Section 1 General

SECTION 1 GENERAL
Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Before returning machine to customer, make
sure machine is functioning properly, especially
the safety systems. Install all guards and
shields.
1-9
GROUP 2 SPECIFICATIONS
1. MAJOR COMPONENT
Battery box Fuel tank Hydraulic tank Main pump
Engine
Oil cooler
Tooth Bucket Turning joint Swing motor Main control valve Radiator
Arm Arm cylinder Boom Boom cylinder Cab Muffler Counterweight
Bucket cylinder Connecting link Idler Carrier roller Sprocket
Side cutter Connecting rod Track roller Track Travel motor
4809S2SP01
1-10
2. SPECIFICATIONS
1) ROBEX 480LC-9S
·7.06 m (23' 2") BOOM, 3.38 m (11' 1") ARM
I(I') D
G
E
C
H
J M
K N
A B(L)
4809S2SP02
Description Unit Specification

Operating weight kg (lb) 48100 (106040)
Bucket capacity (SAE heaped), standard m3 (yd3) 2.15 (2.81)
Overall length A 12060 (39' 7")
Overall width, with 600 mm shoe B 3340 (10' 11")
Overall height C 3730 (12' 3")
Superstructure width D 2980 ( 9' 9")
Overall height of cab E 3190 (10' 6")
Ground clearance of counterweight F 1295 ( 4' 3")
Engine cover height G 2850 ( 9' 4")
Minimum ground clearance H mm (ft-in) 555 ( 1' 10")
Rear-end distance I 3695 (12' 1")
Rear-end swing radius I' 3750 (12' 4")
Distance between tumblers J 4470 (14' 8")
Undercarriage length K 5462 (17' 11")
Undercarriage width L 3340 (10' 11")
Track gauge M 2740 ( 9' 0")
Track shoe width, standard N 600 (24")
Travel speed (low/high) km/hr (mph) 3.2/5.0 (2.0/3.1)
Swing speed rpm 9.0
Gradeability Degree (%) 35 (70)
Ground pressure (600 mm shoe) kgf/cm2 (psi) 0.83 (11.80)
Max traction force kg (lb) 38500 (84880)
1-11
2) ROBEX 520LC-9S
·7.06 m (23' 2") BOOM, 3.38 m (11' 1") ARM
I(I') D
G
E
C
H
J M
K N
A B(L)
4809S2SP03

Overall width, with 600 mm shoe
B 2990/3540 (9' 10"/11' 7")
(transport position / working position)
Engine cover height G 3060 (10' 1")
Undercarriage width
L 2980/3540 (9' 9"/11' 7")
Track gauge
M 2380/2940 (7' 10"/9' 8")
Swing speed rpm 9.0
1-12
3) ROBEX 520LC-9S
·6.55 m (21' 6") BOOM, 2.4 m (7' 10") ARM
I(I') D
G
E
C
H
J M
K N
A B(L)
4809S2SP03

B 2980/3540 (9' 9"/11' 7")
Undercarriage width
L 2980/3540 (9' 9"/11' 7")
Track gauge
M 2380/2940 (7' 10"/9' 8")
Swing speed rpm 9.0
1-13
4) ROBEX 520LC-9S
·9.00 m (29' 6") BOOM, 5.85 m (19' 2") ARM
I(I') D
G
E
C
H
J M
K N
A B(L)
4809S2SP03

B 2980/3540 (9' 9"/11' 7")
Undercarriage width
L 2980/3540 (9' 9"/11' 7")
Track gauge
M 2380/2940 (7' 10"/9' 8")
Swing speed rpm 9.0
1-14
3. WORKING RANGE
1) ROBEX 480LC-9S
·7.06
7.06 m (23' 2") BOOM
A
A'
F
D
B' E
C
B
8ft
4809S2SP04
Description 2.40 m (7' 10") Arm 2.90 m (9' 6") Arm 3.38 m (11' 1") Arm 4.00 m (13' 1") Arm
Max digging reach A 11160 mm (36' 7") 11550 mm (37'11") 12100 mm (39' 8") 12660 mm (41' 6")
Max digging reach on ground A' 10940 mm (35'11") 11340 mm (37' 2") 11900 mm (39' 1") 12470 mm (40'11")
Max digging depth B 6830 mm (22' 5") 7330 mm (24' 1") 7810 mm (25' 7") 8430 mm (27' 9")
Max digging depth (8ft level) B' 6670 mm (21'11") 7190 mm (23' 7") 7670 mm (25' 2") 8320 mm (27' 4")
Max vertical wall digging depth C 5960 mm (19' 7") 5930 mm (19' 5") 6590 mm (21' 7") 7170 mm (23' 6")
Max digging height D 10560 mm (34' 8") 10530 mm (34' 7") 10980 mm (36' 0") 11210 mm (36' 9")
Max dumping height E 7110 mm (23' 4") 7180 mm (23' 7") 7620 mm (25' 0") 7830 mm (25' 8")
Min swing radius F 5090 mm (16' 8") 4910 mm (16' 1") 4780 mm (15' 8") 4910 mm (16' 1")
216.7 [236.4] kN 219.7 [239.6] kN 220.7 [240.7] kN 222.6 [242.9] kN
SAE 22100 [24110] kgf 22400 [24440] kgf 22500 [24550] kgf 22700 [24760] kgf
48720 [53150] lbf 49380 [53870] lbf 49600 [54110] lbf 50040 [54590] lbf
Bucket digging force
251.1 [273.9] kN 254.0 [277.1] kN 255.0 [278.2] kN 256.9 [280.3] kN
ISO 25600 [27930] kgf 25900 [28250] kgf 26000 [28360] kgf 26200 [28580] kgf
56440 [61570] lbf 57100 [62290] lbf 57320 [62530] lbf 57760 [63010] lbf
276.6 [301.7] kN 224.6 [245.0] kN 191.2 [208.6] kN 170.6 [186.2] kN
62170 [67820] lbf 50490 [55080] lbf 42990 [46900] lbf 38360 [41850] lbf
Arm crowd force
290.3 [316.7] kN 234.4 [255.7] kN 199.1 [217.2] kN 176.5 [192.6] kN
65260 [71190] lbf 52690 [57480] lbf 44750 [48820] lbf 39680 [43290] lbf
[ ] : Power boost
1-15
2) ROBEX 480LC-9S
·6.55
6.55 m (21' 6") BOOM
A
A'
F
D
B' E
C
B
8ft
4809S2SP04
Description 2.40 m (7' 10") Arm

Max digging reach A 10610 mm (34'10")
Max digging reach on ground A' 10370 mm (34' 0")
Max digging depth B 6370 mm (20'11")
Max digging depth (8ft level) B' 6190 mm (20' 4")
Max vertical wall digging depth C 5400 mm (17' 9")
Max digging height D 10170 mm (33' 4")
Max dumping height E 6750 mm (22' 2")
Min swing radius F 4620 mm (15' 2")
216.7 [236.4] kN
SAE 22100 [24110] kgf
48720 [53150] lbf
251.1 [273.9] kN
ISO 25600 [27930] kgf
56440 [61570] lbf
276.6 [301.7] kN
SAE 28200 [30760] kgf
62170 [67820] lbf
Arm crowd force
290.3 [316.7] kN
ISO 29600 [32290] kgf
65260 [71190] lbf
[ ] : Power boost
1-16
3) ROBEX 480LC-9S
·9.00
9.00 m (29' 6") BOOM
A
A'
F
D
B' E
C
B
8ft
4809S2SP04

Max digging reach A 16350 mm (53' 8")
Max digging reach on ground A' 16200 mm (53' 2")
Max digging depth B 11560 mm (37'11")
Max vertical wall digging depth C 10320 mm (33'10")
189.3 kN
SAE 19300 kgf
42550 lbf
217.7 kN
ISO 22200 kgf
48940 lbf
107.9 kN
SAE 11000 kgf
24250 lbf
Arm crowd force
110.3 kN
ISO 11250 kgf
24800 lbf
1-17
4) ROBEX 520LC-9S
·7.06
7.06 m (23' 2") BOOM
A
A'
F
D
B' E
C
B
8ft
4809S2SP05
Description 2.40 m (7' 10") Arm 2.90 m (9' 6") Arm 3.38 m (11' 1") Arm 4.00 m (13' 1") Arm
Max digging reach A 11140 mm (36' 7") 11530 mm (37'10") 12080 mm (39' 8") 12640 mm (41' 6")
Max digging reach on ground A' 10890 mm (35' 9") 11290 mm (37' 0") 11840 mm (38'10") 12420 mm (40' 9")
Max digging depth B 6610 mm (21' 8") 7110 mm (23' 4") 7590 mm (24'11") 8210 mm (26'11")
Max digging depth (8ft level) B' 6430 mm (21' 1") 6940 mm (22' 9") 7440 mm (24' 5") 8080 mm (26' 6")
Max vertical wall digging depth C 4880 mm (16' 0") 4780 mm (15' 8") 5470 mm (17'11") 5980 mm (19' 7")
Max digging height D 10640 mm (34'11") 10610 mm (34'10") 11080 mm (36' 4") 11290 mm (37' 0")
Max dumping height E 7290 mm (23'11") 7350 mm (24' 1") 7760 mm (25' 6") 7980 mm (26' 2")
Min swing radius F 5110 mm (16' 9") 4910 mm (16' 1") 4830 mm (15'10") 4910 mm (16' 1")
247.1 [269.6] kN 251.1[273.9] kN 253.0 [276.0] kN 253.0 [276.0] kN
55560 [60610] lbf 56440 [61570] lbf 56880 [62050] lbf 56880 [62050] lbf
286.4 [312.4] kN 290.3 [316.7] kN 292.2 [318.8] kN 292.2 [318.8] kN
64370 [70220] lbf 65260 [71190] lbf 65700 [71670] lbf 65700 [71670] lbf
278.5 [303.8] kN 225.6 [246.1] kN 192.2 [209.7] kN 171.6 [187.2] kN
62610 [68300] lbf 50710 [55320] lbf 43210 [47140] lbf 38580 [42090] lbf
Arm crowd force
291.3 [317.7] kN 235.4 [256.8] kN 200.1 [218.2] kN 177.5 [193.6] kN
65480 [71430] lbf 52910 [57720] lbf 44970 [49060] lbf 39900 [43530] lbf
[ ] : Power boost
1-18
5) ROBEX 520LC-9S
·6.55
6.55 m (21' 6") BOOM
A
A'
F
D
B' E
C
B
8ft
4809S2SP05

Max digging reach on ground A' 10320 mm (33'10")
Max digging depth B 6130 mm (20' 1")
247.1 [269.6] kN
SAE 25200 [27490] kgf
55560 [60610] lbf
286.4 [312.4] kN
ISO 29200 [31850] kgf
64370 [70220] lbf
278.5 [303.8] kN
SAE 28400 [30980] kgf
62610 [68300] lbf
Arm crowd force
291.3 [317.7] kN
ISO 29700 [32400] kgf
65480 [71430] lbf
[ ] : Power boost
1-19
6) ROBEX 520LC-9S
·9.00
9.00 m (29' 6") BOOM
A
A'
F
D
B' E
C
B
8ft
4809S2SP05

Max digging reach on ground A' 16100 mm (52'10")
Max digging depth B 11380 mm (37' 4")
212.8 kN
SAE 21700 kgf
47840 lbf
251.1 kN
ISO 25600 kgf
56440 lbf
107.9 kN
SAE 11000 kgf
24250 lbf
Arm crowd force
110.8 kN
ISO 11300 kgf
24910 lbf
1-20
4. WEIGHT
1) ROBEX 480LC-9S
R480LC-9S
Item
kg lb
Upperstructure assembly 20000 44090
Main frame weld assembly 4430 9770
Engine assembly 940 2070
Main pump assembly 190 420
Main control valve assembly 420 930
Swing motor assembly 230 510
Hydraulic oil tank assembly 450 990
Fuel tank assembly 270 600
7.06 m boom 9200 20280
Counterweight
9.0 m boom 10700 23590
Cab assembly 490 1080
Lower chassis assembly 19000 41890
Track frame weld assembly 7060 15570
Swing bearing 720 1590
Travel motor assembly 440 970
Turning joint 50 110
Track recoil spring 310 680
Idler 250 550
Carrier roller 40 90
Track roller 80 180
Track-chain assembly (600 mm standard triple grouser shoe) 2700 5950
Front attachment assembly (7.06 m boom, 3.38 m arm,
9100 20060
2.15 m3 SAE heaped bucket)
7.06 m boom assembly 3260 7190
3.38 m arm assembly 1630 3590
2.15 m SAE heaped bucket
3 1740 3840
Boom cylinder assembly 830 1830
Arm cylinder assembly 630 1390
Bucket cylinder assembly 300 660
Bucket control rod assembly 155 340
1-21
2) ROBEX 520LC-9S
R520LC-9S
Item
kg lb
Upperstructure assembly 17630 38870
Main frame weld assembly 4430 9770
Engine assembly 940 2070
Main pump assembly 190 420
Main control valve assembly 420 930
Swing motor assembly 230 510
Hydraulic oil tank assembly 450 990
Fuel tank assembly 270 600
7.06 m boom 10200 22500
Counterweight
9.0 m boom 10700 23590
Cab assembly 490 1080
Lower chassis assembly 24100 53130
Lower track frame 2130 4700
Center frame support 8070 17790
Swing bearing 720 1590
Travel motor assembly 440 970
Turning joint 50 110
Track recoil spring 310 680
Idler 250 550
Carrier roller 40 90
Track roller 80 180
Track-chain assembly (600 mm standard triple grouser shoe) 2700 5850
Front attachment assembly (7.06 m boom, 3.38 m arm,
9270 20440
2.15 m3 SAE heaped bucket)
3.38 m arm assembly 1610 3550
2.15 m SAE heaped bucket
3 1740 3840
Boom cylinder assembly 830 1830
Arm cylinder assembly 630 1390
Bucket cylinder assembly 380 840
Bucket control rod assembly 180 400
1-22
5. LIFTING CAPACITIES
1) ROBEX 480LC-9S
(1) 6.55 m (21' 6") boom, 2.40 m (7' 10") arm equipped with 2.15 m3 (SAE heaped) bucket and 600
mm (24") triple grouser shoe and 9200 kg (20280 lb) counterweight.
· : Rating over-front · : Rating over-side or 360 degree
Load radius At max. reach

Load point 3.0 m (10.0 ft) 4.5 m (15.0 ft) 6.0 m (20.0 ft) 7.5 m (25.0 ft) Capacity Reach
height
m (ft)
6.0 m kg *12480 *12480 *11020 9310 *9470 6570 9.15
(20.0 ft) lb *27510 *27510 *24290 20530 *20880 14480 (30.0)
4.5 m kg *18440 *18440 *13960 13040 *11650 9010 *9440 5790 9.65
(15.0 ft) lb *40650 *40650 *30780 28750 *25680 19860 *20810 12760 (31.7)
3.0 m kg *15580 12220 *12420 8610 *9470 5410 9.86
(10.0 ft) lb *34350 26940 *27380 18980 *20880 11930 (32.3)
1.5 m kg *16700 11550 *13000 8240 *9510 5340 9.80
(5.0 ft) lb *36820 25460 *28660 18170 *20970 11770 (32.2)
Ground kg *22790 17330 *16900 11170 *13090 8000 *9480 5590 9.47
Line lb *50240 38210 *37260 24630 *28860 17640 *20900 12320 (31.1)
-1.5 m kg *25320 *25320 *20990 17370 *16060 11060 *12360 7920 *9240 6280 8.83
(-5.0 ft) lb *55820 *55820 *46270 38290 *35410 24380 *27250 17460 *20370 13850 (29.0)
-3.0 m kg *21780 *21780 *17910 17670 *13920 11190 *8390 7800 7.79
(-10.0 ft) lb *48020 *48020 *39480 38960 *30690 24670 *18500 17200 (25.6)
-4.5 m kg *12770 *12770
(-15.0 ft) lb *28150 *28150
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.
1-23
Load
3.0 m (10.0 ft) 4.5 m (15.0 ft) 6.0 m (20.0 ft) 7.5 m (25.0 ft) 9.0 m (30.0 ft) Capacity Reach
point
height m (ft)
6.0 m kg *9220 *9220 *8240 6740 *7490 4800 10.75
(20.0 ft) lb *20330 *20330 *18170 14860 *16510 10580 (35.3)
4.5 m kg *12140 *12140 *10130 9050 *8910 6530 *7530 4320 11.17
(15.0 ft) lb *26760 *26760 *22330 19950 *19640 14400 *16600 9520 (36.6)
3.0 m kg *19830 18930 *14060 12170 *11170 8540 *9450 6260 7470 4070 11.35
(10.0 ft) lb *43720 41730 *31000 26830 *24630 18830 *20830 13800 16470 8970 (37.2)
1.5 m kg *22320 17460 *15610 11360 *12080 8080 *9940 5990 7420 4010 11.30
(5.0 ft) lb *49210 38490 *34410 25040 *26630 17810 *21910 13210 16360 8840 (37.1)
Ground kg *22800 16860 *16390 10850 *12610 7730 *10190 5790 7670 4140 11.02
Line lb *50270 37170 *36130 23920 *27800 17040 *22470 12760 16910 9130 (36.2)
-1.5 m kg *18070 *18070 *21950 16730 *16290 10610 *12600 7550 *10010 5680 *7770 4500 10.49
(-5.0 ft) lb *39840 *39840 *48390 36880 *35910 23390 *27780 16640 *22070 12520 *17130 9920 (34.4)
-3.0 m kg *24350 *24350 *20080 16870 *15280 10610 *11850 7530 *7590 5240 9.66
(-10.0 ft) lb *53680 *53680 *44270 37190 *33690 23390 *26120 16600 *16730 11550 (31.7)
-4.5 m kg *22100 *22100 *16990 *16990 *13120 10820 *9890 7710 *6910 6720 8.43
(-15.0 ft) lb *48720 *48720 *37460 *37460 *28920 23850 *21800 17000 *15230 14820 (27.7)
-6.0 m kg *11930 *11930 *8900 *8900
(-20.0 ft) lb *26300 *26300 *19620 *19620
(3) 9.0 m (29' 6") boom, 5.85 m (19' 2") arm equipped with 1.38 m3 (SAE heaped) bucket and 600 mm
(24") triple grouser shoe and 10700 kg (23590 lb) counterweight.
Load
3.0 m (10.0 ft) 5.0 m (15.0 ft) 7.0 m (25.0 ft) 9.0 m (30.0 ft) 11.0 m (35.0 ft) 13.0 m (45.0 ft) Capacity Reach
point
height m (ft)
10.0 m kg *4310 3590 13.54
(35.0 ft) lb *9500 7910 (44.4)
8.0 m kg *2660 *2660 *4240 2910 14.55
(25.0 ft) lb *5860 *5860 *9350 6420 (47.7)
6.0 m kg *5190 *5190 *4250 3640 *4230 2490 15.20
(20.0 ft) lb *11440 *11440 *9370 8020 *9330 5490 (49.9)
4.0 m kg *6800 *6800 *5710 4950 *4990 3450 *4270 2240 15.55
(15.0 ft) lb *14990 *14990 *12590 10910 *11000 7610 *9410 4940 (51.0)
2.0 m kg *16010 16000 *10420 9730 *7780 6520 *6260 4560 *5280 3230 *4320 2110 15.61
(5.0 ft) lb *35300 35270 *22970 21450 *17150 14370 *13800 10050 *11640 7120 *9520 4650 (51.2)
Ground kg *16790 14290 *11730 8750 *8570 5940 *6720 4210 *5510 3020 *4390 2110 15.38
Line lb *37020 31500 *25860 19290 *18890 13100 *14820 9280 *12150 6660 *9680 4650 (50.5)
-2.0 m kg *10920 *10920 *17330 13650 *12300 8170 *9000 5540 *6970 3950 *5550 2880 *4450 2250 14.87
(-5.0 ft) lb *24070 *24070 *38210 30090 *27120 18010 *19840 12210 *15370 8710 *12240 6350 *9810 4960 (48.8)
-4.0 m kg *14070 *14070 *17370 13550 *12100 7950 *8940 5340 *6850 3820 *4730 2830 *4450 2560 14.02
(-15.0 ft) lb *31020 *31020 *38290 29870 *26680 17530 *19710 11770 *15100 8420 *10430 6240 *9810 5640 (46.0)
-6.0 m kg *17730 *17730 *15490 13780 *11110 7980 *8260 5340 *6160 3850 *4320 3160 12.76
(-20.0 ft) lb *39090 *39090 *34150 30380 *24490 17590 *18210 11770 *13580 8490 *9520 6970 (41.9)
-8.0 m kg *17880 *17880 *12400 *12400 *9090 8270 *6620 5560 *3820 *3820 10.94
(-25.0 ft) lb *39420 *39420 *27340 *27340 *20040 18230 *14590 12260 *8420 *8420 (35.9)
-10.0 m kg *5220 *5220
(-35.0 ft) lb *11510 *11510
1-24
2) ROBEX 520LC-9S
· : Rating over-front · : Rating over-side or 360 degree

Load point 3.0 m (10.0 ft) 4.5 m (15.0 ft) 6.0 m (20.0 ft) 7.5 m (25.0 ft) Capacity Reach
height
m (ft)
7.5 m kg *9680 9450 8.27
(25.0 ft) lb *21340 20830 (27.1)
6.0 m kg *12520 *12520 *10940 10930 *9510 7850 9.07
(20.0 ft) lb *27600 *27600 *24120 24100 *20970 17310 (29.8)
4.5 m kg *18820 *18820 *14060 *14060 *11610 10610 *9480 7010 9.53
(15.0 ft) lb *41490 *41490 *31000 *31000 *25600 23390 *20900 15450 (31.3)
3.0 m kg *15650 14440 *12390 10200 *9510 6620 9.71
(10.0 ft) lb *34500 31830 *27320 22490 *20970 14590 (31.9)
1.5 m kg *16660 13790 *12920 9840 *9540 6600 9.62
(5.0 ft) lb *36730 30400 *28480 21690 *21030 14550 (31.6)
Ground kg *22490 21060 *16730 13430 *12920 9610 *9500 6960 9.26
Line lb *49580 46430 *36880 29610 *28480 21190 *20940 15340 (30.4)
-1.5 m kg *25000 *25000 *20550 *20550 *15740 13350 *12050 9550 *9220 7870 8.59
(-5.0 ft) lb *55120 *55120 *45300 *45300 *34700 29430 *26570 21050 *20330 17350 (28.2)
-3.0 m kg *20980 *20980 *17260 *17260 *13380 *13380 *8260 *8260 7.49
(-10.0 ft) lb *46250 *46250 *38050 *38050 *29500 *29500 *18210 *18210 (24.6)
-4.5 m kg *11720 *11720
(-15.0 ft) lb *25840 *25840
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.
1-25
Load
3.0 m (10.0 ft) 4.5 m (15.0 ft) 6.0 m (20.0 ft) 7.5 m (25.0 ft) 9.0 m (30.0 ft) Capacity Reach
point
height m (ft)
7.5 m kg *7510 6700 10.00
(25.0 ft) lb *16560 14770 (32.8)
6.0 m kg *9190 *9190 *8380 7980 *7470 5810 10.66
(20.0 ft) lb *20260 *20260 *18470 17590 *16470 12810 (35.0)
4.5 m kg *16290 *16290 *12260 *12260 *10120 *10120 *8830 7750 *7510 5290 11.05
(15.0 ft) lb *35910 *35910 *27030 *27030 *22310 *22310 *19470 17090 *16560 11660 (36.3)
3.0 m kg *20110 *20110 *14150 *14150 *11160 10110 *9380 7470 *7590 5040 11.20
(10.0 ft) lb *44330 *44330 *31200 *31200 *24600 22290 *20680 16470 *16730 11110 (36.7)
1.5 m kg *22300 21040 *15600 13560 *12020 9640 *9840 7200 *7680 5000 11.13
(5.0 ft) lb *49160 46390 *34390 29890 *26500 21250 *21690 15870 *16930 11020 (36.5)
Ground kg *22570 20490 *16260 13060 *12490 9310 *10050 7000 *7750 5190 10.82
Line lb *49760 45170 *35850 28790 *27540 20530 *22160 15430 *17090 11440 (35.5)
-1.5 m kg *19050 *19050 *21590 20400 *16040 12850 *12390 9130 *9790 6900 *7740 5670 10.26
(-5.0 ft) lb *42000 *42000 *47600 44970 *35360 28330 *27320 20130 *21580 15210 *17060 12500 (33.7)
-3.0 m kg *25420 *25420 *19580 *19580 *14900 12870 *11510 9130 *7520 6620 9.40
(-10.0 ft) lb *56040 *56040 *43170 *43170 *32850 28370 *25380 20130 *16580 14590 (30.8)
-4.5 m kg *21120 *21120 *16290 *16290 *12560 *12560 *9330 *9330 *6750 *6750 8.11
(-15.0 ft) lb *46560 *46560 *35910 *35910 *27690 *27690 *20570 *20570 *14880 *14880 (26.6)
-6.0 m kg *10870 *10870
(-20.0 ft) lb *23960 *23960
(3) 9.0 m (29' 6") boom, 5.85 m (19' 2") arm equipped with 1.38 m3 (SAE heaped) bucket and 600 mm
(24") triple grouser shoe and 10700 kg (23590 lb) counterweight.
Load
3.0 m (10.0 ft) 5.0 m (15.0 ft) 7.0 m (25.0 ft) 9.0 m (30.0 ft) 11.0 m (35.0 ft) 13.0 m (45.0 ft) Capacity Reach
point
height m (ft)
10.0 m kg *4210 3970 13.66
(35.0 ft) lb *9280 8750 (44.8)
8.0 m kg *4750 *4750 *2800 *2800 *4140 3270 14.63
(25.0 ft) lb *10470 *10470 *6170 *6170 *9130 7210 (48.0)
6.0 m kg *5130 *5130 *4310 4110 *4130 2840 15.25
(20.0 ft) lb *11310 *11310 *9500 9060 *9110 6260 (50.0)
4.0 m kg *8700 *8700 *6790 *6790 *5650 5520 *4910 3900 *4170 2580 15.57
(15.0 ft) lb *19180 *19180 *14970 *14970 *12460 12170 *10820 8600 *9190 5690 (51.1)
2.0 m kg *16120 *16120 *10440 *10440 *7740 7260 *6190 5110 *5190 3670 *4230 2470 15.60
(5.0 ft) lb *35540 *35540 *23020 *23020 *17060 16010 *13650 11270 *11440 8090 *9330 5450 (51.2)
Ground kg *16710 16170 *11660 9800 *8490 6670 *6630 4760 *5400 3460 *4290 2490 15.35
Line lb *36840 35650 *25710 21610 *18720 14700 *14620 10490 *11900 7630 *9460 5490 (50.4)
-2.0 m kg *11290 *11290 *17600 15570 *12130 9250 *8870 6270 *6840 4500 *5410 3320 *4340 2660 14.80
(-5.0 ft) lb *24890 *24890 *38800 34330 *26740 20390 *19550 13820 *15080 9920 *11930 7320 *9570 5860 (48.6)
-4.0 m kg *14480 *14480 *16990 15500 *11860 9040 *8750 6090 *6680 4380 *4170 3290 *4330 3030 13.91
(-15.0 ft) lb *31920 *31920 *37460 34170 *26150 19930 *19290 13430 *14730 9660 *9190 7250 *9550 6680 (45.6)
-6.0 m kg *18200 *18200 *15010 *15010 *10780 9100 *8000 6110 *5900 4430 *4180 3740 12.60
(-20.0 ft) lb *40120 *40120 *33090 *33090 *23770 20060 *17640 13470 *13010 9770 *9220 8250 (41.3)
-8.0 m kg *16860 *16860 *11770 *11770 *8630 *8630 *6210 *6210 *3610 *3610 10.71
(-25.0 ft) lb *37170 *37170 *25950 *25950 *19030 *19030 *13690 *13690 *7960 *7960 (35.1)
1-26
6. BUCKET SELECTION GUIDE
1) ROBEX 480LC-9S
(1) GENERAL BUCKET
1.84 m3 SAE 2.79 m3 SAE

1.00 m3 SAE 1.38 m3 SAE
2.15 m3 SAE 3.03 m3 SAE
heaped bucket heaped bucket
Recommendation
Capacity Width 6.55 m (21' 5") 9.0 m (29' 6")
7.06 m (23' 2") boom
Weight boom boom
SAE CECE Without With 2.4 m arm 2.9 m arm 3.38 m arm 4.0 m arm 2.4 m arm 5.85 m arm
heaped heaped side cutter side cutter (7' 10") (9' 6") (11' 1") (13' 1") (7' 10") (19' 2")
1.00 m3 0.90 m3 915 mm 1065 mm 1220 kg

(1.31 yd3) (1.17 yd3) (36.0") (41.9") (2690 lb)
1.38 m3 1.25 m3 1100 mm 1250 mm 1420 kg

(1.80 yd3) (1.63 yd3) (43.3") (49.2") (3130 lb)
1.84 m3 1.65 m3 1140 mm 1290 mm 1520 kg

(2.41 yd3) (2.16 yd3) (44.9") (50.8") (3350 lb)
2.15 m3 1.92 m3 1415 mm 1565 mm 1740 kg

(2.81 yd3) (2.51 yd3) (55.7") (61.6") (3840 lb)
2.79 m3 2.47 m3 1760 mm 1910 mm 1960 kg

(3.65 yd3) (3.23 yd3) (69.3") (75.2") (4320 lb)
3.03 m3 2.67 m3 1890 mm 2040 mm 2090 kg

(3.96 yd3) (3.49 yd3) (74.4") (80.3") (4610 lb)
Applicable for materials with density of 2000 kg/m3 (3370 lb/yd3) or less
1-27
(2) ROCK-HEAVY DUTY BUCKET
⊙2.20 m3 SAE
⊙2.43 m3 SAE
heaped bucket
Recommendation
Capacity Width 6.55 m (21' 5")
7.06 m (23' 2") boom
Weight boom
SAE CECE Without With 2.4 m arm 2.9 m arm 3.38 m arm 4.0 m arm 2.4 m arm
heaped heaped side cutter side cutter (7' 10") (9' 6") (11' 1") (13' 1") (7' 10")
⊙2.20 m3 1.80 m3 1840 mm 2295 kg

-
(2.88 yd3) (2.35 yd3) (72.4") (5060 lb)
⊙2.43 m3 2.10 m3 1885 mm 2335 kg

-
(3.18 yd3) (2.75 yd3) (74.2") (5150 lb)
⊙ : Rock-heavy duty bucket
1-28
2) ROBEX 520LC-9S
(1) GENERAL BUCKET
★1.38 m3 SAE 2.15 m3 SAE

★1.00 m3 SAE 3.03 m3 SAE
heaped bucket 1.65 m3 SAE 2.79 m3 SAE heaped bucket
Recommendation
Capacity Width 6.55 m 9.0 m
7.06 m (23' 2") boom (21' 6") (29' 6")
Weight boom boom
SAE CECE Without With 2.4 m arm 2.9 m arm 3.38 m arm 4.0 m arm 2.4 m arm 5.85 m arm
heaped heaped side cutter side cutter (7' 10") (9' 6") (11' 1") (13' 1") (7' 10") (19' 2")
1.65 m3 1.48 m3 1140 mm 1290 mm 1520 kg

(2.16 yd3) (1.94 yd3) (44.9") (50.8") (3350 lb)
2.15 m3 1.92 m3 1415 mm 1565 mm 1740 kg

(2.81 yd3) (2.51 yd3) (55.7") (61.6") (3840 lb)
2.79 m3 2.47 m3 1760 mm 1910 mm 1960 kg

(3.65 yd3) (3.23 yd3) (69.3") (75.2") (4320 lb)
3.03 m3 2.67 m3 1890 mm 2040 mm 2090 kg

(3.96 yd3) (3.49 yd3) (74.4") (80.3") (4610 lb)
★1.00 m3 0.90 m3 915 mm 1065 mm 1220 kg

(1.31 yd3) (1.17 yd3) (36.0") (41.9") (2690 lb)
★1.38 m3 1.25 m3 1100 mm 1250 mm 1420 kg

(1.80 yd3) (1.63 yd3) (43.3") (49.2") (3130 lb)
★ : 5.85 m arm only
1-29
(2) HEAVY DUTY AND ROCK-HEAVY DUTY BUCKET
◈2.20 m3 SAE ⊙1.80 m3 SAE ⊙3.20 m3 SAE

heaped bucket heaped bucket heaped bucket
Recommendation
Capacity Width 6.55 m (21' 6")
7.06 m (23' 2") boom
Weight boom
SAE CECE Without With 2.4 m arm 2.9 m arm 3.38 m arm 4.0 m arm 2.4 m arm
heaped heaped side cutter side cutter (7' 10") (9' 6") (11' 1") (13' 1") (7' 10")
◈2.20 m3 1.80 m3 1840 mm 2170 kg

-
(2.88 yd3) (2.35 yd3) (72.4") (4780 lb)
⊙1.80 m3 1.50 m3 1560 mm 2110 kg

-
(2.35 yd3) (1.96 yd3) (61.4") (4650 lb)
⊙3.20 m3 2.80 m3 2095 mm 2900 kg

-
(4.19 yd3) (3.66 yd3) (82.5") (6390 lb)
◈ : Heavy duty bucket

⊙ : Rock-heavy duty bucket
1-30
7. UNDERCARRIAGE
1) ROBEX 480LC-9S
(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) 750 (30) 800 (32) 900 (36)
Operating weight kg (lb) 48100 (106040) 48640 (107230) 48910 (107830) 49180 (108420) 49720 (109610)
R480LC-9S
Ground pressure kgf/cm2 (psi) 0.83 (11.80) 0.72 (10.24) 0.68 (9.67) 0.64 (9.10) 0.57 (8.11)
Overall width mm (ft-in) 3340 (10' 11") 3440 (11' 3") 3490 (11' 5") 3540 (11' 7") 3640 (11' 11")
(3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE

Item Quantity
Carrier rollers 2 EA
Track rollers 9 EA
Track shoes 53 EA
1-31
(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
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
600 mm triple grouser Standard A
700 mm triple grouser Option B
800 mm triple grouser Option C
※ Table 2
Category Applications Applications
Rocky ground, · Travel at low speed on rough ground with large obstacles such as
A river beds, boulders or fallen trees
normal soil
Normal soil, · These shoes cannot be used on rough ground with large obstacles such
soft ground as boulders or fallen trees
B
· Travel at high speed only on flat ground
· Travel slowly at low speed if it is impossible to avoid going over obstacles
Extremely soft gound · Use the shoes only in the conditions that the machine sinks and it is
(swampy ground) impossible to use the shoes of category A or B
· These shoes cannot be used on rough ground with large obstacles such
C
as boulders or fallen trees
1-32
2) ROBEX 520LC-9S
(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 Double grouser
Model Shapes
Shoe width mm (in) 600 (24) 700 (28) 750 (30) 800 (32) 600 (24) 700 (28)
Operating weight kg (lb) 51000 (112430) 51540 (113630) 51810 (114220) 52080 (114820) 51000 (112430) 51540 (113630)
R520LC-9S
Ground pressure kgf/cm2 (psi) 0.88 (12.51) 0.76 (10.81) 0.72 (10.24) 0.67 (9.53) 0.88 (12.51) 0.76 (10.81)
Overall width mm (ft-in) 3540 (11' 7") 3640 (11' 11") 3690 (12' 1") 3740 (12' 3") 3540 (11' 7") 3640 (11' 11")
(3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE

Item Quantity
Carrier rollers 3 EA
Track rollers 9 EA
Track shoes 53 EA
1-33
(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
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
600 mm triple grouser Standard A
600 mm double grouser Option A
700 mm triple grouser, double grouser Option B
※ Table 2
Category Applications Applications
Rocky ground, · Travel at low speed on rough ground with large obstacles such as
A river beds, boulders or fallen trees
normal soil
Normal soil, · These shoes cannot be used on rough ground with large obstacles such
soft ground as boulders or fallen trees
B
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
1-34
8. SPECIFICATIONS FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Cummins QSM 11
Type 4-cycle turbocharged charger air cooled diesel engine
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder bore×stroke 125×147.1 mm (4.92"×5.79")
Piston displacement 10800 cc (659 cu in)
Compression ratio 16.3 : 1
Rated gross horse power (SAE J1995) 353 hp at 1900 rpm (353 Hp / 263 kW at 1900 rpm)
Maximum torque 182.5 kgf·m (1320 lbf·ft) at 1300 rpm
Engine oil quantity 37.85ℓ(10 U.S. gal)
Dry weight 942 kg (2077 lb)
Low idling speed 1950±50 rpm
High idling speed 950+50 rpm
Rated fuel consumption 144 g/Hp·hr at 1900 rpm
Starting motor Delco Remy 42MT (24V-7.2 kW)
Alternator Delco Remy 24V-70A
Battery 2×12V×200Ah
2) MAIN PUMP
Item Specification
Type Variable displacement tandem axis piston pumps
Capacity 2×200 cc/rev
Maximum pressure 330 kgf/cm2 (4690 psi) [360 kgf/cm2 (5120 psi)]
Rated oil flow 2×380ℓ/min (100.4 U.S. gpm / 83.6 U.K. gpm)
Rated speed 1800 rpm
[ ] : Power boost
1-35
3) GEAR PUMP
Item Specification
Type Fixed displacement gear pump single stage
Capacity 16 cc/rev
Maximum pressure 40 kgf/cm2 (570 psi)
Rated oil flow 28.8ℓ/min (7.6 U.S. gpm/6.3 U.K. gpm)
4) MAIN CONTROL VALVE

Specification
Item
R480/520LC-9S R480/520LC-9S Long reach
Type 9 spools
Operating method Hydraulic pilot system
330 kgf/cm2 (4690 psi) 330 kgf/cm2 (4690 psi)
Main relief valve pressure
[360 kgf/cm2 (5120 psi)] -
Boom 380 kgf/cm2 (5400 psi) 380 kgf/cm2 (5400 psi)
Port relief valve pressure Arm 380 kgf/cm2 (5400 psi) 280 kgf/cm2 (3980 psi)
Bucket 380 kgf/cm2 (5400 psi) 280 kgf/cm2 (3980 psi)
[ ]: Power boost
5) SWING MOTOR
Item Specification
Type Fixed displacement axial piston motor
Capacity 151 cc/rev
Relief pressure 285 kgf/cm2 (4050 psi)
Braking system Automatic, spring applied hydraulic released
Braking torque 59 kgf·m (427 lbf·ft)
Brake release pressure 33~50 kgf/cm2 (470~711 psi)
Reduction gear type 2 - stage planetary
6) TRAVEL MOTOR
Item Specification
Type Variable displacement axial piston motor
Relief pressure 330 kgf/cm2 (4690 psi)
Capacity (max / min) 253/158 cc/rev
Reduction gear type 3-stage planetary
Braking system Automatic, spring applied hydraulic released
Brake release pressure (cranking/stroke end) 8.2/9.4 kgf/cm2 (116.6/113.7 psi)
Braking torque 87 kgf·m (629 lbf·ft)
1-36
7) CYLINDER
Item Specification
Bore dia×Rod dia×Stroke Ø170×Ø115×1570 mm
Boom cylinder
Cushion Extend only
Bore dia×Rod dia×Stroke Ø190×Ø130×1820 mm
Arm cylinder
Cushion Extend and retract
Ø160×Ø110×1370 mm (R480LC-9S)
Bore dia×Rod dia×Stroke
Bucket cylinder Ø160×Ø115×1370 mm (R520LC-9S)
Cushion Extend only
※ Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on
the rod surface.
※ Discoloration does not cause any harmful effect on the cylinder performance.
8) SHOE
Item Width Ground pressure Link quantity Overall width
Standard ★600 mm (24") 0.83 kgf/cm2 (11.80 psi) 53 3340 mm (10' 11")
★700 mm (28") 0.72 kgf/cm2 (10.24 psi) 53 3440 mm (11' 3")
R480LC-9S ★750 mm (30") 0.68 kgf/cm2 (9.67 psi) 53 3490 mm (11' 5")
Option
★800 mm (32") 0.64 kgf/cm2 (9.10 psi) 53 3540 mm (11' 7")
★900 mm (36") 0.57 kgf/cm2 (8.11 psi) 53 3640 mm (11' 11")
Standard ★600 mm (24") 0.88 kgf/cm2 (12.51 psi) 53 3540 mm (11' 7")
★700 mm (28") 0.76 kgf/cm2 (10.81 psi) 53 3640 mm (11' 11")
★750 mm (30") 0.72 kgf/cm2 (10.24 psi) 53 3690 mm (12' 1")
R520LC-9S
Option ★800 mm (32") 0.67 kgf/cm2 (9.53 psi) 53 3740 mm (12' 3")
※600 mm (24") 0.88 kgf/cm2 (12.51 psi) 53 3540 mm (11' 7")
※700 mm (28") 0.76 kgf/cm2 (10.81 psi) 53 3640 mm (11' 11")
★ : Triple grouser
※ : Double grouser
1-37
9) BUCKET
Capacity Tooth Width
Item
SAE heaped CECE heaped quantity Without side cutter With side cutter
Standard 2.15 m3 (2.81 yd3) 1.92 m3 (2.51 yd3) 5 1415 mm (55.7") 1565 mm (61.6")
1.00 m3 (1.31 yd3) 0.90 m3 (1.17 yd3) 3 915 mm (36.0") 1065 mm (47.6")
1.38 m3 (1.80 yd3) 1.25 m3 (1.63 yd3) 4 1100 mm (43.3") 1250 mm (49.2")
1.84 m3 (2.41 yd3) 1.65 m3 (2.16 yd3) 5 1140 mm (44.9") 1290 mm (50.8")
R480LC-9S
Option ◎2.20 m3 (2.88 yd3) 1.80 m3 (2.35 yd3) 5 1840 mm (72.4") -
◎2.43 m3 (3.18 yd3) 2.10 m3 (2.75 yd3) 5 1885 mm (74.2") -
2.79 m3 (3.65 yd3) 2.47 m3 (3.23 yd3) 7 1760 mm (69.3") 1910 mm (75.2")
3.03 m3 (3.96 yd3) 2.67 m3 (3.49 yd3) 7 1890 mm (74.4") 2040 mm (80.3")
Standard 2.15 m3 (2.81 yd3) 1.92 m3 (2.51 yd3) 5 1415 mm (55.7") 1565 mm (61.6")
1.65 m3 (2.16 yd3) 1.48 m3 (1.94 yd3) 5 1140 mm (44.9") 1290 mm (50.8")
2.79 m3 (3.65 yd3) 2.47 m3 (3.23 yd3) 5 1760 mm (69.3") 1910 mm (75.2")
3.03 m3 (3.96 yd3) 2.67 m3 (3.49 yd3) 6 1890 mm (74.4") 2040 mm (80.3")
R520LC-9S ★1.00 m3 (1.31 yd3) 0.90 m3 (1.17 yd3) 3 915 mm (36.0") 1065 mm (47.6")
Option
★1.38 m3 (1.80 yd3) 1.25 m3 (1.63 yd3) 5 1100 mm (43.3") 1250 mm (49.2")
◈2.20 m3 (2.88 yd3) 1.80 m3 (2.35 yd3) 5 1840 mm (71.3") -
◎1.80 m3 (2.35 yd3) 1.50 m3 (1.96 yd3) 5 1560 mm (61.4") -
◎3.20 m3 (4.19 yd3) 2.80 m3 (3.66 yd3) 7 2095 mm (82.5") -
★ : 5.85 m arm only
◈ : Heavy duty bucket
◎ : Rock - heavy duty bucket
1-38
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 -20 -10 0 10 20 30 40
ℓ (U.S. gal)
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
SAE 10W
Engine oil pan Engine oil 38 (10.0)
SAE 10W-30
SAE 15W-40
Swing drive 5.0×2 (1.3×2 )

Gear oil SAE 85W-140
10×2
Final drive
(2.6×2)
ISO VG 32
Tank:
262 (69.2)
Hydraulic tank Hydraulic oil ISO VG 46
System:
380 (100)
ISO VG 68
ASTM D975 NO.1

Fuel tank Diesel fuel 621 (164)
ASTM D975 NO.2
NLGI NO.1
Fitting
Grease As required
(Grease nipple) NLGI NO.2
Mixture of
Radiator antifreeze
50 (13.2) Ethylene glycol base permanent type
(Reservoir tank) and water
50 : 50
SAE : Society of Automotive Engineers

API : American Petroleum Institute
ISO : International Organization for Standardization
NLGI : National Lubricating Grease Institute
ASTM : American Society of Testing and Material
1-39
SECTION 2 STRUCTURE AND FUNCTION
Group 1 Pump Device ----------------------------------------------------------------------------------------------------- 2-1

Group 2 Main Control Valve -------------------------------------------------------------------------------------------- 2-22
Group 3 Swing Device ---------------------------------------------------------------------------------------------------- 2-47
Group 4 Travel Device ----------------------------------------------------------------------------------------------------- 2-58
Group 5 RCV Lever --------------------------------------------------------------------------------------------------------- 2-69
Group 6 RCV Pedal --------------------------------------------------------------------------------------------------------- 2-76
SECTION 2 STRUCTURE AND FUNCTION
GROUP 1 PUMP DEVICE
1. STRUCTURE
The pump device consists of main pump, regulator.
Pi1 Psv2
a5
(a1) (a2)
a1
a4
Psv1 PB Pi2
Qmin adjusting screw Qmax adjusting screw Qmin adjusting screw

Regulator Regulator
Psv1
a1 Pi2
(a1)
Dr3
Dr1 PB
Dr2 A1 A2
Dr4
(a2)
a2
B1
Front pump Port block Rear pump
a4 Psv1 A1 a1 a2 A2 Psv2 a5
Port Port name Port size

Front Rear A1,A2 Delivery port SAE6000psi 1"
B1 Suction port SAE2500psi 3"
Dr1~Dr4 Drain port PF 3/4 - 23
Pi1 Pi2
Pi1,Pi2 Pilot port PF 1/4 - 15
Psv1, Psv2 Servo assist port PF 1/4 - 15
a1, a2, a4, a5 Gauge port PF 1/4 - 15
Engine
Pb Gauge port PT 1/8
Dr1,2 B1 Dr3,4
Hydraulic circuit 48092MP01A
2-1
1) MAIN PUMP(1/2)
PUMP
The main pump consists of two piston pumps (front & rear) and valve block.
789 732 532 214 531,548 724 702 792 534 719 901 492 130 706 954 468,728 151 152 113 263 406
535
808
953
886
717
251
406
824
111
774
261
127
710
123
401 490 212 211 153 156 157 490 313 311 124 114 719 466,725 312 956 885 314 012 271 402
492
48092MP02
012 Cylinder block 271 Pump casing 710 O-ring

111 Drive shaft(F) 311 Valve cover(F) 717 O-ring
113 Driven shaft(R) 312 Valve cover(R) 719 O-ring
114 Coupling 313 Valve plate(R) 724 O-ring
123 Roller bearing 314 Valve plate(L) 725 O-ring
124 Needle bearing 401 Hexagon socket bolt 728 O-ring
127 Spacer 402 Hexagon socket bolt 732 O-ring
130 Booster 406 Hexagon socket bolt 774 Oil seal
151 Piston 466 VP Plug 789 Back up ring
152 Shoe 468 VP Plug 792 Back up ring
153 Set plate 490 VP Plug 808 Hexagon head nut
156 Bushing 492 VP Plug 824 Snap ring
157 Cylinder spring 531 Tilting pin 885 Pin
211 Shoe plate 532 Servo piston 886 Spring pin
212 Swash plate 534 Stopper(L) 901 Eye bolt
214 Bushing 535 Stopper(S) 953 Set screw
251 Support plate 548 Feed back pin 954 Set screw
261 Seal cover(F) 702 O-ring 956 Set screw
263 Seal cover(R) 706 O-ring
2-2
2) FRONT REGULATOR (1/2)
412 876 874 Psv A

A 755
897 B 858
612 614
615 FRONT
613 P2
611 Pf
875
A Pi
B
B
Hydraulic circuit
641 728 438
Pi
730 643 708 644 645 646 801 924
SECTION B-B
408 755 541 545 543 722 496 438 413
Psv
Pi Pilot port PF 1/4 - 15
466 Pi Psv Servo assist port PF 1/4 - 15
755
P2 Companion delivery port -
Pf Powershift port -
696 697 735 755 724 725 436
VIEW C
48092RG01
2-3
FRONT REGULATOR (2/2)
655 734 653 654 836 651 652 601 624 629 630 628
641
814
802
C
898
631
627
732
753
733
622
621 623 625 626 887 763 756
SECTION A-A
48092RG02
408 Hexagon socket screw 627 Adjust stem (C) 728 O-ring
412 Hexagon socket screw 628 Adjust screw (C) 730 O-ring
413 Hexagon socket screw 629 Cover (C) 732 O-ring
436 Hexagon socket screw 630 Lock nut 733 O-ring
438 Hexagon socket screw 631 Sleeve, pf 734 O-ring
466 Plug 641 Pilot cover 735 O-ring
496 Plug 642 Adjust screw (QMC) 753 O-ring
541 Seat 643 Pilot piston 755 O-ring
543 Stopper 644 Spring seat (Q) 756 O-ring
545 Steel ball 645 Adjust stem (Q) 763 O-ring
601 Casing 646 Pilot spring 801 Nut
611 Feed back lever 651 Sleeve 802 Nut
612 Lever (1) 652 Spool 814 Snap ring
613 Lever (2) 653 Spring seat 836 Snap ring
614 Center plug 654 Return spring 858 Snap ring
615 Adjust plug 655 Set spring 874 Pin
621 Compensator piston 696 Port cover 875 Pin
622 Piston case 697 Check valve plate 876 Pin
623 Compensator rod 708 O-ring 887 Pin
624 Spring seat (C) 722 O-ring 897 Pin
625 Outer spring 724 O-ring 898 Pin
626 Inner spring 725 O-ring 924 Set screw
2-4
3) REAR REGULATOR (1/2)
728 438
Pi
730 643 708 644 645 646 801 924
SECTION B-B

Pi Pilot port PF 1/4 - 15
Psv Servo assist port PF 1/4 - 15
P2 Companion delivery port -
Pf Powershift port -
48092RG03
2-5
REAR REGULATOR (2/2)
655 734 653 654 836 651 652 601 624 629 630 628
641
814
802
C
898
631
627
732
753
733
622
621 623 625 626 887 763 756
SECTION A-A
48092RG02
079 EPPR valve 626 Inner spring 728 O-ring

407 Hexagon socket screw 627 Adjust stem(C) 730 O-ring
412 Hexagon socket screw 628 Adjust screw(C) 732 O-ring
413 Hexagon socket screw 629 Cover(C) 733 O-ring
436 Hexagon socket screw 630 Lock nut 734 O-ring
438 Hexagon socket screw 631 Sleeve, pf 735 O-ring
482 Plug 641 Pilot cover 753 O-ring
496 Plug 643 Pilot piston 755 O-ring
541 Seat 644 Spring seat(Q) 756 O-ring
543 Stopper 645 Adjust stem(Q) 763 O-ring
545 Steel ball 646 Pilot spring 801 Nut
601 Casing 651 Sleeve 802 Nut
611 Feed back lever 652 Spool 814 Snap ring
612 Lever(1) 653 Spring seat 836 Snap ring
613 Lever(2) 654 Return spring 858 Snap ring
614 Center plug 655 Set spring 874 Pin
615 Adjust plug 697 Check valve plate 875 Pin
621 Compensator piston 699 Port cover 876 Pin
622 Piston case 708 O-ring 887 Pin
623 Compensator rod 722 O-ring 897 Pin
624 Spring seat(C) 724 O-ring 898 Pin
625 Outer spring 725 O-ring 924 Set screw
2-6
4) GEAR PUMP (1/2)
C D
REAR VIEW VIEW A
Port Name Size

B Suction port 1 1/16"-12UN
C Delivery port (fan motor) 7/8"-14UNF
D Delivery port (pilot line) 7/8"-14UNF
48092GP02A
2-7
GEAR PUMP (2/2)
48092GP01
1 Body 1 9 Driven gear 17 Ring

2 Body 2 10 Driven gear 18 Antiextrusion
3 Front cover 11 Screw 19 Antiextrusion
4 Rear cover 12 Washer 20 Flange
5 Thrust plate 13 O-ring 21 Splined connecting shaft
6 Thrust plate 14 Seal 23 Dowel pin
7 Drive gear 15 Seal
8 Drive shaft 16 Shaft seal
2-8
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 (012), piston
shoes (151,152), set plate (153), spherical
bush (156), and cylinder spring (157).
The drive shaft is supported by bearing 313
012
(123,124) at its both ends. 157
The shoe is caulked to the piston to from 156
153
a spherical coupling. It has a pocket to 151
152
relieve thrust force generated by loading
pressure and the take hydraulic balance 111
so that it slides lightly over the shoe plate 211
123
(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. 50072MP01
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 pin 212
(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.
If the servo piston moves to the right and 532 ɷ
left as hydraulic force controlled by the
regulator is admitted to hydraulic chamber
located on both sides of the servo piston, ɷ
the swash plate slides over the swash
plate support via the spherical part of the
tilting pin to change the tilting angle (ɷ)
2-7 (210-7)
2-9
(3) Valve block group
The valve cover group consists of valve
cover (F, 311), valve cover (R, 312), valve 314
312
plate (313, 314), spline coupling (114),
booster (130) and valve plate pin (885). 130
The valve plate having two melon-shaped
114
ports is fixed to the valve cover and feeds 885
311
and collects oil to and from the cylinder
cover.
The oil changed over by the valve plate is
connected to an external pipeline by way
of the valve cover.
Now, if the drive shaft is driven by a prime 885
313
mover (electric motor, engine, etc), it
rotates the cylinder block via a spline 36072MP03
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.
2-10
2) REGULATOR
Regulator consists of the negative flow control, total horse power control and power shift control
function
(1) Negative flow control

