CONTENTS

SECTION 1 GENERAL
Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9

SECTION 2 STRUCTURE AND FUNCTION

Group 1 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
Group 2 Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-19
Group 3 Swing Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-42
Group 4 Travel Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-54
Group 5 RCV Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-68
Group 6 RCV Pedal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-75

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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-12
Group 5 Combined Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-24

SECTION 4 ELECTRICAL SYSTEM

Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Group 2 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3
Group 3 Electrical Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-23
Group 4 Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-35

SECTION 5 MECHATRONICS SYSTEM

Group 1 Outline - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
Group 2 Mode Selection System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3
Group 3 Power Boost System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-4
Group 4 Travel Speed Control System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-5
Group 5 Automatic Warming Up Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-6
Group 6 Engine Overheat Prevention Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-7
Group 7 Anti-Restart System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-8
Group 8 Self-Diagnostic System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
 Group 9 Engine Control System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11
Group 10 EPPR(Electro Proportional Pressure Reducing) Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-17
Group 11 Prolix Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-20
Group 12 Monitoring System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-21

SECTION 6 TROUBLESHOOTING
Group 1 Before Trobleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
Group 2 Hydraulic and Mechanical System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-4
Group 3 Electrical System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-24
Group 4 Mechatronics System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-41

SECTION 7 MAINTENANCE STANDARD

Group 1 Operational Performance Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
Group 2 Major Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Group 3 Track and Work Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29

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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-29
Group 5 Swing Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-43
Group 6 Travel Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-65
Group 7 RCV Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-103
Group 8 Turning Joint - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-118
Group 9 Boom, Arm and Bucket Cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-123
Group 10 Undercarriage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-140
Group 11 Work Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-152

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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-10
Group 6 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-11
Group 7 Work Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-14
 FOREWORD

1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.

SECTION 1 GENERAL
This section explains the safety hints and gives the specification of the machine and major
components.
SECTION 2 STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
SECTION 3 HYDRAULIC SYSTEM
This section explains the hydraulic circuit, single and combined operation.
SECTION 4 ELECTRICAL SYSTEM
This section explains the electrical circuit, monitoring system and each component. It serves not
only to give an understanding electrical system, but also serves as reference material for trouble
shooting.
SECTION 5 MECHATRONICS SYSTEM
This section explains the computer aided power optimization system and each component.
SECTION 6 TROUBLESHOOTING
This section explains the troubleshooting charts correlating problems to causes.
SECTION 7 MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
SECTION 8 DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.
SECTION 9 COMPONENT MOUNTING TORQUE
This section shows bolt specifications and standard torque values needed when mounting
components to the machine.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.

0-1
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating Revised edition mark(ΗΘΙÄ)
Any additions, amendments or other changes will When a manual is revised, an edition mark is
be sent to HYUNDAI distributors. recorded on the bottom outside corner of the
Get the most up-to-date information before you pages.
start any work.
Revisions
Filing method Revised pages are shown at the list of revised
1. See the page number on the bottom of the pages on the between the contents page and
page. section 1 page.
File the pages in correct order.
2. Following examples shows how to read the Symbols
page number. So that the shop manual can be of ample
Example 1 practical use, important places for safety and
2-3 quality are marked with the following symbols.
Item number(2. Structure and
Function)
Consecutive page number for Symbol Item Remarks
each item.
Special safety precautions are
3. Additional pages : Additional pages are necessary when performing the
indicated by a hyphen(-) and number after the work.
Safety
page number. File as in the example. Extra special safety precautions
10 - 4 are necessary when performing
the work because it is under
10 - 4 - 1
Added pages internal pressure.
10 - 4 - 2
Special technical precautions or
10 - 5
other precautions for preserving
ö Caution
standards are necessary when
performing the work.

0-2
 3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.

Example
1. Method of using the Conversion Table to convert from millimeters to inches
Convert 55mm into inches.
(1) Locate the number 50in the vertical column at the left side, take this as ͽ, then draw a
horizontal line from ͽ.
(2) Locate the number 5in the row across the top, take this as ;, then draw a perpendicular line
down from ;.
(3) Take the point where the two lines cross as Ϳ. This point Ϳ gives the value when converting
from millimeters to inches. Therefore, 55mm = 2.165 inches.

2. Convert 550mm into inches.

(1) The number 550 does not appear in the table, so divide by 10(Move the decimal point one place
to the left) to convert it to 55mm.
(2) Carry out the same procedure as above to convert 55mm to 2.165 inches.
(3) The original value(550mm) was divided by 10, so multiply 2.165 inches by 10(Move the decimal
point one place to the right) to return to the original value.
This gives 550mm = 21.65 inches.

Millimeters to inches ; 1mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
Ϳ
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
ͽ
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

0-3
Millimeters to inches 1mm = 0.03937in

0 1 2 3 4 5 6 7 8 9

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound 1kg = 2.2046lb

0 1 2 3 4 5 6 7 8 9

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.5. 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

0-4
Liter to U.S. Gallon 1˶ = 0.2642 U.S.Gal

0 1 2 3 4 5 6 7 8 9

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.631 25.625 25.889 26.153

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

0 1 2 3 4 5 6 7 8 9

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

0-5
kgfÂm to lbfÂft 1kgfÂm = 7.233lbfÂft

0 1 2 3 4 5 6 7 8 9

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 10005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

0-6
kgf/cm2 to lbf/in2 1kgf / cm2 = 14.2233lbf / in2

0 1 2 3 4 5 6 7 8 9

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 5603 2617 2631 2646 2660 2674 2688

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

0-7
TEMPERATURE
Fahrenheit-Centigrade Conversion.
A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice
verse is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table
of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

Á
C Á
F Á
C Á
F Á
C Á
F Á
C Á
F

-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

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

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

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

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

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

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

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

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

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

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

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

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

0-8
 SECTION 1 GENERAL
GROUP 1 SAFETY

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
aÖD Do Not Operate×tag on the right side control
lever.

13031GE02

USE HANDHOLDS AND STEPS

Falling is one of the major causes of personal injury.
When you get on and off the machine, always
maintain a three point contact with the steps and
handrails and face the machine. Do not use any
controls as handholds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
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
earmuffs or earplugs to protect against objectionable
or uncomfortable loud noises.

13031GE06

AVOID POWER LINES

Serious injury or death can result from contact with
electric lines.
Never move any part of the machine or load closer to
electric line than 3m(10ft) plus twice the line insulator
length.

13031GE07

1-2
KEEP RIDERS OFF EXCAVATOR
Only allow the operator on the excavator. Keep
riders off.
Riders on excavator are subject to injury such as
being struck by foreign objects and being thrown off
the excavator. Riders also obstruct the operator's
view resulting in the excavator being operated in an
unsafe manner.

13031GE08

MOVE AND OPERATE MACHINE SAFELY

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

OPERATE ONLY FORM OPERATOR'S SEAT

Avoid possible injury machine damage. Do not start
engine by shorting across starter terminals.
NEVER start engine while standing on ground. Start
engine only from operator's seat.

13031GE26

PARK MACHINE SAFELY

Before working on the machine:
ÂPark machine on a level surface.
ÂLower bucket to the ground.
ÂTurn auto idle switch off.
ÂRun engine at 1/2 speed without load for 2 minutes.
ÂTurn key switch to OFF to stop engine.
Remove key from switch.
ÂMove pilot control shutoff lever to locked position.
ÂAllow 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
13031GE10
manual.

SERVICE COOLING SYSTEM SAFELY

Explosive release of fluids from pressurized cooling
system can cause serious burns.
Shut off engine. Only remove filler cap when cool
enough to touch with bare hands.

13031GE11

HANDLE FLUIDS SAFELY-AVOID FIRES

Handle fuel with care; It is highly flammable. Do not
refuel the machine while smoking or when near open
flame or sparks. Always stop engine before refueling
machine.
Fill fuel tank outdoors.

13031GE12

Store flammable fluids away from fire hazards. Do

not incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and
debris.
Do not store oily rags; They can ignite and burn
spontaneously.

13031GE13

1-4
BEWARE OF EXHAUST FUMES
Prevent asphyxiation. Engine exhaust fumes can
cause sickness or death.
If you must operate in a building, be positive there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air into
the area.

REMOVE PAINT BEFORE WELDING OR HEATING

Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding or heating:
ÂIf you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
ÂIf 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.
13031GE18
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may result.

13031GE19

1-6
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines
or other flammable materials.
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 16Á
C(60Á
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.
3. Get medical attention immediately. 13031GE22

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 waste. 13031GE24

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 tank Main pump

Engine

Radiator
Oil cooler

Bucket Main control valve

Tooth Turning joint Swing motor

Arm Arm cylinder Boom Boom cylinder Cab Muffler Counterweight

Side cutter Idler

Connecting link Track roller Travel motor

Bucket cylinder Connecting rod Carrier roller Track Sprocket

11072SP01

1-9
2. SPECIFICATIONS
1) R110-7
(1) 4.3m(14' 1") MONO BOOM, 2.26m(7' 5") ARM
I(I') D

E
C

G
F

H
J M
K N
A B(L)
11072SP02

Description Unit Specification

Operating weight kg(lb) 11200(24690)

Bucket capacity(SAE heaped), standard m3(ydІ) 0.45(0.59)
Overall length A 7270(23' 10")
Overall width, with 500mm shoe B 2490( 8' 2")
Overall height C 2720( 8' 11")
Superstructure width D 2475( 8' 1")
Overall height of cab E 2800( 9' 2")
Ground clearance of counterweight F 900( 2' 11")
Engine cover height G 1990( 6' 6")
Minimum ground clearance H mm(ft-in) 440( 1' 5")
Rear-end distance I 2110( 6' 11")
Rear-end swing radius I' 2130( 7' 0")
Distance between tumblers J 2610( 8' 7")
Undercarriage length K 3340(10' 11")
Undercarriage width L 2490( 8' 2")
Track gauge M 1990( 6' 6")
Track shoe width, standard N 500(20")
Travel speed(Low/high) km/hr(mph) 3.4/5.5(2.1/3.4)
Swing speed rpm 13.0
Gradeability Degree(%) 35(70)
Ground pressure(500mm shoe) kgf/cm2(psi) 0.39(5.55)

1-10
 2) R110D-7
(1) 4.3m(14' 1") MONO BOOM, 2.26m(7' 5") ARM AND REAR DOZER BLADE

I(I') D

E
C

G
P
F
O

H
Q
J M
K N
A B(L)
11072SP02A

Description Unit Specification

Operating weight kg(lb) 11900(26230)

Bucket capacity(SAE heaped), standard m (ydІ)
3
0.45(0.59)
Overall length A 7650(25' 1")
Overall width, with 500mm shoe B 2500( 8' 2")
Overall height C 2720( 8' 11")
Superstructure width D 2475( 8' 1")
Overall height of cab E 2800( 9' 2")
Ground clearance of counterweight F 900( 2' 11")
Engine cover height G 1990( 6' 6")
Minimum ground clearance H mm(ft-in) 440( 1' 5")
Rear-end distance I 2110( 6' 11")
Rear-end swing radius I' 2130( 7' 0")
Distance between tumblers J 2610( 8' 7")
Undercarriage length K 3340(10' 11")
Undercarriage width L 2500( 8' 2")
Track gauge M 1990( 6' 6")
Track shoe width, standard N 500(20")
Height of blade O 550( 1' 10")
Ground clearance of blade up P 500( 1' 8")
Depth of blade down Q 520( 1' 8")
Travel speed(Low/high) km/hr(mph) 3.4/5.5(2.1/3.4)
Swing speed rpm 13.0
Gradeability Degree(%) 35(70)
Ground pressure(500mm shoe) kgf/cm (psi)
2
0.42(5.97)

1-11
3. WORKING RANGE
1) R110-7
(1) 4.3m(14' 1") MONO BOOM
A
A'
F

D
E
C
B'
B

8ft 11072SP03

Description 1.96m(6' 5") Arm 2.26m(7' 5") Arm 2.81m(9' 3") Arm
Max digging reach A 7460mm (24' 6") 7740mm (25' 5") 8270mm (27' 2")
Max digging reach on ground A' 7320mm (24' 0") 7610mm (25' 0") 8140mm (26' 8")
Max digging depth B 4770mm (15' 8") 5090mm (16' 8") 5620mm (18' 5")
Max digging depth (8ft level) B' 4510mm (14'10") 4870mm (16' 0") 5410mm (17' 9")
Max vertical wall digging depth C 4070mm (13' 4") 4430mm (14' 6") 4940mm (16' 2")
Max digging height D 7900mm (25'11") 8070mm (26' 6") 8460mm (27' 9")
Max dumping height E 5540mm (18' 2") 5710mm (18' 9") 6100mm (20' 0")
Min swing radius F 2340mm ( 7' 8") 2380mm ( 7'10") 2510mm ( 8' 3")
78.5 [85.6] kN 78.5 [85.6] kN 78.5 [85.6] kN
SAE 8000 [8730] kgf 8000 [8730] kgf 8000 [8730] kgf
17640 [19240] lbf 17640 [19240] lbf 17640 [19240] lbf
Bucket digging force
90.2 [98.4] kN 90.2 [98.4] kN 90.2 [98.4] kN
ISO 9200 [10040] kgf 9200 [10040] kgf 9200 [10040] kgf
20280 [22120] lbf 20280 [22120] lbf 20280 [22120] lbf
60.2 [65.7] kN 55.7 [60.8] kN 48.1 [52.4] kN
SAE 6140 [6700] kgf 5680 [6200] kgf 4900 [5350] kgf
13540 [14770] lbf 12520 [13660] lbf 10800 [11780] lbf
Arm digging force
62.9 [68.6] kN 58.1 [63.3] kN 49.7 [54.2] kN
ISO 6410 [6990] kgf 5920 [6460] kgf 5070 [5530] kgf
14130 [15410] lbf 13050 [14240] lbf 11180 [12200] lbf
[ ] : Power boost

1-12
 2) R110D-7
(1) 4.3m(14' 1") MONO BOOM
A
A'
F

D
E
C
B'
B

8ft
11072SP04

Description 1.96m(6' 5") Arm 2.26m(7' 5") Arm 2.81m(9' 3") Arm
Max digging reach A 7460mm (24' 6") 7740mm (25' 5") 8270mm (27' 2")
Max digging reach on ground A' 7320mm (24' 0") 7610mm (25' 0") 8140mm (26' 8")
Max digging depth B 4770mm (15' 8") 5090mm (16' 8") 5620mm (18' 5")
Max digging depth (8ft level) B' 4510mm (14'10") 4870mm (16' 0") 5410mm (17' 9")
Max vertical wall digging depth C 4070mm (13' 4") 4430mm (14' 6") 4940mm (16' 2")
Max digging height D 7900mm (25'11") 8070mm (26' 6") 8460mm (27' 9")
Max dumping height E 5540mm (18' 2") 5710mm (18' 9") 6100mm (20' 0")
Min swing radius F 2340mm ( 7' 8") 2380mm ( 7'10") 2510mm ( 8' 3")
78.5 [85.6] kN 78.5 [85.6] kN 78.5 [85.6] kN
SAE 8000 [8730] kgf 8000 [8730] kgf 8000 [8730] kgf
17640 [19240] lbf 17640 [9240] lbf 17640 [19240] lbf
Bucket digging force
90.2 [98.4] kN 90.2 [98.4] kN 90.2 [98.4] kN
ISO 9200 [10040] kgf 9200 [10040] kgf 9200 [10040] kgf
20280 [22120] lbf 20280 [22120] lbf 20280 [22120] lbf
60.2 [65.7] kN 55.7 [60.8] kN 48.1 [52.4] kN
SAE 6140 [6700] kgf 5680 [6200] kgf 4900 [5350] kgf
13540 [14770] lbf 12520 [13660] lbf 10800 [11780] lbf
Arm digging force
62.9 [68.6] kN 58.1 [63.3] kN 49.7 [54.2] kN
ISO 6410 [6990] kgf 5920 [6460] kgf 5070 [5530] kgf
14130 [15410] lbf 13050 [14240] lbf 11180 [12200] lbf
[ ] : Power boost

1-13
4. WEIGHT
Item kg lb

Upperstructure assembly 3300 7280

Main frame weld assembly 1030 2270
Engine assembly 390 860
Main pump assembly 90 200
Main control valve assembly 130 260
Swing motor assembly 80 180
Hydraulic oil tank assembly 180 400
Fuel tank assembly 130 290
Counterweight 1450 3200
Cab assembly 310 680
Lower chassis assembly 3990 8800
Track frame weld assembly 1260 2780
Swing bearing 160 250
Travel motor assembly 330 730
Turning joint 60 130
Track recoil spring 210 460
Idler 390 860
Carrier roller 30 66
Track roller 300 660
Track-chain assembly(500mm standard triple grouser shoe) 1350 2980
Front attachment assembly(4.3m boom, 2.26m arm,
1640 3620
0.45m3 SAE heaped bucket)
4.3m boom assembly 740 1630
2.26m arm assembly 340 750
0.45m3 SAE heaped bucket 440 970
Boom cylinder assembly 230 510
Arm cylinder assembly 140 310
Dozer blade cylinder 47 100
Bucket cylinder assembly 90 200
Bucket control link assembly 80 180
Dozer blade assembly 700 1540

1-14
5. LIFTING CAPACITIES
1) ROBEX 110-7
(1) 4.3m(14' 1") boom, 2.26m(7' 5") arm equipped with 0.45m3(SAE heaped) bucket and 500mm(20")
triple grouser shoe.

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

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)

6.0m kg *1750 *1750 *1750 *1560 5.99

(20ft) lb *3860 *3860 *3860 *3440 (19.7)
4.5m kg *1790 *1790 *1530 1490 1520 1130 6.92
(15ft) lb *3950 *3950 *3370 3280 3350 2490 (22.7)
3.0m kg *2820 *2820 *2270 *2270 1940 1450 1300 940 7.38
(10ft) lb *6220 *6220 *5000 *5000 4280 3200 2870 2070 (24.2)
1.5m kg *4700 4370 *2970 2250 1840 1360 1240 880 7.46
(5ft) lb *10360 9630 *6550 4960 4060 3000 2730 1940 (24.5)
Ground kg 5660 3950 2830 2060 1760 1280 1300 930 7.18
Line lb 12480 8710 6240 4540 3880 2820 2870 2050 (23.6)
-1.5m kg *5580 *5580 5550 3850 2740 1980 1720 1240 1560 1130 6.49
(-5ft) lb *12300 *12300 12240 8490 6040 4370 3790 2730 3440 2490 (21.3)
-3.0m kg *8530 *8530 *5440 3930 2770 2010 *2270 1730 5.17
(-10ft) lb *18810 *18810 *11990 8660 6110 4430 *5000 3810 (17.0)

(2) 4.3m(14' 1") boom, 1.96m(6' 5") arm equipped with 0.45m3(SAE heaped) bucket and 500mm(20")
triple grouser shoe.
Load radius At max. reach
Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)

6.0m kg *1770 *1770 *1820 1710 5.62

(20ft) lb *3900 *3900 *4010 3770 (18.4)
4.5m kg *1950 *1950 1610 1180 6.62
(15ft) lb *4300 *4300 3550 2600 (21.7)
3.0m kg *3160 *3160 *2410 2390 1870 1380 1350 970 7.10
(10ft) lb *6970 *6970 *5310 5270 4120 3040 2980 2140 (23.3)
1.5m kg *4940 4150 2930 2150 1780 1290 1280 910 7.18
(5ft) lb *10890 9150 6460 4740 3920 2840 2820 2010 (23.6)
Ground kg 5490 3800 2740 1980 1700 1220 1360 960 6.89
Line lb 12100 8380 6040 4370 3750 2690 3000 2120 (22.6)
-1.5m kg *6090 *6090 5440 3750 2670 1910 1670 1200 6.15
(-5ft) lb *13430 *13430 11990 8270 5890 4210 3680 2650 (20.2)
-3.0m kg *9180 *9180 *5080 3880 2750 1980
(-10ft) lb *20240 *20240 *11200 8550 6060 4370
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.

1-15
 (3) 4.3m(14' 1") boom, 2.81m(9' 3") arm equipped with 0.45m3(SAE heaped) bucket and 500mm(20")
triple grouser shoe.
Load radius At max. reach
Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)

6.0m kg *1570 1290 6.66

(20ft) lb *3460 2840 (21.9)
4.5m kg *1640 1570 1330 980 7.50
(15ft) lb *3620 3460 2930 2160 (24.6)
3.0m kg *1920 *1920 *1830 1500 1160 830 7.92
(10ft) lb *4230 *4230 *4030 3310 2560 1830 (26.0)
1.5m kg *4050 *4050 *2690 2340 1890 1410 1100 780 7.99
(5ft) lb *8930 *8930 *5930 5160 4170 3110 2430 1720 (26.2)
Ground kg *3230 *3230 *5580 4110 2900 2130 1790 1310 1150 820 7.74
Line lb *7120 *7120 *12300 9060 6390 4700 3950 2890 2540 1810 (25.4)
-1.5m kg *4960 *4960 5620 3920 2770 2010 1730 1250 1330 960 7.11
(-5ft) lb *10930 *10930 12390 8640 6110 4430 3810 2760 2930 2120 (23.3)
-3.0m kg *7230 *7230 5630 3930 2760 2000 1830 1350 5.96
(-10ft) lb *15940 *15940 12410 8660 6080 4410 4030 2980 (19.6)
-4.5m kg *4480 4100
(-15ft) lb *9880 9040

2) ROBEX 110D-7
(1) 4.3m(14' 1") boom, 2.26m(7' 5") arm equipped with 0.45m3(SAE heaped) bucket and 500mm(20")
triple grouser shoe, and rear dozer blade down.
Load radius At max. reach
Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)

6.0m kg *1750 *1750 *1750 *1750 5.99

(20ft) lb *3860 *3860 *3860 *3860 (19.7)
4.5m kg *1790 *1790 *1530 *1530 1650 1340 6.92
(15ft) lb *3950 *3950 *3370 *3370 3640 2950 (22.7)
3.0m kg *2820 *2820 *2270 *2270 *2060 1710 1420 1140 7.38
(10ft) lb *6220 *6220 *5000 *5000 *4540 3770 3130 2510 (24.2)
1.5m kg *4700 *4700 *2970 2650 2000 1620 1360 1080 7.46
(5ft) lb *10360 *10360 *6550 5840 4410 3570 3000 2380 (24.5)
Ground kg *5860 4750 3060 2460 1910 1540 1430 1140 7.18
Line lb *12920 10470 6750 5420 4210 3400 3150 2510 (23.6)
-1.5m kg *5580 *5580 5980 4640 2970 2370 1880 1500 1700 1360 6.49
(-5ft) lb *12300 *12300 13180 10230 6550 5220 4140 3310 3750 3000 (21.3)
-3.0m kg *8530 *8530 *5440 4720 3000 2400 *2270 2050 5.17
(-10ft) lb *18810 *18810 *11990 10410 6610 5290 *5000 4520 (17.0)

1-16
 (2) 4.3m(14' 1") boom, 1.96m(6' 5") arm equipped with 0.45m3(SAE heaped) bucket and 500mm(20")
triple grouser shoe, and rear dozer blade down.
Load radius At max. reach
Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)

6.0m kg *1770 *1770 *1820 *1820 5.62

(20ft) lb *3900 *3900 *4010 *4010 (18.4)
4.5m kg *1950 *1950 1750 1420 6.62
(15ft) lb *4300 *4300 3860 3130 (21.7)
3.0m kg *3160 *3160 *2410 *2410 2020 1640 1480 1180 7.10
(10ft) lb *6970 *6970 *5310 *5310 4450 3620 3260 2600 (23.3)
1.5m kg *4940 *4940 *3060 2550 1940 1560 1410 1120 7.18
(5ft) lb *10890 *10890 *6750 5620 4280 3440 3110 2470 (23.6)
Ground kg *5870 4580 2970 2370 1860 1480 1490 1180 6.89
Line lb *12940 10100 6550 5220 4100 3260 3280 2600 (22.6)
-1.5m kg *6090 *6090 *5860 4540 2900 2310 1820 1460 6.15
(-5ft) lb *13430 *13430 *12920 10010 6390 5090 4010 3220 (20.2)
-3.0m kg *9180 *9180 *5080 4670 2980 2380
(-10ft) lb *20240 *20240 *11200 10300 6570 5250

(3) 4.3m(14' 1") boom, 2.81m(9' 3") arm equipped with 0.45m3(SAE heaped) bucket and 500mm(20")
triple grouser shoe, and rear dozer blade down.
Load radius At max. reach
Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)

6.0m kg *1570 *1520 6.66

(20ft) lb *3460 *3350 (21.9)
4.5m kg *1640 *1640 1450 1170 7.50
(15ft) lb *3620 *3620 3200 2580 (24.6)
3.0m kg *1920 *1920 *1830 1770 1270 1020 7.92
(10ft) lb *4230 *4230 *4030 3900 2800 2250 (26.0)
1.5m kg *4050 *4050 *2690 *2690 2050 1670 1210 960 7.99
(5ft) lb *8930 *8930 *5930 *5930 4520 3680 2670 2120 (26.2)
Ground kg *3230 *3230 *5580 4910 3130 2530 1950 1570 1290 1000 7.74
Line lb *7120 *7120 *12300 10820 6900 5580 4300 3460 2780 2200 (25.4)
-1.5m kg *4960 *4960 6060 4710 3000 2410 1890 1510 1460 1170 7.11
(-5ft) lb *10930 *10930 13360 10380 6610 5310 4170 3330 3220 2580 (23.3)
-3.0m kg *7230 *7230 *5830 4720 2980 2390 1990 1610 5.96
(-10ft) lb *15940 *15940 *12850 10410 6570 5270 4390 3550 (19.6)
-4.5m kg *4480 *4480
(-15ft) lb *9880 *9880

1-17
6. BUCKET SELECTION GUIDE
1) GENERAL BUCKET

0.30m3 SAE 0.40m3 SAE ö0.45m3 SAE 0.50m3 SAE 0.59m3 SAE
heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket

Recommendation
Capacity Width 4.3m (14' 1")
Weight Mono boom
SAE CECE Without With 1.96m arm 2.26m arm 2.81m arm
heaped heaped side cutter side cutter (6' 5") (7' 5") (9' 3")

0.30m3 0.27m3 610mm 720mm 360kg

(0.39yd3) (0.35yd3) (24.0") (28.3") (790lb)

0.40m3 0.44m3 760mm 870mm 410kg

(0.52yd3) (0.58yd3) (29.9") (34.3") (900lb)

ö0.45m3 0.40m3 830mm 940mm 430kg

(0.59yd3) (0.52yd3) (32.7") (37.0") (950lb)

0.50m3 0.45m3 900mm 1010mm 450kg

(0.65yd3) (0.59yd3) (35.4") (39.8") (990lb)

0.59m3 0.52m3 1020mm 1130mm 490kg

(0.77yd3) (0.68yd3) (40.2") (44.5") (1080lb)

ö : Standard bucket

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

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

1-18
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) 500(20) 600(24) 700(28)

Operating weight kg(lb) 11200(24690) 11500(25350) 11800(26010)
R110-7
Ground pressure kgf/cm2(psi) 0.39(5.55) 0.34(4.84) 0.30(4.27)
Overall width mm(ft-in) 2490(8' 2") 2590(8' 6") 2690(8'10")
Shoe width mm(ft-in) 500(20) 600(24) 700(28)
Overall width mm(ft-in) 11900(26230) 12200(26900) 12500(27560)
R110D-7
Overall width mm(ft-in) 0.42(5.97) 0.36(5.12) 0.31(4.41)
Overall width mm(ft-in) 2500(8' 2") 2590(8' 6") 2690(8'10")

3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE

Item Quantity

Carrier rollers 1EA

Track rollers 6EA
Track shoes 41EA

1-19
 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) 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.

ö Table 1

Track shoe Specification Category

500mm triple grouser Standard A

600mm triple grouser Option A
700mm triple grouser Option B

ö Table 2
Category Applications Precautions

Rocky ground, Â Travel at low speed on rough ground with large obstacles such as
A river beds, boulders or fallen trees
normal soil

Normal soil, Â These shoes cannot be used on rough ground with large obstacles such
soft ground as boulders or fallen trees
B Â Travel at high speed only on flat ground
 Travel slowly at low speed if it is impossible to avoid going over
obstacles

1-20
8. SPECIFICATIONS FOR MAJOR COMPONENTS
1) ENGINE
Item Specification

Model Mitsubishi S4K-T

Type 4-cycle turbocharged diesel engine, low emission
Cooling method Water cooling
Number of cylinders and arrangement 4 cylinders, in-line
Firing order 1-3-4-2
Combustion chamber type Direct injection type
Cylinder boreÝstroke 102Ý130mm(4.02"Ý5.12")
Piston displacement 4249cc(259cu in)
Compression ratio 17:1
Rated gross horse power(SAE J1995) 94Hp at 1950rpm(70kW at 1950rpm)
Maximum torque at 1400rpm 37.9kgfÂm(274lbfÂft)
Engine oil quantity 17.5˶(4.6U.S. gal)
Dry weight 380kg(838lb)
High idling speed 216550rpm
Low idling speed 1050Ü50rpm
Rated fuel consumption 177.4g/HpÂhr at 1950rpm
Starting motor Mitsubishi 24V-5.0kW
Alternator Mitsubishi 24V-50A
Battery 2Ý12VÝ80Ah

2) MAIN PUMP
Item Specification

Type Variable displacement tandem axis piston pumps

Capacity 2Ý57.5cc/rev
Maximum pressure 330kgf/cm2 (4694psi) [360kgf/cm2 (5120psi)]
Rated oil flow 2Ý112˶/min (2Ý29.6U.S.gpm)
Rated speed 1950rpm
[ ]: Pooer boost

1-21
 3) GEAR PUMP
Item Specification

Type Fixed displacement gear pump single stage

Capacity 15cc/rev
Maximum pressure 35kgf/cm2(500psi)
Rated oil flow 29.3˶/min(7.7U.S.gpm/6.4U.K.gpm)

4) MAIN CONTROL VALVE

Item Specification

Type 11 spools mono-block

Operating method Hydraulic pilot system
Main relief valve pressure 330kgf/cm2(4695psi)[360kgf/cm2(5120psi)]
Overload relief valve pressure 380kgf/cm2(5550psi)
[ ]: Pooer boost

5) SWING MOTOR
Item Specification

Type Axial piston motor

Capacity 64.3cc/rev
Relief pressure 240kgf/cm2(3414psi)
Braking system Automatic, spring applied hydraulic released
Braking torque 25kgfÂm2(181lbfÂft)
Brake release pressure 33~50kgf/cm22(469~711psi)
Reduction gear type 2 - stage planetary
Swing speed 13.0rpm

6) TRAVEL MOTOR
Item Specification
Type Variable displacement axial piston motor
Relief pressure 330kgf/cm2(4695psi)
Reduction gear type 2 stage planetary
Braking system Automatic, spring applied hydraulic released
Brake release pressure Less then 9kgf/cm22(128psi)
Braking torque 24.36kgfÂm2(176lbfÂft)

1-22
 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 diaÝRod diaÝStroke ͚95Ý͚70Ý1015mm

Boom cylinder
Cushion Extend only
Bore diaÝRod diaÝStroke ͚110Ý͚75Ý1070mm
Arm cylinder
Cushion Extend and retract
Bore diaÝRod diaÝStroke ͚95Ý͚65Ý855mm
Bucket cylinder
Cushion Extend only
Bore diaÝRod diaÝStroke ͚100Ý͚70Ý240mm
Dozer cylinder
Cushion -
ö Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on
the rod surface.
ö Discoloration does not cause any harmful effect on the cylinder performance.

9) SHOE

Item Width Ground pressure Link quantity Overall width

Standard 500mm(20") 0.39kgf/cm2(5.55psi) 41 2490mm( 8' 2")

R110-7
Option 600mm(24") 0.34kgf/cm2(4.84psi) 41 2590mm( 8' 6")
R110D-7
Option 700mm(28") 0.30kgf/cm2(4.27psi) 41 2690mm( 8' 10")

10) BUCKET
Capacity Tooth Width
Item
SAE heaped CECE heaped quantity Without side cutter With side cutter

STD 0.45m3(0.59yd3) 0.40m3(0.52yd3) 4 830mm(32.7") 940mm(37.0")

0.30m (0.39yd )
3 3
0.27m (0.35yd )
3 3
3 610mm(24.0") 720mm(28.3")
R110-7
0.40m3(0.52yd3) 0.44m3(0.58yd3) 4 760mm(29.9") 870mm(34.3")
R110D-7 OPT
0.50m (0.65yd )
3 3
0.45m (0.59yd )
3 3
4 900mm(35.4") 1010mm(39.8")
0.59m3(0.77yd3) 0.52m3(0.68yd3) 5 1020mm(40.2") 1130mm(44.5")

1-23
9. RECOMMENDED OILS
Use only oils listed below or equivalent.
Do not mix different brand oil.

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

SAE 30

Engine SAE 10W

Engine oil 17.5(4.6)
oil pan
SAE 10W-30

SAE 15W-40

Swing drive 2.5(0.7)

Gear oil SAE 85W-140
2.5Ý2
Final drive (0.7Ý2)

NLGI NO.1
Swing drive Grease 0.35(0.09)
NLGI NO.2

ISO VG 32

Hydraulic tank Hydraulic oil Tank:100(26.4) ISO VG 46

ISO VG 68

ASTM D975 NO.1

Fuel tank Diesel fuel 250(66.0)
ASTM D975 NO.2

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

Mixture of
Radiator antifreeze 24(6.3) Ethylene glycol base permanent type
(Reservoir tank) and water
50 : 50
SAE : Society of Automotive Engineers
API : American Petroleum Institute
ISO : International Organization for Standardization
NLGI : National Lubricating Grease Institute
ASTM : American Society of Testing and Material

1-24
 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 3/4"
B1 Suction port SAE2500psi 2 1/2"
Dr Drain port PF 1/2 - 19
Pi1,i2 Pilot port PF 1/4 - 15
P1 EPPR port PF 1/4 - 13
a1,2 Gauge port PF 1/4 - 15
a3 Gauge port PF 1/4 - 14
a4 Gauge port PF 1/4 - 13
A3 Gear pump delivery port PF 1/2 - 19
B3 Gear pump suction port PF 3/4 - 20.5
11072PM01

2-1
1) MAIN PUMP(1/2)
The main pump consists of two piston pumps(front & rear) and valve block.

702
789, 732 532 214 548 531 724 792 534 901 954 719 151 152 211 113

535
808

953
886 04
717
406
261
774

111
824
127
710
123
251

212
490 153 156 157 313 124 312 114 466 885 314 467 141 981 271 401
725 728 983
14072SF02

04 Gear pump 271 Pump casing 719 O-ring

111 Drive shaft(F) 312 Valve block 724 O-ring
113 Drive shaft(R) 313 Valve plate(R) 725 O-ring
114 Spline couping 314 Valve plate(L) 728 O-ring
123 Roller bearing 401 Hexagon socket bolt 732 O-ring
124 Needle bearing 406 Hexagon socket bolt 774 Oil seal
127 Bearing spacer 466 VP Plug 789 Back up ring
141 Cylinder block 467 VP Plug 792 Back up ring
151 Piston 490 Plug 808 Hexagon head nut
152 Shoe 531 tilting pin 824 Snap ring
153 Set plate 532 Servo piston 885 Pin
156 Bushing 534 Stopper(L) 886 Spring pin
157 Cylinder spring 535 Stopper(S) 901 Eye bolt
211 Shoe plate 548 Pin 953 Set screw
212 Swash plate 702 O-ring 954 Set screw
214 Bushing 710 O-ring 981 Plate
251 Support 717 O-ring 983 Pin
261 Seal cover(F)

2-2
 2) REGULATOR(1/2)

412 875 874

755
A
897 858
B
614
612

438

615 801
613
924
A 611
B
641 730 643 708 644 645 646 728

SECTION B-B

413 438 405 413 438

438

735

656 D

722 496 724 725 436 699 496 724 725 436

VIEW C(FRONT) VIEW C(REAR)

KR36-9N12(FRT) A
KR36-9N1S(RR)

735 722 P2
079
Pf
466
Port Port name port size
Pi
A Delivery port 3/4"

753
B Suction port 2 1/2"
496 755
SECTION D-D Pn Pilot port PF 1/4-15
Pm Qmax cut port PF 1/4-15
B

11072PM03

2-3
 REGULATOR(2/2)

734 653 654 836 651 652 601 624 629 630 628
655

641 801
C
814 925

898

631 627

732

733
732

622

621 623 625 626 887 763 756

140LC-7 ‫׆‬೴ 2-5
SECTION A-A

405 Hexagon socket screw 629 Cover(C) 730 O-ring

412 Hexagon socket screw 630 Lock nut 732 O-ring
413 Hexagon socket screw 631 Sleeve, pf 733 O-ring
436 Hexagon socket screw 641 Pilot cover 734 O-ring
438 Hexagon socket screw 643 Pilot piston 735 O-ring
466 Plug 644 Spring seat(Q) 753 O-ring
496 Plug 645 Adjust stem(Q) 755 O-ring
601 Casing 646 Pilot spring 756 O-ring
611 Feed back lever 651 Sleeve 763 O-ring
612 Lever(1) 652 Spool 801 Nut
613 Lever(2) 653 Spring seat 814 Snap ring
614 Fulcrum plug 654 Return spring 836 Snap ring
615 Adjust plug 655 Set spring 858 Snap ring
621 Compensator piston 656 Block cover 874 Pin
622 Piston case 699 Valve casing 875 Pin
623 Compensator rod 708 O-ring 887 Pin
624 Spring seat(C) 722 O-ring 897 Pin
625 Outer spring 724 O-ring 898 Pin
626 Inner spring 725 O-ring 924 Set screw
627 Adjust stem(C) 728 O-ring 925 Adjust screw(QI)
628 Adjust screw(C)

2-4
3) GEAR PUMP

700 354 351 433

B3

850
355
434
A3
311

312
a3

710 435 361 353 732 309 307 310 308 434 466, 725

140LC-7 ‫׆‬೴ 2-5

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

2-5
2. FUNCTION
1) MAIN PUMP
The pumps may classified roughly into the rotary group performing a rotary motion and working as
the major part of the whole pump function: the swash plate group that varies the delivery rates: and
the valve cover group that changes over oil suction and discharge.

(1) Rotary group

The rotary group consists of drive shaft
(F)(111), cylinder block(141), piston
shoes(151,152), set plate(153), spherical
bush(156) and cylinder spring(157).
The drive shaft is supported by bearing
(123,124) at its both ends.
The shoe is caulked to the piston to from a
spherical coupling. It has a pocket to
relieve thrust force generated by loading
pressure and the take hydraulic balance
so that it slides lightly over the shoe
plate(211). The sub group composed by
a piston and a shoe is pressed against the
shoe plate by the action of the cylinder
spring via a retainer and a spherical bush.
Similarly, the cylinder block is pressed 14072SF04
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
212
pin(531) and servo piston(532).
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
532 ɷ
left as hydraulic force controlled by the
regulator is admitted to hydraulic chamber
located on both sides of the servo piston,
the swash plate slides over the swash ɷ
plate support via the spherical part of the
tilting pin to change the tilting angle(ɷ)

140LC-7 ‫׆‬೴ 2-7

2-6
(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
885
The oil changed over by the valve plate is
connected to an external pipeline by way
of the valve block.
Now, if the drive shaft is driven by a prime
mover(electric motor, engine, etc), it
rotates the cylinder block via a spline
linkage at the same time. If the swash
plate is tilted as in Fig(previous page) the
pistons arranged in the cylinder block 140LC-7 ‫׆‬೴ 2-8

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.

2-7
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 Pn, 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 Pn rises.
With this mechanism, when the pilot
pressure corresponding to the flow
required for the work is commanded, the
pump discharges the required flow only,
and so it does not consume the power Pilot pressure, Pn
uselessly.

2-8
Η Flow reducing function

643 654 651 652 613 646

P1 CL
B(E)
874
897
C
A

875
611

Servo piston Small diameter

D
Large diameter chamber
chamber 548
531

11072PM10

As the pilot pressure Pn 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.

2-9
Θ Flow increasing function

643 654 651 652 613 646

P1 CL
B(E)
874
897
C

875

611

Servo piston D Small diameter

Large diameter 548 chamber
chamber
531

11072PM11

As the pilot pressure Pn 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.

2-10
Ι Adjustment of flow control characteristic
The flow control characteristic can be
adjusted with the adjusting screw.
Adjust it by loosening the hexagon 801
nut(801) and by tightening(or loosening) 924
the hexagonal socket head screw(924).
Tightening the screw shifts the control
chart to the right as shown in the figure.
ö Adjusting values are shown in table.
Adjustment of flow control
characteristic 140LC-7 ‫׆‬೴ 2-12
Speed
Tightening Flow control Flow change
amount of starting amount
adjusting pressure
screw(924) change

Delivery flow, Q
amount

(min -1) (Turn) (kgf/cm2) (˶/min)

1950 +1/4 +1.5 +7.3

Pilot pressure, Pn

2-11
(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 = P1Ýq/2ӕ + P2Ýq/2ӕ
= (P1+P2)Ýq/2ӕ
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).

2-12
Η 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

140LC-7 ‫׆‬೴ 2-14

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.

2-13
Θ Flow reset function

621 651 652 623 612 601 625 626

P1 CL
B(E)
897

P2 P1

875

Large diameter Small diameter

chamber Servo piston D chamber

140LC-7 ‫׆‬೴ 2-15

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.

2-14
Ι 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(͚4) protruding from the large hole(͚8), only the lever
lessening the tilting angle contacts the pin(897) ; the hole(͚8) in the lever of a larger tilting angle
command is freed without contacting the pin(897). Such a mechanical selection method permits
preference of the lower tilting angle command of the flow control and horsepower control.
Κ 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
the screw shifts the control chart to the 801
right and increases the input horsepow-
925
er 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 NÝA turns at first.(A=1.9)
ö Adjusting values are shown in table
140LC-7 ‫׆‬೴ 2-16
Adjustment of outer spring
Speed
Tightenin Compens- Input torque
amount of ationg control change
adjusting pressure amount
Delivery flow, Q

screw(C) change
(924) amount

(min -1) (Turn) (kgf/cm2) (kgfÂm)

1950 +1/4 +19.2 +2.71

Delivery pressure, (P1+P2)

2-15
b. Adjustment of inner spring 626
Adjust it by loosening the hexagon nut
(801) and by tightening(or loosening)
the adjusting screw QI(925). 801
Tightening the screw increases the flow
and then the input horsepower as 925
shown in the figure.
ö Adjusting valves are shown in table
Adjustment of outer spring
Speed
Tightenin Flow Input torque
amount of change change
140LC-7 ‫׆‬೴ 2-17
adjusting amount amount
screw(C)
(925)

Delivery flow, Q
(min -1) (Turn) (˶/min) (kgfÂm)

1950 +1/4 +5.2 +2.3

Delivery pressure, (P1+P2)

2-16
(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

140LC-7 ‫׆‬೴ 2-18

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 MA
X.
(power shift pressure) is admitted to the
horsepower control section of each pump
Delivery pressure, (P1+P2)
regulator through the pump's internal path
to shift it to the same set horsepower
level.
This function permits arbitrary setting of the pump output power, thereby providing the optimum
power level according to the operating condition.
The power shift pressure Pf controls the set horsepower of the pump to a desired level, as shown
in the figure.
As the power shift pressure Pf rises, the compensating rod(623) moves to the right via the
pin(898) and compensating piston(621).
This decreases the pump tilting angle and then the set horsepower in the same way as explained
in the overload preventive function of the horsepower control. On the contrary, the set horsepower
rises as the power shift pressure Pf falls.

2-17
(4) Adjustment of maximum and minimum flows
808
Η Adjust it by loosening the hexagon
nut(808) and by tightening(or loosening)
954
the set screw(954).
The maximum flow only is adjusted
without changing other control
characteristics.
140LC-7 ‫׆‬೴ 2-19(1)
Adjustment of max flow
Speed
Tightening Flow change
amount of amount
adjusting screw

Delivery flow, Q
(954)

(min -1) (Turn) (˶/min)

1950 +1/4 -3.1

Delivery pressure, Pn

Θ Adjustment of minimum flow

Adjust it by loosening the hexagon
806
nut(808) and by tightening(or loosening)
the hexagonal socket head set screw
953
(953). Similarly to the adjustment of the
maximum flow, other characteristics are
not changed.
However, remember that, if tightened too
140LC-7 ‫׆‬೴ 2-19(2)
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)

1950 +1/4 +3.1 Delivery pressure, Pn

2-18
GROUP 2 MAIN CONTROL VALVE

1. STRUCTURE
Mark Port name Port size Tightening torque
Rs Make up for swing motor
Pa1 Travel left pilot port(FW)
Pb1 Travel left pilot port(BW)
Pc1 Travel right pilot port(BW)
Pd1 Travel right pilot port(FW)
Pa20 Boom up pilot port
Pa21 Boom up confluence pilot port
Pb20 Boom down pilot port
Pb21 Lock valve pilot port(Boom)
Pc2 Swing pilot port(RH)
Pd2 Swing pilot port(LH)
Pb3 Arm in confluence pilot port
Pc3 Swing priority pilot port
Pa4 Option A pilot port(Breaker)
Pb4 Arm in regeneration cut port
Pc40 Arm in pilot port
Pc41 Lock valve pilot port(Arm) G1/4 3.5~3.9kgfÂm
Pc42 Arm in regen-cut signal selector port (25.3~28.2lbfÂft)
Pd40 Arm out pilot port
Pd41 Arm out confluence pilot port
Pa5 Bucket in pilot port
Pb5 Bucket out pilot port
Pc5 Option B pilot port
Pd5 Option B pilot port
Pc6 Option C pilot port
Pd6 Option C pilot port
PO Pilot pressure port
Pu Main relief pressure up
Ai Auto idle signal port
Dr0 Drain port(Travel straight)
Dr1 Drain port(Boom holding valve)
Dr2 Drain port(Boom2 & swing priority)
Dr3 Drain port(Arm holding valve)
Pn1 Negative control signal port(P1 port side)
Pn2 Negative control signal port(P2 port side)

A1 Travel motor left side port(FW)

B1 Travel motor left side port(BW)
C1 Travel motor right side port(BW)
D1 Travel motor right side port(FW)
B2 Boom rod side port
C2 Swing motor port(LH)
D2 Swing motor port(RH) G3/4 15~18kgfÂm
B4 Option A port(Breaker) (109~130lbfÂft)
A5 Bucket head side port
B5 Bucket rod side port
C5 Option B port
D5 Option B port
C6 Option C port
D6 Option C port
P1 Pump port(P1 side)
P2 Pump port(P2 side)

A2 Boom head side port 20~25kgfÂm

C4 Arm head side port G1
D4 Arm rod side port (115~180lbfÂft)

SAE3000, 1 1/2 8.5~11.5kgfÂm

T1 Return port (61.5~83.1lbfÂft)
(M12)
14072SF10

2-19
 1 Body 50 Stopper-regeneration
2 Spool-straight travel 51 Piston-cut off
3 Spool-travel 52 Poppet-signal
4 Spool-swing 53 Spring-signal
5 Spool-boom 54 Plug
6 Spool-swing priority 55 Orifice-signal
7 Spool-boom2 56 Coin type filter
8 Spool-arm2 57 Orifice-plug
9 Spool-arm 58 Plug
10 Spool-arm regeneration 59 Plug
& breaker 60 Plug
11 Spool-option 61 Plug-orifice
12 Spool-bucket 62 Poppet-negative control
13 Cover-pilot A 63 Coin type filter
14 Cover-pilot B1 64 Spring seat
15 Cover-Pilot B2 65 Spring-negative control
16 Block-holding 66 Piston-negative control
17 Block-regeneration 67 Socket-negative control
18 Plug 68 Plug
19 Poppet1-check valve 69 Plug
20 Spring-check valve 70 Plug
21 Plug 71 Plug
22 Poppet2-check valve 72 Plug
23 Spring-check valve 73 Plug
24 Spring seat1 74 O-ring
25 Spring seat3 75 O-ring
26 Spacer bolt 76 O-ring
27 Spring-return(L) 77 O-ring
28 Spring-return(S) 78 O-ring
29 Stopper1-TS 79 O-ring
30 Stopper2-priority 80 O-ring
31 Spring seat2 81 O-ring
32 Poppet-TS check valve 82 O-ring
33 Spring-TS check valve 83 O-ring
34 Poppet-lock valve 84 O-ring
35 Restrictor-lock valve 85 O-ring
36 Spring-lock valve pilot 86 Back-up ring
37 Guide poppet 87 Back-up ring
38 Poppet-pilot 88 Back-up ring
39 Seat-poppet 89 Back-up ring
40 Piston1 90 O-ring
41 Guide-piston 91 Bolt with washer
42 Spring1-lock valve 92 Socket head bolt
43 Piston2 93 Socket head bolt
44 Socket-lock valve 94 Main relief valve
45 Spool-lock valve 95 Over load relief valve
46 Spring2-lock valve 96 Plug-relief valve
47 Stopper-lock valve 97 Plug-relief valve
48 Spool-regen selector 98 Plug-relief valve
49 Spring-regeneration 99 Over load relief valve

14072SF11

2-20
2. HYDRAULIC CIRCUIT

14072SF05

2-21
3. FUNCTION
1) CONTROL IN NEUTRAL FUNCTION
(1) P1 SIDE

14072SF13

14072SF15

The hydraulic fluid from pump P1 flows into the main control valve through the inlet port "P1", pass the
travel straight spool, into the P1 bypass passage and P1parallel passage.
The hydraulic fluid from the pump P1 is directed to the tank through the bypass passage of spools :
travel left, boom1, arm2, arm regeneration & option A and bucket, the negative relief valve, tank
passage, and the tank port "T1"

2-22
(2) P2 SIDE

14072SF14

14072SF16

The hydraulic fluid from pump P2 flows into the main control valve through the inlet port "P2", pass the
straight travel spool, into the P2 bypass passage and P2 parallel passage.
The hydraulic fluid from the pump P2 is directed to the tank through the bypass passage of spools :
travel right, swing, boom2 & swing priority, arm1, option "B" and option "C", and the negative relief
valve with the tank passage.

