CONTENTS

Open index screen

SECTION 1 GENERAL

Group 1 Safety Hints --------------------------------------------------------------------------------------------------------- 1-1

Group 2 Specifications (R160LC-9A) ------------------------------------------------------------------------------ 1-10
Group 3 Specifications (R180LC-9A) ------------------------------------------------------------------------------ 1-28

SECTION 2 STRUCTURE AND FUNCTION

Group 1 Pump Device ------------------------------------------------------------------------------------------------------- 2-1

Group 2 Main Control Valve ---------------------------------------------------------------------------------------------- 2-19
Group 3 Swing Device ------------------------------------------------------------------------------------------------------ 2-46
Group 4 Travel Device ------------------------------------------------------------------------------------------------------- 2-57
Group 5 RCV Lever ----------------------------------------------------------------------------------------------------------- 2-65
Group 6 RCV Pedal ----------------------------------------------------------------------------------------------------------- 2-72

SECTION 3 HYDRAULIC SYSTEM

Group 1 Hydraulic Circuit -------------------------------------------------------------------------------------------------- 3-1

Group 2 Main Circuit --------------------------------------------------------------------------------------------------------- 3-2
Group 3 Pilot Circuit ---------------------------------------------------------------------------------------------------------- 3-5
Group 4 Single Operation ------------------------------------------------------------------------------------------------- 3-13
Group 5 Combined Operation ------------------------------------------------------------------------------------------ 3-25

SECTION 4 ELECTRICAL SYSTEM

Group 1 Component Location ------------------------------------------------------------------------------------------ 4-1

Group 2 Electrical Circuit -------------------------------------------------------------------------------------------------- 4-3
Group 3 Electrical Component Specification ------------------------------------------------------------------ 4-21
Group 4 Connectors ---------------------------------------------------------------------------------------------------------- 4-29

SECTION 5 MECHATRONICS SYSTEM

Group 1 Outline ------------------------------------------------------------------------------------------------------------------ 5-1

Group 2 Mode selection System -------------------------------------------------------------------------------------- 5-3
Group 3 Automatic Deceleration System ------------------------------------------------------------------------ 5-6
Group 4 Power Boost System ------------------------------------------------------------------------------------------ 5-7
Group 5 Travel Speed Control System ---------------------------------------------------------------------------- 5-8
Group 6 Automatic Warming Up Function ---------------------------------------------------------------------- 5-9
Group 7 Engine Overheat Prevention Function -------------------------------------------------------------- 5-10
Group 8 Variable Power Control System ------------------------------------------------------------------------- 5-11
Group 9 Attachment Flow Control System --------------------------------------------------------------------- 5-12
Group 10 Anti-Restart System ------------------------------------------------------------------------------------------ 5-13
Group 11 Self-Diagnostic System ------------------------------------------------------------------------------------- 5-14
Group 12 Engine Control System ------------------------------------------------------------------------------------- 5-20
Group 13 EPPR Valve -------------------------------------------------------------------------------------------------------- 5-21
Group 14 Monitoring System --------------------------------------------------------------------------------------------- 5-26
Group 15 Fuel Warmer System ----------------------------------------------------------------------------------------- 5-49

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 --------------------------------------------------------------------------------------- 6-40

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 ------------------------------------------------------------------------------------------------------ 8-68
Group 7 RCV Lever ---------------------------------------------------------------------------------------------------------- 8-100
Group 8 Turning Joint ------------------------------------------------------------------------------------------------------- 8-114
Group 9 Boom, Arm and Bucket Cylinder ---------------------------------------------------------------------- 8-119
Group 10 Undercarriage ---------------------------------------------------------------------------------------------------- 8-137
Group 11 Work Equipment ------------------------------------------------------------------------------------------------ 8-149
SECTION 9 COMPONENT MOUNTING TORQUE

Group 1 Introduction guide ----------------------------------------------------------------------------------------------- 9-1

Group 2 Engine system ---------------------------------------------------------------------------------------------------- 9-2
Group 3 Electric system ---------------------------------------------------------------------------------------------------- 9-4
Group 4 Hydraulic system ------------------------------------------------------------------------------------------------ 9-6
Group 5 Undercarriage ----------------------------------------------------------------------------------------------------- 9-9
Group 6 Structure -------------------------------------------------------------------------------------------------------------- 9-10
Group 7 Work equipment -------------------------------------------------------------------------------------------------- 9-14
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
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
mark(①②③…)
Any additions, amendments or other changes will When a manual is revised, an edition mark is
be sent to HYUNDAI distributors. recorded on the bottom outside corner of the
Get the most up-to-date information before you pages.
start any work.
Revisions
Filing method Revised pages are shown at the list of revised
1. See the page number on the bottom of the pages on the between the contents page and
page. section 1 page.
File the pages in correct order.
2. Following examples shows how to read the Symbols
page number. So that the shop manual can be of ample
Example 1 practical use, important places for safety and
2-3 quality are marked with the following symbols.
Item number(2. Structure and
Function)
Consecutive page number for Symbol Item Remarks
each item.
Special safety precautions are
3. Additional pages : Additional pages are necessary when performing the
indicated by a hyphen(-) and number after the work.
Safety
page number. File as in the example. Extra special safety precautions
10 - 4 are necessary when performing
10 - 4 - 1 the work because it is under
Added pages internal pressure.
10 - 4 - 2
10 - 5 Special technical precautions or

※ Caution
other precautions for preserving
standards are necessary when
performing the work.

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

Example
1. Method of using the Conversion Table to convert from millimeters to inches
Convert 55mm into inches.
(1) Locate the number 50in the vertical column at the left side, take this as ⓐ, then draw a
horizontal line from ⓐ.
(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 ⓒ. This point ⓒ 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
ⓒ
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
ⓐ
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

0-3
Millimeters to inches 1mm = 0.03937in

0 1 2 3 4 5 6 7 8 9

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

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

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

Kilogram to Pound 1kg = 2.2046lb

0 1 2 3 4 5 6 7 8 9

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

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

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

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

0 1 2 3 4 5 6 7 8 9

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

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

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

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

0 1 2 3 4 5 6 7 8 9

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

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

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

0-5
kgf·m to lbf
kgf lbf·ftft 1kgf·m = 7.233lbf·ft

0 1 2 3 4 5 6 7 8 9

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

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

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

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

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

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

0 1 2 3 4 5 6 7 8 9

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

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

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

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

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

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

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

˚C ˚F ˚C ˚F ˚C ˚F ˚C ˚F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

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

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

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

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

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

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

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

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

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

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

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

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

0-8
SECTION 1 GENERAL

Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1

Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10
SECTION 1 GENERAL
GROUP 1 SAFETY

FOLLOW SAFE PROCEDURE

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

WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment
appropriate to the job.

13031GE01

WARN OTHERS OF SERVICE WORK

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

13031GE02

USE HANDHOLDS AND STEPS

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

Be careful of slippery conditions on platforms,

steps, and handrails when leaving the machine.

1-1
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors,
ambulance ser vice, hospital, and fire
department near your telephone.

13031GE04

PROTECT AGAINST FLYING DEBRIS

Guard against injury from flying pieces of metal
or debris; Wear goggles or safety glasses.

13031GE05

PROTECT AGAINST NOISE

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

13031GE06

AVOID POWER LINES

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

13031GE07

1-2
KEEP RIDERS OFF EXCAVATOR
Only allow the operator on the excavator. Keep
riders off.
Riders on excavator are subject to injury such
as being struck by foreign objects and being
thrown off the excavator. Riders also obstruct
the operator's view resulting in the excavator
being operated in an unsafe manner.
13031GE08

MOVE AND OPERATE MACHINE SAFELY

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

OPERATE ONLY FORM OPERATOR'S SEAT

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

13031GE26

PARK MACHINE SAFELY

Before working on the machine:
·Park machine on a level surface.
·Lower bucket to the ground.
·Turn auto idle switch off.
·Run engine at 1/2 speed without load for 2 minutes.
·Turn key switch to OFF to stop engine. Remove key
from switch.
·Move pilot control shutoff lever to locked position.
·Allow engine to cool.

1-3
SUPPORT MACHINE PROPERLY
Always lower the attachment or implement to
the ground before you work on the machine. If
you must wor k on a lifted machine or
attachment, securely support the machine or
attachment.
Do not support the machine on cinder blocks,
hollow tiles, or props that may crumble under
13031GE10
continuous load.
Do not work under a machine that is supported
solely by a jack. Follow recommended
procedures in this manual.

SERVICE COOLING SYSTEM SAFELY

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

13031GE11

HANDLE FLUIDS SAFELY-AVOID FIRES

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

13031GE12

Store flammable fluids away from fire hazards.

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

13031GE13

1-4
BEWARE OF EXHAUST FUMES
Prevent asphyxiation. Engine exhaust fumes
can cause sickness or death.
If you must operate in a building, be positive
there is adequate ventilation. Either use an
exhaust pipe extension to remove the exhaust
fumes or open doors and windows to bring
enough outside air into the area.
REMOVE PAINT BEFORE WELDING OR
HEATING
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint
is heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding or heating:
· If you sand or grind paint, avoid breathing the 13031GE14

dust.
Wear an approved respirator.
·If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area.
Allow fumes to disperse at least 15 minutes
before welding or heating.

ILLUMINATE WORK AREA SAFELY

Illuminate your work area adequately but safely.
Use a portable safety light for working inside or
under the machine. Make sure the bulb is
enclosed by a wire cage. The hot filament of
an accidentally broken bulb can ignite spilled
fuel or oil.

13031GE15

1-5
SERVICE MACHINE SAFELY
Tie long hair behind your head. Do not wear a
necktie, scarf, loose clothing or necklace when
you work near machine tools or moving parts.
If these items were to get caught, severe injury
could result.
Remove rings and other jewelry to prevent
electrical shorts and entanglement in moving
13031GE16
parts.

STAY CLEAR OF MOVING PARTS

Entanglements in moving parts can cause
serious injury.
To prevent accidents, use care when working
around rotating parts.

13031GE17

AVOID HIGH PRESSURE FLUIDS

Escaping fluid under pressure can penetrate the
skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure 13031GE18
fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result.

13031GE19

1-6
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
Flammable spray can be generated by heating
near pressurized fluid lines, resulting in severe
burns to yourself and bystanders. Do not heat
by welding, soldering, or using a torch near
pressurized fluid lines or other flammable
materials.
13031GE20
Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area.
Install fire resisting guards to protect hoses or
other materials.

PREVENT BATTERY EXPLOSIONS

Keep sparks, lighted matches, and flame away
from the top of battery. Battery gas can
explode.
Never check battery charge by placing a metal
object across the posts. Use a volt-meter or
hydrometer.
Do not charge a frozen battery; It may explode.
Warm battery to 16。C (60。F ). 13031GE21

1-7
PREVENT ACID BURNS
Sulfuric acid in battery electrolyte is poisonous.
It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte
is added.
4. Avoiding spilling of dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 10-15
minutes. Get medical attention immediate-
ly. 13031GE22

If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs,
or vegetable oil.
3. Get medical attention immediately.

USE TOOLS PROPERLY

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

Use only recommended replacement parts.

(See Parts catalogue.)

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

REPLACE SAFETY SIGNS

Replace missing or damaged safety signs.
See the machine operator's manual for correct
safety sign placement.

13031GE25

LIVE WITH SAFETY

Before returning machine to customer, make
sure machine is functioning properly, especially
the safety systems. Install all guards and
shields.

1-9
GROUP 2 SPECIFICATIONS (R160LC-9A)

1. MAJOR COMPONENT

Tool box Fuel tank Hydraulic tank Main pump

After
treatment
device

Engine

Radiator
Oil cooler

Tooth Bucket Turning joint Swing motor Main control valve

Arm Arm cylinder Boom Boom cylinder Cab Muffler Counterweight

Swing bearing

Bucket cylinder Control link Idler Track Travel motor

Side cutter Control rod Carrier roller Track roller Sprocket

1609A2SP01

1-10
2. SPECIFICATIONS

1) R160LC-9A
·5.1
5.1 m (16' 9") BOOM and 2.6 m (8' 6") ARM
I(I') D

E
C

G
F
Bucket

H
J M
K N
A B(L)

16092SP02

Description Unit Specification

Operating weight kg (lb) 17800 (39240)
Bucket capacity (SAE heaped), standard m3 (yd3) 0.70 (0.92)
Overall length A 8650 (28' 5")
Overall width, with 600 mm shoe B 2590 ( 8' 6")
Overall height C 2990 ( 9' 10")
Superstructure width D 2475 ( 8' 1")
Overall height of cab E 2980 ( 9' 9")
Ground clearance of counterweight F 1055 ( 3' 6")
Engine cover height G 2465 ( 8' 1")
Minimum ground clearance H mm (ft-in) 460 ( 1' 6")
Rear-end distance I 2480 ( 8' 2")
Rear-end swing radius I' 2530 ( 8' 4")
Distance between tumblers J 3170 (10' 5")
Undercarriage length K 3960 (13' 0")
Undercarriage width L 2590 ( 8' 6")
Track gauge M 1990 ( 6' 6")
Track shoe width, standard N 600 (24")
Travel speed (low/high) km/hr (mph) 3.2/5.5 (2.0/3.4)
Swing speed rpm 11.3
Gradeability Degree (%) 35 (70)
Ground pressure (600 mm shoe) kgf/cm2(psi) 0.43 (6.11)
Max traction force kg (lb) 17000 (37500)

1-11
2) R160LC-9A
· 5.1 m (16' 9") H
HYDRAULIC
YDRAULIC ADJUSTABLE BOOM AND 2.6 m (8' 6") ARM

I(I') D
C

E
G
F

H
J M
K N
A B(L)

16092SP03

Description Unit Specification

Operating weight kg (lb) 18290 (40320)
Bucket capacity (SAE heaped), standard m3 (yd3) 0.70 (0.92)
Overall length A 8610 ( 28' 3")
Overall width, with 600 mm shoe B 2590 ( 8' 6")
Overall height C 3060 ( 10' 0")
Superstructure width D 2475 ( 8' 1")
Overall height of cab E 2980 ( 9' 9")
Ground clearance of counterweight F 1055 ( 3' 6")
Engine cover height G 2465 ( 8' 1")
Minimum ground clearance H mm (ft-in) 460 ( 1' 6")
Rear-end distance I 2480 ( 10' 5")
Rear-end swing radius I' 2530 ( 8' 4")
Distance between tumblers J 3170 (10' 5")
Undercarriage length K 3960 (13' 0")
Undercarriage width L 2590 ( 8' 6")
Track gauge M 1990 ( 6' 6")
Track shoe width, standard N 600 (24")
Travel speed (low/high) km/hr (mph) 3.2/5.5 (2.0/3.4)
Swing speed rpm 11.3
Gradeability Degree (%) 35 (70)
Ground pressure (600 mm shoe) kgf/cm2(psi) 0.44 (6.26)
Max traction force kg (lb) 17000 (37500)

1-12
3) R160LCD-9A
·5.1
5.1 m (16' 9") BOOM and 2.6 m (8' 6") ARM
I(I') D

E
C

G
F
Bucket

Q O
P

H
J M
K N
A B(L)

16092SP04

Description Unit Specification

Operating weight kg (lb) 18800 (41450)
Bucket capacity (SAE heaped), standard m3 (yd3) 0.70 (0.92)
Overall length A 9100 (29' 10")
Overall width, with 600 mm shoe B 2590 ( 8' 6")
Overall height C 2990 ( 9'10")
Superstructure width D 2475 ( 8' 1")
Overall height of cab E 2980 ( 9' 9")
Ground clearance of counterweight F 1055 ( 3' 6")
Engine cover height G 2465 ( 8' 1")
Minimum ground clearance H 460 ( 1' 6")
Rear-end distance I 2480 ( 8' 2")
mm (ft-in)
Rear-end swing radius I' 2530 ( 8' 4")
Distance between tumblers J 3170 (10' 5")
Undercarriage length K 3960 (13' 0")
Undercarriage width L 2590 ( 8' 6")
Track gauge M 1990 ( 6' 6")
Track shoe width, standard N 600 (24")
Height of blade O 640 (2' 1")
Ground clearance of blade up P 615 (2' 0")
Depth of blade down Q 675 (2' 3")
Travel speed (low/high) km/hr (mph) 3.2/5.5 (2.0/3.4)
Swing speed rpm 11.3
Gradeability Degree (%) 35 (70)
Ground pressure (600 mm shoe) kgf/cm2(psi) 0.46 (6.54)
Max traction force kg (lb) 17000 (37500)

1-13
3. WORKING RANGE
1) 5.1 m (16' 9") MONO BOOM
A
A'
F

D
E
C
B'
B

8ft
16092SP05

Description 2.2 m (7' 3") Arm 2.6 m (8' 6") Arm 3.1 m (10' 2") Arm
Max digging reach A 8690 mm (28' 6") 9020 mm (29' 7") 9450 mm (31' 0")
Max digging reach on ground A' 8530 mm (27'12") 8860 mm (29' 1") 9300 mm (30' 6")
Max digging depth B 5660 mm (18' 7") 6060 mm (19'11") 6560 mm (21' 6")
Max digging depth (8ft level) B' 5430 mm (17'10") 5850 mm (19' 2") 6370 mm (20'11")
Max vertical wall digging depth C 5120 mm (16'10") 5380 mm (17' 8") 5710 mm (18' 9")
Max digging height D 8750 mm (28' 8") 8840 mm (29' 0") 8980 mm (29' 6")
Max dumping height E 6110 mm (20' 1") 6220 mm (20' 5") 6390 mm (21' 0")
Min swing radius F 3180 mm (10' 5") 3170 mm (10' 5") 3170 mm (10' 5")
107.9 [117.2] kN 107.9 [117.2] kN 107.9 [117.2] kN
SAE 11000 [11940] kgf 11000 [11940] kgf 11000 [11940] kgf
24250 [26330] lbf 24250 [26330] lbf 24250 [26330] lbf
Bucket digging force
123.6 [134.2] kN 123.6 [134.2] kN 123.6 [134.2] kN
ISO 12600 [13680] kgf 12600 [13680] kgf 12600 [13680] kgf
27780 [30160] lbf 27780 [30160] lbf 27780 [30160] lbf
87.2 [94.7] kN 77.3 [83.9] kN 69.0 [74.9] kN
SAE 8890 [9650] kgf 7880 [8560] kgf 7030 [7630] kgf
19600 [21280] lbf 17370 [18860] lbf 15500 [16830] lbf
Arm crowd force
91.0 [98.8] kN 80.3 [87.2] kN 71.4 [77.5] kN
ISO 9280 [10080] kgf 8190 [8890] kgf 7280 [7900] kgf
20460 [22210] lbf 18060 [19600] lbf 16050 [17430] lbf
[ ] : Power boost

1-14
2) 5.1 m (16' 9") H
HYDRAULIC
YDRAULIC ADJUSTABLE BOOM
A
A'
F

D
E
C
B'
B

8ft
16092SP06

Description 2.2 m (7' 3") Arm 2.6 m (8' 6") Arm

Max digging reach A 8760 mm (28' 9") 9110 mm (29'11")
Max digging reach on ground A' 8590 mm (28' 2") 8950 mm (29' 4")
Max digging depth B 5430 mm (17' 10") 5830 mm (19' 2")
Max digging depth (8ft level) B' 5330 mm (17' 6") 5730 mm (18'10")
Max vertical wall digging depth C 4630 mm (15' 2") 4980 mm (16' 4")
Max digging height D 9420 mm (30' 11") 9610 mm (31' 6")
Max dumping height E 6710 mm (22' 0") 6910 mm (22' 8")
Min swing radius F 3100 mm (10' 2") 2970 mm ( 9' 9")
107.9 [117.2] kN 107.9 [117.2] kN
SAE 11000 [11940] kgf 11000 [11940] kgf
24250 [26330] lbf 24250 [26330] lbf
Bucket digging force
123.6 [134.2] kN 123.6 [134.2] kN
ISO 12600 [13680] kgf 12600 [13680] kgf
27780 [30160] lbf 27780 [30160] lbf
87.2 [94.7] kN 77.3 [83.9] kN
SAE 8890 [9650] kgf 7880 [8560] kgf
19600 [21280] lbf 17370 [18860] lbf
Arm crowd force
91.0 [98.8] kN 80.3 [87.2] kN
ISO 9280 [10080] kgf 8190 [8890] kgf
20460 [22210] lbf 18060 [19600] lbf
[ ] : Power boost

1-15
4. WEIGHT
R160LC-9A R160LCD-9A
Item
kg lb kg lb
Upper structure assembly 7880 17370 ←
Main frame weld assembly 1470 3240 ←
Engine assembly 510 1120 ←
Fan clutch assembly 45 100 ←
Main pump assembly 100 220 ←
Main control valve assembly 140 310 ←
Swing motor assembly 250 550 ←
Hydraulic oil tank assembly 165 360 ←
Fuel tank assembly 130 290 ←
Counterweight 2900 6390 ←
Cab assembly 500 1100 ←
Lower chassis assembly 6900 15210 7900 17420
Track frame weld assembly 2290 5050 2270 5000
Swing bearing 260 570 ←
Travel motor assembly 300 660 ←
Turning joint 60 130 ←
Track recoil spring 140 310 ←
Idler 160 350 ←
Carrier roller 20 45 ←
Track roller 40 90 ←
Track-chain assembly (600 mm standard triple grouser shoe) 1180 2600 ←
Front attachment assembly (5.1 m boom, 2.6 m arm,
3020 6660 ←
0.7 m3 SAE heaped bucket)
5.1 m boom assembly 1040 2290 ←
2.6 m arm assembly 540 1190 ←
0.7 m3 SAE heaped bucket 540 1190 ←
Boom cylinder assembly 155 340 ←
Arm cylinder assembly 180 400 ←
Bucket cylinder assembly 125 280 ←
Bucket control link assembly 120 265 ←
Dozer blade assembly - - 655 1445
Dozer blade cylinder assembly - - 66 146

1-16
5. LIFTING CAPACITIES
1) R160LC-9A
(1) 5.1 m (16' 9") boom, 2.6 m (8' 6") arm equipped with 0.70 m3 (SAE heaped) bucket and 600 mm
(24") triple grouser shoe and 2900 kg (6390 Ib) counterweight.

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

Load radius At max. reach

Load
1.5 m (5.0 ft) 3.0 m (10.0 ft) 4.5 m (15.0 ft) 6.0 m (20.0 ft) 7.5 m (25.0 ft) Capacity Reach
point
height m (ft)
7.5 m kg *3410 3190 6.11
(25.0 ft) lb *7520 7030 (20.0)
6.0 m kg *3040 *3040 *3380 2240 7.37
(20.0 ft) lb *6700 *6700 *7450 4940 (24.2)
4.5 m kg *3790 3150 3000 1820 8.11
(15.0 ft) lb *8360 6940 6610 4010 (26.6)
3.0 m kg *7930 *7930 *5330 4770 *4320 2990 *2830 2020 2730 1630 8.48
(10.0 ft) lb *17480 *17480 *11750 10520 *9520 6590 *6240 4450 6020 3590 (27.8)
1.5 m kg *8090 8060 *6680 4380 4670 2820 3250 1940 2650 1560 8.53
(5.0 ft) lb *17840 17770 *14730 9660 10300 6220 7170 4280 5840 3440 (28.0)
Ground kg *7880 7700 7150 4130 4520 2680 3190 1880 2750 1620 8.28
Line lb *17370 16980 15760 9110 9960 5910 7030 4140 6060 3570 (27.2)
-1.5 m kg *6690 *6690 *10670 7660 7030 4020 4440 2610 3090 1830 7.69
(-5.0 ft) lb *14750 *14750 *23520 16890 15500 8860 9790 5750 6810 4030 (25.2)
-3.0 m kg *9970 *9970 *10310 7780 *6990 4050 4470 2640 *3770 2350 6.64
(-10.0 ft) lb *21980 *21980 *22730 17150 *15410 8930 9850 5820 *8310 5180 (21.8)
-4.5 m kg *7500 *7500 *4980 4230
(-15.0 ft) lb *16530 *16530 *10980 9330
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.

1-17
(2) 5.1 m (16' 9") hydraulic adjustable boom, 2.6 m (8' 6") arm equipped with 0.70 m3 (SAE heaped)
bucket and 600 mm (24") triple grouser shoe and 2900 kg (6390 Ib) counterweight.
Load radius At max. reach
Load
1.5 m (5.0 ft) 3.0 m (10.0 ft) 4.5 m (15.0 ft) 6.0 m (20.0 ft) 7.5 m (25.0 ft) Capacity Reach
point
height m (ft)
6.0 m kg *3450 2160 7.48
(20.0 ft) lb *7610 4760 (24.5)
4.5 m kg 2950 1760 8.20
(15.0 ft) lb 6500 3880 (26.9)
3.0 m kg *4350 2980 *3250 2000 2680 1570 8.57
(10.0 ft) lb *9590 6570 *7170 4410 5910 3460 (28.1)
1.5 m kg *6980 *6980 *6660 4350 4690 2790 3260 1920 2610 1510 8.62
(5.0 ft) lb *15390 *15390 *14680 9590 10340 6150 7190 4230 5750 3330 (28.3)
Ground kg *7040 *7040 7160 4080 4530 2650 3190 1850 2710 1570 8.37
Line lb *15520 *15520 15790 8990 9990 5840 7030 4080 5970 3460 (27.5)
-1.5 m kg *6030 *6030 *9960 7580 7040 3970 4450 2580 3050 1780 7.78
(-5.0 ft) lb *13290 *13290 *21960 16710 15520 8750 9810 5690 6720 3920 (25.5)
-3.0 m kg *9490 *9490 *9860 7730 *6740 4010 4490 2610 *3350 2290 6.76
(-10.0 ft) lb *20920 *20920 *21740 17040 *14860 8840 9900 5750 *7390 5050 (22.2)
-4.5 m kg *6840 *6840 *4560 4220
(-15.0 ft) lb *15080 *15080 *10050 9300

1-18
2) R160LCD-9A
(1) 5.1 m (16' 9") boom, 2.6 m (8' 6") arm equipped with 0.7 m3 (SAE heaped) bucket and 600 mm
(24") triple grouser shoe and 2900 kg (6390 Ib) counterweight.

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

Load radius At max. reach

Load
1.5 m (5.0 ft) 3.0 m (10.0 ft) 4.5 m (15.0 ft) 6.0 m (20.0 ft) 7.5 m (25.0 ft) Capacity Reach
point
height m (ft)
7.5 m kg *3410 3350 6.11
(25.0 ft) lb *7520 7390 (20.0)
6.0 m kg *3040 *3040 *3380 2370 7.37
(20.0 ft) lb *6700 *6700 *7450 5220 (24.2)
4.5 m kg *3790 3310 3340 1940 8.11
(15.0 ft) lb *8360 7300 7360 4280 (26.6)
3.0 m kg *7930 *7930 *5330 5000 *4320 3160 *2830 2140 3040 1730 8.48
(10.0 ft) lb *17480 *17480 *11750 11020 *9520 6970 *6240 4720 6700 3810 (27.8)
1.5 m kg *8090 *8090 *6680 4620 *4950 2980 3620 2070 2960 1670 8.53
(5.0 ft) lb *17840 *17840 *14730 10190 *10910 6570 7980 4560 6530 3680 (28.0)
Ground kg *7880 *7880 *7520 4360 5010 2840 *3490 2010 3080 1730 8.28
Line lb *17370 *17370 *16580 9610 11050 6260 *7690 4430 6790 3810 (27.2)
-1.5 m kg *6690 *6690 *10670 8080 *7650 4260 4930 2780 3450 1950 7.69
(-5.0 ft) lb *14750 *14750 *23520 17810 *16870 9390 10870 6130 7610 4300 (25.2)
-3.0 m kg *9970 *9970 *10310 8200 *6990 4280 *4900 2800 *3770 2500 6.64
(-10.0 ft) lb *21980 *21980 *22730 18080 *15410 9440 *10800 6170 *8310 5510 (21.8)
-4.5 m kg *7500 *7500 *4980 4460
(-15.0 ft) lb *16530 *16530 *10980 9830
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.

1-19
(2) 5.1 m (16' 9") hydraulic adjustable boom, 2.6 m (8' 6") arm equipped with 0.7 m3 (SAE heaped)
bucket and 600 mm (24") triple grouser shoe and 2900 kg (6390 Ib) counterweight.
Load radius At max. reach
Load
1.5 m (5.0 ft) 3.0 m (10.0 ft) 4.5 m (15.0 ft) 6.0 m (20.0 ft) 7.5 m (25.0 ft) Capacity Reach
point
height m (ft)
7.5 m kg *3030 2850 6.73
(25.0 ft) lb *6680 6280 (22.1)
6.0 m kg *2890 *2890 *3050 2090 7.88
(20.0 ft) lb *6370 *6370 *6720 4610 (25.9)
4.5 m kg *3370 3340 *2150 *2150 3040 1740 8.57
(15.0 ft) lb *7430 7360 *4740 *4740 6700 3840 (28.1)
3.0 m kg *4730 *4730 *3950 3180 *3110 2140 2790 1560 8.91
(10.0 ft) lb *10430 *10430 *8710 7010 *6860 4720 6150 3440 (29.2)
1.5 m kg *10240 8720 *6180 4670 *4640 2980 3610 2050 2710 1500 8.96
(5.0 ft) lb *22580 19220 *13620 10300 *10230 6570 7960 4520 5970 3310 (29.4)
Ground kg *8650 8130 *7240 4360 4990 2820 3520 1970 2800 1540 8.73
Line lb *19070 17920 *15960 9610 11000 6220 7760 4340 6170 3400 (28.6)
-1.5 m kg *6290 *6290 *10300 7990 *7610 4210 4880 2730 *3250 1930 3090 1720 8.17
(-5.0 ft) lb *13870 *13870 *22710 17610 *16780 9280 10760 6020 *7170 4250 6810 3790 (26.8)
-3.0 m kg *8930 *8930 *10930 8050 *7230 4190 4870 2710 *3660 2130 7.21
(-10.0 ft) lb *19690 *19690 *24100 17750 *15940 9240 10740 5970 *8070 4700 (23.7)
-4.5 m kg *12410 *12410 *8670 8270 *5820 4310 *3390 3290 5.59
(-15.0 ft) lb *27360 *27360 *19110 18230 *12830 9500 *7470 7250 (18.3)

1-20
6. BUCKET SELECTION GUIDE
1) GENERAL AND HEAVY DUTY BUCKET

0.39 m3 SAE 0.50 m3 SAE 0.64, ※0.70 m3 SAE 0.89 m3 SAE

heaped bucket heaped bucket heaped bucket heaped bucket

Recommendation
Capacity Width 5.1 m (16' 9") 5.1 m (16' 9")
Weight Mono boom Hyd adjustable boom
SAE CECE Without With 2.2 m arm 2.6 m arm 3.1 m arm 2.2 m arm 2.6 m arm
heaped heaped side cutter side cutter (7' 3") (8' 6") (10' 2") (7' 3") (8' 6")

0.39 m3 0.34 m3 620 mm 740 mm 410 kg

(0.51 yd3) (0.44 yd3) (24.4") (29.1") (900 lb)

0.50 m3 0.44 m3 760 mm 880 mm 470 kg

(0.65 yd3) (0.58 yd3) (29.9") (34.6") (1040 lb)

0.64 m3 0.55 m3 920 mm 1040 mm 510 kg

(0.84 yd3) (0.72 yd3) (36.2") (40.9") (1120 lb)

※0.70 m3 0.60 m3 990 mm 1110 mm 540 kg

(0.92 yd3) (0.78 yd3) (39.0") (43.7") (1190 lb)

0.89 m3 0.77 m3 1220 mm 1340 mm 610 kg

(1.16 yd3) (1.01 yd3) (48.0") (52.8") (1340 lb)

※ : Standard bucket
Applicable for materials with density of 2000 kg/m3 (3370 lb/yd3) or less
Applicable for materials with density of 1600 kg/m3 (2700 lb/yd3) or less
Applicable for materials with density of 1100 kg/m3 (1850 lb/yd3) or less

1-21
2) HEAVY DUTY BUCKET

◈ 0.69, 0.72, 0.87 m3 SAE heaped bucket

Recommendation
Capacity Width 5.1 m (16' 9") 5.1 m (16' 9")
Weight Mono boom Hyd adjustable boom
SAE CECE Without With 2.2 m arm 2.6 m arm 3.1 m arm 2.2 m arm 2.6 m arm
heaped heaped side cutter side cutter (7' 3") (8' 6") (10' 2") (7' 3") (8' 6")

◈0.69 m3 0.62 m3 990 mm 700 kg

-
(0.90 yd3) (0.81 yd3) (39.0") (1540 lb)

◈0.72 m3 0.65 m3 985 mm 910 mm 620 kg

(0.94 yd3) (0.85 yd3) (38.8") (35.8") (1370 lb)

◈0.87 m3 0.78 m3 985 mm 910 mm 650 kg

(1.18 yd3) (1.02 yd3) (38.8") (35.8") (1430 lb)

◈ : Heavy duty bucket

Applicable for materials with density of 2000 kgf/m3 (3370 lbf/yd3) or less
Applicable for materials with density of 1600 kgf/m3 (2700 lbf/yd3) or less
Applicable for materials with density of 1100 kgf/m3 (1850 lbf/yd3) or less

1-22
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) 17550 (38690) 17800 (39240) 18050 (39790)
R160LC-9A
Ground pressure kgf/cm2 (psi) 0.51 (7.25) 0.43 (6.11) 0.38 (5.40)
Overall width mm (ft-in) 2490 (8' 2") 2590 (8' 6") 2690 (8' 10")
Shoe width mm (in) 500 (20) ※600 (24) 700 (28)
Operating weight kg (lb) 18550 (40900) 18800 (41450) 19050 (42000)
R160LCD-9A
Ground pressure kgf/cm2 (psi) 0.54 (7.68) 0.46 (6.54) 0.40 (5.69)
Overall width mm (ft-in) 2490 (8' 2") 2590 (8' 6") 2690 (8' 10")
※ : Standard

3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE

Quantity
Item
R160LC/LCD-9A
Carrier rollers 2 EA
Track rollers 7 EA
Track shoes 49 EA

1-23
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 22, 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.

※ Table 1
Track shoe Specification Category
600 mm triple grouser Standard A
500 mm triple grouser Option A
700 mm triple grouser Option B

※ Table 2
Category Applications Applications
Rocky ground, · Travel at low speed on rough ground with large obstacles such as
A river beds, boulders or fallen trees
normal soil
Normal soil, · These shoes cannot be used on rough ground with large obstacles such
soft ground as boulders or fallen trees
B
· Travel at high speed only on flat ground
· Travel slowly at low speed if it is impossible to avoid going over obstacles

1-24
8. SPECIFICATIONS FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Perkins 1204E
Type 4-cycle turbocharged charge air cooled diesel engine
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 bore×stroke 105×127 mm (4.1"×5.0")
Piston displacement 4400 cc (269 cu in)
Compression ratio 16.5 : 1
Rated gross horse power (SAE J1995) 137Hp (102 kW) at 2050 rpm
Maximum torque 57.1 kgf·m (413 lbf·ft) at 1400 rpm
Engine oil quantity 10.5ℓ (2.8 U.S. gal)
Dry weight 507 kg (1119 lb)
High idling speed 2100±50 rpm
Low idling speed 800±100 rpm
Rated fuel consumption 161.8 g/Hp·hr at 2050 rpm
Starting motor 24 V-4.5 kW
Alternator 24 V-85 A
Battery 2×12 V×100 Ah

2) MAIN PUMP
Item Specification
Type Variable displacement tandem axis piston pumps
Capacity 2×80 cc/rev
Maximum pressure 350 kgf/cm2 (4980 psi) [380 kgf/cm2 (5400 psi)]
Rated oil flow 2×160ℓ/min (42.3 U.S. gpm / 35.2 U.K. gpm)
Rated speed 2000 rpm
[ ] : Power boost

1-25
3) GEAR PUMP
Item Specification
Type Fixed displacement gear pump single stage
Capacity 15cc/rev
Maximum pressure 40 kgf/cm2 (570 psi)
Rated oil flow 30ℓ/min (7.9 U.S. gpm / 6.6 U.K. gpm)

4) MAIN CONTROL VALVE

Item Specification
Type 11 spools two-block
Operating method Hydraulic pilot system
Main relief valve pressure 350 kgf/cm2 (4980 psi)[380 kgf/cm2 (5400 psi)]
Overload relief valve pressure 400 kgf/cm2 (5690 psi)
[ ] : Power boost

5) SWING MOTOR
Item Specification
Type Two fixed displacement axial piston motor
Capacity 117.8 cc/rev
Relief pressure 285 kgf/cm2 (4053 psi)
Braking system Automatic, spring applied hydraulic released
Braking torque 59 kgf·m (427 lbf·ft)
Brake release pressure 33~50 kgf/cm2 (469~711 psi)
Reduction gear type 2 - stage planetary

6) TRAVEL MOTOR
Item Specification
Type Variable displacement axial piston motor
Relief pressure 350 kgf/cm2 (4980 psi)
Reduction gear type Planetary & differential type
Braking system Automatic, spring applied hydraulic released
Brake release pressure 11 kgf/cm2 (156 psi)
Braking torque 49.3 kgf·m (357 lbf·ft)

1-26
7) CYLINDER
Item Specification
Bore dia×Rod dia×Stroke Ø115×Ø80×1090 mm
Boom cylinder
Cushion Extend only
Bore dia×Rod dia×Stroke Ø120×Ø85×1355 mm
Arm cylinder
Cushion Extend and retract
Bore dia×Rod dia×Stroke Ø110×Ø75×995 mm
Bucket cylinder
Cushion Extend only
Bore dia×Rod dia×Stroke Ø160×Ø85×650 mm
Adjust cylinder(opt)
Cushion Extend only
Bore dia×Rod dia×Stroke Ø115×Ø80×960 mm
Adjust boom cylinder(opt)
Cushion Extend only
Bore dia×Rod dia×Stroke Ø110×Ø85×320 mm
Dozer cylinder(opt)
Cushion Extend only
※ Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on
the rod surface.
※ Discoloration does not cause any harmful effect on the cylinder performance.

8) SHOE
Item Width Ground pressure Link quantity Overall width
Option 500 mm (20") 0.51 kgf/cm2 (7.25 psi) 49 2490 mm ( 8' 2")
R160LC-9A Standard 600 mm (24") 0.43 kgf/cm2 (6.11 psi) 49 2590 mm ( 8' 6")
Option 700 mm (28") 0.38 kgf/cm2 (5.40 psi) 49 2690 mm ( 8' 10")

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

0.39 m3 (0.51 yd3) 0.34 m3 (0.44 yd3) 3 620 mm (24.4") 740 mm (29.1")
0.50 m3 (0.65 yd3) 0.44 m3 (0.58 yd3) 4 760 mm (29.9") 880 mm (34.6")
0.64 m3 (0.84 yd3) 0.55 m3 (0.72 yd3) 5 920 mm (36.2") 1040 mm (40.9")
R160LC-9A
0.70 m3 (0.92 yd3) 0.60 m3 (0.78 yd3) 5 990 mm (39.0") 1110 mm (43.7")
0.89 m3 (1.16 yd3) 0.77 m3 (1.01 yd3) 6 1220 mm (48.0") 1340 mm (52.8")
◈0.69 m3 (0.90 yd3) 0.62 m3 (0.81 yd3) 5 990 mm (39.0") -
◈ : Heavy duty bucket

1-27
9. RECOMMENDED OILS
Use only oils listed below or equivalent.
Do not mix different brand oil.

