Contents

GENERAL INFORMATION
Contents
AUTO-LUBRICATION ..................................................................................................1
CAB Control Levers and Pedals ........................................................5
Left Control ................................................................................7
Emergency Engine Stop Switch.................................................7
Right Console ............................................................................9
Monitor Display ..........................................................................9
Right Console .......................................................................... 11
Left Console ............................................................................13
Rear Console...........................................................................13
Hour Meter...............................................................................15
CENTER FRAME Center Joint .............................................................................17
Control Valves..........................................................................19
Arm Cylinder Pressure Sensors ..............................................23
Fuel Coolers ............................................................................25
Fuel Tank .................................................................................27
Hydraulic Oil Tank....................................................................29
Swing Motors...........................................................................35
ENGINE ................................................................................................41
Engine Oil Reserve Tank (Left) ................................................47
Fuel System (Modular Common Rail System).........................49
Prelube Pump..........................................................................51
Starter Motors ..........................................................................53
Turbocharger ...........................................................................55
Cold Start Aid ...........................................................................55
Specifications...........................................................................57
Fuel Filters...............................................................................57
Coolant Reservoir ....................................................................59
Air Cleaners and Exhaust Mufflers ..........................................61
Flywheel (Wet Type) ................................................................61
FAST-FILLING SYSTEM ................................................................................................63
Automatic Fill System ..............................................................63
Contents
FOLDING STAIRWAY ................................................................................................67
Limit Switches..........................................................................69
LEFT FRAME Accumulators...........................................................................71
Heater Hoses...........................................................................71
LEFT PUMP ROOM ................................................................................................77
EHC Valve ...............................................................................79
DQR (Dual Quick Response) Valve .........................................79
Pilot Filter.................................................................................81
High Pressure Filters ...............................................................81
Pump Transmission Oil Filter...................................................83
Air Conditioning .......................................................................83
MAINTENANCE ELECTRIC PUMP .........................................................................................87
MAINTENANCE ELECTRIC MOTOR ......................................................................................89
RIGHT FRAME Hydraulic Oil Coolers ...............................................................91
RIGHT PUMP ROOM Main Pumps and 4-Unit Pump.................................................95
Regulators ...............................................................................97
4-Unit Pump.............................................................................97
Pump Transmission Oil Level Sensor ......................................99
EHC Valve ...............................................................................99
Emergency Switch .................................................................101
UNDER CAB Control Box............................................................................103
Air Conditioning .....................................................................107
Air Horn System ....................................................................109
AUTO-LUBRICATION

Pressurized to
Vent Valve Close Return Line

Grease Pump
Drive Motor

Hydraulic Oil Inlet

Hydraulic Oil
Grease Return Line Outlet

0807-001

AUTO-LUBRICATION

Grease from Grease to

Grease Pump Injectors

Grease Pump

Pressure Reducing
Valve 2.94 MPa Solenoid Valve Flow Adjustment

0807-002

-1-
 Auto-Lubrication
Switch
MC

76-13
Pressure Switch 1
Auto-Lubrication)

48-38

76-26

Indicator (Red)
Pressure Switch 2
(Manual-Lubrication)

Ke-CAN IDU

Auto-Lubrication
Interval Switch
76-57 48-18
3 Min.
5 Min.
10 Min.
15 Min.

76-6
76-18
76-5
Key Switch ON Signal 76-71
(Fuse #15)

Pilot
Pump (L)

Pilot
Center Joint, Swing Bearing Pump (R)
Lubrication Circuits

Front Attachment
Lubrication Circuit
Grease Pump
Hose Reel Circuit
(Manual-Lubrication)
Vent Valve

Grease Tank Pressure Auto-Lubrication

Reducing Solenoid Valve
T18N-02-02-005
Valve

-2-
AUTO-LUBRICATION

Pressure Switch for

Manual Operation
23.5 MPa

Pressure Switch for

Automatic Operation
Auto-Lubrication Switch 17.7 MPa

0807-003

AUTO-LUBRICATION

Grease to
Boom Foot Pin Injectors Set
At Min. Volume

Grease Inlet

Grease to
Center Joint

0807-004

-3-
-4-
CAB – Control Levers and Pedals

0807-005

Air Conditioner
Control Panels Key Pad

Radio

0807-006

-5-
DESIGNATIONS AND FUNCTIONS OF
CONTROLS
1. Power Switch 5 10 8 9 7 6 3

2. Air Conditioner Switch

2
3. Ventilation Shift Switch
4. Temperature Control Switches
5. Blower Control Switches
M18G-01-039
6. Air Conditioner Indicator 1
4
7. Ventilation Indicator
8. Temperature Indicator
9. Blower Speed Indicator
10. Liquid Crystal Display (LCD)

-6-
CAB – Left Control

0807-007

EMERGENCY ENGINE STOP SWITCH

Engine Start Switches Engine Stop Switches Key Switch

Emergency Engine Engine Speed

Stop Switch Control Dials

0807-008

-7-
RIGHT CONSOLE
1- Emergency Engine Stop Switch 1
16
2- Engine Speed Control Dial (R) 2
3- Engine Start Switch (R)
15
3
4- Engine Stop Switch (R)
14 4
5- Dome Light Switch
13 5
6- Entrance Light Switch
7- Auto Idle Switch 6

8- Fast-Filling Switch 12 7
9- Key Switch 8
11
10- Buzzer Stop Switch
10
11- Travel Mode Switch 9

12- Maintenance Light Switch

13- Work Light Switch
M18N-01-013
14- Engine Stop Switch (L)
15- Engine Start Switch (L)
16- Engine Speed Control Dial (L)

KEY SWITCH (1)

(2)

1- OFF (Power OFF) (3)

2- ACC (Horn, Radio, etc)

3- ON (Power ON)

M18G-01-034

-8-
CAB – Right Console

Pilot Control
Shut-off Lever

Emergency Engine
Stop Switch

Engine Speed
Control Dials

0807-009

CAB – Monitor Display

Periphery Watch
Monitors

Monitor Display

0807-010

-9-
METER CHECK SCREEN
When key switch is turned to the ON position, meter check 1 2 3 4 5 6 7 8 9 10
screen will be displayed next to starting check screen.

1- Model Name 11
2- Coolant Temperature Gauge (L)
3- Front Type
4- Tachometer (L)
5- Control Lever Pattern 12
6- Engine Oil Pressure Gauge (L)
7- Engine Oil Temperature Gauge (L)
8- Coolant Temperature Gauge (R)
9- Tachometer (R) 13
10- Hour Meter
11- Engine Oil Pressure Gauge (R)
12- Engine Oil Temperature Gauge (R)
13- Clock
14- Fuel Gauge
15- Battery Voltage Gauge 17 16 15 14
M18N-01-009
16- Hydraulic Oil Temperature Gauge
17- Ambient Temperature
18- Alternator Indicator (L)
19- Pump Transmission Oil Level Indicator (L)
20- Engine Stop Indicator (L) 18 19 20 21 30 31 32 33 34 43 44 45 46
21- Engine Oil Pressure Indicator (L)
22- Coolant Overheat Indicator (L)
23- Coolant Level Indicator (L)
24- Engine Over Run Indicator (L)
25- Fuel Temperature Indicator (L)
26- Engine Warning Indicator (L)
27- Exhaust Temperature Indicator (L)
28- Air Cleaner Restriction Indicator (L) 22 23 24 25 35 36 37 38 39 47 48 49 50
29- Prelub Indicator (L)
30- Hydraulic Oil Level Indicator M18N-01-010

