil returns directly to the hydraulic tank through bypass check
valve(1).
The return filter and bypass relief valve are provided in the hydraulic tank.
The oil from right and left side of control valve is combined and filtered by the return filter. A bypass
relief valve is provided in the return filter.
When the filter element is clogged, the bypass relief valve opens at 1.5kg/cm2 (21psi) differential pressure.

3-4
3. DRAIN CIRCUIT

Transmission Travel motor Swing motor

Main pump

Turning
joint

Check valve
Hydraulic 1.5kg/cm 2
tank

Spin filter

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

1) TRAVEL MOTOR DRAIN CIRCUIT

Oil leaking from the travel motor come out of the drain ports provided in the respective motor casing
and join with each other. These oils pass through the turning joint and return to the hydraulic tank
after be filtered by spin filter.
2) SWING MOTOR DRAIN CIRCUIT
Oil leaking from the swing motor come out and return to the hydraulic tank passing through a spin
filter.
3) MAIN PUMP DRAIN CIRCUIT
Oil leaking from main pump come out and return to the hydraulic tank passing through spin filter.
4) TRANSMISSION DRAIN CIRCUIT
Oil leaking from transmission come out and return to the hydraulic tank passing through spin filter.

3-5
GROUP 3 PILOT CIRCUIT

Remote control valve Remote control valve

(LH lever) (RH lever)

Swing parking brake

Control valve
Safety lock
solenoid valve
Solenoid valve
(power boost, travel direction)

Main pump Line filter Travel speed shift port

of transmission
Relief valve
40kg/cm2
Accelerator
pedal

Pilot pump Suction filter

The pilot circuit consists of suction circuit, delivery circuit and return circuit.
The pilot pump is provide with relief valve, receives the oil from the hydraulic tank through the suction
strainer.
The discharged oil from the pilot pump flows to the remote control, valve accelerator pedal, EPPR
valve, solenoid valves, swing parking brake, main control valve and safety lock solenoid valve
through line filter.

3-6
1. SUCTION, DELIVERY AND RETURN CIRCUIT

TRAVEL MOTOR DOZER CYL ARM CYL BOOM CYL BUCKET CYL
FRONT AXLE REAR AXLE

TRANSMISSION

POWER CONTROL ARM1

VALVE ARM2

BOOM1
BOOM2

SWING BUCKET

SWING
MOTOR DOZER OPTION
GEAR
PUMP

TRAVEL

PEDAL RCV LEVER(LH) RCV LEVER(RH)

ACCELERATOR SWING ARM BOOM BUCKET

HYD
SPIN T1~T2 TANK
FILTER
dr1~dr10
PILOT PUMP

SAFETY STRAINER
SOLENOID
VALVE
LINE FILTER
RELIEF VALVE
Pg
Pi

dr10

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

3-7
2. SAFETY SOLENOID VALVE (SAFETY LEVER)

TRAVEL MOTOR DOZER CYL ARM CYL BOOM CYL BUCKET CYL
FRONT AXLE REAR AXLE

TRANSMISSION

POWER CONTROL ARM1

VALVE ARM2

BOOM1
BOOM2

SWING BUCKET

SWING
MOTOR DOZER OPTION
GEAR
PUMP

TRAVEL

PEDAL RCV LEVER(LH) RCV LEVER(RH)

ACCELERATOR SWING ARM BOOM BUCKET

HYD
SPIN T1~T2 TANK
FILTER
dr1~dr10
PILOT PUMP

SAFETY STRAINER
SOLENOID
VALVE
LEVER
DOWN LINE FILTER
RELIEF VALVE
Pg
Pi

dr10
LEVER UP

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

3-8
3. MAIN RELIEF PRESSURE CHANGE CIRCUIT

TRAVEL MOTOR DOZER CYL ARM CYL BOOM CYL BUCKET CYL
FRONT AXLE REAR AXLE

TRANSMISSION

POWER CONTROL ARM1

VALVE ARM2

BOOM1
BOOM2

SWING BUCKET

SWING
MOTOR DOZER OPTION
GEAR
PUMP

TRAVEL

PEDAL RCV LEVER(LH) RCV LEVER(RH) MAIN RELIEF

VALVE Pz
ACCELERATOR SWING ARM BOOM BUCKET

HYD
SPIN T1~T2 TANK
FILTER
dr1~dr10
PILOT PUMP

POWER BOOST
SOLENOID
VALVE STRAINER
Pz
LINE FILTER
RELIEF VALVE
Pg
Pi

dr10

When the power boost switch on the left control lever is pushed ON,the power boost solenoid valve is
actuated, the discharge oil from the pilot pump flows into Pz port of the main relief valve of main
control valve ; then the setting pressure of the main control valve is raises from 320kgf/cm2 to
350kgf/cm2 for increasing the digging power. And even when pressed continuously, it is canceled after
8 seconds.

3-9
4. SWING PARKING BRAKE RELEASE

TRAVEL MOTOR DOZER CYL ARM CYL BOOM CYL BUCKET CYL
FRONT AXLE REAR AXLE

TRANSMISSION

POWER CONTROL
VALVE
ARM1
ARM2

BOOM1
BOOM2

SWING BUCKET
SWING MOTOR DEVICE

Sh DOZER OPTION

Pg
dr3

TRAVEL

A Mu B

PEDAL RCV LEVER(LH) RCV LEVER(RH)

ACCELERATOR SWING ARM BOOM BUCKET

HYD
SPIN T1~T2 TANK
FILTER
dr1~dr10
PILOT PUMP

SAFETY
Sh SHUTTLE VALVE SOLENOID
VALVE STRAINER
LINE FILTER

Pg
Pi RELIEF VALVE
dr10

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

3 - 10
GROUP 4 SINGLE OPERATION

1. BOOM RAISE CIRCUIT OPERATION

TRAVEL MOTOR DOZER CYL ARM CYL BOOM CYL BUCKET CYL
RONT AXLE REAR AXLE

TRANSMISSION

POWER CONTROL
VALVE

XBb1
Op XBb2
XBb2 XBb1
BOOM2 BOOM1

SWING MOTOR
MAKE UP VALVE
RELIEF VALVE

P1 P2 R

HYD FRONT REAR PILOT

TANK PUMP PUMP PUMP

When the right control lever is pulled to boom raise position, the oil flows from pilot pump through the
remote control valve to boom sections of the main control valve.
Here, the spool positions are moved to the boom raise position, and the boom circuits are opened.
The oil flows from the rod end of the cylinders are directed to the tank through the boom1 section of
the main control valve.
Cavitation and excessive pressure in the boom cylinder bottom end circuit is prevented by a overload
relief and make up valve in the main control valve.

3 - 13
2. BOOM DOWN CIRCUIT OPERATION

TRAVEL MOTOR DOZER CYL ARM CYL BOOM CYL BUCKET CYL
RONT AXLE REAR AXLE

TRANSMISSION

RELIEF VALVE
MAKE UP VALVE

POWER CONTROL
VALVE

XAb1
Op XBb2
XBb2 XBb1
BOOM2 BOOM1

SWING MOTOR

P1 P2 R

HYD FRONT REAR PILOT

TANK PUMP PUMP PUMP

When the right control lever is pushed forward to boom down position, the oil flows from pilot pump
through the remote control valve to boom section of the main control valve. Here, the spool positions
are move to the boom down position, and the boom down circuit is opened.
Oil flows from rear pump through boom1 section of the main control valve to the rod end of the boom
cylinders, and to down the boom.
The return oil flows from the bottom end of the cylinders to the tank through the boom1 section of the
main control valve.
Cavitation end excessive pressure in the boom cylinder rod end circuit is prevented by a overload
relief and make up valve in the control valve.

3 - 14
3. ARM ROLL IN CIRCUIT OPERATION

TRAVEL MOTOR DOZER CYL ARM CYL BOOM CYL BUCKET CYL
FRONT AXLE REAR AXLE

TRANSMISSION

MAKE UP VALVE
RELIEF VALVE

Pal

XAa1

XAah XAa2

XBa1
ARM1 ARM2
POWER CONTROL XBa2 XBa2
VALVE

SWING MOTOR

P1 P2 R

ARM HALF SOLENOID VALVE

XAa2

XAah
HYD FRONT REAR PILOT
TANK PUMP PUMP PUMP

Before operating, the outrigger switch is placed forward position.

When the left control lever manually is placed in the arm roll in position.
Then the oil flows from pilot pump through the remote control valve to arm sections of the main
control valve. Here, the spool positions are moved to arm roll in position.
The oil flows from both main pump through arm section of the main control valve to the bottom end of
the arm cylinder, and to roll in arm.
The return oil flows from the rod end of the cylinder through the arm1 section returned to the tank.
Then cavitation which will happen to the bottom of the arm cylinder is prevented by a make up
valve,on other hand. The excessive pressure is also prevented by an overload relief valve in the
main control valve.

3 - 15
6. BUCKET ROLL OUT CIRCUIT OPERATION

TRAVEL MOTOR DOZER CYL ARM CYL BOOM CYL BUCKET CYL
FRONT AXLE REAR AXLE

TRANSMISSION

Ck1
XAk2
CENTER
BYPASS VALVE

POWER CONTROL
VALVE

XAk
BUCKET
XAk2
XBk
Ck2

SWING MOTOR MAKE UP VALVE

RELIEF VALVE

P1 P2 R

HYD FRONT REAR PILOT

TANK PUMP PUMP PUMP

When the right control lever in manually placed in the bucket roll out position. Then the oil flows from
pilot pump through the pilot valve to bucket section of the main control valve. Here the spool position
is moved to bucket roll out position.
The oil flows from rear pump through bucket section of main control valve to the rod end of the bucket
cylinder, and to roll out bucket.
The return oil flows from the bottom end of the cylinder through the bucket section returned to the
tank.
The cavitation which will happen to the rod of the bucket cylinder is prevented by a make up valve, on
other hand. The excessive pressure is also prevented by an overload relief valve in the main control
valve.

3 - 18
7. DOZER UP CIRCUIT OPERATION

TRAVEL MOTOR DOZER CYL ARM CYL BOOM CYL BUCKET CYL
FRONT AXLE REAR AXLE

TRANSMISSION

PILOT CHECK
VALVE

POWER CONTROL
VALVE

SWING MOTOR XAd

RELIEF VALVE
MAKE UP VALVE XBd
DOZER

RCV LEVER(LH) P1 P2 R

SWING DOZER

HYD FRONT REAR PILOT

TANK PUMP PUMP PUMP

SELECTOR
SOLENOID
VALVE
XBa1 XBd XAa1 XAd

Before operating, the outrigger switch is placed backward position.

When the dozer blade switch is pushed backward and left control lever in manually placed in the
dozer blade up position. Then the oil flows from pilot pump through the remote control valve and
selector solenoid valve to dozer section of the main control valve.
Here the spool position is moved to dozer up position. The oil flows from front pump through dozer
section of main control valve to the rod end of the dozer cylinder, and to up the dozer.
The return oil flows from the bottom end of the dozer cylinder through the dozer section returned to
the tank.
The cavitation which will happen to the rod of the dozer cylinder is prevented by a make up valve, on
other hand. The excessive pressure is also prevented by an overload relief valve in the main control
valve.

3 - 19
8. DOZER DOWN CIRCUIT OPERATION

TRAVEL MOTOR DOZER CYL ARM CYL BOOM CYL BUCKET CYL
FRONT AXLE REAR AXLE

TRANSMISSION

PILOT CHECK
VALVE

POWER CONTROL
VALVE

SWING MOTOR XAd

XBd
DOZER
MAKE UP VALVE
RELIEF VALVE

RCV LEVER(LH) P1 P2 R

SWING DOZER

HYD FRONT REAR PILOT

TANK PUMP PUMP PUMP

SELECTOR
SOLENOID
VALVE
XBa1 XBd XAa1 XAd

Before operating, the outrigger switch is placed backward position.

When the dozer blade switch is pushed backward and left control lever in manually placed in the
dozer blade down position. Then the oil flows from pilot pump through the remote control valve and
selector solenoid valve to dozer section of the main control valve.
Here the spool position is moved to dozer down position. The oil flows from front pump through
dozer section of main control valve to the bottom end of the dozer cylinder, and to down the dozer.
the return oil flows from the rod end of the dozer cylinder through the dozer section returned to the
tank.
The cavitation which will happen to the rod of the dozer cylinder is prevented by a make up valve, on
other hand. The excessive pressure is also prevented by an overload relief valve in the main control
valve.

3 - 20
9. SWING OPERATION

TRAVEL MOTOR DOZER CYL ARM CYL BOOM CYL BUCKET CYL
FRONT AXLE REAR AXLE

TRANSMISSION

POWER CONTROL
VALVE

XAs
SWING
XBs
SWING MOTOR DEVICE

Sh

Pg
dr3

B Mu A

PEDAL RCV LEVER(LH) RCV LEVER(RH)

ACCELERATOR SWING ARM BOOM BUCKET

HYD
SPIN
TANK
FILTER
dr1~dr10 FRONT REAR PILOT
PUMP PUMP PUMP

XBs XAs SAFETY

Sh SOLENOID
VALVE
LINE FILTER

Pg
Pi

dr10

When the left control lever is manually placed in the left(right) swing position. Then the oil flows from
front pump through the swing section of the main control valve to swing motor to left(right) swing the
superstructure. The return oil flows from swing motor through the swing section of the main control
valve returned to the tank.
When the control lever placed in the neutral position, the pressure of the pilot oil passage down.
Then the brake release valve returned to the neutral position and the oil is returned from the brake
piston to the tank. And the brake is set to ON.

3 - 21
SWING CIRCUIT OPERATION

PARKING BRAKE

BRAKE RELEASE VALVE

Sh BRAKE OFF

Pg

BRAKE ON

dr

BYPASS VALVE

A MOTOR BRAKE VALVE

B
MAKE UP
PORT(Mu) MAKE UP VALVE

TO/FROM MAIN CONTROL VALVE

1) MOTOR BRAKE VALVE

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

4) BYPASS VALVE
This bypass valve absorbs shocks produced as swing motion stops and reduces oscillation cause
by swing motion.

3 - 22
10. TRAVEL FORWARD AND REVERSE OPERATION

TRAVEL MOTOR DOZER CYL ARM CYL BOOM CYL BUCKET CYL
FRONT AXLE REAR AXLE

TRANSMISSION

POWER CONTROL
TRAVEL PILOT VALVE
SOLENOID

T1
SWING
MOTOR
GEAR
PUMP

XAt

XBt
TRAVEL

MAKE UP VALVE
PEDAL RCV LEVER(LH) RCV LEVER(RH)
P1 P2 R
ACCELERATOR SWING ARM BOOM BUCKET

XBa1 XAa1 XBb1 XAb1 XBk XAk

HYD
XBs XAs
SPIN T1~T2 TANK
FILTER
Sh XAas dr1~dr10 FRONT REAR PILOT
PUMP PUMP PUMP

TRAVEL FORWARD/REVERSE SAFETY

SOLENOID VALVE SOLENOID
XBt XBt VALVE
LINE FILTER

Pg
Pi

dr10

When the LH multifunction switch is manually placed to the forward or reverse position. Then the oil
flows from pilot pump through the travel pilot solenoid of power control valve and travel Forward/
Reverse solenoid valve to travel section of the main control valve. Here, spool position is moved to
forward and reverse position. The oil flows from rear pump through the travel section of the main
control valve and turning joint to the travel motor and move the machine forward and reverse. The
return oil flows from travel motor through the turning joint and travel section returned to the tank. The
cavitation which will happen to the travel motor is prevented by a make up valve.

3 - 23
TRAVEL MOTOR OPERATION

TRAVEL MOTOR

OVERLOAD
RELIEF VALVE

COUNTER BALANCE
VALVE

CHECK VALVE

TURNING
JOINT

1) COUNTER BALANCE VALVE

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

3 - 24
11. FRONT AND REAR AXLE BRAKE SYSTEM(SERVICE BRAKE)

TRAVEL MOTOR DOZER CYL ARM CYL BOOM CYL BUCKET CYL
FRONT AXLE REAR AXLE

TRANSMISSION

POWER ARM1
ARM2
CONTROL BRAKE
VALVE VALVE

BOOM1
BOOM2

SWING BUCKET

T1 DOZER OPTION
SWING MOTOR
GEAR SOLENOID
PUMP VALVE

TRAVEL

HYD
SPIN T1~T2 TANK
FILTER
dr1~dr10 FRONT REAR PILOT
PUMP PUMP PUMP

LINE FILTER

Pg
Pi

dr10

When the brake pedal(valve) pushed, the discharged oil from the gear pump flow into front and rear
axle brake disc through the solenoid valve of power control valve.
This pressure is applied to axle brake disc, thus the brake is applied.

3 - 25
12. STEERING CIRCUIT OPERATION

TRAVEL MOTOR DOZER CYL ARM CYL BOOM CYL BUCKET CYL
FRONT AXLE REAR AXLE

TRANSMISSION

STEERING
CYLINDER

POWER ARM1
ARM2
CONTROL
VALVE

BOOM1
BOOM2

SWING BUCKET

T1 DOZER OPTION
SWING MOTOR
STEERING
VALVE

TRAVEL

GEROTOR

SPOOL

T2

GEAR
PUMP T2 HYD
SPIN
TANK
FILTER
dr1~dr10 FRONT REAR PILOT
PUMP PUMP PUMP

LINE FILTER

Pg
Pi

dr10

When the steering wheel is turned to the left or right, the spool within the steering valve turns in left or
right hand direction : Because the spool connected with steering column.
At this time, the oil discharged from the gear pump flows into steering cylinder through spool and
gerotor within the steering valve.
Then the steering direction is applied.

3 - 26
GROUP 5 COMBINED OPERATION
1. OUTLINE

TRAVEL MOTOR DOZER CYL ARM CYL BOOM CYL BUCKET CYL
FRONT AXLE REAR AXLE

TRANSMISSION

dr1

ARM1 ARM2
POWER CONTROL
VALVE

BOOM2 BOOM1

SWING BUCKET

SWING MOTOR

DOZER OPTION

TRAVEL

P1 P2 R

HYD FRONT REAR PILOT

TANK PUMP PUMP PUMP

In case operation, the oil flows from both main pumps through the neutral oil passage to bypass oil
passage and confluence oil passage. Then the oil is supplied to each actuator and function them.
Check valves and orifices are provided with on these flow passage. These control the oil flows from
the pump corresponding to the each actuator's state of functioning and smooth the combined
operation.

3 - 28
2. COMBINED SWING AND BOOM OPERATION

TRAVEL MOTOR DOZER CYL ARM CYL BOOM CYL BUCKET CYL
FRONT AXLE REAR AXLE

TRANSMISSION

dr1

POWER CONTROL
VALVE

XAb1
Op XBb2
XBb2 XBb1
BOOM2 BOOM1

XAs

XBs
SWING

SWING MOTOR

P1 P2 R

HYD FRONT REAR PILOT

TANK PUMP PUMP PUMP

When the swing and boom functions are operated, simultaneously the swing spool and boom spools
changed. The oil flows from the rear pump through boom1 section of the main control valve to boom
cylinders and the boom functions.
The oil flows from front pump through swing section to swing motor. At the same time the pressure in
the boom circuits can be high while the swing pressure is low therefore the oil flows from front pump
to boom cylinders through boom2 section via confluence passage in case boom raise operation.

3 - 29
3. COMBINED SWING AND ARM OPERATION

TRAVEL MOTOR DOZER CYL ARM CYL BOOM CYL BUCKET CYL
FRONT AXLE REAR AXLE

TRANSMISSION

Pal dr1

XAa1

XAa2 XAa2

XBa1
ARM1 ARM2
POWER CONTROL XBa2 XBa2
VALVE XAas

XAs

XBs
SWING

SWING MOTOR

P1 P2 R

ARM HALF SOLENOID VALVE FROM SWING LEVER

XAa2
XBs XBs
HYD FRONT REAR PILOT
XAah Sh XAas TANK PUMP PUMP PUMP

When the swing and arm functions are operated, simultaneously the swing and arm spools changed.
The oil flows from the front pump through arm1 and swing section of the main control valve to arm
cylinder and swing motor, and the arm and swing functions.
At the same time, the oil flows from the rear pump through arm2 section of the main control valve to
arm cylinder.
Meanwhile, the pilot oil pressure(XAas) of swing shuttle valve flows into the stroke limiter of arm
spool, then the swing priority is maintained.

3 - 30
 SECTION 4 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION

1. LOCATION 1
4
5
6
7
8
9
10
11
12

P
13
1 14
15
2 16
17
18
3

19

20

21

22

23

24
25
26
27
28

1 Horn switch 10 Ram lock switch 20 Cassette & radio

2 RH multifunction switch 11 Arm half switch 21 Warning indicator
3 Cluster 12 Aircon switch 22 Aircon & heater switch
4 Parking switch 13 Service meter 23 CPU controller
5 Starting switch 14 Breaker switch(option) 24 Relay
6 Cigar lighter switch 15 Cold start switch(option) 25 Resistor
7 Hazard switch 16 Beacon switch(option) 26 Prolix switch
8 Outrigger switch 18 Main light switch 27 Emer engine acc lever
9 Dozer blade switch 19 Fuse box 28 LH multifunction switch

4-1
2. LOCATION 2

11
12
1 13
2 14
3 15
4 16
5 17
6 18
7 19
20
16
21

22
23
8
9 24
10

25

10
9

1 Temperature sendor 10 Head lamp 18 Number plate lamp

2 Start relay 11 Hydraulic temperature sendor 19 Engine speed sensor
3 Fuel sendor 12 Heater adapter 20 Engine oil pressure switch
4 Fuel filler pump 13 Heater valve 21 Coolant level sendor
5 Connector plate 14 Over heat switch 22 Altemator
6 Battery relay 15 Adapter 23 Connector plate
7 Battery 16 Rear combination lamp 24 Air cleaner switch
8 Work light 17 Governor motor 25 Connector plate
9 Front combination lamp

4-2
GROUP 2 ELECTRICAL CIRCUIT
MACHINE SERIAL NO. : -#0062 (1/2)

4-3
MACHINE SERIAL NO. : -#0062 (2/2)

RH SIDE ENG. SIDE

4-4
MACHINE SERIAL NO. : #0063- (1/2)

4-5
MACHINE SERIAL NO. : #0063- (2/2)

RH SIDE ENGINE SIDE

ENG. SIDE

4-6
1. POWER CIRCUIT
The negative terminal of battery is grounded to the machine chassis.
When the start switch is in the OFF position, the current flows from the positive battery terminal as
shown below.
1) OPERATING FLOW
Battery Battery relay Fusible linkŭCN-60(1)Ů I/connŭCN-5(1)Ů I/connŭCN-40(1)Ů
Fuse boxŭNo.19Ů I/connŭCN-38(4)Ů I/connŭCN-6(4)Ů Room lampŭCL-1(2)Ů
Cassette radioŭCN-27(7)Ů
Fuse boxŭNo.18Ů I/connŭCN-38(3)Ů I/connŭCN-8(6)Ů ClusterŭCN-57(6)Ů
CPU controllerŭCN-50(10)Ů
Fuse boxŭNo.17Ů I/connŭCN-38(2)Ů Flasher unitŭCR-11(2)Ů
Fuse boxŭNo.16Ů I/connŭCN-38(1)Ů Start key switchŭCS-2(1)Ů
ƓI/conn : Intermediate connector

2) CHECK POINT

Engine Start switch Check point Voltage

‫ ڸ‬- GND (Battery 1 EA) 10 ~ 12.5V

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

4-7
POWER CIRCUIT

4-8
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Battery relay(M8, B+ terminal) Fusible linkŭCN-60(1)Ů
I/connŭCN-5(1)Ů I/connŭCN-40(1)Ů Fuse boxŭNo.16Ů I/connŭCN-38(1)Ů
Start switchŭCS-2(1)Ů

(1) When start key switch is in ON position

Start switch ONŭCS-2(2)Ů I/connŭCN-4(10)Ů Battery relayŭM4 terminalŮ
Battery relay operating(All power is supplied with the electric component)
Start switch ONŭCS-2(3)Ů I/connŭCN-36(1)Ů
Fuse boxŭNo.1Ů
Fuse boxŭNo.3Ů
Fuse boxŭNo.2Ů I/connŭCN-36(3)Ů I/connŭCN-1(3)Ů
Fuel cut-offŭCN-79Ů

(2) When start key switch is in START position

Start switch STARTŭCS-2(5)Ů Start safety relayŭCR-5(2)‫(آ‬4)Ů I/connŭCN-1(1)Ů
Start relayŭCR-23(1)Ů

2) CHECK POINT

Engine Start switch Check point Voltage

‫ ڸ‬- GND (Battery)
‫ ڹ‬- GND (Start key)
‫ ں‬- GND (Battery relay)
Operating Start ‫ ڻ‬- GND (Start B+) 20 ~ 25V
‫ ڼ‬- GND (Start M)
‫ ڽ‬- GND (Start relay)
‫ ھ‬- GND (Battery relay)

Ɠ GND : Ground

4-9
STARTING CIRCUIT

4 - 10
3. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the ON
position.
Charging current generated by operating alternator flows into the battery through the Battery
relay(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse
box.
1) OPERATING FLOW
(1) Warning flow
AlternatorūIŬterminal I/connŭCN-1(2)Ů CPU Alternator power level
ŭCN-51(18)Ů
,
Charging lampŭCN-53(7)Ů I/connŭCN-7(7)Ů Cluster charging warning lamp
ŭCN-56(7)Ů

(2) Charging flow

Alternator B+ terminal Battery relay (M8) Battery(+) terminal
Fusible linkŭCN-60(2)Ů
I/connŭCN-5(2)Ů I/connŭCN-40(2)Ů Fuse Box

2) CHECK POINT

Engine Start switch Check point Voltage

‫ ڸ‬- GND (Battery voltage)
‫ ڹ‬- GND (Battery relay)
‫ ں‬- GND (Alternator B terminal)
ON ON ‫ ڻ‬- GND (Alternator I terminal) 20 ~ 27V
‫ ڼ‬- GND (CPU)
‫ ڽ‬- GND (CPU)
‫ ھ‬- GND (Cluster)

Ɠ GND : Ground

4 - 11
CHARGING CIRCUIT

4 - 12
4. HEAD LIGHT AND CLEARANCE LAMP CIRCUIT
1) OPERATING FLOW
Fuse box (No.12) I/connŭCN-37(1)Ů Main light switchŭCS-21(1), (4)Ů
I/connŭCS-12(1)Ů RH multifunction switch(IG)
passing function operating by RH multifunction
up and down.

(1) Main light switch ON : 1st step

Main light switch ONŭCS-21(5)Ů I/connŭCN-7(9)Ů Cluster illumination lamp ON
ŭCN-56(9)Ů
LH clearance lamp ONŭRear:CL-15(4), Front:CL-24(1)Ů
I/connŭCN-11(10)Ů RH clearance lamp ON
ŭRear:CL-16(4), Front:CL-25(1)Ů
I/connŭCN-3(3)Ů Number plate lamp ONŭCL-21(2)Ů

(2) Main light switch ON : 2nd step

Main light switch ONŭCS-21(2)Ů Switch indicator lamp ONŭCS-21(9)Ů
I/connŭCS-12(2)Ů ‫ ڸ‬or ‫ڹ‬
‫ ڸ‬RH multifunction switch : Lo
I/connŭCS-12(4)Ů Head light low beam ONŭCL-3(1), CL-4(1)Ů
‫ ڹ‬RH multifunction switch : Hi
I/connŭCS-12(6)Ů Head light high beam ONŭCL-3(2), CL-4(2)Ů

2) CHECK POINT

Engine Start switch Check point Voltage

‫ ڸ‬- GND(Fuse box)
‫ ڹ‬- GND(Switch power input)
‫ ں‬- GND(Switch power output)
‫ ڻ‬- GND(Switch power output)
STOP ON 20 ~ 25V
‫ ڼ‬- GND(Switch power input)
‫ ڽ‬- GND(Head lamp)
‫ ھ‬- GND(Clearance lamp)
‫ ڿ‬- GND(Numberplate lamp)

Ɠ GND : Ground

4 - 13
HEAD LIGHT AND CLEARANCE LAMP CIRCUIT

4 - 14
5. WORK LAMP CIRCUIT
1) OPERATING FLOW
Fuse box (No.13) I/connŭCN-37(2)Ů Work light switchŭCS-36(5)Ů
Work light switchŭCS-36(6)Ů

Ɠ When work light switch ON

Work light switch ONŭCS-36(1),(2)Ů I/connŭCN-7(10)Ů Cluster work lamp ONŭCN-56(10)Ů
I/connŭCN-4(6)Ů I/connŭCN-10(2)Ů
Work light ONŭCL-5(2), CL-6(2)Ů
Switch indicator lamp ONŭCS-36(9)Ů

CHECK POINT
2)

Engine Start switch Check point Voltage

‫ ڸ‬- GND(Fuse box)
‫ ڹ‬- GND(Switch power output)
STOP ON ‫ ں‬- GND(Switch power input) 20~25V
‫ ڻ‬- GND(Cluster)
‫ ڼ‬- GND(Work lamp)
Ɠ GND : Ground

4 - 15
WORK LAMP CIRCUIT

4 - 16
6. BEACON LAMP CIRCUIT
1) OPERATING FLOW
Fuse box (No.10) I/connŭCN-36(11)Ů Beacon lamp switchŭCS-23(6)Ů

Ɠ When lamp switch ON

Beacon lamp switch ONŭCS-23(2)Ů I/connŭCN-6(6)Ů I/connŭCN-14(3)Ů
Beacon lamp ONŭCL-7Ů
Switch indicator lamp ONŭCS-23(9)Ů

2) CHECK POINT

Engine Start switch Check point Voltage

‫ ڸ‬- GND (Fuse box)
‫ ڹ‬- GND (Switch power input)
STOP ON 20 ~ 25V
‫ ں‬- GND (Switch power output)
‫ ڻ‬- GND (Beacon lamp)
Ɠ GND : Ground

4 - 17
BEACON LAMP CIRCUIT

4 - 18
7. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
Fuse box (No.5) I/connŭCN-36(6)Ů Inter wiper relayŭCR-6(4)Ů
Wiper relayŭCR-4(2),(6)Ů
Washer tankŭCN-22(2)Ů
I/connŭCN-6(2)Ů I/connŭCN-13(3)Ů
Wiper motorŭCN-21(3)Ů
(1) Washer switch ON
Washer switch ONŭCS-11(2)‫( آ‬1)Ů Inter wiper relayŭCR-6(1) ‫( آ‬3)Ů
Wiper switchŭCS-11(7) ‫( آ‬5)Ů
Wiper relayŭCR-4(4) ‫( آ‬1)Ů
I/connŭCN-6(1)Ů I/connŭCN-13(1)Ů
I/connŭCN-21(1)Ů Wiper motor operating
Washer tankŭCN-22(2) ‫( آ‬1)Ů Washer operating
(2) Wiper switch ON : INT position
Wiper switch ONŭCS-11(2) ‫( آ‬4)Ů Inter wiper relayŭCR-6(6) ‫( آ‬4), CR-6(4) ‫( آ‬3)
ON/OFFŮ Wiper switchŭCS-11(7) ‫( آ‬5)Ů Wiper relayŭCR-4(4) ‫( آ‬1)Ů
I/connŭCN-6(1)Ů I/connŭCN-13(1)Ů I/connŭCN-21(1)Ů
Wiper motor intermittently operating
(3) Wiper switch ON : Lo and Hi position
Wiper switch ONŭCS-11(2) ‫( آ‬5) or (6)Ů Wiper relayŭCR-4(4) ‫( آ‬1)Ů
I/connŭCN-6(1)Ů I/connŭCN-13(1)Ů I/connŭCN-21(1)Ů Wiper motor operating
(4) Auto-parking(when switch OFF)
Wiper motorŭCN-21(1)Ů OFF Fuse box(No.5) I/connŭCN-36(6)Ů
I/connŭCN-6(2)Ů I/connŭCN-13(3)Ů Wiper motorŭCN-21(3) ‫( آ‬4)Ů
Wiper motor stop

2) CHECK POINT

Engine Start switch Check point Voltage

‫ ڸ‬- GND (Fuse box)
‫ ڹ‬- GND (INT wiper relay)
‫ ں‬- GND (INT wiper RY washer output)
‫ ڻ‬- GND (INT wiper RY INT power output)
‫ ڼ‬- GND (INT wiper RY power input)
STOP ON ‫ ڽ‬- GND (INT wiper RY INT output) 20~25V
‫ ھ‬- GND (Relay power input)
‫ ڿ‬- GND (Relay coil)
‫ ۀ‬- GND (Relay output)
‫ ہ‬- GND (Wiper power input)
‫ ۂ‬- GND (Wiper motor)
Ɠ GND : Ground

4 - 19
WIPER AND WASHER CIRCUIT

4 - 20
CONTROLLER CIRCUIT

4 - 21
ELECTRIC CIRCUIT FOR HYDRAULIC

4-22
GROUP 3 MONITORING SYSTEM

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

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

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

Battery(B+) Signal ground

Battery relay Power ground

4 - 25
2. CLUSTER
1) Monitor panel

Fuel gauge Clock and

tachometer

Battery charging Engine coolant

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

Air cleaner
warning lamp Work lamp
POWER MODE indicator lamp
Hyd oil temp H S L F
warning lamp Fuel low
AUTO SELECT level lamp
DECEL
Power mode H M
switch Select switch
TRAVEL SPEED ENGINE SPEED
Automatic
Buzzer stop
deceleration
switch
switch

Travel speed Engine speed

pilot lamp control switch

4 - 26
2) CLUSTER CHECK PROCEDURE
(1) Start key : ON
‫ ڸ‬Check monitor initial 3 seconds
a. All lamps light up.
b. Buzzer sound.

‫ ڹ‬Check monitor after 3 seconds : indicate machine condition

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

‫ ں‬Switch portion
a. Mode selection : S mode
b. Auto decel LED : ON

(2) Start of engine

‫ ڸ‬Check machine condition
a. Tachometer indicate at present rpm
b. Gauge and warning lamp : indicate at present condition.
Ɠ When normal condition : All warning lamp OFF
c. Mode selection : S mode
d. Auto decel : ON(about 800rpm)
e. Travel speed : Low(turtle)

‫ ڹ‬When warming up operation

a. Warming up lamp : ON
b. 3 seconds after engine started, engine speed increases to 1650rpm speed (Auto decel LED :
ON)
Ɠ Others same as above ‫ڸ‬

‫ ں‬When abnormal condition

a. The lamp lights up and the buzzer sounds.

4 - 27
3. CLUSTER CONNECTOR
1) CN-57 CONNECTOR

No. Signal Input/ CN-57

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

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

16 Warming up output

4 - 28
4. CLUSTER FUNCTION
1) TACHOMETER
‫ ڸ‬Tachometer displays the number of engine revolutions.
‫ ڹ‬Refer select switch for the selection and adjustment.

rpm

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

TIME

3) FUEL GAUGE
Green D E ‫ ڸ‬This gauge indicates the amount of fuel in the fuel tank.
F
şSegment A : Approximately 30ֻ(Warning lamp display)
C F şSegment B : Approximately 65ֻ
B şSegment C : Approximately 100ֻ
Red şSegment D : Approximately 138ֻ
A E şSegment E : Approximately 176ֻ
şSegment F : Approximately 214ֻ
şQuantity of fuel tank : Approximately 250ֻ

4) ENGINE COOLANT TEMPERATURE GAUGE

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

4 - 29
5) COOLANT LEVEL WARNING LAMP
‫ ڸ‬This lamp is turned ON when the coolant is below LOW in the
reservoir tank of radiator.
‫ ڹ‬Check if the coolant level is between FULL and LOW in the
reservoir tank locating the side of radiator after opening the
engine cover, and check if there is mixture of oil and coolant.