2-23
2) EACH SPOOL OPERATION
(1) TRAVEL OPERATION
Η Travel forward operation

14072SF17

Θ Travel backward operation

14072SF18

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 spring side of pilot port (pa1, pd1).
And it shifts travel right and left spools in the left direction against springs. Hydraulic fluid from the
pump P1 flow into the travel left spool through the bypass passage and hydraulic fluid from the pump
P2 flow into the travel right spool through the bypass passage.
Then they are directed to the each travel motor through port A1 and D1. As a result, the travel motors
turn and hydraulic fluid returns to the tank passage through the travel spools.
In case of the opposite operation, the operation is similar.

2-24
(2) TRAVEL STRAIGHT FUNCTION

14072SF19

This function keeps straight travel in case of simultaneous operation of other actuators(boom, arm,
bucket, swing) during a straight travel.
Η During travel only :
The hydraulic fluid of the pump P1 is supplied to the travel motor and the pump P2 is supplied to
the other motor.
Thus, the machine keep travel straight.
Θ The other actuator operation during straight travel operation :
When the other actuator spool(s) is selected under straight travel operation, the straight travel
spool is moved.
The hydraulic fluid from pump P1 is supplied actuator through P1 and P2 parallel pass and travel
motors through orifice at side of straight travel spool.
The hydraulic oil fluid from pump P2 is supplied to travel motors(left/right).
Therefore, the other actuator operation with straight travel operation, hydraulic oil fluid from pump
P1 is mainly supplied to actuator, and the hydraulic oil fluid form pump P2 is mainly supplied to
travel motors(left/right).
Then the machine keeps straight travel.

2-25
(3) BOOM OPERATION
Η Boom up operation

14072SF24

14072SF25

During boom up operation, the pilot pressure from RCV is supplied into the port Pa20 and shift the
boom1 spool in the left direction. The hydraulic oil fluid from pump P1 is entered P1 parallel passage
and then passes through the load check valve and boom holding valve then flows into the port A2.
Following this it flows into the head side of the boom cylinder.
(In this case, the boom holding valve is free flow condition)
At the same time the pilot pressure through the port Pa21 shifts the boom2 spool. The hydraulic oil
fluid from pump P2 entered boom summation passage via the P2 parallel passage, the swing priority
spool, the boom2 spool, arm1 spool and the check. The flows combine in passage and are directed
to port A2 and head side of boom cylinder.
The flow from rod side of the boom cylinder return to the boom1 spool through the port B2. There
after it is directed to the hydraulic oil tank through the tank passage.

2-26
 Θ Boom down operation

14072SF26

During the boom lowing operation, the pilot pressure from RCV is supplied to the port Pb20 and shift
the boom1 spool in the right direction.
The hydraulic fluid from the pump P1 enters the parallel passage and is directed to the port B2
through the load check valve. Following this, it 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 through the port
A2 and boom holding valve. Thereafter it is directed to the hydraulic oil tank through tank passage.
For details of the boom holding valve, see page 2-36.

2-27
(4) BUCKET OPERATION
Η Bucket roll in operation

14072SF34

Θ Bucket roll out operation

14072SF35

2-28
Η Bucket roll in operation
During the bucket roll in operation, the pilot pressure from RCV is supplied to port Pa5 and shift
the bucket spool in the left direction.
The hydraulic fluid from pump P1 entered P1 parallel passage and is directed to the port A5
through the check1.
At the same time, the hydraulic fluid from P1 bypass passage is directed to the port A5 through
the check2.
Following this it flows into the head side of the bucket cylinder.
The return flow from the rod side of the bucket cylinder returns to the bucket spool through the
port B5. Thereafter it is directed to the hydraulic oil tank through the tank passage.
Θ Bucket roll out operation
In case of the bucket roll out operation, the operation is similar
Ι Bucket operation with arm or boom operation
When combined operation, mostly same as above but the fluid from bypass passage is empty.
So only the fluid from parallel passage is supplied to the bucket cylinder. Also, parallel passage is
installed the orifice for supplying the fluid from pump to the boom or the arm operation prior to the
bucket operation.

2-29
(5) SWING OPERATION
Η Swing left operation

14072SF32

Θ Swing right operation

14072SF33

The pilot pressure from the RCV is supplied to the Pd2 and shift the swing spool in left direction. The
hydraulic fluid from pump P2 flows into swing spool through the parallel passage. Then it is directed to
swing motor through the port D2. As the result, swing motor turns and flow from the swing motor
returns to the hydraulic oil tank through the port C2, swing spool and the tank passage .
In case of swing right operation, the operation is similar.

2-30
(6) ARM OPERATION
Η Arm roll in operation

14072SF21

14072SF20

ÂArm roll in operation :

During arm roll in operation the pilot pressure from the RCV is supplied to the port Pc40 and Pb3
and shifts arm1 spool and arm2 spool in the right direction.
The hydraulic oil from the pump P2 flows into the arm cylinder head side through P2 parallel
passage, the load check valve and the port C4.
At same time, the hydraulic fluid from the pump P1 flows into the arm summation passage through
parallel passage, the check valve, the arm2 spool and the boom2 spool. Then it entered the arm
cylinder head side with hydraulic fluid from arm1 spool.

2-31
ÂArm regeneration :
The return flow from the arm cylinder rod side is pressurized by self weight of arm and so, returns to
port D4. The pressurized oil returning to port D4 enters the arm regeneration & breaker spool
through the arm holding valve and the arm1 spool. It is suppled the arm cylinder head through
internal passage. This is called the arm regeneration function.
The amount of regeneration fluid are changed by movement of the arm regeneration & breaker
spool.
A few fluid after P2 parallel passage is push piston "C" through the notch of arm regeneration spool
and selector spool. At this time, the selector spool is opened by pilot pressure from RCV.
Then, the arm regeneration spool shift to right side and flow to tank pass increases and
regeneration flow decreases. Therefore, pressure of arm cylinder head increases, then, arm
regeneration flow decreases.
Furthermore, the arm regeneration cut pressure is supplied to port and arm regeneration spool is
move into the right direction fully. The flow from the arm cylinder rod is returned to the hydraulic oil
tank and regeneration function is not activated.

2-32
 Θ Arm roll out operation

14072SF23

14072SF22

During arm roll out operation the pilot pressure from RCV is supplied to the port Pd40 and the Pd41
and shifts arm1 spool and arm2 spool in the right direction.
The hydraulic fluid from pump P2 flows into arm1 spool through the parallel passage. Then it enters
into the arm cylinder rod side through the load check valve, bridge passage, arm holding valve and the
port D4.
Some of the hydraulic fluid from pump P2 bypassed through bypass notch.
The rest of hydraulic fluid from pump P2 flows into the arm summation passage through P1 parallel
passage the check valve arm2 spool and boom2 spool.
Then it enters into the arm cylinder rod side with the fluid from the arm1 spool.
The return flow from the arm cylinder head side returns to the hydraulic tank through the port C4 the
arm1 spool and tank passage.

2-33
(7) SWING PRIORITY FUNCTION

14072SF27

During swing priority operation, the pilot pressure is supplied to the port Pc3 and shift swing priority
spool in the right direction.
The hydraulic fluid from P2 parallel passage flows into the parallel passage of arm1 side through swing
priority spool and the passage "A" and also flows into the boom2 spool.
Due to shifting of the swing priority spool, the fluid from pump P2 flows to swing side more then next
spools to make the swing operation most preferential.

2-34
(8) HOLDING VALVE OPERATION
Η Holding operation

14072SF30

At neutral condition, the pilot piston chamber is connected to drain port through the pilot port.
And the piston "B" is supported with spring "B" and the pressured fluid from actuator entered to inside
of the holding valve through the periphery hole of check, crevice of the check and the plug and the
periphery hole of plug.
Then, this pressured oil pushed the poppet to the poppet seat and the check to the seat of body.
So the hydraulic fluid from actuator is not escaped and the actuator is not moved.

2-35
 Θ Release holding operation

14072SF31

The pilot pressure is supplied to the pilot port for release holding valve and shifts the piston "B" in the
left direction against the spring "B", and shifts the poppet in the left direction through piston "B" and
piston "A" against spring "B" and shifts the spool in the left side.
At same time, the return fluid from actuator returns to the drain port through the periphery hole of
check, crevice of the check and the plug, the periphery hole of the plug, in side of holding valve,
crevice of the poppet and the poppet seat, the periphery hole of the poppet seat, crevice of the socket
and spool and inside of spool.
When the poppet is opened, pressure of inside of holding valve is decreased and the return fluid from
actuator returns to the tank passage through the notch of spool.

2-36
(9) NEGATIVE CONTROL

14072SF28

When no function is being actuated on P1 side, the hydraulic fluid from the pump P1, flows into the
tank passage through the bypass passage and orifice. The restriction caused by this orifice thereby
pressurizes. This pressure is transferred as the negative control signal pressure Pn1 to the pump P1
regulator.
It controls the pump regulator so as to minimize the discharge of the pump P1.
The bypass passage is shut off when the shifting of one or more spools and the flow through bypass
passage became zero. The pressure of negative control signal become zero and the discharge of the
pump P1 become maximum.
The negative control pressure reaches to the set level, the hydraulic fluid in the passage pushes open
negative control valve and escapes into the return passage.
For the pump P2 the same negative control principle.

2-37
(10) OPERATION OF MAIN RELIEF VALVE
The main relief valve is fitted to the straight travel valve block and functions as follows :
Η The pressurized oil passes through the orifice (A) of the plunger is filled up in chamber A of the
inside space, and seats the plunger against the housing securely.

14072SF36

Θ When the pressure at (P) becomes equal to the set pressure of the spring the hydraulic oil
passes through the piston (A) pushes open the poppet and flows to tank passage (T) through the
hole (E).

14072SF37

2-38
Ι Opening the poppet causes the pressure in chamber A to fall and the plunger to open. As the
result the pressurized oil at port P runs into tank passage (T)

14072SF38

Κ High pressure setting pilot signal(Pu) : ON

When the power boost switch is ON, the pilot pressure enters through hole A.
It pushes the piston(B) in the left direction to increase the force of the spring and change the relief
set pressure to the high pressure.

14072SF36

2-39
(11) OPERATION OF PORT RELIEF VALVE
Η Function as relief valve
ͽ The pressurized oil passes through the piston A and orifice is filled up in chamber A of the
inside space and seat the plunger against the socket and the socket against the housing
securely.

14072SF39

; When the pressure at port P becomes equal to the set pressure of the spring, the pressurized
oil pushes open the poppet flows to tank passage (T) through hole E.

14072SF40

2-40
 Ϳ Opening of the poppet causes the pressure in chamber A to fall and the plunger to open. As
the result the pressurized oil at port P runs into tank passage (T).

14072SF41

Θ Make-up function
When negative pressure exists at port P, the oil is supplied through tank passage (T). When the
pressure at tank passage (T) becomes higher than that at port P, the socket moves in the right
direction. Then, sufficient oil passes around the socket from tank passage (T) to port P and fills
up the space.

14072SF42

2-41
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.

Time delay valve Mu Au SH PG PB

Oil gauge port

GA B Dr A GB

SH
PG
Port Port name Port size
Au A Main port PF 3/4
B Main port PF 3/4
Dr Drain port PF 3/8
Dr
Mu Make up port PF 1
GB GA SH Brake release port PF 1/4
PG Stand by port PF 1/4
GA, GB Gage port PF 1/4
B Mu A
Au Air bleed port PF 1/4
Hydraulic circuit
11072SM01

2-42
1) SWING MOTOR

11072SM02

1 Body 16 Brake piston 31 Check

2 Oil seal 17 O-ring 32 Relief valve assy
3 Roll bearing 18 O-ring 33 Reactionless valve assy
4 Snap ring 19 Spring 34 Time delay valve assy
5 Shaft 20 Rear cover 35 Wrench bolt
6 Bushing 21 Needle bearing 36 Plug
7 Pin 22 Pin 37 O-ring
8 Shoe plate 23 Valve plate 38 Plug
9 Cylinder block 24 O-ring 39 Plug
10 Spring 25 O-ring 40 Level gauge
11 Ball guide 26 Wrench bolt 41 Flange
12 Set plate 27 Plug 42 O-ring
13 Piston assy 28 Back up ring 43 Name plate
14 Friction plate 29 O-ring 44 Rivet
15 Plate 30 Spring

2-43
2) REDUCTION GEAR

2 26 27 28 17 1 22 20 21 18 25 8 12 4 10 23 3 19

6
12
11
29
24

7
5
13
9
16

11072SM03

1 Casing 10 Pin No.2 assembly 21 Plug(B)

2 Drive shaft 11 Pin No.1 22 Plug(A)
3 Ring gear 12 Thrust washer(B) 23 Spring pin
4 Planet gear No.2 13 Thrust washer(A) 24 Stop ring
5 Sun gear No.2 16 Knock pin 25 Stop ring
6 Planet gear No.1 17 Sph roller bearing 26 Spacer
7 Sun gear No.1 18 Cyl roller bearing 27 Cover plate
8 Carrier No.2 19 Bolt 28 Bolt
9 Carrier No.1 20 Oil seal 29 Needle cage

2-44
2. FUNCTION
1) ROTARY PART
When high pressurized oil enters a cylinder through port(a), which is the inlet of balance plate(1),
hydraulic pressure acting on the piston causes axial force F. The pressure force F works via the
piston(2) upon the return plate(3) which acts upon the swash plate(4) via an hydrostatic bearing.
Force F1 perpendicular to swash plate(4) and force F2 perpendicular to cylinder center.
Being transferred to the cylinder block(5) through piston, force F2 causes rotational moment at
surroundings of cylinder.
Since cylinder block has 9 equidistantly arrayed pistons, rotational torque is transmitted to cylinder
shaft in order by several pistons connected to the inlet port of high pressurized oil. When the
direction of oil flow is reversed, rotational direction of cylinder is also reversed. Output torque is
given by the equation.
pÝq F
T= , q=ZÂAÂPCDÂtanɾ, F1 = , F2=F tanɾ, S=PCDÝtanɾ
2ӕ COSɾ
Where p : Effective difference of pressure(kgf/cm2)
q : Displacement(cc/rev)
T : Output torque(kgfÂcm)
Z : Piston number(9EA)
A : Piston area(cm2)
ɾ: Tilting angle of swash plate(degree)
S : Piston stroke(cm)
PCD

ɾ S
F2
F1
F

a a Low
High High pressure oil
pressure oil pressure oil

4 3 2 5 1
R140LC-7 ‫׆‬೴2-46

2-45
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

R140LC-7 ‫׆‬೴2-47

2-46
3) RELIEF VALVE

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

(1) Construction of relief valve

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

(2) Function of relief valve

Figure illustrates how the pressure acting
on the relief valve is related to its rising P P=pressure, T=time
process. Here is given the function, Ps
referring to the figure following page.
4
P2

3
P1

T
1
R140LC-7 ‫׆‬೴2-48(2)

2-47
Η Ports (P,R) at tank pressure.

A2 m h n g

A1
P

R140LC-7 ‫׆‬೴2-49

Θ When hydraulic oil pressure(PÝA1) reaches the preset force(FSP) of spring(4), the plunger(3)
moves to the right as shown.
P1ÝA1=Fsp+PgÝA2

Fsp+PgÝA2
P1=
A1

4 g

P=P1

R140LC-7 ‫׆‬೴2-49

2-48
Ι The oil flow chamber g via orifice m and n. When the pressure of chamber g reaches the preset
force(FSP) of spring(4), the piston(6) moves left and stop the piston(6) hits the bottom of bushing(7).

4 m n g

P=P2

R140LC-7 ‫׆‬೴2-49

Κ When piston(6) hits the bottom of bushing(7), it stops moving to the left any further. As the
result, the pressure in chamber(g) equals(Ps).
PsÝA1=Fsp+PsÝA2
Fsp
Ps=
A1-A2

P=Ps

7 6 g

R140LC-7 ‫׆‬೴2-49

2-49
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

R140LC-7 ‫׆‬೴2-48(1)

(2) Mechanical swing parking brake system

The mechanical swing parking brake system is installed to prevent the upper structure from
swinging downhill because of its own weight when the excavator is parked on a slope since it
completely eliminates the hydraulic drift of swing motion while the excavator is on a slop, work can
be done more easily and safely.

Η Brake assembly
Circumferential rotation of separate
plate(14) is constrained by the groove
located at body(1). When housing is
pressed down by brake spring(19)
through lining plate(15), separate 19
plate(14) and brake piston(16), friction
force occurs there. 16
Cylinder(9) is constrained by this friction 14
force and brake acts, while brake
15
releases when hydraulic force exceeds Groove
9
spring force.
1
11072SM05

1 Body 15 Lining plate

9 Cylinder 16 Brake piston
14 Separate plate 19 Spring

2-50
Θ 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(6) to the upward against the force of the spring(7).
Thus, it releases the brake force.

5
7
G SH
6
8

1 Swing control lever

2 Swing control valve(MCV) 9
3 Time delay valve P3
4 Shuttle valve
5 Spool
6 Piston 2 2
7 Brake spring 4
8 Spring
9 Pilot pump
11072SM06

2-51
 b. Meantime, the oil pressure of port D balance with the preset force of spring(7), the pressure of
chamber G keeps constant pressure.

5
7
G SH
6
8

1 Swing control lever

2 Swing control valve(MCV)
3 Time delay valve 9
4 Shuttle valve P3
5 Spool
6 Piston
7 Brake spring 2 2
8 Spring 4
9 Pilot pump
11072SM07

2-52
 c. When the swing control(1) lever is set the neutral position, the spool(5) returns right in the time
delay valve(3).
Then, the piston(6) is moved lower by spring force and the return oil from the chamber G flows
back to tank.
At this time, the poppet works to make a time lag for 5 seconds.

5
7
G SH
6
8

1 Swing control lever

2 Swing control valve(MCV)
3 Time delay valve
4 Shuttle valve
5 Spool 9
6 Piston
P3
7 Poppet
8 Spring
9 Spring 2 2
10 Orifice 4
11 Spring
12 Pilot pump
11072SM07

2-53
 GROUP 4 TRAVEL DEVICE

1. CONSTRUCTION
Travel device consists travel motor and gear box.
Travel motor includes brake valve, parking brake and high/low speed changeover mechanism.

2 speed control port(PP3) Oil fill port(PF 1/2)

M2
M1
Oil level

Pressure gauge port(M1, M2) Drain port(PF 1/2)

T2 P2 P1 T1

R/G

Port Port name Port size

PP3
T1,T2 P1 Main port SAE 5000psi 1"
P2 Main port SAE 5000psi 1"
M1, M2 Gauge port PT 1/4
T1, T2 Drain port PF 1/2
PP3 2 speed control port PF 1/4

M1 M2

P1 P2

11072TM01

2-54
1) BASIC STRUCTURE

Reduction gear

Hydraulic motor

Brake valve

Parking brake

High/low speed
changeover mechanism

Control valve

Hydraulic pump

11072TM02

2-55
 2) STRUCTURE

84
3
83
22 83
22 17
82
8
19
12 21 81
33
32 21 104
37 105
31 39
38
30 36
40
41
40
20
13 103
29 16 11 102
35
28
49 27
26 2 101
25 34
47 24 6
63 61 23
48 15
62 10
46 56 5
45
50 4 86 85
98
9 95
74 42 14
75 41
71 9
44 18 7
79
65
67 43 88 87
68 89
90
60
45 94
59 51
57 46
58 53
63 52 48 98
55 47
66 63 54
64 69
73 49
78 96
72
75 91
70 93
77 76 92
97
11072TM04

2 Shaft 20 Brake piston 37 Retainer 54 Plug 71 Sleeve 89 Carrier

3 Cylinder barrel 21 Friction plate 38 Poppet 55 O-ring 72 Stopper 90 Sun gear B
4 Ball retainer 22 Steel plate 39 Spring 56 Orifice 73 Spring 91 Planetary gear B
5 Retainer 23 Disk spring 40 O-ring 57 Steel ball 74 Plug 92 Bushing
6 Cam 24 Shim(1.0T) 41 Pin 58 Plug 75 O-ring 93 Needle bearing B
7 Piston assembly 25 Shim(1.2T) 42 Bolt 59 O-ring 76 Screw 94 Snap ring
8 Valve plate 26 Shim(1.4T) 43 Motor cover assembly 60 Relief valve assembly 77 Nut 95 Thrust plate(2)
9 Plate 27 Shim(1.6T) 44 Spool assembly 61 Plug 78 O-ring 96 Thrust plate(3)
10 Piston assembly 28 Shim(1.8T) 45 Washer 62 O-ring 79 Rod 97 Thrust plate(4)
11 Ball bearing 29 Shim(2.0T) 46 Spring 63 Plug 81 Casing body 98 Screw
12 Roller bearing 30 O-ring 47 Cover 64 Plug 82 Floating seal 99 Washer
13 Oil seal 31 Back up ring 48 O-ring 65 Plug 83 Angular bearing 100 Parallel pin
14 Spring 32 O-ring 49 Bolt 66 O-ring 84 Ring nut 101 Cover
15 Spring 33 Back up ring 50 Orifice 67 Name plate 85 Casing gear 102 Spring washer
16 Steel ball 34 O-ring 51 Spool 68 Rivet 86 Sun gear A 103 Bolt
17 Pin 35 O-ring 52 Stopper 69 Spring guide 87 Planetary gear A 104 Plug
18 Snap ring 36 Seat 53 Spring 70 Plug 88 Needle bearing A 105 O-ring
19 Spring pin

2-56
2. FUNCTION
1) HYDRAULIC MOTOR
(1) Motoring function

Valve plate
Sun gear(A) Piston
(for 1st stage of
Planetary reduction gear)
Shaft

Spline

Spline

Cam
High Low
Cylinder barrel pressure pressure

11072TM05

High-pressure oil is supplied to the left port of motor.

The oil goes into the cylinder barrel through the valve plate. The high pressure pushes the piston
to the left. The piston moves to the left position and simultaneously rotates the cylinder barrel
sliding on the cam surface. Shaft is connected to the cylinder barrel and the planetary gear (A) is
connected to the shaft. So, the rotation is taken out by the sun gear rotation as shown.
When high-pressure oil is supplied to the opposite port of the motor, then the rotating direction is
reversed and the sun gear (A) rotates in the reversed direction.
The rotation of sun gear (A) is transferred to the reduction gear section.
The torque and speed generated by the motor depends on the displacement (=volume per
revolution) of the motor.
The volume per revolution depends on the cam angle Ø.

2-57
(2) Speed-shifting function
The torque and speed generated by the
motor depends on the displacement of the
motor. And the displacement depends on
Speed shifting piston
the cam angle Ø.
The bigger the cam angle Ø is, the higher
the torque is and the lower the speed is.
The smaller the cam angle Ø is, th lower Low speed mode
the torque is and the higher the speed is. (high torque)

This travel drive is equipped with a speed

shifting piston, and when high pressure oil
is supplied to it, the speed-shifting piston
pushes cam and makes the cam angle
O1
smaller. This means that the mode is
shifted from low speed mode to high
speed mode.

High pressure oil

supplied

High speed mode

(Low torque)

O1 O2
O2

11072TM06

2-58
(3) Parking brake function
This travel drive is equipped with a parking
brake. It gives parking brake torque to the
motor when high pressure oil is NOT
supplied to the motor and the motor is
NOT traveling. Also, it releases parking
Splined
brake when high-pressure oil is supplied
to the motor and the motor is traveling. Disk springs
Brake piston
As high-pressure oil is supplied to the
travel motor, the parking brake is quickly
Friction plates
released and the motor starts rotation. and steel plates
When the high pressure oil supply to the
motor stops, the motor stops rotation and
For brake Brake
the parking brake is slowly activated by releasing enacting
the brake piston motion because of the
Drain
force of a pair of disk springs.
Motoring
Slow activating and quick releasing of pressure
(High pressure)
parking brake can prevent possible Quick releasing Slow activating
damage to friction plates and steel plates.
11072TM07

2-59
2) BRAKE VALVE
(1) Counterbalance valve function
① Level travel GEAR
When high pressure oil is NOT supplied
Parking brake
to the brake valve, CBV spool is at the Relief valve
(Right)
center because of two springs beside it.
Relief valve
Now oil flow passage from motor is (Left)
closed.
When high-pressure oil is supplied to the
right port of brake valve, CBV spool is
moved to the left position because of the
pressure at the right end of CBV spool.
Now that oil-flow passage from the motor
is open at the left shoulder of the CBV
spool, oil flows and motor rotates.
Spring(s)
CBV Spool
When supplied pressure at the right port
is decreased during the vehicle
deceleration or stopping process, there is 11072TM08

a pressure decrease at the right end of

CBV spool.
Then CBV spool is moved to the right
direction because of the spring force at
the left side of CBV spool. Then oil-flow
passage from the motor at the shoulder
of the CBV spool gets narrower and at
last it is closed when high pressure oil
supply is shut-up to brake valve.
In this passage closing process, there
occurs a pressure increase in outlet side
of the motor ("=back pressure").

2-60
② Down-slope travel
・If there is NOT a counterbalance valve
equipped
When the vehicle travels down a slope,
GEAR
gravity makes the travel drives rotate
more speedily than you intended. The
"overrunning" cannot be controlled by the
supplying oil flow rate. Also, the pumps Outlet side Inlet side
cannot maintain the oil supply to the
motors and there will be a negative
pressure in the inlet side of motor. This
might cause cavitation in the travel
motors.
Parking brake
・Function and mechanism of counter- release line Low High
pressure pressure
balance valve
In down-slope traveling, the pressure at
the right port decreases because of lack
of supplied oil. Then, the pressure at the 11072TM09

right end of CBV spool also decreases

and CBV spool moves back to the right
direction from the left position. Now that
oil-flow passage from the motor at the
shoulder of the CBV spool gets narrower
and then there will occur a pressure
increase in outlet side of the motor
(="back pressure").
This "back pressure" can prevent the
motor from "overrunning" and cavitation.
③ Oil supply for parking brake release
For starting the travel drive rotation, when
pump oil is supplied to the right port of
brake valve, CBV spool moves to the left
position and also opens passage to
parking brake releasing.
When the travel drive is in "stop" state,
passage to brake releasing is closed.
As to the detail of parking brake function,
please refer to "(3) parking brake
function".

2-61
 (2) Crossover relief valve function

Shockless
piston

High pressure
Spring

Poppet
High pressure High pressure

(1) (2) (3) (4)

11072TM10

This travel drive is equipped with a pair of shockless crossover relief valves. The purpose is as
below :
・The relief valve prevents the ocurrence of a shock load while travel deceleration or stopping
process.
・It prevents overload to the motor.
・It compensates for the lack of oil during vehicle deceleration or stopping processes.
・The relief valves are "shockless" type, which is effective for shock reduction.
① If there is NOT a crossover relief valves equipped(considering two cases for example)
・ When the vehicle is in slowing down or stopping operation stage, a pressure increase (="back
pressure") occurs in the motor because of the function of counterbalance valve as mentioned in
"2)-(1) counterbalance valve function". If the stopping operation for vehicle is sudden, this "back
pressure" occurs suddenly and it may cause a shocking feeling for the opperator, or in worse
cases, break down of the machine.
・ When the vehicle is in the rotation starting operation stage, high pressure will be applied into the
motor. If the starting operation is too sudden, a sudden pressure increase occurs in the motor.
It may cause a shock.
In order to make the harmful pressure shock softer, and for operator feeling improvement or for
machine protection, this travel drive is equipped with crossover relief valve.

2-62
② Function and mechanism of shock-less crossover relief valves
Please refer to the figures in "2)-(1) counterbalance valve function" and on this page.
The explanation below is described about relief valve(right).
Firstly, the relief valve(right) is in condition (1) previous page.
When a sudden pressure increase occurs in the outlet side of the motor in deceleration or
stopping process, the shock of high pressure pushes down shockless piston in the relief valve as
shown in (2), while relieving high pressure oil with poppet moving up.
During moving down shockless piston, the pressure behind the poppet is not so high because of
the existence of flow moving down the shockless piston, and relieving pressure is rather low.
Next, when the shockless piston has been completely pushed down to the end of stroke as
shown in (3), the relieving pressure increases to the finally intended set pressure, because there
is no more flow moving down the shockless piston, and the pressure behind the poppet is high.
After stopping the motor, when you start rotating the motor again, resetting of shockless piston
occurs, pushing up the shockless piston up with the high pressure in the inlet side of the motor.
③ Oil compensation
During the relieving action, the relief valve also have a function of oil flow compensation giving the
relieved oil flow from the outlet side to the inlet side. This function helps to prevent a vacuum
condition in the motor.

2-63
 (3) Automatic 2-speed shifting function

Spool #2 PP3
for auto shifting "PP3"
(Independent from Inlet
Pilot
pilot fluctuation) ON/OFF R/G
Load pressure

PP3

Spool #1
for switching modes: M1 M2
Auto shifting mode
Low fixed mode Cam
(1) Speed P1 P2
shifting piston
(Light load) Selector valve
Load pressure

For speed
shifting piston Speed
shifting
piston

PP3
(2)-1 T
Steel ball
(Heavy load) Open
Seating
Load pressure

Stop
M2

P1 P2

(2)-2

11072TM11

Automatic 2-speed shifting function has two modes (1) and (2) as below :
・(1) Low speed fixed mode... always low speed
・(2) Automatic 2-speed shifting mode
(2)-1 When motor load pressure is light, High speed.
(2)-2 When motor load pressure is heavy, Low speed.
This function above consists of three components.
・Spool #1 for switching modes
Auto-shifting mode(if PP3 is applied)
Low-speed-fixed mode (if PP3 is NOT applied)
・Spool #2 for auto shifting
If load pressure < set value then High-speed
If load pressure > set value then Low-speed
・Selector valve, which always picks out high pressure and provide it to the SPOOL #2 regardless
of the rotating direction of motor.

2-64
Functions
Please refer to (1) shown above.
When the pilot pressure PP3 is NOT applied, SPOOL #1 is at the right position because of the
spring behind the spool. Now the motor is always at low speed regardless of the position of
SPOOL #2.
When the pilot pressure PP3 is applied, SPOOL #1 is at the left position because of PP3. Now
the motor is at automatic 2-speed-shifting mode. The displacement of the motor can be changed
based on the motor load pressure.
Please refer to (2)-1.
Now the pilot pressure is applied, and the motor is at automatic 2-speed-shifting mode. When the
motor load pressure is low, SPOOL #2 is at the right position because of the spring behind the
spool. And the load pressure is led to the chamber behind the speed-shifting piston and it pushes
piston and changes the cam angle smaller. This means that the motor is at High speed.
Please refer to (2)-2.
Now the pilot pressure is applied, and the motor is at automatic 2-speed-shifting mode. When the
motor load pressure is high, SPOOL #2 is at the left position because of the motor load pressure
pushing the spool to the left. Then the load pressure is locked at the SPOOL #2 and is NOT led to
the chamber behind the speed-shifting piston. The cam angle remains big. This means that the
motor is at Low speed.
As to the detail of cam angle change, please refer to "1) Hydraulic motor section (2) speed-shifting
function".

2-65
3) REDUCTION GEAR
(1) Function Planetary reduction gear system
A general construction of planetary
reduction gear system is as shown right.
The system mainly consists of these parts
below.
NAME Number of teeth
Sun Gear Zs
Planetary gears Zp
Carrier -
Ring gear Zr
① Planetary type
Firstly, let's think about the case that Ring
Gear is fixed and rotation is given to Sun
gear. This is called "PLANETARY TYPE" Carrier
as sun gear rotates clockwise, planetary
Sun gear
gears will revolve around sun gear, and
the revolution will rotate carrier. Planetary gear
Ring gear
Now we can take the clockwise rotation
11072TM12
at carrier by giving a clockwise rotation to
sun gear.
The rotation speed of carrier(output)is
different from that of sun gear(input) as
below.
(input)/(output) is called "Reduction
ratio(i)".
Reduction ratio (i) = (Input)/(Output) = Zr / Zs + 1

② Star type
Next let's think about the case that the
carrier is fixed and rotation is given to sun
gear. This is called "STAR TYPE" as sun
gear rotates clockwise, planetary gears
will rotate at the same position, and they
will make ring gear rotate counter-
clockwise.
Now we can take out a counterclockwise
rotation at ring gear by giving a clockwise
rotation to sun gear.
The rotation speed of ring gear is
different from that of sun gear as below.
Reduction ratio (i) = (Input)/(Output) = Zr / Zs

2-66
③ In the travel drive
This travel drive is equipped with 2-stage
planetary reduction gear system, which
consists of mixture of PLANETARY
TYPE and STAR TYPE.
Input is given to sun gear of 1ST stage and
output is taken out at ring gear.
Ring gear is commonly used in 1ST stage
and 2ND stage.
The reduction ratio is as below
Reduction ratio (i) = (Input)/(Output)
= (Zr / Zs1 + 1) × (Zr / Zs2 + 1) - 1
Here
Zs1 = Number of teeth for 1ST stage
sun gear
Zs2 = Number of teeth for 2ND stage
sun gear
Zr = Number of teeth for ring gear

2-67
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

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
25032RL01

2-68
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 12 Rod seal 22 Handle connector

2 Plug 13 O-ring 23 Nut
3 Plug 14 Push rod 24 Insert
4 O-ring 15 Plate 25 Boot
5 Spool 16 Bushing 26 Handle
6 Shim 17 Joint assembly 27 Switch assembly
7 Spring 18 Swash plate 28 Screw
8 Spring seat 19 Adjusting nut 29 Switch assembly
9 Stopper 20 Lock nut 30 Switch cover
10 Spring 21 O-ring 40 Boot
11 Plug

2-69
CROSS SECTION

14072SF80

2-70
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.

2-71
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

140LC-7 ‫׆‬೴2-70

1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder

2-72
(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.

2-73
(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.

2-74
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.

ä
12.4 12.4
ä

1 2

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

14072SF73

2-75
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) 14 Push rod 26 Bolt

2 Body(2) 15 Spring pin 27 Cam
3 Plug 16 Seal 28 Bushing
4 Plug 17 Steel ball 29 Cam shaft
5 Spring seat 18 Spring 30 Set screw
6 Spring 19 Plate 31 Set screw
7 Spring seat 20 Snap ring 32 Nut
8 Spool 21 Plug 33 Bellows
9 Stopper 22 O-ring 34 Space
10 Spring 23 Rod seal 35 O-ring
11 Rod guide 24 Dust seal 36 O-ring
12 O-ring 25 Cover 37 Bolt
13 Snap ring

2-76
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.

2-77
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

140LC-7 기타2-76

1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder

2-78
(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.

2-79
(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.

2-80
 SECTION 3 HYDRAULIC SYSTEM
GROUP 1 HYDRAULIC CIRCUIT

DR4
10 11 8 9
29
Pn2 Pn1
4 R/G R/G
4
C6
2
T1 T1 33 34 Pc6 D6 E
PP3 PP3 Pd6 28 28
O/R 380k
Pil
DR5
V2
B5

C5 A5 31 30
M2 M1 M1 M2
D5 Pb5 dr7
Pc5
35 36 Pd5 Pa5
1 PUMP
P1 P2 P2 P1 1 Pump
2 MAIN CONTROL VALVE
C4
O/R 380k
23 Main control
SWING MOTORvalve
B4
D4 DR3
34 Swing motor
TRACK MOTOR
Pb4
45
E
F
Pc40
Pc41
RCV
TrackLEVER(L/H)
motor
P Dr B Pa4

56 RCV
RCVLEVER(R/H)
D Pd40
C
A
Lever(L/H)
Pc42 7 RCV PEDAL
12 68 RCV Lever(R/H)
Pk V3 BOOM CYLINDER(L/H)
3 79 RCV Pedal
Pc3(Sh) Pb3
BOOM CYLINDER(R/H)
DR2 10
8 BoomCYLINDER
ARM cylinder(L/H)
Pa21 Pd41
Sh 11
9 BUCKET CYLINDER
Boom cylinder(R/H)
12 TURNING JOINT
B2 10 Arm cylinder
PG
C2
13 CHECK VALVE
D2 O/R
Pb21 A2
11
14 Bucket cylinder
CHECK VALVE
380k DR1
Pc2 Pb20 12
15 Turning joint TANK ASSY
HYDRAULIC
Pd2 Pa20
Dr 16
13 OIL COOLER
Check valve
17
14 AIR BREATHER
Check valve
C1 B1
18 RETURN FILTER
Pc1 Pb1 15
19
Hydraulic tank assy
D1
Pd1 Pa1
A1
STRAINER ASSY
16
20 Oil cooler
SPIN FILTER
27DR0 27
17
21 Air breather
LINE FILTER
A Mu B
P0
22
18 2-CARTRIDGE
Return filter VALVE
M/R 330(360)k 23 1-CARTRIDGE VALVE
Ai
T1 19 Strainer assy
24 ACCUMULATOR
SWING
5 6 7 TRAVEL
P2 P1 Pu 20
25 Spin filter
TERMINAL
ARM BUCKET BOOM
21
26 Line filter
LAST GUARD FILTER
27
22 PRESSURE SWITCH
2-Cartridge valve
28
23 SAFETY
1-CartridgeLOCK
valveVALVE
26 29 SAFETY LOCK VALVE
24 Accumulator
(1) (3) (2) (4) (3) (1) (2) (4) 30 PRESSURE SWITCH
Sh 25
31 Terminal
SHUT OFF VALVE
(1) (2) (3) (4)
Pd1 Pc1 Pa1 Pb1 26
32 Last guard filter
RCV-DOZER
B A D E G F H J
a1 A1 A2 a2 33
27 DOZER
PressureCYL.-L/H
switch
25Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20
13 34 DOZER CYL.-R/H
Dr#,T
3k
1.5k 1 28 Safety lock valve
14 35 CHECK VALVE
32 DOZER 29 Safety lock valve
16 36 CHECK VALVE
17 30 Pressure switch
24 Pi1 Pi2 31 Shut off valve
MCV'Pn2' MCV'Pn1'
23 Pu 22 Pk 26 32 RCV-Dozer
A1 A2 A1 (1) (2) 20 15 18
P4
33 Dozer cyl-L/H
PG(S/Motor) Pd5 Pc5
A2
P3
M 35k
34 Dozer cyl-L/H
P0
19 dr1
P2
21 35 Check valve
P1
T T 36 Check valve
T 11073HC01D

3-1
 GROUP 2 MAIN CIRCUIT

The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit.
The hydraulic system consists of one main pump, one control valve, one swing motor, four cylinders
and two travel motors.
The swash plate type variable displacement axial piston pump is used as the main pump and is
driven by the engine at ratio 1.0 of engine speed.

1. SUCTION AND DELIVERY CIRCUIT

To cylinders To motors

Main control valve To oil cooler

To hydraulic oil tank

Main pump
Suction filter

Hydraulic oil tank

140LC-7기타 3-02

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

Full flow filter Oil cooler Check valve(2)

1.5kgf/cm2

Main control valve Actuators

Check valve(1)
3.0kgf/cm2

Bypass relief valve

1.5kgf/cm2
140LC-7기타 3-03

All oil returned from each actuator returns to the hydraulic tank through the control valve.
The bypass check valves are provided in the return circuit.
The setting pressure of bypass check valves are 1.5kgf/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. When 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 returned from right and left side of control valve is combined and filtered by the full-flow filter. A
bypass relief valve is provided in the full-flow filter.
When the filter element is clogged, the bypass relief valve opens at 1.5kgf/cm2(21psi) differential pressure.

3-3
3. DRAIN CIRCUIT

Travel motor Swing motor

Main pump

Turning joint

Bypass valve
1.5kgf/cm2

Spin filter
Hydraulic
oil tank

140LC-7기타 3-04

Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil have
to be fed to the hydraulic tank passing through spin filter.
When the drain oil pressure exceed 1.5kgf/cm2(21psi), the oil returns to the hydraulic tank directly.

1) TRAVEL MOTOR DRAIN CIRCUIT

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

3-4
 GROUP 3 PILOT CIRCUIT

Remote control valve Remote control valve

RCV pedal RCV dozer
(LH lever) (RH lever)

Safety lock
solenoid valve Swing parking brake

Control valve

Travel speed solenoid valve

Power boost solenoid valve

Line filter
Main pump
Relief valve
35kgf/cm2

Pilot pump
Suction filter

11073HC00

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

3-5
1. SUCTION, DELIVERY AND RETURN CIRCUIT
DOZER ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pc5 Pb5
Pd5 Pa5
DOZER BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pa4
Pd40
ARM 1
Pc42
ARM
SWING MOTOR V3 REGENERATION
Pc3
(sh) Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
A2
D2 Pb21
DR1
Pc2 Pb20
Pd2 Pa20
DOZER SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)
Pd5 Pc5
P0
T1
TRAVEL
Pu

FRONT REAR
Dr#,T PUMP PUMP PILOT
(1) (2) (3) (4)
Pd1 Pc1 Pa1 Pb1 PUMP

SW AM BK BM

Pu Pk

A4 A2 A1
P4 PG
(1) (3) (2) (4) (3) (1) (2) (4)
P3 P0 HYDRAULIC TANK
sh
P2
B A D E G F H J P1
Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20 T LINE FILTER
11073HC02

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

3-6
2. SAFETY VALVE(SAFETY LEVER)

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
DOZER BUCKET

C4
D4 B4
DR3
Pc41 Pb4
Pc40 Pa4
Pd40
ARM 1
Pc42
ARM
SWING MOTOR V3 REGENERATION
Pc3
(sh) Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
A2
D2 Pb21
DR1
Pc2 Pb20
Pd2 Pa20
DOZER SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)
Pd5 Pc5
P0
T1
TRAVEL
Pu

FRONT REAR
Dr#,T PUMP PUMP PILOT
(1) (2) (3) (4)
Pd1 Pc1 Pa1 Pb1 PUMP

SAFETY
SW AM BK BM SOLENOID
VALVE
Pu Pk LEVER
A4 A2 A1
UP
P4 PG
(1) (3) (2) (4) (3) (1) (2) (4)
P3 P0 HYDRAULIC TANK
sh
P2
P1
B A D E G F H J

Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20 T LINE FILTER
LEVER DOWN
11073HC03

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

3-7
 3. SWING PRIORITY SYSTEM
DOZER ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6 SWING
PRIORITY
OPTION
SPOOL
B5
C5 A5
D5 Pc5 Pb5
Pd5 Pa5
DOZER BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pa4
Pd40
ARM 1
Pc42
ARM
SWING MOTOR V3 REGENERATION
Pc3
(sh) Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
A2
D2 Pb21
DR1
Pc2 Pb20
Pd2 Pa20
DOZER SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
TRAVEL(RH) TRAVEL(LH)
Pd5 Pc5
P0
T1
TRAVEL
Pu

FRONT REAR
Dr#,T PUMP PUMP PILOT
(1) (2) (3) (4)
Pd1 Pc1 Pa1 Pb1 PUMP

SW AM BK BM

Pu Pk

A4 A2 A1
P4 PG
(1) (3) (2) (4) (3) (1) (2) (4)
sh P3 P0 HYDRAULIC TANK
P2
P1
B A D E G F H J

Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20 T LINE FILTER
11073HC04

When carrying out the combined operation of swing and boom or arm of the left control valve, the
swing speed can be lowered than operating speed of boom or arm. To prevent it, swing priority spool
is used. Pc3 pressure from shuttle valve(sh) shifts the swing priority spool to the left and decreases
the oil flow rate to the boom or arm section by orifice.
This is called the swing priority system.

3-8
 4. TRAVEL SPEED CONTROL SYSTEM
DOZER ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

CONTROL PISTON

R/G R/G

T1 T1
PP3 PP3
Pn2 Pn1

C6
M2 D6
M2 M1 M1 Pc6
Pd6
OPTION
P1 P2 P2 P1

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
DOZER BUCKET

dr3
C4
Pk
D4 B4
DR3
Pc41 Pb4
Pc40 Pa4
Pd40
ARM 1
Pc42
ARM
SWING MOTOR V3 REGENERATION
Pc3
(sh) Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
A2
D2 Pb21
DR1
Pc2 Pb20
Pd2 Pa20
DOZER SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)
Pd5 Pc5
P0
T1
TRAVEL
Pu

FRONT REAR
Dr#,T PUMP PUMP PILOT
(1) (2) (3) (4)
Pd1 Pc1 Pa1 Pb1 PUMP

SW AM BK BM

Pu Pk

A4 A2 A1
P4 PG
(1) (3) (2) (4) (3) (1) (2) (4)
P3 P0 HYDRAULIC TANK
sh
P2
P1
B A D E G F H J

Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20 T LINE FILTER

11073HC05

When the travel speed switch is pushed, the travel speed solenoid valve is actuated and the
discharged oil from the pilot pump flows to the Pk port of pilot valve in the travel motors.
As a result, the control piston is pushed by the main oil flow, thus the displacement is minimized.
When the travel speed switch is pushed once more, the travel speed solenoid valve is return to
original position by the force of spring, the hydraulic oil of Pk port retums to the hydraulic tank.
As a result, the control piston is returned by the main oil flow, thus the displacement is maximized.

3-9
5. MAIN RELIEF PRESSURE CHANGE SYSTEM

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
DOZER BUCKET

C4
D4 B4
DR3
Pc41 Pb4
Pc40 Pa4
Pd40
ARM 1
Pc42
ARM
SWING MOTOR V3 REGENERATION
Pc3
(sh) Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
A2
D2 Pb21
DR1
Pc2 Pb20
Pd2 Pa20
DOZER SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)
Pd5 Pc5
P0
T1
TRAVEL
Pu

FRONT REAR
Dr#,T PUMP PUMP PILOT
(1) (2) (3) (4)
Pd1 Pc1 Pa1 Pb1 PUMP

SW AM BK BM

Pu Pk

A4 A2 A1
P4 PG
(1) (3) (2) (4) (3) (1) (2) (4)
P3 P0 HYDRAULIC TANK
sh
P2
P1
B A D E G F H J

Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20 T LINE FILTER
11073HC06

When the power boost switch on the left control lever is pushed ON, the power boost solenoid valve is
actuated, the discharged oil from the pilot pump flows into Pu port of the main relief valve of main
control valve; then the setting pressure of the main relief valve is raised from 330kgf/cm2 to 360kgf/cm2 for
increasing the digging power. And even when pressed continuously, it is canceled after 8 seconds.

3 - 10
6. SWING PARKING BRAKE RELEASE
DOZER ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pc5 Pb5
SWING MOTOR Pd5 Pa5
DOZER BUCKET

SH
C4
D4 B4
PG DR3
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
ARM
V3 REGENERATION
Pc3
DR (sh) Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

A Mu
B2
B C2
A2
D2 Pb21
DR1
Pc2 Pb20
Pd2 Pa20
DOZER SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
TRAVEL(RH) TRAVEL(LH)
Pd5 Pc5
P0

T1
TRAVEL
Pu

FRONT REAR
Dr#,T PUMP PUMP PILOT
(1) (2) (3) (4)
Pd1 Pc1 Pa1 Pb1 PUMP

SW AM BK BM

Pu Pk

A4 A2 A1
P4 PG
(1) (3) (2) (4) (3) (1) (2) (4)
SH P3 P0 HYDRAULIC TANK
P2
P1
B A D E G F H J

Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20 T LINE FILTER
11073HC07

When the swing control lever is tilted, the pilot oil flow into SH port of shuttle valve, this pressure move
spool so, discharged oil from pilot valve flow into PG port.
This pressure is applied to swing motor disc, thus the brake is released.
When the swing control lever is set in the neutral position, oil in the swing motor disc cylinder is
drained, thus the brake is applied.