Ambient temperature˚C (˚F)

Capacity
Service point Kind of fluid -50 -30 -20 -10 0 10 20 30 40
ℓ (U.S. gal)
(-58) (-22) (-4) (14) (32) (50) (68) (86) (104)
★SAE 5W-40

SAE 30
Engine
Engine oil 10.5 (2.8) SAE 10W
oil pan
SAE 10W-30
SAE 15W-40

Swing drive 5.0 (1.3) ★SAE 75W-90

Gear oil
5.8×2 SAE 85W-140
Final drive
(1.5×2)

★ISO VG 15
Tank:
160 (42)
Hydraulic
Hydraulic oil ISO VG 46
tank
System:
240 (63.4) ISO VG 68

★ASTM D975 NO.1

Fuel tank Diesel fuel★1 270 (71.3)
ASTM D975 NO.2

Fitting ★NLGI NO.1

(Grease Grease As required
nipple) NLGI NO.2

Mixture of
Radiator Ethylene glycol base permanent type
antifreeze
(Reservoir 27.5 (7.3)
and water ★Ethylene glycol base permanent type (60 : 40)
tank)
50 : 50

SAE : Society of Automotive Engineers ★1 : Ultra low sulfur diesel

API : American Petroleum Institute - sulfur content ≤ 15 ppm
ISO : International Organization for Standardization ★ : Cold region
NLGI : National Lubricating Grease Institute
Russia, CIS, Mongolia
ASTM : American Society of Testing and Materia
UTTO : Universal Tractor Transmission Oil

1-28
GROUP 3 SPECIFICATIONS (R180LC-9A)
1. MAJOR COMPONENT

Tool box Fuel tank Hydraulic tank Main pump

After
treatment
device

Engine

Radiator
Oil cooler

Tooth Bucket Turning joint Swing motor Main control valve

Arm Arm cylinder Boom Boom cylinder Cab Muffler Counterweight

Swing bearing

Bucket cylinder Control link Idler Track Travel motor

Side cutter Control rod Carrier roller Track roller Sprocket

1809A2SP01

1-29
2. SPECIFICATIONS

1) R180LC-9A
·5.1
5.1 m (16' 9") BOOM and 2.6 m (8' 6") ARM
I(I') D

E
C

G
F
Bucket

H
J M
K N
A B(L)

16092SP02

Description Unit Specification

Operating weight kg (lb) 18600 (41010)
Bucket capacity (SAE heaped), standard m3 (yd3) 0.76 (0.99)
Overall length A 8650 (28' 5")
Overall width, with 600 mm shoe B 2850 ( 9' 4")
Overall height C 2990 ( 9' 10")
Superstructure width D 2475 ( 8' 1")
Overall height of cab E 2980 ( 9' 9")
Ground clearance of counterweight F 1055 ( 3' 6")
Engine cover height G 2465 ( 8' 1")
Minimum ground clearance H mm (ft-in) 460 ( 1' 6")
Rear-end distance I 2480 ( 8' 2")
Rear-end swing radius I' 2530 ( 8' 4")
Distance between tumblers J 3360 (11' 0")
Undercarriage length K 4150 (13' 7")
Undercarriage width L 2850 ( 9' 4")
Track gauge M 2250 ( 7' 5")
Track shoe width, standard N 600 (24")
Travel speed (low/high) km/hr (mph) 3.2/5.5 (2.0/3.4)
Swing speed rpm 11.3
Gradeability Degree (%) 35 (70)
Ground pressure (600 mm shoe) kgf/cm2(psi) 0.43 (6.11)
Max traction force kg (lb) 17000 (37500)

1-30
2) R180LC-9A
·5.1
5.1 m (16' 9") H
HYDRAULIC
YDRAULIC ADJUSTABLE BOOM AND 2.6 m (8' 6") ARM

I(I') D
C

E
G
F

H
J M
K N
A B(L)

16092SP03

Description Unit Specification

Operating weight kg (lb) 19090 (42090)
Bucket capacity (SAE heaped), standard m3 (yd3) 0.76 (0.99)
Overall length A 8610 (28' 3")
Overall width, with 600 mm shoe B 2850 ( 9' 4")
Overall height C 3060 ( 10' 0")
Superstructure width D 2475 ( 8' 1")
Overall height of cab E 2980 ( 9' 9")
Ground clearance of counterweight F 1055 ( 3' 6")
Engine cover height G 2465 ( 8' 1")
Minimum ground clearance H mm (ft-in) 460 ( 1' 6")
Rear-end distance I 2480 ( 8' 2")
Rear-end swing radius I' 2530 ( 8' 4")
Distance between tumblers J 3360 (11' 0")
Undercarriage length K 4150 (13' 7")
Undercarriage width L 2850 ( 9' 4")
Track gauge M 2250 ( 7' 5")
Track shoe width, standard N 600 (24")
Travel speed (low/high) km/hr (mph) 3.2/5.5 (2.0/3.4)
Swing speed rpm 11.3
Gradeability Degree (%) 35 (70)
Ground pressure (600 mm shoe) kgf/cm2(psi) 0.44 (6.26)
Max traction force kg (lb) 17000 (37500)

1-31
3) R180LCD-9A
·5.1
5.1 m (16' 9") BOOM and 2.6 m (8' 6") ARM
I(I') D

E
C

G
F
Bucket

Q O
P

H
J M
K N
A B(L)

16092SP04

Description Unit Specification

Operating weight kg (lb) 19660 (43210)
Bucket capacity (SAE heaped), standard m3 (yd3) 0.76 (0.99)
Overall length A 9100 (29' 10")
Overall width, with 600 mm shoe B 2850 ( 9' 4")
Overall height C 2990 ( 9'10")
Superstructure width D 2475 ( 8' 1")
Overall height of cab E 2980 ( 9' 9")
Ground clearance of counterweight F 1055 ( 3' 6")
Engine cover height G 2465 ( 8' 1")
Minimum ground clearance H 460 ( 1' 6")
Rear-end distance I 2480 ( 8' 2")
mm (ft-in)
Rear-end swing radius I' 2530 ( 8' 4")
Distance between tumblers J 3360 (11' 0")
Undercarriage length K 4150 (13' 7")
Undercarriage width L 2850 ( 9' 4")
Track gauge M 2250 ( 7' 5")
Track shoe width, standard N 600 (24")
Height of blade O 640 ( 2' 1")
Ground clearance of blade up P 615 ( 2' 0")
Depth of blade down Q 675 ( 2' 3")
Travel speed (low/high) km/hr (mph) 3.2/5.5 (2.0/3.4)
Swing speed rpm 11.3
Gradeability Degree (%) 35 (70)
Ground pressure (600 mm shoe) kgf/cm2(psi) 0.45 (6.40)
Max traction force kg (lb) 17000 (37500)

1-32
4) R180NLC-9A
·5.1
5.1 m (16' 9") BOOM and 2.6 m (8' 6") ARM

I(I') D

E
C

G
F
Bucket

H
J M
K N
A B(L)

16092SP02

Description Unit Specification

Operating weight kg (lb) 18510 (40810)
Bucket capacity (SAE heaped), standard m3 (yd3) 0.76 (0.99)
Overall length A 8650 (28' 5")
Overall width, with 600 mm shoe B 2600 ( 8' 6")
Overall height C 2990 ( 9'10")
Superstructure width D 2475 ( 8' 1")
Overall height of cab E 2980 ( 9' 9")
Ground clearance of counterweight F 1055 ( 3' 6")
Engine cover height G 2465 ( 8' 1")
Minimum ground clearance H mm (ft-in) 460 ( 1' 6")
Rear-end distance I 2480 ( 8' 2")
Rear-end swing radius I' 2530 ( 8' 4")
Distance between tumblers J 3360 (11' 0")
Undercarriage length K 4150 (13' 7")
Undercarriage width L 2600 ( 8' 6")
Track gauge M 2000 ( 6' 7")
Track shoe width, standard N 600 (24")
Travel speed (low/high) km/hr (mph) 3.2/5.2 (2.0/3.2)
Swing speed rpm 11.3
Gradeability Degree (%) 35 (70)
Ground pressure (600 mm shoe) kgf/cm2(psi) 0.42 (5.97)
Max traction force kg (lb) 17000 (37500)

1-33
3. WORKING RANGE
1) 5.1 m (16' 9") MONO BOOM
A
A'
F

D
E
C
B'
B

8ft
16092SP05

Description 2.2 m (7' 3") Arm 2.6 m (8' 6") Arm 3.1 m (10' 2") Arm
Max digging reach A 8690 mm (28' 6") 9020 mm (29' 7") 9450 mm (31' 0")
Max digging reach on ground A' 8530 mm (27'12") 8860 mm (29' 1") 9300 mm (30' 6")
Max digging depth B 5660 mm (18' 7") 6060 mm (19'11") 6560 mm (21' 6")
Max digging depth (8ft level) B' 5430 mm (17'10") 5850 mm (19' 2") 6370 mm (20'11")
Max vertical wall digging depth C 5120 mm (16'10") 5380 mm (17' 8") 5710 mm (18' 9")
Max digging height D 8750 mm (28' 8") 8840 mm (29' 0") 8980 mm (29' 6")
Max dumping height E 6110 mm (20' 1") 6220 mm (20' 5") 6390 mm (21' 0")
Min swing radius F 3180 mm (10' 5") 3170 mm (10' 5") 3170 mm (10' 5")
107.9 [117.2] kN 107.9 [117.2] kN 107.9 [117.2] kN
SAE 11000 [11940] kgf 11000 [11940] kgf 11000 [11940] kgf
24250 [26330] lbf 24250 [23660] lbf 24250 [26330] lbf
Bucket digging force
123.6 [134.2] kN 123.6 [134.2] kN 123.6 [134.2] kN
ISO 12600 [13680] kgf 12600 [13680] kgf 12600 [13680] kgf
27780 [30160] lbf 27780 [30160] lbf 27780 [30160] lbf
87.2 [94.7] kN 77.3 [83.9] kN 69.0 [74.9] kN
SAE 8890 [9650] kgf 7880 [8560] kgf 7030 [7630] kgf
19600 [21280] lbf 17370 [18860] lbf 15500 [16830] lbf
Arm crowd force
91.0 [98.8] kN 80.3 [87.2] kN 71.4 [77.5] kN
ISO 9280 [10080] kgf 8190 [8890] kgf 7280 [7900] kgf
20460 [22210] lbf 18060 [19600] lbf 16050 [17430] lbf
[ ] : Power boost

1-34
2) 5.1 m (16' 9") H
HYDRAULIC
YDRAULIC ADJUSTABLE BOOM
A
A'
F

D
E
C
B'
B

8ft
16092SP06

Description 2.2m(7' 3") Arm 2.6m(8' 6") Arm

Max digging reach A 8760 mm (28' 9") 9110 mm (29'11")
Max digging reach on ground A' 8590 mm (28' 2") 8950 mm (29' 4")
Max digging depth B 5430 mm (17' 10") 5830 mm (19' 2")
Max digging depth (8ft level) B' 5330 mm (17' 6") 5730 mm (18'10")
Max vertical wall digging depth C 4630 mm (15' 2") 4980 mm (16' 4")
Max digging height D 9420 mm (30' 11") 9610 mm (31' 6")
Max dumping height E 6710 mm (22' 0") 6910 mm (22' 8")
Min swing radius F 3100 mm (10' 2") 2970 mm ( 9' 9")
107.9 [117.2] kN 107.9 [117.2] kN
SAE 11000 [11940] kgf 11000 [11940] kgf
24250 [26330] lbf 24250 [26330] lbf
Bucket digging force
123.6 [134.2] kN 123.6 [134.2] kN
ISO 12600 [13680] kgf 12600 [13680] kgf
27780 [30160] lbf 27780 [30160] lbf
87.2 [94.7] kN 77.3 [83.9] kN
SAE 8890 [9650] kgf 7880 [8560] kgf
19600 [21280] lbf 17370 [18860] lbf
Arm crowd force
91.0 [98.8] kN 80.3 [87.2] kN
ISO 9280 [10080] kgf 8190 [8890] kgf
20460 [22210] lbf 18060 [19600] lbf
[ ] : Power boost

1-35
4. WEIGHT
R180LC-9A R180LCD-9A 180NLC-9A
Item
kg lb kg lb kg lb
Upper structure assembly 7880 17370 ← ←
Main frame weld assembly 1470 3240 ← ←
Engine assembly 510 1120 ← ←
Fan clutch assembly 45 100 ← ←
Main pump assembly 100 220 ← ←
Main control valve assembly 140 310 ← ←
Swing motor assembly 250 550 ← ←
Hydraulic oil tank assembly 165 360 ← ←
Fuel tank assembly 130 290 ← ←
Counterweight 2900 6390 ← ←
Cab assembly 500 1100 ← ←
Lower chassis assembly 7670 16910 8670 19110 7580 16710
Track frame weld assembly 2130 4700 2370 5230 1980 4370
Swing bearing 260 570 ← ←
Travel motor assembly 300 660 ← ←
Turning joint 60 130 ← ←
Track recoil spring 140 310 ← ←
Idler 160 350 ← ←
Carrier roller 20 45 ← ←
Track roller 40 90 ← ←
Track-chain assembly (600 mm standard triple
1180 2600 ← ←
grouser shoe)
Front attachment assembly (5.1 m boom, 2.6 m arm,
3020 6660 ← ←
0.76 m3 SAE heaped bucket)
5.1 m boom assembly 1040 2290 ← ←
2.6 m arm assembly 540 1190 ← ←
0.76 m3 SAE heaped bucket 570 1260 ← ←
Boom cylinder assembly 155 340 ← ←
Arm cylinder assembly 180 400 ← ←
Bucket cylinder assembly 125 260 ← ←
Bucket control link assembly 120 265 ← ←
Dozer blade assembly - - 715 1575 - -
Dozer blade cylinder assembly - - 66 146 - -

1-36
5. LIFTING CAPACITIES
1) R180LC-9A
(1) 5.1 m (16' 9") boom, 2.6 m (8' 6") arm equipped with 0.76 m3 (SAE heaped) bucket and 600 mm
(24") triple grouser shoe and 2900 kg (6390 Ib) counterweight.

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

Load radius At max. reach

Load
1.5 m (5.0 ft) 3.0 m (10.0 ft) 4.5 m (15.0 ft) 6.0 m (20.0 ft) 7.5 m (25.0 ft) Capacity Reach
point
height m (ft)
7.5 m kg *3380 *3380 6.11
(25.0 ft) lb *7450 *7450 (20.0)
6.0 m kg *3020 *3020 *3360 2660 7.37
(20.0 ft) lb *6660 *6660 *7410 5860 (24.2)
4.5 m kg *3770 3720 *3410 2190 8.11
(15.0 ft) lb *8310 8200 *7520 4830 (26.6)
3.0 m kg *7910 *7910 *5310 *5310 *4300 3560 *2810 2420 3130 1970 8.48
(10.0 ft) lb *17440 *17440 *11710 *11710 *9480 7850 *6190 5340 6900 4340 (27.8)
1.5 m kg *8120 *8120 *6650 5270 *4920 3380 *3650 2350 3050 1900 8.53
(5.0 ft) lb *17900 *17900 *14660 11620 *10850 7450 *8050 5180 6720 4190 (28.0)
Ground kg *7910 *7910 *7500 5010 5220 3240 *3470 2280 3170 1970 8.28
Line lb *17440 *17440 *16530 11050 11510 7140 *7650 5030 6990 4340 (27.2)
-1.5 m kg *6710 *6710 *10690 9550 *7620 4900 5140 3170 3560 2220 7.69
(-5.0 ft) lb *14790 *14790 *23570 21050 *16800 10800 11330 6990 7850 4890 (25.2)
-3.0 m kg *9990 *9990 *10280 9680 *6960 4930 *4870 3200 *3750 2830 6.64
(-10.0 ft) lb *22020 *22020 *22660 21340 *15340 10870 *10740 7050 *8270 6240 (21.8)
-4.5 m kg *7470 *7470 *4960 *4960
(-15.0 ft) lb *16470 *16470 *10930 *10930
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.

1-37
2) R180LCD-9A
(1) 5.1 m (16' 9") boom, 2.6 m (8' 6") arm equipped with 0.76 m3 (SAE heaped) bucket and 600 mm
(24") triple grouser shoe and 2900 kg (6390 Ib) counterweight.

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

Load radius At max. reach

Load
1.5 m (5.0 ft) 3.0 m (10.0 ft) 4.5 m (15.0 ft) 6.0 m (20.0 ft) 7.5 m (25.0 ft) Capacity Reach
point
height m (ft)
7.5 m kg *3380 *3380 6.11
(25.0 ft) lb *7450 *7450 (20.0)
6.0 m kg *3020 *3020 *3360 2800 7.37
(20.0 ft) lb *6660 *6660 *7410 6170 (24.2)
4.5 m kg *3770 *3770 *3410 2320 8.11
(15.0 ft) lb *8310 *8310 *7520 5110 (26.6)
3.0 m kg *7910 *7910 *5310 *5310 *4300 3750 *2810 2570 *3500 2090 8.48
(10.0 ft) lb *17440 *17440 *11710 *11710 *9480 8270 *6190 5670 *7720 4610 (27.8)
1.5 m kg *8120 *8120 *6650 5550 *4920 3570 *3650 2490 3490 2020 8.53
(5.0 ft) lb *17900 *17900 *14660 12240 *10850 7870 *8050 5490 7690 4450 (28.0)
Ground kg *7910 *7910 *7500 5280 *5380 3430 *3470 2430 3630 2100 8.28
Line lb *17440 *17440 *16530 11640 *11860 7560 *7650 5360 8000 4630 (27.2)
-1.5 m kg *6710 *6710 *10690 10060 *7620 5180 *5460 3360 *3810 2360 7.69
(-5.0 ft) lb *14790 *14790 *23570 22180 *16800 11420 *12040 7410 *8400 5200 (25.2)
-3.0 m kg *9990 *9990 *10280 10180 *6960 5200 *4870 3390 *3750 3000 6.64
(-10.0 ft) lb *22020 *22020 *22660 22440 *15340 11460 *10740 7470 *8270 6610 (21.8)
-4.5 m kg *7470 *7470 *4960 *4960
(-15.0 ft) lb *16470 *16470 *10930 *10930
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.

1-38
3) R180NLC-9A
(1) 5.1 m (16' 9") boom, 2.6 m (8' 6") arm equipped with 0.76 m3 (SAE heaped) bucket and 600 mm
(24") triple grouser shoe and 2900 kg (6390 Ib) counterweight.

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

Load radius At max. reach

Load point 1.5 m (5 ft) 3.0 m (10 ft) 4.5 m (15 ft) 6.0 m (20 ft) 7.0 m (25 ft) Capacity Reach
height
m (ft)
7.5 m kg *3380 3290 6.11
(25 ft) lb *7450 7250 (20.0)
6.0 m kg *3020 *3020 *3360 2320 7.37
(20 ft) lb *6660 *6660 *7410 5110 (24.2)
4.5 m kg *3770 3250 *3410 1890 8.11
(15 ft) lb *8310 7170 *7520 4170 (26.6)
3.0 m kg *7910 *7910 *5310 4930 *4300 3100 *2810 2090 3110 1690 8.48
(10 ft) lb *17440 *17440 *11710 10870 *9480 6830 *6190 4610 6860 3730 (27.8)
1.5 m kg *8120 *8120 *6650 4550 *4920 2930 *3650 2020 3030 1620 8.53
(5 ft) lb *17900 *17900 *14660 10030 *10850 6460 *8050 4450 6680 3570 (28.0)
Ground kg *7910 *7910 *7500 4290 5180 2790 *3470 1960 3150 1680 8.28
Line lb *17440 *17440 *16530 9460 11420 6150 *7650 4320 6940 3700 (27.2)
-1.5 m kg *6710 *6710 *10690 7980 *7620 4190 5110 2720 3540 1900 7.69
(-5 ft) lb *14790 *14790 *23570 17590 *16800 9240 11270 6000 7800 4190 (25.2)
-3.0 m kg *9990 *9990 *10280 8100 *6960 4210 *4870 2750 *3750 2440 6.64
(-10 ft) lb *22020 *22020 *22660 17860 *15340 9280 *10740 6060 *8270 5380 (21.8)
-1.5 m kg *7470 *7470 *4960 4390
(-15 ft) lb *16470 *16470 *10930 9680
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.

1-39
6. BUCKET SELECTION GUIDE
1) GENERAL BUCKET

0.39 m3 SAE 0.50 m3 SAE 0.64, 0.76 m3 SAE 0.89, 1.05 m3 SAE
heaped bucket heaped bucket heaped bucket heaped bucket

Recommendation
Capacity Width 5.1 m (16' 9") 5.1 m (16' 9")
Weight Mono boom Hyd adjustable boom
SAE CECE Without With 2.2 m arm 2.6 m arm 3.1 m arm 2.2 m arm 2.6 m arm
heaped heaped side cutter side cutter (7' 3") (8' 6") (10' 2") (7' 3") (8' 6")

0.39 m3 0.34 m3 620 mm 740 mm 410 kg

(0.51 yd3) (0.44 yd3) (24.4") (29.1") (900 lb)

0.50 m3 0.44 m3 760 mm 880 mm 470 kg

(0.65 yd3) (0.58 yd3) (29.9") (34.6") (1040 lb)

0.64 m3 0.55 m3 920 mm 1040 mm 510 kg

(0.84 yd3) (0.72 yd3) (36.2") (40.9") (1120 lb)

0.76 m3 0.65 m3 1060 mm 1180 mm 570 kg

(0.99 yd3) (0.85 yd3) (41.7") (46.5") (1260 lb)

0.89 m3 0.77 m3 1220 mm 1340 mm 610 kg

(1.16 yd3) (1.01 yd3) (48.0") (52.8") (1340 lb)

1.05 m3 0.90 m3 1400 mm 1520 mm 680 kg

(1.37 yd3) (1.18 yd3) (55.1") (59.8") (1500 lb)

Applicable for materials with density of 2000 kg/m3 (3370 lb/yd3) or less
Applicable for materials with density of 1600 kg/m3 (2700 lb/yd3) or less
Applicable for materials with density of 1100 kg/m3 (1850 lb/yd3) or less

1-40
2) HEAVY DUTY AND DITCH CLEANING BUCKET

◈ 0.69, 0.72, 0.87 m3 SAE heaped bucket ⊙ 0.75 m3 SAE heaped bucket

Recommendation
Capacity Width 5.1 m (16' 9") 5.1 m (16' 9")
Weight Mono boom Hyd adjustable boom
SAE CECE Without With 2.2 m arm 2.6 m arm 3.1 m arm 2.2 m arm 2.6 m arm
heaped heaped side cutter side cutter (7' 3") (8' 6") (10' 2") (7' 3") (8' 6")

◈0.69 m3 0.62 m3 990 mm 700 kg

-
(0.90 yd3) (0.81 yd3) (39.0") (1540 lb)

◈0.72 m3 0.65 m3 985 mm 910 mm 620 kg

(0.94 yd3) (0.85 yd3) (38.8") (35.8") (1370 lb)

◈0.87 m3 0.78 m3 985 mm 910 mm 650 kg

(1.18 yd3) (1.02 yd3) (38.8") (35.8") (1430 lb)

⊙0.75 m3 0.65 m3 1700 mm 540 kg

-
(0.98 yd3) (0.85 yd3) (70.5") (1190 lb)

◈ : Heavy duty bucket ⊙ : Ditch cleaning bucket

Applicable for materials with density of 2000 kgf/m3 (3370 lbf/yd3) or less
Applicable for materials with density of 1600 kgf/m3 (2700 lbf/yd3) or less
Applicable for materials with density of 1100 kgf/m3 (1850 lbf/yd3) or less

1-41
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) 800 (32)
Operating weight kg (lb) 18350 (40450) 18600 (41010) 18850 (41560) 19100 (42110)
R180LC-9A
Ground pressure kgf/cm2 (psi) 0.51 (7.25) 0.43 (6.11) 0.37 (5.26) 0.33 (4.69)
Overall width mm (ft-in) 2750 (9' 0") 2850 (9' 4") 2950 (9' 8") 3050 (10' 0")
Shoe width mm (in) 500 (20) 600 (24) 700 (28) 800 (32)
Operating weight kg (lb) 19350 (42660) 19600 (43210) 19850 (43760) 20100 (44310)
R180LCD-9A
Ground pressure kgf/cm2 (psi) 0.53 (7.54) 0.45 (6.40) 0.39 (5.55) 0.35 (4.98)
Overall width mm (ft-in) 2750 (9' 0") 2850 (9' 4") 2950 (9' 8") 3050 (10' 0")

3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE

Item Quantity
Carrier rollers 2 EA
Track rollers 7 EA
Track shoes 51 EA

1-42
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 22, then use table 1 to select the shoe.
Wide shoes (categories B and C) have limitations on applications. Before using wide shoes, check
the precautions, then investigate and study the operating conditions to confirm if these shoes are
suitable.
Select the narrowest shoe possible to meet the required flotation and ground pressure.
Application of wider shoes than recommendations will cause unexpected problem such as bending
of shoes, crack of link, breakage of pin, loosening of shoe bolts and the other various problems.

※ Table 1
Track shoe Specification Category
500 mm triple grouser Option A
600 mm triple grouser Standard A
700 mm triple grouser Option B
800 mm triple grouser Option C

※ Table 2
Category Applications Applications
Rocky ground, · Travel at low speed on rough ground with large obstacles such as
A river beds, boulders or fallen trees
normal soil
Normal soil, · These shoes cannot be used on rough ground with large obstacles such
soft ground as boulders or fallen trees
B
· Travel at high speed only on flat ground
· Travel slowly at low speed if it is impossible to avoid going over obstacles
Extremely soft gound · Use the shoes only in the conditions that the machine sinks and it is
(swampy ground) impossible to use the shoes of category A or B
· These shoes cannot be used on rough ground with large obstacles such
C
as boulders or fallen trees
· Travel at high speed only on flat ground
· Travel slowly at low speed if it is impossible to avoid going over obstacles

1-43
8. SPECIFICATIONS FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Perkins 1204E
Type 4-cycle turbocharged charge air cooled diesel engine
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 bore×stroke 105×127 mm (4.1"×5.0")
Piston displacement 4400 cc (269 cu in)
Compression ratio 16.5 : 1
Rated gross horse power (SAE J1995) 137Hp (102 kW) at 2050 rpm
Maximum torque 57.1 kgf·m (413 lbf·ft) at 1400 rpm
Engine oil quantity 10.5ℓ (2.8 U.S. gal)
Dry weight 507 kg (1119 lb)
High idling speed 2100±50 rpm
Low idling speed 800±100 rpm
Rated fuel consumption 161.8 g/Hp·hr at 2050 rpm
Starting motor 24 V-4.5 kW
Alternator 24 V-85 A
Battery 2×12 V×100 Ah

2) MAIN PUMP
Item Specification
Type Variable displacement tandem axis piston pumps
Capacity 2×80 cc/rev
Maximum pressure 350 kgf/cm2 (4980 psi) [380 kgf/cm2 (5400 psi)]
Rated oil flow 2×160ℓ/min (42.3 U.S. gpm / 35.2 U.K. gpm)
Rated speed 2000 rpm
[ ] : Power boost

1-44
3) GEAR PUMP
Item Specification
Type Fixed displacement gear pump single stage
Capacity 15cc/rev
Maximum pressure 40 kgf/cm2 (570 psi)
Rated oil flow 30ℓ/min (7.9 U.S. gpm / 6.6 U.K. gpm)

4) MAIN CONTROL VALVE

Item Specification
Type 11 spools two-block
Operating method Hydraulic pilot system
Main relief valve pressure 350 kgf/cm2 (4980 psi)[380 kgf/cm2 (5400 psi)]
Overload relief valve pressure 400 kgf/cm2 (5690 psi)
[ ] : Power boost

5) SWING MOTOR
Item Specification
Type Two fixed displacement axial piston motor
Capacity 117.8 cc/rev
Relief pressure 285 kgf/cm2 (4053 psi)
Braking system Automatic, spring applied hydraulic released
Braking torque 59 kgf·m (427 lbf·ft)
Brake release pressure 33~50 kgf/cm2 (469~711 psi)
Reduction gear type 2 - stage planetary

6) TRAVEL MOTOR
Item Specification
Type Variable displacement axial piston motor
Relief pressure 350 kgf/cm2 (4980 psi)
Reduction gear type Planetary & differential type
Braking system Automatic, spring applied hydraulic released
Brake release pressure 11 kgf/cm2 (156 psi)
Braking torque 49.3 kgf·m (357 lbf·ft)

1-45
7) CYLINDER
Item Specification
Bore dia×Rod dia×Stroke Ø115×Ø80×1090 mm
Boom cylinder
Cushion Extend only
Bore dia×Rod dia×Stroke Ø120×Ø85×1355 mm
Arm cylinder
Cushion Extend and retract
Bore dia×Rod dia×Stroke Ø110×Ø75×995 mm
Bucket cylinder
Cushion Extend only
Bore dia×Rod dia×Stroke Ø160×Ø85×650 mm
Adjust cylinder(opt)
Cushion Extend only
Bore dia×Rod dia×Stroke Ø115×Ø80×960 mm
Adjust boom cylinder(opt)
Cushion Extend only
Bore dia×Rod dia×Stroke Ø110×Ø85×320 mm
Dozer cylinder(opt)
Cushion Extend only

※ Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on
the rod surface.
※ Discoloration does not cause any harmful effect on the cylinder performance.

8) SHOE
Item Width Ground pressure Link quantity Overall width
Option 500 mm (20") 0.51 kgf/cm2 (7.25 psi) 51 2750 mm ( 9' 0")
Standard 600 mm (24") 0.43 kgf/cm2 (6.11 psi) 51 2850 mm ( 9' 4")
R180LC-9A
Option 700 mm (28") 0.37 kgf/cm2 (5.26 psi) 51 2950 mm ( 9' 8")
Option 800 mm (32") 0.33 kgf/cm2 (4.69 psi) 51 3050 mm (10' 0")

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

0.76 m3 (0.99 yd3) 0.65 m3 (0.85 yd3) 5 1060 mm (41.7") 1180 mm (46.5")
0.39 m3 (0.51 yd3) 0.34 m3 (0.44 yd3) 3 620 mm (24.4") 740 mm (29.1")
0.50 m3 (0.65 yd3) 0.44 m3 (0.58 yd3) 4 760 mm (29.9") 880 mm (34.6")
R180LC-9A 0.64 m3 (0.84 yd3) 0.55 m3 (0.72 yd3) 5 920 mm (36.2") 1040 mm (40.9")
0.89 m3 (1.16 yd3) 0.77 m3 (1.01 yd3) 6 1220 mm (48.0") 1340 mm (52.8")
1.05 m3 (1.37 yd3) 0.90 m3 (1.18 yd3) 6 1400 mm (55.1") 1520 mm (59.8")
◈0.69 m3 (0.90 yd3) 0.62 m3 (0.81 yd3) 5 990 mm (39.0") -
◈ : Heavy duty bucket

1-46
9. RECOMMENDED OILS
Use only oils listed below or equivalent.
Do not mix different brand oil.

Service Ambient temperature˚C(˚F)

Capacity
Kind of fluid
point ℓ (U.S. gal) -50 -30 -20 -10 0 10 20 30 40
(-58) (-22) (-4) (14) (32) (50) (68) (86) (104)
★SAE 5W-40

SAE 30
Engine
Engine oil 10.5 (2.8) SAE 10W
oil pan
SAE 10W-30

SAE 15W-40

Swing drive 5.0 (1.3) ★SAE 75W-90

Gear oil
5.8×2 SAE 85W-140
Final drive
(1.5×2)

★ISO VG 15
Tank:
Hydraulic 160 (42)
Hydraulic oil ISO VG 46
tank System:
240 (63.4) ISO VG 68

★ASTM D975 NO.1

Fuel tank Diesel fuel★1 270 (71.3)
ASTM D975 NO.2

Fitting ★NLGI NO.1

(grease Grease As required
nipple) NLGI NO.2

Mixture of
Radiator Ethylene glycol base permanent type (50 : 50)
antifreeze
(reservoir 27.5 (7.3)
and soft ★Ethylene glycol base permanent type (60 : 40)
tank)
water★2

SAE : Society of Automotive Engineers ★1 : Ultra low sulfur diesel

API : American Petroleum Institute - sulfur content ≤ 15 ppm
ISO : International Organization for Standardization ★2 : Soft water
NLGI : National Lubricating Grease Institute
City water or distilled water
ASTM : American Society of Testing and Material
★ : Cold region
Russia, CIS, Mongolia

1-47
SECTION 2 STRUCTURE AND FUNCTION

Group 1
Pump Device ------------------------------------------------------------------------------------------------------ 2-1
Group 2
Main Control Valve --------------------------------------------------------------------------------------------- 2-19
Group 3
Swing Device ------------------------------------------------------------------------------------------------------ 2-46
Group 4
Travel Device ------------------------------------------------------------------------------------------------------ 2-57
Group 5 RCV Lever ---------------------------------------------------------------------------------------------------------- 2-65
Group 6 RCV Pedal ---------------------------------------------------------------------------------------------------------- 2-72
SECTION 2 STRUCTURE AND FUNCTION
GROUP 1 PUMP DEVICE

1. STRUCTURE
The pump device consists of main pump, regulator and gear pump.

326 414 Qmax adjusting screw

Pi1 EPPR valve
a3
P1
A3

B3

Dr Pi2
B1

Qmin adjusting screw Qmin adjusting screw a1 a2

Regulator Regulator

Pi1 Pi2 A2
A1

VIEW A

Dr
B3

B1

a4

A1 pump A1 A2 A2 pump Gear pump

Valve block

14092MP01
A

Port Port name Port size

A1 A2

a1 a2 A1, A2 Delivery port SAE6000 psi 3/4"

B1 Suction port SAE2500 psi 2 1/2"
Dr Drain port PF 1/2 - 19
Pi1, Pi2 Pilot port PF 1/4 - 15
Pi1 Pi2 P1 EPPR port PF 1/4 - 15
a3 a1, a2, a3 Gauge port PF 1/4 - 15
P1 a4 Gauge port PF 1/4-14
A3
Dr B1 B3 a4
A3 Gear pump delivery port PF 1/2 - 19
B3 Gear pump suction port PF 3/4 - 20.5

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

548
535 789 732 532 531 214 702 792 901 711 312 719 124 151 152 113 406
808 534 808
953 724 954
886
717
406 04
774
111

261 262
127 406
123
710
824
251
490 212 211 153 156 157 467 313 468 466 116 885 314 141 981 271 401
728 727 725 983
14092MP02

04 Gear pump 312 Valve block 717 O-ring

111 Drive shaft (F) 313 Valve plate (R) 719 O-ring
113 Drive shaft (R) 314 Valve plate (L) 724 O-ring
116 1st Gear 326 Cover 725 O-ring
123 Roller bearing 401 Hexagon socket bolt 727 O-ring
124 Needle bearing 406 Hexagon socket bolt 728 O-ring
127 Bearing spacer 414 Hexagon socket bolt 732 O-ring
141 Cylinder block 466 Plug 774 Oil seal
151 Piston 467 plug 789 Back up ring
152 Shoe 468 Plug 792 Back up ring
153 Set plate 490 Plug 808 Hexagon head nut
156 Bushing 531 Tilting pin 824 Snap ring
157 Cylinder spring 532 Servo piston 885 Pin
211 Shoe plate 534 Stopper (L) 886 Spring pin
212 Swash plate 535 Stopper (S) 901 Eye bolt
214 Bushing 548 Pin 953 Set screw
251 Support 702 O-ring 954 Set screw
261 Seal cover (F) 710 O-ring 981 Plate
271 Pump casing 711 O-ring 983 Pin

2-2
2) REGULATOR (1/2)

412 876 874 755

A
B 858 438
897 614
612

C
615 Pi
613
875
611
A
B
641 730 643 708 644 645 646 728 924 801
SECTION B-B

735 413 438 405 413 438

438
Pi Pi
656

722 D

496 724 725 436 699 496 724 725 436

VIEW C (FRONT) VIEW C (REAR) 16092MP04

KR38-9N37 (FRONT) A
079 735 722 466 KR38-9N35 (REAR) Port Port name Port size

P1 P2 A Delivery port SAE6000 psi 3/4"

B Suction port SAE2500 psi 2 1/2"
Pi Pilot port PF 1/4-15
Pi
a

753 496 755 a

SECTION D-D(REAR)
P1
B

2-3
REGULATOR (2/2)

655 734 653 654 836 651 652 601 624 629 630 628 802

641

814

898

631
732

733

622

621 623 625 626 887 763 756 754 627

SECTION A-A
14W92MP05

079 EPPR valve assembly 629 Cover (C) 733 O-ring

405 Hexagon socket screw (R) 630 Lock nut 734 O-ring
412 Hexagon socket screw 631 Sleeve, Pf 735 O-ring
413 Hexagon socket screw 641 Pilot cover 753 O-ring (R)
436 Hexagon socket screw 643 Pilot piston 754 O-ring
438 Hexagon socket screw 644 Spring seat (Q) 755 O-ring
466 Plug (R) 645 Adjust stem (Q) 756 O-ring
496 Plug 646 Pilot spring 763 O-ring
601 Casing 651 Sleeve 801 Nut
611 Feed back lever 652 Spool 802 Nut
612 Lever (1) 653 Spring seat 814 Snap ring
613 Lever (2) 654 Return spring 836 Snap ring
614 Center plug 655 Set spring 858 Snap ring
615 Adjust plug 656 Block cover (F) 874 Pin
621 Compensator piston 699 Valve casing (R) 875 Pin
622 Piston case 708 O-ring 876 Pin
623 Compensator rod 722 O-ring 887 Pin
624 Spring seat (C) 724 O-ring 897 Pin
625 Outer spring 725 O-ring 898 Pin
626 Inner spring 728 O-ring 924 Set screw
627 Adjust stem (C) 730 O-ring
628 Adjust screw (C) 732 O-ring

2-4
3) GEAR PUMP

887 700 354 351 433

B3
434

311
A3
312
850
732
a3 355

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

14092MP06

307 Poppet 353 Drive gear 466 Plug

308 Seat 354 Driven gear 700 Ring
309 Ring 355 Filter 710 O-ring
310 Spring 361 Front case 725 O-ring
311 Screw 433 Flange socket 732 O-ring
312 Nut 434 Flange socket 850 Snap ring
351 Gear case 435 Flange socket 887 Pin

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
124
shoes (151,152), set plate (153), 313
141
spherical bushing (156) and cylinder
156
spring (157). The drive shaft is supported 153
by bearing (123,124) at its both ends. 211
157
The shoe is caulked to the piston to from 111 151
a spherical coupling. It has a pocket to 152
123
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 21092MP06

shoe plate by the action of the cylinder

spring via a retainer and a spherical bush.
Similarly, the cylinder block is pressed
against valve plate (313) by the action of
the cylinder spring.
(2) Swash plate group
531
The swash plate group consists of swash 548
plate (212), shoe plate (211), swash plate 214
support (251), tilting bush (214), tilting pin
(531) and servo piston (532). 251
The swash plate is a cylindrical part 211
formed on the opposite side of the sliding 212
surface of the shoe and is supported by
the swash support.
If the servo piston moves to the right and 532 α
left as hydraulic force controlled by the
regulator is admitted to hydraulic chamber
located on both sides of the servo piston, α
the swash plate slides over the swash
plate support via the spherical part of the
tilting pin to change the tilting angle (α)

2507A2MP14

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
312
ports is fixed to the valve block and feeds
and collects oil to and from the cylinder 313
block.
The oil changed over by the valve plate is
connected to an external pipeline by way 885
of the valve block.
Now, if the drive shaft is driven by a prime
21092MP07
mover (electric motor, engine, etc), it
rotates the cylinder block via a spline
linkage at the same time. If the swash
plate is tilted as in Fig (previous page) the
pistons arranged in the cylinder block
make a reciprocating motion with respect
to the cylinder block, while they revolve
with the cylinder block.
If you pay attention to a single piston, it
performs a motion away from the valve
plate (oil sucking process) within 180
degrees, and makes a motion towards the
valve plate (or oil discharging process) in
the rest of 180 degrees. When the
swash plate has a tilting angle of zero, the
piston makes no stroke and discharges
no oil.

2-7
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 Pi, the
pump tilting angle (delivery flow) is
regulated arbitrarily, as shown in the
figure.
This regulator is of the negative flow

Delivery flow, Q
control in which the delivery flow Q
decreases as the pilot pressure Pi rises.
With this mechanism, when the pilot
pressure corresponding to the flow
required for the work is commanded, the
pump discharges the required flow only,
and so it does not consume the power Pilot pressure, Pi
uselessly.

2-8
① Flow reducing function

643 654 651 652 613 646

P1 CL
B(E)
874
897
C
Pi(From MCV)
A

875

611

Large diameter Servo piston Small diameter

chamber 548 chamber

D 531

14W92MP12

As the pilot pressure Pi rises, the pilot piston (643) moves to the right to a position where the
force of the pilot spring (646) balances with the hydraulic force.
The groove (A) in the pilot piston is fitted with the pin (875) that is fixed to lever 2 (613).
Therefore, when the pilot piston moves, lever 2 rotates around the fulcrum of point B [fixed by
the fulcrum plug (614) and pin (875)]. Since the large hole section (C) of lever 2 contains a
protruding pin (897) fixed to the feedback lever (611), the pin (897) moves to the right as lever 2
rotates. Since the opposing-flat section (D) of the feedback lever is fitted with the pin (548) fixed
by the tilting pin (531) that swings the swash plate, the feedback lever rotates around the fulcrum
of point D, as the pin (897) moves.
Since the feedback lever is connected with the spool (652) via the pin (874), the spool moves to
the right.
The movement of the spool causes the delivery pressure P1 to connect to port CL through the
spool and to be admitted to the large diameter section of the servo piston. The delivery pressure
P1 that is constantly admitted to the small diameter section of the servo piston moves the servo
piston to the right due to the area difference, resulting in decrease of the tilting angle.
When the servo piston moves to the right, point D also moves to the right. The spool is fitted
with the return spring (654) and is tensioned to the left at all times, and so the pin (897) is
pressed against the large hole section (C) of lever 2.
Therefore, as point D moves, the feedback lever rotates around the fulcrum of point C, and the
spool is shifted to the left. This causes the opening between the sleeve (651) and spool (652) to
close slowly, and the servo piston comes to a complete stop when it closes completely.