6) BATTERY CHARGING LAMP

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

7) WORKING LIGHT LAMP

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

8) HYDRAULIC OIL OVERHEAT WARNING LAMP

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

9) ENGINE OIL PRESSURE WARNING LAMP

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

4 - 30
10) AIR CLEANER WARNING LAMP
‫ ڸ‬This lamp operates by the vacuum caused inside when the filter
of air cleaner is clogged which supply air to the engine.
‫ ڹ‬Check the filter and wash or replace it when the lamp operates.

11) OVERHEAT WARNING LAMP

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

12) WARMING UP LAMP

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

13) MODE SELECTION SWITCH

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

14) AUTO DECELERATION SWITCH

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

4 - 31
15) ENGINE SPEED CONTROL SWITCH
‫ ڸ‬This switch is to control the engine speed which is increased by
pressing switch and decreased the engine speed by pressing
ENGINE SPEED
switch.

16) SELECTION SWITCH(tachometer and clock)

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

17) BUZZER
‫ ڸ‬This buzzer sound is stopped by touching this buzzer stop
switch.
‫ ڹ‬This sound is continuous sound which comes out when a
M warning lamp on the cluster or warning indicator lights up.

4 - 32
5. WARNING INDICATOR FUNCTION

Left turning lamp Head light

high beam lamp Right turning lamp

Clutch oil pressure Brake oil pressure

warning lamp warning lamp

Parking lock Working lock

warning lamp Ram lock warning lamp
warning lamp

1) Left turning lamp

‫ ڸ‬This lamp flashes with sound when the RH multifunction switch is
move to forward position.
‫ ڹ‬The flashing sound(50dB) is generated from inside of the cab.

2) Right turning lamp

‫ ڸ‬This lamp flashes with sound when the RH multifunction switch is
move to backward position.
‫ ڹ‬The flashing sound(50dB) is generated from inside of the cab.

3) Head light high beam lamp

‫ ڸ‬When the head light is the lamp flashes.
‫ ڹ‬It also lights up if the head light switch is turned ON.
‫ ں‬When passing other machines ahead, this lamp must be
used for a few seconds to give other machines warning for a
few seconds.

4 - 33
4) Clutch oil pressure warning lamp
‫ ڸ‬The lamp lights ON when the oil pressure of the transmission drops.
‫ ڹ‬When the lamp is ON, stop the engine and check the transmission
system.

5) Brake oil pressure warning lamp

‫ ڸ‬The lamp lights ON when the oil pressure of service brake drops
below the normal range.
‫ ڹ‬When the lamp is ON, stop the engine and check for its cause.
Ɠ Do not operate until any problems are corrected.

6) Parking lock warning lamp

‫ ڸ‬When the parking brake is actuated, the lamp lights ON.
Ɠ Check the lamp is OFF before driving.

P
7) Working lock warning lamp
‫ ڸ‬This lamp lights ON when the parking switch is in the position of
working and the ram lock lamp lights ON at the same time.
‫ ڹ‬Refer to parking switch at page 3-13 for details.

8) Ram lock warning lamp

‫ ڸ‬When the oscillating work is not necessary as the machine is in
operation or parked, a front axle is fixed and oscillating is locked
with the lamp lights ON by operating the ram lock switch.
‫ ڹ‬Also, the lamp lights ON when the parking switch is in the position of
parking or working.

4 - 34
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION

Part name Symbol Specifications Check

Ɠ Check specific gravity

12V ź 120Ah 1.280 over : Over charged
Battery
(2EA) 1.280 ~ 1.250 : Normal
1.250 below : Recharging

Ɠ Check coil resistance(M4 to

Rated load 9 M4)
24V
Battery relay Normal : About 50‫װ‬
100A(continuity)
1000A(30seconds) Ɠ Check contact
CR-1 Normal : ſ‫װ‬

Ɠ Check disconnection
Normal : 0‫װ‬
Fusible link 24V 60A (connect ring terminal and
check resist between terminal
CN-60 1 and 2)
CS-2

Ɠ Check contact
OFF : ſ‫(װ‬For each terminal)
B-BR : 24V 1A
ON : 0‫(װ‬For terminal 1-3)
Start key B-IG : 24V 10A
ſ‫(װ‬For terminal 1-5)
B-R2 : 24V 40A
START : 0‫(װ‬For terminal 1-3
and 1-5)

Pa
10kg/cm2 Ɠ Check contact
Pressure switch
(N. C TYPE) Normal : 0.1‫װ‬
CD-6 CD-3
CD-7 CD-5

Pa
Pressure switch 4 ~ 6kg/cm2 Ɠ Check contact
(for stop lamp) (N. O TYPE) Normal : ſ‫װ‬

CD-4

4 - 35
 Part name Symbol Specifications Check

Pa
Pressure switch 0.5kg/cm2 Ɠ Check contact
(for engine oil) (N. C TYPE) Normal 90‫װ‬

CD-18

Ş
C Ɠ Check resistance
Coolant
50ŞC : 153.9‫װ‬
temperature 
sensor 80ŞC : 51.9‫װ‬
CD-8 100ŞC : 27.4‫װ‬

Ɠ Check resistance
Coolant
 Normal : ſ‫װ‬
overheat sensor
105ŞC over : 0‫װ‬
CD-9

Pa Pressure:635mm
Air cleaner Ɠ Check contact
H2O
pressure switch Normal : ſ‫װ‬
(N.O TYPE)
CD-10

Ɠ Check contact
Coolant level
 High level : ſ‫װ‬
sensor
Low level : 0‫װ‬
CD-16

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

4 - 36
 Part name Symbol Specifications Check

Ɠ Check resistance
Tacho sensor -
Max. 300‫װ‬
CD-17

Ɠ Check resistance
Normal : 400‫װ‬
Relay 24~32V 20A (for terminal 1-3)
: ſ‫װ‬
CR-2 AC RY1 (for terminal 2-4)
CR-5 AC RY2

Ɠ Check resistance
Normal : About 5k‫װ‬
Potentiometer - (for terminal 1-3)
: 0.6K‫~װ‬5k‫װ‬
CN-77 (for terminal 2-3)

Ɠ Check resistance
Normal : 5~6‫װ‬
Governor motor - (for terminal 1-2)
: 5~6‫װ‬
CN-76 (for terminal 3-4)

Ɠ Check resistance
Solenoid valve 24~27V 1.2A Normal : 21.2‫װ‬
CN-66 CN-88
CN-68 CN-89 (for terminal 1-2)
CN-72 CN-122
CN-123

Ɠ Check resistance
EPPR valve 700mA Normal : 17.5‫װ‬
(for terminal 1-2)
CN-75

4 - 37
 Part name Symbol Specifications Check

Ɠ Check resistance
Resistor 50‫װ‬20W
Normal : 50‫װ‬
CN-47

Ɠ Check resistance
Normal : 7.5‫װ‬
Speaker 4‫ װ‬20~40W
Ɠ Output sound pressure
CN-23(LH) level : 95 Ź 2dB
CN-24(RH)

Ɠ Check contact
Switch
24V 8A OFF : ſ‫(װ‬for terminal 1-5,2-6)
(Locking type)
: 0‫(װ‬for terminal 5-7,6-8)
CS-18 CS-23 CS-25
CS-27 CS-36 CS-41
CS-50 CS-52 CS-54

Ɠ Check contact
Normal : 0‫װ‬
Prolix switch 24~125V 15A (for terminal 1-2, 4-5)
Emergency : 0‫װ‬
(for terminal 2-3, 5-6)
CS-7

Ɠ Check contact
OFF : ſ‫װ‬
Switch (for terminal 1-5, 2-4)
24V 8A
(Locking type)
ON : 0‫װ‬
(for terminal 1-5, 2-4)
CS-21

Ɠ Check contact
Switch 24V 8A OFF : ſ‫װ‬
(Non-locking type)
(for terminal 1-5,2-6)

CS-22

4 - 38
 Part name Symbol Specifications Check

Work lamp, 24V 70W

Ɠ Check disconnection
Room lamp, (H3 TYPE)
24V 10W ňNormal : A few ‫װ‬
Number plate
CL-1 CL-5 (Room lamp) ňNormal : 0.4‫(װ‬Room lamp)
lamp
CL-6 CL-21

24V 70W Ɠ Check disconnection

Beacon lamp
(H1 TYPE) Normal : A few ‫װ‬
CL-7

Ɠ Check operation
ňSupply power(24V) to
Fuel filler pump 24V 10A terminal 1 pin
35ֻ/min ňConnect ring terminal with
CN-61 ground and switch turn ON

Ɠ Check operation
ňSupply power(24V) to
Hour meter 16~32V terminal No. 2 and connect
terminal No. 1 and ground
CN-48

Ɠ Check operation
22~28V ňSupply power(24V) to each
Horn
2A 1M‫װ‬ terminal and connect ground
CN-20 CN-25 ňSound level : 110dB

Ɠ Check contact
ňNormal : 0‫(װ‬for terminal 1-2)
: ſ‫(װ‬for terminal 1-3)
Safety switch 24V 15A ňOperating : ſ‫װ‬
(for terminal 1-2)
CS-4 : 0‫װ‬
(for terminal 1-3)

4 - 39
 Part name Symbol Specifications Check

Pa
Ɠ Check contact
Receiver dryer 24V 2.5A
Normal : ſ‫װ‬

CN-29

Ɠ Check contact
W Travel :ſ‫װ‬
Working, P (for terminal 1-2, 4-5)
Traveling, 24~125V 15A Working : 0‫װ‬
W
Parking switch (for terminal 1-2, 4-5)
P
Parking : 0‫װ‬
CS-17 (for terminal 2-3, 5-6)

Ɠ Check resistance
Power ON
ş15W*15W, 4‫ *װ‬4‫װ‬
Cassette radio 24V 2A (for teminal 1-6, 4-8)
ş20~25V
(for terminal 7-GND, 2-GND)
CN-27

Ɠ Check contact
Buzzer 24V 0.3A Normal : 1.9‫װ‬
(for terminal 1-3)
CN-26

M
Ɠ Check contact
Washer pump 24V 2.5A Normal : 26.4‫װ‬
(for terminal 1-2)
CN-22

Ɠ Check resistance
Normal : 10.5‫װ‬
(for terminal 1-2)
Wiper motor 24V 2A
Wiper operating
: 24V(for terminal 1-4)
CN-21 : 0V(for terminal 2-GND)

4 - 40
Part name Symbol Specifications Check

Ɠ Check resistance
Normal : About 240‫װ‬
(for terminal 2-6)
Relay 24~32V 16A : 0‫װ‬
(for terminal 1-3)
CR-4 CR-16 CR-17 : ſ‫װ‬
CR-34 CR-36 (for terminal 1-4)

Intermittent Normal : 0‫װ‬

20~30V 5A
wiper relay (for terminal 1-3)

CR-6

Ɠ Check resistance
Normal : 7.9 - 8.3‫װ‬
24V 5A
Cigar lighter Ɠ Operating time : 5~15sec
BULB 1.4W

CL-2

Ɠ Check contact
Ether 24V 15A
Normal : 1.1‫װ‬
CN-78

Ɠ Check resistance
C
50ŞC: 153.9‫װ‬
Hydraulic  80ŞC: 51.9‫װ‬
temperature 100ŞC: 27.4‫װ‬
CD-1 120ŞC: 16.1‫װ‬

Ɠ Check voltage
Alternator 24V 60A
Normal : 24~27.9V

CN-74

4 - 41
Part name Symbol Specifications Check

Delco Remy
Starter Ɠ Operating or not
28MT 24V

CN-45

Ɠ Check contact
Back buzzer 24V 0.5A
Normal : 5.2‫װ‬

CN-65

Ɠ Check resistance
Fuel cut-off 24V
Normal : 15~25‫װ‬

CN-79

Aircon Ɠ Check contact

24V 79W
compressor Normal : 13.4‫װ‬
CN-28

Ɠ Check contact
Start relay 24V 300A Normal : 11.3‫װ‬
(for teminal 1-2)
CR-23

M
Blower 24V 9A 

4 - 42
 Part name Symbol Specifications Check

Ɠ Check contact
Normal - 1.9‫(װ‬for teminal 2-4)
Aircon resistor 24~28V - 3.3‫(װ‬for teminal 1-3)
- 5.4‫(װ‬for teminal 1-4)
- 5.7‫(װ‬for teminal 1-2)

Mode actuator 9~16V

& 300mA MAX 
Temp actuator

Ɠ Check resistance
Intake actuator 12V Normal92.0‫(װ‬for teminal 1-2)

Ɠ Working temperature of
contact point :
AC ON ‫ ؖ‬4.5Ş C
Thermostat  AC OFF ‫ ؖ‬1.5Ş C
Differential of temperature
‫ ؖ‬3 degree
Reted input volt : 24V

Ɠ Check resistance
Door switch 12~24V 20W Normal : ſ‫װ‬

CS-1

Ɠ Check contact
Horn switch 30V 6A Normal : ſ‫װ‬

CS-5

4 - 43
 Part name Symbol Specifications Check

Arm/Dozer
select solenoid 24V 1A Resistance : 28.9‫װ‬

CN-116

Solenoid valve 24V 1A Resistance : 28.9‫װ‬

CN-67 CN-69
CN-70 CN-71

Flasher unit 24V 85C/M 

CR-11

Ɠ Normal : 1.0‫װ‬
(for terminal 1-3, 2-3)
Head lamp 24V 75/70W
1.5‫װ‬
(for terminal 1-2)
CL-3 CL-4

Ɠ Normal : 4.8‫װ‬
Rear combi 24V 21W ź 2 (for terminal 1-2)
lamp 24V 10W 2.1‫װ‬
(for terminal 2-3, 2-4)
CL-15 CL-16

Ɠ Normal : 2.1‫װ‬
Front combi 24V 21W (for terminal 2-3)
lamp 24V 10W 4.8‫װ‬
(for terminal 1-2)
CL-24 CL-25

4 - 44
 Part name Symbol Specifications Check

Ɠ Check contact
Pedal switch 24V 15A Normal open : ſ‫װ‬
(for terminal)
CS-26

Power max Ɠ Check contact

24V 6A
switch Normal : ſ‫װ‬

CS-29

Ɠ Check resistance
LOW : 0‫(װ‬for terminal 1-4)
ML : 0‫(װ‬for terminal 1-5)
Blower switch  MH : 0‫(װ‬for terminal 1-3)
MI : 0‫(װ‬for terminal 1-6)
CS-17 COM : 0‫(װ‬for terminal 1-2)

4 - 45
GROUP 5 CONNECTORS

1. CONNECTOR DESTINATION

Connector No of Connector part No

Type Destination
number pin Femal Male
CN-1 SWP 8 I/conn(Engine harness-main harness) S814-008000 S814-108000
CN-2 SWP 12 I/conn(Engine harness-main harness) S814-012000 S814-112000
CN-3 SWP 6 I/conn(Engine harness-main harness) S814-006000 S814-106000
CN-4 SWP 14 I/conn(R.H harness-main harness) S814-014000 S814-114000
CN-5 370FASTON 2 I/conn(R.H harness-main harness) S813-030200 S813-130200
CN-6 SWP 8 I/conn(Cabin harness-main harness) S814-008000 S814-108000
CN-7 SWP 12 I/conn(Cabin harness-main harness) S814-012000 S814-112000
CN-8 SWP 14 I/conn(Cabin harness-main harness) S814-014000 S814-114000
CN-9 SWP 4 I/conn(Cabin harness-main harness) S814-004000 S814-104000
CN-10 BS 2 I/conn(Boom harness-main harness) S812-002011 -
CN-11 SWP 12 I/conn(Solenoid harness-main harness) S814-012000 S814-112000
CN-12 SWP 12 I/conn(Aircon evaporator) S814-012000 S814-112000
CN-13 CN 4 I/conn(Wiper harness-main harness) S810-004204 S810-104204
CN-14 CN 4 I/conn(Cabin harness-main harness) S810-004204 -
CN-15 AMP 8 I/conn(Aircon evaporator) S810-008202 S810-108202
CN-16 SWP 1 Emergency power supply(cluster) S814-001000 S814-101000
CN-20 MARK-є 1 Horn S819-010122 -
CN-21 CN 4 Wiper motor S810-004204 -
CN-22 CN 2 Washer tank S810-002202 -
CN-23 - 1 Speaker (LH) S819-010222 S819-110222
CN-24 - 1 Speaker (RH) S819-010222 S819-110222
CN-25 MARK-є 1 Horn S819-010122 -
CN-26 KET 3 Buzzer S814-003000 S814-103000
CN-27 PA 9 Cassette & radio S811-009003 -
CN-28 PACKARD 2 Compressor 0297-3407 -
CN-29 - 2 Receiver dryer S812-002001 -
CN-30 CN 14 Aircon controller S810-006202 -
CN-36 SWP 12 Fuse box S814-012000 -
CN-37 AMP 4 Fuse box S810-003202 -
CN-38 SWP 4 Fuse box S814-008000 -
CN-40 58-L 2 Fuse box S813-030200 -
CN-45 RING-TERM - Start motor B+ S820-310000 -
CN-47 CN 2 Resistor S810-002202 -
CN-48 CN 2 Hour meter S810-002202 -
CN-50 LC 10 CPU & controller S815-010000 -
CN-51 LC 18 CPU & controller S815-018000 -
CN-52 LC 24 CPU & controller S815-024000 -
CN-53 PA 13 CPU & controller AMP,172498-1 -

4 - 46
Connector No of Connector part No
Type Destination
number pin Femal Male
CN-56 ML 16 Cluster AMP,174046-2 -
CN-57 ML 12 Cluster AMP,174045-2 -
CN-60 58-L 2 Fusible link - S813-130200
CN-61 - 1 Fuel filter pump S822-015000 -
CN-63 AMP 7 Warning indicator S811-007002 S811-107002
CN-64 AMP 7 Warning indicator S811-007002 S811-107002
CN-65 - 1 Back buzzer S822-014004 -
CN-66 SWP 2 Braker solenoid S814-002000 S814-102000
CN-67 Jr power 2 Working solenoid 827551-3 -
CN-68 SWP 2 Safety solenoid S814-002000 S814-102000
CN-69 Jr power 2 Ramlock solenoid 827551-3 -
CN-70 SWP 2 Travel solenoid S814-002000 S814-102000
CN-71 Jr power 2 Parking solenoid 827551-3 -
CN-72 SWP 2 Dozer/Outrigger solenoid S814-002000 S814-102000
CN-74 RING-TERM - Alternator "B+" terminal S820-106000 -
CN-75 - 2 EPPR valve S822-014000 -
CN-76 58-X 4 Governor motor S813-060400 -
CN-77 58-X 3 Potentiometer S813-060300 -
CN-78 - 1 Cold start aid S822-014004 S822-114004
CN-79 - 1 Fuel cut-off solenoid S820-105000 -
CN-88 SWP 2 Power max S814-002000 S814-102000
CN-89 SWP 2 Arm half flow solenoid S814-002000 S814-102000
CN-116 AMP 2 Arm/Dozer solenoid S816-002001 S816-102001
CN-122 SWP 2 Forward solenoid S814-002000 S814-102000
CN-123 SWP 2 Reverse solenoid S814-002000 S814-102000
ňRelay
CR-1 RING-TERM - Battery relay S820-104000 -
CR-2 CN 4 Horn relay S810-004202 -
CR-4 CN 6 Wiper relay S810-006202 -
CR-5 CN 4 Start safety relay S810-004202 -
CR-6 CN 6 Intermittent wiper realy S810-006202 -
CR-11 CN 3 Flasher unit S810-003702 -
CR-16 CN 5 Stop lamp relay S810-005202 -
CR-17 CN 6 Transmission relay S810-006202 -
CR-23 CN 2 Start relay S816-002003 -
CR-34 CN 6 Parking relay S810-006202 -
CR-36 CN 6 Ramlock relay S810-006202 -

4 - 47
 Connector No of Connector part No
Type Destination
number pin Femal Male
ňSwitch
CS-1 - 1 Door switch S810-014004 -
CS-2 SWP 6 Start key switch S814-006000 -
CS-4 CN 3 Safety switch S810-003202 -
CS-5 - 1 Horn switch S822-014000 S822-114000
CS-7 CN 6 Prolix switch 810-006202 -
CS-11 KET 8 Multifunction switch(wiper side) S814-008000 S814-108000
CS-12 KET 8 Multifunction switch(RH lever side) S814-008000 S814-108000
CS-13 KET 12 Multifunction switch(LH lever side) S814-012000 S814-112000
CS-17 CN 6 Working, traveling, parking switch S810-006202 S810-106202
CS-18 SWF 10 Ramlock switch SWF,593757 -
CS-21 SWF 10 Main light switch SWF,593757 -
CS-22 SWF 10 Cold start switch SWF,593757 -
CS-23 SWF 10 Beacon switch SWF,593757 -
CS-25 SWF 10 Dozer/Outrigger switch SWF,593757 -
CS-26 - 1 Pedal switch S822-014000 S822-114000
CS-27 SWF 10 Break switch SWF,593757 -
CS-29 - 1 Power max switch S822-014000 S822-114000
CS-36 SWF 10 Work lamp switch SWF,593757 -
CS-41 SWF 10 Hazard switch SWF,593757 -
CS-50 - 10 Arm half control switch SWF,593757 -
CS-52 SWF 10 Arm/Dozer select switch SWF,593757 -
CS-54 SWF 10 Aircon switch SWF,593757 -
CS-58 - 6 Blower switch S810-006202 -
ňLight
CL-1 CN 2 Room lamp YAZAKI,7123-8326 -
CL-2 - 1 Cigar lighter S822-014004 S822-114004
CL-3 CN 3 Head lamp S810-003702 -
CL-4 CN 3 Head lamp S810-003702 -
CL-5 BS 2 Work lamp S812-002011 -
CL-6 BS 2 Work lamp S812-002011 -
CL-7 - 1 Beacon lamp S822-014000 S822-114000
CL-15 SWP 4 Rear combination lamp(RH) S814-004000 S814-104000
CL-16 SWP 4 Rear combination lamp(LH) S814-004000 S814-104000
CL-21 SWP 2 Numberplate lamp S814-002000 S814-102000
CL-24 SWP 3 Front combination lamp(LH) S814-003000 S814-103000
CL-25 SWP 3 Front combination lamp(RH) S814-003000 S814-103000

4 - 48
Connector No of Connector part No
Type Destination
number pin Femal Male
ňSensor, sender
CD-1 MARK-є 1 Hydraulic oil temp sender S819-010112 -
CD-2 CN 2 Fuel sender KET,MG 610220 -
CD-3 ST 1 Brake fail pressure switch S819-010122 -
CD-4 ST 1 Stop lamp pressure switch S819-010122 -
CD-5 ST 1 Transmission oil pressure switch S819-010122 -
CD-6 ST 1 Auto idle pressure switch S819-010122 -
CD-7 ST 1 Auto idle pressure switch S819-010122 -
CD-8 MARK-є 1 Water temp sender S819-010122 -
CD-9 - 1 Over heat sensor S822-014000 S822-114000
CD-10 - 1 Air cleaner switch S822-014000 -
CD-16 CN 2 Water level sensor S810-002202 -
CD-17 PACK 2 Speed sensor S818-020221 S818-120221
CD-18 CN 1 Engine oil pressure switch S810-001202 -

4 - 49
2. CONNECTION TABLE FOR CONNECTORS
1) 58-L TYPE CONNECTOR

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

1 1

S813-030100 S813-130100

1 2 1 2

S813-030200 S813-130200

4 - 50
 2) MULTILOCK TYPE CONNECTOR

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

20 1 10

11 20
S817-020105

4 - 51
 3) PA TYPE CONNECTOR

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

2 5 1 3

1 3 2 5

S811-005002 S811-105002

3 7 1 4

1 4 3 7

S811-007002 S811-107002

4 9 1 5

1 5 4 9
S811-009002 S811-109002

5 11 1 6

11

1 6 5 11
S811-011002 S811-111002

4 - 52
No of pin Receptacle connector(Female) Plug connector(Male)

6 13 1 7

13

1 7 6 13

S811-013002 S811-013002

8 17 1 9

17

1 9 8 17

S811-017002 S811-117002

10 21 1 11

21

1 1 10 21

S811-021002 S811-121002

4 - 53
 4) 58-X TYPE CONNECTOR

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

1 1

S813-060100 S813-160100

1 1

1 2

S813-060200 S813-160200

2 1 3

1 3 2

S813-060200 S813-060200

2 4 1 3

1 3 2 4

S813-060200 S813-060200

4 - 54
 5) J TYPE CONNECTOR

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

1 1

2 2
S816-002001 S816-102001

2 3 1

3 1 2
S816-003001 S816-103001

3 1 4 2

4 2 3 1
S816-004001 S816-104001

6 3 1 8 5 2

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

4 - 55
 6) SWP TYPE CONNECTOR

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

1 1

S814-001000 S814-101000
2 1

1 2

S814-002000 S814-102000

3
1

2 1 23
S814-003000 S814-103000

2 4
1 3

1 3 2 4

S814-004000 S814-104000

4 - 56
No of pin Receptacle connector(Female) Plug connector(Male)

3 6 1 4

3 6
1 4
S814-006000 S814-106000

4 8 1 5

4 8
1 5
S814-008000 S814-108000

4 12 1 5

12

1 9 4 8

S814-012000 S814-112000

3 14 1 11

14

3 14
1 11
S814-014000 S814-114000

4 - 57
 7) CN TYPE CONNECTOR

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

1 1

S810-00120 S810-10120

2 2

1 1

S810-002202 S810-102202

3 2

1 2 1 3

S810-003202 S810-103202

2 4 1 4

1 3 2 3

S810-004202 S810-104202

4 - 58
No of pin Receptacle connector(Female) Plug connector(Male)

3 6 1 4

1 4 3 6
S810-006202 S810-106202
4 8 1 5

1 5 4 8
S810-008203 S810-108203

4 - 59
 8) BS TYPE CONNECTOR

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

1 1

2 2

S812-002001 S812-102001

1 3 1 2

2 3

S812-003001 S812-103001

2 4 1 3

1 3 2 4

S812-004001 S812-104001

3 6 1 4

1 4 3 6

S812-006001 S812-106001

4 - 60
 9) LC TYPE CONNECTOR

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

5 10

1 6

S815-010000
6 12

12

1 7

S815-012000
8 16

16

1 9
S815-016000
9 18

18

1 10
S815-018000

4 - 61
No of pin Receptacle connector(Female) Plug connector(Male)

12 24

24

1 13
S815-024000

4 - 62
 10) 375 FASTEN TYPE CONNECTOR

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

1 2 1 2

S810-002402 S810-102402

4 - 63
 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

LH control RH control Accelerator

Transmission lever lever pedal

Main control valve

IN IN

Bucket
Arm1 Arm2

Swing

Boom

Travel
Arm
Boom2 Boom1

Swing Bucket Pressure

switch
Dozer Service

Travel Arm half flow Drive signal

Main relief solenoid valve
valve Arm half
flow switch
Travel speed
solenoid valve

OFF ON
Power boost
solenoid valve

Engine Engine
speed
sensor

Coolant Overheat
temp sensor switch

M
P Main pump Pilot pump

Fuel injection Governor

pump motor
EPPR valve
Engine speed sensor signal

Power boost
button
potentiometer signal

Hyd temp
Motor drive signal

switch
LH control
Coolant temperature signal

lever
Overheat switch signal

Alternator

Power boost Drive signal

button signal Drive signal
Hyd temp switch signal
CPU controller
Drive signal
Travel speed signal

Hi
Hyd temp signal
TIME bar
rpm Tachometer signal
F Mode lamp signal #1
Mode lamp signal #2 Low Multifunction
E C H
switch(LH)
Mode left switch signal
Mode right switch signal
Travel speed switch signal Drive signal
POWER MODE Auto decel switch signal OFF ON
H S L F Engine speed up switch signal Prolix
AUTO SELECT switch Resistor Battery
DECEL
Engine speed down switch signal
H M
Warming up signal
TRAVEL SPEED ENGINE SPEED
Battery charge warning signal Pressure switch signal

5-2
GROUP 2 MODE SELECTION SYSTEM

Main control valve

Engine Engine
speed
sensor

M
Main pump Pilot pump
P

Fuel injection Governor

pump motor
EPPR valve

Engine speed sensor signal

potentiometer signal

Motor drive signal

POWER MODE Mode switch signal

H S L F
Drive signal
CPU controller OFF ON
ENGINE SPEED
Engine speed switch signal Prolix Resistor Battery
switch

1. OUTLINE
Micro computer based electro-hydraulic pump and engine mutual control system (mode selection
system) optimizes the engine and pump performance.
The combination of 4 power modes(H,S,L,F) makes it possible to use the engine and pump power
more effectively corresponding to the work conditions from a heavy and great power requesting work
to a light and precise work.
Engine rpm
Item Mode Application
Idle rpm Rated rpm
H Heavy duty operation 2250+50 2100

POWER S General operation 2250+50 2100

MODE L Light duty operation 2000+50 1850
F Finishing operation 1650+50 1500

TRAVEL LO Low speed travelling , ,

MODE HI High speed travelling , ,
KEY STARTING , Key switch start position 800Ţ100 ,
AUTO DECEL MODE , Engine deceleration 1200Ţ100 ,
When engine start, S mode, Auto Decel mode are selected automatically.

5-3
2. PUMP CONTROL BY ENGINE SPEED SENSING
If any engine speed drops under the reference şEngine Torque
rpm of each mode set caused by the pump
load are detected by the engine speed sensor,

Engine torque T
H
CPU controller sends calculated current signal
F L S
to EPPR(Electro Proportional Pressure
Reducing) valve to match engine torque with
pump torque optimally by controlling the pump
discharge volume.
şH : Heavy duty operation mode
şS : General operation mode Engine speed N
şL : Light duty operation mode
şF : Finishing operation mode
şEngine horsepower

Engine horsepower HP S
L

Engine speed N

şMain pump delivery

L
Pump discharge volume Q

H
S

Pump delivery pressure P

5-4
3. MAXIMUM POWER OF H MODE şEngine Torque

1) When H mode is selected in the cluster,

Engine torque T
CPU controller moves the engine governor
motor to set the throttle lever to the full
position and sends initial current signal to
the EPPR valve to set the pump absorption
torque high. So, it is possible to maximize
the work performance by using 100$ of the
engine power at this mode.
Engine speed N
2) If the pump load becomes too high and the
engine speed drops, the CPU controller
reduces the pump discharge amount and şEngine horsepower
momentarily resets the engine speed to the
rated point through engine speed sensing.

Engine horsepower HP

Engine speed N

şMain pump delivery

Pump discharge volume Q

Pump delivery pressure P

5-5
4. GENERAL STANDARD POWER OF S MODE şEngine Torque

1) When S mode is selected in the cluster,

Engine torque T
CPU controller moves the engine governor
motor to set the throttle lever to the full
position and sends power shift current to
EPPR valve which reduces the pump
discharge. So the pump absorption
horsepower is reduced by 15$.
2) Engine speed sensing at the matching point
Engine speed N
is the same as for H mode.

şEngine horsepower

Engine horsepower HP

Engine speed N

şMain pump delivery

Pump discharge volume Q

Pump delivery pressure P

5-6
5. ENERGY SAVING AND LIGHT POWER OF şEngine Torque
L MODE

Engine torque T
1) When L mode is selected in the cluster,
CPU controller moves the engine governor
motor to set the throttle lever to the partial
position and it sends large amount of power
shift current to EPPR valve, which reduces
the pump absorption horsepower 30$-
So, at the this mode it is useful for light work
and energy saving. Engine speed N

2) Engine speed and pump absorption

horsepower are different, but the engine şEngine horsepower
sensing at the matching point is the same
as for H mode.

Engine horsepower HP

Engine speed N

şMain pump delivery

Pump discharge volume Q

Pump delivery pressure P

5-7
6. FINISHING WORK OF F MODE şEngine Torque

1) When F mode is selected in the cluster,

Engine torque T
CPU controller moves the engine governor
motor to set the throttle lever to the partial
position and it sends of power shift current
to EPPR valve to reduces the pump
absorption horsepower to the least amount
as much as 50$of full horsepower. So, at
this mode it is useful light work, especially
for finishing work. Engine speed N

2) Engine speed and pump absorption

horsepower are set at highly efficient area şEngine horsepower
for engine fuel consumption, so the fuel
reduction effect is extremely large.

Engine horsepower HP

Engine speed N

şMain pump delivery

Pump discharge volume Q

Pump delivery pressure P

5-8
 Power boost switch OFF Power boost switch ON Other functions
Mode
Power Level of Power Level of Auto Overheat
set achievement set achievement decel prevention

şFull power used by engine şFull power used by engine

speed sensing. speed sensing.
şPower increased by 2-stage
relief solenoid valve.
T

T
115PS/
H ON / OFF ON
2100rpm N

Q N

P
115HP/
2100rpm P
şPower shift by eppr valve.

S 98PS/
ON / OFF ON
2100rpm N
Q

şFuel consumption improved by

partial use of engine power.

L 81PS/
ON / OFF ON
1850rpm
N

şIncrease of fine control range.

şHigh improvement in fuel
consumption by lowering
engine speed.

F 58PS/
ON / OFF ON
1500rpm
N

5-9
GROUP 3 AUTOMATIC DECELERATION SYSTEM

LH control RH control Accelerator

Engine lever lever pedal

Bucket
Swing

Boom

Travel
Arm
M
P

Pressure
Fuel injection Governor switch
pump motor

potentiometer signal

Motor drive signal

AUTO
DECEL Auto decel switch signal
H
CPU controller Pressure switch signal
ENGINE SPEED
Engine speed switch signal

1. WHEN AUTO DECEL LAMP ON

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

Set rpm
Engine rpm

1200 rpm

max. max.
4sec 1.5 sec 1.5 sec

Lever Lever Time

neutral operation

2. WHEN AUTO DECEL LAMP OFF

The engine speed can be set as desired using the engine speed switch, and even if the control levers
are neutral, the engine speed is not reduced.

5 - 10
GROUP 4 ENGINE SPEED UP/DOWN FUNCTION

Engine

M
P

Fuel injection Governor

pump motor

potentiometer signal

Motor drive signal

ENGINE SPEED Engine speed up switch signal

Engine speed down switch signal CPU controller

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

5 - 11
GROUP 5 POWER BOOST SYSTEM

Main control valve

Arm 1 Arm 2

Boom 2 Boom 1

Swing Bucket

Dozer Service

Travel

Main relief Power boost

valve solenoid valve

Engine Engine
speed
sensor

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
lever

Power boost button signal

Drive signal
Drive signal
POWER MODE Mode switch signal CPU controller
H S L F

ş When the power boost switch on the left control lever knob is pushed ON, the maximum digging
power is increased by 10$.
ş When the power set is at H or S and the power boost function is activated, the 2-stage relief solenoid
valve pilot pressure raises the set pressure of the main relief valve to increase the digging power.

