Hyundai.R210LC 3.SM - Ocrbmd

s,ERVICE MANUAL
~HYUNDAI
HEAVY INDUSTRIES CO.,LlD.
FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
SECTION 1 GENERAL
This section explains the safety hints and gives the specification of the machine and major
components.
SECTION 2 STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
SECTION 3 HYDRAULIC SYSTEM
This section explains the hydraulic circuit, single and combined operation.
SECTION 4 ELECTRICAL SYSTEM
This section explains the electrical circuit, monitoring system and each component. It serves not
only to give an understanding electrical system, but also serves as reference material for trouble
shooting.
SECTION 5 MECHATRONICS SYSTEM
This section explains the computer aided power optimization system and each component.
SECTION 6 TROUBLESHOOTING
This section explains the troubleshooting charts correlating problems to causes.
SECTION 7 MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
SECTION 8 DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.
0-1
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating Revised edition mark(‫ںڹڸ‬š)
Any additions, amendments or other changes When a manual is revised, an edition mark is
will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the
Get the most up-to-date information before you pages.
start any work.
Revisions
Filing method Revised pages are shown at the list of revised
1. See the page number on the bottom of the pages on the between the contents page and
page. section 1 page.
File the pages in correct order.
2. Following examples shows how to read the Symbols
page number. So that the shop manual can be of ample
Example 1 practical use, important places for safety and
2-3 quality are marked with the following symbols.
Item number (2. Structure and
Function)
Consecutive page number for Symbol Item Remarks
each item.
Special safety precautions are
3. Additional pages : Additional pages are necessary when performing the
indicated by a hyphen(-) and number after the work.
Safety
page number. File as in the example.
Extra special safety precautions
10 - 4 are necessary when performing
10 - 4 - 1 the work because it is under
Added pages internal pressure.
10 - 4 - 2
10 - 5 Special technical precautions or
Ɠ Caution
other precautions for preserving
standards are necessary when
performing the work.
0-2
3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
Example
1. Method of using the Conversion Table to convert from millimeters to inches
Convert 55mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as ‫ڞ‬, then draw a
horizontal line from ‫ڞ‬.
(2) Locate the number 5 in the row across the top, take this as ‫ڟ‬, then draw a perpendicular line
down from ‫ڟ‬.
(3) Take the point where the two lines cross as ‫ڠ‬. This point ‫ ڠ‬gives the value when converting
from millimeters to inches. Therefore, 55mm = 2.165 inches.
2. Convert 550 mm into inches.

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

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

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

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

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

0 1 2 3 4 5 6 7 8 9
0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

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

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

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

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

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

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

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

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

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
0-8
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
1. MAJOR COMPONENT
Battery box Fuel tank Oil cooler Radiator
CID
Engine
CID
I
Tooth Bucket
Turning joint
Swing motor
Main control valve

Hydraulic oil tank
Ann Ann cylinder Boom Boom cylinder Cab Muffler Counterweight

I
\ .Idler Carrier roller

Connecting rod
Track roller Track Sprocket Travel motor
Connecting link
1-g
2. SPECIFICATION
1) ROBEX 210'3
1(1') D
--
K
A B(L)
Description Unit Specification
Operating weight kg (lb) 20620 (45460)

Bucket capacity(PCSA heaped) ,standard m'(yd') 0.87 (1.14)
Overall length A 9460 (31' O')
Overall width, with 700mm shoe B 2900( 9' 6')
Overall height c 2970( 9' 9")
Superstructure width D 2720 ( 8' 11')
Overall height of cab E 2940( 9' 8')
Ground clearance of counterweight F 1070 ( 3' 6')
Engine cover height G 2230( 7' 4')
Minimum ground clearance H mm(ft-in) 470 ( 1' 7")
Rear-end distance I 2740 ( g O")
Rear-end swing radius I' 2750 ( 9' 0')
Distance between tumblers J 3270 (10' 9')
Undercarriage length
- -K- 4070 (13' 4')
Undercarriage width L 2900( 9' 6')
Track gauge M 2200( 7' 3')
Track shoe width, standard N 700 ( 2' 4")
Travel speed (low/high) km/h~mph) 3.1 / 5.2 (1.9 I 3.2)
Swing speed rpm 12.5
Gradeability degree(%) 35(70)
Ground pressure(700mm shoe) kwcm' (psi) 0.41 (5.83)
1-10
2) AOBEX210LC-3
11') D
()
m
o·
0 I
I
C!l
<F=' ~ u.
J '
K N
A B(l)
Description Unit Specification
Operating weight kg (lb) 21300 (46960)

Bucket capacity(PCSA heaped) ,standard m'(yd') 0.87 (1 .14)
Overall length A 9460 (31' O')
Overall width, with 700mm shoe B 3090 (1 O' 2')
Overall height c - 2970 ( 9' 9")
Superstructure width ID 2720 ( 8' 11')
Overall height of cab E 2940 ( 9' 8")
Ground clearance of counterweight F 1070 ( 3' 6")
Engine cover height G 2230 ( 7' 4")
mm(ft-in)
Minimum ground clearance IH 470 ( 1' 7")
Rear-end distance I 2740 ( 9' O")
Rear-end swing radius I' 2750 ( 9' O")
Distance between tumblers J 3640 (11' 11')
Undercarriage length K 4440 (14' 7")
Undercarriage width l 3090 (1 O' 2' )
Track gauge M 2390 ( 7' 1O")
Track shoe width, standard N 700 ( 2' 4')
Travel speed (low/high) km/h~mph) 3.1 /5.2(1 .9/3.2)
Swing speed rpm 12.5
Gradeability de17ee (%) 35 (70)
Ground pressure(700mm shoe) kg/cm' (psi) 0.39(5.55)
1-1 1
3. WORKl-IG RANGE
1) STANDARD BOOM (5.68m, 18' 8")
Cl
Description 2.Chl(6' 7")Atm 2.4Qn(7' 10')Ann 2.92m(9' 7")Ann 3,00n(12' 9'')Ann

Max. digging reach A 9120 mm (<!111i 9470 rrm (31' 1i 9920rrm ~ 7) 1(l6)rrm (!; 7)
Max. digging reach on ground A' 8940 mm ¥!SJ 4') 9300rrm ~ 6') 9720rrm (31' 11') 10700 rrm (:I> 2)
Max. digging depth B 5820 mm (19 1i 6220mm ~S) 6740rrm ~· 1') morrm ~ 4)
Max. digging depth (Bft level) B' 5580 mm ~8 4') 6010 rrm ~g 9') ~rrm (ll' 3) 7570 rrm (a4' 10)
Max. vertical wall digging depth c 5100 mm (16 9) 5520mm ~8 1i 6040 mm (1910) 7010 rrm ~ 0)
Max. digging height D 9080 mm ¥!SJ 10) 9250 mm (.11 4') 9400 mm (.11 10) ~rrm ~ 6)
Max. dumping height E 6300mm~ 8) 6460 mm (ll' 3' 6620 rrm (ll' 9) 11romm ~ S)
Max. swing radius F 3650rrm (12 0) 3790mm ~2 S) 3580mm ~1' 9') 3>10 rrm (11' 10)
114.7 [125.5] KN 114.7(125.S]KN 114.7(125.5] KN 114.7 (125.5) KN
Bucket digging force 11700(12rol] kgf 11700 [12rol] kgf 11700 [12rol) kgf 11700 (12fl00) kg
25790 (28220] l:Jf 25790 [28220] 111 25790 [28220] l:Jf 25790 (28220] l:Jf
128.0 (140.0] KN 114.1 (124.7] KN 9l2(1~0]KN 762 (83.2] KN
·Arm digging force 1:ni0 [14270] kgf 116:ll (12720] kgf 9500 (10400] kg mo 184901 kgf
28770 (31400] ~ 25640 [20040) ~ 20940 [22!m] l:Jf 171~ [1~)1:Jf
• [ J : PoNer boost
1-12
2) OPTION BOOM (5.2m, 17' 7")
en iD u
8fl
Description 2.011(6 7") Aml 2.4Qn(7' 1O') Ann

Max. diggn ig reach A BS:n1111 (28' 4') 895Qim (29' 4')
Max. digging reach on ground A' 8440Tm (2T 8j 877011111 (28' 9')
Max. digging depth B 547{)rrn (17' 11') 687t) I Ill (19' 3')
Max. <iggi ig depth (8ft level) B' szn1111 (17' 2') 564()rrn {18' 6')
Max. vertical wall diggil 19 depthc 47001111 (15' 5') 49fnm1 (16' 4')
Max. diggiig heiglt D 8620rrrn (28' 3') 87001111 (28' 7j
Max. dumping height E 5850'Tm (19' 2') 594<mn {19' 6')

Max. swing radius F 3500'Tim (11 ' 6') 3410nvn (11 ' 2')
114.7 (125.5) KN 114.7 (125.5) KN
Bucket digging force 11700 [12fro]kg 11700 (12fro] kgf
25700 [28220] ~ 25790 (28220] ~
128.0 (140.0] KN 114.1 (124.7] KN
-
Arm digging force 13)5() (14270] kg 116.lJ (1Z720] kgf
- 28770 (31460] bf 25640 (20040] tt
• [ ] : Power boost
1-13
4. WEIGHT
A21~ R21Clc-3
Item
kg lb kg lb
Upperstructure assembly 8780 19360 -
Main frame weld assembly
Engine a<35el I tty
2600 I
423
5730
933
--
Main~ assembly 120 265 -
Main control valve assembly 193 425
-
SWing motor assembly 190 420 -
Hydraulic oil tank assembly 240 530 -
Fuel tank assembly 130 290 -
Coulterwei(,tit
Cab assembly
3800
275
8380
610
--
-
Undertarriage assembly 8090 17840 8350 18400
Track frame weld assembly 2600 5730 2870 6330
Swing bearing 260 570 -
Tra\IBl motor assembly 305 670 -
Turning joint 50 110 -
Track recoil sprilg Md Ider 270 595 -
Idler 168 370 -
Carrier roller 21 46 -
Track roller
Track-<:hain assembly (standard triple grouser shoe)
38
1520
84
3350 1580
- 3490
Front attachment assembly (5.68 m boom, 2.92 m arm,
0.87 m'(PCSA heaped) buckal)
3700 8160 -
5.68 m boom assembly 1310 2890 -
2.92 marm assembly 680 1500 -
0.87 m' (PCSA heaped) bucket 655 1440 -
Boom cylinder assembly 175 386 -
Arm cylinder assembly 285 628 -
Buclll!t cylinder 9559', tty 140 309 -
Buclll!t conlrol rod assenill'f 73 I 161
-
1-14
5. LFTING CAPACITlES
1) ROBEX 21 ().3
(1) 5.68m(18' 8') boom, 2.92m(9' 7') arm equipped with 0.87m'(PCSA heaped) bud<et and 700nn
(28' ) triple grouser shoe.
• ~ : Rating over-front • ~ : Ratllg over-side or 360 degree
Load radius At max. reach

Load point 1.5m(5' O') 3.0m(10' O') 4.5m(15' O') 6.0m(20' O') 7 .5 m(25' O') Capacity Reach
height
~ ~ ~ ~ ~ sf)
~ ~ ~ ~ ~ ~ m(ft)
7.5m kg ·3110 ' 3110 7.63
(25' 0i I> '6860 ' 6860 (25.0)
6.0m kg '3210 2550 8.63
tro o; I> "7080 5620 (28.3)
4.5m kg '3840 ' 3840 ' 3640 3150 3290 2190 9.23
115' O'l I> '8470 '8470 '8020 6940 7250 4830 130.31
3.0m kg '9460 ' 9460 '5880 '5880 '4600 4400 ' 4010 3000 3060 2010 9.51
(10' O') I> '20860 '20860 ' 12960 ,_
'12960 '10140 9700 '8840
- 6680 6750 4436 (31.2)
:;=.
1.Sm kg '7210 '7210 "7500 6370 '5430 4120 4370 2890 3000 1960 9.52
(5' 0') lb '15900 ·15900 ·15530 14040 '11970 9080 9600 . 6370 6610 4320 (31.2)
..,
'
....
.......·. ·: g-
. ~- ·!·:·::~:: ·:om> •'.'8Sli0
:;m ...;.,·:~= ::;MJ<J
' '.99211. '•'-IC2ee>
·.81 •:44!n. .
..
·::~ :•'9'..25'.~ .
.~~
~.
Groll1ll
I.hi ·.·~· ·.. :1#1AA ~~ ~ :· ~~~. ~ ~·
-1.Sm kg "7880 "7880 '11290 '11290 '8890 5900 5910 3820 4200 2730 3430 2240 8.68
( -5' 0') lb '17370 '17370 '24890 '24890 '19600 13010 13000 8420 9260 6CJeO 7560 4940 (28.5)
-3.0m kg ' 11070 '11070 '12760 11860 '8580 6930 5920 3820 4160 2740 7.71
(·10' Oj lb '24410 f--'24410 '28130 26150 '18920 13070 13060 8420 9170 6040 (25.3)
-4.Sm kg ..10130 '10730 "7390 6110 '4230 4050 6.13
(.15'0' lb '23660 '23660 '16290 13470 "9330 8930 (20.1)
Note 1. Lifting capacity are based on SAE J1097, 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 bad< of the bucket.
4. •indicates load limited by hydraulic capacity.
1· 15
(2) 5.68m(18' 8') boom, 2.0m(6' 7') arm equipped with 0.87m'(PCSA heaped) bucket and 70011111
(28') triple grouser shoe.

Load point 3.0 m(1 O' O') 4.5m(15' O' ) 6.0 m(20' O") 7.5 m(25' O') Capacity Reach
height
~ ~
~ ~ ~ ~ ~ ~ ~ ~ m(ft)
7.5m kg •3750 ' 3750 6.60
(25'0') lb '8270 '8270 (21.7)
6.0m kg '4200 '4200 '3800 3040 7.75
(20' O') lb "9260 "9260 '8380 6700 125.4)
4.5m kg '5460 '5460 '4600 4530 '3910 2560 8.42
(15' O'l lb '12040 '12040 ' 10140 9990 '8620 . 5640 (27.6)
3.cni kg 7070 6700 •5300 4310 •4540 2990 3950 2340 8.74
(10' O') lb '15590 14770 '11680 9500 ·10010 6590 8710 5160 128.7l
1.5m kg '8450 6260 '6000 4100 '4860 2900 3900 2290 8.75
=tt r... ....•.•• •. i.:•.:·• •

( 5' O'l lb '18630 13800 '13230 9040 '10710 6390 8600 5050 (28.7)
.... .·.T...... ·:• »:..;
=-.~\>:: ..·.· .. .
...·,
' ,•.
,:.; ·; ;!::41111•: ····~·
..
~ ;'.:~: ···~~··
~
~·
:: :•' .:~::~::;~::: :~1"!,Q;: ·.:;;~:·

. ~· (~ :· ... :;~:
.
tile ,• •:io7Jo~: ~··
~· .
I
'i •, t t; •••
-1 .Sm kg ' 12160 12140 6060 '6490 3900 •4530 2740 7.81
'8920 •9990
( -5' O'l lb '26810 26760 '19670 13360 '14310 8660 6040 (25.6)
-3.0m kg '11410 '11410 '8110 6170 '5820 4010 '4500 3560 6.69
1-10' 01 1b '25150 ' 25150 '17880 13600 '12830 8840 '9920 7850 121.91
(3) 5.68m(18' 8') boom, 2.40m(7' 1O') arm equipped with 0.87m'(PCSA heaped) bucket and 7001!111

Load point 1.5m(5' O') 3.0m{10' O') 4.5m(15' O' ) 6.0m(20' O') 7.5 m(25' O' ) Capacity Reacll
height
~ ~ ~ ~ ~ ~ ~ 1~ ~ ~ ~ ~ m(fl)
7.5m kg '3420 '3420 7.05

(25' O'l lb I 7540 7540 (23.1)
6.()n kg '3780 '3780 '3490 2790 8.13
(20' O') lb '8330 '8330 7690 6150 (26.7)
4.Sm kg '4230 '4230 '3970 3080 '3620 2370 8.77
(15' O') lb '9330 '9330 '8750 6790 ' 7980 5220 128.81
'6510 '6510 '4960 '4270 3700 2170 9.07
~
3.cni 4320 2980
110' 01 '14350 '14350 '10930 9520 '9410 6570 8160 4780 (29.8)_
1.5m kg '8010 6270 •5720 4080 '4640 2870 3640 2110 9.08
·=~-
( 5' O') lb '17660 13820 '12610 8990 ' 10230 6330 8020 4650 (29.8)
Giant
Lile ~.. :: :·.•.·=· : ...·.·..··•· ;:;=:fil
•)
;:::::::::~ :>.l!ll:la:
;:;:·:::~·= ~·::::·:·;,
~·.•.·!·:·. f.t!IM<t' '.~ ~ ~~Ill
:~ :·. ~...~~; :~
~~= ~aa:=
·1.5m kg '11770 ' 11770 ' 8920 5960 '6450 3850 4260 2480 8.18
I ·5' 0' lb ' 25950 ' 25950 ·19670 13140 ·14220 8400 I 9390 5470 126.8\
-3.0m kg '12820 '12820 '12080 ·120e0 '8350 6030 '6050 3890 •4410 3140 7.14
(· 10' O' ) lb '28260 '28260 '26630 ' 26630 ·19410 t3290 '13340 8580 "9720 6920 (23.il_
-4.Sm kg . "9590 '9590 '6680 6270
(-15' O' lb '21140 '21140 •14730 13820
1-16
(4) 5.68111(18' 8') boom, 3.90m(12' 9') arm equipped with 0.87m'(PCSA heaped) bucket and 700rm
(28") triple grouser shoe.

Load point 1.5m(5' O') 3.0m(1 O' O") 4.5m(15' O') 6.0m(2Q' 0") 7.5m(25' O") 9.0m(30' O') Capacity Aeer:h
height
~ ~ ~ "'f:> ~ ..:> ~ ~ ~ ~ ~ rtf)
~ ~ m(ft)
~
9.0m '2411)
"24701 7!/J
(30' O') . - '5450 '5400 {24.6)
7.5m kg "2210 "2210 '25«l ~ 8.81
(25' O') lb '4870 '4870 '58X) aro (28.9)
6.0m
(20' O")
>--
kg
tb
-.mi
'Sim i
' -.mi
'Sim
'26«) aro 9S7
'S83) 4410 ~.7)
4.Sm kg '3310 '3!10 'Z5l 2100 '2700 mo 103>
(15' 01 I> im:J im:J '4900 4810 im> :Ml '33'Y
I
2120 am !fill 10.~

-
~
3.0m ':ml ':ml '3310 :ml '3110
(10' O'l '81~ "814) 7.DJ fllll 'li8fl) 4610 6310 :ml pq
:-
"1(6)) 1am '623) '623) '«li!O 41!'1) -,mi :ml "3410 am 2IDl l!'8) 10.46
~
1.5m
(s II') 'Zl19l '23150 1373> '13133 '10190 919) '8440 &Bl '753) 4400 6170 343) pq
·~ ••
z~· .'\llil!I);
·1.Sm kg 'S6«l 'li640 "1<ml 'i<m:!

.,,......"""'
:w!Q. Miii:
'-'Ill• '.·'.SB>
'11510 Sl9:l WI!
. .. .·.::··..-i .,.:·g
·~
~·
3700 4&l ~-
·
··:~
:•
:ml
::: ;:r! 17.ll ~
(-5' O') I> 14640 '14640 '2'll!D '2'l75'.)
......._ '1618l 12100 "13290 81Ell 10190 57.lJ elB) 3810 ~.9)
~
·3. 0m 'aTlO 'aTlO '129al 114al '8670 5710 '6210 0040 4100 2iEll 3620 a>40 8.118
(-10• o·; 1978) '1978) '2848) 25310 '19110 12!ro "1:ml ml 10120 5640 7900 4500 {29.1)
2710 ·~
~
-4.5m 11810 '11810 1ml 11700 '8140 Sl9:l '!ml :ml -,mi 75)
(·15' O'l ~ ':9:)40 "2713) 25700 '17!6) 12100 "1:ml 8110 '8440 !':J110 ~
~.Om
~
'9600 '9600 '646) ml
(-20' O') '21340 '21340 '14240 13290 . I
(5) 5.20m(1 T 7') boom, 2.0m(6' 7") arm equipped with 1.34m'(PCSA heaped) bucket and 700tnl

Load point 1.5 m(S' O") 3.0m(10' O') 4.5m(15' O') 6.0 m(20' O') capacity Reach
height
~ ~ ~ ~ ~ ~ ~ rtf)
~ ·~ m(ft)
7.Sm kg '3880 '3880 5.84
(25' 0") lb
6.0m
(20'0") lb
4.Sm kg
kg
'5250 •5250 '4660 4500

'8550
' 3950
'8710
' 4100
lI '8550
3450
7610
2830
(19.2)
7.15
(23.S)
7.88
(15' 0') lb '11570 '11570 ' 10270 992.0 '9040 6240 ~
3.0m kg 'fmO '6770 ·5290 4320 '4280 2550 8.22
.• •
(10' O'l lb . ' 14930 ·14930 ' 1168> 9520 '9440 5620 (27.<I)
1.5m kg '8240 6400 "5990 4120 4260 2490 8.23
< s· O'l lb I ' 18170 14110
. .·.
' 13210 9060 9390 5490 IT/.O)
~ t .· .~:~:~:~:::~· .. ....·.
·:"IUll:•:· .·•':at#.•
:::.:~~~:!~::: :~~:::~::::::: :~:~~~:~:~::fi . ·:maP;·
.
~ ...•
::aci; .
·~'' ..:·:--·-!'·.
:·. ·:· ·::1't.. :;:
·1.Sm kg "10730 •10730 ·13370 12220 "8970 6120 '6450 3950 '4900 3070 721
( -5' O') lb "23660 "23660 '29480 2tl940 "19780 13490 ·14220 8710 '10800 sno (23.7)
-3.0m kg ·11s10 ., 1610 '7990 6240 '4840 4260 5.95
(-10'01 lb "25600 '25600 ' 17610 13760 '10670 9390 119.5\
1-17
(6) 5.20m(17' 7') boom, 2.40m(7' 10') arm equipped with 1.20m'(PCSA heaped) bucket and 700nm

Load point 1.5m(5' 0/ 3.0m(10' O") 4.5m(1S O') 6.0 m(20' O") 7.5m(25' O') Capacity Reach
height -
~ !Of:> ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ m(lt)
7.5111 kg '3520 '3520

6.32
12SO'l I> '77flJ '77flJ nnzi
6.()n kg ·3970 "3970 '3640 3180 7.53
(20'0'\ I> '8750 '8750 '8020 7010 {2.fil
4.5111 Ilg '4270 •4270 '3800 2640 8.22
j15' O') I> '9410 '9410 '8380 5820 m.01
3.0m kg "9850 "9850 "62:20 '62:20 •4950 4350 '4420 2950 '3990 Z380 8.55
(10' 01 I> ' 21720 ·21120 '13710 '13710 '10910 9500 9740 6500 '8800 5250 (26.Jl..
1.5111 kg '7810 8440 ·sno 4130 •4740 2860 3990 2320 8.58
6310 8800 5110 126. i)
t!.Q1 lb
. . ~ •10641>
'17220 14200 ' 12610
,g =~~ ·.'@)
9110 ·10450
:::iBl!l ;;~:~~:;:~: :::::~.:~: :.~ 2'30 ·,~{
~
Gftuld
I.hi .~.~· '138$0 ;:~ ·:·:·:····· ·: ~ : ~.J .
·1.Sm kg ·9990 '9990 '13790 12050 '8990 6050 '8460 3890 '4700 2800 7.58
'22020 '30400 26670 '1982() 13340 '14240 '10060 6170 124.91
-
J.2'.0') lb ·22020
..:l.()n kg ' 15200 "15200 ·12350 12270 '8340 6120
B680
'4830 3720 6.42
HO' O'' I> ' 33510 '33510 '27230 27050 ' 18390 13490 '10650 8200 (21.1)
'9150 ' 9150
~
-4.Sm
1·15' 0' ' ·20110 ' 20170
1·18
2) ROBEX210LC-3
(1) 5.68m(18' 8") boom, 2.92m(9' 7') arm equipped with 0.87m'(PCSA heaped) bucket and 700nm
(28") triple grouser shoe.
• ~ : Rating over-front • ~ : Rating over-side°' 360 degree

Load point 1.5m(5' O') 3.0m(10' O") 4.5m(15' O') 6.0m(20' 0") 7.5 m(25' O') Capacity Reach
height
~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ m(ft)
7.Sm
(25'0')
kg
lb I "3110 '3110 7.63
"6860 '6860 (25.0l
6.tm
120' 0'1
kg
lb I ~
'3210 2640 8.63
7080 58£1) (28.3)
4.Sm kg '3840 "3840 "3640 3260 •3340 2270 9.23
(15' O') lb '8470 "8470 "8020 7190 '7360 5CXXl (30.3)
3.tm kg '9460 '9460 '5880 '5880 '4600 4530 '4010 3140 "3490 2090 9.51
(10' O') lb •20e50 '20860 '12960 "12960 '10140 9990 '8840 6920 '7690 4610 (31 .2)
1.Sm kg 7210 7210 •7500 6580 •5430 4260 •4440 3000 3510 2040 9.52
( 5' O') ' 15900 '15900 ' 16530 14510
..:.m
lb '11970 9390 '9790 6610 7740 4500 (31.2)
. '. . ···:··.:.. •$SSCj· ..:.~
.·.· '.i:vl3ll ... . .. ,.. ~ ···au ..·~
;. ~:~ ~00 =~~·
~ .~- ~-···"
GioU'ld
Lile L.~·::::::::: . .· ~~·
;
.. .:-;~ ..-:.(t(l!Q :.'46alt ·~:ai:
-1.Sm
( -5'0'
kg 7880
lb '17370 "17370
7880 ·11290 ·11290 '8890 6100 '6390 3960 4930
'24890 '24890 '19600 13450 •14090
"'
8730 10870
2840 4010 2330 8.68
6260 8840 5140 (28.5)
-3.tm kg '11070 ·11070 '12760 12240 '8580 6130 '6230 3960 '4260 2840 7.71
(-1 0'0') lb '24410 "24410 "28130 26980 '18920 13510 '13730 8730 ' 9390 6260 (25.3)
-4.Sm
1-15'0'
kg
lb
' 10730
'23660
' 10730
'23660
•7390 6310
'16290 13910
I
·4230 4180 6.13
'0030 9220 120.11
Note '
1. Lifting capacity are based on SAE J1007, ISO 10567.
2. Lifting capacity of the AOBEX series does not exceed 75% of tipping load with the machine
on firm, level ground or 87% ol full hydraulic capacity.
3. The load point is a hook located on the back ol the bucket.
4. *indicates load limited by hydraulic capacity.
1-19
(2) 5.68m{18' 8') boom, 2.0m{6' 7') arm equipped wi1h 0.87m'(PCSA heaped) bucllet and 700m
Load radius Al max. reach

Load point 3.0m(10' O') 4.Sm(15' O') 6.0 m(20' O' ) 7.Sm(25' O') Capacity Reach
height
~ ~ ~ ~ ~ I~ ~ ~ ~
7.Sm
(25'0")
kg
b
I
'3750
'8270
"*'
'3750
'8270
m(ft)
6.60
(21.7)
6.0m kg '4200 '4200 '3800 3140 7.75
(20' O"I lb "9260 '9260 '8380 6920 (25.4)
4.Sm kg '5460 '5460 '4600 "4600 '3910 2650 8.42
(15' 0"1 b "12040 "12040 '10140 ' 10140 "8620 5840 (27.6)
3.0m kg
- 7070 6900 ·~ 4450 •4540 3100 •4050 2Ul 8.74
(10' O'\ b "15590 15210 '11680 9810 ·10010 68:x> "8930 5360 C2B.7)
1.Sm
( 5' O')
Galid
LN
·1.Sm
.,
kg
b
kg
. ·.
"12160
.
12160
.. •. .
'6450
'186:Xl
"8920
64eO
-: a:. ..,... .......

'6000
14240 '13230
:•:.i121!1> .•
'lGIO'
6260 "6490 =·
:::
4240
4060
·. ·~·
"4860
9350 "10710
•:•......
;; :.:~-:
. . ·:· MD· ..
.
:::.~:
~
6610
4040
. '.= ·;= :.
8910
•4530
.•·
2380 a75
5250 (28.7)
2840
· ~:-
:rztJli·
7.81
.
(.5' O'\ lb "26810 26810 '19670 13800 '14310 8950 '9990 6260 (25.6)
-3.0m kg "11410 "1 141 0 ·51 10 I 6370 "5820 4150 '4500 3680 6.69
<·10' O"l lb "25150 "25150 '17880 14040 ' 12830 9150 "9920 8110 121.91
(3) 5.68m(18' 8') boom, 2.40m(9' 7') arm equipped with 0.87m'(PCSA heaped) bucket and 700lml
Load radius Al max. reach

Load point 1.Sm(S' O') 3.0m(10' O") 4.Sm(15' O' ) 6.0m(20' Oj 7.5m(25' O' ) Capacity Reach
height
~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ e.t:> m(ft)
7.Sm kg '3420 '3420 7.rEJ
125'0") lb 7540 7540 (23.1)
6.0m kg '3780 '3700 "3490 2890 8.13
l20' O') I> '8330 '8330 7690 6370 (26.7)
4.Sm kg •4230 •4230 '3970 3180 '3620 2460 8.77
05'0J b "9330 "9330 '8750 7010 79fl0 5420 (28.8)
3.0m kg '6510 '6510 ' 4960 4460 '4270 ro90 '3770 2250 9.07
(10' O'! b '14350 '14350 '10930 9630 '9410 6810 '8310 4960 l~
1.Sm kg '8010 64SO '5720 4220 '4640 2970 3770 2200 9.08
( 5' 0')
-tiW-
·1.Sm kg
b
'I f: : ~:
' 11770
":-
..· .·
-~ .. ..· .·
·,•
: . . -: ·~~:~. ::j;
' 117'10 '8920
'17660 14290 '12610
~-
:<~ ·::emi
:-1~~ ~J31!21i.·:~.
6160 '6450
9300
:::=. .
3990
' 1023)
-~
... ·:,~ :~
6550
<=·.
8310 4850 (29.8)
'4320
·;::;;:
. uo :
~
2580 8.18
ilO"J b '25950 "25950 '19670 13580 '14220 88'.lO "9520 5690 ~
-3.0m kg ·12e:20 ·12e:20 '1200;) "1200;) "8350 ~ '6050 4030 '4410 3250 7.14
~ b "28260 "°28260 "26630 "26630 "18410 13730 '13340 8800 '9720 7170 (23.4)_
-4.Sm kg '9590 '9590 '6680 6470
I·15' O'] b '21140 "21140 "14730 I 14260
1·20
(4) 5.68m(18' 8") boom. 3.90m(9' 7') arm equipped with 0.87m'(PCSA heaped) bucket and 700nm

Load point 1.5m(5' O') 3.0m(10' O') 4.5m(15' O') 6.0m(20' O") 7.5m(25' O') 9.0m(30' O') Capacity Aeoct1
height
9.0m kg
~ "'*' ~ "'*' ~ ~ ~ ~
~ I"'*' ~ ~
~ '"'*'
'2470 ' '2470 7SJ
m(ft)
(30'0') lb '54ffi 'S4fil (l!4b')

7.5m kg 'Z!10 '2210 '25«) '2540 8.81
(25' O') lb
. '4810 '4810 'sax> 'Sim (26,9)
am
~
6.0m '26ll '26ll "(00 9.67
(20' O') '5IDl ,'5!IXl
_ '58al 4500 ~1.'I)
·~
4.5m kg '28JI) '2870 "22fil "22fil '2lm 1810 toa>

(1 5' O') lb 'ml 'ml '400) '400) im> 3900 ~
3,om
(10' 0')
kg
lb
':ml ':ml '3310 313) '3110 zro "2910
'8140 '8140 7.m ~ 'tm) 415) '643)
I 1610
:mi
10.45
(34.3)
(s ()') ~
1.5m
I I I
'10000 '1CBXl '6'2l) I '6'2l) '463) 428.l ':mJ 2960 "3410 213) 2920 I 1Em 10A6
=
'23150 'Z3150 '1373J I'1373J '10100 9440 '8440 6500 75ID 4670 64«} 3'jJI) ~
GIOi'd
I.ht ~- • ~:,~:
;·~f;~: ·=· ·
~
=~f:·liiUI :;~: ·::~t::~
• .. • • •~:
•. . . . ·..i-.191D> :·:~ •:•:tllriJ ::m1
i.-~=,~~::~
::IQQ: :;· ::1119 ..::·~ ~
I
• • •
-1.Sm
(-5'0')
kg
lb
I
'fJ640 'fJ640
'14640
'1cml '1Cll20 'ffi1o 5900 '!ml 3840
'14640 '2'l750 '2'l750 '18700 13210 '13290 8470 '1CIZIO 5950
'4600 2lOO 3:l"l
7140 I 1810 9.71
3900 (31.9)
-3. 0m kg '8110 '8110 '129al 11800 1ll70 5920 '6210 mo
'47.n 2670 ~
' 2130 aal
(-10' 0') lb '19700 '19700 ".?8400 26150 '19110 I 13050 '1:ml 8310 '10410 !llOO ! 'lmO 4700 (29.1)
-4.5m kg '11810 '11810 '12nl 1ml '8140 5900 'Sll30 l!20 ':mJ 3l3) 7.00
(-15' 0" lb "S)40 "S)40 '2713) :am> '17900 13210 '12850 843:) '8440 ~ (24.9)
-6.0m
(-20' 0")
kg
lb .
'9600 '968l '&la) 6'240
"21340 '21340 '14240 13100
I .
(5) 5.20m(18' 8') boom, 2.0m(9' 7") arm equipped with 1.34m'(PCSA heaped) bucket and 700nm

Load point 1.5m(5' O') 3.0m(10' O') 4.5m(15' O') 6.0m(20' O') Capacity Reach
height
~ ~ ~ si:> ~ ~ ~ I ~ ~ ~ m(ft)
7.5m
(25' 0'1
kg
lb
I '38SO
'8550
'38SO
'8550
5.84
(192)
6.0m kg '3950 3560 7.15
(20' O') lb I '8710 7850 (23.5)
4.5m kg '5250 '5250 '4660 4640 '4100 2930 7.88
(15' O') lb I '11570 '11570 '10270 10230 '9040 6460 (25.9)
·mo •5no
~
+
3.0m '5290 4460 '4280 2650 8.22
(10' O'I ' 14930 '14930 '11600 9830 '9440 5840 127.01
1.Sm kg '8240 6000 '5990 4260 4410 2590 8.23
••
I 5' O"I lb '18170 14550 '13210 9390 9720 5710 (27.0)
;z· ,
·~ ,I: t:::,.· ··=~
.. ' .......'. .
•.•;-r.·.·.~ .•.• •....,.-...:-.
1-::;:::::~~:~; :;:~:~~~::: f~;:~:~:~: ::::::::::::: .-~ ·.~1·
~-f·:·'I t ··"' . ··tcooo?
:: .·'to· :
!• ••
•. ·: .
:~· ,.
.,.., :~1
. ··~.w-~~ •:!~::
~·
-1.5m kg '10730 ·10730 ·13370 12.600 '8970 6330 '6450 4090 •4900 3180 721
( -5' 01 lb '23660 I '23600 •2948() 2nso '19780 13960 '14220 9020 '10800
-- 7010 ~
-3.0m kg '11610 ' 11610 '7990 6440 '4840 4400 5.95
(-10' O') lb '25600 '25600 '17610 14200 '10670 9700 119.5)
1-21
(6) 5..20m(18' 8") boom, 2.40m(6' 7") arm equipped with 1.20m'(PCSA heaped) bucket and 7001!111

Load point 1.5 m(S' O") 3.0m(1CY O") 4.5m(15' O") 6.0m(20' O") 7.5m(25' O") Capacity Reach
height
~ ef:> ~ ~ ~ ~ ~ ~ ~ l>f:l ~ ~ m(ft)
1.sm I kg "3520 "3520 6.32

12S"01 b '77f!IJ '77f!IJ l20.7)
6.()n kg I "3970 "39711 "3640 32M 7.53
(20' 01 b I "8750 "8750 "8020 ~ 124.7)
4.5m kg •4270 •4270 "3800 2T.ll 8.22
115'0"\ b "9-110 "9410 "83M 6020 (27.:Ql.
•5220 "6220 •4950 4490 •4420 ~ •3990 2470 ass
.•
3.()n kg '9850 "9850
110" 0"1 b "21720 ·21120 "13710 "13710 "10910 9900 "9740 6750 ·saoo 5450 1?111)
1.5m kg 7810 6650 •5720 4270 •4740 2970 4140 2410 8.56
= ••
( 5' O'I b ·11220 14660 "12610 9410 ·10450 6560 9130 5310 (28.1)
Giant
l.ile 'I l'1084C)
"'' c''"
·9990 "9990 ·13790 12430
.,. ·:~ ::l8300
;~
-~
•9990 6260 "6460
.·.·
:·:~
,:.~
4030
'
:i;~:~:i:=~ =~=~~~~~~~~. \3= ;
"4700
lo.. •
2900 7.58
~·
:m_,;;
-1.Sm kg
c-6' o· lb '22020 ·22020 "30400 27400 "19620 13800 "14240 8880 '10360 6390 ~
·3.()n kg ' 15200 '15200 ·12350 12350 "8340 6300 "4830 3850 6.42
(·10' O"' lb ' 33510 •33510 •27230 •27230 "18390 13960 "10650 8490 121.11
-4.Sm kg '9150 '9150
1-15'0" b '201 70 ·20110 I
1·22
6. BUCKET SELECTION GUIDE
1) GENERAL BUCKET
0.51 m'PCSA 0.80m' PCSA 0.87m' PCSA 0.92m'PCSA

heaped bod<et heaped bucket heaped bod<et heaped lu;ket
capecly Wklh
Weigt'C
PCSA CECE VVithout 'Mth
heaped heaped sk:le o.AEI' sk:le o.AEI'
0.51 m' 0.45m' 700mm 820mm 580kg

(0.67yd') (0.59yd') (27.6') (32.3") (1200 lb)
O.OOm' 0.70m' 1000mm 1120mm 6f;Okg

(1.05yd') (0.92yd') (39.4') (44.1') (143:l lb)
0.87m' 0.75m' 1090mm 1210mm 660kg

(1.14 yd') (0.98yd') (42.9") (47.Sj (14001b)
0.92m' O.OOm' 1130mm 1090mm 710kg

(1.20yd') (1.05yd') (44.5') (42.9") (15701b)
1.05 m' 0.90m' 1250mm 1370mm 740kg

(1.37)d') (1.18)d') (492') (53.9") (163011>)
1.20m' 1.00m' 1400mm 770kg

(t.57)d') (1.31 yd') (56.1') (17001>)
1.34m' 1.15m' 1550mm 800kg

(1.75)d') (1.50)(1') (61.1') (17001b)
OlllllBE Applicable for materials wilh density a 2000 IO'm' (3370 tl)O') Of' less
- Awficable for malerials wilh density a 1600 lqm' (2700 tl)O') Of' less
- Applicable for materials wilh density a 11 oo 19'm' (1850 tl)O') Of' less
1-23
2) ROCK AND SLOPE FINISHING BUCKET
0.67m' PCSA OHlm'PCSA

heaped bud<et heaped bucl<et 0.75m'PCSA 0.86m'PCSA
(770 kg, 1700 b) (860 kg, 1900 lb) heaped bud<et heaped bucl<et
Reooomendallon
Width WfifJrt 5.6&'n (18' 8'') boon 5.2m (17' 7') boon
PCSA CECE Wilhoot Wl1h 2.crnarm 2.4marm 2.!l'anarm 2.crnarm 2.4m arm
heaped heaped sideaJEr sideaJEr (6'7'') (7'10") (9'7') (6'7") (7'10'')
1--~~+-~~-+=~~=1=~~=F~~==1.,.,...,.,.,R'T',,,... .....,.,.,.,
~:-:-:·:·:·;·:·;-: :..;-:·:·;-:..·:. ;. ....•..,.•.·.·.· ....·::;::~:::;~;::.
0.87m'
(1.14~
0.75m'
(0.98~
11Slmm
(45.3')
770kg
(17001b)
·::::::~~::::::: .:·:~:·:·:-::::::
.......·..········· ::::=::::=-::;:::: ~~~~~~~~~?.~~r~
·6'.·
·.r.·.·.·
··i".I
.•.1.·.•.·.·.·.~
······-·~·.·;t,.·
;::~;::~;:;;::: .·.•.•.,.•.•..•.•..•,
.·.1!•.·,•,·.t.".' J'• • .,.,....
•:·;·:·=·=·=-:-: ;:::::::::~:~:=::
~·.·=-=·=·:=:::: ::::·:::::::~;:::
0.67m' 0.75m' 1140mm 860kg ·::;~!:::::~:~ ;::~:;:·:~~:=~
(1 .14 yd') (0.98yd') (44.9') (19001b) :·:·:·:·:·:·;:;:· ;;::::!~'.·:::::·:
::;:::::::::::!;~ :~:;::::=:~<·:=:
0.75m' 0.65m' 1810mm !Blkg
(0.98yd') (0.85yd') (71.3") (19401b)
.........
0.86m' 0.75m' 1400mm 770kg """"'
(1 .12yd') (0.98yd') (55.2') (17001b)
I · ·I Applicable klf materials with density of 2000 lq;j/m' (3370 lb/yd') or less
- Applicable klf materials with density of 1600 lq;j/m' (2700 lb/yd') or less
- Applicable for materials with density of 1100 lq;jlm' (1850 lb/yd') or less
1-24
7. UNDERCARRIAGE
1) TRACKS
X-leg type center frame is integrally welded with reinforced box-section track frames. The design
includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock
absorbing springs, and assembled track-type tractor shoes with triple grousers.
2) TYPES OF SHOES
, Triple grouser
Model Shapes
Shoe widtf'I mm (in) 600 (24) 700(28) 800 (32)

Operating weight kg (lb) 20060 (44890) 20020 (45460) 20900 (46080)
R21().3
Ground pressure kg/cm' (psi) 0.48 (6.83) 0.41 (5.83) 0.37 (5.26)
Overall width mm (ft·in) 2800 ('! 2') 2900 (9' 6') 3000 (9' 1O')
Shoe width mm (in) 600 (24) 700 (28) 800 (32)
Operating weight kg (lb) 21020 (46340) 21300 (46960) 21600 (47620)
R210LC-3
Ground pressure k!)'cm' (psi) 0.45 (6.40) 0.39 (5.55) 0.34(4.84)
Overall widtf'I mm (ft~n) 2990 (9' 10') 3090 (1O'2') 3190 (10' 6')
3) NUMBER OF ROUERS AND SHOES ON EACH SIDE
Quantity
Item
ROBEX 210-3 ROBEX 210LC-3
Carrier rollers 2EA 2EA
Track rollers 7EA 9EA
Track shoes 45EA I 49EA
1-25
8. SPECIFICATIONS FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model CUMMINS 6BT5.9-C

-
Type ~turbocharged, after cooled diesel engine
Cooling method Wateroooling
Number ol cylinders and arrangement 6 cylinders, in-rine
Firing order 1·5-3-6-2-4
Combustion chamber type Direct injection type
- -
Cyinder bol'e x stroke 102x120rrm (4.02" x4.72j
Piston dsplacement 5800 cc (359 cu in)
-
Compression ratio 17.5 : 1
- Rated gross horse power 142 Hp (106kw) at 2100 ipm
Maxinun torque at 1600rpm 55,3 kgf • m (400 lb • fl)
Engine oil quantity 16.4 I (4.3 U.S. gal)
Ory weight 399 lqj (880 lb}
Hl(,tl Idling speed 2250 + 50 ipm
- -
Low Idling speed 800 ± 100 tpm
Rated fuel oonsurr¢on 153.Sg / I-\) ·hf
Starting motor
-
DELCO REMY 37MT(24V)
Alternator DAC HC60(24V-60AMP)
Battery 2x12Vx160Ah
2) MAIN PUMP
Item Spectticatlon
Type Variable displacement 1andem axial piston pumps

- ----+- -
2x105 cdrev
Maximum pressure 320 iO'aTI' (4550 psi) I 350 iO'aTI' (4980 psi)
Rated o~ flow 2 x 220 I/min (58.1 U.S. !JllT1I 48.4 U.K. gpm)
- - --+-- - - '- - 1
Rated speed 2100 tpm
1-26
3) PILOT PUMP
Item Specification
Type Fllllld dsplacement gear pump single stage

capacity 10 cc/rev
Maximum pressure 40 lrljcm' (570 psi)
Rated oil flow 21 I /min (5.5 U.S. gpm/4.6 U.K. gpm)
4) MAIN CONTROL VALVE
Item Specification
Type 9 spools mono-lllock

Operating method HydraUic pilot assist
Main relief valve pfflSSUre 320 lrljcm' (4551 pg) / 350 lt(>'cm' (49SO psi)
0Yer1oad relief valve pressure 380 lrljcm' (5405 psi)
5) SWING MOTOR
Item Specification
Type Two fixed displacement axial piston motor

Gapaoi1y 151 ct:Jrgv
Relief pressure 240 lrljcm' (3698 pgj
Braking system AulomalX:, spring applied l'rydrauic released
Braking lolque 27 kgf • m (195 lb · fl)
Brake release pressure 20-50 Jo'an' (284-711 pg)
Reduction gear type 2 - stage planetary
Swing speed 12.5 rpm
6) TRAVEL MOTOR
Item Specification
Type Variable displacement axial piston motor

Operating pressure 320 )9'an' (4551 pg)
Reduction gear type 3 - slage planelary
Braking system AulomalX:, spring applied l'rydrauic released
Brake release pressure 11 Jgarl (156 psi)
Braking torque 49.3 kgf • m (357 lb · fl)
1·27
7) REMOTE CONTROL VALVE
Item Specification
Type Pressure reducing type

minimum 5.5 kg/an' {78 psi)
Operating pressure
maximum 19.5 kg/an' (277 psi)
lever 61 mm (2.4 in)
Single operation stroke
pedal 123 nm(4.8 in)
8) CYLINDER
Item Specification
Bore dia x Rod dia x Stroke 0120x 085 x 1290mn

Boom cylinder
Cushion Extend only
Bore dia x Rod dia x Stroke 0140x 095x1460nm
Arm cylinder
Cushion Extend and retract
Bore dia x Rod dia x Stroke 0115x0SOX1120 nm
Bucket cylinder
Cushion Extend only
9) SHOE
Item Width Ground pressure Link quantity Overall width
Slandard 70011111(26') 0.41 Jo'an' (5.83 psi) 45 2900 nm( 9' 6j

R21Q-3 600 mn(24") 0.48 Jo'an' (6.83 psi) 45 2800 rrm ( 9' 2")
~
800nm(32") 0.37 IO'an' (5.26 ps~ 45 3000 mm ( 9' 10')
Slandard 700 rrm (28") 0.3919'an' (5.55 psi) 49 3090 mm(1O' 2")
R210LC-3 600 mm(24') 0.4519'an' (6.40 psi) 49 2990 mm ( 9' 1O')
~
800mm(32') 0.34 l<Q/an' (4.84 pst) 49 3190 mm(10' 6')
1·28
•
10) BUCKET
Capacity T004h Width

Item
PCSAheaped CECE heaped q..oantity Without side cutter With side cutter
Standard 0.87 m' (1.14 yd') 0.75 m' (0.98 \If') 4 1090 nm (42.9') 121 Onm (47.6')
0.51 m' (0.67 yd') 0.45 m' (0.59 \If') 3 700 nm (27.6') 820 nm (32.3')
0.80 m' (1.05 yd') 0.70 m' (0.92 \If') 4 1000 nm (39.4') 1120rrm(44.1')
0.92 m' (1.20 yd' 0.80 m' (1.05 \If') 5 1130 nm (44.5') 1090 nm (42.9')
1.05 m' (1.37 \If') 0.90 m' (1.18 yd' 5 1250 nm (49.2') 1370 nm (53.9')
-
1.20 m' (1 .57 \If') 1.00 m'(1.31 yd~ 5 1400nm(55.1') -
Option
1.34 m' (1.75 \If') 1.15 m' (1.50 yd' 6 1550nm(61 .1') -
+o.87 m' (1.14 yd') 0.75 m' (0.98 yd' 5 1150 nm (45.3') -
+o.87 m' (1.14 yd' 0.75 m' (0.98 yd') 5 1140 nm (44.9') -
1110.75 m' (0.98 yd~ 0.65 m' (0.85 yd') - 1810 nm (71.3") -
liJ0.86 m' (1.12 yd' 0.75 m' (0.98 yd') - 1400 nm (55.2') -
~ : Rock bucket
ii : Slope finishing bucket
1-29
10. RECOWJIENDED OILS
Use only oils lls1ed below or equivalent.