By changing the pilot pressure Pi, the
pump tilting angle (delivery flow) is
regulated arbitrarily, as shown in the
figure.
This regulator is of the negative flow
Delivery flow, Q
control in which the delivery flow Q
decreases as the pilot pressure Pi rises.
With this mechanism, when the pilot
pressure corresponding to the flow
required for the work is commanded, the
pump discharges the required flow only,
and so it does not consume the power Pilot pressure, Pi
uselessly.
2-11
Η Flow reducing function
643 654 651 652 613 646
P1 CL
B(E)
874
897
C
A
Pi(from MCV)
875
611
Small diameter
Large diameter Servo piston D 548 chamber
chamber
531
29092MP09A
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.
2-12
Θ Flow increasing function
643 654 651 652 613 646
P1 CL
B(E)
874
897
C
Pi
875
611
Small diameter
Large diameter Servo piston D 548 chamber
chamber
531
29092MP10
As the pilot pressure Pi decreases, the pilot piston (643) moves to the left by the action of the
pilot spring (646) and causes lever 2 (613) to rotate around the fulcrum of point B. Since the pin
(897) is pressed against the large hole section (C) of lever 2 by the action of the return spring
(654) via the spool (652), pin (874), and feedback lever (611), the feedback lever rotates around
the fulcrum of point D as lever 2 rotates, and shifts the spool to the left. Port CL opens a way to
the tank port as the spool moves. This deprives the large diameter section of the servo piston of
pressure, and shifts the servo piston to the left by the discharge pressure P1 in the small
diameter section, resulting in an increase in the flow rate.
As the servo piston moves, point D also moves to the left, the feedback lever rotates around the
fulcrum of point C, and the spool moves to the right till the opening between the spool and sleeve
is closed.
2-13
Ι Adjustment of flow control characteristic
The flow control characteristic can be
adjusted with the adjusting screw.
801
Adjust it by loosening the hexagon nut
924
(801) and by tightening (or loosening)
the hexagonal socket head screw (924).
Tightening the screw shifts the control
chart to the right as shown in the figure.
ö Adjusting values are shown in table.
Adjustment of flow control
characteristic
Speed 2-12 (210-7)
Tightening Flow Flow

amount of control change
adjusting starting amount
screw pressure
Delivery flow, Q
(924) change
amount
(min -1) (Turn) (kgf/cm2) (˶/min)
1800 +1/4 +1.63 +21
Pilot pressure, Pi
2-14
(2) Total horsepower control
The regulator decreases the pump tilting
angle (delivery flow) automatically to limit
the input torque within a certain value with
Delivery flow, Q
a rise in the delivery pressure P1 of the
self pump and the delivery pressure P2 of
the companion pump.
(The input horsepower is constant when
the speed is constant.)
Since the regulator is of the simultaneous
Delivery pressure, (P1+P2)
total horsepower type that operates by the
sum of load pressures of the two pumps
in the tandem double-pump system, the
prime mover is automatically prevented
from being overloaded, irrespective of the
load condition of the two pumps, when
horsepower control is under way.
Since this regulator is of the simultaneous
total horsepower type, it controls the tilting
angles (displacement volumes) of the two
pumps to the same value as represented
by the following equation :
Tin = P1Ýq / 2 ʆ + P2Ýq / 2 ʆ
= (P1+P2)Ýq / 2 ʆ
The horsepower control function is the
same as the flow control function and is
summarized in the following. (For detailed
behaviors of respective parts, refer to the
section of flow control).
2-15
Η Overload preventive function
621 651 652 623 612 601 625 626
P1 CL
B(E)
897
F
P2 P1
875
611
Large diameter Servo piston Small diameter

chamber D chamber
29092MP11
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.
2-16
Θ Flow reset function
621 651 652 623 612 601 625 626
P1 CL
B(E)
897
F
P2 P1
875
611
Large diameter Small diameter

chamber Servo piston D chamber
29092MP12
As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases,
the compensating rod (623) is pushed back by the action of the springs (625 & 626) to rotate
lever 1 (612) around point E. Rotating of lever 1 causes the feedback lever (611) to rotate
around the fulcrum of point D and then the spool (652) to move to the left. As a result, port CL
opens a way to the tank port.
This causes the servo piston to move to the left and the pump's delivery rate to increase.
The movement of the servo piston is transmitted to the spool by the action of the feedback
mechanism to move it till the opening between the spool and sleeve is closed.
2-17
Ι Low tilting angle (low flow) command preferential function
As mentioned above, flow control and horsepower control tilting angle commands are
transmitted to the feedback lever and spool via the large-hole sections (C & F) of levers 1 and 2.
However, since sections C and F have the pins (͚4) protruding from the large hole (͚8), only
the lever lessening the tilting angle contacts the pin (897) ; the hole (͚8) in the lever of a larger
tilting angle command is freed without contacting the pin (897). Such a mechanical selection
method permits preference of the lower tilting angle command of the flow control and
horsepower control.
Κ Adjustment of input horsepower
Since the regulator is of total cumulative horsepower type, adjust the adjusting screws of both
the front and rear pumps, when changing the horsepower set values. The pressure change
values by adjustment are based on two pumps pressurized at the same time, and the values will
be doubled when only one pump is loaded.
a. Adjustment of outer spring

625 626 630 628
the adjusting screw C (628). Tightening
the screw shifts the control chart to the 802
right and increases the input horse-

power 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
627
(627) by N×A turns at first. (A=1.85)
ö Adjusting values are shown in table.
8007A2MP03
Adjustment of outer spring
Speed
Tightening Compensating Input torque
amount of control change
adjusting starting amount
Delivery flow, Q
screw (C) pressure

(627) change
amount
(min -1) (Turn) (kgf/cm2) (kgfÂm)
1800 +1/4 +17.7 +9.7
2-18
b. Adjustment of inner spring
(802) and by tightening (or loosening) 626
802
the adjusting screw QI (627).
Tightening the screw increases the flow
and then the input horsepower as
shown in the figure.
ö Adjusting valves are shown in table.
627
Adjustment of inner spring
Speed
Tightening Flow change Input torque
amount of amount change 8007A2MP04
adjusting (lpm) amount
screw (QI)
(627)
Delivery flow, Q
(min -1) (Turn) (˶/min) (kgfÂm)
1800 +1/4 +18.6 +10.4
2-19
(3) Power shift control
621 651 652 623 612 625 626
P1 CL
B(E)
897
898 F
Pf
P2 P1
611
Large diameter Small diameter

chamber Servo piston D chamber
29092MP13
The set horsepower valve is shifted by varying

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

provided. However, the secondary pressure Pf Pf=
MIN
(power shift pressure) is admitted to the .
Pf=
horsepower control section of each pump M AX
.
regulator through the pump's internal path to
shift it to the same set horsepower level.
This function permits arbitrary setting of the Delivery pressure, (P1+P2)
pump output power, thereby providing the
optimum power level according to the operating condition.
The power shift pressure Pf controls the set horsepower of the pump to a desired level, as shown
in the figure.
As the power shift pressure Pf rises, the compensating rod (623) moves to the right via the pin
(898) and compensating piston (621).
This decreases the pump tilting angle and then the set horsepower in the same way as explained
in the overload preventive function of the horsepower control. On the contrary, the set horsepower
rises as the power shift pressure Pf falls.
2-20
(4) Adjustment of maximum and minimum flows
808
Η Adjustment of maximum flow
Adjust it by loosening the hexagon nut 954
the set screw (954).
The maximum flow only is adjusted
without changing other control
characteristics. 2-19 (1)
Speed Adjustment of max flow spring
Delivery flow, Q
Tightening Flow change
amount of adjusting amount
screw
(954)
(min -1) (Turn) (˶/min)

1800 +1/4 -6.9
Delivery pressure, Pi
Θ Adjustment of minimum flow

Adjust it by loosening the hexagon
nut(808) and by tightening (or loosening)
the hexagonal socket head set screw 808
(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.
Speed Adjustment of min flow spring

Delivery flow, Q
Tightening Flow change

amount of adjusting amount
screw
(953)
(min -1) (Turn) (˶/min)

1800 +1/4 +6.9 Delivery pressure, Pi
2-21
GROUP 2 MAIN CONTROL VALVE
1. STRUCTURE
T4 51 Thread depth
49 67 T3 Mark Port size
(mm)
pc1 DR1, DR2, DR3, pr1, ps1, ps2,
pb5
pc1, pc2, pc6, pa10, pa11, PA, PF 1/4 12
pb9
PT, PP, PH
ps2
49 pb8 pb4 pa1~pa9, pb1~pb9 PF 3/8 14

pa10
A3, A9, B3, B9, P1, P3 PF 1/2 16

49 pb7 pb3
67
pa11
T3, T4 PF 3/4 17
pb6 pb2
ps1 T2 PF 1 21
48
pb1 1 Valve housing (P1) 35 H/D valve assy
2 Valve housing (P2) 36 M/R valve assy
DR3
3 Arm 2 spool assy 37A O/R valve assy
67 48 49 67 4 Bucket spool assy 37B O/R valve assy
VIEW A
5 Boom 1 spool assy 38 Negacon valve assy
6 Travel spool assy 39 Plug assy
49 51
48 62 53 7 TS spool assy 40 Poppet
x
8 Arm 1 spool assy 41 Spring
9 Service spool assy 42 Plug
10 Boom 2 spool assy 43 O-ring
B B
T1 11 Swing spool assy 44 Flange
C C
T2 12A Spool cap-A 45 O-ring
DR1
pb5 pa5 pa9 12B Spool cap-B 46 Plug assy
D pa5 pa9
D B5 A5 A9 B9 13A Spool flange-A 47 Plug assy
pb4 pa4 56 51 pa8 13B Spool flange-B 48 Plug assy
E B4 A4 E pa4 pa8 A8 B8 14 O-ring 49 Plug assy
A 15 Popet 50 Plug assy
pb3 pa3 44 pa7
F B3 A3 F pa3 pa7 A7 B7 16 Spring 51 Socket head bolt
pb2 pa2 pa6
17 Spacer 52 Socket head bolt
G B2 A2 G pa2 pa6 A6 B6 18 O-ring 53 Socket head bolt
PA
pp
19 Back up ring 54 Name plate
pb1 PT pa1
H B1 A1 H PP pa1 P3 20 Spool assy 55 Screw
pr1
P2 21 Spring seat 56 Socket head bolt
I P1 I 22 Spool assy 57 Poppet
23 Spring 58A Service relief valve assy
x
24 O-ring 58B Service relief valve assy
49 47 48 44 52 51 52 44 61 53 25 Plug 59 O-ring
26 Poppet 60 O-ring
49 27 Spring 61 O-ring
28 Poppet 62 Plug
29 Poppet 63 Plug
P1 30 Poppet 64 Flange
31 Spring 65 Socket head bolt
32 Flange 66 O-ring
33 O-ring 67 Socket head bolt
34 Swing priority assy 68 Socket head bolt
48092MC01
2-22
1
B B 2
C C 12A 12A 3
8 14
D ARM 1 D ARM 2
4 50
9
E SERVICE E BUCKET
5
10
F BOOM 2 F BOOM 1
6
11 50
G SWING G TRAVEL
7
6
H TRAVEL H TRAVEL STRAIGHT
13A
12B 14 13B 62 SECTION B-B
I I
14
14
SECTION Z-Z SECTION Y-Y
Z 38 Y
37B 48 24 25 23 21 28 27
59
59
59
61 49
61 20
61 46
60
59 61 22
61 22
49
60 48
27
61 60
21 24 25 23 47 57
61
61 SECTION C-C
61
61
P2 VALVE HOUSING MATING SURFACE
Z Y
48092MC04
2-23
35 33 60 31 65,32 31 33 29 68 64,66 33 32,65 31 29 68 64,66 50 49 33 32,65 31 29 49 45 44
37B 58B 58A
BOOM 2
ARM 1 SERVICE
26
26
49 49 BOOM 1
ARM 2 27 27 BUCKET
SECTION D-D SECTION E-E SECTION F-F

37A 37B
49 33 32,65 31 29 49 33 32,65 31 29 37A 29 31 32,65 33 31 60 33 35
34 56
50 33 50 33 32,65 31 30 39 15 16 17 18,19 44
LEFT BLOCK-P1
36
SWING TRAVEL-LEFT
63
TRAVEL-RIGHT TRAVEL-STRAIGHT
SECTION G-G SECTION H-H SECTION I-I

RIGHT BLOCK-P2
40 41 42 43 37B 49 49 15 16 17 18,19 44
48092MC02
2-24
2. HYDRAULIC CIRCUIT
ps1(Pi1, Pump) ps2(Pi2, Pump)
PS PS
T3 T1 T2 T4
pa11 pa10
DR1
pc1
B5
B9
A5
pb9 A9
pb5
ARM1
pci
pa9 pb9
pa5 ARM2
B4 pa9
A4 B8
A8
P0 pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3 B7
pc2
pb3
BOOM2 pb3
pa3 pb7
B2 BOOM1
A2
pa7
pb2 B6
A6 pa3
DR3
SWING
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
pa1 TRAVEL-RH STRAIGHT
TRAVEL
pr1
P1 PS PT PP PA PH P2
SH PS
48092MC03A
2-25
3. OPERATION
Low pressure Low pressure

relief valve relief valve
ps1 Lc1 Rc1 ps2
Ta pa10 pa11
L2 R2
Ta Bypass cut
spool(R)
Bypass cut
spool(L)
R1
L1
ARM1 ARM2
SERVICE BUCKET
BOOM2 BOOM1
L3 R3 TRAVEL-LH
SWING
TRAVEL
TRAVEL-RH STRAIGHT
L1 R1
P2
P1
L R
48092MC05A
2-26
1) ALL SPOOL NEUTRAL
(1) Neutral passage
Η Oil from pump P1 goes through neutral passage (L1) to the orifice (Lc1) of the low pressure
relief valve and then oil returns to port T1 and T3 via tank passage (Ta).
Θ Oil from pump P2 goes through neutral passage (R1) to the orifice (Rc1) of the low pressure
relief valve and then oil returns to port T1 and T3 via tank passage (Ta).
Ι The pressure of upper chamber (L2), (R2) for the low pressure relief valve flow into pump
through port ps1, ps2 and then controls the discharge of pump P1, P2.
Κ When a large amount of oil flows the neutral passage, the low pressure relief valves is operated.
As a result, the shock pressure of port ps1, ps2 is prevented.
(2) Signal passage
Η Oil from port PP flows into port PT via orifice (Lc3). At the same time, after passing through
passage (Λ) via land (Lc4), oil returns to the tank passage (Ta) via land (Rc3).
Θ Meanwhile, some of oil from port PP flows into port PA via orifice (Lc5) and return to the tank
passage (Ta) from boom 1 spool land (Rc4) via passage (L4, Ξ, R4).
Ι Oil via orifice (Lc6) flows into the tank passage (Ta) from land (Lc7) and return to the tank
passage (Ta) via travel spool land (Rc5) through the passage Κ.
Ta
10
From L3
Arm recycling spool
9 From R3
L5 8
Ta T1
T3
Lc8 Ta
11
ARM1 (Pa5) R4 ARM2

(Pb5) (Pa9) (Pb9)
7
SERVICE (Pa4) BUCKET

(Pb4) (Pa8) (Pb8)
BOOM2 (Pa3) BOOM1

(Pb3) (Pa7) (Pb7)
6 Pc4
SWING (Pa2) TRAVEL

Z (Pb6)
(Pb2) (Pa6)
L4
PA PT
PP Rc3 Rc5
R1
TRAVEL (Pa1) TRAVEL
(Pb1) STRAIGHT
5
L1 P2
P1
L3
4
Ta
Ta
3
L4
PA 2
PT
PP
1
Lc3 Ta
Lc4 Lc5
Lc7 Lc6
DETAIL Z
48092MC06
2-27
2) SINGLE OPERATION
(1) Travel spool
When the RH travel spool is pushed to right by the pilot pressure of port Pb1 the oil discharged
from P1 port flows from the neutral passage (L1) to B1 port.
The oil from port A1 return to the tank via the tank passage (Ta).
When the LH travel spool is pushed to right by the pilot pressure of port Pb6 the oil discharged
from P2 port flows from the neutral passage (R1) to B6 port through the passage S6-1.
At this time, the parallel passage (R3) and passage (S6-1) are to be maintained as same pressure
as poppet (S6-2) is closed. The oil from A6 returns to the tank via the tank passage (Ta).
When the travel spool is pushed to the right by the pilot pressure, the land (Lc4, Rc3) is closed
and the tank passage of the oil discharged from port PP is closed, and then the pressure of PT
port is increased.
Neutral position Rc5
Rc3 TRAVEL-LH
Pb6 Pa6
Ta Ta
R1
Shift position
R3
S6-1
S6-2
B6 A6
B1 A1 PA PT
Lc6
Lc5
Lc3
L3
PP
Neutral position
L1 TRAVEL-RH
Ta Ta
Pb1 Pa1
Shift position Lc4

Ta Lc7
R1 Ta TRAVEL STRAIGHT
48092MC07
2-28
(2) Swing spool
When the swing spool is pushed to the right by the pilot pressure of port Pb2, the neutral
passage (L1) is closed, the oil discharged from pump P1 pushes up the load check valve (S2-1),
passage (S2-2) via parallel passage (L3) and then flows into port B2.
The oil from port A2 return to the tank via the tank passage (Ta).
B2 A2
S2-2
S2-1
SWING
L3
Ta Ta
Pb2 Pa2
L1
Shift position
TRAVEL
Pb6 Pa6
Ta
R3
B6 A6
48092MC08
2-29
3) BOOM SPOOL
(1) Neutral
This valve is providing the anti-drift valve on the cylinder bottom side of boom 1 section. In
neutral, the poppet (AD1) is seated by the pressure of spring chamber (AD5) because the oil
from the port A7 is connection with spring chamber (AD5) via passage (AD2), spool (AD3) and
passage (AD4).
Ta BOOM 2
Ta
Pb3 Pa3
L1
R1 BOOM 1
Pb7 Pa7
Ta
Ta
AD5
AD4
AD3
B7 A7
AD1 AD2
48092MC09
2-30
(2) Boom up (flow summation)
When the boom 1 spool is pushed to the left by the pilot pressure of port Pa7, the neutral
passage (R1) is closed, the oil discharged from pump P2 flows into the port A7 via parallel
passage (R3), the load check valve (S7-1). At the same time, the boom 2 spool is pushed to the
left by the pilot pressure of port Pa3, the neutral passage (L1) is closed, the oil discharged from
pump P1 flows into the port A7 via parallel passage (L3), the load check valve (S3-1) and then
joins to the passage (Μ).
The return oil from port B7 flows into the tank via the tank passage (Ta).
S3-1
L3
BOOM 2
Ta
Pb3 Pa3
Ta
L1
R1 BOOM 1
Pb7 Pa7
Ta
Ta
R3
S7-1
B7 A7
48092MC10
2-31
(3) Boom down (recycling)
When the boom 1 spool is pushed to the right by the pilot pressure of port Pb7, the neutral
passage (R1) is closed, the oil discharged from pump P2 flows into the port B7 via parallel
passage (R3) and the load check valve (S7-1). At the same time, as the port pc2 is pressurizing,
the spool (AD3) of anti-drift valve is pushed up, the pressure of spring chamber (AD5) is released
and the poppet (AD1) is opened and then the oil from port A7 flows into the tank passage (Ta).
Some of returned oil makes the poppet (S7-3) inside boom 1 spool to open and is connected to
the passage (S7-2) and flows together into the port B7.
This prevents the cavitation of cylinder rod side.
S3-1
L3
Ta BOOM 2
Ta
Pb3 Pa3
L1
6
S7-3 BOOM 1
R1
Pb7 Pa7
Ta
Ta AD5
R3
DR2
S7-2 AD4
S7-1
AD3
B7 A7 pc2
AD1 AD2
48092MC11
2-32
4) SERVICE SPOOL
When the service spool is pushed to the left by the pilot pressure of port Pb4, the neutral passage
(L1) is closed, the oil discharged from pump P1 flows into the port B4 via parallel passage (L3), the
load check valve (S4-1) and passage (S4-2).
At the same time, as the port pa10 (see 2-25 page) is pressurizing and the bypass cut spool (R) is
pushed, the oil discharged from pump P2 flows together into the port B7 via passage (11), poppet
(S4-3). The oil returned from port A4 flows into the tank via the tank passage (Ta).
5) BUCKET SPOOL
When the bucket spool is pushed to the left by the pilot pressure of port Pb8, the neutral passage
(R1) is closed, the oil discharged from pump P2 flows into the port B8 via parallel passage (R3),
the load check valve (S8-1) and passage (S8-2).
At the same time, as the port pa11 is pressurizing and the bypass cut spool (R) is pushed, the oil
discharged from pump P1 flows together the passage (S8-2) via passage (7), poppet (S8-3).
The return oil from port A8 flows into the tank via the tank passage (Ta).
B4 A4
S4-1
S4-2
L3
SERVICE
Ta Ta
Pb4 Pa4
L1
11 7
S4-3 S8-3
R1 BUCKET
Pb8 Pa8
Ta Ta
R3
S8-2 S8-1
B8 A8
48092MC12A
2-33
6) ARM SPOOL
(1) Arm out (flow summation)
When the arm 1 spool is pushed to the right by the pilot pressure of port Pb5, the oil discharged
from pump P1 flows into the port B5 via neutral passage (L1), the load check valve (S5-1) and
passage (S5-2).
When the arm 2 spool is pushed to the right by the pilot pressure of port Pb9, the oil discharged
from pump P2 flows together the port B5 the passage (Ρ) via the neutral passage (R1), the load
check valve (S9-1) and passage (S9-2).
The return oil from port A5 flows into the tank via the tank passage (Ta).
B5 A5
S5-1
S5-2
ARM 1
L3 Ta
Pb5 Pa5
L1
10 9
ARM 2
R1
Pb9 Pa9
R3
Ta
S9-2
S9-1
48092MC13
2-34
(2) Arm in (flow summation)
When the arm 1 spool is pushed to the left by the pilot pressure of port Pa5, the oil discharged
from pump P1 flow into the port A5 via neutral passage (L1), the load check valve (S5-1) and
passage (S5-2).
When the arm 2 spool is pushed to the left by the pilot pressure of port Pa9, the oil discharged
from pump P2 flows together into the port A5 via neutral passage (R1), the load check valve
(S9-1) and passage (S9-2).
At the same time, as the port pc1 is pressurizing and the spool (AD3) of anti-drift valve is pushed
down, the pressure of spring chamber (AD5) is released and the poppet (AD1) is opened and
then the oil returned from port B5 flows into the tank passage (Ta) through the passage (S5-4)
inside arm 1 spool to open and is connected to the passage (S5-2) and flows together into the
port A5, the cylinder speed is raised and also is prevents the cavitation of bottom side.
AD3 AD4
AD2
AD1
pc1 B5 A5
S5-1
S5-2
DR1
ARM 1
L3
Ta
Pb5 Pa5
S5-4
10 9
ARM 2
Ta R1
Pb9 Pa9
R3 Ta
S9-2
S9-1
S5-5
S5-3
LC8
Ta
S5-6
48092MC14
2-35
(3) Arm recycling (arm in)
When the arm is at in position, the spool (S5-6) stroke against the passage (S5-2) pressure guided
from the passage (S5-5) is changed according to the opening angle of arm recycling orifice (Lc8).
When the pressure of the passage (S5-2) is high and this stroke is increased, the opening angle
of orifice (Lc8) become large. On the contrary, when the pressure of passage (S5-2) is low, this
stroke is decreased, the opening angle of orifice (Lc8) become small.
Therefore, the flow rate for arm recycling is changed by the pressure in bottom side of arm
cylinder.
AD3 AD4
AD2
AD1
pc1 B5 A5
S5-1
S5-2
DR1
ARM 1
L3
Ta
Pb5 Pa5
S5-4
10 9
ARM 2
Ta R1
Pb9 Pa9
R3 Ta
S9-2
S9-1
S5-5
S5-3
LC8
Ta
S5-6
48092MC14
2-36
7) BYPASS CUT SPOOL
This valve is providing the bypass cut spool at the lowest stream of (upper stream of the low
pressure relief valve) the neutral passage (L1, R1).
As the port pa10 (pa11) is pressurizing and the bypass cut spool (L, R) is pushed, the neutral
passage (L1, R1) is closed. The oil discharged from port P1 flows together into the passage (S8-2,
see 2-33 page) of bucket section via passage (Ν), poppet (S8-3) and the oil discharged from P2
port flows together into the passage (S4-2) of service section via the passage (Ρ) and poppet
(S4-3, see 2-33 page).
8) PARALLEL ORIFICE FOR ARM
The arm 1 and arm 2 section of this valve has orifices in the parallel circuit for arm. These orifices
controls the speed of arm at combined operation.
The parallel circuit of arm 2 section is connected to the passage (S9-2, see 2-35) through orifice
(Rc6) in the edge of the poppet (S9-3) from the parallel passage (R3), the parallel circuit of arm 1
section is connected to the passage (S5-2, see 2-35) through orifice (Lc9) in the edge of the
poppet (S5-8) from the parallel passage (L3).
Bypass cut spool(L)
S5-8
Lc9
L3
L1
S5-2
L2
pa11
11 7
pa10
R2
Rc6 S9-3
R1
R3
Bypass cut spool(R)
48092MC15
2-37
9) RELIEF VALVE
(1) Main relief valve
The oil discharged from P1 port via the poppet (LP) and the oil discharged from P2 port via the
poppet (RP) flow into the main relief valve through the passage (3).
When the main relief valve is operating, the maximum pressure of pump P1, P2 is controlled.
(2) Overload relief valve
Overload relief valves are provided each cylinder ports of boom1, arm1 and bucket. These
prevents the abnormal high pressure of actuators by external force.
Also, when the pressure of cylinder ports create back pressure, this valve opens allowing oil from
tank to cylinder port; and then prevents cavitation.
P1
LP
PH
RP
P2
48092MC16
2-38
4. COMBINED OPERATION
1) TRAVEL COMBINED OPERATION
Η While travel (forward, reverse and pivot turn) and front attachment (except travel section)
functions are operated, the oil discharged from port PP is cut via land (Lc4, Lc7, Rc3, Rc5) and
blocked from signal land except travel section to tank passage (Ta), the pressure of signal
passage rises to the relief setting pressure of pilot pump and the straight travel spool is pushed
to the left by raising of signal pressure and also, the pressure of port PT, PA port rises.
Rc5
Rc3
TRAVEL-RH
Pb6 Pa6
Ta Ta
R1
R3
Lc6
S6-1 PA PT Lc5
S6-2 Lc3
B6 A6
PP
B1 A1 PA PT
SECTION Z1
L3 Z1
PP
Ta TRAVEL-LH
L1
Ta
Pb1 Pa1
Lc4
Ta Ta Lc7
1 2
R1 TRAVEL STRAIGHT
48092MC17
2-39
Θ When the straight travel spool is operated, the oil discharged from port P2 flows into LH travel
section through the neutral passage (L1) and also flows into RH travel section via the neutral
passage (R1) and passage (Θ). The oil discharged from port P2 flows into the parallel passage
(L3) via passage (Η).
Ι In case the load pressure of the section except travel is higher than that of the LH travel section,
the partial oil of discharged from port P1 pushes open the poppet (S6-2) and flows together into
the passage (S6-1) through the orifice at the edge of poppet. The travel (LH, RH) is operated by
the discharged oil from port P1 and the other actuators are operated by the discharged oil from
port P2. Thus, when travel and front attachment functions are operated simultaneously, keeps
the straight travel.
Rc5
Rc3
TRAVEL-RH
Pb6 Pa6
Ta Ta
R1
R3
Lc6
S6-1 PA PT Lc5
S6-2 Lc3
B6 A6
PP
B1 A1 PA PT
SECTION Z1
L3 Z1
PP
Ta TRAVEL-LH
L1
Ta
Pb1 Pa1
Lc4
Ta Ta Lc7
1 2
R1 TRAVEL STRAIGHT
48092MC17
2-40
2) SWING COMBINED OPERATION
When swing and boom up functions are operated, the poppet (S2-1) is seated by pressure of port
pc6 and the poppet (S2-3) only opened and the supply pressure of the parallel passage (L3) is
rises by orifice (S2-4).
As a result, boom and swing simultaneous operation is ensured even if lower load of swing section.
pc6
DR3
S2-4 S2-3
S2-2 S2-1
L3 SWING
Ta
Ta
L1
48092MC18
2-41
5. ANTI-DRIFT VALVE
The anti-drift valve is provided the boom bottom and arm rod side of cylinder port for prevention of
self drifting by boom weight or bucket loads.
1) WHEN NEUTRAL
The oil from cylinder port flows into spring chamber (AD5) via passage (AD2), the around of spool
(AD3) and passage (AD4).
Because of the difference of poppet area and spring force, the poppet (AD1) is seated certainly.
2) WHEN BOOM UP OR ARM OUT
The oil from pump flows into cylinder by pushes open the poppet (AD1).
3) WHEN BOOM DOWN OR ARM IN
The spool (AD3) is pushed down by the pressure of pc1 (pc2).
Then the oil of spring chamber (AD5) flows into the drain port DR1 (DR2) and pushes open the
poppet (AD1).
As a result, the oil from the cylinder port returns to tank passage (Ta).
AD3
AD2
AD4
AD5
B5 (A7)
AD1
NEUTRAL
AD1 AD3 AD5

AD5
B5 (A7) pc1 B5 (A7)
(pc2)
DR1
(DR2)
AD1
ARM OUT ARM IN

(BOOM UP) (BOOM DOWN)
48092MC19
2-42
6. RELIEF VALVE OPERATION
1) MAIN RELIEF VALVE
(1) This relief valve is built-in between the neutral passage (HP) and low pressure passage (LP), and
the pressure oil fills up chamber (D) inside via orifice of main poppet (C).
Thus the sleeve (E) and the main poppet (C) are securely seated by difference area of A an B.
B
E
LP
HP
A
C D
48092MC20
(2) When the pressure in neutral passage(HP) reaches the setting force of spring, pilot poppet(F) is
opened.
The oil flows around poppet and into the low pressure passage(LP) via hole(G).
G
LP
HP
F
48092MC21
(3) When above flow is formed, the pilot poppet is opened; the pressure of chamber(D) drops, the
main poppet(C) is opened and then the oil directly flows into the low pressure passage(LP).
LP
HP
C D
48092MC22
(4) High pressure setting pilot signal(Pi) : ON

The piston(H) moves to left by pilot pressure(Pi); set pressure of spring rises, making high
pressure setting.
H I
LP
HP Pi
48092MC23
2-43
2) OVERLOAD RELIEF VALVE
(1) This relief valve is built-in the cylinder port (HP) and the low pressure (LP), and the pressure oil
fills up chamber (G) inside via hole of piston (C).
Thus the sleeve (K) and the main poppet (D) are securely seated by difference area of A and B.
K
B
LP
HP
A
C D G
48092MC24
(2) When the pressure in cylinder port (HP) reaches the setting force of spring, the pilot poppet (E) is
opened.
The oil flows around poppet and into the low pressure passage (LP) via hole (H).
E H
LP
HP
48092MC25
(3) When above flow is formed, the pilot poppet (E) is opened.
The pressure drops before and behind orifice (I); piston (C) moves to right and the piston (C) is
seated at the tip of poppet (E).
LP
HP
I 48092MC26
2-44
(4) The oil flow from the high pressure passage (HP) to the poppet (D) behind is only around poppet
and orifice (F); then the high pressure passage (HP) is higher than the poppet (D) behind pressure.
Thus the poppet (D) is pushed open and the oil directly flows into low pressure passage(LP).
F
LP
HP
48092MC27
(5) Make up operation

This relief valve is built-in the cylinder port (HP) and the low pressure passage (LP), and the
pressure oil fills up chamber (G) inside via hole of piston (C).
Thus the sleeve (K) and the main poppet (D) are securely seated by difference area of A and B.
LP
HP
48092MC28
2-45
3) LOW PRESSURE RELIEF VALVE
(1) When pump does not operational
"LP"
"HP" 4PS
(5PS)
"LP" 48092MC29
(2) When spool neutral

The neutral passage (HP) oil flows into the low pressure passage (LP) via signal orifice (S).
The signal port 4Ps (5Ps) pressure is raise by negative control orifice (A).
"LP"
"HP" 4PS
(5PS)
A "LP" 48092MC30
(3) Operation of low pressure relief

When the oil pressure neutral passage (HP) reaches the setting force of spring, the poppet is
pushes open; the oil directly flows through passage (HP) to passage (LP) in order to prevent
abnormal pressure.
"LP"
"HP" 4PS
(5PS)
"LP" C
B 48092MC31
2-46
GROUP 3 SWING DEVICE
1. STRUCTURE
Swing device consists swing motor, swing reduction gear.
Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve.
Reduction gear grease

supply port(PT 1/8)
Time delay valve
Reduction gear oil SH
Relief valve PG2
drain port(PT 3/8) Mu PG1
SH Au DR
PG1
PG2 GB
GA
Reduction gear Level gauge & A B

air bleed port(PT 1/8) oil supply port
Reduction gear Swing motor
PG2 4809S2SM01
SH
PG1
A, B Main port ͚20
Dr Drain port PF 1/2
Au Mu Make up port PF 1
GA,GB Gauge port PF 1/4
Au Air vent port PF 1/4
PG 1, 2 Brake release port PF 1/4
Dr SH Brake pilot port PF 1/4
GB GA
B Mu A
Hydraulic circuit
2-47
1) SWING MOTOR
42
DETAIL K
33
7 6 5 12 11 10 17 20 8 23 37 39 31 34 38 47
28
27
29
26
30
K
43
46
45
44
2 3 4 1 9 14 13 16 15 18 19 24 21 22 40 25 35 32
41 36 4809S2SM02
1 Body 17 Brake piston 33 Time delay valve

2 Oil seal 18 O-ring 34 Wrench bolt
3 Roller bearing 19 O-ring 35 Plug
4 Snap ring 20 Spring 36 O-ring
5 Shaft 21 Rear cover 37 Plug
6 Bushing 22 Needle bearing 38 Plug
7 Stop ring 23 Pin 39 Plug
8 Pin 24 Valve plate 40 Name plate
9 Shoe plate 25 Wrench bolt 41 Rivet
10 Cylinder block 26 Plug 42 Level gauge
11 Spring 27 Back up ring 43 Plug
12 Ball guide 28 O-ring 44 O-ring
13 Set plate 29 Spring 45 O-ring
14 Piston assy 30 Check 46 Back up ring
15 Friction plate 31 Relief valve 47 Plug
16 Plate 32 Anti-inversion valve
2-48
2) REDUCTION GEAR
35 34 33 29 30 32 31 38 37 27 28 14
15 13 19 17 18 16 20 21
36
24
23
22
1110
7 12 9 8 12 13 25
2 3 1 38 4 5 26 6
48092SM03
1 Casing 14 Carrier assy 1 27 Thrust plate 3

2 Drive shaft 15 Carrier 1 28 Stop ring
3 Roller bearing 16 Planet gear 1 29 Pinion gear
4 Oil seal 17 Pin 1 30 Spacer
5 Roller bearing 18 Needle cage 31 Cover plate
6 Carrier assy 2 19 Side plate 1 32 Hexagon bolt
7 Carrier 2 20 Side plate 2 33 Lock plate
8 Planet gear 2 21 Stop ring 34 Hexagon bolt
9 Pin assy 2 22 Sun gear 2 35 Lock washer
10 Pin 2 23 Sun gear 1 36 Socket bolt
11 Bush 2 24 Side plate 3 37 Plug
12 Thrust washer 25 Ring gear 38 Plug
13 Spring pin 26 Knock pin
2-49
2. PRINCIPLE OF DRIVING
2.1 Generating the turning force
The high hydraulic supplied from a hydraulic pump flows into a cylinder (10) through valve casing of
motor (21), and valve plate (24).
The high hydraulic is built as flowing on one side of Y-Y line connected by the upper and lower sides of
piston (14).
The high hydraulic can generate the force, F1=PÝA (P : supplied pressure, A : water pressure area),
like following pictures, working on a piston.
This force, F1, is divided as N1 thrust partial pressure and W1 radial partial pressure, in case of the
plate of a tilt angle, ɷ.
W1 generates torque, T=W1ÝR1, for Y-Y line connected by the upper and lower sides of the piston
as following pictures.
The sum of torque (ɨW1ÝR1), generated from each piston (4~5 pieces) on the side of a high
hydraulic, generates the turning force.
This torque transfers the turning force to a cylinder (10) through a piston; because a cylinder is
combined with a turning axis and spline, a turning axis rotates and a turning force is sent.
W1 Piston
Cylinder
R1
N1
O A
f1 F1 P
W1
High Y Low
pressure pressure
2907A2TM07
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.
Relief valve
Make up check valve Make up check valve
A B
21092SM04
2-51
3) RELIEF VALVE
11 1 Body
2 Seat
10
5 3 Plunger
4 Spring
6 5 Adjusting screw
7
6 Piston
7 Bushing
8
8 Spring seat
9
9 Shim
12
10 O-ring
1 11 Back up ring
3 12 O-ring
4
2
14007A2SM05
(1) Construction of relief valve

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

Figure illustrates how the pressure acting
on the relief valve is related to its rising P P=pressure, T=time
process. Here is given the function, Ps
referring to the figure following page.
4
P2
3
P1
T
1
2-48(2)
2-52
Η Ports (P,R) at tank pressure.
A2 m h n g
A1
P
14007A2SM06
Θ When hydraulic oil pressure (PÝA1) reaches the preset force (FSP) of spring (4), the plunger (3)
moves to the right as shown.
P1ÝA1=Fsp+PgÝA2
Fsp+PgÝA2
P1=
A1
4 g
P=P1
14007A2SM07
2-53
Ι The oil flow chamber g via orifice m and n. When the pressure of chamber g reaches the preset
force (FSP) of spring (4), the piston (6) moves left and stop the piston (6) hits the bottom of bushing
(7).
4 m n g
P=P2
7 6
14007A2SM08
Κ When piston (6) hits the bottom of bushing (7), it stops moving to the left any further. As the
result, the pressure in chamber (g) equals (Ps).
PsÝA1=Fsp+PsÝA2
Fsp
Ps=
A1-A2
P=Ps
7 6 g
14007A2SM09
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

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

This is function as a parking brake only when all of the RCV lever (except travel pedal) are not
operated.
Η Brake assembly
Circumferential rotation of separate plate
(16) is constrained by the groove located
at housing (1). When housing is
20
pressed down by brake spring (20)
through friction plate (15), separate plate 10
(16) and brake piston (17), friction force 17
occurs there. 16
Cylinder block (10) is constrained by this 15
friction force and brake acts, while brake 1
Groove
releases when hydraulic force exceeds
spring force.
21092SM15
1 Housing 16 Separate plate

10 Cylinder block 17 Brake piston
15 Friction plate 20 Spring
2-55
Θ Operating principle
a. When one of the RCV lever (1) is set to the operation position, the each spool is shifted to left
or right and the pilot oil flow is blocked. Then the pilot oil go to SH of the time delay valve (3).
This pressure moves spool (5) to the leftward against the force of the spring(8), so pilot pump
charged oil (P3) goes to the chamber G through port PG.
This pressure is applied to move the piston (16) to the upward against the force of the spring
(19). Thus, it releases the brake force.
35
20 5
17 G SH
PG
1 RCV lever
2 Main control valve
3 Time delay valve
5 Spool P3
8 Spring
16 Brake piston 2
19 Brake spring
48092SM04
2-56
b. When all of the RCV lever (1) are set the neutral position, the spool (5) returns to right.
Then, the piston (16) is moved lower by spring force and the return oil from the chamber G
flows back to tank port.
At this time, the brake works.
35
20 5
17 G SH
PG
1 RCV lever
3 Time delay valve
5 Spool P3
8 Spring
16 Brake piston 2
19 Brake spring
48092SM05
2-57
GROUP 4 TRAVEL DEVICE
1. CONSTRUCTION
Travel device consists travel motor and gear box.
Travel motor includes brake valve, parking brake and high/low speed changeover mechanism.
A Travelo motor Reduction gear
P1
P
A
P2
B D
Gi
L
Filling
Oil level
Oil drain
Go
VIEW A
4809S2TM01

D
A, B Main port SAE 5000 psi 1 1/4"
HIGH
P1, P2 Pressure gauge port PF 1/4
LOW
P Pilot port PF 1/4
P D Drain port PF 1/2
L Level gauge PF 1/2
Gi Gear oil filling port PF 1/2
P1 P2
Go Gear oil drain port PF 1/2
AB
HYDRAULIC CIRCUIT
2-58
2. STRUCTURE
1) TRAVEL MOTOR (1/2)
26
1
41
73
98
99
72
45
2
50 56
3
66 6
65 5
402 4
83 404 7
82 405 13
68 401 9
10
74 408 11
414 8
52 403
43 54 13 12
407
409
405
406 14
412
413
500
501
4809S2TM02
1 Rear flange 43 Socket bolt 401 Plunger

2 Spool 45 PT Plug 402 Seat
3 Poppet 50 Needle bearing 403 Body
4 Plug 52 RO Plug 404 Back up ring
5 Check spring 54 Plug 405 O-ring
6 Main spring 56 Plug 406 O-ring
7 Washer 65 Spool 407 Retainer
8 Seat 66 Spring 408 Spring
9 Steel ball 68 Steel ball 409 Piston
10 Spring 72 Orifice 412 Adjust plug
11 Screw 73 Orifice 413 Lock nut
12 Cover 74 O-ring 414 Shim
13 O-ring 82 Plug 500 Reducing valve
14 Socket bolt 83 O-ring 501 Cover
26 O-ring 98 Name plate
41 Valve plate pin 99 Rivet screw
2-59
TRAVEL MOTOR (2/2)
208
204
214
215 213
216
212
209
202
249
267 236
203
206
210
261
207 262
205
233
230
231
71
232
237
480H2TM03
71 Orifice 209 Timing plate 231 O-ring

202 Drive shaft 210 Spring 232 Oil seal
203 Swash plate 212 Piston 233 O-ring
204 Cylinder block 213 Spring 236 Snap ring
205 Piston 214 Spring 237 Snap ring
206 Shoe 215 Friction plate 249 Roller bearing
207 Retainer plate 216 Mating plate 267 Pivot
208 Thrust ball 230 O-ring
2-60
2) REDUCTION GEAR
107
109
108
105
102 125
152
105 150
103 120 184
135
130 131
133 132
101 135
111 112
127
126
123 121
122 185
124
126
110
182
183
145
144
141 180
142
144
181 114
145
143 170
115
113
140
162
151
160
151 480H2TM04
101 Spindle 122 Needle bearing 144 Plate

102 Hub 123 Bushing 145 Snap ring
103 Seat 124 Shaft No. 3 150 Sun gear No.3
105 Angular bearing 125 Spring pin 151 Thrust ring
107 Socket bolt 126 Thrust washer 152 Clip
108 O-ring 127 Spring pin 160 Sun gear No.2
109 Piece 130 Carrier No. 2 162 Clip
110 Coupling 131 Planetary gear No.2 170 Drive gear
111 Socket bolt 132 Needle bearing 180 Cover
112 Thrust plate 133 Shaft No.2 181 Thrust washer
113 Coupling 135 Thrust washer 182 Plug
114 Ring gear 140 Carrier No.1 183 O-ring
115 Snap ring 141 Planetary gear No.1 184 Thrust ring
120 Carrier No. 3 142 Needle bearing 185 Socket bolt
121 Planetary gear No. 3 143 Ring
2-61
3. FUNCTION OF HYDRAULIC MOTOR
1) TURNING FORCE GENERATION
The pressure oil delivered from the hydraulic pump flows to rear flange of the motor, passes
through the brake valve mechanism, and is introduced into cylinder block (204) via timing plate
(209).
This oil constructively introduced only to one side of Y1-Y2 connecting the upper and lower dead
points of stroke of piston (205). The pressurized oil fed to one side in cylinder block (204) pushes
each piston (205) (four or five) and generates a force F(kgf) = P(kgf/cm2) × A (cm2).
This force acts on swash plate (203), and is resolves into components (F2 and F3) because swash
α°) with the axis of drive shaft (202).
plate (203) is fixed at an angle (α°
Radial component (F3) generates respective torques (T=F3 × RI) for (Y1)-(Y2). This residual of
torque (T = S (F3 × RI)) rotates cylinder block (204) via piston (205). Cylinder block (204) is spline
coupled with drive shaft (202).
So the drive shaft (202) rotates and the torque is transmitted.
Y1
Swash plate(203)
F3 Piston(206)
Cylinder block(204)
R1
F2
O α° A
F1 P
F3
Low pressure High pressure

Y2
4809S2TM03
2-62
2) FUNCTION OF RELIEF VALVE
Room D
Room C
Room A
Room B
A1
Orifice A Piston Room g A2 Poppet A
4809S2TM04
(1) The pressured oil that flowed in A room by the neutral position of counter balance spool is applied
to the seat's room B at once. The poppet A is pushed on the left side by being that the room's
pressured oil is forced as much as F1=A1 × P1 on section A1.
At the moment, the pressured oil goes through the orifice of poppet A.
This oil goes into the room C and goes into the room g through the orifice A then the piston is
moved on the right side. The piston is reached to the stroke end, the oil has no way to go
therefore.
A resultant force on force (F2=A2 × P2) pushing section A2 by the pressured oil and spring force
is more than the force (F1=A1 × P1) working on section A1 of the poppet A.
During the piston is moved on the right side, the pressure of oil is kept uniformly.
(2) When the pressure of oil in the room B is higher then [F2 + spring force] the poppet opens and
the pressured oil goes into the room D as a relief function.
In this way, by controlling the pressure in room A, B in two steps, the hydraulic motor is smoothly
braked and to a stop.
2-63
3) FUNCTION BRAKE
101 212 213
CB
202
RF
204 500
215 216 71
Counter balance spool Reducing valve

CB 500
P1 D
HIGH
Position 1
A LOW
Position 2 B
Position 3
P2 P
71
Brake room Orifice B 4809S2TM05
The brake is released by applying to the brake piston the pressure led through the built in
counterbalance spool subassembly. With no pressure working , the brake force is always ensured.
Brake force is generated from friction plate (215) which is combined with cylinder block (204) as
spline, separate plate (216) which is embedded in spindle (101), spindle (101), parking piston
(212).
Without pressure being applied to the brake piston, the brake piston is pushed by fourteen brake
spring (213), and the friction plate and separation plate are held between the brake and spindle.
This holding force functions as the friction force. This friction force restrains the shaft (202) spline
coupled with the cylinder block, and this function is the brake.
Normal
ormal travelling (at position 1 or 3)
During normal travelling, the pressured oil coming through the counter balance spool is applied to
the brake room to release brake, after was decompressed at a reducing valve. At this time, the
slight hydraulic oil is drained through the orifice B (71), but the pressure at brake room releases the
braking by overcoming the spring force. Cause the pressure at brake room is always applied from
the counter balance valve.
Neutral
eutral (at position 2)
The brake room's pressure is decreased by the blocked oil-passage, and the brake is generated by
being that the brake spring force is much than the brake room's pressure. At this time, the hydraulic
oil in the brake room is drained through the orifice B (71), then the spool returns to the neutral
position. When the condition changes from travelling to stop, the brake runs in order of precedence
after stopping motor, so it is preventing the damage of friction plate.
2-64
4) RELEASING METHOD OF BRAKE
In releasing the brake without applying the brake releasing pressure, follow the procedures shown
below.
Details of work Tools

Remove two plugs (45) from the rear flange (RF).
Socket
(For their position, see the attached installation dimension.)
Wrench
Insert in there, tighten an M10 screw of 135 mm in length into a tapped hole of the
6 mm
brake piston. Then the condition having the brake released pressure is attained and
8 mm
the brake release pressure is attained and the brake is released.
ö Even with the negative brake released, the hydraulic motor will not run.
When it is difficult to generate the working pressure due to failure of the pump or so, and the whole
machine is to be pulled for transportation without removing the hydraulic motor, connect pressure
measurement ports Am, Bm with a short hose or something.
Then the machine can be pulled slowly.
45
RF
4809S2TM08
2-65
5) FUNCTION OF COUNTER BALANCE VALVE
AM P BM
L K
D' C'
N
DH CH M
1' 1
F Dv Cv E
G' G
AV BV
480H2TM05
Suppose port Bv is connected to the hydraulic pump and port Av, to the tank.
The oil supplied from the hydraulic pump passes through Bv, Cv and C in sequence, pushes up the
poppet of the check valve, passes through K to port Bm, and is supplied to the hydraulic motor to
turn it.
Therefore, the pump discharge oil pressure incerases, and the pressure is led via passage G to
spring room E and via the ball check valve to dumping room M. When the pressure in rooms E and
M exceeds the value equivalent to the force of the spring which holds the spool at its neutral
position, the spool begins to move left. Since the working oil in room N flows into room F via
throuttle 1 or clearance 2 and that in room F is discharged via passage G through port Av to the
tank, the spool moves left to have passage L-Dm-D-Dv composed. In addition, passage Cv-H-P is
also composed, and the pump discharge pressure in port Bv is led to port P.
Because of the throttle or clearance provided for the working oil flow from room N, this changeover
motion of the spool is comparatively slow. When the pump discharge pressure is higher, the spool
movement is larger and above opening area of the spool is larger.
When the pump discharge pressure falls, pressures in rooms E and M fall and the spool will move
right due to the spring on the room F side.
Since working oil in room M flows to room E via throttle 1 and that in room E, to port Bv via
passage G, the spool moves right.
When the presssure at port Bv, falls down to eh tank pressure, the pressure in room E also falls to
the tank pressure and becomes equal to that in room F, and so the spool returns to neutral position.
2-66
6) FUNCTION OF HIGH/LOW SPEED CHANGEOVER
As a supporting mechanism for the swash plate (203) on which the shoe (262) slide, the pillar
system is adopted to support the load with semi-cylindrical sliding bearings provided at both end of
the mechanism. The capacity is changed by changing the tilting angle of this swash plate.
This is a mechanism that swash plate was pushed by tilting piston, and the tilting angle of the
swash plate is decided in two positions ("large" and "small") by controlling has the flows to and
from these piston rooms with the displacement changeover valve section.
(1) Low speed - at pilot pressure of less than 20 kgf/cm2

When no pilot pressure is supplied from (D) (at a pressure of 20 kgf/cm2 or less), valve (65) is
pressed toward the top by the force of spring (66) and (A) port or (B) port, the pressurized oil
supply port (C) is shut off, and oil in chamber (P) is released into the motor case via valve (65).
Consequently, swash plate (203) is tilted at a maximum angle (Θ1) and the piston displacement
of hydraulic motor becomes maximum, thus leading to low-speed rotation.
A B
01
Pilot(D)
A 65 X
B 66
203 262 261
C P
Drain
4809S2TM06
(2) High speed - at pilot pressure of 20 kgf/cm2 or more.

