R320LC 7 PDF

SECTION 1 GENERAL
Group 1 Safety Hints 1-1

Group 2 Specifications 1-9
1-1
SECTION 1 GENERAL
GROUP 1 SAFETY
FOLLOW SAFE PROCEDURE

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

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

Unexpected machine movement can cause serious
injury.
Before performing any work on the excavator, attach a
「Do Not Operate」tag on the right side control lever.
WARN
DO
NOT
OPERATE
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.
Be careful of slippery conditions on platforms, steps,
and handrails when leaving the machine. 13031GE03
1-1
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your
telephone.
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 ear-
muffs 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
operating the machine in congested areas. Coordinate
hand signals before starting the excavator. 13031GE09
OPERATE ONLY FORM OPERATOR'S SEAT

Avoid possible injury machine damage. Do not start
engine by shorting across starter terminals.
NEVER start engine while standing on ground. Start
engine only from operator's seat.
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
work on a lifted machine or attachment, securely
support the machine or attachment.
Do not support the machine on cinder blocks, hollow
tiles, or props that may crumble under continuous load.
Do not work under a machine that is supported solely by
a jack. Follow recommended procedures in this manual.
13031GE10
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 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
13031GE14
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 parts.
13031GE16
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 fluids.
If an accident occurs, see a doctor immediately. Any 13031GE18
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.
Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area. Install fire
13031GE20
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
PREVENT ACID BURNS

Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, eat holes in clothing, and
cause blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling of dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the
acid.
3. Flush your eyes with water for 10-15 minutes. Get
medical attention immediately.
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil. 13031GE22
3. Get medical attention immediately.
1-7
USE TOOLS PROPERLY
Use tools appropriate to the work. Makeshift tools,
parts, and procedures can create safety hazards.
Use power tools only to loosen threaded tools and
fasteners.
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches.
Use only recommended replacement parts.(See Parts
catalogue.) 13031GE23
DISPOSE OF FLUIDS PROPERLY

Improperly disposing of fluids can harm the environment
and ecology. Before draining any fluids, find out the
proper way to dispose of waste from your local
environmental agency.
Use proper containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
DO NOT pour oil into the ground, down a drain, or into a
stream, pond, or lake. Observe relevant environmental
protection regulations when disposing of oil, fuel,
coolant, brake fluid, filters, batteries, and other harmful
13031GE24
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.
1-8
GROUP 2 SPECIFICATIONS
1. MAJOR COMPONENT
Tool box Fuel tank Hydraulic oil tank Main pump
Engine
Radiator
Tooth Bucket Turning joint Swing motor Main control valve Battery Oil cooler
Arm Arm cylinder Boom Boom cylinder Cab Precleaner Muffler
Bucket cylinder Connecting link Idler Carrier roller Sprocket Counterweight
Side cutter Connecting rod Track roller Track Travel motor
29072SP00
1-9
2. SPECIFICATIONS
I(I’) D
C
E
G
F
H
J M
K N
A B(L)
29072SP01
Description Unit Specification
Operating weight kg(lb) 32200(70990)

Bucket capacity(PCSA heaped), standard m (yd )
3 3
1.44(1.88)
Overall length A 10980(36' 0")
Overall width, with 600mm shoe B 3280(10' 9")
Overall height C 3380(11' 1")
Superstructure width D 2980( 9' 9")
Overall height of cab E 3110(10' 2")
Ground clearance of counterweight F 1215( 3' 12")
Engine cover height G 2580( 8' 6")
Minimum ground clearance H mm(ft-in) 500( 1' 8")
Rear-end distance I 3265(10' 9")
Rear-end swing radius I' 3330(10' 11")
Distance between tumblers J 4030(13' 3")
Undercarriage length K 4940(16' 2")
Undercarriage width L 3280(10' 9")
Track gauge M 2680( 8' 10")
Track shoe width, standard N 600(23.6")
Travel speed(Low/high) km/hr(mph) 3.2/5.4(2.0/3.4)
Swing speed rpm 9.1
Gradeability Degree(%) 35(70)
Ground pressure(600mm shoe) kgf/cm2(psi) 0.62(8.82)
1-10
3. WORKING RANGE
A
A'
F
D
B' E
C
B
8ft
36072SP04
6.45m(21' 2") Arm 6.15m(20' 2")Boom

Description
2.2m(7' 3")Arm 2.5m(8' 2")Arm 3.2m(10' 6")Arm 4.05m(13' 3")Arm 2.2m(7' 3")Arm
Max digging reach A 10330mm (33'11") 10550mm (34' 7") 11140mm (36' 7") 11950mm (39' 2") 10020mm (32'10")
Max digging reach on ground A' 10110mm (33' 2") 10330mm (33'11") 10940mm (35'11") 11760mm (38' 7") 9800mm (32' 2")
Max digging depth B 6370mm (20'11") 6710mm (22' 0") 7370mm (24' 2") 8220mm (26'12") 6160mm (20' 3")
Max digging depth (8ft level) B' 6160mm (20' 3") 6470mm (21' 3") 7210mm (23' 8") 8080mm (26' 6") 5950mm (19' 6")
Max vertical wall digging depth C 5980mm (19' 7") 5920mm (19' 5") 6360mm (20'10") 7260mm (23'10") 5710mm (18' 9")
Max digging height D 10220mm (33' 6") 10170mm (33' 4") 10310mm (33'10") 10710mm (35' 2") 9940mm (32' 7")
Max dumping height E 7050mm (23' 2") 7050mm (23' 2") 7240mm (23' 9") 7630mm (25' 0") 6780mm (22' 3")
Min swing radius F 4700mm (15' 5") 4500mm (14' 9") 4470mm (14' 8") 4470mm (14' 8") 4520mm (14'10")
177.5[193.6] kN 177.5[193.6] kN 177.5[193.6] kN 177.5[193.6] kN 177.5[193.6] kN
SAE 18100[19750] kgf 18100[19750] kgf 18100[19750] kgf 18100[19750] kgf 18100[19750] kgf
39900[43530] lbf 39900[43530] lbf 39900[43530] lbf 39900[43530] lbf 39900[43530] lbf
Bucket digging force
198.1[216.1] kN 198.1[216.1] kN 198.1[216.1] kN 198.1[216.1] kN 198.1[216.1] kN
ISO 20200[22040] kgf 20200[22040] kgf 20200[22040] kgf 20200[22040] kgf 20200[22040] kgf
185.3[202.2] kN 168.7[184.0] kN 132.4[144.4] kN 112.8[123.0] kN 185.3[202.2] kN
SAE 18900[20620] kgf 17200[18760] kgf 13500[14730] kgf 11500[12550] kgf 18900[20620] kgf
Arm crowd force
191.2[208.6] kN 174.6[190.4] kN 136.3[148.7] kN 115.7[126.2] kN 191.2[208.6] kN
ISO 19500[21270] kgf 17800[19420] kgf 13900[15160] kgf 11800[12870] kgf 19500[21270] kgf
[ ] : Power boost
1-11
4. WEIGHT
R320LC-7
Item
kg lb
Upperstructure assembly 14520 31590
Main frame weld assembly 2680 5900
Engine assembly 590 1300
Main pump assembly 180 380
Main control valve assembly 200 440
Swing motor assembly 310 680
Hydraulic oil tank assembly 230 490
Fuel tank assembly 210 450
Counterweight 6200 13670
Cab assembly 310 680
Radiator total assy 280 620
Lower chassis assembly 11500 25770
Track frame weld assembly 3970 8750
Swing bearing 410 900
Travel motor assembly 390 860
Turning joint 50 110
Tension cylinder 210 450
Idler 250 540
Sprocket 80 170
Carrier roller 40 80
Track roller 60 120
Track-chain assembly(600mm standard triple grouser shoe) 1860 4100
Front attachment assembly(6.45m boom, 3.2m arm,
6110 13470
1.44m3 PCSA heaped bucket)
6.45m boom assembly 2590 5710
3.2m arm assembly 1140 2510
1.44m3 PCSA heaped bucket 1110 2450
Boom cylinder assembly 280 620
Arm cylinder assembly 380 840
Bucket cylinder assembly 270 570
Bucket control linkage assembly 370 820
1-12
5. LIFTING CAPACITIES
1) 6.15m(20' 2") boom, 2.2m(7' 3") arm equipped with 1.44m3(PCSA heaped) bucket and 600mm(24")
triple grouser shoe.
・ : Rating over-front ・ : Rating over-side or 360 degree
Load radius At max. reach

Load point 3.0m(10.0ft) 4.5m(15.0ft) 6.0m(20.0ft) 7.5m(25.0ft) Capacity Reach
height
m(ft)
7.5m kg *6910 5680 7.69

(25.0ft) lb *15230 12520 (25.2)
6.0m kg *7760 *7760 *7460 5770 *6960 4510 8.61
(20.0ft) lb *17110 *17110 *16450 12720 *15340 9940 (28.2)
4.5m kg *11210 *11210 *8910 8260 *7850 5630 6180 3920 9.16
(15.0ft) lb *24710 *24710 *19640 18210 *17310 12410 13620 8640 (30.1)
3.0m kg *14450 12090 *10390 7760 8500 5400 5810 3650 9.39
(10.0ft) lb *31860 26650 *22910 17110 18740 11900 12810 8050 (30.8)
1.5m kg *16730 11300 *11700 7330 8250 5180 5780 3610 9.35
(5.0ft) lb *36880 24910 *25790 16160 18190 11420 12740 7960 (30.7)
Ground kg *17390 11020 11570 7070 8080 5030 6090 3800 9.02
Line lb *38340 24290 25510 15590 17810 11090 13430 8380 (29.6)
-1.5m kg *16010 *16010 *16940 11010 11480 7000 8040 5000 6900 4330 8.37
(-5.0ft) lb *35300 *35300 *37350 24270 25310 15430 17730 11020 15210 9550 (27.5)
-3.0m kg *21280 *21280 *15440 11200 *11470 7100 *7700 5530 7.29
(-10.0ft) lb *46910 *46910 *34040 24690 *25290 15650 *16980 12190 (23.9)
-4.5m kg *16550 *16550 *12170 11630
(-15.0ft) lb *36490 *36490 *26830 25640
Note 1. Lifting capacity are based on SAE J1097 and ISO 10567.
2. Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine
on firm, level ground or 87% of full hydraulic capacity.
3. The load point is a hook located on the back of the bucket.
4. *indicates load limited by hydraulic capacity.
1-13
2) 6.45m(21' 2") boom, 2.2m(7' 3") arm equipped with 1.44m3(PCSA heaped) bucket and 600mm
(24") triple grouser shoe.
Load point 3.0m(10.0ft) 4.5m(15.0ft) 6.0m(20.0ft) 7.5m(25.0ft) Capacity Reach
height
m(ft)
7.5m kg *6570 5120 8.07

(25.0ft) lb *14480 11290 (26.5)
6.0m kg *7600 *7600 *7100 5710 6450 4110 8.95
(20.0ft) lb *16760 *16760 *15650 12590 14220 9060 (29.4)
4.5m kg *11460 *11460 *8830 8070 *7610 5520 5730 3590 9.47
(15.0ft) lb *25260 *25260 *19470 17790 *16780 12170 12630 7910 (31.1)
3.0m kg *10320 7530 8350 5260 5400 3350 9.70
(10.0ft) lb *22750 16600 18410 11600 11900 7390 (31.8)
1.5m kg *11580 7090 8080 5030 5370 3310 9.66
(5.0ft) lb *25530 15630 17810 11090 11840 7300 (31.7)
Ground kg *17110 10680 11310 6840 7910 4870 5650 3480 9.34
Line lb *37720 23550 24930 15080 17440 10740 12460 7670 (30.6)
-1.5m kg *13660 *13660 *16560 10730 11240 6780 7870 4830 6350 3940 8.72
(-5.0ft) lb *30120 *30120 *36510 23660 24780 14950 17350 10650 14000 8690 (28.6)
-3.0m kg *20480 *20480 *15160 10930 11360 6890 *7290 4950 7.70
(-10.0ft) lb *45150 *45150 *33420 24100 25040 15190 *16070 10910 (25.3)
-4.5m kg *16460 *16460 *12360 11350
(-15.0ft) lb *36290 *36290 *27250 25020
Load point 3.0m(10.0ft) 4.5m(15.0ft) 6.0m(20.0ft) 7.5m(25.0ft) 9.0m(30.0ft) Capacity Reach
height
m(ft)
7.5m kg *6180 4840 8.34
(25.0ft) lb *13620 10670 (27.4)
6.0m kg *6750 5750 6170 3920 9.19
(20.0ft) lb *14880 12680 13600 8640 (30.2)
4.5m kg *10750 *10750 *8420 8120 *7310 5540 5500 3430 9.70
(15.0ft) lb *23700 *23700 *18560 17900 *16120 12210 12130 7560 (31.8)
3.0m kg *14010 11740 *9940 7550 *8080 5260 5190 3190 9.92
(10.0ft) lb *30890 25880 *21910 16640 *17810 11600 11440 7030 (32.5)
1.5m kg *16290 10880 *11280 7070 8060 5000 5970 3680 5150 3150 9.88
(5.0ft) lb *35910 23990 *24870 15590 17770 11020 13160 8110 11350 6940 (32.4)
Ground kg *16990 10590 11260 6790 7860 4820 5390 3300 9.57
Line lb *37460 23350 24820 14970 17330 10630 11880 7280 (31.4)
-1.5m kg *14220 *14220 *16670 10590 11150 6700 7790 4760 6010 3700 8.97
(-5.0ft) lb *31350 *31350 *36750 23350 24580 14770 17170 10490 13250 8160 (29.4)
-3.0m kg *21440 *21440 *15460 10760 11240 6770 *7290 4590 7.98
(-10.0ft) lb *47270 *47270 *34080 23720 24780 14930 *16070 10120 (26.2)
-4.5m kg *17640 *17640 *12990 11140 *9520 7060 *6680 *6680 6.42
(-15.0ft) lb *38890 *38890 *28640 24560 *20990 15560 *14730 *14730 (21.1)
1-14
Load point 1.5m(5.0ft) 3.0m(10.0ft) 4.5m(15.0ft) 6.0m(20.0ft) 7.5m(25.0ft) 9.0m(30.0ft) Capacity Reach
height
m(ft)
7.5m kg *4880 *4880 *5500 4200 9.06
(25.0ft) lb *10760 *10760 *12130 9260 (29.7)
6.0m kg *6000 5890 5510 3470 9.84
(20.0ft) lb *13230 12990 12150 7650 (32.3)
4.5m kg *7490 *7490 *6640 5640 *5070 3980 4960 3060 10.31
(15.0ft) lb *16510 *16510 *14640 12430 *11180 8770 10930 6750 (33.8)
3.0m kg *12430 12180 *9090 7700 *7490 5320 6140 3830 4690 2850 10.52
(10.0ft) lb *27400 26850 *20040 16980 *16510 11730 13540 8440 10340 6280 (34.5)
1.5m kg *15210 11110 *10610 7150 8090 5020 5970 3670 4640 2800 10.48
(5.0ft) lb *33530 24490 *23390 15760 17840 11070 13160 8090 10230 6170 (34.4)
Ground kg *9720 *9720 *16620 10580 11260 6780 7830 4790 5830 3540 4810 2900 10.19
Line lb *21430 *21430 *36640 23320 24820 14950 17260 10560 12850 7800 10600 6390 (33.4)
-1.5m kg *10800 *10800 *13710 *13710 *16830 10440 11060 6600 7700 4660 5280 3200 9.63
(-5.0ft) lb *23810 *23810 *30230 *30230 *37100 23020 24380 14550 16980 10270 11640 7050 (31.6)
-3.0m kg *14530 *14530 *18410 *18410 *16100 10510 11050 6600 7700 4670 6240 3840 8.74
(-10.0ft) lb *32030 *32030 *40590 *40590 *35490 23170 24360 14550 16980 10300 13760 8470 (28.7)
-4.5m kg *20220 *20220 *14270 10790 *10560 6780 *6880 5250 7.37
(-15.0ft) lb *44580 *44580 *31460 23790 *23280 14950 *15170 11570 (24.2)
-6.0m kg *10450 *10450
(-20.0ft) lb *23040 *23040

Load point 1.5m(5.0ft) 3.0m(10.0ft) 4.5m(15.0ft) 6.0m(20.0ft) 7.5m(25.0ft) 9.0m(30.0ft) Capacity Reach
height
m(ft)
7.5m kg *4760 3440 10.00
(25.0ft) lb *10490 7580 (32.8)
6.0m kg *4160 *4160 4700 2890 10.71
(20.0ft) lb *9170 *9170 10360 6370 (35.1)
4.5m kg *5710 *5710 *5320 4030 4270 2570 11.13
(15.0ft) lb *12590 *12590 *11730 8880 9410 5670 (36.5)
3.0m kg *16820 *16820 *10330 *10330 *7880 *7880 *6640 5380 *5940 3830 4050 2390 11.32
(10.0ft) lb *37080 *37080 *22770 *22770 *17370 *17370 *14640 11860 *13100 8440 8930 5270 (37.1)
1.5m kg *9930 *9930 *13560 11450 *9590 7260 *7630 5030 5940 3630 4000 2340 11.29
(5.0ft) lb *21890 *21890 *29890 25240 *21140 16010 *16820 11090 13100 8000 8820 5160 (37.0)
Ground kg *10280 *10280 *15690 10640 *10950 6770 7790 4730 5750 3460 4120 2410 11.03
Line lb *22660 *22660 *34590 23460 *24140 14930 17170 10430 12680 7630 9080 5310 (36.2)
-1.5m kg *9390 *9390 *12710 *12710 *16580 10290 10950 6490 7580 4540 5630 3350 4450 2620 10.52
(-5.0ft) lb *20700 *20700 *28020 *28020 *36550 22690 24140 14310 16710 10010 12410 7390 9810 5780 (34.5)
-3.0m kg *12370 *12370 *16100 *16100 *16450 10230 10840 6400 7500 4480 5620 3340 5110 3060 9.72
(-10.0ft) lb *27270 *27270 *35490 *35490 *36270 22550 23900 14110 16530 9880 12390 7360 11270 6750 (31.9)
-4.5m kg *15810 *15810 *20640 *20640 *15320 10390 10930 6470 7590 4550 *6410 3940 8.53
(-15.0ft) lb *34860 *34860 *45500 *45500 *33770 22910 24100 14260 16730 10030 *14130 8690 (28.0)
-6.0m kg *18370 *18370 *12770 10780 *9220 6760 *6150 6120 6.71
(-20.0ft) lb *40500 *40500 *28150 23770 *20330 14900 *13560 13490 (22.0)
1-15
6. BUCKET SELECTION GUIDE
1) GENERAL BUCKET
0.9m3 PCSA 1.14m3 PCSA ※1.44m3 PCSA 1.74m3PCSA 2.10m3 PCSA

heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket
Recommendation 6.15m (20'

Capacity Width 6.45m (21' 2") boom 2") boom
Weight
PCSA CECE Without With 2.2m arm 2.5m arm 3.2m arm 4.05m arm 2.2m arm
heaped heaped side cutter side cutter (7' 3") (8' 2") (10' 6") (13' 3") (7' 3")
0.9m3 0.8m3 950mm 1070mm 870kg

(1.18yd3) (1.05yd3) (37.4") (42.2") (1920lb)
1.14m3 1.0m3 1140mm 1260mm 980kg

(1.49yd3) (1.31yd3) (44.9") (49.6") (2160lb)
※1.44m3 1.25m3 1380mm 1500mm 1110kg

(1.88yd3) (1.63yd3) (54.3") (59.1") (2450lb)
1.74m3 1.5m3 1610mm 1730mm 1230kg

(2.28yd3) (1.96yd3) (63.4") (68.1") (2710lb)
2.10m3 1.8m3 1900mm 2020mm 1370kg

(2.75yd3) (2.35yd3) (74.8") (79.5") (3020lb)
※ : Standard bucket
Applicable for materials with density of 2000kgf/m3 (3370lbf/yd3) or less
1-16
2) ROCK AND HEAVY DUTY BUCKET
◈1.44m3 PCSA 1.44m3 PCSA

heaped bucket heaped bucket
Recommendation 6.15m (20'

Capacity Width 6.45m (21' 2") boom 2") boom
Weight
PCSA CECE Without With 2.2m arm 2.5m arm 3.2m arm 4.05m arm 2.2m arm
heaped heaped side cutter side cutter (7' 3") (8' 2") (10' 6") (13' 3") (7' 3")
◈1.44m3 1.25m3 1380mm 1380kg

-
(1.88yd3) (1.63yd3) (54.3") (3040lb)
1.44m3 1.25m3 1380mm 1390kg

-
(1.88yd3) (1.63yd3) (54.3") (3060lb)
◈ : Heavy duty bucket

: Rock bucket
1-17
7. UNDERCARRIAGE
1) TRACKS
X-leg type center frame is integrally welded with reinforced box-section track frames. The design
includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock
absorbing springs and assembled track-type tractor shoes with triple grousers.
2) TYPES OF SHOES
Triple grouser
Model Shapes
Shoe width mm(in) 600(24) 700(28) 800(32) 900(36)

Operating weight kg(lb) 32200(71000) 32800(72300) 33200(73200) 33600(74100)
R320LC-7
Ground pressure kgf/cm (psi)2
0.62(8.82) 0.54(7.68) 0.48(6.83) 0.43(6.11)
Overall width mm(ft-in) 3280(10' 9") 3380(11' 1") 3480(11' 5") 3580(11' 9")
3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE
Item Quantity
Carrier rollers 2EA
Track rollers 9EA
Track shoes 48EA
4) 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, 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
600mm triple grouser Standard A

700mm triple grouser Option B
800mm triple grouser Option C
900mm triple grouser Option C
1-18
※ 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
normal soil
Normal soil, ・ These shoes cannot be used on rough ground with large obstacles such
soft ground 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 gound ・ 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 such
C 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
1-19
8. SPECIFICATIONS FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Cummins C8.3-C

Type 4-cycle turbocharged charger air cooled diesel engine
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder bore×stroke 114×135mm(4.49"×5.32")
Piston displacement 8300cc(505cu in)
Compression ratio 18 : 1
Rated gross horse power(SAE J1995) 259Hp at 1750rpm(193kW at 1750rpm)
Maximum torque 124.3kgf・m(899lbf・ft) at 1300rpm
Engine oil quantity 25.5ℓ(6.7U.S. gal)
Dry weight 588kg(1296lb)
High idling speed 1900+50rpm
Low idling speed 850±50rpm
Rated fuel consumption 158.8g/Hp・hr at 1750rpm
Starting motor Delco Remy 39MT(24V-7.2kW)
Alternator Delco Remy 24V-50A
Battery 2×12V×160Ah
2) MAIN PUMP
Item Specification
Type Variable displacement tandem axis piston pumps

Capacity 2×148.6cc/rev
Maximum pressure 330kgf/cm2 (4690psi)[360kgf/cm2 (5120psi)]
Rated oil flow 2×260ℓ/min (68.7U.S. gpm/ 57.2U.K. gpm)
Rated speed 1750rpm
[ ]: Power boost
1-20
3) GEAR PUMP
Item Specification
Type Fixed displacement gear pump single stage

Capacity 15cc/rev
Maximum pressure 35kgf/cm2(500psi)
Rated oil flow 27˶/min(7.1U.S. gpm/6.0U.K. gpm)
4) MAIN CONTROL VALVE

Item Specification
Type 9 spools
Operating method Hydraulic pilot system
Main relief valve pressure 330kgf/cm2(4690psi)[360kgf/cm2(5120psi)]
Overload relief valve pressure 390kgf/cm2(5550psi)
[ ]: Power boost
5) SWING MOTOR
Item Specification
Type Axial piston motor

Capacity 169.4cc/rev
Relief pressure 265kgf/cm2(3770psi)
Braking system Automatic, spring applied hydraulic released
Braking torque 70kgfÂm(505lbfÂft)
Brake release pressure 26kgf/cm2(370psi)
Reduction gear type 2 - stage planetary
Swing speed 9.1rpm
6) TRAVEL MOTOR
Item Specification
Type Variable displacement axial piston motor

Relief pressure 330kgf/cm2(4700psi)
Capacity(max / min) 279.1/160cc/rev
Reduction gear type 3-stage planetary
Braking system Automatic, spring applied hydraulic released
Brake release pressure 15.7kgf/cm2(225psi)
Braking torque 78.8kgfÂm(570lbfÂft)
1-21
7) REMOTE CONTROL VALVE
Item Specification
Type Pressure reducing type

Minimum 6.5kgf/cm2(92psi)
Operating pressure
Maximum 26kgf/cm2(370psi)
Lever 61mm(2.4in)
Single operation stroke
Pedal 123mm(4.84in)
8) CYLINDER
Item Specification
Bore dia×Rod dia×Stroke Ø150×Ø105×1480mm

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

700mm(28") 0.54kgf/cm2(7.68psi) 48 3380mm(11' 1")
R320LC-7
Option 800mm(32") 0.48kgf/cm2(6.83psi) 48 3480mm(11' 5")
900mm(36") 0.43kgf/cm2(6.11psi) 48 3580mm(11' 9")
1-22
10) BUCKET
Capacity Tooth Width
Item quantity Without side cutter With side cutter
PCSA heaped CECE heaped
Standard 1.44m3(1.88yd3) 1.25m3(1.63yd3) 5 1380mm(54.3") 1500mm(59.1")
0.9m3(1.18yd3) 0.8m3(1.05yd3) 3 950mm(37.4") 1070mm(42.2")
1.14m3(1.49yd3) 1.0m3(1.31yd3) 4 1140mm(44.9") 1260mm(49.6")
1.74m3(2.28yd3) 1.5m3(1.96yd3) 5 1610mm(63.4") 1730mm(68.1")
R320LC-7 Option
2.10m3(2.75yd3) 1.8m3(2.35yd3) 5 1900mm(74.8") 2020mm(79.5")
◈1.44m3(1.88yd3) 1.25m3(1.63yd3) 5 1380mm(54.3") -
1.44m3(1.88yd3) 1.25m3(1.63yd3) 5 1380mm(54.3") -
◈ : Heavy duty bucket
: Rock bucket(Esco type)
1-23
9. RECOMMENDED OILS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Ambient temperature °
C (°
F)
Capacity
Service point Kind of fluid ℓ(U.S. gal) -20 -10 0 10 20 30 40
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
Engine SAE 10W

Engine oil 25(6.6)
oil pan
SAE 10W-30
SAE 15W-40
Swing drive 7.0(1.9)

Gear oil SAE 85W-140
11.0×2
Final drive (2.9×2)
Tank; ISO VG 32
210(55.5)
Hydraulic tank Hydraulic oil ISO VG 46
System;
320(84.5) ISO VG 68
ASTM D975 NO.1

Fuel tank Diesel fuel 480(127)
ASTM D975 NO.2
NLGI NO.1
Fitting Grease As required
(Grease nipple)
NLGI NO.2
Mixture of
Radiator antifreeze
(Reservoir tank) 45(12) Ethylene glycol base permanent type
and water
50 : 50
SAE : Society of Automotive Engineers
API : American Petroleum Institute
ISO : International Organization for Standardization
NLGI : National Lubricating Grease Institute
ASTM : American Society of Testing and Material
1-24
SECTION 2 STRUCTURE AND FUNCTION
Group 1 Pump Device 2-1

Group 2 Main Control Valve 2-21
Group 3 Swing Device 2-47
Group 4 Travel Device 2-58
Group 5 RCV Lever 2-73
Group 6 RCV Pedal 2-80
SECTION 2 STRUCTURE AND FUNCTION
GROUP 1 PUMP DEVICE
1. STRUCTURE
The pump device consists of main pump, regulator and gear pump.
Port Port name Port size
A1,2 Delivery port SAE6000psi 1"

B1 Suction port SAE2500psi 3"
Dr Drain port PF 3/4 - 23
Pi1,i2 Pilot port PF 1/4 - 15
Pm1,m2 Qmax cut port PF 1/4 - 15
Psv Servo assist port PF 1/4 - 15
a1,2,4 Gauge port PF 1/4 - 15
a3 Gauge port PF 1/4 - 14
A3 Gear pump delivery port PF 1/2 - 19
32072ST02
B3 Gear pump suction port PF 3/4 - 20.5
dr3 Gear pump drain port PF 3/8
2-1
1) MAIN PUMP(1/2)
The main pump consists of two piston pumps(front & rear) and valve block.
32072ST03
04 Gear pump 261 Seal cover(F) 717 O-ring

111 Drive shaft(F) 271 Pump casing 719 O-ring
113 Drive shaft(R) 312 Valve block 724 O-ring
114 Spline coupling 313 Valve plate(R) 725 O-ring
123 Roller bearing 314 Valve plate(L) 728 O-ring
124 Needle bearing 401 Hexagon socket bolt 732 O-ring
127 Bearing spacer 406 Hexagon socket bolt 774 Oil seal
141 Cylinder block 435 Flange socket bolt 789 Back up ring
151 Piston 466 VP plug 792 Back up ring
152 Shoe 468 VP plug 808 Hexagon head nut
153 Push plate 490 VP plug 824 Snap ring
156 Bushing 531 Tilting pin 885 Pin
157 Cylinder spring 532 Servo piston 886 Spring pin
158 Spacer 534 Stopper(L) 901 Eye bolt
211 Shoe plate 535 Stopper(S) 953 Set screw
212 Swash plate 548 Pin 954 Set screw
214 Bushing 702 O-ring
251 Swash plate support 710 O-ring
2-2
MAIN PUMP(2/2)
544
543
079
545 725 325
541
466
725
490 407 725 732

B
VIEW A VIEW B
29072MP03
079 Proportional reducing valve 490 Plug 545 Steel ball

325 Casing assy 541 Seat 725 O-ring
407 Hexagon screw 543 Stopper 1 732 O-ring
466 Plug 544 Stopper 2
2-3
2) REGULATOR(1/2)
32072ST04
Port Port name port size
A Delivery port SAE6000psi 1"

B Suction port SAE2500psi 3"
Pi Pilot port PF 1/4-15
Pm Qmax cut port PF 1/4-15
2-4
REGULATOR(2/2)
655 734 653 654 836 651 652 601 624 629 630 628
641 801
925
814
898
631 627
732
C
733
732
622
621 623 625 626 887 763 756

SECTION A-A
29072RE02
412 Hexagon socket screw 631 Sleeve, pf 730 O-ring

413 Hexagon socket screw 641 Pilot cover 732 O-ring
436 Hexagon socket screw 642 Adjust screw(QMC) 733 O-ring
438 Hexagon socket screw 643 Pilot piston 734 O-ring
496 Plug 644 Spring seat(Q) 735 O-ring
601 Casing 645 Adjust stem(Q) 755 O-ring
611 Feed back lever 646 Pilot spring 756 O-ring
612 Lever(1) 647 Stopper 763 O-ring
613 Lever(2) 648 Piston(QMC) 801 Nut
614 Fulcrum plug 651 Sleeve 814 Snap ring
615 Adjust plug 652 Spool 836 Snap ring
621 Compensator piston 653 Spring seat 858 Snap ring
622 Piston case 654 Return spring 874 Spring pin
623 Compensator rod 655 Set spring 875 Pin
624 Spring seat(C) 656 Block cover 887 Pin
625 Outer spring 708 O-ring 897 Pin
626 Inner spring 722 O-ring 898 Pin
627 Adjust stem(C) 723 O-ring 924 Set screw
628 Adjust screw(C) 724 O-ring 925 Adjust screw(QI)
629 Cover(C) 725 O-ring
630 Lock nut 728 O-ring
2-5
3) GEAR PUMP
32072ST01
307 Poppet 353 Drive gear 466 Plug

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

The rotary group consists of drive shaft
(F)(111), cylinder block(141), piston
shoes(151,152), set plate(153), spherical 124
313
bush(156), spacer(158) and cylinder 141
spring(157). The drive shaft is supported 158
151 156
by bearing(123,124) at its both ends. 152 153
The shoe is caulked to the piston to from
111
a spherical coupling. It has a pocket to 157
relieve thrust force generated by loading 123
211
pressure and the take hydraulic balance
so that it slides lightly over the shoe
plate(211). The sub group composed by
a piston and a shoe is pressed against the
shoe plate by the action of the cylinder 2-7(1) 210-7
spring via a retainer and a spherical bush.

Similarly, the cylinder block is pressed
against valve plate(313) by the action of
the cylinder spring.
(2) Swash plate group
531
The swash plate group consists of swash 548
plate(212), shoe plate(211), swash plate 214
support(251), tilting bush(214), tilting
pin(531) and servo piston(532). 212
The swash plate is a cylindrical part 251
211
formed on the opposite side of the sliding
surface of the shoe and is supported by
the swash support.
If the servo piston moves to the right and
left as hydraulic force controlled by the 532 α
regulator is admitted to hydraulic chamber
located on both sides of the servo piston,
the swash plate slides over the swash α
plate support via the spherical part of the
tilting pin to change the tilting angle(α)
2-7 (210-7)
2-7
(3) Valve block group
The valve block group consists of valve
block(312), valve plate(313) and valve
plate pin(885).
The valve plate having two melon-shaped
ports is fixed to the valve block and feeds 312
and collects oil to and from the cylinder
block. 313
The oil changed over by the valve plate is 885
connected to an external pipeline by way
of the valve block.
Now, if the drive shaft is driven by a prime
mover(electric motor, engine, etc), it 2-8 (210-7)
rotates the cylinder block via a spline

linkage at the same time. If the swash
plate is tilted as in Fig(previous page) the
pistons arranged in the cylinder block
make a reciprocating motion with respect
to the cylinder block, while they revolve
with the cylinder block.
If you pay attention to a single piston, it
performs a motion away from the valve
plate(oil sucking process) within 180
degrees, and makes a motion towards the
valve plate(or oil discharging process) in
the rest of 180 degrees. When the
swash plate has a tilting angle of zero, the
piston makes no stroke and discharges
no oil.
2-8
2) REGULATOR
Regulator consists of the negative flow control, total horse power control and power shift control
function.
(1) Negative flow control

By changing the pilot pressure Pi, the
pump tilting angle(delivery flow) is
regulated arbitrarily, as shown in the
figure.
This regulator is of the negative flow
Delivery flow, Q
control in which the delivery flow Q
decreases as the pilot pressure Pi rises.
With this mechanism, when the pilot
pressure corresponding to the flow
required for the work is commanded, the
pump discharges the required flow only, Pilot pressure, Pi
and so it does not consume the power
uselessly.
2-9
① Flow reducing function
643 654 651 652 613 646
P1 CL
B(E)
874
897
C
A
875
611
Servo piston Small diameter

Large diameter D chamber
chamber 548
531
2-10 (210-7)
As the pilot pressure Pi rises, the pilot piston(643) moves to the right to a position where the force of
the pilot spring(646) balances with the hydraulic force.
The groove(A) in the pilot piston is fitted with the pin(875) that is fixed to lever 2(613). Therefore,
when the pilot piston moves, lever 2 rotates around the fulcrum of point B [Fixed by the fulcrum
plug(614) and pin(875)]. Since the large hole section(C) of lever 2 contains a protruding pin(897)
fixed to the feedback lever(611), the pin(897) moves to the right as lever 2 rotates. Since the
opposing-flat section(D) of the feedback lever is fitted with the pin(548) fixed by the tilting pin(531)
that swings the swash plate, the feedback lever rotates around the fulcrum of point D, as the
pin(897) moves.
Since the feedback lever is connected with the spool(652) via the pin(874), the spool moves to the
right.
The movement of the spool causes the delivery pressure P1 to connect to port CL through the
spool and to be admitted to the large diameter section of the servo piston. The delivery pressure
P1 that is constantly admitted to the small diameter section of the servo piston moves the servo
piston to the right due to the area difference, resulting in decrease of the tilting angle.
When the servo piston moves to the right, point D also moves to the right. The spool is fitted with
the return spring(654) and is tensioned to the left at all times, and so the pin(897) is pressed against
the large hole section(C) of lever 2.
Therefore, as point D moves, the feedback lever rotates around the fulcrum of point C, and the
spool is shifted to the left. This causes the opening between the sleeve(651) and spool(652) to
close slowly, and the servo piston comes to a complete stop when it closes completely.
2-10
② Flow increasing function
643 654 651 652 613 646
P1 CL
B(E)
874
897
C
875
611
Small diameter
Servo piston D chamber
Large diameter 548
chamber
531
2-11 (210-7)
As the pilot pressure Pi decreases, the pilot piston(643) moves to the left by the action of the pilot
spring(646) and causes lever 2(613) to rotate around the fulcrum of point B. Since the pin(897) is
pressed against the large hole section(C) of lever 2 by the action of the return spring(654) via the
spool(652), pin(874), and feedback lever(611), the feedback lever rotates around the fulcrum of
point D as lever 2 rotates, and shifts the spool to the left. Port CL opens a way to the tank port as
the spool moves. This deprives the large diameter section of the servo piston of pressure, and
shifts the servo piston to the left by the discharge pressure P1 in the small diameter section,
resulting in an increase in the flow rate.
As the servo piston moves, point D also moves to the left, the feedback lever rotates around the
fulcrum of point C, and the spool moves to the right till the opening between the spool and sleeve is
closed.
2-11
③ Adjustment of flow control characteristic
The flow control characteristic can be
adjusted with the adjusting screw.
Adjust it by loosening the hexagon nut 801
(801) and by tightening(or loosening) the 924
hexagonal socket head screw(924).
Tightening the screw shifts the control
chart to the right as shown in the figure.
※ Adjusting values are shown in table.
Adjustment of flow control
2-12 (210-7)
characteristic
Speed
Tightening Flow control Flow
amount of starting change
adjusting pressure amount
screw(924) change
Delivery flow, Q
amount
(min -1) (Turn) (kgf/cm2) (ℓ/min)

1750 +1/4 +1.7 +19
Pilot pressure, Pi
2-12
(2) Total horsepower control
The regulator decreases the pump tilting
angle(delivery flow) automatically to limit
the input torque within a certain value with
Delivery flow, Q
a rise in the delivery pressure P1 of the
self pump and the delivery pressure P2 of
the companion pump.
(The input horsepower is constant when
the speed is constant.)
Since the regulator is of the simultaneous
Delivery pressure, (P1+P2)
total horsepower type that operates by the
sum of load pressures of the two pumps
in the tandem double-pump system, the
prime mover is automatically prevented
from being overloaded, irrespective of the
load condition of the two pumps, when
horsepower control is under way.
Since this regulator is of the simultaneous
total horsepower type, it controls the tilting
angles(displacement volumes) of the two
pumps to the same value as represented
by the following equation :
Tin = P1×q/2Л + P2×q/2Л
= (P1+P2)×q/2Л
The horsepower control function is the
same as the flow control function and is
summarized in the following.(For detailed
behaviors of respective parts, refer to the
section of flow control).
2-13
① Overload preventive function
621 651 652 623 612 601 625 626
P1 CL
B(E)
897
P2 P1
875
611
Large diameter Servo piston

chamber Small diameter
D chamber
2-14 (210-7)
When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, it
acts on the stepped part of the compensating piston(621). It presses the compensating rod(623)
to the right till the force of the outer spring(625) and inner spring(626) balances with the hydraulic
force. The movement of the compensating rod is transmitted to lever 1(612) via pin(875).
Lever 1 rotates around the pin(875) (E) fixed to the casing(601).
Since the large hole section(F) of lever 1 contains a protruding pin(897) fixed to the feedback
lever(611), the feedback lever rotates around the fulcrum of point D as lever 1 rotates, and then the
spool(652) is shifted to the right. As the spool moves, the delivery pressure P1 is admitted to the
large diameter section of the servo piston via port CL, causes the servo piston move to the right,
reduces the pump delivery, flow rate, and prevents the prime mover from being overloaded.
The movement of the servo piston is transmitted to the feedback lever via point D. Then the
feedback lever rotates around the fulcrum of point F and the spool is shifted to the left. The spool
moves till the opening between the spool(652) and sleeve(651) is closed.
2-14
② Flow reset function
621 651 652 623 612 625 626
P1 CL
B(E)
897
P2 P1
875
Large diameter Small diameter

chamber Servo piston D chamber
2-15 (210-7)
As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases, the
compensating rod(623) is pushed back by the action of the springs(625 & 626) to rotate lever
1(612) around point E. Rotating of lever 1 causes the feedback lever(611) to rotate around the
fulcrum of point D and then the spool(652) to move to the left. As a result, port CL opens a way to
the tank port.
This causes the servo piston to move to the left and the pump's delivery rate to increase.
The movement of the servo piston is transmitted to the spool by the action of the feedback
mechanism to move it till the opening between the spool and sleeve is closed.
2-15
③ Low tilting angle(low flow) command preferential function
As mentioned above, flow control and horsepower control tilting angle commands are
transmitted to the feedback lever and spool via the large-hole sections(C & F) of levers 1 and 2.
However, since sections C and F have the pins(Ø4) protruding from the large hole(Ø8), only the
lever lessening the tilting angle contacts the pin(897) ; the hole(Ø8) in the lever of a larger tilting
angle command is freed without contacting the pin(897). Such a mechanical selection method
permits preference of the lower tilting angle command of the flow control and horsepower control.
④ Adjustment of input horsepower
Since the regulator is of total cumulative horsepower type, adjust the adjusting screws of both the
front and rear pumps, when changing the horsepower set values. The pressure change values
by adjustment are based on two pumps pressurized at the same time, and the values will be
doubled when only one pump is loaded.
a. Adjustment of outer spring 625 626 630 628

Adjust it by loosening the hexagon
nut(630) and by tightening(or loosening)
the adjusting screw C(628). Tightening 801
the screw shifts the control chart to the
925
right and increases the input
horsepower as shown in the figure.
Since turning the adjusting screw C by
N turns changes the setting of the inner
spring(626), return the adjusting screw
QI(925) by N×A turns at first.(A=2.2)
※ Adjusting values are shown in table. 2-16 (210-7)
Adjustment of outer spring

Speed
Tightening Compens- Input torque
Delivery flow, Q
amount of ating control change

adjusting starting amount
screw(C) pressure
(925) change
amount
(min -1) (Turn) (kgf/cm2) (kgf・m)
1750 +1/4 +19 +8

2-16
b. Adjustment of inner spring 626
Adjust it by loosening the hexagon nut
(801) and by tightening(or loosening) the
adjusting screw QI(925). Tightening the
801
screw increases the flow and then the
input horsepower as shown in the figure.
925
※ Adjusting valves are shown in table.
Adjustment of inner spring

Speed
Tightening Flow change Input torque
amount of amount change
adjusting amount
screw(QI)
(925)
Delivery flow, Q
(min -1) (Turn) (lpm) (kgf・m)
1750 +1/4 +14 +7
2-17
(3) Power shift control
621 651 652 623 612 625 626
898 P1 CL
B(E)
897
Pf
P2 P1
875
611
Large diameter Small diameter

chamber Servo piston D chamber
2-18 (210-7)
The set horsepower valve is shifted by

varying the command current level of the
proportional pressure reducing valve
Delivery flow, Q
attached to the pump.

