TO18F-E-01 EX1200-5D Technical Manual (Operation Principle) PDF

INTRODUCTION
TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this manual.
• Be sure to thoroughly read this manual for correct (Note: Do not tear off the form. Copy it for us-
product information and service procedures. age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7173
FAX: 81-29-831-1162
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redelivery and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
IN-01
INTRODUCTION
PAGE NUMBER
• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual
SAFETY ALERT SYMBOL AND HEADLINE

NOTATIONS
• CAUTION:
In this manual, the following safety alert symbol and Indicated potentially hazardous situation which could,
signal words are used to alert the reader to the if not avoided, result in personal injury or death.
potential for personal injury of machine damage.
• IMPORTANT:
This is the safety alert symbol. When you see this Indicates a situation which, if not conformed to the
symbol, be alert to the potential for personal injury. instructions, could result in damage to the machine.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention • NOTE:
to component/part weights. Indicates supplementary technical information or
To avoid injury and damage, be sure to use appropri- know-how.
ate lifting techniques and equipment when lifting heavy
parts.
IN-02
INTRODUCTION
UNITS USED
• SI Units (International System of Units) are used in 2

Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
3 3
m yd 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-03
INTRODUCTION
(Blank)
IN-04
SECTION AND GROUP SECTION 1 GENERAL
CONTENTS Group 1 Specifications
Group 2 Component Layout
SECTION 2 SYSTEM
Group 1 Control System
Group 2 Hydraulic System
TECHNICAL MANUAL Group 3 Electrical System
SECTION 3 COMPONENT OPERATION
(Operational Principle)
Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Pilot Valve
Group 5 Travel Device
Group 6 Signal Control Valve
Group 7 Others(Upperstructure)
Group 8 Others(Undercarriage)
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 General
Group 1 Introduction Group 2 Cross Reference Table
Group 2 Standard Group 3 Component Layout
Group 3 Engine Test Group 4 Troubleshooting A
Group 4 Excavator Test Group 5 Troubleshooting B
Group 5 Component Test Group 6 Troubleshooting C
Group 7 Troubleshooting D
All information, illustrations and speci- Group 8 Electrical System Inspection
fications in this manual are based on
the latest product information available
at the time of publication. The right is
WORKSHOP MANUAL
reserved to make changes at any time
without notice. SECTION 1 GENERAL INFORMA- Group 10 Signal Control Valve
TION Group 11 Oil Cooler Fan Motor
Group 1 Precautions for Disassem- SECTION 3 UNDERCARRIAGE
bling and Assembling Group 1 Swing Bearing
Group 2 Tightening Torque Group 2 Travel Device
SECTION 2 UPPERSTRUCTURE Group 3 Center Joint
Group 1 Cab Group 4 Track Adjuster
COPYRIGHT(C)2007 Group 2 Counterweight Group 5 Front Idler
Hitachi Construction Machinery Co., Ltd. Group 3 Pump Device Group 6 Upper and Lower Roller
Tokyo, Japan Group 4 Control Valve Group 7 Track
All rights reserved Group 5 Swing Device SECTION 4 FRONT ATTACHMENT
Group 6 Pilot Valve Group 1 Front Attachment
Group 7 Pilot Shut-Off Valve Group 2 Cylinder
Group 8 Shockless Valve Group 3 Bushing and Point
Group 9 Solenoid Valve
SECTION 1
GENERAL
CONTENTS
Group 1 Specifications
Specifications ...........................................T1-1-1
Working Range (Backhoe) .......................T1-1-3
Working Range (BE Backhoe) ..................T1-1-4
Working Range (Loading Shovel) .............T1-1-5
Engine......................................................T1-1-6
Engine Accessories ..................................T1-1-9
Hydraulic Devices.....................................T1-1-9
Electrical Equipment...............................T1-1-12
Group 2 Component Layout

Main Components ....................................T1-2-1
Electrical System Components (1)............T1-2-2
On and Around Pumps ...........................T1-2-10
Others .................................................... T1-2-11
18FT-1-1
(Blank)
18FT-1-2
GENERAL / Specifications
SPECIFICATIONS
A
C
E
D
I H
G F
M183-11-001
Model EX1200-5D Hydraulic Excavator

BE Backhoe
Backhoe
Type of Front-End Attachment [7.55 m (24’9”) BE boom,
[9.1 m (29’10”) boom, 3.4 m (11’2”) arm]
3.4 m (11’2”) BE arm]
3 3 3 3 3
Bucket Capacity (Heaped) PCSA 5.0 m (6.5 yd ), CECE 4.4 m PCSA 6.5 m (8.5 yd )
Operating Weight 108000 kg (238000 lb) 109000 kg (243000 lb)
Basic Machine Weight 80500 kg (177500 lb)
-1
Engine CUMMINS QSK23 567 kW/1650 min (771 PS/1650 rpm)
A: Overall Width 5430 mm (17 ft 10 in)
B: Cab Height 4320 mm (14 ft 2 in)
C: Rear End Swing Radius 4850 mm (15 ft 11 in)
D: Minimum Ground Clearance 990 mm (3 ft 3 in) (Excluding shoe lug)
E: Counterweight Clearance 1790 mm (5 ft 10 in)
F: Undercarriage Length 6410 mm (21 ft 0 in)
G: Undercarriage Width 4610 mm (15 ft 2 in)
H: Sprocket Center to Idler
5000 mm (16 ft 5 in)
Center
I: Track Shoe Width 710 mm (28 in) (Grouser shoe)
2 2
Ground Pressure 136 kPa (1.39 kgf/cm , 19.7 psi) 137 kPa (1.40 kgf/cm , 19.9 psi)
-1
Swing Speed 5.8 min (rpm)
Travel Speed (Fast/Slow) 3.5/2.4 km/h (2.2/1.6 mph)
Gradeability 35° (tanθ = 0.70)
T1-1-1
A C
E
D
I
H
G F
T183-01-01-002
Model EX1200-5D Hydraulic Excavator

Type of Front-End Attachment Loading Shovel
3 3
Bucket Capacity (Heaped) PCSA 6.5 m (8.5 yd )
Operating Weight 111000 kg (245000 lb)
Basic Machine Weight 80900 kg (178400 lb)
-1
Engine CUMMINS QSK23 567 kW/1650 min (771 PS/1650 rpm)
A: Overall Width 5430 mm (17 ft 10 in)
B: Cab Height ∗5410 mm (17 ft 9 in)
C: Rear End Swing Radius 4850 mm (15 ft 11 in)
D: Minimum Ground Clearance 990 mm (3 ft 3 in) (Excluding shoe lug)
E: Counterweight Clearance 1790 mm (5 ft 10 in)
F: Undercarriage Length 6410 mm (21 ft 0 in)
G: Undercarriage Width 4610 mm (15 ft 2 in)
H: Sprocket Center to Idler
5000 mm (16 ft 5 in)
Center
I: Track Shoe Width 710 mm (28 in) (Grouser shoe)
2
Ground Pressure 139 kPa (1.42 kgf/cm , 20.2 psi)
-1
Swing Speed 5.8 min (rpm)
Travel Speed (Fast/Slow) 3.5/2.4 km/h (2.2/1.6 mph)
Gradeability 35° (tanθ = 0.70)
NOTE: ∗The standard specification of loading shovel is equipped with an elevated cab.
T1-1-2
WORKING RANGE (BACKHOE)
C
B
A´
A M183-11-002
Boom Length 9.10 m (29′ 10″)

Arm Length 3.40 m (11′ 2″)
A : Maximum Digging Reach 15340 mm (50′ 4″)
A’ : Maximum Digging Reach (on ground) 15000 mm (49′ 3″)
B : Maximum Digging Depth *9340 mm (30′ 8″)
C : Maximum Vertical Wall *7620 mm (25′ 0″)
D : Maximum Cutting Height *13490 mm (44′ 3″)
E : Maximum Dumping Height *8920 mm (29′ 3″)
NOTE: ∗ The dimensions do not include the height of the shoe lug.
T1-1-3
WORKING RANGE (BE BACKHOE)
C
B
A´
A M183-11-003
Boom Length 7.55 m (24′ 9″) BE boom

Arm Length 3.40 m (11′ 2″) BE arm
A : Maximum Digging Reach 13760 mm (45′ 2″)
A’ : Maximum Digging Reach (on ground) 13380 mm (43′ 11″)
B : Maximum Digging Depth *7940 mm (26′ 1″)
C : Maximum Vertical Wall *5080 mm (16′ 8″)
D : Maximum Cutting Height *12300 mm (40′ 4″)
E : Maximum Dumping Height *8020 mm (26′ 4″)
T1-1-4
WORKING RANGE (LOADING SHOVEL)
H
E
G
E´
A
B
C
D
T183-01-01-003
A : Minimum Digging Distance 4460 mm (14′ 8″)

B : Minimum Level Crowding Distance 6520 mm (21′ 5″)
C : Level Crowding Distance 4340 mm (13′ 10″)
D : Maximum Digging Reach 11440 mm (37′ 6″)
E : Maximum Cutting Height *12350 mm (40′ 6″)
E’ : Maximum Dumping Height *8740 mm (28′ 8″)
F : Maximum Digging Depth *5240 mm (17′ 2″)
G : Working Radius at Maximum Dumping Height *6090 mm (20′ 0″)
H : Maximum Bucket Opening Width 1880 mm (6′ 2″)
T1-1-5
ENGINE
MAIN SPECIFICATIONS
Manufacturer ............................................. CUMMINS
Model ........................................................ QSK23 C
Type .......................................................... Diesel, 4 cycle, vertical, 6-cylinder inline, water-cooled, turbo
charged, inter-cooled, direct injection type
Cyl. No.-bore×stroke ................................. 6-170 mm×170 mm (6.7 in×6.7 in)
3 3
Piston displacement .................................. 23150 cm (1412 in )
-1
Rated output (SAE J1995) (GROSS) .... 567 kW/1650 min (771 PS/1650 rpm)
-1
(NET) .......... 538 kW/1650 min (731 PS/1650 rpm)
Dry weight ................................................. 2565 kg (5655 lb)
Firing order................................................ 1-5-3-6-2-4
Rotation direction ...................................... Clockwise (view from fan side)
COOLING SYSTEM
Cooling fan ................................................ Dia. 1219 mm (48 in), draw-in type
Fan pulley ratio.......................................... 0.7 : 1
Thermostat................................................ Cracking temp. : 77 °C (170 °F)
(under atmospheric pressure) ................. Full open temp. : 90 °C (194 °F)
Water pump .............................................. Centrifugal swirl type
LUBRICATION SYSTEM
Lubrication pump type............................... Gear pump
Oil filter ...................................................... Full-flow paper element type with bypass function
Oil pan capacity......................................... 70 L (18.5 US gal)
STARTING SYSTEM
Voltage⋅Output........................................... 24 V⋅7.5 kW×2
PRE-HEAT SYSTEM
Type .......................................................... Air heater
ENGINE STOP SYSTEM

Stop method .............................................. Fuel cut system with solenoid valve
ALTERNATOR
Type .......................................................... AC generator with diode rectifier
Voltage⋅Output........................................... 24 V⋅75 A
FUEL SYSTEM
Injection pump........................................... CUMMINS HPI electronic contrl
Governor ................................................... Electronic all speed control
T1-1-6
PERFORMANCE
Lubrication oil consumption....................... 0.27 g kW⋅h (New engine, at rated horsepower)
Fuel consumption ratio (GROSS) ............. 207 g/kW⋅h (152 g/PS⋅h)
-1
Max. output torque (GROSS) ............. 3580 N⋅m (365 kgf⋅m, 2641 lbf⋅ft) @ 1350±100 min
-1
Max. no load speed ............................. 1850±50 min
T1-1-7
ENGINE PERFORMANCE CURVE
Test Conditions: 1. THIS PERFORMANCE IS APPLIED UNDER CONDITIONS OF 25°C (AMBIENT TEMPERA-
TURE).
100 kPa (750mmHg) (ATMOSPHERIC PRESSURE) AND 1kPa (7.5mmHg) VAPOR PRES-
SURE.
2. WITH MUFFLER, AIR CLEANER, WITHOUT FAN
Max. Torque (Gross)

3472Nm/1350rpm
Rated power (Gross)

567kw/1650rpm
Min. BSFC (Gross)

204g/kwh
T18E-01-01-002
T1-1-8
ENGINE ACCESSORIES
RADIATOR ASSEMBLY
Type .......................................................... Radiator/Inter-cooler tandem type assembly
Weight....................................................... 350 kg (772 lb)
Radiator Inter-cooler
Core type................................................... Corrugated fin Corrugated fin
Capacity .................................................... 63 L (17 US gal) -
Air-tight testing pressure ........................... 196 kPa 980 kPa
2 2
(2.0 kgf/cm , 28 psi) (10 kgf/cm , 142 psi)
Cap opening pressure............................... 88.2 kPa -
2
(0.9 kgf/cm , 12.8 psi)
BATTERY
Capacity .................................................... 176 Ah (5 hours)
Voltage ...................................................... 12 V×2
Weight....................................................... 66 kg (146 lb)×2
Fuel Cooler
Weight....................................................... 6.81 kg (15 lb)
Core type................................................... Corrugated
Capacity .................................................... 3.3 L (0.87 US gal)
HYDRAULIC DEVICES
PUMP DEVICE
Type .......................................................... Spur gear
Gear speed ratio (Engine: Main pump) .... 1 : 1.083
(Engine: Triple pump) ... 1 : 1.106
MAIN PUMP
Model ........................................................ K3V280SH11RL
Type .......................................................... Variable displacement swash plate type plunger pump:
regulator attached type
Max. flow (Theoretical value) .................... 500 L/min (132 US gpm)×3
3-UNIT PUMP
(OIL COOLER FAN MOTOR DRIVE PUMP)
Model ........................................................ K3V63S
Type .......................................................... Variable displacement swash plate type plunger pump:
Regulator attached type
Max. flow (Theoretical value) .................... 115 L/min (30.3 US gpm)
(PILOT PUMP)
Model ........................................................ KFP3228
Type .......................................................... Gear pump
Max. flow (Theoretical value) .................... 51.1 L/min (13.5 US gpm)
(TRANSMISSION LUBRICATION OIL PUMP)

Model ........................................................ KP1015
Type .......................................................... Gear pump
Max. flow (Theoretical value) .................... 27.1 L/min (7.2 US gpm)
T1-1-9
MAIN CONTROL VALVE
Model ........................................................ UH36-403
Type .......................................................... Pilot pressure operated type (4-spool+5-spool)
2
Main relief pressure................................... Normal: 31.4 MPa (310 kgf/cm , 4410 psi)
@340 L/min (89.7 US gpm)
2
High Lift: 33.3 MPa (340 kgf/cm , 4830 psi)
@90 L/min (23.7 US gpm)
2
Overload relief pressure .......................... 33.3 MPa (340 kgf/cm , 4830 psi) @110 L/min (29.0 US gpm)
(Boom, Arm roll-in (BH) / Arm extend (LD), Bucket,
Bucket open (LD))
2
34.3 MPa (350 kgf/cm , 4980 psi) @110 L/min (29.0 US gpm)
(Arm roll-out (BH)/ Arm retract (LD))
2
17.7 MPa (180 kgf/cm , 2560 psi) @500 L/min (132 US gpm)
(Bucket close (LD))
When jack-up prevention switch is ON:
2
9.8 MPa (100 kgf/cm , 1420 psi) @110 L/min (29.0 US gpm)
(Boom Lower)
SWING CONTROL VALVE

Model ........................................................ UH36B2T1C2A2-3
Type .......................................................... Pilot pressure operated type (4-spool)
2
Main relief valve ........................................ 31.4 MPa (320 kgf/cm , 4550 psi)
@170 L/min (44.9 US gpm)
2
Overload relief valve ................................. 31.4 MPa (320 kgf/cm , 4550 psi)
@110 L/min (29.0 US gpm)
SWING DEVICE
Type .......................................................... Two-stage planetary reduction type
SWING MOTOR
Model ........................................................ M2X210 CAB-10A
Type .......................................................... Swash-plate type, fixed displacement plunger motor
SWING BRAKE VALVE

Type .......................................................... Non counter balance valve type
2
Relief pressure .......................................... 29.4 MPa (300 kgf/cm , 4270 psi)
SWING PARKING BRAKE

Type .......................................................... Multiple-wet-plate negative type
+590 +6 2 +85
Cracking pressure for release................... 2260 -0 kPa (23 -0 kgf/cm , 327 -0 psi)
TRAVEL DEVICE
Type .......................................................... Three-stage planetary reduction gear
TRAVEL MOTOR
Model ........................................................ MSF-340VP-EH
Type .......................................................... Swash-plate type, variable displacement plunger motor
TRAVEL BRAKE VALVE

Type .......................................................... Counter balance valve type
2
Relief pressure .......................................... 29.4±1 MPa (300±10 kgf/cm , 4266±142 psi)
T1-1-10
TRAVEL PARKING BRAKE
Type .......................................................... Multiple-wet-plate negative type
2
Cracking pressure for release................... 1.8 MPa (18 kgf/cm , 256 psi)
CYLINDER
(BACKHOE)
Boom Arm Bucket (3.4 m Arm)
Rod Dia. .................................................... 160 mm (6.30”) 180 mm (7.09”) 160 mm (6.30”)
Cylinder Bore............................................. 230 mm (9.06”) 260 mm (10.24”) 230 mm (9.06”)
Stroke ........................................................ 2075 mm (6’ 10”) 2205 mm (7’ 3”) 1790 mm (5’ 10”)
Fully retracted length................................. 3170 mm (10’ 5”) 3385 mm (11’ 1”) 2895 mm (9’ 6”)
Plating thickness ....................................... 30 µm (1.18 µin) 30 µm (1.18 µin) 30 µm (1.18 µin)
or more or more or more
Bucket Bucket Bucket

(BE) (For 4.5 m Arm) (For 5.8 m Arm)
Rod Dia. .................................................... 170 mm (6.70”) 160 mm (6.30”) 130 mm (5.12”)
Stroke ........................................................ 1790 mm (5’ 10”) 1790 mm (5’ 10”) 1555 mm (5’ 1”)
(LOADING SHOVEL)
Boom Arm Level
Rod Dia. .................................................... 160 mm (6.30”) 150 mm (5.91”) 160 mm (6.30”)
Stroke ........................................................ 2075 mm (6’ 10”) 1835 mm (6’ 0”) 790 mm (2’ 7”)
Bucket Bucket open/close

Rod Dia. .................................................... 150 mm (5.91”) 85 mm (3.34”)
Cylinder Bore............................................. 200 mm (7.87”) 140 mm (5.51”)
Stroke ........................................................ 1 600 mm (5’ 3”) 475 mm (1’ 7”)
Fully retracted length................................. 3 405 mm (11’ 2”) 1 090 mm (3’ 7”)
Plating thickness ....................................... 30 µm (1.18 µin) 30 µm (1.18 µin)
or more or more
FRONT ATTACHMENT PILOT VALVE

Model ........................................................ HVP06A-040-101
TRAVEL PILOT VALVE

Model ........................................................ HVP05F-040-101
BUCKET OPEN / CLOSE PILOT VALVE (LOADING SHOVEL)

Model ........................................................ HVP05H-040-101
SOLENOID VALVE UNIT

Solenoid valve (Function) ........................ ⋅ SA : Pump power decreasing (For pump 3)
⋅ SB : Pump power decreasing (For pump 1, 2)
⋅ SC : Boom mode selection
(Max. input flow).............. 50 L/min (13 US grm)
2
Pilot relief valve ......................................... 3.9 MPa (40 kgf/cm , 570 psi)
T1-1-11
FLOW REDUCING SOLENOID VALVE
Function .................................................... Flow reducing
Max. input flow .......................................... 60 L/min (15.8 US gal)
TRAVEL MODE SHIFT SOLENOID VALVE

Function .................................................... Travel mode shifting
Max. input flow .......................................... 30 L/min (7.9 US gal)
2-SPOOL EHC VALVE

Function .................................................... Power increase solenoid valve ST: Speed sensing control
2
Max. input pressure................................... 3.9 MPa (40 kgf/cm , 570 psi)
2
Control pressure........................................ Solenoid Valve ST: 0 to 2.7 MPa (0 to 27.5 kgf/cm , 0 to 391 psi)
Function .................................................... Oil cooler fan control solenoid valve SF
2
Max. input pressure................................... 3.9 MPa (40 kgf/cm , 570 psi)
2
Control pressure........................................ Solenoid Valve SF: 0 to 1.4 MPa (0 to 13.9 kgf/cm , 0 to 198 psi)
OIL COOLER
Weight....................................................... 725 kg (1600 lbf)
Core type................................................... Plate fin
Capacity .................................................... -
2
Air-tight testing pressure ........................... 980 kPa (10 kgf/cm , 142 psi)
OIL COOLER FAN MOTOR

Function .................................................... A2FM63
3
Displacement ............................................ 63 cm /rev
-1 -1
Max Motor speed ...................................... 1400 min (rpm) @ Engine 1650 min (rpm)
2
Relief valve................................................ 21.6 MPa (220 kgf/cm , 3130 psi)
OIL COOLER BYPASS CHECK VALVE

2
Cracking pressure..................................... 245 kPa (2.5 kgf/cm , 36 psi) at 40 L/min (11 US gpm)
ELECTRICAL EQUIPMENT
BATTERY RELAY
Voltage⋅Current ......................................... 24 V⋅100 A
STARTER RELAY 1
STARTER RELAY 2
Voltage⋅Current ......................................... 24 V
LOAD DUMP RELAY

HORN
Specifications ............................................ 24 V⋅2.3 A, 330 Hz
LIGHT
Specifications ............................................ Work lights : halogen 24 V⋅70 W
T1-1-12
AIR CONDITIONER
Refrigerant ................................................ 134 a
Cooler capacity.......................................... 19.73 MJ/h (4600 kcal/h)
3 3
Cooler air flow ........................................... 550 m /h (720 yd /h) or more
Heater capacity ......................................... 21.0 MJ/h (5000 kcal/h) or more
Temperature control .................................. Electronic control
Refrigerant quantity................................... Std. cab : 1250±50 g (2.76±0.1 lb)
Elevated cab : 1300±50 g (2.87±0.1 lb)
3
Compressor oil quantity ............................ 220 cm (0.23 US qt)
(After replacement of the compressor, high pressure hose,
condenser, receiver tank, liquid hose, or air conditioner unit, the
compressor oil quantity is added.)
T1-1-13
(Blank)
T1-1-14
GENERAL / Component Layout
MAIN COMPONENTS
Backhoe
2 3
1
4
5
6
7
8
36
9
37
10
11
12
13
14
31 15
16
30
29
28
27
26
Loading Shovel 4
5 25
32 24 17
3 23 18
2
22 19
1
31 6 21 20
35
30
33
34
T183-01-02-016
1- Bucket Cylinder 11 - Swing Device 20 - Swing Bearing 29 - Accumulator