Do not mix different brand oll. ,_
Ambient temperature °C (°F)
Service point Kind of fluid Capacity
I (U.S. gal) · 20 -10 0 10 20 30 40
{·4) (14) (32) (50) (68) (66) (104)
I
.....·..·.•.·.·.·.·.•
·.·•·..
···".:~
. ·'·"·"·. ···---~
..........:$AJ:'··M .• ··~~ •.,........
..:-·
Engine .
~:::::::::::::::::::::::;:SAs:tow=::::::: ;:::::::::~;:~:.
Engine oil 16.4{4.3)
oil pan
;;::::·:·:;.:.:::·:·:·:·:·:~·:·:·:.;z:;. E~·:·:·:•:·:-:•:•:•:•:•:·:~:..;•:::·:·:
.:-=~·;·:·:::·:~:·:·:. . :·:::::::::,:·:·:·::::~:::.:::::::
I I
Swing drive 5.0 (1.3)
Gear oil :r:~·:::·:».:·:\:·:::.:·:SAE 85W-:1~!:::.;·::!·;~:·:;:!!~~:~:·
3.0 x 2
Final drive (0.79x2)
..,...,.·.·.·.. · ····•····;ISQ:~G~~·.·..·..·.·· ····· · -'• • :l

Tank; ····················"'•'•' . . ··•·•··•·••···•·•·•·•·····
250 (66)
Hydraulic tank Hydraulic oil .·,•.•,·.·.·.·,········'·' ~.1 3 ,mw-.;.•~.· .·~..·.;·:·:·:·:·J
•••• ~•A• ••j
...,,...
System;
330(67.2) :·:~·~·:·:~·:·=·~·!~;J ia;;vG~ 1r..:;:·:·:·: f:·:·:·:·:·:
.....
~=-····CYll ·~-.-n;:~~:;:;
Fuel tank Diesel fuel 300 (79.3)
•,:~;.:.,..·········:AatM
.... •.·.•.•.•. • , •..•.• ...•X11'·.....
•· "91S·•NQ~'f.:·'•·~··· ""-',...
Fitting Grease As required

.·.·••···
r.•.•,•+.• ·.:i!:·:::·:·:·:
(Grease nipple)
...... .......
:·:·:·:•:···:·:··-=·~~NI,~~
~ ·~~:·;..:·:~·:--:~-=~·!·
Mixture of
Radiator antifreeze
(Reservoir tank) and water
35(9.2) :::::!:: •. ~:r.·Y.
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.
1-30
SECTION 2 STRUCTURE AND FUNCTION
I GROUP 1 PUMP DEVICE I
1. STRUCTURE
The pump device consists of main pump, regulator and gear pump.
Pi1 Pm1
Qmin adjusting &;rew Qmin adjusting screw
O ~~ :an,: \\
, .......
II
_//
,___~~~.-------<
Front pump Portbkx:k L Aearpump Gear pump
Port Port name Port size
A1 ,2 Delivery port SAE6000psi 314"

81 Suction port SAE2500psi 2 112"
Dr Drain port PF 314-20
Pm1
Pi1 ,i2 Pilot port PF 1/4-15
Pi1 Pm1,m2 Qmax cut port PF1/4-15
Psv Servo assist port PF1/4-15
a1 ,2,3.4 Gauge port PF1/4 - 15
A3 Gear pump delivery port PF1/2 - 19
B3 Gear pump suction port PF314-20
2-1
1) MAIN PUMP(1f2)
The main pump consists of two piston pumps(front & rear) and valve block.
A
7CJ2.
D
789, 732 532 214 548 531 724 792 534 901 808 954 717 151 152 211 113
535
800
953 --~r
886 'T'~~F'.::!~Jllil:LII.lllJ
717 ---F-~
406
261 ---11'...>..., - ,
774
111
824
127
710
123
251
212
490 153 156 158157 468 313 124 312 114 466 885 314 141 271 401
728 725
04 Gearpump 251 Support 710 0-ring

111 Drive shaft(F) 261 Seal cover(F) 717 0-ring
113 Drive shaft(R) 271 Pump casing 724 0-ring
114 Spline coupling 312 Valve block 725 0-ring
123 Roller bearing 313 Valve plate(R) 728 0-ring
124 Needle bearing 314 Valve plate(L) 732 0-ring
127 Bearing spacer 401 Hexagon socket bolt 774 Oil seal
141 Cylinder block 406 Hexagon socket bolt 789 Back up ring
151 Piston 466 VP Plug 792 Back up ring
152 Shoe 468 VP Plug 806 Hexagon head nut
153 Set plate 490 Plug 808 Hexagon head nut
156 Bushing 531 Tilting pin 824 Snap ring
157 Cylinder spring 532 Servo piston 885 Pin
158 Spacer 534 Stopper(L) 886 Spring pin
211 Shoe plate 535 Stopper(S) 901 Eye bolt
212 Swash plate 548 Pin 953 Set screw
214 Bushing 702 0 -ring 954 Set screw
2-2
MAIN PUMP(2/2)
I
I I
0
I I
I I
544 ~~-+9i===i=::!:=::==~~~~-7~~
I I
I I
I
I
543 - - - - - - 1 - - - - - ' - - - - ' - I----<
545 - - - - - - 1 - - - - + - - ' -- --<.._ ,-'-'•
VIEW A
541 Seat 544 Stopper 2 079 Proportional reducing valve

543 Stopper 1 545 Steel ball
2-3
2) REGULATOR(1f.2)
412 875 874

755
858
614
615
613
611
·~·
647 A
KR3H-9N29
648
723 P2
Pf
642
( )
438
Pm
801
Pi
801
924
641 730 643 708 644 645 646 728

B
SECTION B-B
413 438
656
438
port Port name port size
735 A Delivery port 314"

B Suction port 21/2"
722 Pi Pilot port PF1/4-15
Pm Qmax cut port PF1/4-15
496 724 725 436
VIEW C
2-4
REGULA10R(2fl)
734 653 654 836 651 652 601 624 629 630 628
655
641 801
814 925
631 627
732
733 I I
622
__J J--- .'r -__- \.
\_ _/
732
621 623 625 626 887 763 7fJ3

SECTION A-A
412 Hexagon socket screw 631 Sleeve, pf 730 0-ring

413 Hexagon socket screw 641 Pilot cover 732 0-ring
436 Hexagon socket screw 642 Pilot cover(QMC) 733 0-ring
438 Hexagon socket screw 643 Pilot piston 734 0-ring
496 Plug 644 Spring seat(Q) 735 0-ring
601 Casing 645 Adjust stem(Q) 755 0-ring
611 Feed back lever 646 Pilot spring 756 0-ring
612 Lever(1) 647 Stopper 763 0-ring
613 Lever(2) 648 Piston(QMC) 801 Nut
614 Fulcrum plug 651 Sleeve 814 Snap ring
615 Adjust plug 652 Spool 836 Snap ring
621 Compensator piston 653 Spring seat 858 Snap ring
622 Piston case 654 Return spring 874 Pin
623 Compensator rod 655 Set spring 875 Pin
624 Spring seat(C) 656 Block cover 887 Pin
625 Outer spring 708 0 -ring 897 Pin
626 Inner spring 722 0-ring 898 Pin
627 Adjust stem(C) 723 0 -ring 924 Set screw
628 Adjust screw(C) 724 0-ring 925 Adjust screw(QI)
629 Cover(C) 725 0 -ring
630 Lock nut 728 0 -ring
2-5
3) GEAR PUMP
700 354 351 433
850
355
434
311
312
710 435 361 353 732 309 307 310 308 434 466, 725
307 Poppet 353 Drive gear 466 Plug

308 Seat 354 Driven gear 700 Ring
309 Spring seat 355 Filter 710 0-ring
310 Spring 361 Front case 725 0-ring
311 Screw 433 Flange socket 732 0-ring
312 Nut 434 Flange socket 850 Snap ring
351 Gear case 435 Flange socket
2-6
2.FUNCTION
1) MAIN PUMP
The pumps may classified roughly into the rotary group performing a rotary motion and working as
the major part of the whole pump function: the swash plate group that varies the delivery rates: and
the valve cover group that changes over oil suction and discharge.
(1) Rotary group

The rotary group consists of drive shaft
(F)(111 ), cylinder block(141 ), piston
shoes{151 ,152), set plate(153), spherical
bush(156), spacer(158) and cylinder
spring{157). The drive shaft is supported
by bearing(123,124) at its both ends.
The shoe is caulked to the piston to from
a spherical coupling. It has a pocket to
relieve thrust force generated by loading
pressure and the take hydraulic balance
so that it slides lightly over the shoe
plate(211 ). The sub group composed by
a piston and a shoe is pressed against
the shoe plate by the action of the
cylinder spring via a retainer and a
spherical bush.
Similarly, the cylinder block is pressed
against valve plate{313) by the action of
the cylinder spring.
(2) Swash plate group
The swash plate group consists of swash
plate(212), shoe plate(211 ), swash plate
support(251 ), tilting bush(214), tilting
pin(531) and servo piston(532).
The swash plate is a cylindrical part
formed on the opposite side of the sliding
surface of the shoe and is supported by
the swash support.
If the servo piston moves to the right and
left as hydraulic force controlled by the
regulator is admitted to hydraulic
chamber located on both sides of the
servo piston, the swash plate slides over
the swash plate support via the spherical
part of the tilting pin to change the tilting
angle( a)
2-7
(3) Valve block group
The valve block group consists of valve
block(312), valve plate(313) and valve
plate pin(885}.
The valve plate having two melon-shaped
ports is fixed to the valve block and feeds
and collects oil to and from the cylinder
block.
The oil changed over by the valve plate is
connected to an external pipeline by way
of the valve block.
Now, if the drive shaft is driven by a prime
mover(electric motor, engine, etc), it
rotates the cylinder block via a spline
linkage at the same time. If the swash
plate is tilted as in Fig(previous page) the
pistons arranged in the cylinder block
make a reciprocating motion with respect
to the cylinder block, while they revolve
with the cylinder block.
If you pay attention to a single piston, it
performs a motion away from the valve
plate(oil sucking process) within 180
degrees, and makes a motion towards
the valve plate(or oil discharging process)
in the rest of 180 degrees. When the
swash plate has a tilting angle of zero, the
piston makes no stroke and discharges
no oil.
2-8
2) REGULAlOR
Regulator consists of the negative flow control, total horse power control and power shift control
function.
(1) Negative flow control

By changing the pilot pressure Pi, the
pump t ilting angle(delivery flow) is
regulated arbitrarily, as shown in the
figure.
This regulator is of the negative flow
control in which the delivery flow a
decreases as the pilot pressure Pi rises.
With this mechanism , when the pilot
pressure corresponding to the flow
required for the work is commanded, the
pump discharges the required flow only,
and so it does not consume the power Pilot pressure, Pi
uselessly.
2-9
Q) Flow reducing function
643 654 651 652 613 646
..
--,__. c:::>
',
875 : \.
i 61 1 ! ~--1
~--~---.--- ,i
Servo piston
,i :____, - - - - - _ I_ _- - -1.~~aJI ~:~;e~ :I
large diameter
chamber
i
: c:::> :j D
~
·L 548 i chamber
__ _____ -L _____ _J_ __ __;
L-----~ -- -- ~ ) - 531 1
I
r --------~ cl -/---~----,""' i
~~~- c:::> '\'
',
\ \,
As the pilot pressure Pi rises, the pilot piston(643) moves to the right to a position where the force
of the pilot spring(646} balances with the hydraulic force.
The groove(A) in the pilot piston is fitted with the pin(875) that is fixed to lever 2(613). Therefore,
when the pilot piston moves, lever 2 rotates around the fulcrum of point B [fixed by the fulcrum
plug(614) and pin(875)]. Since the large hole section(C) of lever 2 contains a protruding
pin(897) fixed to the feedback lever(611 ), the pin(897) moves to the right as lever 2 rotates.
Since the opposing-flat section(D) of the feedback lever is fitted with the pin(548) fixed by the
tilting pin(531) that swings the swash plate, the feedback lever rotates around the fulcrum of point
D, as the pin(897) moves.
Since the feedback lever is connected with the spool(652) via the pin(874), the spool moves to
the right.
The movement of the spool causes the delivery pressure P1 to connect to port CL through the
spool and to be admitted to the large diameter section of the servo piston . The delivery
pressure P1 that is constantly admitted to the small diameter section of the servo piston moves
the servo piston to the right due to the area difference, resulting in decrease of the tilting angle.
When the servo piston moves to the right, point D also moves to the right. The spool is fitted
with the return spring(654) and is tensioned to the left at all times, and so the pin(897) is pressed
against the large hole section(C) of lever 2.
Therefore, as point D moves, the feedback lever rotates around the fulcrum of point C, and the
spool is shifted to the left. This causes the opening between the sleeve(651) and spool(652) to
close slowly, and the servo piston comes to a complete stop when it closes completely.
2-10
® Flow increasing function
643 654 651 652 613 646
' 875 i "-----i

i 611 : :--1
, . j ~------'--- -- ,-~m~l-d~~~ :
La d. t , Servo piston : 0 : Q : chamber I
ch~~~~meer ! ! ~ ---,-----.!_ _____ l
"'
_J_ __ _J
L-----~---- ,~ ) - 1 I :
1--------~ ct-- -\ - ~ i I
~~-:-? ',"
\ \
As the pilot pressure Pi decreases, the pilot piston(643) moves to the left by the action of the
pilot spring(646) and causes lever 2(613) to rotate around the fulcrum of point B. Since the
pin(897) is pressed against the large hole section(C) of lever 2 by the action of the return
spring(654) via the spool(652), pin(874), and feedback lever(611 ), the feedback lever rotates
around the fulcrum of point D as lever 2 rotates, and shifts the spool to the left. Port CL opens
a way to the tank port as the spool moves. This deprives the large diameter section of the
servo piston of pressure, and shifts the servo piston to the left by the discharge pressure P1 in
the small diameter section, resulting in an increase in the flow rate.
As the servo piston moves, point D also moves to the left, the feedback lever rotates around the
fulcrum of point C, and the spool moves to the right till the opening between the spool and
sleeve is closed.
2- 11
@ Adjustment of flow control characteristic
The flow control characteristic can be
adjusted with the adjusting screw.
Adjust it by loosening the hexagon 801
924
nut(801) and by tightening(or loosening)
the hexagonal socket head screw(924).
Tightening the screw shifts the control
chart to the right as shown in the figure.
• Adjusting values are shown in table.
Adjustment of flow control

characteristic
Speed
Tigitening Flowcontrd Flow change
amount of starting amount - -,
adjusting pressure \
\
screw(924) change \
\
amount \
\
\
\
\
\
\
(min ·') (Tum) (kgf/cm2) (I /min) \
\
\
2100 +1/4 +1.5 +13.6

Pilot pressure, Pi
2-12
(2) Total horsepower control
The regulator decreases the pump tilting
angle(delivery flow) automatically to limit
the input torque within a certain value a
with a rise in the delivery pressure P1 of ?£
0
;;::::
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, (PHP2)
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
underway.
Since this regulator is of the simultaneous
total horsepower type, it controls the tilting
angles(displacement volumes) of the two
pumps to the same value as represented
by the following equation :
Tin =P1 x q/2 JI + P2 x q/2 JI
=(P1 +P2) x q/2 JI
The horsepower control function is the
same as the flow control function and is
summarized in the following.(For detailed
behaviors of respective parts, refer to the
section of flow control).
2-13
<D Overload preventive function
621 651 652 623 612 601 625 626
I: 611 .1 ~--. I
: Large diameter
I chamber
!
,
Servo piston !
, D
1-----_i_ _- ---r~~1-~i:~~;
, ¢ , chamber
:
I
! ! ~------, - - -- -L _____
_L _ _ -1
~ -- -~:.:_-:-::.:r--- -- T~ --f----- :
I ( - : ---
\ _ ___;
: '"\
'
I
- -- --- - "-
'
\ "
When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, it
acts on the stepped part of the compensating piston(621 ). It presses the compensating
rod(623} to the right till the force of the outer spring(625) and inner spring(626} balances with
the hydraulic force. The movement of the compensating rod is transmitted to lever 1(612) via
pin(875).
Lever 1 rotates around the pin(875) (E) fixed to the casing(601 ).
Since the large hole section(F) of lever 1 contains a protruding pin(897) fixed to the feedback
lever(611 ), the feedback lever rotates around the fulcrum of point D as lever 1 rotates, and then
the spool(652} is shifted to the right. As the spool moves, the delivery pressure P1 is admitted
to the large diameter section of the servo piston via port CL, causes the servo piston move to
the right, reduces the pump delivery, flow rate, and prevents the prime mover from being
overloaded.
The movement of the servo piston is transmitted to the feedback lever via point D. Then the
feedback lever rotates around the fulcrum of point F and the spool is shifted to the left. The
spool moves till the opening between the spool(652) and sleeve(651) is closed.
2-14
® Flow reset function
621 651 652 623 612 601 625 626
I: 875 l, ~--, 1
: ' ~----- -i ____ _, ------.----i
: Large diameter ! 0 ! ! , Small diameter j
I chamber j Servo piston j D l ______ _____ _J_~m~~- -_J
I
--f----- :
I • I
1
~---'-:::.:...~::.r-----r~
I ( - :\_
- __ _): <:=i'""'', I
---- --- \.
\ "
As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases,
the compensating rod(623) is pushed back by the action of the springs(625 & 626) to rotate
lever 1(612) around point E. Rotating of lever 1 causes the feedback lever(611) to rotate
around the fulcrum of point D and then the spool(652) to move to the left. As a result, port CL
opens a way to the tank port.
This causes the servo piston to move to the left and the pump's delivery rate to increase.
The movement of the servo piston is transmitted to the spool by the action of the feedback
mechanism to move it till the opening between the spool and sleeve is closed.
2-15
@ Low tilting angle(low flow) command preferential function
As mentioned above, flow control and horsepower control tilting angle commands are
transmitted to the feedback lever and spool via the large-hole sections(C & F) of levers 1 and 2.
However, since sections C and F have the pins( 0 4) protruding from the large hole( 0 8), only the
lever lessening the tilting angle contacts the pin(897) ; the hole( 0 8) in the lever of a larger tilting
angle command is freed without contacting the pin(897). Such a mechanical selection method
permits preference of the lower tilting angle command of the flow control and horsepower control.
© Adjustment of input horsepower
Since the regulator is of total cumulative horsepower type, adjust the adjusting screws of both the
front and rear pumps, when changing the horsepower set values. The pressure change values
by adjustment are based on two pumps pressurized at the same time, and the values will be
doubled when only one pump is loaded.
a Adjustment of outer spring

Adjust it by loosening the hexagon 625 626 630 628
nut(630) and by tightening(or
loosening) the adjusting screw C(628).
Tightening the screw shifts the control
chart to the right and increases the
input horsepower as shown in the
figure. Since turning the adjusting
screw C by N turns changes the setting
of the inner spring(626), return the
adjusting screw 01(925) by N x A turns
at first.(A=2.2)
• Adjusting values are shown in table.
Adjustment of outer spring

Speed
TigitEri'lg Compens- Input torque 0
amount of ating control change ~
adjusting starting amount 0
;:;::
\
\
screw(C) pressure >.

\
\
...... \
(924) change
.~
\
\
amount Q)
0
(min -') (Tum) (kgf/cm2) (kg!· m)
2100 +1/4 +15.9 +4.2 Delivery pressure, (P1+P2)
2-16
b. Adjustment of inner spring
626
Adjust it by loosening the hexagon nut
(801) and by tightening(or loosening)
the adjusting screw 01(925).
Tightening the screw increases the flow
and then the input horsepower as
shown in the figure.
• Adjusting valves are shown in table.
Adjustment of inner spring

Speed
Tightening Compens- Input torque
amount of ating control change
adjusting starting amount
screw(QI) pressure
(925) change
amount
(min ·') (Tum) (kgf/cm2) (kgf · m)
2100 +1/4 +27.3 +41 ~

Q)
.2:
Q)
Cl
Delivery pressure, (P1+P2)
2-17
(3) Power shift control
621 651 652 623 612 625 626
898
I: 611 :1 ~-- I
:._ ______1_ ____ 1-----. ----i:
: Large diameter , ! r-"-... , Small diameter :
I chamber i Servo piston D ' ,_,,...... ' chamber ,1
: : ~------,------L _
____ _J_ __ -1 i
~---~::_~:_:r----(-i-)--{-- ~--"'- i I
\____; c> ',
- --- ----, "
\ "
The set horsepower valve is shifted by
varying the command current level of
the proportional pressure reducing valve
0
attached to the pump.
Only one proportional pressure reducing
valve is provided.
However, the secondary pressure Pf
(power shift pressure) is admitted to the
horsepower control section of each
pump regulator through the pump's Delivery pressure, (PHP2)
internal path to shift it to the same set
horsepower level.
This function permits arbitrary setting of the pump output power, thereby providing the optimum
power level according to the operating condition.
The power shift pressure Pf controls the set horsepower of the pump to a desired level, as
shown in the figure.
As the power shift pressure Pf rises, the compensating rod(623) moves to the right via the
pin(898) and compensating piston(621 ).
This decreases the pump tilting angle and then the set horsepower in the same way as
explained in the overload preventive function of the horsepower control. On the contrary, the
set horsepower rises as the power shift pressure Pf falls.
2-18
(4) Adjustment of maximum and minimum flows
(!) Adjustment of maximum flow 808
Adjust it by loosening the hexagon
nut(808) and by tightening(or loosening) 954
the set screw(954).
The maximum flow only is adjusted
without changing other control
characteristics.
Adjustment of max flow

Speed
lightening amount Flow change
of adjusting screw amount
(954)
(min ·') (Tum) ( I /min)
2100 +1/4 -6 Delivery pressure, Pi
® Adjustment of minimum flow

nut(808) and by tightening(or loosening)
the hexagonal socket head set screw
806
(953). Similarly to the adjustment of the
maximum flow, other characteristics are
953
not changed.
However, remember that, if tightened too
much, the required horsepower during
the maximum delivery pressure(or during
relieving) may increase.
Adjustment of min flow

Speed
lightening amount Flow change
of adjusting screw amount
(953)
(min ·') (Tum) ( 1/min)
!'~ +1/4
~:E1 Delivery pressure, Pi
2-19
(5) Qmax cut control
647
The regulator regulates 648
the maximum delivery flow
723
by inputting the pilot
pressure Pm. Since this is 642 438
(}
a 2-position control method,
the maximum delivery flow 801
may be switched in two 801
steps by turning on/off the 924
pilot pressure Pm.(The

641 730 643 708 644 645 646 728
maximum control flow
cannot be controlled in
intermediate level.}
(!) Functional explanation

As shown in the figure, the pilot pressure
Pm switches the maximum flow in two
steps.
When the pilot pressure Pm is given, it is Pm
admitted to the lefthand side of the
piston QMC(648}. The piston QMC
moves the stopper(647} and pilot
piston(643} to the right, overcoming the
force of the pilot spring(646}, thereby
reducing the delivery flow of the pump. Pilot pressure, Pi
Since the adjusting screw QMC(642} is
provided with a flange, the piston QMC
stops upon contact with the flange, and
the position of the pilot piston at this time
determines the maximum flow of the
pump.
® Adjustment of Qmax cut flow

nut(801} and by tightening(or loosening}
the adjusting screw QMC(642}.
a
Tightening the screw decreases the
Qmax cut flow as shown in the figure.
! --!----
-~
Cl>
0
Pilot pressure, Pi
2-20
GROUP 2 MAIN CONTROL VALVE
1. STRUCTURE
2-21
STRUCTURE
2-22
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 Dr2
Air bleed port
R/G drain port

R/G grease fill port Time delay valve Sh Pg A B
Sh
Pg A Main port PF 3/4
B Main port PF 3/4
Dr2 Drain port PF 3/8
Dr2
Mu Make up port PF 1
Sh Brake release port PF 1/4
Pg Stand by port PF 1/4
A Mu B
2-43
1) SWING MOTOR
4 5 6 7 8 9 10 11 12 13 14 15 17, 18 35 36
3
2
16 41
1 36
40
17,18
39
38
29 28 27 26 25 24 23 22 21 20 19 43 42 37 34 33 32,31 30
1 Inner ring 16 Piston 31 O-ring

2 Oil seal 17 Cap 32 Back up ring
3 Taper roller bearing 18 O-ring 33 O-ring
4 Plug 19 Coned disc spring 34 Cover
5 Backing spring 20 Teflon ring 35 Relief assembly
6 Cam plate 21 Bushing 36 O-ring
7 Return plate 22 Balance plate 37 Hexagon socket bolt
8 Piston assembly 23 Needle bearing 38 Check
9 Plate 24 Snap ring 39 Spring
10 Lining plate 25 Cylinder 40 Cap
11 O-ring 26 Housing 41 Back up ring
12 Piston 27 Collar 42 Time delay valve
13 O-ring 28 Level gauge assembly 43 Hexagon socket bolt
14 Spring 29 Snap ring
15 Parallel pin 30 Bypass valve assembly
2-44
2) REDUCTION GEAR
1 2 3 4 5 6 26 9 10 11 12 13 14
16
7
15
17
26 25 24 23 22 21 20 19 18 8 27 28
1 Pinion shaft 11 Pin 21 Thrust plate 2

2 Collar 12 Ring gear 22 Spring pin
3 Snap ring 13 Holder 1 23 Holder 2
4 Plate 14 Sun gear 24 Planetary gear 4
5 Roller bearing 15 Shaft 1 25 Plug
6 Gear casing 16 Planetary gear 2 26 Plug
7 Bushing 1 17 Thrust plate 1 27 Lock washer
8 Spring pin 18 Shaft 2 28 Lock bolt
9 Oil seal 19 Bushing
10 Roller bearing 20 Planetary gear 5
2-45
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
a a
High High Low
pressure oil pressure oil pressure oil
4 3 2 5 1
2-46
2) MAKE UP VALVE
In the system using this type of motor, there is no counter balance functioning valve and there
happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation
caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency.
A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure
feed pressure required when the hydraulic motor makes a pumping action. The boost pressure
acts on the hydraulic motor's feed port via the make up valve.
Pressurized oil into the port B, the motor rotate counterclockwise.
If the plunger of MCV moves neutral position, the oil in the motor is drain via left relief valve, the
drain oil run into motor via right make up valve, which prevent the cavitation of motor.
A B
2-47
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
2-48
‫ 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
2-49
‫ 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
2-50
4) BRAKE SYSTEM
(1) Control valve swing brake system

This is the brake system to stop the swing motion of the excavator during operation.
In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance
created by this throttling works as a brake force to slow down the swing motion.
Work Deceleration Stop
A B A B A B
MCV MCV MCV
MCV A, B opened MCV A, B throttled MCV A, B closed
(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 force and brake acts, while 25
brake releases when hydraulic force 26 Groove
exceeds spring force.
9 Separate plate 14 Spring

10 Lining plate 25 Cylinder
12 Brake piston 26 Housing
2-51
‫ 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
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
9 Spring 4
10 Orifice
11 Spring
12 Pilot pump
2-52
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

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
2-53
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

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
2-54
GROUP 4 TRAVEL DEVICE
1. CONSTRUCTION
Travel device consists travel motor and gear box.
Travel motor includes brake valve, parking brake and high/low speed changeover mechanism.
Pressure gauge port(P1~P4)
Oil fill port
C1
P2 P1
DA
P3 P4
B
Oil level check port
Drain port
C1 C2
P2 P3 Port Port name Port size
D A Main port PF 1
B Main port PF 1
P1~P4 Gauge port PF 1/4
C1~C2 Drain port PF 1/2
P1 P4
D 2 speed control port PF 1/4
A B
2-55
1) BASIC STRUCTURE
Reduction gear
Hydraulic motor
Brake valve
Parking brake
High / low speed
changeover mechanism
Control valve
Hydraulic pump
2-56
2) STRUCTURE
101 113 29 112 139 178 116 115 110 105 106 151 103 167 15 8 35 1 25 6 33 126 134 130 127 121 138
165
164
32
154
166 181
163 182
150
102 3
34
141 9
14
20
109 A A 13
122
36
133
7
199
30
19
120 132
118 149
128
140
124
169
143 186 168
161 152
158 4
27 144
142 5 190
138 175 172 176 39 145 104 2 114 40 23 26 24 107 108 12 17 153 162 179 125 123 170 171 180 137 136 179 157 124 185 183
SECTION A-A
1 Hub 24 Ball bearing 105 Piston 124 Plug 143 Spring 167 Steel ball
2 Spindle 25 Needle bearing 106 Shoe 125 Stopper 144 Hexagon socket plug 168 Steel ball
3 Carrier 26 Floating seal 107 Retainer plate 126 Plug 145 Snap ring 169 Expander
4 Ring gear A 27 Pin 108 Thrust ball 127 Valve 149 Roller bearing 170 Hexagon socket bolt
5 Ring gear B 29 O-ring 109 Timing plate 128 Spring 150 Roller bearing 171 Lock washer
6 Cluster gear 30 Hexagon socket bolt 110 Washer 130 Spring 151 Roller 172 Valve seat
7 Sun gear 32 Hexagon bolt 112 Piston 132 Oil seal 152 Hexagon socket plug 175 Spring
8 Coupling gear 33 Lock washer 113 Spring 133 O-ring 153 Thrust plate 176 Ring
9 Shaft 34 Pin 114 Spring 134 O-ring 154 Expander 177 Ring
12 Distance piece 35 Hexagon socket bolt 115 Friction plate 135 Spring pin 157 Stopper 178 O-ring
13 Cover 36 Steel ball 116 Mating plate 136 Body 158 Steel ball 179 O-ring
14 Thrust collar 39 O-ring 118 Valve seat 137 Spool 161 Piston 180 O-ring
15 Ring 40 O-ring 119 Valve 138 O-ring 162 Shoe 181 Pin
17 Pin 101 Rear flange 120 Spring 139 O-ring 163 Valve 182 Hexagon socket bolt
19 Coupling 102 Shaft 121 Plug 140 O-ring 164 Stopper 183 Spring
20 Thrust bearing 103 Swash plate 122 Ring 141 Pin 165 Ring 185 Spring
23 Seal ring 104 Cylinder block 123 Spool 142 Valve 166 Spring 190 Orifice
2. FUNCTION
1) HYDRAULIC MOTOR
(1) Rotary group
F3
F3
101 109 104 103 102
r1
F3
P
Y2
҄
Ş
F1
105 A P
F3
F2
The pressurized oil delivered from the hydraulic pump flows to rear flange(101) of the motor,
passes through the brake valve mechanism, and is introduced into cylinder block(104) via timing
plate(109). This oil constructively introduced only to one side of Y1 - Y2 connecting the upper
and lower dead points of stroke of piston (105). The pressurized oil fed to one side in cylinder
block(104) pushes each piston(105, four or five) and generates a force(F kg = P kg/cm2 źA cm2).
This force acts on swash plate(103), and is resolves into components (F2 and F3) because
swash plate(103) is fixed at an angle(҄ Ş) with the axis of drive shaft(102). Redial component(F3)
generates respective torques(T=F3 ź ri) for Y1-Y2. This residual of torque(T=F3 ź ri) rotates
cylinder block(104) via piston(105). Cylinder block(104) is spline-coupled with drive shaft(102).
So the drive shaft(102) rotates and the torque is transmitted.
2-58
(2) Brake valve
‫ ڸ‬Brake released (starting/running)
When the pressurized oil supplied for
port ʶ, the oil opens valve(127) and
flows into port ʸ at the suction side of
hydraulic motor to rotate motor. At the 112
same time, the pressurized oil passes
136
through pipe line ‫ ڞ‬from a small hole in
137
spool(123) and flows into chamber ‫ڟ‬. C
157 s
The oil acts on the end face of
spool(123) which is put in neutral t p
D E
position by the force of spring(128), thus a
123
causing spool(123) to slide to the left.
When spool(123) slides, port ʹ on the 128 b
passage at the return side of hydraulic
motor, which is closed by the spool
groove during stoppage, communicates
with port ʷ at the tank side and the
return oil from the hydraulic motor runs
into the tank. In consequence, the
hydraulic motor rotates. Moreover, 127
sliding of spool(123) causes the

pressurized oil to flow into ports ˅ and
ˈ.
The pressurized oil admitted into port ˅ B A
activates piston(112) of the parking brake
to release the parking brake force. (For
details, refer to description of the parking
brake.) On the other hand, the
pressurized oil introduced into port ˈ
flows into chamber ‫ ڱ‬and presses
stopper(157) against the inside of
body(136) to prevent spool(137) from
moving, thus disabling communication at
port ʸ side of the hydraulic motor.
(suction side and return side of hydraulic
motor). When the pressurized oil is
supplied from port ʷ, spool(123) and
valve(127) move reversely and the
hydraulic motor also rotates reversely.
2-59
‫ ڹ‬Brake applied(stopping/stalling)
When the pressurized oil supplied from
port ʶ is stopped during traveling, no
hydraulic pressure is applied and
spool(123) which has slided to the left will
return on the right(neutral) via 112
stopper(125) by the force of spring(128).
136
The oil in chamber ‫ ڟ‬will flow to port ʶ
137
side through pipe line ‫ ڞ‬in spool(123). 157 C
s
However, a back pressure produced by
the restricting effect of pipe line ‫ڞ‬, p
D E
whereby the return speed of spool(123) a
123
is controlled. At the same time, the
hydraulic motor will rotate by the force of 128 b
inertia even if the pressurized oil is
125
stopped. Accordingly, the return oil will
return to port ʷ side from port ʹ through
a passage between the groove in
spool(123) and rear flange(101). When
spool(123) completely returns to neutral,
the above-mentioned passage is fully 127
closed and the hydraulic motor stops.

As explained above, the hydraulic motor
is smoothly braked and stopped by
gradually controlling the return oil from B A
the hydraulic motor by the return speed
of spool(123), its shape, etc.
However, the hydraulic motor will rotate
by the force of inertia. This means that
the hydraulic motor will suck oil
functioning as a pump.
However, no oil is supplied because the
pressurized oil is stopped. In consequence,
cavitation occurs on the hydraulic motor,
thus adversely affecting it.
At the same time, the passage closed by
spool(123), whereby the return oil from
the hydraulic motor is enclosed at port ʹ
side and the pressure is increased. This
pressure slides spool(137) to the left to
short-circuit ports ʹ and ʸ, which
prevents pressure rise and cavitation.
(surge cut valve function and anti-
cavitation valve function).
2-60
Valve(127) is activated by a slight
negative pressure to open the oil
passage between the oil line at port ʶ
side and port ʸ at the suction side of
motor, thus preventing cavitation of the
hydraulic motor.
(3) Parking brake

‫ ڸ‬Running
When the pressurized oil is supplied
from the brake valve, the spool of brake
valve in the hydraulic motor assembly 113 112 116 115
actuates to open the passage to the

parking brake and the pressurized oil is
introduced into cylinder chamber ‫ڞ‬
which is composed of the spindle of
reduction gear assembly and
piston(112). When the hydraulic
pressure reaches 9.5 kgf/cm2 (0.93 Mpa)
or more, it overcomes the force of
spring(113) and shifts piston(112). With
shift of piston(112), no pressing force is
applied to pressure plate(116) and
friction plate(115) and the movement of
friction plate(115) becomes free,
whereby the brake force to the cylinder
in the hydraulic motor assembly is
released. When the hydraulic pressure
reaches 45 kgf/cm2 (4.41 Mpa) or more, a
it is reduced by the reducing valve to set
the pressure in cylinder chamber ‫ ڞ‬to
45 kgf/cm2 (4.41 Mpa). Assembled in
the reducing valve is a safety valve
which is set to 100 kgf/cm2 (9.81 Mpa).
2-61
‫ ڹ‬Stopping
113 112 116 115
When the pressurized oil from the brake
valve is shut off and the pressure in
cylinder chamber ‫ ڞ‬drops 9.5 kgf/cm2
(0.93 Mpa) or less, piston(112) will return
by the force of spring(113).
Piston(112) is pushed by this force of
spring(113), and pressure plate(116) and
friction plate(115) in free condition are
pressed against the spindle of reduction
gear assembly.
The friction force produced by this
pressing stops rotation of the cylinder
and gives a braking torque 49.3kgfşm
(483 Nşm) to the hydraulic motor shaft.
Note that oil control through a proper oil
passage ensures smooth operation.
2-62
(4) High/low speed changeover mechanism
‫ ڸ‬At low speed - at pilot pressure of less than 20 kgf/cm2 (1.96 Mpa)
163 166 103
Spindle
B Support
ҋ
1
Motor
case
When no pilot pressure is supplied from port ʶ (at a pressure of 20 kgf/cm2 (1.96 Mpa) or less),
valve(163) is pressed toward the left by the force of spring(166), the pressurized oil supply port
ʷ is shut off, and oil in chamber ʸ is released into the motor case via valve(163).
Consequently, swash plate(103) is tilted at a maximum angle ҋ 1 and the piston displacement of
hydraulic motor becomes maximum, thus leading to low-speed rotation.
‫ ڹ‬At high speed - at pilot pressure of 20 kgf/cm2 (1.96 Mpa) or more
163 166 103 b

A
Spindle
B Support
ҋ
2
Motor
case
161
When a pilot pressure is supplied from port ʶ (at a pressure of 20 kgf/cm2 (1.96 Mpa) or more),
the pressure overcomes the force of spring(166) and valve(163) is pressed toward the right.
The pressurized oil at supply port ʷ is then introduced into chamber ʸ via valve(163).
Piston(161) pushes up swash plate(103) until it touches side ‫ ڟ‬of the spindle. At this time,
swash plate(103) is tilted at a minimum angle ҋ2 and the piston displacement of hydraulic motor
becomes minimum, thus leading to high-speed rotation.
2-63
2) REDUCTION GEAR
(1) Function
The reduction gear unit consists of a
combination of simple planetary gear Planetary gear mechanism
mechanism and differential gear
mechanism.
This mechanism reduce the high speed
rotation from the hydraulic motor and
R
convert it into low speed, high torque to
P2
rotate the hub(or case), which in turn P1
rotates the sprocket.
Input Output
(2) Operating principle
S
Upon rotation of the sun gear(S) via the
K
input shaft, the planetary gear(P)
engages with the fixed ring gear(R) while
rotating on its axis.
Rotation around the fixed ring gear(R) is
transmitted to the carrier(K).
RşP2
i1 = 1 +
SşP1
With rotation of the carrier(K), the

planetary gears(P1) and (P2) rotate Differential gear mechanism
around the fixed ring gear(R).
When a proper difference in number of
teeth is given between(P1) and (R) and D
between (P1) and (P2), a difference in R
rotation is produced on the gear(D) P2
P1
because the gears (P1) and (P2) are on
the same axis.
1 Input Output
i2 =
RşP2
1- K
DşP1
2-64
Upon rotation of the sun gear(S) via the
input shaft, planetary motion is given Combination of planetary gear mechanism and
differential gear mechanism
among the gears(S), (P1) and (R) and
rotation of the gear(P1) around another
gear causes the carrier(K) to rotate.
This carrier rotation gives differential D
motion among the gears(R), (P1), (P2) R

and (D) to rotate the ring gear(D). The P2
P1
motor then rotates since the ring gear(D)
is connected to the hub(case) of the Input Output
motor.
RşP2
1+ K
SşP1
i = i1źi2 =
RşP2
1-
DşP1
2-65
GROUP 5 RCV LEVER
1. STRUCTURE
The casing has the oil inlet port P(primary pressure) and the oil outlet port T(tank). In addition the
secondary pressure is taken out through ports 1, 2, 3, 4 and 5 provided at the bottom face.
Port 5 is only RCV lever of LH.
19Ɓ
19Ɓ
25Ɓ
Single
Simultaneous operation
operation Handle bending direction
(NO.3 push rod direction)
33Ɓ 33Ɓ
3 2
45Ɓ
P T
5
4 1
A Port LH RH Port
size
P Pilot inlet port Pilot inlet port

T Pilot return port Pilot return port
1 Left swing port Bucket out port
2 Arm in port Boom down port PF-1/4
T 3 Right swing port Bucker in port
P
4 Arm out port Boom up port
5 Swing shuttle port
1 5 32 4
2-66
CROSS SECTION
The construction of the pilot valve is shown in the attached cross section drawing. The casing has
vertical holes in which reducing valves are assembled.
The pressure reducing section is composed of the spool(201), spring(241) for setting secondary
pressure, return spring(221), washer 1(215), spring seat(216) and washer 2(217). The spring for
setting the secondary pressure has been generally so preset that the secondary pressure is 5 to 19 ָf/
ֲ (depending on the type). The spool is pushed against the push rod(212) by the return spring.
When the push rod is pushed down by tilting the handle, the spring seat comes down simultaneously
and changes setting of the secondary pressure spring.
In case of the two point type electric switch is fitted, as shown in the attached cross section drawing, the
roller(451), switch lever(452) and switch(455) are built in the inside of the handle(401). When the center
of the handle cap(402) provided at the handle head is pushed, the roller is come down, and the switch
lever contacted with the roller tilts to make the switch function. The cord(456), connected to the switch,
is led through the handle section and casing to the outside.
101 Casing 217 Washer 2 412 Nut

111 Port plate 221 Spring 413 Washer
121 Seal washer 241 Spring 421 Screw 2
122 O-ring 291 *Seat 422 Nut
125 Hex socket bolt 292 *Steel ball 431 Screw 3
126 Spring pin 293 *Plug 451 Roller
131 Bushing 294 *O-ring 452 Lever
151 Plate 301 Universal joint 453 Switch seat 1
201 Spool 302 Plate 454 Switch seat 2
211 Plug 312 Adjust nut 455 Switch
212 Push rod 315 Lock nut 456 Cord
213 Seal 323 Handle bar 457 Bushing
214 O-ring 401 Handle 458 Tube
215 Washer 1 402 Handle cap 459 Terminal
216 Spring seat 411 Screw 1 501 Bellows
*Mark : LH only item.
2-67
CROSS SECTION
451
402
421
422
453
454 452
401
455
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
201
126
101
122
111
Port 2,4 Port 1,3
2-68
2. FUNCTION
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure(=secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port(P) where oil is supplied from hydraulic pump.
(2) Output ports(1,2,3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port(T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port or tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS

The functions of the spool(201) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1,2,3 & 4 or the output port pressure oil to tank port T.
The spring(241) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod(212) is inserted and can slide in the
plug(211).
For the purpose of changing the displacement of the push rod through the plate(302) and adjusting
nut(312) are provided the handle(401) that can be tilted in any direction around the fulcrum of the
universal joint(301) center.
The spring(221) works on the casing(101) and spring seat(216) and tries to return the push
rod(212) to the zero-displacement position irrespective of the output pressure, securing its resetting
to the center position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.
2-69
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown
below and the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.
5 6
3
1
3
P T
2 4
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-70
(1) Case where handle is in neutral position
T
241
221
201
P
1 3
The force of the spring(241) that determines the output pressure of the pilot valve is not applied to
the spool(201). Therefore, the spool is pushed up by the spring(221) to the position of port 3 in the
operation explanation drawing. Then, since the output port is connected to tank port T only, the
output port pressure becomes equal to tank pressure.
2-71
(2) Case where handle is tilted
212
201
1 3
When the push rod(212) is stroked, the spool(201) moves downwards.

Then port P is connected with port 1, and the oil supplied from the pilot pump flows through port 1
to generate the pressure.
When the pressure at port 1 increases to the value corresponding to the spring force set by tilting
the handle, the hydraulic pressure force balances with the spring force. If the pressure at port 1
increases higher than the set pressure, port P is disconnected from port 1 and port T is connected
with port 1. If it decreases lower than the set pressure, port P is connected with port 1 and port T is
disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the
spool contacts with the inside bottom of the push rod and the output pressure is left to be
connected with port P.
2-72
(3) Swing shuttle function(LH only)
212
201
1 5 3

Then port P is connected with port 1, and the oil supplied from the pilot pump flows through port 1
to generate the pressure.
At the same time, the pressure of port P1 applied shuttle valve, the ball moves to the right, and port
P1 is connected with port P5.
In this manner, oil flow swing motor, than swing motor, than swing brake valve is released.
2-73
GROUP 6 RCV PEDAL
1. STRUCTURE
The casing (spacer) has the oil inlet port P(primary pressure), and the oil outlet port T(tank). In
addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face.
Ɓ 12.4
12.4 Ɓ
1 2
3 4
P Pilot oil inlet port

T Pilot oil return port
1 Travel (LH, Forward)
PF 1/4
T 2 Travel (LH, Backward)
P
3 Travel (RH, Forward)
4 Travel (RH, Backward)
1 23 4
Hydraulic circuit
2-73
CROSS SECTION
The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in
which reducing valves are assembled.
The pressure reducing section is composed of the spool(8), spring(11) for setting secondary pressure,
return spring(18), stopper(13), spring seat(12) and shim(9). The spring for setting the secondary
pressure has been generally so preset that the secondary pressure is 5 to 19 kgf/cm2 (depending on the
type). The spool is pushed against the push rod(19) by the return spring.
When the push rod is pushed down by tilting pedal, the spring seat comes down simultaneously and
changes setting of the secondary pressure spring.
25
7 6 24
21 5
22 23
20 16 4
19 17
14 15
15 13
12 11
18
30
1
9, 10
8 26 27 28 29
1 Casing 11 Spring 21 Set screw

2 Pedal 12 Spring seat 22 Nut
3 Pedal cover 13 Stopper 23 Cam shaft
4 Cover 14 Plug 24 Set screw
5 Bushing 15 O-ring 25 Hexagon socket bolt
6 Cam 16 Dust seal 26 Plug
7 Bellows 17 Rod seal 27 Spacer
8 Spool 18 Spring 28 O-ring
9 Shim 19 Push rod 29 Hexagon socket bolt
10 Spring seat 20 Hexagon socket bolt 30 Plug
2-74
2. FUNCTION
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure(=secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
(1) elements.
(2) Inlet port(P) where oil is supplied from hydraulic pump.
(3) Output port(1,2,3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(4) Tank port(T) necessary to control the above output pressure.
(5) Spool to connect output port to inlet port tank port.
Mechanical means to control output pressure, including springs that work on the above spools.
2)
FUNCTIONS OF MAJOR SECTIONS
The functions of the spool(8) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1,2,3 & 4 or the output spool to determine the output pressure.
The spring(11) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod(19) is inserted and can slide in the plug(14).
For the purpose of changing th displacement of the push rod through the cam(6) and adjusting
nut(22) are provided the pedal(2) that can be tilted in any direction around the fulcrum of the cam(6)
center.
The spring(18) works on the casing(1) and spring seat(12) and tries to return the push rod(19) to
the zero-displacement position irrespective of the output pressure, securing its resetting to the
center position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.
2-75
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram
shown below ant the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.
5 6
3
1
2
2 4
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-76
(1) Case where pedal is in neutral position
11
8
T
18
1 2
The force of the spring(11) that determines the output pressure of the pilot valve is not
applied to the spool(8). Therefore, the spool is pushed up by the spring(18) to the
position of port 2 in the operation explanation drawing. Then, since the output port is
connected to tank port T only, the output port pressure becomes equal to tank pressure.
2-77
(2) Case where pedal is tilted
19
1 2

Then port P is connected with port 1, and the oil supplied from the pilot pump flows
through port 1 to generate the pressure.
When the pressure at port 1 increases to the value corresponding to the spring force set
by tilting the handle, the hydraulic pressure force balances with the spring force. If the
pressure at port 1 increases higher than the set pressure, port P is disconnected from
port 1 and port T is connected with port 1. If it decreases lower than the set pressure,
port P is connected with port 1 and port T is disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end
of the spool contacts with inside bottom of the push rod and the output pressure is left to
be connected with port P.
2-78
SECTION 3 HYDRAULIC SYSTEM
GROUP 1 HYDRAULIC CIRCUIT
1 Main pump
2 Main control valve
3 Swing motor
4 Travel motor
5 RCV lever
6 RCV pedal
7 Boom cylinder(RH)
8 Boom cylinder(LH)
9 Arm cylinder
10 Bucket cylinder
11 Turning joint
12 Check valve
13 Check valve
14 Hydraulic tank
15 Oil cooler
16 Air breather
17 Bypass valve
18 Strainer assembly
19 Spin filter
20 Shuttle valve
21 Boom holding valve
22 Safety solenoid valve
23 Solenoid valve(4 cartridge)
24 Swing EPPR valve
25 Line filter
26 Pressure switch
27 Accumulator
28 Last guard filter
29 Last guard filter
3-1
GROUP 2 MAIN CIRCUIT
The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit.
The hydraulic system consists of one main pump, one control valve, one swing motor, four cylinders
and two travel motors.
The swash plate type variable displacement axial piston pump is used as the main pump and is
driven by the engine at ratio 1.0 of engine speed.
1. SUCTION AND DELIVERY CIRCUIT
To cylinders To motors
Main control valve To oil cooler
To hydraulic oil tank
Main pump
Suction filter
Hydraulic oil tank
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.
3-2
2. RETURN CIRCUIT
Full flow filter Oil cooler Check valve(2)

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

1.27kg/cm2
All oil returned from each actuator returns to the hydraulic tank through the control valve.
The bypass check valves are provided in the return circuit.
The setting pressure of bypass check valves are 1.5kg/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. When the oil pressure exceeds 3.0kg/cm2(43psi), the oil returns directly to the
hydraulic tank, resulting in the oil temperature being raised quickly at an appropriate level.
When the oil cooler is clogged, the oil returns directly to the hydraulic tank through bypass check
valve(1).
The full-flow filter is provided in the hydraulic tank.
The oil returned from right and left side of control valve is combined and filtered by the full-flow filter. A
bypass relief valve is provided in the full-flow filter.
When the filter element is clogged, the bypass relief valve opens at 1.27kg/cm2(18psi) differential
pressure.
3-3
3. DRAIN CIRCUIT
Travel motor Swing motor
Main pump
Turning joint
Bypass valve
1.07kg/cm2
Spin filter
Hydraulic
oil tank
Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil have
to be fed to the hydraulic tank passing through spin filter.
When the drain oil pressure exceed 1.07kg/cm2 (15psi), the oil returns to the hydraulic tank directly.
1) TRAVEL MOTOR DRAIN CIRCUIT

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

RCV pedal (RH lever)
(LH lever)
Safety lock
solenoid valve Swing parking brake
Control valve
Travel speed solenoid valve
~------------+-------'------i Arm half flow solenoid valve
Power boost solenoid valve
Max fbN cut off solenoid valve

Line filter
Main pump Swing EPPR valve
Relief valve
40l9'cm
Pilot pump
Suction filter
The pilot circuit consists of suction circuit, delivery circuit and return circuit.
The pilot pump is provided with relief valve, receives the oil from the hydraulic tank through the
suction filter.
The discharged oil from the pilot pump flows to the remote control valve through line filter, EPPR
valve, solenoid valve assemblies, swing parking brake, main control valve and safety lock solenoid
valve.
3-5
1. SUCTION, DELIVERY AND RETURN CIRCUIT
ARM BUCKET
CYLINDER CYLINDER BOOM CYLINDER
TRAVEL MOTOR
PL
SWING MOTOR
R2
RCVPEDAL RCV LEVER(LH)

Pl
'XAtr XBtr " XBtl XAu 'L

1
BP8- ..J 1XAal XBa1 11 XAb XBb " XAI< XBI<'
XAs 1Xss• Pat - - - "
Sh
XAa2 f'!' ~z Pm1_,_ Pm2
PILOT PUMP
LINE FILTER
The pilot pump receives oil from the hydraulic tank. The discharged oil from the pilot pump flows to
the safety solenoid valve through the line filter. The oil is filtered by the line filter. The pilot relief
valve is provided in the pilot pump for limiting the pilot circuit pressure.
The oil filtered by pilot filter flows into the remote control valve through safety solenoid valve.
The returned oil returns to the hydraulic tank through the remote control valve.
3-6
2. SAFETY VALVE(SAFETY LEVER)
ARM BUCKET
TRAVEL MOTOR
PL
Pal
SWING MOTOR
e
R111=j::=:=:==-:'.~l:t===:::::::+:~n
A2
HYDRAULIC PILOT PUMP

1TANK
o-°4
l
LEVER UP
When the lever of the safety solenoid valve is moved downward, oil flows into the remote control
valve through solenoid valve and line filter.
When the lever of the safety solenoid valve is moved upward, oil does not flow into the remote
control valve, because of the blocked port.
3 -7
3. ARM HALF FLOW SYSTEM
ARM BUCKET
TRAVEL MOTOR
Pat. Fr T2
XAa1
X8a1
XAb2- - - -
As Psp
SWING MOTOR
I
P2
LEVER(R~ ~
R2
RCV PEDAL RCV LEVER(LH) RCV

Pz Pl
'XAtr XBtr " XBtl XAtl ' l -@jg- -l •XAal XBa1 11XAb XBb " XAk XBk'
Sn
'xA$ XBs' p.._ 1-----t~--,
SOLENOID VALVE
XAa2 Pk f'.Z Pm1_, _Pm2
l
1TANK
----"'---+-~
0
LINE FILTER
When the arm half flow switch is turned ON, the arm half flow solenoid valve is switched to ON and it
cancels oil flow from XAa1 to XAa2 : so the spool of arm 2 is not actuated.
As a result, the arm in operation is only the arm 1 section.
This function is useful to fine control of the arm in case of finishing work.
3 -8
4. TRAVEL SPEED CONTROL SYSTEM
ARM BUCKET
CONTROL PISTON
Pl
Pill Fr
Pk' 'dr3
SWING MOTOR
ea
)(All ,
RCVLEVEA~H) l:1
R2
RCV PEDAL RCV LEVER(LH)

Pz Pl
' XAtr XBtr" xeu XAtl '~ ~ ..J• XAa1 XBa1"XAb XBb" XAk
XAsShXBs' Pill
SOLENOID VALVE
~ Pk ~z Pm1_,_Pm2

1TANK
.--""-..='l---,
When the travel speed switch is pushed, the travel speed solenoid valve is actuated and the
discharged oil from the pilot pump flows to the Pk port of pilot valve in the travel motors.
As a result, the control piston is pushed by the main oil flow, thus the displacement is minimized.
When the travel speed switch is pushed once more, the travel speed solenoid valve is return to
original position by the force of spring, the hydraulic oil of Pk port returns to the hydraulic tank.
As a result, the control piston is returned by the main oil flow, thus the displacement is maximized.
3-9
5. MAIN RELIEF PRESSURE CHANGE SYSTEM
ARM BUCKET
TRAVEL MOTOR
P&.
SWING MOTOR
XBb
Btr
- - J> X8tr
P2 R2
RCV PEDAL RCV LEVER(LH)
XAti '~-@;& -1°XAa1 XBa1 1'XAb XBb " XAk

0
XAtr XBtr " XBtl
XAs $ti XBs' P&.
SOLENOID VALVE
XAa2 Pk pz Pm1_,_Pm2

1TANK
~~~+-~
When the power boost switch on the left control lever is pushed ON, the power boost solenoid valve
is actuated, the discharged oil from the pilot pump flows into Pz port of the main relief valve of main
control valve; then the setting pressure of the main relief valve is raised from 320kgf/cm 2 to
350kgf/cm2 for increasing the digging power. And even when pressed continuously, it is canceled
after 8 seconds.
3- 10
6. MAX FLOW CUT OFF FUNCTION SYSTEM
ARM BUCKET
TRAVEL MOTOR
PL
SWING MOTOR
$ ""A1l - l - - - - - - ' 1 - - - - - " " 1 - t + l - h
l:I
R2
RCV PEDAL RCV LEVER(L.H) RCVLEVER(RH)