3 - 11
GROUP 4 SINGLE OPERATION
1. BOOM UP OPERATION
DOZER ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC10

When the right control lever is pulled back, the boom spools in the main control valve are moved to the
up position by the pilot oil pressure 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 - 12
2. BOOM DOWN OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC11

When the right 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 front pump flows into the main control valve and then goes to the small chamber of
boom cylinders. At the same time, the oil from the large chamber of boom cylinders returns to the
hydraulic tank through the boom spool in the main control valve.
When the down speed of boom is faster, the oil returned from the large chamber of boom cylinder
combines with the oil from the front pump, and flows into the small chamber of the cylinder.
This prevents cylinder cavitation by the negative pressure when the front pump flow can not match the
boom down speed. And the excessive pressure in the boom cylinder rod end circuit is prevented by
the relief valve.

3 - 13
3. ARM ROLL IN OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC12

When the left control lever is pulled back, the arm spools in the main control valve are moved the to
roll in position by the pilot oil pressure from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the large
chamber of arm cylinder.
At the same time, the oil from small chamber of arm cylinder returns to the hydraulic oil tank through
the arm spool in the main control valve. When this happens, the arm rolls in.
The cavitation which will happen to the bottom of the arm cylinder is also prevented by the make-up
valve in the main control valve.

3 - 14
4. ARM ROLL OUT OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC13

When the left control lever is pushed forward, the arm spool in the main control valve are moved to the
roll out position by the pilot oil pressure from the remote control valve.
The oil from the front 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 rolls out.
The cavitation which will happen to the rod of the arm cylinder is also prevented by the make-up valve
in the main control valve.

3 - 15
5. BUCKET ROLL IN OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC14

When the right control lever is pulled left, the bucket spool in the main control valve is moved to the roll
in position by the pilot oil pressure from the remote control valve.
The oil from the front pump flows into the main control valve and then goes to the large chamber of
bucket cylinder.
At the same time, the oil from the small chamber of bucket cylinder returns to the hydraulic oil tank
through the boom spool in the main control valve. When this happens, the bucket rolls in.
The cavitation which will happen to the bottom of the bucket cylinder is also prevented by the make-up
valve in the main control valve.

3 - 16
6. BUCKET ROLL OUT OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR V3
ARM
REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC15

When the right control lever is pushed right, the bucket spool in the main control valve is moved to the
roll out position by the pilot oil pressure from the remote control valve.
The oil from the front pump flows into the main control valve and then goes to the small chamber of
bucket cylinder.
At the same time, the oil from the large chamber of bucket cylinder retums to the hydraulic oil tank
through the bucket spool in the main control valve. When this happens, the bucket rolls out.
The cavitation which will happen to the rod of the bucket cylinder is also prevented by the make-up
valve in the main control valve.

3 - 17
7. SWING OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER
TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pc5 Pb5
Pd5 Pa5
SWING MOTOR OPTION BUCKET

SH
C4
D4 DR3 B4
PG
Pc41 Pb4
Pc40
Pa4
Pd40
ARM 1
ARM Pc42
V3 REGENERATION
DR Pc3
DR2 Pb3
Pa21 Pd41
BOOM 2 ARM 2

A Mu B C2 B2

D2 Pb21 A2
DR1
Pc2 Pb20
Pd2 Pa20
DOZER SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
TRAVEL(RH) TRAVEL(LH)
Pd5 Pc5
P0
TRAVEL T1
Pz

FRONT REAR
Dr#,T PUMP PUMP PILOT
(1) (2) (3) (4)
Pd1 Pc1 Pa1 Pb1 PUMP

SW AM BK BM

Pu Pk

A4 A2 A1

(1) (3) (2) (4) (3) (1) (2) (4) P4 PG

P3 P0 HYDRAULIC TANK
sh
P2
P1
B A D E G F H J

Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20 LINE FILTER
T

11073HC16

When the left control lever is pushed left or right, the swing spool in the main control valve is moved to
the left or right swing position by the pilot oil pressure from the remote control valve.
The oil from the rear pump flows into the main control valve and then goes to the swing motor.
At the same time, the return oil from the swing motor returns to the hydraulic oil tank through the swing
spool in the main control valve.
When this happens, the superstructure swings to the left or right.
The swing parking brake, make up valve and the overload relief valve are provided in the swing
motors. The cavitation which will happen to the swing motor is also prevented by the make up valve in
the swing motor itself.

3 - 18
SWING CIRCUIT OPERATION

PARKING BRAKE
SH BRAKE RELEASE VALVE
BRAKE OFF
BRAKE ON

DR

MOTOR BRAKE VALVE

A B MAKE UP VALVE
Mu(MAKE UP PORT)

TO/FROM MAIN CONTROL VALVE 11073HC30

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 - 19
8. TRAVEL FORWARD AND REVERSE OPERATION
DOZER ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

R/G R/G

T1 T1
PP3 PP3
Pn2 Pn1

C6
M2 M2 D6
M1 M1 Pc6
Pd6
OPTION
P1 P2 P2 P1

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
DOZER BUCKET

dr3
C4
Pk
D4 B4
DR3
Pc41 Pb4
Pc40 Pa4
Pd40
ARM 1
Pc42
ARM
SWING MOTOR V3 REGENERATION
Pc3
(sh) Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
A2
D2 Pb21
DR1
Pc2 Pb20
Pd2 Pa20
DOZER SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)
Pd5 Pc5
P0
T1
TRAVEL
Pu

FRONT REAR
Dr#,T PUMP PUMP PILOT
(1) (2) (3) (4)
Pd1 Pc1 Pa1 Pb1 PUMP

SW AM BK BM

Pu Pk

A4 A2 A1
P4 PG
(1) (3) (2) (4) (3) (1) (2) (4)
P3 P0 HYDRAULIC TANK
sh
P2
P1
B A D E G F H J

Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20 T LINE FILTER
11073HC17

When the travel levers are pushed forward or reverse position, the travel spools in the main control
valve are moved to the forward or reverse travel position by the pilot oil pressure from the remote
control valve.
The oil from the both pumps flows into the main control valve and then goes to the both travel motors
through the turning joint.
The return oil from both travel motors returns to the hydraulic oil tank through the turning joint and the
travel spools in the main control valve.
When this happens, the machine moves to the forward or reverse.

3 - 20
TRAVEL CIRCUIT OPERATION

Overload relief valve

R/G R/G

T1 T1
PP3 PP3

M2 M1 M1 M2

P1 P2 P2 P1

Check valve
Counter balance valve
Turning joing

11073HC17A

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 at 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 - 21
9. DOZER UP OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pc5 Pb5
Pd5 Pa5
DOZER BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
ARM
SWING MOTOR V3 REGENERATION

Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC18

When the dozer control lever is pulled back, the dozer spool in the main control valve is moved to the
dozer up 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
dozer cylinders.
At the same time, the oil from the large chamber of dozer cylinders returns to the hydraulic oil tank
through the dozer spool in the main control valve. When this happens, the dozer goes up.

3 - 22
10. DOZER DOWN OPERATION
DOZER ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pc5 Pb5
Pd5 Pa5
DOZER BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
ARM
SWING MOTOR V3 REGENERATION

Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC19

When the dozer control lever is pushed forward, the dozer spool in the main control valve is moved to
the dozer 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 large chamber of
dozer cylinders.
At the same time, the oil from the small chamber of dozer cylinders returns to the hydraulic oil tank
through the dozer spool in the main control valve. When this happens, the dozer blade is down.

3 - 23
GROUP 4 SINGLE OPERATION
1. BOOM UP OPERATION
DOZER ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC10

When the right control lever is pulled back, the boom spools in the main control valve are moved to the
up position by the pilot oil pressure 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 - 12
2. BOOM DOWN OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC11

When the right 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 front pump flows into the main control valve and then goes to the small chamber of
boom cylinders. At the same time, the oil from the large chamber of boom cylinders returns to the
hydraulic tank through the boom spool in the main control valve.
When the down speed of boom is faster, the oil returned from the large chamber of boom cylinder
combines with the oil from the front pump, and flows into the small chamber of the cylinder.
This prevents cylinder cavitation by the negative pressure when the front pump flow can not match the
boom down speed. And the excessive pressure in the boom cylinder rod end circuit is prevented by
the relief valve.

3 - 13
3. ARM ROLL IN OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC12

When the left control lever is pulled back, the arm spools in the main control valve are moved the to
roll in position by the pilot oil pressure from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the large
chamber of arm cylinder.
At the same time, the oil from small chamber of arm cylinder returns to the hydraulic oil tank through
the arm spool in the main control valve. When this happens, the arm rolls in.
The cavitation which will happen to the bottom of the arm cylinder is also prevented by the make-up
valve in the main control valve.

3 - 14
4. ARM ROLL OUT OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC13

When the left control lever is pushed forward, the arm spool in the main control valve are moved to the
roll out position by the pilot oil pressure from the remote control valve.
The oil from the front 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 rolls out.
The cavitation which will happen to the rod of the arm cylinder is also prevented by the make-up valve
in the main control valve.

3 - 15
5. BUCKET ROLL IN OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC14

When the right control lever is pulled left, the bucket spool in the main control valve is moved to the roll
in position by the pilot oil pressure from the remote control valve.
The oil from the front pump flows into the main control valve and then goes to the large chamber of
bucket cylinder.
At the same time, the oil from the small chamber of bucket cylinder returns to the hydraulic oil tank
through the boom spool in the main control valve. When this happens, the bucket rolls in.
The cavitation which will happen to the bottom of the bucket cylinder is also prevented by the make-up
valve in the main control valve.

3 - 16
6. BUCKET ROLL OUT OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR V3
ARM
REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC15

When the right control lever is pushed right, the bucket spool in the main control valve is moved to the
roll out position by the pilot oil pressure from the remote control valve.
The oil from the front pump flows into the main control valve and then goes to the small chamber of
bucket cylinder.
At the same time, the oil from the large chamber of bucket cylinder retums to the hydraulic oil tank
through the bucket spool in the main control valve. When this happens, the bucket rolls out.
The cavitation which will happen to the rod of the bucket cylinder is also prevented by the make-up
valve in the main control valve.

3 - 17
7. SWING OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER
TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pc5 Pb5
Pd5 Pa5
SWING MOTOR OPTION BUCKET

SH
C4
D4 DR3 B4
PG
Pc41 Pb4
Pc40
Pa4
Pd40
ARM 1
ARM Pc42
V3 REGENERATION
DR Pc3
DR2 Pb3
Pa21 Pd41
BOOM 2 ARM 2

A Mu B C2 B2

D2 Pb21 A2
DR1
Pc2 Pb20
Pd2 Pa20
DOZER SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
TRAVEL(RH) TRAVEL(LH)
Pd5 Pc5
P0
TRAVEL T1
Pz

FRONT REAR
Dr#,T PUMP PUMP PILOT
(1) (2) (3) (4)
Pd1 Pc1 Pa1 Pb1 PUMP

SW AM BK BM

Pu Pk

A4 A2 A1

(1) (3) (2) (4) (3) (1) (2) (4) P4 PG

P3 P0 HYDRAULIC TANK
sh
P2
P1
B A D E G F H J

Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20 LINE FILTER
T

11073HC16

When the left control lever is pushed left or right, the swing spool in the main control valve is moved to
the left or right swing position by the pilot oil pressure from the remote control valve.
The oil from the rear pump flows into the main control valve and then goes to the swing motor.
At the same time, the return oil from the swing motor returns to the hydraulic oil tank through the swing
spool in the main control valve.
When this happens, the superstructure swings to the left or right.
The swing parking brake, make up valve and the overload relief valve are provided in the swing
motors. The cavitation which will happen to the swing motor is also prevented by the make up valve in
the swing motor itself.

3 - 18
SWING CIRCUIT OPERATION

PARKING BRAKE
SH BRAKE RELEASE VALVE
BRAKE OFF
BRAKE ON

DR

MOTOR BRAKE VALVE

A B MAKE UP VALVE
Mu(MAKE UP PORT)

TO/FROM MAIN CONTROL VALVE 11073HC30

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 - 19
8. TRAVEL FORWARD AND REVERSE OPERATION
DOZER ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

R/G R/G

T1 T1
PP3 PP3
Pn2 Pn1

C6
M2 M2 D6
M1 M1 Pc6
Pd6
OPTION
P1 P2 P2 P1

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
DOZER BUCKET

dr3
C4
Pk
D4 B4
DR3
Pc41 Pb4
Pc40 Pa4
Pd40
ARM 1
Pc42
ARM
SWING MOTOR V3 REGENERATION
Pc3
(sh) Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
A2
D2 Pb21
DR1
Pc2 Pb20
Pd2 Pa20
DOZER SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)
Pd5 Pc5
P0
T1
TRAVEL
Pu

FRONT REAR
Dr#,T PUMP PUMP PILOT
(1) (2) (3) (4)
Pd1 Pc1 Pa1 Pb1 PUMP

SW AM BK BM

Pu Pk

A4 A2 A1
P4 PG
(1) (3) (2) (4) (3) (1) (2) (4)
P3 P0 HYDRAULIC TANK
sh
P2
P1
B A D E G F H J

Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20 T LINE FILTER
11073HC17

When the travel levers are pushed forward or reverse position, the travel spools in the main control
valve are moved to the forward or reverse travel position by the pilot oil pressure from the remote
control valve.
The oil from the both pumps flows into the main control valve and then goes to the both travel motors
through the turning joint.
The return oil from both travel motors returns to the hydraulic oil tank through the turning joint and the
travel spools in the main control valve.
When this happens, the machine moves to the forward or reverse.

3 - 20
TRAVEL CIRCUIT OPERATION

Overload relief valve

R/G R/G

T1 T1
PP3 PP3

M2 M1 M1 M2

P1 P2 P2 P1

Check valve
Counter balance valve
Turning joing

11073HC17A

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 at 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 - 21
9. DOZER UP OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pc5 Pb5
Pd5 Pa5
DOZER BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
ARM
SWING MOTOR V3 REGENERATION

Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC18

When the dozer control lever is pulled back, the dozer spool in the main control valve is moved to the
dozer up 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
dozer cylinders.
At the same time, the oil from the large chamber of dozer cylinders returns to the hydraulic oil tank
through the dozer spool in the main control valve. When this happens, the dozer goes up.

3 - 22
10. DOZER DOWN OPERATION
DOZER ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pc5 Pb5
Pd5 Pa5
DOZER BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
ARM
SWING MOTOR V3 REGENERATION

Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC19

When the dozer control lever is pushed forward, the dozer spool in the main control valve is moved to
the dozer 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 large chamber of
dozer cylinders.
At the same time, the oil from the small chamber of dozer cylinders returns to the hydraulic oil tank
through the dozer spool in the main control valve. When this happens, the dozer blade is down.

3 - 23
GROUP 5 COMBINED OPERATION
1. OUTLINE

DOZER BOOM
CYLINDER ARM BUCKET CYLINDER
CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pc5 Pb5
Pd5 Pa5
OPTION BUCKET

C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
Pc42
ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
D2 A2
Pb21
DR1
Pc2 Pb20
Pd2 Pa20
BOOM 1
SWING

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)
DR0
P0
Ai T1
Pz

HYDRAULIC TANK STRAIGHT

TRAVEL
SPOOL FRONT REAR PILOT
PUMP PUMP PUMP

11073HC20

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 for straight travel is provided in the main control valve.
If any actuator is operated when traveling, the straight travel spool is pushed to the left by the pilot oil
pressure.
Consequently, the left and right travel oil supply passage are connected, and equivalent amount of oil
flows into the left and right travel motors. This keeps the straight travel.

3 - 24
2. COMBINED SWING AND BOOM OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR V3 ARM
REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC21

When the swing and boom functions are operated, simultaneously the swing spool and boom spools
in the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve.
The oil from the rear pump flows into the swing motor through swing spool and the boom cylinder
through boom 2 spool.
The oil from the front pump flows into the boom cylinders through the boom 1 spool.
The superstructure swings and the boom is operated.

3 - 25
3. COMBINED SWING AND ARM OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC22

When the swing and arm functions are operated, simultaneously the swing spool and arm spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve.
The oil from the rear pump flows into the swing motor through swing spool and the arm cylinder
through arm 1 spool.
The oil from the front pump flows into the arm cylinder through the arm 2 spool.
The superstructure swings and the arm is operated.

3 - 26
4. COMBINED SWING AND BUCKET OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6

OPTION
Pd6

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC23

When the swing and bucket functions are operated, simultaneously the swing spool and bucket spool
in the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve.
The oil from the rear pump flows into the swing motor through the swing spool.
The oil from the front pump flows into the bucket cylinder through the bucket spool.

3 - 27
5. COMBINED SWING, BOOM, ARM AND BUCKET OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC24

When the swing, boom, arm and bucket functions are operated, simultaneously each spool in the
main control valve is moved to the functional position by the pilot oil pressure from the remote control
valve.
The oil from the rear pump flows into the swing motor, boom cylinders and arm cylinder through the
swing spool, boom 2 spool, arm 1 spool, and the parallel and confluence oil passage.
The oil from the front pump flows into the boom cylinders, arm cylinder and bucket cylinder through
the boom 1 spool, arm 2 spool, bucket spool and the parallel and confluence oil passage.
The superstructure swings and the boom, arm and bucket are operated.

3 - 28
6. COMBINED SWING AND TRAVEL OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC25

When the swing and travel functions are operated, simultaneously the swing spool and travel spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve and straight travel spool is pushed to the left by the pilot oil pressure from the pilot pump.
The oil from the rear pump flows into the swing motor through the swing spool. The oil from the front
pump flows into the travel motor through the RH travel spool and the LH travel spool via the straight
travel spool.
The superstructure swings and the machine travels straight.

3 - 29
7. COMBINED BOOM AND TRAVEL OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2
Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC26

When the boom and travel functions are operated, simultaneously the boom spools and travel spools
in the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve and the straight travel spool is pushed to the left by the oil pressure from pilot pump.
The oil from the rear pump flows into the boom cylinders through the boom 2 spool and boom 1 spool
via the parallel and confluence oil passage in case boom up operation. The oil from the front pump
flows into the travel motors through the RH travel spool and the LH travel spool via the straight travel
spool.

3 - 30
8. COMBINED ARM AND TRAVEL OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC27

When the arm and travel functions are operated, simultaneously the arm spools and travel spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve and the straight travel spool is pushed to the left by the oil pressure from pilot pump.
The oil from the rear pump flows into the arm cylinders through the arm 1 spool and arm 2 spool via
the parallel and confluence oil passage. The oil from the front pump flows into the travel motors
through the RH travel spool and the LH travel spool via the straight travel spool.
The arm is operated and the machine travels straight.

3 - 31
9. COMBINED BUCKET AND TRAVEL OPERATION

DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pn2 Pn1

C6
D6
Pc6
Pd6
OPTION

B5
C5 C5 A5
D5 D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET

C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR V3
ARM
REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2

B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1

C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1

TRAVEL(RH) TRAVEL(LH)

P0
T1
Pz

HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP

11073HC28

When the bucket and travel functions are operated, simultaneously the bucket spool and travel spools
in the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve, and the straight travel spool is pushed to the left by the oil pressure from pilot pump.
The oil from the rear pump flows into the bucket cylinder through the bucket spool via the confluence
oil passage. The oil from the front pump flows into the travel motors through the RH travel spool and
the LH travel spool via the straight travel spool of the control valve.
The bucket is operated and the machine travels straight.

3 - 32
 SECTION 4 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION

1. LOCATION 1

22
21
20
23

24
19
1
2 18
Switch
3 panel

TONE 2

5 BAL

VOL
ON
BAND

SEEK
push

FAD
TUNE
1

4 PROG
3

PLL
SYNTHESIZE

R
TUNNING

4
5

6
14
20A

15
CAB

SPARE
HOLDER

LAMP
SPARE
FUSE

CABIN

LAMP
LAMP SPARE
BEACON
WORK
F/PUMP
LAMP & HEATER FUEL
AC
HEAD 3

MOTOR SOLENOID
LAMP HONE
WIPER 2
BOOM
SOL. LIGHT
SOLENOID
CIGAR
& HEATER SAFETY 1
AC
PANEL - HEAT SOLENOID
MOTOR PRE
SWITCH
WIPER
RY
CUT-OFF TRAVEL
FUEL
CONVERTOR HONE
PANEL

SWITCH RY -2
CR
COMP
AC RY
-7 ETHER
RY CR
POWER - 36
CR

16
- 35
CR
RY

SAFETY
-5
CR

17
13
7
12
11
10
9
8

11074EL01

1 Main light switch 9 Safety lever 17 Fuse box

2 Quick coupling switch 10 Power max switch 18 Speaker
3 Overload switch 11 One touch decel switch 19 Cassette radio
4 Horn switch 12 Air-con switch 20 Travel alarm stop switch
5 Breaker operation switch 13 Master switch 21 Breaker selection switch
6 Cluster 14 Electric box 22 Beacon switch
7 Hour meter 15 CPU controller 23 Accel dial
8 Emergency engine 16 Prolix resistor 24 Start switch
acceleration lever

4-1
2. LOCATION 2

10

1
ON
1
12
F
OF

11
3 EPPR VLV

START MOTOR
4
AIR HEATER CABLE

A/C COMP.
5
1

11074EL02

1 Lamp 5 Alternator 9 Fuel filler pump

2 Horn 6 Battery 10 Beacon lamp
3 Fuel sender 7 Travel alarm buzzer 11 Heater relay
4 Temp sender 8 Battery relay 12 Air cleaner switch

4-2
GROUP 2 ELECTRICAL CIRCUIT

INTAKE M/ACT TEMP M/ACT MODE(D/FOOT) MODE(VENT) RESISTOR RELAY(HI) RELAY(M2)

2 7 2 7
103 3L FUSE BOX 5W 104
1 4 1 4 BLOWER 3R 105
3 M M 3 M M

3
7

1
7

Lo 1

4
ML 2
MH 3
5 5 POWER RY

M
Hi

4
2

2
5
6
7
5
6
7

5
6
7
1
2
3
4
5
6
7

1
2
3
4

1
2
3
4
1
2
3
4

10

105
1

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

116
5W 104
5W 115
85

86
AC COMP RY

1
2
3
4

30A

10A

20A

20A

10A

10A

10A

20A

10A

20A

20A

20A

10A

10A

10A

20A

10A

10A

10A

30A
2
1

1
4

4
2
3

2
3

5A

5A

5A

5A

5A

5A

5A

5A
87a 87
GW

WR

30
BW

WB

BG
BG

GB

GB

3R
GL

YB

3R
LR

LB
Y

Y
R/DRYER HORN RY

YBr
YW

85
LG

86
YW

CR-35
BG
RY

RY

2B
YB
L

L
20A

87a
9A

9B
21

22
17
20

18
19

23

24
25
16

15

Pa

CN-60
87a 87

CN-95
30
30
86

85
87

CASSETTE RADIO

85

86
36A

2
1
26
35
27

FUEL FILLER P/P

33A

2
1
32
36
6B

6A

CIGAR LIGHTER
29
33

36

28

35

WIPER MOTOR

ANTI-RESTART
FUEL CUT-OFF

BEACON LAMP

87a 87

30
PRE-HEAT RY

CN-29
AC& HEATER

CONVERTOR

AC& HEATER

87a
SAFETY SOL

CR-7
ROOM LAMP

WORK LAMP
AC BLOWER

HEAD LAMP

30
86

85
Or
3L

87
START KEY
W

2
1
B

SOLENOID

SOLENOID
ALT,STOP
CLUSTER
BATTERY

TRAVEL
WIPER+

CR-2
CPU B+

87a
SPARE
CN-36

30
86

85
G42

87
HORN

V/W
103
FUSIBLE LINK

CPU
18
90
HARNESS FRAME

G
G
L
L
60R 60B 60B

BR
BR
106

106
101

R
GY/W

Y
4A
4E
85
RW
GY

OR

OR
GY

GY

GY

GY
BR

BR
HARNESS AIR-CON

2R

2L
W
12V X 2

G
R

R
Y

Y
L
MASTER SW

5A
22
98
5
CR-1

117
102

100

109

110
58
18
99

56

77

39
78
10
88
87

97

83
20
19

26
G31 B

4
5

1
NO. 9 G TO:STARTER "B" TERM.
CN-11 DESTINATION NO. DESTINATION CN-11
1,2 BR 2B 111
1 1 GND(CONTROLLER) 1 AC CONTROLLER GND 1
32 2B 2B G61 BATT RY
2 2 GND(BLOWER) 2 BLOWER MOTOR GND 2
6 RY 2L 4
3 3 FUSE(IG) 3 AC 24V 3
3,4 RW/R 2R 102
4 4 FUSE(Battery) 4 AC CONTROLLER B+ 4
33 2R 2RW 56
5 5 FUSE(Battery) 5 AC CONTROLLER B+ 5 DO-3
30 LW G 101 9E G
6 6 DPS(COMPRESSOR) 6 AC COMP 6 2
31 LY
G32 B DIODE
7 7 CONDENSOR FAN 7 AC CONDENSOR FAN 7 1
5 G
8 R 6F
8 ILLUMINATION 8 ILLUMINATION 8
DO-2
AIR CON 9A G
AIR-CON 92 V
2
DIODE
1
WB 15
BW 16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

1
BR 2
RW/R 3
RW/R 4
5
RY 6

8
9
NO. DESTINATION CN-10
V 100 DO-1
GW

BrR
WR

YBr

9
8
LW

9
BG

BG

BG

GB
1 CASSETTE RADIO 24V 1
BR

G
GL

YB
LG

YB
LR

LB

LY

G
CN-21
Y

R 6E 2
2 ILLUMINATION 2 16A W DIODE

1.25BrR
1.25GB
3 1 1
R 10 WIPER CUT 3 NC 3
B G51
10
11
12
13
14
15
16
17
18

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

1
2
3
4
5
6
7
8
9

CS-53
GY 12 QUICK COUPLING SW 4 GND 4
CN-61

2
8
7
3

9
5

8
2
7

9
1
R 4A 5 NC 5 G4 B M
4 I Y 99 1
TEMP MOTOR ACT(+)

DUCT SENSOR(GND)
TEMP MOTOR ACT(-)

4 8 6 CASSETTE&ROOM LAMP B+ 110

BLOWER RELAY(M1)
BLOWER RELAY(M2)

COMPRESSOR(DPS)

6 G
BLOWER RELAY(LO)

1
2
MODE M/ACT(FOOT)

G
INLET MOTOR(REC)

BLOWER RELAY(HI)
INLET MOTOR(FRE)

2
MODE M/ACT(PBR)
MODE M/ACT(DEF)

5
TEMP M/ACT(PBR)
MOTOR ACT(REF)

CONDENSER FAN

DUCT SENSOR(+)
MODE M/ACT(M+)

9 7 NC
MODE M/ACT(M-)

2A B
L
6 M 2 6 B 112 FUEL PUMP
ILLUMINATION

OR
8 CASSETTE GND 8 G3
CN-25
B

10
5

6
BATTERY(+)
BATTERY(+)

10
5

6
1

CS-24
POWER IG

9 NC

CS-67
9 22A R
G 96

11
WIPER MOTOR 2

10
3

7
2

6
1

4
5

8
DUCT

10
3

7
2

6
10 BEACON LAMP

4
5

8
9
10
SENSOR OR 43
GND
GND

11 CABIN LIGHT 11 HORN

NC

NC
NC
NC
NC
NC G5 B

OR

OR

OR
12 NC

B/W
12 1

R
B

Y
B
22 R
AC&HEATER CONTROLLER CN-141 2

G8

G1
CABIN HARNESS

6A

G2
2A
G 8 CN-20

8
6

4
FEED BACK 1
W 1
MOTOR DRIVE SIG 2 CN-17 NO.
L 9 DESTINATION CN-9
MOTOR DRIVE- 3 1 B G53
R 10 1 W W 9 1 HORN SW 1
MOTOR DRIVE+ 4 2 Y 98 CL-4
B 2 2 B B G4 2 HORN SW 2 G1 B
GND 5 3 B G54 1
GY/W 3 3 GY/W GY/W 3 3 GND 3 6 R
VCC 6 4 2
R 4 4 R R 29 4 NC 4
CONTINUE 24V 7 5 B 13 HEAD LAMP
V 5 5 V V 11 5 ACCEL DIAL(-) 5
WASHER P/P 8 6 W 25
L 6 6 L L 13 6 ACCEL DIAL(SIG) 6
WASHER SIG. 9 7 G/OR 11
BR 7 7 BR BR 10 7 ACCEL DIAL(+) 7
INT. SIG 10 8
OR 11 8 SPARE SW 8
WIPER CUT SW 11
N.C 12 NO. DESTINATION CN-8
CN-6
GY 12 4 OR 1 SPARE SW 1
FEED BACK 13 1 1 FUSE L 59
2 Y 2 TRAVEL ALARM SW 2
WIPER MOTOR CONT. 2 2 QUICK COUPLING SOL Y 97
WIPER MOTOR HARNESS 5
6
R
OR
3 3 FUSE
3
4
BEACON LAMP 24V
BEACON LAMP SIG
3
4
G 96
4 4 NC OR 1A
3 GY/W 5 BRAKER SW 24V 5 CN-66
CL-2 5 5 FUSE GY 95 95 GY
B G5 G1 B 6 BRAKER SIG 6 2
6 6 GND G11 B
GY 1 1 GY 7 SPARE SW 7 1
CIGARLIGHT 7 7 FUSE OR 19A
G 7A 8 B/W 8 TRAVEL ALARM SW 8 BREAKER SOL.
8 8 OVERLOAD PS BR 94
CN-24 9 W 9 START KEY (START SIG) 9
L 12 9 9 SWITCH PANEL R 93
2 CS-1 10 BR 10 START KEY (ACC) 10
Y 11 8 GY 10 10 SWITCH PANEL V 92
1 11 V 11 START KEY (BR) 11
CN-48 11 11 WASHER PUMP W 18A
OR 16 12 R 12 START KEY (COM) 12
SPEAKER LH 12 12 HEAD LAMP

+ -
HOUR METER CN-12
CN-23 DOOR SW h W/OR 15 CS-21
B G9 RH CONSOL G2 B B 2 2 B
CL-5
B 10 10 CR-3 2 1
2 9 10 G 7 OR 43 43A OR V 1 1 V
3 1
1
W 9
4
9
8
RH SIDE HARNESS 4 4
3
V 91
2

CL-1 CN-138 2 R 12 Y 87E

SPEAKER RH 8 GY GY 14 7 2 WORK LAMP
1 24V A B G45
4 Y
24V B G6 7 1 6 1 2 1
2 DC/DC CONVERTER GND B
5 G 7 2A B
OR 22 5 WORK LAMP RY 1
ROOM LAMP 12V 12V C Y 25 1A V
CN-27 4 2
N.C 1 3 CL-6
L 12 V 23 CN-125 CN-125

I 0
S.R- 2 CN-5 CR-36
2 Y 99A 20 L
3 GY 24 13 L 1 1 30
S.R- 1 1 1 SWITCH PANEL 89 R R 93
10 20A L 87a 87 85
B CN-139 23 V 2 2 86
S.L- 4 OR 22 2 2 WORK LAMP
2 LIGHT SW 17 BR 3 3
B 86 107 V
S.L- 5 CN-10 NO. DESTINATION 12V SOCKET B G7 3 3 FUSE 89 R Or 90
87
1 V 62 Y/W
1
1 29 R 4 4 85
N.C 6 1 FUSE 4 4 FUSE
R 2 2 R 14 GY 87a
30 86
ILL+ 7 2 2 ILLUMINATION 5 5 FUSE GPS CONN.
Y 11 15 W/OR PRE-HEAT
S.R+ 8 3 3 6 6 CPU CONTROLLER
3 2B 16 OR
S.R+ 9 4 4 GND CN-56 7 7 FUSE
V 1 BR 17 21 SH
ACC 10 5 5 POWER IG(24V) 1 8 8 CPU CASE EARTH
Y 4a 4 Y B 18 18 B
B+ 11 6 6 FUSE GND 2 9 9 GND
W 9 Y 19 19 Y
S.L+ 12 7 7 RX 3 10 10 CPU CONTROLLER
5 B L 20 20 L
S.L+ 13 8 8 GND TX 4 11 11 CPU CONTROLLER
B 5
GND 14 9 9 CLUSTER 12 12 NC
6 G
10 10 BEACON SW 13 13 NC
CN-143 7 OR 25 Y
11 11 WORK LAMP RY 14 14 FUSE
N.C 1 24 GY
R 20 12 12 15 15 NC
RADIO ON/OFF 2
G 21
BAND
BAND
3
4
L 22 CABIN HARNESS
BR 23
SEEK 5
OR 24 NO. DESTINATION CN-6
SEEK 6 OR 1
CS-26A CS-5 1 QUICK COUPLING SW 1 CN-140
N.C 7 GY 18A B 8 Y 21 21 Y
B 13 1 1 2 QUICK COUPLING SW 2 2
GND 8 GY 5A Y 9 Y 87A G13 B
Y 14 2 2 3 OVERLOAD SW 3 1
VOL/R OUT 9
V 15 BREAKER PEDAL HORN 4 NC 4 DO-5 QUICK COUPLING
VOL/L OUT 10 GY/W 10 10E GY/W
GY 16 5 WIPER MOTOR 24V 5 2
VOL/R IN 11 CS-26 B G52 80A V
W 17 GY 18 6 GND 6 1
VOL/L IN 12 CL-9 GY 83
18 1 7 CIGARLIGHTER 24V
GND 13
B 3 B GY 5 CN-9 NO. DESTINATION 7
B/W 24
DIODE
1 2 8 B
R 19 7 OR 1 1 GND 8 OVERLOAD PS 8
N.C 14 2 W 82
CS-54 BREAKER 9 Y 9 WIPER DRIVE SIG 9 CN-22
B G2 2 2 HORN RELAY 81 10A
CASSETTE RADIO 10 10 G1 B 10 INT. SIG 10
BR GY/W
2 M
9 L 7A 3 3 NC V 80 80 V
CABIN LIGHT 9 11 WASHER PUMP 11 1 CD-14
CN-144 GY 14 4 4 NC R 6 1F Y
B 18 8 11 B 12 HEAD LIHGT SIG 2 Pa
EARTH(VOLUME) 1 3a B 8 5 5 CPU CONTROLLER 12 WASHER PUMP
17 1 2F G
W 6 7 12 W 1
VOLUME L/IN 2 7a OR 2 B 19 6 6 CPU CONTROLLER CN-5
GY 16 2 6 13 G/OR L 79
VOLUME R/IN 3 7 OR 20 7 7 CPU CONTROLLER 1 WASHER SIG 1 CD-13
V 15 CL-8 5 5 14 GY V 91 59
CN-55 1E
4 L Y 1 Y
VOLUME L/OUT 1 8 8 NC 2 WORK LIHGT SIG 2 2 2 Pa
Y 14 4 BR 77 38 G G 2 2E G
VOLUME R/OUT 5 3 CLUSTER 24V 3 1
B 13 CN-8 R 58 1
CL-7 3 CD-31
EARTH(MAIN) 6 G 15 15 G 4 WIPER MOTOR CONT. 4 EXT.TRAVEL
R 19 6 G 2 1 1 NC GY 39 24 B/W CD-12
N.C 12 7 L 7 7 L 5 CONVERTOR 24V 5 2 Pa 1A Y
R 20 3b B M 2 2 TRAVEL ALRAM PS W/OR 61 34 B/W
RADIO ON/OFF 8
1
16 Y 6 HOUR METER SIG 6 1 2 Pa
21 2A G
G
BEACON LAMP TRAVEL ALARM 3 3 FUSE OR 8 1
BAND 9 6 G 7 HOUR METER 24V 7 CN-81
10
L 22 4 4 BEACON LAMP SH 70 OVERLOAD PS 38 G
BAND 17 OR 8 SHIELD 8 1 CD-11
BR 23 CS-23 5 5 FUSE B 113 G14 B 1 Y
SEEK UP 11 G1 18 9 CLUSTER GND 9 2
OR 24 10
B GY
6 6 BRAKER SOL Y 68 2 Pa
SEEK UP 12 9 10 10 CLUSTER SERIAL+ (RX) 2 G
G 6A 19 B 10 TRAVEL BZ 1
9 7 7 NC L 69
REMOCONE 20 OR 11 CLUSTER SERIAL- (TX) 11
8 8 8 FUSE
8 21 BR 12 NC 12
6 7 9 9 SAFETY RELAY
2 Y 16 22 R 13 NC 13
6 10 10 POWER RELAY Y 87
7 23 V 14 WORK LIGHT 24V 14
5 5 11 11 DIODE(DO-2) GY 88
1 24 W 15 HEAD LIGHT 24V 15
4 12 12 FUSE
RH SIDE 37A V/W B G43
3
G 6
2
NO. DESTINATION CN-4 CN-92
1 B G63
1 POWER MAX SW 1
BEACON LAMP SW Y 44
2 POWER MAX SW 2
B G62
3 O/T DECEL SW 3
GY 45
4 O/T DECEL SW 4
CS-27 5 NC 5
B G3 B G64
11
12
G/OR 13

6 SAFETY SW (Com) 6 CN-68

BR 21

22
23
24

10

23
9 10 109 R
GY 5A 7 SAFETY SW (NC) 7 2
9
G 76 76 G
W
R
V

CR-23 8 SAFETY SW (NO) 8 1

B

CN-45

B
8
8
SAFETY SOL
CS-2

M LH CONSOLE
CN-142

B 1 6 7
M 2
5
4

CR-5
6

2
3

C
B
A

B/OR 2 6 17 GY
17
7
5 5
OR B
RH HARNESS 94 BR
30
87a 87 85
+
-
S

1
0, I NO. DESTINATION CN-2 86
1

B+ START RY 4 B G12 3 R
STARTER FROM BATT RY 3
1 START RY 1 87
B/OR 17 37 V/W
2 START RY(GND) 2 85
2 H0 I W 16
TO:PRE-HEAT RY GY 5 3 ALT(I) 87a
30 86
4

3
3
2
6
5

ST C BR ACC H
1 GY 78
CN-74 ACCEL DIAL 4 ALT(R) 4 ANTI-RESTART RY
8R 16 BREAKER SW START KEY SW G 32
U
B+ 5 WATER TEMP SENDOR(S) 5
B 12E
6 WATER TEMP SENDOR(G) 6
~ 3 I 1
W 3
7 TACHO SENSOR 7
Y 67
CR-43
G R 10 L 65 14 L
R 2 8 TACHO SENSOR 8 1 2 1
GY/W 30 2 R
9 ENG OIL PS 9 2
ALTERNATOR V 107 2A R
3
DO-4 10 PRE-HEAT RY 10
B/W
R 10 V/W 85 35 4 4
2 11 AC COMP 3
11
GY 4 OR 49
1 12 EPPR 12 ENGINE STOP RY
BR 75
DIODE 13 EPPR 13
B/W 35
14 FUEL CUT-OFF SOL 14

CN-2 NO. DESTINATION 15 NC 15

CD-8 1 B CN-19B
G 5 1 1 GND HARNESS ENG B G41
C 1 2 B/OR 1
B 6 2 2 SAFETY RY OR 53
2 3 W 2
3 3 CPU,DIODE(DO-1)
WATER TEMP SENDOR 4 GY
4 4 FUSE CN-19 CN-19A
5 G 75 BR BR 48
5 5 CPU CONTROLLER 1 1
6 B 49 OR OR 50
CD-17 6 6 CPU CONTROLLER 2 2
rp Y 7 7 Y CD-10
m 7 7 CPU CONTROLLER L 36
L 8 9 L Pa
8 8 CPU CONTROLLER B G44
9 GY/W
TACHO SENSOR 9 9 CPU CONTROLLER
11 V AIR CLEANER SW
10 10 PRE-HEAT RY
12 V/W CD-16
CD-18 11 11 AIR-CON RY B G33
13 OR 2
12 12 CN-19 G/W 52
Pa GY/W 9 14 BR
13 13 CN-19 CS-29 1
15 B/W B 1
14 14 ENG STOP RY 1 WATER LEVEL
ENG OIL PRESS Y 2
15 15 NC 2

53
OR 8E
POWER MAX CN-4 NO. DESTINATION

OR
FROM START MOTOR ENGINE HARNESS 1
2
B
Y
1 1 GND SH42
CS-19 2 2 CPU CONROLLER

CN-47
B 3 3 B
3 GND

1
1 3

2
CR-24 SH 70 7B
15R GY 4 4 GY
V 11 2 4 4 CPU CONROLLER
ONE TOUCH DECEL 5 5 NC
15R G B
6 6 GND
6 V RESISTER
CS-4 7 7 NC
PRE-HEATER PRE-HEAT RY B C OR 5 7 G
A
V 6 8 8 SAFETY SOL
B
G 7
A C
CN-28
V/W 12
SAFETY SW LH HARNESS
1

28
26
64
19
CS-20
5
12A

OR
27

27
AC COMP

L/W
117
13A

G/OR 11A

8A
12
B/OR 33

44

GY/W 30

16

45
52
36

13
G/OR 11
29
25
B/OR 33
65
67

12

32

28
W/OR 61
Y/W 62
14

48

57
37
54
64
81
82
79

34

66

23
68
69

71
72
73

50

W
66
54

29

R
Y
BR/OR

BR/OR

CN-88
CN-70
CN-79
G/W

1
1
B/W
V/W

B/W

2
2
L/W

OR

OR
GY

GY
BR

BR
B/W 15 SAFETY SW
W

W
W

W
B
W

G
R
B

B
Y

B
G

L
V

73
72
71
B/W 57
7
CD-1

CN-51

CN-50
CD-2
CN-76

1
2

B
1
2
6
5
4
3
2

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
1

G
R
B
1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9
FUEL CUT-OFF
TRAVEL POWER
˚C

CN-126
MAX
SIG
M+

P+
NC
M-

P-

3
4
1
2
WATER TEMP SENDOR

TRAVEL SPEED SOL.

HYD TEMP SENDOR
HYD TEMP

FUEL LEVEL SENSOR

1
5

TACHO SENSOR(+)
CN-75

TACHO SENSOR(-)

ANTI-RESTART RY
2

AIR CLEANER SW

ENG PREHEATER
POWER MAX SOL
M

PROGRAM DUMP
OR 13 FUEL LEVEL
GND (POT&DIAL)

BATTERY 24V(+)
ACCEL DIAL SIG
2

ENG. STOP SIG

GND (SENSOR)
RS232
O/T DECEL SW

OVERLOAD PS

PUMP EPPR(+)
5V (POT&DIAL)

ENG OIL FILTER

WATER LEVEL

PUMP EPPR(-)

ACCEL ACT(+)
HOUR-METER

ACCEL ACT(-)
WIPER DRIVE
BR 14

WASHER SIG
6

POWER MAX

RS232 (GND)
1 CONN.
ENG OIL PS

GND (MAIN)
WIPER INT.

SERIAL-RX
ALT LEVEL

GOV. MOTOR

SERIAL-TX
POWER IG
CN-92

RS232 (+)
RS232 (-)
EPPR VLV
POT-SIG

GND
NC

NC

NC
NC
NC
NC

NC
NC
NC
NC

NC
NC
NC

NC
NC
NC
NC

NC

NC

NC

NC
NC
NC

NC

NC
NC
NC
NC

NC

NC

NC
CPU CONTROLLER
11074EL03

4-3
1. POWER CIRCUIT
The negative terminal of battery is grounded to the machine chassis.
When the start switch is in the OFF position, the current flows from the positive battery terminal as shown
below.
1) OPERATING FLOW
Battery Battery relay Fusible link (CN-60)
Fuse box [No.1] I/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)]
Cassette radio [CN-27(11)]
Fuse box [No.3] I/conn [CN-11(4)] AC & Heater controller [Battery(+)]
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] I/conn [CN-11(5)] Relay(Hi, M2)
ö I/conn : Intermediate connector

2) CHECK POINT
Engine Start switch Check point Voltage

Η - GND (Battery 2 EA) 20~25V

OFF OFF Θ - GND (Battery 2 EA) 20~25V
Ι - GND (Fusible link) 20~25V

ö GND : Ground

4-4
 6 GND 1
5

ST C
CS-2 GND 2
6 RW/R 3
BATTERY(+) 3
3 5 RW/R 4
BATTERY(+) 4

S.L-
S.L-

ILL+

B+
S.R-
S.R-

S.L+
S.L+
N.C
N.C

S.R+
S.R+

B
2

ACC

BR ACC
GND
1 4 ILLUMINATION 5

H
4 3 POWER IG 6

8
9
7
6
5
4
3
2
1

14
13
12
11
10

0, I
2 NC 7

CN-27
W 24

START KEY SW
1 DUCT SENSOR(+) 8

H0 I
Y 4a
DUCT SENSOR(GND) 9
NC 10 2 1
1
NC 11 33 R
2

8 GY

4 Y
8 GY

N.C
NC 12

VCC
GND
3 RELAY(HI)

2
1
NC 13

CL-1

INT. SIG
33
4 4 3

3,4
POWER CIRCUIT

AC&HEATER CONTROLLER

M
NC 14

FEED BACK

FEED BACK
CS-1
2R

WASHER P/P
WASHER SIG.
DOOR SW
2 1

CONTINUE 24V
MOTOR DRIVE-
ROOM LAMP
4 Y
1

WIPER CUT SW
24 W
RW/R

MOTOR DRIVE+
MOTOR DRIVE SIG
33A R

8
7
6
2

2
2

5
9
8
7
5
5
4
3
1

4
1
4
1

9
8
7
6
6
2

3
3

12
11
10

2
4
3
12
11
10

WIPER MOTOR
3

CN-8

9
8
7
3

6
2

5
4
1
CN-10
CN-11
RELAY(M2)

13
12
11
10
4 4 3

CN-141
5
1
2

6
3
4
Y 99

WIPER MOTOR CONT.

