Hx210a L NL SM

CONTENTS
SECTION 1 GENERAL
Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1
Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10
SECTION 2 STRUCTURE AND FUNCTION

Group 1 Pump Device ------------------------------------------------------------------------------------------------------ 2-1
Group 2 Main Control Valve --------------------------------------------------------------------------------------------- 2-17
Group 3 Swing Device ------------------------------------------------------------------------------------------------------ 2-51
Group 4 Travel Device ------------------------------------------------------------------------------------------------------- 2-62
Group 5 RCV Lever ---------------------------------------------------------------------------------------------------------- 2-76
Group 6 RCV Pedal ---------------------------------------------------------------------------------------------------------- 2-83
SECTION 3 HYDRAULIC SYSTEM

Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 3-1
Group 2 Main Circuit --------------------------------------------------------------------------------------------------------- 3-3
Group 3 Pilot Circuit ---------------------------------------------------------------------------------------------------------- 3-6
Group 4 Single Operation ------------------------------------------------------------------------------------------------- 3-16
Group 5 Combined Operation ----------------------------------------------------------------------------------------- 3-26
SECTION 4 ELECTRICAL SYSTEM

Group 1 Component Location ----------------------------------------------------------------------------------------- 4-1
Group 2 Electrical Circuit ------------------------------------------------------------------------------------------------- 4-3
Group 3 Electrical Component Specification ----------------------------------------------------------------- 4-23
Group 4 Connectors --------------------------------------------------------------------------------------------------------- 4-36
SECTION 5 MECHATRONICS SYSTEM

Group 1 Outline ----------------------------------------------------------------------------------------------------------------- 5-1
Group 2 Mode selection System ------------------------------------------------------------------------------------- 5-3
Group 3 Automatic Deceleration System ----------------------------------------------------------------------- 5-6
Group 4 Power Boost System ----------------------------------------------------------------------------------------- 5-7
Group 5 Travel Speed Control System --------------------------------------------------------------------------- 5-8
Group 6 Automatic Warming Up Function ---------------------------------------------------------------------- 5-9
Group 7 Engine Overheat Prevention Function ------------------------------------------------------------- 5-10
Group 8 Variable Power Control System ------------------------------------------------------------------------ 5-11
Group 9 Attachment Flow Control System ------------------------------------------------------------------ 5-12
Group 10 Intelligent Power Control System ------------------------------------------------------------------- 5-13
Group 11 Anti-Restart System ---------------------------------------------------------------------------------------- 5-15
Group 12 Self-Diagnostic System ----------------------------------------------------------------------------------- 5-16
Group 13 Engine Control System ----------------------------------------------------------------------------------- 5-61
Group 14 EPPR (Electro Proportional Pressure Reducing) Valve ------------------------------ 5-62
Group 15 Monitoring System ------------------------------------------------------------------------------------------ 5-67
Group 16 Fuel Warmer System -------------------------------------------------------------------------------------- 5-109
SECTION 6 TROUBLESHOOTING
Group 1 Before Troubleshooting ----------------------------------------------------------------------------------- 6-1

Group 2 Hydraulic and Mechanical System ---------------------------------------------------------------- 6-4
Group 3 Electrical System --------------------------------------------------------------------------------------------- 6-25
Group 4 Mechatronics System ------------------------------------------------------------------------------------- 6-44
Group 5 Air conditioner and heater System ---------------------------------------------------------------- 6-72
SECTION 7 MAINTENANCE STANDARD
Group 1 Operational Performance Test ------------------------------------------------------------------------ 7-1

Group 2 Major Components ------------------------------------------------------------------------------------------ 7-21
Group 3 Track and Work Equipment ----------------------------------------------------------------------------- 7-30
SECTION 8 DISASSEMBLY AND ASSEMBLY
Group 1 Precaution -------------------------------------------------------------------------------------------------------- 8-1

Group 2 Tightening Torque -------------------------------------------------------------------------------------------- 8-4
Group 3 Pump Device --------------------------------------------------------------------------------------------------- 8-7
Group 4 Main Control Valve ------------------------------------------------------------------------------------------ 8-33
Group 5 Swing Device --------------------------------------------------------------------------------------------------- 8-57
Group 6 Travel Device ---------------------------------------------------------------------------------------------------- 8-87
Group 7 RCV Lever -------------------------------------------------------------------------------------------------------- 8-119
Group 8 Turning Joint ----------------------------------------------------------------------------------------------------- 8-133
Group 9 Boom, Arm and Bucket Cylinder -------------------------------------------------------------------- 8-138
Group 10 Undercarriage -------------------------------------------------------------------------------------------------- 8-161
Group 11 Work Equipment ---------------------------------------------------------------------------------------------- 8-173
FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to
perform repairs and make judgements. Make sure you understand the contents of this manual and
use it to full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
SECTION 1 GENERAL
This section explains the safety hints and gives the specification of the machine and major
components.
This section explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
This section explains the hydraulic circuit, single and combined operation.
This section explains the electrical circuit, monitoring system and each component. It serves not
only to give an understanding electrical system, but also serves as reference material for trouble
shooting.
This section explains the computer aided power optimization system and each component.
This section explains the troubleshooting charts correlating problems to causes
causes.
This section gives the judgement standards when inspecting disassembled parts.
This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.
0-1
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating Revised edition mark (①②③…)
Any additions, amendments or other changes will When a manual is revised, an edition mark is
be sent to HYUNDAI distributors. recorded on the bottom outside corner of the
Get the most up-to-date information before you pages.
start any work.
Revisions
Filing method Revised pages are shown at the list of revised
1. See the page number on the bottom of the pages on the between the contents page and
page. section 1 page.
File the pages in correct order.
2. Following examples shows how to read the Symbols
page number. So that the shop manual can be of ample
Example 1 practical use, important places for safety and
2-3 quality are marked with the following symbols.
Item number (2. Structure and
Function)
Consecutive page number for Symbol Item Remarks
each item.
Special safety precautions are
3. Additional pages : Additional pages are necessary when performing the
indicated by a hyphen (-) and number after the work.
Safety
page number. File as in the example. Extra special safety precautions
8-4 are necessary when performing
8-4-1 the work because it is under
Added pages internal pressure.
8-4-2
8-5 Special technical precautions or
※
other precautions for preserving
Caution
standards are necessary when
performing the work.
0-2
3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
Example
1. Method of using the Conversion Table to convert from millimeters to inches
Convert 55mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as ⓐ, then draw a
horizontal line from ⓐ.
(2) Locate the number 5 in the row across the top, take this as ⓑ, then draw a perpendicular line
down from ⓑ.
(3) Take the point where the two lines cross as ⓒ. This point ⓒ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10
SECTION 1 GENERAL
GROUP 1 SAFETY
FOLLOW SAFE PROCEDURE

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

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

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

Falling is one of the major causes of personal
injury.
When you get on and off the machine, always
maintain a three point contact with the steps
and handrails and face the machine. Do not
use any controls as handholds.
Never jump on or off the machine. Never mount
or dismount a moving machine. 13031GE03
Be careful of slippery conditions on platforms,

steps, and handrails when leaving the machine.
1-1
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors,
ambulance ser vice, hospital, and fire
department near your telephone.
13031GE04
PROTECT AGAINST FLYING DEBRIS

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

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

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

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

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

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

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

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

Do not incinerate or puncture pressurized
containers.
Make sure machine is clean of trash,
grease, and debris.
Do not store oily rags; They can ignite and
burn spontaneously.
13031GE13
1-4
BEWARE OF EXHAUST FUMES
Prevent asphyxiation. Engine exhaust fumes
can cause sickness or death.
If you must operate in a building, be positive
there is adequate ventilation. Either use an
exhaust pipe extension to remove the exhaust
fumes or open doors and windows to bring
enough outside air into the area.
REMOVE PAINT BEFORE WELDING OR
HEATING
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint
is heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding or heating:
· If you sand or grind paint, avoid breathing the 13031GE14
dust.
Wear an approved respirator.
·If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area.
Allow fumes to disperse at least 15 minutes
before welding or heating.
ILLUMINATE WORK AREA SAFELY

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

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

Escaping fluid under pressure can penetrate the
skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure 13031GE18
fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result.
13031GE19
1-6
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
Flammable spray can be generated by heating
near pressurized fluid lines, resulting in severe
burns to yourself and bystanders. Do not heat
by welding, soldering, or using a torch near
pressurized fluid lines or other flammable
materials.
13031GE20
Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area.
Install fire resisting guards to protect hoses or
other materials.
PREVENT BATTERY EXPLOSIONS

Keep sparks, lighted matches, and flame away
from the top of battery. Battery gas can
explode.
Never check battery charge by placing a metal
object across the posts. Use a volt-meter or
hydrometer.
Do not charge a frozen battery; It may explode.
Warm battery to 16。C (60。F). 13031GE21
1-7
PREVENT ACID BURNS
Sulfuric acid in battery electrolyte is poisonous.
It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte
is added.
4. Avoiding spilling of dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 10-15
minutes. Get medical attention immediate-
13031GE22
ly.
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs,
or vegetable oil.
3. Get medical attention immediately.
USE TOOLS PROPERLY

Use tools appropriate to the work. Makeshift
tools, parts, and procedures can create safety
hazards.
Use power tools only to loosen threaded tools
and fasteners.
For loosening and tightening hardware, use the
correct size tools. DO NOT use U.S.
measurement tools on metric fasteners. Avoid
bodily injury caused by slipping wrenches. 13031GE23
Use only recommended replacement parts.

(See Parts manual.)
1-8
DISPOSE OF FLUIDS PROPERLY
Improperly disposing of fluids can harm the
environment and ecology. Before draining any
fluids, find out the proper way to dispose of
waste from your local environmental agency.
Use proper containers when draining fluids. Do
not use food or beverage containers that may
mislead someone into drinking from them.
DO NOT pour oil into the ground, down a drain,
or into a stream, pond, or lake. Observe 13031GE24
relevant environmental protection regulations
when disposing of oil, fuel, coolant, brake fluid,
filters, batteries, and other harmful waste.
REPLACE SAFETY SIGNS

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

Before returning machine to customer, make
sure machine is functioning properly, especially
the safety systems. Install all guards and
shields.
1-9
GROUP 2 SPECIFICATIONS
1. MAJOR COMPONENT
Tool box DEF/AdBlue R tank Fuel tank Hydraulic tank Main pump
After
treatment
device
Engine
Charge air cooler

Oil cooler
Tooth Bucket Turning joint Swing motor Main control valve
Radiator
Arm Arm cylinder Boom Boom cylinder Cab Handrail Precleaner Counterweight
Swing
bearing
Bucket cylinder Connecting link Idler Upper roller Sprocket
Side cutter Connecting rod Lower roller Track Travel motor
210A2SP01
1-10
2. SPECIFICATIONS
1) HX210A L, MONO BOOM
I(I') D
C
E
G
F
H
J M
K N
A B(L)
210A2SP02
Unit Specification
Boom 5.65 (18' 6")
Description m (ft-in)
Arm 2.92 (9' 7") 2.00 (6' 7") 2.40 (7' 10") 3.90 (12' 10")
mm (in) Shoe 600 (24)
Operating weight kg (lb) 22150 (48830) 21980 (48460) 22050 (48610) 22360 (49300)
Bucket capacity (SAE heaped), standard m³ (yd³) 0.92 (1.196) 0.92 (1.196) 0.92 (1.196) 0.92 (1.196)
Overall length A 9510 (31' 2") 9650 (31' 8") 9570 (31' 5") 9480 (31' 1")
Overall width B 2990 (9' 10") 2990 (9' 10") 2990 (9' 10") 2990 (9' 10")
Overall height of boom C 3100 (10' 2") 3250 (10' 8") 3170 (10' 5") 3500 (11' 6")
Superstructure width D 2530 (8' 4") 2530 (8' 4") 2530 (8' 4") 2530 (8' 4")
Overall height of cab E 3000 (9' 10") 3000 (9' 10") 3000 (9' 10") 3000 (9' 10")
Ground clearance of counterweight F 1060 (3' 6") 1060 (3' 6") 1060 (3' 6") 1060 (3' 6")
Overall height of engine hood G 2520 (8' 3") 2520 (8' 3") 2520 (8' 3") 2520 (8' 3")
Overall height of handrail G' 3210 (10' 6") 3210 (10' 6") 3210 (10' 6") 3210 (10' 6")
mm (ft-in)
Minimum ground clearance H 470 (1' 7") 470 (1' 7") 470 (1' 7") 470 (1' 7")
Rear-end distance I 2770 (9' 1") 2770 (9' 1") 2770 (9' 1") 2770 (9' 1")
Rear-end swing radius I' 2850 (9' 4") 2850 (9' 4") 2850 (9' 4") 2850 (9' 4")
Distance between tumblers J 3650 (12' 0") 3650 (12' 0") 3650 (12' 0") 3650 (12' 0")
Undercarriage length K 4446 (14' 7") 4446 (14' 7") 4446 (14' 7") 4446 (14' 7")
Undercarriage width L 2990 (9' 10") 2990 (9' 10") 2990 (9' 10") 2990 (9' 10")
Track gauge M 2390 (7' 10") 2390 (7' 10") 2390 (7' 10") 2390 (7' 10")
Track shoe width, standard N 600 (24") 600 (24") 600 (24") 600 (24")
Travel speed (low/high) km/hr (mph) 3.7/5.8 (2.3/3.6) 3.7/5.8 (2.3/3.6) 3.7/5.8 (2.3/3.6) 3.7/5.8 (2.3/3.6)
Swing speed rpm 12.0 12.0 12.0 12.0
Gradeability Degree (%) 35 (70) 35 (70) 35 (70) 35 (70)
Ground pressure kgf/cm² (psi) 0.47 (6.7) 0.47 (6.7) 0.47 (6.7) 0.48 (6.8)
Max traction force kg (lb) 20830 (45922) 20830 (45922) 20830 (45922) 20830 (45922)
1-11
2) HX210A NL, MONO BOOM
I(I') D
C
E
G
F
H
J M
K N
A B(L)
210A2SP02
Unit Specification
Boom 5.65 (18' 6")
Arm 2.92 (9' 7") 2.00 (6' 7") 2.40 (7' 10") 3.90 (12' 10")
mm (in) Shoe 500 (20)
Operating weight kg (lb) 22800 (50270) 22630 (49890) 22700 (50040) 23010 (50730)
Bucket capacity (SAE heaped), standard m³ (yd³) 0.92 (1.196) 0.92 (1.196) 0.92 (1.196) 0.92 (1.196)
Overall length A 9510 (31' 2") 9650 (31' 8") 9570 (31' 5") 9480 (31' 1")
Overall width B 2555 (8' 5") 2555 (8' 5") 2555 (8' 5") 2555 (8' 5")
Overall height of boom C 3100 (10' 2") 3250 (10' 8") 3170 (10' 5") 3500 (11' 6")
Superstructure width D 2530 (8' 4") 2530 (8' 4") 2530 (8' 4") 2530 (8' 4")
Overall height of cab E 3000 (9' 10") 3000 (9' 10") 3000 (9' 10") 3000 (9' 10")
Ground clearance of counterweight F 1060 (3' 6") 1060 (3' 6") 1060 (3' 6") 1060 (3' 6")
Overall height of engine hood G 2520 (8' 3") 2520 (8' 3") 2520 (8' 3") 2520 (8' 3")
Overall height of handrail G' 3210 (10' 6") 3210 (10' 6") 3210 (10' 6") 3210 (10' 6")
mm (ft-in)
Minimum ground clearance H 470 (1' 7") 470 (1' 7") 470 (1' 7") 470 (1' 7")
Rear-end distance I 2770 (9' 1") 2770 (9' 1") 2770 (9' 1") 2770 (9' 1")
Rear-end swing radius I' 2850 (9' 4") 2850 (9' 4") 2850 (9' 4") 2850 (9' 4")
Distance between tumblers J 3650 (12' 0") 3650 (12' 0") 3650 (12' 0") 3650 (12' 0")
Undercarriage length K 4446 (14' 7") 4446 (14' 7") 4446 (14' 7") 4446 (14' 7")
Undercarriage width L 2550 (8' 4") 2550 (8' 4") 2550 (8' 4") 2550 (8' 4")
Track gauge M 2000 (6' 7") 2000 (6' 7") 2000 (6' 7") 2000 (6' 7")
Track shoe width, standard N 500 (20") 500 (20") 500 (20") 500 (20")
Travel speed (low/high) km/hr (mph) 3.7/5.8 (2.3/3.6) 3.7/5.8 (2.3/3.6) 3.7/5.8 (2.3/3.6) 3.7/5.8 (2.3/3.6)
Swing speed rpm 12.0 12.0 12.0 12.0
Gradeability Degree (%) 35 (70) 35 (70) 35 (70) 35 (70)
Ground pressure kgf/cm² (psi) 0.58 (8.3) 0.58 (8.2) 0.58 (8.3) 0.59 (8.4)
Max traction force kg (lb) 20830 (45922) 20830 (45922) 20830 (45922) 20830 (45922)
1-12
3) HX210A NL, 2PCS BOOM
I(I') D
C
E
G
F
H
J M
K N
A B(L)
210A2SP04
Unit Specification
Boom 5.65 (18' 6")
Arm 2.92 (9' 7") 2.00 (6' 7") 2.40 (7' 10")
mm (in) Shoe 500 (20)
Operating weight kg (lb) 24010 (52930) 23840 (52560) 23910 (52710)
Bucket capacity (SAE heaped), standard m³ (yd³) 0.92 (1.196) 0.92 (1.196) 0.92 (1.196)
Overall length A 9520 (31' 3") 9650 (31' 8") 9550 (31' 4")
Overall width B 2555 (8' 5") 2555 (8' 5") 2555 (8' 5")
Overall height of boom C 3030 (9' 11") 3200 (10' 6") 3000 (9' 10")
Superstructure width D 2530 (8' 4") 2530 (8' 4") 2530 (8' 4")
Overall height of cab E 3000 (9' 10") 3000 (9' 10") 3000 (9' 10")
Ground clearance of counterweight F 1060 (3' 6") 1060 (3' 6") 1060 (3' 6")
Overall height of engine hood G 2520 (8' 3") 2520 (8' 3") 2520 (8' 3")
Overall height of handrail G' 3210 (10' 6") 3210 (10' 6") 3210 (10' 6")
mm (ft-in)
Minimum ground clearance H 470 (1' 7") 470 (1' 7") 470 (1' 7")
Rear-end distance I 2770 (9' 1") 2770 (9' 1") 2770 (9' 1")
Rear-end swing radius I' 2850 (9' 4") 2850 (9' 4") 2850 (9' 4")
Distance between tumblers J 3650 (12' 0") 3650 (12' 0") 3650 (12' 0")
Undercarriage length K 4446 (14' 7") 4446 (14' 7") 4446 (14' 7")
Undercarriage width L 2550 (8' 4") 2550 (8' 4") 2550 (8' 4")
Track gauge M 2000 (6' 7") 2000 (6' 7") 2000 (6' 7")
Track shoe width, standard N 500 (20") 500 (20") 500 (20")
Travel speed (low/high) km/hr (mph) 3.7/5.8 (2.3/3.6) 3.7/5.8 (2.3/3.6) 3.7/5.8 (2.3/3.6)
Swing speed rpm 12.0 12.0 12.0
Gradeability Degree (%) 35 (70) 35 (70) 35 (70)
Ground pressure kgf/cm² (psi) 0.61 (8.7) 0.61 (8.7) 0.61 (8.7)
Max traction force kg (lb) 20830 (45922) 20830 (45922) 20830 (45922)
1-13
3. WORKING RANGE AND DIGGING FORCE
1) HX210A L, HX210A NL, MONO BOOM
A
A'
F
D
E
C
B'
B
8ft 210A2SP05
Boom 5.65 (18' 6")

Arm 2.92 (9' 7") 2.00 (6' 7") 2.40 (7' 10") 3.90 (12' 10")
Max digging reach A 9960 (32' 8") 9140 (30' 0") 9500 (31' 2") 10900 (35' 9")
Max digging reach on ground A' 9800 (32' 2") 8960 (29' 5") 9340 (30' 8") 10750 (35' 3")
Max digging depth B 6640 (21' 9") 5750 (18' 10") 6150 (20' 2") 7610 (25' 0")
Max digging depth (8 ft level) B' 6470 (21' 3") 5520 (18' 1") 5950 (19' 6") 7460 (24' 6")
mm (ft-in)
Max vertical wall digging depth C 6250 (20' 6") 5320 (17' 5") 5780 (19' 0") 6940 (22' 9")
Max digging height D 9740 (31' 11") 9270 (30' 5") 9500 (31' 2") 10310 (33' 10")
Max dumping height E 6900 (22' 8") 6450 (21' 2") 6660 (21' 10") 7470 (24' 6")
Min swing radius F 3580 (11' 9") 3710 (12' 2") 3630 (11' 11") 6850 (22' 6")
kN 133.4 [144.8] 133.4 [144.8] 133.4 [144.8] 133.4 [144.8]
kgf SAE 13600 [14770] 13600 [14770] 13600 [14770] 13600 [14770]
lbf 29983 [32560] 29983 [32560] 29983 [32560] 29983 [32560]
Bucket digging force
kN 152.0 [165.0] 152.0 [165.0] 152.0 [165.0] 152.0 [165.0]
kgf ISO 15500 [16830] 15500 [16830] 15500 [16830] 15500 [16830]
lbf 34172 [37100] 34172 [37100] 34172 [37100] 34172 [37100]
kN 102.0 [110.7] 144.2 [156.5] 119.6 [129.9] 84.3 [91.6]
kgf SAE 10400 [11290] 14700 [15960] 12200 [13250] 8600 [9340]
lbf 22928 [24890] 32408 [35190] 26896 [29210] 18960 [20590]
Arm digging force
kN 106.9 [116.0] 151.0 [164.0] 125.5 [136.3] 87.3 [94.7]
kgf ISO 10900 [11830] 15400 [16720] 12800 [13900] 8900 [9660]
lbf 24030 [26080] 33951 [36860] 28219 [30640] 19621 [21300]
[ ] : Power boost
1-14
2) HX210A NL, 2-PIECE BOOM
220A2SP07
Boom 5.65 (18' 6")

Arm 2.92 (9' 7") 2.00 (6' 7") 2.40 (7' 10")
Max digging reach A 10020 (32' 10") 9120 (29' 11") 9530 (31' 3")
Max digging reach on ground A' 9860 (32' 4") 8940 (29' 4") 9360 (30' 9")
Max digging depth B 6400 (21' 0") 5480 (18' 0") 5890 (19' 4")
Max digging depth (8 ft level) B' 6300 (20' 8") 5360 (17' 7") 5770 (18' 11")
mm (ft-in)
Max vertical wall digging depth C 5530 (18' 2") 4560 (15' 0") 4990 (16' 4")
Max digging height D 11080 (36' 4") 10300 (33' 10") 10670 (35' 0")
Max dumping height E 8160 (26' 9") 7390 (24' 3") 7740 (25' 5")
Min swing radius F 2540 (8' 4") 2870 (9' 5") 2670 (8' 9")
kN 133.4 [144.8] 133.4 [144.8] 133.4 [144.8]
kgf SAE 13600 [14770] 13600 [14770] 13600 [14770]
lbf 29983 [32560] 29983 [32560] 29983 [32560]
Bucket digging force
kN 152.0 [165.0] 152.0 [165.0] 152.0 [165.0]
kgf ISO 15500 [16830] 15500 [16830] 15500 [16830]
lbf 34172 [37100] 34172 [37100] 34172 [37100]
kN 102.0 [110.7] 144.2 [156.5] 119.6 [129.9]
kgf SAE 10400 [11290] 14700 [15960] 12200 [13250]
lbf 22928 [24890] 32408 [35190] 26896 [29210]
Arm digging force
kN 106.9 [116.0] 151.0 [164.0] 125.5 [136.3]
kgf ISO 10900 [11830] 15400 [16720] 12800 [11900]
lbf 24030 [26080] 33951 [36860] 28219 [30640]
[ ] : Power boost
1-15
4. WEIGHT
HX210A L HX210A NL
Item
kg lb kg lb
Upperstructure assembly
Main frame weld assembly 1,763 3,890 1,763 3,890
Engine assembly 383 845 383 845
Aftertreatment assembly 53 116 53 116
Main pump assembly 140 309 140 309
Main control valve assembly 220 485 220 485
Swing motor assembly 240 529 240 529
Hydraulic oil tank WA 170 370 191 420
Fuel tank WA 201 440 171 380
Counterweight 3,800 8,380 4,700 10,360
Cab assembly 495 1,090 495 1,090
Lower chassis assembly

Track frame weld assembly 2,553 5,630 2,420 5,340
Swing bearing 290 640 290 640
Travel motor assembly (2EA) 609 1,343 609 1,343
Turning joint 53 120 53 120
Sprocket (2EA) 112 250 112 250
Track recoil spring (2EA) 279 620 279 620
Idler (2EA) 301 660 301 660
Upper roller (2EA) 82 180 82 180
Lower roller (18EA) 675 1,490 675 1,490
Track-chain assembly
- - 2,618 5,770
(500 mm triple grouser shoe) (2EA)
2,712 5,980 2,712 5,980
2,902 6,400 2,902 6,400
(600 mm triple grouser shoe)-HD (2EA)
3184 7020 - -
3750 8270 - -
3458 7624 - -
(700 mm double grouser shoe) (2EA)
Front attachment assembly

5.65 m boom assembly 1,370 3,020 1,370 3,020
2.92 m arm assembly 760 1,680 760 1,680
0.92 m³ SAE heaped bucket 800 1,760 800 1,760
2pcs boom assembly - - 2,585 5,700
2.0 m arm assembly 975 2,150 975 2,150
2.40 m arm assembly 1045 2300 1045 2300
3.90 m arm assembly 1295 2850 1295 2850
Boom cylinder assembly (2EA) 364 800 364 800
Arm cylinder assembly 277 610 277 610
Bucket cylinder assembly 171 380 171 380
Bucket control linkage total 170 370 170 370
1-16
5. LIFTING CAPACITIES
Model Type Boom Arm Counterweight Shoe Wheel Dozer Outrigger
HX210A MONO Length [mm] Length [mm] weight [kg] width [mm] width [mm] Front Rear Front Rear
NL BOOM 5650 2920 4700 500 - - - - -
· : Rating over-front · : Rating over-side or 360 degree A
Lift-point radius (B) At max. reach

Lift-point 1.5 m (4.9 ft) 3.0 m (9.8 ft) 4.5 m (14.8 ft) 6.0 m (19.7 ft) 7.5 m (24.6 ft) Capacity Reach
height (A)
m (ft)
7.5 m kg *4250 *4250 *3190 *3190 6.24

(24.6 ft) lb *9370 *9370 *7030 *7030 (20.5)
6.0 m kg *4440 *4440 *2920 *2920 7.36
(19.7 ft) lb *9790 *9790 *6440 *6440 (24.1)
4.5 m kg *4950 4660 *4730 3270 *2840 *2840 8.05
(14.8 ft) lb *10910 10270 *10430 7210 *6260 *6260 (26.4)
3.0 m kg *7370 6680 *5790 4420 *5090 3170 *2880 2640 8.41
(9.8 ft) lb *16250 14730 *12760 9740 *11220 6990 *6350 5820 (27.6)
1.5 m kg *9140 6200 *6690 4190 *5540 3060 *3040 2540 8.49
(4.9 ft) lb *20150 13670 *14750 9240 *12210 6750 *6700 5600 (27.9)
0.0 m kg *6220 *6220 *10180 5940 *7360 4030 5530 2970 *3360 2590 8.30
(0.0 ft) lb *13710 *13710 *22440 13100 *16230 8880 12190 6550 *7410 5710 (27.2)
-1.5 m kg *6700 *6700 *10680 *10680 *10430 5860 7600 3950 5500 2950 *3920 2800 7.82
(-4.9 ft) lb *14770 *14770 *23550 *23550 *22990 12920 16760 8710 12130 6500 *8640 6170 (25.7)
-3.0 m kg *11310 *11310 *14370 11030 *9920 5910 *7310 3990 *5050 3300 6.98
(-9.8 ft) lb *24930 *24930 *31680 24320 *21870 13030 *16120 8800 *11130 7280 (22.9)
-4.5 m kg *11800 11380 *8290 6120 *6180 4550 5.63
(-14.8 ft) lb *26010 25090 *18280 13490 *13620 10030 (18.5)
Note 1. Lifting capacity are based on ISO 10567.

2. Lifting capacity of the HX series does not exceed 75% of tipping load with the machine on firm,
level ground or 87% of full hydraulic capacity.
3. The Lift-point is bucket pivot mounting pin on the arm (without bucket mass).
4. *Indicates load limited by hydraulic capacity.
※ Lifting capacities are based upon a standard machine conditions.
Lifting capacities will vary with different work tools, ground conditions and attachments.
The difference between the weight of a work tool attachment must be subtracted.
Consult your Hyundai dealer regarding the lifting capacities for specific work tools and
attachments.
Failure to comply to the rated load can cause possible personal injury or property damage.
Make adjustments to the rated load as necessory for non-standard configurations.
1-17
NL BOOM 5650 2000 4700 500 - - - - -

Lift-point 3.0 m (9.8 ft) 4.5 m (14.8 ft) 6.0 m (19.7 ft) 7.5 m (24.6 ft) Capacity Reach
height (A)
m (ft)
7.5 m kg *5720 *5720 4.96
(24.6 ft) lb *12610 *12610 (16.3)
6.0 m kg *5470 4700 *5550 4320 6.32
(19.7 ft) lb *12060 10360 *12240 9520 (20.7)
4.5 m kg *6860 *6860 *5810 4590 *5600 3530 7.11
(14.8 ft) lb *15120 *15120 *12810 10120 *12350 7780 (23.3)
3.0 m kg *8680 6490 *6550 4390 *5750 3180 5730 3170 7.52
(9.8 ft) lb *19140 14310 *14440 9680 *12680 7010 12630 6990 (24.7)
1.5 m kg *7290 4200 5670 3110 5550 3050 7.61
(4.9 ft) lb *16070 9260 12500 6860 12240 6720 (25.0)
0.0 m kg *10590 6000 *7730 4090 5730 3130 7.40
(0.0 ft) lb *23350 13230 *17040 9020 12630 6900 (24.3)
-1.5 m kg *10320 6020 *7670 4080 6410 3470 6.85
(-4.9 ft) lb *22750 13270 *16910 8990 14130 7650 (22.5)
-3.0 m kg *12600 11450 *9240 6150 *6790 4330 5.87
(-9.8 ft) lb *27780 25240 *20370 13560 *14970 9550 (19.3)
-4.5 m kg
(-14.8 ft) lb
attachments.
1-18
NL BOOM 5650 2400 4700 500 - - - - -

height (A)
m (ft)
7.5 m kg *4900 *4900 5.55
(24.6 ft) lb *10800 *10800 (18.2)
6.0 m kg *5010 4750 *4430 3870 6.79
(19.7 ft) lb *11050 10470 *9770 8530 (22.3)
4.5 m kg *6310 *6310 *5450 4620 *4610 3250 *4300 3230 7.53
(14.8 ft) lb *13910 *13910 *12020 10190 *10160 7170 *9480 7120 (24.7)
3.0 m kg *8130 6570 *6240 4400 *5450 3180 *4380 2920 7.92
(9.8 ft) lb *17920 14480 *13760 9700 *12020 7010 *9660 6440 (26.0)
1.5 m kg *9720 6160 *7050 4200 5650 3090 *4650 2810 8.01
(4.9 ft) lb *21430 13580 *15540 9260 12460 6810 *10250 6190 (26.3)
0.0 m kg *10470 5970 *7600 4060 5580 3030 *5170 2870 7.80
(0.0 ft) lb *23080 13160 *16760 8950 12300 6680 *11400 6330 (25.6)
-1.5 m kg *11180 11090 *10420 5950 7670 4030 5820 3150 7.29
(-4.9 ft) lb *24650 24450 *22970 13120 16910 8880 12830 6940 (23.9)
-3.0 m kg *13470 11270 *9600 6050 *7030 4110 *6400 3820 6.38
(-9.8 ft) lb *29700 24850 *21160 13340 *15500 9060 *14110 8420 (20.9)
-4.5 m kg *7230 6330 *6450 5740 4.85
(-14.8 ft) lb *15940 13960 *14220 12650 (15.9)
attachments.
1-19
HX210A 2-PIECE Length [mm] Length [mm] weight [kg] width [mm] width [mm] Front Rear Front Rear
NL BOOM 5647 2000 4700 500 - - - - -

height (A)
m (ft)
7.5 m kg *7000 *7000 *6640 6180 5.02
(24.6 ft) lb *15430 *15430 *14640 13620 (16.5)
6.0 m kg *9600 *9600 *7050 *7050 *5610 4660 *5430 4190 6.37
(19.7 ft) lb *21160 *21160 *15540 *15540 *12370 10270 *11970 9240 (20.9)
4.5 m kg *8100 6950 *5830 4530 *4950 3410 7.15
(14.8 ft) lb *17860 15320 *12850 9990 *10910 7520 (23.5)
3.0 m kg *6410 4300 *4840 3090 *4800 3050 7.56
(9.8 ft) lb *14130 9480 *10670 6810 *10580 6720 (24.8)
1.5 m kg *7140 4090 *5020 3010 *4890 2930 7.65
(4.9 ft) lb *15740 9020 *11070 6640 *10780 6460 (25.1)
0.0 m kg *9770 5820 *7390 3970 *5250 3010 7.44
(0.0 ft) lb *21540 12830 *16290 8750 *11570 6640 (24.4)
-1.5 m kg *8360 5850 *6410 3960 *5030 3340 6.90
(-4.9 ft) lb *18430 12900 *14130 8730 *11090 7360 (22.6)
attachments.
1-20
NL BOOM 5647 2400 4700 500 - - - - -

height (A)
m (ft)
9.0 m kg *6600 *6600 3.38
(29.5 ft) lb *14550 *14550 (11.1)
7.5 m kg *6520 *6520 *4880 *4880 5.62
(24.6 ft) lb *14370 *14370 *10760 *10760 (18.4)
6.0 m kg *6640 *6640 *5300 4720 *4360 3750 6.85
(19.7 ft) lb *14640 *14640 *11680 10410 *9610 8270 (22.5)
4.5 m kg *7560 7070 *5560 4570 *4500 3180 *4200 3110 7.58
(14.8 ft) lb *16670 15590 *12260 10080 *9920 7010 *9260 6860 (24.9)
3.0 m kg *9640 6480 *6130 4320 *4620 3100 *4230 2810 7.97
(9.8 ft) lb *21250 14290 *13510 9520 *10190 6830 *9330 6190 (26.1)
1.5 m kg *10330 6000 *6880 4090 *4850 3000 *4420 2700 8.05
(4.9 ft) lb *22770 13230 *15170 9020 *10690 6610 *9740 5950 (26.4)
0.0 m kg *10010 5790 *7460 3940 *5060 2930 *4710 2760 7.85
(0.0 ft) lb *22070 12760 *16450 8690 *11160 6460 *10380 6080 (25.8)
-1.5 m kg *10590 *10590 *8830 5770 *6710 3900 *4810 3030 7.34
(-4.9 ft) lb *23350 *23350 *19470 12720 *14790 8600 *10600 6680 (24.1)
-3.0 m kg *6690 5900 *4850 4000
(-9.8 ft) lb *14750 13010 *10690 8820

attachments.
1-21
NL BOOM 5647 2920 4700 500 - - - - -

height (A)
m (ft)
9.0 m kg *3940 *3940 4.46
(29.5 ft) lb *8690 *8690 (14.6)
7.5 m kg *6020 *6020 *4590 *4590 *3130 *3130 6.32
(24.6 ft) lb *13270 *13270 *10120 *10120 *6900 *6900 (20.7)
6.0 m kg *6170 *6170 *4950 4800 *2830 *2830 7.43
(19.7 ft) lb *13600 *13600 *10910 10580 *6240 *6240 (24.4)
4.5 m kg *9140 *9140 *6930 *6930 *5220 4630 *4200 3210 *2730 *2730 8.11
(14.8 ft) lb *20150 *20150 *15280 *15280 *11510 10210 *9260 7080 *6020 *6020 (26.6)
3.0 m kg *8690 6610 *5770 4360 *4380 3100 *2750 2530 8.47
(9.8 ft) lb *19160 14570 *12720 9610 *9660 6830 *6060 5580 (27.8)
1.5 m kg *10100 6060 *6520 4090 *4640 2970 *2870 2430 8.55
(4.9 ft) lb *22270 13360 *14370 9020 *10230 6550 *6330 5360 (28.1)
0.0 m kg *10160 5760 *7260 3900 *4890 2880 *3130 2480 8.36
(0.0 ft) lb *22400 12700 *16010 8600 *10780 6350 *6900 5470 (27.4)
-1.5 m kg *10190 *10190 *9300 5680 *6970 3830 *5040 2850 *3600 2680 7.88
(-4.9 ft) lb *22470 *22470 *20500 12520 *15370 8440 *11110 6280 *7940 5910 (25.9)
-3.0 m kg *9470 *9470 *7530 5750 *5620 3870 *3990 3170 7.05
(-9.8 ft) lb *20880 *20880 *16600 12680 *12390 8530 *8800 6990 (23.1)

attachments.
1-22
MONO Length [mm] Length [mm] weight [kg] width [mm] width [mm] Front Rear Front Rear
HX210A L
BOOM 5650 2000 3800 800 - - - - -

height (A)
m (ft)
7.5 m kg *5720 *5720 4.96
(24.6 ft) lb *12610 *12610 (16.3)
6.0 m kg *5470 5230 *5550 4790 6.32
(19.7 ft) lb *12060 11530 *12240 10560 (20.7)
4.5 m kg *6860 *6860 *5810 5110 *5600 3920 7.11
(14.8 ft) lb *15120 *15120 *12810 11270 *12350 8640 (23.3)
3.0 m kg *8680 7370 *6550 4900 5470 3530 5450 3520 7.52
(9.8 ft) lb *19140 16250 *14440 10800 12060 7780 12020 7760 (24.7)
1.5 m kg *7290 4710 5390 3460 5280 3390 7.61
(4.9 ft) lb *16070 10380 11880 7630 11640 7470 (25.0)
0.0 m kg *10590 6850 7370 4590 5450 3480 7.40
(0.0 ft) lb *23350 15100 16250 10120 12020 7670 (24.3)
-1.5 m kg *10320 6870 7360 4580 6100 3870 6.85
(-4.9 ft) lb *22750 15150 16230 10100 13450 8530 (22.5)
-3.0 m kg *12600 *12600 *9240 7000 *6790 4860 5.87
(-9.8 ft) lb *27780 *27780 *20370 15430 *14970 10710 (19.3)
attachments.
1-23
HX210A L
BOOM 5650 2400 3800 800 - - - - -

height (A)
m (ft)
7.5 m kg *4900 *4900 5.55
(24.6 ft) lb *10800 *10800 (18.2)
6.0 m kg *5010 *5010 *4430 4290 6.79
(19.7 ft) lb *11050 *11050 *9770 9460 (22.3)
4.5 m kg *6310 *6310 *5450 5140 *4610 3600 *4300 3580 7.53
(14.8 ft) lb *13910 *13910 *12020 11330 *10160 7940 *9480 7890 (24.7)
3.0 m kg *8130 7460 *6240 4920 *5450 3530 *4380 3240 7.92
(9.8 ft) lb *17920 16450 *13760 10850 *12020 7780 *9660 7140 (26.0)
1.5 m kg *9720 7020 *7050 4700 5370 3440 *4650 3130 8.01
(4.9 ft) lb *21430 15480 *15540 10360 11840 7580 *10250 6900 (26.3)
0.0 m kg *10470 6820 7340 4570 5310 3370 5020 3200 7.80
(0.0 ft) lb *23080 15040 16180 10080 11710 7430 11070 7050 (25.6)
-1.5 m kg *11180 *11180 *10420 6800 7300 4530 5530 3510 7.29
(-4.9 ft) lb *24650 *24650 *22970 14990 16090 9990 12190 7740 (23.9)
-3.0 m kg *13470 13460 *9600 6900 *7030 4610 *6400 4270 6.38
(-9.8 ft) lb *29700 29670 *21160 15210 *15500 10160 *14110 9410 (20.9)
-4.5 m kg *7230 7200 *6450 *6450 4.85
(-14.8 ft) lb *15940 15870 *14220 *14220 (15.9)
attachments.
1-24
HX210A L
BOOM 5650 2920 3800 800 - - - - -

Lift-point 1.5 m (4.9 ft) 3.0 m (9.8 ft) 4.5 m (14.8 ft) 6.0 m (19.7 ft) 7.5 m (24.6 ft) Capacity Reach
height (A)
m (ft)
7.5 m kg *4250 *4250 *3190 *3190 6.24

(24.6 ft) lb *9370 *9370 *7030 *7030 (20.5)
6.0 m kg *4440 *4440 *2920 *2920 7.36
(19.7 ft) lb *9790 *9790 *6440 *6440 (24.1)
4.5 m kg *4950 *4950 *4730 3630 *2840 *2840 8.05
(14.8 ft) lb *10910 *10910 *10430 8000 *6260 *6260 (26.4)
3.0 m kg *7370 *7370 *5790 4940 *5090 3530 *2880 *2880 8.41
(9.8 ft) lb *16250 *16250 *12760 10890 *11220 7780 *6350 *6350 (27.6)
1.5 m kg *9140 7070 *6690 4700 5350 3410 *3040 2830 8.49
(4.9 ft) lb *20150 15590 *14750 10360 11790 7520 *6700 6240 (27.9)
0.0 m kg *6220 *6220 *10180 6790 7310 4530 5260 3320 *3360 2880 8.30
(0.0 ft) lb *13710 *13710 *22440 14970 16120 9990 11600 7320 *7410 6350 (27.2)
-1.5 m kg *6700 *6700 *10680 *10680 *10430 6710 7230 4450 5230 3290 *3920 3120 7.82
(-4.9 ft) lb *14770 *14770 *23550 *23550 *22990 14790 15940 9810 11530 7250 *8640 6880 (25.7)
-3.0 m kg *11310 *11310 *14370 13210 *9920 6770 7260 4490 *5050 3690 6.98
(-9.8 ft) lb *24930 *24930 *31680 29120 *21870 14930 16010 9900 *11130 8140 (22.9)
-4.5 m kg *11800 *11800 *8290 6980 *6180 5110 5.63
(-14.8 ft) lb *26010 *26010 *18280 15390 *13620 11270 (18.5)

attachments.
1-25
HX210A L
BOOM 5650 3900 3800 800 - - - - -

Lift-point 1.5 m (4.9 ft) 3.0 m (9.8 ft) 4.5 m (14.8 ft) 6.0 m (19.7 ft) 7.5 m (24.6 ft) 9.0 m (29.5 ft) Capacity Reach
height (A)
m (ft)
7.5 m kg *2200 *2200 7.47

(24.6 ft) lb *4850 *4850 (24.5)
6.0 m kg *3680 *3680 *2040 *2040 8.42
(19.7 ft) lb *8110 *8110 *4500 *4500 (27.6)
4.5 m kg *3970 *3970 *3920 3670 *2130 *2130 *1990 *1990 9.03
(14.8 ft) lb *8750 *8750 *8640 8090 *4700 *4700 *4390 *4390 (29.6)
3.0 m kg *5840 *5840 *4860 *4860 *4380 3530 *3400 2600 *2010 *2010 9.36
(9.8 ft) lb *12870 *12870 *10710 *10710 *9660 7780 *7500 5730 *4430 *4430 (30.7)
1.5 m kg *9190 *9190 *7830 7200 *5880 4710 *4940 3370 *3930 2530 *2100 *2100 9.43
(4.9 ft) lb *20260 *20260 *17260 15870 *12960 10380 *10890 7430 *8660 5580 *4630 *4630 (30.9)
0.0 m kg *7490 *7490 *9340 6750 *6760 4470 5180 3240 *3690 2470 *2290 *2290 9.26
(0.0 ft) lb *16510 *16510 *20590 14880 *14900 9850 11420 7140 *8140 5450 *5050 *5050 (30.4)
-1.5 m kg *5580 *5580 *9610 *9610 *10100 6530 7100 4320 5090 3150 *2600 2520 8.83
(-4.9 ft) lb *12300 *12300 *21190 *21190 *22270 14400 15650 9520 11220 6940 *5730 5560 (29.0)
-3.0 m kg *8660 *8660 *13300 12690 *10130 6500 7050 4280 5080 3150 *3160 2860 8.10
(-9.8 ft) lb *19090 *19090 *29320 27980 *22330 14330 15540 9440 11200 6940 *6970 6310 (26.6)
-4.5 m kg *12540 *12540 *13730 12970 *9330 6620 *6800 4370 *4350 3590 6.97
(-14.8 ft) lb *27650 *27650 *30270 28590 *20570 14590 *14990 9630 *9590 7910 (22.9)
-6.0 m kg *6950 6950
(-19.7 ft) lb *15320 15320

attachments.
1-26
2-PIECE Length [mm] Length [mm] weight [kg] width [mm] width [mm] Front Rear Front Rear
HX210A L
BOOM 5647 2000 3800 800 - - - - -

height (A)
m (ft)
7.5 m kg *7000 *7000 *6640 *6640 5.02
(24.6 ft) lb *15430 *15430 *14640 *14640 (16.5)
6.0 m kg *9600 *9600 *7050 *7050 *5610 5210 *5430 4690 6.37
(19.7 ft) lb *21160 *21160 *15540 *15540 *12370 11490 *11970 10340 (20.9)
4.5 m kg *8100 7900 *5830 5070 *4950 3810 7.15
(14.8 ft) lb *17860 17420 *12850 11180 *10910 8400 (23.5)
3.0 m kg *6410 4830 *4840 3460 *4800 3410 7.56
(9.8 ft) lb *14130 10650 *10670 7630 *10580 7520 (24.8)
1.5 m kg *7140 4610 *5020 3380 *4890 3280 7.65
(4.9 ft) lb *15740 10160 *11070 7450 *10780 7230 (25.1)
0.0 m kg *9770 6690 7330 4490 *5250 3370 7.44
(0.0 ft) lb *21540 14750 16160 9900 *11570 7430 (24.4)
-1.5 m kg *8360 6720 *6410 4480 *5030 3760 6.90
(-4.9 ft) lb *18430 14820 *14130 9880 *11090 8290 (22.6)
attachments.
1-27
HX210A L
BOOM 5467 2400 3800 800 - - - - -

height (A)
m (ft)
9.0 m kg *6600 *6600 3.38
(29.5 ft) lb *14550 *14550 (11.1)
7.5 m kg *6520 *6520 *4880 *4880 5.62
(24.6 ft) lb *14370 *14370 *10760 *10760 (18.4)
6.0 m kg *6640 *6640 *5300 5280 *4360 4180 6.85
(19.7 ft) lb *14640 *14640 *11680 11640 *9610 9220 (22.5)
4.5 m kg *7560 *7560 *5560 5120 *4500 3550 *4200 3480 7.58
(14.8 ft) lb *16670 *16670 *12260 11290 *9920 7830 *9260 7670 (24.9)
3.0 m kg *9640 7390 *6130 4860 *4620 3470 *4230 3140 7.97
(9.8 ft) lb *21250 16290 *13510 10710 *10190 7650 *9330 6920 (26.1)
1.5 m kg *10330 6880 *6880 4610 *4850 3360 *4420 3030 8.05
(4.9 ft) lb *22770 15170 *15170 10160 *10690 7410 *9740 6680 (26.4)
0.0 m kg *10010 6660 7300 4460 *5060 3290 *4710 3100 7.85
(0.0 ft) lb *22070 14680 16090 9830 *11160 7250 *10380 6830 (25.8)
-1.5 m kg *10590 *10590 *8830 6650 *6710 4420 *4810 3410 7.34
(-4.9 ft) lb *23350 *23350 *19470 14660 *14790 9740 *10600 7520 (24.1)
-3.0 m kg *6690 *6690 *4850 4530
(-9.8 ft) lb *14750 *14750 *10690 9990

attachments.
1-28
HX210A L
BOOM 5647 2920 3800 800 - - - - -

height (A)
m (ft)
9.0 m kg *3940 *3940 4.46
(29.5 ft) lb *8690 *8690 (14.6)
7.5 m kg *6020 *6020 *4590 *4590 *3130 *3130 6.32
(24.6 ft) lb *13270 *13270 *10120 *10120 *6900 *6900 (20.7)
6.0 m kg *6170 *6170 *4950 *4950 *2830 *2830 7.43
(19.7 ft) lb *13600 *13600 *10910 *10910 *6240 *6240 (24.4)
4.5 m kg *9140 *9140 *6930 *6930 *5220 5180 *4200 3590 *2730 *2730 8.11
(14.8 ft) lb *20150 *20150 *15280 *15280 *11510 11420 *9260 7910 *6020 *6020 (26.6)
3.0 m kg *8690 7550 *5770 4900 *4380 3470 *2750 *2750 8.47
(9.8 ft) lb *19160 16640 *12720 10800 *9660 7650 *6060 *6060 (27.8)
1.5 m kg *10100 6960 *6520 4620 *4640 3340 *2870 2730 8.55
(4.9 ft) lb *22270 15340 *14370 10190 *10230 7360 *6330 6020 (28.1)
0.0 m kg *10160 6640 *7260 4430 *4890 3240 *3130 2790 8.36
(0.0 ft) lb *22400 14640 *16010 9770 *10780 7140 *6900 6150 (27.4)
-1.5 m kg *10190 *10190 *9300 6550 *6970 4350 *5040 3220 *3600 3020 7.88
(-4.9 ft) lb *22470 *22470 *20500 14440 *15370 9590 *11110 7100 *7940 6660 (25.9)
-3.0 m kg *9470 *9470 *7530 6630 *5620 4390 *3990 3580 7.05
(-9.8 ft) lb *20880 *20880 *16600 14620 *12390 9680 *8800 7890 (23.1)

attachments.
1-29
HX210A L
BOOM 5647 3900 3800 800 - - - - -

Lift-point 1.5 m (4.9 ft) 3.0 m (9.8 ft) 4.5 m (14.8 ft) 6.0 m (19.7 ft) 7.5 m (24.6 ft) 9.0 m (29.5 ft) Capacity Reach
height (A)
m (ft)
9.0 m kg *2890 *2890 *2530 *2530 6.10

(29.5 ft) lb *6370 *6370 *5580 *5580 (20.0)
7.5 m kg *4370 *4370 *2390 *2390 *2150 *2150 7.56
(24.6 ft) lb *9630 *9630 *5270 *5270 *4740 *4740 (24.8)
6.0 m kg *4400 *4400 *3670 *3670 *1980 *1980 8.50
(19.7 ft) lb *9700 *9700 *8090 *8090 *4370 *4370 (27.9)
4.5 m kg *4900 *4900 *4630 *4630 *3760 3660 *2410 *2410 *1910 *1910 9.10
(14.8 ft) lb *10800 *10800 *10210 *10210 *8290 8070 *5310 *5310 *4210 *4210 (29.9)
3.0 m kg *11780 *11780 *7130 *7130 *5100 5010 *3950 3500 *3230 2550 *1910 *1910 9.43
(9.8 ft) lb *25970 *25970 *15720 *15720 *11240 11050 *8710 7720 *7120 5620 *4210 *4210 (30.9)
1.5 m kg *9340 7140 *5800 4660 *4230 3320 *3330 2470 *1990 *1990 9.50
(4.9 ft) lb *20590 15740 *12790 10270 *9330 7320 *7340 5450 *4390 *4390 (31.2)
0.0 m kg *6980 *6980 *10000 6620 *6590 4380 *4520 3170 *3450 2400 *2140 *2140 9.33
(0.0 ft) lb *15390 *15390 *22050 14590 *14530 9660 *9960 6990 *7610 5290 *4720 *4720 (30.6)
-1.5 m kg *5210 *5210 *9170 *9170 *9770 6380 7060 4210 *4770 3070 *2400 *2400 8.90
(-4.9 ft) lb *11490 *11490 *20220 *20220 *21540 14070 15560 9280 *10520 6770 *5290 *5290 (29.2)
-3.0 m kg *12030 *12030 *8650 6350 *6430 4180 *4700 3070 *2870 2760 8.18
(-9.8 ft) lb *26520 *26520 *19070 14000 *14180 9220 *10360 6770 *6330 6080 (26.8)
-4.5 m kg *6470 *6470 *4670 4280
(-14.8 ft) lb *14260 *14260 *10300 9440

attachments.
1-30
6. BUCKET SELECTION GUIDE
1) HX210A L, 3800 KG COUNTERWEIGHT
General bucket Heavy duty Heavy duty Rock heavy duty

(without side cutter) (with side cutter)
MONO 2-PIECE
Capacity Width
Recommendation mm (ft-in)
Without Weight Tooth
SAE CECE
Type side 5.65 m (18' 6") Boom 5.65 m (18' 6") Boom
Heaped heaped
cutter
2.10 m 2.4 m 2.92 m 3.9 m 2.0m 2.4 m 2.92 m
m3 m3 mm kg
EA (6' 7') (7' 10") (9' 7") (12' 10") (6' 7") (7' 10") (9' 7")
(yd3) (yd3) (in) (lb)
Arm Arm Arm Arm Arm Arm Arm
0.80 0.70 1,070 770
5 ● ● ● ◐ ● ● ●
(1.05) (0.92) (42.1'') (1,700)
0.87 0.76 1,140 804
5 ● ● ● ◐ ● ● ●
(1.14) (0.99) (44.9'') (1,770)
0.92 0.80 1,190 820
5 ● ● ● ■ ● ● ◐
General (1.20) (1.05) (46.9'') (1,810)
bucket 1.10 0.96 1,375 890
(1.44) (1.26) (54.1'') (1,960)
5 ● ◐ ■ ▲ ● ◐ ■
1.20 1.05 1,390 920

(1.57) (1.37) (54.7'') (2,030)
5 ◐ ◐ ■ ▲ ◐ ■ ■
1.34 1.17 1,525 990

(1.75) (1.53) (60.0'') (2,180)
6 ◐ ■ ▲ X ■ ■ ▲
0.90 0.79 1,210 880
5 ● ● ● ■ ● ● ◐
(1.18) (1.03) (47.6'') (1,940)
1.05 0.92 1,355 940
(1.37) (1.20) (53.3'') (2,070)
5 ● ● ◐ ▲ ● ◐ ■
Heavy 0.85 0.76 962 860

4 ● ● ● ◐ ● ● ●
duty (1.11) (0.99) (37.9'') (1,900)
1.00 0.89 1,112 950
(1.31) (1.16) (43.8'') (2,090)
5 ● ● ◐ ▲ ● ● ◐
1.15 1.01 1,262 1,030

(1.50) (1.32) (49.7'') (2,270)
6 ● ◐ ■ ▲ ◐ ◐ ■
Rock
0.87 0.76 1,195 940
heavy 5 ● ● ● ■ ● ● ●
(1.14) (0.99) (47.0'') (2,070)
duty
● Applicable for materials with density of 2100 kg/m3 (3500 lb/yd3) or less
◐ Applicable for materials with density of 1800 kg/m3 (3000 lb/yd3) or less
■ Applicable for materials with density of 1500 kg/m3 (2500 lb/yd3) or less
▲ Applicable for materials with density of 1200 kg/m3 (2000 lb/yd3) or less
X Not recommended
※ These recommendations are for general conditions and average use.
Work tools and ground conditions have effects on machine performance.
Select an optimum combination according to the working conditions and the type of work that is
being done.
Consult your Hyundai dealer for information on selecting the correct boom
boom-armarm-bucket
bucket
combination.
1-31
2) HX210A L, 4700 KG COUNTERWEIGHT

MONO 2-PIECE
Capacity Width
SAE CECE
Heaped heaped
cutter
2.10 m 2.4 m 2.92 m 3.9 m 2.0m 2.4 m 2.92 m
m3 m3 mm kg
EA (6' 7') (7' 10") (9' 7") (12' 10") (6' 7") (7' 10") (9' 7")
(yd3) (yd3) (in) (lb)
0.80 0.70 1,070 770
5 ● ● ● ● ● ● ●
(1.05) (0.92) (42.1'') (1,700)
0.87 0.76 1,140 804
5 ● ● ● ● ● ● ●
(1.14) (0.99) (44.9'') (1,770)
0.92 0.80 1,190 820
5 ● ● ● ◐ ● ● ●
General (1.20) (1.05) (46.9'') (1,810)
bucket 1.10 0.96 1,375 890
5 ● ● ◐ ■ ● ● ◐
(1.44) (1.26) (54.1'') (1,960)
1.20 1.05 1,390 920
(1.57) (1.37) (54.7'') (2,030)
5 ● ● ◐ ▲ ● ◐ ■
1.34 1.17 1,525 990

(1.75) (1.53) (60.0'') (2,180)
6 ● ◐ ■ ▲ ◐ ◐ ■
0.90 0.79 1,210 880

5 ● ● ● ◐ ● ● ●
(1.18) (1.03) (47.6'') (1,940)
1.05 0.92 1,355 940
5 ● ● ● ■ ● ● ◐
(1.37) (1.20) (53.3'') (2,070)
Heavy 0.85 0.76 962 860
4 ● ● ● ● ● ● ●
duty (1.11) (0.99) (37.9'') (1,900)
1.00 0.89 1,112 950
5 ● ● ● ■ ● ● ●
(1.31) (1.16) (43.8'') (2,090)
1.15 1.01 1,262 1,030
(1.50) (1.32) (49.7'') (2,270)
6 ● ● ◐ ▲ ● ◐ ◐
Rock
0.87 0.76 1,195 940
heavy 5 ● ● ● ◐ ● ● ●
(1.14) (0.99) (47.0'') (2,070)
duty
X Not recommended
being done.
boom-armarm-bucket
bucket
combination.
1-32
3) HX210A NL, 3800 KG COUNTERWEIGHT

MONO 2-PIECE
Capacity Width
SAE CECE
Heaped heaped
cutter
2.10 m 2.4 m 2.92 m 3.9 m 2.0m 2.4 m 2.92 m
m3 m3 mm kg
EA (6' 7') (7' 10") (9' 7") (12' 10") (6' 7") (7' 10") (9' 7")
(yd3) (yd3) (in) (lb)
0.80 0.70 1,070 770
(1.05) (0.92) (42.1'') (1,700)
5 ● ● ◐ ▲ ● ◐ ■
0.87 0.76 1,140 804

(1.14) (0.99) (44.9'') (1,770)
5 ● ◐ ■ ▲ ● ◐ ■
0.92 0.80 1,190 820

(1.20) (1.05) (46.9'') (1,810)
5 ● ◐ ■ X ◐ ■ ▲
General
bucket 1.10 0.96 1,375 890
(1.44) (1.26) (54.1'') (1,960)
5 ■ ■ ▲ X ■ ▲ ▲
1.20 1.05 1,390 920
(1.57) (1.37) (54.7'') (2,030)
5 ■ ▲ X X ▲ ▲ X
1.34 1.17 1,525 990
(1.75) (1.53) (60.0'') (2,180)
6 ▲ ▲ X X ▲ X X
0.90 0.79 1,210 880
(1.18) (1.03) (47.6'') (1,940)
5 ● ◐ ■ X ◐ ■ ▲
1.05 0.92 1,355 940
(1.37) (1.20) (53.3'') (2,070)
5 ■ ▲ ▲ X ■ ▲ ▲
Heavy 0.85 0.76 962 860
duty (1.11) (0.99) (37.9'') (1,900)
4 ● ◐ ■ ▲ ● ◐ ■
1.00 0.89 1,112 950

(1.31) (1.16) (43.8'') (2,090)
5 ◐ ■ ▲ X ■ ■ ▲
1.15 1.01 1,262 1,030
(1.50) (1.32) (49.7'') (2,270)
6 ■ ▲ X X ▲ ▲ X
Rock
0.87 0.76 1,195 940
heavy
(1.14) (0.99) (47.0'') (2,070)
5 ● ◐ ■ X ◐ ■ ▲
duty
X Not recommended
being done.
boom-armarm-bucket
bucket
combination.
1-33
4) HX210A NL, 4700 KG COUNTERWEIGHT

MONO 2-PIECE
Capacity Width
SAE CECE
Heaped heaped
cutter
2.10 m 2.4 m 2.92 m 3.9 m 2.0m 2.4 m 2.92 m
m3 m3 mm kg
EA (6' 7') (7' 10") (9' 7") (12' 10") (6' 7") (7' 10") (9' 7")
(yd3) (yd3) (in) (lb)
0.80 0.70 1,070 770
5 ● ● ● ■ ● ● ●
(1.05) (0.92) (42.1'') (1,700)
0.87 0.76 1,140 804
5 ● ● ◐ ■ ● ● ◐
(1.14) (0.99) (44.9'') (1,770)
0.92 0.80 1,190 820
(1.20) (1.05) (46.9'') (1,810)
5 ● ● ◐ ▲ ● ◐ ■
General
bucket 1.10 0.96 1,375 890
(1.44) (1.26) (54.1'') (1,960)
5 ◐ ■ ■ X ◐ ■ ▲
1.20 1.05 1,390 920
(1.57) (1.37) (54.7'') (2,030)
5 ◐ ■ ▲ X ■ ■ ▲
1.34 1.17 1,525 990
(1.75) (1.53) (60.0'') (2,180)
6 ■ ▲ ▲ X ■ ▲ X
0.90 0.79 1,210 880
(1.18) (1.03) (47.6'') (1,940)
5 ● ● ◐ ▲ ● ◐ ■
1.05 0.92 1,355 940

(1.37) (1.20) (53.3'') (2,070)
5 ◐ ◐ ■ ▲ ◐ ■ ▲
Heavy 0.85 0.76 962 860
4 ● ● ◐ ■ ● ● ◐
duty (1.11) (0.99) (37.9'') (1,900)
1.00 0.89 1,112 950
(1.31) (1.16) (43.8'') (2,090)
5 ● ◐ ■ ▲ ◐ ◐ ■
1.15 1.01 1,262 1,030

(1.50) (1.32) (49.7'') (2,270)
6 ◐ ■ ▲ X ■ ■ ▲
Rock
0.87 0.76 1,195 940
heavy
(1.14) (0.99) (47.0'') (2,070)
5 ● ● ◐ ▲ ● ● ◐
duty
X Not recommended
being done.
boom-armarm-bucket
bucket
combination.
1-34
7. UNDERCARRIAGE
1) TYPES OF SHOES
Description Unit Triple grouser Double grouser

Model
width mm (in) 600 (24) 700 (28) 800 (32) 900 (36) 700 (28)
Operating weight kg (lb) 22150 48830 22620 49870 22890 50460 23170 51080 22880 50440
HX210A L Ground pressure kgf/cm² (psi) 0.47 6.71 0.41 5.87 0.37 5.20 0.33 4.68 0.42 5.94
MONO (NA) Overall width mm (ft-in) 2990 9'10" 3090 10'2" 3190 10'6" 3290 10'10" 3090 10'2"
Link quantity EA 49 49 49 49 49
Description Unit Triple grouser

Model
width mm (in) 500 (20) 600 (24)
Operating weight kg (lb) 22800 50270 22900 50490
HX210A NL Ground pressure kgf/cm² (psi) 0.58 8.29 0.49 6.93

MONO (EU) Overall width mm (ft-in) 2555 8' 5" 2655 8' 9"
Link quantity EA 49 49
Operating weight kg (lb) 24010 52930 24410 53150
HX210A NL Ground pressure kgf/cm² (psi) 0.61 8.73 0.51 7.30

2 pcs (EU) Overall width mm (ft-in) 2555 8' 5" 2655 8' 9"
Link quantity EA 49 49
2) SELECTION OF TRACK SHOE

Suitable track shoes should be selected according to operating conditions.
Method of selecting shoes
Confirm the category from the list of applications in table 2,2 then use table 1 to select the shoe.
Wide shoes (categories B and C) have limitations on applications. Before using wide shoes, check
the precautions, then investigate and study the operating conditions to confirm if these shoes are
suitable.
Select the narrowest shoe possible to meet the required flotation and ground pressure. Application
of wider shoes than recommendations will cause unexpected problem such as bending of shoes,
crack of link, breakage of pin, loosening of shoe bolts and the other various problems.
Table 1
Track shoe Specification Category
500 mm triple grouser (HX210A NL) Standard A
600 mm triple grouser (HX210A L) Standard A
600 mm triple grouser HD (HX210A L) Option A
700 mm triple grouser Option B
700 mm double grouser Option B
800 mm triple grouser Option C
900 mm triple grouser Option C
1-35
Table 2
Category Applications Precautions
Rocky ground, · Travel at low speed on rough ground with large obstacles such as
A river beds, boulders or fallen trees or a wide range of general civil engineering work
normal soil
Normal soil, · These shoes cannot be used on rough ground with large obstacles
soft ground such as boulders or fallen trees
B · Travel at high speed only on flat ground
· Travel slowly at low speed if it is impossible to avoid going over
obstacles
Extremely soft ground · Use the shoes only in the conditions that the machine sinks and it is
(swampy ground) impossible to use the shoes of category A or B
· These shoes cannot be used on rough ground with large obstacles
C such as boulders or fallen trees
· Travel at high speed only on flat ground
· Travel slowly at low speed if it is impossible to avoid going over
obstacles
1-36
8. SPECIFICATIONS FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Maker / Model CUMMINS / B4.5
4-cycle, turbocharged, charge air cooled,
Type
electronic controlled diesel engine
Cooling method Water cooled
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-3-4-2
Combustion chamber type Direct injection type
Cylinder bore×stroke 107×124 mm (4.21"×4.88")
Displacement 4.5ℓ(275 cu in)
Compression ratio 17.2 : 1
Gross power 173 Hp (129 kW ) at 2200 rpm
Net power 170 Hp (127 kW) at 2200 rpm
Max. power 190 Hp (142 kW) at 2000 rpm
Peak Torque 780 N·m (575 lb·ft) at 1,500 rpm
Engine oil quantity 11ℓ(2.9 U.S. gal)
Wet weight or Dry weight 383 kg (845 lb)
Starter motor 24 V-4.8 kW
Alternator 24 V-95 A
2) MAIN PUMP
Item Specification
Type Variable displacement tandem axis piston pumps
Capacity 2×130 cc/rev
Maximum pressure 350 kgf/cm2 (4980 psi) [380 kgf/cm2 (5400 psi)]
Rated oil flow 2×234ℓ/min (61.9 U.S. gpm / 51.5 U.K. gpm)
Rated speed 1800 rpm
[ ] : Power boost
1-37
3) GEAR PUMP
Item Specification
Type Fixed displacement gear pump single stage
Capacity 10 cc/rev
Maximum pressure 40 kgf/cm2 (570 psi)
Rated oil flow 18ℓ/min (4.8 U.S. gpm/4.0 U.K. gpm)
4) MAIN CONTROL VALVE

Item Specification
Type 9 spools two-block
Operating method Hydraulic pilot system
Main relief valve pressure 350 kgf/cm2 (4980 psi) [380 kgf/cm2 (5400 psi)]
Boom 400 kgf/cm2 (5690 psi)
Port relief valve pressure Arm 400 kgf/cm2 (5690 psi)
Bucket 400 kgf/cm2 (5690 psi)
[ ] : Power boost
5) SWING MOTOR
Item Specification
Type Axial piston motor
Capacity 142.8 cc/rev
Relief pressure 290 kgf/cm2 (4125 psi)
Braking system Automatic, spring applied hydraulic released
Braking torque 1183 kgf·m (8560 lbf·ft) over
Brake release pressure 20.9 kgf/cm2 (297 psi) over
Reduction gear type 2 - stage planetary
6) TRAVEL MOTOR
Item Specification
Type Variable displacement axial piston motor
Capacity 171.2/108.5 cc/rev
Relief pressure 350 kgf/cm2 (4980 psi)
Braking system Automatic, spring applied hydraulic released
Braking torque 3028 kgf·m (21900 lbf·ft)
Brake release pressure 13.5 kgf/cm2 (192 psi)
Reduction gear type 2-stage planetary
1-38
7) CYLINDER
Item Specification
Bore dia×Stroke Ø85 × 1290 mm
Boom cylinder
Cushion Extend only
Arm cylinder
Cushion Extend and retract
Arm cylinder (2-piece boom)
Cushion Extend and retract
Adjust cylinder (2-piece boom)
Cushion NA
Bucket cylinder
Cushion Extend only
※ Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on
the rod surface.
※ Discoloration does not cause any harmful effect on the cylinder performance.
1-39
9. RECOMMENDED OILS
HYUNDAI genuine lubricating oils have been developed to offer the best performance and service life for
your equipment. These oils have been tested according to the specifications of HYUNDAI and, therefore, will
meet the highest safety and quality requirements.
We recommend that you use only HYUNDAI genuine lubricating oils and grease officially approved by
HYUNDAI.
Ambient temperature˚C(˚F)
Service Capacity
Kind of fluid
point ℓ (U.S. gal) -50 -30 -20 -10 0 10 20 30 40
(-58) (-22) (-4) (14) (32) (50) (68) (86) (104)
★SAE 0W-40
Engine SAE 5W-30
Engine oil 11 (2.9)
oil pan SAE 5W-40
SAE 15W-40
DEF/ Mixture of urea
AdBlue® and deionized 48 (12.6) ISO 22241, High-purity urea + deionized water (32.5:67.5)
tank water
Swing
6.2 (1.6) ★SAE 75W-90
drive
Gear oil
Final 4.5×2 SAE 80W-90
drive (1.2×2)
Tank ★ISO VG 15
155 (40.9) ISO VG 32
Hydraulic
Hydraulic oil
tank ISO VG 46, HBHO VG 46★3
System
275 (72.6) ISO VG 68
★ASTM D975 NO.1

Fuel tank Diesel fuel★1 400 (106)
ASTM D975 NO.2
Fitting ★NLGI NO.1
(grease Grease As required
nipple) NLGI NO.2
Mixture of
Radiator Ethylene glycol base permanent type (50 : 50)
antifreeze
(reservoir 40 (10.6)
and soft ★Ethylene glycol base permanent type (60 : 40)
tank)
water★2
SAE : Society of Automotive Engineers ★ : Cold region (Russia, CIS, Mongolia)
API : American Petroleum Institute ★1 : Ultra low sulfur diesel
ISO : International Organization for Standardization - sulfur content  15 ppm
NLGI : National Lubricating Grease Institute ★2 : Soft water
City water or distilled water
ASTM : American Society of Testing and Material
★3 : Hyundai Bio Hydraulic Oil
DEF : Diesel Exhaust Fluid, DEF compatible with AdBlue®
※ Using any lubricating oils other than HYUNDAI genuine products may lead to a deterioration of performance
and cause damage to major components.
※ Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of
major components.
※ Do not use any engine oil other than that specified above, as it may clog the diesel particulate filter(DPF).
※ For HYUNDAI genuine lubricating oils and grease for use in regions with extremely low temperatures, please
contact HYUNDAI dealers.
1-40
Group 1 Pump Device ---------------------------------------------------------------------------------------------------- 2-1

Group 2 Main Control Valve ------------------------------------------------------------------------------------------- 2-17
Group 3 Swing Device ---------------------------------------------------------------------------------------------------- 2-51
Group 4 Travel Device ----------------------------------------------------------------------------------------------------- 2-62
Group 5 RCV Lever --------------------------------------------------------------------------------------------------------- 2-76
Group 6 RCV Pedal -------------------------------------------------------------------------------------------------------- 2-83
GROUP 1 PUMP DEVICE
1. STRUCTURE
The pump device consists of main pump, regulator and gear pump.
·WITHOUT PTO TYPE
Dr
A3
a4
a5
B3
Dr Psv
a1 B1 a2
Qmin adjusting screw Qmax adjusting screw Qmin adjusting screw A1

A2
Regulator Regulator
a4 a5
VIEW A
Psv
B3
B1
a1 a2
a3
PH1 PH2
A1 A2 235A2MP01
A1 pump A2 pump Gear pump
Valve block
A
a1 A1 PH1 Psv PH2 A2 a2

Port Port name Port size
A1,2 Delivery port SAE6000psi 1"
a4 a5
B1 Suction port SAE2500psi 2 1/2"
Dr Drain port PF 3/4 - 20
Psv Servo assist port PF 3/8 - 17
E PH1,2 Pressure sensor port PF 3/8-17
Dr A3 a1,2 Gauge port PF 1/4 - 15
B1 B3 a3 a3 Gauge port PF 1/4-14
a4,5 Gauge port PF 1/4 - 15
A3 Gear pump delivery port PF 1/2 - 19
B3 Gear pump suction port PF 3/4 - 20.5
2-1
·WITH PTO TYPE
Dr2
Dr
A3
a4
a5
B3
Dr Psv
a1 B1 a2
Qmin adjusting screw Qmax adjusting screw Qmin adjusting screw A1

A2
Regulator Regulator
a4 a5
VIEW A
Psv
B3
B1
a1 a2
a3
PH1 PH2
A1 A2
A1 pump A2 pump Gear pump 235A2MP02
Valve block
A
a1 A1 PH1 Psv PH2 A2 a2 A1,2 Delivery port SAE6000psi 1"
B1 Suction port SAE2500psi 2 1/2"
Dr Drain port PF 3/4 - 20
a4 a5
Psv Servo assist port PF 3/8 - 17

PH1,2 Pressure sensor port PF 3/8-17
E
a3 Gauge port PF 1/4-14
Dr A3
B1 B3 a3
A3 Gear pump delivery port PF 1/2 - 19
B3 Gear pump suction port PF 3/4 - 20.5
2-2
1) MAIN PUMP (1/3)
The main pump consists of two piston pumps (front & rear) and valve block.
497 953 806 537 789 732 535 532 548 531 214 808 901 954 792 702 534 717 981 983
151
251 152
886 211
127 C
B 04
B
774 C
A A
111
261
113
710
272
406
123 467
725
824 271 212 153 466 156 157 468 313 124 711 116 312 724 885 314 401 141
723 726
※ Section A-A, B-B, view C : see next page. 220F2MP05
04 Gear pump 272 Pump casing (R) 723 O-ring

111 Drive shaft (F) 312 Valve block B 724 Square ring
113 Drive shaft (R) 313 Valve plate (R) 725 O-ring
116 1st gear 314 Valve plate (L) 726 O-ring
123 Roller bearing 401 Hexagon socket bolt 732 O-ring
124 Needle bearing 406 Hexagon socket bolt 774 Oil seal
127 Bearing spacer 466 Plug 789 Back up ring
141 Cylinder block 467 Plug 792 Back up ring
151 Piston 468 Plug 806 Hexagon head nut
152 Shoe 497 Plug 808 Hexagon head nut
153 Set plate 531 Tilting pin 824 Snap ring
156 Spherical bushing 532 Servo piston 885 Pin
157 Cylinder spring 534 Stopper (L) 886 Pin
211 Shoe plate 535 Stopper (S) 901 Eye bolt
212 Swash plate 537 Servo cover 953 Set screw
214 Tilting bushing 548 Feedback pin 954 Set screw
251 Support 702 O-ring 981 Name plate
261 Seal cover (F) 710 O-ring 983 Pin
271 Pump casing (F) 711 O-ring
717 O-ring
2-3
MAIN PUMP (2/3)
537 953 806 419
05
VIEW C
414 326
544 724
545 723
541
SECTION A-A SECTION A-A SECTION B-B
With PTO Without PTO
235A2MP06
05 PTO unit 537 Servo cover 723 O-ring

326 Cover 541 Seat 724 Square ring
414 Hexagon socket bolt 544 Stopper 1 806 Hexagon head nut
419 Hexagon socket bolt 545 Steel ball 953 Set screw
2-4
MAIN PUMP (3/3, WITH PTO TYPE)
125
825 468
711
118 710 728
117 262
126
326
414
115
128
826
886 435
885
235A2MP07
115 Idler shaft 262 Cover 711 O-ring

117 Gear No. 2 326 Gear case 728 O-ring
118 Gear No. 3 414 Socket head screw 825 Retainer ring
125 Ball bearing 435 Flange head socket bolt 826 Retainer ring
126 Roller bearing 468 Plug 885 Spring pin
128 Bearing spacer 710 O-ring 886 Pin
2-5
2) REGULATOR (1/2)
601 876 874
497
412
726
614 755
466
414
611
220F2MP08
412 Hexagon socket screw

414 Hexagon socket screw
SECTION A-A 466 Plug
497 Plug
601 Casing
611 Feed back lever
PH
a A Psv
614 Adjust plug
726 O-ring
755 O-ring
a4 874 Pivot pin
876 Pin

A Delivery port SAE 6000 psi 1"
B
B Suction port SAE 2500 psi 2 1/2"
Psv Servo assist port PF 3/8-17
a, a4 Gauge port PF 1/4-15
Pressure sensor
PH PF 3/8-17
port
2-6
REGULATOR (2/2)
898 643 642 644 646 A 418 079 728 645
728 924
641
801
656
402
755
887
758
708
A
220F2MP09
079 644 Spring seat (Q) 755 O-ring

402 Hexagon socket screw 645 Adjust stem (Q) 758 Square ring
418 Hexagon socket screw 646 Pilot spring 801 Nut
641 Pilot plug 656 Cover 887 Pin
642 Pilot spool 708 O-ring 898 Piston piston
632 Pilot sleeve 728 O-ring 924 Set screw
2-7
3) GEAR PUMP
710 700 354 351 887 433
Z
B3
434
A3
311
312
732
a3 850
Z
307 308 355
310 309 466

435 361 353 434 725
SECTION Z-Z 220F2MP10A
307 Poppet 353 Drive gear 466 Plug

308 Seat 354 Driven gear 700 Ring
309 Ring 355 Filter 710 O-ring
310 Spring 361 Front case 725 O-ring
311 Adjusting screw 433 Flange socket bolt 732 O-ring
312 Lock nut 434 Flange socket bolt 850 Snap ring
351 Gear case 435 Flange socket bolt 887 Pin
2-8
4) PROPORTIONAL REDUCING VALVE ASSY
902
351 311 326 324
312 361 362 363 861 901 801 802 220F2MP12
311 Spool 361 O-ring 802 Seal nut

312 Sleeve 362 O-ring 861 O-ring
324 Spring 363 O-ring 901 Name plate
326 Retaining ring 801 Solenoid 902 Function name plate
351 Orifice
2-9
2. MAIN PUMP
The pumps may be classified roughly into the rotary group performing a rotary motion and working
as the major part of the whole pump function: the swash plate group that varies the delivery flow: and
the valve block group that changes over oil suction and discharge: and the PTO group to attach an
auxiliary gear pump.
1) ROTARY GROUP
The rotary group consists of drive shaft (F)
(111), bearing spacers (127), cylinder block
124
(141), piston shoes (151,152), set plates 313
141
(153), spherical bushings (156) and
156
cylinder springs (157). The drive shaft is 153
supported by bearings (123,124) at its both 211
157
ends. 111 151
The shoe is caulked to the piston to form a 152
spherical joint for lessening thrust force
generated by load pressure and has
grooves to slide on the shoe plate (211) 127
123
smoothly and hydraulically balanced. The
piston-shoe sub group is pushed onto the 220S2MP13
shoe plate by the cylinder springs through

the set plate and spherical bushing for
enabling smooth sliding on the shoe plate.
Similarly, the cylinder block is pushed onto
the valve plate (313, 314) by the cylinder
springs.
2) SWASH PLATE GROUP 548 531
The swash plate group consists of swash
plate (212), shoe plate (211), swash plate
support (251), tilting bushing (214), tilting 214
pin (531) and servo piston (532).
251
The swash plate is supported by the swash
plate support at the cylindrical portion 211
formed on the opposite side of the shoe 212
sliding face. 532
When the servo piston is moved to the left
or right by introducing the hydraulic force
controlled by the regulator into the hydraulic
chamber provided on both ends of the
servo piston, the swash plate slides over
the swash plate support through the
spherical portion of the tilting pin and can
vary the tilting angle (α).
220S2MP14
2-10
3) VALVE BLOCK GROUP
The valve block group consists of the valve
block (312), valve plate (313, 314) and
valve plate pin (885). 312
The valve plate having two arc ports is
313
attached to the valve block and feeds and
collects oil to and from the cylinder block.
The oil exchanged by the valve plate is
885
connected to an external piping through the
220S2MP15
valve block.
4) PTO GROUP
The PTO group is composed of the 1st
gear (116), 2nd gear (111) and 3rd gear
(113).
The 2nd gear (111) and 3rd gear (113) are
supported by the bearings, respectively
and attached to the valve block. 113
Now, suppose the drive shaft is rotated by 111
116
the motor or engine, the cylinder block is
also rotated through the spline conection. If 220F2MP11
the swash plate is tilted, the pistons
arranged inside the cylinder reciprocate
relatively to the cylinder, rotating with the
cylinder block. Accordingly, if a piston is
focused on, its motion is separating from
the valve plate (oil suction process) for 180
degrees, and approaching the valve plate
(oil delivery process) for the remaining 180
degrees. When the swash plate has a tilting
angle of zero, the piston makes no stroke
and discharges no oil.
In the meantime, the rotation of the drive
shaft is picked up by the 1st gear (116),
transmitted to the 3rd gear (113) through
the 2nd gear (111), and drives the auxiliary
pump connected to the 3rd gear (113).
2-11
3. REGULATOR
1) OUTLINE
The regulator for the K7V series axial piston pump has various models to satisfy various kinds of
specifications required.
Electric flow control

By changing the pilot electric current I for
proportional reducing valve, the pump
Delivery flow, Q
tilting angle (delivery flow) is controlled
arbitrarily, as shown in the figure.
This regulator has the positive flow control
in which the delivery flow Q increases as
the pilot electric current I increases. With
this commanded, the pump discharges
the required flow only, and so it does not Pilot electric current, I
consume the power uselessly. 220F2MP16
2-12
2) FUNTION
(1) Flow control

By changing the pilot electric current I, the
pump tilting angle (delivery flow) is
regulated arbitrarily, as shown in the
Delivery flow, Q
figure.
Pilot electric current, I
PH
a A Psv
a4
220F2MP17
2-13
① Flow increasing funtion
As the pilot electric current I increases, the secondary pressure of the proportional reducing
valve (079) increases too. Then the pilot spool (642) through the pilot piston (898) moves to the
right to position where the force of the pilot spring (646) balances with the hydraulic force.
The movement of the pilot spool (642) causes the port C1 connects to the tank port (T). This
deprives the pressure of the large-diameter section of the servo piston (531) and moves the
servo piston (532) to the right by the discharge pressure Pd1 in the small-diameter section,
resulting in the flow rate increase.
The feedback lever (611) links both the servo piston (532) and the pilot sleeve (643). When the
servo piston (532) moves, the feedback lever (611) rotates around the pivot A, and the pilot
sleeve (643) moves to the left. This causes the opening between the pilot sleeve (643) and the
pilot spool (642) to close slowly, and the servo piston (532) comes to being stop completely
when the port C1 closes completely.
898 T 643 642 611 Pivot A 646 079
P1
P2
C1 C2
Pcl
P1
Pcl
Small diameter 532 Large diameter
Left Right
(flow reducing) (flow increasing)
220F2MP25
2-14
② Flow reducing function
As the pilot electric current I decreases, the secondary pressure of the proportional reducing
valve (079) decreases too, the pilot spool (642) moves to the left by action of the pilot spring
(646).
The movement of the pilot spool (642) causes the delivery pressure Pd1 to connects to the port
C2 through the pilot spool (642) and to be admitted to the large-diameter section of the servo
piston (532). Although the delivery pressure Pd1 is constantly admitted to the small-diameter
section of servo piston (532), the servo piston (532) moves to the left because of its difference of
the area between large and small-diameter section. As a result, the tilting angle is decreased.
As the servo piston (532) moves, the feedback lever (611) rotates around the pivot A, and the
pilot sleeve (643) moves to the right till the opening between the pilot spool (642) and pilot sleeve
(643) being closed.
898 T 643 642 611 Pivot A 646 079
P1
P2
C1 C2
Pcl
P1
Pcl
Small diameter 532 Large diameter
Left Right
(flow reducing) (flow increasing)
220F2MP26
2-15
4. ADJUSTMENT OF MAXIMUM AND MINIMUM FLOWS
The maximum flow and minimum flow can be adjusted with the adjusting screws (954, 953) of the
pump. The flow control characteristics can be adjusted with the hexagon socket head cap (924). The
horsepower control characteristics can be adjusted with the adjusting screw (C. 628) and adjusting
stem (C, 627) of the regulator. The maximum flow and minimum flow can be adjusted with the
adjusting screws of the pump.
1) ADJUSTMENT OF MAXIMUM FLOW 808 954

(MAIN PUMP SIDE)
Adjust it by loosening the hexagon nut
(808) and by tightening (or loosening) the
hexagonal socket head screw (954). Only
the maxinum flow is adjusted without
changing other control characteristics.
Adjustment of max flow
Delivery flow, Q
Speed
Tightening Flow change
amount of amount
adjusting screw
(954)
(min -1) (Turn) (ℓ/min)
1900 +1/4 -
Pilot electric current, I 220F2MP18
2) ADJUSTMENT OF MINIMUM FLOW 953 806

(MAIN PUMP SIDE)
Adjust it by loosening the hexagon nut
(806) and by tightening (or loosening) the
hexagon socket head set screw (953).
Similarly to the adjustment of the maximum
flow, other characteristics are not changed.
However, remember that, if tightened too
much, the required horsepower at the
Delivery flow, Q
maximum delivery pressure (or during

relieving) may increase.
Adjustment of min flow
Speed
Tightening Flow change
amount of amount
adjusting screw
(953) Pilot electric current, I 220F2MP19
(min -1) (Turn) (ℓ/min)
1900 +1/4 -
2-16
GROUP 2 MAIN CONTROL VALVE
1. STRUCTURE Mark Port name Port size Tightening torque

20~25kgf·m
R2 Make up port for swing PF 1 (115~180lbf·ft)
XAtr Travel right (reverse) pilot port
XBa2 XBtr Travel right (forward) pilot port
(XAo) Optional pilot port
(XBp2)
(PTa) (XBo) Optional pilot port
XBtr
Dr3
XAk Bucket in pilot port
XBk Bucket out pilot port
TRAVEL
d1
CP1
RIGHT XAb1 Boom up pilot port
d2 d3
XBtr Btr Atr XAtr XBb1 Boom down pilot port
7~8kgf·m
XAa2 Arm out confluence pilot port PF 3/8
P1 (50.6~57.8lbf·ft)
LCs SWING XBa2 Arm in confluence pilot port
SWING
XAs Bs As XBs XAtL Travel left (reverse) pilot port
(P3) PRIORITY XBtL Travel left (forward) pilot port
P2 CCb BOOM 2 CCo (P5) PnA2 Dr7
XAs Swing left pilot port
Psp XAb2
Xb2 Dr1
Dr6 Pns
(P4)
XBs Swing right pilot port
XAa1 Arm out pilot port
R1 OPTION
(XAo) (Bo) (Ao) (XBo)
XBa1 Arm in pilot port
LCo
CCk Dr1 Drain port
Pis
(PTa) Travel straight pilot port
ARM 1
XAa1 Ba Dr3 XBa1
(Head)
(Px) Pressure port for attachment
LCa
(Py) Pressure port for travel
BYPASS XBp1 (XBp2) BYPASS Pz Main relief pilot pressure port
CUT P1 PCV1
CUT P2
PCV2
XAa2 PG Pilot pressure port
XAtr
XBk Dr2 Drain port
Dr3 Drain port
PCk
XBp1
Dr6 Drain port
VIEW A VIEW B Dr7 Drain port
Pns Swing logic valve pilot port
PaL Lock valve pilot port (arm rod side) 3.5~3.9kgf·m
PbL Lock valve pilot port (boom head side) PF 1/4 (25.3~28.2lbf·ft)
XAb2 Boom up confluence pilot port
Psp Swing priority pilot port
XBp1 Bypass cut spool pilot port (P1 side)
(XBp2) Bypass cut spool pilot port (P2 side)
(P0) PG
PCk Bucket in stroke limiter pilot port
(Px)
MR
(PTa) XBtr Pis Arm regeneration cut pilot port
TRAVEL Pz
STRAIGHT (PTa) PnA2 Arm2 logic valve pilot port
XAtr
CMR2 CMR1
TRAVEL AtL
(Py)
XBtL XAs Dr2
Atr Travel motor right side (reverse) port
LEFT XAtL C2
BtL XBtL Btr Travel motor right side (forward) port
XBs XAtL CRb (Ao) Optional port
Dr6 Pns BOOM 1 PbL LCb BbR Psp
Pns Dr6
(Bo) Optional port
XBb1 Bb XAb1 XAb1 Ak Bucket cylinder head side port
XBb1 Ab
A XAb2
(Head)
(Rod)
BoR
Bk Bucket cylinder rod side port
LCk (XAo)
AbR BUCKET BkR
PCk Ab Boom cylinder head side port
XAk Bk PCk Bb Boom cylinder rod side port
XAk AkR Ak 5~6.6kgf·m
AoR
(XBo)
(Head) LCAP2
(Rod)
XBk AtL Travel motor left side (reverse) port M10 (36.1~47.7lbf·ft)
XAa1 BaR
AR ARM 2 CRa BtL Travel motor left side (forward) port
XBk XAa2
XBa2 R2 XAa2
Dr3 XBa1 XBa2 PaL As Swing motor left port
LCAT2
PCV1
Bs Swing motor right port
PnA2 Dr7 Dr7 PnA2
Aa
Aa Arm cylinder rod side port
PCV2 (XBp2)
AaR
(Rod)
Ba Arm cylinder head side port
XBp1
P1 Pump port (P1 side)
P2 Pump port (P2 side)
8.5~11.2kgf·m
B R1 Return port M12 (61.5~81.1lbf·ft)
220A2MC01
2-17
1) RELIEF VALVE SIDE VIEW
273x10
B A
153
(Po)
153 Plug
252 Lock valve selector sub assy
273x12 561
273 Socket screw
XAtr MR
C C 561 O-ring
252
602 Port relief valve assy
XBs XAtL
D D 977 Name plate
Dr6 Pns 978 Pin
977 XBb1
XAb2
E 978x2 E
AbR
XAk AkR 252

F AoR (XBo) F
AR
Dr3 XBa1 XBa2

G G
PnA2 Dr7
AaR
H PCV2 (XBp2) H O AaR O
602
A
B
SECTION O-O
220A2MC02
2) TANK PORT SIDE BOTTOM VIEW
XBa2
(XBp2)
153 Plug
Dr3 210 Plate
273 Socket screw
274 Socket screw
561 O-ring
274x4
CCo (P5) PnA2 Dr7
Pns
(P4)
Dr6
P P
153 561
CCk
210 (P5)
SECTION P-P
XAa2
XBk
273x12 PCk 273x10

XBp1 220A2MC03
2-18
3) CASING A SPOOL SECTION
N
101 159 541 542 543 166 101 Casing A
151 Plug
550
156 Plug
159 Plug
(PTa)
166 O-ring
N 168 O-ring
XAtL XBtL 514 Poppet
521 Spring
XBb1 XAb1 541 Steel ball
542 Spring seat
543 Spring
XAk PCk
550 Plug
XBk 551 Plug
XAa2
XBa2
561 O-ring
151 168 151 168 151

168
PG 156
CCo CCk
156
514 521 561 551 551 561 521 514
SECTION A-A SECTION N-N
220A2MC04
4) CASING B SPOOL SECTION
153 561
P1 R1 102
(P3).
975 975
102 Casing B
153 Plug
XBtr XAtr 155 Plug
975 165 O-ring
XAs XBs 167 O-ring
975
561 O-ring
975 Socket screw
Psp XAb2
975
(XAo) (XBo)
975 975
XAa1 XBa1
975
XBp1 (XBp2)
975
975
(P4)
165 165 167 155 165
SECTION B-B
220A2MC05
2-19
5) TRAVEL RIGHT AND TRAVEL STRAIGHT SECTION
152 Plug
154 154 Plug
201 TRAVEL RIGHT TRAVEL STRAIGHT 164 155 Plug
201
336 336 159 Plug
332 332 162 O-ring
335 323
323 335 163 O-ring
322
322 601 164 O-ring
332
332 261
165 O-ring
261 308 201 Spring cover
163
301 204 Spool cover
165 261 O-ring
163 512 264 Square ring
511 522
521 553
301 Travel spool
551 308 Straight travel spool sub assy
561 562 322 Spring
165 562 323 Spring
163
163 553 332 Spring seat
163 522 335 Stopper
512
152 336 Spacer bolt
162 511 Poppet
159 512 Poppet
264
204 159 521 Spring
264
154 164 204 522 Spring
SECTION C-C 551 Plug
553 Plug
220A2MC06 561 O-ring
562 O-ring
601 Main relief valve assy
6) SWING AND TRAVEL LEFT SECTION
201 152 Plug