31- Auto-Lubrication Indicator

32- Stop Valve Indicator
33- Electric Lever Indicator
34- Stairway Position Indicator
35- Fast-Filling Indicator
36- Emergency Engine Stop Indicator
37- Tension Indicator
38- Hydraulic Oil Overheat Indicator 26 27 28 29 40 41 42 51 52 53 54
39- Pump Contamination Indicator M18N-01-010

40- Electrical Equipment Box Indicator

41- Auto-Idle Indicator
42- Travel Mode Indicator
43- Alternator Indicator (R)
44- Pump Transmission Oil Level Indicator (R)
45- Engine Stop Indicator (R)
46- Engine Oil Pressure Indicator (R)
47- Coolant Overheat Indicator (R)
48- Coolant Level Indicator (R)
49- Engine Over Run Indicator (R)
50- Fuel Temperature Indicator (R)
51- Engine Warning Indicator (R)
52- Exhaust Temperature Indicator (R)
53- Air Cleaner Restriction Indicator (R)
54- Prelub Indicator (R)

-10-
CAB – Right Console

Limit Switch for

Electric Lever Pilot Control
Control Unit (ELU) Shut-off Lever

0807-011

CAB – Right Console

Connections for
Front Attachment
Configuration

Connections for Control Lever

Pattern (ISO and Hitachi)

0807-012

-11-
PILOT SHUT-OFF CONTROL
Purpose: The pilot shut-off switch operates the pilot
Ke-CAN
shut-off solenoid valve by operating the
pilot shut-off lever. Pressure oil from the
pilot pump is delivered to the pilot circuit. ELU IDU

Operation:
1. When the pilot shut-off lever is turned ON with the Pilot Pressure Sensor
key switch in the ON position, the pilot shut-off
switch is turned ON. Current from terminal M in
To Pilot Circuit
the key switch flows to ELU and MC through fuse
#20 in the fuse box (cab) and the pilot shut-off Pilot Shut-Off
switch, and excites the pilot shut-off relay at the Relay
same time.
2. ELU and MC recognize the pilot shut-off release
signals respectively, and send them to IDU
through CAN. Pilot Shut-Off
Solenoid Valve
3. When ELU recognizes the pilot shut-off release
signal, ELU outputs the voltage signal.
4. The voltage signal from ELU goes to the pilot
control shut-off solenoid valve through the pilot
shut-off relay. Pilot Pump
5. Therefore, the pilot shut-off solenoid valve is
operated and pressure oil from the pilot pump is
delivered to the pilot circuit.
6. When an alarm signal is sent from the pilot
pressure sensor to ELU, ELU stops outputting the
voltage signal to the pilot shut-off solenoid valve
and stops the pilot shut-off solenoid valve. Pilot Shut-Off
Switch MC

Fuse #20 in
Fuse Box (Cab)

Key Switch
T18G-02-01-007

-12-
CAB – Left Console

Information
Display Unit (IDU)
0807-013

CAB – Rear Console

DC-DC Converter (24-12) Fuse Box

For Periphery Watch Monitors

0807-014

-13-
 1 2 3 4 5

T18G-01-02-030
6

T18G-01-02-028

7 8 9 10 11 12

13

14

15

• T18G-01-02-026
18 17 16

Layout of Power Source Terminal • T146-01-03-023

1 - Electric Lever (Arm, Swing) 6 - Fuse Box (Cab) 11 - Data Link Connector 15 - Power Source Terminal
(ECM (R))
2 - Electric Lever (Bucket Close) 7 - DC-DC Converter 12 - Data Link Connector 16 - DLU (Data Logging Unit)
(Loading Shovel) (DLU)
3 - Electrical Lever (Travel) 8 - Cigar Lighter 13 - Buzzer 17 - Data Link Connector (MMS)
4 - Electric Lever (Bucket Open) 9 - ORBCOMM (Optional) 14 - DC-DC Converter 18 - Controller
(Loading Shovel) (Monitoring Camera)
5 - Electric Lever (Boom, 10 - Data Link Connector (ECM (Optional)
Bucket) (L))

-14-
CAB – Rear Console
ORBCOMM Power Source Data Link Connector
(Option) Terminals (DLU)

Data Logging Unit Data Link Connector DC-DC Converter

(DLU) (ECM) (24-24) (24-12)

0807-015

CAB – Hour Meter

Hour Meter

0807-016

-15-
-16-
CENTER FRAME – Center Joint

Center Joint

Travel Motor
Drain Line

Contamination Sensor
for Travel Motors

0807-017

CENTER FRAME – Center Joint

Cushion Cylinder Pressure

Sensor for Travel Stop Operation

0807-018

-17-
 IDU Travel Reverse Solenoid Valve (Right)
Ke-CAN
Travel Forward Solenoid Valve (Right)
ELU
Left Travel Lever Travel Reverse Solenoid Valve (Left)
Travel Forward Solenoid Valve (Left)
Travel Forward Travel Forward
EHC Valve (Right) (Left)
(Swing, Travel,
Bucket
Open/Close) DQR
Right Travel Lever
Valve 2

Cushion Cylinder End

Pressure Sensor

DQR
Valve 1

Travel Reverse Travel Reverse

(Right) (Left)

Main Pump EHC Valve(R)

Displacement Control (Pump, Oil Cooler
Solenoid Valve Fan Motor Control
Circuit)

EHC Valve(L)
(Pump, Oil Cooler
Fan Motor Control
Circuit)

Regulator Main Pump Regulator

Displacement Control
P6 P2 P4 P12 P8 P10
Solenoid Valve

P5 P1 P3 P11 P7 P9

Pump Transmission (L) Pump Transmission (R)

Left Engine Right Engine

T18N-02-03-002

-18-
CENTER FRAME – Control Valves

Model: KVS-1000
Main Relief Set-Pressure: 29.4 MPa
Overload Relief Set-Pressure: 31.4 MPa
15.7 MPa for Bucket Close

0807-019

CENTER FRAME – Control Valves

Boom Lower Priority

Selector Valve

Boom Raise Priority

Selector Valve

0807-020

-19-
Control Valve 4 (Upper Right) Control Valve 1 (Upper Left)
1- Arm Section 13 - Bucket Section
2- Bucket Open/Close Section (Only LD) 14 - Boom Lower/Arm Extend (LD), Arm Roll-In (BH) Section
3- Boom Raise/Bucket Tilt-In (LD), Bucket Roll-In (BH) Section 15 - Boom Section
4- Left Travel Section 16 - Swing Section

Control Valve 5 (Center Right) Control Valve 2 (Center Left)

5 - Bucket Section 17 - Left Travel Section
6 - Boom Section 18 - Boom Raise/Bucket Tilt-In (LD), Bucket Roll-In (BH)
Section
7 - Arm Section 19 - Bucket Open/Close Section (Only LD)
8 - Right Travel Section 20 - Arm Section

Control Valve 6 (Lower Right) Control Valve 3 (Lower Left)

9- Bucket Section 21 - Right Travel Section
10 - Boom Lower/Arm Extend (LD), Arm Roll-In (BH) Section 22 - Arm Section
11 - Boom Section 23 - Boom Section
12 - Swing Section 24 - Bucket Section