2- Arm 12 - Main Control Valve 21 - Travel Device 30 - Travel Pilot Valve
3- Arm Cylinder 13 - Oil Cooler 22 - Upper Roller 31 - Bucket
4- Boom 14 - Oil Cooler Fan Motor 23 - Lower Roller 32 - Level Cylinder
(Loading Shovel Only)
5 - Boom Cylinder 15 - Intercooler 24 - Swing Control Valve 33 - Pilot Valve (Bucket Open)
6 - Front / Swing Pilot Valve 16 - Radiator 25 - Center Joint 34 - Pilot Valve (Bucket Close)
7 - Hydraulic Oil Tank 17 - Engine 26 - Track Adjuster 35 - Bucket Open/Close
Cylinder
8 - Battery 18 - Pump Device 27 - Pilot Shut-Off Valve 36 - Condenser
(Air Conditioner)
9 - Fuel Tank 19 - Signal Control Valve 28 - Front Idler 37 - Fuel Cooler
10 - Auto-Lubrication Device
T1-2-1
ELECTRICAL SYSTEM COMPONENTS (1)
2
3
Overall Layout 4
5
6
1
7
8
11
9
10
34
12 Refer to T1-2-12
(Refer to T1-2-4)
13
33
32
14
31
30
29
(Refer to T1-2-3) 15
16 (Refer to T1-2-10)
28 17 (Refer to T1-2-10)
(Refer to T1-2-11) 27 18 (Refer to T1-2-10)
26
25 19 (Refer to T1-2-8)
24 20
(Refer to T1-2-11) 23
22 21 T18E-01-02-009
1 - Work Light (on Cab Roof) 10 - Fresh Air Sensor 19 - Engine Speed Sensor 1 28 - Hydraulic Oil Level Switch
(Air Conditioner) (Pump) 1, 2
2 - Monitor 11 - Fuel Temperature Sensor 20 - Engine Speed Sensor 2 29 - DC/DC Converter
(ECM)
3 - Quick Idle Switch 12 - Coolant Level Sensor 21 - Pump Transmission Oil 30 - Horn Switch
Pressure Switch
4 - Work Light 13 - Coolant Temperature Sensor 22 - Oil Pressure Sensor 31 - Work Light
(at the right side of Frame) (Under Cab Floor)
5 - Starter Relay 1 14 - Air Cleaner Restriction Switch 23 - Pilot Pressure Sensor 32 - Sunlight Sensor
(All)
6 - Battery 15 - Starter 24 - Travel Mode Control 33 - Step Light
Solenoid Valve
7 - Battery Relay 16 - Solenoid Valve Unit 25 - Heavy Lift Solenoid Valve 34 - Electrical Equipment
Box
8 - Horn 17 - Flow Rate Decrease 26 - Hydraulic Oil
Solenoid Valve Temperature Sensor
9 - Fuel Sensor 18 - 2-Spool EHC Valve 27 - Pilot Pressure Sensor
(Travel)
T1-2-2
In the Cab
3 1
6 7 8 9 T18E-01-02-010
3 1
2
4
5 M18E-01-009
T18E-01-02-013
1 - 12 V Power Source 4 - Buzzer Cancel Switch 6- Engine Fault Code Display 8- Fault Diagnosing Switch B
Terminal Panel
2 - DC-DC Converter 5 - Travel Alarm Stop 7 - Fault Diagnosing Switch A 9- DLU Check Switch
Switch (Optional)
3 - MC Display Selection
Switch
T1-2-3
Electrical Equipment Box
1 2 3 4 5 6
21
20
19
18
17
16
15
14 13 12 11 10 9 8 7
T18F-01-02-001
1 - Flow Rate Decrease 7 - Power Transistor 3 12 - Fuse Box 2 17 - Wiper Relay 2 (HIGH 2)
Solenoid Valve Relay
2 - Auto-Lubrication Relay 8 - Power Transistor 1 13 - Step Light Relay 18 - Wiper Relay 1 (HIGH 1)
3 - Preheat Indicator Relay 9 - Main Controller A 14 - Load Dump Relay 19 - Wiper Relay (LOW)
(Lower)
4 - *Engine Protection Relay 10 - Main Controller B 15 - Work Light Relay 2 20 - Horn Relay
(Upper)
5 - *Engine Stop Indicator 11 - Fuse Box 1 16 - Washer Relay 21 - Work Light Relay 1
Relay
6 - DLU
T1-2-4
(Blank)
T1-2-5
Around Batteries
1 2
12 13 3
10 11
4
5
6
9
8 7 T18F-01-02-002
1- Air Heater Signal Relay 5- Battery Relay 2 8 - Fusible Link 8 (125A) 11 - Fusible Link 3 (75A)
2- Starter Relay 1 6- 1 Pole Junction 9 - Fusible Link 6 (100A) 12 - Fusible Link 2 (75A)
3- Battery Relay 1 7- Fusible Link 7 (125A) 10 - Fusible Link 4 (45A) 13 - Fusible Link 1 (45A)
4- Fusible Link 5 (250A)
T1-2-6
Used Circuit Fusible Link
Part Name Circuit Connected

Fusible Link 1 Monitor, Back up Power Circuit Fuse Box 1 (#1, #2)
Main Controller B, DLU Main Power Circuit Fuse Box 2 (#1)
ECM Power Circuit
Fusible Link 2 Work Light Relays 1, 2 Power Circuit Fuse Box 2 (#11～14)
Washer Relay, Wiper Relay (L, H1, H2),
Wiper Motor Power Circuit
Air Conditioner Power Circuit
Auto-Lubrication Solenoid Valve Relay, Flow Rate
Decrease Solenoid Valve Relay, Power Transistors 1, 2
and 3
Fusible Link 3 DC-DC Converter Power Circuit Fuse Box 2 (#4～9)
Main Controller A, B Solenoid Power Circuit
Travel Alarm Power Circuit
Monitor, Main Controller A Main Power circuit
Step Light Relay Power Circuit
Air Conditioner
Fusible Link 4 Air Heater Signal Relay Power Circuit Air Heater Signal Relay
Fusible Link 5 Starter Relay Power Circuit Starter Relay 1
Fusible Link 6 Alternator Alternator
Fusible Link 7 Preheat Relay 1 Power Circuit Preheat Relay 1
Fusible Link 8 Preheat Relay 2 Power Circuit Preheat Relay 2
T1-2-7
On and Around Engine
11
2 10 12 6 1
T18E-01-02-011
1 - ECM 4- Engine Speed Sensor 2 7- Preheat Relay 10 - Engine Oil Pressure
(Pump) Sensor
2 - Alternator 5 - Coolant Temperature 8- Starter 11 - Suction Manifold
Sensor (Monitor) Temperature Sensor
3 - Engine Speed Sensor 1 6 - Engine Oil Level Sensor 9- Coolant Temperature 12 - Fuel Temperature Sensor
(ECM) Sensor (ECM)
T1-2-8
Monitor and Switch Panels Monitor Panel
14 15
1
35
2 34
16
33
32
31
3 17
30 18
4 29
19
5
28 20
6
7 27
8 26
25
9
T183-01-02-013
24 23 22 21
10
13
12
11
T183-01-02-010
36
M183-01-035
1 - Monitor Panel 10 - Air Conditioner Control 19 - *Exhaust Gas Temperature 28 - Preheat Indicator
Panel Indicator
2 - Quick Idle Switch 11 - Auto-Lubrication (ALU) 20 - hydraulic Oil Level 29 - Download Indicator
Timer Switch Indicator
3 - Engine Control Dial 12 - Heavy Lift Switch 21 - Engine Warning Indicator 30 - Overheat Indicator
4 - Auto-Idle Switch 13 - Boom Mode Selection 22 - Coolant Level Indicator 31 - Air Filter Restriction
Switch Indicator
5 - Power Mode Switch 14 - Coolant Temperature 23 - Engine Stop Indicator 32 - Lubrication Mode Indicator
Gauge
6 - Travel Mode Switch 15 - Fuel Gauge Switch 24 - Auto-Lubrication Indicator 33 - Liquid Crystal Display
(LCD)
7 - Work Light Switch 16 - Switch Panel 1 25 - Engine Oil Level Indicator 34 - Auto-Idle Indicator
8 - Wiper/Washer Switch 17 - Fuel Level Indicator 26 - Pump Transmission Oil 35 - Quick-Idle Indicator
Pressure Indicator
9 - Key Switch 18 - Alternator Indicator 27 - Engine Oil Pressure 36 - Step Light Switch
Indicator
NOTE: The Item with mark “*” is not used for the machine equipped with CUMMINS engine.
T1-2-9
ON AND AROUND PUMPS
1
Pump Device Front

2
10 3
4
6
T183-01-02-006
Solenoid Valves and Related Components 5
11
18 2-Spool EHC Valve
Solenoid Valve 17 12
16
Unit 15
Front
13
14
T183-01-02-007
1 - Main Pump 3 Regulator 6 - Transmission Lubrication 11 - Power Increase Solenoid 15 - Pilot Relief Valve
Oil Pump Valve (ST)
2 - Main Pump 1 Regulator 7 - Pilot Pump 12 - Oil Cooler Fan Control 16 - Power Decrease Solenoid
Solenoid Valve (SF) Valve (SA)
3 - Main Pump 1 8 - Main Pump 2 13 - Pilot Filter 17 - Power Decrease Solenoid
Valve (SB)
4 - Oil Cooler Fan Motor Drive 9 - Main Pump 2 regulator 14 - Flow Rate Decrease 18 - Boom Mode Selection
Pump Solenoid Valve Solenoid Valve (SC)
5 - Pump Transmission Oil 10 - Main Pump 3
Pressure Switch
T1-2-10
OTHERS
Valves (1) 1
Swing Device 20
2 3
19
9
8 Front
Side
5
7 6 T142-01-02-011
T183-01-02-008
21
Travel Device
Valves (2)
10 11 12
18
22
17
16
13
Valves (1)
15 14
T18E-01-02-002
T183-01-02-012
1 - Pilot Pressure Sensor 7 - Shuttle Valve 13 - Pump 3 Control Valve 18 - Shuttle Valve
(Travel) (Swing Brake Release) (Bucket Roll-In)
2 - Shuttle Valve 8 - Pilot Pressure Sensor (All) 14 - Shockless Valve 19 - Swing Parking Brake
(Auxiliary Circuit) (Front Operation) Release Valve
3 - Reducing Valve 9 - Shuttle Valve 15 - Shuttle Valve 20 - Swing Relief Valve
(Boom Raise Priority) (Swing Make-Up)
4 - Heavy Lift Solenoid Valve 10 - Shuttle Valve 16 - Shock Reducing Valve 21 - Counterbalance Valve
(For Switching Pump 3
Control Pressure)
5 - Travel Mode Control 11 - Arm Preference Valve 17 - Shuttle Valve 22 - Travel Relief Valve
Solenoid Valve (Pilot Pressure Control)
6 - Brake Release Pressure 12 - Signal Control Valve
Switch Valve
T1-2-11
Coolant Level Switch
T18E-01-02-012
T1-2-12
MEMO
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SECTION 2
SYSTEM
CONTENTS
SECTION 1 Control System
Outline .....................................................T2-1-1
Engine Control .........................................T2-1-2
Pump Control .........................................T2-1-12
Valve Control..........................................T2-1-16
Oil Cooler And Fuel Cooler
Fan Motor Control ..................................T2-1-24
Auto-Lubrication Control.........................T2-1-26
SECTION 2 Hydraulic System

Outline .....................................................T2-2-1
Pilot Circuit...............................................T2-2-2
Main Circuit ............................................T2-2-20
Pump Transmission Oil
Cooling Circuit ......................................T2-2-48
Oil Cooler Fan Motor Circuit ...................T2-2-48
SECTION 3 Electrical System

Outline .....................................................T2-3-1
Power Source Circuit................................T2-3-2
Bulb Check Circuit....................................T2-3-3
Engine Start Circuit ..................................T2-3-4
Charging Circuit .......................................T2-3-6
Accessory Circuit .....................................T2-3-8
Surge Voltage Prevention Circuit ............T2-3-10
18FT-2-1
(Blank)
18FT-2-2
SYSTEM / Control System
OUTLINE
Main controllers (A and B) with built-in microcomputers

and ECM (Engine Control Module) are used for ma-
chine control. The main controllers (A and B) and ECM
process signals from the engine control dial, engine
speed sensors (1 and 2) and various switches, actu-
ating the solenoid valves and electronic governor, and
controlling the engine and pumps.
Engine Control
• Engine Speed Control
• Quick-Idle Control
• Auto-Idle Control
• Low Temperature Start Control
• Engine Diagnosing Control
Pump Control
• SP Mode Control
• E Mode Control
• Pump Flow Rate Control at Slow Engine Speed
• Pump Flow Rate Control at Middle Engine Speed
• Power Decrease Control to Prevent Engine
Overheating
• Power Decrease Control Abnormal Engine Oil
Pressure
• Power Decrease Control Low Coolant Level
Valve Control
• Travel Mode Control
• Heavy Lift Control
• Boom Mode Selection Control
• Oil Cooler Fan Motor Control
• Auto-Lubrication Control
T2-1-1
ENGINE CONTROL
Engine Speed Control
Purpose: Controls engine speed in response to en-
gine control dial rotation.
Operation: The electrical signal in response to the

angle of engine control dial is sent to the
ECM. The ECM drives the electronic gov-
ernor due to the electrical signal and con-
trols the engine speed.
Electronic Governor
Key Switch
ECM
Engine Control Dial
T142-04-03-001
T2-1-2
(Blank)
T2-1-3
Quick-Idle Control
Purpose: Reduces fuel consumption by quickly de-
creasing engine speed. This function will
be effective when the machine waits for a
period of time as when waiting for a dump
truck to be set in a loading position.
Operation: When the quick idle switch on top of the

right control lever is turned on, the main
controller sends an electrical signal to the
ECM.
Consequently, the ECM actuates the
electronic governor to lower the engine
speed.
Quick-Idle Switch
Monitor
Controller
Electronic
ECM Governor
T142-04-03-003
T2-1-4
Auto-Idle Control
Purpose: Reduces engine speed, fuels consump-
tion and noise when all control levers are
neutral and the engine is running at a
speed faster than the auto-idle set speed Auto-Idle
with the auto-idle switch ON. Switch
Swing Brake
Release Shuttle
Valve
NOTE: All pilot system pressure is routed to the
swing brake release shuttle valve.
Pressure
Sensor
Operation: When all control levers are in the neutral Main Con-
position, the pressure sensor in the swing troller A
brake release shuttle valve detects the
pilot pressure. Then, approx. 3 second
after main controller A is notified with the
auto-idle switch ON that pilot pressure at
2
the pressure sensor is 0.4 MPa (4 kgf/cm ,
57 psi) or lower, main controller sends out
a signal to the ECM, by which the ECM
-1 SA SB
reduces engine speed down to 1400 min . Pilot Pump
At the same time, main controller sends
out signals to power decrease solenoid
valves (SA and SB). Then, power de-
Power Decrease
crease solenoid valves (SA and SB) are Solenoid Valve
shifted by the delivered signals so that
pilot pressure oil is routed to regulator
ports PG of main pumps (1, 2, and 3).
Consequently, the pump swash angle is
reduced, causing the pump to reduce the
flow rate. Electronic
Governor
When a control lever is operated and the
pressure sensor detects 0.7 MPa
2
(7kgf/cm , 100psi) pressure, main con-
troller stops sending out signals the ECM. T18E-02-01-016
Thereby, engine speed is increased up to Main Pump 3 Main Pump 1
the speed set by the engine control dial. Main Pump 2
Therefore, when engine speed increases
-1
more than 1500 min , main controller A
stops sending out signals to power de-
crease solenoid valves (SA and SB) so
that the pump swash angle is increased,
causing the pump flow rate to increase.
(Refer to the Regulator in the COMPO-
NENT OPERATION / Pump Device group
for regulator operation.)
T2-1-5
Low Temperature Start Control
Purpose: Heats the intake air when the atmos- NOTE:
pheric temperature is low (0°C (32°F) or • When the key switch is turned except ON before
lower) in order to make the engine start the preheat is finished (30 seconds before), the
more easily. preheat is finished automatically and the preheat
lamp is also turned OFF.
Operation: • When the key switch is kept ON (for 30 seconds
1. When the key switch is turned ON, current from or longer) after the preheat is finished, the pre-
the battery magnetizes relay 1 via fusible link 1, heat is finished automatically and the preheat
key switch and fuse box 1. lamp is also turned OFF.
2. When temperature at suction manifold is 0°C • If the preheat is required once more, return the
(32°F) or lower with the condition at step 1, bat- key switch to the OFF position. After 5 minutes or
tery the ECM relay magnetizes the preheat signal longer turn the key switch ON again in order to
relay. perform the preheat. (The preheat cannot be
3. When the preheat signal relay is magnetized, performed in 5 minute or longer after the key
current from the battery magnetizes preheat re- switch is turned OFF in order to protect the en-
lays 1, 2 via battery relay1, fusible link 4, the gine.)
preheat signal relay.
4. When preheat relays 1, 2 are magnetized, current
from the battery activates air heaters 1 and 2 re-
spectively via fusible links 7, 8 and preheat relays
1, 2.
5. At the same time at step 4, current from the bat-
tery magnetizes the preheat lamp relay via fusible
link 8, preheat relay 2 and the fuse.
6. When the preheat lamp relay is magnetized, cur-
rent flows through the preheat indicator in the
monitor controller and the preheat indicator is
turned ON.
7. Air heaters 1, 2 are activated for 30 seconds.
T2-1-6
Air Heater 1
Key Switch
Fusible Preheat
Link 7 Relay 1 From Battery
Fusible Fuse Box 2

Link 1 Fuse #1 20A
Battery
Fusible
Link 8 Fuse Box 2
Preheat Fuse #3 5A
Preheat Signal
Relay 2 Relay
Air Heater 2
Fuse 5A
Preheat Electronic
Indicator Preheat Indi- Governor
cator Relay
Monitor
Controller T18E-02-01-017
T2-1-7
Engine Diagnosing Control
Purpose: Performs when the engine or the related
parts are abnormal, and the engine protec-
tion indicator, engine warning indicator or
engine stop indicator is turned ON.
Operation:
When the key switch is turned ON with fault diag-
nosing switch A ON, the electrical signal from ECM is
sent to the monitor and the fault code is displayed on
the engine fault code display panel.
When pushing fault diagnosing switch B forward or
backward while the fault code is displayed on the
engine fault code display panel, the signal from ECM
is selected and the previous or following fault code is T18E-01-02-006
displayed on the monitor.

(Refer to the Troubleshooting A section, TROU-
BLESHOOTING.)
Fuse Box B
Fuse #3 5A
Engine Protection
Indicator
Engine Warning
Indicator
ECM
Engine Engine
Engine Stop
Diagnostic Diagnostic
Indicator
Switch A Switch B
Protection Lamp
Relay
Monitor Engine Stop

Indicator
Engine Stop Lamp
Relay
CPU
DLU
24V Engine Warning
Indicator
T18E-02-01-018
T2-1-8
(Blank)
T2-1-9
Engine Protection Control
Purpose: Monitors engine operating condition ac- • Reduction in Engine Oil Pressure
cording to input signals delivered from 1. When reduction in engine oil pressure keeps for 5
the coolant temperature sensor, coolant seconds or longer, the engine speed decreases.
level switch, engine oil pressure sensor, 2. At the same time at step 1, ECM turns the protec-
suction manifold temperature sensor and tion lamp on engine fault code display monitor ON
engine speed sensor and reduces engine and sends the signal to DLU.
loads by decreasing pump drive power or 3. After DLU receives the signal, DLU sends the
stops the engine in case any engine signal the monitor and main controller A respec-
trouble is detected. tively.
4. After monitor receives the signal, the stop lamp
• Overheating blinks once. After 5 seconds the engine oil pres-
1. When coolant temperature keeps over 100 °C sure indicator is turned ON and the buzzer rings.
(212 °F) for 5 seconds or longer, the engine 5. After receiving the signal from DLU, main con-
speed decreases. troller A instructs power increase solenoid valve
2. At the same time at step 1, ECM turns the protec- ST so that power increase control is deactivated
tion lamp on engine fault code display monitor ON and only power decrease control by power de-
and sends the signal to DLU. crease solenoid valves (SA and SB) are activated.
3. After DLU receives the signal, DLU sends the (Refer to the Pump Control description pages.)
signal the monitor and main controller A respec- 6. In response to engine oil pressure, the control for
tively. auto-stop performs as following (2 types):
4. After monitor receives the signal, the stop lamp 1 ) After 90 seconds, ECM blinks the stop lamp
blinks once. After 5 seconds, the overheat indi- on engine fault code display monitor. After 30
cator is turned ON and the buzzer rings. seconds, the engine stops automatically.
5. After receiving the signal from DLU, main con- 2 ) The engine stops automatically at once.
troller A instructs power increase solenoid valve
ST so that power increase control is deactivated When the engine stops, only the engine oil pres-
and only power decrease control by power de- sure indicator on monitor is turned ON.
crease solenoid valves (SA and SB) are activated.
(Refer to the Pump Control description pages.)
6. When coolant temperature increases 115°C (239
°F), ECM blinks the stop lamp on engine fault
code display monitor. After 30 seconds, the en-
gine stops automatically. When the engine stops,
only the overheat indicator on monitor is turned
ON.
T2-1-10
(Blank)
T2-1-11
PUMP CONTROL
SP Mode Control
Purpose: Changes the pump flow rate in response
to the engine speed change to utilize en-
gine output effectively when the engine
runs faster than the rated speed. Main
Operation: When engine speed increases over 1550 Controller A
-1 SP Mode Switch
min with the SP mode ON, main con-
troller sends out signals to power increase
solenoid valve ST in response to the sig-
nals from engine speed sensor 1. There-
Engine Speed
fore the signals from main controller A to Sensor 1
Power Increase
power increase solenoid valve ST Solenoid Valve ST
changes as engine speed changes.
Power increase solenoid valve ST deliv- Pilot Pump
ers the pilot oil pressure corresponding to
the received signals to main pump regu-
PZ PZ PZ
lator ports PZ, increasing the pump swash
angle in proportion to the delivered pilot
oil pressure. Then, the pump flow rate in-
creases, accelerating actuator speeds Main Pump
and increasing the engine loads. This op- T183-02-01-009
eration continues until engine speed is
-1
reduced to 1550 min .
E Mode Control
Purpose: Reduces pump 3 flow rate when the ma-
chine is engaged in less production work.
Operation: When the E mode switch is ON, main
controller A sends out signals to power
decrease solenoid valve SA, shifting Main Controller A
power decrease solenoid valve SA. Then, E Mode Switch
the pilot oil pressure is delivered to main
pump 3 regulator port PG, reducing the
main pump 3 swash angle so that the Power Decrease
pump 3 flow rate is reduced. Therefore, Solenoid Valve SA
Pilot
actuator operating speeds are reduced. Pump
NOTE: Since no signals are delivered to power
PG
decrease solenoid valve SB from main
controller A, main pumps 1 and 2 are not
controlled.
NENT OPERATION / Pump Device group Main Pump 3
T142-04-03-006
T2-1-12
Pump Flow Rate Control at Slow Engine Speed
Purpose: Prevents the engine from stalling even if
engine speed is reduced to less than 850
-1
min due to engine load increase while
the engine is running at slow speed. Main
Controller A
Operation: When main controller A is instructed by

signals from engine speed sensor 1 that
Signal
engine speed is reduced to less than 850 Control
-1
min , main controller A sends out signals Flow Rate Decrease Valve
to the flow rate decrease solenoid valve. Solenoid Valve
When the flow rate decrease solenoid
Engine Speed
valve is activated, it closes the pilot Sensor 1
pressure oil circuit from the pump flow
rate control valve in the signal control
valve to main pump 1 and 2 regulator
ports Pi. Consequently, the pump swash
angle is reduced so that the engine load
is reduced. This operation continues until
engine speed increases to more than
-1 Main Pump 2 Main Pump 1
1400 min .
(Refer to the COMPONENT OPERATION T18E-02-01-006
/ Signal Control Valve group for signal
pilot control valve operation.)
T2-1-13
Pump Flow Rate Control at Middle Engine Speed
Purpose: Prevents engine speed from being re-
-1
duced to less than 1400 min due to en-
gine load while the engine is running at
middle speed. Main
Controller A
Operation: When main controller A is instructed by

signals from engine speed sensor 1 that
engine speed is reduced to less than Pilot Pump
-1
1400 min , main controller A sends out
signals to power decrease solenoid Power
valves SA and SB. Decrease
Solenoid
When power decrease solenoid valves Valve
SA and SB are shifted, the pilot pressure
SA SB
oil routed to main pump 1, 2, and 3 regu-
lator ports PG. Consequently, the pump
swash angle is reduced so that the pump
flow rate is reduced, reducing the engine
Engine Speed
loads. This operation continues until en- Sensor 1
gine speed increases to more than 1500
-1
min .
PG PG PG
Main Pump
T18E-02-01-007
T2-1-14
Power Decrease Control to Prevent Engine
Overheat
Power Decrease Control at Abnormal Engine Oil
Pressure
Power Decrease Control at Lower Coolant Level Suction Manifold Tem-
Purpose: Reduces main pump 1, 2, and 3 output to perature Sensor ECM
reduce the engine loads when the coolant
Engine Oil Pressure
temperature increases over 100 °C (212 Sensor
°F), when the engine oil pressure is ab-
DLM
normal, when the coolant level is reduced, Coolant Level Switch
or when temperature of suction manifold
reaches over 85 °C (185 °F). Coolant Tempera-
ture Sensor
Main
Operation: When the coolant temperature increases Controller A
Power Decrease
to 100 °C (212 °F), when engine oil Solenoid Valve
pressure is reduced or when temperature SB
of suction manifold reaches over 85 °C Power Decrease
(185 °F) and if the coolant level is re- Solenoid Valve
SB
duced to lower than the specified level,
main controller A sends out signals to
power decrease solenoid valves SA and Pilot Pump
SB, shifting power decrease solenoid
valves SA and SB. Then, the pilot pres-
sure oil is routed to main pump 1, 2, and 3 PG PG PG
regulator ports PG. Consequently, swash
angle in main pumps 1, 2, and 3 is re-
duced so that the pump flow rate is re-
duced. Thereby, the engine loads are Engine
reduced, preventing the engine from be-
ing overloaded.
Main Main Main
Pump 3 Pump 2 Pump 1
T18E-02-01-014
T2-1-15
VALVE CONTROL
Travel Mode Control
Purpose: Controls the travel mode.
Operation: Slow Mode:
When the travel mode switch is turned to
position, main controller B doesn’t
send signals to the travel mode control
solenoid valve so that the solenoid valve
is deactivated. Therefore, reducing valve
port D is connected to the hydraulic oil
tank. Then, pilot oil pressure delivered
from the pilot pump to the travel motors
via the brake release pressure control
valve and the reducing valve is main-
2
tained at 1.8 MPa (18 kgf/cm , 256 psi) by
the reducing valve.
Accordingly, the travel mode control

valves in the travel motors are not shifted.
Then, pressure oil from the main pump is
not supplied to the tilt pistons so that the
travel motors rotate at slow speed. (Refer
to the Travel Motor in the COMPONENT
OPERATION / Travel Device group for
travel motor swash angle control opera-
tion.)
T2-1-16
From Main
Pump
Pilot Pump
Reducing From Main

Valve 1.8 MPa Pump
Travel Parking
Port D Shuttle Valve Motor Brake
Brake
Release
Pressure Tilt Pis-
Control ton
Valve
OFF
Travel Mode
Control
Solenoid
Valve Travel
Mode
Control
Valve
Shuttle
Valve
Main Controller B From Signal