2-9
② Flow increasing function

643 654 651 652 613 646

P1 CL
B(E)
874
897
C
Pi(From MCV)
A

875

611

Large diameter Servo piston Small diameter

chamber 548 chamber

D 531

14W92MP13

As the pilot pressure Pi decreases, the pilot piston (643) moves to the left by the action of the
pilot spring (646) and causes lever 2 (613) to rotate around the fulcrum of point B. Since the pin
(897) is pressed against the large hole section (C) of lever 2 by the action of the return spring
(654) via the spool (652), pin (874), and feedback lever (611), the feedback lever rotates around
the fulcrum of point D as lever 2 rotates, and shifts the spool to the left. Port CL opens a way to
the tank port as the spool moves. This deprives the large diameter section of the servo piston of
pressure, and shifts the servo piston to the left by the discharge pressure P1 in the small
diameter section, resulting in an increase in the flow rate.
As the servo piston moves, point D also moves to the left, the feedback lever rotates around the
fulcrum of point C, and the spool moves to the right till the opening between the spool and sleeve
is closed.

2-10
③ Adjustment of flow control characteristic
The flow control characteristic can be
adjusted with the adjusting screw.
Adjust it by loosening the hexagon nut 801
(801) and by tightening (or loosening) the 924
hexagonal socket head screw (924).
Tightening the screw shifts the control
chart to the right as shown in the figure.
※ Adjusting value
Adjustment of flow control
Speed characteristic
Tightening Flow control Flow change
amount of starting amount
adjusting pressure
screw (924) change
amount

Delivery flow, Q
(min -1) (Turn) (kgf/cm2) (ℓ/min)

2000 +1/4 +1.5 +9.5

Pilot pressure, Pi

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 = P1×q/2Л + P2×q/2Л
= (P1+P2)×q/2Л
The horsepower control function is the
same as the flow control function and is
summarized in the following. (For detailed
behaviors of respective parts, refer to the
section of flow control).

2-12
① Overload preventive function

621 651 652 623 612 601 625 626

P1 CL
B(E)
897

P2 P1
875

611

Large diameter Small diameter

Servo piston chamber
chamber
D

14W92RG03

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
② Flow reset function

621 651 652 623 612 601 625 626

P1 CL
B(E)
897

P2 P1
875

611

Large diameter Small diameter

Servo piston chamber
chamber
D

14W92RG04

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
③ Low tilting angle (low flow) command preferential function
As mentioned above, flow control and horsepower control tilting angle commands are
transmitted to the feedback lever and spool via the large-hole sections (C & F) of levers 1 and 2.
However, since sections C and F have the pins (Ø4) protruding from the large hole (Ø8), only
the lever lessening the tilting angle contacts the pin (897) ; the hole (Ø8) in the lever of a larger
tilting angle command is freed without contacting the pin (897). Such a mechanical selection
method permits preference of the lower tilting angle command of the flow control and horsepower
control.
④ Adjustment of input horsepower
Since the regulator is of total cumulative horsepower type, adjust the adjusting screws of both
the front and rear pumps, when changing the horsepower set values. The pressure change
values by adjustment are based on two pumps pressurized at the same time, and the values will
be doubled when only one pump is loaded.

a. Adjustment of outer spring

Adjust it by loosening the hexagon nut
625 626 630 628
(630) and by tightening (or loosening)
the adjusting screw C (628).
Tightening the screw shifts the control
chart to the right and increases the
input horsepower as shown in the
figure. Since turning the adjusting
screw C (628) by N turns changes the
setting of the inner spring (626), return
the adjusting stem C (627) by N×A
turns at first. (A=1.85) 802 627

※ Adjusting value 2107A2MP07A

Speed Adjustment of input horsepower

Tightening Compensa- Input torque
Delivery flow, Q

amount of ting control change

adjusting starting amount
screw (C) pressure
(628) change
amount
(min -1) (Turn) (kgf/cm2) (kgf·m)

2000 +1/4 +17.7 +3.5

Delivery pressure, (P1+P2)

2-15
b. Adjustment of inner spring
625 626 630 628
Adjust it by loosening the hexagon nut
(802) and by tightening (or loosening)
the adjusting stem C (627).
Tightening the screw increases the flow
and then the input horsepower as
shown in the figure.
※ Adjusting value

Speed Adjustment of input horsepower

802 627
Tightening Flow change Input torque
amount of amount change 2107A2MP08
adjusting amount
stem (C)
(627)

Delivery flow, Q
(min -1) (Turn) (ℓ/min) (kgf·m)

2000 +1/4 +8.4 +3.8

Delivery pressure, (P1+P2)

2-16
(3) Power shift control

621 651 652 623 612 601 625 626

898
P1 CL
B(E)
897

P2 P1
875

611

Large diameter Small diameter

Servo piston chamber
chamber
D

14W92RG05

The set horsepower valve is shifted by

varying the command current level of
the proportional pressure reducing
Delivery flow, Q

valve attached to the pump.

Only one propor tional pressure Pf=
reducing 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 regulator through the pump's Delivery pressure, (P1+P2)
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
① Adjustment of maximum flow
Adjust it by loosening the hexagon nut 954 808
(808) and by tightening (or loosening)
the set screw (954).
The maximum flow only is adjusted
without changing other control
characteristics.
14W92MP23
Speed Adjustment of max flow
Tightening Flow change
amount of amount

Delivery flow, Q
adjusting screw
(954)

(min -1) (Turn) (ℓ/min)

2000 +1/4 -3.2

Delivery pressure, Pn

② Adjustment of minimum flow

953 808
Adjust it by loosening the hexagon nut
(808) and by tightening (or loosening)
the hexagonal socket head set screw
(953). Similarly to the adjustment of the
maximum flow, other characteristics are
not changed.
14W92MP24
However, remember that, if tightened too
much, the required horsepower during
the maximum delivery pressure (or
during relieving) may increase.
Delivery flow, Q

Speed Adjustment of min flow

Tightening Flow change
amount of amount
adjusting screw
(953)

(min -1) (Turn) (ℓ/min)

Delivery pressure, Pi
2000 +1/4 +3.2

2-18
GROUP 2 MAIN CONTROL VALVE

1. STRUCTURE Mark Port name Port size Tightening torque

Rs Make up for swing motor UNF 1 3/16 18 kgf·m (130 lbf·ft)
Pd0 Straight travel pilot port
Pa1 Travel left pilot port (BW)
MRV Pb1 Travel left pilot port (FW)
Pu
Pc1 Travel right pilot port (FW)
A1 B1
Pd1 Travel right pilot port (BW)
P02 T1
Pa20 Boom up pilot port
P3
Pb21 Dr1 Pa21 Boom up confluence pilot port
ORV P2
A2 B2 B2 Pb20 Boom down pilot port
Pb21 Lock valve pilot port (boom)
ORV
A2 Dr2 Pc2 Swing pilot port (RH)
Pd2 Swing pilot port (LH)
Pb3 Arm in confluence pilot port
B4
P1 Pc3 Swing priority pilot port
ORV ORV
Pa4 Option A pilot port (breaker)
A5 A5 B5 B5 Pb4 Arm in regeneration cut port
Pc40 Arm in pilot port
Dr4 Dr5
Pc41 Lock valve pilot port (arm)
NRV2 Rs NRV1 Pc42 Arm in regen-cut signal selector port
Pd40 Arm out pilot port
Pd41 Arm out confluence pilot port PF 1/4 3.5~3.9 kgf·m
VIEW A Pa5 Bucket in pilot port (25.3~28.2 lbf·ft)
Pb5 Bucket out pilot port
Pc5 Option B pilot port
Pd5 Option B pilot port
Pc6 Option C pilot port (dozer blade down)
Dr0 STRAIGHT
Ai Pd6 Option C pilot port (dozer blade up)
PO
TRAVEL P0 Pilot pressure port
Pu Main relief pressure up pilot port
TRAVEL LEFT Pb1 Pc1 TRAVEL RIGHT C1 D1 TRAVEL RIGHT Pd1 Pa1 TRAVEL LEFT Ai Auto idle signal port
Pa20
Patt
Patt Auto idle signal-attachment
BOOM 1 Pb20 Pc2 SWING C2 D2 SWING Pd2 BOOM 1 P02 Pilot signal port
P03
P03 Boom priority pilot port
ARM 2 Pb3 Pc3 BOOM 2 & ORV ORV BOOM 2 & Pa21 Pd41 ARM 2 P04 Boom parallel orifice pilot port
V3
A SWING PRIORITY - C4 - D4
SWING PRIORITY P05 Breaker summation pilot port
ARM REGENERATION
Pc42 Pb4
ARM REGENERATION
Puo Pilot pressure port
& OPTION-A(BREAKER)
Pc40 ARM 1 C4 D4
Dr3 Pc41
ARM 1 Pa4
& OPTION-A(BREAKER) Dr0 Drain port (travel straight)
Pd40
Dr1 Drain port (boom holding valve)
BUCKET P04 Pc5 ORV
- C5 C5 D5 ORV
- D5
Puo
Pd5 Pa5 BUCKET Dr2 Drain port (boom 2 & swing priority)
P05
OPTION-B
Dr3 Drain port (arm holding valve)
OPTION-B
P04 Pn1 Negative control signal port (P1 port side) 7~8 kgf·m
Pc6 DOZER DOWN C6 D6 DOZER UP Pd6 Pn2 Negative control signal port (P2 port side) PF 3/8 (50.6~57.8 lbf·ft)
P3 Quick clamp port
A1 Travel motor left side port (BW)
B1 Travel motor left side port (FW)
C1 Travel motor right side port (FW)
D1 Travel motor right side port (BW)
B2 Boom rod side port
C2 Swing motor port (RH)
D2 Swing motor port (LH)
B4 Option A port (breaker) 15~18 kgf·m
A5 Bucket head side port PF 3/4 (109~130 lbf·ft)
B5 Bucket rod side port
C5 Option B port
D5 Option B port
C6 Option C pilot port (dozer down port)
D6 Option C pilot port (dozer up port)
Pb5
Pn1 Pn2
P1 Pump port (P1 side)
P2 Pump port (P2 side)
A2 Boom head side port 20~25 kgf·m
C4 Arm head side port PF 1
D4 Arm rod side port (115~180 lbf·ft)
Dr4 Drain port (swing logic valve) 1.5~1.9 kgf·m
Dr5 Drain port (flow summation) PF 1/8
(10.8~13.7 lbf·ft)
T1 Return port SAE3000, 1 1/2 8.5~11.5 kgf·m
1609A2MC01
(M12×1.75) (61.5~83.1 lbf·ft)

2-19
51 53 56 69 3 77 34 65 62 31 49 48 69 46 47 50 56 53 61 30 50 53 56 69 11 43 79 72 28 63 29 80 44 26 62 69 31 25 62 31 62 31

1 Housing-P1 43 Load check-poppet

A A 2 Housing-P2 44 Load check-poppet
3 Spool-straight travel 45 Signal-poppet
B B
4 Spool-travel (LH, RH) 46 Travel straight-sleeve
6 Spool-swing 47 Travel straight-piston
C C
7 Spool-boom 1 48 Orifice signal
D D
8 Spool-swing priority 49 Coin type filter
9 Spool-boom 2 50 Pilot cap
E E 10 Spool-arm 2 51 Pilot cap
11 Spool-arm 1 52 Pilot cap
31 62 43 79 72 28 72 28 79 43 16 42 27 69 59 41 42 67 32 72 28 79 43 29 63 80 4412 69 56 53 51
F F 12 Spool-arm regeneration 53 Socket bolt
A-A (STRAIGHT TRAVEL & SUPPLY)
E-E (ARM 1 & ARM REGENERATION /BREAKER) 13 Spool-option B 54 Socket bolt
50 53 56 69 36 73 64 78 4 29 63 28 72 79 43 78 64 73 36 69 56 53 43 14 Spool-bucket 55 Socket bolt
G G
H 15 Spool-option C (dozer) 56 Washer
I 23 16 Main relief valve 57 Spring washer
792843 72 62 31 1 17 Overload relief valve 58 O-ring
50 53 56 69 18 13 67 32 32 67 19 69 56 53 51 61 30 55 57 18 Overload relief valve 59 O-ring
19 Overload relief valve 60 O-ring
A A 20 Negacon relief valve 61 O-ring
21 Swing logic valve 62 O-ring
B B 22 Bucket logic valve 63 O-ring
23 Option on-off valve 64 O-ring
C C 24 Holding valve kit A1 65 O-ring
50 53 56 69 4 72 28 45 58 33 8149 48 17 69 56 53 51 25 Holding valve kit A2 66 O-ring
B-B (TRAVEL RIGHT & LEFT) D D 26 Holding valve kit B 67 O-ring
37 68 78 64 67 32 43 79 28 72 29 63 32 67 37 68 78 64 27 Regeneration block 68 O-ring
E E 28 Plug 69 O-ring
29 Plug 70 O-ring
F F 30 Plug 71 O-ring
31 Plug 72 O-ring
22 53 56 69 17 43 79 72 28 63 29 80 44 14 17 69 56 53 51 G G 32 Plug 73 O-ring
33 Plug 74 Back up-ring
I
H 34 Plug-parallel 75 Back up-ring
50 53 56 69 69 56 53 51 F-F (OPTION-B & BUCKET) 2 54 57 35 Plug-relief cat 76 Back up-ring
36 Plug-relief cat 77 Back up-ring
21 37 Plug-relief cat 78 Back up-ring
20 15 20 29 63 40 63 75 59
50 53 56 69 6 69 56 53 51 38 Plug-bucket 79 Load check spring
G-G (OPTION-C & NEGATIVE CONTROL) 39 Plug-bucket parallel 80 Load check spring
52 17 53 56 69 8 60 77 34 65 34 65 60 77 32 67 9 69 17 40 Plug-option 81 Poppet signal spring
41 Plug-orifice 82 Pin
42 Plug

51

53 38 63 76 61 75 59 39 61 76 63
56

SECTION I-I SECTION H-H

50 53 56 69 35 71 10 62 31 66 74 31 62 29 63 80 44 29 63 44 80 50 53 56 17 69 7 44 80 63 29 72 28 79 43 26 69 24
D-D (SWING PRIORITY & BOOM 2 & ARM 2) C-C (SWING & BOOM 1) 1609A2MC02

2-20
2. HYDRAULIC CIRCUIT

Pi1 Pi2
(Pump) (Pump)

PS PS
Rs Pn2 Pn1

C6
D6
Pc6
OPTION-C
(DOZER)
Pd6

B5
Puo
A5
C5
D5 Pb5
Pc5
OPTION-B Pa5 BUCKET
P2 (Double
acting solenoid)
Pd5
DR5
P05 P04
Pb3 C4
D4
Pc42 B4
DR3
Pi1 (Arm safety) Pc41 OPTION-A & ARM
Pc40 Pb4
Pa4 REGENERATION CUT
Pd40

Pd41(Shuttle)
Pc42

ARM 1 V3
Pb3
Pc3
DR2
BOOM 2 & Pa21 ARM 2
SWING P05
PRIORITY Pd41
C2
D2 B2
Pc2 Pd40
A2 Pi1 (Boom safety)
SWING Pd2 Pb21
DR1
Pb20
DR4
Pa20
Pa21 BOOM 1
P02 P04
(Boom priority) P03 Patt
PS
B1
C1 A1 Swing motor(SH)
D1 Pb1
Pc1

TRAVEL(RH) Pd1 Pa1 TRAVEL(LH)

P02
DR0
STRAIGHT P0
TRAVEL
BLOCK PS T1
P02 Ai

Pd0 P3 P2 P1 Pu

A1 A2

1609A2MC05

2-21
3. FUNCTION
1) CONTROL IN NEUTRAL
(1) P1 SIDE
The hydraulic fluid from pump A2 flows into the main control valve through the inlet port "P1",
pass the straight travel spool into the P1 bypass passage and P1parallel passage.
The hydraulic fluid from the pump A2 is directed to the tank through the bypass passage of
spools : travel left, boom 1, arm 2, arm regeneration & option A and bucket, the negative relief
valve of P1, tank passage, and the tank port "T1"

P1 port Tank port T1

B B

P1 Bypass passage P1 Parallel passage

SECTION A-A

P1 Bypass passage

A A

TRAVEL(LH)

BOOM 1

ARM 2

ARM REGEN
& OPTION-A

BUCKET

Tank passage

P1 Negative relief valve P2 Negative relief valve

SECTION B-B
1609A2MC11

2-22
(2) P2 SIDE
The hydraulic fluid from pump A1 flows into the main control valve through the inlet port "P2", into
the P2 bypass passage and P2 parallel passage.
The hydraulic fluid from the pump A1 is directed to the tank through the bypass passage of
spools : travel right, swing, boom 2 & swing priority, arm 1, option "B" and option "C" (dozer), the
negative relief valve of P2, tank passage and the tank port "T1".

P2 Bypass passage Tank port T1

Straight travel spool

B B

P2 port P2 Parallel passage

SECTION A-A

P2 Bypass passage

A A

TRAVEL(RH)

SWING

BOOM 2 &
SW PRIORITY

ARM 1

OPTION-B

OPTION-C
(DOZER)

Tank passage
SECTION B-B
1609A2MC12

2-23
2) TRAVEL OPERATION
(1) TRAVEL FORWARD OPERATION

P1 Bypass passage
C1 D1

From RCV

Pc1
TRAVEL RIGHT

Pb1
TRAVEL LEFT

From RCV

Tank passage
A1 B1
P2 Bypass passage

14092MC18

(2) TRAVEL BACKWARD OPERATION

P1 Bypass passage
C1 D1

From RCV

TRAVEL RIGHT
Pd1

Pa1
TRAVEL LEFT

From RCV
Tank passage

A1 B1
P2 Bypass passage
14092MC17

During the travel forward operation, the hydraulic fluid of the pump A2 is supplied to the travel left
motor and the hydraulic fluid of the pump A1 is supplied to the other travel right motor.
The pilot pressure from the pilot control valve is supplied to the spring side of pilot port (pb1, pc1).
And it shifts travel right and left spools in the left direction against springs. Hydraulic fluid from the
pump A1 flow into the travel right spool through the bypass passage and hydraulic fluid from the
pump A2 flow into the travel left spool through the bypass passage.
Then they are directed to the each travel motor through port A1 and C1. As a result, the travel
motors turn and hydraulic fluid returns to the tank passage through the travel spools.
In case of the reverse operation, the operation is similar.

2-24
(3) TRAVEL STRAIGHT FUNCTION

P2 Parallel passage P1 port

P2 Bypass passage Orifice

Check valve

Tank port T1
Straight travel
spool

P2 port
P1 Bypass passage P1 Parallel passage

14092MC19

This function keeps straight travel in case of simultaneous operation of other actuators (boom, arm,
bucket, swing) during a straight travel.
① During travel only :
The hydraulic fluid of the pump A1 is supplied to the travel right motor and the pump A2 is
supplied to the travel left motor.
Thus, the machine keep travel straight.
② 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 A2 is supplied actuator through P2 and P1 parallel pass and travel
motors through orifice at side of straight travel spool.
The hydraulic oil fluid from pump A1 is supplied to travel motors (left/right).
Therefore, the other actuator operation with straight travel operation, hydraulic oil fluid from pump
A2 is mainly supplied to actuator, and the hydraulic oil fluid form pump A1 is mainly supplied to
travel motors (left/right).
Then the machine keeps straight travel.

2-25
3) BOOM OPERATION
(1) BOOM UP OPERATION
During boom up operation, the pilot secondary pressure from RCV is supplied to the port Pa20 of
the spring side and shifts the boom 1 spool in the left direction. The bypass passage is shut off by
the movement of the boom 1 spool and the hydraulic oil fluid from pump A2 is entered P1 parallel
passage and then passes through the load check, bridge passage 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 from RCV is supplied to the port Pa21 of the spring side of
boom 2 and shifts the boom 2 spool. The bypass passage is shut off by the movement of the
boom 2 spool and the hydraulic oil fluid from pump A1 entered boom summation passage via the
P2 parallel passage, the land of the swing priority spool, notch of the boom 2 spool, arm 2 spool
and the check. The flows combine in passage and are directed to port A2 and head side of boom
cylinder.
At the same time, the flow from rod side of the boom cylinder return to the boom 1 spool through
the port B2. Thereafter it is directed to the hydraulic oil tank through the tank passage.

P1 Bypass passage
Tank passage
Swing spool
Boom 1 spool
Holding valve

From RCV

Pa20

B2 A2
Boom summation P1 Parallel passage
passage

P2 Parallel passage Arm summation passage

P2 Bypass passage
Swing priority
spool Boom 2 spool
From RCV

Pa21

Arm 2 spool

Boom
Boomsummation passage
summation passage Load check
1609A2MC24

2-26
(2) BOOM DOWN OPERATION
During the boom lowing operation, the pilot pressure from RCV is supplied to the port Pb20 of the
spring opposite side and shifts the boom 1 spool in the right direction.
The bypass passage is shut off by the movement of the boom 1 spool and the hydraulic fluid from
the pump A2 enters the parallel passage and is directed to the port B2 through the load check.
Following this, it flows into the rod side of the boom cylinder.
At the same time, the return flow from the head side of the boom cylinder returns to the port A2
and boom holding valve. And it is directed to the hydraulic oil tank through opened tank passage
by movement of the boom 1 spool.
Meanwhile some of return flow is directed to P1 parallel passage through the internal passage of
the boom 1 spool. (boom regeneration)
In this case, the holding valve is open condition, for details of the boom holding valve, see page
following page.
During the boom lowering operation, the fluid from A1 pump is not summation.

P1 Bypass passage

Tank passage
Boom 1 spool

Boom holding valve

From RCV

Pb20

B2 A2
Load check P1 Parallel passage

1609A2MC26

2-27
4) HOLDING VALVE OPERATION
(1) HOLDING OPERATION
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".
Also, 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.

SPRING "A" CHECK VALVE PILOT PISTON CHAMBER

POPPET PISTON "A" SPRING "B" PISTON "B"

PLUG

CHECK

PILOT PORT
ACTUATOR PORT POPPET SEAT DRAIN PORT FOR RELEASE
HOLDING VALVE

1609A2MC15

2-28
(2) RELEASE HOLDING OPERATION
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
socket and spool and internal passage 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.

SPRING "A" CHECK VALVE PILOT PISTON CHAMBER

POPPET PISTON "A" SPRING "B" PISTON "B"

PLUG

CHECK

PILOT PORT
ACTUATOR PORT POPPET SEAT DRAIN PORT FOR RELEASE
HOLDING VALVE

1609A2MC16

2-29
5) BUCKET OPERATION
(1) BUCKET IN OPERATION
During the bucket in operation, the pilot secondary pressure from RCV is supplied to port Pa5 of
the spring side and shifts the bucket spool in the left direction.
The bypass passage is shut off by the movement of the bucket spool and the hydraulic fluid from
pump A2 entered P1 parallel passage and is directed to the port A5 through the check 1.
At the same time, the hydraulic fluid from P1 bypass passage is directed to the port A5 through
the check 2.
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.

Tank passage P1 Bypass passage

Bucket spool
From RCV

Pa5

B5 A5
P1 Parallel passage
Check 2
Check 1

16092MC34

2-30
(2) BUCKET OUT OPERATION
During the bucket out operation, the pilot secondary pressure from RCV is supplied to port Pb5
of the spring opposite side and shifts the bucket spool in the right direction.
The bypass passage is shut off by the movement of the bucket spool and the hydraulic fluid from
pump A2 entered P1 parallel passage and is directed to the port B5 through the check 1.
At the same time, the hydraulic fluid from P1 bypass passage is directed to the port B5 through
the check 2.
The return flow from the head side of the bucket cylinder returns to the hydraulic oil tank through
the port A5 and the tank passage.

P1 Bypass passage Tank passage

Bucket spool
From RCV

Pb5

B5 A5
P1 Parallel passage
Check 2 Check 1

140W9A2MC35

2-31
(3) BUCKET IN OPERATION WITH BOOM UP OPERATION
When combined operation, mostly same as previous page.
When bucket in operation with boom up operation, the boom up pilot pressure is supplied the
pilot port of bucket spool stroke limit and piston is shifted to the right and then the bucket spool
stroke is limited and the open of bucket spool is reduced.
Accordingly, the oil of bucket spool is reduced and boom speed up.

P1 Bypass passage
Tank passage P1 Parallel passage

Bucket spool
From RCV

P04
Pa5

B5 A5
Check 1
Check 2

140W9A2MC29

2-32
6) SWING OPERATION
(1) SWING LEFT & RIGHT OPERATION
During the swing left operation, the pilot secondary pressure from the RCV is supplied to the port
Pd2 of the spring side and shift the swing spool in left direction. The bypass passage is shut off by
the movement of the swing spool and the hydraulic fluid from pump A1 flows into swing spool
through the P2 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 to swing left operation but the pilot
secondary pressure from the RCV is supplied to the port Pc2 of the spring opposite side.
Accordingly, the hydraulic fluid from pump A1 flows into swing motor through the port C2 and
returns to the hydraulic oil tank through the port D2 and the tank passage.

Swing logic valve Check

Tank passage Swing spool

C2 D2

From RCV

Pd2

P2
P2Parallel
Parallelpassage
passage P2 Bypass
P2 Bypasspassage
passage
1609A2MC32

2-33
(2) SWING LEFT OPERATION WITH ARM OR BOOM OPERATION
When combined operation, mostly same as previous page but the fluid from P2 bypass passage
is empty.
So only the fluid from parallel passage is supplied to the swing motor. Also, parallel passage is
installed the orifice of swing logic valve for supplying the fluid from pump A1 to the boom or the
arm operation prior to the swing operation. In case of the swing right operation with arm or boom
operation, operation is similar.

Boom up pilot pressure

Po3

Swing logic valve Orifice

Tank passage Swing spool

C2 D2

Boom 1 spool From RCV

Pd2

P2
P2Parallel
Parallelpassage
passage P2
P2Bypass
Bypasspassage
passage
1609A2MC20

2-34
7) ARM OPERATION
(1) ARM IN OPERATION
During arm in operation, the pilot secondary pressure from the RCV is supplied to the port Pc40
of spring opposite side and shifts arm 1 spool in the right direction.
The bypass passage is shut off by the movement of the arm 1 spool and the hydraulic oil from the
pump A1 flows into the arm cylinder head side through P2 parallel passage, the load check valve,
bridge passage and the port C4.
At same time, the pilot secondary pressure from the RCV is supplied to the port Pb3 of spring
opposite side and shifts arm 2 spool in the right direction. The bypass passage is shut off by the
movement of the arm 2 spool and the hydraulic fluid from the pump A2 flows into the arm
summation passage through P1 parallel passage, the check valve, the arm 2 spool and the boom
2 spool. Then it entered the arm cylinder head side with hydraulic fluid from arm 1 spool.

Load check Arm summation passage

P2 Parallel passage Arm 1 spool
C4 D4
Piston C
Selector spool

Pc40

Arm regeneration
cut pilot pressure

Pb4

Pc42

Arm in Tank passage

pilot pressure
Arm regeneration P2 Bypass passage
& breaker spool

Arm summation passage

Boom 2 spool

Arm 2 spool
Arm in pilot
pressure
Pb3

From RCV

P1Bypass
P1 Bypass passage
passage P1P1 Parallel
Parallel passage
passage 1609A2MC21

2-35
ARM 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 arm 1 spool. It is supplied the arm cylinder head through internal
passage. This is called the arm regeneration function.
The amount of regeneration fluid is changed by movement of the arm regeneration spool. A few
fluids 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 shifts 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 the port Pb4 of spring opposite side
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. (The return fluid is
maximum condition)

Load check valve Arm summation passage

P2 Parallel passage Arm 1 spool
C4 D4
Piston C
Selector spool

Pc40

Arm regeneration
cut pilot pressure Arm holding valve

Pb4

Pc42

Tank passage
Arm in
pilot pressure
Arm
Armregeneration
regeneration P2 Bypass passage
&&breaker
breaker spool
spool

1609A2MC22

2-36
(2) ARM OUT OPERATION
During arm out operation, the pilot secondary pressure from RCV is supplied to the port Pd40 of
spring side and shifts arm 1 spool in the left direction.
The bypass passage is shut off by the movement of the arm 1 spool and the hydraulic fluid from
pump A1 flows into arm 1 spool through the P2 parallel passage. Then it enters into the arm
cylinder rod side through the load check, bridge passage, arm holding valve and the port D4.
Also, the pilot secondary pressure from RCV is supplied to the port Pd41 of spring side and shifts
arm 2 spool in the left direction.
The bypass passage is shut off by the movement of the arm 2 spool and some of the hydraulic
fluid from pump A2 bypassed through bypass notch. The rest of hydraulic fluid from pump A2
flows into the arm summation passage through P1 parallel passage, the check valve, arm 2 spool
and boom 2 spool.
Then it enters into the arm cylinder rod side with the fluid from the arm 1 spool.
The return flow from the arm cylinder head side returns to the hydraulic tank through the port C4,
the arm 1 spool and tank passage.

Load check Arm summation passage

P2 Parallel passage Arm 1 spool
C4 D4

Arm out
pilot pressure
Pd40

From RCV

Arm holding valve

Tank passage P2 Bypass passage

Bypass notch
Arm summation passage
Boom 2 spool

Arm 2 spool From RCV

Pd41
Arm roll out
pilot pressure

P1Bypass
P1 passage Check
Bypasspassage Check P1Parallel
P1 Parallel passage
passage 1609A2MC23

2-37
8) SWING PRIORITY FUNCTION
During swing priority operation, the pilot secondary pressure is supplied to the port Pc3 of the
spring side of the swing priority spool and shift swing priority spool in the right direction.
The hydraulic fluid from P2 parallel passage flows into the parallel passage of arm 1 side through
swing priority spool and the path "A" and also flows into the boom 2 spool.
When the swing priority spool is neutral condition, the passage is same as normal condition. But
due to shifting of the swing priority spool, the fluid from pump A1 flows to swing side more then the
boom 2, arm 1, option B and dozer spools to make the swing operation most preferential.

Swing priority spool Path "A" P2 Parallel passage

Swing priority
pilot pressure
Pc3

From RCV Boom 2 spool

Arm
Arm22spool
spool

1609A2MC27

2-38
9) DOZER OPERATION
(1) Dozer
ozer down operation

P2 Parallel passage Dozer spool

C6 D6

From dozer RCV

DOZER Pc6

Tank passage

14W92MC30

(2) Dozer
ozer up operation

P2 Parallel passage Dozer spool

C6 D6

Pd6
DOZER
From dozer RCV

Tank passage

14W92MC31

During the dozer down operation, the pilot pressure from the dozer control valve is supplied into
the port Pc6 of the spring side and it shifts the dozer spool in the left direction.
The hydraulic fluid from the pump A1 enters the parallel passage and is direction to the head side
of the dozer cylinder through port D6.
The return flow from the rod side of the dozer cylinder returns to the dozer spool through C6 port.
Thereafter it is directed to the hydraulic tank through tank passage.
In case of the dozer up operation, operation is similar.

2-39
10) NEGATIVE RELIEF VALVE OPERATION
When no function is being actuated on P1 side, the hydraulic fluid from the pump A2, flows into the
tank passage through the P1 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 A2 regulator.
It controls the pump regulator so as to minimize the discharge of the pump A2.
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 becomes zero and the
discharge of the pump A2 becomes 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 A1 the same negative control principle.

Tank passage P1 Bypass passage P2 Bypass passage

Bucket spool

Negative
control spring
Tank passage

P1 negative Orifice P2 negative

relief valve Pn1port
Pn1 port Pn2port
Pn2 port relief valve
14W92MC28

2-40
11) OPERATION OF MAIN RELIEF VALVE
(1) 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.

Socket Chamber A Piston A Poppet Hole A Spring Piston B

Housing Tank
passage
Plunger T Orifice A
14W92MC36

(2) 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
plunger internal passage, periphery orifice A, chamber A, periphery orifice B and the hole (E).

Piston A Poppet Spring

Periphery orifice B

Tank
passage
T Hole E

14W92MC37

(3) 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).

Plunger Poppet

Tank
passage
T

14W92MC38

2-41
(4) The pressure at port P becomes lower than set pressure of the spring, the poppet is seated by
spring force. Then the pressure at port P becomes equal to set pressure of the spring and the
plunger is seated to the socket.

Socket Poppet Spring

Housing Tank
passage
Plunger T

14W92MC39

(5) 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.

Hole A Spring Piston B

Housing Tank
passage
T

14W92MC40

2-42
12) OPERATION OF OVERLOAD RELIEF VALVE
FUNCTION AS RELIEF VALVE
(1) The pressurized oil passes through the piston A and orifice A is filled up in chamber A of the
inside space and seat the plunger against the socket and the socket against the housing securely.

Piston A Socket Chamber A Poppet Spring

Housing
Tank
passage Plunger Orifice A
T

14W92MC41

(2) When the pressure at port P becomes equal to the set pressure of the spring, the pressurized oil
pushes open the poppet and flows to tank passage (T) through the plunger internal passage,
orifice A, chamber A, periphery orifice B and hole E.

Tank passage Poppet Hole E Spring

T

Housing
Peripheryorifi
Periphery orifice
ce B B

14W92MC42

2-43
(3) 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).

Tank passage Chamber A Poppet

T

Housing
Tank
passage Plunger
T
14W92MC43

(4) The pressure at port P becomes lower than set pressure of the spring, the poppet is seated by
spring force. Then the pressure at port P becomes equal to set pressure of the spring and the
plunger is seated to the socket.

Socket Poppet Spring

Housing
Tank
passage Plunger
T

14W92MC44

2-44
MAKE-UP FUNCTION
(5) 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 of 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.

Tank passage Socket Poppet

T

Housing
Tank
passage
T
14W92MC45

2-45
GROUP 3 SWING DEVICE

1. STRUCTURE
Swing device consists swing motor, swing reduction gear.
Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve.

Reduction gear grease

supply port (PT 1/4)
Time delay valve
Reduction gear oil
drain port (PT 1/2) Relief valve
Mu SH
SH PG
Au Dr
PG
GA GB

Oil level gauge

& oil supply port
Reduction gear A B
air bleed port (PT 1/4)
Reduction gear Swing motor

SH Port Port name Port size

PG A Main port Ø20
B Main port Ø20
Au Dr Drain port PF 1/2
Mu Make up port PF 1
PG Brake release port PF 1/4
SH Stand by port PF 1/4
Dr
GA, GB Gauge port PF 1/4
Au Air vent port PF 1/4
GB GA

B(cw) Mu A(ccw)
Hydraulic circuit
16092SM01

2-46
1) SWING MOTOR

42

DETAIL K

7 6 5 12 11 10 17 20 8 23 37 39 31 33,34 38

28
27
29

26
30
K
43
46
45
44

2 3 4 1 9 13 14 16 15 18 19 24 21 22 40,41 25 35,36 32 16092SM02

1 Body 17 Brake piston 33 Time delay valve

2 Oil seal 18 O-ring 34 Wrench bolt
3 Roller bearing 19 O-ring 35 Plug
4 Snap ring 20 Brake spring 36 O-ring
5 Shaft 21 Rear cover 37 Plug
6 Bushing 22 Needle bearing 38 Plug
7 Stop ring 23 Pin 39 Plug
8 Pin 24 Valve plate 40 Name plate
9 Shoe plate 25 Wrench bolt 41 Rivet
10 Cylinder block 26 Plug 42 Level gauge
11 Spring 27 Back up ring 43 Plug
12 Ball guide 28 O-ring 44 O-ring
13 Set plate 29 Spring 45 O-ring
14 Piston assy 30 Check 46 Back up ring
15 Friction plate 31 Relief valve
16 Separate plate 32 Anti-inversion valve

2-47
2) REDUCTION GEAR

28 3 33 32 4 2 38 37 5 6 9 27 20 15 22 19 21 23 31

24
25

36 35 34 1 7 14 30 13 10 12 18 16 26

180W9A2SM03

1 Casing 15 Spring pin 28 Pinion gear

2 Drive shaft 16 Sun gear 2 30 Knock pin
3 Spacer 18 Carrier 1 31 Socket bolt
4 Roller bearing 19 Planet gear 1 32 Cover plate
5 Oil seal 20 Pin 1 33 Hexagon bolt
6 Roller bearing 21 Needle cage 34 Lock plate
7 Thrust plate 3 22 Side plate 1 35 Hexagon bolt
9 Carrier 2 23 Side plate 2 36 Lock washer
10 Planet gear 2 24 Stop ring 37 Plug
12 Pin 2 25 Sun gear 1 38 Plug
13 Bushing 2 26 Side plate 3
14 Thrust washer 27 Ring gear

2-48
2. PRINCIPLE OF DRIVING
2.1 Generating the turning force
The high hydraulic supplied from a hydraulic pump flows into a cylinder block (10) through rear cover
(21) of motor, and valve plate (24).
The high hydraulic is built as flowing on one side of Y-Y line connected by the upper and lower sides of
piston assy (14).
The high hydraulic can generate the force, F1=P×A (P : supplied pressure, A : water pressure area),
like following pictures, working on a piston.
This force, F1, is divided as N1 thrust partial pressure and W1 radial partial pressure, in case of the
plate of a tilt angle, α.
W1 generates torque, T=W1+R1, for Y-Y line connected by the upper and lower sides of the piston as
following pictures.
The sum of torque (ΣW1×R1), generated from each piston (4~5 pieces) on the side of a high
hydraulic, generates the turning force.
This torque transfers the turning force to a cylinder block (10) through a piston; because a cylinder
block is combined with a turning axis and spline, a turning axis rotates and a turning force is sent.

W1 Pistion
Cylinder
Cylinder block

W1
R1
N1
O A
f1 F1 P

High Y Low
pressure pressure

21078TM05

2-49
2) MAKE UP VALVE
In the system using this type of motor, there is no counter balance functioning valve and there
happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation
caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency.
A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure
feed pressure required when the hydraulic motor makes a pumping action. The boost pressure
acts on the hydraulic motor's feed port via the make up valve.
Pressurized oil into the port B, the motor rotate counterclockwise.
If the plunger of MCV moves neutral position, the oil in the motor is drain via left relief valve, the
drain oil run into motor via right make up valve, which prevent the cavitation of motor.

Relief valve

Make up check valve Make up check valve

A B

21092SM04

2-50
3) RELIEF VALVE

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

2
14007A2SM05

(1) Construction of relief valve

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

(2) Function of relief valve

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

3
P1

T
1
2-48(2)

2-51
① Ports (P, R) at tank pressure.

A2 m h n g

A1
P

14007A2SM06

② When hydraulic oil pressure (P×A1) reaches the preset force (FSP) of spring (4), the plunger (3)
moves to the right as shown.
P1×A1=Fsp+Pg×A2

Fsp+Pg×A2
P1=
A1

4 g

P=P1

14007A2SM07

2-52
③ The oil flow chamber g via orifice m and n. When the pressure of chamber g reaches the preset
force (FSP) of spring (4), the piston (6) moves left and stop the piston (6) hits the bottom of bushing
(7).

4 m n g

P=P2

7 6
14007A2SM08

④ 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).
Ps×A1=Fsp+Ps×A2

Fsp
Ps=
A1-A2

P=Ps

7 6 g
14007A2SM09

2-53
4) BRAKE SYSTEM
(1) Control valve swing brake system
This is the brake system to stop the swing motion of the excavator during operation.
In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance
created by this throttling works as a brake force to slow down the swing motion.

Work Deceleration Stop

A B A B A B

MCV MCV MCV

MCV A, B opened MCV A, B throttled MCV A, B closed

2-48(1)

(2) Mechanical swing parking brake system

This is function as a parking brake only when all of the RCV lever (except travel pedal) are not
operated.

① Brake assembly
Circumferential rotation of separate plate
(16) is constrained by the groove located
at housing (1). When housing is
20
pressed down by brake spring (20)
through friction plate (15), separate plate 10
(16) and brake piston (17), friction force 17
occurs there. 16
Cylinder block (10) is constrained by this 15
friction force and brake acts, while brake 1
Groove
releases when hydraulic force exceeds
spring force.

21092SM15

1 Housing 16 Separate plate

10 Cylinder block 17 Brake piston
15 Friction plate 20 Brake spring

2-54
② Operating principle
a. When one of the RCV lever (1) is set to the operation position, the each spool is shifted to left
or right and the pilot oil flow is blocked. Then the pilot oil go to SH of the time delay valve (33).
This pressure moves spool (5) to the leftward against the force of the spring(8), so pilot pump
charged oil (P3) goes to the chamber G through port PG.
This pressure is applied to move the piston (17) to the upward against the force of the spring
(20). Thus, it releases the brake force.

