Dx140af Lca Shopmanual Compressed 1

Maintenance Manual
ＤＸ１４０ＡＦ／ＤＸ１４０ＬＣＡ
Service Technology Division of DICC PS Department

2017.11.22
Contents
1）Track Excavator Maintenance Safety........1-3

1 Safety
1）Specifications.............................................2-1
2 Specifications
1）General Maintenance Instructions..............3-1

3 General Maintenance
1）Cabin..........................................................4-3
4 Upper Structure
2）Counterweight..........................................4-26
3 ) Swing Bearing...........................................4-34
1）Track Assembly..........................................5-3
5 Lower Structure and Chassis
1）Boom and Arm...........................................6-3

6 Front
2 ) Bucket.......................................................6-13
3) Cylinders...................................................6-21
1）Hydraulic System Troubleshooting, Testing
7 Hydraulic System
and Adjustment .........................................7-1
2 ) Main Pump................................................7-34
3 ) Gear Pump...............................................7-82
4 ) Drive Coupling (Main Pump).....................7-92
5 ) Main Control Valve..................................7-103
6 ) Swing Device..........................................7-178
7 ) Swing Reduction Gear............................7-218
8 ) Travel Device..........................................7-256
9 ) Center Joint.............................................7-334
10 ) Accumulator..........................................7-353
11 ) Remote Control Valve (Work Lever /
Joystick)...............................................7-359
12 ) Travel Control Valve (With Damper)......7-378
1）Electrical System.......................................8-1
8 Electrical System
1）Engine........................................................9-1
9 Engine
1）DX140AF/ DX140LC AHydraulic Drawing.....4

10 Drawing
2）DX140AF/ DX140LC Electrical Drawing........5
Safety
DX140AF/DX140LCA
DX140AF/DX140LCA
Track Excavator
Maintenance
Safety
DX140AF/DX140LCA Track Excavator Maintenance Safety 1-3

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Table of Contents
Track Excavator Maintenance Safety
SAFETY INSTRUCTIONS........................................... 6
SAFETY MESSAGES................................................. 6
GENERAL................................................................... 7
TRANSPORTATION................................................. 20
OPERATION............................................................. 22
MAINTENANCE........................................................ 39
ENVIRONMENT AND CIRCUMSTANCES............... 55

SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual and signs (decals)
on machine. Follow warnings and instructions in
the manuals when making repairs, adjustments or
servicing. Check for correct function after adjustments
repairs or service. Untrained operators and failure to
follow instructions can cause death or serious injury.
SAFETY MESSAGES
Replace with Safety Messages Section on pages
III and IV in the Doosan Operation & Maintenance
Manual.

GENERAL
Safe Operation is Operator’s Responsibility
Only trained and authorized personnel should operate
and maintain the machine.
Follow all safety rules, regulations and instructions
when operating or performing maintenance on
machine.
● Do not operate machine if you are under the
influence of drugs or alcohol. An operator who is

taking prescription drugs must get medical advice to
determine if he or she can safely operate a machine.
● When working with other personnel on a work site,
be sure that all personnel know nature of work and

understand all hand signals that are to be used.
● Be sure that all guards and shields are installed
in their proper location. Have guards and shields

repaired or replaced immediately if damaged.
● B e s u r e t h a t y o u u n d e r s t a n d t h e u s e a n d
maintenance of all safety features such as safety

lever and seat belt. Use them properly.
● Never remove, modify or disable any safety features.
Always keep them in good operating condition.

● A l w a y s c h e c k f o r a n d k n o w t h e l o c a t i o n o f
underground and overhead utility lines before

excavating.
● Failure to use and maintain safety features according
to instructions in this manual, Safety Manual and

Shop Manual can result in death or serious injury.
Know Your Machine

Know how to operate your machine. Know the purpose
of all controls, gauges, signals, indicators and monitor
displays. Know the rated load capacity, speed range,
braking and steering characteristics, turning radius and
operating clearances. Keep in mind that rain, snow,
ice, loose gravel, soft ground, slopes etc., can change
operating capabilities of your machine.

Proper Work Tools and Attachments
Only use work tools and attachments that are
recommended by DOOSAN for use on DOOSAN
machines. When installing and using optional
attachments, read instruction manual for attachment,
and general information related to attachments in this
manual. Because DOOSAN cannot anticipate, identify
or test all attachments that owners may want to install
on their machines, contact DOOSAN for written
authorization and approval of attachments, and their
compatibility with optional kits.
Attachments and attachment control systems that are
compatible with the machine are required for safe and
reliable machine operation. Do not exceed maximum
operating weight (machine weight plus attachment)
that is listed on ROPS certification plate.
Make sure that all guards and shields are in place
on machine and on work tool. Depending on type or
combination of work equipment, there is a potential
that work equipment could interfere with the cabin
or other parts of machine. Before using unfamiliar
work equipment, check if there is any potential of
interference, and operate with caution.
While you are performing any maintenance, testing, or
adjustments to attachments, stay clear of the following
areas:
cutting edges, pinch points, and crushing surfaces.
Never use attachment as a work platform or manlift.
Contact your DOOSAN distributor about auxiliary
hydraulic kits for attachments installation. If you are
in doubt about compatibility of a particular attachment
with a machine, consult your DOOSAN distributor.
Pressurized Fluids
Pressurized air or fluids can cause debris and/or fluids
to be blown out. This could result in death or serious
injury.
Immediately after operations are stopped, coolant,
engine oil, and hydraulic oil are at their highest
temperatures and the radiator and hydraulic tank
are still under pressure. Always wait for temperature
to cool down. Follow specified procedures when
attempting to remove caps, drain oil or coolant,
or replacing filters. Always wait for temperature to
cool down, and follow specified procedures when
performing these operations. Failure to do so can
result in death or serious injury. FG018457
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective Figure 1
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
Pressure can be trapped in a hydraulic system and
must be relieved before maintenance is started.
Releasing trapped pressure can cause sudden
machine movement or attachment movement. Use
caution if you disconnect hydraulic lines or fittings.

High-pressure oil that is released can cause a hose
to whip or oil to spray. Fluid penetration can result in
death or serious injury. If fluid enters skin or eyes, get
immediate medical attention from a physician familiar
with this injury.
Obey all local laws and regulations for disposal of
liquids.
To prevent hot coolant from spraying out, stop engine
and wait for coolant to cool. Using gloves, slowly
loosen cap to relieve pressure. HAOA110L
Figure 2
Flying or Falling Objects
On work sites where there is a potential hazard that
flying or falling objects can hit operator’s cabin, select
and use a guard to match operating conditions for
additional operator protection.
Working in mines, tunnels, deep pits, and loose or
wet surfaces, could produce hazard of falling rocks
or flying objects. Additional protection for operator’s
cabin could be required such as an Operator
Protection Guard (OPG) or window guards. Contact
your DOOSAN distributor for information on available
protective guards.
HAOA100L
To prevent personnel from being struck by flying
objects, keep personnel out of work area. Figure 3

Personal Protective Equipment (PPE)
Do not wear loose clothing and accessories. Secure
long hair.
These items can snag on controls or on other parts of
equipment.
Do not wear oily clothes. They are highly flammable.
Do not forget that some risks to your health may not
be immediately apparent. Exhaust gases and noise
pollution may not be visible, but these hazards can
cause disabling or permanent injuries. Breathing
masks and/or ear protection may be required.
Wear a hard hat, safety shoes, safety goggles, HAOA020L
mask, leather gloves, earplugs and other protective
equipment, as required. Figure 4
While working on machine, never use inadequate
tools. They could break or slip, or they may not
adequately perform intended functions.
Correction of Machine Problems

If any machine problems are found during operation
and maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil leakage, etc.), or if any abnormal
warning alerts are displayed on display monitor,
stop the machine and take the necessary corrective
actions. Do not operate machine until problem has
been corrected.
Crushing and Cutting

Keep objects away from moving fan blades. Fan
blades can throw and cut objects.
Do not use a wire rope that is kinked or frayed, or
a wire rope with any loss of diameter. Wear leather
gloves when handling a wire rope.
When striking a loose retainer pin, it can fly out and
can cause a serious injury. Make sure that area is
clear of personnel when striking a retainer pin. To
avoid injury to your eyes, wear safety goggles when
striking a retainer pin.
Do not put your hand, arm or any other part of your
body between movable parts. If going between
movable parts is necessary, always position and
secure work equipment so it cannot move. Properly
support equipment before performing any work or
maintenance under raised equipment.
If control levers are operated, clearance between
machine and work equipment will change and this
may lead to serious damage or can result in death
or serious injury. Stay clear of areas that may have a
sudden change in clearance with machine movement
or equipment movement. Stay clear of all rotating
and moving parts. Unless instructed, never attempt
adjustments while machine is moving or while engine
is running.

Do not depend on hydraulic cylinders to support raised
equipment. Equipment can fall if a control is moved, or
if a hydraulic line breaks, is loosened or disconnected.
If it is necessary to remove guards to perform
maintenance, always install guards after maintenance
is completed.
HDO1010L
Figure 5
Hot Coolant and Oils - Burn Prevention

Do not touch any part of an operating engine.
Immediately after operations are stopped, coolant,
engine oil, and hydraulic oil are at their highest
temperatures. The radiator and hydraulic tank are still
under pressure. Always wait for temperature to cool
down. Attempting to remove caps, drain oil or coolant,
or replacing filters may lead to serious burns, if done
when hot.
Relieve all pressure in air system, hydraulic oil FG019095
system, lubrication system, fuel system, and cooling
Figure 6
system, before any lines, fittings or related items are
disconnected.
To prevent hot oil or coolant from spraying out, stop

engine, wait for oil and coolant to cool. Using gloves,
slowly loosen cap to relieve pressure.
FG019096
Figure 7

Fire and Explosion Prevention
All fuels, most lubricants and some coolant mixtures
are flammable and can cause a fire resulting in death
or serious injury, and property damage. Flammable
fluids that are leaking or spilled onto hot surfaces or
onto electrical components can cause fire.
Inspect for and remove all flammable materials such
as spilled fuel and oil, and debris from machine. Do
not allow any flammable materials to accumulate on
machine. HDO1015I
● Add fuel, oil, antifreeze and hydraulic fluid to
machine only in a well ventilated area. Machine Figure 8

must be parked with controls, lights and switches
turned “OFF”. Engine must be “OFF” and any
flames, glowing embers, auxiliary heating units or
spark causing equipment must be extinguished, or
turned “OFF” and kept well clear of machine.
● Dust that is generated from repairing or grinding
nonmetallic hoods or nonmetallic fenders can

be toxic, flammable and explosive. Repair these
components in a well ventilated area away from
flames or sparks and wear dust mask when grinding
painted parts.
FG018458
Maintenance Figure 9
The machine and some attachments have components
that are at high temperatures under normal operating
conditions. The primary source of high temperatures
are the engine and exhaust system. If damaged or
incorrectly maintained, the electrical system can be a
source of arcs or sparks.
Flammable debris (leaves, straw, etc.) must be
removed regularly. If flammable debris is allowed to
accumulate, it can
cause a fire hazard. Clean machine often to avoid this
accumulation. Flammable debris in an engine
compartment is a potential fire hazard.
The operator’s area, engine compartment and engine
cooling system must be inspected every day and
cleaned. This is necessary to prevent fire hazards and
overheating.
Operation
Do not use machine where exhaust, arcs, sparks
or hot components can contact flammable material,
explosive dust or gases.
Do not operate machine near any flame.
Exhaust shields (if equipped) protect hot exhaust
components from oil spray or fuel spray in case of a
break in a line, hose, or seal. Exhaust shields must be
correctly installed.

Electrical
Check all electrical wiring and connections for damage
daily.
Keep battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed. Clean all electrical connections and tighten all
electrical connections.
Never check battery charge by placing a metal object
across terminal posts. Use a voltmeter or a hydrometer.
Battery gas can explode and can result in death or
serious injury. Follow procedures in this manual for
connecting battery and for jump-starting. Do not jump-
start or charge a frozen or damaged battery. Keep any
flames or sparks away from batteries. Do not smoke
in battery charging area.
Improper jumper cable connections can cause an
explosion that can result in death or serious injury.
Refer to Operation & Maintenance Manual, for proper
procedure in this manual.
Do not charge a frozen battery. This can cause an
explosion.
After market radios or other electric operated
equipment in cabin must have a fuse in the electrical
circuit.
Hydraulic System
Check hydraulic tubes, hoses and fittings for damage,
wear or for leaks. Hydraulic lines and hoses must
be properly routed and have adequate support and
secure clamps. Leaks can cause fires. Never use a
flame or bare skin to check for leaks.
Tighten or replace any parts that show leakage.
Check that all hose and tube clamps, guards, and
cushions are securely attached. If they are loose, they
can vibrate during operation and rub against other
parts. This can cause damage to hoses and cause
high-pressure oil to spray on hot surfaces, causing a
fire and death or serious injury.
Always clean fluid spills. Do not use gasoline or diesel
fuel for cleaning parts. Use commercial nonflammable
solvents.
EX1400129
Figure 10

Fueling
Use caution when you are refueling a machine.
Fuel is flammable and can catch fire if it is brought
close to a flame.
Stop engine and let it cool before adding fuel. Do
not smoke while you are refueling a machine. Do not
refuel a machine near flames or sparks. Fill fuel tank
outdoors.
Keep fuel and other fluid reservoir caps tight and do
not start engine until caps have been secured.
Store fuels and lubricants in properly marked
containers away from unauthorized personnel. Store
oily rags and any flammable materials in protective
containers.
Static electricity can produce dangerous sparks at
fuel filling nozzle. In very cold, dry weather or other EX1400130
conditions that could produce a static discharge, keep
Figure 11
tip of fuel nozzle in constant contact with neck of fuel
filling nozzle, to provide a ground.
Always place plastic fuel containers on the ground
before filling.
Never Use Ether Starting Aids

Do not use ether or starting fluids on any engine
that has glow plugs, or an electric grid type manifold
heater. These starting aids can cause an explosion
and result in death or serious injury.
Use procedures in this manual for connecting battery
and for jump-starting.
FG018458
Welding and Grinding
Always clean machine and attachment, set battery Figure 12
disconnect switch to “OFF” position, and disconnect
wiring from electronic controllers before welding.
Cover rubber hoses, battery and all other flammable
parts. Keep a fire extinguisher near machine when
welding.
Toxic dust or gas can be produced when grinding or
welding painted parts. Grinding or welding painted
parts must be done in a well ventilated area. Wear
dust mask when grinding painted parts.
Dust generated from repairing nonmetallic parts such
as hoods, fenders or covers can be flammable or
explosive.
Repair such components in a well ventilated area
away from flames or sparks.
Do not weld on lines or on tanks that contain
flammable fluids.
Do not flame cut lines or tanks that contain flammable
fluid.
Clean any such lines or tanks thoroughly with a
nonflammable solvent before welding or flame cutting.

If a Fire Occurs
If a fire occurs:
● Do not attempt to move machine or continue
operations.
● Turn starter switch to “O” (OFF) position to stop
engine.
● Use handrails, guardrails and steps to get off
machine.
● Immediately call for help or fire station.
FG018459
● W h e n u s i n g a f i r e e x t i n g u i s h e r , a l w a y s a i m
extinguisher at base of fire. Figure 13

● If an optional fire extinguishing system is in place,
be familiar with its operating procedures.

NOTE: Depending on job conditions, other procedures
could be necessary if a fire occurs.
Fire Extinguisher and First-aid Kit

(Emergency Medical Kit)
To be prepared in the event of a fire:
● Be sure that fire extinguishers have been provided
and read labels to ensure that you know how to

use them. It is recommended that an appropriately
sized (2.27 kg [5 lb] or larger) multipurpose A/B/C
fire extinguisher be mounted in cabin. Check and
service fire extinguisher at regular intervals and
make sure that all work site crew members are HDO1009L
adequately trained in its use. Figure 14

● Inspect fire extinguisher and service fire extinguisher
regularly.
● Follow instructions on extinguisher instruction plate.
● Keep a first aid kit in storage compartment (Figure
15) and keep another kit at work site. Check kit

periodically and keep it properly supplied.
● Keep emergency numbers for doctor, ambulance
service, hospital and fire department readily

available.
EX1403736
Figure 15

Electrical System and Electrical Shock
Never short across starter terminals or across
batteries.
Shorting could damage electrical system and engine
neutral start system.
When engine is running or immediately after it has
stopped, high voltage is generated at injector terminal
and inside engine controller, so there is a potential for
an electrical shock. Never touch injector terminal or
inside of engine controller.
NOTE: If it is necessary to touch injector terminal or
inside engine controller, contact your DOOSAN
distributor.
Roll-over Protective Structure (ROPS)

The operator’s cabin is a ROPS certified structure
for protecting the seat-belted operator. It absorbs
the impact energy of a rollover impact. Do not allow
machine weight (mass) to exceed certified value on
certification plate. If weight is exceeded, the ROPS
structure will not be able to fulfill its safety function.
Do not increase machine weight beyond certified value
by modifying machine or by installing attachments
on machine. If weight limit of protective equipment
is exceeded, protective equipment will not be able
to protect operator, and this can result in death or
serious injury. Always observe the following:
● This machine is equipped with a protective structure.
Do not remove protective structure and perform

operations without it.
● Never modify the operator’s cabin by welding,
grinding, drilling holes or adding attachments unless

instructed by DOOSAN in writing. Changes to the
cabin can cause loss of operator protection from
roll-over and falling objects, and result in death or
serious injury.
● When protective structure is damaged or deformed
by falling objects or by rolling over, its strength will

be reduced and it will not be able to adequately
protect the operator.
Contact your DOOSAN distributor if you have any
questions about the ROPS. Never repair a damaged
ROPS cabin.
● Always wear your seat belt when operating machine.

ROPS Certification
This DOOSAN excavator has an operator’s cabin that
meets ROPS requirements. The seat belt must be
worn for roll-over protection.
The ROPS certification plate (Figure 16) 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. EX1300529
Never modify the ROPS cabin. Replace the cabin and Figure 16
hardware if damaged. See your DOOSAN distributor
for parts.
ROPS − Roll-over Protective Structure complies with
ISO 12117-2:2008, EN13531:2001.
WARNING
Never modify the operator cabin by welding, grinding,
drilling holes or adding attachments unless instructed
in writing by DOOSAN. Changes to the cabin can
cause loss of operator protection from roll-over and
falling objects, and can result in death or serious
injury.

Protecting Cabin from Flying or Falling Objects (Optional)
In a work site where additional operator protection
is necessary from falling or flying objects, install
adequate protective guards on the cabin.
For breaker operation, install a front guard (1,
Figure 17) and apply a laminated coating sheet to
2
front glass. Contact your DOOSAN distributor for
recommendations.
When performing demolition or cutting operation,
install a front guard and top guard.
Apply a protective laminated coating sheet to outside
of front window. This will prevent glass from being
scratched by dust when cleaning it or running wipers.
When working in mines, quarries or other work

sites where there is a hazard of falling rocks, install FG018595
Operator Protection Guard (OPG) (2, Figure 18) and
Figure 17
apply a laminated coating sheet to front glass.
When OPG is installed, and front window needs to be
cleaned, loosen bolts marked with arrows (Figure 18).
Be sure to tighten bolts when done.
Never attempt to alter or modify any protective
structure reinforcement system, by drilling holes,
welding, remounting or relocating fasteners. Any 1
serious impact or damage to system requires a
complete inspection of the structure. Reinstallation,
recertification and/or replacement of system may be
necessary.
Contact your DOOSAN distributor for available safety
guards and/or recommendations to protect against
objects that could strike operator’s cabin. Make sure
that all other work site crew members are kept away
from excavator when operating.
If any glass on machine is broken, replace it with new
glass immediately.
NOTE: The preceding instructions assume that conditions
are for standard operations, but it may be FG020947
necessary to add additional guards depending on

Figure 18
operating conditions or local rules or regulations
for the work site. Always contact your DOOSAN
distributor for advice.

Emergency Exit from Operator’s Station
This machine is equipped with a glass breaking tool.
It is found on left pillar of cabin. This tool can be used
to break the glass to exit from cabin in an emergency.
Grip handle firmly and use sharp point to break glass.
● Be careful also not to slip on broken pieces of glass
on ground.
EX1300679
WARNING
Figure 19
Protect your eyes when breaking the glass.

TRANSPORTATION
Obey State and Local Over-the-Road Regulations
Check federal, state and local laws and regulations
regarding weight, width and length of a load before
making preparations for transporting on public roads
or highways.
The hauling vehicle, trailer and load must be in
compliance with applicable regulations for the shipping
route.
Partial disassembly of excavator may be necessary
to meet travel restrictions or particular conditions at
work site. See Shop Manual for information on partial
disassembly.
Refer to Operation & Maintenance Manual, for
information on loading, unloading and towing.
The machine can be disassembled into parts for
transporting.
Contact your DOOSAN distributor for assistance with
disassembly.
Loading and Unloading

To prevent machine tipping or roll-over when loading
or unloading machine, always do the following:
● Perform loading and unloading only on firm and
level ground. Maintain a safe distance from edge of

road or drop-off.
● Never use work equipment to load or unload
machine. The machine may fall or tip over.

● Always use loading ramps of adequate strength and
capacity. Be sure that ramps are wide, and long

enough to provide a safe loading slope. Take steps
to prevent ramps from moving out of position or
coming off.
● Clean ramp surfaces so they are free of grease, oil,
ice and loose materials. Remove dirt from machine

tracks and undercarriage. On a rainy day, be careful
since ramp surfaces can be slippery.
● Turn auto idle switch “OFF”.
● Run engine at low speed and travel slowly.
● When on ramps, do not operate any control lever
except for travel lever.

● Never correct your steering on ramps. If necessary,
drive off ramps, correct machine direction, then drive

back onto ramps.
● When driving up or down ramps, the center of
gravity of machine will change suddenly causing

the tracks to drop down to the ramps or trailer. This
will occur at the joint between the ramps and trailer.
Travel slowly over this point.