NOTE: LD: Loading Shovel

BH: Backhoe

-20-
CENTER FRAME – Control Valve

Main Relief Valve

0807-021

CENTER FRAME – Control Valve

Make-Up Valves

Overload Relief
Valves

0807-022

-21-
 1 2 3 4 5 6 7 8

Port P

Port T

T145-02-03-001

1 - Main Poppet 3 - Spring 5- Sleeve 7 - Pilot Poppet

2 - Orifice 4 - Spring Chamber 6- Orifice 8 - Spring
9 - Sleeve

1 2 3

Actuator Port

Port T
T145-02-03-002

1 - Poppet 2 - Sleeve 3 - Spring

-22-
CENTER FRAME – Arm Cylinder Pressure Sensors

Arm Cylinder Rod Arm Cylinder Bottom

Side Pressure Sensor Side Pressure Sensor

0807-023

-23-
-24-
CENTER FRAME – Fuel Coolers

DC24V
3.5 A
220 min-1

Fuel Cooler Fan Fuel Cooler Fan Fuel Tank

(Right) (Left) Breathers

0807-024

CENTER FRAME – Fuel Coolers

Inlets

0807-025

-25-
FUEL TANK

Machine Front

1 2 3 4

T18N-01-03-028

View A

5 6

Fuel Filter

T18N-01-03-032

T18N-01-03-031

1 - Fuel Level Sensor 3 - Fuel Level Switch (H) 5- Fuel Cooler Fan Motor (R) 6- Fuel Cooler Fan Motor (L)
2 - Fuel Level Switch (L) 4 - Fuel Cooler

-26-
CENTER FRAME – Fuel Tank

Fuel Level
Switch (High)

Fuel Level
Switch (Low)

Fuel Tank Capacity

11300 Liters

0807-026

-27-
-28-
CENTER FRAME – Hydraulic Oil Tank

Bypass Filter 5 μm Full-Flow Filters 10 μm

Drain Filter 10 μm Volume of Hydraulic Oil to be

Changed: App. 6200 Liters

0807-027

CENTER FRAME – Hydraulic Oil Tank

Hydraulic Oil
Level Switch 1
(Level Indicator)

Hydraulic Oil
Level Switch 2
(Warning)

0807-028

-29-
 Oil Cooler

Control Valve 1 (Upper Left)

Control Valve 4 (Upper Right)

Control Valve 2
(Middle Left)

Control Valve 5
(Middle Right)

Control Valve 6
(Lower Right)

Control Valve 3 (Lower Left)

Bypass Filter
Low-Pressure
Relief Valve

Hydraulic Oil Tank

Full-Flow Filter

T18N-02-04-005

-30-
CENTER FRAME – Hydraulic Oil Tank

(Inside Box)
Air Bleeding
Solenoid Valve

Cock to be
Opened while
Operating

0807-030

-31-
-32-
CENTER FRAME – Hydraulic Oil Tank
Hydraulic Oil
Temperature
Sensor

Valve Limit Switch

(R-Section)

0807-031

-33-
-34-
CENTER FRAME – Swing Motors

Relief Set Pressure: 24.5 MPa

Parking Brake Release
Pressure: 2.7 MPa

0807-032

CENTER FRAME – Swing Motors

Motor Drain Line Make-Up Line

Contamination
Sensor

Brake Valve

Relief Valve

Swing Parking Brake

Control Line

0807-033

-35-
SWING MOTOR
The swing motor consists of the parking brake section
and the motor section.
The parking brake is a wet-type spring set hydraulic
released multi-disc brake and mainly consists of brake
piston (10), friction plate (8), and plate (9).
The swing motor is a swash plate type axial plunger
motor.
It consists of shaft (4), swash plate (3), shoe (2),
plunger (5), rotor (6), valve plate (7), housing (1), and
the parking brake. Shoe (2) is crimped on plunger (5)
which is inserted into rotor (6). Rotor (6) is splined to
shaft (4).

Parking
Brake
8

6 1

5
2

3 Motor

W117-02-04-005

1- Housing 4 - Shaft 7 - Valve Plate 9 - Plate

2- Shoe 5 - Plunger 8 - Friction Plate 10 - Brake Piston
3- Swash Plate 6 - Rotor

-36-
CENTER FRAME – Swing Motors

Swing Motors

Breathers

0807-034

CENTER FRAME – Swing Motors

Gear Oil Refill Gear Oil Level

Hoses Check Hoses

Gear Oil Drain

Hoses

0807-035

-37-
 Change Gear Oil --- every 1000 hours
(first time after 50 hours)
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.

IMPORTANT: The turbocharger may be damaged if the

engine is not properly shut down.

4. Run the engines at slow idle speed without load for 4 5 4 M118-07-079
five minutes.
5. Stop the engines. Remove the key from the key
switches.
3
6. Pull the pilot control shut-off lever to the LOCK
position.
WARNING: Gear oil may be hot just after
operation. Wait for gear oil to cool before starting
work.

7. Prepare a container of 84 liter (22.2 US gal) or more

capacity for the drain oil.
8. Remove drain plug (5) and loosen drain cock (4) to M118-07-026

drain oil.
9. Tighten drain cock (4) and drain plug (5).
10. Remove oil supply plugs (3) (illastrated are rear, front
are on the top cover of device.) and add oil 84 liters
(22.2 US gal).
11. Check that oil level is in the stepped section at the tip 6
of dipstick (1).
NOTE: When refilling oil from the fast-filling panel: Gear
oil can be refilled from the ground using the
Fast-Filling panel located in the rear of the base
machine. Refer to page 1-38 for the Fast-Filling
panel operation.
M118-07-028

Clean Breather --- every 1000 hours

1. Remove breather cap (6) and clean the element.
6

M118-07-027

-38-
CENTER FRAME – Swing Motors

Dipsticks for Checking

Gear Oil Levels

0807-036

-39-
-40-
ENGINE
Cummins QSKTA50-CE
1044 kW/1800 min-1×2

Fuel Injectors

Double Solenoid Valve

Walled Pipes Connections

0807-037

ENGINE

Exhaust Gas
Temperature Sensors
(Thermocouples)

0807-038

-41-
ENGINE
Manufacturer ........................................................ Cummins
Model ................................................................... QSKTA50-CE
Type ..................................................................... Four-Cycle Diesel Engine, Water-Cooled, 60°V Type,
Direct-Injection, Turbochrged, With After-cooler
Cyl. No.- Bore×Stroke .......................................... 16-159×159 mm (16-6.3×6.3 in)
Total Displacement............................................... 50 L (13.2 US gal.)
Rated Output (Gross)........................................... 1044 kW/1800 min-1 (1420 PS/1800 rpm)
Compression Ratio............................................... 15.0: 1
Weight .................................................................. 5530 kg (12190 lb)
Firing Order .......................................................... 1R-1L-3R-3L-2R-2L-5R-4L-8R-8L-6R-6L-7R-7L-4R-5L
Rotation Direction................................................. Counterclockwise (Viewed from Flywheel End Side)
Dimensions Length×Width×Height ...................... 2803×1471×1785 mm (110×58×70 in)

COOLING SYSTEM
Water Pump...................................................... Centrifugal Pump
Thermostat........................................................ Engine Circuit: Opening Temperature 82 °C (180 °F)
Fully Open Throttle Temperature 94 ° (201 °F)
After-cooled Circuit: Opening Temperature 46 °C (115 °F)
Fully Open Throttle Temperature 57 °C (135 °F)
Coolant Capacities............................................ 140 L (37.0 US gal.) (In Engine Circuit)
30 L (7.9 US gal.) (In After Cooler Circuit)
47.2 L (12.5 US gal.) (In Water Tank)