When a pilot pressure is supplied from port (D) (at a pressure of 20 kgf/cm2 or more), the
pressure overcomes the force of spring (66) and (A) port or (B) port of 2 speed spool (65) is
pressed toward the down.
The pressurized oil at supoly port (C) is then introduced into chamber (P) via 2 speed spool (65).
Piston (261) pushed up swash plate (203) until it touches side X of the spindle.
At this time, swash plate (203) is tilted at a minimum angle (Θ2) and the piston displacement of
hydraulic motor becomes minimum, thus leading to high-speed rotation.
A B 02
X
Pilot(D)
A 65
B 66
203 262 261
C P
Drain
4809S2TM07
2-67
7) WORKING PRINCIPLE OF REDUCTION GEAR
R R C
C3 C2 C1
P3 P2 P1
S3 S2
S1
4809S2TM09
The reduction gear is composed of a three-stage planetary gear mechanism shown in the following
figure. Since the sun gear is designed to have a floating mechanism, errors of the gears and carrier
pin hole pitches will not affect the gear's lives heavily.
The input rotation of the hydraulic motor is transmitted to the drive gear (D) and this drives the No. 1
planetary gears (P1). This No.1 planetary gears (P1) drives the cover gear (C) with the same force
as the meshing tangential force with the drive gear (D), and also the No.1 carrier (C1) with the
same force as the meshing reaction force.
In other words, the No.1 planetary gears (P1) revole rotating. This rotation of the No.1 carrier (C1)
becomes the output of the 1st stage, and is transmitted directly to No.2 sun gear (S2). (No.1 carrier
is spline-coupled with No.2 sun gear.)
Similarly the revolution of the No.2 planetary gears (P2) are transmitted via No.2 carrier (C2) to the
No.3 sun gear (S3). Since the No.3 carrier (C3) supporting the No.3 planetary gears (P3) are fixed,
the No.3 planetary gears (P3) do not revolve, but rotates to drive ring gear (R).
Therefore, the rotating case is driven by the overall driving torque of the cover and ring gear.
This reduction ratio is expressed as shown below :
(ZD + ZC)(ZS2 + ZR)(ZS3 + ZR)

I= -1
ZD × ZS2 × ZS3
ZD : Teeth of the drive gear

ZC : Teeth of the cover gear
ZS2 : Teeth of the No.2 sun gear
ZS3 : Teeth of the No.3 sun gear
ZR : Teeth of the ring gear
The direction of rotation is reverse to that of the input shaft.
2-68
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 Switches
No. LH RH
5 One touch decel Horn
6 Power boost Breaker
5
B
6
19
25
Single
operation Simultaneous
operation DETAIL B
Tilted direction of
handle(RH)
1 P
T Tilted direction of
connector(LH, RH)
2 3
Tilted direction of
handle(LH)
VIEW A
A
Port LH RH Port size
P Pilot oil inlet port Pilot oil inlet port
P T
T Pilot oil return port Pilot oil return port
1 Left swing port Bucket out port
PF 1/4
2 Arm in port Boom down port
3 Right swing port Bucket in port
4 Arm out port Boom up port
1 3 2 4
Hydraulic circuit
21092RL01
2-69
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 (4), spring (6) for setting secondary pres-
sure, return spring (10), stopper (8), spring seat (7, 13) and shim (5). The spring for setting the sec-
ondary pressure has been generally so preset that the secondary pressure is 5 to 20.5 kgf/cm2
(depending on the type). The spool is pushed against the push rod (9, 11) by the return spring.
When the push rod is pushed down by tilting the handle, the spring seat comes down simultaneously
and changes setting of the secondary pressure spring.
2-70
CROSS SECTION
23
25
26
24
22
21
9
19
20 16
17,27
18
14
11 15
8
7
28 10
6
13
5
12
4
3
1
2
Port 1,3 Port 2,4
32092RL01
1 Case 8 Stopper 15 O-ring 22 Lock nut

2 Plug 9 Push rod 16 Rod seal 23 Handle assembly
3 Bushing 10 Spring 17 Plate 24 Handle bar
4 Spool 11 Push rod 18 Boot 25 Nut
5 Shim 12 Spring 19 Joint assembly 26 Boot
6 Spring 13 Spring seat 20 Swash plate 27 Spring pin
7 Spring seat 14 Plug 21 Adjusting nut 28 Bushing
2-71
2. FUNCTIONS
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and apply-
ing the output pressure (secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following ele-
ments.
(1) Inlet port (P) where oil is supplied from hydraulic pump.
(2) Output ports (1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port (T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port or tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool (4) 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 (6) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod (9,11) is inserted and can slide in the plug
(14).
For the purpose of changing the displacement of the push rod through the swash plate (20) and
adjusting nut (21) are provided the handle (23) that can be tilted in any direction around the fulcrum
of the universal joint (19) center.
The spring (10) works on the case (1) and spring seat (7, 13) and tries to return the push rod
(9,11) 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.
2-72
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram
shown below and the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.
5 6
3
1
3
P T
2 4
2-70
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-73
(1) Case where handle is in neutral position
10
T 6
P
4
1 3
21092RL03
The force of the spring (6) that determines the output pressure of the pilot valve is not applied to
the spool (4). 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.
2-74
(2) Case where handle is tilted
11
1 3
21092RL04
When the push rod (11) is stroked, the spool (4) moves downwards.
Then port P is connected with port (1) and the oil supplied from the pilot pump flows through port
(1) to generate the pressure.
When the pressure at port (1) increases to the value corresponding to the spring force set by tilt-
ing the handle, the hydraulic pressure force balances with the spring force. If the pressure at port
(1) increases higher than the set pressure, port P is disconnected from port (1) and port T is con-
nected with port (1). If it decreases lower than the set pressure, port P is connected with port (1)
and port T is disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the
spool contacts with the inside bottom of the push rod and the output pressure is left to be con-
nected with port P.
2-75
GROUP 6 RCV PEDAL
1. STRUCTURE
The casing (spacer) has the oil inlet port P (primary pressure), and the oil outlet port T (tank). In
addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face.
12.4 12.4
2 1
4 3
Port Port Port size
P T P Pilot oil inlet port

T Pilot oil return port
1 Travel (LH, forward)
PF 1/4
2 Travel (LH, backward)
3 Travel (RH, forward)
1 2 3 4 4 Travel (RH, backward)
Hydraulic circuit
21092RP01
2-76
CROSS SECTION
The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in
which reducing valves are assembled.
The pressure reducing section is composed of the spool (8), spring (6) for setting secondary
pressure, return spring (10), stopper (9), and spring seat (7). The spring for setting the secondary
pressure has been generally so preset that the secondary pressure is 5 to 19 kgf/cm2 (depending on
the type). The spool is pushed against the push rod (14) by the return spring.
When the push rod is pushed down by tilting pedal, the spring seat comes down simultaneously and
changes setting of the secondary pressure spring.
27 31 30 29 28 33 36 3
32
24
23 25,26
22
16
21 14
38 17
15 18
13
19
12 20
11
9
5 6
35
4 7
10
3
8
37 1 34 2
21092RP02
1 Body(1) 14 Push rod 27 Cam

2 Body(2) 15 Spring pin 28 Bushing
3 Plug 16 Seal 29 Cam shaft
4 Plug 17 Steel ball 30 Set screw
5 Spring seat 18 Spring 31 Set screw
6 Spring 19 Plate 32 Nut
7 Spring seat 20 Snap ring 33 Bellows
8 Spool 21 Plug 34 Space
9 Stopper 22 O-ring 35 O-ring
10 Spring 23 Rod seal 36 O-ring
11 Rod guide 24 Dust seal 37 Socket bolt
12 O-ring 25 Cover 38 Piston
13 Snap ring 26 Socket bolt
2-77
2. FUNCTION
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure (secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port (P) where oil is supplied from hydraulic pump.
(2) Output port (1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port (T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool (8) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output spool to determine the output pressure.
The spring (6) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod (14) is inserted and can slide in the plug (21).
For the purpose of changing th displacement of the push rod through the cam (27) and adjusting
nut (32) are provided the pedal that can be tilted in any direction around the fulcrum of the cam (27)
center.
The spring (10) works on the casing (1) and spring seat (7) and tries to return the push rod (14) to
the zero-displacement position irrespective of the output pressure, securing its resetting to the
center position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.
2-78
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.
36072SF01
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-79
(1) Case where pedal is in neutral position
T 8
P 10
21092RP03
The force of the spring (6) that determines the output pressure of the pilot valve is not applied to
the spool (8). Therefore, the spool is pushed up by the spring (10) to the position of port 2 in the
operation explanation drawing. Then, since the output port is connected to tank port T only, the
output port pressure becomes equal to tank pressure.
2-80
(2) Case where pedal is tilted
14
21092RP04
When the push rod (14) is stroked, the spool (8) moves downwards.
Then port P is connected with port 1, and the oil supplied from the pilot pump flows through port
1 to generate the pressure.
When the pressure at port 1 increases to the value corresponding to the spring force set by tilting
the handle, the hydraulic pressure force balances with the spring force. If the pressure at port 1
increases higher than the set pressure, port P is disconnected from port 1 and port T is
connected with port 1. If it decreases lower than the set pressure, port P is connected with port
1 and port T is disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the
spool contacts with inside bottom of the push rod and the output pressure is left to be connected
with port P.
2-81
SECTION 3 HYDRAULIC SYSTEM
GROUP 1 HYDRAULIC CIRCUIT (CLUSTER TYPE 1)
10 11 8 9
SH
3
SH
ps1 ps2
PG PG
(Pi1,Pump) (Pi2,Pump)
Au Au
23 PS PS 23
T3 T1 T2 T4
Dr Dr
2
pa11 pa10
GB GA GB GA
DR1
A(CW) Mu B(CCW) A(CW) Mu B(CCW) pc1
B5
A5 B9
A9
pb5
pb9
R/G
4 R/G pa5 PO
pa9
B4
MA MB MA MB
35 B8
A4 A8
Reverse
37
Forward
X X
pb4 pb8 1 Main pump
42
T
T
S S
pa8
pa4 DR2
3 Swing motor
A3
pc2
4 Travel motor
37 B3
A7
5 RCV lever(LH)
RH
LH
B7
pb3
Forward
6 RCV lever(RH)
Reverse
pa3
40 B2 pb7
A B A B
7 RCV pedal
C
B
Bre Bre
A2
pa7
pb2
B6 8 Boom cylinder(LH)
B P A
12 36 A6
D Dr C DR3
pb6
9 Boom cylinder(RH)
pa2
Pk pc6
10 Arm cylinder
pa6
B1
11 Bucket cylinder
A1
pb1
12 Turning joint
PS 24 pa1 13 Check valve
41 A1 A2 P2 A3
26 pr1 14 Check valve

P T
39 P3 15 Hydraulic tank
T 16 Oil cooler
PS
PT PP PA PH
P1
P1
24
P2
17 Air breather
pb4 pa4
PS 24 18 Bypass valve
5 6 26 19 Strainer
SWING P T ARM BUCKET P T BOOM 7 P T TRAVEL 20 Drain filter
21 Solenoid valve
22 Pressure sensor
22 23 P T 48
(2) (1) (4) (3) a4 Psv1 A1 PS PS A2 Psv2 PS a5 23 Pressure sensor
(1,A) (3,B) (2,D) (4,E) (3,F) (1,G) (2,H) (4,J) a1 a2
pa6 pb6 pb1 pa1 A B
24 Pressure sensor
1 25 Terminal
14 13 26 Last guard filter
DR#,dr#
Pi1
(ps1,
27 Last guard filter
16 MCV) 29 Gear pump
27
a b d e f g h j
33 Pi2 33 Shuttle valve
25 27 (ps2,
c
MCV) 35 Accumulator
38 1
17
pb2 PS
pa2 pb5 pa5 pb8 pa8 PS
2 36 Accumulator
24 pa7 24 pb7
3 M 37 Stop valve
pc6 Pk PH
(MCV) (T/Joint) (MCV) 15 38 EPPR valve
21 18 20 Dr1,r2 B1 Dr3,r4 39 2-way pedal(option)
A5 A3 A2 A1
P4
29 B 40 3-way joint
PG(S/Motor) 19
P3 41 Solenoid valve
PP(MCV) Dr
P2 G
42 Shuttle valve
T(dr1)
P1 A
48 Solenoid valve(option)
4809S3HC01P
3-1
■ HYDRAULIC CIRCUIT (CLUSTER TYPE 2)
10 11 8 9
3
SH SH
ps1 ps2
PG PG
(Pi1,Pump) (Pi2,Pump)
Au Au
T3 T1 T2 T4
Dr Dr
2
pa11 pa10
GB GA GB GA
DR1
A(CW) Mu B(CCW) A(CW) Mu B(CCW) pc1
B5
A5 B9
A9
pb5
pb9
R/G
4 R/G pa5 PO
pa9
B4
MA MB MA MB
35 B8
A4 A8
Reverse
37
Forward
X X
pb4 pb8
T
T
S S
pa8
pa4 DR2
A3
pc2
1 Main pump
37 B3
A7
RH
LH
B7
pb3
Forward
3 Swing motor
Reverse
pa3
40 B2 pb7
A B A B
4 Travel motor
C
B
Bre Bre
A2
pa7
pb2
B6 5 RCV lever(LH)
B P A
12 36 A6
D Dr C DR3
pb6
6 RCV lever(RH)
pa2
Pk pc6
7 RCV pedal
pa6
B1
8 Boom cylinder(LH)
A1
pb1
9 Boom cylinder(RH)
pa1 10 Arm cylinder
41 A1
26 pr1 11 Bucket cylinder

P T
39 P3 12 Turning joint
T 13 Check valve
PS
PT PP PA PH
P1
P1
24
P2
14 Check valve
pb4 pa4
PS 24 15 Hydraulic tank
5 6 26 16 Oil cooler
SWING P T ARM BUCKET P T BOOM 7 P T TRAVEL 17 Air breather
18 Bypass valve
19 Strainer
22 22 P T 48
(2) (1) (4) (3) a4 Psv1 A1 PG PG A2 Psv2 PG a5 20 Drain filter
(1,A) (3,B) (2,D) (4,E) (3,F) (1,G) (2,H) (4,J) a1 a2
pa6 pb6 pb1 pa1 A B
21 Solenoid valve
1 22 Screw coupling
14 13 23 Pressure switch
DR#,dr#
24 Pressure switch
16 Pi1 25 Terminal
(ps1, 27
a b d e f g h j MCV) Pi2 26 Last guard filter
25 27 (ps2,
MCV) 27 Last guard filter
pb2 pa2 pb5 pa5 pb8 pa8 pa7 pb7 17 29 Gear pump
M 35 Accumulator
pc6 Pk PH
(MCV) (T/Joint) (MCV) 15 36 Accumulator
21 18 20 Dr1,r2 B1 Dr3,r4 37 Stop valve
A5 A3 A2 A1
P4
29 B 39 2-way pedal(option)
PG(S/Motor) 19
P3 40 3-way joint
PP(MCV) Dr
P2 G
41 Solenoid valve
T(dr1)
P1 A
48 Solenoid valve(option)
4809S3HC01S
3-2
SECTION 3 HYDRAULIC SYSTEM
Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------ 3-1

Group 2 Main Circuit ------------------------------------------------------------------------------------------------------- 3-3
Group 3 Pilot Circuit -------------------------------------------------------------------------------------------------------- 3-6
Group 4 Single Operation ----------------------------------------------------------------------------------------------- 3-13
Group 5 Combined Operation ---------------------------------------------------------------------------------------- 3-23
3-1
GROUP 2 MAIN CIRCUIT
The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit.
The hydraulic system consists of one main pump, one control valve, one swing motor, four cylinders
and two travel motors.
The swash plate type variable displacement tandem axial piston pump is used as the main pump
and is driven by the engine at ratio 1.0 of engine speed.
1. SUCTION AND DELIVERY CIRCUIT
To cylinders To motors
Main control valve To oil cooler
To hydraulic oil tank
Main pump
Suction filter
Hydraulic oil tank
3-02
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.
3-3
2. RETURN CIRCUIT
Check valve(2)
Full flow filter Oil cooler 1.5kgf/cm 2
Main control valve Actuators
Check valve(1)
5.0kgf/cm 2
Check valve(3)
1.5kgf/cm 2
45073CI02
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 1.5 kgf/cm2 (21 psi) and 5.0 kgf/cm2 (71 psi). Usually,
oil returns to the hydraulic tank from the left side of control valve through oil cooler.
When oil temperature is low, viscosity becomes higher and flow resistance increases when passing
through the oil cooler. The oil pressure exceeds 5.0 kgf/cm2 (71 psi), the oil returns directly to the
hydraulic tank, resulting in the oil temperature being raised quickly at an appropriate level.
When the oil cooler is clogged, the oil returns directly to the hydraulic tank through bypass check
valve (1).
The full-flow filter and bypass relief valve are provided in the hydraulic tank.
The oil 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 1.5 kgf/cm2 (21psi) differential
pressure.
3-4
3. DRAIN CIRCUIT
Travel motor Swing motor
From return line Main pump
Turning
joint
Dr#, dr#
Drain filter
Hydraulic
oil tank Dr
Check valve
1.5kgf/cm 2
21093CI02
Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil
have to be fed to the hydraulic tank passing through drain filter and full flow filter in the hydraulic tank.
When the drain oil pressure exceed 1.5 kgf/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
drainfilter.
3) MAIN PUMP DRAIN CIRCUIT
Oil leaking from main pump come out and return to the hydraulic tank passing through drain filter.
3-5
GROUP 3 PILOT CIRCUIT
Remote control valve RCV pedal Remote control valve

(LH lever) (RH lever)
Swing parking brake

MCV Safety lock
solenoid valve
Travel speed solenoid valve
Power boost solenoid valve
Main pump Boom priority EPPR valve
Line filter
Relief valve
40kgf/cm2
Suction filter
Pilot pump
48093CI01
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.
3-6
1. SUCTION, DELIVERY AND RETURN CIRCUIT
ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER
SWING MOTOR
ps1 ps2
PS PS
T3 T1 T2 T4
pa11 pa10
DR1
pc1
B5
A5 B9
pb9 A9
pb5
ARM1
TRAVEL MOTOR pa9
pc1
pa5 pb9
ARM2
PO
pa9
B4 B8
A4
A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3
B7
pb3 pc2
BOOM2 pb3
pa3
B2 pb7
pa3
A2
BOOM1
pa7
B6
pb2
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
SH PS
RCV PEDAL P T TRAVEL
A1 A2
(2) (1) (4) (3) Dr#, dr#

Pa6 Pb6 Pb1 Pa1
FRONT REAR PILOT
PUMP PUMP PUMP
SWING P T ARM BUCKET P T BOOM
SAFETY
Pc6 Pk PH SOLENOID
(MCV) (T/Joint) (MCV) VALVE
A5 A3 A2 A1
PG
P4 (S/Motor)
(1) (3) (2) (4) (3) (1) (2) (4) P3 PP(MCV) HYDRAULIC TANK
P2
a b d e f g h j T P1
c LINE FILTER
Pb2 PS Pa2 Pb5 Pa5 Pb8 Pa8
PS Pb7
Pa7
4809S3HC02
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.
3-7
2. SAFETY SOLENOID VALVE (SAFETY LEVER)
ARM BUCKET BOOM

SWING MOTOR
ps1 ps2
PS PS
T3 T1 T2 T4
pa11 pa10
DR1
pc1 pc1
B5
A5 B9
pb9 A9
pb5
ARM1
TRAVEL MOTOR pa9
pci
pa5 pb9
ARM2
PO
pa9
B4 B8
A4
A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3
B7
pb3 pc2
BOOM2 pb3
pa3
B2
pb7
pa3
A2
BOOM1
pa7
B6
pb2
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
SH PS
A1 A2
(2) (1) (4) (3) Dr#, dr#

Pa6 Pb6 Pb1 Pa1
FRONT REAR PILOT
PUMP PUMP PUMP
SAFETY
SOLENOID
Pc6 Pk PH VALVE
(MCV) (T/Joint) (MCV)
A5 A3 A2 A1 LEVER UP
PG
P4 (S/Motor)
P2
c LINE FILTER
Pb2 PS Pa2 Pb5 Pa5 Pb8 Pa8 LEVER DOWN
PS Pb7
Pa7
4809S3HC03
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.
3-8
3. BOOM PRIORITY SYSTEM
ARM BUCKET BOOM
SWING MOTOR
ps1 ps2
PS PS
T3 T1 T2 T4
pa11 pa10
DR1
pc1
TRAVEL MOTOR B5
A5 B9
pb9 A9
pb5
ARM1
pci
pa9
pa5 pb9
ARM2
PO
pa9
B4 B8
A4
A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3
B7
pb3 pc2
BOOM2 pb3
pa3
B2 pb7
pa3
A2
BOOM1
pa7
Cluster type1 pb2
DR3
SWING
B6
A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
A1 A2
(2) (1) (4) (3) Dr#, dr#

Pa6 Pb6 Pb1 Pa1
FRONT REAR PILOT
BOOM PRIORITY PUMP PUMP PUMP
EPPR VALVE
Pc6 Pk PH
A5 A3 A2 A1
PG
P4 (S/Motor)
P2
c LINE FILTER
PS Pb7
Pa7
4809S3HC04
When carrying out the combined operation of swing and boom up, the boom up operating speed is
lowered then normal operation.
To increase working efficiency, swing speed reducing system is used.
The pilot oil from pilot pump flow into Pc6 port in main control valve through boom EPPR valve. Pc6
oil pressure moves swing reducing spool to right direction and oil flow rate to the swing motor
decreased.
Then, the boom up speed is increased. This is called the boom priority system.
The boom up speed can be adjusted by the cluster. Refer to the 3-12 page of operator's manual
(cluster type 1).
3-9
4. TRAVEL SPEED CONTROL SYSTEM
SWING MOTOR ARM BUCKET BOOM

ps1 ps2
PS PS
T3 T1 T2 T4
pa11 pa10
LH
TRAVEL MOTOR RH
DR1
pc1
B5
R/G R/G
A5 B9
pb9 A9
pb5
MA MB MA MB ARM1
pci
Reverse
pa9
Forward
X X
pa5 pb9
ARM2
PO
pa9
T
B4 B8
S T S
A4
A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
Forward
Reverse
B3
B7
pb3 pc2
A B A B
Bre Bre
BOOM2 pb3
pa3
B2 pb7
pa3
A2
BOOM1
pa7
B6
P pb2
A B
DR3
SWING A6
C Dr D pb6
pa2 TRAVEL-LH
pc6 pa6
Pk B1
A1
pb1
TRAVEL
pr1
P3
A1 A2
(2) (1) (4) (3) Dr#, dr#

Pa6 Pb6 Pb1 Pa1
FRONT REAR PILOT
PUMP PUMP PUMP
SWING P T ARM BUCKET P T BOOM TRAVEL SPEED
SOLENOID VALVE
Pc6 Pk PH
A5 A3 A2 A1
PG
P4 (S/Motor)
P2
c LINE FILTER
PS Pb7
Pa7
4809S3HC05
When the travel speed switch is pushed, the travel speed solenoid valve is actuated and the
discharged oil from the pilot pump flows to the X port of pilot valve in the travel motors.
As a result, the control piston is pushed by the main oil flow, thus the displacement is minimized.
When the travel speed switch is pushed once more, the travel speed solenoid valve is return to
original position by the force of spring, the hydraulic oil of X port returns to the hydraulic tank.
As a result, the control piston is returned by the main oil flow, thus the displacement is maximized.
3-10
5. MAIN RELIEF PRESSURE CHANGE CIRCUIT
ARM BUCKET BOOM

SWING MOTOR
ps1 ps2
PS PS
T3 T1 T2 T4
pa11 pa10
TRAVEL MOTOR DR1
pc1
B5
A5 B9
pb9 A9
pb5
ARM1
pci
pa9
pa5 pb9
ARM2
PO
pa9
B4 B8
A4
A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3
B7
pb3 pc2
BOOM2 pb3
pa3
B2 pb7
pa3
A2
BOOM1
Auto power boost(c/type 1) pb2
B6
pa7
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
A1 A2
(2) (1) (4) (3) Dr#, dr#

Pa6 Pb6 Pb1 Pa1
FRONT REAR PILOT
POWER MAX PUMP PUMP PUMP
SOLENOID VALVE
Pc6 Pk PH
A5 A3 A2 A1
PG
P4 (S/Motor)
P2
c LINE FILTER
PS Pb7
Pa7
4809S3HC06
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 flow into PH port of the main relief valve of main
control valve ; Then the setting pressure of the main control valve is raises from 330 kgf/cm2 to 360 kgf/
cm2 for increasing the digging power. And even when press continuously, it is canceled after 8
seconds. When the auto power boost function is selected to enable on the cluster, the pressure of
the main relief pressure is automatically increased to 380 kgf/cm2 as working condition by the MCU. It
is operated max 8 seconds(cluster type 1).
3-11
6. SWING PARKING BRAKE RELEASE

SH SH
PG PG
Au Au
Dr Dr
ps1 ps2
GB GA GB GA PS
T1
PS
T3 T2 T4
A(ccw) B(cw) A(ccw) B(cw)

pa11 pa10
DR1
pc1
B5
A5 B9
pb9 A9
pb5
ARM1
TRAVEL MOTOR pa9
pci
pa5 pb9
ARM2
PO
pa9
B4 B8
A4
A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3
B7
pb3 pc2
BOOM2 pb3
pa3
B2 pb7
pa3
A2
BOOM1
pa7
B6
pb2
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
A1 A2
(2) (1) (4) (3) Dr#, dr#

Pa6 Pb6 Pb1 Pa1
FRONT REAR
PUMP PUMP
Pc6 Pk PH
A5 A3 A2 A1
PG
P4 (S/Motor)
P2
c LINE FILTER
PS Pb7
Pa7
4809S3HC07
When one of the RCV lever (except travel lever) is tilted, the pilot oil flows into SH port through main
control valve.
This pressure moves spool so, discharged oil from pilot valve flows to swing motor PG port.
This pressure is applied to swing motor disc, thus the brake is released.
When all of the RCV lever are set in the neutral position, oil in the swing motor disc cylinder is
drained, thus the brake is applied.
3-12
GROUP 4 SINGLE OPERATION
1. BOOM UP OPERATION
ARM BUCKET BOOM
SWING MOTOR
ps1 ps2
PS PS
T3 T1 T2 T4
pa11 pa10
TRAVEL MOTOR DR1
pc1
B5
A5 B9
pb9 A9
pb5
ARM1
pci
pa9
pa5 pb9
ARM2
PO
pa9
B4 B8
A4 A8
pa11
pb4 pb8
OPTION BUCKET
Boom holding valve
pa8
pa4 DR2
A3 Relief valve pc2

A7
B3
B7
pb3
pb3 pc2
pb7 pa3 BOOM2 pb3
B2
pb7
pa3
A2
BOOM1
pa7
B6
pb2
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
SH PS
A1 A2
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
4809S3HC10
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 A1 and A2 pump flows into the main control valve and then goes to the large
chamber of boom cylinders.
At the same time, the oil from the small chamber of boom cylinders returns to the hydraulic oil tank
through the boom spool in the main control valve. When this happens, the boom goes up.
The excessive pressure in the boom cylinder 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 BUCKET BOOM

SWING MOTOR
ps1 ps2
PS PS
T3 T1 T2 T4
pa11 pa10
TRAVEL MOTOR DR1
pc1
B5
A5 B9
pb9 A9
pb5
ARM1
pci
pa9
pa5 pb9
ARM2
PO
pa9
B4 B8
A4
A8
pa11
pb4 pb8
OPTION BUCKET
Boom holding valve
pa8
pa4 DR2
A3 Relief valve pc2

A7
B3
B7
pb3
pb3 pc2
pb7 pa3 BOOM2 pb3
B2
pb7
pa3
A2
BOOM1
pa7
B6
pb2
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
SH PS
A1 A2
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
4809S3HC11
When the RH control lever is pushed forward, the boom 1 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 A2 pump flows into the main control valve and then goes to the small chamber of
boom cylinders. At the same time, the oil from the large chamber of boom cylinders returns to the
hydraulic tank through the boom 1 spool in the main control valve.
When the down speed of boom is faster, the oil returned from the large chamber of boom cylinder
combines with the oil from the A2 pump, and flows into the small chamber of the boom cylinder.
This prevents cylinder cavitation by the negative pressure when the A2 pump flow can not match the
boom down speed. And the excessive pressure in the boom cylinder rod end circuit is prevented by
the relief valve.
3-14
3. ARM IN OPERATION
ARM BUCKET BOOM

SWING MOTOR
ps1 ps2
Arm holding valve PS

T3 T1 T2
PS
T4
pa11 pa10
DR1
pc1
Relief valve
B5
A5 B9
pb9 A9
pb5
ARM1
TRAVEL MOTOR pci
pa9
pa5 pb9
ARM2
PO
pa9
B4 B8
A4
A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3
B7
pb3
pb3 pc2
pb7 pa3 BOOM2 pb3
B2
pb7
pa3
A2
BOOM1
pa7
B6
pb2
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
SH PS
A1 A2
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
4809S3HC12
When the LH control lever is pulled back, the arm spools in the main control valve are moved the to
roll in position by the pilot oil pressure from the remote control valve.
The oil from the A1 and A2 pump flows into the main control valve and then goes to the large
chamber of arm cylinder.
At the same time, the oil from small chamber of arm cylinder returns to the hydraulic oil tank through
the arm spool in the main control valve. When this happens, the arm rolls in.
The excessive pressure in the arm cylinder head side is prevented by relief valve.
The cavitation which will happen to the head side of the arm cylinder is also prevented by the make-
up valve in the main control valve.
3-15
4. ARM OUT OPERATION
ARM BUCKET BOOM
SWING MOTOR
ps1 ps2
Arm holding valve PS

T1
PS
T3 T2 T4
pa11 pa10
DR1
Relief valve
pc1
B5
A5 B9
pb9 A9
pb5
ARM1
TRAVEL MOTOR pci
pa9
pa5 pb9
ARM2
PO
pa9
B4 B8
A4
A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3
B7
pb3
pb3 pc2
pb7 pa3 BOOM2 pb3
B2 pb7
pa3
A2
BOOM1
pa7
B6
pb2
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
SH PS
A1 A2
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
4809S3HC13
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 A1 and A2 pump flows into the main control valve and then goes to the small
chamber of arm cylinder.
At the same time, the oil from the large chamber of arm cylinder returns to the hydraulic oil tank
through the arm spools in the main control valve. When this happens, the arm rolls out.
The excessive pressure in the arm cylinder rod side is prevented by relief valve.
When the arm is roll out and the control lever is returned to neutral position, the circuit for the holding
pressure at the rod side of the arm cylinder is closed by the arm holding valve.
The cavitation which will happen to the rod side of the arm cylinder is also prevented by the make-up
valve in the main control valve.
3-16
5. BUCKET IN OPERATION
ARM BUCKET BOOM

SWING MOTOR
ps1 ps2
PS PS
T3 T1 T2 T4
pa11 pa10
DR1
pc1
B5
A5 B9
pb9 A9
pb5
ARM1
TRAVEL MOTOR pci Relief valve
pa9
pa5 pb9
ARM2
PO
pa9
B4 B8
A4 A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3
B7
pb3
pb3 pc2
pb7 pa3 BOOM2 pb3
B2
pb7
pa3
A2
BOOM1
pa7
B6
pb2
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
SH PS
A1 A2
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
4809S3HC14
When the RH control lever is pulled left, the bucket spool in the main control valve is moved to the roll
in position by the pilot oil pressure from the remote control valve.
The oil from the A2 pump flows into the main control valve and then goes to the large chamber of
bucket cylinder. The oil form the A1 pump flows into the large chamber of bucket cylinder through
confluence oil passage in the main control valve by bypass cut pilot pressure (pa11).
At the same time, the oil from the small chamber of bucket cylinder returns to the hydraulic oil tank
through the boom spool in the main control valve. When this happens, the bucket rolls in.
The excessive pressure in the bucket cylinder head side is prevented by relief valve.
The cavitation which will happen to the head side of the bucket cylinder is also prevented by the
make-up valve in the main control valve.
3-17
6. BUCKET OUT OPERATION
ARM BUCKET BOOM

SWING MOTOR
ps1 ps2
PS PS
T3 T1 T2 T4
pa11 pa10
DR1
pc1
B5
A5 B9
pb9 A9
pb5
ARM1
TRAVEL MOTOR pci Relief valve
pa9
pa5 pb9
ARM2
PO
pa9
B4 B8
A4
A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3
B7
pb3
pb3 pc2
pb7 pa3 BOOM2 pb3
B2 pb7
pa3
A2
BOOM1
pa7
B6
pb2
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
SH PS
A1 A2
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
4809S3HC15
When the RH control lever is pushed right, the bucket spool in the main control valve is moved to the
roll out position by the pilot oil pressure from the remote control valve.
The oil from the A2 pump flows into the main control valve and then goes to the small chamber of
bucket cylinder.
At the same time, the oil from the large chamber of bucket cylinder returns to the hydraulic oil tank
through the bucket spool in the main control valve. When this happens, the bucket rolls out.
The excessive pressure in the bucket cylinder rod side is prevented by relief valve.
The cavitation which will happen to the rod side of the bucket cylinder is also prevented by the make-
up valve in the main control valve.
3-18
7. SWING OPERATION
SWING MOTOR
ARM BUCKET BOOM
SH SH
PG PG
Au Au
Dr Dr
ps1 ps2
GB GA GB GA PS PS
T3 T1 T2 T4
A(ccw) B(cw) A(ccw) B(cw)

pa11 pa10
DR1
pc1
B5
A5 B9
pb9 A9
pb5
ARM1
TRAVEL MOTOR pci
pa9
pa5 pb9
ARM2
PO
pa9
B4 B8
A4
A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3
B7
pb3
pb3 pc2
pb7 pa3 BOOM2 pb3
B2 pb7
pa3
A2
BOOM1
pa7
B6
pb2
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
SH PS
A1 A2
(2) (1) (4) (3) Dr#, dr#

Pa6 Pb6 Pb1 Pa1
FRONT REAR PILOT
PUMP PUMP PUMP
Pc6 Pk PH
A5 A3 A2 A1
PG
P4 (S/Motor)
P2
c LINE FILTER
PS Pb7
Pa7 4809S3HC16
When the LH control lever is pushed left or right, the swing spool in the main control valve is moved
to the left or right swing position by the pilot oil pressure from the remote control valve.
The oil from the A1 pump flows into the main control valve and then goes to the swing motor.
At the same time, the return oil from the swing motor returns to the hydraulic oil tank through the
swing spool in the main control valve.
When this happens, the upper structure swings to the left or right.
The swing parking brake, make up valve and the motor brake valve are provided in the swing motor.
The cavitation which will happen to the swing motor is also prevented by the make up valve in the
swing motor itself.
3-19
SWING CIRCUIT OPERATION
SWING MOTOR DEVICE PARKING BRAKE
SH
BRAKE OFF
PG
BRAKE ON
Au
Dr ANTI-INVERSION VALVE
MOTOR BRAKE VALVE
GB GA
MAKE UP VALVE
A(CCW) B(CW)
MAKE UP
PORT(Mu)
TO / FROM MAIN CONTROL VALVE

48093HC17
1) MOTOR BRAKE VALVE

Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing
operation and controls the swing motor operating pressure.
2) MAKE UP VALVE
The make up valves prevent cavitation by supplying return oil to the vacuum side of the motor.
3) PARKING BRAKE
This is function as a parking brake only when all of the RCV lever (except travel pedal) are not
operated.
PARKING BRAKE "OFF" OPERATION
The parking brake is released by the pilot pressure oil from the pilot pump.
When the RCV lever placed in the operating position, the pilot oil flows into SH port through the
MCV. This pressure transferred to the brake release valve and the brake release valve is change
over. Then the pilot oil pressure PG lift the brake piston and release the parking brake.
PARKING BRAKE "ON" OPERATION
When all of the RCV lever placed in the neutral position, the pressure of the pilot oil passage down.
Then the brake release valve returned to the neutral position and the oil is returned from the brake
piston to the tank. And the brake is set to 'ON".
4) ANTI-INVERSION VALVE
This anti-inversion valve absorbs shocks produced as swing motion stops and reduced oscillation
cause by swing motion.
3-20
8. TRAVEL FORWARD AND RE
REVERSE
VERSE O
OPERATION
PERATION
ps1 ps2
PS PS
T3 T1 T2 T4
pa11 pa10
LH
TRAVEL MOTOR RH
DR1
pc1
B5
R/G R/G
A5 B9
pb9 A9
pb5
MA MB MA MB ARM1
pci
Reverse
Forward
X X pa9
pa5 pb9
ARM2
PO
pa9
T
B4 B8
S T S
A4
A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
Forward
Reverse
B3
B7
pb3
pb3 pc2
A B A B
Bre Bre
pb7 pa3 BOOM2 pb3
B2 pb7
pa3
A2
BOOM1
pa7
B6
P pb2
A B
DR3
SWING A6
C Dr D pb6
pa2 TRAVEL-LH
pc6 pa6
Pk B1
A1
pb1
TRAVEL
pr1
P3
SH PS
A1 A2
(2) (1) (4) (3) Dr#, dr#

Pa6 Pb6 Pb1 Pa1
FRONT REAR PILOT
PUMP PUMP PUMP
SWING P T ARM BUCKET P T BOOM TRAVEL SPEED
SOLENOID VALVE
Pc6 Pk PH
A5 A3 A2 A1
PG
P4 (S/Motor)
P2
c LINE FILTER
PS Pb7
Pa7 4809S3HC18
When the travel levers are pushed forward or reverse position, the travel spools in the main control
valve are moved to the forward or reverse travel position by the pilot oil pressure from the remote
control valve.
The oil from the each pump flows into the main control valve and then goes to the each travel motor
through the turning joint.
The return oil from both travel motors returns to the hydraulic oil tank through the turning joint and
the travel spools in the main control valve.
When this happens, the machine moves to the forward or reverse.
3-21
TRAVEL CIRCUIT OPERATION
LH RH
R/G R/G
MA MB MA MB
Reverse
Forward
X X
T S T S
OVERLOAD
RELIEF VALVE
COUNTER
BALANCE VALVE
Forward
Reverse
A Bre B A Bre B
A P B
C Dr D
Pk
TO/FROM MAIN CONTROL VALVE

48093HC19
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 345 kgf/cm2 to prevent high pressure generated at a time
of stopping the machine. Stopping the motor, this valve sucks the oil from lower pressure passage
for preventing the negative pressure and the cavitation of the motor.
3-22
GROUP 5 COMBINED OPERATION
1. OUTLINE
ARM BUCKET BOOM
SWING MOTOR
ps1 ps2
PS PS
T3 T1 T2 T4
pa11 pa10
DR1
pc1
B5
A5 B9
pb9 A9
pb5
ARM1
TRAVEL MOTOR pci
pa9
pa5 pb9
ARM2
PO
pa9
B4 B8
A4 A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3
B7
pb3
pb3 pc2
pb7 pa3 BOOM2 pb3
B2 pb7
pa3
A2
BOOM1
pa7
B6
pb2
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
STRAIGHT
TRAVEL P3
SPOOL
SH PS
A1 A2
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
4809S3HC20
The oil from the A1 and A2 pump flows through the neutral oil passage, bypass oil passage and
confluence oil passage in the main control valve. Then the oil goes to each actuator and operates
them. Check valves and orifices are located on these oil passage in the main control valve. These
control the oil from the main pumps so as to correspond to the operation of each actuator and
smooth the combined operation.
STRAIGHT TRAVEL SPOOL

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

SWING MOTOR
ps1 ps2
PS PS
T3 T1 T2 T4
pa11 pa10
TRAVEL MOTOR DR1
pc1
B5
A5 B9
pb9 A9
pb5
ARM1
pci
pa9
pa5 pb9
ARM2
PO
pa9
B4 B8
A4 A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3
B7
pb3
pb3 pc2
pb7 pa3 BOOM2 pb3
B2
pb7
pa3
A2
BOOM1
pa7
B6
pb2
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
SH PS
A1 A2
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
4809S3HC21
When the swing and boom up functions are operated, simultaneously the swing spool and boom
spools in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve.
The oil from the A1 pump flows into the swing motor through swing spool and the boom cylinder
through boom 2 spool.
The oil from the A2 pump flows into the boom cylinders through the boom 1 spool in the right control
valve. The upper structure swings and the boom is operated.
Refer to page 3-8 for the boom priority system.
3-24
3. COMBINED SWING AND ARM OPERATION
ARM BUCKET BOOM

SWING MOTOR
ps1 ps2
PS PS
T3 T1 T2 T4
pa11 pa10
DR1
pc1
B5
A5 B9
pb9 A9
pb5
ARM1
TRAVEL MOTOR pci
pa9
pa5 pb9
ARM2
PO
pa9
B4 B8
A4 A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3
B7
pb3
pb3 pc2
pb7 pa3 BOOM2 pb3
B2 pb7
pa3
A2
BOOM1
pa7
B6
pb2
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
SH PS
A1 A2
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
4809S3HC22
When the swing and arm functions are operated, simultaneously the swing spool and arm spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve.
The oil from the A1 pump flows into the swing motor through swing spool and the arm cylinder
through arm 1 spool.
The oil from the A2 pump flows into the arm cylinder through the arm 2 spool of the right control
valve. The upper structure swings and the arm is operated.
Refer to page 2-35 for the swing operation preference function.
3-25
4. COMBINED SWING AND BUCKET OPERATION
ARM BUCKET BOOM

SWING MOTOR
ps1 ps2
PS PS
T3 T1 T2 T4
pa11 pa10
DR1
pc1
B5
A5 B9
pb9 A9
pb5
ARM1
TRAVEL MOTOR pci
pa9
pa5 pb9
ARM2
PO
pa9
B4 B8
A4 A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3
B7
pb3
pb3 pc2
pb7 pa3 BOOM2 pb3
B2 pb7
pa3
A2
BOOM1
pa7
B6
pb2
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
SH PS
A1 A2
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
4809S3HC23
When the swing and bucket functions are operated, simultaneously the swing spool and bucket
spool in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve.
The oil from the A1 pump flows into the swing motor through the swing spool in the left control valve.
The oil from the A2 pump flows into the bucket cylinder through the bucket spool in the right control
valve.
The upper structure swings and the bucket is operated.
3-26
5. COMBINED SWING AND TRAVEL OPERATION
ARM BUCKET BOOM

SWING MOTOR
ps1 ps2
PS PS
T3 T1 T2 T4
pa11 pa10
DR1
pc1
B5
A5 B9
pb9 A9
pb5
ARM1
TRAVEL MOTOR pci
pa9
pa5 pb9
ARM2
PO
pa9
B4 B8
A4
A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3
B7
pb3
pb3 pc2
pb7 pa3 BOOM2 pb3
B2
pb7
pa3
A2
BOOM1
pa7
B6
pb2
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
SH PS
A1 A2
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
4809S3HC24
When the swing and travel functions are operated, simultaneously the swing spool and travel spools
in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve and straight travel spool is pushed to the right by the pilot oil pressure from the
pilot pump.
The oil from the A1 pump flows into the travel motors through the RH travel spool of the left control
valve and the LH travel spool of the right control valve via the straight travel spool.
The oil from the A2 pump flows into the swing motor through the swing spool.
The upper structure swings and the machine travels straight.
3-27
6. COMBINED BOOM AND TRAVEL OPERATION
ARM BUCKET BOOM

SWING MOTOR
ps1 ps2
PS PS
T3 T1 T2 T4
pa11 pa10
TRAVEL MOTOR DR1
pc1
B5
A5 B9
pb9 A9
pb5
ARM1
pci
pa9
pa5 pb9
ARM2
PO
pa9
B4 B8
A4
A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3
B7
pb3
pb3 pc2
pb7 pa3 BOOM2 pb3
B2
pb7
pa3
A2
BOOM1
pa7
B6
pb2
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
SH PS
A1 A2
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
4809S3HC25
When the boom and travel functions are operated, simultaneously the boom spools and travel spools
in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve and the straight travel spool is pushed to the right by the oil pressure from pilot
pump.
The oil from the A2 pump flows into the boom cylinders through the boom 2 spool and boom 1 spool
via the parallel and confluence oil passage in case boom up operation.
The boom is operated and the machine travels straight.
3-28
7. COMBINED ARM AND TRAVEL OPERATION
ARM BUCKET BOOM

SWING MOTOR
ps1 ps2
PS PS
T3 T1 T2 T4
pa11 pa10
DR1
pc1
B5
A5 B9
pb9 A9
pb5
ARM1
TRAVEL MOTOR pci
pa9
pa5 pb9
ARM2
PO
pa9
B4 B8
A4
A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3
B7
pb3
pb3 pc2
pb7 pa3 BOOM2 pb3
B2 pb7
pa3
A2
BOOM1
pa7
B6
pb2
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
SH PS
A1 A2
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
4809S3HC26
When the arm and travel functions are operated, simultaneously the arm spools and travel spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve and the straight travel spool is pushed to the right by the oil pressure from pilot pump.
The oil from the A2 pump flows into the arm cylinders through the arm 1 spool and arm 2 spool via
the parallel and confluence oil passage.
The arm is operated and the machine travels straight.
3-29
8. COMBINED BUCKET AND TRAVEL OPERATION
ARM BUCKET BOOM

SWING MOTOR
ps1 ps2
PS PS
T3 T1 T2 T4
pa11 pa10
DR1
pc1
B5
A5 B9
pb9 A9
pb5
ARM1
TRAVEL MOTOR pci
pa9
pa5 pb9
ARM2
PO
pa9
B4 B8
A4 A8
pa11
pb4 pb8
OPTION BUCKET
pa8
pa4 DR2
A3 pc2
A7
B3
B7
pb3
pb3 pc2
pb7 pa3 BOOM2 pb3
B2 pb7
pa3
A2
BOOM1
pa7
B6
pb2
DR3
SWING A6
pb6
pa2 TRAVEL-LH
pc6 pa6
B1
A1
pb1
TRAVEL
pr1
P3
SH PS
A1 A2
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
4809S3HC27
When the bucket and travel functions are operated, simultaneously the bucket spool and travel
spools in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve, and the straight travel spool is pushed to the right by the oil pressure from pilot
pump. The oil from the A1 pump flows into the travel motors through the RH travel spool of the left
control valve and the LH travel spool of the right control valve via the straight travel spool of the
control valve.
The oil from the A2 pump flows into the bucket cylinder through the bucket spool via the confluence
oil passage.
The bucket is operated and the machine travels straight.
3-30
SECTION 4 ELECTRICAL SYSTEM
Group 1 Component Location ----------------------------------------------------------------------------------------- 4-1

Group 2 Electrical Circuit -------------------------------------------------------------------------------------------------- 4-3
Group 3 Electrical Component Specification ------------------------------------------------------------------ 4-38
Group 4 Connectors --------------------------------------------------------------------------------------------------------- 4-46
SECTION 4 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
27 26
28 25
24
29
23
30 22
31 C
A
B
17
21
20
19
1
18
2
3
4
5
6 Electric box
7
8
9
15
14
13
12 CN-16&16A
11 CN-16B
10 16
4809S4EL01
1 Cigar light 12 Emergency engine stop switch 22 USB socket

2 Aircon & heater switch panel 13 One touch decel switch 23 Breake switch
3 Accel dial switch 14 Fuse box 24 Overload switch
4 Horn switch 15 Master switch 25 Beacon switch
5 Breaker operation switch 16 Emergency engine connector 26 Quick clamp switch
6 Air compressor switch 17 MCU 27 Cab light switch
7 Starting switch 18 RS232 service socket 28 Travel alarm switch
8 Cluster 19 Radio & USB player 29 Washer switch
9 Service meter 20 Heated seat switch 30 Wiper switch
10 Safety lever 21 Speaker 31 Main light switch
11 Power max switch
4-1
2. LOCATION 2
4
21 1
1 1
1
23
1
BOOM SOLENOID VALVE CAB
10 22
2 8 9 a3 14
a2
13
a1
12
25 11
6 20
19
7 ps2
ps1
15
H
C
PA
1
16 PT 17
18
SHUTTLE BLOCK MAIN CONTROL VALVE
4809S4EL02
1 Lamp 9 P2 pressure sensor 17 Attach pressure sensor

2 Fuel sender 10 EPPR pressure sensor 18 Travel pressure sensor
3 Fuel filler pump 11 Air cleaner switch 19 P1 nega pressure sensor
4 Beacon lamp 12 Travel alarm buzzer 20 P2 nega pressure sensor
5 Battery 13 Alternator 21 Solenoid valve
6 Battery relay 14 Heater relay 22 Pump EPPR valve
7 Horn 15 Boom up pressure sensor 23 Boom priority EPPR valve
8 P1 pressure sensor 16 Swing pressure sensor
※ Cluster type 1 only : 10, 15, 16, 19, 20
4-2
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
16
15
14
13
12
11
10
16
15
14
13
12
11
10
12
11
10
60
59
58
57
56
55
54
53
52
51
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
8
7
6
5
4
3
2
1
CD-43
NO.
1.2ROr 2A
SUPPLY A
P2
1.2L 1
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
SIG B
GND
GND
GND
1.2BW 4A
HORN
HORN
PRESS
RETURN C CN-1
SHIELD
1 0.8L 85
WIPER IG
CD-42 1
AC 24V
CAMERA 3
CAMERA 2
BUTTON 1
BUTTON 1
BUTTON 2
BUTTON 2
PWM GND
BUTTON 1
BUTTON 1
BUTTON 2
BUTTON 2
PWM GND
1.2ROr 2 1.2ROr
AC GND
2 80P
CAN SHIELD
CLUSTER IG
SUPPLY A 2
CLUSTER TX
CABIN LIGHT
CABIN LIGHT
CLUSTER RX
AC COMP
CAMERA SIG.
P1
CAMERA GND
3
START SW BR
1.2G 0.8G
ILLUMINATION
3 84
CLUSTER GND
ECONO SW NO
PWM SUPPLY
BREAKER SW
BREAKER SW
PWM SUPPLY
START SW ACC
SIG
AIR COMP SW
AIR COMP SW
B 3
RS232 TX2(GPS)
RS232 RX2(GPS)
ECONO SW COM
1.2BW 4
SAFETY SW NC
SAFETY SW NO
4 0.8BW 81P
HEAT SEAT 3GND

AIR-CON
BLOWER SIG.
SWITCH PANEL IG
ACCEL DIAL LED

HOUR METER SIG.
4
POWER MAX SW
POWER MAX SW
RETURN C
CIGAR LIGHTER IG
ILLUMINATION
REVERSE FAN
PRESS
OVERLOAD SW NO
RH CONSOLE
ACCEL DIAL GND
SAFETY SW COM
LH CONSOLE
CLUSTER BATT.24V
PWM TILT SIGNAL

SWITCH PANEL GND
CASSETTE RADIO IG
START KEY SW COM
OVERLOAD SW COM
DESTINATION
REVERSE FAN AUTO
EM'CY STOP JUMP

EM'CY STOP JUMP
BEACON SW COM(IG)
5
GND(SERVICE CONN)
ONE TOUCH DECEL

ONE TOUCH DECEL
ACCEL DIAL SIGNAL
START KEY SW START
BREAKER SW COM(IG)
CD-44
CASSETTE RADIO GND
ACCEL DIAL SUPPLY

WIPER CONT BATT.24V
REVERSE FAN MANUAL

CAN Hi(SERVICE CONN)
HEAT SEAT SW COM(IG)

CAN Lo(SERVICE CONN)
DC-DC CONVERTER 24V

1.2ROr 80Q 6
QUICK COUPLER SW NO
PWM ROTATE SIGNAL

AIR COMP SW POWER
P DUMP(SERVICE CONN.)
SWITCH PANEL PREHEAT

SUPPLY A 6 AC CONTROLLER B+
AC CONDENSOR FAN
A4
RS232 TX(SERVICE CONN.)
0.8G
RS232 RX(SERVICE CONN.)