R4
CN-21
W 18A
2R 102
2RW 56
CR-35
18 W
30

R 4A
87a 87 85
86
103 3L
87

4
POWER RY

R
85
30 86
87a

8
7
6
5
4
3
2
1
CN-17
CN-36

29R
18 W START KEY 30A
1

9
8
7
5
4
1

6
3

15
14
13
12
11
10
99 Y ROOM LAMP 5A
2

CN-5
1022R AC& HEATER 5A
3
10A

R 58
58 R WIPER+
4
117 GY CPU B+ 5A
5
103 3L

20A

4-5
56 RW AC BLOWER
3R 105

6
FUEL CUT-OFF 20A
7
CN-95 CLUSTER 10A
5W 104 8
2 10A
5W 115 CASSETTE RADIO
1 9
CPU 10A
10
CN-60
3R 105 CONVERTOR 5A

CR-1
CN-50 2 11
NC 1 3R 116 5A
1 ALT,STOP
12

FUSIBLE LINK
NC 2
WIPER MOTOR 20A

BATTERY RY
POWER MAX SOL 3 13
HEAD LAMP 10A
HOUR-METER 4 14
ENG PREHEATER 5 WORK LAMP 20A
15
FUSE BOX

ENG. STOP SIG 6 SPARE 20A

GY 117 16
BATTERY 24V(+) 7
5A

60R
BEACON LAMP
PUMP EPPR(-) 8 17
AC& HEATER 20A
NC 9 18
PROGRAM DUMP HORN 10A
10
19
ANTI-RESTART RY 11 CIGAR LIGHTER 10A
20

12V X 2
ACCEL ACT(+) 12
PRE-HEAT RY 10A
5W 104

TRAVEL SPEED SOL. 13 21

TRAVEL 5A
WIPER INT. 14 22
60B

WIPER DRIVE ANTI-RESTART 20A

15
23
16 SAFETY SOL 5A

CPU CONTROLLER
24
NC 17
SOLENOID 10A
RS232 (+) 32 25
SOLENOID 10A
RS232 (-) 33 26
RS232 (GND) FUEL FILLER P/P 10A
34
27
MASTER SW

NC 30A
35
28
PUMP EPPR(+) 36
60B

11074EL04
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Battery relay[CR-1] Fusible link Fuse box No.1
I/conn <CN-8(12)> Start key <CS-2(1)>

ö Start switch : ON
Start switch ON <CS-2(2)> I/conn <CN-8(11)> Diode[DO-2]
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)>
GPS Connector[CN-125(2) Ą CN-125(4)] Power relay [CR-35(86) Ą (87)]
Fuse box No.12 I/conn [CN-2(4)] Alterlator[CN-74(2)]

ö Start switch : START

Start switch START<CS-2(5)> I/conn<CN-8(9)> Anti-restart relay [CR-5(86) Ą (30)]
I/conn [CN-2(2)] Start relay [CR-23]

2) CHECK POINT
Engine Start switch Check point Voltage

Η  GND (Battery)
Θ  GND (Start key)
Ι  GND (Battery relay M4)
Operating Start Κ  GND (Starter B) 20 ~ 25V
Λ  GND (Starter M)
Μ  GND (Start relay)
Ν  GND (Battery relay M8)

ö GND : Ground

4-6
 6
5

ST C
CS-2

~
U
6

89 R

89 R

G
M
BR 21
3 5

3
B
2

BR ACC
1 4

3
R 22

4
1
2
H

STARTER
4 3

B+
M
V 23

B+

I
CN-45
0, I

CN-74

R
2

ALTERNATOR
W 24

START KEY SW
1

H0 I

2
1
4
1

GPS CONN.
CN-125

8R 16
24
23
22
21

W 3
R 10
V
R

Or 90
R 93

2
1
BR

DIODE
DO-4
2

5
4
1

9
8
7
6
3

12
11
10

CR-23
CN-8

START RY

GY 4
B

R 10
STARTING CIRCUIT

V 92
R 93
BR 94

W18A

B/OR 2
1
CR-35
18 W
30
90 Or 87a 87 85

1B

3W
86

4 GY
103 3L

2 B/OR
87

9
8
7
5
4
1
POWER RY

6
3

15
14
13
12
11
10
85
30 86

CN-2
87a

W
GY
CN-36

B G12

78
16
B/OR 17
18 W START KEY 30A
CN-51 1
W 16 5A
ROOM LAMP
2
AC& HEATER 5A
3
WIPER+ 10A
4
CN-50
CPU B+ 5A
NC 1 5
103 3L

AC BLOWER 20A
NC
3R 105

2 6
POWER MAX SOL 3 FUEL CUT-OFF 20A

4-7
7
HOUR-METER 4 10A
CLUSTER
ENG PREHEATER 5 8
CASSETTE RADIO 10A
ENG. STOP SIG 6 9

G31 B
9
CN-95 CPU 10A
BATTERY 24V(+) 7
5W 104 10
2 5A

G
PUMP EPPR(-) 8 CONVERTOR
5W 115

9
11
NC 9 1
78 GY ALT,STOP 5A

92 V
G32 B

9A G
9E G
12

G
16A W
PROGRAM DUMP 10 CN-60
V/W 37 3R 105 WIPER MOTOR 20A

CR-1

1
1
1

2
2
2
ANTI-RESTART RY 11 2 13
3R

DO-1
DO-2
DO-3
ACCEL ACT(+)
116 HEAD LAMP 10A
12 1 14

FUSIBLE LINK
TRAVEL SPEED SOL. 13 WORK LAMP 20A

BATTERY RY
15
FUSE BOX

WIPER INT. 14 20A

SPARE
WIPER DRIVE 16
15
BEACON LAMP 5A

60R

DIODE

DIODE
DIODE
16 17

CPU CONTROLLER
AC& HEATER 20A
NC 17 18
RS232 (+) 32 HORN 10A
19
RS232 (-) 33 10A
CIGAR LIGHTER
20

12V X 2
RS232 (GND) 34
10A
BATTERY PRE-HEAT RY

3
5W 104

NC 35 21

37
94
17
TRAVEL 5A

R
PUMP EPPR(+) 36 22

BR
GY

V/W
60B

3R ANTI-RESTART 20A
23
5A

87
85
86
30
SAFETY SOL

CR-5

87a
24
SOLENOID 10A
25

30
87a 87
SOLENOID 10A
26

86
85
FUEL FILLER P/P 10A
27
MASTER SW

30A
28

ANTI-RESTART RY
60B

11074EL05
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
AlternatorÎIÏterminal I/connÐCN-2(3)Ñ CPU Controller [CN-51(9)]
Cluster warning lamp (Via serial interface)

(2) Charging flow

Alternator "B+" terminal Battery relay Battery(+) terminal
Fusible link Fuse box

2) CHECK POINT

Engine Start switch Check point Voltage

Η - GND (Battery voltage)

Θ - GND (Battery relay)
ON ON Ι - GND (Alternator Bterminal) 20~27V
Κ - GND (Alternator I terminal)
Λ - GND (CPU)

ö GND : Ground

4-8
 ~
U

G
M

3
6
5

ST C
CS-2

STARTER
CR-35

B+
M
6 18 W

B+

I
89 R

CN-45
89 R

ALTERNATOR
CN-74
30

R
5 90 Or 87a 87 85
3 86

B
2

2
1
BR ACC
1 4 103 3L
87

3
R 22

4
1
2
H
3

8R 16
4

POWER RY
V 23 85

0, I
2 30 86
W 24 87a

W 3

2
START KEY SW

1
1

DIODE
H0 I

R 10
2

4
1

DO-4
CR-23
GPS CONN.
CN-125

START RY

GY 4
B

R 10
23 V
22 R

24 W

Or 90
R 93
CN-36

B/OR 2
1
CHARGING CIRCUIT

5
4
1

9
8
7
6
3

12
11
10
18 W START KEY 30A
1

CN-8
ROOM LAMP 5A
2
AC& HEATER 5A

V 92
R 93

W18A

1B
3

3W
4 GY
WIPER+ 10A

2 B/OR
4

9
8
7
5
4
1

6
3

15
14
13
12
11
10
CPU B+ 5A
5

CN-2
103 3L

AC BLOWER 20A
3R 105

W
GY
FUEL CUT-OFF 20A
7

B G12

78
16
CLUSTER 10A
8
CASSETTE RADIO 10A
9
CPU 10A
10
CONVERTOR 5A
11
78 GY ALT,STOP 5A
12
WIPER MOTOR 20A
13

4-9
HEAD LAMP 10A
14
WORK LAMP 20A
15
FUSE BOX

CN-51 SPARE 20A

W 16 16
CN-95 BEACON LAMP 5A
5W 104 17
2 AC& HEATER 20A
5W 115

9
18

G31 B
9 G
1
HORN 10A

92 V
G32 B

9A G
9E G

G
19

16A W
CN-60 10A
3R 105 CIGAR LIGHTER

CR-1

1
1
1

2
2
2
2 20
3R

DO-1
DO-2
DO-3
116 PRE-HEAT RY 10A
5W 104

1 21

FUSIBLE LINK
TRAVEL 5A

BATTERY RY
22
ANTI-RESTART 20A
23
SAFETY SOL 5A

60R

DIODE

DIODE
DIODE
24
SOLENOID 10A
25
SOLENOID 10A
26
FUEL FILLER P/P 10A

12V X 2
27
30A
BATTERY
60B 28

MASTER SW

11074EL06
60B
4. HEAD LAMP CIRCUIT
1) OPERATING FLOW
Fuse box (No.14) I/conn <CN-5(15)> Light switch[CS-21(1)]
ö When lamp switch ON
Light switch[CS-21(7)] I/conn[CN-6(12)]
I/conn [CN-10(2)] Cassette radio illumination [CN-27(7)]
I/conn [CN-11(8)] AC & Heater controller illumination
Head lamp [CL-4(2)] : Head lamp ON
I/conn[CN-6(8)] Cigarlight [CL-2]
Light switch[CS-21(5)] Cigarlight[CL-2]

2) CHECK POINT

Engine Key switch Check point Voltage

Η - GND (Fuse box)

STOP ON Θ - GND (Switch power input) 20~25V
Ι - GND (Switch power output)

ö GND : Ground

4-10
 BR 1

7
5
9

2
GND 1
I 0 BR 2
GND 2
BATTERY(+) 3
BATTERY(+) 4

S.L-
S.L-

ILL+

B+
S.R-
S.R-

S.L+
S.L+
N.C
N.C

S.R+
S.R+

ACC

GND

1
4
10
G5
ILLUMINATION 5

CL-2

CIGARLIGHT

LIGHT SW
CS-21

3
7
9

2
6
POWER IG 6

1
4
5
8
8
9
7
6
5
4
3
2
1

10
14
13
12
11
10
CN-27
NC 7

G 7A
B G5
R2
DUCT SENSOR(+) 8

G7
G7

R 12
B G9

GY 24
DUCT SENSOR(GND) 9 CN-36
HEAD LAMP CIRCUIT

NC 10 START KEY 30A

1
NC 11
ROOM LAMP 5A
NC 12 2
AC& HEATER 5A
NC 13 3

NC 14 WIPER+ 10A
4
CPU B+ 5A
5
AC BLOWER 20A
6
1,2 BR

5G

G1 B

24 GY
2R

12 R
FUEL CUT-OFF 20A
7

9
8
7
5
4
1

6
8
7
6

3
5
4
3
1
2

9
8
7
5
4
1

6
3
12
11
10

15
14
13
12
11
10
3

6
4
1

9
8
7
5
2
CLUSTER 10A

12
11
10
CN-6

CN-5
8

CN-10
CN-11

CASSETTE RADIO 10A

9

R6
R 6E
R 6F
CPU 10A
2B 111

GY 88
10
CONVERTOR 5A
11
ALT,STOP 5A
12
WIPER MOTOR 20A
13

4-11
88 GY HEAD LAMP 10A
14
WORK LAMP 20A
15
FUSE BOX

SPARE 20A
16
BEACON LAMP 5A
17
AC& HEATER 20A
18
HORN 10A
19
CIGAR LIGHTER 10A
20
PRE-HEAT RY 10A
21
TRAVEL 5A
22
ANTI-RESTART 20A
23
SAFETY SOL 5A
24
SOLENOID 10A
25
SOLENOID 10A
26
FUEL FILLER P/P 10A
27
30A
G1 B
6 R 28
2
1
CL-4

HEAD LAMP

11074EL07
5. WORK LAMP CIRCUIT
1) OPERATING FLOW
Fuse box (No.15) I/conn <CN-5(14)> Light switch[CS-21(4)]
ö When work lamp switch ON
Work lamp switch ON <CS-21(2)> I/conn [CN-5(2)] Work lamp relay[CR-3(3)Ą(4)]
I/conn[CN-12(1)] Work lamp ON [CL-5(2), CL-6(2)]

2) CHECK POINT
Engine Key switch Check point Voltage

Η - GND (Fuse box)

Θ - GND (Light switch input)
STOP ON 20~25V
Ι - GND (Light switch output)
Κ - GND (Work lamp)

ö GND : Ground

4-12
 7
5
9

2
I 0

1
4

1
4
10
1
4

2
3

LIGHT SW
CR-3

3
7
9

2
6

1
4
5
8
WORK LAMP RY

10
B
Y
V

CS-21
CN-36
START KEY 30A

V 23
Y 25
91
OR 43
WORK LAMP CIRCUIT

87E
G45
ROOM LAMP 5A
2
AC& HEATER 5A
3
WIPER+ 10A
4
CPU B+ 5A
5
AC BLOWER 20A
6

23 V

25 Y
FUEL CUT-OFF 20A
7

9
8
7
5
4
1

6
3

15
14
13
12
11
10
CLUSTER 10A

CN-5
8
CASSETTE RADIO 10A
9

Y 87
V 91
CPU 10A
10
CONVERTOR 5A
11
ALT,STOP 5A
12
WIPER MOTOR 20A
13
10A

4-13
HEAD LAMP
14
WORK LAMP 20A
15
FUSE BOX

SPARE 20A
16
BEACON LAMP 5A
17
AC& HEATER 20A
18
HORN 10A
G2 B

19
43A OR

CIGAR LIGHTER 10A

20
1
2

PRE-HEAT RY 10A
21
CN-12

TRAVEL 5A
22
V1
B2

ANTI-RESTART 20A
23
SAFETY SOL 5A
24
SOLENOID 10A
25
SOLENOID 10A
26
FUEL FILLER P/P 10A
27
30A
1A V
2A B
1 V
2 B

28
2
1
2
1

CL-6
CL-5

WORK LAMP

11074EL08
6. CAB LAMP CIRCUIT
1) OPERATING FLOW
Fuse box (No.15) I/connÐCN-5(14)Ñ Light switch[CS-21(4)]

ö When Lamp switch ON

Lamp switch ON [CS-21(2)] I/conn [CN-5(2)] Work lamp relay[CR-3(3)Ą(4)]
I/conn [CN-10(11)] Cab light ON [CL-8(2), CL-9(2)]

2) CHECK POINT
Engine Start switch Check point Voltage

Η - GND (Fuse box)

Θ - GND (Light switch input)
STOP ON 20 ~ 25V
Ι - GND (Light switch output)
Κ - GND (Cab lamp)

ö GND : Ground

4-14
 CN-116
HEAD LIGHT OUT 1
WORK LIGHT OUT 2
WORK LIGHT OUT 3
WIPER MOTOR DRIVE 4

3
PRE-HEAT 5

2
1
2
POWER 24V 6

1
CN-46
OR

CL-8
CL-9

CABIN LIGHT

SWITCH PANEL
CABIN LIGHT OUT 7 20A
CAB LAMP CIRCUIT

START KEY
1

OR
CABIN LIGHT OUT 8

OR
ROOM LAMP 5A
HEAD LIHGT 24V 9 2

AC & HEATER 5A
WORK LIGHT 24V 10 3

WORK LIGHT 24V 11 WIPER+ 10A

4
WASHER SIG 12 5A
CPU B+
5
GND 13

2
AC BLOWER 20A
TRAVEL ALARM 14 6

CLUSTER 10A
INT. SIG 15 7
R
CABIN LIGHT 24V 16 CASSETTE RADIO 5A
8
CABIN LIGHT 24V 17 10A
CPU

4
9

CONVERTOR 5A
10

OR
SWITCH PANEL 5A
11

OR

R
FUEL CUT-OFF 20A

6
4
1

9
8
7
5
2

12
11
10
12

CN-10

4-15
WIPER MOTOR 20A

6
4

9
8
7
5
1
2

12
11
10
13

CN-7
5A

OR
HEAD LAMP
14

R
WORK LAMP 10A

OR
FUSE BOX

15

R CABIN LAMP 10A

16

BEACON LAMP 5A
17

AC & HEATER 20A

18
1

HORN 10A
19

CIGAR LIGHTER 10A

20

ETHER(PRE-HEAT) 10A
21

TRAVEL 5A
22

SOLENOID 1 10A
23

SAFETY SOL 5A
24

SOLENOID 3 10A
25

FUEL FILLER P/P 10A

26

SPARE 10A
27
SPARE 20A
28

14074EL09
7. BEACON LAMP CIRCUIT
1) OPERATING FLOW
Fuse box (No.16) I/conn <CN-8(3)> Beacon lamp switch <CS-23(6)>
ö When 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) CHECK POINT

Engine Start switch Check point Voltage

Η - GND(Fuse box)
Θ - GND(Switch power input)
STOP ON 20~25V
Ι - GND(Switch power output)
Κ - GND(Beacon lamp)
ö GND : Ground

4-16
 1
2
8

7
9

5
6
10
6

3
7
9

2
6

1
4
5
8
10
3b

CS-23

BEACON LAMP SW
B
G
6G
3 2B
CN-36

G6
Y 16
BEACON LAMP CIRCUIT

G 6A
B G1
START KEY 30A
1

6
4
1

9
8
7
5
2

12
11
10
5A

CN-10
ROOM LAMP

CL-7
2
AC& HEATER 5A

G 96
3

M
B G51
WIPER+ 10A
4
CPU B+ 5A
5

BEACON LAMP
AC BLOWER 20A
6
FUEL CUT-OFF 20A
7
CLUSTER 10A
8
CASSETTE RADIO 10A

16 Y
9

6 G
CPU 10A

5
4
1

9
8
7
6
3

12
11
10
10
CONVERTOR 5A

CN-8
11
ALT,STOP 5A

4-17
12

G 96
Y 97
WIPER MOTOR 20A
13
HEAD LAMP 10A
14
WORK LAMP 20A
15
FUSE BOX

SPARE 20A
16
97 Y BEACON LAMP 5A
17
AC& HEATER 20A
18
HORN 10A
19
CIGAR LIGHTER 10A
20
PRE-HEAT RY 10A
21
TRAVEL 5A
22
ANTI-RESTART 20A
23
SAFETY SOL 5A
24
SOLENOID 10A
25
SOLENOID 10A
26
FUEL FILLER P/P 10A
27
30A
28

11074EL10
8. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
(1) Key switch ON
Fuse box (No.8) I/conn [CN-5(3)] Cluster[CN-56(1)]
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(Intermittent)
Wiper switch ON [CN-50(14)] I/conn[CN-6(10)] I/conn[CN-17(8)]
Wiper motor controller [CN-141(10) Ą (3)] Wiper motor intermittently operating [CN-21(6)]
(3) Wiper switch ON
Wiper switch ON [CN-50(15)] I/conn [CN-6(9)] I/conn[CN-17(2)]
Wiper motor controller [CN-141(2) Ą (4)] Wiper motor operating [CN-21(2)]
(4) Washer switch ON
Washer switch ON [CN-50(16)] I/conn [CN-5(1)] I/conn [CN-17(7)]
Wiper motor controller [CN-141(9) Ą (8)] I/conn [CN-17(6)] I/conn [CN-6(11)]
Washer operating [CN-22(1)]
Wiper switch ON [CN-50(15)] I/conn [CN-6(9)] I/conn[CN-17(2)]
Wiper motor controller [CN-141(2) Ą (4)] Wiper motor operating [CN-21(2)]
(5) Auto parking(When switch OFF)
Switch OFF [CN-50(15)] Wiper motor parking position by wiper motor controller

2) CHECK POINT

Engine Start switch Check point Voltage

Η - GND(Fuse box)
24V
Θ - GND(Switch power input)
Ι - GND(Switch power output)
STOP ON 0~5V
Κ - GND(Wiper Power input)
Λ - GND(Wiper power output) 24V
Μ - GND(Wiper motor) 0 or 24V
ö GND : Ground

4-18
 6

N.C
VCC
GND

INT. SIG
M

FEED BACK

FEED BACK

TX
RX
GND
WASHER P/P
WASHER SIG.
CONTINUE 24V
MOTOR DRIVE-

WIPER CUT SW
MOTOR DRIVE+
MOTOR DRIVE SIG

CLUSTER
5

2
4

POWER IG(24V)
3

WIPER MOTOR

9
8
7
3

6
2

5
4
1

13
12
11
10
5
1
2

6
3
4

CN-141

L
L
CN-21

R
R
G
W

GY

WIPER MOTOR CONT.

BR

4
3
2
1
L 9
G 8

CN-56
7
6
5
4
GY/W 3
2
9
1
8
GY 12
R 10

R 4A

OR 11
10

12

BR 17

L 20
Y 19
B 18
CS-53
11 OR

WIPER CUT
2A B

6L
5V
2B

4R
1W

7 BR
WIPER AND WASHER CIRCUIT

3 GY/W

8
7
6
5
4
3
2
1
CN-17
CN-36
CN-50 START KEY 30A

W9
1

BR10
L 13
V 11
R 29
NC

B G4
1

GY/W 3
ROOM LAMP 5A
NC 2 2
AC& HEATER 5A
POWER MAX SOL 3 3
HOUR-METER 4 58 R WIPER+ 10A
4
ENG PREHEATER 5 5A
CPU B+
ENG. STOP SIG 6 5
AC BLOWER 20A

4-19
BATTERY 24V(+) 7 6

11 V

29 R
13 L

20 L
9 W

19 Y
FUEL CUT-OFF 20A

10 BR

17 BR
3 GY/W
PUMP EPPR(-) 8 7

9
8
7
5
4
1

6
3
NC 10A

9
8
7
5
9

4
1

6
3
CLUSTER

15
14
13
12
11
10
12
11
10
77 BR
8

CN-5
CN-6
PROGRAM DUMP 10 10A
CASSETTE RADIO

V
9

W
ANTI-RESTART RY 11
CPU 10A

L 69
Y 68
ACCEL ACT(+) 10

R 58
L 79

BR 77
12

80
BR 81
82
GY/W 10
CONVERTOR 5A
TRAVEL SPEED SOL. 13 11
BR 81
WIPER INT. 14 ALT,STOP 5A
W 82 12
WIPER DRIVE 15 20A
L 79 10 GY/W WIPER MOTOR
WASHER SIG 13
16
HEAD LAMP 10A
NC 17 14
WORK LAMP 20A
NC 18 15
FUSE BOX

NC 19 SPARE 20A
16
OVERLOAD PS 20 5A
BEACON LAMP
ENG OIL FILTER 17
21
AC& HEATER 20A

CPU CONTROLLER
NC 22 18
HORN 10A
ACCEL ACT(-) 23 19
POWER IG 24 CIGAR LIGHTER 10A
20
NC 25 10A
PRE-HEAT RY
NC 21
26
TRAVEL 5A
NC 27 22
ANTI-RESTART 20A
GND (MAIN) 28 23
Y 68
SERIAL-TX 29 SAFETY SOL 5A
80 V
80A V

L 69 24
SERIAL-RX 30 10A
10A GY/W

SOLENOID
GND 25
31
10A
1
2

SOLENOID
1
2

RS232 (+) 26
10E GY/W DO-5

32
CN-22

FUEL FILLER P/P 10A

RS232 (-)
DIODE

33 27
M

30A
RS232 (GND) 34 28

11074EL11
NC 35
WASHER PUMP

PUMP EPPR(+) 36
 3
6
M
2
5

1
P-
M-

NC

P+
M+

SIG
S
-
rp

+
m
h

1
2
3
4
5
6
A
B
C

ACCEL DIAL
2
1

GOV MOTOR
CN-142

CN-76
CN-75

EPPR VLV

B
CD-17

W
+ -

CN-48
CN-51

W 29
V 54
G 66
L8
Y7

BR 14
OR13
OR

HOUR METER
NC

B 13A
1

G/OR13
12
11

G/OR11A
POWER MAX 2

W/OR 15
16
NC 3
4
NC 5
NC 19
B 13
GND(POT & DIAL) 20
G/OR 11
5V (POT&DIAL) 21
W 29
CONTROLLER CIRCUIT

POT-SIG 22
W 25
ACCEL DIAL SIG 23

3
1
3

6
9
8
7
6
5
4
6

4
1
2
4
1

8
7
5
3
9
8
7
5

2
2

15
14
13
12
11
10
15
14
13
12
11
10

CN-2

CN-9
CN-5
FUEL LEVEL SENSOR 24

B
W
L 65

OR
TACHO SENSOR(-) 25

L 65
Y 67
Y 67

BR 75
OR 49
8
TACHO SENSOR(+) 26

13

G/OR11
25
W/OR 61
27 CN-36
28 START KEY 30A
1
NC 29 ROOM LAMP 5A
2
NC 30
AC& HEATER 5A
GND (SENSOR) 31 3
WIPER+ 10A
NC 32 4
WATER TEMP SENDOR 33 117 GY CPU B+ 5A
5
HYD TEMP SENDOR 34 AC BLOWER 20A
6
NC 35
FUEL CUT-OFF 20A
NC 36 7
CLUSTER 10A
8

4-20
CN-50 CASSETTE RADIO 10A
NC 1 9
CPU 10A
NC 2 8 OR 10
POWER MAX SOL 3 CONVERTOR 5A
W/OR 61 11
HOUR-METER 4 ALT,STOP 5A

CPU CONTROLLER
12
ENG PREHEATER 5
WIPER MOTOR 20A
ENG. STOP SIG 6 13
GY 117 HEAD LAMP 10A
BATTERY 24V(+) 7 14
BR 48
PUMP EPPR(-) 8 WORK LAMP 20A
15
FUSE BOX

NC 9 SPARE 20A
16
PROGRAM DUMP 10
BEACON LAMP 5A
ANTI-RESTART RY 11 17
V 54 AC& HEATER 20A
ACCEL ACT(+) 12 18
TRAVEL SPEED SOL. 13 HORN 10A
19
14 CIGAR LIGHTER 10A
20

G 66 PRE-HEAT RY 10A
ACCEL ACT(-) 23 21
OR 8A TRAVEL 5A
POWER IG 24 22
NC 25 ANTI-RESTART 20A
23
75 BR
49 OR

NC 26 SAFETY SOL 5A
24
1
2

NC 27
B 23 SOLENOID 10A
PUMP EPPR(+) 28 25
10A
1
2

SOLENOID
1
2

SERIAL-TX 29 26
CN-19B

SERIAL-RX 30 FUEL FILLER P/P 10A

CN-19 CN-19A

27
GND 31 30A
OR 53

OR 50
BR 48

28
B G41

RS232 (+) 32 CN-47

OR 8E
RS232 (-) 33 1
OR 53
RS232 (GND) 34 RESISTER 2
NC 35
OR 50

11074EL13
PUMP EPPR(+) 36
 C

C
TX

Pa
RX
GND

CD-16
CD-18

2
1
2
1

2
1
CN-51

CLUSTER

CD-1
CD-8
POWER IG(24V)

1
2

CD-2
NC 1

HYD TEMP
B
B 6
G 5

FUEL LEVEL
B
POWER MAX 2

WATER LEVEL

BR/OR
NC 3

ENG OIL PRESS

GY/W 9
GY/W 30

G/W 52
4

B/OR 33
12
4
3
2
1

G33

27
NC 5

12A
CN-56
G/W 52
WATER LEVEL

WATER TEMP SENDOR

15
L 36
AIR CLEANER SW 16

BR 17

L 20
Y 19
B 18
5V (POT&DIAL) 21
POT-SIG 22
ACCEL DIAL SIG 23
MONITORING CIRCUIT

GY/W 30
FUEL LEVEL SENSOR 24

20 L
19 Y
18 B

6B
5G
17 BR

9 GY/W
21 SH
TACHO SENSOR(-) 25

9
8
7
5
4
1

6
3

15
14
13
12
11
10
TACHO SENSOR(+) 26

9
8
7
6
5
4
2
3

15
14
13
12
11
10
CN-2
CN-5
NC 27 CN-36
NC 28 START KEY 30A

G 32
1

L 69
Y 68
SH 70

B 12E
B 113
BR 77
NC 29 ROOM LAMP 5A

GY/W 30
2
NC 30
B12 AC& HEATER 5A
GND (SENSOR) 31 3
WIPER+ 10A
NC 32 4
G 32
WATER TEMP SENDOR 33 CPU B+ 5A
BR/OR 27 5
HYD TEMP SENDOR 34 AC BLOWER 20A
6
NC 35
FUEL CUT-OFF 20A
NC 36 7
77 BR CLUSTER 10A
8
CN-50 CASSETTE RADIO 10A

Pa
NC 9

4-21
1

CD-10
CPU 10A
NC 2 10
POWER MAX SOL 3 CONVERTOR 5A
11

AIR CLEANER SW
L 36
HOUR-METER 4 ALT,STOP 5A

CPU CONTROLLER
B G44
12
ENG PREHEATER 5
WIPER MOTOR 20A
ENG. STOP SIG 6 13
HEAD LAMP 10A
BATTERY 24V(+) 7 14
PUMP EPPR(-) 8 WORK LAMP 20A
15
FUSE BOX

NC 9 SPARE 20A
B/W 57 16
PROGRAM DUMP 10
BEACON LAMP 5A
ANTI-RESTART RY 11 17
AC& HEATER 20A
ACCEL ACT(+) 12 18
TRAVEL SPEED SOL. 13 HORN 10A
CN-126 19
14 B 73
1 CIGAR LIGHTER 10A
G 72 20
2 PRE-HEAT RY 10A
ACCEL ACT(-) 23 R 71 21
3
TRAVEL 5A

RS232
POWER IG B/W 57

CONN.
24 4 22
NC 25 ANTI-RESTART 20A
23
NC 26 SAFETY SOL 5A
24
NC 27
SOLENOID 10A
PUMP EPPR(+) 28 25
Y 68 SOLENOID 10A
SERIAL-TX 29 26
L 69
SERIAL-RX 30 FUEL FILLER P/P 10A
27
GND 31 30A
R 71 28
RS232 (+) 32
G 72
RS232 (-) 33
B 73
RS232 (GND) 34
NC 35

11074EL12
PUMP EPPR(+) 36
 OVERLOAD SW QUICK COUPLING SW

1
2
8

7
9
1
2
8

7
9
I

10

5
6
5
6
10

B
3
7
9

2
6

1
4
5
8
10
3
7
9

2
6

1
4
5
8

A
10

CS-50
CS-67

C
B

2
1
2
1
Y
B

OR
OR

POWER MAX
CS-29

CS-19

SAFETY SW
CS-4
A
B
C
Y
B

ONE TOUCH DECEL

GY
L/W
Y
OR

SIG
SIG
G

SIG
24V
24V
24V
OR

GND
GND

GND
R
R

G
G

R
G
W
W

W
1
2
8

7
9

1
2
3
1
2
3
1
2
3

PUMP3 PRESS
PUMP2 PRESS
PUMP1 PRESS
CD-42

CD-44
CD-43

B
V
R
R
R

B
W

BR
ELECTRIC CIRCUIT FOR HYDRAULIC

10

5
6

BREAKER SW
3
7
9

2
6

1
4
5
8
10
CS-27

GND
B

CD-7
GY

INT. SIG
B
PRE-HEAT

Pa 1
POWER 24V
GY

Y WASHER SIG
OR

TRAVEL ALARM

WORK PS
SWITCH PANEL
HEAD LIHGT 24V

CABIN LIGHT 24V

HEAD LIGHT OUT

CABIN LIGHT 24V

WORK LIGHT 24V
WORK LIGHT 24V
CABIN LIGHT OUT
CABIN LIGHT OUT
WORK LIGHT OUT
WORK LIGHT OUT

WIPER MOTOR DRIVE

CD-37 CN-15 CN-15

B
Pa 1 2
Y 17
16
15
14
13
12
11
10
9
7
3

6
2

8
5
4
1

2 1
BREAKER

CN-116
2
1
CS-26

OR
OR/W

2PCS BOOM AUTO-IDLE PS

GY
GY

B
Y

B
Y
B
OR

G
OR
GY

L/W

GY

V
R
OR/W

W
B

BR
CS-20 EARTH 1

SAFETY SW
2

9
8
7
5
4
1

6
1

2
2

9
8
7
5
5

4
1
4

6
9
8
7
6

3
3

8
7
5
4
1

6
3

5
4
1
12
11
10

6
12
11
10

3
CD-1
12
11
10

CN-6

B
CN-7

CN-1
CN-4
CN-8

C 1
BR/OR
B

B
B
Y
2

G
GY

V
B
B
Y

G
OR
GY

BR

HYD TEMP
B/W
OR/W

OR

L/W

CN-51
Y/W
WORKING PS 1
Y
POWER MAX SW 2
OR/W
TRAVEL ALARM SW 3
ENG OIL PS 4
NC 5
NC 6
R
24V(PRES.SENSOR) 7
B
GND(PRES.SENSOR) 8
ALT LEVEL 9
B/W
P1 PRESS SIG. 10
BR
P2 PRESS SIG. 11
V
P3 PRESS SIG. 12
NC 13
GY
O/T DECEL SW 14
WATER LEVEL SW 15
AIR CLEANER SW 16
NC 17
NC 18
NC 19
GND (POT & DIAL) 20
5V (POT & DIAL) 21
POT-SIG 22
ACCEL DIAL SIG 23

CPU CONTROLLER
FUEL LEVEL SENSOR 24
TACHO SENSOR(-) 25

4-22
TACHO SENSOR(+) 26
NC 27
NC 28
NC 29
NC 30
B
GND (SENSOR) 31
NC 32
HORN 10A
WATER TEMP SENDOR 19
33
CIGAR LIGHTER 10A
HYD TEMP SENDOR 34 20
BR/OR
NC ETHER(PRE-HEAT) 10A
35
21
21
NC 36 TRAVEL 5A
Y
22

R SOLENOID 1 10A
CN-50 23
G/W
BOOM PRIORITY SOL 1 SAFETY SOL 5A
BR/W R
24
FUSE BOX

MAX FLOW SOL 2

OR SOLENOID 3 10A
L/W
POWER MAX SOL 25
3
FUEL FILLER P/P 10A
HOUR-METER 4 26

SPARE 10A
ENG PREHEATER 5
27

NC 6 SPARE
27
BATTERY 24V(+) 7
PUMP EPPR(-) 8
NC 9
PROGRAM DUMP 10
ANTI-RESTART RY 11
ACCEL ACT(+) 12
W
TRAVEL SPEED SOL 13
NC 14
NC 15
V
TRAVEL BUZZER 16
PRE-HEAT SW 17
NC 18
NC 19
G
OVERLOAD SIG 20
NC 21
NC 22
B

ACCEL ACT(-) 23
L/W
B
Y
B

POWER IG 24
GY

NC 25
V
G
1
2
1
2

NC 26
CN-68
CN-66

Y
G

NC 27
2
1
1

CN-81
2

GND (MAIN) 28
1
2
SAFETY SOL

TRAVEL BZ
BREAKER SOL.

1
2
CN-140

SERIAL-TX 29
CN-55
CD-31

SERIAL-RX 30
QUICK COUPLING

GND
G 2
Y 1

31
Pa

RS232 (+) 32
OVERLOAD PS

RS232 (-) 33
RS232 (GND) 34
NC 35
2
1
2F
1F

2E
1E

2A
1A

NC 36
Y
Y

G
G
Y

Y
G

1
1
1

2
2
2
1
2

CN-70
CD-12
CD-13

CD-11
CD-14

W
1
Y
Pa
Pa
Pa
Pa

2
TRAVEL

CN-133
G/W
1
R
BOOM

CN-88
L/W
1
PRIORITY1 MAX

R
2
POWER

CN-137
BR/W
1
R
MAX
FLOW

2
14073EL13
GROUP 3 ELECTRICAL COMPONENT SPECIFICATION

Part name Symbol Specification Check

ö Check specific gravity

12V Ý 100Ah 1.280 over : Over charged
Battery
(2EA) 1.280 ~ 1.250 : Normal
1.250 below : Recharging

ö Check coil resistance (M4 to M4)

Rated load 
24V Normal : About 50̫
Battery relay 100A(continuity)
ö Check contact
1000A(30second)
Normal : â̫
CR-1
6
5
4
3
2
1

B öCheck contact
1

Ι ,O
OFF : â̫(For each terminal)
Start key 24V 40A
ON : 0̫(For terminal 1-3 and 1-2)
ΙΙ Ι O H START : 0̫(For terminal 1-5)
6
5

3
2

C ST ACC BR H
CS-2

1
Pa
Pressure switch 3 ~ 6kgf/cm2 ö Check contact
(For overload) 2 (N.O TYPE) Normal : â(OPEN)
CD-11, CD-12, CD-13
CD-14, CD-31

Pa
Pressure switch 0.5 kgf/cm2 ö Check resistance
(For engine oil)
CD-18
(N.C TYPE) Normal 
0̫(CLOSE)

4-23
 Part name Symbol Specification Check

Temperature ö Check resistance

1 C
sensor 50ÁC : 804̫

(Coolant, 80ÁC : 310̫
hydraulic) 2
100ÁC : 180̫
CD-1, CD-8

Air cleaner Pa Pressure: ö Check contact

pressure switch 635mmH2O
Normal : â̫
(N.O TYPE)
CD-10

2 ö Check contact
Coolant level
24V 0.5A High level : â̫
sensor 1
Low level : 0̫
CD-16

ö Check resistance
Full : 50̫ 6/12 : 350̫
2
11/12 : 100̫ 5/12 : 400̫
10/12 : 150̫ 4/12 : 450̫
Fuel sender 1  9/12 : 200̫ 3/12 : 500̫
CD-2 8/12 : 250̫ 2/12 : 550̫
CD-2 7/12 : 300̫ 1/12 : 600̫
Empty warning :700̫

1
m
rp

ö Check resistance
Tacho sensor 2 
Normal : 300̫(For terminal 1,2)
CD-17
CD-17

1 2 1
ö Check resistance
2
Normal : About 200̫
Relay 3 24V 20A
(For terminal 1-3)
4 4 3
: 0̫(For terminal 2-4)
CR-3

4-24
 Part name Symbol Specification Check

30
87a 87 85
86 ö Check resistance
87
Normal : About 160̫
85
Relay 87a
30 86 24V 16A (For terminal 85-86)
: 0̫(For terminal 30-87a)
CR-2 CR-35
CR-5 CR-36 : â̫(For terminal 30-87)
CR-7

M- 6
6 5
M M+ 5
ö Check resistance
NC 4
2
P-
Normal : 1-2̫(For terminal 5-6)
Accel actuator 3 -
3 1
SIG 2 0.8-1.2k̫
P+ 1 (For terminal 1-3)
CN-76

2
ö Check resistance
Solenoid valve 1 24V 1A Normal : 15~25̫
(For terminal 1-2)
CN-66 CN-68 CN-70
CN-88 CN-140

2 ö Check resistance
EPPR valve 700mA Normal : 18~25̫
1 (For terminal 1-2)

CN-75

1
ö Check resistance
Prolix resistor 50̫ 20WÜ 5%
Normal : 50̫
2

CN-47

2
öCheck resistance
Speaker 1 4̫ 20W
Normal : 4̫
CN-23(LH)
CN-24(RH)

4-25
 Part name Symbol Specification Check

ö Check contact
10 9 8 7 6 5 4 3 2 1

10 6 5
Normal
Switch ON - 0̫(For terminal 1-5,2-6)
(Looking type) 24V 8A
9
- â̫(For terminal 5-7,6-8)
8 2 7 1

CS-23, CS-24, OFF - â̫(For terminal 1-5,2-6)

CS-27, CS-54 - 0̫(For terminal 5-7,6-8)

8
2
7

9
1 ö Check contact
I
Normal
ON - 0̫(For terminal 1-5,2-6)
Switch 24V 8A
5

10
- â̫(For terminal 5-7,6-8)
10 OFF - â̫(For terminal 1-5,2-6)
9
3

7
2

6
1

4
5

CS-67 - 0̫(For terminal 5-7,6-8)

24V 70W ö Check disconnection

Lamp 1
(H3 TYPE) Normal : 1.2̫
CL-4, CL-5, CL-6,
CL-8, CL-9

1
ö Check disconnection
Room lamp 24V 10W
2 Nomal : A few ̫
CL-1

1 M
24V 10A ö Check resistance
Fuel filler pump 35 ˶/min
2 Normal : 1.0̫
CN-61

ö Check operation
1
h ÂSupply powe(24V) to
Hour meter 16V ~ 32V
2 terminal No. 2 and connect
terminal No. 1 and ground.
CN-48

4-26
 Part name Symbol Specification Check

ö Check operation
DC 22.0 ~ 28.0V
Horn ÂSupply powe(24V) to each
2A
terminal and connect ground.
CN-20 CN-25

ö Check contact
B C A Normal : 0̫(For terminal A-B)
24V 15A
Safety switch 1 B : â̫(For terminal A-C)
(N.C TYPE)
A C Operating : â̫(For terminal A-B)
CS-4 : 0̫(For terminal A-C)

24V ö Check contact

Safety switch 2 (N.C TYPE) Normal : 0̫(one pin to ground)
CS-20

ö Check resistance
Fuel cut-off 24V
Normal : 15~25̫
CN-79
CN-79

ö Check disconnection
Beacon lamp 24V 70W
Normal : 1.1̫

CL-7

Switch 1
(Power max, öCheck contact
One touch 2 24V 6A
Normal : â̫
decal, Breaker,
Horn) CS-5 CS-19
CS-26 CS-29

4-27
 Part name Symbol Specification Check

2 M
öCheck contact
Washer pump 1 24V 3.8A
Normal : 10.7̫(For terminal 1-2)
CN-22

öCheck coil resistance

Normal : About 1M̫
Cigar lighter 24V 5A 1.4W ö Check contact
Normal : â̫
Operating time : 5~15sec
CL-2

Switch öCheck resistance

(Door, Safety, 24V 2W
Normal : About 5M̫
Wiper cut)
CS-1, CS-20,
CS-53

3 1
2

5 3
4 öCheck contact
Wiper motor 4
5
24V 2A
Normal : 7̫(For terminal 2-6)
6 M 2 6

CN-21

N.C 1

S.R- 2

S.R- 3

S.L- 4
S.L-
N.C
5
6
ö Check voltage
ILL+ 7

Cassette radio S.R+ 8 24V 2A 20 ~ 25V

S.R+ 9
ACC
B+
10
11
(For terminal 10-14,11-14)
S.L+ 12

CN-27 S.L+
GND
13
14

2 Pa
ö Check contact
Receiver dryer 1 24V 2.5A
Normal : 0̫
CN-29

4-28
Part name Symbol Specification Check

ö Check contact
Start relay 24V 300A
Normal : 0.94̫(For terminal 1-2)

CR-23

M
M
Delco Remy ö Check contact
Starter
28MT 24V Normal : 0.1̫
B+
CN-45

G B+
~ 3 ö Check contact
Alternator I 24V 60A Normal : 0̫(For terminal B-1)
U
GND Normal : 24 ~ 27.5V
CN-74

1 ö Check contact
Travel alarm 24V 0.5A
2 Normal : 5.2̫
CN-81

1
Aircon ö Check contact
24V 79W
compressor Normal : 13.4̫
CN-28

ö Check resistance
Normal : About 5K̫
A + (For terminal A-C)
ö Check valtage
Accel dial B S -
Normal : About 5V
C - (For terminal A-C)
CN-142 : 2 ~ 4.5V
(For terminal C-B)

4-29
 Part name Symbol Specification Check

A 24V
DC/DC 24V 24V(A-B)
B GND 12V 3A
Converter 12V(B-C)
C 12V 12V
CN-138

1 M ö Check resistance
Blower motor 24V 9.5A
2.5̫(For terminal 1-2)
2

1 Lo 1 ö Check resistance
2 MH 3 1.12̫(For terminal 4-2)
Resistor -
3 ML 2 2.07̫(For terminal 2-3)
4 Hi 4 3.17̫(For terminal 3-1)

1 ö Check resistance
Duct sensor 1Á
C OFF
: 0̫(For terminal 1-2,
(Switch) 2 4Á
C ON
the atmosphere temp : over 4Á
C)

ö Check contact
Preheater
24V 200A Normal : 0.94̫
relay
(For terminal 1-GND)
CN-24

ö check resistance
Preheater 24V 200A
: 0.25 ~ 0.12̫

4-30
Part name Symbol Specification Check

10

5
4

1
6

2
9

3
10

1
Main light ö Check contact
24V 8A
switch I 0
OFF : â̫(For terminal 1-5, 2-4)

2
9

7
5
CS-21

4-31
GROUP 4 CONNECTORS

1. CONNECTOR DESTINATION
Connectorn No. of Connector part No.
umber Type pin Destination
Female Male
CN-2 AMP 15 Engine harness 2-85262-1 S816-112002
CN-4 AMP 8 LH console wire harness S816-008002 S816-108002
CN-5 AMP 15 RH side harness 2-85262-1 S816-112002
CN-6 AMP 12 RH side harness S816-012002 S816-112002
CN-8 AMP 12 RH console wire harness S816-012002 S816-112002
CN-9 AMP 8 RH console wire harness S816-008002 S816-108002
CN-10 DEUTSCH 12 Cab harness DT06-12S DT04-12P
CN-11 DEUTSCH 8 LH console wire harness DT06-8S -
CN-12 DEUTSCH 2 Work lamp harness DT06-2S-EP06 DT04-2P
CN-17 DEUTSCH 8 Wipe harness DT06-8S DT04-8P
CN-20 MOLEX 2 Horn 35825-0211 -
CN-21 AMP 6 Wiper motor 925276-0 -
CN-22 - 2 Washer tank MG640605 -
CN-23 KET 2 LH speaker MG610070 7322-1520
CN-24 KET 2 RH speaker MG610070 7322-1520
CN-25 MOLEX 2 Horn 35825-0211 -
CN-27 AMP 14 Cassette radio 173852 AMP14P
CN-28 - 1 Air-con comp MWP-01F-B -
CN-29 KET 2 Receiver dryer MG640795 -
CN-45 RING TERM 1 Starter S820-308000 -
CN-47 AMP 2 Emergency resistor S810-002202 -
CN-48 - 2 Hour meter S810-002202 -
CN-50 AMP 36 CPU 3441111-1 -
CN-51 AMP 36 CPU 3441111-1 -
CN-55 AMP 2 Travel alarm pressure switch S816-002002 S816-102002
CN-56 DEUTSCH 4 Cluster - DT04-4P
CN-60 - 2 Fusible link - 7122-4125-50
CN-61 DEUTSCH 2 Fuel filler pump DT06-2S-EP06 DT01-2P-P012
CN-66 DEUTSCH 2 Breaker solenoid valve DT06-2S-EP06 DT04-2P-E005
CN-68 DEUTSCH 2 Safety solenoid valve DT06-2S-EP06 -
CN-70 DEUTSCH 2 Travel speed solenoid valve DT06-2S-EP06 -
CN-74 KET 2 Alternator MG640188-4 -
CN-75 - 2 EPPR valve S816-002002 -
CN-76 DEUTSCH 6 Accel actuator DT06-6S-EP06 -
CN-79 RING TERM 1 Fuel cut-off solenoid S820-104000 -
CN-81 DEUTSCH 2 Travel buzzer DT06-2S-EP06 DP04-2P-E005
CN-88 DEUTSCH 2 Power max solenoid valve DT06-2S-EP06 -
CN-92 AMP 1 Safety S814-101100 S814-001100

4-32
Connectorn No. of Connector part No.
umber Type pin Destination
Female Male
CN-95 KET 2 Fusible link - S813-130200
CN-125 - 4 GPS S816-004002 S816-104002
CN-126 DEUTSCH 4 RS232C connector DT06-4S-P012 DT04-4P-E004
CN-138 DEUTSCH 3 DC/DC converter DT06-3S DT04-3P
CN-139 DEUTSCH 2 12V Socket - DT04-2P
CN-140 DEUTSCH 2 Quick coupling DT06-2S-EP06 DT04-2P-E005
CN-141 AMP 13 Wiper motor control unit 172498-1 -
CN-142 DEUTSCH 3 Accel dial DT06-3S -
CN-143 KET 14 Cassette radio MG610406 -
CN-144 AMP 12 Remocon 174045-2 -
RELAY
CR-1 RING TERM 1 Battery relay S820-104002 -
CR-3 - 4 Work lamp relay S820-104000 -
CR-23 - 2 Start relay S820-104000 -
CR-24 - 1 Pre-heater relay S822-014000 -
CR-43 - 4 Engine stop relay S810-004202 -
SWITCH
CS-1 CB104 1 Door switch S822-014004 -
CS-2 - 6 Start key switch S814-006000 -
CS-4 DEUTSCH 6 Safety switch DT06-3S -
CS-5 DEUTSCH 2 Horn switch - DT04-2P
CS-19 DEUTSCH 2 One touch decel DT06-2S DT04-2P
CS-20 AMP 1 Safety switch S822-014002 -
CS-21 SWF 10 Main light switch SWF593757 -
CS-23 SWF 10 Beacon lamp switch SWF593757 -
CS-24 SWF 10 Overload switch SWF593757 -
CS-26 DEUTSCH 2 Breaker switch SWF593757 -
CS-27 SWF 10 Breaker switch SWF593757 -
CS-29 DEUTSCH 2 Power max DT06-2S DT04-2P
CS-53 AMP 1 Wiper cut switch S822-014002 -
CS-54 SWF 10 Travel alarm SWF593757 -
CS-67 SWF 10 Quick coupling switch SWF593757 -
LAMP
CL-1 KET 2 Cab room lamp MG610392 -
CL-2 - 1 Cigar light S822-014002 -
CL-4 DEUTSCH 2 Head lamp - DT04-2P-E005
CL-5 DEUTSCH 2 Work lamp-LH - DT04-2P
CL-6 DEUTSCH 2 Work lamp-RH - DT04-2P
CL-7 CB104 1 Beacon lamp S822-014004 -
CL-8 DEUTSCH 2 LH cabin light - DT04-2P
CL-9 DEUTSCH 2 RH cabin light - DT04-2P

4-33
Connectorn No. of Connector part No.
umber Type pin Destination
Female Male
SENDER
CD-1 AMP 2 Hydraulic Temp sender 963040-3 -
CD-2 DEUTSCH 2 Fuel sender DT06-2S-EP06 -
CD-8 - 2 Water temp sender 85202-1 -
CD-10 RING TERM 1 Air cleaner switch S820-104002 -
CD-11 AMP 2 Travel alarm pressure switch S816-102002 -
CD-12 AMP 2 Travel alarm pressure switch S816-102002 -
CD-13 AMP 2 Travel alarm pressure switch S816-102002 -
CD-14 AMP 2 Travel alarm pressure switch S816-102002 -
CD-16 - 2 Water level S814-002100 -
CD-17 - 2 Tacho sensor S814-002001 -
CD-18 RING TERM 1 Engine oil pressure switch S819-010122 -
CD-31 DEUTSCH 2 Overload pressure switch DT06-2S-EP06 -

