Manual de Reparacion Dx140lc

DX138LC
DX140LC
Shop Manual
K1027955B
Serial Number 6407 and Up
DOOSAN reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine's package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
K1027955B Shop Manual

Copyright 2013 DOOSAN
1Table of Contents
Safety
Track Excavator Safety......................................................................... SP002984
Specifications
Specification for DX138LC/DX140LC ................................................... SP002985
General Maintenance
General Maintenance Instructions ........................................................ SP002454
Standard Torques ................................................................................. SP002404
Upper Structure
Cabin (NON-ROPS).............................................................................. SP002994
Cabin (ROPS)....................................................................................... SP002995
Counterweight....................................................................................... SP002996
Fuel Tank.............................................................................................. SP002997
Fuel Transfer Pump (Opt)..................................................................... SP000021
Swing Bearing....................................................................................... SP001856
Swing Reduction Gear.......................................................................... SP002526
Lower Structure and Chassis

Track Assembly .................................................................................... SP002986
Engine and Drive Train

Drive Coupling (Main Pump)................................................................. SP001326
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ............... SP002214
Accumulator.......................................................................................... SP000028
Center Joint (Swivel)............................................................................. SP000029
Table of Contents
Page I
Cylinders............................................................................................... SP000030
Swing Motor.......................................................................................... SP002527
Travel Device........................................................................................ SP002920
Main Pump............................................................................................ SP002517
Main Control Valve ............................................................................... SP002998
Remote Control Valve (Work Lever / Joystick) ..................................... SP001646
Travel Control Valve (with Damper)...................................................... SP002999
Solenoid Valve Assembly ..................................................................... SP000445
Breaker EPPR Valve (Option) .............................................................. SP002458
Hydraulic Schematic (DX138LC/DX140LC) ......................................... SP002991
Electrical System
Electrical System (NON-ROPS) ........................................................... SP002992
Electrical System (ROPS)..................................................................... SP002993
Electrical Schematic (NON-ROPS)....................................................... SP002265
Electrical Schematic (ROPS)................................................................ SP002266
Attachments
Boom and Arm...................................................................................... SP001331
Bucket................................................................................................... SP000939
Table of Contents
Page II
1Safety
SP002984
TRACK EXCAVATOR SAFETYSP002984
Track
Excavator
Safety
Edition 1
Track Excavator Safety SP002984

Page 1
MEMO

Page 2
Table of Contents
Track Excavator Safety

Safety Instructions ................................................ 5
Applicable Models ................................................ 5
To the Operator of a DOOSAN Excavator............ 6
General Safety Essentials .................................... 9
Location of Safety Labels ................................... 10
Summary of Safety Precautions for Lifting in
Digging Mode ..................................................... 11
Unauthorized Modifications ................................ 12
General Hazard Information ............................... 12
Before Starting Engine ....................................... 22
Machine Operation ............................................. 25
Maintenance ....................................................... 33
Battery ................................................................ 42
Towing ................................................................ 44
Shipping and Transportation .............................. 45
Lifting With Sling ................................................. 45

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation and
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
MODEL SERIAL NUMBER RANGE

DX138LC 6407 and Up
DX140LC 5001 and Up

Page 5
TO THE OPERATOR OF A
DOOSAN EXCAVATOR
DANGER
AVOID DEATH
Unsafe use of the excavator could lead to serious injury or
death. Operating procedures, maintenance and equipment
practices or traveling or shipping methods that do not
follow the safety guidelines on the following pages could
cause serious, potentially fatal injuries or extensive
damage to the machine or nearby property.
Please respect the importance of taking responsibility for your

own safety, and that of other people who may be affected by
your actions.
The safety information on the following pages is organized into
the following sections:
1. “General Safety Essentials” on page-9
2. “Location of Safety Labels” on page-10
3. “Summary of Safety Precautions for Lifting in Digging
Mode” on page-11
4. “Unauthorized Modifications” on page-12
5. “General Hazard Information” on page-12
6. “Before Starting Engine” on page-22
7. “Machine Operation” on page-25
8. “Maintenance” on page-33
9. “Battery” on page-42
10. “Towing” on page-44
11. “Shipping and Transportation” on page-45
12. “Lifting With Sling” on page-45

Page 6
WARNING
Improper operation and maintenance of this machine can
be hazardous and could result in serious injury or death.
Operator and maintenance personnel should read this
manual thoroughly before beginning operation or
maintenance.
Keep this manual in the storage compartment to the rear of
the operator's seat, and have all personnel involved in
working on the machine read the manual periodically.
Some actions involved in operation and maintenance of the
machine can cause a serious accident, if they are not done
in a manner described in this manual.
The procedures and precautions given in this manual apply
only to intended uses of the machine.
If you use your machine for any unintended uses that are
not specifically prohibited, you must be sure that it is safe
for any others. In no event should you or others engage in
prohibited uses or actions as described in this manual.
DOOSAN delivers machines that comply with all applicable
regulations and standards of the country to which it has
been sent. If this machine has been purchased in another
country or purchased from someone in another country, it
may lack certain safety devices and specifications that are
necessary for use in your country. If there is any question
about whether your product complies with the applicable
standards and regulations of your country, consult
DOOSAN or your DOOSAN distributor before operating the
machine.
SAFETY ALERT SYMBOL

Be Prepared - Get to Know All Operating and Safety
Instructions.
This is the Safety Alert Symbol. Wherever it appears in this
manual or on safety signs on the machine you must be alert
to the potential for personal injury or accidents. Always
observe safety precautions and follow recommended
procedures.

Page 7
Learn Signal Words Used with Safety Alert
Symbol
The words "CAUTION", "WARNING", and "DANGER" used
throughout this manual and on decals on the machine indicate
degree of risk of hazards or unsafe practices. All three degrees
of risk indicate that safety is involved. Observe precautions
indicated whenever you see the Safety Alert "Triangle", no
matter which signal word appears next to "Exclamation Point"
symbol.
CAUTION
This word is used on safety messages and safety labels and
indicates potential of a hazardous situation that, if not
avoided, could result in minor or moderate injury. It may
also be used to alert against a generally unsafe practice.
WARNING
indicates potential threat of a hazardous situation that, if
not avoided, could result in serious injury or death. It may
also be used to alert against highly unsafe practice.
DANGER
indicates an imminent hazard of a situation that, if not
avoided, is very likely to cause death or extremely serious
injury. It may also be used to alert against equipment that
may detonate or explode if handled or treated carelessly.
Safety precautions are described in SAFETY from page -10 on.

DOOSAN cannot predict every circumstance that might involve
a potential hazard in operation and maintenance. Therefore the
safety messages in this manual and on the machine may not
include all possible safety precautions. If any procedures or
actions not specifically recommended or allowed in this manual
are used, you must be sure that you and others can do such
procedures and actions safely and without damaging the
machine. If you are unsure about the safety of any procedures,
contact a DOOSAN distributor.

Page 8
GENERAL SAFETY ESSENTIALS
Accessory Applications
The excavator has been primarily designed for moving earth
with a bucket. For use as a grapple or for other object handling,
contact DOOSAN for proper installation and application. Lifting-
work applications (unless restricted or prohibited by local
regulations) are permitted in approved lift configuration, to rated
capacity only, with no side-loading. DO NOT use the machine
for activities for which it was not intended. DO NOT use the
bucket for lifting work, unless lift slings are used in the approved
configuration.
Use of an accessory hydraulic hammer (breaker), work in rough
terrain, demolition applications or other hazardous operation
may require installation of additional protective structures to
safeguard the operator.
Lifting Capacity Rating Configuration

Lifting capacity ratings that are printed at the end of this safety
section are based on the machine being level, on a firm
supporting surface, with hooks and slings attached in approved
configuration. Loads must be balanced and supported evenly.
Use tag lines to keep the load steady if wind conditions and
large surface area are a problem. Work crew hand signals,
individual tasks and safe procedures should all be universally
understood before the lift is made.
IMPORTANT
Before using the excavator to make lifts check municipal
and regional regulations or statutes that could apply.
Governing ordinances may require that all heavy lifting be
done with single purpose equipment specifically designed
for making lifts, or other local restrictions may apply.
Making heavy lifts with a general purpose excavator that
can be used for digging, loading, grading or other work may
be expressly forbidden by a regional injunction or other
legal prohibition. Always follow all of the other instructions,
guidelines and restrictions for Safe Lifting in the Operation
and Maintenance Manuals.

Page 9
LOCATION OF SAFETY LABELS
Location of safety labels (decals) can vary from unit to unit.
Refer to appropriate Operation and Maintenance Manual, and
parts manual for your unit.
Always replace damaged or faded decals.

Page 10
SUMMARY OF SAFETY
PRECAUTIONS FOR LIFTING IN
DIGGING MODE
DANGER
AVOID DEATH
Unsafe use of the excavator while making rated lifts could
cause serious, potentially fatal injuries or extensive
damage to the machine or nearby property. Do not let
anyone operate the machine unless they've been properly
trained and understand the information in the Operation
and Maintenance Manual.
To lift safely while in Digging Mode, the following items must be

evaluated by the operator and the work site crew.
• Condition of ground support.
• Excavator configuration and attachments.
• Weight, lifting height and lifting radius.
• Safe rigging of the load.
• Proper handling of the suspended load.
Tag lines on opposite sides of the load can be very helpful in
keeping a suspended load secure, if they are anchored safely to
control points on the ground.
WARNING
NEVER wrap a tag line around your hands or body.
NEVER rely on tag lines or make rated lifts when wind gusts
are more than 48.3 km/h (30 MPH). Be prepared for any wind
gust when working with loads that have a large surface area.
Always engage the "Digging Mode" control on the Instrument

Panel before using the excavator for lifting work.
WARNING
If you need more information or have any questions or
concerns about safe operating procedures or working the
excavator correctly in a particular application or in the
specific conditions of your individual operating
environment, please consult your local DOOSAN
representative.

Page 11
UNAUTHORIZED
MODIFICATIONS
Any modification made without authorization or written approval
from DOOSAN can create a safety hazard, for which the
machine owner will be held responsible.
For safety's sake, replace all OEM parts with the correct
authorized or genuine DOOSAN part. For example, not taking the
time to replace fasteners, bolts or nuts with the correct
replacement parts could lead to a condition where the safety of
critical assemblies are dangerously compromised.
GENERAL HAZARD
INFORMATION
Safety Rules
Only trained and authorized personnel can operate and maintain
the machine.
Follow all safety rules, precautions and instructions when
operating or performing maintenance on the machine.
Do not operate the machine if you are not feeling well, if you are
taking medication that makes you feel sleepy, if you have been
drinking, or if you are suffering from emotional problems. These
problems will interfere with your sense of judgment in
emergencies and can cause accidents.
When working with another operator or with a person on work
site traffic duty, be sure that all personnel know the nature of the
work and understand all hand signals that are to be used.
Always observe strictly any other rules related to safety.
Safety Features
Be sure that all guards and covers are installed in their proper
position. Have guards and covers repaired immediately if
damaged.
Be sure that you understand the method of use of safety
features such as safety lock lever and the seat belt, and use
them properly.
Never remove any safety features. Always keep them in good
operating condition.
Failure to use safety features according to the instructions in the
Operation and Maintenance Manual could result in serious
bodily injury.

Page 12
Inside Operator's Cabin
When entering the operator's cabin, always remove all mud and
oil from the soles of your shoes. If you operate the travel pedal
with mud or oil stuck to your shoes, your foot may slip and this
can cause a serious accident.
After using the ashtray, make sure that any matches or
cigarettes are properly extinguished, and be sure to close the
ashtray. If the ashtray is left open, there is a danger of fire.
Do not stick suction pads to the window glass. Suction pads act
as a lens and can cause fire.
Do not leave lighters laying around the operator's cabin. If the
temperature inside the operator's cabin becomes high, there is a
danger that lighter may explode.
Do not use cellular telephones inside the operator's cabin when
driving or operating the machine. There is a danger that this may
lead to an unexpected accident.
Never bring any dangerous objects such as flammable or
explosive items into the operator's cabin.
To ensure safety, do not use the radio or music headphones
when operating the machine. There is a danger that this may
lead to a serious accident.
When operating the machine, do not put your hands or head out
of the window.
When standing up from the operator's seat, always place safety
lock lever securely in the "LOCK" position. If you accidentally
touch the work equipment levers when they are not locked, the
machine may suddenly move and cause serious injury or
damage.
When leaving the machine, completely lower the work
equipment to the ground, set safety lock lever to "LOCK"
position and stop engine. Use the key to lock all the equipment.
Always remove key and take it with you.
Clothing and Personal Protective Items

Secure long hair, and avoid loose clothing and jewelry. These
items have the tendency to catch on controls or protrude into
parts and cause serious injury or death.
Do not wear oily clothes. They are flammable.
Full eye protection, a hard hat, safety shoes and gloves may be
required at the work site.
While working on the machine, never use inadequate tools.
They could break or slip, causing injury, or they may not HAOA020L
adequately perform intended functions. Figure 1

Page 13
Breathing Masks, Ear Protection May Be
Required
Do not forget that some risks to your health may not be
immediately apparent. Exhaust gases and noise pollution may
not be visible, but these hazards can cause disabling or
permanent injuries.
NOTE: The equivalent continuous A-weighted sound
pressure level at the workstation for this machine is
given in the operation manual.
Measurement is obtained on a dynamic machine
following the procedures and cabin conditions as
described in ISO 6396.
NOTE: The guaranteed sound power level emitted by the
machinery for this machine is given in the operation
manual.
Measurement is obtained on a dynamic machine with
the procedures as described in 2000/14/EC.
Vibration Level Information

Hands/Arms: The weighted root mean square acceleration to
which the hands/arms are subjected, is less than 2.5 m/s2.
Whole body: The weighted root mean square acceleration to
which the whole body is subjected, is less than 0.5 m/s2.
Measurements are obtained on a representative machine, using
measuring procedures as described in the following standard:
ISO 2631/1. ISO 5349, and SAE J1166.

Page 14
Recommendations for Limiting Vibrations
1. Select the right machine, equipment and attachments for a
particular application.
2. Replace any damaged seat by a genuine DOOSAN part.
Keep the seat maintained and adjusted.
• Adjust the seat and suspension for the weight and
size of the operator.
• Inspect and maintain the suspension and adjustment
mechanisms of the seat regularly.
3. Check that the machine is properly maintained.
• Tire pressure, brakes, steering, linkages, etc.
4. Steer, brake, accelerate, shift gears, move the
attachments and load the attachments smoothly.
5. Adjust the machine speed and travel path to reduce the
vibration level.
• Slow down if it is necessary when traveling through
rough terrain.
• When driving machine, avoid obstacles and
excessive rough terrain.
6. Keep the machine on terrain where working and traveling
conditions are good.
• Remove any large rocks or obstacles.
• Fill any ditches and holes.
• Provide machines for and schedule time to maintain
good terrain conditions.
7. Travel over longer distances (e.g. on public roads) at
adjusted (medium) speed.
• Always adjust the speed to prevent bouncing.

Page 15
Mounting and Dismounting
Before getting on or off the machine, if there is any oil, grease,
or mud on the handrails, steps, or track shoes, wipe it off
immediately. Always keep these parts clean. Repair any
damage and tighten any loose bolts.
Never jump on or off the machine. In particular, never get on or
off a moving machine. These actions may lead to serious injury.
When getting on or off the machine, always face the machine,
and maintain three-point contact (both feet and one hand or one
foot and both hands) with the handrails, steps, and track shoes
to ensure that you support yourself securely.
Never hold any control levers when getting on or off the
machine.
Apply the door lock securely. If you grip the handrail inside the
door when moving on top of the track shoes, and the door lock is
not applied securely, the door may move and cause you to fall.
Use the points marked by arrows in the diagram when getting on
or off the machine.
FG000355
Figure 2
Fuel, Oil and Hydraulic Fluid Fire Hazards

Fuel, oil and antifreeze will catch fire if it is brought close to a
flame. Fuel is particularly flammable and can be hazardous.
Always strictly observe the following.
Add fuel, oil, antifreeze and hydraulic fluid to the machine only in
a well ventilated area. The machine must be parked with
controls, lights and switches turned "OFF". The engine must be
"OFF" and any flames, glowing embers, auxiliary heating units
or spark causing equipment must be extinguished, turned "OFF"
and/or kept well clear of the machine.
Static electricity can produce dangerous sparks at the fuel filling
nozzle. In very cold, dry weather or other conditions that could
produce a static discharge, keep the tip of the fuel nozzle in
constant contact with the neck of the fuel filling nozzle, to
ARO1050S
provide a ground.
Figure 3
Keep fuel and other fluid reservoir caps tight and do not start the
engine until caps have been secured.

Page 16
Precautions When Handling Fluids at High
Temperature
Immediately after operations are stopped, the coolant, engine
oil, and hydraulic oil are at highest temperatures and the radiator
and hydraulic tank are still under pressure. Attempting to
remove cap, drain the oil or coolant, or replacing the filters may
lead to serious burns. Always wait for the temperature to go
down, and follow the specified procedures when carrying out
these operations.
HAOA050L
Figure 4
To prevent hot coolant from spurting out, stop engine, wait for
the coolant to cool, then loosen the cap slowly to relieve the
pressure.
To prevent hot oil from spurting out, stop engine, wait for the oil
to cool, then loosen the cap slowly to relieve the pressure.
HAOA060L
Figure 5
Asbestos Dust Hazard Prevention

Asbestos dust can be HAZARDOUS to your health if it is
inhaled. Materials containing asbestos fiber can be present on
work site. Breathing air that contains asbestos fiber can ultimately
cause serious or fatal lung damage. To prevent lung damage from
asbestos fiber, observe following precautions:
• Use a respirator that is approved for use in an asbestos-
laden atmosphere.
• Never use compressed air for cleaning.
ARO1770L
• Use water for cleaning to keep down the dust. Figure 6
• Work on the machine or component with the wind at your
back whenever possible.
• Always observe any regulations related to the work site
and working environment.

Page 17
Injury from Work Equipment
Do not enter or put your hand, arm or any other part of your body
between movable parts, such as between the work equipment
and cylinders, or between the machine and work equipment.
If the control levers are operated, the clearance between the
machine and the work equipment will change and this may lead
to serious damage or personal injury.
If going between movable parts is necessary, always position
and secure the work equipment so it cannot move.
HDO1010L
Figure 7
Fire Extinguisher and First Aid Kit

As a precaution if any injury or fire should occur, always do the
following.
• Be sure that fire extinguishers have been provided and
read the labels to ensure that you know how to use them. It
is recommended that an appropriately sized (2.27 kg [5 lb]
or larger) multipurpose "A/B/C" fire extinguisher be
mounted in the cabin. Check and service the fire
extinguisher at regular intervals and make sure that all
work site crew members are adequately trained in its use. HDO1009L
Figure 8
• Provide a first aid kit in the storage compartment and keep
another at the work site. Check the kit periodically and
make any additions if necessary.
• Know what to do in case of injury from fire.
• Keep emergency numbers for doctor, ambulance service,
hospital and fire department near your telephone.
If the machine catches fire, it may lead to serious personal injury
or death. If a fire occurs during operation, escape from the
machine as follows:
• Turn the starter switch to "O" (OFF) position and stop
engine.
• If there is time, use the fire extinguisher to put out as much
of the fire as possible.
• Use the handrails and steps to escape from the machine.
The above is the basic method for escaping from the machine,
but changing the method may be necessary according to the
conditions, so carry out practice drills at the work site.

Page 18
Protection from Falling or Flying Objects
On work sites where there is a danger that falling or flying
objects may hit the operator's cabin select a guard to match the
operating conditions to protect the operator.
Working in mines, tunnels, deep pits or on loose or wet surfaces
could produce danger of falling rock or hazardous flying objects.
Additional protection for the operator's cabin could be required in
the form of a FOPS (Falling Object Protective Structure) or
window guards.
HAOA110L
Figure 9
Never attempt to alter or modify any protective structure

reinforcement system, by drilling holes, welding, remounting or
relocating fasteners. Any serious impact or damage to the
system requires a complete integrity reevaluation.
Reinstallation, recertification and/or replacement of the system
may be necessary.
Contact your DOOSAN distributor for available safety guards
and/or recommendations to prevent danger of getting hit by
objects that could strike the operator's cabin. Make sure that all
other work site crew members are kept well away from the
excavator and safe from possible hazards. HAOA100L
Figure 10
For breaker operation, install a front guard and apply a
laminated coating sheet to the front glass. Contact your
DOOSAN distributor for recommendations.
When carrying out demolition or cutting operation, install a front
guard and top guard, and apply a laminated coating sheet to the
front glass.
When working in mines or quarries where there is a danger of
falling rock, install FOPS (Falling Objects Protective Structure)
and apply a laminated coating sheet to the front glass.
If any glass on the machine is broken, replace it with new glass
immediately.
Attachment Precautions
Option kits are available through your dealer. Contact DOOSAN
for information on available one-way (single-acting) and two-way
(double-acting) piping / valving / auxiliary control kits. Because
DOOSAN cannot anticipate, identify or test all the attachments that
owners may wish to install on their machines, please contact
DOOSAN for authorization and approval of attachments, and
their compatibility with optional kits.

Page 19
Accumulator
The pilot control system is equipped with an accumulator. For a
brief period of time after the engine has been shut down, the
accumulator will store a pressure charge that may enable
hydraulic controls to be activated. Activation of any controls may
enable the selected function to operate under force of gravity.
When performing maintenance on the pilot control system, the
hydraulic pressure in the system must be released as described
in "Handling of Accumulator" in the Operation and Maintenance
Manual.
The accumulator is charged with high-pressure nitrogen gas, so
it is extremely dangerous if it is handled in the wrong way.
Always observe the following precautions:
• Do not drill or make any holes in the accumulator or
expose it to any flames, fire or heat source.
• Do not weld on the accumulator, or try attaching anything
to it.
• When carrying out disassembly or maintenance of the
accumulator, or when disposing of the accumulator, the
charged gas must be properly released. Contact your
DOOSAN distributor.
• Wear safety goggles and protective gloves when working on an
accumulator. Hydraulic oil under pressure can penetrate
the skin and cause serious injuries.
Indoor Ventilation
Engine exhaust gases can cause fatal accidents, and
unconsciousness, loss of alertness, judgment and motor control
and serious injury.
Make sure there is adequate ventilation before starting the
engine in any enclosed area.
You should also be aware of open windows, doors or ductwork
where exhaust may be carried, or blown by the wind, exposing
others to danger.
ARO1770L
Figure 11

Page 20
Emergency Exit
The excavator is equipped with a glass breaking tool. It is behind
the operator seat in the upper right corner of the cabin. This tool
can be used in case of an emergency that requires breaking
glass to exit from the operator's cabin. Grip the handle firmly and
use the sharp point to break the glass.
WARNING
FG000178
AVOID DEATH OR SERIOUS INJURY Figure 12
Protect your eyes when breaking the glass.
Emergency Exit (ROPS)

The excavator is equipped with a glass breaking tool. It is found
on the center of the column to the left of the cabin. This tool can
be used in case of an emergency that requires breaking glass to
exit from the operator's cabin. Grip the handle firmly and use the
sharp point to break the glass.
WARNING
FG015808
Protect your eyes when breaking the glass.

Page 21
BEFORE STARTING ENGINE
Work Site Precautions

Before starting operations, thoroughly check the area for any
unusual conditions that could be dangerous.
Check the terrain and condition of the ground at the work site,
and determine the best and safest method of operation.
Make sure the ground surface is as hard and horizontal as
possible before carrying out operations. If there is a lot of dust
and sand on the work site, spray water before starting
operations.
If you need to operate on a street, protect pedestrians and cars
by designating a person for work site traffic duty or by erecting
fences and posting "No Entry" signs around the work site.
Erect fences, post "No Entry" signs, and take other steps to
prevent people from coming close to or entering the work site. If
people come close to a moving machine, they may be hit or
caught by the machine, and this may lead to serious personal
injury or death.
Waterlines, gas lines, phone lines and high-voltage electrical
lines may be buried under the work site. Contact each utility and DANGER
No Entry
identify their locations. Be careful not to damage or cut any of
these lines. FG000400
Figure 14
Check the condition of the riverbed, and the depth and flow of
the water before operating in water or crossing a river. NEVER
work in water that is more than the permissible water depth.
Any object in vicinity of boom could represent a potential hazard,
or cause the operator to react suddenly and cause an accident.
Use a spotter or signal person when working near bridges,
phone lines, work site scaffolds, or other obstructions.
FG000363
Figure 15
Minimum levels of insurance coverage, work permits or

certification, physical barriers around the work site or restricted
hours of operation may be mandated by governing authorities.
There may also be regulations, guidelines, standards or
restrictions on equipment that may have to be followed for local
requirements. There may also be regulations related to
performing certain kinds of work. If there is any question about
whether your machine and work site complies with the
applicable standards and regulations, contact your local
authorities and agencies.
Avoid entering soft ground. It will be difficult for the machine to
escape. FG000372
Avoid operating your machine to close to the edge of cliffs, Figure 16
overhangs, and deep ditches. The ground may be weak in such
areas. If the ground collapses, the machine could fall or tip over
resulting in serious injury or death.

Page 22
Remember that soil after heavy rain, blasting or after
earthquakes, is weakened.
Newly laid earth and the soil near ditches is typically loose.. It
can collapse under the weight of vibration of your machine and
cause your machine to tip over.
Install the head guard (FOPS) if working in areas where there is
a danger of falling rocks.
Checks Before Starting Engine

Every day before starting the engine for the first time, carry out
the following checks. If these checks are not carried out
properly, there is a danger of serious injury.
Remove all wood chips, leaves, grass, paper and other
flammable materials accumulated in the engine compartment
and around the battery. They could cause a fire. Remove any
dirt from the window glass, mirrors, handrails, and steps.
Do not leave tools or spare parts laying around in the operator's
cabin. The vibration of the machine when traveling or during
operations can cause them to fall and damage or break the
control levers or switches. They may also get caught in the gap
of the control levers and cause the work equipment to
malfunction or move dangerously. This may lead to unexpected
accidents.
Check the coolant, fuel, and hydraulic tank oil levels, and check
for clogged air cleaner and damage to the electrical wiring.
Adjust the operator's seat to a position where it is easy to
operate the machine, and check the seat belt and mounts for
damage and wear.
Check the operation of the gauges and the angle of the mirrors,
and check that safety lever is in "LOCKED" position.
If any abnormalities are found in the above checks, carry out
repairs immediately.
Engine Starting
Walk around your machine before getting in the operator's
cabin. Look for evidence of leaking fluid, loose fasteners,
misaligned assemblies or any other indications of possible
equipment hazard.
All equipment covers and machinery safety guards must be in
place, to protect against injury while the machine is being
operated.
Look around the work site area for potential hazards, people or
property that could be at risk while operation is in progress.
NEVER start the engine if there is any indication that
maintenance or service work is in progress, or if a warning tag is
attached to controls in the cabin.
A machine that has not been used recently, or is being operated
in extremely cold temperatures, could require a warm-up or
maintenance service before start-up.

Page 23
Check gauges and monitor displays for normal operation before
starting the engine. Listen for unusual noises and remain alert
for other potentially hazardous conditions at the start of the work
cycle.
Do not short-circuit the starting motor to start the engine. This is
not only dangerous, but may also damage the machine.
When starting the engine, sound the horn as an alert.
Start and operate the machine only while seated.
Before Operating Machine

If checks are not carried out properly after starting the engine, it
may result in a delay in discovering abnormalities in the
machine, and this may lead to personal injury or damage to the
machine.
Carry out the checks in an open area where there are no
obstructions. Do not let anyone near the machine when carrying
out the checks.
• Check the operating condition of the equipment, and the
movement of the bucket, arm, boom, travel, and swing
systems.
• Check the machine for any abnormal noise, vibration, heat,
smell, or abnormality with the gauges. Check also for
leakage of air, oil, and fuel.
• If any abnormality is found, repair the problem
immediately. If the machine is used without repairing the
problems, it may lead to unexpected injury or failure.
• Clear all personnel from directly around machine and from
the area.
• Clear all obstacles from the machine's path. Beware of
hazards.
• Be sure that all windows are clean. Secure the doors and
the windows in the open position or in the shut position.
• Adjust the rearview mirrors for best visibility close to the
machine. Make sure that horn, the travel alarm (if
equipped), and all other warning devices are working
properly.
• Fasten the seat belt securely.
• Warm up the engine and hydraulic oil before operating
machine.
• Before moving the machine, check undercarriage position.
The normal travel position is with idler wheels to the front
under the cabin and the drive sprockets to the rear. When
the undercarriage is in the reversed position, the travel
controls must be operated in opposite directions.

Page 24
MACHINE OPERATION
When Swinging or Changing Direction of

Travel
Before operating the machine or the work equipment, always
observe the following precautions to prevent serious injury or
death.
• Start and operate the machine only while seated.
• When changing travel direction from forward to reverse or
from reverse to forward, reduce speed early and stop the
machine before changing travel direction. HAOA190L
• Sound the horn to warn people in the area. Figure 17
• Check that there is no one in the area around the machine.
There are blind spots behind the machine, so if necessary,
swing the upper structure to check that there is no one
behind the machine before traveling in reverse.
• When operating in areas that may be hazardous or have
poor visibility, designate a person to direct work site traffic.
• Ensure that no unauthorized person can come within the
turning radius or direction of travel.
Be sure to observe the above precautions even if a travel alarm
or mirrors are installed.
Travel Precautions
TRAVEL POSTURE
Never turn the starting switch to "O" (OFF) position when
traveling. It is dangerous if the engine stops while the machine is
traveling. It will be impossible to operate the steering.
Attachment control levers should not be operated while
traveling.
Do not change selected travel mode (FAST/SLOW) while
traveling.
40 ~ 50 cm (16 ~ 20 in.)
Fold in work equipment so the outer end of the boom is as close
to the machine as possible, and is 40 - 50 cm (16 - 20 in)
aboveground. INCORRECT
Never travel over obstacles or slopes that will cause the
machine to tilt severely. Travel around any slope or obstacle that
causes the machine to tilt 10 degrees or more to the right or left,
or 30 degrees or more from front to rear.
Do not operate the steering suddenly. The work equipment may
hit the ground and cause the machine to lose its balance, and
this may damage the machine or structures in the area.
When traveling on rough ground, travel at low speed, and avoid FG000349
sudden changes in direction. Figure 18

Page 25
Always keep to the permissible water depth. Permissible water
depth is to the centerline of the upper track rollers.
When traveling over bridges or structures on private land, check
first that bridge or structure can withstand the weight of the
machine. When traveling on public roads, check with the local
authorities and follow their instructions.
Traveling on Slopes
Never jump onto a machine that is running away to stop it. There
is a danger of serious injury.
Traveling on slopes could result in the machine tipping over or
slipping. 20~
30 C
m
On hills, banks or slopes, carry the bucket approximately 20 - 30
cm (8 - 12 in) above the ground. In case of an emergency,
quickly lower the bucket to the ground to help stop the machine.
Do not travel on grass, fallen leaves, or wet steel plates. Even
slight slopes can cause the machine to slip to the side, so travel
at low speed and make sure that the machine is always traveling
directly up or down the slope.
Avoid changing travel directiol on a slope. This could result in
tipping or sideslipping of the machine.
When possible, operate the machine up slopes and downslopes. Cm
30
Avoid operating the machine across the slope, when possible. 20~
FG000365
Figure 19

Page 26
Prohibited Operations
Do not dig the work face under an overhang. This can cause the
overhang to collapse and fall on top of the machine.
FG000368
Figure 20
Do not carry out deep digging under the front of the machine.
The ground under the machine may collapse and cause the
machine to fall.
Working heavy loads over loose, soft ground or uneven, broken
terrain can cause dangerous side load conditions and possible
tipover and injury. Travel without a load or a balanced load may
also be hazardous.
Never rely on lift jacks or other inadequate supports when work
is being done. Block tracks fore and aft to prevent any
movement.
FG000170
Figure 21
When using the machine, to prevent accidents caused by

damage to the work equipment and overturning because of an
excessive load, do not use the machine in excess of its ability (in
terms of the maximum load and stability determined by the
structure of the machine).
When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death. Investigate the configuration and ground
conditions of the work site beforehand to prevent the machine
from falling and to prevent the ground, stockpiles, or banks from
collapsing. FG000367
Figure 22

Page 27
Precautions for Operation
Be careful not to mistakenly travel too close to the edge of a cliff.
Use the machine only for its main purpose. Using it for other
purposes will cause failures.
To ensure a good view, always do the following:
• When working in dark areas, attach working lights and
front lights to the machine. If necessary, set up lighting at
the work site.
FG000430
• Stop operations when the visibility is poor, such as in fog,
mist, snow, and rain. Wait for the visibility to improve to a Figure 23
level which causes no problems for the operation.
To avoid hitting the work equipment, always do the following:
• When working in tunnels, on bridges, under electrical
wires, or when parking the machine or carrying out other
operations in places with limited height, be careful not to hit
the bucket or other parts.
• To prevent collisions, operate the machine at a safe speed
when working in confined spaces, indoors, or in crowded
areas.
• Do not pass the bucket over the heads of workers or over
the operator's cabin of dump truck.
Avoid High-voltage Cables

Serious injury or death can result from contact or proximity to
high-voltage electrialcal lines. The bucket does not have to
make physical contact with power lines for current to be
transmitted.
Use a spotter and hand signals to stay away from power lines
not clearly visible to the operator.
Voltage Minimum Safe Distance

6.6 kV 3 m (9' 10") FG000171
33.0 kV 4 m (13' 1") Figure 24
66.0 kV 5 m (16' 5")
154.0 kV 8 m (26' 3")
275.0 kV 10 m (32' 10")
Use these minimum distances as a guideline only. Depending

upon the voltage in the line and atmospheric conditions, strong
current shocks can occur with the boom or bucket as faraway as
4 - 6 m (13 - 20 ft.) from the power line. Very high voltage and
rainy weather could further decrease that safety margin.
NOTE: Before starting any operation near power lines (either
aboveground or buried cable type), you should
always contact the power utility company directly and
work out a safety plan with them.

Page 28
Roll Over Protective Structure (ROPS)
When Required by Local Regulations
Global markets may or may not require a Roll Over Protective
Structure (ROPS). Always comply with all regional and
governmental regulations that apply to your market. The
following information is for a ROPS cabin.
General ROPS Guidelines for ROPS Certified Cabins

The operator's cabin is a ROPS certified structure for protecting
the seat-belted operator. It absorbs the impact energy of a
rollover impact. Do not allow machine weight (mass) to exceed
certified value on certification plate. If weight is exceeded, the
ROPS structure will not be able to fulfill its safety function.
Do not increase machine weight beyond certified value by
modifying machine or by installing attachments on machine. If
weight limit of protective equipment is exceeded, protective
equipment will not be able to protect operator, and operator may
suffer serious injury or death. Always observe the following:
• This machine is equipped with a protective structure. Do
not remove protective structure and carry out operations
without it.
• Never modify the operator’s cabin by welding, grinding,
drilling holes or adding attachments unless instructed by
DOOSAN. Changes to the cabin can cause loss of
operator protection from rollover and falling objects, and
operator may suffer serious injury or death.
• When protective structure is damaged or deformed by
falling objects or by rolling over, its strength will be reduced
and it will not be able to properly fulfill its function. In these
cases, always contact your DOOSAN distributor for advice.
Never repair a ROPS cabin.
• Always wear your seat belt when operating machine.

Page 29
ROPS Certification
This DOOSAN excavator has an operator’s cabin that meets
ROPS requirements. The seat belt must be worn for rollover
protection.
The ROPS certification plate (Figure 25) is found on the left side
of the cabin on most models. It may vary slightly in its location
on some models.
Check the ROPS cabin, mounting, and hardware for damage.
Never modify the ROPS cabin. Replace the cabin and hardware
if damaged. See your DOOSAN dealer for parts.
Figure 25
ROPS − Roll Over Protective Structure complies with
ISO 12117-2:2008.
WARNING
Never modify the operator cabin by welding, grinding,
DOOSAN. Changes to the cabin can cause loss of operator
protection from rollover and falling objects, and result in
serious injury or death.
Protecting Cabin from Falling Object

(Optional)
In a work site where falling objects or flying objects are
expected, be sure to install adequate protective devices for 1
covering the cabin.
When using a breaker, be sure to install the front window
protection guard (1, Figure 26).
FG000112
Figure 26

Page 30
In a work site where falling rocks can cause damage and
possibly crush personnel, or in a mining operation, be sure to
install the falling object protective structure (2, Figure 27).
Be sure to install any other additional protective structures
required for work site conditions.
When the falling object protective structure is installed, and the
front window needs to be cleaned, loosen the bolts marked with
an arrow. Be sure to tighten bolts when done. 2
FG000113
Figure 27
Operate Carefully on Snow, Ice and in Very

Cold Temperatures
In icy cold weather avoid sudden travel movements and stay
away from even slight slopes. The machine could skid off to one
side very easily.
Snow accumulation could hide or obscure potential hazards.
Use care while operating or while using the machine to clear
snow.
Warming up the engine for a short period may be necessary, to
avoid operating with sluggish or reduced working capacity. The
jolting shocks and impact loads caused by bumping or
bottoming the boom or attachment are more likely to cause
severe stress in very cold temperatures. Reducing work cycle
rate and workload may be necessary.
When the temperature rises, frozen road surfaces become soft,
and machine travel becomes unstable.
In cold weather, do not touch metal surfaces with your bare
hands. If you touch a metal surface in extremely cold weather,
your skin may freeze to the metal surface.

Page 31
Operations on Slopes
When working on slopes. there is a danger that the machine
may lose its balance and turn over, when swinging, or when
work equipment is operated. Always carry out these operations
carefully.
Do not swing the work equipment from the uphill side to the
downhill side when the bucket is loaded. This operation is
dangerous.
If the machine has to be used on a slope, pile the soil to make a
FG000212
platform that will keep the machine as horizontal as possible.
Figure 28
In addition, lower the bucket as far as possible, keep it pulled
into the front, and keep the swing speed as low as possible.
Parking Machine
Avoid making sudden stops, or parking the machine wherever it
happens to be at the end of the workday. Plan so the excavator 120
will be on firm and level ground away from traffic and away from
high walls, cliff edges and any area of potential water
accumulation or runoff. If parking on inclines is unavoidable,
Block
block the crawler tracks to prevent movement. Lower the bucket
or other working attachment completely to the ground, or to an
overnight support saddle. There must be no possibility of
unintended or accidental movement.
When parking on public roads, provide fences, signs, flags, or Unlock
lights, and put up any other necessary signs to ensure that
passing traffic can see the machine clearly. Park the machine so
the machine, flags, and fences do not obstruct traffic.
After the front attachment has been lowered to an overnight
storage position and all switches and operating controls are in Lock
the "OFF" position, the safety lock lever must be set to FG000666
"LOCKED" position. This will disable all pilot circuit control Figure 29
functions.
Always close the door of the operator's cabin.
Never Let Anyone Ride on Attachment

Never let anyone ride on any work attachment, such as the
bucket, crusher, grapple, or clamshell (grab bucket). There is a
potential danger of the person falling and suffering serious
injury.
ARO1310L
Figure 30

Page 32
MAINTENANCE
Warning Tag
Alert others that service or maintenance is being performed and
tag operator's cabin controls – and other machine areas if
required – with a warning notice. OSHA mandated control lever
WARNING
lockout can be made with any OSHA certified lockout device and
a length of chain or cable to keep the safety lever in the fully DO NOT OPERATE
lowered, nonactive position. when performing inspection
Warning tags, for controls are available from DOOSAN or maintenance
distributors. 950205-01451
FG018690
Figure 31
Clean Before Inspection or Maintenance

Clean the machine before carrying out inspection and
maintenance. This prevents dirt from getting into the machine
and ensures safety during maintenance.
If inspection and maintenance are carried out when the machine
is dirty, it will become more difficult to locate the problems, and
there is a danger that you may get dirt or mud in your eyes or
that you may slip and injure yourself.
When washing the machine, do the following:
• Wear shoes with nonslip soles to prevent yourself from
slipping and falling on wet places.
• Wear safety glasses and protective clothing when washing
the machine with high-pressure steam.
• Take action to prevent touching high-pressure water and
cutting your skin or having mud fly into your eyes.
ARO1330L
• Do not spray water directly on electrical components
Figure 32
(sensors, connector). If water gets into the electrical
system, there is a danger that it will cause defective
operation and malfunction.
Pick up any tools or hammers that are laying in the workplace.
Wipe up any grease or oil or any other slippery substances, and
clean the area to make it possible to carry out the operation in
safety. If the workplace is left untidy, you may trip or slip and
suffer injury.

Page 33
Proper Tools
Use only tools suited to the task. Using damaged, low quality,
faulty, or makeshift tools could cause personal injury. There is a
danger that pieces from, chisels with crushed heads, or
hammers, may get into your eyes and cause blindness.
HDO1037L
Figure 33
Use of Lighting
When checking fuel, oil, battery electrolyte, or window washing
fluid, always use lighting with antiexplosion specifications. If
such lighting equipment is not used, there is a danger of an
explosion.
If work is carried out in dark places without using lighting, it may
lead to injury, so always use proper lighting.
Even if the place is dark, never use a lighter or flame instead of
lighting. There is a danger of fire. There is also danger that
HDO1040L
battery gas may catch fire and cause an explosion.
Figure 34
Fire Prevention and Explosion Prevention

All fuels, most lubricants and some coolant mixtures are
flammable. Leaking fuel or fuel that is spilled onto hot surfaces
or onto electrical components can cause a fire.
Store all fuels and all lubricants in properly marked containers
and away from all unauthorized persons.
Store oily rags and other flammable material in a protective
container.
Do not smoke while you refuel the machine or while you are in a
HDO1015I
refueling area.
Figure 35
Do not smoke in battery charging areas or in areas that contain
flammable material.
Clean all electrical connections and tighten all electrical
connections. Check the electrical wires daily for wires that are
loose or frayed. Tighten all lose electrical wires before you
operate the machine. Repair all frayed electrical wires before
you operate the machine.
Remove all flammable materials before they accumulate on the
machine.
Do not weld on pipes or on tubes that contain flammable fluids.
Do not flame cut on pipes or on tubes that contain flammable
fluids. Before you weld on pipes or on tubes or before you flame
cut on pipes or on tubes, clean the pipes or tubes thoroughly
with a nonflammable solvent.

Page 34
Burn Prevention
When checking the radiator coolant level, stop engine, let the
engine and radiator cool down, then check the coolant recovery
tank. If the coolant level in the coolant recovery tank is near the
upper limit, there is enough coolant in the radiator.
Loosen the radiator cap gradually to release the internal
pressure before removing the radiator cap.
If the coolant level in the coolant recovery tank is below the
lower limit, add coolant.
Cooling system conditioner contains alkali. Alkali can cause
personal injury. Do not allow alkali to contact the skin, the eyes,
or the mouth.
Allow cooling system components to cool before you drain the
cooling system.
Hot oil and hot components can cause personal injury. Do not
allow hot oil or hot components to contact the skin.
Remove hydraulic tank filter plug only after the engine has been
stopped. Make sure that hydraulic tank filter plug is cool before
you remove it with your bare hand. Remove hydraulic tank filter
plug slowly to relieve pressure.
Relieve all pressure in the hydraulic oil system, in the fuel
system, or in the cooling system before you disconnect any
lines, fittings, or related items.
HAAE1980
Batteries give off flammable fumes that can explode.
Figure 36
Do not smoke while you are checking the battery’s electrolyte
levels.
Electrolyte is an acid. Electrolyte can cause personal injury. Do
not allow electrolyte to contact the skin or the eyes.
Always wear protective glasses when you work on batteries.

Page 35
Welding Repairs
IMPORTANT
When disconnecting or connecting connectors between
ECU and engine, or connector between ECU and the
machine, always disconnect the battery to prevent damage
to ECU.
If you do not follow this procedure, the ECU will be
damaged and/or the engine will not operate properly.
When performing welding repairs, perform welding in a properly

equipped place. Repairs must be performed by a qualified
welder. Welding operations, can create potential hazards,
including generation of gas, fire, or electric shock. Never let an
unqualified welder do welding.
A qualified welder must do the following:
• To prevent battery explosion, turn battery disconnect
switch to "OFF" position.
• To prevent generation of gas, remove paint from location
of the weld.
• If hydraulic equipment, piping or component ports close to
them are heated, a flammable gas or mist could result in
an explosion or fire. To prevent this, protect and insulate
components from excessive heat.
• Do not weld on pipes or on tubes that contain flammable
fluids. Do not flame cut pipes or tubes that contain
flammable fluids. Before welding on pipes or tubes, or
before flaming cut pipes or tubes, clean them thoroughly
with a nonflammable solvent. Make sure pressure inside
pipes or tubes does not cause a rupture of the component
parts.
• If heat is applied directly to rubber hoses or piping under
pressure, they may suddenly break, so cover and insulate
them with a fireproof covering.
• Wear protective clothing.
• Make sure there is good ventilation.
• Remove all flammable objects and make sure a fire
extinguisher is available.

Page 36
Preparation for Electrical Welding On Body Structure
To prevent damage to ECU by electrical welding, observe the
following procedures:
1. Turn battery disconnect switch to "OFF" position.
2. Disconnect the connector (1, Figure 38) between ECU and
machine, and the connector between ECU and engine.
3. Proceed with welding. ON OFF
4. After welding, connect the connector between ECU and

machine, and the connector between ECU and engine. FG020630
Figure 37
5. Clean battery compartment.
6. Turn battery disconnect switch to "ON" position.

7. Close battery compartment door. 1
FG000335
Figure 38
Warning for Counterweight and Front

Attachment Removal
DANGER
AVOID DEATH
DOOSAN warns any user, that removal of the counterweight
from the machine, front attachment or any other part, may
affect the stability of the machine. This could cause
unexpected movement, resulting in death or serious
injuries. DOOSAN is not liable for any misuse.
Never remove counterweight or front attachment unless the FG000371
upper structure is in-line with the lower structure.
Figure 39
Never rotate the upper structure once the counterweight or
front attachment has been removed.

Page 37
Precautions for Removal, Installation, and
Storage of Attachments
Before starting removal and installation of attachments, decide
on the team leader.
Do not allow anyone except the authorized workers close to the
machine or attachment.
Place attachments that have been removed from the machine in
a safe place so they do not fall. Put up a fence around the
attachments and take other measures to prevent unauthorized HDO1041L
persons from entering. Figure 40
Precautions When Working on Machine

When carrying out maintenance operations on the machine,
keep area around your feet clean and tidy to prevent you falls.
Always do the following:
• Do not spill oil or grease.
• Do not leave tools laying about.
• Watch your step when walking.
Never jump down from the machine. When getting on or off the ARO1380L
machine, use the steps and handrails, and maintain a three-
Figure 41
point contact (both feet and one hand or both hands and one
foot) to support yourself securely.
If the job requires it, wear protective clothing.
To prevent injury from slipping or falling, when working on the
hood or covers, never use any area except the area equipped
with nonslip pads.
Lock Inspection Covers

When carrying out maintenance with the inspection cover open,
lock the cover securely in position with the lock bar.
If maintenance work is carried out with the inspection cover
open but not locked, there is a danger that it may suddenly close
and cause injury if there is a gust of wind.

Page 38
Prevention of Crushing and Cutting
You should always have at least two people working together if
the engine must be run during service. One person needs to
remain in the operator's seat, ready to work the controls or stop
the machine and shut off the engine.
Unless you are instructed otherwise, never attempt adjustments
while the machine is moving or while the engine is running.
Stay clear of all rotating parts and moving parts.
Keep objects away from moving fan blades. The fan blades will
throw objects and the fan blades can cut objects.
Do not use a wire rope cable that is kinked or frayed. Wear
gloves when you handle a wire rope cable.
When you strike a retainer pin, the retainer pin might fly out. The
loose retainer pin can injure personnel. Make sure that area is
clear of people when you strike a retainer pin. To avoid injury to
your eyes, wear protective glasses when you strike a retainer
pin.
Track Tension Adjustments Require

Caution
Never turn out the track tension grease valve. To release
pressure from the crawler frame track tension assembly, you
should NEVER attempt to disassemble the track adjuster or
attempt to remove grease fitting or valve assembly.
Keep your face and body away from the valve. Refer to the track
adjustment procedure in the Operator and Maintenance Manual
or Shop Manual.
HAOA110L
Figure 42
Supports and Blocking for Work

Equipment
Do not allow weight or equipment loads to remain suspended.
Lower everything to the ground before leaving the operator's
seat.
Do not use hollow, cracked or unsteady wobbling supports.
Do not work under any equipment supported only by a lifting
jack.
HDO1042L
Figure 43

Page 39
Action When Abnormality Is Found During
Inspection
If any abnormality is found during inspection, always carry out
repairs. In particular, if the machine is used when there are still
problems with the brake or work equipment systems, it may lead
to serious injury.
If necessary depending on the type of failure, please contact
your DOOSAN distributor for repairs.
Precautions with High-pressure Lines,

Tubes and Hoses X
When inspecting or replacing high-pressure piping or hoses,
check to verify that pressure has been released from the circuit.
Failure to release the pressure may lead to serious injury.
Always do the following:
• Wear protective glasses and leather gloves.
• Fluid leaks from hydraulic hoses or pressurized
X
components can be difficult to see but pressurized oil has
enough force to pierce the skin and cause serious injury.
Always use a piece of wood or cardboard to check for
suspected hydraulic leaks. Never use your hands or
expose your fingers.
• Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install lines, tubes or hoses that are
bent or damaged.
• Make sure that all clamps, guards and heat shields are
installed correctly to prevent vibration, rubbing against
other parts, and excessive heat during operation.
– If any of the following conditions are found, replace HDO1045I
the part: Figure 44
– Damage or leakage from hose end.
– Wear, damage, cutting of covering, or exposure of
strengthening wire layer.
– Cover portion is swollen in places.
– There is twisting or crushing at movable parts of
hose.
– Foreign material is embedded in the covering.
– Hose end is deformed.
NOTE: Refer to "Hose In-service Lifetime Limit (European
Standard ISO 8331 and EN982 CEN)" in the
Operation and Maintenance Manual, for additional
European regulations.

Page 40
Waste Materials
Physical contact with used motor oil may pose a health risk.
X
Wipe oil from your hands promptly and wash off any remaining
residue.
Used motor oil is an environmental contaminant and may only
be disposed of at approved collection facilities. To prevent
pollution of the environment, always do the following:
• Never dump waste oil in a sewer system, rivers, etc.
• Always put oil drained from your machine in containers. HAOA470L
Never drain oil directly onto the ground. Figure 45
• Obey appropriate laws and regulations when disposing of
harmful materials such as oil, fuel, solvent, filters, and
batteries.

Page 41
BATTERY
Battery Hazard Prevention

Battery electrolyte contains diluted sulfuric acid and batteries
generate hydrogen gas. Hydrogen gas is highly explosive, and
mistakes in handling them can cause serious injury or fire. To
prevent problems, always do the following:
• Do not smoke or bring any flame near the battery.
• When working with batteries, ALWAYS wear safety
glasses and rubber gloves.
• If you spill battery electrolyte on yourself or your clothes,
immediately flush the area with water.
• If battery electrolyte gets into your eyes, flush them
immediately with large quantities of water and see a doctor
at once.
• If you accidentally drink battery electrolyte, drink a large
quantity of water or milk, raw egg or vegetable oil. Call a
doctor or poison prevention center immediately.
• When cleaning the top surface of the battery, wipe it with a
clean, damp cloth. Never use gasoline, thinner, or any
other organic solvent or detergent.
• Tighten the battery caps securely.
Figure 46
• If the battery electrolyte is frozen, do not charge the battery
or start the engine with power from another source. There
is a danger that battery may catch fire.
• When charging the battery or starting with power from
another source, let the battery electrolyte melt and check
that there is no leakage of battery electrolyte before
starting the operation.
• Always remove battery from the machine before charging.

Page 42
Boost Starting or Charging Engine
Batteries
If any mistake is made in the method of connecting the booster
cables, it can cause an explosion or fire. Always do the
following:
• Turn off all electrical equipment before connecting leads to
the battery. This includes electrical switches on the battery
charger or boost starting equipment.
HAOA310L
• When boost starting from another machine or vehicle do
not allow the two machines to touch. Wear safety glasses Figure 47
or goggles while required battery connections are made.
• 24 volt battery units consisting of two series connected
twelve volt batteries have a cable connecting one positive
terminal on one of the 12 volt batteries to a negative
terminal on the other battery. Booster or charger cable
connections must be made between the nonseries
connected positive terminals and between the negative
terminal of the booster battery and the metal frame of the
machine being boosted or charged. Refer to the procedure
and illustration in "Starting Engine With a Booster Cable" in
the Operation and Maintenance Manual.
• Connect positive cable first when installing cables and
disconnect the negative cable first when removing them.
The final cable connection, at the metal frame of the
machine being charged or boost started, must be as
faraway from the batteries as possible.

Page 43
TOWING
Precautions When Towing

Cloth
If any mistake is made in the method of selecting or inspecting
the towing wire or in the method of towing, it may lead to serious
personal injury. Always do the following:
• Always use the method of towing given in this Operation
and Maintenance Manual. Do not use any other method.
• Use leather gloves when handling the wire rope. Towing Wire
• When carrying out the preparation work for towing with two
or more workers, determine the signals to use and follow
these signals correctly.
• Always fit the towing rope to the left and right hooks and
secure in position.
• If the engine on the problem machine will not start or there
is a failure in the brake system. always contact your
DOOSAN distributor.
• Never go between the towing machine and the towed Towing Wire
machine during the towing operation. FG014876
Figure 48
• It is dangerous to carry out towing on slopes, so select a
place where the slope is gradual. If there is no place where
the slope is gradual, carry out operations to reduce the
angle of the slope before starting the towing operation.
• When towing a problem machine, always use a wire rope
with a sufficient towing capacity.
• Do not use a frayed, kinked rope or a rope with any loss of
diameter.
• Do not use the lightweight towing hook for towing another
machine.

Page 44
SHIPPING AND
TRANSPORTATION
Obey State and Local Over-the-Road

Regulations
Check state and local restrictions regarding weight, width and
length of a load before making any other preparation for
transport.
The hauling vehicle, trailer and load must all be in compliance
with local regulations governing the intended shipping route.
Partial disassembly or teardown of the excavator may be
necessary to meet travel restrictions or particular conditions at
the work site. See the Shop Manual for information on partial
disassembly.
Refer to the Transportation and Shipping section of this
Operation and Maintenance Manual for information on loading,
unloading and towing.
LIFTING WITH SLING
WARNING
Improper lifting can allow load to shift and cause injury or
damage.
1. Refer to Specification section of Operation and

Maintenance Manual for information on weight and
dimensions.
2. Use properly rated cables and slings for lifting.
3. Position machine for a level lift.
4. Lifting cables should have a long enough length to prevent FG016361
contact with the machine. Spreader bars may be required.
Figure 49
NOTE: If spreader bars are used, be sure that cables are
properly secured to them and that the angle of the
cables is factored into the lift strength.

Page 45
Page 46
1Specifications
SP002985
SPECIFICATION FOR DX138LC/DX140LC
SP002985
Specification
for DX138LC/
DX140LC
Edition 1
Specification for DX138LC/DX140LC SP002985

Page 1
MEMO

Page 2
Table of Contents
Specification for DX138LC/DX140LC

General Description .............................................. 6
Component Locations........................................... 6
General Dimensions ............................................. 8
One - Piece Boom ........................................................... 8
Two - Piece Boom ........................................................... 9
Working Range ................................................... 10
One - Piece Boom ......................................................... 10
Two - Piece Boom ......................................................... 11
General Specifications........................................ 12
Engine Performance Curves (Per DIN 6270
Standard) ............................................................ 14
DX138LC....................................................................... 14
DX140LC....................................................................... 16
Approximate Weight of Workload Materials........ 18
Performance Tests ............................................. 20
Excavator Performance Standards..................... 21
Test Conditions ............................................................. 21
Travel Speed and Travel Motor Balance (Steering
Deviation) Tests ............................................................ 22
Swing Speed and Deceleration Force Test................... 24
Cylinder Performance Tests.......................................... 26

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up

Page 5
GENERAL DESCRIPTION
The excavator has three main component sections:
• The Upper Turntable
• The Lower Undercarriage and Track Frames
• The Excavator Front-end Attachment
The following illustration identifies main components and their
locations. (See Figure 1 on page -6.)
COMPONENT LOCATIONS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
39
38
37
36
35 19
34
20
32
21
33
31 25
30 22
29
28
27
26 23
24
FG009601
Figure 1

Page 6
Reference Reference
Description Description
Number Number
1 Counterweight 21 Bucket Cylinder
2 Muffler 22 Guide Link
3 Hood 23 Bucket
4 Hydraulic Oil Tank 24 Push Link
5 Fuel Tank 25 Tooth Point
6 Engine 26 Side Cutter
7 Fuel Tank Fill Cap 27 Idler
8 Radiator and Oil Cooler 28 Track Adjuster
9 Control Valves 29 Track Guide
10 Swing Motor 30 Battery
11 Air Cleaner 31 Lower Roller
12 Swing Bearing 32 Center Joint
13 Cabin 33 Upper Roller
14 Seat 34 Travel Motor
15 Boom Cylinder 35 Track Link and Shoe
16 Work Lever (Joystick) Controls 36 Sprocket
17 Arm Cylinder 37 Suction Filter
18 Boom 38 Return Filter
19 Travel Lever 39 Pumps
20 Arm

Page 7
GENERAL DIMENSIONS
One - Piece Boom
H A
I J B C
O G
F
N
K M D
L E
FG009598
Figure 2
4.6 m (15' 1") One - Piece BOOM

DIMENSION
2.1 m (6' 11") Arm 2.5 m (8' 2") Arm 3.0 m (9' 10") Arm
A 7,690 mm (25' 3") 7,680 mm (25' 2") 7,640 mm (25' 0")
B 2,200 mm (7' 2")
C 5,490 mm (18' 0") 5,480 mm (17' 11") 5,440 mm (17' 10")
D 3,034 mm (9' 11")
E 3,755 mm (12' 4")
F 894 mm (2' 11")
G (Boom) 2,515 mm (8' 3") 2,635 mm (8' 8") 3,035 mm (9' 11")
G (Hose) 2,570 mm (8' 5") 2,710 mm (8' 11") 3,090 mm (10' 2")
H 2,540 mm (8' 4")
I 1,270 mm (4' 2")
J 1,270 mm (4' 2")
K 1,990 mm (6' 6")
L 2,590 mm (8' 6")
M 600 mm (2' 0")
N 410 mm (1' 4")
O 2,773 mm (9' 1")

Page 8
Two - Piece Boom
H A
I J B C
O G
F
N
K M D
L E
FG009724
Figure 3
4.98 m (16' 4") Two - Piece BOOM

DIMENSION
2.1 m (6' 11") Arm 2.5 m (8' 2") Arm
A 8,060 mm (26' 5") 8,015 mm (26' 4")
B 2,200 mm (7' 2")
C 5,860 mm (19' 3") 5,815 mm (19' 1")
D 3,180 mm (10' 4")
E 3,968 mm (13' 0")
F 1,035 mm (3' 4")
G (Boom) 2,560 mm (8' 5") 2,680 mm (8' 10")
G (Hose) 2,655 mm (8' 9") 2,770 mm (9' 1")
H 2,540 mm (8' 4")
I 1,270 mm (4' 2")
J 1,270 mm (4' 2")
K 2,200 mm (7' 2")
L 2,800 mm (9' 2")
M 600 mm (2' 0")
N 455 mm (1' 5")
O 2,925 mm (9' 6")

Page 9
WORKING RANGE
One - Piece Boom
E
9
C
4
3 D
G.L
0
0 1 2 3 4 5 6 7 8 9
-1
-2
B
-3
-4
-5
-6
A
FG009599
Figure 4
4.6 m (15' 1") One - Piece Boom

DIM.
2.1 m (6' 11") Arm 2.5 m (8' 2") Arm 3.0 m (9' 10") Arm
A Max. Digging Reach 7,845 mm (25' 9") 8,300 mm (27' 3") 8,680 mm (28' 6")
B Max. Digging Depth 5,250 mm (17' 3") 5,645 mm (18' 6") 6,150 mm (20' 2")
C Max. Digging Height 8,195 mm (26' 11") 8,675 mm (28' 5") 8,745 mm (28' 8")
D Max. Loading Height 5,875 mm (19' 3") 6,300 mm (20' 8") 6,415 mm (21' 0")
E Min. Swing Radius 2,345 mm (7' 8") 2,375 mm (7' 9") 2,585 mm (8' 6")

Page 10
Two - Piece Boom
E
9
4 C
3 D
G.L
0
0 1 2 3 4 5 6 7 8 9
-1
-2
B
-3
-4
-5
-6
A
FG009725
Figure 5
4.98 m (16' 4") Two - Piece Boom

DIM.
2.1 m (6' 11") Arm 2.5 m (8' 2") Arm
A Max. Digging Reach 8,380 mm (27' 6") 8,805 mm (28' 11")
B Max. Digging Depth 5,440 mm (17' 10") 5,850 mm (19' 2")
C Max. Digging Height 8,820 mm (28' 11") 9,235 mm (30' 4")
D Max. Loading Height 6,420 mm (21' 1") 6,810 mm (22' 4")
E Min. Swing Radius 2,925 mm (9' 7") 2,935 mm (9' 8")

Page 11
GENERAL SPECIFICATIONS
Shipping Weight NON ROPS 14,000 kg (30,860 lb)
ROPS 14,110 kg (31,110 lb)
Includes 10% fuel, 4,600 mm (15' 1") boom, 2,500 mm (8' 2") arm,
standard backhoe bucket and standard shoes
Operating Weight Add weight of full fuel tank and operator
Shipping Weights With Optional Add 310 kg (683 lb) for 500 mm (19.7") shoes
Track Shoes Add 440 kg (970 lb) for 700 mm (34") shoes
Major Component Weights Standard Boom 756 kg (1,667 lb)
2,100 mm (6' 11") Arm 367 kg (809 lb)
2,500 mm (8' 2") Arm 412 kg (908 lb)
3,000 mm (9' 10") Arm 450 kg (992 lb)
Boom Cylinders 122 kg (269 lb) each
Arm Cylinder 145 kg (320 lb)
Bucket Cylinder 92 kg (207 lb)
Counterweight 2,200 kg (4,850 lb)
Upper Turntable 4,100 kg (9,039 lb)
Lower - below Swing Bearing 5,300 kg (11,685 lb)
Digging Forces (At Power Boost):
Bucket Cylinder 94 KN or 9,600 kg (21,200 lb) - (with either 3,000 mm [9' 10"] or
2,500 mm [8' 2"] or 2,100 mm [6' 11"] arm)
Arm Cylinder 62 KN or 6,300 kg (13,900 lb) with 2,500 mm (8' 5") standard arm
Fuel Tank Capacity 267 liters (70.5 U.S. gal)
Hydraulic System Capacity 148 liters (39 U.S. gal)
Hydraulic Reservoir Capacity 99 liters (26 U.S. gal)
Bucket Heaped Capacity Range PCSA 0.24 - 0.76 m3 (0.31 - 0.99 yd3)
IMPORTANT: Refer to the Load Weight, Bucket and Arm Length
Compatibility Table for information on which bucket sizes may be used
safely with which arm length, for load material weights.
Shoe Type Triple Grouser
Shoe Width and Optional Sizes 600 mm (23.5") - standard
700 mm (28") - optional
500 mm (19.7") - optional
Ground Pressure Ratings:
Standard 600 mm (23.6") shoe - 0.36 kg/cm2 (5.1 psi)
Optional 700 mm (28.0") shoe - 0.30 kg/cm2 (4.3 psi)
Optional 500 mm (19.7") shoe - 0.43 kg/cm2 (6.1 psi)
Optional Dozer Blade Sizes 2,490 mm (8' 2") with 500 mm (19.7")
2,590 mm (8' 6") with 600 mm (23.5")
2,690 mm (8' 10") with 700 mm (28")

Page 12
Transport Dimensions
Overall Shipping Length
7,680 mm (25' 2")
(standard boom and arm)
Overall Shipping Width
2,590 mm (8' 6")
(standard shoes)
Overall Shipping Height
2,710 mm (8' 10")
(to top of cylinder hose)
Track Shipping Length 3,755 mm (12' 4")
Transport Trailer Capacity 20 tons (22 short tons), minimum load capacity
Transport Loading Ramp
15° angle CAUTION: Refer to Transport Maximum Procedure for Safe
Allowable Slope
Shipping Instructions.

Page 13
ENGINE PERFORMANCE
CURVES (PER DIN 6270
STANDARD)
DX138LC
Torque (kg.m)
50
45
40
100
Power Output (ps)
80
60
Fuel Consumption (g/ps.h)
160
150
140
800 1,000 1,200 1,400 1,600 1,800
Revolution (rpm)
FG028825
Figure 6

Page 14
Condition Specification
Engine Model DL06
Barometric Pressure 760 mmHg (20° C (68°F))
ø595 mm, SUCKER
Cooling Fan
(23.4 in)
Alternator 24V x 50A
Air Cleaner Installed
Muffler Installed
Performance Standard DIN 6270

90 ps @ 1,850 rpm
Power
(88.7 hp @ 1,850 rpm)
44.5 kg•m @ 1,400 rpm
Max. Torque
(322 ft lb @ 1,400 rpm)
165 g/ps•h
Fuel Consumption (Rated)
(5.47 oz/hp•h)

Page 15
DX140LC
TORQUE (kg.m)
50
40
130
POWER OUTPUT (ps)
100
70
40
FUEL CONSUMPTION (g/ps.h)

170
160
150
800 1000 1500 2000
REVOLUTION (rpm)
FG009717
Figure 7

Page 16
Condition Specification
Engine Model DL06
Barometric Pressure 760 mmHg (20° C (68°F))
ø595 mm, SUCKER
Cooling Fan
(23.4 in)
Alternator 24V x 50A
Air Cleaner Installed
Muffler Installed
Performance Standard DIN 6270

96 ps @ 1,850 rpm
Power
(95 hp @ 1,850 rpm)
44.5 kg•m @ 1,400 rpm
Max. Torque
(322 ft lb @ 1,400 rpm)
165 g/ps•h
Fuel Consumption (Rated)
(5.47 oz/hp•h)

Page 17
APPROXIMATE WEIGHT OF
WORKLOAD MATERIALS
IMPORTANT
Weights are approximations of estimated average volume
and mass. Exposure to rain, snow or groundwater; settling
or compaction because of overhead weight and chemical or
industrial processing or changes because of thermal or
chemical transformations could all increase value of
weights listed in table.
Density Density Density Density

1,200 kg/m3 1,500 kg/m3 1,800 kg/m3 2,100 kg/m3
Material
(2,000 lb/yd3), (2,500 lb/yd3), (3,000 lb/yd3), (3,500 lb/yd3),
or less or less or less or less
401 kg/m3
Charcoal - - -
(695 lb/yd3)
433 kg/m3
Coke, blast furnace size - - -
(729 lb/yd3)
449 kg/m3
Coke, foundry size - - -
(756 lb/yd3)
801 kg/m3
Coal, bituminous slack, piled - - -
(1,350 lb/yd3)
881 kg/m3
Coal, bituminous r. of m., piled - - -
(1,485 lb/yd3)
897 kg/m3
Coal, anthracite - - -
(1,512 lb/yd3)
1,009 kg/m3
Clay, DRY, in broken lumps - - -
(1,701 lb/yd3)
1,746 kg/m3
Clay, DAMP, natural bed - - -
(2,943 lb/yd3)
1,506 kg/m3
Cement, portland, DRY granular - - -
(2,583 lb/yd3)
1,362 kg/m3
Cement, portland, DRY clinkers - - -
(2,295 lb/yd3)
1,522 kg/m3
Dolomite, crushed - - -
(2,565 lb/yd3)
1,202 kg/m3
Earth, loamy, DRY, loose - - -
(2,025 lb/yd3)
1,522 kg/m3
Earth, DRY, packed - - -
(2,565 lb/yd3)
1,762 kg/m3
Earth, WET, muddy - - -
(2,970 lb/yd3)
Gypsum, calcined, (heated, 961 kg/m3
- - -
powder) (1,620 lb/yd3)

Page 18
Density Density Density Density
1,200 kg/m3 1,500 kg/m3 1,800 kg/m3 2,100 kg/m3
Material
(2,000 lb/yd3), (2,500 lb/yd3), (3,000 lb/yd3), (3,500 lb/yd3),
or less or less or less or less
1,522 kg/m3
Gypsum, crushed to 3 inch size - - -
(2,565 lb/yd3)
1,810 kg/m3
Gravel, DRY, packed fragments - - -
(3,051 lb/yd3)
1,922 kg/m3
Gravel, WET, packed fragments - - -
(3,240 lb/yd3)
1,282 kg/m3
Limestone, graded above 2 - - -
(2,160 lb/yd3)
1,362 kg/m3
Limestone, graded 1-1/2 or 2 - - -
(2,295 lb/yd3)
1,522 kg/m3
Limestone, crushed - - -
(2,565 lb/yd3)
1,602 kg/m3
limestone, fine - - -
(2,705 lb/yd3)
1,282 kg/m3
Phosphate, rock - - -
(2,160 lb/yd3)
929 kg/m3
Salt - - -
(1,566 lb/yd3)
529 kg/m3
Snow, light density - - -
(891 lb/yd3)
1,522 kg/m3
Sand, DRY, loose - - -
(2,565 lb/yd3)
1,922 kg/m3
Sand, WET, packed - - -
(3,240 lb/yd3)
1,362 kg/m3
Shale, broken - - -
(2,295 lb/yd3)
529 kg/m3
Sulfur, broken - - -
(891 lb/yd3)

Page 19
PERFORMANCE TESTS
1. Main Relief Pressure
normal operation: 330 kg/cm3 (4,689 psi)
with "Pressure Up": 350 kg/cm3 (4,970 psi)
2. Actuator Speeds
Operation Unit Standard Mode Power Mode

Up sec 3.3 ±0.4 3.0 ±0.4
Boom
Down sec 2.6 ±0.3 2.6 ±0.3
Dump sec 2.2 ±0.3 2.0 ±0.3
Arm
Crowd sec 2.9 ±0.4 2.8 ±0.4
Dump sec 2.3 ±0.3 2.1 ±0.3
Bucket
Crowd sec 4.0 ±0.4 3.8 ±0.4
Swing (3 Revolutions) sec 17.6 ±1.5 16.7 ±1.5
High sec 18.9 ±1.5 18.0 ±1.5
Jack-up Speed (3 Turns)
Low sec 29.8 ±2.0 28.4 ±2.0
High sec 16.0 ±1.0 15.3 ±1.0
Travel Speed 20 m (66 ft)
Low sec 25.0 ±1.5 24.0 ±1.5
High mm (in) 150 (6) 150 (6)
Travel Deviation 20 m (66 ft)
Low mm (in) 150 (6) 150 (6)

Page 20
EXCAVATOR PERFORMANCE
STANDARDS
Evaluation of equipment performance and operating condition
can be made by running the excavator through a series of
different tests, and recording results with a stop watch and tape
measure.
Compare results of performance tests against the specifications
and standards that follow, which are for equipment in new or
renewed condition.
Test Conditions
1. All tests must be performed on a flat, level, firm supporting
ground surface.
2. All recommended, applicable maintenance and adjustment
service must be completed before testing.
3. Hydraulic fluid and engine oil must be of appropriate
viscosity for ambient weather conditions. Warm up
hydraulic oil to standard operating temperature, between
45°C - 55°C (112°F - 135°F).
4. Run all tests with the engine speed control set to maximum
rpm.
5. Repeat tests with Power Mode engine control settings at
both Standard Mode (standard work mode) and Power
Mode (high speed mode). Travel speed tests should also
be repeated at both high and low speed.

Page 21
Travel Speed and Travel Motor Balance
(Steering Deviation) Tests
Speed Test
Prepare the excavator for travel speed tests by extending all
hydraulic cylinders - boom, arm and bucket - to the fully
extended position, shown in Figure 8.
0.3 M - 0.5 M (1' - 2')
FG000466
Figure 8
The lowest part of the bucket linkage must be 0.3 - 0.5 m (1' - 2')
off the ground.
Mark off a 20 m (65' 7-1/2") test distance, with a 3 - 5 m (10' -
15') run-up area, and a 3 - 5 m (10' - 15', or longer) speed run-off
distance.
Travel the excavator back and forth to be sure steering is
centered and side frames are parallel with the test course.
Operate both travel levers at the fully engaged position and
measure the time it takes to cross 20 m (65' 7-1/2"). Compare
measured results against the standard for new machines:
Time
Rate of Travel
Standard Mode Power Mode
High Speed 16.0 ±1.0 sec 15.3 ±1.0 sec
Low Speed 25.0 ±1.5 sec 24.0 ±1.5 sec
Rotate the turntable 180°. Both tests must be repeated three

times. Average all results to obtain a final value.

Page 22
3M - 5M
3M - 5M 20M
(10' - 15')
(10' - 15') (65' 7-1/2'')
FG000467
Figure 9
Travel Deviation
To check steering deviation (travel motor balance), use a long
tape or rope, or the edge of an undeviating straight road curb or
other marker to verify side to side travel motor uniformity.
Deviation distance should always be measured at the 20 m (65'
7-1/2") "finish line". Repeat the test in reverse to measure in
both directions, with starting point becoming the finish line, and
vice versa. (Figure 9)
A greater amount of deviation is allowed with the travel control
set for high speed.
Rate of Travel Max. Distance

High Speed 150 mm (6 in)
Low Speed 150 mm (6 in)

Page 23
Swing Speed and Deceleration Force Test
Swing Speed Test
1.5M
FG000468
Figure 10
Extend the bucket cylinder completely and retract the arm

cylinder, as shown in Figure 10, to test swing speed. The lowest
point of the bucket will be approximately 1.5 m (3') off the
ground.
Use paint marks at the same point on the turntable and
undercarriage, or select alternate measuring locations and use a
stopwatch to time 3 full 360° rotations. The time required for 3
revolutions must be between 16 and 19 seconds in Standard
Mode, 15 and 18 seconds in Power Mode.

Page 24
Swing Deceleration Force Test
4
With the boom, arm and bucket in the same position as for the
swing speed test, rotate the turntable so that the boom is evenly
centered between the side frames, pointing straight ahead.
Locate the 90° reference point, perpendicular to the boom. Mark
the turntable and undercarriage with paint at the 90° point. 3
Make several attempts to rotate the turntable exactly 90°,

starting from the boom straight ahead position. Engage the
swing lever and brake at the 90° point, shown as "swing stop" in
Figure 11. 2
Record how far the turntable drifts past the stop point,
measuring the distance between paint marks. Maximum
distance must be less than 607 mm (23.9"), in both Power Mode
and Standard Mode.
Reference
Description
Number
1 Start Swing
1
2 90° Swing
FG000659
3 Lever Stop
Figure 11
4 Swing Stop

Page 25
Cylinder Performance Tests
NOTE: All tests are performed with standard boom, arm and
bucket configuration. The bucket must be empty.
Boom Cylinders Test

The starting points for the test are with the boom and arm
extended away from the excavator, and the bucket curled
inward. The arm cylinder must be fully retracted; boom and
bucket cylinders must be extended. Test movement in both
directions, several times, and average results for both Standard
Mode and Power Mode.
Arm Cylinder Test

Start with the boom up and the arm cylinder fully retracted. Test
movement in both directions several times, between the "crowd"
and "dump" positions, and average the results of both tests, in
both standard and extra-duty power modes.
Bucket Cylinder Test

Start with the boom up and the teeth of the bucket hanging
vertically, 500 mm (1-1/2' - 2') above the ground. Dump and
crowd the bucket several times, and average results, for both
standard and extra-duty power modes.
Operation Standard Mode Power Mode

Boom Up 2.9 - 3.7 sec 2.6 - 3.4 sec
Boom Down 2.3 - 2.9 sec 2.3 - 2.9 sec
Arm Dump 1.9 - 2.5 sec 1.7 - 2.3 sec
Arm Crowd 2.5 - 3.3 sec 2.4 - 3.2 sec
Bucket Dump 2.0 - 2.6 sec 1.8 - 2.4 sec
Bucket Crowd 3.6 - 4.4 sec 3.4 - 4.2 sec
Hydraulic Cylinder Natural Drop Test

To check boom and arm cylinder tightness against the specified
performance standard for new cylinders, put a full load of dirt in
the bucket and move the attachment cylinders so that the arm
cylinder is extended 20 - 50 mm (1" - 2") and boom cylinders are
retracted the same amount, 20 - 50 mm (1" - 2"). The top of the
bucket must be approximately 2 m (6' - 7') off the ground.
Stop engine and measure cylinder drop after 5 minutes. Bucket
cylinder should not show more than 40 mm (1.57") change,
while the arm and boom cylinders should not fall more than
10 mm (0.39").

Page 26
Travel Motor Jack-up Test
Test travel motor operation on each side by painting or chalking
a mark on one crawler shoe, with a corresponding mark on the
travel frame. Use the attachment to jack up one side of the
machine and operate the raised travel motor. Record the
number of seconds it takes the crawler shoe to make 3 full
rotations, during both high speed and low speed operation.
Operation Standard Mode Power Mode

High Speed 17.4 - 20.4 sec 16.5 - 19.5 sec
Low Speed 27.8 - 31.8 sec 26.4 - 30.4 sec

Page 27
Page 28
1General Maintenance
SP002454
GENERAL MAINTENANCE INSTRUCTIONS
SP002454
General
Maintenance
Instructions
Edition 4
General Maintenance Instructions SP002454

Page 1
MEMO

Page 2
Table of Contents
General Maintenance Instructions

Welding Precautions and Instructions .................. 6
Hydraulic System - General Precautions.............. 7
Maintenance Service and Repair Procedure ........ 9
General Precautions........................................................ 9
Hydraulic System Cleanliness and Oil Leaks ..... 10
Maintenance Precautions for Hydraulic System Service10
Oil Leakage Precautions ............................................... 11
Cleaning and Inspection ..................................... 12
General Instructions ...................................................... 12
Bearing Inspection......................................................... 13

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

ALL MODELS ALL RANGES

Page 5
WELDING PRECAUTIONS AND
INSTRUCTIONS
WARNING
To avoid accidents, personal injury and the possibility of
causing damage to the machine or to components, welding
must only be performed by properly trained and qualified
personnel, who possess the correct certification (when
required) for the specific welding fabrication or specialized
repair being performed.
WARNING
Structural elements of the machine may be built from a
variety of steels. These could contain unique alloys or may
have been heat-treated to obtain particular strength
characteristics. It is extremely important that welding
repairs on these types of steel are performed with the
proper procedures and equipment. If repairs are performed
incorrectly, structural weakening or other damage to the
machine (that is not always readily visible) could result.
Always consult DOOSAN After Sales Service before
welding on integral components (loader arm, frames, car
body, track frames, upper structure, attachment, etc.) of the
machine. It is possible that some types of structurally
critical repairs may require Magnetic Particle or Liquid
Penetrant testing, to make sure there are no hidden cracks
or damage, before the machine can be returned to service.
WARNING
Always perform welding procedures with proper safety
equipment and adequate ventilation in a dry work area.
Keep a fire extinguisher near and wear personal protective
equipment.

Page 6
WARNING
Observe the following safety instructions:
1. Use adequate safety shielding and keep away from
fuel and oil tanks, batteries, hydraulic piping lines or
other fire hazards when welding.
2. Never weld when the engine is running. Battery cables
must be disconnected before the welding procedure is
started.
3. Never weld on a wet or damp surface. The presence of
moisture causes hydrogen embrittlement and
structural weakening of the weld.
4. If welding procedures are being performed near
cylinder rods, operator's cabin window areas or any
other assemblies could be damaged by weld spatters.
Use adequate shielding protection in front of the
assembly.
5. During welding equipment setup, always attach
ground cables directly to the area or component being
welded to prevent arcing through bearings, bushings,
or spacers.
6. Always use correct welding rods for the type of weld
being performed and observe recommended
precautions and time constraints. AWS Class E7018
welding rods for low alloy to medium carbon steel
must be used within two hours after removal from a
freshly opened container. Class E11018G welding rods
for T-1 and other higher strength steel must be used
within 1/2 hour of removal from a freshly opened
container.
HYDRAULIC SYSTEM -
GENERAL PRECAUTIONS
Always maintain oil level in the system at recommended levels.
Assemblies that operate under heavy loads, at high-speed, with
extremely precise tolerances between moving parts (e.g. pistons
and cylinders, or shoes and swash plates), can be severely
damaged if oil supply runs dry.
Assemblies can be run dry and damaged severely in a very
short time when piping or hoses are disconnected to repair leaks
and/or replace damaged components. Hoses that are
inadvertently switched during disassembly (inlet for outlet and
vice versa), air introduced into the system or assemblies that are
low on oil because of neglect or careless maintenance, could all
produce sufficient fluid loss to cause damage or improper
operation.

Page 7
When starting the engine (particularly after long layoff or storage
intervals), make sure that all hydraulic controls and operating
circuits are in neutral, or "OFF". That will prevent pumps or other
components that may be temporarily oil starved from being run
under a load.
Replacement of any hydraulic system component could require
thorough cleaning, flushing, and some amount of prefilling with
fresh, clean oil if the protective seal on replacement parts has
obviously been broken or if seal integrity may have been
compromised. When protective seals are removed before
installation and reassembly, inspect all replacement parts
carefully, before they are installed. If the replacement part
shows no trace of factory prelube or has been contaminated by
dirt or by questionable oils, flushing and prefilling with clean
hydraulic fluid is recommended.
Vibration, irregular or difficult movement or unusual noise from
any part of the hydraulic system could be an indication of air in
the system (and many other types of problems). As a general
precaution (and to help lessen the risk of potential long-term
damage), allow the engine to run at no-load idle speed
immediately after initial start-up. Hydraulic fluid will circulate,
releasing any air that may have been trapped in the system
before load demands are imposed.
Before starting the machine, a daily walk-around safety
inspection, including a quick visual inspection for any exterior
evidence of leaking hydraulic fluid, can help extend the service
life of system components.
IMPORTANT
Hydraulic system operating conditions (repetitive cycling,
heavy workloads, fluid circulating under high-pressure)
make it extremely critical that dust, grit or any other
contamination be kept out of the system. Observe fluid and
filter change maintenance interval recommendations and
always preclean any exterior surface of the system before it
is exposed to air. For example, the reservoir fill cap and
neck area, hoses that have to be disassembled, and the
covers and external surfaces of filter canisters should all be
cleaned before disassembly.

Page 8
MAINTENANCE SERVICE AND
REPAIR PROCEDURE
General Precautions
Fluid level and condition should always be checked whenever
any other maintenance service or repair is being performed.
NOTE: If the unit is being used in an extreme temperature
environment (in subfreezing climates or in high
temperature, high humidity tropical conditions),
frequent purging of moisture condensation from the
hydraulic reservoir drain tap must be a regular and
frequent part of the operating routine. In more
moderate, temperate climates, draining reservoir
sediment and moisture may not be required more
than once or twice every few months.
Inspect drained oil and used filters for signs of abnormal coloring
or visible fluid contamination at every oil change. Abrasive grit or
dust particles will cause discoloration and darkening of the fluid.
Visible accumulations of dirt or grit could be an indication that
filter are overloaded (and will require more frequent
replacement) or that disintegrating bearings or other component
failures in the hydraulic circuit may be imminent or have already
occurred. Open the drain plugs on the main pump casings and
check and compare drain oil in the pumps. Look for evidence of
grit or metallic particles.
Vibration or unusual noise during operation could be an
indication of air leaking into the circuit (Refer to the appropriate
Troubleshooting section for component or unit for procedures.),
or it may be evidence of a defective pump. The gear type pilot
pump could be defective, causing low pilot pressure, or a main
pump broken shoe or piston could be responsible.
NOTE: If equipped, indicated operating pressure, as shown
on the multidisplay digital gauge on the Instrument
Panel ("F-Pump" and "R-Pump") will be reduced
because of a mechanical problem inside the pump.
However, pressure loss could also be because of
cavitation or air leakage, or other faults in the
hydraulic system.
Check the exterior case drain oil in the main pumps. If no
metallic particles are found, make sure there is no air in the
system. Unbolt and remove tank return drain line from the top
part of the swing motor, both travel motors and each main pump.
If there is air in any one of the drain lines, carefully prefill the
assembly before bolting together the drain line piping
connections. Run the system at low rpm.

Page 9
HYDRAULIC SYSTEM
CLEANLINESS AND OIL LEAKS
Maintenance Precautions for Hydraulic

System Service
Whenever maintenance, repairs or any other troubleshooting or
service is being performed, it's important to remember that
hydraulic system - including both the interior and exterior
surfaces of assemblies, and every drop of operating fluid - must
be protected from contamination.
Dust and other foreign contaminants are major contributors to
premature wear in hydraulic circuits. The narrow tolerances,
rapidly moving parts and high operating pressures of the system
require that fluid be kept as clean as possible. The performance
and dependability of the machine (and the service lift of
individual components) can be noticeably reduced if proper
precautions are not observed:
• Use a noncombustible, evaporative type, low residue
solvent and thoroughly clean exterior surfaces of
assemblies before any part of the circuit is opened or
disassembled.
NOTE: It's just as important to clean the cap and
reservoir top before routine fluid changes or
quick checks as it is before major repairs.
(Accumulated dirt attracts moisture, oil and
other fluids - and more dirt.)
• Keep dismantled parts covered during disassembly. Use
clean caps, plugs or tape to protect the disconnected
openings of flanges, manifolds and piping.
• Do not allow cleaning solvents or other fluids to mix with
the oil in the system. Use clean oil to flush any traces of
solvent or other residue before reassembly.
• If metal or rubber fragments are found in the system, flush
and replace all fluid in the system and troubleshoot the
circuit to identify the source of contamination.
IMPORTANT
Make sure that cleaning solvents will be compatible with
rubber materials used in the hydraulic system. Many
petroleum based compounds can cause swelling,
softening, or other deterioration of system sealing
elements, such as O-rings, caps and other seals.

Page 10
Oil Leakage Precautions
Oil that is visibly seeping from joints or seals should always
serve as a "red flag" alarm.
Leaks must alert the machine operator and maintenance crew
that air, water and dirt have an open, free passageway through
which to enter the circuit. Corrosive salt air, freezing and thawing
condensation cycles and working environments that are full of
fine dust are especially hazardous. Clogging of valve spools or
external piping (especially pilot circuit piping) can gradually
diminish or suddenly put a stop to normal hydraulic function. You
can prevent having to make these types of repairs by the
following recommended assembly procedures:
1. Use new O-rings and oil seals whenever hydraulic
assemblies are rebuilt.
2. Prepare joint surfaces before assembly by checking
alignment and flatness. Clean and repair corrosion or any
other damage.
3. Follow bolt torque recommendations and all other
assembly requirements.
NOTE: Grease lip seals before assembly.
Figure 1

Page 11
CLEANING AND INSPECTION
General Instructions
All parts must be clean to permit an effective inspection. During
assembly, it is very important that no dirt or foreign material
enters unit being assembled. Even minute particles can cause
malfunction of close fitting parts such as thrust bearing, matched
parts, etc.
WARNING
Do not inhale vapors or allow solvent type cleaners to
contact skin. Keep solvent away from open flame, arcs or
sparks or other sources of ignition that could start a fire.
1. Clean all metal parts thoroughly using a suitable cleaning

fluid. It is recommended that parts be immersed in cleaning
fluid and moved up and down slowly until all oils,
lubricants, and/or foreign materials are dissolved and parts
are thoroughly clean.
2. For bearings that can be removed, soak them in a suitable
cleaning fluid for a minute or two, then remove bearings
from cleaning fluid and strike flat against a block of wood to
dislodge solidified particles of lubricant. Immerse again in
cleaning fluid to flush out particles. Repeat above
operation until bearings are thoroughly clean. To dry
bearings, use moisture-free compressed air. Be careful to
direct airstream across bearing to avoid spinning bearings
that are not lubricated. DO NOT SPIN BEARINGS WHEN
DRYING; bearings may be rotated slowly by hand to
facilitate drying process.
3. Carefully inspect all bearing rollers, cages and cups for
wear, chipping or nicks to determine condition. Do not
replace a bearing cone or cup individually without replacing
mating cup or cone at the same time. After inspection, dip
bearings in lightweight oil and wrap in clean lintless cloth or
paper to protect them until installation.
For those bearings that are to be inspected in place;
inspect bearings for roughness of rotation, scoring, pitting,
cracked or chipped races. If any of these defects are
found, replace bearings. Also, inspect defective bearing
housing and/or shaft for grooved, galled or burred
conditions that indicate bearing has been turning in its
housing or on its shaft.
4. It is more economical to replace oil seals, O-rings, sealing
rings, gaskets and retaining rings when unit is
disassembled than waiting for premature failures; refer to
latest Micro Fiche and/or Parts Book for replacement items.

Page 12
Be careful when installing sealing members, to avoid
cutting or scratching. Curling under of any seal lip will
seriously impair its efficiency. Apply a thin coat of Loctite
#120 to outer diameter of metal casing and on oil seals to
assure an oil tight install into retainer. Use extreme care
not to get Loctite on lips of oil seals. If this happens, that
portion of the seal will become brittle and allow leakage.
When replacing lip type seals, make sure spring loaded
side is towards oil to be sealed.
5. If available, use magna-flux or similar process for checking
for cracks that are not visible. Examine teeth on all gears
carefully for wear, pitting, chipping, nicks, cracks or scores.
Replace all gears showing cracks or spots where
case-hardening has worn through. Small nicks may be
removed with suitable hone. Inspect shafts and quills to
make certain they have not been sprung, bent, or no
twisted splines, and that shafts are true.
NOTE: Spline wear is not considered detrimental
except where it affects tightness of splined
parts.
Inspect thrust washers for distortion, scores, burs, and
wear. Replace thrust washer if defective or worn.
6. Inspect bores and bearing surfaces of cast parts and
machined surfaces for scratches, wear, grooves and dirt.
Remove any scratches and burrs with crocus cloth.
Remove foreign material. Replace any parts that are
deeply grooved or scratched which would affect their
operation.
Bearing Inspection
The conditions of the bearing are vital to the smooth and
efficient operation of the machinery. When any component
containing bearings is disassembled, always carefully examine
the condition of the bearings and all of its components for wear
and damage.
Once the bearing is removed, clean all parts thoroughly using a
suitable cleaning solution. If the bearing is excessively dirty,
soak the bearing assembly in a light solution and move the
bearing around until all lubricants and/or foreign materials are
dissolved and the parts are thoroughly clean.
When drying bearings, moisture free compressed air can be
used. Be careful not to direct the air in a direction which will
force the bearing to dry spin while not being properly lubricated.
After the bearings have been cleaned and dried, carefully
inspect all bearing rollers, cages and cups for wear, chipping or
nicks. If the bearing cannot be removed and is to be inspected in
place, check for roughness of rotation, scoring, pitting, cracked
or chipped races. If any of these defects are found replace the
whole bearing assembly. NEVER replace the bearing alone
without replacing the mating cup or the cone at the same time.