LUBRICATING SYSTEM
Lubrication Pump Type..................................... Gear Type, Gear Drive
Oil Filter ............................................................ Paper Element (Spin-On Type)
Engine Oil Capacity .......................................... 151 L (40 US gal.) (HIGH), 121 L (32 US gal.) (LOW)

STARTING SYSTEM
Manufacture...................................................... DELCO-REMY
Model ................................................................ 50MT-400
Voltage/Output .................................................. DC24 Vx9 kW×2

-42-
ENGINE

Engine Oil Rifle

Pressure Sensor
Pre-Oil Filter
Pressure Sensor

Two Stage Oil Filters 30 μm

Multi-Layer Protection

0807-039

ENGINE

Suction Line

Engine Oil
Level Sensor

Engine Oil Return Line

Temperature Sensor

0807-040

-43-
-44-
ENGINE

Crank Case Coolant Pressure

Pressure Sensor Sensor

LTA Pump
Outlet Tube

Engine Loop
Bypass Tube

Coolant Filters

0807-041

ENGINE

Alternator
(Leece Neville)
DC24V-140A

0807-042

-45-
-46-
ENGINE – Engine Oil Reserve Tank (Left)
Filling System
Level Switch Pump Unit 1 Pump Unit 2

Filling System
Solenoid Valve

0807-043

ENGINE – Engine Oil Reserve Tank (Left)

Engine Oil Pan 150 L×2
Premium
Reserve Tank 85 L×2
Engine Oil Pan 150 L×2
Standard
Reserve Tank 205 L×2

Engine Oil Level Dipstick

for Reserve Tank

0807-044

-47-
Withdrawal Pipe Suction Line Pump Unit
Screen Pump 1
Screen

Pump 2 Float Switch

Engine Oil Pan

Return Line
Reserve tank

Cock
Shut-off Valve
Drain Line

Supply Line

Electric Circuit Diagram for Automatic Fill System

(6) (7)

(5) (4)

How to operate automatic fill system

1. Turn power switch (4) to ON position.
2. Turn start switch (5) to ON position.
3. The shut-off valve on the reserve tank opens. The
shut-off valve open indicator (6) lights up.
4. Oil can begin filling the reserve tank through the
shut-off valve.
5. When the oil in the reserve tank reaches the
proper full level, the shut-off valve closes and full
indicator (7) lights up.
6. Turn power switch (4) to the OFF position to turn
the power off.

-48-
ENGINE – Fuel System (Modular Common Rail System)
Fuel Pressure Fuel High Pressure Mechanical
Sensor Lines Up to 1600 Bar Dump Valve

Inlet Metering
Valve

High Pressure Pump

0807-045

ENGINE – Fuel System (Modular Common Rail System)

Fuel Supply
Fuel Outlet Line Pressure Sensor

Fuel Inlet Line

Fuel Supply 2nd Stage Fuel Filters

Temperature on Engine 3/3 μm
Sensor

0807-046

-49-
 EX2500-1 EX2500-5 EX2500-6 EX3600-6
Model EX3500-3 EX1900-5 EX1900-6 EX3600-5 EX3600-5
EX5500-1 EX5500-5 EX5500-6 EX8000-6
EPA − Tier1 Tier2 − Tier1 Tier2 Tier1 Tier1 Tier2
Engine Model KTA38 S12A2 QSK38 KTA50 QSK45 QSK50 S16R QSK60 QSK60
Displacement L 37.7 33.9 37.7 50 45 50 65.37 60 60
Cylinder − 12 12 12 16 12 16 16 16 16
Bore mm 159 150 159 159 159 159 170 159 159
Stroke mm 159 160 159 159 190 159 180 190 190
Compression − 13.8 15.0 13.8 13.8 16.5 13.8 15.0 16.5 16.5
Rated output KW 656 765 810 969 1007 1044 1400 1491 1450
Rated Torque N⋅m 3482 4061 4300 5144 5345 5542 8361 7915 7697
Rated Speed min-1 1800 1800 1800 1800 1800 1800 1600 1800 1800
-1
Low Idle min 750 700 700 780 780 780 800 800 800
-1
High Idle min 1990 2000 2000 2080 2050 2050 1740 1900 1900
RAD+ RAD+ RAD+ RAD+ RAD+ RAD+
Cooling System RAD RAD RAD
Intercooler LTA LTA LTA Intercooler LTA
Allowable
° 30 20 20(30) 20(30) 20(30) 20(30) 30 20(30) 20(30)
Inclination (F/R)
Allowable
° 30 30 20(30) 20(30) 20(30) 20(30) 30 20(30) 20(30)
Inclination (R/L)
Cold Start °C 0 -12.2 -12.2 -12.2 0 -12.2 -12.2
Cold Start with Aid °C -20(A/H) -32(ether) -32(ether) -32(ether) -20(A/H) -32(ether) -32(ether)
High Elevation m 2400 2000 3300 2000 4267 3300 2000 3353 3100

MCRS SYSTEM

-50-
ENGINE – Fuel System (Modular Common Rail System)
Engine Control Module (ECM)

ECM 1 (Child) ECM 2 (Child) ECM 3 (Parent)

0807-047

ENGINE – Prelube Pump

Oil to Main
Oil Rifle

Prelube Pump

Oil from Sump

0807-048

-51-
Engine Monitoring & Protection
38-Sensor package 10 existing sensors
6 new sensors
22 AEM sensors (Advanced Engine Monitoring)

• 10 Existing Sensors
• Barometric Air Pressure • Injector Metering Rail Pressure
• Oil Rifle Pressure • Coolant Temperature
• Crankshaft Speed/Position • Crankcase Pressure
• Intake Manifold Pressure • Coolant Pressure
• Intake Manifold Temperature • Coolant Level (OEM fitting)

• 6 New Sensors
• Engine Fuel Temperature • Water-in-Fuel (Off-Engine)
• Fuel Delivery Pressure • Camshaft Speed/Position
• Oil Temperature (Oil Pan) • Turbo Speed (Single-Stage)

• 22 AEM Sensors
„ Additional Sensors
• Intake Manifold Temperature Increased to 4 (3)
• Intake Manifold Pressure to 2 (1)
• Pre & Post-Oil Filter Pressure 1+1 (2)

„ Cylinder Health Monitoring

• Exhaust Gas Temperature Sensors 16 (16)

-52-
ENGINE – Starter Motors

Starter Motors
DC24V-9 kW×2

0807-049

Crankshaft Speed
Sensor for MC

Crankshaft Speed/
Position Sensor
for ECM

Crankshaft Speed/
Position Sensor
Located in Front of
Fuel Pump

Engine Oil Pressure Switch for

Prelube: 4 psi, Normal Open
0807-050

-53-
-54-
ENGINE – Turbocharger

Lubrication Lines

Turbo Charger
Speed Sensing Line

0807-051

ENGINE – Cold Start Aid

Air Cleaner
Warning Switches

Location of Ether
Containers

0807-052

-55-
-56-
ENGINE – Specifications

0807-053

ENGINE – Fuel Filters

1st Stage
Off-Engine 7 μm

Electric
Priming Pump

Fuel Outlet
Line

Cock Fuel Inlet Line

0807-054

-57-
 Replace Fuel Element 1
--- every 250 hours

IMPORTANT: When fuel level reaches top of filter

element in clear cover before 250 hours,
replace fuel element before change
interval.

Be sure to prepare a container large

enough to collect fuel when replacing
fuel filter to avoid ground contamination
and for safety.