4-34
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

4-35
No. of
Receptacle connector(Female) Plug connector(Male)
pin

6 13 1 7

13

1 7 6 13
S811-013002 S811-113002

8 17 1 9

17

1 9 8 17
S811-017002 S811-117002

10 21 1 11

21

1 11 10 21
S811-021002 S811-121002

4-36
2) J TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin

1 1
2

2 12
S816-002001 S816-102001

2 3 1

3 1 2
S816-003001 S816-103001

3 1 4 2

4 2 3 1
S816-004001 S816-104001

6 3 1 8 5 2

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

4-37
3) SWP TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin

1 1

S814-001000 S814-101000

2 1

1 2

S814-002000 S814-102000

3 1

2 1 23

S814-003000 S814-103000

2 4
1 3

1 3
2 4
S814-004000 S814-104000

4-38
No. of
pin Receptacle connector(Female) Plug connector(Male)

3 6
1 4

1 4 3 6
S814-006000 S814-106000
4 8
1 5

1 5 4 8
S814-008000 S814-108000

4 12 1 9

12

1 9 4 12
S814-012000 S814-112000

3 14 1 11

14

1 11 3 14
S814-014000 S814-114000

4-39
4) CN TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
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

4-40
No. of
Receptacle connector(Female) Plug connector(Male)
pin
3 6 1 4

1 4 3 6
S810-006202 S810-106202

4 8 1 5

1 5 8
4
S810-008202 S810-108202

4-41
5) 375 FASTEN TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin

1 2 1 2

S810-002402 S810-102402

6) AMP ECONOSEAL CONNECTOR

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

1
12

1 13
24
36
36
13 25 12
24
25
36
344111-1 344108-1

7) AMP TIMER CONNECTOR

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

85202-1

4-42
8) AMP 040 MULTILOCK CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin

12
1 6

7 12
174045-2

9) AMP 070 MULTILOCK CONNECTOR

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

14 1 6

7 14
173852

10) AMP FASTIN - FASTON CONNECTOR

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

3 1

6 4
1
4 6 3

925276-0 480003-9

4-43
11) KET 090 CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin

2 1

MG610070

12) KET 090 WP CONNECTORS

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

1
2

MG640605

2 1

MG640795

4-44
12) KET SDL CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin

1
14

14 6

MG610406

4-45
13) DEUTSCH DT CONNECTORS
No. of
Receptacle connector(Female) Plug connector(Male)
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

4-46
No. of
Receptacle connector(Female) Plug connector(Male)
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

4-47
14) MOLEX 2CKTS CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin

1 2

35215-0200

15) ITT SWF CONNECTOR

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

2
10

1 10

SWF593757

16) MWP NMWP CONNECTOR

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

1
1

NMWP01F-B

4-48
 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, one touch
deceleration, power boost function, etc. It monitors machine conditions, for instance, engine speed,
coolant temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
It consists of a 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

Mode selection system Pump control system
Power mode selection
Power boost system

Travel speed control system Travel speed control system

Automatic warming up system

NEW CAPO
SYSTEM Engine overheat prevention 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

5-1
SYSTEM DIAGRAM

Travel motor

Regulator

Main control valve

Extra C

Extra B Bucket
(Dozer)
Extra A &
Arm 1
Arm regen
Power boost
Boom 2 Arm 2 solenoid valve
S/Priority

Swing Boom 1 Travel speed

solenoid valve
Travel(RH) Travel(LH)

Straight
Travel Main relief
valve

Engine speed
sensor
Engine

P1 P2
Coolant
temp sensor

Main pump Pilot pump

Accel
Fuel injection Hyd temp
actuator
pump sensor
One touch P M
Horn decel button
EPPR valve
Engine speed sensor signal
Potentiometer signal

Power boost
Option
Motor drive signal

button
button

RH control LH control
lever lever signal Hyd temperature signal
signal
Drive signal
Coolant temperature signal
CPU controller
Drive signal

Accel dial signal

Normal
Accel dial
Emergency
(optional)
Serial Communication(-)
Drive signal
Serial Communication(+)

Prolix Battery
Resistor

11075MS01

5-2
GROUP 2 MODE SELECTION SYSTEM

1. POWER MODE SELECTION SYSTEM

Main control valve

Engine speed
sensor
Engine

Main pump Pilot pump

Accel
Fuel injection actuator
pump
P M
EPPR valve

Engine speed sensor signal

Potentiometer signal

Motor drive signal

Power mode switch signal CPU controller

Accel dial signal

Accel dial

Drive signal
Normal Emergency
Resistor Battery
Option

11075MS02

Mode selection system(Micro computer based electro-hydraulic pump and engine mutual control
system) optimizes the engine and pump performance.
The combination of 3 power modes(H, S, L) 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 ö
Mode Application set
(%) Current Pressure Current Pressure
Unload Load (kgf/cm2) (kgf/cm2)
(mA) (mA)
H High power 100 2050Ü50 1850 245Ü30 4.1 245 4.1
S Standard power 85 1950Ü50 1750 290Ü30 7.5 318 8.8
L Light power 70 1850Ü50 1650 370Ü30 14.5 439 17.4
One touch decel Engine quick deceleration - 950Ü100 - 650Ü30 46 650Ü30 40
KEY START Key switch start position - 950Ü100 - 650Ü30 40 650Ü30 40
ö Other case can be set by pressing the "travel speed" switch and "buzzer stop switch" for 2 seconds
at the same time in "model & version" display on the cluster(for detail, see 5-17)

5-3
GROUP 3 POWER BOOST SYSTEM

Main control valve

Extra C

Extra B Bucket
(Dozer)
Extra A &
Arm 1
Arm regen
Boom 2 Arm 2
S/Priority

Swing Boom 1

Travel(RH) Travel(LH)

Straight
Travel Main relief Power boost
valve solenoid valve

Engine speed
sensor
Engine

Main pump Pilot pump

Accel
Fuel injection actuator
pump
P M EPPR valve
One touch
decel button
Engine speed sensor signal

Power boost
button
Potentiometer signal

Motor drive signal

LH control
lever

Power boost button signal

Drive signal

Mode switch signal Drive signal

CPU controller

11075MS03

 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 set H or S H
Main relief valve set pressure 330kgf/cm2 360ksf/cm2
Even when pressed continuously,
Time of operation -
it is canceled after 8 sec.
ö Default - Power boost solenoid valve : OFF

5-4
GROUP 4 TRAVEL SPEED CONTROL SYSTEM

Travel motor

Main control valve

Extra C

Extra B Bucket
(Dozer) Regulator Regulator
Extra A &
Arm 1
Arm regen
Boom 2 Arm 2
S/Priority

Swing Boom 1

Travel(RH) Travel(LH)

Straight
Travel

Travel spped
solenoid valve

Engine

Main pump Pilot pump

EPPR valve

Travel speed switch signal Drive signal

CPU controller

11075MS04

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
ö Default : Turtle(Lo)

5-5
GROUP 5 AUTOMATIC WARMING UP FUNCTION

Engine

Coolant
temp sensor

Main pump Pilot pump

Accel
Fuel injection actuator
pump
P M EPPR valve

Coolant temperature signal

Potentiometer signal

Motor drive signal

Drive signal

Warming up lamp signal

CPU controller

11075MS05

1. CPU controller reads engine coolant temperature through the temperature sensor, and if the coolant
temperature is less than 30Á
C, it increases the engine speed from key start rpm to 1200rpm.
2. In case of the coolant temperature increases up to 30Á
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 : S mode)
- Mode : Default(S
Actuated Less than 30Á C(After engine run) - Warming up time : 10 minutes(Max)
- Accel dial position is under 3 - Warming up lamp : ON

- Coolant temperature : Above 30Á 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
ö If any of the above conditions is
applicable, the automatic warming up
function is canceled

Warming up lamp - Coolant temperature : Above 30Á

C - Warming up lamp : OFF

5-6
GROUP 6 ENGINE OVERHEAT PREVENTION FUNCTION

Engine

Coolant
temp sensor

Main pump Pilot pump

Accel
Fuel injection actuator
pump
P M EPPR valve

Coolant temperature signal

Potentiometer signal

Motor drive signal

Drive signal

Overheat warming signal

CPU controller

11075MS06

1. CPU controller reads engine coolant temperature through the temperature sensor and when the
engine coolant boils up to 110Á
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 100ÁC, 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 100Á C.
3. LOGIC TABLE
Description Condition Function

- Coolant temperature : Above 110Á

C - Engine rpm drop to accel dial 7 position
Actuated
- Accel dial set : Above 8 - Overheat warning lamp & buzzer : ON

- Coolant temperature : Less than 100ÁC - Return to the mode and accel dial set before
- Changed mode set by operator - Hold on the changed set
Canceled ö If any of the above conditions is
applicable, engine overheat prevention
function is canceled

Overheat warning lamp - Coolant temperature : Less than 100Á

C - Overheat warning lamp : OFF

5-7
GROUP 7 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.

5-8
GROUP 8 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 : Err 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 : Err & 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.

5-9
5. ERROR CODES TABLE

Fault code No. Description

00 No error
01 Short circuit in accel actuator motor system
02 Potentiometer circuit is shorted to Vcc(5V) or battery +
03 Short circuit in pump EPPR valve system
05 Short circuit in travel speed solenoid system
10 Short circuit in hour-meter system
11 Accel dial circuit is shorted to Vcc(5V) or battery +
16 Accel actuator 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
20 Travel speed 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
31 Engine preheater circuit is open or shorted to ground
33 Alternator circuit is open or shorted to ground
34 Actuator input voltage is below 18V
35 Actuator input voltage is over 38V
36 Communication error with cluster
37 Engine speed sensor circuit is open or shorted to ground
40 There is more than 500rpm difference between target speed and actual speed
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
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 +
49 Engine preheater circuit is shorted to battery +

5-10
GROUP 9 ENGINE CONTROL SYSTEM

1. CPU CONTROLLER MOUNTING

TON
EBA
L
VOL
ON BAND
SEEK
push
FAD
TUNE
1
2
4 PRO
3
5 G
6

PLL
SYNT
HESI
ZER
TUNN
ING

20A

SPARE
SPARE
RE
CAB

10A 10A 20A 10A

SPARE

HOLDER
LAMP
SPARE

10A
FUSE
CABIN

LAMP
LAMP SPARE

5A
BEACON

10A
WORK
F/PUMP
LAMP & HEATER FUEL

10A 10A 20A

KEY AC
HEAD

5A
3

20A
START
MOTOR

5A
SOLENOID
LAMP HONE

20A
WIPER 2

5A
BOOM
SOL. LIGHT

5A
SOLENOID
CIGAR
& HEATER

5A
SAFETY 1
AC

5A
PANEL - HEAT

10A
SOLENOID
MOTOR

5A
PRE

5A
SWITCH

5A
WIPER
RY
TRAVEL

5A
CUT-OFF CONVERTOR HONE

5A
10A 20A
FUEL
PANEL
RY -2

10A
SWITCH
CLUSTER CR
COMP
AC RY
C/RADIO

5A
-7 ETHER
RY CR
POWER - 36
CR
- 35
CR
RY

SAFETY
-5
CR

1 CPU controller 1
2 Electric box
3 Bolt(M8)

3
11075MS12

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.

5-11
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

5-12
4. ENGINE ACCEL ACTUATOR
1 Accel actuator
2 Push-pull cable for manual control

11075MS07

1) ENGINE THROTTLE LEVER

SL : Stopper, low idle

Throttle lever SH : Stopper, high idle

SL SH

Accel actuator

11075MS08

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.

5-13
3) ACCEL ACTUATOR

2 4

1 DC motor
2 Cable
3 Nut
4 Ball joint
5 Connector
11075MS09

6 1
Connector 5 2
4 3

Type 6P, female

1 Green(Potentiometer 5V)
2 White(Potentiometer SIG)
Line color 3 Yellow(Potentiometer GND)
& description 4 -
5 Red(Motor+)
6 Blue(Motor -)
Check resistance
Inspection Spec : 10̫(Between No.5-6)
5k̫(Between No.1-3)

5-14
4) ACCEL ACTUATOR CABLE SETTING PROCEDURE
(1) Key ON
Η Set the engine control dial max position and the one touch decel switch OFF.
Θ Connect the ball joint of cable to engine throttle lever.
Ι Pull the cable to high stopper and put nut A edge to yoke of the bracket.
ö Make throttle lever not contact to the edge of high stopper.
(2) Key START
Κ Confirm if the engine speed on cluster is same as each mode specification.
Λ If the engine speed displayed on cluster is highter than each mode specification, then turn the nut
Μ A to counter clockwise and make the engine speed same to each mode specification.
If the engine speed displayed on cluster is lower than each mode specification, then turn the nut
Ν A to clockwise and make the engine speed same to each mode specification.
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 2050Ü50
S 1950Ü50
L 1850Ü50
Key start(one touch decel) 950Ü100

5-15
5. ENGINE SPEED SENSOR
1) DETECT ACTUAL ENGINE RPM AND SEND SIGNAL TO TACHOMETER

3 2

Flywheel housing
2 Gear teeth, flywheel
3 Lock nut, speed sensor
A Clearance
11075MS10/R140LC-7 기타 5-20

2) INSTALLATION
(1) Clean contacting point of sensor.
(2) Loosen lock nut.
(3) Screw speed sensor into flywheel housing.
(4) Turn it back 135Áwhen it contacts with gear teeth.
(5) Tight lock nut and connect wiring.
3) INSPECTION
(1) Check resistance
ÂSPEC : 300̫
(2) Check voltage while engine run.
ÂSPEC : 2~28Vac, dependent on the engine speed(rpm)

5-16
GROUP 10 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 AND ELECTRIC CURRENT VALUE FOR EACH MODE
Pressure Electric current Engine rpm
Mode
kgf/cm2 psi (mA) (At accel dial 10)

H 4.1 Ü 3 58 Ü 40 245 Ü 30 2050 Ü 50

Standard
S 7.5 Ü 3 110 Ü 40 290 Ü 30 1950 Ü 50
(Ver : 1.x)
L 14.5Ü 3 210 Ü 40 370 Ü 30 1850 Ü 50
H 4.1 Ü 3 58 Ü 40 245 Ü 30 2150 Ü 50
Option
(Ver : 2.x) S 8.8 Ü 3 125 Ü 40 318 Ü 30 2050 Ü 50
L 17.4 Ü 3 250 Ü 40 439 Ü 30 1950 Ü 50
ø 19.8 Ü 3 280 Ü 40 471 Ü 30 -
ø Manually operated condition when prolix switch is selected emergency position.

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
11:C1.0press the buzzer stop switch( ) + travel speed control switch( ) at the
same time for 2 seconds.
The display changes to 11:C2.0, 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.

5-17
2. OPERATING PRINCIPLE
1) STRUCTURE

6 7

2 3 4 5

R140LC-7 기타 5-22(1)

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

2) AT H MODE
Pressure line is blocked and A oil returns to tank.

P A
T
P T

3) AT S MODE
Secondary pressure enters into A.

P A
T

P T

A
R140LC-7 기타 5-22(2)

5-18
3. EPPR VALVE CHECK PROCEDURE Spec : 200~500mA
1) CHECK ELECTRIC VALUE AT EPPR VALVE
(1) Start engine.
(2) Set S-mode and cancel auto decel mode.
CN-75
(3) Position the accel dial at 10.
(4) If tachometer show approx 1950Ü50rpm,
disconnect one wire harness from EPPR
valve. EPPR VALVE

Multimeter
(5) Install multimeter as figure.
(6) Check electric current at bucket circuit
relief position. R140LC-7 기타 5-23(1)

2) CHECK PRESSURE AT EPPR VALVE Spec : 2~25kgf/cm2(30~350psi)

(1) Remove plug and connect pressure
gauge as figure.
ÂGauge capacity : 0 to 40-50kgf/cm2
(0 to 580-725psi)
(2) Start engine.
Supply line, pilot press
(3) Set S-mode and cancel auto decel mode.
CN-75
(4) Position the accel dial at 10.
Pressure adjusting
screw
(5) If tachometer show approx 1950Ü50rpm, 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. R140LC-7 기타 5-23(2)

5-19
GROUP 11 PUMP PROLIX

Its the conversion connector to manual control temporarily when the electronic control system is out
of order, until repair work be done.

Normal Emergency

CN-47 CN-47

CN-19&19A CN-19&19B
CN-19B
CN-19A

CN-96A CN-96A
CN-96B CN-96B

16075MS12

1. OPERATING PRINCIPLE WIRING DIAGRAM

16075MS30

1) NORMAL
ÂEPPR 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
ÂIf prolix resistor(CN-19) is connected with CN-19B 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.
ÂIn this case excavator can be operated at an equivalent performance to S mode.

5-20
GROUP 12 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

Preheat switch
Travel speed switch

Buzzer stop switch

Select switch

11075MS11

5-21
2) CLUSTER CHECK PROCEDURE
(1) Start key : ON
Η Check monitor initial 5 seconds
a. All lamps light up.
b. Buzzer sound.
Θ Check monitor after 5 seconds : Indicate cluster version and machine condition
a. Cluster program version : CL : 2.0 Indicates program version 2.0 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
ö During start key ON the engine oil pressure lamp and battery charging lamp go on, but it is not
abnormal.
ö When engine coolant temperature below 30Á C, the warming up lamp lights up.
Ι Indicating lamp state
a. Power mode selection : S mode
b. Preheat : No LED ON
c. Wiper : No LED ON
d. Washer : No LED ON
e. Travel speed pilot lamp : Low(Turtle)
(2) Start of engine
Η Check machine condition
a. Tachometer indicates at present rpm
b. Gauge and warning lamp : Indicate at present condition.
ö When normal condition : All warning lamp OFF
c. Preheat : No LED ON
d. Power mode selection : S mode
e. Wiper : No LED ON
f. Washer : No LED ON
g. Travel speed pilot lamp : Low(Turtle)
Θ When warming up operation
a. Warming up lamp : ON
b. 10 seconds after engine started, engine speed increases to1200rpm(Auto decel LED : ON)
ö Others same as above Η
Ι 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.

5-22
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

5-23
4. CLUSTER FUNCTION
1) MONITORING DISPLAY
Η This displays the current time and machine information such as
engine rpm, coolant/hydraulic oil temperature, hydraulic oil
pressure and also error codes.
ö Refer to the page 5-29 for details.

14073CD03

2) FUEL GAUGE
Η This gauge indicates the amount of fuel in the fuel tank.
Θ Fill the fuel when the white range or warning lamp blinks.
ö 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 poor
21073CD04 connection of electricity or sensor.

3) HYDRAULIC OIL TEMPERATURE GAUGE

Η This indicates the temperature of coolant.
ÂWhite range : 30Á C(86ÁF) below
ÂGreen range : 30-105 Á C(86-221Á F)
Red range ÂRed range : 105Á C(221Á F) above
Θ The green range illuminates when operating.
21073CD05 Ι Keep idling engine at low speed until the green range
illuminates, before operation of machine.
Κ 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

Η This indicates the temperature of coolant.
ÂWhite range : 30Á C(86Á F) below
ÂGreen range : 30-105 Á C(86-221ÁF)
Red range ÂRed range : 105Á C(221Á F) above
Θ The green range illuminates when operating.
21073CD05 Ι Keep idling engine at low speed until the green range
illuminates, before operation of machine.
Κ When the red range illuminates, turn OFF the engine, check the
radiator and engine.

5-24
5) FUEL LOW LEVEL WARNING LAMP
Η This lamp blinks and the buzzer sounds when the level of fuel is
below 28˶(7.4U.S. gal).
Θ Fill the fuel immediately when the lamp blinks.

21073CD04A

6) HYDRAULIC OIL TEMPERATURE WARNING LAMP

Η This warning lamp operates and the buzzer sounds when the
temperature of hydraulic oil is over 105 Á
C 221 Á F) .
Θ Check the hydraulic oil level when the lamp blinks.
Ι Check for debris between oil cooler and radiator.

21073CD05A

7) OVERHEAT WARNING LAMP

Η This lamp blinks and the buzzer sounds when the temperature
of coolant is over the normal temperature 110Á
C 230Á
F) .
Θ Check the cooling system when the lamp blinks.

21073CD06A

8) ENGINE OIL PRESSURE WARNING LAMP

Η This lamp blinks and the buzzer sounds after starting the engine
because of pressure.
Θ If the lamp blinks during engine operation, shut OFF engine
immediately. Check oil level.

21073CD07

9) AIR CLEANER WARNING LAMP

Η This lamp is operated by the vacuum caused inside when the
filter of air cleaner is clogged which supply air to the engine.
Θ Check the filter and clean or replace it when the lamp blinks.

21073CD08

5-25
10) COOLANT LEVEL WARNING LAMP
Η This lamp blinks and the buzzer sounds when the coolant is
below LOW in the reservoir tank of radiator.
Θ Check the reservoir tank when the lamp blinks.

21073CD09

11) CPU CONTROLLER CHECK WARNING LAMP

Η Communication problem with CPU controller makes the lamp
blinks and the buzzer sounds.
Θ With lamp blinks all of the lamp on the cluster LCD will be OFF.

21073CD10

12) BATTERY CHARGING WARNING LAMP

Η This lamp blinks and the buzzer sounds when the starting
switch is ON, it is turned OFF after starting the engine.
Θ Check the battery charging circuit when this lamp blinks, during
engine operation.

21073CD13

13) OVERLOAD WARNING LAMP

Η When the machine is overload, the overload warning lamp
blinks during the overload switch ON.

21073CD15

14) POWER BOOST PILOT LAMP

Η The lamp will be ON when pushing power boost switch on the
LH RCV lever.

21073CD11

5-26
15) ONE TOUCH DECEL PILOT LAMP
Η Operating auto decel or one touch decel makes the lamp ON.
Θ The lamp will be ON when pushing one touch decel switch on
the LH RCV lever.

21073CD17

16) WARMING UP PILOT LAMP

Η This lamp is turned ON when the coolant temperature is below
30ÁC 86 Á F).
Θ The automatic warming up is cancelled when the engine
coolant temperature is above 30 Á
C, or when 10 minutes have
passed since starting.
21073CD18

17) PREHEAT PILOT LAMP

Η This lamp is turned ON when the preheating function is
actuated in cold weather.
Θ Start the engine as this lamp is OFF.

21073CD12

18) POWER MODE SWITCH

Η This switch is to select the machine power mode, which shifts
from high power work to standard power work and light power
work in a raw by pressing the switch.
ÂH : This is used for high power work
ÂS S : This is used for standard power work
11073CD20 ÂL : This is used for light power work

19) WIPER MODE SWITCH

Η This switch is used to operate wiper.
ÂPress the switch once to operate wiper.
ÂPress the switch once more to intermittently operate wiper
low speed.
ÂPress the switch once more to turn off wiper.
11073CD21 ö Wiper motor doesn't operate with front sliding door open.
ö If wiper does not operate with the switch in the ON position,
turn the switch off immediately. Check the cause.
If the switch remains ON, it can result in motor failure.

5-27
20) WASHER SWITCH
Η The washer liquid is sprayed and the wiper is operated only
while pressing this switch.
Θ The indicator lamp is turned ON when operating this switch.

11073CD22

21) PREHEAT SWITCH

Η This switch is used for starting the engine in cold weather.
If pressed, grid heater is activated to get easier engine starting.
ö Never hold the push button switch in for more than 30
seconds, as this can damage the grid heater.
Θ The indicator lamp is turned ON when operating this switch.
11073CD23

22) TRAVEL SPEED CONTROL SWITCH

Η 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

23) BUZZER STOP SWITCH

Η When the starting switch is turned ON first, normally the alarm
buzzer sounds for 5 seconds during lamp check operation.
Θ 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.

24) SELECT SWITCH

Η This switch is used to select the monitor display function.
ö Refer to the page 5-29 for details.
Θ If the switch is pressed for 3 seconds in time display mode, it is
selected time adjusting function, as below.
ÂHour by auto decel switch
21073CD25A ÂMinute by buzzer stop switch.
Ι After time set, the switch is pressed, it is returned clock.

5-28
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
Way 1
Initial Engine rpm
Key switch
ON or START
Way 2 Touch SELECT 1 time Time
Group 0
(Default) Touch WASHER Power shift pressure
switch while pressing Touch SECLET 2 times (EPPR valve)
BUZZER STOP at
group 1~4. Touch SELECT 3 times CPU model & version

Default Battery voltage(V)

Touch SELECT switch Touch SELECT 1 time Potentiometer voltage(V)

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

Touch SELECT switch Default Current error

twice while pressing
Group 2 Recorded error
(Error code)
BUZZER STOP. Touch SELECT 1 time
(Only key switch ON)
In this group BUZZER
STOP LED blinks
Press down( ) & Recorded error deletion
SELECT at the same time (Only key switch ON)

Default Power boost switch or

Touch SELECT switch
3 times while pressing
Touch SELECT 1 time One touch decel switch or
Group 3 BUZZER STOP.
(Switch input) In this group SELECT
Preheat switch
LED blinks at 0.5sec Touch SELECT 2 times
or

interval
Touch SELECT 3 times Overload pressure switch or

Default Hourmeter
Touch SELECT switch Neutral relay
Touch SELECT 1 time (Anti-restart relay)
4 times while pressing
Group 4 BUZZER STOP.
SELECT 2 times
(Output) In this group SELECT Touch Travel speed solenoid or

LED blinks at 1sec Power boost solenoid

interval Touch SELECT 3 times (2-stage relief solenoid)

Touch SELECT 4 times Preheat relay

öBy touching SELECT switch once while pressing BUZZER STOP, display group shifts.
Example : Group 0 1 2 3 4 0

5- 29
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)

Group 0 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(R110-7) and the program version

Model and CPU
11 : C1.0 of the CPU controller is 1.0.
program version
Version display range : 0.0~9.9 by 0.1

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 Range : 0.0~5.0V by 0.1V
voltage

Accel dial It shows that accel dial signal voltage is 3.8V.

Group 1 dL : 3.8V
voltage Range : 0.0~5.0V by 0.1V

It shows that hydraulic oil temperature detected by temperature

Hydraulic oil
Á
Hd : 50Á
C sensor is 50ÁC.
temperature
Range : 0~150Á C by 1Á C

It shows that coolant oil temperature detected by temperature

Coolant
Ct : 85Á
C sensor is 50ÁC.
temperature
Range : 0~150Á C by 1ÁC

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.

5-30
Group Display Name Description

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).

One touch od : on Shows that one touch decel switch is pressed.

od : on or oFF
Group 3 decel switch od : oFF Shows that one touch decel switch is released.

PH : on Shows that preheat switch is pressed.

PH : on or oFF Preheat switch
PH : oFF Shows that preheat switch is released.

Overload ol : on Shows that overload pressure switch is turned ON.

ol : on or oFF
pressure switch ol : oFF Shows that overload pressure switch is turned OFF.

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).
Group 4 ts : on or oFF
solenoid ts : oFF Shows that travel speed solenoid is released
(Low speed).

PS : on Shows that power boost solenoid is activated to

Power boost maximize the power(Power up).
PS : on or oFF
solenoid PS : oFF Shows that power boost solenoid is turned off(Cancel
the power boost function).

PR : on Shows that preheat relay is activated.

PR : on or oFF Preheat relay
PR : oFF Shows that preheat relay is released.

5-31
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 repaired
13031SH03
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 R140LC-7 ‫׆‬೴ 6-2(3)

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.

R140LC-7 ‫׆‬೴ 6-3(1)

STEP 5. Perform troubleshooting

According to where the trouble parts are
located, hydraulic & mechanical system part or
electrical system part or mechatronics system
part, perform troubleshooting the machine refer
to the each system part's troubleshooting
process diagram.

13031SH05

STEP 6. Trace a cause

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

Make a plan of the appropriate repairing

procedure to avoid consequential malfunctions.

R140LC-7 ‫׆‬೴ 6-3(3)

6-3
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM

1. INTRODUCTION
1) MACHINE IN GENERAL
(1) If even a minor fault is left intact and operation is continued, a fatal failure may be caused, entailing
a large sum of expenses and long hours of restoration.
Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look
for the cause based on the troubleshooting principle and perform maintenance and adjustment to
prevent major failure from occurring. Keep in mind that a fault results from a combination of
different causes.
(2) The following lists up commonly occurring faults and possible causes with this machine. For the
troubleshooting of the engine, refer to the coming troubleshooting and repair.
(3) When carrying out troubleshooting, do not hurry to disassemble the components.
It will become impossible to find the cause of the problem.
(4) Ask user or operator the following.
Η Was there any strange thing about machine before failure occurred?
Θ Under what conditions did the failure occur?
Ι Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
Η Check oil and fuel level.
Θ Check for any external leakage of oil from components.
Ι 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 ͽ
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
ͽ 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
ͽ
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.
ͽ
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 ͽ
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.
ͽ when dust plug
under engine fly
Are attachment Is not main relief NO Hydraulic pump is Disassemble and
wheel is removed? NO
and travel valve faulty?
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
Ϳ
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.
Ϳ 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? ͽ
Does swing
YES control valve
Both directions spool move
Is MCV pilot lightly by hand?
YES Swing control valve Disassemble
pressure within
Is Arm speed spool is stuck. and repair.
standard level?
within standard ;
value? NO
Ϳ
NO

Is swing motor's NO
ͽ 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
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
Ϳ setting pressure change when front
YES
and rear pump is broken. and repair.
normal?
discharge hoses
Is safety valve are exchanged? 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 and RH port relief valve is faulty. repair.
valves are
exchanged Shuttle valve is Disassemble and
Does swing control NO
YES faulty. repair.
valve spool move
smoothly by hand?

Is MCV pilot NO Swing control valve Disassemble and

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
ͽ
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
ͽ 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 ͽ
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.
ͽ 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? ͽ
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.
ͽ 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
Hydraulic pump is Disassemble and
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.

Replenish
Short hydraulic oil.

6-15
 5) TRAVEL ACTION IS POWERLESS(Travel only)

Cause Remedy
YES
ͽ
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,
Disassemble
ͽ draw out piston NO Parking brake
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?

Gear pump is Disassemble

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 ͽ
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?

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?
Gear pump is Disassemble
NO
broken. and repair.
Are LH/RH travel
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.
ͽ valve spool move
lightly by hand?
NO Control valve Disassemble
spool is stuck. and repair.

6-18
 2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal.
YES
Are other ͽ
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
Hydraulic pump is Disassemble and
Are both LH/RH faulty. repair.
travel speeds YES Ϳ
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
ͽ 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.
Is engine NO
Ϳ 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? Is 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 symptom faulty. and repair or
change when port
Normal replace.
relief valve is YES
replaced with ͽ
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 cause
hydraulic oil or of hydraulic oil
equivalent being
temperature rise
used?
and lower it to
proper level.

Replace with
NO
genuine
hydraulic oil or
equivalent.

OK
Pressure 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
ͽ 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
symptom change defective. and repair or
YES
when port relief replace.
YES
valve is replaced Does control Cylinder interior is Disassemble
with other valve? valve spool broken. and repair.
Is MCV pilot NO move smoothly
pressure within by hand?
NO
Control valve Disassemble
standard level?
spool is stuck. and repair.

NO Pilot valve is Disassemble

faulty. 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?
ö Frictional
noise will
disappear if
they are kept
used.

Boom foot pin Supply grease

NO
has run out of to it.
grease. ö
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
ö 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.

14076BY01

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

R140LC-7 ‫׆‬೴ 6-20(2)

3. Raise bucket OFF the ground by retracting

the arm cylinder rod.
If oil leaks from piping side and boom
cylinder rod is retracted there is an internal
leak in the cylinder.
If no oil leaks from piping side and boom
cylinder rod is retracted, there is an internal
leak in the control valve.
14076BY02

6-23
GROUP 3 ELECTRICAL SYSTEM

1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR
ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.8.
ÂAfter 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.8

CLUSTER FUSE
POWER IG(24V) 1 3
2 9 NO.8
GND
RX
TX
CN-56 CN-5

Check voltage
11076TS20
YES 20 ~ 30V
NO 0V

6-24
2. COMMUNICATION ERROR "Co : Err" FLASHES ON THE CLUSTER
ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

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
Disconnection in Repair or replace
NO
wiring harness or (After clean)
poor contact
between CN-5
(10,11)-CN-50
(29,30)

CONTROLLER
Check voltage
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

29076ES02

6-25
3. BATTERY CHARGING WARNING LAMP LIGHTS UP(Starting switch : ON)

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

Cause Remedy
YES
Defective controller Replace
YES Check voltage
between CN-51
(9) and chassis Disconnection in Repair or replace
NO
wiring harness or (After clean)
YES Check voltage poor contact
between CN-2
(3) and chassis between CN-51(9)
-CN2(3)

Check voltage Disconnection in Repair or replace

NO wiring harness or (After clean)
between alternator
poor contact
terminal "I" and between
chassis CN-2(3)-alternator
Voltage : 20~32V terminal "I"
Engine : Running

Defective alternator Replace

NO

Check voltage
YES 20 ~ 32V
NO 0V

ALTERNATOR
CLUSTER B+
G

9 3 1 I
~ 3
U
2 R
CN-51 CN-2 CN-74

11076TS21

6-26
4. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP(Engine is started)

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

Cause Remedy
YES
Coolant overheat Check engine
Resistance
YES between CD-8 (110ÁC Ü2ÁC ) cooling system
(1,2) is in range
of 120~150̫?
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

CONTROLLER WATER TEMPERATURE

SENSOR
33 5 1 C

31 6 2

CN-51 CN-2 CD-8

11076TS22

6-27
5. WHEN AIR CLEANER WARNING LAMP LIGHTS UP(Engine is started)

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

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
Starting switch : ON
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 1̫
NO MIN 1M̫

CONTROLLER AIR CLEANER SWITCH

Pa
16
20

CD-10
51
CN-50

25036EL05

6-28
6. WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP(Engine is started)

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

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
Disconnection in Repair or replace
NO
Disconnect CN-51 wiring harness or (After clean)
poor contact
between
CN-51(4)-CD-18

Check resistance
YES MAX 1̫
NO MIN 1M̫

CONTROLLER ENGINE OIL PRESSURE SWITCH

4 9 Pa

CN-51 CN-2 CD-18

11076TS23

6-29
7. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP(Engine is started)

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

Cause Remedy
YES
High temperature Check hydraulic
Resistance oil temperature
YES between CD-1
(1,2) is in range (100ÁC Ü2ÁC ) ,
of 130~150̫? Replace
Starting switch : ON Defective torque Replace
Does display go NO
Disconnect CD-1 sensor
off when
disconnect CD-1? YES
Short circuit Check and repair
Starting switch : ON Resistance
Engine : Start between CN-51
NO (31,34) is 0~1̫?

Starting switch : OFF NO Defective controller Replace

Disconnect CN-51

CONTROLLER HYDRAULIC OIL

TEMPERATURE SENDER

34 2
C
31 1

CN-51 CD-1

29076ES04

6-30
8. WHEN COOLANT LEVEL WARNING LAMP LIGHTS UP(Engine is started)

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

Cause Remedy
YES
Insufficient coolant Refill coolant or
or Defective switch replace switch
Does display go
off when
disconnect CD-
16? YES
Short circuit Check and repair
Starting switch : ON Check resistance
Engine : Start
between CN-51
NO (15) and chassis

Starting switch : OFF NO Defective controller Replace

Disconnect CN-51

Check resistance
YES MAX 1̫
NO MIN 1M̫

COOLANT LEVEL SENSOR

CONTROLLER

15
18 2

51
CN-50 CD-16

25076ES08

6-31
9. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE

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

Cause Remedy
YES
Disconnection in Repair or replace
wiring harness or (After clean)
Is resistance poor contact
YES between CN-51 between
(31) and (33) CN-51-CD-8
over 2k̫?
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 (~29Á C) (30~105Á C) (105ÁC ~)
Unit Resistance(̫) 1646~ 1645~158 ~139
White range Tolerance(%) Ü20 Ü20 Ü20

CONTROLLER WATER TEMPERATURE

SENSOR
33 5 1 C

31 6 2

CN-51 CN-2 CD-8

11076TS22

6-32
10. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)

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

Cause Remedy
YES
Disconnection in Check and repair
wiring harness
Is resistance
YES between CN-51
(24) and (31)
over 1k̫? YES
Defective controller Replace
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
Starting switch : ON

Defective cluster Replace

NO

Check Table
Green range Red range
Level White range Green range Red range
Item
Unit Resistance(̫) 700~601 600~101 ~100
White range Tolerance(%) Ü5 Ü5 Ü5

CONTROLLER
FUEL SENDER

24 1

CD-2

31

CN-51

29076ES06

6-33
11. WHEN SAFETY SOLENOID DOES NOT OPERATE

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.24.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Hydraulic Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
NO
Safety lever : ON-OFF
YES
ͽ
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
wiring harness or (After clean)
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
ͽ between CS-20 (CS-20)
and chassis
NO
Defective switch Repair or replace
Starting switch : ON (CS-4)
Voltage : 20~30V

SAFETY SWITCH

FUSE
CS-20
NO.24
EARTH 1
SAFETY SWITCH
B C A SAFETY SOLENOID
B 2
A C 8 1
CS-4 CN-68
CN-4

14076TS23

6-34
12. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.22 .
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

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 : 15~25̫
Disconnect CN-70
the cluster YES
Starting switch : ON
Defective cluster Replace
Check controller
Y R G
NO
Defective controller Replace
Starting switch : ON
NO

FUSE

NO.22

TRAVEL SOLENOID
CONTROLLER
2

13 1

CN-70

CN-50

21076ES04

6-35
13. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.14.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
NO
Defective lamp Replace switch
switch

Check voltage
YES
between CS-21 YES
(1) and (7) 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
Starting switch : ON NO
Head lamp switch : ON wiring harness or (After clean)
Check voltage
between CN-6(2)
Voltage : 20~30V poor contact
YES and chassis between CN-6(12)
-CL-4(2)
Starting switch : ON
Head lamp switch : ON
Check voltage Voltage : 20~30V Disconnection in Repair or replace
NO
between CS-21 wiring harness or (After clean)
(1) and chassis
poor contact
Starting switch : ON between
Head lamp switch :
ON-OFF
CS-21(7)-CN-6
(12)

YES
Disconnection in Repair or replace
wiring harness or (After clean)
Check voltage poor contact
between CN-5 between CS-21
NO (15) and chassis
(1)-CN-5(15)
Head lamp switch : ON
Recheck fuse Replace
NO

LIGHT SW
9 10 10 1
9
12 2
4 8
2
7 CL-4
7 1 6
5 5
CN-6
4
3
I 0

2 FUSE
1 15
CS-21 NO.14

CN-5 11076TS27

6-36
14. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.15.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
NO
Defective lamp Replace switch
switch

Check voltage YES

YES
between CS-21 ͽ
Check voltage
(2) and (4) YES
between CR-3
(2) and (4)
Starting switch : ON
Defective work Replace relay
Work lamp switch : ON Check voltage Starting switch : ON NO
Voltage : 20~30V between CR-3(3) Work lamp switch : ON lamp relay
YES and chassis Voltage : 20~30V

Starting switch : ON
Work lamp switch : ON NO Disconnection in Repair or replace
Voltage : 20~30V
wiring harness or (After clean)
poor contact
between CS-21(2)
-CR-3(3)
Check voltage YES
between CS-21 Defective bulb Replace
(4) and chassis Check voltage
ͽ between CL-5,6
Starting switch : ON (2) and chassis
Work lamp switch :
ON-OFF
Disconnection in Repair or replace
Starting switch : ON NO
Voltage : 20~30V
Work lamp switch : ON wiring harness or (After clean)
Voltage : 20~30V poor contact
between CR-3(3)-
CL-5(2) & CL-6(2)
YES
Disconnection in Repair or replace
wiring harness or (After clean)
Check voltage poor contact
between CN-7(8)
NO and chassis between CN-116
(10,11)-CN-7(8)
Head lamp switch : ON
Voltage : 20~30V
NO
Recheck fuse Replace

CR-3
3 4 4
LIGHT SW WORK LAMP
3
9 10 10
2 1
9
1 2 1 2
4 8
2
7
WORK LAMP RY 2 CL-5
7 1 6 1
5 5 1 2
4
2 CN-12 CL-6
3
I 0

2 FUSE
1 14
CS-21 NO.15
CN-5 11076TS28

6-37
15. WHEN ENGINE DOES NOT START
START SWITCH
ÂCheck supply of the power at engine stop solenoid while starting switch is ON.
ÂBefore disconnecting the connector, always turn the starting switch OFF.

II I O H
1

I,O
ÂBefore carrying out below procedure, check all the related connectors are properly inserted. 9
2
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified. 10 3 4

H
4

ACC BR
1

B
11 2
3
5
Cause Remedy 12
6
YES

C ST
5
Defective battery Check engine 6
system charge or CN-8
CS-2
replace(After
POWER RY
checking specific
30
gravity of battery) 30 86
86
Check operation YES
Check voltage Defective magnet Replace 87
of start motor YES between starter of start motor 85
magnet coil and 87a 87 85
87a

BATTERY RY
Starting switch : START chassis Defective start relay Replace
NO CR-35
Starting switch : START YES
ͽ, ; MASTER SWITCH

CR-1
SPEC : 20~30V
Check operation YES
Check voltage
NO of start relay
between CR-5 FUSE
(30) and chassis
Disconnection in Repair or replace NO.1
Starting switch : START wiring harness or (After clean)
Starting switch :START DO-1 DO-2

CN-60
CN-95
Check operation poor contact FUSE

2
1

1
of start safety between CR-5
NO relay NO.7
(86) and CN-8(9)

1
2

2
FUSIBLE LINK
YES
Starting switch : ON Check voltage Defective relay Replace
between CR-
CN-51
NO 5(87) and Disconnetion in
chassis NO FUSE 9
wiring harmess or
Starting switch : ON poor contact
NO.13
between CR- CPU CONTROLLER
5(30) and fuse CN-92
No.13 11
YES
Defective fuel cut Replace CN-50
Check voltage START SAFETY RY
ͽ off solenoid
between CN-79 30
86 30 START RY STARTER
and chassis 86
Disconnection in Repair or replace B+ M
NO
Voltage : 20~30V wiring harness or (After clean) 87 2
Starting switch : START poor contact 85 1
between CR-43(4)- 85 87 87a
87a M
CN-79 CR-23
CR-5 CN-3
YES CN-45
Check voltage Defective relay Replace ENGINE STOP RY
; between CR-23 1 2 1
and chassis 2
NO Disconnection in Repair or replace 3 FUEL CUT -OFF
Starting switch : ON wiring harness or (After clean)
poor contact 3 4 4 14
between CR-5(30)- CR-43
CR-23
CPU CONTROLLER CN-2 CN-79
6
CN-50
11076TS25
6 - 38
16. WHEN STARTING SWITCH ON DOES NOT OPERATE
START SWITCH
ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and

II I O H
1

I,O
master switch ON. 9
2
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified. 10 3 4

H
4

ACC BR
1

B
11 2
3
5
12
6

C ST
5
Cause Remedy 6
CN-8
YES CS-2
Disconnection in Repair or replace
POWER RY
wiring harness or (After clean)
30
30 86
poor contact
YES Check voltage 86
between DO-2 between DO-2(2)- 87
(1) and chassis CR-1 or defective 85
87a 87 85
Voltage : 20~30V
battery relay 87a

BATTERY RY
CR-35
YES Check voltage Disconnection in Replace MASTER SWITCH

CR-1
between CS-2 NO
wiring harness or
(2) and chassis FUSE
poor contact
Voltage : 20~30V between CS-2(2)- NO.1
Check voltage DO-1 DO-2

CN-60
CN-95
YES CN-8(11)- DO-2(1)
between CS-2(1) FUSE

2
1

1
and chassis
NO.7

1
2

2
Defective start Replace FUSIBLE LINK
Voltage : 20~30V NO
switch
CN-51
Check voltage Disconnection in Replace
and specific NO FUSE 9
gravity of battery wiring harness or
poor contact NO.13
CPU CONTROLLER
Specific gravity : MIN 1.28
between CS-2(1)- CN-92
Voltage : MIN 24V
11
CN-8(12)-CR-1-
Battery CN-50
START SAFETY RY
30
Battery capacity too Charge or replace 86 30 START RY STARTER
NO 86
low (After clean) B+ M
87 2
85 1
85 87 87a
87a M
CR-5 CR-23
CN-3 CN-45
ENGINE STOP RY
1 2 1
2
3 FUEL CUT -OFF
3 4 4 14
CR-43
CPU CONTROLLER CN-2 CN-79
6
CN-50
11076TS25
6-39
17. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and the fuse
No.4, 8 and 13 is not blown out.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
NO
Defective wiper Replace
cut switch
YES
Disconnection in Repair or replace
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 cluster Replace
NO Check voltage
Front sliding door-close between CN-56
Voltage : 0~1V (1) and chassis
Check operation 1)Recheck fuse Replace
NO NO.8
of cluster LED Starting switch : ON
NO Vottage : 20~30V
ON. 2)Disconnection in Repair or replace
wiring harness or (After clean)
Starting switch : ON ͽ poor contact
Push wiper switch button YES
between CN-
56(1)-Fuse
between CN-
56(2)-Chassis
Check voltage between NO
Defective CPU Replace
CN-50(14) and chassis controller
Intermittent
NO
1) Recheck fuse Replace
Check voltage between NO.4
ͽ CN-50 (16) and chassis 2) Disconnection Repair or replace CN-56
Washing
Check operation in wiring harness (After clean) POWER IG(24V) 1
of wiper motor or poor contact GND 2
Check voltage between and controller between CN- RX 3
CN-50 (15) and chassis YES check voltage 141(7)-Fuse, TX 4
CN-141(7) and CN-21(4)-Fuse CLUSTER
Sarting switch : ON
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 CPU CONTROLLER
between Disconnection in Repair or replace
CN-141(2)-CN-50(15), wiring harness or (After clean) 14
CN-141(9)-CN-50(16), poor contact
CN-141(10)-CN-50(14), 15
; CN-141(5)-Chassis , NO 16
Check wiper Defective wiper Replace
CN-141(1)-CN-21(5), motor resistance motor
CN-141(3)-CN-21(6), CN-50
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 : 3~4̫
11076TS26
6-40
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 : H-mode 2050Ü50rpm S-mode 1950Ü50rpm L-mode 1850Ü50
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(12)
YES -(13)
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

11076TS30

6-41
2) TEST PROCEDURE SPEC : 17.5Ü1̫(20Á
C)
(1) Test 1 : Check resistance at connector
CN-2(12)-(13).
CN-2
Η Starting key OFF.
15 13 12 1
Θ Disconnect connector CN-2.
Ι Check resistance between pin and at
connector CN-2(12)-(13).

Multimeter

11076TS31

(2) Test 2 : Check resistance at connector SPEC : 17.5Ü1̫(20Á

C)
CN-75.
Η Starting key OFF.
Θ Disconnect connector CN-75 from EPPR CN-75
valve at main hydraulic pump.
Ι Check resistance between 2 lines as
figure.

Multimeter

R140LC-7 ‫׆‬೴ 6-38(2)

(3) Test 3 : Check electric current at EPPR valve. SPEC : 200~550mA (S mode)
Η Install multimeter as figure.
Θ Start engine.
Ι Set the accel dial at "10"(MAX)
Κ Set S-mode and cancel auto decel mode. CN-75
Λ If tachometer show approx 1950Ü50rpm,
check electric current.

EPPR VALVE
Multimeter

R140LC-7 ‫׆‬೴ 6-38(3)

6-42
(2) Test 4 : Check pressure at EPPR valve. SPEC : 5~20kgf/cm2(70~280psi)
Η Remove plug and connect pressure
gauge as figure.
ÂGauge capacity : 0 to 40~50kgf/cm2
(0 to 570~710psi)
Θ Start engine. Supply line, pilot press
Ι Set the accel dial at "10"(Max)
Κ Set S-mode and cancel auto decel mode. CN-75
Λ If tachometer show approx 1950Ü50rpm, Pressure adjusting
screw locknut
check pressure.
Μ If pressure is not correct, adjust it.
Ν After adjust, test the machine.