33

20 5

17 G SH

PG

1 RCV lever
2 Main control valve
5 Spool
8 Spring P3
17 Brake piston
20 Brake spring 2
33 Time delay valve

16092SM16

2-55
b. When all of the RCV lever (1) are set the neutral position, the spool (5) returns to right.
Then, the brake piston (17) is moved lower by spring force and the return oil from the chamber
G flows back to tank port.
At this time, the brake works.

33

20 5

17 G SH

PG

1 RCV lever
2 Main control valve
5 Spool
8 Spring P3
17 Brake piston
20 Brake spring 2
33 Time delay valve

16092SM17

2-56
GROUP 4 TRAVEL DEVICE

1. STRUCTURE
A Hydraulic motor includes followings.
·Part of rotary generating turning force
·Part of a valve of relief
·Part of Brake
·Part of a valve of counterbalance
·Part of flowing changeover
·Part of auto changeover
T1 P1 P2 T2

Reduction gear Travel motor

Pm1 Ps Pm2

RED Port Port name Port size

P1, P2 Main port SAE 4694psi 1"
Pm1, Pm2 Gauge port PF 1/4
T1, T2 Drain port PF 1/2
Ps 2 speed
Ps PF 1/4
control port

Pm1 Pm2

P1 P2 T1,T2 16092TM01

Hydraulic circuit

2-57
1) STRUCTURE

95 91-9 91-6 91-8 90-3 90-4 90-6 90-1 3 81 82 83 8 9 17 18 20 19 22,23 26 27 24,25 36 35 32 31 30 64 71 76 40 41 42

91-4 90-5 90-2
28
91-6
65
90-7
10
91-1
70
91-7
29 44
91-5
90-7 69
91-3 43
62
63 39
91-2
73
74 38
94
37
92
13
89 33
14 45
72 34
46
98
77
97
66
96

93 88 86 87 85 84 2 1 6 4 5 7 16 15 11 12 21 67 68 58 57 56 59 47 49,50 48 61 60 51,52 53 55 54
16092TM02

1 Shaft casing 20 Separate plate 39 Spool 58 Plug 77 Shim 91-1 Carrier No.1
2 Plug 21 Parking piston 40 Steel ball 59 Spool 81 Housing 91-2 Sun-gear No.2
3 Oil seal 22 O-ring 41 Spring 60 Orifice 82 Main bearing 91-3 Retaining ring
4 Swash piston 23 Back up ring 42 Plug 61 Orifice 83 Floating seal 91-4 Planetary gear No.1
5 Piston ring 24 O-ring 43 Spring seat 62 Plug 84 Shim 91-5 Needle bearing No.1
6 Shaft 25 Back up ring 44 O-ring 63 O-ring 85 Retainer 91-6 Thrust washer
7 Bearing 26 Orifice 45 Wrench bolt 64 Plug 86 Hex head bolt 91-7 Pin No.1
8 Steel ball 27 O-ring 46 Relief valve assy 65 Pin 87 Parallel pin 91-8 Spring pin
9 Swash plate 28 O-ring 47 Spool 66 Pin 88 Ring gear 91-9 Spring pin
10 Cylinder block 29 Rear cover 48 Guide 67 Spring 89 Coupling 92 Sun gear No.1
11 Spring seat 30 Spool 49 O-ring 68 Spring 90 Carrier assy No.2 93 Cover
12 Spring 31 Check 50 Back up ring 69 Bearing 90-1 Carrier No.2 94 Pad
13 End plate 32 Spring 51 O-ring 70 Valve plate 90-2 Planetary gear No.2 95 Hex socket head bolt
14 Snap ring 33 Plug 52 Back up ring 71 Wrench bolt 90-3 Needle bearing No.2 96 Hex socket Screw
15 Pin 34 O-ring 53 Snap ring 72 Plug 90-4 Thrust washer 97 Hydraulic plug
16 Ball guide 35 Spring seat 54 plug 73 Name plate 90-5 Pin No.2 98 O-ring
17 Set plate 36 Spring 55 O-ring 74 Rivet 90-6 Spring pin 99 Name plate
18 Piston assy 37 Cover 56 Spring 75 Seal kit 90-7 Thrust ring
19 Friction plate 38 Spring 57 Spring seat 76 Orifice 91 Carrier assy No.1

2-58
2. PRINCIPLE OF DRIVING
2.1 Generating the turning force
The high hydraulic supplied from a hydraulic pump flows into a cylinder block (10) through rear cover
(29) of motor, and valve plate (70).
The high hydraulic is built as flowing on one side of Y-Y line connected by the upper and lower sides of
piston assy (18).
The high hydraulic can generate the force, F1 = P×A (P : supplied pressure, A : water pressure area),
like following pictures, working on a piston.
This force, F1, is divided as N1 thrust partial pressure and W1 radial partial pressure, in case of the
plate (09) of a tilt angle, α.
W1 generates torque, T = W1+R1, for Y-Y line connected by the upper and lower sides of piston as
following pictures.
The sum of torque (ΣW1×R1), generated from each piston (4~5 pieces) on the side of a high
hydraulic, generates the turning force.
This torque transfers the turning force to a cylinder block (10) through a piston; because a cylinder
block is combined with a turning axis and spline, a turning axis rotates and a turning force is sent.

W1 Pistion
Cylinder
Cylinderblock

W1
R1
N1
O A
f1 F1 P

High Y Low
pressure pressure

21078TM05

2-59
2.2 Working of relief valve
Relief valve carries on two functions of followings.
1) It standardizes a pressure in case of driving a hydraulic motor ; bypasses and extra oil in a motor
inlet related to acceleration of an inertia to an outlet.
2) In case of an inertia stopped, it forces an equipment stopped, according to generating the pressure
of a brake on the projected side.
Room A is always connected with port A of a motor. If the pressure of port is increased, press
poppet A. And if it is higher than the setting pressure of a spring, the oil of an hydraulic flows from
room A to port B, because poppet A is detached from the contact surface of seat A.

Port A Port B

Chamber A Poppet A
Poppet

21078TM06A

2-60
2.3 Working of negative brake
When the operating pressure is supplied to the brake piston (21) through the spool (simultaneous
peripheral operation online) built in the shaft casing (1), the negative brake is released.
When the pressure does not work, the brake always runs.
The force of a brake is generated by the frictional force among a separate plate (20) fixed by shaft
casing, parking piston (21) and a frictional plate (19) connected through spline outside a cylinder
block (10).
When a pressure does not work on the part of piston, brake spring presses brake piston; oil in a brake
room flows into the drain of a motor through an orifice; in that time, brake piston compresses a
frictional plate and a detached plate in the middle of shaft casing (1) and brake piston (21) according
to the force that presses 10 pieces of brake springs (67, 68); finally, it makes a frictional force.
This frictional force helps the brake fixing a turning shaft (6) connected by a cylinder and spline
operated.

1 6 10 20 19 21 67 68

21092TM07

2-61
2.4 Counterbalance valve
Av port is connected to a hydraulic pump; Bv port is connected to a tank.
An oil supplied from a hydraulic pump presses check valve and flows into L port. It makes a hydraulic
motor circulated. The oil pressure out of a pump is increased and transferred to spring room M
through the path G because negative brake is working on. When the pressure of room M exceeds
the force of spring that keeps spool at its neutral position, the spool begins to move the right side.
An oil in room N is sent to room M by orifice I and discharged from G line to a tank.
Then the spool moves to the right and the oil flows from K to Bv.

M G Av Bv I N

Check valve L Spool K

21078TM08

2-62
2.5 Working description of automatic switch (at normal speed)
Due to no pressure on pilot now, spool (47) is not working.

D1 D

Av Bv

47

2 Speed line
2 Speed line

2 Speed
changeover
pressure port
(Normal
(Normal speed)
Speed)

21078TM09

2-63
2.6 Working description of automatic switch (at high speed)
At normal speed, once the hydraulic oil which is through the inner path of spool (47) flows into high
speed switching pressure port (the pressure of external pilot : Pi = 35 kgf/cm2) spool (47) moves from
right to left.
At high speed, turning pressure of motor (D1) is over 250 kgf/cm2, when the power forcing to spool (59)
(pressure, P1) is stronger than spool (47) and spool (59) is pushed out, after then spool (47) moves
from left to right. So it is switched.

59 D1 D

Av Bv

47
2 speed passage
2 Speed line
2 Speed
changeover
pressure port

(HighSpeed)
(High speed)

21078TM10

2-64
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.

19 Switches
No. LH RH
5 One touch decel Horn
6 Power boost Breaker

B
5
19
25
Single
operation Simultaneous 6
operation

DETAIL B RH SIDE

Tilted direction of
handle(RH)

1 P
T Tilted direction of
connector(LH, RH)
2 3

Tilted direction of
handle(LH)

VIEW A

A
Port LH RH Port size

P T 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 3/8
2 Arm in port Boom down port
3 Right swing port Bucket in port
4 Arm out port Boom up port
1 3 2 4
Hydraulic circuit
1409S2RL01

2-65
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 (3), spring (5) for setting secondary pres-
sure, return spring (9), stopper (7), spring seat (6, 12) and shim (4). The spring for setting the sec-
ondary pressure has been generally so preset that the secondary pressure is 5 to 20.5 kgf/cm2
(depending on the type). The spool is pushed against the push rod (8, 10) by the return spring.
When the push rod is pushed down by tilting the handle, the spring seat comes down simultaneously
and changes setting of the secondary pressure spring.

2-66
CROSS SECTION

22
24

25

23

21

20
8
18
19 15
16,26
17
13
10 14
7

27

6
12
9
11 5
4
3
1
2
Port 2,4 Port 1,3
1409S2RL02

1 Case 8 Push rod 15 Rod seal 22 Handle assembly

2 Bushing 9 Spring 16 Plate 23 Handle bar
3 Spool 10 Push rod 17 Boot 24 Nut
4 Shim 11 Spring 18 Joint assembly 25 Boot
5 Spring 12 Spring seat 19 Swash plate 26 Spring pin
6 Spring seat 13 Plug 20 Adjusting nut 27 Bushing
7 Stopper 14 O-ring 21 Lock nut

2-67
2. FUNCTIONS
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and apply-
ing the output pressure (secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following ele-
ments.
(1) Inlet port (P) where oil is supplied from hydraulic pump.
(2) Output ports (1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port (T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port or tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool (3) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output port pressure oil to tank port T.
The spring (5) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod (8,10) is inserted and can slide in the plug
(13).
For the purpose of changing the displacement of the push rod through the swash plate (19) and
adjusting nut (20) are provided the handle (22) that can be tilted in any direction around the fulcrum
of the universal joint (18) center.
The spring (9) works on the case (1) and spring seat (6, 12) and tries to return the push rod (8,10)
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.

2-68
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram
shown below and the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.

5 6

3
1
3
P T

2 4

2-70

1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder

2-69
(1) Case where handle is in neutral position

T 5

P
3

Port 1 Port 3

1409S2RL03

The force of the spring (5) that determines the output pressure of the pilot valve is not applied to
the spool (3). Therefore, the spool is pushed up by the spring (9) 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.

2-70
(2) Case where handle is tilted

10

Port 1 Port 3

1409S2RL04

When the push rod (10) is stroked, the spool (3) moves downwards.
Then port P is connected with port (1) and the oil supplied from the pilot pump flows through port
(1) to generate the pressure.
When the pressure at port (1) increases to the value corresponding to the spring force set by tilt-
ing the handle, the hydraulic pressure force balances with the spring force. If the pressure at port
(1) increases higher than the set pressure, port P is disconnected from port (1) and port T is con-
nected with port (1). If it decreases lower than the set pressure, port P is connected with port (1)
and port T is disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the
spool contacts with the inside bottom of the push rod and the output pressure is left to be con-
nected with port P.

2-71
GROUP 6 RCV PEDAL

1. STRUCTURE
The casing (spacer) has the oil inlet port P (primary pressure), and the oil outlet port T (tank). In
addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face.

12.4 12.4

2 1

4 3

Port Port Port size

P Pilot oil inlet port
P T T Pilot oil return port
1 Travel (LH, Forward)
PF 1/4
2 Travel (LH, Backward)
3 Travel (RH, Forward)
4 Travel (RH, Backward)
1 2 3 4
Hydraulic circuit

21092RP01

2-72
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 36 3

32
24
23 25,26
22

16
21 14
38 17
15 18
13
19
12 20
11
9
5 6
35
4 7
10
3
8

37 1 34 2
21092RP02

1 Body(1) 14 Push rod 27 Cam

2 Body(2) 15 Spring pin 28 Bushing
3 Plug 16 Seal 29 Cam shaft
4 Plug 17 Steel ball 30 Set screw
5 Spring seat 18 Spring 31 Set screw
6 Spring 19 Plate 32 Nut
7 Spring seat 20 Snap ring 33 Bellows
8 Spool 21 Plug 34 Space
9 Stopper 22 O-ring 35 O-ring
10 Spring 23 Rod seal 36 O-ring
11 Rod guide 24 Dust seal 37 Socket bolt
12 O-ring 25 Cover 38 Piston
13 Snap ring 26 Socket bolt

2-73
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.

2-74
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

2
4

36072SF01

1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder

2-75
(1) Case where pedal is in neutral position

T 8

P 10

21092RP03

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.

2-76
(2) Case where pedal is tilted

14

21092RP04

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.

2-77
SECTION 3 HYDRAULIC SYSTEM

Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 3-1

Group 2 Main Circuit --------------------------------------------------------------------------------------------------------- 3-2
Group 3 Pilot Circuit ---------------------------------------------------------------------------------------------------------- 3-5
Group 4 Single Operation ------------------------------------------------------------------------------------------------- 3-13
Group 5 Combined Operation ------------------------------------------------------------------------------------------ 3-25
SECTION 3 HYDRAULIC SYSTEM
GROUP 1 HYDRAULIC CIRCUIT
53 51 50 T(dr2) E 10 11 8 9

3 dr5
Pi1 Pi2
(Pump) (Pump)
SH
30 30
54 54 23 PS PS 23
PG
56 Rs Pn2 Pn1 V2 Pi1 PS
E

2 31 22
C6
Au
D6 Pc6 52 Pi1
49 T(dr3)
Dr
40 36 dr6 V2
35 37 27
Pd6
B
37 B5
GB GA
C 43 Puo
1 Main pump
C5 A5 2 Main control valve
Pb5
B(CW) Mu A(CCW)
D5 Pc5 3 Swing motor
27 Pa5
4 Travel motor
Pd5 5 RCV lever(LH)
DR5
P05 P04 6 RCV lever(RH)
4
RED RED C4 7 RCV pedal
D4 B4
DR3
Pc41
8 Boom cylinder(LH)
Pb4
Pa4 9 Boom cylinder(RH)
Pd40
Ps 10 Arm cylinder
Pc40
Pc42 11 Bucket cylinder
Pm2 Pm2
V3 12 Turning joint
Pm1
Pc3 Pb3 13 Check valve
DR2 42
Pa21
14 Check valve
P1 P2 T1 T2 P2 P1 C2
Pd41
27 15 Hydraulic tank
D2 Pc2
B2 16 Oil cooler
Pd2 Pb21 A2 17 Air breather
C P D
12 A Dr B DR1 18 Bypass valve
DR4
Pa20 19 Strainer
Pk P02 24 Pb20
20 Drain filter
P03 Patt
PS
B1
21 5 cartridge valve
C1
Pb1 A1 22 Pressure sensor
D1 Pc1
41 PS 24 55 23 Pressure sensor
26 34 32 T 26 A1 A2 P2 A3 A1 A2 Pd1 Pa1
24 Pressure sensor
P T P

DR0 25 Shuttle block

P0 26 Last guard filter
(1) (2) (2) (1) 24 PS Ai T1 27 Shuttle valve(option)
Pd5 Pc5 Pc6 Pd6 P1 T P1 T
Pd0 P3 P2 P1 Pu
30 Boom safety valve(option)
31 Arm safety valve(option)
5 6 BOOM 47
SWING P T ARM BUCKET P T 26 P T TRAVEL
32 RCV dozer lever(option)
7 33 EPPR valve(option)
T B 34 Breaker pedal(option)
P A
35 Accumulator(option)
Psv
(1,A) (3,B) (2,D) (4,E) (3,F) (1,G) (2,H) (4,J) (2)
Pa1
(1)
Pb1
(4)
Pd1
(3)
Pc1
A1 a4 A2 36 Accumulator(option)
A E H F GJ D B a1 a2 37 Stop valve(option)
48 22 PS PS 22 1 40 Selector valve(option)
14 13
41 Solenoid valve(option)
DR#,dr#
John Deere/ISO
16 42 Selector valve(option)
ae hf gj db
a b d e f g h j 25 43 Breaker return filter(option)
17 47 Quick clamp solenoid valve(option)
c d1 h1
1 33 26 48 Pattern change valve(option)
Pd2 Pc2 Pd40 PS Pa5 Pb5 PS 2
15 26 Pi2
Pc3 PS 24 Pc40 Pa20 Pb20 3 Pi1
(MCV, Pn1) 49 Pressure switch(option)
(MCV)
P03 Pb4 Pk Pu 20
(MCV, Pn2) ENG
a3
50 Adjust boom cylinder(option)
(MCV) (MCV) (T/Joint) (MCV) 18 PS 24 51 Adjust boom safety valve(option)
A5 A4 A3 A2 A1 21 Dr B1 B3 A3 52 Port relief valve(option)
P4 PG(S/Motor)
19 53 Dozer cylinder(option)
P3 P0(MCV)
44
P2 54 Double pressure check(opt, dozer)
P1 55 Solenoid valve(opt, dozer & adjust)
T(dr1)
1609A3HC01 56 Selector valve(opt, dozer & adjust)

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

(210-7) 3-03

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 main control valve.
The main control valve controls the hydraulic functions.
The return oil from the actuators flows to the hydraulic tank through the main control valve and the oil
cooler.

3-2
2. RETURN CIRCUIT

Check valve(2)
Full flow filter Oil cooler 1.5kgf/cm 2

Main control valve Actuators

Check valve(1)
3.0kgf/cm 2

Bypass
Bypassrelief
reliefvalve
valve
1.5kgf/cm
1.5 kgf/cm2 2

21073CI01

All oil returned from each actuator returns to the hydraulic tank through the main control valve.
The bypass check valves are provided in the return circuit.
The setting pressure of bypass check valves are 1.5 kgf/cm2 (21 psi) and 3.0 kgf/cm2 (43 psi). Usually, oil
returns to the hydraulic tank from the left side of control valve through oil cooler.
When oil temperature is low, viscosity becomes higher and flow resistance increases when passing
through the oil cooler. When the oil pressure exceeds 3.0 kgf/cm2 (43 psi), the oil returns directly to the
hydraulic tank, resulting in the oil temperature being raised quickly at an appropriate level.
When the oil cooler is clogged, the oil returns directly to the hydraulic tank through bypass check valve (1).
The full-flow filter and bypass relief valve are provided in the hydraulic tank.
The oil returned from right and left side of control valve is combined and filtered by the full-flow filter. A
bypass relief valve is provided in the full-flow filter.
When the filter element is clogged, the bypass relief valve opens at 1.5 kgf/cm2 (21 psi) differential
pressure.

3-3
3. DRAIN CIRCUIT

Travel motor Swing motor

From return line Main pump

Turning
joint

Dr#, dr#

Drain filter
Hydraulic
oil tank Dr

Check valve
1.5kgf/cm 2

21093CI02

Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil have
to be fed to the hydraulic tank passing through drain filter.
When the drain oil pressure exceed 1.5 kgf/cm2 (21 psi), 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 drain filter.
2) SWING MOTOR DRAIN CIRCUIT
Oil leaked from the swing motor returns to the hydraulic tank passing through a drain filter.
3) MAIN PUMP DRAIN CIRCUIT
Oil leaked from main pump returns to the hydraulic tank passing through drain filter.

3-4
GROUP 3 PILOT CIRCUIT

Remote control valve Remote control valve

RCV pedal (RH lever)
(LH lever)

Safety lock
solenoid valve Swing parking brake

MCV
Travel speed solenoid valve

• • Arm regeneration solenoid valve

Power boost solenoid valve

•
Boom priority EPPR valve
• Line filter
Main pump
Relief valve
40kgf/cm2
•

Pilot pump
Suction filter

(210-7) 3-05

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

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

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

Pc6

OPT-C
Pd6 (DOZER)
B5
Puo
TURNING A5
JOINT C5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
C4 P05 P04

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

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
RCV PEDAL P T TRAVEL DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

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

XBtL XAtL XAtr XBtr Dr#, dr#

SWING P T ARM BUCKET P T BOOM A1 A2 PILOT

PUMP PUMP PUMP

SAFETY
P03 Pb4 Pk Pu SOLENOID
(MCV) (MCV) (T/Joint) (MCV) VALVE
A5 A4 A3 A2 A1

P4 PG
(1) (3) (2) (4) (3) (1) (2) (4) (S/Motor)
P3 P0(MCV)
a b d e f g h j P2 HYDRAULIC TANK
d1
c h1 T P1
Pd2 Pc2 Pd40 PS Pa5 Pb5 PS
Pc3 LINE FILTER
Pc40 Pa20 Pb20
PS
1609A3HC02

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 from remote control valve is returned to the hydraulic tank.

3-6
2. SAFETY SOLENOID VALVE (SAFETY LEVER)
ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

Pc6

OPT-C
Pd6 (DOZER)
B5
Puo
TURNING A5
JOINT C5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
C4 P05 P04

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

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
RCV PEDAL P T TRAVEL DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

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

XBtL XAtL XAtr XBtr Dr#, dr#

SWING P T ARM BUCKET P T BOOM A1 A2 PILOT

SAFETY PUMP PUMP PUMP
SOLENOID
P03 Pb4 Pk Pu VALVE
(MCV) (MCV) (T/Joint) (MCV) LEVER UP
A5 A4 A3 A2 A1

PG
P4 (S/Motor)
(1) (3) (2) (4) (3) (1) (2) (4)
P3 P0(MCV)
a b d e f g h j P2 HYDRAULIC TANK
d1
c h1 T P1
Pd2 Pc2 Pd40 PS Pa5 Pb5 PS LINE FILTER
Pc3 Pc40 Pa20 Pb20
LEVER DOWN
PS 1609A3HC03

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 flows into the remote
control valve, because of the blocked port.

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

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

Pc6

OPT-C
Pd6 (DOZER)
TURNING
B5
JOINT Puo

C5 A5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
SWING MOTOR C4 P05 P04

D4 B4
DR3
Pc41
Pb4
Pa4
Pd40
Pc40 Pc42
ARM 1

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
Boom speed BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
RCV PEDAL P T TRAVEL DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

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

XBtL XAtL XAtr XBtr Dr#, dr#

SWING P T ARM BUCKET P T BOOM A1 A2 PILOT

BOOM PRIORITY PUMP PUMP PUMP
EPPR VALVE
P03 Pb4 Pk Pu
(MCV) (MCV) (T/Joint) (MCV)

A5 A4 A3 A2 A1
PG
P4 (S/Motor)
(1) (3) (2) (4) (3) (1) (2) (4)
P3 P0(MCV)
a b d e f g h j P2 HYDRAULIC TANK
d1
c h1 T P1
Pd2 Pc2 Pd40 PS Pa5 Pb5 PS
Pc3 LINE FILTER
Pc40 Pa20 Pb20
PS
1609A3HC04

When carrying out the combined operation of swing and boom up, the boom up operating speed is
lowered than normal operation.
To increase working efficiency, swing speed reducing system is used.
The pilot oil from pilot pump flow into P03 port in main control valve through boom priority EPPR
valve. P03 oil pressure moves swing reducing spool to lower position and oil flow rate to the swing
motor decreased.
Then, the boom up speed is increased. This is called the boom priority system.
The boom up speed can be adjusted by the cluster. Refer to page 3-12 of the operator's manual.

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

PILOT VALVE CONTROL PISTON

TRAVEL MOTOR
RED RED
T* T*

Ps
Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

Pc6

OPT-C
P2(BW) P1(FW) P1(FW) P2(BW) Pd6 (DOZER)
B5
Puo

C5 A5
TURNING D5 Pb5
JOINT Pc5
Pa5
Dr
OPT-B BUCKET
Pk Pd5
DR5
C4 P05 P04

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

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
RCV PEDAL P T TRAVEL DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

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

XBtL XAtL XAtr XBtr Dr#, dr#

SWING P T ARM BUCKET P T BOOM A1 A2 PILOT

TRAVEL SPEED PUMP PUMP PUMP
SOLENOID VALVE

P03 Pb4 Pk Pu
(MCV) (MCV) (T/Joint) (MCV)

A5 A4 A3 A2 A1
PG
P4 (S/Motor)
(1) (3) (2) (4) (3) (1) (2) (4)
P3 P0(MCV)
a b d e f g h j P2 HYDRAULIC TANK
d1
c h1 T P1
Pd2 Pc2 Pd40 PS Pa5 Pb5 PS
Pc3 LINE FILTER
Pc40 Pa20 Pb20
PS
1609A3HC05

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 Ps 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 Ps port returns to the hydraulic tank.
As a result, the control piston is returned by the main oil flow, thus the displacement is maximized.

3-9
5. MAIN RELIEF PRESSURE CHANGE SYSTEM
ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

Pc6

OPT-C
Pd6 (DOZER)
TURNING
B5
JOINT Puo

C5 A5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
SWING MOTOR C4 P05 P04

D4 B4
DR3
Pc41
Pb4
Pa4
Pd40
Pc40 Pc42
ARM 1

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
Auto power boost C2
BOOM 2 ARM 2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
RCV PEDAL P T TRAVEL DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

(2) (1) (4) (3) MAIN RELIEF

XBtL XAtL XAtr XBtr VALVE Dr#, dr#

SWING P T ARM BUCKET P T BOOM A1 A2 PILOT

POWER BOOST PUMP PUMP PUMP
SOLENOID VALVE
P03 Pb4 Pk Pu
(MCV) (MCV) (T/Joint) (MCV)

A5 A4 A3 A2 A1
PG
P4 (S/Motor)
(1) (3) (2) (4) (3) (1) (2) (4)
P3 P0(MCV)
a b d e f g h j P2 HYDRAULIC TANK
d1
c h1 T P1
Pd2 Pc2 Pd40 PS Pa5 Pb5 PS
Pc3 LINE FILTER
Pc40 Pa20 Pb20
PS 1609A3HC06

When the power switch on the left control lever is pushed ON, the power 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 350 kgf/cm2 to 380 kgf/cm2 for
increasing the digging power.
And even when pressed continuously, it is canceled after 8 seconds.
When the auto power function is selected to enable on the cluster, the pressure of the main relief
pressure is automatically increased to 380 kgf/cm2 as working condition by the MCU. It is operated
max 8 seconds.

3-10
6. ARM REGENERATION CUT SYSTEM
ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

Pc6

OPT-C
Pd6 (DOZER)
TURNING
B5
JOINT Puo

C5 A5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
SWING MOTOR C4 P05 P04

D4 B4
DR3
Pc41
Pb4
Pa4
Pd40
Pc40 Pc42
ARM 1
ARM
V3 REGEN
Pb3
Pc3 ARM REGEN
DR2 VALVE Pd41
Pa21
Arm regeneration C2
BOOM 2 ARM 2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
RCV PEDAL P T TRAVEL DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

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

XBtL XAtL XAtr XBtr Dr#, dr#

SWING P T ARM BUCKET P T BOOM A1 A2 PILOT

ARM REGENERATION PUMP PUMP PUMP
SOLENOID VALVE
Pb4
P03 (MCV) Pk Pu
(MCV) (T/Joint) (MCV)

A5 A4 A3 A2 A1
PG
P4 (S/Motor)
(1) (3) (2) (4) (3) (1) (2) (4)
P3 P0(MCV)
a b d e f g h j P2 HYDRAULIC TANK
d1
c h1 T P1
Pd2 Pc2 Pd40 PS Pa5 Pb5 PS
Pc3 LINE FILTER
Pc40 Pa20 Pb20
PS 1609A3HC07

When the arm regeneration is selected to disable on the cluster, the arm regeneration solenoid
valve is activated. The pilot oil from pilot pump flows into Pb4 port in main control valve through
solenoid valve and the arm regeneration spool is shifted to left.
Then, the oil from arm regeneration passage returns to tank and the arm regeneration function is
deactivated.
When the arm regeneration is selected to enable on the cluster, the arm regeneration function is
activated and arm in operation speed is increased.
Refer to page 2-36 for the arm regeneration function.

3-11
7. SWING PARKING BRAKE RELEASE
ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

Pc6

TURNING
JOINT OPT-C
Pd6 (DOZER)
B5
Puo

C5 A5
D5 Pb5
Pc5
Pa5
SWING MOTOR SH
OPT-B BUCKET
Pd5
DR5
PG C4 P05 P04

D4 B4
DR3
Pc41
Pb4
Pa4
Pd40
Pc40 Pc42
ARM 1
Dr
V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
B(cw) A(ccw) BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
RCV PEDAL P T TRAVEL DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

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

XBtL XAtL XAtr XBtr Dr#, dr#

SWING P T ARM BUCKET P T BOOM A1 A2 PILOT

PUMP PUMP PUMP

P03 Pb4 Pk Pu
(MCV) (MCV) (T/Joint) (MCV)

A5 A4 A3 A2 A1
PG
P4 (S/Motor)
(1) (3) (2) (4) (3) (1) (2) (4)
P3 P0(MCV)
a b d e f g h j P2 HYDRAULIC TANK
d1
c h1 T P1
Pd2 Pc2 Pd40 PS Pa5 Pb5 PS
Pc3 LINE FILTER
Pc40 Pa20 Pb20
PS

1609A3HC08

When one of the RCV lever (except travel lever) is tilted, the pilot oil flows into SH port through main
control valve.
This pressure moves spool so, discharged oil from pilot pump flows into swing motor PG port.
This pressure is applied to swing motor disc, thus the brake is released.
When all of the RCV lever are set in the neutral position, oil in the swing motor disc cylinder is
drained, thus the brake is applied.

3-12
GROUP 4 SINGLE OPERATION

1. BOOM UP OPERATION
ARM DOZER BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

C6

D6
Pc6

OPT-C
Pd6 (DOZER)
B5
Puo
TURNING A5
JOINT C5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
C4 P05 P04

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

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21 BOOM
BOOM 2 ARM 2 HOLDING
C2 VALVE B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 RELIEF Pb20
VALVE Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

A1 A2 PILOT
HYDRAULIC TANK PUMP PUMP PUMP

1609A3HC10

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 A1 and A2 pump flows into the main control valve and then goes to the large
chamber of boom cylinders. At the same time, the oil from the small chamber of boom cylinders
returns to the hydraulic oil tank through the boom spool in the main control valve. When this
happens, the boom goes up. The excessive pressure in the boom cylinder head side is prevented
by relief valve. When the boom is up and the control lever is returned to neutral position, the circuit
for the holding pressure at the head side of the boom cylinder is closed by the boom holding valve.
This prevents the hydraulic drift of boom cylinder.

3-13
2. BOOM DOWN OPERATION
ARM DOZER BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

C6

D6
Pc6

OPT-C
Pd6 (DOZER)
B5
Puo
TURNING A5
JOINT C5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
C4 P05 P04

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

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2
RELIEF
SWING VALVE DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

A1 A2 PILOT
HYDRAULIC TANK PUMP PUMP PUMP

1609A3HC11

When the right control lever is pushed forward, the boom 1 spool in the main control valve is moved
to the down position by the pilot oil pressure from the remote control valve.
The oil from the A2 pump flows into the main control valve and then goes to the small chamber of
boom cylinders. At the same time, the oil from the large chamber of boom cylinders returns to the
hydraulic tank through the boom 1 spool in the main control valve.
When the down speed of boom is faster, the oil returned from the large chamber of boom cylinder
combines with the oil from the A2 pump, and flows into the small chamber of the cylinder.
This prevents cylinder cavitation by the negative pressure when the A2 pump flow can not match the
boom down speed. And the excessive pressure in the boom cylinder rod side is prevented by the
relief valve.

3-14
3. ARM IN OPERATION
ARM DOZER BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

C6

D6
Pc6

OPT-C
Pd6 (DOZER)
B5
Puo
TURNING A5
JOINT C5
D5 Pb5
Pc5
MAKE UP Pa5
VALVE
OPT-B BUCKET
Pd5 RELIEF
DR5 VALVE
C4 P05 P04

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

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

A1 A2 PILOT
HYDRAULIC TANK PUMP PUMP PUMP

1609A3HC12

When the left control lever is pulled back, the arm spools in the main control valve are moved to the
arm in position by the pilot oil pressure from the remote control valve.
The oil from the A1 and A2 pump flows into the main control valve and then goes to the large
chamber of arm cylinder.
At the same time, the oil from small chamber of arm cylinder returns to the hydraulic oil tank through
the arm spool in the main control valve. When this happens, the arm rolls in.
The excessive pressure in the arm cylinder head side is prevented by relief valve.
The cavitation which will happen to the head side of the arm cylinder is also prevented by the make-
up valve in the main control valve.

3-15
4. ARM OUT OPERATION
ARM DOZER BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

C6

D6
Pc6

OPT-C
Pd6 (DOZER)
B5
Puo
TURNING A5
JOINT C5
D5 Pb5
Pc5
RELIEF Pa5
VALVE
OPT-B BUCKET
Pd5
DR5
C4 P05 P04
MAKE UP
VALVE
D4 B4
SWING MOTOR DR3
Pc41
Pb4
Pa4
Pd40
ARM
Pc40 HOLDING Pc42
ARM 1
VALVE
V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

A1 A2 PILOT
HYDRAULIC TANK PUMP PUMP PUMP

1609A3HC13

When the left control lever is pushed forward, the arm spools in the main control valve are moved to
the arm out position by the pilot oil pressure from the remote control valve.
The oil from the A1 and A2 pump flows into the main control valve and then goes to the small
chamber of arm cylinder. At the same time, the oil from the large chamber of arm cylinder returns to
the hydraulic oil tank through the arm spool in the main control valve. When this happens, the arm
rolls out. The cavitation which will happen to the rod side of the arm cylinder is also prevented by the
make-up valve in the main control valve. When the arm is roll out and the control lever is returned to
neutral position, the circuit for the holding pressure at the rod side of the arm cylinder is closed by
the arm holding valve. This prevent the hydraulic drift of arm cylinder.

3-16
5. BUCKET IN OPERATION
ARM DOZER BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

C6

D6
Pc6

RELIEF
OPT-C VALVE
Pd6 (DOZER)
MAKE UP
VALVE B5
Puo
TURNING A5
JOINT C5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
C4 P05 P04

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

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

A1 A2 PILOT
HYDRAULIC TANK PUMP PUMP PUMP

1609A3HC14

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 A2 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 bucket spool in the main control valve. When this happens, the bucket rolls in.
The excessive pressure in the bucket cylinder head side is prevented by relief valve.
The cavitation which will happen to the head side of the bucket cylinder is also prevented by the
make-up valve in the main control valve.

3-17
6. BUCKET OUT OPERATION
ARM DOZER BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

C6

D6
Pc6
MAKE UP
VALVE RELIEF
OPT-C VALVE
Pd6 (DOZER)
B5
Puo
TURNING A5
JOINT C5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
C4 P05 P04

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

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

A1 A2 PILOT
HYDRAULIC TANK PUMP PUMP PUMP

1609A3HC15

When the right control lever is pushed right, the bucket spool in the main control valve is moved to
the bucket out position by the pilot oil pressure from the remote control valve.
The oil from the A2 pump flows into the main control valve and then goes to the small chamber of
bucket cylinder.
At the same time, the oil from the large chamber of bucket cylinder returns to the hydraulic oil tank
through the bucket spool in the main control valve. When this happens, the bucket rolls out.
The cavitation which will happen to the rod side of the bucket cylinder is also prevented by the
make-up valve in the main control valve.

3-18
7. DOZER UP OPERATION
ARM DOZER BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

C6

D6
Pc6

OPT-C
Pd6 (DOZER)
B5
Puo
TURNING A5
JOINT C5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
C4 P05 P04

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

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

A1 A2 PILOT
HYDRAULIC TANK PUMP PUMP PUMP

1609A3HC16

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 A1 pump flows into the main control valve and then goes to the small chamber of
dozer cylinder.
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.

3-19
8. DOZER DOWN OPERATION
ARM DOZER BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

C6

D6
Pc6

OPT-C
Pd6 (DOZER)
B5
Puo
TURNING A5
JOINT C5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
C4 P05 P04

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

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

A1 A2 PILOT
HYDRAULIC TANK PUMP PUMP PUMP

1609A3HC17

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 A1 pump flows into the main control valve and then goes to the large chamber of
dozer cylinder.
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 goes down.

3-20
9. SWING OPERATION
ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

C6
D6
Pc6

TURNING
JOINT OPT-C
Pd6 (DOZER)
B5
Puo

C5 A5
D5 Pb5
Pc5
Pa5
SWING MOTOR SH
OPT-B BUCKET
Pd5
DR5
PG C4 P05 P04

D4 B4
DR3
Pc41
Pb4
Pa4
Pd40
Pc40 Pc42
ARM 1
Dr
V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
B(cw) A(ccw) BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
RCV PEDAL P T TRAVEL DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

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

XBtL XAtL XAtr XBtr Dr#, dr#

SWING P T ARM BUCKET P T BOOM A1 A2 PILOT

PUMP PUMP PUMP

P03 Pb4 Pk Pu
(MCV) (MCV) (T/Joint) (MCV)

A5 A4 A3 A2 A1
PG
P4 (S/Motor)
(1) (3) (2) (4) (3) (1) (2) (4)
P3 P0(MCV)
a b d e f g h j P2 HYDRAULIC TANK
d1
c h1 T P1
Pd2 Pc2 Pd40 PS Pa5 Pb5 PS
Pc3 LINE FILTER
Pc40 Pa20 Pb20
PS 1609A3HC18

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.
Also the swing operation preference function is operated by the pilot pressure Pc3 (refer to page
2-38).
The oil from the A1 pump flows into the main control valve and then goes to the swing motor.
At the same time, the return oil from the swing motor returns to the hydraulic oil tank through the
swing spool in the main control valve.
When this happens, the upper structure swings to the left or right.
The swing parking brake, make up valve and the motor brake valve are provided in the swing motor.
The cavitation which will happen to the swing motor is also prevented by the make up valve in the
swing motor itself.
3-21
SWING CIRCUIT OPERATION

SWING MOTOR DEVICE

PARKING BRAKE

SH BRAKE OFF
BRAKE RELEASE VALVE
PG

BRAKE ON
Au
Dr

ANTI-INVERSION VALVE
MOTOR BRAKE VALVE
MAKE UP VALVE

GA GB

B(cw) A(ccw)
MAKE UP
PORT(Mu)

TO / FROM MAIN CONTROL VALVE

14W93HC18A

1) MOTOR BRAKE VALVE

Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing
operation and controls the swing motor operating pressure.
2) MAKE UP VALVE
The make up valves prevent cavitation by supplying return oil to the vacuum side of the motor.
3) PARKING BRAKE
This is function as a parking brake only when all of the RCV lever (except dozer lever and travel
pedal) are not operated.
PARKING BRAKE "OFF" OPERATION
The parking brake is released by the pilot pressure oil from the pilot pump.
When the RCV lever placed in the operating position, the pilot oil flows into SH port through the
MCV. This pressure transferred to the brake release valve and the brake release valve is change
over. Then the pilot oil pressure PG lift the brake piston and release the parking brake.
PARKING BRAKE "ON" OPERATION
When all of the RCV 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".
4) ANTI-INVERSION VALVE
This anti-inversion valve absorbs shocks produced as swing motion stops and reduced oscillation
cause by swing motion.

3-22
8. TRAVEL FORWARD AND REVERSE
REVERSE OPERATION
OPERATION
ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR
RED RED
T* T*

Ps
Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

C6
D6
Pc6

OPT-C
P2(BW) P1(FW) P1(FW) P2(BW) Pd6 (DOZER)
B5
Puo

C5 A5
TURNING D5 Pb5
JOINT Pc5
Pa5
Dr
OPT-B BUCKET
Pk Pd5
DR5
C4 P05 P04

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

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
RCV PEDAL P T TRAVEL DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

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

XBtL XAtL XAtr XBtr Dr#, dr#

SWING P T ARM BUCKET P T BOOM A1 A2 PILOT

PUMP PUMP PUMP

P03 Pb4 Pk Pu
(MCV) (MCV) (T/Joint) (MCV)

A5 A4 A3 A2 A1
PG
P4 (S/Motor)
(1) (3) (2) (4) (3) (1) (2) (4)
P3 P0(MCV)
a b d e f g h j P2 HYDRAULIC TANK
d1
c h1 T P1
Pd2 Pc2 Pd40 PS Pa5 Pb5 PS
Pc3 LINE FILTER
Pc40 Pa20 Pb20
PS
1609A3HC19

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 each pump flows into the main control valve and then goes to the each travel motor
through the turning joint.
The return oil from both travel motors returns to the hydraulic oil tank through the turning joint and
the travel spools in the main control valve.
When this happens, the machine moves to the forward or reverse.