181 7
CASSETTE RADIO BATT.24V
SWITCH PANEL TRAVEL ALARM

SWITCH PANEL WORK LIGHT
SWITCH PANEL HEAD LIGHT
SWITCH PANEL CABIN LAMP

SIG B
WIPER CONT WASHER P/P DRIVE

7
0.8BW 81V 8
RETURN C
PRESS
8
9
CN-75 9 10
9
8
7
6
16
15
14
13
12
11
10
16
15
14
13
12
11
10
12
11
10
2
2
9
8
7
5
9
8
7
5
5
4
3
1
4
1
4
1
6
6
2
3
3
60
59
58
57
56
55
54
53
52
51
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
2
5
4
1
9
8
7
6
3
1.2Br 6
1
8
7
6
0.8Br
5
4
3
1
2
CN-5
CN-4
CN-7
CN-8
1.2RW
0.8RW
7
Pa
2
MAIN
2
2
1
CN-11
PUMP
1
CD-10
2
C 1
CN-68
1.2B
CN-140
0.8Gr
2W
0.8L
1.2B
0.8Y
0.8B
0.8B
0.8B
0.8B
1.2G
0.8L
0.8L
0.8B
0.8B
0.8Y
0.8W
0.8B
0.8Y
0.8B
0.8V
0.8Y
0.8V
1.2V
1.2B
1.2B
1.2V
1.2B
0.8V
0.8V
0.8B
0.8V
0.8V
0.8B
0.8R
0.8R
CD-1
0.8G
0.8G
0.8Gr
0.8Gr
0.8Or
0.8Gr
0.8RW
0.8G
0.8G
0.8W
1.2Br
0.8Br
2L
0.8Gr
1.2Or
1.2Gr
0.8Gr
2Y
2B
0.8BW
0.8BW
0.8BW
0.8LOr
FUEL LEVEL
0.8WOr
HYD TEMP
0.8YW
0.8VW
0.8BW
0.8RW
SAFETY SOL
0.8GW
0.8RW
0.8GrW
0.8GrW
0.8BOr
0.8VOr
1.2ROr
0.8ROr
0.8BrW
0.8BrW
0.8WOr
0.8GrW
0.8GrW
1.2G
0.8G
103
102
0.8B
0.8ROr
0.8Br
AIR CLEANER SW
1.2V
QUICK COUPLER
1.2G
2
4
1
16A
9
8
7
6
5
49
48
46
45
44
43
42
41
40
38
G43
0.8B
192
CD-2 0.8BW
0.8BW
35
34
33
32
31
30
29
28
27
26
25
22
20
18
17
16
15
14
39
13
12
73
74
11
82
3F
191
81T
0.8YOr
0.8YOr
37A
36A
18B
37E
36E
81U
3G
G41
G42
76
77
159
0.8BW
0.8LOr
156
155
190
157
160
21E
21A
19E
19A
53A
52A
51A
10A
7
49
151
150
147
148
129
4
10E
152
134
83
100
81S
81R
101
81Q
21 2V
GROUP 2 ELECTRICAL CIRCUIT
19 2B
CD-70
1.2ROr 80M
SUPPLY A
N1
0.8Y 87
SIG B
0.8BW 81M
PRESS
RETURN C
CD-71
1.2ROr 80L
SUPPLY A
N2
0.8Gr 88
SIG B
0.8BW 81L
RETURN C
PRESS
CR-7
CD-6 148A 0.8L
1.2ROr 80J 30
SUPPLY A 148E 0.8L 87a 87 85
AC
0.8OrW 90 86
SIG B 60 0.8V
0.8BW 81J 87
RETURN C 149 1.2Br
TRAVEL
85
COMP RY
CD-7 30 86
1.2ROr 80H 87a
SUPPLY A
0.8LW 91
SIG B
0.8BW 81H CN-29
WORK
RETURN C 149 1.2Br
2 Pa
CD-44 150 1.2G
CIRCUIT(1/2, CLUSTER TYPE 1)
1.2ROr 80G 1
SUPPLY A
A4
R/DRYER
0.8YW 92
42
43
44
SIG B
135
135
0.8BW 81G
CN-22
PRESS
RETURN C
39A 0.8GrW
2 M
CD-24 13 0.8V
1.2ROr 80E
0.8B
0.8W
1
0.8Gr
SUPPLY A
0.8BW
0.8BW
0.8BOr 94
2.5k
2.5k
SIG B
0.8BW
WASHER P/P
81E DO-5
SWING
RETURN C 39E 0.8GrW
2
6
5
4
1
2
2
6
5
4
1
3
CD-31 13A 0.8V
CN-16B
1.2ROr 80N 1
CN-16
SUPPLY A
0.8V 8
SIG B
0.8B
0.8W
0.8Br
0.8BW
0.8Gr
81N
0.8B
LOAD
0.8LW
OVER
0.8BW
0.8W
0.8Gr
RETURN C
CD-32 CN-259
1.2ROr 80A
SUPPLY A 157A 0.8B
59
58
69
68
67
1
37
99
36
0.8WOr 96
UP
155A 0.8L
123A
SIG B
192
191
0.8BW 81A 2
159 0.8G
BOOM
RETURN C
3
5B 0.8Gr
4
160 0.8V
0.8RW
CAMERA
0.8WOr
5
6
2
1
CN-263
AIR COMP RY
3 2B
CN-51
2B 3
0.8B 3E
GND MAIN 1
0.8R 78
BATT POWER 24V 2
0.8RW 79
POWER IG 3
0.8ROr 80
POWER 24V OUT 4
0.8BW 81
GND PRESSURE 5
0.8Gr 36
POWER_5V OUT 6
0.8B 37
GND 5V 7
190 2W
G/A MOTOR(+) 8 1
G/A MOTOR(-) 9 23A 2W
0.8B
2
CS-74
3A
GND MAIN 10 CS-74B
0.8B 53
MASTER SW
CAN SHIELD 11
0.8BW 82
PROGRAM DUMP 12
TACHO SENSOR- 13
CR-9
TACHO SENSOR+ 14 140 2R
30
PWM OUTPUT2 15 140A 0.8R 87a 87 85
86
PWM OUTPUT1 16 21 2V
87
RESERVE DO2 17 30 0.8Gr
85
RAMLOCK LAMP 18 30 86
0.8W 11 87a
HOUR METER 19
CABIN LAMP RY
0.8V 70
TRAVEL BUZZER 20
0.8V 51
CAN1 Hi-ECM 21
CAN2 Hi-APTC 22
0.8L 2
RS485+(TX)-CLUSTER 23
0.8R 73
RS232C1 TX-HRDT 24
0.8GrW 76 CR-45
RS232C2 TX-RCM 25 G2 0.8B
1
PWM INPUT 1 26 34 0.8WOr 4 5 1
2
ECM
PWM INPUT 2 27 23E 0.8W

0.8L 38 3
TILT SIG. 28
0.8LOr 45 4
ROTATE SIG. 29 139 1.2Gr 3 2
POWER RY
5
AI RESERVE 30
0.8G 52
CAN1 Lo-ECM 31 CR-35
23 2W
CAN2 Lo-APTC 32 30
0.8Y 1 34A 0.8WOr 87a 87 85
RS485-(RX)-CLUSTER 33 86
0.8G 74 138 2WR
RS232C1 RX-HRDT 34 87
0.8BrW 77 G3 0.8B
RS232C2 RX-RCM 35 85
0.8LOr 101 30 86
POWER RY
HYD. TEMP SENDER 36 87a

WATER TEMP SENDOR 37
0.8YOr 100
FUEL LEVEL SENSOR 38
0.8W 66
ALT. LEVEL 39
GOV. POTENTIO SIG. 40
CN-36
CN-52 57 3W ECM 30A
138
1
ARM REGEN SOL 1 25 0.8Y ROOM LAMP/CASSETTE 10A
2
COOLING FAN REVERSE SOL 2 78 0.8R MCU 30A
3
RAMLOCK SOL 3 23 2W START KEY 30A
0.8GW 4
121 147 2Y AIR CON/HEATER 20A
ATT CONFLUX SOL. 4 5
0.8LOr 120 WIPER 10A
ATT PRESS SOL. 5 12 0.8R
5R 146
1.2Br 6
158 6 0.8RW CLUSTER 10A
ATT SAFETY SOL 6 7
139 1.2Gr
0.8BrW 119 5A
POWER MAX SOL 7 56 0.8Or ECM
0.8GOr 8
118 79 0.8RW MCU CONT. 20A
TRAVEL SPEED SOL 8 9
RESERVE EPPR+ 9 86 0.8R MCU EPPR 20A
0.8Or 10
106 32 0.8RW SWITCH PANEL 10A
COOLING FAN EPPR+ 10 11
CRUISE LAMP 26 0.8V CASSETTE 10A
11 12
WORKING BRAKE FAIL LAMP 5 0.8Gr CLUSTER 10A
12 13
RESERVE LAMP 17 1.2V CONVERTER 20A
13 14
TM OIL LOW LAMP 130 2RW WORK LAMP 30A
14 15
0.8Br 123 30A
ANTI RESTART RY 15 140 2R CABIN LAMP(OPTION)
16
MCU
0.8V 122 10A
FUEL WARMER RY 16 39 0.8GrW WIPER
17
ENG PRE-HEAT RY 50 1.2Br HEAD LAMP 20A
17 18
ENG STOP RY 75 2L FUEL HEATER 30A
18
4-3
19
REVERVE EPPR- 131 0.8Y START,STOP 20A
19 20
0.8G 107 10A
COOLING FAN EPPR- 20 124 0.8V HORN
0.8W 21
99 148 2L AC& HEATER 20A
ACCEL DIAL SIG 21 22
WORK BRAKE PRESS 22 134 1.2V SAFETY SOL 10A
23
145 5W
0.8WOr 96 20A
BOOM UP PRESS SENSOR 23 14 1.2ROr SEAT
0.8BOr 24
94 18 1.2Or SOLENOIDE 20A
SWING PRESS SENSOR 24 25
ARM IN OUT BUCKET IN PRESS 25 16 1.2Gr CIGAR 20A
0.8OrW 26
90 20 1.2Br OPTION(BEACON) 20A
TRAVEL PRESS SENSOR(A) 26
0.8Gr 27
88 47 1.2Or SOLENOIDE 20A
N2 PRESS SENSOR 27 28
0.8Br 86 10A
TRAVEL FWD PRESS 28 132 0.8L PRE-HEAT
0.8G 29
84 126 2Y FUEL P/P 20A
P1 PRESS SENSOR 29 30
0.8VOr 9 10A
OVERLOAD SENSOR 30 EPPR
0.8BW 31
98
FUSE BOX
ATT. PRESS SENSOR 31

RESERVE SENSOR 32
BRAKE PRESS FAIL 33
TM OIL PRESS 34
0.8LW 91 CR-46
WORK PRESS SENSOR(A) 35 75
0.8G 181 2L
P3 PRESS SENSOR 36 30
0.8Y 75A 0.8L 87a 87 85
87 86
N1 PRESS SENSOR 37 133 2Br
0.8L 85 87
P2 PRESS SENSOR 38 122 0.8V
0.8G 151 85
BLOWER SIG. 39
30 86
AI RESERVE 40 87a
FUEL HEATER RY
CN-147
CN-53 133 2Br
0.8RW 116 B
ATT FLOW EPPR+ 1 G31 2B
RIGHT TILT EPPR+ 2 A
LEFT TILT EPPR+ 3
0.8R 86
EPPR POWER 4
FUEL HEATER
RIGHT ROTATE EPPR+ 5

LEFT ROTATE EPPR+ 6
CN-61
TRAVEL EPPR+(w) 7 G21 2B M
0.8RW 102 1
PUMP SHIFT EPPR+ 8 126 2Y
0.8RW 104 2
BOOM PRIORITY EPPR+ 9
FUEL PUMP
EPPR 24V 10
0.8LW 117
ATT FLOW EPPR- 11
RIGHT TILT EPPR- 12
LEFT TILT EPPR- 13
0.8B 97
EPPR GND 14
RIGHT ROTATE EPPR- 15
LEFT ROTATE EPPR- 16
TRAVEL EPPR-(w) 17
0.8Br 103
PUMP SHIFT EPPR- 18
0.8W 105
BOOM PRIORITY EPPR- 19
EPPR GND 20
REVERSE FAN MANUAL 21
REVERSE FAN AUTO 22
0.8YOr 83
AIR CLEANER SW 23
NC 24
RAMLOCK SW AUTO 25
TRAVEL/WORK SELECT SW 26 CR-62
PARKING SW 158A 0.8Br
27 1
40 0.8BW 4 5 1
PREHEAT SW 28 2
COOLANT LEVEL SW 29 18A 0.8Or
0.8Y
3
46
POWER MAX SW 30 4
ENG OIL FILTER SW 136 1.2Br 3 2
31 5
BREAKER RY
ENG. OIL PRESS SW 32

RAMLOCK SW OFF 33
RAMLOCK SW ON 34
CRUISE SW 35
TRAVEL LEVER NEUTRAL 36
MODE SW TRAVEL 37
TRAVEL Hi-Lo SW 38
0.8YW 31
TRAVEL ALARM SW 39
0.8GrW 48
ONE TOUCH DECEL SW 40
CN-258
CN-81 3W 00
0.8Or 47G 1
2
0.8V 70 AIR COPM POWER
1
TRAVEL BZ
CN-242
0.8LW 117
1
ATT
0.8RW 116
2
FLOW
CN-70
0.8GOr 118
1
1.2Or 47A
HIGH
2SQ
2
TRAVEL
2SQ
1
2
1
2
35
CN-88
141
CN-95
CN-60
0.8BrW 119
54
53
60
61
66
64
55
5A
56
69
68
67
59
58
52
51
1
156
155
157
157
57E
57A
MAX
1.2Or 47
G23 1.2B
141 1.2G
2
5R
5R
FUSIBLE LINK
1.2G
POWER
G24 0.8B
141E 1.2G
0.8GW
0.8V
3W
3W
0.8W
0.8L
0.8B
0.8Y
0.8B
0.8B
0.8B
0.8V
0.8BOr
0.8G
0.8W
0.8BOr
0.8Or
0.8Gr
0.8Gr
0.8GrW
0.8ROr
5W 144
5W 145
142
143
0.8LW
0.8BW
CN-154
0.8G 107
1
1
1
2
2
FAN
0.8Or 106
CR-1
5
3
4
1
9
8
7
6
2
8
6
7
9
5
4
3
2
1
2
11
12
10
15
14
13
12
11
10
DO-3
DO-1
CN-2
CN-3
BATT RY
COOLING
V
W
2R
2R
SH
SH
1.2L
0.8B
0.8B
1.2B
0.8G
0.8R
0.8W
1.2W
CN-133
0.8Gr
0.8BW
0.8BW
0.8W
0.8BW
105
0.8RW
1.2BOr
0.8GrW
1
1
0.8ROr 3
2
0.8RW 104
20
21
19
18
17
15
14
16
7
9
10
10
2
4
BOOM
5
6
12
11
13
PRIORITY
2SQ
2SQ
143
146
CN-91
0.8G 15
J1939 DATA LINK- 37
0.8V 14
60R
5R
5R
J1939 DATA LINK+ 46

13
SH 16
J1939 DATA LINK SLD 36
J1708 DATA LINK- 27
2
1
J1708 DATA LINK+ 26

7
9
8
10
10F
G25
0.8Gr 21
0.8GrW
CS-74A
R.THROTTLE +5V 48
0.8W 20
R.THROTTLE POS SIG 21
W
SH
12V X 2
0.8B 19
TO:STARTER "B" TERM.
1.2B
0.8B
0.8R
R.THROTTLE POS RTN 49

1
CS-74
1.2ROr
4
0.8BW
6
BATTERY
R.THROTTLE ENABLE SIG 18

43
124A
41
124
127
0.8BW 17
CN-28
11
12
23
24
24
23
R.THROTTLE RETURN 20
3
4
1
2
60B
1.2R
1.2B
1F
1.2L
1
2
1.2W
UNSWITCHED POWER+ 17
CL-3
0.8V
0.8V
AC COMP
1.2G
1.2R 1A
0.8L
0.8Y
CN-249
MASTER SW
0.8L
3W/300
UNSWITCHED POWER+
0.8Y
29
8
0.8GrW
0.8RW
0.8BW
128
130
1.2R 1E
130A
UNSWITCHED POWER+ 7
2
CAMERA
1
1
2
128
CD-69 CN-15
G11
1.2R
RS-1
HEAD LAMP
2E
10
OEM PORT 50P
1.2ROr 1 0.8ROr
28
10
50
80 UNSWITCHED POWER+ 28
5
6
7
8
3
19
11
10
4
2
5
G26
1
64
61
10G
G22
50A
SUPPLY A 1 1.2R 2A
2RG
2RW
0.8BW 2 0.8BW 98 UNSWITCHED POWER+ 18

CR-2
CN-14
0.8VW
0.8RW
SIG B 2 1.2B 25
2B
31P OEM
1.2BW 0.8BW
4
3 81 UNSWITCH POWER RTN- 50

2RG
15A
14A
RETURN C 3
132 0.8L
131 0.8Y
1.2B
1.2B
26
1.2B
123 0.8Br
3
0.8Br
1.2Br
CR-24
UNSWITCH POWER RTN- 40

0.8BOr
22 0.8BOr
55 0.8BOr
54 0.8ROr
1.2ROr
1.2ROr
1.2ROr
0.8GrW
CR-23
0.8BrW
4
87
85
86
CN-236
30
1.2B 27
START RY
2
1
87a
1.2LOr 4 0.8LOr
HORN RY
CR-4
120 UNSWITCH POWER RTN-

1.2R
39
GLOW PLUG RY
1 5 1.2B 28
2
1
1.2Or 1.2Or
0.8V
47E
ATT. PS ATT.
UNSWITCH POWER RTN-

0.8G
5 30
8W
3
3
4
4
2
2
5
5
1
1
2
8W
6
1
1.2B
2
1
29
2
CN-12
87
85
86
30
6 0.8GW 121 UNSWITCH POWER RTN- 29

87a
CR-5
CL-4
CN-149 7 0.8ROr 3
CL-24
CR-36
CR-13
30 86
87a 87 85
1.2Br 7 1.2Br 158 POWER IG

2
1
4
4
38
2B
1 8
1.2Or
3
3
5
5
5
ATT.
2
2R 1
SOL.
WORK LAMP RY
2 9
FROM BATT.RY
HEAD LAMP
2
1
2
1
30 86
87a 87 85
10
HEAD LAMP REAR
CN-237
43
24
22
25
23
34
45
10 1.2B G32
PRE-HEAT RY
1.2GW
127
CN-99
G13
G12
1 11
HEAD LAMP RY
127A
11
ANTI-RESTART RY
1.2Br 136
1.2BOr
1.2Or
1E
15 R
2E
ATT.
1F
1A
12
2A
2F
2
1G
2G
CN-80
1.2B
1.2G
1.2G
1.2B
GLOW PLUG
1.2R
M
1.2B
1.2B
PRESS SAFETY CONFLUX

1.2B
1.2R
1.2R
1.2B
1.2R
B+
2 L
1 P
3 FI
CN-45
B+
4 NC
1
2
1
2
1
2
1
2
ALT.
1
2
1
2
CL-6
SENSOR
CL-5
FUEL HEATER
CN-20
3
HORN
CN-25
CN-74
CL-36
M
CL-37
ACTUATOR
CN-66
STARTER
1.2B
U
1
WORK LAMP
COOLANT LEVEL +5V
0.8Br
COOLANT LEVEL RTN
GRID HEATER ACT SIG
2
COOLANT LEVEL Hi SW
COOLANT LEVEL Lo SW
GRID&SWITCH RETURN
BREAKER
4809S4EL03
·ELECTRICAL
ELECTRICAL CIRCUIT (2/2, CLUSTER TYPE 1)
RELAY
INTAKE M/ACT TEMP M/ACT MODE(D/FOOT) MODE(VENT) BLOWER
Service Tool DC/DC CONVERTER CIGARLIGHT 2 7 2 7
OVERLOAD SW 3 M 1
M 4
3 M 1
M 4 BLOWER
3
7
1
7
HOUR METER
24V
12V SOCKET
RS232 P DUMP
12
12
10
5 5
4
9
M
ECONO SWITCH
12V
4
2
h
5
6
7
5
6
7
5
6
7
RS232 RX
1
2
3
4
5
6
7
1
2
3
4
1
2
3
4
1
2
3
4
12
RS232 TX
12
10
3
4
9
CAN2 Lo
CAN2 Hi
CN-48
CAN Lo
CAN Hi
GND
CN-139
1
IG 24V
2
1
12V
4
2
3
24V
CL-2
CN-138
GND
3
2
1
CS-67
11
1
1
2
8
CS-50
C
A
B
1
10
11
12
CN-21
9
4
8
1
2
3
6
7
11
1 12
1.2Gr
7
8
CS-52
2
1.2B
ROr
0.8W
0.8B
0.8Y
3 1 WIPER CUT
G
H
B
00
C
E
A
10
0.8G
11
F
12
1.2Or
10
9
R 3
8
1
2
3
6
7
24M 1.2B
1.2Or
1.2V
2
24L 1.2B
0.8VOr
9 0.8Br
0.8Or
0.8Or
0.8Br
Gr 12 4
24Q
0.8V
24R 0.8B
12B
5 3
CS-53
35E
HARNESS AIR-CON
24V
21
13
R 4A 5
60
1 0.8BW
0.8Or
4
27F 0.8Br
60
22
0.8G
0.8G
0.8B
24T 0.8B
6 0.8G
6 0.8G
6 0.8G
6 0.8G
2 0.8G
3 0.8R
5 0.8V
4 0.8B
4 G 8 6 NO.
CN-11 DESTINATION
61
11
27
10
61
5 23F 0.8Or 3
L 9 7 7 1
B
6 M 2 6 23F 0.8Or 9 1 GND
62
62
CN-126
Or
8
7
2
2A
4 2 BLOWER SIG
10
9 8
9
8
7
6
5
4
3
2
1
3 3 FUSE(IG)
11
WIPER MOTOR 10
10 4 4 REVERSE FAN
9A 0.8Br
11 5 FUSE(Battery)
0.8BW
24S 0.8B 11 12 5
0.8G
0.8G
0.8R
0.8V
0.8B
12 6 6 DPS(COMPRESSOR)
CN-141 QUICK COUPLING SW 7 7 CONDENSOR FAN
G 8
59
73
72
71
70
69
FEED BACK 1 8 8 ILLUMINATION
W 1
MOTOR DRIVE SIG 2 CN-17 CN-113
L 9 00 0.8B
MOTOR DRIVE- 3 1
R 10 1 W 0.8W 48 1
MOTOR DRIVE+ 4 2 00 0.8G
B 2 2 B 1.2B 24B 2
GND 5 3
GrW 3 3 GrW 0.8ROr 65 BUZZER
VCC 6 4
R 4 4 R 0.8R 14
CONTINUE 24V 7 5
V 5 5 V 0.8V 15
WASHER P/P 8 6
L 6 6 L 0.8L 49
WASHER SIG. 9 7
Br 7 7 Br 0.8Br 50
6 0.8RW
CN-56
INT. SIG 10 8 RW
Or 11 1 BATT.24V
WIPER CUT SW 11 WR
2 SIG 3
N.C 12 81 1.2B B
12 3 GND
FEED BACK 13
Gr WIPER MOTOR HARNESS 1 0.8Y Y
4 TX
10
11
12
13
14
15
16
17
18
10
11
12
13
14
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
5 0.8Gr Gr
WIPER MOTOR CONT. 5 IG 24V
WL
TEMP MOTOR ACT(+)
DUCT SENSOR(GND)
SIG 2
TEMP MOTOR ACT(-)

6
DPS(COMPRESSOR)
MODE M/ACT(FOOT)
0
BLOWER RELAY(Lo)
0
0
INLET MOTOR(REC)
INLET MOTOR(FRE)
1 0.8W
MODE M/ACT(PBR)
MODE M/ACT(DEF)
W
1
2
AMBIENT SENSOR
TEMP M/ACT(PBR)
CONDENSOR FAN
MOTOR ACT(REF)
7 CAMERA SIG
DUCT SENSOR(+)
W/TEMP SENSOR
MODE M/ACT(M+)
POWER TR BASE
MODE M/ACT(M-)
FET(FEED BACK)
2 0.8L L
INCAR SENSOR
8 RX
REVERSE FAN
ILLUMINATION
ILLUMINATION
> > >
BATTERY(+)
CLUSTER
FET(GATE)
POWER IG
POWER TR AMBIENT INCAR W/TEMP
SENSOR SENSOR SENSOR
DUCT
IG 24V
CS-82 CN-5 SENSOR
GND
NC
NC
NC
0.8B 20E 1 0.8Y
12 1 1 MCU RX
12 11 0.8LW 26A 2 0.8L
11 2 2 MCU TX AC & HEATER CONTROLLER(AUTO)
3 SH
10 3 3 MCU GND
10 4 0.8B
8 9 4 4 GND
4 1.2ROr 19A 5 0.8Gr
8 5 5 FUSE
9 6 0.8RW
7 7 6 6 FUSE CS-1
3 7 0.8B CN-24
6 7 7 NC Gr 11 0.8G 2
8 0.8Or 2
5 8 8 NC 0.8V 3 CN-10 NO. DESTINATION
1.2LW 26 59 0.8BW 1
4 9 9 P DUMP(MCU) CL-1 1 1 NC
9 0.8Br DOOR SW Gr 11 SPEAKER RH
3 10 10 QUICK COUPLING SOL 3 2 2 NC
10 0.8V 0.8Y 1 1 0.8Y
12 1 2 11 11 OVERLOAD PS 2 3 3 FUSE
11 0.8VOr 0.8B 6 2 0.8G
1 12 12 MCU OVERLOAD 1 4 4 CASSETTE RH-
12 0.8ROr 3 0.8V
SPARE 13 13 HEAD LAMP RY CN-23 ROOM LAMP 5 5 CASSETTE RH+
13 0.8W 0.8Y 4 4 0.8Y
14 14 MCU HOURMETER 2 6 6 CASSETTE LH-
69 0.8G 0.8L 5 5 0.8L
15 15 RS232 RX(MCU) 1 7 7 CASSETTE LH+
70 0.8R 6 2.0B
16 16 RS232 TX(MCU) SPEAKER LH 8 8 GND
71 0.8B 7 2.0B
17 17 GND CL-7 9 9 GND
14 0.8R 1.2BrW 8 8 1.2BrW
18 18 FUSE 10 10 BEACON SW
15 0.8V M 1.2B 6A 9 2.0V
19 19 WASHER P/P 11 11 CABIN LIGHT RY
72 0.8V 10 2.0V
20 20 CAN Hi BEACON LAMP 12 12 CABIN LIGHT RY
73 0.8G
21 21 CAN Lo
74 SH CL-8 CL-9 HARNESS CABIN
22 22 Shieeld 2.0V 9 10 2.0V
2 2
23 23 NC 1.2B 6B 7 1.2B
65 0.8ROr 1 1
24 24 WIPER FUSE
19 1.2ROr CABIN LIGHT
25 25 FUSE
20 1.2B
26 26 GND
21 1.25Gr
27 27 FUSE ACCEL DIAL LED
22 1.2V
CS-23 28 28 FUSE CS-83
CN-279
0.8B 24J 23 1.2Or 0.8B 19G
12 29 29 FUSE 12 CS-26A
1
2
12 11 0.8BrW 58A 24A 1.2B 12 11 0.8Or 18A 5E 0.8BW
11 30 30 GND 11 2
24E 1.2B 10 4E 0.8G
10 24 2B 31 31 GND 10 0.8G 15
1
10
0.8ROr
8 9 32 32 NC 8 9
BREAKER
0.8B
4 1.2Br 27E 27 1.2Br 4 0.8V 16
8 33 33 FUSE 8
9 28 2V 28A 1.2V 9 0.8BrW 17
7 7 34 34 CABIN LAMP RY 7 7 CN-156
3 19 1.2B
19F
32
3 29 1.2BOr 6 2
6 35 35 ANTI RESTART RY 31 1.2ROr
30 1.2W 1
5 36 36 FUSE 5
1.2BrW 58 0.8Or 18
4 37 37 NC 4 AIR SEAT
28E 0.8Gr 20
0.8V 3
3 38 38 CABIN LAMP RY CN-8 NO. DESTINATION
15 0.8G
12 1 2 39 39 joy stick 12 1 2 1 1 NC
40 NC 1 16 0.8V
1 40 2 2 FUSE
75 0.8BrW
BEACON LAMP SW 41 41 RS232 RX2 CRAB SW 17 0.8BrW
3 CRAB COM
76 0.8GrW
3
42 RS232 TX2 18 0.8Or
CN-125A 42 CS-99 4 4 NC
0.8W 30E 0.8B 19A 19 1.2B
BATTERY POWER 1 43 43 NC 12 5 5 NC
1.2R 47A 44 NC 12 11 0.8GW 21A 20 0.8Gr
KEY "IG" 2 44 11 6 6 CRAB SIG MCU
45 NC 32 0.8ROr
NC 3 45 10 7 7 ILLUMINATION
0.8BrW 75 35 0.8Y 10 22 0.8L
RX232(1)-TX 4 46 46 FUSE 8 9 8 8 NC
0.8B 71A 36 0.8V 4 0.8L 22 23 0.8VW
RX232(1)-GND 5 47 47 FUSE 8 9 9 NC
37 0.8B 9 0.8L 22A 24 0.8R
RX232(2)-RX 6 48 48 GND 7 7 10 10 NC
38 0.8BrW 3 25 0.8LW
RX232(2)-TX 7 49 49 HEAD LAMP RY 6 11 11 NC
39 0.8VW 26 0.8RW
RX232(2)-GND 8 50 50 WORK LAMP RY 5 12 12 NC
0.8GrW 76 00 0.8B 0.8GW 21
RX232(1)-RX 9 51 51 CAMERA GND 4
00 0.8W 0.8RW 26
NC 10 52 52 CAMERA SIG 3
00 SH
53 53 CAMERA SHIELD
MAIN GND 11
0.8B 24H 40 0.8WOr 12 1 2 HARNESS RH,CONSOLE
MAIN GND 12 54 54 PRE-HEAT 1
41 0.8Gr
55 55 CABIN LAMP RY AIR-COMP
RMS 42 0.8YW
56 56 MCU TRAVEL ALARM SW
CN-10 43 0.8RW CS-100
57 57 FUSE 0.8B 19E
NO.
1 NC 1 44 0.8B 12 CN-7 DESTINATION
58 58 GND 12 11 0.8V 29
2 NC 2 45 0.8WOr 11 1 1 NC
0.8Y 35A 59 59 POWER RY 0.8V 29
3 ROOM LAMP 24V 3 46 0.8GW 10 2 2 NC
0.8G 51 60 60 BATT. RY 10 0.8VW 23
4 SPEAKER RH- 4 6 9 3 3 NC
0.8V 53 4 31 1.2ROr
5 SPEAKER RH+ 5 8 4 4 NC
0.8Y 52 9 0.8G 4 4 0.8G
6 SPEAKER LH- 6 5 7 1 5 5 BREAKER SW
0.8L 55 3 0.8R 24 BREAK
B 0.8BW 5 5 0.8BW
7 SPEAKER LH+ 7 6 2 6 6 BREAKER RY
1.2B 24F 24 2B CS-2 0.8R 24A CS-26 0.8B 6 6 0.8B
8 GND 30 1.2W 5 7 GND
H0 I
8 1 7
1.2B 24G 1 0.8Br 30 HORN
R 0.8Grw 7 7 0.8Grw
9 GND 9 46 0.8GW 4 2 8 8 HORN RY
2
0, I
1.2BrW 58 0.8LW 25 CS-5 0.8L 8 8 0.8L
10 BEACON LAMP 10 47 1.2R 3 9 9 NC
3 4
H
1.2V 28F 28 2V 2 L 0.8L 9 9 0.8L
11 CABIN LIGHT 11
4 12 1 2 10 10 NC
BR ACC
1.2V 28G 1 0.8Br 30 0.8Gr 10
B
2 10 0.8Gr
12 CABIN LIGHT 12 3
1 11 11 NC
5 1 Gr 0.8Gr 11 11 0.8Gr
HARNESS CABIN 29 1.2BOr SPARE 12 12 NC
6
CN-142 13 13 NC
ST C
5 0.8Gr 12 12 0.8Gr
6 + A 14 14 MCU 5V
0.8W 13 13 0.8W
START KEY SW S B 15 15 MCU ACCEL SIG.
0.8B 14 14 0.8B
CN-116 - C 16 16 MCU SUPPLY GND
12 NC ACCEL DIAL
44 0.8B
11 GND
43 0.8RW
10 POWER 24V
9 NC
42 0.8YW CS-33
8 TRAVEL ALARM
41 0.8Gr 6 6
7 CABIN LIGHT OUT
40 0.8WOr
6 PRE-HEAT
5 5 HARNESS LH,CONSOLE
49 0.8L 4 4
5 WASHER SIG
48 0.8W 3 3
4 WIPER MOTOR DRIVE
50 0.8Br 2 2 CN-4 NO. DESTINATION
3 INT. SIG
39 0.8VW 1 1
2 WORK LIGHT OUT 1 1 NC
38 0.8BrW
EM'CY STOP SW 2 2 NC
36E
36E
1 HEAD LIGHT OUT

12F
25
68
18
63
31
51
17
35
12
53
16
37
37E
SWITCH PANEL 3 3 NC
36
4 4 NC
0.5ROr
0.8ROr
0.8BOr
0.5BW
0.5GY
0.8Y
0.5YL
0.8Y 4
0.5LY
4
0.5Lg
0.8Or
0.5V
0.5V
MCU POWER MAX

0.8G
5
0.8V
0.5B
0.8Y
0.8V
0.8B
power 1 5
max B 0.8B 5 5 0.8B
cs-29
2 6 6 MCU SIG.GND
0.8Grw 6 6 0.8Grw
CN-246
MCU DECEL
CN-27A
7 7
CN-27
1
decel 0.8B 7 7 0.8B
10
11
12
13
14
15
16
R
1
4
5
10
2
4
5
8
3
6
3
1
2
3
4
5
6
7
9
8
2 8 8 MCU SIG.GND
cs-19 0.8L 8 8 0.8L
9 9 NC
REMOCON GND
2 L 0.8L 9 9 0.8L
SPK FRT RH+
10 NC
SPK FRT LH+
SPK FRT RH-
10
SPK FRT LH-
REMOCON+
0.8Gr 10 10 0.8Gr
USB(GND)
BACK UP+
11 NC
TEL MUTE
AUX GND
AUX GND
USB GND
11
HARNESS RH SIDE
USB(D+)
1 Gr 0.8Gr 11 11 0.8Gr
USB(D-)
ANT 12V
USB D+
AUX S1
USB 5V
AUX S2
USB D-
12 12 NC
AUX R
AUX L
USB+
GND
13 NC
ACC
CS-4 13
ILL+
NC
NC
NC
NC
ILL-
NC
NC
NC
B C 0.8B 12 12 0.8B
A 14 14 GND
0.8V 13 13 0.8V
USB & SOCKET ASSY REMOTE ASSY RADIO & USB PLAYER B 15 15 NC
0.8G 14 14 0.8G
A C 16 16 SAFETY SOL
SAFETY SW
4809S4EL04
4-4
■ ELECTRICAL CIRCUIT (1/2, CLUSTER TYPE 2)
AC
COMP RY
CS-74
R/DRYER 5R 146 146 5R
1
87a 87 85
30 86
WASHER PUMP ECM POWER RY 145 5W 143 5R
Pa
2
POWER RY
M
MASTER SW 138 2WR CS-74A
CABIN LAMP RY
CN-22
CN-29
2
FUSE BOX
DO-5
CR-7
CN-95
87a
5
2
1
3
30
2
86
85
1
87
87a 87 85
MASTER SW
30 86
2
1
5W 145
87a 87 85
30 86
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
2
1
2
3
4
5
6
7
8
9
4
CR-45
5W 144
1
30A
10A
30A
30A
20A
10A
10A
10A
20A
20A
10A
10A
10A
20A
30A
30A
10A
20A
30A
30A
10A
20A
10A
20A
20A
20A
20A
20A
10A
20A
10A
0.8GrW
0.8GrW
5
2
4
3
CR-35
0.8V
148A 0.8L
148E 0.8L
0.8V
FUSIBLE LINK
0.8
0.8
0.8V
0.8
87a
30
86
CR-9
85
87
87a
143
ROOM LAMP/CASSETTE
5R
CABIN LAMP(OPTION)
30
86
85
87
2
OPTION(BEACON)
5R BATTERY
AIR CON/HEATER
142
149
150
NO. DESTINATION CN-11
39E
13A
149
1
39A
0.8B
0.8Y
0.8WOr
60
0.8L
0.8L
SWITCH PANEL
13
129
CS-74B
2B
FUEL HEATER
FUEL HEATER RY
2WR
1 AC GND 1 CN-60
0.8B
AC& HEATER
START,STOP
0.8Gr
CONVERTER
SAFETY SOL
TRAVEL SOL
WORK LAMP
2W
60R 60B
0.8R
SOLENOIDE
MCU CONT.
HEAD LAMP
FUEL PUMP
START KEY
1
2
FUEL HEATER
CASSETTE
2 BLOWER SIG. 2
2R
2V
PRE-HEAT
132A
CLUSTER
55
67
FUEL P/P
148
132
2L
87a 87 85
OPTION
CN-36
3 AC 24V
138
30 86
3
SPARE
G3
WIPER
SPARE
SPARE
M
24
34
WIPER
CIGAR
140
140A
HORN
21
30
2W
2W
4 REVERSE FAN CR-1
ECM
4
MCU
ECM
CN-96
3Y 147 12V X 2
5 AC CONTROLLER B+ 5 G23 1.2B
2
1
CR-46
0.8 150
CN-61
6 AC COMP
87a
6 141 1.2G
30
TO:STARTER "B" TERM.
86
85
87
1
2
7 AC CONDENSOR FAN 7
2Br
0.8GrW
1.2ROr
2B
1.2RW
0.8RW
10E
78 1.2R
25 0.8Y
0.8ROr
0.8Gr
1.2Or
1.2Gr
1.2Or
1.2Br
1.2Br
24 2W
23 2W
8 ILLUMINATION 8
2RW
12 0.8R
147 3Y
1.2V
2.0Y
0.8V
1.2V
0.8L
BATT RY
0.8
0.8
2R
2Y
2L
2L
45 FUEL HEATER
G31
0.8V
2B
2Y
0.8L
AIR-CON
133
2Br
2L
DO-3 CN-14
130
140
131
124
148
134
104
132
126
34 GRID HEATER ACT SIG
79
32
26
26
17
39
50
87
18
16
20
47
141E 0.8G CD-43
5
2 1.2ROr 2A
87A
GRID&SWITCH RETURN
133
122
0.8B 4 A 8 43
87
PRESS
G24 0.8B SUPPLY
G21
126
1 1.2L 1 10 ACTUATOR
SIG B
1.2BW 4A
CN-1 11
P2
RETURN C 23 0.8Y
CN-5 1 CD-42
1
1
0.8L 85 19 23 COOLANT LEVEL RTN
0.8Y 24 0.8L
1 CLUSTER TX 1 1.2ROr 2 2 1.2ROr 80P 7 25 COOLANT LEVEL +5V
PRESS
0.8L 2 SUPPLY A 2 23 0.8Y
2 CLUSTER RX 2 1.2G 3 3 0.8G 84 6 22 COOLANT LEVEL Lo SW
SH 3G SIG B 3 0.8L
24
P1
3 SHIELD 3 1.2BW 4 4 0.8BW 81P 5 24 COOLANT LEVEL Hi SW
0.8B 4 RETURN C 4
4 CLUSTER GND 4 4
5
0.8BW 81P 31P OEM SENSOR
5 CLUSTER IG
0.8Gr 5 CD-44
5 1.2ROr 2 6
PRESS
SUPPLY A
6 CLUSTER BATT.24V 6 1.2G 3 CR-23 CN-45
SIG B
7 ECONO SW COM 7
P3
1.2BW 4 6 1.2L M
8 ECONO SW NO 8
0.8BW 82
RETURN C
1.2B
1
2
M
9 P DUMP(SERVICE CONN.) 9
0.8Br 7
10 QUICK COUPLER SW NO 10 B+
0.8Br 7 CN-3 START RY. FROM BATT.RY
11 OVERLOAD SW COM 11 1.2B 1.2B
0.8ROr 00 1 STARTER
12 OVERLOAD SW NO 12 157 0.8B SH 10
0.8ROr 10A 2
13 ILLUMINATION 13 15 R CN-74
0.8W 11 155 0.8L
3
0.8B 9 RS-1 1.2R
14 HOUR METER SIG. 14 156 0.8Y W 2 B+
0.8G 74 4 8
15 RS232 RX(SERVICE CONN.) 15 5A 0.8Gr 0.8R 7
3W/300
1 G
0.8R 73 5
16 RS232 TX(SERVICE CONN.) 1 P
16
0.8B 3F 6
5 1.2BOr
2 L
3 ~
17 GND(SERVICE CONN) 17 54 0.8ROr 0.8RW 11
0.8R 12 7 CR-24 U
18 WIPER CONT BATT.24V 18 8W 3 FI
13 55 0.8BOr 0.8BW 12
0.8V 8 4 1.2W 4 NC
19 WIPER CONT WASHER P/P DRIVE 19 64 0.8BOr 1.2L 6
20 CAN Hi(SERVICE CONN) 9
20 66 0.8W 1.2BOr 5 8W ALT.
21 CAN Lo(SERVICE CONN) 21 10
61 0.8GrW 1.2W 4
11
22 CAN SHIELD 22 60 0.8V 0.8GrW 13 GLOW PLUG RY
12
23 nc 23 CN-80
0.8GrW 39
24 WIPER IG 24
104
CN-28
1.2ROr 13 0.8GrW
25 OPTION SW 25 1
1.2B 15
26 HEAT SEAT GND 26 GLOW PLUG
1.2Gr 16
27 CIGAR LIGHTER IG 27
1.2V 17 AC COMP
28 DC-DC CONVERTER 24V 28
29 SPARE SW COM(IG) 29
1.2Or 18 CN-75
6 1.2Or
1.2B 19A 2
30 GND 30 19 2B 7 1.2Br
1.2B 19E 1
31 GND 31
32 NC 32 EPPR VLV
1.2Br 20
33 BEACON SW COM(IG) 33
34 CABIN LIGHT 34
1.2V 21A 21 2V CN-2
0.8BOr 22 1
35 START KEY SW START 35
1.2W 23 2
36 START KEY SW COM 36 53 0.8B SH 16
37 CAMERA 3 3
37 51 0.8V V 14 14A 0.8V
CN-99
0.8V 21E 4 A A
38 CABIN LIGHT 38 52 0.8G 0.8G 15 15A 0.8G
5 B
39 REVERSE FAN AUTO 39
40 REVERSE FAN MANUAL 6 C B
40 56 0.8Or 0.8ROr 3
41 RS232 RX2(GPS) 41 7
2SQ 57A 3W 2R 2 2SQ
42 RS232 TX2(GPS) 42 8
58 0.8LW 0.8BW 17
43 NC 43 9
59 0.8BW 0.8BW 18
44 NC 44 10
67 0.8B 0.8B 19
45 NC 45 11
25
68 0.8W 0.8W 20
0.8Y 12
46 CASSETTE RADIO BATT.24V 46 69 0.8Gr 0.8Gr 21
0.8V 26 13
47 CASSETTE RADIO IG 47 2SQ 57E 3W 2R 1 2SQ
0.8B 27 14
48 CASSETTE RADIO GND 48
0.8BrW 28 15
49 SWITCH PANEL HEAD LIGHT 49
0.8VW 29
50 SWITCH PANEL WORK LIGHT 50
29
26
27
28
25
1A
17
1E
2E
2A
20
1F
21
19
18
3
0.8 84
51 CAMERA GND 51
0.8G 15
0.8V 14
16
0.8 84
52 CAMERA SIG. 52
0.8BW
0.8BW
0.8ROr
0.8Gr
0.8W
1.2R
1.2R
1.2R
1.2R
1.2R
0.8B
1.2B
1.2B
1.2B
1.2B
1.2B
53 BREAKER SW 53
SH
54 SWITCH PANEL PREHEAT 54
0.8Gr 30
CN-91
55 SWITCH PANEL CABIN LAMP 55
43
20
17
28
18
50
40
39
30
29
38
32
37
46
36
27
26
48
21
49
0.8RW
56
8
7
SWITCH PANEL TRAVEL ALARM 56
0.8RW 32
57 SWITCH PANEL IG 57
R.THROTTLE ENABLE SIG

0.8B 33
UNSWITCH POWER RTN-

UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
58 SWITCH PANEL GND 58
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
R.THROTTLE POS RTN
0.8WOr 34
R.THROTTLE RETURN
R.THROTTLE POS SIG
59 START SW ACC
J1939 DATA LINK SLD

59
0.8GW 35
60 START SW BR 60
J1939 DATA LINK+
J1708 DATA LINK+

J1939 DATA LINK-
J1708 DATA LINK-
R.THROTTLE +5V
CN-8
POWER IG
1 NC 1
2 NC 2
3 NC 3 CN-16B
0.8B 67
4 NC 4 1
5 GND 5
0.8 18 2.5k
2
0.8W 68 OEM PORT 50P
0.8Gr 69
6 NC 6 3
0.8 18 2.5k 0.8LW 58
7 ILLUMINATION 7 4
0.8BW 59
8 NC 8 5
9 NC 9 6
10 NC 10 CR-36
55 0.8BOr
11 NC CN-16 1
11 44 0.8B 132A 0.8L 4 5 1
0.8B 37 2
12 NC 12 1
43 0.8W 0.8W 99 132 0.8L
2 3
CN-7 42 0.8Gr
3
0.8Gr 36
4
1 NC 1 135 0.8BW 67 0.8Y 3 2
4 5
2 NC 2 135 0.8BW
5 PRE-HEAT RY
3 NC 3 6
0.8 18 CR-5
4 SEAT HEAT 4 131 2.0Y
0.8Or 18 30
5 BREAKER SW 5 22 0.8BOr 87a 87 85
0.8BW 40 86
6 BREAKER SW 6 64 2W
0.8B G42 87
7 HORN 7 123 0.8Br
0.8GrW 41 85
8 HORN 8 30 86
87a
9 BUTTON 2 9
ANTI-RESTART RY
10 BUTTON 2 10
11 BUTTON 1 11 CR-13
50 1.2Br
12 BUTTON 1 12 30
50A 0.8Br 87a 87 85
13 NC 13 86
0.8Gr 42 10 1.2ROr
14 ACCEL DIAL SUPPLY 14 87
0.8W 99 28 0.8BrW
15 ACCEL DIAL SIGNAL 15 85
0.8B 37 30 86
16 ACCEL DIAL GND 16 87a
RH CONSOLE HEAD LAMP RY

CN-4 CL-4
G22 1.2B
1 NC 1 2
2 NC 2 10 1.2ROr
1
3 NC 3 HEAD LAMP
4 NC 4
0.8GrW 00 CR-62 CL-3
5 POWER MAX SW 5 G30 0.8Br G22 1.2B
0.8B 81R 1 2
6 POWER MAX SW 6 40 0.8BW 4 5 1 10 1.2ROr
0.8GrW 48 2 1
7 ONE TOUCH DECEL 7 18 0.8Or
0.8B 81R 3 HEAD LAMP
8 ONE TOUCH DECEL 8 4
9 BUTTON 2 9 136 0.8Br 3 2 CN-12 CL-5
5 G11 2B B 2 2 B
10 BUTTON 2 10 2 1
BREAKER RY 128 2RG V 1 1 V
11 BUTTON 1 11 1 2
12 BUTTON 1 12 WORK LAMP
CR-4 2A B
13 NC 13 130 2RW
1
1.2B G41 30
14 SAFETY SW COM 14 130A 0.8RW 87a 87 85 1A V
86 2
15 SAFETY SW NC 15 128 2RG
CL-6
1.2G 49 87
16 SAFETY SW NO 16 29 0.8VW
85
LH CONSOLE 87a 30 86
WORK LAMP RY
CN-68
1.2G 49
1
1.2V 134
2
SAFETY SOL CR-2
41 0.8GrW
1
CN-140 124A 0.8V 4 5 1
B 152 2
1 124 0.8V
0.8Br 7 3
2 CN-25
4 G12 0.8B
QUICK COUPLER 127 0.8G 3 2 2
5 127 0.8G
1
CD-10 HORN RY
1.2B 81S HORN
Pa 1.2YOr 83
G13 0.8B
2
127 0.8G
1
AIR CLEANER SW
CN-20
CD-2
0.8B 81R
1
0.8 100
2
0.8Br
0.8B
FUEL LEVEL
CD-1
CN-66
0.8B 81
1
2
C 1
0.8 101
2
HYD TEMP
BREAKER SOL
3 2B
27
81H
80A
81J
81J
2B
117
80
90
91
80
90
8A
26
34
OR/W 28
14
47
16
38
39
40
31
45
36
13
G/OR 11
29
25
B/OR 33
65
67
12
55
63
W/OR 61
62
62
50
57
37
64
51
44
46
46
23
68
69
71
72
73
48
BR/OR
3
G/W
R/W
Y/W
B/W
Y/W
Y/W
B/W
V/W
L/W
0.8OrW
OR
OR
0.8OrW
GY
GY
BR
BR
BR
0.8ROr
0.8ROr
0.8ROr
0.8BW
0.8BW
0.8BW
0.8LW
W
W
G
G
G
R
R
Y
B
Y
B
L
47G
105
104
47A
70
118
119
CN-51
CN-50
47
10
11
12
13
14
15
16
17
18
19
20
21
22
23
25
TACHO SENSOR(+) 26
27
28
29
30
31
32
WATER TEMP SENDOR 33
34
35
36
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
CD-6
CD-7
CD-31
0.8V
0.8RW
0.8Or
0.8GOr
0.8BrW
C
C
A
RETURN B
A
RETURN B
C
0.8W
A
RETURN B
0.8Or
0.8Or
ENGINE OIL FILTER
GND(PRES.SENSOR)
TRAVEL SPEED SOL.

TACHO SENSOR(-)
HYD TEMP SENDOR
ANTI-RESTART RY
24V(PRES.SENSOR)
WATER LEVEL SW
POWER MAX SOL.

TRAVEL ALARM SW
PUMP PROLIX SW
BOOM PRIORITY SOL

SUPPLY
SUPPLY
SUPPLY
AIR CLEANER SW
ENG PREHEATER
PROGRAM DUMP
TRAVEL BUZZER
POWER MAX SW
GND (POT&DIAL)
CN-81
BATTERY 24V(+)
MAX FLOW SOL.
ACCEL DIAL SIG
OVERLOAD SIG
GND (SENSOR)
CN-133
CN-70
P1 PRESS SIG.
P2 PRESS SIG.
P3 PRESS SIG.
O/T DECEL SW
1
PUMP EPPR(+)
2
5V (POT&DIAL)
CN-88
PRE-HEAT SW
FUEL HEATER
PUMP EPPR(-)
ACCEL ACT(+)
HOUR-METER
SIG
SIG
SIG
ACCEL ACT(-)
1
2
1
WORKING PS
1
2
RS232 (GND)
CAN SHIELD
TRAVEL PS
ENG OIL PS
GND (MAIN)
SERIAL-RX
ALT LEVEL
SERIAL-TX
POWER IG
RS232 (+)
OVERLOAD PS TRAVEL WORK

RS232 (-)
POT-SIG
CAN LO
CAN HI
GND
BOOM TRAVEL POWER

NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
TRAVEL BZ PRIORITY HIGH MAX

MCU
4809S4EL05
4-5
·ELECTRICAL
ELECTRICAL CIRCUIT (2/2, CLUSTER TYPE 2)
RELAY
Service Tool DC/DC CONVERTER INTAKE M/ACT TEMP M/ACT MODE(D/FOOT) MODE(VENT) BLOWER
CIGARLIGHT
OVERLOAD SW
HOUR METER
24V
RS232 P DUMP
12V SOCKET 2 7 2 7
M 1
M 4
M 1
M 4 BLOWER
12V
ECONO SWITCH 3 7 3 7
h
RS232 RX
12
RS232 TX
5 5
12
10
3
4
9
CAN2 Lo
CAN2 Hi
CN-48
CAN Lo
CAN Hi
GND
IG 24V
12V
24V
CN-139
5
6
7
5
6
7
5
6
7
1
2
3
4
5
6
7
1
2
3
4
1
2
3
4
1
2
3
4
CL-2
GND
CN-138
CS-67
3
2
1
CS-50
1
2
C
A
B
CN-21
11
1
1.2Gr
7
1.2B
CS-52
ROr
0.8W
0.8B
0.8Y
3 1 WIPER CUT
G
H
B
00
C
E
A
10
0.8G
11
F
12
1.2Or
10
9
R
8
1
2
3
6
7
24M 1.2B
1.2Or
1.2V
2
24L 1.2B
0.8VOr
9 0.8Br
0.8Or
0.8Or
12
0.8Br
Gr
24Q
0.8V
24R 0.8B
12B
3
CS-53
5
35E
24V
21
13
R 4A
60
0.8BW
0.8Or
4
27F 0.8Br
60
22
0.8G
0.8G
0.8B
24T 0.8B
0.8G
0.8G
0.8G
0.8G
0.8G
0.8R
0.8V
0.8B
4 G 8 HARNESS AIR-CON
61
11
27
10
61
5 23F 0.8Or
9
2A B
L
6 2 6 CN-11 NO. DESTINATION
6
6
6
6
5
4
3
2
1
M 23F 0.8Or
62
62
Or
CN-126
8
7
1 1 GND
10
9
8
7
6
5
4
3
2
1
11
WIPER MOTOR 2 2 BLOWER SIG
9A 0.8Br 3 3 FUSE(IG)
0.8BW
24S 0.8B 4 4 REVERSE FAN
0.8G
0.8G
0.8R
0.8V
0.8B
CN-141 5 5 FUSE(Battery)
8 QUICK COUPLING SW 6 DPS(COMPRESSOR)
59
73
72
71
70
69
G 6
W 1 7 7 CONDENSOR FAN
CN-17 CN-113
L 9 00 0.8B
8 8 ILLUMINATION
1
R 10 1 W 0.8W 48 1
2 00 0.8G
B 2 2 B 1.2B 24B 2
3
GrW 3 3 GrW 0.8ROr 65
BUZZER
4
R 4 4 R 0.8R 14
5
V 5 5 V 0.8V 15
6
L 6 6 L 0.8L 49
7
Br 7 7 Br 0.8Br 50
8
Or 11
Gr 12
WIPER MOTOR HARNESS
WIPER MOTOR CONT. CN-56
17
10
11
12
13
14
15
16
17
18
10
11
12
13
14
BR
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
RR
1 POWER IG(24V)
18 B
TEMP MOTOR ACT(+)
DUCT SENSOR(GND)
TEMP MOTOR ACT(-)
DPS(COMPRESSOR)
2 GND
MODE M/ACT(FOOT)
BLOWER RELAY(Lo)
INLET MOTOR(REC)
INLET MOTOR(FRE)
19 Y
MODE M/ACT(PBR)
0
0
0
0
MODE M/ACT(DEF)
AMBIENT SENSOR
TEMP M/ACT(PBR)
CONDENSOR FAN
MOTOR ACT(REF)
DUCT SENSOR(+)
W/TEMP SENSOR
RX
MODE M/ACT(M+)
3
POWER TR BASE
MODE M/ACT(M-)
FET(FEED BACK)
20 L
INCAR SENSOR
REVERSE FAN
4
ILLUMINATION
ILLUMINATION
TX
> > >
BATTERY(+)
CLUSTER
FET(GATE)
POWER IG
POWER TR AMBIENT INCAR W/TEMP
CS-82 CN-5 SENSOR SENSOR SENSOR
IG 24V
0.8B 20E 1 0.8Y DUCT
12 1 1 MCU RX
GND
SENSOR
12 11 26A
NC
NC
NC
0.8LW 2 0.8L
11 2 2 MCU TX
3 SH
10 3 3 MCU GND
10 4 0.8B AC & HEATER CONTROLLER(AUTO)
8 9 4 4 GND
4 1.2ROr 19A 5 0.8Gr
8 5 5 FUSE
9
7 7 6 6 NC
3 7 0.8B
6 7 7 NC CS-1 CN-24
8 0.8Or Gr 11 0.8G 2
5 8 8 NC
4
1.2LW 26 59 0.8BW
9 9 P DUMP(MCU) 0.8V 3 CN-10 NO. DESTINATION
9 0.8Br
3 10 10 QUICK COUPLING SOL CL-1 1 1 NC
10 0.8V DOOR SW Gr 11 SPEAKER RH
2 11 11 OVERLOAD PS 3 2 2 NC
12 1 11 0.8VOr 0.8Y 1 1 0.8Y
1 12 12 MCU OVERLOAD 2 3 3 FUSE
12 0.8ROr 0.8B 6 2 0.8G
SPARE 13 13 HEAD LAMP RY 1 4 4 CASSETTE RH-
13 0.8W 3 0.8V
14 14 MCU HOURMETER CN-23 ROOM LAMP 5 5 CASSETTE RH+
69 0.8G 0.8Y 4 4 0.8Y
15 15 RS232 RX(MCU) 6 6 CASSETTE LH-
70 0.8L 5 5 0.8L
0.8R 7 7 CASSETTE LH+
16 16 RS232 TX(MCU) 6 2.0B
71 0.8B
17 17 GND SPEAKER LH 8 8 GND
14 7 2.0B
0.8R 9 9 GND
18 18 FUSE CL-7
15 0.8V 1.2BrW 8 8 1.2BrW
19 19 WASHER P/P 10 10 BEACON SW
72 0.8V 1.2B 6A 9 2.0V
20 20 CAN Hi 11 11 CABIN LIGHT RY
73 0.8G 10 2.0V
21 21 CAN Lo BEACON LAMP 12 12 CABIN LIGHT RY
74 SH
22 22 Shieeld CL-9 HARNESS CABIN
CL-8 10 2.0V
23 23 NC 2.0V 9
65 0.8ROr 2
24 24 WIPER FUSE 1.2B 6B 7 1.2B
19 1.2ROr 1
25 25 FUSE CABIN LIGHT
26 26 GND
21 1.25Gr
27 27 FUSE
22 1.2V
CS-23 28 28 FUSE
0.8B 24J 23 1.2Or ACCEL DIAL LED
12 29 29 FUSE CS-83
CN-279
12 11 0.8BrW 58A 24A 1.2B 0.8B 19G
11 30 30 GND 12 CS-26A
24E 1.2B 12 11 0.8Or 18A 5E 0.8BW
10 24 2B 31 31 GND 11 2
10 4E 0.8G
8 9 32 32 NC 10 1
4 1.2Br 27E 27 10 0.8G 15
0.8ROr
1.2Br
8 33 33 FUSE 8 9
BREAKER
0.8B
9 28 2V 28A 1.2V 4 0.8V 16
7 7 34 34 CABIN LAMP RY 8
3 29 1.2BOr 9 0.8BrW 17
6 35 35 ANTI RESTART RY 7 7 CN-156
3 19 1.2B
19F
30
32
1.2W 2
5 36 36 FUSE 6
1.2BrW 58 31 1.2ROr
4 37 37 NC 5 1
28E 0.8V 0.8Or 18
3 38 38 CABIN LAMP RY 4 AIR SEAT
0.8Gr 20
12 1 2 39 39 NC 3 CN-8 NO. DESTINATION
NC 15 0.8G
1 40 40 12 1 2 1 1 NC
NC 1 16 0.8V
BEACON LAMP SW 41 41 2 2 FUSE
42 42 NC SPARE 17 0.8BrW
CS-27 3 3 CRAB COM
0.8B 24J 43 43 NC 18 0.8Or
12 CS-99 0.8B 19A
4 4 NC
12 11 0.8BrW 58A 44 44 NC 19 1.2B
11 12 5 5 NC
45 45 NC 12 11 0.8GW 21A 20 0.8Gr
10 35 0.8Y
11 6 6 CRAB SIG MCU
10 46 46 FUSE 32 0.8ROr
8 9 36 0.8V
10 7 7 ILLUMINATION
4 0.8 27E 47 47 FUSE 10 22 0.8L
8 37 8 9 8 8 NC
0.8B 4 0.8L 22 23 0.8VW
9 48 48 GND 9
7 7 38 0.8BrW
8 9 DPF REGEN
3 49 49 HEAD LAMP RY 9 0.8L 22A 24 0.8R
6 39 7 7 10 10 DPF COM
0.8VW 3 25 0.8LW
50 50 WORK LAMP RY 6 11 11 DPF INHIBIT
5
0.8 58 51 51 NC 26 0.8RW
4 5 12 12 AIR COMP RY
52 52 NC 0.8GW 21
3 40 0.8 4
53 53 BREAKER SW(JOYSTICK) 0.8RW 26
3
12 1 2 40 0.8WOr
54 54 PRE-HEAT
1 41 0.8Gr 12 1 2
BREAKER SW 42
55 55 CABIN LAMP RY 1 HARNESS RH,CONSOLE
0.8YW
56 56 MCU TRAVEL ALARM SW
CN-10 43 0.8RW SPARE
57 57 FUSE
1 NC 1 44 0.8B CS-100
58 58 GND
2 NC 2 45 0.8WOr 1 CN-7 NO. DESTINATION
0.8Y 35A 59 59 POWER RY
3 ROOM LAMP 24V 3 46 0.8GW 2 1 1 NC
0.8G 51 60 60 BATT. RY
4 SPEAKER RH- 4 3 2 2 NC
0
0.8V 53 0.8VW 23
5 SPEAKER RH+ 5 4 3 3 NC
0,1
0.8Y 52 31 1.2ROr
6 SPEAKER LH- 6 5 4 4 FUSE
0.8L 55 0.8R 24 0.8G
7 SPEAKER LH+ 7 4 R 6 1
4 4 0.8G
5 5 BREAKER SW
1.2B 24F 24 2B
30 1.2W
CS-2 6
BREAK
B 0.8BW 5 5 0.8BW
8 GND 8 7 2 6 6 BREAKER RY
1.2B 24G 0.8R 24A CS-26 0.8B 6 6 0.8B
9 GND 9 46 0.8GW 8 1 7 7 GND
1.2BrW 58 HORN
R 0.8Grw 7 7 0.8Grw
10 BEACON LAMP 10 47 1.2R 10 9 2 8 8 HORN RY
1.2V 28F 28 2V I 0.8LW 25 CS-5 0.8L 8 8 0.8L
11 CABIN LIGHT 11 8 10 9 9 NC
1.2V 28G 2 L 0.8L 9 9 0.8L
12 CABIN LIGHT 12 11 10 10 NC
12 11 0.8Br 30 0.8Gr 10 10 0.8Gr
29 1.2BOr 12 11 11 NC
HARNESS CABIN 1 Gr 0.8Gr 11 11 0.8Gr
SPARE 12 12 NC
CN-142 13 13 AIR COMP RY
0.8Gr 12 12 0.8Gr
START KEY SW + A 14 14 MCU 5V
0.8W 13 13 0.8W
CN-116 S B 15 15 MCU ACCEL SIG.
0.8B 14 14 0.8B
12 NC - C 16 16 MCU SUPPLY GND
44 0.8B
11 GND ACCEL DIAL
43 0.8RW
10 POWER 24V
9 NC
42 0.8YW
8 TRAVEL ALARM
41 0.8Gr
7 CABIN LIGHT OUT
40 0.8WOr
6 PRE-HEAT
HARNESS LH,CONSOLE
49 0.8L
5 WASHER SIG
48 0.8W
4 WIPER MOTOR DRIVE
50 0.8Br
3 INT. SIG CN-4 NO. DESTINATION
39 0.8VW
2 WORK LIGHT OUT 1 1 NC
38 0.8BrW
36E
36E
1 HEAD LIGHT OUT 2 2 NC