● For machines equipped with a cabin, always lock
door after loading machine to prevent door from
suddenly opening during transportation.
Transporting Machine
When transporting machine on a trailer or truck, do
the following:
● The weight, transportation height, and overall
length of machine may change depending on work

equipment attached to it. Always check the machine
dimensions and work equipment’s dimensions
before transporting.
● When passing over bridges or structures on private
land, check that structure is strong enough to

support weight of machine. Before traveling on
public roads, check with appropriate authorities and
follow their instructions.

OPERATION
Always make sure that the machine is properly
maintained.
Before Engine Starting

Machine Condition
Every day before starting engine for first time, perform
the following checks and repair machine before
operating, as necessary. If these checks are not
properly done death or serious injury could result.
● Check coolant, fuel, and hydraulic tank oil levels,
and check for clogged air cleaner and damage to

electrical wiring.
● Check operation of gauges, cameras (if equipped)
and angle of mirrors, and check that safety lever is

in LOCKED position.
● Check that work equipment and travel controls move
freely, and work controls return to “NEUTRAL” when
released.
● Check that attachment is properly attached and
locked.
IMPORTANT
Only use Ultra Low Sulfur Diesel (ULSD) fuel and API
CJ-4/ ACEA E9 grade engine oil with this machine.
Make sure that the machine is equipped with a lighting

system that is adequate for job conditions and lights
are working properly.
Before moving machine, check position of
undercarriage. The normal travel position is with
idler wheels to front under cabin and drive sprockets
to rear. When undercarriage is rotated in reversed
position, directional or travel controls must be
operated in opposite directions.
Before performing checks, move machine to an area
where there are no obstructions, and operate slowly.
Do not allow personnel near machine.
Know maximum operating dimensions of your
machine.

Work Site
Before starting operations, thoroughly check work
area for any hazards, such as underground utility
lines, overhead electrical lines, unstable ground,
excessive slopes, etc.
Before starting engine and moving machine, make
sure that no one is underneath machine, around
machine, or on machine.
Know width and length of your machine and work
DANGER
No Entry
EX1300680
equipment to maintain proper clearance when you
operate machine or work equipment near fences or Figure 20
near boundary obstacles.
Know appropriate work site hand signals and
personnel that are authorized to give hand signals.
Follow hand signals from only one person.
If you need to operate on a street, protect pedestrians
and cars by designating a person for work site traffic
duty or by erecting fences and posting “No Entry”
signs around work site.
Erect barricades or fences, post “No Entry” signs, and
take other steps to prevent people from coming close
to or entering work site. If people come too close to
a moving machine, they may be struck or caught by
machine, and this can result in death or serious injury.

Mounting/Dismounting
Before getting on or off machine, if there is any oil,
grease, or mud on handrails, guardrails, steps, or
track shoes, wipe it off immediately. Always keep
these parts clean. Repair any damage and tighten any
loose bolts.
Never jump on or off machine. In particular, never get
on or off a moving machine. These actions can result
in death or serious injury.
When getting on or off machine, always face machine.
EX1301111
Maintain three-point contact (both feet and one hand
or one foot and both hands) with handrails, guardrails, Figure 21
steps, and track shoes to ensure that you support
yourself securely.
Never hold onto any control levers when getting on or
off machine.
Securely latch door. If you grip handrail inside door
when moving on top of track shoes, and door latch is
not securely engaged, door may move and cause you
to fall.
Use points marked by arrows in diagram when getting
on or off machine. EX1301112
Do not carry tools or supplies when you mount or
Figure 22
dismount the machine.
EX1301113
Figure 23

Cleaning
Remove all straw, wood chips, leaves, grass, paper
and other flammable debris accumulated in engine
compartment, mufflers and around battery. Remove
any dirt from window glass, mirrors, handrails, and
steps.
Do not leave tools or spare parts in operator’s cabin.
Vibration of machine during operation can cause tools
or spare parts to fall and damage or break control
levers or switches. Tools and spare parts can also get
caught in spaces between control levers and cause
accidental movement of work equipment causing
death or serious injury.
When entering operator’s cabin, always remove all
mud and oil from your shoes. If you operate travel
pedal with mud or oil stuck to your shoes, your foot
could slip off the control, or dirt and debris may
interfere with proper operation of control levers.
After using ashtray, make sure that any matches or
cigarettes are properly extinguished, and be sure to
close ashtray.
Clean window glass and working lights for good
visibility.
Do not stick suction pads to window glass. Suction
pads act as a lens and can cause fire.
Never bring flammable or explosive items into
operator’s cabin.
Do not leave cigarette lighters laying around operator’s
cabin. If temperature inside operator’s cabin becomes
too high, there is a potential hazard that lighter could
explode.
Secure all loose items such as lunch boxes, and other
items that are not a part of equipment.
Operator Station
Inspect condition of seat belt and mounting hardware.
Replace any parts that are worn or damaged. Do not
use a seat belt extension on a retractable seat belt.
Adjust seat so full pedal travel can be achieved with
operator’s back against back of seat.
Keep all windows and doors closed on machine.
Adjust operator’s seat to a position where it is easy
to perform operations, and check that there is no
damage or excessive wear to seat belt or mounting
clamps.
Adjust and clean mirrors so area to rear of machine
can be seen clearly from operator’s seat.
When standing up from operator’s seat, always
place safety lever securely in “LOCK” position. If you
accidentally move work equipment levers when they
are not locked, the machine could suddenly move and
cause damage, death or serious injury.

Seat Belt
Check seat belt daily for correct function.
Inspect seat belt system more often if machine is
exposed to severe environmental conditions or
applications. Conduct the following inspections and
replace seat belt system as necessary:
1. Check webbing. If system is equipped with a
retractor, pull webbing completely out and inspect
full length of webbing.
Look for cuts, wear, fraying, dirt and stiffness.
2. Check buckle and latch for correct operation.
3. Make sure latch plate is not excessively worn,
deformed or buckle is not damaged or casing is
broken.
4. Check retractor web storage device (if equipped) by
extending webbing and checking that it spools out
and retracts correctly.
5. Check webbing in areas exposed to ultraviolet (UV)
rays from sun or extreme dust or dirt. If original
color of webbing in these areas is extremely
faded and/or webbing is packed with dirt, webbing
strength may be reduced.
NOTE: Contact your DOOSAN distributor for seat belt
system replacement parts.
WARNING
Failure to properly inspect and maintain seat belt and
seat belt system can cause lack of operator restraint
and can result in death or serious injury.
Before fastening seat belt, check that there is no
problem in belt mounting bracket. If it is worn or
damaged, replace seat belt. Fasten seat belt so it is
not twisted.
Always wear seat belt when operating machine.

Visibility Information
A rear view camera (if equipped) and mirrors provide
the operator with additional means to see the work
area.
NOTE: These devices may vary from one region to
another, depending upon local and regional
regulations. If a machine is moved or sold into
another region or marketplace, it is the owner’s
responsibility to make sure it complies with all
applicable regulations.
WARNING
Failure to check for and clear people from the
surrounding area of a machine can result in death or
serious injury. The operator should make sure that
visual aids (mirrors and camera(s)) are in proper
working condition.
Your machine may be equipped with visual aids such

as mirrors or a rear view camera. Even with these
aids, there still may be areas around the machine
which cannot be seen from the operator’s seat. Always
keep personnel and bystanders out of the work area.
Be careful when operating and always look in direction
of travel.
Adjust visual aids for best visibility around machine.
When swinging work equipment or backing up, press
camera button (if equipped) to change display mode
on display monitor so you can check rear and side of
machine.
Before moving machine, look around work site and
use mirrors and display monitor to confirm that no one
is in the work area.
While operating or traveling in places with poor
visibility it may be impossible to confirm condition of
work site. Inspect and remove any obstacles around
the machine that could be damaged and keep other
personnel out of the work area.
Inspect equipment and repair immediately if there are
problems with visual aids. If machine cannot be fixed
immediately, DO NOT use the machine. Contact your
DOOSAN distributor and arrange for repairs.

Work Site Rules
● If visibility cannot be sufficiently assured, use a
flagman.
The operator should pay careful attention to signals
and follow instructions from flagman.
● Signals should only be given by one flagman.
● When working in dark places, turn “ON” work lights
and front lights on the machine. Set up additional

lighting in area.
● Stop operations if there is poor visibility, such as fog,
snow, rain, or sandstorms.

● Check mirrors and rear view camera (if equipped)
on machine before starting operations. Clean off any

dirt and adjust view for good visibility.
When operating or traveling during poor visibility
conditions, follow the preceding work site rules.
It may not be possible to adjust all visual aids to see
all the way around the machine. Therefore, additional
precautions such as flagman, barricades, etc., must
be taken to keep other personnel out of the work area.
Boost Starting or Charging Engine Batteries

Follow these instructions to prevent an explosion or
fire when connecting booster cables to batteries:
● Turn “OFF” all electric equipment before connecting
leads to battery. This includes electric switches on

battery charger or battery booster equipment.
● When boost starting from another machine or
vehicle do not allow two machines to touch. Wear

safety goggles and gloves while battery connections
are made.
● 24 volt battery units consisting of two series
connected 12 volt batteries have a cable connecting

one positive (+) terminal on one of the 12 volt
batteries to a negative (-) terminal on the other
battery. Booster or charger cable connections
must be made between the nonseries connected
positive (+) terminals and between the negative (-)
terminal of the booster battery and metal frame of
the machine being boosted or charged. The final
booster cable connection, at metal frame of the
machine being charged or boost started, must be
as far away from the batteries as possible. Refer
to Operation & Maintenance Manual, for proper
procedure in this manual.
● Connect positive (+) cable first when installing
cables and disconnect negative (-) cable first when

removing them.

Starting Engine
Only operate the machine from the operator’s seat
with your seat belt fastened.
Only operate controls while engine is running.
Check for proper operation of all controls and all
protective devices while you operate the machine
slowly in an open area.
● Read and understand control pattern before
operating.
Check that movement of the machine matches
display on control pattern label. If it does not match,
replace it immediately with correct control pattern
label.
● Check operation of work equipment, travel system
and swing system.

● Check for any problem with machine. Check for
unusual sounds, vibration, heat, odor, or improper

readings from gauges. Check for any oil or fuel Figure 24
leaks.
● If any problem is found, stop operation and perform
repairs immediately.
Do not use cellular telephones inside operator’s cabin
when driving or operating the machine.
When operating the machine, do not extend your
hands or head out of window.
The boom and arm linkage can allow work tool or
attachment to contact undercarriage or cabin. Be
aware of position of work tool.
● Do not attempt to start engine by short-circuiting
engine starting circuit. This can result in death or

serious injury, or fire. EX1301192
● When starting engine, sound horn as a warning to
alert personnel in the work area. Figure 25

If there is a warning tag or “DO NOT OPERATE” tag
hanging from work levers (joysticks) or travel control
levers, do not start engine or move levers.
● Prevent personnel from walking or standing under
raised boom, unless it is properly supported.

NOTE: When starting engine in cold temperatures,
“white engine exhaust smoke” from the tail pipe
can occur until engine reaches normal operating
temperatures.
Also, a white residue, because of water vapor
inside engine, can form at the engine oil fill
location. These conditions will not affect engine
performance or damage the engine or other
exhaust system components.

Swinging or Traveling
As a machine operator, you should know and follow
local, state and federal laws and regulations when
operating on public roads or highways.
It is important to keep in mind that the machine, in
comparison with the rest of traffic, is a slow moving
and wide vehicle which can cause traffic delays. Pay
attention to traffic behind you and allow traffic to pass
you.
Before operating the machine or work equipment,
always observe the following precautions to prevent
● When changing travel direction from forward to
reverse or from reverse to forward, reduce speed

and stop machine before changing travel direction.
● Sound horn to alert people in area.
● Check that there is no one in area around machine.
There are restricted visibility areas behind machine

':
so, if necessary, swing upper structure slowly to
check that there is no one behind machine before Figure 26
traveling in reverse.
● When operating in areas with poor visibility,
designate a flagman to direct work site traffic.

● Keep unauthorized personnel away from turning
radius or travel path of the machine.

Be sure to observe above precautions even if a travel
alarm or mirrors are installed.
● Check that travel alarm works properly and that
mirrors are clean, not damaged and properly

adjusted.
● Always latch door and windows of operator’s cabin
in position (open or closed).

● On work sites where there is a hazard of flying or
falling objects, or of objects entering operator’s

cabin, check that door and windows are securely
closed. Install additional guards, if work site
application requires them.

Never turn starter switch to “O” (OFF) position when
Travel Position
traveling.
This can lead to a loss of steering control.
Do not operate attachments while traveling.
Do not change selected travel mode (FAST/SLOW)
while traveling.
Never travel over obstacles or excessive slopes that
40 - 50 cm (16 - 20 in.)
will cause machine to tilt severely. Avoid any slope or
obstacle that can cause machine to tilt 10° or more to
right or left, or 30° or more from front to rear.
Do not operate steering controls suddenly. Work
equipment can hit ground and this can damage
machine or structures in area.
When traveling on rough ground, travel at low speed,
and avoid sudden changes in direction.
EX1300681
Always operate within permissible water depth.
Permissible water depth is up to centerline of upper Figure 27
track roller(s).
When passing over bridges or structures on private
land, check that structure is strong enough to support
weight of machine.
Before traveling on public roads, check with
appropriate authorities and follow their instructions.
Never exceed maximum permitted load for bridges.
Always operate machine with idler wheels to front
under cabin and drive sprockets to rear.
Know permitted ground pressure. Ground pressure of
the machine may change depending on attachment
and load.
Keep height and length of attachment in mind.

Lifting and Digging
The operator is responsible for any load carried when
traveling
on public roads and while working with the machine.
● Keep loads secure so they do not fall off while
operating.
● Do not exceed maximum load for the machine.
Machine operation will be affected when center of

gravity changes, caused by extended loads and
different attachments.
To lift loads safely when in digging mode, the following
must be evaluated by the operator and work site crew.
● Condition of ground support.
● Excavator configuration and attachments.
● Weight, lifting height and swing radius.
● Safe rigging of load.

● Proper handling of suspended load.
Always watch load. Bring load close to the machine
before traveling any distances or swinging load.
Lifting capacity decreases as load is moved further
from the machine.
Set tracks at right angles to road shoulder or drop-off
with sprocket at rear when performing operations to
make it easier to move away from the work area.
Do not suddenly lower, swing, or stop work equipment.
● Do not move bucket over head of other personnel
or over the operator’s seat of dump trucks or other

hauling equipment. The load may spill or bucket can
hit dump truck causing property damage or cause

Operation on Slopes
If the machine has to be used on a slope, pile soil
to make a platform that will keep the machine as
horizontal as possible.
Improper traveling on steep slopes could result in 20 -
machine tipping, roll-over or sliding down the slope. 30 c
m (8
- 12
Always fasten your seat belt. in)
When possible, operate machine up slopes and down
slopes.
Avoid operating machine across slope.
On hills, banks or slopes, carry bucket approximately
20 ~ 30 cm (8 - 12 in) above ground. In case of an
emergency, quickly lower bucket or work tool to
ground to help stop machine. in)
12
Do not travel on grass, fallen leaves, or wet steel 8-
cm(
plates. Even slight slopes can cause machine to slide - 30
20
down a slope. Travel at low speed and make sure that
the machine is always traveling directly up or down
slope.
Do not change travel direction on a slope. This could
result in tipping or sliding sideways of machine.
Improper operation when working on slopes can cause
a tip over. Use caution when swinging or operating
work equipment on slopes.
Do not swing work equipment from uphill side to
downhill side when bucket is loaded. This could cause
machine to tip or roll-over. EX1300691
In addition, lower bucket as far as possible, keep it
Figure 28
pulled into front, and keep swing speed as slow as
possible.
If the machine begins to slide down on a grade,

immediately dump load and turn the machine downhill.
Be careful to avoid any ground condition which could
cause the machine to tip. Tipping can occur when you
work on hills, on banks, or on slopes. Tipping can also
occur when you cross ditches, ridges, or travel over
unexpected obstructions.
Keep the machine under control. Do not overload the
machine beyond capacity.
● When traveling up a steep slope, extend work
EX1300682
equipment to front to improve balance, keep work Figure 29

equipment approximately 20 ~ 30 cm (8 ~ 12 in)
above ground, and travel at low speed.
● Do not turn on slopes or travel across slopes.
Always go down to a flat place to change position of

the machine, then travel backup the slope again.

Towing Cloth
To prevent death or serious injury when towing,
always do the following:
● Follow the instruction given in this manual.
● When performing preparation work for towing with
two or more personnel, determine signals to use and

correctly follow these signals. Towing Wire
● Always attach wire rope onto left and right hooks
and secure in position.

● If engine on problem machine will not start or there
is a failure in brake system, always contact your

DOOSAN distributor.
● Never go between towing machine and towed
machine during towing operation.

● Do not perform towing on steep slopes, so select
a place where slope is gradual. If there is no place Towing Wire

where slope is gradual, perform operations to reduce
angle of slope before starting towing operation.
● When towing a machine, always use a wire rope
with a sufficient towing capacity.

● Do not use a wire rope that is kinked or frayed, or
a wire rope with any loss of diameter. Wear leather

gloves when handling a wire rope.
● Do not use lightweight towing hook for towing
another machine. Towing Wire

EX1400132
● Make sure that towing eyes and towing devices are
Figure 30
adequate for towing loads.
● Only connect wire rope to a drawbar or to a hitch.
● Operate the machine slowly and be careful not to
apply any sudden load to wire rope.

Attachment
Never let anyone ride on any work attachment,
such as bucket, crusher, grapple, or clamshell (grab
bucket). This creates a falling and crushing hazard,
The clamshell, grapple, or magnet can swing in all
directions.
Move work levers (joysticks) in a continuous motion.
Failure to move work levers (joysticks) in a continuous
':
motion can cause clamshell, grapple, or magnet to
swing into cabin or into a person in work area. This Figure 31
can result in death or serious injury.
● When using a fork or grapple, do not attempt to pick
up an object with its tips. This could damage the

machine or cause personal injury, if picked-up object
slips off attachment.
● Do not use impact force of work equipment
for demolition work. This could damage work
equipment, cause broken materials to fly off or
tipping. This could result in death or serious injury.
● Do not use work equipment or swing mechanism to
pull load in any direction. This could cause the work

equipment to move suddenly if the load releases
Equipment Lowering with Engine Stopped

Before lowering any equipment with the engine
stopped, clear the area around the equipment of all
personnel and bystanders.
The procedure to use will vary with the type of
equipment to be lowered. Keep in mind most systems
use a high-pressure fluid or air to raise or lower
equipment. The procedure can cause high-pressure
air, or hydraulic pressure, or some other media to be
released to lower the equipment.

Engine Stop
Turn engine starter switch to “O” (OFF) position and
remove engine starter switch key.
Before lowering any equipment with engine stopped,
clear area around equipment of all personnel and
bystanders. This procedure will cause high-pressure
air or hydraulic pressure to be released to lower
equipment.
Do not stop engine immediately after the machine has
been operated under load. This can cause overheating
and
accelerated wear of engine components.
After the machine is parked, allow engine to run for
five minutes before stopping the engine. This allows
hot areas of engine to cool gradually.
● Do not leave operator’s seat when there is a raised
load.
Parking Machine
Avoid making sudden stops, or parking machine
wherever it happens to be at end of workday. Park
machine on firm and level ground away from traffic
and away from high walls, drop-offs and any area of 120
potential water accumulation or runoff.
If parking on inclines is unavoidable, block crawler
tracks to prevent movement. Lower bucket or other
working attachment completely to ground, or to an Block
overnight support saddle. To prevent unintended or
accidental movement.
When parking on public roads, provide fences, signs,
flags, or lights, and put up any other necessary signs
to ensure that passing traffic can see machine clearly.
Park machine so machine, flags, signs and fences do
not obstruct traffic.
After front attachment has been lowered to an Unlock
overnight storage position and all switches and
operating controls are in “OFF” position, safety lever
must be moved to “LOCK” position. This will disable
all pilot control functions. Lock EX1401035
Always close door of operator’s cabin and lock all
equipment to prevent any unauthorized person from Figure 32
operating the machine.
The hydraulic system remains pressurized, provided

accumulator, is charged even when engine is not
running. Accumulator pressure should decrease in a
short time (approximately one minute). While hydraulic
system maintains a charge, hydraulic work tools and
machine controls remain functional.
Machine movement will occur if any controls are
moved. This can result in death or serious injury.
Always move safety lever to “LOCK” position before
stopping off engine or immediately after engine stops
EX1300684
running.
Figure 33

Preservation/Storing Machine
Perform the following if storing excavator for more
than one month.
Conditions Maintenance Required

Pressure wash undercarriage and track assemblies. Inspect for damage or loose
Cleaning
or missing parts.
Perform all daily lubrication procedures.
Apply a coating of light oil to exposed plated metal surfaces, such as hydraulic
Lubrication cylinder rods, etc.
Apply a coating of light oil to all control linkages and control cylinders (control valve
spools, etc.)
Battery Turn “OFF” the battery disconnect switch.
Inspect coolant recovery tank to make sure that antifreeze level in system is at
correct level.
Cooling System Every 90 days, use a hydrometer to measure protection level of coolant. Refer
to Operation & Maintenance Manual, to determine amount of protection cooling
system requires. Add coolant as required.
Once a month, start engine and follow procedures in Operation & Maintenance
Hydraulic System
Manual, listed in this manual.
1. Complete the preceding steps.

2. Wash machine and touch up paint finish to avoid
rusting.
3. Treat exposed parts with antirust agent, lubricate
machine thoroughly and apply grease to unpainted
surfaces like lifting and tilting cylinders etc.
4. Fill fuel tank and hydraulic oil tank to “FULL” marks.
5. Cover exhaust pipe (parking outside).
6. Make sure that coolant is at proper concentration
for expected lowest temperatures.
7. P ark machine on level, firm ground where there
is no risk of freezing, landslide or flooding. Avoid
parking machine on a slope.
Keep in mind that theft and burglary risk can be
minimized by:
● Removing starter key when the machine is left
unattended.
● Locking doors and covers after working hours.
● T u r n i n g o f f e l e c t r i c a l c u r r e n t w i t h b a t t e r y
disconnect switch.
● Park machine where risk of theft, burglary and
damage is minimized.
● Removing valuables from cabin such as cellular
phone, computer, radio and bags.