Power boost switch

Description
OFF ON
Power set H or S H
Main relief valve set pressure 320kg/cm2 350kg/cm2
Even when pressed continuously,
Time of operation - it is canceled after 8 sec.
Ɠ This function does not work when the power mode lamp is at L or F.
Ɠ Default ӧ Power boost solenoid valve : OFF

5 - 12
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
B+
Battery charge warning signal Drive signal
POWER MODE
CPU controller I
H S L F
AUTO SELECT
GND
DECEL
H M

TRAVEL SPEED ENGINE SPEED

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

Main control valve

Transmission
Arm 1 Arm 2

Boom 2 Boom 1

Swing Bucket
Shift pressure
port(High or low)
Dozer Service

Travel

Main relief Travel speed

valve solenoid valve
Power boost
solenoid valve

Engine

Main pump Pilot pump

EPPR valve
LH Multifunction switch
Hi

Low

Drive signal
Travel speed switch signal
TRAVEL SPEED Drive signal
Travel speed lamp signal
CPU controller

1. TRAVEL SPEED SELECTION

Travel speed can be switched manually by turning the travel speed switch on the LH multifunction
switch.

Travel speed Lamp on

Speed solenoid valve cluster Operation

Lo OFF Turtle Low speed, high driving torque in the transmission

Hi ON Rabbit High speed, low driving torque in the transmission
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
350kg/cm2 to increase travel power.

5 - 15
GROUP 9 ARM HALF FLOW SYSTEM

LH control
lever
Main control valve
IN IN
Arm 1 Arm 2

Boom 2 Boom 1

Arm
Swing Bucket

Dozer Service

Travel
Arm half flow
solenoid valve Arm half
Main relief flow switch
valve

OFF ON

Engine

Main pump Pilot pump

When arm half flow switch is turned ON, the arm half flow solenoid valve is switched to ON and it
cancels the junction of the oil flow from two pumps.
This function is useful to fine control of the arm in case of finishing work.

Boom Arm
Mode in Bucket Swing Travel
up down out

H
S
200 100 100 200 200 100 100 100
L
F
Ɠ The portion for one pump is taken as 100$.
Ɠ When the arm out and bucket are operated simultaneously, the Arm half flow function does not
work.

5 - 16
GROUP 10 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

TRAVEL SPEED ENGINE SPEED

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 - 17
 GROUP 11 AUTOMATIC WARMING UP FUNCTION

Engine

Coolant
temp sensor
Coolant temperature signal

M
P Main pump Pilot pump

Fuel injection Governor

pump motor
EPPR valve

potentiometer signal

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

TRAVEL SPEED ENGINE SPEED

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 up to 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

- Coolant temperature : - Mode : Default(S mode)
Actuated Less than 30Ɓ
C(after engine run) - Warming up time : Maximum 10 minutes
- Warming-up lamp : ON

- Coolant temperature : Above 30Ɓ

C - Default mode
- Warming up time : Above 10 minutes - Default mode

Canceled - Changed mode set by operator - Changed mode

ƕ If any of the above conditions is
applicable, the automatic warming-up
function is canceled

Warming-up Coolant temperature : Above 30Ɓ

C Warming-up lamp : OFF
lamp

5 - 18
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 - 19
 GROUP 12 ENGINE OVERHEAT PREVENTION FUNCTION

Engine

Overheat
switch

M
Overheat switch signal

P Main pump Pilot pump

Fuel injection Governor

pump motor
EPPR valve

potentiometer signal

Motor drive signal

TIME bar
rpm

E C H

Drive signal
POWER MODE

H S L F
AUTO
DECEL
SELECT CPU controller
H M

TRAVEL SPEED ENGINE SPEED

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

- Coolant temperature : Above 110Ɓ

C - Mode : H, S, L ơ F
Actuated
-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 - 20
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 - 21
GROUP 13 SELF-DIAGNOSTIC DISPLAY SYSTEM

Engine

M
P

Fuel injection Governor

pump motor

potentiometer signal

Motor drive signal

Mode lamp signal #1
POWER MODE

H S L F
Mode lamp signal #2 CPU controller

If there is any abnormality in the governor motor system, for instance short or open circuit happens
among wire-harness connected to CPU controller, the cluster displays the detected abnormality by
glittering 2 mode lamps alternately.
The CPU controller protects itself from electric damage caused by short circuit in wire harness.

Diagnosis item Description Appearance Display

Governor motor driving Short or open The power mode lamps, POWER MODE
signal circuit H and S, are glittered
alternately. H S L F

Governor motor Short or open The power mode lamps, POWER MODE
potentiometer signal circuit L and F, are glittered
H S L F
alternately.

5 - 22
GROUP 14 ENGINE CONTROL SYSTEM

1. CPU CONTROLLER MOUNTING

1
3

1 CPU controller 2 Controller mounting bracket 3 Screw

2. CPU CONTROLLER ASSEMBLY

1) Remove four pieces of screw(3) for
controller mounting.
2) Disconnect four connectors from CPU CN53
controller.
CN52
3) Remove four pieces of screw and cover of
CPU controller A CN51
4) Inspection : Check PCB(Printed Circuit CN50
Board)
(1) If any damage is found, replace CPU
controller assembly.
(2) If not, but CAPO system does not work
then replace A only.(A : EPROM)
Ɠ Removal : Insert small screwdriver or
knife to bottom of EPROM
and lift up carefully.
Ɠ Assembly : Assemble EPROM to mach
with semicircle mark.

5 - 23
3. ENGINE GOVERNOR MOTOR AND EMERGENCY CABLE MOUNTING

1 Governor motor(step motor)

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

CAB INTERIOR

A
B

1
3
(HIGH)

2 B
(LOW)

1) ENGINE THROTTLE LEVER

Lever, Injection pump

SL : Stopper, low idle

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

Governor motor

2) EMERGENCY CABLE (push-pull cable)

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

5 - 24
3) ENGINE GOVERNOR MOTOR

4 5
A
6

A
9
SECTION A-A

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

Potentiometer Governor motor

2 1 2 1
Connector
3 4 3

Type 3P, female 4P, female

1 Black line on blue Yellow
Line 2 White line on blue Blue line on yellow
Color
3 Blue line on green White line on yellow
4 Ӿ Black line on yellow
şCheck resistance şCheck resistance
Inspection of between No. 1-2 between No. 1-2 and 3-4.
governor motor
şSpec : 0.6 ~ 6k‫װ‬ şSpec : 4 ~ 9‫װ‬

5 - 25
4. ENGINE SPEED SENSOR
1) DETECT ACTUAL ENGINE RPM AND SEND SIGNAL TO TACHOMETER

3 2

2 Gear teeth, flywheel

3 Lock nut, speed sensor
Flywheel housing
A Clearance

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

5 - 26
GROUP 15 EPPR VALVE

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

Pressure
Mode Electric current (mA) Engine rpm
kg/ cm2
psi
H , , 200 Ź 30 2250 + 50
S 9Ź3 130 Ź 40 420 Ź 30 2250 + 50
L 9Ź3 130 Ź 40 420 Ź 30 2000 + 50
F 13 Ź 3 190 Ź 40 510 Ź 30 1650 + 50

ƕ Manually operated condition when prolix switch is selected emergency position.

5 - 27
2. OPERATING PRINCIPLE
1) STRUCTURE

1
1 Solenoid without emergency switch
10 2 Cartridge
8
4 Compresion spring

5 O-ring

6 O-ring

7 O-ring

8 Hexgon socket hed blt

12 10 Plug-in conector
11 4 11 Plate
7 12 Roundhead grooved pin
5
6
2

P Pilot oil supply line(Pilot pressure)

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

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

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

5 - 28
3. EPPR VALVE CHECK PROCEDURE Spec : 390~450mA
1) CHECK ELECTRIC VALUE AT EPPR VALVE
(1) Start engine.
CN-75
(2) Set S-mode and cancel auto decel mode.
(3) If tachometer show approx 2250+50rpm, EPPR VALVE

disconnect one wire harness from EPPR

valve.
(4) Install multimeter as figure.
Multimeter

(5) Check electric current at bucket circuit

relief position.

2) CHECK PRESSURE AT EPPR VALVE Spec : 6~12kg/cm2(85~170psi)

(1) Remove plug and connect pressure
gauge as figure.
Gauge capacity : 0 to 40-50kg / cm2
Pressure
(0 to 570-710psi) gauge

(2) Start engine.

(3) Set S-mode and cancel auto decel mode.
M3

(4) If tachometer show approx 2250+50rpm,

check pressure at relief position of bucket
circuit by operating bucket control lever.
Main pump
(5) If pressure is not correct, adjust it.
(6) After adjust, test the machine.

5 - 29
GROUP 16 PROLIX SWITCH

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

Emergency
CONSOLE BOX-LH

Normal

Never place this switch in EMERGENCY

position when the CPU is in normal operation.

1. OPERATING PRINCIPLE WIRING DIAGRAM

RESISTOR Ɠ Normal :
2 Emergency :
1

CN-47

CPU CONTROLLER PROLIX SWITCH

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

CN-50 CS-7
EPPR VALVE

11 1 2
2 1

CN-51 CN-2 CN-75

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

5 - 30
GROUP 17 HYPER DAT(OPTION)

When a trouble is occurred to the mechatronics system of a machine, HYPER DAT(HYPER Diagnosis-
tool of Advanced Technology) let an operator know what kind of trouble is happened in the system
automatically. And HYPER DAT displays the maintenance reference on its screen by selected sub
function, if the operator selected it. So, the operator can maintain the trouble simply.

1. INSTALLATION
For diagnose the trouble of a machine with HYPER DAT, operator must connect the modular and
signal adapter, including parts in HYPER DAT, between CPU controller and main harness. And
connect the main cable to the main body.
Before installation, please follow the instruction below.
1) Start switch must be OFF.
2) Installation : Refer to the figure.
Ɠ Check points after installation
, Are the cables connected properly?
, Are the connectors connected securely?
, Did you understand how to use HYPER DAT completely?
3) Start switch ON or START.
R
E
LL
O

Pressure transducer
R
T
N
O
C
U
P
C

Controller cable

To pressure port

Signal adapter

Modular

Rom pack
Main body
T
A
D
R
E
P
Y
H

I
A
D
N
U
Y
H

Main cable
Main harness
Printer To cigar lighter

5 - 31
2. FUNCTIONAL FLOW CHART OF HYPER DAT

HYPER DAT
V1.0

HYUNDAI

Press any key

MODEL GROUP SELECTION

1. R130W GROUP
2. R170W-3 GROUP
3. R200LC GROUP
4. R290LC GROUP
5. R320LC GROUP
6. R450-3 GROUP
ENTER SELECT NUMBER [ ]

"1" Selection

MODEL SELECTION
1. ROBEX 130W
2. ROBEX 130LC
3. ROBEX 130LC-3

ENTER SELECT NUMBER [ ]

"1" Selection

TEST SELECTION
1. CONTROLLER PART TEST
2. PRESSURE TEST

ENTER SELECT NUMBER [ ]

"1" Selection "2" Selection

CONTROLLER PART TEST
1. SELF DIAGNOSIS
2. DATA LIST
3. I/O TEST

ENTER SELECT NUMBER [ ]

"1" Selection "2" Selection "3" Selection

SELF DIAGNOSIS 01. CONTINUE POWER I/O TEST PRESSURE TEST
27.5 [V]
MODEL:ROBEX 130W 1. SWITCH PART TEST 1. CH1 TEST
CONDITION:ENGINE START 02. KEY ON POWER 2. SINGLE SWITCH TEST 2. CH2 TEST
27.4 [V] 3. ACTUATOR TEST 3. CH3 TEST
03. EPPR V/V CURRENT 4. CH1, CH2 TEST
AFTER CONFIRMING THE 400 [mA] 5. PRESSURE SPECIFICATION
ENGINE HAS STARTED, PRESS 04. SPEED SENSOR [UNIT:kg/cm2]
THE "ENTER" KEY 1000 [RPM] ENTER SELECT NUMBER [ ] ENTER SELECT NUMBER [ ]

SELF DIAGNOSIS DATA LIST I/O(input/output) TEST HYDRAULIC PRESSURE

MEASUREMENT
Check whether controller Reads electrical signals Checks functionality of Hydraulic pressure can be
and related electronic from sensors or other actuating devices such as measured at any test port,
components function electrical components for lamps, solenoids and using pressure
normally. service reference. switches, sending them TRANSDUCERS supplied
compulsive on off signals. with HYPER DAT.

5 - 32
 SECTION 6 TROUBLESHOOTING
GROUP 1 BEFORE TROUBLESHOOTING

1. INTRODUCTION
When a trouble is occurred in the machine, this section will help an operator to maintain the machine
with easy.
The trouble of machine is parted Hydraulic & Mechanical system, Electrical system and Mechatronics
system. At each system part, an operator can check the machine according to the troubleshooting
process diagram.
Especially in the troubleshooting by HYPER DAT part, usable functions of HYPER DAT related to the
upper 3 system parts are introduced and how to use the relate function, if the abnormal items are
displayed on the main body, is explained with easy.

Hydraulic &
GROUP 2
Mechanical part
şPressure test

Troubles occur Electrical part GROUP 3

şData list
şI/O test

Mechatronics
GROUP 4
part
şSelf diagnosis

Troubleshooting GROUP 5
by HYPER DAT GROUP 6

6-1
2. DIAGNOSING PROCEDURE
To carry out troubleshooting efficiently, the following steps must be observed.

STEP 1. Study the machine system

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

STEP 2. Ask the operator

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

STEP 3. Inspect the machine

Before starting troubleshooting, check the
machine for the daily maintenance points as
shown in the operator's manual.
And also check the electrical system including
batteries, as the troubles in the electrical system
ON THE
such as low battery voltage, loose connections INSPECTION

and blown out fuses will result in malfunction of

the controllers causing total operational failures
of the machine.

6-2
STEP 4. Inspect the trouble actually on the
machine
In case that some trouble cannot be confirmed,
obtain the details of the malfunction from the
operator.
Also, check if there are any in complete
connections of the wire harnesses are or not.

STEP 5. Perform troubleshooting

According to where the trouble parts are
located, hydraulic & mechanical system part or
electrical system part or mechatronics system
part, perform troubleshooting the machine refer
to the each system part's troubleshooting
process diagram.
When HYPER DAT is used in troubleshooting,
perform troubleshooting with the user's manual
of HYPER DAT or the troubleshooting by
HYPER DAT part of in this manual.

STEP 6. Trace a cause

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

Make a plan of the appropriate repairing

procedure to avoid consequential malfunctions.

6-3
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM

1. INTRODUCTION
1) MACHINE IN GENERAL
(1) If even a minor fault is left intact and operation is continued, a fatal failure may be caused,
entailing a large sum of expenses and long hours of restoration.
Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look
for the cause based on the troubleshooting principle and perform maintenance and adjustment to
prevent major failure from occurring. Keep in mind that a fault results from a combination of
different causes.
(2) The following lists up commonly occurring faults and possible causes with this machine. For the
troubleshooting of the engine, refer to the cummins troubleshooting and repair.
(3) When carrying out troubleshooting, do not hurry to disassemble the components.
It will become impossible to find the cause of the problem.
(4) Ask user or operator the following.
‫ ڸ‬Was the any strange thing about machine before failure occurred?
‫ ڹ‬Under what conditions did the failure occur?
‫ ں‬Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
‫ ڸ‬Check oil and fuel level.
‫ ڹ‬Check for any external leakage of oil from components.
‫ ں‬Check for loose or damage of wiring and connections.

6-4
2. DRIVE SYSTEM
1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION

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

6-5
 2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL

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

Is primary pilot
pressure within ‫ڞ‬
NO standard level?

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

Gear pump is Disassemble and

NO broken. repair.

6-6
3. HYDRAULIC SYSTEM
1) HYDRAULIC OIL IS CLOUDY

Cause Remedy
YES
Water is mixed. Put hydraulic oil
still, separate
Drop hydraulic oil water and
sample on hot dispose it or
plate and check if replace hydraulic
foams come up. oil.

Air is intruded. Check suction

NO
line and return
line and eliminate
the air intruding
source.

2) HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY

Cause Remedy
NO
Replenish
specified oil to the
standard level.
Is hydraulic oil YES
volume proper? Clean oil cooler.
Is not oil cooler Secure air
clogged and is circulation route.
YES anything blocking YES ‫ڞ‬
Is fan belt tension
NO proper?
Adjust belt
NO
tension or
replace belt.

Is not the set YES Readjust set

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

6-7
 3) CAVITATION OCCURS WITH PUMP

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

4) HYDRAULIC OIL IS CONTAMINATED

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

6-8
4. SWING SYSTEM
1) BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE

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

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

6-9
 2) SWING SPEED IS LOW

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

Is swing motor's
NO
‫ڞ‬ drain rate within Swing motor is Disassemble and
standard value? broken. repair.
Check that pilot
YES piping is not NO
clogged or oil is not Pilot valve or shuttle Disassemble and
leaking from it? valve is faulty. repair.

Clogged or oil leak. Clean pilot piping

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

6 - 10
 3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION

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

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

4) MACHINE SWINGS BUT DOES NOT STOP

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

Return spring is Disassemble and

NO
faulty. replace.

6 - 11
 5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE

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

Return spring of Disassemble and

NO
swing control valve replace.
is faulty.

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

NO
Adjust swing relief
valve pressure or
replace swing
relief valve.

6 - 12
5. TRAVEL SYSTEM
1) TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE

Cause Remedy
YES
‫ڞ‬
Travel motor relief
YES
valve within
standard pressure
YES Is the travel speed NO
Travel relief valve Disassemble and
solenoid valve is faulty repair or replace.
normal?
Travel speed Disassemble and
NO
Is the travel pilot solenoid valve is repair or replace.
YES
pressure within faulty
standard?
YES
Accelerator pedal Disassemble and
or travel forward/ repair or replace.
Travel pilot Reverse solenoid
NO
solenoid valve
valve is faulty
normal?

Travel pilot Disassemble and

NO
solenoid valve is repair or replace.
Is bucket operation
faulty
possible?
YES
Transmission Disassemble and
unit is faulty. repair.
‫ڞ‬ Does travel motor
rotate?

Travel motor is out Disassemble and

NO
of order. repair.
Does the symptom
change when front
YES
and rear pump Hydraulic pump is Disassemble and
NO
discharge hoses broken. repair.
are exchanged?

6 - 13
 2) TRAVEL ACTION IS POWERLESS(TRAVEL ONLY)

Cause Remedy
YES
‫ڞ‬
Travel motor relief
YES
valve within
standard pressure
YES Is the travel speed NO
Travel relief valve Disassemble and
solenoid valve is faulty repair or replace.
normal?
Travel speed Disassemble and
NO
Is the travel pilot solenoid valve is repair or replace.
YES
pressure within faulty
standard?
YES
Accelerator pedal Disassemble and
or travel forward/ repair or replace.
Travel pilot Reverse solenoid
NO
solenoid valve
valve is faulty
normal?

Travel pilot Disassemble and

NO
Is the travel action solenoid valve is repair or replace.
powerless in both faulty
direction?
YES
Transmission Disassemble and
unit is faulty. repair.
‫ڞ‬ Does travel motor
rotate?

Travel motor is out Disassemble and

NO
of order. repair.

YES
The travel relief Disassemble and
Does the symptom valve is faulty. repair or replace.
change when
YES
NO travel relief valve Travel motor is out Disassemble and
are exchanged? Does the symptom
change when of order. repair.
travel motor
NO
suction hoses are
exchanged? Travel motor Disassemble and
NO
suction valve is repair or replace.
faulty.

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

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

YES
Cylinder interior is Disassemble and
Does control valve
‫ڞ‬ broken. repair.
spool move lightly
by hand?
Control valve spool Disassemble and
NO
is stuck. repair.

6 - 15
 2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal

Does the symptom OK Port relief valve is Disassemble and

YES change when port faulty. repair or replace.
relief valve is
Is speed low only replaced with other
in composite Does control valve valve? Cylinder is faulty. Disassemble and
YES NO
operation? spool move lightly repair.
by hand?
Control valve spool Disassemble and
NO
is stuck. repair.

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

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

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

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

Cylinder is faulty. Disassemble and

NO
repair.

4) BOOM, ARM OR BUCKET POWER IS WEAK

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

Main relief valve is Adjust pressure,

NO
defective. repair or replace.

6 - 17
 5) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED

Cause Remedy
YES
Frictional noise
occurs between
the sliding faces
of boom
cylinder's oil seal
and boom
Is boom foot pin
greased proper.
sufficiently? Ɠ Frictional
noise will
disappear if
they are kept
used.

Boom foot pin has Supply grease to

NO
run out of grease. it.
Ɠ If seizure is in
an initial stage,
supply
sufficient
grease.
If seizure is in
a grown state,
correct it by
paper lapping
or with an oil
stone.

6 - 18
Ɠ HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE

1. Lower the outrigger and / or dozer blade at

ground.
2. Lower the bucket teeth to the ground with
bucket cylinder fully retracted and arm
cylinder rod retracted almost in full.

3. Disconnect hose(A) from rod side of boom

cylinder and drain oil from cylinders and
hose.(Put cups on piping and hose ends) A

4. Raise bucket OFF the ground by retracting

the arm cylinder rod.
'
If oil leaks from piping side and boom
cylinder rod is retracted there is an internal
leak in the cylinder
If no oil leaks from piping side and boom
cylinder rod is retracted, there is an internal
leak in the control valve.

6 - 19
 GROUP 3 ELECTRICAL SYSTEM

1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR
şBefore disconnecting the connector, always turn the starting switch OFF.
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.1(CPU) is not blown out.
şAfter 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
Disconnection in Repair or replace
NO
Check voltage wiring harness or poor (after clean)
YES
between CN-8(5) contact between CN-
and chassis
57(5)-CN-8(5)

Disconnection in Repair or replace

Check voltage NO
between CN-50 wiring harness or poor (after clean)
(7) and chassis contact 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
Disconnection in Repair or replace
NO
wiring harness or poor (after clean)
contact 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
2
check voltage
YES 20 ~ 30V
CN-4
NO 0V

6 - 20
2. BATTERY CHARGING LAMP LIGHTS UP(Engine is started)

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

Cause Remedy
YES
‫ڞ‬
Check voltage
YES
between CN-53
(7) and chassis
Check voltage Defective controller Replace
YES NO
between CN-51
(18) and chassis 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
Defective cluster Replace
Check voltage
‫ڞ‬ 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

check voltage ALTERNATOR

2
"l" TERMINAL
TERMINAL
YES 20 ~ 30V *5V
CN-1
NO Below 26V 0V

6 - 21
3. WHEN COOLANT OVERHEAT LAMP LIGHTS UP(Engine is started)

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

Cause Remedy
YES
Coolant overheat Check engine
(110Ź2Ş C) system

Check resistance YES ‫ڞ‬

YES between CN-3(5) -
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 -3(5)
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
Defective cluster Replace
NO
YES
Check resistance Defective sensor Replace
between CD-9 -
‫ڞ‬
chassis and
sensor-chassis Disconnection in wiring Repair or replace
Starting switch : OFF NO
harness or poor contact (after clean)
between
CN-3(5)-CD-9

CLUSTER CPU CONTROLLER

15 3 1

CN-56 CN-9 CN-51 OVER HEAT

check resistance CN-3 CD-9

YES MAX 1‫װ‬

NO MIN 1M‫װ‬

6 - 22
4. WHEN AIR CLEANER LAMP LIGHTS UP(Engine is started)

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

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

YES
Defective sensor Replace
Check resistance
YES between CD-10-
Does display go off
chassis and sensor-
when disconnect
CD-10 and chassis
connector? Starting switch : OFF Disconnection in Replace
Check resistance NO
Starting switch : ON YES wiring harness or poor
Engine : start
between CN-9(2)
and chassis contact between
CN-9(2)-CD-10
Starting switch : OFF

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)
Before checking,
disconnect CD-10
Defective cluster Replace
NO

CLUSTER
AIR CLEANER SWITCH
14 2 Pa

CN-56 CN-9
CD-10

check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬

6 - 23
5. WHEN ENGINE OIL PRESSURE LAMP LIGHTS UP(Engine is started)

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

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

YES
Disconnection in wiring Repair or replace
harness or poor (after clean)
Check resistance
Does display go off YES contact between
between CN-3(6)
when disconnect and chassis CN-3(6)-CD-18
CD-18 and
connector?
Disconnection in wiring Repair or replace
Starting switch : ON Check resistance NO
YES harness or poor (after clean)
Engine : start between CN-9(1)
and chassis contact between
CN-9(1)-CN-3(6)
Starting switch : OFF

Check resistance Disconnection in wiring Repair or replace

between CN-56 NO
NO harness or poor (after clean)
(13) and chassis
contact between
Starting switch : OFF CN-56(13)-CN-9(1)
Before checking,
disconnect CD-18
Defective cluster Replace
NO

ENGINE OIL PRESSURE SWITCH

CLUSTER

13 1 6 Pa

CN-56 CN-9 CN-3

CD-18

check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬

6 - 24
6. WHEN HYDRAULIC OIL TEMPERATURE LAMP LIGHTS UP(Engine is started)

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

Cause Remedy
YES
Hydraulic oil overheart Check hydraulic oil
or defective sender temperature (105Ź2Ɓ
C) or replace sender

YES
Check resistance ‫ڞ‬ Replace
Does display go YES
between CN-53 (8)
off when and chassis Disconnection in wiring Repair or replace
disconnect CD-1 NO
Check resistance harness or poor contact (after clean)
and connector? YES between CN-7 (12) Starting switch : OFF
between
Starting switch : ON
Engine : start
and chassis CN-7(12)-CN-53(8)
Starting switch : OFF
Check resistance Disconnection in wiring Repair or replace
NO
between CN-56 harness or poor contact (after clean)
NO
(12) and chassis between
Starting switch : OFF
CN-56(12)-CN-7(12)
Before checking,
disconnect CD-1 Defective cluster Replace
NO

Check Defective sender Repair or replace

resistance (after clean)
between CN-4(7)
and chassis Disconnection in wiring Repair or replace
Check resistance NO
Starting switch : OFF
harness or poor contact (after clean)
‫ڞ‬ between CN-52(21) between
and chassis
CN-4(7)-CD-1
Starting switch : OFF
Disconnection in wiring Repair or replace
NO
harness or poor contact (after clean)
between
CN-52(21)-CN-4(7)

check resistance HYDRAULIC OIL

TEMPERATURE SENDER
YES MAX 1‫װ‬
Ş
C
NO MIN 1M‫װ‬ 7

CN-4 CD-1

21

CN-52

CLUSTER CPU CONTROLLER

12 12 8

CN-56 CN-7 CN-53

6 - 25
7. WHEN COOLANT LEVEL LAMP LIGHTS UP(Engine is started)

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

Cause Remedy
YES
Insufficient Refill coolant
coolant or
Defective sender Replace

YES
Check resistance Defective sender Replace
Does display go YES between CD-16(2)-
off when and chassis and
disconnect CD-16 sensor-chassis Disconnection in wiring Repair or replace
and connector? NO
Check resistance Starting switch : OFF harness or poor (after clean)
Starting switch : ON YES
between CN-7 (6)
Engine : start contact between
and chassis
CN-7(6)-CD-16(2)
Starting switch : OFF
Check resistance Disconnection in wiring Repair or replace
between CN-56 NO
NO harness or poor (after clean)
(6) and chassis
contact between
Starting switch : OFF CN-56(6)-CN-7(6)
Before checking,
disconnect CD-16
Defective cluster Replace
NO

CLUSTER WATER LEVEL SENDER

6 6 2
1
CN-56 CN-7
CD-16

check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬

6 - 26
8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
(Check coolant temperature lamp ON/OFF)
şBefore disconnecting the connector, always turn the starting switch OFF.
şBefore carrying out below procedure, check all the related connectors are properly inserted.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Coolant overheat Check coolant
or defective sender temperature or
replace

YES
Disconnection in wiring Repair or replace
harness or poor (after clean)
Check resistance
Does display go off YES between CN-3(4) contact between
when disconnect and chassis CN-3(4)-CD-8
CD-8 and
connector? Starting switch : OFF
Check resistance Disconnection in wiring Repair or replace
Starting switch : ON NO
NO harness or poor (after clean)
Engine : start between CN-8(3)
and chassis contact between
CN-8(3)-CN-3(4)
Starting switch : OFF

Check resistance Disconnection in wiring Repair or replace

between CN-57 NO
NO harness or poor (after clean)
(3) and chassis
contact between
Starting switch : OFF CN-57(3)-CN-8(3)
Before checking,
disconnect CD-8
Defective cluster Replace
YES

Check Table
Temperature
(50Ɓ
C) (80Ɓ
C) (100Ɓ
C) (120Ɓ
C)
Item
C H Unit resistance(‫)װ‬ (153.9) 51.9 27.4 (16.1)
Tolerance +25, -20 +4.9, -1.2 +1.9, -1.2 Ź1.2

WATER TEMPERATURE SENDER

CLUSTER
Ɓ
C
3 3 4

CN-57 CN-8 CN-3

CD-8

6 - 27
9. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)

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

Cause Remedy
YES
Defective cluster Replace
NO
Disconnection in wiring Repair or replace
Check resistance
harness or poor (after clean)
between CN-57(4)
and chassis contact between
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
harness or poor (after clean)
See : TABLE contact between
Check resistance CN-8(4)-CN-4(5)
between CN-4(5)
YES and chassis NO
Disconnection in wiring Repair or replace
See : TABLE harness or poor (after clean)
Check resistance contact between
between CD-2(2)
YES
and chassis CN-4(5)-CD-2(2)

See : TABLE ‫ڞ‬

YES
NO
Disconnection in wiring Repair or replace
harness or poor (after clean)
Check resistance contact between
‫ڞ‬ 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(‫)װ‬ 110 (32.5) 3
E Tolerance Ź3 Ź3 Ź2

CLUSTER FUEL SENDER

4 4 5 2
1
CN-57 CN-8 CN-4
CD-2

6 - 28
10. WHEN SAFETY SOLENOID DOES NOT OPERATE

şBefore disconnecting the connector, always turn the starting switch OFF.
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.8 is not blown out.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Check hydraulic
YES Check operation system
of solenoid
Defective solenoid Replace
NO
Safety lever : ON-OFF
Check voltage
YES
between CN-68(1) Check chassis Replace
- CN-68(2) contact
Starting switch : ON
Voltage : 20~30V Check voltage YES
Disconnection in wiring Repair or replace
Safety state NO between CN-
68(2) with chassis harness or poor
contact between
Safety lever : ON
Check voltage CN-11(1)-CN-68(2)
NO
between CN-11(1)
and chassis YES
Disconnection in wiring Repair or replace
Starting switch : ON harness or poor
Voltage : 20~30V
Check operation contact between
NO of safety switch
CS-4(3)-CN-11(1)
Starting switch : ON ‫ڞ‬
Voltage : 20~30V NO
YES
Disconnect in wiring Repair or replace
harness or poor
Check voltage contact between
‫ڞ‬ 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

1 2
1
CN-11
CN-68

6 - 29
11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE

şBefore disconnecting the connector, always turn the starting switch OFF.
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.4 is not blown out.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
NO
Check voltage Recheck fuse Replace
NO
between CN-36(5)
and chassis Disconnection in wiring Repair or replace
YES
harness or poor contact
between
CN-36(5)-CN-70(2)

YES
Defective hydraulic Check hydraulic
Check voltage YES
Check operation system system
between CN-70(2)
and chassis of solenoid
Defective solenoid Replace
NO
Starting switch : ON
Voltage : 20~30V YES
Check voltage Defective cluster Repair or replace
YES
between CN-57
(7) and chassis Disconnection in wiring Repair or replace
NO
1 speed : 5V harness or poor contact
2 speed : 0V between
CN-51(5)-CN-57(7)

YES
Check voltage YES Defective LH multi- Replace
between CN-51 Check voltage function switch
YES between CS-13
(5) and chassis
(10) and chassis
Starting switch : ON NO
Disconnection in wiring Repair or replace
1 speed : 5V 1 speed : 5V
2 speed : 0V
harness or poor contact
2 speed : 0V
between
CN-51(5)-CS-13(10)

Defective controller Replace

NO

FUSE TRAVEL SOLENOID

5 2
NO.4 1
CN-36
CONTROLLER
2
13 1
CN-70
CN-52
MULTIFUNCTION SWITCH
11 GND
5 10 TR2
CS-13
CN-51

CLUSTER

7 7

CN-8 CN-57

6 - 30
12. WHEN ENGINE DOES NOT START
şCheck supply of the power at fuel stop solenoid while starting switch is ON.
şBefore disconnecting the connector, always turn the starting switch OFF.
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.2, No.4 and No.16 are not blown out. Also, check travel forward/reverse switch is placed
Neutral position.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
START KEY SWITCH
Cause Remedy 1 B+
YES 3 IG
Defective battery Check engine
system Charge(after 5 START

checking specific
CS-2
gravity of battery)
or replace
FUSE
Check YES
Check voltage Defective magnet Replace 3
operation of No.2
YES between starter of start motor 1
start motor
magnet coil
Starting switch : start and chassis CN-36
Defective start Replace
NO
Starting switch : start relay
FUSE 24V
NO 1
Disconnection in wiring Repair or replace No.16
Check operation
NO of start relay
harness or poor contact
CN-38
between
Starting switch : start CN-38(1)-CS2(1) FUEL CUT-OFF
YES START SAFETY RY
Check voltage Defective start Repair or replace 3
Check voltage 3 4
YES between switch 4 1
CS-2(1) and between CS-2 CN-79
YES 3
chassis (5) and chassis CN-1
‫ڞ‬ 2
Starting switch : ON Starting switch : START NO 1 STARTER
NO 1 2
Disconnection in wiring Repair or replace START RY B+
CR-5 M
harness or poor contact
Check voltage 1
between
between CN-79 2
YES CN-36(3)-CN79 M
and chassis
CR-23 CN-45
Check voltage Defective fuel cut- Repair or replace
YES
between CR-5 off solenoid
NO
(4) and chassis FUSE 24V
YES
Starting switch : start Disconnection in wiring Repair or replace
harness or poor contact No.4
Check voltage
between LH MULTIFUNCTION
‫ڞ‬ between CN-1
CN-1(1)-CR23(1) SWITCH
(1) and chassis
1 B+
Starting switch : start Disconnection in wiring Replace 6 NEUTRAL
Voltage :20~30V NO
harness or poor contact
between CS-13
CN-1(1) and CS-2(5)

Defective start Replace

NO
safety relay

6 - 31
13. WHEN STARTING SWITCH ON DOES NOT OPERATE
şBefore disconnecting the connector, always turn the starting switch OFF.
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
START KEY SWITCH
fusible links are not blown out.
1 B+
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
2 BR
3 IG
Cause Remedy 5 START
YES
Disconnection in wiring Repair or replace CS-2
harness or poor (after clean)
Check voltage contact between
YES between
CN-4(10) and CN-4(10)-CR-1 or
IG POWER
chassis defective battery relay 1
Voltage : 20~30V
CN-36
Check voltage Disconnection in wiring Replace
YES between NO
harness or poor
CS-2(2) and 1
chassis contact between
CS-2(2)-CN-4(10) CN-38
Check voltage Voltage : 20~30V
YES between BATTERY POWER
CS-2(1) and Defective start Replace 2
NO CONTINUOUS POWER
key switch 1 24V
Voltage : 20~30V
CN-40
Check voltage Disconnection in wiring Replace BATTERY(12V 2)
NO
and specific harness or poor
gravity of battery contact between
Specific gravity : MIN 1.28 CS-2(1)-CN-38(1)-
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

10

CN-4
TO STARTER
CR-1

6 - 32
14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
şBefore disconnecting the connector, always turn the starting switch OFF.
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.5 is not blown out.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy WIPER MOTOR

YES S1 3 B
‫ڞ‬ 3 4 4
Check voltage B 4
YES 2 3 3 S1
between CN-6(1) E
and chassis Disconnection in wiring Repair or replace 7 2 2
NO S2 E
harness or poor (after clean) 1 1 1 1 2
Check voltage Voltage : 20~30V S2
YES
between CR-4(1) Starting switch : ON contact between
Wiper switch : ѓ CN-6 CN-13 CN-21
and chassis CN-4(1) and CN-6(1)
Check voltage
YES Voltage : 20~30V
between CR-4(4)
Starting switch : ON Defective relay Replace
and chassis Wiper switch : ѓ NO