12F
25
68
18
63
31
51
17
35
12
53
16
37
37E
SWITCH PANEL 3 3 NC
36
4 NC
0.5ROr
4
0.8ROr
0.8BOr
0.5BW
0.5GY
0.5YL
0.5LY
0.5Lg
0.8Or
0.8Y 4 4 0.8Y
0.5V
0.5V
0.8G
0.8V
0.5B
0.8Y
0.8V
0.8B
power 1 5 5 MCU POWER MAX

max B 0.8B 5 5 0.8B
cs-29
2 6 6 MCU SIG.GND
0.8Grw 6 6 0.8Grw
CN-246
CN-27A
CN-27
1 7 7 MCU DECEL
10
11
12
13
14
15
16
1
4
5
10
2
4
5
decel 7
3
6
3
0.8B 7 0.8B
1
2
3
4
5
6
7
9
8
R
2 8 8 MCU SIG.GND
cs-19 0.8L 8 8 0.8L
REMOCON GND
9 9 NC
2 L 0.8L 9 9 0.8L
SPK FRT RH+
SPK FRT LH+

SPK FRT RH-
10 NC
SPK FRT LH-
10
REMOCON+
10
USB(GND)
0.8Gr 10 0.8Gr
BACK UP+
TEL MUTE
AUX GND
AUX GND
USB GND
11 11 NC
USB(D+)
USB(D-)
ANT 12V
USB D+
AUX S1
1 11 0.8Gr
USB 5V
Gr 11
AUX S2
0.8Gr
USB D-
AUX R
12 NC
AUX L
12
USB+
GND
HARNESS RH SIDE
ACC
ILL+
CS-4 13 NC
NC
NC
NC
NC
ILL-
13
NC
NC
NC
C
0.8B 12 12 0.8B
B A 14 14 GND
0.8V 13 13 0.8V
USB & SOCKET ASSY REMOTE ASSY RADIO & USB PLAYER B 15 15 NC
0.8G 14 14 0.8G
A C 16 16 SAFETY SOL
SAFETY SW
4809S4EL06
4-6
MEMORANDUM
HYUNDAI HEAVY INDUSTRIES CO., LTD

CONSTRUCTION EQUIPMENT DIV.
4-7
1. POWER CIRCUIT (CLUSTER TYPE 1)
The negative terminal of battery is grounded to the machine chassis through master switch.
When the start switch is in the OFF position, the current flows from the positive battery terminal as
shown below.
1) OPERATING FLOW
Battery Battery relay Fusible link [CN-60] Master switch [CS-74A]
Fuse box [No.1] I/conn [CN-2 (8, 14)] Engine ECM [CN-91]
Fuse box [No.2] I/conn [CN-5 (46)] I/conn [CN -10 (3)] Room lamp [CL-1 (2)]
Door switch [CS-1]
Radio & USB player [CN-27 (8)]
Hour meter [CN-48 (1)]
Fuse box [No.3] MCU [CN-51 (2)]
Fuse box [No.4] Master switch [CS-74B] l/conn [CN-5 (36)]
Start switch [CS-2 (1)]
RMS controller [CN-125A(1)]
Power relay [CR-35 (30)]
ECM power relay [CR-45 (3)]
Fuse box [No.5] l/conn [CN-11 (5)] AC & Heater controller (3)
Blower relay (3)
Fuse box [No.6] I/conn [CN - 5 (18)] I/conn [CN -17 (5)] Wiper motor controller
[CN-141 (7)]
Wiper motor [CN-21 (4)]
Fuse box [No.7] I/conn [CN - 5 (6)] Cluster [CN - 56 (1)]
Fuse box [No.8] I/conn [CN - 2 (7)] Engine ECM power [CN - 91 (38)]
※ I/conn : Intermediate connector
2) CHECK POINT
Engine Start switch Check point Voltage
Η - GND (battery 1EA) 10~12.5V
Θ - GND (battery 2EA) 20~25V
OFF OFF
Ι - GND (battery 2EA) 20~25V
Κ- GND (fusible link) 20~25V
ö GND : Ground
4-8
CS-33 CR-45
CN-4 0.8B
6 6 1
1 0.8WOr 4 5 1
5 5 CS-74 2
ECM
2 0.8W
MASTER SW
4 4 3
3 3 3 4
1.2Gr 3 2
2 2 4
POWER RY
5
1
2
1 1 5
CR-35
CS-74B
2W
EM'CT STOP SW 12 30
2W
2W
0.8WOr 87a 87 85
13 86
2WR
CN-141 14 87
R 0.8B
CONTINUE 24V 7 15 85
87a 30 86
CN-17
16 POWER RY
CONTROLLER
0.8RW
CN-21 CN-5
WIPER MOTOR
1
3 1 2 1 CN-36
8
7
6
5
4
3
2
1
2 3 2 30A
CN-56
2W ECM
3 3 1
4
Y
B
5
L
Gr
W
0.8Y ROOM LAMP/CASSETTE 10A
WL
RW
WR
R R 0.8R 2
4 5 4 30A
4 0.8R MCU
5 6 5 3
0.8RW 2W START KEY 30A
TX
RX
6 2 6 7 6 4
SIG_2
GND
M
SIG_3
IG 24V
WIPER MOTOR
2Y AIR CON/HEATER 20A
5R
BATT.24V
8 7 5
10A
CAMERA SIG
0.8R WIPER
CLUSTER
8 6
CN-125A 9 0.8RW CLUSTER 10A
0.8W 7
1.2Gr
BATTERY POWER 1 17 0.8Or ECM 5A

1.2R 0.8R 0.8R 8
KEY "IG" 2
RMS
18 MCU CONT. 20A
9
3W
3W
0.8Or
19 MCU_EPPR 20A
138
10
6
20 SWITCH PANEL 10A
2
9
8
7
5
4
1
6
3
15
14
13
12
11
10
5
C ST
CS-2 11
CN-2
21
POWER CIRCUIT (CLUSTER TYPE 1)
CASSETTE 10A
6 22 12
CLUSTER 10A
3 5 23 13
2 CONVERTER 20A
B
1
ACC BR
4 24 14
1.2R WORK LAMP 30A
H
4 3 31 15
30A
0, I
2 32 CABIN LAMP(OPTION)
1.2W 16
1 WIPER 10A
4-9
33
START KEY SW
I 0 H
17
34 HEAD LAMP 20A
18
35 FUEL HEATER 30A
0.8ROr
1.2B
1.2B
1.2B
1.2B
1.2B
1.2R
1.2R
1.2R
1.2R
1.2R
CN-27 1.2W 2W 19
36 START,STOP 20A
5W
7
8
ACC 1 20
38
29
30
39
40
50
18
28
17
20
37 10A
CN-91
HORN
ILL- 2 38 21
AC& HEATER 20A
NC 3 CN-48 39 22
SAFETY SOL 10A
SPK FRT RH- 4 3 42 23
h 2 SEAT 20A
SPK FRT LH- 5 0.8Y 43 24
1 SOLENOIDE 20A
TEL MUTE 6
POWER IG
44 25
20A
HOUR METER
ANT 12V 7 45 CIGAR
0.8Y 0.8Y 0.8Y
26
OEM PORT 50P
OPTION(BEACON) 20A
BACK UP+ 8 46 27
ILL+ 9 47 SOLENOIDE 20A
R.THROTTLE RETURN
28
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
NC 10 48 PRE-HEAT 10A
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
0.8Y
29
SPK FRT RH+ 11 57 FUEL P/P 20A
30
5
4
1
9
8
7
6
3
58
12
11
10
REMOCON+ 10A
RADIO & USB PLAYER

12 0.8WOr 0.8WOr
EPPR
CN-10
59 31
FUSE BOX
REMOCON GND 13
60
CR-1
3
SPK FRT LH+ 14

NC 15
BATT RY
CS-74A
Gr
Gr
5R
GND 16
LINK
0.8Y
1
1
2
1
2
CN-11 5R
FUSIBLE
CN-60
CN-95
2
CS-74
1
2
1
CL-1
2
MASTER SW
2
5W
5W
5R
5R
CS-1
(AUTO)
BATTERY(+) 3
60R
DOOR SW
4
ROOM LAMP
4
2Y
5
AC & HEATER
CONTROLLER
6
(12VX2)
1 2 1 7
BATTERY
3W
4809S4EL07
2 8 CN-258
1
RELAY
3
60B
POWER
BLOWER
4 CN-51
1
3 4 0.8R
AIR COMP
BATT_POWER 24V 2
MCU
■ POWER CIRCUIT (CLUSTER TYPE 2)
The negative terminal of battery is grounded to the machine chassis through master switch.
When the start switch is in the OFF position, the current flows from the positive battery terminal as
shown below.
1) OPERATING FLOW
Battery Battery relay Fusible link [CN-60] Master switch [CS-74A]
Fuse box [No.1] I/conn [CN-2 (8, 14)] Engine ECM [CN-91]
Fuse box [No.2] I/conn [CN-5 (46)] I/conn [CN -10 (3)] Room lamp [CL-1 (2)]
Door switch [CS-1]
Radio & USB player [CN-27 (8)]
Hour meter [CN-48 (1)]
Fuse box [No.3] MCU [CN-50 (7)]
Fuse box [No.4] Master switch [CS-74B] l/conn [CN-5 (36)]
Start switch [CS-2 (1)]
Power relay [CR-35 (30)]
ECM power relay [CR-45 (3)]
Fuse box [No.5] l/conn [CN-11 (5)] AC & Heater controller (3)
Blower relay (3)
Fuse box [No.6] I/conn [CN - 5 (18)] I/conn [CN -17 (5)] Wiper motor controller
[CN-141 (7)]
Wiper motor [CN-21 (4)]
Fuse box [No.8] I/conn [CN - 2 (7)] Engine ECM power [CN - 91 (38)]
Fuse box [No.13] I/conn [CN - 5 (5)] Cluster [CN - 56 (1)]
※ I/conn : Intermediate connector
2) CHECK POINT

Η - GND (battery 1EA) 10~12.5V
Θ - GND (battery 2EA) 20~25V
OFF OFF
Ι - GND (battery 2EA) 20~25V
Κ- GND (fusible link) 20~25V
ö GND : Ground
4-10
CR-45
0.8B
1
0.8L 4 5 1
2
ECM
0.8L
3
4
0.8Y 3 2
POWER RY
CS-74 5
MASTER SW
CN-141 CR-35
R 2W
CONTINUE 24V 7 30
0.8WOr 87a 87 85
86
1
2
CN-17 2WR
87
CONTROLLER
WIPER MOTOR
CS-74B
CN-21 1 0.8B
85
1 2
2W
2W
3 87a 30 86
POWER RY
2 3
BR
5 3 4 CN-5
R R 0.8R
4 5 1 CN-36
4
3
2
1
4
5 6 2 2W ECM 30A
CN-56
3 1
6 M 2 6 7 0.8Y ROOM LAMP/CASSETTE 10A
RR
WIPER MOTOR
4 2
8 0.8Gr 0.8Gr 1.2R MCU 30A
5 3
2W START KEY 30A
6 4
3Y AIR CON/HEATER 20A
TX
5R
RX
7 5
GND
0.8R WIPER 10A
8 6
CLUSTER
9 SPARE 10A
POWER IG(24V)
7
1.2Gr
17 0.8Gr ECM 10A

6 0.8R 0.8R 8
5
C ST
CS-2 18 MCU CONT. 20A
9
6
3W
3W
0.8Or
19 SPARE 20A
138
5 10
3 20 SWITCH PANEL 10A
9
8
7
5
4
1
6
3
15
14
13
12
11
10
2 11
B
1
ACC BR
CN-2
4 21 10A
1.2R CASSETTE
12
H
4
POWER CIRCUIT (CLUSTER TYPE 2)
3 22
0.8 CLUSTER 10A
0, I
2 23 13
1.2W CONVERTER 20A
1 24 14
START KEY SW
I 0 H
WORK LAMP 30A
31 15
CABIN LAMP(OPTION) 30A
32 16
33 WIPER 10A
17
34 HEAD LAMP 20A
4-11
18
35 FUEL HEATER 30A
0.8ROr
1.2B
1.2B
1.2B
1.2B
1.2B
1.2R
1.2R
1.2R
1.2R
1.2R
CN-27 1.2W 1.2W 19

36 START,STOP 30A
5W
7
8
ACC 1 20
38
29
30
39
40
50
18
28
17
20
37 10A
CN-91
HORN
ILL- 2 38 21
AC& HEATER 20A
NC 3 CN-48 39 22
SAFETY SOL 10A
SPK FRT RH- 4 3 42 23
h 2 OPTION 20A
SPK FRT LH- 5 0.8Y 43 24
1 SOLENOIDE 20A
TEL MUTE 6
POWER IG
44 25
20A
HOUR METER
ANT 12V 7 45 CIGAR
0.8Y 0.8Y 0.8Y
26
OEM PORT 50P
OPTION(BEACON) 20A
BACK UP+ 8 46 27
ILL+ 9 47 TRAVEL SOL 20A
R.THROTTLE RETURN
28
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
NC 10 48 PRE-HEAT 10A
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
0.8Y
29
SPK FRT RH+ 11 57 FUEL P/P 20A
30
5
4
1
9
8
7
6
3
58
12
11
10
REMOCON+ EPPR 10A
RADIO & USB PLAYER

12 0.8WOr 0.8WOr
CN-10
59 31
FUSE BOX
REMOCON GND 13
60
CR-1
3
SPK FRT LH+ 14

NC 15 CS-74A
BATT RY
Gr
Gr
5R
GND 16
0.8Y
LINK
1
1
2
1
2
CN-11 5R
CN-60
CN-95
2
CS-74
3
FUSIBLE
1
2
1
CL-1
2
MASTER SW
2
5W
5W
5R
5R
CS-1
(AUTO)
BATTERY(+) 3
60R
DOOR SW
4
ROOM LAMP
4
3Y
5
AC & HEATER
CONTROLLER
6
(12VX2)
1 2 1 7
BATTERY
2 8
4809S4EL08
RELAY
3
60B
BLOWER
4 CN-50
1
3 4 GY
BATTERY 24V(+) 7
MCU
2. STARTING CIRCUIT (CLUSTER TYPE 1)
1) OPERATING FLOW
Battery(+) terminal Battery relay [CR-1] Fusible link [CN-60] Master switch [CS-74]
Fuse box [No.4] Master switch [CS-74B] I/conn [CN-5(36)] Start switch [CS-2(1)]
(1) When start key switch is in ON position
Start switch ON [CS-2 (2)] I/conn [CN-5 (60)] Battery relay [CR-1]
Battery relay operating (all power is supplied with the electric component)
Start switch ON [CS-2 (3)] RMS controller [CN-125A (2)]
(2) When start key switch is in START position
Start switch START [CS-2 (6)] I/conn [CN-5 (35)] Anti-restart relay [CR-5 (2) → (5)]
l/conn [CN-3 (9)] Start relay [CR-23]
2) CHECK POINT
① - GND (battery)
② - GND (start key)
③ - GND (battery relay M4)
OPERATING START ④ - GND (starter B+) 20~25V
⑤ - GND (starter M)
⑥ - GND (start relay)
⑦ - GND (battery relay M8)
※ GND : Ground
4-12
CR-45
0.8B
1
0.8WOr 4 5 1
CS-33 2
ECM
CN-5 0.8W
6 6 3
1
5 5 4
2 1.2Gr 3 2
POWER RY
4 4 5
3
3 3
4 2W CR-35
2 2 30
5 0.8WOr 87a 87 85
1 1 CS-74 86
6 2WR
MASTER SW
EM'CT STOP SW 87
2.5k
2.5k
7 0.8B
85
8
30 86
POWER RY
1
87a
2
2
6
5
4
1
3
9
CN-125A
CS-74B
CN-16B
0.8W 17
BATTERY POWER 1
1.2R 18
KEY "IG" 2
RMS
2W
2W
0.8Br
19 CN-36
20 ECM 30A
1
21 ROOM LAMP/CASSETTE 10A
22 2
MCU 30A
23 3
6 2W START KEY 30A
5
ST C
CS-2 24 4
1.2BOr 20A
6 AIR CON/HEATER
31 5
WIPER 10A
5R
3 5 32 6
2
B
10A
BR ACC
1 4 33 CLUSTER
1.2R 7
1.2Gr
5A
H
4 3 34 ECM
0.8GW 0.8BOr 0.8BOr 8
20A
0, I
2 35 MCU CONT.
1.2W 1.2W 2W 9
138
1 36 20A
START KEY SW
MCU_EPPR
H 0 I
10
37 SWITCH PANEL 10A
CN-52 0.8Br 11
38 ANTI-RESTART RY 15 CASSETTE 10A
2
39 12
MCU
CLUSTER 10A
13
STARTING CIRCUIT (CLUSTER TYPE 1)
57
CONVERTER 20A
58 14
0.8WOr 0.8WOr WORK LAMP 30A
59 15
0.8GW 0.8GW CABIN LAMP(OPTION) 30A
60 16
WIPER 10A
17
4-13
CN-51 HEAD LAMP 20A
0.8W 18
ALT. LEVEL 39
FUEL HEATER 30A
MCU
CN-4 19
0.8Y START,STOP 20A
0.8BOr
0.8Y
0.8BOr
0.8Br
5W
1 20
HORN 10A
0.8W
21
0.8BOr
2
4
2
3
5
1
AC& HEATER 20A

CR-5
3 22
5
4
1
9
8
7
6
3
10A
12
11
10
SAFETY SOL
CN-3
4 23
SEAT 20A
5 24
1.2L
20A
3 2
4 5 1
SOLENOIDE
3
12 25
1.2BOr
13 CIGAR 20A
0.8GW
1.2G
0.8B
1.2G
1.2G
1.2B
26
ANTI-RESTART RY
14 OPTION(BEACON) 20A
27
20A
1
15
2
2
SOLENOIDE
1
28
CR-1
DO-3
DO-1
16 10A
6
PRE-HEAT
1.2L
29
DIODE
DIODE
20A
BATT RY
FUEL P/P
7
30
1
2
EPPR 10A
31
3W/300
FUSE BOX
1
2
RS-1
CR-23
CS-74A
START RY
1.2R
5R
1
1
2
1
2
1
60R
CN-60
CN-95
5R
2
CS-74
15
R
FUSIBLE LINK
5W
5W
5R
5R
1.2BOr
MASTER SW
2 L
(12VX2)
1 P
3 FI
B+
BATTERY
4 NC
M
B+
CN-45
CN-74
ALTERNATOR
60B
4809S4EL09
G
U
M
3W
CN-258
STARTER
1
POWER
AIR COMP
■ STARTING CIRCUIT (CLUSTER TYPE 2)
1) OPERATING FLOW
Battery(+) terminal Battery relay [CR-1] Fusible link [CN-60] Master switch [CS-74]
Fuse box [No.4] Master switch [CS-74B] I/conn [CN-5(36)] Start switch [CS-2(1)]
(1) When start key switch is in ON position
Start switch ON [CS-2 (2)] I/conn [CN-5 (60)] Battery relay [CR-1]
Battery relay operating (all power is supplied with the electric component)
Start switch ON [CS-2 (3)] I/conn [CN-5 (59)] Power relay [CR-35 (86) → (87)]
Fuse box [No.10]
(2) When start key switch is in START position
Start switch START [CS-2 (6)] I/conn [CN-5 (35)] Anti-restart relay [CR-5 (86) → (87)]
l/conn [CN-3 (9)] Start relay [CR-23]
2) CHECK POINT
① - GND (battery)
② - GND (start key)
③ - GND (battery relay M4)
OPERATING START ④ - GND (starter B+) 20~25V
⑤ - GND (starter M)
⑥ - GND (start relay)
⑦ - GND (battery relay M8)
※ GND : Ground
4-14
CR-45
0.8B
1
0.8L 4 5 1
2
ECM
CN-5 0.8L
3
1
4
2 0.8Y 3 2
POWER RY
5
3
4 2W CR-35
30
5 0.8WOr 87a 87 85
CS-74 86
6 2WR
MASTER SW
87
7 0.8B
85
8
30 86
POWER RY
1
87a
2
9
CS-74B
17
18
2W
2W
19 CN-36
20 ECM 30A
1
21 ROOM LAMP/CASSETTE 10A
22 2
MCU 30A
23 3
6 2W START KEY 30A
5
ST C
CS-2 24 4
1.2BOr 20A
6 AIR CON/HEATER
31 5
WIPER 10A
5R
3 5 32 6
2
B
10A
BR ACC
1 4 33 SPARE
1.2R 7
10A
H
4 3 34 ECM
0.8GW 1.2BOr 0.8BOr 8
20A
0, I
2 35 MCU CONT.
1.2W 1.2W 1.2W 9
138
1 36 20A
START KEY SW
SPARE
H 0 I
10
37 SWITCH PANEL 10A
CN-50 V/W 11
38 ANTI-RESTART RY 11 CASSETTE 10A
2
39 12
MCU
CLUSTER 10A
13
STARTING CIRCUIT (CLUSTER TYPE 2)
57
CONVERTER 20A
58 14
0.8WOr 0.8WOr WORK LAMP 30A
59 15
0.8GW 0.8GW CABIN LAMP(OPTION) 30A
60 16
WIPER 10A
17
4-15
CN-51 HEAD LAMP 20A
W 18
ALT. LEVEL 9
FUEL HEATER 30A
MCU
19
0.8Br
2Y START,STOP 30A
2W
0.8BOr
2Y
5W
20
HORN 10A
0.8W
21
0.8BOr
AC& HEATER 20A
85
86
87
30
CR-5
22
87a
5
4
1
9
8
7
6
3
10A
12
11
10
SAFETY SOL
CN-3
23
OPTION 20A
24
1.2L
SOLENOIDE 20A
30 86
87a 87 85
25
1.2BOr
3
CIGAR 20A
0.8B
0.8G
1.2G
1.2B 26
ANTI-RESTART RY
OPTION(BEACON) 20A
27
TRAVEL SOL 20A
2
1
28
6
CR-1
DO-3
PRE-HEAT 10A
29
DIODE
3W/300
20A
BATT RY
FUEL P/P
30
2
1
7
1
2
EPPR 10A
RS-1
31
FUSE BOX
1.2R
CR-23
CS-74A
START RY
5R
1
1
2
1
2
1
60R
CN-60
CN-95
5R
2
CS-74
FUSIBLE LINK
5W
5W
5R
5R
MASTER SW
1.2BOr
15 R
(12VX2)
4
BATTERY
2 L
1 P
3 FI
B+
4 NC
M
4809S4EL10
ALT.
B+
CN-74
60B
3
CN-45
~
G
U
M
STARTER
3. CHARGING CIRCUIT (CLUSTER TYPE 1)
When the starter is activated and the engine is started, the operator releases the key switch to the
ON position.
Charging current generated by operating alternator flows into the battery through the battery relay
[CR-1].
The current also flows from alternator to each electrical component and controller through the fuse box.
1) OPERATING FLOW
(1) Warning flow
Alternator "I" terminal I/conn [CN-3 (10)] MCU alternator level [CN-51 (39)]
Cluster charging warning lamp (Via serial interface)
(2) Charging flow

Alternator "B+" terminal Battery relay(M8) Battery(+) terminal
Fusible link [CN-60] Master switch [CS-74]
Fuse box
2) CHECK POINT

Η - GND (battery voltage)
Θ - GND (battery relay)
RUN ON Ι - GND (alternator B+ terminal) 20~25V
Κ - GND (alternator I terminal)
Λ - GND (MCU)
ö GND : Ground
4-16
CN-36
CN-51 ECM 30A
1
GND_MAIN 1 ROOM LAMP/CASSETTE 10A
BATT POWER_24V 2 2
POWER IG MCU 30A
3
3
POWER_24V OUT 4 START KEY 30A
GND_PRESSURE 5 4
AIR CON/HEATER 20A
5R
POWER_5V OUT 6 5
GND_5V 7 WIPER 10A
G/A MOTOR(+) 8 6
CLUSTER 10A
G/A MOTOR(-) 9 7
GND_MAIN 10 ECM 5A
CAN_SHIELD
8
11 20A
MCU CONT.
PROGRAM DUMP 12 9
TACHO SENSOR- MCU_EPPR 20A
0.8B
SH
0.8L
0.8Y
13
10
TACHO SENSOR+ 14 SWITCH PANEL 10A
PWM OUTPUT2 15 11
5
4
1
9
8
7
6
3
60
59
58
57
0.8L
0.8Y
1.2B
CASSETTE 10A
PWM OUTPUT1 16
CN-5
12
RESERVE_DO2 17 CLUSTER 10A
SH
13
8
7
6
5
4
3
2
1
RAMLOCK LAMP 18
0.8L
0.8B
0.8Y
CONVERTER 20A
CN-56
HOUR METER 19 14
TRAVEL BUZZER 30A
L
Gr
20 WORK LAMP
Y
B
W
WL
WR
RW
15
MCU
CAN1 Hi-ECM 21 30A
CABIN LAMP(OPTION)
CAN2 Hi-APTC 22 16
0.8L 10A
RS485+(TX)-CLUSTER 23 WIPER
17
TX
RX
RS232C1_TX-HRDT 24
SIG_2
GND
HEAD LAMP 20A
SIG_3
IG 24V
RS232C2_TX-RCM 25 18
BATT.24V
FUEL HEATER 30A
CAMERA SIG
PWM INPUT_1
CLUSTER
26
19
PWM INPUT_2 27 START,STOP 20A
145
TILT SIG. 28 20
HORN 10A
ROTATE SIG. 29 21
5W
AI RESERVE 30 AC& HEATER 20A

CAN1 Lo-ECM 31 22
SAFETY SOL 10A
CAN2 Lo-APTC 32 23
0.8Y
RS485-(RX)-CLUSTER 33 SEAT 20A
CHARGING CIRCUIT (CLUSTER TYPE 1)
RS232C1_RX-HRDT
24
34 20A
SOLENOIDE
RS232C2_RX-RCM 35 25
HYD. TEMP SENDER 36 CIGAR 20A
26
WATER TEMP SENDOR 37 20A
OPTION(BEACON)
FUEL LEVEL SENSOR 38 27
0.8W 20A
4-17
ALT. LEVEL 39 SOLENOIDE
28
GOV. POTENTIO SIG. 40 PRE-HEAT 10A
29
0.8W
5
FUEL P/P 20A
30
EPPR 10A
31
5
4
1
9
8
7
6
3
12
11
10
FUSE BOX
CN-3
1.2L
1.2BOr
1.2B
1.2L
CS-74A
3W/300
5R
2
1
1
1
RS-1
1
2
1
2
5R
CR-1
CN-60
CN-95
2
CS-74
FUSIBLE LINK
BATT RY
5R
5R
1.2R
5W
5W
MASTER SW
CR-23
START RY
4
15
R
1.2BOr
60R
2 L
1 P
3 FI
B+
4 NC
M
3W
ALT.
B+
CN-74
3
CN-45
CN-258
(12VX2)
~
BATTERY
U
POWER
M
60B
STARTER
4809S4EL11
AIR COMP
■ CHARGING CIRCUIT (CLUSTER TYPE 2)
When the starter is activated and the engine is started, the operator releases the key switch to the
ON position.
Charging current generated by operating alternator flows into the battery through the battery relay
[CR-1].
The current also flows from alternator to each electrical component and controller through the fuse box.
1) OPERATING FLOW
(1) Warning flow
Alternator "I" terminal I/conn [CN-3 (10)] MCU alternator level [CN-51 (9)]
Cluster charging warning lamp (Via serial interface)
(2) Charging flow

Alternator "B+" terminal Battery relay(M8) Battery(+) terminal
Fusible link [CN-60] Master switch [CS-74]
Fuse box
2) CHECK POINT

Η - GND (battery voltage)
Θ - GND (battery relay)
RUN ON Ι - GND (alternator B+ terminal) 20~25V
Κ - GND (alternator I terminal)
Λ - GND (MCU)
ö GND : Ground
4-18
CN-36
CN-51 ECM 30A
WORKING PS 1 1
ROOM LAMP/CASSETTE 10A
POWER MAX SW 2 2
TRAVEL ALARM SW 3 MCU 30A
ENG OIL PS 4 3
START KEY 30A
NC 5 4
NC 6 AIR CON/HEATER 20A
5 5R
24V(PRES.SENSOR) 7 10A
WIPER
GND(PRES.SENSOR) 8 6
W 10A
ALT LEVEL 9 SPARE
L
Y
B
0.8B
SH
0.8L
0.8Y
7
P1 PRESS SIG. 10 ECM 10A
P2 PRESS SIG. 11 8
20A
4
3
2
1
5
4
1
9
8
7
6
3
MCU CONT.
60
59
58
57
P3 PRESS SIG. 12
5
9
CN-5
CN-56
13 SPARE 20A
10
SH
RR
10A
0.8L
SWITCH PANEL
0.8B
0.8Y
CN-50 11
BOOM PRIORITY SOL 1 10A
CASSETTE
MAX FLOW SOL. 2 12
CLUSTER 10A
POWER MAX SOL. 3 13
TX
HOUR-METER
RX
4 CONVERTER 20A
GND
ENG PREHEATER 5 14
WORK LAMP 30A
FUEL HEATER 6
CLUSTER
15
30A
POWER IG(24V)
BATTERY 24V(+) 7 CABIN LAMP(OPTION)
PUMP EPPR(-) 8 16
WIPER 10A
NC 9 17
PROGRAM DUMP 10 HEAD LAMP 20A
ANTI-RESTART RY
18
11 30A
MCU
FUEL HEATER
ACCEL ACT(+) 12 19
TRAVEL SPEED SOL. START,STOP 30A
13
145
20
NC 14 HORN 10A
NC 15 21
5W
AC& HEATER 20A

TRAVEL BUZZER 16 22
PRE-HEAT SW 17 SAFETY SOL 10A
CHARGING CIRCUIT (CLUSTER TYPE 2)
NC 18 23
OPTION 20A
NC 19 24
OVERLOAD SIG 20 SOLENOIDE 20A
ENGINE OIL FILTER 25
0.8W
21 20A
CIGAR
NC 22 26
4-19
ACCEL ACT(-) 23 OPTION(BEACON) 20A
27
5
4
1
9
8
7
6
3
POWER IG 24
12
11
10
TRAVEL SOL 20A
CN-3
CAN_HI 25 28
CAN_LO PRE-HEAT 10A
26
29
1.2L
CAN_SHIELD 27 FUEL P/P 20A
1.2BOr
GND (MAIN) 28 30
Y EPPR 10A
SERIAL-TX 29 31
L
FUSE BOX
SERIAL-RX 30
GND 31
RS232 (+) 32
RS232 (-) 33
1.2L
3W/300
RS232 (GND) 34
NC 35
2
1
1
2
1.2B
RS-1
PUMP EPPR(+) 36 CS-74A
5R
1
1
2
1
2
5R
1.2R
CR-1
CN-60
CN-95
2
CS-74
FUSIBLE LINK
CR-23
2
BATT RY
5R
5R
5W
5W
MASTER SW
START RY
4
1.2BOr
60R
15 R
3
2 L
1 P
3 FI
B+
4 NC
M
ALT.
B+
CN-74
3
CN-45
(12VX2)
~
BATTERY
U
M
60B
STARTER
4809S4EL12
4. HEAD AND WORK LIGHT CIRCUIT (CLUSTER TYPE 1)
1) OPERATING FLOW
Fuse box (No.15) Work light relay [CR-4 (30, 86)]
Fuse box (No.18) Head light relay [CR-13 (30, 86)]
(1) Head light switch ON
Head light switch ON [CN-116 (1)] l/conn [CN-5 (49)] Head light relay [CR-13 (85) → (87)]
Head light ON [CL-3 (2), CL-4 (2), CL-24 (2)]
l/conn [CN-11 (8)] AC & Heater controller illumination ON [4]
l/conn [CN-5 (13)] Radio & USB player illumination ON [CN-27 (9)]
Cigar light [CL-2]
l/conn [CN-8 (7)] Accel dial LED ON
(2) Work light switch ON

Work light switch ON [CN-116 (2)] l/conn [CN-5 (50)] Work light relay [CR-4 (85) → (87)]
l/conn [CN-12 (2)] Work light ON [CL-5 (2), CL-6 (2), CL-36 (2), CL-37 (2)]
2) CHECK POINT
① - GND (fuse box)

② - GND (switch power output)
③ - GND (head light relay)
④ - GND (head light)
STOP ON 20~25V
⑤ - GND (fuse box)
⑥- GND (switch power output)
⑦ - GND (work light relay)
⑧ - GND (work light)
※ GND : Ground
4-20
NC
GND
2
1
IG 24V
CN-36
CN-279
POWER IG
30A
BATTERY(+)
ECM
0.8B
1
ILLUMINATION
ILLUMINATION
REVERSE FAN
0.8ROr
INCAR SENSOR
AC & HEATER
ACCEL DIAL LED
POWER TR BASE
W/TEMP SENSOR
DUCT SENSOR(+)
2
AMBIENT SENSOR
MCU 30A
DUCT SENSOR(GND)
3
START KEY 30A
4
CONTROLLER(AUTO)
AIR CON/HEATER 20A
9
8
7
6
5
4
3
2
1
14
13
12
11
10
5
WIPER 10A
6
CLUSTER 10A
7
ECM 5A
8
CN-5 MCU CONT. 20A
0.8ROr
1 9
MCU EPPR 20A
2 10
10A
2
2
5
5
4
1
4
1
8
7
6
9
8
7
6
3
3
SWITCH PANEL
12
11
10
3 11
CN-8
10A
CN-11
CASSETTE
CN-27 4 12
ACC 1 5 1 CLUSTER 10A
13
0.8ROr
CONVERTER 20A
ILL- 2 6 14
2RW WORK LAMP 30A
NC 3 7 15
SPK FRT RH- 4 8 CABIN LAMP(OPTION) 30A
16
SPK FRT LH- 5 9 WIPER 10A
17
TEL MUTE 6 10 1.2Br HEAD LAMP 20A
18
ANT 12V 7 11 FUEL HEATER 30A
19
BACK UP+ 8 12 START,STOP 20A
0.8ROr 0.8ROr 0.8ROr
ILL+ 9 13 20
10A
5
HORN
NC 10 14 21
AC& HEATER 20A
SPK FRT RH+ 11 15 22
SAFETY SOL 10A
REMOCON+ 12 16 23
RADIO & USB PLAYER
4-21
SEAT 20A
REMOCON GND 13 17 24
SOLENOIDE 20A
SPK FRT LH+ 14 18 25
NC 15
CL-2 19 CIGAR 20A
26
GND 16 20 OPTION(BEACON) 20A
27
ROr 21 SOLENOIDE 20A
HEAD AND WORK LIGHT CIRCUIT (CLUSTER TYPE 1)
28
41 PRE-HEAT 10A
29
CIGAR LIGHT
42 FUEL P/P 20A
30
43 EPPR 10A
31
44
8
FUSE BOX
45
2RG
2B
2
46
47
1
2
CN-116 48
CN-12
0.8BrW 0.8BrW 0.8BrW

HEAD LIGHT OUT 1 49
2B
2R
0.8VW 0.8VW 0.8VW

WORK LIGHT OUT 2 50
INT. SIG 3 51
3
7
WIPER MOTOR DRIVE 4 52

4
1.2B
1.2B
1.2B
1.2ROr
1.2ROr
1.2ROr
WASHER SIG 5 53
6
2RG
0.8Br
0.8VW
0.8RW
PRE-HEAT 6 54
1.2ROr
0.8BrW
1.2B
1.2B
1.2B
1.2R
1.2R
1.2R
1.2B
1.2R
2RW
1.2Br
CABIN LIGHT OUT 7 55
TRAVEL ALARM 8 56
1
1
2
2
2
1
1
1
1
87
87
2
2
2
85
85
1
86
86
2
30
30
CL-3
CL-4
87a
87a
57
CR-4
CL-5
CL-6
NC 9
SWITCH PANEL
CL-24
CL-37
CL-36
CR-13
POWER 24V 10 58
GND 11 59 30 86
30 86
87a 87 85
87a 87 85
NC 12 60 HEAD LAMP RY
WORK LAMP RY
LAMP
HEAD
LAMP
HEAD LAMP REAR

WORK
4809S4EL13
■ HEAD AND WORK LIGHT CIRCUIT (CLUSTER TYPE 2)
1) OPERATING FLOW
Fuse box (No.15) Work light relay [CR-4 (30, 86)]
Fuse box (No.18) Head light relay [CR-13 (30, 86)]
(1) Head light switch ON
Head light switch ON [CN-116 (1)] l/conn [CN-5 (49)] Head light relay [CR-13 (85) → (87)]
Head light ON [CL-3 (2), CL-4 (2)]
l/conn [CN-11 (8)] AC & Heater controller illumination ON [4]
l/conn [CN-5 (13)] Radio & USB player illumination ON [CN-27 (9)]
Cigar light [CL-2]
l/conn [CN-8 (7)] Accel dial LED ON
(2) Work light switch ON

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

② - GND (switch power output)
③ - GND (head light relay)
④ - GND (head light)
STOP ON 20~25V
⑥- GND (switch power output)
⑦ - GND (work light relay)
⑧ - GND (work light)
※ GND : Ground
4-22
NC
GND
2
1
IG 24V
CN-36
CN-279
POWER IG
30A
BATTERY(+)
ECM
0.8B
1
ILLUMINATION
ILLUMINATION
REVERSE FAN
0.8ROr
INCAR SENSOR
ACCEL DIAL LED
AC & HEATER
POWER TR BASE
W/TEMP SENSOR
DUCT SENSOR(+)
2
AMBIENT SENSOR
MCU 30A
DUCT SENSOR(GND)
3
START KEY 30A
4
CONTROLLER(AUTO)
AIR CON/HEATER 20A
9
8
7
6
5
4
3
2
1
14
13
12
11
10
5
WIPER 10A
6
SPARE 10A
7
ECM 10A
8
CN-5 MCU CONT. 20A
0.8ROr
1 9
SPARE 20A
2 10
10A
2
2
5
5
4
1
4
1
8
7
6
9
8
7
6
3
3
SWITCH PANEL
12
11
10
3 11
CN-8
10A
CN-11
CASSETTE
CN-27 4 12
1 CLUSTER 10A
0.8
ACC 1 5 13
0.8ROr
CONVERTER 20A
ILL- 2 6 14
2RW WORK LAMP 30A
NC 3 7 15
SPK FRT RH- 4 8 CABIN LAMP(OPTION) 30A
16
SPK FRT LH- 5 9 WIPER 10A
17
TEL MUTE 6 10 1.2Br HEAD LAMP 20A
18
ANT 12V 7 11 FUEL HEATER 30A
19
BACK UP+ 8 12 START,STOP 30A
0.8ROr 0.8ROr 0.8ROr
ILL+ 9 13 20
10A
5
HORN
NC 10 14 21
AC& HEATER 20A
SPK FRT RH+ 11 15 22
SAFETY SOL 10A
REMOCON+ 12 16 23
RADIO & USB PLAYER
4-23
OPTION 20A
REMOCON GND 13 17 24
SOLENOIDE 20A
SPK FRT LH+ 14 18 25
NC 15
CL-2 19 CIGAR 20A
26
GND 16 20 OPTION(BEACON) 20A
27
ROr 21 TRAVEL SOL 20A
HEAD AND WORK LIGHT CIRCUIT (CLUSTER TYPE 2)
28
41 PRE-HEAT 10A
29
CIGAR LIGHT
42 FUEL P/P 20A
30
43 EPPR 10A
31
44
FUSE BOX
45
2RG
2B
2
46
47
1
2
CN-116 48
CN-12
0.8BrW 0.8BrW 0.8BrW

HEAD LIGHT OUT 1 49
V
B
0.8VW 0.8VW 0.8VW

WORK LIGHT OUT 2 50
INT. SIG 3 51
3
7

4
1.2B
1.2B
1.2ROr
1.2ROr
WASHER SIG 5 53
6
2RG
0.8Br
V
B
V
B
0.8VW
0.8RW
PRE-HEAT 6 54
1.2ROr
0.8BrW
2RW
1.2Br

TRAVEL ALARM 8 56
1
2
2
1
1
87
87
2
85
85
1
86
86
2
30
30
CL-3
CL-4
87a
87a
57
CR-4
CL-5
CL-6
NC 9
SWITCH PANEL
CR-13
POWER 24V 10 58
GND 11 59
30 86
30 86
87a 87 85
87a 87 85
NC 12 60
HEAD LAMP RY
WORK LAMP RY
LAMP
HEAD
LAMP
WORK
4809S4EL14
5. BEACON LAMP AND CAB LIGHT CIRCUIT (CLUSTER TYPE 1)
1) OPERATING FLOW
Fuse box (No. 27) I/conn [CN-5 (33)] Beacon lamp switch [CN-23 (8)]
Fuse box (No.16) Cab light relay [CR-9 (30, 86)]
(1) Beacon lamp switch ON
Beacon lamp switch ON [CS-23 (4)] Switch indicator lamp ON [CS-23 (11)]
l/conn [CN-10 (10)] Beacon lamp ON [CL-7]
(2) Cab light switch ON
Cab light switch ON [CN-116 (7)] I/conn [CN-5 (55)] Cabin light relay [CR-9 (85) → (87)]
I/conn [CN-5 (34)] I/conn [CN-10 (11, 12)] Cab light ON [CL-8 (2), CL-9 (2)]
2) CHECK POINT

② - GND (switch power input)
③ - GND (switch power output)
④ - GND (beacon lamp)
STOP ON 20~25V
⑥ - GND (cab light relay)
⑦ - GND (switch power output)
⑧ - GND (cab light)
※ GND : Ground
4-24
CN-36
30A
LAMP
ECM
1
CABIN
BEACON
2
MCU 30A
12
M
3
4
9
12
10
3
CL-8
30A
CL-7
LIGHT CL-9
START KEY
4
AIR CON/HEATER 20A
1
1
2
2
5
WIPER 10A
7
8
1
11
6
2V
CLUSTER 10A
2V
1.2B
7
4
10
11
5
9
12
4
8
1.2B
1.2B
1
2
3
6
7
ECM 5A
1.2BrW
CS-23
8
BEACON LAMP SW
MCU CONT. 20A
9
0.8B
20A
1.2Br
MCU EPPR
8
1.2BrW
0.8BrW
10
SWITCH PANEL 10A
11
10A
3
CASSETTE
12
2
CLUSTER 10A
13
5 20A
1.2V
1.2V
1.2BrW
2B
2B
CONVERTER
14
WORK LAMP 30A
15
5
4
1
9
8
7
6
3
12
11
10
2R CABIN LAMP(OPTION) 30A
CN-5 16
CN-10
WIPER 10A
1 17
1.2V
1.2V
1.2B
1.2B
HEAD LAMP 20A
2
1.2BrW
18
FUEL HEATER 30A
3 19
4 START,STOP 20A
20
5 HORN 10A
21
6 AC& HEATER 20A
22
7 SAFETY SOL 10A
23
8
4-25
SEAT 20A
1.2B 1.2B 24
30
1
SOLENOIDE 20A
1.2B 1.2B
31 25
CIGAR 20A
32 26
1.2Br 1.2Br 1.2Br OPTION(BEACON) 20A
33 27
1.2V 1.2V SOLENOIDE 20A
34 28
PRE-HEAT 10A
35 29
FUEL P/P 20A
36 30
37 EPPR 10A
CN-116 0.8V 0.8V 31
38
FUSE BOX
HEAD LIGHT OUT 1

BEACON LAMP AND CAB LIGHT CIRCUIT (CLUSTER TYPE 1)
2 39
WORK LIGHT OUT
INT. SIG 3 51
7
WASHER SIG 5 53
PRE-HEAT 6 54
0.8Gr 0.8Gr 0.8Gr
6

TRAVEL ALARM 8 56
0.8Gr
2V
0.8R
NC 9 57
SWITCH PANEL
2R
POWER 24V 10 58
GND 11 59
87
85
86
30
NC 12 60
87a
CR-9
30 86
87a 87 85
CABIN LAMP RY
4809S4EL15
■ BEACON LAMP AND CAB LIGHT CIRCUIT (CLUSTER TYPE 2)
1) OPERATING FLOW
Fuse box (No. 27) I/conn [CN-5 (33)] Beacon lamp switch [CN-23 (8)]
Fuse box (No.16) Cab light relay [CR-9 (30, 86)]
(1) Beacon lamp switch ON
Beacon lamp switch ON [CS-23 (4)] Switch indicator lamp ON [CS-23 (11)]
l/conn [CN-10 (10)] Beacon lamp ON [CL-7]
(2) Cab light switch ON
Cab light switch ON [CN-116 (7)] I/conn [CN-5 (55)] Cabin light relay [CR-9 (85) → (87)]
I/conn [CN-5 (34)] I/conn [CN-10 (11, 12)] Cab light ON [CL-8 (2), CL-9 (2)]
2) CHECK POINT

④ - GND (beacon lamp)
STOP ON 20~25V
⑥ - GND (cab light relay)
⑦ - GND (switch power output)
⑧ - GND (cab light)
※ GND : Ground
4-26
CN-36
30A
LAMP
ECM
1
BEACON
CABIN
2
MCU 30A
12
M
3
4
9
12
10
3
CL-8
30A
CL-7
LIGHT CL-9
START KEY
4
AIR CON/HEATER 20A
1
1
2
2
5
WIPER 10A
7
8
1
11
6
2V
SPARE 10A
2V
1.2B
7
10
11
4
5
9
12
4
8
1.2B
1.2B
1
2
3
6
7
ECM 10A
1.2BrW
CS-23
8
BEACON LAMP SW
MCU CONT. 20A
9
0.8B
20A
1.2Br
SPARE
8
1.2BrW
0.8BrW
10
SWITCH PANEL 10A
11
10A
3
CASSETTE
12
2
CLUSTER 10A
13
5 20A
2V
2V
1.2BrW
2B
2B
CONVERTER
14
WORK LAMP 30A
15
5
4
1
9
8
7
6
3
12
11
10
2R CABIN LAMP(OPTION) 30A
CN-5 16
CN-10
WIPER 10A
1 17
1.2V
1.2V
1.2B
1.2B
HEAD LAMP 20A
2
1.2BrW
18
FUEL HEATER 30A
3 19
4 START,STOP 30A
20
5 HORN 10A
21
6 AC& HEATER 20A
22
7 SAFETY SOL 10A
23
8
4-27
OPTION 20A
1.2B 1.2B 24
30
1
SOLENOIDE 20A
1.2B 1.2B
31 25
CIGAR 20A
32 26
1.2Br 1.2Br 1.2Br OPTION(BEACON) 20A
33 27
1.2V 1.2V TRAVEL SOL 20A
34 28
PRE-HEAT 10A
35 29
FUEL P/P 20A
36 30
37 EPPR 10A
CN-116 0.8V 0.8V 31
FUSE BOX
1 38
HEAD LIGHT OUT
BEACON LAMP AND CAB LIGHT CIRCUIT (CLUSTER TYPE 2)
2 39
WORK LIGHT OUT
INT. SIG 3 51
7
WASHER SIG 5 53
PRE-HEAT 6 54
0.8Gr 0.8Gr 0.8Gr
6

TRAVEL ALARM 8 56
0.8Gr
2V
0.8R
NC 9 57
SWITCH PANEL
2R
POWER 24V 10 58
GND 11 59
87
85
86
30
NC 12 60
87a
CR-9
30 86
87a 87 85
CABIN LAMP RY
4809S4EL16
6. WIPER AND WASHER CIRCUIT (CLUSTER TYPE 1)
1) OPERATING FLOW
(1) Key switch ON
Fuse box (No.11) I/conn [CN-5 (57)] Switch panel [CN-116 (10)]
Fuse box (No.6) I/conn [CN-5 (18)] I/conn [CN-17 (5)] Wiper motor controller [CN-141(7)]
Wiper motor [CN-21(4)]
Fuse box (No.17) I/conn [CN-5 (24)] l/conn [CN-17 (4)] Wiper motor controller [CN-141 (6)]
Washer pump [CN-22 (2)]
(2) Wiper switch ON : 1st step (Intermittent)
Wiper switch ON [CN-116 (3)] I/conn [CN-17 (8)] Wiper motor controller [CN-141 (10) → (3)]
Wiper motor intermittently operating [CN-21 (6)]
(3) Wiper switch ON : 2nd step (continual)
Wiper switch ON [CN-116(4)] I/conn[CN-17(2)] Wiper motor controller [CN-141(2) → (4)]
Wiper motor operating [CN-21(2)]
(4) Washer switch ON
Washer switch ON [CN-116 (5)] I/conn [CN-17 (7)] Wiper motor controller [CN-141 (9) → (8)]
I/conn [CN-17 (6)] I/conn [CN-5 (19)] Washer pump [CN-22 (1)] Washer operating
Wiper switch ON [CN-116 (4)] I/conn[CN-17 (2)] Wiper motor controller [CN-141 (2) → (4)]
Wiper motor operating [CN-21 (2)]
(5) Auto parking
parking(when switch OFF)
Switch OFF [CN-116 (4)] Wiper motor parking position by wiper motor controller
2) CHECK POINT

24V
STOP ON 0 ~ 5V
④ - GND (wiper power input)
⑤ - GND (wiper power output) 24V
⑥ - GND (wiper motor) 0 or 24V
※ GND : Ground
4-28
CN-5
1
2
3
4 CN-36
5 ECM 30A
6
CN-21 6 1
CS-53 ROOM LAMP/CASSETTE 10A
3 1 7 2
R Or MCU 30A
2 8 3
Gr START KEY 30A
5 3 9 4
R 20A
4 10 AIR CON/HEATER
WIPER CUT
4 G B
5
5 11 0.8R WIPER 10A
L 6
6 M 2 6 12 CLUSTER 10A
WIPER MOTOR
7
13 ECM 5A
8
1
14 20A
MCU CONT.
15 9
MCU_EPPR 20A
16 10
4
0.8RW SWITCH PANEL 10A
17 11
0.8R 0.8R 10A
CN-141 18 CASSETTE
G 0.8V 0.8V 12
FEED BACK 1 19 CLUSTER 10A
W 13
1
MOTOR DRIVE SIG 2 CN-17 20 CONVERTER 20A
L 14
MOTOR DRIVE- 3 1 21 WORK LAMP 30A
R W 0.8W
MOTOR DRIVE+ 4 2 22 15
B B 1.2B CABIN LAMP(OPTION) 30A
GND 5 3 23 16
GrW GrW 0.8ROr 0.8ROr 0.8GrW 0.8GrW WIPER 10A
VCC 6 4 24 17
R R 0.8R HEAD LAMP 20A
CONTINUE 24V 7 5 25 18
V V 0.8V 30A
WASHER P/P 8 6 26 FUEL HEATER
19
1
L L 0.8L
WASHER SIG. 9 7 27 START,STOP 20A
Br Br 0.8Br 20
INT. SIG 10 8 28 HORN 10A
Or 21
WIPER CUT SW 11 29 AC& HEATER 20A
1.2B 1.2B 22
N.C 12 30
WIPER MOTOR CONTROLLER

