EXCAVATOR Models

TECHNICAL MANUAL
OPERATIONAL PRINCIPLE

All information, illustrations and specifications in this manual are based on the latest product information available
at the time of publication.
The right is reserved to make changes at any time without notice.

FIAT-HITACHI EXCAVATORS S.p.A. - ENGINEERING - FORM No. 604.06.807

Edition - X
 IN-1

INTRODUCTION

TO THE READER

• This manual is written for an experienced - If you have any questions or comments, or if you
technician to provide technical information needed found any errors regarding the contents of this
to maintain and repair this machine. manual, please contact:

- Be sure to thoroughly read this manual for correct FIAT-HITACHI S.p.A.

information concerning the service procedures. San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax. ++39 11 6877357

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition

to this service manual:

- Operator’s Manual
- Spare Parts Catalog

SERVICE MANUAL COMPOSITION

• The complete service manual consists of four

books: performance tests, and troubleshooting
- Technical Manual - Operational Principle procedures.
- Technical Manual - Troubleshooting
- Excavator Workshop Manual - The Excavator and the Engine Workshop Manuals
- Engine Workshop Manual include information needed for maintenance and
repair of the machine, tools and devices needed for
- The Technical Manual-Operational Principle maintenance and repair, maintenance standards,
includes the technical information concerning the removal/installation and assembly/disassembly
operation of main devices and systems. procedures.

- The Technical Manual -Troubleshooting includes • The Service Manual for EX215 Excavator consists
the technical information needed for operational of the following book/print numbers:

BOOK PART NUMBER

- Technical Manual - Operational Principle 604.06.807
- Technical Manual - Troubleshooting 604.06.812
- Workshop Manual - Excavator 604.06.817
- Workshop Manual - Engine 604.06.832
IN-2

INTRODUCTION

PAGE NUMBER

• Each page has a number, located on the external upper corner of the page. Each page number contains the
following information:

Example: T 1-2-3

Consecutive page number for each group

Group number (if exist)

Section number

T : Technical Manual
W : Excavator Workshop Manual
EW: Engine Workshop Manual

SYMBOLS

In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for
personal injury or machine damage.

This is the safety alert symbol.

When you see this symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed along with the safety alert symbol.
The safety alert symbol is also used to draw attentio in to component/part weights.
To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy
parts.

UNITS USED

SI Units (International System of Units) are used in this manual.

MKSA system units and English units are also indicated in parentheses just behinds SI units.

Example: 24.5 Mpa (250 kgf/cm, 3560 psi)

A table for conversion from SI units to other system units is shown below for reference purposes.

To To
Quantity convert Into Multiply by Quantity convert Into Multiply by
from (SI) (Others) from (SI) (Others)
Lenght mm in 0.039 37 Pressure MPa kgf/cm2 10.197
mm ft 0.003 281 MPa psi 145.0
L US gal 0.264 2 Power kW PS 1.360
Volume L US qt 1.057 kW HP 1.341
m yd 1.308 Temperature °C °F °C x 1.8 + 32
Weight Kg lb 2.205 Velocity Km/h mph 0.621 4
-1
Force N kgf 0.101 97 min rpm 1.0
N lbf 0.224 8 Flow rate L/min US gpm 0.264 2
Torque N.m Kgf.m 1.0197 ML/rev Cc/rev 1.0
N.m lbf.ft 0.737 5
TECHNICAL MANUAL EX215

OPERATIONAL PRINCIPLE

SECTION AND GROUP CONTENTS

Section 1 - GENERAL

Group 1 Specifications
Group 2 Component Layout

Section 2 - SYSTEM

Group 1 Control System

Group 2 Hydraulic System
Group 3 Electrical System

Section 3 - COMPONENT OPERATION

Group 1 Pump Device

Group 2 Swing Device
Group 3 Control Valve
Group 4 Pilot Valve
Group 5 Travel Device
Group 6 Others (Upperstructure)
Group 7 Others (Undercarriage)
SECTION 1 EX215

GENERAL

CONTENTS

Group 1 - Specification Group 2 - Components layout

Excavator Dimensions Main components ................................ T1-2-1

(Monoblock version) ............................ T1-1-1 Electrical system
Excavator Dimensions (Overall system) .................................. T1-2-2
(Triple articulation version) .................. T1-1-2 Electrical system (Relays) ................... T1-2-3
Excavator performance ....................... T1-1-3 Electrical system
Engine ................................................. T1-1-3 (Monitor and Switch panels) ................ T1-2-4
Engine accessory ................................ T1-1-3 Electrical system (Fuses) .................... T1-2-5
Hydraulic Device ................................. T1-1-4 Pump and related parts ....................... T1-2-6
Electrical Equipment ............................ T1-1-5 Other components ............................... T1-2-7
 T1-1-1

SPECIFICATIONS

EXCAVATOR DIMENSIONS
(Monoblock version)
E
G D/D'

C
I
L

M A
N B

OM0253

VERSIONS A B C D D’ (*) E F G H I L

EX215 3 371 4 171 1 030 2 720 2 750 9 500 2 970 2 455 2 870 915 450
(mm)

EX215 E (mm) 3 371 4 171 1 030 2 720 2 750 9 500 2 970 2 455 2 870 915 450

EX215 LC 3 658 4 458 1 030 2 720 2 750 9 500 2 970 2 455 2 870 915 450
(mm)
(*) Rear swing radius

EX215 EX215 E EX215 LC

M-Track shoe width (mm) 600 700 800 900 500 600 700 600 700 800 900

N-Maximum width (mm) 2 800 2 900 3 000 3 100 2 480 2 580 2 680 2 990 3 090 3 190 3 290

Working weight (kg) 19 440 19 690 19 940 20 190 19 235 19 485 19 735 20 000 20 270 20 540 20 810

Spec. Ground Press. 0.44 0.39 0.33 0.30 0.51 0.46 0.40 0.42 0.37 0.31 0.28
(bar)

DIGGING DATA 5 680 mm Boom

Arm mm 2 000 2 400 2 910 3 500

A mm 9 280 9 480 9 910 10 460

A’ mm 9 110 9 300 9 750 10 300

B mm 5 700 6 080 6 670 7 160

B’ mm 5 480 5 880 6 490 7 000

C mm 9 380 9 280 9 600 9 780

D mm 6 640 6 460 6 780 6 920

E mm 3 600 3 600 3 540 3 560

Break out force:

• Bucket kg 12 000 12 000 12 000 12 000
• Arm kg 12 500 11 500 9 500 7 900
Power Boost ON
• Bucket kg 13 000 13 000 13 000 13 000
• Arm kg 13 400 12 400 10 200 8 500
OM0254
T1-1-2

SPECIFICATIONS

EXCAVATOR DIMENSIONS
(Triple articulation version)

E G

D/D'

H
F

I
L
A M

B N

OM0255

VERSIONS A B C D D’ (*) E F G H I L

EX215 E 3 371 4 171 1 030 2 720 2 750 9 370 3 100 2 455 2 870 915 450
(mm)

EX215 LC (mm) 3 658 4 458 1 030 2 720 2 750 9 370 3 100 2 455 2 870 915 450

(*) Rear swing radius

EX215 E EX215 LC

M-Track shoe width (mm)

500 600 700 600 700 800 900

N-Maximum width 2 480 2 580 2 680 2 990 3 090 3 190 3 290

(mm)

Working weight (kg) 19 850 20 100 20 350 20 615 20 885 21 155 21 425

Spec. Ground Press. 0.53 0.47 0.41 0.46 0.39 0.35 0.32
(bar)

DIGGING DATA 5 680 mm Boom

Arm mm 2 000 2 400 2 910 3 500

A mm 9 121 9 400 9 780 10 300

A’ mm 8 920 9 180 9 600 10 120

B mm 5 440 5 780 6 250 6 850

B’ mm 5 320 5 660 6 140 6 760

C mm 10 322 10 350 10 680 11 020

D mm 7 405 7 360 7 740 8 080

E mm 2 697 2 640 2 280 2 300

Break out force:

• Bucket kg 12 000 12 000 12 000 12 000
• Arm kg 12 500 11 500 9 500 7 900
Power Boost ON
• Bucket kg 13 000 13 000 13 000 13 000
• Arm kg 13 400 12 400 10 200 8 500
OM0256
 T1-1-3

SPECIFICATIONS

EXCAVATOR PERFORMANCE

GRADEABILITY ........................................................................................................... 35° (70%) in continuous

TRAVEL SPEED .................................................................................................... 2.2 / 3.4 mph (3.5/5.5 km/h)

- Slow .................................................................................................................... 0 to 2.2 mph (0 to 3.5 km/h)
- Fast ..................................................................................................................... 0 to 3.4 mph (0 to 5.5 km/h)

ENGINE

MAIN SPECIFICATIONS
- Manufacturer ........................................................................................................................................ IVECO
- Model .......................................................................................................................................... 8065.25.085
- Type ................................................................................. 4 stroke Diesel type, direct injection, turbocharged
- Net power to flywheel
(DIN 6 271) ....................................................................................................... 135-145 HP (*)/99-107 kW (*)
- Net power to flywheel
(SAE J1 349) ............................................................................................................................. 99-107 kW (*)
- Net power to flywheel
(ISO 9249) ................................................................................................................................. 99-107 kW (*)
- Net power to flywheel
(CEE 80/1 269) ......................................................................................................................... 99-107 kW (*)
- Rated Speed .................................................................................................................. 1 950 - 2 150 rpm (*)
- Displacement .................................................................................................................................. 5 861 cm3
- Number of cylinders ...................................................................................................................................... 6
- Bore and stroke .........................................................................................................................104 x 115 mm

(*) With HP mode switch on.

STARTER MOTOR
- Voltage - Output .............................................................................................................................24V - 4 kW

INTAKE AIR HEATER (PRE-HEAT) CIRCUIT

- Intake air Heater Controller .................................................................................................................. IVECO
- Voltage ...................................................................................................................................................... 24V

ALTERNATOR
- Voltage - Output .............................................................................................................................. 28V - 55A

ENGINE ACCESSORY

RADIATOR ASSEMBLY
- Type ............................................................................................. Radiator/Oil Cooler tandem type assembly
- Weight ....................................................................................................................................... 82 kg (181 lb)
- Radiator Capacity .................................................................................................................................... 6.7 L
- Oil Cooler Capacity ................................................................................................................................. 5.1 L

BATTERY
- Capacity ......................................................................................................................................... 100 Ah x 2
- Voltage ................................................................................................................................................ 12V x 2
T1-1-4

SPECIFICATIONS

HYDRAULIC DEVICE

MAIN PUMP
- Model ........................................................................................................................................... HPV102FW
- Type ............................................................... Variable displacement plunger pump: regulator attached type
- Max. flow (Theoretical value) ..................................................................................................... 185 L/min x 2

PILOT PUMP
- Model ..................................................................................................................................... HY/ZFS 11/16.8
- Type ....................................................................................................... Fixed displacement type gear pump
- Max. flow (Theoretical value) ...................................................................... 32.8 L/min; HP Mode: 36.1 L/min

CONTROL VALVE
- Model .......................................................................................................................................... KVMG-200H
- Type ................................................................................................................... Pilot pressure operated type
(4-spool + 5-spool)
- Main relief pressure ................................................................. Normal: 34.3 MPa (350 kgf/cm2) @ 110 L/min
Power Boost: 36.3 MPa (370 kgf/cm2) @ 110 L/min
- Overload relief pressure ......................................................................... 37.3 MPa (380 kgf/cm2) @ 50 L/min
(Boom raise / lower, Arm roll-in, Bucket roll-in)
39.2 MPa (400 kgf/cm2) @ 50 L/min
(Arm roll-out, Bucket roll-out)

SWING DEVICE
- Type ........................................................................................................ Two-stage planetary reduction type

SWING MOTOR
- Model ............................................................................................................................................... M2X146B
- Type .............................................................................. Swash-plate type, fixed-displacement plunger motor

SWING BRAKE VALVE

- Type .............................................................................................................. Non counter balance valve type
- Relief pressure ....................................................................................... 30.9 MPa (315 kgf/cm2) @ 40 L/min

SWING PARKING BRAKE

- Type .............................................................................................................. Multiple-wet-plate negative type
- Cracking pressure for release ................................................................. 1.96 to 2.64 MPa (20 to 27 kgf/cm2)

TRAVEL DEVICE
- Type ..................................................................................................... Three-stage planetary reduction gear

TRAVEL MOTOR
- Model ................................................................................................................................................ HMV116
- Type .............................................................................. Bent-axis type, variable displacement plunger motor

TRAVEL BRAKE VALVE

- Type ..................................................................................................................... Counter balance valve type
- Relief pressure ........................................................................................................... 34.8 MPa (355 kgf/cm2)

TRAVEL PARKING BRAKE

- Type .............................................................................................................. Multiple-wet-plate negative type
- Cracking pressure for release ............................................................. 0.95 to 1.02 MPa (9,7 to 10.4 kgf/cm2)
 T1-1-5

SPECIFICATIONS

CYLINDERS

Boom Arm Bucket Positioning (*)

Rod diameter 85 mm 95 mm 75 mm 90 mm
Cylinder bore 120 mm 130 mm 110 mm 145 mm
Stroke 1221 mm 1475 mm 1060 mm 1050 mm
Fully retracted
length 1759 mm 2040 mm 1590 mm 1670 mm

(*) Triple articulation version

FRONT ATTACHMENT PILOT VALVE

- Model .................................................................................................................................. HVP04S-040-101

TRAVEL PILOT VALVE

- Model ................................................................................................................................... HVP05D-040-101

SOLENOID VALVE UNIT

- Functions ............................................................................................... SC: Arm regenerative control
SD: Speed sensing control
SG: Power boost control
SI: Travel motor swash angle control

OIL COOLER BYPASS CHECK VALVE

- Cracking pressure ........................................................................................... 392 KPa (4 kgf/cm2) at 5 L/min

ELECTRICAL EQUIPMENT

BATTERY RELAY
- Voltage - Current ........................................................................................................................... 24V - 50A

HORN
- Specifications ..................................................................................................................... 24V - 1.5A, 113dB

LIGHT
- Specifications ............................................................................................ Work lights: Halogen 24V - 70W
Dome light: 24V - 10W

INTAKE AIR HEATER CONTROLLER

- Type ..................................................................................................................................................... IVECO
- Voltage ...................................................................................................................................................... 24V
T1-1-6

SPECIFICATIONS

NOTES
 T1-2-1

COMPONENT LAYOUT

MAIN COMPONENTS

1 3

5
6
7

8
9
19

10
18
11
17 12
13
16
14
15

SM0607

1 - Bucket Cylinder 11 - Engine

2 - Arm Cylinder 12 - Radiator
3 - Boom Cylinder 13 - Oil Cooler
4 - Center Joint 14 - Battery
5 - Swing Bearing 15 - Travel Device
6 - Swing Device 16 - Shockless Valve
7 - Fuel Tank 17 - Pilot Shut-Off Valve
8 - Hydraulic Oil Tank 18 - Travel Pilot Valve
9 - Control Valve 19 - Front/Swing Pilot Valve
10 - Pump Device
T1-2-2

COMPONENT LAYOUT

ELECTRICAL SYSTEM (Overall system)

1
2
4
3
5 6

7-8

30
29
28 9

10
27

26 11-12

25 13

14

22
15

24 16

21

23 17

20
18
19
T157-01-01-016
SM0608

1 - Wiper Motor 16 - Pump Delivery Pressure Sensor

2 - Monitor Panel 17 - Engine Oil Pressure Switch
3 - Relays 18 - Engine Oil Level Switch
4 - Pressure Switch (Front) 19 - Alternator
5 - Pressure Switch (Travel) 20 - Overheat Switch
6 - Work Light 21 - Coolant Temperature Sensor
7 - Fuel Sensor 22 - Battery Relay
8 - Low Fuel Level Switch 23 - Coolant Level Switch
9 - Solenoid Valve Unit 24 - Battery
10 - Hydraulic Oil Level Switch 25 - Starter Relay
11 - PC Pressure Sensor (Upper: 5-Spool Side) 26 - Pressure Switch and Sensor
12 - PC Pressure Sensor (Lower: 4-Spool Side) 27 - Windshield Washer Tank
13 - EC Sensor 28 - MC (Main Controller)
14 - EC Motor 29 - Fuse Box
15 - N Sensor 30 - Intake Air Heater Controller
 T1-2-3

COMPONENT LAYOUT

ELECTRICAL SYSTEM (Relays)

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

13

26

25 24 23 22 21 20 19 18 17 16 15 14 31

28

29

30

27

SM0609

1 - Alternator relay (R1) 17 - TBG relay (R17) (opt.)