Only one proportional pressure reducing Pf=
valve is provided. MIN
Pf= .
However, the secondary pressure Pf (power MA
X.
shift pressure) is admitted to the
horsepower control section of each pump
regulator through the pump's internal path to Delivery pressure, (P1+P2)
shift it to the same set horsepower level.
This function permits arbitrary setting of the pump output power, thereby providing the optimum
power level according to the operating condition.
The power shift pressure Pf controls the set horsepower of the pump to a desired level, as shown in
the figure.
As the power shift pressure Pf rises, the compensating rod(623) moves to the right via the pin(898)
and compensating piston(621).
This decreases the pump tilting angle and then the set horsepower in the same way as explained in
the overload preventive function of the horsepower control. On the contrary, the set horsepower
rises as the power shift pressure Pf falls.
2-18
(4) Adjustment of maximum and minimum flows
808
Η Adjustment of maximum flow
Adjust it by loosening the hexagon 954
the set screw(954).
The maximum flow only is adjusted
without changing other control
characteristics. 2-19(1) 210-7
Adjustment of max flow

Speed
Delivery flow, Q
Tightening Flow change
amount of amount
adjusting screw
(954)
(min -1) (Turn) (˶/min)
1750 +1/4 -7 Delivery pressure, Pi
Θ Adjustment of minimum flow

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

Delivery flow, Q
Speed
Tightening Flow change
amount of amount
adjusting screw
(953)
(min -1) (Turn) (˶/min)

Delivery pressure, Pi
1750 +1/4 +7
2-19
(5) Qmax cut control
The regulator regulates the 647
maximum delivery flow by 648
inputting the pilot pressure 723
Pm. Since this is a 2-position
642 438
control method, the maximum
delivery flow may be switched
801
in two steps by turning on/off
801
the pilot pressure Pm.(The 924
maximum control flow cannot
be controlled in intermediate 641 730 643 708 644 645 646 728
level.)
① Functional explanation
As shown in the figure, the pilot pressure
Pm switches the maximum flow in two
steps.
When the pilot pressure Pm is given, it is
admitted to the lefthand side of the piston
Delivery flow, Q
Pm
QMC(648). The piston QMC moves the
stopper(647) and pilot piston(643) to the
right, overcoming the force of the pilot
spring(646), thereby reducing the
delivery flow of the pump.
Since the adjusting screw QMC(642) is Pilot pressure, Pi
provided with a flange, the piston QMC
stops upon contact with the flange, and
the position of the pilot piston at this time
determines the maximum flow of the
pump.
Delivery flow, Q
② Adjustment of Qmax cut flow

the adjusting screw QMC(642).
Tightening the screw decreases the
Pilot pressure, Pi
Qmax cut flow as shown in the figure.
2-20
GROUP 2 MAIN CONTROL VALVE
1. STRUCTURE
Ck1
(PSP) Mark Port name Port size Tightening torque
20~25kgf・m
R1 Make up port for swing PF 1 (115~180lbf・ft)
XAa1
XBtl XBp2
Ck1 Bucket in confluence port 15~18kgf・m
XBs
Ck2 Bucket in confluence port PF 3/4 (109~130lbf・ft)
Py
PH
P1 XAtr Travel right pilot port
Dr1
SP XBtr Travel right pilot port
Btl Bs HEAD
XAo Option pilot port
Aa1 Ck1
CSP FL XBo Option pilot port
CMR2 XAk Bucket out pilot port
Pns
Dr6
LCa1 P2
XBk Bucket in pilot port
FR R2
Atl As ROD XAb1 Boom up pilot port
CMR1 XBb1 Boom down pilot port
Ba1
CCb HV Dr3
XAa2 Arm in confluence pilot port
Pz
PaL XBa2 Arm out confluence pilot port 7~8kgf・m
Dr2 PF 3/8
XAtl Travel left pilot port (50.6~57.8lbf・ft)
XBtl Travel left pilot port
Ck2
Dr4 XAs Swing pilot port
SWING BOOM2 ARM1
R1
TRAVEL
(L)
XBs Swing pilot port
XAa1 Arm in pilot port
XAtl XBp1
VIEW A XBa1 Arm out pilot port
XAs XBa1
XAb2
XAb2 Boom up confluence pilot port
Ck1 Ck1 (Psp) (Swing priority pilot port)
Pns Dr6
(XBp1) (Bucket in confluence pilot port)
PaL Dr3 (XBp2) (Drain port)
Dr3 Dr2
FR FL Pz Main relief pilot pressure
PG MR Py Signal port for travel
NR1 PG Pilot pressure port
Px PH Pilot pressure port
R1 Px Signal for other acutuators
P1
TS Dr1 Drain port
TL S B2 A1 BC BC Dr2 Drain port
A TR OP B1 BK A2
A1 SP(B2) S TL
Dr3 Drain port 3.5~3.9kgf・m
A2 BK B1 OP TR
Dr4 Drain port PF 1/4 (25.3~28.2lbf・ft)
R2(P2)
Dr6 Drain port
FL Negative control signal port(P1 port side)
FR Negative control signal port(P2 port side)
PBP
Pns Swing logic valve pilot port
PaL Lock valve pilot port
Dr4
PbL Lock valve pilot port
PbL
Ck2 PBP Drain port
Ck2
Atr Travel motor right side port
XAtr XAo XAb1 XBk XBa2 Btr Travel motor right side port
(Ao) Option port
(Bo) Option port
TRAVEL OPTION BOOM1 BUCKET ARM2
(R) Ak1 Bucket rod side port
Bk1 Bucket head side port
Ab1 Boom head side port
Dr4 PbL Bb1 Boom rod side port M10 5~6.6kgf・m
Atl Travel motor left side port (36.1~47.7lbf・ft)
Atr HEAD HEAD Btl Travel motor left side port
(Ao)
C1 Ab1 Bk1 As Swing motor port
Bs Swing motor port
LCb1
LCa2
LCo
LCk
Aa1 Arm head side port

C2
CP2
Btr ROD
Ba1 Arm rod side port
ROD
(Bo) P1 Pump port(P1 side)
Bb1 Ak1 PBP
P2 Pump port(P2 side)
29072MC01
8.5~11.5kgf・m
R2 Return port M12 (61.5~83.1lbf・ft)
XBtr XBo XAa2
XBb1 XAk
2-21
A
B P1 103 P1 154 164 974
975
PG 158
P2
L R2
TS
H Pz H K
STRAIGHT K
MR
TS
I TRAVEL
R2(P2) Px
I
R1 XBtr XAtr TR
391
159 TRAVEL(R)
L
TR
TL XAtl XBtl XBo XAo
OP
TL
TRAVEL(L) OPTION
C Pns C
Dr4
OP
S XAs XBs B1
SP XBb1 XAb1
S Dr6 SWING BOOM 1
D D SWING PRIORITY
M N
B1 159
B2 XAb2 (PSP) BK
XAk XBk
B2 PaL BOOM 2 BUCKET
E PbL E
BK
159
A1
A1 XBa1 XAa1 975 XBa2 XAa2
A2
ARM 1 ARM 2
F F
K1
NR2
A2 BC
(XBp1) (XBp2)
Dr3 102 976
G G
Dr2
A M N
104
J J 101 153 561
B 159 273
SECTION A-A SECTION B-B
101 Casing A 301 Travel spool 379 Spring

102 Casing B 302 Arm 1 spool assy 391 Straight travel spool
CS1 CS2 PG
357 103 Straight travel valve 303 Boom 1 spool assy 392 Bypass cut spool
104 Boom priority valve 304 Bucket spool 395 Swing priority spool
NZx
153 Plug 305 Swing spool 401 Spool
154 Plug 306 Arm 2 spool 424 Spring
NZy 155 Plug 307 Boom 2 spool 425 Spring
156 Plug 309 Spool(Option) 438 Rod
Ab1
CCb
Bb1 158 Plug 310 Travel spool 511 Poppet
357 B2
B1 B1 B2 159 Plug 324 Spring 513 Poppet
SECTION H-H
HV 163 O-ring 325 Spring 515 Poppet
Bk1 Ak1 Aa1 164 O-ring 328 Spring 516 Poppet
BK BK
Pz CMR1 CMR2
A1
Ba1 A1 165 O-ring 329 Spring 521 Spring
166 O-ring 331 Spring seat 522 Spring
A2 BC 167 O-ring 332 Spring seat 523 Spring
MR A2 BC 168 O-ring 333 Bolt 551 Plug
338
169 O-ring 334 Stopper 552 Plug
153 561
601 TS
J1 201 Cover 335 Stopper 553 Plug
SECTION M-M SECTION N-N 202 Cover 336 Bolt 554 Plug
203 Cover 337 Stopper 555 Check valve assembly
324 325 204 Cover 338 Stopper 556 Plug
391 209 Flange 339 Stopper 561 O-ring
251 Control valve assy 357 Orifice 601 Main relief valve
SECTION I-I 252 Lock valve assy 370 Spring 602 Port relief valve
254 Swing logic valve assy 372 Spring 611 Nega-con relief valve
261 O-ring 374 Spring 971 Socket screw
29072MC07 262 O-ring 376 Spring 974 Socket screw
264 O-ring 377 Spring 975 Socket screw
273 Socket screw 378 Spring 976 Socket screw
2-22
201
201 379 336
203 203 332 556 XAb2
203 370 XAb1 164 201
333 XAs 336 332 335
333 XAtr XAtl 333 XAo 336
331 332 261
331 331 159 332
334 335 339
334 334 602
329 379 372
329 329 370 159
328 Ab1R 374
328 328 159 332 332
331 331 252 B2
331 261
262 262 261 307
262 166 553 159
AoR 165
168 561 166 165 561
165 552
971 166 CCb 551
165 523 Ab1
165 561 521
As 165 516 511
Atl 209 (Ao)
Atr 165 511 254 165 LCb 561
515 521 CSP 551
164 521 551
521 LCo Pns 561 521
154 SP
551 511 Bb 511
561 303 551
551 251 165
971 Bs
165 561
561 165 (Bo) 264 B1 SP 395
Btr 209 305
Btl 261
309 264 602 332
310 XBb1
561 204 204 370
165 OP S Bb1R
301 553 BoR 376
TR TL 169 339
169 202 169 XBo XBs
166 332
202 336
202 XBtr XBtl
(PSP) 201
164 164
SECTION C-C SECTION D-D SECTION E-E 154 556
201
332 XBk XBa1 201 203 424
201
336 332 336 XBa2 333 425 K1
XBp1
335 336 332 438
331
370 335 335
379 379 372 337
370 378
P P
332 Ba1R 374
261 BkR 332 377
332
261 331
602 261
262 401
602 166
166 392
Dr2
252
516 165 NR2
551 SECTION J-J SECTION P-P
513 523 561
Bk1 552
522 HV 611
561
561 511 165
521 551 561 521 511 551
555 L1
Ck2 LCa1 FR CP2
551 LCa2 C2 C2 561
Ck1 C1
554 Ak1 561 155 521
551
304 Aa1 FL 511
561 611 167
302 551 P2
CP2
264 561 P2
BK A1 306
204
602 264 602 165 A2 BC NR1 551 561 521 511 P2
XAk XAa1
204 169
AkR Aa1R 264 L1
XAa2 XBp2 202
204
SECTION K-K SECTION L-L SECTION L 1 -L 1
SECTION F-F SECTION G-G 29072MC14
2-23
2. HYDRAULIC CIRCUIT
BP
PBP
Ck1
XBp1
PaL Fl Fr XBp2 Dr2
NR1 NR2
HV
Dr1 BC1 BC2

AaR
(HEAD)
Aa1
ARM 1 XAa1
Ba1
XBa2
(ROD) BaR ARM 2
XBa1 XAa2
LCa1
AkR (ROD)
Ak1
XAk
Bk1
CCb BkR (HEAD)
XBk BUCKET
LCk
XAb2 XBp1
BOOM 2 Dr4
Csp PbL
(PSP)
SP HV
Pns (HEAD)
As AbR
XBS Ab1
Bs XAb1
Bb1
SWING BbR (ROD) BOOM 1
XAs XBb1
LCb1
LCs
Dr6
Atl AoR
XBtl (Ao)
Btl XAo
(Bo)
TRAVEL(L) BoR OPTION
XAtl XBo
LCo
C1 C2
Atr
XAtr
Btr
TRAVEL(R)
XBtr
CP2
R1
P2 R2
0.7
STRAIGHT PH
TRAVEL TS
Px
BLOCK
MR
CMR1 CMR2
0.7
0.7
Pz P1 PG Py
29072MC24
2-24
3. FUNCTION
1) CONTROL IN NEUTRAL POSITION
103 P1
TS
STRAIGHT
TRAVEL
21
TL XAtl XBtl
TRAVEL(L)
22
S XAs XBs
SWING
B2 XAb2 (PSP)
BOOM 2
A1 XBa1 XAa1
ARM 1 13
XBp1 (XBp2)
101 4 29072MC25
SECTION A-A
P2 R2
XBtr XAtr TR
TRAVEL(R)
XBo XAo
OP
OPTION
6
XBb1 XAb1 B1
BOOM 1
18
XAk XBk BK
BUCKET
XBa2 XAa2 A2
ARM 2
K1
4
102
29072MC26
SECTION B-B
2-25
XAa2 (XBp1)
4
Dr2
NR2 4
611
FR
LCa2
(Ck1)
FL 611
A2 BC NR1
13
13
XBa2 (XBp2)
29072MC27
SECTION G-G
A
B P1
PG
H PZ H
TS MR
R2(P2) Px
R1
TR TL
C Dr4 Pns C
OP
S
Dr6
D D
B1
B2
PaL
E PbL E
BK
A1
F NR2 F
BC
A2
Dr3
G G
Dr2
A
J J
B
29072MC28
2-26
The hydraulic fluid from the pump P1 flows into casing A(101) through the inlet port(P1), through the
center bypass(21) and the parallel path(22). The hydraulic fluid from the pump P2 flows into casing
B(102) through the inlet port(P2) through the center bypass(18) and the parallel path(6).
The hydraulic fluid from the pump P1 is directed to the tank through the center bypass(21), negative
control orifice(NR1), the return path(13) and the return port(R2). The hydraulic fluid from the pump
P2 also flows to the tank through the center bypass(18), negative control orifice(NR2), return path
(4) and return port(R2). The hydraulic fluid in paths (6) and (22) is blocked and cannot return to the
tank.
In case a control lever is operated, the hydraulic fluid from the pump P2 is supplied to the travel right
spool(301) from path(18) and to the spools: option(309), boom1(303), bucket(304) and arm2(306)
from path(6). Additionally, the hydraulic fluid from the pump P1 is supplied to the travel left spool
(310) from path(7) while the swing(305), boom2(307) and arm(302) spools are supplied from
path(22).
2-27
2) NEGATIVE CONTROL
(1) General operation
303 18 21 3 4 5
10
7
9
611
P2 P1 611
Fl Fr
19 6 27 28 22 13
29072MC29
The negative control signal pressure from the center bypass(18, 21) occurs in the following cases
and controls the discharge of the pump.
1. Neutral condition when no function is being actuated.
2. The pilot control lever is partially operated.
The hydraulic fluid of the pump P1(28) flows into the return passage(13) through the center bypass
(21), the path(3) and orifice(9)(Within the poppet(15)). The restriction caused by this orifice thereby
pressurizes path(3). This pressure is transferred as the negative control signal pressure Fl to the
pump P1 regulator through the negative control line(4). It controls the pump regulator so as to
decrease the discharge of the pump P1(28).
2-28
21
Fl
15
611
16
BC NR1
101
13
(XBp2)
29072MC30
Q Fl
Qmax
Fl1
Qmin
Fl QN
Fl1
29072MC31
The negative control relief valve(611) consists of poppet(15), spring(16) and casing(101). When the
hydraulic fluid in the center bypass increases to the level that the pressure in the path(3) reaches
the set pressure of the spring(16), the hydraulic fluid in the path(3) pushes open the poppet (15)
and escapes into the return path(13).
In the unloaded state, the hydraulic fluid of the pump P1(28) entirely flows to the tank through the
path(21), orifice(9) and the return path(13). Therefore the pressure Fl in the path(3) becomes
maximum(Fl1) because all the discharge is reduced by the orifice(9) which in turn destrokes the
pump P1(28) so as to minimize the tilting angle and consequent discharge of the pump P1(28).
(Qmin)
2-29
(2) Negative control(With fine metering)
303 511 370 379
4 6 LCb1 Ab1
Bb1
Ab1R
Bb1R
XBb1 XAb1
B1
18 19
29072MC32
In the case, for example, when the pilot control lever for main boom is slightly operated, the pilot
pressure XAb1 shifts the main boom spool(303) partially in the left direction. So the path(19) is
partially opened and the center bypass(18) is shut slightly. The hydraulic fluid thereby separates.
One part flows via the orifice(7) through the path(18) and the other portion flows into the parallel
path(6), the path(19) and the port Ab1. The flow from the path(18) through the orifice(7) decreases
slightly and the pressure Fr in the path(10) thereby also slightly decreases. As the pressure Fr
becomes lower, the discharge of the pump P2(27) increases. With the pilot control lever shifted
even more the path(18) is shut off by the shifting of the spool(303) and then the flow through the
bypass becomes zero. The pressure in the path(10) becomes zero and the discharge of the pump
P2(27) becomes maximum.(Qmax)
Because the discharge of the pump is adjusted by operating the pilot control lever slightly, the
precise moving of the actuator is realized.
For the pump P1(28) the same negative control principle of operation occurs utilizing the orifice(9).
2-30
3) EACH SPOOL OPERATION
(1) Boom control
① Boom up operation
511 516 8
303
LCb1 Ab1 18 370 379
Bb1
Bb1R Ab1R
XBb1 XAb1
6 B1
B2 4
13 SP
(PSP)
XAb2
SP CSP CCb
376 370 511 21 511 307 374 372 29072MC33
The main boom up operation becomes fast because the hydraulic fluid from the pump P2 that is
directed to the port P2 is combined in the casing that of the pump P1 which enters port P1. The
confluence flow is supplied to the head side of the boom cylinder. In low speed operation, only the
boom1 spool(303) operates and is supplied with hydraulic fluid from the pump P2.
The hydraulic fluid from the pump P2 flows into the boom1 spool(303) through port P2 and parallel
path(6). The hydraulic fluid from the pump P1 flows to the boom2 spool(307) through pump port P1
and the parallel path(22).
During the boom up operation, the pilot pressure from the pilot control valve is supplied into the port
XAb1 and shifts the boom1 spool(303) in the left direction against the springs (370) and (370). The
hydraulic fluid from the pump P2 enters the parallel path(6) and then passes through the load check
valve LCb1(511) and boom1 spool(303) and check valve HV(516) then flows into the port Ab1.
Following this it flows into the head side of the boom cylinder.
At the same time, the pilot pressure through the port XAb2 shifts the boom2 spool(307) in the left
direction against the springs (374) and (372). The hydraulic fluid from the pump P1 enters via the
parallel path(22) and center bypass(21), then passes through the load check valve CSP(511),
boom2 spool(307) and the load check valve CCb(511). Then flows combine in path(8) and are
directed to port Ab1 and the head side of the boom cylinder.
The flow from the rod side of the boom cylinder returns to the boom1 spool(303) through the port
Bb1. Thereafter it is directed to the return port R2 through path(13).
2-31
② Boom down operation
303 511 516 45 370 379
LCb1 Ab1
Bb1
Bb1R Ab1R
XBb1 XAb1
6 B1
B2 4
13 SP
(PSP)
XAb2
SP CSP CCb
376 370 374 372

511 511 307
29072MC34
During the boom down operation, the pilot pressure from the pilot control valve is supplied to port
XBb1 and PbL and shifts the boom1 spool(303) in the right direction against the springs (370) and
(379).
The hydraulic fluid from the pump P2 enters the parallel path(6) and is directed to the port Bb1
through the load check valve LCb1(511). Following this is flows into the rod side of the boom
cylinder.
The return flow from the head side of the boom cylinder returns to the boom1 spool(303) through
the port Ab1. Thereafter it is directed to the return port R2 through path(4).
Additionally, the return flow is restricted in path(45), which lowers the boom cylinder at a suitable
speed.
2-32
(2) Arm control
① Arm roll out operation
306 374 372
LCa2
XAa2 XBa2
A2
A1
XAa1 XBa1
Aa1R
Ba1R
13 Aa1
LCa1 HV Ba1
22
302 511 516 370 379
29072MC35
During the arm roll out operation, the pilot pressure from the pilot control valve is supplied to the
pilot ports(XBa1& XBa2) and shifts the arm1 spool(302) in the left direction against the springs
(370) and (379) and shifts the arm2 spool(306) in the left direction against the springs (374) and
(372). The hydraulic fluid from the pump P1 flows through the load check valve LCa1(511), lock
valve HV(516), and then through parallel path(22). It is then directed to the rod side of the arm
cylinder through the port Ba1.
At the same time, the pilot pressure through the port XBa2 shifts the arm2 spool(306) in the left
direction against the springs (374) and (372). The hydraulic fluid from the pump P2 enters via the
parallel path(22) and center bypass(21), then passes through the check valve of the boom priority
valve(104), arm2 spool(306). The flows are combined and directed to port Ba1 and the rod side of
the arm cylinder. The flow from the head side of the arm cylinder returns to the arm1 spool(302)
through the port Aa1. Thereafter it is directed to the return port R2 through path(13).
2-33
② Arm roll in operation
・During light load only
306 374 372
LCa2
XAa2 XBa2
A2
(c) (a)
A1
XAa1 XBa1
Aa1R
Ba1R
13 Aa1
LCa1 HV Ba1
22
302 511 516 370 379
29072MC36
2-34
・ The pressure in the arm cylinder head side increases
306 374 372
LCa2
XAa2 XBa2
A2
(d) (e) (f) (a) (b)

A1
XAa1 XBa1
Aa1r
Ba1R
13 Aa1
LCa1 HV Ba1
22
302 511 516 370 379
29072MC37
2-35
During the arm roll in operation, the pilot pressure from the pilot control valve is supplied to the
ports XAa1, XAa2 and PaL and shifts the arm1 spool(302) in the right direction against the
springs (370) and (379) and shifts the arm2 spool(306) in the right direction against the springs
(384) and (372).
During the arm roll in operation, the hydraulic fluid from the pump P1 flows into the arm1
spool(302) through the parallel path(22). Then it enters into the head side of the arm cylinder
through the load check valve LCa1(511), check valve HV(516) and port Aa1.
At the same time, the hydraulic fluid from the pump P2 flows into the arm2 spool(306) through
the parallel path(22). Then it enters into the head side of the arm cylinder through the check
valve of boom priority valve(104) and port Aa1.
The return flow from the rod side of the arm cylinder is pressurized by self-weight of arms and so
on, and returns to port Ba1. The pressurized oil returning to port Ba1 enters into the arm1 spool
through the outside of the arm1 spool. During a light load only, it pushes open the sleeve check
valve, flows the parallel path reversely from spool hole(c), and joints into port Aa1. This is called
the arm regeneration function.
When the pressure in the arm cylinder head side increases, the piston(d) and sub spool(e) are
transferred in the right direction, and at the same time the sleeve check valve(f) is from the arm
cylinder rod side enters flow port Ba1 through the periphery hole(a) of the arm1 spool into the
spool, flows out through the periphery hole(b) of the spool, and returns through the tank port R2
to the hydraulic oil tank.
2-36
(3) Bucket control
① Bucket roll in operation
379 370
511
LCk
Ak1 Bk1
AkR BkR
XAk XBk
BK
13 304 6 4
29072MC38
During the bucket roll in operation, the pilot pressure from the pilot control valve is supplied to port
XBk and shifts the bucket spool(304) in the left direction against the springs (370) and (379).
The hydraulic fluid from the pump P2 enters the parallel path(6) and is directed to the port Bk1
through the load check valve LCk(511). Following this it flows into the head side of the bucket
cylinder.
The retutn flow from the rod side of the bucket cylinder returns to the bucket spool(304) through the
port Ak1. Thereafter it is directed to the return port R2 through path(13).
2-37
② Bucket confluence operation
BC
XBp2 XBp1
Dr2
NR1 NR2
Fl Fr
392 377 378
Ck1
Ck2
29072MC40
During the bucket roll in operation, the pilot pressure from the pilot control valve is supplied to port
XBp1 and shifts the bypass cut spool(392) in the left direction against the springs(392) in the left
direction against the springs (377) and (378).
The hydraulic fluid from the pump P1 enters the center bypass path(21).
But bypass path is shut off by the bypass cut spool. Therefore the hydraulic fluid is directed to port
Ck2 after passing through the check valve Ck1.
Then the fluid is directed to the bucket spool(304).
2-38
③ Bucket out operation
379 370
511
LCk
Ak1 Bk1
AkR BkR
XAk XBk
BK
13 304 6 4
29072MC39
During the bucket roll out operation, the pilot pressure from the pilot control valve is supplied to port
XAk and shifts the bucket spool(304) in the right directed agains the springs (370) and (370).
The hydraulic fluid from the pump P2 enters the parallel path(6) and is directed to the port AK1
through the load check valve LCk(511). Following this it flows into the rod side of the bucket
cylinder.
The return flow from the head side of the bucket cylinder returns to the bucket spool(304) through
the port Bk1. Thereafter it is directed to the return port R2 through path(4).
2-39
(4) Swing control
XBs XAs
22
13
4
Bs As
305 251 254 370 379

Pns
29072MC41
During the swing right or left operation, only the hydraulic fluid of the pump P1 is supplied to the
swing motor.
The pilot pressure from the pilot control valve is supplied to the port XAs and shifts the swing spool
(305) in the left direction against springs (370) and (379). Hydraulic fluid from the pump P1 flows
into the swing spool(305) through the parallel path(22). Then it is directed to the swing motor
through the check valve LCs(254) and the port As. As a result, the swing motor turns and the
return flow from the swing motor enters port Bs. The flow from the motor returns to the tank port R2
through the swing spool(305) and path(13). In the case of the opposite operation, the operation is
similar.
2-40
(5) Travel control
301 328 329
Btr Atr
XBtr XAtr
TR
TL
XBtl XAtl
Btl Atl
310 328 329
29072MC42
During the travel operation, the hydraulic fluid of the pump P1 is supplied to the travel motor and the
hydraulic fluid of the pump P2 is supplied to the other travel motor.
The pilot pressure from the pilot control valve is supplied to the port XAtr and XAtl.
And it shifts the travel right spool(301) and travel left spool(310) in the left direction against springs
(328) and (329). Hydraulic fluid from the pump P1 flows into the travel left spool(310) through the
parallel path and hydraulic fluid from the pump P2 flows into the travel right spool(301). Then they
are directed to the each travel motor through port Atl and Atr. As a result, the travel motors turn and
the return flow from the travel motors enter port Btl and port Btr. The flow from the motors returns to
the tank port R2 through the travel spools(310 and 301).
In the case of the opposite operation, the operation is similar.
2-41
4) CIRCUIT PRESSURE PROTENCTION
The control valve has two kinds of relief valve to limit the pressure in a circuit.
(1) Main relief valve
Limits the pressure of the main hydraulic system.
Pz CMR1 CMR2
MR
338
J
601
TS
324 325
391
29072MC43
The hydraulic fluid from the pump P1 and the pump P2 enters the control valve through ports P1
and P2, respectively. From here the flow is directed to the main relief valve(601) through the check
valve CMR1 or CMR2(511) and path(11). The pressure in path(11) is limited by the main relief
valve(601) to its set pressure.
2-42
・Main relief operation while working
30 35 32 33
14
11 31 38 34 24 39 25
29072MC44
While the pressure in path(11) is lower than the set pressure of main relief valve(601), the poppet
(24) is seated and the hydraulic fluid in path(11) can not escape to the return(14). When the
pressure in path(11) approaches the pressure setting, poppet(24) opens against the spring(39).
As the flow in chamber(33) escapes into the return(14) through path(32), its pressure decreases.
At the same time, hydraulic fluid in path(11) flows into path(30) with a pressure drop across
orifice(31). Then pressure in spring chamber(35) becomes lower because it bleeds off through
path(30). The pressure from path(11) pushes the plunger(38) in the left direction against the
spring(34). Then plunger(38) opens and hydraulic fluid in path(11) escapes into the return(14) and
maintains the pressure setting. The pressure setting is adjusted with adjustment screw(25).
2-43
(2) Port relief valve
Limits the service pressure in a cylinder circuit.
10 9 8 7
6 5 4 3 2 1
29072MC45
Port relief valves and make up valves are fitted between the cylinders of the working devices(Boom,
arm, bucket) and their spools. In the case of an external force acting on the cylinder rod with its
spool in neutral, the pressure in the cylinder could become excessive. The port relief valve(602)
restricts this pressure to the set pressure of the valve.
Port relief valve(602) have also the additional function of a make up valve. It is possible, under the
influence of an external force acting on a cylinder that a condition can occur where insufficient flow
is available to match cylinder velocity. If this occurs then a vacuum and thereby cavitation could
exist. To eliminate such an occurrence, a make up valve operates to break this vacuum by
supplying the return flow into the cylinder.
The hydraulic fluid between the cylinder and its spool flows into the path(6) to pressurize the port
relief valve(602). The hydraulic fluid in the path(6) flows into the spring chamber(3) through the
path(4) in the piston(10). If the pressure is lower than the pressure setting, the poppet(2) is shut off
because the force of the spring(1) overcomes the pressure. So the path(6) and the spring
chamber(3) have the same pressure. Because the spring chamber(3) side pressured area of the
seat(8) and the plunger(9) is larger than that of the path(6) side, seat(8) and the plunger(9) are
pushed in the right direction to be seated securely and then the hydraulic fluid in the path(6) doesn't
escape into the return path(5).
2-44
① Port relief function
10 9 7 13
6 12 5 4 3 2 11 1
29072MC46
When the pressure in the path(6) is pressurized to the pressure setting, the poppet(2) is pushed
open against the spring(1). The hydraulic fluid in the chamber(11) flows into the return path(5)
through the path(13) with reducing its pressure. The piston(10) is shifted in the left direction by the
pressure in the path(6) and stops on the end of the plug(7).
The hydraulic fluid in the path(6) flows into the chamber(11) through the path(4) in the piston(10)
and the spring chamber(3). Because the differential pressure occurs between the pass(6) and the
pass(4) by the orifice between the outernal diameter of the end of the piston(10) and the internal
diameter of the plunger(9), the pressure in the spring chamber(3) becomes low and therefore the
plunger(9) is pushed in the left direction with the path(12) opened so that the hydraulic fluid in the
path(6) flows into the return path(5).
2-45
② Make up function
9 8 11
6 5 4 3
29072MC47
Following this then the case of a port relief valve operating as a make up valve is now explained.
In the case that the hydraulic fluid in the cylinder rod(Head) side escapes from the port relief valve
(602), then hydraulic fluid needs to be supplied because vacuum occurs in the head(Rod) side.
When vacuum occurs in the side of the path(6), it also occurs in the spring chamber(3) through the
path(4). The pressure in the side of the return path(5) acts on the seat(8). The seat(8) is shifted in
the left direction by the return pressure because the spring chamber(3) sides of the seat(8) and the
plunger(9) are under a vacuum. The hydraulic fluid in the return path(5) flows into the path(6) so as
to break the vacuum in the path(6) side.
2-46
GROUP 3 SWING DEVICE
1. STRUCTURE
Swing device consists swing motor, swing reduction gear.
Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve.
Swing reactionless valve block

A, B
PA A B PB
Level gauge
Fill port(IP)
Relief valve C Dr
PG Time delay valve SH
SH R32072SM04
PG
Dr Port Port name Port size
A, B Main port SAE 5000psi 3/4"

Dr Drain port PF 1/2-19
C Make up port PF 1-24
C
PA PB PA, PB Gauge port PF 1/4-12
PG Brake release port PF 1/4-12
SH Brake pilot port PF 1/4-12
IP Gear oil inlet port PT 3/4-19
A B
2-47
1) SWING MOTOR
117 121 118 114 706 707 702 712 472 106 993 488 469 355 351 052 841
438
432 444
106 X X
A 303
471
A 748
443
747
304
468
487
101
491
437
124 433
301 122 123113 116111742 743 031 131 451 401 051 994
464 485
SECTION A - A SECTION X-X

R32072SM02
031 Time delay valve 162 O-ring 468 Plug

051 Relief valve 163 O-ring 469 Plug
052 Valve assy 171 Hexagon screw 471 O-ring
101 Drive shaft 301 Casing 472 O-ring
106 Spacer 303 Casing 485 O-ring
111 Cylinder 304 Front cover 487 O-ring
113 Spherical bush 351 Plunger 488 O-ring
114 Spring 355 Spring 491 Oil seal
116 Push rod 401 Socket bolt 702 Piston
117 Spacer 432 Snap ring 706 O-ring
121 Piston 437 Snap ring 712 Brake spring
122 Shoe 438 Snap ring 742 Friction plate
123 Retainer 443 Roller bearing 743 Separate plate
124 Shoe plate 444 Needle bearing 841 Socket bolt
131 Valve plate 451 Spring pin 993 Level gauge
161 O-ring 464 Plug 994 Air breather
2-48
2) REDUCTION GEAR
R32072RG01
1 Front casing 14 Pin 1 27 Oil seal

2 Middle casing 15 Side plate 1 28 Spring pin
3 Drive shaft 16 Magnet 29 Pressure plug
4 Ring gear 2 17 Side plate 3 30 Spring pin
5 Planet gear 2 18 Gauge bar 31 Stop ring
6 Sun gear 2 19 Gauge pipe 32 Bushing 2
7 Ring gear 1 20 Spacer ring 33 Stop ring
8 Planet gear 1 21 Knock pin 34 Lock washer
9 Sun gear 1 22 Roller bearing 35 Pinion gear
10 Carrier 23 Roller bearing 36 Lock plate
11 Pin 2 24 Needle cage 37 Hexagon bolt
12 Thrust washer 25 Socket bolt 38 Stop ring
13 Thrust button 26 Socket bolt 39 Side plate 2
40 Circle clip
2-49
2. FUNCTION
1) ROTARY PART
When high pressurized oil enters a cylinder through port(a), which is the inlet of balance plate(131),
hydraulic pressure acting on the piston causes axial force F. The pressure force F works via the
piston(121) upon the return plate(123) which acts upon the swash plate(124) via an hydrostatic
bearing. Force F1 perpendicular to swash plate(124) and force F2 perpendicular to cylinder center.
Being transferred to the cylinder block(111) through piston, force F2 causes rotational moment at
surroundings of cylinder.
Since cylinder block has 9 equidistantly arrayed pistons, rotational torque is transmitted to cylinder
shaft in order by several pistons connected to the inlet port of high pressurized oil. When the
direction of oil flow is reversed, rotational direction of cylinder is also reversed. Output torque is
given by the equation.
p×q F
T= , q=Z・A・PCD・tanθ, F1 = , F2=F tanθ, S=PCD×tanθ
2Л COSθ
Where p : Effective difference of pressure(kgf/cm2)
q : Displacement(cc/rev)
T : Output torque(kgf・cm)
Z : Piston number(9EA)
A : Piston area(cm2)
θ: Tilting angle of swash plate(degree)
S : Piston stroke(cm)
Low High
pressure oil pressure oil
F1 F2
131
124 123 121 111 R290SM05(2)
2-50
2) MAKE UP VALVE
In the system using this type of motor, there is no counter balance functioning valve and there
happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation
caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency.
A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure
feed pressure required when the hydraulic motor makes a pumping action. The boost pressure
acts on the hydraulic motor's feed port via the make up valve.
Pressurized oil into the port B, the motor rotate counterclockwise.
If the plunger of MCV moves neutral position, the oil in the motor is drain via left relief valve, the
drain oil run into motor via right make up valve, which prevent the cavitation of motor.
A B
29072SM09
2-51
3) RELIEF VALVE
3
1 Body
5
2 O-ring
4 3 Plug
15 4 O-ring
5 Back up ring
11
6 Plunger
14 7 Piston
7 8 Spring
13
9 Seat spring
9
12
10 Seat
2 11 Sleeve
12 Adjust plug
1 13 O-ring
14 Back up ring
8 15 Nut
10
29072SM03
(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 P P=pressure, T=time
on the relief valve is related to its rising PS
process. Here is given the function, 4
referring to the figure following page.
P1 3
T
1
29072SM05
2-52
① Ports (P,R) at tank pressure.
A1 m 6 7
8 A2
29072SM04
② When hydraulic oil pressure(P×A1) reaches the preset force(FSP) of spring(8), the plunger (6)
moves to the right as shown.
P1×A1 = Fsp + P1×A2
Fsp
P1=
A1 - A2
P=P1
8
29072SM06
2-53
③ When the pressure of chamber g reaches the preset force(Fsp) of spring(8), the piston(7) moves
right and stop the piston(7) hits the end of body.
m 6 7 f g
P=P1
8
29072SM07
④ When piston(7) hits the end of body, it stops moving to the right any further. As the result, the
pressure in chamber(g) equals(Ps).
Ps×A1 = Fsp + Ps×A3
Fsp
Ps =
A1 - A3
m 6 7 g
P=P1
8
29072SM08
2-54
4) BRAKE SYSTEM
(1) Control valve swing brake system
This is the brake system to stop the swing motion of the excavator during operation.
In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance
created by this throttling works as a brake force to slow down the swing motion.
Work Deceleration Stop
A B A B A B
MCV MCV MCV
MCV A, B opened MCV A, B throttled MCV A, B closed
(2) Mechanical swing parking brake system

The mechanical swing parking brake system is installed to prevent the upper structure from
swinging downhill because of its own weight when the excavator is parked on a slope since it
completely eliminates the hydraulic drift of swing motion while the excavator is on a slope, work
can be done more easily and safely.
① Brake assembly
Circumferential rotation of separate
plate(743) is constrained by the groove
located at casing(301). When housing
is pressed down by brake spring(712)
through friction plate(742), separate
plate(743) and brake piston(702), friction
force occurs there.
Cylinder(111) is constrained by this
friction force and brake acts, while brake
releases when hydraulic force exceeds
spring force.
111 Cylinder 712 Brake spring

301 Casing 742 Friction plate
702 Brake piston 743 Separate plate
2-55
② Operating principle
a. When the swing control lever(1) is set to the swing position, the pilot oil go to the swing control
valve(2) and to SH of the time delay valve(3) via the shuttle valve(4), this pressure move
spool(5) to the leftward against the force of the spring(8), so pilot pump charged oil(P3) goes to
the chamber G.
This pressure is applied to move the piston(702) to the upward against the force of the
spring(712). Thus, it releases the brake force.
5
712
G SH
702
8
1 Swing control lever

2 Swing control valve(MCV)
3 Time delay valve
4 Shuttle valve P3
5 Spool
8 Spring
2 2
702 Brake piston
4
712 Brake spring
R290SM07(1)
2-56
b. When the swing control lever(1) is set the neutral position, the time delay valve(3) shifts the
neutral position and the pilot oil blocked chamber G.
Then, the piston(702) is moved lower by spring(712) force and the return oil from the chamber
G is drain.
712
G SH
702
1 Swing control lever

2 Swing control valve(MCV)
3 Time delay valve
4 Shuttle valve
702 Brake piston P3
712 Brake spring
2 2
4
R290SM08(1)
2-57
GROUP 4 TRAVEL DEVICE(up to #1455)
1. CONSTRUCTION
Travel device consists travel motor and gear box.
Travel motor includes brake valve, parking brake and high/low speed changeover mechanism.
MB MA
VA
D Parking brake VB
releasing hole(PF1/4)
FILLING PLUG
OIL LEVEL
DRAIN
PLUG
VIEW A
29072TM01
D P
REG Port Port name Port size
VA, VB Valve port PF 1

MA MB
P Pilot port PF 1/4
T D Drain port PF 1/2
MA, MB Gauge port PF 1/4
VA VB
2-58
2. SPECIFICATIONS
1) TRAVEL MOTOR
38
30 20 23 21 13 7 5 15 6 16 39 36 24 29 41 36 40 32
25
37
35
27
17
34
18 10
9 42
33
19 26 1 12 11 22 4 28 14 3 8 2 31 43,44
29072TM02
1 Casing 16 D-ring(Big) 31 Bearing

2 Rear cover 17 Check valve 32 Hexagon socket bolt
3 Cylinder block 18 C-type retaining ring 33 Shim
4 Shoe retainer 19 Retaining ring 34 Parallel pin
5 Friction plate 20 Inclined piston 35 O-ring
6 Brake piston 21 Steel ball 36 O-ring
7 Separating plate 22 Ball joint 37 O-ring
8 Valve plate 23 Piston seal 38 O-ring
9 Shaft 24 M6 restrictor(0.6) 39 O-ring
10 Coupling 25 M6 restrictor(0.8) 40 Overload relief valve
11 Swash plate 26 Oil seal 41 Pilot valve
12 Pivot 27 Check valve spring 42 Brake valve
13 Spring holder 28 Cylinder spring 43 Plug
14 Piston assy 29 Brake spring 44 O-ring
15 D-ring(Small) 30 Bearing
2-59
2) REDUCTION GEAR
24 17 16 14 13 12 15 21 22 19 18 25 23 20
4
5
1
7
3
10
8
6
9
11
26
29072TM03
1 Cover 10 Sun gear 2 19 Angular bearing

2 Carrier 1 11 Carrier 2 20 Shim
3 Carrier pin 1 12 Carrier pin 2 21 Lock washer
4 Needle bearing 13 Needle bearing 22 Support ring
5 Thrust washer 1 14 Planetary gear 2 23 Floating seal
6 Planetary gear 1 15 Spring pin 24 Hexagon socket bolt
7 Spring pin 16 Thrust washer 2 25 Hexagon socket bolt
8 Thrust plate 17 Ring gear 26 Socket head taper plug
9 Sun gear 1 18 Housing
2-60
3) BRAKE VALVE
VB VA
10 11 9 8 6 5 4 2 1 3 7 12
15,18
1 Body
2 Spool assembly
3 Spring follower
4 Spring
5 O-ring
6 O-ring
VB VA 7 Cover
8 Restrictor
14 9 Spring
10 Plug
11 O-ring
12 Hexagon socket head bolt
13 O-ring
14 Hexagon socket head bolt
15 Plug
16 O-ring
17 O-ring
16 17 13
18 O-ring
T
P
29072TM13
2-61
3. FUNCTION
1) BRIEF EXPLANATION OF STRUCTURE
The motor mainly consists of rotary group producing turning force to drive shaft, negative brake
preventing host machine from self running during its rest, capacity control parts that changes the
motor capacity consequently rotating speed and finally overload relief valve that is attached to the
rear cover.
Here is another valve that plays an important role in controlling the hydraulic circuit.
That is called : Brake valve or counter balance valve.
As to this brake valve, refer to page 2-72 for its function.
(1) Rotary group
The cylinder block(3) is inserted into the spline of shaft(9), both ends of which are supported by
bearings(30, 31). This cylinder block(3) is pushed toward the rear cover(2) together with valve
plate(8) by cylinder spring(28).
Nine pieces of piston assy(14) slide inside the cylinder block(3) along the surface of swash plate
(11). Bearings are provided on the end surface of piston assy(14) to reduce the sliding resistance
and the ends of piston assy(14) are pushed toward swash plate(11) by cylinder spring(28) through
spring holder(13), ball joint(22) and shoe retainer(4).
(2) Negative brake
5 separator plates(7) and 4 friction plates(5) are alternately set on the spline of cylinder block(3)
and pushed together by 12 brake springs(29) through brake piston(6).
(3) Capacity control parts
They consist of : pivots(12) that support swash plate(11) and slide in two half-spherical recesses in
swash plate(11) : Inclined piston(20) that change the angle of swash plate(11) on the pivots(12) :
stopper(1-1) of casing that limits the angle of swash plate(11) : pilot valve(41) that leads the oil to
inclined piston(20) by external pilot signal : three check valves(17) that select the maximum
pressure from the external pilot pressure, inlet pressure and outlet pressure of the motor and send
it to pilot valve(41).
(4) Overload relief valve
This valve is screwed in the motor rear cover(2) and consists of : socket(40-1) that is screwed and
fixed in the rear cover(2) and supports the valve seat(40-3) which metallically seated in the hole of
rear cover(2) : valve(40-2) that contact with valve seat(40-3) by adjusting spring(40-9) and fitted in
the hole of socket(40-1) : coupling piston(40-4) that fitted in the hole of the valve(40-2) and
functions also as an oil passage : piston(40-7) that is inserted in the pilot body(40-6) and : shim
(40-8) that adjust the spring force.
40-1 Socket
40-2 Valve
40-3 Valve seat
40-4 Coupling piston
40-5 Cap
40-6 Pilot body
40-7 Piston
40-8 Shim
40-3 40-1 40-13 40-9 40-12 40-11 40-7 40-9 Adjusting spring
40-10 O-ring
40-2 40-12 40-4 40-8 40-10 40-6 40-5 40-11 Back up ring
40-12 O-ring
29072TM04
40-13 Back up ring
2-62
2) FUNCTION
Direction of shaft rotation

Direction of rotation
Inlet port Outlet port (Viewing from valve side)
VB VA Right(Clock wise)
VA VB Left(Counterclockwise)
VB VA
Port Port
Main port 29072TM01
(1) Motor
High pressure oil delivered from hydraulic pump is led to inlet port that is provided in the brake
valve(42) and, through the rear cover(2) and valve plate(8), led to cylinder block(3). The oil flow
and direction of shaft rotation are indicated in table.
Y
F31 P F1
F31
r1 F2
F32 P
F32
r2
F33 P
r3 F33
P
F34 F34
r4
Y
29072TM01
Figure 5(a) Figure 5(b)
As shown in figure 5(a), 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(11) with inclined angle of αdivides this force F1 into thrust force F2 and radial
force F31-F34(or F35)(Figure 5(b)). 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
(In case high pressure oil is applied to five pieces of pistons, r5・F35 should be added.)
This drive torque is transmitted via cylinder block(3) to driving shaft(9).
2-63
(2) Negative brake
Negative brake is released when high pressure oil, selected by the brake valve(42) that is
connected directly to the rear cover(2), is applied to the brake piston(6).
Otherwise the braking torque is always applied.
This braking torque is generated by the friction between the separator plates(7), inserted into the
casing(1) and friction plates(5), coupled to cylinder block(3) by the outer splines.
When no pressure is activated on the brake piston(6), it is pushed by the brake spring(29) and it
pushes friction plates(5) and separator plates(7) towards casing(1) and generates the friction force
which brakes the rotation of cylinder block(3) and hence the shaft(9).
7 5 6 29
9 1 3 2 42
29072TM07
2-64
(3) Capacity control mechanism
When high speed pilot line is charged with the pressure PA that overcome the spring(41-7), the
spring(41-7) is compressed and spool(41-2) shifts to the right to connect the port P and port C.
Then, the highest pressure is selected by the check valve(17) from inlet and outlet pressure of the
motor and high speed pilot line pressure and pushes inclined piston(20). As a result, swash plate
(11) turns around the line L which connect the two pivots(12) as shown by dotted lines. The turn
stops at the stopper(1-1) of casing and swash plate(11) keeps the position.
In this case, the piston stroke become shorter and motor capacity become smaller and motor
rotates faster, around 1.5 times, by the same volume of oil.
When no pressure is in the high speed pilot line PA, spool(41-2) is pushed back by the spring(41-7)
and pressure that pressed the inclined piston(20) is released to the hydraulic tank. Here, nine
pistons are there and they equally spaced on the swash plate(11). The force that summed up
those of pistons comes to almost the center of the swash plate(11) as shown. Since the pivots(12)
are off set by S from the center, the rotating force of product S and the force moves swash
plate(11) 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, 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(41-6). When the pressure at PB
exceeds predetermined value, spool(41-2) returns to the left by the counter pressure against pin
(41-6) and the pressure on the piston(21) through port C is released to the tank and the motor
comes to low speed.
When PB goes down, the spool(41-2) moves to the right and the speed become high.
To control valve
A B
High speed pilot line
21 20 1-1 14 17 17 17
PA
L S
PB P C
12 12 11
41-2 41-6 41-7
29072TM08
2-65
(4) Overload relief valve
Tow pieces of overload relief 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 relief valve increases, this pressure is applied to the
effective diameter of valve(40-2) which seats on the valve seat(40-3) and at the same time, is
delivered, via small hole, to the connecting piston(40-4) located inside the valve(40-2) and the
piston bore pressure increases up to A port pressure. The valve(40-2) opposes to adjusting
spring(40-9) by the force of the pressure exerted on the area difference between valve seat's
effective diameter and piston bore and keep the predetermined pressure.
When hydraulically braking, the piston(40-7) is at the left position by the driving pressure, and
when A port pressure increases, the pressure is applied also to the piston(40-7) through the small
hole in the valve(40-2) and piston(40-7) moves rightward until it touches the cap(40-5). In this
while, the valve(40-2) maintains A port pressure at comparatively low against the adjusting
spring(40-9) force and exhaust oil to B port side. After the piston reached to the plug, the valve
acts the same as at starting.
Connecting piston Cap

(40-4) (40-5)
Port B
Valve seat
(40-2)
Port A
Small hole Valve Adjusting spring Piston

(40-2) (40-9) (40-7)
29072TM09
2-66
3) REDUCTION GEAR
(1) Planetary gear mechanism
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, 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 gears(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
(2) Two stages reduction gear

When the sun gear S1 is driven by input shaft, planetary action occurs among gears S1, a and b
and revolution of gear b transfers the rotation of carrier K1 to second sun gear S2, and also
evokes planetary action between gear S2, 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
2-67
4) BRAKE VALVE
(1) Function
① Spool
By shifting the spool, 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.
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.
③ Relief valve(Built in hydraulic motor)
When the oil is pressurized either in oil supply or oil discharge passage of hydraulic motor, to the
set value, the pressurized oil is relieved to the passage of lower pressure side. Thus this relief
valve fulfills the function of a safety valve for the circuit.
2-68
(2) Operation
Figures in this chapter show the oil flow and the movement of component parts in each position.
The figures are deformed for ease of understanding and the correct formation should be
ascertained by page 2-65.
① Holding position
When the control valve is at neutral position, VA and VB ports are connected to the tank, and the
spring 4 located on both spool ends holds the spool 2 at central position.
Therefore, the passages from VA to MA and VB to MB are closed, which result in closing MA and
MB port 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 form 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, 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.
VB VA
VB VA
MB MA
T P
MB T MA
29072TM14
2-69
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, 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
leftwards, overcoming the spring 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.
VB VA
VB VA
MB MA
T P
MB T MA
29072TM15
2-70
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 returns to the neutral position by spring 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.
VB VA
VB VA
MB MA
T P
MB T MA
29072TM16
2-71
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 force
moves the spool 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 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 are set in the pilot chamber to
damp the spool movement.
The negative brake is released during pressure adjusting action of the spool.
VB VA
MB MA VB VA
T P
MB T MA
29072TM17
2-72
GROUP 4 TRAVEL DEVICE(#1456 and up)
1. CONSTRUCTION
Travel device consists travel motor and gear box.
Travel motor includes brake valve, parking brake and high/low speed changeover mechanism.
A B
A,B
N
Am Bm
A Dr
Dr
Dr
Pi
Pi
Dr Dr
FILL
Pi
Pi
HEAVY INDUSTRIES CO.,LTD.
P A R T NO. : 31N8-40070
SERIAL NO. : SBTR-
LEVEL
N
IC
SB
DRAIN
Am Bm
VIEW A 300072TM01A
Port Port name Port size