201 SWING TRAVEL LEFT 336
336 332 161 O-ring
332 335 162 O-ring
335 323
322 163 O-ring
321
320 332 165 O-ring
261 201 Spring cover
332 301
261 204 Spool cover
305 250 Logic control valve assy
161 251 Logic control valve assy
163
163 254 Swing Logic poppet assy
254 511 261 O-ring
521 264 Square ring
551
301 Travel spool
561
305 Swing spool
250 320 Spring
321 Spring
322 Spring
152 323 Spring
165
162 332 Spring seat
335 Stopper
264 264
204
336 Spacer bolt
204 163 511 Poppet
SECTION D-D
521 Spring
220F2MC07
551 Plug
2-20 561 O-ring
7) BOOM 1 AND 2 SECTION
202 201 158 Plug
336 BOOM 2 BOOM 1 336 161 O-ring
332 332
335
163 O-ring
339 165 O-ring
327
326 320
332
202 Spring cover
602 204 Spool cover
261 L L
332 261 O-ring
161 261
511 158
264 Square ring
521 523 303 Boom 1 spool sub assy
551 552 307 Boom 2 spool
561 561 311 Swing priority spool
165 513 320 Spring
307 511
163 321 Spring
521 326 Spring
551 551 327 Spring
561 561 329 Spring
311 332 Spring seat
335 Stopper
161 336 Spacer bolt
303 339 Stopper
261 264
332 602
511 Poppet
320 204 513 Poppet
329 163
158 521 Spring
339 523 Spring
332 551 Plug
336 SWING PRIORITY 552 Plug
202
SECTION E-E
SECTION L-L 561 O-ring
220F2MC08
8) BUCKET AND OPTION SECTION

154 Plug
201
201 OPTION BUCKET 336 162 O-ring
336 163 O-ring
332 259 332
335 164 335 164 O-ring
321
321 165 O-ring
332 320
261 602 204 Spool cover
163 261
209 304
206 Spool cover
971x4 209 Flange
165 211 Piston
309
163 258 Plug
163 511 259 Plug
511
521 521 261 O-ring
551 551 264 Square ring
561
561
304 Bucket spool
309 Option spool
163 320 Spring
165 321 Spring
971x4
209 332 Spring seat
602 335 Stopper
163
264
264
206 336 Spacer bolt
603 511 Poppet
211
204
164 561 521 Spring
154 258 551 Plug
SECTION F-F 561 O-ring
220F2MC09
2-21 971 Socket screw
9) ARM 1 AND 2 SECTION
201 152 Plug

336 201
ARM 1 ARM 2 336
332 158 Plug
332 162 O-ring
335 335
323 323 163 O-ring
320 322 165 O-ring
332
257 261 201 Spring cover
332 L L 306 204 Spool cover
261
165 513 251 Logic control valve assy
162 523
561 256 Arm 2 Logic poppet assy
152
165 552 257 Arm regeneration cut sub assy
251 261 O-ring
302
511 264 Square ring
521 302 Arm 1 spool sub assy
551 256
306 Arm 2 spool
561 551
561
320 Spring
163
521 322 Spring
511 323 Spring
332 Spring seat
165
163 335 Stopper
264 336 Spacer bolt
264 204
602 511 Poppet
205 SECTION G-G SECTION L-L 513 Poppet
220A2MC10 521 Spring
523 Spring
551 Plug
552 Plug
561 O-ring
10) BYPASS CUT SECTION
203 612 169 162 152 158 154 164 152 164 154 158 152 162 169 612 152 152 Plug
162
154 Plug
158 Plug
162 162 O-ring
PCV1 PCV2
163 O-ring
164 O-ring
165 O-ring
169 O-ring
203 Spring cover
262 O-ring
333 331 371 331 262 313 165 165 310 163 331 371 331 203 310 Bypass cut spool
370 337 262 337 370 333 313 Bypass cut spool
331 Spring seat
SECTION H-H
220A2MC11 333 Spring seat
337 Stopper
370 Spring
371 Spring
612 Plug
2-22
11) MAIN RELIEF VALVE (601)
541 521 124 561 121 511 621 163 664 661 673 671
R
PL
512 123 125 562 663 122 103 614 613 104 652
220F2MC70
103 Plug 512 Plunger 621 Spring

104 Adjust plug 521 Spring 652 Adjust screw
121 C-ring 541 Seat 661 O-ring
122 Spacer 561 O-ring 663 O-ring
123 C-ring 562 Back-up ring 664 O-ring
124 Filler stopper 611 Poppet 671 Lock nut
125 Filler 613 Stopper 673 Lock nut
163 O-ring 614 Piston
12) PORT RELIEF VALVE (602)
301 564 563 521 124 561 562 611 621 661 651
511 522 161 123 541 125 101 162 102 612 671
220F2MC71
101 Body 511 Plunger 564 Back-up ring

102 Plug 521 Spring 611 Poppet
161 O-ring 522 Spring 612 Spring seat
162 O-ring 541 Seat 621 Spring
123 O-ring 561 O-ring 651 Adjust screw
124 Filler stopper 562 Back-up ring 661 O-ring
125 Filler 563 O-ring 671 Lock nut
2-23
13) PORT RELIEF VALVE (603)
552 521 161 541 561 562 611 661
511 R
671
301
651
P
612
163
102
164
564 563 123 124 125 101 162 621

220F2MC72
101 Body 301 Piston 564 Back-up ring

102 Plug 511 Plunger 611 Poppet
123 C-ring 521 Spring 612 Spring seat
124 Filler stopper 522 Spring 621 Spring
125 Filler 541 Seat 651 Adjust screw
161 O-ring 561 O-ring 661 O-ring
162 O-ring 562 Back-up ring 671 Lock nut
163 O-ring 563 O-ring
2-24
14) ARM 1 SPOOL ASSY (302)
302 317 340 361 371 350

220F2MC73
302 Spool 340 Spring 361 O-ring

317 Plunger 350 Plug 371 Back-up ring
15) BOOM 1 SPOOL ASSY (303)
303 317 340 361 371 350

220F2MC74

16) TRAVEL STRAIGHT SPOOL (308)
308 317 340 361 371 351

220F2MC75

2-25
17) LOCK VALVE SELECTOR (252)
101 Casing
161 O-ring
164 O-ring
166 O-ring
167 O-ring
171 Hex socket head cap screw
101 201
201 Plug
171 541 167 164 321 Spring
511 Spool
541 Sleeve
PLc A B Dr
166 511 161 321

220F2MC76
18) LOGIC CONTROL VALVE ASSY (250, 251)
112 102 114 110 104 101 111
(Dr)
(Pi) (Pin)
(Pout)
113 120 103 115 220F2MC77
101 Casing 110 Plug 114 O-ring

102 Spool 111 Plug 115 O-ring
103 Spring 112 O-ring 120 Hex socket head cap screw
104 Spring seat 113 O-ring
2-26
19) SWING LOGIC POPPET ASSY (254)
B
101 Logic poppet
103 102 Poppet
103 Spring seat
106 104 Plug
106 Spring
104 107 Spring
107
A 102
101
220F2MC78
20) ARM 2 LOGIC POPPET ASSY (256)
B
101 Logic poppet
103 102 Poppet
103 Spring seat
106 104 Plug
106 Spring
104 107 Spring
107
A 102
101
P 220F2MC79
2-27
21) ARM REGENERATION CUT SUB ASSY (257)
267 266 268 265 231 253
Dr
212 211 232

220F2MC80
211 Spool 232 Spring seat 266 O-ring

212 Sleeve 253 Plug 267 O-ring
231 Spring 265 O-ring 268 O-ring
2-28
2. HYDRAULIC CIRCUIT
P4
P5
XBp2
R2
BYPASS
XBp1 CUT
PaL
Aa
Ba
ARM 1
XBa1 XAa2 ARM 2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Bk
Ao
OPTION XAo XAk BUCKET

XBk
PCk
XBo
PbL
Ab
Bb
BOOM 2 XAb2
BOOM 2
XAb1 BOOM 1
SWING XBb1
Psp PRIORITY
Pns Dr1
Bs AtL
As BtL
SWING XAs XAtL TRAVEL(LH)
XBtL
XBs
Dr6 Py
Dr2
Btr Px
Atr
PTa
TRAVEL(RH) XAtr
STRAIGHT
Pz
TRAVEL
XBtr
BLOCK
P1 P3 R1 Po P2 PG
A1 A2
220A2MC12
2-29
3. FUNCTION
1) CONTROL IN NEUTRAL POSITION
P2
3
Casing A
2
308
TRAVEL (PTa)
STRAIGHT
301
XAtL XBtL
TRAVEL(LH) 303
XBb1 XAb1
BOOM 1
304
XAk PCk
BUCKET
XBk
XBa2 XAa2
ARM 2
306
CCo CCk
SPOOL SECTION (P2) 220F2MC15
1 2 307
P1 R1
Casing B
301
XBtr XAtr
TRAVEL(RH)
305
XAs XBs
SWING
Psp XAb2
BOOM 2
SWING
PRIORITY
(XAo) (XBo)
OPTION
309
XAa1 XBa1
ARM 1
302
XBp1 (XBp2)
BYPASS
BYPASS CUT P2
CUT P1
P4
220F2MC16
SPOOL SECTION (P1)
2-30
When all spools are in the neutral positions, the pressurized oil discharged from the hydraulic pump
(A1) passes through Port P1, the main path (1), the bypass circuit (2) passing the spools for travel
right (301), swing (305), boom confluence (boom 2; 307), option (309) and arm 1 (302), and returns
to the hydraulic oil tank through the tank port (R1).
The oil discharged from the hydraulic pump (A2) passes through Port P2, the main path (3), the
bypass circuit (2) passing the spools for travel left (301), boom 1 (303), bucket (304) and arm 2
(306), and returns to the hydraulic oil tank through the tank port (R1).
RCV secondary pressure in neutral position of spool is led to electrically controlled regulator and
controls the pump discharge flow rate to its minimum value.
2-31
2) EACH SPOOL OPERATION
(1) Boom operation
① Boom up operation
H R
511 303
Ab
Bb
XAb1
XAb 2
307
511
220F2MC17
Pilot circuit
Since the boom 1 spool (303) transfers and shuts off the side-bypass path, the pressure at Port
XAb1, XAb2 increases.
Main circuit
During the boom up operation, the pilot pressure enters through Port XAb1 and moves the boom 1
spool (303) in the left direction. The pressurized oil entering through Port P2 passes through the
main path (3) and flows to the bypass circuit (2), but the bypass circuit (2) is shut off due to transfer
of the boom 1 spool (303).Therefore, the pressurized oil flows into the parallel circuit, pushes open
the check valve (511), and flows through the U-shaped path to the boom 1 spool (303).
Then, it flows around the periphery of the boom 1 spool (303) to Port Ab, and is supplied to the
boom cylinder head side (H).
At the same time, the pilot pressure enters also through Port XAb2 to transfer the boom 2 spool
(307) in the right direction. Though the pressurized oil enters into Port P1, the bypass circuit (2) is
shut off due to transfer of the boom 2 spool (307). Therefore, the hydraulic oil flows in the parallel
circuit and flows through the U-shaped path to the boom 2 spool (307). Then, the hydraulic oil
passes through the periphery of the boom 2 spool (307), pushes open the check valve (511), joins
into Port Ab in the inside path, and is supplied to the boom cylinder head side. (Boom confluent
flow)
On the other hand, the return oil from the boom cylinder rod side (R) enters through Port Bb and
returns to the hydraulic oil tank through the tank port (R1).
2-32
② Boom down operation
H R
511
Ab
Bb
XBb1
(c) (b) (a) 303 303-317
220F2MC52
Pilot circuit
Since the boom 1 spool (303) transfers and shuts off the side-bypass path, the pressure at Port
XBb1 increases.Then, the pressure enters also through Port PbL and the release signal is sent to
the lock valve (252).
Main circuit
During the boom down operation, the pilot pressure enters through Port XBb1 and transfers the
boom 1 spool (303) in the right direction.The pressurized oil entering through Port P2 passes
through the main path (3) and flows to the bypass circuit (2), but the bypass circuit (2) is shut off
due to transfer of the boom 1 spool (303).Therefore, the pressurized oil flows into the parallel circuit,
pushes open the check valve (511), and flows through the U-shaped path to the boom 1 spool
(303).Then, it flows around the periphery of the boom 1 spool (303) to Port Bb and is supplied to
the boom cylinder rod side (R).
On the other hand, the return oil from the boom cylinder head side (H) passes to the holes (a) and
the notches (b) of the boom 1 spool (303).
Since this return oil has a sufficient pressure caused by the weight of the boom, it passes through
the path inside the spool, pushes the poppet (303-317) in the spool in the right direction, flows
around the outside of the spool.Then, it is supplied again to the boom cylinder rod side as hydraulic
oil to lower the boom. (Boom regeneration)
Besides, a part of the return oil from the boom cylinder flows from the hole (c) into the tank.
2-33
(2) Arm operation
① Arm out operation
R H
256 511 306

Aa
XAa2
XBa2
XAa1
XBa1
Ba
302 511
220A2MC53
Pilot circuit
Since the arm 2 spool (306) transfers and shuts off the side-bypass path, the pressure at Port
XAa1, XAa2 increases.
Main circuit
During the arm out operation, the pilot pressure enters through Ports XAa1 and XAa2.W h e n t h e
pressure enters through Port XAa1 and XAa2, the spools transfer in the left direction.The hydraulic
oil entering through Port P1 passes through the main path (1) and flows to the bypass circuit (2),
but the bypass circuit is shut off due to transfer of the arm 1 spool (302).
Therefore, the hydraulic oil from the parallel circuit pushes open the check valve (511) and flows
through the U-shaped path to the arm 1 spool (302).Then, it flows around the periphery of the arm
1 spool (302) and the arm 2 spool (306) to Port Aa, and is supplied to the arm cylinder rod side (R).
On the other hand, the hydraulic oil entering through Port P2 passes in the main path (3), and flows
into the bypass circuit (2), and the bypass circuit is shut off due to transfer of the arm 2 spool (306).
The hydraulic oil from the parallel circuit pushes open the logic poppet (256) and the hydraulic oil
from the bypass circuit (2) pushes open the check valve (511) and flows through the U-shaped path
to the arm 2 spool (306).Then, it flows around the periphery of the arm 2 spool (306) in the inside
path and joins into Port Aa.
Besides, the return oil from the arm cylinder head side passes (H) through Port Ba, flows into tank
line in arm 1 side and in arm 2 side, and returns to the hydraulic oil tank through the tank port (R1).
2-34
② Arm in operation
·During
During light load only
Arm self weight
R H
P2
Aa
306
XBa2
XAa2
302-317
XBa1
XAa1
Ba (b)
(a) 302 P1
220A2MC54
Pilot circuit
Since the arm 2 spool (306) transfers and shuts off the side-bypass path, the pressure at Port
XBa1, XBa2 increases. Then, the pressure enters also through Port PaL and the release signal is
sent to the lock valve (252).
Main circuit
During the arm in operation, the pilot pressure enters through Ports XBa1 and XBa2. When the
pressure enters through Port XBa1 and Port XBa2, the spools transfer in the right direction. The hy-
draulic oil entering through Port P1 passes through the main path (1) and flows to the bypass circuit
(2), but the bypass circuit is shut off due to transfer of the arm 1 spool (302).Therefore, the hydraulic
oil from the parallel circuit pushes open the check valve (511) and flows through the U-shaped path
to the arm 1 spool (302). Then, it flows around the periphery of the arm 1 spool (302) to Port Ba,
and is supplied to the arm cylinder head side (H).
On the other hand, the hydraulic oil entering through Port P2 passes in the main path (3), and flows
into the bypass circuit (2), and the bypass circuit is shut off due to transfer of the arm 2 spool (306).
The hydraulic oil from the parallel circuit pushes open the logic poppet (256) and the hydraulic oil
from the bypass circuit (2) pushes open the check valve (511) and flows through the U-shaped path
to the arm 2 spool (306). Then, it flows around the periphery of the arm 2 spool (306) and the arm
1 spool (302) in the inside path and joins into Port Ba.
Besides, the return oil from the arm cylinder rod side (R) is pressurized by self-weight of the arms
and so on, and returns to Port Aa. The pressurized oil returning to Port Aa enters into the spool
through the periphery hole (a) of the arm 1 spool (302).During a light load only, it pushes open the
check valve (302-317) and joins into Port Ba from the spool hole (b).The rest of oil returns to the
hydraulic oil tank through the tank port (R1).This is called the arm regeneration function.
2-35
·The
The pressure in the arm cylinder head side (H) increases
R H
Aa
XBa 2
302-317
XBa1
(c)
Ba
257-211 Pis (a)
220A2MC55
When the pressure in the arm cylinder head side (H) and the U-shaped path increases, the arm
regeneration cut spool (257-211) is transferred in the left direction, and at the same time the
check valve (302-317) is closed by its backpressure. This shuts off the arm regeneration function,
and the return oil from the arm cylinder rod side (R) enters from Port Aa through the periphery
hole (a) of the arm 1 spool (302) into the spool, flows to the arm regeneration cut valve (257)
through the periphery hole (c) of the arm 1 spool (302), and returns through the tank port (R1) to
the hydraulic oil tank.
When the Pilot Port Pis of the arm regeneration cut spool (257-211) is pressurized, a part of the
return oil from the arm cylinder rod side flows to the arm regeneration cut valve (257) and returns
through the tank port (R1) to the hydraulic oil tank. (Variable arm regeneration)
2-36
③ Arm 2 logic control valve operation
251-102
(b)
(a)
256-102
(c) (d) (e)
256-101
306
XAa 2
220A2MC116
During both the arm in operation and the boom up operation, the pilot pressure enters through
Ports XBa1, XBa2, XAb1, XAb2, PaL and electrically controlled pilot pressure enters to PnA2. The
pressure PnA2 transfers the spool (251-102) in the arm 2 logic control valve to the top direction,
and the path from (a) to (b) is closed. Hereby, the pressurized oil pushes open the poppet (256-
102), passes in the path (c) and (d), enters into the chamber (e), and the poppet (256-101) is
pushed to the casing seat. Therefore, the most of pressurized oil entering through Port P2 flows
to the boom 1 spool (303) than the arm 2 spool (306) to make the boom hoisting operation most
preferential.
On the other hand, in the independent arm in operation, the pilot pressure does not enter through
Ports PnA2, and the path from (a) to (b) is not closed, and the hydraulic oil of the chamber (e) flows
to the path (a) and (b). The pressurized oil entering through Port P2 pushes open the poppet (256-
101) and flows to the arm 2 spool (306).
2-37
(3) Bucket operation
① Bucket in operation
H R
Ak Bk
XAk PCk
304
220F2MC57
Pilot circuit
Since the bucket spool (304) transfers and shuts off the side-bypass path, the pressure at Port XAk
increases. Then, the pressure enters also through Port XBp1.
Main circuit
During the bucket in operation, the pilot pressure enters through Port XAk and transfers the bucket
spool (304) in the right direction.The pressurized oil entering through Port P2 passes through the
main path (3) and flows through the bypass circuit (2), but the bypass circuit (2) is shut off due to
transfer of the bucket spool (304).Therefore, the pressurized oil flows into the parallel circuit, pushes
open the check valve (511), and flows through the U-shaped path to the bucket spool (304). Then, it
flows through the periphery of the spool to Port Ak and is supplied to the bucket cylinder head side
(H).
On the other hand, the return oil from the bucket cylinder rod side (R) enters through Port Bk,
passes around the periphery of the spool, and returns to the hydraulic oil tank through the tank port
(R1).
During both the boom up operation and bucket in operation, the pilot pressure enters through
Port PCk and the bucket spool transfers in the half stroke not full stroke. Therefore, the most of
pressurized oil entering through Port P2 flows to the boom 1 spool (303) than the bucket spool
(304) to make the boom up operation most preferential.
2-38
② Bucket out operation
Pilot circuit
Since the bucket spool (304) transfers and shuts off the side-bypass path, the pressure at Port
XBk increases. Then, the pressure enters also through Port XBp1.
Main circuit
During the bucket out operation, the pilot pressure enters through Port XBk and transfers the
bucket spool (304) in the left direction.The pressurized oil entering through Port P2 passes
through the main path (3) and flows through the bypass circuit (2), but the bypass circuit (2) is
shut off due to transfer of the bucket spool (304). Therefore, the pressurized oil flows into the
parallel circuit, pushes open the check valve (511), and flows through the U-shaped path to the
bucket spool (304).Then, it flows through the periphery of the spool to Port Bk and is supplied to
the bucket cylinder rod side (R).
On the other hand, the return oil from the bucket cylinder head side (H) enters through Port Ak,
passes around the periphery of the spool, and returns to the hydraulic oil tank through the tank
port (R1).
H R
Ak Bk
XBk
313 220F2MC58
③ Bucket in/out confluence

During the bucket in/out operation, the pilot pressure enters also through Port XBp1 and transfers
the bypass-cut spool (313). The pressurized oil entering through Port P1 passes through the
main path (1) and flows through the bypass circuit (2), but the bypass circuit (2) is shut off due
to transfer of the bypass-cut spool (313). Therefore, the pressurized oil pushes open the check
valve CCk (514), and flows through inside path and the U-shaped path to the bucket spool (304).
2-39
(4) Swing operation
XBs XAs
305
As Bs
254-101 254-102
250-102
21092MC19
① Swing operation
Pilot circuit
Since the swing spool (305) transfers and shuts off the side-bypass path, the pressure at Port
XAs (or Xbs) increases.
Main circuit
During the swing operation, the pilot pressure enters through Port XAs (or XBs) and transfers the
swing spool (305). The pressurized oil entering through Port P1 passes through the main path (1)
and flows through the bypass circuit (2), but the bypass circuit (2) is shut off due to transfer of the
swing spool (305). Therefore, the pressurized oil flows into the parallel circuit, pushes open the
check valve (511), and flows through the U-shaped path to the swing spool (305). Then, it flows
through the periphery of the spool to Port As (or Bs) and is supplied to the swing motor.
On the other hand, the return oil from the swing motor enters Port Bs (or As) and returns to the
hydraulic oil tank through the tank port (R1).
② Swing logic control valve operation

During both the swing operation and the boom up operation, the pilot pressure enters through
Ports XBs (or XAs), XAb1, XAb2 and electrically controlled pilot pressure enters to PnA2. The
pressure Pns transfers the spool (250-102) in swing logic control valve. Hereby, the pressurized
oil pushes open the poppet (254-102), and the poppet (254-101) is pushed to the casing seat.
Therefore, the most of pressurized oil entering through Port P1 flows to the boom 2 spool (307)
than the swing spool (305) to make the boom up operation most preferential.
On the other hand, in the independent swing operation, the pilot pressure does not enter through
Ports Pns. The pressurized oil entering through Port P1 pushes open the poppet (254-101) and
flows to the swing spool (305).
2-40
③ Swing operation preference function
311
Psp
21092MC20
Pilot circuit
The pilot pressure enters through Port Psp to transfer the swing priority spool (311).
Main circuit
Due to transfer of the swing priority spool (311), the open area of the swing priority spool
decreases, and the most of the pressurized oil entering through Port P1 flows to the swing side to
make the swing operation most preferential.
2-41
(5) Travel operation
301
XBtr
XAtr
Atr Btr
21092MC21
Pilot circuit
Since any of the travel spools (301) on the left or right transfers and shuts off the side-bypass path,
the pressure at Port XBtr (or XAtr) increases.
Main circuit
When Pilot Port XBtr of the travel right spool (301) is pressurized, the bypass circuit (2) in the arm 1
side is shut off and the working fluid discharged from the hydraulic pump (A1) through Port Btr and
flows to the travel right motor.
When Pilot Port XBtL of the travel left spool (301) is pressurized, the bypass circuit (2) in the
boom 1 side is shut off and the working fluid discharged from the hydraulic pump (A2), similarly to
that from the hydraulic pump (A1), through Port BtL and flows to the travel left motor.
On the other hand, the return oil from the right and left travel motor passes flows from Port Atr (AtL)
to the travel right (left) spools (301) and returns to the hydraulic oil tank through the tank port (R1).
In the case of the opposite operation (when the pilot pressure is applied to Ports XAtr and XAtL of
the control valve), the operation is similar.
2-42
(6) Travel straight operation
Simultaneous operating of both travel spools (301) and other spool.
The following the case that both travel spools (301) and swing spool (305) are changed over.
(When the pilot Ports XAtL, XAtr and XAs are pressurized.)
308 P2 P1
PTa
301
220A2MC22
Pilot circuit
Since the side bypass sections of both travel spools (301) close and the side bypass section of the
downstream-side swing closes, the pilot pressure from the port PG enters through the port PTa to
transfer the travel straight spool (308).
Main circuit
After changeover of the travel straight spool (308), the port P1 and both travel spools (301) are
connected preferentially and the port P2 and the parallel paths of swing, boom 2, option and
arm 1 / boom 1, bucket and arm 2 are connected preferentially. Therefore, the pressurized oil
entering through Port P1 passes through mainly ports AtL and Atr, and flows to both travel motors
separately.
On the other hand, the pressurized oil entering through Port P2 flows to Port As and is supplied to
the swing motor.
When the pressure of Port P1 is lower than the pressure of Port P2, the part of oil entering through
Port P2 flows into Port P1 side. Therefore, it prevents the travel velocity from slowing rapidly.
2-43
3) FUNCTION
UNCTION OF LOCK VALVE
The lock valve (252) is fitted between the arm cylinder rod side (R) and the arm 2 spool (306). It
decreases the leakage by the pressure of the cylinder.
Another lock valve (252) is similarly fitted between the boom cylinder head side (H) and the boom 1
spool (303). It decreases the leakage by the pressure of the cylinder.
(1) Neutral positions of spools
The following is the case of the boom 1 spool (303).(The case of the arm 2 spool (306) is in the
same way.)
During the boom 1 spool (303) is in the neutral position, the lock valve (252) is kept in the position
shown in figure.The spool (252-511) in the lock valve is pushed to the seat of the sleeve (252-541)
by the force of the spring (252-321).
In this position, the pressurized oil from the boom cylinder head side (H) enters through the hole
(a), the periphery of the spool (252-511) in the lock valve and the hole (b), and it pushes the
poppet (513) to the casing seat, and the leakage is decreased.
252-321 252-511
252-541
(b)
513
(a)
XBb1
220A2MC135
2-44
(2) Boom down operation
During the boom down operation, the pilot pressure enters through Port PbL and XBb1. The pilot
pressure transfers the spool (252-511) in the lock valve assy in the top direction. By the transfer of
the spool (252-511), firstly the hole (a) is blocked and the flow of oil from the boom cylinder head
side (H) to the spring chamber (RH) stops. Secondly, the oil in the spring chamber (RH) enters
through the hole (b) and flows to drain circuit. Therefore, the poppet (513) is lifted by the pressure
of the boom cylinder head side (H) and the function of the lock valve (252) is released.
252-511
Dr (RH)
(b)
513
(a)
PbL
XBb1
220A2MC136
(3) Boom up operation

During the boom up operation, the pilot pressure enters through Port XAb1. The oil flowing from
the boom 1 spool pushes open the poppet (513) and flows to Port Ab.
2-45
4) CIRCUIT PRESSURE PROTECTION
The control valve has two kinds of relief valve to limit the pressure in a circuit.
(1) Main relief valve
The main relief valve is fitted in the P2 housing and functions as follows.
541 611 621
512 A Pz 103 614
21092MC25
① The hydraulic oil is filled up in the inside space chamber (A) from the path (P) through a hole of the
seat (541) and a restriction of the plunger (512), and seats the plunger (512) against the seat (541)
securely.
② When the pressure in the path (P) becomes equal to the set load of the spring (621), the poppet
(611) opens to make the hydraulic oil flow through a hole of the plug (103), around the poppet
(611) and the hydraulic oil flow into the low pressure path (R).
③ Opening of the poppet (611) causes the pressure in the chamber (A) to fall and the plunger (512)
to open. As the result the pressurized oil in the path (P) runs into the low pressure path (R) directly.
④ When the pressurized oil over 30 kgf/cm2 enters through the port Pz, it pushes the piston (614),
changes the relief set pressure of the spring (621) to the high pressure.
2-46
(2) Port relief valve
The port relief valve is fitted between the cylinder port and low-pressure path. In addition to the
relief valve, it has the function of an anti-cavitation check valve, and functions as follows:
① Function as relief valve
a. The pressurized oil passes through Hole A of the piston (301), fills Chamber B, and seat the
plunger (511) against the seat (541) securely.
A B
R
301 511 541
A B
R
301 511 541
220F2MC66
2-47
b. When the pressure in the path (P) exceeds the set pressure of the spring (621 or 622), the
pressurized oil pushes open the poppet (611), flows around it, and flows to the low pressure
path (R) through hole C.
R
611 621
R
611 621
220F2MC67
2-48
c. Opening of the poppet (611) causes the pressure in Chamber B to fall and the plunger (511) to
open.As the result the pressurized oil in the path (P) runs into the low pressure path (R) directly.
R
511 611
R
511 611
220F2MC68
2-49
② Function as Anti-Cavitation Check Valve
When any negative pressure exists in the path (P), the oil is supplied through the path (R).
When the pressure at the path (R) exceeds it in the path (P), the seat (541) moves in the right
direction. Then, sufficient oil passes from the path (R) to the path (P) around the seat (541) and
prevents cavitation.
R
541
R
541
220F2MC69
2-50
GROUP 3 SWING DEVICE
1. STRUCTURE
Swing device consists swing motor and swing reduction gear.
Swing motor include mechanical parking valve, relief valve, make up valve and port block assy.
Reduction gear oil Port block assy

drain port (PT 1/2)
Relief valve AU MU DR
PG Oil level & PG

air vent port
(PT 1/4)
MA HEAVY INDUSTRIES CO.,LTD.
P A R T NO. :
MB
SERIAL NO. : 39K6-10150
AU DR
MU
MA MB
VA VB
Oil level gauge

& oil supply port
VA VB
Reduction gear Swing motor
AU
PG
DR

VA Main port Ø20
VB Main port Ø20
MA MB Drain port
DR PF 1/2
MU
MU Make up port PF 1 1/4
PG Brake release port PF 1/4
MA, MB Gauge port PF 1/4
AU Air vent port PF 1/4
VA VB
Hydraulic circuit
210A2SM01
2-51
1) SWING MOTOR
3 2 11 10 1 35 42 19 18 22 17 21 20 29 28 39 27 26 25 38 24 41 30 40 24 38 25 26 27
38QB-11100
4 5 7 8 9 12 13 14 15 16 6 23 28 29 37 36 38 34 32 33 31 33 32 34 38 37
235A2SM02
1 Casing 15 Parking piston 29 O-ring

2 Oil seal 16 Brake spring 30 Relief valve assy
3 Shaft 17 Spring pin 31 Anti-rotating valve assy
4 Snap ring 18 O-ring 32 Plug
5 Roller bearing 19 O-ring 33 O-ring
6 Roller bearing 20 Valve plate 34 O-ring
7 Swash plate 21 Spring pin 35 Port block assy
8 Cylinder block 22 O-ring 36 Level gauge assy
9 Spring 23 Valve casing 37 Socket bolt
10 Ball guide 24 Check valve 38 Socket bolt
11 Retainer plate 25 Spring 39 Plug
12 Piston assy 26 Plug 40 Name plate
13 Friction plate 27 O-ring 41 Rivet
14 Separate plate 28 Plug 42 Hex socket bolt
2-52
2) REDUCTION GEAR
2 27 26 28 3 33 8 7 15 12 11 30 14 13 22 23 21 18 19 20
4 5 6 25 29 1 10 16 17 25 24 9
220L2SM03
1 Ring gear 11 Planetary gear 2 21 Thrust washer 1

2 Drive shaft 12 Needle bearing 2 22 Carrier pin 1
3 Taper roller bearing 13 Thrust washer 2 23 Spring pin 1
4 Taper roller bearing 14 Carrier pin 2 24 Sun gear 1
5 Ring nut 15 Spring pin 2 25 Thrust plate
6 Lock plate 16 Sun gear 2 26 Sleeve
7 Hexagon bolt 17 Carrier 1 27 O-ring
8 Casing 18 Planetary gear 1 29 Parallel pin
9 Socket bolt 19 Needle bearing 1 30 Socket bolt
10 Carrier 2 20 Thrust washer 1 33 Plug
2-53
2. PRINCIPLE OF DRIVING
1) GENERATING THE TURNING FORCE
The high hydraulic supplied from a hydraulic pump flows into a cylinder block (8) through valve
casing of motor (23), and valve plate (20).
The high hydraulic is built as flowing on one side of Y-Y line connected by the upper and lower
sides of piston (12).
The high hydraulic can generate the force, F1=P×A (P : supplied pressure, A : water pressure
area), like following pictures, working on a piston.
This force, F1, is divided as N1 thrust partial pressure and W1 radial partial pressure, in case of the
plate of a tilt angle, α.
W1 generates torque, T=W1×R1, for Y-Y line connected by the upper and lower sides of the piston
as following pictures.
The sum of torque (ΣW1×R1), generated from each piston (4~5 pieces) on the side of a high
hydraulic, generates the turning force.
This torque transfers the turning force to a cylinder (8) through a piston; because a cylinder is
combined with a turning axis and spline, a turning axis rotates and a turning force is sent.
W1 Pistion
Cylinder
W1
R1
N1
O A
f1 F1 P
High Y Low
pressure pressure
21078TM05
2-54
2) MAKE UP VALVE
In the system using this type of motor, there is no counter balance functioning valve and there
happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation
caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency.
A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure
feed pressure required when the hydraulic motor makes a pumping action. The boost pressure
acts on the hydraulic motor's feed port via the make up valve.
Pressurized oil into the port B, the motor rotate counterclockwise.
If the plunger of MCV moves neutral position, the oil in the motor is drain via left relief valve, the
drain oil run into motor via right make up valve, which prevent the cavitation of motor.
Relief valve
Make up check valve Make up check valve
A B
21092SM04
2-55
3) RELIEF VALVE
1 Sleeve
10 2 Poppet
9
3 Poppet seat
6 4 Spring
8 5 Spring seat
1
6 Shim
5 7 Piston
9 8 Stopper
11 9 Plug
10 O-ring
2 11 O-ring
4
3
2209A2SM25
(1) Construction of relief valve

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

Figure illustrates how the pressure acting
on the relief valve is related to its rising P P=pressure, T=time
process. Here is given the function, Ps
referring to the figure following page.
4
P2
3
P1
T
1
2-48(2)
2-56
① Ports (P,R) at tank pressure.
A2 m h n g
A1
P
2209A2SM26
② When hydraulic oil pressure (P×A1) reaches the preset force (FSP) of spring (4), the plunger (2)
moves to the right as shown.
P1×A1=Fsp+Pg×A2
Fsp+Pg×A2
P1=
A1
4 g
P=P1
2209A2SM27
2-57
③ The oil flow chamber g via orifice m and n. When the pressure of chamber g reaches the preset
force (FSP) of spring (4), the piston (7) moves left and stop the piston (7) hits the bottom of bushing
(8).
4 m n g
P=P2
8 7
2209A2SM28
④ When piston (7) hits the bottom of bushing (8), it stops moving to the left any further. As the
result, the pressure in chamber (g) equals (Ps).
Ps×A1=Fsp+Ps×A2
Fsp
Ps=
A1-A2
P=Ps
8 7 g
2209A2SM29
2-58
4) BRAKE SYSTEM
(1) Control valve swing brake system
This is the brake system to stop the swing motion of the excavator during operation.
In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance
created by this throttling works as a brake force to slow down the swing motion.
Work Deceleration Stop
A B A B A B
MCV MCV MCV
MCV A, B opened MCV A, B throttled MCV A, B closed

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

This is function as a parking brake only when all of the RCV lever (except swing, arm in) are not
operated.
① Brake assembly
Circumferential rotation of separate plate
(14) is constrained by the groove located
at casing (1). When housing is pressed
down by brake spring (16) through
16
friction plate (13), separate plate (14)
8
and parking piston (15), friction force
15
occurs there.
14
Cylinder block (8) is constrained by this Groove
friction force and brake acts, while brake 13
releases when hydraulic force exceeds 1
spring force.
235ZF2SM35
1 Casing 14 Separate plate

8 Cylinder block 15 Parking piston
13 Friction plate 16 Brake spring
2-59
② Operating principle
a. When the RCV lever (1) is set to the swing operating position, each spool is shifted to left or
right and the pilot oil flow is blocked.
The solenoid valve (5) is shifted to swing position, so pilot pump charged oil (P3) goes to the
chamber G through port PG.
This pressure is applied to move the parking piston (15) to the upward against the force of the
brake spring (16). Thus, it releases the brake force.
35
16
PG
15
G
P
A
1 5
T
1 RCV lever
2 Shuttle valve
5 Solenoid valve P3
15 Parking piston
16 Brake spring
35 Port block assy
2
210A2SM04
2-60
b. When all of the RCV lever (1) are set the neutral position, the solenoid valve (5) is returned to
swing stop position.
Then, the parking piston (15) is moved lower by spring force and the return oil from the
chamber G flows back to tank port.
At this time, the brake works.
35
16
PG
15
G
1
5
T
1 RCV lever
2 Shuttle valve
P3
5 Solenoid valve
15 Parking piston
16 Brake spring
35 Port block assy 2
210A2SM05
2-61
GROUP 4 TRAVEL DEVICE
1. CONSTRUCTION
Travel device consists travel motor and gear box.
Travel motor includes brake valve, parking brake and high/low speed changeover mechanism.
Ps
MA
MB
DR
VA,VB
VB VA
Reduction gear Travel motor
FILL
LEVEL
DRAIN
DR
Ps
VIEW A
R/G
MB MA
220L2TM01

VA, VB Valve port PF 1
Ps Pilot port PF 1/4
VB VA
DR Drain port PF 1/2
Hydraulic circuit
MA, MB Gauge port PF 1/4
2-62
2. SPECIFICATION
1) TRAVEL MOTOR
2 21 22 20 23 24 1 59 31 61,62 32 29 2 36 37 55 42 41 52 35 54 53 47 50 54 58
34 49
59 53
58 51
7 33
56 48
6
57 55
15 59
11
58 39
60 40
46
3 64
4 63
12 14 9 16 17 19 27 26 25 30 8 18 28 10 13 44 46 43 38 45 54
220L2TM02
1 Casing 22 Piston assy 44 Plug

2 Plug 23 Friction plate 45 O-ring
3 Oil seal 24 Separated plate 46 O-ring
4 Thrust plate 25 Parking piston 47 Spool
5 Snap ring 26 D-ring 48 Plug
6 Swash piston 27 D-ring 49 Spring seat
7 Piston seal 28 Valve plate 50 Parallel pin
8 Shaft 29 Parallel pin 51 Spring
9 Cylinder roller bearing 30 Brake spring 52 Connector
10 Needle bearing 31 O-ring 53 O-ring
11 Snap ring 32 Spring pin 54 Hexagon socket head bolt
12 Snap ring 33 Parallel pin 55 Hexagon socket head bolt
13 Snap ring (type 1) 34 Rear cover 56 Check valve
13 Retainer C ring (type 2) 35 Main spool assy 57 Spring
14 Thrust plate 36 Spool cover 58 Plug
15 Steel ball 37 Spring 59 O-ring
16 Pivot 38 Restrictor 60 Plug
17 Swash plate 39 Hexagon socket head bolt 61 Restrictor
18 Cylinder block 40 O-ring 62 Restrictor
19 Spring 41 Spring seat 63 Name plate
20 Ball guide 42 Relief valve assy 64 Rivet
21 Retainer plate 43 Spring
2-63
2) TRAVEL REDUCTION GEAR
8,33 23 22 19 20 21 15 16 11 12 13 14 4 27
25 28,32,34 26 18 1 24 17 10 29 9 5 6 2 7 3
220S2TM22
1 Ring gear 13 Thrust washer 2 25 Thrust plate

2 Ball bearing 14 Carrier pin 2 26 Cover
3 Floating seal assy 15 Spring pin 2 27 Hexagon socket head bolt
4 Nut ring 16 Solid pin 2 28 Plug
5 Lock plate 17 Sun gear 2 29 Snap ring
6 Hexagon bolt 18 Carrier 1 30 Name plate
7 Housing 19 Planetary gear 1 31 Rivet
8 Hexagon socket head bolt 20 Needle bearing 1 32 O-ring
9 Coupling 21 Thrust washer 1 33 Rubber cap
10 Carrier 2 22 Carrier pin 1 34 Rubber cap
11 Planetary gear 2 23 Spring pin 1
12 Needle bearing 2 24 Sun gear 1
2-64
3. OPERATION
1) MOTOR
High pressure oil delivered form hydraulic pump is led to inlet port that is provided in the brake
valve portion and, through the rear cover (34) and valve plate (28), led to cylinder block (18).
The oil flow and direction of shaft rotation are indicated in table.
Shaft rotation Left Shaft rotation Right

(Counterclockwise) (Clockwise)
Inlet Outlet Direction of shaft rotation

port port (viewing from rear cover)
VB VA Right (clockwise)
VA VB Left (counterclock wise)
VB VA
25092TM23
As shown in below figure, high pressure oil is supplied to the pistons which are on one side of the
line Y-Y that connects upper and lower dead points and produces force F1.
F1 = P×A (P : pressure, A : area of piston section)
The swash plate (17) with inclined angle of divides this force F1 into thrust force F2 and radial
force F31-34.
This radial force is applied to axis Y-Y as turning force and generate drive torque of T.
T = r1·F31+r2·F32+r3·F33+r4·F34
This drive torque is transmitted via cylinder block (18) to driving shaft (8).
Y
F31
P F1
r1 F31
F32 P F2
F32
r2
F33 P
r3
F33
P
F34 F34
Y
r4
29092TM07
2-65
2) PARKING BRAKE
Parking brake is released when high pressure oil selected by the brake valve portion that is
connected directly to the rear cover (34), is applied to the parking piston (25).
Otherwise the braking torque is always applied.
This braking torque is generated by the friction between the separated plates (24), inserted into the
casing (1), and friction plates (23), coupled to cylinder block (18) by the outer splines.
When no pressure is activated on the parking piston (25), it is pushed by the brake springs (30)
and it pushes friction plates (23) and separated plates (24) towards casing (1) and generates the
friction force which brakes the rotation of cylinder block (18) and hence the shaft (8).
8 23 24 1 25 18 34
30
25092TM24
2-66
3) CAPACITY CONTROL MECHANISM
Figure typically shows the capacity control mechanism.
When high speed pilot line is charged with the pressure PA that overcome the spring (51), the
spring (51) is compressed and spool (47) shifts to the right to connect the port P and port C.
Then, the highest pressure is selected by the check valve (56) from inlet and outlet pressure of the
motor and high speed pilot line pressure and pushes shifter piston (6). As a result, swash plate (17)
turns around the line L which connect the two pivots (16) as shown by dotted lines. The turn stops
at the stopper (1-1) of casing and swash plate (17) keeps the position.
In this case, the piston stroke become shorter and motor capacity become smaller and motor
rotates faster, around 1.60 times, by the same volume of oil.
When no pressure is in the high speed pilot line PA, spool (35) is pushed back by the spring (51)
and pressure that pressed the shifter piston (6) is released to the hydraulic tank through restrictor
(61).
Here, nine pistons are there and they equally spaced on the swash plate (17). The force that
summed up those of pistons comes to almost the center of the swash plate (17) as shown. Since
the pivots (16) are off-set by S from the center, the rotating force of product S and the force moves
swash plate (17) to the former position and the speed returns to low.
When the power demand exceeds the engine power, such as in steep slope climbing or turning at
high speed mode, the system step down to the low speed automatically. The mechanism is that:
pump pressure is led to the port PB and this pressure activate on pin (50). When the pressure at PB
exceeds predetermined value, spool (47) returns to the left by the counter-pressure against pin (50)
and the pressure on the shifter piston (6) through port C is released to the tank and the motor
comes to low speed.
When PB goes down, the spool (47) moves to the right and the speed become high.
To counterbalance valve
(Brake valve)
MA MB
High speed pilot line
(External Pilot)
56 56 56
8 6 1-1 22
T
PA
47
S
L L VA or VB
PB P C
Load
16 16 17 application point 61 51 50
25092TM19
2-67
4) OVERLOAD RELIEF VALVE
(1) Structure
tructure
This valve is screwed in the motor rear cover (34) and consists of : plug (42-1) that is screwed and
fixed in the rear cover (34), poppet (42-10) and supports the poppet seat (42-11), spring (42-4)
that is operating relief valve setting pressure and supports the spring seat (42-5), that is inserted
in the sleeve (42-6), screw (42-14) that is adjust the spring force, nut (42-15) that fix screw
(42-14), piston (42-7) that reduce the shock.
42-14 42-15 42-1 42-2 42-3 42-4 42-16 42-9 42-8 42-7 42-5 42-6 42-10 42-13 42-12 42-11
25092TM25
42-1 Plug 42-7 Piston 42-12 O-ring

42-2 Guide 42-8 O-ring 42-13 Back-up ring
42-3 O-ring 42-9 Back-up ring 42-14 Socket screw
42-4 Spring 42-10 Poppet 42-15 Hexagon nut
42-5 Spring seat 42-11 Poppet seat 42-16 O-ring
42-6 Sleeve
2-68
(2) Operation
Two pieces of overload valves are located at cross-over position in the counterbalance circuit of
brake valve and have the following functions :
① When hydraulic motor starts, keep the driving pressure below predetermined value and while
accelerating, bypasses surplus oil to return line.
② When stopping the motor, keep the brake pressure, that develops on the outlet side of motor,
under the predetermined value to stop the inertial force.
③ To accelerate sharply while starting, and to mitigate the braking shock while stopping. For these
purposes, the developed pressure is kept comparatively low for a short period, then keep the line
pressure as normal value. While the pressure is low, meshing of reduction gears, crawler and
sprocket etc. can be smoothly done and the shock are absorbed.
When starting, "A" port pressure of overload valve increases, this pressure is applied to the
effective diameter of poppet (42-10) which seats on the poppet seat (42-11) and, at the same
time, is delivered, via small hole, to the spring seat (42-5) located inside the sleeve (42-6) and the
seat bore pressure increases up to "A" port pressure. The poppet (42-10) opposes to spring
(42-4) by the force of the pressure exerted on the area difference between poppet seat's effective
diameter and spring seat bore and keep the predetermined pressure.
When hydraulically braking, the piston (42-7) is at the left position by the driving pressure, and
when "A" port pressure increases, the pressure is applied also to the piston (42-7) through the
small hole in the poppet (42-10) and piston (42-7) moves rightward until it touches the stopper in
rear cover. In this while, the poppet (42-10) maintains "A" port pressure at comparatively low
against the spring (42-4) force and exhaust oil to "B" port side. After the piston reached to the
plug, the valve acts the same as at starting.
Spring(42-4) Piston(42-7) Spring seat(42-5) Poppet seat(42-11)
Port B
Port A
Sleeve(42-6) Small hole
25092TM27
2-69
5) BRAKE VALVE
(1) Structure
The brake valve portion mainly consists of the following parts:
① Spool
By shifting the spool (35), the discharged oil from hydraulic motor is automatically shut off or
restricted according to the condition and give the effect of holding, accelerating, stopping and
counterbalance operations.
(See page 2-74, (2) Operation)
② Check valve (built in the spool)
This valve is located in the oil supplying passage to hydraulic motor, and at the same time
functions to lock oil displacement. Therefore, this valve serves as not only a suction valve but
also a holding valve for hydraulic motor.
44 46 43 38 37 41 35 40
25092TM28
35 Main spool 40 O-ring 44 Plug

37 Spring 41 Spring seat 46 O-ring
38 Restrictor 43 Restrictor spring
2-70
(2) Operation
① Holding operation
When the control valve is at neutral position, VA and VB ports are connected to the tank, and the
spring (37) located on both spool ends holds the spool (35) at central position.
Therefore, the passages from VA to MA and VB to MB are closed, which result in closing MA
and MB ports connected to hydraulic motor.
Since the passage to parking brake is connected to the tank line, the brake cylinder pressure is
equal to the tank pressure and the brake is applied by the springs. Thus, the rotation of the motor
is mechanically prevented.
If external torque is exerted on the motor shaft, the motor would not rotate as usual by this
negative parking brake.
In case the brake should be released for some reason, pressure is built on MA or MB port. But,
due to oil leakage inside hydraulic motor or so, high-pressure oil escapes from the closed circuit
and motor rotates a bit. So, the cavitation tends to occur in the lower pressure side of the closed
circuit. Then, the check valve, built in the spool (35), operates to avoid the cavitation and opens
the passage from VA to MA or from VB to MB. Then the oil equivalent to the leakage is sucked
from the tank line to the closed circuit.
DR
T
MB MA
MB MA
VB VA VB VA
25092TM29
2-71
② Accelerating operation
When VA and VB ports are connected respectively to pump and tank by operating the control
valve, hydraulic oil from pump is forwarded through VA port to push open the check valve
provided inside spool (35), and oil flows to motor via MA port to rotate the motor.
Therefore, the pressure increases and negative brake is released by the pressure supplied from
pump. At the same time, the pressure of pilot chamber increases to push and move the spool
(35) leftwards, overcoming the spring (37) force. Thus, the return line from MB to VB opens to
rotate the motor.
In case inertia load is too big to start rotation, accelerating pressure reaches the set pressure of
relief valve and high pressure oil is being relieved while the motor gains the rotational speed.
As the rotational speed goes up, the relieved volume decreases, and finally the motor rotates at
a fixed speed.
DR
T
MB MA
MB MA
VB VA
VB VA
25092TM30
2-72
③ Stopping operation
Returning the control valve to neutral position while running the motor, the oil supply is cut off
and VA and VB ports are connected to the tank line. Then the pressure of the pilot chamber
located on both spool ends become equal, and the spool (35) returns to the neutral position by
spring (37) force. Thus, the passage from MA to VA is closed.
Owing to the inertia force of the load, the hydraulic motor tends to continue the rotation. Here,
the motor functions as a pump and forwards the oil to MB port but the passage is blocked and
MB port pressure increases. Then the relief valve opens to relieve the pressure and rotational
speed decelerates and at last the motor stops.
Negative brake release pressure is gradually lowered due to the restrictor and finally the brake
works and the motor is mechanically stopped.
DR
T
MB MA
MB MA
VB VA
VB VA
25092TM31
2-73
④ Counterbalance operation
Counterbalance operation is required to decelerate slowly the hydraulic motor while absorbing
inertia force.
In case the hydraulic oil is gradually decreased from pump to VB port, the drive shaft of hydraulic
motor tends to rotate faster than that matched to the volume of oil supply.
Consequently, the pilot chamber pressure on MB to VB side decreases and the spring (37) force
moves the spool (35) leftwards towards neutral position.
Therefore, the area of passage from MA to VA becomes smaller and the pressure on MA side
rises due to increased resistance in the passage and the motor receives hydraulic braking effect.
If the motor rotates slower than that matched to the volume of supplied oil, the pilot chamber
pressure on VB port increases, and spool (35) moves rightwards to enlarge the area of passage
from MA to VA. Therefore the braking effect becomes smaller and the rotational speed of motor
is controlled to correspond to the volume of supplied oil.
In order to give stable counterbalance operation, the restrictors (38) are set in the pilot chamber
to damp the spool (35) movement.
The parking brake is released during pressure adjusting action of the spool (35).
DR
T
MB MA
MB MA
VB VA
VB VA
25092TM32
2-74
6) REDUCTION GEAR
Reduction unit slows down the rotating speed of motor and converts motor torque to strong rotating
force.
This reduction unit utilizes two stages, planetary reduction system.
Planetary reduction system consists of sun gear, planetary gears, (planetary) carriers, and ring
gear.
When the sun gear (s) is driven through input shaft, planetary pinions (b), rotating on their center,
also move, meshing with fixed ring gear (a), around sun gear (s).
This movement is transferred to carrier (k) and deliver the torque.
This mechanism is called planetary gear mechanism.
Fixed ring gear(a)

Ring gear(a)
Carrier(k)
Planetary pinions(b) Carrier(k)
Sun gear(s)
Input Output
Sun gear(s)
Planetary pinions(b)
29072TM10 29072TM11
When the sun gear S1 is driven by input shaft, planetary action occurs among gears S1 S1, a and b
and revolution of gear b transfers the rotation of carrier K1 to second sun gear S2
S2, and also evokes
planetary action between gear S2S2, a and d.
This time, because carrier K2 is fixed to frame, gear d drives ring gear a and then ring gear a
rotates to drive sprocket.
b d
S1 S2
K1 K2
29072TM12
2-75
GROUP 5 RCV LEVER
1. STRUCTURE
The casing has the oil inlet port P (primary pressure) and the oil outlet port T (tank). In addition the
secondary pressure is taken out through ports 1, 2, 3 and 4 provided at the bottom face.
※ Refer to the parts manual for the types of the RCV lever.
1) TYPE M1, M5
8
7
Null 5 5
Null
6 6
TYPEM1
TYPE M1 TYPE
TYPE M5
M5
Switches
Type No. LH RH
5 One touch decel Horn
25 19 M1
Simultaneous Single 6 Power boost Breaker
operation operation
6 Power boost Null
M5
7 CCW rotation Close
8 CW rotation Open
※ Number 7 and 8 : Option attachment
P T
A A
1 3 2 4
Hydraulic circuit
Pilot ports
4 Port LH RH Port size
2 3 P 1 P Pilot oil inlet port Pilot oil inlet port
T T
T Pilot oil return port Pilot oil return port
1 P 3 2
1 Left swing port Bucket out port
4 PF 3/8
2 Arm out port Boom up port
LH RH
VIEW A-A 3 Right swing port Bucket in port
4 Arm in port Boom down port
210A2RL01
2-76
2) TYPE M11, M12
8
7
Null 5
5 Null
6 6
TYPE M12 TYPE M11
Switches
Type No. LH RH
25 19
Single 5 One touch decel Horn
Simultaneous M12
operation
operation 6 Power boost Breaker
6 Power boost Null
M11
7 CCW rotation Close
8 CW rotation Open
※ Number 7 and 8 : Option attachment
P T
A A
1 3 2 4
Hydraulic circuit
Pilot ports
2 4
T 1 Port LH RH Port size
3 P
1 T P Pilot oil inlet port Pilot oil inlet port
P 3 T Pilot oil return port Pilot oil return port
4 2
1 Left swing port Bucket out port
LH RH PF 3/8
2 Arm out port Boom up port
VIEW A-A
3 Right swing port Bucket in port
4 Arm in port Boom down port
210A2RL05
2-77
3) CROSS SECTION
1 Case
2 Bushing
3 Spool
No. Port
4 Shim
24 P
5 Spring
25 1, 2, 3, 4 (RH) 6 Spring seat
25 2, 4 (LH) 7 Spring
26 T (RH) 8 Plug
26 1, 3, T (LH) 9 Push rod
10 O-ring
11 Rod seal
20
12 Plate
13 Spacer
14 Boot
21
15 Joint assembly
22 16 Swash plate
17 17 Adjusting nut
13 18 Bushing
15
19 Plug
20 Handle assembly
23
16 21 Handle bar
22 Nut
9
23 Boot
14 11
24 Last guard filter
12
25 Connector
18 8 26 Connector
27~34
10 27 Connector
6 28 Connector
7 29 Connector
5 30 Connector
4 31 Small guide
2 3 32 Connector
19 33 Big guide
1 34 Connector
24
25
210S2RL06
26
Item numbers are based on the type M1.

The construction of the pilot valve is shown in the attached cross section drawing. The casing has
vertical holes in which reducing valves are assembled.
The pressure reducing section is composed of the spool (3), spring (5) for setting secondary pres-
sure, return spring (7), spring seat (6) and shim (4). The spring for setting the secondary pressure
has been generally so preset that the secondary pressure is 5 to 20.5 kgf/cm2 (depending on the
type). The spool is pushed against the push rod (9) by the return spring.
When the push rod is pushed down by tilting the handle, the spring seat comes down simultaneously
and changes setting of the secondary pressure spring.
2-78
2. FUNCTIONS
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and apply-
ing the output pressure (secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following ele-
ments.
(1) Inlet port (P) where oil is supplied from hydraulic pump.
(2) Output ports (1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port (T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port or tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
Item numbers are based on the type M1.
The functions of the spool (3) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output port pressure oil to tank port T.
The spring (5) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod (9) is inserted and can slide in the plug (8).
For the purpose of changing the displacement of the push rod through the swash plate (16) and
adjusting nut (17) are provided the handle assy (20) that can be tilted in any direction around the
fulcrum of the universal joint (15) center.
The spring (7) works on the case (1) and spring seat (6) and tries to return the push rod (9) to the
zero-displacement position irrespective of the output pressure, securing its resetting to the center
position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.
2-79
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram
shown below and the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.
5 6
3
1
3
P T
2 4
2-70
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-80
(1) Case where handle is in neutral position
T
5
P
3
Port 1 Port 3
300L2RL03
The force of the spring (5) that determines the output pressure of the pilot valve is not applied to
the spool (3). Therefore, the spool is pushed up by the spring (7) to the position of port (1, 3) in
the operation explanation drawing. Then, since the output port is connected to tank port T only,
the output port pressure becomes equal to tank pressure.
2-81
(2) Case where handle is tilted
Port 1 Port 3
300L2RL04
When the push rod (9) is stroked, the spool (3) moves downwards.
Then port P is connected with port (1) and the oil supplied from the pilot pump flows through port
(1) to generate the pressure.
When the pressure at port (1) increases to the value corresponding to the spring force set by tilt-
ing the handle, the hydraulic pressure force balances with the spring force. If the pressure at port
(1) increases higher than the set pressure, port P is disconnected from port (1) and port T is con-
nected with port (1). If it decreases lower than the set pressure, port P is connected with port (1)
and port T is disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the
spool contacts with the inside bottom of the push rod and the output pressure is left to be con-
nected with port P.
2-82
GROUP 6 RCV PEDAL
1. STRUCTURE
The casing (spacer) has the oil inlet port P (primary pressure), and the oil outlet port T (tank). In
addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face.
12.4 12.4
1 3
2 1
4 3
Port Port Port size

P T P Pilot oil inlet port
T Pilot oil return port
1 Travel (LH, Forward)
PF 1/4
2 Travel (LH, Backward)
3 Travel (RH, Forward)
1 2 3 4 4 Travel (RH, Backward)
Hydraulic circuit
130ZF2RP01
2-83
CROSS SECTION
The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in
which reducing valves are assembled.
The pressure reducing section is composed of the spool (7), spring (5) for setting secondary
pressure, return spring (9), stopper (8), and spring seat (6). The spring for setting the secondary
pressure has been generally so preset that the secondary pressure is 6.3±1 to 24.9±1.5 kgf/cm2
(depending on the type). The spool is pushed against the push rod (13) by the return spring.
When the push rod is pushed down by tilting pedal, the spring seat comes down simultaneously and
changes setting of the secondary pressure spring.
27 31 30 29 28 33
32
23
22 25,26
21 2
15
20 13
34
24 16
14 17
12
18
11 19
10
8 3
4
2
1 9
5 2
6
7
130ZF2RP02
1 Body 13 Push rod 25 Cover

2 Plug 14 Spring pin 26 Wrench bolt
3 Plug 15 Seal 27 Cam
4 Spring seat 16 Steel ball 28 Bushing
5 Spring 17 Spring 29 Cam shaft
6 Spring seat 18 Plate 30 Set screw
7 Spool 19 Snap ring 31 Set screw
8 Stopper 20 Plug 32 Hex nut
9 Spring 21 O-ring 33 Bellows
10 Rod guide 22 Rod seal 34 Expand
11 O-ring 23 Dust seal 35 Name plate
12 Snap ring 24 Piston
2-84
2. FUNCTION
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure (secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port (P) where oil is supplied from hydraulic pump.
(2) Output port (1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port (T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool (7) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output spool to determine the output pressure.
The spring (5) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod (13) is inserted and can slide in the plug (20).
For the purpose of changing th displacement of the push rod through the cam (27) and adjusting
nut (32) are provided the pedal that can be tilted in any direction around the fulcrum of the cam (27)
center.
The spring (9) works on the body (1) and spring seat (6) and tries to return the push rod (13) to the
zero-displacement position irrespective of the output pressure, securing its resetting to the center
position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.
2-85
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown
below and the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.
36072SF01
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-86
(1) Case where pedal is in neutral position
7 T
9 P
130ZF2RP03
The force of the spring (5) that determines the output pressure of the pilot valve is not applied to
the spool (7). Therefore, the spool is pushed up by the spring (9) to the position of 1 and port 2.
Then, since the output port is connected to tank port T only, the output port pressure becomes
equal to tank pressure.
2-87
(2) Case where pedal is tilted
13
7 T
PORT 1 PORT 2
220F2RP04
When the push rod (13) is stroked, the spool (7) moves downwards.
Then port P is connected with port 1, and the oil supplied from the pilot pump flows through port
1 to generate the pressure.
When the pressure at port 1 increases to the value corresponding to the spring force set by tilting
the handle, the hydraulic pressure force balances with the spring force. If the pressure at port 1
increases higher than the set pressure, port P is disconnected from port 1 and port T is
connected with port 1. If it decreases lower than the set pressure, port P is connected with port
1 and port T is disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the
spool contacts with inside bottom of the push rod and the output pressure is left to be connected
with port P.
2-88
Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 3-1

Group 2 Main Circuit --------------------------------------------------------------------------------------------------------- 3-3
Group 3 Pilot Circuit ---------------------------------------------------------------------------------------------------------- 3-6
Group 4 Single Operation ------------------------------------------------------------------------------------------------- 3-16
Group 5 Combined Operation ------------------------------------------------------------------------------------------ 3-26
GROUP 1 HYDRAULIC CIRCUIT
1. HYDRAULIC CIRCUIT (1/2)
4 4 3 10 11 8 9
L/H R/H
Dr Dr PG
Ps Ps
GER REG
MA AU
MB MB MA
DR
( 28 ,A)
MB MA
( 2 ,R2)
MU
VB(BW) VA(FW) VB(FW) VA(BW)
VB(CW) VA(CCW)
( 2 ,As) ( 2 ,Bs)
P4
P5 2
( 3 ,MU)
XBp2
12 C A Dr P B D R2
BYPASS
XBp1 CUT
( 2 ,BtL) [Dr#] ( 2 ,Btr)
( 2 ,AtL) ( 2 ,Atr)
PaL
( 21 ,A3) ( 25 ,e)
[ARM HOLDING
RELEASE]
Aa [Rod]
[Head] Ba
XBa1 XAa2
[ARM IN] ( 25 ,e) ( 25 ,d) [ARM2 OUT]
ARM 2 XBa2
XAa1 ARM 1 ( 25 ,e) [ARM2 IN]
[ARM OUT] ( 25 ,d)
5 ( 29 ,P3) ( 29 ,T3) 6 ( 29 ,P1) ( 29 ,T1) 7 ( 29 ,P2) ( 29 ,T2)
SWING 26 ARM BUCKET 26 BOOM 26 TRAVEL

Dr3 Dr7
1 Main pump
T T [Dr#] ( 27 ,A1)
P P P T PnA2
Pis [Td#]
[ARM REGEN' ( 21 ,A4)
ON/OFF] Ak [Head]
2 Main control valve
Bo
Ao Bk [Rod] 3 Swing motor
(1) (3) (2) (4) (3) (1) (2) (4) (2) (1) (4) (3) XAo
XAk
( 25 ,f) [BUCKET IN] 4 Travel motor
BUCKET XBk
OPTION ( 25 ,g) [BUCKET OUT] 5 RCV lever(LH)
24 24 PCk
PS PS
XBo
( 25 ,h) [BOOM PRI']
6 RCV lever(RH)
A B D E F G H h1 J j1 K L M N ( 25 ,j) [BOOM HOLDING
25 a c b d1 d e1 e f1 f g1 g h j k o l m p n
PbL RELEASE] 7 RCV pedal
PS PS PS PS PS PS Ab [Head]
8 Boom cylinder(LH)
[SWING CCW] ( 2 ,XBs)
24 24 24 24 ( 2 ,XAtL) 24 ( 2 ,XAtr) 24
[SWING PRIORITY] ( 2 ,Psp)
24 PS (2 ,XAk)
[LH-FW] [RH-FW] 9 Boom cylinder(RH)
[BUCKET IN] Bb [Rod]
[SWING CW] ( 2 ,XAs)
( 2 ,XBtL) ( 2 ,XBtr) [BOOM2 UP] ( 25 ,h)
XAb2
XAb1 ( 25 ,h) [BOOM1 UP]
10 Arm cylinder
( 2 ,XBk) [LH-BW] [RH-BW]
[ARM OUT] ( 2 ,XAa1) [BUCKET OUT] ( 2 ,XBb1)
Psp
BOOM 2 S/W
PRI'
BOOM 1 XBb1
( 25 ,j) [BOOM DOWN]
11 Bucket cylinder
[SWING PRI'] ( 25 ,c)
[ARM OUT] ( 2 ,XAa2) ( 2 ,PbL) [BOOM HOLDING]
Dr1 ( 12 ,A)
12 Turning joint
( 3 ,VA) Pns
[ARM IN] ( 2 ,XBa1) ( 2 ,XAb1) [BOOM UP] [BOOM PRI'] ( 27 ,A2)
Bs AtL [Dr#]
13 Check valve
[ARM2 IN] ( 2 ,XBa2) ( 2 ,XAb2) [BOOM2 UP]
[ARM HOLDING] ( 2 ,PaL) ( 2 ,PCk) [BOOM PRI'] ( 3 ,VB) [SWING CW] ( 25 ,b)
As BtL
( 25 ,k) [LH-FW] ( 12 ,C)
14 Check valve
XAs XAtL
[SWING CCW] ( 25 ,a) XBs SWING
XBtL
( 25 ,l) [LH-BW] 15 Hydraulic tank
( 12 ,D)
Dr6
Dr2 TRAVEL
Py 16 Oil cooler
[Td#] [Dr#] Btr
Px 17 Air breather
Atr ( 27 ,A3) [TRAVEL STRAIGHT]
( 12 ,B) [RH-FW] ( 25 ,m)
XAtr PTa 18 Return filter w/bypass valve
( 3 ,PG) XBtr TRAVEL 350k
( 5 ,P) ( 5 ,T) [RH-BW] ( 25 ,n) (380k) Pz
( 21 ,A2) [POWER BOOST] 19 Strainer
28 A 29 P3 T3
TRAVEL
20 Drain filter
STRAIGHT
P2 T2
( 7 ,P) ( 7 ,T) 21 5 cartridge valve
( 6 ,P) ( 6 ,T)
( 21 ,A1) P P1
T
T1
P1 P3 R1 Po P2 PG 22 Pressure sensor
P
T
[Td#] 23 Pressure sensor
( 21 ,A1)
1 22 A1
PH1
A2
PH2
22 24 Pressure sensor
a1 PS PS a2
[Dr#]
Psv 25 Shuttle block
Tr# 26 Last guard filter
a4
27 Last guard filter
PS
a5
PS 23 28 Swing parking sol valve
23
( 2 ,PTa) ( 2 ,PnA2)
( 2 ,Pis) ( 29 ,P)
14 13 29 Cross assy
( 2 ,Pz)
( 2 ,Pns) ( 28 ,P)
16 47 Plug
27 21
(12 ,P)
Dr# 70 Solenoid valve
A3 A2 A1 A4 A3 A2 A1 17
P4
E 71 Screw coupling
P3
20 15
P ( 1 ,Psv)
A
T ( 21 ,P4) P2 Dr
18 Td#
T
TRAVEL BOOM BOOM P1
[Dr#]
STRAIGHT PRI'1 PRI'2
(VS SWING) (VS ARM) ARM TRAVEL POWER SAFETY
B1 B3 a3
19
[Dr#] REGEN' 2nd SPEED BOOST
ON/OFF
30
30K6-27200-02 1OF2
3-1
2. HYDRAULIC CIRCUIT (2/2)
<DOUBLE ACTING <DOUBLE ACTING
With PEDAL> ( ,XBp2)

2 With Proportional RCV & Pedal>
26 <SWING FINE CONTROL>
47 ( ,XBp2)
2
48 P [Td#] A1 A2 A3 26 26 P T [Td#] 51
T 3
A1 A2 B GA A1 A2 A3
49 48
42 24 42 P MB MA
or (1) (2) P1 GP or T (1) (2)
41 PS 41 24 265k
50bar P1 GP 265k
T P2 [Td#] PS MU
[LH] [#Dr] [LH] 50bar
T P2
[RH] ( 21
,A1) [PEDAL [BREAKER] [FLOW [RH] [#Dr]
SAFETY] CONFLUX] 60
[PEDAL [EPPR [BREAKER] [FLOW
( 21
,A1) SAFETY] SAFETY] CONFLUX]
43 43 50
400k 400k B A
T1 A B C D E
T1
2 400k 2 400k
[Td#] [Td#] F H
Bo G Bo
Ao Ao
T B XAo T B XAo
A A1 <PATTERN CHANGE> FROM TO
A OPTION A OPTION ITEMPORT
ITEMPORT
C 46 57 J1J2J3J4 2 J1
5
4
B B1 57 J3
A A XBo 2 J4
XBo 6
4 J2
B ISO M1 D
T B T
P4 P4 M2M3M4
M1 M2 J
2 2 57 25
XBp2 XBp2 M3 E
[Tr#] ( 71
,A3) [Tr#] ( 71
,A3) M4 H
T1 BYPASS T1 BYPASS
CUT CUT
[Td#] 45 [Td#] 45
1 Main pump
2 Main control valve
3 Swing motor
5 RCV lever(LH)
<DOUBLE ACTING
<2PCS BOOM>
64
<ROTATING> 6 RCV lever(RH)
( ,XBp2)
2 T 53
With Proportional RCV>
26 47
[Dr#] 52
T
LS M
8 Boom cylinder(LH)
A1 A2
49
A1 A2 A3
E
[Tr#] 9 Boom cylinder(RH)
P <RH>
42
T
P
24 Dr1
10 Arm cylinder
P1 GP 54
or
41
[Td#]
T P2
PS
50bar B
13 Check valve
[LH]
[RH]
[#Dr]
[PEDAL [BREAKER] [FLOW ( 21
,A1)
V2 Pi1 E B
A <LH>
14 Check valve
SAFETY] 67 <ROTATOR>
( 21
,A1)
CONFLUX]
Dr2
55 16 Oil cooler
43
400k
26
48
P T [Td#] 22 Pressure sensor
T1
2 400k [Tr#] R (c) A B 24 Pressure sensor
[Td#]
Bo
[DOWN]
(1) (2)
[UP]
63 26 Last guard filter
T B
Ao
XAo <SWING PARKING BY FORCE>
30 Screw coupling(option)
A
A
C
A1
46 OPTION a b
<ARM SAFETY LOCK>
41 Stop valve(option)
A
B B1 P
( 25
,a) ( 25
,b) ( 21
,A1)
[Dr#]
T E 59 42 Stop valve(option)
XBo 61
T B A1 A2 A3 43 Proportional relief valve(option)
P4
XBp2
2 24
PS
41 Solenoid valve(option)
[Tr#] ( 71
,A3) 50bar
XBp2
P4
P5 44 Solenoid valve(option)
T1 BYPASS
CUT
T
B1 B2 B3 V2 Pi1
45 Proportional relief valve(option)
[Dr#]
[Td#] 45 BYPASS
CUT
30
( 2,PaL) 46 Shuttle valve
( 2,XBs) ( 2,XAs) ( 3,PG)
(Swing CCW)(Swing CW) ( 2,Aa) ( 2,Ba) 47 Solenoid valve(option)
<XBp2> must be connected to shuttle valve with option piping options.
( 3
,PG) 48 2 way padel
A
This 1-sol' valve in standard circuit must be removed in the option of "swing parking by force" 49 EPPR valve(option)
P
(3-sol valve will replace 1-sol valve for the function.)
50 Terminal valve(option)
T
51 Solenoid valve(option)
<SINGLE ACTING>
52 Main pump(option)
42 <BOOM SAFETY LOCK>
53 Proportional valve(option)
400k
41
58 58
54 Stop valve(option)
2 400k
Bo
500bar 55 Stop valve(option)
PS 22 T T [Dr#]
Ao
XAo
<ONE PEDAL S/T> 56 Solenoid valve(option)
OPTION
57 Pattern change valve(option)
43 ( 7,4) ( 7,3)
<QUICK COUPLER> 58 Stop valve(option)
P4 2
14 13
16 T1
XBo
XBp2
2 ( 7,2) ( 7
,1) 59 Stop valve(option)
[Dr#] 62
[Td#] 50bar 24
PS
E Pi1 V2 V2 Pi1 E A1 A2 A3 A4
56 60 Solenoid valve(option)
Po
A1 PS A2 BYPASS
CUT 61 3 solenoid valve(option)
T A 44
( 2,Ab) ( 2,Bb) ( 2,PbL) B T 62 Solenoid valve(option)
B T
P
[Td#]
FL FR BL BR A P
63 Control valve(option)
[Dr#]
[BREAKER] [FLOW
CONFLUX]
( 21
,A1)
( 25
,k)
[LH-FW]
( 25
,m) ( 25
,l)
( 25
,n)
[RH-BW] 64 Cylinder safety valve(option)
[RH-FW] [LH-BW]
67 Gear pump(option)
30K6-27200-02 2OF2
3-2
GROUP 2 MAIN CIRCUIT
The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit.
The hydraulic system consists of one main pump, one control valve, one swing motor, four cylinders
and two travel motors.
The swash plate type variable displacement axial piston pump is used as the main pump and is
driven by the engine at ratio 1.0 of engine speed.
1. SUCTION AND DELIVERY CIRCUIT
To cylinders To motors
Main control valve To oil cooler
To hydraulic oil tank
Main pump
Suction strainer
Hydraulic oil tank
140L3CI01
The pumps receive oil from the hydraulic tank through a suction strainer. The discharged oil from the
pump flows into the control valve and goes out the tank ports.
The oil discharged from the main pump flows to the actuators through the main control valve.
The main control valve controls the hydraulic functions.
The return oil from the actuators flows to the hydraulic tank through the main control valve and the oil
cooler.
3-3
2. RETURN CIRCUIT
3.0
220F3CI01
All oil returned from each actuator returns to the hydraulic tank through the main control valve.
The bypass check valves are provided in the return circuit.
The setting pressure of bypass check valves are 1.5 kgf/cm2 (21 psi) and 3.0 kgf/cm2 (43 psi). Usually, oil
returns to the hydraulic tank from the left side of control valve through oil cooler.
When oil temperature is low, viscosity becomes higher and flow resistance increases when passing
through the oil cooler. When the oil pressure exceeds 3.0 kgf/cm2 (43 psi), the oil returns directly to the
hydraulic tank, resulting in the oil temperature being raised quickly at an appropriate level.
When the oil cooler is clogged, the oil returns directly to the hydraulic tank through bypass check valve (1).
The full-flow filter and bypass relief valve are provided in the hydraulic tank.
The oil returned from right and left side of control valve is combined and filtered by the full-flow filter. A
bypass relief valve is provided in the full-flow filter.
When the filter element is clogged, the bypass relief valve opens at 1.5 kgf/cm2 (21 psi) differential
pressure.
3-4
3. DRAIN CIRCUIT
Travel motor Swing motor

From return line
Tr#
Main pump
Turning
joint
Dr#
Hydraulic
R7 oil tank
Drain filter
Return filter Dr
Td#
Check valve
1.5kgf/cm 2
210A3CI02
Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil have
to be fed to the hydraulic tank passing through drain filter and return filter.
When the drain oil pressure exceed 1.5 kgf/cm2 (21 psi), the oil returns to the hydraulic tank directly.
1) TRAVEL AND SWING MOTOR DRAIN CIRCUIT

Oil leaked from the right and left travel motors comes out of the drain ports provided in the
respective motor casing and join with each other. These oils pass through the turning joint and join
with oil leak line of the swing motor and return to the hydraulic tank after being filtered by return
filter.
2) MAIN PUMP DRAIN CIRCUIT
Oil leaked from main pump returns to the hydraulic tank passing through drain filter.
3-5
GROUP 3 PILOT CIRCUIT
Remote control valve Remote control valve

RCV pedal
(LH lever) (RH lever)
Cross assy
Safety lock
solenoid valve
Travel speed solenoid valve
Swing parking brake
Arm regeneration on/off
solenoid valve
solenoid valve
Power boost solenoid valve
Boom priority EPPR valve

(vs swing)
Boom priority EPPR valve
(vs arm)
Travel straight EPPR valve

Line filter
Main pump
Relief valve
40kgf/cm2
Pilot pump Suction strainer
235A3CI03
The pilot circuit consists of suction circuit, delivery circuit and return circuit.
The pilot pump is provided with relief valve, receives the oil from the hydraulic tank through the
suction strainer.
The discharged oil from the pilot pump flows to the remote control valve through line filter, EPPR
valve, solenoid valve assemblies swing parking brake, solenoid valve and safety lock solenoid valve.
3-6
1. SUCTION, DELIVERY AND RETURN CIRCUIT
ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER
TRAVEL MOTOR SWING MOTOR

P4
P5
XBp2
R2
BYPASS
CUT
XBp1
PaL
Aa
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
PTa Pns PnA2 Ab

(MCV) (MCV) (MCV)
A3 A2 A1
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
P Psp PRIORITY
T
PG SAFETY Pns Dr1
Bs AtL
(S/Motor) SOLENOID
VALVE As BtL
XAs XAtL
Pis P Pz SWING TRAVEL(LH)
(MCV) (T/Joint) (MCV) XBtL
A1 XBs
Dr6 Py
A5 A3 A2
Dr2
P4 Btr
Px
Atr TRAVEL(RH) PTa
P3
XAtr
T P2 P(PUMP) TRAVEL
XBtr STRAIGHT Pz
(dr1)
P1
CROSS ASSY LINE FILTER

P3 T3
P1 P3 R1 Po P2 PG
P2 T2
P1 T1
P T
Tr#
SWING P T ARM BUCKET P T BOOM RCV PEDAL P T TRAVEL

A1 A2 PILOT
PUMP PUMP PUMP
Dr#
(1) (3) (2) (4) (3) (1) (2) (4) (2) (1) (4) (3) Td#
A B D E F G H PS J PS K L M N
h1 j1
HYDRAULIC TANK
a c b d1 d e1 e f1 f g1 g h j k o l m p n
XBs XAs PS PS PS PS PS PS
PS
XAa1 XAa2 XBb1 PbL XAtL XBtL XAtr
XAk XBk XBtr
Psp XAb1 XAb2
XBa1 XBa2 PaL PCk
210A3HC02
The pilot pump receive oil from the hydraulic tank. The discharged oil from the pilot pump flows to
the safety solenoid valve through the line filter. The oil is filtered by the line filter. The pilot relief
valve is provided in the pilot pump for limiting the pilot circuit pressure.
The oil filtered by line filter flows remote control valve through safety solenoid valve and cross assy.
The return oil flow into the hydraulic tank through the cross assy.
3-7
2. SAFETY VALVE (SAFETY LEVER)
ARM BUCKET BOOM

P4
P5
XBp2
R2
BYPASS
CUT
XBp1
PaL
Aa
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
PTa Pns PnA2 Ab

(MCV) (MCV) (MCV)
A3 A2 A1
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
P Psp PRIORITY
T
PG SAFETY Pns Dr1
Bs AtL
(S/Motor) SOLENOID
VALVE As BtL
XAs XAtL
(MCV) (T/Joint) (MCV) LEVER UP XBs
XBtL
A1
Dr6 Py
A5 A3 A2
Dr2
P4 Btr
Px
Atr TRAVEL(RH) PTa
P3
XAtr
T P2 P(PUMP) TRAVEL
XBtr STRAIGHT Pz
(dr1)
P1

P3 T3
LEVER DOWN P1 P3 R1 Po P2 PG
P2 T2
P1 T1
P T
Tr#

A1 A2 PILOT
PUMP PUMP PUMP
Dr#
(1) (3) (2) (4) (3) (1) (2) (4) (2) (1) (4) (3) Td#
h1 j1
HYDRAULIC TANK
PS
XAk XBk XBtr
Psp XAb1 XAb2
XBa1 XBa2 PaL PCk
210A3HC03
When the lever of the safety solenoid valve is moved upward, oil flows into the remote control valve
through the line filter, safety solenoid valve and cross assy.
When the lever of the safety solenoid valve is moved downward, oil does not flow into the remote
control valve, because of the blocked port.
3-8
3. BOOM PRIORITY SYSTEM (vs swing system)
ARM BUCKET BOOM
P4
P5
XBp2
R2
BYPASS
CUT
XBp1
PaL
Aa
Ba
Trucking balance XBa1

ARM 1 ARM 2
XAa2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
PTa Pns PnA2 Ab

(MCV) (MCV) (MCV)
A3 A2 A1
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
P Psp PRIORITY
T
PG Pns Dr1
Bs AtL
(S/Motor)
As BtL
XAs XAtL
A1 XBs
Dr6 Py
A5 A3 A2
Dr2
P4 Btr
Px
Atr TRAVEL(RH) PTa
P3
XAtr
T P2 P(PUMP) TRAVEL
XBtr STRAIGHT Pz
(dr1)
P1

P3 T3
P1 P3 R1 Po P2 PG
P2 T2
P1 T1
P T
Tr#

A1 A2 PILOT
PUMP PUMP PUMP
Dr#
(1) (3) (2) (4) (3) (1) (2) (4) (2) (1) (4) (3) Td#
h1 j1
HYDRAULIC TANK
PS
XAk XBk XBtr
Psp XAb1 XAb2
XBa1 XBa2 PaL PCk
210A3HC04
When carrying out the combined operation of swing and boom up, the boom up operating speed is
lowered then normal operation.
To increase working efficiency, swing speed reducing system is used.
The pilot oil from pilot pump flow into Pns port in main control valve through boom priority (vs swing)
EPPR valve. Pns oil pressure moves swing reducing spool to lower position and oil flow rate to the
swing motor decreased.
Then, the boom up speed is increased. This is called the boom priority system (trucking balance).
The trucking balance can be adjusted by the cluster. Refer to page 3-22 of the operator's manual.
3-9
4. BOOM PRIORITY SYSTEM (vs arm system)
ARM BUCKET BOOM
P4
P5
XBp2
R2
BYPASS
CUT
XBp1
PaL
Aa
Ba
Boom / arm balance XBa1

ARM 1 ARM 2
XAa2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
PTa Pns PnA2 Ab

(MCV) (MCV) (MCV)
A3 A2 A1
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
P Psp PRIORITY
T
PG Pns Dr1
Bs AtL
(S/Motor)
As BtL
XAs XAtL
A1 XBs
Dr6 Py
A5 A3 A2
Dr2
P4 Btr
Px
Atr TRAVEL(RH) PTa
P3
XAtr
T P2 P(PUMP) TRAVEL
XBtr STRAIGHT Pz
(dr1)
P1

P3 T3
P1 P3 R1 Po P2 PG
P2 T2
P1 T1
P T
Tr#

A1 A2 PILOT
PUMP PUMP PUMP
Dr#
(1) (3) (2) (4) (3) (1) (2) (4) (2) (1) (4) (3) Td#
h1 j1
HYDRAULIC TANK
PS
XAk XBk XBtr
Psp XAb1 XAb2
XBa1 XBa2 PaL PCk
210A3HC05
When carrying out the combined operation of boom up and arm in, the boom up operating speed is
lowered then normal operation.
To increase working efficiency, arm in speed reducing system is used.
The pilot oil from pilot pump flow into PnA2 port in main control valve through boom priority (vs arm)
EPPR valve. PnA2 oil pressure moves swing reducing spool to lower position and oil flow rate to the
swing motor decreased.
Then, the boom up speed is increased. This is called the boom priority system (boom/arm balance).
The boom/arm balance can be adjusted by the cluster. Refer to page 3-22 of the operator's manual.
3-10
5. TRAVEL SPEED CONTROL SYSTEM
ARM BUCKET BOOM
SWING MOTOR CYLINDER CYLINDER CYLINDER
PILOT VALVE CONTROL PISTON

TRAVEL MOTOR
L/H R/H
P4
Dr Ps Ps Dr P5
REG REG
XBp2
MB MA MB
R2
BYPASS
CUT
XBp1
PaL
Aa
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Dr
P Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
PTa Pns PnA2 Ab

(MCV) (MCV) (MCV)
A3 A2 A1
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
P Psp PRIORITY
T
PG Pns Dr1
Bs AtL
(S/Motor)
As BtL
XAs XAtL
A1 XBs
Dr6 Py
A5 A3 A2
Dr2
P4 Btr
Px
Atr TRAVEL(RH) PTa
P3
XAtr
T P2 P(PUMP) TRAVEL
XBtr STRAIGHT Pz
(dr1)
P1

P3 T3
P1 P3 R1 Po P2 PG
P2 T2
P1 T1
P T
Tr#

A1 A2 PILOT
PUMP PUMP PUMP
Dr#
(1) (3) (2) (4) (3) (1) (2) (4) (2) (1) (4) (3) Td#
h1 j1
HYDRAULIC TANK
PS
XAk XBk XBtr
Psp XAb1 XAb2
XBa1 XBa2 PaL PCk
210A3HC06
When the travel speed solenoid valve was placed in the Hi position, the pressure oil from pilot pump
through line filter flows to port Ps of travel speed change over valve, and the control piston are
pushed left and right, thus minimizing the displacement.
When the travel speed solenoid valve was placed in the Lo position, the oil of Ps port return to the
tank and the control piston is returned, thus maximizing the displacement.
3-11
6. MAIN RELIEF PRESSURE CHANGE SYSTEM
ARM BUCKET BOOM
P4
P5
XBp2
R2
BYPASS
CUT
XBp1
PaL
Aa
Ba
Auto power boost XBa1

ARM 1 ARM 2
XAa2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
PTa Pns PnA2 Ab

(MCV) (MCV) (MCV)
A3 A2 A1
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
P Psp PRIORITY
T
PG Pns Dr1
Bs AtL
(S/Motor)
As BtL
XAs XAtL
A1 XBs
Dr6 Py
A5 A3 A2
Dr2
P4 Btr
Px
Atr TRAVEL(RH) PTa
P3
XAtr
T P2 P(PUMP) TRAVEL
XBtr STRAIGHT Pz
(dr1)
P1

P3 T3
P1 P3 R1 Po P2 PG
P2 T2
P1 T1
P T
Tr#

A1 A2 PILOT
PUMP PUMP PUMP
Dr#
(1) (3) (2) (4) (3) (1) (2) (4) (2) (1) (4) (3) Td#
h1 j1
HYDRAULIC TANK
PS
XAk XBk XBtr
Psp XAb1 XAb2
XBa1 XBa2 PaL PCk
210A3HC07
When the power boost switch on the left control lever is pushed ON, the power boost solenoid valve
is actuated, the discharged oil from the pilot pump flows into Pz port of the main relief valve of main
control valve; then the setting pressure of the main relief valve is raised from 350 kgf/cm2 (4980 psi) to
380 kgf/cm2 (5400 psi) for increasing the digging power.
And even when pressed switch continuously, it is canceled after 8 seconds.
When the auto power boost function is selected to enable on the cluster, the pressure of the main
relief pressure is automatically increased to 380 kgf/cm2 (5400 psi) as working condition by the MCU.
It is operated max 8 seconds.
3-12
7. ARM REGENERATION CUT SYSTEM
ARM BUCKET BOOM
P4
P5
XBp2
R2
BYPASS
CUT
XBp1
PaL
Aa
Ba
Arm regeneration XBa1

ARM 1 ARM 2
XAa2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
PTa Pns PnA2 Ab

(MCV) (MCV) (MCV)
A3 A2 A1
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
P Psp PRIORITY
T
PG Pns Dr1
Bs AtL
(S/Motor)
As BtL
XAs XAtL
A1 XBs
Dr6 Py
A5 A3 A2
Dr2
P4 Btr
Px
Atr TRAVEL(RH) PTa
P3
XAtr
T P2 P(PUMP) TRAVEL
XBtr STRAIGHT Pz
(dr1)
P1

P3 T3
P1 P3 R1 Po P2 PG
P2 T2
P1 T1
P T
Tr#

A1 A2 PILOT
PUMP PUMP PUMP
Dr#
(1) (3) (2) (4) (3) (1) (2) (4) (2) (1) (4) (3) Td#
h1 j1
HYDRAULIC TANK
PS
XAk XBk XBtr
Psp XAb1 XAb2
XBa1 XBa2 PaL PCk
210A3HC08
When the arm regeneration is selected to disable on the cluster, the arm regeneration solenoid
valve is activated. The pilot oil from pilot pump flow into Pis port in main control valve through
solenoid valve and the arm regeneration spool is shifted to left.
Then, the oil from arm regeneration passage returns to tank and the arm regeneration function is
deactivated.
When the arm regeneration is selected to enable on the cluster, the arm regeneration function is
activated and arm in operation speed is increased.
Refer to page 2-33 for the arm regeneration function.
3-13
8. SWING PARKING BRAKE RELEASE
ARM BUCKET BOOM
TRAVEL MOTOR CYLINDER CYLINDER CYLINDER
SWING MOTOR
P4
PG P5
XBp2
AU
DR R2
BYPASS
CUT
XBp1
MB MA PaL
MU
Aa
Ba
XBa1 XAa2
VB(CW) VA(CCW) ARM 1 ARM 2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
A
XAo XAk
BUCKET
OPTION
XBk
PCk
P XBo
PbL
PTa Pns PnA2 Ab

(MCV) (MCV) (MCV) T SWING
SOLENOID
A3 A2 A1 VALVE Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
P Psp PRIORITY
T
Pns Dr1
Bs AtL
As BtL
XAs XAtL
Pis P Pz PG SWING TRAVEL(LH)
A1 (S/Motor) XBs
Dr6 Py
A5 A3 A2
Dr2
P4 Btr
Px
Atr TRAVEL(RH) PTa
P3
XAtr
T P2 P(PUMP) TRAVEL
XBtr STRAIGHT Pz
(dr1)
P1

P3 T3
P1 P3 R1 Po P2 PG
P2 T2
P1 T1
P T
Tr#

A1 A2 PILOT
PUMP PUMP PUMP
Dr#
(1) (3) (2) (4) (3) (1) (2) (4) (2) (1) (4) (3) Td#
h1 j1
HYDRAULIC TANK
PS
XAk XBk XBtr
Psp XAb1 XAb2
XBa1 XBa2 PaL PCk
210A3HC09
When the swing control lever is tilted, the swing solenoid valve is shifted to the down ward by the
MCU that senses the pilot pressure of the swing control lever.
The discharged oil from pilot pump flows to swing motor PG port through the swing solenoid valve.
This pressure is applied to swing motor disc, thus the brake is released.
When the swing control lever is set in the neutral position, the swing solenoid valve is shifted to the
up ward, oil in the swing motor disc cylinder is drained through the the swing solenoid valve, thus the
brake is applied.
3-14
9. SWING PRIORITY SYSTEM
ARM BUCKET BOOM

P4
P5
XBp2
R2
BYPASS
CUT
XBp1
PaL
Aa
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
PTa Pns PnA2 Ab

(MCV) (MCV) (MCV)
A3 A2 A1
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
P Psp PRIORITY
T
PG SAFETY Pns Dr1
Bs AtL
(S/Motor) SOLENOID
VALVE As BtL
XAs XAtL
A1 XBs
Dr6 Py
A5 A3 A2
Dr2
P4 Btr
Px
Atr TRAVEL(RH) PTa
P3
XAtr
T P2 P(PUMP) TRAVEL
XBtr STRAIGHT Pz
(dr1)
P1

P3 T3
P1 P3 R1 Po P2 PG
P2 T2
P3 T1
P T
Tr#

A1 A2 PILOT
PUMP PUMP PUMP
Dr#
(1) (3) (2) (4) (3) (1) (2) (4) (2) (1) (4) (3) Td#
h1 j1
HYDRAULIC TANK
PS
XAk XBk XBtr
Psp XAb1 XAb2
XBa1 XBa2 PaL PCk
210A3HC09A
When carrying out the combined operation of swing and arm of the left control valve, the swing
speed can be lowered than operating speed of arm.
Psp pressure from the swing shuttle block change the swing priority spool and decreases the oil flow
rate to the next section to make the swing operation most preferential.
This is called the swing priority system. For details, refer to page 2-39.
3-15
GROUP 4 SINGLE OPERATION
1. BOOM UP OPERATION
ARM BUCKET BOOM

P4
P5
XBp2
R2
XBp1 BYPASS
CUT
PaL
Aa
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
Boom PbL
holding valve
Relief valve
Ab
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
Psp PRIORITY
Pns Dr1
Bs AtL
As BtL
XAs XAtL
SWING TRAVEL(LH)
XBtL
XBs
Dr6 Py
Btr Dr2
Px
Atr TRAVEL(RH) PTa
XAtr
TRAVEL
XBtr STRAIGHT Pz
P1 P3 R1 Po P2 PG
A1 A2 PILOT
PUMP PUMP PUMP
HYDRAULIC TANK
210A3HC10
When the right control lever is pulled back, the boom spools in the main control valve are moved to
the up position by the pilot oil pressure (XAb1, XAb2) from the remote control valve.
The oil from the A1 and A2 pump flows into the main control valve and then goes to the large
chamber of boom cylinders.
At the same time, the oil from the small chamber of boom cylinders returns to the hydraulic oil tank
through the boom 1 spool in the main control valve. When this happens, the boom goes up.
The excessive pressure in the boom cylinder head side is prevented by relief valve.
When the boom is up and the control lever is returned to neutral position, the circuit for the holding
pressure at the bottom end of the boom cylinder is closed by the boom holding valve.
This prevents the hydraulic drift of boom cylinder.
3-16
2. BOOM DOWN OPERATION
ARM BUCKET BOOM