Voltage : 20~30V Disconnection in wiring Repair or replace

Starting switch : ON NO
Wiper switch : OFF harness or poor (after clean) MULTIFUNCTION
contact between SWITCH
CN-36(6) and CR-4(4) CS-11
Check operation 1
YES 2
wiper relay Defective relay Replace
3
Check voltage 4
YES YES
Voltage : 20~30V between CR-4(6) Disconnection in wiring Repair or replace

RIGHT LEVER
5
Starting switch : ON 6
Wiper switch : ѓ
and chassis harness or poor (after clean) INT WIPER RELAY
Check voltage 7
Starting switch : ON contact between
Wiper switch : ѓ
between CS-11(4) 8
NO and chassis CR-4(6) and CS-11(4) 1
Check voltage 3
between CR-4(2) Starting switch : OFF ‫ڟ‬
NO
and chassis NO
4
YES
Voltage : 20~30V Disconnection in wiring Repair or replace 6
Starting switch : ON
harness or poor (after clean)
Check voltage contact between CR-6
NO between CN-36(6) CN-36(6) and CR-4(2)
and chassis
WIPER RELAY
Voltage : 20~30V Open circuit of fuse Replace 2 1 3
Starting switch : ON NO
YES 6
Defective wiper Replace
Check voltage 4
motor
‫ڞ‬ between CN-21 2
(low) and chassis 1 WASHER TANK
6 4 3
Disconnection in wiring Repair or replace
NO CR-4 1
Voltage : 20~30V harness or poor (after clean)
Starting switch : ON 2
contact between
CN-6(1) and
CN-22
CN-21(low)

YES FUSE
Defective wiper Replace 6
Check voltage switch NO.5
‫ڟ‬ between CS-11(6) CN-36
and chassis
Poor connection of Replace
NO
Starting switch : OFF chassis

6 - 33
15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHT UP
şBefore disconnecting the connector, always turn the starting switch OFF.
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.12 is not blown out.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

HEAD LAMP
LO 1 1 MULTIFUNCTION
Cause Remedy SWITCH
YES HI 2 4
Check voltage Defective bulb Replace
E 3 9
YES between CL-4(1)-
CL-4 CN-4
chassis and CL-3
(1)- chassis Disconnection in wiring Repair or replace
NO LO 1
Voltage : 20~30V harness or poor (after clean) HI 2
Check voltage

RIGHT LEVER
YES Starting switch : ON contact between
between CN-4(1) Light switch : ON at 1st E 3
CN-4(1)-CL-4(1) and 1
and chassis step CL-3
CN-4(4)-CL-3(1) 2
Voltage : 20~30V 3
Starting switch : ON
Light switch : ON at 1st Disconnection in wiring Repair or replace 4
step NO
harness or poor (after clean) 6
YES
Check voltage
contact between 7
between CS-12(4)
and chassis CS-12(4)-CN-4(1) 8

MAIN LIGHT SWITCH CS-12

Voltage : 20~30V YES
Starting switch : ON Defective main Replace
Light switch : ON at 1st 1
step light switch 2
Check voltage
YES 4
between CS-21 Disconnection in wiring Repair or replace 5
NO

LEFT LEVER
7 1 5
(4) and chassis
harness or poor (after clean) 2 9
Voltage : 20~30V Check voltage contact between 4
Starting switch : ON between CN-37 10
NO CS-21(4)-CN-37(1) 9 10
Check operation (1) and chassis
CS-21
of main light switch Voltage : 20~30V
Recheck fuse Replace
Starting switch : ON NO
Starting switch : ON
Light switch: ON-OFF YES
Disconnection in wiring Repair or replace
harness or poor (after clean)
Check voltage contact between
YES
between CS-21
CS-12(6)-CS-21(4)
(4) and chassis CLUSTER
Light switch : ON at 1st
step Defective main Replace switch 9 9
NO
Check voltage light switch
between CS-21(1) CN-7 CN-56
NO
and chassis YES
Disconnection in wiring Repair or replace
FUSE
Voltage : 20~30V harness or poor (after clean) 1
Starting switch : ON
Check voltage contact between NO.12
CN-37
between CN-37 CN-37(1)-CS-21(1)
NO
(1) and chassis

Recheck fuse Replace

NO

6 - 34
16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
şBefore disconnecting the connector, always turn the starting switch OFF.
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.13 is not belown out.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Disconnection in wiring Repair or replace
harness or poor (after clean) WORK LAMP
Check voltage contact between
YES 1 1
between CN-10 CN-10(2)-CL-6(2)-
(2) and chassis CN-10(2) and CL-5(2) 2 2

Voltage : 20~30V CN-10 CL-5

Starting switch : ON Disconnection in wiring Repair or replace
Check voltage Light switch : ON NO
YES
between CN-4(6) harness or poor (after clean) 1
and chassis contact between
2
Voltage : 20~30V CN-10(2)-CN-4(6)
Starting switch : ON CL-6
Light switch : ON
Disconnection in wiring Repair or replace
NO

CN-4
Check voltage harness or poor (after clean)

9
6
YES
between CS-36(1) contact between
and chassis CN-4(6)-CS-36(1)
Voltage : 20~30V
Starting switch : ON YES
Defective lamp Replace switch
Light switch : ON
switch
Check voltage
YES
CLUSTER
NO between CS-36(5) Disconnection in wiring Repair or replace WORK LIGHT SWITCH
and chassis harness or poor (after clean)
1 10 10
Voltage : 20~30V Check voltage contact between
Starting switch : ON 2
Check operation of NO between CN-37 CN-37(2)-CS-36(5) 1 5
CN-7 CN-56
(2) and chassis 5
7
work lamp switch 6
Voltage : 20~30V 2
Recheck fuse Replace 6
8
Starting switch : ON NO 9
Starting switch : ON
Light switch : ON-OFF YES 10
Disconnection in wiring Repair or replace 10 9 FUSE
2
harness or poor (after clean) CS-36 NO.13
Check voltage contact between CN-37
YES
between CS-36
CS-36(2)-CN-7(10)
(2) and chassis
Light switch : ON-OFF
Defective lamp Replace switch
Check voltage NO
switch
between CS-36
NO
(6) and chassis YES
Disconnection in wiring Repair or replace
Voltage : 20~30V
Starting switch : ON
harness or poor (after clean)
Check voltage contact between
between CN-37
NO CS-36(6)-CN-37(2)
(2) and chassis

Recheck fuse Replace

NO

6 - 35
17. WHEN STARTING SWITCH IS TURNED ON, COMBI LAMP DOES NOT LIGHTS UP
şBefore disconnecting the connector, always turn the starting switch OFF.
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.12 is not belown out.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
CL-24 CL-25
C 1 1 C
Cause Remedy E 2 2 E
YES T 3 3 T
Disconnection in wiring Repair or replace
FRONT COMBI FRONT COMBI
harness or poor contact (after clean) LAMP - LH LAMP - RH
Check voltage between CL-15 CL-16
YES
between CN-11 CN-11(10)-CL-24(1)- C 4 4 C
(10) and chassis CN-11(9) and CL-25(1) T 3 3 T
Voltage : 20~30V E 2 2 E
Starting switch : ON Disconnection in wiring Repair or replace S 1 1 S
Check voltage Light switch : ON NO
YES
between CS-12(1) harness or poor contact (after clean) REAR COMBI REAR COMBI
and chassis between LAMP - LH LAMP - RH
CN-11(10)-CL-15(4) MULTIFUNCTION

CN-11
Voltage : 20~30V
SWITCH

10
9
Starting switch : ON
Light switch : ON
Disconnection in wiring Repair or replace
NO
Check voltage harness or poor contact (after clean)
YES
between CS-21(2) between
and chassis CN-10(9)-CL-16(3)
Voltage : 20~30V

RIGHT LEVER
Starting switch : ON YES CS-12
Defective lamp Replace switch
Light switch : ON 1
switch
2
Check voltage
YES 3
NO between CS-21(5) Disconnection in wiring Repair or replace
and chassis 4
harness or poor contact (after clean)
Check voltage 6
Voltage : 20~30V between
Starting switch : ON 7
Check operation of NO between CN-37 CN-37(1)-CS-21(5)
(1) and chassis 8
main light switch
Voltage : 20~30V Recheck fuse Replace CS-21
Starting switch : ON NO
Starting switch : ON
Light switch : ON-OFF
1
YES
Disconnection in wiring Repair or replace 2
harness or poor contact (after clean) 4
Check voltage between 5
YES 7 1 5
between CS-21(2)
CS-12(2)-CN-37(1) 2 9
and chassis 4
10
Light switch : ON-OFF 9 10
Defective lamp Replace switch CLUSTER
Check voltage NO
switch MAIN LIGHT SWITCH
between CS-21 9 9
NO
(4) and chassis YES
Disconnection in wiring Repair or replace CN-7 CN-56
Voltage : 20~30V
Starting switch : ON
harness or poor contact (after clean)
Check voltage between FUSE
between CN-37 1
NO CS-21(4)-CN-37(1)
(1) and chassis NO.12
CN-37
Recheck fuse Replace
NO

6 - 36
 GROUP 4 MECHATRONICS SYSTEM

1. ALL ACTUATORS SPEED ARE SLOW

Ɠ Boom, arm, bucket, swing and travel speed are slow, but engine speed is good.
Ɠ Spec : H-mode 2250 +50rpm S-mode 2250 +50rpm
L-mode 2000 +50rpm F-mode 1650 +50rpm
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.

1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective
Is pressure hydraulic system.
YES
at EPPR valve
normal?
YES Is electric NO
Defective Replace.
current at EPPR SPEC : 6~12kg/cm2 EPPR valve.
valve normal? See test 4

SPEC:390~450mA Defective CPU Replace.

Is resistance See test 3 NO
controller.
between CN-50(6)
- (8) normal? YES
Short circuit or Check & repair
SPEC:12Ź1‫(װ‬20Ş
C) poor connection wire harness
See test 1 Is resistance at between CN-50 - between CN-50 -
EPPR valve
NO CN-75. CN-75.
normal?
SPEC:12Ź1‫(װ‬20Ş
C) Defective EPPR Replace
See test 2 NO
valve.

Wiring diagram
RESISTOR

2
Ɠ Normal :
1 Emergency :
CN-47

CPU CONTROLLER PROLIX SWITCH

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

CN-50 CS-7
EPPR VALVE

11 1 2
2 1

CN-51 CN-2 CN-75

6 - 37
2) TEST PROCEDURE
SPEC : 12 Ź 1‫(װ‬20Ş
C)
(1) Test 1 : Check resistance (6)-(8) at
connector CN-50.
‫ ڸ‬Starting key OFF. CN-50
‫ ڹ‬Remove CPU controller and disconnect CPU 1 2 3 4 5
connector CN-50. CONTROLLER 6 7 8 9 10
‫ ں‬Check resistance between pin No. 6 and CN53 CN52 CN51 CN-50

No. 8 at connector CN-50.

Multimeter

(2) Test 2 : Check resistance at connector

CN-75. SPEC : 12 Ź 1‫(װ‬20Ş
C)
‫ ڸ‬Starting key OFF.
‫ ڹ‬Disconnect connector CN-75 from
EPPR valve at main hydraulic pump.
CN-75
‫ ں‬Check resistance between 2 lines as
figure.
EPPR VALVE

Multimeter

(3) Test 3 : Check electric current at EPPR

valve. SPEC : 390~450mA
‫ ڸ‬Start engine.
‫ ڹ‬Set S-mode and cancel auto decel
CN-75
mode.
‫ ں‬If tachometer show approx 2250*50rpm,
disconnect one wire harness from EPPR EPPR VALVE

valve.
‫ ڻ‬Install multimeter as figure.
‫ ڼ‬Check electric current at bucket circuit
relief position. Multimeter

6 - 38
(2) Test 4 : Check pressure at EPPR valve.
‫ ڸ‬Remove plug and connect pressure SPEC : 6~12kg/cm2(114~284psi)
gauge as figure.
Gauge capacity : 0 to 40~50kg/cm2 Pressure
gauge
(0 to 570~710psi)
‫ ڹ‬Start engine.
‫ ں‬Set S-mode and cancel auto decel
M3
mode.
‫ ڻ‬If tachometer show approx. 2250+50rpm,
check pressure at relief position of
bucket circuit by operating bucket control Main pump
lever.
‫ ڼ‬If pressure is not correct, adjust it.
‫ ڽ‬After adjust, test the machine.

6 - 39
2. ENGINE SPEED IS SLOW AT ALL MODE
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
Good
If test 7 is good,
Check tachometer check TEST 1~4
YES work properly or
YES
not by changing Misalignment Clean speed
the mode. Is resistance between speed sensor and adjust.
Is resistance between CN-
Good between CN-50(2) See test 6 sensor and fly SEE: 5-26page
No good 52(14) - CN-51(12)
- (3) and (4) - (5) wheel
normal?
normal? ‫ڞ‬
SPEC:0.2~0.4K‫װ‬ NO
SPEC:4~9‫װ‬ See test 7
See test 5 Defective governor Replace governor
Check linkage 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 good
by loosening or
interference of
linkage.
YES
Short circuit or poor Check and repair.
connection between
Is resistance CN-51(12) - CD-
‫ڞ‬ between CD-17(1) 17(2) or CN-52(14) -
- (2) normal? CD-17(1)
SPEC:0.2~0.4K‫װ‬
Wiring diagram See test 8
Defective Replace.
NO
RESISTOR speed sensor.

2
1
Ɠ Normal :
CN-47 PROLIX SWITCH
CPU CONTROLLER 6 Emergency :
5
5 6 4
4 5
3 4
3 3
2 2
9 2
1 1
8 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
10 2 m
24 11 rp
23 1
14 12
CD-17 GOVERNOR MOTOR
CN-52 CN-2 A
1
2 A
3 B
4 B
CN-76

6 - 40
2) TEST PROCEDURE
SPEC : 4 ~ 9K‫װ‬
(1) Test 5 : Check resistance between (2)-(3)
and (4)-(5) at connector CN-50. CPU
‫ ڸ‬Starting key OFF. CONTROLLER
‫ ڹ‬Remove CPU controller and disconnect CN53 CN52 CN51 CN-50

connector CN-50 from CPU controller.

‫ ں‬Check 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.)
‫ ڸ‬Start engine. H-mode 2250+50rpm
‫ ڹ‬Check tachometer reading. S-mode 2250+50rpm Check rpm after
cancel the Auto
L-mode 2000+50rpm decel mode.
F-mode 1650+50rpm

(2) Test 7 : Check resistance between (14) of

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

6 - 41
(4) Test 8 : Check resistance at speed sensor.
‫ ڸ‬Starting key OFF. SPEC : 0.2 - 0.4K‫װ‬
‫ ڹ‬Disconnect connector CD-17 of speed
sensor at engine flywheel housing. Speed sensor
‫ ں‬Check resistance as figure.

CD-17 CD-17
1 2

Engine flywheel

Multimeter

6 - 42
3. ENGINE STALL
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Not enough engine Contact cummins
Is pressure at power. engine dealer.
YES
EPPR valve
normal?
NO
Defective EPPR Replace.
SPEC:10~16kg/cm2 valve.
See test 10
Is electric current
at EPPR valve YES
Defective CPU Replace.
normal?
controller.
SPEC:480~540mA
See test 9
Is resistance
between CN-50(6) YES
Short circuit or poor Check and
NO - (8) normal?
connection repair.
SPEC:12Ź1‫(װ‬20Ş
C) Is resistance at between
See test 1
EPPR valve CN-50 - CN-2 or
NO
normal? CN-50 - CN-75
SPEC:12Ź1‫(װ‬20Ş
C)
See test 2
NO Defective EPPR Replace.
valve.

Wiring diagram
RESISTOR
Ɠ Normal :
2
1 Emergency :

CN-47

CPU CONTROLLER PROLIX SWITCH

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

CN-50 CS-7
EPPR VALVE

11 1 2
2 1

CN-51 CN-2 CN-75

6 - 43
2) TEST PROCEDURE
SPEC : 480~540mA
(1) Test 9 : Check electric current at EPPR
valve at F-mode CN-75

‫ ڸ‬Start engine.
‫ ڹ‬Set F-mode with 1650 +50rpm
EPPR VALVE
‫ ں‬Install multimeter as figure.
‫ ڻ‬Operate bucket lever completely push or
pull and hold arm lever at the end of
stroke.
Multimeter
‫ ڼ‬Check electric current at engine stall
state.

(2) Test 10 : Check pressure at EPPR valve

SPEC : 10~16kg/cm2(140~230psi)
at F-mode
‫ ڸ‬Connect pressure gauge at EPPR valve. Pressure
gauge
‫ ڹ‬Start engine.
‫ ں‬Set F-mode with 1650 +50rpm
‫ ڻ‬Operate bucket lever completely push or
pull and hold arm lever at the end of M3

stroke.
‫ ڼ‬Check pressure at relief position.

Main pump

6 - 44
4. CLUSTER LAMPS ARE OFF IMMEDIATELY AFTER KEY SWITCH OFF
Ɠ Before carrying out below procedure, check all the related connector are properly inserted.
Normal condition : Lamps ON approx. 3~7 seconds after key switch OFF.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective Replace.
CPU controller.

Is voltage at
CN-50(10) YES
Poor connection Check and
normal?
or short circuit repair.
SPEC:24Ź1 VOLT between
See test 11
Is Fuse No. 18 CN-50(10) - CN-
NO normal? 60(1)

See test 12
Defective fuse. Replace.
NO

Wiring diagram

CPU CONTROLLER FUSE BOX

18
10 3 1 1 1

CN-38 CN-40 CN-5 CN-60

CN-50

6 - 45
2) TEST PROCEDURE
SPEC : 24 Ź 1V
(1) Test 11 : Check voltage at (10) of CN-50.
‫ ڸ‬Starting key OFF. CN-50

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

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

Ground

Multimeter

(2) Test 12 : Check fuse at (18) of fuse box.

‫ ڸ‬Starting key OFF. Fuse box

10A 20A 20A 30A 20A 30A 10A 20A 10A 10A

10A 20A 10A 10A 20A 20A 20A 10A 20A 10A 20A 20A
HORN CPU

‫ ڹ‬Selecting the fuse at (18) of fuse box. HEAD LAMP

FUEL
CUT-OFF SOL

‫ ں‬Check if the fuse is defective or not.

WORK LAMP SPARE

AIR-CON CASSETTE &

HEATER RADIO

WIPER &
SPARE
WASHER

START KEY SOL.B+

CIGAR &
CASSETTE B+
ETHER SOL.

MONITOR &
SAFETY SOL.
CPU B+

F/PUMP &
ROOM LAMP
T/ALARM

SPARE BEACON

SPARE
21EM-30520

FUSE
PULLER SPARE

SPEC : 20A

Fuse No. 18 for CPU B+

6 - 46
5. CLUSTER LAMPS ARE STILL ON AFTER STARTING KEY OFF
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Improper Check and
operation of repair.
governor motor.
Is there any
interference So, governor
YES connecting rod motor supplies
when governor signal to
motor move to low cluster panel
rpm side? continuously.

Is voltage at Defective Replace.

NO
CN-50(9) normal? CPU controller.
YES
SPEC : Defective battery Replace.
Key ON : 24Ź1V
Key OFF : 0V relay or contact
See test 13 Is the voltage 24V with continuous
between CN-50(9) power line.
NO
and GND?
Replace.
TEST : NO
Defective CPU
Repeat key switch
ON and OFF
controller
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 - 47
2) TEST PROCEDURE
SPEC :
(1) Test 13 : Check voltage at (9) of CN-50. Key ON : 24Ź1
‫ ڸ‬Starting key ON. Key OFF : 0 V
‫ ڹ‬Disconnect connector CN-50 from CPU
CN-50
controller. CPU 1 2 3 4 5
‫ ں‬Check voltage as figure. CONTROLLER 6 7 8 9 10
CN53 CN52 CN51 CN-50

Ground

Multimeter

(2) Test 14 : Check operating status of main

SPEC :
power supply at (9) of CN-50.
Key OFF : 0V
‫ ڸ‬Starting key ON and OFF.
‫ ڹ‬Disconnect CN-50 from CPU controller.
‫ ں‬Check if the voltage remains at 24Ź1 CN-50
volt in spite of operating key switch ON CPU 1 2 3 4 5
and OFF. CONTROLLER 6 7 8 9 10
Ɠ If there is certain amount of voltage, CN53 CN52 CN51 CN-50

replace CPU controller.

Ground

Multimeter

6 - 48
6. CLUSTER LAMPS ARE NOT CHANGING OR FUNCTION IS ABNORMAL WHEN THE RELATED
SWITCH ARE PUSHED.
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective CPU Replace.
controller.
Is voltage at
abnormal switch
normal?
SPEC :
Switch ON : 0~2 V Defective cluster or Replace.
Switch OFF : 5V NO
See test 15 function switch
line(Function
switch itself)

Wiring diagram

AUTO DECEL PRESS SWITCH

POWER MAX SWITCH
Pa

CLUSTER
CD-6
CS-29
OVERHEAT SWITCH

8 8 CN-3 CD-9
CPU CONTROLLER

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

CN-57 CN-8
CN-50

6 - 49
6-1. ALL CLUSTER LAMPS ARE OFF WHEN START KEY SWITCH IS ON POSITION.
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.

Cause Remedy
YES
Defective cluster Replace.
Is voltage between
YES
CN-57(5)-GND
normal?

NO
Poor connection Check and repair.
Is voltage between
CN-50(7)-GND between CN-50
normal? (7)- CN-57(5).
SPEC :
Key ON : 24VŹ1 V
Key OFF : 0V
See test 16 NO
Defective CPU Replace.
controller.

Wiring diagram

CLUSTER

CPU CONTROLLER

5 5 7

CN-50

CN-8
CN-57

6 - 50
2) TEST PROCEDURE
SPEC : Switch push once : 0~2 V
(1) Test 15 : Check voltage for malfunction Switch push once more : 4.5~5.5 V
switches.
‫ ڸ‬Starting key ON.
‫ ڹ‬Check voltage as figure. CPU
CONTROLLER
CN53 CN52 CN51 CN-50

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

SPEC : 24Ź1V
şCN-50 : output power(24Ź1V)
şCN-57 : input power(24Ź1V)
‫ ڸ‬Starting key ON. CN-50
CPU
‫ ڹ‬Remove cluster from panel. CONTROLLER
1 2 3 4 5
6 7 8 9 10
Ɠ Don't disconnect connector CN-50 from
CN53 CN52 CN51 CN-50
CPU controller.
‫ ں‬Disconnect connector CN-57 from cluster. Ground
‫ ڻ‬Check 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 - 51
7. SLOW ACTION OF ENGINE SPEED CHANGE WHEN CHANGE THE MODE
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Slow action of Check and repair.
engine speed
control due to
interference.
Is there any
interference Are voltage YES
between Defective CPU Replace.
between CN-
connecting rod and controller.
YES 52(24) - CN-51(10)
governor motor. and resistance
between CN-
Is resistance 52(23) - CN-51(10)
Defective governor Replace.
between CN-50(2) normal? NO
motor.
NO - (3) and CN-50(4) SPEC : (24)-(10) : 5Ź1V
- (5) normal? (23)-(10) : 0-5K‫װ‬
See test 18
SPEC : 4~9‫װ‬
See test 17 Defective governor Replace.
NO
motor.

Wiring diagram

CPU CONTROLLER

5
4
3
2

CN-50

POTENTIOMETER
10 5 1
4 2
3 3
CN-51
CN-77

GOVERNOR MOTOR
23 9 1 A
24 10 2 A
11 3 B
12 4 B
CN-52
CN-2 CN-76

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

Multimeter

Test - b

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

Multimeter

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

‫ ڹ‬Check voltage between (24) of CN-52

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

Multimeter

6 - 54
8. AUTO DECEL SYSTEM DOES NOT WORK
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective CPU Replace
Is voltage between controller
YES
CN-51(3)-GND
normal?
SPEC : NO
Open circuit or Replace or repair
Actuator operating poor connection
: 4.5~5.5V
Is voltage between Actuator normal between CN-51(3)
: 0~2V - pressure switch
CN-51(4) - GND
normal?
Defective auto Replace
SPEC : decel pressure
Switch ON : 0~2V
Switch OFF : 4.5~5.5V switch
See test 19

Defective cluster Replace

NO

Wiring diagram

AUTO DECEL PRESSURE SWITCH

CLUSTER CPU CONTROLLER Pa

CD-7

8 8 4 Pa
3
CD-6

CN-56 CN-7 CN-51

6 - 55
2) TEST PROCEDURE
SPEC :
(1) Test 19 : Check voltage at CN-51(4) and Auto decel switch ON(Light ON) : 0~2V
ground. Auto decel switch OFF(Light OFF) : 4.5~5.5V
‫ ڸ‬Starting key OFF.
‫ ڹ‬Turn start key ON. CPU
Check voltage as figure. CONTROLLER
CN53 CN52 CN51 CN-50

CN-51

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

Ground

Multimeter

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

Cause Remedy
YES
Defective cluster or Repair or
Is resistance CPU controller or Replace
YES
between CN-57(3) CD-8(sensor)
- CD-8 normal?
Is resistance
between CN- SPEC : 0‫װ‬ NO
Poor connection Repair
See test 21 between CN-57(3)
52(20) - CN-56(16)
normal? - CD-8
SPEC : 0‫װ‬
See test 20 Poor connection Repair
NO
between CN-
52(20) - CN-56(16)

Wiring diagram

CPU CONTROLLER CLUSTER

20 4 16

CN-52 CN-9

WATER TEMPERATURE SENDER

CN-56
Ɓ
C

CD-8

3 3 4

CN-57 CN-8 CN-3

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

CN-52 from CPU controller.

Cluster
‫ ں‬Remove cluster and disconnect CN-56
from cluster.
‫ ڻ‬Check resistance as figure.
CN-56

9 10 1112 1314 15 16

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

Multimeter

(2) Test 21 : Check resistance between

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

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

Cluster
WATER TEMPERATURE SENDER
Ɓ
C

CD-8

Multimeter

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

Cause Remedy
YES
Defective overheat Replace
switch
Is resistance
between CD-9 - YES
GND normal? Defective CPU Replace
SPEC : Is resistance controller
Region ѓơſ‫װ‬ between CN-51(1)
(Fig.) єơ 0‫װ‬ NO
ѕơſ‫װ‬
- CD-9 normal?
See test 22 Short circuit or poor Check or Repair
SPEC : 0‫װ‬ NO
See test 23 connection between
CN-51(1) - CD-9

coolant
temperature

110Ş
C

Ɠ Overheat switch ON : coolant temperature 110Ş

C
100Ş
C
Ɠ Overheat switch OFF : coolant temperature 100Ş
C

Time
Region ѓ Region є Region ѕ
Temperature curve
Wiring diagram

CPU CONTROLLER
OVER HEAT SWITCH

1 5

CD-9
CN-51 CN-3

CLUSTER

15 3

CN-9

CN-56

6 - 59
2) TEST PROCEDURE
SPEC : Region ѓ, ѕ - ſ‫װ‬
(1) Test 22 : Check resistance between Region є - 0‫װ‬
connector CD-9 - GND. OVER HEAT SWITCH
‫ ڸ‬Starting key OFF.
‫ ڹ‬Disconnect connector CD-9 of overheat
CD-9
switch at engine head.
‫ ں‬Check resistance as figure.

Ground
Multimeter

(2) Test 23 : Check resistance between

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

‫ ں‬Disconnect connector CD-9 of overheat

switch at engine head.
‫ ڻ‬Check resistance as figure.

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 - 60
11. MALFUNCTION OF POWER MAX
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

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
Short circuit or poor Repair or replace
SPEC : 0‫װ‬and power max button ON : 0‫װ‬
connection between
Is voltage between
power max button OFF : ſ‫װ‬ CN-51(15)-CN-
CN-88(2)-GND See test 25
normal? 88(1) and CS-29-
CN-51(2)
SPEC
Switch ON : 24Ź1V
Switch OFF : 0V
Seet test 24
Short circuit or poor Repair or replace
NO
connection between
CN-88(2)-battery
relay(+)

Wiring diagram

CPU CONTROLLER POWER MAX SOLENOID

15 7 1
2 6 2

CN-51 CN-11 CN-88

FUSE BOX

POWER MAX SWITCH

6
7

CS-29
CN-36

6 - 61
2) TEST PROCEDURE
SPEC : key ON - 24Ź1V
(1) Test 24 : Check voltage at (2) of connector key OFF - 0V
CN-88 - GND.
‫ ڸ‬Start key ON.
CN-88
‫ ڹ‬Disconnect connector CN-88 from power CN-88
max. solenoid valve.
‫ ں‬Check voltage as figure. Power max.
solenoid valve

Ground

Multimeter

(2) Test 25 : Check resistance between

connector (15) of CN-51-(1) of SPEC : 0‫װ‬and power max. button ON - 0‫װ‬
CN-88 and CND-(2) of CN-51. power max. button OFF - ſ‫װ‬
‫ ڸ‬Starting key OFF. Power max. switch

‫ ڹ‬Remove CPU controller and disconnect

connector CN-51 from CPU controller.
‫ ں‬Disconnect connector CN-88 from LH lever
power max. solenoid valve.
‫ ڻ‬Check resistance as figure. CPU CN-51
1 2 3 4 5 6 7 8 9
CONTROLLER
10 11 12 13 14 15 16 17 18
CN53 CN52 CN51 CN-50

Multimeter

CN-88

Power max.
solenoid valve
CN-88

6 - 62
12. OPEN OR SHORT CIRCUIT OF GOVERNOR MOTOR SYSTEM
ş Before checking, check all the related connectors are properly inserted.
ş Before carrying out next procedure, connect the disconnected connectors again immediately
unless otherwise specified.

Cause Remedy
YES
Check the power Defective Replace
mode lamps, H & controller
YES
S are glittered
alternately when
change the mode Poor connection Check and repair
Check resistance NO
among pins of Reconnect CN-50 of pin
CN-50 is the Starting switch : ON
YES
same as table 1 Defect, open or Check and
Starting switch : OFF 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 ~ 9‫װ‬
(3) - (2) (3) - (4) 4 ~ 9‫װ‬
(5) - (3) (1) - (3)
(5) - (2) (1) - (4)
Min 1M‫װ‬
Pin(2),(3),(4),(5) Pin (1),(2),(3),(4)
- chassis - chassis

CPU CONTROLLER

GOVERNOR MOTOR
5 9 1 A
4 10 2 A
3 11 3 B
2 12 4 B

CN-2 CN-76
CN-50

6 - 63
13. OPEN OR SHORT CIRCUIT OF POTENTIOMETER SYSTEM
ş Before checking, check all the related connectors are properly inserted.
ş Before carrying out next procedure, connect the disconnected connectors again immediately unless
otherwise specified.

Cause Remedy
Check the power YES
Defective Replace
mode lamps, F & controller
YES
L are glittered
alternately when
change the mode Poor connection Check and repair
Check resistance NO
among pins of Reconnect CN-52 of pin
Starting switch : ON
CN-51/52 is the
same as table 2 YES
Defect, open or Repair or replace
Starting switch : OFF 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
CN-51,CN-52(Female) CN-77(Male) Resistance
(23) - (24) (2) - (3) 0.25 ~ 6 K‫װ‬
(23) - (10) (2) - (1) 0.25 ~ 6 K‫װ‬
(24) - (10) (1) - (3) 4 ~ 6 K‫װ‬

CPU CONTORLLER

POTENTIOMETER
10 5 1 (-)
4 2 SIG
3 3 (+)
CN-51
CN-77

23
24

CN-52 CN-2

6 - 64
 GROUP 5 ELECTRICAL SYSTEM BY HYPER DAT

1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR
ňBefore using the HYPER DAT make sure you understand the user's guide of HYPER DAT.
ňBefore mounting or dismounting the HYPER DAT, always turn the starting switch OFF.
ňBefore starting switch turn ON or OFF, check all related connectors are properly inserted.

Cause Remedy
YES
Disconnection in Repair or replace
wiring harness or (after clean)
poor contact
Does the NO KEY between CN-36(2)
YES ON POWER is -CN-50(9)
displayed, also? If not, check the
fuse No.1(CPU)
şSELF DIAGNOSIS
Does the NO KEY function
ON POWER is Poor contact of Repair or replace
NO
displayed? CN-50(7) pin or
defective controller
şSELF DIAGNOSIS
function
NO
Disconnection in Repair or replace
wiring harness or (after clean)
poor contact
between CN-57(5)
-CN-50(7)
If not, check the
cluster

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
2

check voltage CN-4

YES 20 ~ 30V
NO 0V

6 - 65
2. BATTERY CHARGING LAMP LIGHTS UP(Engine is started)
ňBefore using the HYPER DAT make sure you understand the user's guide of HYPER DAT.
ňBefore mounting or dismounting the HYPER DAT, always turn the starting switch OFF.
ňBefore starting switch turn ON or OFF, check all related connectors are properly inserted.

Cause Remedy
YES
Disconnection in Repair or replace
wiring harness or (after clean)
poor contact
Does the NO between CN-51(18)
ALTERNATOR -alternator terminal
POWER is "I"
displayed?
şSELF DIAGNOSIS YES
Defective alternator Replace
function Does the LOW
ALTERNATOR YES
NO POWER is
Defective controller Repair or replace
Does the or poor contact on (after clean)
displayed?
CHARGE LAMP CN-53(7) pin
şSELF DIAGNOSIS NO state is displayed
function
ON?
NO
Defective cluster Replace

CLUSTER CPU CONTROLLER

7 7
*5V 7
0V
CN-56 CN-7 CN-53

18

CN-51

ALTERNATOR
2
"I" TERMINAL
TERMINAL
CN-1

check voltage
YES 26 ~ 30V *5V
NO Below 26V 0V

6 - 66
3. WHEN COOLANT OVERHEAT LAMP LIGHTS UP(Engine is started)
ňBefore using the HYPER DAT make sure you understand the user's guide of HYPER DAT.
ňBefore mounting or dismounting the HYPER DAT, always turn the starting switch OFF.
ňBefore starting switch turn ON or OFF, check all related connectors are properly inserted.

Cause Remedy
YES
Coolant overheat Check engine
(110Ź2Ş C) system
Does the display
go off when YES
Contact to the Repair or replace
disconnect CD-9
and connector? ground between (after clean)
Does the OVER CN-51(1) -CN-
şCheck by manual
HEAT S/W state is 56(15) or CN-51(1)
NO -CD-9
displayed ON?
şI/O TEST function
Defective cluster Replace
NO

CLUSTER CPU CONTROLLER

15 3 1

CN-56 CN-9 CN-51 OVER HEAT

CN-3 CD-9

check resistance
YES MAX 1‫װ‬
NO MIN 1 M‫װ‬

6 - 67
4. WHEN HYDRAULIC OIL TEMPERATURE LAMP LIGHTS UP(Engine is started)
ňBefore using the HYPER DAT make sure you understand the user's guide of HYPER DAT.
ňBefore mounting or dismounting the HYPER DAT, always turn the starting switch OFF.
ňBefore starting switch turn ON or OFF, check all related connectors are properly inserted.