R140LC-7 ‫׆‬೴ 6-39(1)

6-43
2. ENGINE SPEED IS SLOW AT ALL MODE
ö Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
Good
If test 7 is good,
Check tachometer check TEST 1~4
YES work properly or
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 between CN-51
No good wheel See : 5-16page
(12) - (23) (25) - (26)
SPEC : 0.2~0.4k̫ ͽ
SPEC : 1~2̫
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
ͽ between CN-51-
between CD-17
CN-2-CD-17
(1) - (2)
SPEC : 0.2~0.4k̫
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 M+ 5 M 6
23 6 M-
CN-50 CN-76 ACCEL DIAL
C -
20 5 B S
21 7 A +
22 CN-142
CN-9
TACHO SENSOR
25 8 1
rp
m

26 7 2
CN-51 CN-2 CD-17
11076TS32

6-44
2) TEST PROCEDURE SPEC : 1~2̫
(1) Test 5 : Check resistance between CN-50 Y R G

(12)-(23). CPU
Η Starting key OFF. CONTROLLER
CN-50
Θ Disconnect connector CN-50 from CPU
CN-51
controller.
Ι 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)
Η Start engine. 2050Ü50
H-mode
Θ Check tachometer reading. ö2150Ü50
Check rpm after
1950Ü50
S-mode cancel the Auto decel
ö2050Ü50 mode.
1850Ü50
L-mode
ö1950Ü50
ö Option
(3) Test 7 : Check resistance between CN-51
SPEC : 0.2~0.4k̫
(25) and CN-51(26). Y R G

Η Starting key OFF. CPU

Θ Disconnect connector CN-51 from CPU CONTROLLER
controller. CN-51

Ι Check resistance as figure. CN-50

CN-51 12 1
24 13
36 26 25

Multimeter R29076MS05

6-45
(4) Test 8 : Check resistance at speed SPEC : 0.2~0.4k̫
sensor.
Η Starting key OFF.
Speed sensor
Θ Disconnect connector CD-17 of speed
sensor at engine flywheel housing.
Ι Check resistance as figure. CD-17
CD-17
1 2

Engine flywheel

Multimeter
R140LC-7 ‫׆‬೴ 6-42(1)

6-46
3. ENGINE STALL
ö Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

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 : 17.5Ü1̫(20Á
C) between
See TEST 1 Check resistance CN-50 - CN-2 or
NO at EPPR valve
CN-50 - CN-75
SPEC : 17.5Ü1̫(20Á
C)
See TEST 2 Defective EPPR Replace
NO
valve

11076TS30

6-47
2) TEST PROCEDURE SPEC : 200~550mA
(1) Test 9 : Check electric current at EPPR
valve at S-mode CN-75
Η Install multimeter as figure.
Θ Start engine.
Ι Set the accel dial at "10"(max)
Κ Set S-mode with 1950Ü50rpm.
Λ Check electric current. EPPR VALVE

Multimeter

R140LC-7 ‫׆‬೴ 6-44(1)

(2) Test 10 : Check pressure at EPPR valve SPEC : 5~20kgf/cm2(70~280psi)

at S-mode
Η Connect pressure gauge at EPPR valve.
Θ Start engine.
Ι Set the accel dial at "10"(max) Supply line, pilot press
Κ Set S-mode with 1950Ü50rpm.
Λ Operate bucket lever completely push or CN-75
pull. Pressure adjusting
screw locknut
Μ Hold arm lever at the end of stroke.
Ν Check pressure at relief position.

R140LC-7 ‫׆‬೴ 6-44(2)

6-48
4. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM
ö Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

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 : Err on
NO
the cluster

NO Y R G
ͽ
NO

OK
Check connection Cluster failure Replace
between CN-50
ͽ (29) - CN-5(10) or
CN-50(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-50

FUSE

NO.10(CPU)

20W76MS03

6-49
5. SLOW ACTION OF ENGINE SPEED CHANGE WHEN CHANGE THE MODE
ö Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Slow action of Check and repair
engine speed
control due to
interference
Check interference
between YES
connecting rod and Defective CPU Replace
Check voltage
accel actuator between CN-51(20) controller
YES
-(21) and check
resistance between
CN-51(20)-(22)
Check resistance Defective accel Replace
NO
between CN-50 SPEC : (20)-(21) : 5Ü1V actuator
NO (20)-(22) : 0.1~0.9k̫
(12)-(23) See TEST 12

SPEC : 1~2̫
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 M+ 5 M 6
23 6 M-
CN-50 CN-76 ACCEL DIAL
C -
20 5 B S
21 7 A +
22 CN-142
CN-9
TACHO SENSOR
25 8 1
rp
m

26 7 2
CN-51 CN-2 CD-17

11076TS32

6-50
2) TEST PROCEDURE SPEC : 1~2̫
(1) Test 11 : Check resistance. Y R G

Η Starting key OFF.

CPU
Θ Disconnect connector CN-50 from CPU
CONTROLLER
controller. CN-50
Ι Check resistance between CN-50(12)- CN-51

(23) as figure.

CN-50
12 1
23 13
36 25

Multimeter

R29076MS04

6-51
(2) Test 12 : Check voltage and resistance. SPEC : 0.1~0.9k̫
Η Check resistance between CN-51(20)- Y R G

(22).
CPU
 Starting key OFF. CONTROLLER
 Disconnect connector CN-51 from CPU CN-51

CN-50
controller.
 Check resistance value with multimeter
as figure.

CN-51
12 1
24 22 20 13
36 25

Multimeter
R29076MS08

Θ Check voltage between CN-51(20) and SPEC : 5Ü1V

CN-51(21).
Y R G

 Prepare 2 pieces of thin sharp pin, steel

CPU
or copper. CONTROLLER
 Starting key ON. PIN

 Insert prepared pins to rear side of CN-50

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

R140LC-7 ‫׆‬೴ 6-48(3)/R29076MS09

6-52
6. MALFUNCTION OF WARMING UP
ö Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective cluster or Repair or Replace
Check resistance CPU controller or
YES
between CN-51 CD-8(Sensor)
(31) - CD-8(2)
SPEC : Below10̫ NO Poor connection Repair
Check resistance KEY OFF
between CN-
between CN -51
(33) - CD-8(1) 51(31) - CD-8(2)
SPEC : Below 10̫
KEY OFF

NO
Poor connection Repair
between CN-
51(33) - CD-8(1)

Wiring diagram

CONTROLLER

WATER TEMPERATURE SENSOR

31 6 2 C
33 5 1
CD-8

CN-51 CN-2

11076TS33

6-53
7. MALFUNCTION OF POWER MAX
ö Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES Check resistance
between CN-88 Defective power Repair or replace
Resistance (1) - (2) max. solenoid valve
YES
between CN-51 SPEC: 15-30̫
(2)-GND normal? See TEST 13

NO Short circuit or poor Repair or replace

SPEC : Power max connection
Is voltage between button pressed ON : 0̫ between CN-51(2) -
CN-88(1) -GND Power max button released OFF : â ̫
normal? See Test 14 CS-29 and CN-50
(3) -CN-88(1)
SPEC
KEY ON : 24Ü1V
KEY OFF : 0V
See TEST 13
NO Short circuit or poor Repair or replace
connection
between CN-88(2)-
battery relay(+)

Wiring diagram

CPU CONTROLLER
POWER MAX SOLENOID

3 1
FUSE
CN-50 2
NO.23
CN-88
POWER MAX SWITCH
1 1
2 2 2
CS-29
CN-51 CN-4

11076TS34

6-54
2) TEST PROCEDURE SPEC : Key ON : 24Ü1V
Key OFF : 0V
(1) Test 13: Check voltage between connector Resistance : 15~30̫
CN-88 - GND.
Η Start key ON.
Θ Disconnect connector CN-88 from power Power max. switch
max solenoid valve.
Ι Check voltage as figure.
LH RCV-lever

CN-88
CN-88

Power max.
solenoid valve

Multimeter

R29076MS14

(2) Test 14: Check resistance between

connector CN-51(2)-GND. SPEC : Power max button pressed ON : 0̫
Power max button released OFF : â̫
Η Starting key OFF.
Θ Remove CPU controller and disconnect Y R G

connector CN-51 from CPU controller. CPU

Ι Check resistance as figure. CONTROLLER
CN-51

CN-50

CN-51
12 2
24 13
36 25

Ground

Multimeter
R29076MS15

6-55
 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
operational performance of the machine
meets Hyundai spec.
2) OPERATIONAL PERFORMANCE OF A
WORKING MACHINE
With the passage of time, the machine's
operational performance deteriorates, so
that the machine needs to be serviced
periodically to restore it to its original
performance level.
Before servicing the machine, conduct
performance tests to check the extent of
deterioration, and to decide what kind of
service needs to be done(by referring to the
"Service Limits" in this manual).
3) OPERATIONAL PERFORMANCE OF A
REPAIRED MACHINE
After the machine is repaired or serviced, it
must be tested to confirm that its
operational performance was restored by
the repair and/or service work done. 140LC7MS01

7-1
2. TERMINOLOGY
1) STANDARD
Specifications applied to the brand-new
machine, components and parts.

140LC-7MS02

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.

140LC-7MS03

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
Η Select a hard, flat surface.
Θ Secure enough space to allow the
machine to run straight more than 20m,
and to make a full swing with the front
attachment extended.
Ι If required, rope off the test area and
provide signboards to keep unauthorized
personnel away.
(3) Precautions
Η Before starting to test, agree upon the
signals to be employed for communication
among coworkers. Once the test is
started, be sure to communicate with
each other using these signals, and to
follow them without fail.
Θ Operate the machine carefully and
always give first priority to safety.
Ι 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.
Κ Avoid polluting the machine and the
ground with leaking oil. Use oil pans to
140LC-7 ‫׆‬೴ 7-3
catch escaping oil. Pay special attention
to this when removing hydraulic pipings.
(4) Make precise measurements
Η Accurately calibrate test instruments in
advance to obtain correct data.
Θ Carry out tests under the exact test
conditions prescribed for each test item.
Ι 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, L).
Ι Select the H-mode.
Κ Lightly operate the bucket control lever a
few times, then return the control lever to
neutral. Select one touch decel ON.
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/one touch idle 950Ü100 One touch decal

H mode 2050Ü50
R110-7
S mode 1950Ü50
L mode 1850Ü50
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
Η Adjust the tension of both tracks to be
equal.
Θ 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.
Ι Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
Κ Keep the hydraulic oil temperature at
11077MS04
50Ü5Á C.
(3) Measurement
Η Measure both the low and high speeds of
the machine.
Θ 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
Ι Start traveling the machine in the
3 ~ 5m 20m 3 ~ 5m
acceleration zone with the travel levers at
full stroke.
Κ Measure the time required to travel 20m.
Λ After measuring the forward travel speed,
turn the upperstructure 180Á and
measure the reverse travel speed. 11077MS05
Μ Repeat steps Κ and Λ 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 21.2Ü2.0 26.5

R110-7
2 Speed 13.1Ü1.0 16.4

7-5
4) TRACK REVOLUTION SPEED
(1) Measure the track revolution cycle time
with the track raised off ground.
(2) Preparation
Η Adjust the tension of both side tracks to
be equal.
Θ On the track to be measured, mark one
shoe with chalk. 90 ~ 110
Ι Swing the upperstructure 90Áand lower
the bucket to raise the track off ground.
Keep the boom-arm angle between 90 to Mark
110Áas shown. Place blocks under
machine frame.
Κ Keep the hydraulic oil temperature at
50Ü5Á C.
(3) Measurement
Η Select the following switch positions. 11077MS06

 Travel mode switch : 1 or 2 speed

 Mode selector : H mode
Θ Operate the travel control lever of the
raised track in full forward and reverse.
Ι Rotate 1 turn, then measure time taken
for next 3 revolutions.
Κ Raise the other side of machine and
repeat the procedure.
Λ Repeat steps Ι and Κ 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 21.3Ü2.0 26.6

R110-7
2 Speed 13.0Ü2.0 16.3

7-6
5) TRAVEL DEVIATION
(1) Measure the deviation by the tracks from
a 20m straight line.
(2) Preparation
Η Adjust the tension of both tracks to be
equal.
Θ 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.
Ι Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
Κ Keep the hydraulic oil temperature at
11077MS04
50Ü5Á C.
(3) Measurement
Η Measure the amount of mistracking at
high and low travel speeds.
Θ Before beginning each test, select the
following switch positions. 3~5m extra length
 Mode selector : H mode a

M
20
Ι Start traveling the machine in the
acceleration zone with the travel levers at
full stroke. 3~5m extra length
Κ Measure the distance between a straight
20m line and the track made by the
machine.(Dimension a)
Λ After measuring the tracking in forward
travel, turn the upperstructure 180Áand
measure that in reverse travel.
140LC-7 ‫׆‬೴ 7-7(2)
Μ Repeat steps Κ and Λ three times and
calculate the average values.
(4) Evaluation
Mistrack should be within the following specifications.
Unit : mm / 20m
Model Standard Maximum allowable Remarks
R110-7 200 below 240

7-7
6) SWING SPEED
(1) Measure the time required to swing three
complete turns.
(2) Preparation
Η Check the lubrication of the swing gear
and swing bearing.
Θ Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
Ι 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.
Κ Keep the hydraulic oil temperature at
50Ü5Á C.
11077MS07

(3) Measurement
Η Select the following switch positions.
 Mode selector : H mode
Θ Operate swing control lever fully.
Ι Swing 1 turn and measure time taken to
swing next 3 revolutions.
Κ Repeat steps Θ and Ι three time and
calculate the average values.
(4) Evaluation
The time required for 3 swings should meet the following specifications.
Unit : Seconds / 3 revolutions
Model Standard Maximum allowable Remark

R110-7 13.8Ü1.5 16.6

7-8
7) SWING FUNCTION DRIFT CHECK
(1) Measure the swing drift on the bearing
outer circumference when stopping after a
360Áfull speed swing.
(2) Preparation
Η Check the lubrication of the swing gear
and swing bearing.
Θ Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
Ι 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
11077MS07
foot pin. The bucket must be empty.
Κ Make two chalk marks: one on the swing
bearing and one directly below it on the
track frame.
Λ Swing the upperstructure 360Á.
Μ Keep the hydraulic oil temperature at
50Ü5Á C.
(3) Measurement
Η Conduct this test in the H mode.
Θ Select the following switch positions.
 Mode selector : H mode
Ι 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 360Á
Κ Measure the distance between the two
marks.
Λ Align the marks again, swing 360Á, then
test the opposite direction.
Μ Repeat steps Κ and Λ three times each
and calculate the average values.
140LC7MS08

(4) Evaluation
The measured drift angle should be within the following specifications.
Unit : Degree
Model Mode select switch Standard Maximum allowable Remarks

R110-7 H mode 90 below 157.5

7-9
8) SWING BEARING PLAY
(1) Measure the swing bearing play using a
dial gauge to check the wear of bearing
races and balls.
(2) Preparation
Η Check swing bearing mounting cap
screws for loosening.
Θ Check the lubrication of the swing
bearing. Confirm that bearing rotation is
smooth and without noise.
Ι Install a dial gauge on the track frame as
shown, using a magnetic base.
Κ Position the upperstructure so that the
140LC-7 ‫׆‬೴ 7-10(1)
boom aligns with the tracks facing
towards the front idlers.
Λ Position the dial gauge so that its needle
point comes into contact with the bottom
face of the bearing outer race.
Μ Bucket should be empty.
(3) Measurement
Η With the arm rolled out and bucket rolled Measurement : (h1)
in, hold the bottom face of the bucket to
the same height of the boom foot pin.
Record the dial gauge reading(h1).
Θ Lower the bucket to the ground and use it
to raise the front idler 50cm.
Measurement : (h2)
Record the dial gauge reading(h2).
Ι Calculate bearing play(H) from this
data(h1 and h2) as follows.
H=h2-h1
11077MS09
(4) Evaluation
The measured drift should be within the following specifications.
Unit : mm
Model Standard Maximum allowable Remarks
R110-7 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
Η 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
Θ 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.
Ι To measure the cycle time of the bucket Roll out Roll in
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
Κ Keep the hydraulic oil temperature at
50Ü5Á C.
(3) Measurement
Η Select the following switch positions.
 Mode selector : H mode
Roll out Roll in
Θ To measure cylinder cycle times.
- Boom cylinders. 0.5m
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 11077MS10

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
calculate the average values.
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds
Model Function Standard Maximum allowable Remarks

Boom raise 2.9Ü0.4 3.5

Boom lower 2.6Ü0.4 3.2
Arm in 2.9Ü0.4 3.5
R110-7
Arm out 2.8Ü0.3 3.4
Bucket load 3.6Ü0.4 4.4
Bucket dump 2.1Ü0.3 2.5

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
Η Load bucket fully. Instead of loading the
bucket, weight(W) of the following
specification can be used.
 W=M3Ý1.5
Where :
M3 = Bucket heaped capacity(m3)
1.5= Soil specific gravity
Θ Position the arm cylinder with the rod 20
to 30mm extended from the fully retracted
position.
Ι Position the bucket cylinder with the rod
20 to 30mm retracted from the fully
extended position.
Κ 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.
Λ Keep the hydraulic oil temperature at 11077MS11

50Ü5Á C.
(3) Measurement
Η Stop the engine.
Θ Five minutes after the engine has been
stopped, measure the changes in the
positions of the boom, arm and bucket
cylinders.
Ι Repeat step Θ 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 20

R110-7 Arm cylinder 10 below 20
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
Η Keep the hydraulic oil temperature at
50Ü5ÁC.
(3) Measurement
Η Start the engine.
Θ Select the following switch positions.
 Mode selector : H mode
Ι Operate each boom, arm, bucket and
swing lever at full stroke and measure the
maximum operating force for each.
Κ 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.
Λ Repeat steps Ι and Κ three times and
calculate the average values.
(4) Evaluation
The measured operating force should be within the following specifications.
Unit : kgf
Model Kind of lever Standard Maximum allowable Remarks

Boom lever 1.6 or below 2.0

Arm lever 1.6 or below 2.0
R110-7 Bucket lever 1.6 or below 2.0
Swing lever 1.6 or below 2.0
Travel lever 2.1 or below 3.15

7-14
12) CONTROL LEVER STROKE
(1) Measure each lever stroke at the lever top
using a ruler.
ö 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
50Ü5Á C.
(3) Measurement
Η Stop the engine.
Θ Measure each lever stroke at the lever
top from neutral to the stroke end using a
ruler.
Ι Repeat step Θ 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 87Ü10 109

Arm lever 87Ü10 109
R110-7 Bucket lever 87Ü10 109
Swing lever 87Ü10 109
Travel lever 142Ü10 178

7-15
13) PILOT PRIMARY PRESSURE
(1) Preparation
Η Stop the engine.
Θ Push the pressure release button to
bleed air.
Ι Loosen and remove plug on the pilot
pump delivery port and connect pressure

A
3
gauge.
Κ Start the engine and check for oil
leakage from the port.

P
D

i1
r
Λ Keep the hydraulic oil temperature at
50Ü5Á C.
(2) Measurement
Η Select the following switch positions.
 Engine rpm : 1950rpm
Θ Measure the primary pilot pressure in the
11077MS16
H mode.
(3) Evaluation
The average measured pressure should meet the following specifications:
Unit : kgf / cm2
Model Engine speed Standard Allowable limits Remarks

R110-7 1950rpm 35Ü5 -

7-16
14) FOR TRAVEL SPEED SELECTING PRESSURE:
(1) Preparation
Η Stop the engine.
Θ Push the pressure release button to
bleed air.
Ι To measure the speed selecting pressure:
Install a connector and pressure gauge
Κ assembly to turning joint P port as shown.
Start the engine and check for on
leakage from the adapter. P
B
Λ Keep the hydraulic oil temperature at D
A

50Ü5Á C. C

(2) Measurement Dr

Η Select the following switch positions.

Travel mode switch : 1 speed
2 speed 21077MS13

 Mode selector : H mode

Θ Measure the travel speed selecting
pressure in the Hi or Lo mode.
Ι 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.
Κ Repeat steps Θ and Ι three times and
calculate the average values.
(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 -
R110-7
2 Speed 35Ü5 -

7-17
15) SWING PARKING BRAKE RELEASING PRESSURE
(1) Preparation
Η Stop the engine.
Θ Push the pressure release button to
bleed air.
Ι Install a connector and pressure gauge
assembly to swing motor SH port, as
shown.
Κ Start the engine and check for oil
leakage from the adapter.
Λ Keep the hydraulic oil temperature at
50Ü5Á C. SH

(2) Measurement
Η Select the following switch positions.
 Mode selector : H mode
Θ Operate the swing function or arm roll in
function and measure the swing brake
control pressure with the brake
disengaged. Release the control lever
to return to neutral and measure the
control pressure when the brake is
11077MS12
applied.
Repeat step Θ three times and calculate
the average values.
(3) Evaluation
The average measured pressure should be within the following specifications.
Unit : kgf / cm2
Model Description Standard Allowable limits Remarks

Brake disengaged 35 15~44

R110-7
Brake applied 0 -

7-18
16) MAIN PUMP DELIVERY PRESSURE
(1) Preparation
Η Stop the engine.
Θ Push the pressure release button to
bleed air.
Ι To measure the main pump pressure.
Install a connector and pressure gauge
assembly main pump gauge port as
shown.

P
D

i1
r
Κ Start the engine and check for oil
leakage from the port.
Λ Keep the hydraulic oil temperature at
50Ü5Á C.
(2) Measurement
Η Select the following switch positions.
 Mode selector : H mode
11077MS13
Θ 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
R110-7 High ilde 30Ü5 -

7-19
17) SYSTEM PRESSURE REGULATOR RELIEF SETTING
(1) Preparation
Η Stop the engine.
Θ Push the pressure release button to
bleed air.
Ι To measure the system relief pressure.
Install a connector and pressure gauge
assembly main pump gauge port, as

A
3
shown.
Κ Start the engine and check for oil
leakage from the port.

P
i1
D
r
Λ Keep the hydraulic oil temperature at a2

a1

50Ü5Á C.
(2) Measurement

P
i2
Η Select the following switch positions.
 Mode selector : H mode
Θ Slowly operate each control lever of
boom, arm and bucket functions at full
stroke over relief and measure the
pressure.
Ι In the swing function, place bucket
against an immovable object and
measure the relief pressure.
Κ In the travel function, lock undercarriage
with an immovable object and measure
11077MS14
the relief pressure.
(3) Evaluation
The average measured pressure should be within the following specifications.
Unit : kgf / cm2
Model Function to be tested Standard Port relief seting

Boom, Arm, Bucket 330(360)Ü10 390Ü10

R110-7 Travel 330Ü10 -
Swing 240Ü10 -
( ) : Power boost

7-20
GROUP 2 MAJOR COMPONENT

1. MAIN PUMP
3 1 2

9 5 6 4 7 8 140LC-7 ‫׆‬೴ 7-21

Standard Recommended
Part name & inspection item replacement Counter measures
dimension value
Clearance
between piston(1) & cylinder Replace piston
d D 0.028 0.056
bore(2) or cylinder.
(D-d)

Play between
piston(1) & shoe caulking
0-0.1 0.3
section(3)
(ɺ) Replace
assembly of
Thickness of shoe piston & shoe.
ɺ
(t) t 3.9 3.7

Free height of cylinder

spring(4) Replace cylinder
31.3 30.5
(L) spring.
L

Combined height of set

plate(5) & spherical h H
19.0 18.3 Replace retainer
bushing(6) or set plate.
(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 ÂExistence of scratch, rusting or corrosion. ÂIn 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 ÂExistence of scratch, gnawing, rusting or ÂReplacement when its outside sliding
corrosion. section has scratch(Especially on seals-
contacting section).
ÂO-ring seal sections at both ends. ÂReplacement when its sliding section has
scratch.
ÂInsert spool in casing hole, rotate and ÂCorrection or replacement when O-ring is
reciprocate it. damaged or when spool does not move
smoothly.

Poppet ÂDamage of poppet or spring ÂCorrection or replacement when sealing is

incomplete.
ÂInsert poppet into casing and function it. ÂNormal when it can function lightly without
being caught.

Around spring ÂRusting, corrosion, deformation or breaking ÂReplacement for significant damage.
of spring, spring seat, plug or cover.

Around seal ÂExternal oil leakage. ÂCorrection or replacement.

for spool
ÂRusting, corrosion or deformation of seal ÂCorrection or replacement.
plate.

Main relief valve, ÂExternal rusting or damage. ÂReplacement.

port relief valve &
ÂContacting face of valve seat. ÂReplacement when damaged.
negative control
relief valve ÂContacting face of poppet. ÂReplacement when damaged.
ÂAbnormal spring. ÂReplacement.
ÂO-rings, back up rings and seals. Â100 replacement in general.

Balance plate ÂWorn less than 0.03mm ÂLapping

ÂWorn more than 0.03mm ÂReplace
ÂSliding surface has a seizure(Even through ÂReplace
small).

7-22
3. SWING DEVICE
Part name Inspection item Remedy

Shoe of piston ÂSliding surface has a damage. ÂLapping

assembly
ÂSliding surface depression( ) ÂReplace parts or motor
dimension less than 0.45mm or has a large
damage.

Piston of piston ÂSliding surface has a seizure(Even though ÂReplace motor

assembly small).

Piston hole of ÂSliding surface has a seizure. ÂReplace motor

cylinder assembly
ÂSliding surface has a damage. ÂReplace motor

Taper roller bearing ÂIn case 3000hour operation. ÂReplace

Needle bearing
ÂRolling surface has a damage. ÂReplace
Roller bearing

7-23
4. TRAVEL DEVICE
Disassembling and inspection of the motor must be done in strict accordance with the servicing
standards described here. During servicing, handle each part very carefully not to damage them,
especially for their movable or sliding sections.
1) SEALS
Once the seals(O-rings, oil seals, and floating seals) have been disassembled, they must be
replaced with new ones even if no damage is observed.
2) TABLE OF MAINTENANCE STANDARD
(1) Replace all parts having a seriously damaged appearance.
(2) Replace the part if any one of the states(Symptoms) listed in the table below is observed.
Item Maximum allowable
No. Part name Situation Standard dimension value(Criteria)
Spindle kit
2 ÂSpindle assembly ÂSeriously damaged in
8 ÂÂSpindle appearance.
- -
17 ÂÂCoupling gear
ÂPin ÂGalling or other forms of
excessive wear are observed.

Carrier assembly
3 Carrier ÂThe tooth surface of the cluster
6 Cluster gear gear(6) is nonuniformly worn out
9 Shaft and damaged. - -
14 Thrust collar
ÂThe cluster gear(6) does not
25 Needle bearing
move smoothly.
34 Dowel pin

4 Ring gear A ÂThe tooth surface is

nonuniformly worn out and - -
damaged.

5 Ring gear B ÂThe tooth surface is

nonuniformly worn out and - -
damaged.

7 Sun gear ÂThe tooth surface is

nonuniformly worn out and
- -
damaged.
ÂThe spline section is worn.

8 Coupling gear ÂExcessive wear or pitching is

- -
observed on the tooth surface.

19 Coupling ÂThe spline section is worn. - -

20 Thrust bearing ÂWorn out. Axial clearance Clearance : 0.8mm

between coupling
gear(8) and cover(13)
: 0.3 to 0.6mm

7-24
Item Maximum allowable
No. Part name Situation Standard dimension value(Criteria)

22 Distance piece ÂThe sliding surface is damaged.

- -
ÂThe sliding surface is excessively
worn out.

24 Ball bearing ÂDents are present.

ÂFlaking develops. - -

ÂNonuniform wear is present.

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

102 Shaft ÂThe surface contacting the oil

seal(132) is worn out. - -
ÂThe spline section is worn out.

103 Swash plate ÂSeizure is observed. - -

104 Cylinder block ÂThe spline section is worn out.

ÂThe bore inner surface is worn
out too much. - -
ÂThe sliding surface that contacts
the timing plate(109) is damaged
or nonuniformly worn out.

Piston assembly ÂAn axial clearance is present Clearance : 0.05mm Clearance : 0.15mm
105 Piston between the piston(105) and the
106 shoe shoe(106).
ÂThe shoe is excessively worn out.
ÂThe shoe is nonuniformly worn
out.

107 Retainer plate ÂThe peripheral edge is

- -
nonuniformly worn out.

7-25
Item Maximum allowable
No. Part name Situation Standard dimension value(Criteria)

108 Thrust ball ÂThe spherical sliding section that

contacts the retainer plate(107)
is nonuniformly worn out. - -
109 Timing plate ÂThe sliding surface has the traces
of seizure or nonuniformly wear.

115 Friction plate ÂBoth edges are nonuniformly Braking torque Braking torque
worn out. 49.3kgfÂm or more 49.3kgfÂm or less
116 Mating plate ÂThe required torque cannot be
achieved.
ÂThe traces of seizure are present.

118 Valve seat ÂThe seat surface is damaged. - -

119 Valve ÂThe outer surface is damaged.

- -
ÂThe seat surface is damaged.

Body kit
136 Body ÂThe sliding section that contacts Linear clearance : Linear clearance :
the spool(137) is damaged. 7 to 15 ʂ 20 ʂ
ÂThe clearance against the
spool(137) is too large.
137 Spool ÂThe outer surface is damaged.
ÂThe outer surface is nonuniformly
worn out.

149 Roller bearing ÂDents are present.

150 Ball bearing
ÂFlaking develops. - -
ÂNonuniform wear is observed.

163 Valve ÂThe outer surface is damaged.

- -
ÂThe seat surface is damaged.

164 Stopper ÂThe seat surface is damaged. - -

142 Valve ÂThe outer surface is damaged.

- -
ÂThe seat surface is damaged.

172 Valve seat ÂThe seat surface is damaged. - -

7-26
5. TURNING JOINT

Part name Maintenance standards Remedy

Sliding surface with Plating worn or peeled due to seizure or contamination. Replace
sealing sections.

Sliding surface ÂWorn abnormality or damaged more than 0.1mm Replace

between body and (0.0039in) in depth due to seizure contamination.
Body, stem other than
ÂDamaged more than 0.1mm(0.0039in) in depth. Smooth with oilstone.
Stem sealing section.

Sliding surface ÂWorn more than 0.5mm(0.02in) or abnormality. Replace

with thrust plate.
ÂWorn less than 0.5mm(0.02in). Smooth
ÂDamage due to seizure or contamination remediable Smooth
within wear limit (0.5mm)(0.02in).

Sliding surface ÂWorn more than 0.5mm(0.02in) or abnormality. Replace

with thrust plate.
Cover ÂWorn less than 0.5mm(0.02in). Smooth
ÂDamage due to seizure or contamination remediable Replace
within wear limit (0.5mm)(0.02in).

ÂExtruded excessively from seal groove square ring. Replace

- Extrusion
Square ring

ÂSlipper ring 1.5mm(0.059in) narrower than seal Replace

groove, or narrower than back ring.
Seal set
-
1.5mm (max.)
(0.059in)

ÂWorn more than 0.5mm(0.02in) ~ 1.5mm(MAX.) Replace

(0.059in)

7-27
6. CYLINDER
Part name Inspecting section Inspection item Remedy

Piston rod ÂNeck of rod pin ÂPresence of crack ÂReplace

ÂWeld on rod hub ÂPresence of crack ÂReplace
ÂStepped part to which piston ÂPresence of crack ÂReplace
is attached.
ÂThreads ÂPresence of crack ÂRecondition or replace
ÂPlated surface ÂPlating is not worn off to base ÂReplace or replate
metal.
ÂRust is not present on plating. ÂReplace or replate
ÂScratches are not present. ÂRecondition, replate or replace
ÂRod ÂWear of O.D. ÂRecondition, replate or replace
ÂBushing at mounting part ÂWear of I.D. ÂReplace

Cylinder tube ÂWeld on bottom ÂPresence of crack ÂReplace

ÂWeld on head ÂPresence of crack ÂReplace
ÂWeld on hub ÂPresence of crack ÂReplace
ÂTube interior ÂPresence of faults ÂReplace if oil leak is seen
ÂBushing at mounting part ÂWear on inner surface ÂReplace

Gland ÂBushing ÂFlaw on inner surface ÂReplace if flaw is deeper

than coating

7-28
GROUP 3 TRACK AND WORK EQUIPMENT

1. TRACK
1) TRACK ROLLER

2
1
3 4

21037MS01

Unit : mm
No. Check item Criteria Remedy

Standard size Repair limit

1 Outside diameter of flange
͚170 
Rebuild or
2 Outside diameter of tread ͚140 ͚128 replace
3 Width of tread 39.5 45.5
4 Width of flange 20 
Standard tolerance Standard Clearance
Clearance between shaft size Shaft Hole clearance limit Replace
5
and bushing 0 +0.4 0.35 bushing
͚50 -0.03 +0.35 to 0.43 2.0

Side clearance of roller Standard clearance Clearance limit

6 Replace
(Both side) 0.25~0.65 2.0

7 - 29
2) CARRIER ROLLER

32077MS02

Unit : mm

No. Check item Criteria Remedy

Standard size Repair limit

1 Outside diameter of flange
͚136 
Rebuild or
2 Outside diameter of tread ͚116 ͚108 replace
3 Width of tread 35.5 39.5
4 Width of flange 15 
Standard size & Tolerance Standard Clearance
Clearance between shaft Shaft Hole clearance limit
5 Replace
and bushing +0.085
͚40 ͚40 +0.3 0.165
2.0 bushing
+0.065 +0.25 to 0.235
or shaft
Clearame between shaft and ͚40.8 - 0.05 ͚40.8 +0.3 0.15
6 support - 0.01 +0.1 to 0.4 1.2

7-30
3) IDLER

8
1
2

7
3 5
4

21037MS03

Unit : mm
No. Check item Criteria Remedy

Standard size Repair limit

1 Outside diameter of protrusion
͚510 
2 Outside diameter of tread ͚470 ͚460 Rebuild or
3 Width of protrusion 67  replace

4 Total width 135 

5 Width of tread 34 39
Standard size & tolerance Standard Clearance
Clearance between shaft Shaft Hole clearance limit Replace
6
and bushing 0 +0.05 bushing
͚70 -0.03 ͚70.3 0 0.3 to 0.38 2.0
Clearance between shaft 0 +0.07 Rebuild or
7 and support ͚70 -0.03 ͚70 +0.03 0.03 to 0.1 1.2 Replace

Side clearance of idler Standard clearance Clearance limit Replace

8
(Both side) 0.25~1.15 2.0 bushing

7 - 31
4) TRACK

2 1

4
3

21037MS04

Unit : mm
No. Check item Criteria Remedy

Standard size Repair limit Turn or

1 Link pitch replace
171.45 175.45
2 Outside diameter of bushing ͚50.6 ͚40.8
Rebuild or
3 Height of grouser 20 16 replace
4 Height of link 90 82
5 Tightening torgue Initial tightening torque : 42Ü4kgfÂm Retighten

7 - 31
5) TRACK FRAME AND RECOIL SPRING

3
1

21037MS05

Unit : mm
No. Check item Criteria Remedy

Standard size Tolerance Repair limit

+2
1 Vertical width of idler guide Track frame 103 0
107
-0 Rebuild or
Idler support 100 - 0.5 98
replace
+2
Track frame 192 0 196
2 Horizontal width of idler guide
Idler support 190 - 188

Standard size Repair limit

3 Recoil spring Free Installation Installation Free Installation
length length load length load Replace
͚192Ý470 405 8,497kg  6.978kg

7 - 33
2. WORK EQUIPMENT

A C D E F

B K J I H G

11077MS15

Unit : mm
Pin Bushing
Remedy
Measuring point Normal Recomm. Recomm.
Mark Limit Limit &
(Pin and Bushing) value service service
of use of use Remark
limit limit

A Boom Rear 70 69 68.5 70.5 71 Replace

B Boom Cylinder Head 70 69 68.5 70.5 71 Æ
C Boom Cylinder Rod 70 69 68.5 70.5 71 Æ
D Arm Cylinder Head 65 64 63.5 65.5 66 Æ
E Boom Front 70 69 68.5 70.5 71 Æ
F Arm Cylinder Rod 65 64 63.5 65.5 66 Æ
G Bucket Cylinder Head 65 64 63.5 65.5 66 Æ
H Arm Link 65 64 63.5 65.5 66 Æ
I Bucket and Arm Link 65 64 63.5 65.5 66 Æ
J Bucket Cylinder Rod 65 64 63.5 65.5 66 Æ
K Bucket Link 65 64 63.5 65.5 66 Æ

7 - 34
 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
θD θd
16 16 13.5 20
θd
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.
ö If the hydraulic cylinder has been replaced, carry out this procedure before assembling the rod to
the work equipment.
ö 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
kgfÂm lbfÂft
1 Engine mounting bolt(Engine-Bracket) M12 Ý 1.75 10.0 Ü 0.5 72.3 Ü 3.6
2 Engine mounting bolt(Bracket-Frame, FR) M16 Ý 2.0 55 Ü 3.5 398 Ü 25.3
3 Engine Engine mounting bolt(Bracket-Frame, RR) M20 Ý 2.5 30 Ü 3.5 253 Ü 25.3
4 Radiator mounting bolt, nut M12 Ý 1.75 12.2 Ü 1.3 88.2 Ü 9.4
5 Coupling mounting bolt M16 Ý 2.0 22.0 Ü 1.0 159 Ü 7.2
6 Main pump mounting bolt M16 Ý 2.0 22.1 Ü 2.4 159 Ü 17.3
7 Main control valve mounting bolt M12 Ý 1.75 12.2 Ü1.3 88.2 Ü 9.4
Hydraulic
8 system Fuel tank mounting bolt M20 Ý 2.5 45 Ü 5.1 325 Ü 36.9
9 Hydraulic oil tank mounting bolt M20 Ý 2.5 45 Ü 5.1 325 Ü 36.9
10 Turning joint mounting bolt, nut M12 Ý 1.75 12.3 Ü 1.3 88.2 Ü 9.4
11 Swing motor mounting bolt M16 Ý 2.0 29.6 Ü 3.2 214 Ü 23.1
12 Swing bearing upper mounting bolt M18 Ý 2.0 41.3 Ü 4.5 299 Ü 32.5
13 Power Swing bearing lower mounting bolt M16 Ý 2.0 29.7 Ü 4.5 215 Ü 32.5
train
14 system Travel motor mounting bolt M16 Ý 2.0 23 Ü 2.5 166 Ü 18.1
15 Sprocket mounting bolt M16 Ý 2.0 29.7 Ü 4.5 215 Ü 32.5
16 Carrier roller mounting bolt, nut M16 Ý 2.0 29.7 Ü 4.5 215 Ü 32.5
17 Track roller mounting bolt M16 Ý 2.0 29.7 Ü 4.5 215 Ü 32.5
18 Under Track tension cylinder mounting bolt M16 Ý 2.0 29.7 Ü 4.5 215 Ü 32.5
19 carriage Track shoe mounting bolt, nut M16 Ý 1.5 42 Ü 4 304 Ü 28.9
20 Track guard mounting bolt M16 Ý 2.0 29.7 Ü 4.5 215 Ü 32.5
21 Counter weight mounting bolt M24 Ý 3.0 97.8 Ü 10 707 Ü 72.3
22 Others Cab mounting bolt, nut M12 Ý 1.75 12.2 Ü 1.3 88.2 Ü 9.4
23 Operator's seat mounting bolt M 8 Ý 1.25 1.17 Ü 0.1 8.5Ü 0.7
ö 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
kgfÂm lbfÂft kgfÂm lbfÂft
M 6 Ý 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8 Ý 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8
M10 Ý 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12 Ý 1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14 Ý 2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16 Ý 2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18 Ý 2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20 Ý 2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22 Ý 2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24 Ý 3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30 Ý 3.5 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36 Ý 4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242

2) BOLT AND NUT - Fine thread

8T 10T
Bolt size
kgfÂm lbfÂft kgfÂm lbfÂft
M 8 Ý 1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10 Ý 1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12 Ý 1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14 Ý 1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16 Ý 1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18 Ý 1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20 Ý 1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22 Ý 1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24 Ý 2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890
M30 Ý 2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36 Ý 3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561

8-5
3) PIPE AND HOSE

Thread size Width across flat mm

kgfÂm lbfÂft

1/4" 19 3 21.7
3/8" 22 4 28.9
1/2" 27 5 36.2
3/4" 36 12 86.8
1" 41 14 101

4) FITTING

Thread size Width across flat mm

kgfÂm lbfÂft

1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 6 43.4
3/4" 36 13 94.0
1" 41 15 109

8-6
GROUP 3 PUMP DEVICE

1. REMOVAL AND INSTALL

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

pressure inside the hydraulic tank.

Escaping fluid under pressure can
74
penetrate the skin causing serious 75
injury.
(4) Loosen the drain plug under the hydraulic
tank and drain the oil from the hydraulic A2
A1

tank.
 Hydraulic tank quantity : 100˶
(5) Remove socket bolts(75) and disconnect 5
67
pipe(74). 11078MP01

(6) Disconnect pilot line hoses(11, 13, 14, 35,

37,47).
(7) Remove socket bolts(67) and disconnect
pump suction tube(5). 13

ö When pump suction tube is disconnected,

A
3

the oil inside the piping will flow out, so 35

a4

catch it in oil pan.

P

P
m

i1

47
1
D
r

14
B
3

(8) Sling the pump assembly and remove the

pump mounting bolts.
P
i2

P
m
2

 Weight : 90kg(200lb) 11
ö Pull out the pump assembly from housing. 37
When removing the pump assembly, 11078MP02
check that all the hoses have been
disconnected.

8-7
2) INSTALL
(1) Carry out installation in the reverse order
to removal.
(2) Remove the suction strainer and clean it.
(3) Replace return filter with new one.
(4) Remove breather and clean it.
(5) After adding oil to the hydraulic tank to the
specified level.
(6) Bleed the air from the hydraulic pump.
Η Remove the air vent plug(2EA).
Θ Tighten plug lightly.
Ι Start the engine, run at low idling, and
check oil come out from plug.
Κ Tighten plug.
(7) Start the engine, run at low idling(3~5
minutes) to circulate the oil through the
system.
(8) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.

8-8
2. MAIN PUMP(1/2)
1) STRUCTURE

702
789, 732 532 214 548 531 724 792 534 901 954 719 151 152 211 113

535
808

953
886 04
717
406
261
774

111
824
127
710
123
251

212
490 153 156 157 313 124 312 114 466 885 314 467 141 981 271 401
725 728 983
14072SF02

04 Gear pump 271 Pump casing 719 O-ring

111 Drive shaft(F) 312 Valve block 724 O-ring
113 Drive shaft(R) 313 Valve plate(R) 725 O-ring
114 Spline couping 314 Valve plate(L) 728 O-ring
123 Roller bearing 401 Hexagon socket bolt 732 O-ring
124 Needle bearing 406 Hexagon socket bolt 774 Oil seal
127 Bearing spacer 466 VP Plug 789 Back up ring
141 Cylinder block 467 VP Plug 792 Back up ring
151 Piston 490 Plug 808 Hexagon head nut
152 Shoe 531 tilting pin 824 Snap ring
153 Set plate 532 Servo piston 885 Pin
156 Bushing 534 Stopper(L) 886 Spring pin
157 Cylinder spring 535 Stopper(S) 901 Eye bolt
211 Shoe plate 548 Pin 953 Set screw
212 Swash plate 702 O-ring 954 Set screw
214 Bushing 710 O-ring 981 Plate
251 Support 717 O-ring 983 Pin
261 Seal cover(F)

8-9
 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

Hexagon socket PT plug PO plug Hexagon socket

Name B
head bolt (PT thread) (PF thread) head setscrew
Allen wrench 4 M 5 BP-1/16 - M 8
5 M 6 BP-1/8 - M10
6 M 8 BP-1/4 PO-1/4 M12, M14
B
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, Hexagon socket VP plug
- Henagon nut
socket wrench, double(Single) head bolt (PF thread)
open end spanner
19 M12 M12 VP-1/4
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. 10Ý8Ý200
Torque wrench Capable of tightening with the specified torques

8-10
 (2) Tightening torque
Torque Wrench size
Part name Bolt size
kgfÂm lbfÂft 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 16.0 116 0.47 12
M16 24.0 174 0.55 14
M18 34.0 246 0.55 14
M20 44.0 318 0.67 17
PT Plug(Materal : S45C) PT1/16 0.7 5.1 0.16 4
öWind a seal tape 1 1/2 to 2 PT 1/8 1.05 7.59 0.20 5
turns round the plug
PT 1/4 1.75 12.7 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(Materal : S45C) PF 1/4 3.0 21.7 0.24 6
PF 1/2 10.0 72.3 0.39 10
PF 3/4 15.0 109 0.55 14
PF 1 19.0 137 0.67 17
PF 1 1/4 27.0 195 0.67 17
PF 1 1/2 28.0 203 0.67 17

8-11
3) DISASSEMBLY
(1) Select place suitable to disassembling.
ö Select clean place.
ö 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.

R140LC-7 ‫׆‬೴ MP01

(5) Loosen hexagon socket head bolts(401)

which tighten swash plate support(251),
pump casing(271) and valve block(312).
ö If gear pump and so on are fitted to rear
face of pump, remove them before
starting this work.

(6) Place pump horizontally on workbench

with its regulator-fitting surface down and
separate pump casing(271) from valve
block(312).
ö Before bringing this surface down, spread
rubber sheet on workbench without fail to
prevent this surface from being damaged.

R140LC-7 ‫׆‬೴ MP02

8-12
(7) Pull cylinder block(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.
ö Take care not to damage sliding surfaces
of cylinder, spherical bushing, shoes,
swash plate, etc.

R140LC-7 ‫׆‬೴ MP03

(8) Remove hexagon socket head bolts(406)

and then seal cover(F, 261).
ö Fit bolt into pulling out tapped hole of seal
cover(F), and cover can be removed
easily.
ö Since oil seal is fitted on seal cover(F),
take care not to damage it in removing
cover.
(9) Remove hexagon socket head bolts(408) R140LC-7 ‫׆‬೴ MP04
and then seal cover(R, 262).
In case 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.

R140LC-7 ‫׆‬೴ MP05

(11) Remove shoe plate(211)and swash

plate(212) from pump casing(271).

R140LC-7 ‫׆‬೴ MP06

8-13
(12) Tapping lightly shaft ends of drive shafts
(111, 113) with plastic hammer, take out
drive shafts from swash plate supports.

R140LC-7 ‫׆‬೴ MP07

(13) Remove valve plates(313, 314) from valve

block(312).
ö These may be removed in work(6).

R140LC-7 ‫׆‬೴ MP08

(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).
ö In removing tilting pin, use a protector to
prevent pin head from being damaged.
ö Since loctite is applied to fitting areas of
tilting pin and servo piston, take care not
to damage servo piston.
ö Do not remove needle bearing as far as
possible, except when it is considered to
be out of its life span.
ö Do not loosen hexagon nuts of valve block
and swash plate support.
If loosened, flow setting will be changed.

8-14
4) ASSEMBLY
(1) For reassembling reverse the disassembl-
ing procedures, paying attention to the
following items.
Η Do not fail to repair the parts damaged
during disassembling, and prepare
replacement parts in advance.
Θ Clean each part fully with cleaning oil and
dry it with compressed air.
Ι Do not fail to apply clean working oil to
sliding sections, bearings, etc. before
assembling them.
Κ In principle, replace seal parts, such as
O-rings, oil seals, etc.
Λ For fitting bolts, plug, etc., prepare a
torque wrench or so on, and tighten them
with torques shown in page 8-11, 12.
Μ 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.
ö After servo piston, tilting pin, stopper(L)
and stopper(S) are removed, fit them
soon to pump casing in advance for
reassembling.
ö In tightening servo piston and tilting pin,
use a protector to prevent tilting pin head
R140LC-7 ‫׆‬೴ MP09
and feedback pin from being damaged.
In addition, apply loctite(Medium strength)
to their threaded sections.

8-15
(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
ö swash plate can be removed smoothly.
Apply grease to sliding sections of swash
ö plate and swash plate support, and drive
shaft can be fitted easily.
R140LC-7 ‫׆‬೴ MP10

(4) To swash plate support(251), fit drive

shaft(111) set with bearing(123), bearing
spacer(127) and snap ring(824).
ö Do not tap drive shaft with hammer or so
on.
ö Assemble them into support, tapping
outer race of bearing lightly with plastic
hammer.
Fit them fully, using steel bar or so on.
R140LC-7 ‫׆‬೴ MP11

(5) Assemble seal cover(F, 261) to pump

casing(271) and fix it with hexagon socket
head bolts(406).
ö Apply grease lightly to oil seal in seal
cover(F).
ö Assemble oil seal, taking full care not to
damage it.
ö For tandem type pump, fit rear cover(263)
and seal cover(262) similarly.
R140LC-7 ‫׆‬೴ MP12

(6) Assemble piston cylinder subassembly

Ðcylinder block(141), piston subassembly
(151, 152), set plate(153), spherical bush
(156), spacer(158) and cylinder spring
(157)Ñ.
Fit spline phases of retainer and cylinder.
Then, insert piston cylinder subassembly
into pump casing.

R140LC-7 ‫׆‬೴ MP13

8-16
(7) Fit valve plate(313) to valve block(312),
entering pin into pin hole.
ö Take care not to mistake suction / delivery
directions of valve plate.

R140LC-7 ‫׆‬೴ MP14

(8) Fit valve block(312) to pump casing(271)

and tighten hexagon socket head bolts
(401).
ö At first assemble this at rear pump side,
and this work will be easy.
ö Take care not to mistake direction of valve
block.
ö Clockwise rotation(Viewed from input
shaft side) - Fit block with regulator up and
R140LC-7 ‫׆‬೴ MP16
with delivery flange left, viewed from front
side.
ö Counter clockwise rotation(Viewed from
input shaft side) - Fit block with delivery
flange right, 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).
ö Take care not to mistake regulator of front
pump for that of rear pump.