P4
P5
XBp2
R2
XBp1 BYPASS
CUT
PaL
Aa
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
Boom PbL
holding valve
Ab
Relief valve
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
Psp PRIORITY
Pns Dr1
Bs AtL
As BtL
XAs XAtL
SWING TRAVEL(LH)
XBtL
XBs
Dr6 Py
Btr Dr2
Px
Atr TRAVEL(RH) PTa
XAtr
TRAVEL
XBtr STRAIGHT Pz
P1 P3 R1 Po P2 PG
A1 A2 PILOT
PUMP PUMP PUMP
HYDRAULIC TANK
210A3HC11
When the right control lever is pushed forward, the boom 1 spool in the main control valve is moved
to the down position by the pilot oil pressure (XBb1) from the remote control valve.
The oil from the A2 pump flows into the main control valve and then goes to the small chamber of
boom cylinders. At the same time, the oil from the large chamber of boom cylinders returns to the
hydraulic tank through the boom spool in the main control valve.
When the down speed of boom is faster, the oil returned from the large chamber of boom cylinder
combines with the oil from the A2 pump, and flows into the small chamber of the cylinder.
This prevents cylinder cavitation by the negative pressure when the A2 pump flow can not match the
boom down speed. And the excessive pressure in the boom cylinder rod side is prevented by the
relief valve.
3-17
3. ARM IN OPERATION
ARM BUCKET BOOM


P4
P5
XBp2
R2
XBp1 BYPASS
CUT
Make up PaL
valve
Aa
Relief
valve
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
Ab
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
Psp PRIORITY
Pns Dr1
Bs AtL
As BtL
XAs XAtL
SWING TRAVEL(LH)
XBtL
XBs
Dr6 Py
Btr Dr2
Px
Atr TRAVEL(RH) PTa
XAtr
TRAVEL
XBtr STRAIGHT Pz
P1 P3 R1 Po P2 PG
A1 A2 PILOT
PUMP PUMP PUMP
HYDRAULIC TANK
210A3HC12
When the left control lever is pulled back, the arm spools in the main control valve are moved to the
roll in position by the pilot oil pressure (XBa1, XBa2) from the remote control valve.
The oil from the A1 and A2 pump flows into the main control valve and then goes to the large
chamber of arm cylinder.
At the same time, the oil from small chamber of arm cylinder returns to the hydraulic oil tank through
the arm 1 spool in the main control valve. When this happens, the arm rolls in.
The excessive pressure in the arm cylinder head side is prevented by relief valve.
The cavitation which will happen to the head side of the arm cylinder is also prevented by the make-
up valve in the main control valve.
3-18
4. ARM OUT OPERATION
ARM BUCKET BOOM

P4
P5
XBp2
R2
XBp1 BYPASS
CUT
Arm holding
valve PaL
Aa
Relief
Ba valve
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
Ab
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
Psp PRIORITY
Pns Dr1
Bs AtL
As BtL
XAs XAtL
SWING TRAVEL(LH)
XBtL
XBs
Dr6 Py
Btr Dr2
Px
Atr TRAVEL(RH) PTa
XAtr
TRAVEL
XBtr STRAIGHT Pz
P1 P3 R1 Po P2 PG
A1 A2 PILOT
PUMP PUMP PUMP
HYDRAULIC TANK
210A3HC13
When the left control lever is pushed forward, the arm spools in the main control valve are moved to
the roll out position by the pilot oil pressure (XAa1, XAa2) from the remote control valve.
The oil from the A1 and A2 pump flows into the main control valve and then goes to the small
chamber of arm cylinder.
At the same time, the oil from the large chamber of arm cylinder returns to the hydraulic oil tank
through the arm spools in the main control valve. When this happens, the arm rolls out.
The excessive pressure in the arm cylinder rod side is prevented by relief valve.
When the arm is roll out and the control lever is returned to neutral position, the circuit for the holding
pressure at the rod side of the arm cylinder is closed by the arm holding valve.
The cavitation which will happen to the rod side of the arm cylinder is also prevented by the make-
3-19
5. BUCKET IN OPERATION
ARM BUCKET BOOM

P4
P5
XBp2
R2
XBp1 BYPASS
CUT
PaL
Aa
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Make up
Dr3
valve Dr7
PnA2
Relief
Pis
valve Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
Ab
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
Psp PRIORITY
Pns Dr1
Bs AtL
As BtL
XAs XAtL
SWING TRAVEL(LH)
XBtL
XBs
Dr6 Py
Btr Dr2
Px
Atr TRAVEL(RH) PTa
XAtr
TRAVEL
XBtr STRAIGHT Pz
P1 P3 R1 Po P2 PG
A1 A2 PILOT
PUMP PUMP PUMP
HYDRAULIC TANK
210A3HC14
When the right control lever is pulled left, the bucket spool in the main control valve is moved to the
roll in position by the pilot oil pressure (XAk) from the remote control valve.
The oil from the A2 pump flows into the main control valve and then goes to the large chamber of
bucket cylinder. The oil from the A1 pump flows into the large chamber of bucket cylinder through
confluence oil passage in the main control valve by bypass cut pilot pressure (XBp1).
At the same time, the oil from the small chamber of bucket cylinder returns to the hydraulic oil tank
through the bucket spool in the main control valve. When this happens, the bucket rolls in.
The excessive pressure in the bucket cylinder head side is prevented by relief valve.
The cavitation which will happen to the head side of the bucket cylinder is also prevented by the
make-up valve in the main control valve.
3-20
6. BUCKET OUT OPERATION
ARM BUCKET BOOM

P4
P5
XBp2
R2
XBp1 BYPASS
CUT
PaL
Aa
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Dr3 Make Dr7

PnA2
up valve Relief
Pis
valve Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
Ab
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
Psp PRIORITY
Pns Dr1
Bs AtL
As BtL
XAs XAtL
SWING TRAVEL(LH)
XBtL
XBs
Dr6 Py
Btr Dr2
Px
Atr TRAVEL(RH) PTa
XAtr
TRAVEL
XBtr STRAIGHT Pz
P1 P3 R1 Po P2 PG
A1 A2 PILOT
PUMP PUMP PUMP
HYDRAULIC TANK
210A3HC15
When the right control lever is pushed right, the bucket spool in the main control valve is moved to
the roll out position by the pilot oil pressure (XBk) from the remote control valve.
The oil from the A2 pump flows into the main control valve and then goes to the small chamber of
bucket cylinder.
The oil from the A1 pump flows into the large chamber of bucket cylinder through confluence oil
passage in the main control valve by bypass cut pilot pressure (XBp1).
At the same time, the oil from the large chamber of bucket cylinder returns to the hydraulic oil tank
through the bucket spool in the main control valve. When this happens, the bucket rolls out.
The excessive pressure in the bucket cylinder rod side is prevented by relief valve.
The cavitation which will happen to the rod side of the bucket cylinder is also prevented by the make-
3-21
7. SWING OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
SWING MOTOR
P4
PG P5
XBp2
AU
DR BYPASS
XBp1 R2
CUT
MB MA PaL
MU
Aa
Ba
XBa1 XAa2
VB(CW) VA(CCW) ARM 1 ARM 2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
A
XAo XAk
BUCKET
OPTION
XBk
PCk
P XBo
PbL
PTa Pns PnA2 Ab

(MCV) (MCV) (MCV) T SWING
SOLENOID
A3 A2 A1 VALVE Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
Psp PRIORITY
P2
T1
PG Pns Dr1
Bs AtL
(S/Motor)
As BtL
XAs XAtL
Pis Pk Pz SWING TRAVEL(LH)
A1 XBs
Dr6 Py
A5 A3 A2
Dr2
P4 Btr
Px
Atr TRAVEL(RH) PTa
P3
XAtr
T P2 P(PUMP) TRAVEL
XBtr STRAIGHT Pz
(dr1)
P1
P3 T3
P2 T2 P1 P3 R1 Po P2 PG
P1 T1
P T
Tr#

A1 A2 PILOT
PUMP PUMP PUMP
Dr#
(1) (3) (2) (4) (3) (1) (2) (4) (2) (1) (4) (3) Td#
A B D E F G H J K L M N
HYDRAULIC TANK
a c b d d1 e e2 f f1 g g1 h h1 j j1 k o l m p n
XBs XAs PS PS PS PS PS PS PS PS
PS
XAk XBk XBtr
Psp XAb1 XAb2
XBa1 XBa2 PaL PCk
210A3HC16
When the left control lever is pushed left or right, the swing spool in the main control valve is moved
to the left or right swing position by the pilot oil pressure (XAs or XBs) from the remote control valve.
Also the swing operation preference function is operated by the pilot pressure PCsp (refer to page
2-39).
The oil from the A1 pump flows into the main control valve and then goes to the swing motor.
At the same time, the return oil from the swing motor returns to the hydraulic oil tank through the
swing spool in the main control valve.
When this happens, the upper structure swings to the left or right.
The swing parking brake, make up valve and the motor brake valve are provided in the swing motor.
The cavitation which will happen to the swing motor is also prevented by the make up valve in the
swing motor itself.
3-22
SWING CIRCUIT OPERATION
SWING MOTOR DEVICE
PG
BRAKE RELEASE PORT
AU
DR
PORT BLOCK ASSY
MAKE UP VALVE
MB MA
PARKING BRAKE
R2(MCV)
MU
MOTOR BRAKE VALVE
ANTI-INVERSION VALVE
VB(CW) VA(CCW)
TO/FROM MAIN CONTROL VALVE
210A3HC16A
1) MOTOR BRAKE VALVE

Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing
operation and controls the swing motor operating pressure to 290 kgf/cm2 (4125 psi).
2) MAKE UP VALVE
The make up valves prevent cavitation by supplying return oil to the vacuum side of the motor.
3) PARKING BRAKE
This is function as a parking brake only when the swing control lever or arm in control lever is not
operated.
PARKING BRAKE "OFF" OPERATION
When the swing control lever is tilted, the swing solenoid valve is energized by the MCU that
senses the pilot oil pressure of the swing control lever.
The discharged oil from pilot pump flows to swing motor PG port through the swing solenoid valve.
This pressure is applied to swing parking brake piston, thus the brake is released.
PARKING BRAKE "ON" OPERATION
When the swing control lever is set in the neutral position, the swing solenoid valve is de-energized,
oil in the swing parking brake chamber is drained through the the swing solenoid valve, thus the
brake is applied by spring force.
4) ANTI-INVERSION VALVE
This anti-inversion valve absorbs shocks produced as swing motion stops and reduced oscillation
cause by swing motion.
3-23
8. TRAVEL FORWARD AND REVERSE
REVERSE OPERATION
OPERATION
ARM BUCKET BOOM
PILOT VALVE CONTROL PISTON

TRAVEL MOTOR
L/H R/H SWING
MOTOR
P4
Dr Ps Ps Dr P5
REG REG
XBp2
MB MA MB MA
R2
XBp1 BYPASS
CUT
PaL
Aa
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Dr
P
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
PTa Pns PnA2 Ab

(MCV) (MCV) (MCV)
A3 A2 A1
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
P2 Psp PRIORITY
T1
PG SAFETY Pns Dr1
Bs AtL
(S/Motor) SOLENOID
VALVE As BtL
XAs XAtL
A1 XBs
Dr6 Py
A5 A3 A2
Dr2
P4 Btr
Px
Atr TRAVEL(RH) PTa
P3
XAtr
T P2 P(PUMP) TRAVEL
XBtr STRAIGHT Pz
(dr1)
P1
P3 T3
P2 T2 P1 R1 Po P2 PG
P1 T1
P T
Tr#

A1 A2 PILOT
PUMP PUMP PUMP
Dr#
(1) (3) (2) (4) (3) (1) (2) (4) (2) (1) (4) (3) Td#
A B D E F G H J K L M N
HYDRAULIC TANK
a c b d d1 e e2 f f1 g g1 h h1 j j1 k o l m p n
XBs XAs PS PS PS PS PS PS PS PS
PS
XAk XBk XBtr
Psp XAb1 XAb2
XBa1 XBa2 PaL PCk
210A3HC17
When the travel levers are pushed forward or reverse position, the travel spools in the main control
valve are moved to the forward or reverse travel position by the pilot oil pressure (XAtr, XBtr, XAtL,
XBtL) from the remote control valve.
The oil from the each pump flows into the main control valve and then goes to the each travel motor
through the turning joint.
The return oil from both travel motors returns to the hydraulic oil tank through the turning joint and
the travel spools in the main control valve.
When this happens, the machine moves to the forward or reverse.
3-24
TRAVEL CIRCUIT OPERATION
OVERLOAD
RELIEF VALVE
TRAVEL MOTOR DEVICE
L/H R/H
Dr Ps Ps Dr
REG REG
MB MA MB MA

COUNTER
BALANCE VALVE
P
A B
Dr
C D
P
TO/FROM MAIN CONTROL VALVE
210A3HC17A
Valves are provided on travel motors to offer the following functions.
1) COUNTER BALANCE VALVE

When stopping the motor of slope descending, this valve to prevent the motor over run.
2) OVERLOAD RELIEF VALVE
Relief valve limit the circuit pressure below 350 kgf/cm2 (4980 psi) to prevent high pressure
generated at a time of stopping the machine. Stopping the motor, this valve sucks the oil from lower
pressure passage for preventing the negative pressure and the cavitation of the motor.
3-25
GROUP 5 COMBINED OPERATION
1. OUTLINE
ARM BUCKET BOOM

P4
P5
XBp2
R2
XBp1 BYPASS
CUT
PaL
Aa
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
Ab
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
Psp PRIORITY
Pns Dr1
Bs AtL
As BtL
XAs XAtL
SWING TRAVEL(LH)
XBtL
XBs
Dr6 Py
Btr Dr2
Px
Atr TRAVEL(RH) PTa
XAtr
TRAVEL
XBtr STRAIGHT Pz
P1 P3 R1 Po P2 PG
A1 A2 PILOT
PUMP PUMP PUMP
STRAIGHT
TRAVEL
SPOOL
HYDRAULIC TANK
210A3HC20
The oil from the A1 and A2 pump flows through the neutral oil passage, bypass oil passage and
confluence oil passage in the main control valve. Then the oil goes to each actuator and operates
them. Check valves and orifices are located on these oil passage in the main control valve. These
control the oil from the main pumps so as to correspond to the operation of each actuator and
smooth the combined operation.
STRAIGHT TRAVEL SPOOL

This straight travel spool for straight travel is provided in the main control valve.
If any actuator is operated when traveling, the straight travel spool is pushed to the right by the pilot
oil pressure (PTa).
Consequently, the left and right travel oil supply passage are connected, and equivalent amount of
oil flows into the left and right travel motors. This keeps the straight travel.
3-26
2. COMBINED SWING AND BOOM UP OPERATION
ARM BUCKET BOOM


P4
P5
XBp2
R2
XBp1 BYPASS
CUT
PaL
Aa
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
Ab
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
Psp PRIORITY
Pns Dr1
Bs AtL
As BtL
XAs XAtL
SWING TRAVEL(LH)
XBtL
XBs
Dr6 Py
Btr Dr2
Px
Atr TRAVEL(RH) PTa
XAtr
TRAVEL
XBtr STRAIGHT Pz
P1 P3 R1 Po P2 PG
A1 A2 PILOT
PUMP PUMP PUMP
HYDRAULIC TANK
210A3HC21
When the swing and boom up functions are operated, simultaneously the swing spool and boom
spools in the main control valve are moved to the functional position by the pilot oil pressure (XAb1,
XAs, XBs) from the remote control valve.
The oil from the A1 pump flows into the swing motor through swing spool and the boom cylinder
through boom 2 spool.
The oil from the A2 pump flows into the boom cylinders through the boom 1 spool in the right control
valve. The upper structure swings and the boom is operated.
Refer to page 3-10 for the boom priority system.
3-27
3. COMBINED SWING AND ARM OPERATION
ARM BUCKET BOOM


P4
P5
XBp2
R2
XBp1 BYPASS
CUT
PaL
Aa
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
Ab
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
Psp PRIORITY
Pns Dr1
Bs AtL
As BtL
XAs XAtL
SWING TRAVEL(LH)
XBtL
XBs
Dr6 Py
Btr Dr2
Px
Atr TRAVEL(RH) PTa
XAtr
TRAVEL
XBtr STRAIGHT Pz
P1 P3 R1 Po P2 PG
A1 A2 PILOT
PUMP PUMP PUMP
HYDRAULIC TANK
210A3HC22
When the swing and arm functions are operated, simultaneously the swing spool and arm spools in
the main control valve are moved to the functional position by the pilot oil pressure (XAs, XBs, XAa1,
XBa1, XAa2, XBa2) from the remote control valve.
The oil from the A1 pump flows into the swing motor through swing spool and the arm cylinder
through arm 1 spool.
The oil from the A2 pump flows into the arm cylinder through the arm 2 spool of the right control
valve. The upper structure swings and the arm is operated.
Refer to page 2-39 for the swing operation preference function.
3-28
4. COMBINED SWING AND BUCKET OPERATION
ARM BUCKET BOOM


P4
P5
XBp2
R2
XBp1 BYPASS
CUT
PaL
Aa
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
Ab
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
Psp PRIORITY
Pns Dr1
Bs AtL
As BtL
XAs XAtL
SWING TRAVEL(LH)
XBtL
XBs
Dr6 Py
Btr Dr2
Px
Atr TRAVEL(RH) PTa
XAtr
TRAVEL
XBtr STRAIGHT Pz
P1 P3 R1 Po P2 PG
A1 A2 PILOT
PUMP PUMP PUMP
HYDRAULIC TANK
210A3HC22
When the swing and bucket functions are operated, simultaneously the swing spool and bucket
spool in the main control valve are moved to the functional position by the pilot oil pressure (XAs,
XBs, XAk,XBk) from the remote control valve.
The oil from the A1 pump flows into the swing motor through the swing spool in the left control valve.
The oil from the A2 pump flows into the bucket cylinder through the bucket spool in the right control
valve.
The upper structure swings and the bucket is operated.
3-29
5. COMBINED SWING AND TRAVEL OPERATION
ARM BUCKET BOOM

P4
P5
XBp2
R2
XBp1 BYPASS
CUT
PaL
Aa
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
Ab
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
Psp PRIORITY
Pns Dr1
Bs AtL
As BtL
XAs XAtL
SWING TRAVEL(LH)
XBtL
XBs
Dr6 Py
Btr Dr2
Px
Atr TRAVEL(RH) PTa
XAtr
TRAVEL
XBtr STRAIGHT Pz
P1 P3 R1 Po P2 PG
A1 A2 PILOT
PUMP PUMP PUMP
STRAIGHT
TRAVEL
SPOOL
HYDRAULIC TANK
210A3HC24
When the swing and travel functions are operated, simultaneously the swing spool and travel spools
in the main control valve are moved to the functional position by the pilot oil pressure (XAs, XBs,
XAtr, XBtr, XAtL, XBtL) from the remote control valve and straight travel spool is pushed to the right
by the pilot oil pressure (PG) from the pilot pump.
The oil from the A1 pump flows into the travel motors through the RH travel spool of the left control
valve and the LH travel spool of the right control valve via the straight travel spool.
The oil from the A2 pump flows into the swing motor through the swing spool and travel motor
through the LH travel spool via the check valve and orifice in the straight travel spool.
The upper structure swings and the machine travels straight.
3-30
6. COMBINED BOOM AND TRAVEL OPERATION
ARM BUCKET BOOM

P4
P5
XBp2
R2
XBp1 BYPASS
CUT
PaL
Aa
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
Ab
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
Psp PRIORITY
Pns Dr1
Bs AtL
As BtL
XAs XAtL
SWING TRAVEL(LH)
XBtL
XBs
Dr6 Py
Btr Dr2
Px
Atr TRAVEL(RH) PTa
XAtr
TRAVEL
XBtr STRAIGHT Pz
P1 P3 R1 Po P2 PH PG
A1 A2 PILOT
PUMP PUMP PUMP
STRAIGHT
TRAVEL
SPOOL
HYDRAULIC TANK
210A3HC25
When the boom and travel functions are operated, simultaneously the boom spools and travel
spools in the main control valve are moved to the functional position by the pilot oil pressure (XAb1,
XBb1, XBb2, XAtr, XBtr, XAtL, XBtL) from the remote control valve and the straight travel spool is
pushed to the right by the oil pressure (PG) from pilot pump.
The oil from the A2 pump flows into the boom cylinders through the boom 2 spool and boom 1 spool
via the parallel and confluence oil passage in case boom up operation. Also, the oil from the A2
pump flows into the travel motors through the LH travel spool via the check valve and orifice in the
straight travel spool.
The boom is operated and the machine travels straight.
3-31
7. COMBINED ARM AND TRAVEL OPERATION
ARM BUCKET BOOM

P4
P5
XBp2
R2
XBp1 BYPASS
CUT
PaL
Aa
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
Ab
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
Psp PRIORITY
Pns Dr1
Bs AtL
As BtL
XAs XAtL
SWING TRAVEL(LH)
XBtL
XBs
Dr6 Py
Btr Dr2
Px
Atr TRAVEL(RH) PTa
XAtr
TRAVEL
XBtr STRAIGHT Pz
P1 P3 R1 Po P2 PG
A1 A2 PILOT
PUMP PUMP PUMP
STRAIGHT
TRAVEL
SPOOL
HYDRAULIC TANK
210A3HC26
When the arm and travel functions are operated, simultaneously the arm spools and travel spools in
the main control valve are moved to the functional position by the pilot oil pressure (XAa1, XBa1,
XAa2, XBa2, XAtr, XBtr, XAtL, XBtL) from the remote control valve and the straight travel spool is
pushed to the right by the oil pressure (PG) from pilot pump.
The oil from the A2 pump flows into the arm cylinders through the arm 1 spool and arm 2 spool via
the parallel and confluence oil passage. Also, the oil from the rear pump flows into the travel motors
through the LH travel spool via the check valve and orifice in the straight travel spool.
The arm is operated and the machine travels straight.
3-32
8. COMBINED BUCKET AND TRAVEL OPERATION
ARM BUCKET BOOM

P4
P5
XBp2
R2
XBp1 BYPASS
CUT
PaL
Aa
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
Ab
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
Psp PRIORITY
Pns Dr1
Bs AtL
As BtL
XAs XAtL
SWING TRAVEL(LH)
XBtL
XBs
Dr6 Py
Btr Dr2
Px
Atr TRAVEL(RH) PTa
XAtr
TRAVEL
XBtr STRAIGHT Pz
P1 P3 R1 Po P2 PG
A1 A2 PILOT
PUMP PUMP PUMP
STRAIGHT
TRAVEL
SPOOL
HYDRAULIC TANK
210A3HC27
When the bucket and travel functions are operated, simultaneously the bucket spool and travel
spools in the main control valve are moved to the functional position by the pilot oil pressure (XAk,
XBk, XAtr, XBtr, XAtL, XBtL) from the remote control valve, and the straight travel spool is pushed to
the right by the oil pressure (PG) from pilot pump. The oil from the A1 pump flows into the travel
motors through the RH travel spool of the left control valve and the LH travel spool of the right
control valve via the straight travel spool of the control valve.
The oil from the A2 pump flows into the bucket cylinder through the bucket spool via the confluence
oil passage. Also, the oil from the A2 pump flows into the travel motors through the LH travel spool
via the check valve and orifice in the straight travel spool.
The bucket is operated and the machine travels straight.
3-33
9. COMBINED BOOM UP AND BUCKET OPERATION
ARM BUCKET BOOM

P4
P5
XBp2
R2
XBp1 BYPASS
CUT
PaL
Aa
Ba
XBa1 XAa2
ARM 1 ARM 2
XAa1 XBa2
Bucket in strock
limiter spool
Dr3 Dr7
PnA2
Pis
Ak
Bo
Ao Bk
XAo XAk
BUCKET
OPTION
XBk
PCk
XBo
PbL
Ab
Bb
XAb2
XAb1
BOOM 2 BOOM 1
SWING XBb1
Psp PRIORITY
Pns Dr1
Bs AtL
As BtL
XAs XAtL
SWING TRAVEL(LH)
XBtL
XBs
Dr6 Py
Btr Dr2
Px
Atr TRAVEL(RH) PTa
XAtr
TRAVEL
XBtr STRAIGHT Pz
P1 P3 R1 Po P2 PG
A1 A2 PILOT
PUMP PUMP PUMP
HYDRAULIC TANK
210A3HC28
When the boom up and bucket functions are operated, simultaneously each spool in the main
control valve is moved to the functional position by the pilot oil pressure (XAk, XBk, XAb1, XAb2)
from the remote control valve. Also, the boom up operation preference function is operated by the
pilot pressure PCk (refer to page 2-36).
The oil from the A1 pump flows into the boom cylinders through the boom 2 spool in the left control
valve. The oil from the A2 pump flows into the boom cylinders and bucket cylinder through the boom
1 spool, bucket spool and the parallel and confluence oil passage in the right control valve.
The boom and bucket are operated.
3-34
Group 1 Component Location ----------------------------------------------------------------------------------------- 4-1

Group 2 Electrical Circuit ------------------------------------------------------------------------------------------------- 4-3
Group 3 Electrical Component Specification ----------------------------------------------------------------- 4-23
Group 4 Connectors --------------------------------------------------------------------------------------------------------- 4-36
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
20 23 19
21 18
22
17
1
2
3
4 16
5 15
6
7
8 14
13
12
11
10
9
210A4EL01
1 Cigar lighter 9 Power max switch 17 Speaker

2 Radio & USB player 10 Emergency engine stop switch 18 Exhaust system cleaning switch
3 Jog dial module 11 One touch decel switch 19 Quick clamp switch
4 Horn switch 12 RS232 & J1939 service socket 20 Lower wiper & washer switch
5 Breaker operation switch 13 Fuse & relay box 21 Swing lock switch
6 Starting switch 14 Master switch 22 Free/fine swing switch
7 Cluster 15 Seat heater switch 23 Travel straight switch
8 Service meter 16 Power socket
4-1
2. LOCATION 2
24 4
1
11 1
1
4-cartridge valve
32 BOOM BOOM SAFETY VALVE CAB

2 8 9 10 25
14
3-EPPR valve
a5 12
a4
13
a2
a1
3
15
29
5
6
31
27
7
30
1 34 35 16
19 17 d1
c
18
f1
23 g1
20
22 h1
j1
21 e2
AIR CLEANER SHUTTLE VALVE
210A4EL02
1 Lamp 12 Start relay 23 Air cleaner sensor

2 Fuel sender 13 Heater relay 24 4-cartridge valve
3 Fuel filler pump 14 Alternator 25 Pump EPPR valve
4 Beacon lamp 15 Travel alarm buzzer 27 United MCU
5 Battery 16 Arm out pressure sensor 29 AAVM controller
6 Battery relay 17 Boom up pressure sensor 30 RDU assy
7 Horn 18 Swing pressure sensor 31 PVG32 controller
8 P1 pressure sensor 19 Boom down pressure sensor 32 3-EPPR valve
9 P2 pressure sensor 20 Arm in pressure sensor 34 Bucket out pressure sensor
10 EPPR pressure sensor 21 RH travel pressure sensor 35 Bucket in pressure sensor
11 Overload pressure sensor 22 LH travel pressure sensor
4-2
N7-12
N5-24
RH-SIDE CN-5 N4-10
NC 1
N7-15
CAN 1
CAN 2
NC 2
N5-9
NC 3
NC
UNITED CN-51 34P/KEY-1(DOUBLE LOCK)
4
G 0.75 U108-1 U108-1 MCU CN-52 34P/KEY-2(SINGLE LOCK)
CAN 2_LO 5
V 0.75 U109-1 U109-1
U202
U201
U109
U108
CAN 2_HI 6
CN-53 26P
Y 0.75 U201 U201 CN-54 34P/KEY-1(SINGLE LOCK)
CAN 1_LO 7
L 0.75 U202 U202 B 0.75 U117
CAN 1_HI 8 CAN_SHIELD CAN 2 51-17 CN-126 CN-15 CD-69
B 0.75 N5-25 B 0.75 U210 U1322 U1322 0.75 Gr
CAN_SH 25 CAN_SHIELD CAN 1 52-10 10 1 A SUPPLY
B 0.75 RW U232 U232 0.75 OrW
CLUSTER_GND 9 9 J 2 B SIG
Gr 1.0 f16 G 0.75 U108 U1312 0.75 Br
CLUSTER_IG 10 CAN #2 Lo 51-08 8 H 3 C RETURN
GY 1.0 f09 V 0.75 U109
CLUSTER_BATT 11 CAN #2 Hi 51-09 7 G CN-237
RL 0.75 N5-12 Y 0.75 U201 U216 U216 0.75 OrW
CAM POWER 12 CAN #1 Lo 52-01 6 F 5 1
(A3)
ATT.
BL 0.75 N5-13 L 0.75 U202 F19 1.5 Or
Service Tool
CAM GND 13 CAN #1 Hi 52-02 5 E 4 2
V 1.0 f15 B
RADIO IG 14 4 D CN-149
GrW 1.0 f20 GrY 0.75 U211 U309 U309 0.75 YL
CAN 2
CAN 1
WIPER IG 16 RS232 #1 TX 52-11 3 C 6 1
RBr 1.0 f08 OrG 0.75 U203
ATT. PS CONFLUX SOL

ATT.
WIPER BATT 18 RS232 #1 RX 52-03 2 B
(A1/B)
2
LW 1.0 N5-19 P 0.75 U230
WASHER PUMP 19 PROGRAM DUMP 52-30 1 A CN-150
B 1.0 U214 U214 0.75 WG
F13
WIPER GND 21 add 9 9 1
Y 0.75 N5-22 N7-12
(A1)
SOL
CAM POS 22 15 10 2
L 0.75 N5-23 N7-15
2WAY
CAM NEG 23 54-15 PWT SW(PARKING) CN-66
GrW 0.75 N5-24 N5-241 U419 0.75 RL U208 U208 0.75 VB
QUICK COUPLING 24 54-19 BREAKER OPERATING SIG 1
<HARNESS TWOWAY>
7
V 1.5 f32 N5-24 U420 0.75 WL f31 1.0 BrR
DC/DC CVT_24V 54-20 BOOM FLOATING SELECT SW
(A2)
26
SOL
8 2
V 0.75 N4-101 N5-9 U421 0.75 BrL
QUICK COUPLING 27 54-21 POWER BOOST SW
B 1.5 N4-10
DC/DC CVT_GND 28 54-23 CRUISE SW 50
SAFETY SELECT BREAKER

B 1.5 N4-101
CABIN_GND 29 54-24 TRAVEL SPEED SELECTION SW
f282
SOL. POWER 30 54-29 RAM LOCK SW(OFF) PUMP EPPR Pf PS 51-13
B 1.5 YR 0.75 U114
GND 31 54-30 RAM LOCK SW(AUTO) MAIN PUMP P2 PS 51-14
FLASHER B+ 32 54-31 PWT SW(WORKING) FWD PILOT PS 51-20
V 1.5 2.0 R9-87 U432 0.75 LB WG 0.75 U121
CABIN LAMP RY 34 54-32 ONE TOUCH DECEL SIG ARM IN PS 51-21
·ELECTRICAL CIRCUIT (1/3)
BOr 0.75 R5-2 LY 0.75 U122

ENG. START 35 P1 REGULATOR PS 51-22
W 2.0 N5-36 U419 YL 0.75 U127
START KEY_ACC BR 36 53-14 RAM LOCK SW(ON) ARM OUT PS 51-27
B 1.5 U420 N4-162 1.0 OR GrR 0.75 U128
CABIN_GND 37 53-16 SAFETY LEVER SWITCH NEGATIVE 2(N2) PS 51-28
V 1.5 U320 Or 0.75 U129
f31
BUCKET OUT PS 51-29
F19
CABIN LAMP RY 38 53-17 PWT SW(TRAVEL)
G 1.0 N5-39 U319 0.75 GW
START KEY_ACC BR 39 53-19 HOUR METER(+) WORKING BRAKE PS 51-30
WOr 1.0 R35-861 N4-162 U1323
CAN 2
CAN 1
START KEY_IG 40 53-22 TRAVEL LEVER SW(NEUTRAL)
GrOr 0.75 N5-41 U432 U1322
RX232(2)-TX 41 53-23 CREEP SW
OrW 0.75 N5-42 U421 U320 0.75 BW U1321
RX232(2)-RX 42 53-20 SEAT BELT
P 0.75 N5-43 U319 Gr 1.0 U1325
PROGRAM DUMP 43 SENSOR POWER(10V) 51-32
BrW 0.75 N5-45 U206
CAM POWER 45 PUMP CONFLUX SOL.
YG 0.75 N5-46 U422 P 0.75 U209
GROUP 2 ELECTRICAL CIRCUIT
CAM0 LIN 46 TRAVEL BUZZER 52-09

Br 0.75 N5-47
CAM0 LVDS POS 47 51-04 GND(Pulse in) PUMP FLOW SYNC SOL. 52-04
Or 0.75 N5-48 GB 0.75 U205
CAM0 LVDS NEG 48 51-05 FAN Speed (Hyd) TRAVEL SPEED SOL 52-05
BL 0.75 N5-49 YG 0.75 U207
CAM0 GND 49 51-06 GND(Pulse in) ARM REGEN SOL 52-07
GrW 1.5 R85-5 VB 0.75 U208
BEACON LAMP 50 51-07 Engine speed ATT BREAKER SOL 52-08
GW 0.75 U319 WG 0.75 U214
HOUR METER SIG 51 51-11 Spare (Resistor) 2 WAY SELECT SOL 52-14
OrW 0.75 U216
GREASE RESET 52 51-12 Spare (Resistor) ATT CONFLUX SOL. 52-16
Or 0.75 N5-53
AIR COMP RY 53 51-13 Pump eppr (Pf) PS CREEP SOL. 52-17
LB 0.75 N5-54 GB 0.75 U218
AIR COMP RY 54 51-18 NC SWING PS 52-18
LOr 0.75 N9391
DPF REGEN 55 51-23 Coolant Temp. WORKING PS 52-19
V 0.75 N9362
DPF COM 56 51-27 Arm Out PS
VOr 0.75 N9387
DPF INHIBIT 57 51-29 Bucket Out PS REV. PILOT PS 52-20
GrB 0.75 U221
GREASE LAMP 58 51-34 Sensor 5V(2) OPT PILOT PS 52-21
WOr 1.5 f04 LOr 0.75 U222
ROOM LAMP 24V 59 MAIN PUMP(P1) PS 52-22
Y 0.75 N5-15 U206 0.75 Gr GOr 0.75 U223
WIPER DRIVE 15 52-06 SAFETY SOL BOOM UP PILOT PS 52-23
Or 0.75 N5-17 GW 0.75 U224
CAN 2
CAN 1
WASHER SIG. 17 52-12 NC TRAVEL PEDAL PS(RH) 52-24
L 0.75 N5-20 WBr 0.75 U225
WIPER INT. 20 52-14 Spare(Fan Reverse) BOOM CYL. ROD PS 52-25
P 1.0 U119
FUEL LEVEL 33 52-33 Accelerator Sig TRANSMISSION OIL PS 52-26
B 1.5 Lg 0.75 U227 CD-86
CONT._GND 44 TRAVEL PEDAL PS(LH) 52-27 0.75 Gr
ROr 0.75 R13-871 G 0.75 U228 U1325
ILLUMINATION 60 OVERLOAD PS 52-28 A SUPPLY
U422 0.75 L U127 U127 0.75 YL
OUT
ARM
54-22 SWING LOCK SWITCH BRAKE OIL PS 52-29 B SIG

U1312 0.75 Br
RH CONSOLE CN-8 C RETURN
1.0 WG 0.75 U231
GND-HAPTIC 1 53-16 Travel Alarm SW BOOM DOWN PS 52-31 CD-87
V 0.75 U109-2 U109-2 OrW 0.75 U232 U1325 0.75 Gr
CAN 2_HI 2 53-18 Battery relay(+) ATT PILOT PS 52-32 A SUPPLY
G 0.75 U108-2 U108-2 U234 U129 U129 0.75 Or
OUT
CAN 2_LO 3 53-20 Reverse Fan SW(on) ATT EPPR1 2SE PS 52-34 B SIG
B 0.75 U1312 0.75 Br
CAN_SHIELD 4 53-24 NC C RETURN
BUCKET
NC 5 53-25 Governor motor(+) CD-85

RG 1.0 f091 LBr 0.75 U305 U1325 1.0 U1325 0.75 Gr
HAPTIC_BATT 6 53-26 Governor motor(-) BOOM FLOATING ROD-TK SOL 53-05 A SUPPLY
WR 1.0 f161 GrL 0.75 U306 U231 U231 0.75 WG
HAPTIC_IG 7 BOOM FLOATING HEAD-TK SOL 53-06 B SIG
Gr 0.75 N16-3 LY 0.75 U308 U1312 1.0 U1312 0.75 Br
BOOM
DOWN
5V-DIAL_ECM 8 BOOM DOWN CUTOFF SOL 53-08 C RETURN

GW 0.75 N16-2 YL 0.75 U309
SIG-DIAL_ECM 9 ATT SAFETY SOL 53-09 CD-104
BL 0.75 N16-1 GB 0.75 U310 U1323 1.0 U1323 0.75 Gr
GND-DIAL_ECMC 10 54-08 Cruise eppr(-) POWER BOOST SOL 53-10 A SUPPLY
U224 U224 0.75 GW
54-11 Start Sig(SCANIA) RAM LOCK SOL. 53-12 B SIG
G 0.75 U315 U1311 1.0 U1311 0.75 Br
RH CONSOLE CN-7 54-12 Water level sw BUCKET IN PS 53-15 C RETURN
TRAVEL
WG 1.5 f29
CIGAR 24V 2 54-16 Engine oil PS CD-24
ROr 1.5 f27 U1323 0.75 Gr
CAN 2
CAN 1
AIR SEAT 24V 9 A SUPPLY
BrG 1.5 f301 U218 U218 0.75 GB
SWITCH POWER 8 PUMP SHIFT EPPR(-) 54-01 B SIG
YW 0.75 N7-12 WBr 0.75 U402 U1311 0.75 Br
SWITCH, STRAIGHT 12 P1 REGULATOR EPPR(-) 54-02 C RETURN
ROr 0.75 R13-872 Or 0.75 U403
ILLUMINATION 1 P2 REGULATOR EPPR(-) 54-03 CD-32
Br 0.75 N7-04 LB 0.75 U404 U1323 0.75 Gr
LOW WIPER SW_PF 4 BOOM PRIORITY SWING EPPR(-) 54-04 A SUPPLY
PEDAL(RH) SWING UP
BrOr 0.75 N7-05 YL 0.75 U405 U223 U223 0.75 GOr

LOW WIPER SW_LOW 5 BOOM PRIORITY ARM EPPR(-) 54-05 B SIG
BW 0.75 N7-06 U1311 0.75 Br
BOOM
Or 0.75 U407
LOW WIPER _WASHER 6 TRAVEL STRAIGHT EPPR(-) 54-07 C RETURN
GrG 0.75 U409
CREEP SIG 7 ATT RELIEF SET EPPR1(-) 54-09 CD-90
BY 0.75 U410 U1323 0.75 Gr
DOZER & 2-PCS 11 ATT RELIEF EPPR2(-) 54-10 A SUPPLY
YG 0.75 U321 U4171 U121 U121 0.75 WG
ARM
SWING FINE SIG B SIG

IN PS
13
LY 1.0 N7-15 N9391 BL 1.0 U417 U1311 0.75 Br
SWING LOCK SIG. 15 ATT RELIEF EPPR(+) 54-17 C RETURN
B 1.5 U422 N9362 YR 0.75 U425
CIGAR GND 3 TRAVEL STRAIGHT EPPR(+) 54-25 CN-419
A1
B 1.5 N9387 Br 0.75 U426

SW& AIR SEAT GND 14 P2 REGULATOR EPPR(+) 54-26 1
GrL 0.75 U427
PARK
NC 10 P1 REGULATOR EPPR(+) 54-27 2

SWING
PUMP SHIFT EPPR(+) 54-28 CN-14 CN-420

U4342 N7-15 1.0 LY
RH CONSOLE CN-6 4 1
A2
GrOr 0.75 N5-41 VB 1.0 U4341 f31 1.0 WR

RX232(2)-TX 1 BOOM PRIORITY EPPR+ 54-34 3 2
PARK
B 1.0 U206
SWING
JOYSTIC & SW GND 7

BrB 0.75 R85-5
MCU_RETURN 2
WL 0.75 U420 N5-36 WB 0.75 U302
BOOM FLOAT DOWN 3 SWING LOCK SOL 53-02
Or 1.5 f281 R9-87 Gr 0.75 U303
CAN 2
CAN 1
POWER_SWITCH 4 SWING FINE SOL 53-03 CN-370
OrW 0.75 N5-42 YG 0.75 U321 U303 U303 0.75 Gr
RX232(2)-RX 5 SWING FINE SELEC SW 53-21 1 1
RL 0.75 U419 f29 f31 0.75 BrR
2
FINE
BREAKER 6 2
P 0.75 R2-1 f301 Br 1.0 U131 U1312
HORN RY 8 GND(SENSOR_10V) 51-31 CN-421
f30 U1311 U302 U302 0.75 WB
NC 9 1
CONT. A3
f282 f31 0.75 LR

NC 10 2
f281
PARK
NC
SWING SWING
11
R35-861
NC 12
P 0.75 N5-43 R35-86
PROGRAM DUMP 13
LB 0.75 F12C
f31
F19
PVG_5V 14
WL 0.75
PVG_GND 15
Gr 0.75 N3-10 R13-871 U422 0.75 OrW Br 1.0 U433
ROTATE RH, 2-WAY 16 54-22 A/C BLOWER STATE GROUND(EPPR) 54-33
R13-872 U115 0.75 WY
1.5 B
51-15 ALT VOLTAGE

B 1.0 U102
LH CONSOL CN-4 GND_MAIN 51-02
LB 0.75 N3-7 R2-1 B 1.0
PVG_5V 1 GND_MAIN 51-10
WL 0.75 N3-8
PVG_GND 2 53-01 Urea level full warn.
OrW 0.75 N3-9 U215 0.75 WG BrB 1.0 U125
ROTATE LH 3 52-15 ANTI RESTART RY GND(FOR SENSOR_5V) 51-25
WOr 1.0 R35-86
EM'CY STOP SW 4 CD-37
BrL 0.75 U421 N4-16 U1323 0.75 Gr
MCU_POWER MAX 5 A SUPPLY
1.0 BrB
LB 0.75 U432 f16 U213 0.75 V U221 U221 0.75 GrB

MCU_DECEL 7 52-13 FUEL WARMER RY B SIG
GrW 0.75 N5-241 f161 RW 1.0 F13 U1311 0.75 Br
CAN 2
CAN 1
QUICK COUPLER SW 9 KEY IG 24V 51-26 C RETURN
V 0.75 N4-10 f09
QUICK COUPLER SW 10 53-04 WORKING CUTOFF RELAY
2PCS BOOM
BW 0.75 U320 f091 R 1.0

SEAT BELT 11 53-13 TWO-WAY PEDAL SOL BATT POWER_24V 51-01
f15
NC 12 53-11 PARKING RELAY
OrW 1.0 F12C f20
EM'CY STOP SW 13
BrG 1.0 f30 f08
SW
SWITCH POWER 15 CD-10A

AIR
Or 1.0 N4-16 f32 U133 1.0 Gr 0.75 CD-130

SAFETY SOL 16 51-33 POWER_5V OUT Pa U1323 0.75 Gr
BrB 0.75 N4-161 U107 1.0 BY OrB 1.0 U413
IN
A SUPPLY
MCU_SIG.GND 6 53-07 FAN CLUTCH PWM AIR CLEANER CLOGGING SW 54-13 U315 U315 0.75 G
BrB 0.75 N4-162 f04 U103 1.0 LgR B SIG
MCU_SIG.GND 8 51-03 FAN SPEED INPUT+ CD-2 U1311 0.75 Br
B 1.0 1.0 U125 R5-2 U1241 0.75 C RETURN
SAFETY SW GND 1
BUCKET
14
U124 1.0 BR P 1.0 U119
51-24 GND(Sensor 5V) FUEL LEVEL SENDOR 51-19 2
FUEL
CD-1
N5-39 0.75
1
F11 0.75 OrR LgB 1.0 U116
CLEANER LEVEL HYD
54-18 EPPR POWER 24V HYD TEMP SENDOR 51-16 2

TEMP
N5-53
f02
F13
N5-54 F13 1.0 RW

f02 1.5 R
CD-105
U321 U321 YG U1323 0.75 Gr
A SUPPLY
U125 U125 BrB U227 U227 0.75 Lg
B SIG
U119 U119 P U1311 0.75 Br
C RETURN
TRAVEL
N5-22 0.75 Y
CAN 2
CAN 1
1 LVDS POS add CN-366
N5-12 N5-13 0.75 BL U410 U410 0.75 BY
2 GND CN-260 1
N5-13 N5-23 0.75 L 0.75 U4171 U4171 0.75 Or
ATT
3 LVDS NEG 1 2
CN-249
N5-22 N5-12 0.75 RL 0.75

CAMERA
-
4 POWER 6.5V 2 add CN-365

N5-23 U409 U409 0.75 GrG
SPEAKER
REAR VIEW
5 NC CN-261 1
U417 U417 0.75 BL
ATT
6 ADJUST SIGNAL 4 SPK(-) 2

EPPR2 EPPR1
PEDAL(LH) RELIEF RELIEF
CN-9 3 SPK(+)
OPTION
G8 1.0 B
2 CLU VOUT GND 2 GND
0.75 Y f17 1.0 RG
3 CLU VOUT POS 1 ACC
SIREN SIREN AMP
0.75 L
AAVM
4 CLU VOUT NEG

U108 0.75 G
6 CAN 2 LO
U109 0.75 V
5 CAN 2 HI
N5-45 N5-45 0.75 BrW
7 CAM POWER
N5-46 N5-46 0.75 YG
8 CAM0 LIN CN-262A
N5-47 N5-47 0.75 Br
9 CAM0 VIN POS 1
N5-48 N5-48 0.75 Or CS-61
N5-24
N7-12
N4-10
10 CAM0 VIN NEG 2

N5-49 N5-49 0.75 BL 2 CN-262
11 CAM0 GND CN-262B
FLOAT
1.0 B 1 G 0.75 B
SWITCH
12 GND 1 1
1.0 RG CN-61 N7-12 0.75 YW
1 IG POWER 0.75 L 2 2
N7-04 4 CONTROL
TRAVEL STRAIGHT
CAN 2
CAN 1
0.75 G SWITCH PANEL

N7-05 3
1.5 B
N7-06 2 1 M CN-241
1.5 R U407 U407 0.75 Or
N16-3 1 2 1
FUEL
PUMP
U425 U425 0.75 YR

FILLER
N16-2 2
TRAVEL
N16-1 f17
STRAIGHT
CN-3A CN-81
-
N5-19 f18 1.0 GrW U209 U209

BZ
5 KEY IG 1
U108 0.75 G f28 0.75 WR
+
2 CAN 2 LO DO-23 2
N4-161 U109 0.75 V
1 CAN 2 HI 1 CN-70
N3-7 0.75 B U205 U205 0.75 GB
3 GND 2 1
N3-8 0.75 B f28 0.75 GrW
6 GND CN-18 2
TRAVEL HIGH
N3-9 N4-161 1.0 0.75 B

CN-407
SPEED
4 SAFTY 1 1 add CN-242

N3-10 N3-7 0.75 LB N7-06 0.75 BW U404 U404 0.75 LB
5V POWER 2 2 1
M
7
WASHER P/P
N3-8 0.75 WL U4341 U4341 0.75 VB

PVG EXT. HARNESS
8 5V GND CN-407 2
N3-9 0.75 OrW N7-04 2.0
9 ROTATE LH 1 2 E add CN-243
N3-10 0.75 Gr 0.75 B 1 Pf U405 U405 0.75 YL
10 ROTATE RH 2 1
N7-05 B U4342 U4342 0.75 VB
(M2) SWING ARM
3
1.0
SOL. BOOM BOOM
11 NC 4 2
0.75 ROr
12 NC 3 CD-70
CN-01 A SUPPLY
P1
4 Lo U122 U122 0.75 LY

M 1 B SIG
C RETURN
CAN 2
CAN 1
CD-71
LOW WIPER MOTOR
2.0 U1323 0.75 Gr

CN-11 4 A SUPPLY
P2
B U128 U128 0.75 GrR

1 GND 2 B SIG
U422 U422 0.75 OrW U1311 0.75 Br
2 BLOWER SIG 6 C RETURN
U115 f25 2.0
3 AC 24V CD-43
R7-86
AIR-CON
4 NC A SUPPLY
f07 2.0 Y U114 U114 0.75 YR
4-3
P2
5 CONT. B+ 3 B SIG
1.0 GR
6 AC COMP C RETURN
U108 Y
7 CAN_L0(2) CD-42
N7-04 U109 L
8 CAN_HI(2) A SUPPLY
P1
N7-05 U222 U222 0.75 LOr

PUMP HARNESS
CN-29 5 B SIG
N7-06 1.0 L
REGULATOR REGULATOR PRESS PRESS
CN-16/A 2 Pa C RETURN
N16-1 0.75 B N29-1
1 1
N16-2 0.75 W
2 add CN-342
R/DRYER
U206 N16-3 0.75 Gr U402 U402 0.75 WBR

3 CN-25 CL-5 7 1
P1
f04 0.75 BW 1.0 B U427 U427 0.75 GYL

4 2 1 8 2
f08 1.0 G
5 1 2 add CN-343
F12C U401 U403 0.75 Or
6 CN-20 CL-6 9 1
f15 1.0 B U428 U426 0.75
HORN
Br
2 1 10 2
P2
f20 R2-5 1.0 G

DO-7 1 2
f27 N5-19 0.75 V
CAN 2
CAN 1
1 CN-12 CL-5
f281 0.75 ROr R4-87 2.0 RG
2 1 1
f29 2.0 B
2 2
REGULATOR REGULATOR
CN-22
f30 0.75 V
1 CL-6 CN-135
f32 0.75 ROr U207 U207 0.75 YG
2 1 1
M
WASHER P/P
f28 0.75 WR
ARM
CL-4 2 2
WORK LAMP
N4-16 R13-87 1.5 R

1 CN-88
R2-1 N5-15 1.5 B U310 U310 0.75 GB
RH
2 1
R5-2 N5-17 f28 0.75 WR
CL-3 2
R9-87 N5-20 1.5 R
f07
f25
f33
REGEN BOOST
1
POWER
f201
LH
1.5 B
R7-86
2
R13-871
CL-24
R35-86 1.5 R
N5-24
N4-10
f28
f31
1
F19
CN-68
R85-5 1.5 B R48-4 0.75 Or
SOL
2 1
f26 0.75 GB
LAMP LAMP LAMP
HEAD HEAD HEAD
CN-96 2
N5-36 R46-87 2.0 Br
1 add CN-133
N5-39 2.0 B U404 U404 0.75 LB
2 1
ITY
REAR FUEL
N5-53 U434 U434 0.75 VB

3 2
BOOM
HEATER
N5-54
CAN 2
CAN 1
SAFETY PRIOR_
4
CN-385 CN-140
f281 f281 1.0 W N4-10 0.75 V
4 SOL + 1
f17 U107 1.0 BY N5-24 0.75 GrW
3 SOL(PWM) - 2
QUICK
f18
7 NC
COUPLER
6 NC CN-376
U133 1.0 Gr f14 0.75 WBr
5 SENSOR 5V 1 IG 24V
U301 U124 1.0 BR R4-85 0.75 W
FAN CLUTCH
2 SENSOR GND 4 WORK LIGHT

U215 U103 1.0 LgR R9-85 0.75 G
1 SENSOR OUT 5 CABIN LIGHT
U213 U1241 1.0 BR R13-85 0.75 Br
13 HEAD LIGHT CN-369
R85-1 0.75 GR U308 U308 0.75 LY
SOL
add 15 BEACON 1
BOOM
f201 F19 0.75 V

DOWN
2 NC 2
CUTOFF
f25
16 NC CN-13 CN-367
f07 U306 U306 0.75 GrL
SOL
14 NC 2 1
R7-86 F19 1.5 V
BOOM
DOWN
17 NC 1 2
N5-15 0.75 Y
RDU_MEMBRANE CONT.
3 WIPER CN-368
N5-17 0.75 Or U305 U305 0.75 LBr
11 WASHER 3 1
UP
N5-20 0.75 L
12 INT WIPER 2
SOL
U108 0.75 G
BOOM
18 CAN 2_LO
U109 0.75 V
10 CAN 2_HI
FLOATING FLOATING
0.75 B
26 GND
0.75 B
27 GND CD-124
U1321 U1321 0.75 Gr
CAN 1
9 NC 4 A SUPPLY
U225 U225 0.75 WBr
5 B SIG
U1312 0.75 Br
1.0
6 C RETURN
ROD PS
R29-87
CD-31
BOOM CYL.
U1323 0.75 Gr
A SUPPLY
U228 U228 0.75 G
B SIG
f31 U1311 0.75 Br
B+
LOAD
f26
OVER
F19
C RETURN
MCU R f02 1.5 f28
R48-4
2 30A
ROOM LAMP/RADIO B+ WOr f04 1.5
4 10A
AIR CON / HEATER Y f07 2.0 F19

7 20A
WIPER RBr f08 1.0 R48-4
8 10A
CLUSTER B+ GY f09 1.0 CAN 1 CAN1
9 10A
B+
f26
MCU CONT. RW F13 1.0
13 20A
EPPR OrR F11 1.5
11 20A
RDU IG WBr f14 1.0 N5-39
14 10A
RADIO IG LR f15 1.0
15 10A
CLUSTER IG Gr f16 1.0
16 10A
AAVM / SIREN RG f17 1.0
17 10A
PROPORTIONAL YL f18 1.0
18 10A
F07
SOLENOID V F19 1.5 F13
19 10A ISO MINI
f201 F11
30
1.2B
1.2G
WIPER GrW f20 1.0 87a 87 85

1.2B
f33
1.2G
IG(POWER RY)
20 10A 86
f261
87 CN-263
SAFETY SOL VW f26 1.0 1.5 W
1
2
26 10A 85 2
SEAT HEAT ROr f27 1.5 1.5 L f03
DO-3
27 20A 30 86
87a 1 G5
CR-1
f281 0.75
POWER
CR-13 ISO MINI CN-258 R51-5

SOLENOIDE Or 1.5 f28 1.0 f21 1.5 VW 5.0 W 2.0
BATT RY
AIR COMP.
28 20A 30 1
CIGAR WG f29 1.5 R13-871 0.75 GL 87a 87 85 N95-1 R50-5 2.0
29 20A 86 CD-16
R13-87 1.5 LY N60-1 0.75 BG
f14
87 C RETURN
R2-5
BREAKER BrR f31 1.5 R13-85 0.75 Br N9335 0.75 WR

R85-1
R9-85
R4-87
B SIG
R44-85
R13-85
R46-87
R13-87
R14-87
31 20A 85
R14-871
CONVERTER V f32 1.5 0.75 V

30 86
HEAD LAMP
32 10A 87a CN-95 A SUPPLY

SENSOR
8W
FRONT/REAR
8.0 W
1
90A
FUEL FILLER PUMP Y f33 1.5 8.0 W

33 20A 2 AT10A
2.0 0.75 Br
8W 4 POWER
"B" TERM.
0.75 B
3 RETURN
TO:STARTER
CN-60 5R N2-10 0.75 G

5.0 R
f30
f25
1 2 CAN HIGH
f261
WATER LEVEL SENSOR
R5-2
R2-1
R2-5
N2-11 0.75 V
U215
U213
60A
U206
F12C
N60-2
R4-87
R7-86
R4-85
R85-5
R85-1
R9-85
R9-87
N5-36
N5-54
N5-53
R48-4
N4-16
60R
1 CAN LOW
R35-86
R46-87
2
TANK LEVEL
5R
2.0
CIRCUIT BREAKER
G5
W N95-2 8.0 8.0 N95-2

12V X 2
CS-74
R S74-2 5.0 S74-2 5.0 R
L
2 CL-40
L
S
0.75 W
BATTERY
HEAD LAMP VW f21 2.0 5.0 R

21 20A 1 1
RY N2-01 0.75 GB
DEF
CS-74B 2
f06 2.0 Gr
60B
2
HORN RY f24 1.0 N5-36 2.0 W
MASTER SW
24 10A 1 CN-381
WORK LAMP RL F34 2.0 N5-53 N9340 1.0 Br
34 30A 1
DEF
LINE
CABIN LAMP R F36 2.0 N5-54 1.0 B

36 30A 2
FUEL HEATER L f22 2.0
22 30A N9339 1.0 Br
CN-382
AC / HEATER L 1.5 f25 1.0
25 20A 1
DEF
1.0 B
LINE
OPTION, SWITCH BrG 1.5 f30 1.5

30 20A 2
CN-383
IG(BATTERY RY)
ECM W f01 3.0 N9338 1.0 Br

1 30A 1
ECM Or F12 1.0 1.0 B
DEF
2
LINE
12 5A
OrW F12C 1.0
LAMP HEATER3 HEATER2 HEATER1
AT5
DEF MODULE Gr f03 1.5 N9379 1.0 W
3 15A 9 DEF PUMP MOTOR SUPPLY
LINE HEATER LgR f05 2.0 N9354 1.0 RB
5 15A 8 DEF PUMP MOTOR RETURN
DEF&SCR WY f10 2.0 N9306 1.0 BrR
10 10A 10 DEF PUMP MOTOR PWM
START, AIR-HEAT Lg f23 1.0 N9381 1.0 Or
23 20A 11 DEF REVERTING V/V
N9357 1.0 RBr
12 HS RETURN
N9332 1.0 BG
4 VS OEM RETURN
START KEY Gr 2.0 f06 N9308 1.0 V
6 30A 2 SUPPLY
N9316 1.0 BrY
3.0 B
2.0
3 DEF INJ PRESS
CAN1
2.0 Or
5 DEF SUPPLY POWER
G7 0.75 2.0 B
6 GND
f01
SCR&DEF SUPPLY MODULE
F12
R5-5
U115
U201
R7-87
R36-5
U202
N9376
N9375
N9383
N9303
N9338
CN-100
N9307
TO: HARNESS ENGINE

N9391
N9362
N9387
CN-173
G6
ISO MINI CR-35 CR-9 ISO MINI CN-2 A A

Gr f06 2.0 2.0 F36 2.0 R BY
30 30 AIR HEAT RY 15 B
0.75
85 87 87a WOr R35-86 1.0 0.75 R 87a 87 85

86 86 NC 14 C B
RW R35-87 R9-87 2.0 V WY 0.75
RESISTOR
N9349
87 87 ALT LEVEL 13 AT2A

B 0.75 R9-85 0.75 G OrW 1.5 AT1E
85 85 AC COMP 12
V 0.75 N2-11 24V 1 1 24V
86 30 87a 87a
30 86 CAN_LO 11
CABIN LAMP
G 0.75 N2-10 CAN_LO 2 2 CAN_LO

POWER RELAY
MICRO CR-85 MICRO CAN_HI 10

CAN_HI 3 3 CAN_HI
OUTLET
R85-1 0.75 GR B 0.75

1 1 CAN SH 9
1 5 4 1.5 f30 1.5 BrG 4 5 1 B 1.5 RETURN 4 4 RETURN
2 2 START RY GND 8
NOx SENSOR
0.75 BrG LY 0.75

NOx SENSOR
3 3 START RY 7
TO CN-5 56
TO CN-5 57
TO CN-5 55
YG 0.75 N2-06
BEACON
4 4 RETURN 6
2 3 R85-5 1.5 GrW 3 2 LW 0.75 N2-05
5 5 AIR TEMP 5
LOr 0.75 N2-04
CR-48 MICRO POWER SUPPLY 4
U206 0.75 Gr VW 0.75 N2-03 DOC.
1 AIR PRESS 3 SCR
f261 1.0 VW 4 5 1
2 NC 2
N4-16 0.75 Or RBr 1.0 N2-01 SIDE
3 DEF LAMP 1 AT9A
SAFETY
R48-4 0.75 OrW CN-430

f23
f03
f05
f35
f10
4 4 RETURN
R5-2
0.75 V N1
U215
3 2 1 3 CAN_LO
5 CN-93 0.75 G N2
CONT.
L 0.75 N9341 2
MICRO CR-51 MICRO DPF DIF PS 41 2 CAN_HI
BR 0.75 LW 0.75 N9367 2.0 Br N3
1 1 REMOTE ACCEL SIG 67 3 1 24V
1 5 4 Gr 1.0 4 5 1 LgY 1.0 2.0 B N4
2 2 HS_RETURN 76 4
Gr 1.0 2.0 WB 0.75
EXHAUST GAS
AT32
2.0
3 3 AIR HEATER RY 75
0.75
OrW 0.75 N9353 0.75 GY N5

4 4 STARTER LOCKOUT SIG 83 5 2
N9377 0.75 YR N6
THERMISTOR DEF
2 3 RBr 1.0 R51-5 3 2 G 0.75 N9313

5 5 WATER IN FUEL 13 6 1
f03 RB 0.75 N9342
DEF OUTLET GAS P/S SIG 42
DOSING
MICRO CR-50
MODULE
B 0.75 G5 GR 0.75 AT11A

1 CAC OUT TEMP 24
1 5 4 Or 1.0 F36 V 0.75 0.75 N9362 0.75 BG
2 DEF LEVEL SENSOR RETURN 62 9 1 RETURN
WY 2.0 f30 M9341 0.75 L
3 NC 00 10 2 DPF PS
GY 0.75 0.75 N9353 N9342 0.75 G
4 DEF DOSING V/V Lo 53 11 3 DPF OUTLET PS
Br 2.0 R50-5 G 0.75 N9377 0.75 V
2 3 77 12 4 SUPPLY
5 DEF DOSING V/V Hi
ISO MINI CR-52 CR-4 ISO MINI 00 00
LgR 2.0 F34 2.0 F34 2.0 RL Br 0.75
PS
30 30 DEF LINE HEAT RY- 3

DPF
85 87 87a 0.75 2.0 f22 0.75 RL 87a 87 85 Br 1.0 N9340

DIFF.
86 86 DEF LINE HEAT3 40

Br 2.0 N9338 f25 R4-87 2.0 RG Br 1.0 N9339
Br 0.75 N9303 f24 R4-85 0.75 W Br 1.0 N9338
86 30 30 86 GrG 0.75 N9382
87a 87a DEF TANK HEAT V/V 82 CN-16B
WORK LAMP
RBr 0.75 N9357 0.75 BG

CR-39 CR-46 HS RETURN 57 1
MICRO ISO MINI N9363 0.75 RW 2.5k
LgY 1.0 N9376 2.0 f22 2.0 YR RW 0.75 N9363
1 30 ACCEL 2 _ SIG. 63 2
1 5 4 OrW 0.75 N9383 0.75 87a 87 85 BrY 1.0 N9316 0.75 V
2 86 DEF INJ. PRESS SENSOR 16 3
WG 0.75 R46-87 2.0 Br Or 1.0 N9381 N9362 0.75 V 2.5k
3 87 A/T POWER RY 81 4
U213 V BrR 1.0 N9306 M9367 0.75 LW
DEF MODULE NOx SENSOR LINE HEATER STARTER
DEF P/P TEMP 6 5

LOCKOUT
4 85
2 3 BrG 0.75 N9307 30 86 RB 1.0 N9354
5 87a DEF P/P RETURN 54 6
BR 0.75 N9379
MICRO CR-5 CR-7 ISO MINI DEF PUMP MOTOR RY 79
BrG R5-1 f25 1.0 L BG 1.0 N9332
1 30 OEM SENSOR RTN 32
1 5 4 LY 0.75 R7-86 1.0 L 87a 87 85 WR 0.75 N9335
2 86 ENG. COOLANT LEVEL 35
Lg 0.75 f23 R7-87 1.0 OrW V 1.0 N9308
3 87 OEM SENSOR SUPPLY 8
0.75 B GB 0.75
4 85 DEF SUPPLY HEATER RY(-) 7
FUEL HEATER AC COMP.
2 3 LY 1.0 R5-5 30 86 VOr 0.75

5 87a DPF INHIBIT 87 AT6
LOr 0.75 0.75 RBr
CR-36 DPF REGEN 91 2
MICRO MICRO
V/V
LgY 0.75 R2-1 0.75 P

CR-2 Or 0.75 F12 N9382 0.75 GrG
1 1 KEY SWITCH"ON" 5 1
1 5 4 WB 0.75 N9375 1.0 f24 1.0 RY 4 5 1 Y 0.75 U201
2 2 CAN 1_Lo 46
YR 0.75 f23 0.75 RY L 0.75 U202
HORN
COOLANT
3 3 CAN 1_Hi 22 CD-45

B 0.75 0.75 V
4 4 BATTERY(-) 52 2
ANTI-RESTART PRE-HEAT
N9313 0.75 G
WIF
2 3 BY 0.75 R36-5 R2-5 1.0 G 3 2 B 0.75

5 5 BATTERY(-) 51 1
B 0.75 3.0
BATTERY(-) 50
B 0.75
3.0
BATTERY(-) 49 CD-10
B 0.75 N2-06 1.0 YG
BATTERY(-) 73 1 RETURN
W 0.75 3.0 f01 N2-05 1.0 LW
BATTERY(+) 28 2 AIR TEMP
TEMP
W 0.75 N2-04 1.0 LOr

BATTERY(+) 27 CN-174 3 SUPPLY POWER
W 0.75 L 0.75 U202 N2-03 1.0 VW
BATTERY(+) 26 A A 4 AIR PRESS
W 0.75 Y 0.75 U201
BATTERY(+) 25 B
SENSOR,PRS
W 0.75
BATTERY(+) 1 C
20K6-98320-00
B
3W 120ohm
RESISTOR
DC/DC CONVERTER
RMS 12V SOCKET HOUR METER
24V
12V 12V
1 FUEL LEVEL
h
CN-48
6 DOOR SW
4 CAN1 LO
GND
3 CAN1 HI
24V
CS-33
CN-138
CN-139
5 KEY
7 NC
3
2
CN-125B
1
NC
8 NC
1
2
5 5
3
2
1
CN-21 4 4
0.8YL
3 1 WIPER CUT
0.8B
0.8Y
3 3
1.2Or
1.2BW
R 10
22A 1.2B
1.2Or
1.2Or
2 0.8Br 15
Gr 12 2 2
5 3 0.8G 16
CN-113 1 1
86
93
R 4A
CS-53
85
79
HARNESS LH,CONSOLE
60
9
4 25
60
22
20
4 8 0.8B
G 1 EM'CY STOP SW
5 56 0.8Or
L 9 2
2A B
6 M 2 6
Or
BUZZER CN-247 CN-4 NO. DESTINATION
0.8Gr 1 1 0.8Gr
CN-56B 5V
A 1 1 MCU_5V
11
WIPER MOTOR 59 0.8B RW CAM 6.5V PROPORT- RETURN 0.8Or 2 2 0.8Or
LH
1 B 2 2 MCU_RETURN
8 0.8L WR
IONAL
SIG 0.8LOr 3 3 0.8LOr
2 CAM GND C 3 3 MCU_DIAL SIG
7 0.8Y B
CN-24 15 0.8Br
3 CAM DIFF H CS-1 0.8G 2 4 4 EM'CY STOP SW
CN-141 CN-157 0.8V WL 1.2Gr 11
2 0.8Y 4 4 0.8Y
G 8 4 CAM DIFF L 0.8V 3 power 1 5 5 MCU_POWER MAX
1 1 B 0.8B 5 5 0.8B
FEED BACK W CN-10 NO. DESTINATION
max
2 6 6 MCU_SIG.GND
W 1 CN-17 ANTENA POWER 5 CAM 1 CS-29 0.8Grw 6 6 0.8Grw
MOTOR DRIVE SIG 2 L CL-1
L 9 6 CAM 2 SPEAKER RH 1 1 NC decel R
1
0.8B 7 7 0.8B
7 7 MCU_DECEL
MOTOR DRIVE- 3 1 L 1.2Gr 11
R 10 1 W 0.8GR 69 7 CAM 3 DOOR S.W 3 2 2 DOOR SW
CS-19
2
8 0.8L
8 8 MCU_SIG.GND
MOTOR DRIVE+ 4 2 L CAM SHIELD 0.8Y 1 1 0.8Y
B 2 2 B 1.2B 73 8 2 3 3 FUSE 9 9 Q/COUPLER SOL +
GND 5 3 1.2B 6B 2 0.8G 2 L 9 0.8V
GrW 3 3 GrW 0.8RY 70 CLUSTER 1 4 4 CASSETTE_RH- 10 10 Q/COUPLER SOL -
6 4 3 0.8V
VCC
R 4 4 R 0.8R 14 CN-56A
CN-23 ROOM LAMP 5 5 CASSETTE_RH+ 11 11 NC
7 5 0.8Y 4 4 0.8Y 1 Gr
CONTINUE 24V 10 0.75BW RW 2 12 NC
V 5 5 V 0.8V 15 1 BATT.24V 6 6 CASSETTE_LH- 12
WASHER P/P 8 6 0.8L 5 5 0.8L 16 0.8G
71 9 0.75VBr WR 1 7 7 CASSETTE_LH+ CS-4 13 13 EM'CY STOP SW
L 6 6 L 0.8L 2 IG 24V 6
WASHER SIG. 9 7 59 0.75B 2.0B B C 1.0B 12 12 1.0B
Br 7 7 Br 0.8YOr 72 B 8 8 GND A 14 14 GND
INT. SIG 10 8 0.75L
3 GND SPEAKER LHCL-7 7 2.0B 13 0.8RW
Or 11 8 Y 9 9 GND B 15 15 IG24V_FUSE
WIPER CUT SW 11 4 CAN1_HI 1.2BrW 8 8 1.2BrW 0.8G 14 14 0.8G
7 0.75Y Gr 10 10 BEACON SW A C 16 16 SAFETY SOL
N.C 12 5 CAN1_LO M 1.2B 6A 9 2.0V
6 0.75V WL 11 11 CABIN LIGHT RY
Gr 12 6 CAN2_HI SAFETY SW
FEED BACK 13 WIPER MOTOR HARNESS 5 0.75G
7
W
CAN2_LO BEACON LAMP
10 2.0V
12 12 CABIN LIGHT RY CS-67
WIPER MOTOR CONT. L CL-10 CL-9
8 RS-232 RX CL-8 10
9
L
RS-232 TX 2
2.0V 9 2
2V 10A 10 2.0V
2
HARNESS CABIN 10 9
9
CS-99 90 0.75Y L 2B 2B 7A 7 2B 0.8L 8A
10 AUX LEFT 6 1 1 8
91 0.75L 1 12A
10 L 1.0B
11 AUX RIGHT 6 7
10 9
9 92 0.75B L CABIN LIGHTER 5
12 AUX GND 4 6
8 1.0B 12B
CLUSTER 3 5
6 7 2 0.8V 9
5 0.8YR 37 CN-5 1 4
4 6
0.8Or 32A 1 1 NC 3
3 5 0.8RW 13
2 2 2 NC 8 7 2
1 4 0.8L 8
3 3 NC 1
3
0.8L 39 4 4 NC QUICK COUPLER SW
8 7 2 5 0.75G
0.8W 40 5 5 CAN2_LO
1 6 0.75V
6 6 CAN2_HI
AIR-COMP SW 7 0.75Y
7 CAN1_LO
7
8 0.75L
8 8 CAN1_HI
59 0.75B
9 9 CLUSTER_GND
9 0.75VBr
10 10 CLUSTER_IG 24V
10 0.75BW
11 11 CLUSTER_BATT.24V
11 0.75R
12 12 CAM POWER
12 0.75BW
CS-100 13 13 CAM GND
13 0.75W
14 14 CASSETTE RADIO IG
10 69 0.75GR
10 9 15 15 WIPER MOTOR DRIVE SIG
9 70 0.75RY
16 16 WIPER MOTOR IG24V
8 71 0.75L
17 17 WASHER SIG.
6 7 14 0.75R
5 18 18 WIPER MOTOR BATT24V
4 6 15 0.75V HAPTIC
19 19 WASHER P/P
3 5 72 0.75YBr
2 20 20 INT. SIG
1 4 73 1BR
GND_EME'CY
0.8VW 1 21 WIPER MOTOR_GND
CAN_SHIELD
21
POWER BAT
SIG_EME'CY
3
5V_EME'CY
88 0.75RW
POWER IG
0.8R 2 22 22 LVDS POS
2 89
CAN_LO
8 7 0.75LB
CAN_HI
0.8LW 3 23 23 LVDS NEG
1 65 0.75ROr
GND
GND
N.C
N.C
24 24 Q/COUPLER SOL+
DPF SW 74 1B
25 25 CAN_SH
20 1Or
12
11
10
26 26 DC/DC CONVERTER_24V CN-363
3
6
2
8
5
4
1
9
27 27 NC
22 1BW
0.8BrW
0.8ROr
28 28 DC/DC CONVERTER_GND
0.8BW
23 2B
0.8G
0.8B
0.8V
0.8B
0.8L
29 29 CABIN_GND
SH
24 1ROr CN-156
30 30 POWER_FUSE 1.25B 38E
25 1B 2
31 GND
15A
31 1.25VW 33
17
18
24
22
16
15
19
20
32 NC 1
32
33 33 FUEL LEVEL AIR SEAT
28 2V 28 2VW
34 34 CABIN LAMP RY
CN-427 29 1BR
35 35 ENG. START SIG.
0.8W 33 30 1W
IG 24V 1 36 36 START KEY 24V
0.8R 23 23B 1B CS-79
GND 2 37 37 CABIN_GND
0.8B 6C 28A 1VW
CAN (HIGH) 3 38 38 CABIN LAMP RY 10
0.8.G 5C 32 0.75YBr 10 9
CAN (LOW) 4 39 39 START KEY_BR 9
33 1G 0.8BOr 29
READER 40 40 START KEY_IG 8
87 0.75GrY 0.8B 38C CN-8 NO. DESTINATION
41 41 RX232(2)-TX 6 7 15 0.8B
88 0.75OrG 5 1 1 GND
CN-125A 42 42 RS232(2)-RX 4 6 16 0.8V
1.2W 30B 89 0.75P 0.8BW 30 2 2 CAN_HI
BATTERY POWER 1 43 43 PROGRAM DUMP 3 5 17 0.8G
1.2G 85 1B 2 0.8BOr 29 3 3 CAN_LO
33A 44 44 CONT._GND 1 4 18 SH
KEY "IG" 2 34 0.75R 0.8Br 28 4 4 CAN_SHIELD
0.8V 6A 45 45 CAM0 POWER 3
CAN (HIGH) 3 35 0.75Br 1.2Or 32F 5 5 NC
RX232(1)-TX 4 46 46 CAM0 LIN 8 7 2 19 0.8BrW
36 0.75L 0.8BOr 29A 6 6 POWER_BATT
GND (SERIAL) 5 47 47 CAM0 LVDS POS 1 20 0.8ROr
87 37 0.75Y 7 7 POWER_IG
RX232(2)-TX 6 48 48 CAM0 LVDS NEG LOW WIPER SW
38 0.75B 8 8 5V_ECM
88 49 49 CAM0 GND
RX232(2)-RX 7 39 9 9 SIG_ECM
0.8B 74 1BrW
CAN (SHIELD) 8 50 50 BEACON LAMP
79 0.75YL 10 10 GND_ECM
RX232(1)-RX 9 51 51 HOUR METER SIG CS-108
89
PROGRAM DUMP 10 52 52 NC 10
81 0.75Y 10 9
0.8G 5A 53 53 AIR COMP RY 9
CAN (LOW) 11 40
0.8B 85B 0.75L 0.8Or 31A
MAIN GND 12 54 54 AIR COMP RY 8 CIGAR LIGHTER
41 0.75Gr 0.8Or 32E
55 55 DPF SW_REGEN 6 7 1.2ROr 25
RMS 42 0.75YW 5
56 56 DPF SW_COM 4 6 1.2Gr 26
44 0.75RW
57 57
58
DPF SW_INHIBIT
NC
3
2
5 1.2B 27
HARNESS RH,CONSOLE
58 1 4
45 0.75Y CL-2
59 59 ROOM LAMP 24V 3
46 0.75GW 0.8Or 31
60 60 ILLUMINATION 2
8 7
1 CN-7 NO. DESTINATION
25 1.2ROr
1 1 ILLUMINATION
AUTO GREASE SW 26 1.2Gr
CN-10 2 2 CIGARLIGHT IG24V
CS-2A 27 1.2B
1 NC 1 30 1.2W 3 3 CIGARLIGHT_GND
H0 I
1 28 0.8Br
2 DOOR SW 2 32 0.8YOr CS-107 4 4 WIPER_Pf
0.75Y 45A 2 29 0.8BOr
0, I
3 ROOM LAMP 24V 3 47 1.2R 10 5 5 SWITCH_Lo
0.75G 51 3 4 10 9 30 0.8BW
H
4 SPEAKER RH- 4 9 6 6 SWITCH_WASHER TANK
0.75V 53 4 1 0.8YW 36A 31 1.2Or
BR ACC
5 SPEAKER RH+ 5 2 8 7 7 AUTO GREESE RESET
B
0.75Y 52 5 3 96 0.5Y 0.8B 38 32 1.2Or
6 SPEAKER LH- 6 29 1.2BOr 3 6 7 8 8 SWITCH POWER
0.75L 55 6 5 33 1.2VW
7 SPEAKER LH+ 7 2 4 6 9 9 AIR SHEAT POWER
2B 24 2B
ST C
23 5 34 0.8V
8 GND 8 6 1 3 5 10 10 NC
1B 23A 2
9 GND 9 START KEY SW CS-2C 1 4 11 11 AUTO GREESE LAMP
1BrW 39 36 0.8YW
10 BEACON LAMP 10 3 12 12 TRAVEL ST_SOL
2VW 28 28 2V 0.8Or 32 37 0.8YR
11 CABIN LIGHT 11 3 2 13 13 FINE SWING SIG
1VW 28B 6C 0.75V CAN_H 95 0.5B 8 7 0.8YW 36 38 1.2B
12 CABIN LIGHT 12 A 2 1 14 14 GND
5C 0.75G CAN_L 94 0.5R 39 0.8W
B 1 15 15 SWING LOCK SIG.
STRAIGHT TRAVEL W
HARNESS CABIN CN-27A
85G 0.75B
C
GND
CS-2D
0.75W 13 CS-2B
ACC 1
0.75B 85E
ILL- 2 CN-125 CN-125 CS-52
NC 3 30A 1W
1 1 10
0.75G 51 47 1R R 77 10 9
SPK FRT RH- 4 2 2 9
0.75Y 52 85C 0.75B 0.8Y 35
SPK FRT LH- 5 3 3 8
TEL MUTE 6 33 1G R 77 0.8B 38
4 4 6 7
5
ANT 12V 7 4 6
0.75Y 45A GPS CONN.
BACK UP+ 8 3 5
0.75GW 46 2
ILL+ 9 1 4
0.8Y 35
NC 10 3
0.75V 53 CN-402 0.8Or 32B
SPK FRT RH+ 11 36 0.75L 2
1 LVDS POS 8 7
REMOCON+ 12 38 0.75B 1
2 GND
REMOCON GND 13 37 0.75Y 2PCS & DOZER SW
0.75L 55 3 LVDS NEG
SPK FRT LH+ 14 34 0.75R
4 POWER 24V
NC 15
0.75B 85D 5 NC CS-83
GND 16 35 0.75Br
6 ADJUST SIGNAL 10
CN-27B 10 9
9
FRONT VIEW CAMERA 0.8YW 36A
USB 5V 1 8
USB D- 2 0.8B 38
6 7
USB D+ 3 5
4 6
USB_GND 4 0.8Or 32B
3 5
N.C 5 HARNESS RH SIDE 1
2
4
0.75Y 90
AUX L 6 3
0.75L 91 0.8B 32
AUX R 7 2
0.75B 92 8 7 0.8YW 36
AUX GND 8 1
CASSETTE RADIO FINE SWING SW
CASSETTE RADIO
CS-83
10
10 9
9
0.8W 39A
8
THERMISTOR INTAKE ACT`R TEMP ACT`R MODE ACT`R 6
0.8B 38
7
5
2 7 4 6
1 M 4 3 M 0.8Or 32C
3 M 7 7 3 5
5 2
1 4
CONTROL BOX(A) 3
5
6
7
5
6
7
1
2
3
4
5
6
7
1
2
3
4
2
1
1
2
3
4
0.8B 38
7B 2
GND 1 8 7
20E
0.8W 39
20B
20A
6
23
1
3B
20
3A
15
14
11
10
12
13
2
6
INLET (PBR)
3
4
5
5 SWING LOCK SW
TEMP (PBR) 3
4
MODE(PBR) 4
3 HARNESS AIR-CON
REF(+5V) 5
NC 6 CN-11 NO. DESTINATION
1A 7 CN-126A
BATTERY(+) 7 1 1 AC GND
20F 19 NC 1
SENSOR GND 8 2 2 BLOWER ON SIG. 0.8GrY 15
15 8 RX232(2)-RX 2
INLET ACT`R(REC) 9 3 3 IG 24V 0.8OrG 1
14 RX232(2)-TX 3
INLET ACT`R(FRE) 10 4 4 NC 0.8P 16
13 1 PROGRAM DUMP 4
TEMP ACT`R(COOL) 11 5 5 AC CONTROLLER B+
12 18
TEMP ACT`R(WARM) 12 6 6 COMP(DPS) RMS SERVICE TOOL
11 17
MODE ACT`R(FRONT) 13 7 7 CAN LOW CS-111
10 16
14
MODE ACT`R(FRONT-DEF) 8 8 CAN HI
10
NC 15 10 9
8A 9
IGN.24V 16
8
CONTROL BOX(B) 6 7
5
20 22 4 6
0
>
SENSOR GND 1
20C 3 5
NC 2 0 2
19 1 4
BLOWER ON SIG 3 INCAR SENSOR
18 3 CN-6 NO. DESTINATION
A/C THERMO (+) 4 1 0.8GrY
2 1 1 RX232(2)-TX
NC 5 8 7 2 0.8R
17 1 2 2 MCU_GND
CAN LOW 6 21 3 0.8LW
16 0 BOOM FLOATING SW 3 3 BOOM FLOAT DOWN SIG
>
CAN HI 7 20D 4 0.8G

0 4 4 IGN_24V
NC 8 0.8G 4 15 0.8OrG
1 5 5 RX232(2)-RX
NC 9 AMBIENT SENSOR BREAK B 0.8BW 5 5 0.8B/W
7C 2 6 6 BREAKER
GND 10 CS-26 0.8B 6 6 0.8B
1 7 7 GND
NC 11 HORN
R 0.8Grw 7 7 0.8Grw
26 2 8 8 HORN RY
FET(G) 12 CS-5 0.8L 8 8 0.8L
25A 9 9 NC
FET(D) 13 2 L 0.8L 9 9 0.8L
24A 10 10 NC
BLOWER MOTOR(+) 14 0.8Gr 10 10 0.8Gr
11 11 NC
NC 15 1 Gr 0.8Gr 11 11 0.8Gr
23 12 12 NC
EVAP SENSOR(5V) 16 16 0.8P
CN-246 0.8GrR 12
13 13 PROGRAM DUMP
NC 17 12 0.8GrR
17A
16A
19A
5V
22 A 14 14 MCU_5V
7A
24
25
26
INCAR SENSOR(5V) 18 0.8W 13 13 0.8W

25
24
PROPOR
8
7
RETURN
B 15 15 MCU_SUPPLY GND
RH
21 0.8BY 0.8BY
AMB SENSOR(5V) 19 -TIONAL SIG 14 14
C 16 16 MCU_DIAL SIG
3
2
4
1
2
1
NC 20
CAN CONNECT
WITH APTC
CS-26A
2
4
M
FET 0.8BW 5A
2
1
3
BLOWER BLOWER 0.8G 4A

1
MOTOR RELAY
BREAKER
20K6-98310-00
4-4
CC1D
1 NC
14 NC
N2-05
5 DEF LAMP
CN-3
EX2B 1
7A 2W
1 AIR PRESS 2
7E 2W
8 2B
2 POWER SUPPLY TBAP 3
3 AIR TEMP 4
8 2B
4 RETURN 5
6
7
CC8D 8
N2-10 0.85Y
1 CAN_HI 9
N2-11 0.85YB
2 CAN_LO 10
3 NC 11
4 NC 12
CN-2 CN-28
0.8ROr
1 DEF LAMP 1 10 1.5 OrW
1
2 NC 2 6B 1.5 B
1.2ROr 40
3 AIR PRESS 3
134A
1.2ROr 40
0.8LOr 204
202
205
206
203
G44
207
AC COMP
208
18D
18C
18E
209
210
71A
72A
4 POWER SUPPLY 4
0.8YW 71B
0.8LW 72B
201
1.2ROr 40
G47
5 AIR TEMP 5
206
CR-23 CN-45
210
209
1.2ROr
0.8YW
0.8LW
40
0.8Or
0.8Or
0.8Or
0.8Gr
0.8Br
6 RETURN 6
0.8G
0.8Y
0.8G
0.8B
0.8V
0.8L
0.8B
0.8L
0.8B
1.2ROr 40 15 1.2BOr M
7 START RY 7 2
0.8G
0.8G
0.8Y
0.8B
1.2ROr M
40 16 1.2B
8 GND 8 1
CN-306
1.2ROr
CN-305
40
CN-307
12
11
10
5
4
12
11
10
6
5
4
1
9
2
9
3
9 CAN SH
CN-307
C
9
B
A
1.2ROr START RY.FROM BATT.RY B+
G45
G46
40
207
208
2
4
3
1
10 CAN_HI 10
PWMOUT/DOUT/PVGOUT
PWMOUT/DOUT/PVGOUT
PWMOUT/DOUT/PVGOUT
PWMOUT/DOUT/PVGOUT
PWMOUT/DOUT/PVGOUT
PWMOUT/DOUT/PVGOUT
PWMOUT/DOUT/PVGOUT
PWMOUT/DOUT/PVGOUT
1.2ROr 40 STARTER
5Vdc sensor power+

Sensor power GND-
SIGNAL VOLT(Udc)
11 CAN_LO 11
SIGNAL VOLT(Us)
1.2ROr 40
0.8G
0.8B
C
B
Power ground(+)
A
0.8B
0.8L
Power ground(-)
Power supply(+)
Power supply(+)
12 AC COMP RY 12
AIN/CAN Shield
DIN/AIN/FreqIN
DIN/AIN/FreqIN
DIN/AIN/FreqIN
DIN/AIN/FreqIN
DIN/AIN/FreqIN
1.2ROr 40
13 ALT LEVEL 13 6 1.0 B
RS-1 15 R CN-74
SERVICE TOOL
CN-309
CN-310
14 NC 14
2
1
1
2
ERROR
1.2ROr B+
CAN(+)
40
CAN(-)
15 PRE-HEAT RY 15 3W/300
GND
1 G
DIN
DIN
17 1.2W 3~
L
U P/P VALVE EPPR EPPR CONNECTOR 2(C2_BLACK) CONNECTOR 1(C1_GREY)
(PVG 32) V/V-A2 V/V-A1
CR-24 ALT.
12 1.2GrW
15R
CN-80
PROPORTIONAL VALVE & LEVER
15R
GLOW PLUG RY GLOW PLUG
E/G HARNESS
EasyStart Timer CN-267

0.5 R 303 (a4)
TERMINAL 30 (B+) 1
TERMINAL 58 (LIGHT SIG) 2
0.5 Gr G90C (a5, GND)
TERMINAL 31 (GND) 3
0.5BW 302 (a2)
DIAGNOSIS 4
DAT 5
0.5Y 308
S+ 6
S2 B2 ADR 7
0.75Br ADR 8
- - A A
M 0.75W Temp. Sensor(-) 9
+ + B B
Temp. Sensor(+) 10
WATER PUMP
0.5BL 1
0.5Br 2
FLAME SENSOR
1
2
0.5BL 3
CS-74A
0.5BL 4 AAVM
6.0R
6.0R
TEMPERATURE SENSOR 310 2.5R
0.5R 5
FROM MASTER SW CN-246B
4
3
2
1
0.5R 6 POWER
310
161
149
CN-301 CN-246A
4
3
2
1
VIDEO_OUTH
VIDEO_OUTP
1 0.5BL
CAM3_VOUT
CAM1_VOUT
CAM0_VOUT
OVERHEATING SENSOR
CAM2_VOUT
RS232_GND
CAM3_VINP
1
RS232C_RX
FLAME SENSOR
CAM2_VINN
CAM0_VINN
RS232C_TX
CAM1_VINP
CAM3_VNN
CAM3 GND
CAM1_VNN
CAM2_VNP
CAM0_VNP
CAM2 GND
CAM1 GND
CAM0 GND
2 0.5Br
CAM3 LIN
CS-74A
CAM1 LIN
CAM0 LIN
CAM2 LIN
2 SENSOR GROUND
1
2
CAN Lo
0.5BL
CAN Hi
3
3 TEMPERATURE SENSOR
GND
GND
4 0.5BL
ACC
ACC
4 TEMPERATURE SENSOR FUSE BOX
CN-401
5 0.5R
5 OVERHEATING SENSOR
6 0.5R
6 OVERHEATING SENDOR
CN-261
31
5A
11
12
27
25
20
16
23
26
14
22
17
29
34
13
18
30
35
15
24
19
32
10
310A 1.0R TIMER CONT. (B+) 1.0R 303
1
5
3
7
9
7 N/S 310A 1.0R
8 N/S 310 2.5R 15A HEATER CONT. (B+) 2.5R 300
1.5W 7 7 1.5W
9 GLOW PLUG(+)
1.5Br 8 9 0.75Br
10 WATER PUMP(-) CN-260
10 0.75W
GLOW PLUG 8 1.5Br
11 WATER PUMP(+)
12 GLOW PLUG(-) CN-269
0.75BK 11 11 0.75BK 1.0B G90B (GND)
+ P1 13 BURNER ENGINE(+) 1
12 0.75Br 1.0G 301
M P2 14 BURNER ENGINE(-) 2
0.75Br 12
- P3
B7 CONTROLLER Dosing pump CN-405
BURNER ENGINE 8 0.85Y
B1(S1) 0.85B
1 LVDS POS
2.5R 300 7E
Terminal 30 (B+) 1 2 GND
2.5B G90A 7A 0.85BrW
Terminal 31 (GND) 2 3 LVDS NEG
8 0.85R
Plus signal-Battery Sig. 3 4 POWER 24V
1.0G 301
No. CONN. No. Connector Name Part Number Supply Dosing pump 4 5 NC
0.5BW 302 (4) 8 0.85Gr
Diagnosis (HELJED) 5 6 ADJUST SIGNAL
CN-265 CONTROLLER 3A0973734 VW N/S 6
Heter On 7
0.5Y 308 RIGHT VIEW CAMERA
CN-267 EasyStart Timer 15-97-5101 Molex
N/S 8 CN-406 CN-404
0.8YW 71B 8 0.85Y
A A 1 LVDS POS
CN-269 Dosing pump 282189-1 TE (Tyco) CN-265 0.8LW 72B 7E 0.85B
G90 4.0B
B B 2 GND
0.8B 201 7A 0.85BrW
C C 3 LVDS NEG
BLOCK HEATER & CONTROLLER SUPPLIER PARTS 8 0.85R
SERVICE TOOL 4 POWER 24V
5 NC
8 0.85Gr
6 ADJUST SIGNAL
LEFT VIEW CAMERA

Engine Block Heater CN-403
8 0.85Y
1 LVDS POS
7E 0.85B
PREHEATER HARNESS (ONLY TIMER) 7A 0.85BrW
2 GND
3 LVDS NEG
8 0.85R
4 POWER 24V
5 NC
8 0.85Gr
6 ADJUST SIGNAL
EasyStart Timer REAR VIEW CAMERA
0.5 R 303 (a4)
TERMINAL 30 (B+) 1
0.5 Gr G90C (a5, GND)
TERMINAL 31 (GND) 3
DIAGNOSIS 4
0.5V 309
DAT 5
S+ 6
ADR 7
ADR 8 CN-9
Temp. Sensor(-) 9
1
Temp. Sensor(+) 10
2
CN-267 3
4
5
WEB CONTROLLER 6
0.5 R
TERMINAL 30 (B+) 1 7
DAT 2 8
0.5 Gr
GND 3
0.5BW 302 (a2) 9
DIAGNOSIS 4
10
- 5
11
CN-267A 12
CN-246B
PREHEATER HARNESS (TIMER+WEB)
4
3
2
1
20K6-98330-00
4-5
MEMORANDUM
4-6
1. POWER CIRCUIT
The negative terminal of battery is grounded to the machine chassis directly.
When the start switch is in the OFF position, the current flows from the positive battery terminal as
shown below.
1) OPERATING FLOW
Battery Battery relay [CR-1] Circuit breaker [CN-60] Master switch [CS-74]
Fuse box [No.1] Engine ECM [CN-93 (1, 25, 26, 27, 28)]
Fuse box [No.2] United MCU [CN-51 (01)]
Fuse box [No.3] DEF module [CR-51 (2, 3)]
Urea purging lamp [CL-40 (1)]
Fuse box [No.4] l/conn [CN-5 (59)] l/conn [CN-10 (3)] Room lamp [CL-1 (2)]
Door switch [CS-1]
I/conn [CN-10 (2)] RMS [CN-125B (6)]
Radio & USB player [CN-27A (8)]
Fuse box [No.5] Line heater [CR-52 (30, 86)
Fuse box [No.6] Master switch [CS-74B] l/conn [CN-5 (36)] Start switch [CS-2A(1)]
RMS [CN-125A (1)]
GPS connection [CN-125 (1)]
Power relay [CR-35 (30)]
Fuse box [No.7] l/conn [CN-11 (5)] AC & Heater controller box A (7)
Blower relay (4)
Fuse box [No.8] I/conn [CN-5 (18)] I/conn [CN-17 (5)] Wiper motor controller
[CN-141 (7)]
Wiper motor [CN-21 (4)]
Fuse box [No.9] I/conn [CN-5 (11)] Cluster [CN-56A (1)]
Hour meter [CN-48 (1)]
I/conn [CN-8 (6)] Jog dial module [CN-363 (1)]
Fuse box [No.10] NOx sensor [CR-50 (3)]
Fuse box [No.11] United MCU [CN-54 (18)]
※ I/conn : Intermediate connector
2) CHECK POINT
Engine Start switch Check point Voltage