Page 13
After inspection lightly coat the bearing and related parts with oil
and wrap in a clean lintless cloth or paper and protect them from
moisture and other foreign materials until installation.
It is also important to inspect the bearing housing and/or shaft
for grooved, galled or burred conditions that indicate the bearing
has been turning in its housing or on its shaft.
If available, use magna-flux or similar process for checking for
cracks that are not visible.
The following illustrations will aid in identifying and diagnosing
some of the bearing related problems.
NOTE: The illustrations will only show tapered roller
bearings, but the principles of identifying, diagnosing
and remedying the defects are common to all styles
and types of bearings.
Normal Bearing
Smooth even surfaces with no discoloration or marks.
Figure 2
Bent Cage
Cage damage because of improper handling or tool usage.
Figure 3

Page 14
Replace bearing.
Figure 4
Galling
Metal smears on roller ends because of overheat, lubricant
failure or overload.
Replace bearing - check seals and check for proper lubrication.
Figure 5
Abrasive Step Wear

Pattern on roller ends caused by fine abrasives.
Clean all parts and housings, check all parts and housings,
check seals and bearings and replace if leaking, rough or noisy.
Figure 6

Page 15
Etching
Bearing surfaces appear gray or grayish black in color with
related etching away of material usually at roller spacing.
Replace bearings - check seals and check for proper lubrication.
Figure 7
Misalignment
Outer race misalignment because of foreign object.
Clean related parts and replace bearing. Make sure races are
properly seated.
Figure 8
Indentations
Surface depressions on race and rollers caused by hard
particles of foreign materials.
Clean all parts and housings, check seals and replace bearings
if rough or noisy.
Figure 9

Page 16
Fatigue Spalling
Flaking of surface metal resulting from fatigue.
Replace bearing - clean all related parts.
Figure 10
Brinelling
Surface indentations in raceway caused by rollers either under
impact loading or vibration while the bearing is not rotating.
Replace bearing if rough or noisy.
Figure 11
Cage Wear
Wear around outside diameter of cage and roller pockets
caused by abrasive material and inefficient lubrication.
Replace bearings - check seals.
Figure 12

Page 17
Abrasive Roller Wear
Pattern on races and rollers caused by fine abrasives.
Clean all parts and housings, check seals and bearings and
replace if leaking, rough or noisy.
Figure 13
Cracked Inner Race

Race cracked because of improper installation, cocking or poor
bearing seat.
Replace all parts and housings, check seals and bearings and
replace if leaking.
Figure 14
Smears
Smearing of metal because of slippage caused by poor
installation, lubrication, overheating, overloads or handling
damage.
Replace bearings, clean related parts and check for proper
installation and lubrication.
Replace shaft if damaged.
Figure 15

Page 18
Frettage
Corrosion set up by small relative movement of parts with no
lubrication.
Replace bearing. Clean all related parts. Check seals and check
for proper lubrication.
Figure 16
Heat Discoloration
Heat discoloration can range from faint yellow to dark blue
resulting from overload or incorrect lubrication.
Excessive heat can cause softening of races or rollers.
To check for loss of temper on races or rollers, a simple file test
may be made. A file drawn over a tempered part will grab and
cut metal, whereas a file drawn over a hard part will glide readily
with no metal cutting.
Replace bearing if overheating damage is indicated. Check
seals and other related parts for damage.
Figure 17
Stain Discoloration
Discoloration can range from light brown to black caused by
incorrect lubrication or moisture.
If the stain can be removed by light polishing or if no evidence of
overheating is visible, the bearing can be reused.
Check seals and other related parts for damage.
Figure 18

Page 19
Page 20
SP002404
STANDARD TORQUESSP002404
Standard
Torques
Edition 3
Standard Torques SP002404

Page 1
MEMO

Page 2
Table of Contents
Standard Torques
Torque Values for Standard Metric Fasteners...... 6
Torque Values for Standard U.S. Fasteners ........ 7
Type 8 Phosphate Coated Hardware ................... 9
Torque Values for Hose Clamps ........................ 10
ORFS Swivel Nut Recommended Torque .......... 10
Torque Values for Split Flanges ......................... 11
Torque Wrench Extension Tools ........................ 12
Torque Multiplication ..................................................... 12
Other Uses for Torque Wrench Extension Tools........... 13
Tightening Torque Specifications (Metric) ..................... 14

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

ALL MODELS ALL RANGES

Page 5
TORQUE VALUES FOR
STANDARD METRIC
FASTENERS
NOTE: The units for the torque values are kg•m (ft lb).
Grade
Dia. x Pitch
(mm)
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
(4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M5 x Std.
(1.08) (1.15) (1.80) (1.59) (2.24) (2.02) (3.11) (3.47) (3.61) (5.42) (6.50)
0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.90 1.25 1.50
M6 x Std.
(2.02) (2.16) (3.25) (2.89) (3.97) (3.39) (5.56) (6.14) (6.50) (9.04) (10.84)
0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35
M7 x Std.
(3.11) (3.32) (5.06) (4.55) (6.00) (5.64) (8.67) (9.40) (10.12) (14.10) (16.99)
0.70 0.75 1.10 1.00 1.40 1.25 1.90 2.10 2.20 3.10 3.80
M8 x Std.
(5.06) (5.42) (7.95) (7.23) (10.12) (9.04) (13.74) (15.18) (15.91) (22.42) (27.48)
0.73 0.80 1.20 1.00 1.50 1.35 2.10 2.30 2.40 3.35 4.10
M8 x 1
(5.28) (5.78) (8.67) (7.23) (10.84) (9.76) (15.18) (16.63) (17.35) (24.23) (29.65)
1.35 1.40 2.20 1.90 2.70 2.35 3.70 4.20 4.40 6.20 7.20
M10 x Std.
(9.76) (10.12) (15.91) (13.74) (19.52) (19.99) (26.76) (30.37) (31.18) (44.84) (52.07)
1.50 1.60 2.50 2.10 3.10 2.80 4.30 4.90 5.00 7.00 8.40
M10 x 1.25
(10.84) (11.57) (18.08) (15.18) (22.42) (20.25) (31.10) (35.44) (36.16) (50.63) (60.75)
2.40 2.50 3.70 3.30 4.70 4.20 6.30 7.20 7.50 10.50 12.50
M12 x Std.
(17.35) (18.08) (26.76) (23.86) (33.99) (30.37) (45.56) (52.07) (54.24) (75.94) (90.41)
2.55 2.70 4.00 3.50 5.00 4.50 6.80 7.70 8.00 11.20 13.40
M12 x 1.25
(18.44) (19.52) (28.93) (25.31) (36.16) (32.54) (49.18) (55.69) (57.86) (81.00) (96.92)
3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00
M14 x Std.
(26.76) (28.20) (13.23) (37.61) (54.24) (50.63) (72.33) (83.17) (86.79) (122.96) (144.66)
4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M14 x 1.5
(29.65) (31.10) (47.73) (41.22) (60.03) (54.24) (80.28) (90.41) (94.02) (11.26) (158.12)
5.60 6.00 9.00 8.00 11.50 10.50 15.50 17.90 18.50 26.00 31.00
M16 x Std.
(40.50) (43.39) (65.09) (57.86) (83.17) (75.94) (112.11) (129.47) (133.81) (188.05) (224.22)
6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 35.50
M16 x 1.5
(44.84) (47.01) (70.16) (62.20) (90.41) (81.73) (122.96) (141.04) (144.66) (202.52) (256.77)
7.80 8.30 12.50 11.00 16.00 14.50 21.00 27.50 28.50 41.00 43.00
M18 x Std.
(56.41) (60.03) (90.41) (79.56) (115.72) (104.87) (151.89) (198.90) (206.14) (296.55) (311.01)
9.10 9.50 14.40 12.50 18.50 16.70 24.50 27.50 28.50 41.00 49.00
M18 x 1.5
(65.82) (68.71) (104.15) (90.41) (133.81) (120.79) (177.20) (198.90) (206.14) (296.55) (354.41)
11.50 12.00 18.00 16.00 22.00 19.00 31.50 35.00 36.00 51.00 60.00
M20 x Std.
(83.17) (86.79) (130.19) (115.72) (159.12) (137.42) (227.83) (253.15) (260.38) (368.88) (433.98)
12.80 13.50 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00
M20 x 1.5
(92.58) (97.64) (148.27) (130.19) (180.82) (162.74) (253.15) (285.70) (296.55) (419.51) (491.84)
15.50 16.00 24.50 21.00 30.00 26.00 42.00 46.00 49.00 67.00 75.00
M22 x Std.
(112.11) (115.72) (177.20) (151.89) (216.99) (188.05) (303.78) (332.71) (354.41) (484.61) (542.47)
17.00 18.50 28.00 24.00 34.00 29.00 47.00 52.00 56.00 75.00 85.00
M22 x 1.5
(122.96) (133.81) (202.52) (173.59) (245.92) (209.75) (339.95) (44.76) (405.04) (542.47) (614.80)
20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00
M24 x Std.
(148.27) (155.50) (238.68) (195.29) (289.32) (245.92) (397.81) (419.51) (455.67) (593.10) (655.43)
23.00 35.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.00
M24 x 2.0
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)

Page 6
TORQUE VALUES FOR
STANDARD U.S. FASTENERS
SAE Bolt Head
Type Description
Grade Marking
WILL HAVE NO MARKINGS IN THE CENTER OF THE HEAD.

1 1 or 2
Low or Medium Carbon Steel Not Heat-treated.
WILL HAVE THREE RADIAL LINES.

5 5
Quenched and Tempered Medium Carbon Steel.
WILL HAVE 6 RADIAL LINES.

8 8
Quenched and Tempered Special Carbon or Alloy Steel.
Recommended torque, in foot-pounds, for all Standard

Application Nuts and Bolts, provided:
1. All thread surfaces are clean and lubricated with SAE-30
engine oil. (See Note.)
2. Joints are rigid, that is, no gaskets or compressible
materials are used.
3. When reusing nuts or bolts, use minimum torque values.
NOTE: Multiply the standard torque by:
0.65 When finished jam nuts are used.
0.70 When Molykote, white lead or similar
mixtures are used as lubricants.
0.75 When Parkerized bolts or nuts are used.
0.85 When cadmium plated bolts or nuts and
zinc bolts w/waxed zinc nuts are used.
0.9 When hardened surfaces are used under
the nut or bolt head.
NOTE: When reusing bolts and nuts in service, use
minimum torque values.

Page 7
The following General Torque Values must be used where
SPECIAL TORQUE VALUES are not given.
NOTE: Torque values listed throughout this manual are lubricated (wet) threads; values must be increased
1/3 for nonlubricated (dry) threads.
Heat-treated Material Grade 5 and Grade 8
Grade 5 Grade 8
Thread Size (3 Radial Dashes on Head) (6 Radial Dashes on Head)
Foot-pounds Newton Meter Foot-pounds Newton Meter
(ft lb) (Nm) (ft lb) (Nm)
1/4" - 20 6 8 9 12
1/4" - 28 7 9 11 15
5/16" - 18 13 18 18 24
5/16" - 24 15 20 21 28
3/8" - 16 24 33 34 46
3/8" - 24 27 37 38 52
7/16" - 14 38 52 54 73
7/16" - 20 42 57 60 81
1/2" - 13 58 79 82 111
1/2" - 20 65 88 90 122
9/16" - 12 84 114 120 163
9/16" - 18 93 126 132 179
5/8" - 11 115 156 165 224
5/8" - 18 130 176 185 251
3/4" - 10 205 278 290 393
3/4" - 16 240 312 320 434
7/8" - 9 305 414 455 617
7/8" - 14 334 454 515 698
1" - 8 455 617 695 942
1" - 14 510 691 785 1064
1 1/8" - 7 610 827 990 1342
1 1/8" - 12 685 929 1110 1505
1 1/4" - 7 860 1166 1400 1898
1 1/4" - 12 955 1295 1550 2102
1 3/8" - 6 1130 1532 1830 2481
1 3/8" - 12 1290 1749 2085 2827
1 1/2" - 6 1400 2034 2430 3295
1 1/2" - 12 1690 2291 2730 3701
1 3/4" - 5 2370 3213 3810 5166
2" - 4 1/2 3550 4813 5760 7810
NOTE: If any bolts and nuts are found loose or at values less
than what the chart states, it is recommended that
loose bolt and/or nut be replaced with a new one.

Page 8
TYPE 8 PHOSPHATE COATED
HARDWARE
This chart provides tightening torque for general purpose
applications using original equipment standard hardware as
listed in the Parts Manual for the machine involved. DO NOT
SUBSTITUTE. In most cases, original equipment standard
hardware is defined as Type 8, coarse thread bolts, nuts and
thru hardened flat washers (Rockwell "C" 38 - 45), all phosphate
coated and assembled without supplemental lubrication (as
received) condition.
The torques shown below also apply to the following:
1. Phosphate coated bolts used in tapped holes in steel or
gray iron.
2. Phosphate coated bolts used with phosphate coated
prevailing torque nuts (nuts with distorted threads or plastic
inserts).
3. Phosphate coated bolts used with copper plated weld nuts.
Markings on bolt heads or nuts indicate material grade ONLY
and are NOT to be used to determine required torque.
Standard Torque ±10%

Nominal Thread Diameter Kilogram-meter Foot-pounds
(kg•m) (ft lb)
1/4" 1.1 8
5/16" 2.2 16
3/8" 3.9 28
7/16" 6.2 45
1/2" 9.7 70
9/16" 13.8 100
5/8" 19.4 140
3/4" 33.2 240
7/8" 53.9 390
1" 80.2 580
1 - 1/8" 113.4 820
1 - 1/4" 160.4 1160
1 - 3/8" 210.2 1520
1 - 1/2" 279.4 2020
1 - 3/4" 347.1 2510
2" 522.8 3780

Page 9
TORQUE VALUES FOR HOSE
CLAMPS
The following chart provides the tightening torques for hose
clamps used in all rubber applications (radiator, air cleaner,
operating lever boots, hydraulic system, etc.).
Torque
Radiator, Air Cleaner, Boots, Etc. Hydraulic System
Clamp Type and Size
Kilogram-meter Inch Pounds Kilogram-meter Inch Pounds
(kg•m) (in lb) (kg•m) (in lb)
"T" Bolt (Any Diameter) 0.68 - 0.72 59 - 63 ------- -------
Worm Drive - Under
44 mm (1-3/4 in) Open Diam- 0.2 - 0.3 20 - 30 0.5 - 0.6 40 - 50
eter
Worm Drive - Over 44 mm
0.5 - 0.6 40 - 50 ------- -------
(1-3/4 in) Open Diameter
Worm Drive - All "Ultra-Tite" 0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50
ORFS SWIVEL NUT

RECOMMENDED TORQUE
Torque (kg•m)
Dash Size Hose I.D. Thread Size
Recommended
4 1/4" 9/16" 2.4 - 2.6
6 3/8" 11/16" 3.3 - 3.9
8 1/2" 13/16" 5.1 - 5.7
12 3/4" 1 3/16" 11.7 - 12.7
16 1" 1 7/16" 15.3 - 17.3
20 1 1/4" 1 11/16" 18.0 - 20.0

Page 10
TORQUE VALUES FOR SPLIT
FLANGES
The following chart provides the tightening torques for split
flange connections used in hydraulic systems. Split flanges and
fitting shoulders should fit squarely. Install all bolts, finger tight
and then torque evenly.
NOTE: Over torquing bolts will damage the flanges and/or
bolts, which can cause leakage.
Bolt Torque
Flange Bolt
Kilogram-meter Foot-pounds
Size (*) Size
(kg•m) (ft lb)
1/2" 5/16" 2.1 - 2.5 15 - 18
3/4" 3/8" 3.0 - 3.7 22 - 27
1" 3/8" 3.7 - 4.8 27 - 35
1 - 1/4" 7/16" 4.8 - 6.2 35 - 45
1 - 1/2" 1/2" 6.4 - 8.0 46 - 58
2" 1/2" 7.6 - 9.0 55 - 65
2 - 1/2" 1/2" 10.9 - 12.6 79 - 91
3" 5/8" 19.1 - 20.7 138 - 150
3 - 1/2" 5/8" 16.2 - 18.4 117 - 133
(*) - Inside diameter of flange on end of hydraulic tube or hose
fitting.
NOTE: Values stated in chart are for Standard Pressure
Series (Code 61) Split Flanges.

Page 11
TORQUE WRENCH EXTENSION
TOOLS
Very large diameter, high-grade fasteners (nuts, bolts, cap
screws, etc.) require a great deal of turning force to achieve
recommended tightening torque values.
Common problems that could occur as a result are:
• Recommended torque exceeds the measuring capacity of
the torque wrench.
• Specialized sockets do not fit the adapter on the front end
(nose) of the torque wrench.
• Generating adequate force on the back end (handle) of the
wrench is difficult or impossible.
• Restricted access or an obstruction may make use of the
torque wrench impossible.
• A unique application requires fabrication of an adapter or
other special extension.
Most standard torque wrenches can be adapted to suit any one
of the proceeding needs or situations, if the right extension tool
is used or fabricated.
Torque Multiplication
A wrench extension tool can be used to increase the tightening
force on a high capacity nut or bolt.
For example, doubling the distance between the bolt and the
back (handle) end of the torque wrench doubles the tightening
force on the bolt. It also halves the indicated reading on the
scale or dial of the torque wrench. To accurately adjust or
convert indicated scale or dial readings, use the following
formula:
I = A x T/A + B where:
I = Indicated force shown on the torque wrench scale or dial.
T = Tightening force applied to the nut or bolt (actual Torque). Figure 1
A = Length of the torque wrench (between the center of the nut

or bolt and the center of the handle).
B = Length of the extension.
As an example, if a 12" extension is added to a 12" torque
wrench, and the indicated torque on the dial reads "150 ft lb",
the real force applied to the bolt is 300 ft lb:
AxT 12 x 300 3600

I= = = = 150
A+B 12 + 12 24

Page 12
NOTE: The formula assumes there is no added deflection or
"give" in the joint between the extension and torque
wrench. Readings may also be inaccurate:
• If the extension itself absorbs some of the tightening force
and starts to bend or bow out.
• If an extension has to be fabricated that is not perfectly
straight (for example, an extension made to go around an
obstruction, to allow access to a difficult to tighten
fastener), the materials and methods used must be solid
enough to transmit full tightening torque.
Other Uses for Torque Wrench Extension

Tools
Torque wrench extensions are sometimes made up for reasons
other than increasing leverage on a fastener.
For example, a torque wrench and extension can be used to
measure adjustment "tightness" of a linkage or assembly.
Specially fabricated extensions can be used to make very
precise checks of the force required to engage or disengage a
clutch mechanism, release a spring-applied brake assembly, or
"take up" free play in most any movable linkage.
Once the value of the adjustment force is established, repeated
checks at regular intervals can help to monitor and maintain
peak operating efficiency. These types of adjustment checks are
especially useful if physical measurements of linkage travel are
difficult to make or will not provide the needed degree of
precision and accuracy.
To allow the assembly or mechanism to accept a torque wrench,
welding a nut or other adapter on the end of a linkage shaft or
other leverage point will allow turning the shaft or assembly
manually.

Page 13
Tightening Torque Specifications (Metric)
(For coated threads, prelubricated assemblies.)
IMPORTANT
Disassembly, overhaul and replacement of components on
the machine, installation of new or replacement parts and/
or other service-related maintenance may require the use of
thread or flange sealing assembly compound.
Use the information on this page as a general guide in
selecting specific formulas that will meet the particular
requirements of individual assembly installations. DOOSAN
does not specifically approve a specific manufacturer or
brand name, but the following table of "Loctite"
applications is included for which cross-references to other
manufacturer's products should also be widely available.
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of
fastener adhesives, with Threadlocker sealers 222, 242/243,
262, 271, 272, or 277.

Page 14
I. "Loctite" Fastener Adhesives
Breakaway Cure
Product Application Color Removal Strength (in lb) of
Sealer Alone
Low strength for 6 mm (1/4") or
222 Purple Hand tools 45
smaller fasteners.
Medium strength for 6 mm (1/4") and
242 or 243 Blue Hand tools 80
larger fasteners.
Heat/260°C (500°F)
High strength for high-grade fasteners
262 Red Remove HOT 160
subject to shock, stress and vibration.
(NO solvent)
Extra high strength for fine thread Heat/260°C (500°F)
271 Red 160
fasteners up to 25 mm (1") diameter. Remove HOT
High temperature/high strength for
Heat/316°C (600°F)
272 hostile environments to 232°C Red 180
Remove HOT
(450°F).
Extra high strength for coarse thread
Heat/260°C (500°F)
277 fasteners 25 mm (1") diameter and Red 210
Remove HOT
larger.
II. "Loctite" Pipe Thread Sealant
Product Application Color Removal Required Setup

"No-filler/nonclog" formula for
4 Hours (or 1/2
high-pressure hydraulic systems.
545 Purple Hand tools hour with Locquic
Over application will not restrict or foul
"T" Primer)
system components.
4 Hours (or 1/2
Solvent resistant, higher viscosity
656 White Hand tools hour with Locquic
tapered thread sealer.
"T" Primer)
III. "Loctite" gasket/flange sealer
Product Application Color Notes

Gasket eliminator specifically made
for aluminum flanges/surfaces. For Use Locquic "N" primer for fast (1/2 - 4
518 Red
hydraulic systems to 34,475 kPa hours) setup. Unprimed setup 4 - 24 hours.
(5,000 psi).
Low-pressure/wide-gap gasket
eliminator compound. Fills gaps to Use Locquic "N" primer for faster (1/2 - 4
504 Orange
0.0012 mm (0.030"), cures to rigid hours) setup. Unprimed setup 4 - 24 hours.
seal.
General purpose, fast setup,
flexible-cure gasket eliminator. For Use Locquic "N" primer for faster (1/4 - 2
515 Purple
nonrigid assemblies subject to shock, hours) setup. Unprimed setup 1 - 12 hours.
vibration or deflection.

Page 15
IV. "Loctite" retaining compounds

For bushings, sleeves, press fit
Use Locquic "N" primer for increased bond
bearings, splines and collars. For
609 Green strength and all cold temperature
gaps to 0.0002 mm (0.005"),
applications.
temperatures to 121°C (250°F).
For high temperatures to 232°C
620 Green Same as 609, above.
(450°F).
For high strength bonds and tight
680 clearance gaps, to 0.00008 mm Green Same as 609, above.
(0.002").
V. "Loctite" Adhesives

Black Max instant adhesive for shock May take 120 hours to reach full cure
380 Black
and vibration-resistant bonds. strength.
454 Adhesive for porous surfaces. Clear Full strength in 24 hours.
Increased strength (+50%), shock and
480 Black Full strength in 24 hours.
vibration-resistant.

Page 16
1Upper Structure
SP002994
CABIN (NON-ROPS) SP002994
Cabin
(NON-ROPS)
Edition 1
Cabin (NON-ROPS) SP002994

Page 1
MEMO

Page 2
Table of Contents
Cabin (NON-ROPS)
Cab Identification .................................................. 6
Removal ............................................................... 7
Installation .......................................................... 11

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up
DX180LC 5001 and Up
DX225LC 5434 and Up
DX225LL 5001 and Up
DX225NLC 5001 and Up
DX255LC 5001 and Up
DX300LC 7440 and Up
DX300LL 5001 and Up
DX340LC 5980 and Up
DX350LC 5980 and Up
DX380LC 5109 and Up
DX420LC 5327 and Up
DX480LC 5221 and Up
DX520LC 5117 and Up

Page 5
CAB IDENTIFICATION
The excavator could be equipped with either a ROPS or NON-
ROPS cab.
Figure 1, shows a NON-ROPS cabin (1) and a ROPS cabin (2).
When servicing your cabin use the correct section.
Figure 1
Reference
Description
Number
1 NON-ROPS Cabin
2 ROPS Cabin

Page 6
REMOVAL
CAUTION
AVOID INJURY
Avoid disassembling cabin if there are strong wind gusts,
which could catch large surface area of cabin shell and
push it sideways during lift.
1. Park on firm and level ground. O I

2. Lower front attachment (bucket) to ground.
3. Stop engine.
4. Set safety lever on "RELEASED" position.
5. Turn starter switch to "I" (ON) position. WARNING
DO NOT OPERATE
when performing inspection
WARNING
or maintenance
950205-01451
ON OFF
FG028828
If engine must be run while performing maintenance,
use extreme care. Always have one person in the
cabin at all times. Never leave the cabin with the
engine running.
6. Fully stroke work levers (joysticks) in all directions to

relieve pressure from accumulators.
7. Set safety lever on "LOCK" position.
8. Turn key to "O" (OFF) position and remove from starter
switch.
9. Hang maintenance warning tag on controls.
11. Prepare cabin shell for removal by disconnecting wiring
connectors for:
A. Cabin interior lighting.
B. External light wiring.
C. Radio antenna and connections.
D. Wiper/washer connections.
NOTE: Control console wiring harnesses and hydraulic
piping lines that pass through the floor of the
cabin do not need to be disassembled.
NOTE: If unit is equipped with a cabin protective
structure (for forestry, or hazardous working
conditions), it must be removed.

Page 7
12. Remove floor mat (1, Figure 3).
13. Remove seat (2, Figure 3).
NOTE: Be careful not to damage seat covering.
14. Remove cup holder (3, Figure 3).
Remove front cover (4, Figure 3) and side covers (5 and 6,
Figure 3). When removing cover(4, Figure 3), disconnect
hour meter connector.
NOTE: Don't remove monitor panel (7, Figure 3) and
switch panel (8, Figure 3).
Figure 3
15. After removing rear mat (1, Figure 4), remove rear center
cover (2, Figure 4), cassette cover(3, Figure 4) and rear
side covers (4 and 5, Figure 4).
Figure 4
16. Remove fuse box bracket (1, Figure 5) from left side wall
without disassembly harness connector.
17. Disconnect cabin ground cable located near fuse box
bracket.
18. Remove cassette bracket (2, Figure 5) and disconnect
antenna and speaker wire.
19. Remove electric box (4, Figure 5) without disassembly
harness connectors.
Figure 5

Page 8
20. Remove air ducts (1, 2, 3 and 4, Figure 6) from cabin rear
panel.
21. Remove across bar (5, Figure 6) between left and right
side of cabin.
Figure 6
22. Remove air ducts (1, 2, 3, 4 and 5, Figure 7) right side of

cabin step by step from the front duct.
23. Disconnect washer hose located at floor plate bottom.
24. Disconnect cabin wiring connectors from main harness.
Figure 7
25. Remove four mounting nuts from four corners of cabin floor
(1, Figure 8).
26. Remove four M12 hex bolts (2, Figure 8) and two M10 hex
bolts (3, Figure 8).
Figure 8

Page 9
27. Using a suitable lifting device, attach slings to four lift
points on top of cab (Figure 9).
NOTE: Cabin weights approximately 315 kg (700 lb).
28. Lift cab from 25 ~ 50 mm (1" ~ 2") above deck height.
Check that all electrical connections have been
disconnected and all other items unbolted.
29. Continue lifting with the assist crane to remove the cab
shell. Lower the shell to a prepared safe blocking support.
Figure 9

Page 10
INSTALLATION
points on top of cab (Figure 10).
NOTE: Cabin weights approximately 315 kg (700 lb).
2. Lower cab into position on cab floor.
Figure 10
3. Install four mounting nuts from four corners of cabin floor

(1, Figure 11).
NOTE: Mounting nut torque 21 kg•m (205 Nm, 150 lb
ft).
4. Install four M12 hex bolts (2, Figure 11) and two M10 hex
bolts (3, Figure 11).
NOTE: Mounting nut torque
M12 - 11 kg•m (108 Nm, 80 lb ft).
M10 - 6.5 kg•m (64 Nm, 47 lb ft).
5. Once cab is mounted to floor, unhook lifting device.
Figure 11
6. Connect cabin wiring connectors to main harness.

7. Connect washer hose located at floor plate bottom.
8. Install air ducts (1, 2, 3, 4 and 5, Figure 12) right side of
cabin step by step from the rear duct.
Figure 12

Page 11
9. Install across bar (5, Figure 13) between left and right side
of cabin.
10. Install air ducts (1, 2, 3 and 4, Figure 13) from cabin rear
panel.
Figure 13
11. Install electric box (4, Figure 14).

12. Install cassette bracket (2, Figure 14) and connect antenna
and speaker wire.
13. Connect cabin ground cable located near fuse box
bracket.
14. Install fuse box bracket (1, Figure 14) to left side wall of
the cab.
Figure 14
15. Install rear side covers (4 and 5, Figure 15), cassette cover
(3, Figure 15) and rear center cover (2, Figure 15), last
install rear mat (1, Figure 15).
Figure 15

Page 12
16. Install front cover (4, Figure 16), and side covers (5 and 6,
Figure 16), when install cover (4, Figure 16) connect hour
meter connector.
17. Install seat (2, Figure 16).
NOTE: Be careful not to damage seat covering.
18. Install floor mat (1, Figure 16).
Figure 16

Page 13
Page 14
SP002995
CABIN (ROPS) SP002995
Cabin (ROPS)
Edition 1
Cabin (ROPS) SP002995

Page 1
MEMO

Page 2
Table of Contents
Cabin (ROPS)
Cab Identification .................................................. 6
When Required by Local Regulations ............................. 6
Removal ............................................................... 8
Installation .......................................................... 12

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX140LC 5503 and Up
DX180LC 5209 and Up
DX225LC 5890 and Up
DX225LL 5001 and Up
DX255LC 5150 and Up
DX300LC 8340 and Up
DX300LL 5001 and Up
DX340LC 6113 and Up
DX350LC 5980 and Up
DX380LC 5162 and Up
DX420LC 5368 and Up
DX480LC 10022 and Up

Page 5
CAB IDENTIFICATION
The excavator could be equipped with either a ROPS or NON-
ROPS cab.
Figure 1, shows a NON-ROPS cabin (1) and a ROPS cabin (2).
When servicing your cabin use the correct section.
Figure 1
Reference
Description
Number
1 NON-ROPS Cabin
2 ROPS Cabin

When Required by Local Regulations
Global markets may or may not require a Roll Over Protective
Structure (ROPS). Always comply with all regional and
governmental regulations that apply to your market. The
following information is for a ROPS cabin.
General ROPS Guidelines for ROPS Certified Cabins

The operator's cabin is a ROPS certified structure for protecting
the seat-belted operator. It absorbs the impact energy of a
rollover impact. Do not allow machine weight (mass) to exceed
certified value on certification plate. If weight is exceeded, the
ROPS structure will not be able to fulfill its safety function.
Do not increase machine weight beyond certified value by
modifying machine or by installing attachments on machine. If

Page 6
weight limit of protective equipment is exceeded, protective
equipment will not be able to protect operator, and operator may
suffer serious injury or death. Always observe the following:
• This machine is equipped with a protective structure. Do
not remove protective structure and carry out operations
without it.
• Never modify the operator’s cabin by welding, grinding,
DOOSAN. Changes to the cabin can cause loss of
operator protection from rollover and falling objects, and
operator may suffer serious injury or death.
• When protective structure is damaged or deformed by
falling objects or by rolling over, its strength will be reduced
and it will not be able to properly fulfill its function. In these
cases, always contact your DOOSAN distributor for advice.
Never repair a ROPS cabin.
• Always wear your seat belt when operating machine.
ROPS Certification
This DOOSAN excavator has an operator’s cabin that meets
ROPS requirements. The seat belt must be worn for rollover
protection.
The ROPS certification plate (Figure 2) is found on the left side
of the cabin on most models. It may vary slightly in its location
on some models.
Check the ROPS cabin, mounting, and hardware for damage.
Never modify the ROPS cabin. Replace the cabin and hardware
if damaged. See your DOOSAN dealer for parts.
Figure 2
ROPS − Roll Over Protective Structure complies with
ISO 12117-2:2008.
WARNING
Never modify the operator cabin by welding, grinding,
DOOSAN. Changes to the cabin can cause loss of operator
protection from rollover and falling objects, and result in
serious injury or death.

Page 7
REMOVAL
CAUTION
AVOID INJURY
Avoid disassembling cabin if there are strong wind gusts,
which could catch large surface area of cabin shell and
push it sideways during lift.

3. Stop engine.
DO NOT OPERATE
WARNING
or maintenance
950205-01451
ON OFF
FG028828
engine running.

relieve pressure from accumulators.
switch.
11. Prepare cabin shell for removal by disconnecting wiring
connectors for:
A. Cabin interior lighting.
B. External light wiring.
C. Radio antenna and connections.
D. Wiper/washer connections.
NOTE: Control console wiring harnesses and hydraulic
piping lines that pass through the floor of the
cabin do not need to be disassembled.
NOTE: If unit is equipped with a cabin protective
structure (for forestry, or hazardous working
conditions), it must be removed.

Page 8
12. Remove mats from steps and floor.
13. Remove safety lever cover (1, Figure 4).
14. Remove two screws (2, Figure 4) in safety lever to remove
lever.
1 FG015884
Figure 4
15. Remove duct covers (1 and 2, Figure 5).
FG015885
Figure 5
16. Remove air ducts (3 thru 8, Figure 6) on right-hand side of

operator's cabin.
17. Disconnect monitor and sun sensor connectors. 4
3
18. Disconnect washer hose from floor plate.
7 8
6
5 FG015886
Figure 6
19. Remove glove box pad (1, Figure 7), and two bolts under
pad.
20. Remove three caps (2, Figure 7) from top of rear cover. 2
Remove three bolts securing rear cover in place.
21. Remove two bolts (3, Figure 7) from bottom of rubber
mounts in rear cover. 1
22. Remove rear cover.

3
FG015887
Figure 7

Page 9
23. Remove air ducts (4 thru 6, Figure 8). Remove
4 5
atmospheric air duct (7).
6
FG015888
Figure 8
24. Remove all bolts fastening brackets (8 thru 10, Figure 9) to

separate brackets from body of operator's cabin.
25. Disconnect connectors on interior lights, speakers and
antenna.
8
9
10
FG015889
Figure 9
26. Remove four mounting nuts from four corners of cabin floor
1 1
(2, Figure 10).
27. Remove four bolts (3, Figure 10) from door side of cabin
floor.
2 5
28. Remove four bolts (1, Figure 10) on right-hand side of floor
in operator's cabin. 4
29. Remove two bolts (4, Figure 10) at front of floor in 3 3

operator's cabin, and bolt (5, Figure 10) at rear of floor in
operator's cabin.
FG015890
Quantity Description Figure 10
4 16 mm nuts at each corner of cabin.
4 10 mm x 1.5 bolts at door side of cabin.
10 mm x 1.5 mm bolts, 4 on right side of
cabin and 2 under front window. One bolt is
7
positioned in center of rear part of
operator's cabin.

Page 10
30. Remove ROPS bolt (1, Figure 10).
1
FG015891
Figure 11

points on top of cabin (Figure 12).
NOTE: Cabin weighs approximately 460 kg (1,014 lb).
32. Lift cabin approximately 25 - 50 mm (1" - 2") above deck.
Check that all electrical connections have been
disconnected and all other items unbolted.
33. Continue lifting with assist crane to remove cabin shell.
Lower shell to a prepared safe blocking support.
NOTE: Do not rapidly lift operator's cabin: The bottom
FG015892
of operator's cabin may come into contact with,
Figure 12
and scratch, control stand cover.

Page 11
INSTALLATION
points on top of cabin (Figure 13).
NOTE: Cabin weights approximately 460 kg (1,014 lb).
2. Lower cabin into position on cabin floor.
FG015892
Figure 13
3. Install four mounting nuts in four corners of cabin floor (2,

1 1
Figure 14).
NOTE: Mounting nut torque 21 kg•m (205 Nm,
150 ft lb).
2 5
4. Install four bolts (3, Figure 14) in door side of cabin floor.
4
5. Install four bolts (1, Figure 14) on right of floor in operator's
cabin. 3 3
6. Install two bolts (4, Figure 14) on front of floor in operator's

cabin, and one bolt (5) on rear of floor in operator's cabin.
FG015890
Quantity Description Figure 14

4 16 mm nuts at each corner of cabin.
4 10 mm x 1.5 bolts at door side of cabin.
10 mm x 1.5 mm bolts, 4 on right side of
cabin and 2 under front window. One bolt is
7
positioned in center of rear part of
operator's cabin.
7. Once cabin is mounted to floor, unhook lifting device.

8. Connect cabin ground cable.
9. Connect cabin light wiring connector.
10. Install stereo assembly with bolts (2, Figure 14) after
connecting speaker and antenna wires.
11. Install ROPS bolt (1, Figure 15).
NOTE: Mounting nut torque 250 kg•m (1807 ft lb)
1
FG015891
Figure 15

Page 12
12. Install air ducts (1 thru 5, Figure 16). Install atmospheric air 2
1
duct (6).
4 6
5
FG015893
Figure 16
13. Install brackets (7 thru 9, Figure 17) on body of operator's

cabin.
7
8
9
FG015895
Figure 17
14. Install two bolts (2, Figure 18) and center bolts in center,
and three bolts on top to install dashboard cover. Install
3
cap (3, Figure 18) on top of dashboard cover.
15. Install glove box pad (1, Figure 18).
16. Connect washer hose at floor plate bottom.
1
FG015896
Figure 18
17. Install air ducts (1 thru 4, Figure 19) on right-hand side of

cabin.
18. Connect monitor, sun sensor connector, and washer hose. 4
3
6
5 FG015897
Figure 19

Page 13
19. Install duct covers (1 and 2, Figure 20).
20. Install safety lever. Apply Loctite on screws when installing
lever.
21. Install mats on steps and floor. 2
FG015885
Figure 20

Page 14
SP002996
COUNTERWEIGHT SP002996
Counterweight
Edition 1
Counterweight SP002996
Page 1
MEMO
Page 2
Table of Contents
Counterweight
General ................................................................. 6
Warning for Counterweight and Front Attachment
Removal .......................................................................... 6
Removal ............................................................... 8
Installation ............................................................ 9
Page 3
MEMO
Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up
DX180LC 5001 and Up
DX255LC 5001 and Up
DX300LC 7440 and Up
Page 5
GENERAL
Warning for Counterweight and Front

Attachment Removal
DANGER
AVOID DEATH
DOOSAN warns any user, that the removal of the
counterweight from the machine, front attachment or any
other part, may affect the stability of the machine. This
could cause unexpected movement, resulting in death or
serious injuries. DOOSAN is not liable for any misuse.
Never remove the counterweight or front attachment unless
FG000371
the upper structure is in-line with the lower structure.
Figure 1
front attachment has been removed.
Before any attempt is made to begin removal or installation of

the counterweight, the excavator must be parked on a firm and
level supporting surface, with no sloping surfaces or soft or
muddy ground in the area where the assist lift crane will be
working. Position all accessories in the overnight storage
position.
WARNING
The weight of counterweight is given in the following table.
Use only rated and approved slings and hardware when
removal or installation lifts are being made. Lifting slings,
shackles and all other hardware must be rigged safely. An
assist crane that is rated above weight capacity is required.
Model Weight of Counterweight

DX138LC
2,200 kg (4,850 lb)
DX140LC
DX180LC 3,000 kg (6,614 lb)
4,100 kg (9,039 lb)
DX225NLC
4,700 kg (10,361 lb) (Optional)
DX255LC 4,700 kg (10,361 lb)
5,300 kg (11,685 lb)
DX300LC
5,900 kg (13,007 lb) (Optional)
Page 6
Responsibility must be assigned to one person to be in charge
of the lifting crew, and to verify that required safe lifting
precautions have been taken before each part of this procedure
has been started.
All members of the working crew should know and understand
the signals that will be used between the lifting leader, the assist
crane operator and the remainder of the work crew.
WARNING
If the turntable deck has been unbalanced by removal of
weight from one end only, traveling the excavator, swinging
the turntable, movement over bumps or sloping and uneven
surfaces could cause loss of control and possible
accidents or injuries.
To maintain stability the counterweight must be removed

whenever the front attachment is taken off the machine.
90 ~ 110
15 FG000325
Figure 1
When loading an excavator (either track or wheeled type) on a

trailer for transport after the front attachment has been removed,
always go backwards up the loading ramp. The counterweight
end of the deck has to get on the trailer first, while the cabin is
still going up the ramp (Figure 1).
15
FG000326
Figure 2
Page 7
REMOVAL
2. Lower front attachment (bucket) to the ground.
3. Stop engine.
DO NOT OPERATE
WARNING
or maintenance
950205-01451
ON OFF
FG028828
engine running.

relieve any pressure from accumulators.
switch.
11. Remove engine compartment cover.
12. Using a suitable lifting device capable of handling a heavy
load, partially support counterweight (1, Figure 4) before
loosening four bolts (2). Stop lifting with assist crane as 5
soon as lifting slings are taut.
13. Remove four bolts (2, Figure 4) and washers (3) from
1
counterweight (1).
NOTE: Heat bolts if necessary, to free them.
14. When bolts (2, Figure 4) and washers (3) have been
removed, lift counterweight (1) a very short distance above 4
support frame (4) and stop. Check slings and make sure
counterweight is being supported evenly.
3
FG014409
Figure 4
Page 8
INSTALLATION
1. Using suitable lifting device capable of handling a heavy
load, raise counterweight (1, Figure 5) into position just
above support frame (4) leaving counterweight suspended. 5
Verify that counterweight is level and even.
NOTE: Leave counterweight (1, Figure 5) suspended
1
3 mm (0.125") above support frame (4) until all
four mounting bolts (2) are started in
counterweight mounting holes.
2. Slide washers (3, Figure 5) onto bolts (2). Apply Loctite
#242 to mounting bolt threads. 4
3. Install four bolts (2, Figure 5) with washers (3) into

counterweight until washers contact support frame. Fully 3
lower counterweight onto support frame and finish
tightening bolts. 2
NOTE: Torque bolts (2, Figure 5) to values shown in FG014409

following table. Figure 5
Model Bolt Torque

DX138LC
115 kg•m (832 ft lb)
DX140LC
DX180LC
DX225NLC 150 kg•m (1,085 ft lb)
DX255LC
DX300LC 250 kg•m (1,807 ft lb)
4. Remove lifting device and lifting eyes from counterweight

lifting holes (5, Figure 5).
5. Install engine compartment cover.
Page 9
Page 10
SP002997
FUEL TANK SP002997
Fuel Tank
Edition 1
Fuel Tank SP002997

Page 1
MEMO
Fuel Tank SP002997

Page 2
Table of Contents
Fuel Tank
Parts List ......................................................................... 6
Specifications .................................................................. 7
Removal ............................................................... 8
Installation .......................................................... 12
Start-up Procedures ........................................... 15
Fuel Tank SP002997

Page 3
MEMO
Fuel Tank SP002997

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up
Fuel Tank SP002997

Page 5
GENERAL DESCRIPTION
WARNING
Engine fuel is highly flammable and potentially explosive.
To prevent possible injury and/or damage to equipment,
extinguish or move to a safe distance all potential fire hazards.
Parts List
5
20
20 8
18
19 8
17
51 1
52
7
12
7
12
6 15
16
14
16 13
3
13
2
11
10 9
22
23
Figure 1 FG009752
Fuel Tank SP002997

Page 6
Reference Reference
Number Number
1 Fuel Tank 13 Bolt
2 Cover 14 Shim
3 O-ring 15 Shim
4 Fuel Strainer 16 Spacer
5 Fuel Cap 17 Fuel Sender
6 Level Gauge 18 Bolt
7 Clip 19 Spring Washer
8 O-ring 20 Plug
9 Drain Valve 22 Hose Clamp
10 Bolt 23 Hose
11 Spring Washer 51 O-ring
12 Bolt 52 Plug
Specifications
Fuel tank capacity is 267 liters (70.5 U.S. gal).
Fuel Tank SP002997

Page 7
REMOVAL
1. Look at fuel level display (Figure 2) on instrument panel in
operator's cabin to see what it displays. The display is
divided into ten separated segments, each representing 10
percent of total fuel supply. Also, look at level gauge on
side of tank to estimate volume of fuel left in tank.
NOTE: If possible, work excavator until available fuel
supply in tank has been run down as far as
possible.
E F
FG013666
Figure 2
2. Park on firm and level ground and swing turntable to

approximately a 90° with respect to tracks. See Figure 3.
FG000471
Figure 3
3. Lower front attachment (bucket) to ground. O I

4. Stop engine.
6. Turn starter switch to "I" (ON) position.
WARNING
WARNING DO NOT OPERATE

or maintenance
950205-01451
ON OFF
AVOID DEATH OR SERIOUS INJURY FG028828
If engine must be run while performing maintenance, Figure 4
engine running.

switch.
Fuel Tank SP002997

Page 8
12. Clean area around fuel tank fill cap (11, Figure 5). Open
fuel cap. 11
FG003871
Figure 5
13. Place a large enough container under fuel tank to collect

remaining fuel. Open drain valve (6, Figure 6) at bottom of
tank and drain.
NOTE: Fuel tank capacity is 267 liters (70.5 U.S. gal).
FG003872
Figure 6
14. Tag and disconnect fuel supply line (21, Figure 7) and fuel
return line (19) from fuel tank (1) and carefully drain 1
remaining fuel from lines.
15. Remove clamp (20, Figure 7) holding fuel return line (19) to
tank (1).
19
20
21 FG003873
Figure 7
Fuel Tank SP002997

Page 9
16. If equipped, remove components from fuel filler pump port
(22, Figure 8) on side of fuel tank (1).
1
22
FG003874
Figure 8
17. Remove six bolts (1 and 2, Figure 9) and stay (3) from fuel
tank and frame.
Remove four bolts (4 and 5) and fuel tank cover (6) from 3
fuel tank. 2
Remove two bolts (7) and bracket (8) from tank. 4
Remove four bolts (9) and battery cover (10) from frame.
8 7
5
9
6
10 1
FG009917
Figure 9
18. Tag and disconnect wires leading to fuel sender (16,

Figure 10) on side of fuel tank (1).
1
16
FG003877
Figure 10
Fuel Tank SP002997

Page 10
19. Remove four bolts (35 and 36, Figure 11) and cover (37)
from fuel tank and support.
37
36
35 FG003878
Figure 11
20. Install two 12 mm eyebolts in threaded holes (38 and 39,

Figure 12). Using a suitable lifting device, sling eyebolts.
1
21. Remove six bolts (7) and spacers (13, Figure 12) holding 38
tank (1) to frame. Lift tank 25 mm (1") and make sure it is 39
balanced. Make sure that there are no other electrical
wires or hoses connected to tank. Completely remove tank
after inspection.
NOTE: The clear level gauge on the side of the tank is
easily damaged. Be careful of obstacles and
wind gusts.
22. Remove shims (9, Figure 12).
NOTE: If tank is to be reused note position and amount
of shims used for each mounting bolt location. 9
13
7 FG003879
Figure 12
Fuel Tank SP002997

Page 11
INSTALLATION
1. Install two 12 mm eyebolts in threaded holes (38 and 39,
Figure 13). Using a suitable lifting device, sling eyebolts.
1
2. Set fuel tank (1, Figure 13) into position. Install six bolts (7) 38
and spacers (13) finger tight, to secure tank to frame. 39
NOTE: The clear level gauge on the side of the tank is

easily damaged. Be careful of obstacles and
wind gusts.
3. Install shims (9, Figure 13) as needed to prevent tank (1)
from rocking or stress from mounting bolts (7).
4. Tighten mounting bolts (7, Figure 13) after shims are
installed.
NOTE: Bolt torque is 27 kg•m (200 ft lb). 9
13
7 FG003879
Figure 13
5. Install four bolts (35 and 36, Figure 14) and cover (37) on
fuel tank and support.
37
36
35 FG003878
Figure 14
6. Connect wires as tagged to fuel sender (16, Figure 15) on

side of fuel tank (1).
1
16
FG003877
Figure 15
Fuel Tank SP002997

Page 12
7. Install four bolts (9, Figure 16) and battery cover (10) on
frame.
Install two bolts (7) and bracket (8) on fuel tank.
3
2
Install four bolts (4 and 5) and fuel tank cover (6) on fuel
tank. 4
Install six bolts (1 and 2) and stay (3) on fuel tank and
8 7
frame.
5
9
6
10 1
FG009917
Figure 16
8. Install five bolts (23, Figure 17) and cover (24) on fuel tank.
23
24
FG003875
Figure 17
9. If equipped, connect components to fuel filler pump port

(22, Figure 18) on side of fuel tank (1).
1
22
FG003874
Figure 18
Fuel Tank SP002997

Page 13
10. Connect as tagged, fuel supply line (21, Figure 19) and fuel
return line (19) to fuel tank (1). 1
11. Install clamp (20, Figure 19) to hold fuel return line (19) to
tank (1).
19
20
21 FG003873
Figure 19
12. Make sure fuel tank drain valve (6, Figure 20) on bottom of
tank is closed.
13. Fill fuel tank and check for signs of leaks. Correct any
problems found.
FG003872
Figure 20
Fuel Tank SP002997

Page 14
START-UP PROCEDURES
If engine does not start, the fuel system may need priming.
Prime the fuel system using the following procedure:
1. Stop engine.
2. Open left side door and then there is fuel filter.
FG000413
Figure 21
3. Loosen plug (1, Figure 22) on top of fuel filter head.

1
4. Pump hand operated primer pump (2, Figure 22) by the
fuel injection pump. Pump primer until fuel is present at 2
plug hole in fuel filter head.
5. Tighten plug in fuel filter head.
6. Continue to pump primer pump until a strong resistance is
felt.
7. Start engine and look for signs of leaks.
Repeat procedure if necessary. FG000431
Figure 22
Fuel Tank SP002997

Page 15
Fuel Tank SP002997
Page 16
SP000021
FUEL TRANSFER PUMP (OPT)SP000021
Fuel Transfer
Pump (Opt)
Edition 3
Fuel Transfer Pump (Opt) SP000021

Page 1
MEMO

Page 2
Table of Contents
Fuel Transfer Pump (Opt)

Theory of Operation ........................................................ 6
Troubleshooting .................................................... 7
Replacement of Rotor and Vane .......................... 7
Replacement of Rear Cover ................................. 8
Replacement of Armature..................................... 8

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up
DX225LCA 5167 and Up

Page 5
GENERAL DESCRIPTION
Theory of Operation
Fuel
4
1 2
6 5 3
Fuel Tank
IN OUT
2-2 2-1
FG003881
Figure 1
Reference Reference
Number Number
1 Motor 3 Inlet Hose
2 Pump 4 Outlet Hose
2-1 Pump Cover 5 Check Valve
2-2 Rotor and Vane 6 Strainer Cap
The fuel pump consists of a motor, pump, switch, and hose

assembly.
Pump
Hose
Switch FG001143
Figure 2

Page 6
TROUBLESHOOTING
On some pumps the ON-OFF switch is installed separately at a
Switch Cover
remote location.
Connector "B"
A thermal limiter, built into the motor, will automatically shut off
power if motor is overheating to protect it from being damaged.
NOTE: OPEN TEMP: 150 ±5°C (302 ±41°F). After circuit is Connector "A"
automatically shut off because of overheating the IV
pump will stop running. When temperature drops
below 143°C (289°F) the circuit will reactivate III
V
allowing the pump to restart.
FG003882
Figure 3 With Toggle Switch
Check resistance at connectors "A". If reading is zero, or very

close to zero, the motor is bad and must be replaced. Connector "A"
On units equipped with a toggle switch, check the resistance

through the toggle switch, while the switch is in the "ON"
position. If continuity is not present, the switch is bad. Be sure to
check resistance through the motor. IV
III
V
FG001145
Figure 4 Without Toggle Switch
REPLACEMENT OF ROTOR AND

VANE
If dirt or other foreign materials enter the pump during operation,
it can become lodged between the rotor and/or vanes and
generate heat which can cause the pump damage.
Remove the pump cover and check the rotor and vane. If any
pump parts or components become lost, damaged or
inoperable, immediately replace them with new ones.
FG000670
Figure 5 Without Toggle Switch

Page 7
Insert vane, with the circled edge of vane facing in the
counterclockwise direction. (Detail A)
IN OUT
Insert a new O-ring during reassembly of pump cover.
FG003883
Figure 6
REPLACEMENT OF REAR
COVER
Brush assembly and a thermal limiter are installed in the rear
cover. If you find any damage, replace them with new ones.
Remove switch cover and screw (M5 x L95) from the rear cover.
Remove cover.
At reassembly of rear cover, widen the space of the brush and
insert it to the armature. Then fit the hole of screw in the
housing. Figure 7
Be careful when installing the screw. The cover screw may be

attracted by the motor magnet.
REPLACEMENT OF ARMATURE
Rear Cover
Pump Side
You can replace only the armature in case motor was damaged Side
by a short circuit.
Remove the switch cover and rear cover, than remove armature
from the housing.
Remove the pump cover and remove rotor and vane.
Insert a new armature into the housing. Commutator
Refer to “Replacement of Rear Cover” on page -8, for FG001146

installation of the rear cover. Figure 8
Fit the rotor into the shaft flute of the armature. Insert vane to the
rotor being careful of the direction. Refer to “Replacement of
Rotor and Vane” on page -7.

Page 8
SP001856
SWING BEARING SP001856
Swing Bearing
Edition 3
Swing Bearing SP001856

Page 1
MEMO

Page 2
Table of Contents
Swing Bearing
Swing Bearing Maintenance ................................. 6
Operating Recommendation ........................................... 6
Measuring Swing Bearing Axial Play............................... 6
Measuring Bearing Lateral Play ...................................... 6
Swing Bearing Basic Operation....................................... 7
Disassembly .................................................................... 7
Assembly......................................................................... 9

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 5167 and Up
DX140LC 5001 and Up

Page 5
SWING BEARING
MAINTENANCE
Operating Recommendation
The service life of the swing bearing may be extended if a
conscious, daily effort is made to equalize usage over both ends
of the excavator. If the excavator is used in the same operating
configuration day in and day out (for example, with the travel
motors always under the counterweight, or with the attachment
over one side of the machine more than the other), the bearing's
service life could be reduced. Taking a few minutes in the middle
of each work shift to reposition the excavator, to work the
opposite end of the bearing, will provide a payoff in terms of
more even, gradual rate of wear and extended service life.
Measuring Swing Bearing Axial Play

Periodic, regular checks of bearing displacement must be made
at least twice a year. Use a dial indicator. Push the attachment 1
against the ground to lift the excavator off the ground and take
measurements at 4 points, 90° apart, around the circumference
of the bearing (Figure 1).
2
Record and keep all measurements. Play in the bearing should
increase minimally from one inspection to the next. Eventually,
however, as the bearing begins to approach the limit of its
service life, clearance increases become much more
pronounced and the actual measured play in the bearing could
exceed twice the value that was measured when the machine
was new.
Measuring Bearing Lateral Play

When vertical checks are made, the side to side play in the
bearing can be checked by fully retracting the arm and bucket
cylinders and extending the tip of the bucket as far forward as it
will go. With the excavator parked on a flat, level surface and the FG000533
bucket tip just off the ground, push against the bucket sideways
Figure 1
to take up all of the lateral clearance in the bearing. (Less than
100 lb of force must be required to move the bucket over all the
way.) Check lateral play in both directions and record the values.
When the bearing is beginning to approach the end of its service
life, measured lateral clearance should start to show larger and
larger increases.

Page 6
Swing Bearing Basic Operation
The swing bearing, which connects the upper structure with the
lower structure, consists of a inner ring, outer ring and ball
bearings. During swing movement, power from the swing motor
is transferred to the pinion by planetary gears connected to
gears on the inner ring, which is fixed in the undercarriage. Ball
bearings turn the outer ring.
Reference
Description
Number
1 Outer Ring
2 Inner Ring
3 Tapered Pin
4 Plug
5 Ball
6 Retainer
7 Seal
Figure 2
Disassembly
1. Remove tip of tapered pin (3, Figure 3) using grinder and

tap lightly to remove debris.
Figure 3
2. Remove plug (4, Figure 4) using a M10 x P1.5 bolt.
Figure 4

Page 7
3. Lift outer ring and check that inner ring can move freely.
See Figure 5, if not, replace seal (7, Figure 6).
Figure 5
4. Turn inner ring and use magnet bar (C, Figure 6) to

remove steel balls (5).
Figure 6
5. Turn inner ring and use wire (D, Figure 7) to remove

retainers (6).
Figure 7

Page 8
Assembly
1. Clean (degrease) the seal groove for the outer and inner
seals (7).
Apply instant glue to seal (7).
Install both seals respectively into position.
Figure 8
2. Hoist the outer race by crane horizontally and match it with

the inner race coaxially.
Rotating the outer race, insert balls (5), support (6) into the
plug (4) hole one by one with a round bar.
Figure 9
Figure 10
3. Top plug (4) into outer race (1) and then, drive pin (3) into
the pin hole.
Caulk the head of pin (3) with a punch.
Fill grease through the grease fitting.
Figure 11

Page 9
Page 10
SP002526
SWING REDUCTION GEARSP002526
Swing
Reduction Gear
Edition 1
Swing Reduction Gear SP002526

Page 1
MEMO

Page 2
Table of Contents
Swing Reduction Gear

Reassembly .......................................................... 8
Parts List ......................................................................... 8
Shrinkage Fitting of Shaft and Flexible Bearing . 10
Reassembly of Carrier Sub ................................ 12
Assembly of the Main ......................................... 19
Test..................................................................... 31
Reassembly of motor.......................................... 34

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up
DX140LC-3 1001 and Up, 50001 and Up

Page 5
Page 6
GENERAL DESCRIPTION
Theory of Operation
The swing motor final drive is a two-stage planetary gearbox
with two planet gears, two sun gears and two-stage output
reduction. The planetary gear engages the ring gear. The pinion
gear is connected to the output shaft and spline.
The final drive reduces swing motor rpm to increase swing motor
output torque. The available maximum swing speed provides a
fast turning rate for efficient, rapid work cycling with more than
adequate power for good acceleration.

Page 7
REASSEMBLY
Parts List
19
24
3
12
12
24 11
7 6
13 12
14 13
9
5 23
15
10
8
4
25
12
18
27
20
16
22
1
21
22
17
28
29
2
26
FG005349
Figure 1

Page 8
Reference Reference
Number Number
1 Casing 16 Pin
2 Driveshaft 17 Roller Bearing
3 Ring Gear 18 Roller Bearing
4 Planetary Gear 19 Socket Bolt
5 Sun Gear 2 20 Oil Seal
6 Planetary Gear 21 Plug
7 Sun Gear 1 22 Plug
8 Carrier 2 23 Spring Pin
9 Carrier 1 24 Retaining Ring
10 Pin Assembly 25 Retaining Ring
11 Pin Assembly 26 Ring
12 Adjustment Washer 27 Spring Pin
13 Adjustment Washer 28 Support Plate
14 Level Bar 29 Screw Bolt
15 Level Gauge Piping

Page 9
SHRINKAGE FITTING OF SHAFT
AND FLEXIBLE BEARING
1. Washing of shaft
Remove fluids like anticorrosive fluid applied to the shaft
and use an air conditioner to remove foreign substances.
2. Insert the support plate and the NILOS ring into the
prepared shaft as shown in the figure and heat bearings
(#22314, 2109-1041) on the heater. FG005350
Figure 2
FG005351
Figure 3
FG005352
Figure 4
FG005353
Figure 5

Page 10
3. When bearing is heated up to 90°C - 100°C, remove it from
the heater, hold it with both hands, and insert it into the
shaft evenly.
To do so, slowly insert bearing 4 - 5 mm that it seats itself
and then push it strongly to contact the NILOS ring.
CAUTION
AVOID INJURY FG005354
Do not heat bearing above 120°C. Figure 6
4. After assembling the bearing, let it cooled fully in the air for
1 to 2 hours.
FG005355
Figure 7

Page 11
REASSEMBLY OF CARRIER SUB
1. Washing of carrier
Put in a steam washer the carrier whose burr is removed
completely with corner face-milling and place it on the
assembly die after checking if there is not left any foreign
substance in it.
2. Washing of planetary gear
Check if planetary gear parts are washed or damaged, and
put them on the assembly die.
3. Reassembly of carrier #1 assembly
A. Place the carrier #1 assembly on the assembly jig,
insert the thrust washer in it, and install it to the hole
of carrier.
FG005356
Figure 8
FG005357
Figure 9
B. Put a pressure jig on the pin and use a press to insert

it.
FG005358
Figure 10

Page 12
FG005359
Figure 11
C. Place the carrier with the pin being pressed in on the

jig vertically. Use a hammer to insert the spring pin
(ø6 x 25 liter), and drain valve it.
FG005360
Figure 12
FG005361
Figure 13
FG005362
Figure 14

Page 13
FG005363
Figure 15
D. Assemble 2 other parts in the same way.
FG005364
Figure 16
E. Put the thrust washer (B) in the middle of the carrier

with all of pins being pressed in.
FG005365
Figure 17
F. Insert planetary gear #1 in 3 pins and put two thrust

washers on them as shown in the figure.
FG005366
Figure 18

Page 14
FG005367
Figure 19
G. Install a retaining ring (ø30, C type, and for shaft) on

each and check if gear rotates smooth.
FG005368
Figure 20
FG005369
Figure 21

Page 15
4. Reassembly of carrier #2 assembly
A. Place the carrier #2 assembly on the assembly die,
attach the thrust washer on a side of the planetary
gear #2, and insert it in the carrier with the washer
facing downward.
CAUTION
AVOID INJURY FG005370
The calibers of gear and washer must be fit to Figure 22
holes of the carrier pins.
FG005371
Figure 23
FG005372
Figure 24
B. Place the pin #2 assembly on the assembly die that

pinhole of the spring faces the same direction as the
carrier shaft, and insert it by pressing with hands or
gently tapping with hammer.
FG005373
Figure 25

Page 16
FG005374
Figure 26
FG005375
Figure 27
C. After inserting the pin assembly, set the carrier

vertically as shown in the figure, insert the spring pin
(ø6 x 25 mm) by gently tapping with hammer, and
push it to the end with a jig.
FG005376
Figure 28
FG005375
FG005377
Figure 29

Page 17
FG005378
Figure 30
D. Use a punch to drain valve 2 or 3 places near hole

where spring pin is inserted.
FG005379
Figure 31
FG005380
Figure 32
E. Assemble other 3 parts and check if the gear runs

smooth.
FG005381
Figure 33

Page 18
ASSEMBLY OF THE MAIN
1. Washing of casing and other parts
Wash casing and other parts with steam to remove
remaining foreign substance after casting and machining.
• Washing fluid: PK6540 (alkali)
• Concentration : 3-5%
• Temperature: 60 - 70°C
2. Assembly of shaft and bearing
A. Attach the washed casing on the turnover machine
and rotate the turnover machine so that press fitting
side of the shaft looks upward.
FG005382
Figure 34
FG005383
Figure 35
B. Place the driveshaft assembly where bearing

(#22314) is assembled on the case assembly, put a
press jig on it, and use press to insert it.
CAUTION
AVOID INJURY
Make sure that bearing is not tilted for correct
press fitting before using press. FG005384
Figure 36

Page 19
FG005385
Figure 37
FG005386
Figure 38
FG005387
Figure 39
C. Remove bearing press jig, align the support plate

with the bolt tap of the case, and install 6 Loctite
(#262) applied flat head bolts (M8 x 15 mm) and
tighten them with torque wrench (torque: 320 kg•cm).
FG005388
Figure 40

Page 20
FG005389
Figure 41
FG005400
Figure 42
FG005401
Figure 43
D. After installing the support plate, rotate the turnover

machine so that case is situated as shown in the
figure.
FG005402
Figure 44

Page 21
E. Apply grease to the lip of the oil seal (TC70 x 95 x 13,
2180-1254), insert it in the case, adjust it evenly, put
jig on it, and use press to install it. After installing,
remove jig and check its fitting state.
FG005403
Figure 45
FG005404
Figure 46
FG005405
Figure 47
FG005406
Figure 48

Page 22
FG005407
Figure 49
FG005408
Figure 50
F. Place bearing (2109-1042, NJ313) evenly, put jig on

it, and use press to install it.
FG005409
Figure 51
FG005410
Figure 52

Page 23
FG005411
Figure 53
FG005412
Figure 54
G. After the assembly of the bearing, attach retaining

ring (ø65, shaft ring, C type, S6500650) on the shaft.
FG005413
Figure 55

Page 24
FG005414
Figure 56
H. Install drain valve on PT3/8 tap of the side of the

case.
FG005415
Figure 57
FG005416
Figure 58
FG005417
Figure 59

Page 25
FG005418
Figure 60
3. Reassembly of ring gear and carrier assembly

A. Apply liquid gasket (#1104) to the ring gear assembly
parts of the case, lift the ring gear, and insert it with
its groove facing downward as shown in figures.
CAUTION
AVOID INJURY
Do not rotate the ring gear after it seats itself. FG005419
Figure 61
FG005420
Figure 62
FG005421
Figure 63

Page 26
FG005422
Figure 64
B. Put lock pins on the assigned 4 places, use jig and

hammer to insert them, and install bolts
symmetrically.
FG005423
Figure 65
FG005424
Figure 66
FG005424
Figure 67

Page 27
FG005426
Figure 68
C. Put the prepared carrier #2 assembly on the ring gear

and turn it slowly right and left to have it engaged with
gear. Assemble the spool line part of the carrier to the
shaft in the same way.
FG005427
Figure 69
FG005428
Figure 70

Page 28
D. Install the sun gear #2 in the way as shown in figures.
FG005429
Figure 71
FG005430
Figure 72
E. Assemble the carrier #1 assembly in the same way

as for the carrier #2.
FG005431
Figure 73
FG005432
Figure 74

Page 29
F. Assemble the sun gear #1.
FG005433
Figure 75
FG005434
Figure 76

Page 30
TEST
1. Pneumatic pressure test
A. After the reassembly of the carrier and the sun
assemblies, loosen bolts of the ring gear, place the
pneumatic test jig, and tighten 4 bolts again. Now,
make sure that pressure gauge is set to zero. 4
6
8
2
10
0
FG005054
Figure 77
B. Supply air through valve until pressure gauge

reaches 2 kg/cm2 and check if there is any change in
the pressure gauge for 3 minutes.
C. Remove jig after the pneumatic pressure test. 2
4
6
10
8
FG005055
Figure 78
2. Noise and abnormal sound test

A. After the pneumatic pressure test, fill the reduction
gear with 1 liter of gear oil and connect it to test
motor.
FG005435
Figure 79

Page 31
FG005436
Figure 80
B. Start motor in the advance and reverse directions

(1,875 ±90 rpm, no idle) and check for any noise or
abnormal sound carefully. (Standard noise is 90dB at
30cm away.)
FG005437
Figure 81
Figure 82

Page 32
C. At the end of the test, remove drain port plug to
completely remove contaminated gear oil and wipe
remaining oil on the case surface with a cloth.
FG005438
Figure 83
FG005439
Figure 84

Page 33
REASSEMBLY OF MOTOR
1. Reassembly of motor
A. Remove retaining bolts of ring gear, wipe the motor
assembly cleanly with cloth, and apply fluid gasket
(#1104).
FG005440
Figure 85
B. Use hoist to lift the motor, clean reassembled parts,

and install retaining ring (ø30, shaft ring, and C type)
in the shaft.
FG005441
Figure 86
FG005442
Figure 87

Page 34
C. Place the motor carefully on the reduction gear while
arranging its direction as shown in figures (with
caution not to have flange of the motor contact the
applied fluid gasket). Assemble it by slowly turning it
right and left so that spool line of the shaft engages
with the threads of the sun gear #1.
Align both
holes in a
straight line.
FG007734
Figure 88
Align these
parts in a
straight line.
FG007735
Figure 89

Page 35
D. Insert socket bolts with 10 Loctite (#262) applied
(M12 x 110 mm) in holes and use impact wrench to
tighten them (torque: 1,100 kg•cm). After tightening
bolts, use torque wrench to tighten to specified
torque.
FG005445
Figure 90
FG005447
Figure 91
FG005448
Figure 92

Page 36
FG005449
Figure 93
E. Seal the level gauge port of the motor with teflon tape
and use pipe wrench to tighten the level gauge pipe.
CAUTION
AVOID INJURY
Do not insert the level gauge before filling gear
oil.
FG005450
Figure 94

Page 37
FG005451
Figure 95
FG005452
Figure 96
2. Fill with gear oil and grease

A. Open oil nipple, fill with 2.4 liters of gear oil (EP80W/
90). Install PT1/2 plug again and insert the level
gauge to check oil level.
FG005453
Figure 97

Page 38
B. Fill grease through grease fitting until it is observed
through the opposite hole and install PT1/8 plugs in
both sides.
FG005454
Figure 98
FG005455
Figure 99

Page 39
C. Wipe grease and foreign substance with cloth and
check the motor reassembly position again.
FG005456
Figure 100

Page 40
1Lower Structure and
Chassis
SP002986
TRACK ASSEMBLY SP002986
Track
Assembly
Edition 1
Track Assembly SP002986

Page 1
MEMO

Page 2
Table of Contents
Track Assembly
Track Tension ....................................................... 8
Cleaning and Inspection (Wear Limits and
Tolerances)......................................................... 10
Track Shoe .................................................................... 12
Lower Roller .................................................................. 14
Upper Roller .................................................................. 15
Front Idler ...................................................................... 16
Track Shoes and Links ....................................... 17
Track Removal .............................................................. 17
Track Installation ........................................................... 18
Front Idler ........................................................... 19
Parts List ....................................................................... 19
Disassembly of Front Idler............................................. 20
Reassembly of Front Idler ............................................. 21
Lower Roller ....................................................... 23
Parts List ....................................................................... 23
Lower Roller Removal ................................................... 24
Lower Roller Disassembly............................................. 24
Lower Roller Reassembly ............................................. 25
Lower Roller Installation ................................................ 26
Upper Roller ....................................................... 28
Parts List ....................................................................... 28
Upper Roller Removal ................................................... 29
Upper Roller Disassembly............................................. 29
Upper Roller Reassembly ............................................. 31
Track Spring and Track Adjusting Cylinder ........ 32
Parts List ....................................................................... 32

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up

Page 5
Page 6
GENERAL DESCRIPTION
The track assembly is composed of the following major
components:
1. Track
2. Front Idler Roller
3. Upper Roller
4. Lower Roller
5. Track Spring and Track Adjustment Cylinder

Page 7
TRACK TENSION
WARNING
Measuring track tension requires two people. One person
must be in the operator's seat, operating the controls while
the other person makes dimensional checks. Block frame to
make sure the machine won't move or shift position during
service. Warm up the engine to prevent stalls, park the
excavator in an area that provides level, uniform ground
support and/or use support blocks when necessary.
The track adjusting mechanism is under very
high-pressure. NEVER release grease pressure too fast.
The track tension grease valve should never be loosened
more than one (1) complete turn from the fully tightened
down position. Bleed off grease pressure slowly. Keep your
body away from the valve always. Always wear eye and face
protection when adjusting track tension.
Track shoe link pins and bushings wear with normal usage,
reducing track tension. Periodic adjustment is necessary to
compensate for wear and it may also be required by working
conditions.
1. Track tension is checked by jacking up one side of the
excavator. See Figure 1. Place blocking under frame while
taking measurement.
Turn the track backward by 1 - 2 turns.
90 ~ 110
FG018383
Figure 1
2. Measuring the distance (A, Figure 2) between the bottom

of the side frame and the top of the lowest crawler shoe.
Recommended tension for operation over most types of
terrain is distance "B" in below table.
NOTE: Clean off the tracks before checking clearance
for accurate measurements.
A
3. Too little sag in the crawler track (less than clearance
distance "B" in below table) can cause excessive
component wear. The recommended adjustment can also
be too tight causing accelerated stress and wear if ground
FG000223
conditions are wet, marshy or muddy.
Figure 2

Page 8
4. The increased clearance recommended for muddy, sandy
or snowy ground conditions is between distance "C" in the
below table.
Recommended
Terrain Type
Distance "A"
240 - 260 mm
Normal "B"
(9.45 - 10.24 in)
260 - 290 mm
Muddy, Sandy or Snowy "C"
(10.24 - 11.42 in)
WARNING
The track adjusting mechanism is under very
high-pressure. NEVER release grease pressure too
fast. The track tension grease valve should never be
loosened more than one (1) complete turn from the
fully tightened down position. Bleed off grease
pressure slowly. Keep your body away from the valve
always. Always wear eye and face protection when
adjusting track tension.
5. Track tension adjustments are made through the grease

fitting (1, Figure 3) in the middle of each side frame. Adding 2
grease increases the length of an adjustment cylinder (2).
Extending the adjustment cylinder increases the pressure
on the tension spring pushing the track idler wheel
outward.
6. If there is not enough slack or clearance in the tracks and
the adjustment is too tight, the idler wheel and adjusting
cylinder can be retracted by bleeding off grease through 1
hole in adjustment cylinder (2, Figure 3). 3
FG018365
Figure 3

Page 9
(WEAR LIMITS AND
TOLERANCES)
CAUTION
AVOID INJURY
Refer to "Welding Precautions and Guidelines" information
in "General Maintenance Procedures" section for general
recommendations and specific safety precautions, before
starting any lower travel frame component rebuilding
procedure.
The tables that follow provide factory specified dimensional

limits (as new condition, recommended service and replacement
limit) for lower travel frame components.
Recommended maintenance to renew most listed components
requires welding on additional material and grinding off excess.
Some components must be replaced before the service limit is
exceeded. No maintenance or renewal is possible.
Compare the values in the tables with dimensions and profiles
shown in the adjacent figures.

Page 10
Page 11
Track Shoe
8 10
7
2
9 11
1
3
6
4 5 FG003910
Figure 4

Page 12
Limit for Use
Recommended Limit for
No. Check Item Standard Dimension (Repair - P or
Maintenance
Replace - R)
171.5 mm
1 Link Pitch
(6.752")
Bushing Outside 53.7 mm 50 mm 47 mm [R]
2
Diameter (2.114") (1.969") (1.850")
94.5 mm 89 mm 85 mm [P]
3 Link Height
(3.720") (3.504") (3.346")
18 mm
4 Length at Tip
(0.709")
11 mm
5 Length at Tip
(0.433")
25 mm 20 mm 18 mm
6 Height
(0.984") (0.787") (0.709")
Standard Tolerance Standard Repair
Interference between Dimension Shaft Hole Interference Limit
7
bushing and link 53.7 mm +0.055 -0.126
0.171 - 0.755
(2.114") +0.045 -0.7
8
regular pin and link 36.6 mm +0.05 -0.2
0.2 - 0.3
(1.441") +0 -0.25
Clearance between Dimension Clearance Limit
Shaft Hole
9 regular pin and
bushing 36.6 mm +0.05 +0.75
0.3 - 0.75
(1.441") +0 +0.35
Interference between Dimension Interference Limit
Shaft Hole
10 master pin and
bushing 36.4 mm -0.005 +0
0.0 - 0.045
(1.433") -0.035 -0.05
Clearance between Dimension Clearance Limit
Shaft Hole
11 master pin and
bushing 36.4 mm -0.005 +0.95
0.555 - 0.985
(1.433") -0.035 +0.55

Page 13
Lower Roller
Figure 5
Limit for Use

Maintenance
Replace - R)
Outside Diameter of 170 mm
1
Flange (6.693")
Outside Diameter of 140 mm 128 mm 125 mm [P]
2
Tread (5.512") (5.039") (4.921")
36.5 mm 42 mm 44 mm [P]
3 Width of Tread
(1.437") (1.654") (1.732")
22.5 mm
4 Width of Flange
(0.886")
Clearance between Dimension Shaft Hole Interference Limit
5
shaft and bushing 50 mm -0.05 +0.24 +0.32
(1.969") -0.08 +0.20 +0.25
6
roller and bushing 57 mm +0.103 +0.03 +0.048
(2.244") +0.078 -0.02 +0.123

Page 14
Upper Roller
4 3 4
1
2
FG009714
Figure 6
Limit for Use

Maintenance
Replace - R)
1
flange (5.512")
Outside Diameter of 120 mm 112 mm
2
Tread (4.724") (4.409")
69 mm
3 Width of Tread
(2.717")
25.5 mm 29 mm
4 Width of Tread
(1.004") (1.142")
5
shaft and bushing 45 mm -0.05 +0.25 +0.33
(1.772") -0.08 +0.2 +0.25
6
(2.087") +0.05 -0.02 +0.02

Page 15
Front Idler
Figure 7
Limit for Use

Maintenance
Replace - R)
1
flange (19.252")
Outside Diameter of 454 mm 443 mm 440 mm [P]
2
Tread (17.874") (17.441") (17.323")
68 mm
3 Width of Protrusion
(2.677")
135 mm
4 Total Width
(5.315")
33.5 mm 39 mm 41 mm
5 Width of Tread
(1.319") (1.535") (1.614")
6
shaft and bushing 75 mm 0 +0.40 +0.43
(2.953") -0.03 +0.35 +0.35
7
(3.346") +0.13 0.0 +0.095

Page 16
TRACK SHOES AND LINKS
Track Removal
1. Position machine on a smooth level surface with adequate
room for forward and reverse travel.
2. Relieve track tension. Refer to "Track Tension" in this 4
section for procedure.
3
3. Move machine until master link (1, Figure 8) is positioned 1
at approximately 10 o'clock from top position on front idle 2
roller.
4. Remove four nuts and bolts (2, Figure 8) holding shoe to
link. Remove enough shoes to make access to lock pin
easier. FG003982
Figure 8
NOTE: Support track shoes with blocking so that when
master pin (4, Figure 8) is removed track will not
fall.
5. Straighten lock pin (3, Figure 8) and remove it from master
pin (4). Discard lock pin.
6. Remove master pin from master links.
7. Move unit backward until entire track is laying on ground.
NOTE: Do not drive unit off track.
FG003911
Figure 9
8. Rotate upper structure to 90° from track. Use bucket and

boom to raise track frame off track.
9. Position blocking under frame.
90 ~ 110
FG000345
Figure 10

Page 17
Track Installation
1. Lay rebuilt or new track into position under track frame.
End of track must be positioned under drive sprocket.
2. With upper structure at 90° to track frame. Use bucket and 90 ~ 110
boom to raise track frame off blocking.
3. With blocking removed, lower track frame onto track. Make
sure all rollers are properly positioned on track.
FG000345
Figure 11
4. Move unit forward while feeding track up over drive

sprocket. Continue to pull track back until it engages front
idle roller.
FG003912
Figure 12
5. Align master links and install master pin.

6. Insert new lock pin in master pin. Bend end of pin over so it
is pointing in opposite direction of other end as shown. 4
7. Apply track tension. Refer to "Track Tension" in this 3
section for procedure. 1
2
FG003982
Figure 13

Page 18
FRONT IDLER
Parts List
Figure 14
Reference Reference
Number Number
1 Front 7 Pin
2 Bushing 8 Plug
3 Shaft 9 Track Spring Assembly
4 Bearing 10 Bolt
5 Floating Seal 11 Washer
6 O-ring

Page 19
Disassembly of Front Idler
1. Detach T/Spring assembly from Idler assembly.
Remove 4-M16 bolts and washers (10, 11, Figure 15).
2. Remove the plug (8, Figure 14) from the bearing (4, Figure
14) (using 6mm "L" wrench).
NOTE: About 330cc of oil will be discharged. Prepare
an oil cloth or pan to prevent spillage on the
ground.
Figure 15
3. Using a hammer and pin-removing tool, remove the pin(7,

Figure 16) on one side.
4. Remove the bearing (4, Figure 14) on the side from which
the pin (7, Figure 16) has been removed.
5. From the removed bearing (4, Figure 14) and front (1,
Figure 14), separate the floating seal (5, Figure 14).
6. From the shaft (3, Figure 14), separate the O-ring (6,
Figure 14).
NOTE: If the O-ring is not removed, the bearing sub-
assembly on the opposite side will be difficult to
Figure 16
separate
7. Separate the bearing sub-assembly on the opposite side of
the front (1, Figure 14).
8. Separate the floating seal (5, Figure 14) from the
separated bearing sub-assembly and front (1, Figure 14).
9. Separate the pin (7, Figure 14) from the separated bearing
sub-assembly.
10. Separate the shaft (3, Figure 14) from the bearing (4,
Figure 14).
11. Separate the O-ring (6, Figure 14) from the shaft (3, Figure
14).
Figure 17
12. Separate the bushing (2, Figure 18) from the front (1,
Figure 18).
NOTE: Insert jig 2, and press jig 1 to separate.
Use the hydraulic press for pressing the jig. Be
careful of sputtering.
13. Turn the front upside down. Separate the bushing (2,
Figure 18) in the same manner as described above (Figure
18).
Figure 18

Page 20
Reassembly of Front Idler
1. Take care that foreign matters do not enter the front part.
Wash all parts for assembly.
2. Using the hydraulic press, assemble two bushings (2,
Figure 19) at front (1, Figure 19).
Use the hydraulic press. Take care to prevent accidents.
NOTE: Apply a volatile lubricant on the bushing surface
before insertion.
There must be no dent marks on the flange.
Figure 19
3. Assemble two bearings (4, Figure 20) with the floating seal
(5, Figure 20).
In order not to twist the O-ring, use assembling jig to
assemble the floating seal, as shown in Figure 20. Check
that the floating seal is parallel. Clean up its lapped
surface.
Figure 20
4. On one side of the shaft (3, Figure 21), assemble the O-

ring (6, Figure 21) applied with thin oil (Figure 21).
5. Assemble the shaft (3, Figure 21) with the bearing to which
floating seal has been attached.
6. Insert pin (7, Figure 21)into the bearing on which the shaft
has been assembled.
Figure 21
7. Using the assembling jig, assemble floating seal (5, Figure

14) at the front on which bushing has been assembled.
8. Apply oil to the lapped surface of the floating seal (5,
Figure 14) which was assembled with the bearing.
NOTE: Use engine oil SAE #30/CD or higher grade.
9. Assemble bearing sub-assembly with the front to which the
bushing and floating seal have been assembled (Figure
22).
Figure 22

Page 21
10. Assemble shaft (3, Figure 14) with O-ring (6, Figure 14).
Apply oil to O-ring to prevent damage when assembling
bearing.
11. Apply oil to the lapped surface of the floating seal which
was assembled with the bearing.
12. Assemble the bearing (4, Figure 23) on which the floating
seal has been assembled.
13. Insert pin (7, Figure 23).
14. Rotate front or bearing by 3 rounds to left and right.
15. Assemble plug (8, Figure 23) to the bearing (4, Figure 23) Figure 23
on one side.
NOTE: Use 6mm L wrench to assemble plug, at torque
200 kg•cm
16. Inject oil through the plug hole.
NOTE: Oil quantity: 320 cc (10.8 oz) ± 20 cc
17. Assemble bearing (4, Figure 23) with plug (8, Figure 23).
NOTE: Use 6mm L wrench to assemble plug, at torque
of 200 kg•cm
18. Assemble Idler Assembly with Track Spring assembly
(Figure 24).
Assemble bolt and washer (10 and 11, Figure 24).
NOTE: Apply Loctite #243 to the bolt and washer (10
Figure 24
and 11, Figure 24).
Torque: 2,700 kg•cm

Page 22
LOWER ROLLER
Parts List
2 8
5 6
7
7
8
2 FG000483
Figure 25
Reference Reference
Number Number
1 Roller 5 Pin
2 Collar 6 Floating Seal
3 Shaft 7 O-ring
4 Bushing 8 Plug

Page 23
Lower Roller Removal
1. Relieve track tension. Refer to "Track Tension" in this
section for procedure.
2. Swing upper structure at 90° to frame. 90 ~ 110
3. Using bucket raise track off ground and place blocking
under frame.
4. Remove four bolts and lower roller assembly from track
frame. There is an alignment pin on each end of lower
roller assembly. FG000345
Figure 26
NOTE: To gain access to some rollers the link guard
may have to be removed. Remove four spring
washers and bolts to remove guard.
NOTE: If additional track clearance is required, remove
upper rollers before raising track.
Lower Roller Disassembly

5
1. Remove plug (8, Figure 27) from the collar and drain oil.
2. Pull the pin (5, Figure 27) from the collar.
FG001489
Figure 27
3. Separate the collar (2, Figure 28) from the axle, using
press.
2
FG001490
Figure 28

Page 24
4. Detach O-rings (7, Figure 29) from the axle.
1
5. Separate floating seals (6, Figure 29) from the collar and 6
roller (1).
2
6. Detach collar (2, Figure 29) and O-rings (7) from the axle,
using press.
2
7 6 FG001493
Figure 29
Lower Roller Reassembly

1. Degrease, clean and dry all parts before reassembly.
Insert bushing (4, Figure 30) into roller.
4
FG001491
Figure 30
2. Apply grease to the O-rings (7, Figure 30) and insert into
5
axle.
3. Align collar (2, Figure 31) and axle (3) pin holes and pin (5)
3 7 2
the collar.
FG001492
Figure 31
4. Insert floating seals (6, Figure 32) into the roller (1) and
1
collar (2).
6
NOTE: Apply clean engine oil to the joint side of the
2
floating seal. Apply grease to the floating seal
O-ring.
5. Slide the axle inside the roller.
2
7 6 FG001493
Figure 32

Page 25
6. Install the collar (2, Figure 33), O-ring (7), and pin (5) on
the remaining side. 5
7. Fill with clean engine oil with approximately 330 cc (11.2

oz).
8. Install plug (8, Figure 33) on the collar.
8
2 FG001487
Figure 33
Lower Roller Installation

1. Install four bolts to hold lower roller assembly to track
frame.
NOTE: To gain access to some rollers a link guard may 90 ~ 110
have to be removed. Remove four spring
washers and bolts to remove guard.
FG000345
Figure 34

Page 26
Page 27
UPPER ROLLER
Parts List
3
8
6
Track Frame
4
1
5
11
14
12
7
10
15
13
FG001141
Figure 35

Page 28
Reference Reference
Number Number
1 Roller 9 Plug
2 Shaft 10 Cover
3 Thrust Ring 11 Washer
4 Bushing 12 Bolt
5 Bushing 13 Blot
6 Floating Seal 14 Spring Washer
7 O-ring 15 Spring Washer
8 O-ring
Upper Roller Removal

1. Relieve track tension. This will allow track to be raised so
that links clear top of roller.
2. Position a bottle jack on top of track frame and apply
pressure to track shoe.
3. Remove mounting hardware holding upper roller assembly
to track frame.
FG000524
Figure 36
Upper Roller Disassembly

1. Remove the plug (9, Figure 37) from the cover and drain
oil.
9
FG001494
Figure 37

Page 29
2. Remove the bolts (13, Figure 38) and cover (10). Detach
bolts (12) and washer (11).
11
12
10
13
FG001495
Figure 38
3. Separate the roller (1, Figure 39) from the axle (2).
2
1
FG009907
Figure 39
4. Separate the floating seal (6, Figure 40) from the roller.
1
5. Separate the O-ring (8) and thrust ring (3) from the axle.
6
3
FG009908
Figure 40
6. Separate the bushing (4 and 5, Figure 41) from the roller

with a press and special tool (ST-1919).
ST-1919
FG009909
Figure 41

Page 30
Upper Roller Reassembly
1. Degrease, clean and dry all parts before reassembly.
Insert bushing (4 and 5, Figure 42) into the roller (1). 4
1
5
FG003917
Figure 42
2. Insert floating seal (6, Figure 43) into the roller (1) and
1
bushing.
NOTE: Apply clean engine oil to the joint side of the
floating seal. Apply grease to the floating seal 2
O-ring.
6
3. Install the axle (2), O-ring (8) and thrust ring (3). 8
3
FG003916
Figure 43
4. Install washer (11, Figure 44) and bolt (12).

5. Insert the O-ring (7, Figure 44) to the cover (10). Attach
11
cover (10) and bolt (13) to the roller.
12
7
6. Fill with engine oil with 60 cc.
10
7. Tighten plug (9, Figure 44). 13
9 FG001501
Figure 44

Page 31
TRACK SPRING AND TRACK
ADJUSTING CYLINDER
Parts List
9 11
8
7 3
10
1
12
13
14
2
FG003918
Figure 45
Reference Reference
Number Number
1 Cylinder 8 Lock Plate
2 Piston Rod 9 Bolt
3 Yoke 10 Spring Pin
4 Spacer 11 Spring Washer
5 Shaft 12 Packing
6 Spring 13 Backup Ring
7 Lock Nut 14 Dust Seal

Page 32
1Engine and Drive Train
SP001326
DRIVE COUPLING (MAIN PUMP)SP001326
Drive Coupling
(Main Pump)
Edition 2
Drive Coupling (Main Pump) SP001326

Page 1
MEMO

Page 2
Table of Contents
Drive Coupling (Main Pump)

Drive Coupling ...................................................... 6
Special Tools ........................................................ 7
Installation of Drive Coupling ................................ 8
Installation Procedure...................................................... 9

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up

Page 5
DRIVE COUPLING
It is very important to set specified clearance between the end of
the pump drive shaft (the "Dimension H" described below) and
the coupling hub surface when installing the main pump in the
engine.
The Figure 1 shows installation of a typical drive coupling.
Figure 1

Page 6
SPECIAL TOOLS
This tool is used to adjust the clearance, referred to as "Measure
H" in the installation instructions below, between the pump drive
shaft and the front side of the drive coupling hub (4, Figure 2).
NOTE: Dimensions A and B are the same as Measure H in
Figure 3. Two tools in the figure below are designed
for various models, while only their one end may be
used in some special models.
HAAA8020
Figure 2
A C
B
E G
F
H
Relief
Relief
KNURL
HAAA8360
Figure 3
Model A B C D E F G H
DX138LC/ 10.5 ± 5.0 ± Radius, Radius, Radius, 1.0 mm
20.0mm 7.0 mm
DX140LC 0.1mm 0.1mm 12.0 mm 14.0 mm 25.0 mm X 45°

Page 7
INSTALLATION OF DRIVE
COUPLING
Follow the installation dimensions and procedures whenever
installing the drive coupling in the main pump.
NOTE: Failure to follow the procedures results in noise and
the shortage of the service life of the drive coupling or
the main pump.
2 3
1
7
10
11 6
8
FG009655
Figure 4 Installation of Drive Coupling

Page 8
Parts and Torques
References Parts Q'ty Torque
1 Spring Pin 4
2 Insert 4
3 Bolt 4 Ta
4 Fly Wheel 1
5 Spring Pin 8
6 Insert 4
7 Hub 1
8 Bolt 4 Ta
9 Pump Shaft 1
10 Fixing Nut 2 Tb
11 Element 1
Ensure to follow the specification of Measure H from the front

hub surface to the pump shaft and tightening torques of bolts
and screws.
Coupling Part
Model Measure H Torque of Ta Torque of Tb
Reference
DX138LC/
2414-9009A 3.0 - 7.0 mm 21 - 23 kg•m 10 - 12 kg•m
DX140LC
Installation Procedure
NOTE: Refer to Figure 5 for the installation procedure.

Page 9
1. Install spring pin (1) and then insert (2) with bolt (3) into
engine fly wheel (4).
NOTE: Tighten the bolt using the torque Ta value 4
specified in the table.
2. Install two spring pins (5) and then insert (6) in bolt (8) of
hub (7). 2 3
NOTE: Tighten the bolt using the torque Ta value
1
10 7
3. Install the fly wheel cover in the main pump with bolts.
4. Connect hum (7) with pump shaft (9) as referred to as 9
5
Measure H in Table 1 and fix its position with screws (10).
NOTE: Tighten the screws using the torque Tb value
NOTE: Apply Loctite #262 to fixing screws (10). H
5. Install element (11) in between the engine fly wheel (4) and
the insert. 11 6
8
6. Install the main pump and hub (7) by gently pushing them
with element (11).
7. Bolt down the fly wheel cover and the pump housing on
FG009655-1
the fly wheel housing.
Figure 5
CAUTION
AVOID INJURY
Apply the adhesive to bolts (3 and 8) to prevent the
loosening of seals. Do not use additional adhesive nor any
oil or cleaning solvent. As element (11) cannot resist
adhesive, oil, and grease, take care not have it exposed to
such materials.
Remove oil and dust on the fly wheel cover and the pump
shaft before assembly.
Adjust the arrangement allowance between the pump and
the engine at below 0.6 mm (0.023 in).

Page 10
1Hydraulics
SP002214
HYDRAULIC SYSTEM TROUBLESHOOTING,
TESTING AND ADJUSTMENTSP002214
Hydraulic System
Troubleshooting,
Testing and
Adjustment
Edition 2
Hydraulic System Troubleshooting, Testing and Adjustment SP002214

Page 1
MEMO

Page 2
Table of Contents
Hydraulic System Troubleshooting,

Testing and Adjustment
Hydraulic System - General Notes ....................... 6
Hydraulic Schematic ............................................. 7
General Notes ................................................................. 7
Operation of Working Components ...................... 9
Boom Operating Circuit ................................................... 9
Boom Up Circuit .............................................................. 9
Boom Down Circuit.......................................................... 9
Arm Operating Circuit.................................................... 10
Arm Crowd Circuit ......................................................... 10
Arm Dump Circuit .......................................................... 10
Bucket Operating Circuit ............................................... 11
Bucket Crowd Circuit..................................................... 11
Bucket Dump Circuit...................................................... 11
Swing Operating Circuit................................................. 11
Right Swing Operating Circuit ....................................... 12
Left Swing Operating Circuit.......................................... 12
Swing Relief Valve and Makeup Valve.......................... 12
Travel Operating Circuit ................................................ 12
Forward Travel Circuit ................................................... 13
Reverse Travel Circuit................................................... 13
Procedural Troubleshooting Baseline
Recommendations.............................................. 14
Initial Checks and Tests to Establish Operating Condition
of the Excavator ............................................................ 14
Pilot Pressure ..................................................... 16
Adjustment and Testing................................................. 16
Power Mode Valve ............................................. 17
Current Signal and Hydraulic Pressure Adjustments .... 17
Pressure Up Valve.............................................. 18

Page 3
Checks and Adjustments............................................... 18
Pump Input Power Control ................................. 20
Pump Regulator Adjustment ......................................... 20
Flow Meter and Flow Meter Kit Installation and
Testing ................................................................ 24
Swing System Troubleshooting .......................... 26
Precautions/Initial Checks ............................................. 26
Swing Relief Valve Checking and Adjustment .............. 27
Troubleshooting – Swing Gearbox ..................... 29
Troubleshooting – Hydraulic Problems............... 30
Troubleshooting – Control Valve ........................ 32
Troubleshooting – Travel Control Valve ............. 33
Troubleshooting – Joystick Control Valve........... 34

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up

Page 5
HYDRAULIC SYSTEM -
GENERAL NOTES
CENTER JOINT
TRAVEL MOTOR
TRAVEL MOTOR
FG009803
Figure 1
The hydraulic system has several improvements over

conventional hydraulic systems - including cross-sensing total
horsepower control - to maximize output efficiency.
The system features an electronically controlled output
optimization system, which allows the operator to choose
between two, distinctly different power modes: high-output/rapid
cycling maximum speed power mode, and a standard power
mode for most types of general operation.
Electronic management of hydraulic control valves assists in
optimizing the application speed and overall operator control of
hydraulic actuators and functions.

