SECTION 1 GENERAL

Group 1 Safety Hints 1-1

Group 2 Specifications 1-9
 SECTION 1 GENERAL
GROUP 1 SAFETY

FOLLOW SAFE PROCEDURE

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

WEAR PROTECTIVE CLOTHING

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

WARN OTHERS OF SERVICE WORK

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

DO
NOT
OPERATE

USE HANDHOLDS AND STEPS

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

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

PROTECT AGAINST FLYING DEBRIS

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

PROTECT AGAINST NOISE

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

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.

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.

MOVE AND OPERATE MACHINE SAFELY

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

OPERATE ONLY FORM OPERATOR'S SEAT

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

PARK MACHINE SAFELY

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

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

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.

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.

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.

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

REMOVE PAINT BEFORE WELDING OR HEATING

Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding or heating:
・ If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
・ If you use solvent or paint stripper, remove stripper
with soap and water before welding. Remove
solvent or paint stripper containers and other
flammable material from area. Allow fumes to
disperse at least 15 minutes before welding or
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.

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

STAY CLEAR OF MOVING PARTS

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

AVOID HIGH PRESSURE FLUIDS

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

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

PREVENT ACID BURNS

Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, eat holes in clothing, and
cause blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling of dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the
acid.
3. Flush your eyes with water for 10-15 minutes. Get
medical attention immediately.
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.

1-7
USE TOOLS PROPERLY
Use tools appropriate to the work. Makeshift tools,
parts, and procedures can create safety hazards.
Use power tools only to loosen threaded tools and
fasteners.
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches.
Use only recommended replacement parts.(See Parts
catalogue.)

DISPOSE OF FLUIDS PROPERLY

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

REPLACE SAFETY SIGNS

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

LIVE WITH SAFETY

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

1-8
GROUP 2 SPECIFICATIONS

1. MAJOR COMPONENT

Tool box Fuel tank Hydraulic oil tank Main pump

Engine

Radiator

Tooth Bucket Turning joint Swing motor Main control valve Battery Oil cooler

Arm Arm cylinder Boom Boom cylinder Cab Precleaner Muffler

Bucket cylinder Connecting link Idler Carrier roller Sprocket Counterweight

Side cutter Connecting rod Track roller Track Travel motor

1-9
2. SPECIFICATIONS

I(I’) D
C

E
G
F

H
J M
K N
A B(L)

Description Unit Specification

Operating weight kg(lb) 28900(63710)

Bucket capacity(PCSA heaped), standard m (yd )
3 3
1.27(1.66)
Overall length A 10560(34' 8")
Overall width, with 600mm shoe B 3200(10' 6")
Overall height C 3290(10' 10")
Superstructure width D 2980( 9' 9")
Overall height of cab E 3010( 9' 11")
Ground clearance of counterweight F 1190( 3' 11")
Engine cover height G 3190(10' 6")
Minimum ground clearance H mm(ft-in) 500( 1' 8")
Rear-end distance I 3200(10' 6")
Rear-end swing radius I' 3120(10' 3")
Distance between tumblers J 4030(13' 3")
Undercarriage length K 4940(16' 2")
Undercarriage width L 3200(10' 6")
Track gauge M 2600( 8' 6")
Track shoe width, standard N 600(24")
Travel speed(Low/high) km/hr(mph) 3.0/5.0(1.9/3.1)
Swing speed rpm 11
Gradeability Degree(%) 35(70)
Ground pressure(600mm shoe) kgf/cm2(psi) 0.55(7.82)

1-10
3. WORKING RANGE
1) 6.25m(20' 6") BOOM

A
A'
F

D
B' E
C
B

8ft

Description 2.10m(6' 11") Arm 2.50m(8' 2") Arm 3.05m(10' 0") Arm 3.75m(12' 4") Arm

Max digging reach A 10020mm (32'10") 10280mm (33' 7") 10820mm (35' 6") 11400mm (37' 5")
Max digging reach on ground A' 9820mm (32' 3") 10080mm (33' 1") 10620mm (34'10") 11220mm (36'10")
Max digging depth B 6440mm (21' 1") 6840mm (22' 5") 7500mm (24' 7") 8090mm (26' 7")
Max digging depth (8ft level) B' 6240mm (20' 6") 6630mm (21' 9") 7300mm (23'11") 7920mm (26' 0")
Max vertical wall digging depth C 6000mm (19' 8") 5850mm (19' 2") 6410mm (21' 0") 7080mm (23' 3")
Max digging height D 10070mm (33' 0") 10110mm (33' 2") 10160mm (33' 4") 10360mm (34' 0")
Max dumping height E 6940mm (22' 9") 7030mm (23' 1") 7110mm (23' 4") 7310mm (24' 0")
Min swing radius F 4380mm (14' 4") 4260mm (14' 0") 4230mm (13'11") 4140mm (13' 7")
169[184] kN 169[184] kN 169[184] kN 169[184] kN
SAE 17200[18760] kgf 17200[18760] kgf 17200[18760] kgf 17200[18760] kgf
37920[41370] lbf 37920[41370] lbf 37920[41370] lbf 37920[41370] lbf
Bucket digging force
192[210] kN 192[210] kN 192[210] kN 192[210] kN
ISO 19600[21380] kgf 19600[21380] kgf 19600[21380] kgf 19600[21380] kgf
43210[47140] lbf 43210[47140] lbf 43210[47140] lbf 43210[47140] lbf
170[185] kN 147[161] kN 124[135] kN 109[119] kN
SAE 17300[18870] kgf 15000[16360] kgf 12600[13750] kgf 11100[12110] kgf
38140[41610] lbf 33070[36080] lbf 27780[30310] lbf 24470[26690] lbf
Arm crowd force
178[194] kN 154[168] kN 129[140] kN 112[122] kN
ISO 18100[19750] kgf 15700[17130] kgf 13100[14290] kgf 11400[12440] kgf
39900[43530] lbf 34610[37760] lbf 28880[31510] lbf 25130[27410] lbf
[ ] : Power boost

1-11
4. WEIGHT
R290LC-7
Item
kg lb
Upperstructure assembly 12610 27800
Main frame weld assembly 2361 5210
Engine assembly 590 1300
Main pump assembly 155 340
Main control valve assembly 200 442
Swing motor assembly 311 687
Hydraulic oil tank assembly 227 500
Fuel tank assembly 209 460
Counterweight 4700 10090
Cab assembly 310 680
Lower chassis assembly 10740 23680
Track frame weld assembly 3765 8310
Swing bearing 410 910
Travel motor assembly 350 770
Turning joint 54 240
Track recoil spring and idler 457 1010
Idler 252 560
Carrier roller 40 88
Track roller 54 119
Track-chain assembly(600mm standard triple grouser shoe) 1860 4110
Front attachment assembly(6.25m boom, 3.05m arm,
5450 12020
1.27m3 PCSA heaped bucket)
6.25m boom assembly 2200 4860
3.05m arm assembly 975 2150
1.27m3 PCSA heaped bucket 960 2120
Boom cylinder assembly 290 640
Arm cylinder assembly 375 826
Bucket cylinder assembly 250 551
Bucket control rod assembly 112 248

1-12
5. LIFTING CAPACITIES

1) 6.25m(20' 6") boom, 2.10m(6' 11") arm equipped with 1.27m3(PCSA heaped) bucket and 600mm
(24") triple grouser shoe.

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

Load radius At max. reach

Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach
height
m(ft)
7.5m kg *5760 *5760 *5290 4470 8.01
(25ft) lb *12700 *12700 *11660 9850 (26.3)
6.0m kg *6090 *6090 *5900 4830 *5380 3570 8.90
(20ft) lb *13430 *13430 *13010 10650 *11860 7870 (29.2)
4.5m kg *8940 *8940 *7040 6910 *6210 4710 5150 3120 9.42
(15ft) lb *19710 *19710 *15520 15230 *13690 10380 11350 6880 (30.9)
3.0m kg *11660 9960 *8270 6440 *6800 4490 4870 2910 9.64
(10ft) lb *25710 21960 *18230 14200 *14990 9900 10740 6420 (31.6)
1.5m kg *13520 9270 *9370 6050 7160 4290 4860 2880 9.58
(5ft) lb *29810 20440 *20660 13340 15790 9460 10710 6350 (31.4)
Ground kg *14060 9060 10010 5830 7010 4150 5130 3050 9.23
Line lb *31000 19970 22070 12850 15450 9150 11310 6720 (30.3)
-1.5m kg *13470 *13470 *13770 9080 9940 5770 6980 4120 5830 3490 8.57
(-5ft) lb *29700 *29700 *30360 20020 21910 12720 15390 9080 12850 7690 (28.1)
-3.0m kg *17570 *17570 *12710 9260 *9440 5870 *6180 4490 7.47
(-10ft) lb *38740 *38740 *28020 20410 *20810 12940 *13620 9900 (24.5)
-4.5m kg *14150 *14150 *10330 9660
(-15ft) lb *31200 *31200 *22770 21300
Note 1. Lifting capacity are based on SAE J1097 and ISO 10567.
2. Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine
on firm, level ground or 87% of full hydraulic capacity.
3. The load point is a hook located on the back of the bucket.
4. *indicates load limited by hydraulic capacity.

1-13
 2) 6.25m(20' 6") boom, 2.50m(8' 2") arm equipped with 1.27m3(PCSA heaped) bucket and 600mm
(24") triple grouser shoe.

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach
height
m(ft)
7.5m kg *4880 4230 8.34
(25ft) lb *10760 9330 (27.4)
6.0m kg *5470 4940 *5020 3420 9.19
(20ft) lb *12060 10890 *11070 7540 (30.2)
4.5m kg *8180 *8180 *6610 *6610 *5880 4780 4950 2990 9.69
(15ft) lb 18030 *18030 *14570 *14570 *12960 10540 10910 6590 (31.8)
3.0m kg *10910 10210 *7890 6550 *6530 4550 4680 2790 9.90
(10ft) lb *24050 22510 *17390 14440 *14400 10030 10320 6150 (32.5)
1.5m kg *13040 9410 *9080 6120 *7190 4320 4650 2750 9.84
(5ft) lb *28750 20750 *20020 13490 *15850 9520 10250 6060 (32.3)
Ground kg *13950 9080 9870 5850 7020 4160 4880 2890 9.51
Line lb *30750 20020 *21760 12900 15480 9170 10760 6370 (31.2)
-1.5m kg *14370 *14370 *13930 9030 9910 5740 6950 4090 5480 3270 8.87
(-5ft) lb *31680 *31680 *30710 19910 21850 12650 15320 9020 12080 7210 (29.1)
-3.0m kg *16270 *16270 *18700 *18700 *13110 9160 *9690 5800 *6310 4100 7.82
(-10ft) lb *35870 *35870 *41230 *41230 *28900 20190 *21360 12790 *13910 9040 (25.7)
-4.5m kg *15620 *15620 *11170 9490
(-15ft) lb *34440 *34440 *24630 20920

3) 6.25m(20' 6") boom, 3.05m(10' 0") arm equipped with 1.27m3(PCSA heaped) bucket and 600mm
(24") triple grouser shoe.

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) 9.0m(30ft) Capacity Reach
height
m(ft)
7.5m kg *4460 3740 8.94
(25ft) lb *9830 8250 (29.3)
6.0m kg *4910 *4910 *4600 3080 9.74
(20ft) lb *10820 *10820 *10140 6790 (32.0)
4.5m kg *5960 *5960 *5390 4840 4530 2710 10.20
(15ft) lb *13140 *13140 *11880 10670 9990 5970 (33.5)
3.0m kg *9910 *9910 *9820 *9820 *7280 6630 *6090 4580 *4140 3280 4290 2530 10.40
(10ft) lb *21850 *21850 *21650 *21650 *16050 14620 *13430 10100 *9130 7230 9460 5580 (34.1)
1.5m kg *12250 9550 *8590 6160 *6830 4320 *4900 3150 4250 2490 10.35
(5ft) lb *27010 21050 *18940 13580 *15060 9520 *10800 6940 9370 5490 (34.0)
Ground kg *9590 *9590 *13580 9070 *9550 5820 6980 4120 *4310 3050 4430 2590 10.04
Line lb *21140 *21140 *29940 20000 *21050 12830 15390 9080 *9500 6720 9770 5710 (32.9)
-1.5m kg *10390 *10390 *13470 *13470 *13920 8910 9830 5660 6860 4010 4900 2880 9.44
(-5ft) lb *22910 *22910 *29700 *29700 *30690 19640 21670 12480 15120 8840 10800 6350 (31.0)
-3.0m kg *14060 *14060 *18180 *18180 *13440 8970 9830 5660 6880 4030 5880 3510 8.48
(-10ft) lb *31000 *31000 *40080 *40080 *29630 19780 21670 12480 15170 8880 12960 7740 (27.8)
-4.5m kg *18380 *18380 *17190 *17190 *11970 9220 *8750 5830 *5960 5000 6.97
(-15ft) lb *40520 *40520 *37900 *37900 *26390 20330 *19290 12850 *13140 11020 (22.9)

1-14
 4) 6.25m(20' 6") boom, 3.75m(12' 4") arm equipped with 1.27m3(PCSA heaped) bucket and 600mm
(24") triple grouser shoe.

Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) 9.0m(30ft) Capacity Reach
height
m(ft)
7.5m kg *3930 3230 9.67
(25ft) lb *8660 7120 (31.7)
6.0m kg *4160 *4160 *2370 *2370 *4090 2700 10.40
(20ft) lb *9170 *9170 *5220 *5220 *9020 5950 (34.1)
4.5m kg *4710 *4710 *3720 3460 4060 2390 10.83
(15ft) lb *10380 *10380 *8200 7630 8950 5270 (35.5)
3.0m kg *13490 *13490 *8320 *8320 *6410 *6410 *5470 4640 *4740 3310 3850 2230 11.02
(10ft) lb *29740 *29740 *18340 *18340 *14130 *14130 *12060 10230 *10450 7300 8490 4920 (36.2)
1.5m kg *9980 *9980 *11050 9860 *7850 6270 *6300 4350 5320 3140 3810 2180 10.97
(5ft) lb *22000 *22000 *24360 21740 *17310 13820 *13890 9590 11730 6920 8400 4810 (36.0)
Ground kg *6470 *6470 *10300 *10300 *12890 9170 *9020 5860 6980 4110 5170 3010 3950 2250 10.68
Line lb *14260 *14260 *22710 *22710 *28420 20220 *19890 12920 15390 9060 11400 6640 8710 4960 (35.0)
-1.5m kg *9310 *9310 *12760 *12760 *13720 8860 *9730 5620 6800 3950 5080 2920 4300 2470 10.12
(-5ft) lb *20530 *20530 *28130 *28130 *30250 19530 *21450 12390 14990 8710 11200 6440 9480 5450 (33.2)
-3.0m kg *12290 *12290 *16240 *16240 *13690 8810 9710 5540 6750 3900 5020 2940 9.25
(-10ft) lb *27090 *27090 *35800 *35800 *30180 19420 21410 12210 14880 8600 11070 6480 (30.3)
-4.5m kg *15740 *15740 *18940 18880 *12770 8960 *9310 5620 *5780 3920 7.92
(-15ft) lb *34700 *34700 *41760 41620 *28150 19750 *20530 12390 *12740 8640 (26.0)

1-15
6. BUCKET SELECTION GUIDE
1) GENERAL BUCKET

0.79m3 PCSA 1.03m3 PCSA ※1.27m3 PCSA 1.50m3 PCSA 1.73m3 PCSA 1.85m3 PCSA
heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket

Recommendation
Capacity Width 6.25m (20' 6") boom
Weight
PCSA CECE Without With 2.1m arm 2.5m arm 3.05m arm 3.6m arm
heaped heaped side cutter side cutter (6' 11") (8' 2") (10' 0") (11' 10")

0.79m3 0.70m3 890mm 1010mm 740kg

(1.03yd3) (0.92yd3) (35.0") (39.8") (1630lb)

1.03m3 0.90m3 1090mm 1210mm 850kg

(1.35yd3) (1.18yd3) (42.9") (47.6") (1870lb)

※1.27m3 1.10m3 1290mm 1410mm 960kg

(1.66yd3) (1.44yd3) (50.8") (55.5") (2120lb)

1.50m3 1.30m3 1490mm 1610mm 1020kg

(1.96yd3) (1.70yd3) (58.7") (63.4") (2250lb)

1.73m3 1.50m3 1696mm 1120kg

-
(2.26yd3) (1.96yd3) (66.8") (2470lb)

1.85m3 1.60m3 1800mm 1160kg

-
(2.42yd3) (2.09yd3) (70.9") (2560lb)

※ : Standard bucket

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

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

1-16
 2) ROCK AND HEAVY DUTY BUCKET

◈1.07m3 PCSA ◈1.27m3 PCSA ◈1.46m3 PCSA 1.16m3 PCSA

heaped bucket heaped bucket heaped bucket heaped bucket

Recommendation
Capacity Width
6.25m (20' 6") boom
Weight
PCSA CECE Without With 2.1m arm 2.5m arm 3.05m arm 3.6m arm
heaped heaped side cutter side cutter (6' 11") (8' 2") (10' 0") (11' 10")

◈1.07m3 0.95m3 1060mm 1110kg

-
(1.40yd3) (1.24yd3) (42.0") (2450lb)

◈1.27m3 1.10m3 1220mm 1130kg

-
(1.66yd3) (1.44yd3) (48.0") (2490lb)

◈1.46m3 1.28m3 1370mm 1260kg

-
(1.91yd3) (1.67yd3) (54.0") (2780lb)

1.16m3 1.00m3 1305mm 1260kg

-
(1.52yd3) (1.05yd3) (51.4") (2780lb)

◈ : Heavy duty bucket

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

1-17
7. UNDERCARRIAGE
1) TRACKS
X-leg type center frame is integrally welded with reinforced box-section track frames. The design
includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock
absorbing springs and assembled track-type tractor shoes with triple grousers.
2) TYPES OF SHOES
Triple grouser

Model Shapes

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

Operating weight kg(lb) 28800(63500) 29370(64700) 29750(65600) 30130(66400)
R290LC-7
Ground pressure kgf/cm (psi)
2
0.55(7.82) 0.48(6.83) 0.43(6.11) 0.38(5.40)
Overall width mm(ft-in) 3190(10' 6") 3290(10' 10") 3390(11' 1") 3490(11' 5")

3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE

Item Quantity
Carrier rollers 2EA
Track rollers 9EA
Track shoes 48EA

4) SELECTION OF TRACK SHOE

Suitable track shoes should be selected according to operating conditions.
Method of selecting shoes
Confirm the category from the list of applications in table 2, then use table 1 to select the shoe.
Wide shoes(Categories B and C) have limitations on applications. Before using wide shoes, check
the precautions, then investigate and study the operating conditions to confirm if these shoes are
suitable.
Select the narrowest shoe possible to meet the required flotation and ground pressure. Application
of wider shoes than recommendations will cause unexpected problem such as bending of shoes,
crack of link, breakage of pin, loosening of shoe bolts and the other various problems.
※ Table 1

Track shoe Specification Category

600mm triple grouser Standard A

700mm triple grouser Option B
750mm triple grouser Option B
800mm triple grouser Option C
900mm triple grouser Option C

1-18
※ Table 2
Category Applications Precautions

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

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

Extremely soft gound ・ Use the shoes only in the conditions that the machine sinks and it is
(Swampy ground) impossible to use the shoes of category A or B
・ These shoes cannot be used on rough ground with large obstacles such
C as boulders or fallen trees
・ Travel at high speed only on flat ground
・ Travel slowly at low speed if it is impossible to avoid going over
obstacles

1-19
8. SPECIFICATIONS FOR MAJOR COMPONENTS
1) ENGINE

Item Specification

Model Cummins C8.3-C

Type 4-cycle turbocharged diesel engine
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder bore×stroke 114×135mm(4.49"×5.32")
Piston displacement 8270cc(505cu in)
Compression ratio 17.3 : 1
Rated gross horse power(SAE J1349) 195Hp at 1900rpm(145kW at 1900rpm)
Maximum torque 62.1kgf・m(449lbf・ft) at 1600rpm
Engine oil quantity 18.9ℓ(4.9U.S. gal)
Dry weight 588kg(1296lb)
High idling speed 2093+50rpm
Low idling speed 800±100rpm
Rated fuel consumption 166.3g/Hp・hr at 1900rpm
Starting motor Nippon denso(24V-7.5kW)
Alternator Delco Remy 24V-50A
Battery 2×12V×160Ah

2) MAIN PUMP

Item Specification

Type Variable displacement tandem axis piston pumps

Capacity 2×136.8cc/rev
Maximum pressure 330kgf/cm2 (4690psi)[360kgf/cm2 (5120psi)]
Rated oil flow 2×260ℓ/min (68.7U.S. gpm/ 57.2U.K. gpm)
Rated speed 1900rpm
[ ]: Power boost

1-20
3) GEAR PUMP

Item Specification

Type Fixed displacement gear pump single stage

Capacity 15cc/rev
Maximum pressure 35kgf/cm2(500psi)
Rated oil flow 28.5ℓ/min(7.5U.S. gpm/6.3U.K. gpm)

4) MAIN CONTROL VALVE

Item Specification

Type 9 spools
Operating method Hydraulic pilot system
Main relief valve pressure 330kgf/cm2(4690psi)[360kgf/cm2(5120psi)]
Overload relief valve pressure 390kgf/cm2(5550psi)
[ ]: Power boost

5) SWING MOTOR

Item Specification

Type Two fixed displacement axial piston motor

Capacity 169.4cc/rev
Relief pressure 265kgf/cm2(3770psi)
Braking system Automatic, spring applied hydraulic released
Braking torque 70kgf・m(506lbf・ft)
Brake release pressure 28.5~32kgf/cm2(405~455psi)
Reduction gear type 2 - stage planetary
Swing speed 11rpm

6) TRAVEL MOTOR

Item Specification
Type Variable displacement axial piston motor
Relief pressure 330kgf/cm2(4620psi)
Capacity(max / min) 134.7/87.3cc/rev
Reduction gear type 3-stage planetary
Braking system Automatic, spring applied hydraulic released
Brake release pressure 15.7kgf/cm2(223psi)
Braking torque 78.8kgf・m(570lbf・ft)

1-21
 7) REMOTE CONTROL VALVE

Item Specification

Type Pressure reducing type

Minimum 6.5kgf/cm2(92psi)
Operating pressure
Maximum 26kgf/cm2(370psi)
Lever 61mm(2.4in)
Single operation stroke
Pedal 123mm(4.84in)

8) CYLINDER

Item Specification

Bore dia×Rod dia×Stroke Ø140×Ø100×1465mm

Boom cylinder
Cushion Extend only
Bore dia×Rod dia×Stroke Ø150×Ø110×1765mm
Arm cylinder
Cushion Extend and retract
Bore dia×Rod dia×Stroke Ø140×Ø95×1185mm
Bucket cylinder
Cushion Extend only
※ Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads
on the rod surface.
※ Discoloration does not cause any harmful effect on the cylinder performance.

9) SHOE

Item Width Ground pressure Link quantity Overall width

Standard 600mm(24") 0.55kgf/cm2(7.82psi) 48 3190mm(10' 6")

700mm(28") 0.48kgf/cm (6.83psi)
2
48 3290mm(10' 10")
R290LC-7
Option 800mm(32") 0.43kgf/cm2(6.11psi) 48 3390mm(11' 1")
900mm(36") 0.38kgf/cm (5.40psi)
2
48 3490mm(11' 5")

1-22
 10) BUCKET
Capacity Tooth Width
Item quantity Without side cutter With side cutter
PCSA heaped CECE heaped
Standard 1.27m3(1.66yd3) 1.10m3(1.44yd3) 5 1290mm(50.8") 1410mm(55.5")
0.79m3(1.03yd3) 0.70m3(0.92yd3) 3 890mm(35.0") 1010mm(39.8")
1.03m3(1.35yd3) 0.90m3(1.18yd3) 4 1090mm(42.9") 1210mm(47.6")
◈1.07m3(1.40yd3) 0.95m3(1.24yd3) 5 1060mm(42.0") -
◈1.27m3(1.66yd3) 1.10m3(1.44yd3) 5 1220mm(48.0") -
R290LC-7
Option ◈1.46m3(1.91yd3) 1.28m3(1.67yd3) 5 1370mm(54.0") -
1.16m3(1.52yd3) 1.00m3(1.05yd3) 5 1305mm(51.4") -
1.50m3(1.96yd3) 1.30m3(1.70yd3) 6 1490mm(58.7") 1610mm(63.4")
1.73m3(2.26yd3) 1.50m3(1.96yd3) 6 1696mm(66.8") -
1.85m3(2.42yd3) 1.60m3(2.09yd3) 5 1800mm(70.9") -

◈ : Heavy duty bucket

: Rock bucket(Esco type)

1-23
9. RECOMMENDED OILS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Ambient temperature °
C (°
F)
Capacity
Service point Kind of fluid ℓ(U.S. gal) -20 -10 0 10 20 30 40
(-4) (14) (32) (50) (68) (86) (104)

SAE 30

Engine SAE 10W

Engine oil 19(5.0)
oil pan
SAE 10W-30

SAE 15W-40

Swing drive 7.0(1.8)

Gear oil SAE 85W-140
11×2
Final drive (2.9×2)

Tank; ISO VG 32
210(55)
Hydraulic tank Hydraulic oil ISO VG 46
System;
380(100) ISO VG 68

ASTM D975 NO.1

Fuel tank Diesel fuel 450(119)
ASTM D975 NO.2

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

Mixture of
Radiator antifreeze
(Reservoir tank) 50(13.2) Ethylene glycol base permanent type
and water
50 : 50

SAE : Society of Automotive Engineers

API : American Petroleum Institute
ISO : International Organization for Standardization
NLGI : National Lubricating Grease Institute
ASTM : American Society of Testing and Material

1-24
 SECTION 2 STRUCTURE AND FUNCTION

Group 1 Pump Device 2-1

Group 2 Main Control Valve 2-21
Group 3 Swing Device 2-47
Group 4 Travel Device 2-58
Group 5 RCV Lever 2-73
Group 6 RCV Pedal 2-80
 SECTION 2 STRUCTURE AND FUNCTION
GROUP 1 PUMP DEVICE

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

Pi1 Pm1 Qmax adjusting screw

Dr

A3

B3

Psv
Pm2 Pi2
a4

Qmin adjusting screw Qmin adjusting screw

Regulator Regulator

Pi1 Pm2
Pi2

Pm1
a4

Psv

B3

Dr
B1

a3

a1 a2
Front pump Port block Rear pump Gear pump

Psv Port Port name Port size

A1 a4 A2
A1,2 Delivery port SAE6000psi 1"
a1 a2
B1 Suction port SAE2500psi 3"
Dr Drain port PF 3/4 - 23

Pm1 Pm2
Pi1,i2 Pilot port PF 1/4 - 15
Fl Fr Pm1,m2 Qmax cut port PF 1/4 - 15
(Pi1) (Pi2)
M Psv Servo assist port PF 1/4 - 15
Dr a3
a1,2,4 Gauge port PF 1/4 - 15
B1 B3 A3
a3 Gauge port PF 1/4 - 14
A3 Gear pump delivery port PF 1/2 - 19
B3 Gear pump suction port PF 3/4 - 20.5
1) MAIN PUMP(1/2)
The main pump consists of two piston pumps(front & rear) and valve block.