Gr 1.2B 1.2B SAFETY SOL 10A
FEED BACK 13 31 23
20A
4-29
SEAT
32 24
SOLENOIDE 20A
5
33 25
CIGAR 20A
34 26
WIPER AND WASHER CIRCUIT (CLUSTER TYPE 1)
27
36 SOLENOIDE 20A
28
37 PRE-HEAT 10A
29
38 FUEL P/P 20A
39 30
EPPR 10A
40 31
FUSE BOX
41
42
0.8V
0.8V
0.8GrW
0.8GrW
43
2
1
44
2
1
DO-5
45
CN-22
DIODE
M
46
CN-116
47
HEAD LIGHT OUT 1
WASHER PUMP
48
WORK LIGHT OUT 2
0.8Br 49
INT. SIG 3 50
0.8W
0.8L
WASHER SIG 5 52
PRE-HEAT 6 53
3
TRAVEL ALARM 8 55
SWITCH PANEL
NC 9 56
0.8RW 0.8RW 0.8RW
POWER 24V 10 57
GND 11 58
NC 12 59
60
4809S4EL17
2
■ WIPER AND WASHER CIRCUIT (CLUSTER TYPE 2)
1) OPERATING FLOW
(1) Key switch ON
Fuse box (No.11) I/conn [CN-5 (57)] Switch panel [CN-116 (10)]
Fuse box (No.6) I/conn [CN-5 (18)] I/conn [CN-17 (5)] Wiper motor controller [CN-141(7)]
Wiper motor [CN-21(4)]
Fuse box (No.17) I/conn [CN-5 (24)] l/conn [CN-17 (4)] Wiper motor controller [CN-141 (6)]
Washer pump [CN-22 (2)]
(2) Wiper switch ON : 1st step (Intermittent)
Wiper switch ON [CN-116 (3)] I/conn [CN-17 (8)] Wiper motor controller [CN-141 (10) → (3)]
Wiper motor intermittently operating [CN-21 (6)]
(3) Wiper switch ON : 2nd step (continual)
Wiper switch ON [CN-116(4)] I/conn[CN-17(2)] Wiper motor controller [CN-141(2) → (4)]
Wiper motor operating [CN-21(2)]
(4) Washer switch ON
Washer switch ON [CN-116 (5)] I/conn [CN-17 (7)] Wiper motor controller [CN-141 (9) → (8)]
I/conn [CN-17 (6)] I/conn [CN-5 (19)] Washer pump [CN-22 (1)] Washer operating
Wiper switch ON [CN-116 (4)] I/conn[CN-17 (2)] Wiper motor controller [CN-141 (2) → (4)]
Wiper motor operating [CN-21 (2)]
(5) Auto parking
parking(when switch OFF)
Switch OFF [CN-116 (4)] Wiper motor parking position by wiper motor controller
2) CHECK POINT

24V
STOP ON 0 ~ 5V
④ - GND (wiper power input)
⑤ - GND (wiper power output) 24V
⑥ - GND (wiper motor) 0 or 24V
※ GND : Ground
4-30
CN-5
1
2
3
4 CN-36
5 ECM 30A
6
CN-21 6 1
CS-53 ROOM LAMP/CASSETTE 10A
3 1 7 2
R Or MCU 30A
2 8 3
Gr START KEY 30A
5 3 9 4
R 20A
4 10 AIR CON/HEATER
WIPER CUT
4 G B
5
5 11 0.8R WIPER 10A
L 6
6 M 2 6 12 SPARE 10A
WIPER MOTOR
7
13 ECM 10A
8
1
14 20A
MCU CONT.
15 9
SPARE 20A
16 10
4
0.8RW SWITCH PANEL 10A
17 11
0.8R 0.8R 10A
CN-141 18 CASSETTE
G 0.8V 0.8V 12
FEED BACK 1 19 CLUSTER 10A
W 13
1
MOTOR DRIVE SIG 2 CN-17 20 CONVERTER 20A
L 14
MOTOR DRIVE- 3 1 21 WORK LAMP 30A
R W 0.8W
MOTOR DRIVE+ 4 2 22 15
B B 1.2B CABIN LAMP(OPTION) 30A
GND 5 3 23 16
GrW GrW 0.8ROr 0.8ROr 0.8GrW 0.8GrW WIPER 10A
VCC 6 4 24 17
R R 0.8R HEAD LAMP 20A
CONTINUE 24V 7 5 25 18
V V 0.8V 30A
WASHER P/P 8 6 26 FUEL HEATER
19
1
L L 0.8L
WASHER SIG. 9 7 27 START,STOP 30A
Br Br 0.8Br 20
INT. SIG 10 8 28 HORN 10A
Or 21
WIPER CUT SW 11 29 AC& HEATER 20A
1.2B 1.2B 22
N.C 12 30
WIPER MOTOR CONTROLLER

Gr 1.2B 1.2B SAFETY SOL 10A
FEED BACK 13 31 23
20A
4-31
OPTION
32 24
SOLENOIDE 20A
5
33 25
CIGAR 20A
34 26
WIPER AND WASHER CIRCUIT (CLUSTER TYPE 2)
27
36 TRAVEL SOL 20A
28
37 PRE-HEAT 10A
29
38 FUEL P/P 20A
39 30
EPPR 10A
40 31
FUSE BOX
41
42
0.8V
0.8V
0.8GrW
0.8GrW
43
2
1
44
2
1
DO-5
45
CN-22
DIODE
M
46
CN-116
47
HEAD LIGHT OUT 1
WASHER PUMP
48
WORK LIGHT OUT 2
0.8Br 49
INT. SIG 3 50
0.8W
0.8L
WASHER SIG 5 52
PRE-HEAT 6 53
3
TRAVEL ALARM 8 55
SWITCH PANEL
NC 9 56
0.8RW 0.8RW 0.8RW
POWER 24V 10 57
GND 11 58
NC 12 59
60
4809S4EL18
2
CN-51
GND_MAIN 1
0.8R
2.5k
2.5k
BATT POWER_24V 2
0.8RW
POWER IG 3
-
+
S
2
6
5
4
1
3
POWER_24V OUT 4
ACCEL DIAL
CN-16B
B
A
C
GND_PRESSURE 5
CN-142
0.8Gr
POWER_5V OUT 6
0.8B
0.8W
0.8Gr
0.8B
0.8LW
0.8BW
7
0.8B
GND_5V
0.8W
0.8Gr
G/A MOTOR(+) 8
5
4
1
9
8
7
6
3
TRAVEL BUZZER 20
16
15
14
13
12
11
10
0.8V
CN-7
CAN1 Hi-ECM 21
RH CONSOLE
CAN2 Hi-APTC 22
CN-36
3W ECM 30A
0.8BW
0.8BW
RS232C1_TX-HRDT 24 1
RS232C2_TX-RCM 25 ROOM LAMP/CASSETTE 10A
2
6
5
4
3
2
PWM INPUT_1 26 0.8R MCU 30A
3
CN-16
PWM INPUT_2 27 START KEY 30A
4
TILT SIG. 28
0.8B
20A
0.8W
0.8Gr
AIR CON/HEATER
ROTATE SIG. 29 5
WIPER 10A
AI RESERVE 30 6
0.8G CLUSTER 10A
CAN1 Lo-ECM 31 7
0.8Or ECM 5A
32 8
0.8RW MCU CONT. 20A
CN-52 9
0.8R MCU_EPPR 20A
FUEL WARMER RY
10
16 SWITCH PANEL 10A
ENG PRE-HEAT RY 17 11
CASSETTE 10A
ENG STOP RY 18 12
CLUSTER 10A
REVERVE EPPR- 19 13
CONVERTER 20A
MCU
COOLING FAN EPPR- 20 14
0.8W 30A
ACCEL DIAL SIG 21 WORK LAMP
15
WORK BRAKE PRESS 22 CABIN LAMP(OPTION) 30A
16
BOOM UP PRESSS SENSOR 23 WIPER 10A
17
CONTROLLER CIRCUIT (CLUSTER TYPE 1)
HEAD LAMP 20A

18
CN-53 FUEL HEATER 30A
19
4-32
ATT FLOW EPPR+ 1 START,STOP 20A
20
3W
0.8Gr
0.8W
0.8B
0.8BW
0.8LW
3W
0.8Or
0.8G
0.8V
0.8B
RIGHT TILT EPPR+ 2 10A
HORN
LEFT TILT EPPR+ 3 21
0.8R AC& HEATER 20A
2
9
8
7
5
4
1
6
3
EPPR POWER 4 22
15
14
13
12
11
10
SAFETY SOL 10A
CN-2
RIGHT ROTATE EPPR+ 5 23

20A
V
SEAT
2R
2R
6
SH
LEFT ROTATE EPPR+ 24
0.8B
0.8G
0.8W
0.8Gr
20A
0.8BW
0.8BW
SOLENOIDE
0.8ROr
TRAVEL EPPR+(w) 7
0.8RW 25
PUMP SHIFT EPPR+ 8 CIGAR 20A
26
BOOM PRIORITY EPPR+ 9 OPTION(BEACON) 20A
27
EPPR 24v 10 SOLENOIDE 20A
ATT FLOW EPPR - 11 28
PRE-HEAT 10A
RIGHT TILT EPPR - 12 29
FUEL P/P 20A
LEFT TILT EPPR - 13 30
SPARE 10A
EPPR GND 14 31
FUSE BOX
RIGHT ROTATE EPPR - 15

LEFT ROTATE EPPR - 16
TRAVEL EPPR-(w) 17
0.8Br
PUMP SHIFT EPPR- 18
BOOM PRIORITY EPPR - 19
SH
0.8V
0.8G
1.2R
1.2R
1.2R
1.2R
1.2R
0.8BW
0.8B
0.8W
0.8Gr
SH
0.8V
0.8G
1.2B
1.2B
1.2B
1.2B
1.2B
0.8BW
0.8ROr
EPPR GND
0.8Br
20
0.8RW
CN-126
0.8G
0.8V
REVERSE FAN_MANUAL 21
7
8
10
38
29
30
39
40
50
18
28
17
20
43
49
21
48
26
27
36
46
37
CN-91
REVERSE FAN_AUTO 22
2
1
19
60
59
58
57
27
26
25
24
23
20
22
21
J
2
1
9 IG 24V
CN-5
CN-1
CN-99
8 H CAN2_Lo
SH
9
8
7
5
2
4
1
6
G CAN2_Hi
3
7
0.8V
10
0.8G
0.8G
6 F CAN_Lo
0.8V
5 E CAN_Hi
POWER IG
1.2Br
4 GND
1.2RW
Service Tool
OEM PORT 50P
3 C RS232_TX
R.THROTTLE +5V
J1708 DATA LINK-
J1939 DATA LINK-
J1708 DATA LINK+

J1939 DATA LINK+
1
2
2 B RS232_RX
J1939 DATA LINK SLD
R.THROTTLE POS SIG
R.THROTTLE RETURN
R.THROTTLE POS RTN
CN-75
4809S4EL19
1 RS232 P_DUMP
UNSWITCHED POWER+
A
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCH POWER RTN-

UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
MAIN PUMP
NC CN-51
2.5k
2.5k
B
GND (POT&DIAL) 20
G/OR
5V (POT&DIAL) 21
-
+
S
2
6
5
4
1
3
POT-SIG 22
CN-16B
ACCEL DIAL
W
B
A
C
ACCEL DIAL SIG 23
CN-142
0.8B
0.8W
0.8Gr
0.8LW
0.8BW
0.8B
TACHO SENSOR(-) 25
0.8W
0.8Gr
TACHO SENSOR(+) 26
NC 27
5
4
1
9
8
7
6
3
16
15
14
13
12
11
10
CN-7
NC 28
NC 29
RH CONSOLE
NC 30
GND (SENSOR) 31
0.8BW
0.8BW
CN-36
PUMP PROLIX SW 32
2W ECM 30A
WATER TEMP SENDOR 33 1
6
5
4
3
2
HYD TEMP SENDOR
CN-16
34 2
NC 1.2R MCU 30A
35 3
0.8B
0.8W
0.8Gr
NC 36 START KEY 30A
4
AIR CON/HEATER 20A
CN-50 5
MCU
WIPER 10A
BOOM PRIORITY SOL 1 6
SPARE 10A
MAX FLOW SOL. 2 7
POWER MAX SOL. 3 0.8Gr ECM 10A
8
HOUR-METER 4 0.8RW MCU CONT. 20A
9
ENG PREHEATER 5 SPARE 20A
FUEL HEATER 6 10
SWITCH PANEL 10A
GY
BATTERY 24V(+) 7 11
BR CASSETTE 10A
PUMP EPPR(-) 8 12
CLUSTER 10A
NC 9 13
CONVERTER 20A
PROGRAM DUMP 10 14
ANTI-RESTART RY WORK LAMP 30A
11 15
ACCEL ACT(+) 12 CABIN LAMP(OPTION) 30A
16
TRAVEL SPEED SOL. 13 10A
CONTROLLER CIRCUIT (CLUSTER TYPE 2)
WIPER
17
NC 14 HEAD LAMP 20A
NC 15 18
30A
4-33
FUEL HEATER
TRAVEL BUZZER 16 19
START,STOP 30A
PRE-HEAT SW 17 20
3W
0.8Gr
0.8W
0.8B
0.8BW
0.8LW
3W
0.8Or
0.8G
0.8V
0.8B HORN 10A
NC 18 21
AC& HEATER 20A
NC 19
2
9
8
7
5
4
1
6
3
22
15
14
13
12
11
10
SAFETY SOL 10A
CN-2
OVERLOAD SIG 20 23
V
ENGINE OIL FILTER OPTION 20A
2R
2R
21
SH
0.8B
0.8G
24
0.8W
0.8Gr
0.8BW
0.8BW
NC 22 0.8ROr
SOLENOIDE 20A
ACCEL ACT(-) 25
23 CIGAR 20A
OR
POWER IG 24 26
OPTION(BEACON) 20A
CAN_HI 25 27
TRAVEL SOL 20A
CAN_LO 26 28
PRE-HEAT 10A
CAN_SHIELD 27 29
GND (MAIN) FUEL P/P 20A
28 30
SERIAL-TX 29 EPPR 10A
31
FUSE BOX
SERIAL-RX 30
GND 31
RS232 (+) 32
RS232 (-) 33
RS232 (GND) 34
NC
1.2R
1.2R
1.2R
1.2R
1.2R
1.2B
1.2B
1.2B
1.2B
1.2B
0.8BW
0.8BW
0.8B
0.8W
0.8Gr
SH
0.8V
0.8G
35
0.8ROr
OR
SH
PUMP EPPR(+) 36
7
8
0.8G
0.8V
38
29
30
39
40
50
18
28
17
20
43
49
21
48
26
27
36
46
37
CN-126
CN-91
10
9
7
2
2
4
1
1
8
3
A
B
C
12
11
10
60
59
58
57
27
26
19
25
24
23
20
22
21
9 J IG 24V
CN-5
CN-3
CN-99
8 H CAN2 Lo
A
SH
7 G CAN2 Hi
0.8V
0.8G
0.8G
1.2Br
1.2Or
F
POWER IG
6 CAN Lo
0.8V
5 E CAN Hi
2
1
OEM PORT 50P
R.THROTTLE +5V
4 D
J1708 DATA LINK-
J1939 DATA LINK-
GND
J1708 DATA LINK+
J1939 DATA LINK+
Service Tool
CN-75
3 C RS232 TX
J1939 DATA LINK SLD
R.THROTTLE POS SIG
R.THROTTLE RETURN
R.THROTTLE POS RTN
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
2 B RS232 RX
EPPR VLV
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
4809S4EL20
1 A RS232 P DUMP
10
CN-51 IG 24V J 9
Pa
GND_MAIN 1 CAN2_Lo H 8
CD-10
C 1
2
BATT POWER_24V 2 CAN2_Hi G 7
2
1
0.8G
CD-1
HYD TEMP
CD-2
POWER IG 3 CAN_Lo F 6
FUEL LEVEL
0.8V
POWER_24V OUT 4 CAN_Hi E 5
0.8L
0.8BW
0.8Y
0.8YOr
0.8Gr
0.8BW
0.8RW
0.8BW
0.8BW
0.8LOr
0.8YOr
GND_PRESSURE 5 GND D 4
AIR CLEANER SW
POWER_5V OUT 6 RS232_TX C 3
8
7
6
5
4
3
2
1
GND_5V 7 RS232_RX B 2
CN-56
G/A MOTOR(+) 8 RS232 P_DUMP A 1
L
Gr
Y
B
W
WL
0.8Gr
WR
RW
0.8L
0.8Y
SH
0.8RW
G/A MOTOR(-) 9
0.8V
0.8G
GND_MAIN 10
5
4
1
9
8
7
6
3
60
59
58
57
24
23
22
21
20
19
18
17
CAN_SHIELD 11
TX
RX
CN-5
SIG_2
GND
SIG_3
IG 24V
BATT.24V
SH
0.8V
CAMERA SIG
0.8G
0.8L
CLUSTER
RAMLOCK LAMP 18
0.8Y
0.8Gr
0.8RW
HOUR METER 19
TRAVEL BUZZER 20
0.8V
CAN1 Hi-ECM 21
CAN2 Hi-APTC 22
0.8L
RS232C1_TX-HRDT 24 CN-36
3W ECM 30A
RS232C2_TX-RCM 25 1
PWM INPUT_1 26 ROOM LAMP/CASSETTE 10A
2
PWM INPUT_2 27 MCU 30A
3
TILT SIG. 28 START KEY 30A
4
ROTATE SIG. 29 AIR CON/HEATER 20A
AI RESERVE 30 5
0.8G WIPER 10A
CAN1 Lo-ECM 31 6
0.8RW CLUSTER 10A
CAN2 Lo-APTC 32 7
0.8Y ECM 5A
0.8Or
RS485-(RX)-CLUSTER 33 8
MONITORING CIRCUIT (CLUSTER TYPE 1)
MCU CONT. 20A

RS232C1_RX-HRDT 34
9
RS232C2_RX-RCM 35 MCU_EPPR 20A
0.8LOr 10
HYD. TEMP SENDER 36 SWITCH PANEL 10A
4-34
MCU
11
WATER TEMP SENDOR 37 CASSETTE 10A
0.8YOr 12
FUEL LEVEL SENSOR 38 CLUSTER 10A
0.8Gr
ALT. LEVEL 39 13
3W
3W
0.8Or
0.8G
0.8V
0.8B
CONVERTER 20A
GOV. POTENTIO SIG. 40 14
WORK LAMP 30A
15
9
8
7
5
4
1
6
3
15
14
13
12
11
10
CN-53 30A
CABIN LAMP(OPTION)
CN-2
ATT FLOW EPPR+ 1 16
WIPER 10A
V
2
2R
2R
RIGHT TILT EPPR+
SH
17
0.8G
HEAD LAMP 20A
LEFT TILT EPPR+ 3
0.8ROr
18
EPPR POWER 4 FUEL HEATER 30A
19
RIGHT ROTATE EPPR+ 5 START,STOP 20A
20
LEFT ROTATE EPPR+ 6 HORN 10A
21
TRAVEL EPPR+(w) 7 AC& HEATER 20A
PUMP SHIFT EPPR+ 8 22
SAFETY SOL 10A
BOOM PRIORITY EPPR+ 9 23
SEAT 20A
EPPR 24V 10 24
20A
0.8G
0.8V
1.2R
1.2R
1.2R
1.2R
1.2R
SH
0.8V
0.8G
1.2B
1.2B
1.2B
1.2B
1.2B
SOLENOIDE
0.8ROr
0.8Gr
ATT FLOW EPPR- 11 25

CIGAR 20A
RIGHT TILT EPPR- 12 26
9
8
7
5
2
4
1
6
3
15
14
13
12
11
10
2
1
7
8
OPTION(BEACON) 20A
38
29
30
39
40
50
18
28
17
20
43
49
21
48
26
27
36
46
37
LEFT TILT EPPR- 13

CN-3
CN-91
CN-99
27
EPPR GND 14 SOLENOIDE 20A
0.8R
28
RIGHT ROTATE EPPR- 15 PRE-HEAT 10A
29
LEFT ROTATE EPPR- 16 FUEL P/P 20A
TRAVEL EPPR-(w) 17 30
EPPR 10A
PUMP SHIFT EPPR- 18 31
POWER IG
0.8R
0.8Gr
FUSE BOX
BOOM PRIORITY EPPR- 19
OEM PORT 50P

EPPR GND 20
2
6
5
4
1
R.THROTTLE +5V
J1708 DATA LINK-
J1939 DATA LINK-
3
4
1
2
J1708 DATA LINK+

J1939 DATA LINK+
REVERSE FAN_MANUAL 21
CN-249
CN-259
J1939 DATA LINK SLD
R.THROTTLE POS SIG
R.THROTTLE RETURN
CAMERA
CAMERA
R.THROTTLE POS RTN
REVERSE FAN_AUTO 22
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
0.8YOr
UNSWITCH POWER RTN-

UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
AIR CLEANER SW 23
NC 24
4809S4EL21
CN-51
WORKING PS 1
10
POWER MAX SW 2 J
IG 24V 9
TRAVEL ALARM SW 3 CAN2_Lo H 8
ENG OIL PS 4 CAN2_Hi
Pa
G 7
CD-10
NC 5 0.8G
C 1
2
CAN_Lo F 6
2
1
NC 6 0.8V
CD-1
HYD TEMP
CAN_Hi E
CD-2
5
FUEL LEVEL
24V(PRES.SENSOR) 7
1.2B
GND D 4
0.8
0.8
1.2YOr
AIR CLEANER SW
GND(PRES.SENSOR) 8
0.8B
0.8B
RS232_TX C 3
ALT LEVEL 9
RS232_RX B 2
P1 PRESS SIG. 10
RS232 P_DUMP A 1
P2 PRESS SIG. 11
P3 PRESS SIG. 12
TRAVEL PS 13
L
Y
B
SH
0.8Gr
0.8B
SH
0.8L
0.8Y
0.8V
0.8G
O/T DECEL SW 14
WATER LEVEL SW
4
3
2
1
15
5
4
1
9
8
7
6
3
60
59
58
57
24
23
22
21
20
19
18
17
L
CN-5
CN-56
AIR CLEANER SW 16
NC 17
RR
SH
SH
0.8V
0.8G
0.8L
0.8B
0.8Y
0.8Gr
NC 18
NC 19
GND (POT&DIAL) 20
TX
RX
5V (POT&DIAL)
GND
21
POT-SIG 22
CLUSTER
ACCEL DIAL SIG
POWER IG(24V)
23 CN-36
B/OR
FUEL LEVEL SENSOR 24 30A
2W ECM
TACHO SENSOR(-) 25 1
TACHO SENSOR(+) 26 2
MCU 30A
NC 27 3
START KEY 30A
NC 28 4
NC AIR CON/HEATER 20A
29 5
NC 30 WIPER 10A
B 6
GND (SENSOR) 31 SPARE 10A
MONITORING CIRCUIT (CLUSTER TYPE 2)
7
PUMP PROLIX SW 32 0.8Gr ECM 10A
WATER TEMP SENDOR 33 8
MCU CONT. 20A
HYD TEMP SENDOR 34 9
4-35
SPARE 20A
NC 35 10
SWITCH PANEL 10A
NC 36 11
CASSETTE 10A
12
MCU
CN-50 0.8 CLUSTER 10A
BOOM PRIORITY SOL 1 13
CONVERTER 20A
MAX FLOW SOL. 2 14
30A
3W
3W
0.8Or
0.8G
0.8V
0.8B
WORK LAMP
POWER MAX SOL. 3 15
CABIN LAMP(OPTION) 30A
HOUR-METER 4 16
9
8
7
5
4
1
6
3
15
14
13
12
11
10
ENG PREHEATER 5 WIPER 10A
CN-2
17
FUEL HEATER 6 HEAD LAMP 20A
V
18
2R
2R
SH
BATTERY 24V(+) 7 30A
0.8G
FUEL HEATER
0.8ROr
19
PUMP EPPR(-) 8 START,STOP 30A
NC 9 20
HORN 10A
PROGRAM DUMP 10 21
AC& HEATER 20A
ANTI-RESTART RY 11 22
SAFETY SOL 10A
ACCEL ACT(+) 12 23
OPTION 20A
TRAVEL SPEED SOL. 13 24
14 SOLENOIDE 20A
25
ACCEL ACT(-) 23 CIGAR 20A
1.2R
1.2R
1.2R
1.2R
1.2R
SH
0.8V
0.8G
0.8G
0.8V
1.2B
1.2B
1.2B
1.2B
1.2B
0.8ROr
26
POWER IG 24 OPTION(BEACON) 20A
CAN_HI 27
25
A
B
C
20A
7
8
TRAVEL SOL
38
29
30
39
40
50
18
28
17
20
43
49
21
48
26
27
36
46
37
CN-91
28
CN-99
CAN_LO 26 10A
PRE-HEAT
A
CAN_SHIELD 27 29
FUEL P/P 20A
GND (MAIN) 28 30
Y EPPR 10A
SERIAL-TX 29 31
L
FUSE BOX
SERIAL-RX 30
POWER IG
GND 31
RS232 (+) 32
OEM PORT 50P

R.THROTTLE +5V
J1708 DATA LINK-
J1939 DATA LINK-
RS232 (-) 33
J1708 DATA LINK+
J1939 DATA LINK+
RS232 (GND) 34
J1939 DATA LINK SLD
R.THROTTLE POS SIG
R.THROTTLE RETURN
R.THROTTLE POS RTN
4809S4EL22
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
UNSWITCHED POWER+
NC 35
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
UNSWITCH POWER RTN-
PUMP EPPR(+) 36
GROUP 3 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check
※ Check specific gravity

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

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

ON : 0Ω(for terminal 1-3 and 1-2)
H0 I B-ST : 24V 40A
4
3
2
6
5
STC BR ACC H
START : 0Ω(for terminal 1-5)
CS-2
A SUPPLY
B SIG
Pressure C RETURN
sensor 8~30V ※ Check contact
(cluster type 1) CD-7
CD-6 CD-7 CD-24 Normal : 0.1Ω
CD-31 CD-32 CD-42
CD-43 CD-44 CD-69
CD-70 CD-71
A SUPPLY
B SIG
Pressure
C RETURN 8~30V ※ Check contact
sensor
(cluster type 2) CD-7 CD-7 CD-31 Normal : 0.1Ω
CD-6
CD-42 CD-43 CD-44
4-38
Pre-heat plug 24V 200A ※ Check resistance

0.25~0.12Ω
CN-80
C 1 ※ Check resistance
Temperature
sensor - 50˚C : 804Ω
(hydraulic, 2 80˚C : 310Ω
coolant) CD-8 100˚C : 180Ω
CD-1 CD-8
※ Check contact
Air cleaner Pa
pressure switch (N.O TYPE) High level : ∞Ω
Low level : 0Ω
CD-10
※ Check resistance
Full : 50Ω 6/12 : 350Ω
2 11/12 : 100Ω 5/12 : 400Ω
10/12 : 150Ω 4/12 : 450Ω
Fuel sender -
1 9/12 : 200Ω 3/12 : 500Ω
8/12 : 250Ω 2/12 : 550Ω
CD-2 7/12 : 300Ω 1/12 : 600Ω
Empty warning : 700Ω
3 4 4 ※ Check resistance
3 Normal : About 200Ω
Relay
(air con blower) 2 24V 20A (for terminal 1-3)
1 2 1 0Ω
CR-46 (for terminal 2-4)
1
2
4 5 1 ※ Check resistance
3 Normal : About 160 Ω
Relay (for terminal 1-2)
4 24V 16A
3 2
5 0Ω(for terminal 3-4)
CR-2
CR-2 CR-5
CR-5 CR-36
CR-36 ∞Ω(for terminal 3-5)
CR-45 CR-62
CR-62
4-39
30
87a 87 85 ※ Check resistance
86
87
Normal : About 160 Ω
Relay 85 24V 16A (for terminal 85-86)
87a 30 86
0Ω(for terminal 30-87a)
CR-4CR-4
CR-7CR-7
CR-9CR-9
CR-13 ∞Ω(for terminal 30-87)
CR-13 CR-35 CR-46
CR-35 CR-45 CR-46
1
Solenoid valve 2 24V 1A Normal : 15~25Ω
(cluster type 1)
CN-66
CN-66 CN-68
CN-68 CN-70
CN-70 (for terminal 1-2)
CN-88 CN-135 CN-140
CN-88
CN-149 CN-140 CN-237
CN-236 CN-149
CN-236 CN-237
1
Solenoid valve
2 24V 1A Normal : 15~25Ω
(cluster type 2)
CN-66 CN-68 CN-70
CN-70 (for terminal 1-2)
CN-66 CN-68
CN-88 CN-135 CN-140
CN-88 CN-140 CN-133
CN-149 CN-236 CN-237
1 ※ Check resistance
EPPR valve Normal : 15~25Ω
2 700mA
(cluster type 1)
(for terminal 1-2)
CN-75CN-133
CN-75 CN-133
CN-238
CN-239 CN-240
CN-154 CN-241
CN-242
CN-242
1
Speaker 2
20W
Normal : A fewΩ
CN-23(LH)
CN-24(RH)
※ Check contact
7
6
3
2
1
8
4
12
5
11
10
11
2
8
Normal
Switch
24V 8A ON : 0 Ω(for terminal 3-7, 4-8)
(locking type)
∞Ω(for terminal 7-9, 8-10)
10
12
12
9
4
OFF : ∞Ω(for terminal 3-7, 4-8)

CS-23
CS-23 CS-50
CS-50CS-52
CS-67CS-67
CS-82 0 Ω(for terminal 7-9, 8-10)
CS-83 CS-83
CS-82 CS-99CS-99
CS-100
CS-100
※ Check resist
Normal : About 5kΩ
A + (for terminal A-C)
B S ※ Check voltage
Accel dial -
C - Normal : About 5V
(for terminal A-C)
CN-142 : 2~4.5V
(for terminal C-B)
4-40
3 ※ Check disconnection
Normal : 1.0Ω
2 ON : 0Ω(For terminal 1-2)
Room lamp 24V 10W ∞Ω(For terminal 1-3)
1
OFF : ∞Ω(For terminal 1-2)
CL-1 0Ω(For terminal 1-3)
Head lamp, 1 24V 65W ※ Check disconnection

Work lamp, (H3 Type)
CL-4 Normal : 1.2Ω
Cab lamp CL-3 CL-5
CL-4 CL-6
CL-5
CL-8 CL-9
CL-6 CL-8 CL-9
CL-24 CL-36 CL-37
Beacon lamp 21V 70W ※Check disconnection

M (H1 Type) Normal : A fewΩ
CL-7
-
CL-7
1 M
24V 10A ※Check resistance
Fuel filler pump 2 35ℓ /min Normal : 1.0Ω
CN-61
3 ※Check operation
2
h Supply power(24V) to terminal
Hour meter 16~32V
1 No.2 and connect terminal No.1
CN-48 and ground
1 ※Check operation
Horn DC22~28V Supply power(24V) to each
2 2A terminal and connect ground.
CN-20 CN-25
4-41
※Check contact
2 3 1
Normal : 0Ω(for terminal 1-2)
24V 15A
Safety switch 2 ∞Ω(for terminal 1-3)
(N.C TYPE)
Operating : ∞Ω(for terminal 1-2)
3
1 0Ω(for terminal 1-3)
CS-4
CS-4
24V ※Check contact

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

REMOCON GND
SPK FRT RH+
SPK FRT LH+

SPK FRT RH-
24V 2A
SPK FRT LH-
REMOCON+
USB plalyer 20~25V

BACK UP+
TEL MUTE
ANT 12V
GND
GND
(for terminal 1-3, 3-8)

ACC
ILL+
ILL-
NC
NC
CN-27
Washer pump 24V 3.8A ※Check contact

Normal : 10.7Ω(for terminal 1-2)
CN-22
3 1
2
5 3
4 ※Check disconnection
Wiper motor 4
24V 2A
5
Normal : 7Ω(for terminal 2-6)
6 M 2 6
CN-21
4-42
3 12V 12V
DC/DC 2 24V 24V (1-2)
Converter 1 GND 24V 12V 3A
12V (1-3)
CN-138
※Check coil resistance

Normal : About 1MΩ
Cigar lighter 24V 5A 1.4W ※Check contact
Normal : ∞Ω
Operating time : 5~15sec
CL-2
CL-2
B+
G
1 P
3 ~
2 L
U Delco Remy ※Check contact
Normal : 0Ω (for terminal B+-I)
3 FI
Alternator 4 NC 24V 50A
CN-74 Normal : 24~27.5V
M
M
Starter Denso ※Check contact
24V 4.5kW Normal : 0.1Ω
B+
CN-45
Travel alarm ※Check contact

24V 0.5A
Normal : 5.2Ω
CN-81
1
Aircon ※Check contact
compressor 24V 79W Normal : 13.4Ω
CN-28
4-43
Start relay ※Check contact

24V 300A
Normal : 0.94Ω(for terminal 1-2)
CR-23
1 M ※Check resistance
Blower motor 24V 9.5A
2 Normal : 2.5Ω(for terminal 1-2)
※Check resistance
Duct sensor 2 1˚C OFF Normal : 0Ω(for terminal 1-2),
(switch) 4˚C ON the atmosphere temp :
1
Over 4˚C
Door switch 24V 2W ※Check resistance

Normal : About 5MΩ
CS-1
CS-1
Switch 1
(power max, ※Check resistance
24V 6A
one touch decel, 2 Normal : ∞Ω
horn, breaker)
CS-5 CS-19
CS-26 CS-26A CS-29
2 ※Check disconnection
normal : 0Ω
Fusible link 60A
1 (connect ring terminal and check
resist between terminal 1 and 2)
CN-60 CN-95
4-44
※ Check disconnection
Master switch 6-36V
Normal : 0.1Ω
CS-74 CS-74B
1
24V 200mA
Travel alarm 2 107 ± 4dB
-
CN-113
1
Socket 2
12V 10A -
CN-139
4-45
GROUP 4 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-1 AMP 10 I/conn (Frame harness-Pump PS harness c/type 1) S816-010002 S816-110002
CN-1 AMP 6 I/conn (Frame harness-Pump PS harness c/type 2) S816-006002 S816-106002
CN-2 AMP 12 I/conn (Frame harness-Engine harness) 2-85262-1 368301-1
CN-3 AMP 15 I/conn (Frame harness-Engine harness) S816-012002 S816-112002
CN-4 AMP 16 I/conn (Console harness LH-Frame harness) 368047-1 368050-1
CN-5 DEUTSCH 60 I/conn (Side harness RH-Frame harness) DRB16-60SAE-L018 DRB14-60PAE-L018
CN-7 AMP 16 I/conn (Console harness RH-Frame harness) 368047-1 368050-1
CN-8 AMP 12 I/conn (Console harness RH-Frame harness) S816-012002 S816-112002
CN-10 DEUTSCH 12 I/conn (Cab harness-Side harness RH) DT06-12S-EP06 DT04-12P-BE02
CN-11 DEUTSCH 8 I/conn (Frame harness-Aircon harness) DT06-8S DT06-8S-EP06
CN-12 DEUTSCH 2 I/conn (Frame harness-Boom wire harness) DT06-2S-EP06 DT04-2P-E005
CN-14 DEUTSCH 31 I/conn (Engineharness-Actuator harness) HD36-24-31SE -
CN-15 AMP 12 I/conn (F/harness-Breaker solenoid, cluster type 1) S816-012002 S816-112002
CN-16 AMP 6 Emergency engine start & speed control S816-006002 S816-106002
CN-17 AMP 8 I/conn (Wiper harness-Side harness RH) S816-008002 S816-108002
CN-20 MOLEX 2 Horn 36825-0211 -
CN-21 AMP 6 Wiper motor 925276-0 -
CN-22 KET 2 Washer pump MG640605 -
CN-23 KET 2 Speaker-LH MG610070 -
CN-24 KET 2 Speaker-RH MG610070 -
CN-25 MOLEX 2 Horn 36825-0211 -
CN-27 KUM 16 Radio & USB player PK145-16017 -
CN-28 KUM 1 Aircon compressor MWP-01F-B -
CN-29 KET 2 Receiver dryer MG640795 -
CN-36 - - Fuse & relay box 21Q7-10910 -
CN-45 RING-TERM - Starter motor B+ S820-308000 -
CN-48 KET 1 Hour meter 2-520193-2 -
CN-50 AMP 36 MCU 341111-1 -
CN-51 AMP 36 MCU 341111-1 -
CN-56 AMP 8 Cluster (type 1) - S816-108002
CN-56 DEUTSCH 4 Cluster (type 2) - DT04-4P
CN-60 AMP 2 Fusible link - S813-130201
CN-61 DEUTSCH 2 Fuel filler pump DT06-2S-EP06 -
CN-66 DEUTSCH 2 Breaker solenoid (cluster type 1) DT06-2S-EP06 -
CN-68 DEUTSCH 2 Safety solenoid DT06-2S-EP06 -
CN-70 DEUTSCH 2 Travel high solenoid DT06-2S-EP06 -
4-46
Type Destination
CN-74 AMP 4 Alternator "l" terminal 12186568 -
CN-75 AMP 2 Pump EPPR S816-002002 -
CN-80 RING-TERM - Glow plug S820-306000 -
CN-81 DEUTSCH 2 Travel buzzer solenoid DT06-2S-EP06 -
CN-88 DEUTSCH 2 Power max solenoid DT06-2S-EP06 -
CN-91 DEUTSCH 50 ECM DRC26-50S-01 -
CN-95 AMP 2 Fusible link - S813-130201
CN-96 AMP 4 Fuel warmer 2-967325-3 -
CN-99 AMP 2 Resister S816-002002 -
CN-113 KET 2 Buzzer MG651205-5 -
CN-116 AMP 12 Switch panel 176116 -
CN-125A Econoseal J 4 GPS connector (cluster type 1) DT06-12S -
CN-126 AMP 8 Service tool S816-010002 -
CN-133 DEUTSCH 2 Boom priority solenoid DT06-2S-EP06 -
CN-138 DEUTSCH 3 DC/DC Converter DT06-3S -
CN-139 FASTEN 2 12V socket 170434-2 -
CN-140 DEUTSCH 2 Quick clamp solenoid DT06-2S-EP06 DT04-2P
CN-141 AMP 13 Wiper motor controller 172498-1 DT04-3P-EP10
CN-142 DEUTSCH 3 Accel dial DT06-3S-EP06 -
CN-147 AMP 4 Fuel-heater 15300027 -
CN-149 DEUTSCH 2 Attach safety solenoid (cluster type 1) DT06-2S-EP06 -
CN-156 DEUTSCH 2 Air seat DT04-2P-E005 -
CN-157 AMP 1 Antena power S822-014002 -
CN-170 AMP 2 Heated seat 12052641 12162000
CN-236 DEUTSCH 2 Attach pressure solenoid (cluster type 1) DT06-2S-EP06 -
CN-237 DEUTSCH 2 Attach conflux solenoid (cluster type 1) DT06-2S-EP06 -
CN-242 AMP 2 Attach flow solenoid (cluster type 1) S816-002002 S816-102002
CN-246 AMP 10 USB 316988-6 -
CN-249 AMP 4 Rear view camera (cluster type 1) DT06-4S DT04-4P-E005
·Relay
CR-1 RING-TERM - Battery relay ST710285-2 -
CR-2 - 5 Horn relay - -
CR-4 - 5 Working lamp relay - -
CR-5 - 5 Anti restart relay - -
CR-7 - 5 Aircon compressor relay - -
CR-9 - 5 Head lamp relay - -
CR-13 - 5 Head lamp relay - -
CR-23 AMP 2 Start relay - S814-102001
CR-24 RING TERM 1 Preheat relay S822-014000 -
4-47
Type Destination
CR-35 - 5 Power relay - -
CR-36 - 5 Preheat relay - -
CR-45 - 5 ECM power relay - -
CR-46 - 5 Fuel warmer relay - -
CR-62 - 5 Breaker relay - -
·Switch
CS-1 SHUR 1 Door switch S822-014002 S822-114002
CS-2 WP 6 Start key switch S814-006100 -
CS-4 DEUTSCH 3 Safety switch DT06-3S-EP06 -
CS-5 DEUTSCH 2 Horn switch - DT04-2P-E005
CS-19 DEUTSCH 2 One touch decel switch - DT04-2P-E005
CS-20 AMP 1 Safety switch S822-014002 -
CS-23 SWF 12 Beacon lamp switch SWF589790 -
CS-26 DEUTSCH 2 Breaker switch DT06-2S-EP06 -
CS-26A AMP 2 Breaker pedal switch S816-002002 S816-102002
CS-29 DEUTSCH 2 Power max switch DT06-2S-EP06 -
CS-50 SWF 12 Overload switch SWF589790 -
CS-53 AMP 1 Wiper cut switch S822-014002 -
CS-67 SWF 12 Quick clamp switch SWF 589790 -
CS-74A AMP 2 Master switch S813-030201 -
CS-74B DEUTSCH 2 Master switch DT06-2S-EP06 -
CS-82 SWF 12 Spare switch SWF 589790 -
CS-142 DEUTSCH 3 Accel dial LED DT06-3S-EP06 -
·Light
CL-1 KET 3 Room lamp MG651032 -
CL-2 AMP 1 Cigar light S822-014002 S822-114002
CL-3 DEUTSCH 2 Head lamp-LH DT06-2S-EP06 -
CL-4 DEUTSCH 2 Head lamp-RH DT06-2S-EP06 DT04-2P-E005
CL-5 DEUTSCH 2 Work lamp-LH DT06-2S-EP06 DT04-2P
CL-6 DEUTSCH 2 Work lamp-RH DT06-2S-EP06 DT04-2P
CL-7 SHUR 1 Beacon lamp S822-014002 S822-114002
CL-8 DEUTSCH 2 Cab light-LH DT06-2S-EP06 DT04-2P-E005
CL-9 DEUTSCH 2 Cab light-RH DT06-2S-EP06 DT04-2P-E005
CL-36 DEUTSCH 2 Work lamp-LH DT06-2S-EP06 DT04-2P
CL-37 DEUTSCH 2 Work lamp-RH DT06-2S-EP06 DT04-2P
4-48
Type Destination
·Sensor, sendor
CD-1 AMP 2 Hydraulic oil temp sender 85202-1 -
CD-2 DEUTSCH 2 Fuel sender DT06-2S-EP06 -
CD-6 DEUTSCH 3 Travel pressure switch DT06-3S-EP06 -
CD-7 DEUTSCH 3 Working pressure switch DT06-3S-EP06 -
CD-10 RING TERM - Air cleaner switch ST730135-2 -
CD-24 DEUTSCH 3 Swing sensor (cluster type 1) DT06-3S-EP06 -
CD-31 AMP 3 Overload sensor S816-003002 S816-103002
CD-32 DEUTSCH 3 Boom up sensor (cluster type 1) DT06-3S-EP06 -
CD-42 DEUTSCH 3 Pump pressure 1 DT06-3S-EP06 -
CD-69 DEUTSCH 3 Attach pressure sensor (cluster type 1) DT06-3S-EP06 -
4-49
2. CONNECTION TABLE FOR CONNECTORS
1) PA TYPE CONNECTOR
No. of
pin Receptacle connector (female) Plug connector (male)
2 5 1 3
1 3 2 5
S811-005002 S811-105002
3 7 1 4
1 4 3 7
S811-007002 S811-107002
4 9 1 5
1 5 4 9
S811-009002 3S811-109002
5 11 1 6
11
1 6 5 11
S811-011002 S811-111002
4 - 50
No. of
Receptacle connector (female) Plug connector (male)
pin
6 13 1 7
13
1 7 6 13
S811-013002 S811-113002
8 1 9
17
17
1 9 8 17
S811-017002 S811-117002
1 21
1 11
21
1 11 1 21
S811-021002 S811-121002
4 - 51
2) J TYPE CONNECTOR
No. of
pin
1 1
2
2 12
S816-002001 S816-102001
2 3 1
3 1 2
S816-003001 S816-103001
3 1 4 2
4 2 3 1
S816-004001 S816-104001
8 5 2
6 3 1
8 5 2 6 3 1
S816-008001 S816-108001
4 - 52
3) SWP TYPE CONNECTOR
No. of
pin
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 23
S814-003000 S814-103000
2 4
1 3
1 3 2 4
S814-004000 S814-104000
4 - 53
No. of
pin Receptacle connector (female) Plug connector (male)
3 6
1 4
1 4 3 6
S814-006000 S814-106000
4 8
1 5
1 5 4 8
S814-008000 S814-108000
4 12
1 9
12
4 12
1 9
S814-012000 S814-112000
3 14
1 11
14
1 11 3 14
S814-014000 S814-114000
4 - 54
4) CN TYPE CONNECTOR
No. of
pin
1 1
S810-001202 S810-101202
2 2
1 1
S810-002202 S810-102202
3 2
1 2 1 3
S810-003202 S810-103202
2 4 1 3
1 3 2 4
S810-004202 S810-104202
4 - 55
No. of
pin
3 6 1 4
1 4 3 6
S810-006202 S810-106202
4 8 1 5
1 5 4 8
S810-008202 S810-108202
4 - 56
5) 375 FASTEN TYPE CONNECTOR
No. of
pin
1 2 1 2
S810-002402 S810-102402
6) AMP ECONOSEAL CONNECTOR

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

No. of
pin
85202-1
4 - 57
8) AMP 040 MULTILOCK CONNECTOR
No. of
pin
12 1 6
7 12
174045-2
9) AMP 070 MULTILOCK CONNECTOR

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

No. of
pin
3 1
6
6 4
1
4 6 3
480003-9
925276-0
4 - 58
11) KET 090 CONNECTOR
No. of
pin
1
2
MG610070
12) KET 090 WP CONNECTORS

No. of
pin
1
2
MG640605
2 1
MG640795
4 - 59
13) KET SDL CONNECTOR
No. of
pin
14
7
6
14
MG610406
4 - 60
14) DEUTSCH DT CONNECTORS
DT 06 - 3S - ★★★★
Modifications (see below)

Number of contacts (P : Pin, S : Socket)
04 : Receptacle, 06 : Plug
Deutsch connectors
※ Modification
E003 : Standard end cap - gray
E004 : Color of connector to be black
E005 : Combination - E004 & E003
EP04 : End cap
EP06 : Combination P012 & EP04
P012 : Front seal enhancement - connectors color to black for 2, 3, 4 & 6pin
No. of
pin
1 2 2 1
2
DT06-2S DT04-2P
2 1 1 2
3 3
DT06-3S DT04-3P
4 1 1 4
3 2 2 3
DT06-4S DT04-4P
4 - 61
No. of
pin
6 1 1 6
4 3 3 4
DT06-6S DT04-6P
4 5 5 4
1 8
8 1
DT06-8S DT04-8P
7 6
6 7
12
1 12 12 1
DT06-12S DT04-12P
4 - 62
15) MOLEX 2CKTS CONNECTOR
No. of
pin
1 2
35215-0200
35215-0200
16) ITT SWF CONNECTOR

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

No. of
pin
1
1
NMWP01F-B
4 - 63
18) ECONOSEAL J TYPE CONNECTORS
No. of
pin
S816-001002 S816-101002
1 2 2 1
S816-002002 S816-102002
S816-003002 S816-103002
S816-004002 S816-104002
4 - 64
No. of
pin
S816-006002 S816-106002
S816-008002 S816-108002
10
S816-010002 S816-110002
12
S816-012002 S816-112002
4 - 65
No. of
pin
15
368301-1 2-85262-1
19) METRI-PACK TYPE CONNECTOR

No. of
pin
12040753
20) DEUTSCH HD30 CONNECTOR

No. of
pin
J K
K J
B
23 N T
A B
F
F Q N
Q A
HD36-24-23SN HD34-24-23PN
4 - 66
21) DEUTSCH MCU CONNECTOR
No. of
Receptacle connector (Female) Plug connector (Male)
pin
5
1 6
11 1
10
2
3
11 4
5
21
6
40 21 31
32
7
8
9
33 10
34
35
31 36
37
20
30
20
38
39
35 40
36
30
40
DRC26-40SA/B/C
22) DEUTSCH SERVICE TOOL CONNECTOR

No. of
pin
C
D
E
A
9
F
B
G
H J
HD10-9-96P
23) AMP FUEL WARMER CONNECTOR

No. of
pin
3 2
2-967325-3
4 - 67
24) DEUTSCH E
ENGINE
NGINE ECM CONNECTOR
No. of
pin
1 5
6
11
1
10
2
11 3
4
21 5
21 31
6
7
50 31 41
42
8
9
10 20
43
44
41 45
20
46
47
30
40
30
48
45 49
50
46
50 40
DRC26-50S-04
25) DEUTSCH INTERMEDIATE CONNECTOR

No. of
pin
1
13 12
25 24
31
30
60 37
36
49
48
60
DRB16-60SAE-L018
4 - 68
SECTION 5 MECHATRONICS SYSTEM
Group 1 Outline----------------------------------------------------------------------------------------------------------------- 5-1

Group 2 Mode Selection System ------------------------------------------------------------------------------------ 5-5
Group 3 Automatic Deceleration System ----------------------------------------------------------------------- 5-11
Group 4 Power Boost System ----------------------------------------------------------------------------------------- 5-13
Group 5 Travel Speed Control System --------------------------------------------------------------------------- 5-15
Group 6 Automatic Warming Up System ----------------------------------------------------------------------- 5-17
Group 7 Engine Overheat Prevention System --------------------------------------------------------------- 5-19
Group 8 Variable Power Control System ------------------------------------------------------------------------ 5-21
Group 9 Attachment Flow Control System --------------------------------------------------------------------- 5-22
Group 10 Anti-Restart System ------------------------------------------------------------------------------------------- 5-23
Group 11 Self-Diagnostic System ------------------------------------------------------------------------------------- 5-24
Group 12 Engine Control System ------------------------------------------------------------------------------------- 5-36
Group 13 EPPR Valve -------------------------------------------------------------------------------------------------------- 5-38
Group 14 Monitoring System --------------------------------------------------------------------------------------------- 5-44
Group 15 Fuel Warmer System ----------------------------------------------------------------------------------------- 5-76
SECTION 5 MECHATRONICS SYSTEM
GROUP 1 OUTLINE (CLUSTER TYPE 1)
The CAPO (Computer Aided Power Optimization) system controls engine and pump mutual power at
an optimum and less fuel consuming state for the selected work by mode selection, auto-deceleration,
power boost function, etc. It monitors machine conditions, for instance, engine speed, coolant
temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
It consists of a MCU, a cluster, an ECM, EPPR valves, and other components. The MCU and the
cluster protect themselves from over-current and high voltage input, and diagnose malfunctions caused
by short or open circuit in electric system, and display error codes on the cluster.
Power mode selection (P, S, E)

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

NEW CAPO
SYSTEM
Variable power control system
Attachment flow control system
Anti-restart system
MCU & cluster protection
Self-diagnostic system Open-short diagnosis & error code display
Machine error & ECM fault code display
Machine condition monitoring
Machine monitoring system
Electric signal monitoring
One touch deceleration system
5-1
SYSTEM DIAGRAM (CLUSTER TYPE 1)
Attachment pilot N1 N2 Work Travel

Work tool pressure pressure pressure pressure pressure
MCV
Arm 1 Arm 2
SOLENOID VALVE EPPR VALVE
Option Bucket
Attachment
pressure Boom 2 Boom 1
Travel speed Attachment Swing Travel(LH) Boom priority

conflux EPPR
Power boost Attachment Travel(RH) Attachment

safety flow EPPR
Overload P1
pressure pressure
sensor
P2
pressure
Boom cylinder
Engine Main pump
P1 P2
P3
ECM
Pilot pump
Pump power
shift EPPR
CAN
Signal
Pressure signal
Pressure signal
Drive signal
MCU
Drive signal Pressure signal
Switch signal
Pressure signal Accel dial signal CN-16A CN-16
Power boost
button Normal
One touch
decel button Horn button CN-16B
Emergency
Option
button
LH control RH control Accel dial
lever lever
Serial communication(-)
Serial communication(+)
SL SR BU
Shuttle
block
Swing Boom up
pressure pressure Cluster
4809S5MS01
5-2
■ OUTLINE (CLUSTER TYPE 2)
The NEW CAPO (Computer Aided Power Optimization) system controls engine and pump mutual
power at an optimum and less fuel consuming state for the selected work by mode selection, auto-
deceleration, power boost function, etc. It monitors machine conditions, for instance, engine speed,
coolant temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
It consists of a MCU, a cluster, an ECM, EPPR valves, and other components. The MCU and the
cluster protect themselves from over-current and high voltage input, and diagnose malfunctions caused
by short or open circuit in electric system, and display error codes on the cluster.
Engine control system

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

NEW CAPO
SYSTEM
Anti-restart system
MCU & cluster protection
Self-diagnostic system Open-short diagnosis & error code display
Machine error & ECM fault code display
Machine condition monitoring
Machine monitoring system
Electric signal monitoring
One touch deceleration system
5-3
SYSTEM DIAGRAM (CLUSTER TYPE 2)
Work Travel
pressure pressure
MCV
Arm 1 Arm 2
SOLENOID VALVE EPPR VALVE
Option Bucket
Boom 2 Boom 1
Travel speed Swing Travel(LH)
Power boost Travel(RH) Boom priority

EPPR
Overload P1
pressure pressure
sensor
P2
pressure
Boom cylinder
Engine Main pump
P1 P2
P3
ECM
Pilot pump
Pump power
shift EPPR
CAN
Signal
Pressure signal
Pressure signal
Drive signal
MCU
Drive signal Pressure signal
Sgnal CN-16A CN-16
Accel dial signal
Power boost Normal

One touch button
decel button CN-16B
Horn button Emergency
Option
button Accel dial
LH control RH control
lever lever
Serial communication(-)
Serial communication(+)
Cluster
4809S5MS02
5-4
GROUP 2 MODE SELECTION SYSTEM (CLUSTER TYPE 1)
1. POWER MODE SELECTION SYSTEM
Main control valve
Engine
ECM
Main pump Pilot pump
Pump power
shift EPPR
CAN
Cluster
Drive signal
MCU
Accel dial signal CN-16A CN-16
Normal
CN-16B
Emergency
Power mode Accel dial

pilot lamp
Power mode switch signal
4809S5MS18
Mode selection system (micro computer based electro-hydraulic pump and engine mutual control
system) optimizes the engine and pump performance.
The combination of 3 power modes (P, S, E) and accel dial position (10 set) makes it possible to use
the engine and pump power more effectively corresponding to the work conditions from a heavy and
great power requesting work to a light and precise work.
Engine rpm Power shift by EPPR valve
Power Standard Option Standard Option
Application
mode
Current Pressure Current Pressure
Unload Load Unload Load
(mA) (kgf/cm2) (mA) (kgf/cm2)
P Heavy duty power 1850±50 1950±50 1850±50 1950±50 330±30 10 290±30 8
S Standard power 1750±50 1850±50 1800±50 1900±50 360±30 12±3 330±30 10±3
E Economy operation 1650±50 1750±50 1700±50 1800±50 360±30 12±3 330±30 10±3
AUTO Engine
1100±100 - 1100±100 - 700±30 38±3 700±30 38±3
DECEL deceleration
One touch Engine quick
1000±100 - 1000±100 - 700±30 38±3 700±30 38±3
decel deceleration
KEY Key switch
1000±100 - 1000±100 - 700±30 38±3 700±30 38±3
START start position
※ Power shift (Standard/Option) can be changed by "Service menu" in "Management" on the cluster.
5-5
2. WORK MODE SELECTION SYSTEM
Work mode consists of the general operation (bucket) and the optional attachment (breaker,
crusher).
Attachment pilot
pressure sensor
Main control valve
Work tool
Arm 1 Arm 2
SOLENOID VALVE
Option Bucket
Attachment
pressure
Boom 2 Boom 1
Attachment
Swing Travel(LH) conflux
Travel(RH) Attachment
safety
Engine
ECM
Pump power
shift EPPR
CAN
Cluster
Drive signal
Drive signal
MCU
Pressure signal
Normal
CN-16B
Emergency
Work mode
pilot lamp Work mode switch signal Accel dial
4809S5MS19
1) GENERAL WORK MODE (bucket)

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

Description
Bucket Breaker Crusher
Attachment safety solenoid OFF ON ON
Attachment pressure solenoid OFF OFF ON
Attachment conflux solenoid OFF OFF ON/OFF
Attachment flow EPPR current 100 mA 100~700 mA 0~700 mA
5-6
3. USER MODE SELECTION SYSTEM
Main control valve
Engine
ECM
Pump power
shift EPPR
CAN
Cluster
Drive signal
MCU
Normal
CN-16B
Emergency
User mode Accel dial

pilot lamp
User mode switch signal
4809S5MS20
1) High idle rpm, auto idle rpm and EPPR pressure can be adjusted and memorized in the U-mode.
2) LCD segment vs parameter setting
Step Engine speed Idle speed Power shift

( ) (rpm) (rpm) (bar)
1 1500 800 0
2 1550 850 3
3 1600 900 6
4 1650 950 9
5 1700 1000 (low idle) 12
6 1750 1050 16
7 1800 1100 (decel rpm) 20
8 1850 1150 26
9 1900 1200 32
10 1950 1250 38
5-7
■ MODE SELECTION SYSTEM (CLUSTER TYPE 2)
1. POWER MODE SELECTION SYSTEM
Main control valve
Engine
P1 P2
ECM
Pump shift
EPPR
CAN
Drive signal
Power mode
pilot lamp
MCU
Power mode switch signal Accel dial signal CN-16A CN-16
Work mode switch signal Normal
User mode switch signal
CN-16B
Emergency
Accel dial
Cluster
4809S5MS03
Mode selection system (micro computer based electro-hydraulic pump and engine mutual control
system) optimizes the engine and pump performance.
The combination of 2 power modes (H, S) and accel dial position (10 set) makes it possible to use
the engine and pump power more effectively corresponding to the work conditions from a heavy and
great power requesting work to a light and precise work.
Engine rpm Power shift by EPPR valve
Power Standard Option Standard Option
Application
mode
Current Pressure Current Pressure
Unload Load Unload Load
(mA) (kgf/cm2) (mA) (kgf/cm2)
M Heavy duty power 1900±50 1900±50 1950±50 1950±50 250±30 5 180±30 2
H Standard power 1800±50 1800±50 1850±50 1850±50 280±30 7±3 230±30 4±3
S Economy operation 1700±50 1700±50 1750±50 1750±50 280±30 7±3 260±30 6±3
AUTO Engine
1100±100 - 1100±100 - 700±30 38±3 700±30 38±3
DECEL deceleration
One touch Engine quick
1000±100 - 1000±100 - 700±30 38±3 700±30 38±3
decel deceleration
KEY Key switch
1000±100 - 1000±100 - 700±30 38±3 700±30 38±3
START start position
5-8
2. WORK MODE SELECTION SYSTEM
2 Work modes can be selected for the optional work speed of the machine operation.
Main control valve
Arm 1 Arm 2
Option Bucket
Boom 2 Boom 1
Swing Travel(LH)
Travel(RH)
Engine
ECM
Pump shift
EPPR
CAN
Drive signal
Power mode
pilot lamp MCU
Work mode switch signal Normal
CN-16B
Emergency
Accel dial
Cluster
4809S5MS04
1) HEAVY DUTY WORK MODE

Boom and arm operation speed faster than general work mode.
2) GENERAL WORK MODE
When key switch is turned ON, this mode is selected and swing operation speed is faster than
heavy duty work mode.
Work mode Heavy duty work solenoid Max flow cut-off solenoid
Heavy duty OFF OFF
General ON OFF
5-9
3. USER MODE SELECTION SYSTEM
An operator can change the engine and pump power and memorize it for his preference.
Mode Operation
High idle rpm, auto decel rpm
U
EPPR pressure can be modulated and memorized separately
HOW TO MPDULATE THE MEMORY SET

1) Each memory mode has a initial set which are
mid-range of max engine speed, auto decel
rpm, and EPPR valve input current. ACCEL
DECEL
2) High idle rpm, auto decel rpm, EPPR pressure
EPPR
can be modulated and memorized separately in
the U-mode. 2507A4OP08
※ Refer to the page 5-73 for set of use mode.