R140LC-7 ‫׆‬೴ MP17

(10) Fit drain port plug(468).

This is the end of reassembling procedures.

8-17
 3. REGULATOR
1) STRUCTURE(1/2)

412 875 874

755
A
897 858
B
614
612

438

615 801
613
924
A 611
B
641 730 643 708 644 645 646 728

SECTION B-B

413 438 405 413 438

438

735

656 D

722 496 724 725 436 699 496 724 725 436

VIEW C(FRONT) VIEW C(REAR)

KR36-9N12(FRT) A
KR36-9N1S(RR)

735 722 P2
079
Pf
466
Pi

753 496 755

SECTION D-D

11072PM03

8-18
 REGULATOR(2/2)

734 653 654 836 651 652 601 624 629 630 628
655

641 801
C
814 925

898

631 627

732

733
732

622

621 623 625 626 887 763 756

SECTION A-A
R140LC-7 ‫׆‬೴ 2-5

405 Hexagon socket screw 629 Cover(C) 730 O-ring

412 Hexagon socket screw 630 Lock nut 732 O-ring
413 Hexagon socket screw 631 Sleeve, pf 733 O-ring
436 Hexagon socket screw 641 Pilot cover 734 O-ring
438 Hexagon socket screw 643 Pilot piston 735 O-ring
466 Plug 644 Spring seat(Q) 753 O-ring
496 Plug 645 Adjust stem(Q) 755 O-ring
601 Casing 646 Pilot spring 756 O-ring
611 Feed back lever 651 Sleeve 763 O-ring
612 Lever(1) 652 Spool 801 Nut
613 Lever(2) 653 Spring seat 814 Snap ring
614 Fulcrum plug 654 Return spring 836 Snap ring
615 Adjust plug 655 Set spring 858 Snap ring
621 Compensator piston 656 Block cover 874 Pin
622 Piston case 699 Valve casing 875 Pin
623 Compensator rod 708 O-ring 887 Pin
624 Spring seat(C) 722 O-ring 897 Pin
625 Outer spring 724 O-ring 898 Pin
626 Inner spring 725 O-ring 924 Set screw
627 Adjust stem(C) 728 O-ring 925 Adjust screw(QI)
628 Adjust screw(C)

8-19
 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

Hexagon socket PT plug PO plug Hexagon socket
Name B
head bolt (PT thread) (PF thread) head setscrew

Allen wrench 4 M 5 BP-1/16 - M 8

B
5 M 6 BP-1/8 - M10
6 M 8 BP-1/4 PO-1/4 M12, M14
Double ring spanner,
socket wrench, double(Single) Hexagon head VP plug
open end spanner - Hexagon nut
bolt (PF thread)
B

6 M 8 M 8 -
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 4Ý100mm
Torque wrench Capable of tightening with the specified torques
Pincers -
Bolt M4, Length : 50mm

8-20
 (2) Tightening torque
Torque Wrench size
Part name Bolt size
kgfÂm lbfÂft 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 16.0 116 0.47 12
M16 24.0 174 0.55 14
M18 34.0 246 0.55 14
M20 44.0 318 0.67 17
PT Plut(Materal : S45C) PT1/16 0.7 5.1 0.16 4
öWind a seal tape 1 1/2 to 2 PT 1/8 1.05 7.59 0.20 5
turns round the plug
PT 1/4 1.75 12.7 0.24 6
PT 3/8 3.5 25.3 0.31 8
PT 1/2 5.0 36.2 0.39 10
PF Plut(Materal : S35C) PF 1/4 3.0 21.7 0.24 6
PF 1/2 10.0 72.3 0.39 10
PF 3/4 15.0 109 0.55 14
PF 1 19.0 137 0.67 17
PF 1 1/4 27.0 195 0.67 17
PF 1 1/2 28.0 203 0.67 17

8-21
3) DISASSEMBLY
Since the regulator consists of small
precision finished parts, disassembly and
assembly are rather complicated.
For this reason, replacement of a regulator
assembly is recommended, 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.
ö Choose a clean place.
ö Spread rubber sheet, cloth, or so 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.
ö Take care not to lose O-ring.

R140LC-7 ‫׆‬೴ REG01

(4) Remove hexagon socket head screw

(438) and remove cover(C,629)
ö 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.
R140LC-7 ‫׆‬೴ REG02

8-22
(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.
ö Adjusting ring(Q,645) can easily be drawn
out with M4 bolt.
R140LC-7 ‫׆‬೴ REG03

(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.

R140LC-7 ‫׆‬೴ REG04

(7) Remove snap ring(814) and take out

spring seat(653), return spring(654) and
sleeve(651).
ö Sleeve(651) is fitted with snap ring(836).
ö When removing snap ring(814), return
spring(654) may pop out.
Take care not to lose it.

R140LC-7 ‫׆‬೴ REG05

(8) Remove locking ring(858) and take out

fulcrum plug(614) and adjusting plug
(615).
ö Fulcrum plug(614) and adjusting plug
(615) can easily be taken out with M6 bolt.

R140LC-7 ‫׆‬೴ REG06

8-23
 R140LC-7 ‫׆‬೴ REG07

(9) Remove lever(2, 613). Do not draw out

pin(875).
ö Work will be promoted by using pincers or
so on.

R140LC-7 ‫׆‬೴ REG08

(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).

R140LC-7 ‫׆‬೴ REG09

R140LC-7 ‫׆‬೴ REG10

8-24
(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).
ö Piston case(622) can be taken out by
pushing compensating rod(623) at
opposite side of piston case.
This completes disassembly.

8-25
4) ASSEMBLY
(1) For assembly, reverse disassembly
procedures, but pay attention to the
following items.
Η Always repair parts that were scored at
disassembly.
Θ Get replacement parts ready beforehand.
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.
Ι Always tighten bolts, plugs, etc. to their
specified torques.
Κ Do not fail to coat sliding surfaces with
clean hydraulic oil before assembly.
Λ 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.
ö Confirm that spool and sleeve slide
smoothly in casing without binding.
ö Pay attention to orientation of spool.

Spool

Feedback lever
R140LC-7 ‫׆‬೴ 8-27

8-26
(5) Fit feedback lever(611), matching its pin
hole with pin hole in spool.
Then insert pin(874).
ö Insert pin in feedback lever a little to ease
Lever (1) side Lever (2) side
operation.
(Fulcrum plug of
ö Take care not to mistake direction of
adjusting plug side)
feedback lever.

R140LC-7 ‫׆‬೴ 8-28

(6) Put pilot piston(643) into pilot hole of

casing.
ö 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).

R140LC-7 ‫׆‬೴ REG11

(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.
ö 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. R140LC-7 ‫׆‬೴ REG12

(10) Fit return spring(654) and spring seat

(653) into spool hole and attach snap ring
(814).

R140LC-7 ‫׆‬೴ REG13

8-27
(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).

R140LC-7 ‫׆‬೴ REG02

(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.
ö When fitting spring seat, take care not to
mistake direction of spring seat.

R140LC-7 ‫׆‬೴ REG15

(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. R140LC-7 ‫׆‬೴ REG16

8-28
GROUP 4 MAIN CONTROL VALVE

1. REMOVAL AND INSTALL OF MOTOR

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

pressure inside the hydraulic tank.

Escaping fluid under pressure can
penetrate the skin causing serious
injury.
ö When pipes and hoses are disconnected,
the oil inside the piping will flow out, so
catch it in oil pan.
(4) Remove bolts and disconnect pipe.
(5) Disconnect pilot line hoses.
1408DA10
(6) Disconnect pilot piping.
(7) Sling the control valve assembly and
remove the control valve mounting bolt.
ÂWeight : 80kg(180lb)
(8) Remove the control valve assembly.
When removing the control valve
assembly, check that all the piping have
been disconnected.
2) INSTALL
(1) Carry out installation in the reverse order
to removal. 1408DA11

(2) Bleed the air from below items.

Η Cylinder(Boom, arm, bucket)
Θ Swing motor
Ι Travel motor
ö See each item removal and install.
(3) Confirm the hydraulic oil level and recheck
the hydraulic oil leak or not.

1408DA12

8-29
2. STRUCTURE(1/4)

1408DA13

1 Body 15 Cover-pilot 32 Valve-check

2 Spool 24 Holder-spring 33 Spring-check valve
3 Spool 25 Holder-spring 73 Plug
4 Spool 26 End-spool 74 O-ring
6 Spool 27 Spring 78 O-ring
7 Spool 28 Spring 90 O-ring
9 Spool 29 Stopper 91 Bolt-socket head
11 Spool 30 Stopper 93 Bolt-socket head
13 Cover-pilot 31 Holder-spring 101 Lock-valve
14 Cover-pilot

8-30
STRUCTURE(2/4)

1408DA14

3 Spool 28 Spring 76 O-ring

5 Spool 48 Spool-selector 78 O-ring
8 Spool 49 Spring 80 O-ring
10 Spool 50 Stopper 81 O-ring
12 Spool 51 Piston 86 Back-up ring
13 Cover-pilot 57 Restrictor 88 Back-up ring
14 Cover-pilot 59 Plug 90 O-ring
17 Cover-pilot 60 Plug 91 Bolt-socket head
24 Holder-spring 61 Restrictor 92 Bolt-socket head
25 Holder-spring 68 Plug-socket head 93 Bolt-socket head
26 End-spool\ 69 Plug-socket head 101 Lock-valve
27 Spring 72 Plug

8-31
STRUCTURE(3/4)

1408DA15

18 Plug 58 Plug 80 O-ring

19 Valve-check 70 Plug 81 O-ring
20 Spring-check valve 72 Plug 82 O-ring
21 Plug 73 Plug 83 O-ring
22 Valve-check 77 O-ring 84 O-ring
23 Spring-check valve 78 O-ring 87 Back-up ring

8-32
STRUCTURE(4/4)

1408DA16

16 Cover-pilot 53 Spring-check valve 76 O-ring

34 Valve-lock 54 Plug 77 O-ring
35 Restrictor-lock valve 55 Restrictor 78 O-ring
36 Spring-lock valve 56 Filter-coin type 79 O-ring
37 Holder-spring 62 Poppet-negative 82 O-ring
38 Poppet 63 Filter-coin type 84 O-ring
39 Seat-poppet 64 Holder-spring 85 O-ring
40 Piston 65 Spring-negative 87 Back-up ring
41 Guide-piston 66 Piston-negative 89 Back-up ring
42 Spring-lock valve 67 Socket-negative 94 Relief valve-main
43 Piston 68 Plug 95 Bolt-socket head
44 Socket-lock valve 69 Plug 96 Relief valve-overload
45 Spool-lock valve 71 Plug 97 Plug-relief valve
46 Spring-lock valve 73 Plug 98 Plug-relief valve
47 Plug-lock valve 75 O-ring 99 Relief valve-overload
52 Valve-check

8-33
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)

8-34
3) DISASSEMBLY
(1) Disassembly of spools without holding valve
Η Loosen hexagon socket head bolts with washer
(Hexagon wrench : 5mm)
Θ Remove the pilot cover.
ö Pay attention not to lose the O-ring under the pilot cover.
Ι Remove the spool assembly from the body by hand slightly.
ö When extracting each spool from its body, pay attention not to damage the body.
ö When extracting each spool assembly, it must be extracted from spring side only.
ö When any abnormal parts are found, replace it with completly new spool assembly.
ö When disassembled, tag the components for identification so that they can be reassembled
correctly.

1408DA17

8-35
(2) Disassembly of spools with holding valve(Boom 1, Arm 1 spool)
Η Loosen hexagon socket head bolts with washer
(Hexagon wrench : 5mm)
Θ Remove the pilot cover with internal parts.
ö Pay attention not to lose the O-ring and the poppet under the pilot cover.
ö Pay attention not to damage the "piston A" under pilot cover.
Ι Remove the spool assembly from the body by hand slightly.
ö When extracting each spool from its body, pay attention not to damage the body.
ö When extracting each spool assembly, it must be extracted from spring side only.
ö When any abnormal parts are found, replace it with completly new spool assembly.
ö When disassembled, tag the components for identification so that they can be reassembled
correctly.

1408DA22

8-36
(3) Disassembly of the holding valve
Η Remove the pilot cover with the holding valve as discribed on previous page.
ö Do not disassembled internal parts of the pilot cover.
Θ Loosen the poppet seat and remove the poppet, the spring seat, the spring and the check.
(Spanner : 32mm)
ö Pay attention not to lose the poppet.
ö Do not disassembled internal parts of the check.

1408DA23

8-37
(4) Disassembly of the load check valve and the negative relief valve
Η The load check valve
a. Fix the body to suitable work bench.
ö Pay attention not to damage the body.
b. Loosen the plug (Hexagon wrench : 10mm).
c. Remove the spring and the load check valve with pincers or magnet.
Θ The negative relief valve
a. Loosen the socket (Hexagon wrench : 12mm).
b. Remove the spring, the spring holder, the piston and the negative control poppet.

1408DA21

8-38
(5) Disassembly of the main and overload relief valve
Η Fix the body to suitable work bench.
Θ Remove the main relief valve.
(Spanner : 32mm)
Ι Remove the overload relief valve.
(Spanner : 32mm)
ö When disassembled, tag the relief valve for identification so that they can be reassembled
correctly.
ö Pay attention not to damage seat face.
ö When any abnormal parts are found, replace it with completly new relief valve assembly.

1408DA19

1408DA20

8-39
(6) 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.
Η Control valve
a. Check whole surfaces of all parts for burrs, scratches, notches and other defects.
b. Confirm that seal groove faces of body and block are smooth and free of dust, dent, rust etc.
c. Correct dents and damages and check seat faces within the body, if any, by lapping.
ö Pay careful attention not to leave any lapping agent within the body.
d. Confirm that all sliding and fitting parts can be moved manually and that all grooves and path's
are free 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 it's the prescribed disassembly
and assembly procedures.
g. Replace all seals and O-rings with new ones.
Θ 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 precaution
Η In this assembly section, explanation only is shown.
For further understanding, please refer to the figures shown in the previous structure &
disassembly section.
Θ Pay close attention to keeping all seals free from handling damage and inspect carefully for
damage before using them.
Ι Apply clean grease or hydraulic oil to the seal so as to ensure it is fully lubricated before
assembly.
Κ Do not stretch seals so much as to deform them permanently.
Λ 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.
Μ Tighten fitting bolts for all sections with a torque wrench adjusted to the respective tightening
torque.
Ν Do not reuse removed O-rings and seals.
(2) Load check valve
Η Assemble the load check valve and spring.
Θ Put O-rings on to plug.
Ι Tighten plug to the specified torque.
ÂHexagon wrench : 10mm
ÂTightening torque : 6~7kgfÂm(43.4~50.6lbfÂft)
(3) Negative control relief valve
Η Assemble the nega-con poppet, piston, spring holder and spring together into body.
Θ Put O-ring on to plug and tighten the latter to its specified torque.
ÂHexagon wrench : 12mm
ÂTightening torque : 8~9kgfÂm(57.8~65.1lbfÂft)
(4) Main relief, port relief valves
Install main relief valve, overload relief valve into the body and tighten to the specified torque.
Tightening torque
Component Tools
kgfÂm lbfÂft
Main relief valve Spanner 32mm 8~9 57.8~65.1
Overload relief valve Spanner 32mm 8~9 57.8~65.1

(5) Main spools

Η Carefully insert the previously assembled spool assemblies into their respective bores within of
body.
ö Fit spool assemblies into body carefully and slowly. Do not under any circumstances push them
forcibly in.

8-41
(6) Covers
Η Fit spool covers to the non-spring assembly end of the spool, and tighten the hexagonal socket
head bolts to the specified torque.
ÂHexagon wrench : 5mm
ÂTightening torque : 1~1.1kgfÂm(7.2~7.9lbfÂft)
ö Confirm that O-rings have been fitted.
Θ Fit spring covers to the spring end for the spools, and tighten hexagon socket head bolts to the
specified torque.
ÂHexagon wrench : 5mm
ÂTightening torque : 1~1.1kgfÂm(7.2~7.9lbfÂft)
ö Confirm that O-rings have been fitted.
(7) Holding valves
Η Assemble the check, spring seat and poppet together into body.
Θ Tighten the poppet seat to the specified torque.
ÂSpanner : 26mm
ÂTightening torque : 6~7kgfÂm(43.4~50.6lbfÂft)
Ι Fit the "piston A" under pilot cover with internal parts into hole on the poppet seat.
Κ Tighten hexagon socket head bolt to specified torque.
ÂHexagon wrench : 5mm
ÂTightening torque : 1~1.1kgfÂm(7.2~7.9lbfÂft)

8-42
GROUP 5 SWING DEVICE

1. REMOVAL AND INSTALL OF MOTOR

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

pressure inside the hydraulic tank.

Escaping fluid under pressure can
penetrate the skin causing serious
injury. A 1
B

ö When pipes and hoses are disconnected, 9

2
the oil inside the piping will flow out, so
catch it in oil pan.
(4) Disconnect hose assembly(2).
(5) Disconnect pilot line hoses(3,4,5,6,7,8).
(6) Sling the swing motor assembly(1) and 11078SM01
remove the swing motor mounting bolts
(9).
ö Motor device weight : 32kg(70.5lb)
7 6
(7) Remove the swing motor assembly. 5
ö When removing the swing motor 8
assembly, check that all the piping have
been disconnected.
2) INSTALL
(1) Carry out installation in the reverse order
3
to removal. 4

(2) Bleed the air from the swing motor. 11078SM02

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
check oil come out from plug.
Λ Tighten plug fully.
(3) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.

8-43
2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
1) STRUCTURE

11072SM02

1 Body 16 Brake piston 31 Check

2 Oil seal 17 O-ring 32 Relief valve assembly
3 Roll bearing 18 O-ring 33 Reactionless valve assembly
4 Snap ring 19 Spring 34 Time delay valve assembly
5 Shaft 20 Rear cover 35 Wrench bolt
6 Bushing 21 Needle bearing 36 Plug
7 Pin 22 Pin 37 O-ring
8 Shoe plate 23 Valve plate 38 Plug
9 Cylinder block 24 O-ring 39 Plug
10 Spring 25 O-ring 40 Level gauge
11 Ball guide 26 Wrench bolt 41 Flange
12 Set plate 27 Plug 42 O-ring
13 Piston assembly 28 Back up ring 43 Name plate
14 Friction plate 29 O-ring 44 Rivet
15 Plate 30 Spring

8-44
2) DISASSEMBLY
(1) Lift the motor out. Clean the motor in
kerosene and dry with compressed air.
ö 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 body(1).

32038SM02

(3) Fix the drive shaft(5) on the workbench

with the end of output shaft down. Put
matching marks on body (1) and valve
rear cover(20) for easy reassembly.

32038SM03

(4) Remove the valve(34).

32038SM04

8-45
(5) Remove the relief valve(32) from rear
cover(20).

32038SM05

(6) Remove plug(27) from rear cover(20) and

spring(30), check(31).
ö Be careful not to damage the check seat
assembly.

32038SM06

(7) Remove rear cover(20) from body(1).

Then, remove the valve plate(23) from
rear cover(20) with care.

32038SM07

(8) Remove the brake spring(19) from brake

piston(16).

32038SM08

8-46
(9) Remove brake piston(16) from body(1).

32038SM09

(10) Remove the cylinder(9) from the output

shaft(5) with the motor positioned
horizontally. Remove ball guide(11), set
plate(12), piston(13) and shoe plate(8).

32038SM10

(11) Remove friction plate(14) and separate

plate(15) from body(1).

32038SM11

(12) Remove snap ring(4) and remove drive

shaft(5) from body(1).

11078SM23

8-47
(13) Remove the cone of roller bearing(3) by
press.
ö Do not reuse bearings.
Press

Output shaft

Roller bearing
32038SM15

(14) Remove bushing(6) and oil seal(2) from

body(1).

25038SM05

(15) Remove the needle bearing(21) from the

rear cover(20) by using slide hammer
bearing puller.

32038SM17

8-48
(16) 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
ö 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) Apply three bond of white color on outer
surface of oil seal(2) and insert it to the
body(1).

11078SM22

(2) Install the roller bearing(3) to the drive

shaft(5).

11078SM21

(3) Insert the drive shaft(5) into the body(1)

with the plastic hammer lightly.

11078SM24

(4) Install the snap ring(4) to the body(1).

11078SM25

8-50
(5) Insert the shoe plate(8) with the body(1)
position horizontally.

32038SM28

(6) Insert the ball guide(11) into the cylinder

(9).

32038SM29

(7) Install the piston sub-assembly(13) to the

set plate(12).

32038SM30

(8) Reassemble the piston assembly(9) to the

body(1).

32038SM31

8-51
(9) Assembly friction plate(14) and plate(15)
to the body(1).

11078SM26

(10) Insert O-ring(17) inside the body(1).

32038SM33

(11) Reassemble brake piston(16) to the body

(1).

32038SM34

(12) Reassemble brake spring(19) to the brake

piston(16).

32038SM35

8-52
(13) When assembling the needle bearing(21),
insert the needle bearing(21) into rear
cover(20) by hammering.

32038SM36

(14) Reassemble valve plate(23) to the rear

cover(20) and reassemble O-ring(18).

32038SM37

(15) Connect the rear cover(20) with the body

(1) and tighten the wrench bolt(26).

32038SM38

(16) Insert check(31) and spring(30) in the

valve casing and install O-ring(29) and
back up ring(28). Tighten plug(27) to the
rear cover(20).

32038SM39

8-53
(17) Insert O-rings to the relief valve (32) and
reassemble them to rear cover(20).
This completes assembly.

32038SM42

8-54
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.
ÂReduction gear device weight : 95kg
(209lb)
13031GE18

2) INSTALL
(1) Carry out installation in the reverse order
to removal.
ÂTightening torque : 29.7Ü4.5kgfÂm
(215Ü32.5lbfÂft) 2

11078RD01

8-55
4. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR
1) STRUCTURE

2 26 27 28 17 1 22 20 21 18 25 8 12 4 10 23 3 19

6
12
11
29
24

7
5
13
9
16

11072SM03

1 Casing 10 Pin No.2 assembly 21 Plug(B)

2 Drive shaft 11 Pin No.1 22 Plug(A)
3 Ring gear 12 Thrust washer(B) 23 Spring pin
4 Planet gear No.2 13 Thrust washer(A) 24 Stop ring
5 Sun gear No.2 16 Knock pin 25 Stop ring
6 Planet gear No.1 17 Sph roller bearing 26 Spacer
7 Sun gear No.1 18 Cyl roller bearing 27 Cover plate
8 Carrier No.2 19 Bolt 28 Bolt
9 Carrier No.1 20 Oil seal 29 Needle cage

8-56
2) DISASSEMBLY
(1) Remove gauge bar(14) and gauge pipe
(15) from the swing motor casing.
ö Pour the gear oil out of reduction gear into
the clean bowl to check out the friction
decrease.

14078DA79F

(2) Loosen the socket bolts(19) to separate

swing motor from reduction gear.

14078DA79E

(3) Remove stop ring(24) and then sun

gear1(7).

14078DA70

(4) Tighten two M10 eye bolts to carrier1(9)

and lift up and remove carrier1(9) as
subassembly.

14078DA71

8-57
(5) Disassembling carrier1(9) assembly.
Η Remove stop ring(24).
Θ Remove thrust washer(12), planet gear1
(6), needle cage(29), and thrust
washer(12) from the carrier.
Ι Using M8 solid drill, crush spring pin(23)
so that the pin1(11) can be removed by
hammering.
ö Do not reuse spring pin(23).
14078DA72
ö Do not remove pin1(11), carrier1(9) and
spring pin(23) but in case of replacement.
ö Put matching marks on the planet gear1
(6) and the pin1(11) for easy reassembly.

(6) Remove sun gear2(5) and thrust washer

(13). 13

11078RD02

(7) Remove carrier2(8) assembly from casing

(1).

11078RD03

8-58
(8) Disassembling carrier2(8) assembly
Η Using M8 solid drill, crush spring pin(23)
so that the pin2(10) can be removed.
ö Do not reuse spring pin(23).
Θ Remove pin2(10), planet gear2(4) and
thrust washer(12) from the carrier2(8).
ö Put matching marks on the planet gear2
(4) and the pin2(23) for easy reassembly.
ö Do not disassemble pin2(23), carrier2(8)
14078DA75
and spring pin(23) but in case of
replacement.

(9) Tighten two M16 eyebolt to the ring

gear(3) and then lift the ring gear(3) out of
casing(1).

1
11078RD04

(10) Remove stop ring (25) from the drive

shaft(2).
25
2

11078RD05

(11) Remove the bolt(28) and remove the drive

shaft(2) with roller bearing(17), the
spacer(26) and the cover plate(27).

17
26,27
28
2 11078RD06

8-59
(12) Remove the roller bearing(17), the cover
plate(27) and the spacer(26) from the 17
drive shaft(2).
27

26

11078RD07

(13) Using the bearing disassembly tool,

remove roller bearing(18).
18

11078RD08

(14) Remove the oil seal(20).

20

11078RD09

(15) Remove plugs(21, 22) from the casing(1).

14078DA79B

8-60
3) ASSEMBLY
17
(1) Assemble the space(26), the cover
plate(27) and the roller bearing(17) on the
drive shaft(2). 27

26

11078RD07

(2) Assemble the drive shaft sub assembly(2)

into the casing(1) and tighten the bolt(28)
with loctite No.262.

17
26,27
28
2 11078RD07

(3) Install the oil seal(20) and the roller

bearing(18). 18

20

11078RD10

(4) Install stop ring(25) on the drive shaft (2).

14078DA77

8-61
(5) Apply loctite to the tapped holes of casing
(1).
(6) Tighten 2 M16 eye bolts to the ring
gear(3) and lift up and then assemble it
onto the casing(1).
ö Don't fail to coincide the knock pin(16)
holes.

14078DA76

(7) Assembling carrier2(8) assembly.

Η Install thrust washer(12) and the planet
gear2(4) inside the carrier2(8).
Θ Assemble the pin2(10) to the carrier2(8)
and then press the spring pin(23) by
hammering.
Ι Punch 2 points of the spring pin(23) lip.
ö Take care not to mistake the matching
marks of each part.
14078DA75

(8) Assemble carrier2(8) assembly correctly

to the drive shaft(2).

14078DA74

(9) Assemble sun gear2(5) and thrust gear

(13) to the center of the carrier2(8)
assembly.

14078DA73

8-62
(10) Assembling carrier1(9) assembly.
Η Assemble the pin1(11) to the carrier1(9)
and then press the spring pin(23) by
hammering.
Θ Punch 2 points of the spring pin's(23) lip.
Ι Install needle cage(29) into the planet
gear1(6).
Κ Assemble thrust washer(12), planet
gear1(6), and then stop ring(24) to the
14078DA72
pin1(11).
ö Take care not to mistake the matching
marks of each part.

(11) Assemble carrier1(9) assembly into the

ringgear.

14078DA70A

(12) Hammer 4 knock pins(16) around the ring

gear(3).
(13) Assemble sun gear1(7) and stop ring(24)
to the drive shaft of the swing reduction
gear.

14078DA79D

(14) Apply loctite to the tapped holes of the

ring gear(3) and then mount swing motor
onto the ring gear(3).
ö Don't fail to coincide the gauge bar(14)
hole.
(15) Tighten socket bolts(19) around the swing
19
motor assembly.
ÂTightening torque : 24kgfÂm(173lbfÂft)
11078RD12

8-63
(16) Assemble plugs(21, 22), gauge bar(14)
and gauge pipe(15). 15
14

22
1
21
22
11078RD11

8-64
GROUP 6 TRAVEL DEVICE

1. REMOVAL AND INSTALL

1) REMOVAL
(1) Swing the work equipment 90Áand lower it
completely to the ground.
(2) Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
(3) Loosen the breather slowly to release the 13031GE18

pressure inside the hydraulic tank.

E scaping fluid under pressure can
1
penetrate the skin causing serious
injury.
ö When pipes and hoses are disconnected,
2
the oil inside the piping will flow out, so
catch it in oil pan. T2
P2
PP
P1 3
(4) Remove the track shoe assembly.
For details, see removal of track shoe
assembly.
(5) Remove the cover.
11078TM01

(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 : 165kg(240lb)
2) INSTALL
(1) Carry out installation in the reverse order
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
check oil come out from plug.
Λ Tighten plug fully.
(3) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.

8-65
2. TRAVEL MOTOR
2) STRUCTURE
84
3
83
22 83
22 17
82
8
19
12 21 81
33
32 21 104
37 105
31 39
38
30 36
40
41
40
20
13 103
29 16 11 102
35
28
49 27
26 2 101
25 34
47 24 6
63 61 23
48 15
62 10
46 56 5
45
50 4 86 85
98
9 95
74 42 14
75 41
71 9
44 18 7
79
65
67 43 88 87
68 89
90
60
45 94
59 51
57 46
58 53
63 52 48 98
55 47
66 63 54
64 69
73 49
78 96
72
75 91
70 93
77 76 92
97
11072TM04

2 Shaft 20 Brake piston 37 Retainer 54 Plug 71 Sleeve 89 Carrier

3 Cylinder barrel 21 Friction plate 38 Poppet 55 O-ring 72 Stopper 90 Sun gear B
4 Ball retainer 22 Steel plate 39 Spring 56 Orifice 73 Spring 91 Planetary gear B
5 Retainer 23 Disk spring 40 O-ring 57 Steel ball 74 Plug 92 Bushing
6 Cam 24 Shim(1.0T) 41 Pin 58 Plug 75 O-ring 93 Needle bearing B
7 Piston assembly 25 Shim(1.2T) 42 Bolt 59 O-ring 76 Screw 94 Snap ring
8 Valve plate 26 Shim(1.4T) 43 Motor cover assembly 60 Relief valve assembly 77 Nut 95 Thrust plate(2)
9 Plate 27 Shim(1.6T) 44 Spool assembly 61 Plug 78 O-ring 96 Thrust plate(3)
10 Piston assembly 28 Shim(1.8T) 45 Washer 62 O-ring 79 Rod 97 Thrust plate(4)
11 Ball bearing 29 Shim(2.0T) 46 Spring 63 Plug 81 Casing body 98 Screw
12 Roller bearing 30 O-ring 47 Cover 64 Plug 82 Floating seal 99 Washer
13 Oil seal 31 Back up ring 48 O-ring 65 Plug 83 Angular bearing 100 Parallel pin
14 Spring 32 O-ring 49 Bolt 66 O-ring 84 Ring nut 101 Cover
15 Spring 33 Back up ring 50 Orifice 67 Name plate 85 Casing gear 102 Spring washer
16 Steel ball 34 O-ring 51 Spool 68 Rivet 86 Sun gear A 103 Bolt
17 Pin 35 O-ring 52 Stopper 69 Spring guide 87 Planetary gear A 104 Plug
18 Snap ring 36 Seat 53 Spring 70 Plug 88 Needle bearing A 105 O-ring
19 Spring pin

8-66
2) TOOLS AND TIGHTENING TORQUE
(1) Tools

Tool name Remark

Allen wrench 5, 6, 8, 10, 14 B

Socket 22, 30, 32, 41

OSocket for socket wrench, spanner
Rod 5, 6, 8, 10, 14, 19
Torque wrench Capable of tightening with the specified torques
Pliers -
(-) Driver 150mm
Plastic and iron hammer Wooden hammer allowed. Normal 1 or so
Steel rod approx 7Ý7Ý200mm
Monkey wrench -
Oil seal inserting jig -
Bearing pliers -
Seal tape -
Eye bolt PF1/2, M16
Press(0.5 ton) -
Oil stone -
Bearing assembling jig -
Liquid packing Loctite #577
Screw lock Loctite #243

(2) Tightening torque

Torque
Part name Item Size
kgfÂm lbfÂft
Screw 98 M10 7.0Ü0.5 50.6Ü3.6
Bolt 103 M8 3.6Ü0.2 26.0Ü1.4
Plug 104 PF3/4 10.0Ü1.0 72.3Ü7.2
Bolt 42 M14 19.5Ü1.5 141.0Ü10.8
Orifice 43 NPTF1/16 1.0Ü0.1 7.2Ü0.7
Plug 44 M20 8.6Ü0.8 62.2Ü5.8
Bolt 49 M12 8.0Ü0.8 57.9Ü5.8
Orifice 50 NPTF1/16 1.0Ü0.1 7.2Ü0.7
Plug 54 PF3/8 5.0Ü0.5 36.2Ü3.6
Orifice 56 NPTF1/16 1.0Ü0.1 7.2Ü0.7
Plug 58 PF1/8 2.0Ü0.2 14.5Ü1.4
Relief valve body 60-1 M28 20.0Ü2.0 144.7Ü14.5
Cap nut 60-7 M38 20.0Ü2.0 144.7Ü14.5
Screw 60-10 M10 3.5Ü0.2 25.3Ü1.4
Plug 61 3/4-16UNF 7.0Ü0.5 50.6Ü3.6
Plug 63 NPTF1/16 1.0Ü0.1 7.2Ü0.7
Plug 64 9/16-18UNF 5.0Ü0.5 36.2Ü3.6
Plug 65 PT1/8 2.0Ü0.2 14.5Ü1.4
Plug 70 7/8-14UNF 8.0Ü0.8 57.9Ü5.8
Plug 74 7/8-14UNF 8.0Ü0.8 57.9Ü5.8
Screw 76 M10 3.5Ü0.2 25.3Ü1.4

8-67
3. DISASSEMBLY
1) GENERAL PRECAUTIONS
(1) Before disassembling the motor, check the items to be inspected and, for remedy against trouble,
closely examine the nature of the trouble, so that the motor can be disassembled effectively.
(2) To disassemble the motor, use the disassembling procedures described in section 2) and select a
clean place.
(3) Place a rubber or vinyl sheet or other such protective materials on your working bench to protect
the surface of the motor to be serviced.
(4) During disassembly, give a match mark to the mating surfaces of each part.
(5) Arrange removed parts in order so that they will not become damaged or missing during
disassembly.
(6) Once seals have been disassembled, they should be replaced even if damage is not observed.
Have replacement seals ready on hand before starting your disassembling job.

8-68
2) DISASSEMBLING PROCEDURE
(1) Clean the outside of the travel motor
completely before disassembling.
Be aware that in re-assembling, the parts
must be installed in the original locations.
For this purpose, it is strongly recomm-
ended to record the original positions of
the parts before and during disassembling
process.
(2) Remove the drain plug and drain the
lubricating oil. The capacity of the travel
motor is 2.5 liters (0.55U.K.gal; 0.66U.S.gal).
Place the travel motor on the flat clean
ground.

(3) Remove one relief valve(1) shown in the

picture.

11078TM12

(4) Remove ten bolts(2) and motor cover(3).

ö Removing the relief valve(1) first makes it
easier to remove ten bolts(2) and brake
valve(3) later as shown.
Be careful not to drop a valve plate.
Don't give damage to it. It is on the
motor cover inside surface.

11078TM11

8-69
ö It would be easier to remove motor cover
if you temporarily replace two bolts with
two "tool" bolts(4) of yours as shown.
(You don't have to use them necessarily).
ÂBolt thread size = M12ÝP1.75
ÂBolt length = about 70mm(for example)

11078TM13

(5) Place brake valve(3) on wood blocks(5) as

shown.

11078TM14

(6) Remove back-up ring(6) and O-ring(7)

from the relief valve(1).

11078TM15

8-70
(7) Remove two diagonal bolts(8) on one side
as shown. Then, loosen the two
remaining bolts little by little alternately
until they are removed completely.
Remove cover(9) from the brake valve.
There is strong spring pressure under
the cover(9). For your safety and
preventing damage, be sure to loosen
the bolts carefully so that spring
pressure is under your control. 11078TM16

Follow the procedure below.

ö If it is difficult to pull out the spool
assembly(12) because of vacuum action,
it will be easier by loosening another 4
bolts(8) and cover(9) on the other side a
little. (Face distance 0.5mm is enough)

(8) Remove spring(10), washer(11) and spool

assembly(12) from the brake valve. They
are located behind the cover(9).
ö Don't disassemble spool assembly(12).
The component(12) should be serviced
only as an assembly.

11078TM17

(9) Remove O-ring(13) and plug(14) from the

brake valve.
Remove the O-ring from plug(14).

11078TM18

8-71
(10) Remove stopper(15), spring(16), and
spool(17) located behind plug(14), from
the brake valve.

11078TM19

(11) Remove two plugs(18).

11078TM20

(12) Remove O-ring(19) from each plug.

Remove steel balls(20) from the brake
valve.

11078TM21

(13) Remove one relief valve(21) shown in the

picture.

11078TM22

8-72
(14) Remove back-up ring(22) and O-ring(23)
from the relief valve.

11078TM23

(15) Remove plug assembly(24) from the

brake valve.
ö Don't disassemble plug assembly(24).
The screw setting must be kept at the
original condition.

11078TM24

(16) Remove plug(25).

11078TM25

(17) Remove spring(26), spring guide(27) and

rod(28) behind plug assembly(24).
Remove the O-ring(29) from plug
assembly(24). Remove the O-ring(30)
from plug(25).

11078TM26

8-73
ö You don't have to remove sleeve inside
the brake valve if the speed-shifting is
functioning in order.

11078TM27

(18) Remove four bolts(31) and remove cover

(32). Refer to step 7.

11078TM28

(19) Place the brake valve upside-down as

shown. Remove valve plate(33) from the
brake valve.

11078TM29

(20) If necessary, remove bearing(34) and

location pin(35).

11078TM30

8-74
(21) Remove three O-rings(36)(37)(38), two
disk springs(39), and shim(40) from the
body casing.

11078TM31

(22) Install tooling "Brake piston puller" as

shown.
a. Screw-in two bolts to the brake piston.
b. Turn the center bolt little by little and let
the center bolt push the shaft.
Then the brake piston comes out.
c. Remove brake piston(41).

11078TM32

(23) Remove O-rings(42)(43) and back-up

rings(44)(45) from the brake piston.

11078TM33

8-75
(24) Remove two friction plates(46) and two
steel plates(47) from the body casing,
using a steel wire, a magnet, etc.
Don't pull off the cylinder barrel compon-
ent yet.

11078TM34

11078TM35

(25) Position the travel motor as shown on a

wood block and apply wood wedges that
prevent the travel drive from rolling
around. Remove cylinder barrel assembly
(48) from the body casing.

11078TM36

11078TM37

8-76
(26) Be aware that in re-assembling,
retainer(49), piston assemblies(50) and
cylinder barrel(51) must be installed in the
original locations.
For this purpose, it is strongly recomm-
ended to record the original positions of
the parts before and during disassembling
process.
(27) Remove retainer(49) and piston assembli-
es(50) from barrel(51). Separate the
piston assemblies from the retainer. 11078TM38

(28) Remove retainer ball(52) from the cylinder

barrel.

11078TM39

(29) Remove three pins(53) from the cylinder

barrel.

11078TM40

8-77
(30) Give a slight amount of compression on
plate(54) with a press machine using a
suitable size diameter jig.
Remove snap ring(55). Remove plate(54)
spring(56) and plate(57) from the cylinder
barrel(51).
There is strong spring force behind
plate (54). For your safety and avoid-
ing damage, a press machine should
be used to hold spring compression in 11078TM41

disassembling the internal components

in cylinder barrel.

11078TM42

11078TM43

8-78
(31) Remove cam(58) from the body casing.

11078TM44

11078TM45

(32) Remove two steel balls(59) and piston(60)

from the body casing. Remove the
spring(61) behind the piston.

11078TM46

11078TM47

8-79
(33) Place the travel motor on wood blocks as
shown. Remove sixteen bolts(62) and
washers(63).
To avoid damaging shaft, don't put the
traval motor directly on a flat ground
but use blocks.

11078TM48

11078TM49

(34) With a soft-faced hammer, break the seal

between cover(64) and gear casing(65).
Remove the cover(64).

11078TM50

11078TM51

8-80
(35) Remove three bolts(66) and a thrust
plate(67).

11078TM52

(36) Remove sun gear(68), three planetary

gears(69) and three bearings(70).

11078TM53

11078TM54

(37) Remove carrier(71).

11078TM55

8-81
(38) If necessary, remove three inner races(72)
from the carrier shaft.

11078TM56

(39) Remove sun gear(73).

11078TM57

(40) Remove snap ring(74) from sun gear(73).

11078TM58

(41) Remove four bolts(75) and a thrust plate

(76).

11078TM59

8-82
(42) Remove four planetary gears(77), four
bearings(78), four bushes(79) and four
plates(80).

11078TM60

11078TM61

(43) Remove bolt(81) and washer(82).

11078TM62

(44) Remove pin(83) with a magnet.

If it is difficult, follow the procedure below.
Η Put a cover plate over the tap hole as
shown.
Θ Drill a hole to the pin(83).
Ι Drill a tap to the hole in the pin(83).
Κ Screw-in a bolt to some degree and pull
off the pin with the bolt.
(45) Remove ring nut(84) from the body
casing.
11078TM63

8-83
(46) Remove the gear casing(65) from the
body casing with a hoist.

11078TM64

(47) Remove an angular bearing(85) from the

gear casing.

11078TM65

(48) Put the gear casing upside-down.

Remove a floating seal(86) and another
angular bearing(87) from the gear casing.

11078TM66

(49) Remove another floating seal(88) from

body casing(89).
Remove shaft(90) and bearing(91) from
the body casing by giving force as shown
with an arrow in the picture using a soft-
faced hammer and a proper jig.
Sometimes, bearing(91) may remain in
the body casing. In this case, remove the
bearing(91) as shown in the step 50.

11078TM67

8-84
(50) If necessary, remove a bearing(91) from
the body casing.
Remove an oil seal(92) from the body
casing.

11078TM68

(51) If necessary, remove a bearing(91) from

the shaft(90). If necessary, remove an
inner race(93) from the shaft(90).

This is the end of disassembling process.

11078TM69

8-85
4. ASSEMBLY
1) GENERAL PRECAUTIONS
(1) Reassemble in a work area that is clean and free from dust and grit.
(2) Handle parts with bare hands to keep them free of linty contaminats.
(3) Repair or replace the damaged parts.
Each parts must be free of burrs its corners.
(4) Do not reuse O-rings, oil seal and floating seal that were removed in disassembly.
Provide the new parts.
(5) Wash all parts throughly in a suitable solvent.
Dry throughly with compressed air.
Do not use the cloths.
(6) When reassembling oil motor components of motor, be sure to coat the sliding parts of the
motor and valve with fresh hydraulic oil. (NAS class 9 or above)
(7) Use a torque wrench to tighten bolts and plugs, to the torque specified as follows.

8-86
2) ASSEMBLING PROCEDURE
(1) Make sure that all the parts are complete-
ly clean and free of dirt and debris before
assembling.
Check the condition of all O-rings, back-
up rings, and oil seal used in the travel
motor. If any of them have any damage,
replace them with new ones.
Put the body casing on a clean sheet
spread on the flat base.

(2) Install oil seal to body casing.

Put bearing(91) and inner race(93) on
shaft(90).
Install shaft(90) into the body casing.

11078TM70

ö Before installing floating seals, make the

O-ring(=rubber) and seal ring(=metal)
clean and dry.
After installing the seals, put clean SAE30
engine oil or gear oil 80W-90 on the
contact surfaces of the metal seals.

11078TM71

(3) Place the body casing on wood blocks or

other proper jigs with the shaft side down.
To avoid damaging shaft, don't put the
body casing directly on a flat ground.

11078TM72

8-87
(4) Install floating seal(88) in the body casing,
using tool "Floating seal installer".
Then, put clean SAE30 engine oil or gear
oil 80W-90 on the contact surface(flat
surface) of the metal seal.

11078TM73

11078TM74

(5) Install an angular bearing(85) to the gear

casing.

11078TM75

(6) Put the gear casing upside-down as shown.

Install another angular bearing(87) to the
gear casing.
ö Before installing floating seals, make the
O-ring(=rubber) and seal ring(=metal)
clean and dry.
After the installation of the seals, put clean
SAE30 engine oil or gear oil 80W-90 on
the contact surfaces of the metal seals.
11078TM76

8-88
(7) Install another floating seal(86) in the gear
casing, using tooling "Floating seal
installer".
Then, put clean SAE30 engine oil or gear
oil 80W-90 on the contact surface(flat
surface) of the metal seal.
ö Be careful and don't scratch or damage
the floating seals before and during
assembling the two components.
11078TM77

(8) Hoist a gear casing(65) over the body

casing(89) as shown. Install the gear
casing on the body casing(89).

11078TM78

ö After installing the ring gear on the body

casing, there will be a gap between two
components. This is a normal phenome-
non caused by the floating seals, and the
gap will be eliminated by installing the ring
nut(84).

11078TM79

8-89
(9) Use the following procedure to make a
preload adjustment of bearings(85) and
(87) as follows :
a. Tighten the ring nut(84) strongly enough
until there is no gap among body
casing, two bearings, gear casing, and
ring nut.
b. Rotate gear casing(65) several turns.
c. Turn the ring nut(84) forward/backward
and adjust the tightening position of the 11078TM80

ring nut(84) until the pull-force of spring

scale to the tangent-line direction while
turning(as shown below) is 216~294N
(48.5~66.1lbf).
ö To apply a pin to the ring nut, a new
hole should be drilled at the opposite
position from the original position. lt is
because that the rotating position of ring
nut is not necessarily the same as the
original position when it is adjusted by
the procedure (9).

(10) Put a cover plate over the tap hole. Drill a

new hole between body casing and ring
nut as shown.
Drill hole spec :
ÂDrill hole diameter = ͚8.00~͚8.15mm
ÂDrill hole depth = 11.0~11.5mm

11078TM81

(11) Take away all the debris caused by

drilling. Install pin(83) in a newly drilled
hole between body casing(89) and ring
nut(84).

11078TM82

8-90
(12) Apply Thread Lock "THREE BOND
2403" to bolt(81). Install bolt(81) and
washer(82) to the body casing.
Ü4.9
Tighten the bolt to a torque of 68.6Ü
N¡⁄m(50.6Ü3.6lbf¡⁄ft).

11078TM83

(13) Position the travel motor as shown. Install

two steel balls(59), spring(61) and piston
assembly(60) in the body casing.

11078TM84

(14) Install cam(58) in the travel motor body.

By pushing the cam several times,
confirm that the cam action is smooth.

11078TM85

8-91
(15) Install plate(57), spring(56) and plate(54)
in cylinder barrel(51).
Use a press machine on plate(54), and
compress spring(56).
Install snap ring(55).

11078TM86

11078TM86

(16) Install three pins(53) in the cylinder barrel.

11078TM88

(17) Install retainer ball(52) to the cylinder

barrel. Put clean hydraulic oil on retainer
ball(52).

11078TM89

8-92
(18) Install piston assemblies(50) in their
original holes of retainer(49).
(19) Put clean hydraulic oil in the bores of the
cylinder barrel and piston assemblies(50).
Install the piston assemblies with the
retainer in their original bores in cylinder
barrel(51).

11078TM90

(20) Put clean hydraulic oil on the sliding

surfaces of the cam, nine piston shoe
surfaces sliding against cam, and on the
splined shaft of the motor.
Then, put the travel motor body on its side
and install cylinder barrel assembly(48) on
the shaft as a unit.

11078TM91

(21) Put clean hydraulic oil on two friction

plates(46) and two steel plates(47). Install
the plates in alternating order in the travel
motor body. Start with a friction plate and
end with a steel plate.

11078TM92

11078TM93

8-93
(22) Make sure brake piston(41) is completely
clean and free of dirt and debris. Check
the condition of back-up rings(44)(45) and
O-rings(42)(43). If any of them have any
damage, replace them with new ones.
Install back up rings(44)(45) and O-
rings(42)(43) on brake piston(41) as
shown. Put some grease on the back-up
rings and the O-rings.
Be careful about the installing position of
O-rings and back-up rings. 11078TM94

(23) Put clean hydraulic oil on the surface of

the body casing, which makes contact
with brake piston(41).
Install brake piston(41) in the travel motor
body using a soft-faced hammer.

11078TM95

(24) Install shim(40) in the brake piston.

Next, install two disk springs(39) in the
piston. The combination of the disk spring
in installing is a shown.
Install three O-rings(36)(37)(38) in the
travel motor body.

11078TM96

11078TM96

8-94
(25) Install bearing(34) and location pin(35) in
the brake valve.

11078TM98

(26) Put the motor cover upside-down on

wood blocks. Put some clean hydraulic oil
on spool assembly(12), and install it in the
valve body. Install washer(11) and then
spring(10) in the valve body.
Install O-ring(94) as shown.

11078TM99

11078TM100

(27) Install cover(32) and four bolts(31).

Tighten the bolts to a torque of 78.5Ü7.8
N¡⁄m(57.9Ü Ü5.8lbf¡⁄ft).
Be careful not to let the spool slip off the
motor cover. The spool assembly(12) is
not fixed yet.