789 532 548 724 792 808

732 214 531 702 534 901 954 211 719 211 113 04
535
808
953
886
717
406
261
824

111
774
127
710

123 251 401 211 156 157 114 312 725 314 012 152 401
490 212 153 158 313 124 466 728 151 271 435
885 468

04 Gear pump 261 Seal cover(F) 717 O-ring

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

544

543
079
545 725 325
541

466
725

490 407 725 732

B
VIEW A VIEW B

079 Proportional reducing valve 490 Plug 545 Steel ball

325 Casing assy 541 Seat 725 O-ring
407 Hexagon screw 543 Stopper 1 732 O-ring
466 Plug 544 Stopper 2
2) REGULATOR(1/2)

412 875 874 A

755
KR3H-9C12
A 858
897 B P2
614
612 Pf

Pm
Pi
615
613

A 611
B
B

647
648
723
642
438

801
801

724 924
641
730 643 708 644 645 646 728

SECTION B-B

413 438
438

Port Port name port size

656 A Delivery port 3/4"

Pi B Suction port 2 1/2"
735
Pi Pilot port PF 1/4-15
722
Pm Qmax cut port PF 1/4-15

496 724 725 436

VIEW C
REGULATOR(2/2)

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

641 801

925
814

898

631 627

732
C

733
732

622

621 623 625 626 887 763 756

SECTION A-A

412 Hexagon socket screw 631 Sleeve, pf 730 O-ring

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

700 354 351 433

B3

850
355
434
A3
311

312
a3

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

307 Poppet 353 Drive gear 466 Plug

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

(1) Rotary group

The rotary group consists of drive shaft
(F)(111), cylinder block(141), piston
shoes(151,152), set plate(153), spherical 124
313
bush(156), spacer(158) and cylinder 141
spring(157). The drive shaft is supported 158
151 156
by bearing(123,124) at its both ends. 152 153
The shoe is caulked to the piston to from
111
a spherical coupling. It has a pocket to 157
relieve thrust force generated by loading 123
211
pressure and the take hydraulic balance
so that it slides lightly over the shoe
plate(211). The sub group composed by
a piston and a shoe is pressed against
the shoe plate by the action of the
cylinder 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.
531
(2) Swash plate group 548
The swash plate group consists of swash 214
plate(212), shoe plate(211), swash plate
support(251), tilting bush(214), tilting 212
pin(531) and servo piston(532). 251
211
The swash plate is a cylindrical part
formed on the opposite side of the sliding
surface of the shoe and is supported by
the swash support.
532 α
If the servo piston moves to the right and
left as hydraulic force controlled by the
regulator is admitted to hydraulic
chamber located on both sides of the α
servo piston, the swash plate slides over
the swash plate support via the spherical
part of the tilting pin to change the tilting
angle(α)
(3) Valve block group
The valve block group consists of valve
block(312), valve plate(313) and valve
plate pin(885).
The valve plate having two melon-
shaped ports is fixed to the valve block 312
and feeds and collects oil to and from the
cylinder block. 313
885
The oil changed over by the valve plate is
connected to an external pipeline by way
of the valve block.
Now, if the drive shaft is driven by a prime
mover(electric motor, engine, etc), it
rotates the cylinder block via a spline
linkage at the same time. If the swash
plate is tilted as in Fig(previous page) the
pistons arranged in the cylinder block
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) 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.
① Flow reducing function

643 654 651 652 613 646

P1 CL
B(E)
874
897
C
A

875

611

Servo piston Small diameter

Large diameter D chamber
chamber 548
531

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 Flow increasing function

643 654 651 652 613 646

P1 CL
B(E)
874
897
C

875
611

Small diameter
Servo piston D chamber
Large diameter 548
chamber
531

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

Delivery flow, Q
amount

(min -1) (Turn) (kgf/cm2) (ℓ/min)

1900 +1/4 +2.0 +16

Pilot pressure, Pi
(2) Total horsepower control

The regulator decreases the pump tilting

angle(delivery flow) automatically to limit
the input torque within a certain value

Delivery flow, Q
with 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).
① Overload preventive function

621 651 652 623 612 601 625 626

P1 CL
B(E)
897

P2 P1
875

611

Large diameter Servo piston

chamber Small diameter
D chamber

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 Flow reset function

621 651 652 623 612 601 625 626

P1 CL
B(E)
897

P2 P1

875

Large diameter Small diameter

chamber Servo piston D chamber

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.
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 625 626 630 628
nut(630) and by tightening(or
loosening) the adjusting screw C(628).
Tightening the screw shifts the control 801
chart to the right and increases the
925
input horsepower as shown in the
figure. Since turning the adjusting
screw C by N turns changes the setting
of the inner spring(626), return the
adjusting screw QI(925) by N×A turns
at first.(A=2.2)
※ Adjusting values are shown in table.

Adjustment of outer spring

Speed
Tightening Compens- Input torque
Delivery flow, Q

amount of ating control change

adjusting starting amount
screw(C) pressure
(925) change
amount

(min -1) (Turn) (kgf/cm2) (kgf・m)

1900 +1/4 +2.0 +16 Delivery pressure, (P1+P2)

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

Adjustment of inner spring

Speed
Tightening Compens- Input torque
amount of ating control change
adjusting starting amount
screw(QI) pressure
(925) change
amount

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

1900 +1/4 +18 +4.0

Delivery pressure, (P1+P2)

(3) Power shift control

621 651 652 623 612 625 626

898 P1 CL
B(E)
897

Pf
P2 P1
875

611

Large diameter Small diameter

chamber Servo piston D chamber

The set horsepower valve is shifted by

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

attached to the pump.

Only one proportional pressure reducing Pf=
valve is provided. MIN
Pf= .
However, the secondary pressure Pf MA
X.
(power shift pressure) is admitted to the
horsepower control section of each
pump 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.
(4) Adjustment of maximum and minimum flows
808
Η Adjustment of maximum flow
Adjust it by loosening the hexagon 954
nut(808) and by tightening(or loosening)
the set screw(954).
The maximum flow only is adjusted
without changing other control
characteristics. 2-19(1)

Adjustment of max flow

Speed

Delivery flow, Q
Tightening Flow change
amount of amount
adjusting screw
(954)

(min -1) (Turn) (˶/min)

1900 +1/4 -5.8 Delivery pressure, Pi

Θ Adjustment of minimum flow

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

the maximum delivery pressure(or during

relieving) may increase.

Adjustment of min flow

Delivery flow, Q

Speed
Tightening Flow change
amount of amount
adjusting screw
(953)

(min -1) (Turn) (˶/min)

Delivery pressure, Pi
1900 +1/4 +5.8

2-19
(5) Qmax cut control
647
The regulator regulates 648
the maximum delivery flow
by inputting the pilot 723
pressure Pm. Since this is 642 438
a 2-position control method,
the maximum delivery flow 801
may be switched in two 801
steps by turning on/off the 924
pilot pressure Pm.(The
641 730 643 708 644 645 646 728
maximum control flow
cannot be controlled in
intermediate level.)

① Functional explanation
As shown in the figure, the pilot pressure
Pm switches the maximum flow in two
steps.

Delivery flow, Q
When the pilot pressure Pm is given, it is Pm
admitted to the lefthand side of the
piston QMC(648). The piston QMC
moves the stopper(647) and pilot
piston(643) to the right, overcoming the
force of the pilot spring(646), thereby
reducing the delivery flow of the pump. Pilot pressure, Pi
Since the adjusting screw QMC(642) is
provided with a flange, the piston QMC
stops upon contact with the flange, and
the position of the pilot piston at this time
determines the maximum flow of the
pump.

② Adjustment of Qmax cut flow

Adjust it by loosening the hexagon
nut(801) and by tightening(or loosening)
Delivery flow, Q

the adjusting screw QMC(642).

Tightening the screw decreases the
Qmax cut flow as shown in the figure.

Pilot pressure, Pi
 GROUP 2 MAIN CONTROL VALVE(up to #1176)

1. STRUCTURE

Ck1
Mark Port name Port size Tightening torque
(PSP)

20~25kgfÂm
R1 Make up port for swing PF 1 (115~180lbfÂft)
XAa1
Ck1 Bucket in confluence port 15~18kgfÂm
XBtl XBp2 Ck2 Bucket in confluence port PF 3/4 (109~130lbfÂft)
XBs

Py
PH XAtr Travel right pilot port
P1
Dr1 XBtr Travel right pilot port
SP
Btl Bs HEAD XAo Option pilot port
Aa1 Ck1
XBo Option pilot port
CSP FL XAk Bucket out pilot port
CMR2
XBk Bucket in pilot port
Pns
Dr6

LCa1
FR P2 R2 XAb1 Boom up pilot port
Atl As ROD
CMR1
XBb1 Boom down pilot port
CCb HV
Ba1
Dr3 XAa2 Arm in confluence pilot port
XBa2 Arm out confluence pilot port 7~8kgfÂm
Pz
PaL PF 3/8
Dr2 XAtl Travel left pilot port (50.6~57.8lbfÂft)
XBtl Travel left pilot port
Dr4
XAs Swing pilot port
TRAVEL SWING BOOM2 ARM1
Ck2 XBs Swing pilot port
R1 (L) XAa1 Arm in pilot port
VIEW A XBa1 Arm out pilot port
XAtl
XAs XBa1
XBp1 XAb2 Boom up confluence pilot port
XAb2
Ck1
(Psp) (Swing priority pilot port)
Ck1
(XBp1) (Bucket in confluence pilot port)
Pns Dr6 (XBp2) (Drain port)
PaL Dr3

Dr3 Dr2
Pz Main relief pilot pressure
FR FL Py Signal port for travel
PG MR PG Pilot pressure port
NR1
Px
PH Pilot pressure port
R1
Px Signal for other acutuators
P1 Dr1 Drain port
TS Dr2 Drain port
A
TL S B2 A1 BC BC
A1 SP(B2) S TL Dr3 Drain port 3.5~3.9kgfÂm
TR OP B1 BK A2 A2 BK B1 OP TR Dr4 Drain port PF 1/4 (25.3~28.2lbfÂft)
R2(P2) Dr6 Drain port
FL Negative control signal port(P1 port side)
FR Negative control signal port(P2 port side)
PBP
Pns Swing logic valve pilot port
PaL Lock valve pilot port
Dr4 PbL Lock valve pilot port
PBP Drain port
PbL
Ck2 Ck2
Atr Travel motor right side port
XAb1 XBk XBa2
Btr Travel motor right side port
XAtr XAo (Ao) Option port
(Bo) Option port
TRAVEL OPTION BOOM1 BUCKET ARM2 Ak1 Bucket rod side port
(R) Bk1 Bucket head side port
Ab1 Boom head side port
Bb1 Boom rod side port M10 5~6.6kgfÂm
Dr4 PbL Atl Travel motor left side port (36.1~47.7lbfÂft)
Btl Travel motor left side port
Atr HEAD HEAD
(Ao) As Swing motor port
C1 Ab1 Bk1 Bs Swing motor port
Aa1 Arm head side port
LCb1

LCa2
LCo

LCk
C2

CP2
Ba1 Arm rod side port
Btr ROD ROD P1 Pump port(P1 side)
(Bo)
Bb1 Ak1 PBP P2 Pump port(P2 side)
8.5~11.5kgfÂm
R2 Return port M12 (61.5~83.1lbfÂft)
XBtr XBo XAa2
XBb1 XAk

2-21
 A
B P1 103 P1 154 164 974
975
PG 158
P2
L R2
TS
H Pz H K
STRAIGHT K
MR
TS TRAVEL
R2(P2) Px
I I
R1 XBtr XAtr TR
391
159 TRAVEL(R)
L
TR
TL XAtl XBtl XBo XAo
OP
TL
TRAVEL(L) OPTION
C Pns C
Dr4
OP
S XAs XBs B1
SP XBb1 XAb1
S Dr6 SWING BOOM 1
D D SWING PRIORITY
M N
B1 159
B2 XAb2 (PSP) BK
XAk XBk
B2 PaL BOOM 2 BUCKET
E PbL E
BK
159
A1
A1 XBa1 XAa1 975 XBa2 XAa2
A2
ARM 1 ARM 2
F F

K1
NR2

A2 BC
(XBp1) (XBp2)
Dr3 102 976
G G
Dr2
A M N
104
J J 101 153 561
B 159 273
SECTION A-A SECTION B-B

101 Casing A 301 Travel spool 379 Spring

CS1 CS2 PG
102 Casing B 302 Arm 1 spool assy 391 Straight travel spool
357 103 Straight travel valve 303 Boom 1 spool assy 392 Bypass cut spool
104 Boom priority valve 304 Bucket spool 395 Swing priority spool
NZx
153 Plug 305 Swing spool 401 Spool
154 Plug 306 Arm 2 spool 424 Spring
NZy 155 Plug 307 Boom 2 spool 425 Spring
156 Plug 309 Spool(Option) 438 Rod
CCb
357 Ab1 Bb1 158 Plug 310 Travel spool 511 Poppet
B1 B2 B1 B2 159 Plug 324 Spring 513 Poppet
SECTION H-H
HV 163 O-ring 325 Spring 515 Poppet
Bk1 Ak1 Aa1 164 O-ring 328 Spring 516 Poppet
BK
CMR1 CMR2
A1 BK
A1 165 O-ring 329 Spring 521 Spring
Pz Ba1
166 O-ring 331 Spring seat 522 Spring
A2
167 O-ring 332 Spring seat 523 Spring
BC
MR A2 BC 168 O-ring 333 Bolt 551 Plug
338 169 O-ring 334 Stopper 552 Plug
153 561 201 Cover 335 Stopper 553 Plug
601 J1
TS 202 Cover 336 Bolt 554 Plug
SECTION M-M SECTION N-N
203 Cover 337 Stopper 555 Check valve assembly
325 204 Cover 338 Stopper 556 Plug
324
209 Flange 339 Stopper 561 O-ring
391 251 Control valve assy 357 Orifice 601 Main relief valve
252 Lock valve assy 370 Spring 602 Port relief valve
SECTION I-I
254 Swing logic valve assy 372 Spring 611 Nega-con relief valve
261 O-ring 374 Spring 971 Socket screw
262 O-ring 376 Spring 974 Socket screw
264 O-ring 377 Spring 975 Socket screw
273 Socket screw 378 Spring 976 Socket screw

2-22
 201
201 379 336
203 203 332 556 XAb2
203 370 XAb1 164 201
333 XAs 336 332 335
333 XAtr XAtl 333 XAo 336
331 332 261
331 331 159 332
334 335 339
334 334 602
329 379 372
329 329 370 159
328 Ab1R 374
328 328 159 332 332
331 331 252 B2
331 261
262 262 261 307
262 166 553 159
AoR 165
168 561 166 165 561
165 552
971 166 CCb 551
165 523 Ab1
165 561 521
As 165 516 511
Atl 209 (Ao)
Atr 165 511 254 165 LCb 561
515 521 CSP 551
164 521 551
521 LCo Pns 561 521
154 SP
551 511 Bb 511
561 303 551
551 251 165
971 Bs
165 561
561 165 (Bo) 264 B1 SP 395
Btr 209 305
Btl 261
309 264 602 332
310 XBb1
561 204 204 370
165 OP S Bb1R
301 553 BoR 376
TR TL 169 339
169 202 169 XBo XBs
166 332
202 336
202 XBtr XBtl
(PSP) 201
164 164
SECTION C-C SECTION D-D SECTION E-E 154 556

201
332 XBk XBa1 201 203 424
201
336 332 336 XBa2 333 425 K1
XBp1
335 336 332 438
331
370 335 335
379 379 372 337
370 378
P P
332 Ba1R 374
261 BkR 332 377
332
261 331
602 261
262 401
602 166
166 392
Dr2
252
516 165 NR2
551 SECTION J-J SECTION P-P
513 523 561
Bk1 552
522 HV 611
561
561 511 165
521 551 561 521 511 551
555 L1
Ck2 LCa1 FR CP2
551 LCa2 561
Ck1 C1
554 Ak1 561 155 521
551
304 Aa1 FL 511
561 611 167
302 551 P2
CP2
264 561 P2
BK A1 306
204
602 264 602 165 A2 BC NR1 551 561 521 511 P2
XAk XAa1
204 169
AkR Aa1R 264 L1
XAa2 XBp2 202
204
SECTION K-K SECTION L-L SECTION L 1 -L 1

SECTION F-F SECTION G-G

2-23
2. HYDRAULIC CIRCUIT

BP

PBP
Ck1
XBp1
PaL Fl Fr XBp2 Dr2

NR1 NR2

HV

Dr1 BC1 BC2

AaR

(HEAD)
Aa1
ARM 1 XAa1
Ba1
XBa2
(ROD) BaR ARM 2
XBa1 XAa2

LCa1

AkR (ROD)
Ak1
XAk
Bk1
CCb BkR (HEAD)
XBk BUCKET
LCk
XAb2 XBp1

BOOM 2 Dr4
Csp PbL
(PSP)
SP HV
Pns (HEAD)
As AbR
XBS Ab1
Bs XAb1
Bb1
SWING BbR (ROD) BOOM 1
XAs XBb1
LCb1
LCs
Dr6

Atl AoR
XBtl (Ao)
Btl XAo
(Bo)
TRAVEL(L) BoR OPTION
XAtl XBo
LCo
C1 C2

Atr
XAtr
Btr
TRAVEL(R)
XBtr

CP2

R1

P2 R2
0.7
STRAIGHT PH
TRAVEL TS
Px
BLOCK

MR
CMR1 CMR2
0.7

0.7

Pz P1 PG Py

2-24
3. FUNCTION
1) CONTROL IN NEUTRAL POSITION

103 P1

TS
STRAIGHT
TRAVEL

21

TL XAtl XBtl
TRAVEL(L)
22
S XAs XBs
SWING

B2 XAb2 (PSP)
BOOM 2

A1 XBa1 XAa1
ARM 1 13
XBp1 (XBp2)

101 4
SECTION A-A

P2 R2

XBtr XAtr TR
TRAVEL(R)

XBo XAo
OP
OPTION
6
XBb1 XAb1 B1
BOOM 1
18
XAk XBk BK
BUCKET

XBa2 XAa2 A2
ARM 2
K1

4
102

SECTION B-B

2-25
 XAa2 (XBp1)

4
Dr2
NR2 4

611

FR

LCa2
(Ck1)
FL 611

A2 BC NR1
13
13
XBa2 (XBp2)

SECTION G-G

A
B P1

PG
H PZ H
TS MR
R2(P2) Px
R1

TR TL
C Dr4 Pns C
OP
S
Dr6
D D
B1
B2
PaL
E PbL E
BK
A1

F NR2 F
BC
A2
Dr3
G G
Dr2
A
J J
B

2-26
The hydraulic fluid from the pump P1 flows into casing A(101) through the inlet port(P1), through the
center bypass(21) and the parallel path(22). The hydraulic fluid from the pump P2 flows into casing
B(102) through the inlet port(P2) through the center bypass(18) and the parallel path(6).
The hydraulic fluid from the pump P1 is directed to the tank through the center bypass(21), negative
control orifice(NR1), the return path(13) and the return port(R2). The hydraulic fluid from the pump
P2 also flows to the tank through the center bypass(18), negative control orifice(NR2), return path
(4) and return port(R2). The hydraulic fluid in paths (6) and (22) is blocked and cannot return to the
tank.
In case a control lever is operated, the hydraulic fluid from the pump P2 is supplied to the travel right
spool(301) from path(18) and to the spools: option(309), boom1(303), bucket(304) and arm2(306)
from path(6). Additionally, the hydraulic fluid from the pump P1 is supplied to the travel left spool
(310) from path(7) while the swing(305), boom2(307) and arm(302) spools are supplied from
path(22).

2-27
2) NEGATIVE CONTROL
(1) General operation

303 18 21 3 4 5

10

7
9
611
P2 P1 611

Fl Fr

19 6 27 28 22 13

The negative control signal pressure from the center bypass(18, 21) occurs in the following cases
and controls the discharge of the pump.
1. Neutral condition when no function is being actuated.
2. The pilot control lever is partially operated.
The hydraulic fluid of the pump P1(28) flows into the return passage(13) through the center bypass
(21), the path(3) and orifice(9)(Within the poppet(15)). The restriction caused by this orifice thereby
pressurizes path(3). This pressure is transferred as the negative control signal pressure Fl to the
pump P1 regulator through the negative control line(4). It controls the pump regulator so as to
decrease the discharge of the pump P1(28).

2-28
 21

Fl

15
611
16

BC NR1
101

13
(XBp2)

Q Fl

Qmax

Fl1

Qmin
Fl QN
Fl1

The negative control relief valve(611) consists of poppet(15), spring(16) and casing(101). When
the hydraulic fluid in the center bypass increases to the level that the pressure in the path(3)
reaches the set pressure of the spring(16), the hydraulic fluid in the path(3) pushes open the poppet
(15) and escapes into the return path(13).
In the unloaded state, the hydraulic fluid of the pump P1(28) entirely flows to the tank through the
path(21), orifice(9) and the return path(13). Therefore the pressure Fl in the path(3) becomes
maximum(Fl1) because all the discharge is reduced by the orifice(9) which in turn destrokes the
pump P1(28) so as to minimize the tilting angle and consequent discharge of the pump P1(28).
(Qmin)

2-29
 (2) Negative control(With fine metering)

303 511 370 379

4 6 LCb1 Ab1
Bb1

Ab1R
Bb1R

XBb1 XAb1

B1

18 19

In the case, for example, when the pilot control lever for main boom is slightly operated, the pilot
pressure XAb1 shifts the main boom spool(303) partially in the left direction. So the path(19) is
partially opened and the center bypass(18) is shut slightly. The hydraulic fluid thereby separates.
One part flows via the orifice(7) through the path(18) and the other portion flows into the parallel
path(6), the path(19) and the port Ab1. The flow from the path(18) through the orifice(7) decreases
slightly and the pressure Fr in the path(10) thereby also slightly decreases. As the pressure Fr
becomes lower, the discharge of the pump P2(27) increases. With the pilot control lever shifted
even more the path(18) is shut off by the shifting of the spool(303) and then the flow through the
bypass becomes zero. The pressure in the path(10) becomes zero and the discharge of the pump
P2(27) becomes maximum.(Qmax)
Because the discharge of the pump is adjusted by operating the pilot control lever slightly, the
precise moving of the actuator is realized.
For the pump P1(28) the same negative control principle of operation occurs utilizing the orifice(9).

2-30
 3) EACH SPOOL OPERATION
(1) Boom control
① Boom up operation

511 516 8
303
LCb1 Ab1 18 370 379
Bb1

Bb1R Ab1R

XBb1 XAb1

6 B1
B2 4
13 SP
(PSP)

XAb2

SP CSP CCb
376 370 511 21 511 307 374 372

The main boom up operation becomes fast because the hydraulic fluid from the pump P2 that is
directed to the port P2 is combined in the casing that of the pump P1 which enters port P1. The
confluence flow is supplied to the head side of the boom cylinder. In low speed operation, only the
boom1 spool(303) operates and is supplied with hydraulic fluid from the pump P2.
The hydraulic fluid from the pump P2 flows into the boom1 spool(303) through port P2 and parallel
path(6). The hydraulic fluid from the pump P1 flows to the boom2 spool(307) through pump port
P1 and the parallel path(22).
During the boom up operation, the pilot pressure from the pilot control valve is supplied into the port
XAb1 and shifts the boom1 spool(303) in the left direction against the springs (370) and (370). The
hydraulic fluid from the pump P2 enters the parallel path(6) and then passes through the load check
valve LCb1(511) and boom1 spool(303) and check valve HV(516) then flows into the port Ab1.
Following this it flows into the head side of the boom cylinder.
At the same time, the pilot pressure through the port XAb2 shifts the boom2 spool(307) in the left
direction against the springs (374) and (372). The hydraulic fluid from the pump P1 enters via the
parallel path(22) and center bypass(21), then passes through the load check valve CSP(511),
boom2 spool(307) and the load check valve CCb(511). Then flows combine in path(8) and are
directed to port Ab1 and the head side of the boom cylinder.
The flow from the rod side of the boom cylinder returns to the boom1 spool(303) through the port
Bb1. Thereafter it is directed to the return port R2 through path(13).

2-31
 ② Boom down operation

303 511 516 45 370 379

LCb1 Ab1
Bb1

Bb1R Ab1R

XBb1 XAb1

6 B1
B2 4
13 SP
(PSP)

XAb2

SP CSP CCb

376 370 374 372

511 511 307

During the boom down operation, the pilot pressure from the pilot control valve is supplied to port
XBb1 and PbL and shifts the boom1 spool(303) in the right direction against the springs (370) and
(379).
The hydraulic fluid from the pump P2 enters the parallel path(6) and is directed to the port Bb1
through the load check valve LCb1(511). Following this is flows into the rod side of the boom
cylinder.
The return flow from the head side of the boom cylinder returns to the boom1 spool(303) through
the port Ab1. Thereafter it is directed to the return port R2 through path(4).
Additionally, the return flow is restricted in path(45), which lowers the boom cylinder at a suitable
speed.