① - GND (battery 1EA) 10~12.5V
② - GND (battery 2EA) 20~25V
STOP OFF
③ - GND (battery relay) 20~25V
④ - GND (circuit breaker) 20~25V
※ GND : Ground
4-7
2.0Gr
CR-35
30
2
CN-141 1.0WOr 87a 87 85
R
CN-4 86
3
CONTINUE 24V 7
86 30
2.0WR
1 87
85 87 87a
CN-17 0.75B
POWER BATT
2 85
1
1
2
CONTROLLER
CN-21
LINE HEATER
86
5
4
3
2
1
87
30
85
WIPER MOTOR
87a
30 86
POWER RY
DEF MODULE
3 87a
CR-52
CL-40
CR-51
3 1 2 0.8Br 1.0WOr
5 5 4
2 3
JOG DIAL MODULE

2
CN-363
4 4 5
CS-33
3 4
1.0Gr
1.0Gr
5
UREA PURGING LAMP
2.0LgR
R
0.75W
0.8R
0.75LgR
R 3 3 6
4 5 0.8Br
4 2 2 12
5 6 0.8G 0.8G 1.0OrW
1 1 13
6 M 2 6 7
WIPER MOTOR
14
EM'CY STOP SW
8
0.8BrW
15
16 1.5R MCU
30A 2
1.5WOr ROOM LAMP/RADIO B+
CN-427 10A 4
POWER CIRCUIT
0.8W
IG 24V 1 2.0Y AIR CON / HEATER
CN-5 20A 7
GND 2 1.0RBr WIPER
1 10A 8
h
CAN (HIGH) 3 1.0GY CLUSTER B+
2 10A 9
6
B+
READER
CAN (LOW) 4
CN-8
3
1
2
3
MCU CONT.
CN-48
4 20A 13
1.5OrR EPPR
20A 11
1.0RG
0.8Y
CN-125A 10
HOER METER
1.2W 0.75BW 1.0GY RDU IG
BATTERY POWER 1 10A 14
11 RADIO IG
1.2G 10A 15
RMS
KEY "IG" 2 12 CLUSTER IG
10A 16
17 AAVM / SIREN
0.75R 1.0RBr 10A 17
18 PROPORTIONAL
10A 18
6 19
5
C ST
CS-2A 20
0.75BW
6 SOLENOID
21 10A 19
3 5
22
9
8
7
6
5
4
3
2
1
12
11
2
10
B
1 WIPER
ACC BR
4 10A 20
23
2.0WY
IG(POWER RY)
H
4 3
L
L
L
L
L
Y
B
CN-56A
W
24
Gr
0.8YOr
WL
SAFETY SOL
WR
RW
0, I
2 10A 26
5
4
3
2
1
1.2W 25 SEAT HEAT
1 20A 27
START KEY SW
26
CR-50
I 0 H
GND
4
IG 24V
0.75B
0.75B
0.75B
0.75B
0.75B
32 SOLENOID
0.75W
0.75W
0.75W
0.75W
0.75W
CAN2 HI
CAN1 HI
5
CAN1 LO
20A 28
CAN2 LO
BATT.24V
AUX GND
AUX LEFT
1.0G
RS-232 TX
RS-232 RX
1.0W
33 CIGAR
AUX RIGHT
1
2
20A 29
CLUSTER
1
4-8
NOx SENSOR
34
52
51
50
49
73
28
27
26
25
3
4
1
2
ECM
BREAKER
CN-93
35 20A 31
1.0W 2.0W
CONVERTER
2
36
4
1
3
10A 32
CN-27A
CN-125
37
GPS CONN
ACC 1 FUEL FILLER PUMP
R
38 20A 33
ILL- 2 0.75YBr 1.0G
BATTERY(-)
BATTERY(-)
BATTERY(-)
BATTERY(-)
BATTERY(-)
BATTERY(+)
BATTERY(+)
BATTERY(+)
BATTERY(+)
BATTERY(+)
39
3B
NC 3 1.0G 1.0WOr
40
SPK FRT RH- 4
42
SPK FRT LH- 5
43 CN-100 8.0W
TEL MUTE 6
44 5.0R
ANT 12V 7
3B
0.75Y 45 HEAD LAMP

20A 21
BACK UP+ 8 52
ILL+ 9
1.2G
1.2G
53
NC 10 HORN
0.75Y
54 10A 24
WORK LAMP
SWITCH
1
2
SPK FRT RH+ 11 57 30A 34
CABIN LAMP
5
4
1
9
8
7
6
MASTER
3
CR-1
12
11
10
DO-3
RADIO & USB PLAYER

REMOCON+ 12 58 30A 36
0.75Y 1.5WOr FUEL HEATER
CN-10
REMOCON GND 13 59 30A 22
BATT RY
AC / HEATER
60 L 20A 25
SPK FRT LH+ 14 OPTION, SWITCH
20A 30
1.2Gr
NC S
90A
15
60A
0.8Y
3
1.2Gr
RMS
GND 16 L S 3.0W ECM
IG(BATTERY RY)
CN-11 30A 1
CN-125B
1
2
ECM
1 5A 12
CL-1
1.0OrW
2
1
2
6 DOOR SW
1
2
2
60R
CS-1
DOOR SW
CS-74
3
CS-74B
1.5Gr DEF MODULE
ROOM LAMP
1
2
15A 3
1
2
4 2.0LgR LINE HEATER

1A 2.0Y 15A 5
5.0R
CN-60
CN-95
5.0R
2.0W
2.0Gr
BATTERY(+) 7 5 2.0WY DEF&SCR

10A 10
BOX (A)
(12VX2)
6
5R
5R
START, AIR-HEAT
8W
8W
CIRCUIT BREAKER
BATTERY
20A 23
CONTROL
7
8
1
60B
CN-51, 52, 53 & 54

1 2 1 2.0Gr START KEY
1.0R 30A 6
BATT POWER 24V 51-01 2.0RW
2
RELAY
3
1 0.75OrR
BLOWER
4 EPPR POWER 24V 54-18
5W
210A4EL05
4
3 4
UNITED MCU
1
1
2
CN-258
CN-263
POWER
AIR COMP
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery (+) terminal Battery relay [CR-1] Circuit breaker [CN-60] Master switch [CS-74]
Fuse box [No.6] Master switch [CS-74B] I/conn [CN-5 (36)] Start switch [CS-2A (1)]
Power relay [CR-35 (30)]
(1) When start key switch is in ON position
Start switch ON [CS-2A (2)] I/conn [CN-5 (39)]
Battery relay [CR-1] Battery relay operating (all power is supplied with the electric component)
Start switch ON [CS-2A (3)] GPS conn [CN-125 (2) → (4)
I/conn [CN-5 (40)] Power relay [CR-35 (86) → (87)]
Fuse box [IG (power)]
l/conn [CN-4 (4)]
Emergency engine stop sw [CS-33 (2)→(1)] l/conn [CN-4 (13)]
Fuse box [No. 12] Engine ECM [CN-93 (5)]
Reader [CN-427 (1)]
RMS [CN-125A (2)]
(2) When start key switch is in START position

Start switch START [CS-2A (6)] I/conn [CN-5 (35)] Anti-restart relay [CR-5 (2) → (5)]
l/conn [CN-2 (7)] Start relay [CR-23 (2)] Starter motor operating
2) CHECK POINT

① - GND (battery)
② - GND (start switch)
③ - GND (battery relay M4)
OPERATING START ④ - GND (starter B+) 20~25V
⑤ - GND (starter M)
⑥ - GND (start relay)
⑦ - GND (battery relay M8)
4-9
CN-4 CR-35
1 2.0Gr
30
1.0WOr 87a 87 85
2 86
2.0WR
CN-427 3 87
0.8Br 1.0WOr 0.75B
0.8W 5 5 4
IG 24V 1 85
30 86
POWER RY
4 4 5 87a
CS-33
GND 2
3 3 6
CAN (HIGH) 3
12 MCU
READER
CAN (LOW) 2 2
4 0.8G 1.0OrW 30A 2
1 1 13 ROOM LAMP/RADIO B+
10A 4
EM'CY STOP SW
CN-125 CN-125 14
77 R 1.0G
4 4 AIR CON / HEATER
0.75B 15 20A 7
3 3 WIPER
77 R 1.0R 16 10A 8
2 2 CLUSTER B+
1.0W 10A 9
B+
GPS CONN
1 1 CN-5
1 MCU CONT.
20A 13
2 EPPR
20A 11
CN-125A RDU IG
1.2W 3 10A 14
POWER BATTERY 1
STARTING CIRCUIT
1.2G RADIO IG
4 10A 15
KEY "IG" 2
RMS
CLUSTER IG
22 10A 16
AAVM / SIREN
23 10A 17
6 PROPORTIONAL
5 10A 18
ST C
CS-2A 24
1.2BOr
6 31
3 5 32 SOLENOID
2 10A 19
BR ACC
1 4 33
1.2R
H
4 3 34 WIPER
0.8YOr 1.0BR 0.75BOr 10A 20
0, I
START SW
IG(POWER RY)
2 35
1.2W 1.0W 2.0W SAFETY SOL
1 36 10A 26
H 0 I
SEAT HEAT
37 20A 27
38
0.75YBr 1.0G SOLENOID
2
39 20A 28
1.0G 1.0WOr CIGAR
CN-51, 52, 53 & 54 40 20A 29
0.75WG 1.0B 1.5B
ANTI RESTART RY 52-15 44 BREAKER
20A 31
59 CONVERTER
0.75WY 10A 32
ALT VOLTAGE 51-15 60
FUEL FILLER PUMP
UNITED MCU
20A 33
4-10
0.75LY
8.0W
0.75BY
1.5B
0.75WY
5.0R
HEAD LAMP
8
6
7
4
3
2
1
9
5
15
14
13
12
11
10
20A 21
1.2B
1.2B
1.2G
1.2G
CN-2
1.2W
1
1.2B
2
HORN
1.2GrW
10A 24
1.2BOr
SWITCH
CR-1
DO-3
WORK LAMP
MASTER 30A 34
CABIN LAMP
7
30A 36
BATT RY
6
FUEL HEATER
30A 22
AC / HEATER
L 20A 25
1.0BY
OPTION, SWITCH
S 20A 30
2
1
90A
60A
L S
RS-1
3W/300
ECM
IG(BATTERY RY)
30A 1
2
1
1.0Or ECM
5A 12
1.0OrW
1
2
1
2
CR-23
CS-74
CS-74B
START RY
DEF MODULE
CR-24
1
2
1
2
15A 3
4
LINE HEATER
60R
5.0R
CN-60
CN-95
5.0R
15A 5
2.0W
2.0Gr
0.75Or
1.0LgY
DEF&SCR
0.75WB
15R
15R
0.75OrW
GLOW PLUG RY
10A 10
5R
5R
1.0LY
8W
8W
1.0Lg START, AIR-HEAT

CIRCUIT BREAKER
5
0.75Lg
0.75LY
1.0LgY
0.75BY
0.75YR 20A 23
0.75WB
0.75WG
0.75BrG
0.75BrG
0.75LgY
0.75OrW
76
75
83
5
46
67
CN-93
3
3
3
4
4
4
2
2
2
5
5
5
1
1
1
(12VX2)
BATTERY
2.0Gr START KEY
15 R
CR-5
1.2W
30A 6
B+
CR-39
CR-36
2.0RW
4
4
4
CN-45
3
3
3
5
5
5
60B
CAN 1_Lo
CN-80
B+
2
1
2
1
2
1
1
HS_RETURN
ALT
ECM
M
5W
AIR HEATER RY
CN-74
STARTER
PRE-HEAT RY
GLOW PLUG
3~
KEY SWITCH "ON"
1
ANTI-RESTART RY
REMOTE ACCEL SE
1
G
2
U
POWER
STARTER LOCKOUT RY
CN-263
CN-258
STARTER LOCKOUT SIG

AIR COMP
210A4EL06
3. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the start switch to the
ON position.
Charging current generated by operating alternator flows into the battery through the battery relay
[CR-1].
The current also flows from alternator to each electrical component and controller through the fuse box.
1) OPERATING FLOW
(1) Warning flow
Alternator "L" terminal I/conn [CN-2 (13)] United MCU alternator voltage [CN-51 (15)]
Cluster charging warning lamp (Via CAN interface)
(2) Charging flow

Alternator "B+" terminal Starter [CN-45 (B+)] Battery relay (CR-1)
Battery (+) terminal
Circuit breaker [CN-60] Master switch [CS-74] Fuse box [B+]
Circuit breaker [CN-95] Fuse box [IG, battery] Power relay [CR-35 (30→87)]
Fuse box [IG, power]
2) CHECK POINT

① - GND (battery voltage)
② - GND (battery relay)
OPERATING ON ③ - GND (alternator B+ terminal) 20~25V
④ - GND (alternator L terminal)
⑤ - GND (United MCU)
※ GND : Ground
4-11
MCU
2.0Gr
CR-35 30A 2
30 ROOM LAMP/RADIO B+
87a 87 85 10A 4
86
2.0WR
87 AIR CON / HEATER
20A 7
0.75B WIPER
85 10A 8
0.75B
0.75B
30 86 1.0GY CLUSTER B+
POWER RY
0.75BW
0.75BW
0.75VBr
0.75VBr
87a 10A 9
B+
MCU CONT.
9
8
7
6
5
4
3
2
1
12
11
5
4
1
9
8
7
6
10
60
59
58
57
24
23
22
21
20
19
11
10
20A 13
CN-5
EPPR
20A 11
CN-56A
L
L
L
L
L
RDU IG
Y
B
W
Gr
10A 14
WL
WR
RW
RADIO IG
10A 15
1.0Gr
0.75B
1.0GY
1.0Gr CLUSTER IG
10A 16
GND
AAVM / SIREN
IG 24V
10A 17
CAN2 HI
CAN1 HI
CAN1 LO
CAN2 LO
PROPORTIONAL
BATT.24V
AUX GND
AUX LEFT
RS-232 TX
RS-232 RX
10A 18
AUX RIGHT
CLUSTER
CHARGING CIRCUIT
SOLENOID
10A 19
WIPER
10A 20
IG(POWER RY)
SAFETY SOL
10A 26
SEAT HEAT
20A 27
SOLENOID
20A 28
6 CIGAR
5 CS-2A
ST C
20A 29
CN-51, 52, 53 & 54 6
BREAKER
3 5 20A 31
2
CONVERTER
B
10A 32
BR ACC
0.75WY 1 4
ALT VOLTAGE 51-15
H
4 3 FUEL FILLER PUMP
20A 33
START SW
0, I
2
UNITED MCU
1.2W
1.5B
1
H 0 I
0.75WY
5
1.0W
8
6
7
4
3
2
1
9
5
15
14
13
12
11
10
CN-2
8.0W
1.2B
1.2B
4-12
5.0R
36
CN-5
1.2B
HEAD LAMP
1.2W
1
2
20A 21
1.2BOr
CR-1
DO-3
2.0W
BATT RY
HORN
10A 24
WORK LAMP
SWITCH
2
1
30A 34
CABIN LAMP
MSATER
30A 36
FUEL HEATER
30A 22
3W/300
AC / HEATER
2
1
L 20A 25
RS-1
OPTION, SWITCH
CR-23
20A 30
S
90A
60A
START RY
L S ECM
IG(BATTERY RY)
30A 1
ECM
5A 12
1
2
1
2
CS-74
CS-74B
DEF MODULE
1
2
15A 3
1
2
1
LINE HEATER
15 R
15A 5
5.0R
CN-60
CN-95
5.0R
2.0W
2.0Gr
60R
DEF&SCR
10A 10
4
5R
5R
1.2W
START, AIR-HEAT
8W
8W
CIRCUIT BREAKER
20A 23
3
M
L
B+
B+
ALT
2.0Gr START KEY
CN-45
(12VX2)
30A 6
BATTERY
CN-74
2.0RW
3~
M
U
60B
STARTER
5W
1
1
2
CN-263
POWER
CN-258
AIR COMP
210A4EL07
4. HEAD AND WORK LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.21) Head light relay [CR-13 (30, 86)]
Fuse box (No.34) Work light relay [CR-4 (30, 86)]
Fuse box (No.14) RDU membrane controller [CR-376 (1)]
(1) Head light switch ON

Head light switch ON [CN-376 (13)] Head light relay [CR-13 (85) → (87)]
Head light ON [CL-3 (1), CL-4 (1), CL-24 (1)]
l/conn [CN-7 (1)] Cigar lighter [CL-2]
l/conn [CN-5 (60)] Radio & USB player illumination ON [CN-27A (9)]
(2) Work light switch ON

Work light switch ON [CN-376 (4)] Work light relay [CR-4 (85) → (87)]
l/conn [CN-12 (1)] Work light ON [CL-5 (1), CL-6 (1)]
2) CHECK POINT
① - GND (fuse box)
② - GND (switch power output)
③ - GND (head light relay)
④ - GND (head light)
STOP ON 20~25V
⑤ - GND (fuse box)
⑥ - GND (switch power input)
⑦ - GND (work light relay)
⑧ - GND (work light)
※ GND : Ground
4-13
NC
NC
NC
NC
NC
MCU
GND
GND
30A 2
IG 24V
WIPER
ROOM LAMP/RADIO B+
10A 4
BEACON
WASHER
CAN 2_HI
CAN 2_LO
INT WIPER
HEAD LIGHT
AIR CON / HEATER
CABIN LIGHT
WORK LIGHT
20A 7
CL-2
WIPER
10A 8
CIGAR LIGHTER
CLUSTER B+
10A 9
B+
1.2B
1.2ROr
MCU CONT.
20A 13
10
11
9
3
2
5
4
1
27
26
18
12
17
14
15
13
EPPR
16
20A 11
1.0WBr RDU IG
CN-376
10A 14
RADIO IG
RDU MEMBRANE CONTROLLER

10A 15
CLUSTER IG
0.75W
10A 16
0.75B
0.75B
AAVM / SIREN
0.75Br
5
4
1
9
8
7
6
3
15
14
13
12
11
10
10A 17
2
6
PROPORTIONAL
0.75WBr
CN-7
5
10A 18
CN-5 1.0B
1.5B
1 SOLENOID
0.75ROr
10A 19
2
3 WIPER
10A 20
IG(POWER RY)
4
5 SAFETY SOL
10A 26
SEAT HEAT
6 20A 27
7
HEAD AND WORK LIGHT CIRCUIT
SOLENOID
8 20A 28
CIGAR
9 20A 29
10 BREAKER
20A 31
11 CONVERTER
10A 32
12
13 FUEL FILLER PUMP
20A 33
14
15
16
4-14
17
18
19
2.0VW HEAD LAMP
20 20A 21
CN-27A 21
ACC 1 41 HORN
10A 24
ILL- 2 42 2.0RL WORK LAMP
30A 34
NC 3 43 CABIN LAMP
1
30A 36
FUEL HEATER
7
SPK FRT RH- 4 44 30A 22
8
2.0B
AC / HEATER
2.0RL
2.0RG
0.75W
2.0RG
SPK FRT LH- 5 45 20A 25
0.75RL
1
OPTION, SWITCH
TEL MUTE 6 51 20A 30
1.5B
1.5B
1.5B
1.5R
1.5R
1.5R
ANT 12V 7 58
1.5LY
0.75Br
1.5VW
ECM
0.75GL
4
IG(BATTERY RY)
BACK UP+ 8 59 30A 1
87
85
86
30
ECM
87a
0.75GW 0.75ROr
CR-4
60 5A 12
ILL+ 9
1
2
NC 10
30
CN-12
87a 87
SPK FRT RH+ 11 DEF MODULE
86
85
1
2
2
1
15A 3
2
1
87
85
86
30
87a
CL-4
REMOCON+ 12 LINE HEATER

CL-3
15A 5
CR-13
CL-24
WORK LAMP RY
RADIO AND USB PLAYER

REMOCON GND 13 DEF&SCR
10A 10
30
START, AIR-HEAT
87a 87
SPK FRT LH+ 14 20A 23

86
85
NC 15
HEAD LAMP-RH
HEAD LAMP-LH
HEAD LAMP RY
GND 16
START KEY
30A 6
HEAD LAMP REAR
2
1
2
2
2
1
1
CL-6
CL-5
CL-5
CL-6
WORK LAMP
WORK LAMP
210A4EL08
5. BEACON LAMP AND CAB LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.30) Beacon lamp relay [CR-85 (2, 3)]
Fuse box (No.36) Cab light relay [CR-9 (30, 86)]
Fuse box (No.14) RDU membrane controller [CN-376 (1)]
(1) Beacon lamp switch ON
Beacon lamp switch ON [CN-376 (15)] Beacon lamp relay [CR-85 (1)→ (5)]
I/conn [CN-5 (50)] I/conn [CN-10 (10)] Beacon lamp ON [CL-7]
(2) Cab light switch ON
Cab light switch ON [CN-376 (5)] Cab lamp relay [CR-9 (85) → (87)]
I/conn [CN-5 (34, 38)] I/conn [CN-10 (11)] Cab light ON [CL-8 (2)]
I/conn [CN-10 (12)] Cab light ON [CL-9 (2), CL-10 (2)]
2) CHECK POINT
② - GND (beacon lamp relay)
③ - GND (switch power output)
④ - GND (beacon lamp)
STOP ON 20~25V
⑤ - GND (fuse box)
⑥ - GND (cabin light relay)
⑦ - GND (switch power input)
⑧ - GND (cab light)
※ GND : Ground
4-15
MCU
30A 2
ROOM LAMP/RADIO B+
10A 4
M
NC
NC
NC
NC
NC
GND
GND
AIR CON / HEATER
20A 7
IG 24V
WIPER
WIPER
BEACON
WASHER
2
2
1
1
1
2
CAN 2_HI
10A 8
CAN 2_LO
CL-7
BEACON LAMP
INT WIPER
CLUSTER B+
CL-9
CL-8
CL-10
CAB LIGHT
10A 9
HEAD LIGHT
B+
CABIN LIGHT
WORK LIGHT
2B
2V
MCU CONT.
2V
2B
2B
2V
20A 13
1.2B
EPPR
1.2BrW
20A 11
1.0WBr RDU IG
10A 14
4
RADIO IG
10
11
9
3
2
5
4
1
10A 15
27
26
18
12
17
14
15
13
16
CLUSTER IG
10A 16
CN-376
AAVM / SIREN
10A 17
8
5

PROPORTIONAL
10A 18
0.75B
0.75B
0.75G
3
0.75GR
7
0.75WBr
1.0B SOLENOID
10A 19
2B
2B
2V
2V
WIPER
1.2BrW
10A 20
IG(POWER RY)
SAFETY SOL
5
4
1
9
8
7
6
3
CN-5 10A 26
12
11
10
SEAT HEAT
CN-10
1 20A 27
2
SOLENOID
1.0B
2.0B
1VW
3 20A 28
2.0VW
1.0BrW
CIGAR
4 20A 29
BEACON LAMP AND CAB LIGHT CIRCUIT
5 BREAKER
20A 31
6 CONVERTER
10A 32
28
2.0B 1.5B
29 FUEL FILLER PUMP
20A 33
4-16
30
31
32
33
2.0VW 1.5V
34
35 HEAD LAMP
20A 21
36
1.0B 1.5B
37
1.0VW 1.5V
1
38 HORN
10A 24
39 WORK LAMP
30A 34
2.0R CABIN LAMP
49 30A 36
1.0BrW 1.5GrW FUEL HEATER
50 30A 22
AC / HEATER
51 20A 25
1.5BrG OPTION, SWITCH
20A 30
52
6
53 ECM
IG(BATTERY RY)
30A 1
2.0R
2
1.5BrG
56 ECM
1.5GrW
0.75GR
0.75BrG
5A 12
2.0V
1
0.75R
0.75G
57
58
59 DEF MODULE
15A 3
3
4
2
5
1
LINE HEATER
87
85
86
30
60 15A 5
87a
CR-9
DEF&SCR
CR-85
10A 10
4
START, AIR-HEAT
20A 23
3
5
2
1
30 86
87a 87 85
START KEY
30A 6
CAB LIGHT RELAY
BEACON LAMP RELAY
210A4EL09
6. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
(1) Key switch ON
Fuse box (No.14) RDU membrance controller [CN-376 (1)]
Fuse box (No.8) I/conn [CN-5 (18)] I/conn [CN-17 (5)] Wiper motor controller [CN-141 (7)]
Wiper motor [CN-21 (4)]
Fuse box (No.20) I/conn [CN-5 (16)] l/conn [CN-17 (4)] Wiper motor controller [CN-141 (6)]
Low wiper motor [CN-407 (3)]
Washer pump [CN-22 (2)]
(2) Wiper switch ON (Intermittent)
Wiper switch ON [CN-376 (12)] I/conn [CN-5 (20)] I/conn [CN-17 (8)]
Wiper motor controller [CN-141 (10)→(3)] Wiper motor [CN-21 (6)] Intermittently operating
(3) Wiper switch ON (continual)
Wiper switch ON [CN-376 (3)] I/conn[CN-5 (15)] I/conn[CN-17 (2)]
Wiper motor controller [CN-141 (2) → (4)] Wiper motor [CN-21 (2)] Continual operating
(4) Washer switch ON
Washer switch ON [CN-376 (11)] I/conn [CN-5 (17)] I/conn [CN-17 (7)]
Wiper motor controller [CN-141 (9) → (8)] I/conn [CN-17 (6)] I/conn [CN-5 (19)]
Washer pump [CN-22 (1)] Washer operating
Wiper switch ON [CN-376 (3)] I/conn[CN-5 (15)] I/conn[CN-17 (2)]
Wiper motor controller [CN-141 (2) → (4)] Wiper motor [CN-21 (2)] Continual operating
(5) Auto parking (when switch OFF)
Switch OFF [CN-376 (3,12)] Wiper motor parking position by wiper motor controller
2) OPERATING FLOW (LOW WIPER)

(1) Key switch ON
Fuse box (No. 30) I/conn [CN-7 (8)] Low wiper switch [CS-79 (1, 5)]
(2) Wiper switch ON (1st)
Wiper switch ON [CS-79 (1 → 2)] I/conn [CN-7 (5)] Wiper motor [CN-407 (4)] Wiper operating
(3) Wiper switch ON (2nd)
Wiper switch ON [CS-79 (5 → 4)] I/conn [CN-7 (6)] I/conn [CN-18 (2)] Washer pump [CN-407 (2)]
Washer operating
3) CHECK POINT
② - GND (switch power input)
20~25V
③ - GND (wiper power input)
④ - GND (switch power output)
STOP ON
⑤ - GND (switch power output)
0 ~ 5V
⑥ - GND (wiper power switch input)
⑦ - GND (wiper power output) 24V
⑧ - GND (wiper motor) 0 or 24V
※ GND : Ground
4-17
MCU
NC
NC
NC
NC
NC
CN-5
GND
GND
30A 2
ROOM LAMP/RADIO B+
IG 24V
1
WIPER
10A 4
BEACON
WASHER
CAN 2_HI
2
CAN 2_LO
INT WIPER
AIR CON / HEATER
HEAD LIGHT
3
CABIN LIGHT
WORK LIGHT
20A 7
1.0RBr WIPER
4 10A 8
CLUSTER B+
5 10A 9
B+
8
CN-21 6
1
CS-53 MCU CONT.
3 1 7 20A 13
R Or
10
11
EPPR
9
3
2
5
4
1
27
26
18
12
17
14
15
13
16
2 8 20A 11
Gr 1.0WBr RDU IG
CN-376
3 9 10A 14
5 R RADIO IG

4 10 10A 15
WIPER CUT
4 G B CLUSTER IG
5 11 10A 16
0.75B
0.75B
1
L AAVM / SIREN
10A 17
0.75WBr
6
5
12
0.75L
2
0.75Y
6 M 2 PROPORTIONAL
0.75Or
WIPER MOTOR
1.0B 10A 18
13
14
0.75GR 0.75Y
15 SOLENOID
0.75RY 1.0GrW 10A 19
6
16
WIPER AND WASHER CIRCUIT
0.75L 0.75Or
17 1.0GrW WIPER
0.75R 1.0RBr 10A 20
CN-141
IG(POWER RY)
18
7
G 0.75V 1.0LW
FEED BACK 1 19 SAFETY SOL
1
W 0.75YBr 0.75L 10A 26

MOTOR DRIVE SIG 2 CN-17 20 SEAT HEAT
L 1.0BR 1.0B 20A 27
MOTOR DRIVE- 3 1 21
R W 0.8GR
MOTOR DRIVE+ 4 2 22 SOLENOID
20A 28
B B 1.2B CIGAR
GND 5 3 23 20A 29
GrW GrW 0.8RY
VCC 6 4 24
R R 0.8R BREAKER
CONTINUE 24V 7 5 25 20A 31
V V 0.8V CONVERTER
WASHER P/P 8 6 26 10A 32
L L 0.8L
WASHER SIG. 9 7 27
Br Br 0.8YOr FUEL FILLER PUMP
4-18
INT. SIG 10 8 28 20A 33
Or
WIPER CUT SW 11 29
N.C 12 30
WIPER MOTOR CONTROLLER

Gr
3
FEED BACK 13 31
32
6
33
34 HEAD LAMP
20A 21
35
CS-79 HORN
10 10A 24
WORK LAMP
2
10 9 30A 34
9
0.8BOr CABIN LAMP
8 30A 36
0.8B FUEL HEATER
6 7 CN-7 30A 22
5 AC / HEATER
4 6 1 20A 25
0.8BW 1.5BrG OPTION, SWITCH
5 2
2
1
3 20A 30
8
2 0.8BOr
2.0
CN-18
1 4
0.8Br
3 0.75Br
0.8Br
0.75B
3 ECM
IG(BATTERY RY)
4
0.75ROr
1.2Or 0.8BOr 0.75BrOr 30A 1
LOW WIPER SW
1
8 7 2 5 ECM
0.8BOr 0.8BW 0.75BW 5A 12
1
2
3
4
1 6
CN-407
1.2Or
7 1.5BrG
8 DEF MODULE
9 15A 3
LINE HEATER
2 E
3 B
1 Pf
4 Lo
10 15A 5
4
0.75V
0.75V
0.75ROr
0.75ROr
DEF&SCR
11 10A 10
START, AIR-HEAT
M
2
2
1
1
20A 23
2
2
1
1
12
DO-7
13
DO-23
CN-22
DIODE
1.2B 1.5B
CN-407
M
M
DIODE
14
15 START KEY
30A 6
LOW WIPER MOTOR
WASHER PUMP
WASHER PUMP
210A4EL10
CONTROLLER CIRCUIT
IG(POWER RY) IG(BATTERY RY)
B+
ROOM LAMP/RADIO B+
FUEL FILLER PUMP

AIR CON / HEATER
START, AIR-HEAT
OPTION, SWITCH
PROPORTIONAL
HEAD LAMP
FUEL HEATER
AAVM / SIREN
DEF MODULE
LINE HEATER
CONVERTER
AC / HEATER
SAFETY SOL
CLUSTER B+
WORK LAMP
CABIN LAMP
CLUSTER IG
MCU CONT.
START KEY
SEAT HEAT
SOLENOID
SOLENOID
BREAKER
DEF&SCR
RADIO IG
ECM
RDU IG
WIPER
WIPER
CIGAR
HORN
MCU
EPPR
DEF
ECM
NOx SENSOR MODULE
20A 21
10A 24
30A 34
30A 36
30A 22
20A 25
20A 30
5A 12
10A 10
20A 23
20A 13
20A 11
10A 14
10A 15
10A 16
10A 17
10A 18
10A 19
10A 20
10A 26
20A 27
20A 28
20A 29
20A 31
10A 32
20A 33
2
4
7
8
9
30A 1
30A 6
15A 3
15A 5
1
30A
10A
20A
10A
10A
5
5
3
3
CR-51
4
4
CR-50
2.0WY
1.0Or
1.5Gr
3.0W
5
4
2
1
5
2
4
3
0.75BR
1.0GrB
1.0RBr
2.0WY
0.75B
1.0Gr
1.0Gr
2.0Br
CL-40
0.75W
1
0.75GB
2
UREA LAMP(LED)
0.75L
CN-174
CN-56A A A
RW 0.75Y
BATT.24V 1 B
WR
IG 24V 2 C B
CD-16 B
RETURN C
0.75BG GND
Y
3
0.75L CN-5 RESISTOR
0.75WR CAN1 HI 4
SIG B Gr 0.75Y 1 CN-93
0.75V CAN1 LO 5 0.75W
SUPPLY A WL 2 1 BATTERY(+)
CAN2 HI 6 0.75W
SENSOR, WATER LEVEL W 3 25 BATTERY(+)
CAN2 LO 7 0.75W
L 4 26 BATTERY(+)
CD-10 RS-232 RX 8 0.75W
1.0YG L 5 27 BATTERY(+)
RETURN 1 RS-232 TX 9 0.75W
1.0LW L 6 28 BATTERY(+)
AIR TEMP 2 AUX LEFT 10 0.75Y 0.75Y
1.0LOr L 7 73 BATTERY(-)
SUPPLY POWER 3 AUX RIGHT 11 0.75L 0.75L
1.0VW L 8 49 BATTERY(-)
AIR PRESS 4 AUX GND 12
9 50 BATTERY(-)
SENSOR, PRS TEMP CLUSTER 51 BATTERY(-)
52 BATTERY(-)
0.75L
AT5 22 CAN 1_ Hi
1.0W 0.75Y
DEF PUMP MOTOR SUPPLY 9 46 CAN 1_Lo
1.0RB 0.75Or
DEF PUMP MOTOR RETURN 8 5 KEY SWITCH"ON"
1.0BrR
DEF PUMP MOTOR PWM 10 91 DPF REGEN
1.0Or
DEF REVERTING V/V 11 87 DPF INHIBIT
1.0RBr 0.75GB
HS RETURN 12 7 DEF SUPPLY HEATER RY(-)
1.0BG 1.0V
VS OEM RETURN 4 8 OEM SENSOR SUPPLY
1.0V 1.0BG
SUPPLY 2 32 OEM SENSOR RTN
1.0BrY 0.75WR
DEF INJ PRESS 3 35 ENG. COOLANT LEVEL
2.0Or 0.75BR
DEF SUPPLY POWER 5 79 DEF P/P MOTOR RY
2.0B 1.0RB
GND 6 54 DEF P/P RETURN
1.0BrR
SCR & DEF SUPPLY MODULE 6 DEF P/P TEMP
1.0Or
81 A/T POWER RY
AT10A 0.75Br 1.0BrY
4 16 DEF INJ. PRESS SENSOR
POWER 0.75RW
0.75B 63 ACCEL 2 SIG.
RETURN 3 1.0RBr
0.75G
57 HS RETURN
CAN HIGH 2
0.75V
CN-16B 0.75GrG
1 0.75BG 82 DEF TANK HEAT V/V
CAN LOW 1
0.75BG
0.75GY
0.75YR
0.75RW
0.75G
2.5k 38 DEF LINE HEAT1

CN-4300.75V
0.75V
0.75G
2.0Br
TANK LEVEL SENSOR

0.75L
2.0B
2
0.75V 39 DEF LINE HEAT2
3
2.5k 0.75V 40 DEF LINE HEAT3
11
10
12
5
1
2
3
4
7
8
9
6
4
0.75LW 3 DEF LINE HEAT RY-
5
00 00
N2
N5
N1
N3
N4
N6
CN-173 6 0.75L
41 DPF DIF PS
A A 0.75GY
53 DEF DOSING V/V LO
RESISTOR B 0.75G
77 DEF DOSING V/V HI
B C 0.75V
62 DEF LEVEL SENSOR RETURN
AT9A 24 CAC OUT TEMP SIG

0.75RB
POWER 24V 1 42 DEF OUTLET GAS P/S SIG
0.75G
CAN_HI 2 13 WATER IN FUEL
CAN_LO 3 83 STARTER LOCKOUT SIG

RETURN 4 75 AIR HEATER RY
EXHAUST GAS THERM CONT. 76 HS RETURN

CC1D 0.75LW
AT2A 1
67 REMOTE ACCEL SW
NC
POWER 24V 1
14 NC
CAN LO 2
CN-2 5 DEF LAMP
CAN HI 3 1.0RBr 0.8RBr
1
RETURN 4
2 EX2B
OUTLET NOX 0.75VW 2W
AT1E 3 1 AIR PRESS CD-45
0.75LOr 2W
4 2 0.75V
POWER 24V 1 POWER SUPPLY 2
0.75LW 2B 0.75G
2 5 3 AIR TEMP 1
CAN LO 0.75YG 2B
3 6 4 RETURN
CAN HI WIF SENSOR
RETURN 4 7 TBAP AT6
8 0.75RBr
INLET NOX 2
AT11A 0.75G
9 CC8D 0.75GrG
0.8Y 1
RETURN 1 10 1 CAN_HI
DPF PRESS S/S 2
0.75V
11
0.8YB
2 CAN_LO
COOLANT VLV
OUTLET PRESS S/S 3 12 3 NC
POWER 24V 4 13 4 NC
DPF PRESS SENSOR 14
15
CN-126
10
J 9 CN-01 CN-342
0.75WBR
7 1
H 8 0.75GYL
8 2
G 7
0.75Y P1 REG EPPR
N6
N5
F 6
0.75L CN-343
E 5 0.75Or
AT32
9 1
0.75Br
1
2
D 4 10 2
0.75GrL
0.75WBr
0.75Or
0.75Br
C 3
0.75Y
P2 REG EPPR
0.75L
B 2
DEF DOSING A 1
CN-51, 52, 53 & 54
52-02
54-02
54-03
54-26
52-01
54-27
MODULE
SERVICE TOOL
P2 EPPR EPPR +
P1 EPPR EPPR+
P1 EPPR EPPR -
P2 EPPR EPPR-
CAN #1 LO
CAN #1 HI
UNITED MCU
210A4EL11
4-19
MONITORING CIRCUIT
IG(POWER RY) IG(BATTERY RY)
B+
ROOM LAMP/RADIO B+
FUEL FILLER PUMP

AIR CON / HEATER
START, AIR-HEAT
OPTION, SWITCH
PROPORTIONAL
HEAD LAMP
FUEL HEATER
AAVM / SIREN
DEF MODULE
LINE HEATER
CONVERTER
AC / HEATER
CLUSTER B+
SAFETY SOL
WORK LAMP
CABIN LAMP
CLUSTER IG
MCU CONT.
START KEY
SEAT HEAT
SOLENOID
SOLENOID
BREAKER
DEF&SCR
RADIO IG
ECM
RDU IG
WIPER
WIPER
CIGAR
HORN
MCU
EPPR
ECM
20A 21
10A 24
30A 34
30A 36
30A 22
20A 25
20A 30
5A 12
10A 10
20A 23
20A 13
20A 11
10A 14
10A 15
10A 16
10A 17
10A 18
10A 19
10A 20
10A 26
20A 27
20A 28
20A 29
20A 31
10A 32
20A 33
2
4
7
8
9
30A 1
30A 6
15A 3
15A 5
30A
10A
20A
10A
10A
1.0Or
3.0W
CN-174
0.75L
A A
0.75Y
B
C B
RESISTOR
CN-93
0.75W
1 BATTERY(+)
0.75W
25 BATTERY(+)
0.75W
26 BATTERY(+)
0.75W
27 BATTERY(+)
0.75W
28 BATTERY(+)
73 BATTERY(-)
CN-249
0.75Y 49 BATTERY(-)
LVDS POS 1
0.75BL 50 BATTERY(-)
GND 2
0.75L 51 BATTERY(-)
LVDS NEG 3 52 BATTERY(-)
0.75RL 0.75L
POWER 6.5V 4 22 CAN 1_ Hi
0.75Y
NC 5 46 CAN 1_Lo
0.75Or
ADJUST SIGNAL 6 5 KEY SWITCH"ON"
91 DPF REGEN
REAR VIEW CAMERA
CN-5 87 DPF INHIBIT
7 DEF SUPPLY HEATER RY(-)
1 1.0V
CN-16B 8 OEM SENSOR SUPPLY
2 1
0.75BG 1.0BG
32 OEM SENSOR RTN
2.5k 0.75RW
3 2 35 ENG. COOLANT LEVEL
0.75V
4 3 79 DEF P/P MOTOR RY
2.5k 0.75V
5 4 54 DEF P/P RETURN
0.75LW
CN-56B 11 5 6 DEF P/P TEMP
RW 0.8B 0.75R 0.75RL 6 81 A/T POWER RY
CAM 6.5V 1 12
WR 0.8L 0.75BW 0.75BL 16 DEF INJ. PRESS SENSOR
CAM GND 2 13 0.75RW
B 0.8Y 63 ACCEL 2 SIG.
CAM DIFF H 3
0.8V
14 CN-9 57 HS RETURN
WL
CAM DIFF L 4 20 1 82 DEF TANK HEAT V/V
W
CAM 1 5 21 2 38 DEF LINE HEAT1
L 0.75RW 0.75Y
CAM 2 6 22 3 39 DEF LINE HEAT2
L 0.75LB 0.75L
7 40 DEF LINE HEAT3
CAM 3 23 4
L 3 DEF LINE HEAT RY-
CAM SHIELD 8 24 5
00 00
CLUSTER 6 41 DPF DIF PS
7 53 DEF DOSING V/V LO
8 77 DEF DOSING V/V HI
0.75V
9 62 DEF LEVEL SENSOR RETURN
24 CAC OUT TEMP SIG
10
42 DEF OUTLET GAS P/S SIG
11
13 WATER IN FUEL
12 83 STARTER LOCKOUT SIG
CD-10A
0.75BrB 75 AIR HEATER RY
Pa 1.0OrB 76 HS RETURN
0.75LW
67 REMOTE ACCEL SW
AIR CLEANER SW
CN-401
11 IGN 24V
CD-2 12 IGN 24V
0.75BrB
1
1.0P
2
FUEL LEVEL 4 VIDEO_OUTP
16 VIDEO_OUTH
CD-1
0.75BrB 27 RS232_RX
C 1
1.0LgB
2
AAVM
HYD TEMP
1.5B
1.0OrB
1.0LgB
1.0BrB
0.75Y
0.75L
1.0P
1.0B
1.0B
CN-51, 52, 53 & 54
51-25
51-19
52-02
54-13
52-01
51-16
51-10
51-02
AIR CLEANER CLOGGING SW
GND(FOR SENSOR 5V)
HYD. OIL TEMP SENDOR
FUEL LEVEL SENDOR
GND_MAIN
GND_MAIN
CAN #1 Lo
CAN #1 Hi
UNITED MCU
210A4EL12
4-20
4
6
1
3
8
10
B
max
Decel
1
Power
A
CD-10A
C
CS-29
CS-19
Pa
L
B
7
R
9
Gr
2
5
SW
AIR
1
2
A
B
C
2
1
4
8
3
7
10
9
CLEANER
1
2
5
6
1
1
2
2
SAFETY SW
CN-140
CS-4
QUICK COUPLER
AIR COMP RY
CN-263
CS-67
CD-2
QUICK COUPLER SW
1 CS-99
2
FUEL
1
LEVEL
7 8
2
CD-1
C 1 3
2 4 1
2
5 3
HYD TEMP
CN-385
6 4
NC 7 5
5
4
1
9
8
7
6
3
16
15
14
13
12
11
10
7 6
CN-4
NC 6
8
SENSOR 5V 5
9
SOL + 4 9 10
SOL - 10
3
FAN CLUTCH
SENSOR GND 2 AIR-COMP SW
SENSOR OUT 1
SIG
SUPPLY
RETURN
TRAVEL
B
A
C
2
1
CN-241
STRAIGHT
CD-31
OVERLOAD SW
SENSOR POWER(10V) 51-32
ELECTRIC CIRCUIT FOR HYDRAULIC (1/2)
GND(FOR SENSOR 5V) 51-25

POWER_5V OUT 51-33
OVERLOAD PS 52-28
FAN CLUTCH PWM 53-07
CN-113
GND_MAIN 51-02
1
2
GROUND (SENSOR10V) 51-31
FAN SPEED INPUT+ 51-03 BUZZER
TRAVEL STRAIGHT EPPR(-) 54-07

TRAVEL STRAIGHT EPPR(+) 54-25
GND (SENSOR 5V) 51-24

6
9
8
7
10
12
55
54
53
52
31
30
29
28
27
26
25
24
23
11
CN-5
MCU
30A 2
ROOM LAMP/RADIO B+
10A 4
AIR CON / HEATER

20A 7
WIPER
AIR CLEANER CLOGGING SW 54-13 10A 8
CLUSTER B+
10A 9
B+
MCU CONT.
20A 13
EPPR
20A 11
RDU IG
10A 14
RADIO IG
10A 15
CLUSTER IG
10A 16
AAVM / SIREN
10A 17
PROPORTIONAL
10A 18
SOLENOID
10A 19
WIPER
UNITED MCU
10A 20
SAFETY SOL
IG(POWER RY)
10A 26
SEAT HEAT
20A 27
ARM REGEN SOL 52-07
POWER BOOST SOL 53-10 1.0Or
1.5 SOLENOID
20A 28
CIGAR
20A 29
BREAKER
20A 31
4-21
CONVERTER
10A 32
FUEL FILLER PUMP

BOOM PRIORITY ARM EPPR- 54-05 20A 33
P1 REGULATOR EPPR(+) 54-27
P2 REGULATOR EPPR(+) 54-26
P2 REGULATOR EPPR(-) 54-03
MAIN PUMP P2 PS 51-14

HEAD LAMP
20A 21
BOOM DOWN PS 52-31

HORN
10A 24
WORK LAMP
SWING PS 52-18 30A 34
CABIN LAMP
30A 36
NEGATIVE2(N2) PS 51-28 FUEL HEATER
30A 22
GROUND(EPPR) 54-33 AC / HEATER
20A 25
BOOM UP PS 52-23 OPTION, SWITCH
20A 30
TRAVEL SPEED SOL 52-05
ECM
30A 1
ECM
5A 12
IG(BATTERY RY)
OPT PILOT PS 52-21
DEF MODULE
HYD. OIL TEMP SENDOR 51-16 15A 3
LINE HEATER
15A 5
DEF&SCR
10A 10
FUEL LEVEL SENDOR 51-19 START, AIR-HEAT
20A 23
BUCKET IN PILOT PRESSURE 53-15
ARM IN PS 51-21
START KEY
MAIN PUMP P1 PS 52-22 30A 6
TRAVEL BUZZER 52-09

P1 REGULATOR EPPR(-) 54-02
P1 REG PS 51-22
TRAVEL PEDAL PS(RH) 52-24

BUCKET OUT PS 51-29
ARM OUT PS 51-27
BOOM PRIORITY EPPR+ 54-34
BOOM PRIORITY EPPR- 54-04
CD-86
SUPPLY A
SIG B
OUT
ARM
RETURN C
CD-87
SUPPLY A
SIG B
OUT
RETURN C
BUCKET
CD-85
SUPPLY A
SIG B
BOOM
DOWN
5
3
4
1
9
8
7
6
2
10
RETURN C
CN-01
CD-104
SUPPLY A
SIG B
(RH)
PEDAL
RETURN C
TRAVEL
CD-24
SUPPLY A
SIG B
C
SWING
RETURN
CD-32
SUPPLY A
SIG B
UP
BOOM
RETURN C
2
1
2
1
1
1
2
2
1
1
1
2
2
2
B
A
B
A
B
A
B
A
B
A
B
A
C
C
C
C
C
C
1
2
CD-90
CD-71
CD-37
CD-42
CD-43
CD-70
A
CN-88
CN-70
CN-81
SUPPLY
CD-130
CN-343
CN-342
CN-243
CN-242
CN-135
SIG
SIG
SIG
SIG
SIG
SIG
SIG B
IN
ARM
SUPPLY
SUPPLY
SUPPLY
SUPPLY
SUPPLY
SUPPLY
RETURN C
TRAVEL BZ
RETURN
RETURN
RETURN
RETURN
RETURN
RETURN
BOOM PRI' BOOM PRI'

ARM REGEN
POWER MAX
P2 REG P1 REG
TRAVEL-HIGH
BUCKET 2 PCS (VS ARM) (VS SWING) EPPR EPPR P1 P2 P2 REG P1 REG
IN BOOM PRESS PRESS PRESS PRESS
210A4EL13
4
4
4
6
6
6
1
10
1
10
1
10
3
3
3
8
8
8
LH RH
max
B
2
Decel
2
PRO-
HORN
BREAK
Power
PRO-
3
CS-5
PORTIONAL
PORTIONAL
CS-26
C
CS-29
CS-19
4
7
7
7
9
9
9
L
B
L
5V
R
B
5V
2
5
2
5
2
5
Gr
Gr
SIG
SIG
RETURN
RETURN
10
10
10
4
8
4
8
4
8
1
2
3
7
3
7
3
7
9
9
9
1
2
5
6
1
2
5
6
1
2
5
6
5
4
3
2
1
A
B
C
2
2
2
1
1
1
1
1
2
2
B
A
B
A
C
SAFETY SW
CS-26A
CS-111
SAFETY SOL
CS-4
CS-83
CN-247
BREAKER
CN-68
CR-48
BOOM FLOATING
CS-83
CN-246
SWING LOCK
FINE SWING
SAFETY RELAY
4
6
1
10
78
9
2
5
10
4
8
3
7
9
1
2
5
6
CS-107
5
4
1
9
8
7
6
3
16
15
14
13
12
11
10
STRAIGHT TRAVEL
CN-4
2
1
CN-262
3
3
6
6
4
1
4
1
9
8
7
5
9
8
7
5
2
2
16
15
14
13
12
11
10
15
14
13
12
11
10
CN-6
CN-7
1
2
2
1
CD-105
SUPPLY A MCU
30A 2
CN-262B
SIG B CN-262A 10A 4
ROOM LAMP/RADIO B+
STRAIGHT TRAVEL SOL

C
TRAVEL
RETURN
AIR CON / HEATER
20A 7
PEDAL(LH)
WIPER
10A 8
CN-51, 52, 53 & 54 CLUSTER B+
10A 9
B+
ELECTRIC CIRCUIT FOR HYDRAULIC (2/2)
MCU CONT.
SAFETY SOL 52-06 20A 13
EPPR
20A 11
SENSOR POWER(10V) 51-32 RDU IG
10A 14
GND(SENSOR 5V) 51-25 RADIO IG
10A 15
BOOM CYL. ROD PS 52-25 CLUSTER IG
10A 16
ONE TOUCH DECEL SIG 54-32 AAVM / SIREN
10A 17
1.0YL PROPORTIONAL
ATT CONFLUX SOL. 52-16 10A 18
ATT SAFETY SOL 53-09
ATT BREAKER SOL 52-08 1.5V SOLENOID
10A 19
POWER BOOST SW 54-21 WIPER
10A 20
IG(POWER RY)
SWING FINE SEL SW 53-21

1.0VW SAFETY SOL
GND(SENSOR 10V) 51-31 10A 26
SEAT HEAT
ATT PILOT PS 52-32 20A 27
SOLENOID
20A 28
CIGAR
20A 29
SWING FINE SOL 53-03
1.5BrR BREAKER
20A 31
BREAKER OPER SIG CONVERTER
54-19 10A 32
BOOM FLOAT ROD-TK SOL 53-05
FUEL FILLER PUMP
20A 33
UNITED MCU
TRAVEL PEDAL PS(LH) 52-27
SAFETY LEVER SW 53-16
CAN #2 Lo 51-08
CAN #2 Hi 51-09
HEAD LAMP
20A 21
GROUND(EPPR) 54-33
BOOM FLOAT SEL SW 54-20 HORN

10A 24
BOOM FLOAT HEAD-TK SOL 53-06 WORK LAMP
30A 34
CABIN LAMP
30A 36
FUEL HEATER
ATT RELIEF EPPR2+ 54-17 30A 22
AC / HEATER
ATT RELIEF EPPR2- 54-10 20A 25
OPTION, SWITCH
20A 30
BM DOWN CUTOFF SOL 53-08 ECM

IG(BATTERY RY)
30A 1
ECM
5A 12
SWING LOCK SOL 53-02
2WAY SELECT SOL 52-14
DEF MODULE
15A 3
LINE HEATER
ATT RELIEF EPPR1- 54-09 15A 5
DEF&SCR
10A 10
START, AIR-HEAT
20A 23
CN-366
START KEY
1 30A 6
ATT
2
EPPR2
RELIEF
CN-365
1
ATT
5
3
4
1
9
8
7
6
2
12
11
10
EPPR1
CN-3
RELIEF
CN-369
1
SOL
2
BOOM
DOWN
CUTOFF
CN-368 CN-307
1
UP
ERROR 4
SOL
2 GND 3
BOOM
SIGNAL VOLT(Udc) 2
FLOATING
SIGNAL VOLT(Us) 1
(PVG 32)
CN-367
P/P VALVE
1 CN-13
SOL
2 1
BOOM
DOWN
CN-310
2 2
FLOATING
CD-124 3
EPPR
1
SUPPLY A 4
VALVE-A2
SIG B 5
RETURN C 6 CN-309
ROD PS
2
BOOM CYL.
1
EPPR
CD-69 CN-15
VALVE-A1
SUPPLY A 1 CN-306
SIG B 2 Power ground(+) 12
ATT. PS
RETURN C 3 Power supply(+) 11

4 PWMOUT/DOUT/PVGOUT 10
CN-149 5 PWMOUT/DOUT/PVGOUT 9
1 6 PWMOUT/DOUT/PVGOUT 8
SOL
ATT.
(A1/1B)
8 PWMOUT/DOUT/PVGOUT 6
CN-237
(A3)
ATT.
PWMOUT/DOUT/PVGOUT 3
CN-150
DIN/AIN/FreqIN 2
CONNECTOR 2(C2_BLACK)
1
(A1)
DIN/AIN/FreqIN 1
2
2WAY
PROPORTIONAL VALVE & LEVER
SAFETY CONFLUX SEL SOL
CN-305
CN-66 DIN/AIN/FreqIN 12
1
DIN/AIN/FreqIN 11
(A2)
SOL
2 DIN/AIN/FreqIN 10
Sensor power GND- 9
CN-370 CN-14
5Vdc sensor power+ 8
1 1
DIN 7
FINE
2 2
BREAKER SWING
DIN 6
3
AIN/CAN Shield 5
CN-419 4
CAN(-) 4
CONT SOL A1
1
CAN(+) 3
2
SWING
Power supply(+) 2
CONNECTOR 1(C1_GREY)
Power ground(-) 1
CN-420
A2
1 CN-307
2 C
SWING
B
PARKING PARKING
CN-421 A
A3
1
2
SERVICE TOOL
SWING
PARKING
4-22
210A4EL14
GROUP 3 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check
※ Check specific gravity

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

24V Normal : About 50Ω
Battery relay
100A (continuity) ※ Check contact
1000A (30seconds) Normal : ∞Ω
CR-1
※ Check contact
Glow plug relay
24V 200A Normal : 0.942Ω
(for terminal 1-GND)
CR-24
5
4
1
6
2
3
B
※ Check contact
0, I
B-BR : 24V 1A OFF : ∞Ω(for each terminal)
1
Start key B-ACC : 24V 10A

ON : 0Ω(for terminal 1-3 and 1-2)
H0 I B-ST : 24V 40A
4
3
2
6
5
STC BR ACC H
START : 0Ω(for terminal 1-6)
CS-2
CS-2A
A SUPPLY
B SIG
C RETURN
Pressure
CD-16 CD-7
CD-24 CD-31 CD-32 8~30V ※ Check contact
sensor
CD-37 CD-42 CD-43 CD-69 Normal : 0.1Ω
CD-70 CD-71 CD-85 CD-86
CD-87 CD-90 CD-104 CD-105
CD-124 CD-130
A A
Resistor ※ Check resistance
B 3W
C B A-B : 120Ω
CN-173 CN-174
CN-173
4-23
Glow plug 24V 200A ※ Check resistance

0.25~0.12Ω
CN-80
C 1 ※ Check resistance
Temperature 50˚C : 804Ω
-
sensor 2 80˚C : 310Ω
(hydraulic)
CD-8 100˚C : 180Ω
CD-1
※ Check contact
Air cleaner Pa High level : ∞Ω
pressure switch N.O TYPE
Low level : 0Ω
CD-10A
※ Check resistance
Full : 50Ω 6/12 : 350Ω
2 11/12 : 100Ω 5/12 : 400Ω
10/12 : 150Ω 4/12 : 450Ω
Fuel level - 9/12 : 200Ω 3/12 : 500Ω
sender 1 8/12 : 250Ω 2/12 : 550Ω
CD-2 7/12 : 300Ω 1/12 : 600Ω
Empty warning : 700Ω
3 4 4
Relay 3 Normal : About 200Ω

(air con blower) 2 24V 20A (for terminal 1-3)
1
∞Ω
1 2
(for terminal 2-4)
CR-46
1
2
4 5 1 ※ Check resistance
3 Normal : About 160 Ω
Relay 4
24V 16A (for terminal 1-2)
5 3 2
0Ω(for terminal 3-4)
CR-2 CR-2
CR-5CR-5 CR-36
CR-36 CR-39 ∞Ω(for terminal 3-5)
CR-45 CR-62
CR-48 CR-50 CR-51 CR-85
4-24
30
86
87a 87 85
87 Normal : About 160 Ω
Relay 85 24V 16A (for terminal 85-86)
87a 30 86
0Ω(for terminal 30-87a)
CR-4 CR-4
CR-7 CR-7
CR-9CR-9
CR-13 ∞Ω(for terminal 30-87)
CR-13 CR-35 CR-46
CR-35 CR-46 CR-52
1
2 ※ Check resistance
Solenoid valve CN-66 CN-66
CN-68 CN-68
CN-70
CN-70CN-88 24V 1A Normal : 15~25Ω
CN-88 CN-135 CN-140
CN-135 CN-140 CN-149 CN-150
CN-149 CN-236 CN-237 (for terminal 1-2)
CN-237 CN-262A CN-262B CN-367
CN-368 CN-369 CN-370 CN-419
CN-420 CN-421
2 ※ Check resistance
EPPR valve 700mA Normal : 15~25Ω
CN-241
CN-75 CN-242
CN-133 CN-243
CN-238
(for terminal 1-2)
CN-239 CN-310
CN-309 CN-240 CN-241
CN-342
CN-242
CN-343 CN-365 CN-366
1
Speaker 2 20W
Normal : A fewΩ
CN-23(LH) CN-260
CN-24(RH)
※ Check contact
6
5
2
1
9
3
8
4
10
Normal
2
5
9
Switch ON : 0 Ω(for terminal 2-3, 5-6)

24V 1.5A ∞Ω(for terminal 2-1, 5-4)
(locking type)
OFF : ∞Ω(for terminal 2-3, 5-6)
8
6
1
10
3
4
CS-52
CS-52 CS-67
CS-67 CS-83
CS-73 CS-99
CS-83 0 Ω(for terminal 2-1, 5-4)
CS-99 CS-108
CS-107 CS-107 CS-111
CS-108 CS-111
※ Check disconnection
3
Normal : 1.0Ω
Room lamp 2 ON : 0Ω(For terminal 1-2)
24V 10W ∞Ω(For terminal 1-3)
1
OFF : ∞Ω(For terminal 1-2)
CL-1 0Ω(For terminal 1-3)
4-25
2
Head lamp,
1 24V 65W ※ Check disconnection
Work lamp,
(H3 Type) Normal : 1.2Ω
Cab lamp CL-4CL-4
CL-3 CL-5
CL-5CL-6
CL-6
CL-8 CL-9
CL-8 CL-9 CL-10 CL-24
M 21V 70W ※ Check disconnection

Beacon lamp
(H1 Type) Normal : A fewΩ
CL
-
CL-7
4
3
2 1 M
24V 10A ※ Check resistance
Fuel filler pump 1 2
35ℓ /min Normal : 1.0Ω
CN-61
※ Check operation
Supply power(24V) to terminal
Hour meter 16~32V No.1 and connect terminal No.2
and ground
CN-48
1 ※ Check operation
DC22~28V Supply power(24V) to each
Horn 2
2A terminal and connect ground.
CN-20 CN-25
※ Check contact
Normal : 0Ω(for terminal A-B)
24V 15A
Safety switch ∞Ω(for terminal A-C)
(N.C TYPE)
Operating : ∞Ω(for terminal A-B)
CS-4 0Ω(for terminal A-C)
4-26
Wiper cut ※ Check contact

24V
switch
(N.O TYPE) Normal : 0Ω(one pin to ground)
CS-53
2
Pa ※ Check contact
Receiver dryer 1 24V 2.5A
Normal : ∞Ω
CN-29
10
11
12
13
14
15
16
1
2
3
4
5
6
7
9
8
※ Check voltage
REMOCON GND
Radio &
SPK FRT RH+
SPK FRT LH+

SPK FRT RH-
24V 2A 20~25V
SPK FRT LH-
REMOCON+
BACK UP+
TEL MUTE
USB player
ANT 12V
(for terminal 1-3, 3-8)

GND
GND
ACC
ILL+
ILL-
NC
NC
CN-27A
CN-27
M 2
24V 3.8A ※ Check contact
Washer pump
Normal : 10.7Ω(for terminal 1-2)
1
CN-22 CN-407
3 1
2
5 3
4 ※ Check disconnection
Wiper motor 4
5
24V 2A
Normal : 7Ω(for terminal 2-6)
6 M 2 6
CN-21
3 12V 12V
※ Check voltage
DC/DC 2 24V 12V 3A
1 24V 24V (for terminal 1-2)
Converter GND
12V (for terminal 1-3)
CN-138
4-27
※ Check coil resistance

Normal : About 1MΩ
Cigar lighter 24V 5A 1.4W ※ Check contact
Normal : ∞Ω
Operating time : 5~15sec
CL
-
CL-2
B+
G
L
3~ ※ Check contact
Denso
Alternator U
Normal : 0Ω (for terminal B+-L)
24V 95A
Normal : 24~27.5V
CN-74
M
M
Denso ※ Check contact
Starter
24V 4.8kW Normal : 0.1Ω
B+
CN-45
※ Check contact
1 -
Travel alarm 24V 0.5A Normal : 5.2Ω
2
+
CN-81
1
Air conditioner ※ Check contact
24V 79W
compressor Normal : 13.4Ω
CN-28
※ Check contact
Start relay 24V 300A
Normal : 0.94Ω(for terminal 1-2)
CR-23
4-28
1 M ※ Check resistance
Blower motor 24V 9.5A
2 Normal : 2.5Ω(for terminal 1-2)
2 1˚C OFF
Thermistor Normal : 0Ω(for terminal 1-2),
4˚C ON
(switch) 1 the atmosphere temp :
Over 4˚C
Door switch 24V 2W
Normal : About 5MΩ
CS-1
CS-1
Switch
(power max,
1
one touch ※ Check resistance
24V 6A
decel, horn, 2 Normal : ∞Ω
breaker)
CS-5 CS-19
CS-26 CS-29
※ Check disconnection
2
CN-60 : 60A Normal : 0Ω
Circuit breaker 1 CN-95 : 90A (connect ring terminal and check
CS-60 CN-95
CN-60 CS-95 resist between terminal 1 and 2)
L
S
L S ※ Check disconnection
Master switch 6-36V
Normal : 0.1Ω
1
1
2
CN-74 CN-74B
4-29
1
Quick clamp 24V 200mA
2 -
buzzer 107±4dB
CN-113
1
Socket 2
12V 10A -
CN-139
※ Check contact
6
5
2
1
7
3
9
8
4
10
Normal
9
2
5
ON : 0Ω(for terminal 2-3, 5-6)

Switch 24V 8A
∞Ω(for terminal 2-1, 5-4)
OFF : ∞Ω(for terminal 2-3, 5-6)
10
3
6
4
CS-100
CS-79 0Ω(for terminal 2-1, 5-4)
Fuel heater - -
4
1
2
3
CN-96
1
DEF/AdBlue®
2 - -
line heater
CN-381 CN-382 CN-383
2
WIF sensor 1 - -
CD-45
4-30
1 POWER 24V
2 CAN LO
Nox sensor 3 CAN HI - -
4 RETURN
AT1E AT2A
Temperature
>
2
sensor - -
(A/C) 1
1
DEF/AdBlue®
2 - -
lamp (LED)
CL-40
5V
A
RETURN
Proportional B
SIG - -
valve sensor C
CN-246 CN-247
6
5
2
1
7
3
9
8
4
10
※Check contact
9
2
5
Lower wiper sw 24V 8A Normal

OFF : ∞Ω (for terminal 1-2, 4-5)
10
3
6
4
CS-79
CS-73
1 AIR PRESS
2 POWER SUPPLY
TBAP 3 AIR TEMP - -
4 RETURN
EX2B
4-31
1 RETURN
2 AIR TEMP
Pressure temp
3 SUPPLY POWER -
sensor 4 AIR PRESS
CD-10
2
Coolant valve -
1
AT6
1 RETURN
DPF pressure 2 DPF PS
-
sensor 3 DPF OUTLET PS
4 SUPPLY
AT11A
DEF PUMP MOTOR RETURN
DEF PUMP MOTOR SUPPLY
DEF PUMP MOTOR PWM
DEF SUPPLY POWER

DEF REVERTING V/V
VS OEM RETURN
DEF INJ PRESS

HS RETURN
SUPPLY
SCR and DEF

-
GND
supply module
11
12
10
9
8
4
2
3
5
6
AT5
4 POWER
Tank level 3 RETURN
2 CAN HIGH -
sensor
1 CAN LOW
AT10A
4 SPK(-)
3 SPK(+)
Siren AMP 2 GND -
1 ACC
CN-261
4-32
2
3W/300 ※ Check resistance
Resistor 1 3W
Normal : 300Ω
RS-1
Fuel filler
-
pump
CN-61
1 NC
DEF lamp
14 NC -
connector 5 DEF LAMP
CC1D
1 LVDS POS
2 GND
Camera 3 LVDS NEG
(front, rear, 4 POWER 6.5V -
5 NC
side) 6 ADJUST SIGNAL
CN-249 CN-402 CN-403

CN-404 CN-405
4 SOL +
3 SOL(PWM) -
7 NC
6 NC
Fan clutch 5 SENSOR 5V -
2 SENSOR GND
1 SENSOR OUT
CN-385
2 2
Seat belt sw -
1 1
CS-250
4-33
NC 1
RMS service RX232(2)-RX 2
RX232(2)-TX 3 -
tool PROGRAM DUMP 4
CN-126A
2
Breaker switch 1 -
CS-26A
CAN_H
A
CAN_L
B
Start button GND -
C
CS-2B
1 1
R 77
2 2
3 3
GPS connector
4 4
R 77 -
CN-125
IG 24V 1
GND 2
CAN (HIGH) 3
Reader CAN (LOW) 4 -
CN-427
ERROR 4
GND 3
Proportional SIGNAL VOLT(Udc) 2
-
valve SIGNAL VOLT(Us) 1
CN-307
4-34
1
Dosing pump
2
-
CN-269
1 CAN_HI
Engine side 2 CAN_LO
3 NC
cross over -
4 NC
connector
CC8D
TERMINAL 30 (B+) 1
TERMINAL 31 (GND) 3
DIAGNOSIS 4
DAT 5
Easystart timer S+ 6 -
ADR 7
ADR 8
Temp. Sensor(-) 9
Temp. Sensor(+) 10
CN-267
Exhaust gas
-
temp sensor
AT9A
2
Float switch
1
-
CS-61
4-35
GROUP 4 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-1 AMP 10 I/conn (Frame harness-Pump PS harness) S816-010002 S816-110002
CN-2 AMP 15 I/conn (Frame harness-Engine harness) 2-85262-1 368301-1
CN-3 TYCO 12 I/conn (Frame harness-Pro vlv harness) 174661-2 368537-1
CN-4 AMP 16 I/conn (Console harness LH-Frame harness) 368047-1 368050-1
CN-5 DEUTSCH 60 I/conn (Side harness RH-Frame harness) DRB16-60SAE-L018 DRB14-60PAE-L018
CN-6 AMP 16 I/conn (Console harness RH-Frame harness) 368047-1 368050-1
CN-7 AMP 15 I/conn (Console harness RH-Frame harness) 2-85262-1 368301-1
CN-8 AMP 10 I/conn (Console harness RH-Frame harness) S816-010002 174657-2
CN-9 DEUTSCH 12 I/conn (Frame harness- AAVM harness) DT06-12SA-P021 DT04-12PA-P021
CN-10 DEUTSCH 12 I/conn (Cab harness-Side harness RH) DT06-12S-EP06 DT04-12PA-P021
CN-11 DEUTSCH 8 I/conn (Frame harness-Aircon harness) DT06-8S-EP06 -
CN-12 DEUTSCH 2 I/conn (Frame harness-Boom wire harness) DT06-2S-EP06 DT04-2P-E004
CN-13 AMP 6 I/conn (Frame harness-Boom floating harness) 174262-2 174264-2
CN-14 AMP 4 I/conn (Frame harness-S/f & parking harness) 174257-2 174259-2
CN-15 AMP 10 I/conn (Frame harness-Breaker sol) 174655-2 174657-2
CN-16 AMP 6 Emergency engine start & speed control S816-006002 S816-106002
CN-17 AMP 8 I/conn (Side harness RH-Wiper harness) S816-008002 S816-108002
CN-18 AMP 2 Washer tank 2 174352-2 174354-2
CN-20 DEUTSCH 2 Horn DT06-2S-EP06 -
CN-21 AMP 6 Wiper motor S810-006202 -
CN-22 KET 2 Washer tank 1 MG640605 -
CN-23 KET 2 Speaker-LH MG610070 -
CN-24 KET 2 Speaker-RH MG610070 -
CN-25 DEUTSCH 2 Horn DT06-2S-EP06 -
CN-27A KUM 16 Radio & USB player PK145-16017 -
CN-27B AMP 8 Radio & USB player - 174984-2
CN-28 KUM 2 Aircon compressor MG610320 -
CN-29 KET 2 Receiver dryer MG640795 -
CN-36 - - Fuse & relay box 21Q7-10910 -
CN-45 RING-TERM - Starter motor B+ S820-108000 -
CN-48 KET 1 Hour meter 2-520193-2 -
CN-51 TE 34 United MCU 2-1473285-3 -
CN-52 TE 34 United MCU 4-1437290-1 -
CN-53 TE 26 United MCU 1473416-1 -
CN-54 TE 34 United MCU 4-1437290-0 -
CN-56A AMP 12 Cluster - 174663-2
CN-56B AMP 8 Cluster - 174984-2
4-36
Type Destination
CN-60 YAZAKI 2 Circuit breaker - 7222-4220-30
CN-61 DEUTSCH 4 Fuel filler pump DT06-4S-EP06 DT04-4P-E005
CN-66 DEUTSCH 2 Breaker (A2) DT06-2S-EP06 -
CN-68 DEUTSCH 2 Safety solenoid DT06-2S-EP06 -
CN-70 DEUTSCH 2 Travel high solenoid (A3) DT06-2S-EP06 -
CN-74 RING-TERM 1 Alternator "B+" terminal S820-108000 -
CN-74 RING-TERM 1 Alternator "L" terminal S820-105000 -
CN-80 RING-TERM - Glow plug S820-306000 -
CN-81 DEUTSCH 2 Travel buzzer solenoid DT06-2S-EP06 -
CN-88 DEUTSCH 2 Power max solenoid (A2) DT06-2S-EP06 -
CN-93 DELPHI - ECM 13964577 -
CN-95 YAZAKI 2 Circuit breaker - 7222-4220-30
CN-96 AMP 4 I/conn (Frame harness - Fuel warmer harness) 15300027 2-967402-2
CN-100 KET 1 ECM ground MG640944-5 -
CN-113 KET 2 Buzzer MG651205-5 -
CN-125 Econoseal J 4 RMS connector S816-004002 S816-104002
CN-125A DEUTSCH 12 RMS DT06-12S-P021 DT04-12PA-P021
CN-125B DEUTSCH 8 RMS DT06-8S DT04-8P
CN-126 TE/AMP 10 Service tool 1473416-1 S816-110002
CN-126A DEUTSCH 4 RMS Service tool DT06-4S DT06-4P
CN-135 DEUTSCH 2 Arm regeneration solenoid (A4) DT06-2S-EP06 -
CN-138 FASTEN 3 DC/DC Converter S810-003202 -
CN-139 FASTEN 2 12V socket 172434-2 -
CN-140 DEUTSCH 2 Quick clamp solenoid DT06-2S-EP06 DT04-2P-E005
CN-141 AMP 13 Wiper motor controller 172498-1 -
CN-149 DEUTSCH 2 Attachment safety (A1) DT06-2S-EP06 -
CN-150 DEUTSCH 2 Satety EPPR (A1) DT06-2S-EP06 -
CN-156 DEUTSCH 2 Air seat DT06-2S DT04-2P
CN-157 AMP 1 Antena power S822-014002 -
CN-173 DEUTSCH 3 Resistor DT06-3S-EP06 DT04-3P-EP10
CN-174 DEUTSCH 3 Resistor DT06-3S-EP06 DT04-3P-EP10
CN-237 DEUTSCH 2 Attachment conflux (A3) DT06-2S-EP06 -
CN-241 DEUTSCH 2 Travel straight solenoid (A3) DT06-2S-EP06 -
CN-242 DEUTSCH 2 Boom swing solenoid (A2) DT06-2S-EP06 -
CN-243 DEUTSCH 2 Boom arm solenoid (A1) DT06-2S-EP06 -
CN-246 DEUTSCH 3 Proportional valve-RH DT06-3S DT04-3P
CN-246A DEUTSCH 4 Preheater harness-timer DT06-4S-EP06 -
CN-246B DEUTSCH 4 Preheater harness-timer - DT04-4P-EP06
CN-247 DEUTSCH 3 Proportional valve-LH DT06-3S DT04-3P
4-37
Type Destination
CN-249 DEUTSCH 6 Rear view camera DT06-6S-EP06 DT04-6P-E005
CN-258 KET 1 Air compressor power MG640944-5 MG650943-5
CN-260 MTA 2 Preheater harness-fuse 15A 03 01315 -
CN-261 MTA 2 Preheater harness-fuse 5A 03 01305 -
CN-262 DEUTSCH 2 I/conn (Frame harness - S/travel harness) DT06-2S-EP06 DT04-2P-E005
CN-262A DEUTSCH 2 Straight travel solenoid 1 DT06-2S-EP06 -
CN-262B DEUTSCH 2 Straight travel solenoid 2 DT06-2S-EP06 -
CN-263 DEUTSCH 2 Air compressor relay DT06-2S-EP06 DT04-2P-E005
CN-265 VW 8 Controller 3A0973734 -
CN-267 MOLEX 10 Preheater timer 15-97-5101 -
CN-267A MOLEX 5 Web controller 172646-0513 -
CN-269 TE 2 Dosing pump 282189-1 -
CN-305 DEUTSCH 12 Proportional-connector-1 DTM06-12SA -
CN-306 DEUTSCH 12 Proportional-connector-2 DTM06-12SB -
CN-307 DEUTSCH 3 Proportional-service tool DT06-3S-EP06 DT06-3P-E005
CN-308 AMP 4 Proportional-PVG32 2-967059-1 -
CN-309 DEUTSCH 2 Proportional-EPPR valve-A2 DT06-2S-EP06 -
CN-310 DEUTSCH 2 Proportional-EPPR valve-A1 DT06-2S-EP06 -
CN-342 AMP 2 A1 pump regulator solenoid S816-002002 -
CN-343 AMP 2 A2 pump regulator solenoid S816-002002 -
CN-363 AMP 12 Jog dial module 174045-2 -
CN-365 DEUTSCH 2 Attach EPPR valve-LH DT06-2S-EP06 DT04-2P-E005
CN-366 DEUTSCH 2 Attach EPPR valve-RH DT06-2S-EP06 DT04-2P-E005
CN-367 AMP 2 Boom down floating solenoid 85202-1 DT04-2P-E005
CN-368 DEUTSCH 2 Boom up floating solenoid DT06-2S-EP06 DT04-2P-E005
CN-369 DEUTSCH 2 Boom down cut off solenoid DT06-2S-EP06 DT04-2P-E005
CN-370 DEUTSCH 2 Swing fine control solenoid DT06-2S-EP06 DT04-2P-E005
CN-376 TYCO 23 Membrane controller 7706087-2 -
CN-381 DEUTSCH 2 DEF line heater 1 DT06-2S-EP06 -
CN-385 - 7 Fan clutch 965570 -
CN-401 TE 35 AAVM controller 776164-1 -
CN-402 DEUTSCH 6 Front view camera DT06-6S-P021 DT04-6P-P021
CN-403 DEUTSCH 6 Rear view camera DT06-6S-EP06 DT04-6P-EP14
CN-404 DEUTSCH 6 LH view camera DT06-6S-EP06 DT04-6P-EP14
CN-405 DEUTSCH 6 RH view camera DT06-6S-EP06 DT04-6P-EP14
CN-406 DEUTSCH 3 Service tool DT06-3S-EP05 DT04-3P-E005
CN-407 DEUTSCH 4 Low wiper motor DT06-4S-EP06 DT04-4P-E005
4-38
Type Destination
CN-419 DEUTSCH 2 Swing parking-A1 DT06-2S-EP06 -
CN-427 MOLEX 4 Reader-RMS 039012040 026013096
CN-430 AMP/Econoseal J 12 I/conn (Frame harness - DEF harness) 174661 S816-112002
AT1E TYCO 4 DOC NOx sensor (inlet) 2-1418390-1 -
AT2A TYCO 4 SCR NOx sensor (outlet) 1-1418390-1 -
AT5 TYCO 12 SCR supply module 2-1703639-1 -
AT6 TE 2 Coolant valve 1-967325-3 -
AT9A TYCO 4 DCO thermister 4-1418390-1 -
AT10A DEUTSCH 10 Ureatank level sensor DT06-4S-EP06 -
AT11A DELPHI 4 DEF dif pressure sensor F715600 -
AT32A TYCO 2 DEF dosing valve 1-928405-522 -
CCID DELPHI 14 Cross over connector - 13533441
CC8D DELPHI 4 Engine sensor DT06-4S-CE04 -
EX2B FCI 4 TBAP - 54200419
·Relay
CR-1 RING-TERM - Battery relay ST710289-2 -
CR-2 - 5 Horn relay - -
CR-4 - 5 Working lamp relay - -
CR-5 - 5 Anti restart relay - -
CR-7 - 5 Aircon compressor relay - -
CR-9 - 5 Cabin lamp relay - -
CR-13 - 5 Head lamp relay - -
CR-23 KET 2 Start relay S814-002001 S814-102001
CR-24 RING TERM 1 Preheat relay S822-014000 -
CR-35 - 5 Power relay - -
CR-36 - 5 Preheat relay - -
CR-39 - 5 Starter lock out relay - -
CR-46 - 5 Fuel warmer relay - -
CR-48 - 5 Satety ralay - -
CR-50 - 5 NOX sensor relay - -
CR-51 - 5 DEF module relay - -
CR-52 - 5 Line heater relay - -
CR-85 - 5 Beacon lamp relay - -
·Switch
CS-1 SHUR 1 Door switch S822-014002 S822-114002
CS-2A WP 6 Start switch S814-006100 -
CS-2B DEUTSCH 3 Start button DT06-3S-EP06 DT04-3P-E005
4-39
Type Destination
CS-2C KET 3 BKCU MG651032 -
CS-2D KET 3 Button key - MG641035
CS-4 DEUTSCH 3 Safety switch DT06-3S -
CS-5 DEUTSCH 2 Horn switch - DT04-2P
CS-19 DEUTSCH 2 One touch decel switch - DT04-2P
CS-26 DEUTSCH 2 Breaker switch DT06-2S -
CS-26A AMP 2 Breaker pedal switch S816-002002 S816-102002
CS-29 DEUTSCH 2 Power max switch DT06-2S -
CS-33 AMP 5 Emergency engine stop switch S816-005002 S816-105002
CS-52 CARLING 10 Adjust & dozer switch VC2-01 -
CS-53 AMP 1 Wiper cut switch S822-014002 -
CS-61 AMP 2 Floating switch 174352-2 -
CS-67 CARLING 10 Quick clamp switch VC2-01 -
CS-73 CARLING 10 Swing lock switch VC2-01 -
CS-73A CARLING 10 Fine swing switch VC2-01 -
CS-74 DEUTSCH 2 Master switch DT06-2S-EP06 -
CS-74A KET 2 Power connector MG610558 MG610557
CS-74B DEUTSCH 2 Master switch DT06-2S-EP06 -
CS-79 CARLING 10 Lower wiper switch VC2-01 -
CS-99 CARLING 10 Air compressor switch VC2-01 -
CS-100 CARLING 10 Exhaust system cleaning switch VC2-01 -
CS-107 CARLING 10 Travel straight switch VC2-01 -
CS-108 CARLING 10 Auto grease switch VC2-01 -
CS-111 CARLING 10 Boom floating switch VC2-01 -
CS-250 DEUTSCH 2 Seat switch DT06-2S -
·Light
CL-1 KET 3 Room lamp MG651032 -
CL-2 AMP 1 Cigar lighter S822-014002 S822-114002
CL-3 DEUTSCH 2 Head lamp-LH DT06-2S-EP06 DT04-2P
CL-4 DEUTSCH 2 Head lamp-RH DT06-2S-EP06 DT04-2P
CL-5 DEUTSCH 2 Work lamp-LH DT06-2S-EP06 DT04-2P
CL-6 DEUTSCH 2 Work lamp-RH DT06-2S-EP06 DT04-2P
CL-7 SHUR 1 Beacon lamp S822-014002 S822-114002
CL-8 DEUTSCH 2 Cab light-LH DT06-2S-EP06 DT04-2P
CL-9 DEUTSCH 2 Cab light-RH DT06-2S-EP06 DT04-2P
CL-10 DEUTSCH 2 Cab light-RH DT06-2S-EP06 DT04-2P
CL-24 DEUTSCH 2 Head lamp DT06-2S-EP06 DT04-2P-E005
CL-40 DEUTSCH 2 DEF/AdBlue® purging lamp DT06-2S-EP06 DT04-2P
4-40
Type Destination
·Sensor, sendor
CD-1 AMP 2 Hydraulic oil temp sender 85202-1 -
CD-2 DEUTSCH 2 Fuel sender DT06-2S-EP06 -
CD-10 SUMITOMO 4 Pre temperature sensor 6908-0144 -
CD-10A AMP 2 Air cleaner switch 85202-1 -
CD-16 AMP 3 Water level sensor 1211 0293 -
CD-24 DEUTSCH 3 Swing pilot pressure sw DT06-3S-EP06 -
CD-31 DEUTSCH 3 Overload pressure sensor DT06-3S-EP06 DT04-3P-E005
CD-32 DEUTSCH 3 Boom up pilot pressure sw DT06-3S-EP06 -
CD-37 DEUTSCH 3 2 pcs boom perssure switch DT06-3S-EP06 DT04-3P-E005
CD-42 DEUTSCH 3 A1 pump delivery pressure sw DT06-3S-EP06 -
CD-43 DEUTSCH 3 A2 pump delivery pressure sw DT06-3S-EP06 -
CD-45 DEUTSCH 2 WIF sensor DT06-2S-EP06 -
CD-69 DEUTSCH 3 Attach pressure sensor DT06-3S-EP06 -
CD-70 DEUTSCH 3 N1 pressure sensor (A4) DT06-3S-EP06 -
CD-71 DEUTSCH 3 N2 pressure sensor (A5) DT06-3S-EP06 -
CD-85 DEUTSCH 3 Boom down pilot pressure sw DT06-3S-EP06 -
CD-86 DEUTSCH 3 Arm out pilot pressure sw DT06-3S-EP06 -
CD-87 DEUTSCH 3 Bucket out pilot pressure sw DT06-3S-EP06 -
CD-90 DEUTSCH 3 Arm in pilot pressure sw DT06-3S-EP06 -
CD-104 DEUTSCH 3 RH travel pilot pressure sw DT06-3S-EP06 -
CD-105 DEUTSCH 3 LH travel pilot pressure sw DT06-3S-EP06 -
CD-124 DEUTSCH 3 Boom cylinder rod pressure snensor DT06-3S-EP06 -
CD-130 DEUTSCH 3 Bucket in pilot pressure sw DT06-3S-EP06 -
4-41
2. CONNECTION TABLE FOR CONNECTORS
1) PA TYPE CONNECTOR
No. of
pin Receptacle connector (female) Plug connector (male)
2 5 1 3
1 3 2 5
S811-005002 S811-105002
3 7 1 4
1 4 3 7
S811-007002 S811-107002
4 9 1 5
1 5 4 9
S811-009002 3S811-109002
5 11 1 6
11
1 6 5 11
S811-011002 S811-111002
4 - 42
No. of
Receptacle connector (female) Plug connector (male)
pin
6 13 1 7
13
1 7 6 13
S811-013002 S811-113002
8 1 9
17
17
1 9 8 17
S811-017002 S811-117002
1 21
1 11
21
1 11 1 21
S811-021002 S811-121002
4 - 43
2) J TYPE CONNECTOR
No. of
pin
1 1
2
2 12
S816-002001 S816-102001
2 3 1
3 1 2
S816-003001 S816-103001
3 1 4 2
4 2 3 1
S816-004001 S816-104001
8 5 2
6 3 1
8 5 2 6 3 1
S816-008001 S816-108001
4 - 44
3) SWP TYPE CONNECTOR
No. of
pin
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 23
S814-003000 S814-103000
2 4
1 3
1 3 2 4
S814-004000 S814-104000
4 - 45
No. of
pin Receptacle connector (female) Plug connector (male)
3 6
1 4
1 4 3 6
S814-006000 S814-106000
4 8
1 5
1 5 4 8
S814-008000 S814-108000
4 12
1 9
12
4 12
1 9
S814-012000 S814-112000
3 14
1 11
14
1 11 3 14
S814-014000 S814-114000
4 - 46
4) CN TYPE CONNECTOR
No. of
pin
1 1
S810-001202 S810-101202
2 2
1 1
S810-002202 S810-102202
3 2
1 2 1 3
S810-003202 S810-103202
2 4 1 3
1 3 2 4
S810-004202 S810-104202
4 - 47
No. of
pin
3 6 1 4
1 4 3 6
S810-006202 S810-106202
4 8 1 5
1 5 4 8
S810-008202 S810-108202
4 - 48
5) 375 FASTEN TYPE CONNECTOR
No. of
pin
1 2 1 2
S810-002402 S810-102402
6) AMP ECONOSEAL CONNECTOR

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

No. of
pin
85202-1
4 - 49
8) AMP 040 MULTILOCK CONNECTOR
No. of
pin
12 1 6
7 12
174045-2
9) AMP 070 MULTILOCK CONNECTOR

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

No. of
pin
3 1
6
6 4
1
4 6 3
480003-9
925276-0
4 - 50
11) KET 090 CONNECTOR
No. of
pin
1
2
MG610070
12) KET 090 WP CONNECTORS

No. of
pin
1
2
MG640605
2 1
MG640795
4 - 51
13) KET SDL CONNECTOR
No. of
pin
14
7
6
14
MG610406
4 - 52
14) DEUTSCH DT CONNECTORS
DT 06 - 3S - ★★★★
Modifications (see below)

Number of contacts (P : Pin, S : Socket)
06 : Receptacle, 04 : Plug
Deutsch connectors
※ Modification
E003 : Standard end cap - gray
E004 : Color of connector to be black
E005 : Combination - E004 & E003
EP04 : End cap
EP06 : Combination P012 & EP04
P012 : Front seal enhancement - connectors color to black for 2, 3, 4 & 6pin
No. of
pin
2 1 1 2
2
DT06-2S DT04-2P
1 2 2 1
3 3
DT06-3S DT04-3P
1 4 4 1
2 3 3 2
DT06-4S DT04-4P
4 - 53
No. of
pin
1 6 6 1
3 4 4 3
DT06-6S DT04-6P
5 4 4 5
1 8
8 1
DT06-8S DT04-8P
7 6
6 7
12
12 1 1 12
DT06-12S DT04-12P
4 - 54
15) MOLEX 2CKTS CONNECTOR
No. of
pin
1 2
35215-0200
35215-0200
16) ITT SWF CONNECTOR

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

No. of
pin
1
1
NMWP01F-B
4 - 55
18) ECONOSEAL J TYPE CONNECTORS
No. of
pin
S816-001002 S816-101002
1 2 2 1
S816-002002 S816-102002
S816-003002 S816-103002
S816-004002 S816-104002
4 - 56
No. of
pin
S816-006002 S816-106002
S816-008002 S816-108002
10
S816-010002 S816-110002
12
S816-012002 S816-112002
4 - 57
No. of
pin
15
368301-1 2-85262-1
19) METRI-PACK TYPE CONNECTOR

No. of
pin
12040753
20) DEUTSCH HD30 CONNECTOR

No. of
pin
J K
K J
B
23 N T
A B
F
F Q N
Q A
HD36-24-23SN HD34-24-23PN
4 - 58
21) DEUTSCH SERVICE TOOL CONNECTOR
No. of
Receptacle connector (Female) Plug connector (Male)
pin
C
D
E
A
9
F
B
G
H J
HD10-9-96P
22) AMP FUEL WARMER CONNECTOR

No. of
pin
3 2
2-967325-3
4 - 59
23) DEUTSCH ENGINE
ENGINE ECM CONNECTOR
No. of
pin
1 5
6
11
1
10
2
11 3
4
21 5
21 31
6
7
50 31 41
42
8
9
10 20
43
44
41 45
20
46
47
30
40
30
48
45 49
50
46
50 40
DRC26-50S-04
24) DEUTSCH INTERMEDIATE CONNECTOR

No. of
pin
1
13 12
25 24
31
30
60 37
36
49
48
60
DRB16-60SAE-L018
4 - 60
25) TE MCU CONNECTOR
No. of
pin
8 3
26 14
21
20 23 7
25
13
19
26
1473416-1
1
10 3
4
5
6
7
34 18
27
26 28
29 9
31
32
33
17
25
34
2-1437285-3
4-1437290-0
1
10 3
4
5
6
34 18
7
27
26 28
29 9
31
32
33
17
25
34
4-1437290-1
4 - 61
Group 1 Outline ---------------------------------------------------------------------------------------------------------------- 5-1

Group 2 Mode Selection System ------------------------------------------------------------------------------------ 5-3
Group 3 Automatic Deceleration System ----------------------------------------------------------------------- 5-6
Group 4 Power Boost System ----------------------------------------------------------------------------------------- 5-7
Group 5 Travel Speed Control System -------------------------------------------------------------------------- 5-8
Group 6 Automatic Warming Up System ----------------------------------------------------------------------- 5-9
Group 7 Engine Overheat Prevention System -------------------------------------------------------------- 5-10
Group 8 Variable Power Control System ----------------------------------------------------------------------- 5-11
Group 9 Attachment Flow Control System -------------------------------------------------------------------- 5-12
Group 10 Intelligent Power Control System---------------------------------------------------------------------- 5-13
Group 11 Anti-Restart System ------------------------------------------------------------------------------------------ 5-15
Group 12 Self-Diagnostic System ------------------------------------------------------------------------------------- 5-16
Group 13 Engine Control System ------------------------------------------------------------------------------------- 5-61
Group 14 EPPR Valve ------------------------------------------------------------------------------------------------------- 5-62
Group 15 Monitoring System --------------------------------------------------------------------------------------------- 5-67
Group 16 Fuel Warmer System ---------------------------------------------------------------------------------------- 5-109
GROUP 1 OUTLINE
The ADVANCED CAPO (Computer Aided Power Optimization) system controls engine and pump
mutual power at an optimum and less fuel consuming state for the selected work by mode selection,
auto-deceleration, power boost function, etc. It monitors machine conditions, for instance, engine
speed, coolant temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
It consists of a MCU, a cluster, an ECM, EPPR valves, and other components. The MCU and the
cluster protect themselves from over-current and high voltage input, and diagnose malfunctions caused
by short or open circuit in electric system, and display error codes on the cluster.
Power mode selection (P, S, E)

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

ADVANCED
CAPO
SYSTEM
Variable power control system
Attachment flow control system
Boom floating control system
Intelligent power control system
Anti-restart system
MCU & cluster protection
Self-diagnostic system Open-short diagnosis & error code display
Machine error & ECM fault code display
Machine condition monitoring
Machine monitoring system
Electric signal monitoring
One touch deceleration system
5-1
SYSTEM DIAGRAM
Work tool Attachment pilot

pressure
PS
MCV
EPPR VALVE
SOLENOID VALVE Arm 1 Arm 2
Travel straight
Swing parking Option Bucket
Boom priority
Travel speed Attachment Boom 2 Boom 1 (vs arm)
pressure(opt)
Swing Travel(LH) Boom priority