1. Stop the engine. M18N-07-013

2 2
WARNING: Fuel may be hot just after operation.
Be sure to wait for fuel to cool before starting
work. 7 7

2. Close cock (1) on the inlet line.

4 4
3. Loosen fuel vent cap (2) to break the air lock in the
filter.
4. Open drain valve (3) and drain the fuel level below 6 3 6 3 M18N-07-012

collar (4) level, then close drain valve (3).

5. Using Collar/Vent Cap Wrench (5), remove clear
cover (6) by removing collar (4). Discard the o-ring
from clear cover (6). (A new o-ring is supplied with the
new filter.)
6. Remove filter element (7). Be sure the sealing
grommet is removed from the center stud.
5
7. Install new filter element (7) (supplied with a sealing
grommet inserted into the element.) on the center M18M-07-074

stud by pushing down.

8. After checking the new o-ring (supplied with the new
filter) at clear cover (6) is in place, install clear cover
(6) and collar (4). Hand tighten collar (4) until seated.
Do not use Collar/Vent Cap Wrench (5) to tighten.
9. Remove fuel vent cap (2) from the top of clear cover
(6). Fill clear cover (6) with enough clean fuel to cover
the bottom half of the filter element.
10. Reinstall fuel vent cap (2) and tighten by hand only.
11. Open cock (1) on the inlet line.
12. Start the engine. When the lubrication system
reaches its normal operating pressure, increase
engine speed for one minute.

Refer to the manual for Cummins Engine.

-58-
ENGINE – Fuel Filters

Water-In Fuel
Sensor (WIF)

Drain Valves

0807-055

ENGINE – Coolant Reservoir

Sight Glasses

Two Level Switcher

Located on Both
Sides for Green Lamp

0807-056

-59-
 Replace Fuel Filter
--- every 250 hours

IMPORTANT: Be sure to prepare a container large 1

enough to collect fuel when replacing
fuel filter to avoid ground contamination
and for safety.

1. Stop the engine.

WARNING: Fuel may be hot just after operation.
Be sure to wait for fuel to cool before starting
work.

2. Close cock (1) on the inlet line.

3. Unscrew spin-on filters (2) from the filter head, M18N-07-014

discard filters.

4. Fill the filter with clean fuel. Apply a light even coat of
lubricating oil to the gasket sealing surface prior to
installing the filter.

5. Position filter (2) to the filter head. Tighten by hand

until the seal touches the filter head, tighten an
additional one-half to three-fourths turn.

6. Open cock (1) on the inlet line.

NOTE: Be sure to tighten the filter by hand. If any tools

are used for tightening, breakage or
M18L-07-012
deformation of the filter head may arise. 2

Refer to the manual for Cummins Engine.

-60-
ENGINE – Air Cleaners and Exhaust Mufflers

0807-057

ENGINE – Flywheel (Wet Type)

0807-058

-61-
-62-
FAST-FILLING SYSTEM

Hydraulic Cylinders

0807-059

FAST-FILLING SYSTEM – Automatic Fill System

Full Indicator Fuel Full Indicator

Shut-Off Valve Power Switch Start Switch

Open Indicator

0807-060

-63-
FAST-FILLING SYSTEM
This machine is equipped with the fast-filling system for
adding fuel, hydraulic oil, gear oil, engine oil, coolant and
grease on the ground.

Fast-filling panel (1) at the rear of the machine will be

raised or lowered with fast-filling switch as follows.

1. Pull the pilot control shut-off lever back to the LOCK

position.
2. Run the engine at slow idle. M18N-01-013
2
3. Press fast-filling system switch.
4. Fast-filling indicator (2) will come ON and fast-filling
panel (1) will start to go down.
5. When fast-filling panel (1) is completely lowered, it will
stop going down automatically.
6. Stop the engine.
WARNING: Never operate engine while adding
oil.
NOTE: While fast-filling panel is lowered, the machine
will not be able to swing.

7. Add fuel, hydraulic oil, gear oil, engine oil, coolant and M18N-01-009
grease via the fast-filling panel.
8. Start the engine and run it at slow idle.
9. Press fast-filling system switch again.
10. Fast-filling panel (1) will start to go up.
When fast-filling panel (1) is completely raised, it will stop
going up automatically and fast-filling indicator (2) will go
OFF.

1
Engine Oil In Engine Oil Out Pump Gear Oil Gear Oil M118-07-048

(Reserve Tank) Transmission (Rear Side Swing (Front Side Swing Pump
(Reserve Tank)
(L) Oil (L) Device)(R) Device) (R) Hyd. Oil Transmission Oil (R)
(L)
Engine Oil In
(Reserve Tank)
(R)
Engine Oil Out
(Reserve Tank)
(R)

Fuel

Coolant (L) Engine Oil Gear Oil Gear Oil Grease Engine Oil Coolant (R) M18N-01-019

(Engine Oil Pan) (L) (Rear Side Swing (Front Side Swing (Engine Oil Pan)
Device)(L) Device) (L) (R)

-64-
FAST-FILLING SYSTEM

Slow Return
Check Valve

Check Valve

Lift Cylinder Lower Lift Cylinder Raise

Pressure Pressure

0807-061

FAST-FILLING SYSTEM

Proximity Switch to be OFF as

Fast-Filling Completely Stored

0807-062

-65-
How to operate automatic fill system
7 6 4 5 7 6 4 5
1. Connect the drain hose to OUT port (1). Prepare a
1 3 1
container of 220 liter (58 US gal).
2. Open drain cock (2) to drain the engine oil. 3
3. Check if foreign material like metal particles are
included in the drain oil by filtering it with a clean
cloth.
4. Remove the hose and tighten drain cock (2).
5. Connect the supply hose to IN port (3). M18N-01-019

6. Turn power switch (4) to ON position.

7. Turn start switch (5) to ON position.
8. The shut-off valve on the reserve tank opens. The
shut-off valve open indicator (6) lights up.
9. Oil can begin filling the reserve tank through the hose.
10. When the standard engine oil is used, the reserve
tank reaches the proper full level, the shut-off valve
automatically closes and full indicator (7) lights up.
11. When the premium engine oil is used, oil is C M18N-07-008
replenished to the mark of premium dipstick (8) in
reserve tank.
12. Turn power switch (4) to the OFF position to turn the
power off and remove the supply hose.

2
M18N-07-009

M18N-07-005

Premium Standard

M18N-07-006

-66-
FOLDING STAIRWAY

0807-063

FOLDING STAIRWAY

Retract Switch

Extend Switch

Stairway
Emergency
Stop Switch

0807-064

-67-
Extending
1. Be sure to pull the lever (2) to disengage the lock
(3) before extending. In case the lock is difficult
to disengage, press RETRACT button (4) two to
three times to disengage the lock.
2
2. Press and hold the EXTEND (5) button until the
stairway is fully extended. When the button is
released, the stairway stops extending.
NOTE: • The alarm starts to sound when the lock
(3) is disengaged.
• The alarm continues to sound until
stairway is fully extended.

Retracting
1. Press and hold the RETRACT button (4) until the
stairway is fully retracted. When the button is
released, the stairway stops retracting.
3
2. Be sure to pull the lever (2) down to engage the
lock (3) after fully retracting.
NOTE: • The alarm starts to sound when the
stairway starts to retract. M18M-01-030

• The alarm stops to sound when the lock

(3) is engaged after fully retracted.
NOTE: Swing operation is inoperable unless the
stairway operations are fully retracted and
lock (3) is engaged.

NOTE: • The switch (6) is stairway emergency

stop switch.
• Use the stairway emergency stop switch
(6) only for emergency stop.
• The engine will not stop when the
stairway emergency stop switch (6) is
used.
NOTE: Lubricate the lock lever (2) shaft bearing M18N-01-001

with oil when the lever does not move 4

smoothly.