3-23
TRAVEL CIRCUIT OPERATION

TRAVEL MOTOR DEVICE

RED RED

Ps

Pm1 Pm2 Pm2

Pm1

P1(FW) P2(BW) T1 T2 P2(BW) P1(FW)

OVERLOAD RELIEF TURNING COUNTER BALANCE

VALVE JOINT VALVE

dr
Pk
TO/FROM MAIN CONTROL VALVE

16093HC19A

Valves are provided on travel motors to offer the following functions.

1) COUNTER BALANCE VALVE

When stopping the motor of slope descending, this valve to prevent the motor over run.
2) OVERLOAD RELIEF VALVE
Relief valve limit the circuit pressure below 350 kgf/cm2 to prevent high pressure generated at a time
of stopping the machine. Stopping the motor, this valve sucks the oil from lower pressure passage
for preventing the negative pressure and the cavitation of the motor.

3-24
GROUP 5 COMBINED OPERATION
1. OUTLINE
ARM DOZER BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

C6

D6
Pc6

OPT-C
Pd6 (DOZER)
B5
Puo
TURNING A5
JOINT C5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
C4 P05 P04

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

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

STRAIGHT
TRAVEL A1 A2 PILOT
HYDRAULIC TANK SPOOL PUMP PUMP PUMP

1609A3HC23

The oil from the A1 and A2 pump flows through the neutral oil passage, bypass oil passage and
confluence oil passage in the main control valve. Then the oil goes to each actuator and operates
them. Check valves and orifices are located on these oil passage in the main control valve. These
control the oil from the main pumps so as to correspond to the operation of each actuator and
smooth the combined operation.

STRAIGHT TRAVEL SPOOL

This straight travel spool for straight travel is provided in the main control valve.
If any actuator is operated when traveling, the straight travel spool is pushed to the right by the pilot
oil pressure.
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.

3-25
2. COMBINED SWING AND BOOM UP OPERATION
ARM DOZER BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

C6

D6
Pc6

OPT-C
Pd6 (DOZER)
B5
Puo
TURNING A5
JOINT C5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
C4 P05 P04

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

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(L) SH
TRAVEL(R)
DR0 (S/Motor)

P0
PS T1
Ai
P2 P1 Pu

A1 A2 PILOT
HYDRAULIC TANK PUMP PUMP PUMP

1609A3HC24

When the swing and boom up functions are operated, simultaneously the swing spool and boom
spools in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve.
The oil from the A1 pump flows into the swing motor through swing spool and the boom cylinder
through boom 2 spool.
The oil from the A2 pump flows into the boom cylinders through the boom 1 spool in the right control
valve.
The super structure swings and the boom is operated.
Refer to page 3-8 for the boom priority system.

3-26
3. COMBINED SWING AND ARM OPERATION
ARM DOZER BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

C6

D6
Pc6

OPT-C
Pd6 (DOZER)
B5
Puo
TURNING A5
JOINT C5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
C4 P05 P04

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

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

A1 A2 PILOT
HYDRAULIC TANK PUMP PUMP PUMP

1609A3HC25

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 A1 pump flows into the swing motor through swing spool and the arm cylinder
through arm 1 spool.
The oil from the A2 pump flows into the arm cylinder through the arm 2 spool of the right control
valve.
The super structure swings and the arm is operated.

3-27
4. COMBINED SWING AND BUCKET OPERATION

ARM DOZER BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

C6

D6
Pc6

OPT-C
Pd6 (DOZER)
B5
Puo
TURNING A5
JOINT C5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
C4 P05 P04

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

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1

TRAVEL(R) TRAVEL(L) SH
DR0 (S/Motor)
P0
PS T1
Ai
P2 P1 Pu

A1 A2 PILOT
HYDRAULIC TANK PUMP PUMP PUMP

1609A3HC26

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 A1 pump flows into the swing motor through the swing spool in the left control valve.
The oil from the A2 pump flows into the bucket cylinder through the bucket spool in the right control
valve.
The super structure swings and the bucket is operated.

3-28
5. COMBINED SWING AND TRAVEL OPERATION

ARM DOZER BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

C6

D6
Pc6

OPT-C
Pd6 (DOZER)
B5
Puo
TURNING A5
JOINT C5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
C4 P05 P04

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

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1
SH
TRAVEL(R) TRAVEL(L) (S/Motor)
DR0
P0
PS T1
Ai
P2 P1 Pu

STRAIGHT
TRAVEL A1 A2 PILOT
HYDRAULIC TANK SPOOL PUMP PUMP PUMP

1609A3HC27

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 right by the pilot oil pressure from the
pilot pump.
The oil from the A1 pump flows into the travel motors through the RH travel spool of the left control
valve and the LH travel spool of the right control valve via the straight travel spool.
The oil from the A2 pump flows into the swing motor through the swing spool and travel motor
through the LH travel spool via the check valve and orifice in the straight travel spool.
The upper structure swings and the machine travels straight.

3-29
6. COMBINED BOOM AND TRAVEL OPERATION
ARM DOZER BUCKET BOOM
CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

C6

D6
Pc6

OPT-C
Pd6 (DOZER)
B5
Puo
TURNING A5
JOINT C5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
C4 P05 P04

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

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1
SH
TRAVEL(R) TRAVEL(L) (S/Motor)
DR0
P0
PS T1
Ai
P2 P1 Pu

STRAIGHT
TRAVEL A1 A2 PILOT
HYDRAULIC TANK SPOOL PUMP PUMP PUMP

1609A3HC28

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 right by the oil pressure from pilot
pump.
The oil from the A1 pump flows into the travel motors through the RH travel spool of the left control
valve and the LH travel spool of the right control valve via the straight travel spool.
The oil from the A2 pump flows into the boom cylinders through the boom 2 spool and boom 1 spool
via the parallel and confluence oil passage in case boom up operation. Also, the oil from the A2
pump flows into the travel motors through the LH travel spool via the check valve and orifice in the
straight travel spool.
The boom is operated and the machine travels straight.

3-30
7. COMBINED ARM AND TRAVEL OPERATION

ARM DOZER BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

C6

D6
Pc6

OPT-C
Pd6 (DOZER)
B5
Puo
TURNING A5
JOINT C5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
C4 P05 P04

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

V3
ARM REGEN
Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1
SH
TRAVEL(R) TRAVEL(L) (S/Motor)
DR0
P0
PS T1
Ai
P2 P1 Pu

STRAIGHT
TRAVEL A1 A2 PILOT
HYDRAULIC TANK SPOOL PUMP PUMP PUMP

1609A3HC29

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 right by the oil pressure from pilot pump.
The oil from the A1 pump flows into the travel motors through the RH travel spool of the left control
valve and the LH travel spool of the right control valve via the straight travel spool.
The oil from the A2 pump flows into the arm cylinders through the arm 1 spool and arm 2 spool via
the parallel and confluence oil passage. Also, the oil from the A2 pump flows into the travel motors
through the LH travel spool via the check valve and orifice in the straight travel spool.
The arm is operated and the machine travels straight.

3-31
8. COMBINED BUCKET AND TRAVEL OPERATION

ARM DOZER BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER

TRAVEL MOTOR

Pi1(Pump) Pi2(Pump)
Rs PS Pn2 Pn1 PS

C6

D6
Pc6

OPT-C
Pd6 (DOZER)
B5
Puo
TURNING A5
JOINT C5
D5 Pb5
Pc5
Pa5

OPT-B BUCKET
Pd5
DR5
C4 P05 P04

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

V3 ARM
REGEN Pb3
Pc3
DR2 Pd41
Pa21
BOOM 2 ARM 2
C2
B2
D2 Pc2
Pd2 Pb21 A2

SWING DR1
DR4 Pb20
Pa20
P02
BOOM 1
P03 Patt
PS
B1
C1

D1 Pc1 Pb1 A1

Pd1 Pa1
SH
TRAVEL(R) TRAVEL(L) (S/Motor)
DR0
P0
PS T1
Ai
P2 P1 Pu

STRAIGHT
TRAVEL A1 A2 PILOT
HYDRAULIC TANK SPOOL PUMP PUMP PUMP

1609A3HC30

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 right by the oil pressure from pilot
pump. The oil from the A1 pump flows into the travel motors through the RH travel spool of the left
control valve and the LH travel spool of the right control valve via the straight travel spool of the
control valve.
The oil from the A2 pump flows into the bucket cylinder through the bucket spool via the confluence
oil passage. Also, the oil from the A2 pump flows into the travel motors through the LH travel spool
via the check valve and orifice in the straight travel spool.
The bucket is operated and the machine travels straight.

3-32
SECTION 4 ELECTRICAL SYSTEM

Group 1 Component Location ----------------------------------------------------------------------------------------- 4-1

Group 2 Electrical Circuit -------------------------------------------------------------------------------------------------- 4-3
Group 3 Electrical Component Specification ------------------------------------------------------------------ 4-21
Group 4 Connectors --------------------------------------------------------------------------------------------------------- 4-29
SECTION 4 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION

1. LOCATION 1

26 25
27 24
28 23
29
30
B
A
C

22
21
1 20
2 19
3
4
5
6 Fuel tank
7 16
8
9 15
10 18
11

17
AIR

CN-16&16A
CN-16B

14
13
12

1409A4EL12

1 Cigar lighter 11 Air compressor switch 21 Heated seat switch

2 Air conditioner switch 12 Safety lever 22 Speaker
3 Remote controller 13 Power max switch 23 Overload switch
4 Accel dial switch 14 One touch decel switch 24 Beacon switch
5 Horn switch 15 Emergency engine connector 25 Quick clamp switch
6 Breaker operation switch 16 Fuse & relay box 26 Cab light switch
7 Handsfree 17 Master switch 27 Travel alarm switch
8 Start switch 18 Machine control unit 28 Washer switch
9 Cluster 19 RS232 & J1939 service socket 29 Wiper switch
10 Hour meter 20 Radio & USB player 30 Main light switch

4-1
2. LOCATION 2

4
24
1 1

11

1 26
BOOM BOOM SAFETY VALVE SOLENOID VALVE CAB

2 8 9 10 25
12
13
3 14
16
5

15 6

23
7
Ai 22
1 Pd6
Patt
27

d1 h1

17
18
c 21
Pn2
Pn1

19 20
SHUTTLE BLOCK MAIN CONTROL VALVE
1609A4EL13

1 Lamp 10 P3 pressure sensor 19 Swing pressure sensor

2 Fuel sender 11 Overload pressure sensor 20 Negative 1 pressure sensor
3 Fuel filler pump 12 Heater relay 21 Negative 2 pressure sensor
4 Beacon lamp 13 Alternator 22 Attach pressure sensor
5 Battery 14 Start relay 23 Travel pressure sensor
6 Battery relay 15 Air cleaner switch 24 Solenoid valve
7 Horn 16 Travel alarm buzzer 25 Pump EPPR valve
8 P1 pressure sensor 17 Arm / Bucket in pressure sensor 26 Boom priority EPPR valve
9 P2 pressure sensor 18 Boom up pressure sensor 27 Dozer pressure switch

4-2
GROUP 2 ELECTRICAL CIRCUIT (1/2)

AC COMP RY
CS-74A
R/DRYER 5R 146 146 5R

CS-74
1

87a 87 85

30 86
WASHER P/P 145 8W 143 5R

Pa
MASTER SW ECM 139 1.2Gr 2
CAMERA POWER RY

M
CABIN LAMP RY POWER RY 138

CN-22
ADJUST BOOM

CN-29

DO-5
FUSE BOX

CR-7
60A

87a
CN-95

2
30

1
2
86

87a 87 85
85
87

30 86
2
1
8W 145 MASTER SW

CN-263

87a 87 85

10
1

11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
30 86

00
1
2
3
4
5
6
7
8
9
2

CN-259
8W 144

AIR COPM POWER

5

30A
ROOM LAMP/CASSETTE 10A
30A
30A
20A
10A
10A

20A
20A
10A
10A
10A
20A
30A
30A
10A
20A
30A
20A
10A
20A
10A
20A
20A
20A
20A
20A
10A
20A
10A
1

0.8GrW

5A
0.8GrW

145A
2

1
2
1

4
5
6
3
1.2Br
CS-74

1.2G

3W
1.2Br

CR-35
4

153
0.8V
0.8L
0.8L

0.8V
CIRCUIT BREAKER

CR-45
0.8V

87a
30
86

85
87
CR-9
143

CABIN LAMP(OPTION)
87a
5R

AFTERTREATMENT SIG
30
86

85
87

5
2

4
3
0.8W
148A
148E

CN-258
0.8R
0.8B

CS-74B
BATTERY

5W
5R 142

149
150

0.8RB
CN-11

5B
39E

OPTION(BEACON)
13A
149

AIR CON/HEATER
NO.

SH
DESTINATION 1

DPF IDENTIFICATION
39A

1.2B

0.8WOr
60

1
13

0.8WOr
2B 129

SWITCH PANEL

FUEL FEED P/P

PTC POWER
1
2

2WR

SUPPLY POWER
1 AC GND CN-60

FUEL HEATER
0.8B

SUPPLY POWER
1 30A

1.2Gr
0.8W
0.8Gr

AC& HEATER
2W
0.8B
60B

START,STOP
60R

SAFETY SOL
CONVERTER

TEMP SENSOR
WORK LAMP
151

0.8R
0.8G

CN-255
SOLENOIDE

SOLENOIDE
MCU CONT.

HEAD LAMP

DPF INLET TEMP

START KEY
2 BLOWER SIG.

00
00

2R

MCU EPPR

CASSETTE
2

2V
00
00

PRE-HEAT

AIR INLET TEMP

G14

CLUSTER
138

CLUSTER

2
1
2L 148

FUEL P/P
2W
2W

138
3 AC 24V 3

G3

RETURN
WIPER

RETURN
23
34

WIPER

CIGAR
CN-36
140
140A

HORN
FUEL PUMP

23E

139

SEAT
21
30
4 REVERSE FAN CR-1

ECM
G2

ECM
MCU
4

34
12V X 2

C
3Y 147

CD-98
5 AC CONTROLLER B+ 5 G23 1.2B

nc
M
150

00
00
1.2G

CD-97
6 AC COMP

CD-10
2
1
6 141 1.2G TO:STARTER "B" TERM.
7 AC CONDENSOR FAN FUEL HEATER RY

6
3
7

1
3
4
2
1
39 0.8GrW

2
14 1.2ROr

BREAKER RY
0.8RW

79 1.2RW

32 0.8RW
10E

78 1.2R
25 0.8Y
0.8ROr

56 0.8Or

0.8Gr

18 1.2Or
16 1.2Gr

47 1.2Or
50 1.2Br

20 1.2Br
FUEL HEATER

57 3W

23 2W

CN-61
130 2RW
8 ILLUMINATION

12 0.8R

86 1.2R
147 3Y

26 0.8V

17 1.2V

131 0.8Y
124 0.8V

134 1.2V
8

132 0.8L

00
00
BATT RY

3
140 2R

126 2Y
75 2L

148 2L

87a 87 85

30 86

DPF SOOT SENSOR

1
2

SUPPLY POWER
4
AIR-CON HARNESS

CR-62
DO-3

00
00

2W
2W
2W
2W

2B
3W/120?
CN-96

2B
141E 0.8G

5
2

CAN Shield
1

5
2

4
3
2B
2Y
0.8B 4

4
1
2
3
G24 0.8B

RETURN
CR-46

7A
7E
1

7A

7E
87a
FEED PUMP RY

8
30
86

85

8
87

CAN+
CAN-

2
1
0.8BW
0.8Or
0.8Br

1.2Br
2Br
2B

G21
126
CN-5 FUEL

87a 87 85

30 86

CD-10
0.8Y 1 FEED PUMP
1 CLUSTER TX 1

G31
0.8V
0.8L

2
1

2W
133

5
6

2W
4
2Br

2
1
0.8L 2

2L

159

136
2 CLUSTER RX

40
18
2

M
CN-22
SH 3G
CN-93

75A
133
122
3 SHIELD

CR-7
3

7A
7E
87a
75
4 10 1.2A

30
0.8B

86

85
87
2
1
CN-249 48 BATTERY(+)

2W
2W
4 CLUSTER GND 4

2W
2W
9 1.2A

2B
2B
0.8Gr 5 ECM SH 00
5 CLUSTER IG 5 1 52 BATTERY(+)
0.8RW 6 EARTH 2 0.8B 00 18 1.2A

7A
7E
1.2GrW
6 CLUSTER BATT.24V 53 BATTERY(+)

1.2Br
6 2

7A
7E
1.2V
1.2L
0.8L
3.0R 19 1.2A

8
8
1.2Rw 0.8W 00

1.2V
7 DOZER & 2-PCS SW(IG) 7 3 55 BATTERY(+)
1.2Bw 0.8R 00 19 1.2A
8 DOZER & 2-PCS SW 8 57 BATTERY(+)

148A
148E
4 20 1.2A
82

149
0.8BW 61 BATTERY(-)

60
9 P DUMP(SERVICE CONN.) 9

39A
CAMERA 20 1.2A

13
0.8Br 7
10 QUICK COUPLER SW NO 10 63 BATTERY(-)
0.8V 8 1 1.2A
11 OVERLOAD SW COM 11 65 BATTERY(-)
0.8VOr 9 2 1.2A
12 OVERLOAD SW NO 12
CN-3 67 BATTERY(-)
0.8ROr 10A 2 1.2A
13 ILLUMINATION 13 1 69 BATTERY(-)
0.8W 11 00 SH SH 00 3 0.8A
14 HOUR METER SIG. 14 2 50 CAN A Hi
0.8G 74 00 0.8B 0.8B 00 4 0.8A
15 RS232 RX(SERVICE CONN.) 15 3 34 CAN A Lo
0.8R 73 00 0.8W 0.8W 00 4 0.8A
16 RS232 TX(SERVICE CONN.) 16 4 42 CAN A SHIELD
0.8B 3F 00 0.8R 0.8R 00 5 0.8A
17 GND(SERVICE CONN) 17 5 70 KEY SWITCH"ON"
0.8R 12 3.0R 2.0R 2.0R 3.0R
18 WIPER CONT BATT.24V 18 6 00 NC
0.8V 13 0.8R 0.8R
19 WIPER CONT WASHER P/P DRIVE 19 7 00 NC
51A 18 0.8A
0.8V 8 18 SWITCH RETURN
20 CAN Hi(SERVICE CONN) 20 18 0.8A
0.8G 52A 51 0.8V
21 CAN Lo(SERVICE CONN) 21 9 2 5V SENSOR POWER
53A 52 0.8G 18 0.8A
SH 10 3 5V SENSOR RETURN
22 CAN SHIELD 22 2.0SQ 18 0.8A
2.0SQ
23 CAMERA 2 23 11 4 8V DIGITAL POWER SUPPLY
39 54 0.8ROr 18 0.8A
0.8GrW 12 5 DIGITAL RETURN
24 WIPER IG 24 18 0.8A
1.2ROr 14 55 0.8BOr
25 SPARE 25 13 14 AFTERTREATMENT ID SIG
15 56 0.8Or 18 0.8A
1.2B 14 17 AIR INLET TEMP SENSOR
26 HEAT SEAT GND 26 57A 18 0.8A
1.2Gr 16 2W
27 CIGAR LIGHTER IG 27 15 20 GLOW PLUG RY+
17 18 0.8A
1.2V 16 21 LIFT PUMP RY-
28 DC-DC CONVERTER 24V 28 18 0.8A
1.2Or 18
29 BREAKER SW COM(IG) 29 17 22 IVS SW1
1.2B 19A
30 GND 30 19 2B 18 25 NC
19E 18 0.8A
1.2B 19 26 DPF INLET TEMP SENSOR
31 GND 31 18 0.8A
32 NC 32 20 35 WATER IN FUEL SW
20 66 G 18 0.8A
1.2Br 21 37 CAN C+(DPF SOOT)
33 BEACON SW COM(IG) 33 18 0.8A
1.2V 21A 21 2V 66 G
34 CABIN LIGHT 34 22 38 CAN C-(DPF SOOT)
22 66 G 18 0.8A
0.8BOr 23 39 CAN C- SHIELD
35 START KEY SW START 35 18 0.8A
1.2W 23A
36 START KEY SW COM 36 24 49 COOLANT LEVEL SW
66 G 18 0.8A
37 CAMERA 3 37 25 59 DIGITAL RETURN
21E 0.8W 18 0.8A
0.8V 26 2 66 ACTIVE ANALOGUE
38 CABIN LIGHT 38 0.8
39 REVERSE FAN AUTO 39 1 8 PDL+
40 REVERSE FAN MANUAL 40
CN-2 3W/120? 9 PDL-
0.8BrW 77 1
41 RS232 RX2(GPS) 41 46 Elevate Idle
0.8GrW 76 2
42 RS232 TX2(GPS) 42 0.8 0.8
43 NC 43 3
0.8 0.8
4 CN-28
44 NC 44 00 0.8R 8 1.2V
0.8R 00 1
45 NC 45 5
0.8Y 25 00 0.8R 0.8R AC COMP
46 CASSETTE RADIO BATT.24V 6
46
0.8V 26 7
47 CASSETTE RADIO IG 47 CR-23 CN-45
0.8B 27 8
48 CASSETTE RADIO GND 48 15 1.2BOr M
49 SWITCH PANEL HEAD LIGHT 49
0.8BrW 28
52 0.8G
9
0.8G 2 16 1.2B
2 M
0.8VW 29 10 1
50 SWITCH PANEL WORK LIGHT 50
0.8B 00 11 FROM BATT.RY
51 CAMERA GND 51 54 0.8ROr 0.8ROr 4 START RY. B+
0.8W 00 12
52 CAMERA SIG. 52 55 0.8BOr 5
SH 00 13
0.8BOr STARTER
53 CAMERA SHIELD 53 56 0.8Or 0.8Or 6
54 SWITCH PANEL PREHEAT 54 14
0.8Gr 30 15 15 R CN-74
55 SWITCH PANEL CABIN LAMP 55 57E 1.2W 1.2W 7A RS-1
0.8YW 31 16
56 SWITCH PANEL TRAVEL ALARM 56 57E 1.2W 1.2W 7A 2 B+
0.8RW 32 17 3W/300
57 SWITCH PANEL IG 57 57E 1.2W 1.2W 7A 1 G
0.8B 33 1 P
58 SWITCH PANEL GND 58
0.8WOr 34 57E 1.2W
18
1.2W 7A 17 1.2W
2 L
3 ~
59 START SW ACC 59 19
3 U
0.8GW 35 20 FI
60 START SW BR 60
4 NC

ALT.
CN-8 CR-24
15R
1 NC 1 12 1.2GrW
CD-45 CN-80
2 NC 2 0.8B
3 15R
3 NC 3 0.8V
2
4 NC 4 0.8R
1 GLOW PLUG RY GLOW PLUG
5 GND 5
6 NC
WIF SENSOR
6
7 ACCEL DIAL LED 7 CD-16
0.8 B 3
8 AIR COMP SW POWER 8 C RETURN
0.8 Gr 49
9 SPARE 9 B SIGNAL
0.8 R 2
10 DPF COM 10 A SUPPLY POWER 5V
11 SPARE 11 WATER LEVEL SENSOR
12 AIR COMP RY 12
CR-36
CN-7 55 0.8BOr
1
1 PWM SUPPLY 1 54 0.8ROr 4 5 1
2
2 PWM GND 2 132 0.8L
3
3 PWM TILT SIGNAL 3 4
1.2ROr 14 61 0.8GrW
4 NC 4 3 2
5
0.8Or 18
5 BREAKER SW 5 PRE-HEAT RY
0.8BW 40
6 BREAKER SW 6 CR-5
0.8B G42 123 0.8Br
7 HORN 7 1
0.8GrW 41 22 1.2BOr 4 5 1
8 HORN 8 2
131 0.8Y
9 BUTTON 2 9 3
10 BUTTON 2 10 4
CN-264 64 0.8BOr 3 2
11 BUTTON 1 11 5
153 0.8
12 BUTTON 1 12 2
ANTI-RESTART RY
145A 0.8
13 AIR COMP SW 13 1
0.8Gr 42
14 ACCEL DIAL SUPPLY 14 CR-13
0.8W 43 AIR COMP RY 50 1.2Br
15 ACCEL DIAL SIGNAL 15 30
0.8B 44 50A 0.8Br 87a 87 85
16 ACCEL DIAL GND 16 86
10 1.2ROr
RH CONSOLE HARNESS CN-4 28 0.8BrW
87
85
1 PWM SUPPLY 1 30 86
87a
2 PWM GND 2
HEAD LAMP RY
3 PWM ROTATE SIGNAL 3 CL-4
4 EM'CY STOP SW 4 G22 1.2B
2
0.8Y 46 10 1.2ROr
5 POWER MAX SW 5 1
0.8BW 81T
6 POWER MAX SW 6 CN-126A HEAD LAMP
0.8GrW 48
7 ONE TOUCH DECEL 7 J NC
0.8BW 81U CL-24
8 ONE TOUCH DECEL 8 H NC G22 1.2B
1

Service Tool
0.8G
9 BUTTON 2 9 G CAN2 Hi 10 1.2ROr
0.8G 2
10 BUTTON 2 10 F CAN Lo
11 BUTTON 1
0.8V HEAD LAMP REAR
11 E PDL-
0.8B CL-3
12 BUTTON 1 12 D PDL+ G22 1.2B
1
13 EM'CY STOP SW 13 C NC 10 1.2ROr
1.2B G41 0.8G 2
14 SAFETY SW COM 14 B GND
0.8R HEAD LAMP
15 SAFETY SW NC 15 A IG 24V
1.2G 49
16 SAFETY SW NO 16

LH CONSOLE HARNESS CN-12 CL-5

CN-68 G11 2B 2E B
1 1
1.2G 49 128 2RG 1E V
1 2 2
2
1.2V 134 CN-16B
0.8B 67 CR-4 WORK LAMP
1 130 2A B
SAFETY SOL 2.5k 0.8W 68 2RW
30 1
2 1A V
CN-140 0.8Gr 69 130A 0.8RW
86
87a 87 85
2
B 152 3
1 0.8LW 58 128 2RG
0.8Br 7 2.5k
4
87 CL-6
2 0.8BW 59 29 0.8VW
85
5
QUICK CLAMP 30 86
87a
6
CD-10A WORK LAMP RY
1.2BW 81S CN-16
Pa 1.2YOr 83 44 0.8B 0.8B 37
1
43 0.8W 0.8W 99 CR-2
2 41 0.8GrW
AIR CLEANER SW 42 0.8Gr 0.8Gr 36 1
3 124A 0.8V 4 5 1
CD-2 2
1.2BW 81R 4 124 0.8V
1 3
1.2YOr 100 5 CN-25
2 4 G12 1.2B
6 127 1.2G 1
5 3 2 127 1.2G
FUEL LEVEL 2
CD-1 HORN RY
1.2BW
HORN
81Q G13 1.2B
C 1
1.2LOr 101 1
2 127 1.2G
2
HYD TEMP CN-20

0.8Br 103
80P

81P
107
85

84

0.8RW 102

G32
47E
0.8LOr 120

0.8GW 121
158

136
CN-242

0.8ROr 80
98
81
116 0.8RW
0.8ROr

1.2BW

2
0.8G

0.8V
0.8L

0.8BW
0.8BW
117 0.8LW

1.2Or

0.8Br

0.8Br
1

0.8B
ATT FLOW
CN-1

10
2

6
7
8
9
1

4
3

CN-15

10
11
12
2

6
7
8
9
1

4
3

5
2B 3
1
2
3
4
5

6
7

10
11
2B

1
2
3

4
5
6
7
0.8RW 104
0.8RW 106

0.8GW 121
0.8LOr 120
158
1.2BrW 119
1.2GOr 118

123
122

107

151

0.8RW 116

1.2RW 102

117

103
105
1.2LOr 101

1.2YOr 100
3E

3A
80
81

0.8BrW 77

66
71

82

0.8GrW 76
72

78
79

36
37

53

11
70
51
0.8YW 71

73

52
72

74

99

0.8WOr 96
0.8BOr 94
0.8YW 92
0.8OrW 90
88

84

0.8BW 98

91

87
85

86

97

1.2YOr 83

46

0.8YW 31

0.8YW 31
0.8GrW 48
2

1
3

0.8VOr 9
1.2ROr
1.2RW

1.2BW

0.8BW

0.8LW

0.8LW

0.8LW
0.8YW
0.8LW

0.8Gr

0.8Gr
0.8Br

0.8Br

1.2Br
0.8W

0.8W

0.8W

0.8W
0.8G

0.8G

0.8G

0.8G

0.8G
1.2R

0.8R

1.2R
1.2B

0.8B

1.2B

0.8V
0.8V

0.8Y

0.8V

0.8Y

1.2B

0.8Y
0.8L

0.8L
80M

81M

80G

81G
80H

81H

SH
80E

81E

80A

81A
80L

81L

80A

81A
80J

81J

47G
87

88

0.8OrW 90

91

92

94

0.8WOr 96

107
8

CN-244

47G

G5
105
104
CN-51

CN-52

CN-53

107
106
1.2ROr

1.2ROr

1.2ROr

1.2ROr

1.2ROr

1.2ROr

1.2ROr

47A
0.8BOr

70
1.2ROr
1.2BW

1.2BW

1.2BW

1.2BW

0.8YW
1.2BW

1.2BW

1.2BW

118
0.8LW

1.2BW

119
0.8Br

47
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
37
38
39
40

10
11
12
13
14
15
16
17
18
19
20
21
22
23
SWING PRESS SENSOR 24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

10
11
12
13
14
15
16
17
18
BOOM PRIORITY EPPR- 19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
0.8Y

0.8V

1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9
1
2
0.8GOr

1.2ROr
1.2ROr 2A

1.2ROr 2E

0.8BW
1.2BW
1.2Or
1.2BW 4E

0.8YW
1.2BW 4A

0.8V
1

1.2ROr 2

0.8RW
0.8Or
3

ARM IN OUT BUCKET IN PRESS

1.2BW 4

6
1.2RW 7

TRAVEL PRESS SENSOR(A)

TRAVEL/WORK SELECT SW

1.2GOr
WATER TEMP SENDOR

1.2BrW
0.8RW
BOOM PRIORITY EPPR+
TWO WAY SAFETY SOL

0.8B
BOOM UP PRESS SENSOR

REVERSE FAN MANUAL

0.8W
RIGHT ROTATE EPPR-
COOLING FAN REVERSE SOL

WORK PRESS SENSOR(A)

RS485+(TX)-CLUSTER

1.2Or
COOLING FAN EPPR+

TRAVEL LEVER NEUTRAL

RS485-(RX)-CLUSTER

FUEL LEVEL SENSOR

WORK BRAKE PRESS

1.2Or
LEFT ROTATE EPPR+
RIGHT ROTATE EPPR+
ATT. PRESS SENSOR

PTC CAN2

0.8G
COOLING FAN EPPR-
CD-24

GOV. POTENTIO SIG.

REVERSE FAN AUTO

TRAVEL FWD PRESS
CD-31

LEFT ROTATE EPPR-

COOLANT LEVEL SW

1.2LOr

1.2GW
OVERLOAD SENSOR
CD-70

CD-71

CD-6

CD-7

CD-35

CD-32

HYD. TEMP SENDER

ENG. OIL PRESS SW

AUTO RAMLOCK SW
TRAVEL SPEED SOL

ONE TOUCH DECEL SW

1.2Br

PUMP SHIFT EPPR+

ENG OIL FILTER SW

1.2Or

1.2Or

1.2Or
TRAVEL ALARM SW
ATT CONFLUX SOL.

BRAKE PRESS FAIL

N1 PRESS SENSOR

1.2Br
N2 PRESS SENSOR

PUMP SHIFT EPPR-

P3 PRESS SENSOR
P1 PRESS SENSOR

P2 PRESS SENSOR
1.2G

RESERVE SENSOR
1.2G

0.8Br
1.2L

ENG PRE-HEAT RY
C

RS232C1 RX-HRDT
A
B

A
B

A
B

A
B

A
B

A
B

A
B

FUEL WARMER RY

RIGHT TILT EPPR+

C

RS232C1 TX-HRDT
A
B

1.2B
TRAVEL EPPR+(w)
ANTI RESTART RY

RIGHT TILT EPPR-

CN-262

BATT POWER 24V

ATT FLOW EPPR+

RS232C2 RX-RCM

TRAVEL EPPR-(w)
TACHO SENSOR+

AIR CLEANER SW
RS232C2 TX-RCM

POWER MAX SOL

TRAVEL Hi-Lo SW
PROGRAM DUMP

ATT FLOW EPPR-

ARM REGEN SOL

RESERVE EPPR+

LEFT TILT EPPR+

RESERVE EPPR+
TACHO SENSOR-

CD-50
POWER 24V OUT

TRAVEL BUZZER

LEFT TILT EPPR-

RESERVE EPPR-
ATT PRESS SOL.

REVERVE EPPR-

POWER MAX SW
GND PRESSURE

ST. TRAVEL SOL

RAMLOCK LAMP

CD-69
1
2

ACCEL DIAL SIG

RESERVE LAMP
RESERVE LAMP
POWER 5V OUT

CN-133
PWM OUTPUT1

CN-70
RETURN

RETURN

RETURN

RETURN

RETURN

RETURN

RETURN

PWM OUTPUT2

CN-88
RETURN

ELECTRIC KEY
SUPPLY

SUPPLY

SUPPLY

SUPPLY

SUPPLY

SUPPLY

SUPPLY

2
1
RESERVE DO2
RESERVE DO1

1
2
SUPPLY

CAN2 Lo-APTC

TM OIL PRESS

CN-135
G/A MOTOR(+)

CAN2 Hi-APTC

ENG STOP RY

C
CRUISE LAMP

EPPR POWER

A
B
G/A MOTOR(-)

HOUR METER

BLOWER SIG.

PREHEAT SW
CAN1 Lo-ECM

1
PWM INPUT 1
PWM INPUT 2

1
2
CAN1 Hi-ECM

CN-236

CN-149
PARKING SW

CN-237
RESERVE_DI

2
ROTATE SIG.
CN-75

CN-66
1
2
CD-43

CD-42

CD-44

AI RESERVE
CAN SHIELD

AI RESERVE

DOZZER PS
CRUISE SW

1
2

1
ALT. LEVEL

CN-81

2
1

1
2

2
EPPR GND
SIG

SIG

SIG

SIG

SIG

SIG

SIG
SIG

POWER IG
C

RETURN
GND MAIN

GND MAIN
C
A
B

A
B

A
B

SUPPLY
TILT SIG.