2 - Safety relay (R2) 18 - Engine stop relay (R18)
3 - Anti Load Dump relay (R3) 19 - Hammer relay (R19) (opt.)
4 - Washer relay (R4) 20 - Diodes 2-4
5 - Light relay 2 (R5) 21 - Diodes 5-6
6 - Light relay 1 (R6) 22 - Diodes 7-8
7 - Horn relay (R7) 23 - Diodes 9-10
8 - Wiper relay A (R8) 24 - Diode 11
9 - Wiper relay B1 (R9) 25 - Timer
10 - Wiper relay B2 (R10) 26 - Buzzer for TBG (opt.)
11 - Wiper relay BM (R11) 27 - Air conditioning relays (opt.)
12 - Fuel heat indicator relay (R12) (opt.) 28 - Starter relay
13 - Fuel heat switch relay (R13) (opt.) 29 - Solenoid relay
14 - Air heater indicator relay (R14) 30 - Battery relay
15 - Nordic kit relay (R15) (opt.) 31 - Air intake heater controller
16 - Rotary bucket relay (R16) (opt.)
T1-2-4

COMPONENT LAYOUT

ELECTRICAL SYSTEM (Monitor and Switch panels)

10

24
11
1 12
23 13
22 14

21 15
16
2 20
17
19
3
18
T157-07-02-001
SM0610

5
25
6
32
4
7

8 26
31

9 27

28
30

T157-01-01-009
29 T157-01-01-018
SM0611 SM0612

1 - Monitor Panel 17 - Fuel Level Indicator

2 - Switch Panel 18 - Overheat Indicator
3 - Power Boost Switch 19 - Alternator Indicator
4 - Key Switch 20 - Engine Oil Pressure Indicator
5 - Cigar Lighter 21 - Engine Oil Level Indicator
6 - HP Mode Switch 22 - Coolant Level Indicator
7 - E Mode Switch 23 - HP Mode Indicator
8 - Engine Control Dial 24 - Coolant Temperature Gauge
9 - Air Conditioner Panel 25 - Work Light Switch
10 - Warm Up Complete Indicator 26 - Wiper Switch
11 - Fuel Gauge 27 - Travel Mode Switch
12 - E Mode Indicator 28 - Work Mode Switch
13 - Auto-Idle Indicator 29 - Buzzer Stop Switch
14 - Hydraulic Oil Level Indicator 30 - Auto-Idle Switch
15 - Air heater (Preheat) Indicator 31 - Washer Switch
16 - Air Filter Restriction Indicator 32 - Level Check Switch
 T1-2-5

COMPONENT LAYOUT

ELECTRICAL SYSTEM (Fuses)

Fuse PROTECTED CIRCUIT Rating

No. (AMP)

FUSES IN THE BOX

1 Backup power source 5

2 MC (Power Source) 10
3 EC Motor 10
4 Power supply 5
5 Pump control solenoid 5
6 Switch panel 5
7 Heated seat/breaker (opt) 10
8 Heated fuel filters (opt) 5
OM0231

9 Bucket rot. & overturn sensor (opt) 10

10 Kit for Northern Countries 10
11 Lights 20
12 Wiper 10
20 19 18 17 16 15 14 13 12 11
13 Heater 20
14 Intake air heater controller (15) 3
15 Horn 10 10 9 8 7 6 5 4 3 2 1

16 Radio 5
OM0232
17 Cigar lighter 10
Fuses in the fuse box
18 Cab light 5
19 Air conditioner (opt) 10
20 Intake air heater controller (30) 30

FUSES IN THE AIR FILTER BAY

FUSE 3 FUSE 1
BOX A Main power supply
FUSE 1 with key 40
BOX B BOX A
BOX A
FUSE 2 Heated fuel filters 40 FUSE 4
(OPT) FUSE 2
BOX B Engine start-up
FUSE 3 line protection 80
BOX B Engine stop OM0233
FUSE 4 protection 40
Fuses in the air filter bay
T1-2-6

COMPONENT LAYOUT

PUMP AND RELATED PARTS

3 4

7
2

12

11

1 10
8

SM0613

T157-01-01-017

1 - Pilot Filter 7 - EC Motor

2 - Pilot Relief Valve 8 - EC Sensor
3 - Pilot Pump 9 - Pump Delivery Pressure Sensor (Pump 1)
4 - Regulator (Pump 2) 10 - Pump 1
5 - N Sensor 11 - Pump Delivery Pressure Sensor (Pump 2)
6 - Regulator (Pump 1) 12 - Pump 2
 T1-2-7

COMPONENT LAYOUT

OTHER COMPONENTS

Swing Device Shockless Valve

4
1
5

8
6

T157-01-01-011 T157-07-03-018
SM0626 SM0627

Travel Device Solenoid Valve Unit

FRONT

10

11
12
2
13
3
SM0628 SM0629
T157-01-01-012 W157-02-11-020

1 - Swing Relief Valve 8 - Check Valve

2 - Counterbalance Valve 9 - Pilot Pressure Sensor (Arm Roll-In)
3 - Travel Relief Valve 10 - Solenoid Valve Unit (SC)
4 - Shockless Valve 11 - Solenoid Valve Unit (SD)
5 - Pilot Pressure Switch (Boom Raise) 12 - Solenoid Valve Unit (SI)
6 - Check Valve 13 - Solenoid Valve Unit (SG)
7 - Shockless Valve
T1-2-8

COMPONENT LAYOUT

NOTES
SECTION 2 EX215

SYSTEM

CONTENTS

Group 1 - Control system Group 3 - Electrical system

Outline ................................................. T2-1-1 Outline ................................................. T2-3-1

Engine control ..................................... T2-1-2 Electric power circuit ........................... T2-3-2
Pump control ....................................... T2-1-8 Bulb check circuit ................................ T2-3-3
Valve control ........................................ T2-1-10 Intake air heater circuit ........................ T2-3-4
Other control function .......................... T2-1-14 Starting circuit ..................................... T2-3-6
Charging circuit ................................... T2-3-8
Surge voltage prevention circuit .......... T2-3-9
Accessory circuit ................................. T2-3-10
Group 2 - Hydraulic system Engine stop circuit ............................... T2-3-11
Engine emergency stop ....................... T2-3-12
Main circuit .......................................... T2-2-1
Pilot circuit ........................................... T2-2-2
Neutral circuit ...................................... T2-2-3
Single actuator operation .................... T2-2-3
Combined operation ............................ T2-2-4
 T2-1-1

CONTROL SYSTEM

OUTLINE

Microcomputer built-in main controller (MC) is After processing the sensing signals in the logic
provided to control machine operation. Electronic circuits, the MC sends out the control signals to the
sensing signals from the engine control dial, various EC motor and solenoid valve unit to control the
sensors and switches are sent to the MC. engine, pump, and valve operations.

Sensing signals (Input signals) Control signals (Output signals)

EC sensor →
Normal control
Engine control dial → HP mode control
Pump control pressure sensor → → EC motor: E mode control
Pump delivery pressure sensor → Engine control Auto-Idle control
Engine learning control
N sensor →
Pressure switches (Travel and front) →
Pilot pressure sensor
→ Solenoid valve (SD): Speed sensing control
(Arm roll-in) → Pump control
Pilot pressure switch (Boom raise) → MC
Auto-idle switch →
Learning switch → Power Boost control
HP mode switch → → Solenoid valve (SC, SG, SI): Arm regenerative control
Travel mode switch → Valve control Travel motor swash angle
control
Work mode switch →
Key switch →
Power boost switch → → Work mode control
T2-1-2

CONTROL SYSTEM

ENGINE CONTROL

The engine control system has the following control

functions:

• Normal control
• HP mode control
• E mode control
• Auto-Idle control
• Engine learning control.

Layout of engine control system

Pilot pressure sensor

(Arm Roll-in)

Pressure
Pressure switch (Travel) switch
(Front)
Learning switch

P/V
Key switch

EC sensor
Engine control dial

ENGINE
M
Auto-Idle switch MC
A/I
EC motor
HP mode switch
H/P
E mode switch
E

Pump delivery pressure sensor

(Pump 1, 2)

SM0101
 T2-1-3

CONTROL SYSTEM

Normal Control

Purpose: To control engine speed in response to the

operation angle of the engine control dial on the NOTE - Normally, the governor lever does not come
switch panel. into contact with the full side stopper even if the
engine control dial is turned to the full speed position.
Operation: In response to the operation angle of the (Refer to HP Mode Control).
engine control dial, the MC drives the EC motor,
causing the governor lever to move to control engine
speed.

P/V

Engine control dial

ENGINE
M Min. Max.

MC
A/I Governor lever
EC motor

H/P

SM0102
T2-1-4

CONTROL SYSTEM

HP Mode Control

Purpose: To instantaneously increase the engine

speed only when a little more hydraulic power is
required for arm roll-in operation. For example, to Engine speed
HP mode operation
increase the arm roll-in power while conducting a line
deep ditching work.
200 min-1 (rpm)
Operation: Only when the following conditions are
satisfied, the MC drives the EC motor to operate the
engine faster than normal operation.
1.800 min-1 (rpm)
• Engine Control Dial Setting: 1600 min-1 or faster
• HP Mode Switch: ON 1.600 min-1 (rpm)
• Operation: Arm Roll-In
• Average Delivery Pressures of Pump 1 and 2:
Higher Range

Slow Idle Fast Idle (Max. Speed)

NOTE - The engine governor stopper position is
adjusted in accordance with the HP mode operation. Slow Idle Fast Idle
Therefore, the governor lever does not come into (Max. Speed)
contact with the stopper in the Normal Control mode.
SM0103

Pilot pressure sensor

(Arm Roll-in)

P/V

Engine control dial

ENGINE
M Min. Max.

MC
A/I Governor lever
EC motor
HP mode switch
H/P

E Pump delivery pressure sensor

SM0104
 T2-1-5

CONTROL SYSTEM

E Mode Control
Engine speed
Purpose: To decrease the engine speed at a fixed
rate.
When the E mode switch
Operation: When the E mode switch is ON, the MC is not depressed
instructs the EC motor to run the engine in the speed
range slower than normal operation in proportion to
the engine control dial set angle.

When the E mode

switch is depressed

Slow Idle Fast Idle (Max. Speed)

Slow Idle Fast Idle
(Max. Speed)

SM0105

P/V

Engine control dial

ENGINE
M
MC
A/I EC motor Governor lever

H/P
E mode switch
E

SM0106
T2-1-6

CONTROL SYSTEM

Auto-Idle Control

Purpose: To slow the engine speed when all control control levers are kept in neutral (the pressure
levers are in neutral to reduce fuel consumption and switches for travel and front operations are off) for
noise. more than four seconds, the MC instructs the EC
motor to reduce the engine speed to the auto-idle
Operation: When the auto-idle switch is ON and all speed.

Pressure switch (Travel) Pressure switch

(Front)

P/V

Engine control dial

ENGINE
M
Auto-Idle switch MC
A/I EC motor Governor lever

H/P

SM0107
 T2-1-7

CONTROL SYSTEM

Engine Learning Control

Purpose: To check the governor lever stopper

positions to run the engine at full-speed or to slow idle
as engine control standard data.

Operation: When the learning switch in the rear

console is turned to the engine learning side, the EC
motor is driven by the signal from the MC. Then, the
EC motor moves the governor lever to the slow idle
(Min.), fast idle (Max.) and slow idle (Min.) positions
in order. Thereby, the EC sensor checks the stopper Rear Console
positions for the Max. and Min. operation. The signals
corresponding to each stopper position are sent to
the MC from the EC sensor, and the MC stores the Fuse Box
data.

Learning Switch
IMPORTANT - Be sure to operate the engine Engine Learning
learning control system after replacing the engine,
engine control cable, EC motor, or MC.

NOTE - The replacement of batteries does not Neutral (OFF)

require operation of the engine learning control
system.
SM0108

Learning switch

P/V
Key switch

EC Sensor

ENGINE
M Min. Max.

MC
A/I EC Motor Governor Lever

H/P

SM0109
T2-1-8

CONTROL SYSTEM

PUMP CONTROL

The pump operation is regulated by the speed The pump control valve is provided in the control
sensing system and the pump control valve. valve. (Refer to the Control Valve Group in the
The speed sensing system works via the MC. COMPONENT OPERATION Section).
 T2-1-9

CONTROL SYSTEM

Speed Sensing Control

Purpose: To control the pump drive torque in solenoid valve unit (SD) supplies pilot oil pressure to
response to the variation of loads to the engine or the the pump regulators to control the pump flow rate.
output of the hydraulic pumps to utilize the engine When poor quality fuel is used or if the machine is
output more efficiently. operated at high altitudes, the engine output torque
may decrease, causing the engine to run slower than
Operation: The target engine speed is selected by the target speed. As the MC in the speed sensing
setting the engine speed with the engine control dial. control system instructs the solenoid valve unit (SD)
The MC receives signals for the target engine speed, to reduce the pump flow rate, the pump drive torque
and actual engine running speed from the N sensor. is reduced. Thereby, engine speed reduction or
After processing these input data, the MC sends out engine stall is avoided.
the control signals to the solenoid valve unit (SD).
According to the control signals from the MC, the

N sensor

Engine control dial

Solenoid valve
unit
SD
MC ENGINE

REG REG

SM0110
T2-1-10

CONTROL SYSTEM

VALVE CONTROL

The valve control consists of the power boost control,

arm regenerative control, and travel motor swash
angle control.

Pump control pressure sensor

(5-Spool Side)
Pilot pressure sensor (Arm Roll-In)
Pressure switch (Boom Raise)

Travel motor swash angle

selector valve

Power Boost switch Pressure switch

Travel motor (Front)

Pressure switch
Travel mode switch (Travel)

Relief valve

P/V

Arm cylinder

MC

To MC
SG

Pump delivery
pressure sensor

Solenoid SI SC
valve unit

Arm regenerative
valve

Swing motor REG REG

From pump control Pump control pressure

pressure sensor sensor (4- Spool Side)
(4-Spool Side)

SM0111
 T2-1-11

CONTROL SYSTEM

Power Boost Control

Purpose: To increase hydraulic power by ON, the MC magnetizes solenoid valve unit (SG) for
temporarily increasing the main relief pressure. 8 seconds. When magnetized, solenoid valve unit
(SG) supplies pilot oil pressure to the relief valve to
Operation: When the power boost switch is turned increase the relief set pressure.