6 5
M18M-01-031

-68-
FOLDING STAIRWAY – Limit Switches

Inside Cover:
4 Limit Switches
Installed

0807-065

FOLDING STAIRWAY

Beacon
Light/Alarm

0807-066

-69-
 1 2 3

Section B

Section A 4

5 Section C

11
6

7 8 9 10

B
C

12 13

Section D

14
D

T18N-01-03-007

1 - Folding Stairway Relay (2) 5 - Valve Unit 9- Limit Switch 2 12 - Folding Stairway Cylinder
(Extend Control for Stroke End)
2 - Folding Stairway Relay (3) 6 - Work Light 10 - Limit Switch 1 13 - Limit Switch 5
(Folding Stairway) (Extend Detect for Stroke End) (For Detecting Manual Lock)
3 - Folding Stairway Relay (4) 7 - Limit Switch 4 (Storage Detection) 11 - Folding Stairway Beacon 14 - Lock Lever
4 - Motor Pump Unit 8 - Limit Switch 3 Light/Alarm
(Detection Control for Stroke End)

-70-
LEFT FRAME – Accumulators

Check Valve

Check Valve

Accumulators

0807-067

LEFT FRAME – Heater Hoses

Cock for Fuel Inlet Heater Hoses

0807-068

-71-
-72-
LEFT FRAME

Pump Transmission
Oil Cooler

0807-069

LEFT FRAME

Radiator Front Side Air

Temperature Sensor

0807-070

-73-
Radiator (L)

5 3

1 2 4 6
Machine Front

8
Left Engine
B

T18N-01-03-021

View B 12
Section A

11

9 10
T18N-01-03-022

T18N-01-03-023

1 - LTA Radiator Inlet 4 - Radiator Inlet 7 - After Cooler 10 - LTA Radiator Outlet
Coolant Temperature Coolant Temperature Coolant Temperature
Sensor (L) Sensor (L) Sensor (L)
2 - Coolant Level 5 - Coolant Level 8 - Radiator 11 - Radiator Front Side Air
Warning Sensor (L) Check Switch (L2) Temperature Sensor (L)
3 - Water Tank (L) 6 - Coolant Level 9 - Radiator Outlet 12 - Work Light
Check Switch (L1) Coolant Temperature
Sensor (L)

-74-
LEFT FRAME

Atmospheric
Temperature Sensor

0807-071

-75-
-76-
LEFT PUMP ROOM

EHC Valve

Pilot Shut-Off
Solenoid Valve

Travel Mode
Solenoid Valve

Fast-Filling
Solenoid Valve
Dual Quick
Response Valves
(DQR)

0807-072

LEFT PUMP ROOM

Controls: Bucket
Open & Close, Swing

Controls: Travel

Shuttle Valve

Travel Pilot
Pressure Sensor

Controls: Boom
& Arm

Controls: Bucket

0807-073

-77-
 Control Lever Bucket Open Bucket Close
Travel Travel (Loading (Loading
Arm Swing Bucket Boom (Left) (Right) Shovel) Shovel)

ELU

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

EHC Valve DQR

Valve 2

9 10 11 12 Shuttle
Valve
2 1 7 8

DQR
Valve 1

EHC Valve
To Control Valve

Boom Lower
Priority Selector
Valve Boom Raise
Priority Selector
5
Valve
6

To Control
Pilot Shut-Off Solenoid Valve Valve
Pilot Check Pilot Check
Valve (Left) Valve (Right)

Pilot Pump Pilot Pump Arm Roll-Out Priority

(Left) (Right) Selector Valve
T18N-02-04-002

(Only Backhoe)

1 - Arm Retract (Loading Shovel)/ 5 - Bucket Tilt-Out (Loading Shovel)/ 9 - Left Travel Forward 13 - Bucket Open
Arm Roll-Out (Backhoe) Bucket Roll-Out (Backhoe) (Loading Shovel)
2 - Arm Extend (Loading Shovel)/ 6 - Bucket Tilt-In (Loading Shovel)/ 10 - Left Travel Reverse 14 - Bucket Close
Arm Roll-In (Backhoe) Bucket Roll-In (Backhoe) (Loading Shovel)
3 - Swing Left 7 - Boom Raise 11 - Right Travel Forward
4 - Swing Right 8 - Boom Lower 12 - Right Travel Reverse

-78-
LEFT PUMP ROOM – EHC Valve

Controls: Main
Pumps and Oil
Cooler Fan Motor

0807-074

LEFT PUMP ROOM – DQR (Dual Quick Response) Valve

0807-075

-79-
 Hydraulic Piping

Control Lever

DQR Valve

Spool

Port T

ELU
Port P

Pilot Pump

Actuator
From Pilot Shut-Off
Solenoid Valve

Control Valve
Spring

EHC Valve

Spool Main Hydraulic Oil Tank

Pump

T18G-02-02-002

-80-
LEFT PUMP ROOM – Pilot Filter

Pilot Filter
10 μm
500 Hours

Pilot Relief
Valve 4.4 MPa

Pilot Pressure Sensor

(Swing & Front Attachment)

0807-076

LEFT PUMP ROOM – High Pressure Filters

Pressure
Check Ports

High Pressure
Filters
120 μm
12,000 Hours

0807-077

-81-
-82-
LEFT PUMP ROOM – Pump Transmission Oil Filter

Check Block

Pump Transmission
Oil Filter 500 Hours

0807-078

LEFT PUMP ROOM – Air Conditioning

Hydraulic
Drive Motor

Three
Compressors

0807-079

-83-
AIR CONDITIONING SYSTEM
The air conditioning system consists of the
compressor drive pump, compressor motor (8), air
conditioner units (1, 2, and 3), compressors (4, 7, and
9), condensers (13, 14, and 15), receiver dryers (10,
11, and 12), hot water outlet hose (5), and hot water
inlet hose (6).
Compressor motor (8) is driven by pressure oil from
the compressor drive pump when the engine starts.
When the air conditioner switch in the cab is turned
ON, the compressor clutch is turned ON so that the
compressor is operated, and the cooler is operated.

1
2
3
4

6
15

14

13

View A

12
11
10

9
8
7

T18N-03-07-001
1- Air Conditioner Unit (Front) 5- Hot Water Outlet Hose 8- Compressor (Rear) 6 - Condenser (Rear)
2- Air Conditioner Unit (Side) 6- Hot Water Inlet Hose 9- Receiver Dryer (Rear) 7 - Condenser (Side)
3- Air Conditioner Unit (Rear) 7- Compressor (Front) 10 - Receiver Dryer (Side) 8 - Condenser (Front)
4- Compressor (Side) 8- Compressor Motor 11 - Receiver Dryer (Front)

-84-
LEFT PUMP ROOM

Ground Line
Disconnecting
Switch

0807-080

LEFT PUMP ROOM

Relay Box

0807-081

-85-
RELAY BOX

22 1
T18N-01-03-010

2
21

20
Detail A

19
14
3
13
A
12 4

6
11
7
10

8
T18N-01-03-009

18 17 16 15

T18N-01-03-008

1- Battery Relay (R2) 7- Fusible Link 7 (45 A) 13 - Fusible Link 5 (75 A) 18 - Fuse (No. 3) (30 A)
2- Battery Relay (R1) 8- Fusible Link 1 (75 A) 14 - Fusible Link 6 (75 A) 19 - Zener Diode (L)
3- Fusible Link 11 (75 A) 9- Fusible Link 2 (75 A) 15 - Circuit Breaker (R) (200 A) 20 - Zener Diode (R)
4- Fusible Link 10 (75 A) 10 - Fusible Link 3 (75 A) 16 - Circuit Breaker (L) (200 A) 21 - Battery Relay (L2)
5- Fusible Link 9 (75 A) 11 - Fusible Link 4 (75 A) 17 - Fuse (No. 4) (30 A) 22 - Battery Relay (L1)
6- Fusible Link 8 (45 A) 12 - Fusible Link 12 (45 A)