See Operation & Maintenance Manual, for more
information.

Check After Long-term Parking
● All oil and fluid levels.
● Tension of all belts.
● Air pressure.
● Air cleaner.
● Batteries and electrical connections.
● Lubricate all greasing points.
● Wipe off grease from piston rods.
● Inspect for signs of nests (i.e. birds, rodents, etc.)
● Inspect safety labels (decals). Replace if damaged,
worn, or missing.

MAINTENANCE
Improper operation and maintenance can result in
death or serious injury. Read manual and safety
decals before operating or maintaining the machine.
Follow all instructions and safety messages.
WARNING
Follow instructions before operating or servicing
machine.
Read and understand the Operation & Maintenance
Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
● Never service DOOSAN equipment without

instructions.
● Always lower bucket and blade to ground before
doing any maintenance.

● Use correct procedure to lift and support excavator.
● Cleaning and maintenance are required daily.
● Welding or grinding painted parts must be done in
well ventilated areas.

● Wear a dust mask when grinding painted parts.
Toxic dust and gas can be produced.

● Vent exhaust to outside when engine must be
running for service.

● Exhaust system must be tightly sealed. Exhaust
fumes are hazardous and can cause death or

serious injury.
● Stop and allow engine to cool and clean engine of
flammable materials before checking fluids.

● Never service or adjust machine with engine running
unless instructed to do so in this manual.

● Avoid contact with leaking hydraulic fluid or diesel
fuel under pressure. It can penetrate skin or eyes.

● Never fill fuel tank while engine running, while
smoking, or when near open flame.

● Keep body, jewelry and clothing away from moving
parts, electrical contact, hot parts and exhaust.

● Wear eye protection to guard from battery acid,
compressed springs, fluids under pressure and

flying debris when engines are running or tools are
used Use eye protection approved for welding.

● Lead-acid batteries produce flammable and
explosive gases.
● Keep arcs, sparks, flames and lighted tobacco away
from batteries.
● Batteries contain acid which burns eyes or skin on
contact.
● Wear protective clothing. If acid contacts body,
flush well with water. For eye contact flush well and
get immediate medical attention from a physician
familiar with this injury.
● The maintenance procedures which are given in this
manual can be performed by the owner or operator

without any specific technical training. Maintenance
procedures which are not in this manual must
be performed ONLY BY QUALIFIED SERVICE
PERSONNEL. Always use genuine DOOSAN
replacement parts.
● Only authorized personnel should service and repair
the machine. Do not allow unauthorized personnel

into work area.
● Lower work equipment and stop engine before
performing maintenance.
● Park machine on firm and level ground.
● Turn starter switch to “ON’ position and keep safety
lever in “UNLOCK” position. Cycle work levers

(joysticks) back and forth, left and right at full stroke
2 to 3 times to eliminate remaining internal pressure
in hydraulic circuit.
Then move safety lever to “LOCK” position.
● Check that battery relay is “OFF” and main power
is shut off. (Wait for approximately one minute after

turning “OFF” engine starter switch key and press
horn switch. If horn does not sound, the main power
is shut off.)
● Put blocks under track to prevent the machine from
moving.
● To prevent injury, do not perform maintenance with
engine running. If maintenance must be done with

engine running, perform maintenance with at least
two workers and do the following:
– One worker must always sit in the operator’s
seat and be ready to stop engine at any time. All
workers must maintain contact with other workers.
– When maintenance operations are near fan, fan
belt, or other rotating parts, there is a potential
hazard of being caught in rotating parts. Keep
hands and tools away.
● Never drop or insert tools or other objects into
rotating fan or fan belt. Parts can break off and hit
someone.
● Do not touch any control levers or control pedals.
If any control levers or control pedals must be

operated, always give a signal to other workers and
instruct them to move away.

● When performing maintenance of engine and you
are exposed to engine noise for long periods of time,
wear hearing protection while working.
● If noise from the machine is too loud, it can cause
temporary or permanent hearing problems.

● Do not smoke when you service an air conditioner
or if refrigerant gas is present.

● Inhaling fumes either from a flame or gas from
a cigarette that has contacted air conditioner

refrigerant can cause death or serious injury.
● Never put maintenance fluids into glass containers.
Drain all liquids into a suitable containers.

● Unless instructed otherwise, perform maintenance
with equipment in servicing position. Refer to this

manual for procedure for placing equipment in
servicing position.
Warning Tag
Alert others that service or maintenance is being
performed by attaching a “DO NOT OPERATE”
warning tag to the operator’s cabin controls – and
other machine areas, if required. Use of a chain or
cable to keep the safety lever in the fully lowered
“LOCK” position, complies with OSHA’s lockout
requirements.
“DO NOT OPERATE” warning tags, are available from
your DOOSAN distributor.
● Always attach “DO NOT OPERATE” warning tag
to work equipment control lever in the operator’s

cabin to alert others that you are performing service
or maintenance on the machine. Attach additional
warning tags on the machine, if necessary.
● Keep warning tags in tool box while it is not used. If
there is not tool box or in the owner manual storage

pocket.
● If any other person starts engine, and operates
control levers or control pedals while you are EX1301177

performing service or maintenance, it can result in
death or serious injury. Figure 34
Attach a “DO NOT OPERATE” warning tag to starter
switch or to controls before servicing or repairing
equipment.
Warning tags are available from your DOOSAN
distributor.

Cleaning
Clean machine before performing inspection and
maintenance.
If inspection and maintenance are done when machine
is dirty, it will become more difficult to locate problems,
and you could slip on steps and work platform areas
and injure yourself.
When washing machine, do the following:
• Wear shoes with nonslip soles to prevent slipping
and falling. EX1400134
• Wear safety goggles and protective clothing when Figure 35

washing machine with high-pressure steam or water.
• Do not spray water directly on electrical components
(sensors, connectors). If water gets into electrical
system, it can cause operation problems.
• Pick up any tools or hammers that are laying in
workplace.
Wipe up any grease or oil to prevent slippery
substances, that can cause tripping or slipping.
• When cleaning cabin top window which is made
of polycarbonate material, use tap water. Avoid use
of organic solvents for cleaning, such as benzene,
toluene or methanol. These solvents can cause a
chemical reaction that will dissolve and damage the
window.
Proper Tools and Clothing

Only use tools that are intended for the type of service
to be done. Metal pieces from low quality or damaged
tools, such as chisels or hammers, can break off
and hit a service person in the eyes or face causing
serious injury.
Disassembling Precautions
When using a hammer to remove pins, pins can fly
out or metal particles may break off. Always do the
following:
● Hitting hard metal pins, bucket teeth, cutting edges
or bearings with a hammer, can cause metal pieces

to break or fly off resulting in serious injury. Always
wear safety goggles and leather gloves. Keep other
personnel away.
Use of Lighting
When checking fuel, oil, battery electrolyte, window
washer fluid, or coolant, always use proper lighting
equipment to prevent arcs or sparks that could cause
a fire or explosion resulting in death or serious injury.

Fire and Explosion Prevention
Fuels, most lubricants and some coolant mixtures are
flammable. Flammable fluids that are leaking or spilled
onto hot surfaces or onto electrical components can
cause a fire resulting in property damage or death or
serious injury.
Store all fuels and all lubricants in properly marked
and approved containers and keep away from all
unauthorized personnel. HDO1015I
Store oily rags and other flammable material in a
Figure 36
protective container.
Tighten all fuel and oil caps.
Do not smoke while you refuel machine or while you
are in a refueling area.
Do not smoke in battery charging areas or in areas
that contain flammable material.
Clean all electrical connections and tighten all
electrical connections. Check electrical wires daily for
wires that are loose or frayed. Tighten all loose, and
repair or replace all frayed, electrical wires before
operating machine.
Remove all flammable materials and debris from the
engine compartment, exhaust system components FG018458
and hydraulic lines. Figure 37

Burn Prevention
When checking radiator coolant level, stop engine,
let engine and radiator cool down, then check coolant
recovery tank. If coolant level in coolant recovery tank
is near upper limit, there is enough coolant in radiator.
Using gloves, loosen radiator cap slowly to release
internal pressure before removing radiator cap.
If coolant level in coolant recovery tank is below lower
limit, add coolant.
Cooling system conditioner contains alkali which can
cause personal injury. Do not allow alkali to contact
skin, eyes, or mouth.
Allow cooling system components to cool before
draining cooling system.
Hot oil and hot components can cause personal injury.
Do not allow hot oil or hot components to contact skin.
Vent hydraulic tank only after engine has been
stopped and hydraulic tank is cool. Using gloves,
slowly tilt hydraulic tank air breather to relieve
pressure.
Relieve all pressure in hydraulic oil system, in fuel
system, or in cooling system before disconnecting any
lines, hoses, fittings, or related components.
HAAE1980
Batteries give off flammable fumes that can explode
and start a fire. Figure 38
Do not smoke while you are checking battery
electrolyte level.
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact skin or eyes.
Always wear safety goggles and face protection when
working with batteries.

Rubber That Contains Fluorides
Observe extra great care when it is suspected that
you may have to handle rubber that contains fluorides.
Certain seals which have to withstand high operating
temperatures (e.g. in engines, transmissions, axles,
hydraulic motors and pumps) may be made from
rubber that contains fluorides, which, when exposed
to high heat (fire), forms hydrogen fluoride and
hydrofluoric acid. This acid is very corrosive and
cannot be rinsed or washed off from the skin. It
causes very severe burns which take a long time to
heal.
It usually means that damaged tissue must be
surgically removed. Several hours may pass after
contact with the acid, before any symptoms appear
and therefore one is not given any immediate warning.
The acid may remain on the machine parts for several
years after a fire.
If swelling, redness or a stinging feeling appears and
one suspects that cause may be contact with heated
rubber that contains fluorides, contact a medical
doctor immediately. If a machine, or part of a machine,
has been exposed to fire or severe heat, it must be
handled by specially trained personnel.
In all handling of machines after a fire, thick rubber
gloves and protective goggles must be used.
The area around a part which has been very hot and
which may be made of rubber that contains fluorides
must be decontaminated by thorough and ample
washing with limewater (a solution or suspension of
calcium hydroxide, i.e. slaked lime in water). After the
work has been completed, the gloves must be washed
in limewater and then discarded.

Rubber and Plastics
Polymer materials when heated, can form compounds
that create a health hazard and can harm the
environment.
Scrapped rubber and plastics must never be burned.
Extra precautions must be taken when servicing
machines that have been in a fire or exposed to
extreme heat.
If gas cutting or welding is to be done near such
materials, the following safety instructions must be
followed:
● Protect the material from heat.
● Use protective gloves, protective goggles and an
approved respirator.
Waste Hazardous to the Environment

Painted parts or parts made of plastic or rubber which
are to be scrapped must never be burned, but must be
taken care of by an approved refuse handling plant.
Batteries, plastic objects and anything else which is
suspected of being dangerous to the environment
must be taken care of in an environmentally safe way.
Check List After Fire

When handling a machine which has been damaged
by fire or been exposed to intense heat, the following
protective measures must under all circumstances be
followed:
Use thick, gloves made of rubber and wear goggles
which are certain to protect your eyes.
Never touch burned components with your bare
hands, as there is a risk that you may come into
contact with melted polymer materials. First wash
thoroughly with plenty of limewater (a solution or
suspension of calcium hydroxide, i.e. slaked lime in
water).
As a precaution, seals (O-rings and other oil seals)
should always be handled as if they were made of
rubber that contains fluorides.
Treat skin, which is suspected of having touched
burned rubber that contains fluorides, with Hydrofluoric
Acid Burn Jelly or something similar. Seek medical
advice. Symptom may not appear until several hours
afterwards.
Discard gloves, rags etc. which are suspected of
having touched burned rubber that contains fluorides.

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

a properly equipped place. Repairs must be performed
by a qualified welder. Welding operations, can create
potential hazards, including generation of gas, fire,
or electric shock. Never let an unqualified welder do
welding.
A qualified welder must do the following:
● To prevent battery explosion, turn battery disconnect
switch to “OFF” position.

● Disconnect the connector between ECU and
machine, and the connector between ECU and

engine.
● To prevent generation of gas, remove paint from
location of the weld.

● If hydraulic equipment, piping or component ports
close to them are heated, a flammable gas or mist

could result in an explosion or fire. To prevent this,
protect and insulate components from excessive
heat.
● Do not weld on pipes or on tubes that contain
flammable fluids. Do not flame cut pipes or tubes

that contain flammable fluids. Before welding on
pipes or tubes, or before flaming cut pipes or tubes,
clean them thoroughly with a nonflammable solvent.
Make sure pressure inside pipes or tubes does not
cause a rupture of the component parts.
● If heat is applied directly to rubber hoses or piping
under pressure, they may suddenly break, so cover

and insulate them with a fireproof covering.
● Wear protective clothing.
● Make sure there is good ventilation.
● Remove all flammable objects and make sure a fire
extinguisher is available.

Preparation for Electrical Welding on Body Structure
ON
To prevent damage to ECU by electrical welding,
OFF
observe the following procedures:
1. Turn battery disconnect switch to “OFF” position.
2. Disconnect the connector between ECU and
machine, and the connector between ECU and
engine.
EX1404450
3. Proceed with welding.
4. After welding, connect the connector between ECU Figure 39
and machine, and the connector between ECU and
engine.
5. Clean battery compartment.
6. Turn battery disconnect switch to “ON” position.
7. Close battery compartment door.
Warning for Counterweight and Front Attachment

Removal
WARNING
Removal of the machine counterweight, front
attachment or any other part can affect the stability of
the machine. This could cause unexpected movement,
Never remove counterweight or front attachment
unless the upper structure is in-line with the lower
EX1401352
structure.
Never rotate the upper structure once the Figure 40
counterweight or front attachment has been removed.

Lock Inspection Covers
When performing maintenance with inspection cover
open, use lock bar to secure cover and prevent
accidental lowering of the cover caused by wind or
movement of the machine.
Working on Machine
When performing maintenance operations on
machine, prevent tripping and falling by keeping area
around your feet clean and free of objects and debris.
Always do the following:
● Do not spill oil or grease.
● Do not leave tools laying around.
● Watch your step when walking.
● Never jump down from machine. When getting on or
off machine, use steps and handrails, and maintain

a three-point contact (both feet and one hand or ARO1380L
both hands and one foot) to support yourself. Figure 41

● If job requires it, wear protective clothing.
● To prevent injury from slipping or falling, when
working on hood or covers, never stand or walk on

areas except areas equipped with nonslip pads.
● If it is necessary to work under raised equipment or
the machine, support work equipment and machine

securely with blocks and stands strong enough to
support weight of work equipment and machine.
● Do not work under the machine if track shoes are
lifted off ground and the machine is supported

only with work equipment. If any control levers are
moved, or there is damage to hydraulic system,
work equipment or the machine will suddenly drop
causing death or serious injury.

Accumulator
The pilot control system is equipped with an
accumulator. For a short period of time after engine
has been stopped, accumulator will store a pressure
charge that allow hydraulic controls to be
activated. Activation of any controls will allow selected
functions to operate under force of gravity.
When performing maintenance on pilot control system,
release hydraulic pressure in system as described in
Operation & Maintenance Manual.
The accumulator is charged with high-pressure
nitrogen gas. If it is improperly handled it can explode
causing death or serious injury. Always observe the
following precautions:
● Do not drill or punch holes in accumulator or expose
it to any flames, fire or external heat source.

● Do not weld on accumulator. EX1400135
● When performing disassembly or maintenance of
Figure 42
accumulator, or when disposing of accumulator,
charged nitrogen gas must be properly released.
Contact your DOOSAN distributor for assistance.
● Wear safety goggles and leather gloves when
working on an accumulator. Hydraulic oil under

pressure can penetrate skin and result in death
or serious injury. If fluid enters skin or eyes, get
immediate medical attention from a physician
Compressed Air
● When cleaning filters, radiator or other components
with compressed air, there is a hazard of flying
particles that can result in serious injury.
● Always wear safety goggles, dust mask, leather
gloves, and other protective devices.

Track Tension Adjustments
Track adjusting systems use grease under high-
pressure to keep track under tension. Grease under
high-pressure can penetrate body and result in death
or serious injury. Watch track or track spring to see if
track is being loosened.
NEVER LOOSEN track tension grease valve. To
release pressure from crawler frame track tension
assembly, you should NEVER attempt to disassemble
track adjuster or attempt to remove track tension HAOA110L
grease valve assembly.
Figure 43
Keep your face and body away from grease valve.
Refer to Operation & Maintenance Manual, for proper
procedure in this manual or Shop Manual.
Supports and Blocking for Work Equipment

Do not allow weight or equipment loads to remain
suspended and unsupported.
Lower work group to ground before leaving operator’s
seat.
Do not use hollow, cracked or unsteady wobbling
supports. Do not work under any equipment supported
only by a lifting jack.
HDO1042L
Figure 44

High-pressure Lines, Tubes and Hoses
When inspecting or replacing high-pressure piping
or hoses, check to verify that pressure has been
released from circuit.
Failure to release pressure can result in death or
serious injury.
Release pressure as described in Operation &
Maintenance Manual.
Always do the following:
● Wear eye protection and leather gloves.
● Fluid leaks from hydraulic hoses or pressurized
components can be difficult to see but has enough

force to pierce skin and can result in death or
serious injury. Always use a piece of wood or
cardboard to check for suspected hydraulic leaks.
Never use your hands or expose your fingers. Wear
safety goggles.
● Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install lines, tubes or hoses

that are bent or damaged.
● Make sure that all clamps, guards and heat shields
are correctly installed to prevent vibration, rubbing EX1400129

against other parts, and excessive heat during
operation. Figure 45
● Replace hose or components if any of the following
problems are found:

– Damage or leakage from hose end fitting.
– Wear, damage, cutting of hose covering, or wire
braiding is exposed on any hose.
– Cover portion is swollen in any section.
– The hose is twisted or crushed.
– Foreign material is embedded in hose covering.
– Hose end is deformed.
– Connection fittings are damaged or leaking.
NOTE: Refer to Operation & Maintenance Manual, for
additional European regulations.
High-pressure is generated inside engine fuel lines
when engine is running. Before performing inspection
or maintenance of fuel line system, wait for at least
thirty seconds after stopping engine to let internal
pressure drop and tip breather cap up to release
residual pressure.
Oil or fuel leaks from high-pressure hoses can cause
fire or improper operation, which can result in death or
serious injury. If any loose bolts are found, stop work
and tighten to specified torque. If any damaged hoses
are found, stop operations immediately and contact
your DOOSAN distributor for replacement parts.

Battery
Battery Hazard Prevention
Battery electrolyte contains diluted sulfuric acid and
generates hydrogen gas. Hydrogen gas is highly
explosive, and improper handling can cause death
or serious injury, or fire. Do not allow electrolyte to
contact skin or eyes. Always wear safety goggles and
protective clothing when servicing batteries. Wash
hands after touching batteries and connectors. Use
of acid-resistant gloves is recommended. Always
observe the following precautions.
● Do not smoke or bring any flame near battery.
● When working with batteries, Always wear safety
goggles, protective clothing, and acid-resistant

gloves.
● If you spill battery electrolyte on yourself or your
clothes, immediately flush area with water.

● If battery electrolyte gets into your eyes, flush them
immediately with large quantities of water and

get immediate medical attention from a physician
● If you accidentally drink battery electrolyte, call
a poison prevention center immediately and get

immediate medical attention from a physician
EX1400136
● When cleaning top surface of battery, wipe it with a
clean, damp cloth. Never use gasoline, thinner, or Figure 46

any other organic solvent or detergent.
● Tighten battery caps.
● If battery electrolyte is frozen, do not charge battery
or start engine with power from another source. This

could cause the battery to explode and start a fire.
● When charging battery or starting with power from
another source, let battery electrolyte thaw and

check that there is no leakage of battery electrolyte
before starting operation.
● Always remove battery from machine before
charging.
● Do not use or charge battery if battery electrolyte
level is below LOW LEVEL line. This can cause an

explosion.
Periodically check battery electrolyte level and add
distilled water to bring electrolyte level to FULL
LEVEL line.
● Before maintaining or working with batteries, turn
starter switch to “O” (OFF) position.

Since there is a potential hazard that sparks could be
generated, always do the following:
● Do not let tools, rings or other metal objects make
any contact between battery terminals. Do not leave
tools or other metal objects lying near battery.
● When disconnecting battery terminals, wait for
approximately one minute after turning engine

starter switch key to “O” (OFF) position, and be
sure to disconnect grounding terminal; negative (-)
terminal first. Conversely, when connecting them,
begin with positive (+) terminal and then grounding (-)
terminal, Make sure that all terminals are connected
securely.
● Flammable hydrogen gas is generated when battery
is charged. Remove battery from machine, take it

to a well ventilated place, and remove battery caps,
before charging it.
● After charging, tighten battery caps securely.
● After charging, secure battery back in machine.
When repairing or welding electrical system, wait

for approximately one minute after turning engine
starter switch key “OFF”. Then disconnect negative (-)
terminal of battery to stop flow of electricity.

ENVIRONMENT AND
CIRCUMSTANCES
Work Site Areas Requiring Extra Caution
● Do not operate too close to edge of a quay, ramp,
etc.
● Do not operate too close to edge of a steep slope or
drop-off. Take care when working in a place where

machine may tip over.
● Do not operate on soft ground or near riverbanks
that could collapse or where ground may not support

weight of excavator.
● Observe changes in ground and traction conditions
after a rain or other changes in weather.
Digging Under an Overhang

Do not dig work face under an overhang. This can
cause overhang to collapse and fall on top of the
machine.
● Do not perform overhead demolition work. This can
cause broken objects and debris to fall on top of
machine causing death or serious injury, or property
damage.
EX1300686
Deep Digging Figure 47

Do not perform deep digging under front of machine.
The ground under machine may collapse and cause
machine to fall resulting in death or serious injury.
Working heavy loads on loose, soft or uneven ground,
can cause side load conditions resulting in a tip over
and injury. Traveling without a load or a balanced load
may also be hazardous.
Never rely on lift jacks or other inadequate supports
when work is being done. Block tracks fore and aft to
prevent any movement.
Use machine only for its intended purpose. Using it for
other purposes will cause failures.
● Do not perform demolition work under machine. EX1300687
There is a hazard that the machine may become Figure 48
unstable and tip over.
● When working on or from top of buildings or other
structures, check if structure can support weight

of machine and attachment. If a building structure
collapses, this can cause death or serious injury.