Relief Valve

Power Boost switch

MC

Solenoid
Valve Unit

SM0112
T2-1-12

CONTROL SYSTEM

Arm Regenerative Control

Purpose: To increase arm roll-in speed and prevent is combined with the pump delivery oil and supplied
the arm roll-in hesitation. to the arm cylinder bottom side, increasing the arm
roll-in speed and preventing arm roll-in hesitation.
Operation: When the signals to the MC from the
pump delivery pressure sensor (pump 2), pilot
pressure sensor (arm roll-in), and pressure switch Operation Conditions:
(boom raise) fall into the following conditions, the MC - Pump Delivery Pressure Sensor (Pump 2):
magnetizes the solenoid valve unit (SC). Then, the Delivery pressure from pump 2 is low (requiring
solenoid valve (SC) starts to deliver the pilot pressure less arm operating force).
to actuate the arm regenerative valve, closing the - Pilot Pressure Sensor (Arm Roll-In): Output is large
return circuit to the hydraulic oil tank from the arm (operating the arm control lever with a great
cylinder rod side. stroke).
Thereby, the return oil from the arm cylinder rod side - Pressure Switch (Boom Raise): ON

Pilot pressure sensor (Arm Roll-In)

Pressure Switch (Boom Raise)

Bucket
Arm cylinder

MC

Arm 1
Bucket
cylinder

Pump delivery
Solenoid pressure sensor (Pump 2)
valve unit
Arm regenerative
valve

SM0113
 T2-1-13

CONTROL SYSTEM

Travel Motor Swash Angle Control

Purpose: To change fast/slow travel speed. Operation Conditions:

- Pressure Switch (Travel): ON
Operation: When the travel mode switch is in - Pressure Switch (Front): OFF
position, the travel motor swash angle is held at a - Pump Delivery Pressure Sensors (Pump 1 and 2):
large angle, causing the machine to travel at a slow Pump delivery pressure is low.
speed. - Pump Displacement Target Angle (controlled by
the MC according to signals from sensors and
When the travel mode switch is in position and the switches): Large
signals to the MC from the pressure switch (travel),
pump delivery pressure sensors (pump 1 and 2) fall NOTE - Even if the track is revolved with the track
into the following conditions, the MC magnetizes raised, one side pump displacement target angle
solenoid valve (SI), allowing pilot oil pressure to remains small so that the travel motor speed does not
change the travel motor swash angle control valve increase.
port. Thereby, the travel motor swash angle is The pump displacement target angle is different from
reduced to cause the machine to travel at a fast the travel motor displacement target angle.
speed.

Travel motor swash angle

Pump control Pressure Sensor control valve
(5-Spool Side) Travel motor
Pressure switch (Front):
OFF signal
Pressure switch (Travel):
ON signal
Left side travel

Travel mode Right side

switch travel

MC

To MC

Pump control
Pump delivery Pressure Sensor
Pressure Sensors (4-Spool side)
Solenoid (Pump 1 and 2)
valve unit

From pump control

Pressure Sensor
(4-Spool side)

SM0114
T2-1-14

CONTROL SYSTEM

OTHER CONTROL FUNCTION

Work Mode Control

The work mode includes the four modes of of the full speed to be set when the engine control dial
GENERAL PURPOSE, GRADING, PRECISION, is placed in the full position.
and ATTACHMENT, which can be selected by the The main relief pressure is increased in boom raise
work mode switch. operation. (Refer to T2-1-11)

GENERAL PURPOSE MODE NOTE - Operating speed is reduced but operating

Normal control is applied. force is unchanged.

GRADING MODE ATTACHMENT MODE

To decrease the arm leveling speed, the arm Only when the attachment option kit is installed, this
regenerative control is deactivated. function works. In proportion to the auxiliary pilot
(Refer to T2-1-12) valve lever stroke, the engine speed is controlled by
the MC so as to meet the installed attachment
PRECISION MODE operation. The engine speed setting for the
In all work modes, engine speed is reduced to 70 % attachment mode is made by the Dr.EX.
 T2-2-1

HYDRAULIC SYSTEM

MAIN CIRCUIT

The main pumps (pump 1 and pump 2) draw the hydraulic oil tank via the control valves and the oil
hydraulic oil from the hydraulic oil tank. Pump 1 cooler. When oil temperature is low (viscosity is high),
delivers oil to the 4-spool control valve while pump 2 return oil flowing through the oil cooler will be
delivers oil to the 5-spool control valve. hampered because of the increased flow resistance
Pressure oil from the main pumps are routed to the in the oil cooler. If that happens, the bypass check
motors and cylinders in response to respective valve opens, allowing the return oil to directly flow
control valve spool shifts. back to the hydraulic oil tank.
Return oil from the motors and cylinders flows back to

Boom Cylinder
Arm cylinder

Bucket cylinder

Center joint

Swing motor
Travel (R)
Travel (L) Bucket

Boom 1
Aux.
Hydraulic oil tank

Boom 2 Full-flow filter

Arm 1
Suction filter

Bypass check valve

Swing

Arm 2

Pump 1
Engine Pump 2

Oil cooler

Pressure oil

Return oil

Center joint

Left travel motor Right travel motor

SM0115
T2-2-2

HYDRAULIC SYSTEM

PILOT CIRCUIT

Pressure oil from the pilot pump acts as working control circuit, and in the swing parking brake release
pressure in pilot operating circuit, in the pump/valve line.

Left pilot Travel pilot Right pilot

valve valve valve

Pilot operating circuit

Pilot shut-off Manifold for shockless valves, pressure Hydraulic oil

valve sensor, and for pressure switch tank

Swing parking brake

Swing motor Suction filter
release

Solenoid valve
unit

SG Pump / Valve control Main pump regulator

circuit
SI 2
Control valve

SD
1

SC

Pilot pump

Relief valve Pilot filter

Travel motor Travel motor

SM0116
 T2-2-3

HYDRAULIC SYSTEM

NEUTRAL CIRCUIT SINGLE ACTUATOR OPERATION

When the control levers are in neutral, pressure oil Pressure oil from pump 1 flows to the spools (Travel
from the main pumps returns to the hydraulic oil tank (R), Bucket, Boom 1, and Arm 2) in the 4-spool side
via the control valves. (Refer to the Control Valve section in the control valve. Pressure oil from pump 2
Group in the COMPONENT OPERATION Section). flows to the spools (Swing, Arm 1, Boom 2 , Aux., and
Travel (L)) in the 5-spool side section in the control
valve.
When arm or boom is operated, pressure oil from
both pumps is combined and flows together into the
respective cylinder.

Left travel motor Right travel motor

Pump control valve

Travel (R)

Travel (L)

Bucket Bucket cylinder

Aux.

Boom 2

Boom cylinder

Arm cylinder
Boom 1

Arm 1
Arm 2
Swing

Pump control
valve

5-Spool side 4-Spool side

Hydraulic oil tank

Swing motor Pump 2 Pump 1

SM0117
T2-2-4

HYDRAULIC SYSTEM

COMBINED OPERATION

Swing and Boom Raise Operation

When swing and boom raise operations are to swing the upperstructure. A portion of the pressure
performed at the same time, pilot pressure shifts the oil from pump 2 is detoured to the boom cylinder.
swing, boom 1, and boom 2 spools in the control The detoured oil flow is combined with the oil flow
valves. from pump 1 after flowing through the parallel pas-
Then, pressure oil from pump 1 flows into the boom sage and boom 2 spool in the 5-spool side section in
cylinder via the parallel passage in the 4-spool side the control valve. The boom is raised by combined oil
section in the control valve to raise the boom. flow from pump 1 and pump 2.
Pressure oil from pump 2 flows into the swing motor

Parallel passage

Boom cylinder
Boom 2

Boom 1

Swing

Parallel Passage

5-Spool Side 4-Spool Side

Swing motor Pump 2 Pump 1

SM0118
 T2-2-5

HYDRAULIC SYSTEM

Travel and Arm Roll-In Operation

When travel and arm roll-in operations are performed to the left travel motor via the flow combiner valve and
at the same time, pilot pressure shifts the travel, arm travel (L) spool, actuating it. For this reason, the
1, and arm 2 spools. Pressure in the non-travel signal machine can travel straight even when the arm roll-in
pilot pressure circuit rises due to arm spool operation is performed at the same time, blocking oil
movement, shifting flow combiner valve. flow from pump 2 to the left travel motor.
Then, pressure oil from pump 1 flows into the right Pressure oil from pump 2 flows into the arm cylinder
travel motor via the travel (R) spool, actuating it. via the arm 1 spool, actuating it.
A portion of the pressure oil from pump 1 is detoured

Flow combiner
Left travel motor valve Right travel motor

Pilot pump

Travel (R)

Travel (L)

Signal Pilot
Pressure Circuit

Arm Cylinder

Arm 1 Arm 2

Pump 2 Pump 1

SM0119
T2-2-6

HYDRAULIC SYSTEM

NOTES
 T2-3-1

ELECTRICAL SYSTEM

OUTLINE

The electrical system is classified into the main • Engine Stop Circuit:
circuit, control circuit, and monitor circuit. Stops the engine with the solenoid (Synchro-Start)
when the key switch is placed in OFF position.
• Main circuit operates the engine and accessories.
• Engine Emergency Stop Circuit:
• Control circuit functions to control operations of the Stops the engine in case of the oil pressure drop.
engine, hydraulic pump, and valves (including (Monitor, solenoid (Sinchro-Start), oil pressure
actuators such as solenoid valves, MC (Main switch).
Controller), switch box, sensors, and pressure
switches).

• Monitor circuit operates the monitor devices

consisting of the monitors, sensors, and switches.

In this group, the functions and construction of the

main circuit are introduced.

• Electric Power Circuit:

Supplies electric power to all electric system on this
machine.
(Key Switch, Batteries, Fuses (Fuse Box and
Fusible 40A), Battery Relay)

• Bulb Check Circuit:

Checks for blown indicator bulbs.
(Key Switch, Battery Relay, Fuses, Monitor)

• Intake Air Heater Circuit:

Helps start the engine in cold weather.
(Key Switch, Intake Air Heater controller, Fuel
Solenoid Valve, Flame glow plug, Temperature
Sensor, Air Heater Indicator Light)

• Starting Circuit: starts the engine.

(Key Switch, Starter, Starter Relay)

• Charging Circuit:
Recharges batteries and supplies consumption
electricity. (Alternator, (Regulator))

• Surge Voltage Prevention Circuit:

Prevents surge voltage from occurring when the
engine is stopped.
(Anti Load Dump Relay)

• Accessory Circuit:
Works with the key switch placed in the ACC
position. (Key Switch, Battery, Fuses)
T2-3-2

ELECTRICAL SYSTEM

ELECTRIC POWER CIRCUIT

(Key switch: OFF)

The battery negative terminal is grounded to the

vehicle. Current from the positive terminal flows as
follows with the key switch OFF.

→ Key switch B
Battery ⇒ Fusible 40A → Anti Load Dump Relay (R3)
→ Safety relay (R2)

Terminal 1 - Backup Power Source/Digital clock

Terminal 2 - MC (Power Source)
→ Fuse box Terminal 3 - MC (EC Motor)
Terminal 19 - Air Conditioner
Terminal 20 - Intake Air Heater controller
(terminal 30)

Key Switch
B G1 G2 ACC M ST
H
OFF
ACC
ON
START
1 2 3 4 5 6
Fuse 40A

Batteries Diode 2
- + - + Anti Load Dump
Relay (R3)
Battery
Relay

86 30 11 12 13 14 15 16 17 19 18 20
20A
10A
20A

10A

10A
10A

30A
5A

5A
3A

Fuse Box

to starter relay 85 87 87a

30
86
To Monitor
Air Conditioner

85
87 87a Safety Relay
(R2) 1 2 3 4 5 6 7 8 9 10
10A
10A

10A

10A
10A
5A

5A
5A
5A

5A

Fuse Box

50 31 15 30

Intake Air
Heater
Controller MC (EC Motor)
MC
Backup Power Source

to Radio for digital clock SM0120

 T2-3-3

ELECTRICAL SYSTEM

BULB CHECK CIRCUIT

When the key switch is turned to the ON position, key At the same time, the battery power via the fuse box
switch terminal B connects with key switch terminals is supplied as power source to the work lights, wiper,
M and ACC. heater, Intake air heater controller (terminal 15), MC
The current from terminal M excites the battery relay. (solenoid valve power source), and optional circuits.
Then, the battery power is routed to the monitor
through the battery relay and the fuse box, turning the
indicators on (for bulb check).

Key Switch
B G1 G2 ACC M ST
H
OFF
ACC
ON
START
1 2 3 4 5 6
Fuse 40A

Batteries
K
- + - + Diode 2

Battery
Relay

11 1512 16 14 17 18 19 13 20
10A

20A
20A
10A
10A

10A

30A
5A
3A
5A

Fuse Box

Fuse
80A
Heater
Intake Air Heater Controller
(terminal 15)

Wiper

Light (R5 and R6 Relay)

1 2 3 5 4 6 7 8 9 10
10A
10A
10A
10A
10A
5A

5A
5A
5A

5A

Fuse Box

Optional

Optional

MC
(Solenoid Valve
Power Source)

30
Monitor

SM0121
T2-3-4

ELECTRICAL SYSTEM

INTAKE AIR HEATER CIRCUIT

When the key switch is turned to ON position, the reach the flame glow plug. The evaporated fuel will
intake air heater controller terminal 15 is powered light and heat the intake air.
through the fusible 14. The intake air heater controller The post-heating time depends on the engine coolant
terminal 30 is directly powered from battery supply temperature that is detected from the air heater
through the 40 A fusible. (This power is supplied in all controller through the temperature sensor connected
key switch positions, apart from OFF position). to terminal T.
The air heater controller magnetizes the relay R14 The air heater circuit operates only if engine coolant
that, in turn, provides a ground to the monitor terminal temperature is lower than about 8°C. If the air heater
43 to switch on the air heater indicator light; further circuit does not operate, the power will not supply to
the controller provides the power to the flame glow flame glow plug and the indicator light turns off after
plug for heating. Elapsed the pre-heat period, the air about 2 seconds from turning the key switch to
heater indicator light, located on the monitor, will turn START position. A table related to the air heater
off and the engine can be started turning the key controller operational sequence is shown below.
switch to START position. In this position the power Further, the intake air heater controller provides a
supplied from key switch terminal 6 is routed to failure warning that is displayed to the operator by
controller terminal 50 that allows the excitation of fuel means of the flashing of the indicator light on the
solenoid valve. monitor (make reference to Group T5-4).
The opening of solenoid valve allows the fuel flow to

INTAKE AIR HEATER CONTROLLER OPERATIONAL SEQUENCE

Air heater Flame glow Fuel

Engine indicator plug solenoid valve
coolant Operation or function light powered powered
temperature
ON OFF YES NO YES NO

Greater than Turn the key switch to the ON

the value to turn position
on the pre-heat (Power to the terminal 15). X X X
operation
(about 8°C) After 2 sec. X X X

Turn the key switch to the ON

position
(Power to the terminal 15). X X X

After 2 sec. X X X

Pre-heat phase (elapsed time

depends on temperature). X X X

Turn on the starter motor before the end of

the pre-heat phase (with the indicator light
turned on). The operation is not correct but
Lower than not inhibited, the system is reset. X X X
the value to turn
on the pre-heat End of the pre-heat phase. X X X
operation
(about 8°C) If the starting phase is not carry on within
30 ± 1.5 sec. after pre-heat phase
completing (careless time). X X X

Turn the key switch to START

position.
Engine starting phase (for all period
of starter motor running). X X X

Intake air heater phase with engine

running (post-heat phase). X X X

End of post-heat phase. X X X

 T2-3-5

ELECTRICAL SYSTEM

Key Switch
B G1 G2 ACC M ST
H
OFF
ACC
ON
START
1 2 3 4 5 6

Batteries K
40A
- + - +
Diode 2
to Alternator
Relay R1
Battery
Relay
11 12 13 14 16 17 20 19 15 18 1 2 3 4
20A
10A
20A

10A
30A

10A

10A
Fuse
10A

10A
5A

5A
3A

5A

5A
Box
80A

50
15 30 31 B7
Intake Air Key on Signal
Heater
Air Heater Controller
Indicator
Relay (R14)
B e
Starter Relay
87a 87 85 MC

3 86 L
G g
30 81
Starter MV FGK T
E

Fuel Solenoid to Timer

M
_
B
87a 87 Valve (Terminal 86)
Temp. 1
Sensor
Safety Relay K
C Solenoid K
(R2) Diode 4 Flame
Glow Diode 1
plug
2
18 43 A
Monitor A
Indicator Light
Air Heater

SM0122
T2-3-6

ELECTRICAL SYSTEM

STARTING CIRCUIT
(Key Switch: START)

When the key switch is turned to the START position, relay, shutting-off the power supply to the starter.
terminal B on the key switch is connected to terminals
G2, M, and ST in the switch. The current from terminal Moreover the safety relay (R2) avoids a further
M magnetizes the battery relay, leading the battery starting sequence with engine running.
current to terminals B on the starter and starter relay
via the 80 A fusible. With safety relay (R2) excited, the ground is also
Terminal ST of the key switch is connected to disconnect from the solenoid relay. Therefore, with
terminal “e” on the starter relay so that the battery the solenoid relay de-energized, the power supply to
current flows through the coil and actuate the starter the push coil (B) of solenoid (Synchro-Start) is
relay via the closed contact of safety relay (R2). removed.
The starter relay, closing the contacts, allows the
battery current to flow toward the terminal C on the
starter, and actuated the inner starter relay. Thereby,
the starter begins to rotate.