Cause Remedy
YES YES
Real warning or Replace
Does display go off defective sensor
when disconnect
CD-1 and Does the HYD-OIL
connector? TEMPERATURE
şCheck by manual NO state is displayed YES
over 100Ş C? Defective controller Repair or replace
şDATA LIST function or contact to the (after clean)
şChecking condition :
Does the HYD- ground between
connect CD-1 OIL warning lamp
NO state is displayed CN-53(8)-CN-
ON? 56(12)
şDATA LIST function
NO Defective cluster Replace

HYDRAULIC OIL
check resistance TEMPERATURE SENDER

YES MAX 1‫װ‬

7
NO MIN 1 M‫װ‬
CN-4 CD-1

21

CN-52

CLUSTER CPU CONTROLLER

12 12 8

CN-56 CN-7 CN-53

6 - 68
5. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE
ňBefore using the HYPER DAT make sure you understand the user's guide of HYPER DAT.
ňBefore mounting or dismounting the HYPER DAT, always turn the starting switch OFF.
ňBefore starting switch turn ON or OFF, check all related connectors are properly inserted.

Cause Remedy
NO
Disconnection in Repair or replace
wiring harness or
poor contact
between CN-57(7) -
Does the TRAVEL CN-51(5)
SPEED S/W state If not, defective
is changed when cluster
push the switch?
şI/O TEST function YES
Defective solenoid Replace
Does the TRAVEL
SOLENOID state
is changed when
YES Does the TRAVEL NO Defective controller Replace
push the travel
SOLENOID state
speed switch?
stay ON
şI/O TEST function NO
continually when
push the switch? YES
Disconnection in Repair
wiring harness or
poor contact
between CN-70(2) -
Fuse No.4
If not, check the line
cut between CN-
70(1)-CN-52(13)

FUSE TRAVEL SOLENOID

5 2
NO.4 1
CN-36
CONTROLLER
2
13 1
CN-70
CN-52
MULTIFUNCTION SWITCH
11 GND
5 10 TR2
CS-13
CN-51

CLUSTER

7 7

CN-8 CN-57

6 - 69
6. ENGINE DOES NOT STOP, WHEN TURN THE START KEY OFF
ňBefore using the HYPER DAT make sure you understand the user's guide of HYPER DAT.
ňBefore mounting or dismounting the HYPER DAT, always turn the starting switch OFF.
ňBefore starting switch turn ON or OFF, check all related connectors are properly inserted.

Cause Remedy
YES
Does the NO KEY Defective fuel cut- Replace
ON POWER is off solenoid
displayed when
turn the start key
off? Defective start key Check and repair
şSELF DIAGNOSIS NO
switch or the line,
function
between CN-79-
CS-2(3), is
contacted to the
power wire harness

START KEY SWITCH

1 B+
3 IG
5 START

CS-2

FUSE
3
No.2
1

CN-36

FUSE 24V
1
No.16

CN-38

FUEL CUT-OFF
START SAFETY RY
3
3 4
4 1
CN-79
3
CN-1
2
1 STARTER
1 2
START RY B+
CR-5 M
1
2
M

CR-23 CN-45

FUSE 24V

No.4

LH MULTIFUNCTION
SWITCH
1 B+
6 NEUTRAL

CS-13

6 - 70
 GROUP 6 MECHATRONICS SYSTEM BY HYPER DAT

1. ALL ACTUATORS SPEED ARE SLOW

şBefore using the HYPER DAT make sure you understand the user's guide of HYPER DAT.
şBefore mounting or dismounting the HYPER DAT, always turn the starting switch OFF.
şBefore starting switch turn ON or OFF, check all related connectors are properly inserted.
ƓConfirm the engine speed is normal. If not, fix the engine speed to each mode specification.
Spec : H-mode 2250 +50rpm S-mode 2250 +50rpm
L-mode 2000 +50rpm F-mode 1650 +50rpm

Cause Remedy
YES
Defective hydraulic
system or not
Is pressure at enough engine
YES
EPPR valve power
normal?
şPRESSURE TEST Defective EPPR Replace
Is electric current function NO
at EPPR valve şSPEC : 6~12kg/cm2 valve
normal? , S mode
, Auto decel cancel
şDATA LIST function , No load
şSPEC : 390~450mA
, S mode Defective controller Replace
, Auto decel cancel NO
, No load

Wiring diagram

RESISTOR Ɠ Normal :

2 Emergency :
1

CN-47

CPU CONTROLLER PROLIX SWITCH

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

CN-50 CS-7
EPPR VALVE

11 1 2
2 1

CN-51 CN-2 CN-75

6 - 71
2. CLUSTER LAMPS ARE OFF IMMEDIATELY AFTER KEY SWITCH OFF
şBefore using the HYPER DAT make sure you understand the user's guide of HYPER DAT.
şBefore mounting or dismounting the HYPER DAT, always turn the starting switch OFF.
şBefore starting switch turn ON or OFF, check all related connectors are properly inserted.

Cause Remedy
NO
Defective CPU Replace
controller
Does the NO
CONTINUE
POWER is YES
Poor connection Check and repair
displayed?
between CN-
şSELF DIAGNOSIS
function Is fuse No.18 50(10)-CN-60(1)
YES normal?

Defective fuse Replace

NO

Wiring diagram

CPU CONTROLLER FUSE BOX

18
10 3 1 1 1

CN-38 CN-40 CN-5 CN-60

CN-50

6 - 72
3. CLUSTER LAMPS ARE STILL ON AFTER STARTING KEY OFF
şBefore using the HYPER DAT make sure you understand the user's guide of HYPER DAT.
şBefore mounting or dismounting the HYPER DAT, always turn the starting switch OFF.
şBefore starting switch turn ON or OFF, check all related connectors are properly inserted.

Cause Remedy
Is there any inter- YES
ference on Inproper operation Check and repair
YES connecting rod of governor motor
when governor
Does the NO KEY motor move to low Defective controller Replace
rpm side? NO
ON POWER is
displayed?
şSELF DIAGNOSIS Defective battery Repair
NO
function relay or contact with
şCondition : key off
continuous power
line

Wiring diagram

FUSE BOX

CPU CONTROLLER

1
9 2
1

CN-50 CN-36
START KEY SWITCH
B+
3 IGNITION
START

CS-2

6 - 73
4. CLUSTER LAMPS ARE NOT CHANGING OR FUNCTION IS ABNORMAL WHEN THE RELATED
SWITCH ARE PUSHED
şBefore using the HYPER DAT make sure you understand the user's guide of HYPER DAT.
şBefore mounting or dismounting the HYPER DAT, always turn the starting switch OFF.
şBefore starting switch turn ON or OFF, check all related connectors are properly inserted.

Cause Remedy
YES
Defective cluster or Repair or replace
Does the function switch line
ABNORMAL (Function switch it-
FUNCTION self)
SWITCH state is
changed when Does the YES
push the switch? Defective cluster Replace
RELATED LAMP
şI/O TEST function state is changed
NO when push the
abnormal function Defective controller Replace
switch? NO
şI/O TEST function

Wiring diagram

AUTO DECEL PRESS SWITCH

POWER MAX SWITCH
Pa

CLUSTER
CD-6
CS-29
OVERHEAT SWITCH

8 8 CN-3 CD-9
CPU CONTROLLER

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

CN-57 CN-8
CN-50

6 - 74
5. AUTO DECEL SYSTEM DOES NOT WORK
şBefore using the HYPER DAT make sure you understand the user's guide of HYPER DAT.
şBefore mounting or dismounting the HYPER DAT, always turn the starting switch OFF.
şBefore starting switch turn ON or OFF, check all related connectors are properly inserted.

Cause Remedy
YES
Does the A/I Defective controller Replace
YES PRESS S/W state
is changed when
move the joystick? Open circuit or poor Repair or replace
NO
şI/O TEST function connection
Does the AUTO between CN-51(3)-
DECEL SWITCH pressure switch
state is changed
when push the Defective auto Replace
switch? decel pressure
şI/O TEST function switch

Defective cluster or Repair or replace

NO
open circuit
between CN-51(4)-
CN-56(8)

Wiring diagram

AUTO DECEL PRESSURE SWITCH

CLUSTER CPU CONTROLLER Pa

CD-7

8 8 4 Pa
3
CD-6

CN-56 CN-7 CN-51

6 - 75
6. ENGINE SPEED IS NOT CHANGING WHEN CHANGE THE MODE
şBefore using the HYPER DAT make sure you understand the user's guide of HYPER DAT.
şBefore mounting or dismounting the HYPER DAT, always turn the starting switch OFF.
şBefore starting switch turn ON or OFF, check all related connectors are properly inserted.

Cause Remedy
YES
Defective controller Repair or replace
or motor moving
signal lines are
Does the MOTOR open(or short to the
MOVING SIG ground)
FAILURE is
displayed? YES
Potentiometer Repair
şSELF DIAGNOSIS signal line open or
function
Does the NO
POTENTIOMETER the line is contacted
to the power wire
NO SIG or OVER
POTENTIOMETER harness
SIG is displayed?
Governor motor Repair or replace
NO
moving stop by
interference or
defective governor
motor

Wiring diagram

CPU CONTROLLER

5
4
3
2

CN-50

POTENTIOMETER
10 5 1
4 2
3 3
CN-51
CN-77

GOVERNOR MOTOR
23 9 1 A
24 10 2 A
11 3 B
12 4 B
CN-52
CN-2 CN-76

6 - 76
7. MALFUNCTION OF POWER MAX
şBefore using the HYPER DAT make sure you understand the user's guide of HYPER DAT.
şBefore mounting or dismounting the HYPER DAT, always turn the starting switch OFF.
şBefore starting switch turn ON or OFF, check all related connectors are properly inserted.

Cause Remedy
YES
Defective solenoid Repair or replace
or poor contact
Does the POWER between CN-51(15)
YES MAX SOL. state is
-CN-88(1) or CN-
changed when
push the switch? 88(2)-fuse No. 6
Does the POWER
MAX S/W state is şI/O TEST function
changed when NO
Defective controller Replace
push the switch?
şI/O TEST function
NO
Defective power Repair or replace
max switch or poor
contact between
CN-51(2)-CS-29.

Wiring diagram

CPU CONTROLLER POWER MAX SOLENOID

15 7 1
2 6 2

CN-51 CN-11 CN-88

FUSE BOX

POWER MAX SWITCH

6
7

CS-29
CN-36

6 - 77
8. EXCESSIVE DROP IN ENGINE SPEED OR ENGINE STALLS, WHEN A LOAD IS APPLIED
şBefore using the HYPER DAT make sure you understand the user's guide of HYPER DAT.
şBefore mounting or dismounting the HYPER DAT, always turn the starting switch OFF.
şBefore starting switch turn ON or OFF, check all related connectors are properly inserted.

Cause Remedy
YES
Does the 2nd Drop off in engine Check and repair
pressure of EPPR power or defective
YES hydraulic system
valve is measured
Does the EPPR more then
V/V CURRENT 30kg/cm2? Defective EPPR Replace
NO state is changed NO
şPRESSURE TEST valve
when alter the function
Does the NO load? şFull load condition
EPPR V/V şDATA LIST function Defective engine Repair or replace
NO
CURRENT is şNo load ƥ Full load speed sensor or its
displayed? signal is abnormal
şSELF DIAGNOSIS
function Defective controller Repair or replace
YES
or the EPPR valve
current line is
abnormal

Wiring diagram

RESISTOR Ɠ Normal :
2 Emergency :
1

CN-47

CPU CONTROLLER PROLIX SWITCH

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

CN-50 CS-7
EPPR VALVE

11 1 2
2 1

CN-51 CN-2 CN-75

6 - 78
 SECTION 7 MAINTENANCE STANDARD
GROUP 1 OPERATIONAL PERFORMANCE TEST

1. PURPOSE
Performance tests are used to check:
1) OPERATIONAL PERFORMANCE OF A NEW
MACHINE
Whenever a new machine is delivered in Working
condition
parts and reassembled at a customer's site,
it must be tested to confirm that the
operational performance of the machine
Maintenance
meets Hyundai spec. record

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

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

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

7-2
3. OPERATION FOR PERFORMANCE TESTS
1) Observe the following rules in order to carry
out performance tests accurately and
safely.
(1) The machine
Repair any defects and damage found,
such as oil or water leaks, loose bolts,
cracks and so on, before starting to test.
(2) Test area
‫ ڸ‬Select a hard, flat ground.
‫ ڹ‬Secure enough space to allow the
machine to run straight more than 50m,
and to make a full swing with the front
attachment extended.
‫ ں‬If required, rope off the test area and
provide signboards to keep unauthorized
personnel away.
(3) Precautions
‫ ڸ‬Before starting to test, agree upon the
signals to be employed for communication
among coworkers. Once the test is
started, be sure to communicate with
each other using these signals, and to
follow them without fail.
‫ ڹ‬Operate the machine carefully and
always give first priority to safety.
‫ ں‬While testing, always take care to avoid
accidents due to landslides or contact
with high voltage power lines. Always
confirm that there is sufficient space for
full swings.
‫ ڻ‬Avoid polluting the machine and the
ground with leaking oil. Use oil pans to
catch escaping oil. Pay special attention
to this when removing hydraulic pipings.
(4) Make precise measurements
‫ ڸ‬Accurately calibrate test instruments in
advance to obtain correct data.
‫ ڹ‬Carry out tests under the exact test
conditions prescribed for each test item.
‫ ں‬Repeat the same test and confirm that
the test data obtained can be procured
repeatedly. Use mean values of
measurements if necessary.

7-3
2) ENGINE SPEED
(1) Measure the engine speed at each power
mode
Ɠ The engine speed at each power mode
must meet standard RPM; if not, all other
operational performance data will be
unreliable. It is essential to perform this
test first.
(2) Preparation
‫ ڸ‬Warm up the machine, until the engine rpm Tachometer
coolant temperature reaches 50Ş C or F
more, and the hydraulic oil is 50Ź5Ş
C.
‫ ڹ‬Push the H-mode switch and confirm that
E C H
the fuel injection pump governor lever
comes into contact with the high-idle
stopper.
‫ ں‬To measure engine RPM.
POWER MODE

(3) Measurement H S L F
‫ ڸ‬Start the engine. The engine will run at AUTO SELECT
DECEL
start idle speed. Measure engine speed H M
with a tachometer.
TRAVEL SPEED ENGINE SPEED
‫ ڹ‬Measure and record the engine speed at
each mode(H.S.L.F)
‫ ں‬Select the H-mode.
‫ ڻ‬Lightly operate the bucket control lever a
few times, then return the control lever to
neutral; the engine will automatically
enter the auto-idle speed after 4
seconds.
‫ ڼ‬Measure and record the auto deceleration
speed.

(4) Evaluation
The measured speeds should meet the following specifications.
Unit : rpm

Model Engine speed Standard Remarks

Start idle 800 Ź100

H mode 2250 *50
S mode 2250 *50
R170W-3
L mode 2000 *50
F mode 1650 *50
Auto decel 1200 Ź100

7-4
3) TRAVEL SPEED
(1) Measure the time required for the
excavator to travel a 50m at high speed
and a 20m at low speed test run.
(2) Preparation
‫ ڸ‬Prepare a flat and solid test track 50m in
length, with extra length of 150m for
machine acceleration.
‫ ڹ‬Set the traveling position as figure.
‫ ں‬Keep the hydraulic oil temperature at
50Ź5Ş C.
(3) Measurement
‫ ڸ‬Measure both the low and high speed of
the machine.
‫ ڹ‬Before starting either the low or high
speed tests, adjust the travel mode
switch to the speed to be tested, then
select the following switch positions:
ş Mode selector : H mode
‫ ں‬Start traveling the machine in the extra
length with the two speed switch at high
or low speed. Extra
Extra length Test run length
‫ ڻ‬Measure the time required to travel 50m
100m High speed : 50m 50m
at high speed or 20m at low speed. Low speed : 20m
‫ ڼ‬After measuring the forward travel speed,
turn the upperstructure 180Ş and
measure the reverse travel speed.
‫ ڽ‬Repeat steps ‫ ڻ‬and ‫ ڼ‬three times in
each direction and calculate the average
values.
(4) Evaluation
The average measured time should meet the following specifications:
Unit : Seconds / m

Model Travel speed Standard Maximum allowable Remarks

Low speed 11 13 Seconds / 20m
R170W-3
High speed 7 9 Seconds / 50m

7-5
4) SWING SPEED
(1) Measure the time required to swing three
complete turns.
(2) Preparation
‫ ڸ‬Check the lubrication of the swing gear
and swing bearing.
‫ ڹ‬Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
‫ ں‬Lower the outrigger and dozer blade at
ground.
‫ ڻ‬With the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin. The bucket must be empty.
‫ ڼ‬Keep the hydraulic oil temperature at
50Ź5Ş C.
(3) Measurement
‫ ڸ‬Select the following switch positions:
ş MODE selector : Each mode
‫ ڹ‬Operate swing control lever fully.
‫ ں‬Swing 1 turn, and measure time taken to
swing next 3 revolutions.
‫ ڻ‬Repeat steps ‫ ڹ‬and ‫ ں‬three time and
calculate the average values.
(4) Evaluation
The time required for 5 swings should meet the following specifications:
Unit : Seconds / 3 revolutions

Model Power selector switch Standard Maximum allowable

H mode 12.6Ź1.5 13.0

S mode 10.4Ź1.5 -
R170W-3
L mode 13.0Ź2.3 -
F mode 14.0Ź2.3 -

7-6
5) SWING FUNCTION DRIFT CHECK
(1) Measure the swing drift on the bearing
outer circumference when stopping after a
360Şfull speed swing.
(2) Preparation
‫ ڸ‬Check the lubrication of the swing gear
and swing bearing.
‫ ڹ‬Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
‫ ں‬Lower the outrigger and dozer blade at
ground.
‫ ڻ‬With the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin. The bucket must be empty.
‫ ڼ‬Make two chalk marks: one on the swing
bearing and one directly below it on the
lower frame.
‫ ڽ‬Swing the upperstructure 360Ş .
‫ ھ‬Keep the hydraulic oil temperature at
50Ź5Ş C.
(3) Measurement
‫ ڸ‬Conduct this test in the H mode.
‫ ڹ‬Select the following switch positions:
ş MODE selector : H mode
‫ ں‬Operate the swing control lever fully and
return it to the neutral position when the
mark on the upperstructure aligns with
that on lower frame after swinging 360Ş . 360Şswing
Measure the distance between the two Drift angle
Swing start and stop
‫ ڻ‬marks.
Align the marks again, swing 360Ş , then
‫ ڼ‬test the opposite direction.
Repeat steps ‫ ڻ‬and ‫ ڼ‬three times each
‫ ڽ‬and calculate the average values.
Evaluation
(4)
The measured drift angle should be within the following specifications:
Unit : Degree

Model Mode select switch Standard Maximum allowable Remarks

R170W-3 H mode 90 below 120

7-7
6) HYDRAULIC CYLINDER CYCLE TIME
(1) Measure the cycle time of the boom,
standard arm, and standard bucket
cylinders.
(2) Preparation şBoom cylinder
‫ ڸ‬To measure the cycle time of the boom
Raise
cylinders:
With the arm rolled out and the empty
bucket rolled out, lower the bucket to the
Lower
ground, as shown.
‫ ڹ‬To measure the cycle time of the arm
cylinder:
şArm cylinder
With the empty bucket rolled in, position
the arm so that it is vertical to the ground.
Roll in Roll out
Lower the boom until the bucket is 0.5m
above the ground.

90
‫ ں‬To measure the cycle time of the bucket 0.5m
cylinder:
The empty bucket should be positioned
at midstroke between roll-in and roll-out, şBucket cylinder
so that the sideplate edges are vertical to
the ground.
‫ ڻ‬Keep the hydraulic oil temperature at
50Ź5Ş C. Roll in Roll out

(3) Measurement 0.5m

‫ ڸ‬Select the following switch positions:
ş MODE selector : H mode
‫ ڹ‬To measure cylinder cycle times:
- Boom cylinders:
Measure the time it takes to raise the
boom, and the time it takes to lower the
boom. To do so, position the boom at
one stroke end then move the control
lever to the other stroke end as quickly
as possible.
- Arm cylinder:
Measure the time it takes to roll in the
arm, and the time it takes to roll out the
arm. To do so, position the bucket at
one stroke end, then move the control
lever to the other stroke end as quickly
as possible.

7-8
 -Bucket cylinders
Measure the time it takes to roll in the
bucket, and the time it takes to roll out the
bucket. To do so, position the bucket at
one stroke end, then move the control
lever to the other stroke end as quickly as
possible.
-Repeat each measurement 3 times and
calculate the average values.
(4) Evaluation
The average measured time should meet the following specifications:
Unit : Seconds

Model Function Standard Maximum allowable Remarks

Boom raise 2.8Ź0.3 3.8

Boom lower 2.7Ź0.3 3.0
Arm in 3.2Ź0.4 4.6
R170W-3
Arm out 3.0Ź0.3 3.8
Bucket load 2.8Ź0.4 3.9
Bucket dump 2.1Ź0.3 2.6

7-9
7) DIG FUNCTION DRIFT CHECK
(1) Measure dig function drift, which can be
caused by oil leakage in the control valve
and boom, standard arm, and standard
bucket cylinders, with the loaded bucket.
When testing the dig function drift just after
cylinder replacement, slowly operate each
cylinder to its stroke end to purge air.
(2) Preparation
‫ ڸ‬Load bucket fully. Instead of loading the
bucket, weight(W) of the following
specification can be used.
ş W=M3ź1.5
Where :
M3=Bucket heaped capacity(m3)
1.5=Soil specific gravity
‫ ڹ‬Position the arm cylinder with the rod 20
to 30mm extended from the fully retracted
position.
‫ ں‬Position the bucket cylinder with the rod
20 to 30mm retracted from the fully
extended position.
‫ ڻ‬With the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin.
‫ ڼ‬Keep the hydraulic oil temperature at
50Ź50Ş C.
(3) Measurement
‫ ڸ‬Stop the engine.
‫ ڹ‬Five minutes after the engine has been
stopped, measure the changes in the
positions of the bottom of the bucket, as
well as the boom, arm and bucket
cylinders.
‫ ں‬Repeat step ‫ ڹ‬three times and calculate
the average values.

(4) The measured drift should be within the following specifications:

Unit : mm/5min

Model Drift to be measured Standard Maximum allowable Remarks

Boom cylinder 40 below 55
R170W-3 Arm cylinder 60 below 75
Bucket cylinder 40 below 60

7 - 10
8) CONTROL LEVER OPERATING FORCE
(1) Use a spring scale to measure the
maximum resistance of each control lever
at the middle of the grip.
(2) Preparation
‫ ڸ‬Keep the hydraulic oil temperature at
50Ź5Ş C.
(3) Measurement
‫ ڸ‬Start the engine.
‫ ڹ‬Select the following switch positions:
şMODE selector : H mode
‫ ں‬Operate each boom, arm, bucket and
swing lever at full stroke and measure the
maximum operating force for each.
‫ ڻ‬Repeat steps ‫ ں‬three times and
calculate the average values.
(4) Evaluation
The measured operating force should be within the following specifications
Unit : kgf

Model Kind of lever Standard Maximum allowable Remarks

Boom lever 1.6 or below 1.9
Arm lever 1.6 or below 1.9
R170W-3
Bucket lever 1.6 or below 1.9
Swing lever 1.6 or below 1.9

7 - 11
9) CONTROL LEVER STROKE
(1) Measure each lever stroke at the lever top
using a ruler.
Ɠ When the lever has play, take a half of this
value and add it to the measured stroke.
(2) Preparation
Keep the hydraulic oil temperature at
50Ź5Ş C.
(3) Measurement
‫ ڸ‬Stop the engine.
‫ ڹ‬Measure each lever stroke at the lever
top from neutral to the stroke end using a
ruler.
‫ ں‬Repeat step ‫ ڹ‬three times and calculate
the average values.
(4) Evaluation
The measured drift should be within the following specifications:
Unit : mm

Model Kind of lever Standard Maximum allowable Remarks

Boom lever 65Ź10 85
Arm lever 65Ź10 85
R170W-3
Bucket lever 65Ź10 85
Swing lever 65Ź10 85

7 - 12
10) PILOT PRIMARY PRESSURE
(1) Preparation
‫ ڸ‬Stop the engine.
Gear pump
‫ ڹ‬Remove the hose from pilot pump Pressure
Tee
delivery port and tighten the tee to the Hose gauge
delivery port(A3).
A3
‫ ں‬Commect hose and pressure gauge to
the tee.
‫ ڻ‬Start the engine and check for oil leakage
from the port.
‫ ڼ‬Keep the hydraulic oil temperature at Main pump
50Ź5Ş C.
(2) Measurement
‫ ڸ‬Select the following switch positions:
şMODE selector : H mode
şAuto decel switch : OFF
‫ ڹ‬Measure the primary pilot pressure in the
H mode.
(3) Evaluation
The average measured pressure should meet the following specifications:
Unit : kgf / cm2

Model Engine speed Standard Allowable limits Remarks

R170W-3 H mode 40Ź5 -

7 - 13
11) FOR TRAVEL SPEED SELECTING PRESSURE
(1) Preparation
‫ ڸ‬Stop the engine.
‫ ڹ‬Push the pressure release button to
bleed air. Transmission
Hose
‫ ں‬To measure the speed selecting pressure:
Pressure
Install a connector and pressure gauge gauge
assembly to transmission P1, P2 port as P2
shown.
‫ ڻ‬Start the engine and check for on P1
Adapter
leakage from the adapter.
‫ ڼ‬Keep the hydraulic oil temperature at
50Ź5Ş C.
(2) Measurement
‫ ڸ‬Lower the bucket and dozer blade to the
ground to raise the tire off the ground.
‫ ڹ‬Select the following switch position:
Parking switch : Traveling position
ş MODE selector : H mode
‫ ں‬Operate the travel speed switch turns to
the high or lower position and measure
the port P1 or P2 pressure.
‫ ڻ‬Repeat steps ‫ ں‬three times and
calculate the average values.
(3) Evaluation
The average measured pressure should be within the following specifications:
Unit : kgf / cm2
Standard Allowable limits Remarks
Model Travel speed switch
P1 port P2 port P1 port P2 port
Low speed - 33+2 - 30~35
R170W-3
High speed 33+2 - 30~35 -

7 - 14
12) SWING PARKING BRAKE RELEASING PRESSURE
(1) Preparation
‫ ڸ‬Stop the engine.
‫ ڹ‬The pressure release L wrench to bleed
air.
‫ ں‬Install a connector and pressure gauge
assembly to swing motor SH port, as
shown.
‫ ڻ‬Start the engine and check for oil leakage
from the adapter.
‫ ڼ‬Keep the hydraulic oil temperature at
50Ź5Ş C.
(2) Measurement
‫ ڸ‬Select the following switch positions:
şMODE selector : H mode
‫ ڹ‬Operate the swing function and measure
the swing brake control pressure with the
brake disengaged. Release the control
lever to return to neutral and measure the
control pressure when the brake is
applied.
‫ ں‬Repeat step ‫ ڹ‬three times and calculate
the average values.
(3) Evaluation
The average measured pressure should be within the following specifications:
Unit : kgf / cm2

Model Standard Allowable limits Remarks

Brake disengaged 40 20 ~ 50
R170W-3
Brake applied - -

7 - 15
13) MAIN PUMP DELIVERY PRESSURE
(1) Preparation
‫ ڸ‬Stop the engine.
Pressure
‫ ڹ‬Push the pressure release button to gauge
bleed air.
‫ ں‬To measure the main pump pressure : Gauge port
Remove the gauge port coupling and coupling
connect the pressure gauge as figure.
‫ ڻ‬Start the engine and check for oil
M2
leakage from the port.
M1
‫ ڼ‬Keep the hydraulic oil temperature at
50Ź5Ş C.
Main pump
(2) Measurement
‫ ڸ‬Select the following switch positions:
ş MODE selector : H mode
‫ ڹ‬Measure the main pump delivery
pressure in the H mode(high idle).
(3) Evaluation
The average measured pressure should meet the following specifications:
Unit : kgf / cm2

Model Engine speed Standard Allowable limits Remarks

R170W-3 high idle 35Ź5 -

7 - 16
14) SYSTEM PRESSURE RELIEF SETTING
(1) Preparation
‫ ڸ‬Stop the engine.
‫ ڹ‬Push the pressure release button to
Pressure
bleed air. gauge
‫ ں‬To measure the system relief pressure :
Remove the gauge port coupling and Gauge port
connect pressure gauge assembly to coupling
main pump gauge port, as shown.
‫ ڻ‬Start the engine and check for oil leakage
M2
from the port.
M1
‫ ڼ‬Keep the hydraulic oil temperature at
50Ź5Ş C.
Main pump
(2) Measurement
‫ ڸ‬Select the following switch positions:
şMODE selector : H mode
‫ ڹ‬Slowly operate each control lever of
boom, arm and bucket functions at full
stroke over relief and measure the
pressure.
‫ ں‬In the swing function, place bucket
against an immovable object and
measure the relief pressure.
‫ ڻ‬In the travel function, lock undercarriage
with an immovable object and measure
the relief pressure.
‫ ڼ‬In the power boost function, pushing the
power boost switch at the top of right
control lever an immovable object and
measure the relief pressure.
(3) Evaluation
The average measured pressure should be within the following specifications:
Unit : kgf / cm2

Model Function to be tested Normal Power boost Over load

Boom, Arm, Bucket 320Ź10 350Ź10 380Ź10

R170W-3 Travel 320Ź10 350Ź10 420Ź10
Swing 240Ź10 - -

7 - 17
GROUP 2 MAJOR COMPONENT

1. MAIN PUMP
1) INSPECTIIN INSTRUCTION
1
(1) Drive shafts
‫ ڸ‬Cups free of scratches and no pitting. 1
‫ ڹ‬Free of corrosion, erosion or fretting ; no
damage to splines or keyways.
2

(2) Piston
No scoring and no pitting.

(3) Center pin

No scoring and no pitting.
1 2

(4) Retaining plate

Free of scoring and no evidence of wear.

7 - 18
(5) Cylinder block / control lens
‫ ڸ‬Bores free of scoring, no evidence of
wear.
1
‫ ڹ‬Faces smooth an even, free of cracks
2
and scoring.
1 2
2

(6) Control lens, side guides

Free of scoring, no evidence of wear.

1 1

(7) Control houshing

Sliding surface and side guides free of
scoring and no wear.

(8) Visual check

Bearing areas free of scoring and no
evidence of wear.

7 - 19
(9) Axial piston play. (Inspection with the
retaining plate mounted).

7 - 20
2. MAIN CONTROL VALVE
Part name Inspection item Criteria & measure

Casing şExistence of scratch, rusting or şIn case of damage in following section,

corrosion. replace part.
- Sliding sections of casing fore and
spool, especially land sections
applied with holded pressure.
- Seal pocket section where spool is
inserted.
- Seal section of port where O-ring
contacts.
- Seal section of each relief valve for
main, travel, and port.
- Other damages that may damage
normal functions.

Spool şExistence of scratch, gnawing, şReplacement when its outside sliding

rusting or corrosion. section has scratch(especially on
şO-ring seal sections at both ends. seals-contacting section).

şInsert spool in casing hole, rotate şReplacement when its sliding section
and reciprocate it. has scratch.
şCorrection or replacement when
O-ring is damaged or when spool
does not move smoothly.

Poppet şDamage of poppet or spring şCorrection or replacement when

şInsert poppet into casing and function sealing is incomplete.
it. şNormal when it can function lightly
without being caught.

Around spring şRusting, corrosion, deformation or şReplacement for significant

breaking of spring, spring seat, plug damage.
or cover.

Around seal şExternal oil leakage. şCorrection or replacement.

for spool şRusting, corrosion or deformation of şCorrection or replacement.
seal plate.

Main relief valve, şExternal rusting or damage. şReplacement.

port relief valve & şContacting face of valve seat. şReplacement when damaged.
negative control
relief valve şContacting face of poppet. şReplacement when damaged.
şAbnormal spring. şReplacement.
şO-rings, back up rings and seals. ş100$ replacement in general.

7 - 21
3. SWING DEVICE
Part name Inspection item Remedy

Balance plate şWorn less than 0.03mm şLapping

şWorn more than 0.03mm şReplace
şSliding surface has a seizure(even şReplace
though small).

Shoe of piston şSliding surface has a damage. şLapping

assembly şSliding surface depression( ) şReplace parts or motor
dimension less than 0.45mm or has a
large damage.

Piston of piston şSliding surface has a seizure(even şReplace motor

assembly though small).

Piston hole of şSliding surface has a seizure. şReplace motor

cylinder assembly şSliding surface has a damage. şReplace motor

Taper roller bearing şIn case 3000hour operation. şReplace

Needle bearing şRolling surface has a damage. şReplace
Roller bearing

7 - 22
4. TRAVEL MOTOR
Disassembling and inspection of the motor must
be done in strict accordance with the servicing
standards described here. During servicing,
handle each part very carefully not to damage
them, especially for their movable or sliding
sections.
1) SEALS
Once the seals(O-ring, oil seals, and
floating seals) have been disassembled,
they must be replaced with new ones even
if no damage is observed.
2) CRITICAL SPOTS TO BE CHECKED
(1) Drive shaft
Cups free of scratches and no pittings.

(2) Cylinder block / control lens

‫ ڸ‬Bores free of scoring, no evidence of
wear.
‫ ڹ‬Faces smooth and even, free of cracks
and scoring.

(3) Pistons
No scoring and no pittings.

7 - 23
(4) Center pin
No scoring and no pittings.

(5) Retaining plate

No scoring and no evidence of wear.

(6) Control housing

Sliding surface and side guides free of
scoring and no wear.

7 - 24
5. RCV LEVER
Maintenance
check item Criteria Remark

Leakage The valve is to be replaced when the leakage Conditions :

becomes more than 1000cc/m at neutral handle Primary pressure : 30kgf/cm2
position, or more than 2000cc/m during operation. Oil viscosity : 23cSt

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

Push rod
‫ٻ‬7
1mm

This is to be replaced when the top end has worn

more than 1mm.

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

Operation stability When abnormal noises, hunting, primary pressure

drop, etc. are generated during operation, and
these cannot be remedied, referring to section 6.
Troubleshooting, replace the related parts.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.
2. When loosening the hexagon socket head cap screw(125), replace the seal washers(121)
without fail.

7 - 25
6. TURNING JOINT
Part name Maintenance standards Remedy
Body,Stem Sliding surface with Plating worn or peeled due to seizure or Replace
sealing sections. contamination.

Sliding surface şWorn abnormality or damaged more than 0.1mm Replace

between body and (0.0039in) in depth due to seizure contamination.
stem other than
sealing section. şDamaged more than 0.1mm(0.0039in) in depth.
Smooth with oilstone.
Sliding surface with şWorn more than 0.5mm(0.02in) or abnormality. Replace
thrust plate.
şWorn less than 0.5mm(0.02in).
Smooth
şDamage due to seizure or contamination
Smooth
remediable within wear limit (0.5mm((0.02in).

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

Seal set şExtruded excessively from seal groove square

Replace
ring.

-
Extrusion
Square ring

şSlipper ring 1.5mm(0.059in) narrower than seal

Replace
groove, or narrower than back ring.

1.5mm(max.)
(0.059in)

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

Replace
(0.059in)

7 - 26
7. CYLINDER
Part name Inspecting section Inspection item Remedy

Piston rod şNeck of rod pin şPresence of crack şReplace

şWeld on rod hub şPresence of crack şReplace

şStepped part to which şPresence of crack şReplace

piston is attached.