Pl Pl
'XA1r XB1r" XBU XAll 0 ~BI& j I XAal XBa111 XAb XBb " XAk
XAs&, XBs' Pai.
SOLENOID VALVE
~ ~ pz Pm1
Pm2
p~ Fr
I
dr4
When the L mode is selected on the cluster, max flow cut off solenoid valve actuates automatically.
Thus pilot pressure (Pm1 , 2) is sent to the regulator and pump discharge volume is decreased.
3-11
7. SWING PARKING BRAKE RELEASE
ARM BUCKET
TRAVEL MOTOR CYLINDER CYLINDER BOOM CYLINDER
PL
Pat
'
XMZ
XBa1
SWING MOTOR
~
R2
RCV LEVER(LH) RCV LEVER(RH)

Pz Pl
I
I ~•
I
XAtl' L ~ ...l• XAa1 XBa1tl XAb XBb" XAA XBk
0
' XAtr xa1r" xBtl
Xkl XBs' p.._ _ __,.
Sh ~-~
SOLENOID VALVE
~ Pk P~ Pm1 _,_Pm2
PILOT PUMP
When the swing control lever is tilted, the pilot oil goes to Sh port of shuttle valve, this pressure move
spool so, discharged oil from pilot valve goes to Pg port.
This pressure is applied to swing motor disc, thus the brake is released.
When the swing control lever is set in the neutral position, oil in the motor disc cylinder is drained,
thus the brake is applied.
3 - 12
8. SWING PRIORITY SYSTEM
ARM BUCKET
TRAVEL MOTOR
Pl
PaL Fr T2
,........_.,...,.._..,._, ,_....-+<",____,s_w_1N_G~'~'" so= I
~·
;1t~~~::::::f:=11r;::::~~~-:-t;-=-=~
XAa2!
X8a1
SWING MOTOR
R2
XAd ~
0
'XAtr XBtr " XB11 -B;P3- _J'XAal XBa1 11 XAb XBb "XAk
Sn
XAs XBs' P81.
REDUCING
VALVE
Psp
1
dr4
When carrying out the combined operation of swing and boom or arm of the left control valve, the
swing speed can be lowered than operating speed of boom or arm. To prevent it, reducing valve is
used.
The oil from pilot pump flows into the reducing valve through the line filter.
Psp pressure from reducing valve shifts the swing priority spool to the right and decreases the oil
flow rate to the boom or arm section by orifice.
This is called the swing priority system.
3-13
1. BOOM RAISE OPERATION
ARM BUCKET
P& T1 A Fr T2
SWING MOTOR
Bl
lWI
P2 R2
When the right control lever is pulled back, the boom spools in the main control valve are moved to
the raise position by the pilot oil pressure from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the large
chamber of boom cylinders.
At the same time, the oil from the small chamber of boom cylinders returns to the hydraulic oil tank
through the boom spool in the main control valve. When this happens, the boom goes up.
The excessive pressure in the boom cylinder bottom end circuit is prevented by relief valve.
When the boom is raised and the control lever is returned to neutral position, the circuit for the
holding pressure at the bottom end of the boom cylinder is closed by the boom holding valve.
3-14
2. BOOM DOWN OPERATION
ARM BUCKET
Pm. Tl Fl Fr T2
XBa2
SWING MOTOR
X/U - . J " - - - -
1
I
All
XB11
611
XAll
P2 R2
When the right control lever is pushed forward, the boom spools in the main control valve are moved
to the lower position by the pilot oil pressure from the remote control valve.
The oil frbm the front pump flows into the main control valve and then goes to the small chamber of
boom cylinders. At the same time, the oil from the large chamber of boom cylinders returns to the
hydraulic tank through the boom spool in the main control valve.
When the lowering speed of boom is faster, the oil returned from the large chamber of boom cylinder
combines with the oil from the front pump, and flows into the small chamber of the cylinder.
This prevents cylinder cavitation by the negative pressure when the front pump flow can not match
the boom down speed. And the excessive pressure in the boom cylinder rod end circuit is
prevented by the relief valve.
3 - 15
3. ARM ROLL IN OPERATION
ARM BUCKET
Pai. Tl A Fr T2
XAal 1?,~ - - - J~ -
~I~
ARM HALF SOLENOID VALVE XNiZ 1111 ~
XBa1 - - _, ... - - -
SWING MOTOR
XBb
I1 XNJ
I
I
XAI XBO
I
~
: !><
RI
P2 R2
f " Py
Pc ~ J
FRONT PUMP REAR PUMP
I HYDRAULICTANK
When the left control lever is pulled back the arm spools in the main control valve are moved the to
roll in position by the pilot oil pressure from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the large
chamber of arm cylinder.
At the same time, the oil from small chamber of arm cylinder returns to the hydraulic oil tank through
the arm spool in the main control valve. When this happens, the arm rolls in.
The cavitation which will happen to the bottom of the arm cylinder is also prevented by the make-up
valve in the main control valve.
3-16
4. ARM ROLL OUT OPERATION
ARM BUCKET
Pai. Tl A Fr T2
SWING MOTOR
Bl
XM
,
~!'
Al l - + - -- -
l <>
I~
,-~ FRONT PUMP -1 REAR PUMP
I ¢ 0 I HYDRAULIC TANK
When the left control lever is pushed forward, the arm spool in the main control valve are moved to
the roll out position by the pilot oil pressure from the remote control valve.
The oil from the front & rear pump flows into the main control valve and then goes to the small
chamber of arm cylinder.
At the same time, the oil from the large chamber of arm cylinder returns to the hydraulic oil tank
through the arm spool in the main control valve. When this happens, the arm rolls out.
The cavitation which will happen to the rod of the arm cylinder is also prevented by the make-up
3-17
5. BUCKET ROLL IN OPERATION
ARM BUCKET
Pat.
~~---.-
Tl A
FrT2 -~,11
XAa1
I
XBa2
XAa2
SWING MOTOR
XAb2 _,.,._ __ _
XBb
811
XAll
When the right control lever is pulled left, the bucket spool in the main control valve is moved to the
roll in position by the pilot oil pressure from the remote control valve.
The oil from the front pump flows into the main control valve and then goes to the large chamber of
bucket cylinder.
At the same time, the oil from the small chamber of bucket cylinder returns to the hydraulic oil tank
through the boom spool in the main control valve. When this happens, the bucket rolls in.
The cavitation which will happen to the bottom of the bucket cylinder is also prevented by the make-
up valve in the main control valve.
3- 18
6. BUCKET ROLL OUT OPERATION
ARM BUCKET
PL
Pru. Tl Fl Fr T2
XAal
XBa2
SWING MOTOR
XN>2 · ' " - - -
Bd
XAll XBO
P2 R2
When the right control lever is pushed right, the bucket spool in the main control valve is moved to
the roll out position by the pilot oil pressure from the remote control valve.
The oil from the front pump flows into the main control valve and then goes to the small chamber of
bucket cylinder.
At the same time, the oil from the large chamber of bucket cylinder returns to the hydraulic oil tank
through the bucket spool in the main control valve. When this happens, the bucket rolls out.
The cavitation which will happen to the rod of the bucket cylinder is also prevented by the make-up
3-19
7. SWING OPERATION
ARM BUCKET
Pl
Pai. Fl Fr T2
.
X>al
XBat
SWING MOTOR XAb2 - ~--
Bir
- - ~- XBtr
~
P2 R2
RCV PEDAL RCV LEVER(LH) RCV LEVER(RH)

Pz Pl
0
XAtr XB1r" xsu XAU ~-@]- _J' XAa1 XBa111 XAb XBb " XAk
0
XAsshXBs
SOLENOID VALVE
~ f'!< P,z Pm1_] m2
Pai.-,----::------t__ _~
HYDRAULIC
1TANK
n
When the left control lever is pushed left or right, the swing spool in the main control valve is moved
to the left or right swing position by the pilot oil pressure from the remote control valve.
The oil from the rear pump flows into the main control valve and then goes to the swing motor.
At the same time, the oil returned from the swing motor returns to the hydraulic oil tank through the
swing spool in the main control valve.
When this happens, the superstructure swings to the left or right.
The swing parking brake, make up valve and the overload relief valve are provided in the swing
motors. The cavitation which will happen to the swing motor is also prevented by the make up
valve in the swing motor itself.
3-20
SWING CIRCUIT OPERATION
PARKING BRAKE BRAKE RELEASE VALVE
Sh
Pg
~
dr2- - - - - - - - - - ~ J
MOTOR BRAKE VALVE CitJJJ==={IJ]jJ

~---'r~ -~
I jITJI
: lj ,
<)
- -,1-A-
I ~MAKEUPVALVE
. - irriM-u - B-
TO/FROM CONTROL VALVE
MAKE UP PORT(R1 )
1) MOTOR BREKE 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 oil pressure of the shuttle valve is
transferred to the brake release valve and the brake release valve is change over. Then the pilot
oil pressure lift the brake piston and release the parking brake.
PARKING BRAKE "ON" OPERATION
When the control lever placed in the neutral position, the pressure of the pilot oil passage down.
Then the brake release valve returned to the neutral position and the oil is returned from the brake
piston to the tank. And the brake is set to 'ON".
3-21
8. TRAVEL OPERATION
ARM BUCKET
"
Pk dr3
SWING MOTOR
RCV PEDAL RCV LEVER(LH) ACV LEVER(RH) l:1 Pz P1
I
I~.
I
0
XAtr XB1r" xst1 XAt1 '~ ~ ..J• XAa1 XBa1 1 ' XAb XBb " XAk
XAsSh XBs' p.._
SOLENOID VALVE
XAf'2 ~k P,z Pm1 _,_Pm2
FRONT REAR
PUMP PUMP
dr4
When the travel levers are pushed forward or reverse position, the travel spools in the main control
valve are moved to the forward or reverse travel position by the pilot oil pressure from the remote
control valve.
The oil from the both pumps flows into the main control valve and then goes to the both travel motors
through the turning joint.
The oil returned from both travel motors returns to the hydraulic oil tank through the turning joint and
the travel spools in the main control valve.
When this happens, the machine moves to the forward or reverse.
3-22
TRAVEL CIRCUIT OPERATION
OVERLOAD RELIEF VALVE
CHECK VALVE COUNTER BALANCE VALVE
TURNING JOINT
TO/FROM CONTROL VALVE
Brake valves are provided on travel motors to offer the following functions.
1) CHECK VALVE
This valve assists the counterbalance valve operation and prevent the cavitation of the motor.
2) COUNTER BALANCE VALVE
This valve prevents the motor from overrunning on the slope and blocks the circuits when stopping.
3) OVERLOAD RELIEF VALVE
Relief valve limits the circuit pressure below 350kgf/cm 2 to prevent overload of the motor.
3-23
GROUP 5 COMBINED OPERATION
1. OUTLINE
ARM BUCKET
PL
Pru. Fl Fr T2
XAal
I
~ XBa2
SWING MOTOR
XAs -~~---
1
XBb
I
Ad
XBI
Bl
XAd
~ Pz P1 •.•, Py
Pc ¢
The oil from the front and rear pump flows through the neutral oil passage, bypass oil passage and
confluence oil passage in the main control valve. Then the oil goes to each actuator and operates
them. Check valves and orifices are located on these oil passage in the main control valve.
These control the oil from the main pumps so as to correspond to the operation of each actuator and
smooth the combined operation.
PILOT VALVE FOR STRAIGHT TRAVEL
This pilot valve for straight travel is provided in the main control valve.
If any actuator is operated when traveling, the spool of pilot valve is pushed to the downward by the
pilot oil pressure from the pilot pump. At the same time, the straight travel spool is pushed to the left
by the oil through the pilot valve for straight travel.
Consequently, the left and right travel oil supply passage are connected, and equivalent amount of
oil flows into the left and right travel motors. This keeps the straight travel.
3-24
2. COMBINED SWING & BOOM OPERATION
ARM BUCKET
Pat T1 A Fr T2
SWING MOTOR
XM - J
I
I
AH
XBll
811
XAH J
FRONT PUMP l REAR PUMP
When the swing and boom functions are operated, simultaneously the swing spool and boom spools
in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve.
The oil from the rear pump flows into the swing motor through swing spool and the boom cylinder
through boom 2 spool.
The oil from the front pump flows into the boom cylinders through the boom 1 spool in the right
control valve.
The superstructure swings and the boom is operated.
3 -25
3. COMBINED SWING & ARM OPERATION
ARM BUCKET
Pa T1 A Fr T2
XAa1
" XBl2
SWING MOTOR
XBb
X80
.@
: .!'.'
R11 - + - - - -
l REAR PUMP
When the swing and ann functions are operated, simultaneously the swing spool and ann spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve.
The oil from the rear pump flows into the swing motor through swing spool and the ann cylinder
through ann 1 spool.
The oil from the front pump flows into the ann cylinder through the ann 2 spool of the right control
valve.
The superstructure swings and the ann is operated.
3-26
4. COMBINED SWING & BUCKET OPERATION
ARM BUCKET
Pa1. Tl Fl Fr T2
XBa2
SWING MOTOR
XBb
R2
FRONT PUMP I REARPUMP
When the swing and bucket functions are operated, simultaneously the swing spool and bucket
spool in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve.
The oil from the rear pump flows into the swing motor through the swing spool in the left control
valve.
The oil from the front pump flows into the bucket cylinder through the bucket spool in the right control
valve.
3-27
5. COMBINED SWING, BOOM, ARM & BUCKET OPERATION
ARM BUCKET
l
Pat
SWING MOTOR XBa1 - -
XBb
XBO
l=_t Pz Pl . .@Py
Pc ,
When the swing, boom, arm and bucket functions are operated, simultaneously each spool in the
main control valve is moved to the functional position by the pilot oil pressure from the remote control
valve.
The oil from the rear pump flows into the swing motor, boom cylinders and arm cylinder through the
swing spool, boom 2 spool, arm 1 spool, and the parallel and confluence oil passage in the left
control valve. The oil from the front pump flows into the boom cylinders, arm cylinder and bucket
cylinder through the boom 1 spool, arm 2 spool, bucket spool and the parallel and confluence oil
passage in the right control valve.
The superstructure swings and the boom, arm and bucket are operated.
3-28
6. COMBINED SWING & TRAVEL OPERATION
ARM BUCKET
Pa. T1 A Fr T2
SWING MOTOR
0 XAb2 •'c __ _
{ P1
J I
FRONT PUMP
When the swing and travel functions are operated, simultaneously the swing spool and travel spools
in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve and the spool of pilot valve for straight travel is pushed to the downward by the
pilot oil pressure from the pilot pump.
At the same time, the straight travel spool is pushed to the left by the oil through the pilot valve for
straight travel.
The oil from the rear pump flows into the swing motor through the swing spool. The oil from the
front pump flows into the travel motor through the RH travel spool of the right control valve and the
LH travel spool of the left control valve via the straight travel spool.
3 -29
7. COMBINED BOOM &TRAVEL OPERATION
ARM BUCKET
SWING MOTOR
-@
: .!'.>
Rl f - - + - -- - -
J I
When the boom and travel functions are operated, simultaneously the boom spools and travel
spools in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve and the spool of pilot valve is pushed to the downward by the pilot oil pressure
from the pilot pump. At the same time, the straight travel spool is pushed to the left by the oil
through the pilot valve for straight travel. The oil from the rear pump flows into the boom cylinders
through the boom 2 spool and boom 1 spool via the parallel and confluence oil passage. The oil
from the front pump flows into the travel motors through the RH travel spool of the right control valve
and the LH travel spool of the left control valve via the straight travel spool.
3 - 30
8. COMBINED ARM & TRAVEL OPERATION
ARM BUCKET
0 0
l'
SWING MOTOR
When the arm and travel functions are operated, simultaneously the arm spools and travel spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve and the spool of pilot valve is pushed to the downward by the pilot oil pressure from the
pilot pump. At the same time, the straight travel spool is pushed to the left by the oil through the pilot
valve for straight travel. The oil from the rear pump flows into the arm cylinders through the arm 1
spool and arm 2 spool via the parallel and confluence oil passage. The oil from the front pump
flows into the travel motors through the RH travel spool of the right control valve and the LH travel
spool of the left control valve via the straight travel spool.
The arm is operated and the machine travels straight.
3- 31
9. COMBINED BUCKET & TRAVEL OPERATION
ARM BUCKET
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When the bucket and travel functions are operated, simultaneously the bucket spool and travel
spools in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve, and the spool of pilot valve is pushed to the downward by the pilot oil pressure
from the pilot pump. At the same time, the straight travel. spool is pushed to the left by the oil
through the pilot valve for straight travel. The oil from the rear pump flows into the bucket cylinder
through the bucket spool via the confluence oil passage. The oil from the front pump flows into the
travel motors through the RH travel spool of the right control valve and the LH travel spool of the left
control valve via the straight travel spool of the control valve.
The arm is operated and the machine travels straight.
3-32
SECTION 4 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
12
13
14
1 15
2 16
17
18
19
20
21
22
23
24
25
26
27
3 28
7
8
9
10
11
1 Horn switch 10 Prolix switch 20 Breaker switch

2 Cluster 11 Relay board 21 Overload switch
3 Safety lever 12 Washer switch 22 Overload warning lamp switch
4 Fuse box 13 Wiper switch 23 Beacon switch
5 Aircon & heater switch 14 Head lamp switch 24 Cassette & Radio
6 Speaker 15 Work switch 25 Swing speed switch
7 CPU controller 16 Cab lamp switch 26 Service meter
8 Resistor 17 Travel alarm switch 27 Cigar lighter
9 Emergency engine 18 Cold start switch 28 Starting switch
acceleration lever 19 Arm half flow switch
4-1
2. LOCATION 2
7
1 8
2 9
3 10
11
12
4 13
14
6
16
1 Fuel sender 7 Alternator 12 Start relay

2 Connector plate 8 Water temp sender 13 Air cleaner switch
3 Battery relay 9 Heater valve 14 Engine oil pressure switch
4 Fuel filler pump 10 Heater adapter 15 Overheat switch
5 Battery 11 Hyd temp sender 16 Governor motor
6 Lamp
4-2
GROUP 2 ELECTRICAL CIRCUIT
wt°
FUEL Pl.IMP
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4-3
R210LC-3 (#0227 ~ #0549)
NEW AIRCONDITIONER SYSTEM
R210LC-3 (#0550~)
WATER PROOF CONNECTION SYSTEM
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 Start switch
ŭCS-2(1)Ů
I/connŭCN-40(1)Ů
Fuse boxŭNo.19Ů I/connŭCN-38(8)Ů I/connŭCN-6(4)Ů Room lampŭCL-1(2)Ů
Fuse boxŭNo.18Ů I/connŭCN-38(7)Ů I/connŭCN-8(6)Ů ClusterŭCN-57(6)Ů
CPU controllerŭCN-50(10)Ů
Fuse boxŭNo.17Ů I/connŭCN-38(6)Ů Cassette radioŭCN-27(7)Ů
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 2 EA) 20 ~ 25V
‫ ڻ‬- GND (Fusible link ) 20 ~ 25V
Ɠ GND : Ground
4-4
POWER CIRCUIT
4-5
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Battery relay(M8, B+ terminal) Fusible linkŭCN-60(1)Ů
I/connŭCN-5(1)Ů Start switchŭCS-2(1)Ů
Ɠ Start switch : ON
Start switch ONŭCS-2(2)Ů I/connŭCN-4(2)Ů Battery relayŭM4 terminalŮ
Battery relay operating(All power is supplied with the electric component)
Start switch ONŭCS-2(3)Ů I/connŭCN-38(1)Ů
Fuse box(No. 13)
Fuse box(No. 14)
Fuse box(No. 15) I/connŭCN-38(4)Ů I/connŭCN-1(10)Ů
Fuel cut-offŭCN-79Ů
Ɠ Start switch : START

Start switch STARTŭCS-2(5)Ů I/connŭCN-1(1)Ů Start relayŭCR-23(1)Ů
2) CHECK POINT
‫ ڸ‬- GND (Battery)

‫ ڹ‬- GND (Start key)
‫ ں‬- GND (Battery relay M4)
Operating Start ‫ ڻ‬- GND (Start B+) 20 ~ 25V
‫ ڼ‬- GND (Start M)
‫ ڽ‬- GND (Start relay)
‫ ھ‬- GND (Battery relay M8)
Ɠ GND : Ground
4-6
STARTING CIRCUIT
4-7
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(1,2)Ů
I/connŭCN-5(1,2)Ů I/connŭCN-40(1,2)Ů Fuse Box
2) CHECK POINT
‫ 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
4-8
CHARGING CIRCUIT
4-9
4. HEAD LAMP CIRCUIT
1) OPERATING FLOW
Fuse box (No.8) I/connŭCN-37(1)Ů Head lamp switchŭCS-39(6)Ů
Head lamp relayŭCR-13(4)Ů
Ɠ When lamp switch ON
Head lamp switch ONŭCS-39(2)Ů Head lamp relayŭCR-13(3) ơ (1)Ů Ground
ŭCR-13(4) ơ (2)Ů
Head lamp switch lamp ONŭCS-39(9)Ů
Head lamp ONŭCL-3(2)Ů
I/connŭCN-4(7)Ů Head lamp ONŭCL-4(2)Ů
I/connŭCN-7(9)Ů Cluster head lampŭCN-56(9)Ů
2) CHECK POINT
Engine Key switch Check point Voltage
‫ ڸ‬- GND (Fuse box)

‫ ڹ‬- GND (Switch power input)
‫ ں‬- GND (Switch power output)
STOP ON ‫ ڻ‬- GND (Relay input) 20 ~ 25V
‫ ڼ‬- GND (Relay coil)
‫ ڽ‬- GND (Relay output)
‫ ھ‬- GND (Head lamp)
Ɠ GND : Ground
4 - 10
HEAD LAMP CIRCUIT
4 - 11
5. WORK LAMP CIRCUIT
1) OPERATING FLOW
Fuse box (No.9) I/connŭCN-37(2)Ů Work lamp switchŭCS-36(6)Ů
Work lamp relayŭCR-3(4)Ů
Ɠ When work lamp switch ON
Work lamp switch ONŭCS-36(2)Ů Work lamp relayŭCR-3(3) ơ (1)Ů Ground
ŭCR-3(4) ơ (2)Ů
Work lamp switch lamp ONŭCS-36(9)Ů
I/connŭCN-7(10)Ů Cluster work lamp ONŭCN-56(10)Ů
I/connŭCN-4(4)Ů I/connŭCN-10(2)Ů Work lamp ONŭCL-5(2), CL-6(2)Ů
2) CHECK POINT

‫ ھ‬- GND (Work lamp)
Ɠ GND : Ground
4 - 12
WORK LAMP CIRCUIT
4 - 13
6. CAB LAMP CIRCUIT
1) OPERATING FLOW
Fuse box (No.10) I/connŭCN-37(3)Ů Cab lamp relayŭCR-9(4)Ů
Cab lamp switchŭCS-24(6)Ů
Ɠ When Lamp switch ON
Lamp switch ONŭCS-24(2)Ů Cab lamp relayŭCR-9(3) ơ (1)Ů Ground
ŭCR-9(4) ơ (2)Ů
Cab lamp switch lamp ONŭCS-24(9)Ů
I/connŭCN-6(5)Ů I/connŭCN-14(4)Ů
Cab lamp ONŭCL-8(rear), CL-10(RH), CL-9(LH)Ů
2) CHECK POINT

‫ ھ‬- GND (Cab lamp)
Ɠ GND : Ground
4 - 14
CAB LAMP CIRCUIT
4 - 15
7. WIPER MOTOR CIRCUIT
1) OPERATING FLOW
(1) Wiper motor switch ON
Fuse box (No.1) I/connŭCN-36(6)Ů Wiper motor relayŭCR-4(2) ‫( ؖ‬6)Ů
Wiper switchŭCS-3(6) ‫( ؖ‬2)Ů Ground
Wiper motor relayŭCR-4(4) ‫( ؖ‬1)Ů

I/connŭCN-6(1)Ů I/connŭCN-13(1)Ů
I/connŭCN-21(1)Ů Wiper motor operating
(2) Auto - parking (When switch OFF)

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

‫ ڹ‬- GND (Switch input)
‫ ں‬- GND (Relay)
‫ ڻ‬- GND (Relay coil)
‫ ڼ‬- GND (Relay input)
OFF ON 20 ~ 25V
‫ ڽ‬- GND (Relay)
‫ ھ‬- GND (Wiper power input)
‫ ڿ‬- GND (Wiper power input)
‫ ۀ‬- GND (Wiper motor)
‫ ہ‬- GND (Switch output)
Ɠ GND : Ground
4 - 16
WIPER MOTOR CIRCUIT
4 - 17
CONTROLLER CIRCUIT
4 - 18
ELECTRIC CIRCUIT FOR HYDRAULIC
TRAVEL ALARM S W ARM HALF CONTROL

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CPU CONTROLLER
4-19
MONITORING CIRCUIT
CLUSTER
SIG.GND. 120 120
PONER GND. 110 110
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CPU CONTROLLER
4-20
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 lamp Work lamp
Head lamp Air cleaner warning lamp
Air cleaner switch Coolant overheat warning lamp
Coolant overheat sender Hydraulic oil temp warning lamp
Monitor
Hydraulic oil temp. sender Coolant level lamp
Coolant level sender Fuel gauge
Fuel sender Fuel low level lamp
Coolant temp. sender Coolant temperature gauge
Warming up signal Warming up lamp
Switch Mode selection signal 1

şMode selection switch Mode selection signal 2
Mode selection lamp 1 şAuto decel selection switch Travel speed signal
Mode selection lamp 2 şTravel speed switch Auto decel selection signal
Engine speedųupŴsignal
Engine speedųdownŴsignal
Battery(B+) Signal ground

Battery relay Power ground
4 - 21
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
Work lamp
warning 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
Select switch
TRAVEL SPEED ENGINE SPEED
Automatic
Buzzer stop
deceleration
switch
switch
Travel speed Engine speed
switch control switch
4 - 22
1) CLUSTER CHECK PROCEDURE
(1) Start key : ON
‫ ڸ‬Check monitor initial 3 seconds
a. All lamps light up.
b. Buzzer sound.
‫ ڹ‬Check monitor after 3 seconds : indicate machine condition

a. Tachometer : 0 rpm
b. Fuel gauge : All light up below appropriate level
c. Engine coolant temperature gauge : All light up below appropriate level
d. Warning lamp
Ɠ In case the engine oil pressure lamp and battery charging lamp light on, but it is not abnormal.
Ɠ When engine coolant temperature below 30Ş C, the warming up lamp lights up.
‫ ں‬Switch portion
a. Mode selection : S mode
b. Auto decel LED : ON
c. Travel speed switch : Low(turtle)
(2) Start of engine

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

a. Warming up lamp : ON
b. 3 seconds after engine started, engine speed increases to 1250 rpm (Auto decel LED : ON)
Ɠ Others same as above ‫ڸ‬
‫ ں‬When abnormal condition

a. The lamp lights up and the buzzer sounds.
4 - 23
3. CLUSTER CONNECTOR
1) CN-57 CONNECTOR
No. Signal Input/ CN-57

output
1 Engine speedų downŴ output 6 5 4 3 2 1
2 Engine speedųupŴ output
12 11 10 9 8 7
3 Water temperature sender input
4 Fuel sender input
5 Battery relay power -
6 Battery power(continue) -
7 Travel high/low switch output
8 Mode switch 2 output
9 Mode switch 1 output
10 Tachometer input
11 Power ground -
12 Signal ground -
2) CN-56 CONNECTOR
Input/
No. Signal
output
1 Mode lamp 1 input
2 Mode lamp 2 input
3 Swing lock switch -
4 Pre heater lamp -
5 Engine oil filter switch -
6 Water level switch input
Cluster
7 Charge warning lamp input
8 Auto decel switch output
9 Head lamp input
10 Work lamp input
11 One touch decel switch -
12 Hyd. oil temperature lamp input CN-56
13 Engine oil press switch input
8 7 6 5 4 3 2 1
14 Air cleaner switch input
15 Overheat switch input 16 15 14 13 12 11 10 9
16 Warming up lamp output
4 - 24
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
şWarning lamp display : Approximately 30ֻ
C F
şSegment A : Approximately 50ֻ
B şSegment B : Approximately 100ֻ
Red şSegment C : Approximately 150ֻ
A E şSegment D : Approximately 200ֻ
şSegment E : Approximately 250ֻ
şSegment F : Approximately 300ֻ
şQuantity of fuel tank : Approximately 300ֻ.
4) ENGINE COOLANT TEMPERATURE GAUGE

Green D E ‫ ڸ‬This gauge indicates the temperature of coolant.
F
şSegment A : Approximately 40~60 Ɓ C (White)
C G
Red şSegment B : Approximately 60~67 Ɓ C (Green)
B H şSegment C : Approximately 67~74 Ɓ C (Green)
şSegment D : Approximately 74~81 Ɓ C (Green)
A
C H HI şSegment E : Approximately 81~88 Ɓ C (Green)
White
şSegment F : Approximately 88~95 Ɓ C (Green)
şSegment G : Approximately 95~102 Ɓ C (Green)
şSegment H : Approximately 102~110 Ɓ C (Red)
şSegment I : Approximately 110~ (Red)
4 - 25
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, but it is turned OFF after
starting the engine. Check the battery charging circuit when this
lamp comes ON.
7) WORK LAMP INDICATOR LAMP

‫ ڸ‬When the work lamp switch is turned ON, the work lamp mounted
on boom and the work lamp indicator lamp light ON.
8) HYDRAULIC OIL OVERHEAT WARNING LAMP

‫ ڸ‬This warning lamp operates and the buzzer sounds when the
temperature of hydraulic oil is over 105Ƅ.
‫ ڹ‬Check the coolant when the lamp is turned ON.
9) ENGINE OIL PRESSURE WARNING LAMP

‫ ڸ‬This lamp is turned ON before starting the engine but turned OFF
after starting the engine as the pressure caused from the engine oil
pump lubricates each part.
4 - 26
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(110ƁC)and lose the cooling function.
‫ ڹ‬Check the coolant when the lamp is ON.
12) WARMING UP LAMP

‫ ڸ‬This lamp is turned ON when the coolant temperature is below
30Ƅ.
‫ ڹ‬The automatic warming up is canceled when the engine coolant
temperature is above 30Ɓ
C, 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 şH : This is used for heavy-duty work.
H S L F şS : This is used for ordinary work.
şL : This is used for light-duty work.
şF : 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 - 27
15) ENGINE SPEED CONTROL SWITCH
‫ ڸ‬This switch is to control the engine speed, which is increased by
ENGINE SPEED pressing switch and decreased the engine speed by pressing
switch.
16) SELECTION SWITCH(tachometer and clock)

‫ ڸ‬This switch is used to select the tachometer or clock.
SELECT ‫ ڹ‬When this switch is pressed, each function is selected by turns.
‫ ں‬When this 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) FUEL LOW LEVEL LAMP

‫ ڸ‬This lamp lights on when fuel level is below 30ֻ.
‫ ڹ‬In that case, replenish oil.
18) TRAVEL SPEED SWITCH

‫ ڸ‬This switch controls the travel speed.
‫ ڹ‬When you press the switch once, travel speed is change over high
TRAVEL SPEED
speed(rabbit mark), and press once more, travel speed is changed
over low speed(turtle mark).
19) BUZZER STOP SWITCH

‫ ڸ‬This buzzer sound is stopped by touching this buzzer stop switch.
‫ ڹ‬This sound is continuous sound which comes out when a warning
indicator lamp on the cluster lights up.
M
4 - 28
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check
Ɠ Check specific gravity

12V ź 160Ah 1.280 over : over charged
Battery
(2EA) 1.280 ~ 1.250 : normal
1.250 below : recharging
Rated load 9 Ɠ Check coil resist (M4 to M4)

24V Normal : about 50ѻ
Battery relay Ɠ Check contact
100A(continuity)
1000A(30seconds) Normal : ſѻ
CR-1
Ɠ Check disconnection
Normal : about 0ѻ
Fusible link 60A (connect ring terminal and
check resist between terminal
CN-60 1 and 2)
Ɠ Check contact
CS-2
OFF : ſѻ(for each terminal)

24V 40A ON : 0ѻ(for terminal 1-3
Start key
and 1-2)
START : 0ѻ(for terminal 1-5)
Pressure switch Ɠ Check contact

3 ~ 6kg/cm2
(for travel alarm) Normal : ſ(OPEN)
(N. O TYPE)
CD-11~CD-14
CD-24, CD-34~CD-36
Pressure switch 0.5 kg/cm2 Ɠ Check resist

(for engine oil) (N. C TYPE) Normal 90ѻ(CLOSE)
CD-18
4 - 29
Ɠ Check resist
Coolant 50ŞC : 153.9ѻ
temperature , 80ŞC : 51.9ѻ
sensor 100ŞC: 27.4ѻ
CD-8
Coolant Ɠ Check resist

overheat sensor 24V 0.5A Normal 9ſѻ
105ŞCover 90ѻ
CD-9
Air cleaner Pressure:635mm Ɠ Check contact

pressure switch H2O Normal 9ſѻ
(N.O TYPE)
CD-10
Coolant level Ɠ Check contact

sensor 24V 0.5A High level : ſѻ
Low level : 0ѻ
CD-16
Ɠ Check resist
Full : 3ѻ
2 5/6 : 25ѻ
Fuel sender 4/6 : 35ѻ
, 3/6 : 68ѻ
1
2/6 : 95ѻ
1/6 : 110ѻ
CD-2
CD-2 Empty warning :180ѻ
Ɠ Check contact
Tacho sensor , Normal 9Max 0 ~ 3A
CD-17
CD-17
4 - 30
Ɠ Check resist
Normal - About 200ѻ
Relay 24V 20A (for terminal 1-3)
- ſѻ
(for terminal 2-4)
CR-2, CR-3, CR-7,
CR-9, CR-13
Ɠ Check resist
Normal - About 160ѻ
(for terminal 2-6)
Relay 24V 16A - 0ѻ
(for terminal 1-3)
- ſѻ
(for terminal 1-4)
Ɠ Check resist
Normal - About 5‫ױ‬
Potentiometer , (for terminal 1-3)
- 0.6‫~ױ‬5‫ױ‬
(for terminal 2-3)
CN-77
Ɠ Check resist
Normal - 5~6ѻ
Governor motor , (for terminal 1-2)
- 5~6ѻ
(for terminal 3-4)
CN-76
Ɠ Check resist
Solenoid valve 24V 1A Normal - 15~25ѻ
(for terminal 1-2)
CN-66, CN-68, CN-70,
CN-87, CN-88, CN-89
Ɠ Check resist
EPPR valve 700mA Normal - 18~25ѻ
(for terminal 1-2)
CN-75
4 - 31
Ɠ Check resist
Resistor 90ѻ 20WŹ5$
Normal - 50ѻ
CN-47
Speaker Ɠ Check resist

4ѻ 20W
Normal - 50ѻ
CN-23(LH)
CN-24(RH)
Ɠ Check contact
Normal
Switch ON - 0ѻ (for terminal 1-5,2-6)
24V 8A
(Looking type) - ſѻ (for terminal 5-7,6-8)
OFF - ſѻ (for terminal 1-5,2-6)
- 0ѻ (for terminal 5-7,6-8)
Ɠ Check contact
Normal
Switch ON - 0ѻ (for terminal 1-5,2-6)
24V 8A
(Non-looking type) - ſѻ (for terminal 5-7,6-8)
OFF - ſѻ (for terminal 1-5,2-6)
- 0ѻ (for terminal 5-7,6-8)
24V 70W Ɠ Check disconnection

Head lamp
(H3 TYPE) Normal : 1.2 ѻ
CL-3, CL-4
Work lamp 24V 70W Normal : 1.2ѻ
(H3 TYPE)
CL-5, CL-6
4 - 32
24V 10W Ɠ Check disconnection

Room lamp
Normal : a few ѻ
CL-1
Ɠ Check operation
şSupply power(24V) to
Fuel filler pump 24V 10A terminal 1 pin
35 ֻ/min şConnect ring terminal with
ground and switch turn ON.
CN-61
Ɠ Check operation
şSupply power(24V) to
Hour meter , terminal NO. 2 and connect
terminal NO. 1 and ground.
CN-48
Ɠ Check operation
DC 22.0 ~ 28.0V şSupply power(24V) to each
Horn
2A terminal and connect ground.
CN-20, CN-25
Ɠ Check contact
Normal - 0ѻ (for terminal 1-2)
- ſѻ (for terminal 1-3)
Safety switch 24V 15A Operating - ſѻ
(N.C TYPE) (for terminal 1-2)
- 0ѻ
CS-4 (for terminal 1-3)
Ɠ Check resist
Fuel cut-off 24V 25W Normal - 15 ~ 25ѻ
CN-79
4 - 33
Ɠ Check contact
Overload
Normal - 4.14ѻ (for terminal 1-2)
sensor
- 0ѻ (for terminal 1-3)
- 0ѻ (for terminal 2-3)
CD-37
Auto idle 10bar Ɠ Check contact

pressure switch (N.C type) Normal - 0.1ѻ
CD-6, CD-7
Ɠ Check resist
50ŞC : 153.9ѻ
Hydraulic
, 80ŞC : 51.9ѻ
temperature
100ŞC : 27.4ѻ
CD-1 120ŞC : 16.1ѻ
Cab lamp 24V 60W
Normal : 2.2 ѻ
CL-8 ~ CL-10
Beacon lamp 24V 70W
Normal : 1.1 ѻ
CL-7
Power boost Ɠ Check contact

24V 6A
switch Normal : 15Mѻ
CS-29
4 - 34
Air conditioner 24V Ɠ Check contact

switch Intake switch : 2.97ѻ
CN-32
Ɠ Check contact
1st stage(Low) : 0.2ѻ
24V
Blower 2nd stage(ML) : 0.4ѻ
3rd stage(MH) : 0.3ѻ
4th stage(High) : 0.2ѻ
CN-31
24V 6A Ɠ Check contact

Horn switch
Normal : 15 Mѻ
CS-5
24V 15A Ɠ Check contact

Ether Normal : 1.1 ѻ
CN-78
24V 0.3A Ɠ Check contact

Buzzer Normal : 4.65ѻ (for terminal 2-3)
CN-26
24V 3.8A Ɠ Check contact

Washer tank Normal : 10.7 ѻ(for terminal 1-2)
CN-22
4 - 35
Ɠ Check contact
Pedal switch 24V 15A
Normal ON : 0ѻ(for terminal )
CS-26
Ɠ Check coil resist

Normal : about 1Mѻ
Cigar lighter 24V 5A 1.4W Ɠ Check contact
Normal : ſѻ
Operating time : 5 ~15sec
CL-2
Overload lamp 24V 3A
Normal : a few ѻ
CL-23
Ɠ Check contact
Swing speed Normal : 5.08ѻ (for terminal 1-3)
control switch 0 ѻ~ 5kѻ
3.68ѻ (for terminal 2-3)
5.08ѻ (for terminal 1-2)
CS-51
Ɠ Check resist
Door switch 24V 20W Normal : about 5Mѻ
CS-1
Ɠ Check contact
Normal : 10.5 ѻ(for terminal 1-2)
Washer spray
Wiper motor 24V 2A : 0.2 ѻ(for terminal 1-4)
Wiper operating
: 24V(for terminal 1-4)
CN-21 : 0V(for terminal 2-GND)
4 - 36
Ɠ Check contact
Power ON : 15W +15W,4ѻ +4ѻ
Cassette radio 24V 2A (for terminal 1-6, 4-8)
24 ~ 27V(for terminal
7-GND, 2-GND)
CN-27
Receiver Ɠ Check contact

drier 24V 2.5A
Normal : 0ѻ
CN-29
Ɠ Check contact
Start relay 24V 300A
Normal : 0.94ѻ (for terminal 1-2)
CR-23
DELCO REMY Ɠ Check contact