2-32
 (2) Arm control
① Arm roll out operation

306 374 372

LCa2

XAa2 XBa2

A2

A1

XAa1 XBa1

Aa1R

Ba1R

13 Aa1
LCa1 HV Ba1
22
302 511 516 370 379

During the arm roll out operation, the pilot pressure from the pilot control valve is supplied to the
pilot ports(XBa1& XBa2) and shifts the arm1 spool(302) in the left direction against the springs
(370) and (379) and shifts the arm2 spool(306) in the left direction against the springs (374) and
(372). The hydraulic fluid from the pump P1 flows through the load check valve LCa1(511), lock
valve HV(516), and then through parallel path(22). It is then directed to the rod side of the arm
cylinder through the port Ba1.
At the same time, the pilot pressure through the port XBa2 shifts the arm2 spool(306) in the left
direction against the springs (374) and (372). The hydraulic fluid from the pump P2 enters via the
parallel path(22) and center bypass(21), then passes through the check valve of the boom priority
valve(104), arm2 spool(306). The flows are combined and directed to port Ba1 and the rod side of
the arm cylinder.
The flow from the head side of the arm cylinder returns to the arm1 spool(302) through the port
Aa1. Thereafter it is directed to the return port R2 through path(13).

2-33
 ② Arm roll in operation
・During light load only

306 374 372

LCa2

XAa2 XBa2

A2

(c) (a)
A1

XAa1 XBa1

Aa1R

Ba1R

13 Aa1
LCa1 HV Ba1
22
302 511 516 370 379

2-34
 ・ The pressure in the arm cylinder head side increases

306 374 372

LCa2

XAa2 XBa2

A2

(d) (e) (f) (a) (b)

A1

XAa1 XBa1

Aa1r

Ba1R

13 Aa1
LCa1 HV Ba1
22
302 511 516 370 379

2-35
During the arm roll in operation, the pilot pressure from the pilot control valve is supplied to the
ports XAa1, XAa2 and PaL and shifts the arm1 spool(302) in the right direction against the
springs (370) and (379) and shifts the arm2 spool(306) in the right direction against the springs
(384) and (372).
During the arm roll in operation, the hydraulic fluid from the pump P1 flows into the arm1
spool(302) through the parallel path(22). Then it enters into the head side of the arm cylinder
through the load check valve LCa1(511), check valve HV(516) and port Aa1.
At the same time, the hydraulic fluid from the pump P2 flows into the arm2 spool(306) through
the parallel path(22). Then it enters into the head side of the arm cylinder through the check
valve of boom priority valve(104) and port Aa1.
The return flow from the rod side of the arm cylinder is pressurized by self-weight of arms and so
on, and returns to port Ba1. The pressurized oil returning to port Ba1 enters into the arm1 spool
through the outside of the arm1 spool. During a light load only, it pushes open the sleeve check
valve, flows the parallel path reversely from spool hole(c), and joints into port Aa1. This is called
the arm regeneration function.
When the pressure in the arm cylinder head side increases, the piston(d) and sub spool(e) are
transferred in the right direction, and at the same time the sleeve check valve(f) is from the arm
cylinder rod side enters flow port Ba1 through the periphery hole(a) of the arm1 spool into the
spool, flows out through the periphery hole(b) of the spool, and returns through the tank port R2
to the hydraulic oil tank.

2-36
(3) Bucket control
① Bucket roll in operation

379 370

511
LCk
Ak1 Bk1

AkR BkR

XAk XBk

BK

13 304 6 4

During the bucket roll in operation, the pilot pressure from the pilot control valve is supplied to port
XBk and shifts the bucket spool(304) in the left direction against the springs (370) and (379).
The hydraulic fluid from the pump P2 enters the parallel path(6) and is directed to the port Bk1
through the load check valve LCk(511). Following this it flows into the head side of the bucket
cylinder.
The retutn flow from the rod side of the bucket cylinder returns to the bucket spool(304) through the
port Ak1. Thereafter it is directed to the return port R2 through path(13).

2-37
 ② Bucket confluence operation

BC

XBp2 XBp1

Dr2
NR1 NR2

Fl Fr

392 377 378

Ck1

Ck2

During the bucket roll in operation, the pilot pressure from the pilot control valve is supplied to port
XBp1 and shifts the bypass cut spool(392) in the left direction against the springs(392) in the left
direction against the springs (377) and (378).
The hydraulic fluid from the pump P1 enters the center bypass path(21).
But bypass path is shut off by the bypass cut spool. Therefore the hydraulic fluid is directed to port
Ck2 after passing through the check valve Ck1.
Then the fluid is directed to the bucket spool(304).

2-38
③ Bucket out operation

379 370
511
LCk
Ak1 Bk1

AkR BkR

XAk XBk

BK

13 304 6 4

During the bucket roll out operation, the pilot pressure from the pilot control valve is supplied to port
XAk and shifts the bucket spool(304) in the right directed agains the springs (370) and (370).
The hydraulic fluid from the pump P2 enters the parallel path(6) and is directed to the port AK1
through the load check valve LCk(511). Following this it flows into the rod side of the bucket
cylinder.
The return flow from the head side of the bucket cylinder returns to the bucket spool(304) through
the port Bk1. Thereafter it is directed to the return port R2 through path(4).

2-39
(4) Swing control

XBs XAs

22

13
4

Bs As

305 251 254 370 379

Pns

During the swing right or left operation, only the hydraulic fluid of the pump P1 is supplied to the
swing motor.
The pilot pressure from the pilot control valve is supplied to the port XAs and shifts the swing spool
(305) in the left direction against springs (370) and (379). Hydraulic fluid from the pump P1 flows
into the swing spool(305) through the parallel path(22). Then it is directed to the swing motor
through the check valve LCs(254) and the port As. As a result, the swing motor turns and the
return flow from the swing motor enters port Bs. The flow from the motor returns to the tank port
R2 through the swing spool(305) and path(13). In the case of the opposite operation, the operation
is similar.

2-40
(5) Travel control

301 328 329

Btr Atr

XBtr XAtr

TR

TL

XBtl XAtl

Btl Atl

310 328 329

During the travel operation, the hydraulic fluid of the pump P1 is supplied to the travel motor and the
hydraulic fluid of the pump P2 is supplied to the other travel motor.
The pilot pressure from the pilot control valve is supplied to the port XAtr and XAtl.
And it shifts the travel right spool(301) and travel left spool(310) in the left direction against springs
(328) and (329). Hydraulic fluid from the pump P1 flows into the travel left spool(310) through the
parallel path and hydraulic fluid from the pump P2 flows into the travel right spool(301). Then they
are directed to the each travel motor through port Atl and Atr. As a result, the travel motors turn
and the return flow from the travel motors enter port Btl and port Btr. The flow from the motors
returns to the tank port R2 through the travel spools(310 and 301).
In the case of the opposite operation, the operation is similar.

2-41
4) CIRCUIT PRESSURE PROTENCTION
The control valve has two kinds of relief valve to limit the pressure in a circuit.
(1) Main relief valve
Limits the pressure of the main hydraulic system.

Pz CMR1 CMR2

MR

338

J
601
TS

324 325

391

The hydraulic fluid from the pump P1 and the pump P2 enters the control valve through ports P1
and P2, respectively. From here the flow is directed to the main relief valve(601) through the check
valve CMR1 or CMR2(511) and path(11). The pressure in path(11) is limited by the main relief
valve(601) to its set pressure.

2-42
 ・Main relief operation while working

30 35 32 33
14

11 31 38 34 24 39 25

While the pressure in path(11) is lower than the set pressure of main relief valve(601), the poppet
(24) is seated and the hydraulic fluid in path(11) can not escape to the return(14). When the
pressure in path(11) approaches the pressure setting, poppet(24) opens against the spring(39).
As the flow in chamber(33) escapes into the return(14) through path(32), its pressure decreases.
At the same time, hydraulic fluid in path(11) flows into path(30) with a pressure drop across
orifice(31). Then pressure in spring chamber(35) becomes lower because it bleeds off through
path(30). The pressure from path(11) pushes the plunger(38) in the left direction against the
spring(34). Then plunger(38) opens and hydraulic fluid in path(11) escapes into the return(14) and
maintains the pressure setting. The pressure setting is adjusted with adjustment screw(25).

2-43
(2) Port relief valve
Limits the service pressure in a cylinder circuit.

10 9 8 7

6 5 4 3 2 1

Port relief valves and make up valves are fitted between the cylinders of the working devices(Boom,
arm, bucket) and their spools. In the case of an external force acting on the cylinder rod with its
spool in neutral, the pressure in the cylinder could become excessive. The port relief valve(602)
restricts this pressure to the set pressure of the valve.
Port relief valve(602) have also the additional function of a make up valve. It is possible, under the
influence of an external force acting on a cylinder that a condition can occur where insufficient flow
is available to match cylinder velocity. If this occurs then a vacuum and thereby cavitation could
exist. To eliminate such an occurrence, a make up valve operates to break this vacuum by
supplying the return flow into the cylinder.
The hydraulic fluid between the cylinder and its spool flows into the path(6) to pressurize the port
relief valve(602). The hydraulic fluid in the path(6) flows into the spring chamber(3) through the
path(4) in the piston(10). If the pressure is lower than the pressure setting, the poppet(2) is shut off
because the force of the spring(1) overcomes the pressure. So the path(6) and the spring
chamber(3) have the same pressure. Because the spring chamber(3) side pressured area of the
seat(8) and the plunger(9) is larger than that of the path(6) side, seat(8) and the plunger(9) are
pushed in the right direction to be seated securely and then the hydraulic fluid in the path(6) doesn't
escape into the return path(5).

2-44
① Port relief function

10 9 7 13

6 12 5 4 3 2 11 1

When the pressure in the path(6) is pressurized to the pressure setting, the poppet(2) is pushed
open against the spring(1). The hydraulic fluid in the chamber(11) flows into the return path(5)
through the path(13) with reducing its pressure. The piston(10) is shifted in the left direction by the
pressure in the path(6) and stops on the end of the plug(7).
The hydraulic fluid in the path(6) flows into the chamber(11) through the path(4) in the piston(10)
and the spring chamber(3). Because the differential pressure occurs between the pass(6) and the
pass(4) by the orifice between the outernal diameter of the end of the piston(10) and the internal
diameter of the plunger(9), the pressure in the spring chamber(3) becomes low and therefore the
plunger(9) is pushed in the left direction with the path(12) opened so that the hydraulic fluid in the
path(6) flows into the return path(5).

2-45
② Make up function

9 8 11

6 5 4 3

Following this then the case of a port relief valve operating as a make up valve is now explained.
In the case that the hydraulic fluid in the cylinder rod(Head) side escapes from the port relief valve
(602), then hydraulic fluid needs to be supplied because vacuum occurs in the head(Rod) side.
When cacuum occurs in the side of the path(6), it also occurs in the spring chamber(3) through the
path(4). The pressure in the side of the return path(5) acts on the seat(8). The seat(8) is shifted in
the left direction by the return pressure because the spring chamber(3) sides of the seat(8) and the
plunger(9) are under a vacuum. The hydraulic fluid in the return path(5) flows into the path(6) so as
to break the vacuum in the path(6) side.

2-46
GROUP 2 MAIN CONTROL VALVE(#1177 and up)

1. STRUCTURE
Mark Port name Port size Tightening torque

Rs Make up for swing motor G1 20~25kgfÂm

(145~180lbfÂft)
MRV Pu
A1 B1
T1
Patt Auto idle-attachment
P2
P02
Pb21 Lock valve pilot port(Boom)
Pcb Bucket in confluence port
Pb21 Dr1 A2 B2 Pd40 Arm out pilot port
ORV Pd41 Arm out confluence pilot port 3.5~3.9kgfÂm
-B2 Po1 Pilot pressure G1/4 (25.3~28.2lbfÂft)
ORV
Ptr
Po2 Pilot pressure
-A2 Ptr Auto idle-travel
B4
Dr1 Drain port
P1 Dr2 Drain port
Dr3 Drain port
ORV A5 ORV
-A5 -B5 Ck1 Bucket confluence 17~19kgfÂm
CK2 Ck2 Bucket confluence G3/4 (123~137.4lbfÂft)

Pa1 Travel pilot port-LH(FW)

Pb1 Travel pilot port-LH(BW)
Pc1 Travel pilot port-RH(BW)
Pd1 Travel pilot port-RH(FW)
Pa20 Boom up pilot port
Pa21 Boom up confluence pilot port
Pb20 Boom down pilot port
Pc2 Swing pilot port(LH)
TRAVEL- Pd2 Swing pilot port(RH)
Dr0
STRAIGHT Pb3 Arm in confluence pilot port
P01
C1 D1 Pc3 Swing priority pilot port
ORV Pa4 Option A pilot port(Breaker) 7~8kgfÂm
Pb1 Pc1 TRAVEL(L) ORV -D1 TRAVEL(R) Pd1 Pa1
G3/8 (50.6~57.8lbfÂft)
-C1 Patt Pb4 Arm in regeneration cut port
C2 D2 Pc40 Arm in pilot port
Pb20 Pc2 BOOM 1 SWING Pd2 Pa20 Pc41 Lock valve pilot port(Arm)
Dr2
Pc42 Arm in regen-cut signal selector port
ORV ORV BOOM 2 & Pa5 Bucket in pilot port
Pb3 Pc3 ARM 2 -C4 -D4
SWING PRIORITY Pa21 Pd41
V3 Pb5 Bucket out pilot port
Pc42 Pb4 EXTRA A & C4 D4 Pc5 Option B pilot port
Pc40 ARM ARM 1 Pd40 Pa4
Pd5 Option B pilot port
REGENERATION Dr3 Pc41 Po Pilot pressure port
ORV C5 D5
ORV
Pu Main relief pressure up port
Pb5 Pc5 BUCKET -C5 -D5
EXTRA B Pd5 Pa5 Dr0 Drain port
Pn1 Negative control signal port(P1 port side)
Pn2 Negative control signal port(P2 port side)
A1 Travel motor port-LH(FW)
B1 Travel motor port-LH(BW)
C1 Travel motor port-RH(BW)
D1 Travel motor port-RH(FW)
A2 Boom up port
B2 Boom down port
C2 Swing motor port(LH)
D2 Swing motor port(RH) 7.5~9.2kgfÂm
B4 Option A port(Breaker) SAE 5000, 1 (54.2~66.5lbfÂft)
C4 Arm in port
D4 Arm out port
A5 Bucket in port
CK1
B5 Bucket out port
C5 Option B port
Pn1 Pn2
D5 Option B port
P1 Pump port(P1 side)
P2 Pump port(P2 side)

T1 Return port SAE 3000, 2 6.4~8.6kgfÂm

29072MC50 (M12) (46.2~62.2lbfÂft)

2-46-1
 1 Body(P1) 47 Piston-cut off
15 80 74 3 81 65 68 54 67 60 51 52 74 26 29 28 27 16
2 Body(P2) 48 Poppet-signal
15 80 74 10 21 22 73 20 23 71 24 25 74 26 29 28 18 27 3 Spool-travel straight 49 Spring-signal
4 Spool-travel 50 Plug
5 Spool-swing 51 Orifice-signal
6 Spool-boom 52 Coin type filter
7 Spool-swing priority 53 Orifice-plug
55 8 Spool-boom 2 54 Plug
71 59 79 78 91 49
46 9 Spool-arm 2 55 Plug
21 22 73 20 73 22 21 66 61 83 19 10 Spool-arm 56 Restrictor-lock valve
A-A (STRAIGHT-TRAVEL & SUPPLY)
44 57 45 74 53 11 21 22 73 20 712325 24 74 26 29 28 27 16 11 Spool-arm regeneration 57 Plug
60 67 60 67 60 67 1 12 Spool-bucket 58 Plug
E-E (ARM & ARM REGENRATION)
15 80 74 85 4 71 23 73 20 22 21 85 74 81 26 29 28 27 16 P1 BLOCK SPOOL SECTION 13 Spool-option 59 Plug
14 Spool-bypass cut 60 Plug
15 84 74 12 21 22 20 73 23 71 25 24 84 74 26 29 28 2716 15 Cover-pilot A 61 Plug
16 Cover-pilot B1 62 Plug
60 65 67 60 6065
17 Cover-pilot B2 63 O-ring
18 Block-holding 64 O-ring
19 Block-regeneration 65 O-ring
20 Plug 66 O-ring
15 74 4 24 25 23 73 74 26 29 28 27 16 21 Popet 1-check valve 67 O-ring
B-B (TRAVEL RIGHT& LEFT) 22 Spring-check valve 68 O-ring
23 Plug 69 O-ring
15 84 74 13 21 22 73 20 23 71 25 24 8474 26 29 28 27 16
15 80 74 5 24 25 23 73 74 26 29 81 28 27 16 24 Poppet 2-check valve 70 O-ring
88
25 Spring-check valve 71 O-ring
F-F (OPTION & BUCKET)
26 Spring seat 1 72 O-ring
60 67 14 89 70 90 27 Spring seat 2 73 O-ring
60 67 69 58 2 28 Spacer bolt 74 O-ring
P2 BLOCK SPOOL SECTION
29 Spring-return(L) 75 Back-up ring
30 Stopper 1-TS 76 Back-up ring
31 Stopper 2-priority 77 Back-up ring
32 Spring seat 3 78 Socket head bolt with washer
15 84 80 74 6 24 2523 73 74 26 29 28 27 18
C-C (SWING & BOOM)
33 Poppet-check valve 79 Socket head bolt with washer
34 Spring-check valve 80 Socket head bolt with washer
17 28 27 29 28 84 33 74 7 54 68 65 77 62 70 8 84 74 3329 282717 87 70 62 87 35 Poppet-lock valve 81 Main relief valve
G-G (CENTER BYPASS CUT-OFF & NEGATIVE CONTROL)
36 Spring-lock valve pilot 82 Over load relief valve
37 Guide poppet 83 Plug-relief valve
38 Poppet-pilot 84 Plug-relief valve
39 Seat-poppet 85 Negative control valve
59 40 Piston 1 86 Socket head bolt with washer
35 56
36 38 37 41 Guide-piston 87 Socket head bolt with washer
39 72 7765 57 40 41 42 43 68
42 Spring 1-lock valve 88 Nipple-check valve
15 74 86 9 24 25 23 71 23 25 24 84 74 26 29 28 27 16 33 34 63 30
43 Piston 2 89 Spring-bypass cut spool
DETAIL OF LOCK VALVE (BOOM & ARM)
STRAIGHT-TRAVEL SPOOL DETAIL
44 Spool-regen selector 90 Plug-bypass cut spool
D-D (SWING PRIORITY & BOO2 & ARM2)
45 Spring-regeneration 91 Backup ring
300072MCV02 46 Stopper-regeneration

2-46-2
2. HYDRAULIC CIRCUIT

TRAVEL
(STRAIGHT)

TRAVEL(L) TRAVEL(R)

SWING

BOOM 1

ARM 2 BOOM 2 &

SWING
PRIORITY

EXTRA A &
ARM
REGENERATION ARM 1

BUCKET EXTRA B

29072MC51

2-46-3
3. FUNCTION
1) CONTROL IN NEUTRAL FUNCTION
(1) P1 SIDE
STRAIGHT TRAVEL SPOOL P1 PORT

TANK PORT "T1"

B B

P1 BYPASS PASSAGE P1 PARRALLEL PASSAGE

SECTION A-A
29072MC53

A A

TRAVEL LIFT

BOOM 1

ARM 2

ARM REGENERATION
OPTION "A"

BUCKET

P1 NEGATIVE RELIEF VALVE P2 NEGATIVE RELIEF VALVE

SECTION B-B

29072MC52

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

2-46-4
 (2) P2 SIDE

STRAIGHT TRAVEL SPOOL P2 PARRALLEL PASSAGE

TANK PORT "T1"

B B

P2 PORT P2 BYPASS PASSAGE

SECTION A-A
29072MC54

A A

TRAVEL STRAIGHT

TRAVEL RIGHT

SWING

BOOM 2
SWING PRIORITY

ARM 1

OPTION "B"

SECTION B-B
29072MC55

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

2-46-5
2) EACH SPOOL OPERATION
(1) TRAVEL OPERATION
① Travel forward operation

A1 B1
P1 BYPASS PASSAGE
FROM RCV

FROM RCV
TANK PASSAGE
P2 BYPASS PASSAGE
C1 D1

29072MC56

② Travel backward operation

A1 B1
P1 BYPASS PASSAGE

FROM RCV

FROM RCV
TANK PASSAGE
P2 BYPASS PASSAGE
C1 D1

29072MC57

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

2-46-6
 (2) TRAVEL STRAIGHT FUNCTION

P2 PARALLEL PASSAGE P1 PORT

TRAVEL ORIFICE
STRAIGHT
SPOOL CHECK VLV

P2 BYPASS PASSAGE

P2 PORT P1 BYPASS PASSAGE P1 PARALLEL PASSAGE

29072MC58

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 P1 is supplied to the travel motor and the pump P2 is supplied to
the other 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 P1 is supplied actuator through P1 and P2 parallel pass and travel
motors through orifice at side of straight travel spool.
The hydraulic oil fluid from pump P2 is supplied to travel motors(left/right).
Therefore, the other actuator operation with straight travel operation, hydraulic oil fluid from pump
P1 is mainly supplied to actuator, and the hydraulic oil fluid form pump P2 is mainly supplied to
travel motors(left/right).
Then the machine keeps straight travel.

2-46-7
 (3) BOOM OPERATION
① Boom up operation

P1 BYPASS PASSAGE
TANK PASSAGE
BOOM 1 SPOOL

FROM RCV
HOLDING VLV
B2 A2 P1 PARALLEL PASSAGE

CYLINDER ROD CYLINDER HEAD

29072MC59

ARM SUMMATION PASSAGE

P2 BYPASS PASSAGE

P2 PARALLEL PASSAGE
SWING PRIORITY SPOOL
BOOM 2 SPOOL

FROM RCV

ARM 2 SPOOL
BOOM SUMMATION PASSAGE CHECK
29072MC60

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

2-46-8
 ② Boom down operation

TANK PASSAGE

P1 BYPASS PASSAGE

BOOM 1 SPOOL

FROM RCV
HOLDING VALVE
B2 A2 P1 PARALLEL PASSAGE

CYLINDER ROD CYLINDER HEAD

29072MC61

During the boom lowing operation, the pilot pressure from RCV is supplied to the port Pb20 and shift
the boom1 spool in the right direction.
The hydraulic fluid from the pump P1 enters the parallel passage and is directed to the port B2
through the load check valve. Following this, it flows into the rod side of the boom cylinder.
The return flow from the head side of the boom cylinder returns to the boom1 spool through the port
A2 and boom holding valve. Thereafter it is directed to the hydraulic oil tank through tank passage.
For details of the boom holding valve, see page 2-46-17.

2-46-9
(4) BUCKET OPERATION
① Bucket roll in operation

TANK PASSAGE P1 BYPASS PASSAGE

BUCKET SPOOL

FROM RCV

B5 A5 P1 PARALLEL PASSAGE

CYLINDER ROD CYLINDER HEAD

29072MC62

② Bucket roll out operation

P1 BYPASS PASSAGE
BUCKET SPOOL
TANK PASSAGE

FROM RCV

B5 A5 P1 PARALLEL PASSAGE

CYLINDER ROD CYLINDER HEAD

29072MC63

2-46-10
① Bucket roll in operation
During the bucket roll in operation, the pilot pressure from RCV is supplied to port Pa5 and shift
the bucket spool in the left direction.
The hydraulic fluid from pump P1 entered P1 parallel passage and is directed to the port A5
through the check1.
At the same time, the hydraulic fluid from P1 bypass passage is directed to the port A5 through
the check2.
Following this it flows into the head side of the bucket cylinder.
The return flow from the rod side of the bucket cylinder returns to the bucket spool through the
port B5. Thereafter it is directed to the hydraulic oil tank through the tank passage.
② Bucket roll out operation
In case of the bucket roll out operation, the operation is similar
③ Bucket operation with arm or boom operation
When combined operation, mostly same as above but the fluid from bypass passage is empty.
So only the fluid from parallel passage is supplied to the bucket cylinder. Also, parallel passage
is installed the orifice for supplying the fluid from pump to the boom or the arm operation prior to
the bucket operation.
④ Bucket summation

P2 BYPASS PASSAGE

BUCKET SUMMATION SPOOL

BUCKET SUMMATION TANK PASSAGE

29072MC64

2-46-11
 (5) SWING OPERATION
① Swing left operation

TANK PASSAGE
C2 D2
SWING SPOOL

FROM RCV

P2 PARALLEL PASSAGE

P2 BYPASS PASSAGE

29072MC65

② Swing right operation

C2 D2
SWING SPOOL TANK PASSAGE

FROM RCV

P2 PARALLEL PASSAGE

P2 BYPASS PASSAGE

29072MC66

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

2-46-12
 (6) ARM OPERATION
① Arm roll in operation
CYLINDER ROD
CYLINDER HEAD
ARM SUMMATION PASSAGE
P2 PARALLEL PASSAGE
C4 D4 TANK PASSAGE
ARM 1 SPOOL

ARM
REGENERATION
CUT PILOT
PRESSURE

ARM PILOT
PRESSURE
PISTON C
SELECTOR SPOOL
P2 PARALLEL PASSAGE ARM REGENERATION
& EXTRA SPOOL
29072MC67

ARM SUMMATION PASSAGE

BOOM 2 SPOOL

ARM PILOT
PRESSURE

ARM 2 SPOOL
P1 PARALLEL PASSAGE

P1 BYPASS PASSAGE
29072MC68

·Arm roll in operation :

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

2-46-13
·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 arm1 spool. It is suppled the arm cylinder head through
internal passage. This is called the arm regeneration function.
The amount of regeneration fluid are changed by movement of the arm regeneration & breaker
spool.
A few fluid after P2 parallel passage is push piston "C" through the notch of arm regeneration spool
and selector spool. At this time, the selector spool is opened by pilot pressure from RCV.
Then, the arm regeneration spool shift to right side and flow to tank pass increases and
regeneration flow decreases. Therefore, pressure of arm cylinder head increases, then, arm
regeneration flow decreases.
Furthermore, the arm regeneration cut pressure is supplied to port and arm regeneration spool is
move into the right direction fully. The flow from the arm cylinder rod is returned to the hydraulic oil
tank and regeneration function is not activated.