Further, from key switch terminal ST, the battery

current is led to the fuel solenoid, to allow an increase
of the fuel flow to the injection pump, and to the
terminal 50 of intake air heater controller, for starting
sequence.

At the same time, when the key switch is turned both

ON and START positions, from terminal M, the
power supply is applied, via POWER ON fuse, to
main controller (MC) and to engine stop relay (R18).
This power on signal instructs the main controller
(MC) the key switch is in ON position. The main
controller (MC), when receives the power on signal,
operates the EC motor in order to move the governor
lever.

Further, with key switch in START position, the

voltage from fusible 40A, is routed to the terminal B
of solenoid relay related to push coil of high power to
actuate the solenoid (Synchro-Start).

The solenoid relay is actuated through the timer

control and is maintained actuated for about 1
second, after that the timer inhibits the excitation of
solenoid relay in order to avoid failure the push coil of
solenoid (Synchro-Start). Turning again the key
switch to OFF, after about 3 to 5 seconds, the starting
can be repeated.

The voltage from terminal M of key switch, is led,

through POWER ON fuse and engine stop relay
(R18) in de-energized condition, to the terminal C
related to holding coil of the solenoid (Synchro-Start).

With solenoid (Synchro-Start) powered in both coils

(push (B) (1 sec. max) and holding (C)), the solenoid
is actuated and the fuel flow is opened to injection
pump.

With engine running and alternator generating

voltage, the terminal 18 of monitor operates the
safety relay (R2) that removes the ground to starter
 T2-3-7

ELECTRICAL SYSTEM

Key Switch
B G1 G2 ACC M ST
H 30
OFF
Timer
ACC
ON
85 86 87
START
1 2 3 4 5 6
g
Solenoid Relay

Diode 10 e to Terminal 30
Batteries K
40A Safety Relay
- + - +
Diode 2 (R2)
B
G
Battery
Relay
11 12 13 14 16 17 20 19 15 18
Fuse 3 4
20A
10A
20A

10A
10A
10A
30A

40A
3A

5A
5A

10A

Box
5A
80A
Engine stop
86 Relay (R18)
POWER ON

85 87 87a
15 30 31 50
B7 A17 C B
Key on Signal
Intake Air Heater
B e L Controller

Starter MV FGK T MC Diode 3

Relay
Diodo 11
G g Diode 1 1 A Solenoid
30 81 (Synchro-start)
Starter Safety Relay Fuel
E
Solenoid
(R2)
2
M
_ 87a 87
B

18
C

to Solenoid Relay Monitor

(terminal e)

SM0123
T2-3-8

ELECTRICAL SYSTEM

CHARGING CIRCUIT (Key Switch: ON)

After the engine starts and the key switch is released, In addition, this current is supplied through the fuse
the key switch is returned to the ON position. With the box as a power source to the solenoid valves, switch
key switch kept ON, key switch terminal B is box, hour meter, work lights, wiper, and heater. At the
connected to terminals ACC and M. same time, the current from Alternator B+ flows to the
After the engine starts, the alternator begins to Alternator relay (R1) to turn off the alternator indicator
recharge the batteries. Current from terminal B on the light (battery charging) on monitor, and to Main
alternator flows to the batteries through the fuse 80A Controller (MC) for Alternator power on signal.
and the battery relay, recharging the batteries.

Key Switch
B G1 G2 ACC M ST
H
OFF
ACC
ON
START
1 2 3 4 5 6

Batteries
K
- + - + Diode 2 to Fuse Box
Battery to Fuse Box
Relay

Fuse 86 87 87a
80A
Alternator Relay
(R1)

85 30
Alternator
B+ D+

R
—
B-

42 B1

Monitor MC

SM0124
 T2-3-9

ELECTRICAL SYSTEM

SURGE VOLTAGE PREVENTION CIRCUIT

The surge voltage prevention circuit protects the magnetizing circuit for the Anti Load Dump relay to
electrical parts and components in the controller from close the Anti Load Dump relay (R3). Accordingly,
being damaged by the alternator generating surge even if the key switch is turned OFF while the engine
current developed when the engine is stopped. is running, the battery current can be supplied
While the batteries are being recharged, the through the Anti Load Dump relay (R3) to magnetize
generating current from terminal D+ on the alternator the battery relay, holding the battery relay ON until
is led, via Alternator relay (R1), to terminal 42 on the the alternator stops generating.
monitor, turning the transistor ON for terminal 18 on
the monitor.
Thereby, the battery current is supplied to the

Key Switch
B G1 G2 ACC M ST
H
OFF
ACC
ON
START
1 2 3 4 5 6

Batteries K
Diode 2
- + - +

Battery
Relay

86 87 87a 30 86
Fuse
80A Alternator Relay Relè Anti Load
(R1) Dump (R3)

85 30 87a 87

B+ D+
to Safety Relay
(R2)
W
1 2 3 4 5 6 7 8 9 10
Alternator
Fuse Box
10A

10A
10A
10A
10A
5A

5A
5A

5A
5A

R
—
B-

to MC

42 18 30

Monitor

SM0127
T2-3-10

ELECTRICAL SYSTEM

ACCESSORY CIRCUIT
(Key Switch: ACC)

When the key switch is turned to the ACC position, to each accessory circuit such as the horn, radio,
terminal ACC is connected to terminal B in the key cigar lighter, room lamp, and to the auxiliary circuit to
switch. operate them.
Then, the battery current flows through the fuse box

Key Switch

B G 1 G 2 ACC M ST

OFF

ACC

ON

START
1 2 3 4 5 6

Fusibile
40A

Batteries

- + - +

Battery
Relay

11 15 12 16 14 17 18 19 13 20 1 2 3 4 5 6 7 8 9 10
Fuse Fuse Box
20A
20A
10A
10A

10A

10A

30A

10A
10A
10A
10A

10A
5A

5A

5A
5A
3A
5A

5A

5A

80A

Room Lamp

Cigar Lighter
Radio
Rotary Bucket and
Horn
TBG (opt)

Nordic Kit (opt)

SM0128
 T2-3-11

ELECTRICAL SYSTEM

ENGINE STOP CIRCUIT

(Key Switch: OFF)

When the key switch is turned from the ON position solenoid (terminal C related to the holding coil)
to the OFF position, the signal instructing the MC that located on the injection pump is de-energized
the key switch is ON is cut off. causing the engine to stop for lack of fuel supply.
Then, the MC moves the EC motor to the slow idle
position. At the same time, the Synchro-Start

Key Switch
B G1 G2 ACC M ST
H 3
OFF Timer
ACC
ON
85 86 87
ST
1 2 3 4 5 6 Solenoid Relay
g

Diode 10 e to Terminal 30
Batteries Safety Relay
Diode 2 (R2)
B
- + - +
G
Battery
Relay
3 4
30 86 Fuse
10A
5A

Anti Load Box

Fuse 80A Dump Relay
(R3)
86
87a 87 85
POWER ON

Engine Stop
Relay (R18)

85 87a
87
86 87 87a
C B
Alternator
Relay (R1)

85 30

Alternator
42 8 B1 B7 A17 Diode 11
B+ D+
Key on Signal
Diode 3
W
Monitor
MC A Solenoid
(Synchro-start)
R
—
B-

SM0129
T2-3-12

ELECTRICAL SYSTEM

ENGINE EMERGENCY STOP

If the engine oil pressure drops while the engine is turn, de-energizes the Synchro-Start solenoid and
running, the engine oil pressure switch is actuated therefore the engine will stop for lack of fuel supply.
and sends a signal to monitor (terminal 10) and MC
(terminal B3). NOTE - With Alternator indicator light and engine oil
The engine oil low pressure indicator light on monitor low pressure indicator light turned ON, the Main
and buzzer will turn on. The MC operates (through Controller (MC) will not operate the engine stop relay
the terminal A17) the engine stop relay (R18) that, in (R18) and therefore the engine stop will not happen.

Key Switch
B G1 G2 ACC M ST
H 3
OFF
Timer
ACC
ON
85 86 87
START
1 2 3 4 5 6
Solenoid Relay
g

Diode 10 e to Terminal 30
Batteries Diode 2 Safety Relay (R2)
B
- + - +
G
Battery
Relay
3 4
30 86
Fuse Box
10A
5A

Anti Load Dump

Relay (R3)
Fuse
80A 86 30
POWER ON

87 87 85
Engine Stop
Relay (R18)
to Alternator
85 87a
87

C B

18 10 B3 B7 A17 Diode 11
Monitor
Engine Oil Key on Signal
Pressure Diode 3
Switch
MC A Solenoid
(Synchro-Start)
Engine oil Low
Pressure
Indicator

SM0130
SECTION 3 EX215

COMPONENT OPERATION

CONTENTS

Group 1 - Pump device Group 5 - Travel device

Outline ................................................. T3-1-1 Outline ................................................. T3-5-1

Main pump .......................................... T3-1-2 Travel reduction gear .......................... T3-5-2
Regulator ............................................. T3-1-5 Travel motor ........................................ T3-5-3
Pilot pump ........................................... T3-1-13 Travel brake valve ............................... T3-5-7
N sensor (Engine speed sensor) ......... T3-1-13 Parking brake ...................................... T3-5-9
Pump pressure sensor ........................ T3-1-13

Group 2 - Swing device Group 6 - Others components

(Upperstructure)
Outline ................................................. T3-2-1
Swing motor ........................................ T3-2-2 Pilot shut-off valve ............................... T3-6-1
Brake valve ......................................... T3-2-4 Shockless valve .................................. T3-6-2
Swing parking brake ............................ T3-2-6 Solenoid valve unit .............................. T3-6-4
Swing reduction gear........................... T3-2-7 Pilot relief valve ................................... T3-6-6
EC motor ............................................. T3-6-6

Group 3 - Control valve

Outline ................................................. T3-3-1 Group 7 - Others components

Hydraulic circuit ................................... T3-3-6 (Undercarriage)
Flow combiner valve ............................ T3-3-8
Swing bearing ..................................... T3-7-1
Pump control valve .............................. T3-3-10
Center joint .......................................... T3-7-2
Main relief valve .................................. T3-3-12
Track adjuster ...................................... T3-7-3
Overload relief valve ............................ T3-3-13
Arm regenerative valve ....................... T3-3-14
Boom anti-drift valve,
arm anti-drift valve ............................... T3-3-16
Bucket flow control valve ..................... T3-3-16
Travel flow control valve ...................... T3-3-18
Travel/boom lower
selector valve ...................................... T3-3-18
Boom regenerative valve ..................... T3-3-20

Group 4 - Pilot valve

Outline ................................................. T3-4-1

Operation ............................................ T3-4-3
 T3-1-1

PUMP DEVICE

OUTLINE

The pump device consists of a transmission, main bent-axis plunger-type pumps equipped with pump
pump, and pilot pump. The transmission receives delivery pressure sensors (5) and engine speed
engine power via coupling, then divides and trans- sensor (4) for controlling of the pumps and valves.
mits the power to pump 1 (1), pump 2 (2) and pilot These main pumps are incorporated into a single
pump (3) via gears. Gear ratios on the main pump housing.
drive side and the pilot pump side are 1. Pilot pump (3) is a gear-type pump.
Main pumps (1 and 2) are variable displacement,

3 2 1 Transmission
SM0002

5 SM0001 SM0003

1 - Pump 1 4 - Engine Speed Sensor (N Sensor)

2 - Pump 2 5 - Pump Delivery Pressure Sensor
3 - Pilot Pump
T3-1-2

PUMP DEVICE

MAIN PUMP

Operation

Main pump consists of pump 1 and pump 2, and Therefore, the rotation of shaft (3) is transmitted to
supplies hydraulic oil to actuate main components cylinder block (6), causing cylinder block (6) to slide
such as motors and/or cylinders. along the surface of valve plate (5). Plungers (4)
Shaft (3) is connected to cylinder block (6) via seven reciprocate in the cylinder bores, thus discharging
plungers (4). hydraulic oil to the hydraulic circuits.

SM0005

6 2
3

4
5

SM0004 SM0006

1 - Regulator 4 - Plunger
2 - Housing 5 - Valve Plate
3 - Shaft 6 - Cylinder Block
 T3-1-3

PUMP DEVICE

SM0007
T3-1-4

PUMP DEVICE

Increasing and Decreasing Main Pump Oil Flow

Rate

When the displacement angle of cylinder block (3) is When servo piston (6) is moved up or down, valve
changed, the stroke length of plunger (2) changes. plate (4) moves too, changing the displacement an-
Thus, oil flow rate of the main pump is controlled by gle of cylinder block (3); cylinder block (3) is kept in
changing the displacement angle of cylinder block contact with the surface of valve plate (4) and slides
(3). Servo piston (6) is jointed to valve plate (4) with along it.
pin (5).

Maximum displacement angle

2 3

2
6 4
3
SM0008 SM0006

Minimum displacement angle

SM0009

2 - Plunger 5 - Pin
3 - Cylinder Block 6 - Servo Piston
4 - Valve Plate
 T3-1-5

PUMP DEVICE

REGULATOR

Regulator Construction

Both main pumps (1 and 2) are equipped with a pump pressure and the pilot pressure from the sole-
regulator. Upon receiving various signal pressures, noid valve unit (SD) are routed to the section 2 of the
the regulator controls main pump oil flow rate not to regulator. (Note that, viewed from a regulator, two
exceed the engine horsepower. main pumps are said to be the applicable main pump
Regulator mainly consists of spring (1), sleeve B (2), and the other main pump). Upon receiving various
spool B (3), piston (4), load piston (5), spool A (6), signal pressures stated above, the regulator outputs
sleeve A (7), outer spring (8), and inner spring (9). a pilot pressure to servo piston (10) to change the
The pump control pressure is routed to section 1 and displacement angle of cylinder block (11), thus con-
the applicable main pump pressure, the other main trolling the pump oil flow rate.

1 2 3 4

} Section I

} Section II

5 6 7 8 9

SM0010

12
11

10

SM0006

1 - Spring 5 - Load Piston 9 - Inner Spring

2 - Sleeve B 6 - Spool A 10 - Servo Piston
3 - Spool B 7 - Sleeve A 11 - Cylinder Block
4 - Piston 8 - Outer Spring 12 - Link
T3-1-6

PUMP DEVICE

Regulator Functions

The regulator functions to control pump oil flow rate

as follows:

• Control by Pump Control Pressure Q

The pump control valve attached on the control
Flow rate
valve regulates the pump control pressure. Upon
receiving the pump control pressure from the pump
control valve, the regulator increases or decreases
the pump flow rate accordingly.
When the control valve spool is moved to increase
the pump control pressure, the regulator increases
the pump flow rate. When the control valve spool is
returned to neutral, the pump control pressure
decreases. 0 Pump control pressure Pi
Accordingly, the regulator reduces the pump flow
rate to the minimum flow. (Refer to the Control
Valve Group).