Starter
28MT 24V Normal : 0.1ѻ
CN-45
Ɠ Check contact
Alternator 24V 60A Normal : 0ѻ (for terminal B+ - ѓ)
Normal : 24 ~ 27.5V
CN-74
Ɠ Check contact
Travel alarm 24V 0.5A
Normal : 5.2 ѻ
CN-65
4 - 37
Swing Ɠ Check contact

700mA
Eppr valve Normal : 700mA (for terminal 1-2)
CN-124
Ɠ Check contact
Compressor 24V 79W
Normal : 13.4ѻ
CN-28
Ɠ Check contact
Normal : 0.2ѻ (for terminal 1-2)
24V ~ 150V Emergency
Prolix switch 15A : 1.2ѻ (for terminal 2-3)
: 5.2ѻ (for terminal 2-6)
: 0ѻ (for terminal 5-6)
CS-7
4 - 38
GROUP 5 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-1 SWP 14 I/conn(Engine harness-main harness) S814-014000 S814-114000
CN-2 SWP 12 I/conn(Engine harness-main harness) S814-012000 S814-112000
CN-3 SWP 8 I/conn(solenoid harness-main harness) S814-008000 S814-108000
CN-4 SWP 12 I/conn(R.H harness-main harness) S814-012000 S814-112000
CN-5 370FASTON 2 I/conn(R.H harness-main harness) S813-030200 S813-130200
CN-6 SWP 8 I/conn(Cabin harness-main harness) S814-008000 S814-108000
CN-10 BS 2 I/conn(Boom harness-main harness) MG610574-4 MG640188-4
CN-11 SWP 1 I/conn S814-001000 S814-101000
CN-13 CN 4 I/conn(Wiper harness-cabin harness) S810-004202 S810-104202
CN-14 CN 4 I/conn(Cabin harness-wiper harness) S810-004204 -
CN-20 MARK-є 1 Horn S819-010122 -
CN-21 CN 4 Wiper motor S810-004202 -
CN-22 CN 2 Washer tank S810-002202 -
CN-23 AMP 2 Speaker (LH) S819-020222 S819-120222
CN-24 AMP 2 Speaker (RH) S819-020222 S819-120222
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 CN 2 Compressor S810-001202 -
CN-29 AMP 2 R/dryer S812-002001 -
CN-30 CN 5 Fan speed switch S810-005202 -
CN-31 CN 4 Blower S810-004202 -
CN-32 PA 3 Air-con switch S811-003001 -
CN-36 SWP 12 Fuse box S814-012000 -
CN-37 AMP 3 Fuse box S810-003202 -
CN-38 SWP 8 Fuse box S814-008000 -
CN-40 58-L 2 Fuse box S813-030200 -
CN-45 RING-TERM - Start motor B+ S820-310000 -
CN-47 CN 2 Resistor S810-002202 -
CN-48 CN 2 Hour motor S810-002202 -
CN-50 AMP 10 CPU & controller S811-010002 S815-152000
CN-56 ML 16 Cluster AMP,174046-2 -
4 - 39
Type Destination
CN-57 ML 12 Cluster AMP,174046-2 -
CN-60 58-L 2 Fusible link S813-030200 S813-130200
CN-61 KET 1 Fuel filler pump S822-015000 S822-115001
CN-65 KET 1 Travel alarm buzzer S822-014000 S822-114001
CN-66 KET 2 Breaker solenoid S814-002000 S814-102000
CN-68 KET 2 Safety solenoid S814-002000 S814-102000
CN-70 KET 2 Travel solenoid S814-002000 S814-102000
CN-74 RING-TERM - Alternator "I" term S820-106000 -
CN-75 AMP 2 EPPR valve 174354-2 174352-2
CN-76 58-X 4 Governor motor S813-060400 S813-160400
CN-77 58-X 3 Potentiometer S813-060300 S813-160300
CN-78 KET 1 Ether S822-014000 S822-114001
CN-79 RING-TERM 1 Fuel cut-off solenoid S820-105000 -
CN-86 SWP 2 Swing lock solenoid S814-002000 S814-102000
CN-87 SWP 2 Max flow solenoid S814-002000 S814-102000
CN-88 SWP 2 Power boost solenoid S814-002000 S814-102000
CN-89 SWP 2 Arm half solenoid S814-002000 S814-102000
CN-99 SWP 3 Buzzer S814-003000 S814-103000
CN-124 AMP 2 Swing EPPR valve 174354-2 174352-2
CN-126 SWP 2 Electric socket S814-002000 S814-102000
ňRelay
CR-1 RING-TERM - Battery relay S820-104000 -
CR-2 CN 4 Horn relay S810-004202 -
CR-3 CN 4 Work lamp relay S810-004202 -
CR-4 CN 5 Wiper relay S810-005202 -
CR-7 CN 4 Air-con relay S810-004202 -
CR-9 CN 4 Cabin lamp relay S810-004202 -
CR-13 CN 4 Head lamp relay S810-004202 -
CR-23 CN 2 Start relay S816-002003 -
ňSwitch
CS-1 KET 1 Door switch S810-014000 -
CS-2 SWP 6 Start switch S814-006000 -
CS-3 SWF 10 Wiper switch SWF,593757 -
CS-4 CN 3 Safety switch S810-003202 -
CS-5 KET 1 Horn switch S822-014000 S822-114000
CS-7 CN 6 Prolix switch S810-006202 -
CS-16 SWF 10 Travel alarm switch SWF,593757 -
CS-21 SWF 10 Lamp switch SWF,593757 -
CS-22 SWF 10 Ether switch SWF,593757 -
CS-23 SWF 10 Beacon lamp switch SWF,593757 -
CS-24 SWF 10 Cabin lamp switch SWF,593757 -
4 - 40
Type Destination
CS-26 KET 1 Pedal switch S822-014000 S822-014000
CS-27 SWF 10 Breaker switch SWF,593757 -
CS-29 KET 1 Power boost switch S822-014000 S822-014000
CS-30 SWF 10 Washer switch SWF,593757 -
CS-36 SWF 10 Work lamp switch SWF,593757 -
CS-39 SWF 10 Head lamp switch SWF,593757 -
CS-50 SWF 10 Arm half switch SWF,593757 -
CS-51 SWP 3 Swing speed control switch S814-003000 -
CS-53 SWF 10 Overload switch SWF,593757 -
ňLight
CL-1 CN 2 Room lamp YAZAKI,7123-8326 -
CL-2 KET 1 Cigar lighter S822-014004 S822-114004
CL-3, 4 SWP 2 Head lamp S814-002000 S814-102000
CL-5, 6 SWP 2 Work lamp S814-002000 S814-102000
CL-7 AMP 1 Beacon lamp S822-014000 S822-114000
CL-8 KET 1 Cabin lamp (rear) S822-014000 S822-114000
CL-9 KET 1 Cabin lamp (LH) S822-014000 S822-114000
CL-10 KET 1 Cabin lamp (RH) S822-014000 S822-114000
CL-23 SWF 2 Overload lamp SWF,913328 -
ňSensor,sendor
CD-1 AMP 1 Hydraulic oil temp sender AMP1-150656 -
CD-2 CN 2 Fuel sender KET,MG 610320 -
CD-6 AMP 1 Auto idle press switch S819-010122
CD-7 AMP 1 Auto idle press switch S819-010122
CD-8 MARK-є 1 Water temp sender S819-010122 -
CD-9 KET 1 Overheat sender S822-014000 -
CD-10 KET 1 Air cleaner switch S822-014000 S822-114000
CD-11 KET 1 Travel alarm press switch S822-014000 -
CD-16 CN 2 Water level sender S810-002202 -
CD-17 TWP 2 Tachosensor - S818-120221
CD-18 CN 1 Engine oil press switch S810-001202 -
CD-37 SWP 2 Overload sender S814-002000 S814-102000
4 - 41
-
2. CONNECTION TABLE FOR CONNECTORS
1) 5&-l. TYPE COtflECTOR
No. of Recep tacle connector(Female) Plug connector(Male)

pin
1 1
- ~- - '-I L
I
~f(
1
~CJ
~ ~
1
'-- '--
r It--. --
~ ~ ~.
'-
5813-030100 5813-130100
1.
1 2 1 2
I
. L - 1 ... \ I
o~
~
I
2 '-- I -
'-- I -
I m n
.
- -- I lJ
5813-030200 5813-130200
'
4 -42
r -
No. of
pin Receptacle oonnector(Female)
I Plug oonnector(Male)
lrrcl~Iull ' W I
20 10
)ma3tHIJJ(
11 20
5817-020105
' -
4. 43
r
3)PATYPECONNEC10R
No. of Receptacle connector(Female)
pin Plug connector(Male)
--·
2 5
5 I
1 3 2
8811-005002 8811-1105002
3 7
7 ~l~==::;I
3 7
SS11-007002 S811-107002
4 9 1 5
9
I
1 5 4 9
8811-009002 8811-109002
5 11 6
11
I
6 5 11
8811-011002 8811 - 111002
4-44
r
No. of
pin Receptacle connector(Female) Plug connector(Male)
6 13 7
13
1 "7
5811-013002
6 13
5811-013002
8 17
I==
17 I==
1 9 8 17
8811-017002 5811-117002
1 11
=
21 =
11 10 21
5811-021002 8811-121002
,--...
4-45
4) 58-X TYPE CONt£CTOR
No. of
1 0
5813-060100 5813-16-0100
2 1
2 0
I
D
@ 2
I
1
$813-060200 $813-160200
3 0
I
1 3
5813--060200 5813-060200
2 4 1
\ \
4 0 D
!
2 4
5813-060200 5813-060200
4 - 46
5)JTYPE~
No.of
"
2 2
$816-002001 $816-102001
' '
' \
3 1 2
8816-003001 S816· 103001
3 4 2
\ - \.
~
4 2
\1
$816-004001 $816-104001
3 1 8 5 2
- L
"
8
•
$816-008001 $816-108001
4-47
r
6) SWP TYPE CONNECTOR
No. of Receptacle connector(Female) Plug connector(Male)

pin
1 1
'- I
- '
-
....
1 I I c::::J
.... [
-
- I
- ~-
8814-001000 8814-101000
\
~
2
1
D
~ 0 I
2
S814-002000 $814-102000
3
\
3
2 1 23
8814-003000 8814-103000
2 4
\
2 4
8814-004000 $814-104000
4-48
No. of
3 6 1 4
1 3 6
5814-006000 $81 4-106000
4 8 5
'
I \
1 5
4 8
$814-008000 881 4-108000
4 12 1 9
12
1 9 4 12
5814-012000 5814- 112000
14 11
~
J
14
~
(' ~
1 11
\ 3 14
5814-014000 5814-11 4000
4-49
r •
7) CNTYPE COtlllECTOR