Power boost Attachment
conflux(opt) (vs swing)
Travel(RH) Attachment
Arm regen Attachment
safety(opt) flow
P1 delivery
Overload pressure
pressure
sensor PS
PS P2 delivery
pressure
PS
Boom cylinder
Engine Negacon 1
pressure
PS
PS
Negacon 2
ECM pressure
Main pump Pilot pump
Pump EPPR
valve (P1 & P2)
CAN #1
Signal
Pressure signal
Pressure signal
Drive signal
Drive signal MCU
Pressure signal
Switch signal
Power boost Horn button CAN #2 CN-16A CN-16
button
One touch Normal
Travel
decel button pedal CN-16B
Pressure signal
Option Emergency
button
LH control RH control
lever lever
Jog dial module
SL SR AO AI BI BO BU BD LH RH
CAN #1 & #2
Shuttle
block
PS PS PS PS PS PS PS PS PS
Swing Arm Arm Bkt Bkt Boom Boom Travel Travel Camera
ps out in in out up down left right
ps ps ps ps ps ps ps ps
Cluster
210A5MS01
5-2
GROUP 2 MODE SELECTION SYSTEM
1. POWER MODE SELECTION SYSTEM
Main control valve
Engine
ECM
Pump EPPR
valve (P1 & P2)
CAN #1
Cluster
MCU Drive signal
Jog dial module

Power mode
pilot lamp
Emergency
CN-16B
Power mode switch signal CN-16A CN-16
CAN #1 & #2 CAN #2 Normal
210A5MS02
Mode selection system (micro computer based electro-hydraulic pump and engine mutual control
system) optimizes the engine and pump performance.
The combination of 3 power modes (P, S, E) and acceleration mode (10 set) of jog dial module
makes it possible to use the engine and pump power more effectively corresponding to the work
conditions from a heavy and great power requesting work to a light and precise work.
Engine rpm
Power
Application Standard Option
mode
Unload Load Unload Load
P Heavy duty power 1800±50 1800±50 1900±50 1900±50
S Standard power 1700±50 1700±50 1800±50 1800±50
E Economy operation 1600±50 1600±50 1700±50 1700±50
AUTO Engine
1000±100 - 1000±100 -
DECEL deceleration
One touch Engine quick
850±100 - 850±100 -
decel deceleration
KEY Key switch
850±100 - 850±100 -
START start position
5-3
2. WORK MODE SELECTION SYSTEM
Work mode consists of the general operation (bucket) and the optional attachment (breaker,
crusher).
Attachment pilot
pressure sensor
Work tool PS Main control valve

EPPR VALVE
Arm 1 Arm 2
Travel straight
Option Bucket
Boom priority
Boom 2 Boom 1 (vs arm)
Swing Travel(LH) Boom priority

(vs swing)
flow
Engine
ECM
Pump EPPR
valve (P1 & P2)
CAN #1
Cluster
Drive signal
MCU Drive signal
Pressure signal
Jog dial module
Work mode
pilot lamp
Emergency
CN-16B
Work mode switch signal CN-16A CN-16
CAN #1 & #2 CAN #2 Normal 210A5MS03
1) GENERAL WORK MODE (bucket)

This mode is used to general digging work.
2) ATT WORK MODE (breaker, crusher)
It controls the pump flow and system pressure according to the operation of breaker or crusher.
General mode Work tool

Description
Bucket Breaker Crusher
Attachment safety solenoid OFF - ON
Attachment conflux solenoid OFF ON/OFF ON/OFF
Attachment flow EPPR current 100 mA 100~700 mA 100~700 mA
Breaker solenoid★ OFF ON -
★ When breaker operating button is pushed.
5-4
3. USER MODE SELECTION SYSTEM
Main control valve
Engine
ECM
Pump EPPR
valve (P1 & P2)
CAN #1
Cluster
Drive signal
MCU
Jog dial module
User mode
pilot lamp
Emergency
CN-16B
User mode switch signal CN-16A CN-16
210A5MS04
1) High idle rpm, auto idle rpm and EPPR pressure can be adjusted and memorized in the U-mode.
2) LCD segment vs parameter setting
Step Engine speed Idle speed
( ) (rpm) (rpm)
1 1300 750
2 1400 800
3 1500 850
4 1600 900
5 1700 950
6 1800 1000 (auto decel)
7 1850 1050
8 1900 1100
9 1950 1150
10 2000 1200
5-5
GROUP 3 AUTOMATIC DECELERATION SYSTEM
Main control valve RCV lever

RCV pedal
Engine
PS Work or
travel
pressure
ECM
Pilot pump
Main pump
CAN #1
Cluster
MCU
Pressure signal
Jog dial module

Auto idle
pilot lamp
Emergency
CN-16B
Auto idle switch signal CN-16A CN-16
210A5MS05
1. WHEN AUTO IDLE PILOT LAMP ON

When all of the work equipment control levers including swing and travel levers are at neutral for 4
seconds, MCU sends throttle command to ECM to reduce the engine speed to 1000 rpm. If the
control levers are at neutral for 1 minute, MCU reduces the engine speed to 850 rpm. As the result of
reducing the engine speed, fuel consumption and noise are effectively cut down during non-operation
of the control levers.
When the Auto idle pilot lamp is turned off by pressing the switch or any control lever is operated, the
reduced engine speed rises upto the speed before deceleration in a second.
Engine rpm
Multimodel dial
set rpm
Auto idle 1000 rpm

rpm
4 sec
Low idle 850 rpm
rpm
60 sec 1sec
Lever Lever Time

(pedal) (pedal)
neutral operation 220A5MS105
2. WHEN AUTO IDLE PILOT LAMP OFF

The engine speed can be set as desired using the multimodal dial switch, and even if the control
levers are neutral, the engine speed is not reduced.
※ Auto idle function can be activated when multimodal dial position is over 4.
5-6
GROUP 4 POWER BOOST SYSTEM
MCV
Arm 1 Arm 2
Option Bucket
Boom 2 Boom 1
Swing Travel(LH)
Main relief
Travel(RH) valve
PS
P1 delivery
pressure PS
P2 delivery
pressure Power boost
solenoid valve
Engine
ECM
Power boost Pump EPPR
button valve (P1 & P2)
CAN #1
LH control
lever Signal
Drive signal
Power max button signal
Pressure signal
MCU
Jog dial module
Emergency
CN-16B
Power mode sw signal CN-16A CN-16
Power max
pilot lamp CAN #1 & #2 CAN #2 Normal
Cluster
210A5MS06
· When the power boost switch on the left control lever knob is pushed ON, the power mode is set P
mode and maximum digging power is increased by 10 %.
· When the power boost function is activated, the power boost solenoid valve pilot pressure raises the
set pressure of the main relief valve to increase the digging power.
Description Condition Function
- Power mode : P
- Multimodal dial power : 9
Power boost switch : ON
Activated - Power boost solenoid : ON
Multimodal dial : over 8
- Power boost pilot lmap : ON
- Operating time : max 8 seconds
- Pre-set power mode
Canceled Power boost switch : OFF - Power boost solenoid : OFF
- Power boost pilot lamp : OFF
※ When the auto power boost is set to Enable and power mode is set to P mode on the cluster, the
digging power is automatically increased as working conditions by the MCU. It is operated max 8
seconds.
5-7
GROUP 5 TRAVEL SPEED CONTROL SYSTEM
Main control valve Travel motor
Arm 1 Arm 2
Option Bucket
Boom 2 Boom 1 Regulator
Swing Travel(LH)
Travel(RH)
Travel speed
solenoid valve
Engine

Cluster
Drive signal
MCU
Travel speed
pilot lamp
Travel speed switch signal

CAN #1 & #2
210A5MS07
Travel speed can be switched manually by pressing the travel speed switch on the cluster.
Travel speed Lamp
Speed Operation
solenoid valve on cluster
Low OFF Turtle Low speed, high driving torque in the travel motor
High ON Rabbit High speed, low driving torque in the travel motor
※ Default : Turtle (Low)
5-8
GROUP 6 AUTOMATIC WARMING UP SYSTEM
Main control valve
Engine
Coolant
temp sensor
ECM
Pump EPPR
valve (P1 & P2)
CAN #1
Cluster Hydraulic temp sensor

Drive signal
MCU Jog dial module
Emergency
CN-16B
Warming up pilot lamp signal CN-16A CN-16
Warming up CAN #1 & #2 CAN #2 Normal
pilot lamp
210A5MS08
1. The MCU receives the engine coolant temperature from the ECM, and if the coolant temperature is
below 30˚C, it increases the engine speed from key start rpm to 1000 rpm. At this time the mode
does not change. If the coolant temperature sensor has fault, the hydraulic oil temperature signal is
substituted.
2. In case of the coolant temperature increases up to 30˚C, the engine speed is decreased to key start
speed. And if an operator changes power mode set during the warming up function, the MCU
cancels the automatic warming up function.
3. LOGIC TABLE
- Coolant temperature : - Power mode : Default (E mode)
Actuated below 30˚C (after engine run) - Warming up time : 10 minutes (max)
- Warming up pilot lamp : ON
- Coolant temperature : Above 30˚C - Power mode : set mode
- Warming up time : Above 10 minutes - Warming up pilot lamp : OFF
- Changed power mode set by operator
Canceled - RCV lever or pedal operating
- Auto idle cancel
※ If any of the above conditions is
applicable, the automatic warming up
function is canceled
5-9
GROUP 7 ENGINE OVERHEAT PREVENTION SYSTEM
Main control valve
Engine
Coolant
temp sensor
ECM
Pump EPPR
valve (P1 & P2)
Emergency CAN #1
warning lamp
Cluster
Hydraulic temp signal
Hydraulic temp sensor

Drive signal
MCU Jog dial module
Emergency
CN-16B
Overheat warning signal CN-16A CN-16
Hydraulic temperature
warning lamp
210A5MS09
1. If the engine coolant temperature is overheated over 103˚C or the hydraulic oil temperature is
overheated over 100˚C, the warning lamp is ON and the pump input torque or the engine speed is
reduced as below logic table.
2. LOGIC TABLE
- Coolant temperature : - Warning lamp : ON , buzzer : OFF
Above 103˚C - Pump input torque is reduced.
Activated
- Hydraulic oil temperature : - Warning lamp & buzzer : ON
First step Above 100˚C - Pump input torque is reduced.
warning - Coolant temperature :
Less than 100˚C - Return to pre-set the pump absorption
Canceled
- Hydraulic oil temperature : torque.
Less than 95˚C
- Emergency warning lamp pops up on the
- Coolant temperature : Above 107˚C
Activated center of LCD and the buzzer sounds.
- Hydraulic oil temperature : Above 105˚C
- Engine speed is reduced after 10 seconds.
Second step
warning - Coolant temperature :
- Return to pre-set the engine speed.
Less than 103˚C
Canceled - Hold pump absorption torque on the first
- Hydraulic oil temperature :
step warning.
Less than 100˚C
5-10
GROUP 8 VARIABLE POWER CONTROL SYSTEM
Main control valve
Engine
ECM
Pump EPPR
CAN #1
valve (P1 & P2)
Signal
MCU
Switch signal
Power boost Horn button
button
One touch Travel
decel button pedal
Pressure signal
Option CN-16A CN-16

button CAN #2
Normal
CAN #1 & #2
CN-16B
lever lever Emergency
Shuttle
block Power mode switch signal Jog dial module
Swing Arm Arm Bkt Bkt Boom Boom Travel Travel

ps ps ps ps ps ps ps ps
Power mode
Cluster
210A5MS10
· The variable power control system controls the engine and pump mutual power according to RCV
lever stroke and pump load.
It makes fuel saving and smooth control at precise work.
Description Working condition

Power mode P, S, E
Work mode General (bucket)
Pressure sensor Normal
※ The variable power control function can be activated when the power mode is set to all power
mode.
5-11
GROUP 9 ATTACHMENT FLOW CONTROL SYSTEM
Attachment pilot
pressure sensor
PS Main control valve
Work tool
Arm 1 Arm 2
Option Bucket
Boom 2 Boom 1 Breaker
Swing Travel(LH) Attachment

conflux
safety
Engine
ECM
Pump EPPR
valve (P1 & P2)
CAN #1
Cluster
Drive signal
Drive signal
MCU
Pressure signal
Jog dial module
Emergency
CN-16B
Work mode switch signal CN-16A CN-16
CAN #1 & #2 CAN #2 Normal 210A5MS11
· The system is used to control the pump delivery flow according to set of the work tool on the
cluster by the attachment flow EPPR valve.
Work tool
Description
Breaker Crusher
Flow level 100 ~ 180 lpm 100 ~ 440 lpm
Attach safety solenoid - ON
Attach conflux solenoid ON/OFF ON/OFF
Breaker solenoid★ ON -
※ Refer to the page 5-90 for the attachment kinds and max flow.
★ When breaker operating button is pushed.
5-12
GROUP 10 INTELLIGENT POWER CONTROL SYSTEM
Main control valve
Arm 1 Arm 2
Option Bucket
Boom 2 Boom 1
Swing Travel(LH)
Travel(RH)
Attach flow
EPPR 1
Engine
ECM
Pump EPPR
valve (P1 & P2)
CAN #1
Signal
Power boost Horn button Switch signal
button
One touch Travel Pressure signal
decel button pedal
MCU
Option
button
lever lever
Pressure signal
Shuttle
block
Swing Arm Arm Bkt Bkt Boom Boom Travel Travel

ps ps ps ps ps ps ps ps 210A5MS18
1. When the requirement of pump flow rate is low, IPC mode controls pump flow rate to improve fuel
efficiency.
Condition★1 Function
IPC mode : ON★2

Boom up
Arm in Limitation of pump flow rate : Activated
Not travel motion
Not swing motion
None of upper condition Limitation of pump flow rate : Canceled
★1
AND condition
★2
IPC mode ON/OFF is selected at "Mode setup > IPC mode". See next page.
5-13
2. IPC MODE SELECTION
IPC mode ON/OFF and the levels of flow rate limit can be selected at "Mode setup > IPC mode"
300A3CD52A
IPC mode Description
Balance mode (default) IPC mode ON, limit level 1

Efficiency mode IPC mode ON, limit level 2
Speed mode IPC mode OFF
5-14
GROUP 11 ANTI-RESTART SYSTEM
Engine
Starter
ECM
Anti-restart relay
Drive signal
MCU
220A5MS12
1. ANTI-RESTART FUNCTION
After a few seconds from the engine starts to run, MCU turns off the anti-restart relay to protect the
starter from inadvertent restarting.
5-15
GROUP 12 SELF-DIAGNOSTIC SYSTEM
1. OUTLINE
When any abnormality occurs in the ADVANCED CAPO system caused by electric parts malfunction
and by open or short circuit, the MCU diagnoses the problem and sends the error codes to the
cluster and also stores them in the memory.
2. MONITORING
1) Active fault
300A3CD65A
300A3CD66A 300A3CD67A
· The active faults of the MCU, engine ECM or air conditioner can be checked by this menu.
2) Logged fault
300A3CD68A
300A3CD69A 300A3CD70A
· The logged faults of the MCU, engine ECM or air conditioner can be checked by this menu.
3) Delete logged fault
300A3CD71A
300A3CD72A 300A3CD73A
· The logged faults of the MCU, engine ECM or air conditioner can be deleted by this menu.
5-16
3. MACHINE ERROR CODES TABLE
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
3 10 seconds continuous, Hydraulic Oil Temp. Measurement Voltage > 3.8V ●
4 10 seconds continuous, Hydraulic Oil Temp. Measurement Voltage < 0.3V ●
(Results / Symptoms)
101 1. Monitor – Hydraulic oil temperature display failure
2. Control Function – Fan revolutions control failure
(Checking list)
1. CD-1 (#2) - CN-51 (#16) Checking Open/Short
2. CD-1 (#1) - CN-51 (#25) Checking Open/Short
10 seconds continuous, Working Press. Sensor
0 ●
Measurement Voltage > 5.2V
10 seconds continuous, 0.3V Working Press. Sensor Measurement Voltage
1 ●
< 0.8V
10 seconds continuous, Working Press. Sensor
4 ●
Measurement Voltage < 0.3V
105
1. Monitor – Working Press. display failure
2. Control Function – Auto Idle operation failure, Engine variable horse power control operation
failure
(Checking list)
1. CD-32 (#B) – CN-52 (#23) Checking Open/Short
2. CD-32 (#A) – CN-51 (#32) Checking Open/Short
3. CD-32 (#C) – CN-51 (#31) Checking Open/Short
10 seconds continuous, Travel Oil Press. Sensor
0 ●
10 seconds continuous, 0.3V  Travel Oil Press. Sensor Measurement
1 ●
Voltage < 0.8V
10 seconds continuous, Travel Oil Press. Sensor
4 ●
108
1. Monitor – Travel Oil Press. display failure
2. Control Function – Auto Idle operation failure, Engine variable horse power control operation
failure, IPC operation failure, Driving alarm operation failure
(Checking list)
1. CD-104 or 105 (#B) – CN-52 (#24 or 27) Checking Open/Short
2. CD-104 or 105 (#A) – CN-51 (#32) Checking Open/Short
3. CD-104 or 105 (#C) – CN-51 (#31) Checking Open/Short
※ Some error codes are not applied to this machine.

G : General C : Crawler Type W : Wheel Type
5-17
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
10 seconds continuous, P1 pump delivery pressure sensor Measurement
0 ●
Voltage > 5.2V
10 seconds continuous, 0.3V  P1 pump delivery pressure sensor
1 ●
4 ●
Voltage < 0.3V
120
1. Monitor – P1 pump delivery Press. display failure
2. Control Function – Automatic voltage increase operation failure, Overload at compensation control
failure
(Checking list)
0 ●
Voltage > 5.2V
10 seconds continuous, 0.3V P2 pump delivery pressure sensor
1 ●
4 ●
Voltage < 0.3V
121
1. Monitor – P2 pump delivery Press. display failure
2. Control Function – Automatic voltage increase operation failure, Overload at compensation control
failure
(Checking list)
(when you had conditions mounting pressure sensor)
1 10 seconds continuous, 0.3V  Overload Press. Sensor Measurement ●
Voltage < 0.8V
4 10 seconds continuous, Overload Press. Sensor ●
122 (Results / Symptoms)
1. Monitor – Overload Press. display failure
2. Control Function – Overload warning alarm failure
(Checking list)

5-18
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
10 seconds continuous, Negative 1 Press. Sensor
0 ●
10 seconds continuous, 0.3V Negative 1 Press. Sensor Measurement
1 ●
Voltage < 0.8V
4 ●
1. Monitor – Negative 1 Press. display failure
2. Control Function – IPC operation failure, Option attachment flow control operation failure
(Checking list)
0 ●
10 seconds continuous, 0.3V Negative 2 Press. Sensor Measurement
1 ●
Voltage < 0.8V
4 ●
1. Monitor – Negative 2 Press. display failure
2. Control Function – Option attachment flow control operation failure
(Checking list)
10 seconds continuous, Boom Up Pilot Press. Sensor
0 ●
10 seconds continuous, 0.3V Boom Up Pilot Press. Sensor Measurement
1 ●
Voltage < 0.8V
4 10 seconds continuous, Boom Up Pilot Press. Sensor Measurement < 0.3V ●
127 1. Monitor – Boom Up Pilot Press. display failure
2. Control Function – Engine/Pump variable horse power control operation failure, IPC operation
failure, Boom first operation failure
(Checking list)
3. CD-32 (#C) – CN-5 1(#31) Checking Open/Short

5-19
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
0 10 seconds continuous, Boom Down Pilot Press. Sensor Measurement ●
Voltage > 5.2V
1 10 seconds continuous, 0.3V Boom Down Pilot Press. Sensor ●
4 10 seconds continuous, Boom Down Pilot Press. Sensor Measurement ●
128 Voltage < 0.3V
1. Monitor – Boom Down Pilot Press. display failure
2. Control Function – Boom floating operation failure
(Checking list)
10 seconds continuous, Arm In Pilot Press. Sensor
0 ●
10 seconds continuous, 0.3V Arm In Pilot Press. Sensor Measurement
1 ●
Voltage < 0.8V
10 seconds continuous, Arm In Pilot Press. Sensor
4 ●
1. Monitor – Arm In Pilot Press. display failure
2. Control Function – IPC operation failure
(Checking list)
10 seconds continuous,
0 ●
Arm Out Pilot Press. Sensor Measurement Voltage > 5.2V
1 0.3V Arm Out Pilot Press. Sensor ●
4 ●
Arm Out Pilot Press. Sensor Measurement Voltage < 0.3V
133
1. Monitor – Arm In/Out & Bucket In Pilot Press. display failure
2. Control Function – Engine variable horse power control operation failure
(Checking list)
5-20
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
10 seconds continuous, Swing Pilot Press. Sensor
0 ●
10 seconds continuous, 0.3V Swing Pilot Press. Sensor Measurement
1 ●
Voltage < 0.8V
10 seconds continuous, Swing Pilot Press. Sensor
4 ●
1. Monitor – Swing Pilot Press. display failure
2. Control Function – IPC operation, Boom first operation failure
(Checking list)
Monitor – Select Attachment(breaker / crusher)
0 10 seconds continuous, Attachment Pilot Press. Sensor Measurement ●
Voltage > 5.2V
1 10 seconds continuous, 0.3V Attachment Pilot Press. Sensor Measurement ●
Voltage < 0.8V
4 10 seconds continuous, Attachment Pilot Press. Sensor Measurement ●
138 Voltage < 0.3V
1. Monitor – Attachment Pilot Press. display failure
(Checking list)
10 seconds continuous, 0.3V Option Pilot Press. Sensor Measurement
1 ●
Voltage < 0.8V
10 seconds continuous, Option Pilot Press. Sensor
4 ●
139
1. Monitor – Option Pilot Press. display failure
(N.A)
2. Control Function – Auto Idle operation failure
(Checking list)

5-21
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Detection)
(When Pump regulator EPPR Current is more than 10 mA)
10 seconds continuous, Pump regulator EPPR drive current < 0 mA
5 ●
(Cancellation)
(When Pump regulator EPPR Current is more than 10 mA)
3 seconds continuous, Pump regulator EPPR drive current 10 mA
(Detection)
10 seconds continuous, Pump regulator EPPR drive current > 1.0A
140 6 ●
(Cancellation)
3 seconds continuous, Pump regulator EPPR drive current  1.0 A
1. Control Function – Pump horse power setting specification difference
(Fuel efficiency/speed specification failure)
(Checking list)
1. CN-342 (#1)-CN-54 (#02) or CN-343 (#1)-CN-54 (#03) Checking Open/Short
(Model Parameter) mounting Boom Priority EPPR
(Detection)
(When Boom Priority EPPR Current is more than 10 mA)
5 10 seconds continuous, Boom Priority EPPR drive current < 0 mA ●
(Cancellation)
(When Boom Priority EPPR Current is more than 10 mA)
3 seconds continuous, Boom Priority EPPR drive current  10 mA
(Detection)
141
10 seconds continuous, Boom Priority EPPR drive current > 1.0 A
6 ●
(Cancellation)
3 seconds continuous, Boom Priority EPPR drive current  1.0 A
1. Control Function – Boom first control operation failure
(Checking list)

5-22
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Detection)
(When Travel EPPR Current is more than 10 mA)
10 seconds continuous, Travel EPPR drive current = 0 mA
5 ●
(Cancellation)
(When Travel EPPR Current is more than 100 mA)
3 seconds continuous, Travel EPPR drive current  10 mA
(Detection)
143
10 seconds continuous, Travel EPPR drive current > 1.0 A
(N.A) 6 ●
(Cancellation)
3 seconds continuous, Travel EPPR drive current  1.0 A
1. Control Function – cruise control operation failure
(Checking list)
1. CN-246 (#2) – CN-54 (#39) Checking Open/Short
(Model Parameter) mounting Remote Cooling Fan EPPR
(Detection)
(When Remote Cooling Fan EPPR Current is more than 10 mA)
5 10 seconds continuous, Remote Cooling Fan EPPR drive current = 0 mA ●
(Cancellation)
(When Remote Cooling Fan EPPR Current is more than 10 mA)
3 seconds continuous, Remote Cooling Fan EPPR drive current  10 mA
(Detection)
145
10 seconds continuous, Remote Cooling Fan EPPR drive current > 1.0 A
6 ●
(Cancellation)
3 seconds continuous, Remote Cooling Fan EPPR drive current  1.0 A
1. Control Function – Remote fan control operation failure
(Checking list)

5-23
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Detection)
(When Working Cutoff Relay is Off)
10 seconds continuous, Working Cutoff Relay drive unit Measurement
Voltage  3.0V
4 ●
(Cancellation)
(When Working Cutoff Relay is Off)
3 seconds continuous, Working Cutoff Relay drive unit Measurement Voltage
> 3.0V
(Detection)
164 (When Working Cutoff Relay is On)
(N.A) 10 seconds continuous, Working Cutoff Relay drive current > 6.5 A
6 ●
(Cancellation)
(When Working Cutoff Relay is On)
3 seconds continuous, Working Cutoff Relay drive current  6.5 A
1. Control Function – (Wheel Excavator) In driving mode, attachment hydraulic pilot pressure cut off
failure
(Checking list)
1. CR-47 (#85) – CN-54 (#9) Checking Open/Short
2. CR-47 (#30, #86) – Fuse box (#28) Checking Open/Short
(Detection)
(When Power Max Solenoid is Off)
10 seconds continuous, Power Max Solenoid drive unit Measurement
Voltage  3.0V
4 ●
(Cancellation)
(When Power Max Solenoid is Off)
3 seconds continuous, Power Max Solenoid drive unit
(Detection)
166 (When Power Max Solenoid is On)
5 seconds continuous, Power Max Solenoid drive current > 4.5 A
6 ●
(Cancellation)
(When Power Max Solenoid is On)
3 seconds continuous, Power Max Solenoid drive current  4.5 A
1. Control Function – Voltage increase operation failure
(Checking list)
2. CN-88 (#2) – Fuse box (#28) Checking Open/Short

5-24
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Detection)
(When Travel High Speed Solenoid is Off)
10 seconds continuous, Travel High Speed Solenoid drive unit Measurement
Voltage  3.0V
●
(Cancellation)
Voltage > 3.0V
4 (When Parking mode is not)
(Detection)
Voltage  3.0V ●
(Cancellation)
167
Voltage > 3.0V
(Detection)
(When Travel High Speed Solenoid is On)
10 seconds continuous, Travel High Speed Solenoid drive current > 4.5 A
6 ●
(Cancellation)
(When Travel High Speed Solenoid is On)
3 seconds continuous, Travel High Speed Solenoid drive current  4.5 A
1. Control Function – driving in 1/2 transmission operation failure
(Checking list)

5-25
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
Monitor – Selecting attachment(breaker / crusher)
(Detection)
(When Attachment Conflux Solenoid is Off)
10 seconds continuous, Attachment Conflux Solenoid drive unit
4 Measurement Voltage  3.0V ●
(Cancellation)
(When Attachment Conflux Solenoid is Off)
3 seconds continuous, Attachment Conflux Solenoid drive unit Measurement
Voltage > 3.0V
(Detection)
169 (When Attachment Conflux Solenoid is On)
10 seconds continuous, Attachment Conflux Solenoid drive Current > 6.5 A
6 ●
(Cancellation)
(When Attachment Conflux Solenoid is On)
3 seconds continuous, Attachment Conflux Solenoid drive Current  6.5 A
(Results / symptoms)
1. Control Function – Option attachment flow control – Joining operation failure
(Eco breaker mode, crusher mode)
(Checking list)
(Model Parameter) mounting Arm Regenerating Solenoid
(Detection)
(When Arm Regeneration Solenoid is Off)
10 seconds continuous, Arm Regeneration Solenoid drive unit Measurement
4 Voltage  3.0V ●
(Cancellation)
(When Arm Regeneration Solenoid is Off)
3 seconds continuous, Arm Regeneration Solenoid drive unit Measurement
Voltage > 3.0V
(Detection)
170
(When Arm Regeneration Solenoid is On)
10 seconds continuous, Arm Regeneration Solenoid drive current > 4.5 A
6 ●
(Cancellation)
(When Arm Regeneration Solenoid is On)
3 seconds continuous, Arm Regeneration Solenoid drive current  4.5 A
(Results / symptoms)
1. Control Function – Arm regeneration operation failure
(Checking list)

5-26
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
Monitor – Selecting attachment(crusher)
(Detection)
(When Attachment Safety Solenoid is Off)
10 seconds continuous, Attachment Safety Solenoid drive unit Measurement
(Cancellation)
(When Attachment Safety Solenoid is Off)
Voltage > 3.0V
(Detection)
171 (When Attachment Safety Solenoid is On)
10 seconds continuous, Attachment Safety Solenoid drive current > 6.5 A
6 ●
(Cancellation)
(When Attachment Safety Solenoid is On)
3 seconds continuous, Attachment Safety Solenoid drive current  6.5 A
1. Control Function – Option attachment flow control – Option spool pilot pressure cut off failure
(crusher mode)
(Checking list)
(Detection)
(When Breaker Operating Solenoid is Off)
(Cancellation)
(When Breaker Operating Solenoid is Off)
Voltage > 3.0V
(Detection)
179
(When Breaker Operating Solenoid is On)
10 seconds continuous, Attachment Safety Solenoid drive current > 6.5 A
6 ●
(Cancellation)
(When Breaker Operating Solenoid is On)
3 seconds continuous, Attachment Safety Solenoid drive current  6.5 A
1. Control Function – Option attachment flow control – Breaker operation failure (breaker mode)
(Checking list)

5-27
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Model Parameter) mounting Reverse Cooling Fan Solenoid
(Detection)
(When Reverse Cooling Fan Solenoid is Off)
10 seconds continuous, Reverse Cooling Fan Solenoid drive unit
(Cancellation)
(When Reverse Cooling Fan Solenoid is Off)
3 seconds continuous, Reverse Cooling Fan Solenoid drive unit
181
(N.A)
(Detection)
(When Reverse Cooling Fan Solenoid is On)
10 seconds continuous, Reverse Cooling Fan Solenoid drive current > 4.5 A
6 ●
(Cancellation)
(When Reverse Cooling Fan Solenoid is On)
3 seconds continuous, Reverse Cooling Fan Solenoid drive current  4.5 A
1. Control Function – Cooling Fan reverse control operation failure (not applicable)
(Detection)
(When Pump P1 regulator EPPR current is equal or more than 300 mA)
10 seconds continuous, Pump P1 regulator EPPR drive current < 100 mA
5 ●
(Cancellation)
3 seconds continuous, Pump P1 regulator EPPR drive current  100 mA
(Detection)
188 10 seconds continuous, Attachment Flow EPPR 1 drive current > 1.0 A
6 ●
(Cancellation)
3 seconds continuous, Attachment Flow EPPR 1 drive current  1.0 A
1. Control Function – IPC operation failure, Option attachment flow control operation failure
(Checking list)

5-28
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Detection)
10 seconds continuous, Pump P2 regulator EPPR drive current < 100 mA
5 ●
(Cancellation)
3 seconds continuous, Pump P2 regulator EPPR drive current  100 mA
(Detection)
189 10 seconds continuous, Attachment Flow EPPR 2 drive current > 1.0 A
6 ●
(Cancellation)
3 seconds continuous, Attachment Flow EPPR 2 drive current  1.0 A
(Checking list)
HW145
0 10 seconds continuous,
Attachment flow control EPPR 1 press. Sensor Measurement Voltage > 5.2V
HW145
1 10 seconds continuous,
0.3V Attachment flow control EPPR 1 press. Sensor Measurement Voltage < 0.8V
HW145
196 4 10 seconds continuous,
(N.A) Attachment flow control EPPR 1 press. Sensor Measurement Voltage < 0.3V
1. Control Function – Driving second pump joining function operation failure
(Checking list)
0 10 seconds continuous, Pump EPPR Press. Sensor Measurement Voltage > 5.2V ●
10 seconds continuous, 0.3V Pump EPPR Press. Sensor Measurement
1 ●
Voltage < 0.8V
4 10 seconds continuous, Pump EPPR Press. Sensor Measurement Voltage < 0.3V ●
200 1. Monitor – Pump EPPR Press. display failure
(N.A) 2. Control Function – Pump input horse power control failure, Overload at compensation control
operation failure (Fuel efficiency/speed performance failure)
(Checking list)

5-29
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Mounting pressure sensor)
0 10 seconds continuous, Boom Cylinder Rod Press. Sensor Measurement ●
Voltage > 5.2V
1 10 seconds continuous, 0.3V Boom Cylinder Rod Press. Sensor ●
4 10 seconds continuous, Boom Cylinder Rod Press. Sensor Measurement ●
205 Voltage < 0.3V
1. Monitor – Boom Cylinder Rod Press. display failure
2. Control Function – Boom floating control operation failure
(Checking list)
Mounting pressure sensor (HCESPN128 or HCESPN 205)
(Detection)
(When Boom Up Floating Solenoid is Off)
10 seconds continuous, Boom Up Floating Solenoid drive unit Measurement
(Cancellation)
(When Boom Up Floating Solenoid is Off)
3 seconds continuous, Boom Up Floating Solenoid drive unit Measurement
Voltage > 3.0V
(Detection)
218
(When Boom Up Floating Solenoid is On)
10 seconds continuous, Boom Up Floating Solenoid drive current > 6.5 A
6 ●
(Cancellation)
(When Boom Up Floating Solenoid is On)
3 seconds continuous, Boom Up Floating Solenoid drive current  6.5 A
(Checking list)
5-30
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
Mounting pressure sensor (HCESPN 128 or 205)
(Detection)
(When Boom Down Pilot Pressure Cutoff Solenoid is Off)
Boom Down Pilot Pressure Cutoff Solenoid drive unit
(Cancellation)
(When Boom Down Pilot Pressure Cutoff Solenoid is Off)
Boom Down Pilot Pressure Cutoff Solenoid drive unit
(Detection)
220
(When Boom Down Pilot Pressure Cutoff Solenoid is On)
10 seconds continuous, Boom Down Pilot Pressure Cutoff Solenoid drive
current > 6.5 A
6 ●
(Cancellation)
(When Boom Down Pilot Pressure Cutoff Solenoid is On)
3 seconds continuous, Boom Down Pilot Pressure Cutoff Solenoid drive
current  6.5 A
(Checking list)
(Detection)
(When ATT Relief Setting EPPR 1 Current is equal or more than 10 mA)
5 10 seconds continuous, ATT Relief Setting EPPR 1 drive current = 0 mA ●
(Cancellation)
ATT Relief Setting EPPR 1 Current is equal or more than 10 mA)
3 seconds continuous, ATT Relief Setting EPPR 1 drive current  10 mA
(Detection)
221
10 seconds continuous, ATT Relief Setting EPPR 1 drive current > 1.0 A
6 ●
(Cancellation)
3 seconds continuous, ATT Relief Setting EPPR 1 drive current  1.0 A
1. Control Function – Option attachment flow control – P1 relief pressure setting failure
(Checking list)

5-31
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
Monitor – Selecting attachment(crusher)
(Detection)
5 10 seconds continuous, ATT Relief Setting EPPR 2 drive current = 0 mA ●
(Cancellation)
3 seconds continuous, ATT Relief Setting EPPR 2 drive current  10mA
(Detection)
222
10 seconds continuous, ATT Relief Setting EPPR 2 drive current > 1.0 A
6 ●
(Cancellation)
3 seconds continuous, ATT Relief Setting EPPR 2 drive current  1.0 A
1. Control Function – Option attachment flow control – P2 relief pressure setting failure
(Checking list)
3 10 seconds continuous, Fuel Level Measurement Voltage > 3.8V ●
4 10 seconds continuous, Fuel Level Measurement Voltage < 0.3V ●
301 1. Monitor – Fuel remaining display failure
(Checking list)
1. CD-2 (#2) – CN-51 (#19) Checking Open/Short
2. CD-2 (#1) – CN-51 (#25) Checking Open/Short
(Model Parameter) mounting Fuel Warmer Relay
(Detection)
(When Fuel Warmer Relay is Off)
10 seconds continuous, Fuel Warmer Relay drive unit
(Cancellation)
(When Fuel Warmer Relay is Off)
3 seconds continuous, Fuel Warmer Relay drive unit
(Detection)
325
(When Fuel Warmer Relay is On)
10 seconds continuous, Fuel Warmer Relay drive current > 4.5 A
6 ●
(Cancellation)
(When Fuel Warmer Relay is On)
3 seconds continuous, Fuel Warmer Relay drive current  4.5 A
1. Control Function – Fuel warmer operation failure
(Checking list)
2. CR-46 (#86) – Fuse box (#22) Checking Open/Short

5-32
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
10 seconds continuous, Transmission Oil Press. Sensor Measurement
0 ●
Voltage > 5.2V
10 seconds continuous, 0.3V Transmission Oil Press. Sensor Measurement
1 ●
Voltage < 0.8V
10 seconds continuous, Transmission Oil Press. Sensor Measurement
4 ●
501 Voltage < 0.3V
(N.A) (Results / Symptoms)
1. Monitor – Transmission Oil Press. display failure, Transmission Oil low pressure warning failure
(Checking list)
10 seconds continuous, Brake Oil Press. Sensor
0 ●
10 seconds continuous, 0.3V Brake Oil Press. Sensor Measurement
1 ●
Voltage < 0.8V
10 seconds continuous, Brake Oil Press. Sensor
4 ●
503 Measurement Voltage < 0.3V
1. Monitor – Brake Oil Press. display failure, Brake Oil low pressure warning failure
(Checking list)
10 seconds continuous, Working Brake Press. Sensor Measurement Voltage
0 ●
> 5.2V
10 seconds continuous, 0.3V Working Brake Press. Sensor Measurement
1 ●
Voltage < 0.8V
10 seconds continuous, Working Brake Press. Sensor Measurement Voltage
4 ●
505 < 0.3V
1. Monitor – Working Brake Oil Press. display failure, Working Brake Oil low pressure warning failure
(Checking list)

5-33
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Detection)
(When Parking Relay is Off)
10 seconds continuous, Parking Relay drive unit
Measurement Voltage  3.0V
4 ●
(Cancellation)
(When Parking Relay is Off)
3 seconds continuous, Parking Relay drive unit
(Detection)
514
(When Parking Relay is On)
(N.A)
10 seconds continuous, Parking Relay drive current > 6.5 A
6 ●
(Cancellation)
(When Parking Relay is On)
3 seconds continuous, Parking Relay drive current  6.5 A
1. Control Function – Parking Relay operation failure
(Checking list)
(Detection)
(When Traveling Cutoff Relay is Off)
10 seconds continuous, Traveling Cutoff Relay drive unit Measurement
Voltage  3.0V
4 ●
(Cancellation)
(When Traveling Cutoff Relay is Off)
3 seconds continuous, Traveling Cutoff Relay drive unit Measurement
Voltage > 3.0V
(Detection)
517
(When Traveling Cutoff Relay is On)
(N.A)
10 seconds continuous, Traveling Cutoff Relay drive current > 6.5 A
6 ●
(Cancellation)
(When Traveling Cutoff Relay is On)
3 seconds continuous, Traveling Cutoff Relay drive current  6.5 A
1. Control Function – Traveling Cutoff Relay operation failure
(Checking list)

5-34
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Detection)
(When Ram Lock Solenoid is Off)
10 seconds continuous, Ram Lock Solenoid drive unit Measurement Voltage
 3.0V
4 ●
(Cancellation)
(When Ram Lock Solenoid is Off)
3 seconds continuous, Ram Lock Solenoid drive unit
(Detection)
525
(When Ram Lock Solenoid is On)
(N.A)
10 seconds continuous, Ram Lock Solenoid drive current > 6.5 A
6 ●
(Cancellation)
(When Ram Lock Solenoid is On)
3 seconds continuous, Ram Lock Solenoid drive current  6.5 A
1. Control Function – Ram lock control operation failure
(Checking list)
(Detection)
(When Creep Solenoid is Off)
10 seconds continuous, Creep Solenoid drive unit
4 ●
(Cancellation)
(When Creep Solenoid is Off)
3 seconds continuous, Creep Solenoid drive unit
(Detection)
527
(When Creep Solenoid is On)
(N.A)
10 seconds continuous, Creep Solenoid drive current > 6.5 A
6 ●
(Cancellation)
(When Creep Solenoid is On)
3 seconds continuous, Creep Solenoid drive current  6.5 A
1. Control Function – Creep mode operation failure
(Checking list)

5-35
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
10 seconds continuous, Travel Forward Press. Sensor Measurement Voltage
0 ●
> 5.2V
10 seconds continuous, 0.3V Travel Forward Press. Sensor Measurement
1 ●
Voltage < 0.8V
10 seconds continuous, Travel Forward Press. Sensor Measurement Voltage
4 ●
< 0.3V
530
(N.A)
1. Monitor – Travel Forward Press. display failure
2. Control Function – Driving interoperability power control operation failure
(Checking list)
10 seconds continuous, 0.3V Travel Reverse Press. Sensor Measurement
1 ●
Voltage < 0.8V
10 seconds continuous, Travel Reverse Press. Sensor Measurement Voltage
4 ●
< 0.3V
531
1. Monitor – Travel Reverse Press. display failure
(N.A)
2. Control Function – Driving interoperability power control operation failure
(Checking list)
0 10 seconds continuous, Battery input Voltage > 35V ●
1 10 seconds continuous, Battery input Voltage < 18V ●

1. Control Function – Startup impossibility
(Checking list)
1. CS-74 (#1) – CN-51 (#01) Checking Open/Short
(When Engine is equal or more than 400 rpm) 10 seconds continuous,
1 Alternator Node I Measurement Voltage < 18V ●
(In case 12v goods, Alternator Node I Measurement Voltage < 9V)
1. Control Function – Battery charging circuit failure
(Checking list)
1. CS-74 (#1) – CN-51 (#26) Checking Open/Short

5-36
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Model Parameter) Mounting Acc. Dial
3 ●
10 seconds continuous, Acc. Dial Measurement Voltage > 5.2V
(Model Parameter) Mounting Acc. Dial
4 ●
10 seconds continuous, Acc. Dial Measurement Voltage < 0.3V
714
(N.A)
1. Monitor – Acc. Dial Voltage display failure
2. Control Function – Engine rpm control failure
(Checking list)
(Detection)
(When Travel Alarm (Buzzer) Sound is Off)
10 seconds continuous, Travel Alarm (Buzzer) Sound Relay drive unit
4 ●
(Cancellation)
(When Travel Alarm (Buzzer) Sound Relay is Off)
3 seconds continuous, Travel Alarm (Buzzer) Sound Relay drive unit
(Detection)
(When Travel Alarm (Buzzer) Sound is On)
722 10 seconds continuous, Travel Alarm (Buzzer) Sound Relay drive
current > 4.5 A
6 ●
(Cancellation)
(When Travel Alarm (Buzzer) Sound is On)
3 seconds continuous, Travel Alarm (Buzzer) Sound Relay drive
current  4.5 A
1. Control Function – Driving alarm operation failure
(Checking list)
(When mounting the A/C Controller)
2 ●
60 seconds continuous, A/C Controller Communication Data Error
831 1. Control Function – A/C Controller operation failure
(Checking list)
2 60 seconds continuous, Cluster Communication Data Error ●
1. Control Function – Cluster operation failure
840
(Checking list)
1. CN-56A (#5) – CN-52 (#01) Checking Open/Short

5-37
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
2 10 seconds continuous, ECM Communication Data Error ●
1. Control Function – ECM operation failure
841
(Checking list)
(When mounting the Jog Dial Module)
2 ●
60 seconds continuous, Jog Dial Module Communication Data Error
848 1. Control Function – Jog Dial Module operation failure
(Checking list)
(When mounting the RMCU)
2 ●
60 seconds continuous, RMCU communication Data Error
(Resuluts / Symptoms)
850 1. Control Function – RMCU operation failure
(Checking list)
(When mounting the AAVM)
2 ●
60 seconds continuous, AAVM communication Data Error
866 1. Control Function – AAVM operation failure
(Checking list)
2 60 seconds continuous, RDU communication Data Error ●
1. Control Function – RDU operation failure
867
(Checking list)
5-38
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
2 60 seconds continuous, Switch Controller communication Data Error ●
1. Control Function – Switch Controller operation failure
868
(Checking list)
(When mounting the BKCU)
2 ●
60 seconds continuous, BKCU communication Data Error
869 1. Control Function – BKCU operation failure
(Checking list)
1. CS-2B (#A) – CN-51 (#09) Checking Open/Short
2. CS-2B (#B) – CN-51 (#08) Checking Open/Short

5-39
4. ENGINE FAULT CODE
Fault code
J1939 SPN Item Description
J1939 FMI
111 Engine control module critical internal failure Bad intelligent device or component
629
12
122 Intake manifold 1 pressure sensor circuit Voltage above normal, or shorted to high source
102
3
123 Intake manifold 1 pressure sensor circuit Voltage below normal, or shorted to low source
102
4
124 Intake manifold 1 pressure Data valid but above normal operating range -
102 moderately severe level
16
125 Intake manifold 1 pressure Data valid but below normal operating range -
18
133 Remote accelerator pedal or lever position sensor Voltage above normal, or shorted to high source
974 1 circuit
3
134 Remote accelerator pedal or lever position sensor Voltage below normal, or shorted to low source
974 1 circuit
4
135 Engine oil rifle pressure 1 sensor circuit Voltage above normal, or shorted to high source
100
3
141 Engine oil rifle pressure 1 sensor circuit Voltage below normal, or shorted to low source
100
4
143 Engine oil rifle pressure Data valid but below normal operating range -
18
144 Engine coolant temperature 1 sensor circuit Voltage above normal, or shorted to high source
110
3
145 Engine coolant temperature 1 sensor circuit Voltage below normal, or shorted to low source
110
4
146 Engine coolant temperature Data valid but above normal operating range -
16
147 Accelerator pedal or lever position 1 sensor Data valid but below normal operating range
91 circuit frequency
1
148 Accelerator pedal or lever position sensor 1 Data valid but above normal operational range -
91 most severe level
0
151 Engine coolant temperature Data valid but above normal operational range -
0
※ Some fault codes are not applied to this machine.
5-40
Fault code
J1939 FMI
153 Intake manifold 1 temperature sensor circuit Voltage above normal, or shorted to high source
105
3
154 Intake manifold 1 temperature sensor circuit Voltage below normal, or shorted to low source
105
4
187 Sensor supply 2 circuit Voltage below normal, or shorted to low source
3510
4
197 Coolant level Data valid but below normal operating range -
18
227 Sensor supply 2 circuit Voltage above normal, or shorted to high source
3510
3
234 Engine crankshaft speed/position Data valid but above normal operational range -
0
235 Coolant level Data valid but below normal operational range -
1
237 External speed command input Data erratic, intermittent or incorrect
644 (Multiple unit synchronization)
2
3511
4
3511
3
241 Wheel-based vehicle speed Data erratic, intermittent or incorrect
84
2
242 Wheel-based vehicle speed sensor circuit Abnormal rate of change
84 tampering has been detected
10
271 Engine fuel pump pressurizing assembly 1 circuit Voltage below normal, or shorted to low source
1347
4
272 Engine fuel pump pressurizing assembly 1 circuit Voltage above normal, or shorted to high source
1347
3
285 SAE J1939 multiplexing pgn timeout error Abnormal update rate
639
9
286 SAE J1939 multiplexing configuration error Out of calibration
639
13
5-41
Fault code
J1939 FMI
288 SAE J1939 multiplexing remote accelerator pedal Received network data in error
974 or lever position sensor system
19
293 Auxiliary temperature sensor input 1 circuit Voltage above normal, or shorted to high source
441
3
294 Auxiliary temperature sensor input 1 circuit Voltage below normal, or shorted to low source
441
4
297 Auxiliary pressure sensor input 2 circuit Voltage above normal, or shorted to high source
1388
3
298 Auxiliary pressure sensor input 2 circuit Voltage below normal, or shorted to low source
1388
4
322 Injector solenoid driver cylinder 1 circuit Current below normal or open circuit
651
5
653
5
652
5
654
5
334 Engine coolant temperature Data erratic, intermittent or incorrect
110
2
343 Engine control module warning internal hardware Bad intelligent device or component
629 failure
12
349 Transmission output shaft speed Data valid but above normal operating range -
16
351 Injector power supply Bad intelligent device or component
3597
12
3509
4
3509
3
415 Engine oil rifle pressure Data valid but below normal operational range -
1
5-42
Fault code
J1939 FMI
418 Water in fuel indicator Data valid but above normal operating range -
97 least severe level
15
428 Water in fuel indicator sensor circuit Voltage above normal, or shorted to high source
97
3
429 Water in fuel indicator sensor circuit Voltage below normal, or shorted to low source
97
4
431 Accelerator pedal or lever idle validation switch Data erratic, intermittent or incorrect
558
2
432 Accelerator pedal or lever idle validation switch Out of calibration
558 circuit
13
435 Engine oil rifle pressure Data erratic, intermittent or incorrect
100
2
451 Injector metering rail 1 pressure sensor circuit Voltage above normal, or shorted to high source
157
3
452 Injector metering rail 1 pressure sensor circuit Voltage below normal, or shorted to low source
157
4
488 Intake manifold 1 temperature Data valid but above normal operating range -
16
489 Transmission output shaft speed Data valid but below normal operating range -
18
497 Multiple unit synchronization switch Data erratic, intermittent or incorrect
1377
2
3514
3
3514
4
527 Auxiliary input/output 2 circuit Voltage above normal, or shorted to high source
702
3
529 Auxiliary input/output 3 circuit Voltage above normal, or shorted to high source
703
3
553 Injector metering rail 1 pressure Data valid but above normal operating range -
16
5-43
Fault code
J1939 FMI
555 Crankcase pressure Data valid but above normal operating range -
16
556 Crankcase pressure Data valid but above normal operational range -
0
559 Injector metering rail 1 pressure Data valid but below normal operating range -
18
584 Starter relay driver circuit Voltage above normal, or shorted to high source
677
3
585 Starter relay driver circuit Voltage below normal, or shorted to low source
677
4
599 Auxiliary commanded dual output shutdown Special instructions
640
14
611 Engine shut down hot Condition exists
1383
31
649 Engine oil change interval Condition exists
1378
31
687 Turbocharger 1 speed Data valid but below normal operating range -
18
689 Engine crankshaft speed/position Data erratic, intermittent or incorrect
190
2
691 Turbocharger 1 compressor intake temperature Voltage above normal, or shorted to high source
1172 circuit
3
692 Turbocharger 1 compressor intake temperature Voltage below normal, or shorted to low source
1172 circuit
4
693 Turbocharger 1 compressor intake temperature Data erratic, intermittent or incorrect
1172
7
731 Engine speed / position camshaft and crankshaft Mechanical system not responding or out of
723 misalignment adjustment
7
741 Turbocharger 1 compressor intake pressure Voltage above normal, or shorted to high source
1176 circuit
3
742 Turbocharger 1 compressor intake pressure Voltage below normal, or shorted to low source
1176 circuit
4
5-44
Fault code
J1939 FMI
743 Turbocharger 1 compressor intake pressure Data erratic, intermittent or incorrect
1176
2
769 Brake switch circuit Voltage above normal, or shorted to high source
597
3
771 Brake switch circuit Voltage below normal, or shorted to low source
597
4
778 Engine camshaft speed / position sensor Data erratic, intermittent or incorrect
723
2
1117 Power supply lost with ignition on Data erratic, intermittent or incorrect
3597
2
1239 Accelerator pedal or lever position sensor 2 Voltage above normal, or shorted to high source
2623 circuit
3
1241 Accelerator pedal or lever position sensor 2 Voltage below normal, or shorted to low source
2623 circuit
4
1242 Accelerator pedal or lever position sensor 1 Data erratic, intermittent or incorrect
91
2
1358 Accelerator pedal or lever position sensor 1 Voltage above normal, or shorted to high source
91 circuit
3
1359 Accelerator pedal or lever position sensor 1 Voltage below normal, or shorted to low source
91 circuit
4
1515 SAE J1939 multiplexed accelerator pedal or lever Received network data in error
91 sensor system
19
1539 Auxiliary pressure sensor input 1 circuit Voltage above normal, or shorted to high source
1387
3
1621 Auxiliary pressure sensor input 1 circuit Voltage below normal, or shorted to low source
1387
4
1668 Aftertreatment 1 diesel exhaust fluid tank level Voltage below normal, or shorted to low source
1761 sensor circuit
4
1669 Aftertreatment 1 diesel exhaust fluid tank level Voltage above normal, or shorted to high source
1761 sensor circuit
3
1673 Aftertreatment 1 diesel exhaust fluid tank level Data valid but below normal operational range
1761 -most severe level
1
5-45
Fault code
J1939 FMI
1677 Aftertreatment 1 diesel exhaust fluid tank Voltage below normal, or shorted to low source
3031 temperature sensor
4
1678 Aftertreatment 1 diesel exhaust fluid tank Voltage above normal, or shorted to high source
3
1679 Aftertreatment 1 diesel exhaust fluid tank Data erratic, intermittent or incorrect
3031 temperature
2
1682 Aftertreatment 1 diesel exhaust fluid dosing unit Condition exists
3362 input lines
31
1685 Aftertreatment diesel exhaust fluid quality sensor Voltage below normal, or shorted to low source
3364 circuit
4
1686 Aftertreatment diesel exhaust fluid quality sensor Voltage above normal, or shorted to high source
3364 circuit
3
1695 Sensor supply 5 Voltage above normal, or shorted to high source
3513
3
1696 Sensor supply 5 Voltage below normal, or shorted to low source
3513
4
1713 Aftertreatment 1 diesel exhaust fluid tank heater Data valid but above normal operating range -
16
1714 Aftertreatment diesel exhaust fluid quality Out of calibration
3364
13
1715 Aftertreatment diesel exhaust fluid quality Root cause not known
3364
11
1843 Crankcase pressure circuit Voltage above normal, or shorted to high source
101
3
1844 Crankcase pressure circuit Voltage below normal, or shorted to low source
101
4
1852 Water in fuel indicator Data valid but above normal operating range -
16
1879 Aftertreatment diesel particulate filter differential Voltage above normal
3251 pressure sensor circuit
3
1881 Aftertreatment diesel particulate filter differential Voltage below normal
4
5-46
Fault code
J1939 FMI
1883 Aftertreatment diesel particulate filter differential Data erratic, intermittent or incorrect
3251 pressure sensor
2
1885 Aftertreatment 1 intake NOx sensor circuit Voltage below normal, or shorted to low source
3216
4
1887 Aftertreatment 1 outlet NOx sensor circuit Voltage below normal, or shorted to low source
3226
4
1921 Aftertreatment diesel particulate filter differential Data valid but above normal operating range
3251 pressure
16
3251 pressure
0
1993 Aftertreatment 1 diesel particulate filter missing Condition exists
4795
31
3512
3
3512
4
2311 Electronic fuel injection control valve circuit Condition exists
633
31
2321 Engine crankshaft speed/position Data erratic, intermittent or incorrect
190
2
2322 Engine camshaft speed / position sensor Data erratic, intermittent or incorrect
723
2
2373 Exhaust gas pressure sensor 1 circuit Voltage above normal, or shorted to high source
1209
3
2374 Exhaust gas pressure sensor 1 circuit Voltage below normal, or shorted to low source
1209
4
2448 Coolant level Data valid but below normal operating range -
17
2468 Engine speed Engine crankshaft speed/position - data valid but
190 above normal operating range - moderately
16 severe level
2554 Exhaust gas pressure 1 Data erratic, intermittent or incorrect
1209
2
5-47
Fault code
J1939 FMI
2557 Auxiliary PWM driver 1 circuit Voltage above normal, or shorted to high source
697
3
2558 AuxiliaryPWM driver 1 circuit Voltage below normal, or shorted to low source
697
4
2571 Engine charge air cooler outlet temperature Voltage above normal, or shorted to high source
2630
3
2572 Engine charge air cooler outlet temperature Voltage below normal, or shorted to low source
2630
4
3251 pressure
15
2771 Aftertreatment 1 outlet NOx sensor Abnormal update rate
3226
9
2778 Aftertreatment fuel rate Data valid but above normal operating range -
16
2973 Intake manifold 1 pressure Data erratic, intermittent or incorrect
102
2
2976 Aftertreatment 1 diesel exhaust fluid dosing unit Data erratic, intermittent or incorrect
3361 temperature
2
3133 Aftertreatment 1 diesel particulate filter outlet Voltage above normal, or shorted to high source
3
3134 Aftertreatment 1 diesel particulate filter outlet Voltage below normal, or shorted to low source
4
3135 Aftertreatment 1 diesel particulate filter outlet Data erratic, intermittent or incorrect
3610 pressure
2
3139 Engine air shutoff circuit Voltage above normal, or shorted to high source
3667
3
3141 Engine air shutoff circuit Voltage below normal, or shorted to low source
3667
4
3142 Aftertreatment 1 SCR intake temperature sensor Voltage above normal, or shorted to high source
4360 circuit
3
3144 Aftertreatment 1 SCR intake temperature sensor Data erratic, intermittent or incorrect
4360
2
5-48
Fault code
J1939 FMI
3146 Aftertreatment 1 SCR outlet temperature sensor Voltage above normal, or shorted to high source
4363 circuit
3
3147 Aftertreatment 1 SCR outlet temperature sensor Voltage below normal, or shorted to low source
4363 circuit
4
3148 Aftertreatment 1 SCR outlet temperature sensor Data erratic, intermittent or incorrect
4363
2
3151 Aftertreatment 1 SCR catalyst system missing Condition exists
4974
31
3165 Aftertreatment 1 SCR outlet temperature Data valid but above normal operational range -
4363 most severe
0
3232 Aftertreatment 1 intake NOx sensor Abnormal update rate
3216
9
3235 Aftertreatment 1 SCR outlet temperature Data valid but above normal operating range -
16
3251 Aftertreatment 1 diesel oxidation catalyst intake Data valid but above normal operating range
4765 temperature
16
3253 Aftertreatment 1 diesel particulate filter intake Data valid but above normal operating range
3242 temperature
16
3254 Aftertreatment 1 diesel particulate filter intake Data valid but above normal operating range
3242 temperature
16
3255 Aftertreatment 1 diesel particulate filter outlet Data valid but above normal operating range
3246 temperature
16
3311 Aftertreatment 1 diesel particulate filter intake Data valid but above normal operation
3242 temperature
0
3312 Aftertreatment 1 diesel particulate filter outlet Data valid but above normal operation
3246 temperature
0
3313 Aftertreatment 1 diesel oxidation catalyst intake Voltage below normal, or shorted to low source
4765 temperature sensor circuit
4
3314 Aftertreatment 1 diesel oxidation catalyst intake Voltage above normal, or shorted to high source
3
3315 Aftertreatment 1 diesel oxidation catalyst intake Data erratic, intermittent or incorrect
4765 temperature
2
5-49
Fault code
J1939 FMI
3316 Aftertreatment 1 diesel particulate filter intake Voltage below normal, or shorted to low source
4
3317 Aftertreatment 1 diesel particulate filter intake Voltage above normal, or shorted to high source
3
3318 Aftertreatment 1 diesel particulate filter intake Data erratic, intermittent or incorrect
3242 temperature
2
3319 Aftertreatment 1 diesel particulate filter outlet Voltage above normal, or shorted to high source
3
3321 Aftertreatment 1 diesel particulate filter outlet Voltage below normal, or shorted to low source
4
3322 Aftertreatment 1 diesel particulate filter outlet Data erratic, intermittent or incorrect
3246 temperature
2
3326 SAE J1939 multiplexed accelerator pedal or lever Abnormal update rate
91 sensor system
9
3341 Engine air filter differential pressure - data valid Moderately severe level
107 but above normal operating range
16
3375 Aftertreatment diesel particulate filter Condition exists
5397 regeneration too frequent
31
3376 Aftertreatment diesel particulate filter incomplete Condition exists
5319 regeneration
31
3497 Aftertreatment 1 diesel exhaust fluid tank level Data valid but below normal operating range -
17
3498 Aftertreatment 1 diesel exhaust fluid tank level Data valid but below normal operating range -
18
3527 Accelerator pedal or lever idle validation switch Received network data in error
558
19
3528 Accelerator pedal or lever idle validation switch Abnormal update rate
558
9
3545 Aftertreatment 1 outlet NOx sensor Abnormal rate of change
3226
31
3547 Aftertreatment diesel exhaust fluid tank empty Condition exists
4096
31
5-50
Fault code
J1939 FMI
3558 Aftertreatment 1 diesel exhaust fluid dosing unit Voltage above normal, or shorted to high source
3361
3
3559 Aftertreatment 1 diesel exhaust fluid dosing unit Voltage below normal, or shorted to low source
3361
4
3567 Aftertreatment diesel exhaust fluid dosing valve Current below normal or open circuit
5394
5
3568 Aftertreatment diesel exhaust fluid dosing valve Mechanical system not responding or out of
5394 adjustment
7
3571 Aftertreatment 1 diesel exhaust fluid pressure Voltage above normal, or shorted to high source
4334 sensor
3
3572 Aftertreatment 1 diesel exhaust fluid pressure Voltage below normal, or shorted to low source
4334 sensor
4
3574 Aftertreatment 1 diesel exhaust fluid pressure Data valid but below normal operating range
4334 sensor
18
3575 Aftertreatment 1 diesel exhaust fluid pressure Data valid but above normal operating range
4334 sensor
16
3577 Aftertreatment diesel exhaust fluid return valve Voltage above normal, or shorted to high source
4376
3
3578 Aftertreatment diesel exhaust fluid return valve Voltage above normal, or shorted to low source
4376
4
3583 Aftertreatment 1 outlet nox sensor heater Abnormal rate of change
5031
10
3596 Aftertreatment 1 diesel exhaust fluid pressure Data erratic, intermittent or incorrect
4334 sensor
2
3641 Transmission output retarder Abnormal update rate
748
9
3649 Aftertreatment 1 intake NOx sensor heater Abnormal rate of change
5024
10
3681 Aftertreatment 1 outlet NOx sensor power supply Data erratic, intermittent or incorrect
3228
2
3682 Aftertreatment 1 intake NOx sensor power supply Data erratic, intermittent or incorrect
3218
2
5-51
Fault code
J1939 FMI
3697 Engine control module calibration memory Bad intelligent device or component
630
12
3712 Aftertreatment SCR operator inducement Data valid but above normal operational range -
0
3714 Engine protection torque derate Condition exists
1569
31
3725 Aftertreatment 1 intake NOx sensor Abnormal rate of change
3216
10
3727 High pressure common rail fuel pressure relief Mechanical system not responding or out of
5571 valve adjustment
7
3737 Engine starter mode overcrank protection Condition exists
1675
31
3741 High pressure common rail fuel pressure relief Data valid but above normal operational range
5571 valve
0
3748 Aftertreatment 1 intake NOx sensor Data not rational - drifted high
3216
20
3765 Auxiliary temperature sensor input 2 circuit Voltage above normal, or shorted to high source
442
3
3766 Auxiliary temperature sensor input 2 circuit Voltage below normal, or shorted to low source
442
4
3838 Estimated engine parasitic losses - percent Abnormal update rate
2978 torque
9
3841 Cruise control enable switch Data erratic, intermittent or incorrect
596
2
3843 Cruise control disable command Abnormal update rate
5603
9
3845 Cruise control disable command Condition exists
5603
31
3866 Aftertreatment diesel exhaust fluid quality Data valid but below normal operational range -
1
3868 Aftertreatment diesel exhaust fluid quality Abnormal update rate
3364
9
5-52
Fault code
J1939 FMI
3878 Aftertreatment diesel exhaust fluid quality Data erratic, intermittent or incorrect
3364
2
4151 A f t e r t r e a t m e n t d i e s e l p a r t i c u l a t e f i l t e r Abnormal update rate
5742 temperature sensor module
9
4152 Aftertreatment selective catalytic reduction Abnormal update rate
9
5746 heater relay
4
4158 A f t e r t r e a t m e n t d i e s e l p a r t i c u l a t e f i l t e r Bad intelligent device or component
12
4159 Aftertreatment selective catalytic reduction Bad intelligent device or component
12
4161 A f t e r t r e a t m e n t d i e s e l p a r t i c u l a t e f i l t e r Voltage above normal, or shorted to high source
3
4162 A f t e r t r e a t m e n t d i e s e l p a r t i c u l a t e f i l t e r Voltage below normal, or shorted to low source
4
4163 A f t e r t r e a t m e n t d i e s e l p a r t i c u l a t e f i l t e r Data valid but above normal operating range
16
4164 Aftertreatment selective catalytic reduction Voltage above normal, or shorted to high source
3
4165 Aftertreatment selective catalytic reduction Voltage below normal, or shorted to low source
4
4166 Aftertreatment selective catalytic reduction Data valid but above normal
16
5745 heater
3
5745 heater
4
4249 Aftertreatment 1 diesel exhaust fluid dosing Abnormal rate of change
4337 temperature
10
4251 Aftertreatment 1 diesel exhaust fluid dosing unit Abnormal rate of change
5798 heater temperature
10
5-53
Fault code
J1939 FMI
4259 A f t e r t r e a t m e n t d i e s e l p a r t i c u l a t e f i l t e r Root cause not known
11
4261 Aftertreatment selective catalytic reduction Root cause not known
11
4277 Aftertreatment diesel exhaust fluid quality Abnormal rate of change
3364
10
4284 Desired engine fueling state Abnormal update rate
5793
9
4452 Aftertreatment 1 outlet NOx sensor closed loop Condition exists
3226 operation
7
4484 Engine air shutoff Mechanical system not responding or out of
3667 Adjustment
7
4526 Brake pedal position Data erratic, intermittent or incorrect
521
2
4572 Aftertreatment 1 diesel exhaust fluid tank Abnormal update rate
3031 temperature
9
4584 Aftertreatment diesel particulate filter system Special instructions
3936
14
4585 Aftertreatment 1 SCR catalyst system Special instructions
4792
14
4677 SAE J1939 multiplexing pgn timeout error Abnormal update rate
1761
9
4724 Auxiliary input/output 2 circuit Current below normal or open circuit
702
5
4725 Auxiliary input/output 2 circuit Current above normal or grounded circuit
702
6
4731 Aftertreatment 1 diesel exhaust fluid tank Out of calibration
13
4734 Auxiliary input/output 1 Special instructions
701
14
4737 Aftertreatment 1 diesel exhaust fluid tank Root cause not known
3031 temperature
11
5-54
Fault code
J1939 FMI
4739 Aftertreatment 1 diesel exhaust fluid tank level Root cause not known
1761 sensor
11
4747 Aftertreatment intake oxygen sensor Data not rational - drifted high
3217
20
4748 Aftertreatment intake oxygen sensor Data not rational - drifted low
3217
21
4749 Aftertreatment outlet oxygen Data not rational - drifted high
3227
20
4751 Aftertreatment outlet oxygen Data not rational - drifted low
3227
21
4768 Aftertreatment 1 diesel exhaust fluid property Root cause not known
3521
11
4769 Aftertreatment 1 diesel exhaust fluid tank level Abnormal rate of change
1761 sensor
10
4842 Aftertreatment diesel exhaust fluid quality Data valid but above normal operating range -
3364 Least severe level
15
4863 Aftertreatment diesel exhaust fluid tank low level -
5245 indicator
31
4953 Alternator 1 status Voltage above normal, or shorted to high source
3353
3
4954 Alternator 1 status Voltage below normal, or shorted to low source
3353
4
5248 Tachograph output shaft speed Out of calibration
1623
13
5272 Engine exhaust back pressure regulator control Voltage below normal, or shorted to low source
649 circuit
4
5273 Engine exhaust back pressure regulator control Current below normal or open circuit
649 circuit
5
5274 Engine exhaust back pressure regulator position Data erratic, intermittent or incorrect
5625
2
5275 Engine exhaust back pressure regulator position Voltage above normal, or shorted to high source
5625 sensor circuit
3
5-55
Fault code
J1939 FMI
5276 Engine exhaust back pressure regulator position Voltage above normal, or shorted to low source
5625 sensor circuit
4
5292 Excessive time since last engine air shutoff Condition exists
520809 maintenance test
31
5383 Aftertreatment 1 diesel particulate filter ash load Data valid but above normal operating range -
3720 percent least severe level
15
5576 Engine air filter differential pressure Data valid but above normal operating range -
15
5632 SCR system cleaning inhibited due to inhibit Condition exists
6918 switch
31
5652 Exhaust pressure 1 Data valid but above normal operating range -
15
5653 SCR operator inducement override switch Abnormal update rate
6881
9
5654 SCR operator inducement override switch Out of calibration
6881
13
5655 Aftertreatment 1 scr conversion efficiency Condition exists
4364
31
5689 Aftertreatment 1 outlet nox sensor Root cause not known
3226
11
5715 Aftertreatment 1 diesel particulate filter differential Abnormal rate of change
3521 pressure
10
5716 Aftertreatment 1 diesel particulate filter outlet Abnormal rate of change
3610 pressure
10
5864 Aftertreatment 1 diesel exhaust fluid pump Voltage above normal or shorted to high source
4375 command circuit
3
5865 Aftertreatment 1 diesel exhaust fluid pump Voltage below normal or shorted to low source
4375 command circuit
4
5868 Aftertreatment 1 scr feedback control status Mechanical system not responding or out of
4339 adjustment
7
5935 Aftertreatment 1 diesel exhaust fluid pressure Mechanical system not responding or out of
4334 adjustment
7
5-56
Fault code
J1939 FMI
5936 Aftertreatment 1 diesel exhaust fluid pressure Data valid but above normal operating range -
15
5938 Aftertreatment 1 diesel particulate filter conditions Special instructions
3750 not met for active regeneration
14
Machine constrained operation Abnormal update rate. No communication or an
5939
Invalid data transfer rate has been detected on
520968
the J1939 data link between the ECM and the
9
machine
5941 Machine constrained operation Received network data in error. The received
520968 J1939 datalink message was not valid.
19
6256 Battery 1 voltage Data valid but below normal operating range -
15
6257 Battery 1 voltage Data valid but below normal operating range -
17
6263 Fan control circuit Voltage above normal, or shorted to high source
647
3
6264 Fan control circuit Voltage below normal, or shorted to low source
647
4
6456 Engine fan clutch 2 control circuit Voltage above normal, or shorted to high source
5484
3
6457 Engine fan clutch 2 control circuit Voltage below normal, or shorted to low source
5484
4
6467 Fan speed Data valid but above normal operational range -
15
6468 Fan speed Data valid but below normal operational range -
17
6471 Fan blade pitch position sensor circuit Voltage above normal, or shorted to high source
6799
3
6472 Fan blade pitch position sensor circuit Voltage below normal, or shorted to low source
6799
4
6475 Aftertreatment 1 diesel exhaust fluid tank heater Mechanical system not responding or out of
3363 adjustment
7
6476 Aftertreatment 1 diesel exhaust fluid tank heater Data valid but below normal operating range -
18
5-57
Fault code
J1939 FMI
6477 Aftertreatment diesel exhaust fluid line heater Voltage above normal, or shorted to high source
5491 relay
3
6478 Aftertreatment diesel exhaust fluid line heater Voltage below normal, or shorted to low source
5491 relay
4
6479 Aftertreatment 1 diesel exhaust fluid tank heater Voltage above normal, or shorted to high source
3363
3
6481 Aftertreatment 1 diesel exhaust fluid tank heater Voltage below normal, or shorted to low source
3363
4
6511 Maintain ECM power lamp Voltage above normal, or shorted to high source
6655
3
6512 Maintain ECM power lamp Voltage below normal, or shorted to low source
6655
4
6513 Aftertreatment 1 diesel exhaust fluid dosing unit Data valid but below normal operating range
5745 heater
17
6522 Coolant level sensor 1 circuit Voltage above normal, or shorted to high source
111
3
6523 Coolant level sensor 1 circuit Voltage below normal, or shorted to low source
111
4
6526 Aftertreatment 1 diesel exhaust fluid tank level Out of calibration
1761 sensor
13
6527 Aftertreatment diesel exhaust fluid return valve Mechanical system not responding or out of
4376 adjust
7
5746 heater relay
3
6531 Aftertreatment 1 diesel exhaust fluid line heater 1 Voltage above normal, or shorted to high source
4340 circuit
3
6532 Aftertreatment 1 diesel exhaust fluid line heater 1 Voltage below normal, or shorted to low source
4340 circuit
4
6533 Aftertreatment 1 diesel exhaust fluid line heater 2 Voltage above normal, or shorted to high source
4342 circuit
3
6534 Aftertreatment 1 diesel exhaust fluid line heater 2 Voltage below normal, or shorted to low source
4342 circuit
4
5-58
Fault code
J1939 FMI
6535 Aftertreatment diesel exhaust fluid line heater 3 Voltage above normal, or shorted to high source
4344 circuit
3
6536 Aftertreatment diesel exhaust fluid line heater 3 Voltage below normal, or shorted to low source
4344 circuit
4
6556 Engine intake air heater 1 circuit Voltage above normal, or shorted to high source
729
3
6557 Engine intake air heater 1 circuit Voltage below normal, or shorted to low source
729
4
6563 Auxiliary intermediate (PTO) speed switch Data erratic, intermittent or incorrect
976 validation
2
6568 Aftertreatment regeneration inhibit switch Data erratic, intermittent or incorrect
3695
2
6583 Auxiliary temperature sensor input 1 Special instructions
441
14
6584 Auxiliary pressure sensor input 2 Special instructions
1388
14
6595 Engine speed Root cause not known
190
11
6596 Diesel particulate filter active regeneration Condition exists
3713 inhibited due to system timeout
31
6599 Engine cranks slowly Condition exists
521002
31
6611 Engine starter motor relay control circuit Voltage above normal or shorted to high source
6385
3
6612 Engine starter motor relay control circuit Voltage below normal or shorted to low source
6385
4
6613 SCR monitoring system malfunction Special instructions
5842
14
6618 Parking brake switch Data erratic, intermittent, or incorrect
70
2
6619 Aftertreatment 1 diesel exhaust fluid temperature Abnormal rate of change
3515 2
10
5-59
Fault code
J1939 FMI
6654 Engine exhaust back pressure regulator Mechanical system not responding or out of
5626 adjustment
7
6726 Aftertreatment 1 diesel oxidation catalyst missing Condition exists
4796
31
6752 Aftertreatment diesel exhaust fluid quality Data valid but below normal operating range -
18
6771 Aftertreatment system assembly Special instructions
521032
14
6938 Desired engine fueling state Abnormal update rate
5793
9
6939 Engine start request Abnormal update rate
7745
9
7133 Engine start request Out of calibration
7745
13
7134 Engine start consent Out of calibration
7746
13
7135 Engine turbocharger speed Data valid but above normal operating range -
15
7745 Engine protection torque derate Special instructions
1569
14
7393 Engine start request Abnormal update rate
7745
9
7453 Aftertreatment 1 diesel particulate filter intake Data valid but above normal operating range -
3242 temperature least severe level
15
7454 Aftertreatment 1 diesel particulate filter outlet Data valid but above normal operating range -
3246 temperature least severe level
15
5-60
GROUP 13 ENGINE CONTROL SYSTEM
1. UNITED MCU AND ENGINE ECM
ECM(Engine control module)
LED
2
1
1 United MCU
4
-5
N
C
3
-5
N
C
2
-5
2 Bolt (M8)
N
C
1
-5
N
C
210A5MS13
2. UNITED MCU ASSEMBLY

1) To match the pump absorption torque with the engine torque, united MCU varies EPPR valve
output pressure, which control pump discharge amount whenever feedbacked engine speed drops
under the reference rpm of each mode set.
2) Three LED lamps on the united MCU display as below.
LED lamp Trouble Service

G is turned ON Normal -
G and R are turned ON Trouble on united MCU · Change the united MCU
G and Y are turned ON Trouble on serial · Check if serial communication
communication line lines between united MCU and cluster are
disconnected
Three LED are turned OFF Trouble on united MCU · Check if the input power wire (24 V, GND) of
power united MCU is disconnected
· Check the fuse
G : green, R : red, Y : yellow
5-61
GROUP 14 EPPR VALVE
1. PUMP EPPR VALVE

1) COMPOSITION
EPPR (Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve
installed at main pump.
(1) Electro magnet valve
Receive electric current from MCU and move the spool proportionally according to the specific
amount of electric current value.
(2) Spool valve
Is the two way direction control valve for pilot pressure to reduce main pump flow.
When the electro magnet valve is activated, pilot pressure enters into flow regulator of main pump.
2) HOW TO SWITCH THE POWER SHIFT (STANDARD ↔ OPTION) ON THE CLUSTER

You can switch the EPPR valve pressure set by selecting the power shift (standard ↔ option).
- Management
·Service menu
300A3CD105A
300A3CD106A 300A3CD107A
Enter the password
· Power shift (standard/option) : Power shift pressure can be set by option menu.
5-62
3) OPERATING PRINCIPLE (P1 and P2 pump EPPR valve)
(1) Structure
902
351 311 326 324
312 361 362 363 861 901 801 802 220F2MP12
311 Spool 361 O-ring 801 Seal nut

312 Sleeve 362 O-ring 861 O-ring
324 Spring 363 O-ring 901 Name plate
326 Retaining ring 801 Solenoid 902 Function name plate
351 Orifice
A
P Pilot oil supply line (pilot pressure)
P
T Return to tank
T
A Secondary pressure to flow regulator at main pump
(2) Neutral
eutral
Pressure line is blocked and A oil returns
to tank.
P A
T
P T
A
220F5MP13
(3) Operating
perating
Secondary pressure enters into A.
P A
T
P T
A
220F5MP14
5-63
4) EPPR VALVE CHECK PROCEDURE Spec : 100~700 mA
(1) Check electric current value at EPPR valve
Adapter(P/no.:21Q6-50410)
① Disconnect connector CN-342 (or 343) CN-342 (or 343)
from EPPR valve. Multimeter EPPR valve
② Insert the adapter to CN-342 (or 343)

and install multimeter as figure.
P2 pump
③ Start engine.
P1 pump
④ Set S-mode and cancel auto decel
mode.
⑤ Position the multimodal dial at 10.
⑥ If rpm display show approx 1700±50 Main pump
rpm check electric current at bucket

circuit relief position. CN-342 for P1 pump
CN-343 for P2 pump
⑦ Check electric current at bucket circuit
relief position. 220A5MS21
(2) Check pressure at EPPR valve Spec : 2~25 kgf/cm2 (30~350 psi)
① Remove plug and connect pressure Pressure adjusting
gauge as figure. screw locknut
·Gauge capacity : 0 to 50 kgf/cm2 EPPR valve

(0 to 725 psi)
CN-342 (or 343)
② Start engine. a5
P2
③ Set S-mode and cancel auto decel P1
mode.
a4
④ Position the multimodal dial at 10.
⑤ If tachometer show approx 1700±50
rpm check pressure at relief position of Main pump
bucket circuit by operating bucket control

a4 for P1 pump
lever. a5 for P2 pump
⑥ If pressure is not correct, adjust it. 220A5MS22
⑦ After adjust, test the machine.
5-64
2. BOOM PRIORITY EPPR VALVE
1) COMPOSITION
The boom priority EPPR valve is built in a manifold and mainly consisting of valve body and coil.
This EPPR valve installed under the solenoid valve.
2) CONTROL
The boom priority EPPR valve has to be controlled by a specific electronic amplifier card, which is
supplying the coil with a current 580 mA at 30Ω and 24 V.
3) OPERATING PRINCIPLE
(1) Structure
1 5 4 6
P T
2 Control spool 3
21095MS14
P : Pilot supply line

P
A T : Return to tank
T
A : Secondary pressure to flow MCV
1 O-ring 3 Valve body 5 Connector

2 Support ring 4 Coil 6 Cover cap
(2) Operation
In de-energized mode the inlet port (P) is closed and the outlet port (A) is connected to tank port
(T).
In energized mode the solenoid armature presses onto the control spool with a force
corresponding to the amount of current. This will set a reduced pressure at port A. The setting is
proportional to the amount of current applied.
(3) Maximum pressure relief
If a pressure from outside is applied on port A the valve may directly switch to tank port (T) and
protect the system before overload.
5-65
2) EPPR VALVE CHECK PROCEDURE Spec : 400~600 mA
(combined boom up and swing operation)
(1) Check electric current value at EPPR
valve
① Disconnect connector CN-242 (or 243)
from EPPR valve. P1
A1
A2
A3
② Insert the adapter to CN-242 (or 243) T1

③ Start engine.
vs arm 3 cartridge
④ Set S-mode and cancel auto decel vs swing EPPR valve
mode. CN-242 (vs swing)
CN-243 (vs arm)
⑤ If rpm display approx 1700±50 rpm Adapter
Multimeter
disconnect one wire harness from EPPR (P/no.:21Q6-50410)
valve.
⑥ Check electric current in case of 220A5MS15
combined boom up and swing operation.
(2) Check pressure at EPPR valve Spec : 12~37 kgf/cm2 (170~530 psi)
① Remove hose from A5 port and connect (combined boom up and swing operation)
pressure gauge as figure. Pressure
gauge
·Gauge capacity : 0 to 50 kgf/cm2
(0 to 725 psi)
② Start engine. A2
A1
P1
③ Set S-mode and cancel auto decel
T1 A3
mode.
④ If rpm display approx 1700±50 rpm
check pressure (In case of combined
vs arm 3 cartridge
boom up and swing operation). vs swing EPPR valve
⑤ If pressure is not correct, adjust it. CN-242 (vs swing)

CN-243 (vs arm)
⑥ After adjust, test the machine. Multimeter Adapter

(P/no.:21Q6-50410)
220A5MS16
5-66
GROUP 15 MONITORING SYSTEM
1. OUTLINE
Monitoring system consists of the monitor part and switch part.
The monitor part gives warnings when any abnormality occurs in the machine and informs the
condition of the machine.
Various select switches are built into the monitor panel, which act as the control portion of the machine
control system.
2. CLUSTER
1) MONITOR PANEL
Time display
Warning lamps
(see page 5-73)
Gauge(see page 5.70)
Main menu(see page 5-88)
Tripmeter
(see page 5-103)
Pilot lamps
(see page 5-80)
Switches
(see page 5-84)
210A5CD20A
※ The warning lamp pops up and/or blinks and the buzzer sounds when the machine has a
problem.
The warning lamp blinks until the problem is cleared. Refer to page 5-73 for details.
※ This cluster is adjustable. Forward
· Vertical (forward/backward) : each 15°
· Horizontal (left only) : 8°
Left
Backward
290F3CD47
5-67
2) CLUSTER CHECK PROCEDURE
(1) Start key : ON
① Check monitor
a. Buzzer sounding for 4 seconds with HYUNDAI logo on cluster.
※ If the ESL mode is set to the enable, enter the password to start engine.
② After initialization of cluster, the operating screen is displayed on the LCD.
Also, self diagnostic function is carried out.
a. Engine rpm display : 0 rpm
b. Engine coolant temperature gauge : White range
c. Hydraulic oil temperature gauge : White range
d. Fuel level gauge : White range
③ Indicating lamp state
a. Power mode pilot lamp : E mode or U mode
b. Work mode pilot lamp : General operation mode (bucket)
c. Travel speed pilot lamp : Low (turtle)
(2) Start of engine

① Check machine condition
a. RPM display indicates at present rpm
b. Gauge and warning lamp : Indicate at present condition.
※ When normal condition : All warning lamp OFF
c. Work mode selection : General work
d. Power mode selection : E mode or U mode
e. Travel speed pilot lamp : Low (turtle)
② When warming up operation
a. Warming up pilot lamp : ON
b. After engine started, engine speed increases 1100 rpm.
※ Others same as above.
③ When abnormal condition
a. The warning lamp lights up and the buzzer sounds.
b. If BUZZER STOP switch is pressed, buzzer sound is canceled but the lamp warning lights up
until normal condition.
※ The pop-up warning lamp moves to the original position and blink when the buzzer stop switch is
pushed. Also the buzzer stops.
5-68
3) CLUSTER CONNECTOR
(1) CN-56A
No. Name Signal
1 Battery 24V 20~32V
2 Power IG (24V) 20~32V CN-56B
3 GND - CN-56A
4 CAN 1 (H) 0~5V

5 CAN 1 (L) 0~5V
6 CAN 2 (H) 0~5V
7 CAN 2 (L) 20~32V
8 NC - Cluster 1 6
9 NC -
10 Aux left 0~5V
11 Aux right 0~5V
12 Aux GND - 12
7
CN-56A
(2) CN-56B
1 4
No. Name Signal
1 CAM 6.5V 6.3~6.7V
2 CAM GND -
3 CAM DIFF (H) 0~5V
4 CAM DIFF (L) 0~5V 5 8
CN-56B
5 CAM 1 NTSC signal
6 CAM 2 NTSC signal
7 CAM 3 NTSC signal
8 CAM shield 0~5V 300L5MS14
NTSC : National Television System Committee
5-69
4) GAUGE
(1) Operation screen
When you first turn starting switch ON, the operation screen will appear.
1
2
4
7
5 3
6
8
300A3CD21A
1 RPM / Speed gauge 5 DEF/AdBlue® level gauge

2 Engine coolant temperature gauge 6 Tripmeter display
3 Hydraulic oil temperature gauge 7 Eco guage
4 Fuel level gauge 8 Accel dial gauge
(2) RPM / Speed

peed gauge
① This display the engine speed.
300A3CD22
(3) Engine coolant temperature gauge

① This gauge indicates the temperature of coolant.
·White range : 40-113˚C (104-235˚F)
·Red range : Above 113˚C (235˚F)
② If the indicator is in the red range or lamp pops up and the
buzzer sounds turn OFF the engine and check the engine
cooling system.
※ If the gauge indicates the red range or lamp blinks in
290F3CD53
red even though the machine is on the normal condition,
check the electric device as that can be caused by the poor
connection of electricity or sensor.
5-70
(4) Hydraulic oil temperature gauge
① This gauge indicates the temperature of hydraulic oil.
·White range : 40-105˚C(104-221˚F)
·Red range : Above 105˚C(221˚F)
② If the indicator is in the red range or lamp pops up and the
buzzer sounds reduce the load on the system. If the gauge
stays in the red range, stop the machine and check the cause
290F3CD54
of the problem.
(5) Fuel level gauge

① This gauge indicates the amount of fuel in the fuel tank.
② Fill the fuel when the red range, or lamp pops up and the
buzzer sounds.
290F3CD55
(6) DEF/AdBlue® L
Level
evel gauge
① This gauge indicates the amount of liquid in the DEF/AdBlue®
tank.
② Fill the DEF/AdBlue® when the red range, or lamp pops
up and the buzzer sounds.
③ Do not pour DEF/AdBlue® overfull.
※ Refer to page 5-78
5-78..
290F3CD57
(7) Tripmeter display

① This displays the engine the tripmeter.
※ Refer to page 5-103 for details.
290F3CD56
5-71
(8) Eco gauge
① This gauge indicates the fuel consumption rate and machine
load status. So that operators can be careful with fuel econo-
my.
② The fuel consumption rate or machine load is higher, the
number of segment is increased.
③ The color of Eco gauge indicates operation status.
·White : Idle operation
290F3CD58
·Green : Economy operation
·Yellow : Non-economy operation at a medium level.
·Red : Non-economy operation at a high level.
(9) Accel dial gauge

① This gauge indicates the level of accel dial.
290F3CD59
5-72
5) WARNING LAMPS
Check engine warning lamp Battery charging warning lamp
Engine oil pressure warning lamp Air cleaner warning lamp
Coolant level warning lamp Overload warning lamp
Emergency warning lamp
Engine stop warning lamp Water in fuel warning lamp
Fuel level warning lamp Engine coolant

temperature warning lamp
DEF/AdBlue R
level warning lamp Hydraulic oil temperature
warning lamp
HEST warning lamp
Exhaust system cleaning

inhibit warning lamp
Seat belt reminder warning lamp Exhaust system cleaning warning lamp
Fail in SCR system warning lamp
300A3CD23B
※ Warning lamps and buzzer

Warnings When error happened Lamps and buzzer
All warning lamps Warning lamp pops up on · The pop-up warning lamp moves to the original position and
except below the center of the LCD and blinks, and the buzzer stops when ;
the buzzer sounds - the buzzer stop switch is pushed
- the knob of the jog dial module is pushed
- the lamp of the LCD is touched
Warning lamp pops up on · The pop-up warning lamp moves to the original position and
the center of the LCD and light ON or blinks, and the buzzer stops when ;
the buzzer sounds - the buzzer stop switch is pushed
- the knob of the jog dial module is pushed
- the lamp of the LCD is touched
※ Refer to page 5-78 for details.
the center of the LCD and lights ON, and the buzzer stops when 2 seconds elapsed.
the buzzer sounds
the center of the LCD and blinks, and the buzzer stops when 2 seconds elapsed.
the buzzer sounds
Warning lamp pops up on ※ Refer to page 5-73 for details.
the center of the LCD and
the buzzer sounds
Warning lamp lights ON ※ Refer to page 5-78 for details.
and the buzzer sounds
※ Refer to page 5-85 for the buzzer stop switch and operator's manual page 3-66 for the
jog dial module.
5-73
(1) Engine coolant temperature warning lamp
① Engine coolant temperature warning is indicated two steps.
- 108˚C over : The lamp pops up and the buzzer sounds.
② The pop-up , lamps move to the original position and blinks
290F3CD61
when the buzzer stop switch is pushed. And the buzzer
stops and , lamps keep blink.
③ Check the cooling system when the lamps keep blink.
(2) Hydraulic oil temperature warning lamp

① Hydraulic oil temperature warning is indicated two steps.
② The pop-up , lamps move to the original position and blinks
when the buzzer stop switch is pushed. And the buzzer
290F3CD62
stops and , lamps keep blink.
③ Check the hydraulic oil level and hydraulic oil cooling system.
(3) Fuel level warning lamp

① This warning lamp pops up and the buzzer sounds when the
level of fuel is below 52ℓ(13.7 U.S. gal).
② Fill the fuel immediately when the lamp blinks.
290F3CD63
(4) Emergency warning lamp

① This warning lamp pops up and the buzzer sounds when each
of the below warnings is happened.
- Engine coolant overheating (over 107˚C)
- Hydraulic oil overheating (over 105˚C)
290F3CD64
- MCU input voltage abnormal
- Cluster communication data error
- Engine ECM communication data error
※ The pop-up warning lamp moves to the original position and
blinks when the buzzer stop switch is pushed. And the
buzzer stops.
② When this warning lamp blinks, machine must be checked and
serviced immediately.
5-74
(5) Engine oil pressure warning lamp
engine oil pressure is low.
② If the lamp lights ON, shut OFF the engine immediately.
Check oil level.
290F3CD65
(6) Check engine warning lamp

communication between MCU and engine ECM on the engine
is abnormal, or if the cluster received specific fault code from
engine ECM.
290F3CD66
② Check the communication line between them.
If the communication line is OK, then check the fault codes on
the cluster.
(7) Battery charging warning lamp

battery charging voltage is low.
② Check the battery charging circuit when this lamp blinks.
290F3CD67
(8) Air cleaner warning lamp

filter of air cleaner is clogged.
② Check the filter and clean or replace it.
290F3CD68
(9) Overload warning lamp (opt)

① When the machine is overload, the overload warning lamp
pops up and the buzzer sounds during the overload switch is
ON. (if equipped)
② Reduce the machine load.
290F3CD69
5-75
(10) Engine stop warning lamp
① This warning lamp pops up and the buzzer sounds when 30
minutes elapsed with empty condition of the DEF/AdBlue®
tank, stop the engine immediately and check the DEF/
AdBlue® tank.
290F3CD252
② Fill the DEF/AdBlue® immediately in the DEF/AdBlue® tank.
※ Refer to page 5-78.
③ This lamp pops up and the buzzer sounds when the stationary
exhaust system cleaning is not performed.
※ Please contact your Hyundai service center or local dealer.
※ "Engine shutdown" cluster message up when the exhaust
gas temperature reaches above 800℃.
800
(11) Exhaust system cleaning warning lamp

① This warning lamp lights ON or blinks when the exhaust sys-
tem cleaning is needed as table below.
290F3CD70
Warning lamp
Exhaust Check engine Stop engine
Description
Off Off Off · Automatic exhaust system cleaning

· The status of a manual (stationary) exhaust system cleaning
Blink Off Off when the exhaust system cleaning switch has been activated.
· The aftertreatment exhaust system needs to be cleaned immedi-
· ately.
※ Engine power will be reduced automatically if action is not taken.
On On Off
The exhaust system cleaning can be accomplished by :
- Changing to more challenging duty cycle.
- Performing a manual exhaust system cleaning.
· These lamps will be ON when a stationary (manual) exhaust
system cleaning is not performed.
On On On
· Stop the engine immediatary.
· Please contact your Hyundai service center or local dealer.
(12) Exhaust system cleaning inhibit warning lamp