Pa
GND 5V
RETURN

RETURN

RETURN
SUPPLY

SUPPLY

SUPPLY

SIG
N1 PRESS N2 PRESS TRAVEL WORK ARM IN_OUT SWING OVERLOAD BOOM UP STRAIGHT
NC

TRAVEL SOL BOOM TRAVEL POWER

SIG

SIG

SIG

BUCKET IN ARM DOZER OPTION

MAIN PRIORITY REGEN HIGH MAX ATT. PS ATT. ATT. ATT. BREAKER SOL.
TRAVEL BZ
P2
PUMP PRESS SAFETY CONFLUX
P1 P3 MCU SOL.
PRESS PRESS PRESS
1409A4EC01

4-3
·ELECTRICAL
ELECTRICAL CIRCUIT (2/2)

INTAKE M/ACT TEMP M/ACT MODE(D/FOOT) MODE(VENT) BLOWER RY

Service Tool DC/DC CONVERTER CIGARLIGHT
OVERLOAD SW CS-67 4
2 7
4
2 7
12V SOCKET HOUR METER 1 1

24V
M M M M BLOWER

3
3 7 3 7

12
1

12

10
ECONO SWITCH

4
RS232 P DUMP

9
12V
1 12 5 5

M
2

4
12
00 0.8Or

12

10

5
6
7
5
6
7

5
6
7
1
2
3
4
5
6
7

1
2
3
4

1
2
3
4
3

RS232 RX

1
2
3
4
9

RS232 TX

CN-48
3

CAN2 Lo
CAN2 Hi

GND
CN-139
CAN Lo

12V
24V
9

CL-2
0.8Br

CAN Hi
IG 24V

1
2
1
CN-138

4
2
3
4

GND

3
2
1

11
5

1
1
2

CS-50

8
3
2
1

10
6

11
12
CN-21

0.8ROr

9
4

8
1
2
3

6
7
11
23F 0.8Or 3

1.2Gr
1

8
CS-52

1.2B
7

0.8W
7

0.8B
0.8Y
3 1 WIPER CUT SW

G
9

B
E

A
F
10
23F 0.8Or

11

J
12

1.2Or
R 10

9
4

8
1
2
3

6
7

24M 1.2B

1.2Or
8

1.2V
24L 1.2B

0.8VOr
2
4

0.8Or

0.8Or
1.2Br
Gr 12

24Q

0.8V

24R 0.8B
AIR-CON HARNESS

12B
3 9 8
5

35E
24V

21
CS-53
10

13
R 4A

60
1 0.8BW
10

0.8Or

27F 0.8Br
4

60
22
0.8G

0.8G
0.8B

24T 0.8B

6 0.8G
6 0.8G
6 0.8G
6 0.8G

2 0.8G
3 0.8R
9A

5 0.8V
4 0.8B
4 G 8 0.8Br
11

61
11

27
10

61
5 11 12
CN-11 NO. DESTINATION
L 9 24S 0.8B

B
2 6 12 1 1 GND
6 M

62

62

CN-126
Or

7
2A
QUICK CLAMP SW 2 2 BLOWER SIG

10
9
8
7
6
5
4
3
2
1
3 3 FUSE(IG)

11
WIPER MOTOR 4 REVERSE FAN
4
CN-113

0.8BW
5 5 FUSE(Battery)

0.8Y
00 0.8B

85 0.8L
22A 1.2V

73 0.8G

0.8G
0.8R
0.8V
0.8B
1 6 6 DPS(COMPRESSOR)
00 0.8Or
CN-141 2 7 7 CONDENSOR FAN

86
G 8

59
72
71
70
69
FEED BACK 1 8 8 ILLUMINATION
W 1 BUZZER
MOTOR DRIVE SIG 2 CN-17
L 9
MOTOR DRIVE- 3 1
R 10 1 W 0.8W 48
MOTOR DRIVE+ 4 2
B 2 2 B 1.2B 24B
GND 5 3
GrW 3 3 GrW 0.8ROr 65
VCC 6 4
R 4 4 R 0.8R 14
CONTINUE 24V 7 5
V 5 5 V 0.8V 15
WASHER P/P 8 6
L 6 6 L 0.8L 49
WASHER SIG. 9 7 CN-56
Br 7 7 Br 0.8Br 50
INT. SIG 10 8 6 0.8RW RW
Or 11 1 BATT.24V
WIPER CUT SW 11 84 0.8V WR
2 SIG 3
N.C 12 4 0.8B B
Gr 12 3 GND
FEED BACK 13 WIPER MOTOR HARNESS 1 0.8Y Y

10
11
12
13
14
15
16
17
18

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

1
2
3
4
5
6
7
8
9
4 TX
5 0.8Gr Gr
WIPER MOTOR CONT. 5 IG 24V
83 0.8G WL

0
0

0
0
SIG 2

TEMP MOTOR ACT(+)

6

DUCT SENSOR(GND)
TEMP MOTOR ACT(-)

DPS(COMPRESSOR)

1
2
MODE M/ACT(FOOT)

BLOWER RELAY(Lo)
INLET MOTOR(REC)
INLET MOTOR(FRE)
80 0.8Y

MODE M/ACT(PBR)
W

MODE M/ACT(DEF)

AMBIENT SENSOR
TEMP M/ACT(PBR)

CONDENSOR FAN
MOTOR ACT(REF)

DUCT SENSOR(+)
CAMERA SIG

W/TEMP SENSOR
MODE M/ACT(M+)
CN-170 7

POWER TR BASE
MODE M/ACT(M-)

FET(FEED BACK)

INCAR SENSOR
1.2LW 26 2 0.8L L > > >

REVERSE FAN
ILLUMINATION
ILLUMINATION
1 8 RX

BATTERY(+)
1.2B 20A

FET(GATE)
INCAR W/TEMP

POWER IG
2 CLUSTER POWER TR AMBIENT
SENSOR SENSOR SENSOR
DUCT

IG 24V
SPARE

GND
SENSOR

NC
NC

NC
CS-82 CN-5
1.2B 20 1 0.8Y
12 1 1 MCU RX
12 11 0.8LW 26A 2 0.8L AC&HEATER CONTROLLER(auto)
11 2 2 MCU TX
3 0.8B
10 3 3 MCU GND
10 4 0.8B
8 9 4 4 GND
4 1.2ROr 19 5 0.8Gr CS-1 CN-24
8 5 5 FUSE 1.2Gr 11
9 6 0.8RW 0.8G 2
7 6 6 FUSE 2
7 0.8V 3 CN-10 NO. DESTINATION
3 7 0.8B 1
6 7 7 NC CL-1 1
8 0.8Or 1 NC
5 8 8 NC 1.2Gr 11
DOOR SW 3 SPEAKER-RH 2 2 NC
1.2LW 26 59 0.8BW 1 0.8Y
4 9 9 P DUMP(MCU) 0.8Y 1
9 2 3 3 FUSE
0.8Br 1.2B 6B 2 0.8G
3 10 10 QUICK COUPLING SOL 1 4 4 CASSETTE RH-
10 0.8V 3 0.8V
2 11 11 OVERLOAD PS CN-23 MG651032 5 5 CASSETTE RH+
12 1 11 0.8VOr ROOM LAMP
0.8Y 4 4 0.8Y
1 12 12 MCU OVERLOAD 2 6 6 CASSETTE LH-
12 0.8ROr 0.8L 5 5 0.8L
SPARE 13 13 HEAD LAMP RY 1 7 7 CASSETTE LH+
13 0.8W 6 2.0B
CS-73 14 14 MCU HOURMETER 8 8 GND
0.8B 24K 69 0.8G SPEAKER-LH 7 2.0B
12 15 15 RS232 RX(MCU) CL-7 9 9 GND
12 11 70 0.8R 1.2BrW 8 8 1.2BrW
11 16 16 RS232 TX(MCU) 10 10 BEACON SW
0.8Gr 82 71 0.8B M 1.2B 6A 9 2.0V
10 17 17 GND 11 11 CABIN LIGHT RY
10 0.8YOr 32 14 0.8R 10 2.0V
6 9 18 18 FUSE BEACON LAMP 12 12 CABIN LIGHT RY
4 15 0.8V
8 19 19 WASHER P/P
CL-8 CL-10 CL-9
9
3
5 7
1.2Or 23
72
73
0.8V
0.8G
20 20 CAN Hi
2
2.0V 9
2
2V 10A 10 2.0V
2
HARNESS CABIN
6 21 21 CAN Lo 2B 6 2B 7A 7 2B
0.8B 4A 74 0.8B 1 1 1
II

5 22 22 Shieeld
CABIN LIGHT CABIN LIGHT CABIN LIGHT
0

4 23 23 NC
0.8G 33 65 0.8ROr
3 24 24 WIPER FUSE
19 1.2ROr
2 25 25 FUSE
12 1 0.8Gr 82 20 1.2B
1 26 26 GND
21 1.25Gr CS-83 ACCEL DIAL LED
REVERSE FAN 27 27 FUSE

CN-279
0.8B 19G
22 1.2V 12 CS-26A
CS-23 28 FUSE

1
2
28 12 11 0.8Or 18A
0.8B 24J 23 1.2Or 11 5E 0.8BW
12 29 29 FUSE 2
12 11 0.8BrW 58A 24A 1.2B 10 4E 0.8G
11 30 30 GND 1
10 0.8G 15

0.8ROr
24E 1.2B

0.8B
8 9
10 24 2B 31 31 GND 4 0.8V 16 BREAKER SW
10 8
8 9 32 32 NC 9 0.8BrW 17
4 0.8Br 27E 27 1.2Br 7 7 CN-156

19F
32
8 33 33 FUSE 3 19 1.2B
9 28 2V 28A 1.2V 6 2
7 7 34 34 CABIN LAMP RY 31 1.2ROr
3 29 1.2BOr 5 1
6 35 35 ANTI RESTART RY 0.8Or 18
30 1.2W 4 AIR SEAT
5 36 36 FUSE 0.8Gr 20
1.2BrW 58 84 0.8V 3 CN-8 NO. DESTINATION
4 37 37 NC 15 0.8G
28E 0.8V 2
3 38 CABIN LAMP RY 12 1 1 1 NC
38 16 0.8V
32 0.8YOr 1
2 39 MCU REV FAN AUTO 2 2 FUSE
39 17 0.8BrW
12 1 33 0.8G CRAB SW 3 3 CRAB COM
1 40 40 MCU REV FAN MANUAL 18 0.8Or
75 0.8L CS-99 4 4 NC
BEACON LAMP SW 41 41 RS232 RX2 0.8B 19A 19 1.2B
76 0.8Y 12 5 5 NC
CN-125A 42 42 RS232 TX2 12 11 0.8GW 21A 20 0.8Gr
0.8W 30E 11 6 6 CRAB SIG MCU
BATTERY POWER 1 43 43 NC 32 0.8ROr
85 0.8L 10 7 7 ILLUMINATION
1.2R 47A 44 44 NC 10 22 0.8L
KEY "IG" 2 8
86 0.8Y 8 9 8 NC
45 45 NC 4 0.8L 22 23 0.8VW
NC 3 35 8 9 9 DPF REGEN
0.8L 75 0.8Y
RX232(1)-TX 46 46 FUSE 9 0.8L 22A 24 0.8R
4 36 7 7 10 10 DPF COM
0.8B 71A 0.8V
RX232(1)-GND 47 47 FUSE 3 25 0.8LW
5 37 6 11 11 DPF INHIBIT
0.8B
RX232(2)-RX 48 48 GND 26 0.8RW
6 38 5 12 12 AIR COMP RY
0.8BrW 0.8GW
49 49 HEAD LAMP RY 21
RX232(2)-TX 7 39 4
0.8VW 0.8RW 26
RX232(2)-GND 8 50 50 WORK LAMP RY
79 0.8L 3
0.8Y 76 51 51 CAMERA GND
RX232(1)-RX 9 2
NC 10
80
81
0.8Y
52 52 CAMERA SIG
12 1
1
RH CONSOL HARNESS
0.8B
MAIN GND 11 53 53 CAMERA SHIELD AIR-COMP SW
1.2B 24H 40 0.8WOr
MAIN GND 12 54 54 PRE-HEAT CN-7 NO. DESTINATION
41 0.8Gr CS-100
55 55 CABIN LAMP RY 1 1 NC
RMS 42 0.8YW 1
56 56 MCU TRAVEL ALARM SW 2 2 NC
CN-10 43 0.8RW 2
57 57 FUSE 3
3 3 NC
1 NC 1 31 1.2ROr

0
44 0.8B 0.8VW 23
58 58 GND 4 4 4 FUSE
2 NC 2 45 0.8WOr 0.8G 4 4 0.8G

0,1
0.8Y 35A 59 59 POWER RY 5 BREAK 1 5 5 BREAKER SW
3 ROOM LAMP 24V 3 46 0.8GW B 0.8BW 5 5 0.8BW
0.8G 51 60 60 BATT. RY R 0.8R 24 2 6 6 BREAKER RY
SPEAKER RH- 4 6 CS-26 0.8B 6 6 0.8B
4 4
0.8V 53 6 HORN 1 7 7 GND
SPEAKER RH+ 7 R 0.8Grw 7 7 0.8Grw
5 5 0.8R 24A
0.8Y 52 8
2 8 8 HORN RY
6 SPEAKER LH- 6 CS-5 0.8L 8 8 0.8L
0.8L 55 9
9 9 NC
10 I 2 L 0.8L 9 9 0.8L
7 SPEAKER LH+ 7 0.8LW 25
1.2B 24F 24 2B CS-2 8 10 0.8Gr 10 0.8Gr
10 10 NC
30 1.2W 10

H0 I
8 GND 8 11 11 NC
1.2B 24G 1 11 1 Gr 0.8Gr 11
9 GND 46 0.8GW 12 11 0.8Gr
9 11 0.8Br 30 12 12 NC

0, I
1.2BrW 58 2 12
10 BEACON LAMP 10 47 1.2R
4 CN-142 13 13 AIR COMP RY

H
1.2V 28F 28 2V 3 DPF SW 0.8Gr
11 CABIN LIGHT 12 12 0.8Gr
11 + A 14 14 MCU 5V

BR ACC
1.2V 28G 4 1

B
2 0.8W 13 13 0.8W
12 CABIN LIGHT 12 3 S B 15 15 MCU ACCEL SIG.
5 0.8B 14 14 0.8B
29 1.2BOr - C 16 16 MCU SUPPLY GND
6
CABIN HARNESS ACCEL DIAL

ST C
5
6

START KEY SW
CN-116
12 NC CS-33
44 0.8B
11 GND 5 5
43 0.8RW
10 POWER 24V 4 4
9 NC 3 3
42 0.8YW
8 TRAVEL ALARM 2 2
41 0.8Gr
7 CABIN LIGHT OUT 1 1
40 0.8WOr
49 0.8L
6
5
PRE-HEAT
WASHER SIG
EM'CY STOP SW
LH CONSOL HARNESS
48 0.8W
4 WIPER MOTOR DRIVE
50 0.8Br NO. DESTINATION
3 INT. SIG CN-4
39 0.8VW 1
2 WORK LIGHT OUT 1 NC
38 0.8BrW
1 HEAD LIGHT OUT 2 2 NC
36E
36E

36F

36A
37J

12E
36E

12F

25
68

18

64
25
68
18

34
31
67

25
18

52
55
34

56
57
25
68
18

66

67

51
17
54

35
12

53

16

37
64
63
68
54
66
17
16

37G

3 NC
63
31

37E
37H

3
37K

SWITCH PANEL
36

56
57

4 4 NC
0.5LgW
0.5LgW

0.8ROr
0.5ROr
0.5ROr

0.5RW

0.8Y 4 0.8Y
0.5RW
0.5BW

0.5BW

4
0.5BW
0.5BW

0.5BW
0.5BW

0.5LY

0.5Lg

0.8W

MCU POWER MAX

0.5LY

0.8W

5
0.5Lg

1
0.8G

5
0.8R
0.8R

0.8V
0.8B

0.8Y

0.8V

0.5Y

0.8B
0.5Y

0.8V

0.5Y

0.5Y

0.8Y

0.8B
0.5V
0.5Y

0.5B
0.5Y

0.5Y
0.5B

0.5L
0.5V

0.5Y

0.5B

0.5V

0.5L

0.5L

0.5L

0.8L

power
0.5L

0.5L

0.5L
0.5L
0.5V

CN-125 CN-125 max B 0.8B 5 5 0.8B

1.2W 2 6 6 MCU SIG.GND
30A cs-29 0.8Grw 6 6 0.8Grw
1 1 1 7 7 MCU DECEL
CN-27
CN-144
CN-245
CN-246

47
CN-27A

1.2R R 77 decel R 0.8B 7 7 0.8B

2 2
10
11
12
13
14
15
16

8 MCU SIG.GND
1
2
3
4
5
6
7

2
8
1

4
5

8
2

6
1

4
5

9
2

6
1

4
5

10
11
12
13
14
15
16
17
18
19
20
3

9
2

10
11
12
3

9
10
11
12
1

4
5

8
2

6
3

37A 0.8B cs-19 0.8L 8 8 0.8L

3 3 9 9 NC
45 0.8WOr R 77 2 L 0.8L 9 9 0.8L
4 4 10 NC
REMOCON GND

10
ILLUMINATION
ILLUMINATION

10 0.8Gr
CAR AUDIO(+)

0.8Gr 10
REMOTE SIG+

CAR AUDIO(-)
REMOTE SIG-

SPK FRT RH+

SPK FRT LH+

SPK FRT RH-

11 NC
SPK FRT LH-

GPS CONN. 11
REMOCON+
GND(SEND)

GND(JACK)

GND(MAIN)
GND(JACK)

1 Gr 0.8Gr 11 11 0.8Gr
POWER IG
POWER IG

POWER IG

TEL MUTE
USB(GND)

BACK UP+
TEL MUTE
RX(SEND)
TX(SEND)
RX(JACK)

12 NC
TX(JACK)
USB(+5V)
AUX GND
USB GND

12
H/F IND+
H/F IND-

ANT 12V
USB(D+)
USB(D-)
USB D+
USB 5V
USB D-

SPK(+)
SPK(-)
IND(+)
AUX R

CS-4 13 13 NC
AUX L

MIC+

MIC+
SIG+

MIC-
GND

MIC-
TX/S

TX/S
GND

GND
SIG-

ACC

0.8B 12 12 0.8B
ILL+
ILL-
NC
NC

B C
NC

NC
TX

NC

NC

NC
NC

14 GND
NC

RX

A 14
RH SIDE HARNESS B
0.8V 13 13 0.8V
15 15 NC
USB & SOCKET ASSY REMOTE ASSY HANDSFREE RADIO & USB PLAYER 0.8G 14 14 0.8G
REMOTE ASSY A C 16 16 SAFETY SOL
SAFETY SW

1409A4EC02

4-4
MEMORANDUM

HYUNDAI HEAVY INDUSTRIES CO., LTD

CONSTRUCTION EQUIPMENT DIV.

4-5
1. POWER CIRCUIT
The negative terminal of battery is grounded to the machine chassis through master switch.
When the start switch is in the OFF position, the current flows from the positive battery terminal as
shown below.

1) OPERATING FLOW
Battery Battery relay Circuit breaker [CN-60] Master switch [CS-74A]
Fuse box [No.1] I/conn [CN-3 (6, 7)] Engine ECM [CN -93 (48, 52, 53, 55, 57)]
Fuse box [No.2] I/conn [CN-5 (46)]
I/conn [CN -10 (3)] Room lamp [CL-1 (2)] Door switch [CS-1]
Radio & USB player [CN-27 (8)]
Hour meter [CN-48 (1)]
Fuse box [No.3] MCU [CN-51 (2)]
Fuse box [No.4] ECM power relay [CR-45 (3)]
Power relay [CR-35 (30)]
Master switch [CS-74B] l/conn [CN-5 (36)]
Start switch [CS-2 (1)]
GPS connection [CN-125 (1)]
RMS power [CN-125A (1)]
Fuse box [No.5] l/conn [CN-11 (5)] AC & Heater controller (3)
Blower relay (3)
Fuse box [No.6] I/conn [CN-5 (18)] I/conn [CN-17 (5)]
Wiper motor controller [CN-141 (7)]
Wiper motor [CN-21 (4)]
Fuse box [No.7] I/conn [CN-5 (6)] Cluster [CN-56 (1)]

※ I/conn : Intermediate connector

2) CHECK POINT

Engine Start switch Check point Voltage

① - GND (battery 1EA) 10~12.5V

② - GND (battery 2EA) 20~25V
OFF OFF
③ - GND (battery 2EA) 20~25V
④ - GND (fusible link) 20~25V
※ GND : Ground

4-6
CR-45
CN-4 0.8B
CN-33 1
1 CS-74 0.8WOr 4 5 1
2

ECM
6 6 2 0.8W
3
5 5 3

MASTER SW
4
4 4 4 1.2Gr 3 2

POWER RY

2
1
5
3 3 5
2W CR-35

CS-74B
2 2 6 30
0.8WOr 87a 87 85

EMERGENCY
1 1 12 86
2WR
13 87

2W
2W
0.8B
14 85
30 86

POWER RY
CN-141 87a
R
CONTINUE 24V 7 CN-5
CN-17 1
POWER CIRCUIT

0.8RW
CN-21 1 2 CN-36

ENGINE STOP SW CONTROLLER

3W ECM 30A
1 2 3

8
7
6
5
4
3
2
1
3 1
0.8Y ROOM LAMP/CASSETTE 10A

CN-56
2 3 4
2
5 1.2R MCU 30A

RR
RR
RR
RR
RR
RR
RR
RR
5 3 4 0.8RW 0.8RW 3
R 30A
4 5 6 2W START KEY
4 4
7 3Y AIR CON/HEATER 20A
5R

5 6
5

TX
8

RX
6 7 0.8R WIPER 10A

GND

SIG 2
6 2

SIG 3
M

IG 24V
6

WIPER MOTOR WIPER MOTOR

9

BATT.24V
8 0.8RW CLUSTER 10A

CAMERA SIG

CLUSTER
17 7
5A
1.2Gr

0.8R 0.8R ECM

CN-125A 18 8
0.8W 20A
BATTERY POWER 1 MCU CONT.
19 9

RMS
2WR

MCU EPPR 20A

0.8R
2.0R
CN-138 20 10
6
5 10A

ST C
CS-2 12V 3 21 SWITCH PANEL
12V 1.2V 1.2V 1.2V 11
6 2 10A

7
6
5
4
3
2
1
24V 28 CASSETTE

26
25
24
12
11
12
3 5 24V GND 1 29 CN-3 CLUSTER 10A

DC & DC
2 13

BR ACC
1 4 30 CONVERTER 20A
1.2V

0.8R
2.0R
14

H
4 3

CONVERTER
31 WORK LAMP 30A
15

0, I
2 32 30A
1.2W CABIN LAMP(OPTION)
1 33 16

START KEY SW
10A

H 0 I
WIPER
34 17
HEAD LAMP 20A
35 18

4-7
CN-27 1.2W 1.2W FUEL HEATER 30A
36 19
1.2A
1.2A
1.2A
1.2A
1.2A
1.2A
1.2A
1.2A
1.2A
1.2A

1.2GW
ACC 1 START,STOP 20A
37 20

1.2W
5W

ILL- 2 HORN 10A

38 21
69
67
65
63
61
57
55
53
52
48

3
4
1
2
GND 3 39 AC& HEATER 20A
CN-93

22
SPK FRT RH- 4 42 SAFETY SOL 10A

4
1

3
23
SPK FRT LH- 5 43 SEAT 20A

CN-125

GPS CONN
24
TEL MUTE 6

R
44
ECM

SOLENOIDE 20A
ANT 12V 7 25
45 CIGAR 20A
BATTERY(-)
BATTERY(-)
BATTERY(-)
BATTERY(-)
BATTERY(-)

0.8Y 0.8Y 0.8Y

BATTERY(+)
BATTERY(+)

BATTERY(+)
BATTERY(+)
BATTERY(+)

BACK UP+ 8 46 26
OPTION(BEACON) 20A
ILL+ 9 47 27
SOLENOIDE 20A
NC 10 48 28
PRE-HEAT 10A

5
57

4
1

9
8
7
6
3
29

12
11
10
SPK FRT RH+ 11
FUEL P/P 20A

CN-10
58 30
CR-1

REMOCON+ 12 0.8WOr 0.8WOr 10A

RADIO & USB PLAYER

59 FUEL FEED P/P
REMOCON GND 13 31
3

BATT RY
FUSE BOX

60
SPK FRT LH+ 14

Gr

Gr
NC 15

0.8Y

0.8Y
GND CS-74A
90A

16
30A
5R

1
2
3
2

CN-11

1
2
2

CL-1
60R

CN-48
1
CS-74

CS-1
2
5R

h
DOOR SW
1
2

1
2

HOUR METER
3

ROOM LAMP
MASTER SW

CN-60
CN-95

CIRCUIT BREAKER

4
3Y
5R
5R

3
5W
5W

(12VX2)

BATTERY(+) 5
BATTERY

6
4

7
60B

AC & HEATER
CONTROLLER
8
1

1 2 1 MCU CN-51
1.2R
5B
5W

2 BATT POWER_24V 2
CN-255
3
2 CN-258
4

1409A4EL03
3 4

BLOWER RY
1 1

AIR COMP POWER

PTC POWER
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Battery relay [CR-1] Circuit breaker [CN-60] Master switch [CS-74]
Fuse box [No.4] Master switch [CS-74B] I/conn [CN-5(36)] Start switch [CS-2(1)]
(1) When start key switch is in ON position
Start switch ON [CS-2 (2)] I/conn [CN-5 (60)] Battery relay [CR-1]
Battery relay operating (all power is supplied with the electric component)
Start switch ON [CS-2 (3)] GPS connector [CN-125 (2) →(4)] I/conn [CN-5 (59)]
Power relay [CR-35 (86) → (87)] Fuse box [No.10]
ECM power relay [CR-45 (2) → (5)] I/conn [CN-4 (4)] Emergency engine stop switch
[CS-33 (2) → (1)] I/conn [CN-4 (13)] Fuse box [No.8]
(2) When start key switch is in START position
Start switch START [CS-2 (6)] I/conn [CN-5 (35)] Anti-restart relay [CR-5 (2) → (5)]
l/conn [CN-2 (16)] Start relay [CR-23]

2) CHECK POINT

Engine Start switch Check point Voltage

① - GND (battery)
② - GND (start key)
③ - GND (battery relay M4)
OPERATING START ④ - GND (starter B+) 20~25V
⑤ - GND (starter M)
⑥ - GND (start relay)
⑦ - GND (battery relay M8)

※ GND : Ground

4-8
CN-4
CN-33 1
6 6 2 CR-45
0.8B
5 5 3 1
4 4 0.8WOr 4 5 1
4 2

ECM
0.8W
3 3 5 CS-74 3
2 2 6 4
1.2Gr

EMERGENCY
3 2

POWER RY
1 1 12 5

ENGINE STOP SW
MASTER SW
13 2W CR-35
CN-125 CN-125 30
0.8WOr 14 0.8WOr 87a 87 85
4 4

2
1
86
3 3
2WR

CS-74B
CN-5 87

GPS
R 1.2R 0.8B
2 2 1 85
1.2W
1 1 87a 30 86

POWER RY
2

2W
2W
CN-125A 8
1.2W 9
BATTERY POWER 1
1.2R 31

RMS
2
STARTING CIRCUIT

KEY "IG" CN-36

32 ECM 30A
33 1
6 ROOM LAMP/CASSETTE 10A
5 2

ST C
CS-2 34
1.2BOr 0.8BOr 0.8BOr MCU 30A
6 35 3
1.2W 1.2W 2W START KEY 30A
3 5 36 4
20A
5R

2 AIR CON/HEATER

BR ACC
1 4 37 5
1.2R WIPER 10A

H
4 3 38 6
0.8GW CLUSTER 10A
39

0, I
2 7
1.2W
1.2Gr

1 57 ECM 5A

START KEY SW
8

H 0 I
58 MCU CONT. 20A
0.8WOr 0.8WOr 9
2WR

59 MCU_EPPR 20A
0.8GW 0.8GW

2
60 10
SWITCH PANEL 10A
11
CASSETTE 10A
12
CN-52 0.8Br CLUSTER 10A
ANTI-RESTART RY 15 13
CONVERTER 20A
14
WORK LAMP 30A
CN-51 15

MCU
0.8W CABIN LAMP(OPTION) 30A
ALT VOLTAGE LEVEL 39 16
WIPER 10A
17
HEAD LAMP 20A

4-9
18
FUEL HEATER 30A
19
0.8Y START,STOP 20A
20
5W

HORN 10A

1.2W
1.2W
1.2W
1.2W
21
AC& HEATER 20A
22
0.8Y

10A

9
8
4
3
2
1
0.8Br

SAFETY SOL
0.8BOr

20
19
18
17
16
15
11
10
1.2BOr

23

CN-2
SEAT 20A
4
2
3

5
1

24
CR-5

SOLENOIDE 20A

1.2W
1.2W
1.2W
1.2W
25
CIGAR 20A
26
OPTION(BEACON) 20A
3 2
4 5 1

27
20A

3
SOLENOIDE

0.8B
0.8G
28
PRE-HEAT 10A
ANTI-RESTART RY

29

1.2B
1
FUEL P/P 20A

1.2BOr
CR-1

30

DO-3

6
FUEL FEED P/P 10A

DIODE
31
7

BATT RY
FUSE BOX

3W/300
RS-1
2
1

2
1
1

CS-74A
90A

30A
5R

2
60R

CR-23

START RY
CS-74

1
5R

1
2

1
2
MASTER SW

CN-60
CN-95

CIRCUIT BREAKER

5R
5R
5W
5W

(12VX2)
BATTERY

1.2W
15 R
5
60B

2
1
4

L
P
M

FI
B+
B+

NC
CN-45

CN-74
3
5B
5W

~
CN-258

U
STARTER
CN-255 1
2

1409A4EL04
AIR COMP POWER

ALTERNATOR
1
PTC POWER
3. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the ON
position.
Charging current generated by operating alternator flows into the battery through the battery relay
[CR-1].
The current also flows from alternator to each electrical component and controller through the fuse box.
1) OPERATING FLOW
(1) Warning flow
Alternator "L" terminal [CN-74 (2)] I/conn [CN-2 (18)] MCU alternator voltage level [CN-51 (39)]
Cluster charging warning lamp (via serial interface)

(2) Charging flow

Alternator "B+" terminal Battery relay(M8) Battery(+) terminal
Circuit breaker [CN-60] Master switch [CS-74A]
Fuse box

2) CHECK POINT

Engine Start switch Check point Voltage

① - GND (battery voltage)

② - GND (battery relay)
Run ON ③ - GND (alternator B+ terminal) 20~30V
④ - GND (alternator L terminal)
⑤ - GND (MCU)

※ GND : Ground

4-10
CN-51
GND MAIN 1
BATT POWER 24V 2
POWER IG 3
POWER 24V OUT 4
GND PRESSURE 5
POWER 5V OUT 6
GND 5V 7
G/A MOTOR(+) 8
CN-36
G/A MOTOR(-) 9
GND MAIN 10 ECM 30A
1
CAN SHIELD 11 ROOM LAMP/CASSETTE 10A
PROGRAM DUMP 12 2
TACHO SENSOR- MCU 30A

0.8L
13

0.8Y

SH
3
TACHO SENSOR+ 14 START KEY 30A
PWM OUTPUT2 15 4

5
4
1

9
8
7
6
3
0.8L

60
59
58
57
24
23
22
21
20
19
18
17
0.8Y
1.2B
20A
5R

PWM OUTPUT1 16
AIR CON/HEATER

CN-5
5
RESERVE DO2 17 WIPER 10A

SH
6

8
7
6
5
4
3
2
1
RESERVE DO1 18

0.8L
0.8Y
CLUSTER 10A

CN-56
HOUR METER 19 7
TRAVEL BUZZER 20 ECM 5A

RR

RR
RR

RR
RR

RR
RR
RR
CAN1 Hi-ECM
8
21 20A
CHARGING CIRCUIT

MCU
MCU CONT.
CAN2 Hi-APTC 22 9
0.8L 20A
RS485+(TX)-CLUSTER 23 MCU EPPR
10
RS232C1 TX-HRDT 24

TX
SWITCH PANEL 10A

RX
GND
SIG 3

SIG 2
11

IG 24V
RS232C2 TX-RCM 25

BATT.24V
CASSETTE 10A
PWM INPUT 1 26

CAMERA SIG

CLUSTER
12
PWM INPUT 2 27 CLUSTER 10A
TILT SIG. 28 13
CONVERTER 20A
ROTATE SIG. 29 14
AI RESERVE 30 WORK LAMP 30A
CAN1 Lo-ECM 31
15
CABIN LAMP(OPTION) 30A
CAN2 Lo-APTC 32 16
0.8Y
RS485-(RX)-CLUSTER 33 WIPER 10A
17
RS232C1 RX-HRDT 34 20A
HEAD LAMP
RS232C2 RX-RCM 35 18
HYD. TEMP SENDER FUEL HEATER 30A
36
19
WATER TEMP SENDOR 37 START,STOP 20A
FUEL LEVEL SENSOR 38 20
5W

0.8W HORN 10A

ALT. LEVEL 39 21
GOV. POTENTIO SIG. 40 AC& HEATER 20A
22

5
SAFETY SOL 10A
23
SEAT 20A
24
SOLENOIDE 20A

4-11
25
CIGAR 20A
26

1.2W
1.2W
1.2W
OPTION(BEACON) 20A
27
SOLENOIDE 20A

0.8B
0.8G

9
8
4
3
2
1
4
2

5
1
28

20
19
18
17
16
15
11
10
10A

CN-2
PRE-HEAT

CR-5
29

2
1
FUEL P/P 20A
CR-1
2

30

DO-3

1.2W
1.2W
1.2W
FUEL FEED P/P 10A

DIODE
31

BATT RY
FUSE BOX

30 86
87a 87 85

ANTI-RESTART RY
1
CS-74A
90A

30A
5R

1.2B
2
60R

1.2BOr
1
CS-74
5R

1
2

1
2

3W/300
RS-1
2
1
MASTER SW

CN-60
CN-95

2
1
CIRCUIT BREAKER

5R
5R
5W
5W

(12VX2)
BATTERY

CR-23
60B

START RY
5B
5W

4
1.2W
15 R
CN-255
2 CN-258

2
1
1 1

L
P
M

FI
B+
B+

NC
CN-45 AIR COMP POWER
PTC POWER

CN-74
3
~
M

U
STARTER

1409A4EL05
ALTERNATOR
4. HEAD AND WORK LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.18) Head light relay [CR-13 (30,86)]
Fuse box (No.15) Work light relay [CR-4 (30,86)]

(1) Head light switch ON

Head light switch ON [CN-116 (1)] l/conn [CN-5 (49)] Head light relay [CR-13 (85) → (87)]
Head light ON [CL-3 (2)] , [CL-4 (1)] , [CL-24 (2)]
l/conn [CN-11 (8)] AC & Heater controller illumination ON [4]
l/conn [CN-5 (13)] Remote controller illumination ON [CN-245 (9)]
Cigar light [CL-2]
USB & Socket illumination ON [CN-246 (7)]
Radio & USB player illumination ON [CN-27 (9)]
l/conn [CN-8 (7)] Accel dial LED [CN-279 (2)]

(2) Work light switch ON

Work light switch ON [CN-116 (2)] l/conn [CN-5 (50)] Work light relay [CR-4 (85) → (87)]
l/conn [CN-12 (2)] Work light ON [CL-5 (2), CL-6 (2)]

2) CHECK POINT

Engine Start switch Check point Voltage

① - GND (fuse box)

② - GND (switch power output)
③ - GND (head light relay)
④ - GND (head light)
STOP ON 20~25V
⑤ - GND (fuse box)
⑥- GND (switch power output)
⑦ - GND (work light relay)
⑧ - GND (work light)

※ GND : Ground

4-12
CN-246
USB(+5V) 1
USB(D+) 2

NC
GND
USB(D-) 3

IG 24V
USB(GND) 4
CN-36

POWER IG
RX 5 30A

BATTERY(+)
ECM
1

ILLUMINATION
ILLUMINATION
6

REVERSE FAN
TX

INCAR SENSOR
0.5ROr ROOM LAMP/CASSETTE 10A

POWER TR BASE

W/TEMP SENSOR
DUCT SENSOR(+)
ILLUMINATION 7 2

AMBIENT SENSOR
MCU 30A

2
1
8 CL-2

DUCT SENSOR(GND)
GND 3
START KEY 30A

CN-279
TX/S 9
4
POWER IG 10 AIR CON/HEATER 20A

9
8
7
6
5
4
3
2
1
0.8B

USB & SOCKET ASSY

14
13
12
11
10
ROr 5

ACCEL DIAL LED

0.8ROr
GND(JACK) 11 WIPER 10A
6

AC & HEATER CONTROLLER

NC 12 10A

CIGAR LIGHT
CLUSTER
7
CN-245 ECM 5A
8
POWER IG 1 CN-5 MCU CONT. 20A
1 9
SIG+ 2 MCU EPPR 20A
3 2 10
SIG- 10A

2
2

5
7

4
1
6
1

8
7
6
8

3
5
SWITCH PANEL

12
11
NC 4 3 11

CN-8
10A

CN-11
CASSETTE
H/F IND+ 5 4 12
1
CLUSTER 10A
H/F IND- 6 5 13

0.8ROr
CONVERTER 20A
MIC+ 7 6 14
MIC- 8 2RW WORK LAMP 30A
0.5ROr 7 15
HEAD AND WORK LIGHT CIRCUIT

REMOTE ASSY
ILLUMINATION 9 8 CABIN LAMP(OPTION) 30A
16
REMOTE SIG+ 10 9 WIPER 10A
REMOTE SIG- 11 17
10 1.2Br HEAD LAMP 20A
GND 12 18
11 FUEL HEATER 30A
CN-27 19
12 START,STOP 20A
0.8ROr 0.8ROr
ACC 1 13 20
10A
5

HORN
ILL- 2 14 21
AC& HEATER 20A
GND 3 15 22
SAFETY SOL 10A

4-13
SPK FRT RH- 4 16 23
SEAT 20A
SPK FRT LH- 5 17 24
SOLENOIDE 20A
TEL MUTE 6 18 25
ANT 12V 7 19 CIGAR 20A
26
BACK UP+ 8 20 OPTION(BEACON) 20A
0.8ROr 27
ILL+ 9 21 SOLENOIDE 20A
28
NC 10 41 PRE-HEAT 10A
29
SPK FRT RH+ 11 42 FUEL P/P 20A
REMOCON+ 12 30

RADIO & USB PLAYER

43 FUEL FEED P/P 10A
REMOCON GND 13 31
44
FUSE BOX

SPK FRT LH+ 14 45

2B
2RG

NC 15

2
46
GND 16 47
1
2

CN-116 48
CN-12

0.8BrW 0.8BrW 0.8BrW

HEAD LIGHT OUT 1 49
0.8VW 0.8VW 0.8VW
WORK LIGHT OUT 2 50
INT. SIG 3 51
3
1.2B
1.2B

52
7

WIPER MOTOR DRIVE 4

2RG
2RW

1.2ROr
1.2ROr
0.8RW

0.8VW

WASHER SIG 5 53

6
0.8Br
PRE-HEAT 6 54
V
B
V
B

1.2ROr
0.8BrW
1.2Br

CABIN LIGHT OUT 7 55

TRAVEL ALARM 8 56
2
2
1

1
1
2
1

87
87
2

85
85
1

86
86
2

30
30

87a
87a

CL-3
CL-4
CL-6

57
CR-4
CL-5

NC 9

SWITCH PANEL
CL-24

CR-13

POWER 24V 10 58
GND 11 59
HEAD LAMP
HEAD LAMP

30 86
30 86

87a 87 85
87a 87 85

60
WORK LAMP

NC 12
HEAD LAMP RY
WORK LAMP RY

HEAD LAMP-REAR

1409A4EL06
5. BEACON LAMP AND CAB LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.27) I/conn [CN-5 (33)] Beacon lamp switch [CN-23 (8)]
Fuse box (No.16) Cab light relay [CR-9 (30, 86)]

(1) Beacon lamp switch ON

Beacon lamp switch ON [CS-23 (4)] Switch indicator lamp ON [CS-23 (11)]
l/conn [CN-10 (10)] Beacon lamp ON [CL-7]
(2) Cab light switch ON
Cab light switch ON [CN-116 (7)] I/conn [CN-5 (55)] Cabin lamp relay [CR-9 (85) → (87)]
I/conn [CN-5 (34, 38)] I/conn [CN-10 (12)] Front cab light ON [CL-9 (2), CL-10 (2)]
I/conn [CN-10 (11)] Rear cab light ON [CL-8 (2)]

2) CHECK POINT

Engine Start switch Check point Voltage

① - GND (fuse box)

② - GND (switch power input)
③ - GND (switch power output)
④ - GND (beacon lamp)
STOP ON 20~25V
⑤ - GND (fuse box)
⑥ - GND (cabin light relay)
⑦ - GND (switch power output)
⑧ - GND (cab light)

※ GND : Ground

4-14
12

M
3
4
9

12
10

CL-7

CL-9
CL-8

CL-10
CN-36

1
1
1

2
2
2
ECM 30A

CAB LIGHT
1

7
8

2
11

BEACON LAMP
ROOM LAMP/CASSETTE 10A

2B
2B
2V
2B

2V
2V
2

10
11

5
9
12

4
8

1.2B
1
2
3
6
7
MCU 30A

1.2BrW
3

CS-23

4
BEACON LAMP SW
30A

8
8
START KEY
4

0.8B
AIR CON/HEATER 20A

1.2BrW
0.8Br
0.8BrW
5
WIPER 10A
6
CLUSTER 10A

3
7

2
ECM 5A
8
MCU CONT. 20A
9
MCU EPPR 20A
10

5
4
1

9
8
7
6
3
10A

12
11
10
SWITCH PANEL
11

CN-10
CASSETTE 10A
12
CLUSTER 10A

1.2V
1.2V
1.2B
1.2B
13
5

1.2BrW
CONVERTER 20A
14
WORK LAMP 30A
15
2R CABIN LAMP(OPTION) 30A
16
WIPER 10A
CN-5 17
HEAD LAMP 20A
1 18
FUEL HEATER 30A
2 19
BEACON LAMP AND CAB LIGHT CIRCUIT

START,STOP 20A
3 20
4 HORN 10A
21
5 AC& HEATER 20A
22

4-15
6 SAFETY SOL 10A
23
7 SEAT 20A
1.2B 1.2B 24
1

30 SOLENOIDE 20A
1.2B 1.2B
31 25
CIGAR 20A
32 26
1.2Br 1.2Br 1.2Br OPTION(BEACON) 20A
33 27
1.2V 1.2V SOLENOIDE 20A
34 28
PRE-HEAT 10A
35 29
FUEL P/P 20A
36 30
37 FUEL FEED P/P 10A
CN-116 0.8V 0.8V 31
FUSE BOX

1 38
HEAD LIGHT OUT
2 39
WORK LIGHT OUT
INT. SIG 3 51

7
WIPER MOTOR DRIVE 4 52
WASHER SIG 5 53
PRE-HEAT 6 54
0.8Gr 0.8Gr 0.8Gr
CABIN LIGHT OUT 7 55
2R

TRAVEL ALARM 8 56
6

2V
0.8R

0.8Gr

NC 9 57

SWITCH PANEL
POWER 24V 10 58
GND 11 59
87
85
86
30

NC 12 60
87a
CR-9

30 86
87a 87 85

CABIN LAMP RY

1409A4EL07
6. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
(1) Key switch ON
Fuse box (No.11) I/conn [CN-5 (57)] Switch panel [CN-116 (10)]
Fuse box (No.6) I/conn [CN-5 (18)] I/conn [CN-17 (5)] Wiper motor controller [CN-141(7)]
Wiper motor [CN-21(4)]
Fuse box (No.17) I/conn [CN-5 (24)] l/conn [CN-17 (4)] Wiper motor controller [CN-141 (6)]
Washer pump [CN-22 (2)]

(2) Wiper switch ON : 1st step (Intermittent)

Wiper switch ON [CN-116 (3)] I/conn [CN-17 (8)] Wiper motor controller [CN-141 (10) → (3)]
Wiper motor intermittently operating [CN-21 (6)]
(3) Wiper switch ON : 2nd step (continual)
Wiper switch ON [CN-116(4)] I/conn[CN-17(2)] Wiper motor controller [CN-141(2) → (4)]
Wiper motor operating [CN-21(2)]
(4) Washer switch ON
Washer switch ON [CN-116 (5)] I/conn [CN-17 (7)] Wiper motor controller [CN-141 (9) → (8)]
I/conn [CN-17 (6)] I/conn [CN-5 (19)] Washer pump [CN-22 (1)] Washer operating
Wiper switch ON [CN-116 (4)] I/conn[CN-17 (2)] Wiper motor controller [CN-141 (2) → (4)]
Wiper motor operating [CN-21 (2)]
(5) Auto parking
parking(when switch OFF)
Switch OFF [CN-116 (4)] Wiper motor parking position by wiper motor controller

2) CHECK POINT

Engine Start switch Check point Voltage

① - GND (fuse box)

24V
② - GND (switch power input)
③ - GND (switch power output)
STOP ON 0 ~ 5V
④ - GND (wiper power input)
⑤ - GND (wiper power output) 24V
⑥ - GND (wiper motor) 0 or 24V
※ GND : Ground

4-16
CN-5
1
2
3
4 CN-36
5 ECM 30A

6
CN-21 6 1
ROOM LAMP/CASSETTE 10A
3 1 CS-53 7 2
R Or MCU 30A
2 8 3
Gr START KEY 30A
5 3 9 4
R 20A
4 10 AIR CON/HEATER
4 G B 5
5 0.8R WIPER 10A

WIPER CUT SW
11
L 6
6 M 2 6 12 CLUSTER 10A

WIPER MOTOR
7
13 ECM 5A
8

1
14 20A
MCU CONT.
15 9
MCU_EPPR 20A
16 10

4
0.8RW SWITCH PANEL 10A
17 11
0.8R 0.8R 10A
CN-141 18 CASSETTE
G 0.8V 0.8V 12
FEED BACK 1 19 CLUSTER 10A
W 13

1
MOTOR DRIVE SIG 2 CN-17 20 CONVERTER 20A
L 14
WIPER AND WASHER CIRCUIT

MOTOR DRIVE- 3 1 21 WORK LAMP 30A

R W 0.8W
MOTOR DRIVE+ 4 2 22 15
B B 1.2B CABIN LAMP(OPTION) 30A
GND 5 3 23 16
GrW GrW 0.8ROr 0.8ROr 0.8GrW 0.8GrW WIPER 10A
VCC 6 4 24 17
R R 0.8R HEAD LAMP 20A
CONTINUE 24V 7 5 25 18
V V 0.8V 30A
WASHER P/P 8 6 26 FUEL HEATER
19
1

L L 0.8L
WASHER SIG. 9 7 27 START,STOP 20A
Br Br 0.8Br 20
INT. SIG 10 8 28 HORN 10A
Or 21
WIPER CUT SW 11 29 AC& HEATER 20A
1.2B 1.2B
12
22
N.C 30 10A
SAFETY SOL

WIPER MOTOR CONTROLLER

Gr 1.2B 1.2B
FEED BACK 13 31 23
20A

4-17
SEAT
32 24
SOLENOIDE 20A

5
33 25
CIGAR 20A
34 26
35 OPTION(BEACON) 20A
27
0.8V
0.8V

36 SOLENOIDE 20A
0.8GrW
0.8GrW

28
37 PRE-HEAT 10A
29
38
1

20A
2

FUEL P/P
2
1

39 30
DO-5

FUEL FEED P/P 10A

CN-22

40 31
M
FUSE BOX

41
42
WASHER PUMP

43
44
45
46
CN-116
47
HEAD LIGHT OUT 1
48
WORK LIGHT OUT 2
0.8Br 49
INT. SIG 3 50
0.8W
WIPER MOTOR DRIVE 4 51
0.8L
WASHER SIG 5 52
PRE-HEAT 6 53
CABIN LIGHT OUT 7 54

3
TRAVEL ALARM 8 55
NC 9 56

SWITCH PANEL
0.8RW 0.8RW 0.8RW
POWER 24V 10 57
GND 11 58
NC 12 59

1409A4EL08
60

2
CONTROLLER CIRCUIT
FUSE BOX

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
1
2
3
4
5
6
7
8
9
30A

30A
30A
20A

20A
20A

30A
30A

20A
30A
20A

20A

20A
20A
20A
20A
20A

20A
ROOM LAMP/CASSETTE 10A

10A
10A

10A
10A
10A
20A

10A

10A

10A

10A

10A
5A

CABIN LAMP(OPTION)

OPTION(BEACON)
AIR CON/HEATER

SWITCH PANEL

FUEL FEED P/P

FUEL HEATER

AC& HEATER
START,STOP
CONVERTER

SAFETY SOL
WORK LAMP

SOLENOIDE

SOLENOIDE
MCU CONT.