pin
1
I I
m I
1
/
'
I I
~ i
1
!
8810-001202 8810-10120
2 2
2
~I
w 1
/
I I
~
1
!
I
8810-002202 5810-102202
3 2
I
I
I
e m
.
3 - ::J I . I I
I \ I \
i \ i \
1 2 1 3
8810-003202 8810-103202
2 4 1 3
\ \I i
\ I I
4
_J
--, '
:::J c
i ¢)~
B
!fJ~
I I
(I / \
1
I \
3
I
2
\4
' 8810-004202 8810-1 04202
4-50
No. of
3 6 1
\ I \
~
6
~
I \ i \
1 4 3 6
ss10-000202 s.a 10-1 os202
~~~~~~~~~~~- 8 1--~~~~~~~-1 ~~-
5 ~--I
I \ i
I
\ i \
5 4' 8
$810-008203 S81 0-1 08203
4-51
8) BS TYPE CONNECTOR
No. of Receptacle connector(Female)

pin Plug connector(Male)
1 2
\
2 @I I
[]]
2 1
5812-002001 5812-102001
1 3 2
[]]
3
2 3
$812-003001 $812-103001
2 1 3
1 3 2 4
5812-004001 5812-104001
3 6 1 4
4
CD
~\/.
3 6
5812-006001 $812-106001
4·52
9) LC TYPE CONNECTOR
No. of
pin Receptacle connector(Female) Plug oonnector(Male)
8815-010000
6 12
12
8815-012000
16
8815-016000
9 18
\/
18 ~ IJI .I I
\
I
1 10
\
8815-018000
4-53
pin
24
1 13
5815-024000
- -1-----------
4-54
10) 375 FASTEN TYPE CONNECTOR

pin
2
~ ~I w I
1
I i
\
2
I I
([!]
1
I
: \.
2
SS 10-002402 S810-102402
4.55
SECTION 5 MECHATRONICS SYSTEM
The CAPO(Computer Aided Power Optimization) system mainly consists of the engine control system,
pump control system. By using the CAPO system, an operator can use the machine power in optimal
condition and in fuel economic state.
Engine control system

Mode selection function
Max flow cut-off function
Pump control system
I Auto deceleration system
I Power boost system

CAPO
SYSTEM I Swing Speed control system
Travel speed selection function

-----------~r--c Travel power boost function
I.____Travel control system
Arm half flow function

- - -- - - - ----------'r--c Arm half flow cancel function
I.____Arm half flow system
I Automatic warming up system
I Engine overheat prevention system
5-1
SYSTEM DIAGRAM
Travel
Control lever
LH control RH control
lever lever
Travel motor
}l} ~
Regulator 1
L ___ T ___ J
1 Regulator
L- -- ---------------------1 pressure switch

r --- -- -------- -~ -----,
Main~n~olvalve __
•r--------------r
+,- ___ __ · J
1
I
1
J swing priority
spool
I I
I
IN
Arm 2
I I
I
I
I
Arm hatt flow
solenoid valve
Drive signal
IN I : I
Bucket 1 !_ ___ J ______ J Arm half
flow switch
I
Boom 1 I
Max flow CO 1\1--- ----,
Service I I
I
I
r
I
solenoid valve
l__ 1.. _ ~H trav~I- _:_-+~,-ti .~::,;~~~el\1------,

__
j __ _,
L __ M~~~ief
D
_ _ __ _ _
___ _ ___
_ _
I I
I LL
r
Swing EPPA
valve
I I
IL-r- Travel speed
solenoid valve
I
I
I
I
l
(
I
I Pilot pump
I
____ _
I
_J
Power boost
button
Hydtemp t
s~witchLH control ~
lever J
t
..---'~---L~-'--~~--,
Drive .
CPU controll er
POW8f 5V
Swing speed control signal
Swing
speed dial
--
~,~, ® ®
.®·1·®·1·-
;:.0 1@~
0 Engine speed up switch signal
Engine speed down &witch signal
OFF
- Warmk'lg up signal PreSIUl"e swtlch
5-2
I GROUP 2 MODE SELECTION SY-=STEM
..:...::;::.;:.-:..____..~----~~~-~---............~..-............J
Main control valve
Pilot pump
ft '"ff @ Cf) ._Mode

__ • .,._
. ch_signa__..,.I_ _ __,
OM sognal
CPU controller
••
OFF
ENGINE SP£ED
Engine speed switch slgnal
1.0UTUNE
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.
5- 3
2. PUMP CONTROL BY ENGINE SPEED SENSING
If any engine speed drops under the reference · Engine Torque
rpm of each mode set caused by the pump
load are detected by the engine speed sensor, t-
Q)
CPU controller sends calculated current signal ::J
2'
to EPPR(Electro Proportional Pressure .£
Q)
c
Reducing) valve to match engine torque with ·~
w
pump torque optimally by controlling the pump
discharge volume.
· H : Heavy duty operation mode
· S : General operation mode Engine speed N
· L: Lifting operation mode
· F : Finishing operation mode
· Engine horsepower
ii>
~
~
0
.c
Q)
c
'O>
c
w
Engine speed N
· Main pump delivery
0
Q)
1-------'
E~-----~
::J
~
Q)~----
E>
«l
.c
~
'O
a.
E
::J
a..
Pump delivery pressure P
5-4
3. MAXIMUM POWER OF H MODE · Engine Torque
1) When H mode is selected in the cluster,

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
· Engine horsepower
momentarily resets the engine speed to the
rated point through engine speed sensing.
Engine speed N
· Main pump delivery
a

E1------
:::1
~
~
"§
'6
a.
E
::I
a..
5-5
4. GENERAL STANDARD PO-VER OF S MODE • Engine Torque
1) When S mode is selected in the cluster,

....
CPU controller moves the engine governor Q)
:J
motor to set the throttle lever to the full !:!
,g
Q)
position and sends power shift current to c:
·ai
EPPR valve which reduces the pump c:
w
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.
• Engine horsepower
0..
:I:
l
~
0
..c: .
Q)
c:
·ai
c:
w
Engine speed N
• Main pump delivery
5- 6
5. ENERGY SAV1NG AND LIGHT POWER OF • Engine Torque
LMODE
1) When L mode is selected in the cluster,
''
motor to set the throttle lever to the partial 'I
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 • Engine horsepower
sensing at the matching point is the same
as for H mode.
--· I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Engine speed N
~ -----------
:::1
g
1------
~
~
'6
0..
E
::I
~ '-----------~---
5-7
6. RNISHING WORK OFF MODE • Engine Torque
1) When F mode is selected in the cluster,

motor to set the throttle lever to the partial
position and it sends of power shift current Q)
c
·0i
to EPPR valve to reduces the pump c
LU
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 • Engine horsepower
for engine fuel consumption, so the fuel
reduction effect is extremely large. 0..
:::c
l
~
0
.c '
Q)
c '
·0i '
c '
LU '
Engine speed N
"§
Q) - - - - - - - - - - - .................
',,
-~
' , ......... _____ _
Q)
f
'6
a.
E
:J
a.. L--_ _ _ _ _ _ _ _ ____JL..._- -
5 -8
t GROUP,3 AUTOMATIC DECELERATION SYSTEM
Engine Travel
Control lever
LH control RH control
lever lever
Fuel injection Governor

pump motor
pressure switch
•
AUTO
• OECa. Auto deoel SMtch s9'a1 Pressure sw1tch signal
CPU controller
1. WHEN AUTO DECEL LAMP ON

If all the work equipment control levers including swing and travel levers are at neutral for at least 4
seconds, CPU controller drives the governor motor to reduce the engine speed to 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 upto the speed set before deceleration in a second.
E Set rpm
e- --~-'------.
Q)
c
·a,
c
w
1200 m
max. max.
4sec 1.Ssec 1.Ssec
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- 9
Max flow CO
r solenoid valVe
Swing EPPR
Main control valve vatve
Travel speed
solenoid valVe
Engine
Pilot pump
;-: ":'. ......

H SLf ~\!:I
,.... -- ... CPU controller
1. MAX FLOW CUT-OFF FUNCTION

If the power is selected out of the L mode of
cluster, max flow cut off solenoid valve is
activated.
Thus, pilot pressure(Pi) flows into the Qmax
cut-off port of main pump, and it reduces the
pump discharge volume.
Pilot pressure Pi
5-10
IGROOP S>PONER BOOST SYS1EM
Main control valve
, -- ----- --- --i
Arm 2
Arm 1 Bucket
Boom2 Boom1
Swing Service
Max flow CO
LH travel RH travel r solenoid valve
I I
- ---~- -----r ~~~
L __ ____J : '---~--'
I
I
I
I
Engine I
I
I
I
l
(
I
I Pilot pump
I
_ _ _ _ _ _JI
Power boost
button
i
i6
Power booot button slgnll

l
on.. signal
Mode switcll signal CPU controller on.. signal
=: n
. . _ .....
@ @ i----~-~
· When the power boost switch on the left control lever knob is pushed ON, the maximum digging
power is increased by 10%.
· When the power set is at H or S and the power boost function is activated, the power boost solenoid
valve pilot pressure raises the set pressure of the main relief valve to increase the digging power.
~
Power boost switch
OFF ON
Power set Hors H
Main relief valve set pressure 320 kgtcm2 350 kgtcm2
Even when pressed continuously,
lime of operation - It is canceled after 8 sec.
* This function does not work when the power mode switch is at L or F.
* Default - Power boost solenoid : OFF
5-11
LH control
Main control valve lever
r------
.. - - - - - - - - - - - - ,
I Swing pnomy I
spool Arm 2
Bucket
Cl
c
Boom 1 ·~
(JJ
I
I Service
I
l RH travel
1
pressure
switch
Main relie!D -
- 1_ _ - --_J
-- --J _ - - - -,I
L __ valve
- - -- - - - - L - SwingEPPR
valve
Engine
Pilot pump
CPU controller
Swing speed dial
Pressure switch signal
1. SWING SPEED CONTROL SYSTEM

When turning swing speed control dial to the left or right, the electric current that flows into the swing
EPPR valve is changed, and it adjusts pilot oil flowing into the swing priority spool of MCV.
According to the operating rate of swing priority spool, the oil flow of swing section is changed.
Thus, the swing speed is controlled by change of the swing speed control dial position.
5-12
-
~~·--- --- ------i Arm2 1

I
I
g
Regutatot
r.-..,.,.
~
L___ T___JReoul110t
r - -- --- -"
I
I
I
I r Mu llowCO
I I I y""'
IOltnokl
L __ -- ---'-- --~-~
_ ___J
.:::::.-::.
L_tr .....,
...........
...
I
I
I
I
I
I
I
I
l..
Engine
Pllo4 pump
--
... . 1.............. ----
--
t __ _ _
1. TRAVEL SPEED SELECTION

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

solenoid vaJl/e duster
Lo OFF Turtle Low speed. hiij1 dlivi1g IOlqu& in lra'llll molols
Hi ON Rabbit Higl speed. low dlivi1g IOrque in lraY9I molols
• Default : Turtle(Lo)
2. PONER BOOST IN TRAVEL

When the operation of travel control levers Is detected by travel oil pressure switch, CPU controller
sends control signal to set the pressure of the main relief valve from 320kg/cm' to 350kg/cm' to
increase travel power.
5· 13
•
LH cootrOI
lever
~solenoid
A~~~~~"'!ow ~i}--:r-~~-i Arm half
va.Ne
L __ ___J
I llowswiich
1.... _ __ ,_1I _ _ _ _ _ _ ....JI
Engine
Piiot pump
When ann half flow switch is turned ON, the arm half flow solenoid valve is switched to ON and~
cancels the junction of the oil flow from two pumps.
This function is useful to fine control of the ann in case of finishing work.
B<xim Travel
Mode Swing
up LH RH
H
s 100
200 100 200 100 100 100
L
llE The portion for one pump is taken as 100%.

llE When the arm out and bucket are operated simultaneously, the Ann half flow function does not
work.
5-14
•
I
Plot pump
J
EPPR vatve
CPU oontrollet
1. Cluster reads engine coolant temperature through the temperature sensor, and If the coolant
temperature Is less than 30'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_QQ!ltrol .~ignal from the cluster, it changes the
Q0119mor motor position and set the engine speed td\12:;0 ipm~ At the same time, the mode display
on duster is not changed.
3. If the coolant temperature increases upto 30'C, or an operator changes mode set among the
warming up function, the CPU controller cancels the automatic warming up function.
4.. Logic tallle(1)
Concition Fll'lCtion
• Mode : Default
• Coolant t~ :
Actuated - Wamiing up time : at least 1omites
less lhan ~{after fln9ne run)
- Warming-up l311'4l : ON
• Coolant temperature : abc:M! 30 'C - Default mode
• Warming up time : ai»Je JO_miootes_ • Default mode
- Changed mode set !Jo/'operator - Changed mode
canceled
* Hany of the abc:M! cordtions is
~ica~e. the automatic warming-up
function is canceled
Warming-up
lamp Coolant temperature : abow 30 'C Warming-up lamp : OFF
5-15
•
s. Logic table(2)
Coolant temp. ~ 30-C Coolant temp. > 30-C Description
Signal Low(OV) Hi!1J(SV)

Wanning-~
ON OFF Ouster
lamp
Mode Default Default CPU controller
5· 16
..
Engine
Pilot pulf1)
Fuel Injection Governor

pump motor
MOClt ....... fOJntl .,

I t
EPPRvalve
CPU contrOller
MOClt ..~ ....lt2
1. When the engine coolant boils upto 11o·c. the overheat switch is ON, and if the temperature drops to
1OO'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 duster.
3. If the coolant temperature drops to 1oo·c or mode set is changed among the function, the cluster
sends the overheat prevention cancel siglal to the CPU controller.
Thereby the CPU controller returns the mode to the mode set before.
• 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 1oo·c
4. Logic table(1)
Description Condition Function
• Mode : H, s, L --(F)
Actuated - Coolant te01JefC!ture: above 110'C. • Overheat warning lamp & buzzer : ON
• Coolant le"1JElfClture : less ttian 100'C • Return to the mode set before
• Changed mode by operator • Hold on ttie changed mode
Canceled • If any of ttie above coodttions is
applicable, engine ovemeat prevention
function is canceled
Overheat · Coolant temperature: less ttian 100'C -Lamp OFF
warning la~
5· 17
•
Ovemeat switch
-- ON OFF
Cofdtion Coolant telll>: alxM! 110'C Coolant temp : less than 1oo·c
Sigial Low(GND) Hig1(5V)
Larrc> & buzzer ON OFF
(dustef)
Mode set F Return to the mode set beb"e
(CPU controller)
5· 18
•
GROUP 11 SYSTEM*;
1. CPU CONmOlLER MOUNTING
2
/
1 CPU controller 2 Controller mounting bracket 3 Rubber

4 Bolt
2. CPU CONTROLLER ASSEMBLY

1) Remove four pieces of bolt(4) of controller
0 0
mounting bracket
2) Pull out bracket(2).
3) Disconnect 4 connectors from CPU
controller.
0
o
0
O
Do
A D
4) Remove 4 pieces of screw and cover of
~ Qo
CPU controller
5) Inspection : Check PCB(Printed Circuit 0 0
Board)
o D
(1) II any damage is found, replace CPU 0 0
controller assembly.
(2) If not, but CAPO system does not work
then replace "A" only.(A : EPROM)
• Removal : Insert small screwdriver or
knife to bottom of EPROM
and lilt up carefully.
• Assembly : Assemble EPROM to mach
with semicircle mark.
5-19
3. ENGi-iE GO\IERNOR MOTOR AND EMERGENCYCABLE MOUNTING
1 Governor motor(step motor)

2 Connecting rod
3 Throttle cable for manual control
(Emergency cable)
1) ENGINElliROTTlE LEVER
SL : Stopper, low de
SH SH : Stopper, higl ide
Comedi11g rod c ;As required
2) EMERGENCYCABLE (Jlush1Jul cable)

It controls engine speed by connecting onto the lever of the injection pump when the malfunction of
the CPU controller or the govemor motor happen.
5-20
3) ENGINE TliROTllE LEVER
4 5
6
0
2- -1
1---+
9
0
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)
PotenWllleter G011emor motor
Connector ft ~
OD
\\. 6 / 0 6
L_J I I l.J
Type \ 3ij female 4P, female

1 Red Black
Line 2 White Green
Color
3 Yellow Red
4 - Yellow
• Check resistance value · Check resistance value
Inspection of between No. 1-2 between No. 1-2 and 3-4.
governor motor
·Spec : 0.6- 5Kll ·Spec :7-8D
5-21
4. ENGINE SPEED SENSOR
1) DETECT ACT\JAL ENGl-<IE RPM AND SEND SIGNAL10 TACHOMETER
2 Gear teeth, flywheel

3 Lock nut, speed sensor
A Clearance
2) tSTAl.LATION
(1) Clean contacting point of sensor.
(2) Loosen lock M
(3) Screw in speed sensor to flywheel housing.
(4) Tum it back 135" when ii contact gear teelti.
(5) Tgrt lock nut and connect wiring.
,.
5-22
1. COMPOSmON OF EPPR VALVE
EPPR valve consist of electro magnet and spool val'le installed at main hydraulic pump.
1) aecmo 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 8..ECTFllC CURRENT VALUE FOR EACH MODE
Pressure
Mode Electric current (mA) Engine rpm
k9'Cl'li I psi
H 5.± 3 70 ± 40 (240 ± 30) -2250+50
s 10 ±3 140 ± 40 (320 ± 30) 2250+50
L 17 ± 3 240 ± 40 (420± 30) 2050+50
F .2L± 3 300 ± 40 (470 ± 30) 1850 +50
16 ±3 230 ± 40 (390 ± 30) .
* operated condition when prolix switch is selected emergency position.
* Manually
5-23
2. OPERAmG PRINCIPLE
1) S1RUCTURE
2 3 4 5 _,.
1 .,.
1 Sleeve 2 Spring 3 Spool

4 0-ring 5 0-ring 6 Solenoid valve
7 Connector
P Pilot oil supply line(Pilot pressure)

T Return to tank
A Secondary pressure to flow regulator at hydraulic pump.
2) ATHMODE
Pressure line blocked so, A oil return to tank.
3) ATS, l., FMOOE

Secondary pressure enter to A
i:::.:·
I
I
c::_
.. i
..
i
!
A
..
~c.
5-24
SECTION 6 TROUBLESHOOTING
GROUP 1 HYDRAULIC AND MECHANICAL SYSTEM
1. INTRODUCTION
1) MACHINE IN GENERAL
(1) If even a minor fault is left intact and operation is continued, a fatal failure may be caused,
entailing a large sum of expenses and long hours of restoration.
Therefore when even a small trouble occurs, do not rely on your intuition and experience, but
look for the cause based on the troubleshooting principle and perform maintenance and
adjustment to prevent major failure from occurring. Keep in mind that a fault results from a
combination of different causes.
(2) The following lists up commonly occurring faults and possible causes with this machine. For the
troubleshooting of the engine, refer to the coming troubleshooting and repair.
(3) When carrying out troubleshooting, do not hurry to disassemble the components.
It will become impossible to find the cause of the problem.
(4) Ask user or operator the following.
‫ ڸ‬Was there any strange thing about machine before failure occurred?
‫ ڹ‬Under what conditions did the failure occur?
‫ ں‬Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
‫ ڸ‬Check oil and fuel level.
‫ ڹ‬Check for any external leakage of oil from components.
‫ ں‬Check for loose or damage of wiring and connections.
6-1
2. DRIVE SYSTEM
1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION
Cause Remedy
YES
Coupling element Disassemble and
is broken. repair.
Remove dust plug
under engine
flywheel and check YES
if rubber pieces or Replace hub or
particles are not retighten
present. Coupling hub setscrew.
spline is worn or
NO hub fastening
setscrew is slack.
If hydraulic pump or engine is suspected as
NO
a culprit, refer also to shop manuals
"hydraulic components" and"engine"
6-2
2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL
Cause Remedy
NO
Replenish
specified oil to the
Is oil level in Abnormal noise standard level.
YES YES
hydraulic oil tank comes out of Hydraulic pump is Disassemble and
within standard hydraulic pump broken. repair.
level?
Do not hydraulic
Abnormal noise
pump and pump YES YES
comes out of See item 1).
YES connections make
pump connection
abnormal noise?
Is primary pilot
pressure within ‫ڞ‬
NO standard level?
YES
Clean pilot piping
Is not pilot piping interior or repair
YES clogged or is not
piping.
oil leakage present
on pilot piping?
Pilot valve is faulty. Disassemble and
NO
‫ڞ‬ repair.
YES
Pilot relief valve is Repair of replace.
Is gear pump faulty.
NO delivering oil?
Gear pump is Disassemble and
NO
broken. repair.
6-3
3. HYDRAULIC SYSTEM
1) HYDRAULIC OIL IS CLOUDY
Cause Remedy
YES
Water is mixed. Put hydraulic oil
still, separate
Drop hydraulic oil water and
sample on hot
dispose it or
plate and check if
foams come up. replace hydraulic
oil.
Air is intruded. Check suction
NO
line and return
line and eliminate
the air intruding
source.
2) HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY
Cause Remedy
NO Replenish
standard level.
Is hydraulic oil
volume proper? YES
Clean oil cooler.
In not oil cooler Secure air
clogged and is circulation route.
YES anything blocking YES ‫ڞ‬
air circulation?
Is fan belt tension
NO proper?
Adjust belt
NO
tension or replace
belt.
Is not the set YES Readjust set

pressure of main
relief,port relief and pressure.
‫ڞ‬
travel relief valve
lower than the Is main relief valve YES Reduce load.
standard level? NO used very often?
6-4
3) CAVITATION OCCURS WITH PUMP
Cause Remedy
NO
Replenish
standard level.
Is hydraulic oil
YES
volume proper? Replace oil with
one of proper
Is not viscosity of viscosity.
YES hydraulic oil too YES
high? Clean suction
strainer.
Is not suction
NO Is not air intruding
strainer clogged?
Check for air
NO from pump suction
line? intrusion in
suction line and
retighten or
replace parts.
4) HYDRAULIC OIL IS CONTAMINATED
Cause Remedy
YES
Replace
Has not hydraulic hydraulic oil to be
oil passed specified.
specified replace-
ment hours? Has return filter
NO
been replaced at Flush with
NO
proper intervals? hydraulic oil and
replace return
filter.
6-5
4. SWING SYSTEM
1) BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE
Cause Remedy
NO
Replenish
YES specified oil to the
‫ڞ‬
Is safety valve
YES standard level.
pressure within
standard?
Gear is gear pump Safety valve faulty Repair or replace.
pressure within NO
Is oil in hydraulic or not operated.
YES standard level?
tank within
standard level? Gear pump faulty Repair or replace.
NO
YES
Main relief valve Disassemble and
YES Is not main relief faulty repair.
valve faulty?
Is swing brake
Are attachment Swing motor is out Disassemble and
‫ڞ‬ release valve NO
and travel motions pressure within of order. repair.
impossible at all? standard? Is not pilot relief
valve faulty? Swing brake release Disassemble and
NO NO
valve is out of order. repair.
NO
Swing control valve Disassemble and
YES Does swing control
valve spool move spool is stuck. repair.
Is MCV pilot
YES ‫ڟ‬
pressure within YES
standard level?
Does RH travel ‫ڠ‬
NO
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 release Disassemble and
valve is broken. repair.
Is swing brake
‫ڟ‬ release valve YES
faulty? 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 of Disassemble and
Is gear pump pilot NO
order. repair.
‫ڠ‬ pressure within
standard level? YES
Is not there oil Clean pilot piping
leakage from pilot interior or repair
YES piping or is not it piping.
clogged? Pilot valve is Disassemble and
NO
broken. repair.
6-6
2) SWING SPEED IS LOW
Cause Remedy
YES
Swing port relief Disassemble and
Does swing control
YES valve is faulty. repair or replace.
valve spool move
smoothly by hand?
Swing control valve Disassemble and
NO
Is secondary pilot spool is stuck. repair.
pressure same on
LH and RH sides? YES
Clogged or oil leak. Clean pilot piping
Is not pilot piping
interior or repair
Single direction clogged or is not it
NO piping.
leaking oil?
Is the trouble in NO Pilot valve or main Disassemble and
one direction or in control valve is repair.
both direction? faulty.
YES ‫ڞ‬
Does swing control
YES
Both directions valve spool move
Is MCV pilot lightly by hand?
YES pressure within Swing control valve Disassemble and
NO
Is Arm speed standard level? spool is stuck. repair.
within standard ‫ڟ‬
value? NO
‫ڠ‬
NO
Is swing motor's
‫ڞ‬ NO Swing motor is Disassemble and
drain rate within
standard value? broken. repair.
Check that pilot
YES piping is not NO
Pilot valve or swing Disassemble and
clogged or oil is
not leaking from it? motor is faulty. repair.
Is gear pump pilot Clogged or oil leak. Clean pilot piping

‫ڟ‬ pressure within interior or repair
standard level?
piping.
YES
Is gear pump
defective. repair or replace.
NO delivering oil?
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 Disassemble and
‫ڠ‬ setting pressure change when front
YES broken. repair.
normal and rear pump
discharge hoses
Is safety valve pilot are exchanged? Swing motor faulty. Repair or replace.
NO
pressure within
YES YES
standard level? Pilot relief faulty. Repair or replace.
Is gear pump
output pressure
NO within standard
level Gear pump faulty. Repair or replace.
NO
6-7
3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION
Cause Remedy
YES
Does symptom Swing port relief Disassemble and
change when LH valve is faulty. repair.
YES
and RH port relief
valves are
Does swing exchanged Swing control valve Disassemble and
NO
YES control valve spool or swing motor is repair.
move smoothly by faulty
hand?
Is MCV pilot
pressure same for Swing control valve Disassemble and
NO
LH and RH? spool is stuck. repair.
Check if pilot piping
is not clogged or YES
Pilot valve is Disassemble and
NO does not have oil
leakage. broken. repair.
Clogged or oil
leak. Clean pilot piping
interior or repair
piping.
4) MACHINE SWINGS BUT DOES NOT STOP
Cause Remedy
YES
Swing brake Disassemble and
release valve line is repair or replace.
YES Is MCV pilot YES Is gear pump pilot
pressure within pressure within faulty.
standard value? standard level?
NO
Does swing broken. repair.
YES control valve spool
move smoothly by
hand? Pilot valve is faulty. Disassemble and
NO
repair.
Is swing control
valve's return
spring normal? Swing control valve Disassemble and
NO
spool is stuck. repair.
NO Return spring is Disassemble and

faulty. replace.
6-8
5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE
Cause Remedy
YES
Swing brake Disassemble and
release valve or replace.
YES Is brake spring swing brake is
normal? abnormal.
YES Is brake spring
normal? NO ‫ڞ‬
Is return spring of
swing control Brake spring is Disassemble and
valve normal? NO
faulty replace.
NO Return spring of Disassemble and
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.
6-9
5. TRAVEL SYSTEM
1) TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE
Cause Remedy
YES ‫ڞ‬
Does counterbalance
YES spool in travel brake
valve move lightly by
Is travel brake hand?
YES valve pressure Counter spool in
NO
Disassemble and
within standard Does the symptom travel brake valve repair or replace.
Has travel control level? change when relief is stuck.
YES valve spool valves in travel YES
Relief valve built in Disassemble and
changed over NO motor are
exchanged? travel motor is repair.
positively?
faulty.
YES
Does spool move Control system is Disassemble
lightly when hand defective. inspect and
NO is let free from repair.
control lever?
Is bucket or arm NO
Travel control valve Disassemble and
operation spool is stuck. repair.
possible?
YES
Travel reduction Disassemble and
Do not metallic
particles come out unit is faulty. repair.
‫ڞ‬ of drain port in
travel reduction
unit?
NO Travel motor is out Disassemble and
of order. repair.
Does the symptom
change when front
and rear pump YES
Hydraulic pump is Disassemble and
NO discharge hoses
broken. repair.
are exchanged?
6 - 10
2) SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES
Cause Remedy
YES
Brake valve is Disassemble and
Do LH and RH travel defective. repair or replace.
speeds change
YES when LH and RH
YES
travel brake valves Does the symptom Relief valve built in Disassemble and
are exchanged? change when relief travel motor is repair.
valves in LH and
NO faulty.
Has control valve RH travel motors
YES ‫ڞ‬
spool changed are exchanged? NO
over positively?
YES
Control system is Disassemble,
Does spool move faulty . inspect and
lightly when it is repair.
Is the lower speed
NO cut off from control
(bucket or arm) spool?
within standard Control valve spool Disassemble and
level? NO
is stuck. repair.
YES
Travel relief valve is Disassemble and
Do LH and RH
faulty. repair or replace.
travel speeds Does the symptom
change over when YES
change when front YES
NO travel relief valves and rear pump Hydraulic pump is Disassemble and
are exchanged? Is external pilot discharge hoses broken. repair.
pressure within are exchanged?
NO
standard level?
NO External pilot piping Disassemble and
is clogged or oil is clean.
leaking from it.
Does travel speed
change when
YES parking brake YES Travel motor's Disassemble and
Is leak rate of spring in the slower parking brake is not clean pilot piping.
‫ڞ‬ travel motor within travel motor is
released properly.
standard level?
Travel motor is Disassemble and
NO
faulty. repair.
6 - 11
3) MACHINE DOES NOT STOP ON A SLOPE
Machine is pulled forward as sprocket rotates during digging operation.
Cause Remedy
None Is parking brake YES
Friction plate is Disassemble and
Check if parking friction plate worn?
YES faulty. repair.
brake pilot line is
not clogged.
clogged Disassemble and
clean pilot piping.
Is travel brake Is drain rate of NO
pressure within travel motor within Travel motor is Disassemble and
standard level? standard value? defective or drain repair.
line is clogged.
Brake release Disassemble and

NO
valve is faulty or repair or replace.
pilot relief valve is
abnormal.
4) LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE
Cause Remedy
YES
Inspect according
to the procedure
"Travel does not
function at all on
one side."
However, a case
where both LH
and RH travel
motions are
disabled is
extremely
seldom
Is bucket or arm
statistically.
operation
possible? OK Hydraulic pump is Disassemble and
Disassemble both
travel relief valves faulty. repair.
OK and inspect for
Remove dust plug any fault or check
under engine main relief valve.
OK flywheel and Travel relief valve Disassemble and
Faulty
check that there is is faulty. repair or replace.
no coupling
Check oil volume element particles.
Particles present. Coupling at pump Disassemble and
in hydraulic oil
NO connection is repair.
tank.
broken.
Short Replenish
hydraulic oil.
6 - 12
5) TRAVEL ACTION IS POWERLESS(travel only)
Cause Remedy
YES
‫ڞ‬
YES Is travel motor's
drain rate within
standard level?
YES Is travel brake NO
Travel motor is Disassemble and
pressure within faulty. repair.
standard level?
Is travel relief valve Travel brake valve Disassemble and
pressure within NO
is defective. repair or replace.
standard level?
Travel relief valve Disassemble and

NO
or main relief valve repair or replace.
is faulty.
YES
Hydraulic circuit Disassemble and
Does parking that releases travel clean.
Remove parking Increases brake piston move parking brake is
brake spring in lightly by hand? clogged with dirt.
travel motor, draw
out piston Parking brake Disassemble and
‫ڞ‬ NO
completely, refit piston in travel repair.
cover and check if motor is stuck.
travel power Remains
unchanged Travel reduction Disassemble and
changes.
unit is defective. repair.
6) MACHINE RUNS RECKLESSLY ON A SLOPE
Travel brake valve Cause Remedy

(counterbalance
valve) is faulty or Disassemble and
brake release valve repair or replace.
or line is abnormal.
6 - 13
7) MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND
ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME
Cause Remedy
Is operation of all
YES
spools except arm2 Repair spool
YES Is RCV pilot spool normal? assembly.
pressure normal?
NO
Repair RCV pilot
YES Is T/S valve
normal? line.
Is pilot pressure for T/S valve is faulty. Repair or replace.

NO
travel straight(T/S)
valve within YES Remove dirt on
standard level? Is filter in pilot pilot line filter.
piping between
gear pump and YES Is pilot relief valve NO Pilot relief valve is
NO Disassemble and
control valve not
clogged? normal? defective. repair or replace.
Does gear pump
NO deliver oil?
NO
broken. repair.
6 - 14
6. ATTACHMENT SYSTEM
1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL
Cause Remedy
Does the symptom YES Port relief valve is Disassemble and
change when port faulty. repair or replace.
YES
relief valve is
replaced with other
Is MCV pilot valve? ‫ڞ‬
YES NO
pressure within
standard level? Inspect if pilot
piping is not OK
YES Are other clogged or oil is not Pilot valve is faulty. Disassemble and
attachments NO
leaking from the repair.
operable? piping.
YES
Is gear pump pilot NO
Is gear pump faulty. repair or replace.
pressure within
NO delivering oil?
standard level?
NO
Are LH/RH broken. repair.
operations
possible? OK Hydraulic pump is Disassemble and
Disassemble main broken. repair.
YES relief valve and
Remove dust plug check if it is not
under engine irregular.
OK flywheel and check Main relief valve is Disassemble and
Faulty
if coupling element defective. repair or replace.
particles are not
Inspect oil volume present. Particles present
NO
in hydraulic oil Coupling at pump Disassemble and
tank. connection is repair.
broken.
Short
Replenish
hydraulic oil
YES
Does control valve Cylinder interior is Disassemble and
‫ڞ‬ spool move lightly broken. repair.
by hand?
NO Control valve spool Disassemble and
is stuck. repair.
6 - 15
2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal
YES ‫ڞ‬
Are other
YES attachment speeds
Is speed low only Is combination of within standard
oil streams normal levels? ‫ڟ‬
in composite YES NO
operation? at boom hoisting YES Summation spool
and at arm Repair or replace.
extrusion? Is summation is faulty.
(2 spools) spool
Are LH/RH travel NO
normal?
speeds within Replace spring.
NO NO
standard levels?
YES
Hydraulic pump is Disassemble and
Are both LH/RH faulty. repair.
YES ‫ڠ‬
NO travel speeds low?
Is MCV pilot
pressure within
NO
standard?
NO
‫ڡ‬
Does the symptom OK Port relief valve is Disassemble and
YES change when port faulty. repair or replace.
relief valve is
replaced with other
Does control valve valve? Cylinder is faulty. Disassemble and
YES spool move lightly NO
repair.
by hand?
NO
Control valve spool Disassemble and
Is MCV pilot
‫ڞ‬ pressure within is stuck. repair.
standard level?
YES
Is not secondary Clean pilot piping
pilot pressure interior or repair
piping clogged or
NO piping.
is not there oil
leakage? Pilot valve is Disassemble and
NO
defective. repair.
YES
Is primary pilot
NO Is gear pump faulty. repair or replace.
‫ڟ‬ pressure within
delivering oil?
standard level?
NO
broken. repair.
Is engine
NO
‫ڠ‬ revolution within Adjust engine
standard level? revolution.
YES
Clean orifice in
control valve.
Is not orifice in
‫ڡ‬ control valve YES
clogged? Is pilot piping not Clean pilot piping
clogged or is oil interior or repair
NO not leaking from piping
the piping? Is pilot valve
Pilot valve is faulty. Disassemble and
NO normal? NO
repair.
6 - 16
3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS
Cause Remedy
YES
Port relief valve is Disassemble and
Does the symptom
faulty repair or replace.
change when port
Normal
relief valve is
replaced with YES
‫ڞ‬
normal valve? Is control valve
YES Is not hydraulic oil NO return spring
normal?
temperature high? Control valves Disassemble and
NO
return spring is replace.
faulty.
Is genuine Abnormally high. Locate the cause
hydraulic oil or of hydraulic oil
equivalent being
used? temperature rise
and lower it to
proper level.
NO Replace with
genuine hydraulic
oil or equivalent.
OK
Disassemble and Pressure tightness Disassemble and
inspect check between control repair.
YES
valve in hydraulic valve casing and
circuit and check spool is poor.
Is cylinder internal for any fault.
Abnormal Contact surface Disassemble and
‫ڞ‬ leakage within
between poppet repair.
standard level?
and seat is poor.
NO
Cylinder is faulty. Disassemble and
repair.
6 - 17
4) BOOM, ARM OR BUCKET POWER IS WEAK
Cause Remedy
YES
Check according
Is cylinder internal to the procedure
YES leakage within in Item "Speed is
standard level? low"
Is relief pressure in
YES port relief valve Cylinder is faulty. Disassemble and
NO
within standard repair.
level?
NO
Port relief valve is Adjust pressure,
YES faulty. repair or replace.
Is relief pressure in Is power boost in
main relief valve YES main relief valve YES
Cylinder is faulty. Disassembly and
within standard within standard Is the solenoid
level? repair.
level? valve of power
NO boost
normal(40K)?
Power boost Disassemble and
NO
solenoid valve is repair.
faulty.
Main relief valve is Adjust pressure,

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

NO
possible? repair.
YES
Does the symptom Main relief valve is Adjust pressure,
change when faulty. repair or replace.
LH/RH main relief Does the symptom
NO
valves are change when YES
exchanged? Hydraulic pump is Disassemble and
NO hydraulic pump's
discharge hoses broken. repair.
are exchanged?
6 - 18
6) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED
Cause Remedy
YES
Frictional noise
occurs between
the sliding faces
of boom
cylinder's oil seal
and boom
Is boom foot pin
greased proper.
sufficiently? Ɠ Frictional
noise will
disappear if
they are kept
used.
Boom foot pin has Supply grease to

NO
run out of grease. it.
Ɠ If seizure is in
an initial stage,
supply
sufficient
grease.
If seizure is in
a grown state,
correct it by
paper lapping
or with an oil
stone.
6 - 19
Ɠ HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE
1. Lower the bucket teeth to the ground with

bucket cylinder fully retracted and arm
cylinder rod retracted almost in full.
2. Disconnect hose(A) from rod side of boom

cylinder and drain oil from cylinders and
hose.(Put cups on piping and hose ends) A
3. Raise bucket OFF the ground by retracting

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

rod is retracted there is an internal leak in the
cylinder.
If no oil leaks from piping side and boom
cylinder rod is retracted, there is an internal
leak in the control valve.
6 - 20
GROUP 2
1. WHEN $TARTJ«j SWITCH IS TIJRNED ON, MONroR PANEL DISPLAY DOES NOT APPEAR
· Before disconnecting the connector, always tum the starting switch OFF.
• Before canying out below procedure, check all the related connectors are properly inserted and
short offuse No. 14.
· After checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Delec:IMI c.t.ISler ~
Chedc vollage
~ betwoenCN-57
(5) <nl~
Chx111ec:io11 ii Aepai'or~
NO
Chedcvollage v.1i'g t8nelSs ()( Jm' (a'lerdlm)
'IES belwea1 cm(S)
- o:rlacl~ CN-
amc:hassis
57~
Oisr:o 11edion In Repai or replace

Check vollage NO
between CN-50 ~
v.img harness OI Jm' (atler clean)
(7) IV1d chassis o:rlacl ~CN-
8(5}CN50(7)
Vollago : ro-:JlN
Slll1lng swllc:ll : ON
YES
OlOCX\Uaga ~ari1iJ ~
betwoen~
,.,0 (9)<nlda9
Cleoc111eci111il Aepai'or~
If,)
v.1i'g lan8l!S CKJXXJ' (allerdlm)
o:rlacl~ CN-
~
FUSE
3
N0.14
CN-38
CLUSTER
9
5 5 7
11 11
CH-50
12 12
a+-57 CN"8
check voltage
6·21
r •
2. LJ BATTERY CHARGING LAMP LIGHTS UP(Slartlng switch: ON)
· Before disconnectirng the connector, always turn the starting switch OFF.
· Before carrying out below procedure, check all the related connectors are prQPer1y inserted.
• After checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
- @
Check voltage
YEl?. between~
Check 'A:Jllage
mand chassis - Defeclive cmroler Replace
~ between 0%1 - f>()
(18)<rdchassis
Di&::ou ie..'lion i1 Repair or replace
YES Check llOlage NO
~ between CN-1 (2) - wiri"g harness or poor (after clean)
and chassis CO!iad betlwerl
CN-51(18K:N1(2)
Check voltage Disameclion i1 Repai' or replace
between alternator NO
wiri"g harness or poor (after clean)
lelminaJ 'I' and
chassis corD:I belweEJ1
Vollage : 2.0-30V Cff.1~malor
Engine ; ruming lennilal i •
Defeclive allemallY Replace
NO
~ De!ediYe ckisler Replace
Check voltage
@- betweenCN-
7(7) and chasliis
'- Discon iecii11 in Repair oc replace
t-0
wiri"g lane$orpoor (after ckm)
o::11lacl lletiwel1
CNW}OO(I)
18
CN-51
ALTERNATOR
check voltage 2 < - - - - - - -"
•1• TERMINAL
'5V CN·1
ov
6- 22
r
3. ~ WHEN COOi.ANT OVERHEAT LAMP LIGHTS UP(Engine is started)
• Before disconnecting the connector, always turn the starting switch OFF.
• Before carrying out belOIV procedure, check all the related connectors are properly inserted.
Cause Remedy
YES Coolant ovemeat Ched< engile
(110t: ±2t:) system
Check resism:e @
..
YES between CN-1 (3)-
Does display go -
chassis and Ct-J- -
ctfwhen Repai' or replace
discxmect C0.9
- 51 (1)-dlassis f'i> as:xrnecti:iu il wi'rg
5'arti1g switch : OFF hamessap:nr IXXltD (after dean)
and 00 1 iector'? Oieck resislance
YES between CN-9(3) - belweEn
S1aJ1ing swilch : ON -
Engne :start and chassis ~51(1)<nl
~1(3)
Starting swilch: OFF
Check lesistaroe ~ilwii'g Repair a replace
NO
between CN-56 ~ hamessap:nroorta:t (after dean)
NO (15) and chassis bBween
Slal1ing swildl : OFF ~15}CN-9('3)
Bel0!9 Cheeking.
disoonnea CN-9 D!lhxM<im Replace
NO
YES Replace
Check reslslance ~ Delec1ive semor
oor-iaM -
@- chassis and
~
sensor-chassis
Cilo:rnecill1ii1 wi'rg Repai' a replace
Slanilg &l&h : OFF N:)
hamessap:nroorta:t (after dean)
belwetJl
CN1\3)-ID9
CLUSTER CPU CONTROLLER
15 3 1
CN-56 CN-9 CN-51 OVERHEAT SWFTCH
check resistance CN-1 CD-9

I'""' • YES MAX 1 D
NO MIN 1IQ
6-23
r "
4. @ WHEN AIR CLEANER LAMP LIGHTS UP(Engine is started)
• Before disconnecting the connector, always turn the starting switch OFF.
• Before canying out below procedure, check all the related connectors are property inserted.
· Alter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES Check air filter Repair or replace
(after dean)
~
Clsco111eci:111 in Repair or replace
IWirg harness or poor (after dean)
Does display go"' 0-.eck resism::e aJ1la:1 between
vdl9ll disconnect ~ between CN-1(9)
ID10and
>- anddiassis CN-1(9)-0)-10
OOl 1 ieclor?
Star1ing S'Mlcll : OFF
51a111ng swilcll : ON
Check resistaroe N0 Disarnecm 1in Repair or replace
Engine : slalt YES_
between CN-9(2) - >Mrirg hamess or poor (after dean)
and chassis aJ1la:1 between
S1ar1ing switch : OFF
CN-9(2)-CN-1 (9)
Check ll!Sistlme Discol 1i9C1Kln in Repair or replace

N6 between CN-66
(14)andchassis "° .,,;~ hamessor poor (after dean)
IXllltcd between
Slarting swilth : OFF CN-5&;14}0+9(2)
Belon> cllecking,
disoomect CD-10
Deleclive duslllr ~
"°
CLUSTER AIR CLEANER SWITCH
14 1-------1 2 1-----1 9
CN-56 CN-9 CN-1
check resistance
YES MAX 1 !I
NO MIN 11!1
6-24
r •
S. •Q• WHEN ENGINE OIL PRESSURE LAMP LIGHTS UP(Engine is star1ed)
· Before canying out below procedure, check all the related connectors are properly inserted.
· Alter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
't'ES Engine Cl! leakage, Ched\~oil
or defective SIMldi lewl or replace
switch
~ Osooinedionhlliing Repair or replace

hamessorpoor (after clean)
Does <i;pay go oil Check resis1ance
YE§. belweenCN-1(5) - am::t betYAlerl
when dsameCI -
C0-18a-d and chassis CN-1(5}ID 18
COll1Elttll?
S1anlng ...,;,en: 00 ~hlliing
Engine ; slal1
aleCk msistlnee
~ between CN-9 (1) -
~ Repair°' replace
harness or poor (afterckm)
axi chassis oonlad betYAlerl
Slarting swilx:h : OfF Ct-I«1}<)1-1(5)
Check resistarol
00-between CN-56
(13) and chassis
~ NO lhn1iedkxlhlliing Repair or replace
hamessorpoor (after clean)
oorh:t belweel1I
Sta"*1g s.Wcll : OFF
Belole cheo<ing, CN5fi(13}ffi9(1)
disconnecl(;o.~8
NO DelecMdusler Replace
ENGINE OIL PF.IESSURE SWITCH

CLUSTER
13 I - - - < 5
CN·56 CN·9 CN·1 CC>-18
check resislance
YES MAX 1 !l
NO MIN l lO
6-25
6. 11Jffi WHEN HYDRAUUC OIL TEMPERATURE LAMP LIGHTS UP(Ef9ne Is staned)
· Before canying out below procedure, check all the related connectors are property inserted.
· After d'leOOlg, connect the disoonnected connectors agai'I imnediately unless othelwise specified.
Cause Remedy
YES DelediYe switch Check¥allc
oil leci iperaUe
(1C6t ±2t:)'
Y1 @ Replace
Check resistance
Ooes~g:> YES ~CN-53(8)-
atvhln
ctoca 11ect ro 1
... and chassis
Repair or replac8
and OOI I iecto?
Oieck ll!Sistn:e Slat1ing sWld1 : OFF r..o Oi9:D I eOOl in 'llirilg
S1afting _ , : ON la!lll$a poa cmact (after dean)
Engine : Slart
~ ~CN-7 (12) >-
and chassis belween
CN-7(1~8)
Sianiig switdl : OFF
Cllllld< reslscance N)
Disn:rnecton in..mg Repair or replace
t-i
belween CN-56
(12)andchlssis
- hall'le$a poamU:t (after deen)
~
Stalling switch : OFF cw..6(12}rn.7(12)

8elcnt ched<lng,
clscoc 1 IOCI CO. 1 Defedive clister Replace
ru
'!$
Oieck DefectiYe seOOer Repair()( replace
resiltlnce ($demi)
@- betweenCN· -
52(21) and
chassis N5 cexueb1in'llirilg Rep;Wor replace
Slarl-. : OFF lanassa poaanact (8r<*m)
belwle\
cml!(:l1}ID1
HYllRAUUC OIL
TEMPERAl\JRE SENOER
YES MAX 1 0
NO MIN 111!1
21
#
CN·52
CLUSTER CPU CONTROLLER
2 I 2 ICN·53~
8
ICN·56 12
ICN·7 12 I I
6-26
r
7. ~ WHEN COOL.ANT LEVB. LAMP LIGHTS UP(Engine is started)
· Before carrying out be'°"'f procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
r-- - -- - - - - - - -- -- - --1lnsufficient Refill coolant
coolant Of
[)efedMj swileh Replace
~ Oiso:mdion in v.irilg Repair Of replaoe

harness orpocw (after clean)
Ooesdsplay go Oieck resislance ccntad between
dfwhen ~ ~CN-1 (11)
dscxniect C0.16 ~ and~
CN-1 (11 }C0-16(2)
and COi i iedxlr?
Slalti1g swicl1 : ON Oieck resistn:e Slal1ing swi1ch : OfF NO Oisamectiln 1il lliring Repair Of replace
Englne : S1al1
~ between CN·7 (6) - harness or poor (after clean)
and chassis ccntad between
Slat1lng swhch : OFF CN-7(6}CN-1(11)
N0-=-------1 Disarneciiooin v.irilg Repair Of replace

harness or fXXl' (after clean)
cont&:t~
Slalting slWlch : OFF
GN-06(6}CN-7(6)
clsoomect
- · checldng,
C[).1 S
NO
- = - - - - - - - - - -- - - ; Defective duster Replace
WATER LEVEL
CLUSTER
6 1----1 6 1----111 1----1 2
CN-56 CN·7 CN-1 1
C0-16
check resistance
YES MAX 1 Q
NO MIN 11!1
6-27
i'"
8. WHEN COOLANTTEMPERAlURE GAUGE DOES NOT OPERATE

(Check coolant temperature la111> ONK>FF)
· Before disconnecting the connector, always turn the starting switch OFF.
· Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES Coolant ovemeat Oied<axirt
or Defective senJer terrperab.Jre or
repi<al
~ Oiro:nnedion in lliirg Repair or repace

hamessorpoor (after dean)
Does dsplay gooll Qied< l1i$istln:e cxrlad between
v.tlen discomed - ~ between CN-1(6) ~
CD.a and
CN-1 (6}CIJ.8
and chassis
connecla?
Starting switch : OFF ,,_ lmrlneclioo in wi\"g Repair or repace
Starting swilch : ON Ched< reeistaroe
Engile : start
~ between CN-6(3) -
and chassis
"° harness or poor
cmtactbelween
(afterdean)
Starting swlletl : OFF

<m(3}<:N-1(6)
Check resislarol llscXJlneclioo nwn-g ~orreplace

ooi-icN-57
!'.() (3) and chassis
~
"° haJress or l'.00"

allladbelween
(after dean)
Sta111ng $Wltd\ : OFF CN-57(3)<m('3)
Belore checking.
discoonect CCJ.8
YES Defective duster ReplcK:e
Check Table
--··--...Temperature
Item ~-----.....______ (50"C) ao·c lOO'C (120"C)
Unit Resistance( Q ) (1 53.9) 51.9 27.4 ( 16.1 )

Tolerance + 25, -20 + 4.9, -1.2 + 1.9. -1.2 ±1.2
CLUSTER WATER TEMPERATURE SENDER
I
CN-57
> 3
f---------11I
CN-8
> 3
>---<I1
6
CN-1
\ 1---
I ------1~- CD-8 /l
6-28
9. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ONK>FF)
• Before disconnecting the oonnector, always tum the starting switch OFF.
• Before carrying out below procedure, check all the refated connectors are properly inserted.
Cause Remedy
YES
Defective dusrer RE!JD:e
Check resista1ce YES

belween CN-57(4) L 0Sn1 iocbdn wirilg Repair or replace
and chassis l9rless Cf poCJ (after dean)
oonlact between
51alting - : OfF Check resism::e
See : TABl.E ~(4~f'-1«4)
between CN-8(4) L
YES
00 DS;u1 iOCb I in wirilg
Repair or replace
<nldlassis
l9rless Cf poCJ (after dean)
See :TABLE
oonlact belween
.._ Check resistarce
NO
between CN-4(6) - Cf'-1«4)-0-1<1(6)
and chassis YES
DiloonneditJl in wirilg Repair or replace
See : TABLE harness Cf IJO(J (after clean)
Check resista1ce
between CD-2(2) ,_ ronladbelween
t-.0" and chassis ~6}a)-~
See:TABLE NO @
YES
Check circuit Repair or replace
Check resis1ance betweenC0·2(1) (after clean)
@- belweenCD-2(2) L
lrdctassis
MdCD-2(1)
Defective sender RE!JD:e
See :TABLE NO
Check Table
·--- ··~·-····-..~ Level Empty ( 1/ 2) Full
Item ···---..._
Unit Resistance( a ) 110 (32.5) 3
Tolerance ±3 ±2
FUEL SENDER
2
0 o .
CD·2
6·29
10. WHEN SAFETY SOLENOID DOES NOT OPERATE
· Before disconnecting the oonnector, always tum the starting switch OFF.
· Before canying oot below procedure, ched< aJf the related oonnectors are properly inserted and
short of fuse No. 4.
· Alter checkllg, connect the discomected oonnectors agail immecfiately unless oltlelwise specified.
Cause Remedy
YES Check hyci'aljc
system
~ Oa:k q>ef8lial ~
dsdenoid
DelediYe solenoid Replace
Solely- : ON-Off 00
YES Check chassis Replace
Oieck>dage
between ~1) L contact
-CN-6a(2)
Ched<>dage YES
Sta,qawlldl : ON llscxrnedi()1 irMli'Q Repair or replace
Volage : 2ll· 30v N ~CN- ~
harness or poor
Sal<Mystue 68(2) Wiltl chassis
cmocl betMlen
Saklty le"91' : ON Check '<l:lltage ~S}CN-ffi(2)
belween CN-3(6)
~
L ~ lli:w 11ec1ioo i1 .,,;lill Repair or replace
00
lnfclmsis
harness or poor
Staiq- :ON Ched< vdlage cmocl~
Vcbge ; 2()..3(); belweenCN- ....
NO ~in!clmsis ~6)-CN-00('3)
Slatting .,.;tch ; ON @
Vobage : 20-:lllv t-0
v=
llBxmed i1 llirg Repair or replace
hamess er poor
Clled< qieralim d cinaa~
@- safE!tf Mji ....
~
V<JllQt : 211.;JOv DelecliYe swilch Replace

rt;)
~)
RJSE
1"'--------l 1
2
----l 3
SAFETY SOLENOID
240
'-----l 3 1---- 6 1---l--~ 2
CN-36 CN-3 CN-68
6-30
11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE
· Before disconnecting the connector, always turn the starting switch OFF.
· Before canying out below procedure, check all the related connectors are properly inserted and
short of fuse No. 2.
· Mer checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
NJ Recheck fuse Replace
Chad< vatage
t-Q
betweenCN-36(7)
and chassis H IJis:xl I iedion in \\iilg Repair or rer:Aace
YES
Check vatage harness or pox ClX1lad
NQ betweenCN-3(2) L belwem
and chassis ~
Starling swi1ch : ON
YES IJis:xl I iedion in \\iilg Repair or replace
hamess or po:s ClX1lad
belwem
CH-~
YES
Oefectiv9 hydraulic Check hydrauic
Chad< vatage
h~ system system
between CN-70(2) LL Oieck opera!ioo L
and chassis of solenoid
Defective solenoid Replace
S!anilg swltdl : ON NO
Vctage : 20· 30v
YES
CliioonnedkJl in wirg Repair or replace
hamess or p;lOI" ClX1lad
Chad< volage belwem
YES L-
between CN-57 001(5)Qffi(7)
(7) and chassis
Chad< volage
L betweenC~1
'IES (5) and cha$iS Defective duster Repai" or replace
NJ
Slalting swilctl : ON Deledive cootroller Replace

NJ
CONlllOll.ER TRAVEL SOLENOID
I ) 13 1 -1-------1 3
~ L------- 1
2 '-----------" 2
CN-52
CN- 3 CN-70
5
CN-51
6-31
12. WHEN ENGINE DOES NOT START
şCheck supply of the power at engine 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.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
START S.W
Cause Remedy
1 B+
YES
Defective batteryCheck engine 3 IG
system 5 START
Charge(after
checking specific CS-2
gravity of battery)
or replace 4
Check YES 24V
Check voltage Defective magnet Replace 1
operation of
YES between starter of start motor
start motor magnet coil CN-38
Starting switch : start and chassis Defective start Replace 24V
NO 1
Starting switch : start relay
CN-40
NO
Check operation Disconnection in wiring Repair or replace
of start relay harness or poor contact
NO
FUEL CUT-OFF
between
10
Starting switch : start CN-40(1)-CS2(1)
1
YES
Check voltage Defective start Repair or replace CN-1
between Check voltage
switch CN-79
NO CS-2(1) and between CS-2
chassis (5) and chassis STARTER
‫ڞ‬ START RELAY
Starting switch : start Starting switch : OFF NO
B+
YES
Disconnection in wiring Repair or replace 1
harness or poor contact 2
Check voltage
between CR-23
between CN-79
YES CN-38(4)-CN79 M
and chassis M
NO Defective fuel cut- Repair or replace

off solenoid
NO
Disconnection in wiring Replace
harness or poor contact
Check voltage
between CN-1(1)
‫ڞ‬ between CN-1
and CS-2(5)
(1) and chassis
Starting switch : start
Voltage :20~30V
Disconnection in wiring Repair or replace
YES
harness or poor contact
between
CN-1(1)-CR23(1)
6 - 32
13. WHEN STARTING SWITCH ON DOES NOT OPERATE
şBefore carrying out below procedure, check all the related connectors are properly inserted.
START SWITCH
1 B+
2 ACC
Cause Remedy
3 IG
YES
Disconnection in wiring Repair or replace 5 START
harness or poor (after clean) CS-2
Check voltage contact between
YES between CN-4(2)-CR-1 or
CN-4(2) and
chassis defective battery relay
Voltage : 20~30V
Check voltage Disconnection in wiring Replace IG POWER
YES between NO 1
harness or poor
CS-2(2) and CN-38
chassis contact between
Check voltage Voltage : 20~30V
CS-2(2)-CN-4(2)
BATTERY POWER
YES between 2
CS-2(1) and CONTINUOUS POWER 24V
Defective start Replace 1
NO
switch CN-40
Voltage : 20~30V
Check voltage Disconnection in wiring Replace BATTERY(12Vx2)

NO
and specific harness or poor
gravity of battery contact between
Specific gravity : MIN 1.28 CS-2(1)-CN-5(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
M4 M8
2
CR-1
CN-4
M4 M8
BATTERY RELAY
TO STARTER
6 - 33
14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
şBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse NO.1.
WIPER MOTOR
Cause Remedy
4 S1
YES 3 4
‫ڞ‬ 2 3 3 B
YES
Check voltage
7 2 2 E M
between CN-13
1 1 S2
(1) and chassis 1
Repair or replace
Check voltage Voltage : 20~30V NO Disconnection in wiring
YES harness or poor (after clean) CN-6 CN-13 CN-21
between CN-6 (1) Starting switch : ON
and chassis Wiper switch : ON contact between
CN-13(1)-CN-6(1)
Voltage : 20~30V
Starting switch : ON NO Disconnection in wiring Repair or replace
Wiper switch : ON (after clean)
Check voltage harness or poor
YES
between CR-4 (1) contact between
and chassis CN-6(1)-CR-4(1)
WIPER RELAY
Voltage : 20~30V
Starting switch : ON YES Replace WIPER SWITCH
Defective relay 1
Wiper switch : ON LAMP
2 9
Check voltage YES
Disconnection in wiring Repair or replace 4 10
NO between CR-4 (4) harness or poor (after clean)
and chassis 6 2
Check voltage
contact between 3 6
Voltage : 20~30V between CN-36(6) SWITCH
Check operation Starting switch : ON NO and chassis CR-4(4)-CN-36(6)