Page 6
HYDRAULIC SCHEMATIC
The hydraulic schematic(s) is available in the "Hydraulic and
Electrical Schematic Shop Manual". This manual is a collection
of diagrams and schematics for a number of models.
General Notes
When referring to the schematic, refer to the following items:
• As shown in the schematic, the main pump assembly is
driven by the engine. Mechanical energy is converted to
hydraulic power, generating the required hydraulic flow
which drives the system. Two main pumps (a right side
pump and a left side pump) make up the main pump
assembly.
• Hydraulic output from the right side pump is transmitted to
the right side of the control valve. Output from the left side
pump is transmitted to the valve spools on the left side of
the control valve. Hydraulic output from the pilot pump is
used to control the pump and to operate pilot and solenoid
valves.
• The right half of the hydraulic control valve, supplied by the
right pump in the pump assembly, operates valve spools
for right travel, swing, boom up and arm functions. The
amount of oil flow to the actuators at the output end of each
of those circuits is regulated through the movement of
each individual valve spool.
• The left half of the hydraulic control valve, fed by the left
pump in the pump assembly, has control spools for left
travel, bucket, boom and arm operation.
• Two-stage operation is a feature of boom and arm
function. All of these circuits can be operated using the
output of only one half of the hydraulic pump assembly
(one pump or the other), or – since both halves of the
control valve have a spool and available circuit for these
functions – the output of both pumps can be combined,
allowing higher speed operation. Boom up, arm crowd and
dumping functions can operate in any one of the two
available power modes – the standard or general duty
mode, the high speed/rapid cycling mode.
• Whenever the right travel or left travel control spools are
shifted, output from the main pump assembly flows through
the center joint to one or both of the axial piston motors
driving the side frame crawler tracks. A pilot valve
connected to the swash plate of each travel motor changes
motor capacity (and output) in direct proportion to the
position of the travel switch selected by the operator.
• The hydraulic reservoir return line and the pilot circuit both
have 10 micron full flow filters. The disposable elements in
these two canister type filters trap and remove impurities
from the oil in the system. An 80 mesh, 177 micron

Page 7
reservoir intake strainer also helps maintain system
cleanliness and must be cleaned each time hydraulic fluid
is drained and replaced. An oil cooler in the hydraulic
system helps maintain the operating temperature of the
system at approximately 50°C (122°F).
• The arm cylinder operating circuit includes anticavitation
valves which protect the hydraulic system from vacuum
that could result from external shocks or other unusual
conditions. Boom, Arm, and Bucket cylinder circuit are also
protected by overload relief valves. Whenever high-
pressure is generated as a result of a shock or overload,
excess pressure is dumped to the reservoir return circuit
through the relief valve.
A selection valve in the travel circuit can be used to provide
constant high torque/low speed travel, or variable speed/
variable torque output for travel. To prevent sliding during
simultaneous travel and boom/arm/bucket operation, select the
high torque/low speed travel position.

Page 8
OPERATION OF WORKING
COMPONENTS
Boom Operating Circuit

The boom operating circuit includes the right and left main
hydraulic pumps (both halves of the main pump assembly), both
sides of the control valve and the boom cylinder. The circuit
operates in boom down mode through the first shift position and
through the second shift position in boom up mode. Overload
relief valves set at 360 kg/cm2 (5,112 psi) protect the hydraulic
system from being damaged as a result of overloads or shocks
to the boom.
Boom Up Circuit
When you pull the boom control lever backward, the right side
pilot valve generates secondary boom up pilot pressure that is BOOM
CYLINDER
transmitted to the BOOM1 and BOOM2 spools of the control
valve simultaneously. When secondary pilot pressure reaches 7
- 9 kg/cm2 (100 - 130 psi), boom control valve spools open and BMD BM1 PILOT VALVE BM2
oil from both pumps goes to the boom cylinder. TL PL PR
CONTROL CONTROL
VALVE(L) VALVE(R)
PUMP(L) PUMP(R)
ARS1560L
Figure 2
Boom Down Circuit

When the boom control lever is pushed forward, the right side
pilot valve generates secondary boom down pilot pressure that
is transmitted only to the BOOM1 spool of the control valve. BOOM
CYLINDER
When secondary pilot pressure reaches 7 - 9 kg/cm2 (100 -
130 psi), the BOOM1 spool on the left side of the control valve
opens so that oil from only one pump (PUMP (L)) assembly PILOT VALVE BM1 BMD
goes to the boom cylinder for boom lowering. PL TL

CONTROL
VALVE(L)
PUMP(L)
ARS1570L
Figure 3

Page 9
Arm Operating Circuit
The arm operating circuit includes both the right and left
hydraulic main pumps, the right and left halves of the control
valve, a slow return orifice, and the arm cylinder. The circuit can
be operated in the two-stage speed control mode which works
through both halves of the control valve and doubles the volume
of oil flowing to the cylinder.
Overload relief valves set at 360 kg/cm2 (5,112 psi) have been
installed at the AM 1 and AMD 1 ports on the right side of the
control valve to protect the circuit and system components from
possible damage caused by shocks and/or overload pressure.
Additional protection - to prevent cavitation of the cylinder - is
provided by a makeup valve and reservoir return circuit, which
ensures that the volume of oil going to the cylinder will not
exceed the volume of oil coming out.
Arm Crowd Circuit

When the arm control lever is put in the crowd mode, the left
ARM
side pilot valve generates secondary pressure that is transmitted CYLINDER
to the AM1 and AM2 spools of the control valve simultaneously. REGENERATION VALVE
When secondary pilot pressure reaches 7 - 9 kg/cm (100 - 130

2
AM2 PILOT VALVE AMD1 AM1
psi), the arm control valve spools AM1 and AM2 open. Output
flow from both halves of the pump assembly is directed to the PL TL PR
arm cylinder.
When working in the arm crowd mode, under certain conditions, CONTROL CONTROL
VALVE(L) VALVE(R)
oil in the arm cylinder could suddenly be forced out by the weight
of the arm and bucket. Insufficient oil flow to the cylinder could PUMP(L) PUMP(R)
lead to cavitation in the cylinder and/or surging or irregular
ARS1580L
movement. This is prevented by a regeneration valve attached
to the control valve which maintains the balance between oil Figure 4
flowing into the cylinder and oil flowing out.
Arm Dump Circuit

When the arm control lever is put in "dump" mode, the left side
pilot valve generates secondary pilot pressure that goes to both ARM
CYLINDER
spools AM1 and AM2 of the control valve simultaneously.
When pilot pressure reaches 7 - 9 kg/cm2 (100 - 130 psi), the
control spools open, allowing oil from PUMP (L) and PUMP (R) AM2 AMD2 PILOT VALVE AMD1 AM1
to flow to the arm cylinder. PL TL PR
CONTROL CONTROL
VALVE(L) VALVE(R)
PUMP(L) PUMP(R)
ARS1590L
Figure 5

Page 10
Bucket Operating Circuit
The bucket operating circuit includes the left main pump, the left
half of the control valve and the bucket cylinder. 360 kg/cm2
(5,112 psi) overload relief valves at BKT and BKTD 1 ports of
the control valve protect the circuit and its components from
being damaged.
Bucket Crowd Circuit

When the bucket control lever is placed in the crowd position, BUCKET
CYLINDER
the bucket control valve spool on the left side of the control valve
opens and oil from left main pump flows to the bucket cylinder.
BKTD BKT PILOT VALVE
TL PL
CONTROL
VALVE(L)
PUMP(L)
ARS1600L
Figure 6
Bucket Dump Circuit

When the bucket control lever is put in the dump mode, the BUCKET
CYLINDER
bucket control valve spool in the left half of the control valve
opens to supply oil from the left main pump to the cylinder.
BKTD BKT PILOT VALVE
TL PL
CONTROL
VALVE(L)
PUMP(L)
ARS1770L
Figure 7
Swing Operating Circuit

The swing operating circuit consists of the right main pump in
the pump assembly, the right half of the control valve and the
swing motor. To keep the upper works from coasting when the
swing control is in neutral, an electrical sensor in the control
circuit activates a valve to automatically engage a mechanical
brake.

Page 11
Right Swing Operating Circuit
When the swing control lever is pushed to the right swing
position, pilot pressure from the left side pilot valve is directed to
the right side pump regulator and right half of the control valve. CONTROL
VALVE(L)
Output flow from the right pump is then directed through the PR
and SWR ports of the control valve to the swing motor. SWD SW PILOT VALVE
TL PR
CONTROL
VALVE(R)
PUMP(R) ARS1620L
Figure 8
Left Swing Operating Circuit

When the swing control lever is pushed to the left swing position,
the control valve spool at the right side of the control valve CONTROL
moves in the opposite direction and output flow from the right VALVE(L)
pump is directed through the PR and SWL ports of the control SWD SW PILOT VALVE
valve to the swing motor.
TL PR
CONTROL
VALVE(R)
PUMP(R)
ARS1610L
Figure 9
Swing Relief Valve and Makeup Valve

Whenever the spool is shifted to the neutral mode during swing
operation, the possibility exists that surge pressure in the circuit
- caused by inertial momentum of the upper works and
correspondingly reduced pressure at the opposite motor port -
could produce cavitation in the circuit. To keep that from
happening, a 245 kg/cm2 (3,485 psi) relief valve is installed in
the swing motor and a large capacity makeup valve is connected
to the entrance port of the hydraulic reservoir, helping maintain
acceptable pressures on both sides of the circuit.
Travel Operating Circuit

Output flow from both halves of the pump assembly is directed
to the right and left travel motors through the right and left sides
of the control valve, and the upper works center joint.

Page 12
Forward Travel Circuit
When the right and left travel control levers are pushed forward, TRAVEL
MOTOR(L)
TRAVEL
MOTOR(R)
output from both of the main pumps is directed through the PR,
PL, TRRF, and TRLF ports on the control valve, through the CENTER JOINT
upper works center joint, to the travel motors on each side of the
machine.
TRL TRLD PILOT VALVE TRRD TRR
PL TL PR
CONTROL CONTROL
VALVE(L) VALVE(R)
PUMP(L) PUMP(R)
ARS1630L
Figure 10
Reverse Travel Circuit

When the right and left travel control levers are pushed TRAVEL
MOTOR(L)
TRAVEL
MOTOR(R)
backward, output from both main pumps is directed through the
PR, PL, TRRR, and TRLR ports on the control valve, through CENTER JOINT
the upper works center joint, to the travel motors.
TRL TRLD PILOT VALVE TRRD TRR
PL TL PR
CONTROL CONTROL
VALVE(L) VALVE(R)
PUMP(L) PUMP(R)
ARS1640L
Figure 11

Page 13
PROCEDURAL
TROUBLESHOOTING BASELINE
RECOMMENDATIONS
Initial Checks and Tests to Establish

Operating Condition of the Excavator
Triage Summary
An excavator that fails to deliver designed performance must be
checked for the following:
• Hydraulic flow, first, and.
• Hydraulic pressure, afterwards, in a specified order of
priority through different points of the system.
To verify adequate available hydraulic flow, before any other
tests are performed through the circuit:
Check engine operation -
• at 1,950 rpm with no load.
• at 1,950 rpm stall load.
If engine rpm drops excessively with a load or fails to surpass
rated speed (1,850 rpm), performance problems may be
because of inadequate hydraulic flow caused by lagging
rotational speed.
NOTE: Verify actual flow on the excavator against rated
performance, with a flow meter.
If engine tests meet specifications and adequate torque and
horsepower are available at the pump drive flex coupling, pull
out the electrical tray under the operator's seat to inspect the
self-diagnostic display.
If the EPOS trouble code display is clear, check hydraulic
functions in the following sequence:
• Pilot pressure.
• Negacon, negative control pressure.
• Main relief pressure (front and rear pump)
• Swing pressure.
• Port relief pressure (individual control functions; boom,
arm, bucket, swing, and travel)
• Power boost circuit.
• Standard performance tests; cylinder speed, hydraulic
motor (travel and swing) speed, cylinder oil tightness
"permissible drift" test.

Page 14
NOTE: System specification performance tests of
individual activator function are
determined by flow rate through the
component or circuit, not the control
pressure or system pressure available to
the actuator. Poor flow through the
individual circuit may indicate that the
component is worn beyond tolerance
limits, while all other hydraulic functions
are adequate.
IMPORTANT
It is suggested that the troubleshooter maintain the testing
sequence of the preceding list. Checks and adjustments
nearer the middle or the end of the list may depend on
adequate functioning of systems tested nearer the top of
the list.

Page 15
PILOT PRESSURE
Adjustment and Testing
WARNING
This procedure must be done with two people. To reduce
the chance of accident or unintended start-up, one person
should remain at the operator's control stand while checks
and adjustments are made.
Vent hydraulic pressure from the reservoir before breaking the

seal on fittings to install two in-line "T-style" adapters and test
gauges (60 bar/1,000 psi) at the gear pump outlet port, and at
the joystick control valve pilot line.
Start the engine and turn the engine speed control dial to the
maximum setting. After the excavator has been operated long
enough to reach normal operating temperature, back off the
engine control dial to minimum rated rpm speed. With all
controls in neutral, make sure the left console control stand is
locked in the down (operating) position and check pressure at
the gear pump outlet port and at the joystick.
If gear pump pressure is outside the tolerance specified in the
table, adjust gear pump relief pressure by loosening the lock nut
and turning the set screw in (clockwise) to increase pressure, or
turning it out to decrease it.
NOTE: Be aware that serial number changes and variation in
the joystick assemblies used on different excavators
could produce slight change in actual performance
characteristics. Comparison of part numbers to serial
numbers stamped on your assembly may be
required, if questions or doubt exists.
IMPORTANT
Top off the hydraulic fluid reservoir if there is any
measurable loss of hydraulic oil during test gauge and
adapter fitting installation.
Engine RPM Pilot Pressure @ Pump Pilot Pressure - Joystick

Minimum Speed Setting (full left) 40 ±5 bar 40 ±5 bar
on Speed Control Dial (580 ±73 psi) (580 ±73 psi)

Page 16
POWER MODE VALVE
Current Signal and Hydraulic Pressure

Adjustments
WARNING
The electromagnetic pressure proportioning control (EPPR)

"power mode" valve is on the underside of the pumps (not visible
in the harness connections drawing, because it is underneath
the assembly), near the engine/pump flexible coupling, adjacent
to the pump return line. To test and adjust power shift current
and pressure through the power mode valve a multilead jumper
harness is required. The jumper harness (which is available
through DOOSAN After Sales Service, or could be spliced
together from commonly available, purchased parts) has extra
leads so that a VOM meter can be connected to the circuit.
To set up the testing equipment, stop engine and disconnect the
single electrical lead from the power mode valve. Attach the
jumper harness to the terminal on the valve, connect the test
leads of the multimeter to the extra leads on the harness and
reconnect the valve electrical lead.
Vent the lever on top of the hydraulic tank to relieve pressure
and connect an in-line "T-style" adapter to the valve pressure
port. Install a 60 bar (1,000 psi) test gauge in the adapter.
Restart the engine and increase engine rpm by turning the
speed control to the maximum speed setting. Warm up the
engine and hydraulic system until hydraulic oil temperature is at
least 45°C (113°F). Select Power Mode on the Instrument
Panel. Check current readings (in milliamps) on the VOM meter
and hydraulic pressure gauge readings and make sure both
conform to the values in the table below.
NOTE: If recorded values do not conform to the specified
current or pressure in the table, back off the lock nut
on the end of the valve, turn the adjusting screw 1/4
turn and recheck current and pressure. Repeat
adjustment as required to obtain specified
performance and retighten the valve lock nut.
Mode Engine RPM Current Pressure

150 ±20 mA
Power Mode High Idle: 1,950 rpm Mid-range value corresponding to engine rpm for 0 bar (0 psi)
both current and hydraulic pressure readings.
Standard Mode High Idle: 1,850 rpm 250 mA 9 bar (130.5 psi)

Page 17
PRESSURE UP VALVE
Checks and Adjustments
WARNING
Vent hydraulic pressure from the reservoir to install an in-line "T-

style" adapter and test gauge (60 bar/1,000 psi) at the pilot
pump signal port relief valve outlet.
Start the engine and turn the engine speed dial to maximum.
When normal operating temperature is reached:
• Check pilot pressure and readjust it, if required:
• Select the Instrument Panel rear pump "pressure display".
• Select Power Mode.
• Stall the boom cylinder (towards the extend side).
• Read rear pump pressure on the Instrument Panel display.
Repeat all tests with and without "pressure up" selected through
the console rocker switch and joystick button.
If the two-stage main relief valve was not set correctly and main
relief high-stage pressure ("pressure up") is outside the
tolerance range, begin valve adjustment by loosening the
outside (widest diameter) lock nut on the relief valve. Turn the
adjusting screw clockwise to increase pressure, or
counterclockwise to decrease it. Pressure must be 350 bars
(5075 psi), or up to 10 bars (145 psi) higher.
Because one adjustment can affect the other, check low-stage
main relief pressure by repeating the cylinder stall test without
"pressure up". Readjust standard relief pressure by turning the
innermost (smallest diameter) screw clockwise to increase the
setting, or counterclockwise to decrease it. Pressure must be at
least 330 bars (4,785 psi), but less than 335 bars (4,858 psi).
IMPORTANT
Pressure adjustments and checks cannot be made if pilot
pressure is outside the specified range. Refer to the pilot
pump adjustment procedure if required, then proceed with
any necessary adjustments to main relief pressure settings.

Page 18
Main Pressure and Pilot Pressure and
Power Mode Operation
Tolerance Tolerance
20 - 40 bar 30 bar +10 bar
Power Mode Neutral, No Operation
(290 - 580 psi) (435 psi +145 psi)
330 bar +5 bar 30 bar +10 bar
Power Mode Cylinder Stall
(4,785 psi +75 psi) (435 psi +145 psi)
Power Mode W/ 350 bar +10 bar 30 bar +10 bar
Cylinder Stall
Pressure Up 5,075 psi +145 psi (435 psi +145 psi)
NOTE: The electrical pressure up (power boost) solenoid

valve alongside the swing priority solenoid and arm
speed control solenoid, in compartment rear of the
operator's cabin, must be operating correctly, or
pressure tests and further adjustments cannot be
made.

Page 19
PUMP INPUT POWER CONTROL
Pump Regulator Adjustment
WARNING
To perform these adjustments accurately the use of a flow meter

is strongly recommended, as is consulting the factory (before
starting work) to validate the need for making regulator
adjustments. Vent hydraulic pressure from the reservoir before
breaking the seal on fittings to install the flow meter kit. (Refer to
"Flow meter Installation and Testing" procedure.)
IMPORTANT
Before starting this procedure or going onto make any
changes of adjustment settings:
• Verify engine output to the rated speed – 1,950 ±50
rpm.
• Permanently mark setscrew positions at the current
regulator control setting.
Use a scribe or other permanent marker to identify a reference

point on adjusting screws with a corresponding reference on the
body of the valve. The adjustment process affects a complex
balance and could require some time to complete. If adjustment
has to be interrupted or postponed, reference marks at the
adjustment point allow immediate restoration of original
performance.
This adjustment procedure is normally performed:
• If the engine is being consistently overloaded (and engine
troubleshooting shows engine performance to be at or
above rated output).
• If reduced cylinder speed and diminished work
performance provide an indication that rated, maximum
pump flow may not be available (and all other
troubleshooting gives no indication of other flaws or
hydraulic system defects).
• If pump output is out of balance and one pump is failing to
keep up with the output flow of the other.

Page 20
To check pump imbalance without a flow meter, travel the
excavator forward on flat, level terrain. If the machine veers off
despite neutral control input and even, balanced track
adjustment, the pump which supplies output to the track frame
toward which the excavator is veering is weak.
D
B
F
A
G
E
C
D
1
E 2
F
A G
B
C
FG000654
Figure 12
Refer to the illustration of the pump regulator control valve

(Figure 12) for the location of adjustment screws (1, 2 and 3).
There are two different adjustments, along with the Negacon,
negative control, adjustment screw (3, directly below 1 and 2).
Each one of the adjustment procedures could affect the setting
of the others.

Page 21
Check and record the arm dump speed performance test before
and after input power adjustment, whether or not a flow meter is
used.
NOTE: Regulator adjustments affect total cumulative
horsepower, since each regulator compensates for
the output of the other. It is not necessary to adjust
both regulators at the same time, but after checking
or adjusting one of them, the remaining unit should
also be checked.
Start the engine and turn the engine speed dial to maximum.
When normal operating temperature is reached, loosen the
largest diameter lock nut around the adjustment screw (2) for the
outer regulator spring. Tightening the screw shifts the P/Q
(Pressure/Flow) control curve to the right, and increases
compensating control pressure.
On the other hand, if the persistent cause of performance
problems is engine overloading, decreasing the adjustment by
turning the larger diameter adjusting screw (2) out will decrease
pump input horsepower. 1/4 turn on the adjusting screw is equal
to approximately 17 horsepower.
Figure 13
IMPORTANT
Because changing the position of adjusting screw (2) also
affects the setting of the adjustment for the inner spring,
the smaller diameter adjusting screw (1), turn in the inner
screw 198° (slightly more than 1/2 turn, 180°) before screw
(2) is backed out 1/4 turn (90°).
NOTE: For each full turn of adjustment on the larger

diameter screw (2), the square-tipped adjusting
screw must be turned in the opposite direction 2.2
turns to avoid changing inner spring adjustment.
Pump input power adjustments are normally made in small
increments, 1/4 turn (90°) or less, each time.
Turning the square-tipped, smaller diameter screw (1) clockwise
moves the flow curve up, increasing flow and then input
horsepower.
Figure 14

Page 22
The adjusting screw (1, Figure 12) affects the delivery rate (Q) of
the pump. Tightening the adjusting screw decreases the
maximum cut flow (as shown in Figure 15) while backing out the
screw increases cut flow delivery rate.
Balance both pumps for equal output.
Q
P
HDA3008L
Figure 15

Page 23
FLOW METER AND FLOW
METER KIT INSTALLATION AND
TESTING
Checking regulator and pump output, to assess the output
balance between the front and rear pumps and to verify
operating adjustment of each regulator, will require installation of
a flow meter.
The After Sales Service department of the nearest local
DOOSAN dealer can assist you with these tests or, if you prefer
carrying out your own testing, they must be able to help in
putting together a hose and fitting kit (or the required dimensions
and specifications for hoses and fittings) to allow you to install a
flow meter downstream from the main pump assembly.
Installation and Testing Procedure

• Stop engine and operate controls to release hydraulic
pressure from the accumulator.
• Vent the reservoir to release all pressure from the
hydraulic system.
• Remove guard panels from around the main pump
assembly.
• Disconnect the main pump discharge output line. Install the
input flange of the flow meter on the pump end of the
output line.
• Cap off the unused (input) end of the pump discharge line
with a blocking flange.
• Connect a premeasured length of hydraulic hose, between
the output end of the flow meter assembly and the top of
the reservoir. Use appropriate fittings and adapter flanges
to guarantee a pressure tight seal.
NOTE: Be sure to maintain even tightening torque on
all flange fittings. Use Loctite brand "PST 545"
(or an alternate manufacturer's hydraulic
system joint seal) if required, to give an airtight
seal.
• An assistant – who must remain at the operator's control
station at all times – should restart the engine and run it
long enough (at minimum rpm) to de-aerate the system
and warm up the engine and hydraulic system to operating
temperature.
Record the values of all test results in three columns, comparing
1) pump pressure (from the instrument panel display) with 2)
measured flow, in gallons or liters per minute, from the installed
flow meter.

Page 24
The third column of test results should provide a record of
engine rpm measured during each of the following tests – with
the engine speed control dial set at maximum, the power mode
selector at Power Mode and the work mode selector at digging
mode:
• Unloaded maximum engine speed baseline test (all
controls in neutral).
• Front pump test – operate "travel right" lever. Record
values at all specified pressures.
• Rear pump test – operate "travel left" lever. Record values
at all specified pressures.
Record the values for each of the three tests (neutral, travel right
and travel left) at the following pump pressure levels, with travel
speed control set at "high speed".
Engine RPM Pressure Flow

100 kg/cm2 (1,422 psi)
135 kg/cm (1,930 psi)
2
180 kg/cm2 (2,560 psi)

240 kg/cm2 (3,413 psi)
320 kg/cm2 (4,550 psi)*
*See below note.
Compare recorded values with output shown in the P-Q curve in

the specifications section of this book.
If test results do not measure up to specified values, pump
output tests can be repeated using different control levers.
Recheck front pump operation while stroking the bucket cylinder
out lever, and the rear pump by actuating the swing control
lever.
NOTE: When testing bucket and swing functions, read
maximum flow tests at 330 kg/cm2 (4,785 psi), not
350 kg/cm2 (5075 psi).

Page 25
SWING SYSTEM
TROUBLESHOOTING
Precautions/Initial Checks
1. Stop work. Release all weight or any type of load safely
before proceeding. Avoid risking injury or adding to
damage.
2. Stop engine and disengage control functions until initial
tests are ready to be made.
WARNING
Prevent possible injury and/or loss of operating
control. Stop work and park the excavator at the first
indication of:
1. Equipment breakdown.
2. Inadequate control response.
3. Erratic performance.
Stop the machine, put the boom and arm in the inoperative
(overnight park) position and begin by making the fastest,
simplest checks first:
• Check oil level.
• Check for overheating, oil leaks, external oil cooler
clogging or broken fan belt. Consult service record for prior
repair/service work.
• Drain some tank oil into a clean, clear container. Look for
metal shavings/grit, cloudiness/water or foam/air bubbles
in the oil.
NOTE: Dispose of drained fluids according to local
regulations.
• Check for wobble through the engine/pump flex coupling.
Run engine with the pump input hydraulic power control
nut turned to the lowest power to check the engine.
• Investigate unusual operating noises or vibration. Check
for loose bolts, connections.

Page 26
Swing Relief Valve Checking and
Adjustment
Make a check of operating pressures through the swing relief
valve if:
• The swing motor fails to turn.
• Swings in one direction only.
• Swings but continues to coast.
• There is drifting on a slope.
1. Check operation by connecting:
A. Two 600 bar (8,700 psi) pressure gauges to the inlet
and outlet measuring ports on top of the swing motor.
Pressure must be between 270 and 280 bar (3,916
psi and 4,060 psi), with both swing locks engaged.
With swing locks released, during full acceleration
and deceleration, pressure should approach 250 bar
(3,625 psi) in each direction.
B. Connect a 60 bar (870 psi) pressure gauge at the
"SH" port of the hydraulic brake.
Pressure should always stay at or above 13 bar (190
psi) when operating swing, boom or arm.
C. Connect a 10 bar (145 psi) gauge at the motor
makeup valve.
Pressure should stay consistently above 2.5 bar (36
psi). If pressure falls below the recommended
minimum level, forceful acceleration of the swing
motor could lead to cavitation of the circuit and
stalling, slowed rotation, noise and possible damage.
2. If main inlet and outlet pressures were off in the preceding
tests in Step 1, adjust swing relief valve pressure.
Following adjustment, repeat the operating pressure tests
(with gauges connected to the inlet and outlet test ports on
top of the swing motor) and check pressures with the swing
locks engaged and released.
If pressure adjustment fails to restore adequate
performance, proceed to the Troubleshooting – Swing
table.
3. If pressure tests were at recommended levels through the
main inlet and outlet ports, and through the "SH" port of the
swing brake, the causes of poor swing performance could
include a faulty swing motor, drive train overloading or
gearbox defect, or a problem in the brake assembly or
swing control valve. Proceed to the troubleshooting
information in the next procedure.
If pressure through the "SH" port was tested below the
minimum 13 bar (190 psi) level, check the shuttle valve in
the rear compartment behind cabin.

Page 27
When pressure through the port is at the recommended
level, the brake release valve should disengage the swing
brake, allowing the swing motor to rotate the excavator. If
pressure adjustment to the valve has been restored but the
brake still fails to release, the brake piston or friction plate
may be frozen, requiring disassembly of the motor and
parts repair/replacement.
4. If pressure tested at the motor makeup valve falls below
recommended minimum level, and consequent problems
with cavitation, stalling and surging are observed, check
the restriction valve. If pressure adjustment to the valve
has been restored but if problems with cavitation
continues, disassemble the upper swing motor housing
and clean or replace assembly components as required.
NOTE:If all tested pressures are at or above
recommended levels, and there are no
mechanical problems in the drive train or in the
motor/brake assembly, the problem will require
further hydraulic troubleshooting. It's also
possible that a defective joystick, an intermittent
short in an electrical control circuit or a problem
in the EPOS circuit is causing diminished swing
performance. Pull out the EPOS indicator panel
from underneath the operator's seat and
perform the self-diagnostic test. If the display
panel reads code "0.2", it is reporting that the
swing priority proportional valve is not
functioning, except in the minimum "fail-safe"
mode. Refer to the Electrical section of this
book for more information.

Page 28
TROUBLESHOOTING – SWING
GEARBOX
Problem Possible Cause Remedy
Swing motor fails to operate and:
Three pressure tests at Swing relief valve defective Brake Adjust pressure to recommended range
motor, brake or makeup release valve defective Motor in affected valve.
valve show low reading(s). makeup valve defective.
OR
Disassemble and clean valve assembly.
Replace all valve components that show
damage.
All three pressure checks Exchange front and rear pump inlet If swing and left travel are restored but
are OK but left travel also and outlet hoses to test pump right travel stops working, replace or
fails to run. function. repair P1 pump.
All three pressure tests are Brake assembly or motor friction Check for binding. Disassemble and
OK, but machine fails to plate failing to release. repair.
swing at all. Pilot (control) pressure low or swing Disassemble / Repair pilot pressure
control valve stuck. swing spool (305) and / or swing control
valve.
Swing motor defective. Test motor drain rate. Replace / Repair
motor.
Gear train defective. Refer to "Swing Gear Troubleshooting"
procedure.
Swing functions but only at Causes listed above could also Check above list; then replace oil, test
reduced rpm. produce dragging swing, OR hot or motor drain rate and check for "03"
wrong oil OR worn-out parts. reading (EPOS self-test).
Left travel speed is also Low output at P1 pump or external Clean and repair piping or repair or
reduced. pilot piping leaks/is clogged. replace pump P1.
Swing control movement is Inlet / outlet piping reversed. Reset controls or reverse piping.
reversed.
Machine swings but Swing control valve spool not Replace return spring; clean/ repair
continues coasting on past centered. valve piston and spool.
stopping point. Pilot pressure may be outside Disassemble, clean or replace pilot relief
range. valve or pilot valve.
Swing relief valve may be faulty. Repair/Replace swing relief valve.
Swing movement is in one Check to see that pilot pressure is If pilot pressure is unequal, clean or
direction only. the same right and left. repair piping or repair/replace valve.
Swing control valve spool may be Repair/Replace the swing control valve.
stuck.
Swing relief valve may be faulty. Repair/Replace the swing relief valve.
No rotation and:
Pressure at swing motor Swing brake not releasing. Check brake engagement and
inlet increases. disengagement; check release pressure.
Internal damage to gearbox drive Replace broken gears and drive train
train. assemblies.
Overload. Reduce load weight.

Page 29
Pressure at swing motor Swing motor drive shaft damage. Replace swing motor.
inlet shows no increase, Internal damage to gearbox drive Repair/Replace broken or faulty
and the swing motor is train. assemblies.
making irregular noises.
Pressure at swing motor Hydraulic pump or valve problem. Troubleshoot hydraulic system.
inlet shown no increase, but
without irregular noises
from the swing motor.
Oil Leakage:
From drive shaft From Oil seal damaged Assembly Replace oil seal Disassemble and check
bolted connections or other compound (joint sealer) old and not mating surfaces. Reapply Loctite; torque
assembled surfaces. sealing, bolt not tight or flange bolts to specifications.
warped.
Excess heat:
Gearbox casing becomes Low oil level. Replace oil; refill to specified level.
excessively hot, with or Bearings or gears worn but not Repair or replace gearbox.
without irregular noise (s), completely inoperative.
during operation.
TROUBLESHOOTING –
HYDRAULIC PROBLEMS
Attachment cylinders, swing Main pump(s) malfunction. Repair or replace.
and travel motors are all Low oil level in hydraulic system. Refill.
inoperable. Loud noises are
Main pump inlet (oil supply) piping Repair or replace.
heard from main pump
or hose damaged.
assembly.
Attachment cylinders, swing Pilot pump malfunction. Repair or replace.
and travel motors are all Pilot cutoff solenoid stuck. Repair or replace.
inoperable. No usual or loud
Pilot cutoff switch faulty. Repair or replace.
noises can be heard.
Engine/pump flex coupling Replace flex coupling.
damaged.
Sluggish performance of all Main pump(s) damaged or worn. Repair or replace.
hydraulic functions – Main relief valve pressure off. Readjust pressure.
attachment, swing and
Low oil level in hydraulic system. Refill.
travel.
Hydraulic reservoir intake strainer Clean.
clogged.
Pump inlet (supply side) piping or Tighten connection.
hose allowing air into hydraulic
system.

Page 30
Oil temperature abnormally Oil cooler clogged or air circulation Clean.
high. to cooler blocked.
Cooling fan belt tension too loose. Readjust belt tension.
Relief valve set too low. Readjust valve.
Relief valve in constant use. Reduce or slow work load or cycling rate.
Hydraulic oil severely neglected or Replace oil.
incorrect for application.
One circuit in hydraulic Overload relief valve malfunction. Readjust or replace.
system inoperable. Oil leak at makeup valve. Clean, repair.
Control valve spool damaged. Repair or replace.
Dirt in control valve spool. Clean or replace.
Actuator (joystick, foot pedal) Repair or replace.
damaged or worn.
Internal seal leak in cylinder. Repair or replace.
Cylinder rod damaged. Repair or replace.
Pilot valve or piping malfunction. Repair or replace.
Mechanical linkage frozen, loose or Repair or replace.
damaged.
Travel motors inoperable. Center joint damaged. Repair or replace.
Parking brake not releasing. Repair or replace.
Travel motor worn or damaged. Repair or replace.
Travel motor pilot piping damaged. Repair or replace.
Travel motors operate very Track tension poorly adjusted Low Readjust tension Refill.
slowly. oil in idlers or rollers.
Travel brake dragging. Repair.
Track frame out of alignment, Repair.
deformed or twisted.
Swing motor inoperable. Swing brake not releasing. Repair or replace.
Relief valve malfunction. Repair or replace.
Pilot piping damaged. Repair or replace.
Swing motor operates Swing gear, bearing or mounting Repair or replace.
unevenly. loose or worn.
Lubricant worn away, inadequate. Grease.
Swing relief valve may be faulty. Repair/Replace the swing relief valve.

Page 31
TROUBLESHOOTING –
CONTROL VALVE
Check control valve problems only after other hydraulic circuit
operational tests have been made. Refer to "Troubleshooting
Baseline Recommendations" procedure. Pump flow, pilot
pressure, Negacon pressure, main relief pressure, and port
relief pressure should all be checked before starting to work on
the control valve. Make sure the hydraulic system is topped up
to the required level and free of oil leaks or air in the system that
could cause cavitation problems.

Main relief valve. Particulate contamination. Disassemble, clean main poppet.
Broken or damaged spring. Replace.
Adjusting screw loose. Readjust.
Main poppet sticking. Repair/replace.
Clogged orifice in pilot passage to Clean/replace.
control valve.
Cylinder goes down in spool Excessive clearance between Replace spool or casing.
neutral. casing and spool.
Spool does not return to neutral/ Check secondary pilot pressure.
sticking spool.
Spool does not return to neutral Clean.
because of dirt or other
contaminants.
Main relief or port relief not See above.
operating properly.
Impurities in pilot circuit. Clean.
Cylinder drops before start Rod check valve damaged or Clean/replace.
at boom up operation. clogged.
Poppet sticking. Clean/replace.
Slow operation or response. Excessive clearance between spool Check pilot pressure and/or replace
or casing. spool or casing.
Sticking spool. Clean/replace.
Main or port relief valve damaged. Check pressure/replace.
Swing priority not operating Sticking spool. Clean/replace.
correctly. Solenoid valve faulty. Replace.
Boom and arm cylinders do Priority valve faulty or spool Check pilot pressure.
not perform normally in sticking.
combined operation. Broken or deformed spring. Replace.
Excess clearance between right Clean/replace.
and left casing and valve spool.
Clogged spool passage. Clean/replace, replace filter.
Relief valve malfunctions:

Page 32
Pressure does not increase Main poppet or pilot poppet stuck Clean/replace.
at all. open.
Irregular or uneven Poppet seat damaged or pilot Clean/replace.
pressure. piston sticking to main poppet.
Loose lock nut and adjusting screw. Readjust.
Components worn out, past wear Replace.
limits.
TROUBLESHOOTING – TRAVEL
CONTROL VALVE
Secondary pressure does Low primary pressure. Check primary pressure.
not increase. Broken spring. Replace spring.
Spool sticking. Clean, repair or replace.
Excess spool to casing clearance. Replace spool casing.
Worn or loose universal joint Repair or replace U-joint subassembly.
(handle) subassembly.
Secondary pressure too Dirt, other interference between Clean, repair or replace.
high. valve parts.
Return line pressure too high. Redirect return line.
Secondary pressure does Dirt, other interference between Clean, repair or replace.
not hold steady. valve parts, or worn spool sticking
intermittently.
Interference or binding on spool Clean, repair or replace.
return spring.
Interference, restriction or unsteady Repair or reroute tank return line.
pressure in tank return line.
Air bubbles in piping (temporary) or Vent air, or repair leak.
air leak.
NOTE: Look for evidence of leaking oil.

Page 33
TROUBLESHOOTING –
JOYSTICK CONTROL VALVE
Secondary pressure does Low primary pressure. Check primary pressure.
not increase. Broken spring. Replace spring.
Spool sticking. Clean, repair or replace.
Excess spool to casing clearance. Replace spool casing.
Worn or loose handle subassembly. Repair or replace handle subassembly.
Secondary pressure too Dirt, other interference between Clean, repair or replace.
high. valve parts.
Return line pressure too high. Redirect return line.
Secondary pressure does Dirt, other interference between Clean, repair or replace.
not hold steady. valve parts, or worn spool sticking
intermittently.
Interference or binding on spool Clean, repair or replace.
return spring.
Unsteady pressure in tank return Redirect return line.
line.
Air bubbles in piping (temporary) or Vent air, or repair leak.
air leak.
NOTE: Look for evidence of leaking oil to help locate damaged seals or gaskets that could be the cause of
air leaks.

Page 34
SP000028
ACCUMULATOR SP000028
Accumulator
Edition 3
Accumulator SP000028
Page 1
MEMO
Page 2
Table of Contents
Accumulator
Specifications .................................................................. 8
Page 3
MEMO
Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up
Page 5
GENERAL DESCRIPTION
The accumulator is a gas-charged storage device designed to
hold a reserve quantity of hydraulic fluid under pressure. 1
Accumulators are used in hydraulic circuits in much the same
way that condensers (or capacitors) are used to collect, store 2
and maintain electrical charge in a circuit.
In a hydraulic circuit, minor variations or lags in pump output that
might otherwise cause unsteady or irregular operation are made
up from the supply of pressurized oil in the accumulator.
Reference 3
Description
Number
1 Screw Plug
2 Steel Pressure Vessel
3 Diaphragm 4
4 Fluid Valve
ARS1790L
Accumulators are solidly constructed to resist the high operating Figure 1

pressures of the fluids they contain. There are only three main
moving parts: a plug at the top allows precharging or expelling
gas from the compressible, precharged upper chamber; a valve
assembly at the bottom of the accumulator for passing hydraulic
fluid in and out, and an elastic diaphragm to separate the two
chambers. The flexible diaphragm changes shape to conform to
the changing pressures and volumes of the two fluids in the
upper and lower chambers.
There are six possible positions the diaphragm can be in and
they are as follows: Pressure Fluid Nitrogen
1. With no gas charge in the upper chamber 0 bar (0 psi,

empty) and no oil in the bottom 0 bar (0 psi, dry) the elastic
diaphragm hangs loosely.
2. When the prepressure charge of gas (usually nitrogen) is
introduced through the port at the top of the accumulator,
the diaphragm expands to maximum size. The valve button 1 2 3
in the center of the diaphragm pushes into the fluid
opening in the bottom chamber, sealing off the lower valve.
If the pressure of the gas charge exceeds system oil
pressure, no fluid enters the accumulator. The button also
keeps the diaphragm from protruding into the lower valve
opening.
4 5 6
NOTE: Precharge pressure is referred to as the "P1"
ARS1800L
pressure. The accumulator manufacturer's "P1"
Figure 2
rated pressure must be stamped or marked on
the accumulator's rating plate. Annual checks of
actual precharge pressure must be made by
tapping a hydraulic pressure gauge (and 3-way
adapter coupling) into the valve on the bottom
of the accumulator.
Page 6
When hydraulic fluid is pushed out the lower
valve opening by the pressure of the gas charge
on the other side of the diaphragm - and there is
no counterpressure from system oil - the valve
button on the bottom of the diaphragm
eventually seals off the lower oil passage. Just
after the needle on the gauge reaches its
highest point (when there is 0 bar (0 psi)
resistance from hydraulic system pressure)
pressure on the gauge will drop sharply to zero,
as the accumulator is completely emptied of oil
and the diaphragm button closes.
Record the highest gauge reading and compare to the "P1"
rated precharge pressure on the accumulator
manufacturer's data label. Repeat this test at least once a
year to verify proper functioning of the accumulator.
3. As hydraulic system pressure overcomes accumulator
precharge pressure, the flexible diaphragm begins to
retract upward.
4. When system oil is at highest working pressure and the
accumulator fills to maximum reserve capacity, the flexible
diaphragm is pushed up into the top of the upper chamber.
The highest working pressure is sometimes referred to as
the "P3" pressure and can also be referenced on the
manufacturer's data label on the exterior of the
accumulator.
5. If system oil pressure begins to fall off or is momentarily
checked or interrupted, the energy stored on the other side
of the diaphragm, in the form of compressed gas, pushes
oil back out of the lower chamber, maintaining oil pressure
of the circuit.
6. With minimal system pressure, an equilibrium point may be
reached in which accumulator precharge pressure and
hydraulic system oil pressure achieve a rough balance. In
this condition a minimal amount of oil is stored in the
accumulator.
Page 7
Specifications
Model Serial Number System Charge Pressure Volume
10 kg/cm2 320 cc
DX138LC S/N 6407 and Up Pilot
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX225LCA S/N 5167 and Up Pilot
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX225LL S/N 5001 and Up Pilot
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX225NLC S/N 5001 and Up Pilot
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX300LC S/N 7440 and Up Pilot / Travel
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX300LCA S/N 5001 and Up Pilot / Travel
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX300LL S/N 5001 and Up Pilot
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
Page 8
SP000029
CENTER JOINT (SWIVEL)SP000029
1Center Joint
(Swivel)
Edition 2
Center Joint (Swivel) SP000029

Page 1
MEMO

Page 2
Table of Contents
Center Joint (Swivel)

Parts List ......................................................................... 7
Troubleshooting, Testing and Adjustment ............ 8
Inspection ........................................................................ 8
Testing............................................................................. 8
Disassembly ......................................................... 9
Reassembly ........................................................ 10

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up
DX180LC 5001 and Up
DX225LC 5001 and Up
DX255LC 5001 and Up
DX300LC 5001 and Up

Page 5
GENERAL DESCRIPTION
The center joint (swivel) is designed to allow hydraulic oil
from the upper structure to flow to components in the lower
structure.
It is capable of allowing continuous 360° rotation of the
upper structure in relationship to the lower structure.

Page 6
Parts List
11
1
18
17 12
8
4
9
16 6
15
5
10 7
14
13 FG000536
Figure 1
Reference Reference
Number Number
1 Body 10 O-ring
2 Spindle 11 Plug
3 Cover 12 Plug
4 Spacer 13 Bolt
5 Shim 14 Spring Washer
6 Wear Ring 15 Bolt
7 Slipper Ring 16 Spring Washer
8 O-ring 17 Bolt
9 O-ring 18 Spring Washer

Page 7
TROUBLESHOOTING, TESTING
AND ADJUSTMENT
Inspection
The center joint must be checked for evidence of external oil
leakage every 2,000 operating hours. Leaking or defective O-
rings are an indication that dirt and other contaminants could be
getting inside the assembly, which will promote accelerated,
abnormal wear and can cause early failure of the assembly.
If internal seals or other sliding surface components are
worn and there is internal fluid leakage, complete overhaul
and repair or replacement of the center joint may be
required.
Testing
Pressure
To check pressure through the center joint, make up a test Gauge
kit from the following equipment list:

• 700 bar (10,000 psi) pressure gauge.
• Adapters, connectors, piping and flange block-off plates
Swivel Joint
Body (Outer)
conforming to those used in high-pressure piping Swivel Joint

Stem (Inner)
connections of the excavator.
• A high-pressure relief valve with a setting pressure 1.5
times maximum system pressure.
• A stop valve.
Stop
Valve
• A manually operated, in-line changeover valve.

Manually-Operated
Install the changeover valve upstream from one of the stem Changeover Valve
high-pressure ports. Connect the pressure gauge

downstream from one of the body ports. Install the stop Relief
Valve
valve between the changeover valve and the stem of the (1.5x)
center joint. Other components must be installed according to High Pressure

Pump
the layout in the block diagram. The test kit is used to pressurize Tank
the center swivel above normal working pressure and lock in the 0370
higher pressure (as the stop valve is closed manually) for a leak Figure 2
down test.
NOTE: The same type of kit can also be made up for the
drain port (return line) side of the center joint. Use
appropriate piping, connectors, test gauges, etc., and
follow the same block diagram general layout (Figure
2).

Page 8
DISASSEMBLY
Refer to the assembly drawing of the swivel joint for
component references (Figure 1).
IMPORTANT
Do not unbolt the center joint from the lower car body
until an adequate number of piping block-off plates are
available, for disconnected piping lines. Be sure that
system pressure has been vented - including the
hydraulic accumulator and tank reserve pressure -
before disassembly is started.
1. Clean off the exterior of the swivel joint after it has

been removed.
2. Scribe or otherwise mark a line across the cover and
the body of the center joint, to allow reassembly in the
same configuration.
3. Unbolt the four 12 mm fasteners holding the cover.
Use a vise or V-block to hold the assembly in place.
4. Remove the cover, withdraw the O-ring and remove the
retaining ring holding the thrust plate, taking care to
support the spindle assembly, so that it will not
separate and fall out when retaining ring is removed.
5. If the spindle assembly doesn't separate easily when
the thrust plate and retaining ring are removed, use a
wooden block and hammer to drive it out of the
housing.
6. O-rings and seals must be replaced whenever the
assembly is being overhauled or rebuilt. For repair
procedures or emergency tear down, use a thin but
rounded tip, smoothedge scraper or spatula to remove
O-rings or seals, to avoid causing damage to those
that must be reused.
NOTE: The "backup ring" shown in the assembly
drawing (above the swivel joint spindle lower
seals) should not be overlooked. It is tucked
behind the top slip ring, doubled up inside the
same groove in the body of the spindle.
7. Before reassembling the center swivel, visually inspect
ball bearing surfaces for visible signs of wear, damage
or discoloration and replace any worn component.
Check clearance between the spindle and thrust plate.
Replace any component that shows more than 0.5 mm
(0.020") of visible wear.
Clearance between the spindle and body of the center
swivel must be tight. Replace or repair either
component if there is more than 0.1 mm (0.0039") of
measurable wear.

Page 9
REASSEMBLY
1. Prelubricate O-rings with hydraulic oil, white grease or
petroleum jelly.
CAUTION
AVOID INJURY
Apply a very light film of white grease or petroleum
jelly to the lower rim of the stem and inner surface of
the center swivel body. Apply slow, even-handed
pressure, using both hands, to slowly push the stem
into the body. Seals may be damaged if the stem is
pushed in too quickly.
2. Thoroughly clean all other component surfaces of dirt

or grease before reassembly.
3. Reverse disassembly steps for reassembly.
4. Clean threads of fasteners before preapplying Loctite
#243 to the threads, and before torquing the thrust
plate and cover bolts.
5. Prefill the center swivel with clean hydraulic fluid before
reassembly of high-pressure and drain line piping. Clean
and prefill piping line ends to reduce the amount of air in
the system. Bleed air from the hydraulic system and verify
hydraulic tank fluid level before returning the excavator to
service.

Page 10
SP000030
CYLINDERS SP000030
Cylinders
Edition 2
Cylinders SP000030
Page 1
MEMO
Cylinders SP000030
Page 2
Table of Contents
Cylinders
Parts List ......................................................................... 8
Special Tools and Materials ............................... 10
Piston Nut...................................................................... 10
Piston Jig....................................................................... 12
Steel Bushing Jig........................................................... 14
Dust Wiper Jig ............................................................... 16
Slipper Seal Jig ............................................................. 18
Slipper Seal Straightening Jig ....................................... 20
Disassembly ....................................................... 22
Reassembly ........................................................ 27
Cylinders SP000030
Page 3
MEMO
Cylinders SP000030
Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up
DX180LC 5001 and Up
DX225LC 5434 and Up
DX255LC 5001 and Up
DX300LC 7440 and Up
DX340LC 5980 and Up
DX420LC 5327 and Up
Cylinders SP000030
Page 5
GENERAL DESCRIPTION
Two essentially similar types of hydraulic cylinders are used on
the excavator. The cylinder that is used to operate the excavator
boom or bucket is equipped with a rod stopper, which acts as a
cushion only when the cylinder rod is fully retracted (and the
bucket is pulled close to the arm). This type of cylinder is shown
in the lower drawing.
Arm cylinders have a cushion or stopper for operation in both
directions. This type of cylinder is shown in the upper drawing.
Theory of Operation
1 Piston
2 Oil Path A 1
3 Oil Path B D
Cylinder piston rods are extended or retracted by oil flow to the

back side of the cylinder (shown as ("oil path A") or to the front of 3
the cylinder ("oil path B"). 2
The cylinder rod is extended as oil flow is pumped through the
circuit to the back side of the piston. The force (F1) of the piston
stroke can be expressed by the formula below, where P = circuit FG001456
oil pressure and the inside diameter of the cylinder is expressed Figure 1
by D (Figure 1).
F1 = P x πD2
4
(P: Pressure, π = 3.14, D: Cylinder Inside Diameter)
1 Cylinder Inside Diameter - D

2 Oil Path A
4
3 Oil Path B
4 Rod Diameter - R
1
When the cylinder rod is retracted, oil flow through the circuit
from the pump to the front side of the cylinder generates a force 2
(F2) that can be expressed by the formula in which the diameter
3
of the piston rod is expressed by R, and the other two terms are
the same as in the preceding expression. FG001458
F2 = P x 2
π(D -R )2 Figure 2
4
Cylinders SP000030
Page 6
Because the volume of oil needed to lengthen the cylinder rod
(Q1) is greater than the volume of oil required to retract the
cylinder rod, it takes more time to extend a cylinder than it does
to retract it. 1
Q1 = S x π(D2)
4
Q2 = S x π(D2-R2)
4
Q1 > Q2 FG001459
Figure 3
Cylinders SP000030
Page 7
Parts List
The following parts list is a partial listing only; for full and
complete parts list information, refer to the Hydraulic Equipment
Component Parts List.
Cross section in Figure 4 shows an arm cylinder.
Cross section in Figure 5 shows a boom cylinder.
The bucket and boom cylinders are identical and differ only in
the attached pipes.
20 19 18 21,22 23 24 26
35 4 11,12 9,10 8 6 27 7 5 15 13,14 1 3 16 17
25 2 35
28, 29, 30, 31

FG005226
Figure 4
32, 33, 34
4 35 11, 12 9, 10 8 6 7 15 13, 14 5 3 1
16 17 20 19 18 21,22 23
24 2 35
FG005227
Figure 5
Cylinders SP000030
Page 8
Reference Reference
Number Number
1 Tube Assembly 19 Wear Ring
2 Bushing 20 Ring
3 Rod Assembly 21 O-ring
4 Bushing 22 Backup Ring
5 Rod Cover 23 Piston Nut
6 DD-Bushing 24 Set Screw
7 Retaining Ring 25 Socket Head Bolt
8 Buffer Seal 26 Pipe Band Assembly
9 U-Packing 27 Hex Socket Bolt
10 Backup Ring 28 Check Valve
11 Dust Wiper 29 Spring
12 Retaining Ring 30 Spring Support
13 O-ring 31 Hex Socket Plug
14 Backup Ring 32 Spring Washer
15 O-ring 33 Hex Bolt
16 Cushion Ring 34 Pipe Assembly
17 Piston 35 Grease Nipple
18 Slipper Seal
Cylinders SP000030
Page 9
SPECIAL TOOLS AND
MATERIALS
Piston Nut
( )
15
-0.1
-0.2
C
(C3~C5)
D +0.1
+0.2
A
35
B
∅8 Through Hole
5
0.
R
R(R15 ~ R20)
4-
350
ARS4730L
Figure 6
Material SM45C (AISI 1045)
Rockwell Harden from 22 - 27
Oil Quench
Cylinders SP000030
Page 10
MODEL CYLINDER ∅A ∅B C D MODEL (CYLINDER)
125.0 mm 85.0 mm 12.0 mm 5.0 mm
BOOM
(4.92 in) (3.35 in) (0.47 in) (0.20 in)
DX138LC/ 130.0 mm 90.0 mm 12.0 mm 5.0 mm
ARM
DX140LC (5.12 in) (3.54 in) (0.47 in) (0.20 in)
115.0 mm 75.0 mm 12.0 mm 5.0 mm
BUCKET
(4.53 in) (2.95 in) (0.47 in) (0.20 in)
130.0 mm 90.0 mm 12.0 mm 5.0 mm
BOOM
(5.12 in) (3.54 in) (0.47 in) (0.20 in)
140.0 mm 98.0 mm 12.0 mm 5.0 mm
DX180LC ARM
(5.52 in) (3.86 in) (0.47 in) (0.20 in)
125.0 mm 85.0 mm 12.0 mm 5.0 mm
BUCKET
(4.92 in) (3.35 in) (0.47 in) (0.20 in)
145.0 mm 105.0 mm 12.0 mm 5.0 mm
BOOM
(5.71 in) (4.13 in) (0.47 in) (0.20 in)
145.0 mm 105.0 mm 12.0 mm 5.0 mm
DX225LC ARM
(5.71 in) (4.13 in) (0.47 in) (0.20 in)
130.0 mm 89.0 mm 12.0 mm 5.0 mm
BUCKET
(5.11 in) (3.50 in) (0.47 in) (0.20 in)
145.0 mm 105.0 mm 12.0 mm 5.0 mm
BOOM
(5.71 in) (4.13 in) (0.47 in) (0.20 in)
145.0 mm 105.0 mm 12.0 mm 5.0 mm
DX225NLC ARM
(5.71 in) (4.13 in) (0.47 in) (0.20 in)
130.0 mm 89.0 mm 12.0 mm 5.0 mm
BUCKET
(5.11 in) (3.50 in) (0.47 in) (0.20 in)
140.0 mm 98.0 mm 12.0 mm 5.0 mm
BOOM
(5.52 in) (3.86 in) (0.47 in) (0.20 in)
145.0 mm 105.0 mm 12.0 mm 5.0 mm
DX255LC ARM
(5.71 in) (4.13 in) (0.47 in) (0.20 in)
140.0 mm 98.0 mm 12.0 mm 5.0 mm
BUCKET
(5.52 in) (3.86 in) (0.47 in) (0.20 in)
142.0 mm 102.0 mm 12.0 mm 5.0 mm
BOOM
(5.59 in) (4.02 in) (0.47 in) (0.20 in)
147.0 mm 107.0 mm 12.0 mm 5.0 mm
DX300LC ARM S/ARM
(5.79 in) (4.21 in) (0.47 in) (0.20 in)
140.0 mm 98.0 mm 12.0 mm 5.0 mm
BUCKET S/BUCKET
(5.52 in) (3.86 in) (0.47 in) (0.20 in)
145.0 mm 105.0 mm 12.0 mm 5.0 mm
BOOM OPT BOOM
(5.71 in) (4.13 in) (0.47 in) (0.20 in)
DX340LC/
147.0 mm 107.0 mm 12.0 mm 5.0 mm
DX340LCA/ ARM OPT ARM
(5.79 in) (4.21 in) (0.47 in) (0.20 in)
DX350LC
145.0 mm 105.0 mm 12.0 mm 5.0 mm
BUCKET OPT BUCKET
(5.71 in) (4.13 in) (0.47 in) (0.20 in)
147.0 mm 107.0 mm 12.0 mm 5.0 mm
BOOM
(5.79 in) (4.21 in) (0.47 in) (0.20 in)
147.0 mm 107.0 mm 12.0 mm 5.0 mm
DX380LC ARM
(5.79 in) (4.21 in) (0.47 in) (0.20 in)
145.0 mm 105.0 mm 12.0 mm 5.0 mm
BUCKET
(5.71 in) (4.13 in) (0.47 in) (0.20 in)
147.0 mm 107.0 mm 12.0 mm 5.0 mm
BOOM
(5.79 in) (4.21 in) (0.47 in) (0.20 in)
DX420LC/ 147.0 mm 107.0 mm 12.0 mm 5.0 mm
ARM
DX420LCA (5.79 in) (4.21 in) (0.47 in) (0.20 in)
155.0 mm 115.0 mm 12.0 mm 5.0 mm
BUCKET
(6.10 in) (4.53 in) (0.47 in) (0.20 in)
Cylinders SP000030
Page 11
Piston Jig
( )
15
2-∅"B"
)
F/2
∅8 Through Hole
R(
"
"D
∅
"A"
∅"
C"
35
R(R15~20)
R5
4-
30
ARS4740L
Figure 7
Material SM45C (AISI 1045)
Rockwell Harden from 22 - 27
Oil Quench
Cylinders SP000030
Page 12
MODEL CYLINDER A ( ±0.1) ∅B ∅C ∅D MODEL (CYLINDER)
80.0 mm 11.0 mm 58.0 mm 110.0 mm
BOOM
(3.15 in) (0.43 in) (2.28 in) (4.33 in)
DX138LC/ 80.0 mm 11.0 mm 58.0 mm 110.0 mm
ARM
DX140LC (3.15 in) (0.43 in) (2.28 in) (4.33 in)
70.0 mm 11.0 mm 46.0 mm 95.0 mm
BUCKET
(2.76 in) (0.43 in) (1.81 in) (3.74 in)
90.0 mm 11.0 mm 63.0 mm 115.0 mm
BOOM
(3.54 in) (0.43 in) (2.48 in) (4.53 in)
96.0 mm 13.0 mm 69.0 mm 130.0 mm
DX180LC ARM
(3.78 in) (0.51 in) (2.72 in) (5.12 in)
80.0 mm 11.0 mm 58.0 mm 110.0 mm
BUCKET
(3.15 in) (0.43 in) (2.28 in) (4.33 in)
90.0 mm 11.0 mm 63.0 mm 115.0 mm
BOOM
(3.54 in) (0.43 in) (2.48 in) (4.53 in)
110.0 mm 13.0 mm 75.0 mm 140.0 mm
DX225LC ARM
(4.33 in) (0.51 in) (2.95 in) (5.51 in)
90.0 mm 11.0 mm 63.0 mm 115.0 mm
BUCKET
(3.54 in) (0.43 in) (2.48 in) (4.54 in)
90.0 mm 11.0 mm 63.0 mm 115.0 mm
BOOM
(3.54 in) (0.43 in) (2.48 in) (4.53 in)
110.0 mm 13.0 mm 75.0 mm 140.0 mm
DX225NLC ARM
(4.33 in) (0.51 in) (2.95 in) (5.51 in)
90.0 mm 11.0 mm 63.0 mm 115.0 mm
BUCKET
(3.54 in) (0.43 in) (2.48 in) (4.54 in)
96.0 mm 13.0 mm 69.0 mm 130.0 mm
BOOM
(3.78 in) (0.51 in) (2.72 in) (5.12 in)
110.0 mm 13.0 mm 76.0 mm 140.0 mm
DX255LC ARM
(4.33 in) (0.51 in) (2.99 in) (5.51 in)
96.0 mm 13.0 mm 69.0 mm 130.0 mm
BUCKET
(3.78 in) (0.51 in) (2.72 in) (5.12 in)
110.0 mm 13.0 mm 76.0 mm 140.0 mm
BOOM
(4.33 in) (0.51 in) (2.99 in) (5.51 in)
120.0 mm 13.0 mm 85.0 mm 150.0 mm
DX300LC ARM S/ARM
(4.72 in) (0.513 in) (3.35 in) (5.91 in)
110.0 mm 13.0 mm 76.0 mm 140.0 mm
BUCKET S/BUCKET
(4.33 in) (0.51 in) (2.99 in) (5.51 in)
120.0 mm 13.0 mm 85.0 mm 150.0 mm
BOOM OPT BOOM
(4.72 in) (0.51 in) (3.35 in) (5.91 in)
DX340LC/
130.0 mm 13.0 mm 93.0 mm 165.0 mm
(5.12 in) (0.513 in) (3.66 in) (6.50 in)
DX350LC
120.0 mm 13.0 mm 85.0 mm 150.0 mm
BUCKET OPT BUCKET
(4.72 in) (0.51 in) (3.35 in) (5.91 in)
130.0 mm 13.0 mm 93.0 mm 165.0 mm
BOOM
(5.12 in) (0.513 in) (3.66 in) (6.50 in)
130.0 mm 13.0 mm 93.0 mm 165.0 mm
DX380LC ARM
(5.12 in) (0.513 in) (3.66 in) (6.50 in)
120.0 mm 13.0 mm 85.0 mm 150.0 mm
BUCKET
(4.72 in) (0.51 in) (3.35 in) (5.91 in)
130.0 mm 13.0 mm 93.0 mm 165.0 mm
BOOM
(5.12 in) (0.51 in) (3.66 in) (6.50 in)
DX420LC/ 130.0 mm 13.0 mm 93.0 mm 165.0 mm
ARM
DX420LCA (5.12 in) (0.513 in) (3.66 in) (6.50 in)
130.0 mm 13.0 mm 93.0 mm 165.0 mm
BUCKET
(5.12 in) (0.51 in) (3.66 in) (6.50 in)
Cylinders SP000030
Page 13
Steel Bushing Jig
(5)
"A" - 20
"B" + 40
∅"B"
∅"A"
(∅20)
15 F E
ARS4750L
Figure 8
Material: SM45C which is done thermal refining <QT> Hrc 22 - 28
Undefined Chamfer C/R = 0.5 Max.
1 Place: Finally work to used DNMG Tip <Nose R0.4>
Cylinders SP000030
Page 14
MODEL
MODEL CYLINDER ∅A-0.05 ∅B ( ±0.1) E F+0.05 Part
-0.15 0 (CYLINDER)
71.0 mm 86.0 mm 40.0 mm 6.5 mm
BOOM
(2.80 in) (3.39 in) (1.57 in) (0.26 in)
DX138LC/ 71.0 mm 86.0 mm 40.0 mm 7.0 mm
ARM
DX140LC (2.80 in) (3.39 in) (1.57 in) (0.28 in)
65.0 mm 80.0 mm 30.0 mm 6.0 mm
BUCKET
(2.56 in) (3.14 in) (1.81 in) (0.24 in)
71.0 mm 86.0 mm 50.0 mm 6.0 mm
BOOM
(2.80 in) (3.39 in) (1.97 in) (0.24 in)
71.0 mm 86.0 mm 50.0 mm 6.0 mm
DX180LC ARM
(2.80 in) (3.39 in) (1.97 in) (0.24 in)
71.0 mm 86.0 mm 50.0 mm 6.0 mm
BUCKET
(2.80 in) (3.39 in) (1.97 in) (0.24 in)
80.0 mm 95.0 mm 40.0 mm 6.5 mm
BOOM
(3.15 in) (3.74 in) (1.58 in) (0.26 in)
80.0 mm 95.0 mm 40.0 mm 6.5 mm
DX225LC ARM
(3.15 in) (3.74 in) (1.58 in) (0.26 in)
80.0 mm 95.0 mm 40.0 mm 6.5 mm
BUCKET
(3.15 in) (3.74 in) (1.58 in) (0.26 in)
80.0 mm 95.0 mm 40.0 mm 6.5 mm
BOOM
(3.15 in) (3.74 in) (1.58 in) (0.26 in)
80.0 mm 95.0 mm 40.0 mm 6.5 mm
DX225NLC ARM
(3.15 in) (3.74 in) (1.58 in) (0.26 in)
80.0 mm 95.0 mm 40.0 mm 6.5 mm
BUCKET
(3.15 in) (3.74 in) (1.58 in) (0.26 in)
90.0 mm 105.0 mm 40.0 mm 7.0 mm
BOOM
(3.54 in) (4.13 in) (1.58 in) (0.28 in)
80.0 mm 95.0 mm 35.0 mm 6.5 mm
DX255LC ARM
(3.15 in) (3.74 in) (1.38 in) (0.26 in)
80.0 mm 95.0 mm 35.0 mm 6.5 mm
BUCKET
(3.15 in) (3.74 in) (1.38 in) (0.26 in)
90.0 mm 105.0 mm 40.0 mm 7.0 mm
BOOM
(3.54 in) (4.13 in) (1.58 in) (0.28 in)
90.0 mm 105.0 mm 40.0 mm 6.5 mm
DX300LC ARM S/ARM
(3.54 in) (4.13 in) (1.58 in) (0.26 in)
90.0 mm 105.0 mm 40.0 mm 7.0 mm
BUCKET S/BUCKET
(3.54 in) (4.13 in) (1.58 in) (0.28 in)
100.0 mm 115.0 mm 45.0 mm 7.5 mm
BOOM OPT BOOM
(3.94 in) (4.53 in) (1.77 in) (0.30 in)
DX340LC/
100.0 mm 115.0 mm 45.0 mm 7.5 mm
(3.94 in) (4.53 in) (1.77 in) (0.30 in)
DX350LC
100.0 mm 115.0 mm 45.0 mm 7.5 mm
BUCKET OPT BUCKET
(3.94 in) (4.53 in) (1.77 in) (0.30 in)
100.0 mm 115.0 mm 45.0 mm 7.5 mm
BOOM
(3.94 in) (4.53 in) (1.77 in) (0.30 in)
100.0 mm 115.0 mm 45.0 mm 7.5 mm
DX380LC ARM
(3.94 in) (4.53 in) (1.77 in) (0.30 in)
100.0 mm 115.0 mm 45.0 mm 7.5 mm
BUCKET
(3.94 in) (4.53 in) (1.77 in) (0.30 in)
110.0 mm 130.0 mm 70.0 mm 11.0 mm
BOOM
(4.33 in) (5.12 in) (2.76 in) (0.43 in)
DX420LC/ 110.0 mm 130.0 mm 70.0 mm 11.0 mm
ARM
DX420LCA (4.33 in) (5.12 in) (2.76 in) (0.43 in)
110.0 mm 130.0 mm 70.0 mm 11.0 mm
BUCKET
(4.33 in) (5.12 in) (2.76 in) (0.43 in)
Cylinders SP000030
Page 15
Dust Wiper Jig
1.5
3-C
R0.2
1
DIA. (B+40)
DIA. (A-20)
DIA. A
DIA. B
15 C D
ARS4760L
Figure 9
Material: SM45C which is done thermal refining <QT> Hrc 22 - 28
Undefined Chamfer C/R = 0.5 Max.
1 Place: Finally work to used DNMG Tip <Nose R0.4>
Cylinders SP000030
Page 16
MODEL CYLINDER ∅A-0.2
-0.3 ∅B -0.2
-0.3 C 0-0.1 D MODEL (CYLINDER)
75.0 mm 89.0 mm 6.0 mm 7.0 mm
BOOM
(2.95 in) (3.50 in) (0.24 in) (0.28 in)
DX138LC/ 80.0 mm 94.0 mm 6.0 mm 7.0 mm
ARM
DX140LC (3.15 in) (3.70 in) (0.24 in) (0.28 in)
65.0 mm 79.0 mm 6.0 mm 7.0 mm
BUCKET
(2.56 in) (3.11 in) (0.24 in) (0.28 in)
80.0 mm 94.0 mm 6.0 mm 7.0 mm
BOOM
(3.15 in) (4.29 in) (0.24 in) (0.28 in)
90.0 mm 104.0 mm 6.0 mm 7.0 mm
DX180LC ARM
(3.54 in) (4.10 in) (0.24 in) (0.28 in)
75.0 mm 89.0 mm 6.0 mm 7.0 mm
BUCKET
(2.95 in) (3.50 in) (0.24 in) (0.28 in)
100.0 mm 114.0 mm 6.0 mm 7.0 mm
BOOM
(3.94 in) (4.49 in) (0.24 in) (2.28 in)
100.0 mm 114.0 mm 6.0 mm 7.0 mm
DX225LC ARM
(3.94 in) (4.49 in) (0.24 in) (2.28 in)
80.0 mm 94.0 mm 6.0 mm 7.0 mm
BUCKET
(3.15 in) (3.70 in) (0.24 in) (2.28 in)
100.0 mm 114.0 mm 6.0 mm 7.0 mm
BOOM
(3.94 in) (4.49 in) (0.24 in) (2.28 in)
100.0 mm 114.0 mm 6.0 mm 7.0 mm
DX225NLC ARM
(3.94 in) (4.49 in) (0.24 in) (2.28 in)
80.0 mm 94.0 mm 6.0 mm 7.0 mm
BUCKET
(3.15 in) (3.70 in) (0.24 in) (2.28 in)
90.0 mm 104.0 mm 6.0 mm 7.0 mm
BOOM
(3.54 in) (4.10 in) (0.24 in) (2.28 in)
100.0 mm 114.0 mm 6.0 mm 7.0 mm
DX255LC ARM
(3.94 in) (4.49 in) (0.24 in) (2.28 in)
90.0 mm 104.0 mm 6.0 mm 7.0 mm
BUCKET
(3.54 in) (4.10 in) (0.24 in) (2.28 in)
95.0 mm 109.0 mm 6.0 mm 7.0 mm
BOOM
(3.74 in) (4.29 in) (0.24 in) (2.28 in)
105.0 mm 121.0 mm 6.0 mm 7.0 mm
DX300LC ARM S/ARM
(4.13 in) (4.76 in) (0.24 in) (2.28 in)
90.0 mm 104.0 mm 6.0 mm 7.0 mm
BUCKET S/BUCKET
(3.54 in) (4.10 in) (0.24 in) (2.28 in)
100.0 mm 114.0 mm 6.0 mm 7.0 mm
BOOM OPT BOOM
(3.94 in) (4.49 in) (0.24 in) (2.28 in)
DX340LC/
115.0 mm 131.0 mm 6.0 mm 7.0 mm
(4.53 in) (5.16 in) (0.24 in) (2.28 in)
DX350LC
100.0 mm 114.0 mm 6.0 mm 7.0 mm
BUCKET OPT BUCKET
(3.94 in) (4.49 in) (0.24 in) (2.28 in)
105.0 mm 121.0 mm 6.0 mm 7.0 mm
BOOM
(4.13 in) (4.76 in) (0.24 in) (2.28 in)
115.0 mm 131.0 mm 6.0 mm 7.0 mm
DX380LC ARM S / ARM
(4.53 in) (5.16 in) (0.24 in) (2.28 in)
100.0 mm 114.0 mm 6.0 mm 7.0 mm
BUCKET S / BUCKET
(3.94 in) (4.49 in) (0.24 in) (2.28 in)
115.0 mm 131.0 mm 6.0 mm 7.0 mm
BOOM
(4.53 in) (5.16 in) (0.24 in) (2.28 in)
DX420LC/ 120.0 mm 136.0 mm 6.0 mm 7.0 mm
ARM
DX420LCA (4.72 in) (5.35 in) (0.24 in) (2.28 in)
110.0 mm 126.0 mm 6.0 mm 7.0 mm
BUCKET
(4.33 in) (4.96 in) (0.24 in) (2.28 in)
Cylinders SP000030
Page 17
Slipper Seal Jig
0
R1
R1
∅(A+2)
∅A
∅(A-14)
10°
B
(B+40)
ARS4770L
Figure 10
Cylinders SP000030
Page 18
MODEL CYLINDER ∅A+0.2
+0.1 B+0.2
+0.1
MODEL (CYLINDER)
110.0 mm 28.5 mm
BOOM
(4.33 in) (1.12 in)
DX138LC/ 115.0 mm 28.5 mm
ARM
DX140LC (4.53 in) (1.12 in)
95.0 mm 28.5 mm
BUCKET
(3.74 in) (1.12 in)
115.0 mm 28.5 mm
BOOM
(4.53 in) (1.12 in)
125.0 mm 28.5 mm
DX180LC ARM
(4.92 in) (1.12 in)
110.0 mm 28.5 mm
BUCKET
(4.33 in) (1.12 in)
140.0 mm 28.5 mm
BOOM
(5.51 in) (1.12 in)
150.0 mm 28.5 mm
DX225LC ARM
(5.91 in) (1.12 in)
120.0 mm 28.5 mm
BUCKET
(4.72 in) (1.12 in)
140.0 mm 28.5 mm
BOOM
(5.51 in) (1.12 in)
150.0 mm 28.5 mm
DX225NLC ARM
(5.91 in) (1.12 in)
120.0 mm 28.5 mm
BUCKET
(4.72 in) (1.12 in)
130.0 mm 28.5 mm
BOOM
(5.12 in) (1.12 in)
140.0 mm 28.5 mm
DX255LC ARM S/ARM
(5.51 in) (1.12 in)
130.0 mm 28.5 mm
BUCKET S/BUCKET
(5.12 in) (1.12 in)
140.0 mm 28.5 mm
BOOM
(5.51 in) (1.12 in)
150.0 mm 28.5 mm
DX300LC ARM S/ARM
(5.91 in) (1.12 in)
140.0 mm 28.5 mm
BUCKET S/BUCKET
(5.51 in) (1.12 in)
150.0 mm 28.5 mm
BOOM OPT BOOM
(5.91 in) (1.12 in)
DX340LC/
170.0 mm 34.5 mm
(6.69 in) (1.36 in)
DX350LC
150.0 mm 28.5 mm
BUCKET OPT BUCKET
(5.91 in) (1.12 in)
150.0 mm 28.5 mm
BOOM
(5.91 in) (1.12 in)
170.0 mm 34.5 mm
DX380LC ARM
(6.69 in) (1.36 in)
150.0 mm 28.5 mm
BUCKET
(5.91 in) (1.12 in)
165.0 mm 34.5 mm
BOOM OPT BOOM
(6.50 in) (1.36 in)
DX420LC/ 180.0 mm 41.5 mm
ARM OPT ARM
DX420LCA (7.09 in) (1.63 in)
160.0 mm 34.5 mm
BUCKET OPT BUCKET
(6.30 in) (1.36 in)
Cylinders SP000030
Page 19
Slipper Seal Straightening Jig
1
2-C
R
2-5
∅(A+15)
∅A
1
2-R
100
25
50
ARS4780L
Figure 11
Cylinders SP000030
Page 20
MODEL CYLINDER ∅A+0.2
+0.1
MODEL (CYLINDER)
110.0 mm
BOOM
(4.33 in)
DX138LC/ 115.0 mm
ARM
DX140LC (4.53 in)
95.0 mm
BUCKET
(3.74 in)
115.0 mm
BOOM
(4.53 in)
125.0 mm
DX180LC ARM
(4.92 in)
110.0 mm
BUCKET
(4.33 in)
140.0 mm
BOOM
(5.51 in)
150.0 mm
DX225LC ARM
(5.91 in)
120.0 mm
BUCKET
(4.72 in)
140.0 mm
BOOM
(5.51 in)
150.0 mm
DX225NLC ARM
(5.91 in)
120.0 mm
BUCKET
(4.72 in)
130.0 mm
BOOM
(5.12 in)
140.0 mm
DX255LC ARM S/ARM
(5.51 in)
130.0 mm
BUCKET S/BUCKET
(5.12 in)
140.0 mm
BOOM
(5.51 in)
150.0 mm
DX300LC ARM S/ARM
(5.91 in)
140.0 mm
BUCKET S/BUCKET
(5.51 in)
150.0 mm
BOOM OPT BOOM
(5.91 in)
DX340LC/
170.0 mm
(6.69 in)
DX350LC
150.0 mm
BUCKET OPT BUCKET
(5.91 in)
150.0 mm
BOOM
(5.91 in)
170.0 mm
DX380LC ARM
(6.69 in)
150.0 mm
BUCKET
(5.91 in)
165.0 mm
BOOM OPT BOOM
(6.50 in)
DX420LC/ 180.0 mm
ARM OPT ARM
DX420LCA (7.09 in)
160.0 mm
BUCKET OPT BUCKET
(6.30 in)
Cylinders SP000030
Page 21
DISASSEMBLY
CAUTION
AVOID INJURY
Vent air from the hydraulic system before disconnecting
cylinder piping connections. Use the lever on the reservoir,
while the engine is running. Discharge the hydraulic
accumulator and vent residual tank pressure after the
engine is shut off. Pour clean replacement fluid back into
the system if excessive fluid is lost.
1. Following removal of cylinder from excavator attachment,

support cylinder on some type of sturdy work platform and
drain all oil. Rotate cylinder so that piping ports are on top,
to allow trapped air to vent.
Figure 12
2. Position piston rod so that it is extended approximately one

half meter (20").
Figure 13
Cylinders SP000030
Page 22
3. Remove bolts (27) on the end of cylinder.
NOTE: Wrap a cloth or other protective material around
piston rod, to avoid possibility of accidentally
scratching or scoring rod surface while
fasteners are being loosened and removed.
Component parts (numbered in parentheses)
are keyed to Figure 4.
Figure 14
4. Tap two bolts into cover of cylinder head, 180° apart.

Tighten them in a staggered, even sequence, to back off
piston rod end cover from edge of cylinder wall. Look for
adequate clearance between cover and end of cylinder
wall before using a plastic or other soft-faced hammer for
final disassembly.
Figure 15
5. Begin withdrawing piston rod assembly, away from

cylinder. Attach a lifting support when final 1/3 of rod is still
inside barrel of cylinder. Prepare support blocks for piston
rod before it has been completely withdrawn.
Figure 16
6. Lower piston rod to support blocks and detach wear ring

(outer surface) (19) from end of rod.
Figure 17
Cylinders SP000030
Page 23
7. Immobilize piston rod by inserting a wooden or other
nonscoring, nonmetallic support through end of rod.
Figure 18
8. Remove set screw using socket wrench.
HAOF340L
Figure 19
9. Fabricate or purchase a piston nut removal wrench.

(Dimensions are called off at beginning of this procedure.
This tool may also be ordered through your local DOOSAN
Parts distributor). Remove nut from end of piston.
Figure 20
10. Use second piston tool described at beginning of this

procedure to separate piston. Detach cushion ring (16),
taking care not to damage cushion ring.
Figure 21
Cylinders SP000030
Page 24
11. Use a plastic hammer to evenly pull off rod cover (5) from
end of piston rod. Be careful not to damage rod bushing (6)
and dust wiper, U-packing and other seals.
Figure 22
12. Use a dull, rounded tip tool to pry off O-ring (13) and
backup ring (14).
HAOF37OL
Figure 23
13. Find a screwdriver with an appropriate width tip to facilitate

removal of slipper seal (18), wear ring (19) and slide ring
(20) from piston (17).
Figure 24
14. Remove O-ring (21) and backup ring (22) from cylinder
head.
HAOF38OS
Figure 25
Cylinders SP000030
Page 25
15. During disassembly of cylinder head, be careful not to
damage buffer seal (8) and U-packing (9).
HAOF39OL
Figure 26
16. Disassemble retaining ring (12) and dust wiper (11).

Separate retaining ring (7) and rod bushing (6).
Figure 27
17. Force out pin bushing (2), (4) from body of cylinder.
Figure 28
Cylinders SP000030
Page 26
REASSEMBLY
IMPORTANT
Replace any part that shows evidence of damage or
excessive wear. Replacement of all O-rings and flexible
seals is strongly recommended. Before starting the cylinder
reassembly procedure, all parts must be thoroughly
cleaned and dried, and/or prelubricated with clean
hydraulic fluid. Prepare the work area beforehand to
maintain cleanliness during the reassembly procedure.
NOTE: Reassemble the subassemblies of the cylinder in the

following order:
1. Body of the cylinder.
2. Piston rod.
3. Piston assembly.
4. Cylinder head assembly.
1. Reassemble pin bushing (2), (4) to piston rod and body of
cylinder.
Figure 29
2. Following reassembly of rod cover components, install the

dust wiper (11) and rod bushing (6) to the rod cover (5).
Insert retaining rings (7 and 12).
Figure 30
Cylinders SP000030
Page 27
3. Prelubricate O-rings and seals before reassembly (Figure
31).
Figure 31
4. Before starting to rebuild piston assembly, heat slipper seal

for 5 minutes in an oil bath warmed to 150° - 180°C (302° -
356°F). Use special slipper seal jig (third item in list of
specialized tools at the beginning of this procedure) to
attach seal. Cool seal by pushing a retracting jig against
seal for several minutes. Apply a strip of clean, see-
through sealing tape around slipper seal to keep it free of
dust.
Figure 32
5. Immobilize piston rod on solid support blocks. Assemble

O-ring (21) and backup ring (22). Prepare to attach rod
cover assembly to piston rod. Push rod cover by tightening
piston nut (23).
Figure 33
6. Assemble cushion ring (16) and attach piston assembly to

piston rod.
Figure 34
Cylinders SP000030
Page 28
7. Use specially fabricate or factory sourced tool to tighten
piston nut (23).
Figure 35
8. Assemble wear ring (19), slide ring (20) and set screw (24)
to piston assembly.
Reference
Description
Number
1 Set Screw
Figure 36
9. Immobilize body of cylinder before reassembly.
Figure 37
Preapply fastener locking compound (Loctite #242 or #243 or an

alternate manufacturer's equivalent product) to all end cover
retaining bolts. Wrap a protective cushion around end of rod
while tightening fasteners, to prevent possible damage to
polished surface of rod, should a wrench slip during retightening.
Figure 38
Cylinders SP000030
Page 29
Cylinders SP000030
Page 30
SP002527
SWING MOTOR SP002527
Swing Motor
Edition 1
Swing Motor SP002527

Page 1
MEMO

Page 2
Table of Contents
Swing Motor
Instruction Manual ................................................ 6
Indication of Type ............................................................ 6
Specifications .................................................................. 7
Construction and Principles of Working .......................... 8
Precaution in Use .......................................................... 15
Troubleshooting............................................................. 19
Maintenance Manual .......................................... 22
Disassembling and Assembling .................................... 22
Maintenance Standards ................................................ 35

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up

Page 5
INSTRUCTION MANUAL
Indication of Type
TSM 140 CH B — 10 A -01 / 270
Relief valve
Setting pre.
Design code
Specification
A: Swing specification
Shaft geometry
10: Male spline
20: Female spline
Mechanical brake yes or no

B : Brake built-in
Valve cover code
Displacement
64: 64 cc/rev
72: 72 cc/rev
86: 86 cc/rev
128: 127.9 cc/rev
140: 140.5 cc/rev
Motor type

Page 6
Specifications
Model TSM64 TSM72 TSM86 TSM128 TSM140
Displacement 64 72 86 127.9 140.5
Rated 330 330 330 330 330
Pressure (kg/cm2)
Max 400 400 400 400 400
Maximum speed (min -1) 2500 2200 1900 2000 1800
*1 Theoretical output torque (kg•m) 33.6 37.8 45.1 67.1 73.7
*2 Theoretical output power (KW) 75.8 85.2 86.0 134.2 134.5
Brake torque (kg•m) 36.8 36.8 36.8 70 70
Brake release pressure (kg/cm2) 24 24 24 26 26
Weight (kgf) 42.3 42.3 42.3 62 62
NOTE: *1. The theoretical value at the rated pressure, not

including mechanical efficiency.
*2. The theoretical value at the rated pressure and
the max. speed.
NOTE: TSM86 series can be applied from 64 cc/rev to 86 cc/
rev by the change of displacement.
TSM140 series can be applied from 127.9 cc/rev to
140.5 cc/rev by the change of displacement.

Page 7
Construction and Principles of Working
Construction
202 203 204 205 306 305 307 308 309 112 311 106 102 103 104 105
101
304 110 402

111
303
401
made by
Tong Myung Heavy Industries Co.,Ltd
MFG. NO. :
PART NO. :
DAEWOO HEAVY IND. LTD.

302
108
KOREA
403
212
201
213
404
301
113
206 207 208 209 210 405 400 211 310 210 109 107 312
FG001843
Figure 1 Construction of Motor

Page 8
Reference Reference
Number Number
101 Valve Casing 209 Roller
102 Plug 210 Washer
103 Spring 211 Spring
104 Plunger 212 Ring Snap
105 Swing Reactionless Valve Assembly 213 Valve Plate
106 O-ring 301 Casing
107 Relief Valve 302 Oil Seal
108 Ball Bearing 303 Ball Bearing
109 Socket Bolt 304 Parallel Pin
110 Vp Plug 305 Separation Plate
111 O-ring 306 Friction Plate
112 O-ring 307 O-ring
113 Pin Spring 308 O-ring
201 Driveshaft 309 Brake Piston
202 Swash Plate 310 Brake Spring
203 Shoe 311 PT-plug
204 Piston 312 PT-plug
205 Cylinder Block 400 Brake Valve
206 Thrust Ball 401 Nameplate
207 Retainer Plate 402 Rivet Screw
208 Collar

Page 9
Principles of Working
Motor Part
High-pressure oil from the control valve is routed through valve
casing and valve plate to pistons. When the oil enters the
cylinder bores through port, it forces the pistons against the fixed
inclined swash plate (F1,F2). The force (F2) causes the piston
shoes to slide on the swash plate forcing the rotating group to
turn, thereby rotating the output shaft.
During the second half of the motor's revolution, low-pressure oil
is discharged as the pistons ride to toward a higher position on
the shoe plate.
A small amount of supply oil flows through the center of each
piston to lubricate the piston ball joint and the piston shoe face.
The motor is internally lubricated from leakage inside the motor.
To reverse rotation, system oil flow is changed from inlet port to
outlet port and viceversa. Theoretical output torque is as follow
formula.
p× q
T = -------------
2× π
p : Effective Pressure (kg/cm2)
q : Displacement (cc/rev)
Low Press. Oil High Press. Oil
Swash Plate (3) Shoe (2) Piston Cylinder Block (4)

Outlet Port Inlet Port
F1
F
F2
Drive Shaft
Valve Plate (1)

FG007419
Figure 2 Diagram Showing the Working Explanation

Page 10
Valve Casing Part
1. Anticavitation check valve

The motor can be rotated faster than supplied oil flow
because there is no counterbalancing valve to prevent over
speed;
to prevent cavitation of the motor, oil compensation
insufficient flow is drawn through the anti-cavitation check
valve. C Port
2. relief valve: KRD22EK10C (See Figure 4 on page -12)

We consider that port P is applied pressure by tank Control Valve FG007421
pressure.
Figure 3
Port P, R are affected by tank pressure at first, as shown
fig. 3-(1). The relief valve starts operating when the force
that is determined by multiply the pressure area (A1) of
plunger (301) by pressure P1 is equal to the sum spring
(321) force (Fsp) and the force that is determined by
multiply the pressure area (A2) by pressure Pg of room 'g'
in the plunger (301).
Here, Pg is the pressure of room 'g' applied pressure by
passing oil through orifice m. If Pg arrives at the pressure
which is determined by spring (321) pushing the piston
(302), the piston moves to left side. When piston (302)
moves to left side, room 'h' operates as damping room
because of orifice (n) which is designed at the side of
adjustment plug (401) and piston (302). Because of this
mechanism, the pressure of room 'g' increases smoothly
while the piston (302) reaches end of adjustment plug
(401). (Figure 4-(2))
P1 × A1 = Fsp + Pg × A2
P1 = Fsp + Pg × A2
---------------------------------------
A1
If the piston (302) reaches end of adjustment plug (401), it
doesn't move left side anymore. So, the pressure of room
'g' is Ps and spring (321) force is Fsp. (Figure 4-(3))
Therefore, the pressure P changes as shown Figure 4-(4).
The pressure (Ps) of last state is the following equation.
P1 × A1 = Fsp′ + Pg × A2
Fsp′ -
P1 = --------------------
A1 – A2

Page 11
Spring (321) Piston (302) h g
R Port
(1) P Port
(Pressure : P1)
Hyd. Area Al m Plunger (301) Hyd. Area A2 n Adjustment Plug (401)

(Pressure : Pg)
(2)
(3) Pressure : Ps
Pressure : Ps
Ps
(4)
P1
T FG007422
Figure 4 Relief Valve : KRD22EK10C Working Description

Page 12
3. Swing reactionless valve
By the spool's shift in the main control valve, oil is supplied
to Hydraulic motor's A port (or B port), and the poppet of
reactionless valve moves, then it blocks the bypass and
operates swing-device. (Figure 5-(1))
Returning the spool to neutral position, blocks the two
ports of hydraulic motor, but the swing-device tends to
swing by inertia-force. The swing force is transmitted to
hydraulic motor by reduction gear. After the swing-device
stops by brake pressure which is created in B port (or A
port), the swing body tends to shift to the opposite
direction. Because of the brake pressure, the swing device
stops first, and tends to reverse. Although the oil pressure
of B port tries to shift the poppet to left side, the operating
will be delayed by the orifice of the A port. Now, forms
bypass between A port and B port, and the pressure oil in
B port flows into A port through the bypass. (Figure 5-(2))
And the B side poppet moves to left side till blocking the
bypass. (Figure 5-(3)) At the reverse pressure generating
process of B port, this process prevents the reverse and
stop the motor by bypassing the pressure oil to A port.
Motor Inlet Motor Outlet

A Port B Port
Bypass Way
Orifice Poppet
Bypass Way
FG007423
Figure 5 Swing Reactionless Valve Working Description

Page 13
4. Brake part
The swing brake is spring applied and hydraulically
released. Friction plate are splined to and rotate with
cylinder block (111). separation plates (743) are splined to
the motor casing (301). When the swing controller blocks
pilot pressure at port (SH), the brake springs (712) apply
force on brake piston (702) squeezing the separation and
friction plates together to prevent the upper structure from
swinging.
Oil Press
Spring Force
310
309 305
306
Oil Pressure
301
201 205
FG007424
Figure 6 Brake Working Description

Page 14
Precaution in Use
Inspection
Before installation of a new motor, inspect the following items.
1. Inspect whether or not there is any damage during transit,
or if any parts are lost or missing.
2. Inspect each tightened part to see if it is loose or not.
3. Check whether or not covers for flange surfaces and drain
ports are perfect, and if the inside of the motor is dirty with
intruded dust.
Rotation Direction
The relation between the oil flow and the revolutionary direction
of the shaft is self-explanatory as shown in Figure 7 and table.
The revolutionary direction of a motor vary according to the
slope surface of casing.
Pay attention to discriminate between geometry of casing and
the direction of flange as the direction of tilting angle.
Anti-clockwise Clockwise (Attach a label M type)

FG007425
Figure 7 Brake Working Description
Revolutionary Direction of Shaft

Direction Inlet Port Outlet Port
Facing the Shaft Side
counterclockwise A B Right-handed
Clockwise B A Left-handed

Page 15
External Load of Shaft
Pay attention to the shaft of motor in order not to apply radial or
thrust load.
Hydraulic Fluids and Range of Temperature

1. Mineral oil
Please use a highly viscosity index working fluid which has
additions of anti-foam agent, oxidation inhibitors, corrosion
inhibitors, viscosity index improvers, oiliness agent and the
oil with a high viscosity.
2. Optimal viscosity and temperature (Figure 8)
To obtain the highest performance of the motor, oil which
has a viscosity in a range of 10 to 200 cst is most suitable.
But, a viscosity in a range of 10 to 1000 cst is allowable.
The range of working temperature is limited to -25°C -
-100°C because of the oil seal, O-ring. Further, the
deterioration of the working fluid becomes excessive
beyond 65°C; therefore, it is desirable not to exceed 60°C.
Higher Limits of Viscosity
Higher Temperature Limit

Low Temperature Limit
Optimum Working Range
Low Viscosity Limit
Figure 8 The Proper Range of Viscosity and Temperature FG007426

Page 16
3. Except mineral oil
Incase if using special fluid (phosphate ester compounds,
water-glycol, fluid fatly acid ester compound, etc.), please
consult us for instruction before use.
Filter
If fine particles of dirt and metal are mixed with oil, they enter
into sliding surfaces and accelerate wear in each part, and in the
worst case seizure will be likely to occur.
It is recommended, therefore, that customer not only take
necessary measures to prevent oil from contamination with such
fine particles but also provide an oil filter in the circuit without fail.
For satisfactory service life of these motors in application, the
operating fluid must be continuously filtered to the minimum
cleanliness level of class 9 of NAS. Also, install a 10μ filter in the
hydraulic circuit and MILLIPRE FILTER pollution level
recommends below 2 - 4 mg/100 cc.
Installation and Piping

1. When the motor is installed, its shaft should face
downward.
2. The motor must be installed that it is concentricity below
0.05 mm or less.
3. The tightening torque of bolts for mounting the motor to the
bracket is shown in assembly drawing the customer's
reference.
4. The casing inside should always be kept filled with oil. The
drain must be positioned in such a place as shown in
Figure 9.
5. Motors will tolerate in the casing pressure up to maximum
3 kg/cm2, but for common pressure, 2 kg/cm2 below must
be kept.
6. Piping must be cleaned and flashing well. Figure 9
7. Be care to as the installation to piping.
8. Use the drain pipe bigger than the port size and short as
possible.