-86-
MAINTENANCE ELECTRIC PUMP

Electric Pump
DC24V
10 A
60 L/min

Filter

0807-082

MAINTENANCE ELECTRIC PUMP

Outlet
Inlet

Indicator

0807-083

-87-
-88-
MAINTENANCE ELECTRIC MOTOR

Switch

0807-084

-89-
ELECTRIC PUMP
3
2
This machine is equipped with an electric pump to draw
hydraulic oil from the suction and return pipe lines to the
hydraulic oil tank. The pump is driven by battery power.
Continuously operate it while servicing the machine.

How to Operate Electric Pump

1

WARNING: Hydraulic oil may be hot. Wait for oil

to cool before starting work.

1. Park the machine on a level surface.

M118-07-093
2. Position the machine with the arm cylinder fully
extended and the bucket cylinder fully extended.
Cap (1)

3. Lower the bucket to the ground.

WARNING: Keep body and face away from cap (1). Allow (b)
Turn cap (1) slowly and remove the cap only after
releasing the internal pressure completely. Projection

(1) Insert the wrench as shown and turn the wrench Case Assembly
clockwise and hold the wrench.
(2) Turn cap (1) counter-clockwise about 30 ﾟ, at Projection
which point stop cap (1) to release the air.
(3) Turn cap (1) further and remove cap (1).
Side Hole
(4) Align the projected part of cap (1) with the
Wrench 4 mm
projected part of the case and install cap (1).
4 M110-07-022

4. Connect suction hose (3) of electric pump (2) to quick

coupler (4).
Quick Couplers are located in;
• Suction Line: Right and Left Suction Manifolds
• Return Line: Return Manifold on the Right Engine
bed

5. Before drawing oil, open stop valve (5).

5
M18N-07-002

-90-
RIGHT FRAME – Hydraulic Oil Coolers

Oil Cooler
Fan Motors

Drain Lines

Outlet Lines

Inlet Lines

0807-085

RIGHT FRAME – Hydraulic Oil Coolers

Oil Cooler
Outlet Lines

Hydraulic Oil Temperature

Sensors for Outlet Lines

0807-086

-91-
OIL COOLER FAN MOTOR SPEED
CONTROL
Purpose: The oil cooler fan motor speed control Oil Cooler Fan Motor Speed at Each Stage of Hydraulic Oil
controls the oil cooler fan motor speed at Temperature
three stages according to the hydraulic oil
Hydraulic Oil Pilot Oil Pressure from Oil Cooler Fan
temperature and maintains the hydraulic
Temperature Solenoid Valve Motor Speed
oil temperature in the proper temperature
(°C) (Current from MC) (min-1)
range.
49 °C (120 °F) 0 MPa 160
Operation: or Lower (0 kgf/cm2)
1. The hydraulic oil temperature sensor (for oil [50 mA]
cooler fan motor speed control) sends signals to 50 to 69 °C 2.16 MPa 950
MC according to the hydraulic oil temperature. (122 to 156 °F) (22.0 kgf/cm2)
2. MC controls the oil cooler fan motor speed control [310 mA]
solenoid valve according to the hydraulic oil 70 °C (158 °F) 3.51 MPa 1100
temperature and delivers pilot pressure to the oil or Higher (35.8 kgf/cm2)
cooler fan motor drive pump regulator (Pi). (Refer [400 mA]
to COMPONENT OPERATION/Pump Device.)
3. Therefore, the delivery flow rate of the oil cooler NOTE: Oil cooler fan motor speeds described
fan motor drive pump is controlled, and the oil above are those at the rated engine speed
cooler fan motor speed is adjusted. (1800 min-1).
4. The detection data from the hydraulic oil
temperature sensor is sent to IDU through
Ke-CAN.

-92-
RIGHT FRAME – Hydraulic Oil Coolers

Pressure Sensor
for Oil Cooler Inlet

0807-087

RIGHT FRAME

Valve Limit Switch

0807-088

-93-
 EHC Valve (L)
Oil Cooler Fan Motor (Pump/Oil Cooler Fan
Motor Control Circuit)

Oil Cooler Fan Motor

Drive Pump (L) Oil Cooler Fan
Control Speed
Solenoid Valve (L)

Oil Cooler Fan

Control Speed
Pump Transmission (L) Solenoid Valve (L)

Engine (L)

Hydraulic Oil
Temperature Sensor EHC Valve (L)
(Pump/Oil Cooler Fan
Motor Control Circuit)
MC
IDU

Ke-CAN

Oil Cooler Fan Motor

Drive Pump (R) Oil Cooler Fan
Control Speed
Solenoid Valve (R)

Oil Cooler Fan

Control Speed
Pump Transmission (R) Solenoid Valve (R)

Engine (R)

T18N-02-02-006

-94-
RIGHT PUMP ROOM – Main Pumps and 4-Unit Pump

4-Unit Pump Main Pumps

0807-089

RIGHT PUMP ROOM – Main Pumps and 4-Unit Pump

Contamination Sensors Pump Drain Pressure Sensors

0807-090

-95-
PUMP CONTROL
Main Pump Displacement Control

Purpose: This adjusts the pump delivery flow rate

according to the control lever stroke and
efficiently uses engine output power.

Operation:
1. When operating the control lever, ELU receives
the signal according to the control lever stroke.
2. ELU sends the electric signal current to the main
pump displacement control solenoid valve
according to the control lever stroke.
3. The main pump displacement control solenoid
valve delivers pilot pressure oil to the main pump
regulator according to the electric signal current
and controls the pump delivery flow rate.
4. Therefore, the delivery flow rate from each pump
is regulated to 100 to 425 L/min.
5. ELU detects pilot pressure from the main pump
displacement control solenoid valve to the pump
regulator, and sends the detected value to IDU
through Ke-CAN.

Maximum flow rate of each main pump when operating the control lever:
Max. Flow Rate (L/min)
Operation
MP1 MP2 MP3 MP4 MP5 MP6 MP7 MP8 MP9 MP10 MP11 MP12
Travel Right 100 375 - - - - - - 375 375 - -
Travel Left - - 100 375 - - 375 375 - - - -
Swing - - - - 425 425 - - - - 425 425
Boom Raise 375 375 375 375 425 425 375 375 375 375 425 425
Boom Lower 375 375 - - 425 425 - - 375 375 425 425
LD: Arm Extend 100 100 100 100
375 375 425 425 375 375 425 425
BH: Arm Roll-In 375 375 375 375

LD: Arm Retract 100 100 100 100

375 375 - - 375 375 - -
BH: Arm Roll-Out 375 375 375 375

LD: Bucket Tilt-In 375 375

375 375 375 425 425 375 375 375 425 425
BH: Bucket Roll-In 100 100

LD: Bucket Tilt-Out

100 375 - - 425 425 - - 100 375 425 425
BH: Bucket Roll-Out

Bucket Open/Close
- - 375 375 - - 375 375 - - - -
(LD Only)