2-46-14
② Arm roll out operation

CYLINDER ROD
CYLINDER HEAD
ARM SUMMATION PASSAGE
P2 PARALLEL PASSAGE
C4 D4
ARM 1 SPOOL

ARM PILOT
PRESSURE

TANK PASSAGE

P2 BYPASS PASSAGE
ARM REGENERATION
& EXTRA SPOOL
29072MC69

ARM SUMMATION PASSAGE

BOOM 2 SPOOL

ARM PILOT
PRESSURE

ARM 2 SPOOL
P1 PARALLEL PASSAGE

P1 BYPASS PASSAGE
29072MC70

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

2-46-15
 (7) SWING PRIORITY FUNCTION

P1 PARALLEL PASSAGE
PATH "A"
ARM SUMMATION PASSAGE
SWING PRIORITY SPOOL
BOOM 2 SPOOL

SWING PRIORITY
PILOT PRESSURE

ARM 2 SPOOL

29072MC71

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

2-46-16
 (8) HOLDING VALVE OPERATION
① Holding operation

POPPET
SPRING PISTON "A"
PILOT PISTON CHAMBER
SPRING "B"
PISTON "B"

CHECK

PLUG

POPPET SEAT
PILOT PORT
ACTUATOR PORT FOR RELEASE
DRAIN PORT HOLDING VALVE
29072MC72

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

2-46-17
 ② Release holding operation

POPPET
SPRING PISTON "A"
PILOT PISTON CHAMBER
SPRING "B"
PISTON "B"

CHECK

PLUG

POPPET SEAT PILOT PORT

ACTUATOR PORT FOR RELEASE
DRAIN PORT HOLDING VALVE

29072MC73

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.
When the poppet is opened, pressure of inside of holding valve is decreased and the return fluid from
actuator returns to the tank passage through the notch of spool.

2-46-18
 (9) NEGATIVE CONTROL

NEGATIVE
CONTROL P2 BYPASS PASSAGE
TANK PASSAGE
VALVE P1 BYPASS PASSAGE
BUCKET SPOOL

TANK PASSAGE

P1 NEGATIVE P2 NEGATIVE RELIEF VALVE

RELIEF VALVE NEGATIVE ORIFICE
CONTROL
SPRING Pn1 PORT Pn2 PORT

29072MC74

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

2-46-19
(10) OPERATION OF MAIN RELIEF VALVE
The main relief valve is fitted to the straight travel valve block and functions as follows :
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.

14072SF36

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
hole (E).

14072SF37

2-46-20
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)

14072SF38

④ High pressure setting pilot signal(Pu) : ON

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

14072SF36

2-46-21
(11) OPERATION OF PORT RELIEF VALVE
① Function as relief valve
ⓐ The pressurized oil passes through the piston A and orifice is filled up in chamber A of the
inside space and seat the plunger against the socket and the socket against the housing
securely.

14072SF39

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

14072SF40

2-46-22
ⓒ Opening of the poppet causes the pressure in chamber A to fall and the plunger to open. As
the result the pressurized oil at port P runs into tank passage (T).

14072SF41

② Make-up function
When negative pressure exists at port P, the oil is supplied through tank passage (T). When
the pressure at tank passage (T) becomes higher than that at port P, the socket moves in the
right direction. Then, sufficient oil passes around the socket from tank passage (T) to port P
and fills up the space.

14072SF42

2-46-23
GROUP 3 SWING DEVICE(up to #0373)

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.

A PB B
A,B
PA M

PG Relief valve
Gear oil SH DB
drain port(DR)

Reduction gear Swing motor Time delay valve Gear oil inlet port(IP)

SH
29072SM01

PG
Port Port name Port size
DB
A, B Main port ͚20
DB Drain port PF 1/2-19
M M Make up port PF 1-24
PA, PB Gauge port PF 1/4-15
PA PB PG Brake release port PF 1/4-12
SH Brake pilot port PF 1/4-12
IP Gear oil inlet port PT 3/4-19
DR Gear oil drain port PT 1/2

A B

2-47
1) SWING MOTOR

993 117 121 118 114 706 707 702 712 472 351 355 488 469
106
438
432 303
106 052
A 171
443
471 151
A 161
304
162
163

985
433
101 444
491
437 984
124
401

051
301 994 122 123 113 116 111 742 743 031 131 451
464 485

400 100 702

712

052
SECTION A-A

031 Time delay valve 161 O-ring 464 Plug

051 Relief valve 162 O-ring 469 Plug
052 Valve assy 163 O-ring 471 O-ring
100 Casing 171 Hexagon screw 472 O-ring
101 Drive shaft 301 Casing 485 O-ring
106 Spacer 303 Casing 488 O-ring
111 Cylinder 304 Front cover 491 Oil seal
113 Retainer 351 Plunger 702 Piston
114 Spring 355 Spring 706 O-ring
116 Push rod 400 Valve 707 O-ring
117 Spacer 401 Hexagon screw 712 Brake spring
118 Spacer 432 Snap ring 742 Lining plate
121 Piston 433 Snap ring 743 Separate plate
122 Shoe 437 Snap ring 984 Plug
123 Set plate 438 Snap ring 985 Plug
124 Shoe plate 443 Roller bearing 993 Plug
131 Valve plate 444 Needle bearing 994 Plug
151 Plug 451 Pin

2-48
2) REDUCTION GEAR

1 21 13 6 4 23 2 7 18 19

37 35 20 27 22
10
33

17

31

9
39
38
14

24
8
34 36 3 16 26

11
15

12 29 32 5 28 25 30

1 Front casing 14 Pin 1 27 Oil seal

2 Middle casing 15 Side plate 1 28 Spring pin
3 Drive shaft 16 Magnet 29 Pressure plug
4 Ring gear 2 17 Side plate 3 30 Spring pin
5 Planet gear 2 18 Gauge bar 31 Stop ring
6 Sun gear 2 19 Gauge pipe 32 Bushing 2
7 Ring gear 1 20 Spacer ring 33 Stop ring
8 Planet gear 1 21 Knock pin 34 Lock washer
9 Sun gear 1 22 Roller bearing 35 Pinion gear
10 Carrier 23 Roller bearing 36 Lock plate
11 Pin 2 24 Needle cage 37 Hexagon bolt
12 Thrust washer 25 Socket bolt 38 Stop ring
13 Thrust button 26 Socket bolt 39 Side plate 2

2-49
2. FUNCTION
1) ROTARY PART
When high pressurized oil enters a cylinder through port(a), which is the inlet of balance plate(131),
hydraulic pressure acting on the piston causes axial force F. The pressure force F works via the
piston(121) upon the return plate(123) which acts upon the swash plate(124) via an hydrostatic
bearing. Force F1 perpendicular to swash plate(124) and force F2 perpendicular to cylinder center.
Being transferred to the cylinder block(111) through piston, force F2 causes rotational moment at
surroundings of cylinder.
Since cylinder block has 9 equidistantly arrayed pistons, rotational torque is transmitted to cylinder
shaft in order by several pistons connected to the inlet port of high pressurized oil. When the
direction of oil flow is reversed, rotational direction of cylinder is also reversed. Output torque is
given by the equation.
p×q F
T= , q=Z・A・PCD・tanθ, F1 = , F2=F tanθ, S=PCD×tanθ
2Л COSθ
Where p : Effective difference of pressure(kgf/cm2)
q : Displacement(cc/rev)
T : Output torque(kgf・cm)
Z : Piston number(9EA)
A : Piston area(cm2)
θ: Tilting angle of swash plate(degree)
S : Piston stroke(cm)

Low High
pressure oil pressure oil

F1 F2

131

124 123 121 111

2-50
2) MAKE UP VALVE
In the system using this type of motor, there is no counter balance functioning valve and there
happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation
caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency.
A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure
feed pressure required when the hydraulic motor makes a pumping action. The boost pressure
acts on the hydraulic motor's feed port via the make up valve.
Pressurized oil into the port B, the motor rotate counterclockwise.
If the plunger of MCV moves neutral position, the oil in the motor is drain via left relief valve, the
drain oil run into motor via right make up valve, which prevent the cavitation of motor.

A B

2-51
3) RELIEF VALVE

3
5
1 Body
2 O-ring
4 3 Plug
15 4 O-ring
11 5 Back up ring
6 Plunger
14
7 Piston
13 7 8 Spring
9 Seat spring
9
12 10 Seat
2 11 Sleeve
12 Adjust plug
1
13 O-ring
14 Back up ring
8
15 Nut

10

(1) Construction of relief valve

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

(2) Function of relief valve

Figure illustrates how the pressure acting P P=pressure, T=time
on the relief valve is related to its rising PS
process. Here is given the function, 4
referring to the figure following page.
P1 3

T
1

2-52
① Ports (P,R) at tank pressure.

A1 m 6 7

8 A2

② When hydraulic oil pressure(P×A1) reaches the preset force(FSP) of spring(8), the plunger (6)
moves to the right as shown.
P1×A1 = Fsp + P1×A2

Fsp
P1=
A1 - A2

P=P1

2-53
③ When the pressure of chamber g reaches the preset force(Fsp) of spring(8), the piston(7) moves
right and stop the piston(7) hits the end of body.

m 6 7 f g

P=P1

④ When piston(7) hits the end of body, it stops moving to the right any further. As the result, the
pressure in chamber(g) equals(Ps).
Ps×A1 = Fsp + Ps×A3
Fsp
Ps =
A1 - A3

m 6 7 g

P=P1

2-54
4) BRAKE SYSTEM
(1) Control valve swing brake system
This is the brake system to stop the swing motion of the excavator during operation.
In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance
created by this throttling works as a brake force to slow down the swing motion.

Work Deceleration Stop

A B A B A B

MCV MCV MCV

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

(2) Mechanical swing parking brake system

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

① Brake assembly
Circumferential rotation of separate
plate(743) is constrained by the groove
located at casing(301). When housing is
pressed down by brake spring(712)
through lining plate(742), separate 712
plate(743) and brake piston(702), friction
702
force occurs there.
743
Cylinder(111) is constrained by this
friction force and brake acts, while brake 742
releases when hydraulic force exceeds 111
Groove
spring force. 301

111 Cylinder 712 Brake spring

301 Casing 742 Lining plate
702 Brake piston 743 Separate plate

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

5
712
G SH
702
8

1 Swing control lever

2 Swing control valve(MCV)
3 Time delay valve
4 Shuttle valve
P3
5 Spool
8 Spring
702 Brake piston 2 2
712 Brake spring 4

2-56
 b. When the swing control lever(1) is set the neutral position, the time delay valve(3) shifts the
neutral position and the pilot oil blocked chamber G.
Then, the piston(702) is moved lower by spring(712) force and the return oil from the chamber G
is drain.

712
G S
70 2

1 Swing control lever

2 Swing control valve(MCV)
3 Time delay valve
4 Shuttle valve
702 Brake piston P
712 Brake spring

2 2
4

R290SM08(1)

2-57
GROUP 3 SWING DEVICE(#0374 and up)

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

Swing motor A B
A,B

PA
.
PB

IP

DR PG Relief valve SH DB

SH

PG
Port Port name Port size
DB
A, B Main port ͚20
DB Drain port PF 1/2-19
C Make up port PF 1-24
PA, PB Gauge port PF 1/4-15
C PG Brake release port PF 1/4-12
PA PB
SH Brake pilot port PF 1/4-12
IP Gear oil inlet port PT 3/4-19
DR Gear oil drain port PT 1/2

A B
30572SM01

2-57-1
1) SWING MOTOR

117 121 118 114 706 707 702 712 472 106 469 488 355 351 052 841

432 438
X X
106 303
471 A 748 993

443 A 747
304 444
468
487

746
101

491 745

437 433
124
451

301 122 123 113 116 111 744 742 031 743 131 401 051 994

464 485

30572SM02

031 Brake valve 304 Front cover 488 O-ring

051 Relief valve 351 Plunger 491 Oil seal
052 Valve assy 355 Spring 702 Piston
101 Drive shaft 401 Socket bolt 706 O-ring
106 Spacer 432 Snap ring 707 O-ring
111 Cylinder block 433 Snap ring 712 Brake spring
113 Bushing 437 Snap ring 742 Lining plate
114 Spring 438 Snap ring 743 Separate plate
116 Push rod 443 Roller bearing 744 Plug
117 Spacer 444 Roller bearing 745 Plug
118 Spacer 451 Spring pin 746 Plug
121 Piston 464 Plug 747 Name plate
122 Shoe 468 Plug 748 Rivet screw
123 Retainer 469 Plug 841 Socket bolt
124 Shoe plate 471 O-ring 993 Plug
131 Valve plate 472 O-ring 994 Plug
301 Casing 485 O-ring
303 Casing 487 O-ring

2-57-2
2) REDUCTION GEAR

1 21 13 6 4 23 2

10

33

17
37
31

9
34
39
36
3 38
35
14
20
24
8
27
26
15

22 16 29 11 12 32 5 28 25 30 19 18

30572SR01

1 Front casing 14 Pin 1 27 Oil seal

2 Middle casing 15 Side plate 1 28 Spring pin
3 Drive shaft 16 Magnet 29 Pressure plug
4 Ring gear 2 17 Side plate 3 30 Spring pin
5 Planet gear 2 18 Gauge bar 31 Stop ring
6 Sun gear 2 19 Gauge pipe 32 Bushing 2
7 Ring gear 1 20 Spacer ring 33 Stop ring
8 Planet gear 1 21 Knock pin 34 Lock washer
9 Sun gear 1 22 Roller bearing 35 Pinion gear
10 Carrier 23 Roller bearing 36 Lock plate
11 Pin 2 24 Needle cage 37 Hexagon bolt
12 Thrust washer 25 Socket bolt 38 Stop ring
13 Thrust button 26 Socket bolt 39 Side plate 2

2-57-3
2. FUNCTION
1) ROTARY PART
When high pressurized oil enters a cylinder through port(a), which is the inlet of balance plate(131),
hydraulic pressure acting on the piston causes axial force F. The pressure force F works via the
piston(121) upon the return plate(123) which acts upon the swash plate(124) via an hydrostatic
bearing. Force F1 perpendicular to swash plate(124) and force F2 perpendicular to cylinder center.
Being transferred to the cylinder block(111) through piston, force F2 causes rotational moment at
surroundings of cylinder.
Since cylinder block has 9 equidistantly arrayed pistons, rotational torque is transmitted to cylinder
shaft in order by several pistons connected to the inlet port of high pressurized oil. When the
direction of oil flow is reversed, rotational direction of cylinder is also reversed. Output torque is
given by the equation.
pÝq F
T= , q=ZÂAÂPCDÂtanɾ, F1 = , F2=F tanɾ, S=PCDÝtanɾ
2ӕ COSɾ
Where p : Effective difference of pressure(kgf/cm2)
q : Displacement(cc/rev)
T : Output torque(kgfÂcm)
Z : Piston number(9EA)
A : Piston area(cm2)
ɾ: Tilting angle of swash plate(degree)
S : Piston stroke(cm)

Low High
pressure oil pressure oil

F1 F2

131

124 123 121 111

R290SM05(2)

2-57-4
2) MAKE UP VALVE
In the system using this type of motor, there is no counter balance functioning valve and there
happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation
caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency.
A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure
feed pressure required when the hydraulic motor makes a pumping action. The boost pressure
acts on the hydraulic motor's feed port via the make up valve.
Pressurized oil into the port B, the motor rotate counterclockwise.
If the plunger of MCV moves neutral position, the oil in the motor is drain via left relief valve, the
drain oil run into motor via right make up valve, which prevent the cavitation of motor.

A B

29072SM09

2-57-5
3) RELIEF VALVE

3
1 Body
5 2 O-ring
4 3 Plug
4 O-ring
15
5 Back up ring
11
6 Plunger
14 7 Piston
7 8 Spring
13
9 Seat spring
9 10 Seat
12
2 11 Sleeve
12 Adjust plug
1 13 O-ring
14 Back up ring
8 15 Nut

10

(1) Construction of relief valve

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

(2) Function of relief valve

Figure illustrates how the pressure acting P P=pressure, T=time
on the relief valve is related to its rising PS
process. Here is given the function, 4
referring to the figure following page.
P1 3

T
1
29072SM05

2-57-6
Ι When the pressure of chamber g reaches the preset force(Fsp) of spring(8), the piston(7) moves
right and stop the piston(7) hits the end of body.

m 6 7 f g

P=P1

29072SM07

Κ When piston(7) hits the end of body, it stops moving to the right any further. As the result, the
pressure in chamber(g) equals(Ps).
PsÝA1 = Fsp + PsÝA3
Fsp
Ps =
A1 - A3

m 6 7 g

P=P1

29072SM08

2-57-7
4) BRAKE SYSTEM
(1) Control valve swing brake system
This is the brake system to stop the swing motion of the excavator during operation.
In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance
created by this throttling works as a brake force to slow down the swing motion.

Work Deceleration Stop

A B A B A B

MCV MCV MCV

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

(2) Mechanical swing parking brake system

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

Η Brake assembly
Circumferential rotation of separate
plate(743) is constrained by the groove
located at casing(301). When housing is
pressed down by brake spring(712)
through lining plate(742), separate
plate(743) and brake piston(702), friction
force occurs there.
Cylinder(111) is constrained by this
friction force and brake acts, while brake
releases when hydraulic force exceeds
spring force.

30572SM03

111 Cylinder 712 Brake spring

301 Casing 742 Lining plate
702 Brake piston 743 Separate plate

2-57-8
 Θ Operating principle
a. When the swing control lever(1) is set to the swing position, the pilot oil go to the swing control
valve(2) and to SH of the time delay valve(3) via the shuttle valve(4), this pressure move
spool(5) to the leftward against the force of the spring(8), so pilot pump charged oil(P3) goes to
the chamber G.
This pressure is applied to move the piston(702) to the upward against the force of the
spring(712). Thus, it releases the brake force.

5
712
G SH
702
8

1 Swing control lever

2 Swing control valve(MCV)
3 Time delay valve
4 Shuttle valve P3
5 Spool
8 Spring
702 Brake piston 2 2
712 Brake spring 4

30572SM04

2-57-9
 b. When the swing control lever(1) is set the neutral position, the time delay valve(3) shifts the
neutral position and the pilot oil blocked chamber G.
Then, the piston(702) is moved lower by spring(712) force and the return oil from the chamber
G is drain.

712
G SH
702

1 Swing control lever

2 Swing control valve(MCV)
3 Time delay valve
4 Shuttle valve P3
702 Brake piston
712 Brake spring
2 2
4

30572SM05

2-57-10
GROUP 4 TRAVEL DEVICE(up to #1214)

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

MB MA

VA
D Parking brake VB
releasing hole(PF1/4)

FILLING PLUG
OIL LEVEL

DRAIN
PLUG

VIEW A

29072TM01

Port Port name Port size

VA, VB Valve port PF 1
D P P Pilot port PF 1/4
REG
D Drain port PF 1/2
MA MB MA, MB Gauge port PF 1/4

VA VB

2-58
 2. SPECIFICATIONS
1) TRAVEL MOTOR

38
30 20 23 21 13 7 5 15 6 16 39 36 24 29 41 36 40 32
25
37
35
27
17
34

18 10

9 42

33

19 26 1 12 11 22 4 28 14 3 8 2 31 43,44

1 Casing 16 D-ring(Big) 31 Bearing

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

2-59
2) REDUCTION GEAR

24 17 16 14 13 12 15 21 22 19 18 25 23 20

4
5
1
7
3
10
8
6
9

11

26

1 Cover 10 Sun gear 2 19 Angular bearing

2 Carrier 1 11 Carrier 2 20 Shim
3 Carrier pin 1 12 Carrier pin 2 21 Lock washer
4 Needle bearing 13 Needle bearing 22 Support ring
5 Thrust washer 1 14 Planetary gear 2 23 Floating seal
6 Planetary gear 1 15 Spring pin 24 Hexagon socket bolt
7 Spring pin 16 Thrust washer 2 25 Hexagon socket bolt
8 Thrust plate 17 Ring gear 26 Socket head taper plug
9 Sun gear 1 18 Housing

2-60
3) BRAKE VALVE

VB VA

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

15,18

1 Body
2 Spool assembly
3 Spring follower
4 Spring
5 O-ring
6 O-ring
VB VA
7 Cover
8 Restrictor
14 9 Spring
10 Plug
11 O-ring
12 Hexagon socket head bolt
13 O-ring
14 Hexagon socket head bolt
15 Plug
16 O-ring
16 17 13 17 O-ring
18 O-ring

T
P

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

2-62
2) FUNCTION

Direction of shaft rotation

Direction of rotation
Inlet port Outlet port (Viewing from valve side)

VB VA Right(Clock wise)
VA VB Left(Counterclockwise)
VB VA
Port Port

Main port

(1) Motor
High pressure oil delivered from hydraulic pump is led to inlet port that is provided in the brake
valve(42) and, through the rear cover(2) and valve plate(8), led to cylinder block(3). The oil flow
and direction of shaft rotation are indicated in table.

Y
F31 P F1
F31
r1 F2
F32 P
F32
r2
F33 P
r3 F33
P
F34 F34
r4
Y
Figure 5(a) Figure 5(b)

As shown in figure 5(a), high pressure oil is supplied to the pistons which are on one side of the
line Y-Y that connects upper and lower dead points and produces force F1.
F1 = P × A
(P : Pressure, A : Area of piston section)
The swash plate(11) with inclined angle of αdivides this force F1 into thrust force F2 and radial
force F31-F34(or F35)(Figure 5(b)). This radial force is applied to axis Y-Y as turning force and
generate drive torque of T
T = r1・F31 + r2・F32 + r3・F33 + r4・F34
(In case high pressure oil is applied to five pieces of pistons, r5・F35 should be added.)
This drive torque is transmitted via cylinder block(3) to driving shaft(9).

2-63
(2) Negative brake
Negative brake is released when high pressure oil, selected by the brake valve(42) that is
connected directly to the rear cover(2), is applied to the brake piston(6).
Otherwise the braking torque is always applied.
This braking torque is generated by the friction between the separator plates(7), inserted into the
casing(1) and friction plates(5), coupled to cylinder block(3) by the outer splines.
When no pressure is activated on the brake piston(6), it is pushed by the brake spring(29) and it
pushes friction plates(5) and separator plates(7) towards casing(1) and generates the friction force
which brakes the rotation of cylinder block(3) and hence the shaft(9).

7 5 6 29

9 1 3 2 42

2-64
(3) Capacity control mechanism
When high speed pilot line is charged with the pressure PA that overcome the spring(41-7), the
spring(41-7) is compressed and spool(41-2) shifts to the right to connect the port P and port C.
Then, the highest pressure is selected by the check valve(17) from inlet and outlet pressure of the
motor and high speed pilot line pressure and pushes inclined piston(20). As a result, swash plate
(11) turns around the line L which connect the two pivots(12) as shown by dotted lines. The turn
stops at the stopper(1-1) of casing and swash plate(11) keeps the position.
In this case, the piston stroke become shorter and motor capacity become smaller and motor
rotates faster, around 1.5 times, by the same volume of oil.
When no pressure is in the high speed pilot line PA, spool(41-2) is pushed back by the spring(41-7)
and pressure that pressed the inclined piston(20) is released to the hydraulic tank. Here, nine
pistons are there and they equally spaced on the swash plate(11). The force that summed up
those of pistons comes to almost the center of the swash plate(11) as shown. Since the pivots(12)
are off set by S from the center, the rotating force of product S and the force moves swash
plate(11) to the former position and the speed returns to low.
When the power demand exceeds the engine power, such as in steep slope climbing or turning at
high speed, the system step down to the low speed automatically. The mechanism is that : pump
pressure is led to the port PB and this pressure activate on pin(41-6). When the pressure at PB
exceeds predetermined value, spool(41-2) returns to the left by the counter pressure against pin
(41-6) and the pressure on the piston(21) through port C is released to the tank and the motor
comes to low speed.
When PB goes down, the spool(41-2) moves to the right and the speed become high.

To control valve
A B
High speed pilot line

21 20 1-1 14 17 17 17

PA
L S

PB P C

12 12 11
41-2 41-6 41-7

2-65
(4) Overload relief valve
Tow pieces of overload relief valves are located at cross over position in the counterbalance circuit
of brake valve and have the following functions.
① When hydraulic motor starts, keep the driving pressure below predetermined value and while
accelerating, bypasses surplus oil to return line.
② When stopping the motor, keep the brake pressure, that develops on the outlet side of motor,
under the predetermined value to stop the inertial force.
③ To accelerate sharply while starting, and to mitigate the braking shock while stopping. For these
purposes, the developed pressure is kept comparatively low for a short period, then keep the line
pressure as normal value. While the pressure is low, meshing of reduction gears, crawler and
sprocket etc. can be smoothly done and the shock are absorbed.
When starting A port pressure of overload relief valve increases, this pressure is applied to the
effective diameter of valve(40-2) which seats on the valve seat(40-3) and at the same time, is
delivered, via small hole, to the connecting piston(40-4) located inside the valve(40-2) and the
piston bore pressure increases up to A port pressure. The valve(40-2) opposes to adjusting
spring(40-9) by the force of the pressure exerted on the area difference between valve seat's
effective diameter and piston bore and keep the predetermined pressure.
When hydraulically braking, the piston(40-7) is at the left position by the driving pressure, and
when A port pressure increases, the pressure is applied also to the piston(40-7) through the small
hole in the valve(40-2) and piston(40-7) moves rightward until it touches the cap(40-5). In this
while, the valve(40-2) maintains A port pressure at comparatively low against the adjusting
spring(40-9) force and exhaust oil to B port side. After the piston reached to the plug, the valve
acts the same as at starting.

Connecting piston Cap

(40-4) (40-5)
Port B
alve seat
40-2)

ort A

Small hole Valve Adjusting spring Piston

(40-2) (40-9) (40-7)

2-66
3) REDUCTION GEAR
(1) Planetary gear mechanism
Reduction unit slows down the rotating speed of motor and converts motor torque to strong
rotating force.
This reduction unit utilizes two stages, planetary reduction system.
Planetary reduction system consists of sun gear, planetary gears, carriers and ring gear.
When the sun gear(s) is driven through input shaft, planetary pinions(b), rotating on their center,
also move, meshing with fixed ring gear(a), around sun gears(s).
This movement is transferred to carrier(k) and deliver the torque.
This mechanism is called planetary gear mechanism.

Fixed ring gear(a)

Ring gear(a)
Carrier(k)
Planetary pinions(b) Carrier(k)
Sun gear(s)

Input Output
Sun gear(s)
Planetary pinions(b)

(2) Two stages reduction gear

When the sun gear S1 is driven by input shaft, planetary action occurs among gears S1, a and b
and revolution of gear b transfers the rotation of carrier K1 to second sun gear S2, and also
evokes planetary action between gear S2, a and d.
This time, because carrier K2 is fixed to frame, gear d drives ring gear a and then ring gear a
rotates to drive sprocket.

b d

S1 S2

K1 K2

2-67
4) BRAKE VALVE
(1) Function
① Spool
By shifting the spool, the discharged oil from hydraulic motor is automatically shut off or restricted
according to the condition and give the effect of holding, accelerating, stopping and
counterbalance operations.
② Check valve(Built in the spool)
This valve is located in the oil supplying passage to hydraulic motor, and at the same time
functions to lock oil displacement. Therefore, this valve serves as not only a suction valve but
also a holding valve for hydraulic motor.
③ Relief valve(Built in hydraulic motor)
When the oil is pressurized either in oil supply or oil discharge passage of hydraulic motor, to the
set value, the pressurized oil is relieved to the passage of lower pressure side. Thus this relief
valve fulfills the function of a safety valve for the circuit.