Drop-off or Edge
When working at edge of an excavation or near a
drop-off, the machine could tip over, which can result
in death or serious injury. Always fasten your seat belt.
Check ground conditions of work site before operating
to prevent the machine from falling or roll-over, and to
prevent ground, stockpiles, or banks from collapsing.
Do not travel too close to edge of a drop-off.
Poor Visibility
For good visibility, always do the following:
v
To avoid hitting work equipment and damaging other
property, always do the following:
● When working in tunnels, on bridges, under
electrical wires, or when parking the machine or

performing other operations in places with limited
height, be careful not to hit and damage other
equipment or property.
● To prevent hitting objects, operate machine at
a slow speed when working in confined spaces,

indoors, or in crowded areas.
● Do not swing bucket over the top of personnel or
over operator’s cabin of dump truck.
Loose or Soft Ground

Do not operate on soft ground or near edge of drop-
offs, overhangs, and deep ditches. The ground
can collapse because of the weight of the machine
causing the machine to fall or rollover.
Check ground conditions before beginning work with
the machine. If ground is soft, reposition the machine
before operating.
The excavated material must not be dumped too close
to edge.
How far away from edge of trench excavated material
must be dumped depends on soil type and moisture
content. If loose clay is being excavated, place it at
least 5 m (16 ft) away from edge.
If excavated material is dumped too close to edge, its
weight can cause a landslide.
Thawing of frozen ground, rain, traffic, piling and
blasting are other factors which increase risk of
landslide. The risk also increases on sloping ground. If
it is not possible to dig a trench and adequately slope
its sides, always install shoring equipment.

Loose ground may easily give way under weight of the
machine.
When working on loose or unstable ground, it
is important not to dig too deep and to carefully
reposition the machine. Do not panic and do not raise
bucket, if ground should begin to collapse. Lower work
equipment to improve stability of machine.
Never dig under machine, if there is a potential of
causing a landslide.
High-voltage Cables
Do not travel or operate machine near electrical
cables or overhead power lines. There is a hazard of
electric shock, which can cause property damage and
result in death or serious injury.
The bucket or other attachment does not have to
make physical contact with power lines for current to
cause an electrocution.
Use a spotter and hand signals to stay away from
power lines not clearly visible to operator. On work
EX1300688
sites where machine may operate close to electrical
cables, always do the following: Figure 49
● Remember that electrical voltage determines what
the minimum distance is to stay away from the
power line. See the following table for minimum
distances when working near electrical power lines.
Electrical flashover can occur and damage machine
and cause death or serious injury.
Voltage Minimum Distance
6.6 kV 3 m (9’ 10”)
33.0 kV 4 m (13’ 1”)
66.0 kV 5 m (16’ 5”)
154.0 kV 8 m (26’ 3”)
275.0 kV 10 m (32’ 10”)
● Always contact the power company responsible

before beginning work near high voltage power
lines.

Underground Operation
If excavation is in an underground location or in a
building, make sure there is adequate overhead
clearance, and adequate ventilation.
Special equipment and engines may be required in
some countries. Contact your DOOSAN distributor for
more information.
Check that there is sufficient room for machine and
load.
Move slowly.
Make sure that authorities or companies responsible
for underground cables, utilities, and electrical lines
have been contacted and that their instructions are
EX1300689
followed. Also check which rules apply to ground
Figure 50
personnel regarding exposing cables, utilities and
electrical lines.
Consider all electrical cables as live.
Working in Water
IMPORTANT
Do not exceed maximum permissible water depth. The
water level must not reach higher than centerline of
upper track roller(s) (1, Figure 51).
After working in water, lubricate all lubrication points

on undercarriage, which have been underwater so 1 EX1300690
water is removed. Check that no water has entered
travel gearboxes and undercarriage components. Figure 51
Working in Contaminated Environment

When working within area which is contaminated or
where there is a health risk, check local regulations
and contact your DOOSAN distributor for assistance
with identifying what additional safety precautions
need to be taken.

Operation in Extreme Conditions
Operation In Extreme Cold
In extremely cold weather, avoid sudden travel
movements and stay away from even slight slopes.
The machine could slide down the slope.
Snow accumulation could hide potential hazards and
slippery surfaces.
Warming up engine for a short period may be
necessary to avoid operating with sluggish or reduced
working capacity. The jolting shocks and impact loads
caused by bumping or bottoming boom or attachment
could cause severe stress in very cold temperatures.
Reducing work cycle rate and workload may be
necessary.
If machine is to be operated in extremely cold weather
temperatures, certain precautions must be taken.
The following paragraphs detail checks to be made to
be certain machine is capable of operating at these
temperatures.
1. Preheat the engine before start-up.
● Preheat the engine before start-up. Wait 3 to
4 seconds after preheating until voltage of the

battery return, and then actuate the starter switch.
2. Keep batteries fully charged to prevent freezing. If
distilled water is added to batteries, run engine at
least one hour to mix electrolyte solution.
When temperature drops below -10°C, efficacy of
the battery is reduced accordingly. Insulation of the
battery prevents reduction of efficacy, and supports
improvement of starting power of the starter.
WARNING
Explosion of the battery can cause death or serious
injury. Never attempt to directly heat the battery with
open fire.
3. Keep engine in good mechanical condition for easy

starting and good performance during adverse
weather.
4. Use engine oil with proper specifications for
expected temperatures. Refer to Operation &
Maintenance Manual, in this manual or Shop
Manual for details.
5. A l w a y s k e e p t h e f u e l t a n k f u l l y f i l l e d a f t e r
completion of the operation. Always drain water
from the fuel tank before and after the operation.
In addition, check the water separator, and drain
it if required. The fuel filter, if frozen, may interrupt
the flow of fuel. Periodically remove water from the
fuel tank, drain water from the filter, and replace the
filter upon regular basis. To prevent fuel from being

clogged because of formation of wax in fuel, make
sure that wax formation point of fuel is lower than
atmospheric temperature.
WARNING
Explosion of the fuel tank can cause death or serious
injury. Never attempt to directly heat the fuel tank with
open fire.
6. Lubricate entire machine according to Operation &

Maintenance Manual, in this manual or lubrication
chart on machine.
7. Start engine and allow it to reach normal operating
temperature before operating.
● If mud and ice collects and freezes on any of
moving parts while machine is idle, apply heat to

thaw frozen material before attempting to operate
machine.
● Operate hydraulic units with care until they have
reached a temperature which enable them to

operate normally.
● Check all machine controls and functions to be
sure they are operating correctly.

8. An extra outer air filter must be kept in operator’s
cabin to replace element that could become iced
and cause restricted airflow to engine.
9. Clean off all mud, snow and ice to prevent freezing.
Cover machine with a tarp if possible, keep ends of
tarp from freezing to ground.
Operation in Extreme Heat

Continuous operation of machine in high temperatures
can cause machine to overheat. Monitor engine and
hydraulic system temperatures and stop machine to
let it cool, when necessary.
1. Make frequent inspections and services of fan
and radiator. Check coolant level in radiator.
Check grilles and radiator fins for accumulation of
dirt, debris and insects which could block cooling
passages.
● F o r m a t i o n o f s c a l e a n d r u s t i n c o o l i n g
system occurs more rapidly in extremely high

temperatures. Change antifreeze each year to
keep corrosion inhibitor at full strength.
● If necessary, flush cooling system periodically to
keep passages clear. Avoid use of water with a

high alkali content which increases scale and rust
formation.

2. Check level of battery electrolyte daily. Keep
electrolyte above plates to prevent damage to
batteries. Use a slightly weaker electrolyte solution
in hot climates. Batteries self-discharge at a
higher rate if left standing for long periods at high
temperatures. If machine is to stand for several
days, remove batteries and store in a cool place.
IMPORTANT
Do not store acid type storage batteries near stacks of
tires. Acid fumes can damage rubber.
3. S ervice fuel system as directed in “Check Fuel

Level” and “Check for Leaks in Fuel System”, of
Operation & Maintenance Manual. Check for water
content before filling fuel tank. High temperatures
and cooling off cause condensation in storage
drums.
4. Lubricate as specified in Operation & Maintenance
Manual, in this manual or Lubrication Decal on
machine.
5. Do not park machine in sun for long periods of time.
If possible, park machine under cover to protect it
from sun, dirt and dust.
A. Cover machine if no suitable shelter is available.
Protect engine compartment and hydraulics from
dirt and debris.
B. In hot, damp climates, corrosion will occur on all
parts of machine and will be accelerated during
rainy season. Rust and paint blisters will appear
on metal surfaces and fungus growth on other
surfaces.
C. Protect all unfinished, exposed surfaces with a
film of preservative lubricating oil. Protect cables
and terminals with ignition insulation compound.
Apply paint or suitable rust preventive to
damaged surfaces to protect them from rust and
corrosion.
Operation In Dusty and Sandy Areas

Operation of machine can cause dust in almost any
area.
However, when in predominantly dusty or sandy
areas,
additional precautions must be taken.
1. Keep cooling system fins and cooling areas clean.
Blow out with compressed air, if possible, as often
as necessary.
WARNING
Wear goggles when using compressed air to prevent
face or eye injury.

2. U se care when servicing fuel system to prevent
dust and sand from entering tank.
3. Service air cleaner at frequent intervals, check air
restriction indicator daily and keep dust cup and
dust valve clean. Prevent dust and sand from
entering engine parts and compartments as much
as possible.
4. Lubricate and perform services outlined on current
lubrication chart on machine and “Lubrication
and Service Chart” of Operation & Maintenance
Manual. Clean all lubrication fittings before applying
lubricant. Sand mixed with lubricant becomes very
abrasive and accelerates wear on parts.
5. Protect machine from dust and sand as much as
possible.
Park machine under cover to keep dust and sand
from damaging unit.
Operation in Rainy or Humid Conditions

Operation under rainy or humid conditions is similar to
that as in extreme heat procedures previously listed.
1. Keep all exposed surfaces coated with preservative
lubricating oil. Pay particular attention to damaged
or unpainted surfaces. Cover all paint cracks and
chip marks as soon as possible to prevent corrosive
effects.
Operation in Saltwater Areas

Saltwater and saltwater spray is very corrosive. When
operating in saltwater areas, or in or around snow,
observe the following precautions:
1. When exposed to saltwater, dry machine thoroughly
and rinse with freshwater, as soon as possible.
2. Keep all exposed surfaces coated with preservative
lubricating oil. Pay attention to damaged paint
surfaces.
3. Keep all painted surfaces in good repair.
4. L ubricate machine as prescribed on lubrication
chart on machine or “Lubrication and Service
Chart”, in this manual.
Shorten lubricating intervals for parts exposed to
salt water.
5. C h e c k o p e r a t i n g c o n t r o l s t o e n s u r e p r o p e r
functionality and that they return to “NEUTRAL”
when released.

Operation at High Altitudes
Operation instructions at high altitudes are the same
as those provided for extreme cold. Before operating
at high altitudes, engine fuel and air mixture may
have to be adjusted according to appropriate engine
manual.
1. Check engine operating temperature for evidence
of overheating. The radiator cap must make a
perfect seal to maintain coolant pressure in cooling
system.
● Perform warming-up operation thoroughly. If
machine is not thoroughly warmed up before

control levers or control pedals are operated,
reaction of machine will be slow.
● If battery electrolyte is frozen, do not charge
battery or start engine with a different power

source. There is a potential hazard that could
cause a battery explosion or fire.
● Before charging or starting engine with a different
power source, thaw battery electrolyte and check

for any leakage of electrolyte before starting.
Operation During Electrical Storms

During electrical storms, do not enter or exit machine.
● If you are off machine, keep away from machine
until storm passes.

● If you are in cabin, remain seated with machine
stationary until storm passes. Do not touch

controls or anything metal.
Exhaust Ventilation
Engine exhaust gases can cause unconsciousness,
loss of alertness, judgment and motor control. This
Make sure there is adequate ventilation before starting
engine in any enclosed area.
Check for and be aware of any open windows, doors
or ductwork where exhaust may be carried, or blown
by wind, exposing others to hazardous exhaust gases.
Ventilation for Enclosed Area

If it is necessary to start engine within an enclosed ARO1770L
area, or when handling fuel, flushing oil, or paint; open
Figure 52
doors and windows to ensure that adequate ventilation
is provided to prevent gas poisoning.
Diesel engine exhaust contains products of
combustion which can be harmful to your health.
Always run engine in a well ventilated area. If you are
in an enclosed area, vent exhaust to outside.

Asbestos Information
WARNING
Avoid exposure to dust containing asbestos as it can
cause death or serious injury to the lungs and other
organs (mesothelioma, lung and other cancers, and
asbestosis).
Asbestos dust can be HAZARDOUS to your health if

it is inhaled. Materials containing asbestos fiber can
be present on work sites. Breathing air that contains
asbestos fiber can ultimately cause serious or fatal
lung damage or diseases such as mesothelioma, lung
and other cancers, and asbestosis. To prevent lung
damage from asbestos fiber, observe the following
precautions:
● Use an approved respirator that is approved for use
in an asbestos-laden atmosphere.
● Use water for cleaning to keep down dust.
● Always observe any regulations related to work site
and working environment.

● Avoid brushing or grinding materials that contain
asbestos.
● A vacuum cleaner that is equipped with a high
efficiency particulate air filter can also be used.

● Comply with applicable laws and regulations for
workplace.
● Stay away from areas that might have asbestos
particles in air.
Silica Dust Information
WARNING
Avoid exposure to dust containing crystalline silica
particles as it can cause serious injury to the lungs
(silicosis).
Cutting or drilling concrete containing sand or rock

containing quartz can result in exposure to silica dust.
Do not exceed Permissible Exposure Limits (PEL)
to silica dust as determined by OSHA or other work
site rules, laws and regulations. Use a respirator,
water spray or other means to control dust. Silica dust
can cause lung disease and is known to the state of
California to cause cancer.

Disposal of Hazardous Materials
Physical contact with used motor oil or gear oil could
create a health risk. Wipe oil from your hands promptly
and wash off any remaining residue.
Used motor oil or gear oil is an environmental
contaminant and should only be disposed of at
approved collection facilities. To prevent pollution of
environment, always do the following:
● Never dump waste oil in a sewer system, rivers, etc.
● Always put drained oil from your machine in
approved, leak proof containers. Never drain oil

directly onto ground.
● Obey appropriate laws and regulations when
disposing of harmful materials such as oil, fuel,

solvent, filters, and batteries.
Improperly disposing of waste can threaten
environment.
Potentially harmful fluids must be disposed of
according to local regulations.
Use all cleaning solutions with care. Report all
necessary repairs.
Sound
Sound Level Information: Hearing protection may
be needed when machine is operated with an open
operator station for extended periods or in a noisy
environment.
Sound pressure level (LpA) at operator position

(Measurement according to ISO 6396)
Sound power level (LwA) around the machine
(Measurement according to 2000/14/EC with
applicable appendices and measuring method
according to ISO 6395)
Refer to Operation & Maintenance Manual.

Vibration Information
NOTE: The level of vibration is influenced by many
different parameters such as operator training,
job site organization, weather, material,
environment, machine type, machine and seat
suspension system, attachments, and condition
of the machine.
Measurements are obtained on a representative
machine, using measuring procedures as described in
the following standards:
ISO 2631/1, ISO 5349, and SAE J1166.
Vibration levels were given consideration in
accordance with uncertainty (K) determined to
manufacturer.
Hand/Arm Vibration Level

The vibration total value to which the hand-arm
system is subjected, is less than 2.5 m/s2.
Whole Body Vibration Level

The highest root mean square value of weighted
acceleration to which the whole body is subjected, is
less than 0.5 m/s2.
Guidelines for Use and Working Conditions of Earth-moving

Machinery to Reduce Vibration Levels (ISO/TR 25398 Annex E)
Properly adjusting and maintaining machines,
operating machines smoothly, and maintaining the
terrain conditions can reduce whole-body vibrations.
The following can help the users of earth-moving
machinery reduce whole-body vibration levels.
1. Use the right type and size of machine, equipment,
and attachments.
2. Maintain machines according to the manufacturer’s
recommendations:
● Tire pressure;
● Brake and steering systems;
● Controls, hydraulic system and linkages.
3. Keep the terrain where the machine is working and

travelling in good condition:
● Remove any large rocks or obstacles;
● Fill any ditches and holes;
● Provide machines and schedule time to maintain
terrain conditions.
4. Use a seat in conformance with ISO 7096 and keep
the seat maintained and adjusted:
● Adjust the seat and suspension for the weight and
size of the operator;

● Inspect and maintain the seat suspension and
adjustment mechanisms.

5. Steer, brake, accelerate, shift gears, and move the
attachments smoothly.
6. Adjust the machine speed and travel path to
minimize the vibration level:
● Drive around obstacles and rough terrain
conditions;
● Slow down when it is necessary to go over rough
terrain.
7. Minimize vibrations for long work cycle or long
distance travelling:
● U s e m a c h i n e s e q u i p p e d w i t h s u s p e n s i o n
systems;
● Use lift arm suspensions on wheel loaders;
● If no suspension system is available, reduce
speed to prevent bouncing;

● Haul machines long distances between worksites.
8. Back pain associated with whole-body vibrations

can be caused by other risk factors. To minimize
the risk of back pain:
● Adjust the seat and controls to achieve good
posture;
● Adjust the mirrors to minimize twisted posture;
● Provide breaks to reduce long periods of sitting;
● Avoid jumping down from the cab or access
system;
● Minimize repeated handling and lifting of loads;
● Minimize any shocks and jolts during sports and
leisure activities.

Specifications
DX140AF/DX140LCA Specifications 2-1

ＭＥＭＯ

Table of Contents
Specifications
GENERAL DESCRIPTION.......................................... 4
DIMENSIONS AND WORKING RANGE..................... 5
GENERAL SPECIFICATION....................................... 7
COMPONENT LOCATIONS....................................... 8
STANDARD SPECIFICATION.................................. 10
OVERALL DIMENSIONS.......................................... 11
WORKING RANGE................................................... 12
APPROXIMATE WEIGHT OF WORKLOAD MATERIA
LS............................................................................ � 13
PERFORMANCE TESTS.......................................... 15
Purpose of Performance Tests......................... 15
Kinds of Tests................................................... 15
Performance Standards.................................... 15
Precautions for Evaluation of Test Data........... 15
Definition of “Performance Standard”............... 15
PREPARATION FOR PERFORMANCE TESTS....... 16
The Machine..................................................... 16
Test Area.......................................................... 16
Precautions....................................................... 16
Make Precise Measurement............................. 16
OPERATIONAL PERFORMANCE STANDARD TAB
LE...............................................................................17
OPERATIONAL PERFORMANCE TEST.................. 19
Hydraulic Cylinder Cycle Time.......................... 19
Travel Speed.................................................... 21
Track Revolution Speed................................... 22
Mistrack Check................................................. 24
Swing Speed..................................................... 26
Swing Function Drift Check.............................. 27

SAFETY INSTRUCTIONS
WARNING
GENERAL DESCRIPTION
The excavator has three main component sections:
● The Upper Structure
● The Lower Undercarriage and Track Frames
● The Excavator Front-end Attachment

DIMENSIONS AND WORKING RANGE
DIMENSIONS
DX140AF
Figure 1
BOOM TYPE (mm) 4600

ARM TYPE (mm) 3000
3
BUCKET TYPE (SAE) (m ) 0.51
TAIL SWING RADIUS (mm) N 2203
SHIPPING HEIGHT (BOOM) (mm) O 3076
SHIPPING HEIGHT (HOSE) (mm) P 3243
SHIPPING LENGTH (mm) Q 7703
SHIPPING WIDTH (STD.) (mm) R 3160
C/WEIGHT CLEARANCE (mm) S 1199
HEIGHT OVER CAB. (mm) T 3090
HOUSE WIDTH (mm) U 2533
CAB. HEIGHT ABOVE HOUSE (mm) V 832
CAB. WIDTH (mm) W 1010
TUMBLER DISTANCE (mm) X 3180
TRACK LENGTH (mm) Y 4045
UNDERCARRIDGE WIDTH (mm) Z 3160
SHOE WIDTH (mm) a 800
TRACK HEIGHT (mm) b 1068
CAR BODY CLEARANCE (mm) c 649.5

DX140LCA
Figure 1
4.6m (181.1in)BOOM
Dimension
3.0m (118.1in)ARM
A Shipping Length 7645mm (301in)
B Tail Swing Radius 2205 mm (86.8in)
C Front Shipping Length 5500 mm (216.5in)
D Tumbier Distance 3035 mm (119.5in)
E Track Length 3750 mm (147.6in)
F Counterweight Clearance 869 mm (34.2in)
G Shipping Height 3035 mm (119.5in)
H Shipping Width 2533 mm (99.7in)
I Left Width 1267 mm (49.9in)
J Right Width 1267 mm(49.9in)
K Undercarriage Width(Narrow) 1990 mm(78.3in)
L Undercarriage Width(Standard) 2690 mm(105.9in)
M Shoe Width 700 mm(27.6in)
N Body Clearance 385 mm(15.1in)
O Height Over Cabin 2780 mm(109.5in)

WORKING RANGE
DX140AF
Figure 2
BOOM TYPE (ONE PIECE) (mm) 4600

ARM TYPE (mm) 2500
BUCKET TYPE (SAE) (m3) 0.51
MAX. DIGGING REACH (mm) A 8650.6
MAX. DIGGING REACH (GROUND) (mm) B 8460.8
MAX. DIGGING DEPTH (mm) C 5814.2
MAX. LOADING HEIGHT (mm) D 6749.8
MIN. LOADING HEIGHT (mm) E 2055.9
MAX. DIGGING HEIGHT (mm) F 9128.6
MAX. BUCKET PIN HEIGHT (mm) G 7959
MAX. VERTICAL WALL DEPTH (mm) H 1617
MAX. RADIUS VERTICAL (mm) I 7915.9
MAX. DEPTH TO 8' LINE (mm) J 5811
MIN. RADIUS 8' LINE (mm) K 766
MIN. DIGGING REACH (mm) L 559
MIN. SWING RADIUS (mm) M 2203
REACH TO BUCKET PIN CENTER AT
(mm) O 4117
MAXIMUM HEIGHT
REACH AT MAXIMUM HEIGHT (mm) P 4
BUCKET ANGLE (deg) d 179

DX140LCA
Figure 2
Boom Type 4.6m (181.1in)BOOM

Dimension
Arm Type 3.0m (118.1in)ARM
A Max. Digging Reach 8650.6 mm(340.6in)
B Max. Digging Depth 6119.2 mm(241in)
C Max. Digging Height 8823.6 mm(347.4in)
D Max. Loading Height 6444.8 mm(253.7in)
E Min Swing Radius 2203 mm(86.7in)

GENERAL SPECIFICATION
DX140AF
Specification
Component
Metric English
Bucket CECE 0.46m3 0.6yd3

Capacity PCSA 0.51m3 0.67yd3
Equipment Weight 16.8 metric tons 18.5tons
Model DB58-LBE00
Type Water Cooled - 6 Cylinders
Engine Rated Net Output 100.6KW/1850rpm
Maximum Torque 42kg.m@1400rpm 304ft lb@1400rpm
Fuel Tank Capacity 267L 70.5gal
Type Axial Piston
Hydraulic
Maximum Discharge Quantity 350kg/cm2 343bar
Pump Discharging Pressure 2X114L/min 2X30.1 U.S.gpm
Hydraulic Oil Tank Level 98.8L 26.1 U.S.gal

Capacity System 147.8L 39 U.S.gal
Digging Bucket 97KN
Performance Capability Arm 57.9KN
Swing Speed 10.7rpm
Travel Speed Low-speed 2.5km/hr 1.55MPH
High-speed 4.3km/hr 2.67MPH
Low-speed 160.72KN
Traction Force
High-speed 82KN
Gradeability 35DEG(70%slope)
Ground Pressure 0.36kg/cm2 5.1 psi
Ground Clearance 649.5mm 25.5 in
Track Shoe Width 800mm 31.5 in
Upper Roller Qty. 2 per side
Bottom Roller Qty. 7 per side

DX140LCA
Specification
Component
Metric English
Bucket CECE 0.46m3 0.6yd3

Capacity PCSA 0.51m3 0.67yd3
Equipment Weight 15.2 metric tons 16.7tons
Model DB58-LBE00
Type Water Cooled - 6 Cylinders
Engine Rated Net Output 100.6KW/1850rpm
Maximum Torque 42kg.m@1400rpm 304ft lb@1400rpm
Fuel Tank Capacity 267L 70.5gal
Type Axial Piston
Hydraulic
Maximum Discharge Quantity 350kg/cm2 343bar
Pump Discharging Pressure 2X114L/min 2X30.1 U.S.gpm
Hydraulic Oil Tank Level 98.8L 26.1 U.S.gal

Capacity System 147.8L 39 U.S.gal
Digging Bucket 97KN
Performance Capability Arm 57.9KN
Swing Speed 10.7rpm
Travel Speed Low-speed 2.5km/hr 1.55MPH
High-speed 4.3km/hr 2.67MPH
Low-speed 160.72KN
Traction Force
High-speed 82KN
Gradeability 35DEG(70%slope)
Ground Pressure 0.36kg/cm2 5.1 psi
Ground Clearance 649.5mm 25.5 in
Track Shoe Width 700mm 27.6 in
Upper Roller Qty. 2 per side
Bottom Roller Qty. 7 per side

COMPONENT LOCATIONS
Figure 3

No. Description No. Description
1 Counterweight 20 Arm
2 Hood 21 Bucket Cylinder
3 Muffler 22 Guide Link
4 Hydraulic Oil Tank 23 Bucket
5 Fuel Tank 24 Push Link
6 Engine 25 Tooth Point
7 Fuel Tank Fill Cap 26 Side Cutter
8 Radiator and Oil Cooler 27 Idler
9 Control Valves 28 Track Adjuster
10 Swing Motor 29 Track Guard
11 Air Cleaner 30 Battery
12 Swing Bearing 31 Lower Roller
13 Cabin 32 Center Joint
14 Seat 33 Upper Roller
15 Boom Cylinder 34 Travel Motor
16 Work Lever (Joystick) 35 Track Link and Shoe
17 Arm Cylinder 36 Suction Filter
18 Boom 37 Return Filter
19 Travel Lever 38 Pumps

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

Material
1,100kg/m³ 1,600kg/m³ 2,000kg/m³
Charcoal 401kg/m³ ------- -------
Coke, blast furnace size 433kg/m³ ------- -------
Coke, foundry size 449kg/m³ ------- -------
Coal, bituminous slack,

801kg/m³ ------- -------
piled
Coal, bituminous r. of m.,
881kg/m³ ------- -------
piled
Coal, anthracite 897kg/m³ ------- -------
Clay, DRY, in broken

1,009kg/m³ ------- -------
lumps
Clay, DAMP, natural bed ------- 1,746 kg/m³ -------
Cement, portland, DRY

------- 1,506 kg/m³ -------
granular
Cement, portland, DRY
------- 1,362 kg/m³ -------
clinkers
Dolomite, crushed ------- 1,522 kg/m³ -------
Earth, loamy, DRY, loose ------- 1,202 kg/m³ -------
Earth, DRY, packed ------- 1,522 kg/m³ -------

Low weight or density Middle weight or density High weight or density
Material
1,100kg/m³ 1,600kg/m³ 2,000kg/m³
Earth, WET, muddy ------- ------- 1,762 kg/m³
Gypsum, calcined,
961 kg/m³ ------- -------
(heated, powder)
Gypsum, crushed to 3
------- 1,522 kg/m³ -------
inch size
Gravel, DRY, packed
------- ------- 1,810 kg/m³
fragments
Gravel, WET, packed
------- ------- 1,922 kg/m³
fragments
Limestone, graded above
------- 1,282 kg/m³ -------
2
Limestone, graded 1-1/2
------- 1,362 kg/m³ -------
or 2
Limestone, crushed ------- 1,522 kg/m³ -------
Limestone, fine ------- ------- 1,602 kg/m³
Phosphate, rock ------- 1,282 kg/m³
Salt 929 kg/m³ ------- -------
Snow, light density 529 kg/m³ ------- -------
Sand, DRY, loose ------- 1,522 kg/m³ -------
Sand, WET, packed ------- ------- 1,922 kg/m³
Shale, broken ------- 1,362 kg/m³ -------
Sulfur, broken 529 kg/m³ ------- -------

PERFORMANCE TESTS
Use operational performance test procedure to
quantitatively check all system and functions on the
machine.
Purpose of Performance Tests

1. T o comprehensively evaluate each operational
function by comparing the performance test data
with the standard values.
2. According to the evaluation results, repair, adjust,
or replace parts or components as necessary to
restore the machine’s performance to the desired
standard.
3. To economically operate the machine under optimal
conditions.
Kinds of Tests
1. B ase machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the
operational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to evaluate
the performance test data.
Precautions for Evaluation of Test Data

1. To evaluate not only that test data is correct, but
also in what range the test data is.
2. B e sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
The machine performance does not always
deteriorate as the working hours increase. However,
the machine performance is normally considered
to reduce in proportion to the increase of the
operation hours. Accordingly, restoring the machine
performance by repair, adjustment, or replacement
shall consider the number of the machine’s working
hours.
Definition of “Performance Standard”

1. Operation speed values and dimensions of the new
machine.
2. O perational performance of new components
adjusted to specifications. Allowable errors will be
indicated as necessary.

PREPARATION FOR
PERFORMANCE TESTS
Observe the following rules to perform performance
tests accurately and safety.
The Machine
1. R epair any defects and damage found, such as
oil or water leaks, loose bolts, cracks etc, before
starting to test.
Test Area
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 20 m (65 ft 7 in), and to make a
full swing with the front attachment extended.
3. I f required, rope off the test area and provide
signboards to keep unauthorized personnel away.
Precautions
1. Before starting to test, agree upon the signals to be
employed for communication among coworkers.
Once the test is started, be sure to communicate
with each other using these signals, and to follow
them without fail.
2. Operate the machine carefully and always give first
priority to safety.
3. While testing, always take care to avoid accidents
because of landslides or contact with high voltage
power lines.
Always confirm there is sufficient space for full EX1302009
swings.
Figure 6
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic
pipings.
Make Precise Measurement

1. Accurately calibrate test instruments in advance to
obtain correct data.
2. P erform tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that test data
obtained can be produced repeatedly. Use mean
values of measurements if necessary.

OPERATIONAL PERFORMANCE
STANDARD TABLE
Model DX140AF/DX140LCA
Item Vnit Performanle Standard Tolerance
TRAVEL-MODE rpm - -
POWER-MODE rpm 2000 ±50
STD-MODE rpm 1850 ±50
Noload
ECO-MODE rpm 1750 ±50
E/G Speed
LOW IDLE rpm 1000 ±50
AUTO IDLE rpm 1000 ±50
1 PUMP RELIEF rpm 1850 以上
Load
2 PUMP RELIEF rpm 1850 以上
LOW IDLE mA 600 ±30
AUTO IDLE mA 600 ±30
Valve Crrent TRAVEL-MODE mA - -
-
Eppr POWER-MODE mA 220 ±30
STD-MODE mA 230 ±30
ECO-MODE mA 260 ±30
NORMAL bar 323 0~+10
FRONT
BOOST bar 343 0~+10
Pressure
S/MOTOR MOTOR/PUMP bar 270/290 0~+15/±20
T/MOTOR MOTOR/PUMP bar 323 0~+10
UP sec 3.5 ±0.4
BOOM
DOWN sec 2.6 ±0.4
CROWD sec 2.9 ±0.4
Front ARM
DUMP sec 2.3 ±0.4
CROWD sec 4.0 ±0.5
BUCKET
sec 2.3 ±0.3

Model DX140AF/DX140LCA
Item Vnit Performanle Standard Tolerance
Swing Swing Single 3 Revolution sec 16.5 ±1.0
Travel 1 SPEED sec 31.0 ±1.5
Travel (20m) 2 SPEED sec 15.8 ±1.5
Speed JACK-UP 1 SPEED sec 38.9 ±2.0
(3turns) 2 SPEED sec 19.9 ±2.0
mm/
BOOM 5 ↓
5min
Cylinder mm/
FRONT ARM 5 ↓
Creeping 5min
mm/
BUCKET 20 ↓
5min
TRACK Standard & Impact mm 265~280 -
TRACK
Drooping Packing mm 280~310 -
Travel 1 SPEED mm 150 ↓
Tracel 20m
Devitation 2 SPEED mm 150 ↓

OPERATIONAL PERFORMANCE
TEST
Hydraulic Cylinder Cycle Time
Summary
1. Check the overall operational performance of the
front attachment hydraulic system (between the
hydraulic pumps and each cylinder) by measuring
the cycle time of the boom, arm, bucket, and bucket
dump (open/close) cylinders with the empty bucket.
2. Bucket must be empty.
Preparation
1. Maintain the hydraulic oil temperature at 50 ±5 °C
(122 ±41 °F).
Engine Power Mode Auto-idle
Work Mode
Control Dial Switch Switch
Digging
High Idle Power Mode OFF
Mode
2. Position the front attachment as described in the

following.
Then, measure the operating time until cylinder
reaches the stroke end by fully moving the control
lever.
A. Boom cylinder
1) Boom up speed
Rapidly operate the bucket from the ground,
and measure the time it takes for the boom to
reach the end point.
2) Boom down speed
Rapidly operate the bucket with the boom
reached the end point, and measure the time
EX1301781
it takes for the bucket to reach the ground.
3) Measuring available displacement of the Figure 7
cylinder: Measure and record the extension
of the cylinder rod from when the bucket
is resting on the ground to when the boom
cylinder is extended to its maximum length.

B. Arm cylinder
1) Arm crowd speed
Rapidly operate the arm while kept fully
dumped (extended), and measure the time it
takes for the arm to fold fully.
2) Arm dump speed
Rapidly operate the arm maintained in the
fully folded position, and measure the time it
takes for the arm to extend fully. 0.5 m
3) Measuring available displacement of the
EX1301782
length of the cylinder rod from the point at Figure 8
which the arm cylinder is fully extended
(crowded) to the point at which the arm
cylinder is fully folded (dumped).
C. Bucket cylinder
1) Bucket crowd speed
Rapidly operate the bucket while fully
dumped (extended), and measure the time it
takes for the bucket to fold fully.
2) Bucket dump speed
Rapidly operate the bucket while fully folded,
and measure the time it takes for the bucket
1m
to extend fully. EX1301783
3) Measuring available displacement of the Figure 9
length of the cylinder rod from the point at
which the bucket cylinder is fully extended
(crowded) to the point at which the bucket
cylinder is fully folded (dumped).
NOTE: Jack up the dozer of the wheel-type excavator and

mini-excavator pointing forward, and measure the
time taken to jack it up and to jack it back down.
Measure and record the operating time of the
boom swing (option) of the mini-excavator from
right to left, or from left to right.
NOTE: Record the details of any abnormal noise
heard during measurement, or any abnormal
conditions observed during operation, on a blank
measurement record sheet.

Travel Speed
Summary
Measure the time required for the excavator to travel a
20 m (65.6 ft) test track.
Preparation
1. Adjust the track sag on both side tracks equally.
Arm Rolled-in, Bucket Rolled-in
2. Prepare a flat and solid test track 20 m (65.6 ft) Bucket Height: 0.3 - 0.5 m
in length with extra length of 3 ~ 5 m (9.8 ~ 16 End
ft) on both ends for machine acceleration and
deceleration. Start
20 m
Deceleration
Zone 3 - 5 m
IMPORTANT Acceleration
Zone 3 - 5 m
The bucket teeth will hit the boom if the bucket is EX1301767
rolled-in with the arm fully rolled-in. Figure 10
As for this condition: arm fully rolled-in + bucket fully
rolled-in, set the bucket at fully rolled-in and a perform
arm roll-in operation.
3. Hold the bucket 0.3 ~ 0.5 m (12 ~ 20 in) above the

ground with the arm and bucket rolled-in.
(122 ±41 °F).
Measurement
1. M easure both the slow and fast speeds of the
machine.
2. Measurement conditions are as below.
Travel Engine Power
Work Auto-idle
Mode Control Mode
Mode Switch
Switch Dial Switch
Low Power Digging
High Idle OFF
Mode Mode Mode
High Power Digging
High Idle OFF
Mode Mode Mode
3. Start traveling the machine in the acceleration zone
with the travel levers to full stroke.
4. Measure the time required to travel 20 m (65.6 ft)
5. After measuring the forward travel speed, turn the
upper structure 180° and measure the reverse
travel speed.
6. Perform the measurement three times and calculate
the average values.

Track Revolution Speed
Summary
Measure the track revolution cycle time with the track
raised off ground.
Preparation
1. Adjust the track sag of both side tracks to be equal.
2. Put the mark on the track to be measured, by using
a piece of chalk.
3. Swing the upper structure 90° and lower the bucket
to raise the track off ground. Keep the boom-arm
angle between 90 ~ 110° as shown place blocks
under the machine frame.
CAUTION
AVOID INJURY 90 - 110
Secure support the raised track using wooden blocks.

(122 ±41 °F).
EX1300534
Measurement
1. Measure the both tracks on forward and reverse Figure 11
directions at each travel mode.
Travel Engine Power

Work Auto-idle
Mode Control Mode
Mode Switch
Switch Dial Switch
Low Power Digging
High Idle OFF
Mode Mode Mode
High Power Digging
High Idle OFF
Mode Mode Mode
3. Operate the travel control lever of the raised track

to full stroke.
4. Measure the time required for 3 revolutions in both
directions after a constant track revolution speed is
obtained.
the average values.
NOTE: Record the details of any abnormal noise
heard during measurement, or any abnormal
conditions observed during operation, on a blank
measurement record sheet.

Evaluation
Refer to “Operational Performance Standard Table”
on page -22.
NOTE: T he measurement data obtained through the
raised track revolution test may have wide
variations.
Therefore, the evaluation based on the results
obtained from the 20 m travel speed check
described before is more recommendable.

Mistrack Check
Summary
1. Allow the machine to travel 20 m (65.6 ft). Measure
the maximum tread deviation from the tread chord
line drawn between the travel start and end points
to check the performance equilibrium between both
sides of the travel device systems (from the main
pump to the travel motor).
2. I f measured on a concrete surface, the tread
deviation has a trend to decrease.
Preparation Front Zone

1. Adjust the track sag of both tracks to be equal.
2. Provide a flat, solid test yard 20 m (65.6 ft) in length,
with extra length of 3 ~ 5 m (9.8 ~ 16 ft) on both Max. Distance
ends for machine acceleration and deceleration.
IMPORTANT
The bucket teeth will hit the boom if the bucket is
Acceleration
rolled-in with the arm fully rolled-in.
Zone 3 - 5 m
m
As for this condition: arm fully rolled-in + bucket fully
20
rolled-in, set the bucket at fully rolled-in and a perform
arm roll-In operation.
3. Hold the bucket 0.3 ~ 0.5 m (12 ~ 20 in) above the

ground the arm and bucket rolled-in.
(122 ±41 °C).
EX1301768
Measurement Figure 12
1. Measure the amount of mistracking in both fast, and
slow travel speeds.
Travel Engine Power
Work Auto-idle
Mode Control Mode
Mode Switch
Switch Dial Switch
Low Power Digging
High Idle OFF
Mode Mode Mode
High Power Digging
High Idle OFF
Mode Mode Mode
3. Start traveling the machine in the acceleration zone

with the travel levers al full stroke.

4. Measure the maximum distance between a straight
20 m (65.6 ft) tread chord line and the tread made
by the machine.
5. After measuring the tracking in forward travel, turn
the upper structure 180° and measure in reverse
travel.
the average values.
Evaluation
on page -22.

Swing Speed
Summary
Measure the time required to swing three complete
turns.
Preparation
1. Check the lubrication of the swing gear and swing
bearing.
2. Place the machine on flat, solid ground with ample
space lor swinging. Do not conduct this test on
slopes.
3. With the bucket empty, position the front attachment
as follows.
With the arm cylinder fully retracted, and the bucket
The height as the
cylinder fully extended, raise the boom so bucket boom foot pin height.
pin height is flush with the boom foot pin height.
NOTE: In case of no place to be measured, measure EX1301770
with the boom raised and the arm rolled-in. Figure 13

(122 ±41 °F).
CAUTION
AVOID INJURY
Prevent personal injury. Always make sure that area is
clear and that co-workers are out of the swing area
before starting the measurement.
Measurement
Work Mode
Control Dial Switch Switch
Digging
Mode
2. Operate swing control lever fully.
3. Measure the time required to swing 3 turns in one
direction. (Record the stopwatch measurement to
the second decimal place.)
4. Operate swing control lever fully in the opposite
direction and measure the time required for 3 turns.
the average values.
Evaluation
on page -22.

Swing Function Drift Check
Summary
Measure the swing drift on the bearing outer
circumference when stopping after a 360° full-speed
swing.
Preparation
1. Check the lubrication of the swing gear and swing
bearing.
2. Place the machine on flat, solid ground with ample
space for swinging. Do not conduct this test on a
slope. Two Matching Marks
3. With the bucket empty, position the front attachment EX1301772
as follow. Figure 14
With the arm cylinder fully retracted, and the bucket
cylinder fully extended, raise the boom so bucket
pin height is flush with the boom foot pin height.
4. Put the matching marks on the swing bearing and
on the track frame by using a tape, as illustrated.
5. Swing the upper structure 360°.
(122 ±41 °F).
CAUTION
AVOID INJURY
Prevent personal injury. Always make sure that area is EX1301773
clear and that co-workers are out of the swing area
before starting the measurement. Figure 15
Measurement
Work Mode Measure Difference
Control Dial Switch Switch Between Marks
Digging
Mode
2. Operate swing control lever fully and return it to the

neutral position when the mark on upper structure
aligns with that on track frame after swinging 360°.
Mark on Track Frame
3. Measure the time distance between the two marks.
4. Align the marks again, swing 360°, and then test in Mark on Swing Bearing
EX1301774
the opposite direction.
Figure 16
the average values.
Evaluation
on page -22.

General Maintenance
DX140AF/DX140LCA
DX140AF/DX140LCA
General
Maintenance
Instructions
DX140AF/DX140LCA General Maintenance Instructions 1-3

ＭＥＭＯ

Table of Contents
General Maintenance Instructions

SAFETY INSTRUCTIONS...........................................6
WELDING PRECAUTIONS AND INSTRUCTIONS.....7
HYDRAULIC SYSTEM - GENERAL PRECAUTIONS.8
MAINTENANCE SERVICE AND REPAIR
PROCEDU RE..........................................................10
General Precautions.............................................10
HYDRAULIC SYSTEM CLEANLINESS AND OIL
LEA KS......................................................................11
Maintenance Precautions for Hydraulic System Ser
vice.......................................................................11
Oil Leakage Precautio ns.....................................12
CLEANING AND INSPECTION.................................13
General Instructions.............................................13
Bearing Inspection................................................14

SAFETY INSTRUCTIONS
WARNING

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

WARNING
Observe the following safety instructions:
1. Use adequate safety shielding and keep away from
fuel and oil tanks, batteries, hydraulic piping lines or
other fire hazards when welding.
2. N ever weld when the engine is running. Battery
cables must be disconnected before the welding
procedure is started.
3. Never weld on a wet or damp surface. The presence
of moisture causes hydrogen embrittlement and
structural weakening of the weld.
4. If welding procedures are being performed near
cylinder rods, operator’s cabin window areas or
any other assemblies could be damaged by weld
spatters.
Use adequate shielding protection in front of the
assembly.
5. D uring welding equipment setup, always attach
ground cables directly to the area or component
being welded to prevent arcing through bearings,
bushings, or spacers.
6. A lways use correct welding rods for the type of
weld being performed and observe recommended
precautions and time constraints. AWS Class
E7018 welding rods for low alloy to medium carbon
steel must be used within two hours after removal
from a freshly opened container. Class E11018G
welding rods for T-1 and other higher strength steel
must be used within 1/2 hour of removal from a
freshly opened container.
HYDRAULIC SYSTEM - GENERAL

PRECAUTIONS
Always maintain oil level in the system at
recommended levels.
Assemblies that operate under heavy loads, at high-
speed, with extremely precise tolerances between
moving parts (e.g. pistons and cylinders, or shoes and
swash plates), can be severely damaged if oil supply
runs dry.
Assemblies can be run dry and damaged severely
in a very short time when piping or hoses are
disconnected to repair leaks and/or replace damaged
components. Hoses that are inadvertently switched
during disassembly (inlet for outlet and vice versa), air
introduced into the system or assemblies that are low
on oil because of neglect or careless maintenance,
could all produce sufficient fluid loss to cause damage
or improper operation.

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

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

HYDRAULIC SYSTEM
CLEANLINESS AND OIL LEAKS
Maintenance Precautions for Hydraulic
System Service
Whenever maintenance, repairs or any other
troubleshooting or service is being performed, it’s
important to remember that hydraulic system - including
both the interior and exterior surfaces of assemblies,
and every drop of operating fluid - must be protected
from contamination.
Dust and other foreign contaminants are major
contributors to premature wear in hydraulic circuits.
The narrow tolerances, rapidly moving parts and high
operating pressures of the system require that fluid
be kept as clean as possible. The performance and
dependability of the machine (and the service lift of
individual components) can be noticeably reduced if
proper precautions are not observed:
● Use a noncombustible, evaporative type, low residue
solvent and thoroughly clean exterior surfaces of

assemblies before any part of the circuit is opened
or disassembled.
NOTE: It’s just as important to clean the cap and reservoir
top before routine fluid changes or quick checks
as it is before major repairs.
(Accumulated dirt attracts moisture, oil and
other fluids - and more dirt.)
● Keep dismantled parts covered during disassembly.
Use clean caps, plugs or tape to protect the
disconnected openings of flanges, manifolds and
piping.
● Do not allow cleaning solvents or other fluids to mix
with the oil in the system. Use clean oil to flush any
traces of solvent or other residue before reassembly.
● If metal or rubber fragments are found in the
system, flush and replace all fluid in the system

and troubleshoot the circuit to identify the source of
contamination.
IMPORTANT
Make sure that cleaning solvents will be compatible
with rubber materials used in the hydraulic system.
Many petroleum based compounds can cause
swelling, softening, or other deterioration of system
sealing elements, such as O-rings, caps and other
seals.

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

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

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

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

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

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

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

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

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

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

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

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

Upper Structure
DX140AF/DX140LCA Cabin 4-1

Cabin

ＭＥＭＯ

Table of Contents
Cabin
REMOVAL................................................................... 7
INSTALLATION......................................................... 13
COMPLETING WORK............................................... 13
DIMENSIONS OF CABIN GLASS............................. 14
REMOVAL AND INSTALLATION OF CABIN GLA
SS............................................................................18
Removal of Cabin Glass................................... 18
Installation of Cabin Glass................................ 20
Installation of Upper Door Glass....................... 25
Installation of Upper Front Glass...................... 25

SAFETY INSTRUCTIONS
WARNING
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 roll-over and falling objects,

REMOVAL
1. Make the machine swing about 15 ~ 20° rightward
on the flat ground as shown in Figure 1 before
lowering the bucket on the ground and then stop
engine.
EX1301714
Figure 1
O ACC
2. M ove safety lever to “RELEASED” (UNLOCK) I
position. (Figure 2)
3. Turn starter switch to “I” (ON) position.
LOCK
WARNING OFF OFF
ON
ON
ON OFF
If engine must be running while performing
EX1500510
maintenance, always use extreme caution. Always
have one person in the cabin at all times. Never leave Figure 2
the cabin with engine running.
4. To relieve pressure from accumulators, fully stroke

work levers in all directions. Movement can occur.
5. Move safety lever to “LOCK” position. (Figure 2)
6. Turn key to “O” (OFF) position and remove from
ON
starter switch.
7. Attach maintenance warning tag on controls.
(Figure 3) OFF
EX1500045
Figure 3

NOTE: Removal (installation) procedure of the bolts.
3
5 8
1 2
7 6
4
EX1401809
Figure 4
9. Remove bolts and washers (1, Figure 5) (7 ea) with

under cover (2) on bottom of main frame.
●Tool: 19 mm ( )
●Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
●Under cover weight: 10 kg (22.05 ft lb)
Figure 5 Bottom of Main Frame
10. Disconnect washer hose.
Figure 6 Bottom of Cabin
11. Remove floor mat from the cabin.
EX1402315
Figure 7

13. Remove duct covers (1 and 2, Figure 9).
1 2
WE1400435
Figure 9
14. Disconnect wiper, monitor, sun sensor and hour

meter connectors.
NOTE: Control console wiring harnesses and hydraulic
piping lines that pass through the floor of the
cabin do not need to be disassembled.
NOTE: If cabin is equipped with additional protective
guards over cabin openings, they must be
removed.
WE1400436
Figure 10
15. Remove air ducts (1 thru 6, Figure 11) on right-

hand side of operator’s cabin. 5
3
4
1
WE1400437
Figure 11

16. Remove glove box pad (1, Figure 12).
Remove all the bolts and cover
Figure 12
17. R emove air ducts (1 thru 3, Figure 13) and

atmospheric air duct (4).
1
2 4
3
WE1400439
Figure 13
18. R emove all bolts (1, Figure 14) (17 ea) with
brackets (2 thru 4) from body of operator cabin. 2
3
● Tool: 13 mm ( )
● Torque: 19.6 N.m (2 kg.m, 14.5 ft lb) 1
4
WE1400440
Figure 14

19. Disconnect connectors of interior lights, speakers
and antenna.
WE1400441
Figure 15
20. Using a suitable lifting device, attach slings to four

lift points on top of cabin (Figure 16)
● Lifting hole size: M12 x 1.75, depth: 15 mm
● Cabin weight: about 485 kg (1,069 lb)
Figure 16
21. Remove bolts and washers (1, Figure 17) (11 ea).
● Tool: 19 mm ( )
1 1
2
22. Remove nuts and washers (2) (4 ea) from cabin 1 1
2 1 2
floor.
1 1
● Tool: 24 mm ( )
● Torque: 205.9 N.m (21 kg.m, 151.9 ft lb)
WE1400443
Figure 17

IMPORTANT
Lift cabin approximately 25 ~ 50 mm (1” ~ 2”) above
deck. Check that all electrical connections have been
disconnected and all other items unbolted.
Continue lifting with assist crane to remove cabin
shell. Lower shell to a prepared safe blocking support.
Do not rapidly lift operator’s cabin: The bottom of
operator’s cabin may come into contact with, and WE1400445
scratch, control stand cover. Figure 19

INSTALLATION
1. Using a suitable lifting device, attach slings to four (4)
lift points on top of cabin (Figure 20).
● Cabin weight: 485 kg (1,069 lb)
2. Lower cabin into position on cabin floor.

3. I nstall mounting nuts (Figure 21) (4 ea) and
washers in four corners of cabin floor.
● Tool: 24 mm ( ) WE1400445

Figure 20
Perform installation in the reverse order to removal.
WE1400446
Figure 21
COMPLETING WORK
1. Start the engine and run at low idle for about 5
minutes.
2. Perform the machine performance test.

DIMENSIONS OF CABIN GLASS
Front Glass
Figure 22
NOTE:Unit: mm (1 mm = 0.039 in)

Left Glass
Figure 23

Rear Side Glass
Figure 24

Right Glass
Figure 25

REMOVAL AND INSTALLATION
OF CABIN GLASS
Removal of Cabin Glass
Procedures to remove right-hand glass (1, Figure 26),
rear left, glass, lower door glass and rear glass. 1
CAUTION
AVOID INJURY
When removing the broken or cracked glass, the glass
shards can cause serious injury.
Before removing, use tape to hold the broken or
cracked glass together. Figure 26
1. R emove resin panel, garnish or etc. around the

glass.
3
Reference 1
Description
Number
1 Garnish 4
2 Lower Glass of Door 2
3 Rear Glass
4 Rear Left-hand Glass 5
5 Resin Panel
Figure 27
2. Prick a hole in the adhesive by using an awl (or

1 2
cutter knife).
3
Reference
Description
Number
1 Cabin
2 Cabin Glass
3 Awl
4 Adhesive 4
EX1301298
Figure 28

3. Pass a piano wire (1, Figure 29) (or a wire) through
the hole.
EX1301299
Figure 29
4. W i n d b o t h e n d s o f t h e p i a n o w i r e o n t o t w o Cabin Outside
screwdrivers. 1 2
Draw the wire back and forth to cut the adhesive (3,
Figure 30) between cabin (1) and glass (2).
Remove glass (2, Figure 30) from the cabin (1).
NOTE: Piano wire is easily broken. If a part of the piano
wire turns hot, change the position of the wire and
continue cutting the adhesive. Cabin Inside 3
EX1301300
Figure 30

Installation of Cabin Glass
1
Procedures to install right-hand glass (1, Figure 32),
rear, lefthand glass, lower door glass and rear glass.
2
1. Cut off the remaining adhesive leaving a layer of
old adhesive 1 - 2 mm thick (Figure 31). The new
adhesive will bond to the remaining adhesive.
Cut off Adhesive
NOTE: Do not damage the cabin paint. by 1 - 2 mm Deep
Reference EX1301302
Description
Number
1 Cabin Figure 31
2 Knife
Figure 32
2. Clean the remaining adhesive and metal surfaces

with a general purpose adhesive cleaner.
3
Reference
Description 1
Number
1 Garnish
2 Lower Glass of Door 4
2
3 Rear Glass
4 Rear Left-hand Glass 5
5 Resin Panel
Figure 33
IMPORTANT
Primer must be shaken for about 1 minute and mix
thoroughly before opening the cap.
After opening primer, apply primer as quickly as
possible and replace the cap immediately after using.
After opening primer, all the contents must be used
within 180 days (or 2 hours with the cap off).

3. Apply the damper on cabin body before applying
adhesive.
Damper - Front Upper Glass
787
Length: about 3,530 mm
Adhesive Sides 5
975
5
Section A - A
EX1301354
Figure 34
Damper - Rear Glass
758
Adhesive Sides 5
573
A
Section A - A
EX1301355
Figure 35

Damper - Right-hand Glass
1,492
A
Adhesive Sides 5
1,376
7
Section A - A
EX1301356
Figure 36
Damper - Lower Glass of Door
800
7
184
A
329
R4,329
Adhesive Sides
429
5
R94
606 Section A - A
685
EX1301357
Figure 37
Damper - Rear Left-hand Glass
A
Adhesive Sides
5
Section A - A
EX1301358
Figure 38

4. Clean the mating edge of new glass by using clean
rag and ethylalcohol.
IMPORTANT
Primer (Sika Primer W06G+P) must be shaken for
about 1 minute and mixed thoroughly before opening
the cap.
After opening primer, apply primer as quickly as
possible and replace the cap immediately after using.
After opening primer, all the contents must be used
within 180 days (or 2 hours with the cap off).
5. Using application brush, apply primer for glass (Sika

Primer W06G+P) to the layer of old adhesive from
1
step 1.
Wait for about 15 minutes to let it dry.
2
(Refer to position to apply primer (2, Figure 39).)
NOTE: The painting primer must be applied evenly to 3
leave no blemishes.
Reference
Description EX1301303
Number
1 Cabin Figure 39
2 Application Brush
3 Layer of Old Adhesive on Cabin
6. Cut off the nozzle of adhesive cartridge (Sika Tack-

Drive) into V-shaped by using a knife. (Refer to
page -21.)
7. R emove seal of cartridge. Install the V-shaped
nozzle.
8. Install the cartridge to the manual caulking gun.
9. Apply adhesive to the adhesive position at cabin
side so bead triangle will be even.
(Refer to position to apply adhesive (3, Figure 39).)

Required
Cut Nozzle Required

End into
V-shaped
Adhesive
Apply Bead Here
Application bead
should form
9 even triangle.
12 Remove Seal
Adhesive Cartridge
Panel
EX1401037
Figure 40
NOTE: Unit: mm (1 mm = 0.039 in)
10. T he required amount (just for reference) of

adhesive and primer.
Painted Surface or
Glass Surface
Adhesive Surface
Adhesive Sika
Primer Sika Activator Primer Sika Primer
Tack-drive 310 ml
DM-1 250 ml Can 206G+P 30 ml Bottle
Cartridge
Upper Front Glass 310 ml 0.75 ml 0.67 ml
Lower Glass of Door 150 ml 0.50 ml 0.45 ml
Rear Left-hand Glass 250 ml 0.65 ml 0.60 ml
Rear Right-hand Glass 100 ml 1.00 ml 0.90 ml
Rear Glass 210 ml 0.50 ml 0.45 ml

Installation of Upper Door Glass
1. Before installing the glass, remove garnish (2, 1
Figure 41) around sash assembly (1) from the cabin 2
inside for easy removal. Push the sash assembly 3
by hands and remove sash outside. 4
2. Install glass (3, Figure 41) and glass (4) into the
sash grooves.
3. Install the sash assembly, which the glass is
installed on, onto the door from the outside of cabin.
Secure the sash assembly at the inside of cabin by Figure 41
using the garnish.
Installation of Upper Front Glass

1. Stick seal to the lower side of front upper glass by
using Cemedine SIKAFLEX 255 ultrafast.
Stick and secure both right and left ends (the
thicker part) of seal to the glass by using Cemedine
SIKAFLEX 255 ultrafast.
Stick the mating surface of seal and the glass by
using Cemedine SIKAFLEX 255 ultrafast so no
visible undulation or boss can be found.
NOTE: Cemedine SIKAFLEX 255 ultrafast Glue-state
adhesive, tubed.
Reference
Description
Number
1 Upper Glass
2 Seal
3 Lower Glass
1
4 Damper
Apply Silicone after 4
Fixing 2 (Seal)
Fill with Sealant

2
3
EX1301304
Figure 42

Counterweight
DX140AF/DX140LCA Counterweight 4-26

ＭＥＭＯ

Table of Contents
Counterweight
SAFETY INSTRUCTIONS......................................... 29
GENERAL................................................................. 30
Warning for Counterweight and Front Attachment
Removal............................................................ 30
REMOVAL................................................................. 32
INSTALLATION......................................................... 33

SAFETY INSTRUCTIONS
WARNING

GENERAL
Warning for Counterweight and Front
Attachment Removal
WARNING
DOOSAN warns any user, that removal of the
counterweight from the machine, front attachment
(boom and arm) or any other part, may affect the
stability of the machine. This could cause unexpected
movement, resulting in death or serious injuries.
EX1401352
structure.
Never rotate the upper structure once the Figure 1
Before any attempt is made to begin removal or

installation of the counterweight, the excavator must
be parked on a firm and level supporting surface,
with no sloping surfaces or soft or muddy ground in
the area where the assist lift crane will be working.
Position all accessories in the overnight storage
position.
WARNING
The weight of counterweight is given in the following
table.
Use only rated and approved slings and hardware
when removal or installation lifts are being made.
Lifting slings, shackles and all other hardware must
be rigged safely. An assist crane that is rated above
weight capacity is required.
● Weight: 2,200 kg (4,850 lb)

Responsibility must be assigned to one person to be
in charge of the lifting crew, and to verify that required
safe lifting precautions have been taken before each
part of this procedure has been started.
All members of the working crew should know and
understand the signals that will be used between
the lifting leader, the assist crane operator and the
remainder of the work crew.
WARNING
If the upper structure deck has been unbalanced by
removal of weight from one end only, traveling with
the excavator, swinging the turntable, movement over
bumps or sloping and uneven surfaces could cause
loss of control resulting in tipping or rollover.
To maintain stability the counterweight must be

removed only when the front attachment is taken off
the machine.
90 - 110
15
EX1300746
Figure 2
When loading an excavator (either track or wheeled

type) on a trailer for transport after the front
attachment has been removed, always go backwards
up the loading ramp with the counterweight uphill
(Figure 3).
15
EX1300747
Figure 3

REMOVAL
WARNING O ACC
I

Death or serious injury can occur from a counterweight
falling during removal or installation. Do not allow LOCK
personnel under or around the counterweight during
removal or installation.
OFF OFF
ON
ON
Use certified cables and shackles of adequate load
rating.
ON OFF
Improper lifting can allow the load to shift and cause
EX1500510
Figure 4
1. Park on firm and level ground.
2. Lower front attachment (bucket) to ground.
3. Stop engine.
4. Move safety lever to “UNLOCK” position.
1
WARNING 5

maintenance, use extreme care. Always have one
person in the cabin at all times Never leave the cabin
with the engine running.
6. Fully stroke work levers (joysticks) in all directions

to relieve any pressure from accumulators.
7. Move safety lever to “LOCK” position.
8. Turn key to “O” (OFF) position and remove from 4
starter switch.
3
9. Attach maintenance warning tag on controls.
2
11. Make sure all electrical lines and other items are
disconnected. EX1404761
12. Using a suitable lifting device capable of handling
a heavy load, partially support counterweight from Figure 5
lifting holes (5, Figure 5), counterweight (1) before
loosening four bolts (2).
Stop lifting with assist crane as soon as lifting
slings are taut.
13. Remove four bolts (2, Figure 5) and washers (3)
from counterweight (1, Figure 5).
● Tool: 41 mm ( )
● Weight: 2,200 kg (4,850 lb)
NOTE:Heat bolts, if necessary, to free them.

14. When bolts (2, Figure 5) and washers (3) have
been removed, lift counterweight (1) a very short
distance above support frame (4) and stop. Check
slings and make sure counterweight is being
supported evenly.
INSTALLATION
1. Using suitable lifting device capable of handling the
weight of the counterweight, support counterweight
from lifting holes (5, Figure 6). Raise counterweight
1
(1) into position just above support frame (4) leaving
counterweight suspended. Verify that counterweight 5
is level and even.
NOTE: Leave counterweight (1, Figure 6) suspended 3
mm (0.125”) above support frame (4) until all four
mounting bolts (2) are started in counterweight
mounting holes.
2. Slide washers (3, Figure 6) onto bolts (2). Apply
Loctite #242 to mounting bolt threads.
3. Install four bolts (2, Figure 6) with washers (3) into
4
counterweight until washers contact support frame.
3
Fully lower counterweight onto support frame and
finish tightening bolts. 2
● Tool: 41 mm ( )
● Torque: 1,128 N.m (115 kg.m, 832 ft lb) EX1404761
4. R emove lifting device and lifting eyes from Figure 6

counterweight lifting holes. (5, Figure 6)
5. Make sure all electrical lines and other items are
connected.
6. Turn battery disconnect switch to “ON” position.

Swing Bearing
DX140AF/DX140LCA Swing Bearing 4-34

ＭＥＭＯ

Table of Contents
Swing Bearing
GENERAL................................................................. 38
General Description.......................................... 38
Parts List........................................................... 38
MAINTENANCE GUIDELINES.................................. 39
DISASSEMBLY......................................................... 40
REASSEMBLY.......................................................... 42

SAFETY INSTRUCTIONS
WARNING

GENERAL
General Description
The swing bearing, which connects the upper structure
with the lower structure, consists of a inner ring, outer
ring and ball bearings. During swing movement, power
from the swing motor is transferred to the pinion by
planetary gears connected to gears on the inner ring,
which is fixed in the undercarriage. Ball bearings turn
the outer ring.
Parts List
Figure 1
Reference Reference
Description Description
Number Number
1 Outer Ring 5 Ball
2 Inner Ring 6 Retainer
3 Tapered Pin 7 Seal
4 Plug

MAINTENANCE GUIDELINES
Operating Recommendation
The service life of the swing bearing may be extended
if a 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. Repositioning the
excavator during the work shift, to work the opposite
end of the bearing, will provide a more even and EX1302041
gradual rate of wear and extended service life.
Figure 2
Measuring Swing Bearing Axial Play
Regular checks of bearing displacement must be
made at least twice a year. Use a dial indicator.
With the arm cylinders fully retracted and the bucket
cylinders fully extended, position the arm tip pin height
is flush with the boom foot pin height. (Figure 3)
Push the attachment against the ground to lift up the
excavator above the ground and take measurements
at 4 points, 90° apart, around the circumference of the The height as the
bearing. boom foot pin height.
Record and keep all measurements. Play in the
bearing should increase minimally from one inspection EX1301770
to the next.
Figure 3 Measurement (h1)
Eventually, however, as the bearing begins to
approach the limit of its service life, clearance
increases become much more pronounced and the
actual measured play in the bearing could exceed
twice the value that was measured when the machine
was new.
Measuring Bearing Lateral Play

When vertical checks are made, the side to side play
in the bearing can be checked by fully retracting the
arm and bucket cylinders and extending the tip of the
bucket as far forward as it will go. With the excavator
parked on a flat, level surface and the bucket tip just
off the ground, push against the bucket sideways to EX1301780
take up all the lateral clearance in the bearing. (Less
than 100 lb of force must be required to move the Figure 4
bucket over all the way.) Check lateral play in both
directions and record the values.
When the bearing is beginning to approach the end of
its service life, the measured lateral clearance should
start to show increase in value.

DISASSEMBLY
1. R emove tip of tapered pin (3, Figure 5) using
grinder and tap lightly to remove debris.
Figure 5
2. Remove plug (4, Figure 6) using a M10 x P 1.5 bolt.
Figure 6
3. Lift outer ring and check that inner ring can move
freely. See Figure 7, if not, replace seal (7, Figure 8).
●Weight: 205 kg (452 lb)
WE1401490
Figure 7
4. Turn inner ring and use magnet bar (C, Figure 8) to

remove steel balls (5).
Figure 8

5. Turn inner ring and use wire (D, Figure 9) to
remove retainers (6).
Figure 9

REASSEMBLY
1. Clean (degrease) the seal groove for the outer and
inner seals (7).
Apply instant glue to seal (7).
Install both seals respectively into position.
Figure 10
2. Hoist the outer race by crane horizontally and

match it with the inner race coaxially.
Rotating the outer race, insert balls (5), support (6)
into the plug (4) hole one by one with a round bar.
Figure 11
Figure 12
3. Top plug (4) into outer race (1) and then, drive pin (3)
into the pinhole.
Caulk the head of pin (3) with a punch.
Fill grease through the grease fitting.
Figure 13

Lower Structure
and Chassis
DX140AF/DX140LCA Track Assembly 5-1

Track Assembly

ＭＥＭＯ

Table of Contents
Track Assembly
GENERAL................................................................... 6
TRACK TENSION....................................................... 7
TRACK SHOES AND LINKS....................................... 9
Parts List............................................................. 9
Track Removal.................................................. 10
Track Installation............................................... 12
Wear Limits and Tolerances............................. 13
SPROCKET............................................................... 15
FRONT IDLER........................................................... 16
Overview........................................................... 16
Parts List........................................................... 17
Front Idler Disassembly.................................... 18
Front Idler Reassembly..................................... 19
UPPER ROLLER....................................................... 22
Overview........................................................... 22
Parts List........................................................... 23
Upper Roller Removal...................................... 24
Upper Roller Disassembly................................ 24
Upper Roller Reassembly................................. 26
LOWER ROLLER...................................................... 28
Overview........................................................... 28
Parts List........................................................... 29
Lower Roller Removal...................................... 30
Lower Roller Installation................................... 30
Lower Roller Disassembly................................ 31
Lower Roller Reassembly................................. 32
TRACK ADJUSTER.................................................. 34
Parts List........................................................... 34
Disassembly..................................................... 35
Assembly.......................................................... 36

SAFETY INSTRUCTIONS
WARNING
GENERAL
The track assembly is composed of the following
major
components:
1. Track
2. Front Idler
3. Upper Roller
4. Lower Roller
5. Track Spring and Track Adjuster

TRACK TENSION
WARNING
Measuring track tension requires two people. One person must
be in the operator’s seat, operating the controls while the other
person makes dimensional checks. Block frame to make sure
the machine won’t move or shift position during service. Warm
up the engine to prevent stalls, park the excavator in an area
that provides level, uniform ground support and/or use support
blocks when necessary.
Track shoe link pins and bushings wear with normal

usage, reducing track tension. Periodic adjustment is
necessary to compensate for wear and it may also be
required by working conditions.
1. Track tension is checked by jacking up one side of
the excavator. See Figure 1. Place blocking under
frame while taking measurement.
90 - 110
Turn the track backward 1 ~ 2 turns.
EX1500011
Figure 1
2. Measuring the distance (A, Figure 2) between the
bottom of the side frame and the top of the lowest
crawler shoe.
Recommended tension for operation over most types
of terrain is distance “B” on below table.
NOTE: C l e a n o f f t h e t r a c k s b e f o r e c h e c k i n g
clearance for accurate measurements. A
3. T oo little sag in the crawler track (less than
clearance distance “B” on below table) can cause
excessive component wear. The recommended
FG000223
adjustment can also be too tight causing
accelerated stress and wear if ground conditions Figure 2
are wet, marshy or muddy.
4. The increased clearance recommended for muddy,
sandy or snowy ground conditions is between
distance “C” on below table.

Terrain Type Distance “A”
Normal “B” 265~280
Muddy, Sandy or Snowy “C” 280~310
WARNING
The track adjusting mechanism is under very high-pressure.
NEVER release grease pressure too fast. The track tension
grease valve should never be loosened more than one (1)
complete turn from the fully tightened down position. Bleed off
grease pressure slowly. Keep your body away from the valve
always. Always wear eye and face protection when adjusting
track tension.
5. Track tension adjustments are made through the

grease fitting (1, Figure 3) in the middle of each 2
side frame. Adding grease increases the length of

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

TRACK SHOES AND LINKS
Parts List
1-1
1
1-1A 1-1D
1-1B
1-1H 1-1A
1-1F
1-1H
1-3
1-1G
1-1E
1-1G
1-1B
1-3 1-1C
1-4
FR
ON
T
1-2
1-2 TRACK FRAME
3
4
EX1500012
Figure 4

Reference Reference
Number Number
1 Track Shoe Assembly 600g 1-1G Seal; Dust
1-1 Link Assembly, Track 1-1H Spacer
1-1A A Link - RH 1-2 Bolt
1-1B B Link - LH 1-3 Nut
1-1C C Pin; Regular 1-4 Shoe 600 mm
1-1D D Pin; Master 2 Step
1-1E Bushing; Regular 3 Washer; Spring
1-1F Bushing; Master 4 Bolt
Track Removal
1. Position machine on a smooth level surface with
adequate room for forward and reverse travel.
EX1301081
Figure 5
2. M ove machine until master pin (4, Figure 6) is

positioned at approximately 4 o’clock from top
position on front idle roller.
3. Put a wooden block under track shoes, as shown.
1
2
4
EX1500013
Figure 6
4. Loosen valve (1, Figure 7) for track adjuster to drain
grease out. Use socket wrench 27 mm
NOTE: L
oosen carefully, keeping face, hands, body
away from the valve and nipple. Do not
loosen valve Quickly. 1
5. Remove four nuts and bolts (1 and 2, Figure 6)
holding shoe to link. Remove enough shoes to
make access to master pin.
6. Remove master pin from master link by hammer or
EX1500020
press. Remove pin after detaching shoe.
Figure 7

7. M ove unit forward until entire track is laying on
ground.
NOTE: D
o not drive unit off track.
FG003911
Figure 8
8. R otate upper structure to 90° from track. Use

bucket and boom to raise track frame off track.
9. Position blocking under frame.
90 - 110
EX1500011
Figure 9

Track Installation
1. Lay rebuilt or new track into position under track
frame.
90 - 110
End of track must be positioned under drive
sprocket.
2. W ith upper structure at 90° to track frame. Use
bucket and boom to raise track frame off blocking.
3. W ith blocking removed, lower track frame onto
EX1500011
track. Make sure all rollers are properly positioned
on track. Figure 10
4. M ove unit forward while feeding track up over

drive sprocket. Continue to pull track back until it
engages front idle roller.
5. Align master links and install master pin.
6. Install four nuts and bolts (to fix track shoe).
7. Apply track tension. Refer to ?$paratext>? on page
-6” in this section for procedure.
FG003912
Figure 11

Wear Limits and Tolerances
H J
B B
G G
I K
A
C
F
D E EX1500114
Figure 12

Limit for Use
Recommended Limit
No. Check Item Standard Dimension (Repair - P or
for Maintenance
Replace - R)
A Link Pitch 171.45 mm (6.752”)
Bushing Outside 47.0 mm [R]
B 53.85 mm (2.120”) 50 mm (1.969”)
Diameter (1.850”)
85 mm [P]
C Link Height 94.5 mm (3.720) 89 mm (3.504”)
(3.346”)
D Length at Tip 17 mm (0.669”)
E Length at Tip 11 mm (0.433”)

18 mm
F Height 25 mm (0.984”) 20 mm (0.787”)
(0.709”)
Standard Repair
Interference Bushing Tolerance Link Tolerance
Interference Limit
G between
53.85 mm +0.24 53.5 mm +0.05
bushing and link 0.26 ~ 0.39
(2.120”) -0.04 (2.106”) 0.0
Regular Standard Repair
Interference Tolerance Link Tolerance
Pin Interference Limit
H between
36.65 mm +0.05 36.35 mm +0.05
regular pin and link 0.25 ~ 0.35
(1.443”) 0.0 (1.431”) 0.0
Regular Standard Repair
Clearance between Tolerance Bushing Tolerance
Pin Clearance Limit
I regular pin and
36.65 mm +0.05 37 mm +0.4
bushing 0.3 ~ 0.75
(1.443”) 0.0 (1.456”) 0.0
Standard Repair
Interference Master Pin Tolerance Link Tolerance
Interference Limit
J between
36.55 mm +0.03 36.35 mm +0.05
master pin and link 0.15 ~ 0.23
(1.439”) 0.0 (1.431”) 0.0
Standard Repair
Clearance between Master Pin Tolerance Bushing Tolerance
Clearance Limit
K master pin and
36.55 mm +0.03 37 mm +0.4
bushing 0.42 ~ 0.49
(1.439”) 0.0 (1.456”) 0.0

SPROCKET
A E
D
C
B
Travel Device
EX1500115
Figure 13
No. Check Item Standard Allowable Limit Limit for Use

Dimension for Maintenance (Repair - P or Replace - R)
A Tooth Width 57 mm - -
(2.2”)
B Tooth Bottom Surface 104.7 mm 101.5 mm 100.5 mm (R)
(4.12”) (3.99”) (3.95”)
C Pitch Circle Dimension 131.8 mm - -
(5.18”)
D Tooth Top Land 135.5 mm 133 mm 131.1 mm (R)
(5.33”) (5.23”) (5.16”)
E Accumulated Pitch 171.5 mm - -
Tolerance (6.75”)
● Weight: 35 kg (77 lb)

FRONT IDLER
Overview
489
454
244.5
159
4 - M16 x 2.0
68
135
260
325
EX1500116
Figure 14
Note: Unit: mm (1 mm = 0.039 in)

Parts List
FR
ON
T
5
5-2
5-2G
5-2H
5-2F
5-2A 5-2E
5-2D
5-2B
5-2C
5-2D
5-2E
5-2G
5-2F
5-2H
5-2B
5-1
5-4
5-3
EX1500014
Figure 15

Reference Reference
Number Number
5 Adjuster Assembly, Track 5-2E Seal; Group
5-1 Adjuster; Track 5-2F O-ring
5-2 Idler Assembly 5-2G Pin
5-2A Body 5-2H Plug
5-2B Support 5-3 Bolt M16 x 2.0 x 45
5-2C Shaft 5-4 Washer; Harden
5-2D Bushing
Front Idler Disassembly

1. Detach track spring assembly from Idler assembly.
Remove 4-M16 bolts and washers (10 and 11,
Track Spring
Figure 16). Assembly
● Tool: 24 mm ( )
2. Remove plug (8, Figure 17) from the support (4,
Figure 17). 10, 11 Wrench
Tool: 6 mm (
● )
NOTE: A
bout 330 cc of oil will be discharged. Idler Assembly
Prepare an oilcloth or pan to prevent spillage EX1500015
on the ground. Figure 16
3. Using a hammer and pin-removing tool, remove pin

(7, Figure 17) on one side. Hammer
4. Remove support (4, Figure 17) on the side from Pin Removing
Tool
which the pin (7, Figure 17) has been removed.
4
7
8
EX1500016
Figure 17
5. From the removed support (4, Figure 18) and front

(1, Figure 18), separate the floating seal (5, Figure
18). 1
4
EX1500017
Figure 18

6. From the shaft (3, Figure 19), separate the O-ring 3
(6, Figure 19).
Note: If the O-ring is not removed, the bearing
subassembly on the opposite side will be 6
difficult to separate.
7. Separate the shaft (3, Figure 19) from the support
(4, Figure 19).
8. Separate the O-ring (6, Figure 19) from the shaft
4 EX1500018
(3, Figure 19).
Figure 19
9. Separate the bushing (2, Figure 20) from the front Press Bushing
(1, Figure 20). Removing Jig 1
Note: Insert jig 2, and press jig 1 to separate. Use
1
the hydraulic press for pressing the jig. Be
careful of sputtering.
10. Turn the front upside down. Separate the bushing
(2, Figure 20) in the same manner as described Bushing
2
above (Figure 20). Removing Jig 2
FG022549
Figure 20
Front Idler Reassembly

2 1
1. Take care that foreign materials do not enter the Bushing
front part. Wash all parts for assembly. Insertion Jig 2
2. Using the hydraulic press, assemble two bushings
Press Bushing
(2, Figure 21) at front (1, Figure 21). Insertion Jig
Use the hydraulic press. Take care to prevent Press
accidents.
Note: Apply a volatile lubricant on the bushing surface
before insertion. FG022550
There must be no dent marks on the flange. Figure 21
3. A ssemble two supports (4, Figure 22) with the

Floating Seal
floating seal (5, Figure 22). Assembling Jig
In order not to twist the O-ring, use assembling jig 5
to assemble the floating seal, as shown in Figure
4
22. Check that floating seal is parallel. Clean up its
lapped surface.
FG007847
Figure 22

4. On one side of the shaft (3, Figure 23), assemble
6
the Oring (6, Figure 23) applied with thin oil (Figure
3
23).
5. Assemble the shaft (3, Figure 23) with the support
to which floating seal has been attached.
6. Insert pin (7, Figure 23)into the bearing on which 4
the shaft has been assembled.

7
EX1500019
Figure 23
7. Using the assembling jig, assemble floating seal
(5-2E, Figure) at the front on which bushing has
been assembled.
8. Apply oil to the lapped surface of the floating seal
(5-2E, Figure ) which was assembled with the
bearing.
NOTE: Use gear oil (ISO VG 220EP) or higher
grade.
9. Assemble bearing subassembly with the front to
which the bushing and floating seal have been FG022552
assembled (Figure 24).
Figure 24
10. Assemble shaft (3, Figure ) with O-ring (6, Figure ).

Apply oil to O-ring to prevent damage when Hammer
assembling bearing.
7
11. Assemble the support (4, Figure 25) on which the
floating seal has been assembled. 4
12. Insert pin (7, Figure 25).
8
13. Rotate bearing 3 rounds to left and right.
14. Install plug (8, Figure 25) to the support (4, Figure
25) on one side. FG022553
● Tool: 6 mm ( )
Figure 25
15. Inject oil through the plug hole.

NOTE: Oil quantity: 320 cc (10.8 oz) ±20 cc
16. Assemble idler assembly with track spring Track Spring
Assembly
assembly (Figure 26).
Install bolt and washer (10 and 11, Figure 26).
NOTE: Apply Loctite #243 to the bolt and washer (10
10, 11 Wrench
and 11, Figure 26).
● Tool: 24 mm ( ) Idler Assembly
EX1500015
Figure 26

D
C
E
G
A
B
EX1501419
Figure 27
Limit for Use

Recommended Limit
for Maintenance
Replace - R)
Outside Diameter of
A 489.2 mm (19.260”)
Flange
Outside Diameter of
B 454 mm (17.874”) 443 mm (17.441”)
Tread
C Width of Protrusion 68 mm (2.677”)
D Total Width 135 mm (5.315”)
E Width of Tread 33.5 mm (1.319”) 39 mm (1.535”)

Standard Repair
Shaft Tolerance Bushing Tolerance
Clearance between Clearance Limit
F
shaft and bushing 75 mm -0.06 75 mm 0.4
0.4 ~ 0.9
(2.953”) -0.09 (2.953”) 0.34
Standard Repair
Interference Idler Tolerance Bushing Tolerance
Interference Limit
G between
82 mm +0.035 82 mm 0.19 0.095 ~
idler and bushing
(3.228”) 0 (3.228”) 0.13 0.19

UPPER ROLLER
Overview
243.5
69 98.5
140
120
EX1500118
Figure 28

Parts List
FR
ON
T
8-2
8-6
8-14
8-3
8-8
8-1
8-4
8-11 TRACK FRAME
8-10 8-7
8-9
8-13
8-12
8-5
EX1500021
Figure 29
Reference Reference
Number Number
8 Roller Assembly, Upper 8-8 Bolt M8 x 1.25 x 20
8-1 Body, Roller 8-9 Plate
8-2 Shaft, Roller 8-10 Bolt M10 x 1.5 x 25
8-3 Bushing; (A) 8-11 Washer, Spring
8-4 Bushing; (B) 8-12 Plug
8-5 Cover, Upper 8-13 O-ring
8-6 Ring, Thrust 8-14 Seal, Floating
8-7 Washer, Plain

Upper Roller Removal
1. Relieve track tension. This will allow track to be
raised so links clear top of roller.
2. P osition a bottle jack on top of track frame and
apply pressure to track shoe.
3. Remove mounting hardware holding upper roller
assembly to track frame.
FG022578
WARNING Figure 30

The track adjusting mechanism is under very highpressure.
NEVER release grease pressure too fast.
The track tension grease valve should never be loosened
more than one (1) complete turn from the fully tightened down
position. Bleed off grease pressure slowly. Keep your body away
from the valve always. Always wear eye and face protection when
adjusting track tension.
Upper Roller Disassembly

1. Remove plug (12, Figure 31) from the cover and
drain oil.
12 EX1500022
Figure 31
2. Remove bolts (10, Figure 32) and cover (5).

Remove bolts (8, Figure 32), plate (9) and washer 7
9
(7). 8
5
10
EX1500023
Figure 32

3. Separate the roller (1, Figure 33) from the axle (2). 2
1
FG022581
Figure 33
4. Separate the floating seal (14, Figure 34) from the 1

roller.
5. Separate the thrust ring (6) from the axle.
2
14
6
EX1500024
Figure 34
6. Separate the bushing (3 and 4, Figure 35) from the

roller with a press and special tool.
EX1500025
Figure 35

Upper Roller Reassembly 3
1
1. D e g r e a s e , c l e a n a n d d r y a l l p a r t s b e f o r e
4
reassembly.
Insert bushing (3 and 4, Figure 36) into the roller (1).
EX1500026
Figure 36
2. Insert floating seal (14, Figure 37) into the roller (1) 1
and bushing.
NOTE: A pply clean gear oil (ISO VG 220EP) to the 2
joint side of the floating seal. Apply grease to
the floating seal O-ring. 14
3. Install the axle (2, Figure 37) and thrust ring (6). 6
EX1500027
Figure 37
4. Install washer (7, Figure 38), plate (9) and bolt (8).
● Tool: 13 mm ( )
7
8
5. Insert the O-ring (13, Figure 38) to the cover (5). 13
5
Attach cover (5, Figure 38) and bolt (10) to the
10
roller.
● Tool: 17 mm ( )
● Torque: 63.7 N.m (6.5 kg.m, 47 ft lb)
12 EX1500028
6. Fill with gear oil (ISO VG 220EP) with 60 (2 oz) ±5
cc. Figure 38
7. Tighten plug (12, Figure 38).

D C E
B
A
G
F
EX1500029
Figure 39
Limit for Use

Recommended Limit
for Maintenance
Replace - R)
Outside Diameter of
A 140 mm (5.512”)
Flange
Outside Diameter of 112 mm
B 120 mm (4.724”)
Tread (4.409”)
C Width of Tread 69 mm (2.716”)
29 mm
D Width of Flange 25.5 mm (1.004”)
(1.142”)
31.5 mm
E Width of Flange 28 mm (1.102”)
(1.240”)
Standard Repair
Shaft Tolerance Bushing Tolerance
Clearance between Clearance Limit
F
shaft and bushing 45 mm -0.05 45.2 mm +0.05
0.25 ~ 0.33
(1.772”) -0.08 (1.779”) +0
Standard Repair
Interference Roller Tolerance Bushing Tolerance
Interference Limit
G between
53 mm +0.03 53 mm +0.1
roller and bushing 0.02 ~ 0.12
(2.087”) -0.02 (2.087”) +0.05

LOWER ROLLER
Overview
213
194
89
145
45
4- 17.5
250
286.5
EX1500128
Figure 40

Parts List
5
8
2
6
7
5
3
8 2
FG022554
Figure 41
Reference Reference
Number Number
1 Roller 5 Pin
2 Collar 6 Floating Seal
3 Shaft 7 O-ring
4 Bushing 8 Plug

Lower Roller Removal
1. Relieve track tension. Refer to “Track Tension” in
this section for procedure.
90 - 110
2. Swing upper structure at 90° to frame.
3. U sing bucket raise track off ground and place
blocking under frame.
4. Remove four bolts and lower roller assembly from
track frame. There is an alignment pin on each end
EX1500011
of lower roller assembly.
Note: To gain access to some rollers the link guard may Figure 42
have to be removed. Remove four spring washers
and bolts to remove guard.
Note: If additional track clearance is required, remove
upper rollers before raising track.
Lower Roller Installation

1. Install four bolts to hold lower roller assembly to
track frame.
90 - 110
Note: To gain access to some rollers a link guard may
have to be removed. Remove four spring washers
and bolts to remove guard.
EX1500011
Figure 43

Lower Roller Disassembly
1. R emove plug (8, Figure 44) from the collar and 5
drain oil.
2. Pull the pin (5, Figure 44) from the collar. 8
FG022555
Figure 44
3. Separate the collar (2, Figure 45) from the axle, 2
using press.
FG022556
Figure 45
4. Remove O-rings (7, Figure 46) from the axle. 1

5. S eparate floating seals (6, Figure 46) from the 6
collar and roller (1). 2
6. Remove collar (2, Figure 46) and O-rings (7) from
the axle, using press.
2
7 6
FG022573
Figure 46

Lower Roller Reassembly
1. D e g r e a s e , c l e a n a n d d r y a l l p a r t s b e f o r e
reassembly.
4
Insert bushing (4, Figure 47) into roller.
FG022574
Figure 47
2. A pply grease to the O-rings (7, Figure 48) and

5
insert into axle.
3. Align collar (2, Figure 48) and axle (3) pinholes and
pin (5) the collar. 3 2 7
FG022575
Figure 48
4. Insert floating seals (6, Figure 49) into the roller (1) 1
and collar (2). 6
Note: Apply clean gear oil (ISO VG 220EP) to the 2
joint side of the floating seal. Apply grease to
the floating seal O-ring.
5. Slide the axle inside the roller
2
7 6
FG022573
Figure 49
6. Install the collar (2, Figure 50), O-ring (7, Figure

49), and pin (5) on the remaining side.
5
7. Fill with clean gear oil (ISO VG 220EP) with
approximately 280 (9.5 oz) ±10 cc.
8
8. Install plug (8, Figure 50) on the collar.
2
FG022576
Figure 50

C D
A
B
E
F
EX1500030
Figure 51
Limit for Use

Recommended Limit
for Maintenance
Replace - R)
Outside Diameter
A 170 mm (6.692”)
of Flange
Outside Diameter 125 mm [P]
B 140 mm (5.512”) 128 mm (5.039”)
of Tread (4.921”)
44 mm [P]
C Width of Tread 36.5 mm (1.400”) 42 mm (1.654”)
(1.732”)
D Width of Flange 24.5 mm (0.965”)
Tolerance Tolerance Standard

Clearance Shaft Bushing Repair Limit
Shaft Hole Clearance
E between shaft
and bushing 50 mm -0.05 50 mm +0.24
0.25 ~ 0.32
(1.969”) -0.08 (1.969”) +0.2
Tolerance Tolerance Standard
Interference Roller Bushing Repair Limit
Roller Hole Interference
F between roller
and bushing 57 mm +0.03 57 mm +0.118 0.048 ~
(2.244”) -0.02 (2.244”) +0.078 0.138

TRACK ADJUSTER
Parts List
FR
ON
T
10
11
8
7
IDLER
4
12
13
14
EX1500044
Figure 52

Reference Reference
Number Number
1 Body 9 Pin; Spring
2 Rod, Piston 10 Bolt M10 x 1.5 x 30
3 Yoke 11 Washer, Spring
4 Spacer 12 Packing
5 Shaft 13 Ring; Backup
6 Spring 14 Seal; Dust
7 Nut * Seal Kit; Track Spring
8 Plate; Lock
*: 12, 13, 14
Press Press
Disassembly
1. A pply pressure on spring (6, Figure 53) with a
press.
10
NOTE: T
he spring is under a large installed load. 8
This is dangerous, so be sure to set properly. 7
●Spring set load: 9,220 ±685 kg (20,326 ±1,510 lb) 3
2. Remove bolt (10, Figure 53), spring washer (11) 6
and lock plate (8).
3. Remove lock nut (7, Figure 53).
NOTE: Take enough notice so that the press which
pushes down the spring, should not be
slipped out in its operation.
4. Tighten the press load slowly and remove bracket (3,
Figure 53) and spring (6).
EX1500129
Figure 53
5. Remove piston rod (2, Figure 54) from body (1).