① This warning lamp indicates, when illuminated, the exhaust
system cleaning switch is pushed inhibit position, therefore
automatic and manual exhaust system cleaning can not occur.
※ Refer to the page operator's manual 3-42 for the exhaust
system cleaning switch.
2609A3CD20
5-76
※ Manual exhaust system cleaning
※ Manual exhaust system cleaning applies if the machine is

in a fireproof area.
※ To stop a manual exhaust system cleaning before it has
completed, set to the exhaust system cleaning switch to
the inhibit position or turn OFF the engine.
① Stop and park the machine.
Safety button
1
2
② Pull the safety button and push the switch to position ② to
initiate the manual exhaust system cleaning.
※ Refer to the operator's manual page 3-42 for the exhaust sys-
tem cleaning switch operation.
※ The engine speed may increase to 950~1050 rpm and exhaust
system cleaning begins and it will take approximately 20~30
minutes.
Exhuast warning HEST warning ③ The exhaust system cleaning warning lamp will blink and
lamp blink lamp ON HEST warning lamp will light ON during the exhaust system
cleaning is operating.
④ The exhaust system cleaning and/or HEST warning lamp will

Exhuast warning HEST warning light OFF when the exhaust system cleaning is completed.
lamp OFF lamp ON OFF
220A3CD73B
(13) HEST (High exhaust system temperature) warning lamp

① This warning lamp indicates, when illuminated, that exhaust
temperatures are high due to exhaust system cleaning.
② The lamp will also illuminate during a manual exhaust system
cleaning.
③ When this lamp is illuminated, be sure the exhaust pipe outlet
2609A3CD21 is not directed at any surface or material that can melt, burn, or
explode.
When this lamp is illuminated, the exhaust gas temperature
could reach 800˚C
800 [1500˚F],
[1500 ], which is hot enough to ignite or
melt common materials, and to burn people.
※ The lamp does not signify the need for any kind of equipment
or engine service; It merely alerts the equipment operator to
high exhaust temperatures. It will be common for the lamp to
illuminate on and off during normal equipment operation as the
engine completes exhaust system cleaning.
cleaning
5-77
(14) DEF/AdBlue® level warning lamp
① This warning lamp indicates when ON or blinking, that the
DEF/AdBlue® level is low as table below.
※ It is recommended that the DEF/AdBlue® tank be filled
completely full of the DEF/AdBlue® in order to correct any
fault conditions.
290F3CD257
Warning lamp
Fail in SCR DEF/AdBlue®
Check engine Stop engine
system level
Description
· The DEF/AdBlue® level has fallen below the

On On Off Off
initial warning level (10%).
· The DEF/AdBlue® level has fallen below the
initial derate level (2.5%).
On On On Off
· The engine power will be limited automati-
cally.
· This is happened when 30 minutes elapsed
with empty conditions (0%) of the DEF/
AdBlue® tank.
· The engine will enter the final derate level
On Blink On On which may include low idle lock or engine
shutdown with restart limitations.
· In order to remove the final derate, the DEF/
AdBlue® tank must be filled to above 10
persent gauge reading.
(15) Water in fuel warning lamp

① This warning lamp lights ON and the buzzer sounds when the
water separator is full of water or malfunctioning.
※ When this lamp lights ON, stop the machine and spill water
out of the separator.
300A3CD24A
5-78
(16) Seat belt reminder warning lamp
① When operator don’t fasten the seat belt, the seat belt remind-
er warning lamp pops up and the buzzer sounds.
② Fasten the seat belt.
300A3CD25
(17) Coolant level warning lamp

① This warning lamp indicates lack of coolant.
② Check and refill coolant.
760F3CD58
(18) Fail in SCR system warning lamp

① This warning lamp indicates there are faults related to SCR
system.
② The lamp lights ON when each of the below warnings is hap-
pened.
300A3CD15
a. Low DEF/AdBlue® level
b. Poor quality of DEF/AdBlue®
c. Tempering or malfunction in the aftertreatment system
③ Once the lamp lights ON, the engine will derate shortly.
※ Please contact your Hyundai service center or local dealer.
5-79
6) PILOT LAMPS
RMCU signal strength pilot lamp
Auto safety lock pilot lamp Auto engine shutdown

pilot lamp
Warming up pilot lamp Decel pilot lamp

Preheat pilot lamp
Power max pilot lamp Fuel warmer pilot lamp
Maintenance pilot lamp
Power/User mode pilot mode Auto idle pilot lamp

Work tool mode pilot lamp Travel speed pilot lamp
Smart key pilot lamp
300A3CD26A
(1) Mode pilot lamps

No Mode Pilot lamp Selected mode
Heavy duty power work mode
1 Power mode Standard power mode
Economy power mode
2 User mode User preferable power mode
General operation - IPC speed mode
General operation - IPC balance mode
3 Work mode General operation - IPC efficiency mode
Breaker operation mode
Crusher operation mode
Low speed traveling

4 Travel mode
High speed traveling
5 Auto idle mode Auto idle
(2) Power max pilot lamp

① The lamp will be ON when pushing power max switch on the
LH RCV lever.
② The power max function is operated maximum 8 seconds.
※ Refer to the operator's manual page 3-43 for power max
function.
300A3CD32
5-80
(3) Preheat pilot lamp
① Turning the start key switch ON position starts preheating in
cold weather.
② Start the engine after this lamp is OFF.
290F3CD79
(4) Warming up pilot lamp

① This lamp is turned ON when the coolant temperature is below
30˚C (86˚F ).
② The automatic warming up is cancelled when the engine cool-
ant temperature is above 30˚C, or when 10 minutes have
passed since starting the engine.
290F3CD80
(5) Decel pilot lamp

① Operating one touch decel switch on the RCV lever makes the
lamp ON.
② Also, the lamp will be ON and engine speed will be lowered
automatically to save fuel consumption when all levers and
pedals are at neutral position, and the auto idle function is
300A3CD33 selected.
※ One touch decel is not available when the auto idle pilot
lamp is turned ON.
※ Refer to the operator's manual page 3-45.
(6) Fuel warmer pilot lamp

① This lamp is turned ON when the coolant temperature is below
10˚C (50˚F ) or the hydraulic oil temperature 20˚C (68˚F ).
② The automatic fuel warming is cancelled when the engine
coolant temperature is above 60˚C, and the hydraulic oil tem-
perature is above 45˚C since the start switch was ON position.
300A3CD34
(7) Maintenance pilot lamp

① This lamp will be ON when the consuming parts are needed to
change or replace. It means that the change or replacement
interval of the consuming parts remains below 30 hours.
② Check the message in maintenance information of main menu.
Also, this lamp lights ON for 3 minutes when the start switch is
300A3CD35 ON position.
※ Refer to the page 5-96.
5-81
(8) RMCU signal strength pilot lamp (mobile only)
① This lamp indicates RMCU signal strength as below.
: Searching
: Bad
: Normal
: Good
220A3CD200 : Excellent
(9) Smart key pilot lamp (opt)

① This lamp is ON when the engine is started by the start button.
② This lamp is red when the a authentication fails, green when
succeeds.
300A3CD36A
(10) Auto safety lock pilot lamp

① Auto safety lock system prevents unintended operation of the
machine in order to improve safety.
A ② Only if safety lever is locked, engine is started.
③ If operator unlock safety lever when RCV lever is pressed,
machine is not controlled by RCV lever.
300A3CD37A
300A3CD38
5-82
(11) Auto engine shutdown pilot lamp
① This lamp is turned ON when the auto engine shutdown is
activated.
AUTO
220A3CD202A
5-83
7) SWITCHES
Main menu quick Aircon quick touch switch

touch switch
Work mode
pilot lamp Travel speed pilot lamp
Power/User mode Auto idle pilot lamp
pilot lamp
User mode switch Travel speed switch
Power mode switch Auto idle/Buzzer stop switch
Work mode switch Escape(previous or parent menu)
Rear camera(option)
Work light switch
Cab light switch Overload switch(option)
Head light switch Travel alarm switch
Intermittent wiper switch Beacon switch(option)
Washer switch Wiper switch
300A3CD39A
※ When some of the switches are selected, the pilot lamps are displayed on the LCD. Refer to
the page 5-80 for details.
(1) Power mode switch

① This switch is to select the machine power mode and selected
power mode pilot lamp is displayed on the pilot lamp position.
·P : Heavy duty power work.
·S : Standard power work.
·E : Economy power work.
290F3CD76
② The pilot lamp changes E → S → P → E in order.
(2) Work mode switch

① This switch is to select the machine work mode, which shifts
from general operation mode to optional attachment operation
mode.
· : General operation mode
· : Breaker operation mode (if equipped)
290F3CD88
· : Crusher operation mode (if equipped)
·Not installed : Breaker or crusher is not installed.
※ Refer to the operator's manual page 2-7 for details.
5-84
(3) User mode switch
① This switch is used to memorize the current machine operating
status in the MCU and activate the memorized user mode.
·Memory : Push more than 2 seconds.
·Action : Push within 2 seconds.
·Cancel : Push this switch once more within 2 seconds.
290F3CD89
② Refer to the page 5-89 for another set of user mode.
(4) Travel speed switch

① This switch is used to select the travel speed alternatively.
· : Low speed
· : High speed
※ Do not change the setting of the travel speed switch.
290F3CD91
Machine stability may be adversely affected.
Personal injury can result from sudden changes in machine
stability.
(5) Auto idle/ buzzer stop switch

① This switch is used to activate or cancel the auto idle function.
·Pilot lamp ON : Auto idle function is activated.
·Pilot lamp OFF : Auto idle function is cancelled.
② The buzzer sounds when the machine has a problem.
In this case, push this switch and buzzer stops, but the warn-
290F3CD90
ing lamp blinks until the problem is cleared.
(6) Escape/Camera switch

① This switch is used to return to the previous menu or parent
menu.
② In the operation screen, pushing this switch will display the
view of the camera on the machine (if equipped).
Please refer to page 5-103 for the camera.
290F3CD92
③ If the camera is not installed, this switch is used only ESC
function.
(7) Work light switch

① This switch is used to operate the work light.
② The pilot lamp is turned ON when operating the switch.
290F3CD93
5-85
(8) Head light switch
① This switch is used to operate the head light.
290F3CD94
(9) Intermittent wiper switch

① This switch is used to wipe operates intermittently.
290F3CD95
(10) Wiper
iper switch
① This switch is used to operate the window wiper.
② Note that the wiper will self-park when switched off.
③ The pilot lamp is turned ON when operating the switch.
※ If the wiper does not operate with the switch in ON position,
turn the switch OFF immediately. Check the cause.
290F3CD96 If the switch remains ON, motor failure can result.
(11) Washer
asher switch
① The washer liquid is sprayed and the wiper is operated only
while pressing this switch.
290F3CD100
(12) Cab
ab light switch
① This switch turns ON the cab light on the cab.
290F3CD99
5-86
(13) Beacon
eacon switch (opt)
① This switch turns ON the rotary light on the cab.
290F3CD97
(14) Overload
verload switch (opt)
① When this switch turned ON, buzzer makes sound and over-
load warning lamp comes ON in case that the machine is
overload.
② When it turned OFF, buzzer stops and warning lamp goes out.
Overloading the machine could impact the machines stabil-
290F3CD98 ity which could result in tipover hazard. A tipover hazard
could result in serious injury or death. Always activate the
overload warning device before you handle or lift objects.
(15) Travel
ravel alarm switch
① This switch is to activate travel alarm function surrounding
when the machine travels to forward and backward.
② On pressing this switch, the alarm operates only when the
machine is traveling.
③ The pilot lamp is turned ON when operating the switch.
290F3CD101
(16) Air
ir conditioner quick touch switch
① This switch used to select air conditioner control mode.
290F3CD216
(17) Main
ain menu quick touch switch
① This switch is to activate the main menu in the cluster.
290F3CD217
5-87
8) MAIN MENU
※ You can select or set the menu by the jog dial module or touch screen.
On the operation screen, tap MENU to access the main menu screen.
On the sub menu screen, you can tap the menu bar to access functions or applications.
· Operation screen
Main menu screen Sub menu screen
Tap
+
Press
300A3CD40A
※ Please refer to the jog dial module, operator's manual page 3-66 for selection and change of
menu and input value.
(1) Structure
No Main menu Sub menu Description
Work tool Breaker, Crusher, Not installed
U mode power User mode only
Boom/Arm speed Boom speed, Arm speed
Auto power boost Enable, Disable
1
IPC mode Speed mode, Balance mode, Efficiency mode
Mode Auto engine shutdown (option) One time, Always, Disable
Initial mode Key on initial mode, Accel initial mode / step
290F3CD103 Emergency mode Switch function
Active fault MCU, Engine ECM, AAVM
Logged fault MCU, Engine ECM, AAVM
2 Delete logged fault All logged fault delete, Initialization canceled
Monitoring Machine information, Switch status, Output status,
Monitoring
290F3CD104
Fuel rate information General record, Hourly, Daily, Mode record

Maintenance information Replacement, Change interval oils and filters
Machine security ESL mode setting, Password change
Machine information Model, MCU, Monitor, jog dial module, switch controller,
RMCU, Relay drive unit, FATC, AAVM (opt)
3
Contact A/S phone number, A/S phone number change
Service menu Power shift, Operating hour, Breaker mode pump
Management acting, EPPR current level, Overload pressure
Clinometer Clinometer setting
290F3CD105
Update Cluster, ETC device
Display item Engine speed, Tripmeter A, Tripmeter B, Tripmeter C

Clock Clock
Brightness Manual, Auto
4
Unit setup Temperature, Pressure, Flow, Distance, Date format
Display Language selection Korean, English, Chinese, ETC
290F3CD106
Tripmeter 3 kinds (A, B, C)

Camera Proportional, Camera on/off, AAVM
5
Utilities
290F3CD107
5-88
(2) Mode setup
① Work tool
300A3CD41A
300A3CD42A 300A3CD43A
A B
· Select on installed optional attachment

- A : It can set the user's attachment.
It is available in setting #1~#10.
- B : Max flow - Set the maximum flow for the attachment.
Relief pressure - Set the relief pressure.
② U mode power
Step Engine Idle speed

speed
( ) (rpm) (rpm)
1 1300 750
2 1400 800
3 1500 850
300A3CD44A 4 1600 900
300A3CD45A 5 1700 950
· Engine high idle rpm, auto idle rpm and pump torque 6 1800 1000 (auto decel)
(power shift) can be modulated and memorized sepa- 7 1850 1050
rately in U-mode. 8 1900 1100
· U-mode can be activated by user mode switch. 9 1950 1150
10 2000 1200
※One touch decel & low idle : 850 rpm
5-89
③ Combination speed setting
· Load sensitivity
220A3CD300A
220A3CD301A 220A3CD302A
- The segment is close to low, the load sensitivity is

decreased.
- The segments are close to high, the load sensitivity
is increased.
Be careful of sudden movements when you choose
"high load" but actual load isn't high.
·Trucking
Trucking balance
This is control the swing and boom up speed when
the combined operation is activated.
- The segment is close to swing, the swing speed
has a priority.
- The segments are close to boom, the boom up
speed has a priority. 220A3CD303A
·Boom
Boom / Arm balance
This is control the boom up and arm in speed
when the combined operation is activated.
- The segment is close to arm, the arm in speed
has a priority.
- The segments are close to boom, the boom up
speed has a priority. 220A3CD304A
·Arm
Arm speed
Arm regeneration function can be activated or
cancelled.
- Enable - Arm in speed is up.
- Disable - Normal operation.
220A3CD305A
5-90
④ Auto power boost
300A3CD49A
300A3CD50A
· The power boost function can be activated or cancelled.

Enable - The digging power is automatically increased as working conditions by the MCU.
It is operated max 8 seconds.
Disable - Not operated.
⑤ IPC mode
300A3CD51A 300A3CD52A 210A3CD53A
300A3CD54A 210A3CD55A
300A3CD56A 210A3CD57A
· The IPC mode can be selected by this menu.

- Speed mode
- Balance mode (default)
- Efficiency mode
※ Please update the cluster programs if this mode is not displayed in the mode setup menu. Refer
to the page 3-31.
5-91
⑥ Automatic engine shutdown (option)
300A3CD58A
300A3CD59A 300A3CD60A
· The automatic engine shutdown function can be set by this menu.

- One time
- Always
- Disable
- Wait time setting : Max 40 minutes, min 2 minutes
⑦ Initial mode
300A3CD61A
300A3CD62B
· Key on initial mode

- Selected the power mode is activated when the engine is started.
· Key on initial work mode
- Not installed
- Last setting
- Work mode
· Accel initial mode
- Last setting value
- User setting value
· Accel initial step
- 0~9 step
⑧ Emergency mode
300A3CD63A
300A3CD64A
· This mode can be use when the switches are abnormal on the cluster.
· The cluster switches will be selected by touched each icon.
5-92
(3) Monitoring
① Active fault
300A3CD65A
300A3CD66A 300A3CD67A
· The active faults of the MCU, engine ECM or air conditioner can be checked by this menu.
② Logged fault
300A3CD68A
300A3CD69A 300A3CD70A
· The logged faults of the MCU, engine ECM or air conditioner can be checked by this menu.
③ Delete logged fault
300A3CD71A
300A3CD72A 300A3CD73A
· The logged faults of the MCU, engine ECM or air conditioner can be deleted by this menu.
④ Monitoring
300A3CD74A
300A3CD75A 300A3CD76A
· The machine status such as the engine rpm, oil temperature, voltage and pressure etc. can
be checked by this menu (Analog input).
· The switch status or output status can be confirmed by this menu (Digital input & Digital
output).
· The activated switch or output pilot lamps are light ON.
5-93
(4) Management
① ECO report
This reports the machine’s inefficient operation status in order to improve operator’s improper
working habit.
High idle
300A3CD77A
300A3CD78A
Idle
·Show each usage ratio of high idle, idle and relief
operation when monitor is turned ON.
·Show the usage ratio’s daily record for 7 days and ac-
cumulated record from the first operation.
300A3CD79A
Relief operation
300A3CD80A
5-94
② Fuel rate information
300A3CD81A
300A3CD82A
A
·General
General record (A)
- Average fuel rate (left) (from "Reset" to now)
Fuel consumption devided by engine run time
(service meter time).
- A days fuel used (right)
Fuel consumption from 24:00 (or "Reset" time) to 300A3CD83A
now (MCU real time).

B
·Hourly
Hourly record (B)
- Hourly fuel rates for past 12 hours (service meter
time).
- No record during key-off time.
- One step shift to the right for every one hour.
- Automatic deletion for 12 hours earlier data.
300A3CD84A
- All hourly records deletion by "Reset".
C
·Daily
Daily record (C)
- Daily fuel consumption for past seven days (MCU
real time).
- No record during key-off time.
- One step shift to the right at 24:00 for every day.
- Automatic deletion for 7 days earlier data.
300A3CD85A
- All daily records deletion by "Reset".
D
·Mode
Mode record (D)
- Average fuel rate for each power mode/accel dial (at
least 7) from "Reset" to now.
- No record during idle.
- All mode records deletion by "Reset".
300A3CD86A
5-95
③ Maintenance information
300A3CD87A
300A3CD88A 300A3CD89A
· Alarm lamp ( ) is ON when oil or filter needs to be changed or replaced.

· Replacement : The elapsed time will be reset to zero (0).
· Change interval : The change or replace interval can be changed in the unit of 50 hours.
· Change or relpace interval : Refer to maintenance.
5-96
④ Machine security
300A3CD90A
300A3CD91A 300A3CD92A
· ESL mode setting

- ESL : Engine Starting Limit
- ESL mode is desingned to be a theft deterrent or will pre-
vent the unauthorized operation of the machine.
- If the ESL mode was selected Enable, the password will
be required when the start switch is turned ON.
- Machine security 300A3CD93A
Disable : Not used ESL function
Enable (always) : The password is required whenever the
operator starts engine.
- Interval : The password is required when the operator
starts engine first. But the operator can restart
the engine within the interval time without input-
ting the password.
The interval time can be set maximum 4 hours. 300A3CD94A
※Default
Default password : 00000＋
00000
※Password
Password length : (5~10 digit)＋
digit)
- Smart key (option) : Smart key is registered when equipped with optional smart key. If smart
key is not inside of the cabin, authentication process fails and the pass-
word entering is needed.
· Password change
- The password is 5~10 digits.
300A3CD95A
300A3CD96A 300A3CD91A
Enter the current password
300A3CD98A 300A3CD99A
Enter the new password again Enter the new password
5-97
⑤ Machine Information
300A3CD100A
300A3CD101A
· This can confirm the identification of the model information (ECU), MCU, monitor, jog dial
module, switch controller, RMCU, relay driver unit, FATC (air conditioner controller), AAVM
(opt).
⑥ Contact (A/S phone number)
300A3CD102A
300A3CD103A 300A3CD104A
Enter the new A/S phone number
⑦ Service menu
300A3CD105A
300A3CD106A 300A3CD107A
· Power shift (standard/option) : Power shift pressure can be set by option menu.
· Operating hours : Operating hours since the machine line out can be checked by this menu.
· Breaker mode pump acting (1 pump/2 pump)
· EPPR current level (attach flow EPPR 1 & 2, boom priority EPPR, attach relief pressure EPPR
1& 2)
· Overload pressure : 100 ~ 350 bar
⑧ Clinometer
300A3CD108A
300A3CD109A
· When the machine is on the flatland, if tap the "initialization", the values of X, Y reset "0".
· You can confirm tilt of machine in cluster's operating screen.
5-98
⑨ Update (cluster & ETC devices)
300A3CD110A
300A3CD111A 300A3CD112A
380F3CD06 300A3CD114A
· ETC devices and cluster can be updated through CAN 2 network.

· Insert USB memory stick which includes program files, start download.
⑩ OME (owner menu editing)

The owner of machine can restrict operators access the set of functions.
300A3CD115A
300A3CD116A 300A3CD117A
· Owner can set the status of the function.

- Enable
- Disable
· the menu, owner can set the list of the function to
In
lock or unlock it.
· Owner password (default password : 11111)
- Owner can manage and change the password. 300A3CD118A
- Necessary to input the password to access the set

of function.
5-99
· Password change
- The password is 5~10 digits.
210WF3CD190A
290F3CD140A 290F3CD135A
Enter the current password
290F3CD143A 290F3CD142A
Enter the new password again Enter the new password
※ Before first use, please set user password and owner pasworrd in advance for machine
security.
(5) Display
① Display item
300A3CD119A
300A3CD120A 300A3CD121A
· The center display type of the LCD can be selected by this menu.
· The engine speed or each of the tripmeter (A,B,C) is displayed on the center display.
② Clock
300A3CD122A
300A3CD123A
· The first line's three spots "**/**/****" represent Month/Day/Year each.

· The second line shows the current time. (0:00~23:59)
5-100
③ Brightness
300A3CD124A
300A3CD125A 300A3CD126A
300A3CD127A 300A3CD128A
300A3CD129A
· If "Auto" is chosen, brightness for day and night can be differently set up. Also by using the
bar in lower side, users can define which time interval belongs to day and night.
(in bar figure, white area represents night time while orange shows day time)
④ Unit
300A3CD130A
300A3CD131A 300A3CD132A
· Temperature : ˚C ↔ ˚F
· Pressure : bar ↔ MPa ↔ kgf/cm2
· Volume :ℓ↔ gal
· Flow : lpm ↔ gpm
· Distance : km ↔ mile
· Date format : yy/mm/dd ↔ mm/dd/yy ↔ dd-mm-yy
5-101
⑤ Language
300A3CD133A
300A3CD134A
· User can select preferable language and all displays are changed the selected language.
5-102
(6) Utilities
① Tripmeter
300A3CD143A
300A3CD144A
· Maximum 3 kinds of tripmeters can be used at the same time.

· Each tripmeter can be turned on by choosing "Start" while it also can be turned off by
choosing "Stop".
· If the tripmeter icon is activated in the operation screen, it can be controlled directly there.
② Camera setting
· If the rear camera is not installed on the machine, set disable.
· If the rear camera installed on the machine, set enable.
300A3CD145A
300A3CD146B 300A3CD147A
· Auto Mode (Travel) : Enable

The cluster will automatically show camera view while machine is traveling.
· In the operation screen, rear camera screen show up when ESC/CAM button is pushed.
300A3CD97A
290F3CD221
5-103
③ AAVM (All Around View Monitoring, option)
· The AAVM buttons of the cluster consist of ESC/CAM and AUTO IDLE/Buzzer stop.
Buzzer stop switch
Escape switch
300A3CD149A
- Escape button
· It will enter into the AAVM mode from the beginning screen if the AAVM is installed.
· While in the AAVM mode, select the ESC button to return to the beginning screen.
300A3CD97A
The beginning screen 235SA3CD222A

AAVM mode
- Buzzer stop button

· In AAVM mode, it detects surrounding pedestrians or objects and the warning buzzer sounds.
· User can turn OFF the warning sound by pressing buzzer stop button.
· When the worker or pedestrian go to the blue line
(radius 5 m), an external danger area of equipping
on the cluster screen, the warning buzzer sounds
and it displays the blue rectangular box for the rec-
ognition of the worker and pedestrian.
At this time, the operator should stop work imme-
diately, and stop the buzzer by pressing the buzzer
stop button. And then, please work after you check
290F3CD246A whether the danger factors are solved.
· When the worker or pedestrian go inside of red line

(radius 3 m), an internal danger area of equipping
on the cluster screen, the warning buzzer sounds
and it displays the red rectangular box for the
recognition of the worker and pedestrian.
At this time, the operator should stop work imme-
diately, and stop the buzzer by pressing the buzzer
stop button. And then, please work after you check
290F3CD247A
whether the danger factors are solved.
※ In AAVM mode, a touch screen of the LCD is available only. The multimodal dial of the jog
dial module is not available.
5-104
9) AIR CONDITIONER AND HEATER
Full auto air conditioner and heater system automatically keeps the optimum condition in accor-
dance with operator's temperature configuration sensing ambient and cabin inside temperature.
· Location of air flow ducts
B
B
B
B
D
C
Cluster : or
Jog dial module :
Setting temperature
Power switch Temperature switch
Air conditioner switch Fersh air/air recirculation switch
Auto switch Air mode switch
Fan speed Fan speed switch

220A3CD21A
※ Jog dial module : Refer
efer to the operator's manual page 3-66.
5-105
(1) Power switch
① This switch makes the system ON/OFF.
Just before the power OFF, set values are stored.
② Default setting values
Function Air conditioner In/outlet LCD Temperature Mode
Previous sw Previous sw
290F3CD251 Value OFF Inlet OFF
OFF OFF
(2) Air conditioner switch

① This switch turns the compressor ON/OFF.
※ Air conditioner operates to remove vapor and drains water
through a drain hose. Water can be sprayed into the cab in
case that the drain cock at the ending point of drain hose
has a problem.
290F3CD203 In this case, exchange the drain cock.
(3) Auto switch

① Auto air conditiner and heater system automatically keeps the
optimum condition in accordance with operator's temperature
configuration sensing ambient and cabin inside temperature.
290F3CD223
(4) Setting temperature

① Display the temperature setting out.
290F3CD224
(5) Temperature switch

① Setting temperature indication
· Lo (17˚C), 17.5~31.5˚C, Hi (32˚C)
② Max cool and max warm beeps 5 times.
③ The max cool or the max warm position operates as following
table.
290F3CD225
Temperature Compressor Fan speed In/outlet Mode
Max cool ON Hi (8 step) Recirculation Face
Max warm OFF Hi (7 step) Fresh Def/Foot
④ Temperature unit can be changed between celsius (˚C) and
fahrenheit (˚F)
a. Default status (˚C)
b. Push Up/Down temperature switch simultaneously more than
5 second displayed temperature unit change (˚C → ˚F)
5-106
(6) Fan speed switch
① Fan speed is controlled automatically by setted temperature.
② This switch controls fan speed manually.
· There are 8 up/down steps to control fan speed.
· The maximum step or the minimum step beeps 5 times.
290F3CD226
(7) Fan speed

① Steps 1 through 8 to display the amount of wind.
290F3CD227
(8) Fresh air/air recirculation switch

① It is possible to change the air-inlet method.
a. Fresh air ( )
Inhaling air from the outside.
b. Air recirculation ( )
It recycles the heated or cooled air to increase the energy
290F3CD228 efficiency.
※ Change air occasionally when using recirculation for a
long time.
※ Check out the fresh air filter and the recirculation filter
periodically to keep a good efficiency.
(9) Air mode switch

① Operating this switch, it beeps and displays symbol of each
mode in order. (Face → Face/Rear → Face/Rear/Foot → Foot
→ Def/Foot)
Face Face/Rear Face/Rear/Foot Foot Def/Foot
Mode
switch
290F3CD229
A ● ● ●
B ● ●
Outlet
C ● ● ●
D ●
② When defroster mode operating, FRESH AIR/AIR RECIRCU-

LATION switch turns to FRESH AIR mode and air conditioner
switch turns ON.
5-107
(10) Self diagnosis function
① Diagnostic methods : Diagnostic information window, select
② Diagnostic indication (Displays fault)
Fault code Description Fail safe function

F01 Ambient temperature sensor open
20˚C alternate value control
F02 Ambient temperature sensor short
F03 Cab inside temperature sensor open
F04 Cab inside temperature sensor short
F05 Evaporate temperature sensor open
F06 Evaporate temperature sensor short
F07 Null -
F08 Null -
F09 Mode 1 actuator open/short The alternate value is face
F10 Mode 1 actuator drive circuit malfunction If not, the alternate value is Def/Foot
F11 Intake actuator open/short The alternate value is air recirculation
F12 Intake actuator drive circuit malfunction The alternate fresh air
F13 Temperature actuator open/short If opening amount is 0 %, the alternate value is 0 %
F14 Temperature actuator drive circuit malfunction If not, the alternate value is 100 %
F15 Null -
F16 Null -
5-108
GROUP 16 FUEL
FUEL WARMER SYSTEM
1. SPECIFICATION
SPECIFICATION
1) Operating voltage : 24±4 V
2) Power : 350±50 W
3) Current : 15 A
2. OPERATION
OPERATION Filter head &
fuel warmer
1) T h e c u r r e n t o f f u e l w a r m e r s y s t e m i s
automatically controlled without thermostat
according to fuel temperature.
2) At the first state, the 15 A current flows to the fuel
warmer and engine may be started in 1~2
Prefilter
minutes.
3) If the fuel starts to flow, ceramic-disk in the fuel
warmer heater senses the fuel temperature to
reduce the current as low as 1.5 A.
So, fuel is protected from overheating by this
300L5MS15
mechanism.
3. ELECTRIC
ELECTRIC CIRCUIT
2.0RW
B+ IG(POWER RY) IG(BATTERY RY)
POWER RY
87a 87 85
30 86
ROOM LAMP/RADIO B+
FUEL FILLER PUMP

AIR CON / HEATER
START, AIR-HEAT
OPTION, SWITCH
CR-35
PROPORTIONAL
HEAD LAMP
87a
FUEL HEATER
30
86
85
AAVM / SIREN
87
DEF MODULE
LINE HEATER
CONVERTER
AC / HEATER
CLUSTER B+
SAFETY SOL
WORK LAMP
CABIN LAMP
CLUSTER IG
MCU CONT.
START KEY
SEAT HEAT
SOLENOID
SOLENOID
BREAKER
DEF&SCR
RADIO IG
ECM
1.0WOr
RDU IG
2.0RW
WIPER
WIPER
CIGAR
HORN
0.75B
2.0Gr
MCU
EPPR
ECM
20A 21
10A 24
30A 34
30A 36
30A 22
20A 25
20A 30
5A 12
10A 10
20A 23
20A 13
20A 11
10A 14
10A 15
10A 16
10A 17
10A 18
10A 19
10A 20
10A 26
20A 27
20A 28
20A 29
20A 31
10A 32
20A 33
2
4
7
8
9
30A 1
30A 6
15A 3
15A 5
30A
10A
20A
10A
10A
8.0W
5.0R
1.0RW
3.0W
1.5R
2.0Gr CN-263
8.0W
2
1
CN-96 2.0L 2.0W CN-258
1.0Lg
1.0Or
2.0 Br 5W
MASTER SW
1 1 1
2.0 B 2.0Gr
HEATER
2 2 AIR COMP
FUEL
3 CS-74B POWER
5.0R
4 1
S
L
5.0R
2
L
CR-46
30
2.0YR CN-93 CS-74
0.75W
85 87 87a 0.75YR
86 1 BATTERY(+)
2.0Br 0.75W 90A CN-95
87 25 BATTERY(+) 8W
V 0.75W 2
85 26 BATTERY(+) 8W
86 30 87a 0.75W 1
27 BATTERY(+)
FUEL HEATER RY 0.75W CIRCUIT BREAKER
28 BATTERY(+)
0.75B 5R
73 BATTERY(-)
2
0.75B 5R
1
49 BATTERY(-)
0.75B 60A CN-60
50 BATTERY(-)
0.75B
1.0WOr
51 BATTERY(-)
2.0W
0.75B
52 BATTERY(-) CR-1
0.75WB
CN-5
75 AIR HRATER RELAY 60R 60B

34
35
36
37
38
39
40
41
42
43
57
58
59
60
3
1
4
5
6
7
2
0.75Or
05 KEY SWITCH "ON"
1.0G
1.0W
BATTERY
CN-125 ECM BATT RY (12VX2)
1.0W CN-100
1 1 3B 3B
0.8W
2 2
1.0RW
0.75V
3 3
1.0R
1.0G R
4 4 CN-45
1.2W
1.2G
CN-2
CN-51, 52, 53 & 54
GPS CONN. M
CN-427
1.2W
M
52-13
51-26
51-01
2
4
3
1
4
CN-125A
5
CS-2A
CR-36
1
2
6 B+
1
5
4
1
6
2
3
BATTERY POWER
11
BATT POWER _24V
FUEL WARMER RY
0.75WB 4 5 1 STARTER
2 12
B
0, I 0.75YR
1
3 13
CAN (HIGH)
CAN (LOW)
CR-24
KEY IG 24V
14
KEY "IG"
4 15R
0.75BY 1.0BY
IG 24V
0.75BY 3 2 15 CN-80
GND
I 0 H
5
4
3
2
6
5
15R
C ST ACC BR H
PRE-HEAT RY
READER RMS STARTING SW UNITED MCU GLOW PLUG RY GLOW PLUG
210A5MS26
5-109
Group 1 Before Troubleshooting -------------------------------------------------------------------------------------- 6-1

Group 2 Hydraulic and Mechanical System ------------------------------------------------------------------- 6-4
Group 3 Electrical System ----------------------------------------------------------------------------------------------- 6-25
Group 4 Mechatronics System ---------------------------------------------------------------------------------------- 6-44
Group 5 Air conditioner and Heater System ------------------------------------------------------------------ 6-72
GROUP 1 BEFORE TROUBLESHOOTING
1. INTRODUCTION
When a trouble is occurred in the machine, this section will help an operator to maintain the machine
with easy.
The trouble of machine is parted Hydraulic & Mechanical system, Electrical system, Mechatronics
system and Air conditioner and heater system. At each system part, an operator can check the
machine according to the troubleshooting process diagram.
※ Before carring out troubleshooting procedure, check monitoring menu in the cluster.
Hydraulic &
GROUP 2
Mechanical part
Electrical part GROUP 3
Mechatronics
Troubles occur part GROUP 4
Aircon and
heater part GROUP 5
HCESPN 3digit See page

+ FMI 1 or 2 digit 5-18
Fault codes (machine)
displayed on
monitor display
3 or 4 digit See page
(engine) 5-41
6-1
2. DIAGNOSING PROCEDURE
To carry out troubleshooting efficiently, the following steps must be observed.
STEP 1. Study the machine system

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

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

Before starting troubleshooting, check the
machine for the daily maintenance points as
shown in the operator's manual.
And also check the electrical system including
batteries, as the troubles in the electrical system ON THE
INSPECTION
such as low battery voltage, loose connections
and blown out fuses will result in malfunction of
(210-7) 6-2(3)
the controllers causing total operational failures
of the machine.
6-2
STEP 4. Inspect the trouble actually on the
machine
In case that some trouble cannot be confirmed,
obtain the details of the malfunction from the
operator.
Also, check if there are any in complete
connections of the wire harnesses are or not.
(210-7) 6-3(1)
STEP 5. Perform troubleshooting

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

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

procedure to avoid consequential malfunctions.
(210-7) 6-3(3)
6-3
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM
1. INTRODUCTION
1) MACHINE IN GENERAL
(1) If even a minor fault is left intact and operation is continued, a fatal failure may be caused,
entailing a large sum of expenses and long hours of restoration.
Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look
for the cause based on the troubleshooting principle and perform maintenance and adjustment to
prevent major failure from occurring. Keep in mind that a fault results from a combination of
different causes.
(2) The following lists up commonly occurring faults and possible causes with this machine. For the
troubleshooting of the engine, refer to the coming troubleshooting and repair.
(3) When carrying out troubleshooting, do not hurry to disassemble the components.
It will become impossible to find the cause of the problem.
(4) Ask user or operator the following.
① Was there any strange thing about machine before failure occurred?
② Under what conditions did the failure occur?
③ Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
① Check oil and fuel level.
② Check for any external leakage of oil from components.
③ Check for loose or damage of wiring and connections.
2) MACHINE STATUS MONITORING ON THE CLUSTER
(1) The machine status such as the engine rpm, oil temperature, voltage and pressure etc. can be
checked by this menu.
Note 7
Note 3
Note 5 Note 4
Note 6 Note 2
Note 1
Analog
Analog 11 Analog
Analog22 210A6HS01
(2) Specification
No. Description Specification
Note 1 Work pilot pressure 40 +20 bar
Note 2 Swing pilot pressure 0~40 bar
Note 3 Boom up pilot pressure 0~40 bar
Note 4 Arm/bucket pilot pressure 0~40 bar
Note 5 Pump 1 regulator pressure 0~50 bar
Note 6 Pump 2 regulator pressure 0~50 bar
Note 7 Pump 1 pressure 350 bar
6-4
2. DRIVE SYSTEM
1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION
Cause Remedy
YES
Coupling element Disassemble
is broken. and repair.
Remove dust
plug under engine
flywheel and
YES
check if rubber Replace hub or
pieces or particles retighten
are not present. Coupling hub setscrew.
spline is worn or
NO hub fastening YES
Negative Clean air
setscrew is slack. pressure in pump breather or tank
Check if hydraulic tank
air breather or tank suction strainer
NO
strainer is clogged.
ⓐ
NO
YES Replenish speified

oil to the standard
level.
Is hydraulic oil level

ⓐ in hydaulic oil tank YES Water or air is Refer to the
is low?
included in oil. remedy of 3.1)
Is hydraulic oil
NO cloudy? YES Replace hydraulic
oil to be specified.
Has not hydraulic

NO oil passed specified
replacement
hours?
NO
Return filter is not Flush with
replaced at hydraulic oil and
proper intervals. replace return
filter.
6-5
2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL
Cause Remedy
YES
ⓐ
Is safety Sol
valve operating
properly?
Safety Sol valve Disassemble
NO
is faulty. and repair.
NO
Replenish
specified oil to
the standard
Is oil level in Abnormal noise level.
hydraulic oil YES YES
ⓐ comes out of Hydraulic pump is Disassemble
tank within hydraulic pump
standard level? broken. and repair.
Do not hydraulic Abnormal noise

pump and pump YES comes out of YES
connections pump Coupling element See item 1).
YES
make abnormal connection is broken or worn. at page 6-5
noise?
Is pilot pump
pressure within ⓑ
NO standard level?
See Note 1
YES
Clean pilot
Is pilot piping piping interior or
YES clogged or is oil
repair piping.
leakage present
on pilot piping?
RCV and safety Disassemble
NO
solenoid valve is and repair.
ⓑ faulty.
YES
Pilot relief valve in Repair or
gear pump is replace.
Is gear pump
faulty.
NO delivering oil?
Gear pump is Disassemble

NO
broken. and repair.
6-6
3. HYDRAULIC SYSTEM
1) HYDRAULIC OIL IS CLOUDY
Cause Remedy
YES
Water is mixed. Put hydraulic oil
still, separate
Drop hydraulic oil water and
sample on hot dispose it or
plate and check if replace hydraulic
foams come up. oil.
NO
Air is intruded. Check suction
line and return
line and eliminate
the air intruding
source.
2) HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY
Cause Remedy
NO
Replenish
specified oil to
the standard
Is hydraulic oil level.
volume proper? YES
Oil cooler clogged. Clean oil cooler.
Bypass check Replace
Is oil cooler clogged
and is bypass check valve is defective.
YES valve always open? YES ⓐ
Is fan belt
NO tension proper?
Adjust belt
NO tension or
replace belt.
Is not the set
pressure of main YES Readjust set
relief, port relief pressure.
ⓐ and travel relief
Is main relief
valve lower than
valve used very YES Reduce load.
the standard NO often?
level?
6-7
3) CAVITATION OCCURS WITH PUMP
Cause Remedy
NO Replenish
specified oil to
the standard
Is hydraulic oil level.
volume proper? YES
Replace oil with
one of proper
Is not viscosity viscosity.
of hydraulic oil
YES YES
too high? Clean suction
Is not suction strainer.
NO strainer clogged? Is not air intruding
from pump Check for air
NO intrusion in
suction line?
suction line and
retighten or
replace parts.
4) HYDRAULIC OIL IS CONTAMINATED
Cause Remedy
YES Replace
Has not hydraulic hydraulic oil to be
oil passed specified.
specified replace-
ment hours? Has return filter
NO
been replaced at Flush with
NO proper intervals?
hydraulic oil and
replace return
filter.
6-8
4. SWING SYSTEM
1) BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE
Cause Remedy
NO
Replenish
Does safety YES
ⓐ specified oil to the
YES solenoid valve
standard level.
operation
Is gear pump pilot normal? Safety solenoid Repair or replace.
NO
pressure within valve faulty or not
YES standard level?
Is oil in hydraulic operated.
YES tank within
See Note 1 Gear pump faulty. Repair or replace.
standard level? NO
YES
Are broken pieces Pump connection Disassemble and
of coupling present coupling is broken. repair.
ⓐ when dust plug
under engine fly Is main relief NO
Are attachment wheel is removed? NO valve faulty? Hydraulic pump is Disassemble and
and travel out of order. repair.
motions
impossible at all? NO
Does swing Swing control valve Disassemble and
YES
control valve spool is stuck. repair.
Is MCV swing spool move?
YES pilot pressure YES
ⓑ
within standard See Note 5
level?
ⓒ
Is RH travel See Note 2 NO
NO function normal?
Does not symptom
change when A1 YES
and A2 pump Hydraulic pump is Disassemble and
NO
discharge hoses broken. repair.
are exchanged?
YES
Swing parking Disassemble and
brake release valve repair.
Is swing parking is broken.
ⓑ brake release
valve faulty? YES
Swing reduction Disassemble and
Does swing unit is broken. repair.
NO motor rotate?
Swing motor is Disassemble and
NO
broken. repair.
YES
Pilot relief valve in Disassemble and
NO Is gear pump gear pump is faulty. repair or replace.
delivering oil?
Gear pump is out of Disassemble and
NO
Is gear pump pilot order. repair.
ⓒ pressure within
standard level? YES
Is there oil Clean pilot piping
See Note 1 interior or repair
leakage from
YES pilot piping or is it piping.
clogged? RCV is broken. Disassemble and
NO
repair.
6-9
2) SWING SPEED IS LOW
Cause Remedy
YES
Swing port relief Disassemble and
YES Does swing spool valve is faulty. repair or replace.
move?
Swing control valve Disassemble
Is MCV pilot NO
spool is stuck. and repair.
pressure same
on LH and RH YES Clogged or oil
sides? Clean pilot piping
leak. interior or repair
See Note 2 Is pilot piping
Single direction clogged or is it piping.
NO leaking oil?
Is the trouble in RCV or shuttle Disassemble
one direction or NO
valve is faulty. and repair.
in both direction? YES
ⓐ
YES Does swing spool
Both directions move?
YES Is MCV pilot Swing spool is Disassemble
pressure within NO
Is Arm speed See Note 5 stuck. and repair.
standard level?
within standard ⓑ
value? See Note 2 NO
ⓒ
NO
Is swing motor's NO
ⓐ drain rate within Swing motor is Disassemble
standard value? broken. and repair.
Check that pilot
YES piping is clogged NO
or oil is leaking RCV or shuttle Disassemble
from it? valve is faulty. and repair.
Clogged or oil leak. Clean pilot piping

Is gear pump pilot interior or repair
ⓑ pressure within piping.
standard level?
Pilot relief valve
YES
See Note 1 in gear pump is Disassemble and
Is gear pump defective. repair or replace.
NO delivering oil?
NO
broken. and repair.
NO
Main relief valve Main relief valve
faulty. pressure resetting
or repair.
Is main relief Does the symptom YES Hydraulic pump Disassemble
ⓒ valve setting change when A1
YES is broken. and repair.
pressure normal? and A2 pump
discharge hoses
See Note 7
are exchanged? NO Shuttle valve is Repair or replace.
Is MCV pilot faulty.
YES pressure within
standard level? YES
Is gear pump Pilot relief valve Repair or replace.
See Note 2 output pressure is faulty.
NO within standard
level? Gear pump is Repair or replace.
See Note 1
NO
faulty.
6-10
3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION
Cause Remedy
Does symptom YES
change when LH Swing port relief Disassemble
YES and RH port valve is faulty. and repair.
relief valves of
swing motor are
exchanged? NO Shuttle valve is Disassemble
YES Does swing control faulty. and repair.
valve spool move?
Is MCV pilot Swing control valve Disassemble

NO
pressure same spool is stuck. and repair.
for LH and RH?
NO
See Note 2
Check if pilot RCV is faulty. Disassemble
piping is clogged and repair.
NO or does have oil
leakage. Clogged or oil
YES leak.
Clean pilot piping
interior or repair
piping.
4) MACHINE SWINGS BUT DOES NOT STOP
Cause Remedy
YES
Pilot relief valve is Disassemble
faulty. and repair or
YES Is MCV pilot YES Is gear pump pilot
pressure within pressure within replace.
standard value? standard level?
See Note 2 See Note 1 Gear pump is Disassemble
NO
broken. and repair.
YES Does swing spool
move?
RCV is faulty. Disassemble
NO
and repair.
Is swing control
valve's return
spring normal? Swing spool is Disassemble
NO
stuck. and repair.
Return spring is Disassemble

NO
faulty. and replace.
6-11
5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE
Cause Remedy
YES
ⓐ
YES Is swing shuttle
valve normal?
Shuttle valve is Disassemble
NO
faulty. and replace.
YES Is brake spring
normal?
Is return spring
of swing spool Brake spring is Disassemble
NO
normal? faulty. and replace.
Return spring of Disassemble

NO
swing control and replace.
valve is faulty.
YES
Is drain rate of Swing port relief Disassemble
YES swing motor valve is faulty. and repair or
within standard replace.
Is swing relief value? Swing motor is Disassemble
pressure within NO
ⓐ broken. and repair.
standard level?
SPEC : 300±10kgf/cm2 Adjust swing
NO
relief valve
pressure or
replace swing
relief valve.
6-12
6) LARGE SHOCK OCCURS WHEN STOP SWINGING
Cause Remedy
YES
Swing motor is Disassemble
broken. and repair.
YES Is time delay

valve is normal?
Is swing RCV
output pressure
at neutral and in
swing operation Time delay valve Disassemble
NO
within standard is faulty. and repair or
level? replace.
Malfunction of Disassemble
NO
swing RCV and repair.
7) LARGE SOUND OCCURS WHEN STOP SWINGING
Cause Remedy
YES
Seal of suction Disassemble
valve is faulty. and repair.
Is there a
YES leakage on
suction check
valve?
Is relief valve
setting pressure Internal defect of Disassemble
NO
nomal? swing motor. and repair.
Malfunction of Adjust swing

NO
relief valve. relief valve
pressure or
replace swing
relief valve.
6-13
5. TRAVEL SYSTEM
1) TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE
Cause Remedy
YES
Does ⓐ
YES counterbalance
spool move lightly
by hand? Counter spool is
Is travel brake Disassemble
NO
YES valve pressure stuck. and repair or
level? Does the symptom
change when
relief valves in YES
Relief valve built Disassemble
NO travel motor are
Has travel spool exchanged? in travel motor is and repair.
YES
changed over faulty.
positively?
YES Control system is Disassemble
defective. inspect and
Does travel spool
repair.
NO move?
NO
Travel spool is Disassemble
stuck. and repair.
Is bucket or arm
operation YES Travel reduction Disassemble
possible? Do not metallic
unit is faulty. and repair.
particles come
ⓐ out of drain port
in travel
reduction unit? Travel motor is Disassemble
NO
out of order. and repair.
Does the symptom
NO
change when A1 YES
and A2 pump Hydraulic pump is Disassemble
Does the discharge hoses
symptom change broken. and repair.
are exchanged?
when LH/RH
NO
travel relief valves
are exchanged?
YES
Travel relief Disassemble
valves are faulty. and repair or
replace.
6-14
2) SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES
Cause Remedy
YES
Brake valve is Disassemble
Do LH and RH
travel speeds defective. and repair or
YES change when LH replace.
YES
and RH travel Does the symptom Relief valve built Disassemble
brake valves are change when in travel motor is and repair.
exchanged? relief valves in
faulty.
NO LH and RH
YES Has travel spool travel motors are
changed over exchanged? ⓐ
positively? NO
YES
Control system is Disassemble,
faulty . inspect and
Does spool move? repair.
Is the lower NO
speed (bucket or
arm) within See Note 5, 6 Control valve Disassemble
NO
standard level? spool is stuck. and repair.
YES
Travel relief valve Disassemble
Do LH and RH is faulty. and repair or
travel speeds Does the symptom replace.
change over when change when A1
NO travel relief valves YES and A2 pump YES
Hydraulic pump is Disassemble
are exchanged? discharge hoses
Is external pilot are exchanged? broken. and repair.
pressure within
NO
standard level?
External pilot Disassemble
NO
piping is clogged and clean.
or oil is leaking
Does travel speed from it.
change when
YES parking brake YES
spring in the Travel motor's Disassemble
travel motor is parking brake is and clean pilot
Is drain rate of removed? not released piping.
ⓐ travel motor within
standard level? properly.
Travel motor is Disassemble

NO
faulty. and repair.
6-15
3) MACHINE DOES NOT STOP ON A SLOPE
Machine is pulled forward as sprocket rotates during digging operation.
Cause Remedy
None Is parking brake YES
friction plate Friction plate is Disassemble
YES Check if parking worn? faulty. and repair.
brake pilot line is
clogged.
Clogged Disassemble
and clean pilot
Is drain rate of piping.
Is travel brake YES NO
travel motor
pressure within Travel motor is Disassemble
within standard
standard level? defective. and repair.
value?
SPEC : 15.7 kgf/cm2
Brake valve is Disassemble

NO
faulty. and repair or
replace.
4) LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE
YES
Cause Remedy
Inspect according
to the procedure
"Travel does not
function at all on
one side."
However, a case
where both LH
and RH travel
motions are
disabled is
Is bucket or arm
operation extremely seldom
possible? statistically.
OK
Disassemble both faulty. and repair.
OK travel relief valves
Remove dust and inspect for
plug under engine any fault.
OK flywheel and Travel relief valve Disassemble
check that there is Faulty is faulty. and repair or
no coupling
replace.
element particles.
Check oil volume Particles present. Coupling at pump
in hydraulic oil connection is Disassemble
NO tank. broken. and repair.
Short Replenish
hydraulic oil.
6-16
5) TRAVEL ACTION IS POWERLESS (travel only)
Cause Remedy
YES
ⓐ
Is travel motor's
YES
drain rate within
standard level?
Is travel brake Travel motor is Disassemble
YES NO
pressure within faulty. and repair.
standard level?
Is travel relief
valve pressure Travel brake valve Disassemble
NO
within standard is defective. and repair or
level?
replace.
NO
Travel relief valve Disassemble
is faulty. and repair or
replace.
YES
Hydraulic circuit Disassemble
Does parking that releases and clean.
brake piston travel parking
Increases move lightly by
Remove parking brake is clogged
brake spring in hand?
with dirt.
travel motor,
draw out piston Parking brake Disassemble
ⓐ NO
completely, refit piston in travel and repair.
cover and check motor is stuck.
if travel power
changes. Remains
unchanged Travel reduction Disassemble
unit is defective. and repair.
6) MACHINE RUNS RECKLESSLY ON A SLOPE
Cause Remedy
Travel brake valve
(counterbalance Disassemble
valve) is faulty. and repair or
replace.
6-17
7) MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL
AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME
Cause Remedy
YES
Normal.
YES Is straight spool

normal?
Straight spool is Repair or

Is pilot pressure NO
for travel straight faulty. replace.
spool within
standard level? YES
Remove dirt on
signal orifice.
Is signal orifice
YES Is pilot relief NO
NO clogged? Pilot relief valve is Disassemble
valve normal?
defective. and repair or
Is gear pump
replace.
NO delivering oil?

NO
broken. and repair.
6-18
6. ATTACHMENT SYSTEM
1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL
Cause Remedy
YES
Does the Port relief valve is Disassemble
YES symptom change faulty. and repair or
when port relief replace.
valve is replaced
with other valve? NO ⓐ
YES Is MCV pilot
pressure within
standard level?
Inspect if pilot
See Note 3, 4 piping is clogged OK
RCV is faulty. Disassemble
NO or oil is leaking
YES Are other from the piping. and repair.
attachments
operatable?
YES
Is gear pump
pilot pressure YES Is gear pump faulty. and repair or
NO within standard delivering oil? replace.
level? Gear pump is Disassemble
See Note 1 NO
broken. and repair.
Are LH/RH travel
operations OK
possible? Hydraulic pump is Disassemble
Disassemble broken. and repair.
NO main relief valve
Remove dust plug and check if it is
under engine not irregular.
OK flywheel and
Main relief valveDisassemble
Faulty
check if coupling is defective. and repair or
element particles replace.
Inspect oil are not present. Coupling at pump Disassemble
Particles present
NO
volume in
hydraulic oil tank. connection is and repair.
broken.
Short Replenish
hydraulic oil.
YES
Cylinder interior is Disassemble
Does control broken. and repair.
ⓐ valve spool
move?
MCV spool is Disassemble
See Note 5, 6 NO
stuck. and repair.
6-19
2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal.
YES
Are other ⓐ
YES attachment
Is combination speeds within
Is speed low only of oil streams standard levels? NO ⓑ
in composite YES
normal at boom YES
operation? up and at arm Does spool of flow Replace
extrusion? summation check spring.
NO valve move lightly
Are LH/RH travel by hand? Flow summation Disassemble
NO
NO speeds within check valve is and repair.
standard levels?
stuck.
YES
Are both LH/RH faulty. and repair.
travel speeds YES ⓒ
NO
low? Is MCV pilot
pressure within
NO
standard? ⓓ
NO
See Note 3, 4
OK
Does the Port relief valve is Disassemble
YES
symptom change faulty. and repair or
when port relief
replace.
valve is replaced
Does control with other valve? Cylinder is faulty. Disassemble
YES NO
valve spool and repair.
move ?
See Note 7 MCV spool is Disassemble
Is MCV pilot NO
ⓐ pressure within stuck. and repair.
standard level?
YES
Is not MCV pilot Clean pilot
See Note 3, 4
pressure piping piping interior or
clogged or is not
NO repair piping.
there oil
leakage? RCV is defective. Disassemble
NO
and repair.
YES
Is pilot pressure NO faulty. and repair or
ⓑ Is gear pump
delivering oil?
level?
NO
See Note 1 broken. and repair.
AIs engine NO
ⓒ revolution within Adjust engine
standard level? revolution.
YES
Clean orifice in
control valve.
Is not orifice in
ⓓ main control YES
valve clogged? Clean pilot
Is pilot piping
clogged or is oil piping interior or
NO leaking from the repair piping.
piping? Is RCV normal? RCV is faulty. Disassemble
NO NO
and repair.
6-20
3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS
Cause Remedy
YES
Port relief valve is Disassemble
Does the symptom faulty. and repair or
change when port
Normal
relief valve is replace.
YES
replaced with ⓐ
normal value? Is control valve
return spring
YES
Is not hydraulic NO
normal?
oil temperature Control valve's Disassemble
high? NO
return spring is and replace.
faulty.
Is genuine Abnormally high. Locate the
hydraulic oil or cause of
equivalent being hydraulic oil
used?
temperature rise
and lower it to
proper level.
Replace with
NO
genuine
hydraulic oil or
equivalent.
OK
Pressure Disassemble
Disassemble and tightness and repair.
inspect load between control
YES
check valve in
MCV and check valve casing and
for any fault. spool is poor.
Is cylinder Contact surface Disassemble
internal leakage Abnormal
ⓐ between poppet and repair.
within standard
level? and seat is poor.
Cylinder is faulty. Disassemble

NO
and repair.
6-21
4) BOOM, ARM OR BUCKET POWER IS WEAK
Cause Remedy
YES
Check according
Is cylinder to the procedure
YES internal leakage in Item "Speed is
within standard low".
level?
Is relief pressure
YES in port relief Cylinder is faulty. Disassemble
valve within NO
and repair.
standard level?
Is relief pressure
in main relief Port relief valve is Adjust pressure,
valve within NO
standard level? faulty. repair or replace.
See Note 7
Main relief valve Adjust pressure,
NO
is defective. repair or replace.
5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE
Cause Remedy
NO
Port relief valve is Disassemble
Does the defective. and repair or
YES
symptom change
when port relief replace.
YES
valve is replaced Cylinder interior is Disassemble
with other valve? Does control broken. and repair.
valve spool
Is MCV pilot YES move?
YES
pressure within MCV spool is Disassemble
standard level? See Note 5 NO
stuck. and repair.
See Note 4
Is LH travel RCV is faulty. Disassemble

NO
possible? and repair.
Does the YES

Main relief valve Adjust pressure,
symptom change is faulty. repair or
Does the
when main relief
NO valves are symptom change replace.
when hydraulic YES
exchanged? Hydraulic pump is Disassemble
NO pump's discharge
hoses are broken. and repair.
exchanged?
6-22
6) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED
Cause Remedy
YES
Frictional noise
occurs between
the sliding faces
of boom
cylinder's oil
Is boom foot pin seal and boom
greased proper.
sufficiently?
※ Frictional
noise will
disappear if
they are kept
used.
Boom foot pin Supply grease

NO
has run out of to it.
grease. ※ If seizure is
in an initial
stage, supply
sufficient
grease.
If seizure is
in a grown
state, correct
it by paper
lapping or
with an oil
stone.
7) TIME LAG OF MACHINE WORKING IS LARGE.
Cause Remedy
YES
Refer to 2)
Is overload relief
valve for each
spool working
properly?
Overload relief Disassemble and

NO
valve is faulty. repair.
6-23
※ HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE
1. Lower the bucket teeth to the ground with
bucket cylinder fully retracted and arm
cylinder rod retracted almost in full.
300L6TS01
2. Disconnect hose (A) from rod side of boom

cylinder and drain oil from cylinders and
hose. (put cups on piping and hose ends) A
(210-7) 6-20(2)
3. Raise bucket OFF the ground by retracting

the arm cylinder rod.
If oil leaks from piping side and boom
cylinder rod is retracted there is an internal
leak in the cylinder.
If no oil leaks from piping side and boom
cylinder rod is retracted, there is an internal
leak in the control valve.
300L6TS02
6-24
GROUP 3 ELECTRICAL SYSTEM
1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER DISPLAY DOES NOT APPEAR
·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No. 9, 16.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
Check voltage YES
between Disconnection in Repair or replace
CN-56A (2) wiring harness or (after clean)
and (3)
Check voltage poor contact
Starting switch : ON between CN-5
Voltage : 20~32V between
NO (9) and (10)
CN-5-CN-56A
Starting switch : ON
Voltage : 20~32V Disconnection in Repair or replace
NO
wiring harness or (after clean)
poor contact
between CN-5 (9)
-GND or fuse No.
9, 16
Check voltage
YES 20~32V
NO 0V
CLUSTER
FUSE
BATT 24V 1 11
No.9
IG 24V 2 10
FUSE
GND 3 9
No.16
CN-56A CN-5
300L6ES101
6-25
2. COMMUNICATION ERROR FLASHES ON THE CLUSTER (HCESPN 840, FMI 2)
·Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Check voltage
YES between
CN-56A (6, 7)
and (3) Disconnection in Repair or replace
NO wiring harness or (after clean)
Check voltage Voltage : 2V poor contact
between between CN-56A
CN-5 (5) and (6) (6, 7)-CN-5 (5, 6)
Voltage : 2V Defective united Replace
NO MCU Repair or replace
Disconnection in (after clean)
wiring harness or
poor contact
between CN-5 (5,
6)- CN-51 (08, 09)
Check voltage
YES 2V
NO 0V
CLUSTER
GND 3 9 UNITED MCU
CAN 2 HIGH 6 6 09 CAN 2 HIGH
CAN 2 LOW 7 5 08 CAN 2 LOW
CN-51
CN-56A CN-5
140L6ES102
6-26
3. BATTERY CHARGING WARNING LAMP LIGHTS UP (Starting switch : ON)
Cause Remedy
YES
Defective united Replace
YES Check voltage MCU
between CN-51
(15) and chassis Disconnection in Repair or replace
NO
Check voltage wiring harness or (after clean)
YES Voltage : 20~32V
between CN-2 poor contact
(13) and chassis between CN-51
(15)-CN-2 (13)
Voltage : 20~32V
Check voltage Disconnection in Repair or replace
between alternator poor contact
terminal "L" and between CN-2 (13)
chassis alternator terminal
Engine : Running "L"
Voltage : 20~32V
Defective alternator Replace

NO
Check voltage
YES 20~32V
NO 0V
ALTERNATOR
UNITED MCU B+
G
L 3~
ALT VOLTAGE 15 13
U
CN-74
CN-51 CN-2
220F6ES103
6-27
4. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
YES
Check use HRDT Check or replace
Check resistance
YES between engine
ECM connector
(34)-(83)
Spec : 180Ω~160 kΩ Disconnection in Repair or replace
NO
Check resistance poor contact
between temp between temp
sensor (A)-(B)
sensor-engine
Starting switch : OFF ECM connector
Spec : 180Ω~160 kΩ
See table
Defective coolant Replace

NO
temp sensor
Check Table
Temperature (˚C ) 0 25 50 80 95
Resistance (kΩ) 30~37 9.3~10.7 3.2~3.8 1.0~1.3 0.7~0.8
SERVICE TOOL Engine ECM

CAN Lo F 6 01 ENGINE COOLANT
CN-93 TEMPERATURE SENSOR
CAN Hi E 5 02
22 CAN Hi 34 A
RS232 TX C 3 11
46 CAN Lo 83 B C
RS232 RX B 2 03
Engine ECM
P DUMP A 1 30 connector
CN-126 CN-52
300L6ES104
6-28
5. WHEN AIR CLEANER WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
YES
Clogged air filter or Check filter or
defective switch replace switch
Does display go
off when
disconnect YES
CD-10A Short circuit in Repair or replace
Starting switch : ON wiring harness (After clean)
Engine : Start Check resistance
between CD-10A-
between CN-54
NO CN-54 (13)
(13) and chassis
Starting switch : OFF
Disconnect CN-54
NO
MCU
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
UNITED MCU CN-51 AIR CLEANER SWITCH
GND (FOR SENSOR 5V) 25

Pa
AIR CLEANER CLOGGING SW 13
CD-10A
CN-54
140L6ES106
6-29
6. WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
NO
Defective circuit, Contact Cummins.
sensor or ECM.
NO Fault code 143

active?
Fault code 386 Voltage above Refer to engine
YES
active? normal or shorted fault code 143
to high source
Voltage above Refer to engine
YES
normal or shorted fault code 386
to high source
Signal Return
Engine ECM
ENGINE OIL
CN-93 PRESSURE SENSOR
22 CAN Hi 63 3
54 2
46 CAN Lo
SERVICE TOOL 76 1
CAN Lo F 6 01 Engine ECM

connector
CAN Hi E 5 02 +5V supply
RS232 TX C 3 11
RS232 RX B 2 03
P DUMP A 1 30
CN-126 CN-52
220A6ES107
6-30
7. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
YES
High temperature Check hydraulic
Resistance system
YES between CD-1
(1, 2) is in range
of 164~151Ω?
Does display go Starting switch : ON Defective temp Replace
Disconnect CD-1 NO
off when sensor
disconnect
CD-1? YES
Short circuit Repair or replace
Starting switch : ON between temp
Engine : Start
Resistance
between CN-51 sensor and united
NO (16) and CN-51 MCU
(25) is 0~1Ω?
Starting switch : OFF Defective united Replace
Disconnect CN-51 NO
MCU
Check Table
Temperature (˚C ) ~ -30 ~ -10 ~0 ~ 40 ~ 70 ~ 80 ~ 90 ~ 100 105~
22.22 8.16 5.18 1.06 0.39 0.322 0.243 0.185 0.164
Resistance (kΩ)
~31.78 ~10.74 ~ 6.6 ~1.28 ~0.476 ~0.298 ~0.219 ~0.167 ~0.151
UNITED MCU HYDRAULIC OIL

TEMPERATURE SENDER
HYD TEMP SENDER 16 2 C

GND (FOR SENSOR 5V) 25 1
CD-1
CN-51
140L6ES108
6-31
8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
Cause Remedy
YES
Check use HRDT Check or replace
Check resistance
YES between engine
ECM connector
(34)-(83)
Spec : 180Ω~160 kΩ Disconnection in Repair or replace
NO
between temp between temp
sensor (A)-(B)
sensor-engine
Starting switch : OFF ECM connector
Spec : 180Ω~160 kΩ
See table
Defective coolant Replace

NO
temp sensor
Check Table
Temperature (˚C ) 0 25 50 80 95
Resistance (kΩ) 30~37 9.3~10.7 3.2~3.8 1.0~1.3 0.7~0.8
SERVICE TOOL Engine ECM

CAN Lo F 6 01 ENGINE COOLANT
CN-93 TEMPERATURE SENSOR
CAN Hi E 5 02
22 CAN Hi 34 A
RS232 TX C 3 11
46 CAN Lo 83 B C
RS232 RX B 2 03
Engine ECM
P DUMP A 1 30 connector
CN-126 CN-52
220A6ES104
6-32
9. WHEN FUEL GAUGE DOES NOT OPERATE (HCESPN 301, FMI 3 or 4)
Cause Remedy
YES
Check resistance MCU or cluster
YES between CN-51
(25) and CN-51
(19)
Starting switch : OFF Disconnection in Repair or replace
Check resistance Disconnect CN-51 NO
between fuel Spec : 50~600Ω wiring harness or
sender (1) and poor contact
(2) between fuel
Starting switch : OFF sender-united
Spec : 50~600Ω
See table
MCU
Defective fuel Replace

NO
sender
Check Table
Range Resistance (Ω) Range Resistance (Ω)
Full 50 5/12 400
11/12 100 4/12 450
10/12 150 3/12 500
9/12 200 2/12 550
8/12 250 1/12 600
7/12 300 Empty warning 700
6/12 350 - -
UNITED MCU
FUEL LEVEL SENDER
FUEL LEVEL SENSOR 19 2
GND (FOR SENSOR 5V) 25 1
CD-2
CN-51
140L6ES110
6-33
10. WHEN SAFETY SOLENOID DOES NOT OPERATE
short of fuse No. 26.
Cause Remedy
YES
Hydraulic system Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
NO
Safety lever : ON-OFF
YES
Disconnect in Repair or replace
poor contact
Check voltage
between CN-68 between
(1) - (2) Check resistance CN-4-CN-68 or
YES between CN-4 defective safety
Starting switch : ON relay
Voltage : 20~30V
(16) and chassis
Safety state YES
Starting switch : OFF Disconnect in Repair or replace
Safety state
Spec : 0Ω wiring harness or (after clean)
Check voltage Disconnect CN-4 Check resistance poor contact
between CN-68 between CS-4 between
NO NO
(2) and chassis (A)-(C) CN-4-CS-4
Safety lever : OFF Starting switch : OFF
Starting switch : ON Safety switch : ON-0Ω Defective safety Replace
NO
Voltage : 20~30V OFF-∞ switch
NO
Disconnection in Repair or replace
wiring harness
between CN-68
(2)-fuse No. 26
FUSE
No.26
SAFETY SWITCH
B C A 14 SAFETY SOLENOID
B 15 2
A C 16 1
CS-4 SAFETY RY CN-68
CN-4 1
4 5 1
2
UNITED MCU 3
SAFETY SOL 06 4
5 3 2
CN-52
CR-48
220A6ES109
6-34
11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE (HCESPN 167, FMI 4 or 6)
Cause Remedy
YES
wiring harness or
YES
between CN-70 between CN-70-
(1) and (2) CN-52
Starting switch : OFF Defective solenoid Replace
Spec : 30Ω NO
YES Check fault code Disconnect CN-70
167 active?
YES
Defective hydraulic Check hydraulic
system system
Check voltage
Check if travel between CN-70
speed lamps( , NO (1) and (2)
) change when
pressing the travel Starting switch : ON Disconnection in Repair or replace
Spec : 20~30 V NO
speed switch on wiring harness or
Disconnect CN-70
the cluster poor contact
between CN-70-
fuse No. 28
YES
Check united
MCU
NO
Y R G
NO
MCU
FUSE
No.28
UNITED MCU HIGH SPEED

TRAVEL SOLENOID
TRAVEL SPEED SOL 05 1
CN-70
CN-52
140L6ES107
6-35
12. TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING
Cause Remedy
YES
The fuse is blown Replace the fuse
Check the fuse YES

for travel alarm The travel alarm Check the united
inside fuse box signal of united MCU program
* Prepare with
whether fuse is Check the starting switch MCU is defective
blown or not signal of MCU's OFF, then turn YES
pin for back start engine and The travel buzzer Replace the
buzzer whether carry out is defective travel buzzer
ground signal troubleshooting :
NO (DO) generate
Between CN-81
or not when (2) - chassis * Prepare with
machine travel ground : 20-30 starting switch
mode. voltage . OFF, then carry
Between CN-81 out trouble-
(1) - chassis shooting without
NO ground : Max 1  turning starting
(resistance) switch ON :
Is the above 1. Disconnection
value normal? in wiring or
defective contact
** Note : in connector
Since voltage between CN-81
value , connector (2) inline In case of the Replace
number and pin NO connector-end NO value of connector
number varies connector : Max resistance, Connect the wire
with each model, 1  (resistance) disconnection in
should refer to 2. Short circuit
wiring or defective
the electric circuit with ground
of each model. circuit between contact in
CN-81 (2) inline connector or short
connector-end circuit with ground
connector - circuit
chassis ground :
Min 1M
(resistance)
FUSE FUSE
No.11 No.28
UNITED MCU
EPPR POWER 24V 18

GROUND(EPPR) 33
CN-81
CN-54
2
TRAVEL BUZZER 09 1
CN-52 TRAVEL BUZZER
220A6ES150
6-36
13. HORN DOES NOT SOUND
Cause Remedy
YES
The fuse is blown Replace the fuse
YES
The relay is broken Replace the relay
* Prepare with
starting switch
Check the fuse OFF, then turn
for horn inside YES
starting switch The horn is Replace the horn
fuse box whether ON and carry out
fuse is blown or defective
troubleshooting :
not Between CN-20
(1) or CN-25 (1) -
After replacing chassis ground
the relay for (with horn switch
NO horn, check the turned ON) :
horn operate 20-30 voltage
* Prepare with
starting switch
OFF, then carry
out
troubleshooting
* Prepare with
without turning
starting switch
starting switch
OFF, then carry
ON :
out trouble-
NO Between CN-20
shooting without
(2) or CN-25 (2)-
turning starting
chassis ground :
switch ON :
Max 1 
1. Disconnection
(resistance)
in wiring or
Is the above
defective contact
value normal?
in connector
** Note :
between CN-20
Since voltage
(1) or CN-25 (1) -
value , connector
inline connector- NO In case of the Replace
number and pin NO value of connector.
end connector :
number varies
Max 1  resistance, Connect the wire
with each model,
(resistance) disconnection in
should refer to
2. Short circuit wiring or defective
the wiring
with ground contact in
diagram of each
circuit between connector or short
model.
CN-20 (1) or circuit with ground
<CN-20 (1)/
CN-25 (1) - inline
CN-25 (1) : Horn circuit
connector-end
connector (+)
connector -
terminal CN-20
chassis ground :
(2) /CN-25 (2) :
Min 1M 
Horn connector
(resistance)
(-) terminal>
HORN SW
1 7 CR-2
2 8 1
4 5 1
CS-5 2
CN-6
3
4
FUSE 5 3 2
HORN RY
No.24
CN-25
1
2
HORN
1
2
CN-20
220A6ES151
6-37
14. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE (HCESPN 167, FMI 4 or 6)
Cause Remedy
YES
wiring harness or
YES
between CN-70 between CN-70-
(1) and (2) CN-52
Starting switch : OFF Defective solenoid Replace
Spec : 30Ω NO
YES Check fault code Disconnect CN-70
167 active?
YES
Defective hydraulic Check hydraulic
system system
Check voltage
Check if travel between CN-70
speed lamps( , NO (1) and (2)
) change when
pressing the travel Starting switch : ON Disconnection in Repair or replace
Spec : 20~30 V NO
speed switch on wiring harness or
Disconnect CN-70
the cluster poor contact
between CN-70-
fuse No. 28
YES
Check united Defective cluster Replace
MCU
NO Y R G

NO
Starting switch : ON MCU
FUSE
No.28
UNITED MCU TRAVEL SOLENOID
TRAVEL SPEED SOL 05 1
CN-70
CN-52
220A6ES03
6-38
15. WHEN ENGINE DOES NOT START ( lights up condition)
CN-125
2
CS-2A
short of fuse No. 1, 6, 12, 13, 23.
H0 I
CN-5 1
·After checking, insert the disconnected connectors again immediately unless otherwise specified. 35
0, I
2
40 3 4
H
39
BR ACC
4 1
B
2
3
Cause Remedy 36 5
6
YES
ST C
Defective ECM or Replace 5
6
Check voltage
YES YES CN-93 (5) and battery START KEY SW
chassis CR-35
Disconnection in Repair or replace No.1
NO wiring harness or 30
87a 87 85
Key switch : ON 86
Spec : 20~30V poor contact 87

No.6
between CR-35 85
30 86
(86) -CN-93 (5) 87a
POWER RY
Check operation YES
start motor Check voltage Defective magnet Replace
YES between starter of start motor
Starting switch : START magnet coil and No.12 2.0W
chassis Defective start relay Replace
MASTER SW
S
1
2.0Gr
NO 2
Starting switch : START No.13 CS-74B
Check operation Spec : 20~30V YES 5.0R
YES Check voltage ⓐ 1
S
L
5.0R
of start relay 2
L
NO between CN-2
CR-23 (7) and chassis Disconnection in Repair or replace CS-74
NO
Starting switch : START wiring harness or
Starting switch : START IG (BATT RELAY)
poor contact
Check operation Spec : 20~30V between CN-2 (7) No.23
of anti-restart -CR-5 (5)
NO relay CR-5
YES
Defective anti- Replace CN-93
Check voltage
between CR-5 restart relay BATTERY(+) 26
NO KEY SWITCH "ON" 5 90A CN-95
(1, 2)
NO
ⓑ STARTER LOCKOUT SIG 83 2
1
Starting switch : START HS RETURN 76
Spec : 20~30V REMOTE ACCEL SW 67 2
ECM 1
60A CN-60 BATTERY
YES CN-51
Check voltage Defective start relay Replace KEY IG 24V 26 CIRCUIT BREAKER
ⓐ between CR-23 United MCU
ANTI-RESTART RY 15
and chassis Disconnection in Repair or replace CR-1
NO CN-52
wiring harness or
Starting switch : START poor contact CR-39
1
Spec : 20~30V
between CN-2 (7) 1 5 4
2
-CR-5 (5) BATT RY
3
4 DO-3
2 3 5 2
YES STARTER LOCKOUT
1
Disconnection in Repair or replace DIODE
wiring harness or CR-5
Check voltage poor contact 1
ⓑ between CR-5 between CN-52
1 5 4
2
(2) and chassis (15)-CR-5 (1) 3 CN-2 CR-23 START MOTOR
4
2 3 M
Starting switch : START NO Disconnection in Repair or replace 5 7 2 M
Spec : 20~30V wiring harness or ANTI-RESTART RY 8 1
poor contact START RY B+

between CS-2A CN-45
(6)- CR-5 (2)
220F6ES114
6-39
16. WHEN STARTING SWITCH ON DOES NOT OPERATE
CN-125
2
·Before carrying out below procedure, check all the related connectors are properly inserted, master CS-2A
H0 I
switch ON and check open circuit of circuit breaker (CN-60). CN-5 1
35
0, I
2
·After checking, insert the disconnected connectors again immediately unless otherwise specified. 40 3 4
H
39
BR ACC
4 1
B
2
36 5 3
ST C
5
6
Cause Remedy START KEY SW
YES
Disconnection in Repair or replace CR-35
No.1
wiring harness or (after clean) 30
87a 87 85
86
poor contact
YES Check voltage
87
between DO-3 (2)- No.6
85
between DO-3 CR-1 or defective 30 86
87a
(2) and chassis battery relay POWER RY
Voltage : 20~30V
YES Check voltage NO wiring harness or (after clean)
between CS-2A No.12
poor contact 2.0W
(2) and chassis
MASTER SW
S
1
between CS-2A (2)- 2
2.0Gr
Voltage : 20~30V CN-5(39)- DO-3 (2) No.13 CS-74B

5.0R
Starting switch : ON 1
S
L
5.0R
Defective start Replace 2
L
NO
YES Check voltage switch CS-74
between CS-2A
(1) and chassis YES IG (BATT RELAY)
Disconnection in Replace
wiring harness or
Voltage : 20~30V No.23
poor contact
between CS-2A
Check voltage
(1)-CN-5 (36)
between CN-5
NO CN-93
Check voltage (36) and chassis YES
Disconnection in Charge or replace BATTERY(+) 26
and specific wiring harness or (after clean)
gravity of battery Voltage : 20~30V Check voltage KEY SWITCH "ON" 5 90A CN-95
poor contact STARTER LOCKOUT SIG 83 2
between
Specific gravity : MIN 1.28 between CS-74B HS RETURN 76
1
Voltage : MIN 24V NO CS-74B (1) and (1) -CN-5 (36)
chassis REMOTE ACCEL SW 67 2
ECM 1
Voltage : 20~30V ⓐ 60A CN-60 BATTERY
NO CN-51
KEY IG 24V 26 CIRCUIT BREAKER
United MCU
Battery capacity Charge or replace ANTI-RESTART RY 15
CR-1
NO too low (after clean) CN-52
CR-39
1
1 5 4
YES 2
Defective master Replace BATT RY
Check voltage 3
DO-3
ⓐ switch 4
between CS-74 2 3 5 2
(2)- chassis 1
NO
Disconnection in Charge or replace STARTER LOCKOUT
DIODE
Voltage : 20~30V wiring harness or (after clean) CR-5
poor contact 1
1 5 4
between CS-74 (2) 2
-CR-1 3 CN-2 CR-23 START MOTOR

4
2 3 5 7 2 M
M
ANTI-RESTART RY 8 1
START RY B+
CN-45 220F6ES115
6-40
17. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse
No. 8, 14 and 20 is not blown out. CN-21
3 1
2
5 3
Cause Remedy 4
4 CN-22
NO 5 CN-5
Defective wiper Replace 2 M
6 M 2 6
cut switch
1
NO
Short circuit in Repair or replace WIPER MOTOR WASHER PUMP
Check operation wiring harness or (after clean)
wiper cut switch DO-5
poor contact CN-141
2
between CN-141 FEED BACK 1
Front sliding door (11)- CS-53 1
open-close
Check valtage MOTOR DRIVE SIG 2 CN-17
between CN-141 YES MOTOR DRIVE- 3 1 15
YES (11) and chassis Defective RDU Replace FUSE
MOTOR DRIVE+ 4 2
membrane 16
NO Check voltage GND 5 3 No.20
Front sliding door-close between CN-376 controller 17
Voltage : 4~5V VCC 6 4 FUSE
Check operation (1) and chassis
1)Recheck fuse Replace CONTINUE 24V 7 5 18
of RDU
Starting switch : ON NO No.14 WASHER P/P 8 6 19 No.8
YES membrane Vottage : 20~30V
controller LED 2)Disconnection in Repair or replace WASHER SIG. 9 7
20
ON. wiring harness or (after clean) INT. SIG 10 8
ⓐ poor contact 21
YES WIPER CUT SW 11
Starting switch : ON between
Push wiper switch button N.C 12
CN-376(1)-Fuse
No.14 FEED BACK 13
Check voltage between WIPER MOTOR CONTROLLER

NO
CN-376 (12) and Defective RDU Replace CS-53
chassis membrane
Intermittent
controller
NO
Check voltage CN-376 1) Recheck fuse Replace
ⓐ No.8
(11) and chassis WIPER CUT SW
2) Disconnection Repair or replace FUSE
Washing Check operation in wiring harness (after clean)
of wiper motor or poor contact No.14
Check voltage CN-376 and controller
(3) and chassis between
check voltage CN-141(7)-Fuse,
Sarting switch : ON YES CN-141 (7) and
CN-21(4)-Fuse
Voltage : 0~1V chassis, CN-21
(4) and chassis NO
1) Recheck fuse Replace
Starting switch : OFF No.20
Voltage : 20~30V Check voltage 2) Disconnection Repair or replace
CN-376
CN-141 (6) and CN-141(6)-Fuse (after clean)
10
11
12
13
14
15
16
17
18
19
26
27
1
2
3
4
5
6
7
8
9
YES chassis
No.20
Starting switch : ON ⓑ
Check continuity YES
Voltage : 20~30V
BEACON LAMP SW
NO
between Disconnection in Repair or replace
WORK LIGHT
CABIN LIGHT
HEAD LIGHT
CN-141 (2)-CN-376 (3), wiring harness or (after clean)
INT WIPER
CAN 2_LO
WASHER
CAN 2_HI
CN-141 (9)-CN-376 (11), poor contact
WIPER
IG 24V
GND
GND
CN-141 (10)-CN-376 (12),
NC
NC
NC
NC
ⓑ
NC
NC
NC
NC
NC
NO
CN-141 (5)-Chassis , Check wiper Defective wiper Replace
CN-141 (1)-CN-21 (5), motor resistance motor RDU MEMBRANE CONTROLLER
CN-141 (3)-CN-21 (6),
YES between CN-21
CN-141 (4)-CN-21 (2), (2)-CN-21 (6) Defective wiper Replace
CN-141 (13)-CN-21 (3) YES motor controller
Resistance : 3~4Ω
220A6ES116
6-41
18. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
short of fuse No.14 & 21.
FUSE
Cause Remedy
YES No.21
Defective bulb Replace
Check voltage FUSE
YES between CL-4 (1),
CR-13
CL-3 (1), CL-24 No.14
30 30 86
(1) and chassis Disconnection in Repair or replace 86
Voltage : 20~30V NO
wiring harness or (after clean) 87
poor contact 85
Check voltage between CR-13 87a
87a 87 85
YES
between CR-13 (87)-CL-4 (1), HEAD LAMP RY
(87) and chassis CR-13 (87)-CL-3
(1) or CR-13 (87)- CL-4
Starting switch : ON CL-24 (1)
Head lamp switch : ON 2
Voltage : 20~30V YES 1
Defective RDU Replace
CN-376
Check voltage membrane HEAD LAMP-RH
10
11
12
13
14
15
16
17
18
19
26
27
Check voltage
1
2
3
4
5
6
7
8
9
between CR-13 controller
between CN-376 CL-24
(30) and chassis, NO
CR-13 (86) and (13) and chassis
2
BEACON LAMP SW
chassis Disconnection in Repair or replace
Starting switch : ON NO 1
Starting switch : ON wiring harness or (after clean)
WORK LIGHT
CABIN LIGHT
HEAD LIGHT
Head lamp switch : ON
INT WIPER
Voltage : 20~30V HEAD LAMP-REAR
CAN 2_LO
poor contact
WASHER
CAN 2_HI
Voltage : 20~30V
WIPER
IG 24V
between CN-376
GND
GND
CL-3
NC
NC
NC
NC
NC
NC
NC
NC
NC
(13)-CR-13 (85)
RDU MEMBRANE CONTROLLER 2
1
NO
Disconnection in Repair or replace HEAD LAMP-LH
poor contact
between CR-13
(30) and chassis
or CR-13 (86) -
chassis
Recheck fuse Replace

No. 21
220A6ES117
6-42
19. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
short of fuse No.14 & 34.
Cause Remedy FUSE

YES
Defective bulb Replace No.34
YES
Check voltage
between CL-5 (1)
and chassis
CR-4
Disconnection in Repair or replace FUSE
30 30 86
poor contact No.14 86
between CR-4 87
YES Check voltage 85
between CR-4 (87)-CL-5 (1) 87a 87 85
87a
(87) and chassis
WORK LAMP RY
Starting switch : ON CL-5
Work lamp switch : ON CN-12
Voltage : 20~30V YES
Defective RDU Replace 1 1
Check voltage membrane 2 2
between CR-4 Check voltage controller
(30) and chassis, between CN-376 WORK LAMP
NO
CR-4 (86) (4) and chassis
chassis 1
Starting switch : ON Disconnection in Repair or replace
Work lamp switch : ON NO wiring harness or (after clean) 2
Voltage : 20~30V
Voltage : 20~30V poor contact
CL-6
CN-376
between CR-4
10
11
12
13
14
15
16
17
18
19
26
27
1
2
3
4
5
6
7
8
9
(85)-CN-376 (4) CL-5
1
BEACON LAMP SW
NO 2
WORK LIGHT
CABIN LIGHT
HEAD LIGHT
poor contact
INT WIPER
CAN 2_LO
WORK LAMP
WASHER
CAN 2_HI
between CR-4
WIPER
IG 24V
GND
GND
NC
NC
NC
NC
(30) and chassis
NC
NC
NC
NC
NC
1
or CR-4 (86) and
RDU MEMBRANE CONTROLLER 2
chassis
CL-6
Recheck fuse Replace
No.34
220A6ES118
6-43
GROUP 4 MECHATRONICS SYSTEM
1. ALL ACTUATORS SPEED ARE SLOW

※ Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good.
※ Spec : P-mode 1800 ± 50 rpm S -mode 1700 ± 50 rpm E-mode 1600 ± 50 rpm
※ Before carrying out below procedure, check all the related connectors are properly inserted and
fault code on the cluster.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective
YES Check pressure hydraulic system
at EPPR valve
NO Check electric Defective Replace
current at EPPR SPEC : 2~25 kgf/cm2
NO
EPPR valve
valve See TEST 3
SPEC : 100~700 mA
See TEST 2
Check if HCESPN NO
MCU
140 active fault
display on the LCD YES
Short circuit or Check & repair
poor connection wire harness or
between CN-54 between CN-54
Check resistance
YES at EPPR valve -CN-342 (or 343) -CN-342 (or 343)
SPEC : 15~25Ω(20。C) Defective EPPR Replace

See TEST 1 NO
valve
Wiring diagram
UNITED MCU
FUSE
EPPR POWER 24V 18
No.11
P1 PUMP REG EPPR(+) 27
P1 PUMP REG
P1 PUMP REG EPPR(-) 02 EPPR VALVE
7 1
GROUND(EPPR) 33 8 2
CN-342
P2 PUMP REG
EPPR VALVE
P2 PUMP REG EPPR(-) 03 9 1

P2 PUMP REF EPPR(+) 26 10 2
CN-54 CN-1 CN-343

220A6MS101
6-44
2) TEST PROCEDURE SPEC : 15~25Ω(20˚C)
(1) Test 1 : Check resistance at connector CN-342 (or 343)
CN-342 (or 343). EPPR valve

① Starting switch OFF.
② Disconnect connector CN-342 (or 343) Multimeter
from EPPR valve at main hydraulic P2 pump
pump. P1 pump
③ Check resistance between 2 lines as

figure.
Main pump
CN-342 for P1 pump

CN-343 for P2 pump
220A6MS115
(2) Test 2 : Check electric current at EPPR Spec : 100~700 mA

valve. Adapter(P/no.:21Q6-50410)
① Disconnect connector CN-342 (or 343)
CN-342 (or 343)
from EPPR valve. Multimeter EPPR valve
③ Start engine. P2 pump
④ Set S-mode and cancel auto decel P1 pump
mode.
⑥ If tachometer show approx 1700±50 rpm
disconnect one wire harness from EPPR Main pump
valve.
⑦ Check electric current at bucket circuit CN-342 for P1 pump
relief position. CN-343 for P2 pump
220A5MS21
(3) Test 3 : Check pressure at EPPR valve. Spec : 2~25 kgf/cm2 (30~350 psi)
① Remove plug and connect pressure
Pressure adjusting
gauge as figure. screw locknut

(0 to 725 psi)
CN-342 (or 343)
P2
mode.
④ Position the multimodal dial at 10. a4
⑤ If tachometer show approx 1700±50 rpm
check pressure at relief position of bucket Main pump
circuit by operating bucket control lever.
⑥ If pressure is not correct, adjust it. a4 for P1 pump
a5 for P2 pump
⑦ After adjust, test the machine. 220A5MS22
6-45
2. ENGINE STALL
※ Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Not enough Check engine
engine power fault
YES Check pressure Contact cummins
at EPPR valve
SPEC:2~25 kgf/cm2 Defective EPPR Replace

See TEST 5 NO
Check electric valve
current at EPPR
valve
YES
Short circuit or Check and repair
SPEC : 100~700 mA poor connection wire harness
See TEST 4
Check resistance between
between CN-54-CN-342 (or
NO at EPPR valve
343)
SPEC : 15~25Ω(20˚C)
See TEST 1
NO
Defective EPPR Replace
valve
Wiring diagram
UNITED MCU
FUSE
EPPR POWER 24V 18
No.11
P1 PUMP REG EPPR(+) 27
P1 PUMP REG
P1 PUMP REG EPPR(-) 02 EPPR VALVE
7 1
GROUND(EPPR) 33 8 2
CN-342
P2 PUMP REG
EPPR VALVE
P2 PUMP REG EPPR(-) 03 9 1

P2 PUMP REF EPPR(+) 26 10 2
CN-54 CN-1 CN-343 220A6MS101
6-46
2) TEST PROCEDURE Spec : 100~700 mA
(1) Test 4 : Check electric current at EPPR Adapter(P/no.:21Q6-50410)
valve. CN-342 (or 343)
① Disconnect connector CN-342 (or 343) Multimeter EPPR valve
from EPPR valve.
and install multimeter as figure. P2 pump
③ Start engine.
P1 pump
④ Set S-mode and cancel auto decel
mode.
⑥ If rpm show approx 1700±50 rpm discon-
nect one wire harness from EPPR valve. Main pump
Check electric current at bucket circuit

⑦ relief position. CN-342 for P1 pump
CN-343 for P2 pump
220A5MS21
(2) Test 5 : Check pressure at EPPR valve. SPEC : 2~25 kgf/cm2 (30~350 psi)
① Remove plug and connect pressure Pressure adjusting
screw locknut
gauge as figure.
(0 to 725 psi)
CN-342 (or 343)
P1
mode.
④ Position the multimodal dial at 10.
a4
⑤ If rpm show approx 1700±50 rpm check
pressure at relief position of bucket
circuit by operating bucket control lever. Main pump
⑥ If pressure is not correct, adjust it.
⑦ After adjust, test the machine. a4 for P1 pump
a5 for P2 pump 220A5MS22
6-47
3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM
Cause Remedy
YES
No power supply to Check fuse No.2
See if all lamps the united MCU
YES off in the united
MCU case YES
Y R G United MCU failure Replace
Y R G
See if HCESPN
840 active fault NO
display on the LCD
NO Y R G
ⓐ
NO
OK
Check connection Cluster failure Replace
between CN-51
ⓐ (09) - CN-56A (6)
or CN-51(08) -
CN-56A (7) No connection Check and repair
NO
KEY OFF
Wiring diagram
BATT.24V
IG 24V UNITED MCU
GND
CAN1 HI
CAN1 LO
CAN2 HI 6 6 09 CAN 2 HIGH
CAN2 LO 7 5 08 CAN 2 LOW
RS-232 RX
RS-232 TX CN-56A CN-5 01 BATT POWER_24V
AUX LEFT
CN-51
AUX RIGHT
AUX GND FUSE
CLUSTER No.2
220F6MS102
6-48
4. AUTO DECEL SYSTEM DOES NOT WORK (N.A)
· Fault code : HCESPN 105, FMI 0~4 (work pressure sensor)
HCESPN 108, FMI 0~4 (travel oil pressure sensor)
Cause Remedy
YES
MCU
YES
Check voltage Defective travel Replace
NO between CD-104 pressure sensor
(or 105) (A) and
(C) Short circuit or poor Replace or repair
Check voltage NO
connection
between CN-52 SPEC : 24±2V
Starting switch ON between CN-51
(27)-GND and (32)-CD-104 (or
CN-52 (23)-GND
105) (A) and / or
SPEC : 1~5V CN-51 (31)-CD-
Actuator operating 104 (or 105) (C)
See TEST 7, 8 (fault code 108
YES
displayed)
Replace
Check voltage Defective work
between CD-32 pressure sensor
NO (A) and (C)
Replace or repair
NO
Short circuit or poor
SPEC : 24±2V
Starting switch ON connection
between CN-51
(32)-CD-32 (A) and
/ or CN-51 (31)-CD-
32 (C) (fault code
105 displayed)
Wiring diagram
CD-104
A SUPPLY
B SIG
C RETURN
CN-51
TRAVEL PRESSURE SENSOR(RH)
CD-105
SENSOR POWER(10V) 32 A SUPPLY
B SIG
GND(SENSOR_10V) 31 C RETURN
TRAVEL PRESSURE SENSOR(LH)
UNITED MCU
TRAVEL PEDAL PS(LH) 27 CD-32