• Summation Control (Control by monitoring both

Pressure increase
main pump pressures)
If the delivery oil pressure of either of two main Q
pumps increases so that the average pressure of Flow rate
Flow rate decrease
two main pumps exceeds the values set by the
P-Q line, the regulator functions to reduce pump oil
flow rate of both main pumps to match the P-Q
value to the one on the set P-Q line, preventing
engine overloading. Since the P-Q line is set using
the average pressure of two main pump pressures,
delivery rates of both pumps are approximately
equal to each other. For this reason, a larger load
0 Pressure P
is applied to the pump delivering high pressure oil
while a smaller load is applied to the pump deliver-
ing low pressure oil, keeping the total load applied
to the pumps equal with the engine horsepower
output. (Total Horse Power Control)

Q
• Control by Pilot Pressure Guided from Solenoid
Flow rate
Valve Unit (SD) Processing the target engine
speed, and the actual engine speed, the main
controller MC sends signal to solenoid valve unit
(SD). Solenoid valve unit, in turn, routes a pilot
pressure to the regulator. Then, the regulator re-
duces pump delivery rate accordingly. (Speed
Sensing (Horsepower Reducing) Control) (Refer to
the control system Group in the SYSTEM Section).
0 Pressure P

SM0011
 T3-1-7

PUMP DEVICE

Regulator operation

3 6 2 1

Pi

12

10

Pps
11
9 13
Pd1 Pd2

5
SM0012
7 4

3 2 6 1

Pi

Pd1

11-12
Pps

Pd2

5
9 13
10

7 4 8 SM0013

1 - Piston 8 - Small Chamber

2 - Spool B 9 - Load Piston
3 - Spring 10 - Spool A
4 - Servo Piston 11 - Inner Spring
5 - Link 12 - Outer Spring
6 - Sleeve B 13 - Sleeve A
7 - Large Chamber
T3-1-8

PUMP DEVICE

• Flow Rate Control by Pump Control Pressure

Flow rate increase:

1. Pump control pressure Pi increases when a con- changed by the movement of the servo piston,
trol valve spool is moved. increasing the pump flow rate.
2. Piston (1) pushes spool B (2) and spring (3) to 6. The movement of servo piston (4) is transmitted to
move spool B (2) to the direction indicated by the sleeve B (6) via link (5), moving sleeve B (6) in the
arrow. direction that spool B (2) has moved. When sleeve
3. Large chamber (7) at the end of servo piston (4) is B (6) moves for the same distance spool B (2) has
connected to the hydraulic oil tank line. moved, large chamber (7) is closed to the hydrau-
4. As a result, servo piston (4) moves to the direction lic oil tank line, stopping the servo piston move-
indicated by the arrow. ment, thus stopping the increase of pump flow
5. The displacement angle of the cylinder block is rate at that point.

3 6 2 1

Pi Pressure increase

Pps

Q
Pd1 Pd2
Flow rate

0 Pump control pressure Pi

5
SM0014
7 4
SM0015

1- Piston 5- Link
2- Spool B 6- Sleeve B
3- Spring 7- Large Chamber
4- Servo Piston 8- Small Chamber
 T3-1-9

PUMP DEVICE

Flow rate decrease:

1. When the control valve spool is returned to neu- 5. The displacement angle of the pump decreases.
tral, the pump control pressure Pi decreases. 6. The movement of servo piston (4) is transmitted to
2. Spring (3) pushes back piston (1) and spool B (2), sleeve B (6) via link (5), moving sleeve B (6) in the
returning spool B (2) to the direction indicated by direction that spool B (2) has moved. When sleeve
the arrow. B (6) moves for the same distance spool B (2) has
3. As a result, the servo pressure acting on small moved, large chamber (7) is closed to the hydrau-
chamber (8) is also routed to large chamber (7). lic oil tank line, stopping the servo piston move-
4. Servo piston (4) moves in the direction indicated ment, thus stopping the decrease of pump flow
by the arrow, due to the size difference of the rate at that point.
pressure receiving area between both chambers.

3 6 2 1

Pi Pressure increase

Pps

Q
Pd1 Pd2
Flow rate

0 Pump control pressure Pi

5
SM0016
7 4
SM0017

1- Piston 5- Link
2- Spool B 6- Sleeve B
3- Spring 7- Large Chamber
4- Servo Piston 8- Small Chamber
T3-1-10

PUMP DEVICE

• Summation Control (Flow Rate Control by Monitor-

ing Both Main Pump Pressures)

Flow Rate Increase:

(Note that, viewed from a regulator, two main pumps indicated by the arrow.
are said to be the applicable main pump and the other 5. As the servo piston moves, the displacement
main pump) angle of the cylinder block changes, increasing
the pump flow rate.
1. The pressure from the applicable main pump 6. The movement of servo piston (4) is transmitted to
(Pressure Pd1) or from the other main pump sleeve A (13) via link (5), moving sleeve A (13) in
(Pressure Pd2) decreases. the direction spool A (10) has moved. When
2. Inner spring (11) and outer spring (12) pushes sleeve A (13) moves for the same distance spool
load piston (9) and spool A (10), moving them in A (10) has moved, large chamber (7) is closed to
the direction indicated by the arrow. the hydraulic oil tank line, stopping the servo
3. Large chamber (7) at the end of servo piston (4) is piston movement, thus stopping the increase of
connected to the hydraulic oil tank line. pump flow rate at that point.
4. As a result, servo piston (4) moves in the direction

9 13 10

Pi

11

Pps
Q
12
Flow rate Pd1 Pd2
Pressure decrease

0 (Summation of two main Pd

pump pressures)

5
SM0018

7 4
SM0015

4 - Servo Piston 10 - Spool A

5 - Link 11 - Inner Spring
7 - Large Chamber 12 - Outer Spring
8 - Small Chamber 13 - Sleeve A
9 - Load Piston
 T3-1-11

PUMP DEVICE

Flow rate decrease:

1. The pressure from the applicable main pump by the arrow, due to the size difference of the
(Pressure Pd1) or from the other main pump pressure receiving area between both chambers.
(Pressure Pd2) increases. 5. The displacement angle of the pump decreases.
2. Load piston (9) pushes spool A (10), inner spring 6. When sleeve A (13) moves for the same distance
(11), and outer spring (12), moving spool A (10) in spool A (10) has moved, servo pressure routed to
the direction indicated by the arrow. large chamber (7) is shut out, stopping the servo
3. As a result, the servo pressure acting on small piston movement, thus stopping the decrease of
chamber (8) is also routed to large chamber (7). pump flow rate at that point.
4. Servo piston (4) moves in the direction indicated

9 13 10

Pi

11

Q Pps
Flow rate 12
Pd1 Pd2
Pressure increase

0 (Summation of two main Pd

pump pressures) 5
7
SM0019

SM0020

4 - Servo Piston 10 - Spool A

5 - Link 11 - Inner Spring
7 - Large Chamber 12 - Outer Spring
8 - Small Chamber 13 - Sleeve A
9 - Load Piston
T3-1-12

PUMP DEVICE

• Flow Rate Control by Pilot Pressure Guided from

Solenoid Valve Unit (SD).

Flow rate decrease:

1. Solenoid valve unit (SD) is activated by signals chamber (8) is also routed to large chamber (7).
from the main controller MC, guiding pilot 5. Servo piston (4) moves in the direction indicated
pressure Pps. by the arrow, due to the size difference of the
2. Pilot pressure Pps, together with the applicable pressure receiving area between both chambers.
main pump pressure or with the other main pump 6. The displacement angle of the pump decreases.
pressure, acts on load piston (9). 7. When sleeve A (13) moves for the same distance
3. Load piston (9) pushes spool A (10), inner spring spool A (10) has moved, servo pressure routed to
(11), and outer spring (12), moving spool A (10) in large chamber (7) is shut out, stopping the servo
the direction indicated by the arrow. piston movement, thus stopping the decrease of
4. As a result, the servo pressure acting on small pump flow rate at that point.

9 13 10

Pi

11

Pps
Pressure increase 12
Q Pd1 Pd2
Flow rate

0 P 7
(Summation of two main
pump pressures)
4
SM0021
SM0020

4 - Servo Piston 10 - Spool A

7 - Large Chamber 11 - Inner Spring
8 - Small Chamber 12 - Outer Spring
9 - Load Piston 13 - Sleeve A
 T3-1-13

PUMP DEVICE

PILOT PUMP Suction port

2 1
Drive gear (1) is rotated via the transmission to driven
gear (2).

1 - Drive gear
2 - Driven gear

Delivery port

SM0022

N SENSOR (ENGINE SPEED SENSOR)

The N sensor detects engine speed. Engine speed is

a necessary signal for various controls of the
machine. The N sensor is installed close to the top of 3
the transmission gear; when the gear rotates, gear
tooth tops pass by the top of the N sensor. Then 4
numbers of gear teeth passing by are converted to 5
electrical pulse signals which are sent to the EC.
Thereby, engine speed is detected.

3 - Coil 6 7
4 - Magnet
5 - Gear
6 - Signal output terminal SM0023
7 - Power supply (5 V) SM0024

PUMP PRESSURE SENSOR

The pump pressure sensor detects oil pressure. Oil

pressure is a necessary signal for various controls of
the machine. Oil pressure is received by diaphragm
(11).
Depending on the extent of deformation of the
diaphragm, oil pressure is detected as an electrical
signal. 8 9 10 11

8 - Grounding terminal
9 - Output terminal
10 - Power supply (5V) terminal
11 - Pressure receiving section (diaphragm) SM0025
T3-1-14

PUMP DEVICE

NOTE
 T3-2-1

SWING DEVICE

OUTLINE

The swing device consists of the brake valve unit, the

swing motor unit, and the swing reduction gear unit.

Brake valve unit

Swing motor unit

Swing reduction gear

unit

SM0026
T3-2-2

SWING DEVICE

SWING MOTOR

The swing motor is a swash-plate-type axial plunger consisting of plates (1) and friction plates (2).
motor. Shoes (4) are caulked to each plunger (8) and nine
The major parts of the motor are: fixed-type swash plungers with shoes are provided in rotor (9).
plate (5), rotor (9), plungers (8), valve plate (3), motor Rotor (9) is installed onto shaft (7) with a spline
housing (6), and the parking brake. coupling.
The parking brake is a wet-type multiple disc brake,

9 3

1-2

4 6

5 7

SM0027

1 - Plate 6 - Motor Housing

2 - Friction Plate 7 - Shaft
3 - Valve Plate 8 - Plunger
4 - Shoe 9 - Rotor
5 - Fixed-type Swash Plate
 T3-2-3

SWING DEVICE

Swing speed varies depending on the amount of oil Turning force is transmitted to the swing reduction
delivered from the pump. From port A, high pressure gear unit via shaft (6). The return oil flows to outlet
oil is fed so that plunger (3) is pushed from the top to port B and returns to the hydraulic oil tank.
the bottom. When pressure oil is fed to port B, the motor rotates
Shoe (4) then slides along swash plate (5), in the opposite direction.
developing turning force.

SM0028

Valve Plate 4 - Shoe

1 - Rotor 5 - Swash Plate
3 - Plunger 6 - Shaft
T3-2-4

SWING DEVICE

BRAKE VALVE Relief valve

The brake valve consists of the make-up valve and

the relief valve.

Make-Up Valve
When swing is stopped, if the upperstructure tends to
keep rotating due to swing inertia force, causing the
swing motor to continue rotating further, and to begin Make-up valve
sucking oil from the pump, developing cavitation in
the motor.
The make-up valve sucks hydraulic oil through the
Port C
return circuit (port C) to compensate for the lack of oil,
and prevent cavitation.
Control valve

SM0029

Relief valve

Port C

Make-up valve

Control valve

SM0030
 T3-2-5

SWING DEVICE

Relief Valve Relief valve

When starting or stopping swing operation, oil

pressure in the swing circuit becomes high. The relief
valve prevents the circuit pressure from rising higher
than the specified pressure. Plunger (1) is pushed to
the left by pressure Pp at port (P) and pressure-
receiving area A2.
However, plunger (1) is also pushed back to the right
by spring (2) force and pressure Pg at chamber (g)
and pressure-receiving area A1.
Chamber (g) is routed to port (P) through orifice (m).
When force acting on the right is higher than that on
Port C
the left, the relief valve operates.

Control valve

SM0029

g 2 1

A1 A2

SM0031
T3-2-6

SWING DEVICE

SWING PARKING BRAKE 1

The parking brake is a wet-type multiple disc brake.

The brake is released only when brake release
pressure enters into brake piston chamber (b),
(negative type brake). When swing and/or front
attachment operation is made brake release 2
pressure is supplied from the pilot pump.
During operations other than swing and/or front, or b
while the engine is stopped, brake release pressure
is routed to the hydraulic oil tank and the parking 3
brake is automatically applied by spring (1). 4
5
• When the swing and/or front function is operated,
6
the brake is released: SM0032

When the swing and/or front control lever is

1 - Spring 4 - Friction Plate
operated, the control valve spool for swing and/or 2 - Brake Piston 5 - Motor Housing
front function is moved from the neutral position, 3 - Plate 6 - Rotor
closing the spool passage for the signal pilot
pressure circuit. Then, the pilot oil pressure
increases, and the increased pressure pilot oil is
sent to the pilot port of the switch valve in the brake When the brake is released (OFF):
release circuit. Therefore, the switch valve is Oil pressure timer
opened, allowing the brake release pilot oil
Signal pilot pressure
pressure from the pilot pump to act on brake piston circuit Brake release
pressure
(2) via the oil pressure timer check valve.
Accordingly, brake piston (2) is moved up against
OFF
spring (1), breaking contact between friction plates
(4) and plates (3). Then, the brake is released.

• When the swing and/or front function is not

Swing motor
operated, the brake is applied:
When the swing and/or front control lever is not
operated, the control valve spool for swing and/or Spool Switch valve
front function is in the neutral position, holding the
spool passage for the signal pilot pressure circuit SM0033
open. Then, the pilot oil pressure does not
increase. Therefore, the switch valve in the brake
circuit is kept closed, allowing the brake release
pilot oil pressure on brake piston (2) to flow out to
the hydraulic oil tank via the oil pressure timer
orifice. Accordingly, brake piston (2) is moved When the brake is applied (ON):
down by spring (1) force so that friction plates (4)
Oil pressure timer
come into contact with plates (3). As friction plates
(4) engage the inner circumference of motor Signal pilot pressure
circuit Brake release
housing (5) and plates (3) engage the outer pressure
circumference of rotor (6), rotor (6) is braked by
friction force developed between plates (3) and ON
friction plates (4).

Swing motor

Switch valve
Spool

SM0034
 T3-2-7

SWING DEVICE

SWING REDUCTION GEAR

The swing reduction gear is a two-stage planetary sun gear (7) via first stage planetary gear (1) and first
gear type. Ring gears (2 and 4) in the first and second stage carrier (8). Second stage sun gear (7) rotates
stages are provided on the inside of the housing. shaft (5) via second stage planetary gear (3) and
The housing is bolted to the main frame so that ring carrier (6).
gears (2 and 4) are held stationary. As shaft (5) meshes with the internal gear of the swing
The motor output shaft of the swing motor drives first bearing bolted to the undercarriage, the upperstruc-
stage sun gear (9). ture is rotated.
Then, rotary power is transmitted to second stage

9 1
8

3
7 4
6

SM0035

1 - First Stage Planetary Gear 6 - Second Stage Carrier

2 - First Stage Ring Gear 7 - Second Stage Sun Gear
3 - Second Stage Planetary Gear 8 - First Stage Carrier
4 - Second Stage Ring Gear 9 - First Stage Sun Gear
5 - Shaft (Output Shaft)
T3-2-8

SWING DEVICE

NOTE
 T3-3-1

CONTROL VALVE

OUTLINE

The control valve controls oil pressure, flow rate, and In the 4-spool side section, the Right Travel, Bucket,
flow direction in the hydraulic circuit. A 4-spool side Boom 1, and Arm 2 spool sections are arranged in
section and a 5-spool side section are bolted that order as viewed from the machine front.
together. In the 5-spool side section, the Left Travel, Auxiliary,
The control valve is a pilot-pressure-operated type Boom 2, Arm 1, and Swing spool sections are
which mainly consists of the main relief valve, pump arranged in that order as viewed from the machine
control valves, flow combiner valve, and main spools. front.