Control Valve
Travel
Mode
Switch T183-02-02-013
T2-1-17
Fast Mode:
When the travel mode switch is turned to posi-
tion, main controller B sends out signals to the travel
mode control solenoid valve so that the solenoid valve
is activated. Therefore, pilot oil pressure from the pilot
pump via the brake release pressure control valve and
the travel mode control solenoid valve is routed to re-
ducing valve port D, fully opening the reducing valve.
Then, pilot oil pressure delivered from the pilot pump
to the travel motors is maintained at 3.9 MPa (40
2
kgf/cm , 569 psi).
Accordingly, the travel mode control valves in the

travel motors are shifted. Then, pressure oil from the
main pump is supplied to the tilt pistons so that the
travel motors rotate at fast speed.
(Refer to the Travel Motor in the COMPONENT OP-
ERATION / Travel Device group for travel motor swash
angle control operation.)
T2-1-18
From Main
Pump
Pilot Pump
From Main
Reducing 3.9 MPa Pump
Valve Travel Parking
Port D Shuttle Valve Motor Brake
Brake
Release
Pressure Tilt
Control Piston
Valve
ON Travel
Mode
Control
Solenoid Travel
Valve Mode
Control
Valve
Shuttle
Valve
From Signal Pilot

Main Controller B Control Valve
Travel
Mode
Switch T183-02-02-014
T2-1-19
Heavy Lift Control
Purpose: Increases the main relief set-pressure.
Operation: When the heavy lift switch is turned ON,

main controller A receives signals from
the switch and activates the heavy lift
solenoid valve and activates the flow rate
decrease solenoid valve. Then, the pilot
oil pressure from the pilot pump is routed
to the main relief valve via the heavy lift
solenoid valve, increasing the relief
set-pressure. (refer to the main relief
pressure control on the COMPONENT
OPERATION /Control Valve group.)
Other than the above, the pilot pressure

oil from the pump flow rate control valve
in signal control valve to main pump 1 and
2 regulator ports Pi is blocked by the flow
rate decrease solenoid valve so that main
pump 1 and 2 flow rates are reduced to
minimum.
T2-1-20
Heavy Lift
Switch
Main Control Valve
Main Relief
Valve
Main
Controller A
Signal
Control
Valve
Heavy Lift
Flow Rate Decrease
Solenoid
Solenoid Valve
Valve
Pilot
Pump Pi Pi
REG REG REG
Main Main Main T18E-02-01-012

Pump 3 Pump 2 Pump 1
T2-1-21
Boom Mode Selection Control
Purpose: Reduces machine vibration while per-
forming digging or leveling work.
Operation: When the boom mode selection switch is
turned ON, main controller B activates
boom mode selection solenoid valve SC
so that pressure oil from the pilot pump is
routed to the boom overload relief pres-
sure switch valve via boom mode selec-
tion solenoid valve SC. Then, the boom
overload relief pressure switch valve is
shifted, blocking the pressure oil flow from
the boom cylinder rod side to the overload
relief valve pilot port. Therefore, the
overload relief valve set-pressure is re-
2
duced to 9.8 MPa (100 kgf/cm , 1420 psi).
This reduces machine vibration while
performing digging or leveling, but dis-
enables to lower the bucket to raise the
machine front off ground.
NOTE: Refer to the COMPONENT OPERATION /
Control valve group for the boom overload
relief pressure switch valve.
T2-1-22
Boom Cylinder
Boom Mode Selection

Solenoid Valve SC
Pilot Pump
Boom Overload Relief Overload Relief Valve

Pressure Switch Valve
Main
Controller B
Boom Mode
Selection Switch
Travel Front All

Pilot Pressure
Sensors
T18E-02-01-009
T2-1-23
OIL COOLER AND FUEL COOLER FAN
MOTOR CONTROL
Fuel Temperature
Purpose: Changes the fan motor speed in three Sensor
stages (Low, Middle and High speeds) as
the hydraulic oil and fuel temperatures Hydraulic Oil Temperature Sensor
change to properly maintain the hydraulic
Main Controller A
oil and fuel temperatures.
Operation: Main controller A receives signals in re-

Oil Cooler Fan
sponse to each temperature from the hy- Motor
draulic oil temperature sensor and fuel
temperature sensor. Based on the received
signals, controller A activates fan control Oil Cooler
Fan Motor
solenoid valve SF so that pressure oil from Drive Pump
the pilot pump is routed to the fan motor
drive pump, controlling the fan motor drive
pump speed. Then, the oil cooler fan motor
speed is controlled by pressure oil from the
fan motor drive pump. Oil Cooler Fan
Pilot Pump T183-02-01-015
Control Solenoid
Hydraulic Oil Valve SF
Temperature
If the fan motor speed mode of fuel temperature is

different from that of hydraulic oil temperature, the fan
runs in response to the faster fan motor.
1400±50 min-1
800 min-1 800 min-1
1100 min-1 1100 min-1
Fan Motor Speed

T18E-02-01-011
Oil Temperature VS Fan Motor Speed
Fuel Temperature Oil Cooler Fan Hydraulic Oil Pilot Pressure from Fan Control Fan Motor
Motor Speed Temperature Solenoid Valve [Current from MC] Speed Mode
2
66 °C (151 °F) 800→ 70 °C (157 °F) 0.99 Mpa (10 kgf/cm , 142 psi) Low→Middle
-1
1100 min [285 mA]
2
69 °C (156 °F) 1100→ 80 °C (176 °F) 0 MPa (0 kgf/cm , 0 psi) Middle→High
-1
1400±50 min [200 mA]
2
66 °C (151 °F) 1400±50→ 75 °C (167 °F) 0.99 Mpa (10 kgf/cm , 142 psi) High→Middle
-1
1100 min [285 mA]
2
63 °C (145 °F) 1100→ 65 °C (149 °F) 1.36 Mpa (14 kgf/cm , 199 psi) Middle→ Low
-1
800 min [309 mA]
NOTE: The fan motor speeds shown in the above

table are those driven at engine rated
-1
speed (1650 min ).
T2-1-24
(Blank)
T2-1-25
AUTO-LUBRICATION CONTROL
Purpose: Automatically lubricates the front attach-
ment joint pins with grease.
(Refer to the COMPONENT OPERATION /
Others (Upperstructure) group.)
Operation:
• Auto-Lubrication • Manual Lubrication
1. When the auto-lubrication switch on the monitor 1. When the auto-lubrication switch on the monitor
panel is turned to the AUTO position, the monitor panel is turned to the MANUAL position, the
controller sends a signal to the main controller B. monitor controller sends a signal to the main con-
2. Then, based on signals from the auto-lubrication troller B.
interval switch, main controller B connects the 2. Then, main controller B connects the ground cir-
ground circuit of the power transistor 3. cuit of the power transistor 3. Power transistor 3
3. As long as a signal from main controller B is input, activates the auto-lubrication relay and holds it
power transistor 3 activates the auto-lubrication activated.
relay. 3. Turn the lubricator grease pump switch ON.
4. As long as the auto-lubrication relay is activated. 4. Since the grease pump discharges grease, lubri-
Then, the grease pump is driven, discharging cation can be performed using the lubricator or a
grease. grease gun.
5. In addition, main controller B monitors the 5. When the proximity switch is turned ON, main
auto-lubrication system with the proximity switch controller B receives a signal, deactivating the
to check if it operates normally. auto-lubrication relay. Therefore, the grease
6. When the proximity switch is turned ON, main pump is stopped.
controller B deactivates the auto-lubrication relay.
Therefore, the grease pump is stopped. NOTE: In manual lubrication mode, the
auto-lubrication indicator is always kept
NOTE: In auto-lubrication mode, if the proximity ON.
switch is not shifted to either ON or OFF
position within 5 minutes after the
auto-lubrication relay is activated, main
controller B judges that a system failure
has occurred or the grease volume has
been reduced, lighting the auto-lubrication
indicator.
T2-1-26
Auto-Lubrication Interval Switch

Power
Transistor 3
Fuse #14
Auto-Lubrication To Lubrication Circuit

Relay
Grease
Pump
Switch
Lubricator
Monitor Controller
Grease
Pump
Auto-Lubrication
Main Proximity Switch
Indicator
Controller B T183-02-01-011
T2-1-27
(Blank)
T2-1-28
SYSTEM / Hydraulic System
OUTLINE
The hydraulic system consists of the main circuit, pilot
circuit, pump transmission oil cooling circuit, and oil
cooler fan motor circuit.
Pilot Circuit:
A hydraulic circuit that shifts the control valve spools,
that controls the pumps, valves, and motors, and re-
leases the parking brakes.
Main Circuit:
A hydraulic circuit that actuates cylinders, and motors
by pressure oil delivered from the main pumps.
Pump Transmission Oil Cooling Circuit:

An oil circuit that cools the pump transmission oil by
routing it through the oil cooler.
Oil Cooler Fan Motor Circuit:

A hydraulic circuit that drives the oil cooler fan motor
with pressure oil from the oil cooler fan motor drive
pump.
(Refer to the oil cooler fan motor control in Control
System group.)
T2-2-1
PILOT CIRCUIT
Pressure oil from the pilot pump is used as working
pressure for the following pilot circuits.
• Control Circuit
• Brake Release Circuit
• Travel Motor Overrunning Prevention Circuit
• Main Pump 3 Flow Rate Control Circuit
• Combined Operation Circuit of Arm Roll-Out
(Backhoe) / Arm Retract (Loading Shovel),
Bucket Roll-In (Backhoe) / Tilt-Out (Loading
Shovel), Boom Raise and Swing
• Flow Rate Control Circuit for Boom Raise and
Swing Combined Operation
• Mode Selection Circuit
• Auto-Idle Circuit
• Pump Flow Rate Control Circuit
• Main Relief Set-Pressure Control Circuit
• Boom Raise Priority Circuit
• Travel Mode Control Circuit
• Heavy Lift Circuit
• Boom Mode Selection Circuit
• Swing Motor Make-Up Circuit
T2-2-2
Backhoe
Pilot Pilot Valve Pilot Valve

Valve (Arm / Swing) (Boom / Bucket)
(Travel)
Pilot Shut-Off
Valve
Accumul- Shuttle Valve Shuttle Valve Shockless
ator (Pilot Control) (Bucket Roll-In) Valve
Pilot Check Valve
Shuttle Valve (For

Swing Pump 3
Control Pressure)
Pump 2 Pump 1
Regulator Regulator Arm Preference
Valve
Shockless Shuttle Valve
Valve (Swing Parking
Pump 3 Brake Release)
Regulator
Solenoid
Valves
SC SB SA Pump 3
Pilot Relief Control
Valve Valve
Swing Control
2-Unit Shuttle Valve Signal Pressure Control Valve Valve
EHC
Valve (For Swing
Make-Up)
Pilot Filter
Flow Rate
Decrease Main Control Valve
Oil Cooler
Fan Motor Solenoid
Drive Pump Valve
Travel
Motor
Pilot Pump Reducing
Heavy Lift Valve
Solenoid Travel
Valve Motor
Brake Release Travel
Hydraulic Pressure Control
Oil Tank Mode
Valve Solenoid
Valve
Swing
Motor
Swing
Motor
T18E-02-02-001
T2-2-3
Loading Shovel
Pilot Valve Pilot Pilot Valve Pilot Valve Pilot Valve

(Bucket Close) Valve (Bucket Open) (Arm / Swing) (Boom / Bucket)
(Travel)
Pilot Shut-Off
Valve
Accumul- Shuttle Valve Shuttle Valve
(Pilot Control) Shockless
ator (Bucket Tilt-In) Valve
Pilot Check Valve
Shuttle Valve (For

Swing Pump 3
Control Pressure)
Pump 1
Regulator
Arm Preference
Valve
Pump 2 Shockless
Regulator Valve
Shuttle Valve
(Swing Parking
Pump 3 Pump 3 Brake Release)
Regulator Control
Valve
Solenoid Signal Pressure Control Valve Swing Control

Valves Valve
SC SB SA
2-Unit
Pilot Relief EHC Shuttle Valve
Valve Valve (For Swing
Make-Up)
Oil Cooler
Fan Motor
Pilot Filter Drive Pump
Main Control Valve

Flow Rate
Decrease
Solenoid
Valve Travel
Pilot Pump
Motor
Reducing
Heavy Lift Valve
Solenoid Travel
Valve Motor
Hydraulic
Oil Tank Brake Release Travel
Pressure Control Mode
Valve Solenoid
Valve
Swing
Motor
Swing
Motor
T18E-02-02-002
T2-2-4
(Blank)
T2-2-5
Control Circuit
Pressure oil from the pilot pump flows to the main
control valve and to the swing control valve to shift
control valve spools via the pilot check valve, pilot
shut-off valve, pilot valve, shuttle valve, and shock-
less valve.
When the pilot shut-off valve is closed, pressure oil is

not routed to the pilot valve so that the machine does
not operate even if the control levers are operated. A
couple of accumulators are provided in the control
circuit, allowing pressure oil to be delivered for a
while after the engine is stopped. Therefore, even
after the engine stops due to any trouble with the
front attachment raised, pilot oil pressure is delivered
to the control valve spools so that the front attach-
ment can be lowered.
T2-2-6
Backhoe
Swing Boom /
Travel /Arm Bucket
Accumulator
Pilot Shut-Off
Valve
5 6
Pilot Check Valve
Pilot Pump
Signal Control
Valve Hydraulic
Oil Tank 14 13 3 1 10 9 12 11 4 2 8 7
11
10
1 2 12
9
1
5 8
6 8
7
8 1
7
2
2
3 4
1
4
3 3
4
Swing Control Valve
14
13
Main Control Valve

T18E-02-02-003
1- Boom Raise 5- Left Swing 9- Left Travel Forward 12- Right Travel Reverse
2- Boom Lower 6- Right Swing 10- Left Travel Reverse 13- Auxiliary
3- Arm Roll-Out 7- Bucket Roll-In 11- Right Travel Forward 14- Auxiliary
4- Arm Roll-In 8- Bucket Roll-Out
T2-2-7
Loading Shovel
Swing Boom /
Bucket Close Travel Bucket Open /Arm Bucket
To Pilot Valve
Bucket Open, Close
Accumulator
Pilot Shut-Off
Valve
5 6
Pilot Check Valve
Pilot Pump
Signal Control
Valve Hydraulic
Oil Tank 14 13 3 1 10 9 12 11 4 2 8 7
11
10
1 2 12
9
1
5 8
6 8
7
8 1
7
2
2
3 4
1
4
3 3
4
Swing Control Valve
14
13
Main Control Valve

T18E-02-02-004
1- Boom Raise 5- Left Swing 9- Left Travel Forward 12- Right Travel Reverse
2- Boom Lower 6- Right Swing 10- Left Travel Reverse 13- Bucket Close
3- Arm Retract 7- Bucket Tilt-In 11- Right Travel Forward 14- Bucket Open
4- Arm Extend 8- Bucket Tilt-Out
T2-2-8
Brake Release Circuit Travel Motor
• When traveling or operating front attachment:
When either the travel or the front attachment con-
trol levers are operated, pressure oil from the signal
control valve is routed to the brake release pressure
control valve. Then, pressure oil from the pilot pump
is routed to the travel motor via the brake release
pressure control valve and the reducing valve, re- Pilot Pump
leasing the travel parking brake.
Also, pressure oil that has passed through the brake
release pressure control valve is routed to the swing Reducing Valve Shuttle Valve
parking brake release valve. Then, pressure oil from
the pilot pump flows through the swing parking
brake release valve and release the swing parking
brake. Therefore, dragging of the swing brake will
be prevented when digging work is performed.
Brake Release
Pressure Control
Valve
Swing Motor Shuttle Valve
From Signal Pilot

Pressure Control Valve
Swing Parking Brake

Release Valve
T18E-02-02-005
• When rotating upperstructure: Pilot Pump

When the swing lever is operated, swing pilot pres-
sure oil is routed to the brake release pressure con-
trol valve via the shuttle valves. Then, pressure oil
from the pilot pump flows through the brake release
pressure control valve to the swing parking brake
release valve pilot port, allowing pressure oil from Brake Release
Swing Parking Pressure
the pilot pump to flow through the swing parking Brake Release Control Valve
brake release valve to release the swing parking Swing Motor Valve
brake.
Shuttle Valve
Shuttle Valve
Swing Pilot
Pressure
T18E-02-02-006
T2-2-9
Travel Motor Overrunning Prevention Circuit
When the front attachment control levers are oper-
ated, pilot pressure from the front attachment circuit
is routed to the priority valve pilot port in the signal
control valve, shifting the priority valve.
Then, when the right travel lever is operated under
this condition, the pilot pressure oil from the right
travel spool is routed to the flow combiner valve con-
trol spool pilot port in the signal control valve.
Thereby, pressure oil from the pilot pump flows to the
flow combiner valve pilot port in the main control
valve via the priority valve and the flow combiner
valve control spool, shifting the flow combiner valve.
Then, pressure oil from main pump 2 is also routed
into the left travel motor via the flow combiner valve.
Therefore, the flow combiner valve cannot be shifted
unless the right travel lever is operated.
For example, when the left travel/boom combined
operation is operated with the left track jacked-up
using the boom function, only main pump 1 oil flow is
supplied to the left travel motor since the flow com-
biner valve is closed.
(Without this travel motor overrunning prevention cir-
cuit, two main pump flows could be supplied to the
left travel motor, possibly causing overrunning of the
left travel motor in the above mentioned operation.)
(Refer to the COMPONENT OPERATION /Control
Valve group.)
T2-2-10
Signal Control Valve
Priority Valve
Pilot Pump
Flow Combiner
Valve
Right Travel
(Forward)
Pilot Pressure
Right Travel
(Reverse)
Pilot Pressure
Flow Combiner
Valve Control
Spool
Front Attachment
Pilot Pressure
T18E-02-02-007
T2-2-11
Main Pump 3 Flow Rate Control Circuit
When either function of the arm roll-in (backhoe) / Arm Roll-In
(Backhoe)
arm extend (loading shovel), bucket roll-in (backhoe) Bucket Roll-In
Arm Extend
(Backhoe)
/ tilt-in (loading shovel), boom raise or swing is oper- Tilt-In (Loading
(Loading
ated, the pump 3 control valve is shifted. Then, pres- Shovel) Pilot
Shovel) Pilot
Pressure
sure oil from the pilot pump is routed to the main Pressure
pump 3 regulator as flow rate control pressure Pi, in-
creasing the main pump 3 flow rate. Therefore, ac-
tuator operating speeds when a combine operation
Boom Raise
of arm roll-in (backhoe) / arm extend (loading shovel), Pilot Pressure Shuttle Valve
bucket roll-in / tilt-in (loading shovel), boom raise or
swing is made are ensured.
(Refer to the COMPONENT OPERATION / Pump Right Swing Pi-
Control Valve group.) lot Pressure
Left Swing Pilot

Pressure
Shuttle Valve
REG REG REG
Main Main Main

Pump 3 Pump 3 Pump 2 Pump 1
Control
Valve
Pilot Pump
T18E-02-02-008
T2-2-12
(Blank)
T2-2-13
Combined Operation Circuit of Arm Roll-Out
(Backhoe) / Arm Retract (Loading Shovel),
Bucket Roll-In (Backhoe) / Tilt-Out (Loading
Shovel), Boom Raise, and Swing
When the arm roll-out (backhoe) / arm retract (load-
ing shovel) and swing functions are operated at the
same time for example, the swing pilot pressure oil
shifts the arm preference valve via the shuttle valves.
Therefore, no pilot pressure oil is routed to the arm 3
spool pilot port in the swing control valve so that arm
3 spool is not moved. Then, the return oil from the
arm cylinder cannot pass through arm 3 spool, re-
stricting the return oil flow. Thereby, arm hesitation
while rolling out (backhoe)/retracting the arm (loading
shovel) is prevented.
(Refer to the combined operation circuit in this group
and the COMPONENT OPERATION /Pump Control
Valve group.)
T2-2-14
NOTE: The drawing shown in the below is Back-

hoe.
Left Swing Right Swing Boom Raise Bucket Roll-In Arm Roll-Out
Pilot Pressure Pilot Pressure Pilot Pressure Pilot Pressure Pilot Pressure Arm Cylinder
Shuttle Valve (Pilot

Pressure Control)
Arm
Preference
Valve
Main Control Valve
Swing Control Valve

Boom 3
Swing
Arm 1
Arm 2
Arm 3
Bucket 3
Main Pump 1
Main Pump 2
Main Pump 3
T18E-02-02-009
T2-2-15
Mode Selection Circuit
• Refer to the SP Mode and E Mode Control in the
Control System group.
Auto-Idle Circuit
• Refer to the Auto-Idle Control in the Control System
group.
Pump Flow Rate Control Circuit

• Refer to the Pump Flow Rate Control at Slow En-
gine Speed and the Pump Flow Rate Control at
Middle Engine Speed in the Control System group.
Main Relief Set-Pressure Control Circuit

• Refer to the COMPONENT OPERATION / Main Re-
lief Pressure Setting Change in the Control Valve
group, and Heavy Lift Control in the Control System
group.
Boom Raise Priority Circuit

• Refer to the Main Circuit, Combined Control Circuit,
Boom and Arm Combined Operation (Boom Raise
and Arm Roll-Out) in this group.
Travel Mode Control Circuit

• Refer to the Travel Mode Control in the Control Sys-
tem group.
Heavy Lift Circuit

• Refer to the Heavy Lift Control in the Control Sys-
tem group.
Jack-Up Prevention Circuit

• Refer to the Jack-up Prevention Control in the Con-
trol System group.
T2-2-16
(Blank)
T2-2-17
Swing Motor Make-Up Circuit
Pressure oil from the pilot valve flows into port Pi of

the regulator in the main pump 2 via the shuttle valve
(for swing makeup) and shockless valve when the
swing operation is operated. Therefore, the delivery
volume from the main pump 2 increases.
When the swing control lever is returned to the neu-
tral position, pressure oil routed to port Pi of the
regulator in the main pump 2 decreases, so that the
delivery volume from the main pump 2 tries to de-
crease.
However, the shockless valve prevents the pressure
oil from returning suddenly to the hydraulic oil tank
from port Pi of the regulator in the main pump 2. As a
result, the delivery volume from the main pump 2 is
maintained for a time being.
As delivery volume from the main pump 2 is main-
tained, back pressure of the return oil from the main
control valve 4-spool side increases, so that the
make-up volume to the swing motor increases.
As a result, the cavitation of the swing motor can be
prevented.
T2-2-18
Swing (Right) to Swing Control Valve

Pilot Pressure Shuttle Valve
Right Swing
(for Swing Make-Up)
Swing (Left) to Swing Control Valve

Pilot Pressure Left Swing
Shockless Valve
Pi
Main Pump 2 REG
Main Control Valve
4-Spool
Side
Oil Cooler
Swing Motor
5-Spool
Side
T18E-02-02-010
T2-2-19
MAIN CIRCUIT
Main pumps 1, 2, and 3 draw hydraulic oil from the
hydraulic oil tank. Main pump 1, main pump 2, and
main pump 3 deliver hydraulic oil to the 5-spool sec-
tion of the main control valve, to the 4-spool section of
the main control valve, and the swing control valve,
respectively. The delivered oil is further routed to the
motors and/or cylinders in response to control valve
operation. The return oil from the main control valve
flows back to the hydraulic oil tank through the two re-
turn circuits.
When the return oil temperature is low (high oil viscos-
ity), or when a large amount oil is returned, oil flow re-
sistance in the oil cooler increases. In this case, the
bypass relief valve opens so that the return oil flows
directly back to the hydraulic oil tank.
When the return oil temperature increases (low oil
viscosity), oil flow resistance in the oil cooler de-
creases. Therefore, the bypass relief valve doesn’t
open so that the return oil flows back to the hydraulic
oil tank after passing through the oil cooler.
T2-2-20
Backhoe
Boom Arm Bucket

Cylinder Cylinder Cylinder
Swing Motor
Center
Joint
Hydraulic Oil Tank
Swing
Control Valve
Main Control Valve
Boom 3
(4-Spool Section)
Swing
Right Travel
Bucket 3
Bucket 1
Arm 3
Boom 1
Arm 2
Oil Cooler
Main Control Valve

(5-Spool Section)
Left Travel
Bucket 2
Boom 2
Bypass Relief Valve
Arm 1
Auxiliary
Radiator
Center Joint
Main Pump 3
Main Pump 2
Main Pump 1
Left Travel Motor Right Travel Motor
High Pressure Oil
Low Pressure Oil (Suction)

Low Pressure Oil (Return)
Circuit Oil
Pilot Oil
Drain Oil
T18E-02-02-024
T2-2-21
Loading Shovel Bucket
Level Boom Arm open/close Bucket
Cylinder Cylinder Cylinder Cylinder Cylinder
Swing Motor
Center
Joint
Hydraulic Oil Tank
Swing Control
Valve
Main Control Valve
Boom 3
(4-Spool Section)
Swing
Right Travel
Bucket 3
Bucket 1
Arm 3
Boom 1
Arm 2
Oil Cooler
Main Control Valve

(5-Spool Section)
Left Travel
Bucket 2
Boom 2
Bypass Relief Valve
Arm 1
Bucket
open/close
Radiator
Center Joint
Main Pump 3
Main Pump 2
Main Pump 1
Left Travel Motor Right Travel Motor
High Pressure Oil
Low Pressure Oil (Suction)

Low Pressure Oil (Return)
Circuit Oil
Pilot Oil
Drain Oil
T18E-02-02-025
T2-2-22
(Blank)
T2-2-23
Single Operation Circuit
• Boom Operation
Backhoe
Boom Raise:
Pressure oil from main pump 1 flows through the
boom 2 spool in the 5-spool section of the main
control valve. Pressure oil from main pump 2 flows
through the boom 1 spool in the 4-spool section of
the main control valve. Pressure oil from main
pump 1 and 2 merges, and flows to the boom cyl-
inder bottoms after passing through holding valve
check valve. Pressure oil from main pump 3 flows
through the boom 3 spool in the swing control valve
and the holding valve check valve.
Boom Lower:
Pressure oil from the main pump 2 flows is fed to
the boom cylinder rod side through the boom 1
spool in the 4-spool section of the main control
valve. Pressure oil from the main pump 3 flows
back into the hydraulic oil tank through the boom 3
spool in the swing control valve, so that it does not
flow to the boom cylinder rod side even when the
spool is shifted.
The lowering side of the boom 2 spool in the
5-spool section of the main control valve is exclu-
sively used for boom regeneration. Only the return
oil from the boom cylinder bottom side flows there.