Page 17
Oil Filling and Air Bleeder
1. Fill in the casing with oil by using the drain port before the
operating.
In the motor, there are many kinds of high-speed sliding
surface like bearing, piston, shoe, spherical bushing, and
etc. So If there isn't enough oil, can cause problems like
sticking or breaking in those parts.
Use the PF 1/4 port for venting air.
2. All the air in the motor and circuit must be removed,
otherwise, it will be likely to be cause of imperfect working Air
or a damage of the motor. Bleeder
Precaution in Starting Operations

1. Check if the direction of revolution is correct or not.
2. Check whether or not there is any leakage of oil from the
motor. FG007427
FG007427
Figure 10
3. Check if the equipment vibrates abnormally or not during
operation or when the revolution direction is changed.
4. Check if the oil temperature rises rapidly despite running
for a short period of time.
5. Check whether the pressure varies to a great extent as
compared with the established one.
6. Check if the piping is fully connected or not.

Page 18
Troubleshooting
General Precautions
Here, counter-measures to be taken when troubles have
happened while the motor is in operation are described.
As for general precaution.
1. Consider a cause of the trouble before repairing. Before
setting to work, think whether the same thing has
happened before or not.
Also, think again whether it is the motor that is the cause.
2. Be careful of foreign material.
It is not too much to say that most troubles are ascribed to
dust so take care to avoid foreign materials during
disassembly and reassembly.
3. Handling part
Pay attention to the handling of parts not to damage them,
especially to moving parts such as pistons, bearing and
valves etc.
4. Pay attention when handling O-rings and gaskets. Once
seals have been disassembled, they must be replaced
even if damage is not observed.
Examination of the Motor Body

It is extremely difficult to trace trouble in the hydraulic circuits.
Inspect the following items and investigation whether or not the
fault is caused by the motor.
1. Inspection the oil in casing
Remove drain plug and inspect the hydraulic oil in the
casing. If a large amount of metallic particles come out with
the oil, you should suspect a failure of internal parts.
2. Presence of abnormal noise
Check whether the motor emits an abnormal noise.
3. Pressure measurement of various points.
Measure pressures at various points and check for faults,
instead of disassembling parts at random.
4. Measurement of drain quantity
A. In the case of locking the swing and adding the
pressure oil to motor, it's normal the drain rate would
be about under 25 (10) lpm
B. In normal swing mode, the drain rate would be under
2 (1) lpm
Where ( ) is TSM72.

Page 19
Condition and Countermeasures of Troubles
1. Motor does not rotate
Condition Cause Remedy

The pressure of the 1. Setting pressure of relief valve is 1. Reset the pressure to correct
circuit is not incorrect. value.
increasing
2. Working defectiveness of relief 2.
valve.
1) Plunger stick. 1) Revise or exchange of stick
face.
2) Plugged up an orifice hole of
plunger. 2) disassembly or cleaning.
3. Seat defectiveness of plunger. 3. Replace damaged seat part.
The pressure of the 1. Overload. 1. Load removes.
circuit is increasing
2. Stick of moving parts. 2. Do repair or inspect the piston/
shoe, cylinder block, valve plate
etc.
3. The brake does not release. 3.
1) Do repair or inspect circuit
2) Check the break valve.
3) Assembly and inspection.
4) Assembly and inspection.
Replace the sticking parts.
4. Sticking of brake piston.
5. Sticking of friction plate.
2. The revolutionary direction is reverse

The revolutionary 1. The revolutionary direction of 1. Reassemble correctly.
direction is reverse motor is reverse.
2. Correct piping.
2. The inlet and outlet in piping is
reversely connected.
3. The number of revolution does not reach the established

value

The number of 1. The volume of flowing is not 1. Check discharge volume of pump
revolution does not sufficient. and circuit up to the motor.
reach the established
2. The temperature is too high and 2. Reduce the oil temperature.
value
too much oil is leaking.
3. Valves/pistons/rings etc. are worn 3. Replace it.
away and broken.

Page 20
4. Brake torque is not sufficient.

Brake torque is not 1. Friction plates are worn. 1. Disassembly or inspection.
sufficient Replace the part if excessively
worn.
2. Brake piston is becoming sticking. 2. Disassembly or inspection
3. Brake releasing pressure is not 3. 1) Check for the circuit.
working.
2) Check for the brake valve
4. Spline of friction plates are
4. Disassembly or inspection.
damaged.
1) Replace for damaged parts.
5. Motor is much slip

Investigates the DRAIN quantity for motor.
Normal: app. 200 cc/min (TSM140:500 cc/min)

Motor is much slip 1. Working defectiveness of relief 1. It is the same 1) an item
valve is the same 1) an item.
2. Seat defectiveness of plunger. 2. Replace it.
6. Oil Leak
A. Oil leak from the oil seal

Oil leak from the oil 1. The lip is dirty or damaged. 1. Replace the oil seal.
seal
2. The shaft may be damaged or 2. Replace the driving shaft or
worn out. defective centering of the driving
shaft.
3. The lip is damaged from too 3. Repair the drain piping which is
high-pressure in the casing. closed up.
4. The shaft is rusty. 4. Disassemble, repair, and replace
the oil seal.
B. Oil leak from the blind and union

Oil leak from the 1. O-ring is not in. 1. Insert O-ring.
blind and union
2. O-ring is broken. 2. Replace it.
3. Seal face is defective. 3. Disassemble or repair.
4. The bolt is loose or not tightened. 4. Tighten adequately or replace it.

Page 21
MAINTENANCE MANUAL
Disassembling and Assembling
Tightening Torque of Bolts

In table 1. is shown tightening torque of bolts used in motor. In
case of reassembling, tighten accurately each bolt according to
table 1.
Table 1
Tightening Torque
Bolt Size Name Part No.
(kg•cm)
M6 Hexagon Bolt 120 ±20 400
M20 (M16) Hexagon Socket Bolt 4,400 ±660 (2,400 ±360) 109
M22 RO Plug 1100 ±100 105
M36 (M24) RO Plug 2,450 ±250 (1,300 ±100) 105
PF 1/4 Plug 370 ±20 111
M33 Relief Valve 1,800 ±100 105

Page 22
Necessary Tools
In table 2, 3 Figure 11. is shown necessary tools for
disassembling and reassembling.
Table 2
Name Size 2-face width Application part Tool

Hexagon bolt M6 10 Brake valve Hexagon wrench socket wrench
Hexagon socket bolt M20 (M16) 17 (14) Hexagon wrench
Plug M22 10 RO plug Hexagon wrench
Plug M36 (M24) 17 (12) RO plug Hexagon wrench
Plug VP-1/4 19 VP plug Hexagon wrench socket wrench
36 Relief valve Hexagon wrench socket wrench
Table 3 etc.
Spec.
Dimensions
Tool
Pliers (For lock ring) For ø65 axis (ø50)
Driver - Type 2 ea
Steel rod About 10 x 8 x 200 1 ea
Hammer One each of plastic hammer and metal hammer.
Torque range
• For 100 - 450 kg•cm
Torque wrench
• For 400 - 1,800 kg•cm
• For 1,200 - 4,800 kg•cm
Slide hammer bearing pliers
Special tool for removing the break piston page 24 reference

Page 23
2x 7
40
M10
(Effectiveness
Screw Length : 20)
100
250
11
M10
9 7 M10
136
169 (TSM140)
240
FG007428
Figure 11 Special Tool for Removing the Brake Piston

Page 24
Procedures for Disassembly
Please use the following procedures for the inspection and
repair of the motor.
Numerals given in parentheses following the parts names
indicate the parts number shown by the drawing in the
instruction and maintenance manual.
1. Wind the wire rope at motor outside, lift up the motor, and
clean the motor with cleaning oil.
After cleaning, dry with compressed air.
2. Draw the oil out of the casing (301).
3. Mount on a suitable table for the driven-axis (201) below.
Before disassembling make a match mark on motor casing
(301) and valve casing (101).
FG001856
Figure 12
4. Remove brake valve (400).
FG001857
Figure 13
5. Remove relief valve (107) from valve casing (101).
FG001858
Figure 14

Page 25
6. Remove RO plug (102) and remove spring (103) and
plunger (104) from valve casing (101).
FG001859
Figure 15
7. Remove swing reactionless valve ass'y (105) from valve

casing (101).
FG001860
Figure 16
8. Remove hex socket bolts (109, 110) and disassemble

valve casing (101) from casing (301) (When loosening
bolts, the valve casing will be raised by brake springs
(310). Remove valve plate (213) from the valve casing
(101).
FG001861
Figure 17
9. Remove brake springs (310) from the brake piston (309).
FG001862
Figure 18

Page 26
10. Disassemble brake piston (309) from casing (301) by using
the special tool for removing the brake piston.
Lift it up straight by using the bolt hole in the brake piston.
FG001863
Figure 19
11. After placing the motor horizontally, remove cylinder block

(205) from casing (301).
Remove piston ass'y (203, 204), retainer (207), spherical
bushing (206), spacer (208).
When taking out the cylinder block, be careful not to pull
out roller (209).
Be careful not to damage the sliding parts of the cylinder
block, spherical bushing and shoe.
Washer (210, 2 ea), spring (211), retaining ring (212) are FG001864
not disassemble at the disassembled cylinder block. Figure 20
12. Pull out friction plate (306, 2 ea) and separation plate (305,
3 ea) from casing (301).
(TSM72: friction plate: 3 ea, separation plate: 4 ea)
FG001865
Figure 21
13. Remove swash plate (202) and driveshaft with ball bearing
(303) from casing (301)
Be careful not to damage the ball bearing (303) and oil seal
contact surface.
If you beat a driveshaft end with plastic hammer, it is easy
to be disassembled.
FG001876
Figure 22

Page 27
14. Do next step if required.
A. Remove parallel pin (304) from casing (301).
FG001867
Figure 23
B. Remove ball bearing (303) with a press from the

Press
driveshaft (201).
Strike the rod lightly and do not reuse the Drive Shaft
disassembling bearing.
Ball Bearing
Press Table Hangs

in the Inner Ring.
FG007429
Figure 24
C. Remove oil seal (302) from the casing (301) with a

Press
jig.
Do not reuse the disassembling oil seal (302). Drive Shaft
Ball Bearing
Press Table Hangs

in the Inner Ring.
FG007429
Figure 25
D. Remove ball bearing from the valve casing (303).
FG001870
Figure 26
15. Disassembling is finished, check each component

throughly.

Page 28
Procedures for Assembly
Following are caution to be specially borne in mind.
A. Repair damaged parts and before assembling and
prepare all parts to be replaced.
B. Clean all parts and dry with compressed air.
C. Coat the sliding parts and bearing with clean
hydraulic oil.
D. Replace O-ring, oil seal.
E. For the mounting of bolts to install the various parts,
please use a torque wrench, etc. and tighten the bolts
with the torque shown in table 1.
1. Place casing (301) on the work table with the valve casing
side downward.
FG001871
Figure 27
2. (This procedure is only necessary when oil seal was

disassembled from the casing.)
Insert oil seal (302) at the casing (301) with a using of tool.
(Be careful to note the direction of oil seal. and insert until
fully seated at the casing end.)
FG001872
Figure 28
3. (This procedure is only necessary when ball bearing was

disassembled from the driveshaft.)
Ball bearing (303) is press fit by the heat to driveshaft
(201).
FG001873
Figure 29

Page 29
4. Insert the driveshaft (101) complete with ball bearing into
casing (301).
Impact the outside surface of outer loop uniformly till stop
at casing section.
Coat the lip of the oil seal with grease and tape the shaft
spline for the protection of spline.
Tap evenly.
FG001874
Figure 30
5. (This procedure is only necessary when parallel pin was

disassembled from the casing.)
Assemble parallel pin (304) to casing (301).
FG001875
Figure 31
6. Assemble swash plate (202) to casing (301).

If casing is horizontal position from the bottom, It is easy to
work.
FG001876
Figure 32
7. Insert roller (209) to cylinder block (205).

Make sure that cylinder block is assembled with all
component.
(washer (210), spring (211), ring snap (212))
(Be careful not to damage the sliding surface of the
cylinder block. Insert roller to each hole one by one.)
FG001877
Figure 33

Page 30
8. Place spacer (208), spherical bushing (206) to the cylinder
block (205).
FG001878
Figure 34
9. Assemble the retainer with the piston sub assembly (203,

204) unit to the cylinder block (205).
FG001879
Figure 35
10. Insert cylinder block to driveshaft (101) aligning the spline.
FG001864
Figure 36
11. Place casing (301) downward and assemble separation

plate (305, 3 ea) and friction plate (306, 2 ea) in sequence.
Align 4 tangs to the notches.
Align cut the jaw and assemble that part.
(TSM72: friction plate: 3 ea, separation plate: 4 ea)
FG001880
Figure 37

Page 31
12. Mount O-ring (307, 308) to casing (301).
(Coat the O-rings with grease to protect it.)
FG001881
Figure 38
13. Assemble brake piston (309) to casing (301).

The piston is difficult to assemble because of the restriction
of the O-ring; screw in two M8 bolts on the brake piston
and tap them gently with plastic hammer.
FG001882
Figure 39
14. Assemble brake springs (310) into brake piston (309).

Confirm the springs are fitted to the brake piston
completely.
FG001862
Figure 40
15. (This procedure is only necessary when ball bearing (108)

was disassembled from the valve casing.)
Assemble of ball bearing (108).
Insert it to valve casing (101) while tapping it lightly.
Tap evenly on the outer diameter of the outer race with a
brass drift until it completely stops.
Do not use a steel punch or bar on the bearing since it can
chip or crack the race.
FG001884
Figure 41

Page 32
16. Assemble valve plate (231) to valve casing (101) and
install O-ring (113).
Be careful to note the direction of the valve plate.
Mount the valve plate with its round part toward the
opposite side of the flange.
Coat lightly with grease.
FG001885
Figure 42
17. Mount valve casing (101) to casing (301) and tighten hex
socket bolts (109, 110) to specification.
Be careful to note the mounting direction of the valve
casing. (Reference to the drawing)
Be careful not to drop the valve plate or let the brake
springs pop out.
Tighten the bolts evenly.
FG001886
Figure 43
18. Install plunger (104) and spring (103) to valve casing (101)
and tighten RO plug (102) with O-ring (106).
Confirm the smooth movement of the plunger before
installing the plug.
FG001887
Figure 44
19. Install swing reactionless valve assembly (105) to valve

casing (101).
Confirm the spring in the swing reactionless valve
assembly (105).
FG001888
Figure 45

Page 33
20. Assemble relief valve (107) with O-ring to valve casing
(101).
FG001858
Figure 46
21. Assemble brake valve (400) to casing (301) and tightening

the hex socket bolts to specified torque.
FG001856
Figure 47
22. The assembly is completed.

Page 34
Maintenance Standards
Standards for Replacement of Worn Parts

If the various parts of the motor have been worn out beyond the
following standard values, please replace them. But this shall
apply only to those cases when there is no remarkable outside
damage.
Recommended
Standard Value for
Item Remedy
Dimension (mm) Replacement
(mm)
Clearance between piston and Replace piston or cylinder
0.025 (0.036) 0.055 (0.066)
cylinder bore block.
Gap between piston and caulked Replace piston or shoe.
0.05 0.2
part of shoe (δ)
Thickness of shoe (t) 4.5 (6.5) 4.3 (6.2) Replace piston or shoe.
Assembled height of retainer Replace sperical bushing and
10.8 (13.0) 10.3 (12.5)
(H-h) retainer as a pair.
Thickness of friction plate 3.5 3.1 Replace it.
H
h
Gap between piston and caulked part of shoe (δ). Assembled height of retainer (H-h)
Thickness of shoe (t)
Standard for Correcting Sliding Surfaces

If the surface roughness of the sliding surface of a part exceeds
the following standard, correct it or replace the part.
Table 4 Revise standard
Item Surface Roughness Roughness Requiring Correction
Shoe 0.8 - Z (Ra = 0.2) (Lapping) 3 - Z (Ra = 0.8)
Swash Plate 0.4 - Z (Ra = 0.1) (Lapping) 3 - Z (Ra = 0.8)
Cylinder Block 1.6 - Z (Ra = 0.4) (Lapping) 12.5 - Z (Ra = 3.2)
Valve Plate 0.8 - Z (Ra = 0.2) (Lapping) 6.3 - Z (Ra = 1.6)
NOTE: Lap each sliding surface to a standard roughness

level or finer.
If the sliding surface of the cylinder block, valve plate,
retaining plate.

Page 35
Page 36
SP002920
TRAVEL DEVICE SP002920
Travel Device
Edition 1
Travel Device SP002920

Page 1
MEMO

Page 2
Table of Contents
Travel Device
Product Overview ................................................. 6
General Specifications .................................................... 6
External Dimensions............................................. 7
Operating Description ......................................... 11
Reduction Gear ............................................................. 11
Hydraulic Drives ............................................................ 12
Precautions for Use ............................................ 20
Installation (Refer to Diagram of External Dimensions) 20
Tubing ........................................................................... 21
Fluid Selection............................................................... 21
Maintenance and Inspection............................... 22
Daily Inspection ............................................................. 22
Changing Fluid .............................................................. 23
Changing Lubrication .................................................... 23
Seals Table......................................................... 25
Troubleshooting .................................................. 26
Outline of Maintenance....................................... 28
Tools.............................................................................. 28
Bolts .............................................................................. 28
Equipments ................................................................... 29
Fabricated Tools............................................................ 29
Torque ........................................................................... 33
Weight Table ................................................................. 33
Disassembling .................................................... 34
Work Preparation .......................................................... 34
General Precautions for Work ....................................... 34
Disassembling Order..................................................... 35
Maintenance Standards...................................... 52

Page 3
Seals ............................................................................. 52
Maintenance Standards for Wearable Parts ................. 52
Assembling ......................................................... 54
Preparation.................................................................... 54
General Precautions for Assembling Work ................... 54
Order of Assembling...................................................... 55

Page 4
SAFETY INSTRUCTIONS
WARNING
machine. Read and understand the Operation &
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up
DX140LCR-3 1001 and Up

Page 5
PRODUCT OVERVIEW
This product is a hydraulic driven rotary actuator.
The product contains a reduction gear, hydraulic motor, brake
valve and parking brake in one compact unit. It has been
developed for use as an actuator for application requiring low-
rpm, high torque operation such as construction and marine
machinery.
General Specifications
Item Units Spec
Rated Output Torque kg•m 2,100
Max. Speed min -1 60
Reduction Ratio 1/54.0
Max. Displacement cc/rev 82.8
Max. Speed min-1 3,000
Hydraulic Motor
Max. Pressure kg/cm2 355
2-speed Control Press kg/cm 2 20 - 70
Brake Torque (min) kg•m 21
Parking Brake
Brake Free Pressure kg/cm2 7.7

Page 6
EXTERNAL DIMENSIONS
Figure 1

Page 7
GENERAL DESCRIPTION
Figure 2

Page 8
Reference Reference
Description Q’ty Description Q’ty
Number Number
1 Hub 1 109 Timing Plate 1
2 Spindle 1 110 Washer 2
Carrier Assembly (1) 1 112 Piston 1
3 Carrier (1) 1 113 Spring 10
5 Planetary Gear (1) 3 114 Spring 1
6 Carrier Pin (1) 3 115 Friction Plate 3
11 Thrust Washer (1) 6 116 Mating Plate 4
16 Parallel Pin (1) 3 132 Oil Seal 1
27 Needle Roller Bearing 3 135 O-ring 1
Carrier Assembly (2) 1 139 O-ring 1
7 Carrier (2) 1 145 Retaining Ring 1
9 Planetary Gear (2) 3 149 Ball Bearing 1
10 Carrier Pin (2) 3 150 Ball Bearing 1
12 Thrust Washer (2) 6 151 Needle Roller 3
17 Parallel Pin (2) 3 Piston Assembly 1
28 Needle Roller Bearing 3 161 Piston 1
4 Sun Gear (1) 1 162 Shoe 1
8 Sun Gear (2) 1 167 Pivot 2
13 Thrust Plate 1 171 Parallel Pin 2
14 Cover 1 185 Spring 1
15 Coupling 1 Relief Assembly 2
22 Lock Washer 2 201 Valve Seat 1
23 Shim 1 202 Valve 1
24 Angular Ball Bearing 2 203 Sleeve 1
Floating Seal Kit 1 204 Collar 1
29 Floating Seal 2 205 Plug 1
30 Plug 3 206 Spring 1
31 O-ring 3 207 O-ring 1
32 O-ring 1 208 Back up Ring 2
33 O-ring 2 209 O-ring 1
34 Parallel Pin 2 210 Back up Ring 2
35 Hex. Socket Bolt 12 211 O-ring 1
36 Retaining Ring for Hole 1 212 O-ring 1
102 Shaft 1 213 Shim 1
103 Swash Plate 1 Rear Flange Assembly 1
Cylinder and Piston Kit 1 Rear Flange Kit 1
Piston Kit 1 Spool Assembly 1
Piston Assembly 9 323 Spool 1
105 Piston 1 326 Plug 2
106 Shoe 1 327 Valve 2
104 Cylinder Block 1 330 Spring 2
107 Retainer Plate 1 331 O-ring 2
108 Thrust Ball 1 301 Rear Flange 1

Page 9
Reference Reference
Description Q’ty Description Q’ty
Number Number
324 Plug 2 379 Plug 1
325 Washer 2 380 Plug 2
328 Spring 2 381 Piston 1
329 Orifice 2 383 O-ring 2
336 O-ring 2 384 Orifice 2
352 Plug 3 396 Hex. Socket Plug 2
353 Steel Ball 2 398 Hex. Socket Plug 5
354 Hex. Socket Plug 5 399 Nameplate 1
357 Plug 1 341 Parallel Pin 1
358 O-ring 3 343 Hex. Socket Bolt 10
359 O-ring 1
363 Spool 1
366 Spring 1
376 Orifice 1
377 Filter 1
378 Steel Ball 1

Page 10
OPERATING DESCRIPTION
Reduction Gear
Function
This reduction gear unit is composed of two stage planetary
gear mechanism.
The reduction gear reduces the high-speed of hydraulic motor
and converts it to low-speed, high-torque rotation.
Operating Description
The rotation of hydraulic motor shaft is transmitted to sun gear
(4) of the first stage which is linked with shaft (102) in spline.
At that time, the hub (1) is rotated by the rotation of the planetary
gears (5).
The hub (1) rotation is transmitted to carrier (3) which connected
to planetary gears (5), and that causes sun gear (6) rotation of
the second stage.
The rotation of sun gear (6) is transmitted to the hub by three
planetary gears (7) of the second stage.
The generated rotation of reduction gear is output rotation.
Planetary gear (7) Planetary gear (5)
Sun gear (4)

Shaft (102)
input output
Spindle (2)
Sun gear (6)

Carrier (3)
Hub (1)
FG009760
Figure 3

Page 11
Hydraulic Drives
Function
1. Hydraulic motor
This hydraulic motor is a swash plate type axial piston
motor, converting the hydraulic force from the pump to
rotary motion.
2. Brake valve
A. Controls inertia when stopping the hydraulic motor to
provide smooth stopping.
B. Prevents runaway rotation when the hydraulic motor
is rotated by external force.
This is done by preventing hydraulic cavitation.
C. Prevents the generation of abnormally high-pressure
when the hydraulic motor is stopped suddenly.
3. Parking brake
The parking brake prevents the hydraulic motor from being
rotated by external force while stopped. A friction plate
type mechanism is used, constructed so as to form one
unit with the hydraulic motor.
4. High-low 2-speed switching mechanism
Switches the hydraulic motor between high-speed rotation
with low torque, and low speed rotation with high torque.

Page 12
Operating Principles and Description
1. Hydraulic motor
Hydraulic fluid fed from the hydraulic pump enters the GM
motor through the rear flange (101), passes through the
brake valve and timing plate (109) and enters the cylinder
block (104). This hydraulic fluid is fed only into one side of
a line connecting the upper and lower dead points (Y1 -
Y2) of the piston stroke (105). The hydraulic fluid pushes
each of the pistons (105), creating force F(= P x A). This
force operates on the oblique surface of the swash plate
(103). Force F is separated into components F2 and F3
according to the angle θ of the oblique surface. Of the two
components, the radial component force F3 generates
torque (= F3 x ri).The sum of the torque T(= ∑(F3 x ri) of
each of the pistons (105) is the rotary force of the hydraulic
motor. This rotary force passes through the pistons (105)
and rotates the cylinder block (104) and the shaft (102).
Figure 4

Page 13
2. Brake valve
A. Operation (Brake released)
The pressure oil is led to through port (A), opens
valve (327), and led to port (C) on the section side of
hydraulic motor to rotate hydraulic motor.
At the same time, the pressure oil enters chamber (a)
through orifice (329), and exerts on the end of spool
(323) to generate the force.
Then the force of spring (328) slides the spool (323)
placed on the neutral position leftward.
The sliding of spool (323) forms the space (passage)
between spool (323) and rear flange (301) with spool
groove.
This passage is connected to port (D) and port (B) of
the return circuit of the hydraulic motor, and the oil
returns to tank side, enabling hydraulic motor to
rotate.
Then, the sliding of spool (323) leads pressure oil to
port (E). The pressure oil led to port (E) moves piston
(112) of parking brake, and releases parking braking
force. (For details, refer to item "Parking brake".)
If pressurized oil is supplied from port (B), the
movements of spool (323) and valve (327) are
reversed so hydraulic motor is rotated reversely.
Figure 5

Page 14
B. Stop/Stall (Braking operation)
If pressurized oil supply through the port (A) is
suspended while traveling, the hydraulic force to
push up the spool (323) is lost, and the spool (323)
which is slid to left side, tries to return to the neutral
position because of the spring (328) force. At that
time, through the oil in the chamber (a) tries to flow
out to the port (A) side through the orifice (329), its
flow is restricted and some back pressure is
generated by the throttle effect in the orifice (329)
controlling the return speed of the spool (323). At the
same time, the hydraulic motor tries to rotate with its
inertia force even though the pressurized oil is
suspended, and the return oil from the hydraulic
motor tries to return to the port (B) side from the port
(D) through the passages on spool groove and rear
flange (30l).
When the spool (323) entirely return to neutral
position, the passage on the hydraulic motor of the oil
return side is completely closed by the spool (323),
and the hydraulic motor ceases its rotation. While
machine working, the brake valve smoothly stops
rotation of the hydraulic motor which tries to rotate
with its inertia force, using throttling the return side
passage of the hydraulic motor, generating back
pressure because of shape of the spool groove and
controlling the return speed of the spool. On the other
hand, when braking is operated, the hydraulic motor
tries to rotate with its inertia force and to intake oil
with its pumping function. However, because the
intake side is closed its passage with the spool (323),
the oil supply is suspended. This causes cavitation in
the hydraulic motor. To prevent the cavitation, the
valve (327) is operated by very slight negative
pressure to open the passages of port (A) side and
intake port (C) of the hydraulic motor.
When pressurized oil is supplied through the port (B),
each motion of the mentioned parts above becomes
symmetrical right and left to stop the hydraulic motor.

Page 15
Figure 6

Page 16
C. Self-traveling
While machine is being operated, as the travel speed
is increased because of steep slope, the oil flow rate
of the hydraulic motor is higher than the supply flow
rate of the hydraulic oil pump.
The rotation of the hydraulic motor in this case is
called a self-traveling. (Overrun)
While self-traveling, the pressure is lowered similar to
the stopping condition. Then brake valve is moved
similar to the stopping condition, throttles passage in
the return side of hydraulic motor, and generate
backing pressure.
In addition, the force of inertia decreases the
revolution of hydraulic motor to revolution having a
balance with the supply flow rate of pump.
Figure 7

Page 17
3. High-low 2-speed switching mechanism
A. Low speed
When the pilot pressure is not supplied through the
port (P), the valve (363) is pushed up to the upper
position because of the spring (366) force and
pressurized oil through the port (A) or (B), the
pressurized oil is cut off at port (C), and oil in the
chamber (W) is released into the drain (motor case)
through the valve (363).
Accordingly, the tilt angle of the swash plate (103)
becomes the maximum θ 1 resulting the maximum
stroke volume and low speed rotation of the hydraulic
motor.
Figure 8

Page 18
B. High-speed
When the pilot pressure is supplied through the port
(D), it defeats the spring (366) force and pressurized
oil through the port (A) or (B) to push down the valve
(363) to lower position, the pressurized oil at the port
(C) is led to the chamber (P) through the valve (363),
and the piston (161) pushes the swash plate (103) up
to the plane X and maintain it at its position. At that
time, the tilt angle of the swash plate becomes the
minimum θ 2 resulting the minimum stroke volume
and high-speed rotation of the hydraulic motor.
Figure 9

Page 19
PRECAUTIONS FOR USE
Installation (Refer to Diagram of External

Dimensions)
Before installation remove plugs from oil level check ports, and
confirm that reduction gear oil has penetrated as far as the oil
level check ports.
CAUTION
AVOID INJURY
When lifting a GM motor for transportation or installation,
never stand or work under the GM motor.
Figure 10
During installation, never hit the GM motor with a hammer or

similar instrument.
NOTE: Use mounting bolts of JIS strength class 10.9 or
equivalent.
Mounting Bolt Torque
Thread Bolts Strength

Q'ty Torque
Dimensions Class
252 ±39.2 Nm
Main Unit Mounting Bolts 20 M16 (P2.0)
(25.7 ±4.0 kg•m) JIS B1051 Class
252 ±39.2 Nm 10.9 or Higher
Drive Unit Mounting Bolts 15 M16 (P2.0)
(25.7 ±4.0 kg•m)

Page 20
Tubing
During delivery, ports are covered with plugs or other coverings.
This is to prevent entry of dust, welding scale, etc. Coverings
must be removed before connecting tubing.
WARNING
Before connecting tubing, confirm the direction of GM
motor rotation, and the position of the ports. (Refer to
Diagram of External Dimensions.) Failure to do so can
result in reverse rotation of the motor resulting in death or
serious injury.
NOTE: Before operating the motor, always fill the motor

casing with hydraulic fluid.
Required oil volume in casing: 1.0 liters
Failure to do this can result in early damage to the
hydraulic motor.
Select tubing sizes for drain port back pressure of 0.2 MPa
(2 kg/cm2) (maximum 0.69 MPa (7 kg/cm2)at peak) or less.
Fluid Selection
Selection of hydraulic fluid-recommended grades
1. Use ISO VG32 or VG46 anti-friction hydraulic fluid.
2. Control hydraulic fluid purity to NAS Class 9 or better.
3. Ensure that working fluid operating temperature range and
viscosity range do not exceed the following limits.
Operating temperature range: -10 to +80
Effective viscosity range: 15 to 500 mm2/s
4. Consult the manufacturer before using any hydraulic fluid
other than listed below.
Viscosity (40°C) 32 (mm2/s) 46 (mm2/s) 56 (mm2/s)

Grade
ISO equivalent VG 32 VG 46 *VG 56
Showa Shell Shell Tellas Oil 32 Shell Tellas Oil 46 Shell Tellas Oil 56
Daphne Super Daphne Hydraulic
Idemitsu
Hydro A32 Fluid A46
Cosmo Hydro Cosmo Hydro (Cosmo Hydro
Supplier Cosmo
AW32 AW46 AW56)
Nippon Oil Super Highland 32 Super Highland 46 Super Highland 56
Mobil DTE Oil 24 DTE Oil 25
Japan Energy JOMO Hydrax 32 JOMO Hydrax 46
* VG56 is the support viscosity grade that is prescribed by JIS.
However, it was abolished in March, 1983.
Please use other viscosity grades as much as possible.

Page 21
MAINTENANCE AND
INSPECTION
Daily Inspection
The following daily maintenance and inspection items must be
verified before operating the GM motor.
WARNING
To prevent accidental movement of machine, position
excavator in open area and stop engine before inspecting
or servicing. Allow components to cool down before
touching or servicing.
1. No oil leakage (Hydraulic fluid, lubricating oil)

2. No loose bolts
3. No abnormal sounds
4. Casing temperature not abnormally high
(Maximum external casing temperature during continuous
operation = 80°C)
5. Change interval of lubricating oil. (Refer to page -23)
CAUTION
AVOID INJURY
Prevent burn injuries. Allow motor casing to cool
down after operation and before servicing motor.

Page 22
Changing Fluid
The standard interval for changing hydraulic fluid is every 1,000
hours or one year.
Hydraulic fluid may be changed within the standard interval if
there is significant reduction in volume, subject to the following
standards.
Test item Change standard

Viscosity change (40°C) ±10%
Consult oil supplier.
Total oxidation (mg KOH/g) Additive types vary according
to manufacturer.
Water content (%) 0.1%
Impurities 10 mg/100ml
Impurities (%) 0.05%
Changing Lubrication
Reduction gear lubricating oil (gear oil) is added at time of
delivery.
1. Selecting gear oil - recommended grades
A. Use SAE 90 equivalent gear oil (API type GL-4 or
higher) with ultra-high-pressure additives.
B. Recommended product names follow:
Supplier Product Name

Idemitsu Appoloil Gear HE 90
Esso Esso Gear Oil GP 90
Showa Shell Shell Spirax EP 90
Cosmo Cosmo Gear Oil GL-4 90
Nippon Oil Hypoid Gear Oil SP 90
Mobil Mobilube HD 90
Japan Energy Gear 4
2. Gear oil change interval

A. First change (initial change after starting operation)
after 500 hours
B. Second and the following changes: after 1,000 hours
or one year
C. Change standard
Test item Change standard

Viscosity change (40°C) 10% or less of new
(mm2/s) oil.
Water content (%) 0.2 % or less.

Page 23
Avoid mixing different types of lubricating oils. When changing
the type of lubrication oil, be sure to flush the interior of the
reduction gear.
3. Gear oil change volume: 2.1 liters
4. Gear oil change procedure
CAUTION
AVOID INJURY
Prevent burn injuries. Allow motor casing to cool down
after operation and before servicing motor.
NOTE: If gear oil volume is reduced for any reason, be sure

to confirm the cause and take appropriate measures
before filling with gear oil.
When removing gear oil, always dispose of old oil in
an approved container rather than on the ground.
Also, take care to observe applicable laws and
regulations regarding disposal.
Oil may spray out when plugs are removed.
Turn the plug slowly and allow internal pressure to
escape before removing.
Figure 11
1. Stop the GM motor when the oil fill check port is at the top
and the oil drain port is at the bottom (Figure 11).
2. Place the waste oil receptacle below the GM motor.
3. To change oil, remove plugs on the 3 ports, and drain the
gear oil.
To fill oil, do not remove plugs from the drain ports.
• Tightening torque: 98.1 ±19.6 Nm (10.0 ±2.0 kg•m)
After draining the oil, replace the plug on the oil drain port.
4. Add gear oil to the oil fill port.

Page 24
Stop filling just before the gear oil overflows at the oil level
check port.
5. Re-place the plugs on the oil fill ports and level check port.
6. Re-place the plugs on the oil fill port.
SEALS TABLE
Handle sealing parts carefully.
Once disassembled, replace to the new parts even though no
damage is observed.
No. Name of Part Code Q'ty Remarks

3 31
1 O-ring JIS B 2401-P18-90 2 212
1 359
2 Floating Seal ES100-209-B-A-627 2 29
3 O-ring ARP568-261-70 1 32
4 O-ring JIS B 2401-P7-90 2 33
5 Oil Seal TCZ28 x 48 x 10 x 11.3 1 132
6 O-ring 50OD2039-00 1 135
7 O-ring 60OD2039-00 1 139
8 O-ring JIS B 2401-PIOA-90 2 207
2 209
9 O-ring JIS B 2401-P14-90
2 383
10 O-ring JIS B 2401-P11-90 2 211
11 O-ring JIS B 2401-P32-90 2 336
12 O-ring JIS B 2401-P8-90 3 358
13 Back up Ring JIS B 2407-T2-PIOA 4 208
14 Back up Ring JIS B 2407-T2-P14 4 210

Page 25
TROUBLESHOOTING
Please contact our company, when the disposal to which "O"
mark is attached is required.
Problem 1 Problem 2 Possible Cause Action

Relief set pressure is too
Check the main relief valve
low
Pressure will not
Pump failure Repair
increase
Direction switching valve is
Repair
damaged
Motor does not Brake valve failure Replace or repair brake valve O
turn
Hydraulic motor failure Repair O
Pressure does Gear (reduction) damage Replace GM motor O
increase Excessive load applied Remove excessive load
Orifice of parking brake line
Remove foreign materials.
is blocked.
Repair flaws with grinder,
Leaking from mating Flaws in surface O
crocus cloth, etc.
surface
Bolts loose Retighten
Plug loose Retighten
Leaking from case
Cracked by stone etc. Replace GM motor O
Oil leakage Leaking from Worn-out sliding surface Replace GM motor O
floating seal O-ring creepage Replace GM motor O
Bolts loose Retighten
Leaking from O-ring damaged Replace O-ring O
hydraulic motor Repair flaws with grinder,
Seal surface flawed O
crocus cloth, etc.
Reduced hydraulic motor
Replace GM motor O
increased leakage capacity
During use on a of working fluid Increased internal brake
Replace or repair brake valve O
sloping road, valve leakage
rotates under load Spring damage Replace spring O
Parking brake does
not function Replace friction plate, mating
Friction plate worn down O
plate
Shotage gear oil Fill to recommended level
Reduction gear case surface temperature
Pitching in bearings Replace GM motor O
too high
Working oil in gear case Replace oil seal O

Page 26
Problem 1 Problem 2 Possible Cause Action
Left-right ejection volume
Repair pump
Occurs at imbalance
low-pressure Left-right hydraulic motor
Replace GM motor O
drain volume imbalance
Left-right ejection volume
Meanders when Repair pump
imbalance
used as drive
motor Left-right hydraulic motor
Replace GM motor O
Occurs at high- drain volume imbalance
pressure Left-right brake valve
Replace brake valve O
operation imbalance
Left or right control valve Set pressure correctly, or
has low relief pressure replace relief valve
Pump not operating
Repair or replace pump
Pump ejection property
volume too low High oil leakage outside
Speed too slow Repair or replace pump
pump
High oil leakage outside
Replace GM motor O
hydraulic motor
Hydraulic motor or
From GM motor Replace GM motor O
Abnormal sounds reduction gear damage
From tubing Tubing vibration occurring Clamp tubing
High-pressure selection
Inspect, repair or replace O
check valve malfunction
Does not switch low Switching valve malfunction Repair or replace O
2 -speed to high-speed Pilot pressure too low Set to required pressure
switching does 2-speed switching piston
not function Repair or replace O
malfunction
Does not switch Switching valve malfunction Repair or replace O
from high to low- 2-speed switching piston
speed Repair or replace O
malfunction

Page 27
OUTLINE OF MAINTENANCE
Tools
No. Name Type · Specification Q'ty
2.5 (M5), 3 (M6), 4 (NPTF 1/16,) 5 (PF 1/8), 6 (PF 1/4)
1 Hex-wrench 1
8 (M10,PF 3/8), 10 (M12,PF 1/2)
Socket Wrench
2 (Ratchet Handel) Tumbler type 1
(JIS B 4641)
Torque Wrench Dial type: 50 (N), Dial type: 100 (N),
3 1
(JIS B 4650) Dial type:300 (N), Dial type: 560 (N)
4 Adapter for Torque Wrench 1
5 Hex-Socket Diagonal size 24 mm, 41 mm 1
Extension Bar
6 150 mm 1
(JIS B 4637)
7 Hammer Various 1
8 Plastic Hammer L = 400 mm 1
9 O-driver (JIS B 4609) 50 mm, 150 mm 1
10 Retaining Ring Pliers For axle, For groove 1
11 Pliers (JIS B 4623) 200 mm 1
Lifting Load : 2,940 (N), 300 (kg) min. 1 Set
Eyebolt (M16) 2
12 Lifting Device Eyebolt (M12) 3
Eyebolt (PF 1/2) 2
Hooked wire 1
13 Container General: W450 x D300 x 120 mm 2
14 Leather Gloves 1 Pair
Bolts
No. Name Type · Size Q'ty
1 Long Hex-Bolt M12 (P1.5) x 40 mm 2

Page 28
Equipments
Application
Name Type · Specification Q'ty
(Use or P/N)
Assembling and
Workbench 1
Disassembling
Washing
Wash Tank Washing·final washing 1
(product and parts)
24: press Cap. 9,800 (N) (1,000 (kgf)) min.
24, 104, 149 Press Workbench 104: press cap. 1,960 (N) (200 (kgf)) min. 1
149: press cap. 1,960 (N) (200 (kgf)) min.
Heating Cap: 100°C min
149 Heating Tank 1
Volume: 500 x 500 x 500 min
0.29 - 0.49 (MPa)
Drying after Washing Compressed Air 1
3 - 5 kg/cm2
Fabricated Tools
1. Workbench for travel motor
• For easy and safe work of disassembling and
assembling travel motor.
Figure 12
2. Pressing tool ( )
• Used for inserting spring (114), washer (110), or
retaining ring (145) into the cylinder block (104).
• Used for removing the spring (114) from cylinder
block (104).
FG009805
Figure 13

Page 29
3. Pressing tool (II)
• Used for removing the deep groove ball bearing (149)
from shaft (102).
FG009806
Figure 14
4. Oil seal inserter

• Used for pressure-inserting oil seal (132) into the oil
seal groove on the spindle (2).
FG009807
Figure 15
5. Lock washer inserter

• Used to insert lock washer (22) into the inlet of the
spindle (2).
FG009808
Figure 16
6. Main bearing inserter

• Used to insert angular ball bearing (24) into the hub
(1).
FG009809
Figure 17

Page 30
7. Steel rod (I)
• Used to remove angular ball bearing (24) from the
hub.
FG009810
Figure 18
8. Long eyebolt
• Used to hang travel motor, spindle (2), and hub (1).
Use "A"
Hub M 16
Hub M 10
Spindle M 16
Travel Motor M 16
"A"
FG009811
Figure 19
9. Blade
• Used to remove timing plate (109) from rear flange
(301).
FG009812
Figure 20
10. Floating seal assembler (I)

• Used to assemble floating seal (29) with hub (1).
FG009813
Figure 21

Page 31
11. Floating seal assembler (II)
• Use to assemble floating seal (29) with hub (1) and
spindle (2).
Figure 22
12. Floating seal assembler (III)

• Use to assemble floating seal (29) with spindle (2).
FG009815
Figure 23

Page 32
Torque
Parts Bolts and Nuts
Hex-2 Face Width
(Structural Q'ty Torque (Nm)
Name Spec. (mm)
Diagram)
98.1 ±19.6
30, 357 Plug PF 1/2 10 4
(10.0 ±2.0)
66.7 ±3.92
35 Hex Groove M10 (P1.5) 8 12
(6.8 ±0.4)
Sleeve 24 98.1 ±19.6
203 PF 1/2 2
(assembling Relief Valve) (Socket) (10.0 ±2.0)
29.4 ±4.90
205 Plug PF 1/4 6 2
(3.0 ±0.5)
41 441 ±39.2
324 Plug M36 (P1.5) 2
(Socket) (45.0 ±4.0)
102 ±15.7
343 Hex Groove Bolt M12 (P1.75) 10 10
(10.4 ±1.6)
12.3 ±2.45
352 Plug PF 1/8 5 3
(1.25 ±0.25)
9.81 ±1.96
354 Hex Groove Plug NDTF 1/16 4 5
(1.0 ±0.2)
58.8 ±9.81
380 Plug PF 3/8 8 2
(6.0 ±1.0)
29.4 ±4.90
396 Hex Groove Plug PT 1/4 6 2
(3.0 ±0.5)
12.3 ±2.45
398 Hex Groove Plug PT 1/8 5 5
(1.25 ±0.25)
Weight Table
Parts
Name Mass (kg)
(Structural Diagram)
Travel Motor Assembly Approx. 145
1 Hub Approx. 46
2 spindle Approx. 27
3 Carrier (1) Assembly Approx. 12
7 Carrier (2) Assembly Approx. 24
301 Rear Flange Assembly Approx. 13
NOTE: Use crane to lift up heavy objects. Otherwise, can

result in back injury.

Page 33
DISASSEMBLING
Work Preparation
Prepare the following for disassembling;
1. Workbench
• Prepare the workbench for travel motor.
• The bench must be rigid enough for the
disassembling and reassembling the internal parts of
the travel motor.
The bench must have sufficient area to place all the
parts.
The bench must be stabilized to prevent fall or
movement of parts during work
• The bench must be covered with rubber r vinyl sheet.
2. Tools and devices
• Prepare the tools and devices listed in the paragraph
General Precautions for Work
CAUTION
AVOID INJURY
Gear or hydraulic oil can make parts slippery to handle. To
prevent injury or damage to parts, work carefully to prevent
slipping and falling on work surfaces or dropping of parts.
CAUTION
AVOID INJURY
Kerosene and other cleaning solvents are inflammable and
must be used properly to prevent fires or personal injury.
Always wear proper personal protection equipment (PPE)
when handling or using cleaning solvents.
1. Prepare check list including the characteristics of

anomalies before starting the disassembling work. Keep
the order of disassembling.
2. All the parts are precision parts. Take care with handling,
without collision or dropping.
NOTE: Take care not to cut hands when handling sharp
edged parts.

Page 34
3. Even hard and rigid parts must not be knocked or exerted
with excessive force. Otherwise, the part may become
unable to assemble or degraded in performance. Work
with patience and care.
4. Take measures of rust or dust proofing if disassembled
parts have to be left unassembled for a long while.
Otherwise, the part may be degraded with rust.
5. Mark the fitting surfaces during disassembling.
6. Arrange the disassembled parts to prevent damage or loss
of the parts.
7. Seals, in principle, have to be replaced when
disassembled, even though they look good. Prepare
replacement parts before disassembling.
8. The photos and pictures show typical models. Certain
parts may differ from the actual parts, but the order of
disassembling is the same.
Disassembling Order
1. Washing the travel motor
A. Joint and tighten eyebolts in the M16 bolt holes on
the spindle (2). Lift the travel motor with a crane and
move it to the Wash Tank.
NOTE: Place the two eyebolts symmetrically in
the M16 bolt holes on the spindle.
B. Wash the travel motor with brush.
NOTE: Wash the groove (for floating seal)
between the hub (1) and spindle (2) clean,
where there is dust or foreign material.
2. Mounting the travel motor
A. Place the travel motor on the workbench.
NOTE: Insert the travel motor into the mounting
hole on the workbench lightly, while
matching the screw hole on the spindle (2)
with the screw hole on the workbench.
B. Mount the travel motor with two hex-groove bolts on
symmetric position.
CAUTION
AVOID INJURY
Tighten the hex-groove bolt securely to prevent
the travel motor from falling while servicing.

Page 35
3. Removing the lubricant
A. Lay down the travel motor (with the outlet port
pointing downward).
B. Loosen the plug (30) at the oiling port to release the
pressure in the reduction gear, and tighten the plug
lightly.
NOTE: If the reduction gear was not
depressurized, lubricant may eject out
when the plug on the discharge port is
loosened.
C. Place a container at the end of the oil discharge port,
take the plug out slowly to discharge the lubricant.
NOTE: The container must be large enough to
receive the lubricant in the reduction gear,
which is 2.1L.
D. If the lubricant does not come out smoothly, remove
plug on the oiling port slowly.
E. Remove O-ring (31) from the plug which was taken
out.
NOTE: Once disassembled, the O-ring (31) must be
replaced with a new one, to prevent oil leak.
4. Removing the cover
A. Turn the travel motor over (with the reduction gear
facing upwards)
B. Remove 12-M10 bolt (35).
C. Seal is applied on the fitting surfaces of the cover
(14) and hub (1). insert a metal rod on the top of the
cover, knock the rod to the upside of the slope to
remove cover.
CAUTION FG028731
Figure 24
AVOID INJURY
To prevent a foot injury, keep your feet away from
under the motor cover when removing the cover.

Page 36
D. Mount eyebolts at the PF1/2 port, lift the cover (14)
up from the hub and move it.
FG028732
Figure 25
5. Removing the thrust plate

A. Remove thrust plate (13).
FG028733
Figure 26
6. Removing the 1st stage gears

A. Remove sun gear (1, 4).
NOTE: Take care not to drop the sun gear (1)
down, which is slippery with lubricant.
FG028734
Figure 27
B. Mount eyebolts in the three M12 tabs on the carrier

(1, 3). lift the carrier assembly (1) with crane and
move it.
NOTE: When lifting the carrier (1) assembly up,
align the centerlines of the hub (1) and the
carrier assembly (1), and lift up slowly to
prevent the end of the planetary gear (1, 5)
damaging the teeth inside the hub.
FG028735
Figure 28

Page 37
7. Removing the coupling
A. Remove coupling (15) from the shaft (102).
FG028736
Figure 29
8. Removing the 2nd stage gears

A. Mount eyebolts in the 3 (M12) tabs for lifting on the 3
points of the carrier (2, 7). Lift the carrier assembly
(2) with crane and move it.
NOTE: When lifting the carrier assembly (2) up,
carrier assembly (2), and lift up slowly to
prevent the end of the planetary gear (2, 9)
damaging the teeth inside the hub.
B. Remove sun gear (2, 8). FG028742
Figure 30
NOTE: Take care not to drop the sun gear (2)
down, which is slippery with lubricant.
9. Removing the lock washer
A. Attach on the turn-over table using the M14 hole of
the hub (1).
FG028737
Figure 31
B. Place screwdriver, or an equivalent tool, at the

skimmer of the 2 lock washers (22). Knock the driver
head with a hammer towards the bottom of the slope
to remove lock washer.
FG028738
Figure 32

Page 38
10. Removing the hub
A. Remove hex-groove bolt joining the hub and the turn-
over table.
B. Mount eyebolts (M10) on the hub and lift it up with
crane.
WARNING
AVOID DEATH OR SERIOUS INJURY FG028739
Figure 33
To prevent injury from falling or dropping parts.
• Always use an adequate lifting device to lift
the Hub. Do not Lift Hub at an angle. Lift Hub
aligned with the Spindle shaft.
• Lift Hub slowly and avoid using excessive
force that could damage lifting device.
• Use a press to remove Hub, if necessary.
11. Removing the floating seal

A. Exert force with hand on the inner side of the floating
seal (29) towards upside.
NOTE: Wear gloves to prevent cutting hand by
the edge of the floating seal.
If solidified with soil inside, remove it with
screwdriver or similar tools as leverage.
FG028740
Figure 34
12. Removing the angular ball bearing

A. Place a pin punch on the edge of the outer ring of the
angular ball bearing (24) at 3 or 5 points which divide
the ring in equal intervals. Hammer the punch to
remove bearing small by small.
NOTE: Do not hammer the inner ring of the
angular ball bearing. if the inner ring is
damaged, the baring cannot be used.
Therefore, do not knock the inner ring,
unless the bearing is to be replaced.
When the outer ring of the ball bearing FG028741
(24) is out of the hub (1), the bearing falls
Figure 35
down. Place a pan covered with rubber
mat to receive the bearing.

Page 39
13. Removing the rear flange
A. Turn the travel motor over (with motor side up).
NOTE: Following procedures are for removing the
Plug easily, when disassembling the
inside of the rear flange.
Loosen the plug so it can be removed with
hand.
Do not loosen the plug unless the rear
flange inside is to be disassembled.
B. Loosen the two plugs (324). FG028743
NOTE: Following procedures are for removing the Figure 36
plug easily, when disassembling the inside
of the rear flange.
Do not loosen the plug unless the rear
flange inside is to be disassembled.
When the plug (324) becomes loose, the
spring (328) can move easily. Therefore,
the plug (324) and the spring (328) may be
ejected out. Therefore, care must be taken
for this work.
C. Loosen the two plugs (380).
D. Loosen the two plugs (352).
E. Loosen the plug (357).
FG028744
Figure 37
F. Loosen the two relief valve assemblies (including

203).
FG028745
Figure 38

Page 40
G. Remove two relief valve assemblies (including 203).
NOTE: Do not reuse the removed O-rings (207,
209, 212) and backup rings (208, 210).
FG028746
Figure 39
H. Unscrew the ten hex groove bolts (343) and remove

them from the rear flange (301).
I. Remove rear flange (301) from the spindle (2).
NOTE: Hold the rear flange with both hands, lift it
up carefully to remove it. It removed with
excessive force or by knocking, the timing
plate (109) may be fall down and
damaged. Care must be taken when
removing the rear flange.
FG028747
Figure 40
J. Remove two parallel pins (34) from the spindle (2).
FG028748
Figure 41
K. Remove two O-rings (32, 33) from the spindle (2).

33).
FG028749
Figure 42

Page 41
14. Disassembling the rear flange assembly
A. Place the rear flange (301) with the fitting surface
with the spindle (2) upside.
B. Remove timing plate (109) from the rear flange (301).
NOTE: Removing the rear flange (301) may
require some force because of the oil on
the fitting surface. Insert a blade in the
groove of the fitting surface on the rear
flange (301) and lift the timing plate (109)
up softly to remove it. Do not use sharp
tools, such as screwdriver, which may FG028750
scratch the fitting surface, resulting in oil
Figure 43
leak.
C. Remove deep groove ball bearing (150) from the rear
flange (301).
FG028751
Figure 44
D. Remove parallel pin (341) from the rear flange (301).
FG028752
Figure 45

Page 42
15. Disassembling the brake valve parts in the rear flange
A. Remove two plugs (324) from the rear flange (301).
B. Remove washers (325) and springs (328), 2 each,
from the rear flange (301).
FG028753
Figure 46
C. Remove spool (323) from the rear flange (301).

NOTE: Tilt the plug port of the rear flange (301),
then the spool (323) will slide out. Take it
by lifting the front end.
FG028754
Figure 47
D. Remove O-ring (336) from the plug (324).

NOTE: Do not reuse the removed O-ring (336).
FG028755
Figure 48

Page 43
16. Disassembling the 2-speed switching spool
A. From the rear flange (301), remove plug (357).
B. Remove O-ring (359) from the plug (357).
FG028756
Figure 49
C. Remove spool (363) and spring (366) from the rear

flange (301).
FG028758
Figure 50
17. Disassembling the piston

A. From the rear flange (301), remove two plugs (380).
FG028757
Figure 51
C. Remove piston (381) from the rear flange (301).
FG028759
Figure 52

Page 44
18. Disassembling the check valve ball
A. From the rear flange (301), remove two plugs (352).
FG028760
Figure 53
C. Remove steel ball (353) from the rear flange (301).

NOTE: If it is difficult to remove steel ball, use a
magnet.
FG028761
Figure 54
19. Disassembling the packing brake
CAUTION
AVOID INJURY
If compressed air is injected in rapidly, the piston (112)
may be ejected out from the spindle (2), resulting in
injury or damage. Cover the piston (112) to protect it.
A. Inject the compressed air into the hole in the packing

brake path of the spindle 2, and take the piston (112) FG028762
out from the spindle 2. Figure 55
B. Remove O-rings (135, 139) out from the piston (112).

139).
FG028763
Figure 56

Page 45
20. Disassembling the hydraulic motor parts
NOTE: Oil will come out when the travel motor is laid
down. Place an oil pan under the travel motor.
A. Lay the travel motor down at 90 degrees.
B. Remove oil in the travel motor.
C. Select the four opposite plates (116) and the three
friction plates (115).
FG028764
Figure 57
D. Turn the cylinder block (104) by 2 - 3 rounds with

hands, and remove shoe (106) attached to the swash
plate (103).
NOTE: If the cylinder block (104) is removed in
this state, the shoe (106) remains in the
swash plate (103), and the parts (piston
(105), shoe (106) etc.) will be separated
from the cylinder block (104) and fall
inside the spindle (2). So care must be
taken in this state.
FG028765
Figure 58
E. Remove cylinder block (104) from out of the shaft

(102).
F. Remove piston assembly (piston (105), shoe (106))
and the retainer plate (107) from the cylinder block
(104).
NOTE: Remove piston assembly with the retainer
plate (107) by holding the retainer plate
with both hands.
The piston (105) and the shoe (106) are
jointed by being tightened on the spherical FG028766
surface of the piston. The shoe (106) Figure 59
cannot be separated from the piston (105)
without damaging the shoe (106).
Therefore, if replacement is required,
replace them as a single unit (hereinafter,
will be referred to as the piston assembly.

Page 46
G. From the retainer plate (107), take the piston
assemblies (105, 106) out (9 sets).
FG028767
Figure 60
H. Remove thrust ball (108) from the cylinder block

(104).
FG028768
Figure 61
I. Remove three collars (151) from the cylinder block

(104).
FG028769
Figure 62
21. Removing the spring from the cylinder block

A. Place the cylinder block (104) on the press
workbench.
NOTE: Spring (114) must be taken out only for
replacement.
To remove spring (114), align the axes of
the press tool and the washer (110), to
prevent damage to the cylinder block
(104) by contact.
Cover the cylinder block (104) up with
vinyl sheet to prevent damage on the FG028770
surface of the cylinder block (104). Figure 63

Page 47
B. Place the press tool (1) on the washer (110), press
the tool (1) strongly with a press, and remove
retaining ring (145) out from the retaining ring groove
on the cylinder block (104) with a retaining ring pliers.
CAUTION
AVOID INJURY
Release the press slowly to prevent the spring
(114) from being ejected and causing an injury.
Figure 64
Always wear proper face and eye protection.
C. From the cylinder block (104), remove retaining ring

(145), washer (110), spring (114), and washer (110).
FG028771
Figure 65
22. Removing the swash plate

A. Remove swash plate (103) from the shaft (102).
NOTE: Take care when removing the swash plate
(103), because the pivot (167) may be
attached to the swash plate (103).
FG028772
Figure 66
B. Remove shaft (102) from the spindle (2).

Now, the deep grooved ball bearing (149) will be
separated being attached on the shaft.
NOTE: Shaft (102) can be easily removed by
knocking the end of the shaft on the
reduction gear side with a plastic hammer.
Take care not to strike the shaft, or it may
bound.
C. Remove two (each) pivots (167) and parallel pins
(171) from the spindle (2). FG028773
Figure 67

Page 48
D. Remove 2-speed switching piston assembly and the
spring (185) from the spindle (2).
FG028774
Figure 68
23. Removing the deep grooved ball bearing

NOTE: Remove deep grooved ball bearing only for
replacement.
A. Place a press tool (II) on the press workbench, and
insert the shaft (102) in it.
B. Press the end of the shaft with the press to remove
inner ring (149) of the deep grooved ball bearing from
the shaft (102).
NOTE: Do not reuse the deep grooved ball
bearing.
Figure 69
24. Removing the parts on the spindle

A. Remove seal (23) from the spindle (2).
FG028775
Figure 70

Page 49
B. Remove floating seal (29) from the spindle (2).
FG028776
Figure 71
C. Remove oil seal 132 from the spindle (2).

NOTE: Do not reuse the removed floating seal
(29) and oil seal (132).
Figure 72
25. Washing the parts

A. Classify the hub (1), spindle (2), cover (14), rear
flange (301) and other pats.
B. Wash the hub (1) spindle (2) cove (14) rear flange
(301) in the wash tank.
NOTE: Remove soil on the surface carefully.
Kerosene used for washing is highly
inflammable. Be careful to prevent fire.
NOTE: if the parts are dirty, leave it in the solvent
for a while, until dust, soil, and grease are FG028777
separated and float up. Do not wash dirty
Figure 73
parts from the start, or the dirt may scratch
the surfaces.
C. Wash the other parts in a wash tank with kerosene.

Page 50
26. Final washing
A. Put the parts in the finish washing tank containing
kerosene. Rotate the parts slowly, wash them clean
to the inside.
FG028778
Figure 74
B. Wipe the kerosene off the parts with clean cloth.

NOTE: Dry the inside of the hub (1) and spindle
(2) with compressed air, where there is no
dust and moisture.
After drying, apply hydraulic oil on the
surface of the parts.
Leave the rear flange (301), hydraulic
motor parts, and gears in a place free from
dust and moisture to dry up. When dried,
apply hydraulic oil on their surfaces. FG028779
Figure 75

Page 51
MAINTENANCE STANDARDS
GM Motor has to be disassembled and inspected in compliance
with this standard. Take utmost care not to scratch on the
moving and reciprocating surfaces.
Seals
Seals (O-ring, oil seals, floating seas) must be replaced with
new seals, regardless of the damage, once disassembled.
Maintenance Standards for Wearable Parts

1. Any parts which show visible defect must be replaced with
new ones.
2. Replace the parts which show the following defects.
Part Allowable
Name Defect Description Standard Size
No. Range
• Any major visible defect.
1 Hub • Pinching on the tooth of ring gear. - -
• Abnormal wear such as scratch.
• Any major visible defect.
2 Spindle - -
• Abnormal wear such as scratch.
3, 7 Carrier Assembly • Abnormal wear such as scratch.
4 Sun Gear 1
• Pinching on tooth.
8 Sun Gear 2
• Breaking on the working surface of - -
5 Planetary Gear 1
bearing.
9 Planetary Gear 2
• Dent.
24 Ball Bearing • Breaking. - -
• Biased wear.
Scratch on the reciprocating surface
301 Rear Flange between the Spools (323, 363) and - -
Piston (381).
• Wear on the fitting surface with the
102 Shaft Oil Seal (132). - -
• Worn spline.
103 Swash Plate Sooting. - -
• Worn spline.
• Serious wear on the inside of the
bore.
104 Cylinder Block - -
• Scratch or biased wear on the
reciprocating surface with the
Timing Plate (109).
• Skimmer on the axial direction of
Piston Assembly
105 the Piston (105) and Shoe (106). Skimmer Skimmer
Piston
106 • Abnormal, biased wear of Shoe 0.15 mm 0.15 mm
Shoe
(106).

Page 52
Part Allowable
Name Defect Description Standard Size
No. Range
• Biased wear on the reciprocating
surface with the Shoe (106)
107 Retainer Plate • Scratch or biased wear on the - -
reciprocating surface with the
Thrust Ball (108).
• Biased wear on the spherical
108 Thrust Ball reciprocating surface with the - -
Retainer Plate (107).
• Sooting or biased wear on the
109 Timing Plate - -
reciprocating surface.
• Biased wear on both ends.
Braking Torque Braking Torque
115 Friction Plate • The torque is different from the
206 Nm (21.0 206 Nm (21.0
116 Opposite Plate specified value.
kg•m), min. kg•m), min.
• Sooting.
105 Piston • Scratch or dent on outer surface. - -
• Dent.
149 Deep Grooved Ball
• Breaking. - -
150 Bearing
• Wear.
2-Speed Piston Kit
161 • Abnormal wear on outer surface.
Piston - -
162 • Abnormal, biased wear on Shoe.
Shoe
323 • Biased wear on outer surface.
Spool - -
363 • Dent on outer surface.
381 Piston • Scratch on outer surface. - -

Page 53
ASSEMBLING
Assembling, in principle, shall be done in the reverse order of
the disassembling.
Preparation
Prepare work table, tools, devices, same as those described in
the Disassembling Section.
General Precautions for Assembling Work

1. Cautions for assembling work, in principle, are same as
those defined in the Disassembling Section.
2. Remove any metallic particle and foreign materials from all
the parts. Check and remove rust or scratch with oil stone.
3. Replace O-ring, oil seals and floating seals with new ones.
4. Remove residual adhesive in the screw holes (12) on the
hub (1) through the M10 P1.5 tab.
Wash, degrease the screw holes, blow the holes with
compressed air to remove residual wash liquid.
Replace the hex-groove bolts (35) with new ones.
5. When assembling the O-ring, Oil seals and floating seals,
take care not to damage them (apply a small amount of
grease for smoothness).
6. Be sure to apply clean machine oil (NAS Class 9 or better)
on the moving and reciprocating surfaces of the hydraulic
motor and valves
7. Do not wear cloth gloves while assembling to prevent
malfunction by residual fibers.
8. Tighten the bolts and Plugs by the torque specified in the
See “Torque” on page -33.
9. Plug all ports to prevent dust after assembling.
10. The photos and pictures are on the typical model. Partial
difference may exist, however, the order of assembling
procedures are the same.

Page 54
Order of Assembling
When replacing and reassembling parts, prepressure
adjustment of ball bearing is required. Therefore, make sure that
parts below have been replaced before assembling.
NOTE: Replacement parts for prepressure adjustment of ball
bearing. Hub (1), spindle (2), ball bearing (24)
NOTE: When replacing and reassembling the above listed
parts, make sure to use the pre-adjusted parts.
Otherwise, the travel motor may mal function
resulting in earlier damage.
1. Assembling the hub
A. Place the hub (1) on the press workbench.
B. Insert the ball bearing (24) into the hub (1). Place the
press fitting tool on the outer ring of the ball bearing
(24), press it with press to insert into the hub (1).
C. Turn the hub (1) upside down.
D. Press fit the ball bearing (24) into the hub (1), in the
same method as B.
NOTE: Take care that ball bearing (24) is
assembled in the correct direction.
Figure 76
E. Apply grease on the O-ring of the floating seal (29).

insert the floating seal (29) into the groove on the hub
(1).
NOTE: When applying grease on the O-ring of the
floating seal (29), take the O-ring off of the
floating seal (29) and apply grease on the
whole surface of the O-ring, thin and
evenly.
NOTE: To assemble the floating seal (29), place
the F/S assembling tool (I), floating seal
(29), and F/S assembling tool (II), in the
Figure 77
listed order, and press until F/S
assembling tool (II) touches the F/S
assembling tool (I). Remove F/S
assembling tools and confirm that end
surface of the hub is within 1 mm
difference with the floating seal surface.

Page 55
2. Assembling the spindle part
A. Apply grease on the O-ring of the floating seal (29).
Insert the floating seal (29) into the floating seal
groove on the spindle (2).
NOTE: To assemble the floating seal (29), place
the F/S assembling tool (I), floating seal
(29), and F/S assembling tool (II), in the
listed order, and press until F/S
assembling tool (II) touches the F/S
assembling tool (I). Remove F/S
assembling tools and confirm that end
surface of the hub is within 1 mm
difference with the floating seal surface. Figure 78
B. Join two eyebolts on the spindle (2) at symmetric
position.
C. Place the spindle (2) on the workbench with the hex-
groove bolts are on symmetric position.
CAUTION
AVOID INJURY
Tighten the hex-groove bolt securely to prevent
the travel motor from falling while servicing.
FG028776
Figure 79

Page 56
3. Adjusting the prepressure of the angular ball bearing
NOTE: When the hub (1), angular ball bearing (24) or
spindle (2) is replaced, perform prepressure
adjustment. If the prepressure is not
appropriate, the angular ball bearing may be
fractured soon.
A. Insert the lock washer (22) in the spindle (2), and
measure size C.
B. Measure the width D of the angular ball bearing.
NOTE: Turn hub (1) and angular ball bearing (24)
by a few rounds to remove loose, before
measuring the size. Figure 80
C. Deduct size C with D. Select the seam (23) for which

the skimmer is +0.13 mm - +0.17 mm in the table
below.
Symbol T (mm)
A 0.9
B 1.0
C 1.1
D 1.2
E 1.3
F 1.4 Figure 81
G 1.5
H 1.6
I 1.7
J 1.8
K 1.9
L 2.0
D. Mount the seam (23) on the spindle (2).
FG028775
Figure 82

Page 57
4. Assembling the hub
A. Align the central axes of the hung hub (1) and spindle
(2) straight, lower the spindle (2) slowly and insert
into the angular ball bearing (24).
FG028739
Figure 83
B. Tighten a lock hex-groove bolt in the ø14 hole of the

hub to fix with the workbench.
C. Place a metal rod on the inner ring of the angular ball
bearing (24) on the reduction gear side, knock it
lightly with a hammer to remove looseness of the
inner ring.
FG028737
Figure 84
D. Place the lock washer (22) on the groove on the

spindle (2).
FG028780
Figure 85
E. Insert the lock washer (22) into the spindle groove

with a tool.
NOTE: When assembling the carrier (2, 7), insert
the lock washer (22) fully into the groove to
avoid interference with the lock washer (22).
F. Remove lock hex-groove bolt which has been
connecting the hub (1) with the workbench.
G. Turn the hub (1) by 2 - 3 turns.
NOTE: Turning the hub (1) will settle the fitting FG028781
surface of the floating seal (29) to prevent
Figure 86
leak.
H. Turn the workbench so motor faces upward.

Page 58
5. Assembling the motor parts in the spindle
A. Insert the oil seal (132) into the spindle (2) using oil
seal press-fitting tool and hammer
NOTE: When assembling the oil seal, apply
lithium grease on the oil seal lip
Take care that assembling direction of the oil
seal (132) is correct.
B. Assemble the two parallel pins (171) into the pinholes
of the spindle (2).
C. Apply lithium grease on the semi-spherical surface of
the two pivots (167) and press fit them into the
Figure 87
parallel pins (171) which are inserted in the spindle
(2).
D. Apply grease on the spring (185) and assemble it
with the piston assembly piston (161), shoe (162).
E. Apply machine oil on the reciprocating surface of the
piston assembly and mount it into the piston hole on
the spindle (2).
F. Insert the two parallel pins (34) into the pin groove on
the fitting surface of the rear flange of the spindle (2).
FG028774
Figure 88
6. Assembling the shaft
CAUTION
AVOID INJURY
Wear leather gloves during the assembly work, to
prevent burns or other injuries to hands.
A. Put the deep grooved ball bearing (149) into the

heating tank, heat it for 10 minutes at 100 ±10°C, and Figure 89
insert it onto the shaft (102).
B. Turn the travel motor by 90 degrees.
C. Insert the shaft (102) into the spindle (2).
NOTE: Insert the shaft (102) slowly into the
spindle (2) so lip of the oil seal (132)
inserted into the spindle is not damaged.
Damaged lip will cause oil leak, resulting
in the earlier failure of the travel motor.
FG028773
Figure 90

Page 59
D. Insert the swash plate (103) into the spindle (2).
NOTE: Apply grease on the fitting surface of the
swash plate (103) with the spindle (2).
Insert the swash plate (103) into the
spindle (2) by matching the pivot mounting
grooves on the swash plate (103) with the
two pivots (167) inserted onto the spindle
(2).
FG028772
Figure 91
7. Assembling the inner parts of the cylinder block

NOTE: Insert the THS retaining ring (145) with its sharp
edge facing the inlet.
Insert the washer (110) which contacts with the
fix ring (145) with its sharp edge facing the fix
ring (145).
A. Insert the washer (110), spring (114), washer (110),
and THS retaining ring, in the said order, into the
cylinder block (104).
B. Place the cylinder block (104) on the press
workbench. FG028771
Figure 92
CAUTION
AVOID INJURY
Take care to prevent the ejection of the fix ring
which can occur if the pliers tip slips out of the
groove of the fix ring, when assembling the THS
retaining ring (145). Always wear proper face and
eye protection.
FG028770
NOTE: The pressure of the spring (114) must be Figure 93
112 N (115 kgf) or more.
Protect the cylinder block (104) with a vinyl
cover sheet to prevent damage on the
contact surface with the timing plate (109).
C. Place a press tool (I) on the washer (110), press the
tool with press, and assemble the THS retaining ring
(145) into the fix ring groove on the cylinder block
(104) using fix ring pliers.

Page 60
8. Assembling the hydraulic motor parts
A. Insert the three needle-type collars (151) into the
groove on the cylinder block (104), and place the
thrust ball (108) on them.
FG028768
Figure 94
B. Insert the nine piston assemblies into the retainer

plate (107).
NOTE: Soak the whole assembly in machine oil.
C. Assemble the retainer plate (107) and the nine piston
assemblies with the cylinder block (104).
NOTE: Align the retainer plate (107) and the
spherical surface of the thrust ball (108).
FG028767
Figure 95
D. Insert the cylinder block (104) into the shaft (102).

NOTE: Align the splines on the cylinder block
(104) with those on the shaft (102).
FG028765
Figure 96
E. After assembling the cylinder block (104), turn the

cylinder block (104) with hands to check if there is
any looseness or clicking.
If it clicks, check the assembly.
NOTE: The cylinder block (104) cannot be lifted
up after assembling.
If lifted up, the thrust ball (108) will be
dropped, unable to rotate normally.
FG028764
Figure 97

Page 61
9. Assembling the packing brake
NOTE: Soak the friction plate (115) in machine oil
before assembling.
A. Turn the workbench by 90 degrees.
B. On the cylinder block (104), assemble the four
opposite plates (116) and the three friction plates in
turns.
C. Apply grease thinly and insert the O-rings (135, 139)
into the O-ring groove on the piston (112). FG028782
Figure 98
D. Assemble the piston (112) in the spindle (2).

NOTE: If the piston (112) would not be inserted
into the spindle (2) because of the friction
of the O-rings (135, 139), knock the end of
the piston (112) lightly with a plastic
hammer.
Take care to prevent scratch on the O-ring
when assembling the piston (112).
FG028783
Figure 99
10. Assembling the 2-speed switching spool in the rear

flange
NOTE: Insert the spring (366) and spool (363) into the
rear flange (301).
A. Assemble the O-ring (359) on the plug (357).
NOTE: Apply grease on the O-ring (359).
FG028758
Figure 100
B. Insert the plug (357) into the rear flange (301).

C. Tighten the plug (357) with the rear flange (301)
using a hex-wrench, temporarily.
FG028756
Figure 101

Page 62
11. Assembling the check ball part
A. Assemble the two O-rings (358) with the two plugs
(352).
B. Insert the steel ball (353) into the rear flange (301).
FG028761
Figure 102

FG028760
Figure 103
12. Assembling the piston

A. Assemble the two O-rings (383) with the two plugs
(380).
B. Insert the piston (381) into the rear flange (301).
FG028759
Figure 104

FG028757
Figure 105

Page 63
13. Reassembling the brake valve
A. Insert the spool (323) into the rear flange (301).
NOTE: Apply machine oil on the spool (323) and
insert the spool (323) into the rear flange
(301).
Align the centerlines of the spool (323)
and the rear flange (301) to prevent the
damage on the inner surface of the rear
flange (301) and the outer surface of the
spool (323) by contact. FG028754
Figure 106
If the groove of the rear flange (301) or
outer surface of the spool (301) is
damaged, internal leak can occur after the
reassembling, resulting in the
performance degradation of the travel
motor.
B. Assemble the O-ring (336) on the plug (324).
C. Insert washer (325) and spring (328) into the plug
(324).
FG028755
Figure 107
D. Insert the two plugs (324) into the rear flange (301).
NOTE: Take care when inserting the plug (324)
into the rear flange (301) to prevent the
deformation of the spring (328).
E. Tighten the two plugs (324) on the rear flange (301)
temporarily.
FG028784
Figure 108

Page 64
14. Assembling the rear flange components
A. Apply machine oil on the deep grooved ball bearing
(150) and insert the ball bearing (150) into the rear
flange (301).
B. Insert the parallel pin (341) into the pin groove of the
rear flange (301).
C. Apply grease on the fitting surface of the timing plate
(109) with the rear flange (301).
FG028751
Figure 109
D. Assemble the timing plate (109) with the rear flange

(301) using the parallel pin (341) as the guide.
NOTE: Mount the timing plate (109) until it
contacts with the rear flange (301). The
contacting will prevent the timing plate
(109) from being separated from the rear
flange (301) when mounting the rear
flange (301) on the spindle (2).
FG028785
Figure 110
E. Mount the ten springs (113) on the rear flange (301).

NOTE: Apply grease on the springs (113)
sufficiently to prevent being separated
from the rear flange (301).
FG028786
Figure 111
15. Connecting between the rear flange and spindle

A. Insert the two O-rings (32, 33) into the O-ring grooves
on the spindle (2).
NOTE: Do not apply grease on the O-rings (32,
33). If grease is applied, it may smear on
the fitting surface between the rear flange
(301) and spindle (2) during motor
operation. The smearing may be mistaken
as the oil leak.
B. Pour 1.0 liter of hydraulic oil in the spindle (2). FG028787
Figure 112

Page 65
C. Insert the rear flange (301) into the spindle (2),
aligning the pin groove on the rear flange (301) and
the two parallel pins inserted in the spindle (2).
D. Tighten the ten hex-grooved bolts (343) to the spindle
(2) temporarily, using hex-wrench.
FG028788
Figure 113
16. Tighten all parts by the specified torques.

A. Tighten the ten hex-grooved bolts (343) to the spindle
(2) by specified torque.
– Torque: 102 ±15.7 Nm (10.4 ±1.6 kg•m)
FG028747
Figure 114
B. Tighten the plug (324) by specified torque.

– Torque: 441 ±39.2 Nm (45.0 ±4.0 kg•m)
FG028743
Figure 115
C. Tighten the plug (380) by specified torque.

– Torque: 58.8 ±9.81 Nm (6.0 ±1.0 kg•m)
FG028789
Figure 116

Page 66
D. Tighten the plug (352) by specified torque.
– Torque: 12.3 ±2.45 Nm (1.25 ±0.25 kg•m)
FG028790
Figure 117
E. Tighten the plug (357) by specified torque.

– Torque: 98.1 ±19.6 Nm (10.0 ±2.0 kg•m)
FG028791
Figure 118
17. Assembling the relief valve assembly

A. Mount the two relief valve assemblies (including 203).
FG028746
Figure 119
B. Tighten the two relief valve assemblies (including

203) by specified torque.
– Torque: 98.1 ±19.6 Nm (10.0 ±2.0 kg•m)
FG028745
Figure 120

Page 67
18. Assembling the 2-step gears
A. Turn the workbench so reduction gear faces
upwards.
B. Assemble the sun gear (2, 8) with the carrier (2, 7).
C. Install eyebolts in the three M12 tabs for hanging on
the carrier (2, 7), use a crane to insert the carrier
assembly (2).
NOTE: When inserting the carrier assembly (2),
align the centerlines of the hub (1) and the FG028742
carrier assembly (2) so edge of the
Figure 121
planetary gear (2, 9) does not damage the
inner teeth of the hub (1), and insert the
carrier assembly slowly.
Arrange the planetary gear (2, 9) and the
rear flange (301) port as shown in the
figure on left.
Figure 122
19. Assembling the coupling

A. Assemble the coupling (15) to the shaft (102).
FG028736
Figure 123
20. Assembling the 1st stage gears

A. Insert the carrier assembly (1) for hanging in the Hub
(1).
NOTE: When inserting the carrier assembly (1),
carrier assembly (1) so edge of the
planetary gear (1, 5) does not damage the
inner teeth of the hub (1), and insert the
carrier assembly slowly.
FG028735
Figure 124

Page 68
B. Insert the sun gear (1, 4) into the coupling (15),
aligning the splines.
NOTE: If the sun gear (1, 4) cannot be inserted
because the spline of the sun gear
touches the teeth end of the planetary
gear, as the gears are positioned such,
slowly lift the carrier assembly (1) up until
sun gear (2, 8) leaves the coupling, and
then insert the sun gear (1, 4).
FG028734
Figure 125
C. Assemble the thrust plate (13) with the carrier (1, 3).
FG028733
Figure 126
21. Assembling the cover

A. Apply locktite 515, which is a sealant, on the fitting
surface with the cover (14) of the hub (1).
NOTE: Apply the sealant without interval.
FG028792
Figure 127
B. Mount eyebolts on the PF1/2 port, place the cover

(14) on the hub (1), matching the bolt groove position.
FG028732
Figure 128

Page 69
C. Apply locktite 242 on the tip of the hex-grooved bolt
(35), and tighten with specified torque.
– Torque: 66.7 ±3.92 Nm (6.8 ±0.4 kg•m)
FG028793
Figure 129
22. Lubricant
A. Supply lubricant through the lubricating port.
NOTE: Supply 2.1 liter of lubricant.
Figure 130
FG028794
B. Mount plug (30) on each port and tighten with
specified torque.
– Torque: 98.1 ±19.6 Nm (10.0 ±2.0 kg•m)
FG028795
Figure 131
23. Removing the travel motor

A. Turn the travel motor upside down (with the motor
side facing upward).
B. Remove travel motor fixing bolts from the workbench.
C. Tighten the eyebolt (M16) in the screw hole of the
spindle (2).
D. Join the hook and wire with the eyebolt, remove
Travel Motor from the workbench using a crane.

Page 70
Performance Test
• When the maintenance work of the GM travel motor has
been completed, conduct performance testing as follows.
1. Required instruments
Pressure Gauge 3.43 MPa

1 2
(35 kg/cm2)
2 Mass Cylinder (5 liter) 1
3 Stop Watch 1
2. Test procedures
Mount the GM Motor on the frame and connect piping.

1 GM Motor mounting
Do not put on cover.
& piping [For the performance(unloaded) testing of the GM Motor]
Note) 1. Install the pipeline with the pressure gauge(main circuit)

and to enable the measuring of the drain volume from
the hydraulic motor.
2. Mount the GM Motor softly, using the bolt groove.
Do not knock with hammer.
GM Motor Test GM Motor Direction of Operating

2 Switching Pressure
Operation rpm Rotation Time
Low Speed 10 min -1
Unloaded Left・Right 1 minute min.
High Speed 20 min -1
GM Motor
3
Performance Test
Warming up operation Warm up to following temperatures.

O
1 Hydraulic oil temperature： 45~55 C
O
Outside temperature of the Reduction Gear Hub： 40~80 C
Testing Take following measurements to decide acceptance.

2 Acceptance Criteria Differential Pressure of the GM Motor： 1.57MPa (16kgf/cm 2 ), max., at 10min-1
Drain from Hydraulic Motor： 1.2L/min at 10min-1
Pass Reject
Disassemble
Put cover on. and adjust
again.