2-68
(2) Operation
Figures in this chapter show the oil flow and the movement of component parts in each position.
The figures are deformed for ease of understanding and the correct formation should be
ascertained by page 2-65.
① Holding position
When the control valve is at neutral position, VA and VB ports are connected to the tank, and the
spring 4 located on both spool ends holds the spool 2 at central position.
Therefore, the passages from VA to MA and VB to MB are closed, which result in closing MA and
MB port connected to hydraulic motor.
Since the passage to parking brake is connected to the tank line, the brake cylinder pressure is
equal to the tank pressure and the brake is applied by the springs. Thus, the rotation of the
motor is mechanically prevented.
If external torque is exerted on the motor shaft, the motor would not rotate as usual by this
negative parking brake.
In case the brake should be released for some reason, pressure is built on MA or MB port. But,
due to oil leakage inside hydraulic motor or so, high pressure oil escapes form the closed circuit
and motor rotates a bit. So, the cavitation tends to occur in the lower pressure side of the closed
circuit. Then, the check valve, built in the spool, operates to avoid the cavitation and opens the
passage from VA to MA or from VB to MB. Then the oil equivalent to the leakage is sucked from
the tank line to the closed circuit.

VB VA

VB VA
MB MA
T P
MB T MA

2-69
② Accelerating operation
When VA and VB ports are connected respectively to pump and tank by operating the control
valve, hydraulic oil from pump is forwarded through VA port to push open the check valve
provided inside spool, and oil flows to motor via MA port to rotate the motor.
Therefore, the pressure increases and negative brake is released by the pressure supplied from
pump. At the same time, the pressure of pilot chamber increases to push and move the spool
leftwards, overcoming the spring force. Thus, the return line from MB to VB opens to rotate the
motor.
In case inertia load is too big to start rotation, accelerating pressure reaches the set pressure of
relief valve and high pressure oil is being relieved while the motor gains the rotational speed.
As the rotational speed goes up, the relieved volume decreases, and finally the motor rotates at a
fixed speed.

VB VA

VB VA
MB MA
T P
MB T MA

2-70
③ Stopping operation
Returning the control valve to neutral position while running the motor, the oil supply is cut off and
VA and VB ports are connected to the tank line. Then the pressure of the pilot chamber located
on both spool ends become equal, and the spool returns to the neutral position by spring force.
Thus, the passage from MA to VA is closed.
Owing to the inertia force of the load, the hydraulic motor tends to continue the rotation. Here,
the motor functions as a pump and forwards the oil to MB port but the passage is blocked and
MB port pressure increases. Then the relief valve opens to relieve the pressure and rotational
speed decelerates and at last the motor stops. Negative brake release pressure is gradually
lowered due to the restrictor and finally the brake works and the motor is mechanically stopped.

VB VA

VB VA
MB MA
T P
MB T MA

2-71
Κ Counterbalance operation
Counterbalance operation is required to decelerate slowly the hydraulic motor while absorbing
inertia force.
In case the hydraulic oil is gradually decreased from pump to VB port, the drive shaft of hydraulic
motor tends to rotate faster than that matched to the volume of oil supply.
Consequently, the pilot chamber pressure on MB to VB side decreases and the spring force
moves the spool leftwards towards neutral position. Therefore, the area of passage from MA to
VA becomes smaller and the pressure on MA side rises due to increased resistance in the
passage and the motor receives hydraulic braking effect.
If the motor rotates slower than that matched to the volume of supplied oil, the pilot chamber
pressure on VB port increases, and spool moves rightwards to enlarge the area of passage from
MA to VA.
Therefore the braking effect becomes smaller and the rotational speed of motor is controlled to
correspond to the volume of supplied oil.
In order to give stable counterbalance operation, the restrictors are set in the pilot chamber to
damp the spool movement.
The negative brake is released during pressure adjusting action of the spool.

VB VA

MB MA VB VA
T P

MB T MA

29072TM17

2-72
 GROUP 4 TRAVEL DEVICE(#1215 and up)

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

A B
A,B
N
Am Bm

A Dr
Dr

Dr
Pi

Pi

Dr Dr

FILL

Pi
Pi
HEAVY INDUSTRIES CO.,LTD.

P A R T NO. : 31N8-40070

SERIAL NO. : SBTR-

LEVEL

N
IC
SB

DRAIN

Am Bm
VIEW A 300072TM01A

Port Port name Port size

AB
A, B Valve port PF 1
CIRCUIT DIAGRAM
Pi Pilot port PF 1/4
Dr Drain port PF 1/2
Am, Bm Gage port PF 1/4
N Parking release port PF 1/4

2-72-1
2. SPECIFICATION
1) TRAVEL MOTOR

89-5 89-4 89-3 89-2 89-6 88-6 88-4 88-2 93 88-3 88-5 86 85 87 83 13 14 15 16 25 24 6 28 30 31 4 40 39 43 38 37 71 42 41 47 50
89-6 29
90-2 35
90-3 32
90-4 33
97 A 27
92 21
90-5 49
101
98 75,76
102 48
100 36
11 46
103
73 34
74 44
12
45
91
96
56
89-8 67
89-7
62
104

90-1 A
99
88-8
63
89-1
65
88-7 105 95 94 88-1 5 72 9 8 7 10 84 23 22 82 17 18 19 1 20 26 3 69 2 68 61 64 60 66 57 58,59 70 55 54 53 52 51

SECTION A-A

2907A2TM01

1 Casing 16 Plate 31 Ring 46 Back up ring 61 O-ring 83 Housing 89-1 Carrier No.2 92 Plug
2 Plug 17 Piston 32 Spring 47 Cap 62 Lock screw 84 Bearing 89-2 Planetary gear No.2 93 Lock pin
3 Screw 18 Stopper 33 Valve casing 48 Cap 63 Nut 85 Shim 89-3 Needle No.2 94 Ring gear
4 Screw 19 O-ring 34 Needle bearing 49 Bolt 64 Spool 86 Retainer 89-4 Thrust washer No.2 95 Bolt
5 Pin 20 Back up ring 35 O-ring 50 Socket bolt 65 Plug 87 Bolt 89-5 Pin No.2 96 Thrust ring No.1
6 Pin 21 Cylinder block 36 Pin 51 Seat 66 O-ring 88 Carrier No.3 89-6 Spring pin No.2 97 Cover
7 Stopper 22 Cylinder spring 37 Spool 52 Steel ball 67 Valve plate 88-1 Carrier No.3 89-7 Sun gear No.2 98 Thrust ring No.2
8 O-ring 23 Spacer 38 Screw 53 Stopper 68 Spring 88-2 Planetary gear No.3 89-8 Snap ring No.2 99 Bolt
9 Back up ring 24 Guide 39 Damping check 54 Plug 69 O-ring 88-3 Needle No.3 90 Carrier No.1 100 Motor ring
10 Piston 25 Plate 40 Spring 55 O-ring 70 Socket bolt 88-4 Thrust washer No.3 90-1 Carrier No.1 101 Thrust ring No.3
11 Shaft 26 Piston & Shoe assy 41 O-ring 56 Plug 71 Socket bolt 88-5 Pin No.3 90-2 Planetary gear No.1 102 Thrust ring No.1
12 Spacer 27 Plate 42 Plunger 57 Relief valve 72 Lock screw 88-6 Spring pin No.3 90-3 Needle bearing No.1 103 Pad
13 Roller bearing 28 Plate 43 Spring 58 O-ring 73 Oil seal 88-7 Sun gear No.3 90-4 Thrust washer No.1 104 Thrust ring No.2
14 Stop ring 29 Brake 44 Stopper 59 Back up ring 74 Lock ring 88-8 Snap ring No.3 90-5 Pin No.1 105 Coupling
15 Support 30 Ring 45 O-ring 60 Rod 82 Floating Seal 89 Carrier No.2 91 Sun gear No.1

2-72-2
3. PRINCIPLE OF DRIVING
1) WORKING OF ROTARY GROUP
The high pressurized hydraulic oil which is supplied from a hydraulic pump is flows into a
cylinder(21) through the valve casing(33) of motor, and valve plate(67).
The rotary group has a construction that the above high pressurized hydraulic oil is flow only one
side of the line Y-Y which connect the upper and lower dead point of the piston(26).
This high pressurized hydraulic oil works on the piston and generating the force F1, F1 = P * A(P :
supplied pressure, A : pressure receving area), like following pictures.
This force, F1, is devided by the swash plate(16) having a tilting angle ɷinto the thrust component
N1 and radial component W1.
The W1 generates torque, T = W1 * R1, in respect to the line Y-Y.
This torque generated by each piston on the high pressurized hydraulic oil side is summed up onto
a resultant torqueĮ(W1 * R1), which prodeces torque for rotation.
This torque transfers the rotation force to the cylinder(21) through the pistons.
Since the cylinder block is spline-coupled with the shaft, the rotation force is transmitted to the shaft
accordingly.

W1 Piston
Cylinder

R1
N1
O A
f1 F1 P

W1

High Y Low
pressure pressure

2907A2TM07

2-72-3
2) WORKING OF RELIEF VALVE
Relief valve carries on two function of following.
(1) Relief valve is to keep the starting pressure of the hydraulic motor at a constant value and bypass
to the return line excessive oil generated at the motor inlet depending upon the acceleration speed
of the inertia object.
(2) In case of an inertia object stopped, relief valve is generating a break pressure at the outlet and
stop it forcedly.
The chamber A is always connect with port A of a motor. When the pressure at port A increase
and the force pushing poppet A is higher than the pressure of the spring, then poppet A is pushed
up from the contact surface of seat A, and oil flows from chamber A to port B.

Port A Port B

Chamber A

Poppet A

2907A2TM04

2-72-4
3) WORKING OF NEGATIVE BRAKE
The negative brake is released applying to the brake piston(29) the pressure led through built in the
valve casing(33) spool. With no pressure working, the brake force is always ensured.
The brake force is generated by the frictional force among a plate(28) fixed by pin(6) and shaft
casing, brake piston(29) and a frictional plate(27) connected through spline outside the cylinder
block(21).
Without pressure being applied to the brake piston, the brake piston is pushed by ten brake
springs(32) and the friction plate and separator plate are held between the brake piston and casing.
This friction force restrains the shaft(11) spline-coupled with the cylinder block, and thus functions
the brake.

11 6 28 27 29 32 21 33

300075TM05

2-72-5
4) COUNTERBALANCE VALVE
Av port is connected to a hydraulic pump : Bv port is connected to a tank.
The oil supplied from the hydraulic pump passed through Av Ą Cv Ą C sequence, pushed up the
poppet of the check valve, passed through L to port AM, and is supplied to the hydraulic motor to
turn it. But the brake is operated. Therefore, the pump discharge oil pressure is increases. And the
pressure is led via passage G to spring room M. When the pressure in room M exceed the value
equivalent to the force of the spring which holds the spool at its neutral position, the spool begins to
move right.
The oil in room N is sent to room Dv by orifice I and discharged from Bv port to a tank. So spool
moves to the right. The oil flows as the way of K Ą Dv Ą Bv sequence. Also according to the oil
path as composed way Cv Ą H Ą P sequence, the pressure of Av pump is provided to the port P.
An working oil in room N is discharged through orifice and a gap. Therefore the switching operation
of spool is driving slowly.
When the pump discharge pressure fall, spool moves to the left side by a spring at the side of room N.
Also spool moves to the left, the hydraulic oil in room M is sent to Cv room through orifice I' and
discharged to the Av port.
When the pressure at port Av fall down to the tank pressure, the pressure of room M is as the same
as that the tank pressure and becomes equal to that in room N, and so the spool returns to its
neutral position.

AM P BM

L K
Check valve

H
M I' I N
G

Cv Dv

Av Bv

300072TM06

2-72-6
5) WORKING OF DISPLACEMENT CHANGEOVER
The capacity of the travel motor is changed by changing the tilting angle of this swash plate(16).
The tilting angle changes by displacement changeover valve.
(1) External pilot pressure : Pi = 0(Large displacement)
By means of the built-in high pressure selector mechanism in the valve casing(33), the high
pressure oil working on the motor function to port P of the displacement-changeover valve.
A the spool(64) assembled in the displacement changeover valve is pressed to plug(65) by the
spring(68), the high pressure oil at port P flows to port Sb.
This high pressure oil flows through oil passage(passage A') of valve casing(33) and shaft casing
works to chamber A.
This oil in chamber B flows through passage B' and port Sa into the drain line. The displacement
changeover piston(17) is pushed right and the swash plate(16) moves in the arrowed direction
around rotation center 'O'. The swash plate moves until it touched stopper(18), and then is fixed
there.

External pilot
pressure
Chamber A Chamber B Pi = 0

B'

Drain Sa Sb
A'
P
65

7 10 16 17 18 68 64
High pressure oil

Selector valve

2907A2TM05

2-72-7
(2) External pilot pressure : Pi á 20kgf/cm2(small displacement)
If the force operating on spool(64) of the displacement changeover valve is stronger than the
spring(68), and the spool moves to the left side.
The high pressure oil is works on room B through passage Sa Ą B' from port P.
The oil in chamber A flows into the drain line through the passage A' Ą Sb.
The displacement changeover piston(17) is pushed left and the swash plate(16) moves in the
arrowed direction around rotation center 'O'. The swash plate moves until it touches stopper(7),
and then is fixed there.
If the load increase while the motor is working with its small displacement(Pi á 20kgf/cm2, 2nd
speed) until the motor inlet port pressure reaches the preset value, the motor increase its
displacement in response to the load, while maintaining the pressure at the preset
value(automatic 2 -speed function). As motor inlet port pressure reaches the preset value and
then spool(64) moves right side, inlet pressure oil flows into chamber A through port Sb and the
swash plate moves until it touches stopper(17). If the load further increase until the displacement
of the motor reaches the maximum value, the inlet port pressure increase further.
If the load decreases under this condition, the motor continues reducing its displacement in the
reverse sequence. As the load and inlet port pressure decreases and reaches the preset value,
spool(64) moves left side by the pilot pressure(Pi). Therefore inlet port pressure flow into chamber
B through port Sa and the swash plate moves until it touches stopper(10).

External pilot
pressure
2
Chamber A Chamber B Pi 20kgf/cm

B'

Drain Sa Sb
A'
P
65

7 10 16 17 18 68 64
High pressure oil

Selector valve

2907A2TM06

2-72-8
 6) REDUCTION GEAR
(1) Planetary gear mechanism
Reduction unit slows down the rotating speed of motor and converts motor torque to strong
rotating force.
This reduction unit utilizes two stages, planetary reduction system.
Planetary reduction system consists of sun gear, planetary gears, carriers and ring gear.
When the sun gear(s) is driven through input shaft, planetary pinions(b), rotating on their center,
also move, meshing with fixed ring gear(a), around sun gears(s).
This movement is transferred to carrier(k) and deliver the torque.
This mechanism is called planetary gear mechanism.

Fixed ring gear(a) Ring gear(a)

Carrier(k)
Planetary pinions(b) Carrier(k)
Sun gear(s)

Input Output
Sun gear(s)
Planetary pinions(b)

29072TM10 29072TM11

(2) Two stages reduction gear

When the sun gear S1 is driven by input shaft, planetary action occurs among gears S1, a and b
and revolution of gear b transfers the rotation of carrier K1 to second sun gear S2, and also
evokes planetary action between gear S2, a and d.
This time, because carrier K2 is fixed to frame, gear d drives ring gear a and then ring gear a
rotates to drive sprocket.

b d

S1 S2

K1 K2

29072TM12

2-72-9
GROUP 5 RCV LEVER

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

23.3

19
25
Single
operation Simultaneous
operation

Handle bending direction

(No. push rod direction)

4
P
1
T 3
2
30

30

VIEW A

Port LH RH Port size

P Pilot oil inlet port Pilot oil inlet port
T Pilot oil return port Pilot oil return port
1 Left swing port Bucket out port
PF 1/4
T 2 Arm in port Boom down port
P 3 Right swing port Bucket in port
4 Arm out port Boom up port
1 32 4
Hydraulic circuit

2-73
CROSS SECTION
The construction of the pilot valve is shown in the attached cross section drawing. The casing has
vertical holes in which reducing valves are assembled.
The pressure reducing section is composed of the spool(5), spring(7) for setting secondary pressure,
return spring(10), stopper(9), spring seat(8) and shim(6). The spring for setting the secondary
pressure has been generally so preset that the secondary pressure is 5 to 20.5kgf/cm2(Depending on
the type). The spool is pushed against the push rod(14) by the return spring.
When the push rod is pushed down by tilting the handle, the spring seat comes down simultaneously
and changes setting of the secondary pressure spring.

1 Case 11 Plug 21 O-ring

2 Plug 12 Rod seal 22 Handle connector
3 Plug 13 O-ring 23 Nut
4 O-ring 14 Push rod 24 Insert
5 Spool 15 Plate 25 Boot
6 Shim 16 Bushing 26 Handle
7 Spring 17 Joint assembly 27 Switch assembly
8 Spring seat 18 Swash plate 28 Screw
9 Stopper 19 Adjusting nut 29 Switch assembly
10 Spring 20 Lock nut 30 Switch cover

2-74
CROSS SECTION

26
27
29

30
28
22

24

25
23

20
17

19
18

14

15
12
11
16
9
13

8
6
7
10
21
5
1
3
2
4
Port 1, 3 Port 2, 4

2-75
2. FUNCTIONS
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure(Secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port(P) where oil is supplied from hydraulic pump.
(2) Output ports(1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port(T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port or tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool(5) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output port pressure oil to tank port T.
The spring(7) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod(14) is inserted and can slide in the plug(11).
For the purpose of changing the displacement of the push rod through the switch plate(19) and
adjusting nut(20) are provided the handle(27) that can be tilted in any direction around the fulcrum
of the universal joint(18) center.
The spring(10) works on the case(1) and spring seat(8) and tries to return the push rod(14) to the
zero-displacement position irrespective of the output pressure, securing its resetting to the center
position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.

2-76
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown
below and the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.

5 6

3
1
3
P T

2 4

1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder

2-77
(1) Case where handle is in neutral position

7
10
P 5

1 3

The force of the spring(7) that determines the output pressure of the pilot valve is not applied to
the spool(5). Therefore, the spool is pushed up by the spring(10) to the position of port(1, 3) in the
operation explanation drawing. Then, since the output port is connected to tank port T only, the
output port pressure becomes equal to tank pressure.

2-78
(2) Case where handle is tilted

14

1 3

When the push rod(14) is stroked, the spool(5) moves downwards.

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

2-79
GROUP 6 RCV PEDAL

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

° 12.4
12.4 °

1 2

3 4
Port Port Port size

P Pilot oil inlet port

T Pilot oil return port
1 Travel(LH, Forward)
PF 1/4
2 Travel(LH, Backward)
T
P 3 Travel(RH, Forward)
4 Travel(RH, Backward)
1 23 4
Hydraulic circuit

2-80
CROSS SECTION
The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in
which reducing valves are assembled.
The pressure reducing section is composed of the spool(8), spring(11) for setting secondary pressure,
return spring(18), stopper(13), spring seat(12) and shim(9). 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(19) 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.

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

1 Casing 11 Spring 21 Set screw

2 Pedal 12 Spring seat 22 Nut
3 Pedal cover 13 Stopper 23 Cam shaft
4 Cover 14 Plug 24 Set screw
5 Bushing 15 O-ring 25 Hexagon socket bolt
6 Cam 16 Dust seal 26 Plug
7 Bellows 17 Rod seal 27 Spacer
8 Spool 18 Spring 28 O-ring
9 Shim 19 Push rod 29 Hexagon socket bolt
10 Spring seat 20 Hexagon socket bolt 30 Plug

2-81
2. FUNCTION
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure(Secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port(P) where oil is supplied from hydraulic pump.
(2) Output port(1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port(T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool(8) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output spool to determine the output pressure.
The spring(11) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod(19) is inserted and can slide in the plug(14).
For the purpose of changing th displacement of the push rod through the cam(6) and adjusting
nut(22) are provided the pedal(2) that can be tilted in any direction around the fulcrum of the cam(6)
center.
The spring(18) works on the casing(1) and spring seat(12) and tries to return the push rod(19) to
the zero-displacement position irrespective of the output pressure, securing its resetting to the
center position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.

2-82
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown
below ant the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.

5 6

3
1
2

2 4

1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder

2-83
(1) Case where pedal is in neutral position

11

8
T
18

1 2

The force of the spring(11) 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(18) to the position of port 2 in the
operation explanation drawing. Then, since the output port is connected to tank port T only, the
output port pressure becomes equal to tank pressure.

2-84
(2) Case where pedal is tilted

19

1 2

When the push rod(19) is stroked, the spool(8) moves downwards.

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

2-85
 SECTION 3 HYDRAULIC SYSTEM

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

Group 2 Main Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2
Group 3 Pilot Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5
Group 4 Single Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-13
Group 5 Combined Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-23
 SECTION 3 HYDRAULIC SYSTEM
GROUP 1 HYDRAULIC CIRCUIT(-#1176)

10 11 8 9
4

P P

REG REG

(XBp2) PBP
1 Main pump
MA MB MB MA
Ck1

PaL dr6 Fl
XBp1
Fr dr7
2 2 Main control valve
3 Swing motor
XAa2 4 Travel motor
XAa1
dr5
5 RCV lever(LH)
Aa1
VA VB VB VA
Ba1 XBa2
6 RCV lever(RH)
XBa1 XAa2
7 RCV pedal
XBa2
8 Boom cylinder(LH)
12 XAk
Ak1
9 Boom cylinder(RH)
Bk1
XAb2 XBk 10 Arm cylinder
XBp1 Ck2
Pk
dr4
dr8 11 Bucket cylinder
XBs PbL
As Pns XAb1 12 Turning joint
XAb2 Ab1
Bs
3 XAs Bb1
13 Check valve
SH XBs
dr3
XBb1
14 Check valve
XBtl
Atl
Ao 15 Hydraulic tank
PG 25 Btl Bo
XAo

dr2
XAs
XAtl XBo 16 Oil cooler
XAtr
17 Air breather
Mu Atr

Btr 18 Bypass valve

PA PB XBtr
19 Strainer
R1 20 Spin filter
P2 R2 21 Line filter
24 PH

Px 22 Solenoid valve
A B 23 Accumulator
24 Pressure switch
SWING ARM 5 7 TRAVEL BUCKET BOOM 6 Pz P1 PG Py
24 25 Shuttle valve
26 Last guard filter
1 A1 A2

14 13
XAs XBs XBa1 XAa1 XBk XAk XAb1 XBb1
dr2~dr8 16
(1) (3) (2) (4) (3) (1) (2) (4)
XAtl XBtl XAtr XBtr
(1) (2) (3) (4)
17
23 26 15 Pm1 Pm2

20 Pi1 Pi2
Pns Pk Pm1 Pm2 Pz
22 dr1
(Fl) (Fr)

A5 A4 A3 A2 A1
18
M
P4 PG(S/Motor)
19 dr1
P3 PG(MCV) 21 A3
P2
P1

R29073HC01

3-1
 SECTION 3 HYDRAULIC SYSTEM
GROUP 1 HYDRAULIC CIRCUIT(#1177-)

T(dr5) E 10 11 8 9
3
SH
36 40
37 35 30 30
PG
37 Pn2 Pn1
V2 Pi1 E
B
DB
CK1 Rs
2 31
(dr4) C

Pi1
T(dr6)
V2
PA PB

C
38 B5 dr7

C5
A5 33 32
D5
Pc5
39 Pb5
Pd5
A(CW) B(CCW)
Pa5
CK2

4 C4

Dr Dr D4 B4
DR3 Pc4
1

Pb4
Pa4
Pd4
Pi
Pc42
1 Main pump 21 Line filter
Pc4
27
Pi Pi 2 Main control valve 22 Solenoid valve
Pb3
Pc3
N N DR2 Pd41
3 Swing motor 23 Accumulator
Pa21
4 Travel motor 24 Pressure switch
Am Bm Bm Am B2
V3
A2
5 RCV lever(LH) 25 Shuttle valve
C2
Pb21
D2
DR1
6 RCV lever(RH) 26 Last guard filter
B(BW) A(FW) B(FW) A(BW) Pb2
Pc2

A P B
Pd2
P02
Pa2 7 Rcv pedal 27 Rcv pedal
C Dr D

Pk Patt 8 Boom cylinder(LH) 28 Shockless valve

dr3 C1 B1
24
D1 A1
Pb1
9 Boom cylinder(RH) 29 Solenoid valve
Pc1
Pd1 Pa1
10 Arm cylinder 30 Safety valve
DR0
P01 11 Bucket cylinder 31 Safety valve
12 Turning joint 32 Press switch
Ptr
Pd5 Pc5

Pu
13 Check valve 33 Shut off valve
SWING ARM 5 BUCKET BOOM 6 7 TRAVEL
24 P1 P2 T1

14 Check valve 34 Pedal

15 Hydraulic tank 35 Accumulator
16 Oil cooler 36 Accumulator
Psv
(1) (3) (2) (4) (3) (1) (2) (4)
A1 a4 A2
17 Air breather 37 Stop valve
(2) (1) (4) (3)
28 13 1 18 Bypass valve 38 Port relief valve
Pa1 Pb1 Pd1 Pc1
14 a1 a2
19 Return element 39 Port relief valve
Pc2 Pd2 Pd4 Pc4 Pa5 Pb5 Pa2 Pb2 Dr#,dr#
16
20 Strainer 40 Selector valve
Pb4 Pk Pm1 & Pm2 Pu 23 17
22 (MCV) (T/Joint) (Pump) (MCV)
Pm1 Pm2

Pi1
P4
PG(S/Motor)
15 18 (Pn2,MCV)
Pi2
(Pn1,MCV)
P3 P01(MCV) 20
P2
M
T(dr2) P1

21 19 Dr
a3

B1 Dr3 B3 A3

29073HC30

3-1-1
GROUP 2 MAIN CIRCUIT

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

1. SUCTION AND DELIVERY CIRCUIT

To cylinders To motors

Main control valve To oil cooler

To hydraulic oil tank

Main pump
Suction filter

Hydraulic oil tank

The pumps receive oil from the hydraulic tank through a suction filter. The discharged oil from the
pump flows into the control valve and goes out the tank ports.
The oil discharged from the main pump flows to the actuators through the control valve.
The control valve controls the hydraulic functions.
The return oil from the actuators flows to the hydraulic tank through the control valve and the oil
cooler.