11078TM101

8-95
(28) Put O-ring(30) on plug(25). Install plug
(25) to the brake valve. Tighten the
Ü 7.8N¡⁄m
plug(25) to a torque of 78.5Ü
(57.9Ü5.8lbf¡⁄ft).

11078TM104

(29) Install rod(28), spring guide(27) and

spring(26) to the brake valve.

11078TM102

11078TM103

(30) Put O-ring(29) on plug assembly(24).

Install plug assembly(24) to the brake
valve.
Tighten the plug assembly(24) to a torque
of 78.5ÜÜ7.8N¡⁄m(57.9Ü5.8lbf¡⁄ft).

11078TM106

8-96
(31) Install back-up ring(22) and O-rings(23)
on the relief valve as shown.

11078TM106

(32) Install relief valve(21) in the travel brake

valve body as shown. Tighten the relief
valve body to a torque of 196Ü19.6N¡⁄m
(145ÜÜ14.5lbf¡⁄ft).

11078TM107

(33) Install two balls(20) in the brake valve.

Put O-rings(19) on plugs(18). Install the
plugs to the travel brake valve. Tighten
the plugs to a torque of 19.6Ü Ü2.0N¡⁄m
(14.5Ü1.5lbf¡⁄ft).

11078TM108

11078TM109

8-97
(34) Put spool(17), spring(16), and stopper(15)
in the brake valve body. Put the O-ring on
plug(14). Install plug(14) to the travel
brake valve. Tighten the plug to a torque
of 49ÜÜ4.9N¡⁄m (36.1Ü3.6lbf¡⁄ft).
Put O-ring(13) on the brake valve body.

11078TM110

11078TM111

(35) Install plate(11) and then spring(10) in the

brake valve.
Then, install cover(9) with four bolts(8).
Tighten the bolts(8) to a torque of 78.5Ü Ü
7.8N¡⁄m(57.9Ü5.8lbf¡⁄ft).

11078TM112

11078TM113

8-98
(36) Put the brake valve upside-down.
Install valve plate(33) in its original
position on the brake valve.
Put some clean hydralulic oil on the valve
plate surface.

11078TM114

(37) Position brake valve(3) on the body

casing. Install ten bolts(2) that hold it.
Tighten the bolts to a torque of 191Ü14.7
N¡⁄m (141ÜÜ10.8lbf¡⁄ft).

11078TM115

(38) Instal back-up ring(6) and O-ring(7) on the

relief valve.

11078TM116

(39) Install relief valve(1) to travel brake valve

(3).
Tighten the relief valve body to a torque of
196Ü Ü19.6N¡⁄m(145Ü14.5lbf¡⁄ft).

11078TM117

8-99
(40) Place the travel motor with brake valve
upside down as shown. Apply torque to
shaft(90) to confirm the parking brake
torque. If the shaft starts rotating by a
torque of more than 239N¡⁄m (176lbf¡⁄ft),
it satisfies the spec. If the motor output
shaft rotates at a less torque than above,
shim(40) needs to be replaced with thicker
one in order to get a higher parking brake
torque.
There are some variations of thickeness 11078TM118

available for shim(40). The thicker the

shim is, the higher the parking brake
torque is. The thinner the shim is, the
lower the parking torque is.
Don't apply too thick shim to the travel
motor. It may cause damage to
braking parts because of malfunction in
brake-releasing action in traveling.

(41) Install four plates(80), four bushes(79),

four bearings(78) and four planetary
gears(77) as shown.

11078TM119

(42) Install snap ring(74) to sun gear(73).

11078TM120

8-100
(43) Put thrust plate(76) as shown. Apply
Thread Lock "THREE BOND 2403" to
bolts(75). Install four bolts(75).
Ü4.9
Tighten the bolts to a torque of 68.6Ü
N¡⁄m (50.6Ü3.6lbf¡⁄ft).
Then install sun gear(73).

11078TM121

(44) Install three inner races(72) on the carrier

shaft.

11078TM122

(45) Install carrier(71) as shown.

11078TM123

(46) Install three bearings(70) and three

planetary gears(69) on the carrier shaft
assembly.
Then install sun gear(68).

11078TM124

8-101
(47) Put thrust plate(67) on the carrier. Apply
Thread Lock "THREE BOND 2403" to
bolts(66). Install three bolts(66) that hold
plate(67) to the planetary carrier.
Tighten the bolts to a torque of 68.6ÜÜ4.9
N¡⁄m (50.6Ü3.7lbf¡⁄ft).

11078TM125

(48) Make sure the machined surface of gear

casing(65) and cover(64) is completely
clean, free of dirt and debris, and is dry.
Put a bead of Gasket Maker "THREE
BOND 1389" around the machined
surface of the gear casing as shown. Put
cover(64) in its original position on the
gear casing.

11078TM126

(49) Install sixteen bolts(62) and sixteen

washers(63) that hold the cover. Tighten
Ü2N¡⁄m(26Ü
the bolts to a torque of 35.3Ü
1.5lbf¡⁄ft).
Install lubricating oil from the drain port.
The capacity of the travel motor is
2.5liters(0.55U.K.gal; 0.66U.S.gal).
To prevent damage to the motor, the
case of the motor must be filled with
hydraulic oil before operation.
11078TM127

This is the end of assembling process

8-102
GROUP 7 RCV LEVER

1. REMOVAL AND INSTALL

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

pressure inside the hydraulic tank.

Escaping fluid under pressure can
1
penetrate the skin causing serious
injury.
2
(4) Loosen the socket bolt(2).
(5) Remove the cover of the console box.
3
(6) Disconnect pilot line hoses(3).
(7) Remove the pilot valve assembly(1).
ö When removing the pilot valve assembly,
21078DA06
check that all the hoses have been
disconnected.
2) INSTALL
(1) Carry out installation in the reverse order
to removal.
(2) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.

8-103
2. DISASSEMBLY AND ASSEMBLY
1) STRUCTURE

14072SF80

8-104
 1 Case 12 Rod seal 22 Handle connector
2 Plug 13 O-ring 23 Nut
3 Plug 14 Push rod 24 Insert
4 O-ring 15 Plate 25 Boot
5 Spool 16 Bushing 26 Handle
6 Shim 17 Joint assembly 27 Switch assembly
7 Spring 18 Swash plate 28 Screw
8 Spring seat 19 Adjusting nut 29 Switch assembly
9 Stopper 20 Lock nut 30 Switch cover
10 Spring 21 O-ring 40 Boot
11 Plug

8-105
2) TOOLS AND TIGHTENING TORQUE
(1) Tools

Tool name Remark

Allen wrench 6 B
22
Spanner
27
(+) Driver Length 150
(-) Driver Width 4~5
Torque wrench Capable of tightening with the specified torques

(2) Tightening torque

Torque
Part name Item Size
kgfÂm lbfÂft
Plug 2 PT 1/8 3.0 21.7
Joint 18 M14 3.5 25.3
Swash plate 19 M14 5.0Ü0.35 36.2Ü2.5
Adjusting nut 20 M14 5.0Ü0.35 36.2Ü2.5
Lock nut 21 M14 5.0Ü0.35 36.2Ü2.5
Screw 29 M 3 0.05 0.36

8-106
3) DISASSEMBLY
(1) Clean pilot valve with kerosene.
ö Put blind plugs into all ports
(2) Fix pilot valve in a vise with copper(or
lead) sheets.
(3) Remove end of boot(26) from case(1) and
take it out upwards.
14078DA62

ö For valve with switch, remove cord also

through hole of casing.

14078DA63

(4) Loosen lock nut(21) and adjusting nut(20)

with spanners on them respectively, and
take out handle section as one body.

14078DA64

(5) Remove the boot(40)

14078DA61

8-107
(6) Loosen adjusting nut(20) and plate(19)
with spanners on them respectively, and
remove them.

R140LC-7 ‫׆‬೴ RE04

R140LC-7 ‫׆‬೴ RE05

(7) Turn joint anticlockwise to loosen it,

utilizing jig(Special tool).
ö When return spring(10) is strong in force,
plate(16), plug(11) and push rod(14, 15)
will come up on loosening joint.
Pay attention to this.

R140LC-7 ‫׆‬೴ RE06

R140LC-7 ‫׆‬೴ RE07

8-108
(8) Remove plate(16).

R140LC-7 ‫׆‬೴ RE08

(9) When return spring(10) is weak in force,

plug(11) stays in casing because of
sliding resistance of O-ring.
ö 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.
ö During taking out, plug may jump up due
to return spring(10) force.
R140LC-7 ‫׆‬೴ RE09
Pay attention to this.

(10) Remove reducing valve subassembly

and return spring(10) out of casing.
ö Record relative position of reducing valve
subassembly and return springs.

R140LC-7 ‫׆‬೴ RE10

(11) Loosen hexagon socket head plug(2) with

hexagon socket screw key.

R140LC-7 ‫׆‬೴ RE11

8-109
(12) For disassembling reducing valve section,
stand it vertically with spool(5) bottom
placed on flat workbench. Push down
spring seat(8, 31) and remove two pieces
of semicircular stopper(9) with tip of small
minus screwdriver.
ö Pay attention not to damage spool
surface.
ö Record original position of spring seat(8,
R140LC-7 ‫׆‬೴ RE14
31).
ö Do not push down spring seat more than
6mm.

(13) Separate spool(5), spring seat(8, 31),

spring(7, 30) and shim(6) individually.
ö Until being assembled, they should be
handled as one subassembly group.

R140LC-7 ‫׆‬೴ RE15

(14) Take push rod(14, 15) out of plug(11).

R140LC-7 ‫׆‬೴ RE16

(15) Remove O-ring(13) and seal(12) from

plug(11).
Use small minus screwdriver or so on to
remove this seal.

R140LC-7 ‫׆‬೴ RE17

8-110
 R140LC-7 ‫׆‬೴ RE18

(16) Remove lock nut(21) and then boot(26).

R140LC-7 ‫׆‬೴ RE19

25038RL02(4)

8-111
(17) Cleaning of parts
Η Put all parts in rough cleaning vessel
filled with kerosene and clean them
(Rough cleaning).
ö 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.
ö If this kerosene is polluted, parts will be
damaged and functions of reassembled
valve will be degraded.
Therefore, control cleanliness of
kerosene fully.
Θ Put parts in final cleaning vessel filled
with kerosene, turning it slowly to clean
them even to their insides(Finish
cleaning).
ö 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.
ö If left as they after being cleaned, they will
be rusted and will not display their
functions fully after being reassembled.

8-112
4) ASSEMBLY
(1) Tighten hexagon socket head plug(2) to
the specified torque.
ö Tighten two bolts alternately and slowly.

R140LC-7 ‫׆‬೴ RE29

(2) Put shim(6), springs(7, 30) and spring

seat(8, 31) onto spool(5) in this order.

R140LC-7 ‫׆‬೴ RE30

(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.
ö 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.
R140LC-7 ‫׆‬೴ RE31

(4) Assemble spring(10) into casing.

Assemble reducing valve subassembly
into casing.
ö Assemble them to their original positions.

R140LC-7 ‫׆‬೴ RE32

8-113
(5) Assemble O-ring(13) onto plug(11).

R140LC-7 ‫׆‬೴ RE33

(6) Assemble seal(12) to plug(11).

ö Assemble seal in such lip direction as
shown below.

R140LC-7 ‫׆‬೴ RE34

(7) Assemble push rod(14, 15) to plug(11).

ö Apply working oil on push-rod surface.

R140LC-7 ‫׆‬೴ RE35

(8) Assemble plug subassembly to casing.

ö When return spring is weak in force,
subassembly stops due to resistance of
O-ring.

R140LC-7 ‫׆‬೴ RE36

8-114
(9) When return spring is strong in force,
assemble 4 sets at the same time, utilizing
plate(16), and tighten joint(18) temporarily.

R140LC-7 ‫׆‬೴ RE37

(10) Fit plate(16).

(11) Tighten joint(18) with the specified torque

to casing, utilizing jig.

R140LC-7 ‫׆‬೴ RE38

(12) Assemble plate(19) to joint(18).

ö Screw it to position that it contacts with 4
push rods evenly.
ö Do not screw it over.

R140LC-7 ‫׆‬೴ RE39

(13) Assemble adjusting nut(20), apply

spanner to width across flat of plate(19) to
fix it, and tighten adjusting nut to the
specified torque.
ö During tightening, do not change position
of disk.

R140LC-7 ‫׆‬೴ RE40

8-115
(14) Fit boot(40) to plate.

1408DA61

(15) Fit boot(26) and lock nut(21), and handle

subassembly is assembled completely.

25038RL02(4)

R140LC-7 ‫׆‬೴ RE48

(16) Pull out cord and tube through adjusting

nut hole provided in direction 60Áto 120Á
from casing hole.

1408DA66

8- 116
(17) Assemble bushing(17) to plate and pass
cord and tube through it.
ö Provide margin necessary to operation.

1408DA67

(18) Determine handle direction, tighten lock

nut(21) 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

8-117
GROUP 8 TURNING JOINT

1. REMOVAL AND INSTALL

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

pressure inside the hydraulic tank.

Escaping fluid under pressure can
penetrate the skin causing serious
injury.
ö When pipes and hoses are disconnected,
1
the oil inside the piping will flow out, so
catch it in oil pan.
(4) Disconnect all hoses.
(5) Sling the turning joint assembly (1) and
remove the mounting bolt(2). 11078TJ01

ÂWeight : 54kg(119lb)
ÂTightening torque : 12.3Ü 1.3kgfÂm
(88.2Ü 9.4lbfÂft)
(6) Remove the turning joint assembly.
ö When removing the turning joint, check
that all the hoses have been disconnected.

2) INSTALL
(1) Carry out installation in the reverse order
to removal.
ö Take care of turning joint direction.
ö Assemble hoses to their original positions. 1
ö Confirm the hydraulic oil level and check
the hydraulic oil leak or not.

11078TJ02

8-118
2. DISASSEMBLY AND ASSEMBLY
1) STRUCTURE

14 3
15
10 6
12 4
5
11

11
9
8

21078DA09

1 Hub 6 Shim 11 Wear ring

2 Shaft 7 Slipper seal 12 Retainer ring
3 Cover 8 O-ring 13 Plug
4 Spacer 9 O-ring 14 Hexagon bolt
5 Shim 10 O-ring 15 Spring washer

8-119
2) DISASSEMBLY 14
ö 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 hub(1) on a V-block and by using a

Secure with hand
wood buffer at the shaft end, hit out
Wooden block
shaft(2) to about 1/2 from the body with a
hammer.
ö Take care not to damage the shaft(2)
when remove hub(1) or rest it sideway.
ö Put a fitting mark on hub(1) and shaft(2). V block

Work bench
R140LC-7 ‫׆‬೴ 8-141(3)

(5) Remove six slipper seals(7) and O-ring(9), 11

two ring wear(11) from hub(1).
7

11
9

1
21078DA12

8-120
3) ASSEMBLY
ö Clean all parts.
ö As a general rule, replace oil seals and O-
ring.
ö 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 hub(1).
(2) Fit O-ring(8) to shaft(2). 7

11
9

1
21078DA12

(3) Set shaft(2) on block, tap hub(1) with a

plastic hammer to install. 2

21078DA13

(4) Fit shim(5), spacer(4) and retainer ring 6

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

21078DA11

8-121
(7) Install cover(3) to body(1) and tighten 14
bolts(14).
15
ÂTorque : 10~12.5kgfÂm(72.3~90.4lbfÂft)
3

21078DA10

8-122
GROUP 9 BOOM, ARM AND BUCKET CYLINDER

1. REMOVAL AND INSTALL

1) BUCKET CYLINDER
(1) Removal
ö Expand the arm and bucket fully, lower the
work equipment to the ground and stop
the engine.
ö Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping. 13031GE18

Loosen the breather slowly to release

the pressure inside the hydraulic tank.
ö Escaping fluid under pressure can
penetrate the skin causing serious injury.
Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust
from entering.
Η Set block between bucket cylinder and
arm.
1408DA80

Θ Remove bolt(2), nut(3) and pull out pin

(1).
ö Tie the rod with wire to prevent it from
coming out.

1408DA81

Ι Disconnect bucket cylinder hoses(4) and

put plugs(5) on cylinder pipe.

1408DA82

8-123
 Κ Sling bucket cylinder assembly(8) and
remove bolt(6) then pull out pin (5).
Λ Remove bucket cylinder assembly(8).
ÂWeight : 90kg(200lb)

1408DA83

(2) Install
Η 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.
ö Bleed the air from the bucket cylinder.
ö Confirm the hydraulic oil level and check
the hydraulic oil leak or not.

8-124
2) ARM CYLINDER
(1) Removal
ö Expand the arm and bucket fully, lower the
work equipment to the ground and stop
the engine.
ö Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
Loosen the breather slowly to release 13031GE18

the pressure inside the hydraulic tank.

ö Escaping fluid under pressure can
penetrate the skin causing serious injury.
Fit blind plugs in the hoses after Arm cylinder
disconnecting them, to prevent dirt or
dust from entering.
Η Set block between arm cylinder and Block
boom.

11078CY01

Θ Remove bolt(2) and pull out pin(1).

ö Tie the rod with wire to prevent it from
coming out.

1408DA85

Ι Disconnect arm cylinder hoses(3) and 4

put plugs on cylinder pipe.
3
Κ Disconnect greasing pipings(4).

11078CY02

8-125
 Λ Sling arm assembly(7) and remove bolt
(6) then pull out pin(5).
Μ Remove arm cylinder assembly(7).
ÂWeight : 140kg(310lb) 7

5
6

11078CY03

(2) Install
Η 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.
ö Bleed the air from the arm cylinder.
ö Confirm the hydraulic oil level and check
the hydraulic oil leak or not.

8-126
3) BOOM CYLINDER
(1) Removal
ö Expand the arm and bucket fully, lower the
work equipment to the ground and stop
the engine.
ö Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
Loosen the breather slowly to release 13031GE18

the pressure inside the hydraulic tank.

ö Escaping fluid under pressure can
penetrate the skin causing serious injury.
Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust
from entering.
Η Disconnect greasing hoses(1).
Θ Sling boom cylinder assembly.

1408DA88

Ι Remove bolt(4), stop plate(5) and pull out 4

pin(2). 5
2
ö Tie the rod with wire to prevent it from
coming out.

5
4

21078DA23

Κ Lower the boom cylinder assembly(6) on

a stand.

1408DA89

8-127
 Λ Disconnect boom cylinder hoses(7) and
put plugs on cylinder pipe.

1408DA90

Μ Remove bolt(9) and pull out pin(8).

Ν Remove boom cylinder assembly(6).
ÂWeight : 115kg(255lb)

1408DA91

(2) Install
Η 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.
ö Bleed the air from the boom cylinder.
ö Conformed the hydraulic oil level and
check the hydraulic oil leak or not.

8-128
2. DISASSEMBLY AND ASSEMBLY
1) STRUCTURE
(1) Bucket cylinder

9,10 6,7 8 21 4 3 11,12 5 30 28 11,12 1 2 13 15,16 14 17 18 19 20

Internal detail

26 27

22,24 23,24

25

11078CY05

1 Tube assembly 11 O-ring 21 Hexagon socket head bolt

2 Rod assembly 12 Back up ring 22 Pin bush
3 Gland 13 Cushion ring 23 Pin bush
4 DD2 bush 14 Piston 24 Dust seal
5 Snap ring 15 O-ring 25 Band assembly
6 Rod seal 16 Back up ring 26 Pipe assembly(R)
7 Back up ring 17 Piston seal 27 Pipe assembly(B)
8 Buffer ring 18 Wear ring 28 O-ring
9 Dust wiper 19 Dust ring 29 O-ring
10 Snap ring 20 Lock nut 30 Hexagon socket head bolt

8-129
(2) Arm cylinder

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

26 25 29,31 28 27

32,33,34,35

11078CY07

1 Tube assembly 13 Cushion ring 25 Pin bush

2 Rod assembly 14 Piston 26 Dust seal
3 Gland 15 O-ring 27 Band assembly
4 DD2 Bush 16 Back up ring 28 Pipe assembly(R)
5 Snap ring 17 Piston seal 29 O-ring
6 Rod seal 18 Wear ring 30 O-ring
7 Back up ring 19 Dust ring 31 Hexagon socket head bolt
8 Buffer ring 20 Cushion spear 32 Check valve
9 Dust wiper 21 Steel ball 33 Coil spring
10 Snap ring 22 Set screw 34 O-ring
11 O-ring 23 Lock nut 35 Plug
12 Back up ring 24 Hexagon socket head bolt

8-130
(3) Boom cylinder

9,10 6,7 8 21 4 3 11,12 5 27 29 11,13 1 2 13 15,16 14 17 18 19 20

25 26 24 27,29 22,23

11078CY06

1 Tube assembly 11 O-ring 21 Hexagon socket head bolt

2 Rod assembly 12 Back up ring 22 Pin bush
3 Gland 13 Cushion ring 23 Dust seal
4 DD2 bush 14 Piston 24 Band assembly
5 Snapring 15 O-ring 25 Pipe assembly(R, LH/RH)
6 Rod seal 16 Back up ring 26 Pipe assembly(L, LH/RH)
7 Back up ring 17 Piston seal 27 O-ring
8 Buffer ring 18 Wear ring 28 O-ring
9 Dust wiper 19 Dust ring 29 Hexagon head bolt
10 Snap ring 20 Lock nut

8-131
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tool name B Remark

16
Allen wrench
18 B

10
45
Spanner
50
55
(-) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques

(2) Tightening torque

Torque
Part name Item Size
kgfÂm lbfÂft
Bucket cylinder 21 M12 9.4Ü1 68.0Ü7.2
Gland mounting bolt Boom cylinder 21 M12 9.4Ü1 68.0Ü7.2
(Socket head bolt)
Arm cylinder 24 M14 15.0Ü2.0 109Ü14.5
Bucket cylinder 30 M10 5.4Ü0.5 39.1Ü3.6
Pipe mounting bolt
(Hexagon head bolt) Boom cylinder 29 M 8 2.7Ü0.3 19.6Ü1.8
Arm cylinder 31 M10 5.4Ü0.5 39.1Ü3.6
Bucket cylinder 20 M40 100Ü10.0 723Ü72.3
Lock nut Boom cylinder 20 M40 100Ü10.0 723Ü72.3
Arm cylinder 23 M50 100Ü10.0 723Ü72.3
Bucket cylinder 14 M45 150Ü15.0 1085Ü109
Piston Boom cylinder 15 M45 150Ü15.0 1085Ü109
Arm cylinder 14 M55 150Ü15.0 1085Ü109

8-132
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
ö Procedures are based on the bucket
cylinder.
Η Hold the clevis section of the tube in a
vise.
ö 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.

Θ 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.

1408DA110

Ι Loosen and remove socket bolts(21) of

Hexagon
the gland in sequence. socket wrench 21
ö 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
11078CY21

Κ Draw out cylinder head and rod assembly

together from tube assembly(1).
ö 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
out. However, when rod assembly(2)
has been drawn out to approximately
two thirds of its length, lift it in its center to
draw it completely.
1408DA113

8-133
 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.

Λ Place the removed rod assembly on a

wooden V-block that is set level.
ö Cover a V-block with soft rag.

1408DA116

(2) Remove piston and cylinder head

Η Remove lock nut(20). 13 15,16 14 20
ö Since lock nut(20) is tightened to a high
torque, use a hydraulic and power
wrench that utilizers a hydraulic cylinder,
to remove the lock nut(20).
Θ Remove piston assembly(14), back up
ring(16), and O-ring(15).

11078CY22

Ι Remove the cylinder head assembly

from rod assembly(2).
ö If it is too heavy to move, move it by
striking the flanged part of cylinder head
with a plastic hammer.
ö 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
1408DA115
(5,6,7,8,9,10) by the threads of rod
assembly(2).

8-134
(3) Disassemble the piston assembly
Η Remove wear ring(18). 19 18 17 18 19
Θ Remove dust ring(19) and piston seal
(17).
ö Exercise care in this operation not to
damage the grooves.

11078CY23

(4) Disassemble cylinder head assembly

Η Remove back up ring(11) and O-ring 9 10 7 6 8 4 12 11 5 12 11
(12).
Θ Remove snap ring(10), dust wiper(9).
Ι Remove back up ring(7), rod seal(6) and
buffer ring(8).
ö Exercise care in this operation not to
damage the grooves.
ö Do not remove seal and ring, if does not
11078CY24
damaged.

8-135
3) ASSEMBLY
(1) Assemble cylinder head assembly
ö Check for scratches or rough surfaces if
found smooth with an oil stone.
Η Coat the inner face of gland(3) with
hydraulic oil.

1408DA119

Θ Coat dust wiper(9) with grease and fit

dust wiper(9) to the bottom of the hole of
dust seal.
At this time, press a pad metal to the
metal ring of dust seal.
Ι Fit snap ring(10) to the stop face.

1408DA120

Κ Fit back up ring(7), rod seal(6) and buffer

ring(8) to corresponding grooves, in that
order.
ö Coat each packing with hydraulic oil Wrong Right
before fitting it.
ö Insert the backup ring until one side of it
is inserted into groove.

R140LC-7 ‫׆‬೴ 8-157(3)

ö Rod seal(6) has its own fitting direction.

Therefore, confirm it before fitting them.
ö Fitting rod seal(6) upside down may
damage its lip. Therefore check the
correct direction that is shown in fig.

1408DA121

8-136
Λ Fit back up ring(12) to gland(3).
ö Put the backup ring in the warm water of 12 11 12 11
30~50Á C.
Μ Fit O-ring(11) to gland(3).

11078CY25

(2) Assemble piston assembly

ö Check for scratches or rough surfaces.
If found smooth with an oil stone.
Η Coat the outer face of piston(14) with
hydraulic oil.

R140LC-7 ‫׆‬೴ 8-158(2)

Θ Fit piston seal(17) to piston.

ö Put the piston seal in the warm water of 17
60~100Á C for more than 5 minutes.
ö After assembling the piston seal, press
its outer diameter to fit in.

R140LC-7 ‫׆‬೴ 8-158(3)

Ι Fit wear ring(18) and dust ring(19) to

piston(14). 14 19 18 17 18 19

11078CY26

8-137
(3) Install piston and cylinder head
Η Fix the rod assembly to the work bench.
Θ Apply hydraulic oil to the outer surface of
rod assembly(2), the inner surface of
piston and cylinder head.
Ι Insert cylinder head assembly to rod
assembly.

1408DA124

Κ Insert cushion ring(13) to rod assembly.

ö Note that cushion ring(13) has a direction 13
in which it should be fitted.
Insert

R140LC-7 ‫׆‬೴ 8-159(2)

Λ Fit piston assembly to rod assembly.

Piston assembly
ÂTightening torque : 150Ü15kgfÂm
(1085Ü109lbfÂft)

R140LC-7 ‫׆‬೴ 8-159(3)

Μ Fit lock nut(23) to piston.

ÂTightening torque : 20

Item kgfÂm lbfÂft

Bucket 20 100Ü10 723Ü72.3

Boom 20 100Ü10 723Ü72.3
Arm 23 100Ü10 723Ü72.3

R140LC-7 ‫׆‬೴ 8-159(4)

8-138
(3) Overall assemble
Η Place a V-block on a rigid work bench.
Mount the tube assembly(1) on it and fix
the assembly by passing a bar through
the clevis pin hole to lock the assembly.
Θ Insert the rod assembly in to the tube
assembly, while lifting and moving the
rod assembly with a crane.
ö Be careful not to damage piston seal by
1408DA112
thread of tube assembly.
Ι Match the bolt holes in the cylinder head
flange to the tapped holes in the tube
assembly and tighten socket bolts to a
specified torque.
ö Refer to the table of tightening torque.

1408DA125

8-139
GROUP 10 UNDERCARRIAGE

1. TRACK LINK
1) REMOVAL
(1) Move track link until master pin is over Master pin
front idler in the position put wooden
block as shown.
(2) Loosen tension of the track link.
ö 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

R140LC-‫׆‬೴ 7 8-161(1)

(4) Move the machine slowly in reverse, and

lay out track link assembly (1).
ö Jack up the machine and put wooden
block under the machine.
ö Don't get close to the sprocket side as the
track shoe plate may fall down on your
feet.

1108DA100

2) INSTALL
(1) Carry out installation in the reverse order
to removal.
ö Adjust the tension of the track link. 90 ~ 110

Mark

11078TR01

8-140
2. CARRIER ROLLER Frame
1) REMOVAL
(1) Loosen tension of the track link. Grease
valve

R140LC-‫׆‬೴ 7 8-162(1)

(2) Jack up the track link height enough to

permit carrier roller removal.

Jack Carrier roller

R140LC-‫׆‬೴ 7 8-162(2)

(3) Loosen the lock nut (1). Carrier

1 roller
(4) Open bracket(2) with a screwdriver, push
out from inside, and remove carrier roller 2
assembly.
ÂWeight : 13kg(29lb)

R140LC-‫׆‬೴ 7 8-162(3)

2) INSTALL
(1) Carry out installation in the reverse order
to removal.

8-141
3. TRACK ROLLER Frame
1) REMOVAL
(1) Loosen tension of the track link. Grease
valve

R140LC-‫׆‬೴ 7 8-163(1)

(2) Using the work equipment, push up track

frame on side which is to be removed.
ö After jack up the machine, set a block
under the unit. 90 ~ 110

Mark

11078TR01

(3) Remove the mounting bolt(1) and draw

1 2
out the track roller(2).
ÂWeight : 24.6kg(54.2lb)

R140LC-‫׆‬೴ 7 8-163(3)

2) INSTALL
(1) Carry out installation in the reverse order
to removal.

8-142
4. IDLER AND RECOIL SPRING
1) REMOVAL
(1) Remove the track link.
For detail, see removal of track link.

R140LC-‫׆‬೴ 7 8-164(1)

(2) Sling the recoil spring(1) and pull out idler

and recoil spring assembly from track
frame, using a pry. 1
ÂWeight : 215kg(474lb)

R140LC-‫׆‬೴ 7 8-164(2)

(3) Remove the bolts(2), washers(3) and

separate ilder from recoil spring.

2, 3

R140LC-‫׆‬೴ 7 8-164(3)

2) INSTALL
(1) Carry out installation in the reverse order
to removal.
ö Make sure that the boss on the end face
of the recoil cylinder rod is in the hole of
the track frame.

R140LC-‫׆‬೴ 7 8-164(4)

8-143
3) DISASSEMBLY AND ASSEMBLY OF IDLER
(1) Structure

6 5
8
3
1 2
4

4
3

5
21078DA43

1 Shell 4 Bushing 7 Spring pin

2 Shaft 5 Bracket 8 Plug
3 Seal assembly 6 O-ring

8-144
(2) Disassembly Press
Η Remove plug and drain oil.
Θ Draw out the spring pin(7), using a press.

7 R140LC-‫׆‬೴ 7 8-166(1)

Ι Pull out the shaft(2) with a press.

Κ Remove seal(3) from idler(1) and bracket Press
(5).
Λ Remove O-ring(6) from shaft.

2
R140LC-‫׆‬೴ 7 8-166(2)

Μ Remove the bushing(4) from idler, using

a special tool.
ö Only remove bushing if replacement is
necessity.

4
R140LC-‫׆‬೴ 7 8-166(3)

8-145
(3) Assembly
ö Before assembly, clean the parts.
1 4 Press
ö Coat the sliding surfaces of all parts with
oil.
Η Cool up bushing(4) fully by some dry ice
and press it into shell(1).
Do not press it at the normal temperature,
or not knock in with a hammer even after
the cooling.
R140LC-‫׆‬೴ 7 8-167(1)

Θ Coat O-ring(6) with grease thinly, and

install it to shaft(2). 6
Ι Insert shaft(2) into bracket(5) and drive in
2
the spring pin(7).
5

R140LC-‫׆‬೴ 7 8-167(2)

Κ Install seal(3) to shell(1) and bracket(5).

3

R140LC-‫׆‬೴ 7 8-167(3)

Λ Install shaft(2) to shell(1). 2 1

R140LC-‫׆‬೴ 7 8-167(4)

8-146
Μ Install bracket(5) attached with seal(3).
5

R140LC-‫׆‬೴ 7 8-168(1)

Ν Knock in the spring pin(7) with a hammer.

5 7 1

R140LC-‫׆‬೴ 7 8-168(2)

Ξ Lay bracket(5) on its side.

5
Supply engine oil to the specified level,
and tighten plug.

R140LC-‫׆‬೴ 7 8-168(3)

8-147
4) DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING
(1) Structure

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

13
R210UCG1

1 Body 6 Lock plate 11 Dust seal

2 Tie bar 7 Bolt 12 Rod assembly
3 Spring 8 Spring washer 13 Grease valve
4 Bracket 9 Rod seal
5 Lock nut 10 Back up ring

8-148
(2) Disassembly
Η Apply pressure on spring(3) with a press.
ö The spring is under a large installed load.
This is dangerous, so be sure to set
properly.
ÂSpring set load : 8497kg(18733lb) 4
Θ Remove bolt(7), spring washer(8) and
7, 8
lock plate(6).
3
Ι Remove lock nut(5).
6
Take enough notice so that the press
5
which pushes down the spring, should
not be slipped out in its operation.
Κ Lighten the press load slowly and
remove bracket(4) and spring(3).

R210UCG2(1)

Λ Remove rod(12) from body(1).

1 12
Μ Remove grease valve(13) from rod(12).

13
R210UCG2(2)

Ν Remove rod seal(9), back up ring(10)

and dust seal(11). 1 9 10 11

R210UCG2(3)

8-149
(3) Assembly
Η Install dust seal(11), back up ring(10) and 1 9 10 11
rod seal(9) to body(1).
ö When installing dust seal(11) and rod
seal(9), take full care so as not to
damage the lip.

R210UCG2(3)

Θ Pour grease into body(1), then push in

1 12
rod(12) by hand.
After take grease out of grease valve
mounting hole, let air out.
ö If air letting is not sufficient, it may be
difficult to adjust the tension of crawler.
Ι Fit grease valve(13) to rod(12).
ÂTightening torque : 10Ü1kgÂm
(72.4Ü7.2lbÂft) 13
R210UCG2(4)

Κ Install spring(3) and bracket(4) to body

(1). Press
Λ Apply pressure to spring(3) with a press
and tighten lock nut(5).
ö Apply sealant before assembling.
ö During the operation, pay attention
4
specially to prevent the press from
slipping out.
3

R210UCG2(5)

8-150
Μ Lighten the press load and confirm the
set length of spring(3). Press
Ν After the setting of spring(3), install lock
plate(6), spring washer(8) and bolt(7).
7,8
6

5
3

405±1.5
11078UC01

8-151
GROUP 11 WORK EQUIPMENT

1. STRUCTURE

A
A

SECTION A SECTION B SECTION C

21078DA44

8-152
2. REMOVAL AND INSTALL
1) BUCKET ASSEMBLY
(1) Removal
Η Lower the work equipment completely to
A
ground with back of bucket facing down.
B

R140LC-‫׆‬೴ 7 8-174(1)

Θ Remove nut(1), bolt(2) and draw out the

2
pin(A).
A
1

R140LC-‫׆‬೴ 7 8-174(2)

Ι Remove nut(3), bolt(4) and draw out the

pin(B).
4

B
3

R140LC-‫׆‬೴ 7 8-174(2)

(2) Install
Η 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.
ö Adjust the bucket clearance.
For detail, see operation manual.
R140LC-‫׆‬೴ 7 8-174(4)

8-153
2) ARM ASSEMBLY

(1) Removal
ö Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrated the skin causing serious
injury.
Η Remove bucket assembly.
R140LC-‫׆‬೴ 7 8-175(1)
For details, see removal of bucket
assembly.
Θ Disconnect bucket cylinder hose(1).
Fit blind plugs(5) in the piping at the
chassis end securely to prevent oil
from spurting out when the engine is
started.
Ι Sling arm cylinder assembly, remove
spring, pin stopper and pull out pin.
ö Tie the rod with wire to prevent it from
coming out.
Κ For details, see removal of arm cylinder 1408DA82

assembly.
Place a wooden block under the cylinder
and bring the cylinder down to it.
Λ Remove bolt(2), plate(3) and pull out the
pin(4) then remove the arm assembly. Crane
ÂWeight : 950kg(2090lb)
ö When lifting the arm assembly, always lift
the center of gravity. 2, 3, 4

R140LC-‫׆‬೴ 7 8-175(3)

(2) Install
Η Carry out installation in the reverse order
to removal.
When lifting the arm assembly, always
lift the center of gravity.
ö Bleed the air from the cylinder.

8-154
3) BOOM ASSEMBLY
(1) Removal
Η Remove arm and bucket assembly.
For details, see removal of arm and
bucket assembly.
Θ Remove boom cylinder assembly from
boom.
For details, see removal of arm cylinder
assembly. R140LC-‫׆‬೴ 7 8-176(1)

Ι Disconnect head lamp wiring.

Κ Disconnect bucket cylinder hose(2) and
arm cylinder hose(1).
ö When the hose are disconnected, oil
may spurt out.
Λ Sling boom assembly(3).

1408DA101

Μ Remove bolt(4), plate(5) and pull out the

Crane
pin(6) then remove boom assembly.
ÂWeight :880kg(1940lb)
ö When lifting the boom assembly always
lift the center of gravity.

4, 5, 6
3

R140LC-‫׆‬೴ 7 8-176(3)

(2) Install
Η Carry out installation in the reverse order
to removal.
When lifting the arm assembly, always
lift the center of gravity.
ö Bleed the air from the cylinder.

21078DA46

8-155
 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.
ö Only metric fasteners can be used and
incorrect fasteners may result in machine
damage or malfunction.
ö Before installation, clean all the
components with a non-corrosive cleaner.
Bolts and threads must not be worn or 11079CM14

damaged.

9-1
GROUP 2 ENGINE SYSTEM

1. ENGINE AND ACCESSORIES MOUNTING

3
7

Muffler

4 6

Engine 4
7 3

4
2 1
Throttle lever 2 5

2
Fan

Accel
actuator

B
CA
TO
Air cleaner 11079CM01

ÂTightening torque

Item Size kgfÂm lbfÂft Item Size kgfÂm lbfÂft

1 M 6Ý1.0 1.1Ü0.2 7.95Ü1.45 5 M10Ý1.5 4.4 31.8
2 M 8Ý1.25 2.5Ü0.5 18.1Ü3.6 6 M16Ý2.0 55Ü3.5 398Ü25.3
3 M10Ý1.5 6.9Ü1.4 49.9Ü10.1 7 M20Ý2.5 30Ü3.5 217Ü25.3
4 M12Ý1.75 10Ü20 72.3Ü14.5 - - - -

9-2
2. COOLING SYSTEM AND FUEL TANK MOUNTING

Air conditioner
idle pulley
2
Water Air compressor 3 Cooler & radiator
separator
2
Hyd tank

Fuel tank

A
2

DISCHARGE
Receiver drier
LIQ
UID
-A
1

Condenser

5
VIEW A

3 Radiator
6
Oil cooler
Needle valve
Shroud

2
4

Fan guard

11079CM02

ÂTightening torque

Item Size kgfÂm lbfÂft Item Size kgfÂm lbfÂft

1 M 6Ý1.0 1.05Ü0.2 7.6Ü1.45 4 M12Ý1.75 12.8Ü3.0 92.6Ü21.7
2 M 8Ý1.25 2.5Ü0.5 18.1Ü3.6 5 M20Ý2.5 45Ü5.1 325Ü36.9
3 M10Ý1.5 6.9Ü1.4 49.9Ü10.1 6 - 2.3Ü0.6 16.6Ü4.3

9-3
 GROUP 3 ELECTRIC SYSTEM

1. ELECTRIC COMPONENTS MOUNTING 1

Fuel filler pump Work lamp

2
ON

OFF

EPPR VLV

START MOTOR

AIR HEATER CABLE

A/C COMP.

Travel alarm buzzer

3 3

2
Horn
Battery

1
1

Washer
tank
Battery relay
Fuse box

11079CM03

ÂTightening torque

Item Size kgfÂm lbfÂft Item Size kgfÂm lbfÂft

1 M 6Ý1.0 1.05Ü0.2 7.6Ü1.45 3 M10Ý1.5 6.9Ü1.4 49.9Ü10.1
2 M 8Ý1.25 2.5Ü0.5 18.1Ü3.6 4 M12Ý1.75 12.8Ü3.0 92.6Ü21.7

9-4
2. ELECTRIC COMPONENTS MOUNTING 2

Beacon lamp 3

Wiper motor

1 2 VIEW A

1 Prolix
Electric box resistor
CPU
Cluster controller
2 1

1 YR
G

1
2
Wiper motor cover

11079CM04

ÂTightening torque

Item Size kgfÂm lbfÂft Item Size kgfÂm lbfÂft

1 M 6Ý1.0 1.05Ü0.2 7.6Ü1.45 3 M10Ý1.5 6.9Ü1.4 49.9Ü10.1
2 M 8Ý1.25 2.5Ü0.5 18.1Ü3.6 - - - -

9-5
GROUP 4 HYDRAULIC SYSTEM

1. HYDRAULIC COMPONENTS MOUNTING 1

Air breather
2

4 4
4
A
4

Hydraulic tank A2
A1

Level gauge Main pump

Spin filter

Solenoid
5 valve

10 Main control valve

4
9
6
Swing motor
VIEW A
RCV-LH
7
Main pump
4 housing
1
7
RCV-RH
Terminal 8
1 Coupling

4 5

4 Cross
4
11079CM05

ÂTightening torque

Item Size kgfÂm lbfÂft Item Size kgfÂm lbfÂft

1 M 6Ý1.0 1.05Ü0.2 7.6Ü1.45 6 M12Ý1.75 12.2Ü1.3 88.2Ü9.4
2 M 6Ý1.0 1.44Ü0.3 10.4Ü2.2 7 M16Ý2.0 22.0Ü1.0 159Ü7.2
3 M 8Ý1.25 2.5Ü0.5 18.1Ü3.6 8 M16Ý2.0 22.1Ü2.4 160Ü17.4
4 M10Ý1.5 6.9Ü1.4 49.9Ü10.1 9 M16Ý2.0 29.6Ü3.2 214Ü23.1
5 M10Ý1.5 6.1Ü0.3 44.1Ü2.2 10 M20Ý2.5 45Ü5.1 325Ü36.9

9-6
2. HYDRAULIC COMPONENTS MOUNTING 2

Travel motor(RH)

2 5

2 Turning joint
RCV-pedal Travel motor(LH)
4

Boom safety lock system Arm safety lock system

3
Boom safety
lock valve
1 Arm safety
lock valve E

3
Arm cylinder
1

1
Boom cylinder

11079CM06

ÂTightening torque

Item Size kgfÂm lbfÂft Item Size kgfÂm lbfÂft

1 M 8 Ý1.25 4.05Ü0.8 29.3Ü5.8 4 M12Ý1.75 12.8Ü3.0 92.6Ü21.7
2 M10Ý1.5 6.9Ü1.4 49.9Ü10.1 5 M16Ý2.0 23Ü2.5 166.3Ü18.1
3 M10Ý1.5 8.27Ü1.7 59.8Ü12.3 - - - -

9-7
3. HYDRAULIC COMPONENTS MOUNTING 3

1
Solenoid valve

Check valve 5
2

A
1
P2
P3

A
2
1 P4

Cartridge
Coil
4

5
BOOM CYLINDER

2
2
2
3 2 2

ARM CYLINDER BUCKET CYLINDER

11079CM07

ÂTightening torque

Item Size kgfÂm lbfÂft Item Size kgfÂm lbfÂft

1 M 8Ý1.25 2.7Ü0.3 19.5Ü2.2 5 - 2.0 14.5
2 M10Ý1.5 3.2Ü0.3 23.1Ü2.2
3 M10Ý1.5 5.4Ü0.5 39.1Ü3.6
4 - 0.4 2.9

9-8
GROUP 5 UNDERCARRIAGE

ADJUST COMPONENT

Rod

1
7

Swing bearing

Idler 8
8
4

Idler
7

Carrier roller

9 Track chain
Cover
5
2

3
Adjust
component
Track roller
6
Travel motor Track guard

Sprocket 5
11079CM08

ÂTightening torque

Item Size kgfÂm lbfÂft Item Size kgfÂm lbfÂft

1 M 8 Ý1.25 3.43Ü0.7 24.8Ü5.1 6 M16Ý2.0 29.6Ü3.2 214Ü23.1
2 M10Ý1.5 6.9Ü1.4 49.9Ü10.1 7 M16Ý2.0 29.7Ü4.5 215Ü32.5
3 M12Ý1.75 12.8Ü3.0 92.6Ü21.7 8 M18Ý2.5 41.3Ü6.2 299Ü44.8
4 M16Ý1.5 31.3Ü4.7 226Ü34 9 5/8" 42Ü4.0 304Ü29
5 M16Ý2.0 29.7Ü4.5 215Ü32.5 - - - -

9-9
GROUP 6 STRUCTURE

1. 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

11079CM09

ÂTightening torque

Item Size kgfÂm lbfÂft Item Size kgfÂm lbfÂft

1 M 6Ý1.0 0.49Ü0.1 3.5Ü0.7 4 M10Ý1.5 6.9Ü1.4 49.9Ü10.1
2 M 8Ý1.25 2.5Ü0.5 18.1Ü3.6 5 M12Ý1.75 12.8Ü3.0 92.6Ü21.7
3 M10Ý1.5 4.7Ü0.9 34Ü6.5 6 M16Ý2.0 29.7Ü4.5 215Ü32.5

9-10
2. CAB INTERIOR MOUNTING

Seat
1
1
Storage
4 box cover
Aircon upper
cover

Console 1
box(RH) 5
Storage
Wiper motor box
cover
1 1 5
Defroster 5
hose cover Aircon lower
cover

1 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

14079CM10

ÂTightening torque

Item Size kgfÂm lbfÂft Item Size kgfÂm lbfÂft

1 M 6Ý1.0 0.49Ü0.1 3.5Ü0.7 5 M10Ý1.5 6.9Ü1.4 49.9Ü10.1
2 M 6Ý1.0 1.05Ü0.2 7.6Ü1.4 6 M10Ý1.5 8.27Ü1.7 59.8Ü12.3
3 M 8Ý1.25 3.43Ü0.7 24.8Ü5.1 7 M16Ý2.0 29.7Ü4.5 215Ü32.5
4 M 8Ý1.25 4.05Ü0.8 29.3Ü5.8 - - - -

9-11
3. COWLING MOUNTING

Counterweight
screen
Engine hood

3 4

3
Side cover-RH

3
Tank cover

4
3 1
3 3 Radiator
hood 3

3 3
Support-RH
HY
UN
DA
I

FU
LL

LO
W

MCV hood 2
Aircleaner hood
Support-LH

3
3

11079CM11

ÂTightening torque

Item Size kgfÂm lbfÂft Item Size kgfÂm lbfÂft

1 M 6Ý1.0 0.49Ü0.1 3.5Ü0.7 3 M12Ý1.75 12.8Ü3.0 92.6Ü21.7
2 M 8Ý1.25 2.5Ü0.5 18.1Ü3.6 4 M16Ý2.0 29.7Ü4.5 215Ü32.5

9-12
4. COUNTERWEIGHT AND COVERS MOUNTING

Handle pipe
Counterweight
Fuel tank

Tool box

Upper frame
Pump under cover
Hyd tank under cover Engine under cover
Radiator under cover

1
1
MCV under cover
1
1
Swing bearing grease
drain cover
Cab
under cover(C)
Cab under cover(B)

Cab under cover(A)

1

11079CM12

ÂTightening torque

Item Size kgfÂm lbfÂft Item Size kgfÂm lbfÂft

1 M10Ý1.5 6.9Ü1.4 49.9Ü10.1 3 M24Ý3.0 97.8Ü10 707Ü72.3
2 M12Ý1.75 12.8Ü3.0 92.6Ü21.7 - - - -

9-13
 GROUP 7 WORK EQUIPMENT

Arm cylinder
rod pin

1 Arm cylinder

1
2
Bucket cylinder
head pin
Pin stop
Bucket 1 2 2
cylinder
Arm pin Boom

Bucket cylinder Arm cylinder Boom pin

rod pin head pin Boom cylinder
head pin
Bucket 1
control link
2 Boom 2
3 Bucket cylinder
2
Side cutter(RH)

Bucket control
rod pin

Side cutter(LH)

11079CM13

ÂTightening torque

Item Size kgfÂm lbfÂft Item Size kgfÂm lbfÂft

1 M12Ý1.75 12.8Ü3.0 92.6Ü21.7 3 M20Ý2.5 57.9Ü8.7 419Ü62.9
2 M16Ý2.0 29.7Ü4.5 215Ü32.5 - - - -

9-14