Control Valve group for the holding valve
functions.
T2-2-24
Boom Cylinder Boom Cylinder
Swing Control Valve

Main Control Valve 4-Spool Section
Holding Valve
Check Valve
Holding Valve
Switch Valve
Boom 3
Boom1
Boom 2
Holding Valve
Check Valve
5-Spool Section
Main Pump 1
Holding Valve
Main Pump 2 Switch Valve
Main Pump 3
T18E-02-02-012
T2-2-25
Loading Shovel
Boom Raise:
boom 2 spool in the 5-spool section of the main
control valve. Pressure oil from main pump 2 flows
through the boom 1 spool in the 4-spool section of
pump 1 and 2 merges, and flows to the boom cyl-
inder bottom side and the level cylinder rod side af-
ter passing through holding valve check valve.
boom 3 spool in the swing control valve and the
holding valve check valve.
Boom Lower:
Pressure oil from the main pump 2 flows is fed to
the boom cylinder rod side and the level cylinder
bottom side through the boom 1 spool in the
4-spool section of the main control valve. Pressure
oil from the main pump 3 flows back into the hy-
draulic oil tank through the boom 3 spool in the
swing control valve, so that it does not flow to the
boom cylinder rod side even when the spool is
shifted.
The lowering side of the boom 2 spool in the
5-spool section of the main control valve is exclu-
sively used for boom regeneration. Only the return
oil from the boom cylinder bottom side flows there.

functions.
T2-2-26
Level
Cylinder
Swing Control Valve

Holding Valve
Check Valve
Holding Valve
Switch Valve
Boom 3
Boom 1
Boom 2
Holding Valve
Check Valve
5-Spool Section
Main Pump 1
Holding Valve
Main Pump 3
T18E-02-02-013
T2-2-27
• Arm Operation
Backhoe
Arm Roll-In:
The return oil from the arm cylinder rod side flows
into the arm 1 spool in the 5-spool side of the main
control valve. The return oil is twice reduced by the Check Valve
orifices at the arm 1 spool and the arm regenerative
valve in order to increase the pressure on the arm
cylinder rod side. When this pressure exceeds that
Arm 1 Spool
on the arm cylinder bottom side, the check valve in
the arm 1 spool opens.
The return oil from the arm cylinder rod side com-
bines with that from the main pump 1, and then Orifice
flows again to the arm cylinder bottom side.
Pressure oils from the main pump 2 and main pump
3 flow to the arm cylinder bottom side through the
arm 2 spool in the 4-spool section of the main con-
trol valve and the arm 3 spool of the swing control Arm Re-
generative
valve, respectively. The return oil does not flow Valve
through the swing control valve, because it is
blocked by a check valve in the return route to the Orifice
swing control valve.
Arm Roll-Out:
Pressure oil from main pumps 1 and 2 flows to the
arm cylinder rod side while taking the same oil pas-
sages as those of arm roll-in operation and opening T111-02-05-035
the holding valve check valve. Pressure oil from

main pump 3 passes through arm 3 spool in the
swing control valve, opens the check valve, and
flows to the arm cylinder rod side.

functions.
T2-2-28
Arm
Cylinder
Swing Control Valve
Holding Valve
Check Valve
Arm 3 Arm 1
Arm 2
Check
Valve
5-Spool Section
Holding Valve
Switch Valve Main Pump 1
Main Pump 2 Arm Regenerative Valve
Main Pump 3
T18E-02-02-014
T2-2-29
Loading Shovel
Arm Extend:
The return oil from the arm cylinder rod side flows
into the arm 1 spool in the 5-spool side of the main
control valve. The return oil is twice reduced by the
orifices at the arm 1 spool and the arm regenerative Check Valve
valve in order to increase the pressure on the arm
cylinder rod side. When this pressure exceeds that
on the arm cylinder bottom side, the check valve in
Arm 1 Spool
the arm 1 spool opens.
The return oil from the arm cylinder rod side com-
bines with that from the main pump 1, and then
flows again to the arm cylinder bottom side. Orifice
Pressure oils from the main pump 2 and main pump
3 flow to the arm cylinder bottom side through the
arm 2 spool in the 4-spool section of the main con-
trol valve and the arm 3 spool of the swing control
valve, respectively. The return oil does not flow Arm Re-
generative
through the swing control valve, because it is Valve
blocked by a check valve in the return route to the
swing control valve. Orifice
Arm Retract:
Pressure oil from main pumps 1 and 2 flows to the
arm cylinder rod side while taking the same oil pas-
sages as those of arm extend operation and open-
ing the holding valve check valve. Pressure oil from T111-02-05-035
main pump 3 passes through arm 3 spool in the

swing control valve, opens the check valve, and
flows to the arm cylinder rod side.

functions.
T2-2-30
Arm
Cylinder
Swing Control Valve
Holding Valve
Check Valve
Arm 3 Arm1
Arm 2
Check
Valve
5-Spool Section
Holding Valve
Switch Valve Main Pump 1
Main Pump 2 Arm Regenerative Valve
Main Pump 3
T18E-02-02-015
T2-2-31
• Bucket Operation
Bucket Roll-In (Backhoe) / Tilt-In (Loading Shovel)
Pressure oil from main pump 1, main pump 2, and
main pump 3 flows to the bucket cylinder bottoms
after passing through the bucket 2 spool in the
5-spool section of the main control valve, the bucket
1 spool in the 4-spool section of the main control
valve, and the bucket 3 spool in the swing control.
Bucket Roll-Out (Backhoe) / Tilt-Out (Loading

Shovel)
Pressure oil from main pump1 and 2 is routed to the
bucket cylinder rod side after passing through the
bucket 2 spool in the 5-spool section and the bucket
1 spool in the 4-spool section of the main control
valve, respectively. Pressure oil from main pump 3
doesn’t flow to the bucket cylinder rod side because
the oil circuit from the bucket 3 spool to the bucket
cylinder is blocked.
T2-2-32
NOTE: The drawing shown in the below is

Backhoe.
Bucket
Cylinder
Swing Control Valve
Bucket 1
Bucket 2
Bucket 3
5-Spool Section
Main Pump 1
Main Pump 2
Main Pump 3
T18E-02-02-016
T2-2-33
• Bucket Open/Close Operation (Loading Shovel only)
Bucket Open:
Pressure oil from main pump 1 flows to the bucket
open/close cylinder rod side after passing through
the bucket open/close spool in the 5-spool section
of the main control valve.
Bucket Close:
Pressure oil from main pump1 flows to the bucket
open/close cylinder bottom side after passing
through the bucket open/close spool in the 5-spool
section.
T2-2-34
Bucket Open/close
Cylinder
5-Spool Section
Backet
Open/Close
Main Pump 1
T18E-02-02-017
T2-2-35
• Travel Operation
Left Travel:
Pressure oil from main pump 1 is routed into the left
travel motor via the left travel spool in the 5-spool
section of the main control valve.
Right Travel:
Pressure oil from main pump 2 is routed into the
right travel motor via the right travel spool in the
4-spool section of the main control valve.
• Swing Operation
swing motor via the swing spool in the swing control
valve.
T2-2-36
NOTE: The drawing shown in the below is Backhoe.
Left Right
Travel Travel
Motor Motor
Swing Control Valve
Swing
Swing Motor 5-Spool Section
Main Pump 1
Main Pump 2
Main Pump 3
T18E-02-02-018
T2-2-37
Combined Operations
• Swing and Boom Combined Operation
When swing and boom raise combine operation is
performed, the swing and boom 1, 2, and 3 spools
are shifted. Pressure oil from main pump 1 is routed
to the boom 2 spool after passing through the aux-
iliary and boom 2 spools in the 5-spool section of
pump 2 is routed to the boom 1 spool via the paral-
lel circuit after passing through the right travel spool
in the 4-spool section of the main control valve.
Then, both pressure oils are jointly routed to the
bottom of boom cylinders via the holding valve
check valve. Pressure oil from main pump 3 enters
the swing control valve. Then, it is separately routed
to the boom 3 spool and the swing spool. Pressure
oil from the boom 3 spool is routed to the boom cyl-
inder bottoms via the holding valve check valve.
Pressure oil from the swing spool is routed to the
swing motor via the parallel circuit.
For simultaneous operation of swing and boom low-

ering, the pressure oil from the main pump 2 flows
to the boom cylinder rod side through the travel
(right) spool in the main control valve and the paral-
lel circuit. The pressure oil from the boom 3 spool in
the swing control valve does not flow into the hy-
draulic oil tank, because it is blocked by the swing
spool. The pressure oil from the main pump 3 flows
into the swing spool through the parallel circuit.
The return oil from the boom cylinder flows back
into the hydraulic oil tank through the boom 1 spool
and boom 2 spool.
T2-2-38
NOTE: The drawing shown in the below is Back-

hoe.
Right
Travel
Swing Control Valve
Holding Valve Parallel
Check Valve Circuit Parallel Circuit
Holding Valve
Switch Valve
Boom 3
Swing
Boom 1
Boom 2
Arm 1
Holding Valve
Auxiliary Check Valve
Swing Motor
5-Spool Section
Main Pump 1
Holding Valve
Main Pump 3
T18E-02-02-019
T2-2-39
• Swing and Arm Combined Operation
When swing and arm combined operation is per-
formed, the swing spool and arm spools 1, 2, and 3
are shifted. Pressure oil from main pump 1 is routed
to arm 1 spool via the auxiliary spool in the 5-spool
section of the main control valve. Pressure oil from
main pump 2 is routed to arm 2 spool via the paral-
lel circuit in the 4-spool section of the main control
valve. Then, both pressure oil flows are jointly
routed to the arm cylinder.
Pressure oil from main pump 3 enters the swing

control valve and pressure oil flows to the swing
spool and arm spool 3.
When swing and arm roll-out (backhoe) / arm re-
tract (loading shovel) combined operation is per-
formed, the arm 3 spool in the swing control valve is
not shifted as pilot pressure oil to the arm 3 spool is
blocked by the arm preference valve. Then, the re-
turn oil from the arm cylinder cannot pass through
arm 3 spool, restricting the return oil flow. Thereby,
arm hesitation while rolling out (backhoe) / retracting
the arm (loading shovel) is prevented. When swing,
boom raise, and/or bucket function is operated, the
arm preference valve is shifted, blocking the pilot
pressure oil flow to the arm roll-out (backhoe) / arm
retract (loading shovel) spool.
(Refer to T2-2-15.)
T2-2-40
NOTE: The drawing shown in the below is Swing

and Arm Roll-In (Backhoe) Combined.
Arm
Cylinder
Parallel Circuit
Swing Control Valve Main Control Valve 4-Spool Section
Parallel Circuit
Swing
Arm 2
Arm 3 Arm 1
Auxiliary
Swing
Motor
Arm
Preference
Valve 5-Spool Section
Main Pump 1
Main Pump 2
Main Pump 3
T18E-02-02-020
T2-2-41
• Boom and Arm Combined Operation
Boom Lower and Arm Roll-In (Backhoe) / Arm Ex-
tend (Loading Shovel):
When boom lower and arm roll-in (backhoe) / arm
extend (loading shovel) combine operation is made,
both boom 1, 2, 3 spools and arm 1, 2, 3 spools are
operated.
Pressure oil from main pump 1 is routed to the arm
spool 1 via the auxiliary spool in the 5-spool section
of the main control valve. Pressure oil from main
pump 2 is routed to the boom 1 spool and the arm 2
spool via the parallel circuit in the 4-spool section of
the main control valve.
When pressure in the bottom of the boom cylinder
is higher than pressure in the boom cylinder rod
side, pressure oil in the bottom of the boom cylinder
flows into the boom cylinder rod sides via the boom
2 spool, accelerating the boom lower speed.
Pressure oil from main pump 3 is routed to the arm
3 spool in the swing control valve. Both pressure oil
from the boom 1 spool and the boom 2 spool are
jointly routed into the boom cylinder rod side.
Pressure oil from the arm 1, 2, and 3 spools are

jointly routed into the arm cylinder bottom side.
The holding valve switch valves in the boom 1 and
boom 3 raise circuits are shifted by the boom lower
pilot pressure so that the holding valve check valve
is opened.
The return oil from the boom cylinders flows back to
the hydraulic oil tank through the holding check
valve and the boom 1 and 3 spools.
The holding valve switch valves in the arm 1 roll-out
(backhoe) / retract (loading shovel) circuit are
shifted by the arm roll-out (backhoe) / retract (load-
ing shovel) pilot pressure so that the holding valve
check valve is opened.
The return oil from the arm cylinder is routed to the
arm 1 spool via the holding check valve. The return
oil flow from the arm cylinder is restricted by the ori-
fice in the spool and the arm oil flow regenerative
control valve. When the return oil pressure in-
creases more than the bottom side pressure the
return oil doesn’t flow back to the hydraulic oil tank
but is routed to the arm cylinder bottom through the
arm 1 spool check valve.
(Refer to the COMPONENT OPERATION/Control
Valve group for the boom and arm holding valve and
the arm regenerative valve.)
T2-2-42
NOTE: The drawing shown in the below is Boom

Lower and Arm Roll-In (Backhoe) Com-
bined.
Boom Cylinder Arm Boom Cylinder

Cylinder
Parallel
Circuit
Swing Control Valve

Holding Valve
Holding Valve Check Valve
Check Valve
Boom 3
Boom 1
Boom 2
Arm 1
Arm 3
Holding Valve
Check Valve Arm 2
Holding Valve
Auxiliary Check Valve
5-Spool Section
Holding Valve
Holding Valve Main Pump 1 Switch Valve
Switch Valve Arm Regenerative
Main Pump 2 Valve
Main Pump 3
T18E-02-02-021
T2-2-43
• Boom Raise and Arm Roll-Out (Backhoe) / Arm Re-
tract (Loading Shovel):
When boom raise and arm roll-out (backhoe) / arm
retract (loading shovel) combined operation is made,
both boom 1, 2, 3 spools and arm 1 spool are oper-
ated.
Arm 2 spool is not shifted as pilot pressure oil from
the arm flow rate control valve in the signal control
valve acts on the arm roll-in (Backhoe)/arm extend
(Loading shovel) side of arm 2 spool.
Pressure oil from main pump 1 is routed to the
boom 2 spool via the parallel circuit and the arm 1
spool via the auxiliary spool in the 5-spool section of
boom 1 spool via the parallel circuit in the 4-spool
section of the main control valve.
boom 3 spool in the swing control valve. Pressure
oil is not routed to the arm 3 spool since the parallel
circuit is not provided. Therefore, the boom raise
speed is ensured.
When boom raise and arm roll-out (backhoe) / arm
retract (loading shovel) combined operation is per-
formed, the arm 3 spool is not shifted as pilot pres-
sure oil to arm 3 spool is blocked by the arm pref-
erence valve. Then, the return oil from the arm cyl-
inder cannot pass through arm 3 spool, restricting
the return oil flow. Thereby, arm hesitation while
rolling out (backhoe) / retracting the arm (loading
shovel) is prevented. When swing, boom raise,
and/or bucket function is operated, the arm prefer-
ence valve is shifted, blocking the pilot pressure oil
flow to the arm roll-out (backhoe) / arm retract
(loading shovel) spool.
(Refer to the arm roll-out (backhoe) / arm retract
(loading shovel) and bucket roll-in (tilt-in), boom
raise, swing combined operation circuit.)
Pressure oil from the boom 1 spool, the boom 2
spool, and the boom 3 spool is routed jointly to the
boom cylinder bottoms after passing through the
holding valve check valves. Pressure oil from the
arm 1 spool and the arm 2 spool are jointly routed to
the arm cylinder rod side after passing through the
holding valve check valve.
T2-2-44
Arm Cylinder
Boom Cylinder
Swing Control Valve
Holding Valve Main Control Valve

4-Spool Section
Check Valve
Boom 3
Boom 1
Boom 2
Arm 2
Arm 1
Holding
Arm 3 Valve
Check Holding Valve
Valve Check Valve
Auxiliary
5-Spool Section
Arm
Preference Main Pump 1 Parallel
Boom Raise
Valve Circuit
Pilot Main Pump 2
Pressure
Main Pump 3
Parallel
Arm Roll-Out Circuit
Pilot
Pressure
Arm Flow Rate Signal Control Valve

Control Valve
NOTE: The drawing shown in the

above is Boom Raise and
Arm Roll-Out (Backhoe)
Combined.
T18E-02-02-022
Arm Roll-out (Backhoe)
Boom Raise Pilot
Arm retract (Loading shovel)
Pressure
Pilot Pressure
T2-2-45
• Travel and Front Attachment Combined Operation
When travel and front attachment such as boom
raise combined operation is made, the travel spools
(right and left) and boom 1,2,3 spools are operated.
As the boom spools are moved, the signal pilot
pressure increases so that the flow combiner valve
in the main control valve is shifted. Pressure oil from
main pump 1 is routed to the boom 2 spool via the
auxiliary and arm 1 spools in the 5-spool section of

right travel motor via the right travel spool in the
4-spool section of the main control valve. On the
other hand, pressure oil is routed into the left travel
motor via the flow combiner valve, the left travel
spool so that the machine can travel straight.
boom 3 spool in the swing control valve. Pressure
oil from boom 2 and 3 spools are jointly routed to
the boom cylinder bottoms.
T2-2-46
NOTE: The drawing shown in the below is Backhoe.
Left Right
Travel Travel
Motor Flow Combiner Valve Motor
Right 4-Spool
Main Control Valve Travel Section
Swing Control Valve
Boom 3 Left
Travel
Boom 2
Boom1
Arm 1
Auxiliary
5-Spool Section
Main Pump 1
Main Pump 2
Main Pump 3
T18E-02-02-023
T2-2-47
PUMP TRANSMISSION OIL COOLING
CIRCUIT
The pump transmission oil pump draws transmission

oil and delivers it to the oil cooler. After being cooled in
the oil cooler, the transmission oil is returned into the
pump transmission via each lubricating section.
Thereby, oil temperature increase is prevented, foreign
matter is filtered and removed, and each part in the
pump transmission is lubricated.
OIL COOLER FAN MOTOR CIRCUIT
Refer to the CONTROL SYSTEM Section.
Manifold
Oil Cooler
Engine
Pump
Transmission
Suction Filter Transmission Oil

Filter Pump
T183-02-02-022
T2-2-48
SYSTEM / Electrical System
OUTLINE
The electrical system roughly falls into three sections

such as the main circuit, the control circuit, and the
monitor circuits.
• Main Circuit
Engine and accessory circuit
• Control Circuit
Engine and pump control circuits consisting of ac-
tuators such as solenoid valves, main controller A
and B, ECM (Engine Control Module), sensors,
pressure switches, etc.
• Monitor Circuit
Machine operation status indication circuit consist-
ing of sensors, switches, etc.
Outline of the major functions and construction of the

main circuit are explained hereafter.
• Power Source Circuit

Supplies electric power to all electrical systems on
the machine.
• Bulb Check Circuit

Checks for burned monitor warning lights and indi-
cator bulbs.
• Engine Start Circuit

Rotates the starter to start the engine.
• Charging Circuit
Recharges the batteries and supplies current to all
the electrical components from the alternator.
• Accessory Circuit
Operates when the key switch is in the ACC posi-
tion.
• Surge Voltage Prevention Circuit

Protects the electrical equipment such as the con-
troller from surge voltage developed when stopping
the engine.
T2-3-1
POWER SOURCE CIRCUIT
Negative terminal of the battery is connected to the

vehicle frame. When the key switch is OFF, battery
current is supplied to the monitor, main controller B,
DLU and ECM as backup power.
Fuse Box 1 Key Switch
DLU
Fusible Link
Battery
Relay 2
Fuse Box 2
Load Damp
Relay Battery
Relay 1
Battery
Monitor
Controller
ECM
Main
Controller B
T18E-02-03-007
T2-3-2
BULB CHECK CIRCUIT
When the key switch is turned ON, terminal B is con-

nected to terminals ACC and M in the key switch. The
current from terminal M magnetizes battery relay 2 so
that battery current is routed to the monitor controller
via battery relay 2, the 1 pole junction, and the fuse
box 1, turning all warning lights and indicators on the
monitor panel ON.
Any warning light and/or indicator which doesn’t come
ON at this time may have burned out.
Fuse Box 1 Key Switch
Fusible Link
1 Pole
Junction
Battery
Relay 2
Engine Stop
Solenoid Relay
Battery
Relay 1
Battery
Monitor T18E-02-03-008
Controller
T2-3-3
ENGINE START CIRCUIT
1. When the key switch is turned ON, current from 9. Current from the alternator terminal R is applied
key switch terminal M magnetizes battery relays 1 to starter relay 2 terminal R to demagnetize
and 2 via fuse #10 in fuse box 1. starter relay 2.
2. When battery relays 1 and 2 are magnetized, 10. Consequently, starter relay 2 is turned OFF so
battery current is routed to starter motors (2 used) that starter relay 1 magnetizing current is cut off,
terminals B via battery relays 1 and 2. turning starter relay 1 OFF.
3. When the key switch is set to the START position, 11. When magnetizing current routed to starter motor
current from key switch terminal G2 is applied terminal C from the starter relay 1 is cut off, the
through fuse #19 in fuse box 1 in order to mag- main contactor is turned OFF, causing the pinion
netize starter relay 1. gear in the starter to retract.
4. When starter relay 1 is magnetized, battery cur- 12. At the same time, battery current is cut off so that
rent is routed to terminal S in starter relay 2 via starter motor stops rotating.
battery relay 2, fusible link 5 and starter relay 1. 13. While the engine is rotating (when the alternator
5. When current is routed to terminal S in starter re- is generating), no current is routed to starter ter-
lay 2, the coil in starter relay 2 is magnetized and minal C. Therefore, even if the key switch is
terminal B is connected to terminal C. turned to the START position, the starter will not
6. When terminal B is terminal C in the starter motor, rotate.
the coil in the starter motor is magnetized, draw-
ing main contactor so that the contact point is
closed. At the same time, the pinion gear is ex-
tended to engage with the engine ring gear.
7. When the main contactor contact point is closed,
battery current is routed to the motor from starter
motor terminal B, rotating the motor.
8. Once the engine starts, the alternator begins to
generate electricity and supplies current from al-
ternator terminals B and R.
T2-3-4
Key Switch
Fusible Link 1
Fuse Battery
1 Pole
Box 1 Relay 2
Junction
Fusible Link 5
Fusible
Link 6
Fusible
Link 7 Battery
Relay 1
Fusible
Link 8
Battery
Fuse
Box 2 Alternator
Starter Relay
Safety Relay 2
Starter Motor 2
Safety Relay 1
Starter Motor 1
ECM
T18E-02-03-010
T2-3-5
CHARGING CIRCUIT (KEY SWITCH: ON)
When the key switch is released after the engine Current from alternator terminal B is routed to the bat-
starts, the key switch returns to the ON position. In the teries via fusible link #6 (100 A) and the battery relay,
ON position, key switch terminal B is connected to recharging the batteries. At the same time, current
terminals ACC and M in the key switch. After the en- from alternator terminal B flows to all electrical circuits
gine starts, the alternator is rotated, starting genera- via the junction box, fusible link, fuse box 1, and fuse
tion. box 2. Current from alternator terminal R is routed to
the monitor controller turning the alternator indicator
OFF.
Connection in Fusible Link

Fusible Link Connecting Fuse Box Connected to: Remarks
#1 Fuse Box 1 #1 Monitor (Backup), DLU Backup Power,
(45 A) Main Power
#2 Main Controller B Main Power
Fuse Box 2 #1 ECM Main Power
#2 Fuse Box 1 #11 Work Light Relays 1 and 2 Power
(75 A) #12 Washer Relay, Wiper Relay (L, H1, H2), Power
Wiper Motor
#13 Air Conditioner Power
#14 Auto-Lubrication Solenoid Valve Relay, Power
Flow Rate Decrease Solenoid Valve Relay,
Power Transistors 1, 2 and 3
#3 Fuse Box 1 #4 DC-DC Converter Power
(75 A) #5 Main Controllers A and B Solenoid
Power
#6 Travel Alarm Power
#7 Monitor (Input Power), Main Controller A Main Power
#8 Step Light Relay
#9 Air Conditioner Power
#4 − Preheat Signal Relay Power
(45 A)
#5 − Starter Relay 1 Power
(250 A)
#6 − Alternator Power
(100 A)
#7 − Preheat Relay 1 Power
(125 A)
#8 − Preheat Relay 2 Power
(125 A)
T2-3-6
Key Switch
Fusible Link 1
1 pole Battery Relay 2