şThreads şPresence of crack şRecondition or replace

şPlated surface şPlating is not worn off to şReplace or replate

base metal.
şRust is not present on şReplace or replate
plating.
şScratches are not present. şRecondition, replate or
replace

şRod şWear of O.D. şRecondition, replate or

replace

Cylinder tube şBushing at mounting part şWear of I.D. şReplace

şWeld on bottom şPresence of crack şReplace

şWeld on head şPresence of crack şReplace

şWeld on hub şPresence of crack şReplace

şTube interior şPresence of faults şReplace if oil leak is seen

şBushing at mounting part şWear on inner surface şReplace

Gland şBushing şFlaw on inner surface şReplace if flaw is deeper

than coating

7 - 27
8. AXLE BRAKE LINING WEAR
1) GENERAL
(1) The brake lining wearing test gives a limited information about the overall condition of the brake
plate pack - without disassembly of the planetary carrier, resp. of the plates.
(2) The wearing test has to be carried out in case of the following criteria :
‫ ڸ‬In the course of the oil change intervals(min. once a year)
‫ ڹ‬Braking noises
‫ ں‬Reduced braking power
‫ ڻ‬Change of deceleration, of the brake fluid level as well as of the brake pressure
‫ ڼ‬In case of a general change of the brake performance.
(3) Carry out the wearing test on both final drive sides.
‫ ڸ‬Permitted piston stroke max. : 5.2mm(Front axle), 5.0mm(Rear axle)
‫ ڹ‬Piston stroke in new condition of the plate pack : 3.1-3.5mm(Front and Rear axle)
2) CARRY OUT THE WEARING TEST
A
(1) Turn the planetary carrier until screw plug
A(M16ź1.5) is in the upper position(12
o'clock position).
Now, remove the screw plug.
el
(2) Apply the brake(required brake pressure lev
Oil
min. 40bar).
(3) Screw measuring screw(M16ź1.5) in
until contact is obtained and tighten it with
a torque of 1kgşm.
(4) Determine dimension X according to the
figure on the right.
X
(5) Release the brake and equalize the plate
clearance by resetting the measuring
screw.
Torque limit 1kgşm.
(6) Determine dimension Y according to the
figure on the right.
(7) The difference of the two dimensions (X-
Y) corresponds to the piston stroke
(actual state).
3) RESULT
If the max. permitted piston stroke(5.0mm)
is exceeded, the lining plates must be
renewed on both final drive sides.

7 - 28
GROUP 3 WORK EQUIPMENT

A C D E F

P O N M L B U T S R K J I H G

Unit : mm
Pin Bushing
Remedy
Measuring point Normal Recomm. Limit Recomm. Limit
Mark &
(Pin and Bushing) value service of service of
Remark
limit use limit use
A Boom Rear 75 74 73.5 75.5 76 Replace
B Boom Cylinder Head 70 69 68.5 70.5 71 ţ
C Boom Cylinder Rod 75 74 73.5 75.5 76 ţ
D Arm Cylinder Head 70 69 68.5 70.5 71 ţ
E Boom Front 75 74 73.5 75.5 76 ţ
F Arm Cylinder Rod 70 69 68.5 70.5 71 ţ
G Bucket Cylinder Head 70 69 68.5 70.5 71 ţ
H Arm Link 70 69 68.5 70.5 71 ţ
I Bucket and Arm Link 70 69 68.5 70.5 71 ţ
J Bucket Cylinder Rod 70 69 68.5 70.5 71 ţ
K Bucket Link 70 69 68.5 70.5 71 ţ
L Dozer Link(B) 60 59 58.5 60.5 61 ţ
M Dozer Link(A) 60 59 58.5 60.5 61 ţ
N Dozer Cylinder Rod 70 69 68.5 70.5 71 ţ
O Dozer Link(A) 60 59 58.5 60.5 61 ţ
P Dozer Link(B) 60 59 58.5 60.5 61 ţ
Q Dozer Cylinder Head 70 69 68.5 70.5 71 ţ
R Outrigger Cylinder Head 75 74 73.5 75.5 76 ţ
S Outrigger Foot 70 69 68.5 70.5 71 ţ
T Outrigger Leg 70 69 68.5 70.5 71 ţ
U Outrigger Cylinder Rod 75 74 73.5 75.5 76 ţ

7 - 29
 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.
Ɠ If the hydraulic cylinder has been replaced, carry out this procedure before assembling the rod to
the work equipment.
Ɠ Carry out the same operation on machines that have been in storage for a long time after
completion of repairs.

8-2
3. COMPLETING WORK
1) If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
2) If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
3) If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been
removed for repair, always bleed the air from the system after reassembling the parts.
4) Add the specified amount of grease(molybdenum disulphied grease) to the work equipment related
parts.

8-3
GROUP 2 TIGHTENING TORQUE

1. MAJOR COMPONENTS
Torque
No. Descriptions Bolt size
kgfşm lbfşft
1 Engine mounting bolt, nut M12 ź 1.75 10Ź0.5 72.3Ź3.6
2 Engine Radiator mounting bolt, nut M12 ź 1.75 9.3Ź1.9 67.3Ź13.7
3 Coupling mounting bolt M16 ź 2.0 22.0Ź1.0 159.1Ź7.2
4 Main pump mounting bolt M10 ź 1.5 4.80Ź0.3 34.7Ź2.2
5 Main control valve mounting bolt M12 ź 1.75 12.2Ź1.3 88.2Ź9.4
Hydraulic
6 Fuel tank mounting bolt M20 ź 2.5 46.0Ź5.1 332.7Ź36.9
system
7 Hydraulic oil tank mounting bolt M20 ź 2.5 46.0Ź5.1 332.7Ź36.9
8 Turning joint mounting bolt, nut M12 ź 1.75 12.2Ź1.3 88.2Ź9.4
9 Swing motor mounting bolt M20 ź 2.5 57.9Ź8.7 418.8Ź62.9
10 Swing bearing upper mounting bolt M20 ź 2.5 57.8Ź6.4 418.1Ź46.3
11 Swing bearing lower mounting bolt M20 ź 2.5 57.8Ź6.4 418.1Ź46.3
12 Front axle mounting bolt, nut M16 ź 2.0 29.6Ź3.2 214.1Ź23.1
13 Rear axle mounting bolt, nut M20 ź1.5 58.0Ź6.3 419.5Ź45.6
Power
15 train Transmission mounting bolt M20 ź 2.5 44.0Ź2.0 318.3Ź14.5
system
16 Oscillating cylinder mounting bolt M22 ź 1.5 83.2Ź9.2 601.8Ź66.5
17 Oscillating cylinder support bolt M16 ź 2.0 29.6Ź3.2 214.1Ź23.1
18 Wheel nut M20 ź 1.5 57.5Ź2.5 415.9Ź18.1
19 Front drive shaft mounting bolt, nut M10 ź 1.25 5.9Ź0.6 42.7Ź4.3
20 Rear drive shaft mounting bolt, nut M10 ź 1.25 5.9Ź0.6 42.7Ź4.3
21 Counter weight mounting bolt M30 ź 3.5 146.0Ź21.9 1056.0Ź158.4
22 Others Cab mounting bolt, nut M12 ź 1.75 12.2Ź1.3 88.2Ź9.4
23 Operator's seat mounting bolt M 8 ź 1.25 1.17Ź0.1 8.5Ź0.7
Ɠ For tightening torque of engine and hydraulic components, see each components disassembly and
assembly.

8-4
2. TORQUE CHART
The torques given are standard figures. Any figures specifically described in this manual has priority.
1) METRIC BOLT-coarse thread
8T 10T
Bolt size
kgşm lbşft kgşm lbşft
M 6ź1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8ź1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8
M10ź1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12ź1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14ź2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16ź2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18ź2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20ź2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22ź2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24ź3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30ź3.5 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36ź4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242

2) METRIC BOLT-Fine thread

8T 10T
Bolt size
kgşm lbşft kgşm lbşft
M 8ź1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10ź1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12ź1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14ź1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16ź1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18ź1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20ź1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22ź1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24ź2.0 68 ~ 92 491 ~ 664 90.9 ~ 123 658 ~ 890
M30ź2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36ź3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561

8-5
3) PIPE & HOSE

Thread size Width across flat(mm) kgfşm lbfşft

1/4" 19 3 21.7
3/8" 22 4 28.9
1/2" 27 5 36.2
3/4" 36 12 86.8
1" 41 14 101

4) FITTING

Thread size Width across flat(mm) kgfşm lbfşft

1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 6 43.4
3/4" 36 13 94.0
1" 41 15 109

8-6
GROUP 3 PUMP DEVICE

1. REMOVAL AND INSTALL

1) REMOVAL
(1) Lower the work equipment to the ground
and stop the engine.
(2) Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping
(3) Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
(4) Loosen the drain plug under the hydraulic 1 9
10
tank and drain the oil from the hydraulic
tank.
ş Hydraulic tank quantity : 220ֻ 3

(5) Remove bolts(8,9) and disconnect hoses

2
(1,2). 8
(6) Disconnect pilot line hoses(4,5,6,7).
(7) Remove bolts(10) and disconnect pump
suction tube (3).
Ɠ When pump suction tube is disconnected, 6
the oil inside the piping will flow out, so 4 7
catch it in oil pan.
(8) Sling the pump assembly and remove the 5
pump mounting bolts.
ş Weight : 80kg(176lb)
Ɠ 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 one.
(4) Remove breather and clean it.
(5) After adding oil to the hydraulic tank to the
specified level.

(6) Bleed the air from the hydraulic pump.

‫ ڸ‬Remove the air vent plug(2EA).
‫ ڹ‬Tighten plug lightly.
‫ ں‬Start the engine, run at low idling, and
check oil come out from plug.
‫ ڻ‬Tighten plug.

(7) Start the engine, run at low idling(3~5

minutes) to circulate the oil through the
system.

(8) Confirm the hydraulic oil level and check

the hydraulic oil leak or not.

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

Gear pump

8 26 7 25 9 24 16 17

22

20
6
21

23

5 14 15 Regulator

2 Rotary group 9 Spacer 21 Shaft seal ring

3 Rotary group 14 Locking screw 22 O-ring
5 Pump housing 15 O-ring 23 Locking screw
6 Cover 16 Seal lock nut 24 Locking screw
7 Gear 17 Threaded pin 25 Ball bearing
8 Stub shaft 20 Retaining ring 26 Shaft key

8-9
MAIN PUMP(2/2)
Ҷ Rotary group(item2)

2-12 2-11 2-3 2-10 2-2 2-1 2-4

2-1 Hydraulic section 2-4 Control lens 2-11 Tapered roller bearing
2-2 Pinion gear 2-10 Tapered roller bearing 2-12 Ring nut
2-3 Shim

Ҷ Rotary group(item3)

3-12 3-11 3-3 3-10 3-2 3-1 3-4

3-1 Hydraulic section 3-4 Control lens 3-11 Tapered roller bearing
3-2 Drive shaft 3-10 Tapered roller bearing 3-12 Ring nut
3-3 Shim

8-10
 2) REGULATOR(1/3)

X1 X1

M3

S
M2 M1
A2 A1

48

43
42

42 Socket head screw 43 Socket head screw 48 Locking screw

8-11
 REGULATOR(2/3)

2
10
11
14
15

12
44
A2 A1
13

17

26
37
16
1

A SECTION A-A

2 Control module assy 14 spring collar 26 Hexagon screw

10 control housing 15 Pressure spring 37 Square ring
12 positioning piston 16 piston 44 Cylinder pin
13 Positioning trunnion 17 Threaded pin

8-12
REGULATOR(3/3)

2-1

2-6
2-31 2-5
2-30
2-3 2-7
2-4
2-28
X3 M3
2-8
2-25
2-24

2-27
2-10
2-9
2-11

DETAIL (item 2) SECTION B-B

2-1 Control module 2-8 Spring collar 2-27 O-ring

2-3 Control housing 2-9 Spring collar 2-28 Locking screw
2-4 Control piston 2-10 Pressure spring 2-29 Locking screw
2-5 Spring bush 2-11 Pressure spring 2-30 Lock nut
2-6 pressure spring 2-24 O-ring 2-31 Socket head screw
2-7 Threaded pin 2-25 O-ring 2-32 Double break-off pin

8-13
 3) GEAR PUMP

A
19
8
10
17
16 5 14
15
1
18 7
6 4

12
11

A SECTION A-A

1 Pump cover 8 Locking screw 15 Double brake off pin

4 Sandwich plate 10 Cylinder pin 16 Washer
5 Bearing bushing 11 O-ring 17 O-ring
6 Valve piston 12 O-ring 18 Double brake off pin
7 Pressure spring 14 Socket head screw 19 Pressure control valve

8-14
3. 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

Allen wrench 5, 6, 8, 10, 12, 17

B
Double ring spanner, socket 8, 10, 13, 17, 19
wrench, double(single) open
end spanner
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. 10ź8ź200
Torque wrench Capable of tightening with the specified torques.

8-15
2) TIGHTENING TORQUE
Torque(8.8) Torque(10.9)
Part name Bolt size
kgfşm lbfşft kgfşm lbfşft
M 5 0.6 4.3 0.8 6
M 6 1.0 7.1 1.4 10.1
M 8 2.4 17.3 3.4 24.5
M10 4.8 34.6 6.8 49.1
M12 8.4 60.6 11.8 85.2
M14 13.2 95.3 18.6 134
M16 20.6 149 28.8 209
M18 28.3 205 39.6 287
M20 40.1 290 56.8 411
Bolt size kgfşm lbfşft
M12ź1.5 2.0 14.5
M22ź1.5 6.0 43.3
M26ź1.5 7.0 50.6
M33ź1.5 12.0 86.8

M12ź1.5 3.0 21.7

M14ź1.5 4.0 28.9

M10 2.5 18.1

8-16
4. DISASSEMBLY AND ASSEMBLY
1) SEAL KITS AND SUB-ASSEMBLIES
Seal kit for drive shaft.

Outer seal kit

Rotary group 1, ready to install.

Rotary group 2, ready to install.

8-17
 Rotary group, hydraulic section(order
separately for rotary groups 1 and 2).

2) SUB-ASSEMBLIES
Rotary group 1, mechanical section, ready
to install.

Rotary group 2, mechanical section, ready

to install.

Control, pretested.

8-18
 Auxiliary pump.

Auxiliary drive.

3) SEALING THE DRIVE SHAFT

Press in shaft seal.

If the shaft is deeply grooved, insert shim

behind seal.

8-19
Fit new O-ring, make sure there is a snug
fit.
Grease O-ring and lips of shaft seal.

Fit front cover.

Fit circlip using a punch, then check that

circlip is well seated!

Remove protective cover.

8-20
Free circlip and remove.

Prise off front cover.

Visual check : Shaft seal 1, cover 2, drive

shaft 3, housing 4, O-ring 5. 5
1

2
3

Remove old shaft seal.

8-21
4) SEALING/REPLACING AUXILIARY PUMP
Free auxiliary pump and lift off.

Strip down auxiliary pump.

Visual check : groove(1), O-ring(2), sealing

face(3).

3
2

5) SEALING CONTROL HOUSING

Remove gasket, clean sealing faces.

8-22
 Fit control lenses in sliding surface with
grease.
Place new gasket on pump housing.

Make sure control lenses are fitted in

correct position. Bridge piece 1, large noise
damping notches 2. 2 2

1 1

6) DISASSEMBLY ROTARY GROUPS

Remove control housing.

Remove cylinder block.

8-23
Remove cup springs 1 and spring plates 2.

2
1

Remove fastening screws of retaining plate

(loctited).

Lift out piston assembly with screws,

retaining plate and center pin.

Auxiliary drive
Fit plate of extractor device on drive flange.

8-24
Assemble rest of extractor and pull out drive
shaft.

Lift out drive shaft.

Fit extractor device. Pull out output pinion.

Completely mount device and pull out

bearing.

8-25
7) INSPECTION INSTRUCTIONS
Drive shafts
Cups free of scratches and no pitting. 1
Free of corrosion, erosion or fretting; no
1
damage to splines or keyways.

Piston
No scoring and no pitting.

Center pin
No scoring and no pitting.
1 2

Retaining plate
Free of scoring and no evidence of wear.

8-26
Cylinder block/control lens
Bores free of scoring, no evidence of wear.
Faces smooth an even, free of cracks and
1
scoring. 2

1 2
2

Control lens, side guides

Free of scoring, no evidence of wear.

1 1

Control housing
Sliding surface and side guides free of
scoring and no wear.

Visual check
Bearing areas free of scoring and no
evidence of wear.

8-27
 Axial piston play
Inspection with the retaining plate mounted.

8) ASSEMBLY ROTARY AND AUXILIARY DRIVE

Press bearing into position. Take care to
put pressure only on the outer rings of
bearing.

Pre-warm intermediate gear to 90Ş C and

place in mounting site. Observe position for
inserting(shoulder 1).

Align key with keyway in gear, press in

swiftly.

8-28
Apply loctite to screw lock. Tapped holes
must be absolutely free of oil, grease, dirt
and other contamination which may impair
screw lock.

Place piston assembly, center pin and

retaining plate into position, fit fixing screws.

Fit spring plate 1 and cup springs 2 in

correct position with grease.

Make sure that all parts are fitted in correct

order.

8-29
Thread in piston. Use soft support to
prevent sliding surface from being
damaged. Pre-assemble both rotary
groups in this way.

Pre-warm housing to approx. 80Ş

C

80 C

Insert pre-assembled rotary group 2 dry.

Align marked gear teeth.

Assembly auxiliary drive

Insert rotary group 1, observing marked
gear teeth.

8-30
Marked teeth must mate.

Mount control.

Mount front cover.

8-31
GROUP 4 MAIN CONTROL VALVE

1. REMOVAL AND INSTALL

1) REMOVAL
(1) Lower the work equipment to the ground
and stop the engine.
(2) Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
(3) Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Ɠ When pipes and hoses are disconnected,
the oil inside the piping will flow out, so
catch it in oil pan.
(4) Remove bolts and disconnect pipe.
(5) Disconnect pilot line hoses.
(6) Disconnect pilot piping.
(7) Sling the control valve assembly and
remove the control valve mounting bolt.
ňWeight : 135kg(298lb)
(8) Remove the control valve assembly.
Ɠ When removing the control valve
assembly, check that all the piping have
been disconnected.
2) INSTALL

(1) Carry out installation in the reverse order

to removal.
(2) Bleed the air from below items.
‫ ڸ‬Cylinder (boom, arm, bucket).
‫ ڹ‬Swing motor.
‫ ں‬Travel motor.
Ɠ See each item removal and install.

(3) Confirm the hydraulic oil level and

check the hydraulic oil leak or not.

8-32
2. STRUCTURE(1/2)

31
8
9
41
42

40 32 16
42 15
33 76
34 64
77
78
58 36 6
35 58
15
15
25

27

26
28
15 25 4
3

67
66
15 576
57 56
6 56 65
74
25 66
39 2 67
38 6 56
26 1 72
71
66
6 67
576
25 75 56
89 44 73
45
13 24 2 43
12 23 29
37
19 30
6 15 11
9
68 8
14 58 29
70 31 10
17 30
18 29
15 69 31
16

1 Cap 14 Cap 26 O-ring

2 O-ring 15 O-ring 27 O-ring
3 Socket bolt 16 Cap 28 Housing
4 Spring washer 17 Spring 29 O-ring
6 O-ring 18 Spring guide 30 Retainer
7 Orifice 19 Spool 31 Socket bolt
8 Cap 20 Cap 32 Plunger assy
9 O-ring 21 Spring 33 Plunger assy(Dozer)
10 Cover 22 Check 34 Plunger assy(SW)
11 Socket bolt 23 Cap 35 Plunger assy(BM2)
12 Piston 24 O-ring 36 Plunger assy(AM1)
13 Sleeve 25 O-ring 37 Cover assy

8-33
STRUCTURE(2/2)

8
9 31

42 16
40 15
81 76
42 51 77
52 78
63
58 80
55 54
56 15 15 62
55 657 53 61
56 66 7 60
6 57 67
59
73 79
56 6 56 6 8
55 57 9
566 67
66 1
5766 2
67

49 50
75
6
48 3
4
47
46
24
23
89 15

80
15 2
1
58
29
30 29
22
21 82 31 30
6 9 31
29 8
2
30
31

38 Spring 53 Plunger assy(BM1) 68 Spacer

39 Poppet 54 Plunger assy(AM2) 69 Cover
40 Cover 55 Cap 70 Piston
41 Retainer 56 Back up ring 71 O-ring
42 O-ring 57 Nylon chip 72 Sleeve
43 Cap 58 Overload assy 73 Cap
44 Spring 59 Spring 74 Cap
45 Spool 60 Check 75 Foot relief assy
46 Spool 61 O-ring 76 Plug
47 O-ring 62 Back up ring 77 Back up ring
48 Cover 63 Cap 78 O-ring
49 Socket bolt 64 Main relief assy 79 Cap
50 Housing 65 Cap 80 Make up assy
51 Plunger assy(OPT) 66 Spring 81 Plunger(TR)
52 Plunger assy(BKT) 67 Check 82 Stopper

8-34
3. DISASSEMBLY AND ASSEMBLY
1) PRECAUTION
(1) Disassembly
‫ ڸ‬Handle the components carefully not to
drop them or bump them with each other
as they are made with precision.
‫ ڹ‬Do not force the work by hitting or
twisting as burred or damaged
component may not be assembled or
result in oil leakage or low performance.
‫ ں‬When disassembled, tag the
components for identification so that they
can be reassembled correctly.
‫ ڻ‬Once disassembled, O-rings and backup
rings are usually not to be used
again.(Remove them using a wire with its
end made like a shoehorn. Be careful
not to damaged the slot.)
‫ ڼ‬If the components are left disassembled
or half-disassembled, they may get rust
from moisture or dust. If the work has to
be interrupted, take measures to prevent
rust and dust.
(2) Assembly
‫ ڸ‬Take the same precautions as for
disassembly.
‫ ڹ‬When assembling the components,
remove any metal chips or foreign
objects and check them for any burrs or
dents. Remove burrs and dents with oil-
stone, if any.
‫ ں‬O-rings and backup rings are to be
replaced with new ones, as a rule.
‫ ڻ‬When installing O-rings and backup
rings, be careful not to damage
then.(Apply a little amount of grease for
smoothness.)
‫ ڼ‬Tighten the bolts and caps with specified
torque.(See Disassembly/Assembly.)

8-35
2) MOUNTING AND DISMOUNTING VALVES
(1) Disassembly 2
‫ ڸ‬Remove socket bolts(1, 2) and separate
4 spool valve and 5 spool valve.
(2) Assembly
Ɠ Valves should be mounted after making
sure that all O-rings and caps are placed
on the assembling faces of 4 plunger
valve.
‫ ڸ‬Carry out assembly in the reverse
manner of disassembly.
‫ ڹ‬Tighten the bolts to the specified torque.
ϦTightening torque : 10kgfϦm(72.3lbfϦft)

1
Tools
ϦHexagon socket : 10mm
ϦTorque wrench

8-36
3) PLUNGER
3 2 1
(1) Loosen socket bolt (1) to remove cover
(2).
ϦTightening torque : 3kgfϦm(21.7lbfϦft)
Ɠ Install cover (2) after making sure that O-
ring is placed on the edge of the valve
hole.
Tools
ϦHexagon socket : 6mm
ϦTorque wrench

(2) Pull the plunger out while holding the

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

(3) Place the plunger between holders and

loosen plunger cap (3) by using a vise. Holder
ş Plunger cap
Hexagon socket : 8mm
Tightening torque : 6kgfşm(43.4lbfşft)

(4) Remove plunger cap (3), guide (4), sleeve

(5) and spring (6) in this order.

3 4 5 6 4

Tools
ϦHexagon socket : 8mm
ϦTorque wrench

8-37
 (5) Arm plunger only (Remove check)
Remove cap (7) and disassemble spring
(8) and check (9).
ş Plunger cap
Hexagon socket : 6mm
Tightening torque : 3kgfşm(21.7lbfşft)

9 8 7
Tools
ϦHexagon socket : 6mm
ϦTorque wrench

4) MAIN RELIEF ASSEMBLY

Relief assy is assembled into a single block
1 2 3 4
as a cartridge. Do not disassemble the
relief assembly as a rule.
(1) Loosen the hexagon nut(2) with a holding
adjust screw(1).
(2) Loosen the hexagon nut(3) with a holding
cap(4)
(3) Loosen the cap(4) and remove the
cartridge.

(4) Pull out the sleeve(6) and take off the

main poppet(7), spring(8) and orifice(9). 4 5
Ɠ Can't remove the pilot seat(5) from the
cap(4), because it was locked at the cap.

(5) Loosen each screw and remove.

Item No. Name Socket

1 Adjust screw 22mm
2 Hexagon nut 30mm
3 Hexagon nut 30mm
4 Cap 30mm

9 8 7 6

8-38
5) OVERLOAD RELIEF ASSEMBLY
Relief assembly is assembled into a single 1
block as a cartridge. Do not disassemble
the relief assembly as a rule.
(1) Loosen the relief sleeve (1) and remove
the cartridge.
ϦTightening torque : 4kgfşm(29lbfşft)
Tools
ϦHexagon socket : 27mm
ϦTorque wrench

(2) Loosen the relief seat (2) and remove the

subassembly.
ϦTightening torque : 6kgfşm(43.4lbfşft)

1 2

Tools
ϦHexagon socket : 24mm
ϦTorque wrench

8-39
6) FOOT RELIEF ASSEMBLY
(1) Loosen socket bolt(1) and remove poppet
(2). 1
ϦTightening torque : 6kgfşm(43.4lbfşft)

Tools
ϦHexagon socket : 30mm
ϦTorque wrench

(2) Remove cap (3) and take off shim (4) and
spring (5).
ϦTightening torque : 6kgfşm(43.4lbfşft)
Ɠ Make sure adjust shim quantity. 1

(3) Remove the poppet (3) and take off

piston (4) and spring (5,6).
3

Tools
ϦHexagon socket : 30mm
ϦTorque wrench

8-40
7) BP VALVE ASSEMBLY
(1) Loosen the socket bolt(1) and remove the
cover(2). 2
ϦTightening torque : 1.2kgfşm(8.7lbfşft)
Ɠ Install cover(2) after making sure that O-
ring is placed on the edge of the valve 1
hole.

Tools
ϦHexagon socket : 5mm
ϦTorque wrench

(2) Place the plunger between holders and

remover the cap(3) by using a vise; take
off spring(4) and check(5).
Loosen the socket bolt(6) and remove
spring guide(7, 10), spacer(8) and
spring(9). 3 4 5 6
ϦTightening torque

Item No. Part name kgfşm lbfşft

3 Cap 3.5 25.3
6 Socket bolt 3 21.7

10 9 8 7

Tools
ϦHexagon socket : 6mm
ϦTorque wrench

8-41
8) CENTER BYPASS VALVE ASSEMBLY
(1) Remove cap (1). 1
ϦTightening torque : 8kgfşm(57.9lbfşft)

Tools
ϦHexagon socket : 36mm
ϦTorque wrench

(2) Remove spool (2) and spring (3).

8-42
9) ARM REGENERATION VALVE
(1) Remove cap (1) and take off spring guide
(2) and spring(3).
ϦTightening torque : 6kgfşm(43.4lbfşft)

Tools
ϦHexagon socket : 10mm
ϦTorque wrench

(2) Remove cap(4) and take off spool(5).

3 2 1
Tools
ϦHexagon socket : 27mm
ϦTorque wrench

(3) Take off sleeve(6) and piston(7).

6 7
5 4

8-43
10) ARM STROKE LIMIT ASSEMBLY
1 2
(1) Loosen the socket bolt(1) and remove
cover(2).
ϦTightening torque : 3kgfşm(21.7lbfşft)

Tools
ϦHexagon socket : 6mm
ϦTorque wrench

(2) Remove piston(3) and take off O-ring(4),

spacer(5) from the valve hole.
Ɠ Make sure inserting direction of the
spacer.

5 4 3

11) ARM LOAD HOLDING VALVE

(1) Basic unit
‫ ڸ‬Loosen socket bolt (1) and remove cover 2
assembly (2).
ϦTightening torque : 10kgfşm(72.3lbfşft)
Ɠ Install cover assembly (2) after making
sure that O-ring is placed on the edge of
1
the valve hole. Tools
ϦHexagon socket : 10mm
ϦTorque wrench

‫ ڹ‬Take off spring(3) and check valve(4).

8-44
(2) Cover assembly
8 9 10 11 12 13
‫ ڸ‬Remove cap (5).
Take off spring (6) and check valve (7).
ϦTightening torque : 5 kgfşm(36.2lbfşft)

7
6
5

Tools
ϦHexagon socket : 8mm
ϦTorque wrench

‫ ڹ‬Remove cap (8).

Take off spring (9) and poppet (10).
8 9 10
ϦTightening torque : 5kgfşm(36.2lbfşft)

Tools
ϦHexagon socket : 8mm
ϦTorque wrench

‫ ں‬Remove cap (13) and take off piston (12).

ϦTightening torque : 6 kgfşm(43.4lbfşft)
‫ ڻ‬Push sleeve (11) out with a rod or the like
through the hole of cap (13).
Ɠ Be careful not to damage the guideway
(‫ٻ‬5) of the sleeve. 12 13

Tools
ϦHexagon socket : 10mm
ϦTorque wrench

8-45
12) BOOM FLOW SUMMATION CHECK
(1) Remove the cap(1) and take off spring(2)
and check(3).
ϦTightening torque : 10kgfϦm(72.3lbfϦft) BM1

Boom flow summation check

1 2 3
Tools
ϦHexagon socket : 12mm
ϦTorque wrench

13) BUCKET FLOW SUMMATION CHECK

(1) Remove the cap(1) and take off check(2)
and spring(3). BKT
ϦTightening torque : 6kgfϦm(43.4lbfϦft)

Bucket flow summation check

3 2 1

Tools
ϦHexagon socket : 30mm
ϦTorque wrench

8-46
14) CHECK ASSEMBLY(BOOM, BUCKET, OPT)
(1) Remove cap(1).

Tools
ϦHexagon socket : 30mm
ϦTorque wrench

(2) Remove spring(2) and check valve(3).

ϦTightening torque : 15kgfϦm(108.5lbfϦft)

2 3

15) CHECK ASSEMBLY(SWING, ARM 1)

(1) Remove sleeve(1).

(2) Remove check valve(2) and spring(3).

2 3

8-47
16) CHECK ASSEMBLY(ARM 2)
(1) Remove cap(1).
ϦTightening torque : 15kgfϦm(108.5lbfϦft)

Tools
ϦHexagon socket : 12mm
ϦTorque wrench

(2) Take off spring(2) and check valve(3).

2 3

17) CHECK ASSEMBLY(P1)

(1) Remove cap(1).
ϦTightening torque : 15kgfϦm(108.5lbfϦft)

Tools
ϦHexagon socket : 12mm
ϦTorque wrench

(2) Remove spring(2) and check valve(3).

2 3

8-48
18) ORIFICE ASSEMBLY(P2 valve side)
Socket bolt
(1) Remove cap
Ɠ Install a suitable jig as shown fig and pull Hex. bolt
out the orifice by turning the hexagon bolt
with holding socket bolt(M5ź60).
(2) Assembly Cap
Fit socket bolt to orifice and insert the
orifice by tapping with a hammer.

Orifice

8-49
19) PRESSURE SETTING OF MAIN RELIEF
VALVE
Ɠ Improper setting of relief pressure can be
serious damage the hydraulic components. Surface Z
Ɠ Main relief valve pressure Piston(A)
-High pressure(power boost) : 350kg/cm2
-Low pressure : 320kg/cm2
(1) Pre setting
‫ ڸ‬Tight the adjust screw(1) until the
piston(A) contacts the surface Z.
‫ ڹ‬Loosen and retight the sleeve(10) until
the pilot poppet(B) contacts the poppet 1 2 10 3 4 Pilot poppet(B)
seat. Adjust spring(C)
That is, adjust spring(C) is just
compression point.
‫ ں‬Assemble the pre-setted relief valve
cartridge to main body and tight the
cap(4).
(2) High pressure(power boost)
‫ ڸ‬Set the pressure gauge on the discharge
port of main pump.
‫ ڹ‬Start engine and run high rpm.
‫ ں‬Operate boom, arm or bucket control
lever with full stroke.
‫ ڻ‬Adjust the pressure by turning the
sleeve(10) while reading the gauge.
1/4 turn : About 40kg/cm2
Ɠ Relief valve is very sensitive, therefore
turn the sleeve(10) slowly.
‫ ڼ‬Confirm the relief pressure with spec and
tight the hex head nut(3).
ňTightening torque : 6kgňm(43.4lbňft)
Ɠ Recheck the relief pressure.

(3) Low pressure

‫ ڸ‬After setting high pressure, adjust low
pressure by loosen the adjust screw(1).
‫ ڹ‬Confirm the low pressure, tight the hex
head nut(2).
Ɠ Recheck the relief pressure.

8-50
GROUP 5 SWING DEVICE

1. REMOVAL AND INSTALL OF MOTOR

1) REMOVAL
(1) Lower the work equipment to the ground
and stop the engine.
(2) Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
(3) Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Ɠ When pipes and hoses are disconnected,
the oil inside the piping will flow out, so 5 4
catch it in oil pan.
(4) Disconnect pipe assembly(2).
2
(5) Disconnect pilot line hoses(3,4,5,6). 1
(6) Sling the swing motor assembly(1) and
remove the swing motor mounting bolts
(7).
ş Motor device weight : 190kg(419lb) 3

(7) Remove the swing motor assembly.

Ɠ When removing the swing motor
assembly, check that all the piping have
been disconnected.
2) INSTALL
(1) Carry out installation in the reverse order 7
to removal.
(2) Bleed the air from the swing motor.
‫ ڸ‬Remove the air vent plug. 9
‫ ڹ‬Pour in hydraulic oil until it overflows from
the port.
8
‫ ں‬Tighten plug lightly.
‫ ڻ‬Start the engine, run at low idling and
check oil come out from plug.
‫ ڼ‬Tighten plug fully.

(3) Confirm the hydraulic oil level and check

the hydraulic oil leak or not.

8 - 51
2. SWING MOTOR
1) STRUCTURE

4 5 6 7 8 9 10 11 12 13 14 15 17, 18 30 31

3
2
16 31
1 36
35
17,18
37
38

29 28 27 26 25 24 23 22 21 20 19 34 33 32 39 40 41,42 43

1 Inner ring 16 Piston 30 Relief valve assembly

2 Oil seal 17 Cap 31 O-ring
3 Taper roller 18 O-ring 32 Hexagon socket bolt
4 Plug 19 Coned disc spring 33 Time delay valve
5 Backing spring 20 Teflon ring 34 Hexagon socket bolt
6 Cam plate 21 Bushing 35 Cap
7 Return plate 22 Balance plate 36 Back up ring
8 Piston assembly 23 Needle bearing 37 Spring
9 Plate 24 Snap ring 38 Check valve
10 Lining plate 25 Cylinder assembly 39 Cover
11 O-ring 26 Housing 40 O-ring
12 Piston 27 Collar 41 O-ring
13 O-ring 28 Level gauge assembly 42 Back up ring
14 Spring 29 Snap ring 43 Bypass valve assy
15 Parallel pin

8 - 52
2) DISASSEMBLY

(1) Removal of relief valve assembly

Remove cap of relief valve assembly(30)
with 14mm hexagonal wrench.
Ɠ Assemble removed relief valve assembly
(30) to original state when reassembling.

(2) Removal of make up valve

Loosen cap(35) with 14mm hexagonal
wrench, and remove check valve(38) and
spring(37).

(3) Marking at swing motor

Before disassembling motor, make a
matching mark between cover(39) and
housing(26) for easy reassembling.

(4) Remove mounting bolts of cover

Loosen hexagon socket bolt(32) with
16mm hexagonal wrench.