TRAVEL PEDAL PS(RH) 24 A SUPPLY
BOOM UP PILOT PS 23 B SIG
C RETURN
CN-52 BOOM UP PRESSURE SENSOR

235A6MS03
6-49
2) TEST PROCEDURE (N.A) SPEC : Actuator operating : 1~5 V
(1) Test 7 : Check voltage at CN-52 (24 or
27) and ground.
① Prepare 1 piece of thin sharp pin, steel or MCU
copper. PIN
② Insert prepared pin to rear side of CN-51 CN-52 CN-53 CN-54
connectors : One pin to (24 or 27) of

CN-52.
③ Starting switch ON.
④ Check voltage as figure.
(2) Test 8 : Check voltage at CN-52 (19) and
ground. 9 8 7 6 5 4 3 2 1
① Prepare 1 piece of thin sharp pin, steel or 17 10 CN-52

25 18
copper 24 27 Female
② Insert prepared pin to rear side of 34 33 32 31 30 29 28 27 26
connectors : One pin to (23) of CN-52. Ground

③ Starting key ON. Pin 27
④ Check voltage as figure. or 24
Multimeter
9 8 7 6 5 4 3 2 1
17
23
10 CN-52
25 18
Female
34 33 32 31 30 29 28 27 26
Ground
Pin 23
Multimeter
235A6MS104
6-50
5. MALFUNCTION OF PUMP 1 PRESSURE SENSOR
· Fault code : HCESPN 120, FMI 0~4
Cause Remedy
YES
MCU
YES
Short circuit or Replace or repair
poor connection
YES Check voltage between CN-51
between CN-1
(31)-CN-1 (5)
Check voltage (5)-GND
between CN-51
SPEC : 1~5V Detective P1 Replace or repair
(22) - GND Actuator operating NO
Check voltage pressure sensor
SPEC : 1~5V YES between CD-42 Short circuit or Replace or repair
Actuator operating (A)-(C) poor connection
See TEST 9
between CN-1
SPEC : 24±2V
Starting switch ON (5)-CD-42 (B)
Check voltage
between CN-1 Short circuit or Replace or repair
NO (4)-(6) NO
poor connection
between CD-42
SPEC : 24±2V
Starting switch ON
(A)-CN-1 (4) or
CD-42 (C)-CN-1
(6)

NO
poor connection
between CN-1
(4)-CN-51 (32) or
CN-1 (6)-CN-52
(31)
Wiring diagram
UNITED MCU
CD-42
SENSOR POWER(10V) 32 4 A SUPPLY
5 B SIG
GND(SENSOR_10V) 31 6 C RETURN
CN-51 P1 PUMP DELIVERY
MAIN PUMP (P1) PS 22
CN-52
220A6MS105
6-51
2) TEST PROCEDURE SPEC : Actuator operating : 1~5 V
ground.
① Prepare 1 piece of thin sharp pin, steel or
copper.
② Insert prepared pin to rear side of MCU
connectors : One pin to (22) of CN-52. PIN
③ Starting switch ON. CN-51 CN-52 CN-53 CN-54
9 8 7 6 5 4 3 2 1
17 10 CN-52
25 18
22 Female
34 33 32 31 30 29 28 27 26
Ground
Multimeter
220A6MS106
6-52
6. MALFUNCTION OF PUMP 2 PRESSURE SENSOR
Cause Remedy
YES
MCU
YES
poor connection
YES Check voltage between CN-51
between CN-1
(14)-CN-1 (3)
Check voltage (3)-GND
between CN-51
SPEC : 1~5V Detective P2 Replace or repair
SPEC : 1~5V YES between CD-43 Short circuit or Replace or repair
See TEST 10
between CN-1
SPEC : 24±2V
Check voltage
NO (4)-(6) NO
poor connection
between CD-43
SPEC : 24±2V
Starting switch ON
(A)-CN-1 (4) or
CD-43 (C)-CN-1
(8)

NO
poor connection
between CN-1
(4)-CN-51 (32) or
CN-1 (6)-CN-51
(31)
Wiring diagram
UNITED MCU
CD-43
MAIN PUMP (P2) PS 14 3 B SIG
GND(SENSOR_10V) 31 6 C RETURN
CN-51 P2 PUMP DELIVERY
220A6MS107
6-53
ground.
copper.
MCU
② Insert prepared pin to rear side of
PIN
connectors : One pin to (14) of CN-51.
CN-51 CN-52 CN-53 CN-54
9 8 7 6 5 4 3 2 1
17
14
10 CN-51
25 18
Female
34 33 32 31 30 29 28 27 26
Ground
Multimeter
220A6MS108
6-54
7. MALFUNCTION OF NEGATIVE 1 PRESSURE SENSOR
Cause Remedy
YES
MCU
YES
poor connection
YES Check voltage between CN-51-
between CN-1
(22)-CN-1 (1)
(1)-GND
Check voltage
between CN-51 SPEC : 1~5V Detective N1 Replace or repair
Actuator operating NO
(22) - GND Check voltage pressure sensor
YES between CD-70 Short circuit or Replace or repair
SPEC : 1~5V
See TEST 12 between CN-1
SPEC : 24±2V
Check voltage Short circuit or Replace or repair

NO
between CN-1 poor connection
NO (4)-(6) between CD-70
(A)-CN-1 (4) or
SPEC : 24±2V CD-70 (C)-CN-1
Starting switch ON
(6)

NO poor connection
between CN-1
(4)-CN-51 (32) or
CN-1 (6) - CN-51
(31)
Wiring diagram
UNITED MCU
CD-70
P1 REGULATOR PS 22 1 B SIG
GND (SENSOR_10V) 31 6 C RETURN
P1 REG PRESSURE SENSOR
CN-51 CN-1
235A6MS111
6-55
(1) Test 12 : Check voltage at CN-51 (22)
and ground.
copper.
9 8 7 6 5 4 3 2 1
17
22
10 CN-51
25 18
Female
34 33 32 31 30 29 28 27 26
Ground
Multimeter
140L6MS112
6-56
8. MALFUNCTION OF NEGATIVE 2 PRESSURE SENSOR
Cause Remedy
YES
MCU
YES
poor connection
YES Check voltage between CN-51-
between CN-1
(28)-CN-1 (2)
(2)-GND
Check voltage
between CN-51 SPEC : 1~5V Detective N2 Replace or repair
YES between CD-71 Short circuit or Replace or repair
SPEC : 1~5V
See TEST 13 between CN-1
SPEC : 24±2V
Check voltage Short circuit or Replace or repair

NO
between CN-1 poor connection
NO (4)-(6) between CD-71
(A)-CN-1 (4) or
SPEC : 24±2V
Starting switch ON
CD-71 (C)-CN-1
(6)

NO poor connection
between CN-1
(4)-CN-51 (32) or
CN-1 (6) - CN-51
Wiring diagram (31)
CN-51
CD-71
P2 REGULATOR PS 28 2 B SIG
GND (SENSOR_10V) 31 6 C RETURN
P2 REG PRESSURE SENSOR
UNITED MCU CN-1
235A6MS113
6-57
and ground.
copper.
PIN
9 8 7 6 5 4 3 2 1
17 10 CN-51
25
28
18
Female
34 33 32 31 30 29 28 27 26
Ground
Multimeter
140L6MS114
6-58
9. MALFUNCTION OF SWING PRESSURE SENSOR
Cause Remedy
YES
MCU
Check voltage YES

between CN-52 Detective swing Replace or repair
(18) - GND pressure sensor
SPEC : 1~5V Short circuit or Replace or repair
Actuator operating Check voltage poor connection
See TEST 14 between CD-24 between CN-52
NO (A)-(C) (18)-CD-24 (B)
SPEC : 24±2V
Starting switch ON
NO
poor connection
between CD-24
(A)-CN-51 (32) or
CD-24 (C)-CN-51
(31)
Wiring diagram
SWING PILOLT
UNITED MCU
PRESSURE SENSOR
B SIG
CN-51 CD-24
SWING PILOT PRESSURE 18
CN-52
220A6MS114
6-59
ground.
copper.
9 8 7 6 5 4 3 2 1
17 10 CN-52
25 18 18 Female
34 33 32 31 30 29 28 27 26
Ground
Multimeter
220A6MS116
6-60
10. MALFUNCTION OF ARM OUT PRESSURE SENSOR
Cause Remedy
YES
MCU
Check voltage YES

between CN-51 Detective arm in/ Replace or repair
(27) - GND out & bucket in
SPEC : pressure sensor
Actuator operating: 1~5V Check voltage Short circuit or Replace or repair
See TEST 15 between CD-86 poor connection
NO (A)-(C) between CN-51
(27)-CD-86 (B)
SPEC : 24±2V
Starting switch ON
NO
poor connection
between CD-86
(A)-CN-51 (32) or
CD-86 (C)-CN-
51 (31)
Wiring diagram
UNITED MCU
ARM OUT PILOLT
PRESSURE SENSOR
ARM OUT PILOT PRESSURE 27 B SIG
GND (SENSOR_10V) 31 C RETURN
CD-86
CN-51
220A6MS117
6-61
and ground.
copper.
MCU
② Insert prepared pin to rear side of
PIN
CN-51 CN-52 CN-53 CN-54
9 8 7 6 5 4 3 2 1
17 10 CN-51
25 18
Female
27
34 33 32 31 30 29 28 27 26
Ground
Multimeter
220A6MS118
6-62
11. MALFUNCTION OF BOOM UP PRESSURE SENSOR
Cause Remedy
YES
MCU
Check voltage YES

between CN-52 Detective boom up Replace or repair
NO (A)-(B) (23)-CD-32 (B)
SPEC : 24±2V
Starting switch ON
NO
poor connection
between CD-32
(A)-CN-51 (32) or
CD-32 (C)-CN-
51 (31)
Wiring diagram
BOOM UP PILOLT
UNITED MCU
PRESSURE SENSOR
B SIG
CN-51 CD-32
BOOM UP PILOT PRESSURE 23
CN-52
220A6MS119
6-63
and ground.
copper.
9 8 7 6 5 4 3 2 1
17 10 CN-52
25 18
23 Female
34 33 32 31 30 29 28 27 26
Ground
Multimeter
220A6MS120
6-64
12. MALFUNCTION OF BOOM DOWN PRESSURE SENSOR
Cause Remedy
YES
MCU
Check voltage YES

between CN-52 Detective boom up Replace or repair
NO (A)-(B) (31)-CD-85 (B)
SPEC : 24±2V
Starting switch ON
NO
poor connection
between CD-85
(A)-CN-51 (32) or
CD-85 (C)-CN-
51 (31)
Wiring diagram
BOOM DOWN PILOLT

UNITED MCU PRESSURE SENSOR
B SIG
CN-51 CD-85
BOOM DOWN PILOT PRESSURE 31
CN-52
220A6MS121
6-65
and ground.
copper.
9 8 7 6 5 4 3 2 1
17 10 CN-52
25 18
Female
31
34 33 32 31 30 29 28 27 26
Ground
Multimeter
220A6MS122
6-66
13. MALFUNCTION OF POWER MAX
· Fault code : HCESPN 166, FMI 4 or 6
Cause Remedy
YES
Short circuit or poor Repair or replace
connection between
YES Check resistance CN-88 (1)-CN-53
between CN-88 (10)
(1)-(2)
Defective power Repair or replace
YES Check resistance SPEC: 15-35Ω
NO
between CN-54 See TEST 19 max. solenoid valve
(21)-GND Check hydraulic
system
Is voltage between SPEC Repair or replace
CN-88(2)-GND Power max button Short circuit or poor
pressed ON : 0Ω NO
normal? connection between
pressed OFF : ∞ Ω
CN-54 (21)-CS-29
SPEC (1)
Starting swich
ON : 24±1V Repair or replace
OFF : 0V Short circuit or poor
See TEST 18 NO
connection between
CN-88 (2)-
Fuse No. 28
Wiring diagram
UNITED MCU
CN-88
POWER BOOST SOL 10 1
2
CN-53
POWER MAX SOLENOID
POWER BOOST SW 21 5
FUSE
6
No.28
CN-54 CN-4
CS-29
1
GND(FOR SENSOR_5V) 25
2
CN-51 POWER MAX SWITCH
220A6MS21
6-67
2) TEST PROCEDURE SPEC : Starting switch ON : 24±1V
Starting switch OFF : 0V
(1) Test 18:
18 Check voltage between connector
CN-88 (2) - GND.
① Disconnect connector CN-88 from power
max solenoid valve.
② Start switch ON. Power max switch
③ Check voltage as figure.
LH RCV-lever
CN-88
Power max
solenoid valve
2 1
1 2
Ground
Multimeter
140L6MS123
(2) Test 19:

19 Check resistance of the solenoid SPEC : 15~35Ω
valve between CN-88 (1)-(2).
① Starting switch OFF.
② Disconnect connector CN-88 from power Power max switch
max solenoid valve.
③ Check resistance as figure.
LH RCV-lever
CN-88
Power max 2 1
solenoid valve
1 2
Multimeter 140L6MS124
6-68
14. MALFUNCTION OF BOOM PRIORITY EPPR VALVE
Cause Remedy
YES
Short circuit or poor Repair or
connection between replace
CN-54 (04)-CN-
Check resistance 242 (1) or CN-54
between CN-242 (34)-CN-242 (2) or
(1)-(2) or CN-243 CN-54 (05)-CN-
(1)-(2) 243 (1) or CN-54
SPEC : 20~30V (34)-CN-243 (2)
Starting switch ON
Defective EPPR Repair or

NO
valve replace
Wiring diagram
BOOM PRIORITY
UNITED MCU EPPR VALVE (vs swing)
BOOM PRIORITY SWING EPPR(-) 04 1

BOOM PRIORITY EPPR(+) 34 2
CN-242
BOOM PRIORITY
EPPR VALVE (vs arm)
BOOM PRIORITY ARM EPPR(-) 05 1
CN-54 CN-243
220A6MS123
6-69
15. MALFUNCTION OF ARM REGENERATION SOLENOID
Cause Remedy
YES
MCU
YES Check voltage
YES
(07)-GND
poor connection
Check resistance between CN-52
SPEC : 24±2V
Starting switch ON between arm
Check voltage NO (07)-CN-135 (1)
See TEST 20 regen solenoid
between CN-135
(2) - GND SPEC : 15~35Ω Defective Replace
NO
SPEC : 20~30V solenoid valve
Starting switch ON
Open circuit Replace or repair

NO
between CN-135
(2)-Fuse No. 28
Wiring diagram
UNITED MCU
CN-135
ARM REGEN SOL 07 1
2
ARM REGENERATION SOLENOID
FUSE
No.28
CN-52
220A6MS27
6-70
2) TEST PROCEDURE SPEC : Key ON : 24±2 V
and ground.
copper.
9 8 7 6 5 4 3 2 1
07
CN-52
17 10 Female
25 18
34 33 32 31 30 29 28 27 26
Ground
Multimeter
140L6MS128
6-71
GROUP 5 AIR CONDITIONER & HEATER SYSTEM
1. AIR CONDITIONER DOES NOT OPERATE
Cause Remedy
NO Check air con YES
fuse. Is there Fuse is blown Replace
problem?
NO
When the air con Fan does not operate Refer to 1)
switch is pushed.
Does air con YES Weak air flow Refer to 2)
lamp light up?
Abnormal operation Refer to 3)
Check the air
flow of fan motor. NO Refer to 4)
YES Is there roblem?
(weak flow or no
Check the
flow) NO
compressor. Refer to 5)
NO Does it operate?
Check the
compressor.
YES
Does it operate?
YES Refer to 6)
1) FAN DOES NOT OPERATE

Cause Check Remedy
Fuse is blown or * Fuse

Replace
abnormal relay operation * Does relay normally operate?
Harness short or Check any harness short or

Repair shortage
poor contact abnormal contact of connnector
Supply 24V to 2 lead wire from motor

Fan motor failure Replace
and check the operation
Resistor is broken Check current flow of resistor with tester Replace
Push fan switch by turn and check

Fan switch failure Replace
the operation
6-72
2) WEAK AIR FLOW FROM FAN MOTOR
Cause Check Remedy
Clogged evaporator or
Check if evaporator is contaminated Clean
obstacles around air inlet
Leakage of air flow Check HVAC case assembly Adjust
Duct sensor failure Check if evaporator is frozen Replace
3) ABNORMAL OPERATION OF FAN MOTOR

Cause Check Remedy
4 step only operate Replace resistor

Abnormal operation of
1 or 2 step does not operate Replace control
each step of control
3 or 4 step does not operate Replace relay
4) COMPRESSOR DOES NOT ROTATE OR HARDLY ROTATE

Cause Check Remedy
Loose belt Belt shaking is severe Adjust tension
Failure of compressor
Belt slip Repair or Replace
itself
Low voltage of battery Slip when rotate Charge battery
Replace magnetic
Fieldcoil short Slip when rotate
clutch
Replace magnetic
Oily clutch face Contamination around clutch
clutch, clean
Magnetic clutch does not operate or

Fieldcoil is broken Replace compressor
"∞" resistance
Leakage of refrigerant or Replace compressor

Check if wet with oil
oil inside Charge refrigerant
6-73
5) COMPRESSOR OPERATE NORMALLY AND AIR FLOW IS NORMAL
Cause Check Remedy
When air con operate during 5~10 min

Repair leakage joint
Shortage of refrigerant small temperature difference between
Charge refrigerant
high and low pressure pipes.
*Magnetic clutch on/off rapidly

Recharge refrigerant
Overcharge of refrigerant *High pressure over specification
following specification
*Lukewarm air from nozzle
Shortage of refrigerant Make up refrigerant
Replace
Clogged receive dryer
receive dryer
Lower pressure than
Replace
normal condition at Clogged expansion valve
expansion valve
low side
Replace pipe or
Clogged or crushed pipe
clean
Failure of duct sensor Replace duct sensor
6) COMPRESSOR OPERATE NORMALLY AND AIR FLOW IS NORMAL

Cause Check Remedy
Failure of duct sensor

Replace duct sensor
Magnetic clutch off before air
Lower pressure than or adjust location
temperature sufficiently down
normal condition at
low side Defective compressor gasket
Repair compressor
When compressor off, high and low
or Replace
pressure balance immediatly
Failure of condensing
Clean the condenser
Contamination on condenser or
Repair fan
Higher pressure than insufficient air flow from fan
normal condition at
Overcharge of refrigerant Adjust refrigerant
high side
Vacuum and
Entrained air
recharge
Lower pressure than

normal condition at Shortage of refrigerant Make up refrigerant
high side
6-74
Group 1 Operational Performance Test ------------------------------------------------------------------------------ 7-1

Group 2 Major Components ---------------------------------------------------------------------------------------------- 7-21
Group 3 Track and Work Equipment --------------------------------------------------------------------------------- 7-30
GROUP 1 OPERATIONAL PERFORMANCE TEST
1. PURPOSE
Performance tests are used to check:
1) OPERATIONAL PERFORMANCE OF A
NEW MACHINE
Whenever a new machine is delivered in Working
parts and reassembled at a customer's condition
site, it must be tested to confirm that the
operational performance of the machine
meets Hyundai spec.
2) OPERATIONAL PERFORMANCE OF A Maintenance
record
WORKING MACHINE
With the passage of time, the machine's
operational performance deteriorates, so
that the machine needs to be serviced
periodically to restore it to its original
performance level. Operating
Before servicing the machine, conduct
performance tests to check the extent of
deterioration, and to decide what kind of
service needs to be done(by referring to
the "Service Limits" in this manual).
3) OPERATIONAL PERFORMANCE OF A
REPAIRED MACHINE
After the machine is repaired or serviced, it
must be tested to confir m that its
operational performance was restored by
the repair and/or service work done. 21077MS01
7-1
2. TERMINOLOGY
1) STANDARD
Specifications applied to the brand-new
machine, components and parts.
21077MS02
2) SERVICE LIMIT
The lowest acceptable performance level.
When the perfor mance level of the
machine falls below this level, the machine
must be removed from work and repaired.
Necessary parts and components must be
replaced.
21077MS03
7-2
3. OPERATION FOR PERFORMANCE TESTS
1) Observe the following rules in order to carry
out performance tests accurately and safely.
The machine
(1) Repair any defects and damage found,
such as oil or water leaks, loose bolts,
cracks and so on, before starting to test.
(2) Test area
① Select a hard, flat surface.
② Secure enough space to allow the
machine to run straight more than 20m,
and to make a full swing with the front
attachment extended.
③ If required, rope off the test area and
provide signboards to keep unauthorized
personnel away.
(3) Precautions
① Before starting to test, agree upon the
signals to be employed for communication
among coworkers. Once the test is
started, be sure to communicate with each
other using these signals, and to follow
(290-7TIER) 7-3
them without fail.
② Operate the machine carefully and always
give first priority to safety.
③ While testing, always take care to avoid
accidents due to landslides or contact with
high voltage power lines. Always confirm
that there is sufficient space for full swings.
④ Avoid polluting the machine and the
ground with leaking oil. Use oil pans to
catch escaping oil. Pay special attention
to this when removing hydraulic pipings.
(4) Make precise measurements
① Accurately calibrate test instruments in
advance to obtain correct data.
② Carry out tests under the exact test
conditions prescribed for each test item.
③ Repeat the same test and confirm that the
test data obtained can be procured
r e p e a t e d l y. U s e m e a n va l u e s o f
measurements if necessary.
7-3
2) ENGINE SPEED
(1) Measure the engine speed at each power
mode
※ The engine speed at each power mode
CLUSTER
must meet standard RPM; if not, all other
operational performance data will be
unreliable. It is essential to perform this
test first.
(2) Preparation
① Warm up the machine, until the engine
coolant temperature reaches 50˚C or
more, and the hydraulic oil is 50±5˚C.
② Set the multimodal dial at 10 (Max)
position.
③ Measure the engine RPM. Engine RPM display
(3) Measurement Power mode switch
Pilot lamp(P, S, E)
① Start the engine. The engine will run at
start idle speed. Measure engine speed
with a engine rpm display.
② Measure and record the engine speed at
each mode (P, S, E).
③ Select the P-mode.
④ Lightly operate the bucket control lever a
few times, then return the control lever to
neutral; The engine will automatically
enter the auto-idle speed after 4
seconds.
⑤ Measure and record the auto deceleration 210A7MS01
speed.
(4) Evaluation
The measured speeds should meet the following specifications.
Unit : rpm
Model Engine speed Standard Remarks

Start idle 850±100
P mode 1800±50
S mode 1700±50
HX210A L/NL
E mode 1600±50
Auto decel 1000±100
One touch decel 850±100
Condition : Set the multimodal dial at 10 (Max) position.
7-4
3) TRAVEL SPEED
(1) Measure the time required for the
excavator to travel a 20 m test track.
(2) Preparation
① Adjust the tension of both tracks to be
equal.
② Prepare a flat and solid test track 20 m in
length, with extra length of 3 to 5 m on 0.3~0.5m
both ends for machine acceleration and
deceleration.
③ Hold the bucket 0.3 to 0.5 m above the
ground with the arm and bucket rolled in.
④ Keep the hydraulic oil temperature at
210SA7MS02
50±5˚C.
(3) Measurement
① Measure both the low and high speeds
of the machine.
② Before starting either the low or high
speed tests, adjust the travel mode
switch to the speed to be tested, then
select the following switch positions.
· Power mode switch : P mode
③ Star t traveling the machine in the
acceleration zone with the travel levers 3~5m 20m 3~5m
at full stroke.
④ Measure the time required to travel 20 m.
⑤ After measuring the forward travel
speed, turn the upperstructure 180。
and measure the reverse travel speed. 210A7MS03
⑥ Repeat steps ④ and ⑤ three times in

each direction and calculate the average
values.
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds / 20 m
Model Travel speed Standard Maximum allowable Remarks
1 Speed 19.5±2.0 25
HX210A L/NL
2 Speed 12.4±1.0 16
7-5
4) TRACK REVOLUTION SPEED
(1) Measure the track revolution cycle time
with the track raised off ground.
(2) Preparation
① Adjust the tension of both side tracks to
be equal.
② On the track to be measured, mark one
90~110
shoe with chalk.
③ Swing the upperstructure 90˚ and lower
the bucket to raise the track off ground.
Mark
Keep the boom-arm angle between 90 to
110˚ as shown. Place blocks under
machine frame.
210A7MS04
50±5˚C.
(3) Measurement
① Select the following switch positions.
· Travel mode switch : 1 or 2 speed
· Auto idle switch : OFF
② Operate the travel control lever of the
raised track in full forward and reverse.
③ Rotate 1 turn, then measure time taken
for next 3 revolutions.
④ Raise the other side of machine and
repeat the procedure.
⑤ Repeat steps ③ and ④ three times and
calculate the average values.
(4) Evaluation
The revolution cycle time of each track should meet the following specifications.
Unit : Seconds / 3 revolutions
Model Travel speed Standard Maximum allowable
1 Speed 26.7±2.0 33
HX210A L/NL
2 Speed 16.9±2.0 21
7-6
5) TRAVEL DEVIATION
(1) Measure the deviation by the tracks from
a 20 m straight line.
(2) Preparation
① Adjust the tension of both tracks to be
equal.
② Provide a flat, solid test yard 20 m in
length, with extra length of 3 to 5 m on 0.3~0.5m
both ends for machine acceleration and
deceleration.
③ Hold the bucket 0.3 to 0.5 m above the
ground with the arm and bucket rolled in.
210A7MS02
50±5˚C.
(3) Measurement
① Measure the amount of mistracking at
high and low travel speeds.
② Before beginning each test, select the
following switch positions.
③ Star t traveling the machine in the 3~5 m extra length
acceleration zone with the travel levers at a
M
20
full stroke.
④ Measure the distance between a straight
20 m line and the track made by the 3~5 m extra length
machine. (Dimension a)
⑤ After measuring the tracking in forward
travel, turn the upperstructure 180。and
measure that in reverse travel. (210-7) 7-7(2)
⑥ Repeat steps ④ and ⑤ three times and

(4) Evaluation
Mistrack should be within the following specifications.
Unit : mm / 20 m
Model Standard Maximum allowable Remarks
HX210A L/NL 200 below 240 -
7-7
6) SWING SPEED
(1) Measure the time required to swing three
complete turns.
(2) Preparation
① Check the lubrication of the swing gear Boom foot pin
and swing bearing.
② Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
③ With the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin. The bucket must be empty.
50±5˚C. 210A7MS05
(3) Measurement
② Operate swing control lever fully.
③ Swing 1 turn and measure time taken to
swing next 3 revolutions.
④ Repeat steps ② and ③ three time and
(4) Evaluation
The time required for 3 swings should meet the following specifications.
Unit : Seconds / 3 revolutions
Model Power mode switch Standard Maximum allowable

HX210A L/NL P mode 15.0±1.5 19
7-8
7) SWING FUNCTION DRIFT CHECK
(1) Measure the swing drift on the bearing
outer circumference when stopping after
a 360˚ full speed swing.
(2) Preparation Boom foot pin
① Check the lubrication of the swing gear
and swing bearing.
② Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
③ With the arm rolled out and bucket rolled
210A7MS05
foot pin. The bucket must be empty.
④ Make two chalk marks: one on the swing
bearing and one directly below it on the
track frame.
⑤ Swing the upperstructure 360˚.
⑥ Keep the hydraulic oil temperature at
50±5˚C.
(3) Measurement
① Conduct this test in the M mode.
② Select the following switch positions.
③ Operate the swing control lever fully and
return it to the neutral position when the
mark on the upperstructure aligns with
that on track frame after swinging 360。
④ Measure the distance between the two
marks. Drift angle
⑤ Align the marks again, swing 360。, then
360 swing
test the opposite direction. Swing start & stop
⑥ Repeat steps ④ and ⑤ three times each
and calculate the average values.
21077MS08
(4) Evaluation
The measured drift angle should be within the following specifications.
Unit : Degree
Model Power mode switch Standard Maximum allowable Remarks
HX210A L/NL P mode 90 below 157.5
7-9
8) SWING BEARING PLAY
(1) Measure the swing bearing play using a
dial gauge to check the wear of bearing
races and balls.
(2) Preparation
① Check swing bearing mounting cap
screws for loosening.
② Check the lubrication of the swing
bearing. Confirm that bearing rotation is
smooth and without noise.
③ Install a dial gauge on the track frame as
shown, using a magnetic base.
④ Position the upperstructure so that the
(210-7) 7-10(1)
boom aligns with the tracks facing
towards the front idlers.
⑤ Position the dial gauge so that its needle
point comes into contact with the bottom
face of the bearing outer race.
⑥ Bucket should be empty.
(3) Measurement Measurement : (h1)
① With the arm rolled out and bucket rolled Boom foot pin
in, hold the bottom face of the bucket to
the same height of the boom foot pin.
Record the dial gauge reading (h1).
② Lower the bucket to the ground and use
it to raise the front idler 50 cm.
Measurement : (h2)
Record the dial gauge reading (h2).
③ Calculate bearing play (H) from this data
(h1 and h2) as follows.
H=h2-h1
(4) Evaluation 210A7MS06
The measured drift should be within the following specifications.

Unit : mm
Model Standard Maximum allowable Remarks
HX210A L/NL 0.5 ~ 1.5 3.0
7-10
9) HYDRAULIC CYLINDER CYCLE TIME
(1) Measure the cycle time of the boom,
standard arm, and standard bucket
cylinders.
(2) Preparation
Boom cylinder
① To measure the cycle time of the boom
Raise
cylinders:
With the arm rolled out and the empty
bucket rolled out, lower the bucket to the
ground, as shown. Lower
② To measure the cycle time of the arm
cylinder.
With the empty bucket rolled in, position
the arm so that it is vertical to the Arm cylinder
ground. Lower the boom until the
bucket is 0.5 m above the ground.
Roll out Roll in
③ To measure the cycle time of the bucket
cylinder.
90
The empty bucket should be positioned
0.5m
at midstroke between roll-in and roll-out,
so that the sideplate edges are vertical to
the ground.
④ Keep the hydraulic oil temperature at Bucket cylinder
50±5˚C.
(3) Measurement
Roll out Roll in
② To measure cylinder cycle times.
- Boom cylinders. 0.5m
Measure the time it takes to raise the 210A7MS07
boom, and the time it takes to lower the
boom. To do so, position the boom at
one stroke end then move the control
lever to the other stroke end as quickly
as possible.
- Arm cylinder.
Measure the time it takes to roll in the
arm, and the time it takes to roll out the
arm. To do so, position the bucket at
one stroke end, then move the control
lever to the other stroke end as quickly
as possible.
7-11
- Bucket cylinders
Measure the time it takes to roll in the
bucket, and the time it takes to roll out
the bucket. To do so, position the
bucket at one stroke end, then move the
control lever to the other stroke end as
quickly as possible.
- Repeat each measurement 3 times and
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds
Maximum
Model Function Standard Remarks
allowable
Boom raise 3.5±0.4 4.3
Boom lower 3.4±0.4 4.2
Regen ON 3.0±0.4 3.7
Arm in
HX210A L/NL Regen OFF 3.3±0.4 4.1
Arm out 3.0±0.4 3.7
Bucket in 2.4±0.4 3.1
Bucket out 2.0±0.4 2.6
7-12
10) DIG FUNCTION DRIFT CHECK
(1) Measure dig function drift, which can be
caused by oil leakage in the control valve
and boom, standard arm, and standard
bucket cylinders, with the loaded bucket.
When testing the dig function drift just
after cylinder replacement, slowly operate
each cylinder to its stroke end to purge air.
(2) Preparation
① Load bucket fully. Instead of loading the
bucket, weight (W) of the following
specification can be used.
· W=M3×1.5 Boom foot pin
Where :
M3 = Bucket heaped capacity (m3)
1.5= Soil specific gravity
② Position the arm cylinder with the rod 20
to 30 mm extended from the fully retracted
position.
③ Position the bucket cylinder with the rod
20 to 30 mm retracted from the fully
210A7MS08
extended position.
④ With the arm rolled out and bucket rolled
foot pin.
⑤ Keep the hydraulic oil temperature at
50±5˚C.
(3) Measurement
① Stop the engine.
② Five minutes after the engine has been
stopped, measure the changes in the
positions of the boom, arm and bucket
cylinders.
③ Repeat step ② three times and calculate
the average values.
(4) The measured drift should be within the following specifications.
Unit : mm / 5 min
Model Drift to be measured Standard Maximum allowable Remarks

Boom cylinder 10 below 20
HX210A L/NL Arm cylinder 10 below 20
Bucket cylinder 40 below 60
7-13
11) CONTROL LEVER OPERATING FORCE
(1) Use a spring scale to measure the
maximum resistance of each control lever
at the middle of the grip.
(2) Preparation
① Keep the hydraulic oil temperature at
50±5˚C.
(3) Measurement
① Start the engine.
② Select the following switch positions.
③ Operate each boom, arm, bucket and
swing lever at full stroke and measure the
maximum operating force for each.
④ Lower the bucket to the ground to raise
one track off the ground. Operate the
travel lever at full stroke and measure the
maximum operating force required.
When finished, lower the track and then
jack-up the other track.
⑤ Repeat steps ③ and ④ three times and
(4) Evaluation
The measured operating force should be within the following specifications.
Unit : kgf
Model Kind of lever Standard Maximum allowable Remarks
Boom lever 1.6 or below 2.0
Arm lever 1.6 or below 2.0
HX210A L/NL Bucket lever 1.6 or below 2.0
Swing lever 1.6 or below 2.0
Travel lever 2.1 or below 3.15
7-14
12) CONTROL LEVER STROKE
(1) Measure each lever stroke at the lever top
using a ruler.
※ When the lever has play, take a half of
this value and add it to the measured
stroke.
(2) Preparation
Keep the hydraulic oil temperature at
50±5˚C.
(3) Measurement
② Measure each lever stroke at the lever
top from neutral to the stroke end using a
ruler.
③ Repeat step ② three times and calculate
the average values.
(4) Evaluation
The measured drift should be within the following specifications.
Unit : mm
Model Kind of lever Standard Maximum allowable Remarks

Boom lever 82±10 103
Arm lever 82±10 103
HX210A L/NL Bucket lever 82±10 103
Swing lever 82±10 103
Travel lever 139±10 178
7-15
13) PILOT PRIMARY PRESSURE
(1) Preparation Boom up
pressure sensor
50±5˚C. h1
(2) Measurement
Shuttle valve
· Auto decel switch : OFF n
② Slowly operate the boom control lever of

boom up functions at full stroke over reli-
ef and measure the primary pilot pressu-
re by the monitoring menu of the cluster. Monitoring
(analog)
Cluster
210A7MS13
(3) Evaluation
The average measured pressure should meet the following specifications:
Unit : kgf / cm2

Model Engine speed Standard Allowable limits Remarks
HX210A L/NL P mode Over 34 -
7-16
14) FOR TRAVEL SPEED SELECTING PRESSURE:
(1) Preparation
② Loosen the cap and relieve the pressure
in the tank by pushing the top of the air
breather.
③ To measure the speed selecting pressure:
Install a connector and pressure gauge
④ assembly to turning joint P port as shown.
P
Star t the engine and check for on
D A
leakage from the adapter. C
⑤ Keep the hydraulic oil temperature at
50±5˚C. DR
(2) Measurement
· Power mode switch : P mode 220A7MS14
· Travel mode switch : 1 speed

2 speed
② Measure the travel speed selecting
pressure in the Hi or Lo mode.
③ Lower the bucket to the ground to raise
the track off the ground. Operate the
travel lever at full stroke and measure the
fast speed pressure.
④ Repeat steps ② and ③ three times and
(3) Evaluation
The average measured pressure should be within the following specifications.
Unit : kgf / cm2
Model Travel speed mode Standard Maximum allowable Remarks
1 Speed 0 -
HX210A L/NL
2 Speed 40±5 -
7-17
15) SWING PARKING BRAKE RELEASING PRESSURE
(1) Preparation
② Loosen the cap and relieve the pressure
in the tank by pushing the top of the air
breather.
③ The pressure release L wrench to bleed
air.
④ Install a connector and pressure gauge
assembly to swing motor SH port, as
shown.
⑤ Star t the engine and check for oil
PG
leakage from the adapter.
⑥ Keep the hydraulic oil temperature at
50±5˚C.
(2) Measurement
· Power mode switch : P mode 210A7MS15
② Operate the swing function or arm roll in

function and measure the swing brake
c o n t r o l p r e s s u r e w i t h t h e b ra ke
disengaged. Release the control lever
to return to neutral and measure the
control pressure when the brake is
applied.
Repeat step ② three times and calculate
the average values.
(3) Evaluation
Unit : kgf / cm2
Model Description Standard Allowable limits Remarks
Brake disengaged 40±5 Over 20.9
HX210A L/NL
Brake applied 0 -
7-18
16) MAIN PUMP DELIVERY PRESSURE
(1) Preparation Main pump
50±5˚C.
(2) Measurement
· Power mode switch : P mode a2
a1
② Measure the main pump deliver y

pressure in the P mode (high idle).
Pressure sensor
Monitoring
(analog)
Cluster 210A7MS16
(3) Evaluation
The average measured pressure should meet the following specifications.
Unit : kgf / cm2
Model Engine speed Standard Allowable limits Remarks
HX210A L/NL High idle Under 10 -
7-19
17) SYSTEM PRESSURE REGULATOR RELIEF SETTING
(1) Preparation
① Keep the hydraulic oil temperature at Main pump
50±5˚C.
(2) Measurement
a2
② Slowly operate each control lever of a1
boom, arm and bucket functions at full

stroke over relief and measure the
pressure. Pressure sensor
③ In the swing function, place bucket
against an immovable object and
measure the relief pressure. Monitoring
④ In the travel function, lock undercarriage (analog)
with an immovable object and measure
the relief pressure.
Cluster
210A7MS16
(3) Evaluation
Unit : kgf / cm2
Model Function to be tested Standard Port relief setting
Boom, Arm, Bucket 350 (380)±10 400±10
HX210A L/NL Travel 350±10 -
Swing 290±20 -
( ) : Power boost
7-20
GROUP 2 MAJOR COMPONENT
1. MAIN PUMP
1) WEARING PARTS
3 1 2
9 5 6 4 7 8
220F7MP01
Part name & inspection item Standard dimension Counter measures
Clearance
between piston (1) & Replace piston
d D 0.057
cylinder bore (2) or cylinder.
(D-d)
Play between
piston (1) & shoe caulking
0.3
section (3)
(δ) Replace
assembly of
Thickness of shoe δ piston & shoe.
(t) t 4.8
Free height of cylinder

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

h H Replace set plate
plate (5) & spherical
24.0 or spherical
bushing (6)
bushing
(H-h)
Surface roughness for valve Surface roughness

necessary to be corrected 3z
plate (sliding face) (7,8),
swash plate (shoe plate Lapping
area) (9), & cylinder (2) Standard surface roughness 0.4z or lower
(sliding face) (corrected value)
7-21
2) TROUBLESHOOTING
(1) Overload of prime mover
Cause Countermeasure Caution
The speed or pressure is higher than Set them as specified.

their specified values.
The torque setting of the regulator is Adjust the regulator. See the pump device of the section 2.
higher than specified value.
Seizure or damage of a part inside Replace the damaged part. Check the filter and drain oil for
the pump. abnormal worn metal particles.
Wrong fitting of the regulator piping. Correct the regulator piping.
(2) Extreme decrease of pump delivery flow or delivery pressure does not increase.
Failure of the regulator. Repair the regulator. See the pump device of the section 2.
Seizure or damage of a part inside Replace the damaged parts. Check the filters and drain oil.
the pump.
Failure of the attached pump. Replace the damaged parts. Remove the attached pump and
check the shaft coupling.
Failure of the accessory valve. Replace the accessory valves. See the pump device of the section 2.
Especially, check the poppets, seats
and springs.
Wrong fitting of the regulator piping. Correct the regulator piping.
(3) Abnormal noise and abnormal vibrations
Cavitation Prevention from cavitation. Low boost press.

Check working oil for emulsion.
Damage in the caulking section of the Replace the piston, shoe, shoe plate, Failure of the attached pump.
shoe. etc.
Cracking of the cylinder. Replace the cylinder. Air leakage at the suction pipe.
Wrong installation of the pump. Correct installation. Increased suction resistance.
Hunting of the regulator. Repair the regulator. See the pump device of the section 2.
Hunting of the relief valve of the Repair the accessory valve. See the pump device of the section 2.
accessory valve.
Damage of the gear. Replace the gear.
7-22
2. MAIN CONTROL VALVE
Part name Inspection item Criteria & measure

Casing ·Existence of scratches, rust or corrosion. ·In case of damage in following section,
replace casing.
- Sliding sections of casing hole and spool,
especially land sections applied with held
pressure.
- Seal pocket section where spool is inserted.
- Sealing section of port where O-ring
contacts.
- Sealing section of each relief valve for main
and port.
- Sealing section of plug.
- Other damages that may damage normal
function.
Spool ·Existence of scratch, gnawing, rusting or ·Replacement when its outside sliding section
corrosion. has scratch (especially on seals-contacting
section).
·O-ring seal sections at both ends. ·Replacement when its sliding section has
scratch.
·Insert spool into casing hole, rotate and ·Correction or replacement when O-ring is
reciprocate it. damaged or when spool does not move
smoothly.
Poppet ·Damage of spring ·Replacement.
·Damage of poppet ·Correction or replacement when sealing is
incomplete.
·Insert poppet into casing and function it. ·Normal when it can function lightly and
smoothly without sticking.
Spring and related ·Rusting, corrosion, deformation or breakage ·Replacement for significant damage.
parts of spring, spring seat, plug or cover.
Around seal ·External oil leakage. ·Correction or replacement.
for spool
·Rusting, corrosion or deformation of seal ·Correction or replacement.
plate.
Main relief valve, ·External rusting or damage. ·Replacement.
port relief valve &
·Contacting face of valve seat. ·Replacement when damaged.
negative control
valve ·Contacting face of poppet. ·Replacement when damaged.
·Defect of spring. ·Replacement.
·O-rings and back up rings. ·Replacement in principle.
7-23
3. SWING DEVICE
1) WEARING PARTS
Standard Recommended
Inspection item replacement Counter measures
dimension value
Replace piston or
Clearance between piston and cylinder block bore 0.041 0.060
cylinder block
Thickness of valve plate 6 5.88 Replace
Replace assembly
Play between piston and shoe caulking section (δ) 0.025 0.1
of piston and shoe
Replace assembly
Thickness of shoe (t) 6.6 6.5
of piston and shoe
Replace set of
Combined height of retainer plate and spherical
17.6 17.3 retainer plate and
bushing (H-h)
sperical bushing
Thickness of friction plate 2.94 2.7 Replace
h H
δ
140W77MS12 2609A7MS01
2) SLIDING PARTS
Part name Standard roughness Allowable roughness Remark
Rmax=1S (Ra=0.2a)
Shoe 4S (Ra=0.1a)
(LAPPING)
Rmax=0.4S (Ra=0.1a)
Shoe plate 3S (Ra=0.8a)
(LAPPING)
Rmax=0.4S (Ra=0.1a)
Cylinder 3S (Ra=0.8a)
(LAPPING)
Rmax=0.4S (Ra=0.1a)
Valve plate 2S (Ra=0.5a)
(LAPPING)
7-24
4. TRAVEL MOTOR
Problem Cause Remedy
Does not Pressure is not · Pump failure · Check if action other than traveling is
start developed available. If faulty, repair.
· Control valve malfunction · Check if spool moves correctly. Repair if
necessary.
Pressure in · Brake valve failure · Replace brake valve
developed -Sleeve stick
-Check valve stick
· Motor failure · Replace
-Valve seat seizure -Check hydraulic oil for contamination
· Gear broken and fragment locked · Replace reduction gear
· Overloaded · Reduce load
Oil leakage Leakage from · Scratch on engaging surfaces · Correct surfaces by oilstone or sandpa-
engaging sur- per or replace
faces · Loosening by poor bolt tightening · Check after retightening
Leakage from · Plug loosened · Retighten

casing · Crack formed by stone · Replace reduction gear
Leakage from · Sliding surfaces worn · Replace reduction gear
floating seal · Creep on O-ring · Replace floating seal
Leakage from · Bolt loosened · Tighten properly

hydraulic motor · O-ring damaged · Replace O-ring
· Sealing surface scratched · Correct by oilstone or sandpaper
Coasts on slope excessively · Poor volumetric efficiency of hydraulic · Replace hydraulic motor
motor
· Increase of internal leakage of brake · Replace brake valve
valve
· Parking brake not actuated
-Spring breakage · Replace spring
-Wear of friction plate · Replace parking brake
Excessive temperature on · Pitting on bearing · Replace reduction gear

reduction gear case · Lack of gear oil · Supply gear oil properly
· Hydraulic oil introduced to gear case · Check motor and replace oil seal
Meanders Meanders at · Delivery rate is different between · Repair pump

low pressure right and left
· Motor drain rate is different between · Replace motor
right and left
Meanders at · Delivery rate is different between · Repair regulator or pump
high pressure right and left
· Motor drain rate is different between · Replace motor
right and left
Meanders at · Relief pressure dropped at right and · Replace brake valve
high pressure left brake valve
· Main relief pressure dropped at right · Replace main relief valve
or left of control valve
Pump delivery is poor · Regulator operation poor · Repair regulator
· External leakage of pump is exces- · Repair pump
sive
External leakage of motor is · Replace motor
-
excessive
7-25
5. RCV LEVER
Maintenance
Criteria Remark
check item
Leakage The valve is to be replaced when the leakage Conditions :

becomes more than 1000 cc/m at neutral handle Primary pressure : 40 kgf/cm2
position, or more than 2000 cc/m during operation. Oil viscosity : 23 cSt
Spool This is to be replaced when the sliding surface has The leakage at the left condition is
worn more than 10 μm, compared with the non- estimated to be nearly equal to the
sliding surface. above leakage.
Push rod
Ø7
1 mm
This is to be replaced when the top end has worn

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

drop, etc. are generated during operation, and
these cannot be remedied, referring to section 6.
Troubleshooting, replace the related parts.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.
2. When loosening the hexagon socket head cap screw (125), replace the seal washers (121)
without fail.
7-26
6. RCV PEDAL
Maintenance
Criteria Remark
check item
Leakage The valve is to be replaced when the leakage effect Conditions :

to the system. For example, the primary pressure Primary pressure : 40 kgf/cm2
drop. Oil viscosity : 23 cSt
Spool This is to be replaced when the sliding surface has The leakage at the left condition is
worn more than 10μm, compared with the non- estimated to be nearly equal to the
sliding surface. above leakage.
Push rod
Ø7
1 mm
This is to be replaced when the top end has worn

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

drop, etc. are generated during operation, and
these cannot be remedied, referring to section 6.
Troubleshooting, replace the related parts.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.
7-27
7. TURNING JOINT
Part name Maintenance standards Remedy
Sliding surface with Plating worn or peeled due to seizure or contamination. Replace
sealing sections.
Sliding surface ·Worn abnormality or damaged more than 0.1 mm Replace

between body and (0.0039 in) in depth due to seizure contamination.
Body, stem other than
·Damaged more than 0.1 mm (0.0039 in) in depth. Smooth with oilstone.
Stem sealing section.
Sliding surface ·Worn more than 0.5 mm (0.02 in) or abnormality. Replace
with thrust plate.
·Worn less than 0.5 mm (0.02 in). Smooth
·Damage due to seizure or contamination remediable Smooth
within wear limit (0.5 mm) (0.02 in).
Sliding surface ·Worn more than 0.5 mm (0.02 in) or abnormality. Replace
with thrust plate.
Cover ·Worn less than 0.5 mm (0.02 in). Smooth
·Damage due to seizure or contamination remediable Replace
within wear limit (0.5 mm) (0.02 in).
·Extruded excessively from seal groove square ring. Replace
- Extrusion
Square ring
·Slipper ring 1.5 mm (0.059 in) narrower than seal Replace

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

(0.059 in)
7-28
8. CYLINDER
Part name Inspecting section Inspection item Remedy
Piston rod ·Neck of rod pin ·Presence of crack ·Replace

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

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

than coating
7-29
GROUP 3 TRACK AND WORK EQUIPMENT
1. TRACK
1) LOWER ROLLER
2
1
3 4
21037MS01
Unit : mm
No. Check item Criteria Remedy

Standard size Repair limit
1 Outside diameter of flange
Ø195 -
Rebuild or
2 Outside diameter of tread Ø160 Ø148
replace
3 Width of tread 46 52
4 Width of flange 33.8 -
Standard size & tolerance Standard Clearance
Clearance between shaft Shaft Hole clearance limit Replace
5
and bushing bushing
0 Ø70.1 +0.35 0.30
Ø70 -0.03 2.0
+0.30 to 0.38
Side clearance of roller Standard clearance Clearance limit

6 Replace
(both side) 0.2 to 1.0 2.0
7-30
2) UPPER ROLLER
4 3
5
21037MS02
Unit : mm

1 Outside diameter of flange
Ø169 -
Rebuild or
2 Outside diameter of tread Ø144 Ø134 replace
4 Width of flange 17 -
Tolerance Standard Clearance
Standard size clearance limit
5 Clearance between shaft Shaft Hole Replace
and support 0 +0.3 0.1 bushing
Ø55 -0.03 +0.1 to 0.33 1.2
7-31
3) IDLER
8
1
2
7
3 5
4
21037MS03
Unit : mm

1 Outside diameter of protrusion
Ø560 -
2 Outside diameter of tread Ø520 Ø510 Rebuild or
3 Width of protrusion 82 - replace
4 Total width 160 -

Standard size & tolerance Standard Clearance
Clearance between shaft Shaft Hole clearance limit Replace
6
and bushing 0 +0.42 bushing
Ø75 -0.03 Ø75 +0.35 0.35 to 0.43 2.0
Clearance between shaft 0 +0.07
7 and bracket Ø75 -0.03 Ø75 +0.03 0.03 to 0.1 1.2 Replace
Side clearance of idler Standard clearance Clearance limit Replace

8
(both side) 0.4 to 1.2 2.0 bushing
7-32
4) TRACK
2 1
4
3
21037MS04
Unit : mm
Standard size Repair limit Turn or

1 Link pitch replace
190 194.4
2 Outside diameter of bushing Ø59 Ø51
Rebuild or
3 Height of grouser 26 16 replace
4 Height of link 105 97
5 Tightening torque Initial tightening torque : 78±8 kgf·m Retighten
7-33
5) TRACK FRAME AND RECOIL SPRING
2
3
1
21037MS05
Unit : mm
Standard size Tolerance Repair limit
113 +2
1 Vertical width of idler guide Track frame 117
0
- 0.5 Rebuild or
Idler support 110 - 1.0 106
replace
+2
Track frame 272 276
0
2 Horizontal width of idler guide
Idler support 270 - 267

3 Recoil spring Free Installation Installation Free Installation
length length load length load Replace
Ø235×515 431 13716kg - 10973kg
7-34
2. WORK EQUIPMENT
A C D E F
B K J I H G
210A7MS21
Unit : mm
Pin Bushing
Remedy
Measuring point Normal Recomm. Recomm.
Mark Limit Limit &
(Pin and Bushing) value service service
of use of use Remark
limit limit
A Boom Rear 90 89 88.5 90.5 91 Replace

B Boom Cylinder Head 80 79 78.5 80.5 81 〃
C Boom Cylinder Rod 80 79 78.5 80.5 81 〃
D Arm Cylinder Head 80 79 78.5 80.5 81 〃
E Boom Front 90 89 88.5 90.5 91 〃
F Arm Cylinder Rod 80 79 78.5 80.5 81 〃
G Bucket Cylinder Head 80 79 78.5 80.5 81 〃
H Arm Link 70 69 68.5 70.5 71 〃
I Bucket and Arm Link 80 79 78.5 80.5 81 〃
J Bucket Cylinder Rod 80 79 78.5 80.5 81 〃
K Bucket Link 80 79 78.5 80.5 81 〃
7-35
Group 1 Precaution ---------------------------------------------------------------------------------------------------------- 8-1

Group 2 Tightening Torque ---------------------------------------------------------------------------------------------- 8-4
Group 3 Pump Device ------------------------------------------------------------------------------------------------------ 8-7
Group 4 Main Control Valve --------------------------------------------------------------------------------------------- 8-33
Group 5 Swing Device ----------------------------------------------------------------------------------------------------- 8-57
Group 6 Travel Device ------------------------------------------------------------------------------------------------------ 8-87
Group 7 RCV Lever ---------------------------------------------------------------------------------------------------------- 8-119
Group 8 Turning Joint ------------------------------------------------------------------------------------------------------- 8-133
Group 9 Boom, Arm and Bucket Cylinder ---------------------------------------------------------------------- 8-138
Group 10 Undercarriage ---------------------------------------------------------------------------------------------------- 8-161
Group 11 Work Equipment ------------------------------------------------------------------------------------------------ 8-173
GROUP 1 PRECAUTIONS
1. REMOVAL WORK
1) Lower the work equipment completely to the ground.
If the coolant contains antifreeze, dispose of it correctly.
2) After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
3) When draining oil, prepare a container of adequate size to catch the oil.
4) Confirm the match marks showing the installation position, and make match marks in the
necessary places before removal to prevent any mistake when assembling.
5) To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
6) Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
7) Check the number and thickness of the shims, and keep in a safe place.
8) When raising components, be sure to use lifting equipment of ample strength.
9) When using forcing screws to remove any components, tighten the forcing screws alternately.
10) Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
11) When removing hydraulic equipment, first release the remaining pressure inside the hydraulic tank
and the hydraulic piping.
12) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
number D d L
06 6 5 8
08 8 6.5 11
10 10 8.5 12
12 12 10 15
14 14 11.5 18 Taper 1/8
øD ød
16 16 13.5 20
18 18 15 22
20 20 17 25
L
22 22 18.5 28
24 24 20 30
27 27 22.5 34
8-1
2. INSTALL WORK
1) Tighten all bolts and nuts (sleeve nuts) to the specified torque.
2) Install the hoses without twisting or interference.
3) Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
4) Bend the cotter pin or lock plate securely.
5) When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2-3 drops of adhesive.
6) When coating with gasket sealant, clean the surface and remove all oil and grease, check that
there is no dirt or damage, then coat uniformly with gasket sealant.
7) Clean all parts, and correct any damage, dents, burrs, or rust.
8) Coat rotating parts and sliding parts with engine oil.
9) When press fitting parts, coat the surface with antifriction compound (LM-P).
10) After installing snap rings, check that the snap ring is fitted securely in the ring groove (Check that
the snap ring moves in the direction of rotation).
11) When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
12) When using eyebolts, check that there is no deformation or deterioration, and screw them in fully.
13) When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
14) When operating the hydraulic cylinders for the first time after repairing and reassembling the
hydraulic cylinders, pumps, or other hydraulic equipment or piping, always bleed the air from the
hydraulic cylinders as follows:
(1) Start the engine and run at low idling.
(2) Operate the control lever and actuate the hydraulic cylinder 4-5 times, stopping 100mm before the
end of the stroke.
(3) Next, operate the piston rod to the end of its stroke to relieve the circuit. (The air bleed valve is
actuated to bleed the air.)
(4) After completing this operation, raise the engine speed to the normal operating condition.
※ If the hydraulic cylinder has been replaced, carry out this procedure before assembling the rod
to the work equipment.
※ Carry out the same operation on machines that have been in storage for a long time after
completion of repairs.
8-2
3. COMPLETING WORK
1) If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
2) If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
3) If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been
removed for repair, always bleed the air from the system after reassembling the parts.
4) Add the specified amount of grease (molybdenum disulphied grease) to the work equipment
related parts.
8-3
GROUP 2 TIGHTENING TORQUE
1. MAJOR COMPONENTS
Torque
No. Descriptions Bolt size
kgf·m lbf·ft
1 Engine mounting bolt (engine-bracket) M12 × 1.75 11.5 ± 1.0 83.2 ± 7.2
2 Engine mounting bolt (bracket-frame) M16 × 2.0 29.7 ± 3.0 215 ± 21.7
3 Engine Radiator mounting bolt M16 × 2.0 29.7 ± 4.5 215 ± 32.5
4 Coupling mounting socket bolt M18 × 2.5 21 ±1.0 152 ±7.2
5 Fuel tank mounting bolt M20 × 2.5 57.8 ± 5.8 418 ± 42
6 Main pump housing mounting bolt M10 × 1.5 6.5 ± 0.7 47.0 ± 5.1
7 Main pump mounting socket bolt M20 × 2.5 57.9 ± 8.7 419 ± 62.9
Hydraulic
8 Main control valve mounting nut M12 × 1.75 12.3 ± 1.3 89.0 ± 9.4
system
9 Hydraulic oil tank mounting bolt M20 × 2.5 57.8 ± 5.8 418 ± 42
10 Turning joint mounting bolt, nut M12 × 1.75 12.3 ± 1.3 89.0 ± 9.4
11 Swing motor mounting bolt M20 × 2.5 57.9 ± 5.8 419 ± 42
12 Swing bearing upper part mounting bolt M20 × 2.5 57.9 ± 6.0 419 ± 43.3
Power
13 train Swing bearing lower part mounting bolt M20 × 2.5 57.9 ± 6.0 419 ± 43.3
system
14 Travel motor mounting bolt M16 × 2.0 23 ± 4.5 215 ± 32.5
15 Sprocket mounting bolt M16 × 2.0 29.7 ± 3.0 215 ± 21.7
16 Upper roller mounting bolt, nut M16 × 2.0 29.7 ± 3.0 215 ± 21.7
17 Lower roller mounting bolt M20 × 2.5 57.9 ± 6.0 419 ± 43.4
Under
18 Track tension cylinder mounting bolt M16 × 2.0 29.7 ± 4.5 215 ± 32.5
carriage
19 Track shoe mounting bolt, nut M20 × 1.5 57.9 ± 5.8 419 ± 41.9
20 Track guard mounting bolt (full track) M20 × 2.5 57.9 ± 5.8 419 ± 41.9
21 Counterweight mounting bolt M36 × 3.0 337 ± 33 2727 ± 239
22 Cab mounting bolt M12 × 1.75 12.8 ± 1.3 88.9 ± 9.4
Others
23 Operator's seat mounting bolt M10 × 1.75 6.9 ± 0.5 49.9 ± 3.6
24 Under cover mounting bolt M12 × 1.75 12.8 ± 3.0 92.6 ± 21.7
※ For tightening torque of engine and hydraulic components, see engine maintenance guide and
service manual.
8-4
2. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread
8.8T 10.9T 12.9T
Bolt size
kgf·m lbf·ft kgf·m lbf·ft kgf·m lbf·ft
M 6 × 1.0 0.8 ~ 1.2 5.8 ~ 8.6 1.2 ~ 1.8 8.7 ~ 13.0 1.5 ~ 2.1 10.9 ~ 15.1
M 8 × 1.25 2.0 ~ 3.0 14.5 ~ 21.6 2.8 ~ 4.2 20.3 ~ 30.4 3.4 ~ 5.0 24.6 ~ 36.1
M10 × 1.5 4.0 ~ 6.0 29.0 ~ 43.3 5.6 ~ 8.4 40.5 ~ 60.8 6.8 ~ 10.0 49.2 ~ 72.3
M12 × 1.75 6.8 ~ 10.2 50.0 ~ 73.7 9.6 ~ 14.4 69.5 ~ 104 12.3 ~ 16.5 89.0 ~ 119
M14 × 2.0 10.9 ~ 16.3 78.9 ~ 117 16.3 ~ 21.9 118 ~ 158 19.5 ~ 26.3 141 ~ 190
M16 × 2.0 17.9 ~ 24.1 130 ~ 174 25.1 ~ 33.9 182 ~ 245 30.2 ~ 40.8 141 ~ 295
M18 × 2.5 24.8 ~ 33.4 180 ~ 241 34.8 ~ 47.0 252 ~ 340 41.8 ~ 56.4 302 ~ 407
M20 × 2.5 34.9 ~ 47.1 253 ~ 340 49.1 ~ 66.3 355 ~ 479 58.9 ~ 79.5 426 ~ 575
M22 × 2.5 46.8 ~ 63.2 339 ~ 457 65.8 ~ 88.8 476 ~ 642 78.9 ~ 106 570 ~ 766
M24 × 3.0 60.2 ~ 81.4 436 ~ 588 84.6 ~ 114 612 ~ 824 102 ~ 137 738 ~ 991
M30 × 3.5 120 ~161 868 ~ 1164 168 ~ 227 1216 ~ 1641 202 ~ 272 1461 ~ 1967
(2) Fine thread

8.8T 10.9T 12.9T
Bolt size
kgf·m lbf·ft kgf·m lbf·ft kgf·m lbf·ft
M 8 × 1.0 2.1 ~ 3.1 15.2 ~ 22.4 3.0 ~ 4.4 21.7 ~ 31.8 3.6 ~ 5.4 26.1 ~ 39.0
M10 × 1.25 4.2 ~ 6.2 30.4 ~ 44.9 5.9 ~ 8.7 42.7 ~ 62.9 7.0 ~ 10.4 50.1 ~ 75.2
M12 × 1.25 7.3 ~ 10.9 52.8 ~ 78.8 10.3 ~ 15.3 74.5 ~ 110 13.1 ~ 17.7 94.8 ~ 128
M14 × 1.5 12.4 ~ 16.6 89.7 ~ 120 17.4 ~ 23.4 126 ~ 169 20.8 ~ 28.0 151 ~ 202
M16 × 1.5 18.7 ~ 25.3 136 ~ 182 26.3 ~ 35.5 191 ~ 256 31.6 ~ 42.6 229 ~ 308
M18 × 1.5 27.1 ~ 36.5 196 ~ 264 38.0 ~ 51.4 275 ~ 371 45.7 ~ 61.7 331 ~ 446
M20 × 1.5 37.7 ~ 50.9 273 ~ 368 53.1 ~ 71.7 384 ~ 518 63.6 ~ 86.0 460 ~ 622
M22 × 1.5 51.2 ~ 69.2 370 ~ 500 72.0 ~ 97.2 521 ~ 703 86.4 ~ 116 625 ~ 839
M24 × 2.0 64.1 ~ 86.5 464 ~ 625 90.1 ~ 121 652 ~ 875 108 ~ 146 782 ~ 1056
M30 × 2.0 129 ~ 174 933 ~ 1258 181 ~ 245 1310 ~ 1772 217 ~ 294 1570 ~ 2126
8-5
2) PIPE AND HOSE (FLARE TYPE)
Thread size (PF) Width across flat (mm) kgf·m lbf·ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130.2
1" 41 21 151.9
1-1/4" 50 35 253.2
3) PIPE AND HOSE (ORFS TYPE)

Thread size (UNF) Width across flat (mm) kgf·m lbf·ft
9/16-18 19 4 28.9
11/16-16 22 5 36.2
13/16-16 27 9.5 68.7
1-3/16-12 36 18 130.2
1-7/16-12 41 21 151.9
1-11/16-12 50 35 253.2
4) FITTING
Thread size Width across flat (mm) kgf·m lbf·ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130.2
1" 41 21 151.9
1-1/4" 50 35 253.2
8-6
GROUP 3 PUMP DEVICE
1. REMOVAL AND INSTALL

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

Escaping fluid under pressure can
penetrate the skin causing serious injury. 15
(4) Remove the wirings for the pressure

sensors and so on.
A2
(5) Loosen the drain plug under the hydraulic 24

A1
B1
tank and drain the oil from the hydraulic 11
tank.
24
· Hydraulic tank quantity : 155ℓ 10
23
(6) Remove socket bolts (24) and disconnect 1 210A8MP01
pipe (10, 11).

(7) Disconnect pilot line hoses (2, 3, 4, 5).
2
(8) Remove socket bolts (23) and disconnect
pump suction tube (1).
※ When pump suction tube is disconnected,
the oil inside the piping will flow out, so 4
catch it in oil pan.
(9) Sling the pump assembly and remove the A3 Dr
pump mounting bolts (15).

· Weight : 140 kg (310 lb)
· Tightening torque : 57.9 ± 8.7 kgf·m B3
(419 ± 62.9 lbf·ft)

3
※ Pull out the pump assembly from housing. Psv
When removing the pump assembly,

check that all the hoses have been 5
disconnected. 210A8MP02
8-7
2) INSTALL
(1) Carry out installation in the reverse order
to removal.
(2) Remove the suction strainer and clean it.
(3) Replace return filter with new one.
(4) Remove breather and clean it.
(5) After adding oil to the hydraulic tank to the
specified level.
(6) Bleed the air from the hydraulic pump.
① Remove the air vent plug (2EA).
② Tighten plug lightly.
③ Start the engine, run at low idling, and
check oil come out from plug.
④ Tighten plug.
(7) Start the engine, run at low idling (3~5
minutes) to circulate the oil through the
system.
(8) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.
8-8
2. MAIN PUMP (1/2)
1) STRUCTURE
497 953 806 537 789 732 535 532 548 531 214 808 901 954 792 702 534 717 981 983
151
251 152
886 211
127 C
B 04
B
774 C
A A
111
261
113
710
272
406
123 467
725
824 271 212 153 466 156 157 468 313 124 711 116 312 724 885 314 401 141
723 726
※ Section A-A, B-B, view C : see next page. 220F2MP05
04 Gear pump 272 Pump casing (R) 723 O-ring

111 Drive shaft (F) 312 Valve block B 724 Square ring
113 Drive shaft (R) 313 Valve plate (R) 725 O-ring
116 1st gear 314 Valve plate (L) 726 O-ring
123 Roller bearing 401 Hexagon socket bolt 732 O-ring
124 Needle bearing 406 Hexagon socket bolt 774 Oil seal
127 Bearing spacer 466 Plug 789 Back up ring
141 Cylinder block 467 Plug 792 Back up ring
151 Piston 468 Plug 806 Hexagon head nut
152 Shoe 497 Plug 808 Hexagon head nut
153 Set plate 531 Tilting pin 824 Snap ring
156 Spherical bushing 532 Servo piston 885 Pin
157 Cylinder spring 534 Stopper (L) 886 Pin
211 Shoe plate 535 Stopper (S) 901 Eye bolt
212 Swash plate 537 Servo cover 953 Set screw
214 Tilting bushing 548 Feedback pin 954 Set screw
251 Support 702 O-ring 981 Name plate
261 Seal cover (F) 710 O-ring 983 Pin
271 Pump casing (F) 711 O-ring
717 O-ring
8-9
MAIN PUMP (2/2)
537 953 806 419
05
VIEW C
414 326
544 724
545 723
541
SECTION A-A SECTION A-A SECTION B-B
With PTO Without PTO
235A2MP06
05 PTO unit 537 Servo cover 723 O-ring

326 Cover 541 Seat 724 Square ring
414 Hexagon socket bolt 544 Stopper 1 806 Hexagon head nut
419 Hexagon socket bolt 545 Steel ball 953 Set screw
8-10
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the following list.
Tool name & size Part name
Hexagon socket ROH, VP plug Hexagon socket
Name B
head bolt (Parallel thread) head setscrew
6 M 8 PF 1/4 M12, M14
Allen wrench 8 M10 PF 3/8 M16, M18
B 10 M12 PF 1/2 M20
14 M16, M18 PF 3/4 -
17 M20, M22 PF 1 -
Adjustable angle wrench Medium size, 1 set
Screw driver Minus type screw driver, Medium size, 2 pieces
Hammer Plastic hammer, 1 pieces
Pliers For snap ring, TSR-160
Torque wrench Capable of tightening with the specified torques
8-11
(2) Tightening torque
Torque Wrench size
Part name Bolt size
kgf·m lbf·ft in mm
Hexagon socket head bolt M 5 0.7 5.1 0.16 4

(Material : SCM435) M 6 1.2 8.7 0.20 5
M 8 3.0 21.7 0.24 6
M10 5.8 42.0 0.31 8
M12 10.0 72.3 0.39 10
M14 16.3 118 0.47 12
M16 23.5 170 0.55 14
M18 33.7 244 0.55 14
M20 43.8 317 0.67 17
ROH Plug PF 1/4 3.0 21.7 0.24 6
PF 3/8 or under : S45C PF 3/8 7.5 54.2 0.31 8
PF 1/2 or over : SCM435
PF 1/2 10.0 72.3 0.39 10
PF 3/4 15.3 111 0.47 12
8-12
3) DISASSEMBLY
For disassembling the pump, read this
section thoughly and then disassemble it in
the following sequence. The figures in
parentheses after part names show the
item in structure drawing.
(1) Select place suitable to disassembling.
※ Select clean place.
※ Spread rubber sheet, cloth or so on over-
haul workbench top to prevent parts from
being damaged.
(2) Remove dust, rust, etc, from pump surfac-
es with cleaning oil or so on.
(3) Remove drain port plug (468) and let the
oil out from pump casing (271, 272).
※ For tandem type pump, remove plugs of
both front and rear pumps.
(4) Remove hexagon socket head bolts (412)

and remove regulator.
※ Refer to page 8-28 for disassemble regul-
ator.
220F8MP11
8-13
(5) P l a c e t h e p u m p h o r i z o n t a l l y o n
workbench with its regulator-fitting surface
down, and remove PTO unit from valve
block (if equipped).
※ Before bringing regulator-fitting surface
down, spread rubber sheet on workbench
to avoid damaging the surface.
220S8MP13
※ In case the pump is provided without PTO

unit, remove the cover (326) with the
hexagon socket head cap screws.
220S8MP14
(6) Remove flange sockets (435) and the

gear pump (04).
220S8MP15
(7) Loosen hexagon socket head bolts (401)

which tighten pump casing (F, 271) pump
casing (R, 272), and valve block (312).
220S8MP16
8-14
(8) Separate pump casing (F, 271), pump
casing (272), from valve block (312)
※ Remove the 1st gear (116), when pump
casings are separated from valve block.
220S8MP17
(9) Pull out cylinder block (141), piston-shoes

(011), set plate (153), spherical bushng
(156), and cylinder spr ings (157)
simultaneously from pump casing (F, 271)
and (R, 272), straightly over drive shaft
(111, 113)
※ Take care not to damage sliding surface
of cylinder block (141), spherical bushing
(156), piston-shoes (011), swash plate
(212), drive shaft (111, 113), etc. 220S8MP18
(10) Remove hexagon socket head bolts (406)

and seal cover (F, 261).
※ In the case it is difficult to remove, put flat-
blade screwdriver into the notch of seal
cover. Then the cover can be removed
easily.
※ Since oil seal is fitted on seal cover (F,
261), take care not to damage it while
removing cover.
220S8MP19
(11) Remove the drive shafts (111, 113) from

the pump casing (271, 272), lightly with
plastic hammer, remove them from pump
casing (271, 272)
※ In the case it is difficult to remove, tap the
end of the drive shaft lightly with plastic
hammer.
220F8MP20
8-15
(12) Remove the swash plates (212) and shoe
plates (211) from swash plate support
(251), and pull out the swash plates with
turning shown in this picture from casing.
220S8MP21
220S8MP22
220S8MP23
(13) Remove swash plate supports (251) from

pump casing.
※ In the case it is difficult to remove, tap the
opposite side of the swash plate support
(251) with plastic hammer to remove it
from pump casing easily.
220S8MP24
8-16
(14) Remove valve plates (313, 314) from
valve block (312)
※ There may be removed in work (7).
220S8MP25
(15) If necessary, remove the servo covers

(537), stopper (L, 534), stopper (S, 535),
and servo piston sub (530) from pump
casing (271, 272).
※ Do not remove needle bearing (124) as
far as possible, except the case that the
bearing is considered to be out of its life-
time.
※ Do not loosen hexagon nuts of valve
block (312) and servo cover (537). If
loosened, flow setting will be changed.
8-17
4) REASSEMBLY
(1) For reassembling reverse the disassembli-
ng procedures, paying attention to the
following.
① Do not fail to repair the parts damaged
during dissassembling, and repair
replacement part in advance.
② Clean each part fully with cleaning oil
and dry it with compressed air.
③ Apply clean working oil to sliding
s e c t i o n s , b e a r i n g s , e t c . b e fo r e
assembling them.
④ In general rule, replace the sealing parts,
such as O-ring, oil seal, etc.
⑤ For fitting bolts, plug, etc. prepare a
torque wrench or so on, and tighten them
with torque shown at page 8-12.
⑥ For the tandem type pump, take care not
to mix up parts of the front pump with
those of the rear pump
(2) Insert swash plate supports (251) into the

casing (F, 271) and (R, 272) with fitting.
※ If the servo piston, stopper (L), stopper
(S), and servo cover are removed, fit
them to pump casing in advance for
reassembling.
220S8MP24
8-18
(3) Attach shoe plate (211) to swash plate
(212) and insert tilting pin (531) to tilting
bushing (214) of servo piston (532). As
shown in the right figure, attach to swash
plate support (251) correctly, leaning
swash plate and shoe plate.
※ Confirm with fingers of both hands that
swash plate can moved smoothly.
※ Apply grease to sliding sections of swash
plate and swash plate suppor t, to 220S8MP23
assemble the drive shaft easily.
※ Take care not to damage the sliding
surface of the shoe plate.
220S8MP22
220S8MP21
(4) Fit drive shaft (111, 113) where bearing

(123), bearing spacer (127), snap ring
(824) were set to pump casing (271, 272).
220S8MP20
8-19
(5) Assemble seal cover (F, 261) to pump
casing (271) and fix it with hexagon
socket head bolts (406).
※ Apply grease lightly to oil seal in seal
cover (F).
※ Assemble oil seal, taking full care not to
damage it.
220S8MP26
(6) Assemble piston cylinder sub assembly

[cylinder (141), piston sub assembly (151,
152), set plate (153), spherical bushing
(156) and cylinder spring (157)].
※ Fit spline phases of spherical bushing and
cylinder.
※ Then, insert piston cylinder subassembly
into pump casing.
220S8MP18
(7) Fit valve plate (313) to valve block (312)

according to pin (885).
※ Take care not to mistake suction/delivery
directions of valve plate.
220S8MP27
(8) Place pump horizontally on workbench

with its regulator-fitting surface down, and
attach pump casing (271) to valve block
(312).
※ Before bringing regulator-fitting surface
down, spread rubber sheet on workbench
and do not damage this surface.
※ Take care not to mistake direction of valve
block. [clockwise rotation (viewed from
input shaft side)]. Fit the valve block with 220S8MP17
suction flange left when regulator side
below, viewed from front side.
※ Fit 1st gear simultaneously.
8-20
(9) Fit valve block (312) to pump casing (271,
272) with hexagon socket head bolts
(401, 402).
220S8MP16
(10) Fit gear pump (04) to pump casing (271)

with hexagon socket head bolts.
220S8MP15
(11) Attach the PTO unit (05) by fastening the

flange socket to the valve block (312).
※ Be careful about the attaching direction of
the PTO unit.
220S8MP13
In case the pump is not provided with the

PTO unit (05), attach the cover (326) with
the hexagon socket head cap screws
(414).
220S8MP14
8-21
(12) Putting feedback lever of regulator into
feedback pin (548) of tilting pin (531), fit
regulator with hexagon socket head bolts.
※ Take care not to mix up regulator of front
pump with another.
220F8MP28
(13) Fit drain port plug (467).

This is the end of reassembling procedu-
re.
8-22
3. REGULATOR
1) STRUCTURE (1/2)
601 876 874
497
412
726
614 755
466
414
611
SECTION A-A
PH
a A Psv
a4
220F2MP08
412 Hexagon socket screw 601 Casing 755 O-ring

414 Hexagon socket screw 611 Feedback lever 874 Pivot pin
466 Plug 614 Adjust plug 876 Pin
497 Plug 726 O-ring
8-23
STRUCTURE (2/2)
898 643 642 644 646 A 418 079 728 645
728 924
641
801
656
402
755
887
758
708
SECTION A-A
220F2MP09
402 Hexagon socket screw 645 Adjust stem (Q) 758 Square ring
418 Hexagon socket screw 646 Pilot spring 801 Nut
641 Pilot plug 656 Cover 887 Pin
642 Pilot spool 708 O-ring 898 Pilot piston
632 Pilot sleeve 728 O-ring 924 Set serew
644 Spring seat (Q) 755 O-ring
8-24
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the following list.
Tool name & size Part name
Hexagon socket Pressure plug Hexagon socket
Name B
head cap screw (taper thread) head set screw
Allen wrench 4 M5 - M8
Spanner 5 M6 - M10
B 6 M8 ROH 1/4 M12, M14
22 - VP 3/8 -
27 M18 VP 1/2 -
Adjustable angle wrench Medium size, 1 set
Hexagon socket head cap screw M4, Length : 50 mm
8-25
Torque Wrench size
Part name Bolt size
kgf·m lbf·ft in mm
Hexagon socket head bolt M 5 0.7 5.1 0.16 4
(Material : SCM435) M 6 1.2 8.7 0.20 5
M 7 3.0 21.7 0.24 6
M 8 5.8 42 0.31 8
M 9 10.0 72.3 0.39 10
M14 16.3 118 0.47 12
M16 23.5 170 0.55 14
M18 33.7 244 0.55 14
M20 43.8 317 0.67 17
M22 64.2 464 0.67 17
PT Plug (Material : S45C) PT 1/8 1.2 8.7 0.20 5
※Wind a seal tape 1 1/2 to PT 1/4 2.2 15.9 0.24 6
2 turns round the plug PT 3/8 4.5 32.5 0.31 8
PT 1/2 6.6 47.7 0.39 10
ROH Plug PF 1/4 3.5 25.3 0.24 6
PF 3/8 or under : S45C PF 3/8 7.5 54.2 0.31 8
PF 1/2 or over : SCM435 PF 1/2 11.2 81.0 0.39 10
PF 3/4 17.3 125 0.55 14
8-26
3) DISASSEMBLY
(1) Preparation for disassembling
① Since the regulator consists of small,
precision, and well-finished par ts,
disassembling and assembling are rather
complicated. For this reason, replacem-
ent of a regulator assembly is recomme-
nded, unless there is a special reason. If
in case disassembling is necessary for
an unavoidable special reason, read thro-
ugh this manual to the end before starti-
ng disassembling.
② Since the regulators on the front pump
and the rear pump are set at different
pressure and flow values, mark each of
them so as not to mix up one of front
pump with another.
③ For reason that regulator contain two
parts which are tightened with large
torque, prepare a vise to hold the
regulator stable.
④ The numbers in parentheses after part
names represent those in the cross-
sectional drawings (on page 8-23, 24)
(2) Select a place for disassembling.

※ Spread rubber sheet or cloth to cover the
workbench to prevent parts from being
damaged.
(3) Remove dust, rust, etc. from surfaces of

regulator with clean oil.
(4) Remove hexagon socket head cap

screws (412, 414) and remove regulator
from the pump.
※ If the pump is disassembled, check the
page 7-21 for this axial piston pump.
※ Take care not to lose O-ring while removi-
ng regulator.
8-27
screws (418) and remove the proportion
reducing valve.
※ Do not damage to the propor tional
reducing valve's connector.
(6) Loosen the pilot plug (641).

※ Do not remove the pilot plug (641). If it is
removed, the pilot spring (646) and the
spring stem (Q, 644) will fall from casing.
※ Be careful not to damage regulator casing
(601) while loosening the pilot plug (641).
※ Do not damage to the regulator casing
while using a vise.
220F8MP30

screws (402) and remove cover (656)
※ Cover (656) is fixed with adjusting screw
(924), hexagon nut (801). Do not loosen
screw and nut. If they are loosened,
adjusted pressure-flow setting will be
changed.
220F8MP31
(8) Remove the adjusting stem (Q, 645), the

pilot spring (646), and the spring seat (Q,
644) from regulator.
※ Adjusting stem (Q, 645) can easily be
drawn out with M4 screw.
※ Take care not to lose the pilot spring (646)
and the spring stem (Q, 644) which they
fall from casing when the adjusting stem
(Q, 645) is removed.
220F8MP32
8-28
(9) Remove the pilot plug (641) and the pilot
piston (898).
※ Take care not to lose the pilot piston (898)
because of its smallness.
220F8MP33
(10) Remove the pilot spool (642) from pilot

section.
220F8MP34
(11) Remove the adjusting plug (614) and

feedback lever (611) from the casing.
(601) while loosening the adjusting plug
(614).
※ Do not remove the pin (876) from the
feedback lever (611).
220F8MP35
(12) Remove the pilot sleeve (643).

※ This completes operation.
220F8MP36
※ Since component part are small, take care not to them.
8-29
4) REASSEMBLY
(1) For assembling, reverse disassembling
procedures. But pay attention to the
following.
① Repair parts that were damaged at
disassembling.
Prepare replacement parts beforehand.
② Contamination will cause malfunction.
Therefore, wash parts well with cleaning
oil, let them dry with jet air and handle
them in clean place.
③ Tighten screws, plugs, etc. with their
specified torques.
④ Replace seals such as O-ring with new
ones as a general rule.
(2) Select a place for assembling.

※ Spread rubber sheet or cloth to cover the
workbench to prevent parts from being
damaged.
(3) Fit the pilot sleeve (643) into pilot section

of the casing (601).
※ Be careful not to fit the pilot sleeve (643)
with the wrong way.
※ Confirm the the sleeve slides smoothly in
casing without sticking.
Pilot sleeve 643

(hole inserted the pin (876)
220F8MP37
(4) Insert the pin (876) fixed on feedback

lever (611) to the oval shaped hole of the
sleeve (643) and fit the hole of the
feedback lever to the pin (874) fixed inside
the casing (601).
※ If the pilot spool (642) is in the pilot sleeve
(643), the pin (876) can not be inserted to
the pilot sleeve.
220F8MP38
8-30
(5) Tighten the adjusting plug (614) to the
casing (601).
(601) while tightening the adjusting plug
(614).
※ Confirm that the sleeve slides smoothly in
casing without sticking or excess play
among parts.
220F8MP39
(6) Fit the pilot spool (642) into the pilot

sleeve (643).
※ Be careful not to fit the pilot spool (642)
with the wrong way.
220F8MP40
(7) After the pilot piston (898) is fitted into the

Pilot piston (898)
pilot plug (641), put the plug to the casing (spherical surface)
(601).
※ Be careful not to fit the pilot piston (898)
with the wrong way.
※ At the present stage, it is no need to
tighten the pilot plug (641) with recomme-
nded torque.
220F8MP41
220F8MP42
8-31
(8) Put the spring seat (Q, 644) and the pilot
spring (646) into the pilot section of the
casing (601).
※ Be careful not to fall the spring seat (Q).
Recommended to apply grease to the
spring seat to prevent falling.
220F8MP43
(9) Put the adjusting stem (Q, 645), and

tighten the cover (656) with the adjusting
screw (924) and the hexagon nut (801)
with hexagon socket head cap screws
(402).
220F8MP44
(10) Tight the pilot plug (641) to the casing

(601).
(601) while tightening the pilot plug (641).
※ Do not damage to the regulator casing
while using a vise.
220F8MP45
(11) Tighten the proportional reducing valve

with hexagon socket head cap screw
(418).
※ This completes assembling.
8-32
GROUP 4 MAIN CONTROL VALVE
1. REMOVAL AND INSTALL OF MOTOR

1) REMOVAL
pressure in the hydraulic piping.

penetrate the skin causing serious injury.
※ When pipes and hoses are disconnected,
the oil inside the piping will flow out, so
(4) Remove the wirings for the pressure
sensor and so on. Bracket
(5) Remove mounting bolts and disconnect

pipe. Mounting
bolt 210A8MC01
(6) Disconnect pilot line hoses.

(7) Disconnect pilot piping.
(8) Sling the control valve assembly and
remove the control valve mounting bolt
and bracket.
·Weight : 220kg(485lb)
·Tightening torque : 12.3 ± 1.3 kgf·m
(89.0 ± 9.4 lbf·ft)
(9) Remove the control valve assembly.
When removing the control valve 210A8MC02
assembly, check that all the piping have
been disconnected.
2) INSTALL
to removal.
(2) Bleed the air from below items.
① Cylinder (boom, arm, bucket)
② Swing motor
③ Travel motor
※ See each item removal and install.
(3) Confirm the hydraulic oil level and
recheck the hydraulic oil leak or not. 210A8MC03
8-33
2. STRUCTURE (1/4)
154
164
201
DETAIL A DETAIL B
273
336 336
332 A
332 A 101
B
322 320 B CASING A
A
323 321
335 335
158
332 332
512
261 261 522
562
553
511
521
561
551
601
252
602
CASING A
RH REAR
561
153
513
523
514 561
521 552
561 159
551 LH 162
256 152
561
153
251
FRONT 220F8MC04
101 Casing A 261 O-ring 514 Poppet

152 Plug 273 Socket screw 521 Spring
153 Plug 320 Spring 522 Spring
154 Plug 321 Spring 523 Spring
158 Plug 322 Spring 551 Plug
159 Plug 323 Spring 552 Plug
162 O-ring 332 Seat 553 Plug
164 O-ring 335 Stopper 561 O-ring
201 Spring cover 336 Bolt 562 O-ring
251 Logic control valve 511 Poppet 601 Main relief valve
252 Selector lock valve 512 Poppet 602 Port relief valve
256 Logic poppet 513 Poppet
8-34
STRUCTURE (2/4)
159
CASING A
168
151
156
159
541
543
542
166
550
158
308 602
301
303
264
304 264 204

264 164
306 154
204
264
204
264
206
204
273 211
561
258 220F8MC05
151 Plug 206 Spool cover 308 Straight travel spool

154 Plug 211 Piston 541 Steel ball
156 Orifice 258 Plug 542 Spring seat
158 Plug 264 Square ring 543 Spring
159 Plug 273 Socket screw 550 Plug
164 O-ring 301 Travel, LH spool 561 O-ring
166 O-ring 303 Boom 1 spool 602 Port relief valve
168 O-ring 304 Bucket spool
204 Spool cover 306 Arm 2 spool
8-35
STRUCTURE (3/4)
259 DETAIL A DETAIL B
164
336 336
152
162
201 332 332
603
152 202
257
162 322 326
612 203
154 273 323 327
A
164 C
B 335 339
169 C
C 332 332
D 102
CASING B
REAR 261 261
RH DETAIL C DETAIL D
336 333
161
165 332 331
165
163
320 370
210
167 163 165 321 371
155
165 161 LH 335 337
165 163 165
FRONT
250 332 331
274
254 978 261 262
971
977
209 CASING B 153
165 561
E
E
154 G 551
164
561
E F 521 E
152 511
162 E
158
152 G
975 551 F 162
561
220F8MC06
102 Casing B 201 Spring cover 274 Socket screw 337 Stopper
152 Plug 202 Spring cover 320 Spring 339 Stopper
153 Plug 203 Spring cover 321 Spring 370 Spring
154 Plug 209 Flange 322 Spring 371 Spring
155 Plug 210 Plate 323 Spring 511 Poppet
158 Plug 250 Logic control valve 326 Spring 521 Spring
161 O-ring 254 Logic poppet 327 Spring 551 Plug
162 O-ring 257 Arm regen cut sub 331 Seat 561 O-ring
163 O-ring 259 Plug 332 Seat 603 Port relief valve
164 O-ring 261 O-ring 333 Spacer bolt 612 Plug
165 O-ring 262 O-ring 335 Stopper 971 Socket screw
167 O-ring 273 Socket screw 336 Bolt 975 Socket screw
169 O-ring 8-36
STRUCTURE (4/4)
CASING B
DETAIL A
262
603 331
370
602
371
169
337
331
612
301 333
305
307
DETAIL B
264 261
264 332
310
309 311 204
320
302 204
313 264 329

B
339
264
204 202
A 332
164
205 336
203 154
273
220A8MC07
154 Plug 301 Travel, RH spool 332 Seat

164 O-ring 302 Arm 1 spool 333 Spacer bolt
169 O-ring 305 Swing spool 336 Spacer bolt
202 Spring cover 307 Boom 2 spool 337 Stopper
203 Spring cover 309 Option spool 339 Stopper
204 Spool cover 310 Bypass cut spool 370 Spring
205 Spool cover 311 Swing priority spool 371 Spring
261 O-ring 313 Bypass cut spool 602 Port relief valve
262 O-ring 320 Spring 603 Port relief valve
264 O-ring 329 Spring 612 Plug
273 Socket screw 331 Seat
8-37
3. DISASSEMBLY AND ASSEMBLY
1) GENERAL PRECAUTIONS
(1) All hydraulic components are manufactured to a high precision working. Then, before
disassembling and assembling them, it is essential to select an especially clean place.
(2) In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it.
(3) When a control valve is to be removed from the machine, apply caps and masking seals to all
ports. Before disassembling the valve, recheck that these caps and masking seals are fitted
completely, and then clean the outside of the assembly. Use a proper bench for working, spread
a paper or rubber mat on the bench, and disassemble the valve on it.
(4) Support the body section carefully when carrying or transferring and so on of the control valve.
Do not support the lever exposed spool, end cover section or so on without fail.
(5) After disassembling and assembling of the component it is desired to carry out various tests (for
the relief characteristics, leakage, flow resistance, etc.), but hydraulic test equipment is necessary
for these tests. Therefore, even when its disassembling can be carried out technically, do not
disassemble such components that cannot be tested, adjusted, and so on. Besides, always
prepare clean cleaning oil, hydraulic oil, grease, etc. beforehand.
2) TOOLS
Before disassembling the control valve, prepare the following tools beforehand.
Name of tool Quantity Size (mm)

Vice mounted on bench (soft jaws) 1 unit
Box wrench Each 1 piece 24, 32, 36
Hexagon key wrench Each 1 piece 4, 5, 6, 8, 10 and 12
Loctite #262 1 piece -
32 (main relief valve, 601)
Spanner Each 1 piece
36 (port relief valve, 603)
8-38
3) DISASSEMBLY
The figure in ( ) shown after the part name
in the explanation sentence shows its
number in the structure figures (8-34~37).
(1) Place control valve on working bench.
※ Disassemble it in clean place and pay
attention not to damage flange faces and
plate faces.
21098MC37
(2) Disassembling of main spools

· Travel (301), bucket (304), swing (305),
option (309), arm 2 (306), boom 2 (307),
swing priority (311).
① Loosen the hexagon the socket head
screw (273) and remove the spring cover
(201, 202) and the O-ring (261).
·Hexagon key wrench : 6 mm
21098MC38
② Pull out the spool, spring, spring seats

(331 or 332), stopper (335 or 339) and
spacer bolt (336) in the spool assembly
condition from the casing.
※ When pulling out the spool assembly from
casing, pay attention not to damage the
casing.
21078MC11
8-39
③ Hold the spool in the mouthpiece-attached
vise applying a protection plate (aluminum
plate and the like) in between. Remove the
spacer bolt (336) and disassemble the
stopper (335 or 339) and spring seats
(332).
21098MC40
(3) Disassembling of boom 1 spool (303):

① Loosen the hexagon socket head screw
(273), and remove the spring cover (201)
and the O-ring (261).
② Pull out the boom 1 spool (303), spring
(320, 321), spring seats (332), stopper
(335) and spacer bolt (336) in the spool
assembly condition from the casing A
(101).
casing A (101), pay attention not to
damage casing.
21098MC41
③ Hold the boom1 spool (303) in the
mouthpiece-attached vise applying a
protection plate (aluminum plate and the
like) in between. Remove the spacer bolt
(336), and disassemble the spring (320,
321), spring seats (332) and stopper
(335).
④ Do not consecutively disassemble the
boom1 spool (303) above ③.
8-40
(4) Disassembling of arm 1 spool (302):
② Pull out the arm 1 spool (302), spring
(320, 321), spring seats (332), stopper
(335) and spacer bolt (336) in the spool
assembly condition from the casing B
(102).
21098MC42
casing B (102), pay attention not to
damage casing.
③ Hold the ar m 1 spool (302) in the
(336), and disassemble the spring (320,
(335).
④ Do not consecutively disassemble the arm
1 spool (302) above ③.
(5) Disassembling of travel straight spool (308):

② Pull out the travel straight spool (308),
spring (322, 323), spring seat (332),
stopper (335) and spacer bolt (336) in the
spool assembly condition from the casing
A (101).
casing A (101), pay attention not to
damage casing.
21098MC43
8-41
③ Hold the travel straight spool (308) in the
(336) and disassemble the spring (322,
323), spring seats(332) and stopper (335).
④ Do not consecutively disassemble the
travel straight spool (308) above ③.
(6) Disassembling of bypass cut spool (310, 313):

② Pull out the bypass cut spool (310, 313),
spring (370, 371), spring seats (331),
stopper (337) and spacer bolt (333) in the
spool assembly condition from the casing
B (102).
casing B (102), pay attention not to
damage casing. 21098MC44
③ Hold the bypass cut spool (310, 313) in

the mouthpiece-attached vise applying a
(333) and disassemble the spring (370,
(337).
21098MC45
8-42
(7) Disassembling of spool covers (204, 205, 206):
① Remove the hexagon socket head screw
(273), and remove the spool cover (204,
205, 206) and the O-ring (264).
② In removing the bucket spool cover (206),
at first loosen the plug (258) before it is
removed from the casing B (102). After
removing the bucket spring cover (206)
remove the plug (551), and take out the
piston (211).
·Box wrench : 32 mm
21098MC46
(8) Removal of main relief valve (601) and port

relief valves (602, 603) :
① Remove the main relief valve (601) and
the port relief valves (602, 603) from the
casing.
Main relief valve (601) : spanner 32 mm
Port relief valve (602) : spanner or box
wrench 32 mm
Port relief valve (603) : spanner 36 mm
21098MC47
② Do not consecutively disassemble the

relief valves after the above ①.
21098MC48
8-43
21098MC49
(9) Removal of lock valve selector (252):

(252-171) and remove the lock valve
selector (252) and the O-rings (252-161).
② Do not consecutively disassemble the lock
valve selector (252) after the above ①.
21098MC50
8-44
(10) Removal of arm regeneration cut valve (257):
Remove the plug (257-253), spring (257-
231), spool (257-211), and sleeve (257-
212) from the casing B (102).
21098MC52
(11) Disassembly of logic control valve (250, 251)

and logic poppet (254, 256):
(250-120, 251-120) and remove the logic
control valve (250, 251) and the O-rings
(250-112 and 113, 251-112 and 113).
② Pull out the logic poppet (254, 256), spring
(254-106, 256-106) and spring seat (254-
21098MC53
103, 256-103) from the casing.
③ Do not consecutively disassemble the
logic control valve and the logic poppet
above ②.
21098MC54
(12) Disassembly of check valve :

① CP1, C2, CCb, LCb, LCo, LCk, LCa,
LCAT2
Remove the plug (551) and take out the
poppet (511) and the spring (521).
② CMR1, CMR2
·Hexagon key wrench : 10 mm 21098MC55
8-45
③ CRa, CRb
21098MC56
④ CCk, CCo
Remove the plug (551) and take out
⑤ Remove the plug (550) and take out the
ball (541), spring (543) and spring seat
(542).
21098MC57
(13) Disassembly of flanges (209) :

Loosen the hexagon socket head screw
(971) and remove the flange (209) and the
O-ring (165).
(14) Disassembly of plate (210) :

Loosen the hexagon socket head screw
(274) and remove the plate (210) and the
O-rings (165).
(15) Disassembly of orifices for signal line :

Do not disassemble the plug (151) and
orifice (156), except for particular case.
8-46
(16) Disassembly of casing :
① Except for particular case, do not disasse-
mble the tie screw of the casing B (102).
② Regarding the plugs not described in
above disassembling procedures, the
blind plugs for sacrifice holes and for the
casing sanitation, do not disassemble
them as far as not required specially.
21098MC58
8-47
(17) Inspection after disassembling
Clean all the disassembled parts with clean mineral oil fully, and dry them with compressed air.
Then, place them on clean papers or cloths for inspection.
① Control valve
a. Check whole surfaces of all parts for burrs, scratches, notches and other defects.
b. Confirm that the seal groove faces of the housing and the covers are smooth and free of dust,
dent, rust etc.
c. Correct dents and damages on check seat faces of casing, if any, by lapping.
※ Pay attention not to leave lapping agent in the casing.
d. Confirm that all sliding and fitting parts can be moved manually and that all grooves and paths
are free from foreign matter.
e. If any spring is broken or deformed, replace it with new one.
f. When a relief valve does not function properly, repair it, following its inspection procedures.
g. Replace all the O-rings with new ones.
② Relief valve
a. Confirm that all seat faces at ends of all poppets and seats are free of defects and are uniform
contact faces.
b. Confirm manually that main poppet and seat can slide lightly and smoothly.
c. Confirm that outside face of main poppet and inside face of seat are free from scratches and
so on.
d. Confirm that orifices of the main poppet and seat section are not clogged with foreign matter.
e. Replace all O-rings with new ones.
f. When any light damage is found in above inspections, correct it by lapping.
g. When any abnormal part is found, replace it with a relief valve assembly.
8-48
4) ASSEMBLY
① In this assembling section, explanation only is shown. Refer to figures and photographs shown in
disassembling section.
② Figure in ( ) shown after part name in explanation sentence shows number in structure figure.
③ Cautions in assembling O-rings
a. Pay attention to keep O-rings free from defects in its forming and damages in its handling.
b. Apply grease, hydraulic oil or so on to O-rings and seal-fitting sections for full lubrication.
c. Do not stretch O-rings so much to deform them permanently.
d. In fitting O-ring, pay attention not to roll it into its position. In addition, twisted O-ring cannot
remove its twisting naturally with ease after being fitted, and causes oil leakage.
e. Tighten fixing the bolts for all sections with a torque wrench to their respective tightening
torque.
(1) Assembly of check valve :

① Assemble the poppets (511, 512, 513,
514) and the springs (521, 522, 523) : Put
the O-rings (561) onto the plugs (551,
552). Put the O-rings (562) onto the plugs
(553). Tighten the plugs (551, 552, 553)
with their specified torques.
※ Use the poppets, springs and plugs in
following groups.
Poppet Spring Plug Remember that

511 521 551 511 in 8 positions
512 522 553 512 in 2 positions
21098MC57
513 523 552 513 in 2 positions
514 521 551 514 in 2 positions
Plug Hexagon key Tightening torque

No. wrench (mm) (kgf·m)
551 12 23.5 ~ 26.5
552 12 23.5 ~ 26.5
553 10 13.3 ~ 15.3
21098MC56
8-49
② Assemble of ball (541), spring seat (542)
and spring (543) : Put the O-ring (166)
onto the plug (550), and tighten the plug
(550) with specified torque.
·Tightening torque : 2.55 ~ 2.96 kgf·m
(18.4~21.4 lbf·ft)
21098MC55
(2) Assembly of plate (210) :

Fit the O-rings (165) to the casing B (102),
and tighten the hexagon socket head
screw (274) with specified torque.
(72.3~88.2 lbf·ft)
If this plate face looks downward, turn the
control valve.
(3) Assembly of flange (209) :

Fit the O-rings (165) to the flange (209),
and tighten the hexagon socket head
screw (971) with specified torque.
(36.2~47.7 lbf·ft)
(4) Assemble of logic control valve :

① Put the O-ring (250-115, 251-115) onto
the plug (250-111, 251-111).
21098MC53
8-50
② Assemble the spool (250-102, 251-102),
spring seat (250-104, 251-104) and spring
(251-105, 251-105) into the casing (250-
101, 251-101) of the logic control valve,
and tighten the plug (250-111, 251-111)
with specified torque.
(50.6~58.6 lbf·ft)
③ Assemble the logic poppet (254; poppet,
spring, spring seat) into the casing of the 21098MC54
control valve.
④ Fit the O-rings (250-112 and 113, 251-112
and 113) to the casing (250-101, 251-101)
of the logic control valve, and tighten the
hexagon socket head screw (250-120,
251-120) with specified torque.
(36.2~47.7 lbf·ft)
8-51
(5) Assembly of arm regeneration cut valve
(257) :
Assemble the sleeve (257-212), spool
(257-211), and spring (257-231) into the
casing B (102). Put the O-ring (265) onto
the plug (257-253), and tighten with
specified torque.
(50.6~57.9 lbf·ft)
21098MC52
(6) Assembling of lock valve selector (252) :

Fit the O-rings (252-161) to the lock valve
selector (252) and tighten the hexagon
socket head screw (252-171) with specifi-
ed torque.
(7.2~10.1 lbf·ft)
21098MC50
(7) Assembling of main relief valve (601)

and port relief valve (602, 603) :
Assemble the main relief valve (601) and
the port relief valves (602, 603) to the
casing, and tighten them with specified
torque.
Tightening
Item Tool
torque (kgf·m)
Main relief valve (601) Spanner 32 7.0 ~ 8.1
Spanner 32 or
Port relief valve (602) 7.0 ~ 8.1
box wrench 32
Port relief valve (603) Spanner 36 12.2 ~14.3
21098MC49
8-52
21098MC48
21098MC47
(8) Assemble of travel straight spool (308) :

① Hold the middle of the travel straight spool
(308) in the mouthpiece-attached vise
applying a protection plate (aluminum
plate and so on) in between. Attach the
spring seats (332), springs (322, 323) and
stopper (335), and tighten the spacer bolt
(336) with specified torque.
※ Before tightening the spacer bolt (336),
apply loctite #262 to it.
(11.6~13.0 lbf·ft)
※ Pay attention not to fasten the vise
excessively to the shape of the travel 21098MC43
straight spool (308) is deformed.