Page 71
Page 72
SP002517
MAIN PUMP SP002517
Main Pump
Edition 1
Main Pump SP002517

Page 1
MEMO
Main Pump SP002517

Page 2
Table of Contents
Main Pump
Gear (Pilot) Pump............................................................ 9
Relief Valve ..................................................................... 9
Relief Valve Pump Regulator Description ..................... 10
Horsepower Control ...................................................... 10
Power Shift Control ....................................................... 10
Negative Oil Discharge (Pump Bypass) Control ........... 11
Pump Regulator Operation............................................ 11
Pump Output Decrease................................................. 12
Pump Discharge Decrease ........................................... 12
Pump Discharge Increase ............................................. 12
Horsepower Control ...................................................... 13
Overload Protection....................................................... 13
Regulator Adjustment.................................................... 13
Pump Input Power Control Adjustment ......................... 14
Part List ......................................................................... 16
Specifications ................................................................ 20
Hydraulic Pump Performance Characteristics............... 20
Troubleshooting, Testing and Adjustment .......... 22
Main Pump .................................................................... 22
Disassembly ....................................................... 23
General Disassembly .................................................... 23
Main Pump Disassembly............................................... 25
Pump Regulator Disassembly ....................................... 26
Tolerances)......................................................... 30
Reassembly ........................................................ 32
Pump Regulator Reassembly........................................ 32
Main Pump Reassembly ............................................... 36
Main Pump SP002517

Page 3
MEMO
Main Pump SP002517

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up
Main Pump SP002517

Page 5
Main Pump SP002517
Page 6
GENERAL DESCRIPTION
Figure 1
The main pump assembly contains two variable displacement

axial piston pumps connected in series, driven through a flexible
coupling off the back of the engine. A regulator mounted on
each pump controls the flow output of that pump. A gear type
pilot pump is mounted on the second main pump (farther away
from the engine) and supplies oil to the two regulators and the
control valve.
The axial piston pumps in the main pump assembly are units
that incorporate three main functional subassemblies:
• The rotary group includes a driveshaft, cylinder block,
piston, shoe, push plate, and spherical bushing.
• The rotary group driveshaft is driven directly off the engine
and turns at the same rate as engine rpm. The cylinder
block and pistons revolve around the driveshaft, producing
oil flow through the pump whenever the angle of the swash
plate is tilted past the 0 degree (vertical) angle. Whenever
the pump swash plate angle is at 0 degrees, piston stroke
length is reduced to 0, and there is no output from the
pump.
• The swash plate group includes the shoe plate, swash
plate support, and servo pistons.
Main Pump SP002517

Page 7
• The pump regulator controls the tilt angle of the swash
plate. Increasing the swash plate tilt angle increases the
length of piston stroke, boosting both the output flow and
output pressure of the pump.
• The valve group consists of the valve block, valve plate
and plate pin, providing intake and exhaust port
assemblies for the pump.
• The pump cylinder block slides into the valve plate
whenever piston stroke is tilted past the "0" swash plate
angle, to allow flow of supply oil (input) and positive
discharge (output) through the pump.
Main Pump Output: 63 cc/rev. (3.84 in3/rev.) (1 pump)
Gear (Pilot) Pump Output: 15 cc/rev. (0.92 in3/rev.)
Pilot Pump Relief Valve: Relief pressure set at 40 kg/cm2 (569
psi).
Figure 2
Main Pump SP002517

Page 8
TO LEFT SIDE OF TO RIGHT SIDE OF
CONTROL VALVE CONTROL VALVE
Psv
A2 A1
Pz3
Q2 Q1
PRESS, SENSOR PRESS, SENSOR FRONT
Pz2
Pz1
Pi2 Pi1
REAR
DOOSAN
DL06
a3 96PS/1850rpm
44.5kg.m/1400rpm
A3 B3 B1 Dr
FG009798
Figure 3
Gear (Pilot) Pump

The pilot pump is a gear type pump, driven off the output end of
the second main pump. Gear rotation inside the pump case
produces oil flow from the intake side of the pump to the output
side of the pump.
The function of the pilot pump in the hydraulic circuit is to
maintain a flow of oil - independent of main pump oil flow output
- for the operation of control valves.
Figure 4
Relief Valve
When the discharge pressure of the pilot pump exceeds 40 kg/
cm2 (569 psi), the ball and spool at the top of the valve shift to
the right - maintaining pressure below the targeted 40 kg/cm2
(569 psi) limit - as excess oil returns to the drain port.
Figure 5
Main Pump SP002517

Page 9
Relief Valve Pump Regulator Description
A regulator control valve is integrally mounted to the housing of
each of the two variable displacement hydraulic pumps (Figure
1). The regulator valves perform the task of controlling the rate
of pump discharge for the main pump assembly. Pump output
may need to be varied because of increased or decreased
workload demand, operator input changes to control lever
position and/or to maintain balanced output between pumps,
increasing or decreasing the discharge rate at one pump to
compensate for the output of the other pump.
The two regulators work in conjunction, varying pilot pressure
(Pi) through three different control functions - "Horsepower
Control", "Powershift Control", and "Negative Control".
Figure 6
Horsepower Control
This hydraulic system design feature provides balanced pump
output, maintaining steady and consistent power production
through the hydraulic system.
If there is a momentary increase of outlet pressure (P1) at one
pump, the tilt angle of the swash plate in the remaining pump is
automatically reduced - decreasing the other pump's outlet
pressure (P2) - to equalize system output. The advantage of this
design feature is that it keeps available horsepower through the
system constant, directly proportional to the input rotational
speed (rpm) of the engine.
Power Shift Control

This design feature modifies the total available power output of
the hydraulic system through microprocessor controlled
application of electronic controls. Supplementary electronic
control of the hydraulic system provides increased operating
flexibility.
The electronic proportional reducing valve through which the
system operates is just upstream from the 2 pump regulators. It
responds directly to signals from the EPOS-V microprocessor
and relays control signals to each of the 2 pump regulators to
optimize each pump's power output, according to changes in
secondary pressure, Pf ("Powershift pressure").
Pf pressure is monitored from interior pump passages, through
the horsepower control part of each pump regulator. It allows
simultaneous control of horsepower output at both pumps, for
optimum, efficient response to changing workload demand.
Main Pump SP002517

Page 10
Negative Oil Discharge (Pump Bypass)
Control
The volume of main pump bypass oil is automatically controlled
by pilot pressure, which is regulated by the position of the spool
in the control valve. When the control valve spool is in the
neutral position (high pilot pressure, high bypass), the tilt angle
of the swash plate decreases, reducing the volume of bypass oil
through the main pump. When the control valve spool is at
maximum stroke (low pilot pressure), the tilt angle of the swash
plate increases, boosting main pump bypass oil volume.
Pump Regulator Operation

The relationship between Pump Displacement Flow (Q on the
vertical axis) and Pilot Pressure (Pi on the horizontal axis).
Pump output discharge is controlled by increasing or decreasing
pilot pump pressure (Figure 7).
NOTE: Component parts (numbered in parentheses)

Figure 7
correspond to those in Figure 8.
Figure 8
Main Pump SP002517

Page 11
Pump Output Decrease
When pilot pressure (Pi) increases, the pilot piston (643) shifts
toward the right, stopping at that point at which pilot pressure
and the force of the return spring (646) cancel each other out.
Movement of the pilot piston pushes the pin (875) attached to
the feedback lever assembly (613, 611, 897) around the "B-point
plug" (614) and the pin (875) on the opposite side of the
feedback lever assembly. The pin at the lower end of the
feedback lever is attached to the tilting pin of the swash plate
(531/538 in Figure 1).
NOTE: In Figure 6, the circled capital letter "D" at the lower
end of the feedback lever shows the approximate
location where the assemblies shown in Figure 1,
Figure 6 and Figure 8 react as the pin (897) at the top
of the feedback lever moves and the piston shifts,
maintaining dynamic balance through the valve
between pilot pressure (Pi) and discharge output flow
(Q) as shown in Figure 7.
Pump Discharge Decrease

The regulator feedback lever assembly is also pin connected to
the outermost spool (652) in the discharge port (Cl) of the
regulator (Figure 8). As that spool moves toward the right, in
response to differences in servo pressure, the servo piston
moves to the right, resulting in a decreased swash plate tilt
angle and reduced pump output flow. The system is balanced
and control movement of the spool (and servo piston) stops
when the outermost spool (652) and spool sleeve (651) close
into each other, shutting off oil movement.
Pump Discharge Increase

When pilot pressure (Pi) decreases, the pilot piston shifts toward
the left and the feedback lever assembly pivots around point "D"
(Figure 6), pushing the spool and servo piston left. Swash plate
tilt angle is heightened and pump output flow begins to increase
as a result. Control movement of the spool and servo piston
stops when the feedback lever assembly rotates around point
"C" (Figure 6), moving the spool to the right until it slides into the
sleeve (651) and oil movement is blocked.
Main Pump SP002517

Page 12
Horsepower Control
Horsepower control function occurs as each regulator responds
to changes in the output of the opposite pump. As increases or
decreases in pump output occur (as outlined in the preceding
paragraphs) at one pump, it is necessary for the output of the
remaining pump to compensate to allow equalizing of the total
discharge rate.
The relationship between changes in pressure and changes in
output flow when the operation of both pumps (P1 and P2) is
measured (Figure 9).
Figure 9
Overload Protection
Overload protection occurs automatically, in response to
increased pressure on the piston (621) and compensator rod
(623). Whenever the discharge pressure of Pump 1 and Pump 2
(P1 and P2) are increased beyond a certain point, the higher
pressure acts on the piston and compensator rod (621 and 623),
pushing both toward the right, until hydraulic pressure and the
return force of the inner and outer springs balance out. The
feedback lever assembly pivots around Point "D" and the spool
(652) is pushed toward the right, decreasing pump discharge to
prevent engine overloading.
When discharge output of both pumps (P1 and P2) decreases,
the compensator rod (623) is released, moving the feedback
lever assembly in response to the pressure of the inner and
outer return springs. The regulator "Cl" port is connected to the
tank port. Discharge flow recovery results in an increase of
discharge flow.
Regulator Adjustment
Maximum and minimum discharge flow, horsepower control
characteristics and discharge control characteristics can all be
modified by changing the position of adjustment screws built into
the pump housing (Figure 1) and the end plate of the regulator
valve (Figure 8).
Maximum and minimum discharge flow can be modified by Q
loosening locknuts (808, Figure 1). To decrease maximum
discharge flow (by approximately 5.6 l/min [0.025 gpm]), tighten
adjusting screw (954) by 1/4 turn. Figure 10 shows the effect of
this adjustment on the output characteristics of the pump. P
HDA3008L
Figure 10
Main Pump SP002517

Page 13
To increase minimum discharge flow (also by 5.6 l/min
[0.025 gpm]), tighten adjusting screw (953) by 1/4 turn. Figure
11 shows the effect of this adjustment on the output
characteristics of the pump.
NOTE: Other characteristics of operation should not be
affected, when adjustments to maximum or minimum Q
discharge flow are made, but very large changes to
the adjustment position of either adjustment screw
could cause changes in the maximum discharge
pressure, and require a corresponding adjustment of
P
the main relief valve pressure setting. HDA3009L
Figure 11
Pump Input Power Control Adjustment
IMPORTANT
Input horsepower adjustments that are made to one pump
should also be done on the remaining pump, so both are
adjusted to the same input range.
Horsepower control characteristics can be changed by

loosening the large, thin nut (630) on the end of the regulator.
The larger (outer) adjusting screw (628) affects adjustment of
the outer return spring in the regulator outer spool. Tightening
the outer screw approximately 1/4 turn increases compensator
control pressure approximately 18 kg/cm2 (256 psi), for a torque
increase of 4 kg•m (29 ft lb). Changing the adjustment position
of the outer screw (628) affects the adjustment position of the
inner screw (924), which is the adjustment device for the inner
spring of the regulator outer spool. Loosen the inner screw and
back it out enough to compensate for the tightening adjustment
made to the outer screw, to maintain the original setting.
Changing the adjustment position of the inner screw 1/4 turn
affects the working resistance of the inner spring. Increases in
oil flow of approximately 10 l/min (0.04 gpm) and about 4.8 kg•m
(35 ft lb) of input torque are the result.
The third adjustment screw on the side of the regulator (924)
can be repositioned after the smaller locknut (801) is loosened.
Changing the position of the third adjustment screw (924) affects
pilot pressure. Turning the screw in 1/4 turn increases pilot
pressure by 1.5 kg/cm2 (21 psi), and consequently, because of
the increase in pilot pressure, the discharge flow from the main
pump assembly will increase by about 16 l/min (0.07 gpm)
Main Pump SP002517

Page 14
Electric Proportional Reducing Valve
• Current/Pressure Operating
Characteristics
Condition: Primary Pressure 50 kg/cm2
Load discharge flow: 0 l/min
70 Hz, 400 - 600 mA
Figure 12
Main Pump SP002517

Page 15
Part List
Main Pump
Figure 13
Main Pump SP002517

Page 16
Reference Reference
Number Number
4 Gear Pump 466 VP Plug
111 Shaft (F) 468 VP Plug
113 Shaft (R) 490 Expander
114 Spline Coupling 531 Tilting Pin
123 Roller Bearing 532 Servo Piston
124 Needle Bearing 534 Stopper (L)
127 Bearing Spacer 535 Stopper (S)
141 Cylinder Block 548 Feedback Pin
151 Piston 702 O-ring
152 Shoe 710 O-ring
153 Push Plate 717 O-ring
156 Spherical Bushing 719 O-ring
157 Cylinder Spring 724 O-ring
158 Spacer 726 O-ring
211 Shoe Plate 728 O-ring
212 Swash Plate 732 O-ring
214 Tilting Bushing 774 Oil Seal
251 Support Plate 789 Backup Ring
261 Seal Cover (F) 792 Backup Ring
263 Rear Cover 808 Nut
271 Pump Casing 824 Retaining Ring
312 Valve Block 885 Pin
313 Valve Plate (R) 886 Spring Pin
314 Valve Plate (L) 901 Eyebolt
401 Socket Bolt 953 Set Screw
406 Socket Bolt 954 Adjusting Screw
413 Socket Bolt
Main Pump SP002517

Page 17
Pump Regulator
Figure 14
Main Pump SP002517

Page 18
Reference Reference
Number Number
412 Socket Bolt 653 Spring Seat
413 Socket Bolt 654 Return Spring
436 Socket Bolt 655 Set Spring
438 Socket Bolt 656 Cover
496 Expander 674 Pf Piston
601 Casing 708 O-ring
611 Feedback Lever 722 O-ring
612 Lever (1) 724 O-ring
613 Lever (2) 725 O-ring
614 Portion Plug 728 O-ring
615 Adjusting Plug 730 O-ring
621 Compensator Piston 732 O-ring
622 Piston Case 733 O-ring
623 Piston Rod 734 O-ring
624 Spring Seat (C) 735 O-ring
625 Outer Spring 755 O-ring
626 Inner Spring 756 O-ring
627 Adjusting Ring (C) 763 O-ring
628 Adjusting Screw (C) 801 Nut
629 Cover→(* C *) 814 Retaining Ring
630 Locknut 836 Retaining Ring
631 Pf Sleeve 858 Retaining Ring
641 Pilot Cover 874 Pin
643 Pilot Piston 875 Pin
644 Spring Seat (Q) 887 Pin
645 Adjusting Ring (Q) 897 Pin
646 Pilot Spring 898 Pin
647 Adjusting Screw Bushing 924 Adjusting Screw
651 Sleeve 925 Adjusting Screw (Qi)
652 Spool
Main Pump SP002517

Page 19
Specifications
Main Pump Quantity 2
Displacement 63 cc/rev (3.84 in3/rev)
Max Flow Rate 114 l/min x 2 pumps
Flow Regulator Type Negative Control
Pressurization Air Breather
Weight 85 kg
Pilot Pump Displacement 15 cc/rev (0.9 in3/rev)

Max Flow Rate 27.7 l/min (0.121 gpm)
Relief Valve 40 kg/cm2 (569 psi)
Hydraulic Pump Performance

Characteristics
Main Pump Pressure/Flow Output
Engine Speed 1,850 rpm (High Mode) 1,750 rpm (Standard Mode)
90 ps (88.8 hp) (High Output 76.6 ps (75.6 hp) (Standard Output
Pump Input Horsepower
Power Mode) Standard Mode)
Main Pump Total Displacement 63 cc/rev (3.84 in3/rev) x 2 pumps
Main Pump Pressure 350 kg/cm2 (4,550 psi) (for pressure up)
Pilot Pump Displacement 15 cc/rev (0.9 in3/rev)
Pilot Pump Pressure 40 kg/cm2 (569 psi)
NOTE: Values in the graph marked "K" are pressure, in kg/

cm2.
NOTE: Values in the graph marked "L" are flow, in Liters/
minute.
Main Pump SP002517

Page 20
H-MODE
INPUT RPM : 1850 rpm
INPUT POWER (INCLUDING GEAR PUMP) : 90PS
INPUT TORQUE (INCLUDING GEAR PUMP) : 38.8Kg.m
S-MODE
INPUT RPM : 1750 rpm
INPUT POWER (INCLUDING GEAR PUMP) : 76.6PS
INPUT TORQUE (INCLUDING GEAR PUMP) : 31.3Kg.m
200
150
10.0K
114.0L 175K
1850rpm 112L
FLOW Q (L/min)
[18
1750rpm 50
100 rpm
44K 134K ]
109L 10.0K [17
107L 50 I=
[17 rpm 15
107.7L 50 ] 0m
rpm I=3 A(
] 00 Pf 257K
=0
I=6 mA K) 61L
00 Pi- (P
mA Q f=9
(Pf CU K)
=2 RV
9K E 36.5K
50 )
33.9L 217K 350K
158K 59L 44L
43L Pd= 80 K at Q=max 350K
35L
36.5K
32.0L
0
0 50 100 150 200 250 300 350
2
DISCHARGE PRESSURE Pd (kgf/cm )
0 10 20 30 40
2
PILOT PRESSURE Pi (kgf/cm )
FG009941
Figure 15
Main Pump SP002517

Page 21
TROUBLESHOOTING, TESTING
AND ADJUSTMENT
Main Pump
Problem Possible Causes Remedies

Engine overloading Engine RPM control off Readjust RPM control
Pump regulator set too high Readjust
Pump inner parts worn or damaged Look for impurities or particles inside the filter
and rebuild, replace pump components, as
required
Pump regulator piping clogged or leaking Repair or replace piping
Overloading on one Regulator Regulator compensator piston or pin (898)
pump only sticking. Disassemble, clean.
Pump discharge output Pump regulator faulty or piping Repair or replace regulator or piping
reduced, pressure does clogged, leaking or kinked
not increase
Pump inner parts worn or damaged Look for particles inside the filter and rebuild
or replace pump components
Gear pump (pilot pump) worn or Check pilot pressure and make sure pilot
faulty piston, spool and/or QMC are not sticking
before repairing or replacing pilot pump
Accessory control valve faulty Inspect valve (poppet, seat, spring)
Excessive vibration or Cavitation Look for leaks or evidence of air intrusion.
noise Disconnect return lines, add clean oil and
reassemble to bleed air
Regulator or relief valve hunting Check pressures and inspect for clogged
or damaged inlet piping
Broken or damaged piston, shoe, Repair or replace damaged component.
cylinder
HAOE950L
Main Pump SP002517

Page 22
DISASSEMBLY
General Disassembly
This procedure assumes that main pump assembly will be
removed from the upper deck plate. Use the eyebolts in the
center valve block assembly to move the valve block and the
assembled pumps (still bolted together) to the prepared work
area.
The area where the pumps are to be rebuilt must be well lighted,
clean and protected from dust and/or wind gusts that could carry
in dust or grit. Use a rubber mat or other protective covering on
the workbench area to prevent damage or scratching of any
precision machined components.
IMPORTANT
Clean all the exterior surfaces of the pump before
disassembly. There should not be any visible dirt, grease or
other type of accumulation on the outside of the pump
case. Clean off or blow dry all traces of cleaner and solvent
before starting work.
Open the drain plugs to drain oil from the pump cases before
disassembly.
IMPORTANT
If at all possible, use a clean, dry container to catch gear oil.
A clean container allows an evaluation to be made of the
used oil. The presence or relative lack of metal wear
shavings in the used oil or obvious deterioration or
contamination of the oil can provide a useful indicator of
the pumps' general condition.
NOTE: Used oil is an environmental contaminant and must

be disposed of promptly at approved recycling
facilities. Prolonged physical contact with used oil has
been thought by some to pose a health risk. Clean oil
residue from hands and clothing promptly, and do not
allow used oil containers to accumulate.
NOTE: Main Pump component parts (numbered in
parentheses) are keyed to Figure 14.
NOTE: Dispose of drained fluids according to local
regulations.
Main Pump SP002517

Page 23
1. Loosen socket bolts (412, 413) to begin separation of
regulator valves from two pumps.
NOTE: See “Pump Regulator Disassembly” on page -
26 of this section for disassembly procedures.
2. Unbolt gear pump (rear pilot pump) at rear of main pump
assembly.
HDM3016P
Figure 16
3. When pilot pump and valve regulators have been removed

from assembly, the two pump cylinder blocks (271) can be
unbolted from center valve support plate (251) and valve
block (312). A total of eight 17 mm Allen head hex bolts
hold pump assemblies together - four on each side.
4. Before unbolting eight pump block fasteners, flip pump
assembly top to bottom so regulator mounting surfaces are
facing down.
5. Unbolt all eight 17 mm hex bolts and separate both pumps
from center valve block, taking care not to damage O-rings
HDM3017L
(719) or lose or damage either one of spring pins (886),
Figure 17
between valve block and pump casings.
NOTE: When pump assembly has been disassembled
to three main component sections (center valve
block, front pump and rear pump), the
procedure can be continued in either one of two
ways. Because both pumps, on either side of
the center valve block are identical, both can be
disassembled simultaneously, repeating the
same steps on opposite ends of the assembly
at the same time. If the rebuilding procedure is
at all unfamiliar, though, or there are any other
reasons to take a less aggressive approach,
one pump can be disassembled, rebuilt and
completely reassembled while the other pump
is left for reference, until rebuilding of the first
pump has been completed.
Main Pump SP002517

Page 24
Main Pump Disassembly
1. Pull out cylinder block (141) from pump casing (271), with
all nine pistons (151), nine cylinder springs (157) and nine
shoes (152), including push plate (153) and round bushing
(156).
Figure 18
2. Unscrew two Allen head hex head bolts from front seal
cover plate (261). To separate cover plate from rest of
assembly, screw 6 mm cap screws into threaded holes
tapped into cover. Tighten all four cap screws in a slow,
staggered tightening sequence, taking wrench off of each
cap screw after just a fraction of a turn and proceeding to
next - in regular rotation - until cover drops out.
HDM3019L
Figure 19
3. Separate pump casing (271) from support plate (251) by

tapping lightly with a plastic hammer. Be careful not to
damage either mating surface or O-ring (717).
Figure 20
4. Withdraw driveshaft (111 and 113) on opposite sides of

center valve block) from swashplate support and pull away
valve plates (313 or 314).
Figure 21
Main Pump SP002517

Page 25
NOTE: If a complete tear down and reassembly is
being performed, the only parts which should
NOT be loosened or removed are the hex nut
(808) spring pin servo piston stoppers in the
swash plate supports. (The preset discharge
value would require calibration if they were
removed.) All other remaining parts may be
withdrawn from valve block - needle bearing
(124), spline coupling (114) and pump casing -
with stoppers (534, 535), servo piston (532) and
tilting pin (531) from the top of the pump casing.
Figure 22
IMPORTANT
Separation of servo pistons (532) and tilting pins (531)
must be done with a special fixture. Loctite #609 is
required for reassembly - on servo piston/tilting pin/
feedback pin (538).
NOTE: Do not disassemble the needle bearings (124).

They can only be replaced with new parts if they
are excessively worn or have been damaged.
Pump Regulator Disassembly

1. Remove four Allen head bolts (412, 413) and pump
regulator assembly from pump body. Remove and inspect
O-ring gaskets (708, 724) found between regulator casing
and pump body.
NOTE: The regulator mounting bolts are uneven in
length and must be noted and replaced to the
same location.
Once regulator has been removed from pump, go to a
clean, well lighted, protected area for further disassembly.
Use a rubber mat or other protective covering on the
workbench area to prevent damage or scratching of any
Figure 23
precision machined components.
2. Remove four Allen head bolts (436, 438) and pilot cover
(641) from regulator casing. Remove and inspect O-rings
(725, 730, 732, 734) found between cover and regulator
casing. Remove feedback lever set spring (655) and
adjusting screw bushing (647).
NOTE: These bolts are uneven in length and must be
noted and replaced to the same location. The
pilot cover is under pressure from feedback
lever set spring and care must be used when
removing it.
Figure 24
Main Pump SP002517

Page 26
3. Remove retaining ring (814), spring seat (653) and return
spring (654) from feedback lever spool (652).
4. Remove pin (898) and Pf sleeve (631) from compensator
piston bore.
Figure 25
5. Remove four Allen head bolts (438) and pilot piston lower
cover (629) from regulator casing. Remove and inspect
O-rings (756, 763). Remove inner spring (626), outer
spring (625) and spring seat (624) from Pf piston bore.
Figure 26
6. Remove adjusting ring (645) from bore by threading a

4 mm x 50 mm bolt into center of adjusting ring and gently
pulling it out. Remove and inspect O-ring (728). The shim
(649), pilot spring (646) and spring seat (644) will become
loose and slide out of the bore.
Figure 27
Main Pump SP002517

Page 27
7. Remove four Allen head bolts (438) and cover (656) from
opposite side of portion and adjusting plugs. Remove and
inspect O-rings (722, 735).
Figure 28
8. Remove two retaining rings (858), portion plug (614) and

adjusting plug (615) from bore. A 4 mm x 50 mm bolt can
be threaded into these plugs and gently pulled out, if they
do not freely slide out of the bore. Remove and inspect
O-rings (755).
NOTE: The portion plug (614) and adjusting plug (615)
can be differentiated from each other by the pin
(875) at bottom of the portion plug (614).
Figure 29
9. Remove pilot piston (643) from bore.
Figure 30
Main Pump SP002517

Page 28
10. Disassemble feedback lever (611) assembly by separating
side levers (612, 613). A 2 mm punch can be used to drive
out pins (875) from levers.
Figure 31
11. Remove piston case (622), compensator piston (621) and

piston rod (623) from piston bore. Remove and inspect
O-ring (733) from piston case (622).
Figure 32
12. Remove spool (652) and sleeve (651) from bore by driving
out pin (874). This will release feedback lever (611) from
housing. Inspect retaining ring (836) on sleeve.
Figure 33
Main Pump SP002517

Page 29
(WEAR LIMITS AND
TOLERANCES)
NOTE: Inspect all components and precision surfaces to
confirm that they haven't been worn beyond service
limits. Check the table below for dimensional
specifications.
All parts must be cleaned, air-dried and relubricated
with clean, approved type hydraulic fluid, before final
reassembly or as the final step after the unit has been
put back together again.
Replacement of all O-rings and oil seals with new parts is
generally recommended, unless pump has had very few
operating hours of use.
4
3
a
t
Figure 34
NOTE: Rounded bushings and push plates must always be

replaced in sets. If either one requires replacement,
also replace the other.
1. Clearance Between Piston and Cylinder Bore
(D-d)
2. Spring Free Length (L)
3. Thickness of Shoe (t)
4. Piston Ball - Shoe Socket Clearance (a)
5. Height Between Round Bushing and Push Plate
(H-h)
Main Pump SP002517

Page 30
Service Standards for Replacing Worn Parts
NOTE: When parts exceed the standard, replace them.
When there is conspicuous surface damage, it is
always safer to replace parts, whether standards are
exceeded or not.
Reference Standard Value Replacement

Item Remedy
Number mm (In) Limit mm (In)
Clearance between cylinder 0.032 mm 0.064 mm Replace piston or
1
bore and piston (D-d) (0.00126 in) (0.00252 in) cylinder
Free-length of cylinder spring 47.9 mm 40.30 mm
2 Replace spring
(L) (1.88 in) (1.85 in)
5.0 mm 4.80 mm Replace piston, shoe
3 Thickness of shoe (t)
(0.1968 in) (0.1889 in) assembly parts
Piston ball - shoe socket 0 - 0.1 mm 0.30 mm Replace piston or
4
clearance (a) (0.00394 in) (0.01 in) shoe assembly
Height of push plate, round 13.5 mm 12.5 mm
5 Replace
bushing assembly (H-h) (0.531 in) (0.492 in)
Inspect O-rings and oil seals very carefully for cuts, nicks,
brittleness, softness or any other damage or distortion, before
final reassembly if any must be reused.
Main Pump SP002517

Page 31
REASSEMBLY
Pump Regulator Reassembly

1. Install O-ring (733) and compensator piston (621) to piston
case (622). Insert assembly into compensator bore.
2. Insert compensator piston rod (623) into piston bore.
Figure 35
3. Assemble lever (612) to casing using pin (875).
Figure 36
4. Install retaining ring (836) onto spool sleeve (651) and

insert sleeve into spool bore. Insert spool (652) into sleeve
(already installed in block).
Figure 37
Main Pump SP002517

Page 32
5. Attach feedback lever (611) to spool (652) using pin (874).
Figure 38
NOTE: The notched portion of spool should face down

when mated into feedback lever for correct pin
alignment.(Figure 39)
1, 2 - Feedback lever (611)
3 - Spool (652)
3 2
HAOF220L
Figure 39
6. Insert pilot piston (643) into bore.
Figure 40
Main Pump SP002517

Page 33
7. Assemble lever (613) onto feedback lever (611).
NOTE: Make certain pin (875) at the lower portion of
lever (613) is properly mated with groove in
piston (643).
Figure 41
8. Install O-rings (755) onto portion (614) and adjusting (615)

plugs. Insert pin (875) into portion plug. Install both plugs
into their proper bore and secure with retaining rings (858).
NOTE: Be certain to install plugs into correct bore.
Feedback lever should move freely and not bind
up.
Figure 42
9. Install O-rings (722, 735) into cover and mount cover (656)
onto block using four Allen head bolts (438).
Figure 43
Main Pump SP002517

Page 34
10. Install O-ring (728) onto adjusting ring (645). Insert spring
seat (644), pilot spring (646) and adjusting ring (645) into
adjusting ring bore.
Figure 44
11. Insert spring seat (624), outer spring (625) and inner spring
(626) into Pf piston bore. Install O-rings (756, 763) into pilot
piston lower cover (629). Mount cover onto regulator
casing by using four Allen head bolts (438).
Figure 45
12. Install Pf sleeve (631) and pin (898) into compensator

piston bore.
13. Install return spring (654), spring seat (653) and retaining
ring (814) onto feedback lever spool (652). Insert feedback
lever set spring (655) around spool.
Figure 46
Main Pump SP002517

Page 35
14. Insert adjusting screw bushing (647) into pilot piston bore.
Install O-rings (725, 730, 732, 734) into their proper
locations. Mount pilot cover (641) onto regulator casing by
using four Allen head bolts (436, 438).
NOTE: Cover mounting bolts (436, 438) are uneven in
length and must be replaced to their proper
location.
Figure 47
15. Install O-rings (708, 724) to regulator casing base and

mount regulator to pump body using four Allen head bolts
(412, 413)
NOTE: The regulator mounting bolts (412, 413) are
uneven in length and must be replaced to their
proper location.
Figure 48
Main Pump Reassembly

NOTE: Reassembly must be done by reversing disassembly
steps.
1. Begin reassembly with servo piston (532), tilting pin (531)
and feedback pin (538) at top of pump case. Use Loctite
#609 to hold tilting pin and servo piston if those parts have
been disassembled.
2. Bolt swash plate support (251) to pump casing (271).
Tighten four Allen head mounting bolts.
3. Turn pump case upside down, with regulator mounting
surface on work surface. Insert tilting bushing (214) of
swash plate into tilting pin (531) and assemble swash plate
assembly (212/211) to support (251).
NOTE: Apply lubricant to all parts of swash plate
assembly to make assembly work easier. Use
both hands to check and verify complete free
movement of assembly after parts have been
reinstalled.
Figure 49
Main Pump SP002517

Page 36
4. Subassemble driveshaft (111 or 113) with roller bearing
(123), bearing spacer (127) and retaining ring (824). Install
driveshaft into swash plate support (251).
IMPORTANT
Do not use excessive force, hammer blows or other
tools to install the driveshaft. The subassembly can be
assembled using your hands.
Figure 50
5. Mount outer wheel of bearing on end of driveshaft with

plastic hammer. Use brass rod as a drift to push outer
wheel into final position. Install retaining ring (824).
Figure 51
6. Grease O-ring (710) and oil seal (774) for protection; then
install seal cover (261) and tighten mounting screws.
Figure 52
7. Assemble pistons (151) and shoes (152) and cylinder parts

push plate (153), round bushing (156) and spacer (158) in
cylinder (141) and install assembly in pump casing. Mount
valve plate (313 or 314) on valve block (312) and verify
valve plate inlet and outlet port alignment.
Figure 53
Main Pump SP002517

Page 37
Figure 54
8. When both front and rear pump have been completely

reassembled, verify direction of valve block. Install rear
pump first.
Figure 55
9. Install regulators after pump assembly is bolted together

and replace case drain plugs.
Figure 56
Main Pump SP002517

Page 38
SP002998
MAIN CONTROL VALVESP002998
Main Control
Valve
Edition 1
Main Control Valve SP002998

Page 1
MEMO

Page 2
Table of Contents
Main Control Valve

Composite Operation .................................................... 19
Antidrift Valve ................................................................ 20
Disassembly ....................................................... 22
Precautions for Disassembly......................................... 22
Disassembling Procedures............................................ 22
Washing.............................................................. 28
Inspection ........................................................... 28
Assembling ......................................................... 29
Subassembly................................................................. 29
Assembling Control Valve ............................................. 32
Relief Valve ........................................................ 38
Main Relief Valve .......................................................... 38
Overload Relief Valve.................................................... 42
Negacon Relief Valve.................................................... 45
Adjusting Relief Valve ................................................... 47
Installation .......................................................... 48
Operation ............................................................ 48
Control Valve Specification................................. 49
Troubleshooting .................................................. 50
Control Valve: overall .................................................... 50
Hydraulic System: Overall ............................................. 51

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up

Page 5
Page 6
GENERAL DESCRIPTION
Figure 1

Page 7
Theory of Operation
Service Spool Movement

Remove stopper plug of both pilot caps before using this
section.
When necessary, replace the shutoff valve with an overload
relief valve and remove plug at port (P4).
When the spool is moved by being pressurized through the pilot
port (pb2) (pa2) of the first service (Section 2), the neutral path
(L1) will be closed. The oil supplied through port (P1) flows
through the parallel path (L3) load check valve (S2-1), path (S2-
2), and spool head to port (B2) (A2). Lubricant oil returns from
(A2) (B2) to the tank path Ta by the spool head.
This section makes use of the load check valve which allows
external joining at the (P4) port.
Figure 2

Page 8
Swing Spool Movement
When the swing spool is moved by being pressurized through
the pilot port (pb3) (pa3) of the swing (Section 3), the neutral
path (L1) will be closed.
The oil supplied through port P1 flows from the parallel path
(L3), by the load check valve (S3-1), path (S3-2), and the spool
head to the (B3) (A3) port.
Lubricant oil returns to the tank path Ta from (A3) (B3) by the
spool head.
Figure 3
Bucket Spool Movement

When the bucket spool is moved by being pressurized through
the pilot port (pb7) (pb7) of the bucket (Section 7) the neutral
path (R1) will be closed.
The oil supplied through port (P2) flows from the parallel path R3
to port (B7) (A7) by the load check valve (S7-1) path (S7-2) and
spool head.
Lubricant oil returns to the tank path Ta from (A7) (B7) by spool
head.

Page 9
Boom Spool Movement
1. Neutral
This valve incorporates an antidrift valve on the bottom of
the cylinder of boom 1.
In a neutral state, the poppet (AD1) is fully seated by the
pressure at port (A8) which is applied to the spring
chamber (AD5) through the path (AD2), poppet (AD3), and
path (AD4).
Figure 4

Page 10
2. Upward
When the boom1 spool is moved by being pressurized
through the pilot port pa8 of the boom1 (Section 8, Figure
5), the neutral path (R1, Figure 5) will be closed.
The oil supplied through port P1 flows from the parallel
path (R3, Figure 5) to port (A8, Figure 5) by the load check
valve (S8-1, Figure 5) and spool head.
When the boom2 (Figure 5) spool is also moved by being
pressurized through the pilot port (pa4, Figure 5) of boom2,
the neutral path (L1, Figure 5) will be closed. The oil
supplied through port (P1, Figure 5) joins in port A8 by the
parallel path (L3, Figure 5), load check valve (S4-1, Figure
5), spool head and path (7, Figure 5). Lubricant oil returns
to the tank path (Ta, Figure 5) from port B8 by the spool
head.
Figure 5

Page 11
3. Downward (recycle)
When the boom1 (Section 8) spool is moved by being
pressurized through the pilot port pb8 of the boom1, the
neutral path (R1) will be closed.The oil supplied through
port P2 flows from the parallel path (R3) to port B8 by the
load check valve (S8-1) and spool head.
At the same time, when the poppet (AD3) of the antidrift
valve is moved by pressurizing port pc2 to depressurize
the spring chamber (AD5), the poppet (AD1) will be
opened, enabling the lubricant oil to return from port A8 to
the tank path (Ta). A portion of the lubricant oil pushes
open the poppet (S8-3) inside the boom1 spool, flows
through path (S8-2) and joins at port B8 to prevent
cavitation on the cylinder load side.
Figure 6

Page 12
Arm Spool Movement
1. Dump (2 speed convergence)
When the arm1 (Section 5) spool is moved by being
pressurized through the pilot port pa5 of the arm1, the oil
supplied through the P1 port flows from the neutral path
(R1)to the A5 port by load the check valve (S5-1), path
(S5-2) and spool head.
When the arm2 (Section 9) spool is also moved by being
pressurized through the pilot port pa9 of the arm2, the oil
supplied through port P2 flows from neutral path(R1) to join
at port A5 by the load check valve (S9-1) path (S9-2),
spool head, and path (10). At the same time, a portion of
the oil from port P2 flows from path (R3) to port A5 by the
orifice (S9-3), check valve (S9-4), path (S9-2) and path
(10). The lubricant oil returns to the tank path (Ta) from
port B5 by the spool head of arm1; at the same time, it
returns to the tank path (Ta) from path (11) by the spool
head of arm2.
Figure 7

Page 13
2. Crowd (2 speed convergence)
When the arm1 spool is moved by being pressurized
through the pilot port pb5 of the arm1 (Section 5), the oil
supplied from port P1 flows from the parallel path (L1) to
port B5 by the load check valve (S5-1), path (S5-2), and
spool head.
When the arm2 spool is moved by being pressurized
through the pilot port pb9 of the arm2 (Section 9), the oil
supplied through the P2 port will join at port B5 by the
parallel path (R1), load check valve (S9-1), path (S9-2),
spool head, and path (11). At the same time, a portion of
the oil from port P2 flows to port B5 through the path (R3),
orifice(S9-3), check valve(S9-4), path(S9-2), and path (11).
When the antidrift valve spool (AD3) is moved by being
pressurized through the Pc1 port to depressurize the
spring chamber (AD5), the poppet (AD1) will be opened
and the lubricant oil in the A5 port will return to the tank
path (Ta) by the spool head, path (S5-3), and arm variable
recycle orifice (LC8). A portion of the lubricant oil pushes
the poppet (S5-4) in the arm1 spool open, flows through
path (S5-2) and joins at port B5 to accelerate the cylinder,
preventing cavitation on the bottom side.
Figure 8

Page 14
3. Variable recycle (at crowd control)
In arm crowd operation, the spool (S5-6) will stroke
according to the pressure in the path (S5-2) induced
through the path (S5-5), to change the position of the arm
variable recycle orifice (Lc8). When the pressure in path
(S5-2) is high, the stroke of the spool (S5-6) will be
increased, which will increase the opening of the orifice
(Lc8). Conversely, if the pressure in the path (S5-2) is low,
the stroke of the spool (S5-6) will be decreased, which will
decrease the opening of the orifice (Lc8).
Therefore, the recycle oil volume varies according to the
bottom pressure of the arm cylinder.
Figure 9

Page 15
Parallel Orifices for Arm
In the arm parallel circuit of this valve, both arm1 (Section 5) and
arm2 (Section 9) are equipped with orifices, which control the
arm speed even in composite operation. The parallel circuit of
arm2 (section 9) is throttled at the orifice (Rc6) of the sleeve (S9-
3) in the parallel path (R3), and connected with path (S9-2)
through the poppet (S9-4).
The parallel circuit of the arm1 (Section 5) pushes open the
poppet (S5-8) in the parallel path (L3), is throttled by the orifice
(Lc9) of the parallel variable orifice spool, and connected with
the path (S5-2, Figure 11). The throttle volume of orifice (Lc9)
can be controlled by the pressure at the pilot port (pbu) (Pc3).
Figure 10
Figure 11

Page 16
Neutral Cut Spool Movement (First Service convergence)
This valve is equipped with a neutral cut spool at the
downstream end (upstream of the low-pressure relief valve) of
the neutral path (R1). When port (pcc) is pressurized to move
the neutral cut spool (R), the neutral path (R1) will be closed.
Accordingly, the flow to the negacon relief valve (Rc1) is shut-
off, changing the pressure of the ps2 signal.
In the meantime, the oil supplied through the P2 port joins into
the path (S2-2) by (P4, Figure 2) with the external device check
as media and by the empty part of the poppet (S2-1) of the first
service.
Figure 12
Add-on Spool Movement

As a representative example, the second service is illustrated.
When the spool is moved by pressure in the pilot port prb3
(pra3) of the second service (Section 12), the neutral path (pg)
will be closed. The oil supplied through port Pr flows to port BR3
(AR3) by the parallel path (G3), load check valve (S12-1), path
(S12-2), and spool head.
Lubricant oil returns to the tank path (Ta) from AR3 (BR3) by the
spool head.
Figure 13

Page 17
Relief Valve
1. Main relief valve in the body
The oil supplied through ports P1 and P2 is guided to the
main relief valve by the poppet (LP), and by the poppet
(RP) and path (3) respectively. The maximum pressure of
the P1 and P2 side pumps is controlled by activation of the
main relief valve.
Figure 14
2. Relief valve for add-on Pr

The oil supplied through port Pr is guided to the main relief
valve. The maximum pressure of the Pr pump is controlled
by activation of the main relief valve.
Figure 15
3. Overload relief valve

Each cylinder port of each section is installed with overload
relief valves which prevent excessive pressure in the
actuator generated by external force.
Additionally, these relief valves prevent cavitation by
sucking in oil from the tank when the cylinder port pressure
is negative.

Page 18
Composite Operation
Travel Composite Operation

During simultaneous operation of traveling and left-right turn
(forward, backward or spin turn), when an operation other than
travel is done at the same time, or during any operation except
travel, when simultaneous operations of travel and left-right turn
are done, the oil supplied from port PP is isolated from the tank
path (Ta) at the signal land part of a section except the travel
moved by the land (Lc4), (Lc7), (Rc3), and (Rc5), raising the
pressure in the signal path up to the relief setting pressure of the
signal oil source.
The straight travel spool is moved by the rise of the signal
pressure, with the pressure in the PT and PA ports. When the
straight travel spool is moved, the oil supplied through port P1
flows to travel (Section1) by the neutral path (L1) and, at the
same time, flows to the trave (Section 6)l through the path (2),
straight travel spool head, and neutral path (R1)
The oil supplied through port P2 flows to the parallel path (L3) by
the straight travel spool head and path (1).
Travel (Section1 and 6) is operated by the oil supplied through
port P1, and devices other than travel are operated by the oil
supplied through port P2; therefore, fluctuation in travel can be
prevented even in composite operation combined with travel left-
right operation and other devices.
If the event that the load pressure of other sections is higher
than that of the travel (Section 6), a portion of the oil supplied
through port P2 pushes open the poppet (S6-2), passes through
the orifice at the end of the poppet, and joins into path (S-1),
resulting in travel speed reduction shock as the movement of the
straight travel valve is relieved.
Figure 16

Page 19
Antidrift Valve
An antidrift valve is installed in the cylinder port on the side of
the arm load (arm bottom) which prevents the unwanted self-
lowering of the arm (boom) cylinder.
In the neutral state (Figure 14), cylinder port pressure is guided
to the spring chamber (AD5) through path (AD2), poppet (AD3)
gap, and path (Ad4).
The poppet (AD1) is fully seated by the differential pressure
generated by the spring force and the area difference of the
poppet.
In arm damp (boom upward) operation (Figure 17), the oil
supplied from the pump pushes the poppet (AD1) open and
flows into the cylinder port.
Figure 17

Page 20
In the arm crowd operation (boom upward), pc1 (pc2) is
pressurized to move the poppet (AD3) to induce the oil in the
spring chamber (AD5) to the drain path (DR) by the poppet
(AD3) gap and spool (AD6) gap; consequently, the poppet
(AD1) is opened and the lubricant oil in the cylinder port flows to
the tank path (Ta) by the spool.
Figure 18
Figure 19
Figure 20

Page 21
DISASSEMBLY
Precautions for Disassembly

1. On a level surface, place the main equipment on a level
surface and place all other working devices on the ground.
Ensure that neither the traveling nor the swing motion is
self-activated.
Stop engine and release the pressure from all actuators.
WARNING
If the valve assembly is replaced or the valve is
disassembled under pressurized conditions, high-
pressure oil can be released suddenly or parts can be
ejected. When disassembling, fully lower bucket (or
attachment) and fully release all hydraulic oil pressure.
2. Release air pressure from the tank.

3. Clean the working place so no foreign material can enter
into the valve when disassembling.
4. Tag disassembled parts so they can be easily and
correctly identified for reassembling.
5. Replace all seals (O-rings, backup rings) with new ones
6. Spools are matched with the respective valve housing and
sleeves. Therefore, spools must not be replaced.
Disassembling Procedures
In this disassembly section, the parts for assembly are identified
by
Disassembly of Main Spool

1. Unscrew the socket head bolt (width across flats of hole:
6), disassemble the long cap.
Remove O-ring from the groove of the valve housing.
5), disassemble the cap.
Remove O-ring from the cap.
3. Pick out the spools as in subassembly state from the valve
housing.

Page 22
IMPORTANT
Spools must be removed outward straight so they are
not dented or scratched. Dents or scratches can
damage the wall of the valve body when removing
spools. Making reassembly difficult or impossible or
cause improper operation of the valve. Each spool has
to be identified so it can be reassembled in the correct
position. If incorrectly assembled, the spool actuator
will not function properly.

6), disassemble the short cap.
5. Unscrew the spool end (said new part No.-4) (width across
flats of hole: 6) from the spool, remove spring seat [said
new part No. -2] and spring [said new part No. -3].
6. Unscrew the spool end (width across flats of hole: 6) of the
spool, remove spring seat and spring.
Disassemble the plug (groove width: 3), remove poppet,
spring, O-ring, and backup ring.
7. Unscrew the spool end (width across flats of hole: 6) of the
spool, remove spring seat and spring.
Disassemble the plug (groove width: 3), remove poppet,
spring, O-ring, and backup ring.
CAUTION
AVOID INJURY
When disassembling the spool assembly, use the
wooden vise to secure the spool so spool is not
damaged. To prevent the bending of the spool, grip the
spool as close to the end as possible. Adhesive is
applied on the thread of the spool end. Heat up the
outside of the spool end (thread) with an industrial
dryer or similar tool, until spool end can be easily
tightened (standard heating temperature: 200 - 250°C
(392 - 482°F). In the event of excessive heating, the
spring may be weakened by thermal deformation. In
such cases, replace with a new spring. Do not touch
the heated spool to avoid injury.

Page 23
Disassembly of Sub-Spool
1. Unscrew the spool end (width across flats: 5) of the spool,
remove spring seat and spring.
2. Adhesive is applied on the thread connecting the spool and
spool end. Refer to (Caution: 3) when disassembling them.
Disassembly of Sub-Spool
1. Disassemble the plug (width across flats: 32), remove O-
ring.
2. Remove spring and spool.
3. Use a needle to pick the inside of the front hole of the
sleeve to remove sleeve. The piston will come out with the
sleeve.
4. Remove backup ring and O-ring.
Disassembly of Boom, Arm Antidrift Valve

1. Unscrew the socket head bolt (width across flats: 6),
remove body assembly, and remove O-ring from the
groove of the valve housing.
WARNING
When disassembling the control valve still mounted
on the equipment, parts can be ejected by the inner
hydraulic pressure. Unscrew the socket head bolts
slowly, and then disassemble valve when all hydraulic
inner pressure has been fully released.
2. Remove space assembly using the M6 x 1.0 bolt, remove

O-ring and backup ring.
3. Remove spring and poppet.
4. Grip the body assembly with a wooden vise so contacting
surface on the O-ring mounting side is not damaged.
5. Unscrew the plug assembly (width across flats: 38),
remove O-ring.
6. Remove piston, spool and spring.
7. Disassemble the plug (width across flats: 38), remove O-
ring.

Page 24
CAUTION
AVOID INJURY
When disassembling the control valve still mounted
on the equipment, parts can be ejected by the inner
hydraulic pressure. Unscrew the plug slowly, and then
disassemble valve when it is certain that all hydraulic
inner pressure has been fully released.
8. Remove sleeve and poppet.

From the outside of the sleeve, remove O-rings and
backup rings.
9. Remove spring seat and spring from the hole.
Disassembly of Travel Right, Swing, Bucket, Boom1, 2,

Arm1,Boom Swing, Blade, Second Service, Load
check Valve
1. Disassemble the plug (width across flats: 27) of the load
check valve, remove O-rings.
Disassembly of Check Valve in the Straight Travel Orifice

(travel left section)
1. Disassemble the plug (width across flats: 27) of the straight
travel orifice, remove O-ring from the plug.
2. Remove poppet and spring.
Disassemble of Arm2 Load Check Valve

1. Unscrew the socket head bolt (width across flats: 8),
remove flange from the body.
2. Remove sleeve, springs and poppets.
IMPORTANT
Do not let the spring fall on the floor. Debris can enter
the main spool’s sliding part, which could cause the
spool to stick, resulting in improper operation of the
spol actuator.

Page 25
Disassembly of the External Convergence Check Valve of
the First Service
1. Disassemble the plug (width across flats: 32), remove
O-ring from the plug.
3. Disassemble the plug assembly (width across flats: 27),
remove O-ring.
Disassembly of the Common Check Valve

1. Disassemble the plug (width across flats: 27) of the check
valve, remove O-ring from the plug.
Disassembly of the Arm1 Semi Para Check Valve

remove O-ring.
Disassembly of the Relief Valve

1. Remove overload relief valve (width across flats: 32) from
the main body valve and the spool section of the add-on.
2. Remove main relief valve (width across flats: 32) from
main body valve, remove (width across flats: 24) from the
inlet section of the add-on.
3. Remove negacon relief valve (width across flats: 32) from
the main body valve.
IMPORTANT
The relief valve should not be disassembled. Any
disassembling, reassembling, or adjusting of the relief
valve shall void the warranty.
Disassembly of the Shutoff Valve

remove O-ring and backup ring.
• Not used in this valve.

Page 26
Disassembly of Other Plugs
1. Disassemble the plug assembly (width across flats: 19) of
PP port, remove O-ring.
2. Disassemble the plug (width across flats: 19) in the
preliminary section cap part, remove O-ring.
3. Disassemble the G1/8 plug (width across flats: 5, 3 in all)
remove O-ring.
4. Disassemble the G3/8 plug (width across flats: 8, 4 in all),
remove O-ring.
remove O-ring.
remove O-ring.
7. Disassemble the 7/8-14 UN plug (width across flats: 27),
remove O-ring.
Disassembly of the Add-on Section

1. Remove hex nut (width across flats: 19) (width across flats:
22).
2. Remove outlet housing.
3. Remove valve housing for the spool section, remove
O-ring on the contact surface.
4. Remove inlet housing, remove O-ring on the contact
surface.
5. Remove O-ring on the main body contact surface.
6. Unscrew the tie rod and remove from the main body valve
housing.
IMPORTANT
When removing the add-on section, be very careful not
to dent or scratch the contact surfaces. Dents or
scratches can cause an oil leak at the contacting
surface, resulting in improper operation.
Keep dirt and debris away from valve components to
prevent improper operation of the check valve, spool
or spool actuator. If foreign material touches the spool
sliding surface, the spool may get stuck, causing bad
seating in the load check valve and resulting in the
uncontrolled running of the actuator.

Page 27
WASHING
All disassembled parts have to be washed clean with mineral oil.
Dry with compressed air. Place them on a clean sheet of paper
or a vinyl sheet.
INSPECTION
Perform a visual inspection on all parts for any foreign material,
scratches, or other defects.
1. Inspect the seat of the load check valve in the valve
housing for any scratches, dents, dust, or corrosion. Small
scratches may be removed with an oil stone.
2. Inspect the spool for any scratches or dents. Small
scratches may be removed with an oil stone.
3. Test sliding surfaces by moving lightly. All grooves and
paths must be free from foreign material.
4. If a spring is broken, seriously deformed, or worn, replace it
immediately.
5. If the performance of the relief valve is unsatisfactory,
check according to Clause 6, Relief Valve Maintenance.
6. All removed O-rings and backup rings must be replaced
with new ones.
7. Remove cap and plug, check for any residual painting
around the body holes or plugs positions (paint or coating
debris left in the valve will cause improper operation or oil
leaks).

Page 28
ASSEMBLING
IMPORTANT
Check number of parts, assembling position, and
necessary tools before starting assembly. Before assembly,
make sure all parts and necessary tools are available.
Check the correct position of how all parts are assembled.
Subassembly
Before assembling the parts into valve housing, subassemble
the necessary parts.
Main Spool
1. Apply adhesive on the threads of spool.
Install spring seat, spring, and spool end then fix spool with
wooden vise and tighten spool end.
• Torque: 9.8 - 11.8 Nm
IMPORTANT
Do not apply adhesive excessively. Position the spool
as near to the spool end as possible so tightening
torque does not bend the spool. Excessive torque can
result in spool damage, causing the spool to stick and
improper operation of the spool actuator.
IMPORTANT
The spring in boom 2 spool and the straight travel
spool are different from other parts. Incorrect
assembly of the spools cause a improper operation of
the spool actuator.
2. Assemble poppet and spring in the spool.

Apply adhesive on the spool thread.
Fix the spool with the wooden vise.
Apply adhesive to the tread of the plug.
Insert the plug which is fitted with an O-ring and backup
ring.
• Torque: 9.8 - 11.8 Nm
Assemble spring seat, spring and spool end, and attach
spool end.

Page 29
• Torque: 9.8 - 11.8 Nm
3. Insert poppet and spring into the hollow of the spool.
Apply adhesive to the thread of the spool for plug fitting.
Insert the plug assembled with an O-ring and backup ring.
• Torque: 9.8 - 11.8 Nm
Apply adhesive to the thread of the spool which is
assembled with the spool end.
Install spring seat, spring and spool end. Install the spool
with a wooden vise, and tighten the spool end.
• Torque: 9.8 - 11.8 Nm
IMPORTANT
Improper installation of the O-ring and back-up ring
can cut and damage the components causing
improper operation.
Sub Spool
1. Apply adhesive to the thread of the spool.
2. Install spring seat, spring and spool end. Install the spool
with a wooden vise and tighten the spool end.
• Torque: 19 - 22 Nm
Sub-Spool Part
1. Insert backup ring and O-ring into sleeve.
2. Insert piston into the sleeve fitted with seal.
3. Insert spool into the sleeve.
Boom, Arm Antidrift Valve

1. Insert O-ring nd backup ring into the outer groove of the
sleeve.
IMPORTANT
Improper positioning of the O-ring and back-up ring
can cause improper operation of the spool actuator.
2. Insert poppet and spool into the hole of the sleeve, making
sure the direction is correct.
3. Attach spring seat to the groove at the end of the poppet,
place spring and insert into the body hole with the sleeve.
4. Fix the body at the contacting surface on the O-ring side
using a wooden vise to prevent scratching.

Page 30
IMPORTANT
Apply grease on the spring and spring seat so both
can be correctly positioned on the poppet. If the spring
is not correctly positioned on the spring seat, it can be
damaged or break causing broken spring parts to
result in improper operation of the valve.
5. Insert spring and piston into plug.

6. Install the plug assembly attached with the O-ring to the
plug.
• Torque: 147 - 157 Nm
7. Install the plug attached with O-ring to the body.
• Torque: 147 - 167 Nm
Shutoff Valve
1. Assemble the O-ring and backup ring to the plug.
IMPORTANT
Make sure that O-ring and backup ring are correctly
positioned. If the positions of the two rings are
reversed, the O-ring can be cut and damaged causing
improper operation of the spool actuator.

Page 31
Assembling Control Valve
Assembling Add-on Section

1. Install tie rod in the main body valve housing.
IMPORTANT
Tighten the tie rod to properly align and assemble the
valve section to the valve body. Improper assembly
can cause oil leaks or improper operation of the valve
body. Damage to the tie rod threads can also occur.
2. Install the O-ring on the contact surface of the main body.

3. Using the tie rod as a guide, mount the inlet housing on the
main body valve housing. Install the O-ring on the contact
surface.
4. Using the tie rod as a guide, mount the valve housing for
the spool section on the inlet housing. Install the O-ring on
the contact surface.
5. Using the tie rod as a guide, mount the outlet housing on
the valve hosing for spool section.
IMPORTANT
When installing the add-on section, do not dent or
scratch the contact surfaces. This can cause an oil
leaking resulting in improper operation. Make sure that
all contacts surfaces are clean and that O-ring is
positioned correctly.
IMPORTANT
When installing the add-on section, the tie rod must be
used as a guide for correct positioning. This will
prevent separation of the O-ring from the contact
surface resulting in an oil leak or improper operation.
6. Insert the hex nut into the tie rod and tighten them.
• Torque: 152 ±7 Nm
Insert the hex nut into the tie rod and tighten them.
• Torque: 93 ±4 Nm

Page 32
IMPORTANT
The hex nut must be tightened to the specified torque
to prevent oil leaks. Over-tightening the hex nut can
distort the valve housing causing the spool to stick
resulting in improper operation of the spool actuator.
All hex nuts should be tightened to the same torque.
IMPORTANT
Always follow the instructions provided for
disassembly and reassembly of the add-on valve
section.
Assembling Right Travel, Swing, Bucket, Boom1, 2, Arm1,

and Blade Load Check Part
1. Insert the poppet and spring into the valve housing.
2. Insert the plug assembled with O-ring and tighten them.
• Torque: 103 - 113 Nm
Assembling Arm2 Load Check Valve Part

1. Insert the spring and poppet on the outside of the sleeve.
With the poppet and spring nside the sleeve, insert them
into the valve housing.
2. Mount the O-ring on the valve housing groove. Mount the
flange and tighten with socket head bolt.
IMPORTANT
When assembling the flange, the spring must be
inserted into the flange position or the spring can be
damaged. Socket head bolt must be tightened
uniformly and firmly.

Page 33
Assembling Travel Orifice (left travel section) Check Valve
2. Insert the plug assembled with the O-ring and tighten.
• Torque: 103 - 113 Nm
IMPORTANT
When installing the plug (19), the spring (17) must be
inserted into the plug completely. If the spring is not
fully inserted, it can be broken. Tighten all plugs with
springs fully inserted into the plug.
First Service, Assembling External Joint Flow Check Valve

2. Insert the plug assembled with the O-ring and tighten.
• Torque: 103 - 113 Nm
3. Insert the plug assembly inserted with the O-ring and
tighten them.
Assembling Common Check Valve

2. Insert the plug inserted with the O-ring, and tighten the
plug.
• Torque: 103 - 113 Nm
Assembling Arm1 Semi Para Check Valve

1. Insert the poppet and spring.
2. Tighten the plug assembled with the O-ring.

Page 34
Assembling Boom, Arm Antidrift Valve
1. Insert the O-ring into the contact surface.
2. Insert the poppet into the valve housing
3. Insert the spacer attached with the O-ring and backup ring
into the valve housing with the spring.
IMPORTANT
Insert the spring carefully so it is located in the spacer
position correctly. If the spring is not located in the
spacer position correctly, it can break causing broken
parts to result in improper operation of the valve.
4. Insert the socket head bolt into the body assembly and
tighten them.
Assembling Relief Valve

1. Insert the overload relief valvesand tighten them: total 8.
2. Inset the main body relief valves and tighten them.
3. Insert the add-on main relief valves and tighten them.
4. Insert the negacon relief valves and tighten them.
• Torque: 103 - 113 Nm
Assembling Sub-Spool
1. Insert the spool assembly into the original place.
2. Install the cap attached with the O-ring.
Insert the socket head bolts into the cap and tighten them.
• Torque: 8.8 - 10.5 Nm
IMPORTANT
When installing spool into valve body, move spool
back and forth to check that it slides back and forth
smoothly without any binding.

Page 35
Assembling Sub Spool
1. Insert the spool assembly into the original place.
2. Insert the spring.
3. Insert the plug attached with the O-ring, and tighten the
plug.
• Torque: 103 - 113 Nm
Assembling Main Spool

1. Insert the O-ring into the valve housing.
2. Install the short cap] in the straight travel spool.
Install to other spools.
Insert the socket head bolt into the short cap, and tighten it.
3. As a subassembly, insert the spools into their respective
(original) holes.
4. Install the long cap in the straight travel spool (10).
Install the long cap in the other spools.
Insert the socket head bolt into the long cap, and tighten it.
IMPORTANT
When inserting the cap, be careful not to allow the O-
ring to separate on the contact surface.

Page 36
Assembling Other Plugs
1. Insert the plug assembly assembled with the O-ring.
• Torque: 205 - 227 Nm
• Torque: 13.5 - 16.5 Nm
• Torque: 103 - 113 Nm
• Torque: 116 - 128 Nm
IMPORTANT
When assembled, check for any missing or loose
parts. If loose, an oil leak can occur. All specified
torque values are all in wet condition (applied with oil).

Page 37
RELIEF VALVE
Main Relief Valve
Body Main Relief Valve Operation

1. This relief valve is inserted between the neutral path "HP"
and low-pressure path "LP", oil is filled in the inner space
(C) through the orifice of the main poppet (1). The sleeve
(2) and main poppet (1) are securely seated by the areal
difference between "A" and "B".
Figure 21
2. When the pressure in the neutral path "HP" reaches the

preset pilot spring force, the pilot poppet will be opened. Oil
flows around the pilot poppet (3), through the drill hole (D)
and circular gap (E), and is guided to the tank path "LP".
Figure 22
3. When the pilot poppet (3) is opened, the pressure in the

inner space (C) is decreased to open the main poppet (1).
Therefore, the oil in "HP" flows directly through path "LP".
Figure 23

Page 38
Disassembling / Reassembling Body Main Relief Valve
Figure 24
Disassembling
1. This part is replaced by assembly.
2. When replacing, unscrew plug <width across flats: 32>
with wrench, remove O-ring.
3. If oil leaks at the adjuster kit, disassemble adjuster kit and
replace O-ring.
IMPORTANT
When disassembling the adjuster kit, parts may be
ejected by the spring. Be careful not to lose the poppet.
Assembling
1. Check if there is dust, paint, etc., on the thread of the plug.
Insert a new O-ring.
2. Clean the relief mounting part of the valve housing. Install
a relief valve and insert the plug.
3. When the adjuster kit is disassembled, clean the threads.
Adjust pressure in compliance with the clause.
IMPORTANT
All specified torques values are for wet conditions
(applied with oil).

Page 39
Add-on Main Relief Valve Operation
and the tank path "LP". Oil is filled into the inner space (C)
through the orifice of the main poppet .
The sleeve (2) and main poppet (1) are securely seated by
the areal difference between "A" and "B".
Figure 25
2. When the pressure in the neutral path "HP" reaches the

preset pilot spring force, the pilot poppet (3) will be opened.
Oil flows around the pilot poppet (3), through the drill hole
(E) and circular gap (D), and is guided to the tank path
"LP".
Figure 26
3. When the pilot poppet (3) is opened, the pressure in the

inner space (C) is decreased to open the main poppet (1).
Therefore, the oil in "HP" flows directly through path "LP".
Figure 27

Page 40
Disassembling / Reassembling Add-on Main Relief Valve
Figure 28
Disassembling
1. This part is replaced by assembly.
2. When replacing, unscrew the plug (width across flats: 32)
with a wrench, then remove O-ring.
3. If oil leaks at the adjuster kit, disassemble the adjuster kit
and replace the O-ring.
IMPORTANT
ejected by the spring. Be careful not to lose the poppet.
Assembling
1. Check for dust, paint, etc., on the thread of the plug. Insert
the new O-ring.
2. Clean the relief mounting part of the valve housing. Install
the relief valve, insert plug.
3. When the adjuster kit is disassembled, clean the threads.
Adjust pressure in compliance with the clause.
IMPORTANT
All specified torques values are for wet conditions
(applied with oil).

Page 41
Overload Relief Valve
Relief Valve Operation

and tank path "LP". Oil is filled in the inner space (G)
through the orifice of the piston (C).
The sleeve (K) and main poppet (D) are securely seated by
the areal difference between "A" and "B".
Figure 29
2. When the pressure in the cylinder port "HP" reaches the

preset spring force of the pilot poppet, the pilot poppet (E)
will be opened.
Oil flows around the poppet, through the drill hole (H), and
is guided to the low-pressure path "LP".
Figure 30
3. The pilot poppet (E) opens to make the oil flow through the
orifice (1) of piston (C), differential pressure is generated
between path "HP" and the back side of the piston (C) to
move the piston (C) to seat the poppet (E).
Figure 31

Page 42
4. For the oil flow through the path "HP" and poppet (D), the
pressure difference increases because of throttling by the
poppet (D), circular gap of piston (C), and orifice. The
poppet (D) is opened by the differential pressure and oil
flows directly through path "LP".
Figure 32
Suction operation
1. This relief valve is equipped with an antivoid unit in the
cylinder port "HP", which supplies oil when cavitation
occurs. In the low-pressure side "LP", when the pressure in
the cylinder port "HP" is low, the sleeve (K) is opened by
the differential pressure generated by the areal difference
between "A" and "B". Oil flows from the low-pressure side
"LP" into the cylinder port "HP" to prevent cavitation.
Figure 33

Page 43
Disassembling / Reassembling Overload Relief Valve
Figure 34
Disassembling
1. This part is designed to be replaced by assembly.
2. When replacing, unscrew the cap (hex, width across the
flats: 32) with wrench, and remove O-ring.
3. If oil leaks at the adjuster kit, unscrew the adjuster kit and
replace the O-ring.
IMPORTANT
ejected by the spring. Be careful not to lose the
poppet.
Assembling
1. Check for dust, paint, or dirt on the threaded part of the
cap, insert a new O-ring.
2. Clean the relief valve mounting of the valve housing,
assemble the relief valve, and insert the cap (width across
the flats: 32).
3. If the adjuster kit is disassembled, clean the threaded part
and adjust the pressure in compliance with the clause.
IMPORTANT
All specified torque values are all for wet conditions
(applied with oil).

Page 44
Negacon Relief Valve
Negacon Relief Valve Operation
Figure 35
Generation of Signal Pressure

The oil supplied through the pump port (P1) flows to the tank
path through the neutral path (L1) and the negacon orifice (D) at
the neutral downstream path (A).
In this process, pressure is generated in the path (B) by the
negacon orifice (D), and the pressure is induced in the negacon
signal pressure port (Ps1) through path (E).
When the main spool that is upstream of the neutral downstream
path (A) is activated, the oil flow through the neutral downstream
path (A) is decreased and the negacon signal pressure is
reduced.
Relief Operation
In the event there is excessive oil flow in the neutral downstream
path (A), the pressure generated in path (B) by the negacon
orifice (D) is induced to the back chamber (C) of the poppet. The
poppet is activated by the differential pressure generated by the
difference in the hydraulic area between the path (B) and the
back chamber (C). When this poppet is activated, oil flows to the
tank path (Ta) through path (B) and the drill hole path (F) of the
plug, preventing excessive pressure in the negacon signal
pressure port.

Page 45
Disassembling / Reassembling Negacon Relief Valve
Figure 36
Disassembly
1. This part is designed to be assembly-replaced without
disassembly, in order for the press-in at the "D" part.
Assembling
1. Check for dust, paint or any dirt on the threaded part of the
plug , and insert a new O-ring.
2. Insert a new O-ring into sleeve.
3. Clean the relief valve mounting of the valve housing, insert
the plug (width across the flats: 46) of the relief assembly.
• Torque: 103 - 113 Nm
IMPORTANT
All specified torque values are all for wet conditions
(applied with oil).

Page 46
Adjusting Relief Valve
Main Relief Valve (common for body and add-on)

1. This part is designed for non-disassembly and is not
subject to readjustment. If pressure is adjusted, we cannot
guarantee its proper operation.
2. Install a precise pressure gauge at the circuit inlet.
3. Run the pump at the rated rpm.
4. Move the spool in the control valve, read the pressure
gauge indication at the end of the cylinder stroke.
IMPORTANT
Move the spool of the actuator. The set pressure of the
overload relief valve is higher than that of the main
relief valve actuator spool.
5. Turn the adjuster clockwise until desired pressure is

obtained.
17.8 MPa of pressure is increased by a turn of the adjuster.
6. When the desired pressure is reached, and press the
adjuster so it does not rotate, then tighten the locknut.
7. Raise the pressure again to check that specified pressure
is obtained.
Overload Relief Valve
IMPORTANT
If the set pressure is higher than that of the main relief
valve, it will be activated during the following adjustment. It
is not possible to adjust the overload relief valve. Do not
disassemble or adjust it. Replace with a complete new set
of assembled relief valves.
1. This part is designed for non-disassembly and should not

be adjusted. Replace by assembly. If the pressure has
been adjusted, we cannot not guarantee its proper
operation.
2. Move the control valve spool, and read the pressure gauge
indication at the end of the cylinder stroke.

Page 47
3. Turn the adjuster clockwise until desired pressure is
reached.
21.2 MPa of pressure is increased by each turn of the
adjuster.
4. When the specified pressure is reached, press the adjuster
so it does not rotate, and tighten the locknut.
5. Raise the pressure again to check the rated pressure has
been obtained.
INSTALLATION
1. Piping should not exert unnecessary force on the valves.
2. Bolts must be tightened uniformly.
3. Welding work near the valves can damage the seals
because of excessive heat or flame.
4. Keep the ports covered until connected with a pipe to
prevent dust.
OPERATION
1. Check that hydraulic circuit and oil are clean before
operation.
2. Oil must be hydraulic oil, with an aniline point of 82 - 113°C
3. Keep the relief valve below the specified pressure.
4. The pressure difference between the main relief valve and
the overload relief valve must be set at a minimum of 2.0
MPa.
5. Perform deaeration and warming up before operation.
• In particular, when the temperatures of the hydraulic
oil and valve are low, observe the following
instructions to prevent the stick of the spool by
thermal shock;
• Do not operate the main relief valve and overload
relief valve abruptly without a proper time interval. Let
the hydraulic oil circulate in each actuator to warm up
all the parts uniformly.
• Fine or complex operations which can cause local
overheating at the orifices of each part should not be
done abruptly at low temperature.

Page 48
CONTROL VALVE
SPECIFICATION
Item Specification
160 l/min
Rated Flow (main body)
(At neutral: 30 l/min)
Rated Pressure (main body) 35 MPa
Rated Flow (Add-on Pr) 70 l/min
Max. Pressure (Add-on Pr) 25 MPa
Peak Pressure: 1.5 MPa max.
Allowable Back-pressure (Operating Pressure: 0.5 MPa
max.)
Operating: -25 - 80°C
Allowable Oil Temperature Instantaneous: 100°C max.
(seal: nitrile rubber)

Page 49
TROUBLESHOOTING
Control Valve: overall

Spool does not stroke. Oil temperature is too high. Remove obstructions in the piping line,
which may resist oil flow.
Hydraulic oil is contaminated. Replace hydraulic oil, wash circuit.
Piping port joint is loose. Check torque.
Valve housing is torted after Check by unscrewing joint bolts.
installation.
Pressure is too high. Install pressure gauge to check pressure
at pump and cylinder port.
Spool is bent. Replace with valve assembly.
Return spring is damaged. Replace damaged part.
Spring or cap is separated. Unscrew cap to fix, and tighten it.
Temperature distribution in valve is Warm up the whole circuit.
not uniform.
Dust in valve. Remove dust.
Insufficient pilot pressure Check pilot valve and pilot relief pressure.
Cannot maintain load. Cylinder oil leak. Check cylinder seal.
Oil is bypassed in spool. Check if spool is scratched.
Oil leak at overload relief valve oil. Wash valve housing seat and relief valve
seat.
Oil leak at antidrift valve. Disassemble antidrift valve, wash all the
seats clean.
If seat is scratched, replace the poppet, or
lap the poppet and seat.
If the antidrift valve spool has a problem,
spool and sleeve must be replaced
together (they are match-finished).
When the spool is moved Dust in load check valve. Disassemble and wash check valve.
from neutral to higher Poppet or seat of valve is Replace poppet or lap poppet and seat.
position, load carrying scratched.
capacity is reduced.

Page 50
Relief valve

Pressure does not rise at all Main poppet, sleeve or pilot poppet Replace relief valve.
is stuck open; or there is dust in the
valve seat.
Relief pressure is unstable Pilot poppet seat is scratched.
Piston or main poppet is stuck.
Relief pressure fluctuates Seat worn by dust.
Loose locknut or adjuster Reset the pressure, and tighten the
locknut by specified torque.
Oil leak Relief valve seat is damaged. Replace relief valve.
Parts are stuck with dust.
O-ring is worn. Replace the O-ring in the adjuster or
installation part.
Hydraulic System: Overall

Hydraulic system is not in Pump failure Check pressure, or replace pump.
good condition, or does not Relief valve failure Replace relief valve.
function at all.
Cylinder failure Repair or replace.
Pump load pressure is too heavy. Check circuit pressure.
Valve is cracked. Replace with valve assembly.
Spool does not stroke in full travel. Check spool movement.
Tank oil level is too low. Refill hydraulic oil.
Filter in the circuit is clogged. Wash or replace filter.
Circuit piping line is throttled. Check piping.

Page 51
Page 52
SP001646
REMOTE CONTROL VALVE (WORK LEVER /
JOYSTICK) SP001646
Remote Control
Valve (Work
Lever / Joystick)
Edition 2
Remote Control Valve (Work Lever / Joystick) SP001646

Page 1
MEMO

Page 2
Table of Contents
Remote Control Valve (Work Lever /

Joystick)
Parts List ......................................................................... 8
Specifications ................................................................ 10
Torques ......................................................................... 10
Tools and Materials ............................................ 10
Disassembly ....................................................... 11
Tolerances)......................................................... 14
Reassembly ........................................................ 15

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up
DX180LC 5001 and Up
DX225LC 5434 and Up
DX225LL 5001 and Up
DX300LL 5001 and Up
DX300LC 7440 and Up
DX340LC 5980 and Up
DX350LC 5980 and Up
DX380LC 5109 and Up

Page 5
Page 6
GENERAL DESCRIPTION
Theory of Operation
Structure
The remote control valve contains four push rods, spring
holders, spools and return springs, which are in the valve
casing. The valve works as a pressure reduction valve.
The housing has six ports, which include input port P, tank port
T, and four secondary pressure ports.
The electric horn button is installed in the valve handle.
Gear pump pressure is used for operating control spools.
Function
1. Neutral Position
When the lever is in neutral mode, the spool is pushed
upward by return spring. The force of balancing spring,
which determines the secondary discharge pressure, is not
transmitted to the spool. The input port is closed and the
pressure of the output port is the same as the pressure of
the tank port T.
2. Control Switch
Pressing of the push rod starts to press the balance spring,
whose force is transferred to the spool to connect the P
and T ports, transferring the pilot pressure. Output
pressure acts on the bottom of the spool and press the
spool upwards until it is balanced with the force of the
balance spring.
In short, the second pressure (output pressure) changes in
proportion to the pressing force of the balance spring.

Page 7
Parts List
Figure 1

Page 8
Reference Reference
Number Number
1 Case 20 Boot
2 Plug 21 Joint Assembly
3 Bushing 22 Swash Plate
4 Spool 23 Hex Nut
5 Shim 24 Nut
6 Spring Handle Assembly (RH)
25
7 Spring Seat Handle Assembly (LH)
8 Stopper 26 Handle Bar
9 Spring 27 Spring Pin
10 Stopper 28 Bellows
11 Spring 29 Bushing
12 Push Rod 30 Connector Assembly
13 Spring 31 Switch Kit
14 Spring Seat 32 Spool Kit 1, 3
15 Stopper 33 Spool Kit 2, 4
16 Plug 34 Plug Kit 1, 3
17 O-ring 35 Plug Kit 2, 4
18 Rod Seal 36 Handle Kit (RH)
19 Plate 37 Handle Kit (LH)

Page 9
Specifications
Performance
(2, 4) (1, 3)
40 40 40 40
Secondary Pressure (kgf/cm2)
Secondary Pressure (kgf/cm )

2
Operating Torque (kgf.cm)

26 1.5 26 1.5
(20) (19.6)
(19)
Operating Torque (17.5) Operating Torque
15.9 3 15.4 3
6.5 1 6.5 1
5.5 2 5.5 2
Secondary Pressure
Secondary Pressure
0 1 (6.2) 7.5 8 0 1 (5) 6.5 7

Push Rod Strike (mm) Push Rod Stroke (mm)
FG013492
Figure 2
Torques
No. Tool Standard Remark
2 Plug PT 1/8 370 kg•cm (27 ft lb)
22 Swash Plate 27 mm 1,660 kg•cm (120 ft lb)
23 Hex Nut 22 mm 1,660 kg•cm (120 ft lb)
24 Nut 22 mm 1,660 kg•cm (120 ft lb)
TOOLS AND MATERIALS

No. Tool Standard Remark
2 L-Wrench PT1/8 plug
22 Spanner 27 mm swash plate
23 Spanner 22 mm hex nut
24 Spanner 22 mm nut

Page 10
DISASSEMBLY
1. Remove lead wire from bushing (29).
FG013494
Figure 3
2. Remove lever assembly from case (1).
FG013495
Figure 4
3. Remove hex nut (23) and swash plate (22) from case (1).
FG013496
Figure 5
4. Remove joint assembly (21) from case (1).
FG013497
Figure 6

Page 11
5. Remove plate (19) from case (1).
FG013498
Figure 7
6. Remove plug kit assembly, stopper and spring (11) from

case (1).
FG013499
Figure 8
FG013500
Figure 9
FG013501
Figure 10

Page 12
7. Remove four spool kit assemblies from case (1).
FG013502
Figure 11
FG013503
Figure 12
8. The bushing (3) and plug cannot be removed from case

(1).
FG013504
Figure 13
FG013505
Figure 14

Page 13
FG013506
Figure 15
FG013507
Figure 16

(WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to
"General Maintenance Procedures" section.

Page 14
REASSEMBLY
1. Install four plugs (2) into case (1).
FG013504
Figure 17
FG013507
Figure 18
2. Install bushing (3) into case (1) using jig.
FG013506
Figure 19
FG013508
Figure 20

Page 15
3. Take care when assembling spool kit assemblies (1 and 3,
2 and 4). (They must be assembled in same way).
The assembly order is; spool (4), shim (5), spring (6),
spring seat (7), and stopper (8).
FG013509
Figure 21
FG013503
Figure 22
4. Install spring (9) into case (1).
FG013499
Figure 23
5. Install spool kit assembly into case (1). (The same way is
used for four parts.)
FG013502
Figure 24

Page 16
6. Assemble plug kit insert rod seal (18), O-ring (17), and
push rod (12) into plug (16) in proper order.
FG013511
Figure 25
FG013512
Figure 26
7. Assemble four springs (11) and stoppers and insert

assembled set in case (1) to form a plug kit assembly.
NOTE: Pay attention to measurement specifications of
stoppers (1 and 3, 2 and 4).
FG013499
Figure 27
FG013501
Figure 28

Page 17
8. Install plate (19) into case (1).
FG013498
Figure 29
9. Install joint assembly (21) into case (1).
FG013497
Figure 30
10. Install boot and swash plate (22) and hex nut (23) into case
(1).
FG013513
Figure 31
FG013514
Figure 32

Page 18
11. Insert bar and tighten it with a spanner to check balance of
joint assembly.
FG013515
Figure 33
12. Install bushing (29) into case (1).
FG013516
Figure 34
13. Install lever assembly into case (1).
FG013495
Figure 35
14. Put lead wire in bushing (29), tie it, and arrange boot.
FG013494
Figure 36

Page 19
15. Install lead wire terminal into connector terminal pressing
them together.
FG013118
Figure 37
16. Assemble connector assembly (30), and connect it to lead

wire terminal, and properly route wiring.
FG013519
Figure 38
FG013520
Figure 39

Page 20
START-UP PROCEDURES
1. Start engine and set throttle at "LOW IDLE".
2. Set safety lever on "UNLOCK" position.
HAOB290L
Figure 40
3. Slowly cycle boom, arm, bucket cylinders and swing motor

about five times without a load to vent air from pilot lines.
Do this for five minutes.
ARO0470L
Figure 41

Page 21
Page 22
SP002999
TRAVEL CONTROL VALVE (WITH DAMPER)
SP002999
Travel Control
Valve (with
Damper)
Edition 1
Travel Control Valve (with Damper) SP002999

Page 1
MEMO

Page 2
Table of Contents
Travel Control Valve (with Damper)

Pressure Reducing Valve................................................ 8
Operating Theory of Damper Mechanism ....................... 9
Causes of Faults and Measures ......................... 11
Parts List ....................................................................... 12
Specification .................................................................. 14
Torques ......................................................................... 14
Removal ............................................................. 15
Disassembly ....................................................... 16
Tolerances)......................................................... 18
Reassembly ........................................................ 19
Installation .......................................................... 24

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up
DX180Lc 5001 and Up
DX225LC 5434 and Up
DX225LL 5001 and Up
DX255LC 5150 and Up
DX300LC 7440 and Up
DX300LL 5001 and Up
DX340LC 5980 and Up
DX350LC 5980 and Up
DX420LC 5327 and Up
DX480LC 5221 and Up
DX520LC 5117 and Up

Page 5
Page 6
GENERAL DESCRIPTION
Theory of Operation
The damper valve is divided into two areas of operation. There
is the pressure reducing valve (a) and the damper mechanism
(b). The following hydraulic circuit is an example of a remotely
located control valve.
5
6
P T
4
2
ARS1810L
Figure 1
Reference Reference
Number Number
1 Remote Control Valve 4 Control Valve
2 Pilot Pump 5 Hydraulic Motor
3 Main Pump 6 Hydraulic Cylinder

Page 7
Pressure Reducing Valve
1. Neutral Condition
If pedal is in neutral, spool is pushed up by return spring
and spring seat. Port (P) is blocked by bottom part of spool
and four operating ports (left forward and backward, right
forward and backward) are connected to port (T) through
inner hole of spool.
2. Half Operation Condition
If pedal is moved, push rod moves down, and they transmit
this force through spring seat and control spring to spool. If
spool is moved, primary pressure is transmitted through an
inner hole of spool to operating port. If lever is stopped in
middle position, compressed control spring force and
secondary pressure transmitted through hole acts at
bottom part of spool, balance is maintained by hydraulic
force acted upward, and then this pressure is transmitted
to traveling spool of control valve. That is, primary pressure
is transmitted to operating port as secondary pressure
equivalent to control spring force compressed by spool.
3. Full Operating Condition
If pedal is moved to a maximum, bottom part of push rod
presses spool seat to a maximum, and compresses control
spring to a maximum. Primary pressure is transmitted
through inner hole of spool to operation port, secondary
pressure transmitted through spool overcomes control
spring force and pushes spool up, but spool is restricted by
push rod and does not move any more. That is, when
pedal lever is moved to a maximum, control spring does
not function, spool is restricted by push rod, and then
primary pressure equalizes to secondary pressure.

Page 8
Operating Theory of Damper Mechanism
1. Operation When Operating Lever
When pushing pedal, pushing force pushing push rod and
spool presses cylinder, return spring and hydraulic oil in
cylinder is compressed, piston coming down with push rod
compresses vibration prevention chamber of lower part, oil
of vibration prevention chamber of lower part is flowed
through orifice to oil pressure vibration prevention chamber
of upper part of low pressure, now, ball check valve
becomes closing condition because high pressure
operates to vibration prevention chamber of lower part.
2. Operation When Operating Lever In Neutral Condition
Climbing restoring force acting on push rod, raises piston
in oil pressure prevention chamber and compresses upper
oil pressure prevention chamber. This compression
operation of upper oil pressure prevention chamber
prevents the push rod from quickly rising by restoring
spring, and the damping force is generated.
Figure 2
Reference Reference
Number Number
1 Push Rod 1 Neutral Position
2 Orifice 2 Maximum Operating Angle 12.4"
3 Piston
4 Piston Chamber

Page 9
Page 10
CAUSES OF FAULTS AND
MEASURES
At times it may be difficult to pinpoint the source of the problem.
The following table lists some of the possible problems, possible
causes and remedies. Refer to this table for possible causes
and remedies to assist in correcting the sometimes difficult
problems.
The table only lists some general problems, possible causes
and their remedies. In many cases the problem is not caused by
the failure of a single part but, may be the result of a
combination of problems from related parts and their
components. Possible problems other than the ones list are not
being specified but that is not to say that these are the only
possible problems that can occur. The technician must diagnose
the problem, considering all possible causes and repair the
source of the malfunction.

Secondary pressure will not Low primary pressure. Adjust primary pressure.
increase. Defective secondary pressure Replace with new spring.
select spring.
Gap between damper spool and Replace damper spool casing assembly.
casing is abnormally large.
Defective operating parts and Disassemble/reassemble and replace
components. defective parts.
Unstable secondary Jamming of interconnected parts. Repair/replace cause of jamming.
pressure. Unstable tank line pressure. Install direct line to hydraulic tank.
Air in hydraulic lines. Vent air from system.
Abnormally high secondary High tank line pressure. Install direct line to hydraulic tank.
pressure. Jamming of interconnected parts. Repair/replace cause of jamming.
No dampening. Air in piston chamber. Vent air from system.
Jamming of interconnected parts. Repair/replace cause of jamming.
Worn damper springs. Replace with new parts.
Worn damper spool and housing. Replace damper spool and housing
assembly.
Defective/damaged check valve. Disassemble and examine check valve.
Worn damper spool orifice. Replace damper spool.
Damper spool feels heavy. Defective interconnected Repair/replace defective parts.
components.
Restricted movement of damper Repair/replace damaged piston.
spool.

Page 11
Parts List
Figure 3

Page 12
Reference Reference
Number Number
1 Body (1) 21 O-ring
2 Body (2) 22 Rod Seal
3 Plug 23 Dust Seal
4 Plug 24 Cover
5 Spring Seat 25 Hex Socket Head Bolt
6 Spring 26 Cam
7 Shim 27 Bushing
8 Spool 28 Camshaft
9 Stopper 29 Set Screw
10 Spring 30 Set Screw
11 Spring Pin 31 Hex Nut
12 O-ring 32 Bellows
13 Push Rod 33 Piston
14 Spring Pin 34 O-ring
15 Seal 35 O-ring
16 Steel Ball 36 Expand
17 Spring 37 Spool Kit
18 Plate 38 Plug Kit
19 Snap Ring 39 Cam Kit
20 Plug

Page 13
Specification
40 160
112.6
Secondary Pressure (kgf/cm2)
25 1.5

Operating Torque 91.8
46.4
7.5 1
Secondary Pressure
0 1 0.5 4.8 0.5 5.5
Rush Rod Strike (mm) FG013534

Figure 4
Travel Control Valve Specification

Type Pilot Control (With Damper)
Pressure / Stroke 25 kg/cm2 @ 4.8 mm Stroke

(356 psi @ 0.1890 in Stroke)
Weight 7.8 kg (17 lb)
Torques
No Bolt Size Tool Tightening Torque
88 kg•cm
26 M6 PT1/8
(6 ft lb)
100 kg•cm
30 M8 27 mm
(7 ft lb)
440 kg•cm
32 M10 22 mm
(32 ft lb)
440 kg•cm
37 M10 22 mm
(32 ft lb)

Page 14
REMOVAL
3. Stop engine.
DO NOT OPERATE
WARNING
or maintenance
950205-01451
ON OFF
FG028828
If engine must be running while performing
maintenance, always use extreme caution. Always
have one person in the cab at all times. Never leave the
cab with engine running.

switch.
9. Hang a maintenance warning tag on controls.
10. Disconnect negative (-) battery cable leading to frame from
battery.
11. Remove cabin under cover by loosening bolts. 2
12. Tag and disconnect hoses from pedal valve (1, Figure 6).
Plug and cap hoses and ports to prevent contamination
from entering hydraulic system or component. 1
FG003016
Figure 6

Page 15
DISASSEMBLY
1. Remove bellows (32).
FG013535
Figure 7
2. Remove set screw (29) from cam (26).
FG013536
Figure 8
3. Remove cam shaft (28) from cam (26).
FG013537
Figure 9
4. Remove hex nut (31) and set screw (30) from cam (27).
FG013538
Figure 10

Page 16
5. Remove hex socket head bolt (25) and cover (24) from
each body (1 and 2).
FG013539
Figure 11
FG013540
Figure 12
6. Remove push rod assembly from body (2).
FG013541
Figure 13
7. Remove body (2) from body (1).
FG013542
Figure 14

Page 17
8. Remove damper spool assembly and spring (10) from
body (1).
FG013543
Figure 15
FG013544
Figure 16
9. Remove plug (3 and 4) and O-rings (12 and 34).
FG013545
Figure 17

(WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to
"General Maintenance Procedures" section.

Page 18
REASSEMBLY
1. Insert spring (10) into body (1).
FG013544
Figure 18
2. Assemble in proper order, damper spool (8), shim (7),

spring (6), spring seat (5) and stopper (9).
FG013546
Figure 19
3. Install damper spool assembly into body (1).
FG013547
Figure 20
4. Assemble body (2) onto body (1).
FG013542
Figure 21

Page 19
5. Assemble rod seal (22), dust seal (23) and O-ring (21) into
plug (20).
FG013548
Figure 22
FG013549
Figure 23
6. Assemble seal (15), piston (33), steel ball (16), plate (18),
spring (17) and snap ring (19) into push rod (13).
FG013550
Figure 24
7. Assemble push rod and plug.
FG013551
Figure 25

Page 20
8. Install push rod assembly into body (2).
FG013552
Figure 26
9. Install bushing (27) in cover (24) using jig.
FG013553
Figure 27
10. Assemble cover (24) onto each body (1 and 2) and install
hex socket head bolt (25) using torque wrench.
FG013554
Figure 28

Page 21
11. Install set screws (30) and hex nut (31) into cam (26) and
tighten it.
FG013555
Figure 29
FG013556
Figure 30
12. Position cam (26) on cover (24) and insert cam shaft (29)
using hammer.
FG013557
Figure 31
13. Install set screw (29) in cam (26) and tighten it using torque
wrench.
FG013558
Figure 32

Page 22
14. Check cam balance.
FG013559
Figure 33
15. Install bellows.
FG013560
Figure 34
FG013561
Figure 35

Page 23
INSTALLATION
1. Position pedal valve (1, Figure 36) on cabin floor plate and 2
install four bolts and washers (2).
FG003016
Figure 36
2. Install pedal brackets (3) and levers (4, Figure 37) on pedal
valve and install four bolts and washers (2).
3. Install rubber boots (1, Figure 37). 1
3
3
2
2
FG003019
Figure 37
4. Connect hoses as tagged during removal to pedal valve (1, 2

Figure 38).
5. Install cabin under cover by tightening bolts.
1
FG003016
Figure 38

Page 24
START-UP PROCEDURES
1. Start engine and set throttle at "LOW IDLE".
2. Set safety lever on "UNLOCK" position.
HAOB290L
Figure 39
3. Slowly push and pull both travel lever about five times
without a load to vent air from pilot lines.
HAOB903L
Figure 40

Page 25
Page 26
SP000445
SOLENOID VALVE ASSEMBLYSP000445
1Solenoid Valve
Assembly
Edition 2
Solenoid Valve Assembly SP000445

Page 1
MEMO

Page 2
Table of Contents
Solenoid Valve Assembly

Parts List............................................................... 6
Functions of 5-Solenoid Valve Assembly Package.. 7
Functions of Solenoid Valve Assembly Package ............ 7
Assembly Diagram and Tools Required .......................... 9
Solenoid Valve Diagram................................................ 11
Check Points and Solutions for Problems ..................... 12

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up
DX180LC 5001 and Up
DX255LC 5001 and Up

Page 5
PARTS LIST
Components used for the solenoid valve package are the same
as in the parts list below.
Figure 1
Reference
Description Sizes Quantity Remarks
Number
1 Block Body 95 x 110 x 200 1 1-A1073-05-0
2 Solenoid valve TF-S3A-00 5 C1, C2, C3, C4, C5
3 Check Valve FD-DCP-0-A 1 C6
4 Plug PF 1/4" 3 P4, P5, H0
5 Plug PT 1/8" 9

Page 6
FUNCTIONS OF 5-SOLENOID
VALVE ASSEMBLY PACKAGE
Functions of Solenoid Valve Assembly

Package
This solenoid valve assembly package have the following

functions.
1. Pilot cut-off
2. Breaker pressure supply
3. High travel speed
4. Main pressure increase
5. Work modes control - Swing Priority
Functions and Operations of Solenoid Valves
Reference
Function Operations Remarks
Number
Provides pressure and oil coming from the pilot pump
C1 Pilot cut-off for the pilot pressure supply solenoid valve to drive
each work system.
Breaker Supplies pilot pressure for the breaker valve assembly
C2
operation and the breaker pressure supply solenoid valve.
Sets low travel speed and high travel speed, of shifts
speed between both depending on the state of the
C3 High travel speed
solenoid valve operation or a signal detected in the
EPOS controller.
Main pressure Increases the pressure set for the main relief valve
C4
increase temporally to increase the excavation power.
Operating the C5 solenoid valve starts the Swing
Work modes
C5 Priority valve of the main control valve to improve
control
swing operation.
Detailed Functions and Operations of Solenoid Valves

1. Pilot Cut-Off
It provides pressure and oil coming from the pilot pump for
breaker solenoid valve (C2), high travel speed solenoid
valve (C3), main pressure increase solenoid valve (C4),
and the work modes control solenoid valve (C5). Push
down the Cut-Off lever located on the left side of the
driver's seat, and the electrical signal of the limit switch
starts the pilot cut-off valve to supply pressure and oil to
each pilot pressure supply solenoid valve.

Page 7
2. Breaker pressure supply
Pressing the breaker switch on the joystick operates the
breaker solenoid valve (C2) to supply pilot pressure to the
option valve of the main control valve. The pressure
switches the spool of the option valve, which transfers
pressure and oil from the main pump to the breaker system
for excavation.II
3. High travel speed control
When the automatic travel switch is "Off", the travel speed
switches to "0" (low speed); when the switch turned to the
1st place, the travel speed switches to " I " (high speed);
when the switch turned to the 2nd place, the travel speed
switches to " II ", automatically. In this case, the high travel
speed control shows "Off" when the automatic travel switch
is "Off", "On" when it is in the 1st place, and "On/Off" when
it is in the 2nd place. Specifically speaking, turning the
automatic travel switch to the 2nd place, the EPOS
controller detects the discharge pressure from the main
pump, and automatically turns the high travel speed control
"On" or "Off" depending on if the travel load is high or low
to switch the travel speed to speed 1 or 2. The travel load
is detected by 2 pressure sensors located on the discharge
line of the front and rear pumps. If the load is high
(pressure about 300 kg/cm2), the solenoid valve turns "Off"
for the travel at low; If the load is low (pressure about
160 kg/cm2), the solenoid valve turns "On" for the travel at
high. If the engine control dial is set equal and below
1,400 rpm, however, the solenoid valve always turns "On"
for the travel at low, though the automatic travel switch is
set to the automatic travel (2nd place).
4. Boost main pressure
It increases the pressure of the main relief valve temporally
to increase the excavation power. Pressing the power
boost switch on the work lever sends a signal of the EPOS
controller to start the pressure increase solenoid valve.
Then, as it turns "On", the pressure of the main relief valve
increases about 330 kg/cm2 - 350 kg/cm2, which in turn
increases the excavation power.
5. Work modes control
A work mode can be choses as either Excavation or
Trenching mode using a Trenching mode switch on the
operation panel.
Turning on the Start-on switch, Excavation is automatically
accepted as the work mode and the Swing Priority
solenoid valve turns "Off".
This Excavation mode is used for ordinary excavation
work, loading, and fast levelling work.
Choosing the Trenching mode on the operation panel the
Swing Priority solenoid valve for the control valve turns
"On" and starts to work, reducing the oil lines to booms and
arms to increase the swing capacity.

Page 8
Assembly Diagram and Tools Required
Table 1 shows assembly torques recommended for components
of the solenoid valve package. Designated tools and torques
must be followed.
Figure 2
Reference Torques
Components Screw Sizes Tools
Number (kg/cm)
Hex torque
2 Solenoid valve UNF7/8 - 14" 200 ±25
wrench/1", socket
Hex torque wrench/
2-1 Coil Lock Nut UNF1/2 -20" 60 ±2
19 mm, socket
Hex torque
3 Check Valve UNF7/8 - 14" 400 ±2
wrench/1", socket
Torque wrench/
4 PT 1/4" Plug PF 1/4 19" 250 ±25
19 mm, socket
Torque wrench/
5 PT 1/8" Plug Bolt PT 1/8 28" 280
5 mm, wrench socket

Page 9
Cautions During Disassembly and Reassembly
1. Wipe dust and dirt in the area where disassembly and
reassembly will be performed.
2. For disassembly and reassembly, standard torques and
tools stated in Table in must be used.
3. The directions of disassembly and reassembly are same
as the "Disassembly Direction" and "Reassembly
Direction" as shown in Figure 2.
4. Disassembly and reassembly of the solenoid valve
A. Remove the coil lock nut (2-1) by turning it in the
Disassembly Direction.
– Take care not to damage the valve tube and the
retainer when disassembling the coil lock nut.
– If the valve tube or the retainer is damaged
(bent or deformed), the solenoid valve may not
operate.
B. Grip the coil (2-2) with a hand and pull it out.
C. Remove the solenoid valve (2) by turning it in the
Disassembly Direction.
D. Check disassembled components, and reassemble
them in the reverse order of the disassembly.
E. Torque should not be excessive when assembling he
solenoid valve and coil.
– Excessive torque may damage the solenoid
valve.
5. Take care not allow any contaminant to flow into the
package valve during reassembly after disassembly and
check procedures.
6. Every component must be washed out before reassembly.

Page 10
Solenoid Valve Diagram
Figure 3

Page 11
Check Points and Solutions for Problems
Symptoms Causes How to Check Solutions
Remove
Disassemble the solenoid valve concerned and
Foreign substance, contaminant,
check if there are any contaminant such as
dirt, dust in solenoid wash, and
foreign substance and sludge between the case
valve assemble
and the spool.
compartments.
Tube or retainer of Disassemble the solenoid valve concerned and
Replace the
solenoid valve check if there is any deformation (bending or
solenoid valve.
damaged reduction) in the tube or the retainer.
Malfunction Disassemble the solenoid valve concerned and
of solenoid check the resistance of the coil.
valve Spec : 26.7Ω @ 20°C
Coil broken, short, or Disconnection: ∞
Replace the coil.
burnt Short: Low or excessive resistance
Disassemble the solenoid valve concerned and
check the outside of the coil to see if its molding is
burnt and melted.
Check if the cap housing (where coil lead is Replace housing
Connector terminal
attached) and the housing (across its length) are or terminal
earth defect
earthed properly. concerned.
Refer to Causes
Remove the plug of the "P5" port, set up a
and How to
pressure gage, and check the pilot pressure
Pilot pressure Check of the
discharged from the pilot pump when operating
solenoid valve
the cut-off (C1) valve.
above.
Check if the relief valve installed in the pilot line Remove foreign
Pilot operates properly. substance,
pressure fails Pilot relief valve reassemble, and
to generate • Check if pressure is bypassed because of replace the relief
the presence of foreign substance. valve.
Replace the pilot
Pilot pump Check if the pilot pump works properly.
pump.
Wash,
Check if the mesh screen of the pilot filter is
Pilot filter reassemble, and
contaminated by foreign substance.
replace the filter
Check any defect of the pilot system considering
Treat defect(s)
Pilot system findings from "Pilot pressure fails to generate"
accordingly.
category.
Set up a pressure gage at each outlet port of the Refer to causes
solenoid valve concerned (HO, TR2, PH, and SP and how to
Poor Solenoid valve ports) and check the pressure value discharged check of the
Actuator from the pilot pump when operating the solenoid solenoid valve
Performance valve. above.
Check if main control valve of each component Treat according
Main control valve
works properly. to findings.
Treat according
Other components Check if each component works properly.
to findings.

Page 12
Checking of Pilot Pressure for Defects
Port where pressure gage set up Screw size Remark

Operate the solenoid valve
P1, P3, P4, P5, P6, TR2, PH, HO, SP PF1/4" O ring BOSS
concerned (ON).