of wiper relay Wiper switch : OFF CR-4 CS-3
Voltage : 20~30V Replace
Starting switch : ON NO Recheck fuse WASHER SWITCH
Starting switch : ON
Washer switch : LAMP
YES Replace 10
ON-OFF Defective wiper
Check voltage 9
YES relay
between CS-3(6) 2
and chassis 6
NO Disconnection in wiring Repair or replace
Check voltage Wiper switch : OFF (after clean) 5
harness or poor
between CR-4(6) contact between 1
NO SWITCH
and chassis CS-30
CR-4(6)-CS-3(6)
Voltage : 20~30V
Starting switch : ON 1
NO
Recheck fuse Replace
2
W WASHER TANK
YES Defective wiper Replace CN-22

Check voltage
motor FUSE
‫ڞ‬ between CN-21(1)
and chassis 6
NO NO.1
Starting switch : ON harness or poor (after clean) CN-36
Wiper switch : ON-OFF
contact between
CN-21(1)-CN-13(1)
6 - 34
15. WHEN STARTING SWITCH IS TURNED ON, CAB LAMP DOES NOT LIGHT UP
short of fuse No.10
Cause Remedy
YES
harness or poor (after clean)
Check voltage contact between
YES CL-10
between CN-14 CN-14(4)-(CL-10,
(4) and chassis CL-9, CL-8)
Check voltage
Voltage : 20~30V Disconnection in wiring Repair or replace
Starting switch : ON NO
YES between CN-6 (5) harness or poor (after clean)
cab lamp switch : ON
and chassis contact between CL-9
Voltage : 20~30V
CN-6(5)-CN-14(4)
cab lamp switch : ON Disconnection in wiring Repair or replace 5 4
NO
harness or poor 7 1
Check voltage (after clean)
YES contact between CL-8
between CR-9 (2) CN-6 CN-14
and chassis CR-9(2)-CN-6(5) CAB LAMP
Voltage : 20~30V YES
Defective relay Replace
cab lamp switch : ON
Check voltage
between CR-9(4) YES Disconnection in wiring
NO Repair or replace
and chassis
harness or poor (after clean)
Voltage : 20~30V Check voltage contact between CAB LAMP RELAY
Starting switch : ON between CN-37
NO CR-9(4)-CN-37(3) CAB LAMP SWITCH
(3) and chassis 4
LAMP
Voltage : 20~30V Replace 3 10
Starting switch : ON NO Recheck fuse
1 9
YES 2 2
Check operation 6
of cab lamp relay harness or poor (after clean) CR-9 SWITCH
Check voltage
YES contact between CS-24
between CS-24
Starting switch : ON CR-9(3)-CS-24(2)
cab lamp switch: ON-OFF
(2) and chassis
Cab lamp switch : ON Replace switch
NO
Defective cab FUSE
Check voltage
lamp switch 3
NO between CS-24(6)
and chassis NO.10
YES
CN-37
Starting switch : ON harness or poor
Check voltage (after clean)
between CN-37 contact between
NO
(3) and chassis CS-24(6)-CN-37(3)
NO Recheck fuse Replace
Check the bulb of YES

YES cab lamp
Defective bulb Replace
6 - 35
16. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
short of fuse No.8
Cause Remedy
YES HEAD LAMP
Defective bulb Replace
Check voltage
YES between CL-4(2)
and chassis
Voltage : 20~30V NO
Check voltage harness or poor (after clean)
YES between CN-4 (7) Starting switch : ON
Head lamp switch : ON contact between
and chassis
CN-4(7)-CL-4(2)
Voltage : 20~30V
NO
Disconnection in wiring Repair or replace 1 2
Head lamp switch : ON
harness or poor (after clean) CL-3
Check voltage
YES contact between
between CR-13
(2) and chassis CR-13(2)-CN-4(7)
7 2
Defective relay Replace 9 1
CN-4 CL-4
Check voltage HEAD LAMP
YES Disconnection in wiring
NO between CR-13 Repair or replace
(4) and chassis harness or poor (after clean)
Voltage : 20~30V Check voltage CLUSTER
contact between
NO between CN-37 CR-13(4)-CN-37(1) 9 9
Check operation (1) and chassis
of head lamp relay CN-7 CN-56
Voltage : 20~30V
Starting switch : ON NO Recheck fuse Replace
Starting switch : ON HEAD LAMP RELAY
Head lamp switch : YES
ON-OFF
Disconnection in wiring Repair or replace HEAD LAMP SWITCH
4
harness or poor (after clean) LAMP
Check voltage 3 10
YES contact between
between CS-39(2) 1 9
and chassis CR-13(3)-CS-39(2)
2 2
Defective lamp Replace switch 6
NO CR-13 SWITCH
Check voltage switch CS-39
NO between CS-39(6)
and chassis
YES
Voltage : 20~30V FUSE
Starting switch : ON harness or poor (after clean)
Check voltage 1
contact between
between CN-37
NO CN-37(1)-CS-39(6) NO.8
(1) and chassis CN-37
NO Recheck fuse Replace
6 - 36
17. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
short of fuse No.9.
WORK LAMP
Cause Remedy
YES
Disconnection in wiring Repair or replace 1
harness or poor (after clean) 2
contact between CL-6
Check voltage
YES CN10(2)-CL-6(2)
between CN-10
(2) and chassis and CL-5(2) 9 1 1
4 2 2
Voltage : 20~30V
Starting switch : ON CN-4 CN-10
Check voltage Work lamp switch : ON NO Disconnection in wiring Repair or replace CL-5
YES
between CN-4(4) harness or poor (after clean)
and chassis
contact between
Voltage : 20~30V
CN-10(2)-CN-4(4) CLUSTER
Work lamp switch : ON Disconnection in wiring Repair or replace
NO 10 10
YES
between CR-3 (2) CN-7 CN-56
and chassis contact between
CN-4(4)-CR-3(2) WORK LAMP RELAY
Starting switch : ON Defective relay Replace WORK LAMP SWITCH
4
Work lamp switch : ON LAMP
3 10
Check voltage 1 9
between CR-3(4) YES 2 2
NO Disconnection in wiring Repair or replace
and chassis 6
harness or poor (after clean) CR-3 SWITCH
Voltage : 20~30V Check voltage
Starting switch : ON contact between CS-36
between CN-37
Check operation NO
(2) and chassis CN-37(2)-CR-3(4)
of work lamp relay
Voltage : 20~30V
FUSE
Starting switch : ON NO Recheck fuse Replace
2
Work lamp switch :
ON-OFF CN-37 NO.9
YES
YES
between CS-36 contact between
(2) and chassis
CS-36(2)-CR-3(3)
Work lamp switch :
NO Defective lamp Replace switch
Check voltage
between CS-36 switch
NO
(6) and chassis
YES
between CN-37 contact between
NO
(2) and chassis
CS-36(6)-CN-37(2)
NO Recheck fuse
6 - 37
GROUP 3 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 2050 +50rpm F-mode 1850 +50rpm
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective
Is pressure
YES hydraulic system.
at EPPR valve
normal?
YES Is electric NO
Defective Replace.
current at EPPR SPEC : 8~20 kg/cm2
See test 4 EPPR valve.
valve normal?
SPEC:270~450 mA
NO Defective CPU Replace.
Is resistance See test 3
controller.
between CN-50(6)
- (8) normal? YES
Short circuit or Check & repair
SPEC:17.5Ź1‫(װ‬20Ƅ) poor connection wire harness or
See test 1 Is resistance at between CN-50 - between CN-50 -
EPPR valve
NO CN-75. CN-75.
normal?
SPEC:17.5Ź1‫(װ‬20Ƅ) Defective EPPR Replace
See test 2 NO
valve.
Wiring diagram
2 Ɠ Normal :
1
CN-47 Emergency :
PROLIX S.W
6
5
4
9 3
8 2
6 1
CN-50 CS-7
11 1
EPPR V/V
2
CN-75
CN-51 CN-2
6 - 38
2) TEST PROCEDURE
SPEC : 17.5 Ź 1ѻ(20Ş
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 : 17.5 Ź 1ѻ(20Ş
C)
‫ ڸ‬Starting key OFF.
‫ ڹ‬Disconnect connector CN-75 from
EPPR valve at main hydraulic pump. CN-75
‫ ں‬Check resistance between 2 lines as
Figure.
Multimeter
(3) Test 3 : Check electric current at EPPR

valve. SPEC : 270~450mA
‫ ڸ‬Start engine.
‫ ڹ‬Set S-mode and cancel auto decel
mode.
‫ ں‬If tachometer show approx 2250+50rpm,
CN-75
disconnect one wire harness from EPPR
valve.
‫ ڻ‬Install multimeter as Figure.
‫ ڼ‬Check electric current at bucket circuit
relief position. EPPR VALVE
Multimeter
6 - 39
(2) Test 4 : Check pressure at EPPR valve.
‫ ڸ‬Remove plug and connect pressure SPEC : 8~20 kg/cm2(114~284 psi)
gauge as Figure.
Gauge capacity : 0 to 40~50 kg/cm2
(0 to 569~711 psi)
‫ ڹ‬Start engine.
‫ ں‬Set S-mode and cancel auto decel Supply line, pilot press
mode.
CN-75
‫ ڻ‬If tachometer show approx. 2250+50rpm,
Pressure adjusting
check pressure at relief position of screw
locknut
bucket circuit by operating bucket control
lever.
‫ ڼ‬If pressure is not correct, adjust it.
‫ ڽ‬After adjust, test the machine.
6 - 40
2. ENGINE SPEED IS SLOW AT ALL MODE
Cause Remedy
Good
If test 7 is good,
Check tachometer check TEST 1~4
YES work properly or
YES
not by changing Is resistance Misalignment Clean speed
the mode. between CN- between speed sensor and adjust.
Is resistance
See test 6 52(14) - CN-51(12) sensor and fly SEE: 5-21page
Good between CN-50(2) No good normal?
- (3) and (4) - (5) wheel
normal? SPEC:0.2~0.4‫ױ‬ ‫ڞ‬
See test 7
SPEC:5~6‫װ‬
Check linkage See test 5 Defective governor Replace governor
NO
between governor motor or short circuit motor or harness.
motor - injection or poor connection assembly.
pump. between CN-50 -
CN-2 and CN-2 -
CN-76
Improper operation Adjust or repair.
No good
by loosening or
interference of
linkage.
YES
Short circuit or poor Check and repair.
connection between
Is resistance
‫ڞ‬ CN-51(12) - CD-
between CD-17(1)
17(2) or CN-52(14) -
- (2) normal?
CD-17(1)
SPEC:0.2~0.4‫ױ‬ Defective Replace.
See test 8 NO
speed sensor.
Wiring diagram
2 Ɠ Normal :
1
CN-47 Emergency :
5 PROLIX S.W
4 6
3 5
2 4
9 3
8 2
6 1
CN-50 CS-7
11 1
12
2 EPPR V/V
10
CN-51 CN-2 CN-75 SPEED SENSOR
24 2
23 1
14 CD-17
CN-52 5 1
4 2 POT(POTENTIOMETER)
3 3
7
6 CN-77
9
10 1 A
11 2 A-
12 3 B
4 B-
CN-2
CN-76 GOVERNOR MOTOR
6 - 41
2) TEST PROCEDURE
(1) Test 5 : Check resistance between (2)-(3) CPU
and (4)-(5) at connector CN-50. CONTROLLER
CN53 CN52 CN51 CN-50
‫ ڹ‬Remove CPU controller and disconnect
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 2050+50rpm decel mode.
F-mode 1850+50rpm
(2) Test 7 : Check resistance between (14) of

SPEC : 0.2 ~ 0.4 ‫ױ‬
CN-52 and (12) of CN-51.
‫ ڹ‬Remove CPU controller and disconnect CPU
connector CN-51 and CN-52 from CPU CONTROLLER
controller. CN53 CN52 CN51 CN-50
CN-52 CN-51
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
13 14 1516 17 18 19 20 2122 23 24 10 11 12 13 14 1516 17 18
Multimeter
6 - 42
(4) Test 8 : Check resistance at speed sensor.
‫ ڸ‬Starting key OFF. SPEC : 0.2 - 0.4‫ױ‬
‫ ڹ‬Disconnect connector CD-17 of speed
sensor at engine flywheel housing. Speed sensor
CD-17 CD-17
1 2
Engine flywheel
Multimeter
6 - 43
3. ENGINE STALL
Cause Remedy
YES
Not enough engine Contact cummins
YES Is pressure at power. engine dealer.
EPPR valve
normal?
NO
Defective EPPR Replace.
SPEC:30~40 kg/cm2 valve.
Is electric current See test 10
at EPPR valve YES
normal? Defective CPU Replace.
controller.
SPEC:500~700 mA
See test 9 Is resistance
between CN-50(6) YES
Short circuit or poor Check and
NO - (8) normal?
connection repair.
SPEC:17.5Ź1ѻ(20Ƅ) Is resistance at between
See test 1 EPPR valve CN-50 - CN-2 or
NO
normal? CN-50 - CN-75
SPEC:17.5Ź1ѻ(20Ƅ)
See test 2 Defective EPPR Replace.
NO
valve.
Wiring diagram
Ɠ Normal :
Emergency :
2
1
CN-47
PROLIX S.W
6
5
4
9 3
8 2
6 1
CN-50 CS-7
11 1
EPPR V/V
2
CN-75
CN-51 CN-2
6 - 44
2) TEST PROCEDURE
SPEC : 500~700mA
(1) Test 9 : Check electric current at EPPR
valve at F-mode
‫ ڸ‬Start engine. CN-75
‫ ڹ‬Set F-mode with 1850 +50rpm
‫ ں‬Install multimeter as Figure.
‫ ڻ‬Operate bucket lever completely push or
pull and hold arm lever at the end of
stroke. EPPR VALVE
‫ ڼ‬Check electric current at engine stall
Multimeter
state.
(2) Test 10 : Check pressure at EPPR valve

SPEC : 30~40 kg/cm2(427~569 psi)
at F-mode
‫ ڸ‬Connect pressure gauge at EPPR valve.
‫ ڹ‬Start engine.
‫ ں‬Set F-mode with 1850 +50rpm
‫ ڻ‬Operate bucket lever completely push or Supply line, pilot press
pull and hold arm lever at the end of CN-75

stroke. Pressure adjusting
screw
‫ ڼ‬Check pressure at relief position. locknut
6 - 45
4. CLUSTER LAMPS ARE OFF IMMEDIATELY AFTER KEY SWITCH OFF
Ɠ Before carrying out below procedure, check all the related connector are properly inserted.
Normal condition : Lamps "ON" approx. 3~7 seconds after key switch OFF.
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
FUSE BOX
BATTERY
10 7 18 1 1 1
CN-40 CN-5 CN-60
CN-38
CN-50
6 - 46
2) TEST PROCEDURE
SPEC : 24 Ź 1Volt
(1) Test 11 : Check voltage at (10) of CN-50.
‫ ڸ‬Starting key OFF. CN-50
‫ ڹ‬Disconnect connector CN-50 from CPU CPU 1 2 3 4 5

CONTROLLER 6 7 8 9
controller. 10
Ground
Multimeter
(2) Test 12 : Check fuse at (18) of fuse Box.

‫ ڸ‬Starting key OFF. Fuse box
WIPER &
20A
10A
11
1
SPARE
WASHER
‫ ڹ‬Selecting the fuse at (18) of fuse Box.
20A
10A
SPARE
2
12
SOL. B+
‫ ں‬Check if the fuse is defective or not.

CASSETTE & CIGAR &
20A
10A
13
3
RADIO ETHER SOL.
HORN &
20A
10A
14
CPU
4
SAFETY
FUEL F/PUMP &
20A
10A
15
5
CUT-OFF SOL. T/ALARM
AIR-CON &
20A
10A
16
6
SPARE
HEATER
10A
20A
17
CASSETTE B+
7
SPARE
MONITOR &
20A
20A
18
8
HEAD LIGHT
CPU B+
10A
20A
19
ROOM LAMP
9
WORK LIGHT
20A
10A
10
20
SPARE CABIN LIGHT
20A
SPARE
FUSE
20A
PULLER SPARE
SPEC : 20A
Fuse No. 18 for CPU B+
6 - 47
5. CLUSTER LAMPS ARE STILL ON AFTER STARTING KEY OFF
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 : 24Ź1 VOLT
Key OFF : 0 VOLT 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
START KEY SWITCH

FUSE BOX
9 3 3 START
14
1 IGNITION
CN-38 CS-2
CN-50
6 - 48
2) TEST PROCEDURE
SPEC :
(1) Test 13 : Check voltage at(9) of CN-50. Key ON : 24Ź1 Volt
‫ ڸ‬Starting key "ON". Key OFF : 0 Volt
‫ ڹ‬Disconnect connector CN-50 from CPU
CN-50
controller. CPU 1 2 3 4 5
‫ ں‬Check voltage as Figure. CONTROLLER 6 7 8 9 10
Ground
Multimeter
(2) Test 14 : Check operating status of main

SPEC :
power supply at (9) of CN-50.
Key OFF : 0 Volt
‫ ڸ‬Starting key "ON 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 - 49
6. CLUSTER LAMPS ARE NOT CHANGING OR FUNCTION IS ABNORMAL WHEN THE RELATED
SWITCH ARE PUSHED.
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
CD-6 2
CN-36
OVERHEAT SWITCH
3
CN-1 CD-9
8 8
1
2
3
CN-56 CN-7 4
5
6
7
8
9
7 7
1 1 CN-51
2 2
9 9
8 8
5 5 7
CN-57 CN-8
CN-50
6 - 50
6-1. ALL CLUSTER LAMPS ARE OFF WHEN START KEY SWITCH IS ON POSITION.
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 : 24V
Key OFF : 0V
See test 16 NO
controller.
Wiring diagram
5 5 7
CN-50
CN-8
CN-57
6 - 51
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
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 : 24Ź1 Volt
şCN-50:output power(24Ź1volt)
şCN-57:input power(24Ź1volt)
‫ ڸ‬Starting key ON. CN-50
‫ ڹ‬Remove cluster from panel. CPU 1 2 3 4 5

CONTROLLER
Ɠ Don't disconnect connector CN-50 from 6 7 8 9 10
CPU controller.
‫ ں‬Disconnect connector CN-57 from
Ground
cluster.
‫ ڻ‬Check voltage CN-50,CN-57 with ground
Multimeter
as Figure.
CN-57
1 2 3 4 5 6
7 8 9 10 11 12
Ground
Multimeter
6 - 52
7. SLOW ACTION OF ENGINE SPEED CHANGE WHEN CHANGE THE MODE
Cause Remedy
YES
Slow action of Check and repair.
engine speed
control due to
interference.
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) : 5Ź1 volt
- (5) normal? (23)-(10) : 0-5‫ױ‬
See test 18
SPEC : 7~8‫װ‬
See test 17 Defective governor Replace.
NO
motor.
Wiring diagram
2
3
4
5
CN-50
5 1
4 2 POT(POTENTIOMETER)
10 3 3
CN-77
CN-51
12 4 B-
11 3 B
10 2 A-
24 9 1 A
23
CN-2 CN-76 GOVERNOR MOTOR
CN-52
6 - 53
2) TEST PROCEDURE
Test - a
(1) Test 17 : Check resistance
‫ 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
(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
Multimeter
6 - 54
(2) Test 18 : Check voltage and resistance.
SPEC : 0 ~ 5 ‫ױ‬
‫ 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
from CPU controller.
Ť Check resistance with multimeter as
below.
CN-52 CN-51
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
13 14 1516 17 18 19 20 2122 23 24 10 11 12 13 14 1516 17 18
Multimeter
‫ ڹ‬Check voltage between (24) of CN-52

SPEC : 5 Ź 1Volt
and (10) of CN-51.
CPU
Ť Prepare 2 pieces of thin sharp pin, steel
CONTROLLER
or copper. Pin Pin
Ť Starting key ON.
Ť Insert prepared pins to rear side of
connectors :
One pin to (24) of CN-52
Other pin to (10) of CN-51
Ť Check voltage.
CN-52 CN-51
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
13 14 1516 17 18 19 20 2122 23 24 10 11 12 13 14 1516 17 18
Multimeter
6 - 55
8. AUTO DECEL SYSTEM DOES NOT WORK
Cause Remedy
YES
Is voltage between controller.
YES
CN-51(3)-GND
normal?
Is voltage between SPEC : NO

Open circuit or Replace or repair.
Actuator operating poor connection
CN-51(4) - GND : 4.5~5.5V
normal? Actuator normal between CN-51(3)
: 0~2V - pressure switch
SPEC :
Switch ON : 0~2V
Switch OFF : 4.5~5.5V
See test 19 NO
Defective cluster. Replace.
Wiring diagram
8 8 4
3
CN-56 CN-7 CN-51
AUTO DECEL PRESSURE SWITCH
CD-7 CD-6
6 - 56
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
‫ ڹ‬Turn start key ON. CPU
Check voltage as Figure. CONTROLLER
CN-51
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
Ground
Multimeter
6 - 57
9. MALFUNCTION OF WARMING UP
Cause Remedy
YES
Defective cluster or Repair or
Is resistance CPU controller or Replace.
YES
between CN-57(3) CD-8(sensor)
- CD-8 normal?
Is resistance
between CN- SPEC : 0ѻ NO
Poor connection Repair.
See test 21 between CN-57(3)
52(20) - CN-56(16)
normal? - CD-8.
SPEC : 0ѻ
See test 20 Poor connection Repair.
NO
between CN-
52(20) - CN-56(16).
Wiring diagram
WATER TEMP SENSOR

20 4 16
CD-8
CN-52 CN-9
CN-56
3 6
CN-1
CN-57
6 - 58
2) TEST PROCEDURE
SPEC : 0ѻ
(1) Test 20 : Check resistance between
connector (20) of CN-52 and
(16) of CN-56. CPU
‫ ڸ‬Starting key OFF. CONTROLLER
‫ ڹ‬Remove CPU controller and disconnect CN53 CN52 CN51 CN50
CN-52 from CPU controller.

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

connector (3) of CN-57 - CD-8. SPEC : 0ѻ
CN-57
‫ ڹ‬Remove cluster and disconnect CN-57
12 11 10 9 8 7
from cluster. 6 5 4 3 2 1
‫ ں‬Disconnect connector CD-8 of water
temp sensor at engine head.
Cluster
CD-8 Water temp sensor
Multimeter
6 - 59
10. MALFUNCTION OF OVERHEAT
Cause Remedy
YES
Defective overheat Replace
switch
Is resistance
between CD-9 - YES
GND normal? Defective CPU Replace
SPEC : Is resistance controller
Region ѓơſѻ between CN-51(1)
(Fig.) єơ 0ѻ NO
ѕơſѻ
- CD-9 normal?
See test 22 Short circuit or poor Check or Repair
SPEC : 0ѻ NO
See test 23 connection between
CN-51(1) - CD-9.
coolant
temperature
110Ƅ
Ɠ Overheat switch ON : coolant temperature 110Ƅ 100Ƅ

Ɠ Overheat switch OFF : coolant temperature 100Ƅ
Time
Region ѓ Region є Region ѕ
Temperature curve
Wiring diagram
Overheat switch
1 3
CD-9
CN-51 CN-1
15 3
CN-9
CN-56
6 - 60
2) TEST PROCEDURE
SPEC : 0ѻ
connector CD-9 - GND. CD-9 Overtheat switch
‫ ڹ‬Disconnect connector CD-9 of overheat
switch at engine head.
Ground
Multimeter

SPEC : 0ѻ
connector (1) of CN-51 - CD-9.
CPU
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.
CN-51
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
CD-9
Overtheat switch
Multimeter
6 - 61
11. SWING SPEED CONTROL SYSTEM IS ABNORMAL
Cause Remedy
YES
Defective Hydraulic
system.
YES Is current at EPPR
valve normal?
SPEC : 0~700mA NO
Defective CPU Repair or replace
See test 25 controller or current
Is voltage between supply 2 lines are
CN-52(8)-GND abnormal.
normal?
YES
SPEC : 0~5V Poor connection Repair or replace
See test 24 between CN-52(8)-
CS-51(2) or
Is voltage between
CN-52(7)-GND defective swing
NO
normal? speed control dial
SPEC : 0~5V
itself.
See test 26
NO Defective CPU Repair or replace

controller.
Wiring diagram
1 13
2 14 SWING EPPR
VALVE
CN-1
SWING SPEED
CONTROL DIAL
1 5V
7
CN-124
2 SIG
8
9 3
CN-52 CS-51
6 - 62
2) TEST PROCEDURE
SPEC : 0}5 V
(1) Test 24 : Check voltage between
connector CN-52(8) - GND. CPU
‫ ڸ‬Start key ON. CONTROLLER
‫ ڹ‬Turn the swing speed control dial from CN53 CN52 CN51 CN-50
minimum position to maximum position.

‫ ں‬Check Voltage as Figure.
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
Ground
Multimeter
(2) Test 25 : Check electric current at swing

SPEC : 0}700 mA
EPPR valve.
‫ ڸ‬Start key ON.
‫ ڹ‬Set any mode. CN-124
‫ ں‬Disconnect one wire harness from swing
EPPR valve.
‫ ڻ‬Install multimeter as Figure.
‫ ڼ‬Check electric current and turn swing
speed control dial from minimum
position to maximum position.
Multimeter
(3) Test 26 : Check voltage at EPPR valve.

‫ ڸ‬Start key ON. SPEC : 5 V
‫ ڹ‬Turn the swing speed control dial from
minimum position to maximum position.
‫ ں‬Check Voltage as Figure. Ground
Multimeter
6 - 63
r
SECTION 7 MAINTENANCE STANDARD
1.PURPOSE
Performance tests are used to check:
1) OPERATIONAL PERFORMANCE OF A NEW
~E
Whenever a new machine is delivered in
parts and reassembled at a customer's site,
it must be tested to confirm that the
operational performance of the machine 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
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 manuaQ.
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. TERMN)l.OOY
1) STANDARD
Specifications applied to the brand-new
machine, <XlflllOl 18!1ls and par1s.
2) SERVICE LMT
The lowest acceptable performance level.
When the perfonnance level ol the machine
falls below this lewl, the machine must be
removed from work and repaired.
Necessary parts and components must be
replaced .
..
7-2
r •
3. OPERATION FOR PERFORMANCE TES1S

1) Observe the following rules in order to cany
out performance tests accurately and safely.
(1) The mactllne
Repair any defects and damage found,
such as oil or water leaks, loose bolts,
cracks and so on, before starting to test
(2)Test8188
<D Select a hard, flat surface.
® Secure enough space to allow th e
machine to run straight mo<e than 20m,
and to make a full swing with the front
attachment extended.
@ If required, rope off the test area and
provide signboards to keep unauthorized
personnel i!!llfllf.
(3) P1'9C8utlons
<D Before starting to test, agree upon the
signals to be empic¥ld for comrrunication
among coworkers. Once the test is
started, be sure to communicate with
each other using these signals, and to
follow them without fail.
@ Operate the machine carefully and
always give first priority to safety.
@ While testing, always 1aka cara to aYOid
accidents due to landslides or contact
with higl ~ power lines. Afways
confirm that there is sufficient space lo<
full swings.
© Avoid polluting the machine and the
ground with leaJdng oil. Use oil pans to
calch escaping oil. Pay special attention
to this when removing l'Pydlaulic pipi1gs.
(4) Make precise n.aunllTl8flts
<D Accurately calibrate test instruments in
advance to obtain correct data.
® Carry out tests under the exact test
conditions prescribed for each test item.
@ Repeat the same test and confirm that
the test data obtained can be procured
• repeatedly. Use mean values of
measurements if necessary.
7 -3
r •
2) ENGH: SPEED
(1) Measure the engine speed at each power
mode
• The engine speed at each power mode
must meet standard RPM; ff no~ all other
operational performance data will be
unreliable. It is essential to perform this
test first.
(2) Preparation
<D Warm up the machine, until the engine
coolant temperature reaches so·c or
more, and the hydraulic oil is 50± s·c.
~ Push the H-mode switch and confirm
that the fuel injection pump governor
lever comes into contact with the high-
idle stopper.
(3) To measure engine RPM:
(3) Measurement
<D Slart the engine. The engine wlll run at
slart idle speed. Measure engine speed
with a tachometer.
~ Measure and record the engine speed at
each mode(H.S.LF)
® Select the H-mode.
© l9ttlY operate the bucket control lever a
few tmes, then return the control lever to
neutral; the engine will automatically
enter the auto-idle speed after 4
seconds.
$ Measure and record the auto deceleration
speed.
(4) Evaluation
The measured speeds should meet the following specifications.
Untt: rpm
Model Engine speed Standard Remar1a;
Start ide 800 ± 100

Hmode 2250+ 50
Smode 2250 + 50
R210LC-3
lmode 2060 + 50
-
Fmode 1850 + 50
• Autodecel 1200 + 50
7.4
r
3) TRAVB.SPEED
(1) Measure the time required for the
excavator to travel a 20m test track.
(2) Preparation
<D Adjust the tension of both tracks to be
equal.
@ Prepare a flat and solid test track 20m in
length, with extra length of 3 to 5m on
both ends for machine acceleration and
deceleration.
@ Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
© Keep the hydraulic oil temperature at
SO±s·c.
(3) Measurement
© Measure both the low and high speeds
of the machine.
@ Before starting either the low or high
'i~'.!t~~ "F
speed tests. adjust the travel mode
switch to the speed to be tested, then
select the following swttch positions:
3- Sm 20m 3-Sm
· Mode selector : H mode
@ Start travel ing the machine in the
acceleration zone with the travel levers at
full stroke.
© Measure the time required to travel 20m.
@ After measuring the forward travel
speed, tum the upperstructure 1ao· and
measure the reverse travel speed.
@ Repeat steps © and ® three times in
each direction and calculate the average
values.
(4) Evaluation
The allE!rage measured time should meet the following specifications:
Unit : seconds/20m
Model Travel speed Standard Maximum alowable Remarl<s
1 speed 23.2±2.0 30.2
R210LC-3
2speed 13.8±1.0 17.3
7-5
•
4) TRACK RE\U.l1TlON SPEED

(1) Measure the track revolution cycle lime
wi1h the track raised off gound.
(2) Preparation
<D Adjust the tension of both side tracks to
be equal.
<2> On Ille track to be measured, mark one
shoe with chalk.
® Swing the uppelStruclure 90• and lower
the bucket to raise the track off ground.
Keep the boom-arm angle between 90
to 110· as shown. Place blocks under
machine frame.
© Keep the hya'aulic oi temperature at
so±s·c.
(3) Meaw'ament
<D Select the following switch positions:
Travel mode switch : 1 or 2 speed
• Mode selector : H mode
· Auto deoel switch : OFF
<2> Operate the travel control lever of the
raised track in luD forward and reverse.
Q) Rotate 1 tum, then measure time taken
for next 3 rlM>lutions.
© Raise the other side of machine and
repeal the proceciJre.
<ID Repeat steps ® and © 1hree times and
calculate the 81/erage values.
(4) Evaluation
The revolution cycle time of each track should meet 1he following specifications:
Unit : Seconds/ 3 rtMllutions
Model Travel speed Standatd Maxirun~
1 speed 27.0±2.0 35
R210LC-3
2speed 18.0±2.0 23
7 -6
r
5) TRAVB.. DEVIATlON
(1) Measure the deviation by the tracks from
a 20m straight line.
(2) Preparation
<D Adjust the tension of both tracks to be
equal.
@ Provide a flat, solid test yard 20m in
length, with extra length of 3 to .Sm on
both ends for machine acceleration and
deceleration.
@ Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
so±s·c.
(3) Measurement
(j) Measure the amount of mistracking at
high and low travel speeds.
® Before beginning each test, select the
following switch positions:
· MODE selector : H mode
@ Start t raveling t he machine in the
acceleration zone with the travel levers at
full stroke. 3- Sm extra length
© Measure the distance between a straight
20m line and the track made by the
machine.(dimension a)
@ Alter measuring the tracking in forward
travel, tum the upperstructure 180' and
measure that in reverse travel.
® Repeat steps © and @ three times and
calculate the average values.
(4) Evaluation
Mistrack should be within the following specifications:
Unit : mn'20m
Model Standard Maxinum allowable Remarks
R210LC-3 200below 240
7-7
•
6) SWH> SPEED
(1) Measure the time required to swing three
complete turns.
(2) Preparation
0) Cl1eck the lubricatioo of the swing gear
and swing bearing.
® Place the machine on ftat. solid groynd
with ~ space for swinging. Do not
conduct this test on slopes.
Q) With the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin. The bucket must be empty.
50±5"C.
(3) Measu""'1eflt
· MODE selector : Each mode
<2l Operate swing control lever fully.
Q) Swing 1 tum, and measure time taken to
swing next 3 r8\IOlutions.
© Repeat steps <2l and @ three time and
(4) Evaluation
The time required for 5 swings should meet the following specificatioos:
Unit : Seconds/ 3 reYOlutions
Model Power selector swilch Standard Maxin.m~
Hmode 12.6±1.5 13.0
R210LC-3
Smode 10A±1.5 -
Lmode 7 13.0±"2.3 ) -
Fmode ( l'l.0±2.3 -
•
-
7-8
•
7) SWING FUNCTION DRIFT CHECK

(1) Measure the swing drift on the bearing
outer circumlerenoe when stopping after
a 350• lull speed swing.
(2) Preparation
CD Check the lubrication o1 the swing gear
and swing bearing.
® Place the madline on ftat, solid ground
with ~ space lo< swinging. Do not
conduct this test on slopes.
® Wrth the arm rolled out and bucket rolled
in, hold the bucket so that the heiglt of
loot pin. The bucket must be empty.
© Make two chalk marks: one on the swing
bearing and one directly below It on the
track frame.
@ Swing the upperstructure 360• .
@ Keep the hydraulic oil temperature at
50±5'C.
(3) Measurement
© Conduct this test in the H mode.
® Select the following switch positions:
@ Operate the swing control le'ver fully and
return It to the neutral position when the
mark on the upperstructure aligns with
that on track frame after swinging 350•
© Measure the distance between the two
marks.
@ Al9i the marks again, swing 350•. then
test the opposite direction.
<ID Repeat steps © and ® three times each
and calculate the average values.
(4) Evaluation
The measured drift angle should be within the following specif1Cations:
Unit :degee
Model
A210LC-3
I Mode select switch
H mode
I Standard
90belo.Y
7-9
- •
8) SWWG BEARl«l PLAY

(1) Measure the swilg bearing play using a
dial gauge to checX the wear of bearing
races and balls.
(2) Preparation
 Check swing bearing mounting cap
screws for loosening.
<%> Check the lubrication of the swing
bearing. Confinn that bearing rotation is
smooth and without noise.
(3) Install a dial gauge on the track frame as
shown, using a rnagietic base.
@ Position the upperstructure so that the
boom aligns with the tracks facing
towards the front idlers.
® Position the dial gauge so that its needle
point comes into contact with the bottom
face of the bearing outer race.
@ Bucket should be empty.
(3) Measurement
 With the arm rolled out and bucket rolled
in, hokl the bottom face of the bucket to
the same height of the boom foot pin.
Record the dial gauge reading(h 1)
(2) u-r the IJud(et to the golllld and use
ii to raise the front idler 50 an. Record Measurement :(h2)
~
the dial gauge reacing(h2)
@ Calculate bearing play(H) from this
data(h1 and h2) as follows:
H : h2-h1
(4) Evaluation
The measured drift should be within the following specifications:
Unit : mm
Standard
A210LC-3 0.5-1.5 3.0
•
-
7-10
9) HYDRAULIC CYl.HlER CYCLEDE
(1) Measure the cycle time of the boom,
standard arm, and standard bucket
cyfinders.
(2) Prepandlon
· Boom cyinder Raise
<D To measure the cyde time ol the boom
~~
cylinders:
Wrth the arm rolled out and the empty
bucl<et rolled out. lower the bucl<et to h!
ground, as shown.
® To measure the cycle time of the arm
cylinder:
• Arm cylilder
With the empty bucl<et rolled in, position
the arm so that ii is vertical to the
ground. Lower the boom until the
buc1<et is O.Sm above the ground.
@ To measure the cyde time of the bud<et
cylinder.
The empty bucket should be positioned
at midstroke between roll-in and roll-0u~ · Buc*et cylinder
so that the sideplate edges are vertical to
the ground.
so±s·c. Rollin
(3) Measurement
<D Select the lollowing switch positions:
• MODE selector : H mode
® To 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
leY9r to the other stroke end as quiddy
as possible.
-Arm cylinder:
Measure the time it takes to roll in the
arm, and the time it takes to roll out the
arm. To do so, position the bucket at
one stroke end, then move the control
lever to the other stroke end as quickly
as possible.
7-11
•
-Bucket cylinders
Measure the time it takes to roll in the
bucke~ and the time it takes to roll out
the bucket. To do so, position the
lxJCl<et at one stroke end, then rro"8 the
control lever to the olher stroke end as
quickly as possille.
· Repeat eacti measurement 3 times and
(4) Evaluation
The average measured tine should meet the l:lllowilg specifications:
Unit : seconds
Model Function Standard Maxirun~ Remarks
Boom raise 2.9±0.3 3.8
Boom lower 2.3±0.3 3.0
A210LC-3 Armin 3.5±0.4 4.6
Arm out 2.9±0.3 3.8
Bucket load 3.0±0.4 3.9
Bucket dump 2.0±0.3 2.6
..
7 - 12
1~ DIG FUNC110N DAFT 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
CD Load Qucket fully. Instead of loading the
bucket, we ight(W) of the following
specification can be used.
· W=M'X1.5
Where :
M' =Bucket heaped capacity (ni')
1.5= Soil specific gravity
@ Position the ann cylinder with the rod 20
to 30mm extended from the fully retracted
position.
@ Position the bucket cylinder with the rod
20 to 30mm retracted from ·the fully
extended position.
© With the arm rolled out and bucket rolled
in, hold the bucket so that the height of
foot pin.
® Keep the hydraulic oil temperature at
50±5'C.
(3) Measurement
<D Stop the engine.
® Five 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.
@ Repeat step @ three times and calculate
the average values.
(4) The measured drift should be within the foHowing specifications:

Unit : lmli5min
Model Drift to be mea'lUred Standard Maximum allowable Remarks
Boom cylinder 40below 55
R210LC-3 Ann cylinder 60below 75
Bucket cylinder 40below 60
7-13
•
11) CONTROL LEVER OPERATING FORCE

(1) Use a spring scale to measure the
maximum resistance of each control l8118r
at the middle of the grip.
(2) Preparation
<D Keep the hydraulic oil temperature at
so±s·c.
(3) Measurement
<D Start the engine.
® Select the following switch positions:
· MODE selectoc : H mode
® Operate each boom, arm, bucket and
swing lever at full stroke and measure
the maximum operating force for each.
© Lower the bucket to the ground to raise
one track off the ground. Operate the
travel lever at full stroke and measure
the maximum operating force required.
When finished, lower the track and then
jack-up the other track.
@ Repeat steps ® and © three times and
(4) Evaluation
The measured operating_force should be within the following specifications
Un~:kgf
Model Kindd!Mr Standard Maximum allowable Remai1<s

Boomlewr 1.6 Of' below 1.9
Arm lever 1.6orbelow 1.9
R210LC-3 Bucket lever 1.6 or below 1.9
swmgleller 1.6 or oeKJW 1.9
Trawl lever 2.1 orbelow 2.9
7-14
•
1~ CONTHCll. LEVER STROKE
(1) Measure each lever stroke at the lever top

using a ruler.
• When the lever has play, take a half of
this value and add it to the measured
stroke.
(2) Preparation
Keep the hydraulic oil temperature at
50±5'C.
(3) Measurement
© Stop the engine.
@ Measure each lever stroke at the lever
top from neutral to the stroke end using a
ruler.
Qi Repeat step @three times and calculate
the average values.
(4) Evaluation
The measured drift should be within the following specifications:
Unlt : mm
Model Kind of le'ler Standard Maxinun allowable Remal1ls
Boom leYer 65±10 85
Arm lever 65±10 85
R210LC-3 Bucket leYer 65±10 85
SwingleYer 65±10 85
Travellewr 150±10 195
7-15
•
131 PILOT PRIMRY PRESSURE

(1) Prepenrtlon
<D Stop the engine.
<%> Remove the top cover of the hydraulic
tank oil supply pon with a wrench.
O> Loosen and remove plug on the pilot
pump delivery port and connect
pressure gauge.
© Start the engine and ch eck for oil
leakage from the port.
® Keep the hydraulic oil temperature at
SO±s·c.
(2) Measurement
• MODE selector : H mode
· Auto decel switch : OFF
® Measure the primary pilot pressure in
lheHmode.
(3) Evaluation
The average measured pressure should meet the following specifications:
Um : kgf /cm'
Model
R210LC-3 Hmode
Standard
40±5
Allowable imits
Remarks I
7- 16
•
14) FOR TRAVEL SPEED SELECTING PRESSURE:

(1) Preparation
(i) Stop the engine.
<2> Remove the top cover of the hydraulic
tank oil supply port with a wrench.
® Push the pressure release button to
~ air.
© To measure the speed selecmg prassure;
Install a oonnector and pressure gauge
~ to tumng joint E port as shown.
@ Start the engine and check for on
leakage from the adapter.
so±s·c.
(2) Measurement
Travel mode switch : 1 speed
2speed
<2) Measure the travel speed selecting
pressure in the Hi or Lo mode.
® Lower the bucket to the ground to raise
the track off the ground. Operate the
travel lewr at full stroke and measure the
fast speed pressure.
© Repeat steps (%) and ® three times and
(3) Evaluation
The average measured pressure should be within the blowing specifications:
Unit : kg I an'
Model Tr.Mli speed mode Standard Alowalie limits Remarks
1speed 0 .
R210LC-3 .
2speed 40±5
7· 17
•
15) SWNl MAKING BRAKE flA EASING PRESSURE

(1) Prepenltlon
<D Stop the engine.
~ RerTIO\I& the top cover of the hydraulic
tank oil supply port wilh a wrench.
® The p!8SSUre release L wrench to bleed
air.
© Install a connector and gauge
p!8SSUr8
assembly to swing motor SH port, as
shown.
<S> Start the engine and check for oil
leakage from the adapter.
so±s·c.
(2) Measurement
• MOOE selector : H mode
@ Operate the swing function or arm roll in
function and measure the swing brake
control pressure with the brake
disengaged. Release the control lever
to return to neutral and measure the
control pressure when the brake is
applied.
Repeat step (%) three times and calculate
the average values.
(3) Evaluation
The 8Y8l'aQ8 measured p!8SSUr8 should be within the t:>llcr.Yirlg specifications:
Unit : ~ I an'
Slandarcl Alowalie lirnils
R210LC-3
1-:.-=I 40
0
20-50
7·18
16') MAW PUMP DE1JVERV PRESSURE
(1) Preparation
_,......_
<D Stop the engine.
® Remove the top cover of the hydraulic
@ Push the pressure release button to
bleed air.
© To measure the main pump pressure :
Install a connector and pressure gauge
assembly main pump gauge port as
shown.
@ Start the engine and check for oil
leakage from the port
SO±s·c.
(2) Measurement
® Measure the main pump delivery
pressure in the H mode(h91 idle).
(3) Evaluation
The average measured pressure should meet the following specifications:
Unit : kgf I arr
Model E . """"" Standard Allowable limits
ngine """""
A210LC-3 hicjl ide 35±5
7-19
•
17) SYSTEM PRESSURE REGULATOR RB..EF SETTNl

(1) Preparation
© Stop the engine.
<Z> Remove the top cover of the hydraulic
® Push the pressure release button to
~air.
© To measure the system retie! pressure :
lnstan a connector and pressure gauge
assembly main pump gauge port, as
shown.
@ Start the engine and check for oil
leakage from the port.
so±s·c.
(2) Measurement
• MOOE selector : H mode
<2l Slowly operate each control lever of
boom, arm and bucket functions at full
stroke over relief and measure the
pressure.
@ In the swi ng function , place bucket
against an immovable object and
measure 1he relief pressure.
© In the travel function, lock undercarriage
with an immovable object and measure
the relief pressure.
(3) Evaluation
The average measured pressure should be within the following specilicatioi is:
Unit : 191an'
Model Fll1dion t> be leslell Normal Owrload
llooo1, Ann, ai:kel :m;350}±10 300±10
R210LC.3 Tr.we! :m;350)± 10 .
SWir1J 240±10 .
( ) : Powe< boost
7-20
GROUP 2 MAJOR COMPONENT
1. MAIN PUMP
3 1 2
9 5 6 4 7 8
Standard Recommended
Part name & inspection item replacement Countermeasures
dimension value
Clearance
between piston(1) & Replace
d D 0.039 0.067 piston or
cylinder bore(2)
(D-d) cylinder.
Play between
piston(1) & shoe caulking 0-0.1 0.3
section(3)
(҇) Replace
assembly of
Thickness of shoe ҇ piston & shoe.
(t) t 4.9 4.7
Free height of cylinder Replace

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

h H Replace
plate(5) & spherical
12.0 11.0 retainer or set
bushing(6)
plate.
(H-h)
Surface roughness for Surface roughness necessary

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

Casing 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
seals-contacting section).
şO-ring seal sections at both ends. şReplacement when its sliding section
has scratch.
şInsert spool in casing hole, rotate şCorrection or replacement when
and reciprocate it. O-ring is damaged or when spool
does not move smoothly.
Poppet şDamage of poppet or spring şCorrection or replacement when

sealing is incomplete.
şInsert poppet into casing and function şNormal when it can function lightly
it. 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 şContacting face of poppet. şReplacement when damaged.
relief valve şAbnormal spring. şReplacement.
şO-rings, back up rings and seals. ş100$ replacement in general.
7 - 22
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 - 23
4. TRAVEL DEVICE
Disassembling and inspection of the motor must be done in strict accordance with the servicing
standards described here. During servicing, handle each part very carefully not to damage them,
especially for their movable or sliding sections.
1) SEALS
Once the seals (O-rings, oil seals, and floating seals) have been disassembled, they must be
replaced with new ones even if no damage is observed.
2) TABLE OF MAINTENANCE STANDARD
(1) Replace all parts having a seriously damaged appearance.
(2) Replace the part if any one of the states (symptoms) listed in the table below is observed.
Item Part name Situation Standard dimension Maximum allowable

value (Criteria)
Spindle kit
şSpindle assembly şSeriously damaged in
2 şşSpindle appearance.
8 şşCoupling gear şGalling or other forms of - -
17 şPin excessive wear are
observed.
Carrier assembly
3 Carrier şThe tooth surface of the
6 Cluster gear cluster gear(6) is
9 Shaft nonuniformly worn out - -
14 Thrust collar and damaged.
25 Needle bearing şThe cluster gear(6) does
34 Dowel pin not move smoothly.
4 Ring gear A şThe tooth surface is

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

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

nonuniformly worn out
and damaged. - -
şThe spline section is
worn.
8 Coupling gear şExcessive wear or

pitching is observed on - -
the tooth surface.
19 Coupling şThe spline section is

- -
worn.
7 - 24
value (Criteria)
20 Thrust bearing şWorn out. Axial clearance Clearance : 0.8mm
between coupling
gear (8) and cover
(13) : 0.3 to 0.6mm
22 Distance piece şThe sliding surface is

damaged.
- -
şThe sliding surface is
excessively worn out.
24 Ball bearing şDents are present.

şFlaking develops.
- -
şNonuniform wear is
present.
Rear flange kit

101 Rear flange şThe movable section Linear clearance : Linear clearance :
contacting the spool(123) 10 to 20 ҏ 20 ҏ
is damaged.
şThe clearance against the
spool (123) is too large.
şThe surface contacting
the valve (127) is
damaged.
şThe depth to the surface
contacting the valve (127)
is too large.
123 Spool şThe outer surface is
damaged.
şThe outer surface is
nonuniformly worn out.
102 Shaft şThe surface contacting

the oil seal(132) is worn
out. - -
şThe spline section is worn
out.
103 Swash plate şSeizure is observed. - -
104 Cylinder block şThe spline section is worn

out.
şThe bore inner surface is
worn out too much.
- -
şThe sliding surface that
contacts the timing
plate(109) is damaged or
7 - 25
value (Criteria)
Piston assembly
105 Piston şAn axial clearance is Clearance : 0.05mm Clearance : 0.15mm
106 Shoe present between the
piston(105) and the
shoe(106).
şThe shoe is excessively
worn out.
şThe shoe is nonuniformly
worn out.
107 Retainer plate şThe peripheral edge is

- -
108 Thrust ball şThe spherical sliding

section that contacts the
retainer plate(107) is
nonuniformly worn out. - -
109 Timing plate şThe sliding surface has
the traces of seizure or
nonuniformly wear.
115 Friction plate şBoth edges are Braking torque Braking torque
nonuniformly worn out. 49.3kgfşm or more 49.3kgfşm or less
116 Mating plate şThe required torque
cannot be achieved.
şThe traces of seizure are
present.
118 Valve seat şThe seat surface is

- -
damaged.
119 Valve şThe outer surface is

damaged.
- -
şThe seat surface is
damaged.
Body kit
136 Body şThe sliding section that Linear clearance : Linear clearance :
contacts the spool(137) is 7 to 15 ҏ 20 ҏ
damaged.
şThe clearance against
the spool(137) is too
large.
137 Spool şThe outer surface is
damaged.
şThe outer surface is
7 - 26
value (Criteria)
149 Roller bearing şDents are present.
150 Ball bearing şFlaking develops.
- -
şNonuniform wear is
observed.

damaged.
- -
damaged.
164 Stopper şThe seat surface is

- -
damaged.

damaged.
- -
damaged.
172 Valve seat şThe seat surface is

- -
damaged.
7 - 27
5. RCV LEVER
Maintenance Criteria Remark

check item
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 Oil viscosity : 23cSt
operation.
Spool This is to be replaced when the sliding surface The leakage at the left condition
has worn more than 10 ҏm, compared with the is estimated to be nearly equal
non-sliding surface. to the 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 of a tightened section, adjust it.
more than 2mm due to wears or so on.
Operation stability When abnormal noises, hunting, primary

pressure drop, etc. are generated during
operation, and these cannot be remedied,
referring to section 6. Troubleshooting,
replace the related parts.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.
2. When loosening the hexagon socket head cap screw(125), replace the seal washers(121)
without fail.
7 - 28
6. RCV PEDAL
Maintenance Criteria Remark

check item
Leakage The valve is to be replaced when the leakage Conditions :
effect to the system. For example, the primary Primary pressure : 30kgf/cm2
pressure drop. Oil viscosity : 23cSt
Spool This is to be replaced when the sliding surface The leakage at the left condition
has worn more than 10ҏm, compared with the is estimated to be nearly equal
non-sliding surface. to the above leakage.
Push rod
‫ٻ‬7
1mm
This is to be replaced when th top end has

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

pressure drop, etc. are generated during
operation, and these cannot be remedied,
referring to section 6 troubleshooting, replace
the related parts.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.
7 - 29
7. TURNING JOINT
Part name Maintenance standards Remedy
Sliding surface Plating worn or peeled due to seizure or Replace

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

with thrust plate. şWorn less than 0.5mm (0.02in). Smooth
şDamage due to seizure or contamination
remediable within wear limit (0.5mm((0.02in).
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.
Seal set -
1.5mm (max.)
(0.059in)
şWorn more than 0.5mm(0.02in) ~ 1.5mm(MAX.) Replace

(0.059in)
7 - 30
8. 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
şBushing at mounting part şWear of I.D. şReplace
Cylinder tube 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 - 31
•
1.TRACK
1) TRACK ROLLER
7
11
II
II
I 7/N
' I
~
''I
3 4
Unit : nm
No. Check item . Criteria Remedy
Standard size Repair limit
1 Outside diameter of flange
0193 -
Reboild or
2 Outside diameter of tread 0160 0148 replace
3 Width of tread 46.5 51.5
4 Width of flange 32 -
Standard Tolerance Standard Clearance
Clearance between shaft size Shaft Hole clearance limit
5
and bushing 0 +-0.40 0.35
060 1.5
-0.055 +-0.35 to 0.455 Replace
Interference between roller

Standard Tolerance
size
Standard Interference
Shaft Holel Interference limtt
I bushing
6
and boshing
068
+-0.132 +-0.046 0.006
+-0.102 0
I .
to 0.132
Standard clearance Clearance limit
7 Side clearance of roller Replace
0.35 to 1.3 1.5
•
7-32
2) CAFIRER AOU.ER
UI
nt : nm
No. Check Item Criteria Remedy
Standard size Repair limtt
1 Outside diameter of flange
0169 .
2 Outside diameter of tread 0144 Rebuild or
0134
replace
3 Width of tread 45.7 50.7
4 Width of flange 17 -
Standard size &Tolerance
Clearance between shaft Standard Interference
5 Shaft Bearing
and bearing Replace
.o.033 0
0 50 .Q.017 0&> ·U.012 0-017 to O.ll45
Bearing
, __ Hole
Interference between
6 0 0 82 ·o.o:ll 0.018 to ().()73 Replace
bearing and roller 0 82 ·0.020 ·Wl7J
7.33
•
3) IDLER
~,,
\ \ ' '
Unit : nm
No. Check item Criteria Remedy
Outside diameter of Standard size Repair limit
1
protrusion ii 560 I -
2 Outside diameter of tread i1520 ii 510 Rebuild or
3 Width of protrusion 84 - replace
4 Tolal width 160 I -
5 Width of tread 38 45
Slanda/d size &Toleiance Standard Clearance
Clearance between shaft Shaft Hole clearance limit Replace
6 bushing
and bushing 0 027
Ill tf) -0.W 066.3 .om
-oro 1.5
to 0.41
Clearance between shaft 0 .0.07 0.00
7
and support Ill ffi -0.03 Ill ffi -l-0.03 to 0.1
- Replace
Side clearance of idler Standard clearance Clearance limit Replace

8 (both side) 0.65 to 1.2 2.0 boshIng
I
..
7 - 34
•
4)TRACK
2 1 6
Unit: nm
1 Link pitch Standard size Repair limit
190 201.2 Turn or
replace
2 Outside diameter of bushing "60 "54.4
3 Heiglt of grouser 26 16
4 Heighl of link Replaoe
105±0.2 101
Standard size &Tolerance Standard lntenerence
lnterferenoe between Shaft
- i1terlerence limit
5 Hole
bushing and link -1-0.3!1 0.16
"54.00 +0.1 0.0424 Replace
"$ -l-0.22 0 to 0.42
6
Interference between
regular pin and link "$ : ; : 1037.78 ~ 1 O.al
to 0.40
' 0.1
7 Tightening torque Initial tightening torque : 81 ± 4 lq:j • m Check
7-35
5) TRACK FRAME AND RECOL~
~\~--~~
. ::~~·~~~
- ~~-~-;_§J-~ ~
Unit : nm
smdardsize Tolerance Repair limit
~
1 Vertical width of idler guide Track frame 108 0 112
· 0.5 Rebuild or
Idler support 105 • 1.0
101
replace
-t3
Track frame 249 ·1 254
2 Horizontal width of ider guide
Ider support 247 - 244
Standard size Repair limit
Recoil spring Free lnslallatioo lnstalation Free lnslala.1ial Replace

3
length lengtl load length load
Ill 231x5ffi 437 11132kg - SOO)kg
..
7-36
•
2. WORK EaUIPMEHT'
A c 0 E F
B K J H G
Unit : ITl1l
Pin Bushing
Remedy
Measuring point Normal Reoonvn. Limit Recxmn. Limit &
Mark
(Pin and Bushing) value service of service of Remarll
linit use limit use
) A Boom Rear 80 79 78.5 80.5 81 Replace
- B
c
D
Boom Cylinder Head
Boom Cylinder Rod
Arm Cylinder Head
70
80
80
69
79
79
68.5
78.5
78.5
70.5
80.5
80.5
71
81
81
II
"
,,
E Boom Front 80 79 78.5 80.5 81 ,,
F Arm Cylinder Rod 80 79 78.5 80.5 81 ,,
G Bucket Cylinder Head 70 69 68.5 70.5 71 ,, -
,_
H Arm link 70 69 68.5 70.5 71
>--- "
I Bucket and Arm Link 70 69 68.5 70.5 71 "
J Bucket Cylinder Rod 70 69 68.5 70.5 71 ,,
K Bucket link 70 69 68.5 70.5 71 ,,
7. 37
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
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 M16 ź 2.0 10 72.3
2 Radiator mounting bolt, nut M12 ź 1.75 12.2Ź1.3 88.2Ź9.4
Engine
3 Coupling mounting socket bolt M16 ź 2.0 22.1Ź2.4 159.8Ź17.3
4 Main pump housing mounting bolt M10 ź 1.5 4.8Ź0.3 34.7Ź2.2
5 Main pump mounting socket bolt M20 ź 2.5 42.0Ź4.5 303.8Ź32.5
6 Main control valve mounting bolt M12 ź 1.75 12.2Ź1.3 88.2Ź9.4
7 Hydraulic Fuel tank mounting bolt M20 ź 2.5 46.0Ź5.1 332.7Ź36.9
system
8 Hydraulic oil tank mounting bolt M20 ź 2.5 46.0Ź5.1 332.7Ź36.9
9 Turning joint mounting bolt, nut M16 ź 2.0 29.6Ź3.2 214.1Ź23.1
10 Swing motor mounting bolt M20 ź 2.5 57.8Ź6.4 418Ź46.3
11 Swing bearing upper part mounting bolt M20 ź 2.5 57.8Ź6.4 418Ź46.3
12 P/Train Swing bearing lower part mounting bolt M20 ź 2.5 57.8Ź6.4 418Ź46.3
system
13 Travel motor mounting bolt M16 ź 2.0 23Ź2.5 166.4Ź18.1
14 Sprocket mounting bolt M16 ź 2.0 23Ź2.5 166.4Ź18.1
15 Carrier roller mounting bolt M16 ź 2.0 29.6Ź3.2 214.1Ź23.1
16 Track roller mounting bolt M18 ź 2.5 41.3Ź5.0 298.7Ź36.2
17 Under Track tension cylinder mounting bolt M16 ź 2.0 29.6Ź3.2 214.1Ź23.1
carriage
18 Track shoe mounting bolt, nut M20 ź 1.5 81Ź4.0 585.9Ź28.9
19 Track guard mounting bolt M18 ź 2.5 41.3Ź5.0 298.7Ź36.2
20 Counter weight mounting bolt M30 ź 3.5 199Ź29 1439.4Ź209.8
Others
21 Cab mounting bolt, nut M20 ź 2.5 57.9Ź6.4 418.8Ź46.3
Ɠ For tightening torque of engine and hydraulic components, see each components disassembly and
assembly.
8-4
2. TORQUE CHART
The torques given are standard figures. Any figures specifically described in this manual has priority.
1) METRIC BOLT-coarse thread
8T 10T
Bolt size
kgfşm lbfşft kgfşm lbfşft
M 6 ź 1.0 0.9 ~ 1.3 6.5 ~ 9.4 1.1 ~ 1.7 A8.0 ~ 12.3
M 8 ź 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7
M10 ź 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60.0
M12 ź 1.75 7.4 ~ 11.2 53.5 ~ 81.0 9.8 ~ 15.8 70.9 ~ 114.3
M14 ź 2.0 12.2 ~ 16.6 88.2 ~ 120.0 16.7 ~ 22.5 120.8 ~ 162.7
M16 ź 2.0 18.6 ~ 25.2 134.5 ~ 182.3 25.2 ~ 34.2 182.3 ~ 247.4
M18 ź 2.5 25.8 ~ 35.0 186.6 ~ 253.2 35.1 ~ 47.5 253.9 ~ 343.6
M20 ź 2.5 36.2 ~ 49.0 261.8 ~ 354.4 49.2 ~ 66.6 355.9 ~ 481.7
M22 ź 2.5 48.3 ~ 63.3 349.4 ~ 457.8 65.8 ~ 98.0 475.9 ~ 708.8
M24 ź 3.0 62.5 ~ 84.5 452.1 ~ 611.2 85.0 ~ 115.0 614.8 ~ 831.8
M30 ź 3.5 124.1 ~ 167.9 897.6 ~ 1214.4 169.1 ~ 228.9 1223.1 ~ 1655.6
M36 ź 4.0 174.3 ~ 235.6 1260.7 ~ 1704.0 250.0 ~ 310.0 1808.3 ~ 2242.2
2) METRIC BOLT-fine thread
8T 10T
Bolt size
kgfşm lbfşft kgfşm lbfşft