3-2
2. RETURN CIRCUIT

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

Main control valve Actuators

Check valve(1)
3.0kgf/cm 2

Check valve(3)
1.5kgf/cm 2

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

3-3
3. DRAIN CIRCUIT

Travel motor Swing motor

Turning Main pump

joint From return line

dr2 ~ dr8

Hydraulic Spin filter

oil tank
dr1

Check valve
1.5kgf/cm 2

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

1) TRAVEL MOTOR DRAIN CIRCUIT

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

3-4
GROUP 3 PILOT CIRCUIT

Remote control valve RCV pedal Remote control valve

(LH lever) (RH lever)

Swing parking brake

Control valve Safety lock
solenoid valve
Travel speed solenoid valve

Power boost solenoid valve

Main pump Max flow cut off solenoid valve

Line filter
Swing speed reducing valve
Relief valve
40kgf/cm 2

Pilot pump Suction filter

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 CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR

ARM1 ARM2

SWING MOTOR

BOOM2 BUCKET

SWING

BOOM1

OPTION
TRAVEL(LH)

TRAVEL(RH)

RCV PEDAL
RCV LEVER(LH) TRAVEL RCV LEVER(RH)

SWING ARM BUCKET BOOM

HYD
TANK

PILOT PUMP
SAFETY
SOLENOID VALVE

LINE
FILTER STRAINER
RELIEF VALVE

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 from remote control valve returned to hydraulic tank.

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

TRAVEL MOTOR

ARM1 ARM2

SWING MOTOR

BOOM2 BUCKET

SWING

BOOM1

OPTION
TRAVEL(LH)

TRAVEL(RH)

RCV PEDAL
RCV LEVER(LH) TRAVEL RCV LEVER(RH)

SWING ARM BUCKET BOOM

HYD
TANK

PILOT PUMP
LEVER DOWN SAFETY
LEVER UP SOLENOID VALVE

LINE
FILTER STRAINER
RELIEF VALVE

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

3-7
3. MAIN RELIEF PRESSURE CHANGE CIRCUIT
ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR

ARM1 ARM2

SWING MOTOR

BOOM2 BUCKET

SWING

BOOM1

OPTION
TRAVEL(LH)

TRAVEL(RH)

MAIN RELIEF VALVE

Pz
RCV PEDAL
RCV LEVER(LH) TRAVEL RCV LEVER(RH)

SWING ARM BUCKET BOOM

HYD
TANK

PILOT PUMP
POWER MAX SAFETY
SOLENOID VALVE Pz
SOLENOID VALVE

LINE
FILTER STRAINER
RELIEF VALVE

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

3-8
4. SWING PARKING BRAKE RELEASE

ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR

ARM1 ARM2
SWING MOTOR DEVICE
SH

PG
BOOM2 BUCKET

Mu

SWING

BOOM1

OPTION
A B TRAVEL(LH)

TRAVEL(RH)

RCV PEDAL
RCV LEVER(LH) TRAVEL RCV LEVER(RH)

SWING ARM BUCKET BOOM

HYD
TANK

PILOT PUMP

SH
SAFETY
SHUTTLE VALVE SOLENOID VALVE

PG LINE
FILTER STRAINER
RELIEF VALVE

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

3-9
5. TRAVEL SPEED CONTROL PRESSURE

ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR DEVICE

Lo Hi Hi Lo
REG REG

TRAVEL SPEED
CHANGE OVER
VALVE

ARM1 ARM2

SWING MOTOR
BOOM2 BUCKET

SWING

BOOM1

OPTION
TRAVEL(LH)

TRAVEL(RH)

RCV PEDAL
RCV LEVER(LH) TRAVEL RCV LEVER(RH)

SWING ARM BUCKET BOOM

HYD
TANK

PILOT PUMP
TRAVEL SPEED SAFETY
SOLENOID VALVE Pk
SOLENOID VALVE

PG LINE
FILTER STRAINER
RELIEF VALVE

When the travel speed solenoid valve was placed in the Hi position, the pressure oil from pilot pump
through line filter flows to port(Pk) of travel speed change over valve, and the control piston is pushed
up, thus minimizing the displacement.
When the travel speed solenoid valve was placed in the Lo position, the oil of Pk port return to the
tank and the control piston is returned, thus maximizing the displacement.

3 - 10
6. MAX FLOW CUT OFF SYSTEM

ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR

ARM1 ARM2

SWING MOTOR

BOOM2 BUCKET

SWING

BOOM1

OPTION
TRAVEL(LH)

TRAVEL(RH)

RCV PEDAL
RCV LEVER(LH) TRAVEL RCV LEVER(RH)
SWING ARM BUCKET BOOM

Pm1 Pm2

MAX FLOW CUT OFF SAFETY

SOLENOID VALVE Pm1 Pm2 SOLENOID VALVE M
HYD
TANK
LINE
FILTER

When the breaker operation mode is selected on the cluster, max flow cut off solenoid valve actuates
automatically. Thus pilot pressure(Pm1,Pm2) is sent to the regulator and pump discharge volume is
decreased.

3 - 11
7. BOOM PRIORITY SYSTEM
ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR

ARM1 ARM2

SWING MOTOR

BOOM2 BUCKET

Pns
SWING
SELECT
SPOOL
SWING
BOOM1

OPTION
TRAVEL(LH)

TRAVEL(RH)

RCV PEDAL
RCV LEVER(LH) TRAVEL RCV LEVER(RH)

SWING ARM BUCKET BOOM

HYD
TANK

SWING REDUCING PILOT PUMP

SOLENOID VALVE
SAFETY
Pns SOLENOID VALVE

LINE
FILTER STRAINER
RELIEF VALVE

When carrying out the combined operation of swing and boom or arm of the left control valve, the
boom or arm speed can be lowered than operating speed of swing. When the heary duty working
mode in work mode is selected on the cluster, swing reducing solenoid valve actuates automatically.
The oil from pilot pump flows into the solenoid valve through the line filter.
Pns pressure from solenoid valve change the swing select spool and decreases the oil flow rate to
the swing section by orifice.
This is called the boom priority system.

3 - 12
GROUP 4 SINGLE OPERATION
1. BOOM UP OPERATION

ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR

BOOM HOLDING VALVE

SWING MOTOR

BOOM2
XAb2

PbL
XAb1
XAb2
Ab1

Bb1

XBb1
BOOM1
MAKE UP VALVE

RELIEF VALVE

P2 R2

P1

HYD
TANK FRONT REAR PILOT
PUMP PUMP PUMP

When the RH control lever is pulled back, the boom spools in the main control valve are moved to the
up position by the pilot oil pressure from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the large
chamber of boom cylinders.
At the same time, the oil from the small chamber of boom cylinders returns to the hydraulic oil tank
through the boom spool in the main control valve. When this happens, the boom goes up.
The excessive pressure in the boom cylinder bottom end circuit is prevented by relief valve.
When the boom is up and the control lever is returned to neutral position, the circuit for the holding
pressure at the bottom end of the boom cylinder is closed by the boom holding valve.
This prevents the hydraulic drift of boom cylinder.

3 - 13
2. BOOM DOWN OPERATION

ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR

BOOM HOLDING VALVE

SWING MOTOR

BOOM2
XAb2

PbL
XAb1
XAb2
Ab1

Bb1

XBb1
BOOM1

MAKE UP VALVE
RELIEF VALVE

P2 R2

P1

HYD
TANK FRONT REAR PILOT
PUMP PUMP PUMP

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

3 - 14
3. ARM ROLL IN OPERATION

ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR

ARM HOLDING VALVE

PaL

XAa2
XAa1

Aa1

Ba1 XBa2
ARM1
XAa2
XBa1 ARM2
XBa2
SWING MOTOR
MAKE UP
VALVE
RELIEF
VALVE

P2 R2

P1

HYD
TANK FRONT REAR PILOT
PUMP PUMP PUMP

When the LH control lever is pulled back, the arm spools in the main control valve are moved to the
roll in position by the pilot oil pressure from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the large
chamber of arm cylinder.
At the same time, the oil from the small chamber of arm cylinder returns to the hydraulic oil tank
through the arm spool in the main control valve. When this happens, the arm roll in.
When the roll in speed of arm is faster, the oil returned from the small chamber of arm cylinder
combines with the oil from both pump, and flows into the large chamber of the arm cylinder by a
make up valve.
The excessive pressure in the arm cylinder bottom end circuit is prevented by relief valve.

3 - 15
4. ARM ROLL OUT OPERATION

ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR

ARM HOLDING VALVE

PaL

XAa2
XAa1

Aa1

Ba1 XBa2
ARM1
XAa2
XBa1 ARM2
XBa2
SWING MOTOR

MAKE UP
VALVE
RELIEF
VALVE

P2 R2

P1

HYD
TANK FRONT REAR PILOT
PUMP PUMP PUMP

When the LH control lever is pushed forward, the arm spools in the main control valve are moved to
the roll out position by the pilot oil pressure from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the small
chamber of arm cylinder. At the same time, the oil from the large chamber of arm cylinder returns to
the hydraulic oil tank through the arm spool in the main control valve.
When this happens, the arm roll out. When the roll out speed of arm is faster, the oil returned from the
large chamber of arm cylinder combines with the oil from both pump, and flows into the small
chamber of the arm cylinder by a make up valve.
The excessive pressure in the arm cylinder rod end circuit is prevented by relief valve.
When the arm is rolled out and the control lever is returned to neutral position, the circuit for the
holding pressure at the rod end of the arm cylinder is closed by the arm holding valve.
This prevents the hydraulic drift of arm cylinder.

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

TRAVEL MOTOR

Ck1
XBp1

CENTER
BYPASS VALVE

XAk
SWING MOTOR Ak1

Bk1
XBk
BUCKET
XBp1 Ck2

MAKE UP
VALVE

RELIEF VALVE

P2 R2

P1

HYD
TANK FRONT REAR PILOT
PUMP PUMP PUMP

When the RH control lever is manually placed in the bucket roll in position. Then the oil flows from
pilot pump through the pilot valve to bucket section of the main control valve. Here the spool position
is moved to bucket roll in position.
The center bypass valve is change over by the pilot pressure(XBP1) and then the oil from front pump
is joint to the flow of rear pump via confluence passage.
The oil flows from both pump through rod end of the cylinder through the bucket section returned to
the hydraulic tank.
The cavitation which will happen to the bottom of the bucket cylinder is prevented by a make up
valve, on other hand. The excessive pressure is also prevented by an overload relief valve in the
main control valve.

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

TRAVEL MOTOR

Ck1
XBp1

CENTER
BYPASS VALVE

XAk
SWING MOTOR Ak1

Bk1
XBk
BUCKET
XBp1 Ck2

MAKE UP
VALVE

RELIEF VALVE

P2 R2

P1

HYD
TANK FRONT REAR PILOT
PUMP PUMP PUMP

When the RH control lever is manually placed in the bucket roll out position. Then the oil flows from
pilot pump through the pilot valve to bucket section of the main control valve. Here the spool position
is moved to bucket roll out position.
The oil flows from rear pump through bucket section of main control valve to the rod end of the
bucket cylinder, and to roll out bucket.
The return oil flows from the bottom end of the cylinder through the bucket section returned to the
hydraulic tank.
The cavitation which will happen to the rod of the bucket cylinder is prevented by a make up valve, on
other hand. The excessive pressure is also prevented by an overload relief valve in the main control
valve.

3 - 18
7. SWING OPERATION

ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR

SWING MOTOR

XBs
As Pns

Bs
XAs
SWING

P2 R2

P1
RCV PEDAL
RCV LEVER(LH) TRAVEL RCV LEVER(RH)

SWING ARM BUCKET BOOM

HYD
TANK

FRONT REAR PILOT

XAs XBs PUMP PUMP PUMP
SH
SAFETY
SOLENOID VALVE

PG LINE
FILTER STRAINER

When the LH control lever is manually placed in the left(Right) swing position. Then the oil flows from
front pump through the swing section of the main control valve to swing motor to left(Right) swing the
superstructure. The return oil flows from swing motor through the swing section of the main control
valve returned to the tank.
When the control lever placed in the neutral position, the pressure of the pilot oil passage down.
Then the brake release valve returned to the neutral position and the oil is returned from the brake
piston to the tank. And the brake is set to "ON". The swing parking brake, make up valve and the
overload relief valve are provide in the swing motors. The cavitation which will happen to the swing
motor is prevented by the make up valve in the swing motor itself.

3 - 19
SWING CIRCUIT OPERATION

PARKING BRAKE
SWING MOTOR DEVICE
BRAKE RELEASE VALVE
SH
BRAKE OFF

PG

BRAKE ON
dr2

MAKE UP
PORT(Mu)

MAKE UP VALVE

MOTOR BRAKE VALVE

BYPASS VALVE
A B

TO/FROM MAIN CONTROL VALVE

1) MOTOR BRAKE VALVE

Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing
operation.
2) MAKE UP VALVE
The make up valves prevent cavitation by supplying return oil to the vacuum side of the motor.
3) PARKING BRAKE
In case that the parking, of the machine at slope is required during operation, there is the danger of
involuntary swing caused by the self weight of the machine. The brake is connected to prevent this
involuntary swing.
PARKING BRAKE "OFF" OPERATION
The parking brake is released by the pilot pressure oil from the pilot pump.
When the left control lever placed in the swing position, the pilot pressure at the shuttle valve is
transferred to the brake release valve and the brake release valve is change over. Then the pilot
pressure lift the brake piston and release the parking brake.
PARKING BRAKE "ON" OPERATION
When the control lever placed in the neutral position, the pressure of the pilot oil passage down.
Then the brake release valve returned to the neutral position and the oil is returned from the brake
piston to the tank. And the brake is set to 'ON".
BYPASS VALVE
This bypass valve absorbs shocks produced as swing motion stops and reduced oscillation cause
by swing motion.

3 - 20
8. TRAVEL FORWARD AND REVERSE OPERATION

ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR

TURNING
JOINT

SWING MOTOR

XBtl
Atl

Btl
XAtl
TRAVEL(LH)
XAtr

TRAVEL(RH)
XBtr

P2 R2

P1
RCV PEDAL
RCV LEVER(LH) TRAVEL RCV LEVER(RH)

SWING ARM BUCKET BOOM

HYD
TANK
XAtl XBtl XAtr XBtr
FRONT REAR PILOT
PUMP PUMP PUMP
SAFETY
SOLENOID VALVE

PG LINE
FILTER STRAINER

When the right and left travel levers are manually placed to the forward or reverse position, the oil
flows from pilot pump through the pilot valve to travel sections of the main control valve.
Here, spool position is moved to forward and reverse position. The oil flows from rear pump through
the travel(RH) section of the main control valve and turning joint to the right travel motor and oil flows
from front pump through the travel(LH) section of the main control valve and turning joint to the left
travel motor and move the machine forward or reverse.
The return oil flows from both travel motor through the turning joint and travel(RH, LH) sections
returned to the tank.

3 - 21
TRAVEL CIRCUIT OPERATION

OVERLOAD
TRAVEL MOTOR DEVICE OVERLOAD
RELIEF VALVE RELIEF VALVE

P P

R/G R/G

MA MB MB MA

VA VB VB VA
Pk

COUNTER COUNTER
BALANCE VALVE BALANCE VALVE
TURNING
JOINT

TO/FROM MAIN CONTROL VALVE

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

1) COUNTER BALANCE VALVE

When stopping the motor of slope descending, this valve to prevent the motor over run.
2) OVERLOAD RELIEF VALVE
Relief valve limit the circuit pressure below 365kgf/cm2 to prevent high pressure generated at a time
of stopping the machine. Stopping the motor, this valve sucks the oil from lower pressure passage
for preventing the negative pressure and the cavitation of the motor.

3 - 22
GROUP 5 COMBINED OPERATION
1. OUTLINE
ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER
TRAVEL MOTOR

(XBp2) PBP
Ck1
XBp1
PaL dr6 Fl Fr dr7

XAa2
XAa1
dr5

Aa1

Ba1 XBa2

XBa1 XAa2
ARM1 ARM2
XBa2
XAk
Ak1
SWING MOTOR
Bk1
XAb2 XBk
BOOM2 BUCKET
XBp1 Ck2
dr4
dr8
XBs PbL
As Pns XAb1
XAb2
SWING Ab1
Bs
XAs Bb1

XBb1
BOOM1
dr3
XBtl
Atl

Btl
XAtl
OPTION
TRAVEL(LH)
XAtr
Atr

TRAVEL(RH) Btr

XBtr

R1

P2 R2
PH

Px

STRAIGHT
TRAVEL SPOOL dr2~dr8

Pz P1 PG Py

FRONT REAR PILOT

PUMP PUMP PUMP

HYD
TANK

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

STRAIGHT TRAVEL SPOOL

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

3 - 23
2. COMBINED SWING AND BOOM OPERATION
ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER
TRAVEL MOTOR

(XBp2) PBP
Ck1
XBp1
PaL dr6 Fl Fr dr7

XAa2
XAa1
dr5

Aa1

Ba1 XBa2

XBa1 XAa2
ARM1 ARM2
XBa2
XAk
Ak1
SWING MOTOR
Bk1
XAb2 XBk
BOOM2 BUCKET
XBp1 Ck2
dr4
dr8
XBs PbL
As Pns XAb1
XAb2
SWING Ab1
Bs
XAs Bb1

XBb1
BOOM1
dr3
XBtl
Atl

Btl
XAtl
OPTION
TRAVEL(LH)
XAtr
Atr

TRAVEL(RH) Btr

XBtr

R1

P2 R2
PH

Px

dr2~dr8

Pz P1 PG Py

FRONT REAR PILOT

PUMP PUMP PUMP

HYD
TANK

When the swing and boom functions are operated, simultaneously the swing spool and boom spools
changed. The oil flows from the rear pump through boom1 section of the main control valve to boom
cylinders and the boom functions.
The oil flows from front pump through swing section to swing motor.
At the same time, the pressure in the boom circuits can be high while the swing pressure is low,
therefore the oil flows from front pump to boom cylinders through boom2 section via confluence
passage in case boom raise operation.

3 - 24
3. COMBINED SWING AND ARM OPERATION

ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR

(XBp2) PBP
Ck1
XBp1
PaL dr6 Fl Fr dr7

XAa2
XAa1
dr5

Aa1

Ba1 XBa2

XBa1 XAa2
ARM1 ARM2
XBa2
XAk
Ak1
SWING MOTOR
Bk1
XAb2 XBk
BOOM2 BUCKET
XBp1 Ck2
dr4
dr8
XBs PbL
As Pns XAb1
XAb2
SWING Ab1
Bs
XAs Bb1

XBb1
BOOM1
dr3
XBtl
Atl

Btl
XAtl
OPTION
TRAVEL(LH)
XAtr
Atr

TRAVEL(RH) Btr

XBtr

R1

P2 R2
PH

Px

dr2~dr8

Pz P1 PG Py

FRONT REAR PILOT

PUMP PUMP PUMP

HYD
TANK

When the swing and arm functions are operated, simultaneously the swing spool and arm spools
changed. The oil flows from the front pump through arm1 and swing section of the main control valve
to arm cylinder and swing motor, and the arm and swing functions.
At the same time, the pressure in the arm circuit can be high while the swing pressure is low,
therefore the oil flows from rear pump to arm cylinder through arm2 section via confluence passage.

3 - 25
4. COMBINED SWING AND BUCKET OPERATION

ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR

(XBp2) PBP
Ck1
XBp1
PaL dr6 Fl Fr dr7

XAa2
XAa1
dr5

Aa1

Ba1 XBa2

XBa1 XAa2
ARM1 ARM2
XBa2
XAk
Ak1
SWING MOTOR
Bk1
XAb2 XBk
BOOM2 BUCKET
XBp1 Ck2
dr4
dr8
XBs PbL
As Pns XAb1
XAb2
SWING Ab1
Bs
XAs Bb1

XBb1
BOOM1
dr3
XBtl
Atl

Btl
XAtl
OPTION
TRAVEL(LH)
XAtr
Atr

TRAVEL(RH) Btr

XBtr

R1

P2 R2
PH

Px

dr2~dr8

Pz P1 PG Py

FRONT REAR PILOT

PUMP PUMP PUMP

HYD
TANK

When the swing and bucket functions are operated, the swing and bucket spools changed. The oil
flows from the rear pump through the bucket section of the main control valve to the bucket cylinder
and the bucket functions. The oil flows from front pump through swing section of the main control
valve to the swing motor and swing the superstructure.

3 - 26
5. COMBINED SWING, BOOM, ARM AND BUCKET OPERATION

ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR

(XBp2) PBP
Ck1
XBp1
PaL dr6 Fl Fr dr7

XAa2
XAa1
dr5

Aa1

Ba1 XBa2

XBa1 XAa2
ARM1 ARM2
XBa2
XAk
Ak1
SWING MOTOR
Bk1
BOOM2
XAb2 XBk
BUCKET
XBp1 Ck2
dr4
dr8
XBs PbL
As Pns XAb1
XAb2
SWING Ab1
Bs
XAs Bb1

XBb1
BOOM1
dr3
XBtl
Atl

Btl
XAtl
OPTION
TRAVEL(LH)
XAtr
Atr

TRAVEL(RH) Btr

XBtr

R1

P2 R2
PH

Px

dr2~dr8

Pz P1 PG Py

FRONT REAR PILOT

PUMP PUMP PUMP

HYD
TANK

When the swing, boom, arm and bucket functions are operated, the each spools of the main control
valve changed.
The oil flows from rear pump through arm2, boom1 and bucket section to boom, arm and bucket
cylinders. The oil flows from front pump through swing, boom2 and arm1 section to swing motor,
boom and arm cylinder. Then the functions to each actuators.
According to the state of each actuators functioning, the oil flows from front and rear pump through
the confluence oil passage to the each actuators.

3 - 27
6. COMBINED SWING AND TRAVEL OPERATION

ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR

(XBp2) PBP
Ck1
XBp1
PaL dr6 Fl Fr dr7

XAa2
XAa1
dr5

Aa1

Ba1 XBa2

XBa1 XAa2
ARM1 ARM2
XBa2
XAk
Ak1
SWING MOTOR
Bk1
XAb2 XBk
BOOM2 BUCKET
XBp1 Ck2
dr4
dr8
XBs PbL
As Pns XAb1
XAb2
SWING Ab1
Bs
XAs Bb1

XBb1
BOOM1
dr3
XBtl
Atl

Btl
XAtl
OPTION
TRAVEL(LH)
XAtr
Atr

TRAVEL(RH) Btr

XBtr

R1

P2 R2
PH

Px

STRAIGHT
TRAVEL SPOOL dr2~dr8

Pz P1 PG Py

FRONT REAR PILOT

PUMP PUMP PUMP

HYD
TANK

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

3 - 28
7. COMBINED BOOM AND TRAVEL OPERATION

ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR

(XBp2) PBP
Ck1
XBp1
PaL dr6 Fl Fr dr7

XAa2
XAa1
dr5

Aa1

Ba1 XBa2

XBa1 XAa2
ARM1 ARM2
XBa2
XAk
Ak1
SWING MOTOR
Bk1
XAb2 XBk
BOOM2 BUCKET
XBp1 Ck2
dr4
dr8
XBs PbL
As Pns XAb1
XAb2
SWING Ab1
Bs
XAs Bb1

XBb1
BOOM1
dr3
XBtl
Atl

Btl
XAtl
OPTION
TRAVEL(LH)
XAtr
Atr

TRAVEL(RH) Btr

XBtr

R1

P2 R2
PH

Px

STRAIGHT
TRAVEL SPOOL dr2~dr8

Pz P1 PG Py

ORIFICE FRONT REAR PILOT

PUMP PUMP PUMP

HYD
TANK

When the boom and travel functions are operated, simultaneously the boom spools and travel spools
in the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve. At the same time, the straight travel spool is pushed to the left by the pilot oil pressure
from the pilot pump. The oil from the front pump flows into the boom cylinders through the boom 2
spool and boom 1 spool via the parallel and confluence passage in case boom up operation. The oil
from the rear pump flows into the travel motors through the RH travel spool of the right control valve
and the LH travel spool of the left control valve via the straight travel spool.
When the travel circuit pressure drops lower than boom pressure, as when traveling downhill, boom
priority and smoothness are maintained because of the orifice in the straight travel spool. Thus the
machine will continue to travel straight.

3 - 29
8. COMBINED ARM AND TRAVEL OPERATION

ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR

(XBp2) PBP
Ck1
XBp1
PaL dr6 Fl Fr dr7

XAa2
XAa1
dr5

Aa1

Ba1 XBa2

XBa1 XAa2
ARM1 ARM2
XBa2
XAk
Ak1
SWING MOTOR
Bk1
XAb2 XBk
BOOM2 BUCKET
XBp1 Ck2
dr4
dr8
XBs PbL
As Pns XAb1
XAb2
SWING Ab1
Bs
XAs Bb1

XBb1
BOOM1
dr3
XBtl
Atl

Btl
XAtl
OPTION
TRAVEL(LH)
XAtr
Atr

TRAVEL(RH) Btr

XBtr

R1

P2 R2
PH

Px

STRAIGHT
TRAVEL SPOOL dr2~dr8

Pz P1 PG Py

ORIFICE FRONT REAR PILOT

PUMP PUMP PUMP

HYD
TANK

When the arm and travel functions are operated, simultaneously the arm spools and travel spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve. At the same time, the straight travel spool is pushed to the left by the pilot oil pressure
from the pilot pump. The oil from the front pump flows into the arm cylinders through the arm 1 spool
and arm 2 spool via the parallel and confluence oil passage. The oil from the rear pump flows into
the travel motors through the RH travel spool of the right control valve and the LH travel spool of the
left control valve via the straight travel spool.
When the travel circuit pressure drops lower than arm pressure, as when traveling downhill, arm
priority and smoothness are maintained because of the orifice. Thus the machine will continue to
travel straight.