Fuse Box 1 Fusible Link 2 Junction
Fusible Link 3
Fusible Link 4
Battery Relay 1
Fusible Link 5
Battery
Fusible
Link 6
Fusible
Fuse Box 2 Link 7 Alternator
Fusible Link 8
Starter Relay
Air Heater 2
Air Heater 1
Monitor
Controller
T18E-02-03-011
T2-3-7
ACCESSORY CIRCUIT
When the key switch is turned to the ACC position,

terminal B is connected to terminal ACC in the key
switch. Current from terminal ACC is routed to the ra-
dio, cigar lighter, cab light, and horn via fuses #15, #16,
#17 and #18.
Fuse
Box 1 Key Switch
Fusible
Radio Link #1
Cigar
Lighter
Cab
Light
Horn
Battery Relay 2
Battery Relay 1
Battery
T18E-02-03-009
T2-3-8
(Blank)
T2-3-9
SURGE VOLTAGE PREVENTION CIRCUIT
The surge voltage prevention circuit prevents the oc-

currence of surge voltage developed when the engine
is stopped to protect electronic components such as
the main controller from being damaged by this surge
voltage. When the key switch is turned OFF while the
engine is running, current from key switch terminal M
to the battery relay is interrupted, deactivating the bat-
tery relay.
The engine, however, will continue running for a while

due to its inertia soon after the key switch is turned
OFF. Consequently, if the battery relay is turned OFF
at this time, current from alternator terminal B cannot
flow to the batteries, casing surge voltage to develop
in the circuit. Battery current is constantly routed to
main controller B. To keep the battery relay ON while
the engine is running, the main controller B built in
timer allows the ground circuit of power transistor 3 to
close for 15 seconds after the key switch is turned
OFF. Therefore, the load damp relay is kept ON for 15
seconds so that current to magnetize the battery relay
is kept supplied. Consequently, current from alternator
terminal B is routed to the batteries via the battery re-
lay, preventing the occurrence of surge voltage.
T2-3-10
Key Switch
Fuse
Box 1
Fusible link 1
1 Pole
Junction Battery Relay 2
Fusible link 3
Battery Relay 1
Load Fusible link 5

Damp Battery
Relay Fusible
link 6
Power
Transistor 3 Fusible
link 7 Alternator
Fusible link 8
Main
Controller B
Monitor
Controller
Safety Relay 2
Safety Relay 1
T18E-02-03-012
T2-3-11
(Blank)
T2-3-12
MEMO
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SECTION 3
COMPONENT OPERATION
CONTENTS
Group 1 Pump Device Group 5 Travel Device
Outline .....................................................T3-1-1 Outline .....................................................T3-5-1
Main Pump, Oil Cooler Fan Motor Travel Reduction Gear..............................T3-5-2
Drive Pump ............................................T3-1-2 Travel Motor .............................................T3-5-3
Regulators................................................T3-1-5 Travel Brake Valve ...................................T3-5-5
3-Unit Pump ...........................................T3-1-26 Travel Motor Displacement
Angle Change.......................................T3-5-10
Group 2 Swing Device Parking Brake.........................................T3-5-12
Outline .....................................................T3-2-1
Swing Motor .............................................T3-2-2 Group 6 Signal Control Valve
Valve Unit .................................................T3-2-4 Outline .....................................................T3-6-1
Swing Parking Brake ................................T3-2-6 Pilot Port ..................................................T3-6-2
Swing Reduction Gear..............................T3-2-7 Shuttle Valve ............................................T3-6-6
Shockless Valve .....................................T3-6-10
Group 3 Control Valve Pump 1 and 2 Flow Rate Control Valve...T3-6-14
Outline .....................................................T3-3-1 Arm Flow Rate Control Valve,
Hydraulic Circuit .....................................T3-3-10 Flow Combiner Valve Control Spool,
Flow Combiner Valve..............................T3-3-12 Priority Valve ........................................T3-6-16
Main Relief Valve....................................T3-3-14
Overload Relief Valve .............................T3-3-15 Group 7 Other (Upperstructure)
Make-Up Valve .......................................T3-3-15 Pilot Shut-Off Valve ..................................T3-7-1
Holding Valve .........................................T3-3-16 Shockless Valve .......................................T3-7-2
Arm Regenerative Valve .........................T3-3-18 Solenoid Valve..........................................T3-7-6
Boom Overload Relief Pressure Oil Cooler Fan Motor ................................T3-7-8
Switch Valve .........................................T3-3-20 Accumulator .............................................T3-7-9
Auto-Lubrication System.........................T3-7-10
Group 4 Pilot Valve
Outline .....................................................T3-4-1 Group 8 Other (Undercarriage)
Operation .................................................T3-4-2 Swing Bearing ..........................................T3-8-1
Center Joint..............................................T3-8-2
Track Adjuster ..........................................T3-8-3
18FT-3-1
(Blank)
18FT-3-2
COMPONENTS OPERATION / Pump Device
OUTLINE
The pump device consists of the pump transmission, The 2nd pump is a pilot pump supplying pressure oil
main pumps and 3-unit pump. Power from the engine to the pilot circuit. The 3rd (farthest away from the
is transmitted to each pump through the pump trans- pump transmission) is a transmission oil circulation
mission. The gear reduction ratio for the main pumps pump.
is 1.083 and for the 3-unit pump is 1.106. The oil cooler fan motor drive pump is a variable dis-
The main hydraulic pump is a variable displacement placement swash plate plunger type pump.
swash plate tandem plunger type pump, supplying The pilot pump and the transmission oil circulation
high pressure hydraulic oil to the main circuit. pump are gear pumps.
The 3-unit pump consists of three pumps of various
types. From the pump transmission side, the 1st pump
is the oil cooler fan motor drive pump.
Main Pump 3
Pump
Transmission
Main Pump 2
Main Pump 1
3-Unit Pump
T183-01-02-006
T3-1-1
MAIN PUMP, OIL COOLER FAN MOTOR
DRIVE PUMP
The shaft is connected to the cylinder block via a
spline coupling. The plungers are inserted into the
cylinder block bores.
Engine driving force is transmitted to the shaft via the
pump transmission. As the shaft rotates, the plunger
rotates align with cylinder block, sliding along the sur-
face of the shoe plate. Because the swash plate is po-
sitioned at an angle against the plungers, the plungers
reciprocate in the cylinder block bores, drawing and
discharging hydraulic oil.
Shaft Shoe Plate Servo Piston
Swash Plate Plunger Cylinder Block

W142-02-03-010
T3-1-2
Flow Rate Increasing/Decreasing Operation
The flow rate of the pump is varied by changing the

angle of the swash plate which changes the stroke of
the plunger. When pressure oil from the regulator
moves the servo piston, the swash angle changes
accordingly as the swash plate is connected to the
servo piston.
Servo Piston
Shaft
Valve Plate
Cylinder Block
Plunger
Swash Plate
T142-02-01-001
T3-1-3
(Blank)
T3-1-4
REGULATORS
The regulators are located on the main pump and oil • Horsepower Reducing Control (only for Main
cooler fan motor drive pump to control the flow rate. Pump)
When the E mode switch is turned ON, the horse-
Regulator Controls power reducing control pressure PG, from the
• Constant Torque Control horsepower reducing solenoid valve SA, acts on
Control the pump flow rate depending on the the main pump 3, and reduces the pump swash
pump delivery pressure in order to maximize angle.
-1
utilization of the engine horsepower. The control When the engine speed slows to 1400 min or
includes the following two operations: less, the horsepower reducing control pressure
(1) Overload Prevention Operation: PG, from the horsepower reducing solenoid
When the delivery pressure increases, reduce the valves SA/SB, acts on all main pumps, and re-
flow rate by reducing the pump swash angle. duce the pump horsepower by reducing the pump
(2) Flow Rate Recovery Operation: swash angle.
When the delivery pressure decreases, increase • Horsepower Increasing Control (only for Main
the flow rate by increasing the pump swash an- Pump)
-1
gle. When the engine speed increases to 1550 min
• Flow Rate Control or more, the horsepower increasing control pres-
On the regulator for the main pump, flow rate sure PZ, from the horsepower increasing solenoid
controls pressure Pi from the signal control valve valve ST, increases the pump horsepower by in-
controls the pump swash angle. Consequently, creasing the pump swash angle.
the pump delivers the flow rate according to the • Smaller Swash Angle (Less Flow Rate) Priority
lever operation, reducing the fuel consumption. Control
On the regulator for the oil cooler fan motor drive It two or more orders to increase/decrease the
pump, flow rate control pressure Pi from the fan pump flow rate are given simultaneously to the
pump solenoid valve SF controls the flow rate by regulator, the one to indicate the smallest pump
changing the pump swash angle. flow rate will have the higher priority.
Position of Ports
Main Pump Oil Cooler Fan Motor Drive Pump
Pi
Pi
PZ
Psv
PG
T183-03-01-101
P- Pump Delivery Pressure Pi- Flow Rate Control Pressure (Flow Rate Reducing Solenoid
Valve, Signal Control Valve)
PG- Horsepower Reducing Control Pressure (Horsepower Reduc- Psv- Pump Servo Assisting Pressure (Pilot Pump)
ing Solenoid Valve SA, SB)
PZ- Horsepower Increasing Control Pressure (Horsepower In-
creasing Solenoid Valve)
T3-1-5
Cross Section (Regulator for Main Pump)
B T183-03-01-002
A
Cross Section A-A
1 2 3 4 5 6 7 8 9 10 11
Pi
14 13 12
T117-02-01-006
1- Inner Spring 5- Pin 9 - Pin 12 - Feedback Lever
2- Sleeve 6- Pin 10 - Pilot Piston 13 - Pin
3- Spool 7- Lever 1 11 - Spring 14 - Servo Piston
4- Pin 8- Hole
T3-1-6
Cross Section B-B
15 16 17 18 19 20 21 22 23
Pz
PG
24
T117-02-01-007
15 - Piston 18 - Pin 21 - Outer Spring 23 - Piston

16 - Compensating Piston 19 - Hole 22 - Inner Spring 24 - Pin
17 - Lever 2 20 - Compensating Piston
T3-1-7
Cross Section (Regulator for Fan Motor Drive
Pump)
A
B
A B T183-03-01-102
Cross Section A-A
1 2 3 5 6 25 7 8 9 10 11
Pi
14 13 12
T146-03-01-008
1- Inner Spring 6- Pin 10 - Pilot Piston 13 - Pin

2- Sleeve 7- Lever 1 11 - Spring 14 - Servo Piston
3- Spool 8- Hole 12 - Feedback Lever 25 - Pin
5- Pin 9- Pin
T3-1-8
Cross Section B-B
15 16 17 18 19 20 21 22
24
T146-03-01-005
15- Piston 18- Pin 20- Compensating Piston 22- Inner Spring
16- Compensating Piston 19- Hole 21- Outer Spring 24- Pin
17- Lever 2
T3-1-9
Link Mechanism
Movement of pilot piston (10) is transmitted to lever 1 For this reason, when lever 1 (7) or lever 2 (17) rotates,
(7) via pin (9). Lever 1 (7) rotates around pin (4), which pin (5) comes into contact with the hole edge on the
is fixed to the support plug. lever, and is moved further. As a result, feedback lever
Movement of compensating rod (20) is transmitted to (12) rotates around pin (13) located on servo piston
lever 2 (17) via pin (24). Lever 2 (17) rotates around (14). On the other hand, when compensating rod (20)
pin (18), which is fixed to the housing. and pilot piston (10) are not moved, i.e. levers 1 and 2
Pin (5) is threaded through a hole on feedback lever do not move, and when servo piston (14) is moved,
(12), and the ends of pin (5) are inserted in a hole on feedback lever (12) rotates around pin (5), so that
levers 1(7) and 2 (17) respectively. (The hole is larger spool (3) moves.
than the pin (5) diameter.)
18 NOTE: To decrease swash angle

24 To increase swash angle
17
Housing 19
12
20
6
5
7
8
4
9
3 Support Plug
13
10
14
T117-02-01-009
3- Spool 7- Lever 1 12- Feedback Lever 18- Pin

4- Pin 8- Hole 13- Pin 19- Hole
5- Pin 9- Pin 14- Servo Piston 20- Compensating Rod
6- Pin 10- Pilot Piston 17- Lever 2 24- Pin
T3-1-10
(Blank)
T3-1-11
Constant Torque Control
• Overload Preventing Operation
1. If pump delivery pressure P rises from P1 to P2, 7. As servo piston (14) moves, feedback lever (12)
compensating piston (16) moves compensating moves via pin (13). Since compensating rod (20)
rod (20) to the right until it balances with outer and lever 2 (17) do not move, feedback lever (12)
spring (21) and inner spring (22). rotates counterclockwise around pin (5), shifting
spool (3) to the left until the notches on spool (3)
2. Movement of compensating rod (20) is transmit- and sleeve (2) close completely. As these notches
ted to lever 2 (17) via pin (24), rotating lever 2 close, the pump pressure stops acting on the
(17) counterclockwise around pin (18). servo piston large chamber. Consequently, the
movement of servo piston (14) stops.
3. Since pin (5), which is connected to feedback
lever (12), is inserted into hole (19) on lever 2 8. With the above operation, the pump delivery flow
(17), feedback lever (12) rotates around pin (13) rate decreases from Q1 to Q2, relieving exces-
clockwise as lever 2 (17) rotates, moving spool sive load otherwise applied to the pump.
(3) to the right.
4. As spool (3) is moved, pump pressure P is routed

to the servo piston large chamber via spool (3).
Although pump pressure P is also routed to the
servo piston small chamber, servo piston (14) is
moved to the right due to the difference in pres- Q
sure receiving area between the servo piston (Flow Rate)
ends.
Q1
5. As servo piston (14) is moved to the right, the Q2

pump displacement angle decreases corre-
sponding to the distance that servo piston (14)
has moved, decreasing the pump delivery flow
rate.
P1 P2 P (Pump Delivery
6. As the pump pressure P acts on the compensat- Pressure)
ing piston (16), compensating rod (20) and lever
2 (17) do not move even if servo piston (14)
moves.
T3-1-12
1 2 16 3 17 18 5 19 20 21 22
Pz
PG
Large Chamber Small Chamber Pressure

(P1 → P2)
14 13 12 24
18
24 T117-02-01-010
17
Housing 19
12
2
14
13
T117-02-01-009
1- Spring 12- Feedback Lever 17- Lever 2 21- Outer Spring
2- Sleeve 13- Pin 18- Pin 22- Inner Spring
3- Spool 14- Servo Piston 19- Hole 24- Pin
5- Pin 16- Compensating Piston 20- Compensating Rod
T3-1-13
• Flow Rate Recovery Operation
1. If pump pressure P drops from P2 to P1, com- 6. As servo piston (14) is moved and because com-
pensating piston (16) (along with compensating pensating rod (20) and lever 2 (17) do not move,
rod (20)) is returned to the left until it balances feedback lever (12), which is connected to servo
against outer spring (21) and inner spring (22). piston (14) via pin (13), also rotates clockwise
around pin (5), moving spool (3) to the right until
2. Movement of compensating rod (20) is transmit- the notches on sleeve (2) are completely closed,
ted to lever 2 (17) via pin (24), rotating lever 2 thus closing the line from the servo piston large
(17) clockwise around pin (18) which is fixed to chamber to the hydraulic oil tank. As a result,
the housing. movement of servo piston (14) stops
3. Since pin (5), which is connected to feedback 7. With the above operation, the pump delivery flow
lever (12), is inserted into hole (19) on lever 2 rate increases from Q2 to Q1.
(17), feedback lever (12) rotates around pin (13)
counterclockwise as lever 2 (17) rotates, moving
spool (3) to the left
Q
4. Since pin (5), which is connected to feedback (Flow Rate)
lever (12), is inserted into hole (19) on lever 2 Q1
(17), feedback lever (12) rotates around pin (13)
Q2
counterclockwise as lever 2 (17) rotates, moving
spool (3) to the left
5. As servo piston (14) is moved to the left, the

pump displacement angle increases correspond-
ing to the distance that servo piston (14) has P1 P2 P (Pump Delivery
moved, increasing the pump delivery flow rate. Pressure)
T3-1-14
2 16 3 17 18 19 5 20 21 22 Pz
PG
Large Chamber Small Chamber Pressure

(P2 → P1)
14 13 12 24
Housing 18 T117-02-01-011
24
17
19
20
12
14
13
T117-02-01-009
2- Sleeve 13- Pin 18- Pin 21- Outer Spring
3- Spool 14- Servo Piston 19- Hole 22- Inner Spring
5- Pin 16- Compensating Piston 20- Compensating Rod 24- Pin
12- Feedback Lever 17- Lever 2
T3-1-15
Flow Rate Control
• Flow Rate Increasing Operation
1. On the main pump, flow rate control pressure Pi 6. As servo piton (14) is moved and because pilot
acts on pilot piston (10) by operating the control piston (10) and lever 1 (7) do not move, feedback
lever. On the oil cooler fan motor drive pump, flow lever (12), which is connected to servo piston (14)
rate control pressure Pi from fan pump solenoid via pin (13), rotates clockwise around pin (5),
valve SF acts on pilot piston (10). moving spool (3) to the right until the notches on
As pressure Pi increase, pilot piston (10) is sleeve (2) are completely closed, thus closing the
moved to the right until pilot piston (10) balances line from the servo piston large chamber to the
against spring (11). hydraulic oil tank. As a result, movement of servo
piston (14) stops.
2. As lever 1 (7) is connected to pilot piston (10) via
pin (9), movement of pilot piston (10) rotates lever 7. With the above operation, the pump delivery flow
1 (7) counterclockwise around pin (4) which is rate is increased in proportion to the increment of
fixed to the support plug. pressure Pi.
3. Because pin (5) on feedback lever (12) is inserted NOTE: Refer to the SYSTEM / Hydraulic System /
into hole (8) on lever 1 (7), feedback lever (12) Pilot Circuit description.
rotates counterclockwise around pin (13) as lever
1 (7) rotates, moving spool (3) to the left. Q
(Flow Rate)
4. As spool (3) is moved, pressure oil in the servo
piston large chamber is routed to the hydraulic oil
tank via spool (3). Since pump pressure P is
routed to the servo piston small chamber all the
time, servo piston (14) is moved to the left.

ing to the distance that servo piston (14) has Pi (Flow Rate Control
Pressure)
moved, increasing the pump delivery flow rate.
T3-1-16
2 3 4 7 8 5 10 11
Pi
14 13 12 9
Housing T117-02-01-012
12
7
4
Support Plug
14
13
10
T117-02-01-009
2- Sleeve 5- Pin 9- Pin 12- Feedback Lever

3- Spool 7- Lever 1 10- Pilot Piston 13- Pin
4- Pin 8- Hole 11- Spring 14- Servo Piston
T3-1-17
• Flow Rate Decreasing Operation
1. On the main pump, the pressure Pi decreases by 6. As servo piston (14) moves, feedback lever (12)
returning the control lever, so that pilot piston (10) moves via pin (13). Since pilot piston (10) and
is returned to the left until it, or pressure Pi in lever 1 (7) do not move, feedback lever (12) ro-
other words, balances against spring (11). tates counterclockwise around pin (5), shifting
On the oil cooler fan motor drive pump, the pres- spool (3) to the left until the notches on spool (3)
sure Pi from fan pump solenoid valve SF de- and sleeve (2) closes completely. As these
creases, so that pilot piston (10) is returned to the notches close, the pump pressure stops acting on
left until it, or pressure Pi in other words, balances the servo piston large chamber. Consequently,
against spring (11). the movement of servo piston (14) stops.
2. As lever 1 (7) is connected to pilot piston (10) via 7. With the above operation, the pump delivery flow
pin (9), movement of pilot piston (10) rotates lever rate is decreased in proportion to the degree of
1 (7) clockwise around pin (4) which is fixed to the decrement of pressure Pi.
the support plug.
NOTE: Refer to the SYSTEM / Hydraulic System /
3. Because pin (5) on feedback lever (12) is inserted Pilot Circuit description.
into hole (8) on lever 1 (7), feedback lever (12)
rotates clockwise around pin (13) as lever 1 (7)
Q
rotates, moving spool (3) to the right.
(Flow Rate)
to the servo piston large chamber via spool (3).
Although pump pressure P is also routed to the
moved to the right due to the difference in pres-
sure receiving area between the servo piston
ends.
Pi (Flow Rate Control
5. As servo piston (14) is moved to the right, the Pressure)
sponding to the distance that servo piston (14)
has moved, decreasing the pump delivery flow
rate.
T3-1-18
2 3 4 7 5 8 10 11
Pi
14 13 12 9
T117-02-01-013
12
7
4
Support Plug
14
13
10
T117-02-01-009
2- Sleeve 5- Pin 9- Pin 12- Feedback Lever

3- Spool 7- Lever 1 10- Pilot Piston 13- Pin
4- Pin 8- Hole 11- Spring 14- Servo Piston
T3-1-19
Horsepower Reducing Control (only for Main
Pump)
1. Horsepower reducing control pressure PG acts 6. As servo piston (14) moves, feedback lever (12)
on piston (15). When pressure PG acts on piston moves via pin (13). Since compensating rod (20)
(15), compensating piston (16) and compensating and lever 2 (17) do not move, feedback lever (12)
rod (20) move until they balance against outer rotates counterclockwise around pin (5), shifting
spring (21) and inner spring (22). spool (3) to the left until the notches on spool (3)
and sleeve (2) close completely. As these notches
2. Movement of compensating rod (20) is transmit- close, the pump pressure stops acting on the
ted to lever 2 (17) via pin (24), rotating lever 2 servo piston large chamber. Consequently, the
(17) counterclockwise around pin (18). movement of servo piston (14) stops.
3. Since pin (5), which is connected to feedback 7. With the above operation, the P-Q curve is reset
lever (12), is inserted into hole (19) on lever 2 as illustrated (when horsepower reducing control
(17), feedback lever (12) rotates around pin (13) pressure PG acts on piston (15)). Consequently,
clockwise as lever 2 (17) rotates, moving spool the torque constant control (overall preventing
(3) to the right. operation and delivery flow rate decreasing op-
eration) is performed on this reset P-Q curve.
to the servo piston large chamber via spool (3). NOTE: Refer to the SYSTEM / Hydraulic System /
Although pump pressure P is also routed to the Pilot Circuit description.
moved to the right due to the difference in pres-
sure receiving area between the servo piston Q
ends. (Flow Rate)
5. As servo piston (14) is moved to the right, the

sponding to the distance that servo piton (14) has
moved, decreasing the pump delivery flow rate.
P(Pressure)
T3-1-20
15 2 16 3 17 18 5 19 20 21 22 Pz
PG
14 13 12 24
Housing 18 T117-02-01-014
24
17
19
20
12
14
13
T117-02-01-014
2- Sleeve 13- Pin 17- Lever 2 21- Outer Spring
3- Spool 14- Servo Piston 18- Pin 22- Inner Spring
5- Pin 15- Piston 19- Hole 24- Pin
12- Feedback Lever 16- Compensating Piston 20- Compensating Rod
T3-1-21
Horsepower Increasing Control (only for Main
Pump)
1. When horsepower increasing control pressure Pz 6. As servo piston (14) is moved and because com-
rises, piston (23) moves compensating rod (20) to pensating rod (20) and lever 2 (17) do not move,
the left until it balances against pump pressure P feedback lever (12), which is connected to servo
which is acting on compensating piston (16). piston (14) via pin (13), rotates clockwise around
pin (5), moving spool (3) to the right until the
2. Movement of compensating rod (20) is transmit- notches on sleeve (2) are completely closed, thus
ted to lever 2 (17) via pin (24), rotating lever 2 closing the line from the servo piston large
(17) clockwise around pin (18) which is fixed to chamber to the hydraulic oil tank. As a result,
the housing. movement of servo piston (14) stops.
3. Since pin (5), which is connected to feedback 7. With the above operation, the P-Q curve is reset
lever (12), is inserted into hole (19) on lever 2 as illustrated (when horsepower increasing con-
(17), feedback lever (12) rotates around pin (13) trol pressure Pz rises). Consequently, the con-
counterclockwise as lever 2 (17) rotates, moving stant torque control (overload preventing opera-
spool (3) to the left. tion and delivery flow rate increasing operation) is
performed on this reset P-Q curve.
4. As spool (3) is moved, pressure oil in the servo
piston large chamber is routed to the hydraulic oil NOTE: Refer to the SYSTEM / Hydraulic System /
tank via spool (3). Since pump pressure P is Pilot Circuit description.
routed to the servo piston small chamber all the
time, servo piston (14) is moved to the left. Q
(Flow Rate)
ing to the distance that servo piston (14) has
moved, increasing the pump delivery flow rate.
P(Pressure)
T3-1-22
2 16 3 17 18 19 5 20 21 22 23 Pz
PG
14 13 12 24
Housing 18 T117-02-01-015
24
17
19
20
12
14
13
T117-02-01-014
2- Sleeve 13- Pin 18- Pin 22- Inner Spring
3- Spool 14- Servo Piston 19- Hole 23- Piston
5- Pin 16- Compensating Piston 20- Compensating Rod 24- Pin
12- Feedback Lever 17- Lever 2 21- Outer Spring
T3-1-23
Smaller Swash Angle (Less Flow Rate) Priority
Control
The swash plate angle control by flow rate control or

increasing/reducing horsepower control is transmit-
ted to feedback lever (12) and spool (3) through hole
(8) on lever 1 (7) and hole (19) on lever 2 (17) via pin
(5). (Refer to Flow Rate Control, Horsepower In-
creasing Control and Horsepower Reducing Control).
Pin (5) comes into contact against the sides which
decreases swash plate angle, placed in holes (8) and
(19) on lever 1 (7) and lever 2 (17). Therefore, the
flow rate reducing and horsepower reducing controls
are selected with preferentially.
T3-1-24
Cross Section
3 7 5 8
Pi
12
T117-02-01-013
3 17 5 19 Pz
PG
T117-02-01-014
3- Spool 7- Lever 1 12- Feedback Lever 19- Hole