M 8 ź 1.0 2.2 ~ 3.4 15.9 ~ 24.6 3.0 ~ 4.4 21.7 ~ 31.8
M10 ź 1.25 4.5 ~ 6.7 32.5 ~ 48.5 5.9 ~ 8.9 42.7 ~ 64.4
M12 ź 1.25 7.8 ~ 11.6 56.4 ~ 83.9 10.6 ~ 16.0 76.7 ~ 115.7
M14 ź 1.5 13.3 ~ 18.1 96.2 ~ 130.9 17.9 ~ 21.1 129.5 ~ 174.3
M16 ź 1.5 19.9 ~ 26.9 143.9 ~ 194.6 26.6 ~ 36.0 192.4 ~ 260.4
M18 ź 1.5 28.6 ~ 43.6 206.9 ~ 315.4 38.4 ~ 52.0 277.7 ~ 376.1
M20 ź 1.5 40.0 ~ 54.0 289.3 ~ 390.6 53.4 ~ 72.2 386.2 ~ 522.2
M22 ź 1.5 52.7 ~ 71.3 381.2 ~ 515.7 70.7 ~ 95.7 511.4 ~ 692.2
M24 ź 2.0 67.9 ~ 91.9 491.1 ~ 664.7 90.9 ~ 123.1 657.5 ~ 890.4
M30 ź 2.0 136.9 ~ 185.1 990.2 ~ 1338.8 181.7 ~ 248.3 1314.2 ~ 1796.0
M36 ź 3.0 192.1 ~ 259.9 1389.5 ~ 1879.9 261.8 ~ 354.2 1893.6 ~ 2561.9
8-5
3) PIPE & HOSE
Thread size Width across flat(mm) kgfşm lbfşft
1/4" 19 3 21.7
3/8" 22 4 28.9
1/2" 27 5 36.2
3/4" 36 12 86.8
1" 41 14 101.3
4) FITTING
Thread size Width across flat(mm) kgfşm lbfşft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 6 43.4
3/4" 36 13 94.0
1" 41 15 108.5
8-6
r
1. REMOVAL AND HSTAU.
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 njury.
(4) Loosen the dran plug ooder the hydraulic
tank and drain the oil from the hydraulic
tank.
• Hydraulic tank quantity : 250 I
(5) Remove bolts(12) and disconnect
pipe(1 ,2).
(6) Disconnect pilot line hoses(4,5,6,7,8,9,10).
1 -;\_3
(7) Remove bolts(11) and discomect pump
suction tube (3).
• When pump suction rube is cisoonnected,
the oil inside the piping will flow ou~ so
catch it in oil pan.
(8) Sling the pump assembly and rem<M1 the
pump mouiting bolts.
. Weight : 120 kg (2651>)
• Pul out the pump assembly from ~
When removing the pump assembly,
check that all the hoses have been
disconnected.
8-7
•
2) INSTALL
(1) Carry out installation in Ille reverse order
to removal.
(2) Remo11e 1he suction strainer and clean it.
(3) Repjace return filter with new one.
(4) Aemolle bfealher and clean it.
(5) Alter adding oil to 1he l'rjdrautic tank to 1he
specified level.
(6) Bleed 1he air from 1he hydraulic pump.
<D Remo11e 1he air llllflt plug{2EA).
(2) Tighten plug lightly.
O> Start the engine, run at low Idling, and
check oil come out from plug.
© Tighten plug.
(7) Start the engine, run at low idling(3-5
minutes) to circulate the oil through the
system.
(8) Confirm Ille hydraulic oil level and check
Ille hydraulic oil leak or not.
8-8
•
2. MAIN PUMP(1!2)
1) STRJCT\JRE
211 113
I
251
212
490 153
728 725
\ \,
156 158157 468 313124312 114 466 885 314 141
\ 271 401
04 Gearpump 251 Support 710 O·ring

111 Drive shaft(F) 261 Seal cover(F) 717 O·ring
113 Drive shaft(R) 271 Pump casing 724 O·ring
114 Spline coupling 312 Valve block 725 O·ring
123 Roller bearing 313 Valve plate(R) 728 O·ring
124 Needle bearing 31 4 Valve plate(L) 732 O·ring
127 Bearing spacer 401 Hexagon socket bolt n4 Oilseal
141 Cylinder block 406 Hexagon socket bolt 789 Back up ring
151 Piston 466 VP Plug 792 Back up ring
152 Shoe 468 VP Plug 806 Hexagon head nut
153 Set plate 490 Plug 808 Hexagon head nut
156 Bushing 531 Tiiting pin 824 Snap ring
157 Cylinder spring 532 Servo piston 885 Pin
158 Spacer 534 Stopper(L) 886 Spring pin
211 Shoe plate 535 Stopper(S) 901 Eye bott
212 Swash plate 548 Pin 953 Set screw
214 Bushing 702 O·ring 954 Set screw
8·9
•
I I
ti
I I
543 - - - --1--"'-i---<
545 ~~~-r-:-t---''--.]:..[,.~
........ -~·
1:i1-- 1u
-:J
,,---
VIEW A
541 Seat 544 Stopper 2 079 Proportional reducing valve

543 Stopper 1 545 Steel ball
..
8-10
•
2) 100LS NI> TIGHTENING TORQUE

(1) Tools
The tools necessary to disassemble/reassenille the pump are shown in the follow list.
Tool name & size Part name
Hexagon socket PT plug PO plug Hexagon socket

Name B
head bolt (PT thread) (PF thread) head setscrew
Allen wrench 4 MS BP-1/16 - MS
>- -- M6
-
F B
5
>- - -
6
s
MS
M10
BP-1/ S
BP-1/4
BP-&S
P0-1/4
P0-318
M10
M12, M14
M16, M1S
0 17 M20, M22 BP-1 P0-1, 11/4, 1112 -
Double ring spanner, socket Hexagon Headed VP plug
wrench, dOuble(single) open - bolt Hexagon nut (PF thread)
end spanner
19 M12 M12 VP-114
-I B I-
24 M16 M16 -
27 MlS M1S VP-1/2
0 30 M20 M20 -
36 - - VP.J.14
~uSlable angle wrench Medium size, 1 set
Screw driver Minus type WfHI driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-160
Steel bar Steel bar of key material approx. 1OxSx200
Torque wrench Capable of tightening with the specified torques.
S-11
Torque Wrench size
Part name Bolt size
kgl. m lbf . ft in mm
-
Hexagon sod<el head boll MS 0.7 5.1 0.16 4
{Malerial : SCM435)
- M6
M8
- 12
3.0
I 8.7
21.7
0.20
024
5
6
- M1 0
M12
M14
5.8
10.0
16.0
I 42.0
72.3
115.7
0.31
0.39
0.47
8
10
12
M16 24.0 173.6 0.55 14
M18 34.0 245.9 0.55 14
M20 44.0 318.3 0.67 17
PT pllg{Malerial : 545C) PT 1/16 0.7 5.1 0.16 4
• Wind a seal tape 1 1!2 to 2 PT118 1.05 7.59 0.20 5
'-
turns round the plug PT114 1.75 12.66 0.24 6
PT3/ 8 3.5 25.3 0.31 8
PT112 5.0 36.2 0.39 10
PF plug(Material : 545C) PF1/ 4 3.0 21.7 0.24 6
PF112 10.0 72.3 0.39 10
PF3/ 4 15.0 108.5 0.55 14
PF 1 19.0 137.4 0.67 17
PF 1114 27.0 195.3 0.67 17
PF 1112 28.0 202.5 0.67 17
8·12
•
3) DISASSEMBLY
(1) Select place suitable to disassembling.
• Select clean place.
• Spread rubber sheet, clodl or so on on
ovamaul wor1<ber1ch top to prevent parts
from being damaged.
(2) Remove dust, rust, etc, from pump
surfaoes with cleaning oil or so on.
(3) Remove drain port plug(468) and let oil
out ol pump casing.(front and rear pump)
(4) Remove hexagon socket head botts (41 2,

413) and remove regulator.
(5) Loosen hexagon socket head bolts(401)

which tighten swash plate support(251),
pump caslng(271) and valve bkx:k(312}.
• If gear pump and so on are fitted to rear
face of pump, remove them before
starting this woc1t
(6) Place pump horizontally on workbench

with its regulator-fitting surlace down,
and separate pump casing(271) from
valve bkx:k (312).
• Before bringing this surface down, spread
rubber sheet on workbench without fail to
prwent this surface from being damaged.
8·13
•
(7) Pull cylinder block(141) out of pump

caslng(271) straightly over drive
shaft(111). Pull out also pistons(151),
set plate(153), spherical bush(156) and
cylncler springs(157) simultaneously.
• Take care not to damage sliding surfaces
of cylinder, spherical bushing, shoes,
swash plate, etc.
(8) Rem<lllEl hexagon socket head bolts(406)

and then seal cover(F. 261 ).
• Frt bolt into pulling out tapped hole of seal
cover(F), and cover can be removed
easily.
• Since oil seal Is fitted on seal cover(F),
take care not to damage It in removing
CO'lel'.
(9) Remove hexagon socket head bolts(406)

and then seal cover(R, 262).
In case fitting a gear pump, first, remove
gear pump.
(1q Tapping lightly fitting flange section of
swash plate support(251) on its pump
casf1g side, separate swash plate support
from pump casing.
~Q Remove shoe plate(211 )and swash

plate(212) from pump casf1g(Z71).
8-14
-
~Tapping lightly shaft ends of drive
shafls(111, 113) with plastic hammer,
take out drive shafts from swash plate
Sl4)p0rts.
~Remove valve plates( 313, 314) from

vaMI block(312).
• These may be removed in work (6).
(14} If necessary, remove stopper (L, 534),

stopper (S, 535), servo piston (532) and
tilting pin (531) from pump casing (271 ),
and needle bearing (124) and splined
coupling (114) from vaMI block (312).
• In rem:Mng tilting pin, use a protector to
prayent pin head from bel1g damaged.
• Since loctite is applied to litmg areas of
tillilQ pin and servo piston, lake care not
to damage servo piston.
• Do not remCJl/8 neecle bearilg as far as
pos•He, except when ii is considerad to
be out al its life span.
• Do not loosen hexagon nuts of valve
block and swash plate support.
If loosened, ftow setting will be changed.
8·15
•
4) ASSEMBLY
(1) For reassembling reverse the
disassembling procedures, paying
attention to the following items.
Q) Do not fail to repair the parts damaged
during disassembling, and prepare
replacement parts in advance.
<%> Clean each part fully with cleaning oil
and dry it with compiessed air.
~ Do not fail to apply clean wOll<ing oil to
sliding sectioos, bearings, etc. before
assembling them.
© In principle, replace seal parts, such as
0-rings, oil seals, etc.
@ For fitting bolts, plug, etc.. prepare a
torque wrench or so on, and tighten them
with torques shown In page 8-11, 12.
@ For the double-pump, take care not to
mix 14'.l parts of the front pump with those
of the rear pump.
(2) Fit swash plate support (251) to pump

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

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

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

(cylinder block(141), piston subassembly
(151, 152), set plate (153), spherical bush
(156), spacer (158) and cylinder spring
(157)).
Frt spline phases of retainer and cylinder.
Then, insert piston cylinder subassembly .
into pump casing.
8-17
•
(7) Frt valve plate (313) to valve tb:k (312),

entering pin into pin hole.
• Take care not to mis1ake suction I delivery
directions of valve plate.
(8) Frt val11e block (312) to pump casing

(271) and tighten hexagon socket head
bolts (401 ).
• At first assemble this at rear pump side,
and this work will be easy.
• Take care not to mistake direction of valve
block. 0
ll Clockwise rotation (viewed from input

shaft side) - Fit block with regulator up
and with delivery flange left, viewed from
front side.
ll Counter clockwise rotation (viewed from

input shaft side) - Fit block with delivery
flange right, viewed from front side.
(9) Puttl1g leecl>ack pin of tilti1g pin into

feedback leller of regulator, fit regulator
and tighten hexagon socket head bolts
(412, 413).
• Take care not to mistake regulator of front
pump ftlf that ol rear pi.mp.
(!q Fit drain port plug (468).

This is the end of reassembling procadures.
8-18
3. REGULATOR
1) S1RJCT\JRE(1/2)
412 875 874

755
858
614
615
613
611
647 A
KR3H-9N29
648
723
I
I
642
()
438
001
b!~J.1.1
Pm .+----1:J"i.., J
f'i>+-~
924
641 ~ 643 700 644 645 648 728

B
413 438
VlfWC
8-19
REGULATOR(2fl)
734 653 651 652 001 629 630 628

I I
655 I
814
\ Mt
925
631
732 ,, I
i Lt L_ _ J ---+
+-
I
733
I I I
732
622
- 1/--,l\.___}---
J
621
I
623 625 626
\
8f!l 763 7S6
SECTIONA·A
412 Hexagon socket screw 630 Nut 728 0-ring

413 Hexagon socket screw 631 Sleeve 730 0-ring
436 Hexagon socket screw 641 Pilot cover 732 0-ring
438 Hexagon socket screw 642 Pilot cover(QMC) 733 0-ring
496 Plug 643 Pilot piston 734 O·ring
601 Casing 644 Spring seat(Q) 735 O·ring
611 Feed back lever 645 Adjust stem(Q) 755 0-ring
612 Lever(1) 646 Pilot spring 756 0-ring
613 Lever(2) 647 Stopper 763 0-ring
614 Fulcrum plug 648 Piston(QMC) 801 Nut
615 Adjust plug 651 Sleeve 814 Snap ring
621 Compensator piston 652 Spool 836 Snap ring
622 Piston case 653 Spring seat 858 Snap ring
623 Compensator rod 654 Return spring 874 Pin
624 Spring seat(C) 655 Set spring 875 Pin
625 Outer spring 656 Block cover 887 Pin
626 Inner spring 708 0-ring 897 Pin
627 Adjust stem(C) 722 0-ring 898 Pin
628 Adjust screw(C) 724 0-ring 924 Setscrew
629 Cover(C) 725 0-ring 925 Adjust screw(Q)
8·20
•
2) TOOLS AND llGHmlNG TORQUE

(1) Tools
The tools necessary to disassemble/reassemble lhe pump are shown in lhe follow list.
Tool name & size Part name

j
Hexagon socket J PT plug PO plug Hexagon socket

Name B head bolt (PTlhread) (PF thread) head setscrew
Alen wrench
r
0
Double ri;1g ~nner,
4
5
6
M5
MS
M8
BP-1/16
BP·1/ 8
BP·1/ 4
.
.
f'0..1/4
MB
M10
M12, M14
-
-
socket wrench, double(slngle) Hexagon Headed VP plug

open end spanner . Hexagon nut
bolt (PFlh<ead)
0 6 M8 M8 .
Aquslable 81'/je wrench Smal size, Max 3Ellrm
Screw driver Minus type W!ffl driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Plief's For snap ring, TSA·160
Steel bat 4x 100rrrn
Taque wrench Capable d 19ltening with lhe specified IOlques.
Pincers .
Bolt M4, Length : 50mm
8·21
(2) Tightening torque
Torque Wrench size
Part name Bolt size
kgf • m lbf. ft in mm
Hexagon socket head bolt MS 0.7 5.1 0.16 4
(Material : SCM435) 8.7 0.20 5
M6 1.2
MS 3.0 21 .7 0.24 6
M10 5.8 42.0 0.31 8
M12 10.0 72.3 0.39 10
M14 16.0 115.7 0.47 12
M16 24.0 173.6 0.55 14
M18 34.0 245.9 0.55 14
M20 44.0 318.3 0.67 17
PT plug(Material : S45C) PT1/16 0.7 5.1 0.16 4
• Wind a seal taped 1112 to 2 PT1/ 8 1.05 7.59 0.20 5
turns round the plug
PT 11 4 1.75 12.66 0.24 6
PT3/ 8 3.5 25.3 0.31 8
PT1/ 2 5.0 36.2 0.39 10
PF plug(Material : S35C) PF 1/ 4 3.0 21.7 0.24 6
PF 1/ 2 3.0 21.7 0.39 10
PF3/ 4 10.0 72.3 0.55 14
PF1 15.0 108.5 0.67 17
PF 11/4 27.0 195.3 0.67 17
PF 1112 28 202.5 0.67 17
8·22
•
3) DISASSEMBLY
Since the regulator consists of small
precision finished parts, disassembly and
assembly are rather complicated.
For this reason, replacement of a regulator
assembly Is recommended, IJ1less there Is
a special reason, but in case disasseml:iy is
neoessary lo< an ll'laVOidable reason, read
through this manual to the end before
s1arting~
(1) Choose a place lo< disassentlly.

• Choose a clean place.
• Spread rubber sheet, cloth, or so on on
top of work-bench to prevent parts from
being damaged.
(2) RelTl0\/9 dust, rust, etc. from surfaces ol
regulator with clean oil.
(3) Remove hexagon socket head screw

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

(438) and remove COl/ef (C,629)
• Cover (C) is fitted with adjusting screw
(C,QI) (628, 925), adjusting mg (C, 627),
lock nut (630), hexagon nut (601) and
adjusting screw (924).
Do not loosen these screws and nuls.
If they are loosened, adjusted pressure-
flow setting will vary.
r.
6-23
(5) After removing cover (C, 629)
subassembly, take out outer spring (625), ----/-
inner spring (626) and spring seat (C,
624) from compensating section. )
Then draw out adjusting ring (Q, 645),
pilot spring (646) and spring seat (644)
from pilot sedion.
• Adjusting ring (Q,645) can easily be
drawn out with M4 bolt.
(6) Remove hexagon socket head screws

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

spring seat (653), return spring (654) and
sleeve (651).
• Sleeve (651) is fitted with snap ring (836).
• When removing snap ring (814), return
spring (654) may pop out
Take care not to lose it.
.~ --1
(8) Remove locking ring (858) and take out
fulcrum plug (614) and adjusting
plug(615).
• Fulcrum plug (614) and adjusting plug
(615) can easily be taken out with MS
bolt.
8-24
(9) Remove lever (2)(613). Do not draw out
pin (875).
• Work will be promoted by using pincers or
soon.
(1q Draw out pin (874) and remove

feedback l8118r (611 ).
• Push out pin (874, 4ITTn in <ia.) from above
wilh slender steel bar so that it may not
interfere with lever (1)(612).
8-25
r
(11) Remove lever (1)(612). Do not draw out
pin (875).
~ Draw out pilot piston (643) and spool
(652).
(q Draw out piston case (622),
compensating piston (621 ) and
00111pensali1g rod (623).
• Piston case (622) can be taken out by
pushing compensating rod (623) at
opposite side of piston case.
This completes disassembfy.
..
8-26
4) ASSEMBLY
(1) For assembly, reverse disassembly
procedures, but pay attention to the
following ~ems.
<D Afways repair parts that were scored at
disassem(Jjy.
Get replacement parts ready
beforehand.
@ Mixing of foreigl matter will cause
malfunction.
Therefore, wash parts well with cleaning
oil, let them dry with jet air and handle
them in dean place.
~ Afways tiglten bolts, plugs, etc. to their
specified torques.
© Do not fail to coat sliding surfaces with
dean hydraulic oil before assein(Jjy.
@ Replace seals such as 0-ring with new
ones as a rule.
(2) Put compensating rod (623) into

C0fr4l9nsating hole of casing (601 ).
(3) Put pin force-fitted in IE!118r (1 )(612) into
groove of compensating rod and ffl l8118r
( 1) to pin force-fitted in casing.
(4) Fit spool (652) and sleeve (651) into hole

in spool of casing.
---,
1 '
llE Confirm that spool and sleeve slide
smoothly in casing without binding.
---·-·- · --ED--t-
• Pay attention to orientation of spool. f-· · -t- ·~1
s y\ \ \
Feedback lever ' \
l
r .
8-27
r
(5) Rt feedback lever (611), matching its pin

hole with pin hole in spool.
Then insert pin (874).
• Insert pin in feedback lever a little to ease
operation. Lever (1) side Lever (2) side
• Take care not to mistake direction of (Flkrum plug of
ad~sting plug side)
feeclJack lever.
(6) Put pilot piston (643) into pilot hole of

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

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

(653) into spool hole and attach snap ring
(81 4).
8-28
-
~1) Flt set spring (655) to spool hole and

put compensating piston (621) and piston
case (622) into compensating hole.
Frt pilot COYer (641) and tiglten It with
hexagonal socket head screws (436,
438).
~Put spring seat (644), pilot spring (646)

and aqustillg ring (Q, 645) into pilot hole.
Then foe spring seat (624), inner spring
(626) and outer spring (625) into
compensating hole.
• When flttfng spring seat, take care not to
mistake direction of spring seat
(1~ Install cover (C, 629) fitted with adjusting

screws (628, 925), adjusting ring (C, 627),
lock nut (630), hexagon nut (801) and
adjusting screw (924).
Then tiglten them with hexagonal socket
heed screws (438).
8-29
•
[GROUP 4 llAft CONl1Q. VAiliE

• ~
1. RBO/ALAKJ HSTAll ..._"""""
1) REMOVAL
pressure in the hydraulic piping.
(3) Loosen the breather slowly to release the
pt'8SSUre inside the hydraulic tank.
~ Escaping flu id under pressure can
penetrate the skin causing serious injury.
• When pipes and hoses are discomected,
the oil inside the piping will flow out, so
catch ~ in oil pan.
(4) Remove bol1s and disconnect pipe.
(5) Disconnect pilot Une hoses.
(6) Oisooonect pilot piping.
(7) Sling the control valve assembly and
remoYB the control valve mountilg boll
weiglt : 193kg(426 b)
(8) RemoYB the control valve assembly.
• When removing the control valve
assembly, check that all the piping have
been cflSCOIYlected.
2) tlSTAll.
(1) Carry out installation in the reverse oroer

to removal.
(2) Bleed the air from bebN items.
<D Cylinder (boom, arm, bud<at)
~ SWing mo4of
Q) Travel motor
• See each ~em removal and install.
(3) Confirm the hydraulic oil level and
recheck the hydraulic oil leak or not.
~
•
'-
2. STRUC1\JRE(1/3)
338
325
324
203 391
556
101 Casing A 252 Lock valve 515 Poppet

102 Casing B 308 Arm confluence spool 551 Plug
103 Straight travel block 324 Spring 556 Plug
165 0-ring 325 Spring 601 Relief valve assembly
201 Cover 338 Stopper 602 Port relief valve
202 Cover 357 Orifice 974 Socket screw
203 Cover 391 Straight travel spool
(' .
8-31
S1RJCT\JRE(21J)
556
159
153 561
101 Casing A 301 Spool 376 Spring

153 Plug 302 Arm 1 spool 392 Rod
154 Plug 305 Swing spool 395 Swing priority spool
159 Plug 307 Boom 2spool 511 Poppet
164 0-ring 331 Seat 515 Poppet
165 0-ring 332 Seat 516 Poppet
201 Cover 333 Bolt 521 Spring
202 Cover 334 Stopper 523 Spring
203 Cover 335 Stopper 551 Plug
204 Cover 336 Bolt 552 Plug
'261 0-ring 339 Stopper 556 Plug
262 0-ring 371 Spring 561 0-ring
264 0-ring 372 Spring 602 Port relief valve
273 Socket screw 374 Spring 611 Negative relief valve
8-32
r
333
.l,;'Wc.-_,,. 334
331
329
• """'- 328
331
262
J01
102 Casing B 264 0-ring 339 Stopper

153 Plug 273 Socket screw 371 Spring
154 Plug 301 Spool 372 Spring
155 Plug 303 Boom 1 spool 373 Spring
164 0-ring 304 Bucket spool 375 Spring
165 0-ring 306 Arm2spool 511 Poppet
166 0-ring 309 Option spool 517 Poppet
167 0-ring 328 Spring 521 Spring
201 Cover 329 Spring 551 Plug
202 Cover 331 Seat 553 Plug
203 Cover 332 Seat 561 ().ring
{' 204 Cover 333 Bolt 602 Port relief valve
" Flange
209 334 Stopper 971 Screw
261 0-ring 335 Stopper 974 Socket screw
262 0-ring 336 Bolt 975 Screw
r
1) MAIN RELEFVALVE
123 124 125 561 562 611 661 613
\
:
r
L.,
i
A
I
'
512 521
I
541 121 122
\ 103 104 664
I
673
I'
652 671
103 Plug 512 Plunger 621 Spring

104 Adjusting plug 521 Spring 652 Adjusting screw
121 C-ring 541 Seat 661 0-ring
122 Spacer 561 0-ring 663 0-ring
123 C-ring 562 Back up ring 664 0-ring
124 Filter stopper 611 Poppet 671 Lock nut
125 Filter 613 Stopper 673 Lock nut
163 0-ring 614 Piston
2) PORT Ra.EF VALVE
563 521 123 124 125 612
p
r··
' ' I
I' ~
/'A I
:
I I
511 522 161 541 561 101 162 102 651 671
101 Body 511 Plunger 564 Back up ring

102 Plug 521 Spring 611 Poppet
123 C-ring 522 Spring 612 Spring seat
124 Filter stopper 541 Seat 621 Spring
561 651
• 125 Filter 0-ring Adjusting screw
161 0-ring 562 Back up ring 661 0-ring
162 0-ring 563 0-ring 671 Locknut
301 Piston
8-34
r
3) STIWGHTTRAVEL VALVE BLOCK
561 551 511 103
B-1 A-I
266
~
we
251
561
551
cI
1.
0o@ I
338
325
324 o'\
I
154
\
164
I
391
B-1 A-I
163 156
974 391 166 167 '
I I I \ I
I
'
I'
I
I / 561
/
/
103
357
308
........-551
338 '-f - --103

325 159
' --~-.J,;, -- --- '
0.
- - - -
324 • I
103 Straight travel block 167 Q.ring 391 Straight travel spool assy
154 AO plug 251 Plug 511 Poppet
156 AO plug 266 Q.ring 521 Spring
159 Plug 308 Sequence sub 551 Plug
163 ().ring 324 Spring 561 ().ring
164 ().ring 325 Spring 601 Main relief valve
165 Q.ring 338 Stopper 974 Hex sod<et bolt
166 Q.ring 357 Orifice
8-35
r
Secplrlce sub(308)
356 347 266 375

I \ I
266 0-ring 344 Sleeve 356 Plug

207 0-ring 346 Bushing 375 Spring
308 Spool 347 Stopper 376 Spring seat
309 Piston
4) ARM SPOOL
" .
341
I \\ \
338 313 339 349 342 328 314
I
I
302 312
I
358
\
343 329 359 352
302 Spool 329 Spring A2. 343 Spacer bolt

312 Sub spool 338 Spring 349 Stopper 1
313 Piston 339 C-ring 352 Plug
314 Sleeve 2 341 Plug 358 Spring seat
328 Spring A1 342 Sleeve 1 359 Spring seat
-
5) BOOM SPOOL
353
\
303
303 Spool 353 Plug
6) NEGATIVE CONTROL REl.H VALVE
I
I'__
i "111
---
I
I 4-tJ
11
632 638 611 621 631
611 Poppet 631 Damping rod 638 Filter

621 Spring 632 Bushing
'
7) smAIGHTTRAVELSPOOL
I
391 317 340 352
317 Plunger 3 352 Plug 391 Spool

340 Spring
8) LOCK VALVE ASSEMBLY
301 164 101 162 171 541 511
'
163
101 Casing 164 0-ring 511 Spool

161 0-ring 171 Hex socket bolt 512 Spring
162 0-ring 201 Plug 541 Bushing
163 0-ring 301 Plug
•
r
3. TOOi.SAND TIGHTENNG TORQUES

1) TOOLS
Before disassembling the control valve, prepare the following tools beforehand.
Tool name Remark
VICebench .
27
Box wrench 30
32
cJ
4
5
0
6
Hex key wrench
--
8
10
12
14
Seal tape .
Loctite #241 .
Spanner 32
r
2) TIGHTENING TORQUE
Item Torque
Part name
No. kgf. m lbl. ft
101 8ocfy 69- 78 499.1 -5642
102 Plug 69- 78 499.1 - 564.2
103 Plug 69- 78 499.1 -564.2
154 Plug 69- 78 499.1 -564.2
156 Plug 34-39 245.9 - 282.1
159 Plug 5.9- 8.8 42.7-63.7
201 Plug 74 5352
251 Plug 69- 78 499.1 - 564.2
301 Plug 34-39 245.9 - 282.1
308 Sequence assy 69- 78 499.1 - 564.2
341 Plug 59-69 426.7 - 499.1
343 Spacer bolt 9.8-11.8 70.9-85.3
352 Plug 59-69 426.7 - 499.1
353 Plug 59-69 426.7 - 499.1
356 Plug 69-78 499.1 - 564.2
357 Orifice 15-18 108.5 - 130.2
551 Plug 147 -176 1063.3 - 1273
601 Main reWef valve 69-78 499.1 - 564.2
671 Lock nut 27-31 195.3- 224.2
673 Lock nut 27-31 195.3- 224.2
..
-
4. DISASSE.MBLY AN> ASSEIELY
1) PRECNJT10N
(1) AH hydraulic components are wor1<ed with precision wori<ing. Then, betore disassentlfing and
assembling them, it is essential to selec.1 an especially clean place.
(2) In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it.
(3) When a control valve is to be remOYecl from the machine, apply caps to all ports.
Before disasserroling the valve, recheck that these caps are fitted completely. and then clean the
outside of the asserroly. Use a proper bench for working, spread a paper or rubber mat on the
bench, and disassemble the valve on It
(4) Support the body section carefully in carrying, transferring and so on of the control valve. Do not
support the lever, exposed spool, end oowr section or so on without fall.
(5) Aftef disassembling and assenting of the component it is desired to cany out various tests (klr
the relief characteristics, leakage, flow resistance, etc.), but the hydraulic test equipment is
necessary to these tests.
Thereklre, even when its disassembling can be carried out technically, do not disassemble such
component that cannot be tested, adjusted, and so on.
Besides, prepare dean cleaning oil, hydraulic oil, grease, etc. beforehand.
8-41
r •
2) ~NG
The figure in ( ) shc7.Yn after lhe part name
in the explanation sentence shows its
runber in the structure figures at page 8-31
toll-38.
(1) Ptace control valve on working bench.
• Disassemble it in clean place and pay
attention not to damage flange face.
(2) Removal of straight travel valve block
• Removal
Loosen hexagon socket head bolts to
remoYe straigrt travel valve block (103) in
its assembled slated
• Dl~bllng
<D Hold casing (103) with vice.
® Remove plug (251) and pull out springs
(324, 325), stopper (338) and straight
travel spool assembly (391 ).
@ Remove plug (551) and pull out poppet
{51 1) and spring (521 ).
© Remove main refief va1Ya (601 ).
(Disassemble main relief valve as shc7.Yn
in the~.)
(3) Disassembling of main relief valve

<D Since plug (103) and seat (541) are fixed
with C-ring (121), pull them out to
remove them.
® Take out spring (521) and plunger (512)
from inside ol seat (541 ).
@ Remove lock nut (671 ) and adjusting
SCfeN (652) of adjusting plug {104) and
take out stopper (613), piston (614),
spmg (621 ) and poppet (611).
© Loosen lock rlJl (673) ol plug (103) and
remove adjusting plug (104).
(5) Remove C-ring (121) and spacer (122)
from plug (103).
• • Since filter (125) and filter stopper (124)
are assembled to plug (103) with C-ring
(123), do not disassemble them more
than these conditions.
(4) Dilu9embllng of travel spool
(J) Loosen hexagon socket head bolts (273)
and remove spring COiier (203).
<%> Aemoye travel spool (301), spmgs (328,

329), spring seat (331 ), stopper (334)
and spacer bolt (333) in spool assembly
condition from casing.
• When pulling out spool assembly from
casing, pay attention not to damage
casing.
(3) Hold travel spool (301) in mouthpiece-

attached vise.
Remove spacer bolt (333) and
disassemble springs (328, 329), spring
seat (331) and stopper (334).
(S) DisasMmbllng of arm spool

 Loosen hexagon socket head bolts (273)
and remove ann COllef (206).
0 ..
(2) Remove arm spool (302), springs (371,
372), spring seat (332), stopper (335)
and spacer bolt (336) in spool assembly
oondition from casing.
® Hold arm spool (302) in mouthpiece-

attac:hed vise. Rem<l\19 spacer bolt (336)
and disassemble springs (371, 372),
spring seat (332) and stopper (335).
© Except when there is any problem

specially, do not disassemble arm spool
(302) more than these conditions. If this
is necessary at any oost, disassemble it
in the following procedures.
· Hold middle section of arm spool (302) in
mouthpiece-attached vise and remove
plugs (352, 341) from its both ends.
· Remo11e plugs (352, 341) and pull out
sub-spool (312) In assembly condition.
Remove piston (313) being fitted to
plug(341 ).
• Hold sub-spool (312) In mouthpiece-
attached vise, remove space bolt (343)
and take out spring (329) and spring
seats (358, 359).
• Pay attention not to damage sub-spool
(312).
· Since sub-spool (312), sleeve 2 (314),
spring (328), sleeve 1 (342), stopper
(349) and C-ring (339) are asserrtlled in
.. one, de not disassemble them more than
these conditions.
(6) Dlaanembling of boom spool
(]) Loosen hexagon socket head bolts
(273), remove spring oover (201), and
pull out boom spool (303), sprilgs (371,
372), spring seat {332), stopper (335)
and spacer bolt (336) n spoo1 assembly
oordtion from casi)Q.
~ Hold plug of spool assemtXy end in vise,

remove spacer bolt (336), and
disassemble springs (371, 372), spring
seat (332) and stopper (335).
® Except when there is any problem

specially, do not disassemble boom
spool sub (303) more than these
condttions. If this is necessary at any
cost, disassemble it in the following
procedures.
• Hold middle section of boom spool (303)
in ~ttached vise and~
plug (353).
• Pay attention no1 to delonn boom spool
sub (303) by OYer tigltening vise.
(7) DiuuMlbly of covers

<D Remove hexagon socket head bolts
(273), and remove spool cover (202).
•
(8) Removal of port rellef valve

• Removal
Remove port relief valve (602) from
casing.
• Dk•sembllng
<D Loosen plug (102), remove springs (521,
522) and seat (541) from inside of body
(101) and take out piston (301) and
plunger (511) from inside of seat (541).
® Remove lock nut (671) and adjusting

screw (651) of plug (102) and take out
spring seat (612), spring (621) and
poppet (611 ).
•Since filter (125) and filter stopper (124)
are assembled to plug (102) wi1h C-fing
(123), do not disassemble them more
than these conditions.
°'
(9) Removal lock valve .-nbly
Loosen hexagon socket head bolts and
remove lock valve assembly (252) .
•
•
(1~ Dluulmbly or negative control relief va1ve

CD RemoYe plug (551).
~ RemoYe poppet (611 ), spring (621) and

damping rod (631 ).
•
r-. (11) Dl-..nbly or cf*'t valve
Remove plug (551) and take out poppet
(511) and spring (521).
(12) l"!s RT Umbly of casing

CD Except when required specially, do not
disassemble tie bofts of casing A and B.
.o
~ Since plugs not described in above
disassembling procedures are blind
plugs for sacrifice l'des and blind plugs
for casting sanitation, do not
disassemble them as far as not required
specially.
r .
8-47
3) INSPECTION AFTER DISASSEMBLING
Clean all disassembled parts with dean mineral oil fully, and dry them with compressed air. Then,
place them on clean papers or doths for inspection.
(1) Control valve
<D Chad< whole surfaces of all parts for burrs, scratches, notches and other defects.
(i) Confirm that seal groove faces of casing and block are smooth and free of dust, dent, rust etc.
(;l) Correct dents and damages on check seat faces of casing and block, if any, by lapping.
lll Pay attention not to leave lapping agent in casing and block.
© Confirm that all sliding and fitting parts can be moved manually and that all grooves and paths
are free foreign matter.
@ If any spring is broken or deformed, replace it with new one.
@ When relief valve do not function proper1y, repair it, following its disassembling assembling
procedures.
(]) Replace all seals and 0-rings with new ones.
(2) Relief valve
<D Confirm that all seat faces at ends of all poppets and seats are free of defects and are uniform
contact faces.
@ Confirm manually that main poppet and seat can slide lightly and smoothly.
@ Confirm that outside face of main poppet and inside face of seat are tree from scratches and so
on.
© Confirms that springs are free from breaking, deformation, and wear.
@ Confirm that orifices of main poppet and seat section are not clogged with foreign matter.
@ Replace all ().rings with new ones.
(]) When any light damage is found in above inspections, correct it by lapping.
® When any abnormal part is found, replace it as relief valve assembly.
..
•
4) ASSflB lllG
• In this asserrbing section, explanation only is shown. Reier to figures shown in cisassernbliug
section and structure section.
• Figure in ( ) shown after part name in explanation sentence shows number in structure figure.
• Cautions in assembling seals
• Pay attention to keep seals free from defects In its forming and damages In its handling.
• Apply grease, hydraulic oil or so on to seals and seal-fitting sections for full lubrication.
· Do not stretch seals so much to deform them permanently.
· In fitting 0-ring, pay attention not to roll it into its position. In addition, twisted 0-ring cannot
remove its twislilg naturally wi1h ease after being fitted, and causes oil leakage.
· Tighten filling bolts at al sections wi1h torque wrench to their respective tig1tening torques.
(1) Assembling of casing

Frt 0-rings (1 64, 165) to Casing A (101) and Casing B (1 02) and llghten bolts (974, 975) to
specified torques.
• Check mating faces for dust, etc. and confirm that 0-rings are frtted to 0-ring gl'OOlleS securely.
(2) Assembly of plug
iighten plug (159) to specified torque.
• Since plug (159) is applied with special coating, use new one in reassembling without fail.
However, in case of emergency, PT 118 plug available on market can be used substituti'lely with
seal tape turned in one turn and half on it.
In this case pay fuU attention not to fall piece of seal tape into casing.
• Use of seal tape may cause malfunction of oontrol valve. Do not use it as far as possible.
(3) Assembly of check valve
Asse 1tJle poppets (511, 515, 516, 517) and lighten the tatters to their specified torques.
• Use poppets, springs and plugs in following groups.
Poppel Spring Plug Remember that

511 521 551 - 511 in 10 positions
517 521 551
515 521 551 - 515 in 1 position and 516 in 1 position
516 523 552
(4) Assembling of negative control relief valve

Assemble poppet (611 ), spring (621) and damping rod (631) to Casing A ( 101 ). Put 0-ring (561)
onto plug (551 ) and lighten the latter to its specified torque.
(5) Assembling of lock valve I II I mbly
Frt 0-ring (163) to lock valve assembly (252) and tighten hexagon sod<et head bolts to specified
torque.
-
(6) A.-nbling of port relief valve
Assembling port relief valve (602} to casing and tiglten it to specified torque.
• Assenting procedJres b" reief v.We itself are to be as shown i1 the~ """""\
· Frt ~ (162, 561) and back up ring (562) to plug (102). Frt poppet (611), spring (621) and().
ring (661) to spring seat (612). Then, assemble spring seat (612) into plug (102) temporarily
with adjusting screw (651) and lock nut (ff71 ).
• Confirm that poppet (611) has been fitted to seat section of plug (102) securely.
· Frt 0-ring (563) and back up ring (564) to seat (541) of plunger (511). Then, assemble plunger
(511), piston (301) and springs (521, 522)
• Fit seat (541) assembly to body (101) and tighten plug (102) assembly to specified torque.
• Confim1 that springs (521, 522) are guided securely.
· Since pressure adjustment is carried out according to maim-nee standards, keep adjusting
screN (651 ) as being assembled temporariy.
(7) Aslembllng of boom spool

0) T9'1ten plug (353) to boom spool (303).
(%) Hold boom spool in vise, set spring seat (332), springs (371, 372) and stopper (335), and tighten
spacer bolt (336) to specified torque.
• Before tightening spacer bolt (336), apply Loctite #241 to it.
@ Frt spool assemblies of Items (i) and ®above into Casing B (102).
• Frt spool assemblies into Casing B (102) carefully and slowly. Do not push them forcibly without
fall.
(8) A818mbllng of ann spool
<D Hold ann sut>-spool (312) in mouthpiece -attached vise, fit spring (329) and spring seats (358,
359), and tiglten spacer bolt (343) to specified torque.
• Before tigltening spacer bolt (343), apply Loctite #241 to it
(%) Insert arm sut>-spool (312) assembly into arm spool (302), paying attention not to insert it in
wrong direction.
Confim1 that piston (313) has been inserted in plug (341 ), fit the latter, and tiglten it to specified
torque.
• Confirm that am1 sut>-spool (312) can f'OOll8 lightly in ann spool (302).
@ Hold plug (341) at end of arm spool (302) in vise, set spring seat (332), springs (371, 372) and
stopper (335), and tighten spacer bolt (336) to specified torque.
• Before tightening spacer bolt (336), apply loctite #241 to it.
© Fit spool assemblies of Items (}) and (%) abo'-le into Casing A (102).
• Frt spool assemblies into Casilg A (101) carefully and slowly. Do not push them brci:lly without
fail.
(9) Aslembllng of travel spool
<D Hold end ol travel spool (301 ) in mouthpiece attached vise, set spring seat (331), springs (328,
329) and stopper (334), and tiglten spacer bolt (333) to specified torque.
• Before tightening spacer bolt (333), apply Loctite #241 to it
(%) Insert spool assemblies into Casing A (101) and Casing B (102).
• Fit spool assemblies into Casing A (101) and Casing B (102) carefully and slowly. Do not push
•
them forcibly without fail.
8-50
(1GI Assembling of covers
<D Fit spool covers (202, 204) to sides reverse to spring sides of travel, option, swing, arm 1, boom
1, bucket and arm 2 spools, and tighten hexagon socket head bolts (273) to specified torque.
• Confirm that 0-rings (165, 264) have been fitted.
® Fit spring COYei'S (2o3, 201) to spring sides of traYBI, option, bypass cut, swing, boom 2, arm 1,
bucket, swing preferential boom, and arm 2 spools, and tighten hexagon socket head bolts (273)
to specified torque.
• Confirm that 0-ring (261 & 262) have been fitted.
(11) Assembling of straight travel valve block
Frt 0-rings (165, 166, 167, 266) to straight travel valve block (103), and tighten hexagon socket
head bolt to specified torque.
• Assembling procedures for straight travel valve block itself are to be as shown in the following.
· Hold casing (103) in vise.
· Fit main relief valve (601) to casing and tiglten it to specified torque.
(Assembling procedures for main relief valve itself are shown separately.)
· Fit poppet (511) and spring (521), and tighten plug (551) to specified torque.
· Tighten orifice (357) with hexagon wrench to specified torque. Further, fit 0-ring ( 163) to plug
(156) and tighten plug to specified torque.
· Fit piston (309), spool (308), sleeve (344), spring seat (376) and spring (375), paying attention not
to fit them in wrong direction. Then, fit 0-ring (266) to plug (356) and tighten plug to specified
torque.
· Fit spool (391 ), springs (324, 325) and stopper (338). Fit 0-ring (266) to plug (251) and tighten
plug to specified torque.
~Assembling of main relief valve
<D Fit spacer(122), C-ring (121), 0-rings (163, 561), and bad< up ring (562) to plug (103).
® Fit piston (614) and 0-ring (661) to stopper (613). Fit them to adjusting plug (104) and assemble
them temporarily with adjusting screw (652) and lock nut (671 ).
@ Fit poppet (611) and spring (621) to plug (103), and fit adjusting plug (104) fitted with 0-ring (663,
664).
• Confirm that poppet (611) has been fitted to seat section of plug (103) securely.
© Fit plunger (512) and spring (521) to seat (541).
@ Fit seat to plug (103) assembly, and fix it with C-ring (121).
® Since pressure adjustment is carried out according to maintenance standards, keep adjusting
plug (104) and adjusting scrf!N (652) as being assembled temporarily.
8-51
GROUP 5 SWING DEVICE
1. REMOVAL AND INSTALL OF MOTOR
1) REMOVAL
Escaping fluid under pressure can
Ɠ When pipes and hoses are disconnected,
the oil inside the piping will flow out, so 3
(4) Disconnect hose assembly(2).
1
(5) Disconnect pilot line hoses(3,4,5,6). 4
(6) Sling the swing motor assembly(1) and

remove the swing motor mounting bolts 2
(7).
ş Motor device weight : 191kg(421lb)
(7) Remove the swing motor assembly.
Ɠ When removing the swing motor assembly,
check that all the piping have been
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.
5
‫ ڹ‬Pour in hydraulic oil until it overflows
from the port.
6
‫ ں‬Tighten plug lightly.
‫ ڻ‬Start the engine, run at low idling and
‫ ڼ‬Tighten plug fully.
(3) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.
8-52
2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
1) STRUCTURE
4 5 6 7 8 9 10 11 12 13 14 15 17, 18 35 36
3
2
16 41
1 36
40
17,18
39
38
29 28 27 26 25 24 23 22 21 20 19 43 42 37 34 33 32,31 30
1 Inner ring 16 Piston 31 O-ring

2 Oil seal 17 Cap 32 Back up ring
3 Taper roller bearing 18 O-ring 33 O-ring
4 Plug 19 Coned disc spring 34 Cover
5 Backing spring 20 Teflon ring 35 Relief valve assembly
6 Cam plate 21 Bushing 36 O-ring
7 Return plate 22 Balance plate 37 Hexagon socket bolt
8 Piston assembly 23 Needle bearing 38 Check valve
9 Plate 24 Snap ring 39 Spring
10 Lining plate 25 Cylinder assembly 40 Cap
11 O-ring 26 Housing 41 Back up ring
12 Piston 27 Collar 42 Time delay valve
13 O-ring 28 Level gauge assembly 43 Hexagon socket bolt
14 Spring 29 Snap ring
15 Parallel pin 30 Bypass valve assembly
8 - 53
2) DISASSEMBLY
(1) Removal of relief valve assembly

Remove cap of relief valve assembly(35)
with 14mm hexagonal wrench.
Ɠ Assemble removed relief valve assembly
(35) to original state when reassembling.
(2) Removal of make up valve

Loosen cap(40) with 14mm hexagonal
wrench, and remove check valve(38) and
spring(39).
(3) Marking at swing motor

Before disassembling motor, make a
matching mark between cover(34) and
housing(26) for easy reassembling.
(4) Remove mounting bolts of cover

Loosen hexagon socket bolt(37) with
14mm hexagonal wrench.
8 - 54
(5) Removal of cover assembly
Place shaft of motor assembly to
downward and take cover(34) 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 - 55
(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(34).
(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
picture.
(12) Remove O-rings(11,13) from piston(12)

and housing(26).
8 - 56
(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 - 57
(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 - 58
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 - 59
(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 - 60
‫ 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 - 61
(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 30~50 mm under bottom of
(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 - 62
(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(34).
(11) Assemble bushing(21) with teflon ring(20)

and coned disk spring(19) to bushing
hole of cover(34).
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 - 63
(12) Lubricate locating pin for antirotation of
balance plate(22) of cover(34) with
grease sufficiently and install locating pin
to housing.
(13) Assembly of balance plate

Assemble balance plate(22) to cover(34).
Ɠ Be cautious of assembling direction.
(14) Assemble O-ring(13) to cover(34).

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(34).
8 - 64
(16) Assembly of cover
Assemble cover(34) 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(34).
Ɠ Fit matching marks on housing(26) and
cover(34) made before disassembling.
(17) Tighten cover(34) and housing(26) with

16mm hexagonal socket bolt(37).
ş Tightening torque : 29kgfşm
(210 lbfşft)
(18) Assembly of make up valve

Assemble check(38) and spring(39) to
cover(34) and tighten cap(40) with 14mm
hexagonal socket bolt.
(101 lbfşft)
(19) Assembly of relief assembly

Assemble relief valve assembly(35) to
cover(34) with 14mm hexagonal socket
bolt.
(58 lbfşft)
Ɠ Be cautious of assembling method.
8 - 65
(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 - 66
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 : 191kg(421lb)
şTightening torque : 57.9Ź8.7kgfşm
(418Ź62.9lbfşft)
2) INSTALL
to removal.
8-67
4. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR
1) STRUCTURE
1 2 3 4 5 6 26 9 10 11 12 13 14
16
7
15
17
26 25 24 23 22 21 20 19 18 8 27 28
1 Pinion shaft 11 Pin 21 Thrust plate 2

2 Collar 12 Ring gear 22 Spring pin
3 Snap ring 13 Holder 1 23 Holder 2
4 Plate 14 Sun gear 24 Planetary gear 4
5 Roller bearing 15 Shaft 1 25 Plug
6 Gear casing 16 Planetary gear 2 26 Plug
7 Bushing 1 17 Thrust plate 1 27 Lock washer
8 Spring pin 18 Shaft 2 28 Lock bolt
9 Oil seal 19 Bushing 2
10 Roller bearing 20 Planetary gear 5
8 - 68
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(24) and holder
assembly 2(23) itself.
(3) Disassembly of 2nd holder assembly

‫ ڸ‬Insert spring pin(22) into shaft 2(18) by
hammering.
Ɠ Do not reuse spring pin after removal.
‫ ڹ‬Remove shaft 2(18) from holder 2(23),

planetary gear 5(20) with hands.
8 - 69
(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.
(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(9) after removal.
‫ ں‬Remove roller bearing(10) from gear

casing(6).
8 - 70
‫ ڻ‬Remove oil seal(9) 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 - 71
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 50Ş

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(9).
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 - 72
(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(10) 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 - 73
(5) Assembly of ring gear
‫ ڸ‬Remove oil from mating faces between
gear casing(6) and ring gear(12), and
from pin(11). Assemble collar to gear
casing and apply fluid packing(three
bond of grey color).
‫ ڹ‬Assemble ring gear(12).
(6) Assembly of holder assembly

‫ ڸ‬Assemble bushing(19) to planetary
gear 5(20).
Insert shaft 2(18) after putting plate(21)
and bushing(19) to holder(23).
Ɠ Lubricate gear oil to inside of gear and
outside of shaft.
‫ ڹ‬Insert spring pin(22) by hammering.

Ɠ Insert as the clearance between spring
pins toward gear(20).
8 - 74
(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(24) thrust plate

to gear 5(20).
(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(24) is engaged with
teeth of holder 1(13).
‫ ڹ‬Insert sun gear(14) to planetary gear

2(16).
8 - 75
(9) Check rotation of sun gear by turning 1st
holder assembly with hands.
This completes assembly.
8 - 76
GROUP 6 TRAVEL DEVICE
1. REMOVAL AND INSTALL

1) REMOVAL
(1) Swing the work equipment 90 and lower
it completely to the ground.
When pipes and hoses are disconnected,
1
the oil inside the piping will flow out, so
2
(4) Remove the track shoe assembly.
For details, see removal of track shoe
assembly.
(5) Remove the cover.
(6) Remove the hose.
Fit blind plugs to the disconnected hoses.
(7) Remove the bolts and the sprocket.
(8) Sling travel device assembly (1).
(9) Remove the mounting bolts (2), then
remove the travel device assembly.
Weight : 302kg(672lb)
2) INSTALL
to removal.
(2) Bleed the air from the travel motor.
Remove the air vent plug.
Pour in hydraulic oil until it overflows from
the port.
Tighten plug lightly.
Start the engine, run at low idling, and
Tighten plug fully.
8-77
2. TRAVEL MOTOR
1) STRUCTURE
101 113 29 112 139 178 116 115 110 105 106 151 103 167 15 8 35 1 25 6 33 126 134 130 127 121 138
165
164
32
154
166 181
163 182
150
102 3
34
141 9
14
20
109 A A 13
122
36
133
7
199
30
19
120 132
118 149
128
140
124
169
143 186 168
161 152
158 4
27 144
142 5 190
138 175 172 176 39 145 104 2 114 40 23 26 24 107 108 12 17 153 162 179 125 123 170 171 180 137 136 179 157 124 185 183
SECTION A-A
1 Hub 24 Ball bearing 105 Piston 124 Plug 143 Spring 167 Steel ball
2 Spindle 25 Needle bearing 106 Shoe 125 Stopper 144 Hexagon socket plug 168 Steel ball
3 Carrier 26 Floating seal 107 Retainer plate 126 Plug 145 Snap ring 169 Expander
4 Ring gear A 27 Pin 108 Thrust ball 127 Valve 149 Roller bearing 170 Hexagon socket bolt
5 Ring gear B 29 O-ring 109 Timing plate 128 Spring 150 Roller bearing 171 Lock washer
6 Cluster gear 30 Hexagon socket bolt 110 Washer 130 Spring 151 Roller 172 Valve seat
7 Sun gear 32 Hexagon bolt 112 Piston 132 Oil seal 152 Hexagon socket plug 175 Spring
8 Coupling gear 33 Lock washer 113 Spring 133 O-ring 153 Thrust plate 176 Ring
9 Shaft 34 Pin 114 Spring 134 O-ring 154 Expander 177 Ring
12 Distance piece 35 Hexagon socket bolt 115 Friction plate 135 Spring pin 157 Stopper 178 O-ring
13 Cover 36 Steel ball 116 Mating plate 136 Body 158 Steel ball 179 O-ring
14 Thrust collar 39 O-ring 118 Valve seat 137 Spool 161 Piston 180 O-ring
15 Ring 40 O-ring 119 Valve 138 O-ring 162 Shoe 181 Pin
17 Pin 101 Rear flange 120 Spring 139 O-ring 163 Valve 182 Hexagon socket bolt
19 Coupling 102 Shaft 121 Plug 140 O-ring 164 Stopper 183 Spring
20 Thrust bearing 103 Swash plate 122 Ring 141 Pin 165 Ring 185 Spring
23 Seal ring 104 Cylinder block 123 Spool 142 Valve 166 Spring 190 Orifice
8-78
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tool name Remark
Allen wrench 6
B
10
14
Socket for socket wrench, spanner 19
41
Pliers -
( - ) Driver 150mm
Plastic and iron hammer Wooden hammer allowed. Nominal 1 or so
Steel rod approx 7 7 200mm
Monkey wrench -
Oil seal inserting jig -
Bearing pliers -
Seal tape -
Eye bolt M10
Press (0.5 ton) -
Oil stone -
Bearing assembling jig -
Liquid packing Loctite #577
Screw lock Loctite #243
Torque
Part name Item Size
kgf m lbf ft
Hexagon socket plug 30 PT-1/2 6 2 43.4 14.5
Hexagon bolt 32 M12 1.75 85 10.4 1.6 75.2 11.6
Hexagon socket bolt 35 M18 2.5 40 35.5 5.5 256.8 39.8
Plug 121 PF 1/2 10 2 72.3 14.5
Plug 124 M36 1.5 45 9 325.5 65.1
Plug 126 M36 1.5 26 4 188.1 28.9
Hexagon socket plug 152 PT-1/4 3 0.5 21.7 3.6
Hexagon socket bolt 170 M8 1.25 60 3 0.5 21.7 3.6
Hexagon socket bolt 182 M16 2.0 40 25.7 4 185.9 28.9
8-79
3. DISASSEMBLY
1) GENERAL PRECAUTIONS
(1) Before disassembling the motor, check the items to be inspected and, for remedy against trouble,
closely examine the nature of the trouble, so that the motor can be disassembled effectively.
(2) To disassemble the motor, use the disassembling procedures described in section 2) and select a
clean place.
(3) Place a rubber or vinyl sheet or other such protective materials on your working bench to protect
the surface of the motor to be serviced.
(4) During disassembly, give a match mark to the mating surfaces of each part.
(5) Arrange removed parts in order so that they will not become damaged or missing during
disassembly.
(6) Once seals have been disassembled, they should be replaced even if damage is not observed.
Have replacement seals ready on hand before starting your disassembling job.
8-80
2) DISASSEMBLING PROCEDURE
(1) Disassembling the brake valve

section and the hydraulic motor
section
When inspecting or repairing the motor,
use the disassembling procedures
described below.
Numbers in parentheses ( ) following the
part name denote the item numbers
shown in the attached assembly
drawings.
Prior to disassembly, install the motor on
an inversion working bench.
Loosen the four hexagon socket head

bolts(170) and remove the SCV valve
body(136) from the rear flange(101).
Remove the two O-rings(140,180) from
the rear flange.
Do not reuse the O-rings(140,180) after
removal.
Remove the nine hexagon socket head

bolts(182).
Remove the rear flange(101) from the

spindle(2).
Proceed to pages 8-83 through 8-88 to
see the brake valve disassembling
procedure.
8-81
Remove the timing plate(109), the two
pins(141), the twelve springs(113), the
ball bearing(150), and the two O-
rings(29,39) from the rear flagne(101)
and the spindle(2).
Do not reuse the O-rings(29,39) after
removal.
Proceed to pages 8-89 through 8-91 to
see the description of the hydraulic
motor disassembling procedure.
(2) Disassembling the reduction gear/

hydraulic motor shafts and oil seals
Rotate the working bench through 180
degrees for the motor cover(13) to face
upward.
Remove the hexagon socket head
plug(30).
Remove the twenty hexagon bolts(32)
and the twenty super-lock washers(33).
Hook up and remove the cover(13).

Remove the thrust bearing(20).
Lift off the carrier assembly using the
lifter.
Remove the steel ball(36), the sun
gear(7), the coupling(19) and the thrust
bearing(20).
Rotate the working bench through 90

degrees and drain out the lubricating oil
from the motor.
At this time, place a lubricating-oil
receptacle under the working bench.
Proceed to page 8-92 through 8-96 to
see the reduction gear disassembling
procedure.
8-82
3) DISASSEMBLY OF BRAKE VALVE
(1) Disassembly of the spool
Remove the two plugs(124) from the
rear flange(101).
Remove the O-ring(179) from the
plug(124).
Removal of the plugs(124) from the rear
flange(101) can better be done by
loosening the former beforehand with
the latter remaining connected to the
spindle(2).
Do not reuse the O-ring(179) after
removal.
Remove the two springs(128), the two

stoppers(125), and the spool(123) from
the rear flange(101).
Be careful not to damage the outer
surface of the spool(123) and the sliding
surface of the rear flange(101).
Since the rear flange(101) and the
spool(123) are of the selective fitting
type, replace them together as a kit even
if only one of the two parts is damaged.
(2) Disassembly of the check valves

Remove the two plugs(126) from the