3 - 30
9. COMBINED BUCKET AND TRAVEL OPERATION

ARM CYLINDER BOOM CYLINDER BUCKET CYLINDER

TRAVEL MOTOR

(XBp2) PBP
Ck1
XBp1
PaL dr6 Fl Fr dr7

XAa2
XAa1
dr5

Aa1

Ba1 XBa2

XBa1 XAa2
ARM1 ARM2
XBa2
XAk
Ak1
SWING MOTOR
Bk1
XAb2 XBk
BOOM2 BUCKET
XBp1 Ck2
dr4
dr8
XBs PbL
As Pns XAb1
XAb2
SWING Ab1
Bs
XAs Bb1

XBb1
BOOM1
dr3
XBtl
Atl

Btl
XAtl
OPTION
TRAVEL(LH)
XAtr
Atr

TRAVEL(RH) Btr

XBtr

R1

P2 R2
PH

Px

STRAIGHT
TRAVEL SPOOL dr2~dr8

Pz P1 PG Py

ORIFICE FRONT REAR PILOT

PUMP PUMP PUMP

HYD
TANK

When the bucket and travel functions are operated, simultaneously the bucket spool and travel
spools in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve. At the same time, the straight travel spool is pushed to the left by the pilot oil
pressure from the pilot pump. The oil from the front pump flows into the bucket cylinder through the
bucket spool via the confluence oil passage. The oil from the rear pump flows into the travel motors
through the RH travel spool of the right control valve and the LH travel spool of the left control valve
via the straight travel spool of the control valve.
When the travel circuit pressure drops lower than bucket pressure, as when traveling downhill,
bucket priority and smoothness are maintained because of the orifice.
In either case, the machine will continue to travel straight.

3 - 31
 SECTION 4 ELECTRICAL SYSTEM

Group 1 Component Location 4-1

Group 2 Electrical Circuit (up to #0111) 4-3
Group 3 Electrical Component Specification 4-19
Group 4 Connectors 4-28
Group 5 Electrical Circuit (#0112 and up, TIER II) 4-48
 SECTION 4 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION

1. LOCATION 1

1 Horn switch 13 Washer switch 24 Air con & heater switch panel
2 Cluster 14 Wiper switch 25 One touch decel switch
3 Starting switch 15 Main light switch 26 Power max switch
4 Cigar lighter 16 Speaker 27 Safety lever
5 Accel dial 17 Cassette & radio 28 Emergency engine control lever
6 Breaker switch 18 Emergency engine (Push pull cable, up to #0062)
7 Beacon switch starting connector 29 Overload switch
8 Service meter 19 Resistor 30 Quick clamp switch
9 Breaker selection switch 20 CPU controller 31 Prolix switch
10 Cab light switch 21 RS232 serial port 32 J1939 serial connector
11 Travel alarm stop switch 22 Fuse box (#0112 and up, TIER II)
12 Preheat switch 23 Master switch

4-1
2. LOCATION 2 (up to #0111)

1
ON
1
OFF

CAB BOOM
3 7
6 8
2 9
10
1 11
12

13
14
5
15

1 Lamp 6 Speed sensor 11 Alternator

2 Fuel sender 7 Start relay 12 Air cleaner switch
3 Fuel filler pump 8 Temp sender 13 Travel alarm buzzer
4 Beacon lamp 9 Engine oil pressure switch 14 Battery relay
5 Horn 10 Heater valve 15 Battery

4-2
2. LOCATION 2 (#0112 and up, TIER II)

1 Lamp 5 Horn 9 Air cleaner switch

2 Fuel sender 6 Start relay 10 Travel alarm buzzer
3 Fuel filler pump 7 Heater valve 11 Battery relay
4 Beacon lamp 8 Alternator 12 Battery

4 - 2-1
GROUP 2 ELECTRICAL CIRCUIT (up to #0111)
・ Machine serial no : -# 0062

CS-60
103 3L FUSE BOX 5W 104 104 5W 115 5W
INLET M/ACT TEMP M/ACT MODE(D/FOOT) MODE(VENT) RESISTOR RELAY(HI) RELAY(M2)
3R 105 105 3R 116 3R
60R 60B 60B
2 2
POWER RY
7 7 BLOWER
1 4 1 4 RESET BUTTON CS-61
M M M M

3
3

1
7 3 7

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28
4
1

ML 2
MH 3
5 5

87a 87 85
BATTERY

30 86
M
AC COMP

Lo

Hi

4
2

2
MASTER SW

20A

10A

20A

10A

10A

20A

20A

10A

10A

20A

10A

10A

10A

10A

10A

10A

10A

20A
12V X 2

5A

5A

5A

5A

5A

5A

5A

5A

5A

5A
5
6
7
5
6
7

5
6
7
CR-1

1
2
3
4
5
6
7

1
2
3
4

1
2
3
4
1
2
3
4
R/DRYER HORN RY

1
2
3
4
G2

87a 87 85
B

2
1

30 86
4

4
2
3

2
3
GW

WR

CR-35
BW

WB

BG
BG

GB

GB
GL

YB
LR

LB

87a
9 G

Pa
TO STARTER "B" TERMINAL

30
Y

86

85
87

87a 87 85

30 86
YBr
YW
LG

YW

ETHER(PRE-HEAT)
BG
RY

RY

2B
YB

CASSETTE RADIO
L

FUEL FILLER P/P

L
20A
9A

9B
21

22

CIGAR LIGHTER
17
20

18
19

23

24
25
16

15

SWITCH PANEL

WIPER MOTOR
FUEL CUT-OFF

BEACON LAMP

CN-29
87a
CR-7
BATT RY

AC& HEATER

CONVERTOR

AC& HEATER

30
86

85
3L

87
36A

SAFETY SOL
ROOM LAMP

WORK LAMP
W

CABIN LAMP
AC BLOWER

SOLENOID 1

SOLENOID 3
26
35
27

2
1
B

HEAD LAMP
33A

32
36

START KEY
6B

6A
29
33

36

28

35

CLUSTER
DO-3

CR-2
TRAVEL

87a
WIPER+

CPU B+

SPARE

SPARE

30
86

85
87
9E

18A
G

HORN
103

V/W
CN-46
G1
93
2

CPU

G
G
L
L
G3 B
1

BR
BR
106

R
Y
106
101
GY/W

4A
4E
DIODE

85
L/W
RW
GY

OR

OR
GY

GY

GY
BR

BR
2R

2L
W

G
V

R
Y

Y
L

5A
22
98
DO-2

5
9A G
2

119

117
102

200

100

109

110
18

99

77

78

90

15

10

88

87

86

97

83

20

19
92 V

1
1

DIODE

DO-1
CN-11 NO. DESTINATION 9 G
1,2 BR NO. DESTINATION CN-11 2
1 1 GND(CONTROLLER) 2B 111 16A W
32 2B 1 AC CONTROLLER GND 1 1
2 2 GND(BLOWER) 2B G4
6 RY 2 BLOWER MOTOR GND 2 DIODE
3 3 FUSE(IG) 2L 4
3,4 RW 3 AC 24V 3 CN-61
4 4 FUSE(Battery) 2R 102 G26 B CN-25
33 2R 4 AC CONTROLLER B+ 4 1 M G25 B
5 5 FUSE(Battery) 2RW 200 1
110 G
30 LW 5 AC CONTROLLER B+ 5 2 22A R
6 6 DPS(COMPRESSOR) G 101 2
31 LY 6 AC COMP 6
7 7 CONDENSOR FAN FUEL PUMP HORN
5 G 7 AC CONDENSOR FAN 7 G24 B
8 8 ILLUMINATION R 6F 1
8 ILLUMINATION 8 22 R
AIR CON 2

AIR-CON CN-20
15
16
17
18
19
20
GW 21

22
WR 23

24
25
26
YBr 27

28
29
30
31

CL-5
1
2
3
4
5
6

8
9
CN-12
NO. DESTINATION CN-10 G23 B B 2 2 B
2
BrR
RW
RW

100 1
WB
BW

9
LW

8
BG

BG

BG

GB
BR
BR

RY
GL

YB
LG

YB
LR

LB

LY

1
G

OVERLOAD SW 1 CASSETTE RADIO 24V 91

Y

QUICK COUPLING SW V V 1 1 V
R 6H 1 2
2

1.25LgB
2 ILLUMINATION

2
8
7

8
2
WIPER CUT SW

9
1
1.25G
3
WORK LAMP
3 NC CL-4
10
11
12
13
14
15
16
17
18

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

1
2
3
4
5
6
7
8
9
CN-21 I B
2B G5 G22 B 1
4 GND 4 1
3 1 1A V
R 10 5 NC 5 6 R 2
2

CS-53
2 Y 99

1
2
6 CL-6

10
12 6 CASSETTE&ROOM LAMP B+

6
TEMP MOTOR ACT(+)

GY

10
5

6
DUCT SENSOR(GND)
TEMP MOTOR ACT(-)

BLOWER RELAY(M1)
BLOWER RELAY(M2)

COMPRESSOR(DPS)

HEAD LAMP
BLOWER RELAY(LO)
MODE M/ACT(FOOT)
INLET MOTOR(REC)

BLOWER RELAY(HI)

CS-67
INLET MOTOR(FRE)

5 3
MODE M/ACT(PBR)
MODE M/ACT(DEF)

CS-50
TEMP M/ACT(PBR)

7
MOTOR ACT(REF)

CONDENSER FAN

4A 7 NC
DUCT SENSOR(+)
MODE M/ACT(M+)

R
MODE M/ACT(M-)

10
4 B 112

10
2

6
4
5

4
5

8
9

9
OR
ILLUMINATION

4 G 8 8 CASSETTE GND 8
BATTERY(+)
BATTERY(+)

5
POWER IG

L 9 9 NC 9

L/W
OR

OR
GY
2 G 96

11
6

OR
DUCT 6 M

B
10 BEACON LAMP 10

Y
B
SENSOR
GND
GND

OR 89
NC

NC
NC
NC
NC
NC

11 CABIN LIGHT 11

G1

1A

G2
2A
7
6

4
WIPER MOTOR 12 NC 12
AIRCON & HEATER CONTROLLER
CN-141
G 8 CABIN HARNESS CN-16
FEED BACK 1 CN-66
W 1 95 GY 1 GY
MOTOR DRIVE SIG 2 CN-17 2 2
L 9 NO. DESTINATION CN-9 G21 B 2 B
MOTOR DRIVE- 3 1 B G6 1 1
R 10 1 W W 9 1 HORN SW 1
MOTOR DRIVE+ 4 2 Y 98
B 2 2 B B G3 2 HORN SW 2 BREAKER SOL
GND 5 3
AIRCON & HEATER HARNESS VCC 6
GY/W 3 3 GY/W
4
GY/W 3 3 NC 3
BR 81
R 4 4 R R 29 4 INT. SIG 4
CONTINUE 24V 7 5 B 13 CN-78
V 5 5 V V 11 5 ACCEL DIAL(-) 5 107 GY
WASHER P/P 8 6 V/OR 25
L 6 6 L L 13 6 ACCEL DIAL(SIG) 6 G13 B
WASHER SIG. 9 7 G/OR 11
BR 7 7 BR BR 10 7 ACCEL DIAL(+) 7
INT. SIG 10 8
OR 11 8 SPARE SW 8 ETHER
WIPER CUT SW 11
N.C 12 CN-6 NO. DESTINATION
GY 12 4 OR CN-8
FEED BACK 13 1 1 FUSE
2 Y 1 SPARE SW 1
2 2 QUICK COUPLING SOL
WIPER MOTOR CONT. 5 L/W 2 SPARE SW 2
3 3 OVERLOAD PS Y 97
6 G 3 BEACON LAMP 24V 3
4 4 CPU CONTROLLER G 96
3 GY/W 4 BEACON LAMP SIG 4
CL-2 5 5 FUSE OR 1A
B G5 G1 B 5 BREAKER SW 24V 5
6 6 GND GY 95
CN-24 GY 1 1 GY 6 BREAKER SIG 6
B/W 12 7 7 FUSE
2 CS-1 R 8 8 R 7 SPARE SW 7
GY 11 8 GY 8 8 ILLUMINATION OR 1E
1 9 W 8 SPARE SW 8
9 9 SWITCH PANEL BR 94
CIGARLIGHT 10 BR 9 START KEY (START SIG) 9
SPEAKER RH 10 10 SWITCH PANEL R 93
11 V 10 START KEY (ACC) 10
CN-23 DOOR S.W CN-48 11 11 WASHER PUMP V 92
OR 16 12 L 11 START KEY (BR) 11
B/OR 10 12 12 CPU CONTROLLER W 18
2 1
OR 9 h 2
W/OR 15 CS-52 12 START KEY (COM) 12
1 GY 1E
9 10 10 CN-7
CL-1 G 28
SPEAKER LH 8 GY HOUR METER 9 R 6
1 HEAD LIHGT SIG 1
1
4 Y 8 V 91
2 CN-138 8 2 WORK LIHGT SIG 2
GY 14 6 7 W 82
CN-27
ROOM LAMP 24V 24V
GND
A
B
B G6
2

7
6
B
B
G8
G9
RH SIDE HARNESS 3
4
WIPER DRIVE SIG
PRE HEAT SIG
3
4
BR 44
N.C 1 22 5 L 90
12 OR 5
B/W 12V 12V C 1 5 SW PANEL 24V 5
S.R- 2 4 OR 89
6 CABIN LIGHT SIG 6
S.R- 3 DC/DC CONVERTER GY 88
3
B/OR 10 L 12 7 HEAD LIHGT 24V 7
S.L- 4 2 CN-5 Y 87
G 28 13 L 8 WORK LIHGT 24V 8
S.L- 5 1 1 1 SWITCH PANEL L 79
CN-139 9 WASHER SIG 9
N.C 6 CN-10 NO. DESTINATION OR 22 2 2 NC B G7
R 2 1 V 2 SPARE 10 GND 10
ILL+ 7 1 1 FUSE B G7 3 3 NC OR/W 28
GY 11 2 R 1 29 R 11 TRAVEL ALARM SIG 11
S.R+ 8 2 2 ILLUMINATION 4 4 FUSE R 86
14 GY 12 CABIN LIGHT 24V 12
S.R+ 9 3 3 5 5 FUSE
V 1 3 2B 12V SOCKET 15 W/OR
ACC 10
Y 4a
4 4 GND
16 OR
6 6 CPU CONTROLLER RH CONSOL
B+ 11 5 5 CN-56 7 7 FUSE
OR 9 4 Y RR BR 17 17 BR
S.L+ 12 6 6 FUSE POWER IG(24V) 1 8 8 FUSE NO. DESTINATION CN-3
B 18 18 B B G14
S.L+ 13 7 7 GND 2 9 9 GND 1 GND 1
B 5 5 B Y 19 19 Y GY 17
GND 14 8 8 GND RX 3 10 10 CPU CONTROLLER 2 ENG START SIG 2
L 20 20 L
9 9 TX 4 11 11 CPU CONTROLLER 3 NC 3
CN-143 6 G 21 21 SH W 16
10 10 BEACON SW 12 12 CPU CASE EARTH 4 ALT LEVEL 4
N.C 1 7 OR CLUSTER
R 20 11 11 SWITCH PANNEL
RADIO ON/OFF 2
BAND 3
G 21 12 12 ENG HARNESS1
L 22 DO-4
BAND 4 G20 B
BR 23 1
SEEK 5 21A Y
OR 24 2
SEEK 6 CS-5 CN-140
N.C 7 1.25B 8 21 Y Y
B 13 1 2 2
GND 8 1.25B 9 NO. DESTINATION CN-6 G19 B B
Y 14 2 OR 1 1 1
VOL/R OUT 9 1 QUICK COUPLING SW 24V 1
V 15 HORN Y 21 CD-31 CN-13
VOL/L OUT 10 2 QUICK COUPLING SW SIG 2 QUICK COUPLING
GY 16 CL-9 L/W 84 84 L/W 1 L
VOL/R IN 11 7 OR CS-26 3 OVERLOAD SW 3 2 2 Pa
W 17 2 G 46 G18 B G B
VOL/L IN 12 3 B 1.25B 18 4 OVERLOAD SW 4 1 1
18 1 1
B
1.25B 5 CN-9 NO. DESTINATION GY/W 10
GND 13 5 WIPER MOTOR 24V 5
19 2 8 B CN-91
R 1 1 GND B G8 OVERLOAD PS
N.C 14 6 GND 6
CS-54 9 Y
B G2 BRAKER 2 2 HORN RELAY GY 83
CASSETTE RADIO CABIN LIGHT 10 7 CIGARLIGHTER 24V 7
9 10 3 R 6K
L 7A 3 NC 8 CIGARLIGHTER ILL. 8
9 10 BR
CN-144 GY 14 4 4 WIPER CONTROLLER W 82
B 18 8 9 WIPER DRIVE SIG 9 CN-22
CL-8 11 B BR 81 10A GY/W
EARTH(VOLUME) 1 8 5 5 CPU CONTROLLER M
W 17 7a OR 6 7 10 INT. SIG 10 2
2 12 V/OR V 80 80 V
VOLUME L/IN 2 2 B 19 6 6 CPU CONTROLLER
GY 16 3a B 6 13 11 WASHER PUMP 11 1
1 G/OR
VOLUME R/IN 3 7 OR 20 7 7 CPU CONTROLLER
V 15 5 5 14 GY 12 NC 12 WASHER PUMP
VOLUME L/OUT 4 1 8 8 NC
Y 14 4
VOLUME R/OUT 5 CN-5
B 13 CL-7 3 CN-8 L 79
EARTH(MAIN) 6 G 15 15 G 1 WASHER SIG 1
R 19 6 G 2 1 1 NC 37A V/W B 23E
N.C 7
M L 7 7 L 2 NC 2
R 20 3b B 1 2 2 NC
RADIO ON/OFF 8 16 Y 3 NC 3
G 21 3 3 FUSE V 119 CN-92
BAND 9 SPARE SW 6 G 4 WIPER MOTOR CONT. 4
22 BEACON LAMP
L 4 4 BEACON LAMP GY 78
BAND 10 17 OR 5 CONVERTOR 24V 5
BR 23 CS-23 5 5 FUSE W/OR 61
SEEK UP 11 B G1 18 GY 6 HOUR METER SIG 6
OR 24 10 10 6 6 BREAKER SOL OR 8
SEEK UP 12 9 7 HOUR METER 24V
G 6A 19 B 7
9 7 7 NC BR 77
REMOCONE 20 OR 8 CLUSTER 24V 8
8 8 FUSE B 113
CAB HARNESS 8
6
8
7
21 BR
9 9 SAFETY RELAY
9 CLUSTER GND 9
Y 68
2 Y 16 22 R 10 CLUSTER SERIAL+ (RX) 10
6 10 10 POWER RELAY L 69
7 23 V 11 CLUSTER SERIAL- (TX) 11
5 5 11 11 DIODE(DO-2) SH 70
1 24 W 12 SHIELD 12
4 12 12 FUSE
3
CN-7
RH SIDE
G 6
2 25 R
1 1 HEAD LAMP NO. DESTINATION CN-4
1 4 V
B G9
2 2 WORK LAMP 1 POWER MAX SW 1
26 W
34
BEACON LAMP SW 3 3 WIPER CONTROLLER Y
27 BR 2 POWER MAX SW 2
4 4 CPU CONTROLLER B G10
CS-27 28 L 3 O/T DECEL SW 3
B G3 5 5 FUSE GY 45
10 3 OR 4 O/T DECEL SW 4
9 10 6
GY 5A 6 CABIN LIGHT 5 NC 5
9 29 GY
B G11
7 7 FUSE
8 6 SAFETY SW (Com) 6 CN-68
2 Y

23
8 8 8 FUSE 109 R
6 7 30 L 7 SAFETY SW (NC) 7 1
2 9 9 WIPER CONTROLLER G 76 76 G
8 SAFETY SW (NO) 2

B
6 G1 B 8
7 OR 17 10 10 GND
5 5 31 OR/W SAFETY SOL
1 11 11 CPU CONTROLLER LH CONSOL
4 1 R
12 12 FUSE CR-5
3 17A GY
NO. DESTINATION CN-2 30
2 GY/W 30 94 BR 87a 87 85
GY 5 1 ENG OIL PS 1 86
G4

1 85
4A

3A

2A

1A

V/W 15A L/W

25

26
27
28

29

30

OR/W 31
10

RH HARNESS
4

2 AC COMP 2 87
11
12
G/OR 13
21

22
23
24

BREAKER SW B G15 37 V/W CR-36

3 GND 3 85
OR
OR
GY
BR

BR

20 L
V/OR
W
R

R
R

17
V
V

Y
Y

GY
L

BR

30 86 30
W

4 FUEL CUT-OFF(Start sig)

R

4 87a
V

L 87a 87 85
B

L/W 15 20A
CN-116

86
5 FUEL CUT-OFF(IG) 5
CS-2

SAFETY RY 107 GY
1

4
5

8
2

6
3

CN-142
10
11
12
13
14
15
16
17

B 12E 87
5
4

1
6

2
3

6 WATER TEMP SENDOR 6

C
B
A

62 Y/W
G 32 85
B 7 WATER TEMP SENDOR 7
30 86
+
S
-

87a
1

0, I
WIPER MOTOR DRIVE

8 NC 8
L 74
9 PUMP EPPR V/V 9 PRE-HEAT
WORK LIGHT OUT
WORK LIGHT OUT

CABIN LIGHT OUT

CABIN LIGHT OUT

WORK LIGHT 24V

WORK LIGHT 24V

CABIN LIGHT 24V

HEAD LIGHT OUT

CABIN LIGHT 24V

HEAD LIHGT 24V

Y 75
TRAVEL ALARM

10 PUMP EPPR V/V 10

WASHER SIG

67
POWER 24V

H 0 I ll W
PRE-HEAT

11
4
3
2

11 TACHO SENSOR
6
5

ST C BR ACC H
B 65
INT. SIG

ACCEL DIAL 12 TACHO SENSOR 12

GND

START KEY SW
CN-28
14 CN-81
V/W
1 CN-1 19A Y
R 14 1
SWITCH PANEL 1
1 P1,P2,P3 B+ 51 V
2
2 NC 2
AC COMP B 47
3 P1,P2,P3 GND 3 TRAVEL BUZER
B/W 38
CD-8 4 PUMP1 PRESS SIG 4 CN-47
B 15 BR 39 8E OR
DC 1 5 PUMP2 PRESS SIG 5 2
G 16 CN-45 CR-23 V 40 24A OR
2 CN-3 NO. DESTINATION 6 PUMP3 PRESS SIG 6 1
M B 1 1 B
WATER TEMP SENDOR M GY 2 2 GY
1 1 GND ENG HARNESS2 CD-10
RESISTOR
2 2 SAFETY RY L 36 CS-7
CD-18 Pa B
3 3 NC B 23A
B+ G12 6 6 4
3 W 5
GY/W 1 FROM BATT.RY START RY 4 4 CPU,DIODE(DO-1) 74 L 5
Pa 5 4 6
STARTER AIR CLEANER SW 48 B/W
CN-2 NO. DESTINATION 4
1 GY/W 24 OR 1
CD-16 3 3
ENG OIL PRESS 1 1 CPU CONTROLLER 2
CN-74 75 Y 2
CN-79
B 2
14
2
V/W
B
2 2 AC COMP RY
B+
15R 4 ENGINE HARNESS 1 2
B
G/W
G12
35 52 L/OR
2 1 3

T
E 3 3 3 GND G 1 1
GY 3 3 GY
~3
S 2 4 4 SAFETY RY W 3 PROLIX SW
L/W 4 4 L/W I CD-6 WATER LEVEL
I 1 5 5 FUSE U R
GND 31
15 B Pa 1
FUEL CUT-OFF 6 6 CPU CONTROLLER B G16
16 G 2
7 7 CPU CONTROLLER ALTERNATOR
CN-75 8 8 NC TRAVEL
L 5 5 L
PS
2 9 9 PROLIX SW SH 70 B 7
Y 6 6 Y
1 10 10 PROLIX SW CS-29
7 W B 1
EPPR V/V 11 11 CPU CONTROLLER 1
8 B Y 2
12 12 CPU CONTROLLER 2
CD-17
rp W 7 CN-4 NO. DESTINATION
m 2 POWER MAX 1 B
B 8 1 1 GND
1 2 Y
CS-19 2 2 CPU CONROLLER
TACHO SENSOR B 3 3 B
CD-42 CN-16 CN-1 1 3 3 GND
GY 4 4 GY
108

R R 1 1 R 9 R

3E

3A
Y/W 26

64
19

55

63

60
24V 3 1 1 1 CPU CONTROLLER 2 4 4 CPU CONROLLER

3
G B/W 3 5
SIG 2 2 2 2 NC 5 NC

BR/W
27

ONE TOUCH DECEL

G/W
2

L/W
10
Y

W B 2 B B
12A

6 6 NC

117
13A

11A

W
GND 1 3 3 3 CPU CONTROLLER

R
Y
8A
12
33

GR/OR 27
26
34
28
30

14
47
16
38
39
40
31
45
35
36

13
11
29
25
33
65
67

12
24
32

55
60
63
61
62

48

37
54
64

51
44

46

66

23
68
69

71
72
73

52
66
54

29

3 B/W 11 B/W CS-4 6 V

CPU CONTROLLER 7 7 NC
CN-15

4 4 4 OR 5
BR/OR

CN-133
PUMP1 PRESS G

CN-88

CN-137
CN-70
2
1

12 B C
OR/W

W/OR

W/OR
BR A
GY/W

BR/W
BR

G/OR
B/OR

V/OR
B/OR
G/OR

L/OR
8
G17

8 SAFETY SOL
G/W

G/W

2
CPU CONTROLLER

1
5
Y/W

B/W

Y/W

B/W

V/W
108

L/W
5 V 6

OR

OR
GY

GY
BR

BR
W

W
13
B

V B
W

G
5
R

R
V
B

B
Y

B
R

L
B

CD-43

73
72
71
6 6 6 CPU CONTROLLER

7
1A G 7
R R C
CD-1

CN-51

A
CD-2

3
CN-76

CN-50
24V
B
Y

BR 4
1
2

B
1
2
6
5
4
3
2
1

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

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

R
B
1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9
SIG 2 SAFETY SW
CN-15

W B 2A TRAVEL MAX
DC

POWER
2PCS BOOM AUTO-IDLE PS

GND 1

CN-126
CD-7

FLOW
2

MAX
SIG
M+

P+

BOOM
NC
M-

P-

3
4
1
2
PUMP2 PRESS CS-20 PRIORITY1

WATER TEMP SENDOR

FUEL LEVEL SENSOR
1
5

BOOM PRIORITY SOL

GND(PRES.SENSOR)

5 HYD
2

OR

TRAVEL SPEED SOL

HYD TEMP SENDOR
24V(PRES.SENSOR)
TRAVEL ALARM SW
M
Pa

TACHO SENSOR(+)
FUEL

TACHO SENSOR(-)

ANTI-RESTART RY
WATER LEVEL SW

PUMP PROLIX SW
CD-44

BRAKE FAIL LAMP

TEMP
AIR CLEANER SW

ENG PREHEATER
POWER MAX SOL
TRAVEL Hi/Lo SW

TRAVEL BUZZER
POWER MAX SW

GND (POT&DIAL)

CO CANCEL SOL

ENG OIL FILTER SW

LEVEL

BATTERY 24V(+)
ACCEL DIAL SIG
BKT&ARM IN PS

RS232
HEAVY LIFT SW

MAX FLOW SOL

OVERLOAD SIG
1E
TRAVEL OIL PS

BRAKE FAIL PS

GND (SENSOR)
R R
ENGINE HARNESS 2
P1 PRESS SIG.
P2 PRESS SIG.
P3 PRESS SIG.