8 - 53
(5) Removal of cover assembly
Place shaft of motor assembly to
downward and take cover(39) out.

(6) Remove O-ring(13) from cover.

(7) Remove snap ring(24) with steel pointer

and remove inner race of needle-
bearing(23) by bearing puller.

(8) Remove bushing(21) and coned disk

spring(19) from teflon ring(20).

8 - 54
(9) Remove balance plate
Balance plate(22) is adhered on end surface
of cylinder(25) by oil viscosity. Take off
balance plate(22) with hands. Assembling
method of balance plate(22) depends on
cover(39).
(Band groove and round groove of highş low
pressure transmission area)
Before removing, check and record location of
balance plate(22) to prevent misassembling.

(10) Removal of spring(14, break area)

Remove spring(14) from piston(12).
Check and record original position of each
spring(14) for correct assembling.

(11) Removal of brake piston

When removing piston(12) from housing
(26), there is a sliding resistance against
tightening of O-rings(11,13). Use tap
hole(M6) on piston(12) as shown in the
fig.

(12) Remove O-rings(11,13) from piston(12)

and housing(26).

8 - 55
(13) Remove friction plate(9) and lining
plate(10) from housing(26).

(14) Removal of cylinder assembly

Holding end of cylinder assembly(25) with
hand, draw out cylinder assembly from
housing.
Ɠ Oil seal(2) and outer race of taper roller
bearing(3) are left inside of housing.
Ɠ End surface of cylinder(25) is sliding face.
So, protect the surface with a scrap of
cloth against damage.
Ɠ Make a matching mark on piston hole of
cylinder(25) and piston assembly(8) to fit
piston into the same hole when
reassembling.

(15) Separate outer race of taper roller

bearing(3) from housing.

(16) Removal of oil seal

Remove oil seal(2) from housing(26) with
driver and hammer.
Ɠ Do not reuse oil seal after removal.

8 - 56
(17) Disassembly of cylinder assembly
‫ ڸ‬Removal of inner race of taper roller
bearing(3).
After removing snap ring(29), lift out
cylinder(25) with 2 inner race of roller
bearing(3) by applying gear puller at the
end of spline in the cylinder.

‫ ڹ‬Separate cam plate(6), piston assembly

(8), return plate(7) from cylinder(25).

‫ ں‬Get cam plate(6) slide on sliding face of

piston assembly(8) and remove it.
Ɠ Be cautious not to damage on sliding
face of cam plate.

‫ ڻ‬Remove backing spring(5) from

cylinder(25).

This completes disassembly.

8 - 57
3) ASSEMBLY
(1) Preparation
Before reassembling, perform below
procedure.
‫ ڸ‬Check each part for damage caused by
using or disassembling. If damaged,
eliminate damage by grinding with proper
sandpaper, wash them with cleaning oil
and dry with compressed air.
‫ ڹ‬Replace seal with new one.
‫ ں‬Grind sliding face of piston assembly (8),
balance plate(22) and cam plate(6) with
sandpaper #2000.

‫ ڻ‬When assembling, lubricate with

specified clean hydraulic oil.
‫ ڼ‬When assembling piston assembly(8) to
piston hole of cylinder(25), check
matching mark between them.

8 - 58
(2) Assembly of cylinder assembly
‫ ڸ‬Lubricate grease on round area
(contacting area with spring(5)) of
cylinder(25) and assemble spring(5).

‫ ڹ‬Insert piston assembly(8) in hole of return

plate(7).

‫ ں‬Assemble piston assembly(8) and return

plate(7) to cylinder(25). When
assembling, check matching mark
between them. Before assembling,
lubricate specified hydraulic oil in piston
hole of cylinder(25).

‫ ڻ‬Lubricate specified hydraulic oil on shoe

sliding face of piston assembly(8) and
assemble cam plate(6).

8 - 59
‫ ڼ‬Assemble inner race of taper roller
bearing(3) to cylinder(25).

‫ ڽ‬Apply loctite to bearing mounting area of

inner race of cylinder(25) lightly.

‫ ھ‬Assemble inner race(1) to cylinder(25).

(3) Assembly of oil seal

Apply three bond of white color on outer
surface of oil seal(2) and assemble and
insert it.
Ɠ Before assembling, lubricate lip of oil seal
with grease.

8 - 60
(4) Assemble outer race of taper roller
bearing(3) to motor housing(26).

(5) Assembly of cylinder assembly

Hold end of cylinder assembly(25) with
hands and assemble cylinder assembly to
housing(26). Be careful to prevent
damage of seal by spline of shaft.
Ɠ When assemble cylinder assembly, spline
shaft of cylinder is protruded from end of
housing, therefore put pads with length
30~50mm under bottom of housing.

(6) Assemble plate(9) and lining plate(10).

Ɠ Lubricate specified hydraulic oil on each
side.

(7) Insert O-rings(11,13) into housing(26) and

piston(12).
Ɠ Lubricate O-ring with grease.

8 - 61
(8) Assembly of brake piston
Lubricate specified hydraulic oil on outer
sliding face of piston(12) and assemble
brake piston to housing(26).
Ɠ It is too tight to assemble piston(11)
because O-rings(11,13) are fitted,
therefore it is recommended to push
piston(12) horizontally by hands at once.

(9) Assembly of spring(14, brake unit)

Assemble spring(14) to piston(12) of
brake unit.
Ɠ Insert spring(14) into original position.

(10) Assemble inner race of needle bearing

(23) and snap ring(24) to cover(39).

(11) Assemble bushing(21) with teflon ring(20)

and coned disk spring(19) to bushing hole
of cover(39).
Ɠ Lubricate on both end surfaces of
bushing(21) and outer face of teflon
ring(20) with grease and assemble cover
to housing, and parts are adhered on
cover by grease viscosity which makes
assembling easy.

8 - 62
(12) Lubricate locating pin for antirotation of
balance plate(22) of cover(39) with
grease sufficiently and install locating pin
to housing.

(13) Assembly of balance plate

Assemble balance plate(22) to cover(39).
Ɠ Be cautious of assembling direction.

(14) Assemble O-ring(13) to cover(39).

Ɠ Lubricate O-ring with grease.

(15) Apply three bond of white color to

distinguish oil leakage from remaining oil
in bolt hole(M16) of cover(39).

8 - 63
(16) Assembly of cover
Assemble cover(39) and balance plate
(22) to housing(26) lightly, holding them
up with hands.
Ɠ When assembling, be careful not to
detach balance plate(22) and bushing
(21) from cover(39).
Ɠ Fit matching marks on housing(26) and
cover(39) made before disassembling.

(17) Tighten cover(39) and housing(26) with

16mm hexagonal socket bolt(32).
ş Tightening torque : 29kgfşm(210 lbfşft)

(18) Assembly of make up valve

Assemble check(38) and spring(37) to
cover(39) and tighten cap(35) with 14mm
hexagonal socket bolt.
ş Tightening torque : 14kgfşm(101lbfşft)

(19) Assembly of relief assembly

Assemble relief valve assembly(30) to
cover(39) with 14mm hexagonal socket
bolt.
ş Tightening torque : 8kgfşm(58lbfşft)
Ɠ Be cautious of assembling method.

8 - 64
(20) Check of assembly
Load pilot pressure of 30kgf.cm2 to brake
release port after opening inlet and outlet
port.
Check if output shaft is rotated smoothly
around torque of 2~3kgfşm.
If not rotated, disassemble and check.

This completes assembly.

8 - 65
3. REMOVAL AND INSTALL OF REDUCTION GEAR
1) REMOVAL
(1) Remove the swing motor assembly.
For details, see removal of swing motor
assembly.
(2) Slide reduction gear assembly(1) and
remove mounting bolts(2).
(3) Remove the reduction gear assembly.
ş Motor device weight : 190kg(419lb)
şTightening torque : 57.9Ź8.7kgfşm
(418Ź62.9lbfşft)

2) INSTALL
(1) Carry out installation in the reverse order
to removal.

8 - 66
4. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR

1) STRUCTURE

1 2 3 4 5 6 7 8 9 10 11 12 13 14

23 22 21 20 19 18 17 16 15
24

1 Pinion shaft 9 Roller bearing 17 Shaft 2

2 Collar 10 Pin 18 Bushing
3 Snap ring 11 Planetary gear 4 19 Planetary gear 5
4 Plate 12 Ring gear 20 Thrust plate 2
5 Roller bearing 13 Holder assembly 1 21 Spring pin
6 Gear casing 14 Sun gear 22 Holder 2
7 Plug 15 Lock bolt 23 Plug
8 Oil seal 16 Lock washer 24 Holder assembly 2

8 - 67
2) DISASSEMBLY
(1) Removal of sun gear and 1st holder
assembly
Remove sun gear(14) and holder
assembly1(13) itself.

(2) Removal of planetary gear 4 and 2nd

holder assembly
Remove planetary gear 4(11) and holder
assembly 2(24) itself.

(3) Disassembly of 2nd holder assembly

‫ ڸ‬Insert spring pin(21) into shaft 2(17) by
hammering.
Ɠ Do not reuse spring pin after removal.

‫ ڹ‬Remove shaft 2(17) from holder 2(22),

planetary gear 5(19) with hands.

8 - 68
(4) Removal of ring gear
‫ ڸ‬Remove ring gear(12) from casing(6).
Ɠ Fluid packing is applied on contacting
face of ring gear and gear casing.
Therefore, remove ring gear through tap
hole of gear casing with (-) driver.
‫ ڹ‬Remove pin(10) concurrently.

(5) Removal of pinion shaft assembly

‫ ڸ‬Remove snap ring(3) through hole of
gear casing with (-)driver.

‫ ڹ‬Press end face of pinion shaft(1) with

hydraulic press to gain space(approx.
300mm) needed for removing pinion shaft
at flange part of gear casing, and remove
pinion shaft(1), collar(2), plate(4), roller
bearing(5) as assembly.
Do not reuse oil seal(8) after removal.

‫ ں‬Remove roller bearing(9) from gear

casing(6).

8 - 69
 ‫ ڻ‬Remove oil seal(8) from gear casing(6).

(6) Disassembly of pinion shaft assembly

‫ ڸ‬Remove roller bearing(5), plate(4) and
collar(2) by pressing output pinion
shaft(1) and end face of the other side.
Ɠ Exchange pinion shaft assy if they have
defect.

This completes disassembly.

8 - 70
3) ASSEMBLY
(1) Assembly of pinion shaft assembly
‫ ڸ‬Insert collar(2) into pinion shaft(1) and
assemble plate(4).
Ɠ Be cautious of assembling direction.

‫ ڹ‬Heat roller bearing(5) up to 50 Ş C plus

surrounding temperature and assemble it
to pinion shaft(1).
Ɠ Heat roller bearing up more than 100Ş
C.

‫ ں‬Lubricate on outer face of roller

bearing(5) with grease.
Capacity : 400cc

(2) Installation of oil seal

Remove oil from assembled face of oil
seal of gear casing(6) and oil seal(8).
Apply fluid packing(three bond of white
color) on outer face of oil seal and
assemble at pressing jig of gear casing.
After inserting with press, lubricate on oil
seal lip with grease.

8 - 71
(3) Assembly of pinion shaft assembly
‫ ڸ‬Be careful lest oil seal lip damage by
spline of pinion shaft(1).
Assemble pinion shaft assembly by
using seal guide.

‫ ڹ‬Put pinion shaft of gear casing(6)

upward.
Assemble pinion shaft assembly to gear
casing by tightening eye bolt into tap
hole(M8) of output side of pinion shaft(1).

‫ ں‬Assemble snap ring(3).

Ɠ When assembling, loosen cutting place of
snap ring about 30mm from connections of
gear casing for easy disassembly.

(4) Assembly of roller bearing

Put gear casing under pinion shaft. Heat
inner race of roller bearing(9) up to 50Ş
C
plus surrounding temperature and
assemble to center of pinion shaft.
Assemble roller bearing by putting
between gear casing and pinion shaft.

8 - 72
(5) Assembly of ring gear
‫ ڸ‬Remove oil from mating faces between
gear casing(6) and ring gear(12), and
from pin(10). Assemble pin to gear
casing and apply fluid packing(three
bond of grey color).

‫ ڹ‬Assemble ring gear(12).

(6) Assembly of holder assembly

‫ ڸ‬Assemble bushing(18) to planetary gear
5(19).
Insert shaft 2(17) after thrust plate 2(20)
and bushing(18) to holder 2(22).
Ɠ Lubricate gear oil to inside of gear and
outside of shaft.

‫ ڹ‬Insert spring pin(21) by hammering.

Ɠ Insert as the clearance between spring
pins toward planetary gear 5(19).

8 - 73
(7) Assembly of 2nd holder assembly and
planetary gear 4
‫ ڸ‬Insert holder assembly being engaged
with internal teeth of ring gear(12).
Rotate holder assembly lightly so that
splines of pinion shaft(1) are engaged.

‫ ڹ‬Insert planetary gear 4(11) to planetary

gear 5(19).

(8) Assembly of sun gear and 1st holder

assembly
‫ ڸ‬Insert holder assembly being engaged
with internal teeth of ring gear(12).
Rotate holder assembly lightly so that
planetary gear 4(11) is engaged with
teeth of holder assembly 1(13).

‫ ڹ‬Insert sun gear(14).

8 - 74
(9) Check rotation of sun gear by turning 1st
holder assembly with hands.

This completes assembly.

8 - 75
GROUP 6 TRAVEL MOTOR

1. REMOVAL AND INSTALL

1) REMOVAL
(1) Lower the work equipment to the ground
and stop the engine.
(2) Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
(3) Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
4
(4) Loosen the socket bolt(1) and remove the 5
pipe assy(2).
7
(5) Disconnect hoses(3,4,5).
(6) Loosen the hex bolt(6) and remove travel
motor(7). 2
şWeight : 105kg(230lb) 1 6
Ɠ When removing the travel motor 3
assembly, check that all the hoses have
been disconnected.

2) INSTALL
(1) Carry out installation in the reverse order
to removal.
(2) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.

8-76
2. MOTOR UNIT

1 2 3 5 6 7 10 25 24 11 14 15 29 31

13

12
26 18 20 17 16 28 30 19 28

1 Socket head screw 10 Ring 19 Shim

2 Seal ring 11 Spacer 20 Housing
3 Flange 12 Taper roller bearing 24 Threaded pin
4 Seal ring 13 Drive shaft 25 Threaded pin
5 O-ring 14 Piston 26 Screw plug
6 Shim 15 Retainer ring 28 Retainer ring
7 Retainer ring 16 Thrust washer 29 Cylinder block
8 Nut 17 Socket head screw 30 Pressure spring
9 Taper roller bearing 18 Center pivot 31 Ring

8-77
REGULATOR

22,23,24 25,27,28,26,29 16 18
42
30,34,32,31,
15 36,37,38
21 16
41 3
5
2

40
10

8
9
55
56
16
61

60
1 7 6 4 41 58 59

1 Bushing 21 Screw plug 36 O-ring

2 Port plate 22 Pilot 37 Support ring
3 Housing 23 Valve piston 38 Screw plug
4 Pipe 24 Screw plug 40 Seal ring
5 Cylinder pin 25 Shim 41 O-ring
6 Cylinder pin 26 Pressure spring 42 Socket head screw
7 Finger 27 Spring plate 55 O-ring
8 Piston 28 Shim 56 Support ring
9 Ring 29 Screw plug 58 Cover
10 Threaded pin 30 O-ring 59 Threaded pin
15 Housing 31 Valve seat 60 Nut
16 Screw plug 32 Valve sleeve 61 Socket head screw
18 Nozzle 34 Valve seat

8-78
3. TIGHTENING TORQUE
The torques given are standard figures. Any figures specifically described in the procedure has
priority.
1) METERIC BOLT - Coarse thread
8.8 10.9 12.9
Size
kgşm lbşft kgşm lbşft kgşm lbşft
M5 0.6 4.3 0.8 5.8 1.0 7.2
M6 1.0 7.2 1.4 10.1 1.7 73.1
M8 2.5 18.1 3.5 25.3 4.1 29.7
M10 4.9 35.4 6.9 49.9 8.3 60.0
M12 8.6 62.2 12.0 86.8 14.5 104.9
M14 13.5 97.6 19.0 137.4 23.0 166.4
M16 21.0 151.9 29.5 213.3 35.5 256.8
M18 29.0 209.8 40.5 292.9 48.5 350.8
M20 41.0 396.6 58.0 419.5 69.0 499.1
M22 55.0 397.8 78.0 564.2 93.0 672.7
M24 71.0 513.5 100.0 723.3 120.0 868.0

2) METRIC BOLT - Fine thread

8.8 10.9 12.9
Size
kgşm lbşft kgşm lbşft kgşm lbşft
M 8ź1 2.7 19.5 3.8 27.5 4.5 32.5
M10ź1 4.8 34.7 7.0 50.6 8.3 60.0
M12ź1.5 9.0 65.1 12.5 90.4 15.0 108.5
M14ź1.5 15.0 108.5 21.0 151.9 25.0 180.8
M16ź1.5 22.5 162.7 31.5 227.8 38.0 274.9
M18ź1.5 32.5 235.1 46.0 332.7 55.0 297.8
M20ź1.5 46.0 332.7 64.0 462.9 77.0 556.9
M22ź1.5 61.0 441.2 86.0 622.0 105.0 759.5
M24ź2 78.0 564.2 110.0 795.6 130.0 940.0
M27ź2 115.0 831.8 160.0 1157.3 195.0 1410.4

8-79
4. DISASSEMBLY AND ASSEMBLY
1) GENERAL PRECAUTIONS
(1) Disassembly
‫ ڸ‬Before disassembling the motor, check the items to be inspected and, for remedy against trouble,
closely examine the nature of the trouble, so that the motor can be disassembled effectively.
‫ ڹ‬To disassemble the motor, use the disassembling procedures described in section 2) and select a
clean place.
‫ ں‬Place a rubber or vinyl sheet or other such protective materials on your working bench to protect
the surface of the motor to be serviced.
‫ ڻ‬During disassembly, give a match mark to the mating surfaces of each part.
‫ ڼ‬Arrange removed parts in order so that they will not become damaged or missing during
disassembly.
‫ ڽ‬Once seals have been disassembled, they should be replaced even if damage is not observed.
Have replacement seals ready on hand before starting your disassembling job.
(2) Assembly
‫ ڸ‬Reassemble in a work area that is clean and free from dust and grit.
‫ ڹ‬Handle parts with bare hands to keep them free of linty contanminats.
‫ ں‬Repair or replace the damaged parts.
Each parts must be free of burrs its corners.
‫ ڻ‬Do not reuse O-ring oil seal and floating seal that were removed in disassembly.
Provide the new parts.
‫ ڼ‬Wash all parts thoroughly in a suitable solvent.
Dry thououghly with compressed air.
Do not use the cloths.
‫ ڽ‬When reassembling oil motor components of motor, be sure to coat the sliding parts of the motor
and valve with fresh hydraulic oil.(NAS class 9 or above)
‫ ھ‬Use a torque wrench to tighten bolts and plugs, to the torque specified as follows.

8-80
2) INSPECTION
Examination of valve plate and cylinder
barrel.

3) ASSEMBLY
(1) Valve plate and cylinder barrel.

Ɠ Bore 1 in the valve plate must be min tilt angle max tilt angle
assembled toward the maximum tilt
angle position.
Oil Ports 2 in the valve plate housing
must be off-set toward the maximum tilt
angle position.
Cleansed sealing faces of valve plate
2
housing before assembly(apply sealant 1
thinly to both sides).

8-81
(2) Inserting pistons into cylinder barrel
ş Pistons 1+2 are inserted to the left while
pistons 3+4, 5+6 and 7 are laying to the
right of the housing.
ş When pistons 1+2 are entered into the
cylinder barrel follow the same procedure
with pistons 3+4, 5+6 and 7 while
2 7
gradually lowering the barrel. 1+ 3+
4
5+
6

Ɠ The pistons are shown in the drawing

shaded according to numbers.

(3) Assembly the valve plate and valve plate

housing to the cylinder barrel, using a
3mm steelrod to centralize the assembly.
Cover 1 (with the adjustment for minimum
tilt angle) should not be fitted at this
stage.
Ɠ The grub screw is assembled with Loctite
CVV. It may be removed cold, but in 1
cases of difficulty, gently apply local heat
to assist the removal.

8-82
4) CORRECT ASSEMBLY
(1) Centralise valve plate.

(2) Measure depth "a".

a

8-83
(3) Compress the spring.

(4) Remove the circlip.

(5) Release the spring.

(6) Remove the spring.

8-84
(7) Reassemble the ring and circlip(without
the spring).

(8) Centralise the barrel with jig.

(9) Set zero on the clock gauge.

8-85
(10) Measure dimension "b" between the
cylinder barrel and casing.

b
(11) Shim to give correct preload dimension. 0.2 +0.1
Depth "a" - Dimension "b"
= Clearance + Shim thickness
it is necessary to add or subtract shims(to
achieve a clearance of 0.2 +0.1
-0 mm).

8-86
(12) Replace spring.

(13) Finalise assembly.

8-87
5) DRIVE SHAFT
(1) Disassembly
‫ ڸ‬Extract the shaft seal housing(including
the shaft seal).

‫ ڹ‬Remove the grub screws at the top and

bottom of the housing flange(to facilitate
removal of the retainer ring).
When removing the grub screws, first
heat to 150Ş C.

8-88
8-89
‫ ں‬Tap the drive shaft slightly inward.
(1mm approximately)

‫ ڻ‬Remove the retainer ring.

8-90
‫ ڼ‬Extract the drive shaft.

8-91
(2) Measurement
‫ ڸ‬Mounting dimension "e" and spacer shim e
thickness "s".
‫ ڹ‬In case of changing the radial axial roller 1

bearings of motor, the dimension "e" has

to be measured without spacer shim in
order to find the right setting of articulation
point.
‫ ں‬For the type "retainer ring" the setting of
articulation point is obtained for the
housing by using a suitable retainer ring
and for the drive shaft assembly by using
a spacer shim. In case of repairing the
retainer ring has to be left with the
housing. s
2

1 Retainer ring
2 Spacer shim

Spacer shim
Measuring dimension(e)
Thickness "s" Spare parts no.
74.75-74.80 0.5mm 206.327.20.00
74.65-74.69 0.62mm 206.327.20.02
74.60-74.64 0.68mm 206.327.20.03

8-92
(3) Reassembly

‫ ڸ‬The drive shaft must not be pushed

inward more than is necessary for the
assembly of the retainer ring.

‫ ڹ‬Retainer ring set

Mount on top of drive shaft.

8-93
‫ ں‬Assemble the grub screws with Loctite
CVV.
+0
şTightening torque : 1 -0.2 kgşm
+0
(7.2 -1.4 lbşft)

+0
şTightening torque : 1 -0.2kgşm
(7.2 +0-1.4 lbşft)

Ɠ Before assembling the shaft seal housing

first fit the O-ring.

8-94
Use the special guide tool for the
assembly of the shaft seal and seal
housing over the shaft. Align the
securing bolt holes during assembly with
an extended stud.

8-95
6) DISPLACEMENT CONTROLLER
(1) Disassembly the piston
‫ ڸ‬Shown as a sectioned model with control
piston.

‫ ڹ‬Remove the grub screw(1) with an

extended hexagon key.
Ɠ The grub screw is assembled with Loctite
CVV. It may be removed cold but if this
proves difficult, apply local heat.

8-96
 ‫ ں‬Control and regulator pistons.

(2) Limiting the minimum tilt angle

‫ ڸ‬Adjust in bottom cover.

8-97
GROUP 7 RCV LEVER

1. REMOVAL AND INSTALL

1) REMOVAL
(1) Lower the work equipment to the ground
and stop the engine.
(2) Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
(3) Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious injury. 2
(4) Loosen the socket bolt(2).
(5) Remove the cover of the console box. 1
(6) Disconnect pilot line hoses(3).
(7) Remove the pilot valve assembly(1). 3
Ɠ When removing the pilot valve assembly,
check that all the hoses have been
disconnected.

2) INSTALL
(1) Carry out installation in the reverse order
to removal.
(2) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.

8-98
2. DISASSEMBLY AND ASSEMBLY
1) STRUCTURE

451

402
421
422
453
454 452

401
455
458 431

457 411 456

412
413
501
323
301
459 315
302

212-2 312

213
212-1
211
151
214
215
121
216-1
125
241-1
216-2 217
241-2 221
131 201
126
101
122
111

Port 2,4 Port 1,3

8-99
 101 Casing 216-1 Spring seat(port 1,3) 413 Plain washer
111 Port plate 216-2 Spring seat(port 2,4) 421 Screw 2
121 Seal washer 217 Washer 2 422 Nut
121 O-ring 221 Spring 431 Screw 3
122 Hex socket screw 241-1 Spring(port 1,3) 451 Roller
125 Spring pin 241-2 Spring(port 2,4) 452 Lever
126 Bushing 301 Universal joint 453 Switch seat 1
131 Plate 302 Plate 454 Switch seat 2
151 Spool 312 Adjust nut 455 Switch
201 Plug 315 Lock nut 456 Cord
212-1 Push rod(port 1,3) 323 Handle bar 457 Bushing
212-2 Push rod(port 2,4) 401 Handle 458 Tube
213 Seal 402 Handle cap 459 Terminal
214 O-ring 411 Screw 1 501 Bellows
215 Washer 1 412 Nut

8-100
2) TOOLS AND TIGHTENING TORQUE
(1) Tools

Tool name Remark

Allen wrench 6 B
22
Spanner
27
( + ) Driver Length 150
( - ) Driver Width 4 ~ 5
Torque wrench Capable of tightening with the specified torques.

(2) Tightening torque

Torque
Part name Item Size
kgfşm lbfşft
Socket head bolt 125 M8 3.0 Ź 0.3 21.7 Ź 2.2
Joint 301 M 14 3.5 Ź 0.25 25.3 Ź 1.8
Adjusting nut 312 M 14 5.0 Ź 0.35 36.2 Ź 2.5
Lock nut 315 M 14 5.2 Ź 0.35 36.2 Ź 2.5
Screw 1 411 M4 0.05 0.36
Screw 2 421 M4 0.01 0.07
Screw 3 431 M5 0.09 Ź 0.01 0.65 Ź 0.07

8-101
3) DISASSEMBLY
(1) Clean pilot valve with kerosene.
Ɠ 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.

Ɠ 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.

8-102
(5) Loosen adjusting nut(312) and plate(302)
with spanners on them respectively, and
remove them.

(6) Turn joint anticlockwise to loosen it,

utilizing jig (special tool).
Ɠ When return spring(221) is strong in
force, plate(151), plug(211) and push
rod(212-1, 2) will come up on loosening
joint. Pay attention to this.

8-103
(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.
Ɠ 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.
Ɠ 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.
Ɠ Record relative position of reducing valve
subassembly and return springs.

(10) Loosen hexagon socket head cap screws

with hexagon socket screw key.

8-104
(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(216-1, 2) and remove two
pieces of semicircular washers1(215) with
tip of small minus screwdriver.
Ɠ Pay attention not to damage spool
surface.
Ɠ Record original position of spring
seat(216-1, 2).
Ɠ Do not push down spring seat more than
6mm.

(14) Separate spool(201), spring seat(216),

spring(241-1, 2) and washer 2(217)
individually.
Ɠ Until being assembled, they should be
handled as one subassembly group.

8-105
(15) Take push rod(212-1, 2) 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).

8-106
(18) Remove handle cap(402).
Ɠ For valve without switch, remove cap
(403) too.

(19) Loosen machine screw 2(421) with plus

screwdriver and remove it together with
nut(422).
Ɠ 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).

8-107
(21) Disassemble handle(401) into two.
Ɠ For valve with switch, switch lever (452),
switch(455) and switch seats 1 & 2(453 &
454) can be taken out.

(22) Cleaning of parts

‫ ڸ‬Put all parts in rough cleaning vessel
filled with kerosene and clean them
(rough cleaning)
Ɠ 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.
Ɠ If this kerosene is polluted, parts will be
damaged and functions of reassembled
valve will be degraded.
Therefore, control cleanliness of
kerosene fully.
‫ ڹ‬Put parts in final cleaning vessel filled
with kerosene, turning it slowly to clean
them even to their insides(finish
cleaning).
Ɠ 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.
Ɠ If left as they after being cleaned, they will
be rusted and will not display their
functions fully after being reassembled.

8-108
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).
Ɠ Keep such assembling position that
spring pin(126) can enter into casing hole.

8-109
(3) Tighten hexagon socket head cap
screws(125) to the specified torque.
Ɠ Tighten two bolts alternately and slowly.

(4) Put washer 2(217), spring(241-1, 2) and

spring seat(216-1, 2) 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.
Ɠ 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.
Ɠ Assemble them to their original positions.

8-110
(7) Assemble O-ring(214) onto plug(211).

(8) Assemble seal(213) to plug(211).

Ɠ Assemble seal in such lip direction as
shown below.

(9) Assemble push rod(212-1,2) to plug(211).

Ɠ Apply working oil on push-rod surface.

(10) Assemble plug subassembly to casing.

Ɠ When return spring is weak in force,
subassembly stops due to resistance of
O-ring.

8-111
(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 plate(302) to joint(301).

Ɠ Screw it to position that it contacts with 4
push rods evenly.
Ɠ Do not screw it over.

8-112
(15) Assemble adjusting nut(312), apply
spanner to width across flat of plate(302)
to fix it, and tighten adjusting nut to the
specified torque.
Ɠ 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.
Ɠ Pay attention to projections/ depression
for assembling on switch seat, switch,
switch lever, etc.

(18) Assemble remaining handle(401).

8-113
(19) Assemble cap(402) and tighten machine
screw 2(421) and nut(422) to their
specified torques.
Ɠ For valve with switch, assemble roller
(451) instead 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
LOC

specified torque.
Ɠ Apply loctite #241 to threaded sections of
machine screws 1, 2 and 3.

(22) Fit handle cap(402).

8-114
(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
60Şto 120Şfrom casing hole.

(25) Assemble bushing(457) to plate and pass

cord and tube through it.
Ɠ Provide margin necessary to operation.

8-115
(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.

8-116
GROUP 8 TURNING JOINT

1. REMOVAL AND INSTALL

1) REMOVAL
(1) Lower the work equipment to the ground
and stop the engine.
(2) Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
(3) Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Ɠ When pipes and hoses are disconnected,
the oil inside the piping will flow out, so
2
catch it in oil pan. 1
(4) Disconnect all hoses.
(5) Sling the turning joint assembly (1) and
remove the mounting bolt(2).
şWeight : 76kg(168lb)
şTightening torque : 12.2Ź 1.3kgfşm
(88.2Ź 9.4lbfşft)
(6) Remove the turning joint assembly.
Ɠ When removing the turning joint, check
that all the hoses have been disconnected.

2) INSTALL
(1) Carry out installation in the reverse order
to removal. 1
Ɠ Take care of turning joint direction.
Ɠ Assemble hoses to their original positions.
Ɠ Confirm the hydraulic oil level and check
the hydraulic oil leak or not.

8-117
2. DISASSEMBLY AND ASSEMBLY
1) STRUCTURE

3 6 10
15

16
14

12, 13
11

1 Hub 7 Slipper seal 12 Plug

2 Shaft assembly 8 O-ring 13 Plug
3 Cover 9 O-ring 14 Retainer ring
4 Spacer 10 O-ring 15 Hexagon head bolt
5 Shim 11 Plug 16 Spring washer
6 Shim

8-118
2) DISASSEMBLY
15
(1) Before the disassembly, clean the turning
16
joint.
Remove bolts(15), washer(16) and cover 3
(3).

(2) Remove shim(6) and O-ring(10).

6
(3) Remove retainer ring(11), spacer(4) and 10
shim(5). 11
4
5

(4) Place hub(1) on a V-block and by using a

wood buffer at the shaft end, hit out Secure with hand
Wooden block
shaft(2) to about 1/2 from the hub with a
hammer.
Ɠ Take care not to damage the shaft(2)
when remove hub(1) or rest it sideway.
Ɠ Put a fitting mark on hub(1) and shaft(2). V block

Work bench

(5) Remove fifteen slipper seals(7) and O-

ring(9) from hub(1).
9
7

8-119
3) ASSEMBLY
Ɠ Clean all parts.
Ɠ As a general rule, replace oil seals and O-
ring.
Ɠ Coat the sliding surfaces of all parts with
engine oil or grease before installing.

(1) Fix fifteen slipper seal(7) and O-ring(9) to

hub(1).
9
(2) Fit O-ring(8) to shaft(2).
7

(3) Set shaft(2) on block, tap hub(1) with a

plastic hammer to install.
2

(4) Fit shim(5), spacer(4) and retainer ring(14)

to shaft(2). 6
10
(5) Fit O-ring(10) to hub(1). 14
(6) Fit shim(6) to shaft(2). 4
5

8-120
(7) Install cover(3) to hub(1) and tighten
bolts(15). 15
şTorque : 10 ~ 12.5kgfşm(72 ~ 90lbfşft) 16
3

8-121
GROUP 9 STEERING VALVE

1. REMOVAL AND INSTALL

1) REMOVAL
(1) Lower the work equipment to the ground
and stop the engine.
(2) Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
(3) Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Steering column
(4) Disconnect steering line hoses(3).
3
(5) Loosen the hexagon bolt(2) and remove 2
the steering valve assembly(1).
2) INSTALL
3
(1) Carry out installation in the reverse order 1
to removal.
(2) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.
Ɠ When removing the steering valve
assembly, check that all the hoses
have been disconnected.

8-122
2. STEERING VALVE
1) STRUCTURE

26

2
26

25 2

1 2
24
27
29
5
2 6
9 7
2 34 8
2
12
2

11

13
14
15 18
16 21
15
16 23
17
18
20
22

1 Dust seal ring 11 Shaft 21 Screw

2 *Housing assy 12 Spring set 22 Name plate
3 Ball 13 O-ring 23 Drive screw
4 Bushing 14 Distributor plate 24 Pressure relief valve
5 O-ring 15 Gearwheel set 25 Wire spring
6 Kin ring 16 O-ring 26 Shock valve
7 Bearing assy 17 End cover 27 Ball
8 Ring 18 Washer 28 Bushing
9 Cross pin 20 Pin screw
* Housing, spool and sleeve(Check valve and the seats for relief and dual shock valves are loctited).

8-123
2) TOOLS
(1) Holding tool.

(2) Assembly tool for O-ring(5,13,16) and kin-

ring(6).

(3) Assembly tool for cardan shaft(11).

(4) Assembly tool for dust seal(1).

8-124
(5) Torque wrench : 0~7.1kgfşm
(0~54.4lbfşft).
13mm socket spanner.
6, 8mm and 12mm hexagon sockets.
12mm screwdriver.
2mm screwdriver.
13mm ring spanner.
6, 8mm and 12mm hexagon socket
spanners.
Plastic hammer.
Tweezers.

8-125
3) TIGHTENING TORQUE AND HYDRAULIC CONNECTIONS
(1) Hydraulic connections

L : Left port
R : Right port
T : Tank
P : Pump

(2) Tightening torque

ğkgfşm(lbfşft)Ġ
Max. tightening torque
Screwed
connection With cutting With copper With aluminum
With O-ring
edge washer washer
1.4 BSP.F 4.1(29.7) 2.0(14.5) 3.1(22.4) -
3/8 BSP.F 6.1(44.1) 2.0(14.5) 5.1(36.9) -
1/2 BSP.F 10.2(73.8) 3.1(22.4) 8.2(59.3) -
7/16-20 UNF - - - 2.0(14.5)
3/4-16 UNF - - - 6.1(44.1)
M12ź1.5 4.1(29.7) 2.0(14.5) 3.1(22.4) 2.0(14.5)
M18ź1.5 7.1(51.4) 2.0(14.5) 5.1(36.9) 5.1(36.9)
M22ź1.5 10.2(73.8) 3.1(22.4) 8.2(59.3) 7.1(51.4)

8-126
4) DISASSEMBLY
(1) Dissemble steering column from steering
valve and place the steering valve in the
holding tool.
Screw out the screws in the end cover(6-
off plus one special screw).