Page 13
Page 14
SP002458
BREAKER EPPR VALVE (OPTION)SP002458
2Breaker EPPR
Valve (Option)
Edition 3
Breaker EPPR Valve (Option) SP002458

Page 1
MEMO

Page 2
Table of Contents
Breaker EPPR Valve (Option)

Structure ............................................................... 6
Parts List ......................................................................... 6
Functions and Operation ...................................... 7
Cautions for Operation ......................................... 7
Maintenance Instructions...................................... 8
Maintenance.................................................................... 8
Disassembly .................................................................... 9
Assembly....................................................................... 10

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up
DX380LC-3 10001 and Up

Page 5
STRUCTURE
Parts List
Figure 4
Reference Reference
Number Number
1 Solenoid 5 Pin
2 Valve casing 6 Spring
3 Sleeve 7 O-ring
4 Spool 8 O-ring

Page 6
FUNCTIONS AND OPERATION
The proportional reducing valve shall be adjusted so its reduced
pressure is proportional to the current pressure of the solenoid.
The proportional solenoid shall be changed with pressure
proportional to the electrical input signal. Flow increases
corresponding to the force of the solenoid. As the solenoid (1)
receives pressure, the spool (4) opens and oil flows from P to A.
Pressure of the port A influences the top surface of the pin (5).
When it reaches the valve set of the solenoid, the spool starts to
move and oil flow from P to A decreases.
CAUTIONS FOR OPERATION

1. Wiring of the solenoid
• The solenoid has no polarity.
2. Input electricity
• Do not supply electric current more than 0.7A to the
solenoid coil.
3. Adjustment screw
• It was adjusted to the standard.
• The pressure of the port A increases when turning
the adjustment screw clockwise.
4. Symptoms and Solutions of Problems
Symptoms Causes Solutions

Poor wiring Fix wiring
Pressure does not Solenoid damaged Replace the solenoid
increase nor change Piston or spool stuck Fix, or clean and grind
Amplifier damaged Repair or replace the amplifier
Poor opening space
Unnatural pressure Too wide Readjust
change Too narrow
Piston or spool stuck Fix, or clean and grind
Poor opening space
Unnatural pressure Too wide Readjust
Too narrow
Slow reaction Low-pressure supplied Readjust

Page 7
MAINTENANCE INSTRUCTIONS
Maintenance
Bolt Tightening Torque

Table 1 shows torques used to tighten bolts of the motor.
Make sure that assembly work must be done according to Table 1.
Used Torques
Bolt Sizes Names
(kg•cm)
M 35 Hex bolt 450 ±50
M 10 Hex bolt 200 ±20
NPTF 1/16 Plug 90
Tools Used for Disassembly and Assembly

Table 2 shows tools necessary for disassembly and assembly.
As bolts and plugs to be used depend on types, they must be
checked accordingly in advance.
For Sizes Used Torques Used Tools

Solenoid M 35 450 ±50 Wrench
Sleeve M 10 200 ±20 Hex bar wrench
NPTF plug 1/16 90 Hex bar wrench

Page 8
Disassembly
1. Determine a place for disassembly.
• It must be clean.
• Lay a rubber board or a cloth on the table and take
care not to damage parts.
2. Remove dust and rust of the proportional pressure
reducing valve with cleansing oil.
3. Disassemble the solenoid
• Take care not to damage O-rings of the solenoid.
FG003690
Figure 5
4. Disassemble the spool, the spring, and the pin.
FG003691
Figure 6
5. Disassemble the sleeve.

• Take care not to damage O-rings of the sleeve.
FG003692
Figure 7

Page 9
Assembly
Assembly shall be done in the reverse order of disassembly
described above, taking into consideration the following points.
• Parts damaged during disassembly must be repaired
without fail and spare parts must be prepared in advance.
• Every part must be cleaned thoroughly with cleaning oil
and dried with compressed air before starting assembly.
• Sliding parts and bearings must be applied clean active oil
before their assembly.
• Make it a rule to replace O-rings and oil seals.
• Use a torque wrench to tighten or engage bolts and plugs
according to reference torques as described in
Maintenance Guide.
1. Assemble the sleeve.
FG003693
Figure 8
• Take care not to damage O-rings of the sleeve.
FG003694
Figure 9

Page 10
2. Assemble the spool, the spring, and the pin.
FG003695
Figure 10
• Make sure the spring and the pin do not fall off.
FG003696
Figure 11

Page 11
3. Assemble the solenoid correctly.
PART No.: 426-00266

SERIAL No.:
FG003697
Figure 12
• Take care not to damage O-rings of the solenoid.
FG003698
Figure 13

Page 12
SP002991
HYDRAULIC SCHEMATIC (DX138LC/DX140LC)
SP002991
3Hydraulic
Schematic
(DX138LC/
DX140LC)
Edition 2
Hydraulic Schematic (DX138LC/DX140LC) SP002991

Page 1
MEMO

Page 2
Table of Contents
Hydraulic Schematic (DX138LC/DX140LC)

DX138LC/DX140LC ............................................. 7

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up

Page 5
Page 6
DX138LC/DX140LC
FG028827
Figure 1

7
1Electrical System
SP002992
ELECTRICAL SYSTEM (NON-ROPS)
SP002992
Electrical
System
(NON-ROPS)
Edition 1
Electrical System (NON-ROPS) SP002992

Page 1
MEMO

Page 2
Table of Contents
Electrical System (NON-ROPS)

Introduction ........................................................... 8
Electrical Supply System ...................................... 9
Engine Starting Circuit ........................................ 12
Start Operation .............................................................. 12
After Start ...................................................................... 14
Engine Preheating System ................................. 16
Engine Stop ........................................................ 18
Charging System ................................................ 20
Monitoring System .............................................. 21
Instrument Panel ........................................................... 22
Monitoring System Schematic....................................... 24
Operation ............................................................ 26
Instruments.................................................................... 26
Warning and Indicator Lights .............................. 28
Indication of Warning Lights .......................................... 28
Indication of Multifunction Gauge and Letter Information
Area............................................................................... 29
Initial Operation .................................................. 31
Mode Selector Switch ......................................... 31
Graphic Information Area Display....................... 32
Overview ....................................................................... 32
Main Menus for the Graphic Display Area..................... 33
Menu Selector Buttons .................................................. 33
Main Menu .......................................................... 34
Language ...................................................................... 34
Set Clock ....................................................................... 35
Filter/Oil Info .................................................................. 35
Adjust Display................................................................ 36

Page 3
Set Password ................................................................ 37
Special Menu ...................................................... 38
Entering/Accessing and Exiting/Escaping Menus ......... 38
Special Menu Selections ............................................... 39
Electronic Hydraulic Control System (EPOS) ..... 56
Control System Schematic ............................................ 56
Power Mode Control ........................................... 58
Operation....................................................................... 60
Power / Economy Mode Control - Circuit Diagram . 63
Engine Control System ....................................... 64
Engine Control Dial............................................. 65
Engine Control Circuit Diagram .......................... 66
Automatic Deceleration Control (Auto Idle Control) . 68
Engine Overheat Protection System .................. 70
Power Boost Mode ............................................. 72
Operation....................................................................... 72
Power Boost Control - Circuit Diagram ......................... 74
Automatic Travel Speed Control......................... 76
Automatic Travel Speed Control - Circuit Diagram ....... 78
Self-diagnostic Function ..................................... 79
EPOS Controller............................................................ 79
Air Conditioner System ....................................... 81
Outline ........................................................................... 81
Internal and External Filters .......................................... 82
Air-Conditioning System Layout .................................... 84
Air Conditioner/heater Circuit Diagram.......................... 85
Air Conditioner/heater Unit ............................................ 86
Ambient Air Temperature Sensor.................................. 91
Sun Sensor.................................................................... 92
Control Panel................................................................. 92
Compressor................................................................... 99
Receiver Dryer .............................................................. 99

Page 4
Troubleshooting ................................................ 100
Weight of R134a Gas Used In Machines ......... 102
Refrigerant System Repairs ............................. 103
Refrigerant Safe Handling Procedures........................ 103
Repair and Replacement Procedure ........................... 104
Refrigerant Recovery .................................................. 106
Vacuuming Refrigerant System................................... 106
Leakage Check ........................................................... 108
Refrigerant Charging ................................................... 108
Inspecting System For Leakage.................................. 110
Wiper System ................................................... 111
Wiper Circuit................................................................ 111
Wiper operation ........................................................... 112
Lighting System ................................................ 114
Lighting System Circuit Diagram ................................. 114
Kind of Light ................................................................ 115
Operation..................................................................... 115
Audio Controller ................................................ 116
Audio Controller Circuit Diagram................................. 116

Page 5
Page 6
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up

Page 7
INTRODUCTION
The electrical system for this equipment is DC 24 volts. The
rated voltage for all electric components is 24 volts with the
exception of the stereo and the air-conditioning control actuator.
The system contains two 12 volt batteries connected in series
and a three phase AC generator with a rectifier. The electric
wiring used in the system is easily identifiable by the insulator
color. The color symbols used in the electrical system are listed
in the following chart.
Electric Wire Color
Symbol Color
W White
G Green
Or Orange
B Black
L Blue
Lg Light green
R Red
Gr Gray
P Pink
Y Yellow
Br Brown
V Violet
NOTE: RW: Red wire with White stripe

R - Base Color, W - Stripe Color
NOTE: 0.85G: Nominal sectional area of wire core less
insulator = 0.85 mm2

Page 8
ELECTRICAL SUPPLY SYSTEM
The electric power circuit supplies electric current to each
electric component. It consists of a battery, battery relay, starter
switch, circuit breaker, fusible link and fuse box.
The negative terminal of the battery is grounded to the vehicle
body.
Even when the starter switch (5) is in the "OFF" position, electric
current is supplied to the following components through battery
(1) →fusible link (3) →fuse box (6).
1. Terminal "1" of DC-DC converter (for memory backup of
stereo)
2. Terminal "B" of starter switch
3. Hour meter
4. Engine controller
5. Fuel feeder pump switch
6. Terminal "6" of wiper motor
7. Terminal "13" of wiper controller
8. Terminal "CN6-11" of instrument panel
9. Terminal "CN9-6" of air conditioner panel
10. Cabin light
When the starter switch (5) is in the "ON or START" positions,
the current flows from the battery (1) →fusible link (3) →fuse box
(6) →"B" terminal of starter switch (5) →"BR" terminal of starter
switch (5) →"BR" terminal of battery relay (2) which activates the
coil of the battery relay and the electric supply system is
energized.
When the battery relay's contacts are connected, all electric
devices can be operated.
While the engine is not running, the electric power for all electric
devices are supplied by the battery. Once the engine is started
the power is supplied from the alternator (7).

Page 9
ACC C
B
R2
5
BR
0.5G
R1
6
3
8
4 2
B A
BR
E
- + - +
12V 100AH 12V 100AH
STARTER SWITCH CONNECTION R(I) P(R) B(B+)
0.5 uF 1
PST TML B BR R1 R2 C ACC B+
OFF I(L)
ON 7
REG.
TRIO DIODE
START
F+ FIELD
F-
E
GRD
FG007233
Figure 1 Electric Power Circuit Diagram
Reference Reference
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode

Page 10
Page 11
ENGINE STARTING CIRCUIT
Start Operation
When the starter switch is turned to "START" position, the "S"
and "E" terminals of the starter controller (7) are connected. Now
the contacts in the starter relay (8) are closed by the current flow
from the battery (1) →fusible link (3) →fuse box (6) →"B" terminal
of starter switch (5) → "C" terminal of starter switch (5) → "30"
terminal of starter relay (12) - "87a" terminal → "C" terminal of
starter relay (8) - "D" terminal →"S" terminal of starter controller
(7) - "E" terminal →ground.
When the contact point "B" and "PP" of starter relay (8) are
connected, the pinion gear of the starter (9) is pushed forward
and makes contact with the ring gear of the flywheel and the
internal contacts of the starter are connected. The current flows
from the battery (1) →"A" terminal of the battery relay (2) →"B"
terminal of the battery relay (2, Figure 3) →"B" terminal of the
starter (9). The starter motor is rotated and the engine is started.
If the instrument panel has the password function activated,
input number should match the set number, otherwise the start
circuit closes and the engine does not start.
NOTE: If the security system is "LOCKED", a four-digit
password will be required to start the engine. If the
system is "UNLOCKED", no password will be
required and this display screen will not appear.
ENTER
In the event the security system is locked, current PASSWORD
flows from battery (1) →fusible link (3) →fuse box (6)
→ "B" terminal of starter switch (5) →"ACC" terminal
of starter switch (5) → "86" terminal of starter relay
(12) →"85" terminal of starter relay (12) →"CN1-15"
terminal of EPOS (13) → ground. This current flow
causes the coil in starter relay (12) to be activated, FG013717
opening contacts at "87a" terminal. This prevents Figure 2
starter relay (8) from functioning.

Page 12
7 8 9
N S D PP C
P C B B
B E
11
A
87a
30
87
85 86 ACC
C
B 5
R2 BR
12 R1
3
CN1-15
6
4
B A
CN2-1
BR
13 E
11
STARTER SWITCH CONNECTION
R(I) P(R) B(B+)
2
0.5 uF
B+
PST TML B BR R1 R2 C ACC
I(L)
OFF
ON REG.
TRIO DIODE
10 - + - +
START F+ FIELD 1
F-
E
GRD
FG007234
Figure 3 Starter Circuit (1) - While Starting
Reference Reference
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
5 Starter Switch 12 Starter Relay 2
6 Fuse Box 13 EPOS Controller
7 Starter Controller

Page 13
After Start
Once the engine has been started, the belt driven alternator (10)
generates a current.
The output generated by the alternator (10) is a square wave
pulse voltage through the "P" terminal and the frequency of the
pulse voltage is proportional to the rotation of the alternator.
The starter controller (7) monitors the frequency of the output
current. Once the frequency is equivalent to 500 rpm, it is
sensed and the connection between "S" and "E" terminals and
the connection between "B" and "PP" terminals are opened. As
a result the rotation of the starter (9) is stopped. Once the engine
is running, the starter (9) will not operate even if the starter
switch (5) is moved to the start position, preventing possible
damage to the starter.

Page 14
Operation of the Start Circuit (2) - Immediately After Start
7 8 9
N S D PP C
P C B B
B E
11
A
87a
30
87
85 86 ACC
C
B 5
R2 BR
12 R1
3
CN1-15
6
4
B A
CN2-1
BR
13 11
E
R(I) P(R) B(B+)
0.5 uF 2
B+
I(L)
REG.
OFF - + - +
10
TRIO DIODE
ON F+ FIELD
START F- 1
E
GRD
FG007237
Figure 4 Operation of Start Circuit (2) - Immediately After Start
Reference Reference
Number Number

Page 15
ENGINE PREHEATING SYSTEM
An air heater (8) is installed in the intake manifold of the engine.
When the starter switch (5) is turned "ON", the current flows
of starter switch (5) →"BR" terminal of starter switch (5) →"1-39"
terminal of engine controller (12), causing current to flow though
"1-16" terminal of engine controller (12) →"C and D" terminals of
preheat relay (7) →"1-04" terminals of engine controller (12) →
ground.
This current flow causes the coil in preheat relay (7) to be
activated, closing contacts.
When the contacts of the preheat relay (7) are closed, the
heating coils of the air heating device (8) are heated by current
flowing from the battery (1) →battery relay (2) →preheat relay (7)
→air heater (8) →ground.
The duration of the heating cycle depends on the temperature of
engine coolant. The preheat indicator light in the instrument
panel (9) will turn "ON" during preheating cycle.
The preheat relay (7) is controlled by the engine controller (12)
and operates only at temperatures of 10°C (50°F) and below.
The longer the preheating period, the lower the temperature of
coolant is.

Page 16
3
9 4
CN6-1,2 2
ACC C B A
PREHEAT CN7-4,5,6
L5 B 5
R2 BR
R1 BR E
10
CN4-4,5,6
CN2-1
- + - +
11 1
C B
-
200A
1-34,35 7 STARTER SWITCH CONNECTION
1-40 PST TML B BR R1 R2 C ACC

(1)
1-13 D OFF
H +
1-07 ON
START
12
FG007137
Figure 5 Engine Preheat Circuit
Reference Reference
Number Number
1 Battery 7 Preheat Relay
2 Battery Relay 8 Air Heater
3 Fusible Link 9 Preheat Indicator Light
5 Starter Switch 11 EPOS Controller
6 Fuse Box 12 Engine Controller

Page 17
ENGINE STOP
When starter switch (5) is turned "ON" the engine controller (8)
is activated. The engine controller monitors and controls the
engine including the injector solenoid (9). It controls the fuel
deliver rate and the injection timing for each cylinder.
NOTE: There is an individual injector solenoid (9) for each of
the six cylinders. Only one solenoid is shown in
Figure 7.
When starter switch (5) is turned "OFF", the engine controller
stops suppling power to the injector solenoid (9). This stops fuel
from being injected into the engine cylinder, thus stopping the
engine.
In the event that the engine can be shut down using the starter
switch (5), an emergency stop switch (10) is provided to stop
engine. To activate the emergency stop switch, move it to "I"
O I
(EMERGENCY STOP) position.
The emergency stop switch (10) is in its "O" (OFF) position
during normal operation. The switch must be moved and held in
the "I" (EMERGENCY STOP) position until the engine stops.
When released it will automatically move back to "O" (OFF)
position.
FG001344
Figure 6 Engine Emergency Stop Switch

Page 18
OFF
ON
START
8
6
0.5G
3
ACC C
10 B 5
R2
1-19 2 3 BR
4 2
R1 B A
1-45
1-39 BR
E
7
9
- + - +
1
FG001473
Figure 7 Engine Stop Circuit
Reference Reference
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 7 Diode
3 Fusible Link 8 Engine Controller
4 Circuit Breaker 9 Injector Solenoid
5 Starter Switch 10 Emergency Stop Switch

Page 19
CHARGING SYSTEM
When the starter switch (5) is turned to "ON" position, an initial
excited current flows to the field coil of the alternator (7) through
the battery relay (2) and circuit breaker (4). When the engine is
started from this condition the alternator (7) starts charging. The
current flows from the "B(B+)" terminal of alternator (7) →circuit
breaker (4) →battery relay (2) →battery (1).
The alternator also supplies electric current to other electrical
components. When the alternator (7) starts to operate, a current
flows from the "R(I)" terminal of alternator →diode (8) →battery
relay (2) coil securing a path for the charging current to the
battery (1). Thus preventing the possibility of a high voltage build
up and possible damage to the electric system.
ACC C
B
5
R2
BR
0.5G
R1
6
3
8
4 2
B A
BR
E
8
- + - +
12V 100AH 12V 100AH
R(I) P(R) B(B+)
0.5 uF 1
STARTER SWITCH CONNECTION B+
PST TML B BR R1 R2 C ACC I(L)
OFF REG.
TRIO DIODE 7
ON FIELD
F+
START F-
E
GRD
FG007238
Figure 8 Charging Circuit
Reference Reference
Number Number

Page 20
MONITORING SYSTEM
1 2
5 7
8
4
E F
C H C H
9
3
10
1 2 3 4 5
6 7 8 9 0
6
11
13 12
FG013493
Figure 9
Reference Reference
Number Number
1 Instrument Panel 8 Warning Buzzer
2 Battery Pump Discharge Pressure
9
3 Light Switch Sensor
4 Return Filter Switch Hydraulic Oil Temperature
10
Sensor
5 Pilot Filter Switch
11 Fuel Sensor
6 EPOS Controller
12 Air Cleaner Indicator
7 Alternator
13 Engine Controller
The monitoring system displays the various data and warning

signals onto the instrument panel by processing the information
gathered from the EPOS controller. It displays information
selected by the operator.

Page 21
Instrument Panel
7 8 9 10 11 12 5
6 1
1 CHECK
E
< CONNECTOR AND TERMINAL NO.>
F 4
16
C H C H 18
AMP 040 28P
14 20 6 5 4 3 2 1 8 7 6 5 4 3 2 1
22 12 11 10 9 8 7 16 15 14 13 12 11 10 9
13 (CN7) (CN6)
1 2 3 4 5
23
6 7 8 9 0
15
17 19 21 FG013521
Figure 10
Gauges Warning Lights Mode Selector Switches

1. Fuel Gauge 7. Charge Warning 14. Power Mode Selector Button
2. Engine Coolant Temperature 8. Engine Oil Pressure Warning 15. Economy Mode Selector
Gauge Button
9. Engine Coolant Temperature
3. Hydraulic Oil Temperature Warning 16. Auto Idle Selector Button
Gauge
10. Engine Check Warning 17. Flow Control Button
4. Multifunction Gauge and
11. Preheat Indicator 18. Up Arrow Button
Letter Information Area
12. Work Light Indicator Light 19. Down Arrow Button
5. Digital Clock
13. Warning Light 20. Display Selector Button
6. Hour Meter
21. Selector Button
22. Home Selector Button
23. Camera Selector Button
When the engine starter switch is turned to "I" (ON) position, all
gauge bands, switch/button indicator lights and warning lights
will turn "ON" and the alarm buzzer will sound about two
seconds.
During this functional check, a LOGO will appear on the multi
function gauge in the graphic information area

Page 22
Page 23
Monitoring System Schematic
19
CN6-1
3
CN6-3
ILL.
CN6-2
CN6-12
2
CN6-11
17
CN6-9 4
CN6-10 16
R2 B
B
BR
14
22 E
CN6-4
CN6-5
CN2-1 A
CN6-6
CN6-7
LCD DISPLAY PANEL
WATER TEMPERATURE
FUEL LEVEL 18
OIL TEMPERATURE 15
SIG CN3-1
5
CN3-2
CN7-9 SIG CN3-3

GRAPHIC DISPLAY 6 CN3-4 CN5-7
CN7-10
9
WARNING LAMP CN7-4 CN4-4 CN2-17

10
CN7-5 CN4-5 CAN A
CN7-6 CN4-6 CN2-18
11
21 CN4-3 GND
CN5-3
1-62 CN4-2 RxD 12
1-65 CN4-1 TxD
1-35
1 CN3-7
1-34
CN3-8 8
1-33 2
3
1-53 CN3-9
4 20
1-52 CN3-10 7
5
1-51
6
14
R(I) CN2-14
13
FG013522
Figure 11

Page 24
Reference Reference
Number Number
1 Instrument Panel 12 Return Filter Switch
2 Pilot Buzzer 13 Alternator
3 Light Switch 14 EPOS Controller
4 Starter Switch 15 Battery
5 Front Pump Pressure Sensor 16 Battery Relay
6 Rear Pump Pressure Sensor 17 Circuit Breaker
Hydraulic Oil Temperature 18 Fusible Link
7
Sensor 19 Fuse Box
8 Fuel Sensor 20 Check Connector
9 Pedal Pressure Switch (Optional) 21 Engine Controller
10 Air Cleaner Indicator 22 Rearview Camera

Page 25
OPERATION
Instruments
Sensor Specification
Function Display
Input Terminal Input Specification
Blue
Coolant ECU-CAN
Temperature 61 C 102 C Communication
41 C 107 C
C H
White Red
FG013527
Blue
1/10 LCD (Red Zone)

CN3-7
Fuel Level Blinking →over 5K ohms
CN3-8
1/10 FULL →under 525 ohms
E F
Red Full
FG014894
Blue
40°C (104°F) →1,397 ohms
50°C (122°F) →1,139 ohms
Hydraulic Oil CN3-9 60°C (140°F) →881 ohms

Temperature 50 C 94 C CN3-10 94°C (201°F) →190 ohms
40 C 96 C
C H 96°C (205°F) →177 ohms
White Red (When reading increase)
FG013529
45 l/min →610 mA
102 114
80 110 52 l/min →583 mA
94
73 87 (Output
58 l/min →555 mA
Terminal)
Flow 65
58 73 l/min →495 mA
Adjusting CN1-19
52 (Default Set)
CN1-20
45 102 l/min →375 mA
(None)
FG017003 114 l/min →290 mA

Page 26
Function Display
N = 146 f / 60
Tachometer E/G SPEED 1750 RPM

ECU-CAN
Communication
N = Engine speed (rpm)
f = Frequency of engine
speed sensor (Hz)
FG013531
Voltmeter BATTERY 28.0 VOLT CN2-14 0 - 32 VDC
FG000050
Main pump
discharge CN3-1
pressure
FRONT PUMP 320 BAR
CN3-2
(front pump)
V = 0.00816 x P + 1.0
FG000051
V: Sensor output voltage (V)
P: Displayed pressure (Bar)
Main pump
discharge CN3-3
pressure
REAR PUMP 313 BAR
CN3-4
(rear pump)
FG000052

Page 27
WARNING AND INDICATOR
LIGHTS
Indication of Warning Lights

Input
Description Symbol Operation Remarks
Terminal
This symbol appears
in case of no charge
[voltage of "R(I)" Normally, it lights
terminal is below when starting engine
Charge CN2 - 14
12 ±1V] or and is out after engine
overcharge [voltage starts.
HAOA610L
of "R(I)" terminal is
above 33(V)].
After starting engine,

This symbol appears
ECU-CAN if engine oil pressure
Engine Oil when engine oil
Communic is insufficient after 8
Pressure pressure is below the
ation seconds, a warning
reference.
buzzer will sound.
HAOA620L
ECU-CAN This symbol appears

Engine CHECK Communic in case of failure in
Check
ation engine system.
FG000045
This symbol appears

ECU-CAN when engine coolant
Coolant
Communic temperature sensor
Temperature
ation resistant is below
about 128 ohms.
HAOD350L
Preheating period
depends on coolant
This symbol appears temperature.
during preheating
("CN5-2" terminal No preheating at
Preheating CN5-2 voltage is below 2V) above 10°C
and turns "OFF" after 10 sec preheating at
completion of 5°C
HAOA639L preheating.
20 sec preheating at
below 0°C

Page 28
Input
Terminal
This symbol appears

Work Light CN2 - 6 when work light turns
"ON" (24V applied).
HB4O2003
Indication of Multifunction Gauge and

Input
Terminal
CN3-9 When hydraulic oil

Hydraulic Oil
temperature is above
Temperature CN3-10 about 96°C.
FG000056
Fuel CN3-7 When fuel is almost

Exhausted CN3-8 exhausted.
FG000057
When air cleaner is

Air Cleaner CN2-17
clogged.
FG000053
When return filter

pressure is above
Return Filter CN5-3
about 1.50 kg/cm²
(21 psi)
FG000054

Page 29
When pilot filter
pressure is above
Pilot Filter CN2-18
about 1 kg/cm² (14
psi)
FG000055
Warning buzzer also

It flickers in case of
starts when boom
2.71V and above and
CN3-5 pressure sensor
Overload lights continuously in
output voltage is
Warning CN3-6 case of 2.8V and
about 2.7V while
above (and warning
overload warning
buzzer also starts).
FG000253 switch is "ON".
This symbol appears

Boost CN2-2 when boost is
selected.
FG000554
This symbol appears

Breaker CN2-10 when breaker is
selected.
FG001470
This symbol appears

Shear CN2-9 when shear is
selected.
FG001471
This symbol appears

when the water
separator is full.
Water CN3-19
Separator This symbol appears
CN3-20
when water separator
sensor output voltage
FG010520 is about 1.5V below.

Page 30
INITIAL OPERATION
Item Input (Terminal) Output (Operation and initial setting mode)
Initial When "CN6-1,2" is applied • LCD, all of LED and warning lights are turned
Operation battery voltage (starter switch "ON" and turned "OFF" after about 2 seconds.
shifts from "OFF" to "ON"
• Warning buzzer is activated and turned "OFF"
after about 2 seconds.
• Power mode: Standard mode.
• Auto Idle: High Output (Activation).
• Display: Indicating coolant temperature, Fuel
level, Hydraulic oil temperature, Engine speed.
• Clock: Current time display.
NOTE: Refer to method for setting clock in operation manual

for setting time.
MODE SELECTOR SWITCH

Power Mode Switch
EPOS Output
Output Check
(Operation Electromagnetic
Operation Mode Proportional Pressure Swing Priority 7-Segment
mode display
LED) Reducing Valve (E.P.P.R Solenoid Valve Display
Valve) Current (mA)
No-load: 150 ±20mA
Power Mode ON Load: Variable output - 9x
(Max. current: 600 ±20mA)
No-load: 250 ±20mA
Power
Standard Mode OFF Load: Variable output - 7x
Mode
No-load: 400 ± 20mA
Economy Mode Load: Variable output - 5x
(Max. current: 600 ± 60mA)
NOTE: When the engine speed is below 1,000 rpm, the output
current of E.P.P.R valve is fixed to be 600 ±60 mA.
Auto Idle Switch
Operation Mode Output Check (Operation mode display LED)

Activation ON
Auto Idle
Cancellation OFF

Page 31
GRAPHIC INFORMATION AREA
DISPLAY
Overview
Many kinds of condition of machine are displayed on the letter
information display department. The information display
department is divided into two menus. One is main menu for
user and the other is special menu for specialist. These menus
can be moved from normal display mode by the combination of
selector buttons.
E F
C H C H 1
5
1 2 3 4 5
6 7 8 9 0
2 3 FG013562
Figure 12
Selector Buttons Graphic Display Area

1. Up Arrow Button 5. Home Button
2. Down Arrow Button 6. Letter Information Display Department
3. Enter Button
4. Escape Button

Page 32
Main Menus for the Graphic Display Area
1. Main menu: Language setting, Time setting, Filter/Oil
information, Brightness adjustment, Password
2. Special menu: Information of machine status, failure
information, Information of machine operation.
Menu Selector Buttons

1. Up Arrow Button ( , 1 on Figure 12): Move the cursor to
up, left and previous screen.
2. Down Arrow Button ( , 2 on Figure 12): Move the cursor
to down, right and next screen.
3. Enter Button ( , 3 on Figure 12): Move the menu to
selected mode. When setting the menu, this button is used
to function as the selector button.
4. Escape Button (ESC, 4 on Figure 12): Move a screen to
previous menu or main menu.
5. Home Button (HOME, 5 on Figure 12): Move a screen to
default menu.

Page 33
MAIN MENU
When the "ESC" button is pressed for more than 3 seconds, the
main menu screen is displayed. MAIN MENU
Main menu offers sub-menus (language setting, time setting, or L 1. Language
filter/oil information, brightness adjustment, password) to the l
2. Set Clock
l
operator.
3. Filter / Oil Info
Refer to "Operation and Maintenance Manual" for details.
4. Adjust Display
5. Set Password
: UP : DOWN : SELECT
FG013563
Figure 13
Language
MAIN MENU
Put the cursor on Language in the main menu and put the Enter
Button ( , 3 on Figure 12) and the language select view
L 1. Language
l
2. Set Clock
l
appears.
The default language is Korean, but it will memorize and use the
newly set language. 4. Adjust Display
Use the Up Arrow Button ( , 1 on Figure 12) or Down Arrow
5. Set Password
Button ( , 2 on Figure 12) to move cursor to a language to be : UP : DOWN : SELECT
selected on the Language Select display and press the Enter FG013563
Button ( , 3 on Figure 12) and the selected language is Figure 14
indicated in the right bottom of the screen.
At this point pressing the Enter Button ( , 3 on Figure 12) or
the Escape Button (ESC, 4 on Figure 12) more than 1 second L Languag
brings the main menu with changed language and then pressing
the ESC button again shows the default view. 1. Korean
Without pressing a button more than 20 seconds, the default 2. English
view appears.
FG013564
Figure 15

Page 34
Set Clock
MAIN MENU
It is used to adjust time of the digital clock.
L 1. Language
Pressing the Enter Button ( , 3 on Figure 12) in the Main l
2. Set Clock
l
Menu after putting cursor on Set Clock brings Set Clock display.
Without pressing a button more than 20 seconds, the default 4. Adjust Display
view appears.
5. Set Password
Please refer to the Operation Manual for detailed information on
Time Setting. : UP : DOWN : SELECT
FG013565
Figure 16
SET CLOCK
02:30:30
2003 11/04
FG013566
Figure 17
Filter/Oil Info
MAIN MENU
This mode displays total operating hours of filters and oils.
L 1. Language
After changing the filter and oil, reset the operating hour and l
2. Set Clock
l
then the operating hours until the next service interval can be
easily checked. 3. Filter / Oil Info
4. Adjust Display
5. Set Password
FG013567
Figure 18
Filter/Oil Information
R
1. Fuel Filter
Hrs : 0045Hrs 42m
FG013568
Figure 19

Page 35
Menu Display Order and Icon Explanation
1. Fuel Filter 2. Air Cleaner 3. Engine Oil Filter 4. Hyd. Oil Filter
5. Pilot Filter 6. Engine Oil 7. Hydraulic Oil 8. Coolant Water

FG001358
Figure 20
Adjust Display
MAIN MENU
Pressing the Enter Button ( , 3 on Figure 12) in the main
menu after putting cursor on Adjust Display brings Adjust
L 1. Language
l
2. Set Clock
l
Display.
Screen brightness can be adjusted using the Up Arrow Button
( , 1 on Figure 12) or the Down Arrow Button ( , 2 on Figure 4. Adjust Display
12). 5. Set Password
The default brightness is set to 50%. : UP : DOWN : SELECT
FG013569
Figure 21
1. Adjust Display
2. Adjust Display (Camera)
FG013835
Figure 22

Page 36
Day Mode
The default brightness is set to 50%. Adjust Display
The default contrast is set to 50%. Brightness llllllllllllllllllllllll l 50%
l
The default back light is set to 90%.
Contrast lllllllllllllllllllllllll l 50%
l
Night Mode
Back Light llllllllllllllllllllllll l 50%
l
The default brightness is set to 50%.
The default contrast is set to 30%. : UP : DOWN : SELECT
The default back light is set to 10%. FG013570
Figure 23
Set Password
MAIN MENU
This menu is used to apply (lock), release, or change password.
L 1. Language
Please refer to the Operation Manual for detailed information on l
2. Set Clock
l
Password Setting.
4. Adjust Display
5. Set Password
FG013571
Figure 24

Page 37
SPECIAL MENU
In this menu, many types of operating conditions and functions
can be accessed and displayed, including the EPOS controller.
This menu is mainly used for machine testing and failure
diagnostics.
The special menu offers three sub-menus:
1. Machine status.
2. Failure information.
3. Information on machine operation.
Entering/Accessing and Exiting/Escaping

Menus
Entering/Accessing Menus 4
When normal mode screen is displayed, if the enter button ( ,
3) and escape button (ESC, 4) are pressed simultaneously for
more than 3 seconds, normal mode screen (Figure 26) will be
changed to special menu screen (Figure 27).
3 FG013581
Figure 25
Normal Mode Screen

NOTE: Normal mode screen can display many kinds of
display mode by selecting, for example, engine
speed (RPM), battery voltage (VOLT), front pump
pressure (BAR), rear pump pressure (BAR) and so
on by selecting.
E F
C H C H
FG013591
Figure 26

Page 38
Special Menu Screen
NOTE: Displayed language on the special menu screen SPECIAL MENU
consists of Korean and English.
1. Machine Information
If any language except for Korean is selected during
language selection mode of main menu, only English 2. Failure Information
will be displayed on special menu screen.
3. Operating Hours
FG013592
Figure 27
Exiting/Escaping Menus
1. If escape button (ESC, 4 on Figure 25) is pressed for more
than 1 second, the special menu screen will be returned to
the normal mode screen.
2. If this special menu is "ON" without any activity, for more
than 20 seconds, it will turn to the normal mode screen.
3. After the turning starter switch to "OFF" position, turn it
back to "ON" position, and the normal mode screen
displayed once again.
Special Menu Selections

Submenu Selection Method
Various sub-menus can be selected by pressing "Up ( , Figure

SPECIAL MENU
25)" and "Down ( , Figure 25)" button. 1. Machine Information
Move the cursor to desired menu and a selected menu will be
inverse displayed. 2. Failure Information
When the selected menu is inverse displayed, press the "Enter
( , 3 on Figure 25)" button for menu selection. 3. Operating Hours
FG013592
Figure 28
Information of Machine Status

1. Entering Sub-menus: When cursor is located on "Machine MACHINE INFORMATION
Info" of special menu screen, press "Enter ( , 3 on
Figure 25)" button and the "Machine Info" will be displayed.
1. Analog Input State
2. Exiting Sub-menus: If escape button (ESC, 4 on Figure 25) 2. Digital input State
is pressed for more than 1 second, display will be turned to
previous screen. 3. Digital Output State
FG013593
Figure 29

Page 39
Analog Inputs Description
Analog Input Items Display Remark

1. Pump P/V mA Current in pump proportional valve.
2. Cooling Fan P/V mA N.A.
3. Flow Control P/V mA N.A.
4. Dial mV Indicating dial voltage.
5. TPS mV N.A.
6. E/G Control Motor mV N.A.
7. Boom Pressure BAR Boom cylinder head pressure.
8. Pilot Gear Pump Press BAR N.A.
9. Boost Pressure BAR Pump pressure for boost.
Temperature of air incoming to
10. Intake Manifold Temperature °C
intake manifold.
11. E/G Oil Pressure BAR Engine oil pressure.
12. Fuel Temperature °C Fuel temperature.
13. E/G Oil Temperature °C Engine oil temperature.
14. Load At Cur. Spd % Current load ratio of equipment.
Submenu Selections
1. Power Shift P/V : 0598mA 6. E/G Control Motor : 2095mV

2. Cooling Fan Ctrl P/V : N.A 7. Boom Pressure : 205BAR
3. Flow Control P/V : 0000mA 8. Pilot Gear Pump Press : 33BAR
4. E/G Control Dial : 2095mV 9. Boost Pressure : 000BAR
5. TPS : 2095mV 10. Intake Manifold Temp. : 000 C
: UP : DOWN : UP : DOWN
11. E/G Oil Pressure : 000BAR

12. Fuel Temp. : 000 C
13. E/G Oil Temp. : 000 C
14. Pecent Load At Cur. Spd : 00%
: UP : DOWN
FG013594
Figure 30

Page 40
Page 41
Digital Inputs Descriptions
Digital Inputs Items Mark Remark

Lights up when output at alternator
1. Alternator
"R(I)" terminal is above 12 ±1V.
2. Travel Select SW N.A. (only for wheel type equipment)
Lights up when the travel speed
3. High Speed Sel. SW (M)
selector switch is set to "I" position.
4. High Speed Sel. SW (A)
selector switch is set to "II" position.
Lights up when the pressure switch
5. Pressure SW (Py)
(Py) is "ON".
6. Pressure SW (Px)
(Px) is "ON".
7. E/G Oil Press. SW N.A. (only for mechanical engine)
Lights up when the air cleaner
8. Air Cleaner Clogged
indicator contact is "ON".
Lights up when the return filter
9. Return Filter Clogged
pressure switch is "ON".
Lights up when the pilot filter
10. Pilot Filter Clogged
Lights up when the overload
11. OWD Warning SW
warning selector switch is "ON".
12. Brake Oil Press. SW ON / OFF N.A. (only for wheel type equipment)
Lights up when the pedal pressure
13. Pedal Press. SW
switch is ON.
Lights up when the selector switch is
14. One Way Sel. SW
turned to breaker.
Lights up when the Selector Switch
15. Two-way Sel. SW
is turned to "SHEAR".
Lights up when the boost button is
16. Power Max. SW "ON" with the Select switch turned
to "BOOST".
17. Breaker SW "ON" with the selector switch turned
to "BREAKER".
18. Preheat Select N.A.
Lights up when the Quick Coupler
19. Quick Coupler
switch is "ON".
20. F and R Lever N.A. (only for wheel type equipment)
Lights up during preheating (CN5-2)
21. Preheat Select
terminal voltage is below 2V.
22. Reverse Fan SW N.A.
23. Pilot Cutoff SW N.A.
24. Water in fuel Lights up when WIF sensor is "ON".

Page 42
Menu Select
1. Alternator : 7. E/G Oil Press.SW : N.A

2. Travel Select SW : N.A 8. Air Cleaner Clogged :
3. High Speed Sel. (M) : 9. Return Filter Clogged :
4. High Speed Sel. (A) : 10. Pilot Filter Clogged :
5. Pressure SW (Py) : 11. OWD Warning SW :
6. Pressure SW (Px) : 12. Breake Oil Press SW : N.A
19. Quick Coupler : 13. Pedal Press. SW :

20. F & R Lever : N.A 14. One Way Sel. :
21. Preheat Select : 15. Two Way Sel. :
22. Reverse Fan SW : N.A 16. Booster SW :
23. Pilot Cutoff SW : N.A 17. Breaker SW :
24. Water in fuel : 18. Preheat Select :
FG013611
Figure 31

Page 43
Digital Outputs Descriptions
Digital Outputs Items Mark Remark

Lights up when the relief press up
1. Relief Press. Up S/V
solenoid valve is "ON".
Lights up when the high speed
2. High Speed S/V
ON / OFF solenoid valve is "ON".
3. Reverse Fan S/V N.A.
4. Starter Relay When the starter relay is "ON".
5. After Heat Relay N.A.
Menu Select
DIGITAL INPUT STATE
1. Relift Press UP S/V :
2. High Speed S/V :
3. Reverse Fan S/V :
4. Starter Relay :
5. Afterheat Relay :
: UP : DOWN
FG013612
Figure 32
Failure Information
1. Entering Sub-menus: When a cursor is located in "Failure SPECIAL MENU
Info" of special menu screen press enter button ( , 3 on
Figure 25) and "Failure Info" screen is displayed.
2. Exiting Sub-menus: If escape button (ESC, 4 on Figure 25) 2. Failure Information
is pressed for more than 1 second, this information screen
will be returned to previous screen. 3. Operating Hours
FG013613
Figure 33
* Real-time Failure:
Current status of failure is displayed. FAILURE INFORMATION
* Failure Log:
Memorized record of past failure is displayed. 1. Realtime Fail
* Delete Fail Log: 2. Failure Log
This mode is used to delete all of the
memorized record of past failure.
3. Delete Fail Log
FG013614
Figure 34

Page 44
A. Current failure information
Current status of failure is displayed (Failure code, REALTIME FAILURE
failure contents). 1/2 CODE : V204 - 05
When a number of failures are produced, failure 2/2 CODE : E011 - 04
information can be checked using "UP" ( , 1 on
Figure 25) or "DOWN" ( , 2 on Figure 25) button. Relief Pressure Up S/V
* 1/2: A serial number of current failure/ total quantity Open
of failure.
: UP : DOWN
* Vxxx-xx: Vxxx is a unique code and xx is a FMI FG013615
(Failure Mode Identifier) number. Figure 35
- V: Machine related failure code
- E: Engine related failure code
Refer to the failure information code for unique codes
and FMI numbers.
This example shows one of two failures.
B. Past failure information
Memorized record of past failure is displayed (Failure FAILURE LOG
code, failure contents). 1/2 CODE : V204 - 05
Time : 00254 Hr 29m Count :28
Figure 25) or "DOWN" ( , 2 on Figure 25) button.
Relief Pressure Up S/V
NOTE: " Number: xxx ": "xxx" means that the Open
totally counted number of the same failure.
: UP : DOWN
" Period:xxxxxHrxxm ": It indicates the FG013616
period for which machine has operated Figure 36
until a failure takes place. (For more than
two occurrences of the same failure, until
the first occurrence time.)
C. Failure record deletion
This mode is used to delete the memorized record of DELETE FAIL LOG
past failure. If this mode is selected, all records will
be deleted.
All Fail Log
When "YES" ( , 3 on Figure 25) button is pressed,
the memorized record will be deleted.
will be DELETED.
Now, deletion signal will be displayed and the screen
will move to previous menu after deletion.
: Yes ESC: No
This screen will be displayed during 3 seconds.
FG013617
Figure 37

Page 45
Input your password with one of No. 1 - 8 switches.
When "NO" (ESC, 4 on Figure 25) button is pressed, DELETE FAIL LOG
the screen will recover to previous menu without
deletion.
ENTER PASSWD
: YES ESC : NO
FG013618
Figure 38
Delete Completed screen will appear 3 seconds and

the screen will move to Failure Info screen. DELETE FAIL LOG
It has been shown 3 seconds upon deleting Fail Log.
DELETED !!!
: YES ESC : NO
FG013619
Figure 39
The screen shown on the left will appear 3 seconds in

case of wrong password input and then Enter DELETE FAIL LOG
Password screen appears again.
It has been shown 3 seconds in case of password X PASSWORD ERR!!!
failure.
: YES ESC : NO
FG013620
Figure 40

Page 46
Failure Information Code at Machine Side
Measuring Correct Value

Code Failure Component Remarks
Points Active Passive
Gauge Panel CN7-4 It is a
V201 Communication Error
- R = 60 ±5 Ω composite
CN7-5
resistance of
CAN line. This
value has to be
CN4-4 measured by
V202 Ecu Communication Error - R = 60 ±5 Ω
CN4-5 connected
condition of
CAN line.
Pump
CN1-10 R = 18 ±2 Ω proportional
V210 Pump P/V -
(25°C (77°F)) pressure
CN1-21
reducing valve.
V211 Cooling Fan P/V - - N.A.
Flow control
V212 Flow Control P/V -
CN1-20
reducing valve.
Breaker/boost/
shear selector
switch has to
be selected as
CN1-1 a boost
V = V_volt (Note R = 26.2 ±2 Ω
V213 Relief Pressure Up S/V
4.) (25°C (77°F))
function and
CN1-11 the boost
switch on the
right-hand
joystick is "ON"
status.
Voltage is only
measured
CN1-1 R = 26.2 ±2 Ω when the
V214 High Speed S/V V = V_volt
CN1-12
switch (Py) is
turned "ON".
Work mode
CN1-1 has to be
R = 26.2 ±2 Ω
V215 Swing Priority S/V V = V_volt
(25°C (77°F))
selected as a
CN1-13 trenching
mode.
V216 Reverse Fan Speed S/V - - N.A.
It has to be
CN1-1 measured in
V217 Starter Relay V = V_volt -
engine start up
CN1-15
state.
V218 After Heat Relay - - N.A.

Page 47
CN3-1 It has to be
V220 Front Pump Press. Sensor V = IV - measured in
CN3-2
engine stop
CN3-3 state.
V221 Rear Pump Press. Sensor V = IV -
CN3-4
R = 2.45 ±0.25
kΩ (25°C
CN3-9
V222 Hyd. Oil Temperature Sensor - (77°F))
CN3-10
R = 320 ±32 Ω
(80°C (176°F))
V223 Water Temperature Sensor - - N.A.
V224 Engine Speed Sensor - - N.A.
Empty: 5 ±0.25
CN3-7
V225 Fuel Level Sensor - kΩ
CN3-8
Full: 320 ±32 Ω
It has to be
CN2-14 measured in
V226 Alternator Potential V = 2 ±1V -
engine stop
CN1-8
state.
R = 1.0 ±0.3 kΩ
CN3-16
V227 Dial - R = 4.0 ±1.5
CN3-7
kΩ
V228 Tps (Wheel) - - N.A.
V229 Parking Brake Press. Sensor - - N.A.
V230 E/g Control Motor Sensor - - N.A.
NOTE: 1. Active value: Starter switch has to be turned "ON"

Measuring points between component and wire
harness have to be connected.
2. Passive value: Starter switch has to be turned
"OFF"
harness have to be disconnected.
3. Measuring points are engine controller's points and
passive value is each component's value.
4. V–batt: Source power of equipment.

Page 48
Failure Information Code at Engine Side
Measuring Current Valve

2-26 R=186 ±5 Ω
E011 Coolant temperature sensor
2-15
- (100°C
(212°F))
2-26 R=186 ±5 Ω
E012 Fuel temperature sensor - (100°C
2-35 (212°F))
2-36 R=186 ±5 Ω
E013 Boost air temperature sensor
2-25
- (100°C
(212°F))
V= It has to be
2-33 1,071 ±58mV measured in
E014 Boost air pressure sensor (at 23°C (73°F) - engine running
2-34 and absolute state.
pressure 1bar)
2-28 R=186 ±5 Ω
E017 E/G oil temperature sensor
2-24
- (100°C
(212°F))
V= It has to be
E018 E/G oil pressure sensor (at 23°C (73°F) - engine running
pressure 3bar)
1-03 V = V–volt
E021 Battery voltage
(Note 4.)
-
1-06
V= It has to be
E022 Fuel pressure sensor (at 23°C (73°F) - engine running
pressure 300bar)
2-14 R=2.60 ±3.15
Fuel pressure monitoring
E032 MPROP
- Ω
2-12 (20°C (68°F))
It is a composite
resistance of
1-53 and CAN line.
1-52 R=60 ±5 Ω
E037 CAN module - This value has
1-35 and (20°C (68°F)) to be measured
1-34 by connected
condition of
CAN line.
E038 Engine overspeed - -
E039 Main relay (ECU) - -
Abnormal
E041 Redundant shutoff path - -
engine stop.
2-23 R=860 ±6 Ω
E042 E/G speed (Crankshaft) -
(20°C (68°F))
2-19

Page 49
2-09
E043 E/G speed (Camshaft) - -
2-10
Synchronizing
error between
crank shaft
E044 Engine speed sensor - -
speed sensor
and cam shaft
speed sensor.
Data storing
E045 EEPROM - - error when
engine stop.
E046 Recovery - -
When the
pressure sensor
of common rail
E047 Monitoring of PRV - - or
high-pressure
pump has a
defect.
1-03
E048 Power supply V = V–volt -
1-06
E049 Booster voltage C1 - -
Booster voltage C2 (#6, 2
E051 and 4)
- -
3-13 R=0.31 ±0.42

E058 Solenoid power stage 1 - Ω
3-04 (20°C (68°F))
3-11
E059 Solenoid power stage 2 - -
3-06
3-05
3-12
3-03
3-14
3-01
3-16
3-02
3-15
Preheat light (E/G: Lowside 1-56
E066 Power stage 2)
- -
1-06
Voltage is only
measured when
Preheat relay (E/G: Highside 1-13 R=40 ±5 Ω afterheat
E072 Power stage 1)
V = V–volt
(25°C (77°F)) function is
1-07
operating
status.

Page 50
Fuel metering
Fuel HI pressure pump
unit error of
E083 (E/G: Current controlled - - -
high-pressure
Highside power stage 1)
pump.
Power supply
System start-up test for error
E091 shutoff path
- - -
Engine
controller error.
Injector error
Speed signal
Monitoring of misfire cylinder error of cam
E092 1
- - - shaft speed
sensor or crank
shaft speed
sensor.
Monitoring of misfire cylinder
E093 2
- - -

E094 3
- - -

E095 4
- - -

E096 5
- - -

E097 6
- - -
Monitoring of misfire multiple

E098 cylinder
- - -
E099 Monitoring of overrun - - -

E101 Engine speed redundant - - -

"OFF"

Page 51
FMIs (Failure Mode Identifier)
FMI 0 Above normal range (DATA VALID but ABOVE NORMAL OPERATIONAL RANGE)
FMI 1 Below normal range (DATA VALID but BELOW NORMAL OPERATIONAL RANGE)
FMI 2 Incorrect signal (DATA ERRATIC, INTERMITTENT OR INCORRECT)
FMI 3 Voltage above normal (VOLTAGE ABOVE NORMAL OR SHORTED TO HIGH SOURCE)
FMI 4 Voltage below normal (VOLTAGE BELOW NORMAL OR SHORTED TO LOW SOURCE)
FMI 5 Current below normal (CURRENT BELOW NORMAL OR OPEN CIRCUIT)
FMI 6 Current above normal (CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT)
FMI 8 Abnormal signal (ABNORMAL FREQUENCY OR PULSE WIDTH OR PERIOD)
FMI 11 Failure mode not identifiable (ROOT CAUSE NOT KNOWN - Malfunction)
FMI 31 NOT AVAILABLE OR CONDITION EXISTS
Information of Machine Operation

Accumulated operation hour of each mode and status is
displayed.
1. Operating Hour Information
A. Entering Sub-menus: When a cursor is located in SPECIAL MENU
"Operating Hrs" of special menu screen (Figure 41)
press enter button ( , 3 on Figure 25) and
"Operating Hrs" screen will be displayed (Figure 42).
2. Failure Information
3. Operating Hours
FG013621
Figure 41
B. Information screen of machine operation (Figure 42).

OPERATING HOURS
Operating Hours
Reset Hours
FG013622
Figure 42

Page 52
C. Operating Hours Screen
D. Exiting Sub-menus: If escape button (ESC, 4 on OPERATING HOURS
Figure 25) is pressed for more than 1 second, this 1. Power : 00042 Hr
information screen will be returned to previous 2. Economy : 00120 Hr
screen. 3. Auto Idle : 00159 Hr
4. Travel Speed
I Speed : 00005 Hr
II Speed : 00001 Hr
: UP : DOWN
FG013623
Figure 43
Information contents of operation hour
Item Information Contents Detection Method

Power mode switch (Instrument panel) -
Operation hours used power mode
Power Mode "ON" status and Alternator signal
are displayed.
(CN2-14) is "HI"
Economy mode switch (Instrument
Operation hours used economy
Economy Mode panel) - "ON" status and Alternator
mode are displayed.
signal (CN2-14) is "HI"
Auto idle switch (Instrument panel) -
Operation hours used auto idle
Auto Idle "ON" status and Alternator signal
status are displayed.
(CN2-14) is "HI"
Travel Speed: 1st: High speed s/v "OFF" status
Operation hours used low speed
-1st and high speed are displayed. 2nd: High speed s/v and travel pressure
- 2nd switch "Py" (control valve) - "ON" status.
Hydraulic Oil Temperature Temperature of hydraulic oil is The resistance delivered from
Distribution (°C (°F)) classified 6 steps. And operation temperature sensor of hydraulic oil is
hours of each step are displayed classified 6 steps. And operation hours
of each step are displayed. (Alternator
Under 30°C (87°F)
output HI status)
31 - 50°C (88 - 123°F)
51 - 75°C (124 - 168°F)
76 - 85°C (169 - 186°F)
86 - 95°C (187 - 203°F)
Over 96°C (204°F)
Coolant Temperature Temperature of coolant is classified The resistance delivered from coolant
Distribution (°C (°F)) 6 steps. And operation hours of sensor is classified 6 steps. And
each step are displayed. operation hours of each step are
displayed. (Alternator output HI status)
Under 40°C (105°F)
41 - 60°C (106 - 141°F)
61 - 85°C (142 - 186°F)
86 - 95°C (187 - 204°F)
96 - 105°C (205 - 222°F)
Over 106°C (223°F)

Page 53
Menu Selection of Operation Hour Information
1. Power Mode 2. Economy Mode 3. Auto Idle 4. Travel Speed 1st, 2nd
6. Coolant Temperature Distribution 5. Hydraulic Oil Temperature Distribution

FG013856
Figure 44
Example of Machine Operation Info Screen
OPERATING HOURS OPERATING HOURS

1. Power : 00042 Hr 5. Hyd.Oil Temp. [ c]
2. Economy : 00042 Hr 30 : 00140 Hr
3. Auto Idle : 00159 Hr 31-50 : 00054 Hr
4. Travel Speed 51-75 : 00087 Hr
I Speed : 00005 Hr 86-95 : 00001 Hr
II Speed : 00001 Hr 96 : 00000 Hr
OPERATING HOURS
6. Coolant Temp. [ c]
40 : 00140 Hr
41-60 : 00054 Hr
61-85 : 00087 Hr
96-105 : 00001 Hr
105 : 00000 Hr
: UP : DOWN
FG013624
Figure 45
2. Operation hour reset

A. Entering Sub-menus: When cursor is located in OPERATING HOURS
"Reset Hrs" of information screen of operating hours
Operating Hours
"Machine Operation Info" screen will be displayed.
Reset Hours
FG013625
Figure 46

Page 54
B. Reset screen of operation hour
C. Exiting Sub-menus: If escape button (ESC, 4 on OPERATING HOURS
Figure 25) is pressed for more than 1 second, this
information screen will be returned to previous
screen. All Opearting hours
NOTE: When "YES" ( , 3 on Figure 25) button is will be DELETED.
pressed, operation hours will reset.
Now, resetting signal will be displayed and the
screen will move to previous menu after : Yes ESC: No
resetting. FG013626
NOTE: When "NO" (ESC, 4) button is pressed, the Figure 47
screen will recover to previous menu without
resetting.
Machine Operation Info Screen

1. If you press the YES" ( , 3 on Figure 25) button,
OPERATING HOURS
password entrance screen appears.
ENTER PASSWD
: YES ESC : NO
FG013627
Figure 48
2. When right password is input, machine operation periods

will be deleted and Reset Completed screen will appear 3 OPERATING HOURS
seconds.
DELETED !!!
: YES ESC : NO
FG013628
Figure 49
3. If you press the "NO" (ESC, 4) button, the previous screen

appears without resetting operation periods. OPERATING HOURS
X PASSWORD ERR!!!
: YES ESC : NO
FG013629
Figure 50

Page 55
ELECTRONIC HYDRAULIC
CONTROL SYSTEM (EPOS)
Control System Schematic
15
6 6
7 7 11 13
8
8
12
14
E/G
4 4 5
3
9 10
Work Mode
2 Auto Idle
Machine Info
E/G speed order E F

C H C H
22 1
6
2
7
3
8
4
9
5
R UP
WE
PO
16 20 18 17 21 19
FG013630
Figure 51

Page 56
Reference Reference
Number Number
1 Instrument Panel 11 Solenoid Valve (Boost)
2 EPOS Controller 12 Solenoid Valve (High Speed)
3 Engine Controller (ECU) 13 Solenoid Valve (Breaker)
4 Main Pump 14 Travel Motor
5 Aux Pump 15 Main Relief Valve
6 Control Valve 16 Engine Control Dial
7 Pressure Switch Breaker/Boost/Shear Selector
17
8 Pump Pressure Sensor Switch
Electromagnetic Proportional 18 Auto Travel Selector Switch
9 Pressure Reducing Valve 19 Boost Switch (Right Work Lever)
(Attachment) 20 Sensor
Electromagnetic Proportional 21 Aux Mode Switch
10 Pressure Reducing Valve
22 Aux Mode Resistor
(Mode Control)

Page 57
POWER MODE CONTROL
6 6
E/G
5
4 4
3
10
2
1
1 2 3 4 5
17 6 7 8 9 0
23 22
FG013631
Figure 52
Reference Reference
Number Number
Instrument Panel Electromagnetic Proportional
1
(Power Mode Selector Switch) 10 Pressure Reducing Valve
2 EPOS Controller (Mode Control)
3 Engine Controller (ECU) 17 Engine Control Dial
4 Main Pump 22 Aux Mode Switch
5 Aux Pump 23 Aux Mode Resistor
6 Control Valve

Page 58
The power mode switch permits the selection of the appropriate
engine power depending on the working condition. One of the
two, Power Mode or Standard Mode, setting can be selected.
When the engine starter switch is turned "ON", the power mode
is automatically defaulted to standard mode. The desired mode
can be selected by pressing the selector button on the
instrument panel. When the power mode is selected, the
indicator light will turn "ON" to display the selected mode.
The quantity of oil discharged by the pump and the engine
speed are determined by the mode selected by the operator.
The pump output in each mode is determined by the mode
selection and is listed in the following table
Mode Standard Mode Power Mode

Output (%) Approximately 85% 100%

Page 59
Operation
1. Power Mode
This mode must be selected for high speed work. In this
mode the engine output is most efficiently utilized because
of the discharged oil volume being controlled based on the
equivalent horsepower curve at various loaded pressures.
The EPOS controller compares the target engine speed
with the actual engine speed and controls the signal to the
E.P.P.R. (Electromagnetic Proportional Pressure
Reducing) valve which in turn varies the pump output
quantity.
If the load increases, the engine speed will fall below the
rated speed. When this occurs, the controller senses this FG013632
decrease and immediately reduces the pump discharge Figure 53
volume to maintain the engine speed at the rated level.
On the other hand, if the load is decreased the controller
increases the discharge volume of the pump to maintain
the engine speed at the rated level.
By repeating these control operations, the engine speed is
maintained at the rated speed so that maximum power can
be generated.
In Power Mode, the EPOS controller receives engine
speed signals from the engine control dial and the engine
controller (ECU) and converts it to an operating signal
current and is then transferred to the pump's E.P.P.R
valve. Now the E.P.P.R. valve converts the electric signal
to the corresponding control pressure and sends it to the
two pumps, adjusting the pump discharge volume to the
desired level.
A C
B D
FG000580
Figure 54
Reference Reference
Number Number
A Engine Horsepower (hp) Pump Discharge Pressure
D
B Engine Speed (rpm) (kg/cm2)
C Pump Discharge Volume (lpm)

Page 60
2. Standard Mode
Standard Mode is used for general work. When this mode
is selected it will reduce noise and fuel consumption in
comparison with Power Mode. The EPOS controller
compares the target engine speed with the actual engine
speed and controls the signal to the E.P.P.R. valve which
in turn varies the pump output quantity and it is the same
method with power volume.
A C
B D
FG000581
Figure 55
Reference Reference
Number Number
D

Page 61
3. Economy Mode
Economy mode is used for light loading work. When this
mode is selected, it will reduce noise and fuel consumption
in comparison with standard mode.
Engine torque curve is changed by ECU.
E.P.P.R. valve which in turn varies the pump output
quantity and it is the same method with power volume.
FG013671
Figure 56
A C
B D FG013633
Figure 57
Reference Reference
Number Number
A Engine Horsepower (hp) C Pump Discharge Volume (lpm)
B Engine Speed (rpm) D Pump Discharge Pressure (kg/cm2)
4. Operation in case of failure in the control system (Aux

mode operation)
Though it is impossible to control current of the E.P.P.R
(Electromagnetic Proportional Pressure Reducing) Valve
controlling the discharge volume of pump because of fault
in control system, the machine can be operated in the aux
mode.
Upon turning "ON" the aux mode switch, the E.P.P.R Valve
controlling the discharge volume of pump comes into
contact with the aux mode resistor to let current of a certain
value flow. Now, the discharge volume of pump follow the
control by the pump regulator, nearly at quantity roughly
similar to that in the standard mode.

Page 62
POWER / ECONOMY MODE
CONTROL - CIRCUIT DIAGRAM
1
15A
CN6-1
CN6-2
26
4 26 15A 26 10A
CN6-9
25
CN6-10
CN1-1
CN7-4 CN4-4 CN1-2
CN7-5 CN4-5 CAN
CN7-6 CN4-6
CN1-8 24
CN1-9 11
3
23
1-35
1-34 22
1-33 CN1-10 1 10
5
P/V-(A)
1-53 2
1-52 CN1-21 3
VEHICLE 6
1-51 4
CONN
(CONN.1) 1-05
1-06
17
+(5V) CN3-15 1
1-10 CW LOW
SIG CN3-16 2
1-11
GND CN3-17 3
HIGH
1-02
1-03
1-08
15A 26
1-09
1-40 BR B 10A 26
28
AMP 070 16P AMP 040 12P AMP 040 20P AMP 070 18P AMP MIC 21P
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
VEHICLE CONN. (ECU CONNECTOR) AMP 040 28P
18 35 6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 17
12 11 10 9 8 7 16 15 14 13 12 11 10 9
36 53
7 11 54 71
(CN7) (CN6)
1 6 72 89
ECU CON.1 (89-PIN)

FG008165
Figure 58
Reference Reference
Number Number
1 Instrument Panel 23 Aux Mode Resistor
3 Engine Controller 24 Battery
4 EPOS Controller 25 Battery Relay
E.P.P.R. Valve (Electromagnetic 26 Fuse
10
Proportional Pressure Reducing) 27 Fusible Link
17 Engine Control Dial 28 Starter Switch
22 Aux Mode Switch

Page 63
ENGINE CONTROL SYSTEM
4 17
(Drive Signal) (Command Signal)
FG000584
Figure 59
Reference Reference
Number Number
3 Engine Controller 17 Engine Control Dial
4 EPOS Controller
When the engine control dial is moved the output voltage

changes according to the dial position.
The EPOS controller converts this output voltage of dial to digital
signal and sends it to the engine controller by CAN line.
According to the dial command, the quantity of fuel injection is
adjusted.

Page 64
ENGINE CONTROL DIAL
1st Step 7th Step 13th Step
CCW CW
Mechanical Mechanical
Stop Stop
5
4.0V
4
Output Voltage (V)
3 2.5V
2
1.0V
1
0 Step
1st 2nd ...... 7th ...... 12th 13th
CCW CW
Stop Stop
1 2 3
FG018941
Figure 60
Reference Reference
Number Number
1 Knob 2 Hall Effect Sensor
The engine control dial has a built in potentiometer. When the

control knob is moved the output voltage (through "2 and 3"
terminals) will vary from the 5 V supplied from the EPOS
controller as shown in the graph.

Page 65
ENGINE CONTROL CIRCUIT
DIAGRAM
1
15A
CN6-1
CN6-2
26
4 26 15A
CN6-9 25
CN6-10
CN1-1
CN7-4 CN4-4 CN1-2
CN7-5 CN4-5 CAN
CN7-6 CN4-6
CN1-8 24
CN1-9 28
3
1-35
1-34
1-33
1-53
1-52
VEHICLE 1-51
29
CONN Py
CN2-15
(CONN.1) 1-05
17
1-06
Px +(5V) CN3-15 1
1-10 CN2-16 CW LOW
SIG CN3-16 2
1-11
GND CN3-17 3
1-02
30 HIGH
1-03
26 15A
1-08
1-09
BR B 10A
1-40
27 26
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
18 35 6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 17
12 11 10 9 8 7 16 15 14 13 12 11 10 9
36 53
7 11 54 71
(CN7) (CN6)
1 6 72 89
ECU CON.1 (89-PIN) FG008166

Figure 61

Page 66
Reference Reference
Number Number
1 Instrument Panel 26 Fuse
3 Engine Controller 27 Starter Switch
4 EPOS Controller 28 Fusible Link
17 Engine Control Dial 29 Pressure Switch (Py)
24 Battery 30 Pressure Switch (Px)
25 Battery Relay

Page 67
AUTOMATIC DECELERATION
CONTROL (AUTO IDLE CONTROL)
E/G
4
3
1
1 2 3 4 5
6 7 8 9 0
5 5
FG013634
Figure 62
Reference Reference
Number Number
Instrument Panel 3 Engine Controller
1
(Auto Idle Switch) 4 Engine Control Dial
2 EPOS Controller 5 Pressure Switch

Page 68
If the machine is idling without the controls being operated or is
waiting for a dump truck the engine speed is automatically
lowered. Once the controls are operated and work is being
started the machine will be restored to the previous settings. As
a result, noise and fuel consumption will be reduced. This
function can be selected or cancelled through the Auto Idle
Selector Switch on the instrument panel.
The initial setting at start-up is with this switch in the select
position. Approximately 4 seconds after this function is selected,
if all work levers are in the neutral position, the EPOS controller
compares the automatic reduction signal with the signal set by
engine control dial. The lower of the two signals is selected, the
EPOS controller sends a signal to the engine controller to
control the engine speed.
The neutral status of the machine is detected by the two
pressure switches in the control valve. When the work levers are
in the neutral position, the switch is in the "OFF" position.

Page 69
ENGINE OVERHEAT
PROTECTION SYSTEM
6 6
E/G
4 4 5
3
31
7
(Pump control signal)
2
1
(E/G overheating signal)
E F
C H C H
(E/G overheating signal) 1
6
2
7
3
8
4
9
5
FG013635
Figure 63
Reference Reference
Number Number
1 Instrument Panel 6 Control Valve
2 EPOS Controller E.P.P.R. Valve
3 Engine Controller 7 (Electromagnetic Proportional
Pressure Reducing Valve)
4 Main Pump
31 Warning Buzzer
5 Aux Pump

Page 70
When the engine coolant temperature increases to over 107°C
(225°F), the engine controller detects it from the sensor
mounted in the coolant line and will send a signal to the EPOS
controller. The EPOS controller sends a overheat signal to the
instrument panel turning "ON" the warning light and buzzer
simultaneously.
Also, the EPOS controller returns an overheat signal to the
engine controller and changes power mode to standard mode.
The engine speed is then set to a low speed by the engine
controller.
When coolant temperature falls below 95°C (203°F), normal
operation will resume.

Page 71
POWER BOOST MODE
Operation
16
6 6
11
E/G
4 4 5
3
2
1
E F
C H C H
1 2 3 4 5
6 7 8 9 0
UP
WER
PO
20
18
FG013636
Figure 64
Reference Reference
Number Number
2 EPOS Controller 16 Main Relief Valve
3 Engine Controller Breaker/Boost/Shear Selector
18
4 Main Pump Switch
5 Aux Pump Power Boost Switch
20
(Top of Right Work Lever)
6 Control Valve

Page 72
The Power Boost function is used to temporarily increase the
main relief pressure to enhance excavation ability. When the
breaker/boost/shear selector switch is set to "BOOST" and the
power boost button on the center of the right-hand work lever
(joystick) is pressed during work, the EPOS controller will
activate the power boost solenoid valve and increase the relief
valve pressure from 330 - 350 kg/cm2 (4,700 - 5,000 psi). The
excavation ability is increased by approximately 6%.
When the power boost function is in activated, a power boost
symbol appears on the information display department of
instrument panel.
NOTE: Do not use this switch for more than 10 seconds.

Page 73
Power Boost Control - Circuit Diagram
1
15A
CN6-1
CN6-2
26
2 26 15A 26 20A
CN6-9 25
CN6-10
CN1-1 18
CN7-4 CN4-4 CN1-2
CN7-5 CN4-5 CAN
CN7-6 CN4-6 PST SHEAR PRESS BREAKER
TML 1 0 2
24
10
11
3
(C4) 14
CN1-11
13
6
CN2-2 (POWER MAX)
16
CN1-8 12
CN1-9
6 3
(Center)
(POWER MAX / BREAKER)
20
(CN2) (CN1)
FG000
Figure 65
Reference Reference
Number Number
1 Instrument Panel Power Boost Switch (Top of
20
2 EPOS Controller Right Work Lever)
11 Solenoid Valve (Pressure Up) 24 Battery
Breaker/Boost/Shear Selector 25 Battery Relay
18
Switch 26 Fuse

Page 74
Page 75
AUTOMATIC TRAVEL SPEED
CONTROL
6 6
13
E/G 8
15
4 4 5
3
17 2 19
FG000799
Figure 66
Reference Reference
Number Number
2 EPOS Controller 8 Pump Pressure Sensor
3 Engine Controller 13 Solenoid Valve (High speed)
5 Aux Pump 17 Engine Control Dial
6 Control Valve Selector Switch For Automatic
19
7 Pressure Switch (Py Port) Travel

Page 76
If the automatic travel speed control switch is set to "OFF"
position, the travel motor will run in the I-speed (low speed)
range. If the selector switch is set to "I" position, the travel motor
will run in the II-speed (high speed) range. If the selector switch
is set to "II" position, the EPOS controller will monitor the main
pump discharge pressure and automatically select the "ON" -
"OFF" status of the II - speed travel solenoid valve based on the
travel load. The travel speed is changed between the I-speed
and the II-speed mode.
The travel load is monitored by the two pressure sensors in the
discharge lines of the front (upper) and rear (lower) pumps.
When the travel load is high (pressure over 300 kg/cm2
(4,300 psi) the solenoid valve is turned "OFF" and I-speed (low)
is selected. In the case when the travel load is low (pressure
under 160 kg/cm2 (2,280 psi), the solenoid valve will be turned
"ON" and the II-speed will be selected. But, if the engine speed
control switch dial is set below approximately 1,400 rpm, the
travel speed will be set to I-speed mode.

Page 77
Automatic Travel Speed Control - Circuit
Diagram
15A
26
2 26 15A 26 15A
25
8 CN1-1
+ CN1-2
SIG CN3-1
CN3-2
- 13
(C3) 24
+ CN1-12
SIG CN3-3
CN3-4
- 19
9 3
0
2
CN2-4 I
II
0
I 5
CN2-5 6 II
7 8
17
CN1-8 +(5V) CN3-15 1
CW LOW
CN1-9 SIG CN3-16 2
GND CN3-17 3
HIGH
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
AMP 040 28P
6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
(CN7) (CN6)
FG000587
Figure 67
Reference Reference
Number Number
2 EPOS Controller Selector Switch For Automatic
19
8 Pressure Sensor (Front Pump) Travel
9 Pressure Sensor (Rear Pump) 24 Battery
13 Solenoid Valve (High speed) 25 Battery Relay
17 Engine Control Dial 26 Fuse

Page 78
SELF-DIAGNOSTIC FUNCTION
EPOS Controller
The system operation status and malfunction codes can be
checked through the display on top of the EPOS controller box
the rear cover behind the operator's seat.
1 2
4 3
FG000588
Figure 68
Reference Reference
Number Number
1 Upper Digit Power Monitor
2 Lower Digit 4 (Stays "ON" While Power Is In
Normal Range.)
Engine Speed Monitor LED
3 (Flash Interval Increases With
Engine Speed.)
1. Power Monitor
This LED is turned "OFF" when the input voltage to the
EPOS controller is below 18.5 ±1 V or above 32.5 ±1 V.
Stays "ON" while in normal range.
2. Engine Speed Monitor
This LED light flashes according to the engine speed. The
flashing interval is proportional to the engine speed.

Page 79
3. Normal Operation Display Readout
Display Readout
Mode Selection Operation Status
Upper Digit Lower Digit
Normal Operation
Power Mode
Power Mode
HAOH340L HAOH370L
Normal Operation
Power Mode Standard Mode
Standard Mode
HAOH350L HAOH370L
Normal Operation
Economy Mode
Economy Mode
FG013637 HAOH370L
4. Communication Monitor
What are shown in the 7-SEGMENT LED are same as
those in the Error Codes.
Error Code Indication Code Fault Location

Communication error in instrument
V201 01
panel.
Communication error in engine
V202 02
controller.

Page 80
AIR CONDITIONER SYSTEM
Outline
A
C
FG013857
Figure 69
Solid-type heater and air conditioner are installed in the cover

behind the operator's seat.
Temperature of the operator's room is adjusted automatically to
the temperature set by operator.

Page 81
(Please refer to the Operation Manual for detailed full automatic
control.
Vent mode selects the direction of discharged air.
Outlets by vent modes
Modes
Outlets A A+B B B+C C
Internal and External Filters

Internal and external air purification filters are installed for the
operator's room.
Filters must be cleaned every 500 hours.
If machine operates in an excessively contaminated
environment, filters must be cleaned more frequently and if
necessary, replaced with new ones.
How to Check Internal Air Filter

1. Press both levers on the left and right side at the top of the
filter installed at the rear of the operator's seat.
FG000422
Figure 70
How to Check External Air Filter

1. Open the door at the left side of machine and loosen four
marked bolts to remove the cover (1, Figure 71).
1
TOP
Donaldson.
FG000440
Figure 71

Page 82
2. Turn marked knobs (1, Figure 72) at the rear side of the
cabin to open the cover.
FG000441
Figure 72
3. Remove the filter attached to the cover and clean the

contaminated filter using compressed air.
4. Close the cover, replace the knobs, and secure the cover
to the support with butterfly bolts.
FG000342
Figure 73

Page 83
Air-Conditioning System Layout
10 2
11
6
1
5
5
4
8
9
FG007144
Figure 74
Reference Reference
Number Number
1 Air Conditioner/heater Unit 7 Liquid Hose (1)
2 Condenser 8 Liquid Hose (2)
3 Compressor 9 Ambient Temperature Sensor
4 Receiver Dryer 10 Sun Sensor
5 Discharge Hose 11 Control Panel
6 Suction Hose

Page 84
Air Conditioner/heater Circuit Diagram
0.5RW
FUSIBLE LINK
LAMP SWITCH
20A STARTER SWITCH

BATTERY RELAY
A/C CONTROL PANEL AIRCON UNIT BATT.

1.25LR CN11-2 42C 24V
LED 1~12 130C CN9-6
0.85LR CN10-8 42D
54E CN9-11 0.5WR
CN10-18 46B
ILL 42B CN9-5 1.25LR
0.85BW
0.85LR
RECEIVER DRIER
BLOWER A/C
42E 46A
RELAY RELAY
COMPRESSOR
168B CN8-10 0.5LG CN10-16 168A
A/C THERMO (LOW) 105B CN9-8 0.5LB CN10-5 105A CN11-4 0.85LW 47C
106B CN8-11 CN10-6 106A 47A 47B

0.5LY
FET
DIODE 4
1.25B CN11-1 99 - +
M
107B CN8-12 0.5LW CN10-1 107A 0.85B 0.85B
BLOWER
108A CN9-13 0.5GrG CN10-2 108B FRE (P1)

INTAKE
109A CN9-12 0.5GrY CN10-20 109B REC (P2) ACTUATOR
M
110A CN9-15 0.5OrR CN10-12 110B DEF (P1)

111A CN9-14 0.5OrW CN10-13 111B VENT (P2)
M
MODE
43A CN9-16 0.5YB CN10-11 43B Vref MODE
ACTUATOR
44A CN9-17 0.5YW CN10-10 44B MODE F/BACK
99 CN9-10 1.25B
112A CN9-1 0.5LgW CN10-19 112B WARM (P1)

113A CN9-18 0.5LgB CN10-3 113B COOL (P2)
M
114A CN9-3 0.5YR CN10-7 114B Vref MIX Temp. Control
115A CN9-4 0.5YW CN10-9 115B MIX F/BACK ACTUATOR
167C CN9-2 1.25BL CN10-4 167A GND
116A CN8-2 0.5OrB CN10-15 116B

DUCT
SENSOR
45A CN8-1 0.5LgR CN10-14 45B

WATER
SENSOR
2
48A CN8-5 0.5LY CN10-17 48B 1 INCAR
SENSOR
SUN LOAD SENSOR
0.5Lg 2 - + 1 CN10 AMP 20P CN11 KET 4P

142A CN8-3
142B 0.5YR
114C 0.85BL 167B 2
49A CN8-4 0.85YG 0.85YG 49B 1 AMBIENT TEMP
SENSOR
CN8 CN9
AMP 18P + 12P
AMP 040-III 20P

KET 4P AMP 070 18P AMP 070 12P
2 1 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 10
4 3 18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
(CN11) (CN10) (CN9) (CN8)
FG001463
Figure 75

Page 85
Air Conditioner/heater Unit
Air Flow Diagram
External Air Inlet
Cold Box
Internal Air Inlet
Outlet
Vent Rear
Outlet
Vent
Front
Outlet
Foot
DEF Outlet
Outlet
External Air
VENT
COOL
DOOR
DOOR -INTAKE
-MIX
DEF Internal Air
WARM
Heater Evaporator Fan

Core
FOOT
FG001359
Figure 76

Page 86
Door Open by Vent Modes
Mode
Door
Vent Bi-level Foot Def/foot Def
Vent 100 60 0 0 0
Foot 0 40 100 80 60
Def 0 0 0 20 40
Main Components
Actuator
- Temp A/C
Control Relay Blower
Relay
Duct
Sensor
Air Flow
Control
Module
Actuator
Blower
-Wind Direction
Motor
Control
Water Temp
Sensor
Actuator
Evaporator - Internal/external
Air Exchanger
Internal
Internal Air Sensor
Air Filter FG007754
Figure 77

Page 87
Actuator - Wind Direction Control
Change of discharged air flow according to selected wind
direction mode
Change of wind direction: Direction changes in the order of
VENT→BI-LEVEL →FOOT →FOOT/DEF →VENT.
Actuator - Temperature Control

Change of discharged air temperature by controlling the position
of temperature control door.
FG001361
Figure 78
Wind Direction Mode Output Terminal Voltage

Vent 0.5 ± 0.2V
Bi-level 1.3 ± 0.2V
c(+): CN10-10
Foot 2.45 ± 0.2V
b(-): CN10-4
Foot/def 3.5 ± 0.2V
Def 4.5 ± 0.2V
Set Temperature Output Terminal Voltage

Max cooling c(+): CN10-9 Below 0.4V
Max heating b(-): CN10-4 Above 4.5V

Page 88
Actuator - Internal/external Air Exchange
CN10-20 CN10-2
FG001055
Figure 79
Mode Output Terminal Output

Moving of exchange door
Intake P1(+), P2(-)
by selecting intake.
Recirculate P1(-), P2(+)
by selecting recirculate.
Air Flow Control Module

Air flow is controlled through the control of voltage between
GATE and SOURCE.
DRAIN
(CN10-1)
SOURCE GATE
(CN11-1) (CN10-6)
FG001056
Figure 80
Air flow Output Terminal Output

1st 10 ± 0.5V
2nd 12.5 ± 0.5V
3rd 15 ± 0.5V
4th CN11-2 CN10-1 17.5 ± 0.5V
5th 20.0 ± 0.5V
6th 22.0 ± 0.5V
7th More than 25V
Input voltage is 27.5V.

The air flow is based on manual set.

Page 89
Relay - Blower: Power is supplied to the blower motor when the
system is turned "ON".
Specifications
Rated voltage 24V
Rated current 20A
Figure 81
Relay - A/C: Power is supplied to the magnetic clutch of the

compressor.
Specifications
Rated voltage 24V L S1 (+)
Rated current 10A
B S2
(-)
FG001058
Figure 82
Duct Sensor: It is inserted in the core of the evaporator to

prevent freezing of the evaporator.
The sensor consist of negative characteristic thermistor that
resistant value increases and decreases when the temperature
rises and falls, respectively.
Temperature (°C) Resistance (KΩ)

0 11.36 ±0.1
2 10.39 ±0.2
2.5 10.17 ±0.2
3 9.95 ±0.2 Figure 83
3.5 9.73 ±0.2
4 9.52 ±0.2
5 9.12 ±0.2
10 7.36 ±0.15
25 4.02 ±0.08
30 3.33 ±0.07

Page 90
Water Temperature Sensor: It senses the temperature of
coolant water in the heater core.

-10 55.8 ±1.7
0 32.9 ±0.9
15 15.76 ±0.5
25 10.0 ±0.3
35 6.5 ±0.2
Figure 84
Internal Air Temperature Sensor: Built in the internal air filter,

it senses the internal temperature.

-15 218.2 ±7.5
0 97.83 ±0.9
15 47.12 ±0.7
25 30.0 ±0.36
35 19.60 ±0.3
Figure 85
Ambient Air Temperature Sensor

Built at the bottom of the cockpit, it senses the temperature of
external air.

-10 163 ±4.9
0 96.9 ±2.9
10 59.4 ±1.8
20 37.4 ±1.1
FG001064
25 30 ±0.9
Figure 86
30 24.2 ±0.7

Page 91
Sun Sensor
Built beside the socket of spare power, it senses the quantity of
the sun radiation to optimize discharge temperature and air flow
as set by operator.
83.7
OUTPUT VOLTAGE(mV)
76.2
67.7
58.8
46.6
36.0
21.4
1.0 2.0 3.0 4.0 5.0 6.0 7.0

LUX(x10,000)
FG001062
Figure 87
Control Panel
Appearance and Terminal Arrangement
A/C OUTSIDE
AUTO A/C
AUTO MAX
TEMP
OFF
SEL MODE
AMP 070 18P AMP 070 12P

8 7 6 5 4 3 2 1 5 4 3 2 1
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
(CN9) (CN8) FG001063

Figure 88
Refer to "Air Conditioner and Heater" of operation manual.

Page 92
Terminal Terms
CN Term No. Terms CN Term No. Terms

Temperature control Water temperature
1 1
(warm) sensor
2 Sensor ground 2 Duct sensor
Temperature control
3 3 Sun sensor
Power (5V)
Ambient air temperature
4 Mix feedback 4
sensor
Internal air temperature
5 Power (KEY "ON") 5
CN8 sensor
6 Back-up 6 -
7 - 7 -
8 A/C output (LOW) 8 -
9 - 9 -
10 Ground 10 D.P.S CHECK
CN9 11 Illumination 11 Air flow module (gate)
Intake/Recirculate
12 12 Blower motor (feedback)
(Recirculate)
Intake/Recirculate
13
(Intake)
Wind direction control
14
(VENT)
15
(DEF.)
16
Power (5V)
17
(feedback)
Temperature control
18
(cool)
Control Logic
Categories Inputs System Operation

AUTO Set temperature 1. Automatically adjust room temperature as set and then
next items.
sensor Temperature, Wind direction, Recirculate/Intake, Air flow,
Compressor
sensor 2. Auto mode is released when manually setting any switch
except, Temperature Control switch in Auto mode.
Water temperature sensor
3. Upon the releasing of Auto mode, all of functions except
Sun sensor
selected switch are controlled automatically.

Page 93
Sensor Set temperature 1. In case of sensor failure, following defaults are applied:
compensation
Internal air temperature Internal air temperature sensor: 25°C, Ambient air
sensor temperature sensor: 25°C, Duct sensor: -2°C
Ambient air temperature Temperature control actuator:
sensor
- Set Temperature 17 - 24.5°C: Max cooling, Set
Water temperature sensor Temperature 25 - 32°C: Max heating
Wind direction mode actuator
- VENT: VENT fix, modes other than VENT: Fixed to DEF
* Sun sensor is not compensated.
Max cooling/ Auto Setting 1. Set Temperature 32°C: Max heating
heating control
2. Set Temperature 17°C: Max cooling
Max Cooling (17 C) Max Heating (32 C)
Temp Control
FULL COOL FULL HOT
Actuator
Air Flow MAX HI AUTO HI
Compressor Forced ON OFF
Intake/Recircle Recircle Intake
Wind Direction Mode VENT FOOT
* Max cooling/heating control is possible only in Auto mode.

Starting Auto mode 1. Prevention of discharge of hot air before discharge
Control of temperature drops enough in hot summer weather
Duct sensor
Cooling
2. Start conditions (AND condition)
(1) A/C on (AUTO or manual)
(2) Temperature sensed by the duct sensor is above 30°C
(3) Air flow: Auto mode
3. One time control in the cycle of engine OFF →engine run
4. Initial cooling control is executed when the Auto switch is
"ON" in the manual status (A/C "OFF" and manual control
of air flow) in 5 seconds after engine run.
5. Initial cooling control must be before max cooling.
6. Release condition (OR condition)
(1) A/C "OFF"
(2) Air flow: Manual control
(3) Release is possible with the "OFF" switch but not
allowed within 12 seconds (after Start "ON") while the
system is off using the "OFF" switch and during the time of
initial cooling control.

Page 94
1. Start condition (AND condition)
(1) When wind direction mode is one of the following
modes in the Auto or manual control mode
- BI-LEVEL, FOOT or FOOT/DEF
(2) The Water temperature sensor is stable and the water
temperature < 73°C
(4) Set temperature > Internal air temperature + 3°C
* Air flow falls gradually up to 12 seconds when operation
released.
Water temperature sensor 2. One time control in the cycle of engine OFF →engine run
Starting Internal air temperature 3. Initial heating control must be before max heating.
control of sensor
4. Air flow is controlled only when the wind direction is in the
heating (1) Auto mode manual mode and BI-LEVEL, FOOT, or FOOT/DEF is set.
Set Temperature 5. Control through the water temperature sensor for start.
6. Starting control of heating (2) starts in case of fault of the
water temperature sensor during controlling.
7. Operation release (OR condition)
(1) Only air flow is released if it is selected manually.
(2) When handling the wind direction mode switch, only
wind direction is released but the air flow control is
performed only for the remaining period of the starting
control of heater.
(3) When Max Cooling (17°C) is selected.
(4) Water temperature sensor > 73°C.

Page 95
Starting Water temperature sensor 1. Entry condition (AND condition)
control of
Ambient air temperature (1) Auto Mode
heating (2)
sensor (2) Ambient air temperature < 5°C and difference between
Internal air temperature ambient and internal air temperature ≤5°C
sensor (3) Failure of water temperature sensor
Auto mode 2. Only one time of engine OFF →engine run
3. Starting control of heating is before max heating.
(1) Air flow: Manual selection
control of heater.
(3) Difference between internal and ambient air
temperature>15°C
5. Exceptional case
Starting control of heating is performed only once during
the remaining period if the entry condition is satisfied
within the starting control period that is the accumulation
of initial start times.
(Inclusive of Auto mode "ON" case within the period of
starting control of heater.)
* Air flow must be reduced slowly for up to 12 seconds in
case of exceptional entry case.
Duct sensor 1. Function: Magnetic clutch of compressor is turned "ON/
OFF" depending on temperature of the duct sensor to
prevent the freezing of the evaporator with A/C being
"ON".
2. Control pattern.
Compressor 2.0 0.5 C 3.5 0.5 C

control
External temperature 1. Function: Prevention of compressor in winter.
sensor
2. Control pattern.
*Only for Auto mode.

Page 96
Self Diagnosis
How to start self diagnosis
Starter Switch ON
Set temp to 25 C Set temp to 77 F
Press the SEL switch more than 3 times in

5 secs while pressing the A/C switch
Auto diagnosis starts after every graphic

in LCD displays twice every 0.5 sec.
A code concerned blinks in the cycle of 0.5-sec ON

and 0.5-sec OFF. In case of two or more errors, codes
concerned blink twice at a time.
For normal, E0 lights; for error, the first

error code is indicated.
For 2 or more error, error codes are indicated

upstreams/downstreams if the temp control switch is
set to up/down. (For normal condition, only EO lights.)

5 secs while pressing the A/C switch. Return to default status if no switch
operated for 30 secs in diagnosis mode.
Return to position before auto diagnosis

starts.
FG001367
Figure 89

Page 97
Error codes
Code Description
E0 Normal
E1 Internal air temperature sensor short
E2 Internal air temperature sensor open
E3 Ambient air temperature sensor short
E4 Ambient air temperature sensor open
E5 Duct sensor short
E6 Duct sensor open
E7 Sun sensor short
E8 Sun sensor open
E9 Water temperature sensor short
E10 Water temperature sensor open
E11 D.P.S open
E12 Position error of wind direction actuator
E13 Position error of temperature control actuator
NOTE: The position error means that it fails to move to

designated place in 40 seconds.
Sun sensor displays E8 in case of no sunlight. E1 E1 E2 E2 E3
2 and more fails: Codes concerned blinks twice at a
time.
0.5 0.5
FG001067
Figure 90
Ambient Temperature Display

Selection of both the SEL and MODE switch for more than 3
seconds indicates the ambient temperature in the set
temperature display department.
- Range of temperature display: -40 - +60°C
NOTE: Display of ambient temperature may be released in
the same way for its entry way.
It returns automatically to default mode 5 seconds
after entering the ambient air temperature display
mode.

Page 98
Compressor
Categories Specifications Relief Valve
Output 155.3 cc/rev
Oil Level 120 cc (ND-OIL8)
Refrigerant R134a
Rated Voltage 24V
Open: 35 - 42.2 kg/cm2G
Relief Valve
Close: 28.1 kg/cm2G
Compressor sucks in refrigerant which evaporates completely in

FG001365
the evaporator and discharges it to the condenser.
Figure 91
Refrigerant undergoes repeated status change in the order of
liquid, gas, and liquid in the freezing cycle, and the compressor
makes evaporated refrigerant a high temperature and
high-pressured gas to freeze it in the condenser.
Receiver Dryer
The receiver dryer reserves refrigerant enough to ensure High/Low Pressure Switch
smooth freezing cycle responding immediately to the change of
level in the freezing cycle.
As liquid refrigerant from the condenser may contain refrigerant
gas with bubbles whose presence in the expansion valve
decreases the freezing power excessively, it separates liquid
and gas and sends liquid only to the expansion valve.
Water in refrigerant shall be eliminated with dryer and through
filter.
FG001366
Figure 92
MAX. 0.25 kg/cm2

32 2 kg/cm2
Volume of refrigerant by model
Model Volume of Refrigerant

DX140LC 800 ± 20 grams 2.0 0.2 kg/cm2 6 2 kg/cm2
DX180LC 800 ± 20 grams
FG001462
DX225NLC 800 ± 20 grams Figure 93

Page 99
TROUBLESHOOTING
Refrigerant Pressure Check
1. Open all doors and windows.
2. Install manifold gauge set.
3. Start engine and maintain engine speed at 1,800 - 2,000
rpm.
LO HI
HDA6074L
Figure 94
4. Check high / low-pressure of refrigerant.
High-pressure: 8.0 - 10.0 kg/cm2 (114 - 142 psi)

1
Low-pressure: Approximately 1.0 kg/cm2 (14 psi)
Possible Cause: Low Refrigerant Level
Step Inspection Item Remedy
Reassemble using correct tightening
Yes
1 Check for traces of refrigerant oil. torque.
No Go to next step.
Using a leak detection device or soapy water Yes Repair leaking component.
2 check for refrigerant leakage at all major No Recharge system to correct
components and joints. pressure.
High-pressure: Over 23 kg/cm2 (327 psi)

2
Low-pressure: Approximately 2.5 - 3.0 kg/cm2 (36 - 43 psi)
Possible Cause: Overcharge, Frost on condenser
Check for condenser pin damage or Yes Clean, repair or replace condenser.
1
contamination. No Refrigerant overcharge.
High-pressure: Approximately 20 - 25 kg/cm2 (285 - 356 psi)

3
Possible Cause: Air in system.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long period of time, replace the receiver dryer.

Page 100
4
Low-pressure: Approximately 760 mmHg (Negative Pressure)
Possible Cause: Refrigerant does not circulate
1. Connect manifold gauge and start engine.
2. Turn on air conditioner. Moisture in system, replace receiver
Yes
dryer.
3. Set blower switch to HIGH position.
4. Turn air conditioner OFF and wait 10
1 minutes.
5. Recheck high / low-pressure readings. Contaminated system, replace
No expansion valve.
High-pressure: 13.0 - 19.0 kg/cm2 (185 - 270 psi) (Replace evaporator core assembly.)
Low-pressure: 1.5 - 3.3 kg/cm2 (21.3 - 46.9 psi)
High-pressure: Over 6 - 18 kg/cm2 (85 - 256 psi)

5
Low-pressure: 500 mmHg (Negative Pressure) - Dial indicator needle unstable.
Possible Cause: Moisture in system has iced up the expansion valve.
NOTE: When the absorbed moisture freezes the pressure readings may look normal. Careful readings
must be made to determine whether pressure is in normal range.
3. Recharge system.
High-pressure: Over 22.0 - 23 kg/cm2 (313 - 327 psi)

6
Low-pressure: 2.5 kg/cm2 (36 psi)
Possible Cause: Refrigerant pressure problem because of defective expansion valve or temperature sensor.
Inspect whether the temperature sensor is Yes Replace expansion valve.
1
installed properly. No Exchange duct sensor.
High-pressure: Over 7.0 - 11.0 kg/cm2 (100 - 156 psi)

7
Low-pressure: 4.0 - 6.0 kg/cm2 (57 - 85 psi)
Possible Cause: Low refrigerant pressure because of poor compressor compression.
Inspect and replace compressor if necessary.