5- Pin 8- Hole 17- Lever 2
T3-1-25
3-UNIT PUMP
The engine power is transmitted through the pump
transmission to the shaft. As the shaft turns, the three
pumps are operated simultaneously.
The oil cooler fan motor drive pump (A) is a variable
displacement swash plate plunger type pump. It has
the cylinder block splined to the shaft. As the shaft and
cylinder block rotate, the plungers move in and out of
their bores, drawing and pushing hydraulic oil.
Pilot pump (B) and transmission oil circulation pump
(C) are gear type pumps. The shaft drives the drive
gear, and the driven gear are driven by the drive gear.
Hydraulic oil drawn into the pump housings are deliv-
ered to the outlets along the housing inner surfaces.
C B A
T183-03-01-003
A- Oil Cooler Fan Motor Drive Pump C- Transmission Oil Circulation Pump
(Variable Displacement Swash Plate Plunger Type Pump) (Tandem Gear Pump)
B- Pilot Pump (Tandem Gear Pump)
Suction Side
Driven Gear Drive Gear
Housing
Delivery Side
(Outlet)
T137-02-03-005
T3-1-26
COMPONENT OPERATION / Swing Device
OUTLINE
The swing device consists of the valve unit, motor , The reduction gear functions to reduce the rotation
and reduction gear. speed of swing motor and to increase its torque before
The motor is driven by pressure oil from the pump and transmitting the rotational force from swing moter to
transmits rotational force to the reduction gear. the pinion shaft.
The valve unit functions to protect the swing circuit.
Motor Valve Unit
Reduction Gear
T142-02-02-001
T3-2-1
SWING MOTOR
The swing motor is a swash-plate-type axial plunger The spherical end of plunger (5) is installed in shoe (2)
motor. by a ball-and-socket joint. The shaft part of plunger (5)
The swing motor consists of shaft (4), swash plate (3), is inserted into rotor (6). Rotor (6) is installed onto
shoes (2), plungers (5), rotor (6), valve plate (9), shaft (4) with a spline coupling.
housing (1), and parking brake. The parking brake is a wet-type multiple disc brake,
consisting of friction plates (7) and plates (8).
7 1
6
2
5
3
T142-02-02-002
1 - Housing 4 - Shaft 6 - Rotor 8 - Plate

2 - Shoe 5 - Plunger 7 - Friction Plate 9 - Valve Plate
3 - Swash Plate
T3-2-2
Operational Principle
Swing speed varies depending on the amount of oil The rotational force is then transmitted to the swing
delivered from the pump. reduction gear via the shaft. As the rotor is rotated,
When pressure oil is fed into the rotor bores via port the plungers are moved to port (B) side one by one,
(A), the plungers are pushed from the top dead returning oil to the hydraulic oil tank. When pressure
center to the bottom dead center causing the shoes oil is fed via port (B), the motor rotates in the
to slide along the swash plate, developing rotational opposite direction
force.
Plunger
Shoe
Shaft
T142-02-02-004
T3-2-3
VALVE UNIT
The valve unit consists of the make-up valve and the
relief valve.
Drain Port
Make-Up Valve
When swing is stopped, the upperstructure tends to Make-Up Valve
keep rotating due to swing inertia force, causing the
Port M
swing motor to continue rotating further, and to begin Make-Up Port
drawing oil from the pump, developing cavitation the
motor.
The make-up valve draws hydraulic oil through the Relief Valve
Port M (Return Circuit) to compensate for the lack of
oil, and prevent cavitation.
Control Valve
T142-02-02-005
Relief Valve
Make-Up Valve
Control Valve
T140-02-04-002
T3-2-4
Relief Valve
When starting or stopping swing operation, oil
pressure in the swing circuit becomes high. The relief
valve prevents the circuit pressure from rising higher
than the specified pressure. Plunger is pushed to the
left by pressure Pp at port (P) and pressure-receiving
area A2.
However, plunger is also pushed back to the right by
spring force and pressure Pg at chamber (g) and
pressure-receiving area A1.
Chamber (g) is connected to port (P) through orifice
(m). When force acting on the right is higher than Relief Valve
that on the left, the relief valve operates.
Control Valve
T142-02-02-005
Spring A1 Plunger A2
Port P
Chamber (g) m
T142-02-02-006
T3-2-5
SWING PARKING BRAKE
When the brake is released (OFF): Pressure Oil
The swing parking brake is a wet-type multiple disc from Pilot
brake. Swing Parking Signal Circuit
1 Brake Release via Shuttle
Also, the swing parking brake is a negative type, i.e. Valve Valve
the brake is released when brake release pressure is
routed into brake-piston chamber (b).
The brake release pressure is supplied from the pilot
pump when a control lever is operated.
When the control levers are in neutral (or while the
engine is stopped), the brake release pressure is
returned to the hydraulic oil tank and the swing parking
brake is automatically applied by spring (1).
(Refer to the pilot circuit diagram in the Hydraulic
Brake
System Group of the System Section.)
Chamber (b) Release
Pressure from
• When Parking Brake is Released (OFF) (When 2 Pilot Pump
Control Lever is Operated) 6 3 4 5
When a control lever is operated, the pressure in T142-02-02-007
the pilot signal circuit rises because the

corresponding control valve spool is shifted. The
pressure in the pilot signal circuit acts on the
switch valve of the parking brake release valve,
When the brake is applied (ON):
shifting it. As the switch valve is shifted, the brake
release pressure from the pilot pump is routed
into chamber (b) via the swing parking release Drain Port
valve, acting on and pushing brake piston (2). As
a result, plates (3) and friction plates (4) become
contact free with each other, thus releasing the
parking brake.
• When Parking Brake is Applied (ON) (When

Control Levers are in Neutral.)
When the control levers are in neutral, the
pressure in the pilot signal circuit does not rise.
For this reason, the switch valve is not shifted and 7
5 Chamber (b)
the parking brake release pressure is not routed 4
to chamber (b). The pressure oil in chamber (b) is 3
6 T142-02-02-007
released to the motor drain port.

Thus, plates (3), which are secured to the outer
circumference of rotor (6), and friction plates (4),
which are secured to the inner wall of motor
housing (5), are pushed by spring (1) via brake
piston (2), coming into tight contact with each
other. As a result, rotor (6) is secured immovable,
thus applying the swing parking brake.
1- Spring 5 - Motor Housing

2- Brake Piston 6 - Rotor
3- Plate 7 - Orifice
4- Friction Plate
T3-2-6
SWING REDUCTION GEAR
The swing reduction gear is a planetary-gear-type two The motor shaft rotates first stage sun gear (9). As the
stage reduction gear. first stage reduction takes place between first stage
Both first and second stage ring gears are immovable planetary gears (1) and first stage carrier (7), second
because they are fixed to the housing. stage sun gear (5) is rotated. Then, the second stage
reduction takes place between second stage planetary
gears (2) and second stage carrier (4) before the
rotational force is transmitted to shaft (3).
9
1
7 2
4
3
W142-02-06-003
1 - First Stage Planetary Gear 4 - Second Stage Carrier 6 - Second Stage Ring Gear 8 - First Stage Ring Gear
2 - Second Stage Planetary 5 - Second Stage Sun Gear 7 - First Stage Carrier 9 - First Stage Sun Gear
Gear
3 - Shaft
T3-2-7
(Blank)
T3-2-8
COMPONENT OPERATION / Control Valve
OUTLINE
Two kinds of control valves, main control valve and 4-Spool Section: Right travel, Bucket 1, Boom 1, and
swing control valve, are used on this machine. The arm 2 in that order viewed from the front side. 5-Spool
control valve regulates oil pressure, flow rate and flow Section: Left Travel, Bucket 2, Boom 2, Arm 1, and
direction in the hydraulic circuit. The main control Auxiliary in that order viewed from the front side.
valve consists of two blocks, the 5-spool and 4-spool Swing Control Valve: Boom 3, Swing, Bucket 3, and
blocks. The swing control valve is a one block arm 3 in that order viewed from the front side. Pres-
(4-spool) type. Major components of the control valve sure oil from the pilot pump is routed to the signal pilot
are a main relief valve, oil flow combiner valve, and pressure circuit to control each operation.
spools. Both the main and swing control valves are pi- NOTE: BH: Backhoe
lot-pressure operated type. The spool arrangements in LD: Loading Shovel
the control valve are as follows:
Left Travel
Bucket 2
Main Control Valve Front Side Right Travel
Arm Regenerative Valve Bucket 1
Boom 1
Make-Up
Valve (Arm 2) Boom 2 Arm 2
Overload Relief
Slow Valve (Boom
Return Mode Selection)
Valve
Overload Re-
lief Valve
(Bucket 2) 4-Spool
Block
Arm 1
Boom Overload Overload

Relief Pressure Relief Valve
Overload Re- 5-Spool Switch Valve (Aux.:BH,
lief Valve Block Bucket
Auxiliary (Backhoe) Open/Close:
(Boom)
Bucket Open/Close LD)
Overload Re- (Loading Shovel)
lief Valve 4-Spool
Holding Valve Block Overload Re-
(Bucket) Front Side lief Valve
Switch Valve 5-Spool
(Boom) Main Relief Holding Valve (Arm)
Valve T183-03-03-029 Block
Switch Valve
Shuttle Valve (Arm) T183-03-03-028
Swing Control Valve

Holding Valve Switch
Valve
Front Side
(Boom) Mack-Up Valve
Main Relief (Arm 3)
Valve
Overload
Relief Valve
(Swing)
Boom 3
Swing
Bucket 3
Arm 3
T183-03-03-030 T183-03-03-031
Front Side
T3-3-1
Main Control Valve Auxiliary: BH
2 3 4 5 6 7 8 9 Bucket
Open/Close: LD
10
34
Arm 1
Arm 2
11
33 Boom 2
Boom 1
12
32
13
31 14
Bucket 2
15
Bucket 1
16
30
17
Left Travel 18
29
28
Right Travel
19
27
26 25 24 23 22 21 20 T18E-03-03-001
NOTE: BH: Backhoe

LD: Loading Shovel
1 - Holding Valve Switch 10 - Overload Relief Valve 19 - Load Check Valve (Left 27 - Main Relief Valve
Valve (Boom) (Aux.: BH, Travel Tandem Circuit)
Bucket Open/Close: LD)
2 - Load Check Valve 11 - Overload Relief Valve 20 - Load Check Valve (Left 28 - Load Check Valve
(Arm 2 Tandem Circuit) (Arm) Travel Parallel Circuit) (Bucket 1 Tandem Circuit)
3 - Load Check Valve 12 - Holding Valve Check 21 - Load Check Valve 29 - Overload Relief Valve
(Arm 2 Parallel Circuit) Valve (Arm) (Bucket 2 Parallel Circuit) (Bucket 1)
4 - Arm Regenerative Valve 13 - Load Check Valve 22 - Check Valve (Main Relief 30 - Load Check Valve
(Boom 2 Tandem Circuit) Pressure Combining Circuit) (Boom1 Parallel Circuit)
5 - Load Check Valve 14 - Load Check Valve 23 - Flow Combiner Valve 31 - Overload Relief Valve
(Arm 1 Parallel Circuit1) (Boom 2 Parallel Circuit) (Boom)
6 - Load Check Valve 15 - Overload Relief Valve 24 - Check Valve (Travel Flow 32 - Holding Valve Check Valve
(Arm 1 Parallel Circuit2) (Boom Mode Selection) Combine Circuit) (Boom)
7 - Load Check Valve 16 - Boom Overload Relief 25 - Check Valve (Main Relief 33 - Slow Return Valve
(Auxiliary Tandem Circuit) Pressure Switch Valve Pressure Combining Circuit)
8 - Load Check Valve 17 - Load Check Valve 26 - Shuttle Valve 34 - Make-Up Valve (Arm 2)
(Arm 1 Tandem Circuit) (Bucket 2 Tandem Circuit)
9 - Holding Valve Switch 18 - Overload Relief Valve
Valve (Arm) (Bucket 2)
T3-3-2
11 9 15, 16 18 Section A
G F E D C B A 26 27
25
10
Front
27
4
26
31 29
T183-03-03-003
24 23
T183-03-03-002
33 1
Section C 39 40
Section B 35 36
Right Travel Left Travel Bucket 1 Bucket 2
18
29
17
19 28
21
20
18
29
T183-03-03-004 T183-03-03-005
37 38 41 42
NOTE: BH: Backhoe

LD: Loading Shovel
35 - Right Travel (Forward) Port 37 - Left Travel (Reverse) Port 39 - Bucket 1 (Roll-Out : BH, 41 - Bucket 1 (Roll-In : BH,
Tilt-Out : LD) Port Tilt-In : LD) Port
36 - Left Travel (Forward) Port 38 - Right Travel (Reverse) Port 40 - Bucket 2 (Roll-Out : BH, 42 - Bucket 2 (Roll-In : BH,
Tilt-Out : LD) Port Tilt-In : LD) Port
T3-3-3
Auxiliary: BH
2 3 4 5 6 7 8 9 Bucket
Open/Close: LD
10
34
Arm 1
Arm 2
11
33 Boom 2
Boom 1
12
32
13
31 14
Bucket 2
15
Bucket 1
16
30
17
Left Travel 18
29
28
Right Travel
19
27
26 25 24 23 22 21 20 T18E-03-03-001
NOTE: BH: Backhoe

LD: Loading Shovel
1 - Holding Valve Switch 10 - Overload Relief Valve 19 - Load Check Valve (Left 27 - Main Relief Valve
Valve (Boom) (Aux.: BH, Travel Tandem Circuit)
Bucket Open/Close: LD)
2 - Load Check Valve 11 - Overload Relief Valve 20 - Load Check Valve 28 - Load Check Valve
(Arm 2 Tandem Circuit) (Arm) (Left Travel Parallel Circuit) (Bucket 1 Tandem Circuit)
3 - Load Check Valve 12 - Holding Valve Check 21 - Load Check Valve 29 - Overload Relief Valve
(Arm 2 Parallel Circuit) Valve (Arm) (Bucket 2 Parallel Circuit) (Bucket 1)
4 - Arm Regenerative Valve 13 - Load Check Valve 22 - Check Valve (Main Relief 30 - Load Check Valve
(Boom 2 Tandem Circuit) Pressure Combining Circuit) (Boom1 Parallel Circuit)
5 - Load Check Valve 14 - Load Check Valve 23 - Flow Combiner Valve 31 - Overload Relief Valve
(Arm 1 Parallel Circuit1) (Boom 2 Parallel Circuit) (Boom)
6 - Load Check Valve 15 - Overload Relief Valve 24 - Check Valve (Travel Flow 32 - Holding Valve Check Valve
(Arm 1 Parallel Circuit2) (Boom Mode Selection) Combine Circuit) (Boom)
7 - Load Check Valve 16 - Boom Overload Relief 25 - Check Valve (Main Relief 33 - Slow Return Valve
(Auxiliary Tandem Circuit) Pressure Switch Valve Pressure Combining Circuit)
8 - Load Check Valve 17 - Load Check Valve 26 - Shuttle Valve 34 - Make-Up Valve (Arm 2)
(Arm 1 Tandem Circuit) (Bucket 2 Tandem Circuit)
9 - Holding Valve Switch 18 - Overload Relief Valve
Valve (Arm) (Bucket 2)
T3-3-4
43 44
Section D Section E 47 4 48
Boom 1 Boom 2
Arm 2 Arm 1
16 12
33 34
31 9
15
13
30
6
3 8
14
2
31 11
T183-03-03-007
49 50
1 32 46
T183-03-03-006
45 51
10
Auxiliary (BH) Section G
Section F Bucket Open/Close (LD)
11
T183-03-03-009
9
34 52
T183-03-03-008
43 - Boom 1 (Lower) Port 46 - Boom 2 (Raise) Port 49 - BH: Arm 2 (Roll-In) Port 51 - BH: Auxiliary Port
LD: Arm 2 (Extend) Port LD: Bucket (Open) Port
44 - Boom 2 (Lower) Port 47 - BH: Arm 2 (Roll-Out) Port 50 - BH: Arm 1 (Retract) Port 52 - BH: Auxiliary Port
LD: Arm 2 (Retract) Port LD: Arm 1 (Extend) Port LD: Bucket (Open) Port
45 - Boom 1 (Raise) Port 48 - BH: Arm 1 (Roll-Out) Port
LD: Arm 1 (Roll-In) Port
T3-3-5
Swing Control Valve
1 2
11
Boom 3
10 3
Swing
4
Bucket 3
5
9
Arm 3
6
8 7 T18E-03-03-002
1 - Main Relief Valve 4 - Load Check Valve 7 - Check Valve (Arm 3) 10 - Holding Valve Switch Valve
(Bucket 3)
2 - Load Check Valve (Boom 5 - Load Check Valve (Arm 3) 8 - Make-Up Valve (Arm 3) 11 - Holding Valve Check Valve
3) (Boom 3)
3 - Load Check Valve (Swing) 6 - Load Check Valve 9 - Overload Relief Valve
(Arm 3 Parallel Circuit) (Swing)
T3-3-6
12 14 16 18
Section A
1
B C D E F
1 10 9 T183-03-03-011
T183-03-03-012
13 15 17 19
Section C 14
Section B 11
Swing
Boom 3
9
10
9
T183-03-03-014
11
T183-03-03-013 15
13
12 - Boom 3 (Lower) Port 13 - Boom 3 (Raise) Port 14 - Swing (Left) Port 15 - Swing (Right) Port
T3-3-7
1 2
11
Boom 3
10 3
Swing
4
Bucket 3
5
9
Arm 3
6
8 7 T18E-03-03-002
4 - Main Relief Valve 7 - Load Check Valve 10 - Check Valve (Arm 3) 12 - Holding Valve Switch Valve
(Bucket 3)
5 - Load Check Valve (Boom 8 - Load Check Valve (Arm 3) 11 - Make-Up Valve (Arm 3) 13 - Holding Valve Check Valve
3) (Boom 3)
6 - Load Check Valve (Swing) 9 - Load Check Valve 12 - Overload Relief Valve
(Arm 3 Parallel Circuit) (Swing)
T3-3-8
16 18
Section D Section E
Bucket 3 Arm 3
4 6
T183-03-03-015
17 19 7 T183-03-03-016
Section F
T183-03-03-017
7
NOTE: BH: Backhoe
LD: Loading Shovel
16 - Bucket 3 (Roll-Out) Port 17 - Bucket 3 (Roll-In) Port 18 - BH: Arm 3 (Roll-Out) Port 19 - BH: Arm 3 (Roll-In) Port
LD: Arm 3 (Retract) Port LD: Arm 3 (Extend) Port
T3-3-9
HYDRAULIC CIRCUIT
Main Circuit
Pressure oil from main pump 1, main pump 2, and
main pump 3 are routed to the 5-spool section of the
main control valve, the 4-spool section of the main
control valve, and the swing control valve respectively.
Each main circuit is provided with a parallel circuit,
making combined operations possible. The main re-
lief valve regulates the maximum oil pressure in the
main circuit. Overload relief valves are provided in
the boom, arm, bucket, swing, and auxiliary circuits.
Pilot Control Circuit

Pressure oil (indicated by figure No.) from the pilot
valve acts on the spool ends in the control valve to
operate the spools.
External Pilot Pressure Circuit

• Pilot Pressure from boom mode selection solenoid
valve (SC) shifts the boom overload relief pressure
switch valve.
(Refer to the SYSTEM / Control System group.)
• Pilot pressure from the flow combiner valve control
spool in the signal control valve shifts the flow
combiner valve.
(Refer to the SYSTEM / Hydraulic System group.)
T3-3-10
From Flow Combiner

Valve Control Spool in Main Relief
Signal Control Valve Valve
Main Relief Overload

Valve Relief Valve
Flow Combiner Valve
1 2
9 10
12 11
7 8
6 7 8 7
8 1 1 2
Boom Over- 2 1
load Relief
Pressure
Switch Valve
3 4 4 3
3 4
14 13 Overload
Relief Valve
Overload
Relief Valve
Overload
Relief Valve
Main Pump 1
From Boom
Mode Selection Main Pump 2
Solenoid Valve
Main Pump 3
T18E-03-03-003
1 - Boom Raise 5 - Left Swing 9 - Left Travel Forward 12 - Right Travel Reverse
2 - Boom Lower 6 - Right Swing 10 - Left Travel Reverse 13 - Bucket Close
(Loading Shovel)
3 - Arm Roll-Out (Backhoe) 7 - Bucket Roll-In (Backhoe) 11 - Right Travel Forward 14 - Bucket Open
Arm Retract (Load- Bucket Tilt-In (Loading Shovel) (Loading Shovel)
ing Shovel)
4 - Arm Roll-In (Backhoe) 8 - Bucket Roll-Out (Backhoe)
Arm Roll-Out (Load- Bucket Tilt-Out (Loading
ing Shovel) Shovel)
T3-3-11
FLOW COMBINER VALVE
1. Normally, the spring pushes the spool, blocking
the valve ports.
2. When the front attachment and travel control lev-
ers are operated at the same time, the right travel
pilot oil pressure shifts the flow combiner valve
control spool in the signal control valve so that the
pilot pressure shifts the flow combiner valve
spool.
3. When the flow combiner valve spool is shifted,
pressure oil from main pump 2 is routed to the left
travel spool.
4. Therefore, pressure oil from main pump 2 is
routed to the left travel spool in parallel with the
right travel spool and pressure oil from main
pump 1 is routed to the front attachment. Conse-
quently, the machine can travel straight when a
combine operation of travel and front attachment
is performed.
Travel Motor Travel Motor (Right)
Flow Combiner Valve Pilot Pressure from Flow Combiner Valve

Control Spool in Signal Pilot Pressure Con-
trol Valve
Spring
Main Pump 2 T183-03-03-022
T3-3-12
In Neutral: In Operation:
Spring Spring
Spool Spool
To Left Travel To Left Travel

Spool Spool
Pressure Oil from Pressure Oil from

Main Pump 2 Main Pump 2
Pilot Pressure
from Flow Com-
biner Valve Con-
trol Spool
T183-03-03-023 T183-03-03-024
T3-3-13
MAIN RELIEF VALVE
Main relief valve set pressure is shifted in two stages High Relief Pressure Setting
by the pilot pressure from the heavy lift solenoid valve. When the heavy lift switch is turned ON, the heavy lift
When the heavy lift system is activated, the main relief solenoid valve is magnetized by main controller A so
pressure is set in the high stage. When the heavy lift that the pilot pressure is routed to shuttle valve PF1.
system is deactivated, the main relief pressure is set Then, the pilot pressure pushes the piston to the left,
in the low stage. compressing the spring. Then, the pilot poppet is
pushed by increased force, increasing the main relief
Low Relief Pressure Setting valve set-pressure. The relief valve operation is the
When the heavy lift switch is turned OFF, the heavy same as that in the low relief set-pressure.
lift solenoid valve is demagnetized so that the signal
pilot pressure is not routed to shuttle valve PF1.
Since shuttle valve PF2 is connected to the hydraulic
oil tank, the piston doesn’t move to the left, reducing
pilot poppet pushing force. When pressure at port HP
increases over the spring set-force, the pilot poppet
is unseated, allowing pressure oil to flow to port LP
through passage A. When the pilot poppet is un-
seated, pressure in the spring chamber A is reduced
so that the main poppet is unseated, allowing pres-
sure oil to flow from port HP to port LP.
Main Poppet Pilot Poppet Spring Piston
LP
HP
LP
PF2 PF1 Shuttle Valve
Spring Chamber A Passage A Heavy Lift Solenoid Valve
T111-02-05-014
T3-3-14
OVERLOAD RELIEF VALVE
(With Make-Up Function)
1 2 a 3 4
Overload relief valves are provided at the output ports
to the swing motors, and the boom, arm, and bucket HP
cylinders. The overload relief valve prevent the actua-
tor circuit pressure from increasing excessively when
the actuator(s) is (are) moved by external loads. When
pressure in port HP increases up to set-force of spring
(4), pilot poppet (3) is unseated, allowing pressure oil
to flow to port LP from chamber (a) via the clearance LP
around main poppet (2). Then, pressure difference
arises between port HP and chamber (a) due to the
orifice located between them. When this pressure dif- 5 Orifice T111-02-05-019
ference increases over set-force of spring (5), piston