O/T DECEL SW

PUMP EPPR(+)
5V (POT&DIAL)
CD-37

PRE-HEAT SW
PUMP EPPR(-)

ACCEL ACT(+)
HOUR-METER

T/M OIL LAMP

ACCEL ACT(-)
3
WORKING PS

24V

PARKING SW
BOOM UP PS

RS232 (GND)
1
2

5 CONN.
ENG OIL PS

GND (MAIN)
G V ACCEL ACTUATOR

SERIAL-RX
ALT LEVEL

T/M OIL PS
ACCEL SW

SERIAL-TX
POWER IG
2 WORK CN-92

RS232 (+)
SIG

RS232 (-)
LH HARNESS
POT-SIG

W B 2E PS
GND 1 SAFETY SW

GND
Pa

NC
NC

NC

NC

NC

NC

NC

NC
NC
NC
NC

NC
PUMP3 PRESS
CPU CONTROLLER

4-3
・ Machine serial no : # 0063-0111

CS-60
103 3L FUSE BOX 5W 104 104 5W 115 5W
INLET M/ACT TEMP M/ACT MODE(D/FOOT) MODE(VENT) RESISTOR RELAY(HI) RELAY(M2)
3R 105 105 3R 116 3R
60R 60B 60B
2 2
POWER RY
7 7 BLOWER
1 4 1 4 RESET BUTTON CS-61
M M M M

3
3

1
7 3 7

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28
4
1

ML 2
MH 3
5 5

87a 87 85
BATTERY

30 86
M
AC COMP

Lo

Hi

4
2

2
MASTER SW

20A

10A

20A

10A

10A

20A

20A

10A

10A

20A

10A

10A

10A

10A

10A

10A

10A

20A
12V X 2

5A

5A

5A

5A

5A

5A

5A

5A

5A

5A
5
6
7
5
6
7

5
6
7
CR-1

1
2
3
4
5
6
7

1
2
3
4

1
2
3
4
1
2
3
4
R/DRYER HORN RY

1
2
3
4
G2

87a 87 85
B

2
1

30 86
4

4
2
3

2
3
GW

WR

CR-35
BW

WB

BG
BG

GB

GB
GL

YB
LR

LB

87a
9 G

Pa
TO STARTER "B" TERMINAL

30
Y

86

85
87

87a 87 85

30 86
YBr
YW
LG

YW

ETHER(PRE-HEAT)
BG
RY

RY

2B
YB

CASSETTE RADIO
L

FUEL FILLER P/P

L
20A
9A

9B
21

22

CIGAR LIGHTER
17
20

18
19

23

24
25
16

15

SWITCH PANEL

WIPER MOTOR
FUEL CUT-OFF

BEACON LAMP

CN-29
87a
CR-7
BATT RY

AC& HEATER

CONVERTOR

AC& HEATER

30
86

85
3L

87
36A

SAFETY SOL
ROOM LAMP

WORK LAMP
W

CABIN LAMP
AC BLOWER

SOLENOID 1

SOLENOID 3
26
35
27

2
1
B

HEAD LAMP
33A

32
36

START KEY
6B

6A
29
33

36

28

35

CLUSTER
DO-3

CR-2
TRAVEL

87a
WIPER+

CPU B+

SPARE

SPARE

30
86

85
87
9E

18A
G

HORN
103

V/W
CN-46
G1
93
2

CPU

G
G
L
L
G3 B
1

BR
BR
106

R
Y
106
101
GY/W

4A
4E
DIODE

85
L/W
RW
GY

OR

OR
GY

GY

GY
BR

BR
2R

2L
W

G
V

R
Y

Y
L

5A
22
98
DO-2

5
9A G
2

119

117
102

200

100

109

110
18

99

77

78

90

15

10

88

87

86

97

83

20

19
92 V

1
1

DIODE

DO-1
CN-11 NO. DESTINATION 9 G
1,2 BR NO. DESTINATION CN-11 2
1 1 GND(CONTROLLER) 2B 111 16A W
32 2B 1 AC CONTROLLER GND 1 1
2 2 GND(BLOWER) 2B G4
6 RY 2 BLOWER MOTOR GND 2 DIODE
3 3 FUSE(IG) 2L 4
3,4 RW 3 AC 24V 3 CN-61
4 4 FUSE(Battery) 2R 102 G26 B CN-25
33 2R 4 AC CONTROLLER B+ 4 1 M G25 B
5 5 FUSE(Battery) 2RW 200 1
110 G
30 LW 5 AC CONTROLLER B+ 5 2 22A R
6 6 DPS(COMPRESSOR) G 101 2
31 LY 6 AC COMP 6
7 7 CONDENSOR FAN FUEL PUMP HORN
5 G 7 AC CONDENSOR FAN 7 G24 B
8 8 ILLUMINATION R 6F 1
8 ILLUMINATION 8 22 R
AIR CON 2

AIR-CON CN-20
15
16
17
18
19
20
GW 21

22
WR 23

24
25
26
YBr 27

28
29
30
31

CL-5
1
2
3
4
5
6

8
9
CN-12
NO. DESTINATION CN-10 G23 B B 2 2 B
2

BrR
RW
RW

100 1
WB
BW

9
LW

8
BG

BG

BG

GB
BR
BR

RY
GL

YB
LG

YB
LR

LB

LY

1
G
OVERLOAD SW 1 CASSETTE RADIO 24V 91
Y

QUICK COUPLING SW V V 1 1 V
R 6H 1 2
2

1.25LgB
2 ILLUMINATION

2
8
7

8
2
WIPER CUT SW

9
1
1.25G
3 WORK LAMP
3 NC CL-4
10
11
12
13
14
15
16
17
18

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

1
2
3
4
5
6
7
8
9
CN-21 I B
2B G5 G22 B 1
4 GND 4 1
3 1 1A V
R 10 5 NC 5 6 R 2
2

CS-53
2 Y 99

1
2
6 CL-6

10
12 6 CASSETTE&ROOM LAMP B+

6
TEMP MOTOR ACT(+)

GY

10
5

6
DUCT SENSOR(GND)
TEMP MOTOR ACT(-)

BLOWER RELAY(M1)
BLOWER RELAY(M2)

COMPRESSOR(DPS)

HEAD LAMP
BLOWER RELAY(LO)
MODE M/ACT(FOOT)
INLET MOTOR(REC)

BLOWER RELAY(HI)

CS-67
INLET MOTOR(FRE)

5 3
MODE M/ACT(PBR)
MODE M/ACT(DEF)

CS-50
TEMP M/ACT(PBR)

7
MOTOR ACT(REF)

CONDENSER FAN

4A 7 NC
DUCT SENSOR(+)
MODE M/ACT(M+)

R
MODE M/ACT(M-)

10
4 B 112

10
2

6
4
5

4
5

8
9

9
OR
ILLUMINATION

4 G 8 8 CASSETTE GND 8
BATTERY(+)
BATTERY(+)

5
POWER IG

L 9 9 NC 9

L/W
OR

OR
GY
2 G 96

11
6

OR
DUCT 6 M

B
10 BEACON LAMP 10

Y
B
SENSOR
GND
GND

OR 89
NC

NC
NC
NC
NC
NC

11 CABIN LIGHT 11

G1

1A

G2
2A
7
6

4
WIPER MOTOR 12 NC 12
AIRCON & HEATER CONTROLLER
CN-141
G 8 CABIN HARNESS CN-16
FEED BACK 1 CN-66
W 1 95 GY 1 GY
MOTOR DRIVE SIG 2 CN-17 2 2
L 9 NO. DESTINATION CN-9 G21 B 2 B
MOTOR DRIVE- 3 1 B G6 1 1
R 10 1 W W 9 1 HORN SW 1
MOTOR DRIVE+ 4 2 Y 98
B 2 2 B B G3 2 HORN SW 2 BREAKER SOL
GND 5 3
AIRCON & HEATER HARNESS VCC 6
GY/W 3 3 GY/W
4
GY/W 3 3 NC 3
BR 81
R 4 4 R R 29 4 INT. SIG 4
CONTINUE 24V 7 5 B 13 CN-78
V 5 5 V V 11 5 ACCEL DIAL(-) 5 107 GY
WASHER P/P 8 6 V/OR 25
L 6 6 L L 13 6 ACCEL DIAL(SIG) 6 G13 B
WASHER SIG. 9 7 G/OR 11
BR 7 7 BR BR 10 7 ACCEL DIAL(+) 7
INT. SIG 10 8
OR 11 8 SPARE SW 8 ETHER
WIPER CUT SW 11
N.C 12 CN-6 NO. DESTINATION
GY 12 4 OR CN-8
FEED BACK 13 1 1 FUSE
2 Y 1 SPARE SW 1
2 2 QUICK COUPLING SOL
WIPER MOTOR CONT. 5 L/W 2 SPARE SW 2
3 3 OVERLOAD PS Y 97
6 G 3 BEACON LAMP 24V 3
4 4 CPU CONTROLLER G 96
3 GY/W 4 BEACON LAMP SIG 4
CL-2 5 5 FUSE OR 1A
B G5 G1 B 5 BREAKER SW 24V 5
6 6 GND GY 95
CN-24 GY 1 1 GY 6 BREAKER SIG 6
B/W 12 7 7 FUSE
2 CS-1 R 8 8 R 7 SPARE SW 7
GY 11 8 GY 8 8 ILLUMINATION OR 1E
1 9 W 8 SPARE SW 8
9 9 SWITCH PANEL BR 94
CIGARLIGHT 10 BR 9 START KEY (START SIG) 9
SPEAKER RH 10 10 SWITCH PANEL R 93
11 V 10 START KEY (ACC) 10
CN-23 DOOR S.W CN-48 11 11 WASHER PUMP V 92
OR 16 12 L 11 START KEY (BR) 11
B/OR 10 12 12 CPU CONTROLLER W 18
2 1
OR 9 h 2
W/OR 15 CS-52 12 START KEY (COM) 12
1 GY 1E
9 10 10 CN-7
CL-1 G 28
SPEAKER LH 8 GY HOUR METER 9 R 6
1 HEAD LIHGT SIG 1
1
4 Y 8 V 91
2 CN-138 8 2 WORK LIHGT SIG 2
GY 14 6 7 W 82
CN-27
ROOM LAMP 24V 24V
GND
A
B
B G6
2

7
6
B
B
G8
G9
RH SIDE HARNESS 3
4
WIPER DRIVE SIG
PRE HEAT SIG
3
4
BR 44
N.C 1 22 5 L 90
12 OR 5
B/W 12V 12V C 1 5 SW PANEL 24V 5
S.R- 2 4 OR 89
6 CABIN LIGHT SIG 6
S.R- 3 DC/DC CONVERTER GY 88
3
B/OR 10 L 12 7 HEAD LIHGT 24V 7
S.L- 4 2 CN-5 Y 87
G 28 13 L 8 WORK LIHGT 24V 8
S.L- 5 1 1 1 SWITCH PANEL L 79
CN-139 9 WASHER SIG 9
N.C 6 CN-10 NO. DESTINATION OR 22 2 2 NC B G7
R 2 1 V 2 SPARE 10 GND 10
ILL+ 7 1 1 FUSE B G7 3 3 NC OR/W 28
GY 11 2 R 1 29 R 11 TRAVEL ALARM SIG 11
S.R+ 8 2 2 ILLUMINATION 4 4 FUSE R 86
14 GY 12 CABIN LIGHT 24V 12
S.R+ 9 3 3 5 5 FUSE
V 1 3 2B 12V SOCKET 15 W/OR
ACC 10
Y 4a
4 4 GND
16 OR
6 6 CPU CONTROLLER RH CONSOL
B+ 11 5 5 CN-56 7 7 FUSE
OR 9 4 Y RR BR 17 17 BR
S.L+ 12 6 6 FUSE POWER IG(24V) 1 8 8 FUSE NO. DESTINATION CN-3
B 18 18 B B G14
S.L+ 13 7 7 GND 2 9 9 GND 1 GND 1
B 5 5 B Y 19 19 Y GY 17
GND 14 8 8 GND RX 3 10 10 CPU CONTROLLER 2 ENG START SIG 2
L 20 20 L
9 9 TX 4 11 11 CPU CONTROLLER 3 NC 3
CN-143 6 G 21 21 SH W 16
10 10 BEACON SW 12 12 CPU CASE EARTH 4 ALT LEVEL 4
N.C 1 7 OR CLUSTER
R 20 11 11 SWITCH PANNEL
RADIO ON/OFF 2
BAND 3
G 21 12 12 ENG HARNESS1
L 22 DO-4
BAND 4 G20 B
BR 23 1
SEEK 5 21A Y
OR 24 2
SEEK 6 CS-5 CN-140
N.C 7 1.25B 8 21 Y Y
B 13 1 2 2
GND 8 1.25B 9 NO. DESTINATION CN-6 G19 B B
Y 14 2 OR 1 1 1
VOL/R OUT 9 1 QUICK COUPLING SW 24V 1
V 15 HORN Y 21 CD-31 CN-13
VOL/L OUT 10 2 QUICK COUPLING SW SIG 2 QUICK COUPLING
GY 16 CL-9 L/W 84 84 L/W 1 L
VOL/R IN 11 7 OR CS-26 3 OVERLOAD SW 3 2 2 Pa
W 17 2 G 46 G18 B G B
VOL/L IN 12 3 B 1.25B 18 4 OVERLOAD SW 4 1 1
18 1 1
B
1.25B 5 CN-9 NO. DESTINATION GY/W 10
GND 13 5 WIPER MOTOR 24V 5
19 2 8 B CN-91
R 1 1 GND B G8 OVERLOAD PS
N.C 14 6 GND 6
CS-54 9 Y
B G2 BRAKER 2 2 HORN RELAY GY 83
CASSETTE RADIO CABIN LIGHT 10 7 CIGARLIGHTER 24V 7
9 10 3 R 6K
L 7A 3 NC 8 CIGARLIGHTER ILL. 8
9 10 BR
CN-144 GY 14 4 4 WIPER CONTROLLER W 82
B 18 8 9 WIPER DRIVE SIG 9 CN-22
CL-8 11 B BR 81 10A GY/W
EARTH(VOLUME) 1 8 5 5 CPU CONTROLLER M
W 17 7a OR 6 7 10 INT. SIG 10 2
2 12 V/OR V 80 80 V
VOLUME L/IN 2 2 B 19 6 6 CPU CONTROLLER
GY 16 3a B 6 13 11 WASHER PUMP 11 1
1 G/OR
VOLUME R/IN 3 7 OR 20 7 7 CPU CONTROLLER
V 15 5 5 14 GY 12 NC 12 WASHER PUMP
VOLUME L/OUT 4 1 8 8 NC
Y 14 4
VOLUME R/OUT 5 CN-5
B 13 CL-7 3 CN-8 L 79
EARTH(MAIN) 6 G 15 15 G 1 WASHER SIG 1
R 19 6 G 2 1 1 NC 37A V/W B 23E
N.C 7
M L 7 7 L 2 NC 2
R 20 3b B 1 2 2 NC
RADIO ON/OFF 8 16 Y 3 NC 3
G 21 3 3 FUSE V 119 CN-92
BAND 9 SPARE SW 6 G 4 WIPER MOTOR CONT. 4
22 BEACON LAMP
L 4 4 BEACON LAMP GY 78
BAND 10 17 OR 5 CONVERTOR 24V 5
BR 23 CS-23 5 5 FUSE W/OR 61
SEEK UP 11 B G1 18 GY 6 HOUR METER SIG 6
OR 24 10 10 6 6 BREAKER SOL OR 8
SEEK UP 12 9 7 HOUR METER 24V
G 6A 19 B 7
9 7 7 NC BR 77
REMOCONE 20 OR 8 CLUSTER 24V 8
8 8 FUSE B 113
CAB HARNESS 8
6
8
7
21 BR
9 9 SAFETY RELAY
9 CLUSTER GND 9
Y 68
2 Y 16 22 R 10 CLUSTER SERIAL+ (RX) 10
6 10 10 POWER RELAY L 69
7 23 V 11 CLUSTER SERIAL- (TX) 11
5 5 11 11 DIODE(DO-2) SH 70
1 24 W 12 SHIELD 12
4 12 12 FUSE
3
CN-7
RH SIDE
G 6
2 25 R
1 1 HEAD LAMP NO. DESTINATION CN-4
1 4 V
B G9
2 2 WORK LAMP 1 POWER MAX SW 1
26 W
34
BEACON LAMP SW 3 3 WIPER CONTROLLER Y
27 BR 2 POWER MAX SW 2
4 4 CPU CONTROLLER B G10
CS-27 28 L 3 O/T DECEL SW 3
B G3 5 5 FUSE GY 45
10 3 OR 4 O/T DECEL SW 4
9 10 6
GY 5A 6 CABIN LIGHT 5 NC 5
9 29 GY
B G11
7 7 FUSE
8 6 SAFETY SW (Com) 6 CN-68
2 Y

23
8 8 8 FUSE 109 R
6 7 30 L 7 SAFETY SW (NC) 7 1
2 9 9 WIPER CONTROLLER G 76 76 G
8 SAFETY SW (NO) 2

B
6 G1 B 8
7 OR 17 10 10 GND
5 5 31 OR/W SAFETY SOL
1 11 11 CPU CONTROLLER LH CONSOL
4 1 R
12 12 FUSE CR-5
3 17A GY
NO. DESTINATION CN-2 30
2 GY/W 30 94 BR 87a 87 85
GY 5 1 ENG OIL PS 1 86
G4

1 85
4A

3A

2A

1A

V/W 15A L/W

25

26
27
28

29

30

OR/W 31
10

RH HARNESS
4

2 AC COMP 2 87
11
12
G/OR 13
21

22
23
24

BREAKER SW B G15 37 V/W CR-36

3 GND 3 85
OR
OR
GY
BR

BR

20 L
V/OR
W
R

R
R

17
V
V

Y
Y

GY
L

BR

30 86 30
W

4 FUEL CUT-OFF(Start sig)

R

4 87a
V

L 87a 87 85
B

L/W 15 20A
CN-116

86
5 FUEL CUT-OFF(IG) 5
CS-2

SAFETY RY 107 GY
1

4
5

8
2

6
3

CN-142
10
11
12
13
14
15
16
17

B 12E 87
5
4

1
6

2
3

6 WATER TEMP SENDOR 6

C
B
A

62 Y/W
G 32 85
B 7 WATER TEMP SENDOR 7
30 86
+
S
-

87a
1

0, I
WIPER MOTOR DRIVE

8 NC 8
L 74
9 PUMP EPPR V/V 9 PRE-HEAT
WORK LIGHT OUT
WORK LIGHT OUT

CABIN LIGHT OUT

CABIN LIGHT OUT

WORK LIGHT 24V

WORK LIGHT 24V

CABIN LIGHT 24V

HEAD LIGHT OUT

CABIN LIGHT 24V

HEAD LIHGT 24V

Y 75
TRAVEL ALARM

10 PUMP EPPR V/V 10

WASHER SIG

67
POWER 24V

H 0 I ll W
PRE-HEAT

11
4
3
2

11 TACHO SENSOR
6
5

ST C BR ACC H
B 65
INT. SIG

ACCEL DIAL 12 TACHO SENSOR 12

GND

START KEY SW
CN-28
14 CN-81
V/W
1 CN-1 19A Y
R 14 1
SWITCH PANEL 1
1 P1,P2,P3 B+ 51 V
2
2 NC 2
AC COMP B 47
3 P1,P2,P3 GND 3 TRAVEL BUZER
B/W 38
CD-8 4 PUMP1 PRESS SIG 4 CN-47
B 15 BR 39 8E OR
DC 1 5 PUMP2 PRESS SIG 5 2
G 16 CN-45 CR-23 V 40 24A OR
2 CN-3 NO. DESTINATION 6 PUMP3 PRESS SIG 6 1
M B 1 1 B
WATER TEMP SENDOR M GY 2 2 GY
1 1 GND ENG HARNESS2 CD-10
RESISTOR
2 2 SAFETY RY L 36 CS-7
CD-18 Pa B
3 3 NC B 23A
B+ G12 6 6 4
3 W 5
GY/W 1 FROM BATT.RY START RY 4 4 CPU,DIODE(DO-1) 74 L 5
Pa 5 4 6
STARTER AIR CLEANER SW 48 B/W
CN-2 NO. DESTINATION 4
1 GY/W 24 OR 1
CD-16 3 3
ENG OIL PRESS 1 1 CPU CONTROLLER 2
CN-74 75 Y 2
CN-79
B 2
14
2
V/W
B
2 2 AC COMP RY
B+
15R 4 ENGINE HARNESS 1 2
B
G/W
G12
35 52 L/OR
2 1 3

T
E 3 3 3 GND G 1 1
GY 3 3 GY
~3
S 2 4 4 SAFETY RY W 3 PROLIX SW
L/W 4 4 L/W I CD-6 WATER LEVEL
I 1 5 5 FUSE U R
GND 31
15 B Pa 1
FUEL CUT-OFF 6 6 CPU CONTROLLER B G16
16 G 2
7 7 CPU CONTROLLER ALTERNATOR
CN-75 8 8 NC TRAVEL
L 5 5 L
PS
2 9 9 PROLIX SW SH 70 B 7
Y 6 6 Y
1 10 10 PROLIX SW CS-29
7 W B 1
EPPR V/V 11 11 CPU CONTROLLER 1
8 B Y 2
12 12 CPU CONTROLLER 2
CD-17
rp W 7 CN-4 NO. DESTINATION
m 2 POWER MAX 1 B
B 8 1 1 GND
1 2 Y
CS-19 2 2 CPU CONROLLER
TACHO SENSOR B 3 3 B
CD-42 CN-16 CN-1 1 3 3 GND
GY 4 4 GY
108

R R 1 1 R 9 R

3E

3A
Y/W 26

64
19

55

63

60
24V 3 1 1 1 CPU CONTROLLER 2 4 4 CPU CONROLLER

3
G B/W 3 5
SIG 2 2 2 2 NC 5 NC

BR/W
27

ONE TOUCH DECEL

G/W
2

L/W
10
Y

W B 2 B B
12A

6 6 NC

117
13A

11A

W
GND 1 3 3 3 CPU CONTROLLER

R
Y
8A
12
33

GR/OR 27
26
34
28
30

14
47
16
38
39
40
31
45
35
36

13
11
29
25
33
65
67

12
24
32

55
60
63
61
62

48

37
54
64

51
44

46

66

23
68
69

71
72
73

52
66
54

29

3 B/W 11 B/W CS-4 6 V

CPU CONTROLLER 7 7 NC
CN-15

4 4 4 OR 5
BR/OR

CN-133
PUMP1 PRESS G

CN-88

CN-137
CN-70
2
1

12 B C
OR/W

W/OR

W/OR
BR A
GY/W

BR/W
BR

G/OR
B/OR

V/OR
B/OR
G/OR

L/OR
8
G17

8 SAFETY SOL

G/W

G/W

2
CPU CONTROLLER

1
5
Y/W

B/W

Y/W

B/W

V/W
108

L/W
5 V 6

OR

OR
GY

GY
BR

BR
W

W
13
B

V B
W

G
5
R

R
V
B

B
Y

B
R

L
B

CD-43

73
72
71
6 6 6 CPU CONTROLLER

7
1A G 7
R R C
CD-1

CN-51

A
CD-2

3
CN-76

CN-50
24V
B
Y

BR 4
1
2

B
1
2
6
5
4
3
2
1

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

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

R
B
1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9
SIG 2 SAFETY SW
CN-15

W B 2A TRAVEL MAX
DC

POWER
2PCS BOOM AUTO-IDLE PS

GND 1

CN-126
CD-7

FLOW
2

MAX
SIG
M+

P+

BOOM
NC
M-

P-

3
4
1
2
PUMP2 PRESS CS-20 PRIORITY1

WATER TEMP SENDOR

FUEL LEVEL SENSOR
1
5

BOOM PRIORITY SOL

GND(PRES.SENSOR)

5 HYD
2

OR

TRAVEL SPEED SOL

HYD TEMP SENDOR
24V(PRES.SENSOR)
TRAVEL ALARM SW
M
Pa

TACHO SENSOR(+)
FUEL

TACHO SENSOR(-)

ANTI-RESTART RY
WATER LEVEL SW

PUMP PROLIX SW
CD-44

BRAKE FAIL LAMP

TEMP
AIR CLEANER SW

ENG PREHEATER
POWER MAX SOL
TRAVEL Hi/Lo SW

TRAVEL BUZZER
POWER MAX SW

GND (POT&DIAL)

CO CANCEL SOL

ENG OIL FILTER SW

LEVEL

BATTERY 24V(+)
ACCEL DIAL SIG
BKT&ARM IN PS

RS232
HEAVY LIFT SW

MAX FLOW SOL

OVERLOAD SIG
1E
TRAVEL OIL PS

BRAKE FAIL PS

GND (SENSOR)
R R
ENGINE HARNESS 2
P1 PRESS SIG.
P2 PRESS SIG.
P3 PRESS SIG.

O/T DECEL SW

PUMP EPPR(+)
5V (POT&DIAL)
CD-37

PRE-HEAT SW
PUMP EPPR(-)

ACCEL ACT(+)
HOUR-METER

T/M OIL LAMP

ACCEL ACT(-)
3
WORKING PS

24V

PARKING SW
BOOM UP PS

RS232 (GND)
1
2

5 CONN.
ENG OIL PS

GND (MAIN)
G V ACCEL ACTUATOR

SERIAL-RX
ALT LEVEL

T/M OIL PS
ACCEL SW

SERIAL-TX
POWER IG
2 WORK CN-92

RS232 (+)
SIG

RS232 (-)