② Insert the spool assemblies of ① items
above into the casing A (101).
※ Fit spool assemblies into casing A (101)
carefully and slowly.
※ Do not push them forcibly without fail.
8-53
(9) Assembling of boom 1 spool (303) :
① Hold the middle of the boom1 spool (303)
in the mouthpiece-attached vise applying
a protection plate (aluminum plate and so
on) in between. Attach the spring seats
(332), springs (320, 321) and stopper
(335), and tighten the spacer bolt (336)
(11.6~13.0 lbf·ft)
excessively to the shape of the boom 1 21098MC41
spool (303) is deformed.

② Insert the spool assemblies of items ①
above into the casing A (101).
※ Fit spool assemblies into the casing A
(101) carefully and slowly.
(10) Assembling of arm 1 spool (302) :

① Hold the middle of the arm1 spool (302) in
the mouthpiece-attached vise applying a
protection plate (aluminum plate and so
(335) and tighten the spacer bolt (336)
·Hexagon key wrench : 10 mm 21098MC42

(11.6~13.0 lbf·ft)
excessively to the shape of the arm 1
spool (302) is deformed.
above into the casing B (102).
※ Fit spool assemblies into the casing B
8-54
(11) Assembling of main spool (travel (301),
bucket (304), swing (305), option (309),
arm 2 (306), boom 2 (307), swing priority
(311)):
① Hold the middle of each spool in the
(332), springs and stopper (335 or 339)
and tighten the spacer bolt (336) with
specified torque.
21098MC39
(11.6~13.0 lbf·ft)
excessively to the shape of the spool is
deformed.
above into the casing A (101) and casing
B (102).
※ Fit spool assemblies into casing A (101)
and casing B (102) carefully and slowly.
21098MC38
8-55
(12) Assembling of bypass cut spool (310, 313) :
① Hold the middle of each spool in the
(337) and tighten the spacer bolt (333)
(11.6~13.0 lbf·ft)
excessively to the shape of the bypass cut 21098MC44
spool (310, 313) is deformed.
② Insert the spool assemblies of Items ①
above into the casing B (102).
※ Fit spool assemblies into the casing B
(13) Assembling of covers :

① Fit the O-rings (264) to the spool covers
(204, 205, 206) to sides reverse to the
spring sides of spools, and tighten the
hexagon socket head screw (273) with
specified torque.
※ Confirm that O-rings (264) have been
fitted to the spool covers (204, 205, 206).
(18.1~25.3 lbf·ft)
② Bucket spool cover (206 ) : Assemble
piston (355) into bucket spool cover (206).
Put O-ring (561) onto plug (258) and
tighten it with specified torque.
·Box wrench : 32 mm 21098MC46
(111~133 lbf·ft)
③ Fit the O-rings (261, 262) to spring covers
(201, 202, 203) to the spring sides of
spools, and tighten the hexagon socket
head screw (273) with specified torque.
※ Confirm that O-rings (261,262) have been
fitted to spring covers (204, 205, 206).
(18.1~25.3 lbf·ft)
8-56
GROUP 5 SWING DEVICE
1. REMOVAL AND INSTALL OF MOTOR

1) REMOVAL
(3) Loosen the breather slowly to release the
Escaping fluid under pressure can pen-
13031GE18
etrate the skin causing serious injury.
(4) Disconnect hose assembly (2). A
2 B
(5) Disconnect pilot line hoses (3, 4, 5, 6, 7,
8).
1
(6) Sling the swing motor assembly (1) and
remove the swing motor mounting socket
bolts (9).
·Motor device weight : 61 kg (135 lb)
·Tightening torque : 57.9 ± 5.8 kgf·m
220A8SM01
(419 ± 42 lbf·ft)
(7) Remove the swing motor assembly.
※ When removing the swing motor assem-
bly, check that all the piping have been 3
disconnected. 4
2) INSTALL
(1) Carry out installation in the reverse order Dr 8
to removal.
(2) Bleed the air from the swing motor. 9 Mu
① Remove the air vent plug. 5

② Pour in hydraulic oil until it overflows from PG
the port.
③ Tighten plug lightly.
④ Start the engine, run at low idling and
check oil come out from plug. 6
⑤ Tighten plug fully.

(3) Confirm the hydraulic oil level and check 210A8SM02
8-57
2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
1) STRUCTURE
3 2 11 10 1 35 42 19 18 22 17 21 20 29 28 39 27 26 25 38 24 41 30 40 24 38 25 26 27
38QB-11100
4 5 7 8 9 12 13 14 15 16 6 23 28 29 37 36 38 34 32 33 31 33 32 34 38 37
235A2SM02
1 Casing 15 Parking piston 29 O-ring

2 Oil seal 16 Brake spring 30 Relief valve assy
3 Shaft 17 Spring pin 31 Anti-rotation valve assy
4 Snap ring 18 O-ring 32 Plug
5 Roller bearing 19 O-ring 33 O-ring
6 Roller bearing 20 Valve plate 34 O-ring
7 Swash plate 21 Spring pin 35 Port block assy
8 Cylinder block 22 O-ring 36 Level gauge assy
9 Spring 23 Valve casing 37 Socket bolt
10 Ball guide 24 Check valve 38 Socket bolt
11 Retainer plate 25 Spring 39 Plug
12 Piston assy 26 Plug 40 Name plate
13 Friction plate 27 O-ring 41 Rivet
14 Separate plate 28 Plug 42 Hex socket bolt
8-58
2) DISASSEMBLY
(1) Disassemble drive shaft
① Unloosing socket bolt (port block assy,
42) and disassemble port block assy
(35) from casing (1).
2209A8SM51
② Disassemble level gauge assy (36) from

casing (1).
2209A8SM52
③ Hang valve casing (23) on hoist, unloose

socket bolt (37, 38) and disassemble
from casing (1).
2209A8SM53
④ Disassemble brake spring (16) and using

a jig, disassemble parking piston (15)
from casing (1).
2209A8SM54
8-59
⑤ Disassemble respectively cylinder block
sub (8), friction plate (13), separate plate
2209A8SM55
⑥ Disassemble swash plate (7) from casing

(1).
2209A8SM56
⑦ Using a plier jig, disassemble snap ring

2209A8SM57
⑧ Disassemble shaft assy (3), oil seal (2)

and O-ring (18, 22) from casing (1).
2209A8SM58
8-60
(2) Disassemble cylinder block sub
① Disassemble piston assy (12) from cylin-
der block (8).
2209A8SM59
② Disassemble ball guide (10) and spring

(cylinder block, 9) from cylinder block (8).
·Ball guide×1EA
·Spring×9EA
2209A8SM60
(3) Disassemble valve casing sub

① Disassemble spring pin (17, 21), valve
plate (20), O-ring (22) from valve casing
(23).
2209A8SM61
② Using a torque wrench, disassemble

relief valve assy (30) from valve casing
(23).
2209A8SM62
8-61
③ Using a torque wrench, disassemble
plug (32) from valve casing (23) and dis-
assemble O-ring (33, 34) and reaction-
less valve assy (31).
2209A8SM63
④ Using a torque wrench, disassemble

check valve (24) from valve casing (23).
2209A8SM64
⑤ Disassemble plug (28), O-ring (29) from

valve casing (23).
2209A8SM65
8-62
3) ASSEMBLING
(1) Assemble shaft sub
① Put roller bearing (5) on preheater and
provide heat to inner race.
(Temperature in conveyor : 120°C for 3~5
minutes)
2209A8SM66
② Using a robot machine, assemble and

press preheated roller bearing (5) into
shaft (3).
2209A8SM67
(2) Assemble cylinder block sub

① Assemble 9 springs (cylinder block, 9)
into cylinder block (8).
·Spring×9EA
2209A8SM68
② Assemble ball guide (10) into cylinder

block (8).
·Ball guide×1EA
2209A8SM69
8-63
③ Assemble 9 piston assy (12) into retainer
plate (11).
·Piston assy×9EA
·Retainer plate×1EA
2209A8SM70
④ Assemble parts of procedure ② and ③.
2209A8SM71
(3) Assemble valve casing sub

① Assemble make up check valve sub
Assemble check valve (24), O-ring (27),
plug (26) in that order and then screw it
torque wrench.
·Make up check valve×2EA
·Spring×2EA
·Plug×2EA
·O-ring×2EA
2209A8SM72
② Assemble anti-rotating valve assy

Assemble anti-rotating valve assy (31),
plug (32), O-ring (33, 34) in that order
and then screw it a torque wrench.
·Reactionless valve assy (31)×2EA
·Plug (32)×2EA
·O-ring (33, 34)×2EA
2209A8SM73
8-64
③ Using a torque wrench, assemble relief
valve (30) 2 sets into valve casing (23).
·Relief valve (30)×2EA
2209A8SM74
④ Assemble plug (28) and O-ring (27) into

valve casing (23).
·Plug (28)×3EA
·O-ring (27)×3EA
2209A8SM75
⑤ Assemble roller bearing (6) into valve

casing (23) and assemble spring pin (17,
21) into valve casing (23).
·Roller bearing (6)×1EA
·Spring pin (17, 21)×1EA
2209A8SM76
⑥ Apply some grease valve plate (20) and

assemble it into valve casing (23).
2209A8SM77
8-65
(4) Assemble drive shaft sub
① Using a jig, assemble oil sealing (2) into
casing (1).
2209A8SM78
② Fit shaft sub (shaft+roller bearing) into

casing (1).
2209A8SM79
③ Using a plier jig, assemble snap ring (4)

to shaft (3).
·Snap ring×1EA
2209A8SM80
④ Apply some grease swash plate (7) and

assemble it into casing (1).
·Swash plate×1EA
2209A8SM81
8-66
⑤ Insert O-ring (18, 19) into casing (1).
·O-ring (18)×1EA
·O-ring (19)×1EA
2209A8SM82
⑥ Assemble cylinder block (8) into casing

(1).
2209A8SM83
⑦ Assemble separate plate (14) and friction

plate (13) 4 sets into casing (1) and fit
parking piston (15) into casing (1) by a jig
or a press.
·Separate plate×4EA
·Friction plate×4EA
·Parking piston×1EA
2209A8SM84
⑧ Assemble spring (parking piston, 16) into

parking piston (15).
·Spring×26EA
2209A8SM85
8-67
⑨ Lift up valve casing (23) on casing (1) by
a crane and assemble it with socket bolts
(37, 38).
2209A8SM86
⑩ Assemble level gauge assy (36) and

plug (39) into casing (1).
2209A8SM87
⑪ Assemble port block assy (35) into valve

casing (23) with socket bolt (42).
·Port block assy×1EA
·Socket bolt×3EA
2209A8SM88
⑫ Air pressing test

Be sure of leakage, after press air into
assembled motor and put it in water for 1
minute (pressure : 2 kgf/cm2).
2209A8SM89
8-68
⑬ Leakage check
Place motor on a bench tester and after
cleaning motor by color check No.1,
paint No.3 and be sure of leakage.
2209A8SM90
⑭ Mount test bench

Mounting motor a test bench, test the
availability of each part.
2209A8SM91
8-69
3. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR
1) STRUCTURE
2 27 26 28 3 33 8 7 15 12 11 30 14 13 22 23 21 18 19 20
4 5 6 25 29 1 10 16 17 25 24 9
220L2SM03
1 Ring gear 11 Planetary gear 2 21 Thrust washer 1

2 Drive shaft 12 Needle bearing 2 22 Carrier pin 1
3 Taper roller bearing 13 Thrust washer 2 23 Spring pin 1
4 Taper roller bearing 14 Carrier pin 2 24 Sun gear 1
5 Ring nut 15 Spring pin 2 25 Thrust plate
6 Lock plate 16 Sun gear 2 26 Sleeve
7 Hexagon bolt 17 Carrier 1 27 O-ring
8 Casing 18 Planetary gear 1 29 Parallel pin
9 Socket bolt 19 Needle bearing 1 30 Socket bolt
10 Carrier 2 20 Thrust washer 1 33 Plug
8-70
2) DISASSEMBLY
(1) Preparation
① The reduction gear removed from machine
is usually covered with mud.
Wash out side of reduction gear and dry it.
② Setting reduction gear on work stand for dis-
assembling.
③ Mark for mating
Put marks on each mating parts when dis-
assembling so as to reassemble correctly as
before.
Take great care not to pinch your hand
2209A8SM01
between parts while disassembling not let
fall parts on your foot while lifting them.
(2) Disassembly
① Remove every “Socket bolt (M10)” that
secure swing motor and reduction gear.
② Removing carrier sub assy & sun gear
a. Removing No.1 sun gear from No.1 carrier
sub assy.
※ Be sure maintaining it vertical with ground
when disassembling No.1 sun gear.
2209A8SM02
b. Removing No.1 carrier sub assy screwing

I-bolt to tab hole (M10) in No.1 carrier.
Lifting it gradually maintaining it vertical
with ground.
※ It’s impossible to disassemble No.1 spring
pin. If No.1 spring pin has problem, change
whole No.1 carrier sub assy.
2209A8SM03
8-71
c. Removing No.2 sun gear from No.2 carrier
sub assy.
※ Be sure maintaining it vertical with ground
when disassembling No.2 sun gear.
2209A8SM04
d. Removing No.2 carrier sub assy screwing

I-bolt to tab hole (M10) in No.2 carrier.
Lifting it gradually maintaining it vertical with
ground.
※ It’s impossible to disassemble No.2 spring
pin. If No.2 spring pin has problem, change
whole No.2 carrier sub assy.
2209A8SM05
③ Removing ring gear

After unscrewing every socket bolt (M16),
remove ring gear from casing.
※ Because of liquid gaskets between ring gear
and casing, put sharp punch between ring
gear and casing and tapping it to remove
them.
2209A8SM06
8-72
④ Removing drive shaft sub assy
a. Unscrew every hex head bolt (M12) to
remove lock plate.
2209A8SM07
b. Rolling ring nut for removing them from

drive shaft sub assy.
2209A8SM08
※ Use special tool to roll ring nut to counter

clockwise. Ø40
A
36
35
VIEW A
68
2-Ø9.7 Ø113
P.C.D Ø135
Ø161
220L8SM01
8-73
c. Remove drive shaft sub assy from casing.
※ Set a rack for flange of casing, and remove
drive shaft sub assy from casing by using
press.
2209A8SM09
d. Remove oil seal & taper bearing (small)

from casing.
※ Do not re-use oil seal. It is impossible to dis-
assemble drive shaft sub assy.
2209A8SM10
2209A8SM11
8-74
4. ASSEMBLY REDUCTION UNIT
1) GENERAL NOTES
(1) Clean every part by kerosene and dry them in a cool and dry place.
(2) Loctite on surface must be removed by solvent.
(3) Check every part for any abnormal.
(4) Each hexagon socket head bolt should be used with loctite #242 applied on its threads.
(5) Apply gear oil slightly on each part before assembling.
Take great care not to pinch your hand between parts or tools while assembling nor let fall parts
on your foot while lifting them.
Inspection before assembling.
Thrust washer
·Check the seizure, abnormal wear or uneven wear.
·Check the unallowable wear.
Gear
·Check the pitting or seizure on tooth surface.
·Check the cracks on the root of tooth.
Bearing
·Rotate it by hands to check such noise or uneven rotation.
2) ASSEMBLING NO.1 CARRIER SUB ASSY
(1) Put thrust plate firmly in No.1 carrier.

2209A8SM12
(2) After assembling No.1 needle bearing to
No.1 planetary gear, put a pair of No.1 thrust
washer on both sides of bearing and install
them to No.1 carrier.
2209A8SM13
8-75
(3) Make of spring pin hole No.1 pin and No.1
carrier of spring pin hole in line, press No.1
spring pin into the holes.
Make No.1 spring pin hole head for No.1
planetary gear.
2209A8SM14
(4) Caulk carrier holes to make No.1 spring pin

settle down stably.
2209A8SM15
※ Refer to “Caulking details”

CAULKING
Use paint marker for marking after caulking.
SLOT DIRECTION TURNS CALK TWO PLACES
TO COVER SIDE 180 DEGREES APART
COVER A PIN BY CALKING 0.5 mm
1~2 mm INSERT A PIN
220SA8TM147
8-76
2) ASSEMBLING NO.2 CARRIER SUB ASSY
(1) Put thrust plate in firmly No.2 carrier.
2209A8SM17
(2) After assembling No.2 needle bearing to

No.2 planetary gear, put 2 pieces of No.2
thrust washer on both sides of bearing and
install them to No.2 carrier.
2209A8SM18
(3) Align No.2 spring pin hole and No.2 carrier

spring pin hole, put No.2 spring pin into the
holes.
Make No.2 spring pin cutting line face to No.2
planetary gear.
2209A8SM19
(4) Caulk carrier holes to make No.2 spring pin

CAULKING
settle down stably.
※ Refer to “Caulking details” CALK TWO PLACES
SLOT DIRECTION TURNS
TO COVER SIDE 180 DEGREES APART
Use paint marker for marking after caulking.
COVER A PIN BY CALKING 0.5 mm
1~2 mm INSERT A PIN
220SA8TM147
8-77
3) ASSEMBLING PINION GEAR SUB ASSY
(1) Prepare drive shaft pinion gear vertical with

ground.
2209A8SM21
(2) Fully apply grease (albania EP02) to O-ring

groove of sleeve.
※ Be sure to maintain it vertical with ground
when assembling it.
(3) Put O-ring into O-ring groove of sleeve.
Fully apply grease on O-ring.
2209A8SM22
(4) Assemble taper bearing and sleeve into drive

shaft using press jig.
Use special jig for pressing. Leave no space
between sleeve and taper bearing.
2209A8SM23
8-78
2209A8SM24
4) ASSEMBLING BEARING CUP & OIL SEAL (PRESSING)
(1) Put top, bottom bearing cup into casing.

Use special jig for pressing. Pay attention to
foreign materials while assembling bearing
cup.
※ Flip over casing to assemble oil seal.
2209A8SM25
2209A8SM26
8-79
(2) Assemble oil seal to casing.
Use special jig for pressing. Pay attention to
direction of dust seal and dent.
2209A8SM27
※WHILE ASSEMBLING OIL SEAL

1. Be sure to set dust seal to gear oil.
2. Before assembling, charge enough grease in
oil seal.
3. Before assembling, apply enough grease
inside and outside of oil seal.
2209A8SM28
5) ASSEMBLING SHAFT SUB ASSY & RING NUT
(1) After assembling casing & drive shaft sub

assy, flip it over.
2209A8SM29
8-80
(2) Put drive shaft sub assy into casing.
※ Be sure to maintain it vertical with ground
when assembling it.
2209A8SM30
(3) Put taper bearing into it.

Rotate bearing by hands for checking after
assembly.
2209A8SM31
(4) Put ring nut into drive shaft sub assy by using
special jig.
The tightening torque (M95) = 3.5±0.4 kgf·m
(25.3±2.9 lbf·ft)
2209A8SM32
※ Apply enough loctite #242 before screwing

bolts.
2209A8SM33
8-81
(5) Align bolt screw of ring nut with lock plate’s
hole.
In case of misalign between bolt screw ring
nut and lock plate’s hole, put lock plate as
near as possible to hole of bolt screw of ring
nut and make it in line by increasing tighten-
ing torque.
2209A8SM34
2209A8SM35
(6) Screw 4 bolts (M12×16) to connect ring nut

and lock plate by using torque wrench.
Bolt (M12, 4EA) = 10.9T
The tightening torque = 8.8±0.9 kgf·m
(63.7±6.5 lbf·ft)
bolts.
2209A8SM36
(7) Use paint marker for checking surplus parts

after assembling.
2209A8SM37
8-82
6) ASSEMBLING RING GEAR
(1) Apply loctite #515 bottom of casing sub assy

contacting with ring gear without disconnec-
tion.
2209A8SM38
Refer to loctite detail. LOCTITE #515
235ZF8SM39
(2) Put parallel pin into hole of casing sub assy.

Mark parallel pin position using paint marker.
2209A8SM40
(3) Align ring gear with parallel pin to put them

into casing sub assy.
※ Be sure to maintain them vertical with ground
while using press.
2209A8SM41
8-83
(4) Screw 12 bolts (M16×45) to connect casing
sub assy and ring gear (01) by using torque
wrench.
Bolt (M16, 12EA) = 12.9T
The tightening torque = 27±2.7 kgf·m
(195±19.5 lbf·ft)
bolts.
2209A8SM42
(5) Use paint marker for checking surplus parts

after assembling.
2209A8SM43
2209A8SM44
8-84
7) ASSEMBLING CARRIER SUB ASSY & SUN GEAR
(1) Put No.2 carrier sub assy along spline of

drive shaft spline.
- Screw M10 I-bolt to No.2 carrier sub assy.
- Lifting up No.2 carrier sub assy and align
planetary gear and tooth of ring gear by
rotating planetary gear by hands.
- Rotate No.2 carrier sub assy by hands to fit
No.2 carrier sub assy into drive shaft spline.
2209A8SM45
(2) Put No.2 sun gear into No.2 carrier sub assy.
2209A8SM46
8-85
(3) Put No.1 carrier sub assy into No.2 sun gear
along spline.
- Screw M10 I-bolt to No.1 carrier sub assy.
- Lifting up No.1 carrier sub assy and align
planetary gear and tooth of ring gear by
rotating planetary gear by hands.
- Rotate No.1 carrier sub assy by hands to fit
No.1 carrier into No.2 sun gear spline.
2209A8SM47
(4) Put No.1 sun gear into No.1 carrier sub assy.
Be sure to maintain it vertical with ground.
And align with No.1 planetary gear spline.
(5) Rotate No.1 carrier sub assy by hands to
check noise.
2209A8SM48
8) MEASURING CLEARANCE & ASSEMBLING NAME PLATE
(1) Check the clearance between ring gear and

No.1 sun gear using a tool with dial gauge.
Check the clearance
Dial gauge = -0.3 ~ +2.95
2209A8SM49
8-86
GROUP 6 TRAVEL DEVICE

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

penetrate the skin causing serious 1
injury.
※ When pipes and hoses are disconnected, 2

(4) Remove the track shoe assembly.
For details, see removal of track shoe
assembly. 25098TM30
(5) Remove the cover.

(6) Remove the hoses.
※ Fit blind plugs to the disconnected hoses.
(7) Remove the bolts and the sprocket.
(8) Sling travel device assembly (1).
(9) Remove the mounting bolts (2), then
remove the travel device assembly.
·Weight : 305 kg (670 lb)
·Tightening torque : 23 ± 4.5 kgf·m
(166 ± 32.5 lbf·ft)
2) INSTALL
to removal.
(2) Bleed the air from the travel motor.
① Remove the air vent plug.
② Pour in hydraulic oil until it overflows from
the port.
③ Tighten plug lightly.
④ Start the engine, run at low idling, and
check oil come out from plug.
⑤ Tighten plug fully.
(3) Confirm the hydraulic oil level and check
8-87
2. TRAVEL MOTOR
1) STRUCTURE
2 21 22 20 23 24 1 59 31 61,62 32 29 2 36 37 55 42 41 52 35 54 53 47 50 54 58
49
34 53
33 51
7 56 48
6 57
15 59 55
11 58
39
60 40
46
3 64
4 63
12 14 9 16 17 19 27 26 25 30 8 18 28 10 13 44 46 43 38 45 54
2209A2TM21
1 Casing 22 Piston assy 44 Plug

2 Plug 23 Friction plate 45 O-ring
3 Oil seal 24 Separated plate 46 O-ring
4 Thrust plate 25 Parking piston 47 Spool
5 Snap ring 26 D-ring 48 Plug
6 Piston 27 D-ring 49 Spring seat
7 Piston seal 28 Valve plate 50 Parallel pin
8 Shaft 29 Parallel pin 51 Spring
9 Cylinder roller bearing 30 Spring 52 Connector
10 Needle bearing 31 O-ring 53 O-ring
11 Snap ring 32 Spring pin 54 Hexagon socket head bolt
12 Snap ring 33 Parallel pin 55 Hexagon socket head bolt
13 Snap ring (type 1) 34 Rear cover 56 Check valve
13 Retainer C ring (type 2) 35 Main spool assy 57 Spring
14 Thrust plate 36 Cover 58 Plug
15 Steel ball 37 Spring 59 O-ring
16 Pivot 38 Restrictor 60 Plug
17 Swash plate 39 Hexagon socket head bolt 61 Restrictor
18 Cylinder block 40 O-ring 62 Restrictor
19 Spring 41 Spring seat 63 Name plate
20 Ball guide 42 Relief valve assy 64 Rivet
21 Retainer plate 43 Spring
8-88
(1) Tools
Tool name Remark
Hexagon wrench Width across flat 5, 6, 8, 10, 14 mm
Snap ring prier For shaft Ø60~80 mm
Snap ring prier For bore Ø32~58 mm
Plastic hammer 1 piece
Screw dirver Minus (-), medium size, 2 pieces
Torque wrench 10 kgf·m (72.3 lbf·ft), 33 kgf·m (238.6 lbf·ft), 45 kgf·m (325.4 lbf·ft)
100
Gig for inserting oil seal
58
25098TM31
230
12
M
8 8
Gig for inserting parking piston
30
(M10×100 bolt 2EA, M12×100 bolt 1EA)
187
25098TM32
30
20 24.5 24.5
23
24.5
2
13
Gig for pulling out brake piston

150
195
263
13
24.5
24.5 24.5
25098TM33
8-89
Torque
Item Name Size
kgf·m lbf·ft
2 Plug NPTF 1/16 1.1±0.1 7.9±0.72
39 Hexagon socket head bolt M12 1.0±1.0 72.3±7.2
42 Relief valve 1 5/16 34±3.4 246±24.6
44 Plug PF 1/4 2.8±0.3 20.3±2.17
48 Plug PF 3/8 5.5±0.5 39.8±3.6
52 Connector PF 3/8 5.5±0.5 39.8±3.6
54 Hexagon socket head bolt M18 38±3.8 275±27.5
55 Hexagon socket head bolt M18 38±3.8 275±27.5
58 Plug PF 1/8 1.5±0.1 10.8±0.72
60 Plug PF 1/4 3±0.3 21.7±2.17
8-90
3. DISASSEMBLING
1) GENERAL INSTRUCTIONS
Combustibles such as white kerosene are used for washing parts.
These combustibles are easily ignited, and could result in fire or injury.
Be very careful when using.
Internal parts are coated with hydraulic fluid during disassembling and are slippery.
If a part slips out of your hand and fails, it could result in bodily injury or could damage the
park.
Be very careful when handling.
(1) Generally, hydraulic equipment is precisely manufactured and clearances between each parts
are very narrow. Therefore, disassembling and assembling works should be performed on the
clean place where dusts hardly gather. Tools and kerosene to wash parts should also be clean
and handled with great care.
(2) When motor is removed from the host machine, wash around the ports sufficiently and put the
plugs so that no dust and/or water may invade. Take off these plugs just before the piping works
when re-attach it to the host machine.
(3) Bofore disassembling, review the sectional drawing and prepare the required parts, depending
on the purpose and the range of disassembling.
Seals, O-rings, etc., if once disassembled, are not reusable.
There are some parts that should be replaced as a subassembly.
Consult with the parts manual in advance.
(4) The piston can be inserted to whichever cylinder block for the initial assembling.
However, their combination should not be changed if they are once used. To reuse them, put the
matching mark on both pistons and cylinder block before disassembling.
Take great care not to pinch your hand between parts while disassembling nor let fall parts
8-91
2) DISASSEMBLING TRAVEL MOTOR
(1) Disassemble the wrench bolt (39) to tighten

the spool cover (36) and rear cover (34) by
using the L-wrench or impact wrench and
then disassemble the spring (37), spring seat
(41) and main
spool assy (35)
in order.
25098TM034 25098TM035
(2) Disassemble the wrench bolt (54, 55) to

tighten the casing (1) and rear cover (34) by
using the L-wrench or impact wrench.
25098TM036
(3) Separate the casing (1) and rear cover (34).
25098TM037
(4) Disassemble the brake spring (30, 18EA)

from the piston.
25098TM118
8-92
(5) Disassemble the parking piston (25) by using
the jig for disassembling parking piston.
DISASSEMBLING JIG
25098TM039 25098TM040
(6) Disassemble the separated plate (24, 5EA)

and friction plate (23, 4EA) from the casing.
25098TM041 25098TM042
25098TM043 25098TM044
(7) Turn the casing (1) horizontal by using the

assemble truck and disassemble the cylinder
block kit form the casing (1).
25098TM045
8-93
(8) Disassemble the cylinder block (18), retainer plate (21), piston assy (22), ball guide (20) and
spring (19) from the cylinder block kit.
25098TM046 25098TM047 25098TM048
25098TM049 25098TM050
(9) Disassemble the swash plate (17) from the

casing.
25098TM051 25098TM052
(10) Disassemble the steel ball (15) and swash

piston (6) from the casing.
25098TM053 25098TM054 25098TM055
8-94
(11) Disassemble the pivot (16, 2EA) from the
casing.
25098TM056
(12) Disassemble the snap ring (11) from the

shaft (8) with the pryer for retaining ring.
25098TM057
(13) Disassemble the shaft (8) from the casing

(1).
25098TM058 25098TM059
(14) Disassemble the snap ring (5) from the

casing (1) with the pryer for retaining ring.
25098TM060
8-95
(15) Disassemble the thrust plate (4) from the
casing (1).
25098TM061
(16) Disassemble the oil seal (3) from the casing

(1) with suitable tool.
25098TM062 25098TM063
(17) Disassemble the O-ring (31) from the

casing (1).
25098TM064
(18) Disassemble the valve plate (28) from the

casing (1).
25098TM065
8-96
(19) Disassemble the relief valve (42, 2EA) from the rear cover (34) by using the torque wrench.
25098TM066 25098TM067 25098TM068
(20) Disassemble both side of the plug (48) and connector (52) from the rear cover (34) by using the
torque wrench and then disassemble the spring (51), spring seat (49), parallel pin (50) and spool
(47) in order.
25098TM069 25098TM070 25098TM071
(21) Disassemble the plug (60) from the rear

cover.
25098TM072
(22) Disassemble the plug (58) and then

disassemble the spring (57) and check valve
(56) from the rear cover in order.
25098TM073 25098TM074
8-97
4. REASSEMBLING
1) ASSEMBLING MOTOR
- REAR COVER ASSY
(1) Assemble the check valve (56) and the

spring (57) to the rear cover and then tighten
the plug (60) by using the L-wrench.
25098TM075 25098TM076
(2) Apply the loctite #242 on the NPTF 1/16 plug

(2, 12EA) and tighten it.
25098TM077 25098TM078
(3) Assemble the spool (47), parallel pin (50), spring seat (49) and spring (51) into the rear cover (34)
and tighten both side of the plug (48) and connector (52) into the rear cover (34).
25098TM079 25098TM080 25098TM081
(4) Assemble the relief valve (42, 2EA) into rear cover (34).
25098TM082 25098TM083 25098TM084
8-98
(5) Tight fit the needle bearing (10) into rear
cover (34) by using pressing jig.
25098TM085
(6) Assemble the spring pin (32) and parallel pin

(29) into rear cover (34) by using round bar
or small hammer.
25098TM086
(7) Assemble the valve plate (28) into rear cover

(34).
Before assembling, apply some grease on
contact surface of the valve plate.
25098TM087
(8) Apply some grease on the O-ring and fit it

into groove.
25098TM088
8-99
(9) Assemble the casing (1) on the assembling Assembling truck
truck.
25098TM089
(10) Tight fit the oil seal (3) into the casing (1) by
using jig.
※ Be careful direction of the oil seal.
25098TM090 25098TM091
(11) Assemble the thrust plate (4) into the

casing (1).
25098TM092
(12) Assemble the snap ring (5) into the casing

(1) with the plier for retaining ring.
25098TM093
8-100
(13) Heat the roller bearing (9) and fit it into the
shaft with shrink fitting.
a. Shrink fitting can be used induction heating
system and set the temperature at 100°C.
b. Be careful not to damage the sliding
surface of the oil seal of the shaft.
25098TM096
25098TM094 25098TM095
(14) Assemble the heat-fitted shaft (8) into casing

(1).
25098TM097
(15) Assemble the snap ring (11) into the

casing (1) with the plier for retaining ring.
25098TM098
(16) Apply a little grease on the pivot (16, 2EA)

and assemble it into the casing (1).
25098TM099
8-101
(17) Heat the piston seal (7) and fit it into the
swash piston (6) and then tighten it a few
minutes by band or tie. Loosen the band or
tie and assemble it to the casing (1).
25098TM100 25098TM101
(18) Apply a little grease on the steel ball (15) and

assemble it into the swash plate (17).
25098TM102 25098TM103
(19) Apply some grease on the steel ball hole of

the swash plate (17) and assemble it casing
(1).
25098TM104 25098TM105
8-102
(20) Assemble the spring (19), ball guide (20), retainer plate (21) and piston assy (22) into cylinder
block (18) in order.
25098TM106 25098TM107 25098TM108
25098TM109 25098TM110
(21) Tilt the casing (1) sideways and assemble

the cylinder block kit into the casing (1).
25098TM111
(22) Assemble the separated plate (24) and

friction plate (23) into the cylinder block
alternately.
Friction plate :
4EA
Separated plate :
5EA
25098TM112 25098TM113
8-103
25098TM114 25098TM115
(23) Apply some grease on the D-ring and

assemble it parking piston.
25098TM116
(24) Insert the parking piston into the casing and

assemble it by using jig.
25098TM117
(25) Assemble the brake spring (30, 18EA) into

the piston.
25098TM118
8-104
(26) Place the rear cover (34) on the casing (1).
25098TM119
(27) Tighten the casing (1) and rear cover (34)

specified torque with wrench bolt (54, 55) by
using the impact wrench and torque wrench.
25098TM120
(28) Confirm the insert direction of the main spool

assy (35) exactly and assemble it into the
rear cover (34).
※ Assure that four
balance hole is
d i r e c t e d VA
port.
25098TM121 25098TM122
(29) Assemble the spring seat (41), spring (37)

and main spool cover (36) into valve plate
and tighten the wrench bolt (39, M12x35) by
using L-wrench or impact wrench.
25098TM123 25098TM124 25098TM125
8-105
2) TRAVEL REDUCTION GEAR
8,33 23 22 19 20 21 15 16 11 12 13 14 4 27
25 28,32,34 26 18 1 24 17 10 29 9 5 6 2 7 3
220S2TM22
1 Ring gear 13 Thrust washer 2 25 Thrust plate

2 Ball bearing 14 Carrier pin 2 26 Cover
3 Floating seal assy 15 Spring pin 2 27 Hexagon socket head bolt
4 Ring nut 16 Solid pin 2 28 Plug
5 Lock plate 17 Sun gear 2 29 Snap ring
6 Hexagon bolt 18 Carrier 1 30 Name plate
7 Housing 19 Planetary gear 1 31 Rivet
8 Hexagon socket head bolt 20 Needle bearing 1 32 O-ring
9 Coupling 21 Thrust washer 1 33 Rubber cap
10 Carrier 2 22 Carrier pin 1 34 Rubber cap
11 Planetary gear 2 23 Spring pin 1
12 Needle bearing 2 24 Sun gear 1
8-106
6. DISASSEMBLING
1) GENERAL INSTRUCTIONS
Combustibles such as white kerosene are used for washing parts.
These combustibles are easily ignited, and could result in fire or injury.
Be very careful when using.
Internal parts are coated with gear oil during disassembling and are slippery.
If a part slips off from your hand and fails, it could result in bodily injury or could damage the
park.
Be very careful when handling.
(1) Therefore, disassembling and assembling works should be performed on the clean place where
dusts hardly gather.
Tools and kerosene to wash parts should also be clean and handled with great care.
(2) Bofore disassembling, review the sectional drawing and prepare the required parts, depending
on the purpose and the range of disassembling.
Seals, O-rings, etc., if once disassembled, are not reusable.
There are some parts that should be replaced as a subassembly.
Consult with the parts manual in advance.
Take great care not to pinch your hand between parts while disassembling nor let fall parts
8-107
2) DISASSEMBLING TRAVEL REDUCTION GEAR
(1) Preparation for disassembling

① The reduction units removed from excavator
are usually covered with mud. Wash outside
of propelling unit and dry it.
② Locate reducer in order for drain port to be
at the lowest level, loosen taper screw plug
of drain port, and drain oil from reduction
gear.
※ While oil is still hot, inside of the unit may be
pressurized.
Take care of the hot oil gushing out of the 25098TM126
unit when loosening the plug.

③ Mark for mating
Put marks on each mating parts when
disassembling so as to reassemble correctly
as before.
(2) Setting reduction unit (or whole propelling

unit) on work stand for disassembling
① Remove 7/16-14UNC hexagon socket head
bolts at 3 places from cover almost equally
apart each other, and then install 7/16-
14UNC eye bolts.
Take great care not to pinch your hand
between parts while disassembling nor let
fall parts on your foot while lifting them.
25098TM127
(3) Removing cover

① Remove the rest of 7/16-14UNC hexagon
socket head bolts that secure cover and ring
gear. Loosen all the socket bolts and then,
disassemble cover.
② As the cover is adhered to ring gear,
disassemble ring gear and cover by lightly
hammering slantwise upward using sharpen
punch inserted between the cover and ring
gear. 25098TM128
8-108
(4) Removing No.1 carrier sub assembly
① Screw three M10 eye-bolt in No.1 carrier
and lift up and remove No.1 carrier assy.
25098TM129
② Remove No.1 sun gear.

※ Be sure to maintain it vertical with the
ground when disassembling No.1 sun gear.
25098TM130
(5) Removing No.2 carrier sub assembly

① Screw three M10 eye-bolt in No.2 carrier
and lift up and remove No.2 carrier assy.
25098TM131
② Remove No.2 sun gear.

※ Be sure to maintain it vertical with the
ground when disassembling No.1 sun gear.
25098TM132
8-109
(6) Removing coupling
① Remove coupling.
25098TM133
(7) Removing ring nut & lock plate

① Remove M12 hexagon head bolts that
secure ring nut and lock plate.
② Remove lock plate.
25098TM134
③ Remove ring nut from motor casing. Ø40

A
※ Remove the ring nut by using the special 36
35
tool for removing the ring nut. VIEW A

68
2-Ø9.7 Ø217
P.C.D Ø239
Ø265
220L8TM01
(8) Removing housing sub assembly & ring

gear
① Screw 7/16-14UNC eye bolt in housing and
lift up ring gear and housing assembly
including anguler bearing and floating seal.
25098TM135
8-110
② Setting reduction unit on work stand for
disassembling. Remove M16 hexagon
socket head bolts that secure ring gear and
housing assembly.
25098TM136
③ As the ring gear is adhered to housing assy,

disassemble housing assy and ring gear by
lightly hammering slantwise upward using
sharpen punch inserted between the
housing assy and ring gear.
25098TM137
(9) Removing floating seal

① Lift up a piece of floating seal of motor side.
25098TM138
(10) Removing housing sub assembly

① Setting housing assembly on work stand for
disassembling.
② After setting housing, lift up a piece of
floating seal from housing and then remove
it.
※ Don't disassemble angular bearing.
25098TM139
8-111
(11) Disassembling No.1 carrier
① Remove thrust plate.
25098TM140
② Knock spring pin fully into No.1 pin.
25098TM141
③ Remove planetary, thrust washer, No.1 pin,

bearing from carrier.
25098TM142
(12) Disassembling No.2 carrier

① Knock spring pin fully into No.2 pin.
② Remove No.2 solid pin.
③ Remove planetary, thrust washer, No.2 pin,
bearing from carrier.
25098TM143
8-112
7. ASSEMBLY REDUTION UNIT
1) GENERAL NOTES
(1) Clean every part by kerosene and dry them by air blow.
(2) Surfaces to be applied by loctite must be decreased by solvent.
(3) Check every part for any abnormal.
(4) Each hexagon socket head bolt should be used with loctite No.242 applied on its threads.
(5) Apply gear oil slightly on each part before assembling.
Take great care not to pinch your hand between parts or tools while assembling nor let fall parts
Inspection before reassembling.
Thrust washer
·Check if there are seizure, abnormal wear or uneven wear.
·Check if wear is over the allowable limit.
Gear
·Check if there are pitting or seizure on the tooth surface.
·Check if there are cracks on the root of tooth by die check.
Bearing
·Rotate by hand to see if there are something unusual such as noise or uneven rotation.
Floating seal
·Check flaw or score on sliding surfaces or O-ring.
2) ASSEMBLING CARRIER 1 ASSY
(1) Put No.1 carrier on a flat place.

(2) Install No.1 needle bearing into No.1
planetary gear, put 2EA of No.1 thrust
washer on both sides of planetary gear, and
then, install it into carrier.
25098TM144
(3) Install No.1 pin into No.1 carrier where the

holes for No.1 pin are to be in line with those
of No.1 carrier, and then, install spring pins
into the holes.
25098TM145
8-113
(4) Caulk carrier holes as shown on the picture.
25098TM146
3) ASSEMBLING CARRIER 2 ASSY

CAULKING
(1) Put No.2 carrier on a flat place.
SLOT DIRECTION TURNS CALK TWO PLACES
(2) Install No.2 needle bearing into No.2 TO COVER SIDE 180 DEGREES APART
planetary gear, put 2EA of No.2 thrust COVER A PIN BY CALKING 0.5 mm
washer on both sides of planetary gear, and
then, install it into carrier.
1~2 mm INSERT A PIN
220SA8TM147
(3) After install solid pin into the holes, install

No.2 pin into No.1 carrier where the holes for
No.1 pin are to be in line with those of No.1
carrier, and then, install spring pins into the
holes.
(4) Caulk carrier holes as shown on the picture.
25098TM148
4) ASSEMBLING FLOATING SEAL

(1) Assemble floating seal into motor by use of
pressing jig.
Grease the contact parts for floating seal
which is assembled into motor.
※ Be sure to maintain it vertical with the ground
when assembling bearing and floating seal.
25098TM149
8-114
5) ASSEMBLING HOUSING
(1) Heat housing at 60~70˚C while clearing it out
and then, assemble floating seal into housing
by use of pressing jig.
(2) Setting housing assembly on work stand for
assembling.
Assemble angular bearing into housing by
use of pressing jig.
25098TM150
(3) Assemble floating seal into housing by use of

pressing jig.
Do not reuse the disassembling O-ring.
Grease the contact parts for floating seal
which is assembled into housing.
when assembling bearing and floating seal.
25098TM151
6) ASSEMBLING HOUSING ASSY AND RING

GEAR
(1) Setting r ing gear on wor k stand for
assembling.
Apply loctite #515 on ring gear for housing
without gap.
25098TM152
LOCTITE #515
235ZF8SM39
8-115
(2) Install M16 eye-bolt on the tap of housing.
(3) Lift housing and then, assemble into housing
in order for bolt hole of ring gear and bolt
hole of housing to be in line.
(4) Apply loctite #242 on M16 hexagon socket
head bolt, and then, bolt.
25098TM154
7) ASSEMBLING HOUSING ASSY AND

MOTOR
(1) Install 7/16-14UNC eye-bolt on the tap of ring
gear.
(2) Assemble housing assembly into motor by
use of hoist and eye-bolt.
※ Be sure to tighten eye-bolt deep enough.
25098TM155
8) ASSEMBLING MAIN BEARING

(1) Assemble angular bearing into housing by
use of pressing jig.
when assembling bearing.
25098TM156
9) ASSEMBLING NUT RING AND LOCK

PLATE
(1) Tighten nut ring to specified torque, utilizing
special tool.
·Tightening torque : 60.3 kgf·m
(436 lbf·ft)
(2) After install lock plate, apply loctite #242 on
M12 hexagon head bolt, and then, bolt.
Tighten M12 hexagon head bolt to specified
25098TM157
torque, with torque wrench.
8-116
10) ASSEMBLING COUPLING
(1) Install coupling on spline of the motor.
25098TM158
11) A S S E M B L I N G N O. 2 C A R R I E R S U B
ASSEMBLY
(1) Install M10 eye-bolt on No.2 carr ier
assembly.
(2) Lift No.2 carrier assembly and then, slowly
put it down on ring gear.
(3) Rotate planetary gear by hands and install
on ring gear.
(4) Rotate No.2 carrier assembly by hands and
install on motor. 25098TM159
※ Match pin hole of No.2 carrier with main (A,

B) port of motor.
12) ASSEMBLING NO.2 SUN GEAR

(1) Install No.2 sun gear on the No.2 planetary
gear, matching teeth of them.
25098TM160
13) A S S E M B L I N G N O. 1 C A R R I E R S U B
ASSEMBLY
(1) Install M10 eye-bolt on No.1 carr ier
assembly.
(2) Lift No.1 carrier assembly and then, slowly
put it down on ring gear.
(3) Rotate planetary gear by hands and install
on ring gear.
(4) Rotate No.1 carrier assembly by hands and
install on No.2 sun gear. 25098TM161
8-117
14) ASSEMBLING NO.1 SUN GEAR
(1) Put down No.1 sun gear on No.1 carrier,
maintaining it vertical with spline of coupling.
(2) Install No.1 sun gear on No.1 planetary gear,
matching their teeth.
25098TM162
15) ASSEMBLING THRUST PLATE

(1) Assembly thrust plate into No.1 carrier.
※ Edge of thrust plate direction turns to cover
side.
25098TM163
16) ASSEMBLING COVER LOCTITE #515

(1) Apply loctite #515 on the ring gear for cover
without gap.
235ZF8SM39
(2) Put cover on ring gear, apply loctite #242 on

7/16-14UNC hexagon socket head bolt, and
then, bolt.
Tighten 7/16-14UNC hexagon socket head
bolt to specified torque, with torque wrench.
(3) Fill gear oil (6 liter) into drain port.
(4) Apply gear oil on PF3/4 hydraulic plug and
then, bolt.
25098TM165
8-118
GROUP 7 RCV LEVER

1) REMOVAL

(4) Loosen the socket bolt (1).
1
Tightening torque : 1.05 ± 0.2 kgf·m
(7.6 ± 1.45 lbf·ft)
(5) Remove the cover of the console box. 2
(6) Disconnect pilot line hoses (3).

(7) Remove the pilot valve assembly (2). 3
※ When removing the pilot valve assembly,
check that all the hoses have been
disconnected.
2) INSTALL
to removal.
(2) Confirm the hydraulic oil level and check 220S8RL01
8-119
1) STRUCTURE
1 Case
2 Bushing
3 Spool
4 Shim
5 Spring
6 Spring seat
7 Spring
8 Plug
9 Push rod
10 O-ring
11 Rod seal
20 12 Plate
13 Spacer
14 Boot
15 Joint assembly
21
16 Swash plate
22 17 Adjusting nut
17 18 Bushing
13 19 Plug
15
20 Handle assembly
21 Handle bar
23 22 Nut
16
23 Boot
9 24 Last guard filter
14 11 25 Connector
12 26 Connector
8
27 Connector
18
28 Connector
10
27~34 27 Connector
6 29 Connector
7 30 Connector
5
31 Small guide
4
32 Connector
2 3
33 Big guide
19
34 Connector
1
24
25
26
210S2RL06
8-120
(1) Tools
Tool name Remark
Allen wrench 6 B
22
Spanne
27
(+) Driver Length 150
(-) Driver Width 4~5

Torque
Part name Item Size
kgf·m lbf·ft
Joint 15 M14 3.8 27.5
Swash plate 16 M14 7.0±0.40 50.6±2.9
Adjusting nut 17 M14 7.0±0.40 50.6±2.9
Lock nut 22 M14 5.0±0.35 36.2±2.5
8-121
3) DISASSEMBLY
※ Procedures are based on the type M1.
(1) Clean pilot valve with kerosene.
※ Put blind plugs into all ports
(2) Fix pilot valve in a vise with copper (or
lead) sheets.
(3) Remove end of boot (23) from case (1)
and take it out upwards. 300E8RL01
※ For valve with switch, remove cord also

through hole of casing.
300E8RL02
(4) Loosen lock nut (22) and adjusting nut

(17) with spanners on them respectively,
and take out handle section as one body.
300E8RL03
(5) Remove the boot (14).
1408DA61
8-122
(6) Loosen adjusting nut (17) and swash
plate (16) with spanners on them
respectively, and remove them.
36078RL01
36078RL02
(7) Turn joint anticlockwise to loosen it,

utilizing jig (Special tool).
※ When return spring (7) is strong in force,
plate (12), plug (8) and push rod (9) will
come up on loosening joint.
Pay attention to this.
36078RL03
36078RL04
8-123
(8) Remove plate (12).
36078RL05
(9) When return spring (7) is weak in force,

plug (8) stays in casing because of
sliding resistance of O-ring.
※ Take it out with minus screwdriver.
Take it out, utilizing external periphery
groove of plug and paying attention not to
damage it by partial loading.
※ During taking out, plug may jump up due
to return spring (7) force.
36078RL06
Pay attention to this.
(10) Remove reducing valve subassembly

and return spring (7) out of casing.
※ Record relative position of reducing valve
subassembly and return springs.
36078RL07
(11) Separate spool (3), spring seat (6), spring

(5) and shim (4) individually.
※ Pay attention not to damage spool
surface.
※ Record original position of spring seat (6).
※ Until being assembled, they should be
handled as one subassembly group.
36078RL10
8-124
(12) Take push rod (9) out of plug (8).
36078RL11
(13) Remove O-ring (10) and seal (11) from

plug (8).
Use small minus screwdriver or so on to
remove this seal.
36078RL12
36078RL13
8-125
(14) Remove lock nut (22) and then boot (23).
36078RL14
2507ARL10
8-126
(15) Cleaning of parts
① Put all parts in rough cleaning vessel
filled with kerosene and clean them
(rough cleaning).
※ If dirty part is cleaned with kerosene just
after putting it in vessel, it may be
damaged. Leave it in kerosene for a
while to loosen dust and dirty oil.
※ If this kerosene is polluted, parts will be
damaged and functions of reassembled
valve will be degraded.
Therefore, control cleanliness of
kerosene fully.
② Put parts in final cleaning vessel filled
with kerosene, turning it slowly to clean
them even to their insides (finish
cleaning).
※ Do not dry parts with compressed air,
since they will be damaged and/or rusted
by dust and moisture in air.
(16) Rust prevention of parts
Apply rust-preventives to all parts.
※ If left as they after being cleaned, they will
be rusted and will not display their
functions fully after being reassembled.
8-127
4) ASSEMBLY
(1) Put shim (4), springs (5) and spring seat
(6) onto spool (3) in this order.
36078RL16
(2) Assemble spring (7) into casing (1).

Assemble reducing valve subassembly
into casing.
※ Assemble them to their original positions.
36078RL18
(3) Assemble O-ring (10) onto plug (8).
36078RL19
(4) Assemble seal (11) to plug (8).

※ Assemble seal in such lip direction as
shown below.
36078RL20
8-128
(5) Assemble push rod (9) to plug (8).
※ Apply working oil on push-rod surface.
36078RL21
(6) Assemble plug subassembly to casing.

※ When return spring is weak in force,
subassembly stops due to resistance of
O-ring.
36078RL22
(7) When return spring is strong in force,

assemble 4 sets at the same time,
utilizing plate (12), and tighten joint (15)
temporarily.
36078RL23
(8) Fit plate (12).
(9) Tighten joint (15) with the specified torque

to casing, utilizing jig.
36078RL24
8-129
(10) Assemble swash plate (16) to joint (15).
※ Screw it to position that it contacts with 4
push rods evenly.
※ Do not screw it over.
36078RL25
(11) Assemble adjusting nut (17), apply

spanner to width across flat of plate (16)
to fix it, and tighten adjusting nut to the
specified torque.
※ During tightening, do not change position
of disk.
36078RL26
(12) Fit boot (14) to plate.
1408DA61
8-130
(13) Fit boot (23) and lock nut (22), and handle
subassembly is assembled completely.
2507ARL10
36078RL27
(14) Pull out cord and tube through adjusting

nut hole provided in direction 60。to
120。from casing hole.
1408DA66
(15) Assemble bushing (18) to plate and pass

cord and tube through it.
※ Provide margin necessary to operation.
300E8RL04
8-131
(16) Determine handle direction, tighten lock
nut (22) to specified torque to fix handle.
300E8RL05
(17) Apply grease to rotating section of joint

and contacting faces of disk and push
rod.
300E8RL06
(18) Assemble lower end of bellows to casing.

(19) Inject volatile rust-preventives through all
ports and then put blind plugs in ports.
300E8RL07
8-132
GROUP 8 TURNING JOINT

1) REMOVAL

(4) Disconnect all hoses. B
D A
(5) Sling the turning joint assembly (1) and
remove the mounting bolt (2). C
1
·Tightening torque : 12.3± 1.3 kgf·m
(90.0± 9.4 lbf·ft)
(6) Remove the turning joint assembly. 220A8TJ01
※ When removing the turning joint, check

that all the hoses have been disconnected.
2) INSTALL
to removal.
※ Take care of turning joint direction.
※ Assemble hoses to their original positions. Pk 1
※ Confirm the hydraulic oil level and check
220A8TJ02
8-133
1) STRUCTURE
14 3
15 6
10
12 4
11 5
11
9
8
21098TJ01
1 Hub 6 Shim 11 Wear ring

2 Shaft 7 Slipper seal 12 Retainer ring
3 Cover 8 O-ring 13 Plug
4 Spacer 9 O-ring 14 Hexagon bolt
5 Shim 10 O-ring 15 Spring washer
8-134
2) DISASSEMBLY 14
※ Before the disassembly, clean the turning 15
joint.
3
(1) Remove bolts (14), washer (15) and cover
(3).
21078DA10
(2) Remove shim (6) and O-ring (10). 6

10
(3) Remove retainer ring (12), spacer (4) and
12
shim (5).
4
5
21078DA11
(4) Place hub (1) on a V-block and by using a Secure with hand
wood buffer at the shaft end, hit out shaft Wooden block
(2) to about 1/2 from the body with a
hammer.
※ Take care not to damage the shaft (2)
when remove hub (1) or rest it sideway.
V block
※ Put a fitting mark on hub (1) and shaft (2).
Work bench
8-14(3) (360-7)
(5) Remove six slipper seals (7) and O-ring 11

(9), two wear ring (11) from hub (1).
7
11
9
21078DA12
8-135
3) ASSEMBLY
※ Clean all parts.
※ As a general rule, replace oil seals and
O-ring.
※ Coat the sliding surfaces of all parts with
engine oil or grease before installing.
(1) Fix seven slipper seal (7) and O-ring (9), 11

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

plastic hammer to install. 2
21078DA13
(4) Fit shim (5), spacer (4) and retainer ring 6

(12) to shaft (2). 10
12
(5) Fit O-ring (10) to hub (1).
4
(6) Fit shim (6) to shaft (2).
5
21078DA11
8-136
(7) Install cover (3) to body (1) and tighten
14
bolts (14).
15
·Torque : 10~12.5 kgf·m
(72.3~90.4 lbf·ft) 3
21078DA10
8-137
GROUP 9 BOOM, ARM AND BUCKET CYLINDER

1) BUCKET CYLINDER
(1) Removal
※ Expand the arm and bucket fully, lower
the work equipment to the ground and
stop the engine.
※ Operate the control levers and pedals
13031GE18
※ Loosen the breather slowly to release the
penetrate the skin causing serious
injury.
※ Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust
from entering.
① Set block between bucket cylinder and
arm.
300A8DA01
② Remove bolt (2), nut (3) and pull out pin

(1).
※ Tie the rod with wire to prevent it from
coming out.
·Tightening torque (2) : 57.9± 8.7 kgf·m
(419± 62.9 lbf·ft)
300A8DA02
③ Disconnect bucket cylinder hoses (4),

grease line hose (7) and put plugs (5) on
cylinder pipe.
300A8DA03
8-138
④ Sling bucket cylinder assembly (8) and
remove bolt (6) then pull out pin (5).
⑤ Remove bucket cylinder assembly (8).
(215± 32.5 lbf·ft)
300A8DA04
(2) Install
① Carry out installation in the reverse order
to removal.
When aligning the mounting position of
the pin, do not insert your fingers in the
pin hole.
※ Bleed the air from the bucket cylinder.
8-139
2) ARM CYLINDER
(1) Removal
stop the engine.
※ Loosen the breather slowly to release the 13031GE18

injury. Arm cylinder
disconnecting them, to prevent dirt or
dust from entering. Block
① Set block between arm cylinder and
boom.
300A8CY01
② Disconnect grease line hose (9).

③ Remove bolt (2) and pull out pin (1).
coming out.
(215± 32.5 lbf·ft)
300A8CY02
④ Disconnect arm cylinder hoses (4) and

put plugs on cylinder pipe.
⑤ Disconnect greasing pipings (5).
300A8CY03
8-140
⑥ Sling arm cylinder assembly(8) and
remove bolt (7) then pull out pin (6).
(215± 32.5 lbf·ft)
⑦ Remove arm cylinder assembly (8).
300A8CY04
(2) Install
to removal.
When aligning the mounting position
of the pin, do not insert your fingers in
the pin hole.
※ Bleed the air from the arm cylinder.
8-141
3) BOOM CYLINDER
(1) Removal
stop the engine.
※ Loosen the breather slowly to release the 13031GE18

injury.
disconnecting them, to prevent dirt or dust
from entering.
① Disconnect greasing hoses (1).
② Sling boom cylinder assembly.
300A8CY05
③ Remove bolt (4), stopper (5) and pull out

pin (2).
coming out.
(215± 32.5 lbf·ft)
300A8CY06
④ Lower the boom cylinder assembly (6)

on a stand.
220A8CY07
8-142
⑤ Disconnect boom cylinder hoses (7) and
put plugs on cylinder pipe.
7
220A8CY08
⑥ Remove bolt (9) and pull out pin (8).

(215± 32.5 lbf·ft)
⑦ Remove boom cylinder assembly (6).
6
8
9
220A8CY09
(2) Install
to removal.
When aligning the mounting position
of the pin, do not insert your fingers in
the pin hole.
※ Bleed the air from the boom cylinder.
※ Conformed the hydraulic oil level and
check the hydraulic oil leak or not.
8-143
1) STRUCTURE
(1) Bucket cylinder
① Standard (CHANGZHOU)
9,10 6,7 8 4,5 23 31 30 22 11,12 3 1 2 13 14 17 16 15 18,19 20 21
Internal detail
24,26 28 27 29 25,26
31Q6-60111CGG
1 Tube assembly 12 Back up ring 23 Hexagon socket head bolt

2 Rod assembly 13 Cushion ring 24 Dimple bushing
3 Gland 14 Piston 25 Dimple bushing
4 DD2 bushing 15 Piston seal 26 Dust seal
5 Snap ring 16 Wear ring 27 Band assembly
6 Rod seal 17 Dust ring 28 Pipe assembly-R
7 Back up ring 18 O-ring 29 Pipe assembly-B
8 Buffer ring 19 Back up ring 30 O-ring
9 Dust wiper 20 Lock nut 31 Hexagon socket head bolt
10 Snap ring 21 Hexagon socket set screw
11 O-ring 22 O-ring
8-144
Standard (SHPAC)
4,5 6,7 8 9,10 23 27 26 13 11,12 3 1 2 14 15 18 17 16 19,20 21 22
Internal detail
29,30 25 28 24 29,30
31Q6-60111EGG
1 Tube assembly 11 O-ring 21 Lock nut

2 Rod assembly 12 Back up ring 22 Hexagon socket set screw
3 Gland 13 O-ring 23 Hexagon socket head bolt
4 Dust wiper 14 Cushion ring 24 Pipe assembly-B
5 Retaining ring 15 Piston 25 Pipe assembly-R
6 Rod seal 16 Piston seal 26 O-ring
7 Back up ring 17 Wear ring 27 Hexagon socket head bolt
8 Buffer ring 18 Dust ring 28 Band assembly
9 Dry bearing 19 O-ring 29 Dimple bushing
10 Retaining ring 20 Back up ring 30 Dust seal
8-145
(2) Arm cylinder
① Standard (CHANGZHOU)
9,10 6,7 8 4,5 23 34 33 22 11,12 3 1 2 13 14 17 16 15 18,19 20 21
Internal detail
24,25 30 32 31 24,25
26,27,28,29
31Q6-50132CGG
1 Tube assembly 13 Cushion ring 25 Dust seal

2 Rod assembly 14 Piston 26 Check valve
3 Gland 15 Piston seal 27 Coil spring
4 DD2 bushing 16 Wear ring 28 O-ring
5 Snap ring 17 Dust ring 29 Plug
6 Rod seal 18 O-ring 30 Band assembly-R
7 Back up ring 19 Back up ring 31 Band assembly-B
8 Buffer ring 20 Lock nut 32 Pipe assembly-R
9 Dust wiper 21 Hexagon socket set screw 33 O-ring
10 Snap ring 22 O-ring 34 Hexagon socket head bolt
11 O-ring 23 Hexagon socket head bolt
12 Back up ring 24 Dimple bushing
8-146
Standard (SHPAC)
4,5 6,7 8 9,10 28 31 30 13 11,12 3 1 2 14 15 18 17 16 19,20 21 22
23,24
Internal detail
33 29 32 37,38
37,38 Part no. 34,35,36 34,35,36 25,26,27

31Q6-50132EGG
1 Tube assembly 14 Cushion ring 27 Plug

2 Rod assembly 15 Piston 28 Hexagon socket head bolt
3 Gland 16 Piston seal 29 Pipe assembly-R
4 Dust wiper 17 Wear ring 30 O-ring
5 Retaining ring 18 Dust ring 31 Hexagon socket head bolt
6 Rod seal 19 O-ring 32 Band assembly-B
7 Back up ring 20 Back up ring 33 Band assembly-R
8 Buffer ring 21 Lock nut 34 U-bolt
9 Dry bearing 22 Hexagon socket set screw 35 Hexagon nut
10 Retaining ring 23 Cushion plunger 36 Spring washer
11 O-ring 24 Stop ring 37 Pin bushing
12 Back up ring 25 Check valve 38 Dust seal
13 O-ring 26 Coil spring
8-147
② 2-piece boom (SHPAC)
4,5 6,7 8 9,10 28 31 33 13 11,12 3 1 2 14 15 18 17 16 19,20 21 22
23,24
Internal detail
37,38,39 36,38,39
30
25,26,27
Part no.
41,42 35 34 29,31,32 41,42
31K6-53211E
1 Tube assembly 15 Piston 39 Pipe assembly-B

2 Rod assembly 16 Piston seal 30 Pipe assembly-R
3 Gland 17 Wear ring 31 O-ring
4 Dust wiper 18 Dust ring 32 Hexagon socket head bolt
5 Retaining ring 19 O-ring 33 Hexagon socket head bolt
6 Rod seal 20 Back up ring 34 Band assembly-B
7 Back up ring 21 Lock nut 35 Band assembly-R
8 Buffer ring 22 Hexagon socket set screw 36 U-bolt
9 Dry bearing 23 Cushion plunger 38 Hexagon nut
10 Retaining ring 24 Stop ring 39 Spring washer
11 O-ring 25 Check valve 40 O-ring
12 Back up ring 26 Coil spring 41 Dimple bushing
13 O-ring 27 Plug 42 Dust seal
14 Cushion ring 28 Hexagon socket head bolt
8-148
(3) Boom cylinder (CHANGZHOU)
9,10 6,7 8 4,5 23 31 30 22 11,12 3 1 2 13 14 17 16 15 18,19 20 21
Internal detail
24,26 28 27 29 25,26
31Q6-50110CGG
1 Tube assembly 12 Back up ring 23 Hexagon socket head bolt

2 Rod assembly 13 Cushion ring 24 Dimple bushing
3 Gland 14 Piston 25 Dimple bushing
4 DD2 bushing 15 Piston seal 26 Dust seal
5 Snap ring 16 Wear ring 27 Band assembly
6 Rod seal 17 Dust ring 28 Pipe assembly-R
7 Back up ring 18 O-ring 29 Pipe assembly-B
8 Buffer ring 19 Back up ring 30 O-ring
9 Dust wiper 20 Lock nut 31 Hexagon socket head bolt
10 Snap ring 21 Hexagon socket set screw
11 O-ring 22 O-ring
8-149
Boom cylinder (SHPAC)
4,5 6,7 8 9,10 23 27 26 22 11,12 3 1 2 14 15 18 17 16 19,20 21 22
Internal detail
Part no.
33,34 25 28 24 32,24
31Q6-50110EGG
1 Tube assembly 13 O-ring 25 Pipe assembly-R

2 Rod assembly 14 Cushion ring 26 O-ring
3 Gland 15 Piston 27 Hexagon socket head bolt
4 Dust wiper 16 Piston seal 28 Band assembly
5 Retaining ring 17 Wear ring 29 U-bolt
6 Rod seal 18 Dust ring 30 Hexagon nut
7 Back up ring 19 O-ring 31 Spring washer
8 Buffer ring 20 Back up ring 32 Dimple bushing
9 Dry bearing 21 Lock nut 33 Dimple bushing
10 Retaining ring 22 Hexagon socket set screw 34 Dust seal
11 O-ring 23 Hexagon socket head bolt
12 Back up ring 24 Pipe assembly-B
8-150
(4) Adjustment cylinder (SHPAC)
4,5 3 6,7 8 11,12 9,10 2 1 13 16 14 15 17,18,19
Internal detail
23,24,25 27,28
27,28 20 21,25 Part no. 22,24,25 26
31K6-54151E
1 Tube assembly 11 O-ring 21 Safety valve

2 Rod assembly 12 Back up ring 22 Pipe assembly-B
3 Gland 13 Piston 23 Pipe assembly-R
4 Dust wiper 14 Piston seal 24 O-ring
5 Retaining ring 15 Wear ring 25 Hexagon socket head bolt
6 Rod seal 16 O-ring 26 Band assembly
7 Back up ring 17 Lock nut 27 Pin bushing
8 Buffer ring 18 Lock washer 28 Dust seal
9 Dry bearing 19 Hexagon socket set screw
10 Retaining ring 20 Hexagon socket head bolt
8-151
(1) Tools
Tools Remark
6
8 B
Allen wrench
10
12
14
17
7
Spanner
8
(-) Driver Small and large sizes

Torque
Part name Item Size
kgf·m lbf·ft
23★1★3 M16 23.0±2.0 166±14.5
23★1★4 M16 26.7±2.7 193±19.5
Bucket cylinder
31★3 M10 5.4±0.5 39.1±3.6
27★4 M10 6.5±0.7 47.0±5.1
23★1★3 M16 23.0±2.0 166±14.5
23★1★4 M16 26.7±2.7 193±27.5
Boom cylinder
31★3 M10 5.4±0.5 39.1±3.6
27★4 M10 6.5±0.7 47.0±5.1
Socket head bolt
23★1★3 M18 32.0±3.0 232±21.7
28★1★4 M18 38.0±3.8 275±27.5
28★1★5 M18 38.0±3.8 275±27.5
Arm cylinder
34★3 M12 9.4±1.0 68.0±7.2
31★4 M12 11.3±1.1 81.7±8.0
33★5 M12 11.3±1.1 81.7±8.0
20★1★4 M20 52.2±5.2 378±37.6
Adjustment cylinder
25★4 M10 6.5±0.7 47.0±5.1
★1 : Apply loctite #243 on the thread of bolt.
★3 : CHANGZHOU
★4 : SHPAC
★5 : 2-piece boom
8-152
Torque
Part name Item Size
kgf·m lbf·ft
20★3 - 100±10.0 723±72.3
Bucket cylinder
21★4 M62 100±10.0 723±72.3
20★3 - 100±10.0 723±72.3
Boom cylinder
21★4 M56 100±10.0 723±72.3
Lock nut
20★3 - 150±15.0 1085±108
Arm cylinder 21★4 M70 150±15.0 1085±108
21★5 M70 150±15.0 1085±108
Adjustment cylinder 17★4 M65 62±6.0 448±43.4
14★3 - 150±15.0 1085±108
Bucket cylinder
15★4 M75 150±15.0 1085±108
14★3 - 150±15.0 1085±108
Boom cylinder
15★4 M75 150±15.0 1085±108
Piston
14★3 - 200±20.0 1447±145
Arm cylinder 15★4 M90 200±20.0 1447±145
15★5 M90 200±20.0 1447±145
Adjustment cylinder 13★4 M75 97±10 702±72.3
21★3 M8 2.7±0.3 19.5±2.2
Bucket cylinder
22★4 M8 1.7±0.2 12.3±1.4
21★3 M8 2.7±0.3 19.5±2.2
Boom cylinder
22★4 M8 1.7±0.2 12.3±1.4
Set screw
21★3 M10 5.4±0.5 39.1±3.6
Arm cylinder 22★4 M10 2.5±0.3 18.1±2.2
22★5 M10 2.5±0.3 18.1±2.2
Adjustment cylinder 19★4 M8 1.7±0.2 12.3±1.4
★1 : Apply loctite #243 on the thread of bolt.
★3 : CHANGZHOU
★4 : SHPAC
★5 : 2-piece boom
8-153
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
※ Procedures are based on the bucket
cylinder. (CHANGZHOU type)
① Hold the clevis section of the tube in a
vise.
※ Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
② Pull out rod assembly (2) about 200 mm

(7.1 in). Because the rod assembly is
rather heavy, finish extending it with air
pressure after the oil draining operation.
m
0m
20
21078DA30
③ Loosen and remove socket bolts (23) of

Hexagon
the gland in sequence. socket wrench
※ Cover the extracted rod assembly (2) 23
with rag to prevent it from being
accidentally damaged during operation. Turn counter
clockwise
Cover here
with rag
2
21098DA31
④ Draw out cylinder head and rod assembly

together from tube assembly (1). Lift
※ Since the rod assembly is heavy in this
case, lift the tip of the rod assembly (2)
with a crane or some means and draw it Full straight
sideways
out. However, when rod assembly (2)
has been drawn out to approximately
two thirds of its length, lift it in its center
Oil pan
to draw it completely.
21078DA32
8-154
Note that the plated surface of rod
assembly (2) is to be lifted. For this
reason, do not use a wire sling and
others that may damage it, but use a
strong cloth belt or a rope.
⑤ Place the removed rod assembly on a

wooden V-block that is set level.
Piston assy
※ Cover a V-block with soft rag.
Wooden block
21078DA33
(2) Remove piston and cylinder head 13 14 18 19 20 21

① Remove set screw (21).
② Remove lock nut (20).
※ Since piston (14) and lock nut (20) are
tightened to a high torque, use a
hydraulic and power wrench that utilizers
a hydraulic cylinder, to remove the piston
(14) and lock nut (20).
③ Remove piston assembly (14), back up
2907A8CY02
ring (19), and O-ring (18).
④ Remove cushion ring (13).
Plastic
hammer
⑤ Remove the cylinder head assembly
Lift with a crane
from rod assembly (2).
※ If it is too heavy to move, move it by
Pull straight
striking the flanged part of cylinder head
with a plastic hammer.
※ Pull it straight with cylinder head
assembly lifted with a crane.
21078DA35
Exercise care so as not to damage the
lip of rod bushing (4) and packing
(5,6,7,8,9,10) by the threads of rod
assembly (2).
8-155
(3) Disassemble the piston assembly 17 16 15 16 17
① Remove wear ring (16).
② Remove dust ring (17) and piston seal
(15).
※ Exercise care in this operation not to
damage the grooves.
2907A8CY03
(4) Disassemble cylinder head assembly

10 9 6 7 8 4 5 22 12 11
① Remove back up ring (12), O-ring (11)
and O-ring (22).
② Remove snap ring (10), dust wiper (9).
③ Remove back up ring (7), rod seal (6)
and buffer ring (8).
※ Exercise care in this operation not to
damage the grooves.
※ Do not remove seal and ring, if does not
220S8DA36
damaged.
※ Do not remove bushing (4).
8-156
3) ASSEMBLY
(1) Assemble cylinder head assembly
※ Check for scratches or rough surfaces if
found smooth with an oil stone.
① Coat the inner face of gland (3) with
hydraulic oil.
21078DA37
② Coat dust wiper (9) with grease and fit Press here
dust wiper (9) to the bottom of the hole of (Straight down)
dust seal.
Metal
At this time, press a pad metal to the 9
metal ring of dust seal.
③ Fit snap ring (10) to the stop face.
8-157(2)
④ Fit back up ring (7), rod seal (6) and

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

Push bar
Therefore, confirm it before fitting them.
※ Fitting rod seal (6) upside down may
damage its lip. Therefore check the
correct direction that is shown in fig.
21078DA38
8-157
⑤ Fit back up ring (12) to gland (3).
※ Put the backup ring in the warm water of 11
30~50˚C . 12
⑥ Fit O-ring (11) and O-ring (22) to gland 22
(3).
220S8DA39
(2) Assemble piston assembly

※ Check for scratches or rough surfaces.
If found smooth with an oil stone.
① Coat the outer face of piston (14) with
hydraulic oil.
8-158(2)
② Fit piston seal (15) to piston.

※ Put the piston seal in the warm water of 15
60~100˚C for more than 5 minutes.
※ After assembling the piston seal, press
its outer diameter to fit in.
2907A8CY04
③ Fit wear ring (16) and dust ring (17) to

17 16 15 16 17
piston (14).
14
2907A8CY05
8-158
(3) Install piston and cylinder head
① Fix the rod assembly to the work bench. Cylinder head assembly
② Apply hydraulic oil to the outer surface of Rod assembly
rod assembly (2), the inner surface of
piston and cylinder head.
③ Insert cylinder head assembly to rod
assembly.
21078DA40
④ Insert cushion ring (13) to rod assembly.

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

·Tightening torque : 150±15.0 kgf·m
(1085±108 lbf·ft)
50078CY09
⑥ Fit lock nut (20) and tighten the screw 20 21

(21).
·Tightening torque :
Item 20 : 100±10.0 kgf·m (723±72.3 lbf·ft)
Item 21 : 2.7±0.3 kgf·m (19.5±2.2 lbf·ft)
50078CY10
8-159
(3) Overall assemble Fix with a bar
① Place a V-block on a rigid work bench.
Mount the tube assembly (1) on it and Lift
fix the assembly by passing a bar
through the clevis pin hole to lock the
assembly. Straight
② Insert the rod assembly in to the tube
assembly, while lifting and moving the
rod assembly with a crane. Appply liquid packing
21078DA41
※ Be careful not to damage piston seal by
thread of tube assembly.
③ Match the bolt holes in the cylinder head
flange to the tapped holes in the tube Turn clockwise
assembly and tighten socket bolts to a Apply loctite
specified torque.
※ Refer to the table of tightening torque.
Place rag
21078DA42
8-160
GROUP 10 UNDERCARRIAGE
1. TRACK LINK
1) REMOVAL
(1) Move track link until master pin is over
front idler in the position put wooden Master pin
block as shown.
(2) Loosen tension of the track link.
※ If track tension is not relieved when the
grease valve is loosened, move the
machine backwards and forwards.
※ Unscrew the grease nipple after release
the tension by pushing the poppet only
when necessarily required.
Grease leaking hole is not existing. So, Block
while unscrew the grease nipple, grease
is not leaking until the grease nipple is
completely coming out. If the tension is
not released in advance, the grease
nipple can be suddenly popped out by
pressurized grease.
220S8UC01
(3) Push out master pin by using a suitable
tool.
(4) Move the machine slowly in reverse, and

lay out track link assembly (1).
※ Jack up the machine and put wooden
block under the machine.
※ Don't get close to the sprocket side as the
track shoe plate may fall down on your
feet.
1
8-161(2)
2) INSTALL
to removal.
※ Adjust the tension of the track link.
90~110
210A8UC03
8-161
2. UPPER ROLLER Frame
1) REMOVAL
(1) Loosen tension of the track link. Grease
valve
8-162(1)
(2) Jack up the track link height enough to

permit upper roller removal.
Jack Upper roller
220SA8UC02
(3) Loosen the lock nut (1). 1 Upper roller

(4) Open bracket(2) with a screwdriver, push
2
out from inside, and remove upper roller
assembly.
·Weight : 41 kg (90.4 lb)
·Tightening torque : 29.7±4.5 kgf·m
(215±32.5 lbf·ft)
220SA8UC03
2) INSTALL
to removal.
8-162
3. LOWER ROLLER Frame
1) REMOVAL
Grease
(1) Loosen tension of the track link. valve
8-163(1)
(2) Using the work equipment, push up track

frame on side which is to be removed.
※ After jack up the machine, set a block
under the unit.
90-110°
8-163(2)
(3) Remove the mounting bolt (1) and draw

out the lower roller (2). 1 2
·Weight : 37.5 kg (82.7 lb)
(419±62.9 lbf·ft)
8-163(3)
2) INSTALL
to removal.
8-163
4. IDLER AND RECOIL SPRING
1) REMOVAL
(1) Remove the track link.
For detail, see removal of track link.
220A8UC10
(2) Sling the recoil spring (1) and pull out idler
and recoil spring assembly from track
frame, using a pry. 1
220A8UC11
(3) Remove the bolts (2), washers (3) and

separate ilder from recoil spring.
(215±32.5 lbf·ft)
2
3
220A8UC12
2) INSTALL
to removal.
※ Make sure that the boss on the end face
of the recoil cylinder rod is in the hole of
the track frame.
220A8UC13
8-164
3) DISASSEMBLY AND ASSEMBLY OF IDLER
(1) Structure
8 3
1 4
6
7
5
6
220S8DA43
1 Shell 4 Bushing 7 Spring pin

2 Shaft 5 Bracket 8 Plug
3 Seal assembly 6 O-ring
8-165
(2) Disassembly
① Remove plug and drain oil.
② Draw out the spring pin (7), using a
press.
7 300S8UC21
③ Pull out the shaft (2) with a press.

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

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

install it to shaft (2).
③ Insert shaft (2) into bracket (5) and drive 4
in the spring pin (7). 3
300S8UC22
④ Install seal (3) to shell (1) and bracket (5).

3
8-167(3)
⑤ Install shaft (2) to shell (1). 2 1
8-167(4)
8-167
⑥ Install bracket (5) attached with seal (3).
6
300S8UC23
⑦ Knock in the spring pin (7) with a

hammer. 6
7
1
300S8UC24
⑧ Lay bracket (5) on its side.

5
Supply engine oil to the specified level,
and tighten plug.
8-168(3)
8-168
4) DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING
(1) Structure (standard)
4 7, 8 6 3 5 2 14 1 9, 10 11 12
13
220L8UC100
1 Body 6 Lock plate 11 Dust seal

2 Tie bar 7 Bolt 12 Rod
3 Spring 8 Spring washer 13 Grease valve
4 Bracket 9 Rod seal 14 Spring pin
5 Lock nut 10 Back up ring
8-169
(2) Disassembly Press
① Apply pressure on spring (3) with a
press.
※ The spring is under a large installed load. 4
This is dangerous, so be sure to set 7, 8

properly.
6
② Remove bolt (7), spring washer (8) and
3
lock plate (6).
③ Remove lock nut (5). 5
Take enough notice so that the press

which pushes down the spring, should
not be slipped out in its operation.
④ Lighten the press load slowly and
remove bracket (4) and spring (3).
220S8UCG01
⑤ Remove rod (12) from body (1).

⑥ Remove grease valve (13) from rod (12).
1 12
220S8UCG02
⑦ Remove rod seal (9), back up ring (10)

and dust seal (11).
1 9 10 11
220S8UCG03
8-170
(3) Assembly
Install dust seal (11), back up ring (10)
and rod seal (9) to body (1). 1 9 10 11
※ When installing dust seal (11) and rod

seal (9), take full care so as not to
damage the lip.
220S8UCG03
② Pour grease into body (1), then push in

rod (12) by hand.
After take grease out of grease valve 1 12
mounting hole, let air out.

※ If air letting is not sufficient, it may be
difficult to adjust the tension of crawler.
③ Fit grease valve (13) to rod (12).
(94±7.2 lbf·ft)
220S8UCG04
④ Install spring (3) and bracket (4) to body Press

(1).
⑤ Apply pressure to spring (3) with a press
and tighten lock nut (5).
·Spring set load : 13716 kg (30239 lb)
※ Apply sealant before assembling. 4
※ During the operation, pay attention

specially to prevent the press from 3
slipping out.
220S8UCG05
8-171
⑥ Lighten the press load and confirm the Press
set length of spring (3).
- Set length : 431 ± 1.5 mm
⑦ After the setting of spring (3), install lock
plate (6), spring washer (8) and bolt (7).
7, 8
(108±3.6 lbf·ft) 6
3
5
Set length
220S8UCG06
8-172
GROUP 11 WORK EQUIPMENT
1. STRUCTURE
SECTION A SECTION B SECTION C

220A8WE10
8-173
1) BUCKET ASSEMBLY
(1) Removal
① Lower the work equipment completely to
A
ground with back of bucket facing down.
B
36078AT04
② Remove nut (1), bolt (2) and draw out the

pin (A). 2
·Tightening torque (1) : 57.9±8.7 kgf·m A
(419± 62.9 lbf·ft) 1
300L8WE01
③ Remove nut (3), bolt (4) and draw out the

4
pin (B).
·Tightening torque (1) : 57.9±8.7 kgf·m 3 B
(419± 62.9 lbf·ft)
300L8WE02
(2) Install
to removal.
When aligning the mounting position of
the pin, do not insert your fingers in the
pin hole.
※ Adjust the bucket clearance.
For detail, see operation manual.
300A8WE03
8-174
2) ARM ASSEMBLY
(1) Removal
※ Loosen the breather slowly to release
the pressure inside the hydraulic tank.
penetrated the skin causing serious
injury.
① Remove bucket assembly.
For details, see removal of bucket 8-175(1)
assembly.
② Disconnect bucket cylinder hose (1).
Fit blind plugs (5) in the piping at the
chassis end securely to prevent oil from 5
spurting out when the engine is started.
③ Sling arm cylinder assembly, remove 4
spring, pin stopper and pull out pin.
coming out.
4
④ For details, see removal of arm cylinder
assembly.
220S8DA16
Place a wooden block under the cylinder
and bring the cylinder down to it.
⑤ Remove bolt (2), plate (3) and pull out
the pin (4) then remove the ar m
assembly.
·Weight : 1095 kg (2410 lb) Crane
·Tightening torque (2) : 29.7±45 kgf·m
(215± 32.5 lbf·ft)
※ When lifting the arm assembly, always lift 2, 3, 4
the center of gravity.
8-175(3)
(2) Install
① Carry out installation in the reverse
order to removal.
When lifting the arm assembly, always lift
the center of gravity.
※ Bleed the air from the cylinder.
8-175
3) BOOM ASSEMBLY
(1) Removal
① Remove arm and bucket assembly.
For details, see removal of arm and
bucket assembly.
② Remove boom cylinder assembly from
boom.
For details, see removal of boom cylind-
er assembly. 8-176(1)
③ Disconnect head lamp wiring.

④ Disconnect bucket cylinder hose (2)
1
and arm cylinder hose (1).
2
※ When the hose are disconnected, oil
may spurt out.
⑤ Sling boom assembly (3).
220A8DA45
⑥ Remove bolt (4), plate (5) and pull out

Crane
the pin (6) then remove boom assembly.
·Weight :1790 kg (3950 lb)
·Tightening torque (4) : 29.7±45 kgf·m
(215± 32.5 lbf·ft)
※ When lifting the boom assembly always
lift the center of gravity. 4, 5, 6
3
8-176(3)
(2) Install 4
① Carry out installation in the reverse order 5
6
to removal.
When lifting the arm assembly, always
lift the center of gravity.
※ Bleed the air from the cylinder.
220A8DA46
8-176

Hx210a L NL SM

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CONTENTS

SECTION 2 STRUCTURE AND FUNCTION

SECTION 3 HYDRAULIC SYSTEM

SECTION 4 ELECTRICAL SYSTEM

SECTION 5 MECHATRONICS SYSTEM

Group 1 Before Troubleshooting ----------------------------------------------------------------------------------- 6-1

SECTION 7 MAINTENANCE STANDARD

Group 1 Operational Performance Test ------------------------------------------------------------------------ 7-1

SECTION 8 DISASSEMBLY AND ASSEMBLY

Group 1 Precaution -------------------------------------------------------------------------------------------------------- 8-1

2. Convert 550 mm into inches.

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

Kilogram to Pound 1kg = 2.2046lb

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

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

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

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

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

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

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

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

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

Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

USE HANDHOLDS AND STEPS

Be careful of slippery conditions on platforms,

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

AVOID POWER LINES

MOVE AND OPERATE MACHINE SAFELY

OPERATE ONLY FORM OPERATOR'S SEAT

PARK MACHINE SAFELY

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

Store flammable fluids away from fire hazards.

ILLUMINATE WORK AREA SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HIGH PRESSURE FLUIDS

PREVENT BATTERY EXPLOSIONS

USE TOOLS PROPERLY

Use only recommended replacement parts.

REPLACE SAFETY SIGNS

LIVE WITH SAFETY

Charge air cooler

Bucket cylinder Connecting link Idler Upper roller Sprocket

Side cutter Connecting rod Lower roller Track Travel motor

Boom 5.65 (18' 6")

Boom 5.65 (18' 6")

Lower chassis assembly

Front attachment assembly

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

Lift-point radius (B) At max. reach

7.5 m kg *4250 *4250 *3190 *3190 6.24

Note 1. Lifting capacity are based on ISO 10567.

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

Lift-point radius (B) At max. reach

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

7.5 m kg 4250 4250 3190 3190 6.24

7.5 m kg 4250 4250 3190 3190 6.24

7.5 m kg 2200 2200 7.47

9.0 m kg 2890 2890 2530 2530 6.10