(1) and main poppet (2) are unseated so that pressure a
1 2
oil flows directly to port LP from port HP. In addition,
this relief valve draws oil from the hydraulic oil tank if
pressure in the actuator becomes negative to prevent HP
cavitation in the circuit (make-up function).
1 - Piston 4 - Spring
2 - Main Poppet 5 - Spring
3 - Pilot Poppet
LP
T111-02-05-021
MAKE-UP VALVE
Make-up valves are provided at the output ports of the 7 6
arm 2 and 3 spool sections, assisting the makeup d1
function of the overload relief valve. When pressure in d2
HP
port HP is higher than port LP, poppet (7) is kept
seated due to difference (d1-d2) in pressure receiving
areas on poppet (7). Therefore, when pressure in port
HP is reduced lower than port LP, poppet (7) is pushed
to the right to unseat due to difference (d1-d2) in
pressure receiving areas on poppet (7).
LP
6 - Spring 7 - Poppet
b T111-02-05-023
HP
LP
T111-02-05-024
T3-3-15
HOLDING VALVE
The holding valves are provided at the output ports of • In Neutral
the main control valve to the boom raise and the arm The cylinder holding pressure at cylinder port C is
roll-out circuit and at the output port of the swing con- routed to camber (a) through orifice (b) in check
trol valve to the boom raise circuit, preventing cylinder valve (2). Then, Check valve (2) is kept seated due
drift. to difference (d1-d2) in pressure receiving areas,
completely blocking cylinder port (c).
External Force
1
g
a
a
d1 2
Holding
b Pressure
g
c
b
d2 3
d c
3
Pi
f
T111-02-05-025
f d e
• When lowering the boom or rolling the arm in: At the same time, spool (3) is shifted, pressure oil
Pilot pressure Pi is routed to switch valve (1), causing from (c) to (f) via (d) to allow the cylinder to move.
chamber (a) to connect to the hydraulic oil tank.
Then, pressure in chamber (a) is reduced so that
check valve (2) is unseated.
a
a
3
3
d c
Pi
f
T111-02-05-026
1 - Switch Valve 2 - Check Valve 3 - Spool
T3-3-16
(Blank)
T3-3-17
ARM REGENERATIVE VALVE
1
The arm regenerative valve is provided to prevent arm PB
cylinder hesitation while rolling in the arm so that arm PR
controllability is greatly improved. i
8
The return oil flow from the cylinder rod side is re- 3
stricted in two stages at orifice (A) in spool (2) and ori- 2
fice (B) in arm regenerative valve so that pressure PR h
at the cylinder rod side increases. When pressure PR A
at the cylinder rod side increases more than pressure
PB at the cylinder bottom side, check valve (3) is
opened. Then, the return oil from the cylinder rod side e C
is combined with pressure oil from the pump and sup-
plied again to the cylinder bottom side. 7
b 6
9
d B
a
1
T111-02-05-035
PR PB
8 9
A
h
f e a i d
e
7 B
d
c
T111-02-05-028
6 5 4
1 - Arm Cylinder 4 - Piston 6 - Spring 8 - Holding Valve
2 - Spool 5 - Spool 7 - Arm Regenerative Valve 9 - Load Check Valve
3 - Check Valve
T3-3-18
When pressure PB at the bottom side is higher than
the rod side, check valve (3) is closed, blocking the 1
return oil circuit. In addition, oil pressure from the PB
pump is routed to piston (4) end in arm regenerative PR
flow control valve (7) via passage (b), moving spool (5) i
to the left so that orifice (B) is widened. Therefore, the
8
return oil from the rod side can flow out via passage 3
(d) to the hydraulic oil tank. 2
h
A
e C
7
b 6
9
d B
a
1
T111-02-05-035
PR PB
8 9
A
h
f e a i d
e
7 B
d
c
T111-02-05-029
6 5 4
1 - Arm Cylinder 4 - Piston 6 - Spring 8 - Holding Valve

2 - Spool 5 - Spool 7 - Arm Regenerative Valve 9 - Load Check Valve
3 - Check Valve
T3-3-19
BOOM OVERLOAD RELIEF PRESSURE
SWITCH VALVE
The boom overload relief pressure switch valve is pro-
vided at the output port to the boom cylinders. The
boom overload relief pressure switch valve is operated
by the pilot oil pressure from boom mode selection
solenoid valve (SC) so that the overload relief valve
set pressure in the boom cylinder rod side is reduced.
Normally, pressure oil in port HP is routed to chamber
(c) via piston (6), closing main poppet (5). Therefore,
the overload relief valve set-pressure is maintained.
When the pilot oil pressure from boom mode selection
solenoid valve (SC) is routed to piston (1), piston (1)
unseats poppet (2). When poppet (2) is unseated,
chamber (a) and (b) are connected to port LP via pas-
sage (d). When pressure at chamber (c) increases up
to set-force of spring (3), pilot poppet (4) is unseated,
reducing pressure in chamber (c) so that piston (6)
and main poppet (5) are moved to the left. Thereby,
main poppet (5) is unseated, allowing pressure oil to
directly flow to port LP from port HP. Consequently, the
overload relief valve set-pressure is reduced.
(Refer to the SYSTEM/Control System group)
T3-3-20
1 2 a 3 4 5 6
Pilot
Pressure HP
LP
d b c
T183-03-03-018
1 2 a 3 4 5 6
Pilot
Pressure HP
LP
b c
T183-03-03-019
1 2 a 3 4 5 6
Pilot
Pressure HP
b LP
T183-03-03-020
1 - Piston 3 - Spring 5 - Main Poppet 6 - Piston

2 - Poppet 4 - Pilot Poppet
T3-3-21
(Blank)
T3-3-22
COMPONENT OPERATION / Pilot Valve
OUTLINE
The pilot valve functions to control pilot pressure oil, The pilot valves have the same mechanism to the
causing the control valve spools to move. reducing valve, except the mechanism of the cam part
The two types of 4-port pilot valves are used for the which press the pusher between the pilot valves for
front swing operations and travel operations as a front swing/travel operations and bucket operations.
standard. The 2-port pilot valve is used for the bucket
opens/closes operations (loading shovel only).
Front / Swing Pilot Valve Travel Pilot Valve Bucket Open / Close Pilot Valve
(Only for Loading Shovel)
T
T
P
P
3 4
1
4 1 2
T183-03-04-001
P 2 1
3 T178-03-04-001 T178-03-04-002
• Front/Swing Pilot Valve • Travel Pilot Valve

Right 1 Travel Left Forward
H (Hitachi)
Port # ISO Lever Type 2 Travel Left Reverse
Pattern
Common to 1 Bucket Roll-Out ← 3 Travel Right Reverse

Backhoe and 2 Boom Lower ← 4 Travel Right Forward
Loading 3 Bucket Roll-In ←
Shovel 4 Boom Raise ← • Bucket Open/Close Pilot Valve
(Only for Loading Shovel)
Left
H (Hitachi) Left 1 Bucket Close
Port # ISO Lever Type
Pattern Right 2 Bucket Open
1 Arm Roll-In Swing Left
2 Swing Right Arm Roll-In
Backhoe
3 Arm Roll-Out Swing Right
4 Swing Left Arm Roll-Out
1 Arm Roll-In Swing Left
Loading 2 Swing Right Arm Roll-Out
Shovel 3 Arm Roll-Out Swing Right
4 Swing Left Arm Roll-In
T3-4-1
OPERATION
Spool (6) head comes in contact with the upper face of
spring guide (3) which is kept raised by return spring
(5).
NOTE: The pilot valve for bucket open/close has

the same internal structure as the pilot
valve for travel.
Refer to the movement of the pilot valve for
travel.
Neutral (Output Diagram: A to B):

1. When neutral, spool (6) totally blocks pressure oil
E F
port P (from the pilot pump).The output port is
opened to port T (hydraulic oil tank) through the
passage in spool (6). Therefore, oil pressure in D
the output port (to the control valve) is equal to Pilot
Pressure
that in port T.
2. When the control lever is slightly tilted, cam (1) is
tilted, moving pusher (2) downward. Then, pusher C
(2) compress return spring (5) along with spring
guide (3). At this time, as oil pressure in the
A B
output port is equal to that in port T, spool (6) Lever Stroke
moves downward while keeping the under face of T522-02-05-001
the spool head in contact with spring guide (3).
3. This status continues until hole (7) on spool (6) is
opened to port P.
T3-4-2
Front Attachment / Swing Pilot Valve
1 1
2 2
6
3 3 Port T
4 4
7
5 5 Port P
6 Output Port
6
Port T Port T
7 Port P 7 Port P
Output Port T183-03-04-002

Travel Pilot Valve

1 1
2 2 Port T
7
Port P
3 3 6
4 4
5 Output Port
5
6
Port T Port T
6
Port P Port P
7 7

1 - Cam 3 - Spring Guide 5 - Return Spring 7 - Hole

2 - Pusher 4 - Balance Spring 6 - Spool
T3-4-3
During Metering or Decompressing (Output
Diagram: C to D)
1. When the control lever is further tilted to move E F
pusher (2) downward more, hole (7) on spool (6)
is opened to port P, allowing pressure oil in port P
D
to flow into the output port.
Pilot
2. Oil pressure in the output port acts on the bottom Pressure
face of spool (6) so that spool (6) is pushed
upward.
C
3. However, until upward force acting on the bottom
face of spool (6) overcomes balance spring (4)
force, balance spring (4) is not compressed. Then, A B
Lever Stroke
spool (6) is not raised, allowing oil pressure in the
output port to increase. T522-02-05-001
4. As oil pressure in the output port increases, force

to push spool (6) upward increases. When, this
force overcomes balance spring (4) force,
balance spring (4) is compressed so that spool
(6) is moved upward.
5. As spool (6) is moved upward, hole (7) is closed
so that pressure oil from port P stops flowing into
the output port, stopping pressure oil in the output
port to increase.
6. As spool (6) is moved downward, balance spring
(4) is compressed, increasing the spring force.
Therefore, oil pressure in the output port
becomes equal to the oil pressure acting on the
bottom face of spool (6) being balanced in
position with the spring force.
T3-4-4
1 1
2 2
3 3
4 4
5 5
6 6
Port T Port T
7 Port P 7 Port P

Travel Pilot Valve

1 1
2 2
3 3
4 4
5 5
6 6
Port T Port T
Port P Port P
7 7


T3-4-5
Full Stroke (Output Diagram: E to F)
1. When the control lever is fully stroked, pusher (2)
is moved downward until pusher (2) in the front E F
attachment / swing pilot valve comes in contact
with the casing shoulder, or cam (1) on the travel
D
pilot valve comes in contact with the casing. Pilot
2. At this moment, the bottom of pusher (2) directly Pressure
pushes spool (6). Therefore, even if oil pressure
in the output port increases further, hole (7) on
C
spool (6) is kept open.
3. Consequently, oil pressure in the output port is
equal to oil pressure in port P. A B
Lever Stroke
T522-02-05-001
NOTE: Total lever strokes for the front attachment
and swing controls are determined by
stroke dimension (E) of pusher (2). Total
lever stroke for the travel control is
determined by stroke dimension (E) of cam
(1).
T3-4-6
2 2
4
5
6
Port T
7 Port P

T183-03-04-002
Travel Pilot Valve

1
1
E
2
4
5
6
Port T
Port P
7
T183-03-04-003

T3-4-7
(Blank)
T3-4-8
COMPONENT OPERATION / Travel Device
OUTLINE
The travel device consists of a travel motor (12),
planetary reduction gear (1) to (11), (13) and sprocket
(14).
3
2
1
7
8
9
10
11
12
14
13
T183-03-01-001
1- Third Stage Carrier 5- Ring Gear 9 - Second Stage Carrier 12 - Travel Motor
2- Third Stage Sun Gear 6- Shaft 10 - Third Stage Planetary Gear 13 - Drum
3- Second Stage Planetary Gear 7- First Stage Carrier 11 - Housing 14 - Sprocket
4- First Stage Planetary Gear 8- Second Stage Sun Gear
T3-5-1
TRAVEL REDUCTION GEAR
The travel reduction gear is a three stage planetary As third stage carrier (2) is held stationary with
gear. When the travel motor rotates clockwise, shaft housing (11), ring gear (1) rotates.
(6) rotates clockwise, transmitting this motor driving Ring gear (1) is bolted to drum (13) so that sprocket
power to ring gear (1) via first stage planetary gears (12) is rotated.
(8), first stage carrier (5), second stage sun gear (7),
second stage planetary gears (9), second stage carrier
(4), third stage sun gear (3), third stage planetary
gears (10) and third stage carrier (2).
11 12 13 1
2
3
4
6
7
Third Second First

Stage Stage Stage
8
10 9
T183-03-05-002
1- Ring Gear 5 - First Stage Carrier 8 - First Stage Planetary Gear 11 - Housing (Travel Motor)
2- Third Stage Carrier 6 - Shaft 9 - Second Stage Planetary Gear 12 - Sprocket
3- Third Stage Sun Gear 7 - Second Stage Sun Gear 10 - Third Stage Planetary Gear 13 - Drum
4- Second Stage Carrier
T3-5-2
TRAVEL MOTOR
The travel motor is a variable displacement swash Four of tilt piston (9) are located in casing (8). The
plate axial plunger type, consisting of swash plate (7), pressure to change travel speed acts on these tilt
rotor (16), plungers (4) with shoes, valve plate (1), out- pistons (9) to change swash plate (7) angle.
put shaft (11), tilt pistons (9), casing (8), and so forth. Rotor (16) is preloaded against valve plate (1) by
spring (14) to prevent oil from leaking at the clear-
ance between them.
Hydraulically released type disc parking brake (3) is
installed in the travel motor.
1 2 3 4 5 6 7 8 9 10
11
17
16
T183-03-05-003
15 14 13 12
1- Valve Plate 6- Retainer Plate 10 - Spring 14 - Spring

2- Spring 7- Swash Plate 11 - Output Shaft 15 - Brake Piston
3- Parking Brake 8- Casing 12 - Roller Bearing 16 - Rotor
4- Plunger 9- Tilt Piston 13 - Ball 17 - Valve Cover
5- Holder
T3-5-3
Pressure oil from the pump flows to port A of valve As output shaft (6) rotates, rotor (2) also rotates. Then,
plate (1), and enters into one-sided bores in rotor (2) when plungers (3) reach port B, oil is routed to the hy-
located just behind the right-side crescent-shaped oil draulic oil tank.
port (port A side) of valve plate (1). Whether pressure oil from the pump is supplied to port
Then, plungers in the right half side of rotor (2) are A or port B determines the travel direction.
pushed out toward swash plate (5), and slide on the
swash plate to rotate rotor (2) and output shaft (6).
Port B Port A
Port B
Port A
1
2
4
6 5
Valve Plate
T183-03-05-009
1 - Valve Plate 3 - Plunger 5 - Swash Plate 6 - Output Shaft

2 - Rotor 4 - Shoe
T3-5-4
TRAVEL BRAKE VALVE
The travel brake valve is located on the travel motor
head and consists of the following valves:
Counterbalance Valve: Check Valve:

ensures smooth starts and stops and prevents ensures smooth starts and stops, and prevents
overrunning when traveling down slopes. cavitation from occurring in the motor circuit by
Overload Relief Valve: functioning together with counterbalance valve.
prevents overloads and surge pressure in the Travel Speed Shift Valve:
motor circuit. controls the tilt pistons when travel mode switch
is operated.
Cross Section A-A-A

Overload Relief Counterbalance
Valve Valve
Travel Speed
Shift Valve
Check Valve
A A A
Overload Relief Counterbalance
Valve Valve
T183-03-05-004
T3-5-5
Travel Operation
When supply oil from the main control valve is routed
to port P1, supply oil flows around spool CB, opens
check valve BC and is led to motor port BM. However,
return oil from motor port AM is blocked by spool CB
in the counterbalance valve.
As supply oil pressure at port P1 increases, supply oil
is routed to chamber G through orifice F in spool CB,
moving spool CB down against spring force. Conse-
quently, return oil from motor port AM starts to flow
into port P2 through notch H in spool CB, allowing
the travel motor to rotate.
When the travel levers are returned to the neutral

position, the oil in both ports P1 and P2 are routed to
the hydraulic oil tank through the control valve. Thus,
oil pressure in chamber G decrease, and spool CB is
moved back to the original position by spring force.
Then, the oil flow circuits is blocked, causing the
travel motors to stop rotating.
Descending Operation
When the machine travels down a slope, the travel
motors are forcibly driven by the machine weight so
that the motor draws oil like a pump. When the motor
draws oil, oil pressure at port P1 and chamber G de-
crease, causing spool CB to move upwards to restrict
return circuit from the motor.
Then, the return oil flow from the motor is restricted
by the spool, increasing pressure at port AM.
The increased pressure at port AM brakes the motor.
Thus, the restricted return oil flow from the travel
motor increases the pressure at port P1 again, mov-
ing spool CB back down. This repeated movement of
the spool (hydraulic brake action) prevents the ma-
chine from overrunning.
T3-5-6
(Travel Operation) Check Valve
BM BC G Spool CB
Spool CB
F
P1
P1
To BM
P2
P2
From AM
AM Counterbalance Valve
T183-03-05-005
(Descending Operation)
BM G Spool CB
G
Spool CB
P1
P1
To BM
P2
P2
From AM
AM
T183-03-05-006
T3-5-7
Circuit Protection
If pressure in the circuit increases over the setting
pressure of the overload relief valve, this valve opens Overload Re-
lief Valve
to relieve peak pressure to the lower pressure side to
protect the motor from overloading. This valve also
functions to release shock pressure caused by inertia
force developed when the motor stops.
Poppet
Low Pressure
High Pressure
T183-03-05-011
T3-5-8
(Blank)
T3-5-9
TRAVEL MOTOR DISPLACEMENT ANGLE
CHANGE
The travel speed mode changes as the displacement
angle of swash plate (3) is changed by tilt piston (5).
• Slow Speed Travel

(Maximum Displacement Angle)
While pilot pressure (7) that pressure is reduced by With the above, the swash plate (3) displacement an-
the signal pressure from the travel 2nd speed shift gle is fixed to the large side, and thus the plunger (6)
solenoid valve is supplied to travel speed shift valve stroke becomes maximum. Accordingly, the amount of
(1), spool A (8) is held in neutral by spring (2), block- oil required to rotate the travel motor (per turn) be-
ing pressure oil from the control valve. Pilot pres- comes maximum, resulting in slow speed travel motor
sure (7) is routed to the parking brake through the operation.
passage of spool A (8) via the circumference clear- (Refer to the Control System Group in the SYSTEM
ance of spool B (9) to release the parking brake. At Section for the control circuit.)
the same time, the line to tilt pistons (5) is opened to
the hydraulic oil tank line 9 7 8 1 2
Travel Speed Shift Valve
5 6
To Hydraulic Oil Tank
Parking Brake
4 3
From Con-
trol Valve T183-03-05-007
1 - Travel Speed Shift Valve 4 - Ball 6 - Plunger 8 - Spool A

2 - Spring 5 - Tilt Piston 7 - Pilot Pressure (from Reducing Valve) 9 - Spool B
3 - Swash Plate
T3-5-10
• Fast Speed Travel
(Minimum Displacement Angle)
While non-pressure-reduced pilot pressure (7) is Tilt pistons (5) push swash plate (3), changing the dis-
supplied to travel speed shift valve (1), pilot pres- placement angle to the minimum, resulting in the fast
sure (7) is supplied to chamber (a) via the circum- speed travel motor operation.
ference clearance of spool B (9), shifting spool A (8) (Refer to the Control System Group in the SYSTEM
to the right. Also, the pilot pressure (7) is supplied to Section for the control circuit.)
the parking brake via chamber (b) in spool A (8) to
release the parking brake. By the movement of
spool A (8), pressure oil from the control valve ex-
erts on tilt pistons (5).
9 a 7 b 8 1 2
Travel Speed Shift Valve
5 6
From Travel
Speed Shift Valve
Parking Brake
4 3
From Control
Valve
T183-03-05-008
1 - Travel Speed Shift Valve 4 - Ball 6 - Plunger 8 - Spool A

2 - Spring 5 - Tilt Piston 7 - Pilot Pressure (from Reducing Valve) 9 - Spool B
3 - Swash Plate
T3-5-11
PARKING BRAKE
The parking brake is a negative-type brake released The friction plates are connected to the rotor, and the
when pilot oil pressure is applied to parking brake plates to the casing via spline couplings respectively.
chamber M. Whenever the travel control valve spools When the spring pushes the piston to the right, the
are in neutral, the parking brake is automatically ap- friction plates come into contact with the plates, ap-
plied. plying the parking brake.
(Refer to the pilot circuit diagram in the Hydraulic Cir-
cuit Group, the SYSTEM Section, for pilot oil flow.)
Spring Piston Plate

M
Friction Plate
Casing
Rotor
T183-03-05-003
T3-5-12
Brake ON Spring
When the control lever is in the neutral position, the
friction plates and plates are pressed down by spring
force, braking the motor. Pressure oil in brake cham-
ber M is released to the hydraulic oil tank.
Spring
Plate
Friction Plate
Casing
Rotor
T111-03-04-007
Brake OFF Spring

When the control lever is operated, pilot oil is led to
brake chamber M and pushes the brake piston
against spring force. Consequently, the friction plates M
are separated from the plates, releasing the parking
brake.
Spring
Plate
Friction Plate
Casing
Rotor
T111-03-04-008
T3-5-13
(Blank)
T3-5-14
COMPONENT OPERATION / Signal Control Valve
OUTLINE
The signal control valve is provided in the pilot circuit
between the pilot valve and the control valve, and con-
trols pilot signal pressure used to regulate the pumps
and various kinds of valves.
The signal control valve consists of shuttle valves,
shockless valve, pump 1 and 2 flow rate control valve,
flow combiner valve control spool, arm flow rate con-
trol valve and priority valve.
Pilot Valve
Side
T178-03-06-016
Cross Section A-A
Shockless Valve
Arm Flow Rate Control Auxiliary
Pump 1 and 2 Flow Rate Control Valve Auxiliary
Flow Combiner Valve

Priority Valve Control Spool
T178-03-06-002
T3-6-1
PILOT PORT
NOTE: BH: Backhoe

LD: Loading Shovel
Pilot Valve Side
Port Name Connecting to Note
Port A Right Pilot Valve Boom Raise Pilot Pressure
Port B Right Pilot Valve Boom Lower, Bucket Roll-Out Pilot Pressure
Port C Left Pilot Valve Arm Roll-Out Pilot Pressure (BH)
Arm Roll-In Pilot Pressure (LD)
Port D Right Pilot Valve Boom Raise Pilot Pressure
Port E Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port F Left Pilot Valve Arm Roll-Out Pilot Pressure (BH)
Port G Left Pilot Valve Arm Roll-In Pilot Pressure (BH)
Arm Roll-Out Pilot Pressure (LD)
Port H Right Pilot Valve Bucket Roll-In Pilot Pressure
Port I Travel Pilot Valve Left Travel Reverse Pilot Pressure
Port J Travel Pilot Valve Left Travel Forward Pilot Pressure
Port K Travel Pilot Valve Right Travel Reverse Pilot Pressure
Port L Travel Pilot Valve Right Travel Forward Pilot Pressure
Port M Auxiliary Pilot Valve (BH) Auxiliary Pilot Valve (BH)
Bucket Open Pilot Valve (LD) Bucket Open Pilot Valve (LD)
Port N Auxiliary Pilot Valve (BH) Auxiliary Pilot Valve (BH)
Bucket Open Pilot Valve (LD) Bucket Open Pilot Valve (LD)
Port SA Pump 1 and 2 Regulator Pump 1 and 2 Control Pressure
Port SB − Plug
Port PI Pilot Shut-Off Valve Primary Pilot Pressure
Port PH Pilot Shut-Off Valve Primary Pilot Pressure (Heat Circuit)
Port SH − Plug
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank
T3-6-2
Pilot Valve Connecting Side

PH
C
A
E
M
D
H
B
F
SB
PI G
Pilot Valve
Side
K N
I
SH
J
DF
SA L
T178-03-06-016
T3-6-3
NOTE: BH: Backhoe

LD: Loading Shovel
Control Valve Side
Port Name Connecting to Note
Port 1 Control Valve Boom Raise Pilot Pressure
Port 2 − Plug
Port 3 − Plug
Port 4 − Plug
Port 5 − Plug
Port 6 Control Valve Arm Roll-Out Pilot Pressure (BH)
Port 7 Control Valve Arm Roll-In Pilot Pressure (BH)
Arm Roll-Out Pilot Pressure (LD)
Port 8 Control Valve Bucket Roll-In Pilot Pressure
Port 9 Control Valve Left Travel Reverse Pilot Pressure
Port 10 Control Valve Left Travel Forward Pilot Pressure
Port 11 Control Valve Right Travel Reverse Pilot Pressure
Port 12 Control Valve Right Travel Forward Pilot Pressure
Port 13 Control Valve Auxiliary Close Pilot Pressure (BH)
Bucket Close Pilot Pressure (LD)
Port 14 Control Valve Auxiliary Open Pilot Pressure (BH)
Bucket Open Pilot Pressure (LD)
Port SE Shuttle Valve Boom Raise Priority Pilot Pressure
Port SM Shuttle Valve Auxiliary
Port SN Shuttle Valve Swing Brake Release
Port SP Shuttle Valve Swing Brake Release
Port SL Control Valve Combiner Valve Shifting Pressure
Port SK − Plug
T3-6-4
Control Valve Connecting Side