Machine Front Right travel

Bucket

Left travel Boom 1

Main relief valve

Arm 2

Auxiliary

4-spool side section

Boom 2

Arm 1

Swing

Pump control valve (5-spool side)

5-spool side section

Machine Rear

SM0036
T3-3-2

CONTROL VALVE

Control valve layout

Left travel motor Right travel motor

3 4 5 6 7 8 9 10
2
1
11
41
12
13
14
40
15
16
39
Bucket cylinder
38
37
36
Boom cylinder
35
34

Arm cylinder
17
18
33
32 19
31 20
30 21
29 22
23
26
27
24
28 25

Swing motor

SM0037

1 - Hydraulic Timer 15 - Overload Relief Valve (Bucket) 29 - Load Check Valve (Arm Tandem
2 - Travel Flow Control Valve 16 - Overload Relief Valve (Bucket) Circuit)
3 - Load Check Valve (Travel 17 - Overload Relief Valve (Boom) 30 - Check Valve
Parallel Circuit) 18 - Overload Relief Valve (Boom) 31 - Arm Regenerative Valve
4 - Check Valve 19 - Boom Anti-Drift Valve (Check 32 - Check Valve
5 - Main Relief Valve Valve) 33 - Overload Relief Valve (Arm)
6 - Check Valve 20 - Boom Anti-Drift Valve (Switch 34 - Overload Relief Valve (Arm)
7 - Check Valve Valve) 35 - Arm Anti-Drift Valve (Check
8 - Flow Combiner Valve 21 - Boom Regenerative Valve Valve)
9 - Load Check Valve (Bucket) 22 - Check Valve 36 - Arm Anti-Drift Valve (Switch
10 - Bucket Flow Control Valve 23 - Pump Control Valve (4-Spool Valve)
(Switch Valve A) Side) 37 - Load Check Valve (Boom 2
11 - Bucket Flow Control Valve 24 - Check Valve Parallel Circuit)
(Switch Valve B) 25 - Restriction (4-Spool Side 38 - Travel/Boom Lower Selector
12 - Bucket Flow Control Valve Parallel Circuit) Valve
(Poppet Valve) 26 - Load Check Valve (Arm Parallel 39 - Check Valve
13 - Load Check Valve (Boom 1 Circuit) 40 - Load Check Valve (Travel
Parallel Circuit) 27 - Restriction (Arm 1 Parallel Tandem Circuit)
14 - Load Check Valve (Boom 1 Circuit) 41 - Pump Control Valve (5-Spool
Tandem Circuit) 28 - Load Check Valve (Swing) Side)
 T3-3-3

CONTROL VALVE
Section A
H A
B 5
G C
D
E
F

41 8

SM0036 SM0038

Section C Auxiliary Bucket

15

12
39 11

Section D
9
Boom 2

16
Boom 1
Section B SM0040

L. Travel R. Travel
38 20

34 21
19
37
3
2 13

14
10
40
18

SM0039 SM0041
T3-3-4

CONTROL VALVE

Control valve layout

Left travel motor Right travel motor

3 4 5 6 7 8 9 10
2
1
11
41
12
13
14
40
15
16
39
Bucket cylinder
38
37
36
Boom cylinder
35
34

Arm cylinder
17
18
33
32 19
31 20
30 21
29 22
23
26
27
24
28 25

Swing motor SM0037

1 - Hydraulic Timer 17 - Overload Relief Valve (Boom) 31 - Arm Regenerative Valve

2 - Travel Flow Control Valve 18 - Overload Relief Valve (Boom) 32 - Check Valve
3 - Load Check Valve (Travel 19 - Boom Anti-Drift Valve (Check 33 - Overload Relief Valve (Arm)
Parallel Circuit) Valve) 34 - Overload Relief Valve (Arm)
4 - Check Valve 20 - Boom Anti-Drift Valve (Switch 35 - Arm Anti-Drift Valve (Check
5 - Main Relief Valve Valve) Valve)
6 - Check Valve 21 - Boom Regenerative Valve 36 - Arm Anti-Drift Valve (Switch
7 - Check Valve Valve)
8 - Flow Combiner Valve 22 - Check Valve 37 - Load Check Valve (Boom 2
9 - Load Check Valve (Bucket) 23 - Pump Control Valve (4-Spool Parallel Circuit)
10 - Bucket Flow Control Valve Side) 38 - Travel/Boom Lower Selector
(Switch Valve A) 24 - Check Valve Valve
11 - Bucket Flow Control Valve 25 - Restriction (4-Spool Side 39 - Check Valve
(Switch Valve B) Parallel Circuit) 40 - Load Check Valve (Travel
12 - Bucket Flow Control Valve 26 - Load Check Valve (Arm Parallel Tandem Circuit)
(Poppet Valve) Circuit) 41 - Pump Control Valve (5-Spool
13 - Load Check Valve (Boom 1 27 - Restriction (Arm 1 Parallel Side)
Parallel Circuit) Circuit)
14 - Load Check Valve (Boom 1 28 - Load Check Valve (Swing)
Tandem Circuit) 29 - Load Check Valve (Arm Tandem
15 - Overload Relief Valve (Bucket) Circuit)
16 - Overload Relief Valve (Bucket) 30 - Check Valve
 T3-3-5

CONTROL VALVE
Section E (2) Arm 1
Arm 2

31

32

Section E (1)
Section F
Arm 1 Arm 2

Swing
SM0042
36

17
35 28
24

26 25

27 23
29 22

33 SM0043 SM0045
30
Section H

Section G

6 7

SM0044 SM0046
T3-3-6

CONTROL VALVE

HYDRAULIC CIRCUIT

Main Circuit Signal Pilot Pressure Circuit

Pressure oil from pump 1 and from pump 2 is routed The pilot pressure from the pilot pump flows through
to the 4-spool side section in the control valve and to the control valve.
the 5-spool side section in the control valve, When the causes the travel signal pilot pressure
respectively. circuit to be restricted, increasing the travel signal
A parallel passage is provided in both right and left pilot pressure, thus turning on the pressure switch
main circuits, making combined operations possible. (travel) and shifting the travel/boom lower selector
The main circuit pressure is restricted by the main valve.
relief valve. Moreover, two overload relief valves are When a control lever other than the travel levers is
provided in each of boom, arm, and bucket circuits. operated, the signal pilot pressure in the front att.
Also, a pump control valve is provided at the most signal pilot pressure circuit increases, thus turning on
downstream position of each of right and left neutral the pressure switch (front) and shifting the flow
passages. combiner valve, travel flow control valve, and swing
parking brake shift valve.

Flow combiner valve

Swing parking brake Pressure switch Pressure switch
shift valve (Front) (Travel)
Neutral passage
Main relief valve

Signal pilot pressure

circuit

Left travel motor

Pump control valve
(5-spool side)
Right travel motor
Auxiliary

Overload relief valves

Travel flow control Bucket
valve

Travel/Boom lower
selector valve

Boom
Arm
Overload relief valves
Overload relief valves

Parallel Pump control valve

passages (4-spool side)
Swing

Main circuits
Neutral passage

5-spool side 4-spool side

Pilot pump
Pump 2 Pump 1

SM0047
 T3-3-7

CONTROL VALVE

Pilot Valve Guided Pilot Pressure Circuit

Pilot pressure via the pilot valve exerts on the control • When the boom lower lever is operated, the pilot
valve spools, shifting them. At the same time, it also pressure exerts on the boom anti-drift valve (switch
exerts on switch valves. (Arm anti-drift valve, Boom valve), shifting it.
anti-drift valve, Bucket flow control valve)
Besides shifting of control valve spools (when control In addition, an air bleed circuit is provided in the top
levers are operated), the pilot valve guided pilot part of the control valve, automatically bleeding air
pressure functions as follows: trapped in the circuit.
• When the arm roll-in lever is operated, the pilot
pressure via the pilot valve exerts on the bucket
flow control valve and the anti-drift valve (switch Solenoid Valve Guided Pilot Pressure Circuit
valve), shifting them. The pilot pressure guided via the solenoid valve unit
• When the boom raise lever is operated, the pilot (SG and SC) shifts the main relief valve and the arm
pressure exerts on the bucket flow control valve as regenerative valve. (Refer to the Control System
the valve shift pressure. Group in the SYSTEM Section).

Main relief valve

From the solenoid valve unit (SG)
Bucket flow control valve

1 2 11 12
8
5
3 4 13 14

Arm anti-drift valve 5

5

Arm regenerative valve

7 8
From the solenoid valve 8 7 Boom anti-drift valve
unit (SC)

Air bleed circuit

9 10

Pump 2 Pump 1

SM0048

1 - Left Travel Forward 6 - Boom Lower 11 - Right Travel Reverse

2 - Left Travel Reverse 7 - Arm Roll-out 12 - Right Travel Forward
3 - Auxiliary 8 - Arm Roll-in 13 - Bucket Roll-in
4 - Auxiliary 9 - Swing Left 14 - Bucket Roll-out
5 - Boom Raise 10 - Swing Right
T3-3-8

CONTROL VALVE

FLOW COMBINER VALVE

When a control lever other than the travel levers is the pilot pressure to shift the flow combiner valve.
operated, the signal movement of the control valve As a result, the pressure oil from the pump 1 is routed
spool restricts the signal pilot pressure in the front to both right and left travel spools, securing straight
attachment signal pilot pressure circuit, increasing travel in travel combined operations.
 T3-3-9

CONTROL VALVE

Front attachment signal

pilot pressure circuit
Left travel motor Flow combiner valve Right travel motor

Pilot pump

Arm cylinder

Pump 2 Pump 1

SM0049
T3-3-10

CONTROL VALVE

PUMP CONTROL VALVE

A pump control valve is provided on the most In addition, the pump control pressure sensor detects
downstream part of the neutral passage in each of the the pump control pressure, sending signals to MC for
4-spool and 5-spool side sections. travel motor displacement angle control. (Refer to the
The pump control pressure altered by the pump Control System Group in the SYSTEM Section).
control valve exerts on the regulator, changing the
pump displacement angle. (Refer to the Pump
Device Group in this section).

Pump control valve

(5-spool side)
To the pump 2 regulator and
to pump control pressure sensor Neutral passage

Pump control valve

(4-spool side)

To the pump 1 regulator and

to the pump control pressure sensor

4-spool side
5-spool side

Neutral passage

SM0050
 T3-3-11

CONTROL VALVE

Operation with Control Valve Spool Activated

When a control valve spool is shifted, oil flowing raising the pump control pressure.
through the neutral passage and through the pump This increased pump control pressure exerts on the
control valve decreases. regulator and, in return, the regulator increases the
As oil flowing through the pump control valve pump displacement angle, increasing the pump
decreases, the pump control valve spool shifts to the delivery oil flow.
left, increasing the relief valve set pressure, thus

From the pilot pump

Pump control pressure passage

Pump control Hydraulic oil tank

pressure sensor

Pressure
increase
Pump control valve

To the regulator
Neutral passage

Small oil flow

SM0051

Operation with Control Valve Spools in Neutral

Position
When control valve spools are returned to the neutral As the pump control pressure decreases to a
position, the neutral passage is fully opened and all minimum, the regulator decreases the pump
pump oil flow goes through the neutral passage and displacement angle to have the minimum pump
the pump control valve so that the pump control valve delivery flow, contributing to fuel efficiency.
spool moves to the right, decreasing the relief valve
set pressure so as to have the lowest pump control
pressure.

From the pilot pump

Pump control pressure passage

Pump control Hydraulic oil tank

pressure sensor

Pressure
Decrease
Pump control valve

To the regulator
Neutral passage

Large oil flow

SM0052
T3-3-12

CONTROL VALVE

MAIN RELIEF VALVE

The main relief valve regulates main circuit pressure. When oil pressure at port Hp matches the spring set
The set pressure of the main relief valve is shifted by force, the pilot poppet opens. Oil at port Hp flows to
the pilot pressure guided via the solenoid valve unit port Lp through passage A.
(SG). (Refer to the Control System Group in the As the pilot poppet opens, oil pressure in spring
SYSTEM Section). chamber A decreases, opening the main poppet,
thus directly routing pressure oil at port Hp to port Lp.
Valve Operation
When the pilot pressure is not guided to the main
relief valve via the solenoid valve unit (SG):

Main poppet

Pilot poppet

Lp

Hp Port SG

Lp

Spring A Passage A

SM0053

When the pilot pressure is guided to the main relief of spring B, thus requiring higher port Hp pressure to
valve via the solenoid valve unit (SG): open the pilot poppet.
When the pilot pressure via the solenoid valve unit For this reason, the main relief valve set pressure
exerts on port (SG), the piston is pushed to the left in increases.
the set position, increasing the compressional force

Pilot poppet

Piston

Lp

Port SG
Hp

Lp

Spring B

SM0054
 T3-3-13

CONTROL VALVE

OVERLOAD RELIEF VALVE

(With Make-Up Function)

Overload relief valves are provided in each port of the force.

boom, bucket, and arm cylinders, and regulate oil Moreover, these relief valves function to suction oil
pressure in the cylinder circuits to protect them from from the return (hydraulic oil tank) line to prevent the
damage due to excessive high pressure that might occurrence of cavitation if negative oil pressure
develop if a cylinder is moved by excessive external arises in a cylinder (the make-up function).

1 2 3 4 5

10

9 8 G 7 6

SM0055

1 - Spring 6 - Adjusting Screw

2 - Plug 7 - Plug
3 - Pilot Poppet 8 - Main Poppet
4 - Spring 9 - Sleeve
5 - Spring 10 - Piston
T3-3-14

CONTROL VALVE

ARM REGENERATIVE VALVE

The arm regenerative valve is shifted by the pilot increasing the arm roll-in speed, improving the arm
pressure guided via the solenoid valve unit (SC). controllability in general, and preventing arm
When the arm regenerative valve is shifted, the movement hesitation from occurring in arm roll-in
return oil line from the cylinder rod side is closed. operations. (Refer to the Control System Group in
Then, the return oil is combined with the pump SYSTEM Section).
delivery oil to be supplied to the cylinder bottom side,

Arm cylinder

From the solenoid valve unit (SC)

Arm regenerative valve

SM0056
 T3-3-15

CONTROL VALVE

Arm regenerative
valve

Arm 1
From the solenoid valve
unit (SC)

Pump 2 Pump 1

SM0057
T3-3-16

CONTROL VALVE

BOOM ANTI-DRIFT VALVE, ARM ANTI-

DRIFT VALVE

An anti-drift valve is provided on the bottom side of When the arm roll-in or boom lower is operated, the
the boom cylinder and on the rod side of the arm pilot pressure via the pilot valve shifts the switch valve
cylinder so as to reduce cylinder drift. of the anti-drift valve. The oil pressure exerted on the
When the control valve spool is in neutral, the switch check valve is returned to the hydraulic oil tank via the
valve part of the anti-drift valve is not shifted and the restriction in the switch valve.
pressure in the boom cylinder bottom side (the arm (The check valve is designed to close by a signal
cylinder rod side) exerts on the check valve of the pressure, which arises when the switch valve is not
anti-drift valve via the switch valve, closing the check shifted, and to open when the signal pressure is not
valve. exerted (when the switch valve is shifted.)).