rear flange(101).
Removal of the plugs(126) from the rear
flange(101) can better be done by
loosening the former beforehand with
the latter remaining connected to the
spindle(2).
8-83
Remove the two springs(130) and the
two valves(127) from the rear flange
(101).
Be careful not to damage the seat
sections of the valves(127) or rear
flange(101).

plug(126).
removal.
(3) Disassembly of the valve(119) from

the rear flange(101)
Press and hold down the valve seat(118) Steel bar
using a steel bar, and in that state, as Ring(122)
Valve(119)
shown in the figure, press the notch in Valve seat(118)
Spring(120)
the ring(122) using a sharp-pointed steel
bar.
This deforms the ring(122), disengaging
it from the ring groove in the rear
flange(101).
The ring(122) can now be removed from
After disassembly, do not reuse ring(122)
and O-ring(133). Ring(122)
Removing the ring(122) damages the
hole section.
Repair the hole section after
Sharp pointed steel bar
disassembly. Notch
Remove the ring(122) only when the
valve(119) is to be replaced.
8-84
After filling up the hole section of the
valve seat(118), inject compressed air
from the parking brake access hole and
remove the valve seat(118).
Holding the rear flange(101) by hand
and lightly shaking it with its hole section
facing downward allows the valve(119)
and the spring(120) to be removed or
using tweezers or any other such tool,
remove the valve(119) and the
spring(120) from the rear flange(101).
Remove the O-ring(133) from the valve
seat(118).
When using compressed air(3~5
kgf/cm2) to remove the valve seat(118),
insert the spool(123) into the rear
flagne(101).

Steel bar
Press and hold down the stopper(164)
using a steel bar, and in that state, as Ring(165) Stopper(164)
shown in the figure, press the notch in Spring(166)

Valve(163)
bar.
flange(101).
After disassembly, do not reuse the

ring(165).
Removing the ring(165) damages the Ring(165)
hole section.
disassembly.
Remove the ring(165) only when the Sharp pointed steel bar
Notch
8-85
Make the hole section of the removed
ring(165) face down-ward, and lift the
rear flange(101).
This allows the stopper(164), the
spring(166) and the valve(163) from the
rear flange(101).
If removal is not possible even with the
hole section facing downward, gently
apply compressed air from the speed
selector port.

the rear flange(101) Steel bar
Press and hole down the valve seat(172)
Ring(176)
using a steel bar, and in that state, as
Valve seat(172)
shown in the figure, press the notch in
Spring(175)
bar.
flange(101).
After disassembly, do not reuse the

ring(176).
Removing the ring(176) damages the Ring(176)
hole section.
disassembly.
Remove the ring(176) only when the Sharp pointed steel bar
Notch
8-86
Remove the valve(142) from the rear
flange(101).
At this time, holding the rear flange(101)
by hand and lightly shaking it with its
hole section facing downward allows the
valve(142) to be removed.
Do not disassemble the spring pin(135),
spring(143), steel balls(158), or
expanders(169) that are contained in the
valve(142).
If the assembly mentioned is to be
replaced, use the following reducing
valve assembly as the new one.
Components of a reducting valve
assembly to be used.
Valve(142)
Spring pin(135)
Spring(143)
Steel ball(158)
Expander(169)
Use pliers or any other suitable tools if
the valve(142) cannot be removed even
with the hole section facing downward.
Be careful not to damage the valve(142)
at this time.
(6) Disassembly of the internal parts of

the body kit
Remove the plug(124) from the
body(136).
Removal of the plug(124) from the
body(136) can be easily done by
loosening that plug beforehand with it
remaining connected to the rear
flange(101).
plug(124).
removal.
8-87
Remove the springs(183,185), the
stopper(157) and the spool(137), in that
order, from the body(136).
Since the body(136) and the spool(137)
are of the selective-fitting type, replace
them together as a kit even if only one of
the two parts is damaged.
Be careful not to damage the outer
surface of the spool(137) and the sliding
surface of the rear flange(101).
8-88
4) DISASSEMBLY OF HYDRAULIC MOTOR
(1) Disassembly of the parking brake parts
Remove the piston(112) by injecting
compressed air from the parking brake
access hole in the spindle(2).
Take care that abrupt injection of
compressed air(3~5 kgf/cm2) may cause
the piston(112) to pop out.
To ensure your safety, apply a protective
cover to the piston.
Remove the O-rings(139,178) from the

piston(112).
Do not reuse O-rings(139,178) after
removal.
(2) Disassembly of the internal parts of

the motor
Lay the motor body on the side.
Drain out the oil from the motor.
Hold the cylinder block(104) with both
hands, and remove it from the spindle(2).
Place an oil receptacle under the motor to
receive the oil flowing out as the motor is
being laid on the side.
Before removal, hold the cylinder block(104)
with both hands and turn it two or three
times in a clockwise and a counterclockwise
direction alternately to detach the shoe(106)
from the swash plate(103).
Be careful that if an attempt is made to
remove the cylinder block(104) without
detaching the shoe(106) from the swash
polate(103), then the piston, shoe, and other
parts that are connected to the cylinder
block may come loose and fall into the
spindle.
8-89
Remove the four mating plates(116) and
three friction plates(115) that are
mounted on the outer surface of the
removed cylinder block(104).
Remove the piston assembly[piston
(105), shoe(106)], retainer plate(107),
thrust ball(108), and six rollers(151) from
the removed cylinder block(104).
Remove the swash plate(103) from the

spindle(2).
Remove the two steel balls(167) from
the spindle(2).
Remove the speed slector piston
assembly [piston(161) and shoe(162)]
from the spindle(2) by feeding
compressed air(3 to 5 kgf/cm2) from the
access hole in the spindle(2).
Since the piston and the shoe together
from a single unit, replace the entire
piston assembly even if only one of
Compressed air suction port
those two parts needs replacing.
Spindle(2)
(3) Disassembly of the inside of the

cylinder block
Place the cylinder block(104) on a press
working bench, and then while pressing
(120 kgf or more) and holding down a
retainer against the washer(110), remove
the snap ring(145) using snap ring pliers.
Protect the sliding surface of the cylinder
block with a vinyl sheet.
8-90
Remove the snap ring(145) the
washer(110), the spring(114), and the
washer(110), in that order, from the
cylinder block(104).
Remove the spring(114) only if it is to be
replaced.
(4) Disassembly of the shaft(102) and the

roller bearing(149)
Remove the shaft(102) from the
spindle(2).
At this time, the roller bearing(149) can
also be removed in conjunction with the
shaft(102).
The oil seal(132), however, cannot be
removed.
After placing a retainer on the press

Press
working bench, insert the shaft(102) into
the retainer without removing the roller
bearing(149) from the shaft. Shaft(102)
Inner racing of
Then, hold down the end of the shaft roller bearing(149)
using a press and remove the inner Retainer
lacing of the roller bearing(149).
Remove the roller bearing(149) only
when it is to be replaced.
Do not reuse the roller bearing(149) after
removal.
8-91
5) DISASSEMBLY OF REDUCTION GEAR
(1) Disassembly of ring gear A(4)
Before removing ring gear A, give an
alignment match mark to both the ring
gear and hub(1).
Remove the ring gear A(4) using a
crowbar or any other suitable tool.
After ring gear A(4) has been removed,
remove any adhesive residue from the
mating surfaces of the ring gear and the
hub.
Remove the ten dowel pins(27) from the
hub(1).
Ring gear A(4)
Crowbar
(2) Disassembly of the hub(1), ring gear

B(5), and the coupling gear(8)
Remove the ten hexagon socket head

bolts(35).
Since the hexagon socket head bolts(35)
have their threaded sections coated with
an adhesive, a loosening torque larger
than the tightening one is needed to
remove the bolts.
Tightening torque : 35.5 5.5 kgf m
(256.8 39.8 lbf ft)
Be extra careful during removal not to let
the threaded sections of the hexagonal
socket head bolts(35) seize.
Before removing the coupling gear(8)
from the spindle(2), mark the mating
surfaces of the coupling gear(8) and the
spindle(2) using a paint marker.
8-92
Mount ring bolts in the M12 tapped holes
of the hub(1),and then lift the hub(1) Lift up Hub(1)
Spindle(2)
using lifter and separtate the hub(1) and
the spindle(2).
This also disconnects the two ball
bearings(24), the seal ring(23), the O-
ring(40), the coupling gear(8), ring gear
B(5), the ring(15), and the distance
piece(12).
Proceed as follows if disassembly is not
possible with the method mentioned
above :
Rotate the motor through 180 degress to
let the spindle side of the motor face
upward.
As shown in the photo, lightly tap the
edge of the hub(1) equally with an
aluminum rod and a hammer until the
hub(1) has become disconnected from
the spindle(2).
This will also disconnect the following
parts :
Two ball bearing(24), seal ring(23), O-
ring(40), coupling gear(8), ring gear B(5),
ring(15), distance piece(12).
Lay a rubber mat under the working
bench to the prevent damage to hub(1)
and other parts due to possible fall from
the working bench.
8-93
(3) Disassembly of the inside of the
spindle(2) Hammer
Screwdriver
spindle(2).
Rotate the spindle(2) through 180
degrees. Spindle(2)
Oil seal(132)
Remove the oil seal(132) from the
spindle(2).
(To remove the oil seal, set a ( )
screwdriver at the cylindrical edge of the
oil seal and lightly tap with a hammer.)
removal.
Remove the oil seal(132) only if it is to be
replaced.
Do not reuse the oil seal(132) once it has
been removed.
Remove the floating seal(26) from the

spindle(2).
8-94
(4) Disassembly of the inside of the hub(1)
Place the hub(1) on the working bench
so that the cover side of the hub faces
upward.
Remove one of the two ball bearings(24)

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

removal.
8-95
(5) Disassembly of the coupling gear(8)
Remove the ring(15) from ring gear B(5).
Do not reuse the ring(15) after removal.
Remove the coupling gear(8) from ring

gear B(5).
Except for their replacement, do not
disassemble the coupling gear(8) or ring
gear B(5).
(6) Disassembly of the carrier assembly

Do not disassemble the carrier assembly
any further.
If a component of the carrier assembly is
irrecoverably damaged, replace the
entire carrier assembly with a new one.
Components of the carrier assembly
Carrier(3)
Cluster gear(6)
Shaft(9)
Thrust collar(14)
Needle bearing(25)
Dowel pin(34)
8-96
4. ASSEMBLY
1) GENERAL PRECAUTIONS
(1) Reassemble in a work area that is clean and free from dust and grit.
(2) Handle parts with bare hands to keep them free of linty contaminats.
(3) Repair or replace the damaged parts.
Each parts must be free of burrs its corners.
(4) Do not reuse O-rings, oil seal and floating seal that were removed in disassembly.
Provide the new parts.
(5) Wash all parts throughly in a suitable solvent.
Dry throughly with compressed air.
Do not use the cloths.
(6) When reassembling oil motor components of motor, be sure to coat the sliding parts of the
motor and valve with fresh hydraulic oil. (NAS class 9 or above)
(7) Use a torque wrench to tighten bolts and plugs, to the torque specified as follows.
8-97
2) ASSEMBLY OF BRAKE VALVE
(1) Assembly of the check valve

Fit the O-ring(134) on the plug(126).
Insert the spring(130) and the valve(127)
into the plug(126), and then grease the
spring(130) and the valve(127) and
hand-lock the former.
Insert the plug(126) in conjunction with
the sprign(130) and the valve(127) into
the rear flange(101), and tighten the plug
to the required torque.
Apply grease to the O-ring(134).
Tighten the plug(126) to a torque of
26 4 kgf m(188 29 lbf ft).
(2) Assembly of the spool

Insert the spool(123) into the rear
flange(101).
Apply a working fluid to the spool(123)
and insert it into the rear flange(101).
The spool must be remounted with its
axial center accurately in line with the
hole center of the rear flange.
This prevents the inner surface of the
rear flange and the outer surface of the
spool from damage due to their contact.
Attach the O-ring(179) to the plug(124).
Install stopper(125) and the spring(128)
into both plugs(124), and tighten the
plugs(124) into the rear flange(101) at
the required torque.
Damage to the hole section of the rear
flange or the outer surface of the spool
may cause internal leakage to occur
after reassembling, and motor
performance to deteriorate.
Required torque :
45 9 kgf m(325 65 lbf ft)
Even if either the rear flange(101) or the
spool(123) is to be replaced, their entire
assembly(kit) must be replaced.
8-98
(3) Assembly of the surge cut off valve
Apply a working fluid to the spool(137),
and insert it into the body(136).
The spool(137) must be remounted with
its axial center accurately in line with the
hole center of the body(136).
This prevents the inner surface of the
body and the outer surface of the spool
from damage due to their contact.
Fit the O-ring(179) to the plug(124).

Install the stopper(157) and the
springs(183,185) into the plug(124).
Tighten the plug(124) into the body(136)
at the required torque.
Damage to the hole section of the body
or the outer surface of the spool may
cause internal leakage to occur after
reassembling, and motor performance to
deteriorate.
When screwing the plug(124) down into
the body(136), be careful not to let the
springs(183,185) deform.
8-99
(4) Assembly of the parking brake valve
Mount the O-ring(133) on the valve
seat(118).
Insert the valve(119), the spring(120),
and the valve seat(118), in that order,
into the rear flange(101).
Slightly bend a new ring (see the figure)

and place it in the rear flange(101).
Then, fit the new ring into the ring groove
of the rear flagne.
Use a new ring(122).
Spring(120)
Valve seat(118)
Valve(119)
8-100
(5) Assembly of the valve(163)
Holding the rear flange(101) with its
surface contacting the spindle(2) upward,
place the rear flange on a working bench.
Insert the valve(163) into the rear
flange(101).
Fit the spring(166) into the valve(163),
and mount the stopper(164) on it.
Slightly bench a new ring(165) and insert
it into the rear flange(101) from the top of
the stopper(164).
Then, fit the new ring into the ring groove
of the rear flange.
The ring(165) used must be fitted snugly
into the ring groove of the rear
flange(101).
Improper insertion of the ring(165) into
the ring groove may cause unstable
action of the valve(163), thus disabling
high/low speed selection.
The ring(165) must be a new one.
(6) Assembly of the valve(142)

Assemble the reducing valve assembly, Steel bar
the valve seat(172), and the spring(175)
Ring(176)
into the rear flange(101).
Valve seat(172)
Press and hold down the valve Spring(175)
seat(172) using a steel bar, and in that
state, mount the ring(176) in the ring
groove of the rear flange(101).
The ring(176) will remain deformed while
inside the rear falgne(101).
Before inserting the ring(176) into the
ring groove of the rear flange(101),
therefore, both ends of the ring must be
extended using snap-ring pliers(special
ones for holes).
The ring(176) must be a new one. Extent
(Right-hand side)
8-101
3) ASSEMBLY OF REDUCTION GEAR AND HYDRAULIC MOTOR
Before reassembling the reduction gear and the hydraulic motor following completion of parts
replacement, one of the following two operations must be carriedu out :
Selecting a distance piece(12) of the appropriate thickness.
Selecting a thrust bearing(20) of the appropriate thickness
Reassembling must be down only after clearance adjustment of these parts.
Prior to the start of reassembling, check for parts that require replacment.
A : Reassembling
No
(see pages 8-103
through 8-115)
Parts
replacement
Parts to be replaced
B : Thickness selection of a
Hub kit
distance piece(12)
Spindle kit
(see page 8-116)
Ball bearing(24)
Yes
C : Thickness selection of a
thrust bearing(20)
Carrier assembly
(see pages 8-117
Cover(13)
through 8-119)
When the parts listed above are to be replaced, use correctly preadjusted parts as the
replacement ones.
Reassembling with nonadjusted parts may cause motor malfunctions, resulting in early damage.
8-102
A : REASSEMBLING
Hammer
(1) Assembly of the hub section Force-fitting jig
Mount the hub(1) on a working bench so
that the mounting side of the cover(13) Ball bearing
faces upward. Hub
Insert the ball bearing(24) into the hub(1)
using a force-fitting jig.
Heat the hub(1) to a temperature of
90 5 C
Shrinkage-fit the ball bearing(24).
If a force-fitting jig is not available, insert
the ball bearing(24) into the hub(1) and
then hammer the former.
Rotate the hub(1) through 180 degress
to make the mounting side of the
spindle(2) face upward.
Insert th ball bearing(24) into the hub(1)
using a force-fitting jig.
Shrinkage-fit the ball bearing(24).
Assemble the O-ring(40) into the hub(1).
Apply a thin coat of grease to the O-
ring(40).
Assemble the seal ring(23) into the
hub(1).
The seal ring can better be assembled
into the hub by tapping the edge of the
seal ring lightly with a plastic hammer.
When assembling the seal ring(23) into
the hub(1).
Be extra careful not to damage the O-
ring(40).
8-103
(2) Assembly of the spindle(2) section
Mount the two floating seals(26) in the
spindle(2).
Apply a thin coat of grease to the O-ring
in the floating seal(26).
Be extra careful to ensure that dust does
not stick to the seal surface.
(3) Assembly of the hub(1) and the spindle(2)

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

ring gear B(5) and ring gear B(5)
Mount the coupling grar(8) in ring gear
B(5).
Fit the ring(15) into the ring groove of
ring gear B(5).
Do not reuse the ring(15) after removal.
Use a new one during reassembling.
8-104
(5) Assembly of the coupling gear(8)
Attach a distance piece(12) to the
coupling gear(8) using grease.
During attachment, apply a thin coat of
grease to the mounting surface of the
coupling gear(8) to prevent possible fall
of the distance piece(12).
B : Proceed to thickness
Hub kit
section of a distance piece(12)
Spindle kit
(see page 8-116)
Ball bearing(24)
No parts to Proceed directly to

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

(fitted with ring gear B(5)) on a coupling
gear lifter, and then lift it with the crane
and mount it in the spindle.
Match the match marks on the coupling
gear(8) and the spindle(2).
Insert the ten pins(17), and caulk the pin
hole edges of the coupling gear(8).
Do not reuse the pins(17) after removal.
Use new ones during reassembling.
Tighten the ten hexagonal socket

bolts(35) to the required torque using a
torqur wrench.
Tightening torque : 35.5 5.5 kgf m
(256.8 39.8 lbf ft)
Apply an adhesive to the threaded
section of the spindle(2) and the pin
holes after degreasing both.
After completely degreasing the
hexagonal socket bolts(35), apply
molycoat to the bottom of each such bolt
neck.
Rotate the motor through 180 degrees to
make the spindle side face upward.
8-105
(6) Assembly of the oil seal(132)
Fit the oil seal(132) into the oil seal
mounting hole of the spindle(2).
Apply white petrolatum or lithium grease
to the lip section of the oil seal(132).
Use a new oil seal during reassembling.
(7) Assembly of the roller bearing(149)

Shrinkage-fit the roller bearing(149) onto
the shaft(102).
If the roller bearing(149) has been
removed from the shaft(102) during
disassembling, replace the former with a
new one and then shrinkage-fit it onto
the shaft(102).
Shrinkage-fitting temperature :
100 10 C.
Apply molybdenum disulfide grease to
the outer contact surface of the roller
bearing(149).
When inserting(149) use leather gloves
and take care not to get burned.
8-106
(8) Assembly of the piston assembly
(161, 162)
Mount the piston assembly(161, 162) in
the piston hole of the spindle(2).
Piston kit
Spindle
(9) Assembly of the steel balls(167)

Mount the two steel balls(167) in the
steel-ball hole of the spindle(2).
(10) Assembly of cylinder block section

Insert washer(110), spring(114),
washer(110) and snap ring(145) in that
order, into the shaft bore of cylinder
block(104).
8-107
Set cylinder block in the press in order to
compress the spring(114).
Place retainer on the washer(110) and
push down this tool with the press arbor
until the snap ring groove becomes
cleared.
Fit snap ring(145) into the groove.
When working on the cylinder block,
protect its sliding face by covering it with
a vinyl sheet.
A push of about 120 kgf(265 lbf) will be
needed to compress the spring.
(11) Assembly of piston motor sub assembly

Fit 6-rollers(151) into the pin holes of
cylinder block(104), and then, put thrust
ball(108) on it.
Immerse piston assembly in hydraulic oil.
Insert piston assembly into retainer

plate(107).
Mount the piston assembly in the
After mounting, immerse the entire them
in a working fluid.
8-108
As shown in the figure, mount the swash
plate(103), the thrust plate(153), the
thrust ball(108), the retainer plate(107),
the roller(151), the cylinder block(104),
and the piston assembly (105,106) in the
shaft(102).
Then, mount a lifter( ) and make the
shaft(102) upright.
The outer lacing of the roller bearing
(149) must be mounted in the spindle(2)
beforehand.
Accurately align and assemble the
retainer plate(107) and the spherical
section of the thrust ball(108).
Lift the motor assembly using a lifter, and Lifter
mount it in the spindle(2).
Mounting must be done so that the steel-
ball hole in the swash plate(103) and the
steel ball(167) come into a fit. Mounting
must also be done gently so that no
parts come into contact with the Spindle(2)
spindle(2) or other sections.
Contact may damage parts.
After the motor assembly has been
mounted, turn the cylinder block by hand
to check for backlash. Perform
inspections if back-lash is present.
8-109
(12) Assembly of the parking brake
section
Fit the mating plate(116) first and then
the friction plate(115), one by one, into
the grooves of the outer surface of the
This order of fitting must be strictly
observed.
Immerse the friction plates(115) in a
working fluid before fitting them into the
grooves.
Fit the O-rings(139,178) in the O-ring

grooves of the piston(112).
rings(139,178).
Mount the piston(112) in the spindle(2).

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

in the spring mounting hole of the
piston(112).
8-110
Fit the two O-rings(39) and the O-
ring(29) in the O-ring grooves of the
spindle(2).
Apply a thin coat of grease to the two O-
rings(39).
Remount the O-ring(29) without
greaseing it.
If this O-ring is greased and remounted,
possible oozing of the grease from the
contact surfaces of the rear flange(101)
and the spindle(2) during motor
operation may be mistaken for oil
leakage.
Fill the spindle(2) with a working fluid.

Quantity required : 1.2 liters.
(13) Assembly of the rear flange(101) back

in the spindle(2)
Mount the ball bearing(150) in the rear
flange(101).
Apply molybdenum disulfide grease to
the outer contact surface of the ball
bearing(150).
Fit the two dowel pins(141) into the pin

holes of the rear flange(101).
Using the dowel pins(141) as a guide,
mount the timing plate(109) in the rear
flange(101).
At this time, apply grease to the contact
surfaces of the timing plate(109) and the
rear flange(101).
Fit the two dowel pins(181) into the
spindle(2).
Mount the timing plate(109) firmly in the
rear flange(101) to prevent the former
from falling out of the latter.
8-111
Mount the rear flange(101) on the
spindle(2).
At this time, the two dowel pins that have
been fitted into the spindle(2) must be
aligned with the pin holes.
When mounting the rear flange(101) on
the spindle(2), a crane must be used
because the former weighs very much.
Tighten the nine hexagon socket head

bolts into the spindle(2) at the required
torque.
Tightening torque :
25.7 4 kgf m(185.9 28.9 lbf ft)
If, in step (12)- above, the piston(112)
does not fit into the spindle(2) because of
the resistances of the O-rings, proceed
as follows to mount the rear flange(101)
on the spindle(2) : mount four hexagon
socket bolts(182) in diagonal form, and
tighten them equally so that the rear
flange(101) is kept horizontal.
(14) Assembly of the surge cut off valve

assembly back in the rear flange(101)
Fit the two O-rings(140,180) in the rear
flange(101).
Assemble the body(136) of the surge cut
off valve, which was mounted previously
in (3) of page 8-99, into the rear flange
(101).
Then, tighten the four hexagon socket
bolts(170) into the rear flange(101) at the
required torque.
rings(140,180).
Tightening torque :
3 0.5 kgf m(21.7 3.6 lbf ft)
8-112
(15) Assembly of the carrier assembly
Attach one of the two thrust bearing(20)
to the coupling gear(8) using grease.
Apply a thin coat of molybdenum
disulfide grease to the thrust
bearing(20).
Parts to be replaced if C : Thickness selection of a

required : thrust bearing(20)
Hub kit and spindle kit carrier (see pages 8-117
assembly cover(13) through 8-119)

Mount the coupling(19) on the

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

gear(7), and place the sun gear in the
coupling(19).
8-113
Insert the carrier assembly into the
hub(1), and correctly engage the teeth of
ring gear B(5) and teeth B of the cluster
gear(6).
This must be done only after determining
the timing point of carrier assembly
reassembling
(see next for further details).
Determining the timing point of

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

cluster gears(6) at the positions shown.
At those positions, engage the sun gear
installer correctly with the cluster
gears(6) and fix the sun gear installer.
hub(1). This dismounts the sun gear
installer automatically.
(16) Assembly of ring gear A(4)
Mount ring gear A(4) on the hub(1). Insert
Check at this time that the teeth of ring
Match mark Ring gear A(4)
gear A and teeth A of the cluster gear
are in correct engagement.
Hub(1)
Rotate the hub(1) to fit the match marks
on ring gear A and the hub.
Fit the ten dowel pins(27) into the
hub(1).
After completely degreasing that surface
of ring A(4) that contacts the hub(1),
apply a thin coat #SS60F hermetic
sealant to that contact surface.
Fill the reducer section with a lubricating
oil.
Quantity required : Approx. 3.3 liters
8-114
(17) Assembly of the cover(13)
Attach the thrust bearing(20) to the
carrier(3) using grease.
disulfide grease to the surface of the
thrust bearing(20).
Parts to be replaced if C : Thickness selection of a

required : thrust bearing(20)
Hub kit and spindle kit carrier (see pages 8-117
assembly cover(13) through 8-119)

Install cover(8) to hub(1).

Apply slightly three-bond No.1211 to that
matching face of cover which is to mate
with the surface of hub(1).
Fasten cover(13) to hub(1) with 20

hexagonal bolts(32) and 20 supper lock
washers(33), applying to the specified
torque.
Tightening torque :
10.4 1.6 kgf m(75.2 11.6 lbf ft)
Before tighting bolts, apply loctite 242 to
the hexagon bolts(32).
Tighten 3-plugs(30) to cover(13) to the
specified torque.
Tightening torque :
6 2 kgf m(45 14 lbf ft)
Before tighting plugs, wrap the threaded
portion of each plug with two lagers of
the seal tape.
Tighten each plug until the last thread
becomes nearly flush with the cover
surface within an extent equal to plus or
minus one thread relative to the surface.
8-115
B : THICKNESS SELECTION OF A DISTANCE
PIECE(12)
(1) If the parts listed below have been
replaced, select a distance piece(12) of
the appropriate thickness.
After selection, return to the original
reassembling procedure [procedure (5) of
subsection 3] and carry out the next step
of that procedure.
Hub kit
Parts replacement Spindle kit
Ball bearing(24)
(2) Steps(1) through(4) of the original

reassembling procedure must be carried
out as directed.
Mount a measure plate on the spindle(2)
without inserting a distance piece(12).
Lightly tighten a few hexagon socket
bolts(35).
As shown in the figure at right, measure
dimension A using a depth micrometer.
Tighten the hexagon socket head bolts
equally.
Measure dimension C of the coupling
gear(8) to be mounted see the figure at
right.
Using the clearance measurements, Measure plate for distance Depth micrometer
piece thickness
calculate the appropriate distance piece
Spindle(2)
thickness as follows.
Measure the clearance between the
A
B
edge of the spindle(2) and that of the ball

X
bearing(24).
Take this clearance as X.
X=A-B Coupling gear(8)
Ball bearing(24)
Next, determine the distance piece of the
appropriate thickness.
c
Take this thickness as T.
T = (C + X) 0.1
Using the results of steps (1) through (5)

above, select the appropriate thickness. A : Dimension required
B : Jig dimension
Then, proceed with the original
reassembling operation.
8-116
C : THICKNESS SELECTION OF A THRUST
BEARING(20)
(1) If the parts listed below have been
replaced, select a thrust bearing(20) of
the appropriate thickness.
After selection, return to the original
reassembling procedure [procedure (15)
at page 8-113] and carry out the next
step of that procedure.
Hub kit
Spindle kit
Parts replacement
Carrier assembly
Cover(13)
(2) Steps(1) through(4) of the original

reassembling procedure must be carried
out as directed.
Attach one of the two thrust bearings(20)
to the coupling gear(8).
At this time, use the thinnest distance
piece.
Mount the coupling(19) on the
shaft(102).
Place the sun gear(7) in the
coupling(19).
hub(1), and correctly engage the teeth B
of the cluster gear(6).
This must be done only after
determining the timing point of carrier
assembly reassembling (see page 8-114
for further details.)
Do not apply molybdenum disulfide
grease to the thrust bearing(20).
8-117
Fit the match marks on ring gear A(4)
and the hub(1), and mount the ring gear Insert
on the hub. Check at this time that teeth
Match mark Ring gear A(4)
A of the cluster gear(6) and the teeth of
ring gear A(4) are in correct engagement. Hub(1)
Mount a thrust-bearing adjusting plate on

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

Depth micrometer
dimension A using a depth micrometer. Thrust bearing
adjusting plate
A
B
X
Carrier
Ring gear A(4)
Measure dimension C of the cover(13) to

be mounted.
See the figure at right.
Cover (13)
8-118
Using the clearance measurements,
calculate the appropriate thrust bearing
thickness as follows.
Measure the clearance between the
edge of the carrier(3) and that of ring
gear A(4).
Take this clearance as X
X=B-A
A : Dimension required
B : Jig dimension
Next, determine the thrust bearing of the
appropriate thickness.
Take this thickness as T.
T = (C - X) - (0.3 to 0.6)
Using the results of steps(7) through(9)
above,select the appropriate thickness
from three types.
Then, proceed with the original
reassembling operation.
8-119
GROUP 7 RCV LEVER

1) REMOVAL
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
to removal.
8-118
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
201
126
101
122
111
Port 2,4 Port 1,3
8-119
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 Lever
131 Bushing 301 Universal joint 453 Switch seat 1
151 Plate 302 Plate 454 Switch seat 2
201 Spool 312 Adjust nut 455 Switch
211 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
8-120
(1) Tools
Tool name Remark
Allen wrench 6 B
22
Spanner
27
( + ) Driver Length 150
( - ) Driver width 4 ~ 5
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
8-121
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.
8-122
(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.
8-123
(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.
8-124
(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.
8-125
(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).
8-126
(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).
8-127
(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.
8-128
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.
8-129
(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.
8-130
(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.
8-131
(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.
8-132
(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).
8-133
(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).
8-134
(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.
8-135
(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.
8-136
•
GROUP 8 ltRWGJOlfl'
1. REMC1t'AL AM> t6TALL

1) REMOVAL
(1) Lower lhe work equipment to 1he ground
pressure in lhe hydraulic piping.
(3) Loosen the brealher slowly to release the
pressure ilside the hydraulic tank.
~ Escaping fluid under pressure can
penebate the skin causing serious injury.
• When pipes and hoses are disoomected,
the oil inside lhe piping will flow out. so
(4) Disconnect all hoses .
(5) Sling the turning joint assembly (1) and
rerTl0\18 the mounting boH(2).
· Weight : 50kg(11 Olb)
· Tg1111ig~ : 29.6±321q · m
(214.1±2.3.1 b . ft)
(6) Remolle the tu~ joint assenilly.
• When removing 1he turning joint, check
Iha! aR !he hoses have been discooi18Cled.
2) INSTALL
(1) Carry out installation in the reverse order 1 - I "_ , v- 2
to removal.
• Take care of turning joint direction.
• Assemble hoses to their original positions.
• Confirm the hydraulic oil ~ and check
the trydrautic oil leak or nol
0.
8-139
1) STRUCTURE
10 13 6 3
14
ug:::=-- 1s
_,
9 '
8
2
12 11
1 Hub 6 Shim 11 PT Plug

2 Shaft assembly 7 Slipper seal 12 PT Plug
3 Cover 8 0-ring 13 Plug
4 Spacer 9 0-ring 14 Retainer ring
5 Shim 10 0-ring 15 Spring washer
8-140
•
2) llSASSE.MBl.Y
• Before the disassemljy, clean the turning y 14
joint
(1) Remove bolts(14), washer(15) and ro-3

i 15
~
<XM!f13).
(2) Remove shim(6) and O.ring(10).

(3) Remove retainer ring(13), spacer(4) and
shim(S).
(4) Place body(1) on a V·block and by using

a wood buffer at the shaft end, hit out Secure with hand
Wooden block
shaft(2) to about 1/2 from the body with a
hammer.
• Take care not to damage the shaft(2)
when l'9mCMI body(1) or rest it sideway.
• Put a fitting marl< on body(1) and shaft(2).
WOlkbendl/
(5) Remove six slipper seals(7) and O.ring(9)

from body(1 ).
Q--9
0---1
~ W-1
I® l
@
0.
8-1 41
3) ASSEMel...Y
llf Clean all parts.
llf As a general rule, replace oil seals and
0-ring.
• Coat the sliding surfaces of all parts with
engine oil or grease before installing.
(1) Rx seven slipper seaJ(7) and O-ring(9) to

body(1).
Q -9
(2) Frt 0-ring(S) to shaft(2).
0 -1
~-1
(3) Set shaft(2) on !;jock, tap body(1) with a

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

ring(13) to shaft(2).
(5) Frt O-ring(10) to body(1 ).

(6) Frt shim(6) to shaft(2).
8-142
•
(7) Install COYer{3) to body(1) and tighten

bolts(14).
· Torque : 10-12.5 kgf · m
v 14
~ 15
~3
8· 143
GROUP 9 BOOM, ARM AND BUCKET CYLINDER

1) BUCKET CYLINDER
(1) Removal
Ɠ Expand the arm and bucket fully, lower
the work equipment to the ground and
stop the engine.
Ɠ Operate the control levers and pedals
Loosen the breather slowly to release the
Ɠ Escaping fluid under pressure can
Bucket cylinder
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 bolt(2), nut(3) and pull out

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

put plugs on cylinder pipe.
8-144
‫ ڻ‬Sling bucket cylinder assembly(7), and
remove bolt(6), then pull out pin(5). 7
‫ ڼ‬Remove bucket cylinder assembly(7)
şWeight : 140kg(309lb)
(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
8-145
2) ARM CYLINDER
(1) Removal
stop the engine.
Block
dust from entering.
‫ ڸ‬Set block between arm cylinder and

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

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

put plugs on cylinder pipe. 3
‫ ڻ‬Disconnect greasing hoses(4).
4
8-146
‫ ڼ‬Sling arm assembly(7), and remove
7
bolt(6), then pull out pin(5).
‫ ڽ‬Remove arm cylinder assembly(7)
(2) Install
to removal.
pin hole.
Ɠ Bleed the air from the arm cylinder.
Ɠ Confirm the hydraulic oil level and check
8-147
3) BOOM CYLINDER
(1) Removal
stop the engine.
dust from entering.
1
‫ ڸ‬Disconnect greasing hoses(1).
‫ ڹ‬Sling boom cylinder assembly.
‫ ں‬Remove bolt(4), nut(5), pin stopper(3)

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

a stand.
8-148
‫ ڼ‬Disconnect boom cylinder hoses(7), and
put plugs on cylinder pipe.
‫ ڽ‬Remove bolt(9) and pull out pin(8).

‫ ھ‬Remove boom cylinder assembly(6).
6 9
8
(2) Install
to removal.
pin hole.
Ɠ Bleed the air from the boom cylinder.
Ɠ Conformed the hydraulic oil level and
check the hydraulic oil leak or not.
8-149
1) STRUCTURE
(1) Bucket cylinder
8,9 10 5,6 7 4 22 33 32 3 11,12 1 2 13 14 15,16 17 18 19 20
Internal detail
25,28,29 30 31 33,34
23,24,26,27
1 Tube assembly 13 Cushion ring 25 Pipe clamp

2 Rod assembly 14 Piston 26 Hexagon bolt
3 Gland 15 O-ring 27 Spring washer
4 Du bushing 16 Back up ring 28 Hexagon bolt
5 Rod seal 17 Piston seal 29 Spring washer
6 Back up ring 18 Wear ring 30 Pipe assembly(R)
7 Buffer ring 19 Dust ring 31 Pipe assembly(B)
8 Dust wiper 20 Lock nut 32 O-ring
9 Snap ring 22 Hexagon socket head bolt 33 Hexagon socket head bolt
10 Wear ring 23 Band assembly 34 Pin bush
11 O-ring 24 Band 35 Dust seal
12 Back up ring
8-150
(2) Arm cylinder
8,9 10 5,6 7 4 24 36 35 3 11,12 1 2 13 14 15,16 17 18 19 22 20,21
Internal detail
25,26,29,32 27,28
37,38
30,31,32 33 34
1 Tube assembly 14 Piston 28 Band(B)

2 Rod assembly 15 O-ring 29 Hexagon bolt
3 Gland 16 Back up ring 30 U-bolt
4 Du bushing 17 Piston seal 31 Hexagon nut
5 rod seal 18 Wear ring 32 Spring washer
6 Back up ring 19 Dust ring 33 Pipe assembly(R)
7 Buffer ring 20 Cushion spear 34 Pipe assembly(B)
8 Dust wiper 21 Steel ball 35 O-ring
9 Snap ring 22 Lock nut 36 Hexagon socket head bolt
10 Wear ring 24 Hexagon socket head bolt 37 Pin bush
11 O-ring 25 Band assembly(R) 38 Dust seal
12 Back up ring 26 Band(R)
13 Cushion ring 27 Band assembly(B)
8-151
(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
23,24,25,28 30
33,35 34,36
29
26,27,28
1 Tube assembly 13 Cushion ring 26 U-bolt

2 Rod assembly 14 Piston 27 Hexagon nut
3 Gland 15 O-ring 28 Spring washer
4 Du bushing 16 Back up ring 29 Pipe assembly(R)
5 Rod seal 17 Piston seal 30 Pipe assembly(B)
6 Back up ring 18 Wear ring 31 O-ring
7 Buffer ring 19 Dust ring 32 Hexagon socket head bolt
8 Dust wiper 20 Lock nut 33 Pin bushing(R)
9 Snap ring 22 Hexagon socket head bolt 34 Pin bushing(B)
10 Wear ring 23 Band assembly 35 Dust seal
11 O-ring 24 Band 36 Dust seal
12 Back up ring 25 Hexagon bolt
8-152
(1) Tools
Tool name Remark
8 B
Allen wrench 14
17
17
Spanner
19
( - ) Driver Small and large sizes
Torque
Part name Item Size
kgfşm lbfşft
bucket cylinder 22 M18 32Ź3 231.5Ź21.7
Socket head bolt boom cylinder 22 M20 46Ź5 332.7Ź36.2
arm cylinder 24 M22 63Ź6 455.7Ź43.4
bucket cylinder 33 M10 5.4Ź0.5 39.1Ź3.6
Socket head bolt boom cylinder 32 M10 5.4Ź0.5 39.1Ź3.6
arm cylinder 36 M10 5.4Ź0.5 39.1Ź3.6
bucket cylinder 20 M55 150Ź15 1085Ź108.5
Lock nut boom cylinder 20 M60 150Ź15 1085Ź108.5
arm cylinder 22 M70 150Ź15 1085Ź108.5
Hexagon bolt boom cylinder 25 M10 3.2Ź0.3 23.1Ź2.2
arm cylinder 29 M10 3.2Ź0.3 23.1Ź2.2
Lock nut boom cylinder 27 M10 3.2Ź0.3 23.1Ź2.2
arm cylinder 31 M10 3.2Ź0.3 23.1Ź2.2
bucket cylinder 14 - 100Ź10 723.3Ź72.3
Piston boom cylinder 14 - 100Ź10 723.3Ź72.3
arm cylinder 14 - 100Ź10 723.3Ź72.3
8-153
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
‫ ڸ‬Hold the clevis section of the tube in a
vise.
Ɠ Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
‫ ڹ‬Pull out rod assembly(2) about 200mm

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

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

together from tube assembly(1).
Ɠ Since the rod assembly is heavy in this Lift
case, lift the tip of the rod assembly(2)
with a crane or some means and draw it
Full straight
out. However, when rod assembly(2) has sideways
been drawn out to approximately two
thirds of its length, lift it in its center to
Oil pan
draw it completely.
8-154
Note that the plated surface of rod
assembly(2) is to be lifted. For this
reason, do not use a wire sling and
others that may damage it, but use a
strong cloth belt or a rope.
‫ ڼ‬Place the removed rod assembly on a

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

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

Plastic
from rod assembly(2). hammer
Ɠ If it is too heavy to move, move it by Lift with a crane
striking the flanged part of cylinder head
with a plastic hammer. Pull straight
Ɠ Pull it straight with cylinder head
assembly lifted with a crane.
Exercise care so as not to damage the
lip of rod bushing(4) and packing
(5,6,7,8,9,10) by the threads of rod
assembly(2).
8-155
(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 10 6 5 7 4 11 12
(11).
‫ ڹ‬Remove snap ring(9), dust wiper(8).
‫ ں‬Remove wear ring(10), back up ring(6),
rod seal(5) and buffer ring(7).
Ɠ Exercise care in this operation not to
damage the grooves.
Ɠ Do not remove seal and ring, if does not
damaged.
8-156
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.
‫ ڹ‬Coat dust wiper(8) with grease and fit Press here

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

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

Push bar
Therefore, confirm it before fitting them.
Ɠ Fitting rod seal(5) upside down may
damage its lip. Therefore check the
correct direction that is shown in fig.
5
8-157
‫ ڼ‬Fit back up ring(12) to gland(3).
Ɠ Put the backup ring in the warm water of 12
30}50Ɓ C 11
‫ ڽ‬Fit O-ring(11) to gland(3).
(2) Assemble piston assembly

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

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

piston(14). 19 18 17 18 19
14
8-158
(3) Install piston and cylinder head
‫ ڸ‬Fix the rod assembly to the work bench. Cylinder head assy
‫ ڹ‬Apply hydraulic oil to the outer surface of
Rod assembly
rod assembly(2), the inner surface of
piston and cylinder head.
‫ ں‬Insert cylinder head assembly to rod
assembly.
‫ ڻ‬Insert cushion ring(13) to rod assembly.

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

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

şTightening torque : 20
Item kgfşm lbfşft
Bucket 20 150Ź15 1085Ź108

Boom 20 150Ź15 1085Ź108
Arm 22 150Ź15 1085Ź108
8-159
(4) Overall assemble
Fix with a bar
‫ ڸ‬Place a V-block on a rigid work bench.
Mount the tube assembly(1) on it and fix
Lift
the assembly by passing a bar through
the clevis pin hole to lock the assembly.
‫ ڹ‬Insert the rod assembly in to the tube
assembly, while lifting and moving the Straight
rod assembly with a crane.
Ɠ Be careful not to damage piston seal by Apply liquid packing
thread of tube assembly.
‫ ں‬Match the bolt holes in the cylinder head
flange to the tapped holes in the tube
assembly and tighten socket bolts to a Turn clockwise
specified torque. Apply loctite
Ɠ Refer to the table of tightening torque.
Place rag
8-160
GROUP 10 UNDERCARRIAGE
1. TRACK LINK
1) REMOVAL
(1) Move track link until master pin is over
front idler in the position put wooden
Master pin
block as shown.
(2) Loosen tension of the track link.
Ɠ If track tension is not relieved when the
grease valve is loosened, move the
machine backwards and forwards.
(3) Push out master pin by using a suitable
tool.
Block
(4) Move the machine slowly in reverse, and

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

permit carrier roller removal.
Jack Carrier roller
(3) Loosen the lock nut (1).

1 Carrier
(4) Open bracket(2) with a screwdriver, push roller
out from inside, and remove carrier roller 2
assembly.
şWeight : 20.6kg(45.4lb)
2) INSTALL
to removal.
8-162
3. TRACK ROLLER Frame
1) REMOVAL
(1) Loosen tension of the track link. Grease
valve
(2) Using the work equipment, push up track

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

out the track roller(2). 1 2
şWeight : 38.3kg(84.4 lb)
2) INSTALL
to removal.
8-163
4. IDLER AND RECOIL SPRING
1) REMOVAL
(1) Remove the track link.
For detail, see removal of track link
(2) Sling the recoil spring(1) and pull out

idler and recoil spring assembly from
track frame, using a pry.
1
şWeight : 450kg (990 lb)
(3) Remove the bolts(2), washers(3) and

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

2 Shaft 5 Bracket 8 Plug
3 Seal assembly 6 O-ring
8-165
(2) Disassembly press
‫ ڸ‬Remove plug and drain oil.
‫ ڹ‬Draw out the spring pin(7), using a
press.
‫ ں‬Pull out the shaft(2) with a press.

press
‫ ڻ‬Remove seal(3) from idler(1) and
bracket(5).
‫ ڼ‬Remove O-ring(6) from shaft.
‫ ڽ‬Remove the bushing(4) from idler,

using a special tool.
Ɠ Only remove bushing if replacement is
necessity.
8-166
(3) Assembly
Ɠ Before assembly, clean the parts.

1 4 Press
Ɠ Coat the sliding surfaces of all parts with
oil.
‫ ڸ‬Cool up bushing(4) fully by some dry
ice and press it into shell(1).
Do not press it at the normal temperature,
or not knock in with a hammer even after
the cooling.
‫ ڹ‬Coat O-ring(6) with grease thinly, and

install it to shaft(2).
6
‫ ں‬Insert shaft(2) into bracket(5), and drive
in the spring pin(7). 2
‫ ڻ‬Install seal(3) to shell(1) and bracket(5).

3
‫ ڼ‬Install shaft(2) to shell(1).

2 1
8-167
‫ ڽ‬Install bracket(5) attached with seal(3).
‫ ھ‬Knock in the spring pin(7) with a

hammer. 5 7 1
‫ ڿ‬Lay bracket(5) on its side.

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

2 Tie bar 7 Bolt 12 Rod assembly
3 Spring 8 Spring washer 13 Grease valve
4 Bracket 9 Rod seal
5 Lock nut 10 Back up ring
8-169
(2) Disassembly
‫ ڸ‬Apply pressure on spring(3) with a
press.
Ɠ The spring is under a large installed load.
This is dangerous, so be sure to set
properly. 4
Spring set load : 11132kg (24542lb)
7, 8
‫ ڹ‬Remove bolt(7), spring washer(8) and
3
lock plate(6).
6
‫ ں‬Remove lock nut(5).
5
Take enough notice so that the press
which pushes down the spring, should
not be slipped out in its operation.
‫ ڻ‬Lighten the press load slowly, and
remove bracket(4) and spring(3).
‫ ڼ‬Remove rod(12) from body(1).

‫ ڽ‬Remove grease valve(13) from rod(12). 1 12
13
‫ ھ‬Remove rod seal(9), back up ring(10)

and dust seal(11).
1 9 10 11
8-170
(3) Assembly
‫ ڸ‬Install dust seal(11), back up ring(10) and
1 9 10 11
rod seal(9) to body(1).
Ɠ When installing dust seal(11) and rod seal
(9), take full care so as not to damage
the lip.
‫ ڹ‬Pour grease into body(1), then push in

rod(12) by hand. 1 12
After take grease out of grease valve
mounting hole, let air out.
Ɠ If air letting is not sufficient, it may be
difficult to adjust the tension of crawler.
‫ ں‬Fit grease valve(13) to rod(12).
Tightening torque : 5Ź0.5kgşm
(36.2Ź3.6lbşft) 13
‫ ڻ‬Install spring(3) and bracket(4) to body

(1). Press
‫ ڼ‬Apply pressure to spring(3) with a
press and tighten lock nut(5).
Ɠ Apply sealant before assembling.
Ɠ During the operation, pay attention
specially to prevent the press from 4
slipping out.
3
8-171
‫ ڽ‬Lighten the press load and confirm the Press
set length of spring(3).
‫ ھ‬After the setting of spring(3), install lock
plate(6), spring washer(8) and bolt(7).
7, 8
3
6
5
437
8-172
" 1. STRJC'TURE
SECTION A SECTION B SECTION C
,,,..-..,. .
8-173
•
2. REMOIAL AN> INSTALL

1) BUCKER ASSEMBLY
(1) Removal
<D Lower the wOl1< equipment CXll'TIPleteiy to
ground with bade ol buck.el facing down.
CZ> Ret1lOll8 rut(1) and bolt(2), and draw out

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

the pin(B).
(2) Install
<D Cany out installation in the r!M!!Se Older
to mmowl.
II. When alig1ing the mounting position ol
pin hole.
• Adjust the bucket clearance.
For detail, see operation manual.
..
8-174
1) ARM ASSEMBLY
(1) Removal
• Loosen the breather slowly to release the
A Escaping fluid under pressure can
penetrated the skin causing serious
inµy.
(]) AemoYe bucket assembly.
For details, see remova l of bucket
numbly.
(%) DiscolYlect bucket cy1inder hose(1).
A Flt blind plugs in the piping at the
chassis end securely to preYe11t oil from
spurting out when the engine is started.
C!l Sling ann cylinder assembly, remove
spring, pin stopper and pull out pin.
• ne the rod with wire to prevent ii from
coming out.
For details, see removal of arm
cylinder assemblly.
© Place a wooden block under the cylinder
and bring the cylinder down to it.
G> Aemolle bolt(2), plate(3) and pull out the
pin(4) then remove the arm assembly.
· Weiglt : 880kg(1940lb)
• When lifting the arm assembly, always lilt
the center of gravity.
(2) Install
<D Carry out installation in the l'IM!ISe order
to remowl.
A When lifting the ann assembly, always lilt
• Bleed the air from the cylinder.
8-175
•
3) BOOM CYl.NlER
(1) Removal
<D Remove arm and bud<et assembly.
For details, see removal of arm and
bucket asMmbly.
~ Remove boom cylinder assembly from
boom.
For details, see removal of arm
cylinder aaembly.
® Disconnect head tamp wirilg.

© Disconnect bud<et cylinder hose(2) and
a1T11 cylinder hose(1).
• When the hose are disconnected, oil
may spurt out
G> Sling boom assembly(3).
<ID Remove bolt{4), plate(5) and pull out the

pin(6) then remove boom assembly. Crane
· Weigl! :1685kg(37101b)
• When lifting the boom assembly always
lift the center of gravity.
(2) Install
<D Carry out lnstalation in the ~ order
to removal.
A When lifting the a1T11 assembly, always lift
• Bleed the air from the cylinder.
..
'-'
8-176

Hyundai.R210LC 3.SM - Ocrbmd

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Hyundai.R210LC 3.SM - Ocrbmd

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Verfügbare Formate

s,ERVICE MANUAL

2. Convert 550 mm into inches.

Millimeters to inches ‫ڟ‬ 1mm = 0.03937 in

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

Kilogram to Pound 1kg = 2.2046 lb

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

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

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

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

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

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

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

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

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

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

USE HANDHOLDS AND STEPS

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

AVOID POWER LINES

MOVE AND OPERATE MACHINE SAFELY

OPERATE ONLY FORM OPERATOR'S SEAT

PARK MACHINE SAFELY

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

Store flammable fluids away from fire hazards. Do not

REMOVE PAINT BEFORE WELDING OR HEATING

ILLUMINATE WORK AREA SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HIGH PRESSURE FLUIDS

PREVENT BATTERY EXPLOSIONS

PREVENT ACID BURNS

DISPOSE OF FLUIDS PROPERLY

REPLACE SAFETY SIGNS

LIVE WITH SAFETY

Battery box Fuel tank Oil cooler Radiator

Main control valve

Ann Ann cylinder Boom Boom cylinder Cab Muffler Counterweight

\ .Idler Carrier roller

Description Unit Specification

Operating weight kg (lb) 20620 (45460)

Description Unit Specification

Operating weight kg (lb) 21300 (46960)

Description 2.Chl(6' 7")Atm 2.4Qn(7' 10')Ann 2.92m(9' 7")Ann 3,00n(12' 9'')Ann

Description 2.011(6 7") Aml 2.4Qn(7' 1O') Ann

Max. dumping height E 5850'Tm (19' 2') 594<mn {19' 6')

• ~ : Rating over-front • ~ : Ratllg over-side or 360 degree

Load radius At max. reach

Note 1. Lifting capacity are based on SAE J1097, ISO 10567.

Load radius At max. reach

=tt r... ....•.•• •. i.:•.:·• •

:: :•' .:~::~::;~::: :~1"!,Q;: ·.:;;~:·

Load radius At max. reach

7.5m kg '3420 '3420 7.05

Load radius At max. reach

2120 am !fill 10.~

·1.Sm kg 'S6«l 'li640 "1<ml 'i<m:!

Load radius At max. reach