·LCD
LCD segment vs parameter setting
SYSTEM MENU
Segment ACCEL DECEL EPPR
( ) (rpm) (rpm) (mA)
Monitoring Diagnosis Management
1 1500 1000 (low idle) 150
2 1550 1050 200 Settings Display User Mode
3 1600 1100 (decel rpm) 250 User mode icon

4 1650 1150 300
5 1700 1200 350
ACCEL
6 1750 1250 400
DECEL
7 1800 1300 450 EPPR
8 1850 1350 500

9 1900 1400 550
10 1950 1450 600
3009SH4OP05
5-10
GROUP 3 AUTOMATIC DECELERATION SYSTEM (CLUSTER TYPE 1)
Work Travel
pressure pressure
Main control valve

Engine
ECM
Cluster
CAN
Pressure signal

MCU
Normal
Auto idle
pilot lamp CN-16B
Emergency
Accel dial
Auto idle switch signal
4809S5MS05
1. WHEN AUTO IDLE PILOT LAMP ON

When all of the work equipment control levers including swing and travel levers are at neutral for 4
seconds, MCU sends throttle command ECM to reduce the engine speed to 1100 rpm. If the control
levers are at neutral for 1 minute, MCU reduces the engine speed to 1000 rpm. As the result of
reducing the engine speed, fuel consumption and noise are effectively cut down during non-operation
of the control levers.
When the Auto idle pilot lamp is turned off by pressing the switch or any control lever is operated, the
reduced engine speed rises upto the speed before deceleration in a second.
Engine rpm
Accel dial
set rpm
Auto idle 1100 rpm

rpm
4 sec
Low idle 1000 rpm
rpm
60 sec 1sec
Lever Lever Time

neutral operation
4809S5MS07
2. WHEN AUTO IDLE PILOT LAMP OFF

The engine speed can be set as desired using the accel dial switch, and even if the control levers are
neutral, the engine speed is not reduced.
※ Auto idle function can be activated when accel dial position is over 4.
5-11
■ AUTOMATIC DECELERATION SYSTEM (CLUSTER TYPE 2)
Work Travel
pressure pressure
Main control valve

Engine
P3
ECM
Pump power
shift EPPR
CAN
Signal
Pressure signal
MCU Accel dial signal CN-16A CN-16
Normal
CN-16B
Emergency
Auto decel
pilot lamp
Accel dial
Cluster
4809S5MS06
1. WHEN AUTO IDLE PILOT LAMP ON

When all of the work equipment control levers including swing and travel levers are at neutral for 4
seconds, MCU sends throttle command ECM to reduce the engine speed to 1100 rpm. If the control
levers are at neutral for 1 minute, MCU reduces the engine speed to 1000 rpm. As the result of
reducing the engine speed, fuel consumption and noise are effectively cut down during non-operation
of the control levers.
When the Auto idle pilot lamp is turned off by pressing the switch or any control lever is operated, the
reduced engine speed rises upto the speed before deceleration in a second.
Engine rpm
Accel dial
set rpm
Auto idle 1100 rpm

rpm
4 sec
Low idle 1000 rpm
rpm
60 sec 1sec
Lever Lever Time

neutral operation
4809S5MS07
2. WHEN AUTO IDLE PILOT LAMP OFF

The engine speed can be set as desired using the accel dial switch, and even if the control levers are
neutral, the engine speed is not reduced.
※ Auto idle function can be activated when accel dial position is over 4.
5-12
GROUP 5 TRAVEL SPEED CONTROL SYSTEM (CLUSTER TYPE 1)
Main control valve Travel motor
Arm 1 Arm 2
Option Bucket
Boom 2 Boom 1 Regulator
Swing Travel(LH)
Travel(RH)
Travel speed
solenoid valve
Engine
Cluster
Drive signal
MCU
Travel speed
pilot lamp
Travel speed switch signal
3809SH5MS05
Travel speed can be switched manually by pressing the travel speed switch on the cluster.
Travel speed Lamp

Speed Operation
solenoid valve on cluster
Low OFF Turtle Low speed, high driving torque in the travel motor
High ON Rabbit High speed, low driving torque in the travel motor
※ Default : Turtle (Low)
5-15
■ TRAVEL SPEED CONTROL SYSTEM (CLUSTER TYPE 2)
Main control valve Travel motor
Arm 1 Arm 2
Option Bucket
Boom 2 Boom 1 Regulator
Swing Travel(LH)
Travel(RH) Travel speed

solenoid valve
Engine
Drive signal
Travel speed pilot lamp MCU
Travel speed switch signal
Cluster
3809SH5MS25
Travel speed can be switched manually by pressing the travel speed switch on the cluster.
Travel speed Lamp
Speed Operation
solenoid valve on cluster
Low OFF Turtle Low speed, high driving torque in the travel motor
High ON Rabbit High speed, low driving torque in the travel motor
※ Default : Turtle (Low)
5-16
GROUP 6 AUTOMATIC WARMING UP SYSTEM (CLUSTER TYPE 1)
Main control valve

Engine
ECM

Pump power
shift EPPR
CAN
Hydraulic temp signal

Cluster MCU Drive signal Hydraulic temp sensor
Normal
CN-16B
Emergency
Accel dial
Warming up pilot lamp signal
Warming up pilot lamp
4809S5MS10
1. The MCU receives the engine coolant temperature from the ECM, and if the coolant temperature is
below 30˚C, it increases the engine speed from key start rpm to 1100 rpm. At this time the mode
does not change. If the coolant temperature sensor has fault, the hydraulic oil temperature signal is
substituted.
2. In case of the coolant temperature increases up to 30˚C, the engine speed is decreased to key start
speed. And if an operator changes power mode set during the warming up function, the MCU
cancels the automatic warming up function.
3. LOGIC TABLE
Description Condition Function

- Coolant temperature : - Power mode : Default (E mode)
Actuated below 30˚C (after engine run) - Warming up time : 10 minutes (max)
- Warming up pilot lamp : ON
- Coolant temperature : Above 30˚C - Power mode : set mode

- Warming up time : Above 10 minutes - Warming up pilot lamp : OFF
- Changed power mode set by operator
Canceled - RCV lever or pedal operating
- Auto idle cancel
※ If any of the above conditions is
applicable, the automatic warming up
function is canceled
5-17
■ AUTOMATIC WARMING UP SYSTEM (CLUSTER TYPE 2)
Main control valve

Engine
ECM

Cluster Pump power
CAN shift EPPR
Coolant temp signal

Warming up
pilot lamp MCU Coolant temp sensor
Drive signal
Warming up pilot lamp signal
Normal
CN-16B
Emergency
Accel dial
4809S5MS11
1. The MCU recives engine coolant temperature from the ECM, and if the coolant temperature is below
30˚C, it increases the engine speed from key start rpm to 1100 rpm. At this time the mode does not
change.
2. In case of the coolant temperature increases up to 30˚C, the engine speed is decreased to key start
speed. And if an operator changes mode set during the warming up function, the MCU cancels the
automatic warming up function.
3. LOGIC TABLE
- Coolant temperature : - Power mode : Default (S mode)
Actuated below 30˚C (after engine run) - Warming up time : 10 minutes (max)
- Accel dial poisition is under 3 - Warming up lamp : ON
- Coolant temperature : Above 30˚C - Power mode : set mode

- Warming up time : Above 10 minutes - Warming up pilot lamp : OFF
- Changed mode set by operator
Canceled - Increase engine speed by rotating accel
dial clockwise
※ If any of the above conditions is
applicable, the automatic warming up
function is canceled
Warming up lamp - Coolant temperature : Above 30˚C - Warming up lamp : OFF
5-18
GROUP 7 ENGINE OVERHEAT PREVENTION SYSTEM (CLUSTER TYPE 1)
Main control valve

Engine
ECM

Pump power
CAN shift EPPR

Emergency
warning lamp MCU Drive signal
Hydraulic temp sensor
Cluster
Normal
CN-16B
Emergency
Accel dial
Overheat warning signal
Coolant temperature Hydraulic temperature

warning lamp warning lamp
4809S5MS12
1. The engine coolant temperature or the hydraulic oil temperature is overheated over 100˚C, the
warning lamp is ON and the pump input torque or the engine speed is reduced as below logic table.
2. LOGIC TABLE
- Coolant or hydraulic oil temperature : - Warning lamp & buzzer : ON
Activated
First step Above 100˚C - Pump input torque is reduced.
warning - Coolant or hydraulic oil temperature : - Return to pre-set the pump input torque.
Canceled
Less than 95˚C
- Emergency warning lamp pops up on the
- Coolant or hydraulic oil temperature :
Activated center of LCD and the buzzer sounds.
Above 105˚C
Second step - Engine speed is reduced after 10 seconds.
warning - Return to pre-set the engine speed.
- Coolant or hydraulic oil temperature :
Canceled - Hold pump input torque on the first step
Less than 100˚C
warning.
5-19
■ ENGINE OVERHEAT PREVENTION SYSTEM (CLUSTER TYPE 2)
Main control valve

Engine
ECM

Pump power
shift EPPR
CAN
Hydraulic temperature Coolant temperature MCU Drive signal Hydraulic temp sensor
warning lamp warning lamp
Normal
CN-16B
Emergency
Accel dial
Overheat warning signal
Cluster
4809S5MS13
1. MCU receives engine coolant temperature from the ECM and when the engine coolant boils up to
110˚C, it sends overheat warning signal to the cluster and decrease the engine speed same as accel
dial 7 position.
2. If the coolant temperature drops less than 100˚C, the MCU returns the mode to the mode set before.
And if mode set is changed during the function, the MCU cancels the function.
Even if the overheat prevention function is canceled by mode change, the overheat warning lamp
turns OFF only when the coolant temperature is less than 100˚C.
3. LOGIC TABLE

- Coolant temperature : Above 110˚C - Engine rpm drop to accel dial 7 position
Actuated
- Accel dial set : Above 8 - Overheat warning lamp & buzzer : ON
- Coolant temperature : Less than 100˚C - Return to the mode and accel dial set before
- Changed mode set by operator - Hold on the changed set
Canceled ※ If any of the above conditions is
applicable, engine overheat
prevention function is canceled
Overheat warning lamp - Coolant temperature : Less than 100˚C - Overheat warning lamp : OFF
5-20
GROUP 8 VARIABLE POWER CONTROL SYSTEM (CLUSTER TYPE 1)
Work Travel
pressure pressure
Main control valve
P1 P2
pressure pressure
Engine
ECM
Pump power
shift EPPR
CAN
Signal
Pressure signal
MCU Pressure signal

Switch signal
Pressure signal Accel dial signal CN-16A CN-16
LH control RH control
lever lever Normal
CN-16B
Emergency
BU
Accel dial
Shuttle
block
Boom up
pressure
E mode power
Cluster
4809S5MS14
· The variable power control system controls the engine and pump mutual power according to RCV
lever stroke and pump load.
It makes fuel saving and smooth control at precise work.
Description Working condition
Power mode E
Work mode General (bucket)
Pressure sensor Normal
※ The variable power control function can be activated when the power mode is set to E mode.
5-21
GROUP 9 ATTACHMENT FLOW CONTROL SYSTEM (CLUSTER TYPE 1)
Attachment pilot
pressure sensor
Main control valve
Work tool
Arm 1 Arm 2
SOLENOID VALVE
Option Bucket
Attachment
pressure
Boom 2 Boom 1
Attachment
Travel(LH) conflux
Swing
Attachment
Travel(RH) safety
Engine
ECM
Attachment
flow EPPR
CAN
Cluster Drive signal
Drive signal
MCU
Pressure signal
Normal
CN-16B
Emergency
Accel dial
Work mode
pilot lamp Work mode switch signal
4809S5MS15
· The system is used to control the pump delivery flow according to set of the work tool on the
cluster by the attachment flow EPPR valve.
Work tool
Description
Breaker Crusher
Max 7 step, Max 4 step,
Flow level reduced 10 lpm each step reduced 20 lpm each step
Attach safety solenoid ON ON
Attach pressure solenoid OFF ON
Attach conflux solenoid OFF ON/OFF
※ Refer to the page 5-56 for the attachment kinds and max flow.
5-22
GROUP 10 ANTI-RESTART SYSTEM
Engine
ECM
CAN
Start safety relay
Drive signal
MCU
Normal
CN-16B
Emergency
Accel dial
4809S5MS16
1. ANTI-RESTART FUNCTION
After a few seconds from the engine starts to run, MCU turns off the start safety relay to protect the
starter from inadvertent restarting.
2. When a replacement or taking-off of the MCU is needed, connect CN-16 and CN-16B to ensure the
engine start without the MCU.
5-23
GROUP 11 SELF-DIAGNOSTIC SYSTEM (CLUSTER TYPE 1)
1. OUTLINE
When any abnormality occurs in the ADVENCED CAPO system caused by electric parts
malfunction and by open or short circuit, the MCU diagnoses the problem and sends the error codes
to the cluster and also stores them in the memory.
2. MONITORING
1) Active fault
21093CD66
21093CD66A 21093CD66B
· The active faults of the MCU or engine ECM can be checked by this menu.
2) Logged fault
21093CD66C
21093CD66D 21093CD66E
· The logged faults of the MCU or engine ECM can be checked by this menu.
3) Delete fault
21093CD66F
21093CD66G 21093CD66H
· The logged faults of the MCU or engine ECM can be deleted by this menu.
5-24
■ SELF-DIAGNOSTIC SYSTEM (CLUSTER TYPE 2)
1. OUTLINE
When any abnormality occurs in the NEW CAPO system caused by electric parts malfunction and
by open or short circuit, the MCU diagnoses the problem and sends the error codes to the cluster
and also stores them in the memory.
2. CURRENT
URRENT ERROR DISPLAY
(Error display)
(Recorded error delete)
5-25
3. MACHINE ERROR CODES TABLE(Cluster type 1)
Error code
Description
HCESPN FMI
3 Hydraulic oil temperature sensor circuit - Voltage above normal, or shorted to high source.
101
4 Hydraulic oil temperature circuit - Voltage below normal, or shorted to low source.
0 Working pressure sensor data above normal range.
1 Working pressure sensor data below normal range.
105
2 Working pressure sensor data error.
4 Working pressure sensor circuit - Voltage below normal, or shorted to Low source.
0 Travel oil pressure sensor data above normal range.
1 Travel oil pressure sensor data below normal range.
108
2 Travel oil pressure sensor data error.
4 Travel oil pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Main pump 1 (P1) pressure sensor data above normal range.
1 Main pump 1 (P1) pressure sensor data below normal range.
120 2 Main pump 1 (P1) pressure sensor data error.
Main pump 1 (P1) pressure sensor circuit - Voltage below normal, or shorted to low
4
source.
0 Main pump 2 (P2) pressure sensor data above normal range.
1 Main pump 2 (P2) pressure sensor data below normal range.
121 2 Main pump 2 (P2) pressure sensor data error.
Main pump 2 (P2) pressure sensor circuit - Voltage below normal, or shorted to low
4
source.
0 Overhead pressure sensor data above normal range.
1 Overhead pressure sensor data below normal range.
122
2 Overhead pressure sensor data error.
4 Overhead pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Negative 1 pressure sensor data above normal range.
1 Negative 1 pressure sensor data below normal range.
123
2 Negative 1 pressure sensor data error.
4 Negative 1 pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Negative 2 Pressure sensor data above normal range.
1 Negative 2 Pressure sensor data below normal range.
124
2 Negative 2 Pressure sensor data error.
4 Negative 2 Pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Pilot pump (P3) pressure sensor data above normal range.
1 Pilot pump (P3) pressure sensor data below normal range.
125
2 Pilot pump (P3) pressure sensor data error.
4 Pilot pump (P3) pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Boom up pilot pressure sensor data above normal range.
1 Boom up pilot pressure sensor data below normal range.
127
2 Boom up pilot pressure sensor data error.
4 Boom up pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Arm in/out & bucket in pilot pressure sensor data above normal range.
1 Arm in/out & bucket in pilot pressure sensor data below normal range.
133 2 Arm in/out & bucket in pilot pressure sensor data error.
Arm in/out & bucket in pilot pressure sensor circuit - Voltage below normal, or shorted to
4
low source.
※ Some error codes are not applied to this machine.
5-26
Error code
Description
HCESPN FMI
0 Swing pilot pressure sensor data above normal range.
1 Swing pilot pressure sensor data below normal range.
135
2 Swing pilot pressure sensor data error.
4 Swing pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Attachment pilot pressure sensor data above normal range.
1 Attachment pilot pressure sensor data below normal range.
138
2 Attachment pilot pressure sensor data error.
4 Attachment pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
5 Pump EPPR valve circuit - Current below normal, or open circuit.
140
6 Pump EPPR valve circuit - Current above normal.
5 Boom priority EPPR valve circuit - Current below normal, or open circuit.
141
6 Boom priority EPPR valve circuit - Current above normal.
5 Travel EPPR valve circuit - Current below normal, or open circuit.
143
6 Travel EPPR valve circuit - Current above normal.
5 Attachment flow EPPR valve circuit - Current below normal, or open circuit.
144
6 Attachment flow EPPR valve circuit - Current above normal.
5 Remote cooling fan EPPR valve circuit - Current below normal, or open circuit.
145
6 Remote cooling fan EPPR valve circuit - Current above normal.
5 Left rotate EPPR valve circuit - Current below normal, or open circuit.
150
6 Left rotate EPPR valve circuit - Current above normal.
5 Right rotate EPPR valve circuit - Current below normal, or open circuit.
151
6 Right rotate EPPR valve circuit - Current above normal.
5 Left tilt EPPR valve circuit - Current below normal, or open circuit.
152
6 Left tilt EPPR valve circuit - Current above normal.
5 Right tilt EPPR valve circuit - Current below normal, or open circuit.
153
6 Right tilt EPPR valve circuit - Current above normal.
5 Power max solenoid circuit - Current below normal, or open circuit.
166
6 Power max solenoid circuit - Current above normal.
5 Travel speed solenoid circuit - Current below normal, or open circuit.
167
6 Travel speed solenoid circuit - Current above normal.
5 Attachment pressure solenoid circuit - Current below normal, or open circuit.
168
6 Attachment pressure solenoid circuit - Current above normal.
5 Attachment conflux solenoid circuit - Current below normal, or open circuit.
169
6 Attachment conflux solenoid circuit - Current above normal.
5 Arm regeneration solenoid circuit - Current below normal, or open circuit.
170
6 Arm regeneration solenoid circuit - Current above normal.
5 Attachment safety solenoid circuit - Current below normal, or open circuit.
171
6 Attachment safety solenoid circuit - Current above normal.
5 Remote cooling fan reverse solenoid circuit - Current below normal, or open circuit.
181
6 Remote cooling fan reverse solenoid circuit - Current above normal.
5 Fuel level sensor circuit - Voltage above normal, or shorted to high source.
301
6 Fuel level sensor circuit - Voltage below normal, or shorted to low source.
Engine coolant temperature sensor circuit - Voltage above normal, or shorted to high
3
source.
304
Engine coolant temperature sensor circuit - Voltage below normal, or shorted to low
4
source.
310 8 Engine speed signal error - Abnormal frequency or pulse width.
3 Engine preheat relay circuit - Voltage above normal, or shorted to high source.
322
4 Engine preheat relay circuit - Voltage below normal, or shorted to low source.
3 Fuel warmer relay circuit - Voltage above normal, or shorted to high source.
325
4 Fuel warmer relay circuit - Voltage below normal, or shorted to low source.
5-27
Error code
Description
HCESPN FMI
3 Potentiometer (G/A) circuit - Voltage above normal, or shorted to high source.
340
4 Potentiometer (G/A) circuit - Voltage below normal, or shorted to low source.
5 Governor actuator circuit - Current below normal, or open circuit.
341
6 Governor actuator circuit - Current above normal.
0 Transmission oil pressure sensor data above normal range.
1 Transmission oil pressure sensor data below normal range.
501
2 Transmission oil pressure sensor data error.
4 Transmission oil pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Brake pressure sensor data above normal range.
1 Brake pressure sensor data below normal range.
503
2 Brake pressure sensor data error.
4 Brake pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Working brake pressure sensor data above normal range.
1 Working brake pressure sensor data below normal range.
505
2 Working brake pressure sensor data error.
4 Working brake pressure sensor circuit - Voltage below normal, or shorted to low source.
3 Working brake lamp circuit - Voltage above normal, or shorted to high source.
506
4 Working brake lamp circuit - Voltage below normal, or shorted to low source.
3 Ram lock lamp circuit - Voltage above normal, or shorted to high source.
520
4 Ram lock lamp circuit - Voltage below normal, or shorted to low source.
5 Ram lock solenoid circuit - Current below normal, or open circuit.
525
6 Ram lock solenoid circuit - Current above normal.
0 Travel F pilot pressure sensor data above normal range.
1 Travel F pilot pressure sensor data below normal range.
530
2 Travel F pilot pressure sensor data error.
4 Travel F pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Travel R pilot pressure sensor data above normal range.
1 Travel R pilot pressure sensor data below normal range.
531
2 Travel R pilot pressure sensor data error.
4 Travel R pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
3 Hourmeter circuit - Voltage above normal, or shorted to high source.
701
4 Hourmeter circuit - Voltage below normal, or shorted to low source.
0 MCU input voltage high.
705
1 MCU input voltage low.
707 1 Alternator node I voltage low.
3 Acc. dial circuit - Voltage above normal, or shorted to high source.
714
4 Acc. dial circuit - Voltage below normal, or shorted to low source.
3 Rotate signal input circuit - Voltage above normal, or shorted to high source.
715
4 Rotate signal input circuit - Voltage below normal, or shorted to low source.
3 Tilt signal input circuit - Voltage above normal, or shorted to high source.
716
4 Tilt signal input circuit - Voltage below normal, or shorted to low source.
3 Travel alarm (buzzer) circuit - Voltage above normal, or shorted to high source.
722
4 Travel alarm (buzzer) circuit - Voltage below normal, or shorted to low source.
830 12 MCU internal memory error.
840 2 Cluster communication data error.
841 2 ECM communication data error.
843 2 Option #1 (CAN 2) communication data error.
850 2 RCM communication data error.
5-28
■ MACHINE ERROR CODES TABLE(
TABLE(Cluster
Cluster type 2)
Error code No. Description

1 Short circuit in accel actuator system
2 Potentiometer circuit is shorted to Vcc (5V) or battery +
3 Short circuit in pump EPPR valve system
4 Short circuit in boom down EPPR valve system
5 Short circuit in travel speed solenoid system
6 Short circuit in power boost solenoid system
7 Short circuit in max flow solenoid system
10 Short circuit in hour-meter system
11 Accel dial circuit is shorted to Vcc (5 V) or battery +
12 P1 pressure sensor circuit is shorted to power supply (24V) line
15 Boom down pressure circuit is shorted to power supply (24V) line
16 Accel actuator circuit is open or shorted to ground
17 Potentiometer circuit is open or shorted to ground
18 Pump EPPR valve circuit is open or shorted to ground
19 Boom down EPPR valve circuit is open or shorted to ground
20 Travel speed solenoid circuit is open or shorted to ground
21 Power boost solenoid circuit is open or shorted to ground
22 Max flow solenoid circuit is open or shorted to ground
25 Hour-meter circuit is open or shorted to ground
26 Accel dial circuit is open or shorted to ground
27 P1 pressure sensor circuit is open or shorted to ground
30 Boom down pressure sensor circuit is open or shorted to ground
31 Engine preheater circuit is open or shorted to ground
32 Travel alarm buzzer circuit is open or shorted to ground
33 Altemator circuit is open or shorted to ground
34 Controller input voltage is below 18V
5-28-1
5-29
Error code No. Description
35 Controller input voltage is below 38V
36 Communication error with cluster
37 Engine speed sensor circuit is open or shorted to ground
38 Aati-restart relay circuit is open or shorted to ground
39 Accel actuator does not stop at a target position
40 There is more than 500 rpm difference between target speed and actual speed
41 Hydraulic oil temperature sensor circuit is shorted to ground
42 Fuel level sensor circuit is shorted to ground
43 Coolant temperature sensor circuit is shorted to ground
44 Boom up pressure sensor circuit is shorted to power supply (24V) line
45 Hydraulic oil temperature sensor circuit is open or shorted to battery +
46 Fuel level sensor circuit is open or shorted to battery +
47 Coolant temperature sensor circuit is open or shorted to battery +
48 Boom up pressure sensor circuit is open or shorted to ground
49 Engine preheater circuit is shorted to battery +
51 Heavy duty work solenoid circuit is open or shorted to battery +
56 Travel alarm buzzer circuit is shorted to battery +
58 Heavy duty work solenoid circuit is shorted to battery +
5-28-2
5-30
4. ENGINE FAULT CODE
Fault code
J1939 SPN Reason Effect (only when fault code is active)
J1939 FMI
111 Error internal to the ECM related to memory Engine will not start.
629 hardware failures or internal ECM voltage
12 supply circuits.
115 No engine speed signal detected at both engine Engine will die and will not start.
190 position sensor circuits.
2
121 No engine speed signal detected from one of None on performance.
190 the engine position sensor circuits.
10
122 High voltage detected on the intake manifold Derate in power output of the engine.
102 pressure circuit.
3
123 Low voltage detected on the intake manifold Derate in power output of the engine.
4
131 High voltage detected at the throttle position Severe derate (power and speed). Limp home
91 signal circuit. power only.
3
132 Low voltage detected at the throttle position Severe derate (power and speed). Limp home
91 signal circuit. power only.
4
133 High voltage detected at the remote throttle None on performance if remote throttle is not
974 position signal circuit. used.
3
134 Low voltage detected at the remote throttle None on performance if remote throttle is not
974 position signal circuit. used.
4
135 High voltage detected at the oil pressure circuit. No engine protection for oil pressure.
100
3
141 Low voltage detected at the oil pressure circuit. No engine protection for oil pressure.
100
4
Oil pressure signal indicates oil pressure below Progressive power and speed derate with
143 the low oil pressure engine protection limit. increasing time after alert. If engine protection
100
18 shutdown feature is enable, engine will shut
down 30 seconds after red lamp starts flashing.
H i g h vo l t a g e d e t e c t e d a t t h e c o o l a n t Possible white smoke. Fan will stay on if
144 temperature circuit. controlled by the electronic control module
110
3 (ECM). No engine protection for coolant
temperature.
145 L o w vo l t a g e d e t e c t e d a t t h e c o o l a n t Possible white smoke. Fan will stay on if
110 temperature circuit. controlled by electronic control module (ECM).
4 No engine protection for coolant temperature.
147 A frequency of less then 100Hz was detected at Calibration dependent power and speed
91 the frequency throttle signal pin of the actuator derate.
8 harness connector at the ECM.
148 A frequency of more than 100Hz was detected Calibration dependent power and speed
91 at the frequency throttle signal pin of the derate.
8 actuator harness connector at the ECM.
Coolant temperature signal indicates coolant Progressive power derate with increasing time
151 temperature above 104˚C (220˚F). after alert. If engine protection shutdown
110
0 feature is enabled, engine will shut down 30
seconds after red lamp starts flashing.
※ Some fault codes are not applied to this machine.
5-29
111Fault code
J1939 FMI
153 High voltage detected at the intake manifold Possible white smoke. Fan will stay on if
154 Low voltage detected at the intake manifold Possible white smoke. Fan will stay on if
Intake manifold temperature signal indicates Progressive power derate with increasing time
155 temperature above 87.8˚C (190˚F). after alert. If engine protection shutdown
105
187 Low voltage detected on the ECM voltage Engine will run derated. No engine protection
620 supply line to some sensors (VSEN2 supply). for oil pressure and coolant level.
4
198 High voltage detected at the ICON lamp circuit The ICON system will be disabled. Only
612 when low voltage was expected by the ECM. mandatory shutdown will be enabled.
3
199 Less than 6 VDC (low voltage) detected at the The ICON system will be disabled. Only
612 ICON lamp circuit when high voltage was mandatory shutdown will be enabled.
4 expected by the ECM.
211 Additional machine diagnostic codes have been None on engine performance.
1484 logged. Check other ECM's for diagnostic
31 codes.
212 High voltage detected at the oil temperature No engine protection for oil temperature.
175 circuit.
3
213 Low voltage detected at the oil temperature No engine protection for oil temperature.
175 circuit.Low voltage detected at the oil
4 temperature circuit.
Oil temperature signal indicates oil temperate Progressive power derate with increasing time
214 above 123.9˚C (225˚F). after alert. If engine protection shutdown
175
0 feature is enabled, engine will shut down 30sec
after the red lamp starts flashing.
219 Low oil level was detected in the CentinelTM N o n e o n p e r fo r m a n c e . C e n t i n e l T M
1380 makeup oil tank. deactivated.
17
221 High voltage detected at the ambient air Derate in power output of the engine.
3
222 Low voltage detected at the ambient air Derate in power output of the engine.
4
223 Incorrect voltage detected at the CentinalTM None on performance. CentinelTM deactivated.
1265 actuator circuit by the ECM.
4
227 High voltage detected on the ECM voltage Engine will run derated. No engine protection
620 supply line to some sensors (VSEN2 supply). for oil pressure and coolant level.
3
234 Engine speed signal indicates engine speed is Fuel shutoff valve is closed unit the engine
190 greater than 2650 rpm. speed drops. The fuel shutoff valve will open
0 when engine speed falls below 2000 rpm.
Coolant level signal indicates coolant level is Progressive power derate with increasing time
235
below the normal range. after alert. If engine protection shutdown
111
feature is enabled, engine will shut down 30
1
5-30
Fault code
J1939 FMI
Duty cycle of the throttle input signal to the All engines(primary and secondary) are shut
237 primary or secondary engine for multiple unit down with increasing time after alert if hard-
644 synchronization is less than 3 percent or more coupled. Only secondary engines are shut
2 than 97 percent. down with increasing time after alert if soft-
coupled.
The ECM lost the vehicle speed signal. Engine speed limited to maximum engine
241 speed without vehicle speed sensor parameter
84 value Cruise Control. Gear-Down Protection
2 and Road Speed Governor will not work
(automotive only).
Invalid or inappropriate vehicle speed signal Engine speed limited to maximum engine
242 detected. Signal indicates an intermittent speed without vehicle speed sensor parameter
84 connection or VSS tampering. value Cruise Control. Gear-Down Protection
10 and Road Speed Governor will not work
(automotive only).
245 Less than 6 VDC detected at fan clutch circuit The fan may stay on at all times.
647 when on. Indicates an excessive current draw
4 from the ECM or faulty ECM output circuit.
254 Less than 6 VDC detected at FSO circuit when The ECM turns off the FSO supply voltage.
647 on. Indicates an excessive current draw from The engine will shut down.
4 the ECM or a faulty ECM output circuit.
255 Externally supplied voltage detected going to None on performance. Fuel shutoff valve stays
632 the fuel shutoff solenoid supply circuit. open.
3
285 The ECM expected infor mation from a At least one multiplexed device will not operate
639 multiplexed device but did not receive it soon properly.
9 enough or did not receive it at all.
286 The ECM expected info from a multiplexed At least on multiplexed device will not operate
639 device but only received a portion of the properly.
13 necessary information.
287 The machine vehicle electronic control unit The engine will only idle.
91 (VECU) detected a fault with its throttle pedal.
19
288 The machine vehicle electronic control unit The engine will not respond to the remote
974 (VECU) detected a fault with its remote throttle. throttle.
19
293 High voltage detected at the machine No engine protection for machine temperature.
1083 temperature sensor signal pin of the 31-pin
3 machine connector.
294 L ow vo l t a g e d e t e c t e d a t t h e m a c h i n e No engine protection for machine temperature.
1083 temperature sensor signal pin of the 31-pin
4 machine connector.
295 An error in the ambient air pressure sensor Engine is derated to no air setting.
108 signal was detected by the ECM.
2
297 High voltage detected at the machine pressure No engine protection for machine pressure.
1084 sensor signal pin of the 31-pin machine
3 connector.
298 Low voltage detected at the machine pressure No engine protection for machine pressure.
1084 sensor signal pin of the 31-pin machine
4 connector.
Engine shutdown by device other than key No action taken by the ECM.
299 switch before proper engine cool down resulting
1384
31 in filtered load factor above maximum shutdown
threshold.
5-31
Fault code
J1939 FMI
311 Current detected at No.1 injector when voltage The injector for cylinder number 1 is turned off.
651 is turned off.
6
312 Current detected at No.5 injector when voltage The injector for cylinder number 5 is turned off.
655 is turned off.
6
313 Current detected at No.3 injector when the The injector for cylinder number 3 is turned off.
653 voltage is turned off
6
314 Current detected at No 6 injector when the The injector for cylinder number 6 is turned off.
656 voltage is turned off.
6
652 voltage is turned off.
6
319 Real time clock lost power. None on performance. Data in the ECM will
251 not have accurate time and date information.
2
654 voltage is turned on.
6
322 Injector solenoid driver cylinder 1 circuit-current The current to the injector is shut off. The
656 below normal, or open circuit. Current detected engine can possibly misfire or run rough.
5 at injector number 1 when voltage is turned off.
Severe loss of data from the ECM. Possible no noticeable performance effects OR
341 engine dying OR hard star ting. Fault
630
2 information, trip information and maintenance
monitor data may be inaccurate.
343 Internal ECM error. Possible none on performance or severe
629 derate.
12
349 A frequency greater than calibrated threshold Calibration dependent power and speed
191 was detected at the tail shaft governor signal pin derate.
16 of the 31-pin machine connector.
352 Low voltage detected on the ECM voltage Engine is derated to no air setting.
620 supply line to some sensors (VSEN 1 supply).
4
386 High voltage detected on the ECM voltage Engine is derated to no air setting.
620 supply line to some sensors (VSEN 1 supply).
3
5-32
Fault code
J1939 FMI
387 High voltage detected on the ECM voltage Engine will only idle.
1043 supply line to the throttle (VTP supply)
3
Less than 6 VDC detected at the engine brake Engine brake 1 can not be activated.
388 circuit 1 when on indicates an excessive current
1072
11 draw from the electronic control module (ECM)
or faulty ECM output circuit.
Less than 6 VDC detected at the engine brake Engine brake 2 can not be activated.
392 circuit 2 when on indicates an excessive current
1073
11 draw from the electronic control module (ECM)
or faulty ECM output circuit.
Oil pressure signal indicates oil pressure below Progressive power derate with increasing time
415 the very low oil pressure engine protection limit. from alert. If engine protection shutdown
100
418 Water has been detected in the fuel filter. Possible white smoke, loss of power, or hard
097 starting.
15
419 An error in the intake manifold pressure sensor Engine is derated to no air setting.
1319 signal was detected by the ECM.
2
422 Voltage detected simultaneously on both the No engine protection for coolant level.
111 coolant level high and low signal circuits OR no
2 voltage detected on both circuits.
426 Communication between the ECM and the None on performance. J1939 devices may not
639 J1939 data link has been lost. operate.
2
428 High voltage detected at water-in-fuel sensor. None on performance.
97
3
429 Low voltage detected at water-in-fuel sensor. None on performance.
97
4
431 Voltage detected simultaneously on both the None on performance.
558 idle validation off-idle and on-idle circuits.
2
Voltage detected at idle validation on-idle circuit Engine will only idle.
when voltage at throttle position circuit indicates
432 the pedal is not at idle OR voltage detected at
558
13 idle validation off-idle circuit when voltage at
throttle position circuit indicates the pedal is at
idle.
Voltage signal at intake manifold pressure circuit Derate to no air setting.
433 indicates high intake manifold pressure but
102
2 other engine characteristics indicate intake
manifold pressure must be low.
Supply voltage to the ECM fell below 6.2 VDC Possible no noticeable performance effects OR
434 for a fraction of a second OR the ECM was not possibility of engine dying OR hard starting.
627
2 allowed to power down correctly (retain battery Fault infor mation, trip infor mation and
voltage for 30 seconds after key off). maintenance monitor data may be inaccurate.
435 An error in the oil pressure sensor signal was None on performance. No engine protection
100 detected by the ECM. for oil pressure.
2
441 Battery voltage below normal operating level. Possible no noticeable performance effects OR
168 possibility of rough idle.
18
5-33
Fault code
J1939 FMI
442 Battery voltage below normal operating level. None on performance.
168
16
443 Low voltage detected on the ECM voltage Engine will only idle.
1043 supply line to the throttle(s) (VTP supply).
4
465 High voltage detected at the wastegate actuator Engine will run derated.
1188 number 1 circuit when no voltage was being
3 supplied by the electronic control module (ECM).
Less than +6 VDC detected at the wastegate Engine will run derated.
466 actuator number 1 circuit when on indicates an
1188 excessive current draw from the electronic
4 control module (ECM) or faulty ECM output
circuit.
472 Either high or low voltage detected on the None on performance.
1380 crankcase oil level sensor circuit by the Centinel system deactivated.
2 electronic control module (ECM).
474 Either low voltage detected when +12 VDC are Either the engine will not start or the engine will
1321 commanded or voltage detected when no not have starter lockout protection.
2 voltafe is commanded.
475 Low voltage was detected on the electronic air Air compressor will not shut off.
1351 compressor circuit when high voltage was
4 expected.
476 High voltage or an open circuit detected at the Air compressor runs continuously or not at all.
1351 electronic air compressor governor actuator
3 circuit.
489 Auxiliary speed frequency on input pin indicated Engine will only idle.
191 that the frequency is below a calibration
18 dependent threshold.
491 High voltage detected at the wastegate actuator Engine will run derated.
1189 number 2 circuit when no voltage was being
3 supplied by the electronic control module (ECM).
Less than +6 VDC detected at the wastegate Engine will run derated.
492 actuator number 2 circuit when activated
1189 indicates an excessive current draw from the
4 electronic control module (ECM) or faulty ECM
output circuit.
527 Less than 17.0 VDC detected at the dual output No action taken by the ECM.
702 A signal pin of the 31-pin machine connector.
3
093 B signal pin of the 31-pin machine connector.
2
703 B signal pin at the ECM.
3
Either low voltage detected on autoshift low Top 2 lockout solenoid will not function properly.
536 gear actuator circuit when +12 VDC are Transmission will not shift properly.
718
11 commanded or voltage detected when no
voltage is commanded.
Either low voltage detected on autoshift high Top 2 shift solenoid will not function properly.
537 gear actuator circuit when (+) 12 VDC are Transmission will not shift properly.
717
5-34
Fault code
J1939 FMI
Either low voltage detected on autoshift neutral Top 2 neutral actuator will not function properly.
538 gear actuator circuit when +12 VDC are Transmission will not shift properly.
719
544 Autoshift failure ; at least three shift attempts
Top 2 transmission will not be controlled
611 were missed. correctly. Transmission remains in manual
7 mode.
551 No voltage detected simultaneously on both the Engine will only idle.
558 idle validation off-idle and on-idle circuits.
4
581 High voltage detected at the fuel inlet restriction Fuel inlet restriction monitor deactivated.
1381 sensor signal pin.
3
582 Low voltage detected at the fuel inlet restriction Fuel inlet restriction monitor deactivated.
1381 sensor signal pin
4
583 Restriction has been detected at the fuel pump Fuel inlet restriction monitor warning is set.
1381 inlet.
18
588 High voltage detected at the alarm circuit when The ICON system will be disabled. Only
611 low voltage was expected by the ECM. mandatory shutdown will be enabled.
3 Engine can be started normally.
589 Less than +6 VDC detected at the engine start The ICON idle control system will be disabled.
611 alarm circuit when high voltage was expected Only mandatory shutdown will be enabled.
4 by the ECM. Engine can be started normally.
596 High battery voltage detected by the battery Yellow lamp will be lit until high battery voltage
167 voltage monitor feature. condition is corrected.
16
ICONTM has restarted the engine three times Yellow lamp will be lit until low battery voltage
within three hours due to low battery voltage condition is corrected. The ECM may increase
597 (automotive only) OR low battery voltage idle speed and deactivate idle decrement
167
16 detected by the battery voltage monitor feature. switch if idle speedup is enabled. The engine
will run continuously if ICONTM is active
(automotive only).
598 Very low battery voltage detected by the battery Red lamp lit until very low battery voltage
167 voltage monitor feature. condition is corrected.
1
611 Engine shutdown by operator before proper No action taken by the ECM.
1383 engine cool down resulting in filtered load factor
31 above maximum shutdown threshold.
951 A power imbalance between cylinders was Engine may have rough idle or misfire.
166 detected by the ECM.
2
5-35
GROUP 12 ENGINE CONTROL SYSTEM
1. MCU (Machine Control Unit)
HY
UN
MO DA
DE I
L:
R3
20
-9
FUEL TANK
TOOL BOX
Fuel tank
LED
HY
UN
MO DA
DE I
L:
R2
10
-9
CN
-51
1
2 CN
-52 CN
-53
ECM(Engine control module)
38095MS02
2. MCU ASSEMBLY
1) To match the pump absorption torque with the engine torque, MCU varies EPPR valve output
pressure, which control pump discharge amount whenever feedbacked engine speed drops under
the reference rpm of each mode set.
2) Three LED lamps on the MCU display as below.
LED lamp Trouble Service

G is turned ON Normal · -
G and R are turned ON Trouble on MCU · Change the MCU
G and Y are turned ON Trouble on serial · Check if serial communication
communication line lines between controller and cluster are
disconnected
Three LED are turned Trouble on MCU power · Check if the input power wire (24 V, GND) of
OFF controller is disconnected
· Check the fuse
G : green, R : red, Y : yellow
5-36
3. EXCHANGE METHOD OF THE ROM IN
2
THE CLUSTER (TYPE 2)
1) Disassemble screws (2) and wiper motor 4
cover (1).
3
2) Disassemble hexgon socket bolts (3) and 1
cluster (4).
3009SH5MS28
4) Loosen the screws (6EA) located back of

the cluster. Screw
5) Then you can open the upper case of the

Cluster
cluster easily.
Upper case
3009SH5MS29
6) Install the new ROM. (Be careful of

direction and assemlbe the cluster in the
reverse order to removal).
Same
direction
21075MS14
5-37
GROUP 13 EPPR VALVE (CLUSTER TYPE 1)
1. PUMP EPPR VALVE

1) COMPOSITION
EPPR (Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve
installed at main pump.
(1) Electro magnet valve
Receive electric current from MCU and move the spool proportionally according to the specific
amount of electric current value.
(2) Spool valve
Is the two way direction control valve for pilot pressure to reduce main pump flow.
When the electro magnet valve is activated, pilot pressure enters into flow regulator of main pump.
(3) Pressure and electric current value for each mode
Pressure Electric current Engine rpm
Mode
kgf/cm
2 psi (mA) (at accel dial 10)
P 10 ± 3 142 ± 40 330 ± 30 1850 ± 50
Standard
S 12 ± 3 171 ± 40 360 ± 30 1750 ± 50
(Stage : 1.0)
E 12 ± 3 171 ± 40 360 ± 30 1650 ± 50
P 8±3 114 ± 40 290 ± 30 1850 ± 50
Option
S 10 ± 3 142 ± 40 330 ± 30 1800 ± 50
(Stage : 2.0)
E 10 ± 3 142 ± 40 330 ± 30 1700 ± 50
2) HOW TO SWITCH THE STAGE (1.0 ↔ 2.0) ON THE CLUSTER

You can switch the EPPR valve pressure set by selecting the stage (1.0 ↔ 2.0).
- Management
·Service menu
21093CD67M
21093CD67N 21093CD67P
Enter the password
21093CD67ZZ
· Power shift (standard/option) : Power shift pressure can be set by option menu.
5-38
■ EPPR VALVE (CLUSTER TYPE 2)
1. PUMP EPPR VALVE

1) COMPOSITION
EPPR (Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve
installed at main pump.
(1) Electro magnet valve
Receive electric current from MCU and move the spool proportionally according to the specific
amount of electric current value.
(2) Spool valve
Is the two way direction control valve for pilot pressure to reduce hydraulic pump flow.
When the electro magnet valve is activated, pilot pressure enters into flow regulator of hydraulic
pump.
So, pump flow decreases to prevent engine stall.
(3) Pressure and electric current value for each mode
Pressure Electric current Engine rpm
Mode
kgf/cm
2 psi (mA) (at accel dial 10)
M 5±3 71 ± 40 250 ± 30 1900 ± 50
Standard
H 7±3 100 ± 40 280 ± 30 1800 ± 50
(Stage : 1.0)
S 7±3 100 ± 40 280 ± 30 1700 ± 50
M 2±3 28 ± 40 180 ± 30 1950 ± 50
Option
H 4±3 57 ± 40 230 ± 30 1850 ± 50
(Stage : 2.0)
S 6±3 85 ± 40 260 ± 30 1750 ± 50
2) HOW TO SWITCH VERSION (3.1 ↔ 4.1) ON THE CLUSTER

You can switch the EPPR valve pressure set by selecting the version (3.1 ↔ 4.1).
- Dual mode
·Changing the MCU mode
5-39
3) OPERATING PRINCIPLE (pump EPPR valve, cluster type 1,2)
(1) Structure
6 7
2 3 4 5
5-22(1)
1 Sleeve 4 O-ring 6 Solenoid valve

2 Spring 5 O-ring 7 Connector
3 Spool
A
P Pilot oil supply line (pilot pressure)
P
T Return to tank
T
A Secondary pressure to flow regulator at main pump
(2) Neutral
eutral
Pressure line is blocked and A oil returns
to tank.
P A
P T
T
A
(3) Operating
perating
Secondary pressure enters into A.
P A
T
P T
A
5-22(2)
5-40
4) EPPR VALVE CHECK PROCEDURE Spec : 100~700 mA
(Cluster type 1,2)
Adapter(P/no.:21Q6-50410)
(1) Check electric current value at EPPR valve
CN-75
① Disconnect connector CN-75 from Multimeter
EPPR valve.
② Insert the adapter to CN-75 and install
multimeter as figure. EPPR valve
③ Start engine.
④ Set power-mode and cancel auto decel
mode.
Main pump
: cluster type 1 : S mode
cluster type 2 : H mode
⑤ Position the accel dial at 10.
21095MS21
⑥ If tachometer show approx 1750±50
rpm (cluster type 1), 1800±50 rpm
(cluster type 2) disconnect one wire
harness from EPPR valve.
⑦ Check electric current at bucket circuit
relief position.
(2) Check pressure at EPPR valve

Spec : 4~20 kgf/cm2 (60~280 psi)
① Remove plug and connect pressure
gauge as figure. Pressure adjusting
screw locknut
·Gauge capacity : 0 to 50 kgf/cm2 Supply line,
pilot pressure CN-75
(0 to 725 psi)
② Start engine.
③ Set power-mode and cancel auto decel
EPPR valve
mode.
: cluster type 1 : S mode
cluster type 2 : H mode
④ Position the accel dial at 10.
⑤ If tachometer show approx 1750±50
rpm (cluster type 1), 1800±50 rpm
(cluster type 2) check pressure at relief
29095MS10
position of bucket circuit by operating
bucket control lever.
⑥ If pressure is not correct, adjust it.
⑦ After adjust, test the machine.
5-41
2. BOOM PRIORITY EPPR VALVE (Cluster type 1, 2)
1) COMPOSITION
The boom priority EPPR valve is built in a manifold and mainly consisting of valve body and coil.
This EPPR valve installed under the solenoid valve.
2) CONTROL
The boom priority EPPR valve has to be controlled by a specific electronic amplifier card, which is
supplying the coil with a current 580 mA at 30Ω and 24 V.
3) OPERATING PRINCIPLE
(1) Structure
1 5 4 6
P T
2 Control spool 3
21095MS14
P : Pilot supply line

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

2 Support ring 4 Coil 6 Cover cap
(2) Operation
In de-energized mode the inlet port (P) is closed and the outlet port (A) is connected to tank port
(T).
In energized mode the solenoid armature presses onto the control spool with a force
corresponding to the amount of current. This will set a reduced pressure at port A. The setting is
proportional to the amount of current applied.
(3) Maximum pressure relief
If a pressure from outside is applied on port A the valve may directly switch to tank port (T) and
protect the system before overload.
5-42
2) EPPR VALVE CHECK PROCEDURE Spec : 400~600 mA
(combined boom up and swing operation)
(1) Check electric current value at EPPR
valve
① Disconnect connector CN-133 from Solenoid valve
EPPR valve.
② Insert the adapter to CN-133 and install Boom priority
multimeter as figure. EPPR valve
③ Start engine.
④ If rpm display approx 1750±50 rpm CN-133
(cluster type 1), 1800±50 rpm (cluster
type 2) disconnect one wire harness
from EPPR valve. Adapter
Multimeter (P/no.:21Q6-50410)
⑤ Check electric current in case of
21095MS15
combined boom up and swing operation.
(2) Check pressure at EPPR valve Spec : 12~37 kgf/cm2 (170~530 psi)
① Remove hose from A5 port and connect (bucket relief operation)
pressure gauge as figure.
·Gauge capacity : 0 to 50 kgf/cm2 Pressure
gauge
(0 to 725 psi)
A5
② Start engine.
③ If rpm display approx 1750±50 rpm
(cluster type 1), 1800±50 rpm (cluster Solenoid valve
type 2) check pressure at relief position
of bucket circuit by operating bucket Boom priority
EPPR valve
control lever.
④ If pressure is not correct, adjust it.
⑤ After adjust, test the machine.
21095MS16
5-43
GROUP 14 MONITORING SYSTEM (CLUSTER TYPE 1)
1. OUTLINE
Monitoring system consists of the monitor part and switch part.
The monitor part gives warnings when any abnormality occurs in the machine and informs the
condition of the machine.
Various select switches are built into the monitor panel, which act as the control portion of the machine
control system.
2. CLUSTER
1) MONITOR PANEL
Time display
Warning lamps
(See page 5-48)
Gauge(See page 5-47)