Page 101
WEIGHT OF R134a GAS USED IN
MACHINES
Model Weight of Gas

DX140LC 800 ±20 grams (28 ±0.7 oz)
DX180LC 800 ±20 grams (28 ±0.7 oz)
DX225LC 800 ±20 grams (28 ±0.7 oz)
DX225NLC 800 ±20 grams (28 ±0.7 oz)
DX255LC 800 ±20 grams (28 ±0.7 oz)
DX300LC 800 ±20 grams (28 ±0.7 oz)
DX340LC 800 ±20 grams (28 ±0.7 oz)
DX420LC 800 ±20 grams (28 ±0.7 oz)
DX480LC 800 ±20 grams (28 ±0.7 oz)
DX520LC 800 ±20 grams (28 ±0.7 oz)

Page 102
REFRIGERANT SYSTEM
REPAIRS
WARNING
Always wear protective glasses and gloves when handling
refrigerant. If refrigerant comes in contact with the skin or
eyes, immediately flush with clean, running water and
consult a physician.
Select a clean and well ventilated area to work.
The refrigerant container is under high-pressure and must
be stored below 40°C (104°F). Be careful not to drop the
container from a high location.
The contents are under high-pressure and should not be
used with compressed air or near an open flame.
Refrigerant Safe Handling Procedures
UNION NUT
TORQUE WRENCH
CORRECT WRONG
WRONG
WRONG
CORRECT
O - RING POSITION
CAP & PLUG CORRECT WRONG WRONG
HDA6066L
Figure 95
The following procedures must be observed for safe handling of

refrigerant during vacuum and charging process.
1. Use an approved recovery / charging device which can
safely perform vacuum and charge work simultaneously.

Page 103
2. The new refrigerant has improved cooling characteristics
than the old type and care must be used not to overcharge
the system.
3. Do not over tighten connections when working on
refrigerant system.
4. The new refrigerant system standards require new tools,
equipment and parts. DO NOT attempt to use equipment
use in servicing the old refrigerant system.
5. The new refrigerant oil (PAG type) has a high moisture
absorption characteristic. When the refrigerant system
vacuum seal has been broken, immediately plug up all
openings to prevent moisture from entering into the
system.
6. When joining unions which use O-ring seals, lightly coat O-
rings with refrigerant oil. Be careful not to drip oil on the
threads of the nut.
7. Be certain the O-rings are seated properly on the
refrigerant line lip. Always use new O-rings when
reassembling parts. Do not reuse old O-rings.
8. Use a vacuum pump to evacuate refrigerant system of air.
9. When charging the refrigerant system with the engine
running, do not open the high-pressure valve on the
manifold gauge as the reverse flow of high-pressure
refrigerant will rupture the hose.
10. When releasing the high-pressure hose after completing
the charging process, quickly disconnect the hose to
minimize refrigerant released to the air.
Repair and Replacement Procedure

1. Work Procedure
A. Before repairing or replacing any refrigerant
components first, return all refrigerant oil to the
compressor and perform recovery procedures.
2. Operating Condition
A. Run engine at maximum engine speed.
B. Select 'HI' blower fan speed and select A/C switch to
'ON'.
C. Set the temperature control switch for maximum
cooling and leave running for approximately 20
minutes.
NOTE: The manifold gauge dial pointer can vary
depending on the outdoor temperatures.

Page 104
INSTALL REPAIR TOOL
RECOVER REFRIGERANT
REPAIR / REPLACE DEFECTIVE PARTS
VACUUM SYSTEM (OVER 5 MINUTES)
CHECK SYSTEM FOR AIR LEAKAGE REPAIR
CHARGE SYSTEM (APPROXIMATELY 100 g)
CHECK SYSTEM FOR REFRIGERANT LEAKAGE
CHARGE SYSTEM TO PROPER LEVEL

(Standard Capacity less Initial Charge)
CHECK FOR PROPER REFRIGERANT LEVEL
RUN SYSTEM
RECOVER REFRIGERANT IN CHARGING HOSE
REMOVE REPAIR TOOLS

HDA6067L
Figure 96

Page 105
Refrigerant Recovery
Reference
Description 2 3
Number
1 4
1 To Compressor
2 Low-pressure Side
3 High-pressure Side
4 From Receiver
5 Refrigerant Recovery Tank
1. Attach the manifold gauges and the refrigerant recovery 5

unit to the refrigerant lines as shown. HDA6067L
Figure 97
NOTE: Be careful not to switch the connections for the
low and high-pressure valves.
2. Open the high-pressure valve slowly to release the
refrigerant to the recovery unit.
NOTE: Open the valve slowly, while checking to see
that refrigerant is not leaking out.
3. When the manifold gauge dial falls below 3.5 kg/cm2 (50
psi), slowly open the low-pressure valve.
4. Open both the high and low-pressure valves slowly until
the manifold gauge dials indicates 0 kg/cm2 (0 psi).
Vacuuming Refrigerant System

2 3
Reference
Description 1 4
Number
1 To Compressor
2 Low-pressure Side
4 From Receiver
5 Vacuum Pump 5
HDA6068L
1. Vacuuming Procedure Figure 98
NOTE: When the A/C system has been exposed to the
air, it must be vacuumed out. Perform vacuum
process for 30 minutes for complete moisture
and air evacuation.
A. Attach the manifold gauges and vacuum pump to the
refrigerant system as shown.
B. Turn on the vacuum pump and open both valves.
C. When the low-pressure gauge shows approximately
710 mmHg, close both valves and turn off vacuum
pump.

Page 106
2. Check system for vacuum leak.
Allow system to sit for 10 minutes and check whether the
system is holding the pressure. If the pressure has
dropped, it must be repaired before proceeding to the next
step.
3. Vacuuming Procedure
If the system is holding the pressure and it has not
changed for 10 minutes, vacuum out the system for an
additional 20 minutes.
HDA6069L
A. Turn on the vacuum pump and slowly open both
Figure 99
valves.
B. Allow vacuum pump to run for additional 20 minutes
until the low-pressure gauge dial reads approximately
750 mmHg.
C. Close both valves and stop the vacuum pump.
4. Installation of Refrigerant Container
Reference 1
Description
Number
1 Handle
2 Hose Connection
2
3 Mounting Disk
3
A. Before mounting valve on the container, make sure
the handle is in the counterclockwise most position,
with the puncture pin retracted and the mounting disk HDA6070L
is in the raised position. Figure 100
B. Attach the manifold gauge center hose to the valve
assembly.
C. Turn the disk in the clockwise direction and securely
mount valve onto refrigerant container.
D. Turn the valve handle in the clockwise direction and
puncture the container seal with the pin.
E. Once the can has been punctured, turn the handle in
the counterclockwise direction so the refrigerant can
flow into the manifold gauge center hose. Now, do
not open the low and high-pressure valves of the
manifold gauge.
F. Press the manifold gauge low side valve to eliminate
the trapped air in the hose.

Page 107
Leakage Check
NOTE: Perform the leakage check after completing
vacuuming process.
1. After attaching the manifold gauge, open the high side
valve.
2. Charge system until the low side gauge dial indicates a
pressure of 1 kg/cm2 (14 psi) and close the high side valve.
3. Using a refrigerant leak detector or soapy water check
each joint for leakage.
1
Reference
Description
Number
1 Refrigerant Leak Detection Device
4. If a leak is detected, check for O-ring damage or correct

tightening torque and replace or repair as necessary.
5. If no leaks are detected, proceed with the charging process.
HDA6071L
Figure 101
WARNING
For accurate refrigerant leak detection, perform leak
detection procedure in a well ventilated area.
Refrigerant Charging
1. Perform the vacuuming procedure, vacuum holding and
leaking tests as described in the proceeding headings.
NOTE: First charge the refrigerant system with 100g
(3.5 ounces) of refrigerant with the engine off.
Then using the manifold gauges as a guide fully
charge the system with the engine running.
When exchanging refrigerant containers, press
the manifold gauge low side valve to eliminate
air from the charging hose.
Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low-pressure Side
4 From Receiver
5 Refrigerant Supply Container
2. Charge the system by opening the manifold gauge low

5
side valve. HDA6072L
Figure 102
Initial charge amount: 100 g (3.5 ounces).

Page 108
3. If refrigerant does not flow freely into system, try starting
engine first before operating air conditioner.
• Temperature control switch setting: Maximum
Cooling
Blower Speed Setting: Hi (3 step)
Engine Speed: 1,300 - 1,500 rpm
WARNING
When charging refrigerant system with the engine
running:
• Always keep refrigerant supply container in the
upright position.
• Never open the high side pressure valve.
4. Open the manifold gauge low side valve and charge

system to standard capacity.
Gauge Dial Standard Reading
High Side Gauge 13 - 20 kg/cm2

(185 - 285 psi)
Low Side Gauge 1.5 - 3.5 kg/cm2

(22 - 50 psi)
NOTE: These standards are for outside temperatures

between 30° - 35°C (86° - 95°F). The gauge
readings may vary for extreme temperature
conditions.
WARNING
• When outside temperature is low, warm the
refrigerant supply container with warm water not
exceeding 40°C (104°F). Do not allow water to
come in contact with the charging adapter valve
handle.
• When outside temperature is high, cool off
refrigerant supply container and condenser to aid
the refrigerant charging process.
5. Close low-pressure side valve.

6. Shut off engine and close refrigerant supply container
adapter valve. Disconnect manifold gauge hoses from
vehicle.

Page 109
Inspecting System For Leakage
After completing charging procedures, clean all joints and
connections with a clean dry cloth. Using a refrigerant leak
detecting device or soapy water, inspect system for leaks
2
starting from the high-pressure side.
1
NOTE: When the refrigerant circulation has been stopped
the high-pressure will start to decrease and the low-
pressure will start to increase until they are
equalized. Starting the inspection from the high side 3
will result in a accurate test.
Reference 4
Description HDA6073L
Number Figure 103
1 Pressure
2 High-pressure
3 Low-pressure
4 Compressor Stop
Inspection Procedure
1. High-pressure Side
Compressor outlet →condenser inlet →receiver dryer inlet
→air conditioner unit inlet.
2. Low-pressure side
Compressor inlet →air conditioner unit outlet.
3. Compressor
Compressor shaft area, bolt hole area and magnetic clutch
area.
4. Receiver dryer
Pressure switch and plug area.
5. Connection valve area
Inspect all valve areas.
Verify all valves are capped to prevent leaking.
Check for foreign material inside of valve cap.
6. Interior of air-conditioning unit.
After stopping engine, insert detector probe into drain
hose. (Leave inserted for 10 seconds minimum.)
NOTE: When inspecting leakage from the air-
conditioning unit, perform the inspection in a
well ventilated area.

Page 110
WIPER SYSTEM
Wiper Circuit
5 6 7
- 2 3 5 (Continuous mode) 3
+
M
8 (Intermittent 1 mode) 4
4 4
5 6 11 (Washer mode) 6
1 7 8
12 - + 1
P
1
6 9 13 2
9 2 8
AMP MIC 13P
CN12 CN13 KET 8P
15A 10A 10A 15A

4
10
2
3
AMP MIC 13P 1
1 2 3 4 5 6 4 3 2 1 4 5 6
1 2
7 8 9 10 11 12 13 9 8 7 6 5
(CN12) (CN13) (Wiper Motor)
FG000589
Figure 104
Reference Reference
Number Number
1 Battery 6 Wiper Controller
2 Battery Relay 7 Wiper Switch Panel
3 Fusible Link 8 Window Washer
4 Fuse Box 9 Wiper Cutoff Switch
5 Wiper Motor 10 Light Switch

Page 111
Wiper operation
Continuous operation
- Operation of wiper motor
Pressing the successive operation switch on the wiper switch
panel (7) changes the voltage of the "5" terminal of the wiper
controller (6) from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and
also current flows by the "3" terminal of the wiper controller (6) →
the "2" and "4" terminals of the wiper motor (5) →the "4" terminal
of the wiper controller (6) to run the wiper motor (5)
continuously.
- Stop of wiper motor
Pressing again the successive operation switch on the wiper
switch panel (7) changes the voltage of the "5" terminal of the
wiper controller (6) from LOW (0+0.5V) to HIGH (about
5.5 ±0.5V). As the "5" and "6" terminals of the wiper motor are
connected still that power is supplied to "6" terminal of the wiper
controller (6),
However, the controller (6) runs the wiper motor continuously
and then rotates the motor reversely by " letting current flow by
the "4" terminal of the wiper controller (6) → the "2" and "4"
terminals of the wiper motor (5) →the "3" terminal of he wiper
controller (6) when the "1" and "6" terminals of he wiper motor
(5) are connected and thus power voltage is supplied to "7"
terminal of the wiper controller (6).
The Wiper motor (5) stops reverse revolution when the contact
of a cam switch connected to "6" terminal of the wiper motor (5)
moves to an insulation area of the cam plate to disconnect the
"5" and "6" terminals of the wiper motor (5).
When the wiper motor (5) stops, arm and blade connected to it
move to the stop positions of the right pole in the cabin.
Intermittent operation
- Intermittent 1st (3-second)
Pressing once the Intermittent switch in the switch panel (7)
changes voltage of the "8" terminal in the wiper controller (6)
from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and current flows
through the "3" terminal in the wiper controller (6) →the "2" and
"4" terminals in the wiper motor (5) →the "4" terminal in the wiper
controller (6) to start the cycle that wiper stops 3 seconds after
every operation.
- Intermittent 2nd (6-second)
Pressing twice the Intermittent switch in the switch panel (7)
every operation.

Page 112
- Stopping the intermittent action
Pressing three times the Intermittent switch in the switch panel
(7) while the wiper is operating stops the action of the wiper
motor.
NOTE: The wiper system does not work when the wiper
cutoff switch (9) is "ON".

Page 113
LIGHTING SYSTEM
Lighting System Circuit Diagram
7
13 87a
30
87
*15 85 86
*16
*9
87a
6
30 87a
*14 87
87
30
85 86
85 86
12
*8
87a
87
30 *5
0 0
85 86 3 I 2 2 I 3
II II
0
I 5 5
0
I
4
6 II II 6
7 8 8 7
20A
15A
10 30A
CN6-1 15A
CN6-2 15A
CN6-9
11
L6 CN6-10 3
CN2-6
CN7-4 CN4-4
2
CN7-5 CN4-5 CAN
CN7-6 CN4-6 CN1-1
CN1-2
CN1-8
1
CN1-9
FG000590
Figure 105

Page 114
Reference Reference
Number Number
1 Battery Front Cabin Light /
9
2 Battery Relay Rear Work Light Relay
3 Fuse Box 10 Instrument Panel
5 Cabin Light Switch 12 Headlight (2 ea.)
Headlight Relay (Work Light 13 Work Light (2 ea.)
6
Indicate Light) 14 Front Cabin Light (4 ea.)
7 Work Light Relay 15 Rear Cabin Light (2 ea.)
8 Front Cabin Light Relay 16 Rear Work Light (1 ea.)
NOTE: The "*" mark are optional parts.
Kind of Light
The lighting system is consists of headlights, work lights, cabin
lights (optional), relays and switches.
Operation
Connected Terminal
Switch Position Activated Relay Lit Light
of switch
1 "2-3" Terminal - Illumination Light of Switch
"2-3" Terminal - Illumination Light of Switch
Headlight Relay Headlight (2 ea.)
Light Switch
2 Work Light (2 ea.)
"5-6" Terminal
Work Relay Indicator Light of Work Light
(L6)
Front Cabin Light (2 ea.) or
1 "2-3" Terminal Front Cabin Light Relay
Front Cabin Light (4 ea.)
Cabin Light Front Cabin Light (2 ea.) or
"2-3" Terminal Front Cabin Light Relay
Switch Front Cabin Light (4 ea.)
2
Rear Cabin Light Relay / Rear Cabin Light (2 ea.) and
"5-6" Terminal
Rear Work Light Relay Rear Work Light (1 ea.)

Page 115
AUDIO CONTROLLER
Audio Controller Circuit Diagram
ANTENNA
7 8 10
MODULE
2 15
3 Vcc(+5V) 9
11 3 16 (LH) (RH)
15A 1 MICOM
4 13
+ - + -
5 Vcc(+5V)
7
3 14
10A 1 DC/DC 17
CONVERTER 1 2 5 2
6 10
10A 87a 3
30 11
87 4
86 85
4
9 10 11 12 13 14 15 16 17 18
1 2 3 4
1 1 2 3 4 5 6 7 8
(Audio Control Panel) (STEREO)
FG000591
Figure 106
Reference Reference
Number Number
1 Battery 7 Audio Control Panel
2 Battery Relay 8 Stereo
3 Fuse Box 9 Speaker
4 Fusible Link 10 Antenna Module
5 Converter 11 Light Switch
6 Stereo Relay
Operations by Audio Control Panel
Switch Connected Terminal of switch Measured values Operations

PWR 4.36 ±0.2V Stereo ON, OFF
1.24 ±0.2V Volume up
"3-4"
0+0.2V Volume down
SCAN 2.49 ±0.2V Frequency selection

Page 116
SP002993
ELECTRICAL SYSTEM (ROPS)SP002993
Electrical
System
(ROPS)
Edition 1
Electrical System (ROPS) SP002993

Page 1
MEMO

Page 2
Table of Contents
Electrical System (ROPS)

Introduction ........................................................... 8
Electrical Supply System ...................................... 9
Engine Starting Circuit ........................................ 11
Start Operation .............................................................. 11
After Start ...................................................................... 13
Engine Preheating System ................................. 16
Engine Stop ........................................................ 18
Charging System ................................................ 20
Monitoring System .............................................. 21
Instrument Panel ........................................................... 22
Monitoring System Schematic....................................... 24
Operation ............................................................ 26
Instruments.................................................................... 26
Warning and Indicator Lights .............................. 28
Indication of Warning Lights .......................................... 28
Indication of Multifunction Gauge and Letter Information
Area............................................................................... 29
Initial Operation .................................................. 31
Mode Selector Switch ......................................... 31
Graphic Information Area Display....................... 32
Overview ....................................................................... 32
Main Menus for the Graphic Display Area..................... 33
Menu Selector Buttons .................................................. 33
Main Menu .......................................................... 34
Language ...................................................................... 34
Set Clock ....................................................................... 35
Filter/Oil Info .................................................................. 35
Adjust Display................................................................ 36

Page 3
Set Password ................................................................ 37
Special Menu ...................................................... 38
Entering/Accessing and Exiting/Escaping Menus ......... 38
Special Menu Selections ............................................... 39
Electronic Hydraulic Control System (EPOS) ..... 56
Control System Schematic ............................................ 56
Power Mode Control ........................................... 58
Operation....................................................................... 60
Power / Economy Mode Control - Circuit Diagram . 63
Engine Control System ....................................... 64
Engine Control Dial............................................. 65
Engine Control Circuit Diagram .......................... 66
Automatic Deceleration Control (Auto Idle Control) . 68
Engine Overheat Protection System .................. 70
Power Boost Mode ............................................. 72
Operation....................................................................... 72
Power Boost Control - Circuit Diagram ......................... 74
Automatic Travel Speed Control......................... 76
Automatic Travel Speed Control - Circuit Diagram ....... 78
Self-diagnostic Function ..................................... 79
EPOS Controller............................................................ 79
Air Conditioner System ....................................... 81
Outline ........................................................................... 81
Internal and External Filters .......................................... 82
Air-Conditioning System Layout .................................... 84
Air Conditioner/heater Circuit Diagram.......................... 85
Air Conditioner/heater Unit ............................................ 86
Ambient Air Temperature Sensor.................................. 91
Sun Sensor.................................................................... 92
Control Panel................................................................. 92
Compressor................................................................... 99
Receiver Dryer .............................................................. 99

Page 4
Troubleshooting ................................................ 100
Weight of R134a Gas Used In Machines ......... 102
Refrigerant System Repairs ............................. 103
Refrigerant Safe Handling Procedures........................ 103
Repair and Replacement Procedure ........................... 104
Refrigerant Recovery .................................................. 106
Vacuuming Refrigerant System................................... 106
Leakage Check ........................................................... 108
Refrigerant Charging ................................................... 108
Inspecting System For Leakage.................................. 110
Wiper System ................................................... 111
Wiper Circuit................................................................ 111
Wiper operation ........................................................... 112
Lighting System ................................................ 114
Lighting System Circuit Diagram ................................. 114
Kind of Light ................................................................ 115
Operation..................................................................... 115
Audio Controller ................................................ 116
Audio Controller Circuit Diagram................................. 116

Page 5
Page 6
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX140LC 5001 and Up

Page 7
INTRODUCTION
The electrical system for this equipment is DC 24 volts. The
rated voltage for all electric components is 24 volts with the
exception of the stereo and the air-conditioning control actuator.
The system contains two 12 volt batteries connected in series
and a three phase AC generator with a rectifier. The electric
wiring used in the system is easily identifiable by the insulator
color. The color symbols used in the electrical system are listed
in the following chart.
Electric Wire Color
Symbol Color
W White
G Green
Or Orange
B Black
L Blue
Lg Light green
R Red
Gr Gray
P Pink
Y Yellow
Br Brown
V Violet
NOTE: RW: Red wire with White stripe

R - Base Color, W - Stripe Color
NOTE: 0.85G: Nominal sectional area of wire core less
insulator = 0.85 mm2

Page 8
ELECTRICAL SUPPLY SYSTEM
The electric power circuit supplies electric current to each
electric component. It consists of a battery, battery relay, starter
switch, circuit breaker, fusible link and fuse box.
The negative terminal of the battery is grounded to the vehicle
body.
Even when the starter switch (5) is in the "OFF" position, electric
current is supplied to the following components through battery
(1) →fusible link (3) →fuse box (6).
1. Terminal "1" of DC-DC converter (for memory backup of
stereo)
2. Terminal "B" of starter switch
3. Hour meter
4. Engine controller
5. Fuel feeder pump switch
6. Terminal "6" of wiper motor
7. Terminal "13" of wiper controller
8. Terminal "CN6-11" of instrument panel
9. Terminal "CN9-6" of air conditioner panel
10. Cabin light
When the starter switch (5) is in the "ON or START" positions,
the current flows from the battery (1) →fusible link (3) →fuse box
(6) →"B" terminal of starter switch (5) →"BR" terminal of starter
switch (5) →"BR" terminal of battery relay (2) which activates the
coil of the battery relay and the electric supply system is
energized.
When the battery relay's contacts are connected, all electric
devices can be operated.
While the engine is not running, the electric power for all electric
devices are supplied by the battery. Once the engine is started
the power is supplied from the alternator (7).

Page 9
ACC C
B
R2
5
BR
0.5G
R1
6
3
8
4 2
B A
BR
E
- + - +
12V 100AH 12V 100AH
STARTER SWITCH CONNECTION R(I) P(R) B(B+)
0.5 uF 1
PST TML B BR R1 R2 C ACC B+
OFF I(L)
ON 7
REG.
TRIO DIODE
START
F+ FIELD
F-
E
GRD
FG007233
Figure 1 Electric Power Circuit Diagram
Reference Reference
Number Number

Page 10
ENGINE STARTING CIRCUIT
Start Operation
When the starter switch is turned to "START" position, the "S"
and "E" terminals of the starter controller (7) are connected. Now
the contacts in the starter relay (8) are closed by the current flow
of starter switch (5) → "C" terminal of starter switch (5) → "30"
terminal of starter relay (12) - "87a" terminal → "C" terminal of
starter relay (8) - "D" terminal →"S" terminal of starter controller
(7) - "E" terminal →ground.
When the contact point "B" and "PP" of starter relay (8) are
connected, the pinion gear of the starter (9) is pushed forward
and makes contact with the ring gear of the flywheel and the
internal contacts of the starter are connected. The current flows
from the battery (1) →"A" terminal of the battery relay (2) →"B"
terminal of the battery relay (2, Figure 3) →"B" terminal of the
starter (9). The starter motor is rotated and the engine is started.
If the instrument panel has the password function activated,
input number should match the set number, otherwise the start
circuit closes and the engine does not start.
NOTE: If the security system is "LOCKED", a four-digit
password will be required to start the engine. If the
system is "UNLOCKED", no password will be
required and this display screen will not appear.
ENTER
In the event the security system is locked, current PASSWORD
flows from battery (1) →fusible link (3) →fuse box (6)
→ "B" terminal of starter switch (5) →"ACC" terminal
of starter switch (5) → "86" terminal of starter relay
(12) →"85" terminal of starter relay (12) →"CN1-15"
terminal of EPOS (13) → ground. This current flow
causes the coil in starter relay (12) to be activated, FG013717
opening contacts at "87a" terminal. This prevents Figure 2
starter relay (8) from functioning.

Page 11
7 8 9
N S D PP C
P C B B
B E
11
A
87a
30
87
85 86 ACC
C
B 5
R2 BR
12 R1
3
CN1-15
6
4
B A
CN2-1
BR
13 E
11
R(I) P(R) B(B+)
2
0.5 uF
B+
I(L)
OFF
ON REG.
TRIO DIODE
10 - + - +
START F+ FIELD 1
F-
E
GRD
FG007234
Figure 3 Starter Circuit (1) - While Starting
Reference Reference
Number Number

Page 12
After Start
Once the engine has been started, the belt driven alternator (10)
generates a current.
The output generated by the alternator (10) is a square wave
pulse voltage through the "P" terminal and the frequency of the
pulse voltage is proportional to the rotation of the alternator.
The starter controller (7) monitors the frequency of the output
current. Once the frequency is equivalent to 500 rpm, it is
sensed and the connection between "S" and "E" terminals and
the connection between "B" and "PP" terminals are opened. As
a result the rotation of the starter (9) is stopped. Once the engine
is running, the starter (9) will not operate even if the starter
switch (5) is moved to the start position, preventing possible
damage to the starter.

Page 13
Operation of the Start Circuit (2) - Immediately After Start
7 8 9
N S D PP C
P C B B
B E
11
A
87a
30
87
85 86 ACC
C
B 5
R2 BR
12 R1
3
CN1-15
6
4
B A
CN2-1
BR
13 11
E
R(I) P(R) B(B+)
0.5 uF 2
B+
I(L)
REG.
OFF - + - +
10
TRIO DIODE
ON F+ FIELD
START F- 1
E
GRD
FG007237
Figure 4 Operation of Start Circuit (2) - Immediately After Start
Reference Reference
Number Number

Page 14
Page 15
ENGINE PREHEATING SYSTEM
An air heater (8) is installed in the intake manifold of the engine.
When the starter switch (5) is turned "ON", the current flows
of starter switch (5) →"BR" terminal of starter switch (5) →"1-39"
terminal of engine controller (12), causing current to flow though
"1-16" terminal of engine controller (12) →"C and D" terminals of
preheat relay (7) →"1-04" terminals of engine controller (12) →
ground.
This current flow causes the coil in preheat relay (7) to be
activated, closing contacts.
When the contacts of the preheat relay (7) are closed, the
heating coils of the air heating device (8) are heated by current
flowing from the battery (1) →battery relay (2) →preheat relay (7)
→air heater (8) →ground.
The duration of the heating cycle depends on the temperature of
engine coolant. The preheat indicator light in the instrument
panel (9) will turn "ON" during preheating cycle.
The preheat relay (7) is controlled by the engine controller (12)
and operates only at temperatures of 10°C (50°F) and below.
The longer the preheating period, the lower the temperature of
coolant is.

Page 16
3
9 4
CN6-1,2 2
ACC C B A
PREHEAT CN7-4,5,6
L5 B 5
R2 BR
R1 BR E
10
CN4-4,5,6
CN2-1
- + - +
11 1
C B
-
200A
1-34,35 7 STARTER SWITCH CONNECTION
1-40 PST TML B BR R1 R2 C ACC

(1)
1-13 D OFF
H +
1-07 ON
START
12
FG007137
Figure 5 Engine Preheat Circuit
Reference Reference
Number Number
1 Battery 7 Preheat Relay
2 Battery Relay 8 Air Heater
3 Fusible Link 9 Preheat Indicator Light
5 Starter Switch 11 EPOS Controller
6 Fuse Box 12 Engine Controller

Page 17
ENGINE STOP
When starter switch (5) is turned "ON" the engine controller (8)
is activated. The engine controller monitors and controls the
engine including the injector solenoid (9). It controls the fuel
deliver rate and the injection timing for each cylinder.
NOTE: There is an individual injector solenoid (9) for each of
the six cylinders. Only one solenoid is shown in
Figure 7.
When starter switch (5) is turned "OFF", the engine controller
stops suppling power to the injector solenoid (9). This stops fuel
from being injected into the engine cylinder, thus stopping the
engine.
In the event that the engine can be shut down using the starter
switch (5), an emergency stop switch (10) is provided to stop O I
engine. To activate the emergency stop switch, move it to "I"
(EMERGENCY STOP) position.
The emergency stop switch (10) is in its "O" (OFF) position
during normal operation. The switch must be moved and held in
the "I" (EMERGENCY STOP) position until the engine stops.
When released it will automatically move back to "O" (OFF)
position.
FG016039
Figure 6 Engine Emergency Stop Switch

Page 18
OFF
ON
START
8
6
0.5G
3
ACC C
10 B 5
R2
1-19 2 3 BR
4 2
R1 B A
1-45
1-39 BR
E
7
9
- + - +
1
FG001473
Figure 7 Engine Stop Circuit
Reference Reference
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 7 Diode
3 Fusible Link 8 Engine Controller
4 Circuit Breaker 9 Injector Solenoid
5 Starter Switch 10 Emergency Stop Switch

Page 19
CHARGING SYSTEM
When the starter switch (5) is turned to "ON" position, an initial
excited current flows to the field coil of the alternator (7) through
the battery relay (2) and circuit breaker (4). When the engine is
started from this condition the alternator (7) starts charging. The
current flows from the "B(B+)" terminal of alternator (7) →circuit
breaker (4) →battery relay (2) →battery (1).
The alternator also supplies electric current to other electrical
components. When the alternator (7) starts to operate, a current
flows from the "R(I)" terminal of alternator →diode (8) →battery
relay (2) coil securing a path for the charging current to the
battery (1). Thus preventing the possibility of a high voltage build
up and possible damage to the electric system.
ACC C
B
5
R2
BR
0.5G
R1
6
3
8
4 2
B A
BR
E
8
- + - +
12V 100AH 12V 100AH
R(I) P(R) B(B+)
0.5 uF 1
STARTER SWITCH CONNECTION B+
PST TML B BR R1 R2 C ACC I(L)
OFF REG.
TRIO DIODE 7
ON FIELD
F+
START F-
E
GRD
FG007238
Figure 8 Charging Circuit
Reference Reference
Number Number

Page 20
MONITORING SYSTEM
1 2
5 7
8
4
E F
C H C H
9
3
10
1 2 3 4 5
6 7 8 9 0
6
11
13 12
FG016911
Figure 9
Reference Reference
Number Number
1 Instrument Panel 8 Warning Buzzer
2 Battery Pump Discharge Pressure
9
3 Light Switch Sensor
4 Return Filter Switch Hydraulic Oil Temperature
10
Sensor
11 Fuel Sensor
6 EPOS Controller
12 Air Cleaner Indicator
7 Alternator
13 Engine Controller
The monitoring system displays the various data and warning

signals onto the instrument panel by processing the information
gathered from the EPOS controller. It displays information
selected by the operator.

Page 21
Instrument Panel
7 8 9 10 11 12 5
6 1
1 CHECK
E
< CONNECTOR AND TERMINAL NO.>
F 4
16
C H C H 18
AMP 040 28P
14 20 6 5 4 3 2 1 8 7 6 5 4 3 2 1
22 12 11 10 9 8 7 16 15 14 13 12 11 10 9
13 (CN7) (CN6)
1 2 3 4 5
23
6 7 8 9 0
15
17 19 21 FG013521
Figure 10
Gauges Warning Lights Mode Selector Switches

1. Fuel Gauge 7. Charge Warning 14. Power Mode Selector Button
2. Engine Coolant Temperature 8. Engine Oil Pressure Warning 15. Economy Mode Selector
Gauge Button
9. Engine Coolant Temperature
3. Hydraulic Oil Temperature Warning 16. Auto Idle Selector Button
Gauge
10. Engine Check Warning 17. Flow Control Button
4. Multifunction Gauge and
11. Preheat Indicator 18. Up Arrow Button
12. Work Light Indicator Light 19. Down Arrow Button
5. Digital Clock
13. Warning Light 20. Display Selector Button
6. Hour Meter
21. Selector Button
22. Home Selector Button
23. Camera Selector Button
When the engine starter switch is turned to "I" (ON) position, all
gauge bands, switch/button indicator lights and warning lights
will turn "ON" and the alarm buzzer will sound about two
seconds.
During this functional check, a LOGO will appear on the multi
function gauge in the graphic information area

Page 22
Page 23
Monitoring System Schematic
19
CN6-1
3
CN6-3
ILL.
CN6-2
CN6-12
2
CN6-11
17
CN6-9 4
CN6-10 16
R2 B
B
BR
14
22 E
CN6-4
CN6-5
CN2-1 A
CN6-6
CN6-7
LCD DISPLAY PANEL
WATER TEMPERATURE
FUEL LEVEL 18
OIL TEMPERATURE 15
SIG CN3-1
5
CN3-2
CN7-9 SIG CN3-3

GRAPHIC DISPLAY 6 CN3-4 CN5-7
CN7-10
9
WARNING LAMP CN7-4 CN4-4 CN2-17

10
CN7-5 CN4-5 CAN A
CN7-6 CN4-6 CN2-18
11
21 CN4-3 GND
CN5-3
1-62 CN4-2 RxD 12
1-65 CN4-1 TxD
1-35
1 CN3-7
1-34
CN3-8 8
1-33 2
3
1-53 CN3-9
4 20
1-52 CN3-10 7
5
1-51
6
14
R(I) CN2-14
13
FG013522
Figure 11

Page 24
Reference Reference
Number Number
1 Instrument Panel 12 Return Filter Switch
2 Pilot Buzzer 13 Alternator
4 Starter Switch 15 Battery
5 Front Pump Pressure Sensor 16 Battery Relay
6 Rear Pump Pressure Sensor 17 Circuit Breaker
Hydraulic Oil Temperature 18 Fusible Link
7
Sensor 19 Fuse Box
8 Fuel Sensor 20 Check Connector
9 Pedal Pressure Switch (Optional) 21 Engine Controller
10 Air Cleaner Indicator 22 Rearview Camera

Page 25
OPERATION
Instruments
Function Display
Blue
Coolant ECU-CAN
Temperature 61 C 102 C Communication
41 C 107 C
C H
White Red
FG013527
Blue
1/10 LCD (Red Zone)

CN3-7
Fuel Level Blinking →over 5K ohms
CN3-8
1/10 FULL →under 525 ohms
E F
Red Full
FG014894
Blue
40°C (104°F) →1,397 ohms
50°C (122°F) →1,139 ohms
Hydraulic Oil CN3-9 60°C (140°F) →881 ohms

Temperature 50 C 94 C CN3-10 94°C (201°F) →190 ohms
40 C 96 C
C H 96°C (205°F) →177 ohms
White Red (When reading increase)
FG013529
45 l/min →610 mA
102 114
80 110 52 l/min →583 mA
94
73 87 (Output
58 l/min →555 mA
Terminal)
Flow 65
58 73 l/min →495 mA
Adjusting CN1-19
52 (Default Set)
CN1-20
45 102 l/min →375 mA
(None)
FG017003 114 l/min →290 mA

Page 26
Function Display
N = 146 f / 60
Tachometer E/G SPEED 1750 RPM

ECU-CAN
Communication
N = Engine speed (rpm)
f = Frequency of engine
speed sensor (Hz)
FG013531
Voltmeter BATTERY 28.0 VOLT CN2-14 0 - 32 VDC
FG000050
Main pump
discharge CN3-1
pressure
FRONT PUMP 320 BAR
CN3-2
(front pump)
V = 0.00816 x P + 1.0
FG000051
V: Sensor output voltage (V)
P: Displayed pressure (Bar)
Main pump
discharge CN3-3
pressure
REAR PUMP 313 BAR
CN3-4
(rear pump)
FG000052

Page 27
WARNING AND INDICATOR
LIGHTS
Indication of Warning Lights

Input
Terminal
This symbol appears
in case of no charge
[voltage of "R(I)" Normally, it lights
terminal is below when starting engine
Charge CN2 - 14
12 ±1V] or and is out after engine
overcharge [voltage starts.
HAOA610L
of "R(I)" terminal is
above 33(V)].
After starting engine,

This symbol appears
ECU-CAN if engine oil pressure
Engine Oil when engine oil
Communic is insufficient after 8
Pressure pressure is below the
ation seconds, a warning
reference.
buzzer will sound.
HAOA620L
ECU-CAN This symbol appears

Engine CHECK Communic in case of failure in
Check
ation engine system.
FG000045
This symbol appears

ECU-CAN when engine coolant
Coolant
Communic temperature sensor
Temperature
ation resistant is below
about 128 ohms.
HAOD350L
Preheating period
depends on coolant
This symbol appears temperature.
during preheating
("CN5-2" terminal No preheating at
Preheating CN5-2 voltage is below 2V) above 10°C
and turns "OFF" after 10 sec preheating at
completion of 5°C
HAOA639L preheating.
20 sec preheating at
below 0°C

Page 28
Input
Terminal
This symbol appears

Work Light CN2 - 6 when work light turns
"ON" (24V applied).
HB4O2003
Indication of Multifunction Gauge and

Input
Terminal
CN3-9 When hydraulic oil

Hydraulic Oil
temperature is above
Temperature CN3-10 about 96°C.
FG000056
Fuel CN3-7 When fuel is almost

Exhausted CN3-8 exhausted.
FG000057
When air cleaner is

Air Cleaner CN2-17
clogged.
FG000053
When return filter

pressure is above
Return Filter CN5-3
about 1.50 kg/cm²
(21 psi)
FG000054

Page 29
When pilot filter
pressure is above
Pilot Filter CN2-18
about 1 kg/cm² (14
psi)
FG000055
Warning buzzer also

It flickers in case of
starts when boom
2.71V and above and
CN3-5 pressure sensor
Overload lights continuously in
output voltage is
Warning CN3-6 case of 2.8V and
about 2.7V while
above (and warning
overload warning
buzzer also starts).
FG000253 switch is "ON".
This symbol appears

Boost CN2-2 when boost is
selected.
FG000554
This symbol appears

Breaker CN2-10 when breaker is
selected.
FG001470
This symbol appears

Shear CN2-9 when shear is
selected.
FG001471
This symbol appears

when the water
separator is full.
Water CN3-19
Separator This symbol appears
CN3-20
when water separator
sensor output voltage
FG010520 is about 1.5V below.

Page 30
INITIAL OPERATION
Item Input (Terminal) Output (Operation and initial setting mode)
Initial When "CN6-1,2" is applied • LCD, all of LED and warning lights are turned
Operation battery voltage (starter switch "ON" and turned "OFF" after about 2 seconds.
shifts from "OFF" to "ON"
• Warning buzzer is activated and turned "OFF"
after about 2 seconds.
• Power mode: Standard mode.
• Auto Idle: High Output (Activation).
• Display: Indicating coolant temperature, Fuel
level, Hydraulic oil temperature, Engine speed.
• Clock: Current time display.
NOTE: Refer to method for setting clock in operation manual

for setting time.
MODE SELECTOR SWITCH

Power Mode Switch
EPOS Output
Output Check
(Operation Electromagnetic
Operation Mode Proportional Pressure Swing Priority 7-Segment
mode display
LED) Reducing Valve (E.P.P.R Solenoid Valve Display
Valve) Current (mA)
No-load: 150 ±20mA
Power Mode ON Load: Variable output - 9x
No-load: 250 ±20mA
Power Standard Mode OFF Load: Variable output - 7x
Mode
No-load: 400 ± 20mA
Load: Variable output
Economy Mode - 5x
(Max. current:
600 ± 60mA)
NOTE: When the engine speed is below 1,000 rpm, the output
current of E.P.P.R valve is fixed to be 600 ±60mA.
Auto Idle Switch
Operation Mode Output Check (Operation mode display LED)

Activation ON
Auto Idle
Cancellation OFF

Page 31
GRAPHIC INFORMATION AREA
DISPLAY
Overview
Many kinds of condition of machine are displayed on the letter
information display department. The information display
department is divided into two menus. One is main menu for
user and the other is special menu for specialist. These menus
can be moved from normal display mode by the combination of
selector buttons.
E F
C H C H 1
5
1 2 3 4 5
6 7 8 9 0
2 3 FG013562
Figure 12
Selector Buttons Graphic Display Area

1. Up Arrow Button 5. Home Button
2. Down Arrow Button 6. Letter Information Display Department
3. Enter Button
4. Escape Button

Page 32
Main Menus for the Graphic Display Area
1. Main menu: Language setting, Time setting, Filter/Oil
information, Brightness adjustment, Password
2. Special menu: Information of machine status, failure
information, Information of machine operation.
Menu Selector Buttons

1. Up Arrow Button ( , 1 on Figure 12): Move the cursor to
up, left and previous screen.
2. Down Arrow Button ( , 2 on Figure 12): Move the cursor
to down, right and next screen.
3. Enter Button ( , 3 on Figure 12): Move the menu to
selected mode. When setting the menu, this button is used
to function as the selector button.
4. Escape Button (ESC, 4 on Figure 12): Move a screen to
previous menu or main menu.
5. Home Button (HOME, 5 on Figure 12): Move a screen to
default menu.

Page 33
MAIN MENU
When the "ESC" button is pressed for more than 3 seconds, the
main menu screen is displayed. MAIN MENU
Main menu offers sub-menus (language setting, time setting, or L 1. Language
filter/oil information, brightness adjustment, password) to the l
2. Set Clock
l
operator.
Refer to "Operation and Maintenance Manual" for details.
4. Adjust Display
5. Set Password
FG013563
Figure 13
Language
MAIN MENU
Put the cursor on Language in the main menu and put the Enter
Button ( , 3 on Figure 12) and the language select view
L 1. Language
l
2. Set Clock
l
appears.
The default language is Korean, but it will memorize and use the
newly set language. 4. Adjust Display
Use the Up Arrow Button ( , 1 on Figure 12) or Down Arrow
5. Set Password
Button ( , 2 on Figure 12) to move cursor to a language to be : UP : DOWN : SELECT
selected on the Language Select display and press the Enter FG013563
Button ( , 3 on Figure 12) and the selected language is Figure 14
indicated in the right bottom of the screen.
At this point pressing the Enter Button ( , 3 on Figure 12) or
the Escape Button (ESC, 4 on Figure 12) more than 1 second L Languag
brings the main menu with changed language and then pressing
the ESC button again shows the default view. 1. Korean
Without pressing a button more than 20 seconds, the default 2. English
view appears.
FG013564
Figure 15

Page 34
Set Clock
MAIN MENU
It is used to adjust time of the digital clock.
L 1. Language
Pressing the Enter Button ( , 3 on Figure 12) in the Main l
2. Set Clock
l
Menu after putting cursor on Set Clock brings Set Clock display.
Without pressing a button more than 20 seconds, the default 4. Adjust Display
view appears.
5. Set Password
Please refer to the Operation Manual for detailed information on
Time Setting. : UP : DOWN : SELECT
FG013565
Figure 16
SET CLOCK
02:30:30
2003 11/04
FG013566
Figure 17
Filter/Oil Info
MAIN MENU
This mode displays total operating hours of filters and oils.
L 1. Language
After changing the filter and oil, reset the operating hour and l
2. Set Clock
l
then the operating hours until the next service interval can be
easily checked. 3. Filter / Oil Info
4. Adjust Display
5. Set Password
FG013567
Figure 18
Filter/Oil Information
R
1. Fuel Filter
Hrs : 0045Hrs 42m
FG013568
Figure 19

Page 35
Menu Display Order and Icon Explanation
1. Fuel Filter 2. Air Cleaner 3. Engine Oil Filter 4. Hyd. Oil Filter
5. Pilot Filter 6. Engine Oil 7. Hydraulic Oil 8. Coolant Water

FG001358
Figure 20
Adjust Display
MAIN MENU
Pressing the Enter Button ( , 3 on Figure 12) in the main
menu after putting cursor on Adjust Display brings Adjust
L 1. Language
l
2. Set Clock
l
Display.
Screen brightness can be adjusted using the Up Arrow Button
( , 1 on Figure 12) or the Down Arrow Button ( , 2 on Figure 4. Adjust Display
12). 5. Set Password
The default brightness is set to 50%. : UP : DOWN : SELECT
FG013569
Figure 21
1. Adjust Display
2. Adjust Display (Camera)
FG013835
Figure 22

Page 36
Day Mode
The default brightness is set to 50%. Adjust Display
The default contrast is set to 50%. Brightness llllllllllllllllllllllll l 50%
l
The default back light is set to 90%.
Contrast lllllllllllllllllllllllll l 50%
l
Night Mode
Back Light llllllllllllllllllllllll l 50%
l
The default brightness is set to 50%.
The default contrast is set to 30%. : UP : DOWN : SELECT
The default back light is set to 10%. FG013570
Figure 23
Set Password
MAIN MENU
This menu is used to apply (lock), release, or change password.
L 1. Language
Please refer to the Operation Manual for detailed information on l
2. Set Clock
l
Password Setting.
4. Adjust Display
5. Set Password
FG013571
Figure 24

Page 37
SPECIAL MENU
In this menu, many types of operating conditions and functions
can be accessed and displayed, including the EPOS controller.
This menu is mainly used for machine testing and failure
diagnostics.
The special menu offers three sub-menus:
1. Machine status.
2. Failure information.
3. Information on machine operation.
Entering/Accessing and Exiting/Escaping

Menus
Entering/Accessing Menus 4
When normal mode screen is displayed, if the enter button ( ,
3) and escape button (ESC, 4) are pressed simultaneously for
more than 3 seconds, normal mode screen (Figure 26) will be
changed to special menu screen (Figure 27).
3 FG013581
Figure 25
Normal Mode Screen

NOTE: Normal mode screen can display many kinds of
display mode by selecting, for example, engine
speed (RPM), battery voltage (VOLT), front pump
pressure (BAR), rear pump pressure (BAR) and so
on by selecting.
E F
C H C H
FG013591
Figure 26

Page 38
Special Menu Screen
NOTE: Displayed language on the special menu screen SPECIAL MENU
consists of Korean and English.
If any language except for Korean is selected during
language selection mode of main menu, only English 2. Failure Information
will be displayed on special menu screen.
3. Operating Hours
FG013592
Figure 27
Exiting/Escaping Menus
1. If escape button (ESC, 4 on Figure 25) is pressed for more
than 1 second, the special menu screen will be returned to
the normal mode screen.
2. If this special menu is "ON" without any activity, for more
than 20 seconds, it will turn to the normal mode screen.
3. After the turning starter switch to "OFF" position, turn it
back to "ON" position, and the normal mode screen
displayed once again.
Special Menu Selections

Submenu Selection Method
Various sub-menus can be selected by pressing "Up ( , Figure

SPECIAL MENU
25)" and "Down ( , Figure 25)" button. 1. Machine Information
Move the cursor to desired menu and a selected menu will be
inverse displayed. 2. Failure Information
When the selected menu is inverse displayed, press the "Enter
( , 3 on Figure 25)" button for menu selection. 3. Operating Hours
FG013592
Figure 28
Information of Machine Status

1. Entering Sub-menus: When cursor is located on "Machine MACHINE INFORMATION
Info" of special menu screen, press "Enter ( , 3 on
Figure 25)" button and the "Machine Info" will be displayed.
1. Analog Input State
2. Exiting Sub-menus: If escape button (ESC, 4 on Figure 25) 2. Digital input State
is pressed for more than 1 second, display will be turned to
previous screen. 3. Digital Output State
FG013593
Figure 29

Page 39
Analog Inputs Description
Analog Input Items Display Remark

1. Pump P/V mA Current in pump proportional valve.
2. Cooling Fan P/V mA N.A.
3. Flow Control P/V mA N.A.
4. Dial mV Indicating dial voltage.
5. TPS mV N.A.
6. E/G Control Motor mV N.A.
7. Boom Pressure BAR Boom cylinder head pressure.
8. Pilot Gear Pump Press BAR N.A.
9. Boost Pressure BAR Pump pressure for boost.
Temperature of air incoming to
10. Intake Manifold Temperature °C
intake manifold.
11. E/G Oil Pressure BAR Engine oil pressure.
12. Fuel Temperature °C Fuel temperature.
13. E/G Oil Temperature °C Engine oil temperature.
14. Load At Cur. Spd % Current load ratio of equipment.
Submenu Selections
1. Power Shift P/V : 0598mA 6. E/G Control Motor : 2095mV

2. Cooling Fan Ctrl P/V : N.A 7. Boom Pressure : 205BAR
3. Flow Control P/V : 0000mA 8. Pilot Gear Pump Press : 33BAR
4. E/G Control Dial : 2095mV 9. Boost Pressure : 000BAR
5. TPS : 2095mV 10. Intake Manifold Temp. : 000 C
11. E/G Oil Pressure : 000BAR

12. Fuel Temp. : 000 C
13. E/G Oil Temp. : 000 C
14. Pecent Load At Cur. Spd : 00%
: UP : DOWN
FG013594
Figure 30

Page 40
Page 41
Digital Inputs Descriptions
Digital Inputs Items Mark Remark

Lights up when output at alternator
1. Alternator
"R(I)" terminal is above 12 ±1V.
2. Travel Select SW N.A. (only for wheel type equipment)
3. High Speed Sel. SW (M)
selector switch is set to "I" position.
4. High Speed Sel. SW (A)
selector switch is set to "II" position.
5. Pressure SW (Py)
(Py) is "ON".
6. Pressure SW (Px)
(Px) is "ON".
7. E/G Oil Press. SW N.A. (only for mechanical engine)
Lights up when the air cleaner
8. Air Cleaner Clogged
indicator contact is "ON".
Lights up when the return filter
9. Return Filter Clogged
Lights up when the pilot filter
10. Pilot Filter Clogged
Lights up when the overload
11. OWD Warning SW
warning selector switch is "ON".
12. Brake Oil Press. SW ON / OFF N.A. (only for wheel type equipment)
Lights up when the pedal pressure
13. Pedal Press. SW
switch is ON.
Lights up when the selector switch is
14. One Way Sel. SW
turned to breaker.
Lights up when the Selector Switch
15. Two-way Sel. SW
is turned to "SHEAR".
16. Power Max. SW "ON" with the Select switch turned
to "BOOST".
17. Breaker SW "ON" with the selector switch turned
to "BREAKER".
18. Preheat Select N.A.
Lights up when the Quick Coupler
19. Quick Coupler
switch is "ON".
20. F and R Lever N.A. (only for wheel type equipment)
Lights up during preheating (CN5-2)
21. Preheat Select
terminal voltage is below 2V.
22. Reverse Fan SW N.A.
23. Pilot Cutoff SW N.A.
24. Water in fuel Lights up when WIF sensor is "ON".

Page 42
Menu Select
1. Alternator : 7. E/G Oil Press.SW : N.A

2. Travel Select SW : N.A 8. Air Cleaner Clogged :
3. High Speed Sel. (M) : 9. Return Filter Clogged :
4. High Speed Sel. (A) : 10. Pilot Filter Clogged :
5. Pressure SW (Py) : 11. OWD Warning SW :
6. Pressure SW (Px) : 12. Breake Oil Press SW : N.A
19. Quick Coupler : 13. Pedal Press. SW :

20. F & R Lever : N.A 14. One Way Sel. :
21. Preheat Select : 15. Two Way Sel. :
22. Reverse Fan SW : N.A 16. Booster SW :
23. Pilot Cutoff SW : N.A 17. Breaker SW :
24. Water in fuel : 18. Preheat Select :
FG013611
Figure 31

Page 43
Digital Outputs Descriptions
Digital Outputs Items Mark Remark

Lights up when the relief press up
1. Relief Press. Up S/V
solenoid valve is "ON".
Lights up when the high speed
2. High Speed S/V
ON / OFF solenoid valve is "ON".
3. Reverse Fan S/V N.A.
4. Starter Relay When the starter relay is "ON".
5. After Heat Relay N.A.
Menu Select
DIGITAL INPUT STATE
1. Relift Press UP S/V :
2. High Speed S/V :
3. Reverse Fan S/V :
4. Starter Relay :
5. Afterheat Relay :
: UP : DOWN
FG013612
Figure 32
Failure Information
1. Entering Sub-menus: When a cursor is located in "Failure SPECIAL MENU
Info" of special menu screen press enter button ( , 3 on
Figure 25) and "Failure Info" screen is displayed.
2. Exiting Sub-menus: If escape button (ESC, 4 on Figure 25) 2. Failure Information
is pressed for more than 1 second, this information screen
will be returned to previous screen. 3. Operating Hours
FG013613
Figure 33
* Real-time Failure:
Current status of failure is displayed. FAILURE INFORMATION
* Failure Log:
Memorized record of past failure is displayed. 1. Realtime Fail
* Delete Fail Log: 2. Failure Log
This mode is used to delete all of the
memorized record of past failure.
3. Delete Fail Log
FG013614
Figure 34

Page 44
A. Current failure information
Current status of failure is displayed (Failure code, REALTIME FAILURE
failure contents). 1/2 CODE : V204 - 05
information can be checked using "UP" ( , Figure
25) or "DOWN" ( , Figure 25) button. Relief Pressure Up S/V
* 1/2: A serial number of current failure/ total quantity Open
of failure.
: UP : DOWN
* Vxxx-xx: Vxxx is a unique code and xx is a FMI FG013615
(Failure Mode Identifier) number. Figure 35
- V: Machine related failure code
- E: Engine related failure code
Refer to the failure information code for unique codes
and FMI numbers.
This example shows one of two failures.
B. Past failure information
Memorized record of past failure is displayed (Failure FAILURE LOG
code, failure contents). 1/2 CODE : V204 - 05
Time : 00254 Hr 29m Count :28
Figure 25) or "DOWN" ( , 2 on Figure 25) button.
Relief Pressure Up S/V
NOTE: " Number: xxx ": "xxx" means that the Open
totally counted number of the same failure.
: UP : DOWN
" Period:xxxxxHrxxm ": It indicates the FG013616
period for which machine has operated Figure 36
until a failure takes place. (For more than
two occurrences of the same failure, until
the first occurrence time.)
C. Failure record deletion
This mode is used to delete the memorized record of DELETE FAIL LOG
past failure. If this mode is selected, all records will
be deleted.
All Fail Log
When "YES" ( , 3 on Figure 25) button is pressed,
the memorized record will be deleted.
will be DELETED.
Now, deletion signal will be displayed and the screen
will move to previous menu after deletion.
: Yes ESC: No
This screen will be displayed during 3 seconds.
FG013617
Figure 37

Page 45
Input your password with one of No. 1 - 8 switches.
When "NO" (ESC, 4 on Figure 25) button is pressed, DELETE FAIL LOG
the screen will recover to previous menu without
deletion.
ENTER PASSWD
: YES ESC : NO
FG013618
Figure 38
Delete Completed screen will appear 3 seconds and

the screen will move to Failure Info screen. DELETE FAIL LOG
It has been shown 3 seconds upon deleting Fail Log.
DELETED !!!
: YES ESC : NO
FG013619
Figure 39
The screen shown on the left will appear 3 seconds in

case of wrong password input and then Enter DELETE FAIL LOG
Password screen appears again.
It has been shown 3 seconds in case of password X PASSWORD ERR!!!
failure.
: YES ESC : NO
FG013620
Figure 40

Page 46
Failure Information Code at Machine Side

Gauge Panel CN7-4 It is a
V201 Communication Error
- R = 60 ±5 Ω composite
CN7-5
resistance of
CAN line. This
value has to be
CN4-4 measured by
V202 Ecu Communication Error - R = 60 ±5 Ω
CN4-5 connected
condition of
CAN line.
Pump
V210 Pump P/V -
CN1-21
reducing valve.
V211 Cooling Fan P/V - - N.A.
Flow control
V212 Flow Control P/V -
CN1-20
reducing valve.
Breaker/boost/
shear selector
switch has to
be selected as
CN1-1 a boost
V = V_volt (Note R = 26.2 ±2 Ω
V213 Relief Pressure Up S/V
4.) (25°C (77°F))
function and
CN1-11 the boost
switch on the
right-hand
joystick is "ON"
status.
Voltage is only
measured
CN1-1 R = 26.2 ±2 Ω when the
V214 High Speed S/V V = V_volt
CN1-12
switch (Py) is
turned "ON".
Work mode
CN1-1 has to be
R = 26.2 ±2 Ω
V215 Swing Priority S/V V = V_volt
(25°C (77°F))
selected as a
CN1-13 trenching
mode.
V216 Reverse Fan Speed S/V - - N.A.
It has to be
CN1-1 measured in
V217 Starter Relay V = V_volt -
engine start up
CN1-15
state.
V218 After Heat Relay - - N.A.

Page 47
CN3-1 It has to be
V220 Front Pump Press. Sensor V = IV - measured in
CN3-2
engine stop
CN3-3 state.
V221 Rear Pump Press. Sensor V = IV -
CN3-4
R = 2.45 ±0.25
kΩ (25°C
CN3-9
V222 Hyd. Oil Temperature Sensor - (77°F))
CN3-10
R = 320 ±32 Ω
(80°C (176°F))
V223 Water Temperature Sensor - - N.A.
V224 Engine Speed Sensor - - N.A.
Empty: 5 ±0.25
CN3-7
V225 Fuel Level Sensor - kΩ
CN3-8
Full: 320 ±32 Ω
It has to be
CN2-14 measured in
V226 Alternator Potential V = 2 ±1V -
engine stop
CN1-8
state.
R = 1.0 ±0.3 kΩ
CN3-16
V227 Dial - R = 4.0 ±1.5
CN3-7
kΩ
V228 Tps (Wheel) - - N.A.
V229 Parking Brake Press. Sensor - - N.A.
V230 E/g Control Motor Sensor - - N.A.

"OFF"

Page 48
Failure Information Code at Engine Side

2-26 R=186 ±5 Ω
E011 Coolant temperature sensor
2-15
- (100°C
(212°F))
2-26 R=186 ±5 Ω
E012 Fuel temperature sensor - (100°C
2-35 (212°F))
2-36 R=186 ±5 Ω
E013 Boost air temperature sensor
2-25
- (100°C
(212°F))
V= It has to be
E014 Boost air pressure sensor (at 23°C (73°F) - engine running
pressure 1bar)
2-28 R=186 ±5 Ω
E017 E/G oil temperature sensor
2-24
- (100°C
(212°F))
V= It has to be
E018 E/G oil pressure sensor (at 23°C (73°F) - engine running
pressure 3bar)
1-03 V = V–volt
E021 Battery voltage
(Note 4.)
-
1-06
V= It has to be
E022 Fuel pressure sensor (at 23°C (73°F) - engine running
pressure 300bar)
2-14 R=2.60 ±3.15
Fuel pressure monitoring
E032 MPROP
- Ω
2-12 (20°C (68°F))
It is a composite
resistance of
1-53 and CAN line.
1-52 R=60 ±5 Ω
E037 CAN module - This value has
1-35 and (20°C (68°F)) to be measured
1-34 by connected
condition of
CAN line.
E038 Engine overspeed - -
E039 Main relay (ECU) - -
Abnormal
E041 Redundant shutoff path - -
engine stop.
2-23 R=860 ±6 Ω
E042 E/G speed (Crankshaft) -
(20°C (68°F))
2-19

Page 49
2-09
E043 E/G speed (Camshaft) - -
2-10
Synchronizing
error between
crank shaft
E044 Engine speed sensor - -
speed sensor
and cam shaft
speed sensor.
Data storing
E045 EEPROM - - error when
engine stop.
E046 Recovery - -
When the
pressure sensor
of common rail
E047 Monitoring of PRV - - or
high-pressure
pump has a
defect.
1-03
E048 Power supply V = V–volt -
1-06
E049 Booster voltage C1 - -
Booster voltage C2 (#6, 2
E051 and 4)
- -
3-13 R=0.31 ±0.42

E058 Solenoid power stage 1 - Ω
3-04 (20°C (68°F))
3-11
3-06
3-05
3-12
3-03
3-14
3-01
3-16
3-02
3-15
Preheat light (E/G: Lowside 1-56
E066 Power stage 2)
- -
1-06
Voltage is only
measured when
Preheat relay (E/G: Highside 1-13 R=40 ±5 Ω afterheat
E072 Power stage 1)
V = V–volt
(25°C (77°F)) function is
1-07
operating
status.

Page 50
Fuel metering
Fuel HI pressure pump
unit error of
E083 (E/G: Current controlled - - -
high-pressure
Highside power stage 1)
pump.
Power supply
System start-up test for error
E091 shutoff path
- - -
Engine
controller error.
Injector error
Speed signal
Monitoring of misfire cylinder error of cam
E092 1
- - - shaft speed
sensor or crank
shaft speed
sensor.
E093 2
- - -

E094 3
- - -

E095 4
- - -

E096 5
- - -

E097 6
- - -
Monitoring of misfire multiple

E098 cylinder
- - -
E099 Monitoring of overrun - - -

E101 Engine speed redundant - - -

"OFF"

Page 51
FMIs (Failure Mode Identifier)
FMI 0 Above normal range (DATA VALID but ABOVE NORMAL OPERATIONAL RANGE)
FMI 1 Below normal range (DATA VALID but BELOW NORMAL OPERATIONAL RANGE)
FMI 2 Incorrect signal (DATA ERRATIC, INTERMITTENT OR INCORRECT)
FMI 3 Voltage above normal (VOLTAGE ABOVE NORMAL OR SHORTED TO HIGH SOURCE)
FMI 4 Voltage below normal (VOLTAGE BELOW NORMAL OR SHORTED TO LOW SOURCE)
FMI 5 Current below normal (CURRENT BELOW NORMAL OR OPEN CIRCUIT)
FMI 6 Current above normal (CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT)
FMI 8 Abnormal signal (ABNORMAL FREQUENCY OR PULSE WIDTH OR PERIOD)
FMI 11 Failure mode not identifiable (ROOT CAUSE NOT KNOWN - Malfunction)
FMI 31 NOT AVAILABLE OR CONDITION EXISTS
Information of Machine Operation

Accumulated operation hour of each mode and status is
displayed.
1. Operating Hour Information
A. Entering Sub-menus: When a cursor is located in SPECIAL MENU
"Operating Hrs" of special menu screen (Figure 41)
"Operating Hrs" screen will be displayed (Figure 42).
2. Failure Information
3. Operating Hours
FG013621
Figure 41
B. Information screen of machine operation (Figure 42).

OPERATING HOURS
Operating Hours
Reset Hours
FG013622
Figure 42

Page 52
C. Operating Hours Screen
D. Exiting Sub-menus: If escape button (ESC, 4 on OPERATING HOURS
Figure 25) is pressed for more than 1 second, this 1. Power : 00042 Hr
information screen will be returned to previous 2. Economy : 00120 Hr
screen. 3. Auto Idle : 00159 Hr
4. Travel Speed
I Speed : 00005 Hr
II Speed : 00001 Hr
: UP : DOWN
FG013623
Figure 43
Information contents of operation hour
Item Information Contents Detection Method

Power mode switch (Instrument panel) -
Operation hours used power mode
Power Mode "ON" status and Alternator signal
are displayed.
(CN2-14) is "HI"
Economy mode switch (Instrument
Operation hours used economy
Economy Mode panel) - "ON" status and Alternator
mode are displayed.
signal (CN2-14) is "HI"
Auto idle switch (Instrument panel) -
Operation hours used auto idle
Auto Idle "ON" status and Alternator signal
status are displayed.
(CN2-14) is "HI"
Travel Speed: 1st: High speed s/v "OFF" status
Operation hours used low speed
-1st and high speed are displayed. 2nd: High speed s/v and travel pressure
- 2nd switch "Py" (control valve) - "ON" status.
Hydraulic Oil Temperature Temperature of hydraulic oil is The resistance delivered from
Distribution (°C (°F)) classified 6 steps. And operation temperature sensor of hydraulic oil is
hours of each step are displayed classified 6 steps. And operation hours
of each step are displayed. (Alternator
Under 30°C (87°F)
output HI status)
31 - 50°C (88 - 123°F)
51 - 75°C (124 - 168°F)
76 - 85°C (169 - 186°F)
86 - 95°C (187 - 203°F)
Over 96°C (204°F)
Coolant Temperature Temperature of coolant is classified The resistance delivered from coolant
Distribution (°C (°F)) 6 steps. And operation hours of sensor is classified 6 steps. And
each step are displayed. operation hours of each step are
displayed. (Alternator output HI status)
Under 40°C (105°F)
41 - 60°C (106 - 141°F)
61 - 85°C (142 - 186°F)
86 - 95°C (187 - 204°F)
96 - 105°C (205 - 222°F)
Over 106°C (223°F)

Page 53
Menu Selection of Operation Hour Information
1. Power Mode 2. Economy Mode 3. Auto Idle 4. Travel Speed 1st, 2nd
6. Coolant Temperature Distribution 5. Hydraulic Oil Temperature Distribution

FG013856
Figure 44
Example of Machine Operation Info Screen
OPERATING HOURS OPERATING HOURS

1. Power : 00042 Hr 5. Hyd.Oil Temp. [ c]
2. Economy : 00042 Hr 30 : 00140 Hr
3. Auto Idle : 00159 Hr 31-50 : 00054 Hr
4. Travel Speed 51-75 : 00087 Hr
I Speed : 00005 Hr 86-95 : 00001 Hr
II Speed : 00001 Hr 96 : 00000 Hr
OPERATING HOURS
6. Coolant Temp. [ c]
40 : 00140 Hr
41-60 : 00054 Hr
61-85 : 00087 Hr
96-105 : 00001 Hr
105 : 00000 Hr
: UP : DOWN
FG013624
Figure 45
2. Operation hour reset

A. Entering Sub-menus: When cursor is located in OPERATING HOURS
"Reset Hrs" of information screen of operating hours
Operating Hours
"Machine Operation Info" screen will be displayed.
Reset Hours
FG013625
Figure 46

Page 54
B. Reset screen of operation hour
C. Exiting Sub-menus: If escape button (ESC, 4 on OPERATING HOURS
Figure 25) is pressed for more than 1 second, this
information screen will be returned to previous
screen. All Opearting hours
NOTE: When "YES" ( , 3 on Figure 25) button is will be DELETED.
pressed, operation hours will reset.
Now, resetting signal will be displayed and the
screen will move to previous menu after : Yes ESC: No
resetting. FG013626
NOTE: When "NO" (ESC, 4) button is pressed, the Figure 47
screen will recover to previous menu without
resetting.
Machine Operation Info Screen

1. If you press the YES" ( , 3 on Figure 25) button,
OPERATING HOURS
password entrance screen appears.
ENTER PASSWD
: YES ESC : NO
FG013627
Figure 48
2. When right password is input, machine operation periods

will be deleted and Reset Completed screen will appear 3 OPERATING HOURS
seconds.
DELETED !!!
: YES ESC : NO
FG013628
Figure 49
3. If you press the "NO" (ESC, 4) button, the previous screen

appears without resetting operation periods. OPERATING HOURS
X PASSWORD ERR!!!
: YES ESC : NO
FG013629
Figure 50

Page 55
ELECTRONIC HYDRAULIC
CONTROL SYSTEM (EPOS)
Control System Schematic
15
6 6
7 7 11 13
8
8
12
14
E/G
4 4 5
3
9 10
Work Mode
2 Auto Idle
Machine Info
E/G speed order E F

C H C H
22 1
6
2
7
3
8
4
9
5
1
16 20 18 17 21 19
FG016912
Figure 51

Page 56
Reference Reference
Number Number
2 EPOS Controller 12 Solenoid Valve (High Speed)
3 Engine Controller (ECU) 13 Solenoid Valve (Breaker)
5 Aux Pump 15 Main Relief Valve
6 Control Valve 16 Engine Control Dial
7 Pressure Switch Breaker/Boost/Shear Selector
17
8 Pump Pressure Sensor Switch
Electromagnetic Proportional 18 Auto Travel Selector Switch
9 Pressure Reducing Valve 19 Boost Switch (Right Work Lever)
(Attachment) 20 Sensor
Electromagnetic Proportional 21 Aux Mode Switch
10 Pressure Reducing Valve
22 Aux Mode Resistor
(Mode Control)

Page 57
POWER MODE CONTROL
6 6
E/G
5
4 4
3
10
2
1
1 2 3 4 5
17 6 7 8 9 0
23 22
FG013631
Figure 52
Reference Reference
Number Number
Instrument Panel Electromagnetic Proportional
1
(Power Mode Selector Switch) 10 Pressure Reducing Valve
2 EPOS Controller (Mode Control)
3 Engine Controller (ECU) 17 Engine Control Dial
4 Main Pump 22 Aux Mode Switch
5 Aux Pump 23 Aux Mode Resistor
6 Control Valve

Page 58
The power mode switch permits the selection of the appropriate
engine power depending on the working condition. One of the
two, Power Mode or Standard Mode, setting can be selected.
When the engine starter switch is turned "ON", the power mode
is automatically defaulted to standard mode. The desired mode
can be selected by pressing the selector button on the
instrument panel. When the power mode is selected, the
indicator light will turn "ON" to display the selected mode.
The quantity of oil discharged by the pump and the engine
speed are determined by the mode selected by the operator.
The pump output in each mode is determined by the mode
selection and is listed in the following table
Mode Standard Mode Power Mode

Output (%) Approximately 85% 100%

Page 59
Operation
1. Power Mode
This mode must be selected for high speed work. In this
mode the engine output is most efficiently utilized because
of the discharged oil volume being controlled based on the
equivalent horsepower curve at various loaded pressures.
E.P.P.R. (Electromagnetic Proportional Pressure
Reducing) valve which in turn varies the pump output
quantity.
If the load increases, the engine speed will fall below the
rated speed. When this occurs, the controller senses this FG013632
decrease and immediately reduces the pump discharge Figure 53
volume to maintain the engine speed at the rated level.
On the other hand, if the load is decreased the controller
increases the discharge volume of the pump to maintain
the engine speed at the rated level.
By repeating these control operations, the engine speed is
maintained at the rated speed so that maximum power can
be generated.
In Power Mode, the EPOS controller receives engine
speed signals from the engine control dial and the engine
controller (ECU) and converts it to an operating signal
current and is then transferred to the pump's E.P.P.R
valve. Now the E.P.P.R. valve converts the electric signal
to the corresponding control pressure and sends it to the
two pumps, adjusting the pump discharge volume to the
desired level.
A C
B D
FG000580
Figure 54
Reference Reference
Number Number
D

Page 60
2. Standard Mode
Standard Mode is used for general work. When this mode
is selected it will reduce noise and fuel consumption in
comparison with Power Mode. The EPOS controller
compares the target engine speed with the actual engine
speed and controls the signal to the E.P.P.R. valve which
in turn varies the pump output quantity and it is the same
method with power volume.
A C
B D
FG000581
Figure 55
Reference Reference
Number Number
D

Page 61
3. Economy Mode
Economy mode is used for light loading work. When this
mode is selected, it will reduce noise and fuel consumption
in comparison with standard mode.
Engine torque curve is changed by ECU.
E.P.P.R. valve which in turn varies the pump output
quantity and it is the same method with power volume.
FG013671
Figure 56
A C
B D FG013633
Figure 57
Reference Reference
Number Number
A Engine Horsepower (hp) C Pump Discharge Volume (lpm)
B Engine Speed (rpm) D Pump Discharge Pressure (kg/cm2)
4. Operation in case of failure in the control system (Aux

mode operation)
Though it is impossible to control current of the E.P.P.R
(Electromagnetic Proportional Pressure Reducing) Valve
controlling the discharge volume of pump because of fault
in control system, the machine can be operated in the aux
mode.
Upon turning "ON" the aux mode switch, the E.P.P.R Valve
controlling the discharge volume of pump comes into
contact with the aux mode resistor to let current of a certain
value flow. Now, the discharge volume of pump follow the
control by the pump regulator, nearly at quantity roughly
similar to that in the standard mode.

Page 62
POWER / ECONOMY MODE
CONTROL - CIRCUIT DIAGRAM
1
15A
CN6-1
CN6-2
26
4 26 15A 26 10A
CN6-9
25
CN6-10
CN1-1
CN7-4 CN4-4 CN1-2
CN7-5 CN4-5 CAN
CN7-6 CN4-6
CN1-8 24
CN1-9 11
3
23
1-35
1-34 22
1-33 CN1-10 1 10
5
P/V-(A)
1-53 2
1-52 CN1-21 3
VEHICLE 6
1-51 4
CONN
(CONN.1) 1-05
1-06
17
+(5V) CN3-15 1
1-10 CW LOW
SIG CN3-16 2
1-11
GND CN3-17 3
HIGH
1-02
1-03
1-08
15A 26
1-09
1-40 BR B 10A 26
28
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
18 35 6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 17
12 11 10 9 8 7 16 15 14 13 12 11 10 9
36 53
7 11 54 71
(CN7) (CN6)
1 6 72 89
ECU CON.1 (89-PIN)

FG008165
Figure 58
Reference Reference
Number Number
1 Instrument Panel 23 Aux Mode Resistor
3 Engine Controller 24 Battery
4 EPOS Controller 25 Battery Relay
E.P.P.R. Valve (Electromagnetic 26 Fuse
10
Proportional Pressure Reducing) 27 Fusible Link
17 Engine Control Dial 28 Starter Switch
22 Aux Mode Switch

Page 63
ENGINE CONTROL SYSTEM
4 17
(Drive Signal) (Command Signal)
FG000584
Figure 59
Reference Reference
Number Number
3 Engine Controller 17 Engine Control Dial
4 EPOS Controller
When the engine control dial is moved the output voltage

changes according to the dial position.
The EPOS controller converts this output voltage of dial to digital
signal and sends it to the engine controller by CAN line.
According to the dial command, the quantity of fuel injection is
adjusted.

Page 64
ENGINE CONTROL DIAL
1st Step 7th Step 13th Step
CCW CW
Mechanical Mechanical
Stop Stop
5
4.0V
4
Output Voltage (V)
3 2.5V
2
1.0V
1
0 Step
1st 2nd ...... 7th ...... 12th 13th
CCW CW
Stop Stop
1 2 3
FG018941
Figure 60
Reference Reference
Number Number
1 Knob 2 Hall Effect Sensor
The engine control dial has a built in potentiometer. When the

control knob is moved the output voltage (through "2 and 3"
terminals) will vary from the 5 V supplied from the EPOS
controller as shown in the graph.

Page 65
ENGINE CONTROL CIRCUIT
DIAGRAM
1
15A
CN6-1
CN6-2
26
4 26 15A
CN6-9 25
CN6-10
CN1-1
CN7-4 CN4-4 CN1-2
CN7-5 CN4-5 CAN
CN7-6 CN4-6
CN1-8 24
CN1-9 28
3
1-35
1-34
1-33
1-53
1-52
VEHICLE 1-51
29
CONN Py
CN2-15
(CONN.1) 1-05
17
1-06
Px +(5V) CN3-15 1
1-10 CN2-16 CW LOW
SIG CN3-16 2
1-11
GND CN3-17 3
1-02
30 HIGH
1-03
26 15A
1-08
1-09
BR B 10A
1-40
27 26
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
18 35 6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 17
12 11 10 9 8 7 16 15 14 13 12 11 10 9
36 53
7 11 54 71
(CN7) (CN6)
1 6 72 89
ECU CON.1 (89-PIN) FG008166

Figure 61

Page 66
Reference Reference
Number Number
1 Instrument Panel 26 Fuse
3 Engine Controller 27 Starter Switch
4 EPOS Controller 28 Fusible Link
17 Engine Control Dial 29 Pressure Switch (Py)
24 Battery 30 Pressure Switch (Px)
25 Battery Relay

Page 67
AUTOMATIC DECELERATION
CONTROL (AUTO IDLE CONTROL)
E/G
4
3
1
1 2 3 4 5
6 7 8 9 0
5 5
FG013634
Figure 62
Reference Reference
Number Number
Instrument Panel 3 Engine Controller
1
(Auto Idle Switch) 4 Engine Control Dial
2 EPOS Controller 5 Pressure Switch

Page 68
If the machine is idling without the controls being operated or is
waiting for a dump truck the engine speed is automatically
lowered. Once the controls are operated and work is being
started the machine will be restored to the previous settings. As
a result, noise and fuel consumption will be reduced. This
function can be selected or cancelled through the Auto Idle
Selector Switch on the instrument panel.
The initial setting at start-up is with this switch in the select
position. Approximately 4 seconds after this function is selected,
if all work levers are in the neutral position, the EPOS controller
compares the automatic reduction signal with the signal set by
engine control dial. The lower of the two signals is selected, the
EPOS controller sends a signal to the engine controller to
control the engine speed.
The neutral status of the machine is detected by the two
pressure switches in the control valve. When the work levers are
in the neutral position, the switch is in the "OFF" position.

Page 69
ENGINE OVERHEAT
PROTECTION SYSTEM
6 6
E/G
4 4 5
3
31
7
(Pump control signal)
2
1
(E/G overheating signal)
E F
C H C H
(E/G overheating signal) 1
6
2
7
3
8
4
9
5
FG013635
Figure 63
Reference Reference
Number Number
1 Instrument Panel 6 Control Valve
2 EPOS Controller E.P.P.R. Valve (Electromagnetic
3 Engine Controller 10 Proportional Pressure Reducing
Valve)
4 Main Pump
31 Warning Buzzer
5 Aux Pump

Page 70
When the engine coolant temperature increases to over 107°C
(225°F), the engine controller detects it from the sensor
mounted in the coolant line and will send a signal to the EPOS
controller. The EPOS controller sends a overheat signal to the
instrument panel turning "ON" the warning light and buzzer
simultaneously.
Also, the EPOS controller returns an overheat signal to the
engine controller and changes power mode to standard mode.
The engine speed is then set to a low speed by the engine
controller.
When coolant temperature falls below 95°C (203°F), normal
operation will resume.

Page 71
POWER BOOST MODE
Operation
16
6 6
11
E/G
4 4 5
3
E F
C H C H
1 2 3 4 5
6 7 8 9 0
20
18
FG016913
Figure 64
Reference Reference
Number Number
2 EPOS Controller 16 Main Relief Valve
3 Engine Controller Breaker/Boost/Shear Selector
18
4 Main Pump Switch
5 Aux Pump Power Boost Switch
20
(Top of Right Work Lever)
6 Control Valve

Page 72
The Power Boost function is used to temporarily increase the
main relief pressure to enhance excavation ability. When the
breaker/boost/shear selector switch is set to "BOOST" and the
power boost button on the center of the right-hand work lever
(joystick) is pressed during work, the EPOS controller will
activate the power boost solenoid valve and increase the relief
valve pressure from 330 - 350 kg/cm2 (4,700 - 5,000 psi). The
excavation ability is increased by approximately 6%.
When the power boost function is in activated, a power boost
symbol appears on the information display department of
instrument panel.
NOTE: Do not use this switch for more than 10 seconds.

Page 73
Power Boost Control - Circuit Diagram
1
15A
CN6-1
CN6-2
26
2 26 15A 26 20A
CN6-9 25
CN6-10
CN1-1 18
CN7-4 CN4-4 CN1-2
CN7-5 CN4-5 CAN
CN7-6 CN4-6 PST SHEAR PRESS BREAKER
TML 1 0 2
24
10
11
3
(C4) 14
CN1-11
13
6
CN2-2 (POWER MAX)
16
CN1-8 12
CN1-9
6 3
(Center)
(POWER MAX / BREAKER)
20
(CN2) (CN1)
FG000
Figure 65
Reference Reference
Number Number
1 Instrument Panel Power Boost Switch
20
2 EPOS Controller (Top of Right Work Lever)
11 Solenoid Valve (Pressure Up) 24 Battery
Breaker/Boost/Shear Selector 25 Battery Relay
18
Switch 26 Fuse

Page 74
Page 75
AUTOMATIC TRAVEL SPEED
CONTROL
6 6
13
E/G 8
15
4 4 5
3
17 2 19
FG016914
Figure 66
Reference Reference
Number Number
2 EPOS Controller 8 Pump Pressure Sensor
3 Engine Controller 13 Solenoid Valve (High speed)
5 Aux Pump 17 Engine Control Dial
6 Control Valve Selector Switch For Automatic
19
7 Pressure Switch (Py Port) Travel

Page 76
If the automatic travel speed control switch is set to "OFF"
position, the travel motor will run in the I-speed (low speed)
range. If the selector switch is set to "I" position, the travel motor
will run in the II-speed (high speed) range. If the selector switch
is set to "II" position, the EPOS controller will monitor the main
pump discharge pressure and automatically select the "ON" -
"OFF" status of the II - speed travel solenoid valve based on the
travel load. The travel speed is changed between the I-speed
and the II-speed mode.
The travel load is monitored by the two pressure sensors in the
discharge lines of the front (upper) and rear (lower) pumps.
When the travel load is high (pressure over 300 kg/cm2 (4,300
psi) the solenoid valve is turned "OFF" and I-speed (low) is
selected. In the case when the travel load is low (pressure under
160 kg/cm2 (2,280 psi), the solenoid valve will be turned "ON"
and the II-speed will be selected. But, if the engine speed control
switch dial is set below approximately 1400 rpm, the travel
speed will be set to I-speed mode.

Page 77
Automatic Travel Speed Control - Circuit
Diagram
15A
26
2 26 15A 26 15A
25
8 CN1-1
+ CN1-2
SIG CN3-1
CN3-2
- 13
(C3) 24
+ CN1-12
SIG CN3-3
CN3-4
- 19
9 3
0
2
CN2-4 I
II
0
I 5
CN2-5 6 II
7 8
17
CN1-8 +(5V) CN3-15 1
CW LOW
CN1-9 SIG CN3-16 2
GND CN3-17 3
HIGH
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
AMP 040 28P
6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
(CN7) (CN6)
FG000587
Figure 67
Reference Reference
Number Number
2 EPOS Controller Selector Switch For Automatic
19
8 Pressure Sensor (Front Pump) Travel
9 Pressure Sensor (Rear Pump) 24 Battery
13 Solenoid Valve (High speed) 25 Battery Relay
17 Engine Control Dial 26 Fuse

Page 78
SELF-DIAGNOSTIC FUNCTION
EPOS Controller
The system operation status and malfunction codes can be
checked through the display on top of the EPOS controller box
the rear cover behind the operator's seat.
1 2
4 3
FG000588
Figure 68
Reference Reference
Number Number
1 Upper Digit Power Monitor
2 Lower Digit 4 (Stays "ON" While Power Is In
Normal Range.)
Engine Speed Monitor LED
3 (Flash Interval Increases With
Engine Speed.)
1. Power Monitor
This LED is turned "OFF" when the input voltage to the
EPOS controller is below 18.5 ±1 V or above 32.5 ±1 V.
Stays "ON" while in normal range.
2. Engine Speed Monitor
This LED light flashes according to the engine speed. The
flashing interval is proportional to the engine speed.

Page 79
3. Normal Operation Display Readout
Display Readout
Mode Selection Operation Status
Upper Digit Lower Digit
Normal Operation
Power Mode
Power Mode
HAOH340L HAOH370L
Normal Operation
Power Mode Standard Mode
Standard Mode
HAOH350L HAOH370L
Normal Operation
Economy Mode
Economy Mode
FG013637 HAOH370L
4. Communication Monitor
What are shown in the 7-SEGMENT LED are same as
those in the Error Codes.
Error Code Indication Code Fault Location

Communication error in instrument
V201 01
panel.
Communication error in engine
V202 02
controller.

Page 80
AIR CONDITIONER SYSTEM
Outline
FG017007
Figure 69
Solid-type heater and air conditioner are installed in the cover

behind the operator's seat.
Temperature of the operator's room is adjusted automatically to
the temperature set by operator.

Page 81
(Please refer to the Operation Manual for detailed full automatic
control.
Vent mode selects the direction of discharged air.
Outlets by vent modes
Modes
Outlets A A+B B B+C C
Internal and External Filters

Internal and external air purification filters are installed for the
operator's room.
Filters must be cleaned every 500 hours.
If machine operates in an excessively contaminated
environment, filters must be cleaned more frequently and if
necessary, replaced with new ones.
How to Check Internal Air Filter

1. Press both levers on the left and right side at the top of the
filter installed at the rear of the operator's seat.
FG016045
Figure 70
How to Check External Air Filter

1. Open the cover by using the starter KEY in the left side of
the cabin.
FG016043
Figure 71

Page 82
2. Remove filter (Figure 72) and inspect for any damage.
3. Use compressed air to clean filter. If filter is still dirty, then
change to new one.
4. Reassemble in reverse order.
FG016044
Figure 72

Page 83
Air-Conditioning System Layout
10
11
2
5
6
5
7
4
1
6
8
9 FG016941
Figure 73
Reference Reference
Number Number
1 Air Conditioner/heater Unit 7 Liquid Hose (1)
2 Condenser 8 Liquid Hose (2)
3 Compressor 9 Ambient Temperature Sensor
4 Receiver Dryer 10 Sun Sensor
5 Discharge Hose 11 Control Panel
6 Suction Hose

Page 84
Air Conditioner/heater Circuit Diagram
0.5RW
FUSIBLE LINK
LAMP SWITCH
20A STARTER SWITCH

BATTERY RELAY
A/C CONTROL PANEL AIRCON UNIT BATT.

1.25LR CN11-2 42C 24V
LED 1~12 130C CN9-6
0.85LR CN10-8 42D
54E CN9-11 0.5WR
CN10-18 46B
ILL 42B CN9-5 1.25LR
0.85BW
0.85LR
RECEIVER DRIER
BLOWER A/C
42E 46A
RELAY RELAY
COMPRESSOR
168B CN8-10 0.5LG CN10-16 168A
A/C THERMO (LOW) 105B CN9-8 0.5LB CN10-5 105A CN11-4 0.85LW 47C
106B CN8-11 CN10-6 106A 47A 47B

0.5LY
FET
DIODE 4
1.25B CN11-1 99 - +
M
107B CN8-12 0.5LW CN10-1 107A 0.85B 0.85B
BLOWER
108A CN9-13 0.5GrG CN10-2 108B FRE (P1)

INTAKE
109A CN9-12 0.5GrY CN10-20 109B REC (P2) ACTUATOR
M
110A CN9-15 0.5OrR CN10-12 110B DEF (P1)

111A CN9-14 0.5OrW CN10-13 111B VENT (P2)
M
MODE
43A CN9-16 0.5YB CN10-11 43B Vref MODE
ACTUATOR
44A CN9-17 0.5YW CN10-10 44B MODE F/BACK
99 CN9-10 1.25B
112A CN9-1 0.5LgW CN10-19 112B WARM (P1)

113A CN9-18 0.5LgB CN10-3 113B COOL (P2)
M
114A CN9-3 0.5YR CN10-7 114B Vref MIX Temp. Control
115A CN9-4 0.5YW CN10-9 115B MIX F/BACK ACTUATOR
167C CN9-2 1.25BL CN10-4 167A GND
116A CN8-2 0.5OrB CN10-15 116B

DUCT
SENSOR
45A CN8-1 0.5LgR CN10-14 45B

WATER
SENSOR
2
48A CN8-5 0.5LY CN10-17 48B 1 INCAR
SENSOR
SUN LOAD SENSOR
0.5Lg 2 - + 1 CN10 AMP 20P CN11 KET 4P

142A CN8-3
142B 0.5YR
114C 0.85BL 167B 2
49A CN8-4 0.85YG 0.85YG 49B 1 AMBIENT TEMP
SENSOR
CN8 CN9
AMP 18P + 12P
AMP 040-III 20P

KET 4P AMP 070 18P AMP 070 12P
2 1 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 10
4 3 18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
(CN11) (CN10) (CN9) (CN8)
FG001463
Figure 74

Page 85
Air Conditioner/heater Unit
Air Flow Diagram
External Air Inlet
Internal Air Inlet
External Air
VENT
COOL
DOOR
-INTAKE
DOOR
DEF -MIX
Internal Air
WARM
Evaporator Fan
Heater
FOOT Core
FG016942
Figure 75

Page 86
Door Open by Vent Modes
Mode
Door
Vent Bi-level Foot Def/foot Def
Vent 100 60 0 0 0
Foot 0 40 100 80 60
Def 0 0 0 20 40
Main Components
Internal
Air Sensor
Blower
Motor
Actuator
- Internal/external
Air Exchanger
Internal
Air Filter
FG016943
Figure 76

Page 87
Change of discharged air flow according to selected wind
direction mode
Change of wind direction: Direction changes in the order of
VENT→BI-LEVEL →FOOT →FOOT/DEF →VENT.

Change of discharged air temperature by controlling the position
of temperature control door.
FG001361
Figure 77
Wind Direction Mode Output Terminal Voltage

Vent 0.5 ± 0.2V
Bi-level 1.3 ± 0.2V
c(+): CN10-10
Foot 2.45 ± 0.2V
b(-): CN10-4
Foot/def 3.5 ± 0.2V
Def 4.5 ± 0.2V
Set Temperature Output Terminal Voltage

Max cooling c(+): CN10-9 Below 0.4V
Max heating b(-): CN10-4 Above 4.5V

Page 88
Actuator - Internal/external Air Exchange
CN10-20 CN10-2
FG001055
Figure 78
Mode Output Terminal Output

Intake P1(+), P2(-)
by selecting intake.
Recirculate P1(-), P2(+)
by selecting recirculate.
Air Flow Control Module

Air flow is controlled through the control of voltage between
GATE and SOURCE.
DRAIN
(CN10-1)
SOURCE GATE
(CN11-1) (CN10-6)
FG001056
Figure 79
Air flow Output Terminal Output

1st 10 ± 0.5V
2nd 12.5 ± 0.5V
3rd 15 ± 0.5V
4th CN11-2 CN10-1 17.5 ± 0.5V
5th 20.0 ± 0.5V
6th 22.0 ± 0.5V
7th More than 25V
Input voltage is 27.5V.

The air flow is based on manual set.

Page 89
Relay - Blower: Power is supplied to the blower motor when the
system is turned "ON".
Specifications
Rated voltage 24V
Rated current 20A
Figure 80
Relay - A/C: Power is supplied to the magnetic clutch of the

compressor.
Specifications
Rated voltage 24V L S1 (+)
Rated current 10A
B S2
(-)
FG001058
Figure 81
Duct Sensor: It is inserted in the core of the evaporator to

prevent freezing of the evaporator.
The sensor consist of negative characteristic thermistor that
resistant value increases and decreases when the temperature
rises and falls, respectively.

0 11.36 ±0.1
2 10.39 ±0.2
2.5 10.17 ±0.2
3 9.95 ±0.2 Figure 82
3.5 9.73 ±0.2
4 9.52 ±0.2
5 9.12 ±0.2
10 7.36 ±0.15
25 4.02 ±0.08
30 3.33 ±0.07

Page 90
Water Temperature Sensor: It senses the temperature of
coolant water in the heater core.

-10 55.8 ±1.7
0 32.9 ±0.9
15 15.76 ±0.5
25 10.0 ±0.3
35 6.5 ±0.2
Figure 83
Internal Air Temperature Sensor: Built in the internal air filter,

it senses the internal temperature.

-15 218.2 ±7.5
0 97.83 ±0.9
15 47.12 ±0.7
25 30.0 ±0.36
35 19.60 ±0.3
Figure 84
Ambient Air Temperature Sensor

Built at the bottom of the cockpit, it senses the temperature of
external air.

-10 163 ±4.9
0 96.9 ±2.9
10 59.4 ±1.8
20 37.4 ±1.1
FG001064
25 30 ±0.9
Figure 85
30 24.2 ±0.7

Page 91
Sun Sensor
Built beside the socket of spare power, it senses the quantity of
the sun radiation to optimize discharge temperature and air flow
as set by operator.
83.7
OUTPUT VOLTAGE(mV)
76.2
67.7
58.8
46.6
36.0
21.4
1.0 2.0 3.0 4.0 5.0 6.0 7.0

LUX(x10,000)
FG001062
Figure 86
Control Panel
Appearance and Terminal Arrangement
A/C OUTSIDE
AUTO A/C
AUTO MAX
TEMP
OFF
SEL MODE
AMP 070 18P AMP 070 12P

8 7 6 5 4 3 2 1 5 4 3 2 1
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
(CN9) (CN8) FG001063

Figure 87
Refer to "Air Conditioner and Heater" of operation manual.