(2) Remove the end cover, sideways.

(3) Lift the gearwheel set(with spacer if fitted)

off the unit.
Take out the two O-rings.

(4) Remove cardan shaft.

8-127
(5) Remove distributor plate.

(6) Screw out the threaded bush over the

check valve.

(7) Remove O-ring.

(8) Shake out the check valve ball and

suction valve pins and balls.

8-128
(9) Take care to keep the cross pin in the
sleeve and spool horizontal. The pin can
be seen through the open end of the
spool. Press the spool inwards and the
sleeve, ring, bearing races and needle
bearing will be pushed out of the housing
together.

(10) Take ring, bearing races and needle

bearing from sleeve and spool. The
outer(thin)bearing race can sometimes
"stick" in the housing, therefore check that
it has come out.

(11) Press out the cross pin. Use the special

screw from the end cover.

Ɠ A small mark has been made with a

pumice stone on both spool and sleeve
close to one of the slots for the neutral
position spring as figure.
If the mark is not visible, remember to
leave a mark of your own on sleeve and
spool before the neutral position springs
are disassembled.

8-129
(12) Carefully press the spool out of the sleeve.

(13) Press the neutral position springs out of

their slots in the spool.

(14) Remove dust seal and O-ring/kin ring.

8-130
(15) Disassemble the dual shock valve
‫ ڸ‬Remove plugs from shock valves using a
6mm hexagon socket spanner.

‫ ڹ‬Remove seal washers(2-off).

‫ ں‬Unscrew the setting screws using a 6mm

hexagon socket spanner.

‫ ڻ‬Shake out the two springs and two valve

balls into your hand. The valve seats
are bonded into the housing and cannot
be removed.

8-131
‫ ڼ‬The dual shock valves are now
disassembled.

8-132
(16) Disassemble the pressure relief valve
(cartridge)
‫ ڸ‬Screw out the plug using an 8mm
hexagon socket spanner. Remove seal
washers.

‫ ڹ‬Unscrew the setting screw using an 8mm

hexagon socket spanner.

‫ ں‬Shake out spring and piston. The valve

seat is bonded into the housing and
cannot be removed.

‫ ڻ‬The pressure relief valve is now

disassembled.

8-133
‫ ڼ‬The steering valve is now completely
disassembled.

Ɠ Cleaning
Clean all parts carefully in shellsol K or
the like.
Ɠ Inspection and replacement
Replace all seals and washers. Check
all parts carefully and make any
replacements necessary.
Ɠ Lubrication
Before assembly, lubricate all parts with
hydraulic oil.

8-134
5) ASSEMBLY
(1) Assemble spool and sleeve.
When assembling spool and sleeve only
one of two possible ways of positioning
the spring slots is correct. There are three
slots in the spool and three holes in the
sleeve in the end of the spool / sleeve
opposite to the end with spring slots.
Place the slots and holes opposite each
other so that parts of the holes in the
sleeve are visible through the slots in the
spool.

(2) Place the two flat neutral position springs

in the slot.
Place the curved springs between the flat
ones and press them into place(see
assembly pattern).

Ɠ Assembly pattern.
şPart no : 150N4035

(3) Line up the spring set.

8-135
(4) Guide the spool into the sleeve. Make
sure that spool and sleeve are placed
correctly in relation to each other.

(5) Press the springs together and push the

neutral position springs into place in the
sleeve.

(6) Line up the springs and center them.

(7) Guide the ring down over the sleeve.

Ɠ The ring should be able to rotate free of
the springs.

8-136
(8) Fit the cross pin into the spool / sleeve.

(9) Fit bearing races and needle bearing as

shown on below drawing.

Ɠ Assembly patted for standard bearings

1
1 Outer bearing race
2
2 Needle bearing
3 Inner bearing race 3
4 Spool
5 Sleeve 4

Installation instruction for O-ring/Kin-ring

(10) Turn the steering unit until the bore is
horizontal. Guide the outer part of the
assembly tool into the bore for the spool /
sleeve.

8-137
(11) Grease O-ring and kin-ring with hydraulic
oil and place them on the tool.

(12) Hole the outer part of the assembly tool in

the bottom of the steering unit housing
and guide the inner part of the tool right to
the bottom.

(13) Press and turn the O-ring / kin-ring into

position in the housing.

8-138
(14) Draw the inner and outer parts of the
assembly tool out of the steering unit bore,
leaving the guide from the inner part in the
bore.

(15) With a light turning movement, guide the

spool and sleeve into the bore.
Ɠ Fit the spool set holding the cross pin
horizontal.

(16) The spool set will push out the assembly

tool guide. The O-ring and kin-ring are
now in position.

(17) Turn the steering unit until the bore is

vertical again. Put the check valve ball
into the hole indicated by the arrow.

8-139
(18) Screw the threaded bush lightly into the
check valve bore. The top of the bush
must lie just below the surface of the
housing.

Assembly of the two suction valve

(19) Place a ball in the two holes indicated by
the arrows.

(20) Place a pin in the same two holes.

(21) In some cases a spring has to be fitted on

the pin before it is placed in the housing.

8-140
(22) Grease the O-ring with mineral oil approx
viscosity 500 cST at 20Ş
C.

(23) Place the distributor plate so that the

channel holes match the holes in the
housing.

(24) Guide the cardan shaft down into the bore

so that the slot is parallel with the
connection flange.

(25) Place the cardan shaft as shown so that it

is held in position by the mounting fork.

8-141
(26) Grease the two O-rings with mineral oil
approx. viscosity 500 cST at 20Ş C and
place them in the two grooves in the gear
rim. Fit the gearwheel and rim on the
cardan shaft.

(27) Fit the gearwheel(rotor) and cardan shaft

so that a tooth base in the rotor is
positioned in relation to the shaft slot as
shown. Turn the gear rim so that the
seven through holes match the holes in
the housing.

(28) Fit the spacer, if any.

(29) Place the end cover in position.

8-142
(30) Fit the special screw with washer and
place it in the hole shown.

(31) Fit the six screws with washers and insert

them. Cross-tighten all the screws and
the rolled pin.
ş tightening torque : 3.0Ź0.6kgfşm
(22.4Ź4.3lbfşft)

(32) Place the dust seal ring in the housing.

The dust seal ring must be placed only
after the pressure relief valve and shock
valves have been fitted.

(33) Fit the dust seal ring in the housing.

8-143
(34) Press the plastic plugs into the connection
ports.
Ɠ Do not use a hammer!

Assembly of the pressure relief valve

(35) Fit the piston.

(36) Fit the spring.

(37) Screw in the setting screw with an 8mm

hexagon socket spanner. Make the
pressure setting on a panel or the
machine.

8-144
(38) Screw plug with dust seal into the housing
using an 8mm hexagon socket spanner.
ş tightening torque : 5.1Ź1kgfşm
(36.9Ź7.2lbfşft)

Assembly of the dual shock valve

(39) Put a ball in the two holes indicated by the
arrows.

(40) Place springs and valve cones over the

two balls.

(41) Screw in the two setting screws using a

6mm hexagon socket spanner. Make the
pressure setting on a panel or the
machine.

8-145
(42) Screw plug with seal ring into the two
shock valves using a 6mm hexagon socket
spanner.
ş Tightening torque : 3.1kgfşm
(22.4lbfşft)

Steering valve is now assembled.

8-146
GROUP 10 TRANSMISSION

1. REMOVAL TRANSMISSION
1
1) Transmission mounting bolt(1, M20)
3
°§Tightening torque : 44 ° æ 2kgf°§m
(318.2 ° æ 14lb°§ft)
2) Travel motor mounting bolt(2, M16)
°§Tightening torque : 29.6 ° æ 3.2kgf°§m
(214 ° æ 23.1lb°§ft)
3
3) Propeller shaft mounting nut(3, M10)
°§Tightening torque : 5.9 ° æ 0.6kgf°§m 4
(42.7 ° æ 4.3lb°§ft)
4) Hose assy(4, PF3/8)
°§Tightening torque : 5kg°§m(36.2lb°§ft)
2
5) Transmission weight : 132kg(290lb)

8-147
2. GENERAL INSTRUCTIONS
1) GENERAL WORKING INSTRUCTIONS
(1) This manual has been developped for the skilled serviceman, trained by the ZF-Passau.
(2) During all operations, pay attention to cleanliness and skilled working.
Therefore,transmission removed from the machine, must be cleaned prior to open them.
(3) We assume that the special tools, specified by ZF, will be used.
The special tools are available from ZF-Passau.
(4) After the disassembly, all components must be cleansed, especially corners, cavities and
recesses of housing and covers.
(5) The old sealing compound must be carefully removed.
(6) Check lubricating holes, grooves and pipes for free passage. They must be free of residues,
foreign material or protective compounds.
(7) The latter refers expecially to new parts.
(8) Parts which have been inevitably damaged in a disassembly operation, must be generally
replaced by new ones, e.g. rotary seal rings, O-rings, U-section rings, cap boots, protective caps
etc..
(9) Components such as roller bearings, thrust washers, synchronizing parts etc. which are subject to
normal wear in automotive operation, must be checked by the skilled Serviceman.
He will decide if the parts can be reused.
(10) For the heating of bearings etc., hot plates, rod heaters or heating furnaces must be used.
(11) Never heat parts directly with the flame. An auxiliary solution would be to immerse the bearing in
a vessel filled with oil, which is then heated with the flame.
In this way, damage to the bearings could be avoided.
(12) Ball bearings, covers, flanges and parts like that must be heated to about 90 to 100°£C.
(13) Hot-mounted parts must be reset after cooling in order to assure a proper contact.
(14) Before pressing shafts, bearings etc. in position, both parts must be lubricated.
(15) During to reassembly, all specified adjustment values, testing specifications and tightening torque
must be respected.
(16) After the repair, units are filled up with oil.
(17) After the oil filling, the oil level plugs and oil drain plugs must be tightened to the specified
tightening torque.

8-148
2) IMPORTANT INSTRUCTIONS CONCERNING THE LABOUR SAFETY
(1) In principle, repairers are themselves responsible for the labour safety.
(2) The observance of all valid safety regulations and legal rules is a precondition to prevent damage
to individuals and products during the maintenance and repair operations.
(3) Before starting the work, the repairers have to make themselves familiar with these regulations.
(4) The proper repair of these products requires especially trained personnel.
(5) The repairer himself is obliged to provide for the training.
3) LUBRICANT SPECIFICATIONS
(1) API GL-5
(2) SAE 10W-30, 15W-40

8-149
4) BRAKE LINING WEARING TEST
(1) General
® The brake lining wearing test gives a limited information about the overall condition of the brake
Á plate pack - without disassembly of the planetary carrier, resp. of the plates.
The wearing test has to be carried out in case of the following criteria :
® - In the course of the oil change intervals(min. once a year)
Ë - Braking noises
- Reduced braking power
- Change of deceleration, of the brake fluid level as well as of the brake pressure
- In case of a general change of the brake performance.
Carry out the wearing test on both final drive sides.
- Permitted piston stroke max. : 5.0mm
® - Piston stroke in new condition of the plate pack : 3.1-3.5mm

(2) Carry out the wearing test

® Turn the planetary carrier until screw plug
A
Á A(M16°ø1.5) is in the upper position(12
o'clock position).
Now, remove the screw plug.
Apply the brake(required brake pressure
® min. 40bar). el
lev
Ë Screw measuring screw(M16°ø1.5) in Oil

until contact is obtained and tighten it

® with a torque of 1kg°§m.
È Determine dimension X according to the
figure on the right.
Release the brake and equalize the plate
®Í clearance by resetting the measuring
screw.
X
®Î Torque limit 1kg°§m.
Determine dimension Y according to the
figure on the right.
The difference of the two dimensions
®Ï (X-Y) corresponds to the piston stroke
(actual state).
(3) Result
If the max. permitted piston stroke(5.0mm)
is exceeded, the lining plates must be
renewed on both final drive sides.

8-150
GROUP 11 FRONT AXLE

1. REMOVAL FRONT AXLE

1) Pivot pin mounting bolt(1, M12)
°§Tightening torque : 9.3° æ 1.9kgf°§m
(67.3° æ 13.7lb°§ft)
2) Propeller mounting nut(2, M10)
°§Tightening torque : 5.9° æ 0.6kgf°§m
(42.7° æ 4.3lb°§ft) 5
3) Wheel nut(3, M20)
+0 6 4
°§Tightening torque : 60 -5 kgf°§m
+0
(434 -36lb°§ft)
7
4) Oscillating cylinder supporting mounting
2
bolt(4, M16) 6
°§Tightening torque : 29.6° æ 3.2kgf°§m 1
(214° æ 23.1lb°§ft)
5) Hose assy(5, PF 3/8)
3
°§Tightening torque : 5.0kgf°§m(36.2lb°§ft)
6) Hose assy(6, PF 1/4)
°§Tightening torque : 4.0kgf°§m(28.9lb°§ft)
7) Hose assy(7, PF 1/2)
°§Tightening torque : 6.0kgf°§m(43.4lb°§ft)
8) Transmission weight : 502kg(1110lb)

8-202
2. GENERAL INSTRUCTIONS
1) GENERAL WORKING INSTRUCTIONS
(1) This manual has been developped for the skilled serviceman, trained by the ZF-Passau.
(2) During all operations, pay attention to cleanliness and skilled working.
Therefore, axle removed from the machine, must be cleaned prior to open them.
(3) We assume that the special tools, specified by ZF, will be used.
The special tools are available from ZF-Passau.
(4) After the disassembly, all components must be cleansed, especially corners, cavities and
recesses of housing and covers.
(5) The old sealing compound must be carefully removed.
(6) Check lubricating holes, grooves and pipes for free passage. They must be free of residues,
foreign material or protective compounds.
(7) The latter refers expecially to new parts.
(8) Parts which have been inevitably damaged in a disassembly operation, must be generally
replaced by new ones, e.g. rotary seal rings, O-rings, U-section rings, cap boots, protective caps
etc..
(9) Components such as roller bearings, thrust washers, synchronizing parts etc. which are subject to
normal wear in automotive operation, must be checked by the skilled Serviceman.
He will decide if the parts can be reused.
(10) For the heating of bearings etc., hot plates, rod heaters or heating furnaces must be used.
(11) Never heat parts directly with the flame. An auxiliary solution would be to immerse the bearing in
a vessel filled with oil, which is then heated with the flame.
In this way, damage to the bearings could be avoided.
(12) Ball bearings, covers, flanges and parts like that must be heated to about 90 to 100°£C.
(13) Hot-mounted parts must be reset after cooling in order to assure a proper contact.
(14) Before pressing shafts, bearings etc. in position, both parts must be lubricated.
(15) During to reassembly, all specified adjustment values, testing specifications and tightening torque
must be respected.
(16) After the repair, units are filled up with oil.
(17) After the oil filling, the oil level plugs and oil drain plugs must be tightened to the specified
tightening torque.

8-203
2) IMPORTANT INSTRUCTIONS CONCERNING THE LABOUR SAFETY
(1) In principle, repairers are themselves responsible for the labour safety.
(2) The observance of all valid safety regulations and legal rules is a precondition to prevent damage
to individuals and products during the maintenance and repair operations.
(3) Before starting the work, the repairers have to make themselves familiar with these regulations.
(4) The proper repair of these products requires especially trained personnel.
(5) The repairer himself is obliged to provide for the training.
3) LUBRICANT SPECIFICATIONS
(1) Gear oils with limited - slip additives.
(2) API GL-5
(3) MIL-L-2105D(SAE 85W-90, 85W-140 with LS-Additive)

8-204
GROUP 12 REAR AXLE

1. REMOVAL REAR AXLE

1) Rear axle mounting bolt(1, M20)
°§Tightening torque : 58 ° æ 6.3(kgf°§m)
(419.5 ° æ 45.6lb°§ft) 1
2) Propeller shaft mounting bolt(2, M10)
°§Tightening torque : 5.9 ° æ 0.6kgf°§m
4
(42.7 ° æ 4.3lb°§ft)
3) Wheel nut(3, M20)
+0
°§Tightening torque : 60 -5 kgf°§m
0
(434 -36 lb°§ft)
2
4) Hose assy(4, PF 1/4) 3
°§Tightening torque : 4kgf°§m(28.9lb°§ft)
5) Axle weight : 402kg(890lb)

8-263
2. GENERAL INSTRUCTIONS
1) GENERAL WORKING INSTRUCTIONS
(1) This manual has been developped for the skilled serviceman, trained by the ZF-Passau.
(2) During all operations, pay attention to cleanliness and skilled working.
Therefore, axle removed from the machine, must be cleaned prior to open them.
(3) We assume that the special tools, specified by ZF, will be used.
The special tools are available from ZF-Passau.
(4) After the disassembly, all components must be cleansed, especially corners, cavities and
recesses of housing and covers.
(5) The old sealing compound must be carefully removed.
(6) Check lubricating holes, grooves and pipes for free passage. They must be free of residues,
foreign material or protective compounds.
(7) The latter refers expecially to new parts.
(8) Parts which have been inevitably damaged in a disassembly operation, must be generally
replaced by new ones, e.g. rotary seal rings, O-rings, U-section rings, cap boots, protective caps
etc..
(9) Components such as roller bearings, thrust washers, synchronizing parts etc. which are subject to
normal wear in automotive operation, must be checked by the skilled Serviceman.
He will decide if the parts can be reused.
(10) For the heating of bearings etc., hot plates, rod heaters or heating furnaces must be used.
(11) Never heat parts directly with the flame. An auxiliary solution would be to immerse the bearing in
a vessel filled with oil, which is then heated with the flame.
In this way, damage to the bearings could be avoided.
(12) Ball bearings, covers, flanges and parts like that must be heated to about 90 to 100°£C.
(13) Hot-mounted parts must be reset after cooling in order to assure a proper contact.
(14) Before pressing shafts, bearings etc. in position, both parts must be lubricated.
(15) During to reassembly, all specified adjustment values, testing specifications and tightening torque
must be respected.
(16) After the repair, units are filled up with oil.
(17) After the oil filling, the oil level plugs and oil drain plugs must be tightened to the specified
tightening torque.

8-264
2) IMPORTANT INSTRUCTIONS CONCERNING THE LABOUR SAFETY
(1) In principle, repairers are themselves responsible for the labour safety.
(2) The observance of all valid safety regulations and legal rules is a precondition to prevent damage
to individuals and products during the maintenance and repair operations.
(3) Before starting the work, the repairers have to make themselves familiar with these regulations.
(4) The proper repair of these products requires especially trained personnel.
(5) The repairer himself is obliged to provide for the training.
3) LUBRICANT SPECIFICATIONS
(1) Gear oils with limited - slip additives.
(2) API GL-5
(3) MIL-L-2105D(SAE 85W-90, 85W-140 with LS-Additive)

8-265
GROUP 13 BOOM, ARM, BUCKET AND DOZER CYLINDER

1. REMOVAL AND INSTALL

1) BUCKET CYLINDER
(1) Removal
Ɠ Expand the arm and bucket fully, lower the
work equipment and dozer blade to the
ground and stop the engine.
Ɠ Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
Ɠ Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can Bucket cylinder
penetrate the skin causing serious injury.
Ɠ Fit blind plugs in the hoses after
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

‫ ں‬Loosen socket bolt(4) to disconnect

bucket cylinder hoses(5) and put plugs on
cylinder pipe.

5
4

8-306
 ‫ ڻ‬Sling bucket cylinder assembly(9), and
remove nut(8), bolt(7), then pull out
pin(6). 9 7
‫ ڼ‬Remove bucket cylinder assembly(9)
şWeight : 135kg(298lb) 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 Confirm the hydraulic oil level and check
the hydraulic oil leak or not.

8-307
2) ARM CYLINDER
(1) Removal
Ɠ Expand the arm and bucket fully, lower the
work equipment and dozer blade to the
ground and stop the engine.
Ɠ Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
Ɠ Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious in
injury.
Arm cylinder
Ɠ Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust
from entering.
‫ ڸ‬Set block between arm cylinder and Boom
boom.
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

‫ ں‬Loosen socket bolt(4) to disconnect arm

cylinder hose(5) and put plugs on cylinder
5
pipe. 4
‫ ڻ‬Disconnect greasing hoses(6).
6

8-308
 ‫ ڼ‬Sling arm cylinder assembly(10), and
remove nut(9), bolt(8), then pull out 8
10
pin(7).
‫ ڽ‬Remove arm cylinder assembly(10). 7

şWeight : 183kg(403lb) 9

(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 arm cylinder.
Ɠ Confirm the hydraulic oil level and check
the hydraulic oil leak or not.

8-309
3) BOOM CYLINDER
(1) Removal
Ɠ Expand the arm and bucket fully, lower the
work equipment and dozer blade to the
ground and stop the engine.
Ɠ Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
Ɠ Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Ɠ Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or
dust from entering.
Boom 1
‫ ڸ‬Disconnect greasing hoses(1).
‫ ڹ‬Sling boom cylinder assembly.

Boom cylinder

‫ ں‬Remove nut(4), bolt(3) and pull out pin(2).

4
Ɠ Tie the rod with wire to prevent it from
coming out.

4 3

‫ ڻ‬Lower the boom cylinder assembly(5) on

a stand.

8-310
‫ ڼ‬Disconnect boom cylinder hoses(6), and
put plugs on cylinder pipe.

‫ ڽ‬Remove spring(9), pin stopper(8), then

pull out pin(7).
‫ ھ‬Remove boom cylinder assembly(5).
8
şWeight : 145kg(320lb)
5 7
9

(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 boom cylinder.
Ɠ Confirm the hydraulic oil level and check
the hydraulic oil leak or not.

8-311
4) DOZER CYLINDER
(1) Removal
Ɠ Expand the arm and bucket fully, lower the
work equipment to the ground and stop
the engine.
Ɠ Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
Ɠ Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Ɠ Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or
dust from entering.
‫ ڸ‬Lower the dozer blade to the ground.
Dozer cylinder

Dozer blade

‫ ڹ‬Disconnect dozer cylinder hoses(1), and

1
put plugs on cylinder pipe.

Dozer cylinder

‫ ں‬Sling dozer cylinder assembly.

‫ ڻ‬Remove bolt(2) and pull out pin(3).
Ɠ Tie the rod with wire to prevent it from
Wire
coming out.

3
2

8-312
‫ ڼ‬Lower the dozer cylinder rod side on a
wooden block.
Wire

Wooden block

‫ ڽ‬Loosen the bolt(4) and remove lock 8

washer(5), hook plate(6), and spacer(7). 9
Wire
‫ ھ‬Remove bolt(8) and pull out pin(9).
‫ ڿ‬Remove the dozer cylinder assy(10). 10
şWeight : 62kg(140lb)
76
5

(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 dozer cylinder.
Ɠ Confirm the hydraulic oil level and check
the hydraulic oil leak or not.

8-313
2. DISASSEMBLY AND ASSEMBLY
1) STRUCTURE
(1) Bucket cylinder

22 4 3 10,11 33,34 32 10,12 1 2 13 15,16 14 17 18 19 20

7
6
5
8
9

Internal detail

35,36 23-6 30 31 35,36

23 23 23-3

1 Tube assembly 11 Back up ring 22 Hexagon socket head bolt

2 Rod assembly 12 Back up ring 23 Band assembly
3 Gland 13 Cushion ring 23-3 Hexagon bolt
4 Du bushing 14 Piston 23-6 Hexagon bolt
5 Rod seal 15 O-ring 30 Pipe assembly(R)
6 Back up ring 16 Back up ring 31 Pipe assembly(B)
7 Step seal 17 Piston seal 32 O-ring
8 Dust wiper 18 Wear ring 33 Hexagon bolt
9 Snap ring 19 Dust ring 34 Spring washer
10 O-ring 20 Lock nut 35 Pin bushing
36 Dust seal

8-314
(2) Arm cylinder

24 4 3 10,11 36,37 35 10,12 1 2 13 15,16 14 17 18 19 22

7
6
5 40
8
21
9
20

Internal detail

38,39 25-4,25-5 25 29 38,39

33 34

1 Tube assembly 13 Cushion ring 25-4 Hexagon bolt

2 Rod assembly 14 Piston 25-5 Hexagon bolt
3 Gland 15 O-ring 29 Band assembly(B)
4 Du bushing 16 Back up ring 33 Pipe assembly(R)
5 Rod seal 17 Piston seal 34 Pipe assembly(B)
6 Back up ring 18 Wear ring 35 O-ring
7 Step seal 19 Dust ring 36 Hexagon bolt
8 Dust wiper 20 Cushion spear 37 Spring washer
9 Snap ring 21 Steel ball 38 Pin bushing
10 O-ring 22 Lock nut 39 Dust seal
11 Back up ring 24 Hexagon socket head bolt 40 Set screw
12 Back up ring 25 Band assembly(R)

8-315
(3) Boom cylinder

8,9 10 5,6 7 4 22 32 31 3 11,12 1 2 13 14 15,16 17 18 19 20

Internal detail

23-5 23 23-4 30
33,35 34,36

29

1 Tube assembly 12 Back up ring 23-4 Hexagon bolt

2 Rod assembly 13 Cushion ring 23-5 Hexagon nut
3 Gland 14 Piston 29 Pipe assembly(R)
4 Du bushing 15 O-ring 30 Pipe assembly(B)
5 Rod seal 16 Back up ring 31 O-ring
6 Back up ring 17 Piston seal 32 Hexagon bolt
7 Step seal 18 Wear ring 33 Spring washer
8 Dust wiper 19 Dust ring 34 Pin bushing
9 Snap ring 20 Lock nut 35 Pin bushing
10 O-ring 22 Hexagon socket head bolt 36 Dust seal
11 Back up ring 23 Band assembly 37 Dust seal

8-316
(4) Dozer cylinder

32 3 5,6 7 4 10,11 28 27 1 2 26 12 15 13,1416 17,18

19
8,9

20
29,31 30,31

1 Tube assembly 10 O-ring 20 Band assembly

2 Rod assembly 12 Piston 26 Pipe assembly
3 Gland 13 O-ring 27 O-ring
4 Du bushing 14 Back up ring 28 Hexagon socket head bolt
5 Rod seal 15 Piston seal 29 Pin bushing
6 Back up ring 16 Wear ring 30 Pin bushing
7 Step seal 17 Set screw 31 Dust seal
8 Dust wiper 18 Steel ball 32 Grease nipple
9 Snap ring 19 Hexagon socket head bolt

8-317
(5) Outrigger cylinder

12,13,14
5,6 3 7 4 10,1129 28 26 1 2 26 15,16 17,18 27

19
8,9

32

30,31
20

1 Tube assembly 10 O-ring 20 Band assembly

2 Rod assembly 12 Piston 26 Pipe assembly(R)
3 Gland 13 O-ring 27 Pipe assembly(B)
4 Du bushing 14 Back up ring 28 O-ring
5 Rod seal 15 Piston seal 29 Hexagon socket head bolt
6 Back up ring 16 Wear ring 30 Pin bushing
7 Step seal 17 Set screw 31 Dust seal
8 Dust wiper 18 Steel ball 32 Grease nipple
9 Snap ring 19 Hexagon socket head bolt

8-318
2) TOOLS AND TIGHTENING TORQUE
(1) Tools

Tool name Remark

Allen wrench 14 B

spanner 13
17
19
(-)Driver Small and large sizes.
Torque wrench Capable of tightening with the specified torques

(2) Tightening torque

Torque
Part name Item Size
kgfşm lbfşft
Socket head bolt Bucket cylinder
22 M18 32Ź3.0 231.5Ź21.7
Boom cylinder
Arm cylinder 24 M20 46Ź5.0 332.7Ź36.2
Socket head bolt Dozer cylinder
19 M16 23Ź2.0 116.4Ź14.5
Outrigger cylinder
Dozer cylinder 28
M8 2.7Ź0.3 19.5Ź2.2
Ortirgger cylinder 29
Hexagon head bolt Bucket cylinder 23-3
Arm cylinder 25-4 M10 3.2Ź0.3 23.1Ź2.2
Boom cylinder 23-4
Bucket cylinder 23-6 M12 5.5Ź0.6 39.8Ź4.3
Arm cylinder 36
Boom cylinder 32 M10 5.4Ź0.5 39.1Ź3.6
Bucket cylinder 33
Hexagon head bolt Dozer cylinder
20-4 M10 3.2Ź0.3 23.1Ź2.2
Outrigger cylinder
Hexagon head nut Arm cylinder 25-5
M10 3.2Ź0.3 23.1Ź2.2
Boom cylinder 23-5
Lock nut Bucket cylinder
20 ,
Boom cylinder 100Ź10 723.3Ź72.3
Arm cylinder 22 ,
Piston Bucket cylinder
Arm cylinder 14
Boom cylinder , 150Ź15 1085.0Ź108.5
Dozer cylinder
12
Outrigger cylinder
Set screw Dozer cylinder 17
Outrigger cylinder 17 M 8 2.7Ź0.3 19.5Ź2.2
Arm cylinder 40

8-319
1) 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(8in).

Because the piston rod is rather heavy,
finish extending it with air pressure after mm
200
the oil draining operation.

‫ ں‬Loosen and remove socket bolts(22) of

Hexagon
the cylinder head in sequence. socket wrench
Ɠ Cover the extracted piston rod(2) with rag
to prevent it from being accidentally
damaged during operation.

3
2 22
Cover here
with rag

‫ ڻ‬Draw out gland(3) and piston rod

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

8-320
 Ɠ 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 16 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
rings(16), and O-ring(15) and cushion
ring(13).

‫ ں‬Remove the cylinder head assembly Lift with a crane

Plastic
from piston rod(2). hammer
8,9 5,6 4
Ɠ If it is too heavy to move, move it by
striking the flanged part of gland(3) with a
Pull straight
plastic hammer.
Ɠ Pull it straight with gland assembly lifted
with a crane.
Exercise care so as not to damage the lip
of Du bushing(4) and packing (5,6,8,9) by 3 2
the threads of piston rod(2).

8-321
(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 9 8 6 5 7 11 10 12 10
(10).
‫ ڹ‬Remove back up ring(11) and O-ring(10).
‫ ں‬Remove snap ring(9) and dust wiper(8).
‫ ڻ‬Remove back up ring(6), rod seal(5) and
step seal(7).
Ɠ Exercise care in this operation not to
damage the grooves.
Ɠ Do not remove seal and ring, if does not
damaged.

8-322
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 gland(3) with
hydraulic oil. 3

‫ ڹ‬Coat dust wiper(8) with grease and fit Press here

dust wiper(8) to the bottom of the hole of (Straight down)
Metal
dust wiper.
8
At this time, press a pad metal to the
metal ring of dust wiper.
‫ ں‬Fit snap ring(9) to the stop face.

‫ ڻ‬Fit back up ring(6), rod seal(5)and step

seal(7) to corresponding grooves, in that
order. Wrong Right
Ɠ Coat each packing with hydraulic oil
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.

Therefore, confirm it before fitting them. Push bar
Ɠ Fitting rod seal(5) up side down may
damage its lip. Therefore check the
correct direction that is shown in fig.
5

8-323
‫ ڼ‬Fit back up ring(11,12) to gland(3).
Ɠ Put the backup ring in the warm water of
10
30}50Ɓ C 12
‫ ڽ‬Fit O-rings(10) to gland(3). 10
11

(2) Assemble piston assembly

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

‫ ڹ‬Fit piston seal(17) to piston(14).

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). 16 15 16 19 18 17 18 19
‫ ڻ‬Fit back up rings(16) and O-ring(15) to
piston(14).

8-324
(3) Install piston and cylinder head
‫ ڸ‬Fix the piston rod assembly to the work
Gland assembly
bench.
Piston rod
‫ ڹ‬Apply hydraulic oil to the outer surface of
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(2).

şTightening torque : Piston assembly
100Ź10kgfşm(723.3 Ź72.3lbfşft) Piston rod

‫ ڽ‬Fit lock nut(20) to piston rod(2).

şTightening torque Piston rod Lock nut
Item kgfşm lbfşft

Bucket(20)
Boom(20) 150Ź15 1085Ź109
Arm(22)

8-325
(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 Oil pan
moving the piston rod assembly with a Apply liquid packing
crane.
Ɠ Be careful not to damage piston seal by
thread of tube assembly.
‫ ں‬Match the bolt holes in the gland flange to Tube
the tapped holes in the cylinder tube
assembly and tighten socket bolts to a
specified torque. Piston rod
Ɠ Refer to the table of tightening torque.
Hexagon
socket wrench

Gland

8-326
GROUP 14 WORK EQUIPMENT

1. STRUCTURE

B
C

SECTION A SECTION B SECTION C

8-327
2. REMOVAL AND INSTALL
1) BUCKET ASSEMBLY
(1) Removal
‫ ڸ‬Lower the work equipment completely to 2
ground with back of bucket facing down. 1

GROUND

‫ ڹ‬Remove nut(4), bolt(3), and draw out the

pin(1).

3
1

‫ ں‬Remove nut(4), bolt(3), and draw out the

pin(2).

3
2

(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 Adjust the bucket clearance.
For detail, see operation manual.

8-328
2) ARM ASSEMBLY
(1) Removal
Ɠ Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
Ɠ Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrated the skin causing serious
injury.
‫ ڸ‬Remove bucket assembly.
For details, see removal of bucket
assembly.
‫ ڹ‬Loosen socket bolt(2) to disconnect
bucket cylinder hoses(1).
Fit blind plugs in the piping at the
chassis end securely to prevent oil from 1
spurting out when the engine is started. 2
‫ ں‬Sling arm cylinder assembly, and remove
nut, bolt, then pull out pin.
Ɠ Tie the rod with wire to prevent it from
coming out.
For details, see removal of arm
cylinder assembly. Crane
‫ ڻ‬Place a wooden block under the cylinder
and bring the cylinder down to it.
‫ ڼ‬Remove nut(5), bolt(4) and pull out the
pin(3) then remove the arm assembly.
3, 4, 5
şWeight : 820kg(1808lb)
Ɠ When lifting the arm assembly, always lift
the center of gravity.

(2) Install
‫ ڸ‬Carry out installation in the reverse order
to removal.
When lifting the arm assembly, always lift
the center of gravity.
Ɠ Bleed the air from the cylinder.

8-329
3) BOOM ASSEMBLY
(1) Removal
‫ ڸ‬Remove arm and bucket assembly.
For details, see removal of arm and
bucket assembly.
‫ ڹ‬Remove boom cylinder assembly from
boom.
For details, see removal of boom
cylinder assembly.

‫ ں‬Disconnect head work wiring.

‫ ڻ‬Disconnect bucket cylinder hose(2) and
arm cylinder hose(1).
Ɠ When the hoses are disconnected, oil
may spurt out.
2

‫ ڼ‬Sling boom assembly(3).

Crane
‫ ڽ‬Remove bolt(4), nut(5) and pull out the
pin(6) then remove boom assembly.
şWeight :1354kg(2985lb)
Ɠ When lifting the boom assembly always
lift the center of gravity.

3 4, 5, 6

(2) Install
‫ ڸ‬Carry out installation in the reverse order
to removal.
When lifting the boom assembly, always 4
lift the center of gravity. 6
Ɠ Bleed the air from the cylinder.
5

8-330