HEAD LAMP
START KEY

MCU_EPPR

CASSETTE

PRE-HEAT
CLUSTER

CLUSTER

FUEL P/P
WIPER

WIPER

CIGAR
CN-36

HORN

SEAT
MCU
ECM

ECM
1.2RW
0.8Or
1.2R

1.2R
3W

2Y
CN-61
2B 2W
M 1
2Y 2
2 2W
1
FUEL PUMP CN-3 3W/120?
1
2 CN-93
1.2A
CN-126A 3 48 BATTERY(+)
1.2A
NC J 4 52 BATTERY(+)
1.2A
NC H 5 53 BATTERY(+)
0.8G 1.2A
CAN2 Hi G 6 55 BATTERY(+)
0.8G 1.2A
CAN Lo F 7 57 BATTERY(+)
0.8V
PDL- E 8 61 BATTERY(-)
0.8B
PDL+ D 9 63 BATTERY(-)
NC C 10 65 BATTERY(-)
0.8G
GND B 11 67 BATTERY(-)
0.8R
IG 24V A 12 69 BATTERY(-)
0.8A
SERVICE TOOL 13 50 CAN A Hi
0.8A
14 34 CAN A Lo
15 42 CAN A SHIELD
0.8A
2W 16 70 KEY SWITCH"ON"
2
2W 17 00 NC
1
18 00 NC
0.8A
CD-10 19 18 SWITCH RETURN
2W 0.8A
SUPPLY POWER 1 20 2 5V SENSOR POWER
0.8A
RETURN 2 21 3 5V SENSOR RETURN
2B 0.8A
CAN- 4 22 4 8V DIGITAL POWER SUPPLY
2B 0.8A
CAN+ 5 23 5 DIGITAL RETURN
0.8A
CAN Shield 6 24 14 AFTERTREATMENT ID SIG
0.8A
DPF SOOT SENSOR 25 17 AIR INLET TEMP SENSOR
26 20 GLOW PLUG RY+
CD-45
0.8B 21 LIFT PUMP RY-
3 0.8A
0.8V CN-2 22 IVS SW1
2
0.8R 1 25 NC
1 0.8A
2 26 DPF INLET TEMP SENSOR
WIF SENSOR 3
0.8A
35 WATER IN FUEL SW
0.8A
CD-16 4 37 CAN C+(DPF SOOT)
0.8B 0.8A
RETURN C 5 38 CAN C-(DPF SOOT)
0.8Gr
SIGNAL B 6 39 CAN C- SHIELD
0.8R 0.8A
SUPPLY POWER 5V A 7 49 COOLANT LEVEL SW
WATER LEVEL SENSOR 8 59 DIGITAL RETURN
0.8A
9 66 ACTIVE ANALOGUE
CN-7 10 8 PDL+
1 CN-16B 11 9 PDL-
0.8B
2 1 12 46 Elevate Idle
2.5k 0.8W
2 13
3 0.8Gr CD-10
3 14 2W
4 2.5k 0.8LW
15 1 SUPPLY POWER
4 2W
5 0.8BW 2 RETURN
5 16 2B
6 6 17 3 TEMP SENSOR
7 18 4 nc

8 19 DPF INLET TEMP

20 CD-97
9 2W
1 SUPPLY POWER
10 2W
3 AFTERTREATMENT SIG
2B
11 6 RETURN
12 DPF IDENTIFICATION
CN-142 13 CD-98
0.8Gr
+ A 14 2 C
0.8W
S B 15 CN-16 1
0.8B 0.8B 0.8B
- C AIR INLET TEMP
16 1
0.8W 0.8W
ACCEL DIAL RH CONSOLE 2 0.8W
2
0.8Gr 0.8Gr
3 0.8
1
4 CN-126 3W/120?
5
CN-5
10
6 1
9 J nc
2 8 H nc
3 7 G nc
0.8G 0.8G
19 6 F CAN Lo
0.8LW 0.8LW 0.8V
20 5 E CAN Hi
0.8G
21 4 D GND
22 3 C RS232 TX
2 B RS232 RX
23
1 A RS232 P DUMP
24
SERVICE TOOL
1.2RW

0.8Gr

0.8W
0.8G
1.2R

1.2R
0.8B

0.8V
CN-51

CN-52

CN-53
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

20
21
22
23
1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
RIGHT ROTATE EPPR+
RS485+(TX)-CLUSTER

WORK BRAKE PRESS

LEFT ROTATE EPPR+

COOLING FAN EPPR-

RIGHT TILT EPPR+

RS232C1 TX-HRDT
BATT POWER_24V

ATT FLOW EPPR+

TACHO SENSOR+

RS232C2 TX-RCM
PROGRAM DUMP

LEFT TILT EPPR+

TACHO SENSOR-
POWER 24V OUT

TRAVEL BUZZER
GND PRESSURE

ACCEL DIAL SIG

POWER 5V OUT

PWM OUTPUT1
PWM OUTPUT2

RESERVE DO2
RESERVE DO1
G/A MOTOR(+)

CAN2 Hi-APTC

EPPR POWER
G/A MOTOR(-)

HOUR METER

CAN1 Lo-ECM
PWM INPUT 1
PWM INPUT 2
CAN1 Hi-ECM

ROTATE SIG.
AI RESERVE
CAN SHIELD
POWER IG
GND MAIN

GND MAIN

TILT SIG.

TILT SIG.
GND 5V

MCU 1409A4EL09

4-18
MONITORING CIRCUIT

FUSE BOX

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
1
2
3
4
5
6
7
8
9
30A

30A
30A
20A

20A
20A

30A
30A

20A
30A
20A

20A

20A
20A
20A
20A
20A

20A
ROOM LAMP/CASSETTE 10A

10A
10A

10A
10A
10A
20A

10A

10A

10A

10A

10A
5A

CABIN LAMP(OPTION)

OPTION(BEACON)
AIR CON/HEATER

SWITCH PANEL

FUEL FEED P/P

FUEL HEATER

AC& HEATER
START,STOP
CONVERTER

SAFETY SOL
WORK LAMP

SOLENOIDE

SOLENOIDE
MCU CONT.

HEAD LAMP
START KEY

MCU EPPR

CASSETTE

PRE-HEAT
CLUSTER

CLUSTER

FUEL P/P
WIPER

WIPER

CIGAR
CN-36

HORN

SEAT
MCU
ECM

ECM
CN-249
1

0.8Or
2
3W

CN-3 4

1 CAMERA
2 CN-93
1.2A
3 48 BATTERY(+)
1.2A
CN-259 4 52 BATTERY(+)
1.2A
1 5 53 BATTERY(+)
1.2A
2 6 55 BATTERY(+)
1.2A
3 7 57 BATTERY(+)
1.2A
4 8 61 BATTERY(-)
1.2A
5 9 63 BATTERY(-)
1.2A
6 10 65 BATTERY(-)
1.2A
11 67 BATTERY(-)
CAMERA 1.2A
12 69 BATTERY(-)
13 50 CAN A_Hi
14 34 CAN A_Lo
15 42 CAN A_SHIELD
0.8A
2W 16 70 KEY SWITCH"ON"
2
2W 17 00 NC
1
18 00 NC
0.8A
CD-10 19 18 SWITCH RETURN
2W 0.8A
SUPPLY POWER 1 20 2 5V SENSOR POWER
0.8A
RETURN 2 21 3 5V SENSOR RETURN
2B 0.8A
CAN- 4 22 4 8V DIGITAL POWER SUPPLY
2B 0.8A
CAN+ 5 23 5 DIGITAL RETURN
0.8A
CAN Shield 6 24 14 AFTERTREATMENT ID SIG
0.8A
DPF SOOT SENSOR 25 17 AIR INLET TEMP SENSOR
26 20 GLOW PLUG RY+
CD-45
0.8B 21 LIFT PUMP RY-
3 0.8A
0.8V CN-2 22 IVS SW1
2
0.8R 1 25 NC
1 0.8A
2 26 DPF INLET TEMP SENSOR
WIF SENSOR 0.8A
3 35 WATER IN FUEL SW
0.8A
CD-16 4 37 CAN C+(DPF SOOT)
0.8B 0.8A
RETURN C 5 38 CAN C-(DPF SOOT)
0.8Gr
SIGNAL B 6 39 CAN C- SHIELD
0.8R 0.8A
SUPPLY POWER 5V A 7 49 COOLANT LEVEL SW
WATER LEVEL SENSOR 8 59 DIGITAL RETURN
0.8A
9 66 ACTIVE ANALOGUE
10 8 PDL+
CN-16B 11 9 PDL-
0.8B
1 12 46 Elevate Idle
2.5k 0.8W
2 13
0.8Gr CD-10
3 14 2W
2.5k 0.8LW 1 SUPPLY POWER
4 15 2W
0.8BW 2 RETURN
5 16 2B
6 17 3 TEMP SENSOR
18 4 nc
CN-56 CN-5
RW
1 1
19 DPF INLET TEMP
BATT.24V
WR 20 CD-97
SIG_3 2 2 2W
B 1 SUPPLY POWER
GND 3 3 2W
Y 3 AFTERTREATMENT SIG
TX 4 4 2B
Gr 6 RETURN
IG 24V 5 5
SIG_2
WL
6 6 DPF IDENTIFICATION
CAMERA SIG
W
7 7 CD-98
L 22 2 C
RX 8
23 1
CLUSTER
24 AIR INLET TEMP
37
0.8W
38 2
0.8
51 1
52 3W/120?
53
CD-10A
1.2BW
Pa 1.2YOr

AIR CLEANER SW
CD-2
1.2BW
1
1.2YOr
2
FUEL LEVEL
CD-1
1.2BW
C 1
1.2LOr
2

HYD TEMP
1.2YOr

1.2YOr
1.2LOr
0.8Y
0.8L

CN-53
CN-51

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
37
38
39
40

22
23
24
25
1
2
3
4
5
6
7
8
9

WATER TEMP SENDOR

RS485+(TX)-CLUSTER

FUEL LEVEL SENSOR

RS485-(RX)-CLUSTER

REVERSE FAN_AUTO
HYD. TEMP SENDER

GOV.POTENTIO SIG.
RS232C1_RX-HRDT
RS232C1_TX-HRDT
BATT POWER_24V

RS232C2_RX-RCM
RS232C2_TX-RCM
TACHO SENSOR+

AIR CLEANER SW
POWER_24V OUT

PROGRAM DUMP
TACHO SENSOR-
GND_PRESSURE

TRAVEL BUZZER
POWER_5V OUT

PWM OUTPUT1
RESERVE_DO2
RESERVE_DO1
PWM OUTPUT2

CAN2 Lo-APTC
G/A MOTOR(+)

CAN2 Hi-APTC

PWM INPUT_1
PWM INPUT_2
G/A MOTOR(-)

HOUR METER

CAN1 Lo-ECM
CAN1 Hi-ECM

ROTATE SIG.
CAN_SHIELD

AI RESERVE

ALT. LEVEL
GND_MAIN

GND_MAIN
POWER IG

TILT SIG.
GND_5V

NC

MCU
1409A4EL10

4-19
CD-70 ROr

N1
SUPPLY A

SIG
max

SIG
SIG
ker

C
Y

Decel
Horn

2
2

1
1
Brea

Power
SIG B

A
BW

2
1
2
1
Pa

PRESS
1
SUPPLY
RETURN C

SUPPLY
SUPPLY

RETURN
RETURN
RETURN
C

CD-2

CD-1
CN-75
CS-5

CS-29
CS-26

CS-19
-
CD-71

HYD TEMP
+
S

MAIN PUMP
L
L

B
B

B
A
ROr

2
1

C
B
A
B
A
R
R

C
C
Gr
Gr

FUEL LEVEL
Br

N2
SUPPLY A

CD-44
CD-43

PUMP1 PRESS

PUMP3 PRESS
CD-42
PUMP2 PRESS

RW
SAFETY SW
Br

DOZER PS
CS-26A

A
B
C

CD-50
SIG B

A
1
2

B
C

BW
BW

LOr
YOr
1
1
1
1

2
2
2
2

CS-4
BW

ACCEL DIAL

L
B

V
G
CN-142
RETURN C

YW

BW
BW
BW

ROr
ROr
ROr
BREAKER SW

L
L
L
L

B
B
Y
B

B
G
CD-6

Gr
Gr
Gr
Gr

V
B
Gr
ROr

G
BW
GrW

GrW
SUPPLY A
OrW
SIG B
BW

PRESS SENSOR
RETURN C
CD-7 ROr
SUPPLY A
LW
SIG B
BW
RETURN C

SENSOR
CD-35
ROr
SUPPLY A
YW

5
2

4
1

9
8
7
6
3
SIG B

10
BW

CN-1
RETURN C

TRAVEL PS WORK PS ARM IN

CS-73
CD-24 ROr 1
SUPPLY A 2 12
BOr
SIG B 2
BW
RETURN C 3
CD-31 4
ROr
SUPPLY A 5
V
SIG B Or
BW 6
RETURN C 3

2
2

5
5

4
1
4
1

9
8
7
6
9
8
7
6

3
3
ELECTRIC CIRCUIT FOR HYDRAULIC

16
15
14
13
12
11
10
16
15
14
13
12
11
10

7 7
CN-7

CN-4
CD-32 ROr 9
SUPPLY A 8
WOr 4
SIG B 9 8
BW
10
REVERSE FAN SW

RETURN C
10

SWING OVERLOAD BOOM UP

CN-51 11
GND MAIN 1 B 11 12
12
BATT POWER_24V 2
POWER IG 3 CS-50
ROr 1
POWER 24V OUT 4
BW 2 12
GND PRESSURE 5 2
Gr Or
POWER 5V OUT 6 3
B VOr
GND 5V 7 4
G/A MOTOR(+) 8 5
G/A MOTOR(-) 9 6
Br 3
GND MAIN 10 7 7
CAN SHIELD V 9
11 8
PROGRAM DUMP 12 4
9 8
OVERLOAD SW

10
10
HOUR METER 19 Or
V 11

5
2

4
1

6
3
TRAVEL BUZZER 20 B 11 12
12

CN-16
CAN1 Hi-ECM 21
CAN2 Hi-APTC 22 CS-67
RS485+(TX)-CLUSTER 23 1
2 12
RS232C1 TX-HRDT 24 2
RS232C2 TX-RCM 25 3
Br
PWM INPUT 1 26 4
PWM INPUT 2 27 5
TILT SIG. 28 6
ROTATE SIG. 29 3
7 7
AI RESERVE 30 Or 9
8
CAN1 Lo-ECM 31 4
9 8
QUICK CLAMP SW

CAN2 Lo-APTC 32 10
10
RS485-(RX)-CLUSTER 33 Br
11
RS232C1 RX-HRDT 34 B 11 12
12
RS232C2 RX-RCM 35
LOr
HYD. TEMP SENDER 36
WATER TEMP SENDOR 37
YOr CN-113
FUEL LEVEL SENSOR 38
1
ALT. LEVEL 39
2
GOV. POTENTIO SIG. 40
BUZZER
6

9
8
7

10

12

60
59
58
57
35
34
33
32
31
30
29
28
27
11

CN-52
CN-5

RW
ARM REGEN SOL 1
COOLING FAN REVERSE SOL 2
GOr
ST. TRAVEL SOL 3
GW
ATT_CONFLUX SOL. 4
LOr
ATT_PRESS SOL. 5
Br
TWO WAY SAFETY SOL 6

4-20
BrW
POWER MAX SOL 7
GOr
TRAVEL SPEED SOL 8
CN-140
Br
ANTI RESTART RY 15 2
FUEL WARMER RY 16 GrW
1
QUICK
CLAMP

ENG PRE-HEAT RY 17
ENG STOP RY 18 CN-36
REVERVE EPPR- 19

MCU
ECM 30A
COOLING FAN EPPR- 20 1
W ROOM LAMP/CASSETTE 10A
ACCEL DIAL SIG 21 2
WORK BRAKE PRESS 22 MCU 30A
WOr 3
BOOM UP PRESS SENSOR 23 START KEY 30A
BOr 4
SWING PRESS SENSOR 24 20A
YW AIR CON/HEATER
ARM IN_OUT BUCKET IN PRESS 25 5
OrW WIPER 10A
TRAVEL PRESS SENSOR(A) 26 6
Br 10A
N2 PRESS SENSOR 27 CLUSTER
7
TRAVEL FWD PRESS 28 ECM 5A
G 8
P1 PRESS SENSOR 29 MCU CONT. 20A
VOr 9
OVERLOAD SENSOR 30
W MCU EPPR 20A
ATT. PRESS SENSOR 31 10
SWITCH PANEL 10A
RESERVE SENSOR 32 11
BRAKE PRESS FAIL 33 CASSETTE 10A
12
TM OIL PRESS 34 CLUSTER 10A
LW 13
WORK PRESS SENSOR(A) 35 CONVERTER 20A
V
P3 PRESS SENSOR 36 14
Y WORK LAMP 30A
N1 PRESS SENSOR 37 15
L CABIN LAMP(OPTION) 30A
P2 PRESS SENSOR 38
16
BLOWER SIG. 39 WIPER 10A
17
AI RESERVE 40 20A
HEAD LAMP
18
CN-53 FUEL HEATER 30A
RW 19
ATT FLOW EPPR+ 1 START,STOP 20A
RIGHT TILT EPPR+ 2 20
HORN 10A
LEFT TILT EPPR+ 3 21
AC& HEATER 20A
EPPR POWER 4 22
RIGHT ROTATE EPPR+ 5 V SAFETY SOL 10A
23
LEFT ROTATE EPPR+ 6 SEAT 20A
7 24
TRAVEL EPPR+(w) 20A
RW Or SOLENOIDE
PUMP SHIFT EPPR+ 8 25
RW CIGAR 20A
BOOM PRIORITY EPPR+ 9 26
RESERVE EPPR+ Br OPTION(BEACON) 20A
10
LW 27
ATT FLOW EPPR- 11 Or SOLENOIDE 20A
28
RIGHT TILT EPPR- 12 PRE-HEAT 10A
LEFT TILT EPPR- 13 29
FUEL P/P 20A
EPPR GND 14 30
FUEL FEED P/P 10A
RIGHT ROTATE EPPR- 15 31
FUSE BOX

LEFT ROTATE EPPR- 16

TRAVEL EPPR-(w) 17
Br
PUMP SHIFT EPPR- 18
W
BOOM PRIORITY EPPR- 19
RESERVE EPPR- 20
REVERSE FAN MANUAL 21
REVERSE FAN AUTO 22
2

5
4
1

9
8
7
6
3

12
11
10
CN-15

AIR CLEANER SW 23
NC 24
AUTO RAMLOCK SW 25
TRAVEL/WORK SELECT SW 26
Br
Br

Or
BW

PARKING SW 27
PREHEAT SW 28
COOLANT LEVEL SW 29
B
V
V
G

Br
Br

Or
Or
Or
Or
Or
Or
Or
Or

Y
LW
BW
BW

RW
LOr
RW
RW

GW
4
2
3

5
1

ROr
GOr
GOr

BrW

POWER MAX SW 30
CR-62

YW
1
1

1
1
1
1
1
1
1

2
2

2
2
2
2
2
2
2

2
1
2

1
2

DOZZER PS 37
CD-69
CN-88
CN-70

CN-66
CN-81
CN-68

TRAVEL Hi-Lo SW 38
CN-242
CN-237
CN-149
CN-236
CN-262
CN-135
CN-133
3 2
4 5 1

B SIG
BREAKER RY

TRAVEL ALARM SW 39
GrW
ONE TOUCH DECEL SW 40
A SUPPLY

C RETURN

ATT
ATT

ATT
ARM

STRAIGHT

ATT FLOW
ATT PS

PRESS SOL

SAFETY SOL
TRAVEL SOL
SAFETY SOL

POWER MAX
TRAVEL-HIGH
TRAVEL BZ

CONFLUX SOL

BREAKER SOL
BOOM PRIORITY

REGENERATION

1409A4EL11
GROUP 3 ELECTRICAL COMPONENT SPECIFICATION

Part name Symbol Specifications Check

※ Check specific gravity

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

Rated load : ※ Check coil resistance (M4 to M4)

24V
Normal : About 50Ω
Battery relay 100A (continuity)
※ Check contact
1000A (30 seconds)
Normal : ∞Ω
CR-1

※ Check contact
Glow plug relay 24V 200A Normal : 0.942Ω
(For terminal 1-GND)
CR-24
5
4

1
6

2
3

B B-BR : 24V 1A ※ Check contact

0, I
OFF : ∞Ω(for each terminal)
1

Start key B-ACC : 24V 10A

B-ST : 24V 40A ON : 0Ω(for terminal 1-3 and 1-2)
H0 I
4
3

START : 0Ω(for terminal 1-5)

2
6
5

STC BR ACC H

CS-2

A SUPPLY
B SIG
※ Check contact
Pressure sensor C RETURN 8~30V
Normal : 0.1Ω
CD-6 CD-7 CD-24
CD-31 CD-32 CD-35
CD-42 CD-43 CD-44
CD-69 CD-70 CD-71

A A
B ※ Check resistance
Resistor 4W
A-B : 120Ω
C B
CN-173

4-21
Part name Symbol Specifications Check

※ Check resistance
Glow plug 24V 200A
0.25~0.12Ω

CN-80

C 1 ※ Check resistance
Temperature 50˚C : 804Ω
sensor -
2 80˚C : 310Ω
(hydraulic)
100˚C : 180Ω
CD-8
CD-1

※ Check contact
Air cleaner Pa High level : ∞Ω
(N.O TYPE)
pressure switch Low level : 0Ω

CD-10

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

3 4 4 ※ Check resistance
3 Normal : About 200Ω
Relay
2 24V 20A (for terminal 1-3)
(air con blower)
1 2 1 0Ω
CR-46 (for terminal 2-4)

1
4 5 1 ※ Check resistance
2
3
Normal : About 160 Ω
Relay 4 24V 16A (for terminal 1-2)
5 3 2 0Ω(for terminal 3-4)
CR-2 CR-5 CR-36 ∞Ω(for terminal 3-5)
CR-45 CR-62

4-22
Part name Symbol Specifications Check

30
87a 87 85 ※ Check resistance
86

87
Normal : About 160 Ω
Relay 85 24V 16A (for terminal 85-86)
30 86
87a 0Ω(for terminal 30-87a)
CR-4 CR-7 CR-9 ∞Ω(for terminal 30-87)
CR-13 CR-35 CR-46

1
※ Check resistance
Solenoid valve 2 Normal : 15~25Ω
24V 1A
CN-66 CN-68 CN-70 (for terminal 1-2)
CN-88 CN-135 CN-140
CN-149 CN-236 CN-237
CN-262 CN-263

1
※ Check resistance
EPPR valve Normal : 15~25Ω
2 700mA
(for terminal 1-2)
CN-75 CN-133
CN-75 CN-133CN-238
CN-242CN-240 CN-241
CN-239
CN-242

1
※ Check resistance
Speaker 2 20W
Normal : A fewΩ
CN-23(LH)
CN-24(RH)
7
6

3
2
1
8

4
12

5
11
10

※ Check contact
11

2
8

Normal
Switch ON : 0 Ω(for terminal 3-7, 4-8)
24V 8A
(locking type) ∞Ω(for terminal 7-9, 8-10)
10

12
12

9
4

CS-23 CS-50
CS-23 CS-50CS-67
CS-52CS-82 OFF : ∞Ω(for terminal 3-7, 4-8)
CS-83 CS-99
CS-67 CS-73CS-100
CS-82 0 Ω(for terminal 7-9, 8-10)
CS-83 CS-99 CS-100

※ Check resist
Normal : About 5kΩ
A + (for terminal A-C)
Accel dial B S ※ Check voltage
-
C - Normal : About 5V
(for terminal A-C)
CN-142
: 2~4.5V
(for terminal C-B)

4-23
Part name Symbol Specifications Check

3 ※ Check disconnection
Normal : 1.0Ω
Room lamp 2 ON : 0Ω(For terminal 1-2)
24V 10W
1 ∞Ω(For terminal 1-3)
OFF : ∞Ω(For terminal 1-2)
CL-1 0Ω(For terminal 1-3)

2
Head lamp, ※ Check disconnection
24V 65W
Work lamp, 1
(H3 Type) Normal : 1.2Ω
Cab lamp
CL-3
CL-4 CL-4 CL-6
CL-5 CL-5
CL-8
CL-6 CL-9
CL-8 CL-9
CL-10 CL-24

21V 70W ※Check disconnection

Beacon lamp M (H1 Type) Normal : A fewΩ

CL-7
-
CL-7

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

3 ※Check operation
Service meter 2
h Supply power(24V) to terminal
16~32V
1 No.2 and connect terminal No.1
and ground
CN-48

1 ※Check operation
DC22~28V
Horn 2 Supply power(24V) to each
2A
terminal and connect ground.
CN-20 CN-25

4-24
Part name Symbol Specifications Check

2 3 ※Check contact
1
Normal : 0Ω(for terminal 1-2)
2 24V 15A
Safety switch ∞Ω(for terminal 1-3)
(N.C TYPE)
3 Operating : ∞Ω(for terminal 1-2)
1
0Ω(for terminal 1-3)
CS-4
CS-4

24V ※Check contact

Wiper cut switch
(N.O TYPE) Normal : 0Ω(one pin to ground)
CS-53

1
P 24V 2.5A ※Check contact
Receiver dryer
2 Normal : ∞Ω

CN-29
CN-29
10
11
12
13
14
15
16
1
2
3
4
5
6
7

9
8

※Check voltage
REMOCON GND

Radio &
SPK FRT RH+

SPK FRT LH+

SPK FRT RH-

24V 2A 20~25V
SPK FRT LH-

REMOCON+
BACK UP+
TEL MUTE

USB plalyer
ANT 12V

(for terminal 1-3, 3-8)

GND

GND
ACC

ILL+
ILL-

NC

NC

CN-27

※Check contact
Washer pump 24V 3.8A
Normal : 10.7Ω(for terminal 1-2)

CN-22

3 1
2

5 3
4 ※Check disconnection
Wiper motor 4
5
24V 2A
Normal : 7Ω(for terminal 2-6)
6 M 2 6

CN-21

4-25
Part name Symbol Specifications Check

3 12V 12V
※Check voltage
DC/DC 2 24V
1 24V 12V 3A 24V (for terminal 1-2)
Converter GND
12V (for terminal 1-3)
CN-138

※Check coil resistance

Normal : About 1MΩ
Cigar lighter 24V 5A 1.4W ※Check contact
Normal : ∞Ω
Operating time : 5~15sec
CL-2
CL-2

B+
G
1 P
3~
※Check contact
2 L
Alternator 3 FI U 24V 85A Normal : 0Ω(for terminal B+-P)
4 NC Normal : 24~27.5V
CN-74

M
M
Denso ※Check contact
Starter
24V 4.5kW Normal : 0.1Ω
B+
CN-45

※Check contact
Travel alarm 24V 0.5A
Normal : 5.2Ω

CN-81

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

4-26
Part name Symbol Specifications Check

※Check contact
Start relay 24V 300A
Normal : 0.94Ω(for terminal 1-2)

CR-23

1 M ※Check resistance
Blower motor 24V 9.5A
2 Normal : 2.5Ω(for terminal 1-2)

※Check resistance
Duct sensor 2 1˚C OFF Normal : 0Ω(for terminal 1-2),
(switch) 1 4˚C ON the atmosphere temp :
Over 4˚C

※Check resistance
Door switch 24V 2W
Normal : About 5MΩ

CS-1
CS-1

Switch
1 ※Check resistance
(power max, one
24V 6A
touch decal, 2 Normal : ∞Ω
horn, breaker)
CS-5 CS-19
CS-26 CS-29

2
※Check disconnection
CN-60 (30A) normal : 0Ω
Circuit breaker 1
CN-95 (60A) (connect ring terminal and check
CN-60 CN-95 resist between terminal 1 and 2)

4-27
Part name Symbol Specifications Check

※Check disconnection
Master switch 6-36V
Normal : 0.1Ω

CS-74A CS-74B

1
Quick clamp 24V 200mA
buzzer 2 107±4dB
-
CN-113

1
Socket
2
12V 10A -

CN-139

2
※ Check contact
WIF sensor 1 -
Normal : 68.8 ~ 4.94Ω
CD-45

4-28
GROUP 4 CONNECTORS

1. CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-1 AMP 10 I/conn (Frame harness-Pump PS harness) S816-010002 S816-110002
CN-2 AMP 20 I/conn (Frame harness-Engine harness) 936777-2 936780-2
CN-3 AMP 26 I/conn (Frame harness-Engine harness) 1897009-2 1897013-2
CN-4 AMP 16 I/conn (Console harness LH-Frame harness) 368047-1 368050-1
CN-5 DEUTSCH 60 I/conn (Side harness RH-Frame harness) DRB16-60SAE-L018 DRB14-60PAE-L018
CN-7 AMP 16 I/conn (Console harness RH-Frame harness) 368047-1 368050-1
CN-8 AMP 12 I/conn (Console harness RH-Frame harness) S816-012002 S816-112002
CN-10 DEUTSCH 12 I/conn (Cab harness-Side harness RH) DT06-12S-EP06 DT04-12P-BE02
CN-11 DEUTSCH 8 I/conn (Frame harness-Aircon harness) DT06-8S -
CN-12 DEUTSCH 2 I/conn (Frame harness-Boom wire harness) DT06-2S-EP06 DT04-2P-E005
CN-15 AMP 12 I/conn (Frame harness-Two way harness) S816-012002 S816-112002
CN-16 AMP 6 Emergency engine start & speed control S816-006002 S816-106002
CN-17 AMP 8 I/conn (Wiper harness) S816-006002 S816-108202
CN-20 MOLEX 2 Horn 36825-0211 -
CN-21 AMP 6 Wiper motor S816-006202 -
CN-22 KET 2 Washer pump MG640605 -
CN-23 KET 2 Speaker-LH MG610070 -
CN-24 KET 2 Speaker-RH MG610070 -
CN-25 MOLEX 2 Horn 36825-0211 -
CN-27 KUM 16 Radio & USB player PK145-16017 -
CN-27A AMP 8 USB player S816-008002 S816-108002
CN-28 KUM 1 Aircon compressor NMWP01F-B -
CN-29 KET 2 Receiver dryer MG640795 -
CN-36 - - Fuse box 21Q7-10920 -
CN-45 RING-TERM - Starter motor B+ S820-308000 -
CN-48 KET 1 Service meter 2-520193-2 -
CN-51 DEUTSCH 40 MCU DRC26-40SA -
CN-52 DEUTSCH 40 MCU DRC26-40SB -
CN-53 DEUTSCH 40 MCU DRC26-40SC -
CN-56 AMP 8 Cluster - S816-108002
CN-60 YAZAKI 2 Circuit breaker - S813-130201
CN-61 DEUTSCH 2 Fuel filler pump DT06-2S-EP06 -
CN-66 DEUTSCH 2 Breaker solenoid DT06-2S-EP06 -
CN-68 DEUTSCH 2 Safety solenoid DT06-2S-EP06 -
CN-70 DEUTSCH 2 Travel high solenoid DT06-2S-EP06 -
CN-74 RING-TERM - Alternator "L" terminal - S820-105000

4-29
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-75 AMP 2 Pump EPPR S816-002002 -
CN-80 RING-TERM - Glow plug S820-306000 -
CN-81 DEUTSCH 2 Travel buzzer solenoid DT06-2S-EP06 -
CN-88 DEUTSCH 2 Power max solenoid DT06-2S-EP06 -
CN-93 DEUTSCH 64 Engine ECM 776469-1 -
CN-95 AMP 2 Circuit breaker - S813-130201
CN-96 AMP 4 Fuel warmer 15300027 -
CN-113 KET 2 Buzzer MG651205-5 -
CN-116 AMP 12 Switch panel 176116 -
CN-125 Econoseal J 4 GPS connector S816-004002 S816-104002
CN-126 AMP 10 Service tool S816-010002 S816-110002
CN-133 DEUTSCH 2 Boom priority solenoid DT06-2S-EP06 -
CN-135 DEUTSCH 2 Arm regeneration solenoid DT06-2S-EP06 -
CN-138 FASTEN 3 DC/DC Converter S810-003202 -
CN-139 FASTEN 2 12V socket 172434-2 -
CN-140 DEUTSCH 2 Quick clamp solenoid DT06-2S-EP06 DT04-2P-E005
CN-141 AMP 13 Wiper motor controller 172498-1 DT04-3P-EP10
CN-142 DEUTSCH 3 Accel dial DT06-3S-EP06 -
CN-144 KET 20 Handsfree MG610240 -
CN-145 DEUTSCH 2 Fuel pump DT06-2S-EP06 -
CN-149 DEUTSCH 2 Attach safety solenoid DT06-2S-EP06 -
CN-156 DEUTSCH 2 Air seat DT04-2S-E005 DT06-2P-EP06
CN-157 AMP 1 Antena power S822-014002 -
CN-170 AMP 2 Heated seat S816-002002 S816-102002
CN-173 AMP 2 Resistor S816-002002 -
CN-231 DEUTSCH 2 I/conn (Master switch-Fuse box) S813-030201
CN-236 DEUTSCH 2 Attach pressure solenoid DT06-2S-EP06 -
CN-237 DEUTSCH 2 Attach conflux solenoid DT06-2S-EP06 -
CN-242 DEUTSCH 2 Attach flow solenoid DT06-2S-EP06 DT04-2P-E005
CN-244 DEUTSCH 3 CAN 2 - DT04-3P-EP06
CN-245 AMP 12 Remote controller assy 368542-1 -
CN-246 AMP 12 USB & Socket assy 174045-2 -
CN-249 AMP 4 Rear view camera S816-004002 S816-104002
CN-255 AMP 12 PTC power S813-030201 -
CN-259 AMP 6 Camera S816-006002 -
CN-262 DEUTSCH 2 Straight travel solenoid DT06-2S-EP06 -
CN-263 DEUTSCH 2 Adjust boom solenoid DT06-2S-EP06 -
CN-279 AMP 2 Accel dial LED S816-002002 S816-102002

4-30
Connector No. of Connector part No.
Type Destination
number pin Female Male
·Relay
CR-1 RING-TERM - Battery relay ST710285-2 -
CR-2 - 5 Horn relay - -
CR-4 - 5 Work lamp relay BJA003526-001 -
CR-5 - 5 Anti restart relay - -
CR-7 - 5 Aircon compressor relay BJA003526-001 -
CR-9 - 5 Cabin lamp relay BJA003526-001 -
CR-13 - 5 Head lamp relay BJA003526-001 -
CR-23 RING TERM - Start relay S814-002001 S814-102001
CR-24 RING TERM - Preheat relay S822-014000 -
CR-35 - 5 Power relay - -
CR-36 - 5 Preheat relay - -
CR-45 AMP 5 ECM power relay BJA003526-001 24L1-05100
CR-46 - 5 Fuel warmer relay BJA003526-001 -
CR-62 - 5 Breaker relay BJA003526-001 -
·Switch
CS-1 SHUR 1 Door switch S822-014002 S822-114002
CS-2 WP 6 Start key switch S816-006100 -
CS-4 DEUTSCH 3 Safety switch DT06-3S-EP06 -
CS-5 DEUTSCH 2 Horn switch - DT04-2P-E005
CS-19 DEUTSCH 2 One touch decel switch - DT04-2P-E005
CS-23 SWF 12 Beacon lamp switch SWF589790 -
CS-26 DEUTSCH 2 Breaker switch DT06-2S-EP06 -
CS-26A AMP 2 Breaker pedal switch S816-002002 S816-102002
CS-33 AMP 6 Emergency engine stop switch S816-006002 S816-106002
CS-29 DEUTSCH 2 Power max switch DT06-2S-EP06 -
CS-50 SWF 12 Overload switch SWF589790 -
CS-52 SWF 12 Econo switch SWF589790 -
CS-53 AMP 1 Wiper cut switch S822-014002 -
CS-67 SWF 12 Quick clamp switch SWF 589790 -
CS-73 SWF 12 Reverse fan SWF 589790 -
CS-74A DEUTSCH 2 Master switch DT06-2S-EP06 -
CS-74B AMP 2 Master switch S813-030201 -
CS-82 SWF 12 Heated seat switch SWF 589790 -
CS-83 SWF 12 Spare switch SWF 589790 -
CS-99 SWF 12 Air compressor switch SWF 589790 -
CS-100 SWF 12 Spare switch SWF 589790 -

4-31
Connector No. of Connector part No.
Type Destination
number pin Female Male
·Light
CL-1 KET 3 Room lamp MG651032 -
CL-2 AMP 1 Cigar light S822-014002 S822-114002
CL-3 DEUTSCH 2 Head lamp-LH DT06-2S-EP06 DT04-2P-E005
CL-4 DEUTSCH 2 Head lamp-RH DT06-2S-EP06 DT04-2P-E005
CL-5 AMP 2 Work lamp-LH 180923-0 -
CL-6 AMP 2 Work lamp-RH 180923-0 -
CL-7 SHUR 1 Beacon lamp S822-014002 S822-114002
CL-8 DEUTSCH 2 Front cab light-LH DT06-2S-EP06 DT04-2P
CL-9 DEUTSCH 2 Front cab light-RH DT06-2S-EP06 DT04-2P
CL-10 DEUTSCH 2 Rear cab light-LH DT06-2S-EP06 DT04-2P
CL-24 DEUTSCH 2 Work lamp-rear DT06-2S-EP06 DT04-2P-E005
·Sensor, sendor
CD-1 AMP 2 Hydraulic oil temp sender 85202-1 -
CD-2 DEUTSCH 2 Fuel level sender DT06-2S-EP06 -
CD-6 DEUTSCH 3 Travel pressure sensor DT06-3S-EP06 -
CD-7 DEUTSCH 3 Working pressure sensor DT06-3S-EP06 -
CD-10 AMP 4 DPF inlet temp sensor 776487-2 -
CD-10A AMP 2 Air cleaner switch 85202-1 -
CD-16 DELPHI 3 Water level sensor 12110293 -
CD-24 DEUTSCH 3 Swing sensor DT06-3S-EP06 -
CD-31 DEUTSCH 3 Overload sensor DT06-3S-EP06 -
CD-32 DEUTSCH 3 Boom up sensor DT06-3S-EP06 -
CD-35 DEUTSCH 3 Arm & bucket in sensor DT06-3S-EP06 -
CD-42 DEUTSCH 3 Pump pressure 1 DT06-3S-EP06 -
CD-43 DEUTSCH 3 Pump pressure 2 DT06-3S-EP06 -
CD-44 DEUTSCH 3 Pump pressure 3 DT06-3S-EP06 -
CD-45 AMP 3 WIF sensor 776429-3 -
CD-50 KET 2 Dozer pressure switch MG640795 -
CD-69 DEUTSCH 3 Attach pressure sensor DT06-3S-EP06 -
CD-70 DEUTSCH 3 N1 pressure sensor DT06-3S-EP06 -
CD-71 DEUTSCH 3 N2 pressure sensor DT06-3S-EP06 -
CD-97 AMP 6 Aftertreatment 776433-3 -
CD-98 AMP 2 Air intake temp sensor 776427-1 -
CD-107 AMP 6 DPF soot sensor 776433-3 -