Main menu(See page 5-55)
Engine rpm/Tripmeter
(See page 5-47)
Pilot lamps
(See page 5-51)
Switches
(See page 5-53)
4809S5MS21
5-44
2) CLUSTER CHECK PROCEDURE
(1) Start key : ON
① Check monitor
a. Buzzer sounding for 4 seconds with HYUNDAI logo on cluster.
※ If the ESL mode is set to the enable, enter the password to start engine.
② After initialization of cluster, the operating screen is displayed on the LCD.
Also, self diagnostic function is carried out.
a. Engine rpm display : 0 rpm
b. Engine coolant temperature gauge : White range
c. Hydraulic oil temperature gauge : White range
d. Fuel level gauge : White range
※ When engine coolant temperature below 30˚C, the warming up pilot lamp lights up.
③ Indicating lamp state
a. Power mode pilot lamp : E mode or U mode
b. Work mode pilot lamp : General operation mode (bucket)
c. Travel speed pilot lamp : Low (turtle)
(2) Start of engine

① Check machine condition
a. RPM display indicates at present rpm
b. Gauge and warning lamp : Indicate at present condition.
※ When normal condition : All warning lamp OFF
c. Work mode selection : General work
d. Power mode selection : E mode or U mode
e. Travel speed pilot lamp : Low (turtle)
② When warming up operation
a. Warming up pilot lamp : ON
b. After engine started, engine speed increases to 1100rpm.
※ Others same as above.
③ When abnormal condition
a. The warning lamp lights up and the buzzer sounds.
b. If BUZZER STOP switch is pressed, buzzer sound is canceled but the lamp warning lights up
until normal condition.
※ The pop-up warning lamp moves to the original position and blink when the select switch is
pushed. Also the buzzer stops.
5-45
3. CLUSTER CONNECTOR
No. Name Signal
1 Battery 24V 20~32V
2 Signal 3 NTSC Cluster
3 GND -
4 Serial + (TX) 0~5V
5 Power IG (24V) 20~32V
6 Signal 2 NTSC 1 4
7 Camera signal NTSC
8 Serial - (RX) 0~5V CN-56
5 8
21095MS17
5-46
2) GAUGE
(1) Operation screen
Default Option 1 Engine coolant temperature gauge
2 Hydraulic oil temperature gauge
3 3 3 Fuel level gauge
1 2
1 4 RPM / Tripmeter display
2
4 4
21093CD07A
※ Operation screen type can be set by the screen type menu of the display.
Refer to page 5-65 for details.
(2) Engine coolant temperature gauge

① This gauge indicates the temperature of coolant.
·White range : 40-105˚C (104-221˚F)
·Red range : Above 105˚C (221˚F)
② If the indicator is in the red range or lamp blinks in red,
turn OFF the engine and check the engine cooling system.
※ If the gauge indicates the red range or lamp blinks in
21093CD07G
red even though the machine is on the normal condition,
check the electric device as that can be caused by the poor
connection of electricity or sensor.
(3) Hydraulic oil temperature gauge

① This gauge indicates the temperature of hydraulic oil.
·White range : 40-105˚C(104-221˚F)
·Red range : Above 105˚C(221˚F)
② If the indicator is in the red range or lamp blinks is red,
reduce the load on the system. If the gauge stays in the red
range, stop the machine and check the cause of the problem.
21093CD07E ※ If the gauge indicates the red range or lamp blinks in
(4) Fuel level gauge

① This gauge indicates the amount of fuel in the fuel tank.
② Fill the fuel when the red range, or lamp blinks in red.
※ If the gauge indicates the red range or lamp blinks in
21093CD07F
(5) RPM / Tripmeter display

① This displays the engine rpm or the tripmeter.
※ Refer to page 5-65 for details.
21093CD02D
5-47
3) WARNING LAMPS
Battery charging warning lamp Air cleaner warning lamp

Check engine warning lamp Overload warning lamp
Engine oil pressure warning lamp
Emergency warning lamp
Fuel level warning lamp

Engine coolant
temperature warning lamp Hydraulic oil temperature
warning lamp
4
21093CD08D
※ Each warning lamp on the top of the LCD pops up on the center of LCD and the buzzer sounds
when the each warning is happened. The pop-up warning lamp moves to the original position and
blinks when the select switch is pushed. And the buzzer stops.
Refer to page 5-49 for the select switch.
(1) Engine coolant temperature

① Engine coolant temperature warning is indicated two steps.
- 100˚C over : The lamp blinks and the buzzer sounds.
- 105˚C over : The lamp pops up on the center of LCD and
the buzzer sounds.
② The pop-up lamp moves to the original position and blinks
21093CD08A
when the select switch is pushed. Also, the buzzer stops and
lamp keeps blink.
③ Check the cooling system when the lamp keeps ON.
(2) Hydraulic oil temperature

① Hydraulic oil temperature warning is indicated two steps.
- 100˚C over : The lamp blinks and the buzzer sounds.
- 105˚C over : The lamp pops up on the center of LCD and
the buzzer sounds.
② The pop-up lamp moves to the original position and blinks
when the select switch is pushed. Also, the buzzer stops and
21093CD08C
lamp keeps blink.
③ Check the hydraulic oil level and hydraulic oil cooling system.
(3) Fuel level

① This warning lamp blinks and the buzzer sounds when the level
of fuel is below 61ℓ(16.1 U.S. gal).
② Fill the fuel immediately when the lamp blinks.
21093CD08B
5-48
(4) Emergency warning lamp
① This lamp pops up and the buzzer sounds when each of the
below warnings is happened.
- Engine coolant overheating (over 105˚C)
- Hydraulic oil overheating (over 105˚C)
- Pump EPPR circuit abnormal or open
21093CD30
- Attachment flow EPPR circuit abnormal or open
- MCU input voltage abnormal
- Accel dial circuit abnormal or open
- Cluster communication data error
- Engine ECM communication data error
※ The pop-up warning lamp moves to the original position and
blinks when the select switch is pushed. Also the buzzer stops.
This is same as following warning lamps.
② When this warning lamp blinks, machine must be checked and
serviced immediately.
(5) Engine oil pressure warning lamp

① This lamp blinks when the engine oil pressure is low.
② If the lamp blinks, shut OFF the engine immediately. Check oil
level.
21093CD32
(6) Battery charging warning lamp

① This lamp blinks when the battery charging voltage is low.
② Check the battery charging circuit when this lamp blinks.
21093CD34
(7) Air cleaner warning lamp

① This lamp blinks when the filter of air cleaner is clogged.
② Check the filter and clean or replace it.
21093CD35
5-49
(8) Overload warning lamp (opt)
① When the machine is overload, the overload warning lamp
blinks during the overload switch is ON. (if equipped)
② Reduce the machine load.
21093CD36
(9) Check engine warning lamp

① This lamp blinks when the communication between MCU and
engine ECM on the engine is abnormal, or if the cluster
received any fault code from engine ECM.
② Check the communication line between them.
If the communication line is OK, then check the fault code on
21093CD33
the cluster.
③ This lamp blinks when "Engine check water in fuel" is dis-
played in the message box then check water separator.
29093CD03
5-50
4) PILOT LAMPS
Work tool mode pilot lamp Message display

Work mode pilot lamp Travel speed pilot lamp
Power/User mode pilot lamp 4
Auto idle pilot lamp
Power max pilot lamp Maintenance pilot lamp
Preheat pilot lamp Fuel warmer pilot lamp
Warming up pilot lamp Decel
Decel pilot
pilotlamp
lamp
21093CD09
(1) Mode pilot lamps

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

4 Travel mode
High speed traveling
5 Auto idle mode Auto idle
4
6 Work tool mode Oil flow level of breaker or crusher mode
7 Message display "Setting is completed" display after selection
(2) Power max pilot lamp

① The lamp will be ON when pushing power max switch on the
LH RCV lever.
② The power max function is operated maximum 8 seconds.
※ Refer to the operator's manual page 3-38 for power max
function.
21093CD38
5-51
(3) Preheat pilot lamp
① Turning the start key switch ON position starts preheating in
cold weather.
② Start the engine after this lamp is OFF.
21093CD39
(4) Warming up pilot lamp

① This lamp is turned ON when the coolant temperature is below
30˚C (86˚F ).
② The automatic warming up is cancelled when the engine
coolant temperature is above 30˚C, or when 10 minutes have
passed since starting the engine.
21093CD40
(5) Decel pilot lamp

① Operating one touch decel switch on the RCV lever makes the
lamp ON.
② Also, the lamp will be ON and engine speed will be lowered
automatically to save fuel consumption when all levers and
pedals are at neutral position, and the auto idle function is
21093CD41
selected.
※ One touch decel is not available when the auto idle pilot lamp
is turned ON.
※ Refer to the operator's manual page 3-38.
(6) Fuel warmer pilot lamp

10˚C (50˚F ) or the hydraulic oil temperature 20˚C (68˚F ).
② The automatic fuel warming is cancelled when the engine
coolant temperature is above 60˚C, or the hydraulic oil temper-
ature is above 45˚C since the start switch was ON position.
21093CD43
(7) Maintenance pilot lamp

① This lamp will be ON when the consuming parts are needed to
change or replace. It means that the change or replacement
interval of the consuming parts remains below 30 hours.
② Check the message in maintenance information of main menu.
Also, this lamp lights ON for 3 minutes when the start switch is
21093CD44
ON position.
5-52
5) SWITCHES
Power/User mode Auto idle pilot lamp

pilot lamp
Work mode Travel speed pilot lamp
pilot lamp
Power mode switch Escape(previous or parent menu)

Rear camera(option)
Work mode switch Auto idle/Buzzer stop switch
User mode switch Travel speed switch
Select switch
21093CD45
※ When the switches are selected, the pilot lamps are displayed on the LCD. Refer to the page
5-51 for details.
(1) Power mode switch

① This switch is to select the machine power mode and selected
power mode pilot lamp is displayed on the pilot lamp position.
·P : Heavy duty power work.
·S : Standard power work.
·E : Economy power work.
21093CD45A
② The pilot lamp changes E → S → P → E in order.
(2) Work mode switch

① This switch is to select the machine work mode, which shifts
from general operation mode to optional attachment operation
mode.
· : General operation mode
· : Breaker operation mode (if equipped)
21093CD45C
· : Crusher operation mode (if equipped)
·Not installed : Breaker or crusher is not installed.
※ Refer to the operator's manual page 4-6 for details.
5-53
(3) User mode switch
① This switch is used to memorize the current machine operating
status in the MCU and activate the memorized user mode.
·Memory : Push more than 2 seconds.
·Action : Push within 2 seconds.
·Cancel : Push this switch once more within 2 seconds.
21093CD45D
② Refer to the page 5-56 for another set of user mode.
(4) Select switch

① This switch is used to select or change the menu and input
value.
② Knob push
·Long (over 2 sec) : Return to the operation screen
·Medium (0.5~2 sec) : Return to the previous screen
21093CD45E
·Short (below 0.5 sec) : Select menu
③ Knob rotation
This knob changes menu and input value.
·Right turning : Down direction / Increase input value
·Left turning : Up direction / Decreased input value
(5) Auto idle/ buzzer stop switch

① This switch is used to activate or cancel the auto idle function.
·Pilot lamp ON : Auto idle function is activated.
·Pilot lamp OFF : Auto idle function is cancelled.
② The buzzer sounds when the machine has a problem.
In this case, push this switch and buzzer stops, but the
21093CD45F
warning lamp blinks until the problem is cleared.
(6) Travel speed control switch

① This switch is used to select the travel speed alternatively.
· : High speed
· : Low speed
21093CD45G
(7) Escape/Camera switch

① This switch is used to return to the previous menu or parent
menu.
② In the operation screen, pushing this switch will display the
view of the camera on the machine (if equipped).
Please refer to page 5-66 for the camera.
21093CD45H
③ If the camera is not installed, this switch is used only ESC
function.
5-54
6) MAIN MENU
Press
21093CD64
21093CD64B
21093CD64A
※ Please refer to select switch, page 5-49 for selection and change of menu and input value.
(1) Structure
No Main menu Sub menu Description
Work tool Breaker, Crusher, Not installed
U mode power User mode only
Boom/Arm speed Boom speed, Arm speed
1
Auto power boost Enable, Disable
Mode Initial mode Default, U mode
21093CD64D Cluster switch (back up) Switch function
Active fault MCU, Engine ECM
Logged fault MCU, Engine ECM
Delete logged fault All logged fault delete, Initialization canceled
2
Monitoring (analog) Machine information
Monitoring
Monitoring Monitoring (digital) Switch status, Output status
21093CD64E Operating hours Operating hours for each mode
Maintenance information Replacement, Change interval oils and filters
Machine security ESL mode setting, Password change
Machine Information Cluster, MCU, Engine, Machine
3
A/S phone number A/S phone number, A/S phone number change
Management Service menu
Management Power shift, Hourmeter start, Replacement history,
21093CD64F Update
Display item Engine speed, Tripmeter A, Tripmeter B, Tripmeter C
Clock Clock
Brightness Manual, Auto
4 Unit Temperature, Pressure, Flow, Date format
Language Korean, English, Chinese
Display
Display
Screen type A type, B type
21093CD64G
Tripmeter 3 kinds (A, B, C)

DMB DMB select, DAB select, Channel scan, Exit
Entertainment Play MP4, codec.
5
Camera setting Basic direction, Display switching, Full screen
Utilities Message box Record for fault, attachment etc.
21093CD64H
5-55
(2) Mode setup
① Work tool
21093CD65
21093CD65A 21093CD65B
A B
· A : Select one installed optional attachment.

· B : Max flow - Set the maximum flow for the attachment.
Flow level - Reduce the operating flow from maximum flow.
Breaker - Max 7 steps, Reduced 10 lpm each step.
Crusher - Max 4 steps, Reduced 20 lpm each step.
※ The flow level is displayed with the work mode pilot lamp.
② U mode power
Step Engine Idle speed Power

speed shift
( ) (rpm) (rpm) (bar)
1 1500 800 0
2 1550 850 3
21093CD65D 3 1600 900 6
4 1650 950 9
21093CD65E
5 1700 1000 (low idle) 12
· Engine high idle rpm, auto idle rpm and pump torque 6 1750 1050 16
(power shift) can be modulated and memorized 7 1800 1100 (decel rpm) 20
separately in U-mode. 8 1850 1150 26
· U-mode can be activated by user mode switch. 9 1900 1200 32
10 1950 1250 38
③ Boom/Arm speed
21093CD65F
21093CD65G
· Boom speed
- Control type
Manual - Boom up speed is fixed as set steps.
Auto - Boom up speed is automatically adjusted as working conditions by the MCU.
- Speed setting - Boom up speed is increased as much as activated steps.
· Arm speed
- Regeneration - Arm regeneration function can be activated or cancelled.
Enable - Arm in speed is up.
Disable - Fine operation.
5-56
④ Auto power boost
21093CD65L
21093CD65M
· The power boost function can be activated or cancelled.

· Enable - The digging power is automatically increased as working conditions by the MCU.
It is operated max 8 seconds.
· Disable - Not operated.
⑤ Initial mode
21093CD65P
21093CD65Q
· Default - The initial power mode is set E mode when the engine is started.
· U mode - The initial power mode is set U mode when the engine is started.
⑥ Cluster switch (back up)
21093CD65S
21093CD65T
- The cluster switch can be selected and changed by this menu when the switches are
abnormal on the cluster.
- In order to exit "Cluster switch" mode, please put the cursor on the ESC/CAM switch by
turning the select switch and push the select switch.
- In "Cluster switch", other switches except "Select switch" do not work.
5-57
(3) Monitoring
① Active fault
21093CD66
21093CD66A 21093CD66B
· The active faults of the MCU or engine ECM can be checked by this menu.
② Logged fault
21093CD66C
21093CD66D 21093CD66E
· The logged faults of the MCU or engine ECM can be checked by this menu.
③ Delete logged fault
21093CD66F
21093CD66G 21093CD66H
· The logged faults of the MCU or engine ECM can be deleted by this menu.
④ Monitoring
Monitoring(Analog)
21093CD66J
21093CD66K 21093CD66L
· The machine status such as the engine rpm, oil temperature, voltage and pressure etc. can
be checked by this menu.
5-58
⑤ Monitoring (digital)
21093CD66M
21093CD66N 21093CD66P
· The switch status or output status can be confirmed by this menu.

· The activated switch or output pilot lamps are light ON.
⑥ Operating hours
21093CD66Q
21093CD66R
· The operating hour of each mode can be confirmed by this menu.
5-59
(4) Management
① Maintenance information
21093CD67
21093CD67A
21093CD67Q 21093CD67R
21093CD67S 21093CD67T
· Alarm( ) : Gray - Normal

Yellow - First warning
Red - Second warning
· Replacement : The elapsed time will be reset to zero (0).
· Change interval : The change or replace interval can be changed in the unit of 50 hours.
· OK : Return to the item list screen.
· Change or relpace interval
No Item Interval
1 Engine oil 250
2 Final gear oil 1000
3 Swing gear oil 1000
4 Hydraulic oil 5000
5 Pilot line filter 1000
6 Drain filter 1000
7 Hydraulic oil return filter 1000
8 Engine oil filter 250
9 Fuel filter 500
10 Pre-filter 500
11 Hydraulic tank breather 250
12 Air cleaner (inner) 500
13 Radiator coolant 2000
14 Swing gear pinion grease 1000
5-60
② Machine security
21093CD67C
21093CD67D 21093CD67E
· ESL mode
- ESL : Engine Starting Limit
- ESL mode is desingned to be a theft deterrent or will
prevent the unauthorized operation of the machine.
- If the ESL mode was selected Enable, the password will
be required when the start switch is turned ON.
21093CD67EE
- Disable : Not used ESL function
Enable (always) : The password is required whenever the
operator start engine.
Enable (interval) : The password is required when the oper-
ator start engine first. But the operator
restarts the engine within the interval
time, the password is not required.
The interval time can be set maximum 4 21093CD67H
hours.
21093CD67U Enter the current password 21093CD67V
· Password change
- The password is 5~10 digits.
Enter the new password 21093CD67VV
21093CD67X 21093CD67XX
The new password is stored in the MCU. Enter the new password again
5-61
③ Machine Information
21093CD67F
21093CD67G
· This can confirm the identification of the cluster, MCU, engine and machine.
④ A/S phone number
21093CD67J
21093CD67K 21093CD67L
21093CD67Z 21093CD67Y
⑤ Service menu
21093CD67M
21093CD67N 21093CD67P
Enter the password
21093CD67ZZ
· Power shift (standard/option) : Power shift pressure can be set by option menu.
· Hourmeter start : Operating hours since the machine line out can be checked by this menu.
· Replacement history : Replacement history of the MCU and cluster can be checked by this
menu.
· Update : Firm ware can be upgraded by this menu. (the USB port is located under the
cluster)
5-62
(5) Display
① Display item
21093CD68
21093CD68A 21093CD68W
21093CD68B 21093CD68E
Center display
Center display
· The center display type of the LCD can be selected by this menu.
· The engine speed or each of the tripmeter (A,B,C) is displayed on the center display.
② Clock
21093CD68C
21093CD68D
· The first line's three spots "**/**/****" represent Month/Day/Year each.

· The second line shows the current time. (0:00~23:59)
5-63
③ Brightness
21093CD68F
21093CD68G 21093CD68H
Manual (1st~10th step)
21093CD68J 21093CD68K
Auto (day/night)
※ If "Auto" is chosen, brightness for day and night can be differently set up. Also by using the
bar in lower side, users can define which time interval belongs to day and night.
(in bar figure, gray area represents night time while white shows day time)
④ Unit
21093CD68L
21093CD68M 21093CD68N
· Temperature : ˚C ↔ ˚F
· Pressure : bar ↔ MPa ↔ kgf/cm2
· Flow : lpm ↔ gpm
· Date format : yy/mm/dd ↔ mm/dd/yy ↔ dd-Mar-yy
⑤ Language
21093CD68R
21093CD68S 21093CD68T
· User can select preferable language and all displays are changed the selected language.
5-64
⑥ Screen type
21093CD68U
21093CD68V 21093CD68W
A Type Standard
21093CD68Y
B Type 21093CD68X Option
(6) Utilities
① Tripmeter
21093CD69
21093CD69A 21093CD69B
· Maximum 3 kinds of tripmeters can be used at the same time.

· Each tripmeter can be turned on by choosing "Start" while it also can be turned off by
choosing "Stop".
· If the tripmeter icon is activated in the operation screen, it can be controlled directly there.
② DMB
21093CD69C
21093CD69D 21093CD69E
· DMB select : TV channel can be selected by this menu.

· DAB select : Audio channel can be selected by this menu.
· Channel scan : This menu can be used other region for TV/Audio.
· Exit : Exit DMB menu
5-65
③ Entertainment
· Play MP4 or codec file of external hard disk through USB port.
· The USB port is located under the cluster.
21093CD69F
21093CD69G
④ Camera setting
21093CD69J
21093CD69K 21093CD69L
· Three cameras can be installed on the machine.

· The display order can be set by this menu.
21093CD69M 21093CD69N
· If the camera was not equipped, this menu is not useful.

· In the operation screen, if the ESC/CAM switch is pushed, the first ordered display camera
will be viewed.
· Turnning the select switch in clockwise direction, the next ordered will be shown and in
counter-clockwise direction, the previously ordered will be shown.
· Push the select switch, the displayed screen will be enlargement.
⑤ Message box
· The history of the machine operating status can be checked by this menu.
21093CD69Q
21093CD69R
5-66
■ MONITORING SYSTEM (CLUSTER TYPE 2)
1. OUTLINE
Monitoring system consists of the monitor part and switch part.
The monitor part gives warnings when any abnormality occurs in the machine and
informs the condition of the machine.
Various select switches are built into the monitor panel, which act as the control portion of
the machine control system.
2. CLUSTER
1) MONITOR PANEL
LCD main operation display

(See page 5-68)
Warning lamp Pilot lamp

(See page 5-74) (See page 5-74)
4809S5MS22
5-67
2) LCD main operation display
Default screen
screen screen
Option screen 1 Time display
2 2
1 1 2 RPM display
4
4
5
3 Hydraulic oil temperature gauge
3 3
5 4 Fuel level gauge
1607A3CD02A 1607A3CD02B 5 Engine coolant temperature gauge
(1) Time display

① This displays the current time.
※ Refer to the page 5-72 to set time for details.
1607A3CD02C
(2) RPM display

① This displays the engine rpm.
1607A3CD02C
(3) Hydraulic oil temperature gauge
12th step
① This gauge indicates the temperature of hydraulic oil in 12 step
gauge.
·1st step : Below 30˚C (86˚F)
·2nd~10th step : 30-105˚C (86-221˚F)
1st step ·11th~12th step : Above 105˚C (221˚F)
1607A3CD02D
② The gauge between 2nd and 10th steps illuminates when
operating.
③ Keep idling engine at low speed until the gauge between 2nd
and 10th steps illuminates, before operation of machine.
④ When the gauge of 11th and 12th steps illuminates, reduce
the load on the system. If the gauge stays in the 11th~12th
steps, stop the machine and check the cause of the problem.
(4) Fuel level gauge
1st step ① This gauge indicates the amount of fuel in the fuel tank.
② Fill the fuel when the 1st step or fuel icon blinks in red.
※ If the gauge illuminates the 1st step or fuel icon blinks in
1607A3CD02E
(5) Engine coolant temperature gauge
12th step
① This gauge indicates the temperature of coolant in 12 step
gauge.
·1st step : Below 30˚C (86˚F)
·2nd~10th step : 30-105˚C (86-221˚F)
1st step
·11th~12th step : Above 105˚C (221˚F)
1607A3CD02F ② The gauge between 2nd and 10th steps illuminates when
operating.
③ Keep idling engine at low speed until the gauge between 2nd
and 10th steps illuminates, before operation of machine.
④ When the gauge of 11th and 12th steps illuminates, turn OFF
the engine, check the radiator and engine.
5-68
3) Warning
arning of main operation screen
(1) Warning display
① Engine coolant temperature
- This lamp blinks and the buzzer sounds
when the temperature of coolant is over
the normal temperature 105˚C (221˚F).
- Check the cooling system when the lamp
blinks.
② Fuel level
when the level of fuel is below 61ℓ (16.1
U.S. gal).
- Fill the fuel immediately when the lamp
blinks.
③ Hydraulic oil temperature
- This warning lamp operates and the
buzzer sounds when the temperature of
hydraulic oil is over 105˚C (221˚F).
- Check the hydraulic oil level when the
lamp blinks.
- Check for debris between oil cooler and
radiator.
④ All gauge
when the all gauge is abnormal.
- Check the each system when the lamp
blinks.
⑤ Communication error
- Communication problem between MCU
and cluster makes the lamp blinks and
the buzzer sounds.
- Check if any fuse for MCU burnt off.
If not check the communication line
between them.
(2) Pop-up icon display
No Switch Selected mode Interval No Switch Selected mode Interval
1 Work mode General work 3 Auto Light ON

switch mode deceleration
switch
Heavy duty Light OFF
work mode
2 Power mode High power 4 Travel speed Low speed

switch work mode control
switch
Standard power High speed
work mode
5-69
4) LCD
1 : LCD
SYSTEM MENU
: Escape,
1
Monitoring Diagnosis Management
2
Settings Display User Mode
Return to the previous menu
3 : Down / Left Direction
4 : Up/Right Direction
: Select (enter)
5
2 Activate the currently chosen item
4
3 5
2209S3CD05
(1) Main menu

1 2 3 4
1 : Menu information
: Monitoring
2
- Equipment, Switch, Output
: Diagnosis
3
- Current error, Recorded error
5 6 7 4 : Maintenance
2507A4OP94
: Settings
5 - Time set, Dual mode
- System lock (reserved)
: Display
6
- Operation skin, Brightness, Language
7 : User mode
5-70
(2) Display map
① Monitoring
② Diagnosis
a. Protocol type 1
(Error display)
(Recorded error delete)
5-71
b. Protocol type 2
- If there are more than 2 error codes, each one can be displayed by pressing or switch
respectively.
- 3 error codes (①SPN200200, ②FMI06, ③SPN6789, ④FMI04, ⑤345) display.
① ② ⑤ No change
① ③ ④
① ③ ③
③ Maintenance
④ Setting
a. Time set
: Adjusting
: Setting
b. System lock - Reserved
5-72
c. Dual mode
- Changing the MCU mode
⑤ Display
a. Operation skin
b. Brightness
c. Language
⑥ User mode
Usermode(U) is not selected.
: Adjusting : Adjusting : Adjusting

: Setting : Setting : Setting
5-73
5) Warning
arning and pilot lamp
(1) Engine oil pressure warning lamp
① This lamp blinks and the buzzer sounds after starting the
engine because of the low oil pressure.
② If the lamp blinks during engine operation, shut OFF engine
immediately. Check oil level.
21073CD07
(2) Air cleaner warning lamp

① This lamp blinks and the buzzer sounds when the filter of air
cleaner is clogged.
② Check the filter and clean or replace it.
21073CD08
(3) CPU controller check warning lamp

① If any fault code is received from MCU, this lamp blinks and the
buzzer sounds.
② Check the communication line between MCU and cluster.
21073CD10
(4) Battery charging warning lamp

① This lamp blinks and the buzzer sounds when the starting
switch is ON, it is turned OFF after starting the engine.
② Check the battery charging circuit when this lamp blinks during
engine operation.
21073CD13
(5) Overload warning lamp

① When the machine is overload, the overload warning lamp
blinks during the overload switch is ON.
21073CD15
5-74
(6) Power max pilot lamp
① The lamp will be ON when pushing power max switch on the LH
RCV lever.
21073CD11
(7) Decel pilot lamp

① Operating auto decel or one touch decel makes the lamp ON.
② The lamp will be ON when pushing one touch decel switch on
the LH RCV lever.
21073CD17
(8) Warming up pilot lamp

30˚C (86˚F).
② The automatic warming up is cancelled when the engine cool-
ant temperature is above 30˚C, or when 10 minutes have
passed since starting.
21073CD18
(9) Preheat pilot lamp

Turning the start key switch ON position starts preheating in cold
weather.
Start the engine as this lamp is OFF.
21073CD12
(10) Check engine warning lamp

① This lamp blinks and the buzzer sounds when the
communication between MCU controller and ECM on the
engine is abnormal, or if any fault code received from ECM.
② Check the communication line between them.
If the communication line is OK, then check the fault code on
29073CD10
the cluster.
5-75
GROUP 15 F
FUEL
UEL WARMER SYSTEM
1. S
SPECIFICATION
PECIFICATION
1) Operating voltage : 24±4 V
2) Power : 350±50 W
3) Current : 15 A
2. O
OPERATION
PERATION
1) T h e c u r r e n t o f f u e l w a r m e r s y s t e m i s Fuel warmer
automatically controlled without thermostat
according to fuel temperature.
2) At the first state, the 15 A current flows to the fuel
warmer and engine may be started in 1~2 Prefilter
minutes.
3) If the fuel starts to flow, ceramic-disk in the fuel
warmer heater senses the fuel temperature to
reduce the current as low as 1.5 A.
So, fuel is protected from overheating by this
2507A5MS12
mechanism.
3. E
ELECTRIC
LECTRIC CIRCUIT
145 5W
5R 146
5R
5R
CS-74A
138 2WR
2
1
FUSE BOX
POWER RY
10
1
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
87a 87 85
30 86
30A
10A
30A
30A
20A
10A
10A
10A
20A
20A
10A
10A
10A
20A
30A
30A
10A
20A
30A
30A
10A
20A
10A
20A
20A
20A
20A
20A
10A
20A
10A
CS-74
ROOM LAMP/CASSETTE
CABIN LAMP(OPTION)
CR-35
87a
30
86
85
87
OPTION(BEACON)
AIR CON/HEATER
MASTER SW
SWITCH PANEL
0.8WOr
FUEL HEATER
AC& HEATER
2WR
START,STOP
0.8B
SAFETY SOL
CONVERTER
WORK LAMP
SOLENOIDE
SOLENOIDE
MCU CONT.
2W
HEAD LAMP
2W START KEY
CN-95
MCU EPPR
CASSETTE
PRE-HEAT
CLUSTER
CLUSTER
5W
FUEL P/P
2
WIPER
WIPER
CIGAR
5W
HORN
CN-36
EPPR
SEAT
1
ECM
0.8R MCU
ECM
CN-60
5R
2
2L
5R
1
FUSIBLE LINK
MASTER SW
1.2B
CR-1
CN-51
60R 60B
2
CS-74B
BATTERY POWER 24V(+)

2
1
BATTERY
BATT RY (12VX2)
2W
2W
MCU
CN-5
17
18
19
20
21
22
23
24
31
32
33
34
35
36
37
38
39
42
43
44
45
46
47
48
57
58
59
60
3
6
7
8
9
1
4
5
2
1.2R
0.8W
1.2R
CN-52
16
CN-125A
CS-2
10
11
12
3
4
5
6
7
8
9
1
2
5
4
1
6
2
3
CR-46
CN-96
FUEL WARMER RY
1
2
3
4
87a
30
87
86
85
B
BATTERY POWER
0, I
1
RX232(1)-GND
RX232(2)-GND
85 87 87a
RX232(2)-RX
RX232(1)-RX
RX232(1)-TX
RX232(2)-TX
86 30
MAIN GND
MAIN GND
KEY "IG"
H 0 I FUEL WARMER
4
3
2
6
5
MCU
ST C BR ACC H
NC
NC
START KEY SW FUEL WARMER RY

RMS 4809S5MS17
5-76
SECTION 6 TROUBLESHOOTING
Group 1 Before Troubleshooting -------------------------------------------------------------------------------------- 6-1

Group 2 Hydraulic and Mechanical System ------------------------------------------------------------------- 6-4
Group 3 Electrical System ----------------------------------------------------------------------------------------------- 6-24
Group 4 Mechatronics System ---------------------------------------------------------------------------------------- 6-56
SECTION 6 TROUBLESHOOTING
GROUP 1 BEFORE TROUBLESHOOTING
1. INTRODUCTION
When a trouble is occurred in the machine, this section will help an operator to maintain the machine
with easy.
The trouble of machine is parted Hydraulic & Mechanical system, Electrical system and
Mechatronics system. At each system part, an operator can check the machine according to the
troubleshooting process diagram.
※ Before carring out troubleshooting procedure, check monitoring menu in the cluster.
Hydraulic &
Mechanical part GROUP 2
Electrical part GROUP 3
Mechatronics
Troubles occur part GROUP 4
Cluster type 1
Fault codes HCESPN 3digit
displayed on + FMI 1 digit See page
monitor display (machine) 5-26
Cluster type 2
2 digit See page
(machine) 5-28-1
3 or 4 digit See page

(engine) 5-29
6-1
2. DIAGNOSING PROCEDURE
To carry out troubleshooting efficiently, the following steps must be observed.
STEP 1. Study the machine system

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

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

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

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

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

procedure to avoid consequential malfunctions.
(210-7) 6-3(3)
6-3
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM
1. INTRODUCTION
1) MACHINE IN GENERAL
(1) If even a minor fault is left intact and operation is continued, a fatal failure may be caused,
entailing a large sum of expenses and long hours of restoration.
Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look
for the cause based on the troubleshooting principle and perform maintenance and adjustment to
prevent major failure from occurring. Keep in mind that a fault results from a combination of
different causes.
(2) The following lists up commonly occurring faults and possible causes with this machine. For the
troubleshooting of the engine, refer to the coming troubleshooting and repair.
(3) When carrying out troubleshooting, do not hurry to disassemble the components.
It will become impossible to find the cause of the problem.
(4) Ask user or operator the following.
① Was there any strange thing about machine before failure occurred?
② Under what conditions did the failure occur?
③ Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
① Check oil and fuel level.
② Check for any external leakage of oil from components.
③ Check for loose or damage of wiring and connections.
2) MACHINE STATUS MONITORING ON THE CLUSTER (CLUSTER TYPE 1)
(1) The machine status such as the engine rpm, oil temperature, voltage and pressure etc. can be
checked by this menu.
Note 6
Note 3
Note 4
Note 5
Note 2
Note 1
Analog 1
Analog 1 Analog22
Analog 3009SH6HS01
(2) Specification
No. Description Specification
Note 1 Pilot pump pressure 40 +20 bar
Note 2 Swing pilot pressure 0~40 bar
Note 3 Boom up pilot pressure 0~40 bar
Note 4 P1 pump control pressure 0~25 bar
Note 5 P2 pump control pressure 0~25 bar
Note 6 Pump 1 pressure 350 bar
6-4
2. DRIVE SYSTEM
1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION
Cause Remedy
YES
Coupling element Disassemble
is broken. and repair.
Remove dust
plug under engine
flywheel and YES
check if rubber Replace hub or
pieces or particles retighten
are not present. Coupling hub setscrew.
spline is worn or
NO hub fastening
setscrew is slack.
If hydraulic pump or engine is
suspected as a culprit refer to this
NO
manual "Structure and function".
6-5
2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL
Cause Remedy
NO
Replenish
specified oil to
the standard
Is oil level in Abnormal noise level.
hydraulic oil YES comes out of YES
Hydraulic pump is Disassemble
tank within hydraulic pump
standard level? broken. and repair.
Do not hydraulic Abnormal noise

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

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

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

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

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

NO
swing control and replace.
valve is faulty.
YES
Is drain rate of Swing port relief Disassemble
YES swing motor valve is faulty. and repair or
within standard replace.
Is swing relief value? Swing motor is Disassemble
pressure within NO
ⓐ broken. and repair.
standard level?
SPEC : 300±10kgf/cm2 Adjust swing
NO
relief valve
pressure or
replace swing
relief valve.
6-12
5. TRAVEL SYSTEM
1) TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE
Cause Remedy
YES
Does ⓐ
YES counterbalance
spool move lightly
by hand? Counter spool is
Is travel brake Disassemble
NO
YES valve pressure stuck. and repair or
within standard replace.
level? Does the symptom
change when
relief valves in YES
Relief valve built Disassemble
NO travel motor are
Has travel spool exchanged? in travel motor is and repair.
YES
changed over faulty.
positively?
YES Control system is Disassemble
defective. inspect and
Does travel spool
repair.
NO move?
NO
Travel spool is Disassemble
stuck. and repair.
Is bucket or arm
operation YES Travel reduction Disassemble
possible? Do not metallic
unit is faulty. and repair.
particles come
ⓐ out of drain port
in travel
reduction unit? Travel motor is Disassemble
NO
out of order. and repair.
Does the symptom
NO
change when front YES
and rear pump Hydraulic pump is Disassemble
Does the discharge hoses
symptom change broken. and repair.
are exchanged?
when LH/RH
NO
travel relief valves
are exchanged?
YES
Travel relief Disassemble
valves are faulty. and repair or
replace.
6-13
2) SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES
Cause Remedy
YES
Brake valve is Disassemble
Do LH and RH
travel speeds defective. and repair or
YES change when LH replace.
YES
and RH travel Does the symptom Relief valve built Disassemble
brake valves are change when in travel motor is and repair.
exchanged? relief valves in
faulty.
NO LH and RH
YES Has travel spool travel motors are
changed over exchanged? ⓐ
positively? NO
YES
Control system is Disassemble,
faulty . inspect and
Does spool move? repair.
Is the lower NO
speed (bucket or
arm) within See Note 5, 6 Control valve Disassemble
NO
standard level? spool is stuck. and repair.
YES
Travel relief valve Disassemble
Do LH and RH is faulty. and repair or
travel speeds Does the symptom replace.
change over when change when
NO travel relief valves YES front and rear YES
pump discharge Hydraulic pump is Disassemble
are exchanged?
Is external pilot hoses are broken. and repair.
pressure within exchanged?
NO
standard level?
External pilot Disassemble
NO
piping is clogged and clean.
or oil is leaking
Does travel speed from it.
change when
YES parking brake YES
spring in the Travel motor's Disassemble
travel motor is parking brake is and clean pilot
Is drain rate of removed? not released piping.
ⓐ travel motor within
standard level? properly.
Travel motor is Disassemble

NO
faulty. and repair.
6-14
3) MACHINE DOES NOT STOP ON A SLOPE
Machine is pulled forward as sprocket rotates during digging operation.
Cause Remedy
None Is parking brake YES
friction plate Friction plate is Disassemble
YES Check if parking worn? faulty. and repair.
brake pilot line is
clogged.
Clogged Disassemble
and clean pilot
Is drain rate of piping.
Is travel brake YES NO
travel motor
pressure within Travel motor is Disassemble
within standard
standard level? defective. and repair.
value?
SPEC : 15.7kgf/cm2
Brake valve is Disassemble

NO
faulty. and repair or
replace.
4) LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE
YES
Cause Remedy
Inspect according
to the procedure
"Travel does not
function at all on
one side."
However, a case
where both LH
and RH travel
motions are
disabled is
Is bucket or arm
operation extremely seldom
possible? statistically.
OK
Disassemble both faulty. and repair.
OK travel relief valves
Remove dust and inspect for
plug under engine any fault.
OK flywheel and Travel relief valve Disassemble
check that there is Faulty is faulty. and repair or
no coupling
replace.
element particles.
Check oil volume Particles present. Coupling at pump
in hydraulic oil connection is Disassemble
NO tank. broken. and repair.
Short Replenish
hydraulic oil.
6-15
5) TRAVEL ACTION IS POWERLESS (travel only)
Cause Remedy
YES
ⓐ
Is travel motor's
YES
drain rate within
standard level?
Is travel brake Travel motor is Disassemble
YES NO
pressure within faulty. and repair.
standard level?
Is travel relief
valve pressure Travel brake valve Disassemble
NO
within standard is defective. and repair or
level?
replace.
NO
Travel relief valve Disassemble
is faulty. and repair or
replace.
YES
Hydraulic circuit Disassemble
Does parking that releases and clean.
brake piston travel parking
Increases move lightly by
Remove parking brake is clogged
brake spring in hand?
with dirt.
travel motor,
draw out piston Parking brake Disassemble
ⓐ NO
completely, refit piston in travel and repair.
cover and check motor is stuck.
if travel power
changes. Remains
unchanged Travel reduction Disassemble
unit is defective. and repair.
6) MACHINE RUNS RECKLESSLY ON A SLOPE
Cause Remedy
Travel brake valve
(counterbalance Disassemble
valve) is faulty. and repair or
replace.
6-16
7) MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL
AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME
Cause Remedy
YES
Normal.
YES Is straight spool

normal?
Straight spool is Repair or

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

NO
broken. and repair.
6-17
6. ATTACHMENT SYSTEM
1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL
Cause Remedy
YES
Does the Port relief valve is Disassemble
YES symptom change faulty. and repair or
when port relief replace.
valve is replaced
with other valve? NO ⓐ
YES Is MCV pilot
pressure within
standard level?
Inspect if pilot
See Note 3 piping is clogged OK
RCV is faulty. Disassemble
NO or oil is leaking
YES Are other from the piping. and repair.
attachments
operatable?
YES
Is gear pump
pilot pressure YES Is gear pump faulty. and repair or
NO within standard delivering oil? replace.
level? Gear pump is Disassemble
See Note 1 NO
broken. and repair.
Are LH/RH travel
operations OK
possible? Hydraulic pump is Disassemble
Disassemble broken. and repair.
YES main relief valve
Remove dust plug and check if it is
under engine not irregular.
OK flywheel and
Main relief valveDisassemble
Faulty
check if coupling is defective. and repair or
element particles replace.
Inspect oil are not present. Coupling at pump Disassemble
Particles present
NO
volume in
hydraulic oil tank. connection is and repair.
broken.
Short Replenish
hydraulic oil.
YES
Cylinder interior is Disassemble
Does control broken. and repair.
ⓐ valve spool
move?
MCV spool is Disassemble
See Note 5, 6 NO
stuck. and repair.
6-18
2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal.
YES
Are other ⓐ
YES attachment
Is combination speeds within
Is speed low only of oil streams standard levels? NO ⓑ
in composite YES
normal at boom YES
operation? up and at arm Does spool of flow Flow summation Disassemble
extrusion? summation check check valve is and repair.
NO valve move lightly stuck.
Are LH/RH travel by hand?
NO speeds within NO
standard levels?
YES
Are both LH/RH faulty. and repair.
travel speeds YES ⓒ
NO
low? Is MCV pilot
pressure within
NO
standard? ⓓ
NO
See Note 3
OK
Does the Port relief valve is Disassemble
symptom change faulty. and repair or
YES
when port relief
valve is replaced replace.
Does control with other valve? Cylinder is faulty. Disassemble
YES valve spool NO
and repair.
move ?
See Note 7
NO MCV spool is Disassemble
Is MCV pilot
ⓐ pressure within stuck. and repair.
standard level?
Is not MCV pilot YES
Clean pilot
See Note 3
pressure piping piping interior or
clogged or is not
NO
there oil repair piping.
leakage? RCV is defective. Disassemble
NO
and repair.
YES
Is pilot pressure NO faulty. and repair or
ⓑ Is gear pump
within standard
delivering oil? replace.
level?
NO
See Note 1
broken. and repair.
AIs engine NO
ⓒ revolution within Adjust engine
standard level? revolution.
YES
Clean orifice in
control valve.
Is not orifice in
ⓓ main control YES
valve clogged? Is pilot piping Clean pilot
clogged or is oil piping interior or
NO leaking from the repair piping.
piping? Is RCV normal? RCV is faulty. Disassemble
NO NO
and repair.
6-19
3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS
Cause Remedy
YES
Port relief valve is Disassemble
Does the symptom faulty. and repair or
change when port
Normal
relief valve is replace.
YES
replaced with ⓐ
normal value? Is control valve
return spring
YES
Is not hydraulic NO
normal?
oil temperature Control valve's Disassemble
high? NO
return spring is and replace.
faulty.
Is genuine Abnormally high. Locate the
hydraulic oil or cause of
equivalent being hydraulic oil
used?
temperature rise
and lower it to
proper level.
Replace with
NO
genuine
hydraulic oil or
equivalent.
OK
Pressure Disassemble
Disassemble and tightness and repair.
inspect load between control
YES
check valve in
MCV and check valve casing and
for any fault. spool is poor.
Is cylinder Contact surface Disassemble
internal leakage Abnormal
ⓐ within standard between poppet and repair.
level? and seat is poor.
Cylinder is faulty. Disassemble

NO
and repair.
6-20
4) BOOM, ARM OR BUCKET POWER IS WEAK
Cause Remedy
YES
Check according
Is cylinder to the procedure
YES internal leakage in Item "Speed is
within standard low".
level?
Is relief pressure
YES in port relief Cylinder is faulty. Disassemble
valve within NO
and repair.
standard level?
Is relief pressure
in main relief Port relief valve is Adjust pressure,
valve within NO
standard level? faulty. repair or replace.
See Note 7
Main relief valve Adjust pressure,
NO
is defective. repair or replace.
5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE
Cause Remedy
YES
Port relief valve is Disassemble
Does the defective. and repair or
YES
symptom change
when port relief replace.
YES
valve is replaced Cylinder interior is Disassemble
with other valve? Does control broken. and repair.
valve spool
Is MCV pilot NO move?
YES
pressure within MCV spool is Disassemble
standard level? See Note 5 NO
stuck. and repair.
Is RH travel RCV is faulty. Disassemble

NO
possible? and repair.
Does the YES

Main relief valve Adjust pressure,
symptom change is faulty. repair or
Does the
when main relief
NO valves are symptom change replace.
when hydraulic YES
exchanged? Hydraulic pump is Disassemble
NO pump's discharge
hoses are broken. and repair.
exchanged?
6-21
6) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED
Cause Remedy
YES
Frictional noise
occurs between
the sliding faces
of boom
cylinder's oil
Is boom foot pin seal and boom
greased proper.
sufficiently?
※ Frictional
noise will
disappear if
they are kept
used.
Boom foot pin Supply grease

NO
has run out of to it.
grease. ※ If seizure is
in an initial
stage, supply
sufficient
grease.
If seizure is
in a grown
state, correct
it by paper
lapping or
with an oil
stone.
6-22
※ HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE
1. Lower the bucket teeth to the ground with
bucket cylinder fully retracted and arm
cylinder rod retracted almost in full.
29076TS01
2. Disconnect hose (A) from rod side of boom

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

the arm cylinder rod.
If oil leaks from piping side and boom
cylinder rod is retracted there is an internal
leak in the cylinder.
If no oil leaks from piping side and boom
cylinder rod is retracted, there is an internal
leak in the control valve.
29076TS01
6-23
GROUP 3 ELECTRICAL SYSTEM (CLUSTER TYPE 1)
1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR
·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.7, 13.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
Check voltage YES

Disconnection in Repair or replace
between CN-56
(3) and (5) wiring harness or (after clean)
Check voltage poor contact
Starting switch : ON between
Voltage : 20~32V between
NO CN- 5 (4) and (5)
CN-5-CN-56
Starting switch : ON
Voltage : 20~32V Disconnection in Repair or replace
NO
wiring harness or (after clean)
poor contact
between CN-5 (4)
-GND or fuse
No.7, 13
Check voltage
YES 20~32V
NO 0V
FUSE
CLUSTER NO.7
POWER(24V) 1 6
FUSE
POWER IG(24V) 5 5
NO.13
GND 3 4
CN-56 CN-5
4809S6ES01
6-24
2. COMMUNICATION ERROR FLASHES ON THE CLUSTER (HCESPN 840, FMI 2)
·Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Defective cluster Replace
YES Check voltage

between CN-56
(4, 8) and (3) Disconnection in Repair or replace
NO wiring harness or (after clean)
Check voltage Voltage : 2V poor contact
between between CN-56
CN-5 (1) and (2) (4, 8)-CN-5 (1, 2)
Voltage : 2V Defective MCU Replace
NO Disconnection in Repair or replace
poor contact
between CN-5 (1,
2)- CN-51(23, 33)
Check voltage
YES 2V
NO 0V
CLUSTER
GND 3 4 MCU
RS485 RX 8 2 23 RS485 RX
RS485 TX 4 1 33 RS485 TX
CN-51
CN-56 CN-5
3009SH6ES02
6-25
3. BATTERY CHARGING WARNING LAMP LIGHTS UP (Starting switch : ON)
Cause Remedy
YES
Defective MCU Replace
YES Check voltage
between CN-51
(39) and chassis Disconnection in Repair or replace
NO
Check voltage wiring harness or (after clean)
YES Voltage : 20~32V
between CN-3 poor contact
(10) and chassis between CN-51
(39)-CN-3 (10)
Voltage : 20~32V
Disconnection in Repair or replace
Check voltage NO wiring harness or (after clean)
between CN-74 poor contact
(2) and chassis between CN-3
(10)- CN-74 (2)
Engine : Running
Voltage : 20~32V
Defective alternator Replace

NO
Check voltage
YES 20~32V
NO 0V
ALTERNATOR
B+
MCU
G
1 P
39 10 2 L
3 ~
U
3 FI
4 NC
CN-74
CN-51 CN-3
4809S6ES02
6-26
4. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP (engine is started)
ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Check use HRDT Check or replace
Check resistance
YES between engine
harness connector
(15)-(38)
Spec : 180̫~160 k̫ Disconnection in Repair or replace
NO
Check resistance poor contact
between temp between temp
sensor (A)-(B)
sensor-engine
Starting switch : OFF harness connector
Spec : 180̫~160 k̫
See table
Defective coolant Replace

NO
temp sensor
Check Table
Temperature (˚C ) 0 25 50 80 95
Resistance (k̫) 30~37 9.3~10.7 3.2~3.8 1.0~1.3 0.7~0.8
Engine ECM
IG 24V
CN-91 ENGINE COOLANT
CAN2 Lo
CAN2 Hi TEMPERATURE SENSOR
CAN_Hi
CAN Lo 6 21 5 37 15 A
CAN Hi 5 20 4 46 CAN_Lo 38 B C
GND
RS232 TX
RS232 RX OEM Engine harness
RS232 P DUMP connector connector
CN-126 CN-5 CN-3
SERVICE TOOL
CN-51
CAN1 Hi-ECM 21
CAN1 Lo-ECM 31
MCU
4809S6ES03
6-27
5. WHEN AIR CLEANER WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
YES
Clogged air filter or Check filter or
defective switch replace switch
Does display go
off when
disconnect YES
CD-10? Short circuit in Repair or replace
Starting switch : ON wiring harness (after clean)
Engine : Start Check resistance
between CD-10-
between CN-53
NO CN-53(23)
(23) and chassis
Starting switch : OFF
Disconnect CN-51
Defective MCU Replace
NO
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
MCU AIR CLEANER SWITCH

Section 1 General

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Section 1 General

Caricato da

Copyright:

Formati disponibili

SECTION 1 GENERAL

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

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

USE HANDHOLDS AND STEPS

Be careful of slippery conditions on platforms,

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

AVOID POWER LINES

MOVE AND OPERATE MACHINE SAFELY

OPERATE ONLY FORM OPERATOR'S SEAT

PARK MACHINE SAFELY

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

Store flammable fluids away from fire hazards.

ILLUMINATE WORK AREA SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HIGH PRESSURE FLUIDS

PREVENT BATTERY EXPLOSIONS

USE TOOLS PROPERLY

Use only recommended replacement parts.

REPLACE SAFETY SIGNS

LIVE WITH SAFETY

Battery box Fuel tank Hydraulic tank Main pump

Arm Arm cylinder Boom Boom cylinder Cab Muffler Counterweight

Bucket cylinder Connecting link Idler Carrier roller Sprocket

Side cutter Connecting rod Track roller Track Travel motor

Description Unit Specification

Description Unit Specification

Description Unit Specification

Description Unit Specification

Description 2.40 m (7' 10") Arm

Description 5.85 m (19' 2") Arm

Description 2.40 m (7' 10") Arm

Description 5.85 m (19' 2") Arm

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

Load radius At max. reach

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

Load radius At max. reach

1.84 m3 SAE 2.79 m3 SAE

1.00 m3 0.90 m3 915 mm 1065 mm 1220 kg

1.38 m3 1.25 m3 1100 mm 1250 mm 1420 kg

1.84 m3 1.65 m3 1140 mm 1290 mm 1520 kg

2.15 m3 1.92 m3 1415 mm 1565 mm 1740 kg

2.79 m3 2.47 m3 1760 mm 1910 mm 1960 kg

3.03 m3 2.67 m3 1890 mm 2040 mm 2090 kg

⊙2.20 m3 1.80 m3 1840 mm 2295 kg

⊙2.43 m3 2.10 m3 1885 mm 2335 kg

⊙ : Rock-heavy duty bucket

★1.38 m3 SAE 2.15 m3 SAE

1.65 m3 1.48 m3 1140 mm 1290 mm 1520 kg

2.15 m3 1.92 m3 1415 mm 1565 mm 1740 kg

2.79 m3 2.47 m3 1760 mm 1910 mm 1960 kg

3.03 m3 2.67 m3 1890 mm 2040 mm 2090 kg

★1.00 m3 0.90 m3 915 mm 1065 mm 1220 kg

★1.38 m3 1.25 m3 1100 mm 1250 mm 1420 kg

◈2.20 m3 SAE ⊙1.80 m3 SAE ⊙3.20 m3 SAE

◈2.20 m3 1.80 m3 1840 mm 2170 kg

⊙1.80 m3 1.50 m3 1560 mm 2110 kg

⊙3.20 m3 2.80 m3 2095 mm 2900 kg

◈ : Heavy duty bucket

(3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE