En SM DX210W K1017314a 1005
En SM DX210W K1017314a 1005
En SM DX210W K1017314a 1005
DX210W
Serial Number 5766 and Up
Shop
Manual
K1017314AE-1
WARNING
CALIFORNIA PROPOSITION 65
WARNING
Diesel engine exhaust and some of its constituents are
known to the state of California to cause cancer, birth
defects and other reproductive harm.
WARNING
CALIFORNIA PROPOSITION 65
WARNING
Battery posts, terminals and related accessories contain
lead and lead compounds, chemicals known to the State
of California to cause cancer and birth defects or other
reproductive harm. WASH HANDS AFTER HANDLING.
05-2010
DX210W
Shop Manual
K1017314AE-1
Serial Number 5766 and Up
DOOSAN reserves the right to improve our products in a continuing process to provide the best possible
product to the marketplace. 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.
Instructions
Specifications
Specification for DX210W ................................................................... SP000957
General Maintenance
General Maintenance Procedures ...................................................... SP000016
Standard Torques ................................................................................ SP000813
Upper Structure
Cabin (NON-ROPS)............................................................................. SP002194
Cabin (ROPS) ...................................................................................... SP002191
Counterweight....................................................................................... SP002207
Fuel Tank ............................................................................................. SP002208
Fuel Transfer Pump ............................................................................ SP000021
Swing Bearing...................................................................................... SP001869
Swing Reduction Gear ........................................................................ SP002204
Table of Contents
Page I
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ........... SP002227
Accumulator.......................................................................................... SP000984
Center Joint (Swivel) ........................................................................... SP000919
Cylinders............................................................................................... SP001098
Main Control Valve.............................................................................. SP000966
Swing Motor ......................................................................................... SP000985
Travel Motor......................................................................................... SP001110
Counterbalance Valve.......................................................................... SP000991
Main Pump & PTO ............................................................................. SP000988
Gear Pump........................................................................................... SP000989
Service Brake Supply Valve ............................................................... SP000990
Dozer Control Valve ............................................................................ SP000992
Steering Valve...................................................................................... SP000993
Accelerator Pedal Valve (Hydraulic)................................................... SP000964
One Spool Valve ................................................................................. SP000996
Remote Control Valve (Work Lever / Joystick) ................................ SP000069
Breaker EPPR Valve (Opt)................................................................. SP000192
Service Brake Pedal Valve................................................................. SP001006
Solenoid Valve Assembly.................................................................... SP000997
Hydraulic Schematic ............................................................................ SP001107
Electrical System
Electrical System (NON-ROPS).......................................................... SP002209
Electrical System (ROPS) ................................................................... SP002210
Electrical Schematic DX140W/160W/170W/190W/210W................... SP002201
Attachments
Boom and Arm .................................................................................... SP001255
Bucket................................................................................................... SP001001
Table of Contents
Page II
1Safety
SP002195
WHEEL EXCAVATOR SAFETYSP002195
Wheel
Excavator
Safety
Edition 1
Safety Precautions............................................... 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 ...................................... 21
Machine Operation ............................................ 24
Maintenance ....................................................... 33
Battery ................................................................ 42
Towing ................................................................ 44
Shipping and Transportation ............................. 45
Lifting with Sling ................................................ 45
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling the load.
Remember, that ultimately safety is your own
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
DANGER
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.
CAUTION
This word is used on safety messages and safety labels
and indicates potential threat 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
This word is used on safety messages and safety labels
and 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
This word is used on safety messages and safety labels
and 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.
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.
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 the other instructions, guidelines and
restrictions for Safe Lifting in the Operation and
Maintenance Manuals.
DANGER
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.
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.
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.
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 may 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.
FG007146
Figure 2
HAOA060L
Figure 5
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.
Accumulator
The pilot and brake control system are 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, and emergency brake is
applied during pressing service brake pedal.
When performing maintenance on the pilot and brake 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.
Emergency Exit
This machine 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 the breaking of glass to exit from the operator's
cabin. Grip the handle firmly and use the sharp point to
break the glass.
WARNING FG000178
Figure 12
Protect your eyes when breaking the glass.
WARNING FG015808
Figure 13
Protect your eyes when breaking the glass.
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.
FG007148
Figure 15
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.
traveling.
Incorrect
Do not change selected travel mode (HIGH/ECONO/LOW/
CREEP) while traveling.
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.
Never travel over obstacles or slopes that will cause the
machine to tilt severely. Travel around any slope or obstacle FG008635
that causes the machine to tilt 10 degrees or more to the Figure 18
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 sudden changes in direction.
Always keep to the permissible water depth. Permissible
water depth is to the centerline of the axles.
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.
FG006114
Figure 19
FG007135
Figure 20
WARNING
Never modify the operator 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
result in serious injury or death.
FG000175
FG000112
Figure 26
Operations on Slopes
When working on slopes. there is a danger that 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 FG009194
make a platform that will keep the machine as horizontal as Figure 28
possible.
In addition, lower the bucket as far as possible, keep it pulled
into the front, and keep the swing speed as low as possible.
ARO1310L
Figure 30
Warning Tag
Alert others that service or maintenance is being performed WARNING
and tag operator's cabin controls – and other machine areas
if required – with a warning notice. OSHA mandated control
lever lockout can be made with any OSHA certified lockout
DO NOT OPERATE
device and a length of chain or cable to keep the safety when performing inspection
lever in the fully lowered, nonactive position.
or maintenance
Warning tags, for controls are available from DOOSAN
190-00695A
distributors.
FG012202
Figure 31
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 HDO1040L
danger that battery gas may catch fire and cause an
Figure 34
explosion.
CAUTION
When you connect or disconnect connectors between
ECU and Engine or connector between ECU and the
machine, always disconnect the source power to protect
damage of the ECU.
If you don't observe this procedure, the ECU would be
damaged or the engine would operate abnormally.
FG000335
Figure 38
DANGER
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 upper structure is in-line with the lower structure.
Never rotate the upper structure once the counterweight
or front attachment has been removed.
FG007095
Figure 39
WARNING
Improper lifting can allow load to shift and cause injury
or damage.
Specification
for DX210W
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 7
Component Locations .......................................... 8
General Dimensions .......................................... 10
Working Range .................................................. 12
Front Pin size .................................................... 15
Hydraulic Cylinders ............................................ 17
General Specifications ....................................... 18
Hydraulic System Component Specifications... 19
System Component Specifications ................... 20
Engine Performance Curves
(Per DIN 6270 Standard) ................................. 22
Approximate Weight of Workload Materials .... 24
Performance Tests and Standards .................. 26
Excavator Performance Standards ................... 27
Test Conditions............................................................. 27
Travel Speed Tests...................................................... 27
Swing Speed and Deceleration Force Test ............... 29
Cylinder Performance Tests ........................................ 30
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 41 22 17
38
37
36
35
33 24
23
18
34 32 30 31 29 28 27 26 39 40 25 21 20 19
FG008677
Figure 1
A
E
I
D
C
H
G
F
L J K
B
FG008161
Figure 2
Dimension
5.6 m (18' 4") One-Piece Boom
No. Description
3.0 m (9' 10") 2.4 m (7' 10")
2.75 m (9') Arm 2.0 m (6' 7") Arm
Arm Arm
A Shipping Length 9,400 mm 30' 10" 9,420 mm 30' 11" 9,470 mm 31' 8" 9,520 mm 31' 3"
B Shipping Width 2,500 mm 8' 2" 2,500 mm 8' 2" 2,500 mm 8' 2" 2,500 mm 8' 2"
Shipping Height
C 3,490 mm 11' 5" 3,200 mm 10' 6" 3,200 mm 10' 6" 3,250 mm 10' 8"
(Boom)
D Height Over Cab 3,140 mm 10' 4" 3,140 mm 10' 4" 3,140 mm 10' 4" 3,140 mm 10' 4"
Counter Weight
E 2,750 mm 9' 2,750 mm 9' 2,750 mm 9' 2,750 mm 9'
Swing Clearance
F Ground Clearance 1' 2" 1' 2" 1' 2" 1' 2"
350 mm 350 mm 350 mm 350 mm
G Frame Clearance 1,259 mm 4' 2" 1,259 mm 4' 2" 1,259 mm 4' 2" 1,259 mm 4' 2"
Engine Cover
H 2,485 mm 8' 2" 2,485 mm 8' 2" 2,485 mm 8' 2" 2,485 mm 8' 2"
Height
Upper Housing
I 2,530 mm 8' 4" 2,530 mm 8' 4" 2,530 mm 8' 4" 2,530 mm 8' 4"
Width
J Wheel Base 2,850 mm 9' 4" 2,850 mm 9' 4" 2,850 mm 9' 4" 2,850 mm 9' 4"
K,L Tread Width 1,914 mm 6' 3" 1,914 mm 6' 3" 1,914 mm 6' 3" 1,914 mm 6' 3"
I E
C
H
G
J
L
B
FG008162
Figure 3
Dimension
No. Description 5.4 m (17' 9") Two-Piece Boom
2.4 m (7' 10") Arm 2.0 m (6' 7") Arm
A Shipping Length 9,210 mm 30' 3" 9,275 mm 30' 5"
B Shipping Width 2,500 mm 8' 2" 2,500 mm 8' 2"
Shipping Height
C 3,140 mm 10' 4" 3,140 mm 10' 4"
(Boom)
D Height Over Cab 3,140 mm 10' 4" 3,140 mm 10' 4"
Counter Weight Swing
E 2,750 mm 9' 2,750 mm 9'
Clearance
F Ground Clearance 350 mm 1' 2" 350 mm 1' 2"
G Frame Clearance 1,259 mm 4' 2" 1,259 mm 4' 2"
H Engine Cover Height 2,485 mm 8' 2" 2,485 mm 8' 2"
I Upper Housing Width 2,530 mm 8' 4" 2,530 mm 8' 4"
J Wheel Base 2,850 mm 9' 4" 2,850 mm 9' 4"
K,L Tread Width 1,914 mm 6' 3" 1,914 mm 6' 3"
WARNING
The actual value for "Digging Reach," depends on the
stability and support provided by ground conditions.
Digging too far underneath the excavator if soil
conditions are wet, loose or unstable can collapse
ground support, which could cause injury and/or
equipment damage.
C
D
B
A FG008672
Figure 4
Dimension
5.6 m (18' 4") One-Piece Boom
No. Description
2.4 m (7' 10") 2.0 m (6' 7")
3.0 m (9' 10") Arm 2.75 m (9') Arm
Arm Arm
A Max. Digging Reach 10,000 mm (32' 10") 9,730 mm (31' 11") 9,430 mm (30' 11") 9,050 mm (29' 8")
B Max. Digging Depth 6,255 mm (20' 6") 6,010 mm (19' 9") 5,655 mm (18' 7") 5,255 mm (17' 3")
C Max. Digging Height 10,050 mm (32' 12") 9,800 mm (32' 2") 9,690 mm (31' 9") 9,435 mm (30' 11")
D Max. Loading Height 7,250 mm (23' 9") 7,020 mm (23' 0") 6,890 mm (22' 7") 6,650 mm (21' 10")
E Min. Swing Radius 3,440 mm (11' 3") 3,375 mm (11' 1") 3,390 mm (11' 1") 3,680 mm (12' 1")
C
D
A
FG008673
Figure 5
Dimension
No. Description 5.4 m (17' 9") Two-Piece Boom
2.4 m (7' 10") Arm 2.0 m (6' 7") Arm
A Max. Digging Reach 9,405 mm (30' 10") 9,005 mm (29' 6")
B Max. Digging Depth 5,625 mm (18' 5") 5,225 mm (17' 2")
C Max. Digging Height 10,560 mm (34' 8") 10,210 mm (33' 6")
D Max. Loading Height 7,620 mm (24' 12") 7,275 mm (23' 10")
E Min. Swing Radius 3,185 mm (10' 5") 3,380 mm (11' 1")
A C E D F
B K H J G
FG009222
Figure 6
A D C E G F H
B M J L I
FG009246
Figure 7
Pilot Accumulator
PilotNitrogen Charge: 15 kg/cm2 (213 psi)
Volume: 320 cc (19.5 in3)
Brake Accumulator
Nitrogen Charge: 30 kg/cm2 (427 psi)
Volume: 750 cc (45.8 in3)
STEERING SYSTEM
Steering Cylinder (Built-in Front Axle)
Bore Size 100.0 mm (3.94 in)
Rod Diameter 50.0 mm (1.97 in)
Stroke 86.0 mm (3.39 in)
Maximum Pressure 180.0 kg/cm2 (2,560 psi)
CHOCKING SYSTEM
Chocking Valve
Maximum Working Pressure 400 kg/cm2 (5,689 psi)
Check Valve Cracking Pressure 2.0 kg/cm2 (28.4 psi)
Make-up Pressure
3.0 kg/cm2 (42.7 psi)
Oscillating Angle ± 8°
80
TORQUE (kg.m)
70
60
150
POWER OUTPUT (ps)
100
150
140
REVOLUTION (rpm)
FG007171
Figure 8
Test Conditions
1. All tests should be performed on a flat, level, firm
supporting ground surface.
2. All recommended, applicable maintenance and
adjustment service should be completed before testing.
3. Hydraulic fluid and engine oil should be of appropriate
viscosity for ambient weather conditions. Warm up
hydraulic oil to standard operating temperature,
between 45° - 55°C (112° - 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 FG007172
Power Mode (high speed mode). Travel speed tests Figure 9
should also be repeated at both high and low speed.
3
4
FG007173
Figure 10
1 Travel Motor
2 Transmission
3 Propeller Shaft
4 Front Axle
5 Swivel Joint
1.5 m
FG007174
Figure 11
Measurement in Seconds
Operation Power Mode Standard Mode
One-Piece Boom Up 3.2 ± 0.4 3.6 ± 0.4
One-Piece Boom Down 2.1 ± 0.4 2.2 ± 0.4
Two-Piece Boom Up 5.8 ± 0.5 6.0 ± 0.5
Two-Piece Boom Down 5.8 ± 0.5 5.8 ± 0.5
Arm Dump 2.5 ± 0.4 2.6 ± 0.4
Arm Crowd 2.9 ± 0.4 3.0 ± 0.4
Bucket Dump 2.1 ± 0.4 2.3 ± 0.4
Bucket Crowd 3.5 ± 0.4 3.6 ± 0.4
General
Maintenance
Procedures
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
Welding Precautions and Guidelines ................. 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 Service
...................................................................................... 10
Oil Leakage Precautions.............................................. 11
Cleaning and Inspection ................................... 12
General Guidelines ....................................................... 12
Bearing Inspection ........................................................ 13
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
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 be caused. Always consult DOOSAN After
Sales Service before welding on integral components
(loader arm, frames, car body, track frames, turntable,
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.
CAUTION
Always perform welding procedures with the proper
safety equipment on hand. Adequate ventilation and a
dry work area are absolutely essential. Keep a fire
extinguisher nearby and always wear protective clothing
and the recommended type of eye protection.
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 dimensional tolerances
between moving parts - pistons and cylinders, or shoes and
swash plates, for example - 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 due to neglect or careless
maintenance, could all produce sufficient fluid loss to cause
damage.
IMPORTANT
Hydraulic system operating conditions (repetitive
cycling, heavy work loads, fluid circulating under high-
pressure) make it extremely critical that dust, grit or any
other type of 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.
General Precautions
Fluid level and condition should always be checked
whenever any other type of maintenance service or repair is
being performed.
NOTE: If the unit is being used in an extreme temperature
environment (in sub-freezing climates or in high
temperature, high humidity tropical conditions),
frequent purging of moisture condensation from the
hydraulic reservoir drain tap should 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 elements 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 as a
result of a mechanical problem inside the pump.
However, pressure loss could also be due to
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 the 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.
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.
Figure 1
General Guidelines
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
Care should be exercised to avoid inhalation of vapors,
exposure to skin and creating fire hazards when using
solvent type cleaners.
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
Normal Bearing
Smooth even surfaces with no discoloration or marks.
Figure 2
Bent Cage
Cage damage due to improper handling or tool usage.
Figure 3
Figure 4
Galling
Metal smears on roller ends due to overheat, lubricant
failure or overload.
Replace bearing - check seals and check for proper
lubrication.
Figure 5
Figure 6
Figure 7
Misalignment
Outer race misalignment due to 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
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
Figure 13
Figure 14
Smears
Smearing of metal due to slippage caused by poor fitting,
lubrication, overheating, overloads or handling damage.
Replace bearings, clean related parts and check for proper
fit and lubrication.
Replace shaft if damaged.
Figure 15
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 over heating 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
Standard
Torques
Edition 1
Standard Torques
Safety Precautions............................................... 5
Applicable Models................................................ 5
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
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
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Grade
Dia. x Pitc
h (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)
NOTE: Torque values listed throughout this manual are lubricated (wet) threads; values should 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 the loose bolt and/or nut be
replaced with a new one.
Torque
Radiator, Air Cleaner, Boots,
Hydraulic System
Etc.
Clamp Type And Size
Kilogram Kilogram
Inch Pounds Inch Pounds
Meter Meter
(in lb) (in lb)
(kg•m) (kg•m)
"T" Bolt (Any Diameter) 0.68 - 0.72 59 - 63 ------- ------
Worm Drive - Under
44 mm (1-3/4 in) Open 0.2 - 0.3 20 - 30 0.5 - 0.6 40 - 50
Diameter
Worm Drive - Over
44 mm (1-3/4 in) Open 0.5 - 0.6 40 - 50 ------- ------
Diameter
Worm Drive - All
0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50
"Ultra-Tite"
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
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 Figure 1
Torque).
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:
A x 12 x 300 3600
I T
= = = 150
= A + 12 + 12 24
B
CAUTION
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 endorse a specific
manufacturer or brand name but the following table of
"Loctite" applications is included for which
cross-references to other makers' products should also
be widely available.
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of
fastener adhesives, with Thread locker sealers 222, 242/
243, 262, 271, 272, or 277.
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.
242 or Medium strength for 6 mm (1/4")
Blue Hand tools 80
243 and larger fasteners.
High strength for high grade Heat/260°C (500°F)
262 fasteners subject to shock, stress Red Remove HOT 160
and vibration. (NO solvent)
Extra high strength for fine thread
Heat/260°C (500°F)
271 fasteners up to 25 mm (1") Red 160
Remove HOT
diameter.
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
Heat/260°C (500°F)
277 thread fasteners 25 mm (1") Red 210
Remove HOT
diameter and larger.
V. "Loctite" Adhesives
Cabin
(NON-ROPS)
Edition 1
Cabin
(NON-ROPS)
Safety Precautions............................................... 5
Applicable Models................................................ 5
Cab Identification ................................................. 6
Removal ............................................................... 7
Installation .......................................................... 11
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling the load.
Remember, that ultimately safety is your own
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
CAUTION
Avoid disassembling cabin if there are strong wind
gusts, which could catch large surface area of cabin
shell and push it sideways during lift.
WARNING or maintenance
190-00695A
FG016934
If engine must be run while performing Figure 2
maintenance, use extreme care. Always have one
person in the cabin at all times. Never leave the
cabin with the engine running.
4 6 FG016935
Figure 3
17. After removing rear mat (1, Figure 4), remove rear
center cover (2. Figure 4), cassette cover (3) and rear
side covers (4 and 5, Figure 4)
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
7. Install cross bar (5, Figure 12) between left and right
side of cabin.
8. Install air ducts (1,2,3 and 4, Figure 12) to cabin rear
panel.
Figure 12
Figure 13
13. Install rear side covers (4 and 5, Figure 14) and install
cassette cover (3, Figure 14).
14. Install rear center cover (2, Figure 14) and install rear
mat (1, Figure 14) sequently.
Figure 14
15. Install front cover (4, Figure 15) and side covers (5
and 6, Figure 15). Before installing front cover (4), 2
connect hour meter connector.
16. Install cup holder (3, Figure 15). 8
4 6 FG016935
Figure 15
Cabin (ROPS)
Edition 1
Cabin (ROPS)
Safety Precautions............................................... 5
Applicable Models................................................ 5
Cab Identification ................................................. 6
Roll Over Protective Structure (ROPS)
When Required by Local Regulations .......................... 6
Removal ............................................................... 8
Installation .......................................................... 12
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling the load.
Remember, that ultimately safety is your own
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
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,
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
result in serious injury or death.
CAUTION
Avoid disassembling cabin if there are strong wind
gusts, which could catch large surface area of cabin
shell and push it sideways during lift.
WARNING or maintenance
190-00695A
FG016919
If engine must be run while performing Figure 3
maintenance, use extreme care. Always have one
person in the cabin at all times. Never leave the
cabin with the engine running.
2
1 FG016920
Figure 4
FG016921
Figure 5
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 2
cover. Remove three bolts securing rear cover in place.
21. Remove two bolts (3, Figure 7) from bottom of rubber
mounts in rear cover. 1
FG015887
Figure 7
FG015888
Figure 8
10
FG015889
Figure 9
1
FG015891
Figure 11
FG015892
Figure 13
Quantity Description
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
7
is positioned in center of rear part of
operator's cabin.
1
FG015891
Figure 15
4 6
5
FG015893
Figure 16
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
3
cover. Install 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
6
5 FG015897
Figure 19
FG016921
Figure 20
Counterweight
Edition 1
Counterweight SP002207
Page 1
MEMO
Counterweight SP002207
Page 2
Table of Contents
Counterweight
Safety Precautions............................................... 5
Applicable Models................................................ 5
General................................................................. 6
Warning for Counterweight and Front Attachment
Removal .......................................................................... 6
Removal ............................................................... 8
Installation .......................................................... 10
Counterweight SP002207
Page 3
MEMO
Counterweight SP002207
Page 4
SAFETY PRECAUTIONS
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Counterweight SP002207
Page 5
GENERAL
DANGER
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.
Never rotate the upper structure once the counterweight
or front attachment has been removed.
FG007176
Before any attempt is made to begin removal or installation Figure 1
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.
Counterweight SP002207
Page 6
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.
90 ~ 110
15 FG007177
Figure 2
15
FG007178
Figure 3
Counterweight SP002207
Page 7
REMOVAL
1. Park on firm and level ground. O I
2. Lower front attachment (bucket) to the ground.
3. Shut down 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
190-00695A
FG016934
If engine must be run while performing Figure 4
maintenance, use extreme care. Always have one
person in the cabin at all times. Never leave the
cabin with the engine running.
Counterweight SP002207
Page 8
12. Remove two caps (1, Figure 5) from counterweight (2).
3
1
13. Install two lifting eyes in lifting holes (3, Figure 5).
3
Model Lifting Eye Size
DX210W M48 x 5.0
4 FG007180
Figure 5
Counterweight SP002207
Page 9
INSTALLATION
1. Using suitable lifting device capable of handling a
3
heavy load, raise counterweight (2, Figure 6) into 1
position just above support frame (6) leaving
counterweight suspended. Verify that counterweight is 3
level and even.
NOTE: Leave counterweight (2, Figure 6) suspended
3 mm (0.12") above support frame (6) until all 2
four mounting bolts (4) are started in
counterweight mounting holes.
2. Slide washers (5, Figure 6) onto bolts (4). Apply Loctite
#242 to mounting bolt threads.
3. Install four bolts (4, Figure 6) with washers (5) into
counterweight until washers contact support frame.
Fully lower counterweight onto support frame and finish
tightening bolts.
NOTE: Torque bolts (4, Figure 6) to values shown in
following table.
Counterweight SP002207
Page 10
SP002208
FUEL TANK SP002208
Fuel Tank
Edition 1
Fuel Tank
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Parts List......................................................................... 6
Specifications .................................................................. 7
Removal ............................................................... 8
Installation .......................................................... 12
Start-up Procedures........................................... 15
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
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
11
10
17 18
16
12
15
14
15
14
9
13
2
8
7 3
13
5
6
4 7 FG007181
Figure 1
Specifications
Fuel tank capacity is 350 liters (92.5 U.S. gal).
FG013666
Figure 2
FG007193
Figure 3
WARNING
WARNING DO NOT OPERATE
when performing inspection
or maintenance
190-00695A
11
FG007182
Figure 5
FG007183
Figure 6
14. Tag and disconnect fuel supply line (21, Figure 7) and
fuel return line (19) from fuel tank (1) and carefully 1
drain remaining fuel from lines.
15. Remove clamp (20, Figure 7) holding fuel return line
(19) to tank (1).
19
20
21
FG007184
Figure 7
22
FG007185
Figure 8
17. Remove five bolts (23, Figure 9) and cover (24) from 23
fuel tank.
24
FG007186
Figure 9
18. Remove six bolts (25 and 26, Figure 10) and stay (27)
from fuel tank and frame.
27
Remove four bolts (28 and 29) and fuel tank cover
(30) from fuel tank. 28
26
Remove two bolts (31) and bracket (32) from tank.
Remove four bolts (33) and battery cover (34) from
frame. 32
33
29
31
30
34
25 FG007187
Figure 10
FG007188
Figure 11
20. Remove four bolts (35 and 36, Figure 12) and cover
(37) from fuel tank and support.
36 37
35 FG007189
Figure 12
22. Remove six bolts (7) and spacers (13, Figure 13)
holding tank (1) to frame. Lift tank 25 mm (1") and
make sure it is 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.
23. Remove shims (9, Figure 13).
9
NOTE: If tank is to be reused note position and amount
13
of shims used for each mounting bolt location.
7 FG007190
Figure 13
2. Set fuel tank (1, Figure 14) into position. Install six
bolts (7) and spacers (13) finger tight, to secure tank
to frame.
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 14) as needed to prevent tank
(1) from rocking or stress from mounting bolts (7).
4. Tighten mounting bolts (7, Figure 14) after shims are 9
installed.
13
NOTE: Bolt torque is 27 kg•m (195 ft lb).
7 FG007190
Figure 14
5. Install four bolts (35 and 36, Figure 15) and cover (37)
on fuel tank and support.
36 37
35 FG007189
Figure 15
FG007188
Figure 16
34
25 FG007187
Figure 17
8. Install five bolts (23, Figure 18) and cover (24) on fuel
23
tank.
24
FG007186
Figure 18
22
FG007185
Figure 19
19
20
21
FG007184
Figure 20
12. Make sure fuel tank drain valve (6, Figure 21) on
bottom of tank is closed.
13. Fill fuel tank and check for signs of leaks. Correct any
problems found.
14. Connect negative (-) battery cable to battery.
FG007183
Figure 21
FG007191
Figure 22
Fuel Transfer
Pump
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 7
Theory of Operation ....................................................... 7
Troubleshooting .................................................... 8
Replacement of Rotor and Vane ....................... 8
Replacement of Rear Cover............................... 9
Replacement of Armature ................................... 9
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Theory of Operation
Fuel
4
1 2
6 5 3
Fuel Tank
IN OUT
2-2 2-1
FG007017
Figure 1
Reference Reference
Description Description
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
Hose
Switch FG001143
Figure 2
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
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 the switch cover and screw (M5 x L95) from the
rear cover.
Remove cover.
At reassembly of rear cover, widen the space of the brush Figure 7
and insert it to the armature. Then fit the hole of screw in
the housing.
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 Side
damaged by a short circuit.
Remove the switch cover and rear cover, than remove the
armature from the housing.
Remove the pump cover and remove the rotor and vane.
Insert a new armature into the housing. Commutator
Swing Bearing
Edition 1
Swing Bearing
Safety Precautions............................................... 5
Applicable Models................................................ 5
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
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
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.
Reference
Description
Number
1 Outer Ring
2 Inner Ring
3 Tapered Pin
4 Plug
5 Ball
6 Retainer
7 Seal
Figure 2
Disassembly
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
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
Swing
Reduction
Gear
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 7
Theory of Operation ....................................................... 7
Parts List......................................................................... 8
Specifications .................................................................. 9
Troubleshooting, Testing and Adjustment........ 10
Removal ............................................................. 11
Disassembly ....................................................... 12
Cleaning and Inspection (Wear Limits and
Tolerances)......................................................... 18
Reassembly ........................................................ 19
Shaft and S/R Bearing Heat-fit................................... 19
Assembly of Carrier Subassemblies ........................... 21
Assembly of Main Case .............................................. 27
Installation .......................................................... 44
Start-up Procedures........................................... 44
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
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 in order 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.
24
32
26
23
25 22
21
20
6
18 14
13
10
12
30
11
8 15
19
29
27
1
28
27
4
3
16
5
31
33
17
Figure 1 FG007053
Specifications
Swing Reduction Gearbox Specification
Drive Type Two-stage Planetary Gear
Reduction Ratio 19.636
Maximum Output Speed 81 rpm
1,178 kg•m
Maximum Output Torque
(8,521 lb•ft)
182 kg
Weight
(401 lb)
WARNING or maintenance
190-00695A
FG016934
If engine must be running while performing Figure 2
maintenance, always use extreme caution. Always
have one person in cab at all times. Never leave
cab with engine running.
CAUTION
The motor should be separated without damage or
any foreign substance.
Figure 4
CAUTION
Care should be taken not to damage mounting
surface of motor. Carefully remove all gasket
material from mounting surfaces.
Figure 5
CAUTION
Care should be taken not to damage teeth of No. 1
sun gear.
Figure 6
Figure 8
CAUTION
Care should be taken not to damage teeth of No. 2
sun gear.
Figure 9
Figure 10
CAUTION
Care should be taken not to damage teeth of No. 2
carrier and ring gear.
Figure 11
Figure 12
Figure 14
CAUTION
Care should be taken not to damage mounting
surfaces of ring gear and case. Carefully remove all
gasket material from mounting surfaces.
Figure 15
Figure 17
Figure 18
Figure 19
CAUTION
Care should be taken not to have drive shaft drop
to floor when it is pressed out of case.
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
Figure 28
Cleaning Carrier
Put carrier, to whose corners grinding was made to remove
all foreign substances like burr, on steam washer if there
remain any foreign substance and put it on assembly die.
Figure 29
Figure 30
Figure 31
Figure 33
Figure 34
Figure 35
Figure 36
Figure 37
Figure 38
FG000888
Figure 39
FG000889
Figure 40
FG000890
Figure 41
FG000891
Figure 42
FG001354
Figure 43
FG000893
Figure 44
FG000894
Figure 45
FG000895
Figure 46
FG000897
Figure 48
FG000898
Figure 49
FG000899
Figure 50
Figure 51
Figure 52
Figure 53
Figure 55
Figure 56
Figure 57
FG000920
Figure 59
CAUTION
Make sure that there is no foreign substances on
lip area. Use care not to damage seal when
inserting it. Chack for proper installation after
pressing seal into position.
FG000921
Figure 60
FG000922
Figure 61
FG000924
Figure 63
FG000925
Figure 64
FG000926
Figure 65
N J2218E
FG004972
Figure 67
FG000929
Figure 68
FG000930
Figure 69
FG000932
Figure 71
FG000933
Figure 72
FG000934
Figure 73
FG000936
Figure 75
FG000937
Figure 76
FG000938
Figure 77
FG001353
Figure 78
FG000940
Figure 79
Assembly of Carrier.
1. Using a suitable lifting device, lower No. 2 carrier
assembly into ring gear, making sure that planetary
gears are engaged. Continue to lower carrier and
engaging it onto splines of pinion shaft. Make sure that
carrier is resting on bearing.
NOTE: Make sure that carrier and drive shaft can
rotate.
FG000941
Figure 80
FG000942
Figure 81
CAUTION
The shorter part of the tongued washer should be
placed on the thread of the thrust washer 3 and
then bolt tightened. To prevent the washer from
Figure 83
moving, use a proper device like one shown in the
figure below to press a part of the washer and
tighten the bolt.
Figure 84
Figure 85
Figure 86
Figure 87
FG000944
Figure 88
Figure 89
Figure 90
Figure 91
Figure 92
Figure 93
FG000954
Figure 95
Figure 96
Figure 98
Figure 99
WARNING
Do not insert the level gauge bar before supplying
gear oil.
Figure 100
Figure 101
Figure 102
Figure 103
2. After the supply of oil, stick the level gauge into tank
and check the oil level.
Figure 104
Figure 105
Figure 106
Figure 107
Figure 108
Figure 110
START-UP PROCEDURES
IMPORTANT
If air is not vented from system, it will cause damage to
swing motor and bearings.
Ram Lock
Valve
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
Sectional Drawing and Part Names................... 6
Hydraulic Circuit................................................... 6
Operational Principle ........................................... 7
In Case of No Pilot Pressure at PI Port..................... 7
In Case of Pilot Pressure (Approx. 20 kg•cm2) at PI
Port.................................................................................. 7
Disassembly and Assembly ................................ 7
General Cautions............................................................ 7
Assembly and Disassembly of Chocking Valve .......... 8
Performance Test ................................................ 9
Oil Leakage Test............................................................ 9
Operational Test ............................................................. 9
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling the load.
Remember, that ultimately safety is your own
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
4 3 1 2
FG007630
Figure 1
Reference Reference
Description Description
Number Number
1 Body 4 Cover Plate
2 Cartridge Ass'y 5 Bolt
3 Plunger
HYDRAULIC CIRCUIT
Figure 2
General Cautions
It is the principle that the manufacturer carry out
disassembly and assembly of this valve. In case you
inevitably need to disassemble or assemble the valve
elsewhere, please observe the following cautions.
1. This chocking valve is precisely processed and the
gaps among each part are extremely tiny. Thus,
disassembly and assembly should be performed very
carefully so any foreign material such as dust or sand
cannot intrude into the valve.
2. For disassembly, you should start disassembly after
fully understanding the structure of this chocking valve
with structural drawings and reference drawings.
3. When you need to leave the disassembled parts of this
chocking valve unassembled for a while, be sure to
apply rust prevent oil to the parts and seal them to
prevent rusting.
4. Do not hit or treat any part of the product roughly even
in case disassembly and assembly is not peformed
smoothly.
5. After disassembly, attach ID tags to each part for
accurate assembly.
6. It is recommended to use new O-rings for replacement,
and be sure not to damage one during assembly.
(Apply a small portion of grease on the parts for
smooth assembly.)
Figure 3
Figure 4
Figure 5
BL BL
Y
Y
PI
PI BR BR
FG007635
Figure 6
Operational Test
1. Apply pressure of 350 kg•cm2 to the BR port.
2. When gradually increasing the pressure at the PI port,
the hydraulic oil should flow out to the Y port at
pressure of 19 kg•cm2 or less.
3. Apply pressure of 350 kg•cm2 to the BL port.
4. When gradually increasing the pressure at the PI port,
the hydraulic oil should flow out to the Y port at
pressure of 19 kg•cm2 or less.
Selector Valve
Edition 1
Selector Valve
Safety Precautions............................................... 5
Applicable Models................................................ 5
Sectional Drawing and Part Names................... 6
Hydraulic Circuit................................................... 6
Operational Principle ........................................... 7
Neutral Position : A → B.............................................. 7
Selective Position : A → C .......................................... 7
Disassembly and Assembly ................................ 8
General Cautions............................................................ 8
Assembly and Disassembly of Selector Valve ............ 9
Performance Test .............................................. 11
Oil Leakage Test.......................................................... 11
Operational Test ........................................................... 11
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling the load.
Remember, that ultimately safety is your own
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Figure 1
Reference Reference
Description Description
Number Number
1 Body 7 O-ring (1BP28)
2 Spool 8 Bolt 1 (M6 X 35L)
3 Cover 1 9 Spacer Bolt (M8 X 10L)
4 Spring Seat 10 Bolt 2 (M6 X 55L)
5 Spring 11 Cover 2
6 Spring 12 O-ring (1BP41)
HYDRAULIC CIRCUIT
Figure 2
Neutral Position : A → B
Hydraulic oil, flowing into the A port, passes through the
spool to flow out to the B port.
Selective Position : A → C
When pilot pressure is applied to the P port, the spool
moves to the right. This operation blocks the oil passage to
the B port and opens the oils passage to the C port, which
makes the hydraulic oil from the A port discharged to the C
port.
NOTE: The leaked oil, generated in process of this
operation, drains out to the T port.
Figure 3
General Cautions
It is the principle that the manufacturer carry out
disassembly and assembly of this valve. In case you
inevitably need to disassemble or assemble the valve
elsewhere, please observe the following cautions.
1. This selector valve is precisely processed and the gaps
among each part are extremely tiny. Thus, disassembly
and assembly should be performed very carefully so
any foreign material such as dust or sand cannot
intrude into the valve.
2. For disassembly, you should start disassembly after
fully understanding the structure of the valve with
structural drawings and reference drawings.
3. When you need to leave the disassembled parts
unassembled for a while, be sure to apply rust prevent
oil to the parts and seal them to prevent rusting.
4. Do not hit or treat any part of the product roughly even
in case disassembly and assembly is not peformed
smoothly.
5. After disassembly, attach ID tags to each part for
accurate assembly.
6. It is recommended to use new O-rings for replacement,
and be sure not to damage one during assembly.
(Apply a small portion of grease on the parts for
smooth assembly.)
7. Fasten bolts with the specified standard torque.
8. Be careful not to damage or scratch the O-ring
contacting parts of this valve for preventing oil leakage.
Figure 4
Figure 5
Figure 6
4. Insert the O-ring into the cover #2 for the opposite side
and fasten the cover #2 to the body with bolts.
A. Bolt Fastening Torque : 0.8 kg•m - 1.2 kg•m
Figure 8
Figure 9
Operational Test
1. Apply pressure of 140 kg•cm2 and 120 lpm to the A
port.
2. Check if the spool changes when applying pressure of
40 kg•cm2 to the P port.
3. Check if the position of the spool is restored when
reducing the pressure at the P port to 5 kg•cm2.
Double Pilot
Check Valve
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
Sectional Drawing & Parts ................................. 6
Hydraulic Diagram ............................................... 7
Operational Principle ........................................... 8
A → C, D → B ............................................................. 8
B → D, C → A ............................................................. 8
Disassembly and Assembly ................................ 9
General Cautions............................................................ 9
Assembly and Disassembly of Double Pilot Check
Valve ............................................................................. 10
Performance Test .............................................. 12
Cracking Pressure Test for Check Cartridge Ass'y .. 12
Pilot Cracking Pressure Test ...................................... 12
Oil Leakage Test.......................................................... 13
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Figure 1
Reference Reference
Description Description
Number Number
1 Body 7 Poppet (2 ea)
2 Plunger 8 Sleeve (2 ea)
3 Nipple (2 ea) 9 Spring Seat (2 ea)
4 O-ring (1B-P28, 2 ea) 10 Spring (2 ea)
5 O-ring (1B-P18, 2 ea) 11 O-ring (1B-P16, 2 ea)
6 Back-up Ring (1B-P18, 2 ea) 12 Plug (2 ea)
Figure 2
Figure 3
A → C, D → B
The pressured oil, flowed in through the A port, is to be
flowed out to the C port through oil passage of the side of
the nipple (3) while pressing the poppet (7) and the sleeve
(8) simultaneously. The pressure of the hydraulic oil, flowed
in through the A port, pushes the plunger (2) of the center
to the left side. And if the pressure is greater than the
spring (10) force, the poppet is to be pushed back to make
a gap between the sleeve (8) and the plunger (2) and it
discharges the hydraulic oil, flowed in from the D port, to
the B port.
B → D, C → A
The same principle of 3.1 is to be applied to case of the
hydraulic oil, flowed in through the port B.
General Cautions
It is the principle that disassembly and assembly of the
Double Pilot Check Valve (hereinafter referred as DPC V/V)
should be carried out by the manufacturer. In case
disassembly and assembly is inevitably required elsewhere,
the following cautions must be observed.
1. The DPC V/V is precisely processed and the
clearances among each part are extremely tiny. Thus,
disassembly and assembly should be performed very
carefully at a clean place so that any foreign material
such as dust or sand can not intrude into the DPC V/
V.
2. For disassembly of DPC V/V, a technician should start
disassembly after fully understanding the structure of
the valve with structural drawings and reference
drawings.
3. In case the DPC V/V needs to be placed unassembled
for a while, it must be treated with rust prevent oil and
sealed to prevent rusting.
4. Even in case disassembly and assembly of DPC V/V is
not peformed smoothly, do not hit or treat any part of
the product roughly.
5. After disassembly, attach ID tags to each part for
accurate assembly.
6. For O-rings and back up-rings, it is the principle to use
new ones. And be sure not to damage one during
assembly. (Apply a small portion of grease on the parts
for smooth assembly.)
7. Fasten bolts, nipples and plugs with the specified
standard torque.
8. Be careful not to damage the O-ring contacting parts of
the DPC V/V for preventing oil leakage.
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Solenoid Valve
Edition 1
Solenoid Valve
Safety Precautions............................................... 5
Applicable Models................................................ 5
Single Solenoid Valve Diagram.......................... 6
Functions of Single Solenoid Valve ................... 7
Disassembly and Reassembly Diagrams........... 8
Troubleshooting of Each Part............................. 9
Double Solenoid Valve Diagram ...................... 10
Functions of Double Solenoid Valve ............... 11
Disassembly and Reassembly Diagrams......... 12
Troubleshooting of Each Part........................... 13
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
3 4
6
LOT NO. C
5 1
FG007737
Figure 1
Cap Housing
Disassembly
Retaining Bolt
Aassembly
Solenoid Piece
Spool
Guide
Spring Holder
Spring
CAUTION
1. Clean the work area completely before starting
disassembly and reassembly.
2. For disassembly and reassembly, always follow
references in table of page -6.
3. Do not remove plates installed with coil.
4. Do not remove the logic valve.
5. Take care to prevent entering of contaminating
substances into valves after disassembly and
reassembly.
6. Always wash every removed part before its
reassembly.
3 4
C1 C2
T LOT NO.
6
5 7 1
FG007739
Figure 3
Cap Housing
Disassembly
Retaining Bolt
Aassembly
Solenoid Piece
Plate Logic Valve
Spool
Guide
Spring Holder
Spring
CAUTION
1. Clean the work area completely before starting
disassembly and reassembly.
2. For disassembly and reassembly, always follow
references in table of page -10.
3. Do not remove plates installed with coil.
4. Do not remove the logic valve.
5. Take care to prevent entering of contaminating
substances into valves after disassembly and
reassembly.
6. Always wash every removed part before its
reassembly.
Front Axle
Edition 1
Front Axle
Safety Precautions............................................... 5
Applicable Models................................................ 5
Examples of Gear-Tooth-Contact Patterns
for the Gleason Gear-Tooth System ............................ 6
Lubrication and Maintenance Specifications for
Axle MS-E 3050/3060/3070 ................................ 8
Brake Wear Measurement on Axles of MT/MS-E
3050/3060/3070 Range ..................................... 10
Disassembly ....................................................... 12
Steering ......................................................................... 12
Output............................................................................ 16
Differential - Input ........................................................ 24
Pivot Bearing ................................................................ 29
Reassembly ........................................................ 30
Input .............................................................................. 30
Input Flange.................................................................. 42
Output............................................................................ 43
Pivot Bearing ................................................................ 62
Steering ......................................................................... 63
Oil Drain-Oil Filler and Oil Control Plugs and Grease
Lubrication Points ......................................................... 72
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
BSS0090L
Figure 1
BSS0100L
Figure 2
(+) BSS0110L
Figure 3
BSS0130L
Figure 4
(-) BSS0120L
Figure 6
BSS0150L
Figure 7
BSS0160L
Figure 8
Oil Change
A horizontal installation position of the axle in every direction
is precondition for an oil change according to specifications!
Place vehicle in a horizontal position!
Carefully clean all drain -, filler- and control plugs prior to
opening!
Drain oil only right after a longer travel period!
4
5
2
3
5 1
2
FG002279
Figure 9
Reference Reference
Description Description
Number Number
Oil Drain Hole Oil Filler / Oil Check Hole
1 3
(M36x1.5 Axle Drive Housing) (M36x1.5 Axle Drive Housing)
Oil Drain / Oil Filler Hole 4 Brake Connection Pipe
2
(M36x1.5 Output Units) 5 Brake Breather Valve
Brake
The following oils are admissible for the pneum.-hydr.
operated or accumulator operated brake actuation
1. Motor oils SAE 10 W acc. to specification MIL-L 2104
C, MIL-L 46152, API-CC, CD, SC, SD, SE
2. ATF. oils type A, Suffic A, Dexron von II D
WARNING
The measurement of wear on the multi-disc brake only
gives limited information on the total state of the plate
pack.
without disassembling the output.
CAUTION
To avoid injury when opening the oil drain/oil filler plug
(1), due to a possible pressure build-up in the planetary FG006855
carrier bring drain hole to topmost position (12 o’clock) Figure 10
and carefully unscrew oil drain and filler plug (1).
Then turn output until oil filler/ oil drain hole (1) is on 9
o’clock position. Figure 10. 3
Reference
Description
Number
1 Oil filler-/oil drain hole 4 5 6 7
Gauge hole (ø = 10 mm) in ring gear - 9
2
o’clock position FG002281
3 Dial indicator with solenoid support Figure 11
4 Planetary carrier
5 Ring gear
6 Piston
7 Plate pack
X Piston stroke
FG002282
Figure 12
WARNING
Secure axle by means of a support (arrow).
Figure 13
Steering
1. View - Steering installed in axle.
Figure 14
Figure 15
WARNING
Drive out tie rod from bevel seat.
use suitable mandrel (brass / aluminium).
Figure 16
Figure 17
CAUTION
If work is just to be done on sealing elements and
/ or piston rod or guide, no disassembly of the
steering cylinder ass’y is required and you may
continue with Figure 24.
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
13. Drive out piston rod together with guide from cylinder
tube.
Figure 27
Figure 28
Output
1. Loosen screw plug and drain oil from the axle.
CAUTION
Use suitable collecting basin - environmental
protection!
Figure 29
WARNING
To avoid injury due to a possible pressure build-up
in the oil system of the planetary carrier, bring oil
filler and control plug to 12 o’clock position and
carefully unscrew! use suitable mandrel (brass /
aluminium).
Then bring drain hole to 6 o’clock position and
drain the oil!
Figure 30
CAUTION
Use suitable collecting basin - environmental
protection!
WARNING
Pay attention to seal ring in the axle housing - risk
Figure 31
of damage!
Planetary Carrier
1. Loosen both cylinder screws and separate planetary
carrier from hub.
Figure 32
2. Unsnap circlip.
Figure 33
Figure 34
Figure 35
Brake / Hub
1. Unsnap retaining ring and remove both thrust washers.
Figure 36
Figure 37
Figure 38
Figure 39
Figure 40
Figure 41
Figure 42
Figure 43
Figure 44
CAUTION
Pay attention to the releasing bearing inner ring
Figure 45
Figure 46
Figure 47
Figure 48
Knuckle Housing 7
1. Legend to the sketch
Reference
Description
Number
1 Bearing Pin 6
3
2 Knuckle Housing
2 5
3 Axle Housing
4 Shim (Only on Lower Bearing Pin) 4
1
FG002333
5 O-ring
Figure 49
6 Sealing Cap
7 Taper Roller Bearing
WARNING
Remove lower bearing pin - by means of lifting
device / see Figure 51 - not before securing the
knuckle housing.
Figure 50
CAUTION
Pay attention to releasing shim.
Figure 51
Figure 52
WARNING
Pay attention to seal ring in the axle housing - risk
of damage
Figure 53
WARNING
Pay attention to seal ring in the axle housing - risk
of damage
Figure 54
Figure 55
Figure 56
Figure 57
Figure 58
WARNING
Pay attention to the seal ring in the axle housing - risk
of damage.
WARNING
Pay attention to the releasing differential.
Figure 59
CAUTION
Mark shim (regarding position / bearing allocation) -
assembly aid.
Figure 60
Figure 61
4. Pull out bearing outer ring and the shim behind from
the bearing hole of axle housing part / I.
CAUTION
Mark shim (regarding position / bearing allocation) -
assembly aid.
Figure 62
Figure 63
CAUTION
n version "D-750" the hex. screws are installed with
locking compound (Loctite) - disassembly is more
difficult - if required, warm up area of threaded
joint (disassembly aid).
Figure 64
FG002349
Figure 65
B. Version "D-750" X
FG002350
Figure 66
Figure 67
Figure 68
Reference
Description
Number
1 Input Pinion 9
7
2 Hex. Nut
3 Washer 8
4 Input Flange 6 5
5 Screen Sheet 3 4
6 Seal Ring
2
7 Taper Roller Bearing
FG002353
8 Spacer Ring (Bearing Rolling Moment) Figure 69
9 Shim (Contact Pattern)
10 Input Housing
WARNING
Pay attention to support of axle housing (arrow).
Figure 70
3. Remove flange.
If required. remove screen sheet from output flange.
Figure 71
Figure 72
CAUTION
If taper roller bearings should not be replaced, pay
attention that the outside bearing inner ring - with
all its rolls - is in contact with bearing outer ring
when driving out the input pinion.
Figure 73
Figure 74
Figure 75
Figure 76
9. Drive out bearing outer ring from the inner bearing hole
- pay attention to the shim behind.
CAUTION
Mark shim (reg. position / bearing allocation) -
assembly aid.
Figure 77
Pivot Bearing
If required:
Provide bushings with a separating slot - see arrow -
(bushings are destroyed by this).
Then remove bushings from holes.
Figure 78
Reference
Description
Number
1 Drive Pinion
2 Differential (With Crown Wheel)
3 Shim for Contact Pattern (Bevel Gear Set)
Spacer Ring
4
(Bearing Rolling Moment / Pinion Bearing)
5 Shim For Backlash
Shim
6 (Bearing Rolling Moment / Differential Figure 79
Bearing)
7 Input Flange
8 Seal Ring
9 Axle Drive Housing
10 Axle Housing / Part I (Loa = O-ring)
11 Axle Housing / Part Ii (Crown Wheel Side)
Figure 80
CAUTION
Measure dimension "III" bearing width, observing
that the rollers are located without any play (rotate
bearing inner ring in both directions several times -
roller setting).
Figure 83
Figure 84
Figure 85
Figure 86
CAUTION
We would reconunend to re-install the spacer ring
found during disassembly. If, however, the required
rolling moment of 1.0 ~ 2.0 N•m (without seal ring)
is not achieved - see bearing rolling moment test - Figure 87
correct the bearing rolling moment by means of a
corresponding spacer ring.
Figure 88
Figure 89
CAUTION
If the rolling moment differs from the required
value, correct it with a suitable spacer ring (See
Figure 21 on page -14). Figure 90
CAUTION
Reassemble seal ring - as shown in page -42~74
(after completed differential assembly and positive
contact pattern check).
Figure 91
2. Assembly Specification:
Bring slotted pin(s) in a position where slot shows into
the direction of force (arrow).
In case of double slotted pins - bring the slots in a
1800 degrees offset position to each other.
To sketch:
Reference
Description
Number
1 Differential Carrier Figure 92
2 Slotted Pin
Slotted Pin
3
(Just for Double Slotted Pin Version)
X Direction of Force
Figure 93
CAUTION
Put driving lugs of thrust washer into driving holes
/ differential carrier - do not locate in oil supply
recesses.
Figure 94
CAUTION
Ensure radial installation position of thrust
washers.
Figure 95
Figure 96
CAUTION
Put driving lugs of thrust washer into driving holes
/ differential carrier - do not locate in oil supply
recesses. Figure 97
CAUTION
Ensure radial installation position - designation (ZF-
Nr. ...) at the same time corresponds to radial
position marking.
Figure 98
Figure 99
B. Version "D-750"
CAUTION
Just for version "D-750", insert hex screws
with locking agent Loctite-no.262).
Figure 100
Version "D-500"
Tightening torque (M 12x1.5/12.9) .......... MA = 145 N•m
Version "D-750"
Tightening torque (M 12x1.5/10.9) .......... MA = 122 N•m
Tightening torque (M 16x1.5/10.9) .......... MA = 300 N•m
Install both bearing inner rings (arrows).
Figure 101
Figure 102
CAUTION
Bring axle drive housing / axle housing into upright
position.
CAUTION
However, the required backlash is decisive for the Figure 103
shim(s) be used.
Figure 104
CAUTION
Locate the bearing outer ring on the bearing inner
ring, until all rollers are located without any play.
For this purpose rotate differential and bearing
outer ring both directions several times - roller
setting.
Figure 105
CAUTION
A correct positioning of bearing outer ring and
differential imperative for the following measuring
operation.
CAUTION
Make measurement on several points and calculate
mean value.
Figure 106
Figure 107
CAUTION
Instal (stick) bearing outer ring into hole with
grease - assembly aid.
Figure 108
Figure 109
Backlash
MS-E 3050/3060 = 0.12 - 0.24 mm
MS-E3070 = 0.15 - 0.27 mm
Figure 111
3. Remove differential.
Compare contact pattern (see arrow) with contact
pattern examples on page -6~9).
CAUTION
If the contact pattern differs considerably, an error
was made when measuring the shim (See Figure
103 on page -37), which needs to be corrected by
all means. Figure 112
Figure 113
Figure 114
Figure 115
WARNING
Bring axle into horizontal position and secure with
a support (arrow).
Figure 116
7. Disassemble flange.
Figure 117
Reference
Description
Number
1 Drive Pinion
2 Hex. Nut
3 Washer
4 Input Flange
5 Screen
6 Seal Ring
7 Bevel Roller Bearing
8 Spacer Nng
9 Input Housing
Installation Dimension Figure 118
X MS-E 3050/3060 → 13.0 +0.2 mm
MS-E 3070 → 13.5 +0.2 mm
CAUTION
Illustration shows version - MS-E 3060
CAUTION
Ensure plane installation position of seal ring - use
suitable driver.
CAUTION
Screen / thrust plate must not be deformed when
mounted - use suitable driver.
Figure 120
WARNING
Secure hex. nut with locking agent (Loctite-no. 262).
Figure 121
Output
1. Comment on Figure 122
Reference
Description
Number
1 Axle Housing
2 Knuckle Housing
3 Hub
4 Multi-disc Brake
5 Planetary Carrier Figure 122
WARNING
Pay attention to seal ring in the axle housing - risk
of damage.
Other required work steps (bearing pin and tie rod Figure 123
assembly) can be taken in extracts from the complete
assembly (“Knuckle Housing” on page 45 ~ 53 and
“Steering” on page 63).
Reference
Description
Number
1 Axle Housing
2 Bushing (Observe Installation Position)
3 Seal Ring (Observe Installation Position)
4 Bearing Outer Rings (Pivot Bearing)
X Oil Chamber Side
Figure 124
Bushing - lubrication groove outlet installed in 6 o’clock
position (referred to the axle mounted in the vehicle).
2. Flush-mount bushing in the axle housing hole,
considering the installation position (see detailed
sketch).
Figure 125
Reference
Description
Number
1 Axle Housing
2 Bushing
Oil Chamber Side Observe Installation
X
Position of Bushing
CAUTION
Contact face (outer diameter) of seal ring:
- Wet it with spirit (assembly aid) if rubber-coated
- Apply sealing agent (Loctite no. 574) if made of
metal
Figure 127
Apply grease on seal and dust lip of the seal ring.
Figure 128
WARNING
Carefully install u-joint shaft (Risk of damage - seal
ring).
Figure 129
Knuckle Housing
1. Just for assembly of a new knuckle housing (Figure
130):
Shut machining openings (3x - see arrows) of oil
supply holes with plugs.
Figure 130
Reference
Description
Number
1 Knuckle Housing
2 Bushing (Observe Installation Position)
3 Seal Ring (Observe Installation Position)
Installation Dimension (Seal Ring)
E MS-E 3050 → Flush
MS-E 3060/3070 → 4.00 + 0.3 mm
Installation position of bushing Figure 131
Figure 132
Detailed sketch:
Reference
Description
Number
1 Knuckle housing
2 Bushing
Oil chamber side Observe installation
position of bushing Lubrication groove
X outlet in 6 o’clock position (referred to
knuckle housing / axle mounted in
vehicle). Figure 133
Figure 134
CAUTION
Ensure plane installation position of seal ring - use
suitable driver.
CAUTION
Locate pre-assembled knuckle housing on axle
housing, carefully mount u-joint shaft Seal ring -
risk of damage).
Figure 135
Reference
Description
Number
1 Bearing Pin
2 Sealing Cap
3 O-ring
4 Bevel Roller Bearing
5 Shim (just on Lower Bearing Pin)
6 Lubrication Nipple
Figure 136
7 Knuckle Housing
8 Axle Housing
X Area/Anti-corrosive Agent
Figure 137
Figure 138
Figure 139
CAUTION
Observe installation position - mount bearing pin
with lubrication nipple showing to axle centre.
Figure 140
Figure 141
CAUTION
Observe installation position - oil supply holes for
multi-disc brake.
Figure 142
Figure 143
CAUTION
Try to achieve the upper value of bearing roller
moment. Figure 145
In case of a deviation from the specified bearing
rolling moment, correct it with a suitable shim. (See
Figure 139)
Reference
Description
Number
Effective torque on the central swivel
TE
point (bearing pin center)
Distance - from torque wrench point of
attach (hex. screw center) to grip
L Figure 146
center (torque wrench) e.g. L = 300
mm (0.3 m)
Distance - from torque wrench socket
(hex. screw center) to bearing pin
A
center (central swivel point) e.g. A =
60 mm (0.06 m)
Value of the torque to be read from
TS
the scale
TS × ( L + A )
TE = ---------------------------------
L
TE × L
TS = -----------------
L+A
As a result the scale of the torque wrench must
indicate a value of 46 ~ 50 N•m, which corresponds to
an effective bearing rolling moment of 50 ~ 60 N•m in
the swivel bearing.
Hub
1. Install heated bearing inner ring until contact is
obtained.
Figure 147
Figure 148
Figure 149
Reference
Description
Number
1 Hub
2 Shaft Seal
X Installation Dimension
Figure 150
Figure 151
X = 6.0 +0.2 mm
CAUTION
Apply sealing agent (Loctite-Nr. 574) to contact
face shaft seal / hub.
Figure 153
Figure 154
Figure 155
CAUTION
Apply lubricant (e.g. MOLYCOTE PASTE 1000) to
thread - knuckle housing / slotted nut.
Figure 156
CAUTION
While tightening the slotted nut rotate hub in both
directions several times - roller setting.
Figure 157
CAUTION
Pay attention to installation position of inner discs
- See Figure 159.
Figure 158
CAUTION
Take the actually required disc fitting from the
corresponding spare parts list.
WARNING
Bring inner clutch discs in a position where one of
the tooth recesses (arrow) is in 6 o’clock position -
with axle being installed in the vehicle.
CAUTION
Stick O-ring by means of grease - assembly aid.
Figure 160
CAUTION
Pay attention to installation position and
arrangement of sealing elements.
Figure 161
Reference
Description
Number
1 Ring Gear
2 Support Ring
3 U-ring
4 U-ring
5 Support Ring
Figure 162
Figure 163
Figure 164
Reference
Description
Number
1 Hex. Screw
2 Spring Sleeve
3 Compress. Springs (Outer)
4 Compress. Springs (Inner)
CAUTION
Use hex. screws just once for assembly.
Figure 166
CAUTION
Ensure exact toothing position of oil supply holes -
knuckle housing / ring gear (pressure oil supply to
brake piston).
Figure 167
Detail "B"
Figure 168
CAUTION
Apply lubricant (e.g. MOLYCOTE PASTE 1000) on
thread - knuckle housing / slotted nut.
Figure 169
CAUTION
First tighten slotted nut with 1400 N•m, then
retighten slotted nut until a fixing hole overlaps a
threaded hole in the knuckle housing - in this
connection also refer to Figure 176.
Figure 170
CAUTION
While tightening the slotted nut rotate hub in both
directions several times - roller setting.
CAUTION
Breathe brake completely before starting the test.
• Test media:
Motor oils SAE-lO W correspond to, MIL-L 2104
C, MIL-L 46152, API-CC, CD, SC, SD, SE, ATF- Figure 171
oils type A, Suffic A Dexron of II D
• High-pressure test:
Build up test pressure p = 100 bar and close
locking valve of HP pump.
A pressure drop by max.3 bar is permissible
during a 5-minute test duration.
Reference
Description
Number
1 Ring Gear
2 Piston
3 Compress. Springs (Outer)
4 Disc Clearance / Piston Stroke
Figure 172
CAUTION
Breathe brake completely before starting the test.
Figure 173
Dismantle HP pump.
Just for transport protection, install screw plug with O-
ring in oil supply hole.
Tightening torque (M 14 x 1.5) ............... MA = 23 N•m
Figure 175
Figure 176
CAUTION
Observe installation position - ensure that both
lugs of the thrust washer are engaged each in a
spare fixing hole of the slotted nut.
Figure 177
Figure 178
Planetary Carrier
Adjust axial play of sun gear shaft: 0.3 ~ 1.0 mm (Figure
179 ... Figure 186)
1. Determine dimension I from mounting face of planetary
carrier to contact face of thrust washer.
Dimension I, e.g. ......................................... 260.65 mm
Figure 179
Figure 181
Reference
Description
Number
1 Planetary Gear
2 Roller Bearing
3 Washer
4 Circlip Figure 182
Reference
Description
Number
1 Planetary Gear
Bearing Inner Ring with Cylinder
2
Rollers
3 Plastic Ring (Assembly Aid)
4 Angle Ring
Figure 183
CAUTION
Mount planetary gear or bearing inner ring with
large radius looking to planetary carrier
(downwards).
Figure 184
Figure 185
Figure 186
Figure 187
Pivot Bearing
Heat pivot bearing hole by means of hot-air blower and
insert super-cooled bushing(s).
CAUTION
Observe installation position for bushing version with
slot, insert bushings - with slot in 12 o’clock position.
Figure 188
Figure 189
Reference Reference
Description Description
Number Number
Steering Cylinder (Cylinder Tube 7 Rod Wiper
1
with Brake Head) 8 Dual Ring
2 Brake Head (Loose Part) 9 Circlip
3 Piston Rod 10 O-ring
4a O-ring Piston 11 Retaining Ring
4b Form Seal Ring Sealing 12 Flange
5 Guide Ring 13 Circlip
6 U-ring 14 Wrench Socket (Piston Rod)
CAUTION
Observe installation position - in this connection
see detailed sketch.
Figure 190
Figure 191
Figure 192
3. Install form seal ring (4a) and press with inner installer
(S2) into annular groove (arrow) of piston (3).
Figure 193
Figure 194
Figure 195
CAUTION
Observe installation position - insert piston rod (3)
with wrench point of attach (14 - See Figure 189)
showing in direction of arrow.
Figure 196
CAUTION
Slightly oil all sealing elements before installing the
piston rod.
Figure 197
Detailed Sketch:
Figure 198
CAUTION
Slightly oil all sealing elements before inserting the
brake head.
Figure 199
Figure 200
Figure 201
Figure 202
CAUTION
Observe installation position of flange - chamfer
(circlip contactarrow) to show towards circlip.
Figure 203
Figure 204
Figure 205
Reference
Description
Number
1 Axial Joint
2 Ball Joint with Tube
3 Clamp
CAUTION
Observe installation position of tie rods - offset to
show towards knuckle housing /axle housing (see
arrow).
CAUTION
Use locking nut just once for assembly.
Figure 208
Figure 209
Reference Reference
Description Description
Number Number
1 Straightedge Stop Screw with Stop Washer
4
2 Measuring Device (Internal)
3 Clamp 5 Stop Screw (Outer)
CAUTION
During track setting, the axial position of the piston
rod must not be changed any more.
CAUTION
Make setting on both sides.
CAUTION
For a toe-in and toe-out setting, which might be
required, stick to the vehicle manufacturer’s
specification.
CAUTION
Set steering angle - not before track setting is
completed.
Figure 210
CAUTION
Take the value of the steering angle "L" to be set
(See Figure 209) from the vehicle manufacturer’s
specification.
Figure 212
3. Mount oil drain, oil filler and oil control plug with
solenoid insert (3) - fitted with "new" O-ring - in both
outputs.
Tightening torque (M 36 x 1.5) ............... MA = 50 N•m
CAUTION
Prior to putting the axle into operation, observe ZF
lubrication and maintenance instructions - see page
0/8 and 0/9 - as well as the vehicle manufacturer’s Figure 213
regulations and instructions.
Rear Axle
Edition 1
Rear Axle
Safety Precautions............................................... 5
Applicable Models................................................ 5
Examples of Gear-Tooth-Contact Patterns
for the Gleason Gear-Tooth System ............................ 6
Lubrication and Maintenance Specifications for
Axle MT-E 3050/3060/3070 ................................ 8
Brake Wear Measurement on Axles of MT/MS-E
3050/3060/3070 Range ..................................... 10
Disassembly ....................................................... 12
Reassembly ........................................................ 18
Hub Carrier / Hub ........................................................ 18
Multi Disc Brake ........................................................... 22
Planetary Carrier .......................................................... 27
Assembly of An Output Ass’y (Figure 78)................. 29
Disassembly ....................................................... 30
Differential / Input......................................................... 30
Input - HL Transmission .............................................. 31
Differential Type "D 500" and "D-750"....................... 33
Reassembly ........................................................ 35
Differential / Input......................................................... 35
Reassembly of Output Ass’y (Figure 123 ~ 125) ..... 44
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
BSS0090L
Figure 1
Drive side (convex)
BSS0100L
Figure 2
Pinion distance must be increased
(+) BSS0110L
Figure 3
BSS0130L
Figure 4
(-) BSS0120L
Figure 6
BSS0150L
Figure 7
BSS0160L
Figure 8
Oil Change
A horizontal installation position of the axle in every direction
is precondition for an oil change according to specifications.
Place vehicle in a horizontal position.
Carefully clean all drain -, filler- and control plugs prior to
opening.
Drain oil only right after a longer travel period.
4 2
4
5
3
1
2
5
FG002507
Figure 9
Reference Reference
Description Description
Number Number
Oil Drain Hole Oil Filler / Oil Check Hole
1 3
(M36x1.5 Axle Drive Housing) (M36x1.5 Axle Drive Housing)
Oil Drain / Oil Filler Hole 4 Brake Connection Pipe
2
(M36x1.5 Output Units) 5 Brake Breather Valve
Brake
The following oils are admissible for the pneum.-hydr.
operated or accumulator operated brake actuation:
1. Motor oils SAE 10 W acc. to specification MIL-L 2104
C, MIL-L 46152, API-CC, CD, SC, SD, SE
2. ATF. oils type A, Suffic A, Dexron of II D
WARNING
The measurement of wear on the multi-disc brake only
gives limited information on the total state of the plate
pack - without disassembly of output.
CAUTION
To avoid injury when opening the oil drain / oil filler plug
(1), due to a possible pressure build-up in the planetary FG006855
carrier bring drain hole to topmost position (12 o’clock) Figure 10
and carefully unscrew oil drain and oil filler plug (1),
Then turn output until oil filler / oil drain hole (1) is on 9
o’clock position - Figure 10.
Sketches in Figure 11, Figure 12 are shown turned by 90°
Legend to Figure 10, Figure 11 and Figure 12 3
Reference
Description
Number
1 Oil Filler-Oil Drain Hole
2 Gauge Hole (∅ = 10 mm) in Ring Gear -
9 o’clock Position 4 5 6 7
3 Dial Indicator With Solenoid Support
4 Planetary Carrier
FG002281
5 Ring Gear Figure 11
6 Piston
7 Plate Pack
X Piston Stroke
FG002282
Figure 12
Figure 13
2. Loosen oil drain plug and drain oil from the axle - use
suitable collecting basin.
Figure 14
WARNING
To avoid injury when opening the oil drain and oil
filler plug, due to a possible pressure build-up in
the oil system of the planetary carrier
- bring drain hole to topmost position (12 o’clock)
and carefully unscrew oil drain and oil filler plug.
Then bring drain hole to lowermost position (6
o’clock) and drain oil from outputs - use suitable Figure 15
collecting basin! Then bring drain hole to 6 o’clock
position and drain the oil.
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24
CAUTION
Pay attention to the releasing O-ring (arrow)
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
CAUTION
Pay attention to the releasing bearing inner ring
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
Reference
Description
Number
1 Axle Housing
2 Hub Carrier
3 Hub
4 Multi-disc Brake
5 Planetary Carrier Figure 36
Figure 37
Figure 38
Figure 39
Figure 40
Figure 41
Figure 42
Reference
Description
Number
1 Hub
2 Shaft Seal
X Rim Offset
Figure 43
Figure 44
CAUTION
Apply sealing agent (Loctite-Nr. 574) to contact
face of shaft seal / hub.
CAUTION
Wet contact face of shaft seal / hub carrier with
spirit at the very beginning of the assembly -
assembly aid.
Figure 46
Figure 47
Figure 48
12. Bring hub bearing into contact position. for this purpose
tighten slotted nut with a tightening torque of max.
1,400 N•m.
CAUTION
Apply thread - hub carrier / slotted nut - with
lubricant
Figure 49
CAUTION
While tightening the slotted nut rotate hub in both
directions several times - roller setting
Figure 50
CAUTION
Pay attention to installation position of inner discs
- See Figure 52
CAUTION Figure 51
Take the actual necessary plate arrangement from
the corresponding spare parts list.
CAUTION
Position inner discs in such a way that one of the
tooth recesses (arrow) is in 6 o’clock position -
when axle is installed in vehicle
CAUTION Figure 52
CAUTION
Stick O-ring by means of grease - assembly aid.
Figure 53
CAUTION
Pay attention to installation position and
arrangement of sealing elements.
Figure 54
Reference
Description
Number
1 Ring Gear
2 Support Ring
3 U-ring
4 U-ring
5 Support Ring
Figure 55
Figure 56
Figure 57
Reference
Description
Number
1 Hex. Screw
2 Spring Sleeve
3 Compression Springs (Outer)
4 Compression Springs (Inner)
Figure 58
CAUTION
Use hex. screws just once for assembly
Figure 59
Figure 60
Detail "B"
Figure 61
CAUTION
Apply thread - hub carrier / slotted nut - with
lubricant
Figure 62
CAUTION
First tighten slotted nut with 1,400 N•m, then
retighten slotted nut until a fixing hole overlaps a
threaded hole in the hub carrier - in this
connection also refer to Figure 69
Figure 63
CAUTION
While tightening the slotted nut rotate hub in both
directions several times - roller setting
Test media
Motor oils SAE-10W correspond, MIL-L 2104 C, MIL-L
46152, API-CC, CD, SC, SD, SE, ATF-oils type A,
Suffic A, Dexron of II D
A. High pressure test
Build up testing pressure p = 100 bar and close Figure 64
locking valve of HP-pump.
The pressure is allowed to fall by max. 3 bar
during a 5-minute test duration.
B. Low pressure test
Reduce testing pressure to p = 5 bar and close
locking valve.
Reference
Description
Number
1 Ring Gear
2 Measuring Hole
3 Piston
X Disc Clearance / Piston Stroke Figure 65
CAUTION
If the required disc clearance / piston stroke (X =
1.2 .... 1.8 mm) is not achieved, correct it with Figure 67
corresponding inner clutch disc(s) - See Figure 52!
Figure 68
Figure 69
Planetary Carrier
adjust axial play of sun gear shaft : 0.3 ~ 1.0 mm (Figure
70~ 80)
1. Determine dimension I, from mounting face of planetary
carrier to contact face of thrust washer.
Dimension I, e.g. ......................................... 260.65 mm
Figure 70
Figure 72
Reference
Description
Number
1 Planetary Gear
2 Roller Bearing
3 Washer
Figure 73
4 Circlip
Reference
Description
Number
1 Planetary Gear
2 Bearing Inner Ring
3 Plastic Ring (Assembly Aid)
4 Angel Ring
Figure 74
CAUTION
Mount planetary gear or bearing inner ring with
large radius looking to planetary carrier
(downwards).
Figure 75
Figure 76
Figure 77
Figure 78
WARNING
Prior to putting the axle into operation fill it with oil -
for this purpose stick to lubrication and maintenance
instructions, page -8~12.
In addition observe the vehicle manufacturer's
regulations and instructions.
Differential / Input
1. Loosen oil drain plug and drain oil from the axle - use
suitable collecting basin.
Figure 79
WARNING
To avoid injury when opening the oil drain and oil
filler plug due to a possible pressure build-up in
the oil system of the planetary carrier - bring drain
hole to topmost position (12 o’clock) and carefully
unscrew oil drain and oil filler plug.
Then bring drain hole to lowermost position (6
o’clock) and drain oil from outputs - use suitable
Figure 80
collecting basin.
CAUTION
When working on the differential you can dismantle
the output(s) as a complete unit (Figure 81).
Figure 81
Figure 82
CAUTION
For assembly and disassembly of the HL
transmission stick to Repair Manual "2 HL 250/270/
290".
Figure 83
Figure 84
CAUTION
Secure axle by means of a support (arrow).
CAUTION
Pay attention to releasing differential.
Figure 85
Figure 86
CAUTION
Mark shim (installation position / bearing allocation)
- assembly aid.
Figure 87
CAUTION
Mark shim (installation position / bearing allocation)
- assembly aid!
Figure 88
Figure 89
Figure 90
A. Version "D-500"
Figure 91
B. Version "D-750"
CAUTION
At Version "D-750" screw connection are insert
with Loctite - difficult disassembly - heating-up
if necessary.
Figure 92
Figure 93
Figure 94
Differential / Input
Figure 95
Assembly Specifications
Position slotted pin(s) so that slot is looking into the
direction of force (arrow). In case of double slotted pins
- bring the slots in a 180° degrees offset position to
each other.
To Sketch:
Reference
Description
Number
1 Differential Carrier
Figure 96
2 Slotted Pin
Slotted Pin
3
(Just for Double Slotted Pin Version)
4 Force Direction
Figure 97
CAUTION
Put driving lugs of thrust washer into driving holes
/ differential carrier - do not position in oil supply
recesses.
Figure 98
CAUTION
Ensure radial installation position of thrust
washers.
Figure 99
Figure 100
WARNING
Put driving lug of thrust washer into driving bores /
differential carrier - do not position in oil supply
recesses.
Figure 101
Figure 102
B. Version "D-750"
Figure 103
CAUTION
Only version "D-750" - insert the hex. screws with
locking compound (Loctite No. 262).
Figure 104
WARNING
Ensure radial installation position - designation
corresponds to radial position marking.
A. Version "D-500"
Tightening torque (M 12x1.5/12.9) . MA = 145 N•m
B. Version "D-750"
Tightening torque (M 12x1.5/10.9) . MA = 122 N•m
Tightening torque (M 16x1.5/10.9) . MA = 300 N•m
Figure 105
Figure 106
Backlash
MT-E 3050/3060 = 0.12 - 0.24 mm
MT-E 3070 = 0.15 - 0.27 mm
Legend to Figure 107 ~ Figure 117
Reference
Description
Number
1 Axle Drive Housing
2 Shim Ring (∅ = 160 mm)
3 Differential (Crown Wheel)
4 Shim (Backlash)
5 Axle Housing Half
6 O-ring
7 Hexagon Screws (With Washer) Figure 107
Mounting Face / Axle Drive Housing Until
A
Shim Ring (Outer Diameter)
B ½ ∅ Of Shim Ring
Mounting Face / axle Drive Housing Until
C
Plane Face / Crown Wheel
Distance - Plane Face / Crown Wheel Until
D
Centre / Differential (Imprinted On Crown Wheel)
Mounting Face / Axle Drive Housing Until
X
Centre/Axle Drive Housing (Drive Pinion Bore)
WARNING
However, the required backlash is decisive for the
shim(s) to be used. Figure 108
CAUTION
Ensure that inserted differential is perfectly
positioned (for this purpose rotate in both
directions several times - roller setting).
Figure 110
CAUTION
Upon determination of dimension "C" take a
corrective value of + 0.07 mm (½ value of bearing
preload of differential bearing) into consideration.
CAUTION
If the value of dimension "X" is not achieved, use
a corresponding shim for correction (see item 4 -
Figure 107).
CAUTION
Position the bearing outer ring on the bearing inner
ring, until all rollers are located without any play.
For the following determination of dimension pay
attention to an exact contact of the bearing outer
ring and to a correct positioning of the differential.
CAUTION
A bearing preload of 0.15 mm corresponds to a
bearing rolling moment of approx. 3.0 ~ 4.0 N•m,
when using new taper roller bearings.
Figure 113
Figure 114
Figure 115
Figure 116
Backlash
MT-E 3050/3060 = 0.12 - 0.24 mm
MT-E 3070 = 0.15 - 0.27 mm
Figure 118
CAUTION
If contact pattern differs considerably, check pinion
distance of HL transmission - for this purpose refer
to repair manual 2 HL-250/270/290 acc.
Figure 119
4. Reinstall differential.
Figure 120
Figure 121
Figure 122
Figure 123
CAUTION
Observe O-ring (arrow).
Figure 124
WARNING
Prior to putting the axle into operation fill it with oil
- for this purpose stick to the lubrication and
maintenance instructions, page -8 ~ 12. Figure 125
In addition observe the vehicle manufacturer's
regulations and instructions.
Transmission
Edition 1
Transmission SP000962
Page 1
MEMO
Transmission SP000930
Page 2
Table of Contents
Transmission
Safety Precautions............................................... 5
Applicable Models................................................ 5
Layout 2 HL 250/270/290 Axle Attachment ...... 6
Layout 2 HL 250/270/290 Separate Installation 7
Measuring Points and Connections or
Installation View 2 HL 250/270/290 Layout "Axle
Attachment" .......................................................... 8
Measuring Points and Connections on the 2 HL
250/270/290 Transmission - Version "Separate
Installation" ......................................................... 10
Notes to the Required Oil Quality and Oil Filling
Capacity.............................................................. 11
Separate the HL-Transmission from the Axle
Casing ................................................................ 12
Disassembly - Brake / Clutch / Planet Carrier
............................................................................ 13
Lube Oil Pump/Downshift Interlock ............................. 13
Speed Transmitter ........................................................ 14
Emergency Release (Parking Brake).......................... 14
Input Housing and Modulation Valve ......................... 15
Brake / Clutch .............................................................. 16
Planet Carrier ............................................................... 22
Disassembly - Output........................................ 26
Version - Axle Attachment .......................................... 26
Version - "Separate Installation" ................................. 30
Reassembly - Output ........................................ 34
Version - Axle Attachment .......................................... 34
Reassembly - Brake / Clutch / Planet Carrier 53
Planet Carrier ............................................................... 53
Brake/Clutch .................................................................. 59
Modulation Valve and Input Housing ......................... 72
Emergency Release (Parking Brake).......................... 74
Transmission SP000962
Page 3
MEMO
Transmission SP000930
Page 4
SAFETY PRECAUTIONS
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Transmission SP000962
Page 5
LAYOUT 2 HL 250/270/290
AXLE ATTACHMENT
INPUT
OUTPUT OUTPUT
FG007281
Figure 1
Reference Reference
Description Description
Number Number
Cup Springs for Multi-disk Brake 6 Lube Oil Pump
1
and Multi-disk Clutch 7 Spur Gear Drive
2 Input Shaft Output Pinion - Rear Axle Direct
8
3 Multi-disk Brake Attachment
4 Multi-disk Clutch 9 Output Flange - Front Axle
5 Planetary Drive 10 Attachment Hydro - Motor
Transmission SP000962
Page 6
LAYOUT 2 HL 250/270/290
SEPARATE INSTALLATION
1 2 3 4 5 6
INPUT
OUTPUT OUTPUT
10 9 8
FG007282
Figure 2
Reference Reference
Description Description
Number Number
Cup Springs for Multi-disk Brake 6 Lube Oil Pump
1
and Multi-disk Clutch 7 Spur Gear Drive
2 Input Shaft 8 Output Flange - Rear Axle
3 Multi-disk Brake 9 Output Flange - Front Axle
4 Multi-disk Clutch 10 Attachment Hydro - Motor
5 Planetary Drive
Transmission SP000962
Page 7
MEASURING POINTS AND
CONNECTIONS OR
INSTALLATION VIEW 2 HL 250/
270/290 LAYOUT "AXLE
ATTACHMENT"
(With electr, downshift interlock integranted in the vehicle)
Figure 3
Reference Reference
Description Description
Number Number
8 Lube Oil Pump S Lubrication Pressure (M10x1)
B Brake (M16x1.5) Bleeder Valve (Emergency
EN
K Clutch (M16x1.5) Actuation Parking Brake)
J Road Speed (Brake - M10x1) Pressure Relief Valve
UN (Emergency Actuation Parking
M Off-road Speed (Clutch - M10x1)
Brake)
N Speed Transmitter (Output Speed)
Transmission SP000962
Page 8
Figure 4
Reference Reference
Description Description
Number Number
Oil Filter and Oil Drain Plug Oil Drain Plug - Transmission
1 12
(M36x1.5) (M24x1.5)
2 Wheel Head LH and RH Model Identification Plate -
13
3 Bleeder Service Brake Transmission
Connection Service Brake (13/16 EB Bleeder Valve (Brake)
4
- 16 UNF) EK Bleeder Valve (Clutch)
5 Axle Casing Emergency Actuation Parking
6 Axle Drive Housing PN Brake (Grease Nipple -
Connection to Din 71 412)
7 Model Identification Plate - Axle
Pressure Relief Valve
8 Lube Oil Pump
UN (Emergency Actuation Parking
9 Transmission 2 HL 250/270/290 Brake)
10 Connection Hydro-motor
11 Output Flange - Front Axle
Transmission SP000962
Page 9
MEASURING POINTS AND
CONNECTIONS ON THE 2 HL
250/270/290 TRANSMISSION -
VERSION "SEPARATE
INSTALLATION"
(With electr, downshift interlock integranted in the vehicle)
3
4
3 4
7 2
1 8
1
2
5
11
7
6
10
5
8 9
6
9
10
11
FG007283
Figure 5
Reference Reference
Description Description
Number Number
Pressure Oil Connection - Multi- Bleeder Pressure Relief Valve
1
disk Clutch 7 (Emergency Release Parking
Pressure Oil Connection - Multi- Brake)
2
disk Brake 8 Speed Transmitter
3 Bleeder Valve - Clutch Measuring Point - Road Speed
9
4 Bleeder Valve - Brake (Brake)
Lubrication Nipple (Emergency Measuring Point - Off-road
5 10
Release Parking Brake) Speed (Clutch)
Bleeder Valve (Emergency Measuring Point - Lubrication
6 11
Release Parking Brake) Pressure
Transmission SP000962
Page 10
NOTES TO THE REQUIRED OIL
QUALITY AND OIL FILLING
CAPACITY
Oil Quality / Oil Grade
Only oils according to the "Table of Recommended
Lubricants" pages of operation manual.
Transmission SP000962
Page 11
SEPARATE THE HL-
TRANSMISSION FROM THE
AXLE CASING
(Only for the Version "Axle Attachment")
1. Drain oil from the axle casing.
use a suitable collector.
Figure 6
Figure 7
Transmission SP000962
Page 12
DISASSEMBLY - BRAKE /
CLUTCH / PLANET CARRIER
1. Mount the transmission to the assembly truck.
CAUTION
Illustration shows the HL-Version "Axle Attachment"
Figure 8
Figure 9
CAUTION
Figure 10
Cpl. disassembly of the lube oil pump/downshift
interlock - See “Disassembly - Lube Oil Pump/Downshift
Interlock” on page -81..
Transmission SP000962
Page 13
Speed Transmitter
Loosen the screw and pull off the speed transmitter.
Figure 11
CAUTION
Position of the single connection or bleeder valves /
lubrication nipples etc. ... as to the Version
"Transmission Installation Position Horizontal" - See
Figure 215 on page -78. Figure 12
Figure 13
Figure 14
Transmission SP000962
Page 14
4. Remove the lubrication nipple, both screw plugs and
the bleeder valve - see arrow.
Figure 15
CAUTION
Loosen the bolt connection of the input housing equally
- the input housing is subject to a cup spring and
compression spring preload.
Figure 16
Figure 17
Transmission SP000962
Page 15
2. Modulation valve:
Remove the compression spring and the O-ring (arrow).
Figure 18
Figure 19
Brake / Clutch
1. Remove the cup springs from the brake.
Figure 20
Transmission SP000962
Page 16
2. Remove the cup springs from the clutch.
Figure 21
Figure 22
Figure 23
WARNING
Attach 2 (two) eyebolts and pull the piston
cautiously out of the housing - risk of damage.
Figure 24
Transmission SP000962
Page 17
5. Remove both seals (arrows) from the piston.
Figure 25
Figure 26
Figure 27
WARNING
Remove the pressure ring with ring - also See
Figure 29 - cautiously by means of lever action -
risk of damaging the sealing surfaces.
CAUTION
Figure 28
Ring can also remain in the housing - disassemble
the ring separately.
Transmission SP000962
Page 18
WARNING
Remove the pressure ring from the ring cautiously
by means of lever action - risk of damaging the
sealing surfaces.
Figure 29
Figure 30
9. Take the disc set of the brake with end shim(s) out of
the housing.
CAUTION
Illustration shows version / components of the 2 HL-
290.
Figure 31
Figure 32
Transmission SP000962
Page 19
11. Remove the snap ring and the shim.
Figure 33
12. Take the disc set of the clutch (with end shim/s) out of
the internal gear.
CAUTION
Illustration shows version / components of the 2 HL-
290.
Figure 34
13. Remove the cpl. input shaft with internal gear from the
housing.
Figure 35
Figure 36
Transmission SP000962
Page 20
15. Press the input shaft out of the ball bearing/internal
gear.
Figure 37
Figure 38
CAUTION
In case of an extremely fixed seat - heat the
centering disc - disassembly aid.
Figure 39
18. Unsnap the retaining ring and remove the ball bearing.
Figure 40
Transmission SP000962
Page 21
Planet Carrier
1. Remove the axial needle cage with both thrust
washers.
Figure 41
CAUTION
Cpl. disassembly of the lube oil pump/downshift
interlock - See “Disassembly - Lube Oil Pump/
Downshift Interlock” on page -81.
Figure 42
Figure 43
CAUTION
Pay attention to the released planet carrier and the
bearing innerring.
Figure 44
Transmission SP000962
Page 22
5. Pull the second bearing inner ring from the planet
carrier.
Figure 45
CAUTION
If the taper roller bearings are reused - pay
attention to the bearing location, i.e. respective
bearing inner ring to bearing outer ring.
Figure 46
Figure 47
Figure 48
Transmission SP000962
Page 23
9. Pull off the bearing inner ring ñ in case of an
extremely fixed seat heat the bearing inner ring.
Figure 49
Figure 50
CAUTION
Countersunk screws are installed with locking
compound (Loctite) - heating for disassembly, if
necessary. Figure 51
Transmission SP000962
Page 24
12. Remove the screen sheet (2) from the planet carrier
(1).
Figure 52
Transmission SP000962
Page 25
DISASSEMBLY - OUTPUT
Figure 53
Figure 54
Figure 55
CAUTION
Pay attention to the released bearing inner ring and
the adjusting ring (rolling moment / pinion bearing)
behind it.
Figure 56
Transmission SP000962
Page 26
5. Remove the O-ring (arrow) and the bush from the
pinion.
Figure 57
Figure 58
CAUTION
Pay attention to the shim behind it (pinion gap
setting).
Figure 59
Transmission SP000962
Page 27
8. Pull off the bearing cover.
Figure 60
Figure 61
Figure 62
11. Lift the output gear with oil baffle plate out of the
housing.
Remove the oil baffle plate from the output gear.
Figure 63
Transmission SP000962
Page 28
12. Remove the screen sheet.
Figure 64
13. Expel the bearing outer ring from the housing bore
(arrow).
Figure 65
Figure 66
Transmission SP000962
Page 29
Version - "Separate Installation"
(HL-Transmission installed separately from the axle)
In case of the transmission version "Separate Installation" it
is possible, differently from the transmission version "Axle
Attachment", to remove and to install the output - without
the previous disassembly of brake/clutch and planet carrier.
2 3
FG007292
Figure 67
1. Legend to Figure 67
Reference
Description
Number
1 Input
2 Output - Front Axle
3 Output - Rear Axle
Transmission SP000962
Page 30
2. Fasten the output flange by means of the fixture.
Loosen the bolt connection ñ pull off washer, O-ring
and flange.
Figure 68
CAUTION
Install the second output flange and the shaft seal
analogously.
Figure 69
Figure 70
Figure 71
Transmission SP000962
Page 31
6. Press the output gear out of the ball bearing/cover.
remove the released oil baffle plate.
Figure 72
Figure 73
Figure 74
Figure 75
Transmission SP000962
Page 32
10. Expel the ball bearing from the housing bore.
Figure 76
Transmission SP000962
Page 33
REASSEMBLY - OUTPUT
Only when a new housing is installed (Figure 77):
Seal the finished holes (8x) of the oil supply bores with
screw plugs.
Figure 77
CAUTION
Observe the installation position. See Figure 78.
Figure 79
Figure 80
Transmission SP000962
Page 34
4. Position the screen sheet - with slotted pin (See Figure
80) into the fixing bore (arrow).
CAUTION
Observe the installation position - slotted pin =
radial fixing of the screen sheet.
Figure 81
Figure 82
CAUTION
Installation position of the shaft seal - Sealing lip
showing to the oil sump (See Figure 84). Figure 83
CAUTION
Install the shaft seal (1) considering the required
installation position (Dim. "X" - See Figure 84).
CAUTION
Grease the shaft seal in the area around the
sealing and dust lip.
Transmission SP000962
Page 35
7. Exact installation position of the shaft seal is
guaranteed by use of the specified mounting tool.
Legend to the sketch:
Reference
Description
Number
1 Shaft seal
2 Bearing cover
X Installation Dimension → 69.5 - 0.5 mm
Figure 84
Determine Adjusting Shim for Pinion Gap
Reference
Description
Number
1 Pinion
2 Roller Bearing
3 Bearing Cover
4 Ball (ø = 7 mm)
A Auxiliary Dimension
B Bearing Width
C Reference Dimension
Contact Surface / Bearing Cover to
D
Contact / Bearing Bore
E 73.0 mm (Constant Value)
Pinion Dimension (Engraved on the
X
Pinion)
189.0 mm (Contact Surface / Bearing
Z
Cover to Center / axle Casing)
Figure 85
CAUTION
For a correct installation and positioning of the
pinion, the following steps are to be carried out as
exactly as possible.
Transmission SP000962
Page 36
2. Determine the auxiliary dimension "A".
Position the ball (ø = 7 mm) into the centering bore of
the pinion and determine Dim. "A", from the contact
surface /pinion shoulder to the ball.
Auxiliary dimension "A" = e.g. 42.56 mm
CAUTION
Auxiliary dimension "A" is obligatory to determine
the reference dimension "C" - on the installed
pinion (Figure 112).
Figure 86
CAUTION
Since the installed roller bearing is subject to a
preload, deducting an empirical value of - 0.1 mm is
to be considered.
Figure 88
Figure 89
Transmission SP000962
Page 37
EXAMPLE:
Dim. "Z" ....................................................... 189.00 mm
Dim. "X" z.B. ............................................ - 116.00 mm
Result → Dim. "E" .................................... = 73.00 mm
Dim. "E" ......................................................... 73.00 mm
Dim. "B+D" (e.g. 36.55 + 34.50) ............. - 71.05 mm
Result → required shim "S" ....................... = 1.95 mm
6. Insert the determined shim(s) "S" = e.g. 1.95 mm and
install the bearing outer ring subsequently until contact
is obtained.
Figure 90
7. Oil the O-rings (arrows) and insert them into the ring
grooves of the bearing cover.
Figure 91
Figure 92
Transmission SP000962
Page 38
9. Mount the oil baffle plate on the bearing cover.
CAUTION
Observe the installation position - locate the fixing
lug of the oil baffle plate into the recess of the
bearing cover (see arrow).
Figure 93
Figure 94
11. Mount the heated bearing inner ring until contact and
after
cooling-down install it subsequently until contact is
obtained.
Figure 95
Transmission SP000962
Page 39
12. Mount the bush, oil the O-ring (arrow) and put it into
the ring groove.
Figure 96
Figure 97
Figure 98
Transmission SP000962
Page 40
Determine the Adjusting Ring for Rolling Moment/Pinion
Bearing
1. Rotate the transmission by 180°.
Mount the adjusting ring (s = optional).
CAUTION
It is recommended to reinstall the adjusting ring
(e.g. s = 1.35 mm) from the disassembly, if
however the required rolling moment of 1.5 ~ 3.0 Figure 99
N•m (without shaft seal) is not obtained - see
bearing rolling moment check Figure 104 - the
bearing rolling moment is to be corrected with an
adequate adjusting ring.
Figure 100
Figure 101
CAUTION
Rotate the pinion - when tightening - in both
directions (aligning of rollers) several times.
Transmission SP000962
Page 41
5. Turn back the pinion fastening and remove the
clamping bar respectively.
Figure 103
CAUTION
If the required rolling moment deviates, it is to be
corrected with an adequate adjusting ring (See
Figure 99).
Figure 104
Figure 105
Transmission SP000962
Page 42
Shaft Seal/Output Flange
1. Contact face (external shell of the shaft seal) if
• rubberized ⇒ to be wet with spirit
• metal ⇒ to be provided with sealing compound
(Loctite No. 586).
CAUTION
Installation position of the shaft seal. Sealing lip
showing to the oil sump (See Figure 107).
Reference
Description
Number
1 Shaft Seal
2 Screen Sheet
3 Flange
4 Roller Bearing
5 Bearing Cover
M Installation Dimension → 17.6 - 0.5 mm
Figure 107
N Installation Dimension → 27.5 + 0.3 mm
Figure 108
Transmission SP000962
Page 43
3. Only for installation of a new flange/screen sheet or if
removed (Figure 109) Install the screen sheet (2),
considering the required installation position (Dim. "N" -
See Figure 107).
Exact installation position of the screen sheet is
guaranteed by use of the specified mounting tool.
Figure 109
Figure 110
Figure 111
Transmission SP000962
Page 44
CAUTION
If the constant value of Dim. "E" = 73.00 ± 0.05 mm
is not achieved, it is to be corrected with an
adequate shim / pinion gap (See Figure 90).
Transmission SP000962
Page 45
Version Separate Installation
(HL-Transmission installed separately from the axle)
In case of the transmission version "Separate Installation" it
is possible, differently from the transmission version "Axle
Attachment", to remove and to install the output - without
the previous disassembly of brake/clutch and planet carrier.
Figure 113
Reference Reference
Description Description
Number Number
1 Transmission Housing 9 Output Gear
2 Ball Bearing 10 Shaft Seal
3 Screen Sheet 11 Output Flange
4 Cover 12 Stud Bolt
5 Ball Bearing 13 Dirt Deflector
6 Retaining Ring 14 O-ring
7 O-ring 15 Washer
8 Oil Baffle Plate 16 Hexagon Screw
Transmission SP000962
Page 46
1. Insert ball bearing (2) until contact is obtained.
Figure 114
Figure 115
CAUTION
Observe the installation position - slotted pin =
radial fixing of the screen.
Figure 116
Figure 117
Transmission SP000962
Page 47
5. Oil both O-rings (arrows) and put it into the ring
grooves of the planet carrier.
Figure 118
Figure 119
CAUTION
Observe the installation position - locate the fixing
lug (arrow) into the recess of the bearing cover
(radial fixing).
Figure 120
CAUTION
Rest the ball bearing against the bearing inner ring.
Figure 121
Transmission SP000962
Page 48
9. Heat the bearing inner ring of the ball bearing.
Figure 122
Figure 123
CAUTION
Observe the installation position of the bearing
cover (2) in the transmission (1) - Transmission
Installation "Vertical" or "Horixontal" - see detailed
sketches below
Figure 124
Figure 125
Transmission SP000962
Page 49
Shaft Seal/Output Flange
1. Legend to the sketch: N 3
M
2 5
Reference
Description
Number 1
1 Shaft Seal
4
2 Screen Sheet
3 Flange
4 Ball Bearing
FG007318
5 Bearing Cover Figure 126
M Installation Dimension → 17.6 - 0.5 mm
N Installation Dimension → 27.5 + 0.3 mm
CAUTION
Installation position of the shaft seal - Sealing lip
showing to the oil sump (See Figure 126).
Figure 127
CAUTION
Install the shaft seal (1) considering the required
installation position (Dim. "M" - See Figure 126).
CAUTION
Exact installation position of the shaft seal is
guaranteed by use of the specified mounting tool.
Transmission SP000962
Page 50
3. Only for installation of a new flange or if stud bolts
were removed (Figure 128)
CAUTION
Install the stud bolts.
Installation position - Stud bolts with short thread
length into flange.
CAUTION
Exact installation position of the screen sheet is
guaranteed by use of the specified mounting tool.
Figure 129
Figure 130
Figure 131
Transmission SP000962
Page 51
7. Position the washer and fasten the output flange by
means of hexagon screws.
CAUTION
Install the second shaft seal/output flange (front
axle output) analogously.
Transmission SP000962
Page 52
REASSEMBLY - BRAKE /
CLUTCH / PLANET CARRIER
Planet Carrier
1. Illustration shows the HL-Version "Axle Attachment".
Install the bearing outer ring until contact.
CAUTION
Observe the bearing location - bearing inner ring to
bearing outer ring - also see instructions for
disassembly page -23, Figure 46. Figure 133
CAUTION
Observe the bearing location - bearing inner ring to
bearing outer ring - also see instructions for
disassembly page -23, Figure 46.
Figure 134
CAUTION
Insert the screen sheet and fasten it with
countersunk screws.
Secure the countersunk screws with locking
compound (Loctite No. 243).
Figure 135
Transmission SP000962
Page 53
4. Install the screen sheet (2) considering the installation
dimension "X" (see detail sketch) onto the planet
2
carrier (1).
3
1
Figure 136
Reference
Description
Number 1
2 X
1 Planet Carrier
3
2 Screen Sheet
Contact Surface - Axial Needle Cage/
3
axial Washer
X Install. Dim. 1.5 - 0.5 mm
Figure 137
CAUTION
Prior to installation grease the slotted pin -
X
assembly aid.
Figure 138
Transmission SP000962
Page 54
Legend to the sketch:
1
Reference
Description 2
Number
1 Planet Carrier
2 Slotted Pins (6x)
3 Center (Planet Carrier)
3
Figure 139
Reference
Description
Number
1 Bearing inner ring with cyl. rollers
1a Packing Sleeve + Assembly Aid
2 Planetary Gear
3 Cyl. Rollers
3a Packing Sleeve + Assembly Aid
4 Shim
Figure 140
CAUTION
Keep the bearing inner ring to contact and rotate
the planetary gear by 180°. Figure 141
7. Position the cyl. rollers (3) onto the planetary gear (2).
Figure 142
Transmission SP000962
Page 55
8. By means of the mounting tool press the cyl. rollers (2)
into the planetary gear (2).
Then remove the two loose packing sleeves (3a).
Figure 143
CAUTION
Keep the bearing inner ring with cyl. rollers to
contact - and mount the preassembled the
planetary gear to the planet carrier pin.
Figure 144
Figure 145
CAUTION
Install the retaining ring subsequently until contact
at the groove base is obtained.
Transmission SP000962
Page 56
11. Press the bearing inner ring onto the planet carrier until
contact ist obtained.
Figure 147
Figure 148
Figure 149
Transmission SP000962
Page 57
14. Rotate the transmission by 180°.
Check locating of the bearing outer ring (arrow) -
installation of the bearing outer ring - See Figure 133.
Figure 150
Figure 151
Figure 152
Transmission SP000962
Page 58
17. Fasten the fixture to the output flange.
CAUTION
Tighten the hexagon screws equally - risk of
distortion.
Figure 153
WARNING
When tightening the hexagon bolts rotate the planet
carriers - into both directions. several times
(aligning of rollers).
Brake/Clutch
1. Mount the heated centering disc and press it until
contact is obtained.
Figure 154
Figure 155
Transmission SP000962
Page 59
3. Insert the ball bearing into the internal gear and fasten
it by means of the retaining ring.
Figure 156
Figure 157
Figure 158
Figure 159
Transmission SP000962
Page 60
7. Rotate the transmission by 180°.
Position the axial needle cage with both thrust washers
(1x each, underneath and onto the axle needle cage
resp. - see Figure).
CAUTION
Fix the axial needle cage and the thrust washers by
means of grease centrically - assembly aid.
Figure 160
Figure 161
Reference
Description
Number
Figure 162
Lower Ring Groove (2 HL-290, Item
A
Retaining Ring -1)
Upper Ring Groove (2 HL-250/270,
B
Item Retain. Ring -1)
1 Retaining Ring
2 End Shim / Brake (1 Pc.)
3 Outer Disc / Brake (9 Pcs.)
4 Inner Disc / Brake (8 Pcs.)
5 Inner Disc / Clutch (12 Pcs.)
6 Inner Disc / Clutch (11 Pcs.)
Transmission SP000962
Page 61
Reference
Description
Number
7 Transmission Housing
8 Disc Carrier / Internal Gear
Reference
Description
Number
Lower Ring Groove (2 Hl-290, Item
A
Retaining Ring -1)
Upper Ring Groove (2 Hl-250/270,
B
Item Retain. Ring -1)
1 Retaining Ring
2 End Shim / Brake (1 Pc.)
3 Outer Disc / Brake (6 Pcs.)
4 Inner Disc / Brake (6 Pcs.)
5 End Shim / Clutch (1 Pc.)
6 Inner Disc / Clutch (10 Pcs.)
Figure 163
7 Inner Disc / Clutch (9 Pcs.)
8 Transmission Housing
9 Disc Carrier / Internal Gear
Reference
Description
Number
Lower Ring Groove (2 Hl-290, Item
A
Retaining Ring -1)
Upper Ring Groove (2 Hl-250/270,
B
Item Retain. Ring -1)
1 Retaining Ring
2 End Shim / brake (2 Pcs.)
3 Outer Disc / brake (5 Pcs.)
4 Inner Disc / brake (4 Pcs.)
5 End Shim / clutch (2 Pcs.)
6 Inner Disc / clutch (8 Pcs.)
Figure 164
7 Inner Disc / clutch (7 Pcs.)
8 Transmission Housing
9 Disc Carrier / internal Gear
Transmission SP000962
Page 62
A. Brake
Snap the retaining ring (1) into the ring groove
(A).
CAUTION
Observe the installation position of the
retaining ring (1) - ring groove (A) only for
Version "2 HL-290"
Figure 165
Figure 166
CAUTION
Position the outer disc (1 Pc.) s = variable 2.8
~ 3.7 mm, in the disc set on the top (piston-
side).
With outer disc s = variable, the disc
clearance /piston stroke will be adjusted - See Figure 167
Figure 180.
D. Clutch:
Insert the disc set (outer / inner discs) - beginning
with an outer disc - alternately.
CAUTION
Position the outer disc (1 Pc.) s = variable 1.2
~ 1.6 mm, in the disc set on the top (piston
side).
With outer disc s = variable, the disc Figure 168
clearance /piston stroke will be adjusted - See
Figure 179.
Transmission SP000962
Page 63
Adjust and check the Disc Clearance/Piston Stroke of
Brake and Clutch
1. Mount the pressure piece (without compression spring).
Figure 169
2. Oil the axial roller cage and mount it with both thrust
washers (1x each, positioned underneath and onto the
axial needle cage respectively - see Figure).
Figure 170
Figure 171
Figure 172
Transmission SP000962
Page 64
5. Insert both cup springs / clutch.
Fix the cup springs by means of grease and position
them centrically. assembly aid.
CAUTION
Observe the installation position - also see Figure
175.
Figure 173
CAUTION
Observe the installation position - also see Figure
175.
Figure 174
Reference l ll lll
Description
Number
1 Measuring Fixture D C B A
5
2 Piston / Clutch 3 X
Y
3 Cup Springs / Clutch 2 4
4 Piston / Brake 6
5 Cup Springs / Brake
6 Transmission Housing FG002838
Figure 175
Measuring Bore (Disc Clearance /
I
Clutch)
Measuring Bore (Disc Clearance /
II
Brake)
A Mounting Face / Housing - Face / Piston
Mounting Face / Housing - Piston
B
Contact / Housing
C Mounting Face / Housing - Face / Piston
Mounting Face / Housing - Piston
D
Contact / Housing
Transmission SP000962
Page 65
CAUTION
Locate the measuring fixture with hexagon screws
equally (risk of breakage) until contact is obtained.
Figure 176
Figure 177
Figure 178
Transmission SP000962
Page 66
WARNING
If the required disc clearance (piston stroke) is not
obtained, this is to be corrected with a suitable
outer disc - See Figure 168.
WARNING
If the required disc clearance (piston stroke) is not
obtained, this is to be corrected with a suitable
outer disc n see Figure 167.
Figure 181
12. Insert the oil baffle plate into the disc carrier and fix it
with the snap ring.
Figure 182
Transmission SP000962
Page 67
13. Oil the sealing faces and the O-ring.
Insert the O-ring (arrow) into the groove and insert the
ring.
CAUTION
Observe the installation position - See Figure 183.
Figure 183
Figure 184
Figure 185
16. Insert the seal (1) with the sealing lip showing to the
oil sump. also see detail sketch.
Put both O-rings (2) into the ring grooves of the
pressure ring (3) and insert the preassembled pressure
ring - observe the installation position.
Figure 186
Transmission SP000962
Page 68
17. By means of the mounting tool locate the pressure ring
until contact.
Figure 187
Figure 188
Figure 189
Transmission SP000962
Page 69
20. Oil the axial roller cage and mount it with both thrust
washers (1x each to be positioned underneath and
onto the axial needle cage respectively - See Figure).
Figure 190
Figure 191
Reference
Description
Number
1 Housing
2 Seal (With Sealing Lip)
3 Seal
4 Piston / Brake
5 Seal (With Sealing Lip)
6 Seal (With Sealing Lip)
7 Piston / Clutch
Figure 192
Figure 193
Transmission SP000962
Page 70
24. Insert the preassembled piston / brake until contact is
obtained.
CAUTION
Piston is to be positioned that the oil supply bore
(arrow) - with the HL-Transmission installed into the
vehicle n is at 12 o’clock position.
Observe the version as to the transmission
installation position "Horizontal - Vertical". Figure 194
Figure 195
Figure 196
Figure 197
Transmission SP000962
Page 71
28. Press the piston axially, contrary to the compression
spring preload, and seal the pressure oil supply bore
by means of screw plug / sealing ring (arrow) - thus the
piston is kept in axial position - assembly aid for input
housing assembly (Figure 204 and 213).
Figure 198
CAUTION
Observe the installation position - See Figure 199
and also Figure 175 respectively.
Figure 199
CAUTION
Observe the installation position -See Figure 200
and also Figure 175.
Figure 200
Figure 201
Transmission SP000962
Page 72
2. Place the O-ring (arrow) and insert the compression
spring.
Figure 202
3. Input housing:
Oil the O-ring and put it into the ring groove of the
input housing.
Figure 203
Figure 204
WARNING
Locate the input housing with hexagon screws
equally (risk of breakage) until contact is obtained.
Figure 205
Transmission SP000962
Page 73
Emergency Release (Parking Brake)
Legend to Figure 206:
Reference
Description
Number
1 Input Housing
2 Housing
3 O-ring
4 Threaded Element (Orifice)
5 Ball
6 Compression Spring
7 O-ring
8 Bleeder
Position of lubrication nipple for the Figure 206
version "Transmission Installation Position
9 Vertical" - Position of lubrication nipple for
the version "Transmission Installation
Position Horizontal" -See Figure 211
Figure 207
Figure 208
Transmission SP000962
Page 74
3. Insert the compression spring (6).
Figure 209
Transmission SP000962
Page 75
Check the Emergency Release for Leak Tightness
CAUTION
Illustration shows the Version "Transmission Installation
Position Vertical" (Figure 210)
CAUTION
For the version "Transmission Installation Position
Horizontal" the connection and positions respectively of
the bleeder valves / lubrication nipple etc. ... are to be
considered according to the illustration in Figure 211.
Reference
Description
Number
Bleeder/pressure-relief Valve (Emerg.
1
Release - Park. Brake)
2 Screw Plug
Bleeder Valve (Emergency Release -
3
Parking Brake)
Lubrication Nipple (Emergency Release
4
- Parking Brake) Figure 211
5 Bleeder Valve (Multi-disc Clutch)
6 Bleeder Valve (Multi-disc Brake)
Pressure Oil Connection - Multi-disc
7
Brake
Pressure Oil Connection - Multi-disc
8
Clutch
Transmission SP000962
Page 76
2. Install the bleeder valve (1), screw plugs (2) with O-
ring screw plug (3) with O-ring and compressed air
connection piece (4).
Tightening torque
Bleeder valve (M 10x1) ........................... MA = 22 N•m
Screw plug (M 10x1 with O-ring) ........... MA = 25 N•m
Screw plug (M 18x1.5 with O-ring) ........ MA = 35 N•m
Compr.air connect. piece (M 10x1) w. seal. ring) ..MA = 15
N•m
Figure 212
Figure 213
Figure 214
Transmission SP000962
Page 77
Check the Multi-Disc Brake and Multi-Disc Clutch for
Leak Tightness as well as Closing Pressure
Legend to Figure 215:
Reference
Description
Number
1 Transmission Housing
2 Input Housing
AB Pressure Oil Connection - Multi-disc Brake
AK Pressure Oil Connection - Multi-disc Clutch
EB Bleeder Valve - Multi-disc Brake
EK Bleeder Valve - Multi-disc Clutch
Figure 215
CAUTION
Illustration shows the version "Transmission Installation
Position Vertical"
CAUTION
For the version "Transmission Installation Position
Horizontal" the connections and positions respectively
of the bleeder valves / lubrication nipple etc. ... are to be
considered according to the illustration in Figure 211.
1. Multi-disc brake:
Connect the HP-Pump ("AB" - See Figure 215 and
Figure 211), Build up a pressure of p = 30 ... max. 35
bar
- Bleed the pressure chamber (several times).
Close the shut-off valve.
During a test duration of 3 minutes no measurable
pressure drop is allowed!
Test medium:
Figure 216
According to List of Lubricants TE-ML 07
Transmission SP000962
Page 78
2. Closing pressure test (Cup spring preloading force):
When measuring the closing pressure the valve block
is not allowed to be attached to the transmission due
to the by-pass function between brake and clutch.
Connection "AK" (See Figure 215 and Figure 211
respectively) open (not closed and tank connection
respectively).
Reduce the pressure slowly, when pressure range 11 ~
9 bar (closing pressure) is reached, the input shaft has
to be locked at a tightening torque of 50 ± 5 N•m.
Figure 217
3. Multi-disc clutch:
Connect the HP-Pump ("AK" - See Figure 215 and
Figure 211), Build up a pressure of p = 30 ... max. 35
bar
- Bleed the pressure chamber (several times).
Close the shut-off valve.
During a test duration of 3 minutes no measurable
pressure drop is allowed.
Test medium:
Figure 218
According to the "Table of recommended lubricants" of
operation manual.
4. Closing pressure test (Cup spring preloading force):
When measuring the closing pressure the valve block
(only for the version "with" mounted electr. downshift
interlock) is not allowed to be attached to the
transmission due to the by-pass function between brake
and clutch.
Connection "AB" (See Figure 215 and Figure 211
respectively) open (not closed and tank connection
respectively).
Reduce the pressure slowly, when pressure range 15.5
~ 13.5 bar (closing pressure) is reached, the input Figure 219
shaft has to be locked at a tightening torque of 50 ± 5
N•m.
Speed Transmitter
Install the speed transmitter with O-ring.
Tightening torque (M 8/8.8) .............................. MA = 23 N•m
Figure 220
Transmission SP000962
Page 79
Lube Oil Pump/Downshift Interlock
1. Install the lube oil pump (with O-rings) or the downshift
interlock - depending on the version - (Illustration
shows - Version "Lube Oil Pump").
CAUTION
Cpl. assembly of the lube oil pump / downshift
interlock - See “Reassembly - Lube Oil Pump/
Downshift Interlock” on page -88. Figure 221
WARNING
Prior to put the unit into operation the
specifications and regulations respectively as well
as the instructions of the transmission operating
and maintenance instructions as well as the
specifications and instructions of the vehicle
manufacturer have to be observed
Transmission SP000962
Page 80
DISASSEMBLY - LUBE OIL
PUMP/DOWNSHIFT INTERLOCK
Figure 222
Figure 223
Figure 224
Transmission SP000962
Page 81
4. Loosen the pump cover bolt connection, keep the
housing in vertical position - disassembly aid (also see
Figure 226).
Figure 225
CAUTION
Keep pump to contact and rotate it by 180°.
disassembly aid.
Figure 226
6. Remove the outer (1) and internal rotor (2) and take
the released ball [(3) driver] out of the control housing
(4).
CAUTION
Outer, internal rotor and control housing = rotor set
Figure 227
Figure 228
Transmission SP000962
Page 82
8. Unsnap the retaining ring.
Figure 229
Figure 230
10. Unsnap the retaining ring and press the ball bearing
from the shaft.
Figure 231
Figure 232
Transmission SP000962
Page 83
Version "with" hydr. Downshift Interlock
1. Disassemble both oil tubes.
Figure 233
Figure 234
Figure 235
Figure 236
Transmission SP000962
Page 84
5. Loosen pump cover bolt connection.
Figure 237
CAUTION
Keep pump to contact and rotate it by 180° -
disassembly aid.
Figure 238
7. Remove the outer (1) and internal rotor (2) and take
the released ball [(3) driver] out of the control housing
(4).
Outer, internal rotor and control housing = rotor set
Figure 239
Figure 240
Transmission SP000962
Page 85
9. Unsnap the retaining ring.
Figure 241
10. Pull the cpl. pump shaft out of the pump cover.
Figure 242
11. Unsnap the retaining ring and press the ball bearing
from the shaft.
Figure 243
Figure 244
Transmission SP000962
Page 86
Legend to the Sketch No. 24:
Reference
Description
Number
1 Housing
2 O-rings
3 Check Valve (010)
4 G.shift Piston
5 Check Valve (009)
6 Check Valve (008)
Figure 245
7 Pressure Limiting Valve
Figure 246
CAUTION
Make no further disassembly - electr. downshift
interlock can only be replaced as complete part.
Figure 247
Transmission SP000962
Page 87
REASSEMBLY - LUBE OIL
PUMP/DOWNSHIFT INTERLOCK
Figure 248
Figure 249
3. Insert the compression springs (1) and ball (2) into the
bores (see arrows - 3x).
WARNING
Prior to installation oil single parts of the pump /
rotor set (control housing, internal and outer rotor)
- use oil acc. to the "table of recommended
lubricants" pages of operation manual.
Figure 250
CAUTION
Keep the pump shaft / cover in "vertical" position -
pay attention to the position of the inserted balls /
compression springs - See Figure 250 ~. Figure
256).
Transmission SP000962
Page 88
4. Mount the control housing.
Control housing/internal and outer rotor = rotor set
Figure 251
Figure 252
CAUTION
Place the groove of the internal rotor over the
driving ball (see arrows).
Figure 253
Figure 254
Transmission SP000962
Page 89
8. Check passage of the orifice / oil bore in the housing
bottom.
CAUTION
Insert the needle sleeve to installation dimension
"X".
CAUTION
The exact installation position is ensured by use of
the specified mounting tool.
CAUTION
Insert the needle sleeve with marked face showing
upwards.
Figure 256
CAUTION
Keep the assembled pump to contact.
10. Rotate the housing by 180° and fasten the pump with
hexagon screws.
Figure 257
Transmission SP000962
Page 90
11. Fasten the pump finally.
Tightening torque (M6/8.8) ...................... MA = 9.5 N•m
Figure 258
Figure 259
13. Oil both O-rings (arrows) and put them into the ring
groove of the housing.
Figure 260
Figure 261
Transmission SP000962
Page 91
15. Insert the pressure limiting valve.
Tightening torque ...................................... MA = 20 N•m
Figure 262
Figure 263
Figure 264
Figure 265
Transmission SP000962
Page 92
19. Place the cover and fasten it with hexagon screws and
washers.
Tightening torque (M8/8.8) ....................... MA = 23 N•m
Figure 266
Figure 267
21. Mount the cpl. lube oil pump and fasten it with cap
screws and washers.
Tightening torque (M8/10.9) ..................... MA = 23 N•m
Figure 268
Transmission SP000962
Page 93
Version "with" hydr. Downshift Interlock
Legend to Figure 269:
Reference
Description
Number
1 Housing
2 G.shift Piston
3 Pressure Limiting Valve
4 Check Valve (008)
5 Check Valve (009)
6 Check Valve (010)
Figure 269
7 Filter
8 Lube Oil Pump
Figure 270
Figure 271
Transmission SP000962
Page 94
3. Insert the compression spring, oil and mount the
preassembled piston.
Figure 272
Figure 273
CAUTION
Observe the installation position of the different
check valves.
Oil the single parts acc. to the "table of
recommended lubricants" pages of operation
manual.
Figure 274
1 = Pressure limiting valve (cpl.) ............ MA = 10 N•m
2 = Check valve (cpl.) ............................. MA = 10 N•m
3 = Check valve (cpl.) ............................. MA = 10 N•m
4 = Check valve (cpl.) ............................. MA = 10 N•m
Transmission SP000962
Page 95
6. Secure the check valves and the pressure limiting
valve by two blows each with the center punch.
Figure 275
CAUTION
Insert the needle sleeve to installation dimension
"X".
CAUTION
The exact installation position is ensured by use of
the specified mounting tool.
CAUTION
Insert the needle sleeve with marked face showing
upwards.
8. Mount the ball bearing onto the shaft and fasten it with
the retaining ring.
Figure 277
Transmission SP000962
Page 96
9. Press the preassembled pump shaft into the pump
cover and fasten it with the retaining ring.
Figure 278
10. Insert the compression springs (1) and ball (2) into the
bores (see arrows - 3x).
WARNING
Prior to installation oil single parts of the pump /
rotor set (control housing, internal and outer rotor)
- use oil acc. to the "table of recommended
lubricants" pages of operation manual.
Figure 279
CAUTION
Keep the pump shaft / cover in "vertical" position -
pay attention to the position of the inserted balls /
compression springs - See Figure 250 ~ Figure
256).
Figure 280
Transmission SP000962
Page 97
12. Position the ball - see arrow -(drive for internal rotor)
with grease (assembly aid) into the recess of the pump
shaft.
Figure 281
CAUTION
Place the groove of the internal rotor over the
driving ball (see arrows).
Figure 282
Figure 283
Figure 284
Transmission SP000962
Page 98
CAUTION
Keep the assembled pump to contact and rotate
the housing by 180°.
Figure 285
Figure 286
Figure 287
CAUTION
Pay attention to different screw length.
Figure 288
Transmission SP000962
Page 99
19. Oil both O-rings (arrows) and put them into the ring
grooves of the housing.
Figure 289
CAUTION
Pay attention to different screw length.
Figure 290
21. Install both screw-in sleeves and the screw plug (see
arrows) - with O-rings.
Tightening torque:
Screw-in sleeve (M 16 x 1.5) .................. MA = 23 N•m
Screw plug (M 18 x 1.5) ......................... MA = 35 N•m
Figure 291
Reference
Description
Number
1 Oil Tube
2 Union Screw (M 16 X 1.5)
3 Sealing Ring
4 Union Screw (M 14 X 1.5)
5 Sealing Ring
Figure 292
Transmission SP000962
Page 100
22. Install both oil tubes.
Tightening torque:
Union screw (M 14 x1.5) ......................... MA = 25 N•m
Union screw (M 16 x1.5) ......................... MA = 45 N•m
Figure 293
Figure 294
WARNING
Prior to put the unit into operation the
specifications and regulations respectively as well
as the instructions of the transmission operating
and maintenance instructions as well as the Figure 295
specifications and instructions of the vehicle
manufacturer have to be observed.
Transmission SP000962
Page 101
ATTACH THE HL-
TRANSMISSION TO THE AXLE
(only for the version "Axle Attachment")
1. Position the cpl. HL-Transmission to the axle.
Figure 296
WARNING
Prior to put the unit into operation the
specifications and regulations respectively as well
as the instructions of the transmission operating
and maintenance instructions as well as the Figure 297
specifications and instructions of the vehicle
manufacturer have to be observed.
Transmission SP000962
Page 102
SP000963
DRIVE COUPLING (MAIN PUMP)SP000963
1Drive Coupling
(Main Pump)
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
Drive Coupling ..................................................... 7
Special Tools ....................................................... 9
Drive Coupling Installation ................................ 10
Installation Procedure ................................................... 12
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling the load.
Remember, that ultimately safety is your own
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
ARS1710L
Figure 1
ARS1720L
Figure 2 S340LC-V - S470LC-V
A C
B
E G
F
H
RELIEF
RELIEF
KNURL
HAAA8360
Figure 5
2 3
1
7
10
5 H
11 5
8
HAAA8040
Figure 6 Drive Coupling Installation
CAUTION
1. Bolts (3 and 8) are coated against loosening
with a bonding compound. Do not use any
additional bonding compounds, oils or
cleaning solvents on them.
2. Element (11) is nonresistant to bonding
compounds, oil or grease. Be careful not to
expose it to them.
3. Remove oil or dirt from flywheel cover and
pump shaft before assembly.
4. Misalignment between pump and engine
should be controlled to less than 0.6 mm
(0.023 in).
Hydraulic System
Troubleshooting,
Testing and
Adjustment
Edition 1
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Center Joint
Travel Motor
Transmission
FG007723
Figure 1
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 travel control spools are shifted,
output from the main pump assembly passes
through the center joint to the axial piston motors
driving the wheel.
Boom Up Circuit
When you pull the boom control lever backward, the right
side pilot valve generates secondary boom up pilot pressure
that is transmitted to the right and left sides of the control
valve simultaneously. When secondary pilot pressure
reaches 7 - 9 kg/cm2 (100 - 128 psi), boom control valve
spools open and oil from both pumps goes to the boom
cylinder.
Figure 2
Figure 3
Figure 5
Figure 6
Figure 8
Triage Summary
An excavator that fails to deliver designed performance
should 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 (power mode)
• at 1,880 rpm with no load.
• at 1,800 rpm stall load.
If engine rpm drops excessively with a load or fails to
surpass rated speed (1,800 rpm), performance problems
may be due to 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.
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.
WARNING
This procedure should 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.
IMPORTANT
Top off the hydraulic fluid reservoir if there is any
measurable loss of hydraulic oil during test gauge and
adapter fitting installation.
WARNING
This procedure should 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.
WARNING
This procedure should 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.
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.
WARNING
This procedure should 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.
IMPORTANT
Before starting this procedure or going onto make any
changes of adjustment settings:
• Verify engine output to the rated speed –
2,070 ± 50 rpm.
• Permanently mark setscrew positions at the
current regulator control setting.
2
2
1
1 ASS0320L
Figure 10
Figure 12
The adjusting screw (1, Figure 10) affects the delivery rate
(Q) of the pump. Tightening the adjusting screw decreases
the maximum cut flow (as shown in Figure 13) while
backing out the screw increases cut flow delivery rate.
Balance both pumps for equal output.
Q
P HDA3008L
Figure 13
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. Shut down 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 to a clean, clear container.
Look for metal shavings/grit, cloudiness/water or
foam/air bubbles in the oil.
• 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.
TROUBLESHOOTING –
HYDRAULIC PROBLEMS
Problem Possible Cause Remedy
Attachment cylinders, Main pump(s) malfunction. Repair or replace.
swing and travel motors Low oil level in hydraulic system. Refill.
are all inoperable. Loud
Main pump inlet (oil supply) Repair or replace.
noises are heard from
piping or hose damaged.
main pump assembly.
Attachment cylinders, Pilot pump malfunction. Repair or replace.
swing and travel motors Pilot cutoff solenoid stuck. Repair or replace.
are all inoperable. No
Pilot cutoff switch faulty. Repair or replace.
usual or loud noises can
be heard. Engine/pump flex coupling Replace flex coupling.
damaged.
Sluggish performance of Main pump(s) damaged or worn. Repair or replace.
all 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.
TROUBLESHOOTING – TRAVEL
CONTROL VALVE
Problem Possible Cause Remedy
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 Repair or reroute tank return line.
unsteady pressure in tank return
line.
Air bubbles in piping (temporary) Vent air, or repair leak.
or air leak.
NOTE: Look for evidence of leaking oil.
Accumulator
Edition 1
Accumulator SP000984
Page 1
MEMO
Accumulator SP000984
Page 2
Table of Contents
Accumulator
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Specifications .................................................................. 8
Accumulator SP000984
Page 3
MEMO
Accumulator SP000984
Page 4
SAFETY PRECAUTIONS
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Accumulator SP000984
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 2
collect, store 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.
3
Reference
Description
Number
1 Screw Plug
2 Steel Pressure Vessel
4
3 Diaphragm
ARS1790L
4 Fluid Valve
Figure 1
Accumulators are solidly constructed to resist the high
operating 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
Accumulator SP000984
Page 6
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.
Accumulator SP000984
Page 7
Specifications
Model Serial Number System Charge Pressure Volume
DX140W 15 kg/cm2 320 cc
Pilot
DX160W (213 psi) (19.53 in3)
S/N 5001 and Up
DX190W 30 kg/cm2 750 cc
DX210W Brake
(427 psi) (45.77 in3)
Accumulator SP000984
Page 8
SP000919
CENTER JOINT (SWIVEL)SP000919
1Center Joint
(Swivel)
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Parts List......................................................................... 7
Troubleshooting, Testing and Adjustment.......... 8
Inspection ........................................................................ 8
Testing............................................................................. 8
Disassembly ......................................................... 9
Reassembly ........................................................ 13
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
6 7 11 8
Figure 1
Reference Reference
Description Description
Number Number
1 Spindle 12 Bolt
2 Body 13 Spring Washer
3 Rotary Seal 14 Socket Plug
4 O-ring 15 Socket Plug
5 O-ring 16 Socket Plug
6 Shim-A 17 Socket Plug
7 Thrust Plate 18 Socket Plug
8 Retaining Ring 19 Plug
9 O-ring 20 O-ring
10 Cover 21 Bolt
11 Shim-B
Inspection
The center joint should 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 may 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
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.
FG003764
Figure 3
2. Remove Cover
• Remove the bolts and washers using a spanner
(wrench) or air impact.
• Remove the cover.
FG003767
Figure 4
Figure 5
FG003769
Figure 6
FG003770
Figure 7
FG003771
Figure 8
Figure 9
Figure 10
Figure 11
CAUTION
O-rings and seals should be replaced whenever the
assembly is being overhauled or re-assemble.
For repair procedures or emergency tear down, use
a thin, smooth-edged scraper or spatula with a Figure 12
rounded tip to remove the O-rings or seals, to
avoid causing damage to those that can be reused.
The "back-up ring" shown in the assembly drawing
(above the swivel joint stem 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 stem.
Figure 13
CAUTION
Be sure to check for any dent-like scratches in the
direction of operation.
CAUTION
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.
Cylinders
Edition 1
Cylinders SP001098
Page 1
MEMO
Cylinders SP001098
Page 2
Table of Contents
Cylinders
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Theory of Operation ....................................................... 6
Parts List......................................................................... 8
Special Tools and Materials ............................. 14
Piston Nut ..................................................................... 14
Piston Jig ...................................................................... 16
Steel Bushing Jig ......................................................... 18
Dust Wiper Jig ............................................................. 20
Slipper Seal Jig ............................................................ 22
Slipper Seal Straightening Jig ..................................... 24
Disassembly ....................................................... 26
Reassembly ........................................................ 31
Cylinders SP001098
Page 3
MEMO
Cylinders SP001098
Page 4
SAFETY PRECAUTIONS
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Cylinders SP001098
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
Cylinders SP001098
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 FG001459
Q1 > Q 2 Figure 3
Cylinders SP001098
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.
Arm Cylinder
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
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 SP001098
Page 8
Reference Reference
Description Description
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 SP001098
Page 9
Dozer Cylinder
LH
RH
23,24
27,28
26 25
16 17 18,19 20 21
4 22 10 5 13 9 8 11,12 6,7 3 1 14 15
22 2
FG008717
Figure 6
Reference Reference
Description Description
Number Number
1 Tube Assembly 15 Slipper Seal
2 Rolled Bush 16 Wear Ring
3 Rod Assembly 17 Slyd Ring
4 Rolled Bush 18 O-Ring
5 Rod Cover 19 Backup Ring
6 DU-Bush 20 Piston Nut
7 Retaining Ring 21 Set Screw
8 Buffer Seal 22 Grease Nipple
9 U-Packing 23 Pipe Assembly
10 Dust Wiper 24 O-Ring
11 O-Ring 25 Valve Assembly
12 Backup Ring 26 Hex Socket Bolt
13 O-Ring 27 Hex Socket Bolt
14 Piston 28 Washer
Cylinders SP001098
Page 10
Outrigger Cylinder
LH
RH
23,24
27,28
26 25
16 17 18,19 20 21
4 22 10 5 13 9 8 11,12 6,7 3 1 14 15
2
FG008718
Figure 7
Reference Reference
Description Description
Number Number
1 Tube Assembly 15 Slipper Seal
2 Rolled Bush 16 Wear Ring
3 Rod Assembly 17 Slyd Ring
4 Rolled Bush 18 O-Ring
5 Rod Cover 19 Backup Ring
6 DU-Bush 20 Piston Nut
7 Retaining Ring 21 Set Screw
8 Buffer Seal 22 Grease Nipple
9 U-Packing 23 Pipe Assembly
10 Dust Wiper 24 O-Ring
11 O-Ring 25 Valve Assembly
12 Backup Ring 26 Hex Socket Bolt
13 O-Ring 27 Hex Socket Bolt
14 Piston 28 Washer
Cylinders SP001098
Page 11
Ram Cylinder
1 7 2 3 4 5 6
8 9 10
RH
LH Port Detail
FG008719
Figure 8
Reference Reference
Description Description
Number Number
1 Body 6 Retaining Ring
2 Wear Ring 7 Rod
3 U-Packing 8 Plug A
4 Backup Ring 9 O-Ring
5 Dust Wiper 10 Dust Cap
Cylinders SP001098
Page 12
Cylinders SP001098
Page 13
SPECIAL TOOLS AND
MATERIALS
Piston Nut
( )
15
-0.1
C -0.2
(C3~C5)
D +0.1
+0.2
A
35
B
∅8 Through Hole
5
0.
R
R(R15 ~ R20)
4-
350
ARS4730L
Figure 9
Material SM45C (AISI 1045)
Rockwell Harden from 22 - 27
Oil Quench
Cylinders SP001098
Page 14
MODEL CYLINDER ∅A ∅B C D MODEL (CYLINDER)
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)
147.0 mm 107.0 mm 12.0 mm 5.0 mm
DX340LC ARM OPT 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 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
DX420LC ARM
(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)
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)
130.0 mm 90.0 mm 12.0 mm 5.0 mm
ARM
(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
DX140W (4.53 in) (2.95 in) (0.47 in) (0.20 in)
DX160W 120.0 mm 79.0 mm 10.0 mm 5.0 mm
DOZER
(4.72 in) (3.11 in) (0.39 in) (0.20 in)
125.0 mm 85.0 mm 12.0 mm 5.0 mm
OUTRIGGER
(4.92 in) (3.35 in) (0.47 in) (0.20 in)
TWO-PIECE 155.0 mm 115.0 mm 12.0 mm 5.0 mm
BOOM (4.79 in) (4.21 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
ARM
(5.51 in) (3.86 in) (0.47 in) (0.20 in)
DX190W
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)
TWO-PIECE 155.0 mm 115.0 mm 12.0 mm 5.0 mm
BOOM (6.10 in) (4.53 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)
142.0 mm 102.0 mm 12.0 mm 5.0 mm
ARM
(5.59 in) (4.02 in) (0.47 in) (0.20 in)
DX210W
125.0 mm 102.0 mm 11.0 mm 4.5 mm
BUCKET
(4.92 in) (4.02 in) (0.43 in) (0.18 in)
TWO-PIECE 155.0 mm 115.0 mm 12.0 mm 5.0 mm
BOOM (6.10 in) (4.53 in) (0.47 in) (0.20 in)
Cylinders SP001098
Page 15
Piston Jig
( )
15
2-∅"B"
)
F /2
∅8 Through Hole
R(
"
"D
∅
"A"
∅"
C "
R(R15~20)
( ) 35
R5
4-
30
ARS4740L
Figure 10
Material SM45C (AISI 1045)
Rockwell Harden from 22 - 27
Oil Quench
Cylinders SP001098
Page 16
MODEL CYLINDER A ( ±0.1) ∅B ∅C ∅D MODEL (CYLINDER)
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)
130.0 mm 13.0 mm 93.0 mm 165.0 mm
DX340LC ARM OPT 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 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) (0.51 in) (3.66 in) (6.50 in)
130.0 mm 13.0 mm 93.0 mm 165.0 mm
DX420LC ARM
(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)
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)
80.0 mm 11.0 mm 58.0 mm 110.0 mm
ARM
(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
DX140W (2.76 in) (0.43 in) (1.81 in) (3.74 in)
DX160W 70.0 mm 11.0 mm 53.0 mm 95.0 mm
DOZER
(2.76 in) (0.43 in) (2.09 in) (3.74 in)
80.0 mm 11.0 mm 58.0 mm 110.0 mm
OUTRIGGER
(3.15 in) (0.43 in) (2.28 in) (4.33 in)
TWO-PIECE 130.0 mm 13.0 mm 93.0 mm 165.0 mm
BOOM (5.12 in) (0.51 in) (3.66 in) (6.5 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
ARM
(3.78 in) (0.51 in) (2.72 in) (5.12 in)
DX190W
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)
TWO-PIECE 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)
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)
110.0 mm 13.0 mm 76.0 mm 140.0 mm
ARM
(4.33 in) (0.51 in) (2.99 in) (5.51 in)
DX210W
90.0 mm 11.0 mm 63.0 mm 115.0 mm
BUCKET
(3.54 in) (0.43 in) (2.48 in) (4.53 in)
TWO-PIECE 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)
Cylinders SP001098
Page 17
Steel Bushing Jig
( )
(5)
"A" - 20
"B" + 40
∅"B"
∅"A"
(∅20)
15 F E
ARS4750L
Figure 11
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 SP001098
Page 18
MODEL CYLINDER ∅ A-0.05
-0.15
∅ B ( ±0.1) E F+0.05
0
Part MODEL (CYLINDER)
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)
100.0 mm 115.0 mm 45.0 mm 7.5 mm
DX340LC ARM OPT 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 OPT 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)
110.0 mm 130.0 mm 70.0 mm 11.0 mm
DX420LC ARM
(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)
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)
71.0 mm 86.0 mm 40.0 mm 7.0 mm
ARM
(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
DX140W (2.56 in) (3.14 in) (1.18 in) (0.24 in)
DX160W 60.0 mm 70.0 mm 30.0 mm
DOZER -
(2.36 in) (2.76 in) (1.18 in)
60.0 mm 75.0 mm 30.0 mm 6.5 mm
OUTRIGGER
(2.36 in) (2.95 in) (1.18 in) (0.26 in)
TWO-PIECE 90.0 mm 105.0 mm 40.0 mm 6.0 mm
BOOM (3.54 in) (4.13 in) (1.57 in) (0.24 in)
71.0 mm 86.0 mm 40.0 mm 7.0 mm
BOOM
(2.80 in) (3.39 in) (1.57 in) (0.28 in)
71.0 mm 86.0 mm 40.0 mm 7.0 mm
ARM
(2.80 in) (3.39 in) (1.57 in) (0.28 in)
DX190W
71.0 mm 86.0 mm 40.0 mm 7.0 mm
BUCKET
(2.80 in) (3.39 in) (1.57 in) (0.28 in)
TWO-PIECE 90.0 mm 105.0 mm 40.0 mm 6.0 mm
BOOM (3.54 in) (4.13 in) (1.57 in) (0.24 in)
80.0 mm 95.0 mm 35.0 mm 6.5 mm
BOOM
(3.15 in) (3.74 in) (1.38 in) (0.26 in)
90.0 mm 105.0 mm 40.0 mm 6.5 mm
ARM
(3.54 in) (4.13 in) (1.57 in) (0.26 in)
DX210W
65.0 mm 80.0 mm 35.0 mm 6.5 mm
BUCKET
(2.56 in) (3.15 in) (1.38 in) (0.26 in)
TWO-PIECE 90.0 mm 105.0 mm 40.0 mm 6.0 mm
BOOM (2.54 in) (4.13 in) (1.57 in) (0.24 in)
Cylinders SP001098
Page 19
Dust Wiper Jig
. 5
C1
3-
R0.2
1
)
DIA. (B+40)
DIA. (A-20)
)
DIA. A
DIA. B
(
(
15 C D
ARS4760L
Figure 12
Material: SM45C which is done thermal refining <QT> Hrc 22 - 28
Undefined Chamfer C/R = 0.5 Max.
Cylinders SP001098
Page 20
MODEL CYLINDER ∅A-0.2
-0.3 ∅B -0.2
-0.3 C 0-0.1 D MODEL (CYLINDER)
95.0 mm 109.0 mm 6.0 mm 7.0 mm
BOOM
(3.74 in) (4.29 in) (0.24 in) (0.28 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) (0.28 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) (0.28 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) (0.28 in)
115.0 mm 131.0 mm 6.0 mm 7.0 mm
DX340LC ARM OPT ARM
(4.53 in) (5.16 in) (0.24 in) (0.28 in)
100.0 mm 114.0 mm 6.0 mm 7.0 mm
BUCKET OPT BUCKET
(3.94 in) (4.49 in) (0.24 in) (0.28 in)
115.0 mm 131.0 mm 6.0 mm 7.0 mm
BOOM
(4.53 in) (5.16 in) (0.24 in) (0.28 in)
120.0 mm 136.0 mm 6.0 mm 7.0 mm
DX420LC ARM
(4.72 in) (5.35 in) (0.24 in) (0.28 in)
110.0 mm 126.0 mm 6.0 mm 7.0 mm
BUCKET
(4.33 in) (4.96 in) (0.24 in) (0.28 in)
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)
80.0 mm 94.0 mm 6.0 mm 7.0 mm
ARM
(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
DX140W (2.56 in) (3.11 in) (0.24 in) (0.28 in)
DX160W 60.0 mm 74.0 mm 5.0 mm 6.0 mm
DOZER
(2.36 in) (2.91 in) (0.20 in) (0.24 in)
70.0 mm 84.0 mm 0.5 mm 6.0 mm
OUTRIGGER
(2.76 in) (3.31 in) (0.02 in) (0.24 in)
TWO-PIECE 90.0 mm 104.0 mm 6.0 mm 7.0 mm
BOOM (3.54 in) (4.10 in) (0.24 in) (0.28 in)
80.0 mm 94.0 mm 6.0 mm 7.0 mm
BOOM
(3.15 in) (3.70 in) (0.24 in) (0.28 in)
90.0 mm 104.0 mm 6.0 mm 7.0 mm
ARM
(3.54 in) (4.09 in) (0.24 in) (0.28 in)
DX190W
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)
TWO-PIECE 115.0 mm 131.0 mm 6.0 mm 7.0 mm
BOOM (4.53 in) (5.16 in) (0.24 in) (0.28 in)
85.0 mm 99.0 mm 6.0 mm 7.0 mm
BOOM
(3.35 in) (3.90 in) (0.24 in) (0.28 in)
95.0 mm 109.0 mm 6.0 mm 7.0 mm
ARM
(3.74 in) (4.29 in) (0.24 in) (0.28 in)
DX210W
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)
TWO-PIECE 115.0 mm 131.0 mm 6.0 mm 7.0 mm
BOOM (4.53 in) (5.16 in) (0.24 in) (0.28 in)
Cylinders SP001098
Page 21
Slipper Seal Jig
0
R1
R1
∅(A+2)
∅A
∅(A-14)
5
B
10°
(B+40)
ARS4770L
Figure 13
Cylinders SP001098
Page 22
MODEL CYLINDER ∅A+0.2
+0.1 B+0.2
+0.1 MODEL (CYLINDER)
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)
170.0 mm 34.5 mm
DX340LC ARM OPT ARM
(6.69 in) (1.36 in)
150.0 mm 28.5 mm
BUCKET OPT BUCKET
(5.91 in) (1.12 in)
165.0 mm 34.5 mm
BOOM OPT BOOM
(6.50 in) (1.36 in)
180.0 mm 41.5 mm
DX420LC ARM OPT ARM
(7.09 in) (1.63 in)
160.0 mm 34.5 mm
BUCKET OPT BUCKET
(6.30 in) (1.36 in)
110.0 mm 28.5 mm
BOOM
(4.33 in) (1.12 in)
115.0 mm 28.5 mm
ARM
(4.53 in) (1.12 in)
95.0 mm 28.5 mm
BUCKET
DX140W (3.74 in) (1.12 in)
DX160W 100.0 mm 28.5 mm
DOZER
(3.94 in) (1.12 in)
110.0 mm 28.5 mm
OUTRIGGER
(4.33 in) (1.12 in)
TWO-PIECE 150.0 mm 28.5 mm
BOOM (5.91 in) (1.12 in)
115.0 mm 28.5 mm
BOOM
(4.53 in) (1.12 in)
110.0 mm 28.5 mm
ARM
(4.33 in) (1.12 in)
DX190W
110.0 mm 28.5 mm
BUCKET
(4.33 in) (1.12 in)
TWO-PIECE 180.0 mm 41.5 mm
BOOM (7.09 in) (1.63 in)
135.0 mm 28.5 mm
BOOM
(5.31 in) (1.12 in)
135.0 mm 28.5 mm
ARM
(5.31 in) (1.12 in)
DX210W
115.0 mm 28.5 mm
BUCKET
(4.53 in) (1.12 in)
TWO-PIECE 180.0 mm 41.5 mm
BOOM (7.09 in) (1.63 in)
Cylinders SP001098
Page 23
Slipper Seal Straightening Jig
1
2-C
R
2-5
∅(A+15)
∅A
1
2-R
100
25
50
ARS4780L
Figure 14
Cylinders SP001098
Page 24
MODEL CYLINDER ∅A+0.2
+0.1 MODEL (CYLINDER)
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)
170.0 mm
DX340LC ARM OPT ARM
(6.69 in)
150.0 mm
BUCKET OPT BUCKET
(5.91 in)
165.0 mm
BOOM OPT BOOM
(6.50 in)
180.0 mm
DX420LC ARM OPT ARM
(7.09 in)
160.0 mm
BUCKET OPT BUCKET
(6.30 in)
110.0 mm
BOOM
(4.33 in)
115.0 mm
ARM
(4.53 in)
95.0 mm
BUCKET
DX140W (3.74 in)
DX160W 130.0 mm
DOZER
(5.12 in)
130.0 mm
OUTRIGGER
(5.12 in)
TWO-PIECE 150.0 mm
BOOM (5.91 in)
115.0 mm
BOOM
(4.35 in)
125.0 mm
ARM
(4.92 in)
DX190W
110.0 mm
BUCKET
(4.33 in)
TWO-PIECE 180.0 mm
BOOM (7.09 in)
135.0 mm
BOOM
(5.31 in)
135.0 mm
ARM
(5.31 in)
DX210W
115.0 mm
BUCKET
(4.53 in)
TWO-PIECE 180.0 mm
BOOM (7.09 in)
Cylinders SP001098
Page 25
DISASSEMBLY
CAUTION
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.
Figure 15
Figure 16
Figure 17
Cylinders SP001098
Page 26
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 18
Figure 19
Figure 20
Figure 21
Cylinders SP001098
Page 27
8. Remove set screw using socket wrench.
HAOF340L
Figure 22
Figure 23
Figure 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 25
Cylinders SP001098
Page 28
12. Use a dull, rounded tip tool to pry off O-ring (13) and
backup ring (14).
HAOF37OL
Figure 26
Figure 27
14. Remove O-ring (21) and backup ring (22) from cylinder
head.
HAOF38OS
Figure 28
HAOF39OL
Figure 29
Cylinders SP001098
Page 29
16. Disassemble retaining ring (12) and dust wiper (11).
Separate retaining ring (7) and rod bushing (6).
Figure 30
17. Force out pin bushing (2), (4) from body of cylinder.
Figure 31
Cylinders SP001098
Page 30
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 should be
thoroughly cleaned and dried, and/or prelubricated with
clean hydraulic fluid. Prepare the work area beforehand
to maintain cleanliness during the reassembly
procedure.
Figure 32
Figure 33
Cylinders SP001098
Page 31
3. Prelubricate O-rings and seals before reassembly
(Figure 34).
Figure 34
Figure 35
Figure 36
Figure 37
Cylinders SP001098
Page 32
7. Use specially fabricate or factory sourced tool to tighten
piston nut (23).
Figure 38
8. Assemble wear ring (19), slide ring (20) and set screw
(24) to piston assembly.
Reference
Description
Number
1 Set Screw
Figure 39
Figure 40
Figure 41
Cylinders SP001098
Page 33
Cylinders SP001098
Page 34
SP000966
MAIN CONTROL VALVESP000966
Main Control
Valve
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
Control Valve Operation...................................... 6
Arm Priority Circuit ......................................................... 7
Bucket (Junction) Circuit ................................................ 8
Main Relief Valve ........................................................... 9
Overload Relief Valve .................................................. 10
Arm Load Holding Valve ............................................. 12
Boom Load Holding Valve .......................................... 15
Arm Regeneration ........................................................ 17
Boom Regeneration...................................................... 19
Foot Relief Valve ......................................................... 20
Parts List....................................................................... 21
Specifications ................................................................ 29
Control Valve Drawing and Hydraulic Circuit.. 30
Disassembly and Reassembly .......................... 34
General Disassembly ................................................... 34
General Reassembly .................................................... 34
Plunger Replacement ................................................... 34
Main Plunger Element - Disassembly and Assembly
...................................................................................... 35
Tool ............................................................................... 35
Main Relief Valve ......................................................... 38
Overload Relief Valve .................................................. 40
Arm Load Holding Valve ............................................. 42
Boom Load Holding Valve .......................................... 44
Arm Regeneration Valve.............................................. 45
Bucket Unity Check ..................................................... 46
Foot Relief Valve ......................................................... 47
Center Bypass Valve (CB Valve) ............................... 48
Boom Parallel Switch Valve ........................................ 49
Boom Unity Check Valve ............................................ 50
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Fr
F1
Arm Priority Circuit
TR
TL OPT
SW BKT
BM-2 BM-1
SPOOL;BP
Pa1
Aa1 Ba1 P1 P2
XAa1
AM-1 BM-1
XBb1
FG007226
Page 7
SP000966
Page 8
Figure 2
Pp P2 P1
TR
Bucket (Junction) Circuit
OPT
BKT
BM-1
AM-2
XAk2
Center Bypass
Valve CK1
To tank SPOOL;CB
thru the Foot R/V P1 P2
AK1
BK1 BKT
XAk
CK2
BKT
FG007227
SP000966
1. Hydraulic oil from the P2 pump flows to the bucket. Oil
from the P1 pump and the bucket plunger that controls
pilot pressure act simultaneously on the center bypass
valve triggering spool CB to send oil from the center
bypass through an external line (CK1 => CK2) which
opens the bucket pressure check valve and joins with
oil flow from the P2 pump.
HAOG250P
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 15
Figure 16
Figure 17
Parallel Route
Aa1 Ba1 C2
C1
Tank Route
XAa1
Aa1 Ba1 C2
C1
Tank Route
XAa1
FG003187
Figure 19
2. Oil returning from the rod side flows back to the tank
through regeneration valve route (2) to route (1).
C1
Tank Route
XAa1
2 1 3 4
Spring C
Pistion A Spool B
FG003188
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24
Reference Reference
Description Description
Number Number
1 Plunger 11 Cap
2 Bolt With Hole 12 Backup Ring
3 Cover 13 O-ring
4 Plunger Cap 14 Sleeve
5 Spring 15 Backup Ring
6 Spring Guide 16 O-ring
7 Spacer 17 Check Valve
8 O-ring 18 Spring
9 O-ring 19 Spring
10 Retainer 20 Check Valve
Figure 25
Reference Reference
Description Description
Number Number
1 Adjusting Screw 10 Sleeve
2 Hexagonal Nut 11 Orifice
3 Adjusting Screw 12 Spring
4 Hexagonal Nut 13 O-ring
5 Cap 14 Pilot Sheet
6 Spring 15 Piston
7 Pilot Poppet 16 O-ring
8 O-ring 17 Backup Ring
9 Main Poppet 18 O-ring
Figure 26
Reference Reference
Description Description
Number Number
1 Hex Nut 11 Main Poppet
2 Cap 12 Piston
3 O-ring 13 O-ring
4 Sleeve 14 Pilot Sheet
5 Spring 15 Pilot Poppet
6 Spring 16 Spring
7 O-ring 17 O-ring
8 Backup Ring 18 Spring Tray
9 Backup Ring 19 Adjusting Screw
10 O-ring
Figure 27
Reference Reference
Description Description
Number Number
1 Spring 4 Backup Ring
2 Check 5 Cap
3 O-ring
Figure 28
Reference Reference
Description Description
Number Number
1 Cover 8 Spring Seat
2 Spool 9 Spring
3 Spring 10 Manifold
4 Cap 11 Poppet
5 O-ring 12 Bolt With Hole
6 Backup Ring 13 O-ring
7 O-ring 14 O-ring
Reference
Description
Number
1 Cap
2 O-ring
3 Stopper
4 Spring
5 Check
Figure 29
Reference
Description
Number
1 Cap
2 Shim
3 Shim
4 Cap
5 Spring
6 Poppet
7 O-ring
Figure 31
Reference 1, 2 3 4 5 6 7 8 9 10
Description
Number
1 Cap 11
2 O-Ring
3 Spool 12
4 Spring
5 Check
6 Bolt ; Socket FG003199
7 Spring Guide Figure 32
8 Spacer
9 Spring
10 Seam
11 Bolt ; Socket
12 Cover
Reference
Description
Number
1 Cap
2 Spacer
3 Backup Ring
4 O-ring
5 Spring
6 Nylon Chip
7 Check Figure 33
Reference
Description
Number
1 Cap
2 Spacer
3 Backup Ring
4 O-ring
5 Spring
6 Nylon Chip
7 Check Figure 34
Reference
Description
Number
1 Cap
2 Backup Ring
3 O-ring
4 Spring
5 Nylon Chip
6 Check
Figure 35
Cap
Reference
Description
Number
1 Cap
2 Backup Ring
3 O-ring
4 Nylon Chip
Figure 36
Cap
Reference
Description
Number
1 Cap
2 O-ring
3 Backup Ring
Figure 37
Reference
Description
Number
1 Cap
2 O-ring
3 Spring
4 Cb Spool
Figure 39
Figure 40
Reference Reference
Description Description
Number Number
1 Poppet 12 O-ring
2 Spring 13 Poppet
3 O-ring 14 Spring
4 O-ring 15 O-ring
5 O-ring 16 Cap
6 Cap 17 Bolt With Hole
7 Piston 18 Cover
8 Backup Ring 19 Cap
9 O-ring 20 Spring
10 Sleeve 21 Check
11 Backup Ring
A B B A
A B B A
C C C C
Control Valve Top View Control Valve Bottom View
Control Valve Left View A-A Control Valve Right View B-B
Control Valve Front View C-C Control Valve Rear View D-D FG007245
Figure 41
MR
XAt
Bt TR(R)
XBt At XAd
Dr5 (ROD)
XBo DOZER Bd
OPT XBd (HEAD)
Bo Ad
XAo Ao
(Ck2)
XBk XAs
SWING Bs
(ROD) BUCKET
XAk Bk1 As
XBs
(HEAD) Ak1
(HEAD)
Bb1
P1 XBb1
BOOM1 BOOM2 OP
Dr1 XBb2
XAb1 Ab1
(ROD)
XBa2 XBa1
ARM2 ARM1
Ba1 XAa1(ROD)
XAa2
Aa1 (HEAD)
PBP HV
NR2 NR1 BC
22
B
Ts TR
B
TL OPT
SW BKT
BM-2 BM-1
AM-1 AM-2
C
C C
D
FG007247
Figure 43
1
13 12
14 10
15 11
16 11
11 11
11 10
20 9
21 FG007248
Figure 44
A-A ARM2
7 ARM1
D-D C-C
B-B
FG007249
Figure 45
TR OPT
TL
2 3
BKT
6
BM-1
SW
BM-2
FG007250
Figure 46
Reference Reference
Description Quantity Description Quantity
Number Number
1 Main Plunger 9 Check Valve (OPT, BKT,
11 5
2 Main Relief Valve 1 BM-1, BM-2, AM-1)
3 Overload Relief Valve 8 12 Check Valve 1
4 Bucket 2-Speed Check 1 13 Check Valve 2
5 Boom Holding Valve 1 14 Cap 3
6 Boom 2-Speed Check 1 15 Check Valve (TL) 1
Arm Regeneration 16 Check Valve (SW) 1
7 1
Valve 17 Plug assembly 1
8 Foot Relief Valve 2 Center Bypass Valve
20 1
Arm Priority Valve (CB Valve)
9 1
(AP Valve) 21 Arm Holding Valve 1
10 Check Valve (AM-2) 1 22 Orifice (Px, Py) 1
General Reassembly
Stand control valve on flat surface and tighten bolts with
correct torque.
15 kg•m
Socket Bolt Tightening Torque
(108 ft lb)
Socket Bolt
IMPORTANT FG007251
Figure 47
Be sure to use extreme care when assembling and
disassembling control valve. All O-rings should be
replaced with new ones. Never reuse old O-rings.
Plunger Replacement
1. The plunger is selected and toothed into the housing;
as a result it is a non serviceable part and cannot be
replaced on site.
A. If for some reason it needs to be replaced, please
contact us with the following information;
Make and/or model number.
Identification color for selected teething as
inscribed on the name plate.
B. Identification color is painted on the right or left
edge of the machine body. It is visible from the
bottom if the paint has been removed.
FG007252
Figure 48
IMPORTANT
When disassembling Main Plunger element tag and label
each component so that all parts can be reassembled in
the proper order.
IMPORTANT
The hydraulic control valve used in the S200W-V uses 3
different plungers. Care should be taken when
disassembling and reassembling plunger assemblies.
Tool
This holding tool is used to clamp and hold plunger for
further disassembly, without damaging it. The holder is
comprised of 2 halves of a hexagonal rod made from soft
brass, with the appropriate size hole and outside
dimensions.
Outside
Inside Diameter Application
Diameter
28.20 mm 41.0 mm
Main Plunger
(1.1102 in) (1.6142 in)
100.0 mm Figure 49
Length
(3.9370 in)
Figure 50
Reference Reference
Description Description
Number Number
1 8 mm Hex Head Bolts 3 Plunger Cap Bolt
2 Plunger Cover
IMPORTANT
Do not force out plunger. Pull out plunger slowly,
to avoid damage.
Figure 51
Reference
Description
Number
1 Plunger Holding Tool
2 Spring Guide
Plunger Cap Bolt
3 Tightening Torque: 6 kg•m (43 ft
lb)
Figure 52
IMPORTANT
Use caution when disassembling and assembling
plungers. The travel straight plunger does not have
a spacer. In addition the spring and plunger cap
bolts are different.
Figure 53
Figure 54
Figure 55
Figure 56
Reference
Description Size
Number
1 Adjusting Screw 22 mm
2 Hexagonal Nut 30 mm
3 Hexagonal Nut 30 mm
4 Cap 30 mm
5 Pilot Sheet
6 Lower Sleeve
7 Sleeve 27 mm
Figure 57
1. Hold adjusting screw (1, Figure 57) and loosen
hexagonal nut (2).
2. Hold cap (4, Figure 57) and loosen hexagonal nut (3).
3. Loosen cap (4, Figure 57) and remove valve assembly
by unscrewing cap (4).
Reference
Description
Number
6 Lower Sleeve
8 Piston
9 Spring
10 Orifice
IMPORTANT
Further disassembly of pilot sheet from the cap is
not recommended, as it is pressed in at the factory.
Reassembly
1. Insert piston (A) into sleeve (7). Assemble hex nut (2)
onto adjust screw (1). Assemble adjust screw (1) to
sleeve (7), until piston (A) is seated.
2. Insert pilot poppet (B) into pressure adjust spring (C)
and insert into sleeve (7). Assemble cap (4) onto
sleeve (7), making sure pilot poppet (B) is properly
seated.
3. Insert orifice (10), spring (9) and piston (8) into lower
sleeve (6).
4. Assemble lower sleeve (6) onto cap (4).
5. Insert assembled relief valve into control valve body
and tighten cap (4).
10 kg•m
Tightening Torque
(72 ft lb)
IMPORTANT
Improper relief valve pressure settings may cause
severe damage to the hydraulic system. Extreme caution
should be taken when making pressure adjustments.
IMPORTANT
Inspect all O-ring gaskets for damage and replace as
Figure 59
necessary. Never reuse damaged or questionable O-
rings.
IMPORTANT
The relief valve is extremely sensitive and sudden
extreme changes should be avoided.
6 kg•m
TIghtening Torque
(43 ft lb)
6 kg•m
TIghtening Torque
(43 ft lb)
IMPORTANT
When disassembling Overload Relief Valve, tag and label
each component so that all parts can be reassembled in
the proper order.
IMPORTANT
Do not disassemble the pressure adjustment element.
The pressure is factory set and cannot be correctly
adjusted on the vehicle.
IMPORTANT
Each Overload Relief Valve must be reinstalled into its
original position.
Reference
Description
Number
1 Sleeve
2 Cap
Figure 60
Reference
Description
Number
2 Cap
3 Spring
4 Poppet
Reference
Description
Number
1 Pilot Seat
2 Outer Spring
3 Inner Spring
4 Piston
5 Main Poppet
Figure 62
Figure 63
IMPORTANT
When disassembling Arm Load Holding Valve, tag and
label each component so that all parts can be
reassembled in the proper order.
Figure 64
IMPORTANT
When assembling cover, inspect O-rings for any
damage and replace as necessary.
Figure 65
1. Loosen cap (1) and remove spring (2) and check (3).
Figure 67
Figure 68
3. Loosen cap (9) and remove spring (8) and poppet (7).
IMPORTANT
Be careful not to damage the edges of the inner Figure 69
and outer surfaces of the sleeve.
IMPORTANT
When disassembling Boom Load Holding Valve, tag and
label each component so that all parts can be
reassembled in the proper order.
Figure 70
Reference Reference
Description Quantity Description Quantity
Number Number
1 Cover 9 5 Spring Tray 1
2 Spool 1 6 Allen Head Bolt 1
3 Spring 8 7 Spring 1
4 cap 1 8 Poppet 2
IMPORTANT
When assembling cover, inspect O-rings for any
damage and replace as necessary.
Figure 71
3. Loosen cap (4) and remove spring (3) and spool (2).
Figure 72
IMPORTANT
When disassembling Arm Regeneration Valve, tag and
label each component so that all parts can be
reassembled in the proper order.
Reference
Description
Number 1 2 3 4 5 6 7
1 Cap
2 Cap
3 Spring
4 Spring Guide
5 Spool
6 Sleeve
7 Piston
FG003253
Figure 73
5
6
FG003255
Figure 75
IMPORTANT
When disassembling Arm Regeneration Valve, tag and
label each component so that all parts can be
reassembled in the proper order.
Reference
Description
Number
1 Cap
2 Check
3 Spring
Figure 76
Figure 77
IMPORTANT
When disassembling foot relief valve, tag and label each
component so that all parts can be reassembled in the
proper order.
Reference
Description
Number
1 Cap
2 Poppet
3 Cap
4 Shim
5 Spring
Figure 78
Figure 79
IMPORTANT
Shim is necessary for correct pressure adjustment
and must not be left out.
Figure 80
IMPORTANT
When disassembling Center Bypass Valve, tag and label
each component so that all parts can be reassembled in
the proper order.
Reference
Description
Number
1 Cap
2 Spring
3 Spool
Figure 81
1. Loosen cap (1) and remove spring (2) and spool (3).
Figure 82
IMPORTANT
When disassembling Boom Parallel Switch Valve, tag
and label each component so that all parts can be
reassembled in the proper order.
Special Tool
This holding tool is used to clamp and hold AP Spool for
further disassembly, without damaging it. The holder is
comprised of 2 halves of a hexagonal rod made from soft
brass, with the appropriate size hole and outside
dimensions.
Figure 83
Length 100.0 mm (3.9370 in)
Reference
Description
Number 1 2 3 4 5 6 7 8 9 10 11
1 Cap
2 Spring
3 Check
4 Spool
5 Bolt with Hole
6 Spring Guide
FG003199-1
7 Spacer Figure 84
8 Bolt with Hole
9 Spring
10 Shim
11 Cover
IMPORTANT
When assembling AP spool, inspect O-rings and
backup rings for any damage and replace as
necessary.
FG003263
Figure 85
5
FG003264
Figure 86
IMPORTANT
When disassembling Boom Unity Check Valve, tag and
label each component so that all parts can be
reassembled in the proper order.
IMPORTANT
When assembling components, inspect O-rings for any
damage and replace as necessary.
Figure 87
Figure 88
F SW BM1
AM-2
FG007269
Figure 89
DOZER
F
SW
D
BM-2
D
AM-1
HAAA7660
Figure 90
Check Valve
IMPORTANT
When disassembling Check Valves, tag and label each
component so that all parts can be reassembled in the
proper order.
Reference
Description
Number
1 Cap
2 Spring
3 Check
Figure 91
Reference
Description
Number
1 Cap
2 Spring
3 Check
Figure 92
Reference
Description
Number
1 Cap
2 Spring
3 Check
Figure 93
IMPORTANT
Even though the valve caps look the same, they are
different, and cannot be interchanged.
Reference
Description
Number
1 Cap
2 Spring
3 Check
Figure 94
3 O-ring
IMPORTANT
Even though the valve caps look the same, they are
different, and cannot be interchanged.
Reference
Description
Number
1 Cap
2 Spring
3 Check
Figure 96
Swing Motor
Edition 1
Swing Motor
Safety Precautions............................................... 5
Applicable Models................................................ 5
Instruction Manual ............................................... 6
Indication of Type .......................................................... 6
Specifications .................................................................. 7
Construction & Principles of Working ........................... 8
Precaution in Use ........................................................ 16
Troubleshooting............................................................. 20
Maintenance Manual ......................................... 23
Disassembling & Assembling ...................................... 23
Maintenance Standards................................................ 36
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Indication of Type
Relief Valve
Setting Pre.
Design Code
Specification
A: Swing Specification
Shaft Geometry
10 : Male Spline
20 : Female Spline
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
Construction
The Construction
202 203 204 205 306 305 307 308 309 112 311 106 102 103 104 105
101
made by
Tong Myung Heavy Industries Co.,Ltd
MFG. NO. :
PART NO. :
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
Reference Reference
Description Description
Number Number
101 Valve Casing 209 Roller
102 Plug 210 Washer
103 Spring 211 Spring
104 Plunger 212 Ring Snap
105 Swing Reactionless Valve Ass’y 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 Drive Shaft 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 Name Plate
207 Retainer Plate 402 Rivet Screw
208 Collar
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 (kgf/cm2)
q : Displacement (cc/rev)
F1
F
F2
Drive Shaft
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 following equation.
P1 × A1 = Fsp′ + Pg × A2
Fsp′
P1 = ---------------------
A1 – A2
R Port
(1) P Port
(Pressure : P1)
(2)
(3) Pressure : Ps
Pressure : Ps
Ps
(4)
P1
T FG007422
Figure 4 Relief Valve : KRD22EK10C Working Description
Orifice Poppet
Bypass Way
FG007423
Figure 5 Swing Reactionless Valve Working Description
Oil Press
Spring Force
310
309 305
306
Oil Pressure
301
201 205
FG007424
Figure 6 Brake Working Description
Inspection
Prior to 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 missing.
2. Inspect each tightened part is loosened or not.
3. Check whether or not covers for flange surface and
drain port are perfect, and 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.
FG007426
Figure 8 The Proper Range of Viscosity and Tempera-
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 the customer not only will
take necessary measures to prevent oil from contamination
with such fine particles but also to provide an oil filter in the
circuit without fail. For satisfactory service life of these
motors in application, the operating fluid should 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 ~ 4mg/100cc.
General Cautions
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 in
trouble.
2. Be careful of dust
It is not too much to say that most troubles are
ascribed to dust so that measures for dust prevention
is taken into consideration with utmost care in the case
of partial disassembling.
3. Handling part
Pay attention to the handling of parts not to injure
them, especially to moving parts such as pistons,
bearing and valves etc.
4. Pay attention to work the handling of o-ring, gasket
Once seals have been disassembled, they should be
replaced even if damage is not observed.
6. Oil Leak
A. Oil leak from the oil seal
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
FG001856
Figure 12
FG001857
Figure 13
FG001858
Figure 14
Figure 15
Figure 16
Figure 17
FG001862
Figure 18
Figure 19
12. Pull out friction plate (306, 2EA) and separation plate
(305, 3EA) from casing (301).
(TSM72 : friction plate : 3EA
separation plate : 4EA)
Figure 21
13. Remove swash plate (202) and drive shaft 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 drive shaft end with plastic hammer, it is
easy to be disassembled.
Figure 22
FG001867
Figure 23
Ball Bearing
C. Take out oil seal (302) from the casing (301) with
a using of tool.
Do not reuse the disassembling oil seal (302). Press
Oil Seal
Rod Casing
FG007430
Figure 25
FG001870
Figure 26
FG001871
Figure 27
FG001872
Figure 28
FG001873
Figure 29
Figure 30
FG001875
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
Figure 36
FG001880
Figure 37
FG001881
Figure 38
FG001882
Figure 39
FG001862
Figure 40
Figure 42
Figure 43
Figure 44
Figure 45
FG001858
Figure 46
FG001856
Figure 47
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 Replace piston or shoe.
0.05 0.2
caulked 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 bush 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)
Travel Motor
Edition 1
Travel Motor
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Repair Guidelines.................................. 7
Seal Kits and Sub-assemblies ........................... 8
Replace Seal Nut ......................................................... 10
Disassembly ....................................................... 11
Sealing the Drive Shaft ............................................... 11
Seal of the Control Parts ............................................ 12
Seal fo the Relief Valve / Counter-balance Valve .... 14
Spare Parts List ........................................................... 16
Diassembly of the Port Plate ...................................... 18
Remove of the Positioning Piston .............................. 19
Remove Rotary Group ................................................. 21
Exchanging of the Rotary Group ................................ 22
Inspection Notes........................................................... 23
Assembly ............................................................ 26
Rotary Group Assembly............................................... 26
Rotary Group Adjustment (See Service Information) 28
Assembly of the Port Plate ......................................... 30
Tightening Torques............................................ 32
Shaft Bolts .................................................................... 32
Locking Screws VSTI................................................... 32
Seal-Lock Nuts ............................................................. 33
Cross-slotted Lens Head Screws DIN 7985 .............. 33
Test Procedure .................................................. 34
Hydraulics Schematic ................................................... 36
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
CAUTION
Observe the following notices when carrying out repair
work at hydraulic aggregates.
HB7M3002
Figure 2
HB7M3003
Figure 3
HB7M3004
Figure 4
CAUTION
Rework of sealing area f. ex. with abrasive paper
can damage surface.
HB7M3005
Figure 5
HB7M3006
Figure 6
HB7M3007
Figure 7
HB7M3008
Figure 8
HB7M3009
Figure 9
HB7M3010
Figure 10
HB7M3011
Figure 11
6. Counter-balance Valve
HB7M3012
Figure 12
Figure 13
HB7M3014
Figure 14
HB7M3015
Figure 15
HB7M3016
Figure 16
HB7M3017
Figure 17
HB7M3018
Figure 18
CAUTION
Pay attention to pressing depth
CAUTION
Figure 19
Mark for pressing depth.
Assemble retaining ring.
HB7M3020
Figure 20
FG007441
Figure 21
CAUTION
3 HB7M3022
Installation position differs according to the control Figure 22
components
Reference
Description 1
Number
5
1 Input Flow of Oil Control
2 High Pressure / Low Pressure 2 3
3 High Pressure / Low Pressure
4 Leckage Oil
5 Control Piston 4
HB7M3023
Figure 23
HB7M3024
Figure 24
CAUTION
Attention! Spring load. X
Reference
Description 1
Number
1 Check of O-ring
HB7M3026
Figure 26
Reference
Description
Number 1
2
O-ring / High Pressure - Small Control
1
Piston Side 4
2 O-ring / Control Pressure
3 O-ring / High Pressure - Check Valve 3
4 O-ring / High Pressure - Check Valve
HB7M3027
Figure 27
HB7M3028
Figure 28
Figure 29
HB7M3030
Figure 30
Counter-balance Valve
2 8
1
12
15 2
13 10
12 18
7
11
16
3
15
9
5 14
11
17 FG008821
Figure 31
Reference Reference
Description Description
Number Number
1 Valve 10 Plug
2 O-ring 11 O-ring
3 Shuttle Valve 12 O-ring
4 Brake Valve 13 O-ring
5 Housing 14 Plug
6 Cover 15 Plug
7 Cover 16 Screw
8 Plug 17 Socket Bolt
9 Socket Bolt 18 Socket Bolt
Reference
Description
Number
1 Brake Piston
2 Valve Bushing
3 Throttle Pin
4 Valve Screw
5 Bolt Figure 32
6 Spring Collar
11 Pressure Spring
Reference 12
Description
Number
10 Valve Screw 10
11 Valve Bush
12 Ball
HB7M3033
Figure 33
CAUTION
For disassembly of the port plate, swivel always
rotary group to zero position.
Piston rings to hang out of the cylinder boring.
Figure 34
HB7M3035
Figure 35
3. Check O-ring.
CAUTION
Stick new O-ring with some grease.
Do not swivel rotary group.
Piston rings to hang out from the cylinder boring.
HB7M3036
Figure 36
HB7M3037
Figure 37
HB7M3038
Figure 38
HB7M3039
Figure 39
CAUTION
Use new screw.
Precote coating.
Note tightening torque!
Figure 40
CAUTION
Stick control lens in sliding surface with grease.
Assembly in reversal order.
Mount port plate.
HB7M3041
CAUTION Figure 41
HB7M3042
Figure 42
HB7M3043
Figure 43
CAUTION
If the bearings are used again
do not hit on the drive shaft.
HB7M3044
Figure 44
CAUTION
Setting of hydraulic part necessary.
HB7M3010
Figure 45
1. Rotary group
A. Mechanical part: Adjust drive shaft with bearing.
B. Hydraulic part:
CAUTION
Adjustment necessary.
FG003029
Figure 46
HB7M3047
Figure 47
CAUTION
Screws are glued.
Use Torx-tools.
HB7M3048
Figure 48
Inspection Notes
1. Free of corrosion, erosion or fretting; no damage to
splines or keyways.
HB7M3049
Figure 49
2. Pistons
No scoring and no pittings.
HB7M3050
Figure 50
HB7M3051
Figure 51
4. Retaining plate
No scoring and no evidence of wear
HB7M3052
Figure 52
HB7M3053
Figure 53
HB7M3054
Figure 54
HB7M3055
Figure 55
Figure 56
Figure 57
HB7M3058
Figure 58
Figure 59
Figure 60
Figure 61
2. * Disc
Figure 62
HB7M3063
Figure 63
Figure 64
5. Check dimension X.
Figure 65
CAUTION
Take care of assembly design.
Tighten fixing screws with torque.
Figure 66
HB7M3067
Figure 67
FG007441
Figure 68
CAUTION
Take care of press-in depth.
Figure 69
Figure 69
HB7M3030
Figure 70
Shaft Bolts
(Metric ISO Standard Thread)
PX2 = 0 MPa
PSP = 3 MPa
0 (40) Q(cm3 )
Loosen the threaded-pin for HA regulation
52.5 2.1
PX2 = 0MPa
PSP = 3MPa
8 Check response Qmin → Qmax : slow
Check response while switching PA(=25⇔35MPa) on the following Qmax → Qmin : slow
conditions
Speed n= 1250 min -1(QN=50L/min) : clockwise
Pressure PX = 0MPa
PX2 = 0MPa
PSP = 3MPa
9 Set relief valves Pmax = 40.0 MPa
Check max. pressure PMA(PMB) = 36.0 ± 1.0 MPa
Set setting pressure of relief valves
on the fol Iwlng conditions
Set both A and B
Speed n= 467 min -1(QN=50L/min)Qmax
Pressure PSP = 3MPa
10 Release Function Test regular as to the outside
• All values within the tolerances drawing (Y120191505)
Figure 71
Counterbalance
Valve
Edition 1
Counterbalance Valve
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
While Operating to Run Forward.................................. 6
While Operating to Stop ................................................ 6
While Operating to Back ............................................... 7
Adjustment of Relief Valve ............................................ 8
Troubleshooting .................................................... 9
Counterbalance Valve ....................................... 10
Recommended Tools ................................................... 10
Disassembly .................................................................. 10
Order of Disassembly and Torque Values ................ 11
Reassembly................................................................... 12
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Recommended Tools
Disassembly
NOTE: Disassemble counterbalance valve in reverse order
of assembly.
Figure 3
Figure 4
2. Apply Loctite #242 to plug (4) and install into spool (2).
Torque to 75.5 ±7 kg•m (548 ±50 ft lb). Install plugs
on other side following steps 1 and 2.
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
12. Install spring (19) into body (1), then install cover (6).
Figure 15
Figure 16
14. Install plunger (8) and spring (18), in that order, into
body (1).
Figure 17
15. Install plug (14) into body (1) (both sides) and torque
to 71.2 ±1.5 kg•m (505 ±10 ft lb).
Figure 18
16. Install plug (33) into body (1) (both sides) and torque
to 71.9 ±2.3 kg•m (520 ±16 ft lb).
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
Section.................................................................. 7
General Repair Guidelines.................................. 8
Seal Kits and Sub-assemblies ........................... 9
Disassembly ....................................................... 13
Sealing the Drive Shaft ............................................... 13
Gear Pump Sealing ..................................................... 15
Control Housing ............................................................ 16
Control Module LR ....................................................... 19
Control Module H ......................................................... 20
Controller ....................................................................... 21
Rotary Groups .............................................................. 23
Intermediate Wheel ...................................................... 26
Auxiliary Drive............................................................... 28
Inspection Hints ................................................. 31
Assembly ............................................................ 36
Rotary Group ................................................................ 36
Pump ............................................................................. 37
Hydraulic Component - Measurement "D" ................. 40
Control Housing ............................................................ 43
Intermediate Wheel ...................................................... 46
Gear Pump ................................................................... 47
Cover / Auxiliary Drive ................................................ 48
Assembly Guidelines for Tightening Torques.. 49
Bolts (to N 08.001) ...................................................... 49
Plugs with Internal Hexagon and Profile Seal Ring
(to N 02.009) ................................................................ 50
Seal-Lock - Sealing Nuts (to N 02.100) .................... 50
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Figure 1
CAUTION
Observe the following notices when carrying out repairs
on hydraulic units!
HB7M3002
Figure 2
HB7M3003
Figure 3
HB7M3004
Figure 4
CAUTION
Re-work of the sliding surfaces by using, for
example with abrasive paper, can damage the
surface.
HB7M3005
Figure 5
Figure 6
FG003063
Figure 7
Figure 8
FG003065
Figure 9
Figure 10
CAUTION
Direction of rotation.
Figure 11
Figure 12
Figure 13
8. Control, pre-adjusted.
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
HB7M3017
Figure 20
HB7M3018
Figure 21
CAUTION
Take note of press-in depth!
Install mark for press-in depth of safety ring.
Figure 22
Figure 23
Visual Check :
Reference
Description
Number
1 O-ring
2 Sealing Surface of the Housing
Figure 24
Figure 25
CAUTION
Control lenses can fall down.
Figure 26
Figure 27
Reference
Description
Number
1 Setting Screw Qmax
Setting Screw Hydraulic Stroke
2
Limitation
Setting Screw Power Characteristic
3
(Begin of Regulation)
Figure 29
Figure 30
Figure 31
Figure 32
CAUTION
Do not change the setting screw (1).
Figure 33
CAUTION
Fit control lens - torque support.
Figure 34
CAUTION
Loosen adhesive with a "gentle" flame (approx.120°C ).
Figure 35
Figure 36
Figure 37
Figure 38
Figure 39
Figure 40
Figure 41
Figure 42
Figure 43
CAUTION
Pos. * Drive shafts with bearing set are the
smallest assembly group.
CAUTION
Fixing screw - Retaining device
Intermediate Wheel
1. * Press in bolt into the gear wheel. (Fixed pressing fit).
Can only be disassembled with a hydraulic press.
Figure 45
CAUTION
Install sleeve.
Press out bolt with a hydraulic manual press.
Figure 46
Figure 48
Figure 49
Figure 50
Figure 51
Figure 52
Figure 53
Figure 54
Figure 55
Figure 56
Figure 57
Figure 58
2. Visual Check:
To ensure that the bearing seats are free of scores.
Figure 59
3. Visual Check:
Check to see that the bearing area is free of scores
and that there is no evidence of wear.
Figure 60
Figure 61
Figure 62
6. Piston
Check to ensure that they are free of scores and that
there are no pittings.
HB7M3050
Figure 63
7. Central Pin
Check to ensure that it is free of scores and that there
are no pittings.
Figure 64
8. Retaining Plate
Check to ensure that it is free of scores and that there
is no evidence of wear.
HB7M3052
Figure 65
10. Check
Control land 1, internal control drilling 2, pin cups 3.
Figure 67
11. Check
That sliding surfaces 1 are free of scores, seal 2.
Figure 68
CAUTION
Adjustment of the hydraulic component is
necessary.
Figure 69
Figure 70
Rotary Group
1. The threads must be free of oil, grease, dust or any
other contaminants which may impair the locking of the
screws.
Figure 71
2. Fit the retaining plate with pistons and centre pin into
place.
Use screws that have a Precote coating.
* For tightening torques, see service information.
Figure 72
Figure 73
Figure 74
Figure 75
Pump
1. Warm up the housing to approx. 80 °C.
Figure 76
Figure 77
Figure 78
Figure 79
CAUTION
Adjustment of measurement D.
Control hydraulic part!
HB7M3002
Figure 80
Figure 81
Assembly Guideline
1. Retaining Force
After the rotary group has been fitted into the housing,
it has to be pressed in until the end stop is reached.
Allow the housing to cool down from its assembly
temperature (approx. 80°C) to room temperature.
2. Adjustment of the Hydraulic Component of the Rotary
Group
The adjustment of dimension D is carried outusing
spring plates of differing thickness, so that the correct
clearance is achieved between the rotary group which
is fitted in the housing and the centre pinand spring
plates.
Dimension (D) = 0.4 ± 0.1 mm
After assembly of the complete unit the breakaway
torque of the rotary group has to be checked with the
torque wrench.
Figure 82
2. Mounting Position
Ensure that the correct mounting position is used.
The numbers on the top of the measuring device (*)
refer to the piston diameter.
Figure 83
A. NG / size 80 - 107
Figure 85
Figure 86
Figure 87
Figure 88
4. Measuring Procedure
Turn down by 4 turns on the dial gauge.
Check: 2 mm clearance, set dial gauge to "Zero".
Clearance: Size 28 - 200 0.4 mm ± 0.1
A. NG / size 80 - 107
Figure 89
Figure 90
5. Measuring Procedure
Turn down, using the hand wheel, until resistance is
met.
Read the measured value.
CAUTION
Don't use excessive force.
Figure 92
Control Housing
Figure 93
Figure 94
Figure 95
Figure 96
Figure 98
Figure 99
CAUTION
Cool down the bolt with nitrogen and place it.
3. Press in bearing.
Figure 100
Figure 101
Figure 102
CAUTION
Take care of press-in depth!
Figure 103
Figure 104
Gear Pump
Edition 1
Gear Pump
Safety Precautions............................................... 5
Applicable Models................................................ 5
Single Gear Pump............................................... 6
Disassembly .................................................................... 6
Reassembly..................................................................... 8
Double Gear Pump ........................................... 12
Disassembly .................................................................. 12
Reassembly................................................................... 14
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Disassembly
1. Clean exterior of pump.
FG001072
Figure 1
FG001074
Figure 2
FG001073
Figure 3
FG001075
Figure 4
FG000834
Figure 5
FG000835
Figure 6
FG001076
Figure 7
FG001077
Figure 8
FG001078
Figure 9
Reassembly
1. Clean all components with care.
FG001078
Figure 10
FG000839
Figure 11
FG000840
Figure 12
FG001079
Figure 13
FG001080
Figure 14
Inlet Side
FG001401
Figure 15
FG001081
Figure 16
FG001082
Figure 17
FG001083
Figure 18
FG001084
Figure 19
FG001085
Figure 20
FG000851
Figure 21
Disassembly
1. Clean exterior of pump.
FG000830
Figure 22
FG000831
Figure 23
FG000832
Figure 24
FG000833
Figure 25
FG000834
Figure 26
FG000835
Figure 27
FG000836
Figure 28
FG000837
Figure 29
FG000838
Figure 30
Reassembly
1. Clean all components with care.
FG000838
Figure 31
FG000839
Figure 32
FG000840
Figure 33
FG000841
Figure 34
FG000842
Figure 35
Inlet Side
FG001401
Figure 36
FG000844
Figure 37
FG000845
Figure 38
FG000846
Figure 39
FG000847
Figure 40
FG000848
Figure 41
FG000849
Figure 42
FG000850
Figure 43
FG000851
Figure 44
Service Brake
Supply Valve
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
Diagram of Brake Supply Valve Assembly Package .. 7
Functions of Brake Supply Valve Assembly Package 8
Exploded View and Tools ........................................... 10
Cautions for Disassembly and Re-assembly ............. 11
Troubleshooting Guide ................................................. 12
How to Check Brake Pressure ................................... 13
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Figure 1
Functions
This Brake Supply Valve Assembly Package has functions
as below:
1. Prevents overload on brake pump saving energy.
2. Performs a function as a safety device of the brake
control device.
3. Supplies brake control pressure.
Disassembly
Assembly
FG007444
Figure 2
Assembly Torque
No. Part Name Screw Spec Assembling Tools
(kg•cm)
1 Logic valve M20 x 1.5 450 ± 50 Torque wrench/32mm Hex. socket
2 Relief valve UNF7/8-14" 450 ± 50 Torque wrench/1" Hex. socket
3★ 3 Check Valve UNF7/8-14" 450 ± 50 Torque wrench/1" Hex. socket
4 Unloading Valve M20 x 1.5 450 ± 50 Torque wrench/32mm Hex. socket
5★ 3 PT 1/4" Plug PT 1/4-19" 500 Torque wrench/6mm Wrench socket
6★ 6 PT 1/8" Plug bolt PT 1/8-28" 280 Torque wrench/5mm Wrench socket
7★ 3 PF 1/4" Plug PF 1/4-19" 250 ± 25 Torque wrench/19mm Hex.socket
Dozer Control
Valve
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
Structure ............................................................... 6
Parts List .............................................................. 7
Performance Curve.............................................. 8
Hydraulics Symbol ............................................... 8
Disassembly & Assembly Tools ......................... 8
Disassembly ......................................................... 9
Assembly ............................................................ 12
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Figure 1
Secondary Pressure
(kgf/cm2)
(kgf/cm2)
16.6 3
5 1 Operating Torque
2.4 1.5
0 1 5 4 6 6.5 0.5
Push-rod Stroke (mm)
FG007450
Figure 2
HYDRAULICS SYMBOL
T P
1 2
FG007451
Figure 3
Figure 4
FG003783
Figure 5
FG003786-1
Figure 6
Figure 7
FG003787
Figure 9
FG003788
Figure 10
FG003789
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
FG003789
Figure 16
FG003791
Figure 17
FG003788
Figure 18
FG003792
Figure 19
FG003787
Figure 20
Figure 21
Figure 22
FG003786-1
Figure 23
FG007458
Figure 24
FG003794
Figure 25
FG003794-1
Figure 26
FG003783
Figure 27
FG003795
Figure 28
Figure 29
FG003781-1
Figure 30
Steering Valve
Edition 1
Steering Valve
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Theory of Operation ....................................................... 7
OSPC / OSPF ................................................................ 8
TOOLS ............................................................... 10
Disassembly ....................................................... 12
Dismantling the Shock Valves for OSPC/OSPC LS..... 16
Dismantling the Pressure Relief Valve for OSPC ..... 17
Dismantling the Pressure Relief Valve (cartridge) for
OSPC LS/OSPC LSR .................................................. 18
Cleaning ........................................................................ 19
Inspection and Replacement ....................................... 19
Lubrication ..................................................................... 19
Assembly ............................................................ 20
Assembly Pattern for Standard Bearing ..................... 22
Assembly Pattern for Double Bearing ........................ 23
Installation Instructions for O-ring/Kin-ring /Roto Glyd
...................................................................................... 23
Installation Instructions for Lip Seal ........................... 24
Assembly of the Pressure Relief Valve for OSPC ... 29
Assembly of the Shock Valves for OSPC/OSPC LS/
OSPC LSR ................................................................... 30
Hydraulic Connections.................................................. 32
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Figure 1
Reference Reference
Description Description
Number Number
1 Knuckle Arm 3 Steering Valve
2 Steering Cylinder
L R
T L R P
2815
Figure 2
32
32
1
33
38
34
31
30 5
37 7
10
3 4
36 11
35
2
13
14
12
15
16
23
17
24
40 18
39
19
20
22
17
FG007462
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
FG003286
Figure 10
FG003287
Figure 11
3. Lift the gearwheel set (with spacer if fitted) off the unit.
Take out the two o-rings.
FG003288
Figure 12
FG003289
Figure 13
FG003290
Figure 14
FG003291
Figure 15
7. Remove O-ring.
FG003292
Figure 16
CAUTION
On some pins in the OSPC there are two springs
(see page 3, pos. 28). See also spare parts list for
OSPC HN.21.UA.52. Replace this pins prior to the FG003293
reassembly! Figure 17
FG003294
Figure 18
FG003295
Figure 19
11. Press out the cross pin. Use the special screw from
the end cover.
Note next point/paragraph!
FG003296
Figure 20
FG003299
Figure 23
FG003300
Figure 24
FG003301
Figure 25
FG003302
Figure 26
FG003303
Figure 27
FG003304
Figure 28
4. Shake out the two springs and two valve balls into
your hand. The valve seats are bonded into the
housing and cannot be removed.
FG003305
Figure 29
FG007473
Figure 30
FG003307
Figure 31
FG003308
Figure 32
FG003309
Figure 33
FG003310
Figure 34
FG003311
Figure 35
FG003312
Figure 36
FG007476
Figure 37
FG007476
Figure 38
Cleaning
Clean all parts carefully in Shellsol K or the like.
Lubrication
Before assembly, lubricate all parts with hydraulic oil.
FG003314
Figure 39
FG003315
Figure 40
FG003316
Figure 41
4. Guide the spool into the sleeve. Make sure that spool
and sleeve for OSPB LS, OSPBX LS, OSPC LS,
OSPC LSR and OSPF are placed correctly in relation
to each other (See page -8).
FG003317
Figure 42
CAUTION
OSPB LS, OSPBX LS, OSPC LS, OSPC LSR and
OSPF
When assembling spool and sleeve only one of two
possible ways of positioning the spring slots is
correct. FG003318
There are three slots in the spool and three holes Figure 43
in the sleeve in the end of the spool/sleeve
opposite to the end with spring slots. Place the
slots and holes opposite each other so that parts
of the holes in the sleeve are visible through the
slots in the spool.
OSPB CN and OSPC CN
Assemble the spool/sleeve and make sure the
marks on spool and sleeve are opposite each other
(see drawing page 10).
FG003319
Figure 44
FG003320
Figure 45
FG003321
Figure 46
CAUTION
The ring should be able to move - free of the
springs.
FG003322
Figure 47
FG003323
Figure 48
FG003324
Figure 49
5 Sleeve 5
FG003325
Figure 50
* The inside chamfer on the inner bearing race must face FG003326
the inner spool. Figure 51
FG003327
Figure 52
FG003328
Figure 53
FG003330
Figure 54
FG003332
Figure 55
FG003333
Figure 56
FG003334
Figure 57
FG003335
Figure 58
3. Press and turn the lip seal into place in the housing.
FG003336
Figure 59
CAUTION
Fit the spool set holding the cross pin horizontal.
FG003337
Figure 60
5. The spool set will push out the assembly tool guide.
The O-ring and kin-ring/roto Glyd are now in position.
FG003338
Figure 61
FG003339
Figure 62
FG003340
Figure 63
FG003341
Figure 64
FG003342
Figure 65
FG003343
Figure 66
11. Grease the O-ring with mineral oil approx. viscosity 500
mm2/s at 20°C.
FG003344
Figure 67
FG003345
Figure 68
13. Guide the cardan shaft down into the bore so that the
slot is parallel with the connection flange.
FG003346
Figure 69
FG003347
Figure 70
FG003348
Figure 71
CAUTION
Fit the gearwheel (rotor) and cardan shaft so that a
tooth base in the rotor is positioned in relation to
the shaft slot as shown. Turn the gear rim so that
the seven trough holes match the holes in the
housing.
FG003349
Figure 72
FG003350
Figure 73
FG003351
Figure 74
18. Fit the special screw with washer and place it in the
hole shown.
FG003352
Figure 75
19. Fit the six screws with washers and insert them. Cross-
tighten all the screws and the rolled pin with a torque
of 3.0 +/-0.6 daNm. The OSPB, OSPB LS and OSPBX
LS can now be function tested.
FG003353
Figure 76
FG003354
Figure 77
FG003355
Figure 78
FG003356
Figure 79
FG003357
Figure 80
FG003358
Figure 81
CAUTION
The blue spring applies to setting range 90-180 bar.
The untreated spring applies to setting range 170-
260 bar. (See OSPC spare parts list HN.21.UA.52).
FG003359
Figure 82
FG003360
Figure 83
4. Screw plug with seal ring into the two shock valves
and tighten them with a torque of 3 +1 daNm using a
6 mm hexagon socket spanner.
Steering unit type OSPB, OSPB LS, OSPBX LS,
OSPC, OSPC LS or OSPC LSR is now assembled.
FG003360-1
Figure 84
FG003475
Figure 85
FG003476
Figure 86
FG003477
Figure 87
Hydraulic Connections
Reference Number Description
L Left Port
R Right Port
T L P R
T Tank
P Pump
FG003478
Figure 88
Accelerator
Pedal Valve
(Hydraulic)
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
STructure .............................................................. 6
Parts List .............................................................. 6
Performance Curve.............................................. 7
Hydraulics Symbol ............................................... 7
Disassembly & Assembly Tools ......................... 7
Disassembly ......................................................... 8
Assembly .............................................................. 9
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
ll-13
ll-10
ll-9
ll-12
ll-11 l-6
l-5
l-7 2
l-4
l-3 1
FG007504
Figure 1
PARTS LIST
No. Part Name Standard Material Q’ty Remark
1 Body 1 AJV12D101
2 Plug 2 WPT18
l Spool Kit JA3G3010
l-3 Spool 1 AJV12D102
l-4 Spring Seat 1 AJV12D103
l-5 Spring 1 JA3G3001A
l-6 Spring Seat 1 JA3G3006
l-7 Stopper 1 set AJV12D106
8 Spring 1 JA3G3007
ll Plug Kit JA3G3011
ll-9 Plug 1 AJV12D108
ll-10 Seal DYR10 N.B.R 1 RSY10
ll-11 O-ring P14 N.B.R 1 PO 014
ll-12 Push Rod 1 JA3G3002
ll-13 Dust Seal DRP10 N.B.R 1 DSP10
40
e
28 1.5
ur
ess
Pr
22
ry
da
ue
n
co
rq
Se
To
12 1
ing
at
er
Op
1.6
0 1.2 0.5 3.76 0.5 6.8
5 0.5 13 1
HYDRAULICS SYMBOL
- T -
- A -
- P -
FG007508
Figure 3
FG007509
Figure 4
FG007510
Figure 5
FG007511
Figure 6
FG007512
Figure 7
FG007513
Figure 8
FG007512
Figure 9
Figure 10
FG007511
Figure 11
Figure 12
FG007510
Figure 13
FG007509
Figure 14
One Spool
Valve
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
Outside Drawing .................................................. 7
Hydraulic Circuit................................................... 7
Operational Principle ........................................... 8
In the Neutral Condition ................................................ 8
Spool Operation.............................................................. 8
Disassembly and Assembly ................................ 9
General Cautions............................................................ 9
Replacement of Spool Ass'y (Pilot Type) .................. 10
Replacement of Main Relief Valve ............................. 12
Replacement of Overload Relief Valve ...................... 13
Replacement of Sub-Block Ass'y ................................ 14
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Figure 1
Reference Reference
Description Description
Number Number
1 Inlet Block 4 Main Relief Valve
2 Work Block 5 Overload Relief Valve
3 T Block
HYDRAULIC CIRCUIT
Figure 2
Figure 3
Spool Operation
1. When Pilot Pressure "Pa" is impressed
When pilot pressure is impressed at the "Pa" port, the
pressured oil flowed from the P port is to be
discharged to the A port through the load check poppet
and the spool, as the hydraulic oil passage for bypass
is blocked.
Figure 4
Figure 5
General Cautions
It is the principle that disassembly and assembly of this
valve should carried out by the manufacturer. In case
disassembly and assembly is inevitably required elsewhere,
the following cautions must be observed.
1. This valve is precisely processed and the gaps among
each part are extremely tiny. This, disassembly and
assembly should be performed very carefully so that
any foreign material such as dust or sand can not
intrude into the valve.
2. For disassembly, a technician should start disassembly
after fully understanding the structure of the valve with
structural drawings and reference drawings.
3. When the valve needs to be removed from a machine,
be sure to put caps on each port and to wash the
exterior of the assembly after checking the caps on
each port again before assembling.
4. In case the disassembled parts need to be placed
unassembled for a while, they must be treated with
rust prevent oil and sealed to prevent rusting.
5. Do not hold a pilot cap, a relief valve and a overload
relief valve when this valve needs to be moved.
6. Even in case disassembly and assembly is not
peformed smoothly, do not hit or treat any part of the
product roughly.
7. After disassembly, attach ID tags to each part for
accurate assembly.
8. For O-rings and back up-rings, it is the principle to use
the new ones. And be sure not to damage one during
assembly. (Apply a small portion of grease on the parts
for smooth assembly.)
9. Fasten bolts, overload relief valves and main relief
valves with the specified standard torque.
10. As various tests (relief characteristics test, leakage test,
operational test, etc.) are essential after disassembly
and assembly, do not disassemble this valve if those
tests are not available.
11. Be careful not to damage the O-ring contacting parts of
this valve for preventing oil leakage.
12. Be cautious about safety during operation as this valve
assembly is heavy.
CAUTION
For replacement of a spool, it must be replaced with a
sub-assembly of spool.
CAUTION
During assembly operation of a spool sub-assembly, be
careful so that a foreign material can not intrude into
the sub-assembly.
Figure 6
Figure 7
2. Removing Spool
After fixing the main body and removing the return
spring and the spring seat first, pull the spool in the
horizontal direction (parallel to the spool hole) to
remove it from the main body.
Too much impressed force for disassembly may
damage the spool. When the spool is stuck, therefore,
push it back smoothly and try to pull the spool while
rotating it.
While removing the spool, check which end has the
mark. Figure 8
Figure 9
Figure 10
Figure 11
CAUTION
Be careful not to damage the seat of the removed main
relief valve.
CAUTION
As the main relief valve is a very important part, related
to performance and safety, and hard to be set for the
pressure again, be sure to replace it with an assembly if
needed, not disassembling it.
CAUTION
During assembly of a main relief valve, be careful so
that a foreign material cannot intrude into the main
frame.
Figure 12
Figure 13
Figure 14
CAUTION
As the removed overload relief valves may have
different setting values for each position, identify them
for the original position with tags for accurate assembly.
CAUTION
As the overload relief valve is a precision part, be
cautious about damage or intrusion of foreign materials.
CAUTION
As the overload relief valve is a very important part,
related to performance and safety, and hard to be set
for the pressure again, be sure to replace it with an
assembly if needed, not disassembling it.
CAUTION
During disassembly of a overload relief valve, be careful
not to damage the return cap by the spanner.
Figure 15
Figure 16
Figure 17
CAUTION
During assembly of the sub-block assembly, be careful
so that a foreign material cannot intrude into the main
body.
Figure 18
Figure 19
Figure 20
4. Assembling Nuts
Arrange the main frame and fasten the four nuts at the
specified standard torque with a torque wrench (13mm).
Before completely fastening the nuts, check if each
sub-lock is properly arranged based on the surface
plate.
Standard Torque: 2.05 kgf•m
Figure 21
Remote Control
Valve (Work
Lever / Joystick)
Edition 1
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
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.
28
24
18
25A
16 23
17
36
12 18
22 16
32 11 17
25 15 35
8 20 12
14
11
13 10
34 8
5 7
21
30
6
4 33
5
19
27 9
4
26 1
9
3 4
2 1
29
37 : 24 ~ 28
3
Figure 1 FG003938
Performance
(19.6)
PRESSURE (kgf/cm2)
PRESSURE (kgf/cm )
Operating Torque
TORQUE (kgf.cm)
TORQUE (kgf.cm)
2
(20)
Operating Torque
15.9 3 15.4 3
5.5 2 5.5 2
Secondary Pressure
Secondary Pressure
(6.2) (5)
FG003944
Figure 2
Torques
No. Tool Standard Remark
500 kg•cm
3 Plug PF 3/8
(36 ft lb)
1,660 kg•cm
19 Swash Plate 27 mm
(120 ft lb)
1,660 kg•cm
20 Hex Nut 22 mm
(120 ft lb)
1,660 kg•cm
22 Nut 22 mm
(120 ft lb)
FG000804
Figure 3
FG000805
Figure 4
3. Remove hex nut (23) and swash plate (22) from case.
FG000806
Figure 5
FG000807
Figure 6
FG000808
Figure 7
FG000809
Figure 8
FG000810
Figure 9
FG000811
Figure 10
FG000812
Figure 11
FG000813
Figure 12
FG000814
Figure 13
FG000815
Figure 14
FG000817
Figure 16
REASSEMBLY
1. Install four plugs (2) into case (1).
FG000815
Figure 17
FG000817
Figure 18
FG000814
Figure 19
FG000818
Figure 21
FG000819
Figure 22
FG000812
Figure 23
FG000820
Figure 24
5. Install spool kit assembly into case (1). (The same way
is used for four parts.)
FG000821
Figure 25
6. Assemble plug kit insert rod seal (18), O-ring (17), and
push rod (2) into plug (16) in proper order.
FG000822
Figure 26
FG000810
Figure 27
FG000809
Figure 28
FG000811
Figure 29
FG000823
Figure 30
FG000808
Figure 31
FG000807
Figure 32
10. Install wash plate (22) and hex nut (23) into case (1).
FG000806
Figure 33
FG000824
Figure 34
12. Install boot (20) and bushing (29) into case (1).
FG000825
Figure 35
FG000805
Figure 36
14. Put lead wire in bushing (29), tie it, and arrange boot.
FG000826
Figure 37
FG000827
Figure 38
FG001097
Figure 39
FG000828
Figure 40
FG000829
Figure 41
START-UP PROCEDURES
1. Start engine and set throttle at "LOW IDLE."
2. Set safety lever on "UNLOCK" position.
HAOB290L
Figure 42
ARO0470L
Figure 43
1Breaker EPPR
Valve (Opt)
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
Structure ............................................................... 6
Numbers and Names of Parts ...................................... 6
Functions and Operation..................................... 7
Cautions for Operation ........................................ 7
Maintenance Instructions ..................................... 8
Maintenance .................................................................... 8
Disassembly .................................................................... 9
Assembly ....................................................................... 10
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Figure 44
Reference Reference
Description Description
Number Number
1 Solenoid 5 Pin
2 Valve Casing 6 Spring
3 Sleeve 7 O-ring
4 Spool 8 O-ring
Maintenance
Used Torques
Bolt Sizes Names
(kgf.cm)
M 35 Hex bolt 450 ± 50
M 10 Hex bolt 200 ± 20
NPTF 1/16 Plug 90
FG003690
Figure 45
FG003691
Figure 46
FG003692
Figure 47
FG003693
Figure 48
FG003694
Figure 49
FG003695
Figure 50
FG003696
Figure 51
FG003697
Figure 52
FG003698
Figure 53
Service Brake
Pedal Valve
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
Functions of Brake Pedal ................................... 7
Internal Structure and Operation Principles....... 8
Internal Structure ............................................................ 8
Operation Principles ..................................................... 10
Disassembly ....................................................... 11
Reassembly ........................................................ 11
Reassembly of the Lower Part ................................... 11
Reassembly of the Upper Part ................................... 13
Assembly of Pedal Plate ............................................. 16
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Figure 1
Internal Structure
Figure 2
Figure 3
2. During Operation
A. Operation of pedal causes action of main spring
(13) and spool (3). The load of spring (13)
generates pressure B port seating pressure.
B. P and BR ports are connected and pressure is
generated, which moves to orifice to act pilot
pressure to the floor of spool (3).
C. If pilot pressure is higher than pressure set to
spring (13), spool (3) moves up and pressure
decreases.
D. If pilot pressure is lower than pressure set to
spring (13), spool (3) moves down to close T port
and pressure increases.
E. Operation angle of pedal changes load of spring Figure 4
(13) and thus the second pressure of BR port.
Refer to the Curve 80
70
P1, P2 ports: Supply pressure
60
T1, T2 ports: Tank port 50
BR1, BR2 ports: Brake supply port 40
30
BL1, BL2 ports: Brake pressure sensor location
20
10
2 4 6 8 10 12 14 16 18 22 24
Operation Angles FG007749
Figure 5
REASSEMBLY
4 3 2 1 5 6 7
FG003651
Figure 6
Reference Reference
Description Description
Number Number
1 Lower Part 5 O-ring
2 Spool 6 Spring Guide
3 Lower Spring 7 Upper Spring
4 Plug
1. Insert spool (2) and lower spring (3) in lower part (1).
CAUTION
Take care to prevent dust or foreign substances
entering into valves after washing.
FG003652
Figure 7
FG003653
Figure 8
FG003654
Figure 9
FG003655
Figure 10
1 2 3 4 5
6 7 8 9 10
FG003656
Figure 11
Reference Reference
Description Description
Number Number
1 Upper Part 6 Spool
2 Oil Seat 7 Spring Retainer
3 Plain Washer 8 Main Spring
4 Retaining Ring 9 Holder
5 Drive Bearing 10 Rubber Cover
1. Install oil seal (2), plain washer (3), retaining ring (4),
and drive bearing on lower part (1).
Tools: Drive bearing jig and snap ring plier.
CAUTION
Use a jig to press and push bearing.
Never remove the dry bearing.
FG003657
Figure 12
CAUTION
Take care to prevent dust or foreign substances
entering into valves after washing.
FG003658
Figure 13
CAUTION
Do not forget to install O-ring.
FG003659
Figure 14
FG003560
Figure 15
FG003662
Figure 16
FG003663
Figure 17
FG003664
Figure 18
1 2 3 4
5 6 7 8 9 10 11 12 10
FG003665
Figure 19
Reference Reference
Description Description
Number Number
1 Rubber Pedal 7 Ratch Lock Pin
2 Lock Plate 8 Retaining Ring
3 Pedal 9 Pedal Lock Pin
4 Retaining Ring 10 Hexagon Bolt
5 Ratch 11 Pedal Plate
6 Ratch Spring 12 Double Torsion Spring
FG003666
Figure 20
FG003667
Figure 21
3. Install the lock pin retaining ring at the end of lock pin
(9).
Tools: Shaft snap ring flyer
CAUTION
When removing lock pin, remove the retaining ring
first.
FG003668
Figure 22
CAUTION
Apply grease to the inside of ratch spring.
FG003669
Figure 23
CAUTION
When removing lock pin, remove the retaining ring
first. (Damage to pedal plate)
FG003670
Figure 24
FG003671
Figure 25
FG003673
Figure 27
FG003674
Figure 28
FG003676
Figure 30
FG003677
Figure 31
Solenoid Valve
Assembly
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
2-Solenoid Valve.................................................. 7
Diagram of 2-Solenoid Valve Assembly Package ....... 7
Exploded View and Tools ............................................. 8
Cautions for Disassembly and Re-assembly ............... 9
Troubleshooting Guide ................................................. 10
6-Solenoid Valve................................................ 11
Diagram of 6-Solenoid Valve Assembly Package ..... 11
Functions of 6-Solenoid Valve Assembly Package ... 12
Exploded View and Tools ........................................... 14
Cautions for Disassembly and Re-assembly ............. 15
Troubleshooting Guide ................................................. 16
4-Solenoid Valve................................................ 18
Diagram of 4-Solenoid Valve Assembly Package ..... 18
Functions of 4 Solenoid Valve Assembly Package .. 19
Exploded View and Tools ........................................... 21
Cautions for Disassembly and Re-assembly ............. 22
Troubleshooting Guide ................................................. 24
3-Solenoid .......................................................... 25
Diagram of 3-Solenoid Valve Assembly Package ..... 25
Functions of 3 Solenoid Valve Assembly Package .. 26
Exploded View and Tools ........................................... 28
Cautions for Disassembly and Re-Assembly ............. 29
Troubleshooting Guide ................................................. 31
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Figure 1
Figure 2
Assembly
No. Part Name Screw Spec Assembling Tools
Torque (kg•cm)
2 Solenoid Valve UNF7/8-14" 200 ± 25 Torque wrench/1" hex. socket
2-1 Coil Lock Nut UNF1/2-20" 200 ± 25 Torque wrench/ 19mm hex. socket
CAUTION
Do not damage the tube and retainer of
Solenoid Valve when disassembling the coil
lock nut.
In case the tube and retainer gets damaged
(dented, deformed), solenoid valve will not
work.
CAUTION
Excessive use of torque will result in defects
on solenoid valve.
Coil Nut
Coil
Cap Housing
Tube &
Retainer
Case
FG007535
Figure 3
Troubleshooting Guide
K1
00
28
19
TS
5
C3
C5
HO
C4
S
SW
PS
R
1
PS
P 2
4 BM
3
FG000005
Figure 4
Functions
This solenoid valve package has functions as below:
1. Supplies pressure to braker.
2. Boosts main pressure.
3. Controls the operation mode, - swing priority
4. Drives forward and backward.
5. Controls cruise driving.
2-1
Disassembly
Aassembly 3
2-2
2-3
K1
00
28
19
TS
C3
C5
HO
C4
S
SW
PS PS
R P
1 BM
2
5
4
FG007536
Figure 5
Assembly
No. Part Name Screw Spec Assembling Tools
Torque (kg•cm)
2-1 Coil Lock Nut UNF1/2-20" 60 ± 2 Torque wrench/19mm hex. socket
2-3 Solenoid Valve UNF7/8-14" 200 ± 25 Torque wrench/1" hex. socket
3 Pilot Shift Valve UNF7/8-14" 200 ± 25 Torque wrench/1" hex. socket
4 PT 1/4" Plug Bolt PT 1/4-19" 500 Torque wrench/6mm wrench socket
5 PT 1/8" Plug Bolt PT 1/8-28" 280 Torque wrench/5mm wrench socket
CAUTION
Do not damage the tube and retainer of
Solenoid Valve when disassembling the coil
lock nut.
In case the tube and retainer gets damaged
(dented, deformed), solenoid valve will not
work.
CAUTION
Excessive use of torque will result in defects
on solenoid valve.
Coil Nut
Coil
Cap Housing
Tube &
Retainer
Case
FG007535
Figure 6
Troubleshooting Guide
Parts
Figure 7
Functions
This solenoid valve package has functions as below:
1. Operates devices. (Selects the outrigger for operation/
options.)
2. Performs a ram lock function.
3. Controls driving speed.
4. Cuts off pilot pressure.
2-1
Disassembly
2-2
Aassembly
2-3
4
FG007550
Figure 8
Assembly
No. Part Name Screw Spec Assembling Tools
Torque (kg•cm)
2-1 Coil Lock Nut UNF1/2-20" 60 ± 2 Torque wrench/ 19mm hex. socket
2-3 Solenoid Valve UNF7/8-14" 200 ± 25 Torque wrench/1" hex. socket
3 Check Valve UNF7/8-14" 200 ± 25 Torque wrench/1" hex. socket
4 PT 1/8" Plug PT 1/8-28" 280 Torque wrench/5mm wrench socket
Bolt
CAUTION
Do not damage the tube and retainer of
Solenoid Valve when disassembling the coil
lock nut.
In case the tube and retainer gets damaged
(dented, deformed), solenoid valve will not
work.
CAUTION
Excessive use of torque will result in defects
on solenoid valve.
Coil Nut
Coil
Cap Housing
Tube &
Retainer
Case
FG007535
Figure 9
Parts
4 C1
C3
10K
28 0
SD GT 20
S
A
3
CH C6
P
IC
5
PS
6
FG000008
Figure 10
Functions
This solenoid valve package has functions as below:
1. Selects devices for operation (dozer blade/ STD).
2. Performs a ram lock function.
3. Controls driving speed.
4. Cuts off pilot pressure.
2-1
Disassembly
2-2
Assembly
4
2-3
C1
C3
10K
28 0
20
GT
S
C6
3
CH P
IC
PS A
5
6
FG007551
Figure 11
Assembly
No. Part Name Screw Spec Assembling Tools
Torque (kg•cm)
2-1 Coil Lock Nut UNF1/2-20" 60 ± 2 Torque wrench/19mm hex. socket
2-3 Solenoid Valve UNF7/8-14" 200 ± 25 Torque wrench/1" hex. socket
3 Check Valve UNF7/8-14" 200 ± 25 Torque wrench/1" hex. socket
4 Dummy Plug UNF7/8-14" 200 ± 25 Torque wrench/1" hex. socket
5 PF 1/4" Plug PF 1/4-19" 250 ± 25 Torque wrench/19mm hex. socket
6 PT 1/8" Plug Bolt PT 1/8-28" 280 Torque wrench/5mm wrench socket
CAUTION
Do not damage the tube and retainer of
Solenoid Valve when disassembling the coil
lock nut.
In case the tube and retainer gets damaged
(dented, deformed), solenoid valve will not
work.
CAUTION
Excessive use of torque will result in defects
on solenoid valve.
Coil Nut
Coil
Cap Housing
Tube &
Retainer
Case
FG007535
Figure 12
Parts
1Hydraulic
Schematic
Edition 1
Hydraulic Schematic
Safety Precautions............................................... 5
Applicable Models................................................ 5
DX210W (4-INDI)................................................. 7
DX210W (ONE-PIECE BOOM)........................... 8
DX210W (TWO-PIECE BOOM) .......................... 9
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
W
1 3
1 1 2 4 4
RH HIGH
RH HIGH 1 P T 2 1 P 3 2 T 4 1 P 3 2 T 4
1 T P 2 1 T P 2
XAd XBd
(DN) (UP)
A1 B1
R3
S1 26 BAR
R1 TRANSMISSION
A2 B2 SOCKLESS PRESSURE
VALVE WARNING
W
P
T
W
P A
AUTO IDLE
MODULATION VALVE
W
T T 19 BAR BR1 P1
PL 1.5 BAR
R TRAVEL MODE P2 Py Pg Px P3 P4 P1 Pz Rs 4.6 BAR T1
w W
PG
W
DB TANK CRUISE BL1
2.5 BAR A2 A1 RELEASE
MRV
C BR2 P2
P P B2 S1 B1
330bar 2.0 BAR 4.6 BAR T2
270 270
350bar PA PB W
from JOYSTICK(R) SWITCH XBt BL2
W
from SELECT SWITCH CRUISE
Bt to ONE SPOOL VALVE
TRAVEL 65굇4 BAR RELEASE BRAKE VALVE
Hammer Select 시 작동 AUTO RAM 80 BAR
XAt OPERATE
Shear Select 시 작동
At A (LH) B (RH)
XBo XAd
Rear
Bo ROD 360
Bd Axle
L OPTION DOZER/STAB.
C1 XAo
CF
BUCKET XBd
A B Ao HEAD Front
360 Ad
Axle P
EF
R.H C
Ck2
XBk 邈0.9
PROPORTIONAL VALVE XAs
P A 360 CENTER LS
X Bk1 ROD BUCKET SWING Bs 3 3
1 1
1 1 3 3 1 1 3 3 1 3 1
Fr
XAk
邈0.9 8 8 2 2 8 8 4 4 8 8 2 4 4 JOINT
XBs
T 4 5 13 14 10 11 8 9 3 15 7 6 1 12 2
XAb1 Ak1 360 HEAD As
X1 SOCKLESS
L
(Front) VALVE STEERING VALVE
XBb1 BOOM2 Xop
L.H 360 LS
A 220kg/cm 2
HEAD BOOM1 op
Pi XBb2
Dr1 Ab1 360 ROD
T B(HIGH) K(LOW) 175 +10
BAR
0
ARM2 ARM1
CHOCK
BP P
X
XBa1 320cc/rev
XBa2
360 X(IC)
ROD Ba1
XAa1 G
XAa2 Aa1 U T
1 M
B G EXT
LH HIGH RH HIGH HEAD 360 GP GP
J B (REV) Pi BL
Valve; GP GP
One Spool M
ARM Dr4
BOOM BC qmax
S
STEER
pa
HOLDING CYLINDER
B A
qmin
Y BR
C2 C2
A(FWD)
E E Fr Dr3 Fl XAk2 Par Ck1 Pal CHOCK
M A
ROTATING PUMP T M
P 2 3 +20
225 0BAR
M 2
TRAVEL MOTOR
X
R T L
2 Right Turn
80kg/cm 2
Pi2 Pi1 (TU)
Pi1 Pi1
FRONT AXLE Left Turn
OIL TANK T T
BRAKE
(RETURN ROOM) T V2 V2
pb
100kg/cm 2
LOCK VALVE
to Shuttle Block
REAR AXLE
'8' port
BRAKE
QUICK CLAMP VALVE V2 T Pil E
LH HIGH
C2
RH HIGH A B P
P3
T
LOCK VALVE
ARM
W
1 3
1 1 2 4 4
RH HIGH
RH HIGH 1 P T 2 1 P 3 2 T 4 1 P 3 2 T 4
1 T P 2 1 T P 2
XAd XBd
(DN) (UP)
A1 B1
R3
S1 26 BAR
R1 TRANSMISSIO
N
A2 B2 SOCKLESS PRESSURE
VALVE WARNING
W
P
T
to ONE SPOOL
VALVE M2
C1 SWING ARM BOOM BUCKET
A2 G-TS P
P2
P1 B2 B1 1 2 3 4 5 6
M 0.35 L INCHING RTAVEL
HO (Front)
C2 PZ 15 BAR IC C3
A2 S1 A1 ROTATING PUM
P
PL T GP P1
7 13 8 14 9 15 10 16 11 17 12 18 X1
ENGINE Vgmax Vgmin Fr
XBs XAs XBk PB C6 M
SWS XBa2 XAa2 XAk XAk2 DL06
(L) (R)
C3 XBa1 XAa1 XBb1 XAb1 C4
(DU) (CR) (UP) (DN) (CR) (DU) C1
PILOT SUPPLY 2x0.7 L
PS CUT-OFF C5
BM2 30BAR
C4 XBb2 M3
C6 C3
PBP C2 PSA
PSP CH P B(HIGH) 103 BAR
X3
C5 XBt 125 BAR
Vgmax Vgmin K(LOW)
PBR C4 ACC A
C6 C1
XAt Fl 160 BAR
X1 C2 ACC B
C5
PAR
T T
BRAKE
C7 T BLOCK P BLOCK SUPPLY
(Rear) PSD W
M VALVE
P1
A1
TS
M1
R2 S G1 AC AB
65 BAR
Front Rear LOW
T
Axle Axle PRESSURE
WARNING
19 BAR
W
P A
AUTO IDLE
MODULATIONVALVE
W
T T 19 BAR BR1 P1
PL 1.5 BAR
R TRAVEL MODE P2 Py Pg Px P3 P4 P1 Pz Rs 4.6 BAR T1
w W
PG
W
DB TANK CRUISE BL1
2.5 BAR A2 A1 RELEASE
MRV
C BR2 P2
P P B2 S1 B1
330bar 2.0 BAR 4.6 BAR T2
270 270
350bar PA PB W
from JOYSTICK(R) SWI
TCH XBt BL2
W
from SELECT SWI
TCH CRUISE
Bt to ONE SPOOL
VALVE
TRAVEL 65±4 BAR RELEASE BRAKEVALVE
HammerSelect ½Ã ÀÛµ¿ AUTO RAM 80 BAR
XAt OPERATE
Shear Select ½Ã ÀÛµ¿
At A (LH) B (RH)
XBo XAd
Rear
Bo ROD 360
Bd Axle
L OPTION DOZER/S
TAB.
BUCKET C1 XAo XBd
A B Ao HEAD Front
Ad
CF
360
R.H Ck2 Axle
C
P
EF
XBk Ø0.9
PROPORTIONALVALVE XAs
P A 360 CENTER
X Bk1 ROD BUCKET SWING Bs 3 3
1 1
1 1 3 3 1 1 3 3 1 3 1
Fr
XAk
Ø0.9 8 8 2 2 8 8 4 4 8 8 2 4 4 JOINT
XBs LS
T 4 5 13 14 10 11 8 9 3 15 6 1 12 2
XAb1 Ak1 360 HEAD As
X1 SOCKLESS
L
(Front) VALVE
XBb1 BOOM2 STEERING
VALVE
Xop
L.H A 220kg/cm 2 360
HEAD BOOM1 op LS
Pi XBb2 GP
360 GP
J B (REV) Pi BL
Valve; GP
One Spool M
ARM Dr4
BOOM BC DOZER qmax
S
STEER
pa
HOLDING CYLINDER
B A
qmin
Y BR
C2 C2
A(FWD)
E E Fr Dr3 Fl XAk2 Par Ck1 Pal CHOCK
M A
ROTATING PUM
P T M
P 2 3
M 2
TRAVEL MOTOR +20
225 BAR
0
Pi2 GP X 2
R T L
80kg/cm 2
Pi1 (TU)
Right Turn
Pi1 Pi1
REARAXLE FRONTAXLE
OILTANK T T Left Turn
BRAKE BRAKE
(RETURNROOM) T V2 V2
pb
100kg/cm 2
LOCKVALVE
to Shuttle Block
'8' port
QUICK C
LAMPVALVE V2 T Pil E
LH HIGH
C2
RH HIGH A B P
P3
T
LOCKVALVE
ARM
W
1 3
1 1 2 4 4
RH HIGH
RH HIGH 1 P T 2 1 P 3 2 T 4 1 P 3 2 T 4
1 T P 2 1 T P 2
XAd XBd
(DN) (UP)
A1 B1
R3
S1 26 BAR
R1 TRANSMISSIO
N
A2 B2 SOCKLESS PRESSURE
VALVE WARNING
W
P
T
to ONE SPOOL
VALVE M2
C1 SWING ARM BOOM BUCKET
A2 G-TS P
P2
P1 B2 B1 1 2 3 4 5 6
M 0.35 L INCHING RTAVEL
HO (Front)
C2 PZ 15 BAR IC C3
A2 S1 A1 ROTATING PUM
P
PL T GP P1
7 13 8 14 9 15 10 16 11 17 12 18 X1
ENGINE Vgmax Vgmin Fr
XBs XAs XBk PB C6 M
SWS XBa2 XAa2 XAk XAk2 DL06
(L) (R)
C3 XBa1 XAa1 XBb1 XAb1 C4
(DU) (CR) (UP) (DN) (CR) (DU) C1
PILOT SUPPLY 2x0.7 L
PS CUT-OFF C5
BM2 30BAR
C4 XBb2 M3
C6 C3
PBP C2 PSA
PSP CH P B(HIGH) 103 BAR
X3
C5 XBt 125 BAR
Vgmax Vgmin K(LOW)
PBR C4 ACC A
C6 C1
XAt Fl 160 BAR
X1 C2 ACC B
C5
PAR
T T
BRAKE
C7 T BLOCK P BLOCK SUPPLY
(Rear) PSD W
M VALVE
P1
A1
TS
M1
R2 S G1 AC AB
65 BAR
Front Rear LOW
T
Axle Axle PRESSURE
WARNING
19 BAR
W
P A
AUTO IDLE
MODULATIONVALVE
W
T T 19 BAR BR1 P1
PL 1.5 BAR
R TRAVEL MODE P2 Py Pg Px P3 P4 P1 Pz Rs 4.6 BAR T1
w W
PG
W
DB TANK CRUISE BL1
2.5 BAR A2 A1 RELEASE
MRV
C BR2 P2
P P B2 S1 B1
330bar 2.0 BAR 4.6 BAR T2
270 270
350bar PA PB W
from JOYSTICK(R) SWI
TCH XBt BL2
W
from SELECT SWI
TCH CRUISE
Bt to ONE SPOOL
VALVE
TRAVEL 65±4 BAR RELEASE BRAKEVALVE
HammerSelect ½Ã ÀÛµ¿ AUTO RAM 80 BAR
XAt OPERATE
Shear Select ½Ã ÀÛµ¿
At A (LH) B (RH)
XBo XAd
Rear
Bo ROD 360
Bd Axle
L OPTION DOZER/S
TAB.
BUCKET C1 XAo XBd
A B Ao HEAD Front
Ad
CF
360
R.H Ck2 Axle
C
P
EF
XBk Ø0.9
PROPORTIONALVALVE XAs
P A 360 CENTER
X Bk1 ROD BUCKET SWING Bs 3 3
1 1
1 1 3 3 1 1 3 3 1 3 1
Fr
XAk
Ø0.9 8 8 2 2 8 8 4 4 8 8 2 4 4 JOINT
XBs LS
T 4 5 13 14 10 11 8 9 3 15 6 1 12 2
XAb1 Ak1 360 HEAD As
X1 SOCKLESS
L
(Front) VALVE
XBb1 BOOM2 STEERING
VALVE
Xop
L.H A 220kg/cm 2 360
HEAD BOOM1 op LS
Pi XBb2 GP
360 GP
J B (REV) Pi BL
Valve; GP
One Spool M
ARM Dr4
BOOM BC DOZER qmax
S
STEER
pa
HOLDING CYLINDER
B A
qmin
Y BR
C2 C2
A(FWD)
E E Fr Dr3 Fl XAk2 Par Ck1 Pal CHOCK
M A
ROTATING PUM
P T M
P 2 3
M 2
TRAVEL MOTOR +20
225 BAR
0
Pi2 GP X 2
R T L
80kg/cm 2
Pi1 (TU)
Right Turn
Pi1 Pi1
REARAXLE FRONTAXLE
OILTANK T T Left Turn
BRAKE BRAKE
(RETURNROOM) T V2 V2
pb
100kg/cm 2
LOCKVALVE
to Shuttle Block
'8' port
QUICK C
LAMPVALVE V2 T Pil E
LH HIGH
C2
RH HIGH A B P
P3
T
LOCKVALVE
ARM
Electrical
System
(NON-ROPS)
Edition 1
Electrical System
(NON-ROPS)
Safety Precautions............................................... 6
Applicable Models................................................ 6
Introduction ........................................................... 7
Electrical Supply System .................................... 8
Engine Starting Circuit ...................................... 10
Start Operation ............................................................. 10
After Start ..................................................................... 12
Engine Preheating System ............................... 14
Engine Stop ....................................................... 16
Charging System ............................................... 18
Monitoring System ............................................. 19
Instrument Panel .......................................................... 20
Monitoring System Schematic ..................................... 22
Operation ............................................................ 24
Instruments.................................................................... 24
Warning and Indicator Lights ........................... 26
Indication of Warning Lights........................................ 26
Indication of Multifunction Gauge and Letter
Information Area ........................................................... 27
Initial Operation.................................................. 29
Mode Selector Switch ....................................... 30
Graphic Information Area Display .................... 31
Overview ....................................................................... 31
Main Menus for the Graphic Display Area ................ 32
Menu Selector Buttons ................................................ 32
Main Menu ......................................................... 33
Language ...................................................................... 33
Set Clock ...................................................................... 34
Filter/Oil Info ................................................................. 34
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
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
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)
PREHEAT
ON
REG.
TRIO DIODE 7
FIELD
START F+
F-
E
GRD
FG004584
Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM
Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode
Start Operation
When the starter switch is turned to the "START" position,
the "S" and "E" terminals of the starter controller (7) are
connected. At this time 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) → "30" 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 e-EPOS (13) → ground. This
current flow causes the coil in starter relay (12) to be FG013717
activated, opening contacts at "87a" terminal. This Figure 2
prevents starter relay (8) from functioning.
85 86 ACC
C
B 5
R2 BR
12 R1
3
CN1-15
6
4
B A
CN2-1
BR
E
13 11
R(I) P(R) B(B+)
2
STARTER SWITCH CONNECTION 0.5 uF
B+
OFF - + - +
REG.
TRIO DIODE
10
PREHEAT
ON F+ FIELD
1
F-
START E
GRD
FG004587
Figure 3 STARTER CIRCUIT (1) - WHILE STARTING
Reference Reference
Description Description
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
3 Fusible Link 10 Alternator
4 Circuit Breaker 11 Diode
5 Starter Switch 12 Starter Relay 2
6 Fuse Box 13 e-EPOS Controller
7 Starter Controller
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
R(I) P(R) B(B+)
11
STARTER SWITCH CONNECTION 0.5 uF 2
B+
ON F+ FIELD
START
F-
E 1
GRD
FG004588
Figure 4 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START
Reference Reference
Description Description
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
3 Fusible Link 10 Alternator
4 Circuit Breaker 11 Diode
5 Starter Switch 12 Starter Relay 2
6 Fuse Box 13 e-EPOS Controller
7 Starter Controller
6
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
CN5-2
- + - +
11 C B 1
-
200A
1-56
7 STARTER SWITCH CONNECTION
1-33,34,35 8 TML
1-39 PST B BR R1 R2 C ACC
1-16 D OFF
H +
1-04 ON
START
12
FG007757
Figure 5 Engine Preheat Circuit
Reference Reference
Description Description
Number Number
1 Battery 7 Preheat Relay
2 Battery Relay 8 Air Heater
3 Fusible Link 9 Preheat Indicator Light
4 Circuit Breaker 10 Diode
5 Starter Switch 11 e-EPOS Controller
6 Fuse Box 12 Engine Controller
In the event that the engine can be shut down using the
starter switch (5), an emergency stop switch (10) is provided O I
to shut down engine. To activate the emergency stop switch,
move it to the "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 the "O" (OFF) position.
FG001344
Figure 6 ENGINE EMERGENCY STOP
SWITCH
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
Description Description
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
ACC C
B
R2
5
BR
0.5G
R1
6
3
8
4 2
B A
BR
E
- + - +
I R B+ 12V 150AH 12V 150AH
0.5 uF
1
B+
STARTER SWITCH CONNECTION
I(L)
FG007765
Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode
1
5 7
2
CHECK
4
3 9
8
E F 17
10
C H C H
6 11
1 2 3 4 5
6 7 8 9 0 16
12
18
15 14
13
20 19
21
FG016922
Figure 9
Reference Reference
Description Description
Number Number
1 Instrument Panel 12 Air Cleaner Indicator
2 Battery 13 Engine Control Unit
3 Light Switch 14 Parking Brake Sensor
4 Return Filter Switch 15 Brake Oil Pressure Switch
5 Pilot Filter Switch 16 Pilot Relay
6 e-EPOS Controller 17 Parking Brake Switch
7 Alternator 18 Steering Console
8 Warning Buzzer 19 Right Side Combination Switch
9 Pump Discharge Pressure Sensor 20 Left Side Combination Switch
10 Oil Temperature Sensor 21 Ram Lock Switch
11 Fuel Sensor
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
12 11 10 9 8 7 16 15 14 13 12 11 10 9
22
13 (CN7) (CN6)
1 2 3 4 5
23
6 7 8 9 0
15
17 19 21 FG013521
Figure 10
1
21
2
19
18
4
16
20
17
5
6 10
11
12
31 13
14
7
22
8
15
23
24
25
26
27
28
29
30
FG007781
Figure 11
Instruments
Sensor Specification
Function Display Input
Input Specification
Terminal
Blue
Coolant ECU-CAN
Temperature 61 C 102 C Communication
41 C 107 C
C H
White Red
FG013527
Blue
Blue
40°C (104°F) → 1,397 ohms
50°C (122°F) → 1,139 ohms
N = 146 f / 60
ECU-CAN N = Engine speed (rpm)
Tachometer E/G SPEED 1750 RP Communication
f = Frequency of engine
speed sensor (Hz)
FG013531
FG000050
Main pump
CN3-1
discharge
pressure
FRONT PUMP 320 BA
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
It lights in case of
no charge [voltage
Normally, it lights
of "R(I)" terminal is
when starting engine
Charge CN2 - 14 below 12 ±1V] or
and is out after
overcharge [voltage
engine starts.
of "R(I)" terminal is
HAOA610L above 33(V)].
FG000045
It lights when
ECU-CAN engine coolant
Coolant
Communic temperature sensor
Temperature
ation resistant is below
about 128 ohms.
HAOD350L
Preheating period
depends on coolant
It lights during temperature.
preheating ("CN5-2"
terminal voltage is No preheating at
Preheating CN5-2 below 2V) and turns above 10°C
"OFF" after 10 sec preheating at
completion of 5°C
HAOA639L preheating.
20 sec preheating at
below 0°C
Input
Description Symbol Operation Remarks
Terminal
FG000056
FG000057
FG000053
FG000554
It lights when
Breaker CN2-10
breaker is selected.
FG001470
FG001471
Lights up when
Quick Clamp CN2-11 quick clamp was
release.
FG002195
FG004605
HB4O2003
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.
e-EPOS Output
Output Check
(Operation Electromagnetic
Operation Mode Proportional Pressure Swing Priority 7-Segment
mode
display) Reducing Valve (E.P.P.R Solenoid Valve Display
Valve) Current (mA)
No-load: 150 ± 20mA
Power Mode ON Load: Variable output - 9 x
(Max. current: 400 ± 20mA)
No-load: 300 ± 20mA
Power
Standard Mode OFF Load: Variable output - 7 x
Mode
(Max. current: 600 ± 60mA)
No-load: 350 ± 20mA
Economy Mode Load: Variable output - 5 x
(Max. current: 600 ± 60mA)
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
l
the operator.
3. Filter / Oil Info
Refer to the "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
L 1. Language
l
2. Set Clock
l
view appears.
The default language is Korean, but it will memorize and
3. Filter / Oil Info
use the newly set language. 4. Adjust Display
Use the Up Arrow Button ( , 1 on Figure 12) or Down
5. Set Password
Arrow Button ( , 2 on Figure 12) to move cursor to a : UP : DOWN : SELECT
language to be selected on the Language Select display and FG013563
press the Enter Button ( , 3 on Figure 12) and the Figure 14
selected language is indicated in the right bottom of the
screen.
: UP : DOWN : SET
FG013564
Figure 15
l
Menu after putting cursor on Set Clock brings Set Clock
display.
3. Filter / Oil Info
4. Adjust Display
Without pressing a button more than 20 seconds, the default
view appears. 5. Set Password
Please refer to the Operation Manual for detailed information : UP : DOWN : SELECT
on Time Setting. FG013565
Figure 16
SET CLOCK
02:30:30
2003 11/04
: UP : DOWN : SELECT
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
: UP : DOWN : SELECT
FG013567
Figure 18
Filter/Oil Information
R
1. Fuel Filter
Hrs : 0045Hrs 42m
: UP : DOWN : SELECT
FG013568
Figure 19
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, contrast, back light can be adjusted using
3. Filter / Oil Info
the Up Arrow Button ( , 1 on Figure 12) or the Down 4. Adjust Display
Arrow Button ( , 2 on Figure 12). 5. Set Password
: UP : DOWN : SELECT
FG013569
Figure 21
1. Adjust Display
: UP : DOWN : SELECT
FG013835
Figure 22
l
The default back light is set to 90%. Contrast lllllllllllllllllllllllll l 50%
l
Night Mode
BackLight 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
l
2. Set Clock
l
Please refer to the Operation Manual for detailed information
on Password Setting. 3. Filter / Oil Info
4. Adjust Display
5. Set Password
: UP : DOWN : SELECT
FG013571
Figure 24
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
E F
C H C H
FG013591
Figure 26
Submenu Selections
: UP : DOWN
FG016953
Figure 30
Menu Select
DIGITAL INPUT STATE
1. Relift Press UP S/V :
2. Pilot Relay :
3. Reverse Fan S/V :
4. Starter Relay :
5. After Heat Relay :
: UP : DOWN
FG017006
Figure 32
Failure Information
1. Entering Sub-menus: When a cursor is located in SPECIAL MENU
"Failure Info" of special menu screen press enter
button ( , 3 on Figure 25) and "Failure Info" screen
1. Machine Information
is displayed.
2. Failure Information
2. Exiting Sub-menus: If escape button (ESC, 4 on Figure
25) is pressed for more than 1 second, this information
screen will be returned to previous screen.
3. Operating Hours
: UP : DOWN : SELECT
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
: UP : DOWN : SELECT
FG013614
Figure 34
: YES ESC : NO
FG013618
Figure 38
: YES ESC : NO
FG013619
Figure 39
: YES ESC : NO
FG013620
Figure 40
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
Operating Hours
Reset Hours
: UP : DOWN : SELECT
FG013622
Figure 42
1. Power Mode 2. Economy Mode 3. Auto Idle 4. Travel Speed 1st, 2nd
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
: UP : DOWN : SELECT
FG013625
Figure 46
: YES ESC : NO
FG013627
Figure 48
DELETED !!!
: YES ESC : NO
FG013628
Figure 49
X PASSWORD ERR!!!
: YES ESC : NO
FG013629
Figure 50
16
6 6
7 7
11 12 14
8
8
13
15
E/G
4 4 5
3
9 10 Work Mode
Auto Idle
Machine Info
E/G Speed
Order C H
E F
C H
1 2 3 4 5
6 7 8 9 0
24 23
1
17 21 19 18 22 20
FG016925
Figure 51
6 6
E/G
4 4
3
10
24
1 2 3 4 5
6 7 8 9 0
19 23 22
17
FG016926
Figure 52
Reference Reference
Description Description
Number Number
1 Instrument Panel 10 Electric Proportional Reducing
2 e-EPOS Controller V/V (Mode Control)
3 Engine Controller (ECU) 17 Engine Control Dial
4 Main Pump 19 Work/Travel Select Switch
5 Aux Pump 22 Aux Mode S/W
6 Control Valve 23 Aux Mode Resistance
24 Acceleration Pedal
1. Power Mode
This mode should be selected for high speed work. In
this mode the engine output is most efficiently utilized
due to the discharged oil volume being controlled
based on the equivalent horsepower curve at various
loaded pressures. The e-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 FG013632
senses this decrease and immediately reduces the Figure 53
pump discharge 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 e-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. At this time 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
Description Description
Number Number
A Engine Horsepower (hp) C Pump Discharge Volume (lpm)
B Engine Speed (rpm) D Pump Discharge Pressure (kg/cm2)
A C
B D
FG000581
Figure 55
Reference Reference
Description Description
Number Number
A Engine Horsepower (hp) C Pump Discharge Volume (lpm)
B Engine Speed (rpm) D Pump Discharge Pressure (kg/cm2)
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.
The e-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.
FG013671
Figure 56
B D FG013633
Figure 57
Reference Reference
Description Description
Number Number
A Engine Horsepower (hp) C Pump Discharge Volume (lpm)
B Engine Speed (rpm) D Pump Discharge Pressure (kg/cm2)
1
27
27 27 27 2 27 26
19 28
23 25
29
3 22
10
24
17
FG007791
Figure 58
Reference Reference
Description Description
Number Number
1 Instrument Panel 22 Aux Mode S/W
2 e-EPOS Controller 23 Aux Mode Resistance
3 Engine Controller 24 Acceleration Pedal
E.P.P.R. Valve 25 Battery
10 (Electromagnetic Proportional 26 Battery Relay
Pressure Reducing) Valve
27 Fuse
17 Engine Control Dial
28 Fusible Link
19 Work/Travel Selector Switch
29 Start S/W
24
(Drive Signal)
2 (Command Signal)
17
FG007793
Figure 59
Reference Reference
Description Description
Number Number
2 e-EPOS Controller 17 Engine Control Dial
3 Engine Controller 24 Acceleration Pedal
CCW ( 10 ) ( 10 ) CW
MECHANICAL MECHANICAL
STOP STOP
(V)
5
4.0V
4
3 2.5V
2
2 1.0V
1
0 SETUP
1ST 2nd 7th 12th 13th
CCW CW
STOP STOP
FG000866
Figure 60
Reference Reference
Description Description
Number Number
1 Knob 2 Potentiometer (Variable Resistor)
ACCELERATOR ASS'Y
A 0.5R 3
POSITION B 0.5B 2
SENSOR
C 0.5W 1
IDLE E 0.5G 4
VALIDATION
F 0.5L 5
D 0.850r 6
STROKE 17.5
FOOT PEDAL
DETAIL "A"
4 3
5 2
"A"
6 1
OV C B A F D E
C.W. +VE C.W. 77 2%
V span
IDLE ON IDLE OFF 64% 4%
Output
Voltage
PIN
DESCRIPTION COLOR (% Vref)
B LOCATION
C A THROTTLE POSITION + V SUPPLY RED
A 13 2%
B THROTTLE POSITION SIGNAL BLACK
E
C THROTTLE POSITION RETURN WHITE 0%
0 Datum
F
45.8%
-5.2 C.T
58.3%
48.3% W.O.T
Degrees
D COMMON
-2.7
ORANGE
-11.0
-15.2
D Travel
E OFF IDLE POSITION (NO) GREEN
Angle Tolerance 2%
PEDAL SENSOR F ON IDLE POSITION (NC) BLUE Driver Travel
Sensor Rotation
FG007794
Figure 61
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
29
1-51
CONN Py
CN2-15
(CONN.1) 1-03
1-09 17
Px +(5V) CN3-15 1
1-14 CN2-16 CW LOW
SIG CN3-16 2
1-15
GND CN3-17 3
HIGH
1-01 30
1-07
26 15A
1-12
1-13
BR B 10A
1-39
26
27
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)
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
E/G
4
3
1
1 2 3 4 5
6 7 8 9 0
5 5
FG016931
Figure 63
Reference Reference
Description Description
Number Number
Instrument Panel 3 Engine Controller
1
(Auto Idle Switch) 4 Engine Control Dial
2 e-EPOS Controller 5 Pressure Switch
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
6
2
7
3
8
4
9
5
FG013635
Figure 64
Reference Reference
Description Description
Number Number
1 Instrument Panel 6 Control Valve
2 e-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
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 65
Reference Reference
Description Description
Number Number
1 Instrument Panel 11 Solenoid Valve (Boost)
2 e-EPOS Controller 16 Main Relief Valve
3 Engine Controller Breaker/Boost/Shear Selector
18
4 Main Pump Switch
5 Aux Pump Power Boost Switch (Top of
20
Right Work Lever)
6 Control Valve
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
UP
TML 1 0 2
9
24
11 10
3
(C4) 14
CN1-11
13
11
6
CN2-2 (POWER MAX)
16
15
CN1-8 12
CN1-9
6 3
(Center)
(POWER MAX / BREAKER)
20
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)
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)
FG000586
Figure 66
Reference Reference
Description Description
Number Number
1 Instrument Panel Power Boost Switch (Top of
20
2 e-EPOS Controller Right Work Lever)
11 Solenoid Valve (Pressure Up) 24 Battery
Breaker/Boost/Shear Selector 25 Battery Relay
18
Switch 26 Fuse
Operation
40
6
3
35 36
4 5
15 32 37
38
I II
N
39
24 17
FG009233
Figure 67
Reference Reference
Description Description
Number Number
3 Engine Controller (ECU) 32 Pressure Switch (Py)
4 Main Pump 35 Cruise Solenoid Valve
5 Aux Pump 36 Forward Solenoid Valve
6 Control Valve 37 Pilot Relay
15 e-EPOS Controller 38 Cruise Switch
17 Engine Control Dial 39 Brake Pedal
24 Acceleration Pedal 40 Travel Motor
I II
dial. When engine speed control dial is adjusted to R
Switch
desired speed, the unit will travel at a constant speed. R
2. Cancel
When the brake is applied the cruise control will be
canceled.
Bring the forward/reverse lever back to neutral (N), will
also cancel the cruise control.
If the engine is running at an excessive rpm when the
cruise control is canceled, reduce the engine rpm
setting.
NOTE: If the auto idle is "ON" when the cruise control is HAOA690L
canceled, the engine will return to idle in Figure 69
approximately four seconds. When the cruise
control is turned back "ON" the engine will
return to the rpm setting control by the engine
speed control dial.
3. Cruise Operation
4 3 2
5
11
6 8
12 13
10 9
7
BCS0700L
Figure 70
Reference Reference
Description Description
Number Number
1 Battery 7 Cruise Relay (1)
2 Battery Relay 8 Forward/Reverse Lever Switch
3 Fuse 9 Brake Light Switch
4 Pilot Relay 10 Pressure Switch
5 Forward Run Relay 11 Forward Run Solenoid Valve
6 Cruise Relay (2) 12 Cruise Solenoid Valve
6 6
13
E/G 8
15
4 4 5
3
17 2 19
FG000799
Figure 71
Reference Reference
Description Description
Number Number
2 e-EPOS Controller 8 Pump Pressure Sensor
3 Engine Controller 13 Solenoid Valve (High speed)
4 Main Pump 15 Travel Motor
5 Aux Pump 17 Engine Control Dial
6 Control Valve Selector Switch For Automatic
19
7 Pressure Switch (Py Port) Travel
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
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)
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 72
Reference Reference
Description Description
Number Number
2 e-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
e-EPOS Controller
The system operation status and malfunction codes can be
checked through the display on top of the e-EPOS controller
box the rear cover behind the operator's seat.
1 2
4 3
FG000588
Figure 73
Reference Reference
Description Description
Number Number
1 Upper Digit Power Monitor (Stays "ON"
2 Lower Digit 4 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 e-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.
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.
Wiper Circuit
5 6 7
- 2 3 5 ON 16-10
+
M
8 J1 15-9 16-9
4 4
10 J2 15-10 16-12
5 6 ON
OFF
1 7 J1
J2
11 16-11
12 - + 8
P
6
1 CN15 CN16
9 13
9 2
AMP MIC 13P
CN12
7 8 9 10 11 12 13 9 8 7 6 5
Reference Reference
Description Description
Number Number
1 Battery 6 Wiper Controller
2 Battery Relay 7 Combination Switch
3 Fusible Link (Wiper & Washer)
4 Fuse Box 8 Window Washer
5 Wiper Motor 9 Wiper Cutoff Switch
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 via 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 the "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 via 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 the "7" terminal of the wiper
controller (6).