4-32
2. CONNECTION TABLE FOR CONNECTORS
1) PA TYPE CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin

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 - 33
No. of
Receptacle connector (female) Plug connector (male)
pin

6 13 1 7

13

1 7 6 13
S811-013002 S811-113002

8 1 9
17

17

1 9 8 17
S811-017002 S811-117002
1 21
1 11

21

1 11 1 21
S811-021002 S811-121002

4 - 34
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

8 5 2
6 3 1

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

4 - 35
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 - 36
No. of
Receptacle connector (female) Plug connector (male)
pin
3 6
1 4

1 4 3 6

S814-006000 S814-106000
4 8
1 5

1 5 4 8
S814-008000 S814-108000

4 12
1 9

12

4 12
1 9
S814-012000 S814-112000
3 14
1 11

14

1 11 3 14

S814-014000 S814-114000

4 - 37
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 3

1 3 2 4
S810-004202 S810-104202

4 - 38
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 4 8
S810-008202 S810-108202

4 - 39
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

12
1

1 13
24
36
36 25
13 12
24
25 36

344111-1 344108-1

7) AMP TIMER CONNECTOR

No. of
Receptacle connector (female) Plug connector (male)
pin

85202-1

4 - 40
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

1 6
14

7 14
173852

10) AMP FASTIN - FASTON CONNECTOR

No. of
Receptacle connector (female) Plug connector (male)
pin

6
6
1
4

925276-0

4 - 41
11) KET 090 CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin

1
2

MG610070

12) KET 090 WP CONNECTORS

No. of
Receptacle connector (female) Plug connector (male)
pin

1
2

MG640605

2 1

MG640795

4 - 42
13) KET SDL CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin

14
7

6
14

MG610406

4 - 43
14) DEUTSCH DT CONNECTORS
DT 06 - 3S - ★★★★

Modifications (see below)

Number of contacts (P : Pin, S : Socket)
04 : Receptacle, 06 : Plug
Deutsch connectors
※ Modification
E003 : Standard end cap - gray
E004 : Color of connector to be black
E005 : Combination - E004 & E003
EP04 : End cap
EP06 : Combination P012 & EP04
P012 : Front seal enhancement - connectors color to black for 2, 3, 4 & 6pin
No. of
Receptacle connector (female) Plug connector (male)
pin

1 2 2 1

DT06-2S DT04-2P

2 1 1 2

3 3

DT06-3S DT04-3P

4 1 1 4

3 2 2 3

DT06-4S DT04-4P

4 - 44
No. of
Receptacle connector (female) Plug connector (male)
pin

6 1 1 6

4 3 3 4

DT06-6S DT04-6P

4 5 5 4

1 8
8 1

DT06-8S DT04-8P

7 6
6 7

12

1 12 12 1

DT06-12S DT04-12P

4 - 45
15) MOLEX 2CKTS CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin

1 2

35215-0200
35215-0200

16) ITT SWF CONNECTOR

No. of
Receptacle connector (female) Plug connector (male)
pin

2
10

1 10

SWF593757

17) MWP NMWP CONNECTOR

No. of
Receptacle connector (female) Plug connector (male)
pin

1
1

NMWP01F-B

4 - 46
18) ECONOSEAL J TYPE CONNECTORS
No. of
Receptacle connector (female) Plug connector (male)
pin

S816-001002 S816-101002

1 2 2 1

S816-002002 S816-102002

S816-003002 S816-103002

S816-004002 S816-104002

4 - 47
No. of
Receptacle connector (female) Plug connector (male)
pin

S816-006002 S816-106002

S816-008002 S816-108002

10

S816-010002 S816-110002

12

S816-012002 S816-112002

4 - 48
No. of
Receptacle connector (female) Plug connector (male)
pin

15

368301-1 2-85262-1

19) METRI-PACK TYPE CONNECTOR

No. of
Receptacle connector (female) Plug connector (male)
pin

12040753

20) DEUTSCH HD30 CONNECTOR

No. of
Receptacle connector (female) Plug connector (male)
pin

J K
K J
B

23 N T

A B
F
F Q N
Q A
HD36-24-23SN HD34-24-23PN

4 - 49
21) DEUTSCH MCU CONNECTOR

No. of
Receptacle connector (female) Plug connector (male)
pin

5
1 6
11 1
10
2
3
11 4
5
21
6
40 21 31
32
7
8
9
33 10
34
35

31 36
37
20
30
20
38
39
35 40

36
30
40

DRC26-40SA/B

22) DEUTSCH SERVICE TOOL CONNECTOR

No. of
Receptacle connector (female) Plug connector (male)
pin

C
D
E

A
9
F
B
G
H J
HD10-9-96P

23) AMP FUEL WARMER CONNECTOR

No. of
Receptacle connector (female) Plug connector (male)
pin

3 2

2-967325-3

4 - 50
24) DEUTSCH E
ENGINE
NGINE ECM CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin

1 5
6
11
1
10
2
11 3
4
21 5
21 31
6
7
50 31 41
42
8
9
10 20
43
44
41 45
20

46
47
30
40
30
48
45 49
50
46
50 40
DRC26-50S-04

25) DEUTSCH INTERMEDIATE CONNECTOR

No. of
Receptacle connector (female) Plug connector (male)
pin

1
13 12
25 24
31
60 30
37
36
49
48

60
DRB16-60SAE-L018

4 - 51
SECTION 5 MECHATRONICS SYSTEM

Group 1 Outline----------------------------------------------------------------------------------------------------------------- 5-1

Group 2 Mode Selection System ------------------------------------------------------------------------------------ 5-3
Group 3 Automatic Deceleration System ----------------------------------------------------------------------- 5-6
Group 4 Power Boost System ----------------------------------------------------------------------------------------- 5-7
Group 5 Travel Speed Control System --------------------------------------------------------------------------- 5-8
Group 6 Automatic Warming Up System ----------------------------------------------------------------------- 5-9
Group 7 Engine Overheat Prevention System --------------------------------------------------------------- 5-10
Group 8 Variable Power Control System ------------------------------------------------------------------------ 5-11
Group 9 Attachment Flow Control System --------------------------------------------------------------------- 5-12
Group 10 Anti-Restart System ------------------------------------------------------------------------------------------- 5-13
Group 11 Self-Diagnostic System ------------------------------------------------------------------------------------- 5-14
Group 12 Engine Control System ------------------------------------------------------------------------------------- 5-20
Group 13 EPPR Valve -------------------------------------------------------------------------------------------------------- 5-21
Group 14 Monitoring System --------------------------------------------------------------------------------------------- 5-26
Group 15 Fuel Warmer System ----------------------------------------------------------------------------------------- 5-51
SECTION 5 MECHATRONICS SYSTEM
GROUP 1 OUTLINE

The ADVANCED CAPO (Computer Aided Power Optimization) system controls engine and pump
mutual power at an optimum and less fuel consuming state for the selected work by mode selection,
auto-deceleration, power boost function, etc. It monitors machine conditions, for instance, engine
speed, coolant temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
It consists of a MCU, a cluster, an ECM, EPPR valves, and other components. The MCU and the
cluster protect themselves from over-current and high voltage input, and diagnose malfunctions caused
by short or open circuit in electric system, and display error codes on the cluster.

Power mode selection (P, S, E)

Mode selection system Work mode selection
User mode system (U)
Auto deceleration system

Power boost system

Travel speed control system

Automatic warming up system

Engine overheat prevention system

ADVANCED
CAPO
SYSTEM
Variable power control system

Attachment flow control system

Anti-restart system
MCU & cluster protection
Self-diagnostic system Open-short diagnosis & error code display
Machine error & ECM fault code display
Machine condition monitoring
Machine monitoring system
Electric signal monitoring

One touch deceleration system

5-1
SYSTEM DIAGRAM

Attachment pilot N1 N2 Work Travel

Work tool pressure pressure pressure pressure pressure
PS PS PS PS PS

MCV
Option C
(Dozer)
Option B Bucket
Option A &
Arm 1 Arm regen
SOLENOID VALVE EPPR VALVE
Boom 2 Arm 2
Travel speed Attachment
pressure(opt) Swing Boom 1

Power boost Attachment Travel(RH) Travel(LH) Boom priority

conflux(opt) EPPR
Straight
Attachment Attachment
Arm regen safety(opt) travel flow EPPR

P1
Overload pressure
pressure
sensor PS
PS P2
pressure
PS
Boom cylinder

Engine
P1 P2
P3 P3
pressure
PS
ECM
Main pump Pilot pump
Pump power
shift EPPR
CAN

Signal

Pressure signal
Pressure signal
Drive signal
Drive signal MCU
Pressure signal
Switch signal
Pressure signal Accel dial signal CN-16A CN-16
Power boost
button Normal
One touch Horn button
decel button
CN-16B
Emergency
Option
LH control button RH control
lever lever Accel dial

Serial communication(-)
Serial communication(+)
SL SR AO AI BI BU

Shuttle
block

PS PS PS

Swing Arm in/out Boom up

pressure & Bucket in pressure Rear view camera
pressure
Cluster

145Z9A5MS01

5-2
GROUP 2 MODE SELECTION SYSTEM

1. POWER MODE SELECTION SYSTEM

Main control valve

Engine

ECM
Main pump Pilot pump
Pump power
shift EPPR
CAN

Cluster

Drive signal
MCU

Accel dial signal CN-16A CN-16

Normal

CN-16B
Emergency

Power mode Accel dial

pilot lamp

Power mode switch signal

2609A5MS02

Mode selection system (micro computer based electro-hydraulic pump and engine mutual control
system) optimizes the engine and pump performance.
The combination of 3 power modes (P, S, E) and 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.

Engine rpm Power shift by EPPR valve

Power Standard Option Standard Option
mode Application
Current Pressure Current Pressure
Unload Load Unload Load (mA) (kgf/cm2) (mA) (kgf/cm2)

P Heavy duty power 1950±50 2050±50 1950±50 2050±50 290±30 8 160±30 0

S Standard power 1850±50 1950±50 1850±50 1950±50 330±30 10±3 250±30 5±3
E Economy operation 1750±50 1850±50 1800±50 1900±50 365±30 13±3 330±30 10±3
AUTO Engine
1000±100 - 1000±100 - 700±30 38±3 700±30 38±3
DECEL deceleration
One touch Engine quick
950±100 - 950±100 - 700±30 38±3 700±30 38±3
decel deceleration
KEY Key switch
950±100 - 950±100 - 700±30 38±3 700±30 38±3
START start position

※ Power shift (standard/option) can be changed by "Service menu" in "Management" on the cluster.

5-3
2. WORK MODE SELECTION SYSTEM
Work mode consists of the general operation (bucket) and the optional attachment (breaker,
crusher).

Attachment pilot
pressure sensor Main control valve
Work tool PS
Option C
(Dozer)
Bucket SOLENOID VALVE
Option B
Option A & Attachment
Arm 1 Arm regen pressure

Boom 2 Arm 2 Attachment

conflux

Swing Boom 1 Attachment

safety
Travel(RH) Travel(LH)
Straight
travel

Engine

ECM
Main pump Pilot pump
Pump power
shift EPPR
CAN

Cluster

Drive signal

Drive signal
MCU
Pressure signal

Accel dial signal CN-16A CN-16

Normal

CN-16B
Emergency

Work mode
pilot lamp Work mode switch signal Accel dial

145Z9A5MS02

1) GENERAL WORK MODE (bucket)

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

General mode Work tool

Description
Bucket Breaker Crusher
Attachment safety solenoid OFF ON ON
Attachment pressure solenoid OFF OFF ON
Attachment conflux solenoid OFF OFF ON/OFF
Attachment flow EPPR current 100 mA 100~700 mA 100~700 mA

5-4
3. USER MODE SELECTION SYSTEM

Main control valve

Engine

ECM
Main pump Pilot pump
Pump power
shift EPPR

CAN

Cluster

Drive signal
MCU

Accel dial signal CN-16A CN-16

Normal

CN-16B
Emergency

User mode Accel dial

pilot lamp

Power mode switch signal

2609A5MS04

1) High idle rpm, auto idle rpm and EPPR pressure can be adjusted and memorized in the U-mode.
2) LCD segment vs parameter setting
Step Engine speed Idle speed Power shift
( ) (rpm) (rpm) (bar)
1 1400 900 0
2 1500 950 3
3 1600 1000 (auto decel) 6
4 1700 1050 9
5 1800 1100 12
6 1900 1150 16
7 2000 1200 20
8 2050 1250 26
9 2100 1300 32
10 2150 1350 38
※ One touch decel & low idle : 950 rpm

5-5
GROUP 3 AUTOMATIC DECELERATION SYSTEM

Work Travel
pressure pressure
PS PS

Main control valve

Engine

ECM
Main pump Pilot pump
CAN

Cluster

MCU
Pressure signal

Accel dial signal CN-16A CN-16

Normal
Auto idle CN-16B
pilot lamp Emergency

Accel dial
Auto idle switch signal
2609A5MS05

1. WHEN AUTO IDLE PILOT LAMP ON

When all of the work equipment control levers including swing and travel levers are at neutral for 4
seconds, MCU sends throttle command to ECM to reduce the engine speed to 1000 rpm. If the
control levers are at neutral for 1 minute, MCU reduces the engine speed to 950 rpm. As the result of
reducing the engine speed, fuel consumption and noise are effectively cut down during non-operation
of the control levers.
When the Auto idle pilot lamp is turned off by pressing the switch or any control lever is operated, the
reduced engine speed rises upto the speed before deceleration in a second.

Engine rpm

Accel dial
set rpm

Auto idle 1000 rpm

rpm
4 sec
Low idle 950 rpm
rpm
60 sec 1sec

Lever Lever Time

neutral operation
1609A5MS05

2. WHEN AUTO IDLE PILOT LAMP OFF

The engine speed can be set as desired using the accel dial switch, and even if the control levers are
neutral, the engine speed is not reduced.
※ Auto idle function can be activated when accel dial position is over 4.

5-6
GROUP 4 POWER BOOST SYSTEM
Main control valve

Option C
(Dozer)
Option B Bucket
Option A &
Arm 1 Arm regen

Boom 2 Arm 2

Swing Boom 1

Travel(RH) Travel(LH)
Straight Main relief
valve
travel

PS
P1 P2
pressure pressure
PS

Power boost
solenoid valve
Engine

ECM
Main pump Pilot pump
Power boost Pump power
button
shift EPPR
CAN

Signal
LH control
lever
Drive signal
Power max button signal
Pressure signal
MCU
Accel dial signal CN-16A CN-16

Normal

CN-16B
Emergency

Accel dial
Power mode sw signal
Power max
pilot lamp

Cluster 145Z9A5MS04

· When the power boost switch on the left control lever knob is pushed ON, the power mode is set P
mode and maximum digging power is increased by 10 %.
· When the power boost function is activated, the power boost solenoid valve pilot pressure raises the
set pressure of the main relief valve to increase the digging power.

Description Condition Function

- Power mode : P
- Accel dial power : 9
Power boost switch : ON
Activated - Power boost solenoid : ON
Accel dial : over 8
- Power boost pilot lmap : ON
- Operating time : max 8 seconds
- Pre-set power mode
Canceled Power boost switch : OFF - Power boost solenoid : OFF
- Power boost pilot lamp : OFF
※ When the auto power boost is set to Enable and power mode is set to P mode on the cluster, the
digging power is automatically increased as working conditions by the MCU. It is operated max 8
seconds.

5-7
GROUP 5 TRAVEL SPEED CONTROL SYSTEM

Main control valve

Option C
(Dozer)
Option B Bucket Travel motor

Option A &
Arm 1 Arm regen

Boom 2 Arm 2

Boom 1 Regulator
Swing

Travel(RH) Travel(LH)
Straight
travel Travel speed
solenoid valve

Engine

Main pump Pilot pump

Cluster

Drive signal
MCU

Travel speed
pilot lamp

Travel speed switch signal

145Z9A5MS05

Travel speed can be switched manually by pressing the travel speed switch on the cluster.

Travel speed Lamp

Speed Operation
solenoid valve on cluster
Low OFF Turtle Low speed, high driving torque in the travel motor
High ON Rabbit High speed, low driving torque in the travel motor
※ Default : Turtle (Low)

5-8
GROUP 6 AUTOMATIC WARMING UP SYSTEM

Main control valve

Engine

ECM
Main pump Pilot pump
Pump power
CAN shift EPPR

Cluster Hydraulic temp signal

Hydraulic temp sensor

Drive signal
MCU

Accel dial signal CN-16A CN-16

Normal

CN-16B
Emergency

Warming up pilot lamp signal

Accel dial

Warming up pilot lamp

2609A5MS08

1. The MCU receives the engine coolant temperature from the ECM, and if the coolant temperature is
below 30˚C, it increases the engine speed from key start rpm to 1200 rpm. At this time the mode
does not change. If the coolant temperature sensor has fault, the hydraulic oil temperature signal is
substituted.
2. In case of the coolant temperature increases up to 30˚C, the engine speed is decreased to key start
speed. And if an operator changes power mode set during the warming up function, the MCU
cancels the automatic warming up function.
3. LOGIC TABLE
Description Condition Function
- Coolant temperature : - Power mode : Default (E mode)
Actuated below 30˚C (after engine run) - Warming up time : 10 minutes (max)
- Warming up pilot lamp : ON

- Coolant temperature : Above 30˚C - Power mode : set mode

- Warming up time : Above 10 minutes - Warming up pilot lamp : OFF
- Changed power mode set by operator
Canceled - RCV lever or pedal operating
- Auto idle cancel
※ If any of the above conditions is
applicable, the automatic warming up
function is canceled

5-9
GROUP 7 ENGINE OVERHEAT PREVENTION SYSTEM

Main control valve

Engine

ECM
Main pump Pilot pump
Pump power
shift EPPR
CAN

Emergency
warning lamp
Cluster Hydraulic temp signal

Hydraulic temp sensor

Drive signal
MCU

Accel dial signal CN-16A CN-16

Normal

CN-16B
Emergency

Overheat warning signal

Accel dial

Hydraulic temperature
warning lamp
2609A5MS09

1. If the engine coolant temperature or the hydraulic oil temperature is overheated over 100˚C, the
warning lamp is ON and the pump input torque or the engine speed is reduced as below logic table.
2. LOGIC TABLE
Description Condition Function
- Coolant temperature : - Warning lamp : ON, buzzer : OFF
Above 103˚C
Activated
- Hydraulic oil temperature : - Pump input torque is reduced.
First step Above 100˚C
warning - Coolant temperature :
Less than 100˚C - Return to pre-set the pump absorption
Canceled
- Hydraulic oil temperature : torque.
Less than 95˚C
- Coolant temperature :
- Emergency warning lamp pops up on the
Above 107˚C
Activated center of LCD and the buzzer sounds.
- Hydraulic oil temperature :
- Engine speed is reduced after 10 seconds.
Second step Above 105˚C
warning - Coolant temperature :
- Return to pre-set the engine speed.
Less than 103˚C
Canceled - Hold pump absorption torque on the first
- Hydraulic oil temperature :
step warning.
Less than 100˚C

5-10
GROUP 8 VARIABLE POWER CONTROL SYSTEM

N1 N2 Work Travel
pressure pressure pressure pressure
PS PS PS PS

Main control valve

PS
P1 P2
pressure pressure
Engine PS

ECM
Main pump Pilot pump
Pump power
shift EPPR
CAN

Signal

Pressure signal
Switch signal
LH control RH control Pressure signal MCU
lever lever
Pressure signal

Accel dial signal CN-16A CN-16

Normal

CN-16B
Emergency
AO AI BI BU

Shuttle Accel dial

block

PS PS
Power mode switch signal

Arm in/out Boom up

& Bucket in pressure
pressure

E mode power

Cluster
2609A5MS10

· The variable power control system controls the engine and pump mutual power according to RCV
lever stroke and pump load.
It makes fuel saving and smooth control at precise work.

Description Working condition

Power mode E
Work mode General (bucket)
Pressure sensor Normal

※ The variable power control function can be activated when the power mode is set to E mode.

5-11
GROUP 9 ATTACHMENT FLOW CONTROL SYSTEM

Attachment pilot
pressure sensor Main control valve
PS
Option C
(Dozer)
Option B Bucket
Option A &
Work tool Arm 1 Arm regen
SOLENOID VALVE
Boom 2 Arm 2
Attachment
Swing Boom 1 pressure

Attachment
Travel(RH) Travel(LH) conflux
Straight Attachment
travel safety

Engine

ECM
Main pump Pilot pump
Attachment
flow EPPR
CAN

Cluster

Drive signal

Drive signal
MCU
Pressure signal

Accel dial signal CN-16A CN-16

Normal

CN-16B
Emergency
Work mode
pilot lamp Work mode switch signal
Accel dial

145Z9A5MS06

· The system is used to control the pump delivery flow according to set of the work tool on the
cluster by the attachment flow EPPR valve.

Work tool
Description
Breaker Crusher
Max 7 step, Max 4 step,
Flow level reduced 10 lpm each step reduced 20 lpm each step
Attach safety solenoid ON ON
Attach pressure solenoid OFF ON
Attach conflux solenoid OFF ON/OFF

※ Refer to the page 5-38 for the attachment kinds and max flow.

5-12
GROUP 10 ANTI-RESTART SYSTEM

Engine

Starter

ECM

Start safety relay

Drive signal

MCU

Accel dial signal CN-16A CN-16

Normal

CN-16B
Emergency

Accel dial

2609A5MS12

1. ANTI-RESTART FUNCTION
After a few seconds from the engine starts to run, MCU turns off the start safety relay to protect the
starter from inadvertent restarting.

2. When a replacement or taking-off of the MCU is needed, connect CN-16 and CN-16B to ensure the
engine start without the MCU.

5-13
GROUP 11 SELF-DIAGNOSTIC SYSTEM

1. OUTLINE
When any abnormality occurs in the ADVANCED CAPO system caused by electric parts malfunction
and by open or short circuit, the MCU diagnoses the problem and sends the error codes to the
cluster and also stores them in the memory.

2. MONITORING
1) Active fault

21093CD66

21093CD66A 2609A3CD53

· The active faults of the MCU or engine ECM can be checked by this menu.

2) Logged fault

21093CD66C

21093CD66D 2609A3CD56

· The logged faults of the MCU or engine ECM can be checked by this menu.

3) Delete fault

21093CD66F

21093CD66G 2609A3CD59

· The logged faults of the MCU or engine ECM can be deleted by this menu.

5-14
3. MACHINE ERROR CODES TABLE
Error code
Description
HCESPN FMI
3 Hydraulic oil temperature sensor circuit - Voltage above normal, or shorted to high source.
101
4 Hydraulic oil temperature circuit - Voltage below normal, or shorted to low source.
0 Working pressure sensor data above normal range.
1 Working pressure sensor data below normal range.
105
2 Working pressure sensor data error.
4 Working pressure sensor circuit - Voltage below normal, or shorted to Low source.
0 Travel oil pressure sensor data above normal range.
1 Travel oil pressure sensor data below normal range.
108
2 Travel oil pressure sensor data error.
4 Travel oil pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Main pump 1 (P1) pressure sensor data above normal range.
1 Main pump 1 (P1) pressure sensor data below normal range.
120 2 Main pump 1 (P1) pressure sensor data error.
Main pump 1 (P1) pressure sensor circuit - Voltage below normal, or shorted to low
4
source.
0 Main pump 2 (P2) pressure sensor data above normal range.
1 Main pump 2 (P2) pressure sensor data below normal range.
121 2 Main pump 2 (P2) pressure sensor data error.
Main pump 2 (P2) pressure sensor circuit - Voltage below normal, or shorted to low
4
source.
0 Overload pressure sensor data above normal range.
1 Overload pressure sensor data below normal range.
122
2 Overload pressure sensor data error.
4 Overload pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Negative 1 pressure sensor data above normal range.
1 Negative 1 pressure sensor data below normal range.
123
2 Negative 1 pressure sensor data error.
4 Negative 1 pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Negative 2 Pressure sensor data above normal range.
1 Negative 2 Pressure sensor data below normal range.
124
2 Negative 2 Pressure sensor data error.
4 Negative 2 Pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Pilot pump (P3) pressure sensor data above normal range.
1 Pilot pump (P3) pressure sensor data below normal range.
125
2 Pilot pump (P3) pressure sensor data error.
4 Pilot pump (P3) pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Boom up pilot pressure sensor data above normal range.
1 Boom up pilot pressure sensor data below normal range.
127
2 Boom up pilot pressure sensor data error.
4 Boom up pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Arm in/out & bucket in pilot pressure sensor data above normal range.
1 Arm in/out & bucket in pilot pressure sensor data below normal range.
133 2 Arm in/out & bucket in pilot pressure sensor data error.
Arm in/out & bucket in pilot pressure sensor circuit - Voltage below normal, or shorted to
4
low source.
※Some error codes are not applied to this machine.
※SPN : Suspect Parameter Number
FMI : Failure Mode Identifier

5-15
Error code
Description
HCESPN FMI
0 Swing pilot pressure sensor data above normal range.
1 Swing pilot pressure sensor data below normal range.
135
2 Swing pilot pressure sensor data error.
4 Swing pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Attachment pilot pressure sensor data above normal range.
1 Attachment pilot pressure sensor data below normal range.
138
2 Attachment pilot pressure sensor data error.
4 Attachment pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
5 Pump EPPR valve circuit - Current below normal, or open circuit.
140
6 Pump EPPR valve circuit - Current above normal.
5 Boom priority EPPR valve circuit - Current below normal, or open circuit.
141
6 Boom priority EPPR valve circuit - Current above normal.
5 Travel EPPR valve circuit - Current below normal, or open circuit.
143
6 Travel EPPR valve circuit - Current above normal.
5 Attachment flow EPPR valve circuit - Current below normal, or open circuit.
144
6 Attachment flow EPPR valve circuit - Current above normal.
5 Remote cooling fan EPPR valve circuit - Current below normal, or open circuit.
145
6 Remote cooling fan EPPR valve circuit - Current above normal.
5 Left rotate EPPR valve circuit - Current below normal, or open circuit.
150
6 Left rotate EPPR valve circuit - Current above normal.
5 Right rotate EPPR valve circuit - Current below normal, or open circuit.
151
6 Right rotate EPPR valve circuit - Current above normal.
5 Left tilt EPPR valve circuit - Current below normal, or open circuit.
152
6 Left tilt EPPR valve circuit - Current above normal.
5 Right tilt EPPR valve circuit - Current below normal, or open circuit.
153
6 Right tilt EPPR valve circuit - Current above normal.
5 Power max solenoid circuit - Current below normal, or open circuit.
166
6 Power max solenoid circuit - Current above normal.
5 Travel speed solenoid circuit - Current below normal, or open circuit.
167
6 Travel speed solenoid circuit - Current above normal.
5 Attachment pressure solenoid circuit - Current below normal, or open circuit.
168
6 Attachment pressure solenoid circuit - Current above normal.
5 Attachment conflux solenoid circuit - Current below normal, or open circuit.
169
6 Attachment conflux solenoid circuit - Current above normal.
5 Arm regeneration solenoid circuit - Current below normal, or open circuit.
170
6 Arm regeneration solenoid circuit - Current above normal.
5 Attachment safety solenoid circuit - Current below normal, or open circuit.
171
6 Attachment safety solenoid circuit - Current above normal.
5 Remote cooling fan reverse solenoid circuit - Current below normal, or open circuit.
181
6 Remote cooling fan reverse solenoid circuit - Current above normal.
5 Fuel level sensor circuit - Voltage above normal, or shorted to high source.
301
6 Fuel level sensor circuit - Voltage below normal, or shorted to low source.
Engine coolant temperature sensor circuit - Voltage above normal, or shorted to high
3
source.
304
Engine coolant temperature sensor circuit - Voltage below normal, or shorted to low
4
source.
310 8 Engine speed signal error - Abnormal frequency or pulse width.
3 Engine preheat relay circuit - Voltage above normal, or shorted to high source.
322
4 Engine preheat relay circuit - Voltage below normal, or shorted to low source.
3 Fuel warmer relay circuit - Voltage above normal, or shorted to high source.
325
4 Fuel warmer relay circuit - Voltage below normal, or shorted to low source.
※Some error codes are not applied to this machine.
※SPN : Suspect Parameter Number
FMI : Failure Mode Identifier
5-16
Error code
Description
HCESPN FMI
3 Potentiometer (G/A) circuit - Voltage above normal, or shorted to high source.
340
4 Potentiometer (G/A) circuit - Voltage below normal, or shorted to low source.
5 Governor actuator circuit - Current below normal, or open circuit.
341
6 Governor actuator circuit - Current above normal.
0 Transmission oil pressure sensor data above normal range.
1 Transmission oil pressure sensor data below normal range.
501
2 Transmission oil pressure sensor data error.
4 Transmission oil pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Brake pressure sensor data above normal range.
1 Brake pressure sensor data below normal range.
503
2 Brake pressure sensor data error.
4 Brake pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Working brake pressure sensor data above normal range.
1 Working brake pressure sensor data below normal range.
505
2 Working brake pressure sensor data error.
4 Working brake pressure sensor circuit - Voltage below normal, or shorted to low source.
3 Working brake lamp circuit - Voltage above normal, or shorted to high source.
506
4 Working brake lamp circuit - Voltage below normal, or shorted to low source.
3 Ram lock lamp circuit - Voltage above normal, or shorted to high source.
520
4 Ram lock lamp circuit - Voltage below normal, or shorted to low source.
5 Ram lock solenoid circuit - Current below normal, or open circuit.
525
6 Ram lock solenoid circuit - Current above normal.
0 Travel F pilot pressure sensor data above normal range.
1 Travel F pilot pressure sensor data below normal range.
530
2 Travel F pilot pressure sensor data error.
4 Travel F pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Travel R pilot pressure sensor data above normal range.
1 Travel R pilot pressure sensor data below normal range.
531
2 Travel R pilot pressure sensor data error.
4 Travel R pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
3 Hourmeter circuit - Voltage above normal, or shorted to high source.
701
4 Hourmeter circuit - Voltage below normal, or shorted to low source.
0 MCU input voltage high.
705
1 MCU input voltage low.
707 1 Alternator node I voltage low.
3 Acc. dial circuit - Voltage above normal, or shorted to high source.
714
4 Acc. dial circuit - Voltage below normal, or shorted to low source.
3 Rotate signal input circuit - Voltage above normal, or shorted to high source.
715
4 Rotate signal input circuit - Voltage below normal, or shorted to low source.
3 Tilt signal input circuit - Voltage above normal, or shorted to high source.
716
4 Tilt signal input circuit - Voltage below normal, or shorted to low source.
3 Travel alarm (buzzer) circuit - Voltage above normal, or shorted to high source.
722
4 Travel alarm (buzzer) circuit - Voltage below normal, or shorted to low source.
830 12 MCU internal memory error.
840 2 Cluster communication data error.
841 2 ECM communication data error.
843 2 Option #1 (CAN 2) communication data error.
850 2 RMCU communication data error.
※Some error codes are not applied to this machine.
※SPN : Suspect Parameter Number
FMI : Failure Mode Identifier
5-17
4. ENGINE FAULT CODE
SPN FMI Fault code No. Description
91 2 SPN91-FMI2 Throttle Position Sensor Data Erratic, Intermittent, or Incorrect
3 SPN91-FMI3 (Secondary) Throttle Position Sensor Voltage Above Normal or Shorted High
4 SPN91-FMI4 (Secondary) Throttle Position Sensor Voltage Below Normal or Shorted Low
8 SPN91-FMI8 (Secondary) Throttle Position Sensor Abnormal Frequency or Period
12 SPN91-FMI12 (Secondary) Throttle Position Sensor Bad Device or Component
100 1 SPN100-FMI1 Engine Oil pressure Low-Warning
2 SPN100-FMI2 Engine Oil Pressure Low-Derate
3 SPN100-FMI3 Engine Oil Pressure Sensor Voltage Above Normal or Shorted High(Shutdown)
4 SPN100-FMI4 Engine Oil Pressure Sensor Voltage Below Normal or Shorted Low
105 10 SPN100-FMI10 Engine Oil Pressure Sensor 5V Supply Connection Open Circuit
1 SPN105-FMI1 Inlet Manifold Air Temp High-Warning
2 SPN105-FMI2 Inlet Manifold Air Temp High-Derate
3 SPN105-FMI3 Inlet Manifold Air Temp Sensor Voltage Above Normal or Shorted High
4 SPN105-FMI4 Inlet Manifold Air Temp Sensor Voltage Below Normal or Shorted Low
106 3 SPN106-FMI3 Inlet Manifold Pressure Sensor Voltage Above Normal or Shorted High
4 SPN106-FMI4 Inlet Manifold Pressure Sensor Voltage Below Normal or Shorted Low
10 SPN106-FMI10 Inlet Manifold Pressure Sensor 5V Supply Connection Open Circuit
110 1 SPN110-FMI1 Engine Coolant Temp High-Warning
2 SPN110-FMI2 Engine Coolant Temp High-Derate
3 SPN110-FMI3 Engine Coolant Temp Sensor Voltage Above Normal or Shorted High(Shutdown)
4 SPN110-FMI4 Engine Coolant Temp Sensor Voltage Below Normal or Shorted Low
157 3 SPN157-FMI3 Fuel Rail Pressure Sensor Voltage Above Normal or Shorted High
4 SPN157-FMI4 Fuel Rail Pressure Sensor Voltage Below Normal or Shorted Low
157 2 SPN158-FMI2 Keyswitch Data Erratic, Intermittent, or Incorrect
168 0 SPN168-FMI0 Engine ECM Battery Power Excessive
1 SPN168-FMI1 Engine ECM Battery Power Low
2 SPN168-FMI2 Engine ECM Battery Power Intermittent
190 1 SPN190-FMI1 Engine Overspeed - Warning
8 SPN190-FMI8 Speed/Timing Sensor Abnormal Signal Frequency
558 2 SPN558-FMI2 (Secondary) Throttle Position Sensor Idle Validation Switch
630 2 SPN630-FMI2 Customer or System Parameters Data Incorrect
631 2 SPN631-FMI2 Engine Software Data Incorrect
637 11 SPN637-FMI11 Primary to Secondary Engine Speed Signal Calibration Fault
639 9 SPN639-FMI9 SAE J1939 Data Link Abnormal Update
646 5 SPN646-FMI5 Turbo Wastegate Solenoid Current Low
6 SPN646-FMI6 Turbo Wastegate Solenoid Current High
651 5 SPN651-FMI5 Cylinder #1 Injector Current Low
※Some error codes are not applied to this machine.
※SPN : Suspect Parameter Number
FMI : Failure Mode Identifier

5-18
SPN FMI Fault code No. Description
651 6 SPN651-FMI6 Cylinder #1 Injector Current High
7 SPN651-FMI7 Cylinder #1 Injector Not Responding
652 5 SPN652-FMI5 Cylinder #2 Injector Current Low
6 SPN652-FMI6 Cylinder #2 Injector Current High
7 SPN652-FMI7 Cylinder #2 Injector Not Responding
653 5 SPN653-FMI5 Cylinder #3 Injector Current Low
6 SPN653-FMI6 Cylinder #3 Injector Current High
7 SPN653-FMI7 Cylinder #3 Injector Not Responding
654 5 SPN654-FMI5 Cylinder #4 Injector Current Low
6 SPN654-FMI6 Cylinder #4 Injector Current High
7 SPN654-FMI7 Cylinder #4 Injector Not Responding
655 5 SPN655-FMI5 Cylinder #5 Injector Current Low
6 SPN655-FMI6 Cylinder #5 Injector Current High
7 SPN655-FMI7 Cylinder #5 Injector Not Responding
656 5 SPN656-FMI5 Cylinder #6 Injector Current Low
6 SPN656-FMI6 Cylinder #6 Injector Current High
7 SPN656-FMI7 Cylinder #6 Injector Not Responding
676 5 SPN676-FMI5 Glow Plug Start Aid Relay Current Low
6 SPN676-FMI6 Glow Plug Start Aid Relay Current High
678 3 SPN678-FMI3 Engine ECM 8V DC Supply Voltage Above Normal or Shorted High
4 SPN678-FMI4 Engine ECM 8V DC Supply Voltage Below Normal or Shorted Low
723 8 SPN723-FMI8 Secondary Engine Speed Sensor Abnormal Signal Frequency
1079 3 SPN1079-FMI3 5V Sensor DC Supply Voltage Above Normal or Shorted High
4 SPN1079-FMI4 5V Sensor DC Supply Voltage Below Normal or Shorted Low
1188 7 SPN1188-FMI7 Turbo Wastegate Not Responding
1347 5 SPN1347-FMI5 Fuel Rail Pump Output Current Low
6 SPN1347-FMI6 Fuel Rail Pump Output Current High
7 SPN1347-FMI7 Fuel Rail Pump Output Not Responding
※Some error codes are not applied to this machine.
※SPN : Suspect Parameter Number
FMI : Failure Mode Identifier

5-19
GROUP 12 ENGINE CONTROL SYSTEM

1. MCU and Engine ECM (Electronic Control Module)

ECM(Engine control module)

HY
UN
MO DA
DE I
L:
R3
20
-9

FUEL TANK

TOOL BOX

LED

HY
UN
MO DA
DE I
L:
R2
10
-9

CN
-51

1
2 CN
-52 CN
-53

1 MCU
2 Bolt (M10)
1409A5MS13

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

LED lamp Trouble Service

G is turned ON Normal -

G and R are turned ON Trouble on MCU · Change the MCU

G and Y are turned ON Trouble on serial · Check if serial communication
communication line lines between controller and cluster are
disconnected
Three LED are turned OFF Trouble on MCU power · Check if the input power wire (24 V, GND) of
controller is disconnected
· Check the fuse
G : green, R : red, Y : yellow

5-20
GROUP 13 EPPR VALVE

1. PUMP EPPR VALVE

1) COMPOSITION
EPPR (Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve
installed at main pump.
(1) Electro magnet valve
Receive electric current from MCU and move the spool proportionally according to the specific
amount of electric current value.
(2) Spool valve
Is the two way direction control valve for pilot pressure to reduce main pump flow.
When the electro magnet valve is activated, pilot pressure enters into flow regulator of main pump.
(3) Pressure and electric current value for each mode
Pressure Electric current Engine rpm
Mode
kgf/cm2 psi (mA) (at accel dial 10)

P 8±3 114 ± 40 290 ± 30 1950 ± 50

Standard 10 ± 3 142 ± 40 330 ± 30 1850 ± 50
S
(Stage : 1.0)
E 13 ± 3 185 ± 40 365 ± 30 1750 ± 50
P 0 0 160 ± 30 1950 ± 50
Option
S 5±3 71 ± 40 250 ± 30 1850 ± 50
(Stage : 2.0)
E 10 ± 3 142 ± 40 330 ± 30 1800 ± 50

2) HOW TO SWITCH THE STAGE (1.0 ↔ 2.0) ON THE CLUSTER

You can switch the EPPR valve pressure set by selecting the stage (1.0 ↔ 2.0).
- Management
·Service menu

2609A3CD128 2609A3CD88 2609A3CD129

Enter the password

2609A3CD130

· Power shift (standard/option) : Power shift pressure can be set by option menu.

5-21
3) OPERATING PRINCIPLE (pump EPPR valve)
(1) Structure

6 7

2 3 4 5

5-22(1)

1 Sleeve 4 O-ring 6 Solenoid valve

2 Spring 5 O-ring 7 Connector
3 Spool

A
P Pilot oil supply line (pilot pressure)
P
T Return to tank
T
A Secondary pressure to flow regulator at main pump

(2) Neutral
eutral
Pressure line is blocked and A oil returns
to tank.

P A
P T
T
A

(3) Operating
perating
Secondary pressure enters into A.

P A
T

P T

A
5-22(2)

5-22
4) EPPR VALVE CHECK PROCEDURE Spec : 100~700 mA
(1) Check electric current value at EPPR valve
Adapter(P/no.:21Q6-50410)
① Disconnect connector CN-75 from
EPPR valve. EPPR valve
Multimeter
CN-75
② Insert the adapter to CN-75 and install
multimeter as figure.
③ Start engine.
Valve casing
④ Set S-mode and cancel auto decel
mode.
⑤ Position the accel dial at 10.
⑥ If tachometer show approx 1850± Main pump

50 rpm disconnect one wire harness

f