Boom cylinders

Boom 1
Boom lower
pilot pressure

Anti-drift valve (check valve)

Anti-drift valve (switch valve)

SM0058

BUCKET FLOW CONTROL VALVE

The bucket flow control valve restricts the bucket shifting the switch valve (B) of the bucket flow control
circuit in the combined operations of the bucket, arm valve.
roll-in, and boom raise, so as to raise the boom Thus, the back pressure exerting on the poppet valve
sufficiently. rises, applying a force to close the poppet valve, thus
When the arm is rolled in, the arm roll-in pilot pressure restricting oil flow through the poppet valve. For this
shifts switch valve (A) of the bucket flow control valve. reason, the oil flow to the bucket is restricted,
If the boom is raised at the same time, the boom raise supplying an oil flow to the higher-load-applied boom
pilot pressure is routed through the switch valve (A), raise side.

Arm roll-in pilot pressure

Poppet valve
Switch valve A

Boom raise pilot pressure

Bucket
Switch valve B

Bucket pilot pressure

Bucket cylinder

SM0059
 T3-3-17

CONTROL VALVE

Bucket flow control valve

Arm anti-drift valve

Boom anti-drift
valve

Pump 2 Pump 1

SM0048
T3-3-18

CONTROL VALVE

TRAVEL FLOW CONTROL VALVE

When the front attachment is operated while timer, so as to gradually restrict the parallel circuit.
traveling, the non-travel signal pilot pressure exerts As the parallel circuit is gradually restricted, shock
on the travel flow control valve, which is located in the loads, occurring due to the front attachment
parallel circuit, after flowing through the hydraulic operation, are reduced.

Hydraulic timer

To the travel motor

Left Non-travel signal pilot pressure

travel spool

Travel flow control valve

Non-travel spool

Travel parallel circuit SM0060

TRAVEL/BOOM LOWER SELECTOR VALVE

The boom lower operation is actuated by the oil flow To prevent this from occurring, in travel-combined
via the boom 1 section. However, in travel-combined boom lower operations, the boom 2 spool is shifted to
operations, the oil flow from pump 1 does not flow in route the oil flow from pump 2 to the boom lower
the downstream boom 1 spool as it goes to the section so that the boom lowers to sufficiently
upstream travel spool. If the boom is positioned up in perform the machine jack-up operation.
the air at the moment, the boom would be lowered by When the travel spool is shifted, the travel signal pilot
its own weight. However, if the travel-combined pressure shifts the travel/boom lower selector valve,
boom lower operation is performed with the base allowing the boom lower pilot pressure to exert on the
machine raised off the ground, the boom does not boom 2 spool. Thus, the boom lower operation is
lower. sufficiently performed in travel-combined operations.

Right travel spool

Boom 2
Boom 1

To the boom cylinder

Travel/Boom lower
selector valve

Pump 2 SM0061
 T3-3-19

CONTROL VALVE

Hydraulic timer

Travel flow
control valve Signal pilot pressure circuit

Left travel motor

Right travel motor

Bucket

Travel/Boom lower
selector valve

Boom

Parallel passages

Pilot pump

Pump 2 Pump 1

SM0047
T3-3-20

CONTROL VALVE

BOOM REGENERATIVE VALVE

In boom lower operations, the return oil from the spool.

cylinder bottom side is combined with the oil flow from By this boom regenerative valve operation, the boom
the pump, supplying an additional oil flow to the lower operation is improved and cavitation is
cylinder rod side, via the check valve in the boom prevented from occurring.

Boom regenerative
valve

Boom cylinders

Boom 1
Boom lower
pilot pressure

SM0062
 T3-4-1

PILOT VALVE

OUTLINE

The pilot valve controls pilot pressure oil to move the Except for the cam construction to push the pusher
control valve spools. There are two types of pilot down, the construction of the pilot valve in both the
valves. One is for front/swing operation; the other is front/swing pilot valve and the travel pilot valve is the
for travel operation. Both have standard four oil ports. same.
An optional two-oil-port type is available.

• Right and left pilot valves (Front/Swing)

Port No. Control

1 Bucket roll-out
Right 2 Boom lower
3 Bucket roll-in
4 Boom raise
1 Swing left
Left 2 Arm roll-in
3 Swing right
4 Arm roll-out T 3 4 P
3 4
T P

P T 2 1

SM0065

1 3 2 4

SM0063
T3-4-2

PILOT VALVE

• Travel pilot valve

Port No. Control

1 Left travel forward
2 Left travel reverse
3 Right travel reverse
T
4 Right travel forward
T

4
P T 1

2
1 2 3 4
3

SM0064 SM0066
 T3-4-3

PILOT VALVE

OPERATION

• Front and Swing Pilot Valve

The lower face of spool (8) head is suspended by the In neutral

upper face of spacer (4); they are kept in contact by (Corresponding to A to B in the output diagram):
setting force of balance spring (6). Spacer (4) is
installed between pusher (3) and spring guide (5) and When control lever (1) is in the neutral position (no
supported by return spring (7). Piston (9) is located pusher stroke), spool (8) completely blocks pressure
inside spool (8). The lower end of piston (9) makes oil from entering port P. Since the delivery port is open
contact with the plate, preventing the piston from to port T, pressure at the delivery port equals that in
moving further downward. the hydraulic oil tank.
Above piston (9), a chamber is provided and it is led When control lever (1) is slightly moved, cam (2)
to the outside of spool (8) through holes provided in moves together, pressing down on pusher (3).
spool (8). Then, pusher (3), spacer (4), and spring guide (5)
move downward as a unit, compressing return spring
(7).
The lower face of spool (8) is kept in contact with the
upper face of spacer (4) by setting force of balance
spring (6) and moves downward together with spacer
(4). However, even if control lever (1) is moved
further, until clearance (A) at section (a) reaches
zero, the delivery port remains open to port T,
keeping pressure at the delivery port equal to that in
the hydraulic oil tank.

Delivery port
pressure
(pilot pressure)
1

2
A B Pusher stroke

3 OUTPUT DIAGRAM

4
5
6

SECTION
(a)
7
(A) 8
Port T
(A)=0
Delivery port

Port P
9

SM0067

1 - Control Lever 6 - Balance Spring

2 - Cam 7 - Return Spring
3 - Pusher 8 - Spool
4 - Spacer 9 - Piston
5 - Spring Guide
T3-4-4

PILOT VALVE

Ready to start operation

(Corresponding to B to C section in the output
diagram):

When control lever (1) is tilted slightly further from the (8) moves upward against setting force of balance
position where clearance (A) in section (a) reaches spring (6).
zero, and pusher (3) is pushed downward, spool (8) Once spool (8) moves upward, upper clarance at
is moved downward, opening notched section (b) to section (a) is opened and lower notch section at
allow pressure oil at the port P to flow into the delivery section (b) is closed, leading oil pressure at the
port. delivery port to port T, and decreasing oil pressure at
This oil pressure is also led to the inside of spool (8) the delivery port.
via orifice (10), and acts to push spool (8) upward. When oil pressure at the delivery port decreases, the
Until this oil pressure force reaches the setting force force to push up spool (8) is reduced so that balance
of balance spring (6), balance spring (6) will not be spring (6) stretches to move spool (8) downward,
compressed so that spool (8) is not moved upward, closing both the clearance and the notch at sections
closing the clearance at section (a), keeping the (a and b).
notch at section (b) opened, and letting the oil Thus, original position of spool (8) is kept resumed.
pressure to increase at the delivery port. The oil pressure will continue to increase until it is
If the oil pressure at the delivery port increases, and equal to setting force of balance spring (6) (shown by
the upward-pushing force of spool (8) slightly the point C in the output diagram).
exceeds the setting force of balance spring (6), spool

Delivery port
pressure
1 (Pilot pressure)

B Pusher stroke

OUTPUT DIAGRAM
3

Section (a) 8

Port T
Clearance (A) reaches zero
Delivery port Section (b)
10
Port P

SM0068

1 - Control Lever 8 - Spool

3 - Pusher 9 - Piston
6 - Balance Spring 10 - Orifice
 T3-4-5

PILOT VALVE

Operation corresponding to the control lever stroke

(Corresponding to C to D in the output diagram):

As control lever (1) is moved further to push pusher When spool (8) moves upward until the clearance at
(3) downward, spool (8) is pushed down to open the section (a) opens, the delivery port is opened to port
notch at section (b), increasing oil pressure at the T, stopping oil pressure increase at the delivery port
delivery port. and stopping movement of spool (8).
As pressure increases, the force to push up spool (8) Accordingly, when compressed by pusher (3), spring
increases. Then, when force to push up spool (8) force of balance spring (6) increases in proportion to
exceeds the setting force of balance spring (6), spool the pusher stroke, Then, oil pressure increases to
(8) starts to move upward, compressing balance counteract against this spring force.
spring (6).

Delivery port
pressure
(Pilot pressure)
1
D

Pusher stroke

OUTPUT DIAGRAM

Section (a)
8

Port T

Delivery port
Section (b)

Port P

SM0069

1 - Control Lever 6 - Balance Spring

3 - Pusher 8 - Spool
T3-4-6

PILOT VALVE

Operation close to pusher stroke end

(Corresponding to D to E in the output diagram):

As pusher (3) is pressed down, balance spring (6) is spool (8) cannot move upward, closing the oil
compressed, reducing clearance (B) between passage from the delivery port to port T, and opening
pusher (3) and the top of spool (8) (shown at section the oil passage from the delivery port to port P.
(c)), finally to zero. Then, oil pressure at the delivery port increases until
After that, pusher (3) directly pushes spool (8). it reaches port P pressure.
Even if oil pressure at the delivery port increases,

Delivery port E
pressure
(Pilot pressure)
D

Pusher stroke

3 OUTPUT DIAGRAM

Section (c)

Clearance (B) reaches zero

6

Port T

Delivery port

Port P

SM0070

3 - Pusher 8 - Spool
6 - Balance Spring
 T3-4-7

PILOT VALVE

Full stroke operation

(Corresponding to E to F section in the output
diagram):

Even if control lever (1) is tilted further to push down (section (d)) of the casing.
pusher (3), spool (8) moves downward along with This position is the stroke end of pusher (3)
pusher (3), only widening the notch at lower section (corresponding to F position in the output diagram).
(b) of spool (8). This process corresponds with E to F section in the
Thus, oil pressure at the delivery port is kept same as output diagram.
at port P. Pusher (3) can be pressed down until spring The total stroke of the control lever is decided by
guide (5) comes into contact with the shoulder dimension C.

Delivery port E F
pressure
1 (Pilot pressure)

Pusher stroke

3 OUTPUT DIAGRAM

Section (d)

C
5

Port T

Delivery port
Section (b)
Port P

SM0071

1 - Control Lever 5 - Spring Guide

3 - Pusher 8 - Spool
T3-4-8

PILOT VALVE

• Travel Pilot Valve

In neutral Full stroke operation:

(Corresponding to A to B in the output diagram): Lever - Full Stroke (Pusher Stroke)
Lever - In Neutral (Pusher Stroke: A to B)
When the control lever is moved full stroke, pusher
In neutral, spool (6) closes port P (the input port) and (2) is moved down until spring guide (3) comes into
tank port T is connected to delivery port through contact with the shoulder of the valve casing (Lever
clearance (A). Thus, the pressure at delivery port is Stroke End), opening notch (B) further to port P.
the same as that at tank port T. The output pressure (pilot pressure to the control
When the control lever is moved slightly from A to B, valve) remains at the pilot system pressure (the port
pusher (2) and spring guide (3) together move down P pressure).
against return spring (5) and balance spring (4). At Dimension (C) in the figure right shows the control
this time, as both oil pressures above and below lever full stroke.
spool (6) are the same as the tank pressure, spool (6)
moves down together with spring guide (3) until
clearance (A) becomes zero.

Delivery port
Operation corresponding to the control lever stroke pressure
(Corresponding to C to D in the output diagram): (Pilot pressure)
Lever - Operated D
(Pusher Stroke: C to D — Metering)

When the control lever is moved further to push

pusher (2) down, port P is connected to delivery port C
through notch (B) and passage in spool (6), routing
pilot pump pressure. However, when the pressure
applied into spool (6) overcomes the balance spring A B Pusher stroke
force, spool (6) moves up, closing port P. When
pusher (2) is moved further down, compressing
return spring (5) and balance spring (4), the larger the
balance spring force; thus, the output pressure OUTPUT DIAGRAM
increases in proportion to the increase in the balance
spring force.
SM0072
 T3-4-9

PILOT VALVE

Pusher stroke: A to B

4
5
Port T
(A) Clearance A: 0

Port P

Delivery port

SM0073 SM0075

Pusher stroke: C to D Pusher stroke: full stroke

2
2

(C)
4

5
3
Port T Port T
(B)

Port P 6 Port P

Delivery port Delivery port

SM0074 SM0076

1 - Cam 4 - Balance Spring

2 - Pusher 5 - Return Spring
3 - Spring Guide 6 - Spool
T3-4-10

PILOT VALVE

NOTE
 T3-5-1

TRAVEL DEVICE

OUTLINE

The travel device consists of travel motor (14),

planetary reduction gears (1) to (12), and sprocket
(13).

8
2

1
9

10

11
12

13

14

SM0077

1 - Third Stage Carrier 8 - Ring Gear

2 - Third Stage Sun Gear 9 - First Stage Planetary Gear
3 - Second Stage Planetary Gear 10 - Third Stage Planetary Gear
4 - Second Stage Carrier 11 - Drum
5 - Second Stage Sun Gear 12 - Hub
6 - First Stage Carrier 13 - Sprocket
7 - Propel Shaft 14 - Travel Motor
T3-5-2

TRAVEL DEVICE

TRAVEL REDUCTION GEAR

The travel reduction gear is a third stage planetary second stage carrier (4), third stage sun gear (3), and
gear type. The travel motor rotates propel shaft (7) third stage planetary gear (10).
and this driving force is transmitted to third stage Third stage carrier (2) is held stationary by housing
planetary carrier (2) and ring gear (1) via first stage (13) of the travel motor and hub (12).
planetary gear (8), first stage carrier (6), second As ring gear (1) and sprocket (11) are bolted to drum
stage sun gear (5), second stage planetary gear (9), (14), they all rotate together.

1 2

1 2 3 4 5 9 6

13

7
10
13 9
12
12 8
14
Third Second First
stage stage stage
11 10
11

SM0078

1 - Ring Gear 8 - First Stage Planetary Gear

2 - Third Stage Carrier 9 - Second Stage Planetary Gear
3 - Third Stage Sun Gear 10 - Third Stage Planetary Gear
4 - Second Stage Carrier 11 - Sprocket
5 - Second Stage Sun Gear 12 - Hub
6 - First Stage Carrier 13 - Housing (Travel Motor)
7 - Propel Shaft 14 - Drum
 T3-5-3

TRAVEL DEVICE

TRAVEL MOTOR

This travel motor is a variable-displacement bent- friction plates (11), and plates (10).
axis axial-plunger type that includes a parking brake Rotor (14) is pre-loaded against valve plate (2) by
(wet-multi-disc negative type). spring (4). As oil pressure in the rotor bores
The main parts of the motor are plate (1), valve plate increases, the pressure acts on end faces (A) of the
(2), rotor (14), plungers (13), center shaft (5), drive rotor bores and assists spring (4) to force rotor (14)
disc (7), servo piston (16), parking brake piston (12), against valve plate (2).