SM
3
1 5
13
2 4
SK
SE
S3 8
14
Control Valve 7
Side
9
6
10
SN
SL
11
Pressure Sensor (Travel) 12 SP T178-03-06-015
T3-6-5
SHUTTLE VALVE
NOTE: BH: Backhoe

LD: Loading Shovel
The shuttle valve selects the pilot pressure oil used to
perform each operation and routes it to the corre-
sponding flow rate control valves and/or switch valve
spools. The flow rate control valves and/or switch
valve spools corresponding to each operation are as
follows:
Pump 1 and 2 Flow Arm Flow Rate Flow Combiner Priority Valve
Control Valve Control Valve Valve
Control Spool
Boom Raise { { − {
Boom Lower { − − {
Arm Roll-Out (BH)
{ − − {
Arm Roll-In (LD)
Arm Roll-In (BH)
{ − − {
Arm Roll-Out (LD)
Bucket Roll-In { − − {
Bucket Roll-Out { − − {
Right Travel { − { −
Left Travel − − − −
Auxiliary (Close) (BH)
− − − {
Bucket Close (LD)
Auxiliary (Open) (BH)
− − − {
Bucket Open (LD)
T3-6-6
Swing Arm Boom Bucket Left Travel Right Travel
1 2 3 4 5
Shockless Valve
6
Arm Flow Rate Control
Valve
P1 and P2 Pump Flow
Rate Control Valve
Flow Combiner Valve
Control Spool
Priority Valve
T183-03-06-001
17 16 15 14 13 12 11 10 9 8 7
1 - Auxiliary (BH), Bucket 6 - Right Travel 10 - Boom Raise, Arm Roll-Out 14 - Boom, Arm, Bucket
Open/Close (LD) (BH), Arm Roll-In (LD), Auxil-
iary (BH), Bucket Open/Close
(LD), Left Travel
2 - Arm Roll-Out (BH), Arm Roll-In 7 - Left Travel, Right 11 - Boom, Arm, Bucket, Right 15 - Boom Raise, Arm Roll-Out
(LD), Auxiliary (BH), Bucket Travel Travel (BH), Arm Roll-In (LD)
Open/Close (LD)
3 - Arm Roll-Out (BH), Arm Roll-In 8 - Boom, Arm, 12 - Arm Roll-In (BH), Arm 16 - Boom Raise, Arm. Roll-Out
(LD) Bucket, Right Roll-Out (LD), Bucket Roll-In (BH), Arm Roll-In (LD)
Travel
4 - Boom, Bucket Roll-Out 9 - Left Travel 13 - Room Raise, Arm, Bucket 17 - Boom Raise, Arm. Roll-Out
(BH), Arm Roll-In (LD), Aux-
iliary (BH), Bucket
Open/Close (LD)
5 - Boom, Arm Roll-Out (BH), Arm
Roll-In (LD), Bucket Roll-Out
NOTE: BH: Backhoe

LD: Loading Shovel
T3-6-7
Swing Arm Boom Bucket Left Travel Right Travel
1 2 3 4 5
Shockless Valve
6
Arm Flow Rate
Control Valve
P1 and P2 Pump Flow
Rate Control Valve
Flow Combiner Valve
Control Spool
Priority Valve
T183-03-06-001
17 16 15 14 13 12 11 10 9 8 7
NOTE: BH: Backhoe

LD: Loading Shovel
T3-6-8
Pilot Valve
Side
T178-03-06-016
Cross Section B-B
9
5
8
7
16
17
15
13
11
14
6 10
12
3
1
4
2
T178-03-06-009
1 - Auxiliary (BH), Bucket 6 - Right Travel 10 - Boom Raise, Arm Roll-Out 14 - Boom, Arm, Bucket
Open/Close (LD) (BH), Arm Roll-In (LD), Auxil-
iary (BH), Bucket Open/Close
(LD), Left Travel
2 - Arm Roll-Out (BH), Arm Roll-In 7 - Left Travel, Right 11 - Boom, Arm, Bucket, Right 15 - Boom Raise, Arm Roll-Out
(LD), Auxiliary (BH), Bucket Travel Travel (BH), Arm Roll-In (LD)
Open/Close (LD)
3 - Arm Roll-Out (BH), Arm Roll-In 8 - Boom, Arm, 12 - Arm Roll-In (BH), Arm 16 - Boom Raise, Arm Roll-Out
(LD) Bucket, Right Roll-Out (LD), Bucket Roll-In (BH), Arm Roll-In (LD)
Travel
4 - Boom, Bucket Roll-Out 9 - Left Travel 13 - Room Raise, Arm, Bucket 17 - Boom Raise, Arm Roll-Out
(BH), Arm Roll-In (LD), Aux-
iliary (BH), Bucket
Open/Close (LD)
5 - Boom, Arm Roll-Out (BH), Arm
Roll-In (LD), Bucket Roll-Out
T3-6-9
SHOCKLESS VALVE Detail of C
The shockless valve is provided in the boom raise

circuit and functions during boom lowering operation.
During Boom Raising Operation:

1. Boom raise pilot pressure oil is routed into port A
and acts on the spool.
2. Immediately after operation is started, the low pi-
lot pressure oil flows to port 1 via clearance C
T183-03-06-002
between the spool and the housing, and inner Pilot Valve Side
passage 2. Inner Passage 1 Port A C Spool
3. The set-force of spring A is weaker than that of Spring B
spring B. Therefore, when the pilot pressure in-
creases, the spool is moved to the left.
4. As the spool is moved to the left, port A is con-
nected to port 1, increasing pressure in port 1 so
that the spools of the boom 1 and 2 in the main
control valve is moved.
Inner Pas- Oil Chamber

Port 1 sage 2
Spring A T178-03-06-013
Control Valve Side
T3-6-10
During Boom Raising Operation: Boom Raise Pilot Pressure

Spool Port A
Inner Passage 2
Spring B
Spring A
Port 1 T183-03-06-003
Boom Raise Pilot Pressure

Spool Port A
Port 1 T183-03-06-004
to Spools of Boom 1 and 2 in

Main Control Valve
T3-6-11
During Boom Lowering Operation (Shock Re- Detail of C
ducing Operation)
1. When the boom is lowered, the return oil from the
boom raise spools of the boom 1 and 2 in the
main control valve is routed to port 1.
2. Since the spool blocks the oil passage between
port 1 and port A, the return oil cannot flow di-
rectly to port A.
3. Port 1 is connected to spring A side via inner
passage 1 and to the oil chamber via inner pas-
T183-03-06-002
sage 2. Pilot Valve Side
4. Pressure oil in the oil chamber flows out from Inner Passage 1 Port A C Spool
clearance C between the spool and the housing, Spring B
reducing pressure in the oil chamber. Then, the
spool is moved to the right by pressure in the
spring A side. Thereby, clearance C between the
spool and the housing is closed, blocking pres-
sure oil flow.
5. When clearance C is closed, pressure in the oil
chamber increases, moving the spool to the left.
Therefore, clearance C is opened again allowing
pressure oil to flow to port A.
6. As operation in steps (4 and 5) are repeated,
pressure oil is gradually returned to port A so that
the spools of the boom 1 and 2 in the main con-
trol valve returns slowly.
Inner Passage Oil Chamber
Port 1 2
Spring A T178-03-06-013
Control Valve Side
T3-6-12
During Boom Lowering Operation (Shock Reducing Operation)
Inner Passage 1
to Pilot Valve
Spring A Spool Port A
Inner Passage 2 Oil Chamber

Port 1 T183-03-06-003
from Spools of Boom 1 and 2 in
Main Control Valve
Inner Passage 1 Spool
Port A

Port 1 T183-03-06-005
Spring A from Spools of Boom 1 and 2 in
Main Control Valve
Spool to Pilot Valve
Port A

Port 1 T183-03-06-004
from Spools of Boom 1 and 2 in
Main Control Valve
T3-6-13
PUMP 1 AND 2 FLOW RATE CONTROL
VALVE
The pump flow rate control valve delivers pump con-
trol pressure Pi to the pump regulator in response to
the pilot oil pressure from the pilot valve, and controls
the swash angle of the pump 1 and 2 to deliver the
flow rate required by the control lever.
1. Pilot oil pressure from the pilot valve in the travel

and front operation system is routed into the
spring chamber side of the pump 1 and 2 flow
rate control valve after being selected by the shut-
tle valves in the signal pilot pressure control
valve.
2. Then, the spool is moved to the right, causing the
primary pilot pressure to flow in port SA.
3. Therefore, pressure in port SA increases.
4. Oil pressure in port SA acts on the right end of the
spool. Thus, the spool is moved back to the left
until pressure force in port SA is balanced with
pilot pressure force in the spring chamber so that
pressure in port SA stops increasing. In other
words, the primary pilot pressure is reduced to
the pressure which is corresponding to the pilot
pressure from the pilot valve, and deliver the
pressure as Pi pressure to the regulators in pump
1 and 2 from port SA.
T3-6-14
Port SA
Spring Spool
Primary Pilot Pressure
Pilot Pressure
Shuttle Valve
T178-03-06-017
T3-6-15
ARM FLOW RATE CONTROL VALVE,
FLOW COMBINER VALVE CONTROL
SPOOL, PRIORITY VALVE
NOTE: The three captioned spools are indicated in

operational principle. Arm Flow Rate Control Valve:
BH: Backhoe
LD: Loading Shovel Arm Roll-Out
(BH) / Arm
To Hydraulic Roll-In (LD)
The arm flow rate control valve delivers the arm Oil Tank Pilot Pressure
roll-out (BH)/arm roll-in (LD) pilot pressure to the roll-in Spool Spring
(BH)/roll-out (LD) side of the arm 2 spool in the main
control valve by shifting the spool using boom raise
pilot pressure.
T178-03-06-014
Boom Raise To Arm 2 Spool Roll-In
Pilot Pressure Side (BH) / Roll-Out
Side (LD)
The flow combiner valve control spool delivers the pilot Flow Combiner Valve Control Spool:
pressure to the flow combiner valve in the main control
valve from the priority valve by shifting the spool using To Hydraulic Pilot Pressure from
Oil Tank Priority Valve
right travel pilot pressure.
Spool Spring
T178-03-06-014
Right Travel To Flow Com-
Pilot Pressure biner Valve
The priority valve delivers the primary pilot pressure to

Priority Valve:
flow combiner valve control spool by shifting the spool
using boom, arm, bucket and auxiliary (BH)/bucket To Hydraulic Primary Pilot
open/close (LD) pilot pressure. Oil Tank Pressure
Spool Spring
T178-03-06-014
Boom, Arm, To Flow Combiner
Bucket, Auxiliary Valve Control Spool
(BH) / Bucket
Open/Close (LD)
Pilot Pressure
T3-6-16
COMPONENT OPERATION / Others (Upperstructure)
PILOT SHUT-OFF VALVE
The pilot shut-off valve is a manually operated switch
valve. The valve spool is rotated when the pilot control
shut-off lever is operated, switching ON and OFF the
pilot pressure oil to the pilot valve. Cross Section Z-Z
Operation with Pilot Control Shut-Off Lever in

LOCK Position
When the pilot control shut-off lever is in the LOCK

position, the pilot shut-off valve is set in neutral
(OFF), blocking pilot pressure oil from the pilot pump
to enter the pilot valves. Pressure oil is routed to the
signal control valve via port A5. Pilot pressure oil on
the pilot valve side is routed to the hydraulic tank via
port T4. As a result, the pilot valve becomes
inoperable with the control levers.
T178-03-07-002
A5 Port P Port
Operation with Pilot Control Shut-Off Lever in from Pilot
to Signal Control
UNLOCK Position Valve Pump
When the pilot control shut-off lever is moved to the

UNLOCK position, the pilot shut-off valve is turned to
the ON position, blocking the line to the tank from
the pilot valve and, at the same time, routing the pilot
pressure oil from the pilot pump to the pilot valves
via ports A1, A2 and A3. Thus, the pilot valves
become operable with the control levers.
A2 A1 Z
T1 T2 A3 A4 T4
T3 P
A5 T178-03-07-003
A1 - Travel Pilot Valve A4 - Signal Control Valve (Port PI) T1 - Travel Pilot Valve T4 - Hydraulic Oil Tank
A2 - Left Pilot Valve A5 - Signal Control Valve (Port PH) T2 - Left Pilot Valve
A3 - Right Pilot Valve P - Primary Pilot Pressure T3 - Right Pilot Valve
T3-7-1
SHOCKLESS VALVE To Boom Lower Spool
and Holding Valve Control
Valve Plunger
The shockless valve is located in the boom lower pilot A
operation circuit and pump 2 regulator Pi pressure
circuit. The shockless valve in the boom lower pilot
operation circuit controls boom lower pilot pressure
and the flow of the holding valve control valve for
boom lowering to cushion abrupt movement at the
boom lower spool and holding valve control valve.
The shockless valve of the pump 2 regulator Pi
pressure circuit controls the flow between port Pi of
the regulator in the pump 2 and the pilot valve at the
swing stopping operation to prevent rapidly decrease
of the delivery amount from pump 2.
(Refer to the Hydraulic Pressure System Group in the
SYSTEM Section for the swing motor make-up
circuit.)
B Orifice
T183-03-07-008
From Pilot Valve
To Boom Lower Spool and

Shockless Valve in Boom Lower Pilot Operation Holding Valve Control Valve
Circuit Plunger
A
• When a control lever is operated, the pilot valve
routes the pilot pressure to port B of the shockless
valve. Just after the control lever operation, the pilot
pressure oil flows to Port A through the shockless
valve only via orifice of the plunger. When pressure
from the pilot valve increases further, the plunger
move to the left, so that hydraulic oil volume
increases.
B
T183-03-07-009
From Pilot Valve
T3-7-2
• Return oil from the boom lower spool in the control From Boom Lower Spool
valve and holding valve control valve is returned to Valve Plunger
the hydraulic oil tank via orifice. When the quantity A
of return oil increases, increasing the pressure in
the A side of the shockless valve, the plunger is
moved to the right in proportion to the pressure to
restrict the return oil.
B Orifice
T183-03-07-008
via Pilot Valve
From Boom Lower Spool

Valve Plunger
A
B
T183-03-07-010
via Pilot Valve
T3-7-3
To Port Pi of Regulator in
Shockless Valve in Pump 2 Regulator Pi Pressure Pump 2 Plunger
Circuit A
• When a control lever is operated, the pilot valve

routes the pilot pressure to port B of the shockless
valve. Just after the control lever operation, the pilot
pressure oil flows through the shockless valve only
via orifice. Then, it enters into Port A and act on the
port Pi of the regulator in the pump 2. When the
pressure increases further, the plunger move to the
left, so that hydraulic oil volume increases.
B Orifice
T183-03-07-008
From Pilot Valve
To Port Pi of Regulator in
Pump 2 Plunger
A
B
T183-03-07-009
From Pilot Valve
T3-7-4
From Port Pi of Regulator
• Return oil from port Pi of the regulator in the pump 2 in Pump 2 Plunger
is returned to the hydraulic oil tank via orifice. When A
the quantity of return oil increases, increasing the
pressure in the A side of the shockless valve, the
plunger is moved to the right in proportion to the
pressure to restrict the return oil.
B Orifice
T183-03-07-008
via Pilot Valve
From Port Pi of Regulator
in Pump 2 Plunger
A
B
T183-03-07-010
via Pilot Valve
T3-7-5
SOLENOID VALVE Solenoid Valve Unit
Boom Mode Horsepower Horsepower
Solenoid Valve Unit Selection Reducing Reducing
Upon receiving signals from the main controller, the Solenoid Solenoid Solenoid
Valve Valve Valve
solenoid valve unit controls the main pump flow.
The solenoid vale unit consists of two horsepower
reducing solenoid valves (SA, SB), boom mode Pilot Relief Valve
SC SB SA
selection solenoid valve (SC) and pilot relief valve.
Solenoid Valve SA: Horsepower Reducing Solenoid
Valve: used for the main pump 3 oil flow control.
Solenoid Valve SB: Horsepower Reducing Solenoid
Valve: used for the main pump 1 and 2 oil flow
control.
Solenoid Valve SC: Boom Mode Selection Solenoid
Valve: used for the pilot pressure control of the
overload relief pressure switch valve.
(Refer to the Control System Group in the SYSTEM
Section for the pump control.)
T183-03-07-003
Spring Spool Solenoid
• Solenoid Valve Operation

In Neutral: The spool is pushed to the right
by the spring. Pilot pressure P
is blocked.
When Magnetized: The spool is pushed to the left
by the energized solenoid. Pilot
pressure P is connected to the
output port.
P Output T2 T111-02-07-003
Port Tank Port
Spool Spring
• Pilot Relief Valve Operation

The pilot relief valve sets the pilot pressure
delivered to the port P at a certain level.
The relief port T1 is connected to the heat circuit in
the shockless valve. T111-02-07-004
P T1
T3-7-6
Flow Rate Reducing Solenoid Valve
Upon receiving signals from the main controller A,
the flow reducing solenoid valve controls the main
pump 1 and 2 flow.
Section for the pump control.)
Travel Mode Solenoid Valve

Upon receiving signals from the main controller A,
the travel 2nd speed shift solenoid valve controls
Reducing Flow
the swash angle of the travel motor. Rate Solenoid
(Refer to the Control System Group in the Valve
SYSTEM Section for the valve control.)
T183-03-07-004
Heavy Lift Solenoid Valve

Heavy Lift
Upon receiving signals from the main controller A, Solenoid Valve
the heavy lift solenoid valve changes the main relief
pressure from the main control valve.
Section for the valve control.)
2-Spool EHC Valve Travel Mode

This valve consists of the horsepower increasing Solenoid Valve
solenoid valve ST and oil cooler fan control solenoid
valve SF.
The pressure corresponding to the electric signal
from the main controller A is output to the main pump T183-03-07-005
and regulator of the oil cooler fan motor drive pump 2-Spool EHC
from this valve. Valve
(Refer to the Control System Group in the SYSTEM Horsepower
Section.) Increasing
Solenoid Valve ST
Horsepower Increasing Solenoid Valve ST:
Control of the increasing delivery volume from the Oil Cooler Fan
main pump. Control Solenoid
Valve SF
Oil Cooler Fan Control Solenoid Valve SF:
Control of the oil cooler fan motor rotation speed.
T183-03-07-006
T3-7-7
OIL COOLER FAN MOTOR
The oil cooler fan motor is a inclined-shaft type, fixed
displacement axial plunger motor. The operating
principle of this motor is the same as the travel motor.
(Refer to the Travel Device section in this manual.)
Drive Disk
Rotor
T142-06-04-021
T3-7-8
ACCUMULATOR
The accumulator is provided in the pilot circuit to
buffer fluctuations in oil pressure, and to maintain the
pilot pressure for a short time period after the engine
is stopped.
The accumulator mainly consists of body (5), holder
(4), bladder (2), which encloses nitrogen gas (N2), and
poppet (1). 6
1
• Pressure oil from the pilot pump enters into the

accumulator via port A. Pilot pressure Nitrogen Gas
compresses the nitrogen gas in bladder (2) until 5 (N2)
2
they balance against each other.
4
• When pressure supply is stopped due to engine
stall or any other reasons, bladder (2) starts
expanding, supplying accumulated oil into the Pilot Pressure Oil
pilot circuit via port A. 3
T105-02-10-003
1 - Poppet 4 - Holder
2 - Bladder 5 - Body
3 - Oil Port 6 - Gas Plug
T3-7-9
AUTO-LUBRICATION SYSTEM
The auto-lubrication system lubricates the front joint Grease Pump
pin automatically. Switch
The main components are grease pump,
auto-lubrication interval switch, auto-lubrication shift
switch and grease pump switch.
This system can be switched AUTO/OFF/MANUAL by
the auto-lubrication shift switch. If the switch is turned
AUTO, the lubrication is performed at the interval set Grease Pump
by the auto-lubrication interval switch. If the switch is
turned OFF, the lubrication is not performed. If the
switch is turned MANUAL, the lubrication must be
performed by using a grease gun (lubrication is not
performed automatically).
T183-03-07-007
T3-7-10
COMPONENT OPERATION / Others (Undercarriage)
SWING BEARING
This bearing is a single-row shear ball-type bearing, The internal gear of inner race (3) engages with the
comprising outer race (1), inner race (3), balls (6), output shaft of the swing reduction gear.
supports (5), rod and turn buckle (7) and seals (2), (4).
Outer race (1) is bolted to the upperstructure and inner
race (3) is bolted to the undercarriage.
W142-03-01-002
1 - Outer Race 3 - Inner Race 5 - Support 7 - Rod and Turn Buckle

2 - Seal 4 - Seal 6 - Ball
T3-8-1
CENTER JOINT
The center joint is a 360° rotating joint. When the Hydraulic oil flows to the right and left travel motors via
upperstructure is rotated, the center joint avoids the spindle and the oil ports of the body. Seals prevent
twisting of hoses and allows hydraulic oil to flow oil leaks between the spindle and body into adjacent
smoothly to or from the travel motors. The spindle is passages.
attached to the main frame, and the body is bolted to
the swing center of the undercarriage.
Spindle
Body
Seal
W183-03-08-001
T3-8-2
TRACK ADJUSTER
The track adjuster located on the side frame is
composed of spring (5) and adjuster cylinder (6).
Spring (5) absorbs loads applied to the front idler.
Adjuster cylinder (6) adjusts track sag.
• Grease is applied through grease fitting into

chamber A of adjuster cylinder (6) as illustrated
below. The pressure of the grease pushes piston
rod (8) out and decreases track sag.
• To increases track sag, loosen valve (1) 1 to 1.5
turns counterclockwise to release grease from 1
the track adjuster cylinder through the grease Grease Fitting
discharge hole.
CAUTION: The adjusting cylinder is highly

pressurized. Loosening valve (1) quickly
and/or excessively may cause valve (1) to fly
off and the highly pressurized grease to
spout out, possibly resulting in personal
injury. Grease Discharge Hole
Be sure to loosen valve (1) slowly and
gradually, keeping face and body parts away
M104-07-119
from valve (1). In addition, never attempt to
loosen grease fitting (2).
1 2 3 4 A 5 6 7 8
W142-03-04-016
1 - Valve 3 - Washer 5 - Spring 7 - Flange

2 - Nut 4 - Spacer 6 - Adjuster Cylinder 8 - Piston Rod
T3-8-3
(Blank)
T3-8-4
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162
SERVICE MANUAL REVISION REQUEST FORM
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INTRODUCTION

• Each page has a number, located on the center

Consecutive Page Number for Each Group

SAFETY ALERT SYMBOL AND HEADLINE

• SI Units (International System of Units) are used in 2

Group 2 Component Layout

Model EX1200-5D Hydraulic Excavator

Model EX1200-5D Hydraulic Excavator

Boom Length 9.10 m (29′ 10″)

Boom Length 7.55 m (24′ 9″) BE boom

A : Minimum Digging Distance 4460 mm (14′ 8″)

ENGINE STOP SYSTEM

Max. Torque (Gross)

Rated power (Gross)

Min. BSFC (Gross)

(TRANSMISSION LUBRICATION OIL PUMP)

SWING CONTROL VALVE

SWING BRAKE VALVE

SWING PARKING BRAKE

TRAVEL BRAKE VALVE

Bucket Bucket Bucket

Bucket Bucket open/close

FRONT ATTACHMENT PILOT VALVE

TRAVEL PILOT VALVE

BUCKET OPEN / CLOSE PILOT VALVE (LOADING SHOVEL)

SOLENOID VALVE UNIT

TRAVEL MODE SHIFT SOLENOID VALVE

2-SPOOL EHC VALVE

OIL COOLER FAN MOTOR

OIL COOLER BYPASS CHECK VALVE

LOAD DUMP RELAY

1- Bucket Cylinder 11 - Swing Device 20 - Swing Bearing 29 - Accumulator

Used Circuit Fusible Link

Part Name Circuit Connected

Pump Device Front

Solenoid Valves and Related Components 5

Coolant Level Switch

SECTION 2 Hydraulic System

SECTION 3 Electrical System

Main controllers (A and B) with built-in microcomputers

Operation: The electrical signal in response to the

Engine Control Dial

Operation: When the quick idle switch on top of the

Fusible Fuse Box 2

displayed on the monitor.

Monitor Engine Stop

Operation: When main controller A is instructed by

Operation: When main controller A is instructed by

Accordingly, the travel mode control

Reducing From Main

Main Controller B From Signal

Accordingly, the travel mode control valves in the

From Signal Pilot

Operation: When the heavy lift switch is turned ON,

Other than the above, the pilot pressure

Main Control Valve

Main Main Main T18E-02-01-012

Boom Mode Selection

Boom Overload Relief Overload Relief Valve

Travel Front All

Operation: Main controller A receives signals in re-

If the fan motor speed mode of fuel temperature is

800 min-1 800 min-1