NOTE: LD: Loading Shovel

BH: Backhoe

-96-
RIGHT PUMP ROOM – Regulators
Flow Rate
Control Line

Power Increase
Pilot Line

Power Decrease
Line

Pump Servo Assist

Pressure Line
0807-091

RIGHT PUMP ROOM – 4-Unit Pump

Plunger Pump for Oil
Cooler Fan Motor

Pilot Pump

• A/C Compressor Drive Pump (L) Pump T/M Oil

• Auxiliary (R) Circulation Pump
0807-092

-97-
 Pi Pf Psv Pz

T141-04-04-004

Pz Psv Pi

P - Own Pump Delivery Pressure Pf - Pump Power Decrease Control Pressure

(from Power Decrease Solenoid Valve)
Psv - Pump Servo Assist Pressure Pz - Power Increase Control Pressure
(from Pilot Pump) (from Power Increase Solenoid Valve)
Pi - Flow Rate Control Pressure
(Main Pump: from Solenoid Valve for Main Pump
Displacement Angle Control,
Oil Cooler Fan Motor Drive Pump: from Oil Cooler Fan
Speed Control Solenoid Valve)

A B C D

T117-02-01-017

Left 4-Unit Pump Right 4-Unit Pump

A. Oil Cooler Fan Motor Drive Pump (Plunger Pump) A. Oil Cooler Fan Motor Drive Pump (Plunger Pump)
B. Pilot Pump (Tandem Gear Pump) B. Pilot Pump (Tandem Gear Pump)
C. Air Conditioner Compressor Drive Pump (Tandem Gear C. Auxiliary
Pump)
D. Pump Transmission Oil Circulation Pump (Gear Pump) D. Pump Transmission Oil Circulation Pump (Gear Pump)

-98-
RIGHT PUMP ROOM – Pump Transmission Oil Level Sensor

Oil Level Sensor

0807-093

RIGHT PUMP ROOM – EHC Valve

EHC Valve Controls:

Main Pumps and Oil
Pilot Filter Cooler Fan Motor

0807-094

-99-
 MC

Level Sensor

Engine

T/M Oil Overheat Warning T/M Oil level Warning

Oil Level
ON High

Low

OFF
10 sec

110 115 °C
Warning
ON

OFF

(T)
(While the engine is running)

-100-
RIGHT PUMP ROOM – Emergency Switch

0807-095

-101-
 Emergency
Switch 3 Air Bleed
(Engine Room L1) Solenoid Valve
ECM (R)
Emergency Emergency Emergency
Switch 7 Switch 6 Emergency Switch 1
(Engine Room R) (Engine Room R2) Switch 2 (Cab)
(Engine Room L)

Emergency Emergency
Switch 5 Switch 4
ECM (L) (Engine Room R1) (Engine Room L2)
Engine Stop Valve Valve Limit
Switch (R) Limit Switch Switch
(R-Suction) (Return-U)

Valve Limit Switch

Engine Stop (Return-L)
Switch (L)
Valve Limit
Alternator (L) Switch
(L-Suction)

Engine Start
Prelub Timer Relay (R)
Switch (L)

Starter (L1)
(Upper Side)
Engine
Prelub Timer Relay (L)
Start
Switch (R)

Starter (L2)
(Lower Side)
Fuse Box 3
Fuse #47

Fusible Link 4
Alternator (R)
Fuse Box 2
Battery Relay (L1) Fuse #26

Circuit Breaker (L)

(200 A) Battery Relay (L2)

Fuse Box
Circuit Breaker (R) (Cab)
(200 A)
Starter (R1)
(Upper Side) Battery Relay (R1)

Battery Relay (R2)

Starter (R2)
(Lower Side) From Battery
Key Switch
T18N-02-05-015

-102-
UNDER CAB – Control Box

Hydraulic System
Monitoring Unit
(HMU)

Main Controller
(MC)

Engine Heat- Modular Mining

Balance Control System (MMS)
(EHU)

Contamination Engine Fault

Sensing Unit Indicator
(CSU)

0807-096

UNDER CAB – Control Box

Fuse Box 1

Fuse Box 2

Fuse Box 3

Fuse Box 4

0807-097

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OUTLINE
The controllers are controlled for each control
respectively. They are connected through CAN
(network provided for machine) for monitoring all
machine operating conditions including the engine,
and for indicating operating information on the display
in the cab.

• MC：Main Controller
• ELU：Electric Lever Control Unit
• IDU：Information Display Unit
• ECM：Engine Control Module
• DLU：Data Logging Unit
• CSU：Contamination Sensing Unit
• HMU：Hydraulic System Monitoring Unit
• EHU：Engine Heatbalance Control Unit
∗MMS: Modular Mining System

ECM (R) ECM (L)

Service Tool
(Palm)

J1939-CAN ORBCOMM
GPS Antenna (Optional)
DLU

Ke-CAN MMS Communicator Unit

ELU (Optional)
IDU MC

∗MMS
(Optional)
Display
EHU CAN
Keypad
HMU CSU

T18N-02-01-001

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UNDER CAB

Grease Interval
Selection Switch
3, 5, 10 & 15 min
0807-098

UNDER CAB

Connector for MMS

0807-099

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HOW TO READ FAULT CODES
2
1. Stop the engine, and turn the key switch ON.
2. In case a fault code exists, only the engine
warning lamp (amber) lights, but in case no fault 1 3
code exists, no lamp lights.
3. Turn the engine diagnostic switch of the engine at
the side where the engine warning lamp lights 6 4
ON.
4. The engine warning lamp (amber) blinks once, 5
and in a second, the engine stop lamp (red)
indicates the fault code twice consecutively, which 10
7
is repeated.
5. A fault code has four digits at the maximum. A 9
numeral is indicated by the number of blinking 8
times of the engine stop lamp (red) for each digit,
and the lamp goes out for 1 second between digit T18N-05-05-002

change. 1- Engine Maintenance Lamp (L) (Yellow)

6. When the key switch is turned OFF, indication of 2- Engine Warning Lamp (L) (Amber)
the fault code is finished. 3- Engine Stop Lamp (L) (Red)
4- Engine Stop Lamp (R) (Red)
5- Engine Warning Lamp (R) (Amber)
NOTE: In case a plural number of fault codes are 6- Engine Maintenance Lamp (R) (Yellow)
in existence, the engine warning lamp 7- Engine Diagnostic Switch (R)
(amber) blinks once each time indication of 8- Fault Code INC/DEC Switch (R)
9- Fault Code INC/DEC Switch (L)
a fault code is over, and a second later, the 10 - Engine Diagnostic Switch (L)
engine stop lamp (red) indicates the next
fault code twice, which is repeated.
Example: Blinking Status of engine stop lamp (Red)
NOTE: When indication of all the fault codes is in case of fault code 132
over, the engine warning lamp (amber)
flickers once, and a second later, the 100s digit 10s digit 1s digit
engine stop lamp (red) repeats indication of ON
the fault codes from the first one.

NOTE: In case the fault code INC/DEC switch is

moved toward INC once, indication of the
next fault code begins. In case the fault
code INC/DEC switch is moved toward OFF
DEC once, indication is changed to the 1 second 1 second T141-05-03-004
previous fault code.

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UNDER CAB – Air Conditioning

Condensers

Receivers

0807-100

UNDER CAB – Air Conditioning

Air Circulation
Filters

0807-101

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-108-
UNDER CAB – Air Horn System

Filter for
Compressor

Air Compressor

Air Tank

0807-102

Air Horns Air Filter for

Air System

0807-103

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