AB
A, B Valve port SAE 6000psi 1"
CIRCUIT DIAGRAM
Pi Pilot port PF 1/4
Dr Drain port PF 1/2
Am, Bm Gage port PF 1/4
N Parking release port PF 1/4
2-72-1
2. SPECIFICATION
1) TRAVEL MOTOR
89-5 89-4 89-3 89-2 89-6 88-6 88-4 88-2 93 88-3 88-5 86 85 87 83 13 14 15 16 25 24 6 28 30 31 4 40 39 43 38 37 71 42 41 47 50
89-6 29
90-2 35
90-3 32
90-4 33
97 A 27
92 21
90-5 49
101
98 75,76
102 48
100 36
11 46
103
73 34
74 44
12
45
91
96
56
89-8 67
89-7
62
104
90-1 A
99
88-8
63
89-1
65
88-7 105 95 94 88-1 5 72 9 8 7 10 84 23 22 82 17 18 19 1 20 26 3 69 2 68 61 64 60 66 57 58,59 70 55 54 53 52 51
SECTION A-A
2907A2TM01
1 Casing 16 Plate 31 Ring 46 Back up ring 61 O-ring 83 Housing 89-1 Carrier No.2 92 Plug
2 Plug 17 Piston 32 Spring 47 Cap 62 Lock screw 84 Bearing 89-2 Planetary gear No.2 93 Lock pin
3 Screw 18 Stopper 33 Valve casing 48 Cap 63 Nut 85 Shim 89-3 Needle No.2 94 Ring gear
4 Screw 19 O-ring 34 Needle bearing 49 Bolt 64 Spool 86 Retainer 89-4 Thrust washer No.2 95 Bolt
5 Pin 20 Back up ring 35 O-ring 50 Socket bolt 65 Plug 87 Bolt 89-5 Pin No.2 96 Thrust ring No.1
6 Pin 21 Cylinder block 36 Pin 51 Seat 66 O-ring 88 Carrier No.3 89-6 Spring pin No.2 97 Cover
7 Stopper 22 Cylinder spring 37 Spool 52 Steel ball 67 Valve plate 88-1 Carrier No.3 89-7 Sun gear No.2 98 Thrust ring No.2
8 O-ring 23 Spacer 38 Screw 53 Stopper 68 Spring 88-2 Planetary gear No.3 89-8 Snap ring No.2 99 Bolt
9 Back up ring 24 Guide 39 Damping check 54 Plug 69 O-ring 88-3 Needle No.3 90 Carrier No.1 100 Motor ring
10 Piston 25 Plate 40 Spring 55 O-ring 70 Socket bolt 88-4 Thrust washer No.3 90-1 Carrier No.1 101 Thrust ring No.3
11 Shaft 26 Piston & Shoe assy 41 O-ring 56 Plug 71 Socket bolt 88-5 Pin No.3 90-2 Planetary gear No.1 102 Thrust ring No.1
12 Spacer 27 Plate 42 Plunger 57 Relief valve 72 Lock screw 88-6 Spring pin No.3 90-3 Needle bearing No.1 103 Pad
13 Roller bearing 28 Plate 43 Spring 58 O-ring 73 Oil seal 88-7 Sun gear No.3 90-4 Thrust washer No.1 104 Thrust ring No.2
14 Stop ring 29 Brake 44 Stopper 59 Back up ring 74 Lock ring 88-8 Snap ring No.3 90-5 Pin No.1 105 Coupling
15 Support 30 Ring 45 O-ring 60 Rod 82 Floating Seal 89 Carrier No.2 91 Sun gear No.1
2-72-2
3. PRINCIPLE OF DRIVING
1) WORKING OF ROTARY GROUP
The high pressurized hydraulic oil which is supplied from a hydraulic pump is flows into a
cylinder(21) through the valve casing(33) of motor, and valve plate(67).
The rotary group has a construction that the above high pressurized hydraulic oil is flow only one
side of the line Y-Y which connect the upper and lower dead point of the piston(26).
This high pressurized hydraulic oil works on the piston and generating the force F1, F1 = P * A(P :
supplied pressure, A : pressure receving area), like following pictures.
This force, F1, is devided by the swash plate(16) having a tilting angle ɷinto the thrust component
N1 and radial component W1.
The W1 generates torque, T = W1 * R1, in respect to the line Y-Y.
This torque generated by each piston on the high pressurized hydraulic oil side is summed up onto
a resultant torqueĮ(W1 * R1), which prodeces torque for rotation.
This torque transfers the rotation force to the cylinder(21) through the pistons.
Since the cylinder block is spline-coupled with the shaft, the rotation force is transmitted to the shaft
accordingly.
W1 Piston
Cylinder
R1
N1
O A
f1 F1 P
W1
High Y Low
pressure pressure
2907A2TM07
2-72-3
2) WORKING OF RELIEF VALVE
Relief valve carries on two function of following.
(1) Relief valve is to keep the starting pressure of the hydraulic motor at a constant value and bypass
to the return line excessive oil generated at the motor inlet depending upon the acceleration speed
of the inertia object.
(2) In case of an inertia object stopped, relief valve is generating a break pressure at the outlet and
stop it forcedly.
The chamber A is always connect with port A of a motor. When the pressure at port A increase
and the force pushing poppet A is higher than the pressure of the spring, then poppet A is pushed
up from the contact surface of seat A, and oil flows from chamber A to port B.
Port A Port B
Chamber A
Poppet A
2907A2TM04
2-72-4
3) WORKING OF NEGATIVE BRAKE
The negative brake is released applying to the brake piston(29) the pressure led through built in the
valve casing(33) spool. With no pressure working, the brake force is always ensured.
The brake force is generated by the frictional force among a plate(28) fixed by pin(6) and shaft
casing, brake piston(29) and a frictional plate(27) connected through spline outside the cylinder
block(21).
Without pressure being applied to the brake piston, the brake piston is pushed by ten brake
springs(32) and the friction plate and separator plate are held between the brake piston and casing.
This friction force restrains the shaft(11) spline-coupled with the cylinder block, and thus functions
the brake.
11 6 28 27 29 32 21 33
300075TM05
2-72-5
4) COUNTERBALANCE VALVE
Av port is connected to a hydraulic pump : Bv port is connected to a tank.
The oil supplied from the hydraulic pump passed through Av Ą Cv Ą C sequence, pushed up the
poppet of the check valve, passed through L to port AM, and is supplied to the hydraulic motor to
turn it. But the brake is operated. Therefore, the pump discharge oil pressure is increases. And the
pressure is led via passage G to spring room M. When the pressure in room M exceed the value
equivalent to the force of the spring which holds the spool at its neutral position, the spool begins to
move right.
The oil in room N is sent to room Dv by orifice I and discharged from Bv port to a tank. So spool
moves to the right. The oil flows as the way of K Ą Dv Ą Bv sequence. Also according to the oil
path as composed way Cv Ą H Ą P sequence, the pressure of Av pump is provided to the port P.
An working oil in room N is discharged through orifice and a gap. Therefore the switching operation
of spool is driving slowly.
When the pump discharge pressure fall, spool moves to the left side by a spring at the side of room N.
Also spool moves to the left, the hydraulic oil in room M is sent to Cv room through orifice I' and
discharged to the Av port.
When the pressure at port Av fall down to the tank pressure, the pressure of room M is as the same
as that the tank pressure and becomes equal to that in room N, and so the spool returns to its
neutral position.
AM P BM
L K
Check valve
H
M I' I N
G
Cv Dv
Av Bv
300072TM06
2-72-6
5) WORKING OF DISPLACEMENT CHANGEOVER
The capacity of the travel motor is changed by changing the tilting angle of this swash plate(16).
The tilting angle changes by displacement changeover valve.
(1) External pilot pressure : Pi = 0(Large displacement)
By means of the built-in high pressure selector mechanism in the valve casing(33), the high
pressure oil working on the motor function to port P of the displacement-changeover valve.
A the spool(64) assembled in the displacement changeover valve is pressed to plug(65) by the
spring(68), the high pressure oil at port P flows to port Sb.
This high pressure oil flows through oil passage(passage A') of valve casing(33) and shaft casing
works to chamber A.
This oil in chamber B flows through passage B' and port Sa into the drain line. The displacement
changeover piston(17) is pushed right and the swash plate(16) moves in the arrowed direction
around rotation center 'O'. The swash plate moves until it touched stopper(18), and then is fixed
there.
External pilot
pressure
Chamber A Chamber B Pi = 0
B'
Drain Sa Sb
A'
P
65
7 10 16 17 18 68 64
High pressure oil
Selector valve
2907A2TM05
2-72-7
(2) External pilot pressure : Pi á 20kgf/cm2(small displacement)
If the force operating on spool(64) of the displacement changeover valve is stronger than the
spring(68), and the spool moves to the left side.
The high pressure oil is works on room B through passage Sa Ą B' from port P.
The oil in chamber A flows into the drain line through the passage A' Ą Sb.
The displacement changeover piston(17) is pushed left and the swash plate(16) moves in the
arrowed direction around rotation center 'O'. The swash plate moves until it touches stopper(7),
and then is fixed there.
If the load increase while the motor is working with its small displacement(Pi á 20kgf/cm2, 2nd
speed) until the motor inlet port pressure reaches the preset value, the motor increase its
displacement in response to the load, while maintaining the pressure at the preset
value(automatic 2 -speed function). As motor inlet port pressure reaches the preset value and
then spool(64) moves right side, inlet pressure oil flows into chamber A through port Sb and the
swash plate moves until it touches stopper(17). If the load further increase until the displacement
of the motor reaches the maximum value, the inlet port pressure increase further.
If the load decreases under this condition, the motor continues reducing its displacement in the
reverse sequence. As the load and inlet port pressure decreases and reaches the preset value,
spool(64) moves left side by the pilot pressure(Pi). Therefore inlet port pressure flow into chamber
B through port Sa and the swash plate moves until it touches stopper(10).
External pilot
pressure
2
Chamber A Chamber B Pi 20kgf/cm
B'
Drain Sa Sb
A'
P
65
7 10 16 17 18 68 64
High pressure oil
Selector valve
2907A2TM06
2-72-8
6) REDUCTION GEAR
(1) Planetary gear mechanism
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, 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 gears(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
(2) Two stages reduction gear

When the sun gear S1 is driven by input shaft, planetary action occurs among gears S1, a and b
and revolution of gear b transfers the rotation of carrier K1 to second sun gear S2, and also
evokes planetary action between gear S2, 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
2-72-9
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.
23.3
19
25
Single
operation Simultaneous
operation
Handle bending direction

(No. push rod direction)
4
P
1
T 3
2
30
30
VIEW A
25032RL01
A
Port LH RH Port size

P Pilot oil inlet port Pilot oil inlet port
T Pilot oil return port Pilot oil return port
1 Left swing port Bucket out port
PF 1/4
T 2 Arm in port Boom down port
P 3 Right swing port Bucket in port
4 Arm out port Boom up port
1 32 4
Hydraulic circuit
2-73
CROSS SECTION
The construction of the pilot valve is shown in the attached cross section drawing. The casing has
vertical holes in which reducing valves are assembled.
The pressure reducing section is composed of the spool(5), spring(7) for setting secondary pressure,
return spring(10), stopper(9), spring seat(8) and shim(6). The spring for setting the secondary
pressure has been generally so preset that the secondary pressure is 5 to 20.5kgf/cm2(Depending on
the type). The spool is pushed against the push rod(14) 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.
1 Case 11 Plug 21 O-ring

2 Plug 12 Rod seal 22 Handle connector
3 Plug 13 O-ring 23 Nut
4 O-ring 14 Push rod 24 Insert
5 Spool 15 Plate 25 Boot
6 Shim 16 Bushing 26 Handle
7 Spring 17 Joint assembly 27 Switch assembly
8 Spring seat 18 Swash plate 28 Screw
9 Stopper 19 Adjusting nut 29 Switch assembly
10 Spring 20 Lock nut 30 Switch cover
40 Boot
2-74
CROSS SECTION
14072SF80
2-75
2. FUNCTIONS
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure(Secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port(P) where oil is supplied from hydraulic pump.
(2) Output ports(1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port(T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port or tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool(5) 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(7) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod(14) is inserted and can slide in the plug(11).
For the purpose of changing the displacement of the push rod through the switch plate(19) and
adjusting nut(20) are provided the handle(27) that can be tilted in any direction around the fulcrum
of the universal joint(18) center.
The spring(10) works on the case(1) and spring seat(8) and tries to return the push rod(14) 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.
2-76
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
36072RL01
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-77
(1) Case where handle is in neutral position
7
10
P 5
1 3
25032RL03
The force of the spring(7) that determines the output pressure of the pilot valve is not applied to
the spool(5). Therefore, the spool is pushed up by the spring(10) 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.
2-78
(2) Case where handle is tilted
15
1 3 25032RL04
When the push rod(14) is stroked, the spool(5) moves downwards.

Then port P is connected with port(1) and the oil supplied from the pilot pump flows through
port(1) to generate the pressure.
When the pressure at port(1) increases to the value corresponding to the spring force set by tilting
the handle, the hydraulic pressure force balances with the spring force. If the pressure at port(1)
increases higher than the set pressure, port P is disconnected from port(1) and port T is
connected with port(1). If it decreases lower than the set pressure, port P is connected with
port(1) and port T is disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the
spool contacts with the inside bottom of the push rod and the output pressure is left to be
connected with port P.
2-79
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 2
14072SF73
3 4
Port Port Port size
P Pilot oil inlet port

T Pilot oil return port
1 Travel(LH, Forward)
PF 1/4
T 2 Travel(LH, Backward)
P 3 Travel(RH, Forward)
1 23 4 4 Travel(RH, Backward)
Hydraulic circuit
2-80
CROSS SECTION
The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in
which reducing valves are assembled.
The pressure reducing section is composed of the spool(8), spring(6) for setting secondary pressure,
return spring(10), stopper(9), and spring seat(7). The spring for setting the secondary pressure has
been generally so preset that the secondary pressure is 5 to 19 kgf/cm2 (depending on the type). The
spool is pushed against the push rod(14) 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 25,26
24
23 3
22 36
14 15
16
21 17
13 18
12
19
11 20
9
6
5
7
4
10
3 8
37 1 35 34 2
14072SF70
1 Body(1) 13 Snap ring 25 Cover

2 Body(2) 14 Push rod 26 Bolt
3 Plug 15 Spring pin 27 Cam
4 Plug 16 Seal 28 Bushing
5 Spring seat 17 Steel ball 29 Cam shaft
6 Spring 18 Spring 30 Set screw
7 Spring seat 19 Plate 31 Set screw
8 Spool 20 Snap ring 32 Nut
9 Stopper 21 Plug 33 Bellows
10 Spring 22 O-ring 34 Space
11 Rod guide 23 Rod seal 35 O-ring
12 O-ring 24 Dust seal 36 O-ring
37 Bolt
2-81
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(8) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output spool to determine the output pressure.
The spring(6) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod(14) is inserted and can slide in the plug(21).
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(10) works on the casing(1) and spring seat(7) and tries to return the push rod(14) 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.
2-82
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown
below ant the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.
5 6
3
1
2
2 4
2-76 (140-7)
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-83
(1) Case where pedal is in neutral position
T 8
10
P
1 2
14072SF74
The force of the spring(6) that determines the output pressure of the pilot valve is not applied to
the spool(8). Therefore, the spool is pushed up by the spring(10) to the position of port 2 in the
operation explanation drawing. Then, since the output port is connected to tank port T only, the
output port pressure becomes equal to tank pressure.
2-84
(2) Case where pedal is tilted
14
1 2 14072SF75
When the push rod(14) is stroked, the spool(8) 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.
2-85
SECTION 3 HYDRAULIC SYSTEM
Group 1 Hydraulic Circuit 3-1

Group 2 Main Circuit 3-2
Group 3 Pilot Circuit 3-5
Group 4 Single Operation 3-13
Group 5 Combined Operation 3-23
SECTION 3 HYDRAULIC SYSTEM
GROUP 1 HYDRAULIC CIRCUIT
1 Main pump
2 Main control valve
3 Swing motor
4 Travel motor
5 RCV lever(LH)
6 RCV lever(RH)
7 RCV pedal
8 Boom cylinder(LH)
9 Boom cylinder(RH)
10 Arm cylinder
11 Bucket cylinder
12 Turning joint
13 Check valve
14 Check valve
15 Hydraulic tank
16 Oil cooler
17 Air breather
18 Bypass valve
19 Strainer
20 Spin filter
21 Line filter
22 Solenoid valve
23 Accumulator
24 Pressure switch
25 Shuttle valve
26 Last guard filter
R32073HC01
3-1
GROUP 2 MAIN CIRCUIT
The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit.
The hydraulic system consists of one main pump, one control valve, one swing motor, four cylinders
and two travel motors.
The swash plate type variable displacement tandem axial piston pump is used as the main pump and
is driven by the engine at ratio 1.0 of engine speed.
1. SUCTION AND DELIVERY CIRCUIT
To cylinders To motors
Main control valve To oil cooler
To hydraulic oil tank
Main pump
Suction filter
Hydraulic oil tank
3-02 (290-7)
The pumps receive oil from the hydraulic tank through a suction filter. The discharged oil from the
pump flows into the control valve and goes out the tank ports.
The oil discharged from the main pump flows to the actuators through the control valve.
The control valve controls the hydraulic functions.
The return oil from the actuators flows to the hydraulic tank through the control valve and the oil
cooler.
3-2
2. RETURN CIRCUIT
Check valve(2)
Full flow filter Oil cooler 1.5kgf/cm 2
Main control valve Actuators
Check valve(1)
3.0kgf/cm 2
Check valve(3)
1.5kgf/cm 2
R29073CI01
All oil from each actuator returns to the hydraulic tank through the control valve.
The bypass check valves are provided in the return circuit.
The setting pressure of bypass check valves are 1.5kgf/cm2(21psi) and 3.0kgf/cm2(43psi). Usually, oil
returns to the hydraulic tank from the left side of control valve through oil cooler.
When oil temperature is low, viscosity becomes higher and flow resistance increases when passing
through the oil cooler. The oil pressure exceeds 3.0kgf/cm2(43psi), the oil returns directly to the
hydraulic tank, resulting in the oil temperature being raised quickly at an appropriate level.
When the oil cooler is clogged, the oil returns directly to the hydraulic tank through bypass check
valve(1).
The full-flow filter and bypass relief valve are provided in the hydraulic tank.
The oil from right and left side of control valve is combined and filtered by the return filter. A bypass
relief valve is provided in the full-flow filter.
When the filter element is clogged, the bypass relief valve opens at 1.5kgf/cm2(21psi) differential
pressure.
3-3
3. DRAIN CIRCUIT
Travel motor Swing motor
Turning Main pump

joint From return line
dr2 ~ dr8
Hydraulic Spin filter

oil tank
dr1
Check valve
1.5kgf/cm 2
R29073CI02
Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil have
to be fed to the hydraulic tank passing through spin filter and full flow filter in the hydraulic tank.
When the drain oil pressure exceed 1.5kgf/cm2(21psi), the oil returns to the hydraulic tank directly.
1) TRAVEL MOTOR DRAIN CIRCUIT

Oil leaking from the right and left travel motors comes out of the drain ports provided in the
respective motor casing and join with each other. These oils pass through the turning joint and
return to the hydraulic tank after being filtered by full flow filter in the hydranlic tank.
2) SWING MOTOR DRAIN CIRCUIT
Oil leaking from the swing motor come out and return to the hydraulic tank passing through a spin
filter.
3) MAIN PUMP DRAIN CIRCUIT
Oil leaking from main pump come out and return to the hydraulic tank passing through spin filter.
3-4
GROUP 4 SINGLE OPERATION
1. BOOM UP OPERATION
R32073HC09
When the RH control lever is pulled back, the boom spools in the main control valve are moved to
the up position by the pilot oil pressure from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the large
chamber of boom cylinders.
At the same time, the oil from the small chamber of boom cylinders returns to the hydraulic oil tank
through the boom spool in the main control valve. When this happens, the boom goes up.
The excessive pressure in the boom cylinder bottom end circuit is prevented by relief valve.
When the boom is 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.
3-13
2. BOOM DOWN OPERATION
R32073HC10
When the RH control lever is pushed forward, the boom spools in the main control valve are moved
to the down position by the pilot oil pressure from the remote control valve.
The oil from the rear pump flows into the main control valve and then goes to the 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 rear pump, and flows into the small chamber of the boom cylinder.
This prevents cylinder cavitation by the negative pressure when the rear pump flow can not match
the boom down speed. And the excessive pressure in the boom cylinder rod end circuit is
prevented by the relief valve.
3-14
3. ARM ROLL IN OPERATION
R32073HC11
When the LH 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 from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the large
chamber of arm cylinder.
At the same time, the oil from the small chamber of arm cylinder returns to the hydraulic oil tank
through the arm spool in the main control valve. When this happens, the arm roll in.
When the roll in speed of arm is faster, the oil returned from the small chamber of arm cylinder
combines with the oil from both pump, and flows into the large chamber of the arm cylinder by a
make up valve.
The excessive pressure in the arm cylinder bottom end circuit is prevented by relief valve.
3 - 15
4. ARM ROLL OUT OPERATION
R32073HC12
When the LH 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 from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the small
chamber of arm cylinder. At the same time, the oil from the large chamber of arm cylinder returns to
the hydraulic oil tank through the arm spool in the main control valve.
When this happens, the arm roll out. When the roll out speed of arm is faster, the oil returned from
the large chamber of arm cylinder combines with the oil from both pump, and flows into the small
chamber of the arm cylinder by a make up valve.
The excessive pressure in the arm cylinder rod end circuit is prevented by relief valve.
When the arm is rolled out and the control lever is returned to neutral position, the circuit for the
holding pressure at the rod end of the arm cylinder is closed by the arm holding valve.
This prevents the hydraulic drift of arm cylinder.
3-16
5. BUCKET ROLL IN OPERATION
R32073HC13
When the RH control lever is manually placed in the bucket roll in position. Then the oil flows from
pilot pump through the pilot valve to bucket section of the main control valve. Here the spool
position is moved to bucket roll in position.
The center bypass valve is change over by the pilot pressure(XBP1) and then the oil from front
pump is joint to the flow of rear pump via confluence passage.
The oil flows from both pump through rod end of the cylinder through the bucket section returned to
the hydraulic tank.
The cavitation which will happen to the bottom of the bucket cylinder is prevented by a make up
valve, on other hand. The excessive pressure is also prevented by an overload relief valve in the
main control valve.
3-17
6. BUCKET ROLL OUT OPERATION
R32073HC14
When the RH control lever is manually placed in the bucket roll out position. Then the oil flows from
pilot pump through the pilot valve to bucket section of the main control valve. Here the spool
position is moved to bucket roll out position.
The oil flows from rear pump through bucket section of main control valve to the rod end of the
bucket cylinder, and to roll out bucket.
The return oil flows from the bottom end of the cylinder through the bucket section returned to the
hydraulic tank.
The cavitation which will happen to the rod of the bucket cylinder is prevented by a make up valve,
on other hand. The excessive pressure is also prevented by an overload relief valve in the main
control valve.
3-18
7. SWING OPERATION
R32073HC15
When the LH control lever is manually placed in the left(Right) swing position. Then the oil flows
from front pump through the swing section of the main control valve to swing motor to left(Right)
swing the superstructure. The return oil flows from swing motor through the swing section of the
main control valve returned to the tank.
When the control lever placed in the neutral position, the pressure of the pilot oil passage down.
Then the brake release valve returned to the neutral position and the oil is returned from the brake
piston to the tank. And the brake is set to "ON". The swing parking brake, make up valve and the
overload relief valve are provide in the swing motors. The cavitation which will happen to the swing
motor is prevented by the make up valve in the swing motor itself.
3-19
SWING CIRCUIT OPERATION
R32073HC16
1) MOTOR BRAKE VALVE

Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing
operation.
2) MAKE UP VALVE
The make up valves prevent cavitation by supplying return oil to the vacuum side of the motor.
3) PARKING BRAKE
In case that the parking, of the machine at slope is required during operation, there is the danger of
involuntary swing caused by the self weight of the machine. The brake is connected to prevent this
involuntary swing.
PARKING BRAKE "OFF" OPERATION
The parking brake is released by the pilot pressure oil from the pilot pump.
When the left control lever placed in the swing position, the pilot pressure at the shuttle valve is
transferred to the brake release valve and the brake release valve is change over. Then the pilot
pressure lift the brake piston and release the parking brake.
PARKING BRAKE "ON" OPERATION
When the control lever placed in the neutral position, the pressure of the pilot oil passage down.
Then the brake release valve returned to the neutral position and the oil is returned from the brake
piston to the tank. And the brake is set to 'ON".
BYPASS VALVE
This bypass valve absorbs shocks produced as swing motion stops and reduced oscillation cause
by swing motion.
3-20
8. TRAVEL FORWARD AND REVERSE OPERATION
R32073HC17
When the right and left travel levers are manually placed to the forward or reverse position, the oil
flows from pilot pump through the pilot valve to travel sections of the main control valve.
Here, spool position is moved to forward and reverse position. The oil flows from rear pump through
the travel(RH) section of the main control valve and turning joint to the right travel motor and oil
flows from front pump through the travel(LH) section of the main control valve and turning joint to
the left travel motor and move the machine forward or reverse.
The return oil flows from both travel motor through the turning joint and travel(RH, LH) sections
returned to the tank.
3-21
TRAVEL CIRCUIT OPERATION
R32073HC18
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 365kgf/cm2 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.
3-22
GROUP 5 COMBINED OPERATION
1. OUTLINE
R32073HC19
The oil from the front and rear pump flows through the neutral oil passage, bypass oil passage and
confluence oil passage in the main control valve. Then the oil goes to each actuator and operates
them. Check valves and orifices are located on these oil passage in the main control valve. These
control the oil from the main pumps so as to correspond to the operation of each actuator and
smooth the combined operation.
STRAIGHT TRAVEL SPOOL

This straight travel spool is provided in the main control valve.
If any actuator is operated when traveling, the straight travel spool is pushed to the left by the pilot oil
pressure from the pilot pump.
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.
3-23
2. COMBINED SWING AND BOOM OPERATION
R32073HC20
When the swing and boom functions are operated, simultaneously the swing spool and boom
spools changed. The oil flows from the rear pump through boom1 section of the main control valve
to boom cylinders and the boom functions.
The oil flows from front pump through swing section to swing motor.
At the same time, the pressure in the boom circuits can be high while the swing pressure is low,
therefore the oil flows from front pump to boom cylinders through boom2 section via confluence
passage in case boom raise operation.
3-24
3. COMBINED SWING AND ARM OPERATION
R32073HC21
When the swing and arm functions are operated, simultaneously the swing spool and arm spools
changed. The oil flows from the front pump through arm1 and swing section of the main control
valve to arm cylinder and swing motor, and the arm and swing functions.
At the same time, the pressure in the arm circuit can be high while the swing pressure is low,
therefore the oil flows from rear pump to arm cylinder through arm2 section via confluence passage.
3-25
4. COMBINED SWING AND BUCKET OPERATION
R32073HC22
When the swing and bucket functions are operated, the swing and bucket spools changed. The oil
flows from the rear pump through the bucket section of the main control valve to the bucket cylinder
and the bucket functions. The oil flows from front pump through swing section of the main control
valve to the swing motor and swing the superstructure.
3-26
5. COMBINED SWING, BOOM, ARM AND BUCKET OPERATION
R32073HC23
When the swing, boom, arm and bucket functions are operated, the each spools of the main control
valve changed.
The oil flows from rear pump through arm2, boom1 and bucket section to boom, arm and bucket
cylinders. The oil flows from front pump through swing, boom2 and arm1 section to swing motor,
boom and arm cylinder. Then the functions to each actuators.
According to the state of each actuators functioning, the oil flows from front and rear pump through
the confluence oil passage to the each actuators.
3-27
6. COMBINED SWING AND TRAVEL OPERATION
R32073HC24
When the swing and travel functions are operated, simultaneously the swing spool and travel spools
in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve. At the same time, the straight travel spool is pushed to the left by the pilot oil
pressure from the pilot pump.
The oil from the front pump flows into the swing motor through the swing spool. The oil from the
rear pump flows into the travel motor through the RH travel spool of the right control valve and the
LH travel spool of the left control valve via the straight travel spool.
The superstructure swings and the machine travels straight.
3-28
7. COMBINED BOOM AND TRAVEL OPERATION
R32073HC25
When the boom and travel functions are operated, simultaneously the boom spools and travel
spools in the main control valve are moved to the functional position by the pilot oil pressure from
the remote control valve. At the same time, the straight travel spool is pushed to the left by the pilot
oil pressure from the pilot pump. The oil from the front pump flows into the boom cylinders through
the boom 2 spool and boom 1 spool via the parallel and confluence passage in case boom up
operation. The oil from the rear pump flows into the travel motors through the RH travel spool of the
right control valve and the LH travel spool of the left control valve via the straight travel spool.
When the travel circuit pressure drops lower than boom pressure, as when traveling downhill, boom
priority and smoothness are maintained because of the orifice in the straight travel spool. Thus the
machine will continue to travel straight.
3-29
8. COMBINED ARM AND TRAVEL OPERATION
R32073HC26
When the arm and travel functions are operated, simultaneously the arm spools and travel spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve. At the same time, the straight travel spool is pushed to the left by the pilot oil pressure
from the pilot pump. The oil from the front pump flows into the arm cylinders through the arm 1
spool and arm 2 spool via the parallel and confluence oil passage. The oil from the rear pump flows
into the travel motors through the RH travel spool of the right control valve and the LH travel spool of
the left control valve via the straight travel spool.
When the travel circuit pressure drops lower than arm pressure, as when traveling downhill, arm
priority and smoothness are maintained because of the orifice. Thus the machine will continue to
travel straight.
3-30
9. COMBINED BUCKET AND TRAVEL OPERATION
R32073HC27
When the bucket and travel functions are operated, simultaneously the bucket spool and travel
spools in the main control valve are moved to the functional position by the pilot oil pressure from
the remote control valve. At the same time, the straight travel spool is pushed to the left by the pilot
oil pressure from the pilot pump. The oil from the front pump flows into the bucket cylinder through
the bucket spool via the confluence oil passage. The oil from the rear pump flows into the travel
motors through the RH travel spool of the right control valve and the LH travel spool of the left
control valve via the straight travel spool of the control valve.
When the travel circuit pressure drops lower than bucket pressure, as when traveling downhill,
bucket priority and smoothness are maintained because of the orifice.
In either case, the machine will continue to travel straight.
3-31
SECTION 4 ELECTRICAL SYSTEM
Group 1 Component Location 4-1

Group 2 Electrical Circuit 4-3
Group 3 Electrical Component Specification 4-19
Group 4 Connectors 4-28
SECTION 4 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
32074EL01
1 Horn switch 11 Travel alarm stop switch 20 RS232 serial port

2 Cluster 12 Preheat switch 21 Fuse box
3 Starting switch 13 Washer switch 22 Master switch
4 Cigar lighter 14 Wiper switch 23 Aircon & heater switch panel
5 Accel dial 15 Main light switch 24 One touch decel switch
6 Breaker switch 16 Speaker 25 Power max switch
7 Beacon switch 17 Cassette & radio 26 Safety lever
8 Service meter 18 Resistor 27 Overload switch
9 Breaker selection switch 19 CPU controller 28 Quick coupling switch
10 Cab light switch
4-1
2. LOCATION 2
32074EL02
1 Lamp 6 Speed sensor 11 Alternator

2 Fuel sender 7 Start relay 12 Air cleaner switch
3 Fuel filler pump 8 Temp sender 13 Travel alarm buzzer
4 Beacon lamp 9 Engine oil pressure switch 14 Battery relay
5 Horn 10 Heater valve 15 Battery
4-2
GROUP 2 ELECTRICAL CIRCUIT
32074EL03
4-3
1. POWER CIRCUIT
The negative terminal of battery is grounded to the machine chassis through master switch.
When the start switch is in the OFF position, the current flows from the positive battery terminal as
shown below.
1) OPERATING FLOW
Battery Battery relay Fusible link〔CN-60〕
Fuse box〔No.1〕 l/conn〔CN-8(12)〕 Start switch〔CS-2(1)〕
Power relay〔CR-35(30)]
Fuse box〔No.2〕 I/conn〔CN-10(6)〕 Room lamp〔CL-1(2)〕 Door switch〔CS-1〕
Cassette radio〔CN-27(11)〕
Fuse box〔No.3〕 I/conn〔CN-11(5)〕 Relay(Hi, M2)
Fuse box〔No.4〕 I/conn〔CN - 5(4)〕 I/conn〔CN -17(5)〕 Wiper motor controller
〔CN-141(7)〕
Wiper motor〔CN-21(4)〕
Fuse box〔No.5〕 CPU controller〔CN-50(7)〕
Fuse box〔No.6〕 l/conn〔CN-11(4)〕 AC & Heater controller〔CN -116(3, 4)〕
※ 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
OFF OFF
③ - GND (Battery 2EA) 20~25V
④ - GND (Fusible link) 20~25V
※ GND : Ground
4-4
POWER CIRCUIT
32074EL04
4-5
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal 〔CR-1〕
Battery relay Reset button〔CS-61〕 Fuse box〔No.1〕
I/conn〔CN-8(12)〕 Start switch〔CS-2(1)〕
(1) When start key switch is in ON position
Start switch ON〔CS-2(2)〕 I/conn〔CN-8(11)〕 Battery relay〔CR-1〕
Battery relay operating (All power is supplied with the electric component)
Start switch ON〔CS-2(3)〕 I/conn〔CN-8(10)〕 Power relay〔CR-35(86) → (87)〕
Fuse box〔No.12〕 l/conn〔CN-2(5)〕 Fuel cut-off〔CN-79 (1)〕
(2) When start key switch is in START position
Start switch START〔CS-2(5)〕 I/conn〔CN-8(9)〕 Safety relay〔CR-5(86) → (30)〕
l/conn〔CN-3(2)〕 Start relay〔CR-23〕
l/conn〔CN-2(4)〕 Fuel cut off〔CN-79(2)〕
2) CHECK POINT
① - GND(Battery)
② - GND(Start key)
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)
※ GND : Ground
4-6
STARTING CIRCUIT
32074EL05
4-7
3. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the ON
position.
Charging current generated by operating alternator flows into the battery through the battery relay
(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse box.
1) OPERATING FLOW
(1) Warning flow
Alternator "I" terminal I/conn〔CN-3(3)〕 CPU alternator level〔CN-51(9)〕
Cluster charging warning lamp(Via serial interface)
(2) Charging flow

Alternator "B+" terminal Battery relay(M8) Battery(+) terminal
Reset button〔CS-61〕 Fuse box
2) CHECK POINT
① - GND(Battery voltage)
② - GND(Battery relay)
Run ON ③ - GND(Alternator B+ terminal) 20~30V
④ - GND(Alternator I terminal)
⑤ - GND(CPU)
※ GND : Ground
4-8
CHARGING CIRCUIT
32074EL06
4-9
4. HEAD AND WORK LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.14) I/conn〔CN-7(7)〕 Switch panel〔CN-116(9)〕
Fuse box (No.15) I/conn〔CN-7(8)〕 Switch panel〔CN-116(10,11)〕
(1) Head light switch ON
Head light switch ON〔CN-116(1)〕 l/conn〔CN-7(1)]
Head light ON〔CL-4(2)〕
l/conn〔CN-10(2)〕 Cassette radio illumination ON〔CN-27(7)〕
l/conn〔CN-11(8)〕 AC & Heater controller illumination ON
l/conn〔CN-6(8)〕 Cigarlight〔CL-2〕
(2) Work light switch ON
Work light switch ON〔CN-116(2,3)〕 l/conn〔CN-7(2)〕 l/conn〔CN-12(1)〕
Work light ON〔CL-5(2), CL-6(2)〕
2) CHECK POINT
① - GND(Fuse box)
② - GND(Switch power input)
STOP ON 20~25V
③ - GND(Switch power output)
④ - GND(Head light)
⑤ - GND(Fuse box)
⑥ - GND(Switch power input)
STOP ON 20~25V
⑦- GND(Switch power output)
⑧ - GND(Work light)
※ GND : Ground
4-10
HEAD AND WORK LIGHT CIRCUIT
32074EL07
4-11
5. BEACON LAMP AND CAB LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.17) I/conn〔CN-8(3)〕 Beacon lamp switch〔CN-23(6)〕
Fuse box (No.16) I/conn〔CN-7(12)〕 Switch panel〔CN-116(16, 17)〕
(1) Beacon lamp switch ON
Beacon lamp switch ON〔CS-23(2)〕 Switch lndicator lamp ON〔CS-23(9)〕
l/conn〔CN-8(4)〕 l/conn〔CN-10(10)〕
Beacon lamp ON〔CL-7〕
(2) Cab light switch ON
Cab light switch ON〔CN-116(7, 8)〕 I/conn〔CN-7(6)〕 I/conn〔CN-10(11)〕
Cab light ON〔CL-8(2), CL-9(2)〕
2) CHECK POINT
① - GND(Fuse box)
STOP ON 20~25V
④ - GND(Beacon lamp)
⑤ - GND(Fuse box)
⑥ - GND(Switch power input)
STOP ON 20~25V
⑦ - GND(Switch power output)
⑧ - GND(Cab light)
※ GND : Ground
4-12
CN-116
HEAD LIGHT OUT 1 CN-7
WORK LIGHT OUT 2 1
WORK LIGHT OUT 3 2
WIPER MOTOR DRIVE 4 3
7
PRE-HEAT 5 4
POWER 24V 6 5
OR OR
CABIN LIGHT OUT 7 6
OR
CABIN LIGHT OUT 8 7
CN-46
HEAD LIHGT 24V 9 8
START KEY 20A
WORK LIGHT 24V 9 1
10
ROOM LAMP 5A
WORK LIGHT 24V 11 10 2
SWITCH PANEL
WASHER SIG 12 11 AC & HEATER 5A
R 3
GND 13 12
WIPER+ 10A
4
6
TRAVEL ALARM 14
CPU B+ 5A
INT. SIG 15 CN-10 5
R AC BLOWER
1 20A
CABIN LIGHT 24V 16 6
R
CABIN LIGHT 24V 17 2 CLUSTER 10A
7
3
CASSETTE RADIO 5A
4 8
CPU 10A
5 9
6 CONVERTOR 5A
10
7 SWITCH PANEL 5A
BEACON LAMP AND CAB LIGHT CIRCUIT
11
8
FUEL CUT-OFF 20A
9 12
G
10 WIPER MOTOR 20A
OR 13
11 HEAD LAMP 5A
5
14
12
WORK LAMP 10A
4
15
4-13
8
R CAB LAMP 10A
G
B
B
B
16
OR
OR
Y BEACON LAMP 5A
17
1
2
8
7
9
AC & HEATER 20A
2
1
2
1
18
CL-7
CL-9
CL-8
HORN 10A
19
M
1
CIGAR LIGHTER 10A

20
CAB LIGHT
CAB LIGHT
5
6
10
ETHER(PRE-HEAT) 10A
21
BEACON LAMP
3
7
9
2
6
1
4
5
8
10
TRAVEL 5A
22
CS-23
BEACON LAMP SW
SOLENOID 1 10A
23
Y
B
G
G
SAFETY SOLENOID 5A
24
SOLENOID 3 10A
CN-8 25
3
2
1 FUEL FILLER PUMP 10A
26
2 SPARE 10A
Y 27
3 SPARE
20A
G 28
4
5
FUSE BOX
6
7
8
9
10
11
12
29074EL08
6. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
(1) Key switch ON
Fuse box (No.11) I/conn〔CN-7(5)〕 Switch panel〔CN-116(6)〕
Fuse box (No.4) I/conn〔CN-5(4)〕 I/conn〔CN-17(5)〕 Wiper motor controller〔CN-141(7)〕
Wiper motor〔CN-21(4)〕
Fuse box (No.13) I/conn〔CN-6(5)〕 l/conn〔CN-17(4)〕 Wiper motor controller〔CN-141(6)〕
Washer pump〔CN-22(2)〕
(2) Wiper switch ON : 1st step(Intermittent)
Wiper switch ON〔CN-116(15)〕 I/conn〔CN-9(4)〕 I/conn 〔CN-6(10)〕 I/conn 〔CN-17(8)〕
Wiper motor controller〔CN-141(10) → (3)〕 Wiper motor intermittently operating〔CN-21(6)〕
(3) Wiper switch ON : 2nd step(Low speed)
Wiper switch ON〔CN-116(4)〕 I/conn〔CN-7(3)〕 I/conn〔CN-6(9)〕 I/conn 〔CN-17(2)〕
Wiper motor controller〔CN-141(2) → (4)〕 Wiper motor operating〔CN-21(2)〕
(4) Washer switch ON
Washer switch ON〔CN-116(12)〕 I/conn〔CN-7(9)〕 I/conn〔CN-5(1)〕 I/conn〔CN-17(7)〕
Wiper motor controller〔CN-141(9) → (8)〕 I/conn〔CN-17(6)〕 I/conn〔CN-6(11)〕
Washer pump〔CN-22(1)〕 Washer operating
Fuse box (No.13) I/conn〔CN-6(5)〕 I/conn〔CN-17(4)〕
Wiper motor controller〔CN-141(6) → (4)〕 Wiper motor operating〔CN-21(2), Low speed〕
(5) Auto parking(When switch OFF)
Switch OFF〔CN-116(15)〕 Wiper motor parking position by wiper motor controller
2) CHECK POINT
① - GND(Fuse box)
STOP ON 20~25V
④ - GND(Wiper Power input)
⑤ - GND(Wiper power output)
⑥ - GND(Wiper motor)
※ GND : Ground
4-14
CN-9 CN-46
1 START KEY 20A
1
2
ROOM LAMP 5A
1
3 2
BR AC & HEATER 5A
4 3
5 V WIPER+ 10A
4
6
CPU B+ 5A
5
7
AC BLOWER 20A
8 6
CN-116 CLUSTER 10A
3
HEAD LIGHT OUT 1 7
CASSETTE RADIO 5A
WORK LIGHT OUT 2 8
WORK LIGHT OUT 3 CPU 10A
1
W
CN-7 9
WIPER MOTOR DRIVE 4 1 CONVERTOR 5A
10
PRE-HEAT 5 2
L W L SWITCH PANEL 5A
POWER 24V 6 3 11
FUEL CUT-OFF 20A
CABIN LIGHT OUT 7 4
L 12
CABIN LIGHT OUT 8 5 GY/W WIPER MOTOR 20A
WIPER AND WASHER CIRCUIT
13
HEAD LIHGT 24V 9 6 HEAD LAMP
2
5A
WORK LIGHT 24V 10 14
7
WORK LAMP 10A
WORK LIGHT 24V 11 8 15
SWITCH PANEL
L L
1
WASHER SIG 12 9 CAB LAMP 10A

16
GND 13 10 BEACON LAMP 5A
17
3
TRAVEL ALARM 14 11
BR AC & HEATER 20A
INT. SIG 15 12 18
HORN 10A
CABIN LIGHT 24V 16
19
CABIN LIGHT 24V 17 CIGAR LIGHTER 10A
20
3
CN-5 L ETHER(PRE-HEAT) 10A
21
1
TRAVEL 5A
2 22
4-15
CS-53 SOLENOID 1 10A
OR 3
6
V 23
CN-21 4 SAFETY SOLENOID 5A
24
3 1 5
R SOLENOID 3 10A
2 6 25
GY FUEL FILLER PUMP 10A
5 3 7 26
R
4 8 SPARE 10A
WIPER CUT SW
4 G 27
5 9 SPARE
L 20A
6 10 28
6 M 2
WIPER MOTOR
11
12
FUSE BOX
4
CN-141
G
FEED BACK 1 CN-6
W
MOTOR DRIVE SIG 2 CN-17 1
L
MOTOR DRIVE- 3 1 2
R W W
MOTOR DRIVE+ 4 2 3
B B B
GND 5 3 4
GY/W GY/W GY/W GY/W
VCC 6 4 5
R R R
CONTINUE 24V 7 5 6
V
V V V
GY/W
WASHER P/P 8 6 7
L L L
WASHER SIG. 9 7 8
2
BR BR BR BR
INT. SIG 10 8 9
CN-22
OR BR
M
WIPER CUT SW 11 10
V
N.C 12 11
WIPER MOTOR CONTROLLER

GY
FEED BACK 13 12
WASHER PUMP
29074EL09
CONTROLLER CIRCUIT
32074EL10
4-16
ELECTRIC CIRCUIT FOR HYDRAULIC
32074EL11
4-17
MONITORING CIRCUIT
32074EL12
4-18
GROUP 3 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check
※ Check specific gravity

12V × 160Ah 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
Continuous :
180AMPS ※ Check disconnection
Master switch
Rush : Normal : About 0Ω
1000AMPS
6
5
4
3
2
1
B ※ Check contact
B-BR : 24V 1A
1
Ι ,O OFF : ∞Ω(For each terminal)

Start key B-ACC : 24V 10A
ON : 0Ω(For terminal 1-3 and 1-2)
B-ST : 24V 40A
ΙΙ Ι O H START : 0Ω(For terminal 1-5)
6
5
3
2
C ST ACC BR H
CS-2
Pressure switch 1 10kgf/cm2 ※ Check contact

Pa
(Travel, working) 2 (N.C TYPE) Normal : 0.1Ω
CD-6 CD-7 CD-37
4-19
Pressure switch 2 Pa 3~6kgf/cm2 ※ Check contact

(For overload) 1 (N.O TYPE) Normal : ∞Ω
CD-31
Pressure switch 0.5kgf/cm2 ※ Check resistance

Pa
(For engine oil) (N.C TYPE) Normal : ∞Ω(CLOSE)
CD-18
Temperature C 1 ※ Check resistance

sensor 50°C : 804Ω
-
(Coolant, 2 80°C : 310Ω
Hydraulic) 100°C : 180Ω
CD-8
CD-1 CD-8
※ Check contact
Air cleaner Pa -
High level : ∞Ω
pressure switch
Low level : 0Ω
CD-10
2 ※ Check contact
Coolant level 24V 0.5A High level : ∞Ω
Sensor 1 Low level : 0Ω
CD-16
※ Check resistance
Full : 50Ω 6/12 : 350Ω
2 11/12 : 100Ω 5/12 : 400Ω
- 10/12 : 150Ω 4/12 : 450Ω
Fuel sender 9/12 : 200Ω 3/12 : 500Ω
1
8/12 : 250Ω 2/12 : 550Ω
CD-2 7/12 : 300Ω 1/12 : 600Ω
CD-2 Empty warning : 700Ω
4-20
m
rp
Tacho sensor 2 -
Normal : 300Ω(For terminal 1-2)
CD-17
30
86
87a 87 85 ※ Check resistance
87 Normal : About 160 Ω
Relay 85
30 86
24V 16A (For terminal 85-86)
87a
0Ω(For terminal 30-87)
CR-2 CR-3 CR-5 ∞Ω(For terminal 30-87)
CR-7 CR-35 CR-36
M- 6
6
M
5
M+ 5 ※ Check resistance
NC 4 Normal : 1~2Ω(For terminal 5-6)
Accel actuator 2 -
3 1
P- 3 0.8~1.2kΩ
SIG 2
(For terminal 1-3)
P+ 1
1
Solenoid valve 24V 1A Normal : 15~25Ω
2
(For terminal 1-2)
CN-66 CN-68 CN-70 CN-87
CN-88 CN-89 CN-133 CN-137
2
EPPR valve 700mA Normal : 15~25Ω
1 (For terminal 1-2)
CD-75
1
※Check resistance
Resistor 45Ω 20W±5%
2 Normal : 45Ω
CD-47
4-21
※ Check disconnection
Speaker 20W
Normal : 0~2Ω
CN-23(LH)
CN-24(RH)
10 9 8 7 6 5 4 3 2 1 ※ Check contact
10 6 5 Normal
ON : 0 Ω (For terminal 1-5, 2-6)
Switch
24V 8A ∞ Ω (For terminal 5-7, 6-8)
(Locking type)
OFF : ∞ Ω (For terminal 1-5, 2-6)
9 8 2 7 1
0 Ω (For terminal 5-7, 6-8)
CS-23 CS-27 CS-50
CS-52 CS-54
※Check resistance
Door switch 24V 2W
Normal : About 5MΩ
CS-1
CS-1 CS-20
CS-53
※ Check resist
Normal : About 5kΩ
A + (For terminal A-C)
Accel dial B S - Normal : Abowt 5V
C - (For terminal A-C)
: 2~4.5V
CN-142 (For terminal C-B)
※ Check disconnection
8
2
7
9
1
I
Normal : 1.0Ω
ON : 0Ω(For terminal 1-5, 2-6)
Switch 24V 8A ∞Ω(For terminal 5-7, 6-8)
5
10
OFF : ∞Ω(For terminal 1-5, 6-8)

10
9
3
7
2
6
1
4
5
0Ω(For terminal 5-7, 6-8)

CS-67
2
Head lamp, 24V 70W ※ Check disconnection
Work lamp, (H3 Type)
24V 70W : About 10Ω
Room lamp, 1 24V 10W
Cab lamp (Room lamp) 24V 10W : About 50Ω
CL-1 CL-4 CL-5
CL-6 CL-8 CL-9
4-22
21V 70A ※Check disconnection

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

Safety switch 2
(N.C TYPE) Normal : 0Ω(One pin to ground)
CS-20
4-23
1
Pa ※Check contact
Receiver dryer 24V 2.5A
Normal : ∞Ω
2
CN-29
N.C 1
S.R- 2
S.R- 3
S.L- 4
S.L- 5
N.C
ILL+
6
7
※Check voltage
S.R+ 8
Cassette radio S.R+ 9 24V 2A 20~25V

ACC 10
B+
S.L+
11
12
(For terminal 10-14, 11-14)
S.L+ 13
GND 14
CN-27
※Check contact
Washer pump 24V 3.8A
Normal : 10.7Ω(For terminal 1-2)
CN-22
3 1
2
5 3
4
4
※Check disconnection
Wiper motor 5 24V 2A
6 M 2 6
CN-21
A 24V
24V 24V(A-B)
DC/DC
B GND 12V 3A
Converter 12V (B-C)
C 12V 12V
CN-138
※Check coil resistance