The Wiper motor (5) stops reverse revolution when the
contact of a cam switch connected to the "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)
changes voltage of the "10" 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
5
10
3 11
6
13
1
4 14
4 8 9
19 15 15 19
*
* 21 21
20 20
12
16 17 18 17 16
FG007795
Figure 75
Type
Lighting system consists of headlamp, work lights, cabin light
(optional), and S/W devices and relays to control them.
Operation
Connected
Activated Relay/
Switch Position Terminal of Lit Light
Operated Switch
Switch
Illumination Light of Switch/
Position Light of Head Light/
1st "2-3" Terminals - Position LIght of Rear
Light Switch (5) Combination Light
Position Light of Arm
"2-3" Terminals - "
2nd
"5-6" Terminals Head Light Relay (10) Low Beam of Head Light (2 Ea.)
"56-56b" Operated Light
Low Beam of Head Light (2 Ea.)
Terminals Switch (2nd)
"56-56a" Operated Light
High Beam of Head Light (2 Ea.)
Terminals Switch (2nd)
"30-56a"
- High Beam of Head Light (2 Ea.)
Combination Terminals
Switch (6) Front Turn Signal Light (L.H.)
"49a-L" Terminals - Side Turn Signal Light (L.H.)
Rear Combination Light (L.H.)
Front Turn Signal Light (R.H.)
"49a-R" Terminals - Side Turn Signal Light (R.H.)
Rear Combination Light (R.H.)
Transmission
Switch (Reverse ON (+) - R Terminals Reverse Relay Back up Light (2 Ea.)
Position) (8)
Stop Light Stop Light of Rear Combination
ON ON -
Switch (9) Light (2 Ea.)
4 1
5
ARS1260L
Figure 76
Reference Reference
Description Description
Number Number
1 Battery 4 e-EPOS Controller
2 Battery Relay 5 OWD Selector Switch
3 Fuse Box 6 Pressure Sensor
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 3 4
1 2 3 4 5 6 7 8
1
(Audio Control Panel) (STEREO)
FG000591
Figure 77
Reference Reference
Description Description
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
Connected Terminal of
Switch Measured values Operations
switch
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
4
12
9
9 3
9 8
13
9
11 7 5 3
9
10
9
9 6
14
FG007796
Figure 78
Reference Reference
Description Description
Number Number
1 Battery 8 Ram Lock Relay
2 Battery Relay 9 Diode
3 Fuse 10 Ram Lock Pressure Switch
4 Parking Brake Switch 11 Ram Lock Solenoid Valve
5 Pilot Relay 12 Console
6 Combination Switch (F/R) 13 Ram Lock Switch
7 Work/Travel Switch 14 e-EPOS Controller
Outline
A
C
C
B
FG016929
Figure 79
Modes
FG000422
Figure 80
Donaldson.
FG000440
Figure 81
FG000441
Figure 82
FG000342
Figure 83
10
11
2
5
6
5
7
4
1
8
9 FG003919
Figure 84
Reference Reference
Description Description
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
0.5RW
FUSIBLE LINK
LAMP SWITCH
A/C THERMO (LOW) 105B CN9-8 0.5LB CN10-5 105A CN11-4 0.85LW 47C
DIODE 4
1.25B CN11-1 99 - +
M
107B CN8-12 0.5LW CN10-1 107A 0.85B 0.85B
BLOWER
99 CN9-10 1.25B
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
Vent
Front
Outlet
Foot
DEF
Outlet
Outlet
External Air
VENT
COOL
DOOR
-INTAKE
DOOR
DEF -MIX
Internal Air
WARM
Evaporator Fan
Heater
FOOT Core
FG001359
Figure 86
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
- Internal/external
Evaporator Air Exchanger
Internal
Internal Air Sensor
Air Filter FG001360
Figure 87
N P2
c
b
e
P2 P1
b c e
FG001361
Figure 88
Output
Wind Direction Mode Voltage
Terminal
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
Output
Set Temp Voltage
Terminal
Max cooling c(+): CN10-9 Below 0.4V
Max heating b(-): CN10-4 Above 4.5V
N P2
P1
CN10-20 CN10-2
P2 P1
c e
FG001055
Figure 89
Output
Sel mode Output
Terminal
Internal Air Moving of exchange
P1(+), P2(-) door by selecting
external air
External Moving of exchange
Air P1(-), P2(+) door by selecting internal
air
DRAIN
(CN10-1)
SOURCE GATE
(CN11-1) (CN10-6)
FG001056
Figure 90
FG001057
Figure 91
Relay - A/C
Power is supplied to the magnetic clutch of the compressor.
Specifications
L S1 (+)
Rated voltage 24V
Rated current 10A
B S2
(-)
FG001058
Figure 92
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.
83.7
OUTPUT VOLTAGE(mV)
76.2
67.7
58.8
46.6
36.0
21.4
Control Panel
A/C OUTSIDE
AUTO A/C
AUTO MAX
TEMP
OFF
SEL MODE
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
Control Logic
Temp Control
FULL COOL FULL HOT
Actuator
FG001367
Figure 99
Code Description
E0 Normal
E1 Internal Air Temp Sensor Short
E2 Internal Air Temp Sensor Open
E3 Ambient Air Temp Sensor Short
E4 Ambient Air Temp Sensor Open
E5 Duct Sensor Short
E6 Duct Sensor Open
E7 Sun Sensor Short
E8 Sun Sensor Open
E9 Water Temp Sensor Short
E10 Water Temp Sensor Open
E11 D.P.S OPEN
Position Error of Wind Direction
E12
Actuator.
Position Error of Temp Control
E13
Actuator.
0.5 0.5
FG001067
Figure 100
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 102
Electrical
System
(ROPS)
Edition 1
Safety Precautions............................................... 6
Applicable Models................................................ 6
Introduction ........................................................... 7
Electrical Supply System .................................... 8
Engine Starting Circuit ...................................... 10
Start Operation ............................................................. 10
After Start ..................................................................... 12
Engine Preheating System ............................... 14
Engine Stop ....................................................... 16
Charging System ............................................... 18
Monitoring System ............................................. 19
Instrument Panel .......................................................... 20
Monitoring System Schematic ..................................... 22
Operation ............................................................ 24
Instruments.................................................................... 24
Warning and Indicator Lights ........................... 26
Indication of Warning Lights........................................ 26
Indication of Multifunction Gauge and Letter
Information Area ........................................................... 27
Initial Operation.................................................. 29
Mode Selector Switch ....................................... 30
Graphic Information Area Display .................... 31
Overview ....................................................................... 31
Main Menus for the Graphic Display Area ................ 32
Menu Selector Buttons ................................................ 32
Main Menu ......................................................... 33
Language ...................................................................... 33
Set Clock ...................................................................... 34
Filter/Oil Info ................................................................. 34
Adjust Display ............................................................... 35
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
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
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)
PREHEAT
ON
REG.
TRIO DIODE 7
FIELD
START F+
F-
E
GRD
FG004584
Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM
Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode
Start Operation
When the starter switch is turned to the "START" position,
the "S" and "E" terminals of the starter controller (7) are
connected. At this time 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) → "30" 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 e-EPOS (13) → ground. This
current flow causes the coil in starter relay (12) to be FG013717
activated, opening contacts at "87a" terminal. This Figure 2
prevents starter relay (8) from functioning.
85 86 ACC
C
B 5
R2 BR
12 R1
3
CN1-15
6
4
B A
CN2-1
BR
E
13 11
R(I) P(R) B(B+)
2
STARTER SWITCH CONNECTION 0.5 uF
B+
OFF - + - +
REG.
TRIO DIODE
10
PREHEAT
ON F+ FIELD
1
F-
START E
GRD
FG004587
Figure 3 STARTER CIRCUIT (1) - WHILE STARTING
Reference Reference
Description Description
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
3 Fusible Link 10 Alternator
4 Circuit Breaker 11 Diode
5 Starter Switch 12 Starter Relay 2
6 Fuse Box 13 e-EPOS Controller
7 Starter Controller
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
R(I) P(R) B(B+)
11
STARTER SWITCH CONNECTION 0.5 uF 2
B+
ON F+ FIELD
START
F-
E 1
GRD
FG004588
Figure 4 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START
Reference Reference
Description Description
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
3 Fusible Link 10 Alternator
4 Circuit Breaker 11 Diode
5 Starter Switch 12 Starter Relay 2
6 Fuse Box 13 e-EPOS Controller
7 Starter Controller
6
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
CN5-2
- + - +
11 C B 1
-
200A
1-56
7 STARTER SWITCH CONNECTION
1-33,34,35 8 TML
1-39 PST B BR R1 R2 C ACC
1-16 D OFF
H +
1-04 ON
START
12
FG007757
Figure 5 ENGINE PREHEAT CIRCUIT
Reference Reference
Description Description
Number Number
1 Battery 7 Preheat Relay
2 Battery Relay 8 Air Heater
3 Fusible Link 9 Preheat Indicator Light
4 Circuit Breaker 10 Diode
5 Starter Switch 11 e-EPOS Controller
6 Fuse Box 12 Engine Controller
In the event that the engine can be shut down using the
starter switch (5), an emergency stop switch (10) is provided O I
to shut down engine. To activate the emergency stop switch,
move it to the "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 the "O" (OFF) position.
FG016039
Figure 6 Engine Emergency Stop Switch
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
Description Description
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
ACC C
B
R2
5
BR
0.5G
R1
6
3
8
4 2
B A
BR
E
- + - +
I R B+ 12V 150AH 12V 150AH
0.5 uF
1
B+
STARTER SWITCH CONNECTION
I(L)
FG007765
Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode
1
5 7
2
CHECK
4
3 9
8
E F 17
10
C H C H
6 11
1 2 3 4 5
6 7 8 9 0 16
12
18
15 14
13
20 19
21
FG016928
Figure 9
Reference Reference
Description Description
Number Number
1 Instrument Panel 12 Air Cleaner Indicator
2 Battery 13 Engine Control Unit
3 Light Switch 14 Parking Brake Sensor
4 Return Filter Switch 15 Brake Oil Pressure Switch
5 Pilot Filter Switch 16 Pilot Relay
6 e-EPOS Controller 17 Parking Brake Switch
7 Alternator 18 Steering Console
8 Warning Buzzer 19 Right Side Combination Switch
9 Pump Discharge Pressure Sensor 20 Left Side Combination Switch
10 Oil Temperature Sensor 21 Ram Lock Switch
11 Fuel Sensor
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
12 11 10 9 8 7 16 15 14 13 12 11 10 9
22
13 (CN7) (CN6)
1 2 3 4 5
23
6 7 8 9 0
15
17 19 21 FG013521
Figure 10
1
21
2
19
18
4
16
20
17
5
6 10
11
12
31 13
14
7
22
8
15
23
24
25
26
27
28
29
30
FG007781
Figure 11
Instruments
Sensor Specification
Function Display Input
Input Specification
Terminal
Blue
Coolant ECU-CAN
Temperature 61 C 102 C Communication
41 C 107 C
C H
White Red
FG013527
Blue
Blue
40°C (104°F) → 1,397 ohms
50°C (122°F) → 1,139 ohms
N = 146 f / 60
ECU-CAN N = Engine speed (rpm)
Tachometer E/G SPEED 1750 RP Communication
f = Frequency of engine
speed sensor (Hz)
FG013531
FG000050
Main pump
CN3-1
discharge
pressure
FRONT PUMP 320 BA
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
FG000045
Preheating period
depends on coolant
This symbol during temperature.
preheating ("CN5-2"
terminal voltage is No preheating at
Preheating CN5-2 below 2V) and turns above 10°C
"OFF" after 10 sec preheating at
completion of 5°C
HAOA639L preheating.
20 sec preheating at
below 0°C
Input
Description Symbol Operation Remarks
Terminal
FG000056
FG000057
FG000053
FG000554
FG001470
FG001471
Symbol up when
Quick Clamp CN2-11 quick clamp was
release.
FG002195
FG004605
HB4O2003
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.
e-EPOS Output
Output Check
(Operation Electromagnetic
Operation Mode Proportional Pressure Swing Priority 7-Segment
mode
display) Reducing Valve (E.P.P.R Solenoid Valve Display
Valve) Current (mA)
No-load: 150 ± 20mA
Power Mode ON Load: Variable output - 9 x
(Max. current: 400 ± 20mA)
No-load: 300 ± 20mA
Power
Standard Mode OFF Load: Variable output - 7 x
Mode
(Max. current: 600 ± 60mA)
No-load: 350 ± 20mA
Economy Mode Load: Variable output - 5 x
(Max. current: 600 ± 60mA)
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
l
the operator.
3. Filter / Oil Info
Refer to the "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
L 1. Language
l
2. Set Clock
l
view appears.
The default language is Korean, but it will memorize and
3. Filter / Oil Info
use the newly set language. 4. Adjust Display
Use the Up Arrow Button ( , 1 on Figure 12) or Down
5. Set Password
Arrow Button ( , 2 on Figure 12) to move cursor to a : UP : DOWN : SELECT
language to be selected on the Language Select display and FG013563
press the Enter Button ( , 3 on Figure 12) and the Figure 14
selected language is indicated in the right bottom of the
screen.
: UP : DOWN : SET
FG013564
Figure 15
l
Menu after putting cursor on Set Clock brings Set Clock
display.
3. Filter / Oil Info
4. Adjust Display
Without pressing a button more than 20 seconds, the default
view appears. 5. Set Password
Please refer to the Operation Manual for detailed information : UP : DOWN : SELECT
on Time Setting. FG013565
Figure 16
SET CLOCK
02:30:30
2003 11/04
: UP : DOWN : SELECT
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
: UP : DOWN : SELECT
FG013567
Figure 18
Filter/Oil Information
R
1. Fuel Filter
Hrs : 0045Hrs 42m
: UP : DOWN : SELECT
FG013568
Figure 19
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, contrast, back light can be adjusted using
3. Filter / Oil Info
the Up Arrow Button ( , 1 on Figure 12) or the Down 4. Adjust Display
Arrow Button ( , 2 on Figure 12). 5. Set Password
: UP : DOWN : SELECT
FG013569
Figure 21
1. Adjust Display
: UP : DOWN : SELECT
FG013835
Figure 22
l
The default back light is set to 90%. Contrast lllllllllllllllllllllllll l 50%
l
Night Mode
BackLight 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
l
2. Set Clock
l
Please refer to the Operation Manual for detailed information
on Password Setting. 3. Filter / Oil Info
4. Adjust Display
5. Set Password
: UP : DOWN : SELECT
FG013571
Figure 24
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
E F
C H C H
FG013591
Figure 26
Submenu Selections
: UP : DOWN
Figure 30 FG016953
Menu Select
DIGITAL INPUT STATE
1. Relift Press UP S/V :
2. Pilot Relay :
3. Reverse Fan S/V :
4. Starter Relay :
5. After Heat Relay :
: UP : DOWN
FG017006
Figure 32
Failure Information
1. Entering Sub-menus: When a cursor is located in SPECIAL MENU
"Failure Info" of special menu screen press enter
button ( , 3 on Figure 25) and "Failure Info" screen
1. Machine Information
is displayed.
2. Failure Information
2. Exiting Sub-menus: If escape button (ESC, 4 on Figure
25) is pressed for more than 1 second, this information
screen will be returned to previous screen.
3. Operating Hours
: UP : DOWN : SELECT
FG013613
Figure 33
* Real-time Failure:
Current status of failure is displayed. SPECIAL MENU
* Failure Log:
Memorized record of past failure is displayed. 1. Machine Information
* Delete Fail Log: 2. Failure Information
This mode is used to delete all of the
memorized record of past failure.
3. Operating Hours
: UP : DOWN : SELECT
FG013613
Figure 34
: YES ESC : NO
FG013618
Figure 38
: YES ESC : NO
FG013619
Figure 39
: YES ESC : NO
FG013620
Figure 40
CN1-1 It has to be
V217 Starter Relay V = V_volt - measured in engine
CN1-15 start up state.
1-16
V218 After Heat Relay - - N.A.
1-04
Front Pump Press. CN3-1
V220 Sensor
V = 1V - It has to be
CN3-2
measured in engine
Rear Pump Press. CN3-3 stop state.
V221 Sensor
V = 1V -
CN3-4
R = 2.45 ± 0.25
kΩ (25°C
Hyd. Oil CN3-9
V222 - (77°F))
Temperature Sensor CN3-10
R = 320 ± 32 Ω
(80°C (176°F))
Water Temperature
V223 Sensor
- - N.A.
Engine Speed
V224 Sensor
- - N.A.
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
Operating Hours
Reset Hours
: UP : DOWN : SELECT
FG013622
Figure 42
1. Power Mode 2. Economy Mode 3. Auto Idle 4. Travel Speed 1st, 2nd
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
: UP : DOWN : SELECT
FG013625
Figure 46
: YES ESC : NO
FG013627
Figure 48
DELETED !!!
: YES ESC : NO
FG013628
Figure 49
X PASSWORD ERR!!!
: YES ESC : NO
FG013629
Figure 50
16
6 6
7 7
11 12 14
8
8
13
15
E/G
4 4 5
3
9 10 Work Mode
Auto Idle
Machine Info
E/G Speed
Order C H
E F
C H
1 2 3 4 5
6 7 8 9 0
24 23
1
17 21 19 18 22 20
FG016930
Figure 51
6 6
E/G
4 4
3
10
24
1 2 3 4 5
6 7 8 9 0
19 23 22
17
FG016926
Figure 52
Reference Reference
Description Description
Number Number
1 Instrument Panel 10 Electric Proportional Reducing
2 e-EPOS Controller V/V (Mode Control)
3 Engine Controller (ECU) 17 Engine Control Dial
4 Main Pump 19 Work/Travel Select Switch
5 Aux Pump 22 Aux Mode S/W
6 Control Valve 23 Aux Mode Resistance
24 Acceleration Pedal
1. Power Mode
This mode should be selected for high speed work. In
this mode the engine output is most efficiently utilized
due to the discharged oil volume being controlled
based on the equivalent horsepower curve at various
loaded pressures. The e-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 FG013632
senses this decrease and immediately reduces the Figure 53
pump discharge 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 e-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. At this time 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
Description Description
Number Number
A Engine Horsepower (hp) C Pump Discharge Volume (lpm)
B Engine Speed (rpm) D Pump Discharge Pressure (kg/cm2)
A C
B D
FG000581
Figure 55
Reference Reference
Description Description
Number Number
A Engine Horsepower (hp) C Pump Discharge Volume (lpm)
B Engine Speed (rpm) D Pump Discharge Pressure (kg/cm2)
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.
The e-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.
FG013671
Figure 56
B D FG013633
Figure 57
Reference Reference
Description Description
Number Number
A Engine Horsepower (hp) C Pump Discharge Volume (lpm)
B Engine Speed (rpm) D Pump Discharge Pressure (kg/cm2)
1
27
27 27 27 2 27 26
19 28
23 25
29
3 22
10
24
17
FG007791
Figure 58
Reference Reference
Description Description
Number Number
1 Instrument Panel 22 Aux Mode Switch
2 e-EPOS Controller 23 Aux Mode Resistance
3 Engine Controller 24 Acceleration Pedal
E.P.P.R. Valve 25 Battery
10 (Electromagnetic Proportional 26 Battery Relay
Pressure Reducing) Valve
27 Fuse
17 Engine Control Dial
28 Fusible Link
19 Work/Travel Selector Switch
29 Start Switch
24
(Drive Signal)
2 (Command Signal)
17
FG007793
Figure 59
Reference Reference
Description Description
Number Number
2 e-EPOS Controller 17 Engine Control Dial
3 Engine Controller 24 Acceleration Pedal
CCW ( 10 ) ( 10 ) CW
MECHANICAL MECHANICAL
STOP STOP
(V)
5
4.0V
4
3 2.5V
2
2 1.0V
1
0 SETUP
1ST 2nd 7th 12th 13th
CCW CW
STOP STOP
FG000866
Figure 60
Reference Reference
Description Description
Number Number
1 Knob 2 Potentiometer (Variable Resistor)
ACCELERATOR ASS'Y
A 0.5R 3
POSITION B 0.5B 2
SENSOR
C 0.5W 1
IDLE E 0.5G 4
VALIDATION
F 0.5L 5
D 0.850r 6
STROKE 17.5
FOOT PEDAL
DETAIL "A"
4 3
5 2
"A"
6 1
OV C B A F D E
C.W. +VE C.W. 77 2%
V span
IDLE ON IDLE OFF 64% 4%
Output
Voltage
PIN
DESCRIPTION COLOR (% Vref)
B LOCATION
C A THROTTLE POSITION + V SUPPLY RED
A 13 2%
B THROTTLE POSITION SIGNAL BLACK
E
C THROTTLE POSITION RETURN WHITE 0%
0 Datum
F
45.8%
-5.2 C.T
58.3%
48.3% W.O.T
Degrees
D COMMON
-2.7
ORANGE
-11.0
-15.2
D Travel
E OFF IDLE POSITION (NO) GREEN
Angle Tolerance 2%
PEDAL SENSOR F ON IDLE POSITION (NC) BLUE Driver Travel
Sensor Rotation
FG007794
Figure 61
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
29
1-51
CONN Py
CN2-15
(CONN.1) 1-03
1-09 17
Px +(5V) CN3-15 1
1-14 CN2-16 CW LOW
SIG CN3-16 2
1-15
GND CN3-17 3
HIGH
1-01 30
1-07
26 15A
1-12
1-13
BR B 10A
1-39
26
27
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)
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
Reference Reference
Description Description
Number Number
1 Instrumental Panel 26 Battery Relay
3 Engine Controller 27 Fuse
4 e-EPOS Controller 28 Start S/W
17 Engine Control Dial 29 Fusible Link
24 Acceleration Pedal 30 Pressure S/W (Py)
25 Battery 31 Pressure S/W (Px)
E/G
4
3
1
1 2 3 4 5
6 7 8 9 0
5 5
FG013634
Figure 63
Reference Reference
Description Description
Number Number
1 Instrument Panel (Auto Idle Switch) 4 Engine Control Dial
2 e-EPOS Controller 5 Pressure Switch
3 Engine Controller
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
6
2
7
3
8
4
9
5
FG013635
Figure 64
Reference Reference
Description Description
Number Number
1 Instrument Panel 6 Control Valve
2 e-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
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
FG016932
Figure 65
Reference Reference
Description Description
Number Number
1 Instrument Panel 11 Solenoid Valve (Boost)
2 e-EPOS Controller 16 Main Relief Valve
3 Engine Controller Breaker/Boost/Shear Selector
18
4 Main Pump Switch
5 Aux Pump Power Boost Switch (Top of
20
Right Work Lever)
6 Control Valve
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
UP
TML 1 0 2
9
24
11 10
3
(C4) 14
CN1-11
13
11
6
CN2-2 (POWER MAX)
16
15
CN1-8 12
CN1-9
6 3
(Center)
(POWER MAX / BREAKER)
20
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)
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)
FG000586
Figure 66
Reference Reference
Description Description
Number Number
1 Instrument Panel Power Boost Switch (Top of
20
2 e-EPOS Controller Right Work Lever)
11 Solenoid Valve (Pressure Up) 24 Battery
Breaker/Boost/Shear Selector 25 Battery Relay
18
Switch 26 Fuse
Operation
40
6
3
35 36
4 5
15 32 37
38
I II
N
39
24 17
FG009233
Figure 67
Reference Reference
Description Description
Number Number
3 Engine Controller (ECU) 32 Pressure Switch (Py)
4 Main Pump 35 Cruise Solenoid Valve
5 Aux Pump 36 Forward Solenoid Valve
6 Control Valve 37 Pilot Relay
15 e-EPOS Controller 38 Cruise Switch
17 Engine Control Dial 39 Brake Pedal
24 Acceleration Pedal 40 Travel Motor
I II
dial. When engine speed control dial is adjusted to R
Switch
desired speed, the unit will travel at a constant speed. R
2. Cancel
When the brake is applied the cruise control will be
canceled.
Bring the forward/reverse lever back to neutral (N), will
also cancel the cruise control.
If the engine is running at an excessive rpm when the
cruise control is canceled, reduce the engine rpm
setting.
NOTE: If the auto idle is "ON" when the cruise control is HAOA690L
canceled, the engine will return to idle in Figure 69
approximately four seconds. When the cruise
control is turned back "ON" the engine will
return to the rpm setting control by the engine
speed control dial.
3. Cruise Operation
4 3 2
5
11
6 8
12 13
10 9
7
BCS0700L
Figure 70
Reference Reference
Description Description
Number Number
1 Battery 7 Cruise Relay (1)
2 Battery Relay 8 Forward/Reverse Lever Switch
3 Fuse 9 Brake Light Switch
4 Pilot Relay 10 Pressure Switch
5 Forward Run Relay 11 Forward Run Solenoid Valve
6 Cruise Relay (2) 12 Cruise Solenoid Valve
6 6
13
E/G 8
15
4 4 5
3
17 2 19
FG016914
Figure 71
Reference Reference
Description Description
Number Number
2 e-EPOS Controller 8 Pump Pressure Sensor
3 Engine Controller 13 Solenoid Valve (High speed)
4 Main Pump 15 Travel Motor
5 Aux Pump 17 Engine Control Dial
6 Control Valve Selector Switch For Automatic
19
7 Pressure Switch (Py Port) Travel
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
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)
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 72
Reference Reference
Description Description
Number Number
2 e-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
e-EPOS Controller
The system operation status and malfunction codes can be
checked through the display on top of the e-EPOS controller
box the rear cover behind the operator's seat.
1 2
4 3
FG000588
Figure 73
Reference Reference
Description Description
Number Number
1 Upper Digit Power Monitor (Stays "ON"
2 Lower Digit 4 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 e-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.
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.
Wiper Circuit
5 6 7
- 2 3 5 ON 16-10
+
M
8 J1 15-9 16-9
4 4
10 J2 15-10 16-12
5 6 ON
OFF
1 7 J1
J2
11 16-11
12 - + 8
P
6
1 CN15 CN16
9 13
9 2
AMP MIC 13P
CN12
7 8 9 10 11 12 13 9 8 7 6 5
Figure 74
Reference Reference
Description Description
Number Number
1 Battery 6 Wiper Controller
2 Battery Relay Combination Switch
7
3 Fusible Link (Wiper & Washer)
4 Fuse Box 8 Window Washer
5 Wiper Motor 9 Wiper Cutoff Switch
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 via 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 the "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 via 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 the "7" terminal of the wiper
controller (6).
The Wiper motor (5) stops reverse revolution when the
contact of a cam switch connected to the "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)
changes voltage of the "10" 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
5
10
3 11
6
13
1
4 14
4 8 9
19 15 15 19
*
* 21 21
20 20
12
16 17 18 17 16
FG007795
Figure 75
Type
Lighting system consists of headlamp, work lights, cabin light
(optional), and S/W devices and relays to control them.
Operation
Connected
Activated Relay/
Switch Position Terminal of Lit Light
Operated Switch
Switch
Illumination Light of Switch/
Position Light of Head Light/
1st "2-3" Terminals - Position LIght of Rear
Combination Light
Light Switch (5) Position Light of Arm
"2-3" Terminals - "
2nd Head Light Relay
"5-6" Terminals Low Beam of Head Light (2 Ea.)
(10)
"56-56b" Operated Light
Low Beam of Head Light (2 Ea.)
Terminals Switch (2nd)
"56-56a" Operated Light
High Beam of Head Light (2 Ea.)
Terminals Switch (2nd)
"30-56a"
- High Beam of Head Light (2 Ea.)
Combination Terminals
Switch (6) Front Turn Signal Light (L.H.)
"49a-L" Terminals - Side Turn Signal Light (L.H.)
Rear Combination Light (L.H.)
Front Turn Signal Light (R.H.)
"49a-R" Terminals - Side Turn Signal Light (R.H.)
Rear Combination Light (R.H.)
Transmission
Switch (Reverse ON (+) - R Terminals Reverse Relay Back up Light (2 Ea.)
Position) (8)
Stop Light Stop Light of Rear Combination
ON ON -
Switch (9) Light (2 Ea.)
4 1
5
ARS1260L
Figure 76
Reference Reference
Description Description
Number Number
1 Battery 4 e-EPOS Controller
2 Battery Relay 5 OWD Selector Switch
3 Fuse Box 6 Pressure Sensor
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 3 4
1 2 3 4 5 6 7 8
1
(Audio Control Panel) (STEREO)
FG000591
Figure 77
Reference Reference
Description Description
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
Connected Terminal of
Switch Measured values Operations
switch
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
4
12
9
9 3
9 8
13
9
11 7 5 3
9
10
9
9 6
14
FG007796
Figure 78
Reference Reference
Description Description
Number Number
1 Battery 8 Ram Lock Relay
2 Battery Relay 9 Diode
3 Fuse 10 Ram Lock Pressure Switch
4 Parking Brake Switch 11 Ram Lock Solenoid Valve
5 Pilot Relay 12 Console
6 Combination Switch (F/R) 13 Ram Lock Switch
7 Work/Travel Switch 14 e-EPOS Controller
Outline
FG016933
Figure 79
Modes
FG016045
Figure 80
FG016043
Figure 81
FG016044
Figure 82
10
11
2
5
6
5
7
4
1
6
8
9 FG016941
Figure 83
Reference Reference
Description Description
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
0.5RW
FUSIBLE LINK
LAMP SWITCH
A/C THERMO (LOW) 105B CN9-8 0.5LB CN10-5 105A CN11-4 0.85LW 47C
DIODE 4
1.25B CN11-1 99 - +
M
107B CN8-12 0.5LW CN10-1 107A 0.85B 0.85B
BLOWER
99 CN9-10 1.25B
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
External Air
VENT
COOL
DOOR
-INTAKE
DOOR
DEF -MIX
Internal Air
WARM
Evaporator Fan
Heater
FOOT Core
FG016942
Figure 85
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 86
N P2
c
b
e
P2 P1
b c e
FG001361
Figure 87
Output
Wind Direction Mode Voltage
Terminal
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
Output
Set Temp Voltage
Terminal
Max cooling c(+): CN10-9 Below 0.4V
Max heating b(-): CN10-4 Above 4.5V
N P2
P1
CN10-20 CN10-2
P2 P1
c e
FG001055
Figure 88
Output
Sel mode Output
Terminal
Moving of exchange door
Internal Air P1(+), P2(-)
by selecting external air
Moving of exchange door
External Air P1(-), P2(+)
by selecting internal air
DRAIN
(CN10-1)
SOURCE GATE
(CN11-1) (CN10-6)
FG001056
Figure 89
FG001057
Figure 90
Relay - A/C
Power is supplied to the magnetic clutch of the compressor.
Specifications
L S1 (+)
Rated voltage 24V
Rated current 10A
B S2
(-)
FG001058
Figure 91
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.
83.7
OUTPUT VOLTAGE(mV)
76.2
67.7
58.8
46.6
36.0
21.4
Control Panel
A/C OUTSIDE
AUTO A/C
AUTO MAX
TEMP
OFF
SEL MODE
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
Control Logic
Temp Control
FULL COOL FULL HOT
Actuator
FG001367
Figure 98
Code Description
E0 Normal
E1 Internal Air Temp Sensor Short
E2 Internal Air Temp Sensor Open
E3 Ambient Air Temp Sensor Short
E4 Ambient Air Temp Sensor Open
E5 Duct Sensor Short
E6 Duct Sensor Open
E7 Sun Sensor Short
E8 Sun Sensor Open
E9 Water Temp Sensor Short
E10 Water Temp Sensor Open
E11 D.P.S OPEN
Position Error of Wind Direction
E12
Actuator.
Position Error of Temp Control
E13
Actuator.
0.5 0.5
FG001067
Figure 99
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 101
1Electrical
Schematic
DX140W/160W/
170W/190W/
210W
Edition 1
Electrical Schematic
Safety Precautions............................................... 5
Applicable Models................................................ 5
DX140W/160W/170W/190W/210W....................... 7
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
FG016940
Figure 1
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
Front Attachment Pin Specifications .................. 6
Front Attachment - Removal and Installation.... 8
Arm Removal Procedure ............................................... 8
Boom Removal Procedure........................................... 10
Installation .......................................................... 11
Arm Installation Procedure .......................................... 11
Boom Installation Procedure........................................ 11
Start-up Procedures........................................... 11
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
One-Piece Boom
A C E D F
B K H J G
FG009222
Figure 1
A D C E G F H
B M J L I
FG009246
Figure 2
DANGER
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.
Never rotate the upper structure once the counterweight
or front attachment has been removed.
IMPORTANT
FG007095
Always break down the front attachment by removing Figure 3
outermost sections first - the bucket before the arm, the
arm before the boom. Reinstallation of the attachment
should begin with the boom and end with the bucket.
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.
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 1,130 kg
[2,491 lb], not including the weight of accessories or
fixtures).
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.
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.
START-UP PROCEDURES
Once the boom has been serviced, it should be lubricated
as outlined in the initial start-up procedures of the operation
manual. Refer to the appropriate operation and maintenance
manual for unit.
1Bucket
Edition 1
Bucket SP001001
Page 1
MEMO
Bucket SP001001
Page 2
Table of Contents
Bucket
Safety Precautions............................................... 5
Applicable Models................................................ 5
Bucket Tooth Inspection and Replacement....... 6
Bucket O-ring Replacement ................................ 7
Bucket Attachment, Removal and Reversal ...... 9
Detaching the Bucket..................................................... 9
Attaching the Bucket ...................................................... 9
Reversing the Bucket................................................... 10
Bucket SP001001
Page 3
MEMO
Bucket SP001001
Page 4
SAFETY PRECAUTIONS
CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Bucket SP001001
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
Bucket SP001001
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.
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 1 4
2
move the arm or bucket link (4) out of the way.
HAOC710L
Figure 4
HAOC701L
Figure 5
Bucket SP001001
Page 7
5. Roll the new O-ring (1, Figure 6) into the O-ring
groove. 1
HAOC720L
Figure 6
Bucket SP001001
Page 8
BUCKET ATTACHMENT,
REMOVAL AND REVERSAL
CAUTION
Use care pulling out the pin to avoid damaging the dust
seals on either end of the arm.
Bucket SP001001
Page 9
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 and cause a severe injury. Match holes by
visually lining them up. Use the sharp-tipped, soft point FG004543
of a pencil or a similar tool to check for high spots or Figure 8
irregularities.
WARNING
Bucket curl and dump levers must be used in opposite
directions, after the bucket has been reversed.
Bucket SP001001
Page 10