1 2 3 4
5
6

16
10
11
12
15

14
A
13

SM0079

1 - Plate 9 - Roller Bearing

2 - Valve Plate 10 - Plate
3 - Disc Spring 11 - Friction Plate
4 - Spring 12 - Brake Piston
5 - Center Shaft 13 - Plunger
6 - Housing 14 - Rotor
7 - Drive Disc 15 - Link
8 - Roller Bearing 16 - Servo Piston
T3-5-4

TRAVEL DEVICE

Pressure oil supplied to port AM of the valve plate (1) (2) also rotates.
flows into the rotor bores (2) underneath port AM, When the plungers (3) moves to port BM side, oil is
pushing the plungers (3). The vertical component routed to the hydraulic oil tank.
force (FV) of plunger pushing force (F) rotates the Whether pressure oil from the pump is supplied to
drive disc (4). As the drive disc (4) rotates, the rotor port AM or BM determines travel direction.

3
BM 4

AM

FR

FV

SM0080

1 - Valve plate 3 - Plunger

2 - Rotor 4 - Drive disc
 T3-5-5

TRAVEL DEVICE

Travel Speed Selection

Servo piston (1) is interconnected to valve plate (6)

via link (5) so that when servo piston (1) is moved,
swash angle of rotor (7) is shifted through valve plate
(6), leading to travel speed change.

• Slow speed

When the slow speed travel mode is selected, the Since the pressure-receiving area in chamber “C”
MC (Main Controller) does not send out an is larger than that in chamber “B”, servo piston (1)
electronic control signal to the solenoid valve unit moves upward, increasing swash angle to the
(SI). maximum.
Therefore, speed change pilot pressure is not Accordingly, as the stroke of the plungers in the
routed to servo piston (1). Thus, spool (3) is held motor is increased, slower revolution of the travel
down by spring (2). Then, pressure oil P from the motor for low speed mode is obtained.
motor port is led to both chambers “B” and “C”.

7 1

Drain

P B

5
4 Pilot pressure

SM0081

1 - Servo Piston 5 - Link

2 - Spring 6 - Valve Plate
3 - Spool 7 - Rotor
4 - Orifice
T3-5-6

TRAVEL DEVICE

• Fast speed travel mode

When the fast speed travel mode is selected, chamber “B”, servo piston (1) is moved down,
corresponding to travel loads, the MC sends out an reducing the swash angle of rotor (7).
electronic control signal to the solenoid valve unit Accordingly, as the stroke of the plungers in the
(SI). Therefore, speed change pilot pressure is motor is decreased, faster revolution of the travel
routed to chamber “D”, moving spool (3) upward. motor for fast speed mode is obtained.
Then, passage “E” opens and oil in chamber “C” is (Refer to the Control System Group in the SYSTEM
drained through the inner passages in spool (3). Section).
As pressure oil P from the motor port is led to

1
6

7 2
Drain

B
3

E
5
Pilot pressure
4 Drain
P

Position of servo piston at initial

stage of fast speed travel operation:

Pilot pressure

Position of servo piston during

stage of fast speed travel operation

SM0082

1 - Servo Piston 5 - Link

2 - Spring 6 - Valve Plate
3 - Spool 7 - Rotor
4 - Orifice
 T3-5-7

TRAVEL DEVICE

TRAVEL BRAKE VALVE

The travel brake valve is located on the travel motor

head and consists of the following valves.

- Check Valve (1): - Overload Relief Valve (4):

Ensures smooth starts and stops, and prevents Prevents overloads and surge pressure in the
cavitation from occurring in the motor circuit by motor circuit.
functioning together with counterbalance valve (5).
- Counterbalance Valve (5):
- Reducing Valve (2): Ensures smooth starts and stops and prevents
Reduces parking brake release pressure and overrunning when traveling down slopes.
prevents sudden operation of the brake.
- Servo-Piston Operating Shuttle Valve (6):
- Parking Brake Release Shuttle Valve (3): Leads divided hydraulic oil flow for travel motor
Leads travel motor drive pressure to the parking operation to the servo-piston.
brake.

Section B-B

1
3
1
A 2

4 B
AM BM

AV BV C

Section A-A
A

Section C-C
6
SM0083

1 - Check Valve 4 - Overload Relief Valve

2 - Reducing Valve 5 - Counterbalance Valve
3 - Parking Brake Release Shuttle Valve 6 - Servo-Piston Operating Shuttle Valve
T3-5-8

TRAVEL DEVICE

Travel Operation motors are forcibly driven by the machine weight so

that the motor draws oil like a pump. When the motor
When supply oil from the control valve is routed to draws oil, oil pressure at port BV and chamber “G”
port BV, supply oil flows around spool CB, opens decreases, causing spool CB (7) to move to the right.
check valve BC (9) and is led to motor port BM. Then, the return oil flow from the motor is restricted by
However, return oil from motor port AM is blocked by the spool, increasing pressure at port AM.
check valve AC (8) and spool CB (7). The increased pressure at port AM brakes the motor.
As supply oil pressure at port BV increases, supply oil Thus, the restricted return oil flow increases the
is routed to chamber “G” through orifice “F” in spool pressure at port BV again, moving spool CB (7) back
CB (7), moving spool CB (7) to the left against spring to the left. This repeat movement of the spool
force. (hydraulic brake action) prevents the machine from
Consequently, return oil from motor port AM starts to overrunning.
flow into port AV through notch “H” in spool CB (7),
allowing the travel motor to rotate.
When the travel levers are returned to the neutral Circuit Protectors
position, the oil in both ports AV and BV are routed to
the hydraulic oil tank through the control valve. Thus, If pressure in the circuit increases over the setting
oil pressure in chamber “G” decreases, and spool CB pressure of the overload relief valve (4), this valve
(7) is moved back to the original position by spring opens to relieve peak pressure to the lower pressure
force. Then, the oil flow circuit is blocked, causing the side to protect the motor from overloading. This valve
travel motors to stop rotating. also functions to release shock pressure caused by
inertia force developing when the motor stops.
When the motor draws oil because of pumping
Descending Operation operation, check valve BC (9) opens to make up
vacuum, so that cavitation will not develop in the
When the machine travels down a slope, the travel circuit.

7
4

9
8
AM BM

AV BV

H G F
SM0084

4 - Overload relief valve 8 - Check valve AC

7 - Spool CB 9 - Check valve BC
 T3-5-9

TRAVEL DEVICE

PARKING BRAKE

When the brake is applied: When the brake is released:

1 3
K
2 4

M
5

SM0085

1 - Disc Spring 4 - Plate

2 - Piston 5 - Housing
3 - Friction Plate 6 - Drive Disc
T3-5-10

TRAVEL DEVICE

The parking brake is a negative-type brake released chamber “G” located at the end of spool CB (9).
when oil pressure “K” is applied to parking brake Parking brake release pressure is blocked by spool
chamber “M”. Whenever the travel control valve CB (9). When pressure increases, spool CB (9)
spools are in neutral, the parking brake is moves to the right. Pressurized oil flows to reducing
automatically applied. valve (7) via the orifice “I” of spool CB (9), then flows
Friction plates (3) are connected to drive disc (6), and to parking brake chamber “M” to release the travel
plates (4) to motor housing (5) via spline coupling parking brake.
respectively. When disc spring (1) pushes piston (2)
to the right, friction plates (3) come into contact with When the machine is not traveling:
plates (4), applying the parking brake. Pressure oil from the travel motor is not routed
through shuttle valve (8), and parking brake chamber
Starting to travel: “M” is led to the drain circuit through reducing valve
When travel lever is pulled reverse, pressurized oil (7). Piston (2) is gradually forced to the right by disc
from the pump flows to port AM via the control valve. spring (1), making friction plates (3) come into contact
The pressurized oil flows to the travel motor and with plates (4).

Drain

AM
BM

G I 8 9

SM0086

7 - Reducing valve 9 - Spool CB

8 - Shuttle valve
 T3-6-1

OTHERS COMPONENTS (Upperstructure)

PILOT SHUT-OFF VALVE To pilot valve

The pilot shut-off valve is a manual-operated switch

valve. The spool in the pilot shut-off valve is rotated To hydrayulic
by moving the pilot control shut-off lever to turn on or oil tank
off the pilot oil flow to the pilot valves.
From pilot
pump

To shockless valve From pilot valve

SM0087

• Valve Operation with Pilot Control Shut-Off From pilot valve

Lever in LOCK Position
The pilot shut-off valve is set in the neutral position.
Pressure oil from the pilot pump does not flow into
the pilot valves, but it is routed to the shockless
To shockless valve
valve. Pilot oil on the pilot valve side is routed to the
hydraulic tank as drain passages in the pilot shut-
off valve open.

To hydraulic From pilot

oil tank pump

SM0088

To pilot valve
• Valve Operation with Pilot Control Shut-Off
Lever in UNLOCK Position
The pilot shut-off valve is set in the operating
position, allowing pressure oil from the pilot pump
to flow into the pilot valves. The pilot pressure can
be and will be routed to the control valve to operate
the respective hydraulic cylinders and/or motors as
the pilot valves are operated, in other words, as the
control levers are operated.

From pilot pump

SM0089
T3-6-2

OTHERS COMPONENTS (Upperstructure)

SHOCKLESS VALVE 1 2

Check valves, pilot pressure sensor (for arm roll in),

and pilot pressure switch (for boom raise) are built
into the shockless valve block in addition to the
shockless valves.
The shockless valves regulate secondary pilot
pressure (pilot pressure between the pilot valves and
6
the control valve spools) for the arm roll-out and for
boom raise functions, preventing abrupt and rapid 5
movement of the respective control valve spools.

4 3
SM0090

7
• When the arm roll out or the boom raise is operated,
secondary pilot pressure from the pilot valve is
routed to the side B of the shockless valve. To control A B From pilot
Immediately after operating the control lever, the valve spool valve
secondary pilot pressure routed to the side B flows
to the control valve spool via orifice (9). As the
secondary pilot pressure increases, check valve 9 8
(7) opens.
SM0091

• Return oil from the control valve spool flows back to

the hydraulic oil tank via orifice (9). As the pressure
at the side A increases, spool (8) moves in
To hydraulic
proportion to the pressure increase, regulating the oil tank via
return oil flow. From control A B pilot valve
valve spool

9 8

SM0092

1 - Shockless Valve
2 - Pilot Pressure Switch (Boom Raise)
3 - Check Valve
4 - Check Valve
5 - Shockless Valve
6 - Pilot Pressure Sensor (Arm Roll In)
7 - Check Valve
8 - Spool
9 - Orifice
 T3-6-3

OTHERS COMPONENTS (Upperstructure)

Warm-up circuit

When the pilot shut-off valve is in the LOCK position, For this reason, the pilot circuit is warmed as this
pilot oil via the pilot shut-off valve flows into the heated oil flows into the shockless valve and into the
shockless valve. The oil is heated as it flows through pilot valves.
the restriction located at the inlet of the shockless
valve.

To pilot valve To control valve

To pilot valve To control valve

To pilot valve To control valve

To pilot valve To control valve

Shockless valve

Pilot shut-off valve

From pilot pump

SM0093
T3-6-4

OTHERS COMPONENTS (Upperstructure)

SOLENOID VALVE UNIT

Front
The solenoid valve unit functions to control the pump
regulator, control valve and travel motor servo piston
upon receiving signals from the main controller MC.
The solenoid valve unit consists of four solenoid
valves (SC), (SD), (SI), and (SG). (Refer to the
Control System Group in the SYSTEM Section).

SC : Controls the arm regenerative valve located in

the control valve.

SD : Controls the pump regulator.

(Speed Sensing)
SC
SI : Controls the travel motor servo piston. SD
(Travel Speed Selection) SG

SG : Functions to increase the main relief valve

SI
pressure setting

SM0094
 T3-6-5

OTHERS COMPONENTS (Upperstructure)

Proportional Solenoid Valve

Upon receiving an electric current signal from the into output port S, increasing the pressure at output
MC, the proportional solenoid valve outputs hydraulic port S. The pressure at port S acts on the two banks
pressure proportional to the degree of the electric of walls on the spool. (See detail “a.”).
current. Because of the pressure receiving area difference
between the two walls, the pressure at port S acts
• When not energized (In neutral): as a force to push the spool to the right. As the
The spring pushes the spool to the right, pressure at port S increases, the force to push the
connecting the output port S to the tank port T. spool to the right also increases. When this force
overcomes the force to push the spool to the left by
• When energized: solenoid, the spool moves back to the right side,
The solenoid pushes the spool to the left for a closing the passage between output port S and port
distance proportional to the electric current flowing P. As a result, pressure increase at port S stops.
through the solenoid. Pilot oil from port (P) flows

Spool

S Spring

Solenoid
T P

SM0095
T3-6-6

OTHERS COMPONENTS (Upperstructure)

PILOT RELIEF VALVE

The pilot relief valve functions to regulate the pilot pump pressure oil routed to port P to a set constant
pressure.

Pilot relief valve

P A

SM2200

EC MOTOR

The EC motor is used to control engine speed. A motor rotation to calculate the governor lever
worm gear is incorporated into the EC motor to position. (Refer to the Control System Group in
prevent a loss of synchronism from occurring. The SYSTEM Section).
EC sensor is provided to detect the degrees of the EC

Output shaft Worm gear

Output gear

Sensor gear
Motor

EC sensor
Worm wheel

SM0097
 T3-7-1

OTHERS COMPONENTS (Undercarriage)

SWING BEARING

This bearing is a single-row shear ball-type bearing, bolted to the undercarriage.

comprising outer race (1), inner race (3), balls (6), The internal gear of inner race (3) engages with the
supports (5), and seals (2), (4). Outer race (1) is output shaft of the swing reduction gear.
bolted to the upperstructure and inner race (3) is

6
4

SM0098

1 - Outer Race 4 - Seal

2 - Seal 5 - Support
3 - Inner Race 6 - Ball
T3-7-2

OTHERS COMPONENTS (Undercarriage)

CENTER JOINT

The center joint is a 360° rotating joint. When the the swing center of the undercarriage.
upperstructure is rotated, the center joint avoids Hydraulic oil flows to the right and left travel motors
twisting of hoses and allows hydraulic oil to flow via spindle (1) and the oil ports of body (2). Seals (3)
smoothly to or from the travel motors. Spindle (1) is prevent oil leaks between spindle (1) and body (2)
attached to the main frame, and body (2) is bolted to into adjacent passages.

To left travel To right travel To left travel To right travel

motor (Reverse) motor (Forward) motor (Forward) motor (Forward)
To left travel To right travel
To left travel To right travel motor (Reverse) motor (Reverse)
motor (Forward) motor (Reverse)
1
Pilot pressure for Pilot pressure for
travel speed selection travel speed selection
Drain

Drain

Drain
3

Drain
Forward
Reverse
Pilot pressure for
travel speed selection

SM0099

1 - Spindle 3 - Seal
2 - Body
 T3-7-3

OTHERS COMPONENTS (Undercarriage)

TRACK ADJUSTER

The track adjuster located on the side frame is

composed of spring (5) and adjuster cylinder (6). ! CAUTION
Spring (5) absorbs loads applied to the front idler.
Do not loosen valve (1) quickly or loosen too
Adjuster cylinder (6) adjusts track sag.
much since high-pressure grease in the adjusting
cylinder may spout out.
• Grease is applied through grease fitting into
Loosen carefully, keeping body parts and face
chamber A of adjuster cylinder (6) as illustrated
away from valve (1). Never loosen grease fitting.
below. The pressure of the grease pushes piston
rod (7) out and decreases track sag.

• To increase track sag, loosen valve (1) 1 to 1.5

turns counterclockwise to release grease from the
track adjuster cylinder through the grease
discharge hole.
1

Grease fitting

Grease discharge hole

1 2 3 4 A 5 6 7

SM0100

1 - Valve 5 - Spring
2 - Nut 6 - Adjuster Cylinder
3 - Flange 7 - Piston Rod
4 - Spacer
T3-7-4

OTHERS COMPONENTS (Undercarriage)

NOTE