Normal : About 1MΩ
Cigar lighter 24V 5A 1.4W ※Check contact
Normal : ∞Ω
Operating time : 5~15sec
CL-2
4-24
※Check contact
Ether 24V 15A
Normal : 1.1Ω
CN-78
B+ G
※Check contact
3~
Alternator 24V 55A Normal : 0Ω(For terminal B+-I)
Ι
U Normal : 24~27.5V
GND
CN-74
B+
M
Delco Remy ※Check contact
Starter
28MT 24V Normal : 0.1Ω
M
CN-45
※Check contact
Travel alarm 24V 0.5A
Normal : 5.2Ω
CN-65
3 E
※Check resistance
Fuel cut-off 2 S 24V
Normal : 15~25Ω
1 I
CN-79
1
Aircon ※Check contact
24V 79W
compressor Normal : 13.4Ω
CN-28
4-25
※Check contact
Start relay 24V 300A
CR-23
2 ※Check resistance
Blower 24V 9.5A
1
1 Lo 1 ※Check resistance
2 MH 3 Normal : 1.12Ω(For terminal 4-2)
Aircon resistor -
3 ML 2 2.07Ω(For terminal 2-3)
4 Hi 4 3.17Ω(For terminal 3-1)
※Check resistance
1 1°
C OFF Normal : 0Ω(For terminal 1-2),
Duct sensor
2 4°
C ON the atmosphere temp :
Over 4°C
Switch
(Power max, 1 ※Check resistance
one touch decel, 24V 6A Normal : ∞Ω
2
horn)
CS-5 CS-19
CS-26 CS-29
1
※Check contact
Quick coupling 2 24V 6A
Normal : 28.9MΩ(For terminal 1-2)
CN-140
4-26
※Check resistance
Normal : About 200Ω
1
Relay 24V 20A (For terminal 1-3)
2 0Ω
CS-5 CS-19 (For terminal 2-4)
CS-26 CS-29
3 24V
0bar : 1V(For terminal 1-2)
Transducer 2 SIG
500bar 500bar : 5V(For terminal 1-2)
1 GND
CD-32 CD-33
CD-42 CD-43
3 24V
0bar : 1V(For terminal 1-2)
Transducer 2 SIG 50bar 50bar : 5V(For terminal 1-2)
1 GND
CD-44
4-27
GROUP 4 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
number Type Destination
pin Female Male
CN-1 AMP 6 I/conn(Frame harness-main pump) S816-006002 S816-106002
CN-2 AMP 12 I/conn(Frame harness-engine harness) S816-012002 S816-112002
CN-3 AMP 8 I/conn(Frame harness-engine harness) S816-008002 S816-108002
CN-4 AMP 8 I/conn(Wire harness LH-frame harness) S816-008002 S816-108002
CN-5 AMP 15 I/conn(Side harness RH-frame harness) 2-85262-1 368301-1
CN-6 AMP 12 I/conn(Side harness RH-frame harness) S816-012002 S816-112002
CN-7 AMP 15 I/conn(Wire harness RH-frame harness) 2-85262-1 368301-1
CN-8 AMP 12 I/conn(Wire harness RH-frame harness) S816-012002 S816-112002
CN-9 AMP 8 I/conn(Wire harness RH-frame harness) S816-008002 S816-108002
CN-10 DEUTSCH 12 I/conn(Cab harness-frame harness) DT06S-12S DT04-12P
CN-11 DEUTSCH 8 I/conn(Air con harness-frame harness) DT06-8S DT06-8P
CN-12 DEUTSCH 2 Boom wire harness DT06-2S DT06-2P
CN-16 AMP 6 Pump pressure harness S816-006002 S816-106002
CN-20 MOLEX 2 Horn 35825-0211 -
CN-21 AMP 6 Wiper motor 925276-0 -
CN-22 KET 2 Washer tank MG640605 -
CN-23 KET 2 Speaker-LH MG610070 -
CN-24 KET 2 Speaker-RH MG610070 -
CN-25 MOLEX 2 Horn 35825-0211 -
CN-27 AMP 14 Cassette radio 173852 -
CN-28 MWP 1 AC compressor NMWP01F-B -
CN-29 KET 2 Receiver dryer MG640795 -
CN-36 - - Fuse box S820-106000 -
CN-45 RING-TERM - Start motor B 21N8-20041 -
CN-47 AMP 2 Resistor S810-002202 S810-102202
CN-48 KET 1 Hour meter GP890469 -
CN-50 AMP 36 CPU controller 3441110 -
CN-51 AMP 36 CPU controller 3441110 -
CN-56 DEUTSCH 4 Cluster - DT04-4P
CN-60 YAZAKI 2 Battery relay contact 7122-4125-50 21N4-01320
CN-61 DEUTSCH 2 Fuel filler pump DT06-2S DT04-2P
CN-66 DEUTSCH 2 Breaker solenoid DT06-2S DT04-2P
CN-68 DEUTSCH 2 Safety solenoid DT06-2S DT04-2P
CN-70 DEUTSCH 2 Travel solenoid DT06-2S DT04-2P
4-28
pin Female Male
CN-74 RING-TERM - Alternator "l" term S820-105000 -
CN-75 AMP 2 EPPR valve S816-002002 -
CN-76 DEUTSCH 6 DC motor DT06-6S -
CN-79 PACKARD 3 Fuel cut off S818-020311 -
CN-81 DEUTSCH 2 Travel buzzer DT06-2S DT04-2P
CN-88 DEUTSCH 2 Power max solenoid DT06-2S DT04-2P
CN-91 DEUTSCH 8 Overload switch harness DT06-2S DT04-2P
CN-92 KET 1 Spare connector S814-001100 S814-101100
CN-95 YAZAKI 2 Battery relay contact S813-130200 21N4-01311
CN-116 PA 17 Switch panel S811-017002 -
CN-126 DEUTSCH 4 RS 232 connector DT06-4S DT04-4P-E004
CN-138 DEUTSCH 3 DC/DC converter DT06-3S -
CN-139 DEUTSCH 2 12V socket DT06-2S DT04-2P
CN-141 AMP 13 Wiper motor controller 142176-2 -
CN-142 DEUTSCH 3 Accel dial DT06-3S -
CN-143 KET 12 Cassette radio(With remocon) MG610406 -
CN-144 AMP 12 Remocon-cassette radio 174045-2 -
・Relay
CR-1 RING-TERM - Battery relay - S820-104002
CR-23 RING-TERM 2 Start relay ST710095-3 -
CR-24 RING-TERM - Pre-heater relay S820-106000 -
CR-24 RING-TERM - Pre-heater relay S820-406000 -
・Switch
CS-1 SHUR 1 Door switch S822-014004 -
CS-2 SWP 6 Start key switch S814-006000 -
CS-4 DEUTSCH 3 Safety switch DT06-3S -
CS-5 DEUTSCH 2 Horn switch - DT04-2PS
CS-7 DEUTSCH 6 Prolix switch DT06-6S -
CS-19 DEUTSCH 2 One touch decel DT06-2S -
CS-23 SWF 10 Beacon lamp switch SWF 593757 -
CS-26 DEUTSCH 2 Breaker switch DT06-2S -
CS-27 SWF 10 Breaker switch SWF 593757 -
CS-29 DEUTSCH 2 Powe max switch DT04-2P -
CS-50 SWF 10 Overload switch SWF 593757 -
CS-52 SWF 10 Boom damping switch SWF 593757 -
CS-53 SHUR 1 Wiper cut switch S822-014002 -
CS-54 SWF 10 Spear switch SWF 593757 -
CS-60 RING-TERM - Reset button - S820-205002
CS-61 RING-TERM - Reset button - S820-305002
4-29
pin Female Male
・Light
CL-1 KET 2 Room lamp MG 610406 -
CL-2 AMP 1 Cigar light S822-014002 -
CL-4 DEUTSCH 2 Head lamp DT06-2S DT04-2P
CL-5 DEUTSCH 2 Work lamp-LH DT06-2S DT04-2P
CL-6 DEUTSCH 2 Work lamp-RH DT06-2S DT04-2P
CL-7 SHUR 1 Beacon lamp S822-014004 S822-114004
CL-8 DEUTSCH 2 Cab light-LH DT06-2S DT04-2P
CL-9 DEUTSCH 2 Cab light-RH DT06-2S DT04-2P
・Sensor, sendor
CD-1 AMP 2 Hydraulic oil temp sender 85202-1 -
CD-2 DEUTSCH 2 Fuel sender DT06-2S DT04-2P
CD-6 KET 2 Travel pressure switch MG 640795 -
CD-7 KET 2 Working pressure switch MG 640795 -
CD-8 AMP 2 Water temp sender 85202-1 -
CD-10 RING-TERM - Air cleaner switch - S820-104002
CD-16 KET 2 Water level S814-002100 -
CD-17 PACKARD 2 Tachosensor - S818-120221
CD-18 RING-TERM 1 Engine oil pressure switch - S820-104000
CD-31 DEUTSCH 2 Overload pressure switch DT06-2S DT04-2P
CD-42 AMP 3 Pump pressure 1 S816-003002 -
・Diode
DO-1 AMP 2 - 21EA-50550 -
DO-2 AMP 2 - 21EA-50550 -
DO-3 AMP 2 - 21EA-50550 -
4-30
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
4-31
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
10 21
1 11
21
1 11 10 21
S811-021002 S811-121002
4-32
2) J TYPE CONNECTOR
No. of
pin
1 2
1
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
4-33
3) SWP TYPE CONNECTOR
No. of
pin Receptacle connector(Female) Plug connector(Male)
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 23
S814-003000 S814-103000
2 4 1 3
1 3 2 4
S814-004000 S814-104000
4-34
No. of
pin
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
4-35
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 4
1 3 2 3
S810-004202 S810-104202
4-36
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
4-37
5) 375 FASTEN TYPE CONNECTOR
No. of
pin
1 2 1 2
S810-002402 S810-102402
6) AMP ECONOSEAL CONNECTOR

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

No. of
pin
85202-1
4-38
8) AMP 040 MULTILOCK CONNECTOR
No. of
pin
12
1 6
7 12
174045-2
9) AMP 070 MULTILOCK CONNECTOR

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

No. of
pin
3 1
6 4
1
4 6 3
925276-0 480003-9
4-39
11) KET 090 CONNECTOR
No. of
pin
2 1
MG610070
12) KET 090 WP CONNECTORS

No. of
pin
1
2
MG640605
2 1
MG640795
4-40
13) KET SDL CONNECTOR
No. of
pin
1
14
14 6
MG610406
4-41
14) DEUTSCH DT CONNECTORS
No. of
pin
1 2 2 1
2
DT06-2S DT06-2P
2 1 1 2
3 3
DT06-3S DT06-3P
4 1 1 4
3 2 2 3
DT06-4S DT06-4P
6 1 1 6
4 3 3 4
DT06-6S DT06-6P
4-42
No. of
pin
4 5 5 4
1 8 8 1
DT06-8S DT06-8P
6 7 7 6
12
1 12 12 1
DT06-12S DT06-12P
4-43
15) MOLEX 2CKTS CONNECTOR
No. of
pin
1 2
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
4-44
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 Anti-Restart System 5-11
Group 9 Self-Diagnostic System 5-12
Group 10 Engine Control System 5-15
Group 11 EPPR(Electro Proportional Pressure Reducing) Valve 5-21
Group 12 Prolix System 5-24
Group 13 Monitoring System 5-25
SECTION 5 MECHATRONICS SYSTEM
GROUP 1 OUTLINE
The NEW 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 for a CPU controller, a cluster, an accel actuator, an EPPR valve, and other components.
The CPU controller 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.
Engine control system

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

NEW CAPO
SYSTEM
Max flow control system
Anti-restart system
Controller & cluster protection

Self-diagnostic system
Open-short diagnosis & error code display
Machine condition monitoring
Machine monitoring system
Electric signal monitoring
One touch deceleration system
Boom priority system
5-1
SYSTEM DIAGRAM
32075MS01
5-2
GROUP 2 MODE SELECTION SYSTEM
1. POWER MODE SELECTION SYSTEM
32075MS02
Mode selection system(Micro computer based electro-hydraulic pump and engine mutual control
system) optimizes the engine and pump performance.
The combination of 2 power modes(H, S) and accel dial position(10 set) 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.
Power shift by EPPR valve

Engine rpm
Power Default Other case
Mode Application set
(%) Current Pressure Current Pressure
Unload Load (kgf/cm2) (kgf/cm2)
(mA) (mA)
M Maximum Power 95 1960Ü50 1750 230Ü30 4 160 0
H High power 85 1850Ü50 1650 270Ü30 6 230 4
S Standard power 70 1750Ü50 1550 270Ü30 6 270 6
AUTO DECEL Engine deceleration - 1100Ü100 - 670Ü30 31 670Ü30 31
One touch decel Engine quick deceleration - 850Ü100 - 700Ü30 35 700Ü30 35
KEY START Key switch start position - 850Ü100 - 700Ü30 35 700Ü30 35
5-3
2. WORK MODE SELECTION SYSTEM
3 work modes can be selected for the optional work speed of the machine operation.
32075MS03
1) HEAVY DUTY WORK MODE

The boom priority solenoid is activated to make the boom operation speed faster.
2) GENERAL WORK MODE
When key switch is turned ON, this mode is selected and swing operation speed is faster than
heavy duty work mode.
3) BREAKER OPERATION MODE
It sets the pump flow to the optimal operation of breaker by activating the max flow cut-off solenoid.
Work mode Boom priority solenoid Max flow cut-off solenoid

Heavy duty ON OFF
General OFF OFF
Breaker OFF ON
5-4
3. USER MODE SELECTION SYSTEM
An operator can change the engine and pump power and memorize it for his preference.
Mode Operation
High idle rpm, auto decel rpm

U EPPR pressure can be modulated and memorized separately
HOW TO MODULATE THE MEMORY SET

1) Each memory mode has a initial set which are
mid-range of max engine speed, auto decel rpm,
and EPPR valve input current. When you select
M or U, cluster LCD displays.
2) To change the engine high idle speed, press the
USER mode switch and SELECT switch at the 21074OP03G
same time and then ACCEL blinks at 0.5 seconds
interval.
- By pressing or switch, will increase or
decrease.
3) To change DECEL rpm, press the USER mode
switch and SELECT switch once more and then
DECEL blinks at 0.5 seconds interval.
decrease.
4) To change EPPR current, press the USER mode
switch and SELECT switch one more and then
EPPR blinks at 0.5 seconds interval.
decrease.
ÂLCD segment vs parameter setting
Segment ACCEL DECEL EPPR
( ) (rpm) (rpm) (mA)
1 High idle-900 Low idle(850) 150
2 High idle-800 950 200
3 High idle-700 1000 250
4 High idle-600 1050 300
5 High idle-500 Decel rpm(1100) 350
6 High idle-400 1150 400
7 High idle-300 1200 450
8 High idle-200 1250 500
9 High idle-100 1300 550
10 High idle 1350 600
5) To memorize the final setting, press the USER

21074OP03H
mode switch and SELECT switch one more time.
5-5
GROUP 3 AUTOMATIC DECELERATION SYSTEM
Work equipment
pressure switch Travel oil pressure switch
Accel
Fuel injection actuator
pump
P M
Main control valve
Potentiometer signal
Motor drive signal
Auto decel switch signal Pressure switch signal

CPU controller
Accel dial signal
Accel dial
21075MS04
1. WHEN AUTO DECEL LAMP ON

If all the work equipment control levers including swing and travel levers are at neutral for at least 4
seconds, CPU controller drives the governor motor to reduce the engine speed to 1100rpm. As the
result of reducing the engine speed, fuel consumption and noise are effectively cut down during non-
operation of the control levers.
When the Auto decel lamp is turned off by pressing the switch or any control lever is operated, the
reduced engine speed rises upto the speed set before deceleration in a second.
32075MS05
2. WHEN AUTO DECEL LAMP OFF

The engine speed can be set as desired using the engine speed switch, and even if the control levers
are neutral, the engine speed is not reduced.
Note : Auto decel function can be activated when accel dial position is over 4.
5-6
GROUP 4 POWER BOOST SYSTEM
Main control valve
Arm 1 Arm 2
Boom 2 Bucket
Swing Boom 1
LH travel Option
Boom priority RH travel

spool
Main relief Power boost

valve solenoid valve
Engine speed
sensor
Engine
Main pump Pilot pump
Accel Max flow

Fuel injection actuator CO valve
pump
P M
EPPR valve
Engine speed sensor signal
LH control
Motor drive signal
lever
Power boost
button
Power boost button signal

Drive signal
Mode switch signal Drive signal

CPU controller
21075MS06
・ When the power boost switch on the left control lever knob is pushed ON, the maximum digging
power is increased by 10%.
・ When the power set is at H or S and the power boost function is activated, the power boost solenoid
valve pilot pressure raises the set pressure of the main relief valve to increase the digging power.
Power boost switch

Description
OFF ON
Power seat H or S OFF
Main relief valve set pressure 330kgf/cm2 OFF
Even when pressed continuously,
Time of operation -
it is canceled after 8 sec.
※ Default - Power boolst solinoid valve : OFF
5-7
GROUP 5 TRAVEL SPEED CONTROL SYSTEM
Travel motor
Main control valve
Arm 1 Arm 2
Regulator Regulator
Boom 2 Bucket
Swing Boom 1
LH travel Service
RH travel
Travel spped
solenoid valve
Engine
Max flow
CO valve
EPPR valve
Travel speed switch signal Drive signal

CPU controller
21075MS07
Travel speed can be switched manually by pressing the travel speed switch on the cluster.
Travel speed Lamp
Speed Operation
solenoid valve on cluster
Lo OFF Turtle Low speed, high driving torque in the travel motor
Hi ON Rabbit High speed, low driving torque in the travel motor
※ Default : Turtle(Lo)
5-8
GROUP 6 AUTOMATIC WARMING UP FUNCTION
Engine
Coolant
temp sensor
Accel Max flow

pump
P M
EPPR valve
Coolant temperature signal
Motor drive signal
Drive signal
Warming up lamp signal

CPU controller
21075MS08
1. CPU controller reads engine coolant temperature through the temperature sensor, and if the coolant
temperature is less than 30°
C, it increases the engine speed from key start rpm to 1100rpm. At this
time the mode does not change.
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 mode set during the warming up function, the CPU controller
cancels the automatic warming up function.
3. LOGIC TABLE
Description Condition Function

- Coolant temperature : - Mode : Default(S mode)
Actuated Less than 30° C(After engine run) - Warming up time : 10 minutes(Max)
- Accel dial position is under 3 - Warming up lamp : ON
- Coolant temperature : Above 30° C - Default mode

- Warming up time : Above 10 minutes - Default mode
- Changed mode set by operator - Changed mode
Canceled - Increase engine speed by rotating accel
dial clockwise
※ If any of the above conditions is
applicable, the automatic warming up
function is canceled
Warming up lamp - Coolant temperature : Above 30°

C - Warming up lamp : OFF
5-9
GROUP 7 ENGINE OVERHEAT PREVENTION FUNCTION
Engine
Coolant
temp sensor
Accel Max flow

pump
P M
EPPR valve
Coolant temperature signal
Motor drive signal

Drive signal
Overheat warming signal

CPU controller
21075MS09
1. CPU controller reads engine coolant temperature through the temperature sensor and when the
engine coolant boils up to 110°
C, it sends overheat warning signal to the cluster and decrease the
engine speed same as accel dial 7 position.
2. If the coolant temperature drops less than 100° C, the CPU controller returns the mode to the mode
set before. And if mode set is changed during the function, the CPU controller cancels the function.
Even if the overheat prevention function is canceled by mode change, the overheat warning lamp
turns OFF only when the coolant temperature is less than 100° C.
3. LOGIC TABLE
Description Condition Function
- Coolant temperature : Above 110°

C - Engine rpm drop to accel dial 7 position
Actuated
- Accel dial set : Above 8 - Overheat warning lamp & buzzer : ON
- Coolant temperature : Less than 100°C - Return to the mode and accel dial set before
- Changed mode set by operator - Hold on the changed set
Canceled ※ If any of the above conditions is
applicable, engine overheat prevention
function is canceled
Overheat warning lamp - Coolant temperature : Less than 100°

C - Overheat warning lamp : OFF
5-10
GROUP 8 ANTI-RESTART SYSTEM
Engine
Starter
Start safety relay
Drive signal
CPU controller
CN-92a
CN-92b
21075MS10
1. ANTI-RESTART FUNCTION
After 10 seconds from the engine starts to run, CPU controller turns off the start safety relay to protect
the starter from inadvertent restarting.
2. When a replacement or taking-off of the CPU controller is needed, connect CN-92a and CN-92b to
ensure the engine start without the CPU controller.
5-11
GROUP 9 SELF-DIAGNOSTIC SYSTEM
1. OUTLINE
When any abnormality occurs in the NEW CAPO system caused by electric parts malfunction and by
open or short circuit, the CPU controller diagnoses the problem and sends the error codes to the
cluster and also stores them in the memory.
The current or recorded error codes are displayed at the error display mode selected by touching
SELECT switch 2 times while pressing BUZZER STOP switch.
2. CURRENT ERROR DISPLAY
Cluster displays Co : Er and makes buzzer sound itself to warn the communication error when
communication problem caused by wire-cut or malfunction of the CPU controller occurs.
Cluster displays real time error codes received from CPU controller through communication. In case
of no problem it displays CHECK Er : 00.
If there are more than 2 error codes, each one can be displayed by pressing and switch
respectively.
Examples :
1) Communication Error
Co : Er & Buzzer sound
2) No problem
CHECK Er : 0 0
3) 4 Error codes(03, 06, 10, 43) display

CHECK Er : 0 3
Press Press Press

0 3 0 6 1 0 4 3 No change
Start Press Press Press Press
3. RECORDED ERROR DISPLAY

The recorded error can be displayed only when the key switch is at ON position.
Examples : 5 Recorded error codes(03, 06, 10, 20, 32) display
TIME Er : 0 3
Press Press Press Press

0 3 0 6 1 0 2 0 3 2 No change
Start Press Press Press Press Press
4. DELETE ALL RECORDED ERROR CODES

Select recorded error(TIME Er) display and press engine and select switch at the same time for
2 seconds or more. Cluster display changes to TIME Er : 00, which shows that CPU controller deleted
all the recorded error codes in the memory.
5-12
5. ERROR CODES TABLE
Fault code No. Description
1 Short circuit in governor motor system

2 Potentiometer circuit is shorted to Vcc(5V) or battery +
3 Short circuit in pump EPPR valve system
4 Short circuit in boom down EPPR valve system
5 Short circuit in travel speed solenoid system
6 Short circuit in power boost solenoid system
7 Short circuit in max flow solenoid system
10 Short circuit in hour-meter system
11 Accel dial circuit is shorted to Vcc(5V) or battery +
12 P1 pressure sensor circuit is shorted to power supply(24V) line
13 P2 pressure sensor circuit is shorted to power supply(24V) line
14 P3 pressure sensor circuit is shorted to power supply(24) line
15 Boom down pressure circuit is shorted to power supply(24V) line
16 Governor motor circuit is open or shorted to ground
17 Potentiometer circuit is open or shorted to ground
18 Pump EPPR valve circuit is open or shorted to ground
19 Boom down EPPR valve circuit is open or shorted to ground
20 Travel speed solenoid circuit is open or shorted to ground
21 Power boost solenoid circuit is open or shorted to ground
22 Max flow solenoid circuit is open or shorted to ground
25 Hour-meter circuit is open or shorted to ground
26 Accel dial circuit is open or shorted to ground
27 P1 pressure sensor circuit is open or shorted to ground
30 Boom down pressure sensor circuit is open or shorted to ground
31 Engine preheater circuit is open or shorted to ground
32 Travel alarm buzzer circuit is open or shorted to ground
33 Alternator circuit is open or shorted to ground
34 Controller input voltage is below 18V
35 Controller input voltage is over 38V
36 Communication error with cluster
37 Engine speed sensor circuit is open or shorted to ground
38 Anti-restart relay circuit is open or shorted to ground
39 Accel actuator does not stop at a target position
40 There is more than 500rpm difference between target speed and actual speed
5-13
Fault code No. Description
41 Hydraulic oil temperature sensor circuit is shorted to ground

42 Fuel level sensor circuit is shorted to ground
43 Coolant temperature sensor circuit is shorted to ground
44 Boom up pressure sensor circuit is shorted to power supply(24V) line
45 Hydraulic oil temperature sensor circuit is open or shorted to battery +
46 Fuel level sensor circuit is open or shorted to battery +
47 Coolant temperature sensor circuit is open or shorted to battery +
48 Boom up pressure sensor circuit is open or shorted to ground
49 Engine preheater circuit is shorted to battery +
51 Boom priority solenoid circuit is open or shorted to ground
56 Travel alarm buzzer circuit is shorted to battery +
58 Boom priority solenoid circuit is shorted to battery +
5-14
GROUP 10 ENGINE CONTROL SYSTEM
1. CPU CONTROLLER MOUNTING
1 CPU controller
2 Electric box
3 Bolt(M8)
21075MS11
2. CPU CONTROLLER ASSEMBLY

1) Remove four pieces of bolt(3) of electric box(2).
2) Disconnect 2 connectors from CPU controller.
3) Remove 6 pieces of screw and open the cover of CPU controller.
4) Inspection : Check PCB(Printed Circuit Board)
(1) If any damage is found, replace CPU controller assembly.
(2) If not, but CAPO system does not work please report it to HHI dealer or A/S department.
5-15
3. EXCHANGE METHOD OF THE ROM
1) Disassemble the ash tray(2).
2) Disassemble the wiper motor cover(3).
3) Disassemble the cluster(1).
21075MS12
4) Loosen the screws(6EA) located back of

the cluster.
5) Then you can open the upper case of the
cluster easily.
21075MS13
6) Install the new ROM.(Be careful of direction

and assmelbe the cluster in the reverse
order to removal).
21075MS14
5-16
4. ENGINE ACCEL ACTUATOR
1 Accel actuator
2 Push-pull cable for manual control
32075MS16
1) ENGINE THROTTLE LEVER
Throttle lever
SL : Stopper, low idle
SH : Stopper, high idle
SL SH
Accel actuator
5-18(2) 210-7
2) EMERGENCY CABLE (Push-pull cable)

It controls engine speed by connecting onto the lever of the injection pump when the malfunction of
the CPU controller or the accel actuator happen.
5-17
3) ACCEL ACTUATOR
2 4
5
1 DC motor
2 Cable
3 Nut
4 Ball joint
5 Connector
5-19(1) 210-7
6 1
Connector 5 2
4 3
Type 6P, female

1 White(Potentiometer 5V)
2 Blue(Potentiometer SIG)
Line color 3 Black(Potentiometer GND)
& description 4 -
5 Green(Motor+)
6 Yellow(Motor -)
Check resistance
Inspection Spec : 1~2Ω(Between No.5-6)
0.8~1.2kΩ(Between No.1-3)
5-18
4) ACCEL ACTUATOR CABLE SETTING PROCEDURE
(1) Key OFF
① Connect the ball joint of cable to engine throttle lever.
② Pull the cable to high stopper and put nut A edge to yoke of the bracket.
※ Make throttle lever not contact to the edge of high stopper.
③ Turn nut A to clockwise until touching to the edge of high stopper.
④ Make 1 turn more to clockwise in condition of the nut A contact to the edge of high stopper.
(2) Key START
⑤ Confirm if the engine speed on cluster is same as each mode specification.
⑥ If the engine speed displayed on cluster is highter than each mode specification, then turn the nut
A to counter clockwise and make the engine speed same to each mode specification.
⑦ If the engine speed displayed on cluster is lower than each mode specification, then turn the nut
A to clockwise and make the engine speed same to each mode specification.
⑧ Turn nut B to clockwise and fix the cable to bracket.
Nut A Nut B Ball joint Throttle lever
Hi Lo
Cable Bracket
130W5MS05
Mode RPM
H 1960±50
S 1850±50
Auto decel 1100±100
Key start 850±100
5-19
5. ENGINE SPEED SENSOR
1) DETECT ACTUAL ENGINE RPM AND SEND SIGNAL TO TACHOMETER
3 2
2 Gear teeth, flywheel

3 Lock nut, speed sensor
Flywheel housing A Clearance
5-20 (210-7)
2) INSTALLATION
(1) Clean contacting point of sensor.
(2) Loosen lock nut.
(3) Screw speed sensor into flywheel housing.
(4) Turn it back 135°when it contacts with gear teeth.
(5) Tight lock nut and connect wiring.
3) INSPECTION
(1) Check resistance
・SPEC : 300Ω
(2) Check voltage while engine run.
・SPEC : 2~28Vac, dependent on the engine speed(rpm)
5-20
GROUP 11 EPPR VALVE
1. COMPOSITION OF EPPR VALVE

EPPR(Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve
installed at main hydraulic pump.
1) ELECTRO MAGNET VALVE
Receive electric current from CPU controller and move the spool proportionally according to the
specific amount of electric current value.
2) SPOOL VALVE
Is the two way direction control valve for pilot pressure to reduce hydraulic pump flow.
When the electro magnet valve is activated, pilot pressure enters into flow regulator of hydraulic pump.
So, pump flow decreases to prevent engine stall.
3)
Pressure Electric current Engine rpm
Mode
kgf/cm2
psi (mA) (At accel dial 10)
M 4Ü3 71 Ü 40 230 Ü 30 1960 Ü 50

Standard
H 6Ü3 85 Ü 40 270 Ü 30 1850 Ü 50
(Ver : 1.x)
S 6Ü3 85 Ü 40 270 Ü 30 1750 Ü 50
M 0Ü3 0 Ü 40 160 Ü 30 1960 Ü 50
Option
H 4Ü3 57 Ü 40 230 Ü 30 1960 Ü 50
(Ver : 2.x)
S 6Ü3 85 Ü 40 270 Ü 30 1850 Ü 50
ø 10 Ü 3 142 Ü 40 320 Ü 30 -
ø Manually operated condition when prolix resistor is connected in emergency operation.
2. HOW TO SWITCH THE VERSION(1.x Ĉ 2.x) ON THE CLUSTER

You can switch the EPPR valve pressure set by selecting the version(1.x Ĉ 2.x).
Step 1. Turn the key switch ON.
Step 2. Press the SELECT switch 3 times.
Step 3. While 7 segment on the cluster shows the version of the CPU controller program, for example
32C1.0 press the buzzer stop switch( ) + travel speed control switch( ) at the same
time for 2 seconds.
The display changes to 32C2.0, and it indicates that version 2.0(Option) is selected.
ö If you want to get back to ver:1.x, go to step 1~3.
5-21
2. OPERATING PRINCIPLE
1) STRUCTURE
6 7
2 3 4 5
1
5-22(1) 210-7
1 Sleeve 4 O-ring 6 Solenoid valve

2 Spring 5 O-ring 7 Connector
3 Spool
P Pilot oil supply line(Pilot pressure)

P A T Return to tank
T A Secondary pressure to flow regulator at hydraulic pump
5-22A (210-7)
2) AT H MODE
Pressure line is blocked and A oil returns to tank.
P A
T P T
A
5-22B (210-7)
3) AT S MODE
Secondary pressure enters into A.
P A
T
P T
5-22C (210-7)
A
5-22(1) 210-7
5-22
3. EPPR VALVE CHECK PROCEDURE Spec : 200~450mA
1) CHECK ELECTRIC VALUE AT EPPR VALVE
(1) Start engine.
(2) Set S-mode and cancel auto decel mode.
(3) Position the accel dial at 10. CN-75
(4) If tachometer show approx 1850±50rpm,

disconnect one wire harness from EPPR
valve.
EPPR VALVE
(5) Install multimeter as figure. Multimeter
(6) Check electric current at bucket circuit

relief position.
5-23(1) 210-7
2) CHECK PRESSURE AT EPPR VALVE Spec : 2~25kgf/cm2(30~350psi)

(1) Remove plug and connect pressure
gauge as figure.
・Gauge capacity : 0 to 40-50kgf/cm2
(0 to 580-725psi)
(2) Start engine.
(3) Set S-mode and cancel auto decel mode. Supply line, pilot press
(4) Position the accel dial at 10. CN-75

Pressure adjusting
(5) If tachometer show approx 1850±50rpm, screw
locknut
check pressure at relief position of bucket
circuit by operating bucket control lever.
(6) If pressure is not correct, adjust it.
(7) After adjust, test the machine. 5-23(2) 210-7
5-23
GROUP 12 PROLIX SYSTEM
Is the prolix resistor connected to manual control temporarily when the electronic control system is
out of order, until repair work be done.
32075MS15
1. OPERATING PRINCIPLE WIRING DIAGRAM
14075MS19
1) NORMAL
・EPPR valve supply specified amount of pilot pressure to the flow regulator of hydraulic pump and
regulate hydraulic pump delivery amount depending upon the signal of CPU controller by selected
mode.
2) EMERGENCY
・If prolix resistor is connected with the emergency connector when any abnormality occurs in
NEW CAPO system, constant electric current from battery flows to EPPR valve so that EPPR
valve can be fixed at the predetermined position.
・In this case excavator can be operated at an equivalent performance to S mode.
5-24
GROUP 13 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
32075MS12
5-25
2) CLUSTER CHECK PROCEDURE
(1) Start key : ON
① Check monitor initial 5 seconds
a. All lamps light up.
b. Buzzer sound.
② Check monitor after 5 seconds : Indicate cluster version and machine condition
a. Cluster program version : CL : 1.4 Indicates program version 1.4 for 2 seconds.
b. Tachometer : 0rpm
c. Fuel gauge : All light up below appropriate level
d. Hydraulic temperature : All light up below appropriate level
e. Engine coolant temperature gauge : All light up below appropriate level
f. Warning lamp
※ During start key ON the engine oil pressure lamp and battery charging lamp go on, but it is not
abnormal.
※ When engine coolant temperature below 30° C, the warming up lamp lights up.
③ Indicating lamp state
a. Work mode selection : General work
b. Power mode selection : S mode
c. User mode selection : No LED ON
d. Auto decel LED : ON
e. Travel speed pilot lamp : Low(Turttle)
(2) Start of engine
① Check machine condition
a. Tachometer 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 : S mode
e. User mode selection : No LED ON
f. Auto decel LED : ON
g. Travel speed pilot lamp : Low(Turttle)
② When warming up operation
a. Warming up lamp : ON
b. 10 seconds after engine started, engine speed increases to1200rpm(Auto decel LED : ON)
※ Others same as above ①.
③ When abnormal condition
a. The lamp lights up and the buzzer sounds.
b. If BUZZER STOP switch is pressed, buzzer sound is canceled but the lamp light up until normal
condition.
5-26
3. CLUSTER CONNECTOR
No. Signal Input / Output
1 Power IG(24V) Input(20~32V)

Cluster
2 GND Input(0V)
3 Serial-(RX) Input(Vpp=12V)
4 Serial+(TX) Output(Vpp=4V)
21075MS16
5-27
4. CLUSTER FUNCTION
1) MONITORING DISPLAY
(1) This displays the current time and machine information such as
engine rpm, coolant/hydraulic oil temperature, hydraulic oil
pressure and also error codes.
※ Refer to the page 5-33 for details.
21073CD03A
2) FUEL GAUGE
(1) This gauge indicates the amount of fuel in the fuel tank.
(2) Fill the fuel when the white range or warning lamp blinks.
※ If the gauge illuminates the white range or warning lamp
White range
blinks even though the machine is on the normal condition,
check the electric device as that can be caused by the
21073CD04
poor connection of electricity or sensor.
3) HYDRAULIC OIL TEMPERATURE GAUGE

(1) This indicates the temperature of coolant.
・White range : 30° C(86°F) below
・Green range : 30-105 ° C(86-221° F)
・Red range : 105° C(221° F) above
Red range
(2) The green range illuminates when operating.
21073CD05
(3) Keep idling engine at low speed until the green range
illuminates, before operation of machine.
(4) When the red range illuminates, reduce the load on the system.
If the gauge stays in the red range, stop the machine and
check the cause of the problem.
4) ENGINE COOLANT TEMPERATURE GAUGE

(1) This indicates the temperature of coolant.
・White range : 30° C(86°F) below
・Green range : 30-105 ° C(86-221° F)
・Red range : 105° C(221° F) above
Red range
(2) The green range illuminates when operating.
21073CD05
(3) Keep idling engine at low speed until the green range
illuminates, before operation of machine.
(4) When the red range illuminates, turn OFF the engine, check
the radiator and engine.
5-28
5) FUEL LOW LEVEL WARNING LAMP
(1) This lamp blinks and the buzzer sounds when the level of fuel
is below 31ℓ(8.2U.S. gal).
(2) Fill the fuel immediately when the lamp blinks.
21073CD04A
6) HYDRAULIC OIL TEMPERATURE WARNING LAMP

(1) This lamp blinks and the buzzer sounds when the temperature
of coolant is over the normal temperature 105°
C( 221°
F) .
(2) Check the cooling system when the lamp blinks.
21073CD05A
7) OVERHEAT WARNING LAMP

(1) This warning lamp operates and the buzzer sounds when the
temperature of hydraulic oil is over 105°
C(221°
F).
(2) Check the hydraulic oil level when the lamp blinks.
(3) Check for debris between oil cooler and radiator.
21073CD05A
8) ENGINE OIL PRESSURE WARNING LAMP

(1) This lamp blinks and the buzzer sounds after starting the
engine because of pressure.
(2) If the lamp blinks during engine operation, shut OFF engine
immediately. Check oil level.
21073CD07
9) AIR CLEANER WARNING LAMP

(1) This lamp is operated by the vacuum caused inside when the
filter of air cleaner is clogged which supply air to the engine.
(2) Check the filter and clean or replace it when the lamp blinks.
21073CD08
5-29
10) CPU CONTROLLER CHECK WARMING LAMP
(1) Communication problem with CPU controller makes the lamp
blinks and the buzzer sounds.
(2) With lamp blinks all of the lamp on the cluster LCD will be OFF.
21073CD10
11) BATTERY CHARGING WARNING LAMP

(1) This lamp blinks and the buzzer sounds when the starting
switch is ON, it is turned OFF after starting the engine.
(2) Check the battery charging circuit when this lamp blinks, during
engine operation.
21073CD10
12) OVERLOAD WARNING LAMP

(1) When the machine is overload, the overload warning lamp
blinks during the overload switch ON.
21073CD15
13) POWER MAX PILOT LAMP

(1) The lamp will be ON when pushing power max switch on the
LH RCV lever.
21073CD11
14) ONE TOUCH DECEL PILOT LAMP

(1) Operating auto decel or one touch decel makes the lamp ON.
(2) The lamp will be ON when pushing one touch decel switch on
the LH RCV lever.
21073CD17
5-30
15) 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
coolant temperature is above 30 °
C, or when 10 minutes have
passed since starting.
21073CD18
16) PREHEAT PILOT LAMP

(1) Turning the start key switch ON position starts preheating in
cold weather.
(2) Start the engine as this lamp is OFF.
21073CD12
17) WORK MODE SWITCH

(1) This switch is to select the machine operation mode, which
shifts from general operation mode to heavy operation mode
and breaker mode in a raw by pressing the switch.
・ : Heavy duty work mode
・ : General work mode
21073CD20 ・ : Breaker operation mode
18) USER MODE SWITCH

(1) This switch is to select the memory sets, at which you can
change the engine and pump power and memorize it into MI
and MII mode for your preference.
21073CD21
19) AUTO DECELERATION SWITCH

(1) This switch is used to actuate the auto deceleration function so
the engine speed is lowered automatically when all control
levers and pedals are at neutral position to save the fuel.
・Light ON : Auto deceleration function is selected.
・Light OFF : Auto deceleration function is cancelled so that the
21073CD22 engine speed increased to previous setting value.
(2) Operating the auto deceleration function makes the decel
indicate lamp on the LCD panel ON.
5-31
20) POWER MODE SWITCH
(1) The lamp of selected mode is turned ON by pressing the
switch( ), when selecting the mode to use.
・H : This is used for high power work.
・S : This is used for standard power work.
21073CD23
21) TRAVEL SPEED CONTROL SWITCH

(1) This switch is to control the travel speed which is changed to
high speed(Rabbit mark) by pressing the switch and low
speed(Turtle mark) by pressing again.
21073CD24
22) BUZZER STOP SWITCH

(1) When the starting switch is turned ON first, normally the alarm
buzzer sounds for 2 seconds during lamp check operation.
(2) The red lamp lights ON and the buzzer sounds when the
machine has a problem.
In this case, press this switch and buzzer stops, but the red
21073CD25
lamp lights until the problem is cleared.
23) SELECT SWITCH

(1) This switch is used to select the monitor display function.
(2) If the switch is pressed for 3 seconds in time display mode, it is
selected time adjusting function, as below.
・Hour by auto decel switch
21073CD25A
・Minute by buzzer stop switch.
(3) After time set, the switch is pressed, it is returned clock.
5-32
5. MONITORING DISPLAY
1) OUTLINE
Information of machine performance as monitored by the CPU controller can be displayed on the
cluster when the operator selects a display mode by touching SELECT switch alone or with BUZZER
STOP switch on the cluster as below.
How to select display mode
Display group Name Display on the cluster
Group selection Display mode selection
Initial Engine rpm
Way 1 Touch SELECT 1 time Time

Key switch Power shift pressure
ON or START Touch SECLET 2 times (EPPR valve)
Group 0 Touch SELECT 3 times CPU model & version
Way 2
(Default)
Touch AUTO DECEL
Touch SELECT
switch while pressing 4 times Option Front pump pressure
BUZZER STOP at (Only when
group 1~4. Touch SELECT
a pressure Rear pump pressure
5 times
sensor is
Touch SELECT installed) Pilot pressure
6 times
Default Battery voltage(V)
Touch SELECT switch Touch SELECT 1 time Potentiometer voltage(V)

Group 1 once while pressing
(Volt, temp, Touch SELECT 2 times
BUZZER STOP. Accel dial voltage(V)
EPPR press, In this group SELECT
version) Hydraulic oil
LED ON Touch SELECT 3 times temperature(° C)
Touch SELECT 4 times Coolant temperature(°

C)
Touch SELECT switch Default Current error

twice while pressing
Group 2 Recorded error
BUZZER STOP. Touch SELECT 1 time
(Error code) (Only key switch ON)
In this group BUZZER
Press down( ) & Recorded error deletion
STOP LED blinks
SELECT at the same time (Only key switch ON)
Default Pump prolix switch or
Touch SELECT 1 time Auto decel pressure switch or
Touch SELECT switch Power boost switch

Touch SELECT 2 times or
3 times while pressing
Group 3 BUZZER STOP.
Touch SELECT 3 times Travel oil pressure switch or
(Switch input) In this group SELECT
LED blinks at 0.5sec
Touch SELECT 4 times One touch decel switch or
interval
Touch SELECT 5 times Travel alarm switch or
Touch SELECT 6 times Preheat switch or
5-33
How to select display mode
Display group Name Display on the cluster
Group selection Display mode selection
Default Hourmeter or
Neutral relay
Touch SELECT 1 time (Anti-restart relay) or
Touch SELECT 2 times Travel speed solenoid or

Touch SELECT switch
4 times while pressing Power boost solenoid
Touch SELECT 3 times (2-stage relief solenoid) or
Group 4 BUZZER STOP.
(Output) In this group SELECT
LED blinks at 1sec Touch SELECT 4 times Boom priority solenoid or
interval
Touch SELECT 5 times Travel alarm or
Touch SELECT 6 times Max flow cut off solenoid or
Touch SELECT 7 times Preheat relay or
※By touching SELECT switch once while pressing BUZZER STOP, display group shifts.
Example : Group 0 1 2 3 4 0
5-34
2) DESCRIPTION OF MONITORING DISPLAY
Group Display Name Description
It displays current engine speed detected by engine speed

2250 rpm Engine speed sensor from 500 to 3000rpm.
Range : 500~3000rpm by 10rpm
It displays current time(12 is hour and 30 is minute)

TIME 12 : 30 Time
Range : Hour(1~12), minute(00~59)
Power shift It shows that pump power shift pressure of EPPR valve being
EP : 10bar pressure of controlled by the CPU controller is 10bar.
EPPR valve Range : 00~50bar by 1bar
It shows that machine model(R320LC-7) and the program

Model and CPU
32 : C1.0 version of the CPU controller is 1.0
Group 0 program version
Version display range : 0.0~9.9 by 0.1
It displays front pump pressure of 100bar which is detected by

P1 : 100bar Front pump
pressure sensor.
(Option) pressure
Range : 000~500bar by 10bar
It displays rear pump pressure of 200bar which is detected by

P2 : 200bar Rear pump
pressure sensor.
(Option) pressure
It displays pilot pump pressure of 30bar which is detected by

P3 : 30bar Pilot pump
pressure sensor.
(Option) pressure
It shows that battery power of 24.8V is supplied into CPU controller.

b24 : 8V Battery voltage
Range : 00.0~48.0V by 0.1V
Potentiometer It shows that potentiometer signal voltage is 2.5V.

Po : 2.5V
voltage Range : 0.0~5.0V by 0.1V
Accel dial It shows that accel dial signal voltage is 3.8V.

dL : 3.8V
voltage Range : 0.0~5.0V by 0.1V
Group 1
It shows that hydraulic oil temperature detected by temperature
Hydraulic oil
°C
Hd : 50° sensor is 50°C.
temperature
Range : 0~150° C by 1° C
It shows that coolant oil temperature detected by temperature

Coolant
°C
Ct : 85° sensor is 50°C.
temperature
Range : 0~150° C by 1°C
5-35
It shows that current error of 03(Short circuit in pump EPPR valve

system) is diagnosed by self diagnosis system in the CPU controller.
CHECK Er : 03 Current error If more than 2 errors, when pressing or switch, other
error codes show.
Range : 00~58
Group 2 It shows recorded error code of 03 which is diagnosed before.

If more than 2 error codes, when pressing or switch,
TIME Er : 03 Recorded error
other error codes show.
Range : 00~58
Recorded error It shows all recorded error codes are removed in the CPU
TIME Er : 00
deletion controller memory.
PP : on Shows that pump prolix switch is turned on(At

Pump prolix emergency position).
PP : on or oFF
switch PP : oFF Shows that pump prolix switch is turned off(At normal
position).
dP : on Shows that auto decel pressure switch is pressed on

Auto decel (No operation of control lever).
dP : on or oFF
pressure switch dP : oFF Shows that auto decel pressure switch is released off
(Operation of control lever).
Pb : on Shows that power boost switch is pressed on

Power (Activated).
Pb : on or oFF
boost switch Pb : oFF Shows that power boost switch is released off
(Canceled).
Group 3
oP : on Shows that travel oil pressure switch is pressed on
Travel oil (No operation of travel control lever).
oP : on or oFF
pressure switch oP : oFF Shows that travel oil pressure switch is released off
(Operation of travel control lever).
One touch od : on Shows that one touch decel switch is pressed.

od : on or oFF
decel switch od : oFF Shows that one touch decel switch is released.
Travel alarm br : on Shows that travel alarm function is selected.

br : on or oFF
switch br : oFF Shows that travel alarm function is canceled.
PH : on Shows that preheat switch is pressed.

PH : on or oFF Preheat switch PH : oFF Shows that preheat switch is released.
5-36
Ho : on Shows that hourmeter is activated by CPU controller.

Ho : on or oFF Hourmeter Ho : oFF Shows that hourmeter is turned off.
nr : on Shows that neutral relay for anti-restarting function is

Neutral relay activated(Engine start is possible).
nr : on or oFF (Anti-restart nr : oFF Shows that neutral relay is turned off to disable the
relay) engine restart.
ts : on Shows that travel speed solenoid is activated

Travel speed (High speed).
ts : on or oFF ts : oFF Shows that travel speed solenoid is released
solenoid
(Low speed).
PS : on Shows that power boost solenoid is activated to

Group 4 Power boost maximize the power(Power up).
PS : on or oFF PS : oFF Shows that power boost solenoid is turned off(Cancel
solenoid
the power boost function).
Boom priority bs : on Shows that boom priority solenoid is activated.

bs : on or oFF bs : oFF Shows that boom priority solenoid is released.
solenoid
Ru : on Shows that travel buzzer is activated.

Ru : on or oFF Travel alarm Ru :oFF Shows that travel buzzer is canceled.
Max flow cut off FS : on Shows that max flow cut off solenoid is activated.
FS : on or oFF FS : oFF Shows that max flow cut off solenoid is released.
solenoid
PR : on Shows that preheat relay is activated.

PR : on or oFF Preheat relay PR : oFF Shows that preheat relay is released.
5-37
SECTION 6 TROUBLESHOOTING
Group 1 Before Troubleshooting 6-1

Group 2 Hydraulic and Mechanical System 6-4
Group 3 Electrical System 6-24
Group 4 Mechatronics System 6-40
SECTION 6 TROUBLESHOOTING
GROUP 1 BEFORE TROUBLESHOOTING
1. INTRODUCTION
When a trouble is occurred in the machine, this section will help an operator to maintain the machine
with easy.
The trouble of machine is parted Hydraulic & Mechanical system, Electrical system and Mechatronics
system. At each system part, an operator can check the machine according to the troubleshooting
process diagram.
Hydraulic &
GROUP 2
Mechanical part
Troubles occur Electrical part GROUP 3
Mechatronics
GROUP 4
part
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 story of
malfunctions from a witness --- the operator.
1) How the machine is used and when it is
serviced?
2) When the trouble was noticed and what
work the machine was doing at that time?
3) What is the phenomenon of the trouble?
Was the trouble getting worse, or did it
come out suddenly for the first time?
4) Did the machine have any troubles
previously? If so, which parts were
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
the controllers causing total operational failures 6-2(3) 290-7
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.
6-3(1) 290-7
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.
6-3(3) 290-7
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.
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
setscrew is slack.
If hydraulic pump or engine is
suspected as a culprit refer to this
NO
manual "Structure and function".
6-5
2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL
Cause Remedy
NO
Replenish
specified oil to
the standard
Is oil level in Abnormal noise level.
hydraulic oil YES comes out of YES
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 See item 1).
YES make abnormal
connection at page 6-5
noise?
Is primary pilot
pressure within ⓐ
NO standard level?
YES
Clean pilot
Is not pilot piping piping interior or
YES clogged or is not
oil leakage present repair piping.
on pilot piping?
NO
Pilot valve is Disassemble
ⓐ faulty. and repair.
YES
Pilot relief valve is Repair or
Is gear pump faulty. replace.
NO delivering oil?
NO Gear pump is Disassemble

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
Clean oil cooler.
Is not oil cooler Secure air
clogged and is circulation route.
YES anything blocking YES
ⓐ
air circulation?
Is fan belt
NO tension proper?
Adjust belt
NO
tension or
replace belt.
Is not the set YES
pressure of main Readjust set
relief, relief and pressure.
ⓐ
travel relief valve Is main relief
lower than the YES
valve used very Reduce load.
standard level? NO often?
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
suction line? intrusion in
suction line and
retighten or
replace parts.
4) HYDRAULIC OIL IS CONTAMINATED
Cause Remedy
YES
Replace
Has not hydraulic hydraulic oil to be
oil passed specified.
specified replace-
ment hours? Has return filter
NO
been replaced at Flush with
NO proper intervals?
hydraulic oil and
replace return
filter.
6-8
4. SWING SYSTEM
1) BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE
Cause Remedy
NO
Replenish
YES specified oil to the
Is safety solenoid ⓐ
YES
valve pressure standard level.
Is gear pump pilot within standard? Safety valve faulty Repair or replace.
NO
pressure within or not operated.
YES standard level?
Is oil in hydraulic
YES tank within
Gear pump faulty. Repair or replace.
standard level? NO
YES
Are broken pieces Pump connection Disassemble and
of coupling present coupling is broken. repair.
ⓐ when dust plug
under engine fly Is not main relief NO Hydraulic pump is
Are attachment wheel is removed? NO valve faulty? Disassemble and
and travel out of order. repair.
motions
impossible at all? NO Swing control valve Disassemble and
Does swing
YES control valve spool is stuck. repair.
spool move
Is MCV pilot
YES
pressure within
lightly by hand? YES ⓑ
standard level?
Does RH travel NO
ⓒ
NO function?
Does not symptom
change when front YES
Hydraulic pump is Disassemble and
NO and rear pump
discharge hoses broken. repair.
are exchanged?
YES
Swing brake Disassemble and
release valve is repair.
Is swing brake broken.
ⓑ 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 is Disassemble and

NO Is gear pump faulty. repair or replace.
delivering oil?
Gear pump is out Disassemble and
Is gear pump pilot NO
of order. repair.
ⓒ pressure within
standard level? YES
Is not there oil Clean pilot piping
leakage from interior or repair
YES pilot piping or is piping.
not it clogged? Pilot valve is Disassemble and
NO
broken. repair.
6-9
2) SWING SPEED IS LOW
Cause Remedy
YES
Swing port relief Disassemble and
YES
Does swing control valve is faulty. repair or replace.
valve spool move
smoothly by hand?
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
Is not pilot piping
Single direction clogged or is not piping.
NO it leaking oil?
Is the trouble in Pilot valve or shuttle Disassemble
one direction or NO
valve is faulty. and repair.
in both direction? YES ⓐ
Does swing
YES control valve
Both directions spool move
Is MCV pilot lightly by hand?
YES Swing control valve Disassemble
pressure within NO
Is Arm speed spool is stuck. and repair.
standard level?
within standard ⓑ
value? NO
ⓒ
NO
Is swing motor's NO
ⓐ drain rate within Swing motor is Disassemble
standard value? Check that pilot broken. and repair.
piping is not
YES clogged or oil is NO
Pilot valve or Disassemble
not leaking from shuttle valve is and repair.
it? faulty.
Clogged or oil leak. Clean pilot piping
Is gear pump pilot interior or repair
ⓑ pressure within piping.
standard level?
YES
Pilot relief valve Disassemble and
Is gear pump is defective. repair or replace.
NO delivering oil?
Gear pump is Disassemble
NO
broken. and repair.
NO
Main relief valve Main relief valve
faulty. pressure resetting
or repair.
Is main relief valve Does the symptom YES Hydraulic pump Disassemble
ⓒ setting pressure change when front
YES
and rear pump is broken. and repair.
normal?
discharge hoses
Is safety valve are exchanged? NO Shuttle valve is Repair or replace.
pilot pressure faulty.
YES within standard
level? YES
Is gear pump Pilot relief valve Repair or replace.
output pressure is faulty.
NO within standard
level? Gear pump is Repair or replace.
NO
faulty.
6-10
3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION
Cause Remedy
Does symptom YES
Swing port relief Disassemble and
change when LH
YES valve is faulty. repair.
and RH port relief
valves are
exchanged Shuttle valve is Disassemble and
Does swing control NO
YES faulty. repair.
valve spool move
smoothly by hand?
Is MCV pilot Swing control valve Disassemble and

NO
pressure same spool is stuck. repair.
for LH and RH?
Check if pilot YES
Pilot valve is faulty. Disassemble and
piping is not repair.
clogged or does
NO not have oil
Clogged or oil
leakage. leak. Clean pilot piping
interior or repair
piping.
4) MACHINE SWINGS BUT DOES NOT STOP
Cause Remedy
YES Pilot relief valve is Disassemble and
Is MCV pilot faulty. repair or replace.
YES YES Is gear pump pilot
pressure within pressure within
standard value? standard level?
Gear pump is Disassemble and
NO
broken. repair.
YES Does swing control
valve spool move
smoothly by hand? Pilot valve is faulty. Disassemble and
NO
repair.
Is swing control
valve's return
spring normal? Swing control Disassemble and
NO
valve spool is repair.
stuck.
Return spring is Disassemble and
NO
faulty. replace.
6-11
5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE
Cause Remedy
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 control Brake spring is Disassemble
NO
valve normal? faulty. and replace.
NO Return spring of Disassemble

swing control and replace.
valve is faulty.
YES
Is drain rate of Swing relief valve Disassemble
YES swing motor is faulty. and repair or
within standard replace.
Is swing relief value? Disassemble
NO Swing motor is
ⓐ pressure within broken. and repair.
standard level?
NO Adjust swing
relief valve
pressure or
replace swing
relief valve.
6-12
5. TRAVEL SYSTEM
1) TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE
Cause Remedy
YES
Does counterbalance ⓐ
YES spool in travel
brake valve move
lightly by hand?
Is travel brake Counter spool in Disassemble
NO
YES valve pressure travel brake valve and repair or
within standard is stuck. replace.
level? Does the symptom
change when
relief valves in YES
Relief valve built Disassemble
Has travel NO travel motor are
YES control valve exchanged? in travel motor is and repair.
spool changed faulty.
over positively?
YES
Control system is Disassemble
defective. inspect and
Does spool move repair.
NO lightly by hand?
NO Travel control Disassemble

valve spool is and repair.
stuck.
Is bucket or arm
operation YES Disassemble
Travel reduction
possible? Do not metallic
particles come unit is faulty. and repair.
ⓐ out of drain port
in travel
reduction unit? Travel motor is Disassemble
NO
out of order. and repair.
Does the symptom
NO
change when front YES
and rear 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.
6-13
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.
and RH travel YES
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
Has control valve travel motors are
YES
spool changed exchanged? ⓐ
over positively? NO
YES
Control system is Disassemble,
Does spool move faulty . inspect and
lightly when it is
repair.
Is the lower NO cut off from
speed(Bucket or control spool?
arm) within 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
NO travel relief valves YES front and rear YES
pump discharge Hydraulic pump is Disassemble
are exchanged?
Is external pilot hoses are broken. and repair.
pressure within exchanged?
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
slower travel parking brake is and clean pilot
Is leak rate of motor is removed? not released piping.
ⓐ travel motor within
standard level? properly.
Travel motor is Disassemble

NO
faulty. and repair.
6-14
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
not clogged.
Clogged Disassemble
and clean pilot
Is drain rate of piping.
Is travel brake YES travel motor NO
pressure within Travel motor is Disassemble
within standard
standard level? defective. and repair.
value?
Brake valve is Disassemble

NO
faulty. and repair or
replace.
4) LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE
Cause Remedy
YES
Inspect according
to the procedure
"Travel does not
function at all on
one side."
However, a case
where both LH
and RH travel
motions are
Is bucket or arm disabled is
operation extremelyseldom
possible? statistically.
OK
Disassemble both faulty. repair.
OK travel relief valves
Remove dust and inspect for
plug under engine any fault.
OK flywheel and Travel relief valve Disassemble and
check that there is Faulty
is faulty. repair or replace.
no coupling
element particles.
Check oil volume Particles present. Coupling at pump Disassemble and
in hydraulic oil connection is repair.
NO tank.
broken.
Short Replenish
hydraulic oil.
6-15
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 pressure within NO
faulty. and repair.
standard level?
Is travel relief
valve pressure Travel brake Disassemble
NO
within standard valve 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.
6-16
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 select valve

normal?
Select valve is Repair or

Is pilot pressure NO
for travel select faulty. replace.
valve within
standard level? YES
Remove dirt on
Is filter in pilot pilot line filter.
piping between
gear pump and YES Is pilot relief NO
NO control valve not Pilot relief valve is Disassemble
valve normal?
clogged? defective. and repair or
Is gear pump
replace.
NO delivering oil?

NO
broken. and repair.
6-17
6. ATTACHMENT SYSTEM
1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL
Cause Remedy
YES
Does the Port relief valve is Disassemble
symptom change faulty. and repair or
YES
when port relief
replace.
valve is replaced
Is MCV pilot with other valve? NO ⓐ
YES
pressure within
standard level?
Inspect if pilot
piping is not
OK
clogged or oil is Pilot valve is Disassemble
Are other NO
YES
not leaking from faulty. and repair.
attachments the piping.
operatable?
YES
Pilot relief valve is Disassemble
Is gear pump pilot YES
Is gear pump faulty. and repair or
pressure within
NO delivering oil? replace.
standard level?
NO
broken. and repair.
Are LH/RH
operations OK
possible? Hydraulic pump is Disassemble
Disassemble broken. and repair.
YES main relief valve
Remove dust plug and check if it is
under engine not irregular.
OK flywheel and Faulty
Main relief valve Disassemble
check if coupling is defective. and repair or
element particles replace.
Inspect oil are not present. Particles present Coupling at pump Disassemble
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
lightly by hand?
NO Control valve Disassemble
6-18
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? hoisting and at Flow summation Disassemble and
Does spool of flow
arm extrusion? summation check check valve spool repair.
NO valve move lightly is stuck.
Are LH/RH travel
by hand?
NO speeds within NO
standard levels?
YES
Are both LH/RH faulty. repair.
travel speeds YES ⓒ
NO
low? Is MCV pilot
pressure within
NO
standard? ⓓ
NO
OK
Does the Port relief valve is Disassemble and
symptom change faulty. repair or replace.
YES
when port relief
valve is replaced
Does control with other valve? Cylinder is faulty. Disassemble and
YES NO
valve spool move repair.
lightly by hand?
NO Control valve spool Disassemble and

Is MCV pilot
ⓐ pressure within is stuck. repair.
standard level?
YES
Clean pilot piping
Is not MCV pilot
pressure piping interior or repair
NO clogged or is not piping.
there oil leakage? Pilot valve is Disassemble and
NO
defective. repair.
YES
Pilot relief valve is Disassemble and
Is primary pilot NO Is gear pump faulty. repair or replace.
ⓑ pressure within
delivering oil?
standard level?
NO
Gear pump is Disassemble and
broken. repair.
AIs engine NO
ⓒ revolution within Adjust engine
standard level? revolution.
YES
Clean orifice in
control valve.
Is not orifice in
ⓓ control valve YES
clogged? Is pilot piping not Clean pilot piping
clogged or is oil interior or repair
NO not leaking from piping.
the piping? aIs pilot valve
Pilot valve is faulty. Disassemble and
NO normal? NO
repair.
6-19
3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS
Cause Remedy
YES
Port relief valve is Disassemble
Does the sympto faulty. and repair or
change when
Normal replace.
port relief valve is YES
replaced with ⓐ
normal valve? 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.
YES inspect check between control
valve in hydraulic
circuit and check valve casing and
for any fault. spool is poor.
Is cylinder internal Abnormal Contact surface Disassemble
ⓐ leakage within between poppet and repair.
standard level?
and seat is poor.
Cylinder is faulty. Disassemble

NO
6-20
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
faulty. repair or replace.
standard level?
Main relief valve Adjust pressure,

NO
is defective. repair or replace.
5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE
Cause Remedy
YES
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
Does control
with other valve? valve spool broken. and repair.
Is MCV pilot NO move smoothly
YES
pressure within by hand? Control valve Disassemble
standard level? NO
Is RH travel Pilot valve is Disassemble

NO
possible? faulty. 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
NO pump's discharge
hoses are broken. Disassemble
exchanged? and repair.
6-21
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.
6-22
※ 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.
R29076TS01
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
6-20(2) 290-7
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.
R29076TS01
6-23
GROUP 3 ELECTRICAL SYSTEM
1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR
・Before disconnecting the connector, always turn the starting switch OFF.
・Before carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.7.
・After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective clucter Replace
YES Check voltage
between CN-56
(1) and chassis Disconnection in Repair or
NO
wiring harness or replace
Check voltage
between CN-5(3) poor contact (After clean)
and chassis between CN-5(3)-
CN-56(1)
Starting switch : ON
Voltage : 20~32V
NO Disconnection in Repair or
wiring harness or replace
poor contact (After clean)
between CN-5(3)-
and fuse No.7
Check voltage
YES 20 ~ 32V R32076ES01
NO 0V
6-24
2. COMMUNICATION ERROR "Co : Er" FLASHES ON THE CLUSTER
・Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Defective controller Replace
YES Check voltage

between CN-56
(3,4) and chassis
Disconnection in Repair or replace
NO wiring harness or (After clean)
Check voltage
between CN-5 poor contact
between CN-56
(10,11)and (3,4) CN-5(10,11)
chassis
KEY ON
NO
wiring harness or (After clean)
poor contact
between CN-5
(10,11)-CN-50
(29,30)
Check voltage CONTROLLER
YES *4V *12V 29
NO 0V 0V
30
CN-50
CLUSTER
POWER IG(24V)
GND 2 9
RX *12V
3 10
TX *4V 4 11
CN-56 CN-5
R29076ES02
6-25
3. BATTERY CHARGING WARNING LAMP LIGHTS UP(Starting switch : ON)
Cause Remedy
YES
YES Check voltage
between CN-51
(9) and chassis Disconnection in Repair or replace
NO
YES Check voltage poor contact
between CN-3
(3) and chassis between CN-51(9)
-CN3(3)
Check voltage Disconnection in Repair or replace

NO wiring harness or (After clean)
between alternator
poor contact
terminal "I" and between
chassis CN-3(3)-alternator
Voltage : 20~32V terminal "I"
Engine : Running
Defective alternator Replace

NO
Check voltage
YES 20 ~ 32V
NO 0V
32076ES50
6-26
4. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Coolant overheat Check engine
Resistance
YES between CD-8 (110°
C±2° C) cooling system
(1,2) is in range
of 120~150Ω?
NO
Defective temp Replace
Disconnect CD-8 sensor
Does display go
off when
disconnect CD-8?
YES
Starting switch : ON Short circuit in Repair or replace
Engine : Start Resistance wiring harness (After clean)
between CN-51
NO
(31,33) is 0~1
Defective Controller Replace
Disconnect CN-51 NO
KEY OFF
R32076MS12
6-27
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 CD-
10? YES
Short circuit in Repair or replace
Engine : Start Check resistance wiring harness (After clean)
between CN-51
NO
(16) and chassis
Starting switch : OFF Defective controller Replace
NO
Disconnect CN-51
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
CONTROLLER AIR CLEANER SWITCH
Pa
16
20
CD-10
CN-50
51
25036EL05
6-28
6. WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Engine oil leakage, Check engine oil
or defective switch level or replace
Does display go off switch
when disconnect
YES
CD-18? Defective controller Replace
Starting switch : ON Check resistance
Engine : Start between CN-51
NO
(4) and chassis
Starting switch : OFF
NO
Disconnect CN-51 wiring harness or (After clean)
poor contact
between
CN-51(4)-CD-18
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
CONTROLLER ENGINE OIL PRESSURE SWITCH
4 1 Pa
CN-51 CN-2 CD-18
R29076ES03
6-29
7. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
High temperature Check hydraulic
Resistance oil temperature
YES between CD-1 (100° C±2° C) ,
(1,2) is in range replace
of 130~150Ω?
Starting switch : ON Defective torque Replace
Does display go Disconnect CD-1 NO
sensor
off when
disconnect CD-1? YES
Short circuit Check and repair
Engine : Start
Resistance
between CN-51
NO (31,34) is 0~1Ω?

Starting switch : OFF NO
Disconnect CN-51
CONTROLLER HYDRAULIC OIL

TEMPERATURE SENDER
34 2
C
31 1
CN-51 CD-1
R29076ES04
6-30
8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
Cause Remedy
YES
Is resistance poor contact
YES between CN-51 between
(31) and (33) CN-51-CD-8
over 2kΩ?
Starting switch : OFF YES
Disconnect CN-50 Defective controller Replace
Does the gauge
light up and Check resistance
down at lamp NO
between CN-2(5)
check? and (6)
Defective temp Replace
See Table
NO
Starting switch : ON sensor
Defective cluster Replace

NO
Check Table
Green range Red range Temperature White range Green range Red range
Item (~29° C) (30~105° C) (105°C ~)
Unit Resistance(Ω) 1646~ 1645~158 ~139
White range Tolerance(%) ±20 ±20 ±20
R32076MS12
6-31
9. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)
Cause Remedy
YES
Disconnection in Check and repair
wiring harness
Is resistance
YES between CN-51
(24) and (31)
over 1kΩ? YES
Starting switch : OFF
Disconnect CN-51
Check resistance
Does the gauge between CD-2(1)
light up and NO and (2)
down at lamp Defective fuel Replace
NO
check? Disconnect CD-2
sensor
See Table

NO
Check Table
Green range Red range
Level White range Green range Red range
Item
Unit Resistance(Ω) 700~601 600~101 ~100
White range Tolerance(%) ±5 ±5 ±5
CONTROLLER
FUEL SENDER
24 1
CD-2
31
CN-51
R29076ES06
6-32
10. WHEN SAFETY SOLENOID DOES NOT OPERATE
short of fuse No.24.
Cause Remedy
YES
Hydraulic Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
NO
Safety lever : ON-OFF
YES
ⓐ
YES Check voltage
between CS-4
Check voltage (C) and chassis
between CN-68 Disconnect in Repair or replace
(1) - CN-68(2) Check voltage Starting switch : ON NO
YES between CN-4(8) Voltage : 20~30V wiring harness or (After clean)
Starting switch : ON and chassis Disconnect CN-4 poor contact
Voltage : 20~30V between
Safety state Starting switch : ON CN-4(8)-CS-4(C)
Voltage : 20~30V
Disconnect CN-4
Check voltage Disconnect in Repair or replace
between CN-68 NO
NO (1) with chassis
poor contact
Safety lever : OFF between
Starting switch : ON CN-4(8)-CN-68(1)
Voltage : 20~30V
NO Disconnection in Replace
fuse
YES
Defective switch Repair or replace
Check voltage
ⓐ between CS-20 (CS-20)
and chassis
NO
Defective switch Repair or replace
Starting switch : ON (CS-4)
Voltage : 20~30V
32076TS23
6-33
11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE
short of fuse No.22 .
Cause Remedy
YES
Defective hydraulic Check hydraulic
system system
YES Check voltage YES Check operation
between CN-50 YES
of solenoid Defective controller Replace
(13) and chassis
Check resistance
Check if travel Starting switch : ON Starting switch : ON between CN-70
Volage : 20~30V : OFF NO
speed lamps( , (1) and (2)
Disconnect CN-50 : ON
) change when Defective solenoid Replace
Starting switch : OFF NO
pressing the travel
speed switch on SPEC : 15~25Ω
Disconnect CN-70
the cluster YES
Check controller
Y R G
NO
NO
32076TS25
6-34
12. WHEN ENGINE DOES NOT START
・Check supply of the power at engine stop solenoid while starting switch is ON.
Cause Remedy
YES
Defective battery Check engine
system charge or
replace(After
checking specific
gravity of battery)
Check operation YES
Check voltage Defective magnet Replace
of start motor YES between starter of start motor
magnet coil and
Starting switch : START chassis Defective start relay Replace
NO
Starting switch : START YES
SPEC : 20~30V ⓐ, ⓑ
Check operation YES
Check voltage
NO of start relay
between CR-5
(30) and chassis
Starting switch : START
NO
Starting switch :START wiring harness or (After clean)
Check operation poor contact
of start safety between CR-5
NO relay
(86) and CN-8(9)
YES
Check voltage Defective relay Replace
between CR-
NO 5(87) and ⓒ
NO
YES
Defective fuel cut Replace
Check voltage
off solenoid
ⓐ between CN-79
(B) and chassis
NO
Voltage : 20~30V wiring harness or (After clean)
Starting switch : START poor contact
between CN-2(4)-
CN-79(B)
YES
Check voltage Defective relay Replace
ⓑ between CR-23
and chassis
NO Disconnection in Repair or replace
Starting switch : ON wiring harness or (After clean)
poor contact
between CR-5(30)-
CR-23(2)
YES
Check voltage Defective fuel cut- Replace
ⓒ between CN-79 off solenoid
(A) and chassis 32076TS24
NO
Starting switch : ON wiring harness or (After clean)
poor contact
between CN-2(5)
and Fuse No.12
6 - 35
13. WHEN STARTING SWITCH ON DOES NOT OPERATE
master switch ON.
Cause Remedy
YES
poor contact
YES Check voltage
between DO-2 between DO-2(2)-
(1) and chassis CR-1 or defective
Voltage : 20~30V
battery relay
YES Check voltage Disconnection in Replace

between CS-2 NO
wiring harness or
(2) and chassis
poor contact
Voltage : 20~30V between CS-2(2)-
Check voltage
YES CN-8(11)- DO-2(1)
between CS-2(1)
and chassis
Defective start Replace
Voltage : 20~30V NO
switch
Check voltage Disconnection in Replace

and specific NO
gravity of battery wiring harness or
poor contact
Specific gravity : MIN 1.28
Voltage : MIN 24V between CS-2(1)-
CN-8(12)-CR-1-
Battery
Battery capacity too Charge or replace

NO
low (After clean)
32076TS24
6-36
14. 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.4,11 and 13 is not blown out.
Cause Remedy
NO
Defective wiper Replace
cut switch
YES
Check operation wiring harness or (After clean)
wiper cut switch poor contact
between CN-141
Front sliding door Check valtage (11)- CS-53
open-close
between CN-141 YES
YES (11) and chassis Defective switch Replace
panel
NO Check voltage
Front sliding door-close between CN-116
Voltage : 0~1V (6) and chassis
Check operation 1)Recheck fuse Replace
Starting switch : ON NO NO.11
of switch panel
NO Vottage : 20~30V
LED ON. 2)Disconnection in Repair or replace
Starting switch : ON ⓐ poor contact
Push wiper switch button YES
between CN-
116(6)-Fuse
between CN-
116(13)-Chassis
Check voltage between NO
Defective switch Replace
CN-116(4) and chassis panel
Intermittent
NO
1) Recheck fuse Replace
Check voltage CN-116 NO.4
ⓐ (12) and chassis 2) Disconnection Repair or replace
Washing
Check operation in wiring harness (After clean)
of wiper motor or poor contact
Check voltage CN-116 and controller between CN-
(15) and chassis check voltage 141(7)-Fuse,
YES CN-141(7) and
Sarting switch : ON CN-21(4)-Fuse
Voltage : 0~1V
chassis, CN-21(4)
and chassis NO
1) Recheck fuse Replace
Starting switch : OFF NO.13
Voltage : 20~30V Check voltage
2) Disconnection Repair or replace
CN-141(6)-and
YES chassis CN-141(6)-Fuse (After clean)
Starting switch : ON ⓑ
Check continuity YES
Voltage : 20~30V
NO
between Disconnection in Repair or replace
CN-141(2)-CN-116(4), wiring harness or (After clean)
CN-141(9)-CN-116(12), poor contact
CN-141(10)-CN-116(15),
ⓑ NO
CN-141(5)-Chassis , Check wiper Defective wiper Replace
CN-141(1)-CN-21(5), motor resistance motor
CN-141(3)-CN-21(6), R32076ES11
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
6-37
15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
Cause Remedy
NO HEAD LAMP
Defective lamp Replace switch
switch 1
2
CL-4
Check voltage
YES
between CN-116 YES
(1) and (9) Defective bulb Replace
YES
Check voltage
Starting switch : ON between CL-4(2)
Head lamp switch : ON and chassis
Voltage : 20~30V Disconnection in Repair or replace CN-7
Starting switch : ON NO CN-116
Head lamp switch : ON wiring harness or (After clean) 1 1 HEAD LIGHT OUT
Check voltage 2 WORK LIGHT OUT
between CN-7(1)
Voltage : 20~30V poor contact
3 WORK LIGHT OUT
YES and chassis between CN-7(1)- 4 WIPER MOTOR DRIVE
CL-4(2) 5 PRE-HEAT
Starting switch : ON 6 POWER 24V
Head lamp switch : ON 7 7 CABIN LIGHT OUT
Check voltage Voltage : 20~30V Disconnection in Repair or replace 8 CABIN LIGHT OUT
NO 9
between CN-116 wiring harness or (After clean) HEAD LIHGT 24V
10 WORK LIGHT 24V
(9) and chassis 10
poor contact 11 WORK LIGHT 24V
12 WASHER SIG
Starting switch : ON between
Head lamp switch : 13 GND
ON-OFF
CN-116(1)-CN- 14 TRAVEL ALARM
7(1) 15 INT. SIG
16 CABIN LIGHT 24V
17 CABIN LIGHT 24V
YES
Disconnection in Repair or replace SWITCH PANEL
Check voltage poor contact
between CN- between CN-116
NO 7(7) and chassis FUSE
(9)-CN-7(7)
Head lamp switch : ON NO.14
Recheck fuse Replace
NO
R29076ES12
6-38
16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
Cause Remedy WORK LAMP

NO
Defective lamp Replace switch
1
switch
2
CL-5
CN-12 WORK LAMP
Check voltage
YES
between CN-116 YES 1 1
(10,11) and (2,3) Defective bulb Replace
2 2
Check voltage
YES
Starting switch : ON between CL-5(2)
CL-6
Work lamp switch : ON and chassis
Voltage : 20~30V Disconnection in Repair or replace
Starting switch : ON NO
Work lamp switch : ON wiring harness or (After clean)
Check voltage Voltage : 20~30V poor contact
between CN-7(2) CN-7
between CN-7(2) CN-116
YES and chassis
1 HEAD LIGHT OUT
-CL-5(2) and 2 2 WORK LIGHT OUT
Starting switch : ON 3
Work lamp switch : ON
CL-6 (2) WORK LIGHT OUT
Check voltage 4 WIPER MOTOR DRIVE

Voltage : 20~30V 5 PRE-HEAT
between CN-116
(10,11) and Disconnection in Repair or replace 6 POWER 24V
NO 8 7 CABIN LIGHT OUT
chassis wiring harness or (After clean) 8 CABIN LIGHT OUT
Starting switch : ON poor contact 9 HEAD LIHGT 24V
Work lamp switch : 10 WORK LIGHT 24V
ON-OFF
between CN-116 10
11 WORK LIGHT 24V
Voltage : 20~30V (2,3)-CN-7(2) 12 WASHER SIG
13 GND
14 TRAVEL ALARM
YES 15 INT. SIG
Disconnection in Repair or replace 16 CABIN LIGHT 24V
17 CABIN LIGHT 24V
Check voltage SWITCH PANEL
poor contact
between CN-7(8) between CN-11
NO and chassis
(10,11)-CN-7(8)
Head lamp switch : ON FUSE
Voltage : 20~30V
NO Recheck fuse Replace NO.15
R29076ES13
6-39
GROUP 4 MECHATRONICS SYSTEM
1. ALL ACTUATORS SPEED ARE SLOW

ö Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good.
ö Spec : M-mode 1960 Ü 50rpm H-mode 1850 Ü 50rpm S-mode 1750 Ü 50rpm
ö Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective
YES Check pressure hydraulic system
at EPPR valve
NO
Check electric NO Defective Replace
SPEC : 5~20kgf/cm2
YES current at EPPR See TEST 4
EPPR valve
valve
Check if Err : 03
on the cluster SPEC : 200~550mA Defective CPU Replace
See TEST 3 NO
controller
Check resistance
between CN-2(9)-
YES (10)
YES
Short circuit or Check & repair
SPEC : 17.5Ü1̫(20Á
C)
See TEST 1
poor connection wire harness or
Check resistance between CN-50 - between CN-50-
NO at EPPR valve CN-75 CN-75
SPEC : 17.5Ü1̫(20Á
C) Defective EPPR Replace
See TEST 2 NO
valve
Wiring diagram
CN-92
FUSE Emergency
CN-2 NO.9
CN-75 CN-47
2 9 1 1
1 10 2 2
EPPR V/V PROLIX
RESISTOR
CN-50
8 24 Normal
CONTROLLER
14076TS28
6-40
2) TEST PROCEDURE SPEC : 17.5±1Ω(20°
C)
(1) Test 1 : Check resistance at connector Y R G
CN-50(8)-(36). CN-50
CPU 12 8 1
① Starting key OFF. CONTROLLER 24 13
② Disconnect connector CN-50. 36 25
③ Check resistance between pin and at CN-50 CN-51
connector CN-50(8)-(36).
Multimeter
R29076MS02
(2) Test 2 : Check resistance at connector

SPEC : 17.5±1Ω(20°
C)
CN-75.
① Starting key OFF.
② Disconnect connector CN-75 from EPPR
CN-75
valve at main hydraulic pump.
③ Check resistance between 2 lines as
figure.
Multimeter
6-38(2) 290-7
(3) Test 3 : Check electric current at EPPR SPEC : 200~450mA(S mode)

valve.
① Install multimeter as figure.
② Start engine.
③ Set the accel dial at "10"(MAX)
CN-75
④ Set S-mode and cancel auto decel mode.
⑤ If tachometer show approx 1850±50rpm,
check electric current.
EPPR VALVE
Multimeter
6-38(3) 290-7
6-41
(2) Test 4 : Check pressure at EPPR valve. SPEC : 5~20kgf/cm2(70~280psi)
① Remove plug and connect pressure
gauge as figure.
・Gauge capacity : 0 to 40~50kgf/cm2
(0 to 570~710psi)
② Start engine. Supply line, pilot press
③ Set the accel dial at "10"(Max).
④ Set S-mode and cancel auto decel mode. CN-75
⑤ If tachometer show approx 1850±50rpm, Pressure adjusting
check pressure. screw locknut
⑥ If pressure is not correct, adjust it.

⑦ After adjust, test the machine.
6-39(1) 290-7
6-42
2. ENGINE SPEED IS SLOW AT ALL MODE
※ Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
Good
If test 7 is good,
Check tachometer check TEST 1~4
YES work properly or
not by changing YES
Misalignment Clean speed
the mode. between speed sensor and
Is resistance
YES Is resistance See TEST 6 sensor and fly adjust
between CN-50 No good between CN-51 wheel See : 5-20page
(12) - (23) (25) - (26)
SPEC : 0.2~0.4kΩ ⓐ
SPEC : 1~2Ω
See TEST 7 NO
See TEST 5
Check cable
between accel Defective accel Replace accel
NO
actuator and actuator or short actuator or
injection pump. circuit or poor harness
connection assembly
between CN-50-
CN-76
Improper operation Adjust or repair

NO
by loosening or
interference of cable
YES
Short circuit or poor Check and repair
connection
Is resistance
ⓐ between CN-50-
between CD-17
CN-2-CD-17
(1) - (2)
SPEC : 0.2~0.4kΩ
NO
Defective Replace
See TEST 8
speed sensor
Wiring diagram
ACCEL ACTUATOR
CPU CONTROLLER
1 P+
2
2 SIG
1 3
12 3 P-
4 NC
5
5 M+ M 6
23 6 M-
CN-76 ACCEL DIAL
CN-50
C -
20 5 B S
21 7 A +
22 CN-142
CN-9
TACHO SENSOR
25 12 1
rp
m
26 11 2
CN-51 CN-2 CD-17 R29076MS03
6-43
2) TEST PROCEDURE SPEC : 1~2Ω
(1) Test 5 : Check resistance between CN-50 Y R G
(12)-(23). CPU
① Starting key OFF. CONTROLLER
② Disconnect connector CN-50 from CPU CN-50
controller. CN-51
③ Check resistance as figure.
CN-50
12 1
23 13
36 25
Multimeter R29076MS04
Unit : rpm
(2) Test 6 : Check tachometer(Work properly
Spec Remark
or not)
① Start engine. H-mode 1960±50 Check rpm after cancel
the Auto decel mode.
② Check tachometer reading. S-mode 1850±50
(3) Test 7 : Check resistance between CN-51

SPEC : 0.2~0.4kΩ
(25) and CN-51(26).
① Starting key OFF. Y R G
② Disconnect connector CN-51 from CPU CPU

CONTROLLER
controller.
CN-51
CN-50
CN-51 12 1
24 13
36 26 25
Multimeter R29076MS05
6-44
(4) Test 8 : Check resistance at speed
SPEC : 0.2~0.4kΩ
sensor.
② Disconnect connector CD-17 of speed Speed sensor
sensor at engine flywheel housing.
CD-17 CD-17
1 2
Engine flywheel
Multimeter
6-42(1) 290-7
6-45
3. ENGINE STALL
Cause Remedy
YES
Not enough engine Contact cummins
YES Check pressure power engine dealer
at EPPR Valve
Defective EPPR Replace
SPEC:5~20kgf/cm2 NO
See TEST 10 valve
Check electric
current at EPPR YES
valve Defective CPU Replace
controller
SPEC : 200~550mA
See TEST 9 Check resistance YES
between CN-50 Short circuit or Check and repair
NO (8)-(24) poor connection
SPEC : 17.5±1Ω(20°
C) between
See TEST 1 Check resistance CN-50 - CN-2 or
NO at EPPR valve
CN-50 - CN-75
SPEC : 17.5±1Ω(20°
C)
See TEST 2 Defective EPPR Replace
NO
valve
Wiring diagram
CN-92
FUSE Emergency
CN-2 NO.9
CN-75 CN-47
2 9 1 1
1 10 2 2
EPPR V/V PROLIX
RESISTOR
CN-50
8 24 Normal
CONTROLLER
14076TS28
6-46
2) TEST PROCEDURE SPEC : 200~450mA
(1) Test 9 : Check electric current at EPPR
valve at S-mode CN-75
① Install multimeter as figure.
② Start engine.
③ Set the accel dial at "10"(max)
④ Set S-mode with 1850±50rpm.
⑤ Check electric current. EPPR VALVE
Multimeter
6-44(1) 290-7
(2) Test 10 : Check pressure at EPPR valve SPEC : 5~20kgf/cm2(70~280psi)

at S-mode
① Connect pressure gauge at EPPR valve.
② Start engine.
③ Set the accel dial at "10"(max) Supply line, pilot press
④ Set S-mode with 1850±50rpm.
⑤ Operate bucket lever completely push or CN-75
pull. Pressure adjusting
screw locknut
⑥ Hold arm lever at the end of stroke.
⑦ Check pressure at relief position.
6-44(2) 290-7
6-47
4. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM
Cause Remedy
YES
No power supply to Check fuse
See if all lamps the CPU controller
YES
off in the CPU
controller case YES
Y R G CPU failure Replace
Y R G
See if Co : Er
NO
on the cluster
NO Y R G
ⓐ
NO
OK
Check connection Cluster failure Replace
between CN-51
ⓐ (29) - CN-5(10) or
CN-51(30) - CN-
5(11) No connection Check and repair
NO
KEY OFF
Wiring diagram
CPU CONTROLLER
CLUSTER
POWER IG(24V) 24
GND 28
RX 3 10 29
TX 4 11 30
CN-56 CN-5 CN-51
50
FUSE
NO.9(CPU)
R29076MS06
6-48
5. SLOW ACTION OF ENGINE SPEED CHANGE WHEN CHANGE THE MODE
Cause Remedy
YES
Slow action of Check and repair
engine speed
control due to
interference
Check interference
between YES
connecting rod and Defective CPU Replace
Check voltage
accel actuator between CN-5(20)- controller
YES
(21) and check
resistance between
CN-51(20)-(22)
Check resistance Defective accel Replace
NO
between CN-50 SPEC : (20)-(21) : 5±1V actuator
NO (20)-(22) : 0.1~0.9kΩ
(12)-(23) See TEST 12
SPEC : 1~2Ω
See TEST 11 Defective accel Replace
NO
actuator
Wiring diagram
ACCEL ACTUATOR
CPU CONTROLLER
1 P+
2
2 SIG
1 3
12 3 P-
4 NC
5
5 M+ M 6
23 6 M-
CN-76 ACCEL DIAL
CN-50
C -
20 5 B S
21 7 A +
22 CN-142
CN-9
TACHO SENSOR
25 12 1
rp
m
26 11 2
CN-51 CN-2 CD-17
R29076MS03
6-49
2) TEST PROCEDURE
SPEC : 1~2Ω
(1) Test 11 : Check resistance. Y R G

CPU
② Disconnect connector CN-50 from CPU CONTROLLER
controller. CN-50
③ Check resistance between CN-50(12)- CN-51
(23) as figure.
CN-50
12 1
23 13
36 25
Multimeter
R29076MS04
6-50
(2) Test 12 : Check voltage and resistance. SPEC : 0.1~0.9kΩ
① Check resistance between CN-51(20)- Y R G
(22). CPU
CONTROLLER
- Starting key OFF.
CN-51
- Disconnect connector CN-51 from CPU
CN-50
controller.
- Check resistance value with multimeter
as figure.
CN-51
12 1
24 22 20 13
36 25
Multimeter
R29076MS08
② Check voltage between CN-51(20) and SPEC : 5±1V

CN-51(21). Y R G
- Prepare 2 pieces of thin sharp pin, steel CPU

or copper. CONTROLLER
PIN
- Starting key ON.
CN-50
- Insert prepared pins to rear side of CN-51
connectors : One pin to CN-51(20)

Other pin to CN-51(21)
- Check voltage.
CN-51
12 1
24 21 20 13
36 25
Multimeter
R29076MS09
6-51
6. AUTO DECEL SYSTEM DOES NOT WORK
Cause Remedy
YES
Defective CPU Replace
controller
NO
Check resistance Short circuit or Replace or repair
between CN-51 poor connection
(1)-GND and vetween CN-51(1),
CN-51(13)-GND
(13)- pressure
SPEC : switches
Actuator operating :
11~13V
Actuator stop :0~2V Defective auto Replace
See TEST 13 NO
See TEST 14 decel pressure
switch
Wiring diagram
AUTO DECEL PRESSURE SWITCH

CPU CONTROLLER
1
Pb
1 2
CD-7
13 1
Pa
2
CN-51 CD-6
R29076MS10
6-52
2) TEST PROCEDURE SPEC : Actuator stop : 11~13V
(1) Test 13 : Check voltage at CN-51(1) and Actuator operating : 0~2V
ground. Y R G
① Prepare 1 piece of thin sharp pin, steel or CPU

CONTROLLER
copper. PIN
② Starting key ON. CN-50
CN-51
③ Insert prepared pin to rear side of
connectors : One pin to (1) of CN-51.
④ Check voltage as figure.
(2) Test 14 : Check voltage at CN-51(13)and
ground.
① Prepare 1 piece of thin sharp pin, steel or CN-51 12
24
1
copper 36 25
② Starting key ON.

Ground
③ Insert prepared pin to rear side of
connectors : One pin to (13)of CN-51
④ Check voltage as figure. Multimeter
CN-51 12 1
24 13
36 25
Ground
Multimeter
R29076MS11
6-53
7. MALFUNCTION OF WARMING UP
Cause Remedy
YES
Defective cluster or Repair or Replace
Check resistance CPU controller or
YES
between CN-51 CD8(Sensor)
(31) - CD-8(1)
SPEC : Below10Ω NO Poor connection Repair
Check resistance KEY OFF
between CN-
between CN -51
(33) - CD-8(2) 51(31) - CD-8(1)
SPEC : Below 10Ω
KEY OFF
NO
Poor connection Repair
between CN-
51(33) - CD-8(2)
Wiring diagram
R32076MS12
6-54
8. MALFUNCTION OF POWER MAX
Cause Remedy
YES Check resistance
between CN-88 Defective power Repair or replace
(1) - (2) max. solenoid valve
YES
Resistance
between CN-51 SPEC: 15-30Ω
(2)-GND normal? See TEST 15
NO Short circuit or poor Repair or replace

SPEC : Power max button pressed ON : 0 connection
Is voltage between Power max button released OFF : between CN-51(2) -
CN-88(2) -GND See Test 16
normal? CS-29 and CN-50
(3) -CN-88(2)
SPEC
KEY ON : 24±1V
KEY OFF : 0V
See TEST 15
NO Short circuit or poor Repair or replace
connection
between CN-88(1)-
battery relay(+)
Wiring diagram
CPU CONTROLLER
POWER MAX SOLENOID
3 2
1
CN-50
1 CN-88
2 2
FUSE
CN-51 CN-4 NO.23
POWER MAX SWITCH
2
CS-29
R29076MS13
6-55
2) TEST PROCEDURE SPEC : Key ON : 24±1V
Key OFF : 0V
(1) Test 15: Check voltage between connector Resistance : 15~30Ω
CN-88 - GND.
① Start key ON.
② Disconnect connector CN-88 from power Power max. switch
max solenoid valve.
③ Check voltage as figure.
LH RCV-lever
CN-88
CN-88
Power max.
solenoid valve
Multimeter
R29076MS14
(2) Test 16: Check resistance between

connector CN-51(2)-GND. SPEC : Power max button pressed ON : 0Ω
Power max button released OFF : ∞Ω
② Remove CPU controller and disconnect Y R G
connector CN-51 from CPU controller. CPU

③ Check resistance as figure. CONTROLLER
CN-51
CN-50
CN-51
12 2
24 13
36 25
Ground
Multimeter
R29076MS15
6-56
SECTION 7 MAINTENANCE STANDARD
Group 1 Operational Performance Test 7-1

Group 2 Major Components 7-21
Group 3 Track and Work Equipment 7-31
SECTION 7 MAINTENANCE STANDARD
GROUP 1 OPERATIONAL PERFORMANCE TEST
1. PURPOSE
Performance tests are used to check:
1) OPERATIONAL PERFORMANCE OF A NEW
MACHINE
Whenever a new machine is delivered in
parts and reassembled at a customer's site,
it must be tested to confirm that the Working
operational performance of the machine condition
meets Hyundai spec.
2) OPERATIONAL PERFORMANCE OF A
WORKING MACHINE
With the passage of time, the machine's Maintenance
operational performance deteriorates, so record
that the machine needs to be serviced
periodically to restore it to its original
performance level.
Before servicing the machine, conduct
performance tests to check the extent of Operating
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 21077MS01
must be tested to confirm that its

operational performance was restored by
the repair and/or service work done.
7-1
2. TERMINOLOGY
1) STANDARD
Specifications applied to the brand-new
machine, components and parts.
21077MS02
2) SERVICE LIMIT
The lowest acceptable performance level.
When the performance level of the machine
falls below this level, the machine must be
removed from work and repaired.
Necessary parts and components must be
replaced.
21077MS03
7-2
3. OPERATION FOR PERFORMANCE TESTS
1) Observe the following rules in order to carry
out performance tests accurately and
safely.
(1) The machine
Repair any defects and damage found,
such as oil or water leaks, loose bolts,
cracks and so on, before starting to test.
(2) Test area
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
7-3 (210-7)
follow 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
repeatedly. Use mean values of
measurements if necessary.
7-3
2) ENGINE SPEED
(1) Measure the engine speed at each power
mode
ö The engine speed at each power mode
must meet standard RPM; if not, all other
operational performance data will be
unreliable. It is essential to perform this
test first.
(2) Preparation
Η Warm up the machine, until the engine
coolant temperature reaches 50Á C or
more, and the hydraulic oil is 50Ü5Á
C.
Θ Set the accel dial at 10(Max) position.
Ι Push the H-mode switch and confirm that
the fuel injection pump governor lever
comes into contact with the high-idle
stopper.
Κ Measure the engine RPM.
(3) Measurement
Η Start the engine. The engine will run at
start idle speed. Measure engine speed
with a tachometer.
Θ Measure and record the engine speed at
each mode(H, S).
Ι Select the H-mode.
Κ 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.
Λ Measure and record the auto deceleration
speed.
(4) Evaluation
The measured speeds should meet the following specifications.
Unit : rpm
Model Engine speed Standard Remarks
Start idle 850Ü100

M mode 1960Ü50
R320LC-7 H mode 1850Ü50
S mode 1750Ü50
Auto decel 1100Ü50
Condition : Set the accel dial at 10(Max) position.
7-4
3) TRAVEL SPEED
(1) Measure the time required for the
excavator to travel a 20m test track.
(2) Preparation
① Adjust the tension of both tracks to be
equal.
② Prepare a flat and solid test track 20m in
length, with extra length of 3 to 5m on
0.3~0.5m
both ends for machine acceleration and
deceleration.
③ Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
④ Keep the hydraulic oil temperature at 290LC7MS01
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.
・ Mode selector : H mode
③ Start traveling the machine in the
acceleration zone with the travel levers at 3 ~ 5m 20m 3 ~ 5m
full stroke.
④ Measure the time required to travel 20m.
⑤ After measuring the forward travel
speed, turn the upperstructure 180°and 290LC7MS02
measure the reverse travel speed.
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 / 20m
Model Travel speed Standard Maximum allowable Remarks
1 Speed 22.5±2.0 28.1

R320LC-7
2 Speed 13.3±1.0 16.6
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.
Keep the boom-arm angle between 90 to Mark
110°as shown. Place blocks under
machine frame.
④ Keep the hydraulic oil temperature at 21077MS06
50±5° C.
(3) Measurement
① Select the following switch positions.
・ Travel mode switch : 1 or 2 speed
・ Auto decel 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 35.0±2.0 43.8

R320LC-7
2 Speed 20.0±2.0 25.0
7-6
5) TRAVEL DEVIATION
(1) Measure the deviation by the tracks from
a 20m straight line.
(2) Preparation
① Adjust the tension of both tracks to be
equal.
② Provide a flat, solid test yard 20m in
length, with extra length of 3 to 5m on
0.3~0.5m
both ends for machine acceleration and
deceleration.
③ Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
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. 3~5m extra length
・ Mode selector : H mode a
M
20
③ Start traveling the machine in the
acceleration zone with the travel levers at
full stroke. 3~5m extra length
④ Measure the distance between a straight
20m line and the track made by the
machine.(Dimension a)
⑤ After measuring the tracking in forward
travel, turn the upperstructure 180°and
measure that in reverse travel.
7-7(2) 210-7
⑥ Repeat steps ④ and ⑤ three times and
(4) Evaluation
Mistrack should be within the following specifications.
Unit : mm / 20m
Model Standard Maximum allowable Remarks
R320LC-7 200 below 250
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
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.
(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 selector switch Standard Maximum allowable
R320LC-7 H mode 19.8±2.0 24.7
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
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
the bucket pin is the same as the boom 290LC7MS03
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 H 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
test the opposite direction. 360 swing
⑥ Repeat steps ④ and ⑤ three times each Swing start & stop
and calculate the average values.
21077MS08
(4) Evaluation
The measured drift angle should be within the following specifications.
Unit : Degree
Model Mode select switch Standard Maximum allowable Remarks
R320LC-7 H mode 90 below 112.5
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 7-10(1) 210-7
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
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 50cm.
Measurement : (h2)
Record the dial gauge reading(h2).
③ Calculate bearing play(H) from this
data(h1 and h2) as follows.
H=h2-h1
290LC7MS04
(4) Evaluation
The measured drift should be within the following specifications.
Unit : mm
Model Standard Maximum allowable Remarks
R320LC-7 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 ground. Arm cylinder
Lower the boom until the bucket is 0.5m
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.
Bucket cylinder
④ Keep the hydraulic oil temperature at
50±5° C.
(3) Measurement
・ Mode selector : H mode Roll out Roll in
② To measure cylinder cycle times.
0.5m
- Boom cylinders.
210LC7MS10
Measure the time it takes to raise the
boom, and the time it takes to lower the
boom. To do so, position the boom at
one stroke end then move the control
lever to the other stroke end as quickly
as possible.
- Arm cylinder.
Measure the time it takes to roll in the
arm, and the time it takes to roll out the
arm. To do so, position the bucket at one
stroke end, then move the control lever
to the other stroke end as quickly as
possible.
7-11
- 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
Model Function Standard Maximum allowable Remarks
Boom raise 3.5±0.4 4.4

Boom lower 3.2±0.4 4.0
Arm in 3.8±0.4 4.7
R320LC-7
Arm out 3.2±0.3 4.0
Bucket load 3.0±0.4 3.8
Bucket dump 2.6±0.3 3.3
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
Where :
M3 = Bucket heaped capacity(m3)
1.5= Soil specific gravity
② Position the arm cylinder with the rod 20
to 30mm extended from the fully retracted
position.
③ Position the bucket cylinder with the rod
20 to 30mm retracted from the fully
extended position.
④ With the arm rolled out and bucket rolled
290LC7MS05
the bucket pin is the same as the boom
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 / 5min
Model Drift to be measured Standard Maximum allowable Remarks
Boom cylinder 10 below 15

R320LC-7 Arm cylinder 10 below 15
Bucket cylinder 40 below 50
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 1.5 or below 1.7

Arm lever 1.5 or below 1.7
R320LC-7 Bucket lever 1.5 or below 1.7
Swing lever 1.5 or below 1.7
Travel lever 1.8 or below 2.25
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 87±10 109

Arm lever 87±10 109
R320LC-7 Bucket lever 87±10 109
Swing lever 87±10 109
Travel lever 142±10 178
7-15
13) PILOT PRIMARY PRESSURE
(1) Preparation
② Remove the top cover of the hydraulic
tank oil supply port with a wrench.
③ Loosen and remove plug on the pilot
pump delivery port and connect pressure
A
3
gauge.
④ Start the engine and check for oil
leakage from the port.
⑤ Keep the hydraulic oil temperature at
50±5° C.
(2) Measurement
・ Auto decel switch : OFF 290LC7MS10
② Measure the primary pilot pressure in the
H mode.
(3) Evaluation
The average measured pressure should meet the following specifications:
Unit : kgf / cm2
Model Engine speed Standard Allowable limits Remarks
R320LC-7 H mode 35±5 -
7-16
14) FOR TRAVEL SPEED SELECTING PRESSURE
(1) Preparation
③ Push the pressure release button to
bleed air.
④ To measure the speed selecting pressure:
Install a connector and pressure gauge
P
assembly to turning joint P port as shown. B
A
⑤ Start the engine and check for on D
C
leakage from the adapter.

⑥ Keep the hydraulic oil temperature at Dr
50±5° C.
(2) Measurement
① Select the following switch positions. 21077MS13
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 -
R320LC-7
2 Speed 35±5 -
7-17
15) SWING PARKING BRAKE RELEASING PRESSURE
(1) Preparation
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 Start the engine and check for oil
SH
leakage from the adapter.
50±5° C.
(2) Measurement
② Operate the swing function or arm roll in
function and measure the swing brake
control pressure with the brake
disengaged. Release the control lever 290LC7MS11
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 35 26~44

R320LC-7
Brake applied 0 -
7-18
16) MAIN PUMP DELIVERY PRESSURE
(1) Preparation
bleed air.
④ To measure the main pump pressure.
assembly main pump gauge port as
shown.
50±5° C. 290LC7MS07
(2) Measurement
② Measure the main pump delivery
pressure in the H mode(High idle).
(3) Evaluation
The average measured pressure should meet the following specifications.
Unit : kgf / cm2
Model Engine speed Standard Allowable limits Remarks
R320LC-7 High ilde 40±5 -
7-19
17) SYSTEM PRESSURE REGULATOR RELIEF SETTING
(1) Preparation
bleed air.
④ To measure the system relief pressure.
assembly main pump gauge port, as
shown.
50±5° C.
(2) Measurement
② Slowly operate each control lever of
boom, arm and bucket functions at full 290LC7MS07
stroke over relief and measure the
pressure.
③ In the swing function, place bucket
against an immovable object and
measure the relief pressure.
④ In the travel function, lock undercarriage
with an immovable object and measure
the relief pressure.
(3) Evaluation
Unit : kgf / cm2
Model Function to be tested Standard Maximum allowable
Boom, Arm, Bucket 330(360)±10 390±10

R320LC-7 Travel 360±10 -
Swing 265±10 -
( ) : Power boost
7-20
GROUP 2 MAJOR COMPONENT
1. MAIN PUMP
3 1 2
9 6 5 4 7 290LC7MS08
Standard Recommended
Part name & inspection item replacement Counter measures
dimension value
Clearance
between piston(1) & cylinder Replace piston
d D 0.0375 0.078 or cylinder.
bore(2)
(D-d)
Play between
piston(1) & shoe caulking
0-0.1 0.35
section(3)
(δ) Replace
assembly of
Thickness of shoe piston & shoe.
δ
(t) t 5.4 5.0
Free height of cylinder Replace cylinder

spring(4) spring.
40.9 40.1
(L)
L
Combined height of set

Replace retainer
plate(5) & spherical
23.8 22.8 or set plate.
bushing(6) h H
(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), & Standard surface roughness 0.4z or lower
cylinder(2)(Sliding face) (Corrected value)
7-21
2. MAIN CONTROL VALVE
Part name Inspection item Criteria & measure

Casing ・Existence of scratch, rusting or corrosion. ・In case of damage in following section,
replace part.
- Sliding sections of casing fore and spool,
especially land sections applied with
holded pressure.
- Seal pocket section where spool is inserted.
- Seal section of port where O-ring contacts.
- Seal section of each relief valve for main,
travel, and port.
- Other damages that may damage normal
functions.
Spool ・Existence of scratch, gnawing, rusting or ・Replacement when its outside sliding
corrosion. section has scratch(Especially on seals-
contacting section).
・O-ring seal sections at both ends. ・Replacement when its sliding section has
scratch.
・Insert spool in casing hole, rotate and ・Correction or replacement when O-ring is
reciprocate it. damaged or when spool does not move
smoothly.
Poppet ・Damage of poppet or spring ・Correction or replacement when sealing is

incomplete.
・Insert poppet into casing and function it. ・Normal when it can function lightly without
being caught.
Around spring ・Rusting, corrosion, deformation or breaking ・Replacement for significant damage.
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
relief valve ・Contacting face of poppet. ・Replacement when damaged.
・Abnormal spring. ・Replacement.
・O-rings, back up rings and seals. ・100% replacement in general.
Balance plate ・Worn less than 0.03mm ・Lapping

・Worn more than 0.03mm ・Replace
・Sliding surface has a seizure(Even through ・Replace
small).
7-22
3. SWING DEVICE
Part name Inspection item Remedy
Shoe of piston ・Sliding surface has a damage. ・Lapping

assembly
・Sliding surface depression( ) ・Replace parts or motor
dimension less than 0.45mm or has a large
damage.
Piston of piston ・Sliding surface has a seizure(Even though ・Replace motor

assembly small).
Piston hole of ・Sliding surface has a seizure. ・Replace motor

cylinder assembly
・Sliding surface has a damage. ・Replace motor
Taper roller bearing ・In case 3000hour operation. ・Replace

Needle bearing
・Rolling surface has a damage. ・Replace
Roller bearing
7-23
4. TRAVEL MOTOR
The followings are the general maintenance standards. However, it is the most important to
determine which parts should be replaced, depending on the characteristics before disassembling,
damages and discoloration of exterior view, the purpose of disassembling, the expected remaining
service life. etc..
Item Check item Measuring method Criteria Allowable Remedy
Cylinder block,
valve plate, Surface roughness of Measure the surface
Replace or
swash plate cylinder bolck of valve roughness by Below 0.4Zμ Below 0.4Zμ
repair
※ Lap together plate and swash plate roughness tester
the surfaces of
both cylinder
Measure the surface
block and valve
Swash plate hardness of swash plate Over HS78 HS74 Replace
plate to remedy
by hardness tester
their roughness
Measure outer dia of
Outer dia of piston
Clearance piston and bore of 0.01mm 0.05mm
d max - d min
between piston cylinder block at least 3
and cylinder block places in the longitudinal Replace
※ In exchanging Inner dia of cylinder bore direction with piston or
0.01mm 0.022mm
pistons, replace D max - D min micrometer and obtain cylinder
all of nine (max outer dia = d max block
pistons at the min outer dia = d min
0.037~
same time Clearance D-d max inner dia = D max 0.065mm
0.047mm
min inner dia = D min)
With the jig of figure C,

hold down the shoe on
work stand and pull up
Play between Play between calked Replace
the piston vertical 0~0.1mm 0.3mm
piston and shoe piston and shoe(δ) piston
direction to measure
the play between piston
and shoe
After completion of
assembly, set the torque Replace all
wrench on the shaft separator
Negative brake 78.8kgf・m 70.9kgf・m
Parking brake torque end, and measure the and friction
torque (570lbf・ft) (513lbf・ft)
braking torque plates and
generated when the springs
shaft starts to rotate
7-24
Item Measuring method Judging criteria and remedy
If the depth of shaft wear is less than 0.05mm, the

Measure the wear at contacting
shaft is reusable.
Sahft surface of oil seal(26) with the
※ In case of replacing the shaft(9), replace oil seal
surface roughness tester
(26) at the same time.
※ In case replacing the bearings(30, 31), replace
both inner and outer races at the same time.
Replace bearings(30, 31) before
※ Also the bearing shims(33) must be readjusted
Bearings hour meter of host machine
when replaced shaft(9) and/or bearings(30, 31).
indicates 10,000hours
Contact dealers for jigs and tools required.
Replace if the wear of splines ※ If the wear of splines is less than 0.3mm, the
Splines exceeds the allowable value spline is reusable.
Do not try to adjust the valve,

Overload relief valve since special hydraulic test Replace relief valve part as an assembly each
part bench is required for inspecting time the host machine works for 10,000 hours.
and adjusting the pressure
45
+0.2
33.5+0.1
Dial gauge
Piston
90
Jig
Magnet
stand Shoe
Work
stand
Figure A Figure B Figure C

Play Method Jig for measuring play
290LC7MS14
7-25
5. TRAVEL REDUCTION GEAR
The followings are the general maintenance standards. However, it is most important to determine
which parts should be replaced, depending on the characteristics shown before disassembling,
damages or discoloration of exterior view, the purpose of disassembling, the expected remaining
service life etc..
Item Part name Criteria Allowable limit Remedy
Smooth, without Change 3 pieces as

A Wear of planetary shaft abnormal wear or seizure a set
Smooth, without 1.6 of pitching, no Change 3 pieces as
B Condition of tooth surface abnormal wear or seizure a set for planet pinion
cracks at root
Thrust clearance of angular From : -0.08mm Adjust shim
C To : 0.02mm Refer to 8-81(6)
bearings
D Thickness of thrust washer 1(5) 2.7±0.2mm Wear 0.1mm Replace
E Thickness of thrust washer 2(16) 3.2±0.2mm Wear 0.1mm Replace
F Thickness of thrust plate(8) 4.5±0.16mm Wear 0.15mm Replace
G Lubrication oil 2000 Working hours(Hour meter) Exchange
D F C
290LC7MS13
7-26
6. RCV LEVER
Maintenance
Criteria Remark
check item
Leakage The valve is to be replaced when the leakage Conditions :

becomes more than 1000cc/m at neutral handle Primary pressure : 30kgf/cm2
position, or more than 2000cc/m during operation. Oil viscosity : 23cSt
Spool This is to be replaced when the sliding surface has The leakage at the left condition is
worn more than 10μm, compared with the non- estimated to be nearly equal to the
sliding surface. above leakage.
Push rod
Ø7
1mm
This is to be replaced when the top end has worn

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

drop, etc. are generated during operation, and
these cannot be remedied, referring to section 6.
Troubleshooting, replace the related parts.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.
2. When loosening the hexagon socket head cap screw(125), replace the seal washers(121)
without fail.
7-27
7. 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 : 30kgf/cm2
drop. Oil viscosity : 23cSt
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
1mm
This is to be replaced when the top end has worn

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

drop, etc. are generated during operation, and
these cannot be remedied, referring to section 6.
Troubleshooting, replace the related parts.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.
7-28
8. 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 0.1mm Replace

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

with thrust plate.
・Worn less than 0.5mm(0.02in). Smooth
・Damage due to seizure or contamination remediable Smooth
within wear limit (0.5mm)(0.02in).
Sliding surface ・Worn more than 0.5mm(0.02in) or abnormality. Replace

with thrust plate.
Cover ・Worn less than 0.5mm(0.02in). Smooth
・Damage due to seizure or contamination remediable Replace
within wear limit (0.5mm)(0.02in).
・Extruded excessively from seal groove square ring. Replace
- Extrusion
Square ring
・Slipper ring 1.5mm(0.059in) narrower than seal Replace

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

(0.059in)
7-29
9. 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
7-30
GROUP 3 TRACK AND WORK EQUIPMENT
1. TRACK
1) TRACK ROLLER
32077MS01
Unit : mm
No. Check item Criteria Remedy
Standard size Repair limit

1 Outside diameter of flange
Ø216 Ø204
Rebuild or
2 Outside diameter of tread Ø180 Ø168 replace
3 Width of tread 50 56
4 Width of flange 27 21
Standard size & tolerance Standard Clearance
Clearance between shaft Shaft Hole clearance limit Replace
5
and bushing 0 +0.05 bushing
Ø75 -0.03 Ø75.35 0 0.35 to 0.43 2.0
Side clearance of roller Standard clearance Clearance limit

6 Replace
(Both side) 0.16~1.24 2.0
7 - 31
2) CARRIER ROLLER
32077MS02
Unit : mm

1 Outside diameter of flange
Ø200 Ø186
Rebuild or
2 Outside diameter of tread Ø168 Ø154 replace
3 Width of tread 54 61
4 Width of flange 19 12
5
and bushing +0.085 +0.37 0.245 bushing
Ø55 +0.066 Ø55 +0.33 to 0.304 2.0
Clearance between shaft 0 +0.5

6 and support Ø58 -0.1 Ø58 +0.3 0.3 to 0.6 1.2 Replace
7-32
3) IDLER
8
1
2
7
3 5
4
21073MS03
Unit : mm

1 Outside diameter of protrusion
Ø646 Ø636
2 Outside diameter of tread Ø594 Ø584 Rebuild or
3 Width of protrusion 102 92 replace
4 Total width 203 -

5 Width of tread 50.5 55.5
6
and bushing 0 +0.05 bushing
Ø90 -0.035 Ø90.35 0 0.35 to 0.435 2.0
Clearance between shaft 0 +0.09
7 and support Ø90 -0.035 Ø90 +0.036 0.036 to 0.125 1.2 Replace
Side clearance of idler Standard clearance Clearance limit

8 Replace
(Both side) 0.4 to 1.2 2.0
7 - 33
4) TRACK
32077MS04
Unit : mm
Standard size Repair limit Turn or

1 Link pitch replace
216 223
2 Outside diameter of bushing Ø66.5 Ø58.5
Rebuild or
3 Height of grouser 30 21 replace
4 Height of link 116 104
5 Tightening torque Initial tightening torque : 115±5kgf・m Retighten
7 - 34
5) TRACK FRAME AND RECOIL SPRING
2
3
1
21073MS05
Unit : mm
Standard size Tolerance Repair limit
+2
1 Vertical width of idler guide Track frame 132 0
138
0 Rebuild or
Idler support 130 - 1.5 124
replace
+2
Track frame 292 0 298
2 Horizontal width of idler guide
Idler support 290 - 286

Free Installation Installation Free Installation
3 Recoil spring length length load length load Replace
Ø253×710 580 19012kg - 15210kg
7 - 35
2. WORK EQUIPMENT
A C D E F
B K J I H G
21077MS20
Unit : mm
Pin Bushing
Normal Remedy
Measuring point Recomm. Recomm.
Mark Limit Limit &
(Pin and Bushing) value service service
of use of use Remark
limit limit
A Boom Rear 110 109 108.5 110.5 111

B Boom Cylinder Head 100 99 98.5 100.5 101
C Boom Cylinder Rod 100 99 98.5 100.5 101
D Arm Cylinder Head 100 99 98.5 100.5 101
E Boom Front 100 99 98.5 100.5 101
F Arm Cylinder Rod 100 99 98.5 100.5 101 Replace
G Bucket Cylinder Head 90 89 88.5 90.5 91
H Arm Link 90 89 88.5 90.5 91
I Bucket and Arm Link 100 99 98.5 100.5 101
J Bucket Cylinder Rod 90 89 88.5 90.5 91
K Bucket Link 100 99 98.5 100.5 101
7 - 36
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 8-30
Group 5 Swing Device 8-43
Group 6 Travel Device 8-67
Group 7 RCV Lever 8-92
Group 8 Turning Joint 8-107
Group 9 Boom, Arm and Bucket Cylinder 8-112
Group 10 Undercarriage 8-129
Group 11 Work Equipment 8-141
SECTION 8 DISASSEMBLY AND ASSEMBLY
GROUP 1 PRECAUTIONS
1. REMOVAL WORK
1) Lower the work equipment completely to the ground.
If the coolant contains antifreeze, dispose of it correctly.
2) After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
3) When draining oil, prepare a container of adequate size to catch the oil.
4) Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
5) To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
6) Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
7) Check the number and thickness of the shims, and keep in a safe place.
8) When raising components, be sure to use lifting equipment of ample strength.
9) When using forcing screws to remove any components, tighten the forcing screws alternately.
10) Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
11) When removing hydraulic equipment, first release the remaining pressure inside the hydraulic tank
and the hydraulic piping.
12) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
number D d L
06 6 5 8
08 8 6.5 11
10 10 8.5 12
12 12 10 15
14 14 11.5 18 Taper 1/8
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, nut M24 × 3.0 90 ± 7.0 651 ± 51
2 Radiator mounting bolt M16 × 2.0 29.7 ± 4.5 215 ± 32.5
Engine
3 Coupling mounting socket bolt M20 × 2.5 46.5 ± 2.5 336 ± 18.1
4 Main pump housing mounting bolt M10 × 1.5 2.81 ± 0.3 20.3 ± 2.2
5 Main pump mounting socket bolt M20 × 2.5 42 ± 4.5 304 ± 32.5
6 Main control valve mounting bolt M12 × 1.75 12.2 ± 1.3 88.2 ± 9.4
Hydraulic
7 Fuel tank mounting bolt M20 × 2.5 45 ± 5.1 32.5 ± 37
system
8 Hydraulic oil tank mounting bolt M20 × 2.5 46 ± 5.0 333 ± 36
9 Turning joint mounting bolt, nut M12× 1.75 12.3 ± 1.3 88.9 ± 9.4
10 Swing motor mounting bolt M20 × 3.0 100 ± 1.0 723 ± 72
11 Swing bearing upper part mounting bolt M24 × 3.0 97.8 ± 10 707 ± 72.3
Power
12 train Swing bearing lower part mounting bolt M24 × 3.0 97.8 ± 10 707 ± 72.3
system
13 Travel motor mounting bolt M24 × 3.0 84 ± 8 608 ± 58
14 Sprocket mounting bolt M20 × 2.5 57 ± 6.0 412 ± 43.3
15 Carrier roller mounting bolt, nut M16 × 2.0 29.7 ± 4.5 215 ± 32.5
16 Track roller mounting bolt M20 × 2.5 57.9 ± 8.6 419 ± 62.2
17 Under Track tension cylinder mounting bolt M12 × 1.75 15 ± 0.5 108 ± 3.6
carriage
18 Track shoe mounting bolt, nut M22 × 1.5 115 ± 5.0 831 ± 36
19 Track guard mounting bolt M20 × 2.5 57.9 ± 8.7 419 ± 62.9
20 Counter weight mounting bolt M36 × 3.0 308 ± 46 2228 ± 333
21 Others Cab mounting bolt M12 × 1.75 12.8 ± 3.0 92.6 ± 21.7
22 Operator's seat mounting bolt M 8 × 1.25 4.05 ± 0.8 29.3 ± 5.8
※ For tightening torque of engine and hydraulic components, see each component disassembly and
assembly.
8-4
2. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT - Coarse thread
8T 10T
Bolt size
kgf・m lbf・ft kgf・m lbf・ft
M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8×1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7
M10×1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60.0
M12×1.75 7.4 ~ 11.2 53.5 ~ 81.0 9.8 ~ 15.8 70.9 ~ 114
M14×2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 163
M16×2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18×2.0 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 344
M20×2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22×2.5 48.3 ~ 63.3 349 ~ 458 65.8 ~ 98.0 476 ~ 709
M24×3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30×3.0 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1656
M36×4.0 174 ~ 236 1261 ~ 1704 250 ~ 310 1808 ~ 2242
(2) Fine thread

8T 10T
Bolt size
kgf・m lbf・ft kgf・m lbf・ft
M 8×1.0 2.2 ~ 3.4 15.9 ~ 24.6 3.0 ~ 4.4 21.7 ~ 31.8
M10×1.2 4.5 ~ 6.7 32.5 ~ 48.5 5.9 ~ 8.9 42.7 ~ 64.4
M12×1.25 7.8 ~ 11.6 56.4 ~ 83.9 10.6 ~ 16.0 76.7 ~ 116
M14×1.5 13.3 ~ 18.1 96.2 ~ 131 17.9 ~ 24.1 130 ~ 174
M16×1.5 19.9 ~ 26.9 144 ~ 195 26.6 ~ 36.0 192 ~ 260
M18×1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20×1.5 40.0 ~ 54.0 289 ~ 391 53.4 ~ 72.2 386 ~ 522
M22×1.5 52.7 ~ 71.3 381 ~ 516 70.7 ~ 95.7 511 ~ 692
M24×2.0 67.9 ~ 91.9 491 ~ 665 90.9 ~ 123 658 ~ 890
M30×2.0 137 ~ 185 990 ~ 1339 182 ~ 248 1314 ~ 1796
M36×3.0 192 ~ 260 1390 ~ 1880 262 ~ 354 1894 ~ 2562
8-5
2) PIPE AND HOSE
Thread size Width across flat(mm) kgf・m lbf・ft

1/4" 19 3 21.7
3/8" 22 4 28.9
1/2" 27 5 36.2
3/4" 36 12 86.8
1" 41 14 101
3) FITTING
Thread size Width across flat(mm) kgf・m lbf・ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 6 43.4
3/4" 36 13 94.0
1" 41 15 109
8-6
GROUP 3 PUMP DEVICE
1. REMOVAL AND INSTALL

1) REMOVAL
(1) Lower the work equipment to the ground
and stop the engine.
(2) Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
13031GE18
(3) Loosen the drain plug under the hydraulic

tank and drain the oil from the hydraulic
tank. 13
・ Hydraulic tank quantity : 210ℓ
(4) Remove bolts(13) and disconnect pipe 1
(1,2).
2
(5) Disconnect pilot line hoses(4, 5, 6, 7, 8, 9,
10, 11).
3
(6) Remove bolts(12) and disconnect pump
12
suction tube (3). 29078MP01
※ When pump suction tube is disconnected,
the oil inside the piping will flow out, so
catch it in oil pan.
4
(7) Sling the pump assembly and remove the 5
pump mounting bolts. 6
・ Weight : 155kg(342lb)
※ Pull out the pump assembly from housing.
When removing the pump assembly,
check that all the hoses have been 7
disconnected. 8
10
9 11 29078MP02
8-7
2) INSTALL
(1) Carry out installation in the reverse order
to removal
(2) Remove the suction strainer and clean it.
(3) Replace the return filter with a 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) Confirmed the hydraulic oil level and
check the hydraulic oil leaks or not.
8-8
2. MAIN PUMP(1/2)
1) STRUCTURE
32072ST03
04 Gear pump 261 Seal cover(F) 710 O-ring

111 Drive shaft(F) 271 Pump casing 717 O-ring
113 Drive shaft(R) 312 Valve block 719 O-ring
114 Spline coupling 313 Valve plate(R) 724 O-ring
123 Roller bearing 314 Valve plate(L) 725 O-ring
124 Needle bearing 401 Hexagon socket bolt 728 O-ring
127 Bearing spacer 406 Hexagon socket bolt 732 O-ring
141 Cylinder block 435 Flange socket bolt 774 Oil seal
151 Piston 466 VP plug 789 Back up ring
152 Shoe 468 VP plug 792 Back up ring
153 Push plate 490 VP plug 808 Hexagon head nut
156 Bushing 531 Tilting pin 824 Snap ring
157 Cylinder spring 532 Servo piston 885 Pin
158 Spacer 534 Stopper(L) 886 Spring pin
211 Shoe plate 535 Stopper(S) 901 Eye bolt
212 Swash plate 548 Pin 953 Set screw
214 Bushing 702 O-ring 954 Set screw
251 Swash plate support
8-9
MAIN PUMP(2/2)
544
543
079
545 725 325
541
466
725
490 407 725 732

B
VIEW A VIEW B
29072MP03
079 Proportional reducing valve 490 Plug 545 Steel ball

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

Allen wrench Hexagon socket PT plug PO plug Hexagon socket
B head bolt (PT thread) (PF thread) head setscrew
4 M 5 BP-1/16 - M 8
5 M 6 BP1/ 8 - M10
B
6 M 8 BP-1/ 4 PO-1/4 M12, M14
8 M10 BP-3/ 8 PO-3/8 M16, M18
17 M20, M22 BP-1 PO-1, 1 1/4, 1 1/2 -
Double ring spanner, VP plug
- Hexagon head bolt Hexagon head bolt (PF thread)
socket wrench,
double(Single) open end 19 M12 M12 VP-1/4
spanner
24 M16 M16 -
B
27 M18 M18 VP-1/2
30 M20 M20 -
36 - - VP-3/4
Adjustable angle wrench Medium size, 1 set
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-160
Steel bar Steel bar of key material approx. 10×8×200
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 16.0 115.7 0.47 12
M16 24.0 173.6 0.55 14
M18 34.0 245.9 0.55 14
M20 44.0 318.3 0.67 17
PT plug(Material : S45C) PT 1/16 0.7 5.1 0.16 4
※ Wind a seal tape 1 1/2 to
PT 1/ 8 1.05 7.59 0.20 5
2 turns round the plug
PT 1/ 4 1.75 12.66 0.24 6
PT 3/ 8 3.5 25.3 0.31 8
PT 1/ 2 5.0 36.2 0.39 10
PF plug(Material : S45C) PF 1/ 4 3.0 21.7 0.24 6
PF 1/ 2 10.0 72.3 0.39 10
PF 3/ 4 15.0 108.5 0.55 14
PF 1 19.0 137.4 0.67 17
PF 1 1/4 27.0 195.3 0.67 17
PF 1 1/2 28.0 202.5 0.67 17
8-12
3) DISASSEMBLY
(1) Select place suitable to disassembling.
※ Select clean place.
※ Spread rubber sheet, cloth or so on, on
overhaul workbench top to prevent parts
from being damaged.
(2) Remove dust, rust, etc, from pump
surfaces with cleaning oil or so on.
(3) Remove drain port plug(468) and let oil
out of pump casing.(Front and rear pump).
(4) Remove hexagon socket head bolts(412,

413) and remove regulator.
Remove hexagon socket head bolts(416)
and remove gear pump.
MP01 (290-7)
(5) Loosen hexagon socket head bolts(401)

fixing swash plate support(251), pump
casing(271) and valve block(312).
(6) Place pump horizontally on workbench

with its regulator-fitting surface down,
and separate pump casing(271) from
valve block (312).
※ Before bringing this surface down, spread
rubber sheet on workbench without failing
to prevent this surface from being
damaged.
MP02 (290-7)
8-13
(7) Pull cylinder(141) out of pump casing
(271) straightly over drive shaft(111). Pull
out also pistons(151), set plate(153),
spherical bush(156) and cylinder springs
(157) simultaneously.
※ Take care not to damage sliding surfaces
of cylinder, spherical bushing, shoes,
swash plate, etc.
MP03 (290-7)
(8) Remove hexagon socket head bolts(406)

and then seal cover(F) (261).
Fit bolt into pulling out tapped hole of seal
cover(F), and cover can be removed
easily.
※ Since oil seal is fitted on seal cover(F),
take care not to damage it when removing
cover.
(9) Remove hexagon socket head bolts(408) MP04 (290-7)
and then seal cover(R, 262).
In case of fitting a gear pump, first,
remove gear pump.
(10) Tapping lightly fitting flange section of
swash plate support(251) on its pump
casing side, separate swash plate support
from pump casing.
MP05 (290-7)
(11) Remove shoe plate(211)and swash

plate(212) from pump casing(271).
MP06 (290-7)
8-14
(12) Tapping lightly shaft's end of drive shafts
(111, 113) with plastic hammer, take out
drive shafts from swash plate supports.
MP07 (290-7)
(13) Remove valve plates(313, 314) from valve

block(312).
※ These may be removed in work 6.
MP08 (290-7)
(14) If necessary, remove stopper(L, 534),

stopper(S, 535), servo piston(532) and
tilting pin(531) from pump casing(271),
and needle bearing(124) and splined
coupling(114) from valve block(312).
※ In removing tilting pin, use a protector to
prevent pin head from being damaged.
※ Since loctite is applied to fitting areas of
tilting pin and servo piston, take care not
to damage servo piston.
※ Do not remove needle bearing as far as
possible, except when it is considered to
be out of its life span.
※ Do not loosen hexagon nuts of valve block
and swash plate support.
Once loosened, flow setting will be
changed.
8-15
4) ASSEMBLY
(1) For reassembling reverse the
disassembling procedures, paying
attention to the following items.
① Do not fail to repair the parts damaged
during disassembling, and prepare
replacement parts in advance.
② Clean each part fully with cleaning oil and
dry it with compressed air.
③ Do not fail to apply clean working oil to
sliding sections, bearings, etc. before
assembling them.
④ In principle, replace seal parts, such as
O-rings, oil seals, etc.
⑤ For fitting bolts, plug, etc., prepare a
torque wrench or so on, and tighten them
with torques shown in Section 2-3.
⑥ For the double-pump, take care not to
mix up parts of the front pump with those
of the rear pump.
(2) Fit swash plate support(251) to pump

casing(271), tapping the former lightly with
a hammer.
※ After servo piston, tilting pin, stopper(L)
and stopper(S) are removed, fit them soon
to pump casing in advance for
reassembling.
※ In tightening servo piston and tilting pin,
use a protector to prevent tilting pin head
MP09 (290-7)
and feedback pin from being damaged.
In addition, apply lock-tight(Medium
strength) to their threaded sections.
8-16
(3) Place pump casing with its regulator fitting
surface down, fit tilting bush of swash
plate to tilting pin(531), and fit swash plate
(212) to swash plate support(251)
correctly.
※ Confirm with fingers of both hands that
swash plate can be removed smoothly.
※ Apply grease to sliding sections of swash
plate and swash plate support, and drive
MP10 (290-7)
shaft can be fitted easily.
(4) To swash plate support(251), fit drive shaft

(111) set with bearing(123), bearing
spacer(127) and snap ring(824).
※ Do not tap drive shaft with hammer or so
on.
※ Assemble them into support, tapping outer
race of bearing lightly with plastic hammer.
※ Fit them fully, using steel bar or so on.
MP11 (290-7)
(5) Assemble seal cover(F, 261) to pump

casing(271) and fix it with hexagon socket
head bolts(406).
※ Apply grease lightly to oil seal in seal
cover(F).
※ Assemble oil seal, taking full care not to
damage it.
※ For tandem type pump, fit rear cover(263)
and seal cover(262).
MP12 (290-7)
(6) Assemble piston cylinder subassembly

〔Cylinder(141), piston subassembly(151,
152), set plate(153), spherical bush(156),
spacer(158) and cylinder spring(157).〕
Fit spline phases of retainer and cylinder.
Then, insert piston cylinder subassembly
into pump casing.
MP13 (290-7)
8-17
(8) Fit valve plate(313) to valve block(312),
entering pin into pin hole.
※ Take care not to mistake suction / delivery
directions of valve plate.
MP14 (290-7)
(8) Fit valve block(312) to pump casing (271)

and tighten hexagon socket head
bolts(401).
※ At first assemble this at rear pump side,
and this work will be easy.
※ Take care not to mistake direction of valve
block.
MP14 (290-7)
※ Clockwise rotation(Viewed from input

shaft side)
※ Fit block with regulator up and with
delivery flange left, viewed from front side.
(9) Putting feedback pin of tilting pin into

feedback lever of regulator, fit regulator
and tighten hexagon socket head bolts
(412, 413).
※ Take care not to mistake regulator of front
pump for that of rear pump.
MP17 (290-7)
(10) Fit drain port plug(468).

This is the end of reassembling procedures.
8-18
3. REGULATOR
1) STRUCTURE(1/2)
32072ST04
Port Port name port size

A Delivery port SAE6000psi 1"
B Suction port SAE2500psi 3"
Pi Pilot port PF 1/4-15
Pm Qmax cut port PF 1/4-15
8-19
REGULATOR(2/2)
655 734 653 654 836 651 652 601 624 629 630 628
641 801
925
814
898
631 627
732
C
733
732
622
621 623 625 626 887 763 756

SECTION A-A
29072RE02
412 Hexagon socket screw 631 Sleeve, pf 728 O-ring

413 Hexagon socket screw 641 Pilot cover 730 O-ring
436 Hexagon socket screw 642 Adjust screw(QMC) 732 O-ring
438 Hexagon socket screw 643 Pilot piston 733 O-ring
496 Plug 644 Spring seat(Q) 734 O-ring
601 Casing 645 Adjust stem(Q) 735 O-ring
611 Feed back lever 646 Pilot spring 755 O-ring
612 Lever(1) 647 Stopper 756 O-ring
613 Lever(2) 648 Piston(QMC) 763 O-ring
614 Fulcrum plug 651 Sleeve 801 Nut
615 Adjust plug 652 Spool 814 Snap ring
621 Compensator piston 653 Spring seat 836 Snap ring
622 Piston case 654 Return spring 858 Snap ring
623 Compensator rod 655 Set spring 874 Spring pin
624 Spring seat(C) 656 Block cover 875 Pin
625 Outer spring 708 O-ring 887 Pin
626 Inner spring 722 O-ring 897 Pin
627 Adjust stem(C) 723 O-ring 898 Pin
628 Adjust screw(C) 724 O-ring 924 Set screw
629 Cover(C) 725 O-ring 925 Adjust screw(QI)
630 Lock nut
8-20
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
Tool name & size Part name

Hexagon socket PT plug PO plug Hexagon socket
Allen wrench B head bolt (PT thread) (PF thread) head setscrew
4 M 5 BP-1/16 - M 8
B
5 M 6 BP1/ 8 - M10
6 M 8 BP-1/ 4 PO-1/4 M12, M14
Socket wrench, VP plug
double(single) open end - Hexagon head bolt Hexagon nut (PF thread)
B
6 M8 M8 -
Adjustable angle wrench Small size, Max 36mm
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-160
Steel bar Steel bar of key material approx. 10×8×200
Torque wrench Capable of tightening with the specified torques.
Pincers -
Bolt M4, Length : 50mm
8-21
Torque Wrench size
Part name Bolt size
kgf・m lbf・ft in mm
Hexagon socket head bolt M 5 0.7 5.1 0.16 4
(Material : SCM435)
M 6 1.2 8.7 0.20 5
M 8 3.0 21.7 0.24 6
M10 5.8 42.0 0.31 8
M12 10.0 72.3 0.39 10
M14 16.0 115.7 0.47 12
PT plug(Material : S45C) PT 1/16 0.7 5.1 0.16 4
※ Wind a seal tape 1 1/2 to
PT 1/ 8 1.05 7.59 0.20 5
2 turns round the plug
PT 1/ 4 1.75 12.66 0.24 6
PF plug(Material : S45C) PT 1/ 4 3.0 21.7 0.24 6
8-22
3) DISASSEMBLY
Since the regulator consists of small
precision finished parts, disassembly and
assembly are rather complicated.
For this reason, replacement of a regulator
assembly is not recommended, unless there
is a special reason, but in case disassembly
is necessary for an unavoidable reason,
read through this manual to the end before
starting disassembly.
(1) Choose a place for disassembly.
※ Choose a clean place.
※ Spread rubber sheet, cloth, or so on on
top of work-bench to prevent parts from
being damaged.
(2) Remove dust, rust, etc. from surfaces of
regulator with clean oil.
(3) Remove hexagon socket head screw

(412, 413) and remove regulator main
body from pump main body.
※ Take care not to lose O-ring.
REG01 (290-7)
(4) Remove hexagon socket head screw

(438) and remove cover(C,629).
※ Cover(C) is fitted with adjusting screw
(C,QI)(628, 925), adjusting ring(C, 627),
lock nut(630), hexagon nut(801) and
adjusting screw(924).
Do not loosen these screws and nuts.
If they are loosened, adjusted pressure-
flow setting will vary.
REG02 (290-7)
8-23
(5) After removing cover(C, 629) subassembly,
take out outer spring(625), inner spring
(626) and spring seat(C, 624) from
compensating section.
Then draw out adjusting ring(Q, 645), pilot
spring(646) and spring seat(644) from
pilot section.
※ Adjusting ring(Q,645) can easily be drawn
out with M4 bolt.
REG03 (290-7)
(6) Remove hexagon socket head screws

(436, 438) and remove pilot cover(641).
After removing pilot cover, take out set
spring(655) from pilot section.
REG04 (290-7)
(7) Remove snap ring(814) and take out

spring seat(653), return spring(654) and
sleeve(651).
Sleeve(651) is fitted with snap ring(836).
※ When removing snap ring(814), return
spring(654) may pop out.
※ Take care not to lose it.
REG05 (290-7)
(8) Remove locking ring(858) and take out

fulcrum plug(614) and adjusting plug
(615).
※ Fulcrum plug(614) and adjusting plug
(615) can easily be taken out with M6 bolt.
REG06 (290-7)
8-24
REG07 (290-7)
(9) Remove lever(2, 613). Do not draw out

pin(875).
※ Work will be promoted by using pincers or
so on.
REG08 (290-7)
(10) Draw out pin(874) and remove feedback

lever(611).
※ Push out pin(874, 4mm in dia.) from above
with slender steel bar so that it may not
interfere with lever(1, 612).
REG09 (290-7)
REG10 (290-7)
8-25
(11) Remove lever(1, 612). Do not draw out
pin(875).
(12) Draw out pilot piston(643) and spool(652).
(13) Draw out piston case(622), compensating
piston(621) and compensating rod(623).
※ Piston case(622) can be taken out by
pushing compensating rod(623) at
opposite side of piston case.
This completes operation.
8-26
4) ASSEMBLY
(1) For assembly, reverse disassembly
procedures, but pay attention to the
following items.
① Always repair parts that were scored at
disassembly.
Get replacement parts ready beforehand.
② Mixing of foreign matter will cause
malfunction.
Therefore, wash parts well with cleaning
oil, let them dry with jet air and handle
them in clean place.
③ Always tighten bolts, plugs, etc. to their
specified torques.
④ Do not fail to coat sliding surfaces with
clean hydraulic oil before assembly.
⑤ Replace seals such as O-ring with new
ones as a rule.
(2) Put compensating rod(623) into

compensating hole of casing(601).
(3) Put pin force-fitted in lever(1, 612) into
groove of compensating rod and fit lever
(1) to pin force-fitted in casing.
(4) Fit spool(652) and sleeve(651) into hole in

spool of casing.
※ Confirm that spool and sleeve slide
smoothly in casing without binding.
※ Pay attention to orientation of spool.
Spool
Feedback lever
8-26 (290-7)
8-27
(5) Fit feedback lever(611), matching its pin
hole with pin hole in spool.
Then insert pin(874).
※ Insert pin in feedback lever a little to ease
operation. Lever 1 side Lever 2 side
(adjust plug fulcrum
※ Take care not to mistake direction of
plug side)
feedback lever.
8-27 (290-7)
(6) Put pilot piston(643) into pilot hole of

casing.
※ Confirm that pilot piston slides smoothly
without binding.
(7) Put pin force-fitted in lever(2, 613) into
groove of pilot piston.
Then fix lever(2).
REG11 (290-7)
(8) Fit fulcrum plug(614) so that pin force-

fitted in fulcrum plug(614) can be put into
pin hole of lever(2).
Then fix locking ring(858).
(9) Insert adjusting plug(615) and fit locking
ring.
※ Take care not to mistake inserting holes
for fulcrum plug and adjusting plug.
At this point in time move feedback lever
to confirm that it has no large play and is
free from binding. REG12 (290-7)
(10) Fit return spring(654) and spring seat

(653) into spool hole and attach snap ring
(814).
REG13 (290-7)
8-28
(11) Fit set spring(655) to spool hole and put
compensating piston(621) and piston
case(622) into compensating hole.
Fit pilot cover(641) and tighten it with
hexagonal socket head screws(436, 438).
REG14 (290-7)
(12) Put spring seat(644), pilot spring(646) and

adjusting ring(Q, 645) into pilot hole.
Then fix spring seat(624), inner spring(626)
and outer spring(625) into compensating
hole.
※ When fitting spring seat, take care not to
mistake direction of spring seat.
REG15 (290-7)
(13) Install cover(C, 629) fitted with adjusting

screws(628, 925), adjusting ring(C, 627),
lock nut(630), hexagon nut(801) and
adjusting screw(924).
Then tighten them with hexagonal socket
head screws(438).
This completes assembly.
REG16 (290-7)
8-29
GROUP 4 MAIN CONTROL VALVE

1) REMOVAL
(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

※ When pipes and hoses are disconnected,
the oil inside the piping will flow out, so Atr
catch it in oil pan. Btr
Atl
(4) Remove bolts and disconnect pipe. Ba

1
As
Btl
Bs
1
Aa
(5) Disconnect pilot line hoses.

(6) Disconnect pilot piping.
21078MC01
(7) Sling the control valve assembly and
remove the control valve mounting bolt.
・Weight : 200kg(425lb)
(8) Remove the control valve assembly.
When removing the control valve
assembly, check that all the piping have
been disconnected.
2) INSTALL
to removal.
21078MC02
(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 D
recheck the hydraulic oil leak or not.
21078MC03
8-30
2. STRUCTURE(1/5)
551
561
521
511
551 338
561
521 325
511
324
C1
C2
Cp2
391
102 103 601

252
602
425
424
438
401
357
561
602
551
165 254
104
251
101
252
29078MC04
101 Casing A 324 Spring 438 Rod

102 Casing B 325 Spring 511 Poppet
103 Block 338 Stopper 521 Spring
104 Block 357 Oriffice 551 Plug
165 O-ring 391 Travel spool 561 O-ring
251 Control valve 401 Bypass cut spool 601 Main relief valve
252 Lock valve 424 Spring 602 Port relief valve
254 Logic valve 425 Spring
8-31
STRUCTURE(2/5)
203
556
201
164
201 333
331
201 336 334
332 329
336 335 328
273 203 332 379 331
339 262
370
336 372
332 332
374
335 261
333 310
379 332
331
261
337 370 305
378 332
377 307
261
331
262 302
395
392
K
A
W
A
S
A
K
I
T
(L
)
S
B
2
A
1
B
C
29078MC05
164 O-ring 329 Spring 372 Spring

201 Cover 331 Seat 374 Spring
203 Cover 332 Seat 377 Spring
261 O-ring 333 Bolt 378 Spring
273 Socket screw 334 Stopper 379 Spring
302 Arm 1 spool 335 Stopper 392 Bypass cut spool
305 Swing spool 336 Bolt 395 Priority spool
307 Boom 2 spool 337 Stopper 556 Plug
310 Travel spool LH 339 Stopper
328 Spring 370 Spring
8-32
STRUCTURE(3/5)
551
611
561 159
159
K
A
W
A
S
A
K
I
T
(L
)
S
B
2
A
1
B
C
516
523
561
515 552
521
561
511 551
521
561
551
555
Arm1
561
561 551
153
561 602
551
611 169
264
261
264 273
202
204
169
204 332
202 339
376
370
332
336
273
201
164
556
164 154 29078MC06
153 Plug 273 Socket screw 521 Spring

154 Plug 332 Seat 523 Spring
159 Plug 336 Bolt 551 Plug
164 O-ring 339 Stopper 552 Plug
169 O-ring 370 Spring 555 Check valve
201 Cover 376 Spring 556 Plug
202 Cover 551 Poppet 561 O-ring
204 Cover 515 Poppet 602 Port relief valve
261 O-ring 516 Poppet 611 Main relief valve
264 O-ring
8-33
STRUCTURE(4/5)
203
203
201 333
331
201 333 334
331 329
201 336 334 328
332 329
273 331
336 335 328 262
332 379
331
335 370 262
336
379 332
332
370 261 301
335
332
372
261 309
374
332 303
261
304
306
T
(R
)
602
O
P
T
B
1
B
K
A
2
168
165
29078MC07
165 O-ring 303 Boom 1 spool 334 Stopper

166 O-ring 304 Plug 335 Stopper
168 O-ring 306 Arm 2 spool 336 Bolt
201 Cover 309 Spool(Option) 370 Spring
203 Cover 328 Spring 372 Spring
261 O-ring 329 Spring 374 Spring
262 O-ring 331 Seat 379 Spring
273 Socket screw 332 Seat 602 Port relief valve
301 Travel spool RH 333 Bolt
8-34
STRUCTURE(5/5)
552 159
561
523 163
516 154
164
LCo 976
159
551 158
561 974
521 553,561
551 511
561
554 521 155
561 511
522 167
513
T
(R
)
551 971
O
P
T
561
B
1
209 Bo
154
B
K
165 164
A
2
975
971
Ao
209
165
169
Boom 264
273
202
202
561 204
204
553
602 204
602
29078MC08
154 Plug 204 Cover 551 Plug

155 Plug 209 Flange 552 Plug
158 Plug 264 O-ring 553 Plug
159 Plug 273 Socket screw 554 Plug
163 O-ring 551 Poppet 561 O-ring
164 O-ring 513 Poppet 602 Port relief valve
165 O-ring 516 Poppet 971 Screw
167 O-ring 521 Spring 974 Screw
169 O-ring 522 Spring 975 Screw
202 Cover 523 Spring 976 Screw
8-35
3. DISASSEMBLY AND ASSEMBLY
1) GENERAL PRECAUTIONS
(1) All hydraulic components are manufactured to a high precision. Consequently, 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 remove 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
paper or a rubber mat on the bench, and disassemble the valve on it.
(4) Support the body section carefully when carrying or transferring the control valve. Do not lift by
the exposed spool, end cover section etc.
(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. Additionally one
should 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 -
Hexagon wrench Each 1 piece 5, 6, 10, 12 and 14
Socket wrench Each 1 piece 27 and 32
Spanner Each 1 piece 32(Main relief valve)
8-36
3) DISASSEMBLY
The figure in ( ) shown after the part name
in explanation sentence shows its number
in the construction figures.
(1) Place control valve on working bench.
※ Disassemble the valve in a clean and dry
environment and pay careful attention not
to damage the sealing flange faces.
(2) Travel straight valve block

Loosen hexagon socket head bolts to and
remove straight travel valve block(103) in
its assembled state.
・Hexagon wrench : 14mm
21078MC09
(3) Main spool

① Loosen hexagon socket head bolts(273)
and remove spring cover(201, 203).
21078MC10
② Remove spool, springs, stopper, spring

seats and spacer bolt in spool assembly
condition from casing.
※ When extracting each spool assembly
from its casing, pay attention not to
damage the casing.
21078MC11
8-37
(4) Covers
Loosen hexagon socket head bolts(273)
and then remove the spool cover(202,
204).
21078MC12
(5) Removal of port relief

Remove port relief valves(602) from
casing.
・Socket wrench : 32mm
21078MC13
(6) Removal of plug(Option section)

Remove plugs(553) from casing.
・Socket wrench : 27mm
(7) Lock valve

Loosen hexagon socket head bolts and
remove lock valve(252).
21078MC14
8-38
(8) Negative control relief valve
① Remove plug(551).
21078MC15
② Remove poppet(611), spring(621) and

damping rod(631).
21078MC16
(9) Swing logic valve and check valve

① Loosen hexagon socket head bolts(251)
and remove logic valve(251) and take
check valve(254).
② Remove plug(551) or (552) and take out
poppet(511) or (515, 516) and spring
(521) or (523).
・Hexagon wrench : 6, 12mm
21078MC17
(10) Boom priority valve

Loosen hexagon socket head bolts(104)
and remove boom priority valve(104).
8-39
(11) Inspection after disassembly
Clean all 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 seal groove faces of casing and block are smooth and free of dust, dent, rust etc.
c. Correct dents and damages and check seat faces within the casing, if any, by lapping.
※ Pay careful attention not to leave any lapping agent within 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 the prescribed disassembly
and assembly procedures.
g. Replace all seals and 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 show uniform
and consistent 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 springs are free from breakage, deformation, and wear.
e. Confirm that orifices of main poppet and seat section are not clogged with foreign matter.
f. Replace all O-rings with new ones.
g. When any light damage is found in above inspections, correct it by lapping.
h. When any abnormal part is found, replace it with a completely new relief valve assembly.
8-40
4) ASSEMBLY
(1) General comments
① In this assembly section, explanation only is shown.
For further understanding, please refer to the figures and photographs shown in the previous
disassembly section.
② Figure in ( ) shown after the part name in the explanation refers to the reference identity number
shown on the construction figure shown in the spares section.
③ Cautions in assembling seal
a. Pay close attention to keeping all seals free from handling damage and inspect carefully for
damage before using them.
b. Apply clean grease or hydraulic oil to the seal so as to ensure it is fully lubricated before
assembly.
c. Do not stretch seals so much as to deform them permanently.
d. In fitting O-rings, pay close attention not to roll them into their final position in addition, a twisted
O-ring cannot easily untwist itself naturally and could thereby cause inadequate sealing and
thereby both internal and external oil leakage.
e. Tighten fitting bolts for all sections with a torque wrench adjusted to the respective tightening
torque as shown on the corss section drawings of the spares section.
(2) Check valve

① Assemble poppets(511, 515, 516) and spring(521, 523).
② Put O-rings(561) on to plugs(551, 552).
③ Tighten plugs(551, 552) to the specified torque.
・Tightening torque : 23~27kgf・m(166~195lbf・ft)
(3) Negative control relief valve
① Assemble the poppets, springs and damping rods(611×2) together into casing A(101).
② Put O-ring(561) on to plug(551) and tighten the latter to its specified torque.
・Tightening torque : 23~27kgf・m(166~195lbf・ft)
(4) Lock valve
① Put O-rings onto the casing.
② Tighten hexagon socket head bolts to their specified torques.
・Tightening torque : 1~1.4kgf・m(7.23~10.12lbf・ft)
(5) Assembly of main relief, port relief valves
① Install main relief valve(601), port relief valve(602) into the casing and tighten to the specified
torque.
Tightening torque
Components Tools
kgf・m lbf・ft
Main relief valve Spanner 32mm 7~8 50.6~57.8
Port relief valve Socket wrench 32mm 7~8 50.6~57.8
8-41
(6) Main spools
① Carefully insert the previously assembled spool assemblies into their respective bores within of
casing A(101) and casing B(102).
※ Fit spool assemblies into casing A(101) and casing B(102) carefully and slowly. Do not under
any circumstances push them forcibly in.
(7) Covers
① Fit spool covers(202, 204) to the nonspring assembly end of the spool, and tighten the
hexagonal socket head bolts(273) to the specified torque.
・Tightening torque : 2.5~3.5kgf・m(18~25.3lbf・ft)
※ Confirm that O-rings(169, 264) have been fitted.
② Fit spring covers(201, 203) to the spring end for the spools, and tighten hexagon socket head
bolts(273) to the specified torque.
・Tightening torque : 2.5~3.5kgf・m(18~25.3lbf・ft)
※ Confirm that O-rings(261, 262) have been fitted.
(8) Travel straight valve, swing logic valve and boom priority valve
① Put O-rings onto the casing.
② Tighten hexagon socket head bolts to their specified torques.
Tightening torque
Components Tools
kgf・m lbf・ft
Travel straght valve Hexagon wrench 14mm 28~32 202~231
Swing logic valve Hexagon wrench 6mm 2.5~3.5 18~25.3
Boom priority valve Hexagon wrench 10mm 8.5~11.5 61.5~83.1
8-42
GROUP 5 SWING DEVICE
1. REMOVAL AND INSTALL OF MOTOR

1) REMOVAL
(2) Loosen the breather slowly to release the
penetrate the skin causing serious in
13031GE18
injury.
catch it in oil pan. 5
(3) Disconnect pipe assy(2, 3). 6
(4) Disconnect pilot line hoses(4, 5, 6, 7, 8). 4
(5) Sling the swing motor assembly(1)and

remove the swing motor mounting bolts(9). 2
1
・ Motor device weight : 58kg(130lb)
3
・ Tightening torque : 58.4kgf・m
29078SM01
(422.4lbf・ft)
(6) Remove the swing motor assembly.
※ When removing the swing motor
assembly, check that all the piping have
been disconnected. 7 8
2) INSTALL 9

to removal.
(2) Bleed the air from the swing motor. 29078SM02
① Remove the air vent plug.
② Pour in hydraulic oil until it over flows
from the port.
③ Tighten plug lightly.
④ Start the engine, run at low idling, and
⑤ Tighten plug fully.
(3) Confirmed the hydraulic oil level and
check the hydraulic oil leak or not.
8-43
2. SWING MOTOR
1) STRUCTURE
R32072SM02
031 Time delay valve 162 O-ring 468 Plug

051 Relief valve 163 O-ring 469 Plug
052 Valve assy 171 Hexagon screw 471 O-ring
101 Drive shaft 301 Casing 472 O-ring
106 Spacer 303 Casing 485 O-ring
111 Cylinder 304 Front cover 487 O-ring
113 Spherical bush 351 Plunger 488 O-ring
114 Spring 355 Spring 491 Oil seal
116 Push rod 401 Socket bolt 702 Piston
121 Piston 437 Snap ring 712 Brake spring
122 Shoe 438 Snap ring 742 Friction plate
123 Retainer 443 Roller bearing 743 Separate plate
124 Shoe plate 444 Needle bearing 841 Socket bolt
131 Valve plate 451 Spring pin 993 Plug
161 O-ring 464 Plug 994 Plug
8-44
2) DISASSEMBLY
(1) Lift the motor out. Clean the motor in
kerosene and dry with compressed air.
※ To avoid dust inside the motor, mask all
the ports of the motor with tapes.
32038SM01
(2) Loosen the drain plug to discharge oil in

the casing(301).
32038SM02
(3) Fix the drive shaft(101) on the workbench

with the end of output shaft down. Put
matching marks on casing (301) and valve
casing(303) for easy reassembly.
32038SM03
(4) Remove the valve(031).
32038SM04
8-45
(5) Remove the relief valve(051) from valve
casing(303).
32038SM05
(6) Remove plug(469) from valve casing

(303) and spring(355), plunger(351).
※ Be careful not to damage the plunger seat
assembly.
32038SM06
(7) Remove valve casing(303) from casing

(301). Then, remove the valve plate(131)
from valve casing(303) with care.
32038SM07
(8) Remove the brake spring(712) from brake

piston(702).
32038SM08
8-46
(9) Remove brake piston(702) from casing
(301).
32038SM09
(10) Remove the cylinder(111) from the output

shaft (101) with the motor positioned
horizontally. Remove piston(121),
pushing plate(123), retainer(113), spacer
(117) and shoe plate(124).
※ If shoe plate would not removed easily, try
again after procedure(14).
32038SM10
(11) Remove friction plate(742) and separate

plate(743) from casing(301).
32038SM11
(12) Remove snap ring(437) with plier and

remove the front cover(304) from
casing(301).
※ Front cover could be removed with sliding
shaft if necessary.
32038SM12
8-47
(13) Remove drive shaft(101) from casing (301).
32038SM13
(14) Remove the shoe plate(124) from casing

(301).
32038SM14
(15) Proceed with following job only when

necessary.
① Remove the snap ring(432), spacer(106)
from drive shaft(101) and remove the
cone of roller bearing(443) by press.
※ Do not reuse bearings.
Press
Output shaft 32038SM15
Roller bearing
8-47 (290-7)
② Remove oil seal(491) from front cover

(304).
32038SM16
8-48
③ Remove the roller bearing(444) from the
valve casing(303) by using slide hammer
bearing puller.
32038SM17
④ When disassembling the relief valve,

release the plug(3). 3
Remove the piston(7), spring seat(9), 5
spring(8) and plunger(6) with the body(1) 4
downwards. 15
※ Do not release the lock nut(15). 11
14
7
13
9
12
2
1
10
29078SM04
This completes disassembly.
8-49
3) ASSEMBLY
Do the reassembly in the reverse procedure
of the disassembly.
(1) Place the casing(301) on the workbench
with the valve casing(303) downward.
32038SM20
(2) When reassembling the roller bearing,

install the snap ring(432), and spacer(106)
to the drive shaft(101). Insert the collar
and cone of the roller bearing(443).
Install the spacer(106) and stop ring(432).
Install stop ring(433) to the output shaft
(101) by heating the cone of the roller
bearing(444).
32038SM21
Out put
Roundring parts of
the collar toward
spacer
Spacer
32038SM22
(3) Insert the drive shaft(101) into the casing

(301) with the end of output shaft upward
and tap the outer race of roller bearing
with the hammer.
32038SM23
8-50
(4) Tack O-ring(471) to the casing(301).
32038SM25
(5) Reassemble the front cover(304) to the

casing(301).
※ Apply grease to the rib of oil seal to avoid
damage to the rib.
32038SM26
(6) Install the snap ring(437) to the casing

(301).
32038SM27
(7) Insert the shoe plate(124) with the casing

(301) position horizontally.
32038SM28
8-51
(8) Insert the push rod(116) into the cylinder
(111). Place the retainer(113) assembled
with spacer(117) onto the cylinder.
※ Insert two push rods in each hole.
32038SM29
(9) Install the piston sub-assembly(121, 122)

to the set plate(123).
32038SM30
(10) Reassemble the piston assembly(121,

122) to the cylinder(111).
32038SM31
(11) Place the casing(301) under the front

cover(304) and reassemble 3 sheets of
separate plate(743) and then 2 sheets of
friction plate(742) to the casing(301).
32038SM32
8-52
(12) Insert O-ring(706, 707) inside the casing
(301).
32038SM33
(13) Reassemble brake piston(702) to the

casing(301).
32038SM34
(14) Reassemble brake spring(712) to the

brake piston(702).
32038SM35
(15) When assembling the roller bearing(444),

insert the roller bearing(444) into valve
casing(303) by hammering.
32038SM36
8-53
(16) Reassemble valve plate(131) to the valve
casing(303) and reassemble O-ring(472).
32038SM37
(17) Connect the valve casing(303) with the

casing(301) and tighten the hexagon
screw(401).
32038SM38
(18) Insert plunger(351) and spring(355) in the

valve casing and install O-ring(488).
Tighten plug(469) to the valve casing.
32038SM39
(19) Insert O-rings(051-1) to the relief valve

(051) and reassemble them to valve
casing(303).
32038SM42
8-54
(20) Tighten the plug(468) to valve casing(303)
with O-ring(487) and tighten the plug(464)
to casing(301) with O-ring(485).
32038SM43
(21) Connect the valve casing(303) with the

casing(301).
This completes assembly.
8-55
3. REMOVAL AND INSTALL OF REDUCTION GEAR
1) REMOVAL
(1) Remove the swing motor assembly.
For details, see removal of swing motor
assembly.
(2) Sling reduction gear assembly(1) and
remove mounting bolts(2).
(3) Remove the reduction gear assembly.
・Reduction gear device weight : 250kg
13031GE18
(550lb)
2) INSTALL
to removal.
・Mounting bolt : 49.2~66.6kgf・m
(356~481lbf・ft)
1
2
29078SR01
8-56
4. REDUCTION GEAR
1) STRUCTURE
R32072RG01
1 Front casing 14 Pin 1 27 Oil seal

2 Middle casing 15 Side plate 1 28 Spring pin
3 Drive shaft 16 Magnet 29 Pressure plug
4 Ring gear 2 17 Side plate 3 30 Spring pin
5 Planet gear 2 18 Gauge bar 31 Stop ring
6 Sun gear 2 19 Gauge pipe 32 Bushing 2
7 Ring gear 1 20 Spacer ring 33 Stop ring
8 Planet gear 1 21 Knock pin 34 Lock washer
9 Sun gear 1 22 Roller bearing 35 Pinion gear
10 Carrier 23 Roller bearing 36 Lock plate
11 Pin 2 24 Needle cage 37 Hexagon bolt
12 Thrust washer 25 Socket bolt 38 Stop ring
13 Thrust button 26 Socket bolt 39 Side plate 2
40 Circle clip
8-57
2) DISASSEMBLY
(1) Spread off the 4 corners of lock washer
(34) with a tool.
※ Do not reuse lock washer(34).
Loosen the hexagon bolts(37) and then
remove lock washer(34) and lock
plate(36) from the pinion gear(35).
Remove pinion gear(35) and spacer ring
(20) from the drive shaft(3). R32078RG01
(2) Remove gauge bar(18) and gauge pipe

(19) from the swing motor casing.
Pour the gear oil out of reduction gear into 18
the clean bow1 to check out the friction
19
decrease.
29078SR04
(3) Loosen the socket bolt(26) to separate

swing motor from reduction gear.
26
29078SR05
(4) Remove stop ring(31) and then sun gear

1(9).
31
29078SR06
8-58
(5) Tighten two M10 eye bolts to carrier(10)
and lift up and remove carrier(10) as
subassembly.
10
29078SR07
(6) Disassembling carrier assembly

① Remove stop ring(38).
② Remove side plate2(39), planet gear1(8),
10 17 39 38 14 24 8 15
needle cage(24), side plate1(15) and
side plate3(17).
③ Using M8 solid drill, crush spring pin(30) 30
so that the pin1(14) can be removed by
hammering.
※ Do not reuse spring pin(30).
※ Do not remove pin1(14), carrier(10) and 29078SR08
spring pin(30) but in case of replacement.

※ Put matching marks on the planet gear1
(8) and the pin1(14) for easy reassembly. 38
39
24 10
8 17
15
14
29078SR09
(7) Remove sun gear2(6) and then remove

stop ring(33) when needed.
33
29078SR10
8-59
(8) Remove ring gear(7) from middle casing
(2).
※ Put matching mark for easy reassembly.
7
RK
MA
29078SR11
(9) Loosen the socket bolt(25) and tighten 2

M18 eye bolts to middle casing(2) and
then lift up and remove middle casing(2).
25
2
29078SR12
(10) Remove knock pin(21) and then remove

ring gear2(4).
※ Put marks at the knock pin hole and
across the matching line between ring
gear2(4) and front casing(1) and then
remove ring gear2(4) for easy reassembly.
4 21
1 RK
MA
29078SR13
(11) Using the bearing disassembly tool,

remove roller bearing(23).
23
29078SR14
8-60
(12) Tighten three M12 eye bolts to drive shaft
(3) and remove drive shaft(3) as
subassembly.
29078SR15
(13) Disassembling drive shaft assembly.

① Insert the spring pin(28) into the pin2(11) 28 5 32 12
by hammering. 11
② Remove pin2(11), thrust washer(12), 22 13 3
bush2(32) and planet gear2(5) from the
drive shaft(3).
※ Do not proceed and but in case of
replacement.
※ Thrust button(13) is assembled in the
29078SR16
drive shaft(3) and when replacement
needed, use M8 trimming screw of 25mm
depth and remove it.
※ Do not remove roller bearing(22). When
replacement needed, exchange the roller 32
11
bearing(22) with drive shaft assembled. 12
12
3
29078SR17
(14) Remove circle clip(40) and oil seal(27)

from the front casing (1).
※ Do not reuse oil seal once removed. 1
27
29078SR18
8-61
3) ASSEMBLY
22
(1) Assembling drive shaft assembly.
① Soak the roller bearing(22) in boiled oil
(80~100° C) and then take out and install
3
it to the drive shaft(3).
※ Confirm assembly coincidence.
② Put pinion shaft of drive shaft(3)
downwards.
29078SR19
③ Assemble thrust button(13) into the drive

shaft(3) hole. 13
※ Depth from the drive shaft(3) outer
section to the thrust button(13) is 135mm.
※ Take care not to damage oil seal.
3
④ Assemble bush2(32) and two thrust
washers(12) to the planet gear2(5) and 5
then install them to the drive shaft(3).
29078SR20
⑤ Assemble pin2(11) to the drive shaft(3)

and then press the spring pin(28) into the
pin2(11) by hammering.
11
3
29078SR21
⑥ Heat the roller bearing(23) in the boiled

oil and the take out and assemble it to
the drive shaft(3).
3
23
29078SR22
8-62
(2) Fit oil seal(27) and circle clip(40) to the
inside of front casing (1).
27 1
29078SR23
(3) Mount drive shaft assembly to the front

casing(1).
※ Take care not to damage oil seal(27).
※ Assemble drive shaft straightly to the front
casing(1).
1
29078SR24
(4) Apply loctite to the front casing(1) and

then coincide the matching mark and
assemble ring gear2(4).
4
1
29078SR25
(5) Hammer 4 knock pins(21) around the front

casing(1).
21
1
29078SR26
8-63
(6) Apply loctite to the ring gear2(4) and then
mount middle casing(2) on the front
casing(1).
2
1
29078SR27
(7) Tighten socket bolts(25) around the

middle casing(2).
2
25
29078SR28
(8) Assemble stop ring(33) to the sun gear2

(6) and then insert sun gear2(6) into the
drive shaft(3).
6
33
29078SR29
(9) Apply loctite to the tapped holes of the

middle casing(2) and then assemble ring
gear1(7).
7
There is just one tapped hole which has
different pitch value.
Don't fail to coincide this hole.
2
29078SR30
8-64
(10) Assembling carrier assembly.
① Assemble the pin1(14) to the carrier(10) 38
and then press the spring pin(30) by 39
hammering. 24 10
② Punch 2 points of the spring pin(30) lip.
8 17
③ Assemble side plate3(17) onto the center
of the carrier(10) and then assemble side 15
plate1(15) to the pin1(14).
④ Assemble needle gauge(24) and planet 14
29078SR31
gear1(8) to the pin1(14).
⑤ Install side plate2(39) and stop ring(38) to

the pin1(14).
38
39
10
29078SR32
(11) Assemble carrier(10) correctly so that the

side plate3(17) can be fixed on the sun 9
gear2(6).
10
(12) Assemble sun gear1(9) onto the side plate
3(17).
29078SR33
(13) Assemble stop ring(31) to the drive shaft

of the swing motor.
32078SR34
8-65
(14) Apply loctite to the tapped holes of the ring
gear1(17) and then mount swing motor.
※ Don't fail to coincide the gauge bar hole.
Tighten socket bolts(26) around the swing
motor.
・Tightening torque : 34kgf・m(246lbf・ft)
26
29078SR35
(15) Assemble pressure plug(29), gauge

bar(18) and gauge pipe(19). 18
19
29
29078SR36
(16) Turn the swing motor assembly upside

down and install spacer ring(20) and
pinion gear(35) to drive shaft(3) end.
Assemble lock plate(36) on the pinion
gear(35).
Assemble 2 lock washers(34) on the lock
plate(36) with their 2 holes coincided
individually.
Tighten hexagon bolts(37) to the drive
R32078RG01
shaft(3) and then fold all the lock washer
(34) corners over the hexagon bolts(37).
・Tightening torque : 24kgf・m(173lbf・ft)
(17) Inject oil into the reduction gear.
8-66
GROUP 6 TRAVEL DEVICE(up to #1455)

1) REMOVAL
(1) Swing the work equipment 90Áand lower it
completely to the ground.

ö When pipes and hoses are disconnected, 1
catch it in oil pan. 2
(4) Remove the track shoe assembly.

For details, see removal of track shoe
assembly.
(5) Remove the cover.
29078TM01
(6) Remove the hose.
ö 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.
ÂWeight : 305kg(670lb)
2) INSTALL
to removal.
(2) Bleed the air from the travel motor.
Η Remove the air vent plug.
Θ Pour in hydraulic oil until it overflows from
the port.
Ι Tighten plug lightly.
Κ Start the engine, run at low idling, and
Λ Tighten plug fully.
(3) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.
8-67
2. TRAVEL MOTOR
1) STRUCTURE
38
30 20 23 21 13 7 5 15 6 16 39 36 24 29 41 36 40 32
25
37
35
27
17
34
18 10
9 42
33
19 26 1 12 11 22 4 28 14 3 8 2 31 43,44
29078TM02
1 Casing 16 D-ring(Big) 31 Bearing

2 Rear cover 17 Check valve 32 Hexagon socket head bolt
3 Cylinder block 18 C type retaining ring 33 Shim
4 Shoe retainer 19 Retaining ring 34 Parallel pin
5 Friction plate 20 Inclined piston 35 O-ring
6 Brake piston 21 Steel ball 36 O-ring
7 Separating plate 22 Ball joint 37 O-ring
8 Valve plate 23 Piston seal 38 O-ring
9 Shaft 24 M6 restrictor(0.6) 39 O-ring
10 Coupling 25 M6 restrictor(0.8) 40 Overload relief valve
11 Swash plate 26 Oil seal 41 Pilot valve
12 Pivot 27 Check valve spring 42 Brake valve
13 Spring holder 28 Cylinder spring 43 Plug
14 Piston assy 29 Brake spring 44 O-ring
15 D-ring(Small) 30 Bearing
8-68
(1) Tools
Description Specification
Hexagon key Width across flat 5, 6, 10, 14mm

Spanner Width across flat 19, 27, 32, 35mm
Snap ring prier For shaft Ø45
Snap ring prier For bore Ø32~Ø80
Plastic hammer -
Screw driver Minus(-), medium size, 2 pieces
Torque wrench 0~33kgf・m(0~238.7lbf・ft)
Gear(Bearing) puller Work size : Dia 75 × Width 45 can be handled
Mount metal(2 pieces)
L
90
Jig for inserting oil seal
10
W
100
15
65
H
Mount metal Jig for inserting oil seal
2- 20 P.C.D. 251
Jig for inserting brake piston Thru
25
10
195
215
280
Jig for inserting brake piston
Others Seal tape, kerosene, grease, hydraulic oil, compressed air,

waists etc.

Torque Wrench size
Item Part name Size
Kgf・m lbf・ft in mm
10 Hexagon socket head bolt M8 2 14.5 0.24 6

32 Hexagon socket head bolt M18 33 239 0.55 14
40 Overload relief valve ORV-240L6 10~12 72.3~86.8 1.26 32
43 Plug PF 1/4 2.5~3 18.1~21.7 0.25 6.35
8-69
3. TRAVEL REDUCTION GEAR
1) STRUCTURE
24 17 16 14 13 12 15 21 22 19 18 25 23 20
4
5
1
7
3
10
8
6
9
11
26
29078TM03
1 Cover 10 Sun gear 2 19 Angular bearing

2 Carrier 1 11 Carrier 2 20 Shim
3 Carrier pin 1 12 Carrier pin 2 21 Lock washer
4 Needle bearing 13 Needle bearing 22 Support ring
5 Thrust washer 1 14 Planetary gear 2 23 Floating seal
6 Planetary gear 1 15 Spring pin 24 Hexagon socket head bolt
7 Spring pin 16 Thrust washer 2 25 Hexagon socket head bolt
8 Thrust plate 17 Ring gear 26 Socket head taper plug
9 Sun gear 1 18 Housing
8-70
(1) Tools
Description Specification
Torque wrench For 0~50kgf・m(0~361lbf・ft)

Hexagon socket wrench Width across flats 8, 14mm
Outer dia >

_ 500
_ 200
Work stand Inner dia =. 390
H>
Thickness 16mm
Micro depth gauge 0~15mm

Vernier caliper 0~150mm
For knocking in spring pins item 7 and 15
Pin
Ø4.5×80, Ø9.5×60
Eye bolt M10 and M20(Or equiv. hooks) each 3 pcs each
Kerosene as cleaner, solvent, gear oil, grease,
Others small items
Loctite No.242 and No.515, seal tape, waists etc.
Vertical press and jigs To press in angular bearings and to assemble its lock washers.

Torque Wrench size
Item Part name Size
Kgf・m lbf・ft in mm
24 Socket head bolt M10 × 30 7 50.61 0.31 8
25 Socket head bolt M18 × 110 38.5 278.4 0.55 14
26 Socket head plug R(PT) 3/4 10 72.3 0.75 19
8-71
4. DISASSEMBLING
1) GENERAL INSTRUCTIONS
(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) Before 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 on
your foot while lifting them.
8-72
2) DISASSEMBLING REDUCTION UNIT
(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 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
unit when loosening the plug.
③ Mark for mating
Put marks on each mating parts when
disassembling so as to reassemble
correctly as before.
※ Figure in ( ) shown after the part name
corresponds to the number on structure
drawing.
(2) Setting reduction unit(Or whole
propelling unit) on work stand for
disassembling Mating mark
① Remove M10 hexagon socket head
bolts(24) at 3 places from cover(1)
almost equally apart each other, then
install M10 eye bolts.
Lift up the unit using them and place it on
work stand with cover(1) upward.
Take great care not to pinch your hand
between parts while disassembling nor let
fall parts on your foot while lifting them.
29078TM05
8-73
(3) Removing cover
① Remove the rest of M10 hexagon socket
head bolts(24) that secure cover(1).
29078TM06
② As the cover(1) is adhered to ring gear

(17), remove cover(1) by lightly
hammering slantwise upward by wooden
bar aiming at projection of cover(1).
29078TM07
(4) Removing carrier 1 assembly

① Remove thrust plate(8).
② Remove sun gear 1(9).
③ Screw three M10 eye bolts in carrier 1(2)
and lift up and remove carrier 1 as
subassembly(2, 3, 4, 5, 6, 7).
29078TM08
(5) Removing carrier 2 assembly

① Remove sun gear 2(10).
② Screw three M10 eye bolts in carrier 2(11)
and lift up and remove carrier 2 as
subassembly(11, 12, 13, 14, 15, 16).
29078TM09
8-74
(6) Removing housing assembly
① Remove support ring(22).
② Take off lock washers(21) by tapping on
screw driver or on similar tool placed at
parting surface of them.
③ Screw three M10 eye bolts in ring
gear(17) and remove housing assembly
including ring gear(17), housing(18),
angular bearing(19), and a piece of
floating seal(23) together. 29078TM10
29078TM11
(7) Disassembling housing assembly

① Place housing assembly on steel blocks 19 25 18
or a stand with ring gear(17) below.
Make the mating mark on both housing
(18) and ring gear(17).
② Remove floating seal(23) from housing
Over 300
(18).
③ Remove M18 hexagon socket head bolts
(25), leaving two of them at 180°apart
position.
④ Loosen the two hexagon socket head
bolts(25) and tap lightly the head of them 29078TM12
then ring gear(17) can be easily removed
from housing(18).
※ Take care not to damage the sliding
surface of floating seal(23) or its O-ring.
※ Bearings(19) have been tightly press
fitted in housing(18). Don't remove the
bearings(19) unless their exchange is
needed.
In case bearings removed, don't reuse
them. New bearings should be used and
shim adjusting be required.
8-75
(8) Removing floating seal
① Remove a piece of floating seal(23) of
motor side.
29078TM13
(9) Disassembling carrier 1 assembly

※ When carrier pins 1(3) are to be reused,
mark each pin with its mated hole of
carrier 1(2) to assure the same
combination as before.
① Knock spring pins(7) fully into carrier pins
1(3).
② Tap carrier pins 1(3) out from carrier 1(2).
③ Remove thrust washers 1(5), planetary
gears 1(6) and needle bearings(4). 29078TM14
④ Knock out spring pins(7) from carrier pins
1(3) for reassembling.
※ When carrier pin 1(3) or planetary gear
1(6) is needed to be exchanged, three
pins or three gears should be all
exchanged.
29078TM15
29078TM17
8-76
(10) Disassembling carrier 2 assembly
※ When carrier pins 2(12) are to be reused,
mark each pin with its mated hole of
carrier 2(11) to assure the same
combinations as before.
① Knock spring pins(15) fully into carrier
pins 2(12).
② Tap carrier pins 2(12) out from carrier
2(11).
③ Remove planetary gears 2(14) and 29078TM19
spherical roller bearings(13).
④ Knock out spring pins(15) from carrier
pins 2(12) for reassembling.
※ When carrier pin 2(12) or planetary gear
2(14) is needed to be exchanged, three
pins or three gears should be all
exchanged.
29078TM21
3) DISASSEMBLING TRAVEL MOTOR

(1) Removing accessory valves 41 17
Before disassembling motor, remove
accessory valves.
① Remove brake valve(42).
② Remove pilot valve(41).
③ Remove check valve(17).
④ Remove overload relief valves(40).
⑤ Remove coupling(10).
※ According to disassembling purpose,
select the valves to be removed.
However, you cannot disassemble the
motor without removing valves.
10 42
29078TM04
8-77
(2) Disassembling motor
① Place the motor with the shaft horizontal, Hole for
remove hexagon socket head bolt(32) of releasing brake piston
rear cover(2) leaving two on diagonally
upper and lower position. 6 29
② Loosen slowly and simultaneously the 36,38
remaining two hexagon socket head bolt
(32).
③ Remove rear cover(2) and brake springs
(29) taking care cylinder block(3) is not
coming out stuck with rear cover(2).
※ Do not fall, at this moment, valve plate(8),
brake springs(29) and/or O-rings(36, 38).
※ If cylinder block(3) would come out with
rear cover(2), then push in the cylinder
block(3) by a rounded point bar of Ø5~8
through the oil hole of rear cover(2),
taking care not to make any scratch on
these parts, pulling out the rear cover(2)
only.
④ Remove valve plate(8) without pulling out 8 31 2 32
cylinder block(3). 29078TM23
※ Put the matching mark on both valve

plate(8) and rear cover(2) so that valve
plate(8) should not be reversed on
reassembly.
⑤ Using removed hexagon socket head
bolt, fasten two mount metals so as to
push in cylinder bolck(3) without
damaging it then inner race of rear
bearing(31) comes out.
⑥ Put two fingers of gear(Bearing) puller
under the inner race of rear bearing(31)
and remove the race.
⑦ Attaching a hand on brake piston(6),
supply plant air through oil hole for
releasing brake and push out the piston(6).
Be aware of piston popping out.
29078TM24
8-78
⑧ Put as a mark on a piston assembly(14)
such as a paper pipe and put a matching 4 22 7 5 3
mark on cylinder block(3) so that they
can be reassembled at the same position
as before.
⑨ Remove cylinder block(3), spring holder
(13) and cylinder spring(29).
⑩ Remove separator plates(7) and friction
plates(5).
⑪ Remove 9 piston assemblys(14), shoe
retainer(4) and ball joint(22) as an
assembly.
※ Put piston assemblys(14) into the Matching
mark
cylinder block(3) matching the matching
mark with shoe retainer(4) as if assembled.
The purpose is to put piston assemblys
(14) in the same bore of cylinder block(3)
as before when reassembled.
※ Take care not to scratch polished 13 28 14
surfaces. 29078TM25
Do not reuse damaged ones.

※ It is impossible to disassemble piston
and shoe because they are calked
together.
※ Above disassembling is mentioned as a
motor only and naturally can be applied
to the motor with reduction gears. The
situation is rather easier for with
reduction gears because the shaft is
rather restricted by a gear to move.
8-79
⑫ Remove swash plate(11).
⑬ Do not detach inclined piston(20). If Hole for
forced to detach, attach a hand on releasing
shifter piston
inclined piston and supply plant air 19 26 30 1
through the hole shown and push it out.
Be aware of piston popping out. 20 11
⑭ Shaft(9) can comes out now.
⑮ Remove retaining ring(19) and knock out
oil seal(26).
⑯ If bearings happen to be changed,
remove inner races and outer races using
bearing puller if needed and exchange to
new ones as an assembly.
※ Under the outer race of rear bearing(31)
are shim(33). Reuse them as they are
when reassembling.
※ When changing bearings(30, 31),
shaft(9), casing(1) or rear cover(2), it
affects the clearance of the bearings.
So shim(33) should be adjusted.
Shim adjustment should be performed by 9 12
measuring correctly the clearance for 29078TM26
shim and change shim that meets the

clearance.
Other jigs and tools are needed to
measure and decide the thickness of the
shim.
Please contact dealers for them if
necessary.
※ Do not remove pivots(12).
If forced to remove them, put matching
mark on pivots(12) with casing(1).
※ Never detach oil seal(26) only for the
purpose of inspecting it.
If disassembled, never fail to replace oil
seal(26) with new one.
8-80
⑰ Deciding shim thickness for tapered roller
bearings.
※ This work should be done only when you
E S
have changed bearings(30, 31), shaft(9),
casing(1) or rear cover(2).
a. Measure the assembling width E
※ Take care not to tip shaft(9)
b. Measure the depth F of rear cover(2)
※ Measure them at crossed 4 places on
the circuit, then calculate their mean
value.
c. When thickness of shim(33) to be
used is placed as S, the clearance Y
can be calculated as follows:
Y = F - (E + S)
d. Select one or two shim(33) so as the F
clearance Y to come to 0~0.1mm
(Clearance) on this unit.
※ Select from the shim kit.
29078TM27
(3) Disassembling overload relief valve

① Remove overload relief valve(40) as an 40-2 40-4 40-9 40-10 40-6 40-7
assembly utilizing hexagonal flats on
socket(40-1).
② As a rule, overload relief valve(40)
should be handled as one service part.
If forced to disassemble it, detach cap
(40-5) from socket(40-1) and take out 40-1 40-13 40-12 40-5
40-3 40-12 40-8 40-11
component parts.
※ Valve seat(40-3) is fitted tight to the hole 29078TM28
of socket(40-1).
Never disassemble them if not required,
since the hole of socket may be
damaged.
8-81
5. REASSEMBLING
(1) Wash each parts sufficiently with kerosene
and blow them by plant air.
(2) Assemble sliding parts after coating clean
hydraulic oil on them.
between parts or tools while assembling
nor let fall parts on your foot while lifting
them.
2) REASSEMBLING MOTOR
(1) Coat outer surface of oil seal(26) and
Jig for inserting oil seal
inner face of casing(1) with grease.
Using jig, rightly and evenly press in the
oil seal(26) into casing(1).
(2) Fix oil seal(26) by retaining ring(19).
(3) Put the outer race of bearing(30) on
casing(1)(This fit is loose), and press the
inner race on shaft(9)(This fit is tight).
※ It is easier to fit inner race if the inner race 1 26
is heated or boiled under 100° C.
Never over heat. 29078TM29
(4) Insert shaft(9) into casing(1) after coating

19 26 30 1
grease on the contact surface to oil seal
(26) lip.
20 11
(5) Put inclined piston(20) into casing(1).
(6) Insert pivots(12) into the casing(1).
Take care to match the matching mark
with casing(1) and also to coincide the
direction of sliding trace on sphere surface
with those contact trace on swash plate
(11) if the motor was operated for a
certain hours.
(7) Coat three spherical recess of swash
plate(11) with ample grease and
assemble it in casing(1).
9 12
29078TM30
8-82
(8) Insert piston assemblys(14), shoe retainer
(4), ball joint(22), spring holder(13), 4 14 13 3
cylinder spring(28) on to cylinder block(3)
as shown and then insert the whole
assembly to shaft(9).
※ Piston assemblys(14) should be inserted
into the same bore as before.
(9) Rightly knock in the inner race of rear
bearing(31) to the rear end of shaft(9).
13 22 28
29078TM31
(10) Install all the separator plates(7) and

friction plates(5) alternately between
casing(1) and cylinder block(3) adjusting
on the notches and splines. 1 7 5 15 16 32
Separator plates(7) comes both first and
last.
(11) Insert brake piston(6) into casing(1) using
inserting jig after attaching D-rings(15, 16)
Jig for
to brake piston(6).
inserting
※ Two kinds of D-rings are used on brake brake piston
piston(6). The larger one(16) is first
inserted into the hole, then the smaller
one(15) enters.
It is impossible to see how the smaller ring
goes into the hole. Therefore, never push
it forcibly into the hole. Otherwise, it may
be scraped off by the edge of the hole of 31 6
casing(1).
29078TM32
8-83
(12) Lay down rear cover(2) to mount valve
plate(8) coinciding matching mark made
1 31 36,38 29 31 33
prior to disassembling and also place
brake springs(29) with ample grease to be
attached to rear cover(2) while this
assembling.
Also set O-ring(39) on rear cover(2).
Then, insert rear cover(2) to casing(1) and
fasten hexagon socket head bolt(32).
(13) Put coupling(10) on the shaft(9).
※ Tightening torque of hexagon socket head
bolt(32) is 33kgf・m(238.6lbf・ft) with rust
preventive on the threads.
6 39 8 2 32
29078TM33
3) ASSEMBLING ACCESSORY VALVES

After reassembling motor, assemble
41 17
accessory valves.
(1) Assemble brake valve(42).
(2) Assemble check valve(17).
(3) Assemble pilot valve(41).
(4) Assemble overload relief valves(40).
(5) Assemble coupling(10).
10 42
29078TM34
8-84
4) ASSEMBLING REDUCTION GEAR
(1) General notes
① Clean every part by kerosene and dry
them by air blow. Surfaces to be applied
by loctite must be decreased by solvent.
② Check every part for any abnormals.
③ Each hexagon socket head bolt should
be used with loctite No.242 applied on its
threads.
④ Apply gear oil slightly on each part before
assembling.
between parts or tools while assembling
nor let fall parts on your foot while lifting them.
※ Inspection before reassembling
a. Thrust washer
・Check if there are seizure, abnormal
wear or uneven wear.
・Check if wear is over the allowable
limit.
b. Gears
・Check if there are pitting or seizure on
the tooth surface.
・Check if there are cracks on the root
of tooth by die check.
c. Bearings
・Rotate by hand to see if there are
something unusual such as noise or
uneven rotation.
d. Floating seal
・Check flaw or score on sliding
surfaces or on O-rings.
8-85
(2) Assembling carrier 2 assembly
① Install retaining rings(16) into planetary
gear 2(14) if removed.
Install planetary gears 2(14) and
spherical roller bearings(13) into carrier
2(11).
② Install carrier pins 2(12) into carrier 2(11)
where the holes for spring pins(15) are to
be in line with those of carriers 2(11).
③ Install spring pins(15) into carrier 2(11) 29078TM35
and at the same time into carrier pins
2(12).
29078TM37
(3) Assembling carrier 1 assembly

① Install planetary gears 1(6), needle
bearings(4) and thrust washers 1(5) into
carrier 1(2).
② Install carrier pins 1(3) into carrier 1(2)
where the holes for spring pins(7) are to
be in line with those of carrier 1(2).
③ Install spring pins(7) into carrier 1(2) and
at the same time into carrier pins 1(3).
29078TM38
29078TM40
8-86
(4) Installing floating seal
① Install a piece of floating seal(23) on
motor casing and also install another
piece of floating seal(23) on housing(18).
※ Clean the groove for floating seals(23) to
eliminate oil, dust, paint or other foreign
material.
※ Apply gear oil slightly on sliding surfaces
of floating seals(23) before assembling
but stricly dry on O-rings and on its 29078TM41
grooves.
※ Confirm that O-ring of floating seal(23)
Correct Incorrect Incorrect
are not twisted and that floating seal is
correctly installed. i.e. parallel as shown
each other between housing(18) and
motor casing after assembled.
It is recommended to use jig to install
floating seal.
29078TM42
(5) Assembling housing assembly

① Apply loctite No.515 on mating surfaces Loctite #515
of housing(18) and ring gear(17) without
a gap.
② Install three M24 eye bolts equally apart
on housing(18). Using the bolts, hang
the housing(18) by wire rope and place it
on ring gear(17), coinciding mating
marks. Housing side
③ After applying loctite No.242 on the
29078TM43
threads of 25 pieces of M18×110
hexagon socket head bolts(25), tighten
them with torque wrench to 38.5kgf・m 23 25 18
(278.3lbf・ft).
17
29078TM44
8-87
(6) Deciding shim thickness for angular
bearings
※ This work should be done only when you
have to change at least one of motor
casing(23), housing(18), bearing(19) and
lock washer(21). Unless otherwise use
the same shim as before.
① Fit in two bearings(19) on housing(18)
pressing their outer laces.
② Pressing inner laces of two bearings(19)
lightly and evenly, measure the
assembling width(A) for inner laces. S
③ Measure the motor side assembling D A
C B
width(B) for bearings(19).
④ Measure the groove width(C) of motor
casing(23).
⑤ Measure the thickness(D) of lock washer
(21).
※ Measure them at 4 places evenly apart 29078TM45
on the circumferences then calculate and
use those mean values.
※ Measure them to the accuracy of 0.01mm.
⑥ When thickness of shim(20) to be used is
placed as S, the clearance X can be
calculated as follows:
X = (B + C) - (A + D + S)
⑦ Select a shim(20) so as the clearance X
to come to -0.08mm(Interfrence) - 0.02mm
(Clearance) on this unit.
(7) Pressing motor in 17 21 22 18 19 20

① Place motor on work stand with the shaft
upward, and put the selected shim(20)
on the bearing end of motor casing.
② Install three M10 eye bolts on ring gear
(17) almost equally apart and lift it up.
Descend it concentric with motor and put
bearings(19) of housing(18) into motor
casing. Use press machine and press
29078TM46
inner lace of bearing(19) into full depth.
8-88
③ While pressing flange of housing(18),
install lock washers(21) into groove.
29078TM47
④ Install support ring(22) over outside of

lock washers(21).
29078TM48
(8) Installing carrier 2 assembly

① Position three planetary gears 2(14) as
shown on figure 27), put carrier 2
assembly into ring gear(17) and mesh
the splines to those of motor.
② Insert and mesh sun gear 2(10) on
center.
29078TM49
※ Positioning carrier 2 assembly is

Carrier2 Planetary gear2
important to obtain better lubrication.
Pilot valve
11
35
8.8
8.8
35
11
VB
VA
Notch of carrier2
Brake valve
29078TM51
8-89
(9) Installing carrier 1 assembly
① Putting carrier 1 assembly in ring gear
(17), rotate planetary gears 1(6) by hand
and adjust carrier 1(2) to mesh with sun
gear 2(10).
② Marking sure that coupling is on the shaft
end, install sun gear 1(9) on center.
29078TM52
③ Facing sharp edged side to cover(1),

place thrust plate(8) on carrier 1(2).
29078TM54
(10) Installing cover

※ Gear oil can be filled before installing Loctite #515
cover(1) if you can measure presscribed
volume of oil.
① Apply loctite No.515 on mating surfaces
of cover(1) and ring gear(17) and install
cover(1) on ring gear(17).
② Apply loctite No.242 on threads of 18
- M10×30 hexagon socket head bolts
Cover side
(24) and tighten them with the torque of 29078TM55
7kgf・m(50.6lbf・ft).
(11) Filling gear oil

① Fill gear oil(SAE 90 API class GL-4 or
GL-5, 11 litters) from two R(PT) 3/4 ports
for taper screw plugs(26).
② Wrap taper plugs(26) with seal tape and
put and tighten them on cover(1).
29078TM56
8-90
※ Inspection after assembled
a. Lubrication
After installing the propelling unit, position
the drain port at the lowest position and
check if lubrication oil comes out when
loosen the level plug.
b. Rotating inspection
Put the unit on the test stand and rotate
with no load and check if there are
abnormal noise or leak of oil. This
inspection can be done also on an
excavator, after mounting the unit, by
lifting one side of crawlers by front
attachment.
Take care not to overspeed the motor.
Rotate within specified flow rate.
8-91
GROUP 6 TRAVEL DEVICE(#1456 and up)

1) REMOVAL
(1) Swing the work equipment 90Áand lower it
completely to the ground.

E scaping fluid under pressure can
penetrate the skin causing serious
injury. 1
ö When pipes and hoses are disconnected,
2
(4) Remove the track shoe assembly.
For details, see removal of track shoe
assembly.
29078TM01
(5) Remove the cover.

(6) Remove the hose.
ö 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.
ÂWeight : 305kg(670lb)
2) INSTALL
to removal.
(2) Bleed the air from the travel motor.
Η Remove the air vent plug.
Θ Pour in hydraulic oil until it overflows from
the port.
Ι Tighten plug lightly.
Κ Start the engine, run at low idling, and
Λ Tighten plug fully.
8-91-1
2. TRAVEL MOTOR
1) STRUCTURE
89-5 89-4 89-3 89-2 89-6 88-6 88-4 88-2 93 88-3 88-5 86 85 87 83 13 14 15 16 25 24 6 28 30 31 4 40 39 43 38 37 71 42 41 47 50
89-6 29
90-2 35
90-3 32
90-4 33
97 A 27
92 21
90-5 49
101
98 75,76
102 48
100 36
11 46
103
73 34
74 44
12
45
91
96
56
89-8 67
89-7
62
104
90-1 A
99
88-8
63
89-1
65
88-7 105 95 94 88-1 5 72 9 8 7 10 84 23 22 82 17 18 19 1 20 26 3 69 2 68 61 64 60 66 57 58,59 70 55 54 53 52 51
SECTION A-A
2907A2TM01
1 Casing 16 Plate 31 Ring 46 Back up ring 61 O-ring 83 Housing 89-1 Carrier No.2 92 Plug
2 Plug 17 Piston 32 Spring 47 Cap 62 Lock screw 84 Bearing 89-2 Planetary gear No.2 93 Lock pin
3 Screw 18 Stopper 33 Valve casing 48 Cap 63 Nut 85 Shim 89-3 Needle No.2 94 Ring gear
4 Screw 19 O-ring 34 Needle bearing 49 Bolt 64 Spool 86 Retainer 89-4 Thrust washer No.2 95 Bolt
5 Pin 20 Back up ring 35 O-ring 50 Socket bolt 65 Plug 87 Bolt 89-5 Pin No.2 96 Thrust ring No.1
6 Pin 21 Cylinder block 36 Pin 51 Seat 66 O-ring 88 Carrier No.3 89-6 Spring pin No.2 97 Cover
7 Stopper 22 Cylinder spring 37 Spool 52 Steel ball 67 Valve plate 88-1 Carrier No.3 89-7 Sun gear No.2 98 Thrust ring No.2
8 O-ring 23 Spacer 38 Screw 53 Stopper 68 Spring 88-2 Planetary gear No.3 89-8 Snap ring No.2 99 Bolt
9 Back up ring 24 Guide 39 Damping check 54 Plug 69 O-ring 88-3 Needle No.3 90 Carrier No.1 100 Motor ring
10 Piston 25 Plate 40 Spring 55 O-ring 70 Socket bolt 88-4 Thrust washer No.3 90-1 Carrier No.1 101 Thrust ring No.3
11 Shaft 26 Piston & Shoe assy 41 O-ring 56 Plug 71 Socket bolt 88-5 Pin No.3 90-2 Planetary gear No.1 102 Thrust ring No.1
12 Spacer 27 Plate 42 Plunger 57 Relief valve 72 Lock screw 88-6 Spring pin No.3 90-3 Needle bearing No.1 103 Pad
13 Roller bearing 28 Plate 43 Spring 58 O-ring 73 Oil seal 88-7 Sun gear No.3 90-4 Thrust washer No.1 104 Thrust ring No.2
14 Stop ring 29 Brake 44 Stopper 59 Back up ring 74 Lock ring 88-8 Snap ring No.3 90-5 Pin No.1 105 Coupling
15 Support 30 Ring 45 O-ring 60 Rod 82 Floating Seal 89 Carrier No.2 91 Sun gear No.1
8-91-2
2) TOOL AND TIGHTENING TORQUE
(1) Tools
Name of tools B-size Name of part applied
Hexagonal 4 Plug(2), Orifice screw(3, 4, 38)

L-Wrench 8 Hex socket bolt(50), Lock screw(62, 72), Plug(65)
10 Hex socket bolt(49)
46 Hex(57)
Socket 19 Hp plug(54)
wrench/spanner 24 Hex nut(63)
27 Hp plug(56)
Snap-ring plier(for holes, axis) Ring stop(14), Ring lock(74)
Solder hammer Needle bearing(34), Pin(5, 6, 36)
Torque wrench Size : 500, 3000
Jig for assembling oil seal Oil seal(73)
Induction heating apparatus for bearing Roller bearing(13)

Torque
NO. Part name Standard Size
kgfÂm lbfÂft
2 Plug NPTF 1/16 4 7~11 50.63~79.5
3, 4, 38 Orifice screw NPTF 1/16 4 7 50.63
49 Hex socket bolt M12 10 100 723.3
50 Hex socket bolt M10 8 67 484.6
54 Plug PF 1/4 19 37 267.6
56 Plug PF 1/2 27 110 795.6
57 Relief valve HEX 46 46 170~190 1230~1374
63 Nut M16 24 240 1736
65 Plug PF 3/8 8 75 542.4
70, 72 Hex socket bolt M16 14 240 1736
71 Hex socket bolt M16 14 240 1736
8-91-3
2. DISASSEMBLING
(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) Before 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
on your foot while lifting them.
8-91-4
2) DISASSEMBLEING TRAVEL MOTOR
(1) Fix a hydraulic motor on jig with four

pieces of bolts(M16Ý60L).
ö When rotating jig up to 90Áin disassembling
and assembling, fix a motor making drain
plug(56) faced to the bottom.
300072TM20
(2) After disassembling drain plug(56), let an

oil in a case of a motor discharged.
ö Check whether manufactured chips or
metal dust are added in a drain oil.
300072TM21 300072TM21A
(3) In order to making the out-put axis of a

hydraulic motor faced upward, disassemble
ring lock(74) with a plier after rotating jig up
to 90Áin disassembling and assembling.
300072TM22
(4) Disassemble hexgon socket bolts(70, 71)

holding valve casing.
300072TM23
8-91-5
(5) After detaching valve casing sub,
disassemble valve plate(67).
ö In case of serious abrasion of valve plate,
exchange it to a new one.
300072TM24A 300072TM24
(6) After taking brake spring(32) and then

bonding two pieces of M16 bolts to brake
piston(29), disassemble it pulling it upward.
ö There are 10 pieces of brake spring.
300072TM25
300072TM25A
300072TM25B
(7) First, rotate jig in disassembling and

assembling up to 90Á then let a motor
faced toward the horizon. then disassemble
a cylinder and piston sub.
300072TM26
(8) disassemble stopper L(18) and piston

swash(17).
ö Piston swash : Use M5 bolt
300072TM27
8-91-6
(9) Disassemble swash plate(16).
300072TM28
(10) After put M12 into support(15), disassemble

support.
300072TM29
(11) disassemble piston swash(10) and

stopper(7).
300072TM30
(12) In order to making the turning axis(11)

faced upward, put it way from shaft casing
tapping the bottom of the turning axis with
hammer, after rotating jig up to 90Áin
disassembling and assembling.
ö Try to deal with roller bearing(13) without
any damage.
300072TM31
8-91-7
(13) Disassemble valve casing sub.
ö Try to deal with needle bearing(3) without
any damage.
Η Disassemble plowing road(60), automatic

changeover spring(68), and automatic
changeover spool(64).
ö Do not touch hexagon nut(63) for
controlling the amount of an oil and lock
300072TM32
screw(62). 300072TM32A
If there is any abnormality on plowing 300072TM32B
spool and spring, exchange them to new

ones.
Θ After unloading hexagon socket bolts(49,

50) and taking caps(47,48) away,
disassemble parts of counter balance
valve(37~46).
ö In disassembling counter balance valve,
be careful of figuring out the directions
such as the right or the left of finger.
If there is any abnormality in spool spring
check, exchange it to new one.
300072TM33
300072TM33A
300072TM33B
300072TM33C
300072TM33D
8-91-8
(14) Disassemble cylinder sub.
Η Disassemble set plate(25) and piston(26)

sub.
300072TM34
Θ Disassemble friction plate(27) and lee

plate(28) in cylinder block(21).
300072TM35
Ι Dismantle ball guide(24), spacer(23), and

cylinder spring(22).
300072TM36
300072TM36B
300072TM36A
8-91-9
3) ASSEMBLING TRAVEL MOTOR
(1) Assemble the sub of a turning axis.
Η After assembling bearing spacer(12) into

a turning axis(11), have cylinder roller
bearing(13) thermal-reacted.
a. In the thermal reaction of cylinder roller
bearing, use and induction heating
300072TM51
apparatus and adjust the temperature 300072TM51A
300072TM51B
as about 100Á C.
b. Deal moisturized copper part oil seal in
a turning axis without any damage of it.
(2) Assemble ring stop(14) with a plier.

ö Be careful of the direction of ring stop.
(The direction of round is the side of
bearing)
300072TM52
(3) Assemble valve casing sub.
Η Bond seven pieces of plug(2) in valve

casing(33) with standard torque.
Θ After taping plug with seal taper and
spread rock tight, assemble it.
ÂTightening torque : 7~11kgfÂm
(50.63~79.5lbfÂft)
300072TM53
8-91-10
(4) Compress pin(36) into.
ö Using a hammer, make the height of pin
5mm from the a contact surface of valve
plate.
300072TM54
(5) Assemble needle bearing(34).
300072TM55
(6) Assemble seat(51), ball(52), stopper(53),

and hp plug(54) with O-ring(55),
respectively.
Η Be careful of the procedure and direction
of assembling seat and stopper. 300072TM56 300072TM56A
ÂTightening torque : 37kgfÂm
(267.6lbfÂft)
(7) Assemble hp plug(54) set up with O-

ring(55).
Â5sites
(267.6lbfÂft)
300072TM57
8-91-11
(8) Bond orifice screw(38) on the right and left
side of spool c.b(37) with a standard
torque.
ÂTightening torque : 7kgfÂm (50.63lbfÂft)
300072TM58
(9) Insert hold spool c.b(37) and damper

check(39) into valve casing.
300072TM59 300072TM59A
300072TM59B 300072TM59C
(10)Bond cap R(47) and cap L(48) with

hexagon socket bolts(49, 50).
Η Remember not to exchange cap R, L
each other in assembling.
Tightening torque
ÂM12 : 100kgfÂm (item 49)
ÂM10 : 67kgfÂm (item 50)
300072TM60
(11)After fastening with torque, insert

automatic plowing spool(04), spring(68)
and O-ring(69).
(542.4lbfÂft)
300072TM61 300072TM61A
8-91-12
(12)Assemble swash road(60) inserted by O-
ring(61).
300072TM62
(13)Insert O-ring(32) into valve casing.
300072TM63
(14)Bond drain plug(30) inserted by O-ring(31)

with standard torque.
(723.3lbfÂft)
300072TM64
(15)Assemble cylinder sub.

Η Assemble cylinder spring(22), spacer
(23), and spherical surface bush(24) into
cylinder(21).
Set the position of spline of spherical
surface bush and cylinder.
300072TM65
300072TM65A
300072TM65B
8-91-13
(16)Assemble friction plate(27) and separated
plate(28) into cylinder.
300072TM66
(17)After insert piston shoe(26) into set

plate(25), assemble it into cylinder.
300072TM67 300072TM67A
(18)Using jig, compress oil seal(73) into shaft

casing(01).
300072TM68
(19)Assemble the body of a motor.

Η Bond seven piece of plug(02) in shaft
casing plug with standard torque.
a. After taping plug with seal taper and
spread rock tight, assemble it. 300072TM69 300072TM69A
ÂTightening torque : 7~11kgfÂm

(50.63~79.5lbfÂft)
8-91-14
(20)Using a hammer and a handle, compress
pin(5, 6).
Η Pin(5) : Set the height as 10mm from the
contact surface of a plate
supporter. - 2pieces. 300072TM70 300072TM70A
Pin(6) : Set the height as 19mm from the

manufactured surface of shaft
casing. - 4pieces.
(21)Assemble sub of a turning axis.
300072TM71
(22)Assemble plate supporter(15) with M12

bolt.
ö Be careful of the direction of plate
supporter driven.
300072TM72
(23)Assemble plate(16) into plate supporter.

Η Spread grease in moisturized copper part
of plate.
Θ Confirm the soft movement of plate.
300072TM73
8-91-15
(24)Assemble stopper L(36) combined by
plowing piston(35) and O-ring(42).
300072TM74 300072TM74A
(25)Rotating dismantling and assembling jig

up to 90Ámake shaft from perpendicular to
horizontal.
ö Be careful that plate is not segregated
from plate supporter.
300072TM75
(26)Assemble cylinder sub.

ö Adjusting pin into holes of separated plate,
assemble it.
300072TM76
(27)Rotating dismantling and assembling jig

up to 90Á, make the direction of shaft from
the horizon to the perpendicular.
300072TM77
8-91-16
(28)Assemble piston ring(30), piston ring
252(30) and 278(31) into brake piston(29).
300072TM78
(29)Assemble brake piston into shaft casing.

ö Be careful of the direction of assembling
brake piston.
300072TM79
(30)Assemble brake spring(32).

ö Quantity : Spring-10pieces, Holes-
11pieces
ö Do not assemble on the top of brake
piston.
300072TM80
(31)Insert O-ring(69), after fastening orifice

screw(4) with standard torque.
ÂQuantity and size : (4)2 pieces-͚1.0
(56)1pieces-͚1.5
ÂTightening torque : 7kgfÂm (50.63lbfÂft)
300072TM81
8-91-17
(32)After inserting valve plate(67) into valve
casing, bond it into shaft casing with
hexagon socket bolt(70).
Η Spread grease on the back side of valve
plate, in order for valve plate to be
adhered well.
Θ Use a crane in assembling it into valve
plate shaft casing.
Ι Set holes, ͚5, of valve plate heading
toward the port of the inlet and outlet of 300072TM82
valve casing.
Κ Spread grease in the side of plowing
spool of plowing spring in order that
plowing spring can not be detached.
(1736lbfÂft)
ÂTightening torque : 180Ü10kgfÂm
(1302Ü72.3lbfÂft)
(33)Bond relief valve(57) with standard torque.
300072TM83
(34)Unloosen four pieces of bolts(M20Ý50L)

fixing a motor and remove the motor away
from jig.
300072TM84
8-91-18
3. DISASSEMBLING REDUCTION UNIT
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.
ö While oil is still hot, inside of the unit
may be pressurized.
300078RD01
Take care of the hot oil gushing out of
the 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 hexagon socket head bolts(M10,
19) at 3 places from cover(17) almost
equally each other, and then install eye
bolts(M10).
Lift up the unit using them and place it on
work stand with cover upward.
ö Take great care not th pinch your hand
between parts while disassembling nor
let fall parts on your foot while lifting
them.
3) Removing cover
(1) Remove the rest of hexagon socket head
bolts(M10, 19) that secure ring gear.
Loosen all the socket bolts and then,
disassemble cover.
(2) As the cover(17) is adhered to ring
gear(14), dissemble ring gear(14) and
cover(17) by lightly hammering slantwise
upward using sharpen punch inserted
between the cover and ring gear.
8-91-19
4) Removing NO.1 carrier sub assy
(1) Remove No.1 sun gear
ö Be sure to maintain it vertical with the
ground when disassembling No.1 sun
gear.
300078RD02
(2) Screw three eye bolt(M10, 15) in No.1

carrier and lift up and remove No.1 carrier
assy.
300078RD03
5) Removing No. 2 carrier sub assy

(1) Remove No.2 sun gear
gear.
300078RD04
(2) Screw three M10 eye bolt in No.2 carrier

and lift up and remove No.2 carrier assy.
300078RD05
8-91-20
6) Removing ring gear
(1) Remove hexagon socket head bolts(M14,
15) that secure ring gear and housing.
300078RD06
(2) As the ring gear(14) is adhered to

housing(3), disassemble ring gear(14) and
15 Ring gear
housing(3) by lightly hammering slantwise
upward using sharpen punch inserted Hammer
between the ring gear and housing. Housing
ö Carefully disassembling ring gear not to
make scratch on it.
2907A8RD01
(3) Screw three eye bolt(M10) in ring gear and

lift up and remove it.
Hoist
I-Bolt
Ring gear
Housing
2907A8RD02
8-91-21
7) Remove No.3 carrier sub assy
(1) Removing No.3 sun gear
gear.
300078RD09
(2) Screw three eye bolt(M10) in No.3 carrier

and lift up and remove No.3 carrier assy.
Hoist
#3 Carrier assy
Housing
2907A8RD03
8) Remove coupling
(1) Remove coupling
Housing Coupling
2907A8RD04
8-91-22
9) Remove motor ring
(1) Remove motor ring using hand.
300078RD12
10) Removing retainer & shim

(1) Remove hexagon socket(M12) head bolts
that retainer and motor.
(2) Remove retainer & shim.
300078RD13
11) Removing housing sub assy

(1) Screw eye bolt(M14) in housing and lift up
housing assembly including angular
bearing and floating seal.
Hoist
12) Removing floating seal
(1) Lift up a piece of floating seal of motor Housing
side.
2907A8RD05
13) Dissembling housing assembly

(1) After turning housing, lift up a piece of
floating seal from housing and then
remove it.
ö Don't disassemble angular bearing.
300078RD15
8-91-23
14) Dissembling No.1 carrier
(1) Remove thrust ring(16) from carrier.
(2) Knock spring pin(89-6) fully into No.1
pin(90-5).
(3) Remove planetary, thrust washer, No.1
pin, bearing from carrier.
15) Disassembling No.2,3 carrier

(1) Disassemble(14) carriers, using the same
method for No.1 carrier assembly. 300078RD15
8-91-24
6. ASSEMBLING REDUCTION GEAR
- General precautions
Clean every part by kerosene and dry them by air blow.
Surfaces to be applied by locktite must be decreased by solvent.
Check every part for any abnormals.
Each hexagon socket head bolt should be used with locktite No. 242 applied on its threads.
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 reassembling

Thrust washer
ÂCheck if there are seizure, abnormal wear or uneven wear.
ÂCheck if wear is over the allowable limit.
Gears
ÂCheck if there are pitting or seizure on the tooth surface.
ÂCheck if there are cracks on the root of tooth by die check.
Bearings
ÂRotate by hand to see if there are something unusual such as noise or uneven rotation.
Floating seal
ÂCheck flaw or score on sliding surface or on O-rings.
8-91-25
1) Assembling No.1 carrier
(1) Put No.1 carrier(90-1) on a flat place. Pin 1
(2) Install No.1 needle bearing(90-3) into No.1
planetary gear(90-2), put 2 ea of No.1 Thrust washer 1
2 Planetary gear 1
thrust washer(90-4) on both sides of
1
bearing, and then install it into carrier.
(3) Install No.1 pin(90-5) into No.1 carrier 3
where the holes for No.1 pin(90-5) are to Bearing 1
be in line with those of No.1 carrier, and Spring pin
then, install spring pins into the holes. 2907A8RD06
(4) Caulk carrier holes as shown on the
picture.
(5) Assembly ring thrust(96) into carrier.
300078RD15
Caulk at two points
Install spring pin into the

hole after caulk
0.5
1.0 - 2.0
2907A8RD19
8-91-26
2) Assembling No.2 carrier Planetary gear 2
(1) Make No.2 planetary gear(89-2) vertical, Pin 2
Needle bearing 2
assemble 8-9 ea of No.2 needle(89-3), Assembly jig
and then, assemble the remaining No.2
needle by use of the assembly jig for No.2
pin(89-5).
(2) Remove out the assembly jig for No.2 pin
and assemble 2 ea of No.2 thrust
washer(89-4) into No.2 carrier(89-1).
(3) Insert No.2 pin(89-5) into carrier where the 2907A8RD07
holes of No.2 pin(89-5) are in line with
those of carrier.
(4) Hammer spring pin(89-6) to insert into Pin 2
carrier hole and No.2 pin hole, and then,
caulk. Assemble 2 sets using the same Thrust washer 1
2
method.
Planetary gear 1
(5) Assemble ring thrust(98) into carrier.
1
3) Assembling No.3 carrier
(1) Assemble 4 sets, using the same method
3
for assembly of No.2 carrier. Bearing 1
Spring pin
2907A8RD08
4) Installing floating seal

(1) Assemble floating seal into motor by use
of pressing jig. Pressing jig
Press
(2) Grease the contact parts for floating seal
which is assembled into motor.
Floating seal
Housing
2907A8RD09
300078RD21
8-91-27
5) Assembling housing
(1) Heat housing at 60~70Á C while clearing it
out and then, assemble bearing.
Main bearing
(2) Assemble floating seal into housing by use
of pressing jig as shown on the picture. Housing Press
ground when assembling bearing and
floating seal.
2907A8RD10
Floating seal Pressing jig

Press
Housing
Main bearing
2907A8RD11
6) Installing housing assembly

(1) Install 2 ea of eye bolt(M14) into housing
assembly. Hoist
(2) Assemble housing into motor by use of
hoist and eye bolt.
ö Be sure to tighten eye bolt deep enough.
Housing
2907A8RD12
7) Installing main bearing

(1) Heat main bearing at 60~70ÁC and then,
install.
Main bearing
Housing
ground when assembling bearing.
2907A8RD13
8-91-28
8) Installing retainer(86) and shim(85)
(1) Measure clearance between main bearing
Retainer
and retainer by use of jig to decide the
thickness of shim and select and Shim
appropriate shim, and then, assemble Housing
retainer.
(2) Apply locktite(#242) on hexagon socket
head bolt(M12), and then, bolt.
2907A8RD14
300078RD13
9) Installing motor ring

(1) Insert motor ring into motor to install.
Motor ring
Housing
2907A8RD15
10) Installing coupling

(1) Install coupling on spline of the motor.
Coupling
Housing
2907A8RD16
8-91-29
11) Installing No.3 carrier sub assy
(1) Install eye bolt(M10) on No.3 carrier
assembly.
(2) Lift No.3 carrier assembly and then, Hoist
assemble it into reducer.
Carrier assy 3
ö Match it vertical with the spline of the
motor and the, slowly lower.
Housing
2907A8RD17
12) Installing ring gear

(1) Apply three bond #1104(Locktite #515) on
housing for ring gear without gap.
(2) Insert lock pin into housing hole.
(3) Install eye bolt(M12) on the tap for cover of
ring gear.
(4) Lift ring gear and then, assemble into
housing.
(5) Apply locktite to hexagon socket bolt(M14)
and then, bolt, having appropriate torque. 300078RD30
300078RD31
300078RD06
8-91-30
13) Installing No.3 sun gear(88-7)
(1) Install snap ring(88-8) in No.3 sun
gear(88-7) by use if snap ring flier.
(2) Install No.3 sun gear on the spline of No.3
carrier, matching teeth of them.
300078RD32
300078RD09

assembly.
(2) Lift No.2 carrier assembly and then, slowly
put it down on ring gear.
(3) Rotate planetary gear by hands and install
in ring gear.
300078RD05
8-91-31
15) Installing No.2 sun gear(89-7)
(1) Install snap ring(89-8) on No.2 sun
gear(89-7) by use of snap ring flier.
(2) Install No.2 sun gear on the spline of No.2
carrier and No.2 planetary gear, matching
teeth of them.
300078RD33
300078RD04

assembly.
(2) Lift No.1 carrier assembly and then, put it
down on ring gear slowly.
(3) Rotate planetary gear by hands to install
on ring gear, matching their teeth.
300078RD03
17) Installing No.1 sun gear(91)

(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.
300078RD02
8-91-32
18) Installing cover(97)
(1) Beat pad with plastic hammer, and press it
into the center of cover.
Pad Plastic hammer
(2) Apply three bond #104(locktite #515) on
the ring gear for without gap. Cover
(3) Put cover on ring gear, apply locktite(#242)
in hexagon socket head bolt(M10), and
then, bolt.
(4) Fill gear oil(8L) into drain port.
(5) Apply sealing tape(teflon) on PT3/4 plug
2908ARD18
and then, bolt.
300078RD35
8-91-33
GROUP 7 RCV LEVER

1) REMOVAL

penetrate the skin causing serious injury. 1
(4) Loosen the socket bolt(1).

2
(5) Remove the cover of the console box.
(6) Disconnect pilot line hoses(3).
3
(7) Remove the pilot valve assembly(2).
※ When removing the pilot valve assembly,
check that all the hoses have been
disconnected. 21078DA06
2) INSTALL
to removal.
8-92
1) STRUCTURE
14072SF80
8-93
1 Case 11 Plug 21 O-ring
2 Plug 12 Rod seal 22 Handle connector
3 Plug 13 O-ring 23 Nut
4 O-ring 14 Push rod 24 Insert
5 Spool 15 Plate 25 Boot
6 Shim 16 Bushing 26 Handle
7 Spring 17 Joint assembly 27 Switch assembly
8 Spring seat 18 Swash plate 28 Screw
9 Stopper 19 Adjusting nut 29 Switch assembly
10 Spring 20 Lock nut 30 Switch cover
40 Boot
8-94
(1) Tools
Tool name Remark
Allen wrench 6 B
22
Spanner
27
(+) Driver Length 150
(-) Driver Width 4~5
Torque
Part name Item Size
kgf・m lbf・ft
Plug 2 PT 1/8 3.0 21.7
Joint 18 M14 3.5 25.3
Swash plate 19 M14 5.0±0.35 36.2±2.5
Adjusting nut 20 M14 5.0±0.35 36.2±2.5
Lock nut 21 M14 5.0±0.35 36.2±2.5
Screw 29 M 3 0.05 0.36
8-95
3) DISASSEMBLY
(1) Clean pilot valve with kerosene.
※ Put blind plugs into all ports
(2) Fix pilot valve in a vise with copper(or
lead) sheets.
(3) Remove end of boot(25) from case(1) and
take it out upwards.
1408DA62
※ For valve with switch, remove cord also

through hole of casing.
1408DA63
(4) Loosen lock nut(20) and adjusting nut(19)

with spanners on them respectively, and
take out handle section as one body.
1408DA64
(5) Remove the boot(40)
1408DA61
8-96
(6) Loosen adjusting nut(19) and plate(18)
with spanners on them respectively, and
remove them.
36078RL01
36078RL02
(7) Turn joint anticlockwise to loosen it,

utilizing jig(Special tool).
※ When return spring(10) is strong in force,
plate(15), plug(11) and push rod(14) will
come up on loosening joint.
Pay attention to this.
36078RL03
36078RL04
8-97
(8) Remove plate(15).
36078RL05
(9) When return spring(10) is weak in force,

plug(11) 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(10) force.
36078RL06
Pay attention to this.
(10) Remove reducing valve subassembly

and return spring(10) out of casing.
※ Record relative position of reducing valve
subassembly and return springs.
36078RL07
(11) Loosen hexagon socket head plug(2) with

hexagon socket screw key.
36078RL08
8-98
(12) For disassembling reducing valve section,
stand it vertically with spool(5) bottom
placed on flat workbench. Push down
spring seat(8) and remove two pieces of
semicircular stopper(9) with tip of small
minus screwdriver.
※ Pay attention not to damage spool
surface.
※ Record original position of spring seat(8,
36078RL09
31).
※ Do not push down spring seat more than
6mm.
(13) Separate spool(5), spring seat(8),

spring(7) and shim(6) individually.
※ Until being assembled, they should be
handled as one subassembly group.
36078RL10
(14) Take push rod(14) out of plug(11).
36078RL11
(15) Remove O-ring(13) and seal(12) from

plug(11).
Use small minus screwdriver or so on to
remove this seal.
36078RL12
8-99
36078RL13
(16) Remove lock nut(20) and then boot(25).
36078RL14
25038RL02
8-100
(17) 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.
(18) 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.
8-101
4) ASSEMBLY
(1) Tighten hexagon socket head plug(2) to
the specified torque.
※ Tighten two bolts alternately and slowly.
36078RL15
(2) Put shim(6), springs(7) and spring seat(8)

onto spool(5) in this order.
36078RL16
(3) Stand spool vertically with its bottom

placed on flat workbench, and with spring
seat pushed down, put two pieces of
semicircular stopper(9) on spring seat
without piling them on.
※ Assemble stopper(9) so that its sharp
edge side will be caught by head of spool.
Do not push down spring seat more than
6mm.
36078RL17
(4) Assemble spring(10) into casing(1).

Assemble reducing valve subassembly
into casing.
※ Assemble them to their original positions.
36078RL18
8-102
(5) Assemble O-ring(13) onto plug(11).
36078RL19
(6) Assemble seal(12) to plug(11).

※ Assemble seal in such lip direction as
shown below.
36078RL20
(7) Assemble push rod(14) to plug(11).

※ Apply working oil on push-rod surface.
36078RL21
(8) Assemble plug subassembly to casing.

※ When return spring is weak in force,
subassembly stops due to resistance of
O-ring.
36078RL22
8-103
(9) When return spring is strong in force,
assemble 4 sets at the same time,
utilizing plate(15), and tighten joint(17)
temporarily.
36078RL23
(10) Fit plate(15).
(11) Tighten joint(17) with the specified torque

to casing, utilizing jig.
36078RL24
(12) Assemble swash plate(18) to joint(17).

※ Screw it to position that it contacts with 4
push rods evenly.
※ Do not screw it over.
36078RL25
(13) Assemble adjusting nut(19), apply

spanner to width across flat of plate(18) to
fix it, and tighten adjusting nut to the
specified torque.
※ During tightening, do not change position
of disk.
36078RL26
8-104
(14) Fit boot(40) to plate.
1408DA61
(15) Fit boot(25) and lock nut(20), and handle

subassembly is assembled completely.
25038RL02(4)
36078RL27
(16) Pull out cord and tube through adjusting

nut hole provided in direction 60°to 120°
from casing hole.
1408DA66
8-105
(17) Assemble bushing(16) to plate and pass
cord and tube through it.
※ Provide margin necessary to operation.
1408DA67
(18) Determine handle direction, tighten lock

nut(20) to specified torque to fix handle.
1408DA68
(19) Apply grease to rotating section of joint

and contacting faces of disk and push rod.
1408DA69
(20) Assemble lower end of bellows to casing.

(21) Inject volatile rust-preventives through all
ports and then put blind plugs in ports.
25038RL04
8-106
GROUP 8 TURNING JOINT

1) REMOVAL

(4) Disconnect all hoses .
(5) Sling the turning joint assembly (1) and
1
remove the mounting bolt(2).
21078DA07
・Tightening torque : 12± 1.3kgf・m
(88± 9.4lbf・ft)
(6) Remove the turning joint assembly.
※ When removing the turning joint, check
that all the hoses have been disconnected.
2) INSTALL
to removal. 1
※ Take care of turning joint direction.
※ Assemble hoses to their original positions.
※ Confirm the hydraulic oil level and check
the hydraulic oil leak or not. 2
29078TJ02
8-107
1) STRUCTURE
10 13 6 3
14
15
8
2
1 11
29078TJ02
1 Hub 6 Shim 11 Wear ring

2 Shaft assembly 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
8-108
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

(3) Remove retainer ring(12), spacer(4) and 10
12
shim(5).
4
5
21078DA11
(4) Place body(1) on a V-block and by using

a wood buffer at the shaft end, hit out Secure with hand
Wooden block
shaft(2) to about 1/2 from the body with a
hammer.
※ Take care not to damage the shaft(2)
when remove body(1) or rest it sideway.
※ Put a fitting mark on body(1) and shaft(2). V block
Work bench
8-141(3) 210-7
(5) Remove six slipper seals(7) and O-ring(9),

11
two ring wear(11) from body(1).
7
11
9
1
21078DA12
8-109
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 ring wear(11) to body(1).
(2) Fit O-ring(8) to shaft(2). 7
11
9
1
21078DA12
(3) Set shaft(2) on block, tap body(1) with a

plastic hammer to install. 2
21078DA13
(4) Fit shim(5), spacer(4) and retainer ring

6
(12) to shaft(2). 10
(5) Fit O-ring(10) to body(1). 12
(6) Fit shim(6) to shaft(2). 4

5
21078DA11
8-110
(7) Install cover(3) to body(1) and tighten
bolts(14). 14
・Torque : 10~12.5kgf・m(72.3~90.4lbf・ft) 15
21078DA10
8-111
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
pressure in the hydraulic piping. 13031GE18
Loosen the breather slowly to release the

※ Escaping fluid under pressure can Bucket Cylinder
Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust
from entering.
① Set block between bucket cylinder and Arm
arm.
Wooden block
29078CY001
② Remove bolt(2), nut(3) and pull out pin 2

(1).
※ Tie the rod with wire to prevent it from 3
coming out.
29078CY002
③ Disconnect bucket cylinder hoses(4) and

put plugs(5) on cylinder pipe. 5
29078CY003
8-112
④ Sling bucket cylinder assembly(8) and
8
remove bolt(6) then pull out pin (5).
⑤ Remove bucket cylinder assembly(8).
6 13031GE18
(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.
8-113
2) ARM CYLINDER
(1) Removal
※ Expand the arm and bucket fully, lower
the work equipment to the ground and
stop the engine.
Loosen the breather slowly to release the 13031GE18
※ Escaping fluid under pressure can
Fit blind plugs in the hoses after Arm cylinder
disconnecting them, to prevent dirt or dust
from entering.
① Set block between arm cylinder and
boom. Block
29078CY01
② Remove bolt(2) and pull out pin(1).

※ Tie the rod with wire to prevent it from
coming out.
2
29078CY02
③ Disconnect arm cylinder hoses(4) and 5

put plugs on cylinder pipe. 4
④ Disconnect greasing pipings(5).
29078CY03
8-114
⑤ Sling arm assembly(8) and remove bolt
(7) then pull out pin(6).
⑥ Remove arm cylinder assembly(8). 8
6
7
29078CY04
(2) Install
to removal.
pin hole.
※ Bleed the air from the arm cylinder.
8-115
3) BOOM CYLINDER
(1) Removal
※ Expand the arm and bucket fully, lower the
work equipment to the ground and stop
the engine.
Loosen the breather slowly to release the 13031GE18
※ Escaping fluid under pressure can
Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust 1
from entering.
① Disconnect greasing hoses(1).
② Sling boom cylinder assembly.
29078CY05
③ Remove bolt(4), stop plate(5) and pull out

4
pin(2). 5
2
coming out.
5
4
29078CY06
④ Lower the boom cylinder assembly(6) on

a stand.
29078CY07
8-116
⑤ Disconnect boom cylinder hoses(7) and
put plugs on cylinder pipe.
29078CY08
⑥ Remove bolt(9) and pull out pin(8).

⑦ Remove boom cylinder assembly(6).
・Weight : 290kg(620lb) 6
8
9
29078CY09
(2) Install
to removal.
pin hole.
※ Bleed the air from the boom cylinder.
※ Conformed the hydraulic oil level and
check the hydraulic oil leak or not.
8-117
1) STRUCTURE
(1) Bucket cylinder
32078BY01
32078BY02
1 Tube assembly 12 Back up ring 22 Hexagon socket head bolt

2 Rod assembly 13 Cushion ring 23 Band assembly
3 Gland 14 Piston 24 Pipe assembly
4 DD2 bushing 15 O-ring 25 Pipe assembly
5 Snap ring 16 Back up ring 26 O-ring
6 Rod seal 17 Piston seal 27 Hexagon socket head bolt
7 Back up ring 18 Wear ring 28 Hexagon socket head bolt
8 Buffer ring 19 Dust ring 29 Pin bushing
9 Dust wiper 20 Lock washer 30 Dust seal
10 Snap ring 21 Lock nut
11 O-ring
8-118
(2) Arm cylinder
32078AC01
32078AC02
1 Tube assembly 13 Cushion ring 25 Lock nut

2 Rod assembly 14 Piston 26 Hexagon socket head bolt
3 Gland 15 O-ring 27 Band assembly
4 DD2 bushing 16 Back up ring 28 Band assembly
5 Snap ring 17 Piston seal 29 Pipe assembly
6 Rod seal 18 Wear ring 30 Pipe assembly
7 Back up ring 19 Dust ring 31 O-ring
8 Buffer ring 20 Cushion spear 32 Hexagon socket head bolt
9 Dust wiper 21 Check valve 33 Hexagon socket head bolt
10 Snap ring 22 Coil spring 34 Pin bushing
11 O-ring 23 Stop ring 35 Dust seal
12 Back up ring 24 Lock washer
8-119
(3) Boom cylinder
32078BC01
32078BC02
1 Tube assembly 11 O-ring 21 Lock nut

2 Rod assembly 12 Back up ring 22 Hexagon socket head bolt
3 Gland 13 Cushion ring 23 Band assembly
4 DD2 bushing 14 Piston 24 Pipe assembly
5 Snap ring 15 O-ring 25 Pipe assembly
6 Rod seal 16 Back up ring 26 O-ring
7 Back up ring 17 Piston seal 27 Hexagon socket head bolt
8 Buffer ring 18 Wear ring 28 Pin bushing
9 Dust wiper 19 Dust ring 29 Dust seal
10 Snap ring 20 Lock washer
8-120
(1) Tools
6
8 B
Allen wrench
14
17
7
Spanner
8
(-) Driver Small and large sizes

Torque
Part name Item Size
kgf・m lbf・ft
Bucket cylinder 22 M18 32.0±3.0 232±21.7
Socket head bolt Boom cylinder 22 M18 46.0±5.0 333±36.2
Arm cylinder 26 M20 46.0±5.0 333±36.2
Bucket cylinder 27 M12 9.4±1.0 68.0±7.2
Boom cylinder 27 M12 9.4±1.0 68.0±7.2
Socket head bolt
32 M12 9.4±1.0 68.0±7.2
Arm cylinder
33 M10 5.4±0.5 39.1±3.6
Bucket cylinder 21 M70 100±10.0 723±72.3
Lock nut Boom cylinder 21 M70 100±10.0 723±72.3
Arm cylinder 25 M80 100±10.0 723±72.3
Bucket cylinder 14 - 150±15.0 1085±109
Piston Boom cylinder 14 - 150±15.0 1085±109
Arm cylinder 14 - 150±15.0 1085±109
8-121
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
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 200mm

(7.1in). Because the rod assembly is
rather heavy, finish extending it with air
pressure after the oil draining operation.
m
0m
20 2
21078DA30
③ Loosen and remove socket bolts(22) of

the gland in sequence. Hexagon
socket wrench 22
※ Cover the extracted rod assembly(2) with
rag to prevent it from being accidentally
damaged during operation. Turn counter
clockwise
Cover here
with rag
2
21078DA31
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
out. However, when rod assembly(2) sideways
has been drawn out to approximately
two thirds of its length, lift it in its center to
draw it completely. Oil pan
21078DA32
8-122
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.
※ Cover a V-block with soft rag. Piston assy
Wooden block
21078DA33
(2) Remove piston and cylinder head

① Remove lock nut(21). 13 16 15 14 22 21
※ Since lock nut(20) and lock washer(20)
is tightened to a high torque, use a
hydraulic and power wrench that utilizers
a hydraulic cylinder, to remove the lock
nut(21) and lock washer (20).
② Remove piston assembly(14), back up
ring(16), and O-ring(15).
21078DA34
③ Remove the cylinder head assembly

from rod assembly(2). Plastic
hammer
※ If it is too heavy to move, move it by
Lift with a crane
striking the flanged part of cylinder head
with a plastic hammer.
Pull straight
※ Pull it straight with cylinder head
assembly lifted with a crane.
Exercise care so as not to damage the
lip of rod bushing(4) and packing
21078DA35
(5,6,7,8,9,10) by the threads of rod
assembly(2).
8-123
(3) Disassemble the piston assembly
19 18 17 18 19
① Remove wear ring(18).
② Remove dust ring(19) and piston seal
(17).
※ Exercise care in this operation not to
damage the grooves.
8-156(1) 210-7
(4) Disassemble cylinder head assembly

① Remove back up ring(12) and O-ring 10 9 6 7 8 4 5 12 11
(11).
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
21078DA36
damaged.
8-124
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(9) to the stop face.
8-157(2) 210-7
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) 210-7
※ 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
8-125
⑤ Fit back up ring(12) to gland(3).
※ Put the backup ring in the warm water of
11
30~50° C.
⑥ Fit O-ring(11) to gland(3). 12
21078DA39
(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) 210-7
② Fit piston seal(17) to piston.

※ Put the piston seal in the warm water of 17
60~100° C for more than 5 minutes.
※ After assembling the piston seal, press its
outer diameter to fit in.
8-158(3) 210-7
③ Fit wear ring(18) and dust ring(19) to

19 18 17 18 19
piston(14).
14
8-158(4) 210-7
8-126
(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 direction 13
in which it should be fitted.
Insert
8-159(2) 210-7
⑤ Fit piston assembly to rod assembly.

Piston assembly
・Tightening torque : 150±15.0kgf・m
(1085±109lbf・ft)
8-159(3) 210-7
⑥ Fit lock nut to piston.

・Tightening torque : 21
Item kgf・m lbf・ft
Bucket 21 100±10 723.3±72.3

Boom 21 100±10 723.3±72.3
Arm 25 100±10 723.3±72.3
8-159(4) 210-7
8-127
(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 fix
Lift
the assembly by passing a bar through
the clevis pin hole to lock the assembly.
② Insert the rod assembly in to the tube Straight
assembly, while lifting and moving the
rod assembly with a crane.
※ Be careful not to damage piston seal by Appply liquid packing
21078DA41
thread of tube assembly.
③ Match the bolt holes in the cylinder head
flange to the tapped holes in the tube
assembly and tighten socket bolts to a Turn clockwise
specified torque. Apply loctite
※ Refer to the table of tightening torque.
Place rag
21078DA42
8-128
GROUP 10 UNDERCARRIAGE
1. TRACK LINK
1) REMOVAL
(1) Move track link until master pin is over
front idler in the position put wooden block Master pin
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.
(3) Push out master pin by using a suitable
tool.
Block
8-161(1) 210-7
(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) 210-7
2) INSTALL
to removal.
※ Adjust the tension of the track link.
90 ~ 110
8-161(3) 210-7
8-129
2. CARRIER ROLLER Frame
1) REMOVAL
Grease
(1) Loosen tension of the track link. valve
8-162(1) 210-7
(2) Jack up the track link height enough to

permit carrier roller removal.
Jack Carrier roller

8-162(2) 210-7
(3) Loosen the lock nut (1).

1 Carrier
(4) Open bracket(2) with a screwdriver, push roller
out from inside, and remove carrier roller 2
assembly.
8-162(3) 210-7
2) INSTALL
to removal.
8-130
3. TRACK ROLLER Frame
1) REMOVAL
Grease
(1) Loosen tension of the track link. valve
8-163(1) 210-7
(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) 210-7
(3) Remove the mounting bolt(1) and draw

1 2
out the track roller(2).
8-163(3) 210-7
2) INSTALL
to removal.
8-131
4. IDLER AND RECOIL SPRING
1) REMOVAL
(1) Remove the track link.
For detail, see removal of track link.
8-164(1) 210-7
(2) Sling the recoil spring(1) and pull out idler

and recoil spring assembly from track
frame, using a pry. 1
8-164(2) 210-7
(3) Remove the bolts(2), washers(3) and

separate ilder from recoil spring.
2, 3
8-164(3) 210-7
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.
8-164(4) 210-7
8-132
3) DISASSEMBLY AND ASSEMBLY OF IDLER
(1) Structure
5
1
2
2
7
5
6
7
4
4
3
6
29078ID01
1 Shell 4 O-ring 7 Spring pin

2 Bushing 5 Seal assembly 8 Plug
3 Shaft 6 Bracket
8-133
(2) Disassembly Press
① Remove plug and drain oil.
② Draw out the spring pin(7), using a press.
7 8-166(1) 210-7
③ Pull out the shaft(2) with a press.

④ Remove seal(5) from shell(1) and Press
bracket(6).
⑤ Remove O-ring(4) from shaft.
3
8-166(2) 210-7
⑥ Remove the bushing(2) from idler, using

a special tool.
※ Only remove bushing if replacement is
necessity.
2
8-166(3) 210-7
8-134
(3) Assembly
※ Before assembly, clean the parts.
※ Coat the sliding surfaces of all parts with 1 2 Press
oil.
① Cool up bushing(2) 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) 210-7
② Coat O-ring(4) with grease thinly, and

install it to shaft(3). 4
③ Insert shaft(3) into bracket(6) and drive in
the spring pin(7). 3
8-167(2) 210-7
④ Install seal(5) to shell(1) and bracket(6).

5
8-167(3) 210-7
⑤ Install shaft(3) to shell(1).

3 1
8-167(4) 210-7
8-135
⑥ Install bracket(6) attached with seal(5).
8-168(1) 210-7
⑦ Knock in the spring pin(7) with a

6 7 1
hammer.
8-168(2) 210-7
⑧ Lay bracket(6) on its side.

6
Supply engine oil to the specified level,
and tighten plug.
8-168(3) 210-7
8-136
4) DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING
(1) Structure
36078UC02
1 Body 6 Lock plate 11 Dust seal

2 Tie bar 7 Bolt 12 Rod assembly
3 Spring 8 Spring washer 13 Grease valve
4 Bracket 9 Rod seal 14 Stopper tube
5 Lock nut 10 Back up ring 15 Spring pin
8-137
(2) Disassembly
① Apply pressure on spring(3) with a press.
※ The spring is under a large installed load.
This is dangerous, so be sure to set
properly.
・Spring set load : 19012kg(41826lb)
② Remove bolt(7), spring washer(8) and
lock plate(6).
③ Remove lock nut(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).
36078UC03
⑤ Remove rod(12) from body(1).

⑥ Remove grease valve(13) from rod(12).
36078UC04
⑦ Remove rod seal(9), back up ring(10)

and dust seal(11).
36078UC05
8-138
(3) Assembly
① Install dust seal(11), back up ring(10) and
rod seal(9) to body(1).
※ When installing dust seal(11) and rod
seal(9), take full care so as not to
damage the lip.
36078UC05
② Pour grease into body(1), then push in

rod(12) by hand.
After take grease out of grease valve
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).
・Tightening torque : 13.0±1.0kgf・m
(94±7.2lbf・ft)
36078UC06
④ Install spring(3) and bracket(4) to body

(1).
⑤ Apply pressure to spring(3) with a press
and tighten lock nut(5).
※ Apply sealant before assembling.
※ During the operation, pay attention
specially to prevent the press from
slipping out.
36078UC07
8-139
⑥ Lighten the press load and confirm the
set length of spring(3).
⑦ After the setting of spring(3), install lock
plate(6), spring washer(8) and bolt(7).
32078UC08
8-140
GROUP 11 WORK EQUIPMENT
1. STRUCTURE
A
A
SECTION A SECTION B SECTION C
29078WE01
8-141
1) BUCKET ASSEMBLY
(1) Removal
① Lower the work equipment completely to
A
ground with back of bucket facing down.
B
8-174(1) 210-7
② Remove nut(1), bolt(2) and draw out the

2
pin(A).
A
1
8-174(2) 210-7
③ Remove nut(3), bolt(4) and draw out the

pin(B).
4
B
3
8-174(3) 210-7
(2) Install
to removal.
pin hole.
※ Adjust the bucket clearance.
For detail, see operation manual.
8-174(4) 210-7
8-142
2) ARM ASSEMBLY
(1) Removal
※ Loosen the breather slowly to release the
penetrated the skin causing serious
injury.
① Remove bucket assembly.
For details, see removal of bucket 8-175(1) 210-7
assembly.
② Disconnect bucket cylinder hose(1).
Fit blind plugs in the piping at the
chassis end securely to prevent oil from 5
spurting out when the engine is started.
4
③ Sling arm cylinder assembly, remove
spring, pin stopper and pull out pin.
coming out. 4
④ For details, see removal of arm cylinder
assembly.
8-175(2) 210-7
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 arm assembly.
※ When lifting the arm assembly, always lift Crane
the center of gravity.
2, 3, 4
8-175(3) 210-7
(2) Install
to removal.
When lifting the arm assembly, always lift
※ Bleed the air from the cylinder.
8-143
3) BOOM CYLINDER
(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 arm cylinder
assembly. 8-176(1) 210-7
③ Disconnect head lamp wiring.

④ Disconnect bucket cylinder hose(2) and
1
arm cylinder hose(1). 2
※ When the hose are disconnected, oil
may spurt out.
⑤ Sling boom assembly(3).
1
21078DA45
⑥ Remove bolt(4), plate(5) and pull out the

Crane
pin(6) then remove boom assembly.
※ When lifting the boom assembly always
lift the center of gravity.
4, 5, 6
3
21078DA45
(2) Install
to removal.
When lifting the arm assembly, always lift
※ Bleed the air from the cylinder.
21078DA46
8-144
SECTION 9 COMPONENT MOUNTING TORQUE
Group 1 Introduction guide 9-1

Group 2 Engine system 9-2
Group 3 Electric system 9-4
Group 4 Hydraulic system 9-6
Group 5 Undercarriage 9-9
Group 6 Structure 9-10
Group 7 Work equipment 9-14
SECTION 9 COMPONENT MOUNTING TORQUE
GROUP 1 INTRODUCTION GUIDE
1. This section shows bolt specifications and

standard torque values needed when
mounting components to the machine.
2. Use genuine Hyundai spare parts.
We expressly point out that Hyundai will not
accept any responsibility for defects resulted
from non-genuine parts.
In such cases Hyundai cannot assume
liability for any damage.
※ Only metric fasteners can be used and
incorrect fasteners may result in machine
damage or malfunction.
※ Before installation, clean all the components
with a non-corrosive cleaner. Bolts and
threads must not be worn or damaged. 29079CM00
9-1
GROUP 2 ENGINE SYSTEM
ENGINE AND ACCESSORIES MOUNTING
32079CM01
・Tightening torque
Item Size kgf・m lbf・ft Item Size kgf・m lbf・ft

1 M 6×1.0 1.05±0.2 7.6±1.45 5 M12×1.75 10.0±2.0 72.3±14.5
2 M 8×1.25 2.5±0.5 18.1±3.6 6 M12×1.75 12.8±3.0 92.6±21.7
3 M10×1.5 4.4±0.9 31.8±6.5 7 M24×3.0 90±7.0 651±51
4 M10×1.5 6.9±1.4 49.9±10.1 - - - -
9-2
COOLING SYSTEM AND FUEL TANK MOUNTING
32079CM02

1 M 6×1.0 1.05±0.2 7.6±1.45 5 M12×1.75 12.8±3.0 92.6±21.7
2 M 8×1.25 2.5±0.5 18.1±3.6 6 M16×2.0 29.7±4.5 215±32.5
3 M 8×1.25 4.05±0.8 29.3±5.8 7 M20×2.5 45±5.1 325±36.9
4 M10×1.5 6.9±1.4 49.9±10.1 8 - 2.3±0.6 16.6±4.3
9-3
GROUP 3 ELECTRIC SYSTEM
ELECTRIC COMPONENTS MOUNTING 1
32079CM03

1 M 6×1.0 1.05±0.2 7.6±1.45 3 M10×1.5 6.9±1.4 49.9±10.1
2 M 8×1.25 2.5±0.5 18.1±3.6 4 M12×1.75 12.8±3.0 92.6±21.7
9-4
ELECTRIC COMPONENTS MOUNTING 2
32079CM04

1 M 6×1.0 1.05±0.2 7.6±1.45 3 M10×1.5 6.9±1.4 49.9±10.1
2 M 8×1.25 2.5±0.5 18.1±3.6 - - - -
9-5
GROUP 4 HYDRAULIC SYSTEM
HYDRAULIC COMPONENTS MOUNTING 1
32079CM05

1 M 6×1.0 1.05±0.2 7.6±1.45 7 M16×2.0 29.7±4.5 215±32.5
2 M 8×1.25 2.5±0.5 18.1±3.6 8 M20×2.5 42±4.5 304±32.5
3 M10×1.5 2.81±0.3 20.3±2.2 9 M20×2.5 46±5.0 333±36
4 M10×1.5 6.9±1.4 49.9±10.1 10 M20×2.5 46.5±2.5 336±18.1
5 M12×1.75 12.2±1.3 88.9±9.4 11 M20×3.0 100±10 723±72
6 M12×1.75 14.7±2.2 106±15.9 - - - -
9-6
32079CM06

1 M 8×1.25 4.05±0.8 29.3±5.8 4 M12×1.75 9.4±1.0 68±8.0
2 M10×1.5 6.9±1.4 49.9±10.1 5 M24×3.0 84±8 608±58
3 M12×1.75 12.8±3.0 92.6±21.7 - - - -
9-7
32079CM07

1 M10×1.5 3.2±0.3 23.1±2.2 5 M18×2.5 32±3.0 232±21.7
2 M10×1.5 5.4±0.5 39.1±3.6 6 M20×2.5 46±5.0 333±36.2
3 M12×1.75 5.5±0.6 39.8±4.3 7 M22×2.5 4.1 29.6
4 M12×1.75 9.4±1.0 68.0±7.2 8 M27×3.0 5.1 36.9
9-8
GROUP 5 UNDERCARRIAGE
UNDERCARRIAGE MOUNTING
ADJUST COMPONENT
Rod
5
Swing bearing
Idler
9
9
9
Idler
7
Carrier roller
8 Track chain
Cover
4
1
2
Adjust
component
Track roller
Track guard
Travel motor
7
Sprocket 6
29079CM08
·Tightening torque
Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft

1 M10×1.5 6.9±1.4 49.9±10.1 6 M20×2.5 57±6.0 412±43.3
2 M12×1.75 12.8±3.0 92.6±21.7 7 M20×2.5 57.9±8.7 419±62.9
3 M12×1.75 15±0.5 108±3.6 8 M22×1.5 115±5.0 831±36
4 M16×2.0 29.7±4.5 215±32.5 9 M24×3.0 97.8±10 707±72.3
5 M16×1.5 31.3±4.7 226±34 - - - -
9-9
UNDERCARRIAGE MOUNTING(HIGH WALKER)
Sprocket
2
Idler
1
2
2 Roller
4
Mono track guard type
Track guard
Full track guard type
29079CM11
·Tightening torque
Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft

1 M10×1.5 6.9±1.4 49.9±10.1 4 M20×2.5 57.9±8.6 419±62.2
2 M12×1.75 12.2±1.3 88.2±9.4 5 M24×3.0 100±15 723±108
3 M20×2.5 51±4.0 369±28.9 6 - - -
9-9-1
GROUP 6 STRUCTURE
CAB AND ACCESSORIES MOUNTING
2
Sun roof
4
Sun visor 1
Latch
Cab
A Air vent cover

4
4 4
VIEW A 5
3
2
5
Door latch
6 Striker
36079CM09

1 M 6×1.0 0.49±0.1 3.5±0.7 4 M10×1.5 6.9±1.4 49.9±10.1
2 M 8×1.25 2.5±0.5 18.1±3.6 5 M12×1.75 12.8±3.0 92.6±21.7
3 M10×1.5 4.7±0.9 34±6.5 6 M16×2.0 29.7±4.5 215±32.5
9-10
CAB INTERIOR MOUNTING
Seat
1
1
Storage
4 box cover
Aircon upper
cover
Console 1 5
box(RH) Storage
Wiper motor box
cover 1 5
Defroster 5
hose cover Aircon lower
cover
2 Console box(LH)
6 3
Travel
lever 5 Safety lever
Slide rail 2
Seat base 7
Pedal bracket
5
Viscous
mount
5
Foot rest
Bottom plate
5
Foot rest bracket
36079CM10

1 M 6×1.0 0.49±0.1 3.5±0.7 5 M10×1.5 6.9±1.4 49.9±10.1
2 M 6×1.0 1.05±0.2 7.6±1.4 6 M10×1.5 8.27±1.7 59.8±12.3
3 M 8×1.25 3.43±0.7 24.8±5.1 7 M16×2.0 29.7±4.5 215±32.5
4 M 8×1.25 4.05±0.8 29.3±5.8 - - - -
9-11
COWLING MOUNTING
32079CM11

1 M 8×1.25 2.5±0.5 18.1±3.6 3 M16×2.0 29.7±4.5 215±32.5
2 M12×1.75 12.8±3.0 92.6±21.7 - - - -
9-12
COUNTERWEIGHT AND COVERS MOUNTING
32079CM12

1 M10×1.5 6.9±1.4 49.9±10.1 3 M36×3.0 308±46 2228±333
2 M12×1.75 12.8±3.0 92.6±21.7 - - - -
9-13
GROUP 7 WORK EQUIPMENT
32079CM13

1 M16×2.0 29.7±4.5 215±32.5 3 M22×2.5 81.9±16.1 592±116
2 M20×2.5 57.9±8.7 419±62.9 - - - -
9-14

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SECTION 1 GENERAL

Group 1 Safety Hints 1-1

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

USE HANDHOLDS AND STEPS

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

AVOID POWER LINES

MOVE AND OPERATE MACHINE SAFELY

OPERATE ONLY FORM OPERATOR'S SEAT

PARK MACHINE SAFELY

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

Store flammable fluids away from fire hazards. Do not

REMOVE PAINT BEFORE WELDING OR HEATING

ILLUMINATE WORK AREA SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HIGH PRESSURE FLUIDS

fluid injected into the skin must be surgically removed

PREVENT BATTERY EXPLOSIONS

PREVENT ACID BURNS

DISPOSE OF FLUIDS PROPERLY

REPLACE SAFETY SIGNS

LIVE WITH SAFETY

Tool box Fuel tank Hydraulic oil tank Main pump

Arm Arm cylinder Boom Boom cylinder Cab Precleaner Muffler

Bucket cylinder Connecting link Idler Carrier roller Sprocket Counterweight

Side cutter Connecting rod Track roller Track Travel motor

Description Unit Specification

Operating weight kg(lb) 32200(70990)

6.45m(21' 2") Arm 6.15m(20' 2")Boom

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

Load radius At max. reach

7.5m kg *6910 5680 7.69

7.5m kg *6570 5120 8.07

Load radius At max. reach

0.9m3 PCSA 1.14m3 PCSA ※1.44m3 PCSA 1.74m3PCSA 2.10m3 PCSA

Recommendation 6.15m (20'

0.9m3 0.8m3 950mm 1070mm 870kg

1.14m3 1.0m3 1140mm 1260mm 980kg

※1.44m3 1.25m3 1380mm 1500mm 1110kg

1.74m3 1.5m3 1610mm 1730mm 1230kg

2.10m3 1.8m3 1900mm 2020mm 1370kg

◈1.44m3 PCSA 1.44m3 PCSA

Recommendation 6.15m (20'

◈1.44m3 1.25m3 1380mm 1380kg

1.44m3 1.25m3 1380mm 1390kg

◈ : Heavy duty bucket

Shoe width mm(in) 600(24) 700(28) 800(32) 900(36)

3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE

4) SELECTION OF TRACK SHOE

Track shoe Specification Category

600mm triple grouser Standard A

Model Cummins C8.3-C

Type Variable displacement tandem axis piston pumps

Type Fixed displacement gear pump single stage

4) MAIN CONTROL VALVE

Type Axial piston motor