Page 92
Terminal Terms
CN Term No. Terms CN Term No. Terms

Temperature control Water temperature
1 1
(warm) sensor
2 Sensor ground 2 Duct sensor
Temperature control
3 3 Sun sensor
Power (5V)
4 Mix feedback 4
sensor
5 Power (KEY "ON") 5
CN8 sensor
6 Back-up 6 -
7 - 7 -
8 A/C output (LOW) 8 -
9 - 9 -
10 Ground 10 D.P.S CHECK
CN9 11 Illumination 11 Air flow module (gate)
Intake/Recirculate
12 12 Blower motor (feedback)
(Recirculate)
Intake/Recirculate
13
(Intake)
14
(VENT)
15
(DEF.)
16
Power (5V)
17
(feedback)
Temperature control
18
(cool)
Control Logic

AUTO Set temperature 1. Automatically adjust room temperature as set and then
next items.
sensor Temperature, Wind direction, Recirculate/Intake, Air flow,
Compressor
sensor 2. Auto mode is released when manually setting any switch
except, Temperature Control switch in Auto mode.
Water temperature sensor
3. Upon the releasing of Auto mode, all of functions except
Sun sensor
selected switch are controlled automatically.

Page 93
Sensor Set temperature 1. In case of sensor failure, following defaults are applied:
compensation
Internal air temperature Internal air temperature sensor: 25°C, Ambient air
sensor temperature sensor: 25°C, Duct sensor: -2°C
Ambient air temperature Temperature control actuator:
sensor
- Set Temperature 17 - 24.5°C: Max cooling, Set
Water temperature sensor Temperature 25 - 32°C: Max heating
Wind direction mode actuator
- VENT: VENT fix, modes other than VENT: Fixed to DEF
* Sun sensor is not compensated.
Max cooling/ Auto Setting 1. Set Temperature 32°C: Max heating
heating control
2. Set Temperature 17°C: Max cooling
Max Cooling (17 C) Max Heating (32 C)
Temp Control
FULL COOL FULL HOT
Actuator
Air Flow MAX HI AUTO HI
Compressor Forced ON OFF
Intake/Recircle Recircle Intake
Wind Direction Mode VENT FOOT
* Max cooling/heating control is possible only in Auto mode.

Starting Auto mode 1. Prevention of discharge of hot air before discharge
Control of temperature drops enough in hot summer weather
Duct sensor
Cooling
2. Start conditions (AND condition)
(1) A/C on (AUTO or manual)
(2) Temperature sensed by the duct sensor is above 30°C
3. One time control in the cycle of engine OFF →engine run
4. Initial cooling control is executed when the Auto switch is
"ON" in the manual status (A/C "OFF" and manual control
of air flow) in 5 seconds after engine run.
5. Initial cooling control must be before max cooling.
6. Release condition (OR condition)
(1) A/C "OFF"
(2) Air flow: Manual control
(3) Release is possible with the "OFF" switch but not
allowed within 12 seconds (after Start "ON") while the
system is off using the "OFF" switch and during the time of
initial cooling control.

Page 94
1. Start condition (AND condition)
(1) When wind direction mode is one of the following
modes in the Auto or manual control mode
- BI-LEVEL, FOOT or FOOT/DEF
(2) The Water temperature sensor is stable and the water
temperature < 73°C
(4) Set temperature > Internal air temperature + 3°C
* Air flow falls gradually up to 12 seconds when operation
released.
Water temperature sensor 2. One time control in the cycle of engine OFF →engine run
Starting Internal air temperature 3. Initial heating control must be before max heating.
control of sensor
4. Air flow is controlled only when the wind direction is in the
heating (1) Auto mode manual mode and BI-LEVEL, FOOT, or FOOT/DEF is set.
Set Temperature 5. Control through the water temperature sensor for start.
6. Starting control of heating (2) starts in case of fault of the
water temperature sensor during controlling.
(1) Only air flow is released if it is selected manually.
control of heater.
(4) Water temperature sensor > 73°C.

Page 95
Starting Water temperature sensor 1. Entry condition (AND condition)
control of
Ambient air temperature (1) Auto Mode
heating (2)
sensor (2) Ambient air temperature < 5°C and difference between
Internal air temperature ambient and internal air temperature ≤5°C
sensor (3) Failure of water temperature sensor
Auto mode 2. Only one time of engine OFF →engine run
3. Starting control of heating is before max heating.
(1) Air flow: Manual selection
control of heater.
(3) Difference between internal and ambient air
temperature>15°C
5. Exceptional case
Starting control of heating is performed only once during
the remaining period if the entry condition is satisfied
within the starting control period that is the accumulation
of initial start times.
(Inclusive of Auto mode "ON" case within the period of
starting control of heater.)
* Air flow must be reduced slowly for up to 12 seconds in
case of exceptional entry case.
Duct sensor 1. Function: Magnetic clutch of compressor is turned "ON/
OFF" depending on temperature of the duct sensor to
prevent the freezing of the evaporator with A/C being
"ON".
2. Control pattern.
Compressor 2.0 0.5 C 3.5 0.5 C

control
External temperature 1. Function: Prevention of compressor in winter.
sensor
2. Control pattern.
*Only for Auto mode.

Page 96
Self Diagnosis
How to start self diagnosis
Starter Switch ON
Set temp to 25 C Set temp to 77 F

5 secs while pressing the A/C switch
Auto diagnosis starts after every graphic

in LCD displays twice every 0.5 sec.
A code concerned blinks in the cycle of 0.5-sec ON

and 0.5-sec OFF. In case of two or more errors, codes
concerned blink twice at a time.
For normal, E0 lights; for error, the first

error code is indicated.
For 2 or more error, error codes are indicated

upstreams/downstreams if the temp control switch is
set to up/down. (For normal condition, only EO lights.)

5 secs while pressing the A/C switch. Return to default status if no switch
operated for 30 secs in diagnosis mode.
Return to position before auto diagnosis

starts.
FG001367
Figure 88

Page 97
Error codes
Code Description
E0 Normal
E1 Internal air temperature sensor short
E2 Internal air temperature sensor open
E3 Ambient air temperature sensor short
E4 Ambient air temperature sensor open
E5 Duct sensor short
E6 Duct sensor open
E7 Sun sensor short
E8 Sun sensor open
E9 Water temperature sensor short
E10 Water temperature sensor open
E11 D.P.S open
E12 Position error of wind direction actuator
E13 Position error of temperature control actuator
NOTE: The position error means that it fails to move to

designated place in 40 seconds.
Sun sensor displays E8 in case of no sunlight. E1 E1 E2 E2 E3
2 and more fails: Codes concerned blinks twice at a
time.
0.5 0.5
FG001067
Figure 89
Ambient Temperature Display

Selection of both the SEL and MODE switch for more than 3
seconds indicates the ambient temperature in the set
temperature display department.
- Range of temperature display: -40 - +60°C
NOTE: Display of ambient temperature may be released in
the same way for its entry way.
It returns automatically to default mode 5 seconds
after entering the ambient air temperature display
mode.

Page 98
Compressor
Categories Specifications Relief Valve
Output 155.3 cc/rev
Oil Level 120 cc (ND-OIL8)
Refrigerant R134a
Rated Voltage 24V
Open: 35 - 42.2 kg/cm2G
Relief Valve
Close: 28.1 kg/cm2G
Compressor sucks in refrigerant which evaporates completely in

FG001365
the evaporator and discharges it to the condenser.
Figure 90
Refrigerant undergoes repeated status change in the order of
liquid, gas, and liquid in the freezing cycle, and the compressor
makes evaporated refrigerant a high temperature and
high-pressured gas to freeze it in the condenser.
Receiver Dryer
The receiver dryer reserves refrigerant enough to ensure High/Low Pressure Switch
smooth freezing cycle responding immediately to the change of
level in the freezing cycle.
As liquid refrigerant from the condenser may contain refrigerant
gas with bubbles whose presence in the expansion valve
decreases the freezing power excessively, it separates liquid
and gas and sends liquid only to the expansion valve.
Water in refrigerant shall be eliminated with dryer and through
filter.
FG001366
Figure 91
MAX. 0.25 kg/cm2

32 2 kg/cm2
Volume of refrigerant by model
Model Volume of Refrigerant

DX140LC 800 ± 20 grams 2.0 0.2 kg/cm2 6 2 kg/cm2
FG001462
DX225NLC 800 ± 20 grams Figure 92

Page 99
TROUBLESHOOTING
Refrigerant Pressure Check
1. Open all doors and windows.
2. Install manifold gauge set.
3. Start engine and maintain engine speed at 1,800 - 2,000
rpm.
LO HI
HDA6074L
Figure 93
4. Check high / low-pressure of refrigerant.
High-pressure: 8.0 - 10.0 kg/cm2 (114 - 142 psi)

1
Low-pressure: Approximately 1.0 kg/cm2 (14 psi)
Possible Cause: Low Refrigerant Level
Reassemble using correct tightening
Yes
1 Check for traces of refrigerant oil. torque.
No Go to next step.
Using a leak detection device or soapy water Yes Repair leaking component.
2 check for refrigerant leakage at all major No Recharge system to correct
components and joints. pressure.

2
Possible Cause: Overcharge, Frost on condenser
Check for condenser pin damage or Yes Clean, repair or replace condenser.
1
contamination. No Refrigerant overcharge.
High-pressure: Approximately 20 - 25 kg/cm2 (285 - 356 psi)

3
Possible Cause: Air in system.
3. Recharge system.

Page 100
4
Low-pressure: Approximately 760 mmHg (Negative Pressure)
Possible Cause: Refrigerant does not circulate
1. Connect manifold gauge and start engine.
2. Turn on air conditioner. Moisture in system, replace receiver
Yes
dryer.
3. Set blower switch to HIGH position.
4. Turn air conditioner OFF and wait 10
1 minutes.
5. Recheck high / low-pressure readings. Contaminated system, replace
No expansion valve.
High-pressure: 13.0 - 19.0 kg/cm2 (185 - 270 psi) (Replace evaporator core assembly.)
Low-pressure: 1.5 - 3.3 kg/cm2 (21.3 - 46.9 psi)
High-pressure: Over 6 - 18 kg/cm2 (85 - 256 psi)

5
Low-pressure: 500 mmHg (Negative Pressure) - Dial indicator needle unstable.
Possible Cause: Moisture in system has iced up the expansion valve.
NOTE: When the absorbed moisture freezes the pressure readings may look normal. Careful readings
must be made to determine whether pressure is in normal range.
3. Recharge system.
High-pressure: Over 22.0 - 23 kg/cm2 (313 - 327 psi)

6
Low-pressure: 2.5 kg/cm2 (36 psi)
Possible Cause: Refrigerant pressure problem because of defective expansion valve or temperature sensor.
Inspect whether the temperature sensor is Yes Replace expansion valve.
1
installed properly. No Exchange duct sensor.
High-pressure: Over 7.0 - 11.0 kg/cm2 (100 - 156 psi)

7
Low-pressure: 4.0 - 6.0 kg/cm2 (57 - 85 psi)
Possible Cause: Low refrigerant pressure because of poor compressor compression.
Inspect and replace compressor if necessary.

Page 101
WEIGHT OF R134a GAS USED IN
MACHINES
Model Weight of Gas

DX140LC 800 ±20 grams (28 ±0.7 oz)
DX180LC 800 ±20 grams (28 ±0.7 oz)
DX225LC 800 ±20 grams (28 ±0.7 oz)
DX225NLC 800 ±20 grams (28 ±0.7 oz)
DX255LC 800 ±20 grams (28 ±0.7 oz)
DX300LC 800 ±20 grams (28 ±0.7 oz)
DX340LC 800 ±20 grams (28 ±0.7 oz)
DX420LC 800 ±20 grams (28 ±0.7 oz)
DX480LC 800 ±20 grams (28 ±0.7 oz)
DX520LC 800 ±20 grams (28 ±0.7 oz)

Page 102
REFRIGERANT SYSTEM
REPAIRS
WARNING
Always wear protective glasses and gloves when handling
refrigerant. If refrigerant comes in contact with the skin or
eyes, immediately flush with clean, running water and
consult a physician.
Select a clean and well ventilated area to work.
The refrigerant container is under high-pressure and must
be stored below 40°C (104°F). Be careful not to drop the
container from a high location.
The contents are under high-pressure and should not be
used with compressed air or near an open flame.
Refrigerant Safe Handling Procedures
UNION NUT
TORQUE WRENCH
CORRECT WRONG
WRONG
WRONG
CORRECT
O - RING POSITION
CAP & PLUG CORRECT WRONG WRONG
HDA6066L
Figure 94
The following procedures must be observed for safe handling of

refrigerant during vacuum and charging process.
1. Use an approved recovery / charging device which can
safely perform vacuum and charge work simultaneously.

Page 103
2. The new refrigerant has improved cooling characteristics
than the old type and care must be used not to overcharge
the system.
3. Do not over tighten connections when working on
refrigerant system.
4. The new refrigerant system standards require new tools,
equipment and parts. DO NOT attempt to use equipment
use in servicing the old refrigerant system.
5. The new refrigerant oil (PAG type) has a high moisture
absorption characteristic. When the refrigerant system
vacuum seal has been broken, immediately plug up all
openings to prevent moisture from entering into the
system.
6. When joining unions which use O-ring seals, lightly coat O-
rings with refrigerant oil. Be careful not to drip oil on the
threads of the nut.
7. Be certain the O-rings are seated properly on the
refrigerant line lip. Always use new O-rings when
reassembling parts. Do not reuse old O-rings.
8. Use a vacuum pump to evacuate refrigerant system of air.
9. When charging the refrigerant system with the engine
running, do not open the high-pressure valve on the
manifold gauge as the reverse flow of high-pressure
refrigerant will rupture the hose.
10. When releasing the high-pressure hose after completing
the charging process, quickly disconnect the hose to
minimize refrigerant released to the air.
Repair and Replacement Procedure

1. Work Procedure
A. Before repairing or replacing any refrigerant
components first, return all refrigerant oil to the
compressor and perform recovery procedures.
2. Operating Condition
A. Run engine at maximum engine speed.
B. Select 'HI' blower fan speed and select A/C switch to
'ON'.
C. Set the temperature control switch for maximum
cooling and leave running for approximately 20
minutes.
NOTE: The manifold gauge dial pointer can vary
depending on the outdoor temperatures.

Page 104
INSTALL REPAIR TOOL
RECOVER REFRIGERANT
REPAIR / REPLACE DEFECTIVE PARTS
CHECK SYSTEM FOR AIR LEAKAGE REPAIR
CHARGE SYSTEM (APPROXIMATELY 100 g)
CHARGE SYSTEM TO PROPER LEVEL

(Standard Capacity less Initial Charge)
CHECK FOR PROPER REFRIGERANT LEVEL
RUN SYSTEM
RECOVER REFRIGERANT IN CHARGING HOSE
REMOVE REPAIR TOOLS

HDA6067L
Figure 95

Page 105
Refrigerant Recovery
Reference
Description 2 3
Number
1 4
1 To Compressor
2 Low-pressure Side
4 From Receiver
5 Refrigerant Recovery Tank
1. Attach the manifold gauges and the refrigerant recovery 5

unit to the refrigerant lines as shown. HDA6067L
Figure 96
NOTE: Be careful not to switch the connections for the
low and high-pressure valves.
2. Open the high-pressure valve slowly to release the
refrigerant to the recovery unit.
NOTE: Open the valve slowly, while checking to see
that refrigerant is not leaking out.
3. When the manifold gauge dial falls below 3.5 kg/cm2 (50
psi), slowly open the low-pressure valve.
4. Open both the high and low-pressure valves slowly until
the manifold gauge dials indicates 0 kg/cm2 (0 psi).
Vacuuming Refrigerant System

2 3
Reference
Description 1 4
Number
1 To Compressor
2 Low-pressure Side
4 From Receiver
5 Vacuum Pump 5
HDA6068L
1. Vacuuming Procedure Figure 97
NOTE: When the A/C system has been exposed to the
air, it must be vacuumed out. Perform vacuum
process for 30 minutes for complete moisture
and air evacuation.
A. Attach the manifold gauges and vacuum pump to the
refrigerant system as shown.
B. Turn on the vacuum pump and open both valves.
C. When the low-pressure gauge shows approximately
710 mmHg, close both valves and turn off vacuum
pump.

Page 106
2. Check system for vacuum leak.
Allow system to sit for 10 minutes and check whether the
system is holding the pressure. If the pressure has
dropped, it must be repaired before proceeding to the next
step.
3. Vacuuming Procedure
If the system is holding the pressure and it has not
changed for 10 minutes, vacuum out the system for an
additional 20 minutes.
HDA6069L
A. Turn on the vacuum pump and slowly open both
Figure 98
valves.
B. Allow vacuum pump to run for additional 20 minutes
until the low-pressure gauge dial reads approximately
750 mmHg.
C. Close both valves and stop the vacuum pump.
4. Installation of Refrigerant Container
Reference 1
Description
Number
1 Handle
2 Hose Connection
2
3 Mounting Disk
3
A. Before mounting valve on the container, make sure
the handle is in the counterclockwise most position,
with the puncture pin retracted and the mounting disk HDA6070L
is in the raised position. Figure 99
B. Attach the manifold gauge center hose to the valve
assembly.
C. Turn the disk in the clockwise direction and securely
mount valve onto refrigerant container.
D. Turn the valve handle in the clockwise direction and
puncture the container seal with the pin.
E. Once the can has been punctured, turn the handle in
the counterclockwise direction so the refrigerant can
flow into the manifold gauge center hose. Now, do
not open the low and high-pressure valves of the
manifold gauge.
F. Press the manifold gauge low side valve to eliminate
the trapped air in the hose.

Page 107
Leakage Check
NOTE: Perform the leakage check after completing
vacuuming process.
1. After attaching the manifold gauge, open the high side
valve.
2. Charge system until the low side gauge dial indicates a
pressure of 1 kg/cm2 (14 psi) and close the high side valve.
3. Using a refrigerant leak detector or soapy water check
each joint for leakage.
1
Reference
Description
Number
1 Refrigerant Leak Detection Device
4. If a leak is detected, check for O-ring damage or correct

tightening torque and replace or repair as necessary.
5. If no leaks are detected, proceed with the charging process.
HDA6071L
Figure 100
WARNING
For accurate refrigerant leak detection, perform leak
detection procedure in a well ventilated area.
Refrigerant Charging
1. Perform the vacuuming procedure, vacuum holding and
leaking tests as described in the proceeding headings.
NOTE: First charge the refrigerant system with 100g
(3.5 ounces) of refrigerant with the engine off.
Then using the manifold gauges as a guide fully
charge the system with the engine running.
When exchanging refrigerant containers, press
the manifold gauge low side valve to eliminate
air from the charging hose.
Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low-pressure Side
4 From Receiver
5 Refrigerant Supply Container
2. Charge the system by opening the manifold gauge low

5
side valve. HDA6072L
Figure 101
Initial charge amount: 100 g (3.5 ounces).

Page 108
3. If refrigerant does not flow freely into system, try starting
engine first before operating air conditioner.
• Temperature control switch setting: Maximum
Cooling
Blower Speed Setting: Hi (3 step)
Engine Speed: 1,300 - 1,500 rpm
WARNING
When charging refrigerant system with the engine
running:
• Always keep refrigerant supply container in the
upright position.
• Never open the high side pressure valve.
4. Open the manifold gauge low side valve and charge

system to standard capacity.
Gauge Dial Standard Reading
High Side Gauge 13 - 20 kg/cm2

(185 - 285 psi)
Low Side Gauge 1.5 - 3.5 kg/cm2

(22 - 50 psi)
NOTE: These standards are for outside temperatures

between 30° - 35°C (86° - 95°F). The gauge
readings may vary for extreme temperature
conditions.
WARNING
• When outside temperature is low, warm the
refrigerant supply container with warm water not
exceeding 40°C (104°F). Do not allow water to
come in contact with the charging adapter valve
handle.
• When outside temperature is high, cool off
refrigerant supply container and condenser to aid
the refrigerant charging process.
5. Close low-pressure side valve.

6. Shut off engine and close refrigerant supply container
adapter valve. Disconnect manifold gauge hoses from
vehicle.

Page 109
Inspecting System For Leakage
After completing charging procedures, clean all joints and
connections with a clean dry cloth. Using a refrigerant leak
detecting device or soapy water, inspect system for leaks
2
starting from the high-pressure side.
1
NOTE: When the refrigerant circulation has been stopped
the high-pressure will start to decrease and the low-
pressure will start to increase until they are
equalized. Starting the inspection from the high side 3
will result in a accurate test.
Reference 4
Description HDA6073L
Number Figure 102
1 Pressure
2 High-pressure
3 Low-pressure
4 Compressor Stop
Inspection Procedure
1. High-pressure Side
Compressor outlet →condenser inlet →receiver dryer inlet
→air conditioner unit inlet.
2. Low-pressure side
Compressor inlet →air conditioner unit outlet.
3. Compressor
Compressor shaft area, bolt hole area and magnetic clutch
area.
4. Receiver dryer
Pressure switch and plug area.
5. Connection valve area
Inspect all valve areas.
Verify all valves are capped to prevent leaking.
Check for foreign material inside of valve cap.
6. Interior of air-conditioning unit.
After stopping engine, insert detector probe into drain
hose. (Leave inserted for 10 seconds minimum.)
NOTE: When inspecting leakage from the air-
conditioning unit, perform the inspection in a
well ventilated area.

Page 110
WIPER SYSTEM
Wiper Circuit
5 6 7
- 2 3 5 (Continuous mode) 3
+
M
4 4
5 6 11 (Washer mode) 6
1 7 8
12 - + 1
P
1
6 9 13 2
9 2 8
AMP MIC 13P
CN12 CN13 KET 8P
15A 10A 10A 15A

4
10
2
3
AMP MIC 13P 1
1 2 3 4 5 6 4 3 2 1 4 5 6
1 2
7 8 9 10 11 12 13 9 8 7 6 5
(CN12) (CN13) (Wiper Motor)
FG000589
Figure 103
Reference Reference
Number Number
1 Battery 6 Wiper Controller
2 Battery Relay 7 Wiper Switch Panel
3 Fusible Link 8 Window Washer
4 Fuse Box 9 Wiper Cutoff Switch
5 Wiper Motor 10 Light Switch

Page 111
Wiper operation
Continuous operation
- Operation of wiper motor
Pressing the successive operation switch on the wiper switch
panel (7) changes the voltage of the "5" terminal of the wiper
controller (6) from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and
also current flows by the "3" terminal of the wiper controller (6) →
the "2" and "4" terminals of the wiper motor (5) →the "4" terminal
of the wiper controller (6) to run the wiper motor (5)
continuously.
- Stop of wiper motor
Pressing again the successive operation switch on the wiper
switch panel (7) changes the voltage of the "5" terminal of the
wiper controller (6) from LOW (0+0.5V) to HIGH (about
5.5 ±0.5V). As the "5" and "6" terminals of the wiper motor are
connected still that power is supplied to "6" terminal of the wiper
controller (6),
However, the controller (6) runs the wiper motor continuously
and then rotates the motor reversely by " letting current flow by
the "4" terminal of the wiper controller (6) → the "2" and "4"
terminals of the wiper motor (5) →the "3" terminal of he wiper
controller (6) when the "1" and "6" terminals of he wiper motor
(5) are connected and thus power voltage is supplied to "7"
terminal of the wiper controller (6).
The Wiper motor (5) stops reverse revolution when the contact
of a cam switch connected to "6" terminal of the wiper motor (5)
moves to an insulation area of the cam plate to disconnect the
"5" and "6" terminals of the wiper motor (5).
When the wiper motor (5) stops, arm and blade connected to it
move to the stop positions of the right pole in the cabin.
Intermittent operation
- Intermittent 1st (3-second)
Pressing once the Intermittent switch in the switch panel (7)
every operation.
- Intermittent 2nd (6-second)
Pressing twice the Intermittent switch in the switch panel (7)
every operation.

Page 112
- Stopping the intermittent action
Pressing three times the Intermittent switch in the switch panel
(7) while the wiper is operating stops the action of the wiper
motor.
NOTE: The wiper system does not work when the wiper
cutoff switch (9) is "ON".

Page 113
LIGHTING SYSTEM
Lighting System Circuit Diagram
7
13 87a
30
87
*15 85 86
*16
*9
87a
6
30 87a
*14 87
87
30
85 86
85 86
12
*8
87a
87
30 *5
0 0
85 86 3 I 2 2 I 3
II II
0
I 5 5
0
I
4
6 II II 6
7 8 8 7
20A
15A
10 30A
CN6-1 15A
CN6-2 15A
CN6-9
11
L6 CN6-10 3
CN2-6
CN7-4 CN4-4
2
CN7-5 CN4-5 CAN
CN7-6 CN4-6 CN1-1
CN1-2
CN1-8
1
CN1-9
Figure 104 FG000590
Reference Reference
Number Number
1 Battery Front Cabin Light /
9
2 Battery Relay Rear Work Light Relay
3 Fuse Box 10 Instrument Panel
5 Cabin Light Switch 12 Headlight (2 ea.)
Headlight Relay (Work Light 13 Work Light (2 ea.)
6
Indicate Light) 14 Front Cabin Light (4 ea.)
7 Work Light Relay 15 Rear Cabin Light (2 ea.)
8 Front Cabin Light Relay 16 Rear Work Light (1 ea.)
NOTE: The "*" mark are optional parts.

Page 114
Kind of Light
The lighting system is consists of headlights, work lights, cabin
lights (optional), relays and switches.
Operation
Connected Terminal
Switch Position Activated Relay Lit Light
of switch
1 "2-3" Terminal - Illumination Light of Switch
"2-3" Terminal - Illumination Light of Switch
Headlight Relay Headlight (2 ea.)
Light Switch
2 Work Light (2 ea.)
"5-6" Terminal
Work Relay Indicator Light of Work Light
(L6)
Front Cabin Light (2 ea.) or
1 "2-3" Terminal Front Cabin Light Relay
Front Cabin Light (4 ea.)
Cabin Light Front Cabin Light (2 ea.) or
"2-3" Terminal Front Cabin Light Relay
Switch Front Cabin Light (4 ea.)
2
Rear Cabin Light Relay / Rear Cabin Light (2 ea.) and
"5-6" Terminal
Rear Work Light Relay Rear Work Light (1 ea.)

Page 115
AUDIO CONTROLLER
Audio Controller Circuit Diagram
ANTENNA
7 8 10
MODULE
2 15
3 Vcc(+5V) 9
11 3 16 (LH) (RH)
15A 1 MICOM
4 13
+ - + -
5 Vcc(+5V)
7
3 14
10A 1 DC/DC 17
CONVERTER 1 2 5 2
6 10
10A 87a 3
30 11
87 4
86 85
4
9 10 11 12 13 14 15 16 17 18
1 2 3 4
1 1 2 3 4 5 6 7 8
(Audio Control Panel) (STEREO)
FG000591
Figure 105
Reference Reference
Number Number
1 Battery 7 Audio Control Panel
2 Battery Relay 8 Stereo
3 Fuse Box 9 Speaker
4 Fusible Link 10 Antenna Module
5 Converter 11 Light Switch
6 Stereo Relay
Operations by Audio Control Panel
Switch Connected Terminal of switch Measured values Operations

PWR 4.36 ±0.2V Stereo ON, OFF
1.24 ±0.2V Volume up
"3-4"
0+0.2V Volume down
SCAN 2.49 ±0.2V Frequency selection

Page 116
SP002265
ELECTRICAL SCHEMATIC (NON-ROPS)SP002265
1Electrical
Schematic
(NON-ROPS)
Edition 2
Electrical Schematic (NON-ROPS) SP002265

Page 1
MEMO

Page 2
Table of Contents
Electrical Schematic (NON-ROPS)

DX138LC/DX140/180/225/255LC/DX225LL/
DX225NLC ........................................................... 7

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up
DX180LC 5001 and Up
DX225LC 5434 and Up
DX225LL 5001 and Up
DX255LC 5001 and Up

Page 5
Page 6
DX138LC/DX140LC/DX180LC/DX225LC/DX255LC/DX225LL/DX225NLC
6-LAMP ASS’Y (OPT) 00 LOWER WIPER (OPT)
WIPER MTORO
WIPER
CONT ROLLER WIPER
SWITCHPANEL
AUDIO
CONTROL PANEL
l
129B 0.85RG
ROTATING BEACON (OPT) 0.85R
1.25RG 0.85RG 129C WORKING LAMP 50B
- 155B 2 0.85LW 3 155A 159A 5 (CONT) 0.5LR 3 159B
(RR) L 36B 0.85R 0.85G 37B 1
+
STARTER SWITCH CONNECTION 0.85B 0.85B 30 2RY TELESCOPIC BEACON 0.85R 0 M
51B 2 36A 8 (INT-1) 4 CONT. POWER
1.25RG 2RG 51A 87 33C
160A 0.5LY 160B
0.85Or 88B 3 I 156A 4 0.85LB 4 156B
TML B BR R1 R2 C ACC (REAR) 10 (INT-2) 5 INT SEEK
PST REAR WORKING LAMP 1.25RG 87a 0.85RG 129D (RH) 1.25B 0.5B 85 86 0.5RG ROTATING 161A 0.5LG 161B ANTENNA
0.5B 7 8 54L
+
30 125E 1.25RL 0.85B STOP RUN B 88H 0.85BR WASHER VOL.
OFF 87 (RL) BEACON SWITCH 162A 11 (WASHER
) 0.5L 6 162B 00
129A 0.85B 55C 0.5WR
ON 51C M WINDOW WASHER MODULE CAR STERE O
0.5B 85 86 128B 0.5RG 1.25B 1.25RG ROTATING BEACON 124B LOWER WIPER SW 157B 1 0.85WL 7 157A
127B 0.85RG CABIN LAMP 1 0 S 37A 0.85G 0.85G (300654-00037)-RADIO
START WORKING LAMP RELAY -
(LH) 2 0.85RG 158B 5 0.85WB 6 158A 35C 12 0.85RB - + 0.85L 1 34E (300637-00009)-MP3
1.25B 33B 0.85Or 33A 3 E 0.85B 0.85BR 0.85BR
(FR) 0.85B I P SPEAKER
63C 6 0.85WR 35A 34C 2 121B 0.5WG 121A 15
0.85B 0.5B 7 8 0.5WR Vcc(+5V)
CABIN LAMP RELAY 2 HEAD LAMP 0.5RB 0.5L
127C 0.85RG 87a 52D 3 123B 0.5W 123A 16 (LH) (RH)
LOWER WIPER MOTOR 35B 34D 54D MICOM
CABIN LAMP SWITCH 30 1.25R 54K 0.5WR 1
(FMR) 0.85B 53B DIODE 5
0.85RW 1.25RW 53A 87 34B 1 0.85L 0.85L 4 169A 0.5BL 169B 13
2B 125B (RH) 54C + - + -
0 0.85B 0.5B 85 86 0.5RG LAMP SWITCH 130B 13 0.5RW 0.5WR 2
(FRONT) 0.5WR 126A 3 I 2 0.5RL CN14 MOLEX 4P 117B 118B 119B 120B
30 125D 2RL Vcc(+5V)
II 55B 0 0.85B 0.85Lg 9 138A 99 2 0.85B 0.5B 8
127D 0.85RG 2RG 127A 87 14 99 117A 7 0.5GrR
0.85WR 54A 3 I 2 52B 0.85R 138B AMP MIC 13P
(FML) 0 125C 53C
0.85B 85 86 126B 0.85RW HEAD LAMP RELAY II WIPER CUT SW CN12 CN13 KET 8P 118A 17 0.5BY
0.5B 5
I 0.5RL
0.5RG 128A 6 II
(LH) 0.85B 0 FUEL PUMP (OPT) 0.85BR 0.85WR 5 15C 119A 2 0.5GrL
I 5 52C 0.5R
127E 0.85RG 7 8 0.5WR 0.5WR 120A 10 0.5BW
0.5B 55A 0.5WR
CABIN LAMP RELAY 1 0.5RG 6 II 0.5WR 3 54R
99 11 0.5B
(FL) 0.85B 54F
0.5B 7 8 54G 0.5WR
FUEL PUMP FUEL PUMP SW CIGAR LIGHTER
2B 2RL 0.85BR 0.85BR 4 88E
CABIN LAMP SEAT HEATER (OP T) 1.25R
1.25B 64B 1.25WL 64A 1 2 63B 1.25WR
2RY P
1 0
2 143B 1.25RB 1.25B
LCD GAUGEPANEL 0.85WR STEREOLREAY STARTER RELAY 1
1.25B 144B 1.25R 144A 3 I
REAR VI
EW CAMERA
7 8 54Q 87a
0.5B SEAT AIR SUSPENSIONT)
(OP 1.25RB 1.25RB 30 0.85Y
V+ 9V 195A CN6-4 0.5Y 195B 62B STARTER CONTROLLER
SEAT HEATER 0.85LR 13E 87
5A
0.85WR
1.25R
0.85BR
V- 196A CN6-5 0.5YB 196B AIR SUSPENSION
0.85L
0.5RW
SEAT HEATER SWITCH 1.25W N S 14B
TERMINAL NO 197B 2RY 14C 0.85BW 14A 85 86
Sig 197A CN6-6 0.5YL
1.25B 143C 1.25RB 2 132A 1.25R
198B P 0.85RG 0.85RG 1.25LR 1
00 DC/DC 12B
Sig Gnd 198A CN6-7 0.5YW +
CONVERTER 3 132B
0.5RG 131B 12V POWER 18B
KET 118 9P DIAGNOSTIC CONN. 14P 99 SOCKET
3 54B 0.5WR 0.5WR 0.5WR -
0.85BL
ILL. 54B CN6-3 E B P
0.85Y
4 3 2 1 0.85B
28B CN6-1 1 28B 0.5R 0.85R 0.85R 0.5RW 1.25B 13B
1.25WG
STARTER RE
LAY 2
9 8 7 6 5 3 2 1 28C CN6-2 2 28C 0.5R 2RL 2RL 1.25RB
PILOT BUZZER 87a
7 6 5 4 0.85LR 0.85BL
(CN13) 0.85RY
0.85BY 30
11 10 9 8
+ 87 12A
14 13 12
0.5R 28G TRAVEL/SWING ALARM ASS’Y (OPT) FUEL HEATER (OP T) 11B
MOLEX 4P 29B CN6-12 12 29B 0.5WB 29A - 0.5LR 86 85 0.5GB
+ 31B 0.85RY 13C 89A STARTER
130D CN6-11 11 130D 0.5RW ALARM BUZZER 87a
1.25WR
1 2 3 4 (CN15) - 0.85B 30 20C 2RG 0.5RG
0.85WR
0.85BR
1.25R
0.85R
0.85RG
1.25W
1.25LR
0 24V 7KW
59A 87
2RG
2.5R
2RY
0.85L
2RL
(CN14) 3 2 30B 1 0 5C
0.5P I 0.5W 87a 2
99 CN6-9 9 99 0.5B 30 59B 85 86
104C II 32B 0.85RG 0.5RY 39A 3 I 125A 50A 20A 28A 52A 63A 124A 62A 131A 34A 88A 15A
ECU CONNECTOR 99 CN6-10 10 99 0.5B 31A 87 0.5B 20B
0 39B 0.5B 7 8
9 10 11 12 13 14 1 2 3 4 5 6 7 8 6A 1.25WR
I 5 0.5W 0.5W 85 86 0.5RG
0.85B 122B 0.85V 122A 6 II 54K 30A 20A 20A 15A 15A 15A 10A 10A 10A 10A 10A 10A 10A 10A
32C 32A FUEL HE
ATER
1.25WR
30C FUEL HE
ATER 1.25WR 2WR
0.85LR
0.85BY
12 17 18 35
36 53
OVER LOAD WARNING (OPT) 4bar
7 8 0.5WR RELAY SWITCH
4G
17 18 2E
4D
15
2B
16
11A
54M ALARM RELAY
7 11 54 71 SWING PRESS SW
ALARM SWITCH 5W 5W ACC C
1 6 72 89
0.5B 2.5B FUSE BOX 2 FUSE BOX 1 15R 98A B
OVER LOAD 5W 5W 13A
ONLY SWING (OP
T) FUEL HE
ATER
99 CN6-9 0.5B WARNING SWITCH B
4F 2D 4E 10A 6B BR 0.85Br
99 CN6-10 0.5B
ECU CON.1 (89-PIN) 1 0 0.5RG 0.5P 15 16 2WR 17 18 2C 2WR R2
2 140B 0.5BrY 57B 0.85RY 7A
VEHICLECONN.
0.5B 3 I 0.5RW 0.5RW HORN 1 10A 10A 10A 10A 10A 10A 10A 10A 30A 20A 20A 15A 15A 15A
H.F 0.85B HORN RELAY R1
0.5B 7 8 54P 0.5WR 0.5WR 0.5WR A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 STARTER SWITCH
87a
1.25RB
0.5WR
0.5RW
30 56B 0.85RB
0.5GB
0.5BG
0 56A 66A 30A 93A 166A 40A 130A 83A 42A 133A 143A 21A 19A
28D 0.85R CN5-4 140A 141A 3 I 2 21B 0.5RL 57C 0.85RY 0.85RY 57A 87 60B
+ HORN 2
0.85WR
0.85RB
0.85LB
0.85RL
0.85Y
II
0.85RG
0.5RW
PRESSURE SENSOR
0.5GBr
CN3-5 L.F
2RW
139B 0.85BrW 139A 85 86
1.25BrR
CN2-6 0.85B 56C 0.5RB
1.25RB
1.25RL
LCD DISPLAY PANEL 51D 0.5RG 0.5G 58A
SIG 0.5Br
2LR
(OWD) 0
WATER TEMPE RATURE 145A 0.85W CN3-6 145B NOTE.2 141B CN2-4 0.5BrB (MANUAL) 0.5BrB 5 21L
- I 0.5RL 0.85LB 2WR
FUEL ELVEL 2WR
EPOS 22B CN2-5 0.5BrW (AUTO) 0.5BrW 22A 6 II
CONTROLLER 0.85RG 0.85RG
28G 0.85R 0.5B 7 8 54H 0.5WR
ECU CON.3 (16-PIN) ECU CON.2 ( PIN) GRAPHIC DISP
LAY 0.5G 0.5GBr
WIF SENSOR 193A 0.85 CN3-19 193C
60R
CYLINDER
CONN. ENGINECONN. 0.85Y 2RW
194A 0.85 CN3-20 194C HIGH SPEED SWITCH 0.85Br 27A
WARNINGLAMP 10B CN2-1 0.5BG KEY SW ’S
TART’ 0.5BG 0.5BG 0.5BG
89B CN1-15 START RELAY 0.5GB 0.5GB 0.5GB 2WR 2R
DIODE ARRAY CN3-15 90A +5V 0.5GB
(DX225DTC) Py 1.25BrR 8W 7B 2A 1B
104A CN2-15 0.85P 104B 0.85B AUTO IDLE (1
)
5 6 7 8 3 4 PRESSURE SENSOR(A) / TRAVEL SW 0.5RW 0.5RW 0.5RW FUSIBLE LINK
28E 0.85R, 90D 0.85GR(DX225DTC) 19bar
(FRONT PUMP
) + HOUR METER DIODE 2
21C CN1-1 0.85RL 0.5WR 0.5WR CIRCUIT BREAKER
74B 0.85GR CN3-1 74A 2R
SIG 6C
21D CN1-2 0.85RL 1.25RL 1.25RL 1.25RL 1.25RL 1 0.5WR
1 2 3 4 1 2 75A 0.85W CN3-2 75B 8A 1A
- 9D 3 B
9D CN2-14 0.5RW ALT ’I’ 0.5RW 0.5RW 0.5RW HOUR 2 0.5B 8W A
8W
DA1 ~ DA3 DA4 ~ DA6 28F 0.85R, 90E 0.85GR(DX225DTC) 185B CN5-1 0.5RW (FAN CONTROL) 0.5RW 185A NC 0.85RL ROOM LAMP 4B 3B
PRESSURE SENSOR(B) + 3A 60R
COM 40B 0.85Y
1.25BrW
15R
(REAR PUMP) 76B 0.85GY CN3-3 76A 99 CN1-8 0.85B 0.85YG 41A NO 1.25BrW 8C BR
SIG OFF 10W
77A 0.85WL CN3-4 77B 99 CN1-9 0.85B SOL-VALVE ASS’
Y 0.5B E DR B+ 0.5WR
- 0.85YG 41B PILOT CUT-OFF SWITCH 8B E
3 41C PILOT QUICK CLAMP(OPT) ON 83B 1.25B
80A CN7-4 0.5Y 0.5Y CN4-4 80B DA4-1
1 CUT OFF BATTERY RELAY
0.85B 99 0.5Br 0.85Br DIODE 1 MASTER SWITCH
81A CN7-5 0.5YB 0.5YB CN4-5 81B (C1) 1
CAN A ( `⁄)
0.85YL 0.85YL 61C 2 0.85LB
82A CN7-6 SHIELD SHIELD CN4-6 82B 84C 84B 2RW 60B 1 60B
(˙fi‚†) 3 2 60R
4 61B 66B 9B
202A CN7-9 0.5Gr DA4-2 BREAKER 0.5Br 0.5Br
84A
DIODE 6
PREHEAT FUSE
AMP 040 12P
2 99
201A CN7-10 0.85B
0.5Or (C2) 0.85W 0.85W
AMP MIC 21P
SOL-VALVE QUICK CLAMP SW

0.85RL 0.85RL 21F 0.85BG 0.85BG 200A
CN7 CN6 3A 98B
6 21J HIGH 0.85B 0.5RW - + - +
AMP 040 12P+16P DA1-2
0.85BG
1.25BrR
INJECTOR
0.85RL
0.85W
0.5GBr
24C CN1-12 0.85Gr 0.85Gr SPEED 12V 100AH 12V 100AH
0.5G
0.5Br
24B 2 24A
2RW
SOLENOIDS 0.5WR AIRCON UNIT
CN4
(C3)
3-04 0.85RL 0.85RL 21E DIODE 4
CN1
CYLINDER VEHICLE 0.5RW BATTERY

CYL.1 3-13 5 21H
CONN CONN DA1-1 RELIEF 1.25LR CN11-2 42C
LED 1~12 130C CN9-6
23C CN1-11 0.85GrW 23B 1 0.85GrW 23A PRESS UP
0.5LR CN10-8 42D 0.85W
(C4) 54E CN9-11 0.5WR
15W
3-05 0.85RL 150J CN10-18 46B 153B 4B
CYL.3 ILL 42B CN9-5 1.25LR AVX 8W
3-12 5 150K BREAKER AUXI MODE RESISTOR 0.5BW C B
DA1-3
AMP 070 18P
SELECT DIODE 9 AVX 1.25WG

0.85B 1 99 0.85YL 0.85GY (545-00011 ) RECEIVER DRIER
94A 93B 0.85LR
(C5) 0.85BrB 0.85RL AVX 2RW
3-11 61D 71A BLOWER A/C
0.85BrR 42E 46A
CYL.2 RELAY RELAY
3-06 18A 4A 9A
84D CN2-11 0.5Br (QUICK CLAMP) 0.5Br 154A D H P(R) B(B+) R(I)
CN2
168B CN8-10 CN10-16 168A 15L

0.85RL 0.5LG 0.85BG
3-01 100A
60B CN2-2 0.5BrW (POWER MAX) 0.5BrW A/C THERMOLOW)
( 105B CN9-8 0.5LB CN10-5 105A 100B
CYL.5 3-16 BREAKER SHEAR SELECT SW +
0.5RG CN4-3 137A GND 71B CN2-10 0.5GY (BREAKER) 0.5GY PREHEAT RELAY
106B CN8-11 0.5LY CN10-6 106A
0.5B FET
0.5GW CN4-2 136A RxD 150E CN2-8 0.5RL (1-WAY) 0.5RL PST SHEAR PRESS BREAKER COMPRESSO
R
SG
3-02 UP 1.25B CN11-1 99 - +
0.5GL CN4-1 135A TxD 151C CN2-9 0.5RY (2-WAY) 0.5RY M
CYL.6 3-15 201C TML 1 0 2
1-62 RS-232 99
0.85RL 9 107B CN8-12 0.5LW CN10-1 107A BLOWER MAGNET
202C 1-65 47A 0.85LW
0.5WR 54J CN11-4 47C CLUTCH
0.85BG
1.25BrR
(CONN.3)
0.85W
10 R
0.5GBr
3-03 CHECK 1
0.5G
0.5Br
2RW
101A CN1-10 0.85Or 101B 0.85RY 151A 108A CN9-13 0.5GrG CN10-2 108B FRE (P1) 47B -
CONN 5 3 INTAKE 15B F
CYL.4 3-14 ENGINE 80C 1-35 CAN BH 0.5Y 0.85LgR P/V-(A)
0.5GL 135B 94B 2 0.85BrR 133G 109A CN9-12 0.5GrY CN10-20 109B REC (P2) ACTUATOR E
CONN
DIODE 4
1 95A 95B 14 M
81C 1-34 CAN BL 0.5YB
0.5GW 136B 102B CN1-21 0.85OrB 102A 3 0.85BrR 133H
SHIELD 2 6 0.85LgW 13 AIR HEATER E
FUEL HIGH PRESSURE 3-09 0.5RG 137B 0.85RL 150A 110A CN9-15 0.5OrR CN10-12 110B DEF (P1) 0.85B 0.85B 99 ALTERNATOR 60A
3 0.85B 4 11
PUMP 96B 96A PUMP 111A CN9-14 0.5OrW CN10-13 111B VENT (P2) 8B
3-10 80D 1-53 CAN AH 0.5Y 0.5Y 80E M
4 PROPORTIONAL V/V 6 MODE ALTERNATOR 80A(OPTION
)
BOOST PRESSURE 3-07 1-52 81E AUXILIARY MODE W
S 0.5BrW 60A 43A CN9-16 0.5YB CN10-11 43B Vref MODE
81D CAN AL 0.5YB 0.5YB ACTUATOR
ACTUATOR(EPW) 5 16
3-08 44A CN9-17 0.5YW CN10-10 44B MODE F/BACK
SHIELD SHIELD 82E 0.85BrL 134B
6 15
3 2-32 61A 99 CN9-10 1.25B TERMINAL NO
0.85YL
OIL PRESSURE P& 4 2-27
7 12
SENSOR
(ODFT)
t 1 2-24
8 JOYSTICK EVER
L SWI TCH 112A CN9-1 0.5LgW CN10-19 112B WARM (P1)
(0 281 002 420) 9 (420-00469 ) AMP MIC 13P AMP 070 18P AMP MIC 21P
2 2-28 113A CN9-18 0.5LgB CN10-3 113B COOL (P2)
V 10 99 6 3 58B 0.5G
M 1 2 3 4 5 6 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
0.5B 114A CN9-3 0.5YR CN10-7 114B Vref MIX
3 165A 1-89 0.5BW 0.5BW 165B ROTATING S/V (OP
T) MIX
2-33 11 (HORN) (C) ACTUATOR
BOOST PRESSURE P& 4 2-34
E/G EMERGENCY STOP SW
0.5GBr 166B
115A CN9-4 0.5YW CN10-9 115B MIX F/BACK 7 8 9 10 11 12 13 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
SENSOR 12 181A CN1-7 0.85GrL 181B CCW 146C 146B 1 0.85OrB 0.85OrB 146A 4 1 133B 0.85BrR
(LDF 6 T)
t 1 2-25 3 0.5B 99 167C CN9-2 1.25BL CN10-4 167A GND (CN12) WIPER CONT. (CN2) (CN1)
13 COOLINGFAN SPEE
D 3 (ROTATING-CCW) (L)
(0 281 002 576) 163A 1-29 0.5R 163B 2 2 164A 192B (A) DA5-1
2
0.85BG
2-36 182B 0.85GrR 182A PROPORTIONAL V/V 116A CN8-2 0.5OrB CN10-15 116B AMP 040 28P AMP 070 16P AMP 040 12P AMP 040 20P
0.85W
V 14 CN1-18 1 0.85OrR 147A 5 2 133C 0.85BrR
0.5GBr
DUCT
0.5Br
2RW
164B 1-87 0.5BL
FUEL (ROTATING-CW) SENSOR
1 2-35 CN15 78A CN1-19 0.85Lg 78B (R)
TEMPEAR TURE 0.5B 147C 147B 2 0.85OrR 8 7 6 5 4 3 2 1
t P/V-(C) (OPTION) CW (ON JOYSTICK L.H)
6 5 4 3 2 1 8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
0.85BrR
SENSOR 2 2-26 CN4-7 192A 45A CN8-1 CN10-14 45B
V 0.5GBr FLOW CONTROL 4 0.5LgR WATER
12 11 10 9 8 7 16 15 14 13 12 11 10 9 12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11
(0 281 002 209) 79B CN1-20 0.85LgB 79A (B) DA5-2 (OPTION)
16 15 14 13 12 11 10 9
178B CN5-2 178A PROPORTIONAL V/V PEDAL SWI
TCH SENSOR
1-56 0.5LW (PREHEAT LAMP) 2 3 0.85B
0.85BrL 134C 133J 0.85BrR 2 (CN7) (CN6) (CN5) (CN4) (CN3)
COOLANT 2 99 Px
1-10 0.85B
TEMPEA R TURE t 72B 0.85YR CN3-7 72A 103A CN2-16 0.85V 103B 0.85B AUTO IDLE (2)W
S 48A CN8-5 0.5LY CN10-17 48B 1 INCAR AMP 040-III 20P
1
AMP 040 20P
2-15 99 FUEL SENSOR

SENSOR V 1-11 0.85B 2B
73B 0.85BR CN3-8 73A 19bar SHEAR S/V (OP
T) - E3C
SUNLOAD SENSO
R
SENSOR KET D/L 4P AMP 070 18P AMP 070 12P
(0 281 002 209) 99 1-05 0.85B 2 1 8 7 6 5 4 3 2 1 5 4 3 2 1
1 DA6-1 1 0.85OrY 9 8 7 6 5 4 3 2 1
2-23 67A CN2-17 0.85BW 67B 0.85B INDICATOR 0.85BrL 134A 0.85BrR
INCREMENT SPEED SENSOR 99 6 3 133D CN10 AMP 20P CN11 KET 4P
(CRANKSHAFT)(DG6)(VR)#1
N 2 2-19
1-06 0.85B 2B
(CLOSE)
148C 148B 1 5 71C 4 0.85GY 142A CN8-3 0.5Lg 2 - + 1 4 3
20 19 18 17 16 15 14 13 12 11 10
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
26B 0.85LgR CN3-9 26A (BREAKER/P
OWER MAX) (C)
(TONE WHEEL WITH L STSO ) 2B OIL TEMP SENSOR 7 148D 142B 0.5YR
V (CN11) (CN9) (CN8)
CN3
27B 0.85LgW CN3-10 27A 68A CN2-18 0.85BG 68B 0.85B PILOT FILTER SW 71D 0.85OrY 148A 4 1 133E 0.85BrR (CN10)
AMP 070 16P
(0 281 002 662) 114C 0.85BL 167B 2

3 DA6-3 6 AMBIENT TEMP
(SHEAR-CLOSE) (L) 49A CN8-4 0.85YG 0.85YG 49B 1 SENSOR
2 2-09 2
SEGMENT SPEED SENSOR
(CAMSHAFT)(DG6)(VR)#2
N 1 2-10 ENGCONTROL DIAL 69A CN5-3 0.85RB 69B 0.85B 149C 149B DA6-2 2 0.85Or 0.85Or 149A 5 2 133F 0.85BrR CN8 CN9
RETURN FILTER SW (OPEN)
(TONE WHEEL WITH S O LTS) 1.5bar 8 (SHEAR-OPEN) AMP 12P + 18P
V LOW CW 1 90B 0.5GR CN3-15 90A +(5V) DA6-4 149D (R)
CN5
(0 281 002 662) A/C CONTROL PANEL

2 91B 0.5G CN3-16 91A SIG 70A CN5-7 0.85GB 70B 0.85B PEDAL BRAEKER 4 3 0.85B JOYSTICK EVER
L SWI
TCH
3 19B 1-08 0.85RW PRESSURE SW (OPTION) (420-00468 )
2-13
RAIL PRESSURE SENSO R P 19C 3 92A 0.5GB CN3-17 92B GND (ON JOYSTICK R.H)
2 2-14 1-09 0.85RW 2RW
HIGH
(RGS3) 19D 0.5GBr 0.5GBr 0.5GBr
V 1 2-12 1-02 0.85RW
(0 281 002 534)
19E 1-03 0.85RW 2RW 2RW 2RW 2RW
7C 1-40 0.5Br (KEY SW) 0.5Br 0.5Br 0.5Br
153A 1-13 0.85W (AIR HEATER RELAY) 0.85W 0.85W 0.85W
154B 1-07 0.85BG (AIR HEATER RELAY) 0.85BG 0.85BG 0.85BG
(CONN.2) (CONN.1) FG017141

Figure 1

7
SP002266
ELECTRICAL SCHEMATIC (ROPS)SP002266
1Electrical
Schematic
(ROPS)
Edition 2
Electrical Schematic (ROPS) SP002266

Page 1
MEMO

Page 2
Table of Contents
Electrical Schematic (ROPS)

DX140LC/DX180LC/DX225LC/DX225LL/
DX225NLC/DX255LC ........................................... 7

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX140LC 5503 and Up
DX180LC 5209 and Up
DX225LL 5001 and Up
DX225LC 5890 and Up
DX255LC 5150 and Up

Page 5
Page 6
DX140LC/DX180LC/DX225LC/DX225LL/DX225NLC/DX255LC
6-LAMP ASS’Y (OPT) LOWER WIPER (OPT) WIPER
CONT ROLLER WIPER AUDIO
WIPER M OTOR SWITCH PANEL CONTROL PANE L
129B 0.85RG
ROTATING BEACON (OPT) 0.85R
1.25RG 0.85RG 129C WORKING LAMP 50B
- 155B 2 0.85LW 3 155A 159A 5 (CONT) 0.5LR 3 159B
(RR) L 36B 0.85R 0.85G 37B 1
+
STARTER SWITCH CONNECTION 0.85B 0.85B 30 2RY TELESCOPIC BEACON 0.85R 0 M
51B 2 36A 8 (INT-1) 4 CONT. POWER
1.25RG 2RG 51A 87 33C
160A 0.5LY 160B
0.85Or 88B 3 I 156A 4 0.85LB 4 156B
TML B BR R1 R2 C ACC (REAR) 10 (INT-2) 5 INT SEEK
PST REAR WORKING LAMP 1.25RG 87a 0.85RG 129D (RH) 1.25B 0.5B 85 86 0.5RG ROTATING 161A 0.5LG 161B ANTENNA
0.5B 7 8 54L
+
30 125E 1.25RL 0.85B STOP RUN B 88H 0.85BR WASHER VOL.
OFF 87 (RL) BEACON SWITCH 162A 11 (WASHER) 0.5L 6 162B
129A 0.85B 55C 0.5WR
ON 51C M WINDOW WASHER MODULE CAR STERE O
0.5B 85 86 128B 0.5RG 1.25B 1.25RG ROTATING BEACON 124B LOWER WIPER SW 157B 1 0.85WL 7 157A
127B 0.85RG CABIN LAMP 1 0 S 37A 0.85G 0.85G
START WORKING LAMP RELAY -
(LH) 2 0.85RG 158B 5 0.85WB 6 158A 35C 12 0.85RB - + 0.85L 1 34E
1.25B 33B 0.85Or 33A 3 E 0.85B 0.85BR 0.85BR
(FR) 0.85B I P SPEAKER
63C 6 0.85WR 35A 34C 2 121B 0.5WG 121A 15
0.85B 0.5B 7 8 0.5WR Vcc(+5 V)
CABIN LAMP RELAY 2 HEAD LAMP 0.5RB 0.5L
127C 0.85RG 87a 52D 3 123B 0.5W 123A 16 (LH) (RH)
LOWER WIPER MOTOR 35B 34D 54D MICOM
CABIN LAMP SWITCH 30 1.25R 54K 0.5WR 1
(FMR) 0.85B 53B DIODE 5
0.85RW 1.25RW 53A 87 34B 1 0.85L 0.85L 4 169A 0.5BL 169B 13
2B 125B (RH) 54C + - + -
0 0.85B 0.5B 85 86 0.5RG LAMP SWITCH 130B 13 0.5RW 0.5WR 2
(FRONT) 0.5WR 126A 3 I 2 0.5RL CN14 MOLEX 4P 117B 118B 119B 120B
30 125D 2RL Vcc(+5 V)
II 55B 0 0.85B 0.85Lg 9 138A 99 2 0.85B 0.5B 8
127D 0.85RG 2RG 127A 87 14 99 117A 7 0.5GrR
0.85WR 54A 3 I 2 52B 0.85R 138B AMP MIC 13P
(FML) 0 125C 53C
0.85B 85 86 126B 0.85RW HEAD LAMP RELAY II WIPER CUT SW CN12 CN13 KET 8P 118A 17 0.5BY
0.5B 5
I 0.5RL
0.5RG 128A 6 II
(LH) 0.85B 0 FUEL PUMP (OPT) 0.85BR 0.85WR 5 15C 119A 2 0.5GrL
I 5 52C 0.5R
127E 0.85RG 7 8 0.5WR 0.5WR 120A 10 0.5BW
0.5B 55A 0.5WR
CABIN LAMP RELAY 1 0.5RG 6 II 0.5WR 3 54R
99 11 0.5B
(FL) 0.85B 54F
0.5B 7 8 54G 0.5WR
FUEL PUMP FUEL PUMP SW CIGAR LIGHTER
2B 2RL 0.85BR 0.85BR 4 88E
CABIN LAMP SEAT HEATER (OP T) 1.25R
1.25B 64B 1.25WL 64A 1 2 63B 1.25WR
2RY P
1 0
0.85WR
2 143B 1.25RB 1.25B
LCD GAUGEPANE L STEREO RE
LAY STARTER RELAY 1
1.25B 144B 1.25R 144A 3 I
REAR VI
EW CAMERA 2 132A 1.25R
7 8 54Q DC/DC 87a
0.5B SEAT AIR SUSPENSIONT)
(OP 1.25RB 1.25RB 1 30 0.85Y
V+ 9V 195A CN6-4 0.5Y 195B 62B CONVERTER (1) 132B + STARTER CONTROLLER
SEAT HEATER 131B 3 99 12V POWER 0.85LR 13E 87
5A
0.85WR
1.25R
0.85BR
196A CN6-5 0.5YB 196B AIR SUSPENSION
1.25W
V-
0.85L
0.5RW
TERMINAL NO
SEAT HEATER SWITCH
2RY 1.25B - SOCKET(7A) N 14C S 14B 0.85BW 14A 85 86
Sig 197A CN6-6 0.5YL 197B 2 203A 1.25W
1.25B 143C 1.25RB DC/DC
Sig Gnd 198A CN6-7 0.5YW 198B P 0.85RG 1.25RG 1 12B
CONVERTER (2) 203B +
0.5RG 30E 3 12V POWER
18B
KET 118 9P DIAGNOSTIC CONN. 14P 99 - SOCKET(7A)
3 54B 0.5WR 0.5WR 0.5WR
0.85BL
ILL. 54B CN6-3 E B P
0.85Y
4 3 2 1 0.85B
28B CN6-1 1 28B 0.5R 0.85R 0.85R 0.5RW 1.25B 13B
1.25WG
STARTER RELAY 2
9 8 7 6 5 3 2 1 28C CN6-2 2 28C 0.5R 2RL 2RL 1.25RB (2544-9033 )
PILOT BUZZER 87a
7 6 5 4 0.85LR 0.85BL
(CN13) 0.85RY
0.85BY 30
11 10 9 8
+ 87 12A
14 13 12
0.5R 28G TRAVEL/SWING ALARM ASS’Y (OPT) FUEL HEATER (OPT) 0.85RG 11B
MOLEX 4P 29B CN6-12 12 29B 0.5WB 29A - 0.5LR 86 85 0.5GB
+ 31B 0.85RY 13C 89A STARTER
130D CN6-11 11 130D 0.5RW ALARM BUZZER 87a
1.25WR
1 2 3 4 (CN15) - 0.85B 30 20C 2RG 0.5RG
0.85WR
0.85BR
1.25R
0.85R
0.85RG
1.25W
1.25LR
0 24V 7KW
59A 87
2RG
2.5R
2RY
0.85L
2RL
(CN14) 3 2 30B 1 0 5C
0.5P I 0.5W 87a 2
99 CN6-9 9 99 0.5B 30 59B 85 86
104C II 32B 0.85RG 0.5RY 39A 3 I 125A 50A 20A 28A 52A 63A 124A 62A 131A 34A 88A 15A
ECU CONNECTOR 99 CN6-10 10 99 0.5B 31A 87 0.5B 20B
0 39B 0.5B 7 8
9 10 11 12 13 14 1 2 3 4 5 6 7 8 6A 1.25WR
I 5 0.5W 0.5W 85 86 0.5RG
0.85B 122B 0.85V 122A 6 II 54K 30A 20A 20A 15A 15A 15A 10A 10A 10A 10A 10A 10A 10A 10A
32C 32A FUEL HE
ATER
1.25WR
30C FUEL HE
ATER 1.25WR 2WR
0.85LR
0.85BY
12 17 18 35
36 53
OVER LOAD WARNING (OPT) 4bar
7 8 0.5WR RELAY SWITCH
4G
17 18 2E
4D
15
2B
16
11A
54M ALARM RELAY
7 11 54 71 SWING PRESS SW
ALARM SWITCH 5W 5W ACC C
1 6 72 89
0.5B 2.5B FUSE BOX 2 FUSE BOX 1 15R 98A B
OVER LOAD 5W 5W 13A
ONLY SWING (OP
T) FUEL HE
ATER
99 CN6-9 0.5B WARNING SWITCH B
4F 2D 4E 10A 6B BR 0.85Br
99 CN6-10 0.5B
ECU CON.1 (89-PIN) 1 0 0.5RG 0.5P 15 16 2WR 17 18 2C 2WR R2
2 140B 0.5BrY 57B 0.85RY 7A
VEHICLECONN.
0.5B 3 I 0.5RW 0.5RW HORN 1 10A 10A 10A 10A 10A 10A 10A 10A 30A 20A 20A 15A 15A 15A
H.F 0.85B HORN RELAY R1
0.5B 7 8 54P 0.5WR 0.5WR 0.5WR A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 STARTER SWITCH
87a
1.25RB
0.5WR
0.5RW
30 56B 0.85RB
0.5GB
0.5BG
0 56A 66A 30A 93A 166A 40A 130A 83A 42A 133A 143A 21A 19A
28D 0.85R CN5-4 140A 141A 3 I 2 21B 0.5RL 57C 0.85RY 0.85RY 57A 87 60B
+ HORN 2
0.85WR
0.85RB
0.85LB
0.85RL
0.85Y
II
0.85RG
0.5RW
PRESSURE SENSOR
0.5GBr
CN3-5 L.F
2RW
139B 0.85BrW 139A 85 86
1.25BrR
CN2-6 0.85B 56C 0.5RB
1.25RB
1.25RL
LCD DISPLAY PANEL 51D 0.5RG 0.5G 58A
SIG 0.5Br
2LR
(OWD) 0
WATER TEMPERATURE 145A 0.85W CN3-6 145B NOTE.2 141B CN2-4 0.5BrB (MANUAL) 0.5BrB 5 21L
- I 0.5RL 0.85LB 2WR
FUEL LEVEL 2WR
EPOS 22B CN2-5 0.5BrW (AUTO) 0.5BrW 22A 6 II
CONTROLLER 0.85RG 0.85RG
28G 0.85R 0.5B 7 8 54H 0.5WR
ECU CON.3 (16-PIN) ECU CON.2 ( PIN) GRAPHIC DISP LAY 0.5G 0.5GBr
WIF SENSOR 193A 0.85 CN3-19 193C
60R
CYLINDER CONN. ENGINECONN. 0.85Y 2RW
194A 0.85 CN3-20 194C HIGH SPEED SWITCH 0.85Br 27A
WARNING LAMP 10B CN2-1 0.5BG KEY SW ’S
T ART’ 0.5BG 0.5BG 0.5BG
89B CN1-15 START RELAY 2WR 2R
DIODE ARRAY CN3-15 90A +5V 0.5GB 0.5GB 0.5GB 0.5GB
(DX225DTC) Py 1.25BrR 8W 7B 2A 1B
104A CN2-15 0.85P 104B 0.85B AUTO IDLE (1
)
5 6 7 8 3 4 PRESSURE SENSOR(A) / TRAVEL SW 0.5RW 0.5RW 0.5RW FUSIBLE LINK
28E 0.85R, 90D 0.85GR(DX225DTC) 19bar
(FRONT PUMP
) + HOUR METER DIODE 2
21C CN1-1 0.85RL 0.5WR 0.5WR CIRCUIT BREAKER
74B 0.85GR CN3-1 74A 2R
SIG 6C
21D CN1-2 0.85RL 1.25RL 1.25RL 1.25RL 1.25RL 1 0.5WR
1 2 3 4 1 2 75A 0.85W CN3-2 75B 8A 1A
- 9D 3 B
9D CN2-14 0.5RW ALT ’I’ 0.5RW 0.5RW 0.5RW HOUR 2 0.5B 8W A
8W
DA1 ~ DA3 DA4 ~ DA6 28F 0.85R, 90E 0.85GR(DX225DTC) 185B CN5-1 0.5RW (FAN CONTROL) 0.5RW 185A NC 0.85RL ROOM LAMP 4B 3B
PRESSURE SENSOR(B) + 3A 60R
COM 40B 0.85Y
1.25BrW
15R
(REAR PUMP) 76B 0.85GY CN3-3 76A 99 CN1-8 0.85B 0.85YG 41A NO 1.25BrW 8C BR
SIG OFF 10W
77A 0.85WL CN3-4 77B 99 CN1-9 0.85B SOL-VALVE ASS’
Y 0.5B E DR B+ 0.5WR
- 0.85YG 41B PILOT CUT-OFF SWITCH 8B E
3 41C PILOT QUICK CLAMP(OPT) ON 83B 1.25B
80A CN7-4 0.5Y 0.5Y CN4-4 80B DA4-1
1 CUT OFF BATTERY RELAY
0.85B 99 0.5Br 0.85Br DIODE 1 MASTER SWITCH
81A CN7-5 0.5YB 0.5YB CN4-5 81B (C1) 1
CAN A ( `⁄)
0.85YL 0.85YL 61C 2 0.85LB
82A CN7-6 SHIELD SHIELD CN4-6 82B 84C 84B 2RW
4 61B (˙fi‚†) 3 60B 1 2 60B 60R
202A CN7-9 DA4-2 66B 9B
0.5Gr BREAKER 0.5Br 0.5Br
84A
DIODE 6
PREHEAT FUSE
AMP 040 12P
2 99
201A CN7-10 0.85B
0.5Or (C2) 0.85W 0.85W
AMP MIC 21P
SOL-VALVE QUICK CLAMP SW

0.85RL 0.85RL 21F 0.85BG 0.85BG 200A
CN7 CN6 3A 98B
6 21J HIGH 0.85B 0.5RW - + - +
AMP 040 12P+16P DA1-2
0.85BG
1.25BrR
INJECTOR
0.85RL
0.85W
0.5GBr
24C CN1-12 0.85Gr 0.85Gr SPEED 12V 100AH 12V 100AH
0.5G
0.5Br
24B 2 24A
2RW
SOLENOIDS 0.5WR AIRCON UNIT
CN4
(C3)
3-04 0.85RL 0.85RL 21E (920-00127A) DIODE 4
CN1
CYLINDER VEHICLE 0.5RW BATTERY

CYL.1 3-13 5 21H
CONN CONN DA1-1 RELIEF 1.25LR CN11-2 42C
LED 1~12 130C CN9-6
23C CN1-11 0.85GrW 23B 1 0.85GrW 23A PRESS UP
0.5LR CN10-8 42D 0.85W
(C4) 54E CN9-11 0.5WR
15W
3-05 0.85RL 150J CN10-18 46B 153B 4B
CYL.3 ILL 42B CN9-5 1.25LR AVX 8W
3-12 5 150K BREAKER AUXI MODE RESISTOR 0.5BW C B
DA1-3
AMP 070 18P
SELECT DIODE 9 AVX 1.25WG

0.85B 1 99 0.85YL 0.85GY (545-00011 ) RECEIVER DRIER
94A 93B 0.85LR
(C5) 0.85BrB 0.85RL AVX 2RW
3-11 61D 71A BLOWER A/C
0.85BrR 42E 46A
CYL.2 RELAY RELAY
3-06 18A 4A 9A
84D CN2-11 0.5Br (QUICK CLAMP) 0.5Br 154A D H P(R) B(B+) R(I)
CN2
168B CN8-10 CN10-16 168A 15L

0.85RL 0.5LG 0.85BG
3-01 100A
60B CN2-2 0.5BrW (POWER MAX) 0.5BrW A/C THERMOLOW)
( 105B CN9-8 0.5LB CN10-5 105A 100B
CYL.5 3-16 BREAKER SHEAR SELECT SW +
0.5RG CN4-3 137A GND 71B CN2-10 0.5GY (BREAKER) 0.5GY PREHEAT RELAY
106B CN8-11 0.5LY CN10-6 106A
0.5B FET
0.5GW CN4-2 136A RxD 150E CN2-8 0.5RL (1-WAY) 0.5RL PST SHEAR PRESS BREAKER COMPRESSO
R
SG
3-02 UP 1.25B CN11-1 99 - +
0.5GL CN4-1 135A TxD 151C CN2-9 0.5RY (2-WAY) 0.5RY M
CYL.6 3-15 201C TML 1 0 2
1-62 RS-232 99
0.85RL 9 107B CN8-12 0.5LW CN10-1 107A BLOWER MAGNET
202C 1-65 47A 0.85LW
0.5WR 54J CN11-4 47C CLUTCH
0.85BG
1.25BrR
(CONN.3)
0.85W
10 R
0.5GBr
3-03 CHECK 1
0.5G
0.5Br
2RW
101A CN1-10 0.85Or 101B 0.85RY 151A 108A CN9-13 0.5GrG CN10-2 108B FRE (P1) 47B -
CONN 5 3 INTAKE 15B F
CYL.4 3-14 ENGINE 80C 1-35 CAN BH 0.5Y 0.85LgR P/V-(A)
0.5GL 135B 94B 2 0.85BrR 133G 109A CN9-12 0.5GrY CN10-20 109B REC (P2) ACTUATOR E
CONN
DIODE 4
1 95A 95B 14 M
81C 1-34 CAN BL 0.5YB
0.5GW 136B 102B CN1-21 0.85OrB 102A 3 0.85BrR 133H
SHIELD 2 6 0.85LgW 13 AIR HEATER E
FUEL HIGH PRESSURE 3-09 0.5RG 137B 0.85RL 150A 110A CN9-15 0.5OrR CN10-12 110B DEF (P1) 0.85B 0.85B 99 ALTERNATOR 60 A
3 0.85B 4 11
PUMP 96B 96A PUMP 111A CN9-14 0.5OrW CN10-13 111B VENT (P2) 8B
3-10 80D 1-53 CAN AH 0.5Y 0.5Y 80E M
4 PROPORTIONAL V/V 6 MODE ALTERNATOR 80A(OPTION )
BOOST PRESSURE 3-07 1-52 81E AUXILIARY MODE W
S 0.5BrW 60A 43A CN9-16 0.5YB CN10-11 43B Vref MODE
81D CAN AL 0.5YB 0.5YB ACTUATOR
ACTUATOR(EPW) 5 16
3-08 44A CN9-17 0.5YW CN10-10 44B MODE F/BACK
SHIELD SHIELD 82E 0.85BrL 134B
6 15
3 2-32 61A 99 CN9-10 1.25B TERMINAL NO
0.85YL
OIL PRESSURE P& 4 2-27
7 12
SENSOR
(ODF T)
t 1 2-24
8 JOYSTICK EVER
L SWI
TCH 112A CN9-1 0.5LgW CN10-19 112B WARM (P1)
9 AMP MIC 13P AMP 070 18P AMP MIC 21P
2 2-28 113A CN9-18 0.5LgB CN10-3 113B COOL (P2)
V 10 99 6 3 58B 0.5G
M 1 2 3 4 5 6 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
0.5B 114A CN9-3 0.5YR CN10-7 114B Vref MIX
3 165A 1-89 0.5BW 0.5BW 165B ROTATING S/V (OP T) MIX
2-33 11 (HORN) (C) ACTUATOR
BOOST PRESSURE P& 4 2-34
E/G EMERGENCY STOP SW
0.5GBr 166B
115A CN9-4 0.5YW CN10-9 115B MIX F/BACK 7 8 9 10 11 12 13 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
SENSOR 12 181A CN1-7 0.85GrL 181B CCW 146C 146B 1 0.85OrB 0.85OrB 146A 4 1 133B 0.85BrR
(LDF 6T)
t 1 2-25 3 0.5B 99 167C CN9-2 1.25BL CN10-4 167A GND (CN12) WIPER CONT. (CN2) (CN1)
13 COOLINGFAN SPEED 3 (ROTATING-CCW) (L)
163A 1-29 0.5R 163B 2 2 164A 192B (A) DA5-1
2
0.85BG
2-36 182B 0.85GrR 182A PROPO RTIONAL V/ V 116A CN8-2 0.5OrB CN10-15 116B AMP 040 28P AMP 070 16P AMP 040 12P AMP 040 20P
0.85W
V 14 CN1-18 1 0.85OrR 147A 5 2 133C 0.85BrR
0.5GBr
DUCT
0.5Br
2RW
164B 1-87 0.5BL
FUEL (ROTATING-CW) SENSOR
1 2-35 CN15 78A CN1-19 0.85Lg 78B (R)
TEMPERATURE 0.5B 147C 147B 2 0.85OrR 8 7 6 5 4 3 2 1
t P/V-(C) (OPTION) CW (ON JOYSTICK L.H)
6 5 4 3 2 1 8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
0.85BrR
SENSOR 2 2-26 CN4-7 192A 45A CN8-1 CN10-14 45B
V 0.5GBr FLOW CONTROL 4 0.5LgR WATER
12 11 10 9 8 7 16 15 14 13 12 11 10 9 12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11
79B CN1-20 0.85LgB 79A (B) DA5-2 16 15 14 13 12 11 10 9
178B 1-56 0.5LW (PREHEAT LAMP) CN5-2 178A PROPO RTIONAL V/ V
0.85B PEDAL SWITCH (OPTION) SENSOR
2 3
0.85BrL 134C 133J 0.85BrR 2 (CN7) (CN6) (CN5) (CN4) (CN3)
COOLANT 2 99 Px
1-10 0.85B
TEMPERATURE t 72B 0.85YR CN3-7 72A 103A CN2-16 0.85V 103B 0.85B AUTO IDLE (2) S W 48A CN8-5 0.5LY CN10-17 48B 1 INCAR AMP 040-III 20P
1
AMP 040 20P
2-15 99 FUEL SENSOR

SENSOR V 1-11 0.85B 2B
73B 0.85BR CN3-8 73A 19bar SHEAR S/V (OP
T) - E3C
SUNLOAD SENSO
R
SENSOR KET D/L 4P AMP 070 18P AMP 070 12P
99 1-05 0.85B DA6-1 1 0.85OrY
2 1 8 7 6 5 4 3 2 1 5 4 3 2 1
1 2-23 67A CN2-17 0.85BW 67B 0.85B INDICATOR
9 8 7 6 5 4 3 2 1
INCREMENT SPEED SENSOR 99 0.85BrL 134A 6 3 133D 0.85BrR CN10 AMP 20P CN11 KET 4P
(CRANKSHAFT)(DG6)(VR)#1
N 2 2-19
1-06 0.85B 2B
(CLOSE)
148C 148B 1 5 71C 4 0.85GY 142A CN8-3 0.5Lg 2 - + 1 4 3
20 19 18 17 16 15 14 13 12 11 10
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
26B 0.85LgR CN3-9 26A (BREAKER/POWER M AX) (C)
(TONE WHEEL WITH S LOTS) 2B OIL TEMP SENSOR 7 148D 142B 0.5YR
V (CN11) (CN9) (CN8)
CN3
27B 0.85LgW CN3-10 27A 68A CN2-18 0.85BG 68B 0.85B PILOT FILTER SW 71D 0.85OrY 148A 4 1 133E 0.85BrR (CN10)
AMP 070 16P
114C 0.85BL 167B 2

3 DA6-3 6 AMBIENT TEMP
(SHEAR-CLOSE) (L) 49A CN8-4 0.85YG 0.85YG 49B 1 SENSOR
2 2-09 (426-00263 ) 2
SEGMENT SPEED SENSOR
(CAMSHAFT)(DG6)(VR)#2
N 1 2-10 ENGCONTROL DIAL 69A CN5-3 0.85RB 69B 0.85B 149C 149B DA6-2 2 0.85Or 0.85Or 149A 5 2 133F 0.85BrR CN8 CN9
RETURN FILTER SW (OPEN)
(TONE WHEEL WITH S LOTS) 1.5bar 8 (SHEAR-OPEN) AMP 12P + 18P
V LOW CW 1 90B 0.5GR CN3-15 90A +(5V) DA6-4 149D (R)
CN5
2 91B 0.5G CN3-16 91A SIG 70A CN5-7 0.85GB 70B 0.85B PEDAL BRAEKER 4 3 0.85B JOYSTICK L EVER SWITCH A/C CONTROL PANEL
3 19B 1-08 0.85RW PRESSURE SW (OPTION) (420-00468 )
2-13
RAIL PRESSURE SENSO R P 19C 3 92A 0.5GB CN3-17 92B GND (ON JOYSTICK R.H)
2 2-14 1-09 0.85RW 2RW
HIGH
(RGS3) 19D 0.5GBr 0.5GBr 0.5GBr
V 1 2-12 1-02 0.85RW
19E 1-03 0.85RW 2RW 2RW 2RW 2RW
7C 1-40 0.5Br (KEY SW) 0.5Br 0.5Br 0.5Br
153A 1-13 0.85W (AIR HEATER RELAY) 0.85W 0.85W 0.85W
154B 1-07 0.85BG (AIR HEATER RELAY) 0.85BG 0.85BG 0.85BG
(CONN.2) (CONN.1)
FG017142
Figure 1

7
1Attachments
SP001331
BOOM AND ARM SP001331
Boom and Arm
Edition 2
Boom and Arm SP001331

Page 1
MEMO

Page 2
Table of Contents
Boom and Arm

Front Attachment Pin Specifications..................... 6
One-Piece Boom ............................................................. 6
Two-Piece Boom ............................................................. 7
Front Attachment - Removal and Installation........ 8
Arm Removal Procedure ................................................. 9
Boom Removal Procedure ............................................ 11
Installation .......................................................... 12
Arm Installation Procedure ............................................ 12
Boom Installation Procedure ......................................... 12

Page 3
MEMO

Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up

Page 5
FRONT ATTACHMENT PIN
SPECIFICATIONS
The table below has a complete listing of dimensional
specifications for all mounting pins used on the front attachment.
NOTE: Some mounting pins must be drilled and tapped for
lubrication fittings and piping, or may have other
required specifications. Consult DOOSAN After Sales
Service for information on wear tolerances and
replacement limits for mounting pins.
One-Piece Boom
A C E
D F
B K J I H
FG009704
Figure 1
Mounting Pin Diameter, mm (Inches) Length, mm (Inches)

A 71 mm (2.80 in) 678 mm (26.69 in)
B 71 mm (2.80 in) 207 mm (8.15 in)
C 71 mm (2.80 in) 670 mm (26.38 in)
D 71 mm (2.80 in) 429 mm (16.89 in)
E 71 mm (2.80 in) 217 mm (8.54 in)
F 71 mm (2.80 in) 217 mm (8.54 in)
G 65 mm (2.56 in) 203 mm (7.99 in)
H 65 mm (2.56 in) 384 mm (15.12 in)
I 65 mm (2.56 in) 441 mm (17.36 in)
J 65 mm (2.56 in) 384 mm (15.12 in)
K 65 mm (2.56 in) 441 mm (17.36 in)

Page 6
Two-Piece Boom
A D C E G F H
B M J L I FG009801
Figure 2
Mounting Pin Diameter, mm (Inches) Length, mm (Inches)

A 71 mm (2.80 in) 678 mm (26.69 in)
B 71 mm (2.80 in) 207 mm (8.15 in)
C 71 mm (2.80 in) 670 mm (26.38 in)
D 71 mm (2.80 in) 429 mm (16.89 in)
E 71 mm (2.80 in) 217 mm (8.54 in)
F 71 mm (2.80 in) 217 mm (8.54 in)
G 65 mm (2.56 in) 203 mm (7.99 in)
H 65 mm (2.56 in) 384 mm (15.12 in)
I 65 mm (2.56 in) 441 mm (17.36 in)
J 65 mm (2.56 in) 384 mm (15.12 in)
K 65 mm (2.56 in) 441 mm (17.36 in)
L 65 mm (2.56 in) 384 mm (15.12 in)
M 65 mm (2.56 in) 441 mm (17.36 in)

Page 7
FRONT ATTACHMENT -
REMOVAL AND INSTALLATION
DANGER
AVOID DEATH
DOOSAN warns any user, that the removal of the
counterweight from the machine, front attachment or any
other part, may affect the stability of the machine. This
could cause unexpected movement, resulting in death or
serious injuries. DOOSAN is not liable for any misuse.
Never remove the counterweight or front attachment unless
the upper structure is in-line with the lower structure.
front attachment has been removed. FG000371
Figure 3
IMPORTANT
Always break down the front attachment by removing
outermost sections first - the bucket before the arm, the
arm before the boom. Reinstallation of the attachment must
begin with the boom and end with the bucket.
Refer to the appropriate Bucket section for its removal and

installation procedure before going onto the initial step of the
front attachment removal or installation procedure.

Page 8
Arm Removal Procedure
WARNING
This procedure is only intended for routine removal or
replacement of the attachment, while working under
normal, safe operating conditions. In the event of a major
structural collapse of some part of the attachment, an
accident or complete loss of attachment hydraulic function,
DO NOT proceed with attachment disassembly unless you
are completely sure of what you are doing. Please call your
local DOOSAN distributor or DOOSAN After Sales Service
for assistance. DO NOT allow personnel to stand
underneath a weakened or only partially supported
attachment section. Keep clear of hydraulic lines that may
have fluid escaping at high-pressure - it can cause severe
or even fatal injuries.
Complete the bucket end removal procedure by pulling out the

two bucket linkage pins and the bucket cylinder mounting pin, on
the arm. Use an assist crane or hoist to lift the cylinder and
relieve weight on mounting pins.
Park the excavator away from obstructions and all traffic on
clear, flat, level ground. Extend the arm cylinder and crowd the
arm into the boom. Partially retract the boom cylinder so that the
boom is stretched out in front of the excavator, as low to the
ground as possible, with the arm crowded under the boom.
The tip of the arm point must be lowered to secure blocking that
will safely support the weight of the arm. Place the blocking
directly in front of the excavator and make sure that it will not be
unbalanced with an initial weight load that is all to one end,
under the arm point.
Shut off the engine and release hydraulic system pressure -
move any of the control levers with the engine off to release
pressure built up in the accumulator. Manually vent residual
hydraulic pressure in the tank by moving the lever near the cap,
on top of the reservoir.

Page 9
WARNING
Secure the swing lock and tag and lock out controls in the
operator's cabin to keep anyone from moving or
inadvertently starting the engine. Restrict access to the
work site while sections of the attachment are in the air, or
while they are being supported by the assist crane. The safe
lifting capacity of the assist crane or hoist that is used must
exceed the weight of the heaviest section of the attachment,
the boom (approximately 756 kg [1,667 lb], not including the
weight of accessories or fixtures).
Before beginning the disassembly of attachment mounting pins,

disconnect the arm cylinder hydraulic hose couplings and put a
clean plug in the end of each one. Use any and all reasonable
precautions necessary to avoid introducing dirt or other
contaminants into the hydraulic system. Wipe down coupling
points before disconnecting hydraulic lines and use evaporative
type solvent spray cleaner. Tag and mark hoses for reassembly,
if necessary.
Place a sling under the arm cylinder (the cylinder used to extend
and retract the attachment arm, pinned to the top of the boom).
Lift the sling so that the weight load on the rod end of the arm
cylinder (pinned to the ears on the inner end of the arm) is
released. Prepare blocking under the arm that will securely
support the weight of the arm and arm cylinder.
CAUTION
AVOID INJURY
To make sure that the polished surfaces of cylinder rod
ends will not suffer accidental damage during disassembly
or removal procedures, wrap exposed rod surfaces
(especially those of boom cylinders) with a protective
covering material. Immediately following disassembly and
removal, cylinder rods should always be fully retracted.
This eases handling problems and also avoids possible
damage.
Remove retainers on the end of the mounting pin for the arm
cylinder rod end. Use the assist crane to relieve the weight load
and withdraw the pin. Lower the arm down to the blocking
support for any continued disassembly procedures.

Page 10
Boom Removal Procedure
NOTE: Boom removal may be simplified if the shell of the
operator's cabin is taken off the turntable deck first.
Refer to the Operator's Cabin Removal procedure
before continuing, if both components are to be
removed from the excavator.
After the bucket, arm and arm cylinder have been removed,
lower the end of the boom to a stable, secure blocking support.
Attach the assist crane sling to the body of either boom cylinder,
break the mounting pin connection to the boom by tapping
through the pin from the same side of the boom and repeat for
the opposite cylinder.
Release hydraulic pressure and disconnect line couplings as
previously outlined in the Arm Removal Procedure, observing
the same precautions.
Disconnect wiring for work light assemblies and any other
accessory lines or connections. Locate the sling of the assist
crane near the center of gravity, optimum lift point for the boom,
and use the crane to take pressure off the boom foot pin. Drive
out the pin after disassembling retainers and carefully lift away
the boom.
WARNING
Traveling the excavator, swinging the turntable or
movement over bumps or sloping, uneven surfaces could
all produce loss of control and possible accidents or
injuries, if the turntable deck has been unbalanced by
removal of weight from one end only.
To maintain stability, the counterweight must be removed

whenever the front attachment is taken off the machine.

Page 11
INSTALLATION
Arm Installation Procedure

Reattach the base of the arm cylinder to the mounting point on
top of the boom.
WARNING
Before assembling the front attachment, make sure that the
individual boom, arm and bucket sections are all
compatible and can be used safely for work intended. Refer
to the General Safety Pages, Lift Ratings, Working Range
Diagrams and Weights of Materials sections in the
Operation and Maintenance Manual. Consult your dealer or
DOOSAN After Sales Service for more information if you
have any questions or require more information.
Begin with the arm securely supported on blocking in front of the

excavator. Pregrease the mounting pin for the rod end of the
arm cylinder and push it through the ears on the end of the arm.
Attach a sling around that mounting pin and lift the arm with an
assist crane until it is in position for the boom-arm pin
connection to be made.
Relieve hydraulic pressure from all points of the system before
any hydraulic lines are opened, then carefully assemble
hydraulic connections to the arm cylinder.
Remove the sling from around the rod end arm cylinder pin,
withdraw the pin and lift the body of the arm cylinder to re-pin the
mounting connection.
Boom Installation Procedure

Before reassembling the attachment, make sure to inspect all
bushings and pivot points of each section. To avoid damaging
the seats, bushings should never be hammered or chiseled out
of their seats.
Installation is otherwise a reversal of the removal procedures.
START-UP PROCEDURES
Once the boom has been serviced, it must be lubricated as
outlined in the initial start-up procedures of the operation
manual. Refer to the appropriate operation and maintenance
manual for unit.

Page 12
SP000939
BUCKET SP000939
1Bucket
Edition 2
Bucket SP000939
Page 1
MEMO
Bucket SP000939
Page 2
Table of Contents
Bucket
Bucket Tooth Inspection and Replacement .......... 6
Bucket O-ring Replacement ................................. 7
Bucket Attachment, Removal and Reversal ......... 9
Detaching the Bucket ...................................................... 9
Attaching the Bucket ..................................................... 10
Reversing the Bucket .................................................... 10
Bucket SP000939
Page 3
MEMO
Bucket SP000939
Page 4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
APPLICABLE MODELS

DX138LC 6407 and Up
DX140LC 5001 and Up
DX225LC 5434 and Up
DX255LC 5001 and Up
Bucket SP000939
Page 5
BUCKET TOOTH INSPECTION
AND REPLACEMENT
There are several different types of attachment methods for
replaceable bucket teeth. Some of the most common types are
shown in the following drawings.
Bucket teeth are usually replaced in sets but it may sometimes
be necessary to replace individual teeth.
Look for the following indications of wear or damage:
• Lock pins protrude unevenly on one side.
• Lock pins have been worn down so far that they no longer
make full contact through the length of the pin hole.
• Lock washers or pins show obvious damage or weakness.
• Wear points on the working surfaces of tooth points - pits,
cracks, chips or craters - are larger than 8 mm to 10 mm
(1/3" to 1/2") across.
HAOC680L
Figure 1
1. On a routine basis, inspect the bucket teeth to make sure

that tooth wear or breakage has not developed. Do not
allow the replaceable bucket teeth to wear down to the
point that the bucket adapter is exposed. See Figure 1.
2. To replace a tooth (1, Figure 2), use a hammer and punch
to drive the locking pin (2) and lock washer (3) out of the
tooth adapter (4). 4
3. Once the worn tooth has been removed, use a putty knife 3
to scrape the adapter as clean as possible.
4. Slide the new tooth into position and insert the lock 2 1 FG000346
washer. Figure 2
5. Insert the locking pin into the tooth and with a hammer,
drive the pin in until the lock washer seats in the locking
groove.
Bucket SP000939
Page 6
BUCKET O-RING
REPLACEMENT
WARNING
Due to possibility of flying metal objects, always wear
safety helmet, protective gloves and eye protection when
changing pins.
1. Inspect the bucket O-rings on a routine basis. If worn or

damaged, replacement is necessary.
FG007780
Figure 3
2. Roll the old O-ring (1, Figure 4) onto the boss (2) around
the bucket pin (3). Remove the bucket pin and move the 1 4
arm or bucket link (4) out of the way. 2
ARO1390L
Figure 4
3. Remove the old O-ring and temporarily install the new O-

ring (1, Figure 5) onto the bucket boss (2). Make sure that 1 4
the O-ring groove on both the bucket link (4) and boss 2
have been cleaned.
4. Realign the arm or link with the bucket pin hole and insert
the bucket pin (3, Figure 4).
ARO1391L
Figure 5
Bucket SP000939
Page 7
5. Roll the new O-ring (1, Figure 6) into the O-ring groove.
ARO1392L
Figure 6
Bucket SP000939
Page 8
BUCKET ATTACHMENT,
REMOVAL AND REVERSAL
Detaching the Bucket

Park the excavator away from obstructions on clear, flat, level
ground. Lower the bucket carefully to preassembled blocking on
the ground. Brace the bucket so that there is no load weight on
the pin connecting the bucket and arm. Disassemble the
fasteners on the end of the bucket pin and pull out the pin.
If the pin sticks and resists normal withdrawal, there may be a
load on it. Raise and lower the arm slightly until an unstressed
pin position is located.
CAUTION
AVOID INJURY
Use care pulling out the pin to avoid damaging the dust
seals on either end of the arm.
When the pin has been withdrawn, move the operating joystick
slightly to take weight off the remaining link pin. Disassemble the
link pin end retainers and pull out the pin.
Lift the arm away from the bucket so that the bucket can be
carried away or another end attachment can be put on the
excavator.
Bucket SP000939
Page 9
Attaching the Bucket
Carefully inspect all parts before reassembling the bucket
linkage. Look for cracks or any other evidence of physical
damage and replace any seal or O-ring that is not in like-new
condition. Prelube linkage pins before reassembly.
Use an old cylinder rod, a long breaker bar or a similar, relatively
thin diameter support bar for making the first (temporary) pin
connection, between the bucket and arm. If the support bar is
straight, the arm can be raised and the bucket will hang level,
allowing direct insertion of the bucket ear-attachment linkage FG000606
pin. Figure 7
When the link pin has been installed, withdraw the temporary
support rod from the bucket pin holes, lower and raise the arm
and boom and install the bucket pin.
WARNING
When making linkage alignments, never insert fingers into
pin holes. The attachment or bucket could shift position
FG000607
and cause a severe injury. Match holes by visually lining
them up. Use the sharp-tipped, soft point of a pencil or a Figure 8
similar tool to check for high spots or irregularities.
Reversing the Bucket

Follow instructions for "Detaching the Bucket" and remove both
the bucket and link pins. Rotate the bucket 180° to change
bucket configuration. This procedure is greatly simplified if some
type of rotating or swiveling support can be used, on the ground
underneath the bucket. Follow instructions for "Bucket
Attachment" to replace pins.
WARNING
Bucket curl and dump levers must be used in opposite
directions, after the bucket has been reversed.
Bucket SP000939
Page 10

Manual de Reparacion Dx140lc

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DX138LC

K1027955B Shop Manual

Lower Structure and Chassis

Engine and Drive Train

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