1 2
6. Remove grease valve (21, Figure 54) from piston
rod (2).
21
EX1500130
Figure 54

7. Remove rod packing (12, Figure 55), backup ring
(13) and dust seal (14) from body (1).
1
12, 13
14
EX1500131
Figure 55
Assembly
1. Install rod packing (12, Figure 56), backup ring (13)
1
and dust seal (14) to body (1). 12, 13
Note: When installing rod packing (12, Figure 56),
backup ring (13) and dust seal (14) take full
care as not to damage the lip. 14
EX1500131
Figure 56
2. Grease into body (1, Figure 57), then push in piston

rod (2) by hand.
1 2
Note: Fill up “B” part with grease. Press fit the piston
rod (2, Figure 57) by maximum to *84 mm.
Remove air in the “B” part and the piston rod
and install the grease valve (21).
Note: If air letting is not sufficient, it may be difficult to B 21
adjust the tension of crawler. EX1500132
● Tool: 27 mm ( )
● Grease valve torque: 93.2 N.m (9.5 kg.m, 68.7 ft lb)
Figure 57
3. I nstall piston rod (2, Figure 58) to body, and

assemble spacer (4) with the shaft (5) after
3 5 4 9
assembling the shaft (5) with spring pin (9).
4. Install spring (6, Figure 58) and bracket (3) to body.
5. Apply pressure to spring (6, Figure 58) with a press
and tighten lock nut (7).
Note: Apply sealant before assembling. 2
Note: During the operation, pay attention specially to 7 6 EX1500133
prevent the press from slipping out.
Figure 58

6. Tighten the press load and confirm the set length of 6
spring (6, Figure 59).
● Length A: 400 mm (15.7 in)
A
EX1500134
Figure 59
Press Press
7. After the setting of spring (6, Figure 60), install lock
plate (8), spring washer (11) and bolt (10).
Note: Apply loctite on bolt (10, Figure 60). 10
● Tool: 17 mm ( ) 8
● Torque: 63.7 N.m (6.5 kg.m, 47 ft lb) 7
3
6
EX1500129
Figure 60
8. Install the bolt (3, Figure 61) and washer (4).

● Tool: 24 mm ( )
● Torque: 265 N.m (27 kg.m, 195.3 ft lb)
4 3 EX1403472
Figure 61

Front
DX140AF/DX140LCA Boom and Arm 6-1

Boom and Arm

ＭＥＭＯ

Table of Contents
Boom and Arm

SPECIFICATIONS....................................................... 7
FRONT........................................................................ 8
REMOVAL................................................................... 9
Arm Removal...................................................... 9
Boom Removal................................................. 11
INSTALLATION......................................................... 12
Arm Installation................................................. 12
Boom Installation.............................................. 12
COMPLETING WORK............................................... 12

SAFETY INSTRUCTIONS
WARNING

SPECIFICATIONS
The table below has a complete listing of dimensional
specifications for all mounting pins used on the front
attachment.
NOTE: Some mounting pins must be drilled and tapped
for lubrication fittings and piping, or may have
other required specifications. Consult DOOSAN
After Sales Service for information on wear
tolerances and replacement limits for mounting
pins.

FRONT
FRONT LINK PIN SIZES
Figure 1
POINT DIA. (mm) LENGTH (mm)

A 71 686
B 71 200
C 71 670
D 71 429
E 71 217
F 71 217
G 65 203
H 65 364
I 65 434
J 65 364
K 65 434

REMOVAL
WARNING
AVOID DEATH
DOOSAN warns any user, that removal of the
counterweight from the machine, front attachment or
any other part, may affect the stability of the machine.
This could cause unexpected movement, resulting in
death or serious injuries.
structure.
Never rotate the upper structure once the
EX1401352
IMPORTANT Figure 2
Always break down the front attachment by removing

outermost sections first - the bucket before the
arm, the arm before the boom. Reinstallation of the
attachment must begin with the boom and end with
the bucket.
Refer to the appropriate Bucket section for its removal

and installation procedure before going onto the initial
step of the front attachment removal or installation
procedure.
Arm Removal
WARNING
This procedure is intended for routine removal or
replacement of the attachment by ONLY authorized
and trained service persons. Call you local Doosan
distributor for assistance.
DO NOT allow other personnel to go under the boom,
arm or attachment sections, if not properly supported.
Keep away from pressurized hydraulic lines to prevent
death or serious injury from high-pressure oil.
Complete the bucket end removal procedure by

pulling out the two bucket linkage pins and the bucket
cylinder mounting pin, on the arm. Use an assist
crane or hoist to lift the cylinder and relieve weight on
mounting pins.

Park the excavator away from obstructions and all
traffic on clear, flat, level ground. Extend the arm
cylinder and crowd the arm into the boom. Partially
retract the boom cylinder so the boom is stretched
out in front of the excavator, as low to the ground as
possible, with the arm crowded under the boom.
The tip of the arm point must be lowered to secure
blocking that will safely support the weight of the arm.
Place the blocking directly in front of the excavator
and make sure that it will not be unbalanced with an
initial weight load that is all to one end, under the arm
point.
Shut off the engine and release hydraulic system
pressure - move any of the control levers with
the engine off to release pressure built up in the
accumulator. Manually vent residual hydraulic
pressure in the tank by moving the lever near the cap,
on top of the reservoir.
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 736 kg (1,623lb), not including the
weight of accessories or fixtures).
Before beginning the disassembly of attachment

mounting pins, disconnect the arm cylinder hydraulic
hose couplings and put a clean plug in the end of
each one. Use any reasonable precautions necessary
to avoid introducing dirt or other contaminants into the
hydraulic system. Wipe down coupling points before
disconnecting hydraulic lines and use evaporative
type solvent spray cleaner. Tag and mark hoses for
reassembly, if necessary.
Place a sling under the arm cylinder (the cylinder used
to extend and retract the attachment arm, pinned to
the top of the boom).
Lift the sling so the weight load on the rod end of the
arm cylinder (pinned to the ears on the inner end of
the arm) is released. Prepare blocking under the arm
that will securely support the weight of the arm and
arm cylinder.

IMPORTANT
To make sure that polished surfaces of cylinder rod
ends are not damaged during disassembly or removal
procedures, wrap exposed rod surfaces (especially
those of boom cylinders) with a protective covering
material.
Immediately the following disassembly and removal,
cylinder rods should always be fully retracted. This
eases handling problems and avoids possible
damage.
Remove retainers on the end of the mounting pin

for the arm cylinder rod end. Use the assist crane
to relieve the weight load and withdraw the pin.
Lower the arm down to the blocking support for any
continued disassembly procedures.
Boom Removal
NOTE: Boom removal may be simplified if the shell
of the operator’s cabin is taken off the turntable
deck first.
Refer to the Operator’s Cabin Removal
procedure before continuing, if both components
are to be removed from the excavator.
After the bucket, arm and arm cylinder have been
removed, lower the end of the boom to a stable,
secure blocking support.
Attach the assist crane sling to the body of either
boom cylinder, break the mounting pin connection to
the boom by tapping through the pin from the same
side of the boom and repeat for the opposite cylinder.
Release hydraulic pressure and disconnect line
couplings as previously outlined in the Arm Removal
Procedure, observing the same precautions.
Disconnect wiring for work light assemblies and any
other accessory lines or connections. Locate the sling
of the assist crane near the center of gravity, optimum
lift point for the boom, and use the crane to take
pressure off the boom foot pin. Drive out the pin after
disassembling retainers and carefully lift away the
boom.
WARNING
If either the front attachment or counterweight has
been removed, stability of the excavator will be
affected. Never travel with the excavator, swing the
turntable or drive over uneven or sloping terrain if one
of these components have been removed. Tipping or
a rollover could result in death or serious injury.
To maintain stability, the counterweight must be

removed whenever the front attachment is taken off
the machine.

INSTALLATION
Arm Installation
Reattach the base of the arm cylinder to the mounting
point on top of the boom.
WARNING
Before assembling the front attachment, make sure
that individual boom, arm and bucket sections are all
compatible for work intended. Refer to the General
Safety Pages, Lift Ratings, Working Range Diagrams
and Weights of Materials sections in the Operation
& Maintenance Manual. Consult your dealer or
DOOSAN After Sales Service for more information if
you have any questions.
Begin with the arm securely supported on blocking in

front of the excavator. Pregrease the mounting pin for
the rod end of the arm cylinder and push it through the
ears on the end of the arm.
Attach a sling around that mounting pin and lift the
arm with an assist crane until it is in position for the
boom-arm pin connection to be made.
Relieve hydraulic pressure from all points of the
system before any hydraulic lines are opened, then
carefully assemble hydraulic connections to the arm
cylinder.
Remove sling from around the rod end arm cylinder
pin, withdraw the pin and lift the body of the arm
cylinder to repin the mounting connection.
Boom Installation
Before reassembling the attachment, make sure to
inspect all bushings and pivot points of each section.
To avoid damaging the seats, bushings should never
be hammered or chiseled out of their seats.
Installation is otherwise a reversal of the removal
procedures.
COMPLETING WORK
Once the boom has been serviced, it must be
lubricated as outlined in the initial start-up procedures
of the operation manual. Refer to the appropriate
Operation & Maintenance Manual for unit.

Bucket
DX140AF/DX140LCA Bucket 6-13

ＭＥＭＯ

Table of Contents
Bucket
BUCKET TOOTH INSPECTION AND
REPLACEMENT..................................................... ..17
BUCKET O-RING REPLACEMENT.......................... 18
Installation......................................................... 19
BUCKET DETACHING AND REVERSAL................. 20
Detaching.......................................................... 20
Reversal............................................................ 20

SAFETY INSTRUCTIONS
WARNING

BUCKET TOOTH INSPECTION
AND REPLACEMENT
There are several different types of attachment
methods for replaceable bucket tooth. Some of
the most common types are shown in the following
drawings.
Bucket tooth 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

pinhole.
● Lock washers or pins show obvious damage or
weakness. FG004607
● Wear points on the working surfaces of tooth points
Figure 1
- pits, cracks, chips or craters - are larger than 8 mm
to 10 mm (1/3” to 1/2”) across.
HDO5057I-1
Figure 2
1. O n a routine basis, inspect the bucket tooth to

make sure that tooth wear or breakage has not
developed. Do not allow the replaceable bucket
tooth to wear down to the point that bucket adapter
is exposed. See Figure 1.
2. To replace a tooth (1, Figure 3), use a hammer and
punch to drive the locking pin (2) and lock washer (3)
out of the tooth adapter (4). 4
3
3. Once the worn tooth has been removed, use a putty 2 1
knife to scrape the adapter as clean as possible.
4. Slide the new tooth into position and insert the lock EX1403298
washer.
Figure 3
5. Insert the locking pin into the tooth and with a
hammer, drive the pin in until lock washer seats in
the locking groove.

BUCKET O-RING REPLACEMENT
WARNING
Due to possibility of flying metal objects, always wear
safety helmet, protective gloves and eye protection
when changing pins.
1. Roll the old O-ring (1, Figure 4) onto the boss.

1 Arm 1
1 1
EX1404393
Figure 4
2. Remove double nut (1, Figure 5) and bolt.

●Tool: 24 mm ( ) 1
WE1401454
Figure 5
3. Remove the bucket pin (1, Figure 6).

●Bucket pin weight: about 11 kg (24.3 lb)
1
WE1401455
Figure 6

4. Separate the arm from the bucket and remove the
O-ring (1, Figure 7).
1
WE1401456
Figure 7
Installation
1. Perform installation in the reverse order to remove.
NOTE: Assemble double nut like Figure 9.
WE1401457
Figure 8
1 ~ 2 mm
EX1404398
Figure 9

B U C K E T D E TA C H I N G A N D
REVERSAL
Detaching
Park the excavator away from obstructions on clear,
flat, level ground. Lower the bucket carefully to
preassembled blocking on the ground. Brace the
bucket so that there is no load weight on the pin
connecting the bucket and arm. Disassemble the
fasteners on the end of the bucket pin and pull out the
pin.
If the pin sticks and resists normal withdrawal, there
may be a load on it. Raise and lower the arm slightly
until an unstressed pin position is located.
CAUTION
AVOID INJURY
Use care pulling out the pin to avoid damaging the
dust seals on either end of the arm.
When the pin has been withdrawn, move the operating

joystick slightly to take weight off the remaining link
pin. Disassemble the link pin end retainers and pull
out the pin.
Lift the arm away from the bucket so that the bucket
can be carried away or another end attachment can
be put on the excavator.
Reversal
Follow instructions for “Detaching” and remove both
the bucket and link pins. Rotate the bucket 180° to
change bucket configuration. This procedure is greatly
simplified if some type of rotating or swiveling support
can be used, on the ground underneath the bucket.
Follow instructions for “Bucket Attachment” to replace
pins.
WARNING
Bucket curl and dump levers must be used in opposite
directions, after the bucket has been reversed.

Cylinders
DX140AF/DX140LCA Cylinders 6-21

ＭＥＭＯ

Table of Contents
Cylinders
GENERAL................................................................. 24
General Description.......................................... 24
Specification..................................................... 24
Parts List........................................................... 25
Theory of Operation.......................................... 33
Seal of Cylinder................................................ 34
DISASSEMBLY......................................................... 36
REASSEMBLY.......................................................... 41
TROUBLESHOOTING.............................................. 45

SAFETY INSTRUCTIONS
WARNING
GENERAL
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 below drawing. Arm cylinders have a cushion or
stopper for operation in both directions.
Specification
Rod O.D
Tube I.D
Stroke
Closed Length
EX1400068
Figure 1
Boom (Mono) Arm (Boom 4.6 m) Bucket

Quantity 2 1 1
Tube I.D ø110 ø115 ø100
Rod O.D ø75 ø80 ø70
Stroke (mm) 1,085 1,099 900
Closed Length (mm) 1,585 1,665 1,375
Head End Cushion X O X
Rod End Cushion O O O
Weight (kg) 117 143 86.5

Parts List
The following parts list is component Parts List.
Boom Cylinder (LH)
33
32
30
35
31
34 35
34
36
A 29
28
37
1 27 24
26 23
B
38
39
24
B 17
22
21
22
19
18
19
20
16
25 14
C
13
15
7
6
5
8
A
9
10
C
11
3
12
EX1500007
Figure 2

Reference Reference
Number Number
1 Tube Assembly 21 O-ring
2 Bushing, Sintering 22 Ring; Backup
3 Rod Assembly, Cylinder 23 Nut, Piston
4 Bushing, Sintering 24 Screw; Set
5 Cover, Rod 25 Bolt; Socket M14 x 2.0 x 70
6 Bush-DD 26 Band, Pipe
7 Ring, Retaining 27 Band, Pipe
8 Seal; Buffer 28 Washer; Spring
9 U-packing 29 Bolt
10 Ring, Backup 30 Pipe Assembly; (LH)
11 Wiper; Dust 31 O-ring
12 Ring; Retaining 32 Washer; Spring
13 O-ring 33 Bolt; Socket
14 Ring; Backup 34 Washer; Spring
15 O-ring 35 Bolt
16 Ring; Cushion 36 Pipe Assembly; (LH)
17 Piston 37 O-ring
18 Seal; Slipper 38 Washer
19 Ring; Wear 39 Bolt; Socket
20 Ring, Dust * Seal Kit
*: 8, 9, 10, 11, 13, 14, 15, 18, 19, 20, 21, 22

Boom Cylinder (RH)
33
32
29
27
28 31
30
35
1 34 35
34
26
24
23
B A B
36
37
24
38
39 17
22
21
22
19
18
19
20
16
14
25
13
15
7
6 C
5
8 A
9
10
C
11
12
EX1500008
Figure 3

Reference Reference
Number Number
1 Tube Assembly 21 O-ring
2 Bushing, Sintering 22 Ring; Backup
3 Rod Assembly, Cylinder 23 Nut, Piston
4 Bushing, Sintering 24 Screw; Set
5 Cover, Rod 25 Bolt; Socket M14 x 2.0 x 70
6 DD-Bush 26 Band, Pipe
7 Ring; Retaining 27 Band, Pipe
8 Seal; Buffer 28 Washer; Spring
9 U-packing 29 Bolt
10 Ring; Backup 30 Pipe Assembly; H (RH)
11 Wiper; Dust 31 O-ring
12 Ring; Retaining 32 Washer; Spring
13 O-ring 33 Bolt; Socket
14 Ring; Backup 34 Washer; Spring
15 O-ring 35 Bolt
16 Ring; Cushion 36 Pipe Assembly; R (RH)
17 Piston 37 O-ring
18 Seal; Slipper 38 Washer
19 Ring; Wear 39 Bolt; Socket
20 Ring; Dust * Seal Kit
*: 8, 9, 10, 11, 13, 14, 15, 18, 19, 20, 21, 22

Arm Cylinder
48
47 49
2
46
44
43
45
36 35 42
41
34
28 33
29
30
31
1 32 24
23
B
37
B
A 38
24
17
20
39 19
40 18
19
20
21
22
16 C
14
27 13
15
7
A 6
5
8
3
9
10
C
11
12
EX1500009
Figure 4

Reference Reference
Number Number
1 Tube Assembly 27 Bolt; Socket
2 Bushing, Sintering 28 28 Valve; Check
3 Rod Assembly, Cylinder 29 29 Spring
4 Bushing, Sintering 30 30 Support; Spring
5 Cover, Rod 31 31 O-ring
6 DD-Bush 32 32 Plug
7 Ring; Retaining 33 33 Band, Pipe
8 Seal; Buffer 34 34 Band, Pipe
9 U-packing 35 35 Washer; Spring
10 Ring; Backup 36 36 Bolt
11 Wiper; Dust 37 37 Pipe, Cylinder; R
12 Ring; Retaining 38 38 O-ring
13 O-ring 39 39 Washer; Spring
14 Ring; Backup 40 40 Bolt; Socket
15 O-ring 41 41 Clamp, Pipe
16 Ring; Cushion 42 42 Washer, Spring
17 Piston 43 43 Bolt
18 Seal; Slipper 44 44 Flange, Port
19 Ring; Wear 45 45 O-ring
20 Ring; Dust 46 46 Washer; Spring
21 O-ring 47 47 Bolt; Socket
22 Ring; Backup 48 48 Port
23 Nut, Piston 49 49 O-ring
24 Screw; Set * * Seal Kit
*: 8, 9, 10, 11, 13, 14, 15, 18, 19, 20, 21, 22

Bucket Cylinder
33
32
31
30
26
38
39
2
40
1
28
29
27
26
23 24
27
28
29 24
38
39
A
40 17
34
35 22
21
20
19
36 18
37 19
20
16
25
14
13
15
7
A 6
8
9
10
11
3
12
WE1401498
Figure 5

Reference Reference
Number Number
1 Tube Assembly 22 Ring; Backup
2 Bushing, Sintering 23 Nut, Piston
3 Rod, Cylinder 24 Screw; Set
4 Bushing, Carburizing 25 Bolt
5 Cover, Rod 26 Band Assembly, Pipe
6 Bush-DU 27 Band, Pipe
7 Ring, Retaining 28 Washer; Spring
8 Seal; Buffer 29 Bolt
9 U-packing 30 Pipe Assembly
10 Ring, Backup 31 O-ring
11 Wiper; Dust 32 Washer
12 Ring; Retaining 33 Bolt; Socket
13 O-ring 34 Pipe Assembly; R
14 Ring; Backup 35 O-ring
15 O-ring 36 Washer
16 Ring; Cushion 37 Bolt; Socket
17 Piston 38 Clamp, Pipe
18 Seal; Slipper 39 Washer; Spring
19 Ring; Wear 40 Bolt M10 x 1.5 x 45
20 Ring, Dust * Seal Kit
21 O-ring
*: 8, 9, 10, 11, 13, 14, 15, 18, 19, 20, 21, 22

Theory of Operation
1 Piston
2 Oil Path A
3 Oil Path B 1
Cylinder piston rods are extended or retracted by oil D

flow to the back side of the cylinder (shown as (“oil
path A”) or to the front of the cylinder (“oil path B”). 3
The cylinder rod is extended as oil flow is pumped 2
through the circuit to the back side of the piston. The
force (F1) of the piston stroke can be expressed by
FG001456
the formula below, where P = circuit oil pressure and
the inside diameter of the cylinder is expressed by D Figure 6
(Figure 6).
πD2
F1=Px
4
(P: Pressure, π = 3.14, D: Cylinder Inside Diameter)

1 Cylinder Inside Diameter - D
2 Oil Path A 4
3 Oil Path B
4 Rod Diameter - R 1
When the cylinder rod is retracted, oil flow through the

2
circuit from the pump to the front side of the cylinder
3
generates a force (F2) that can be expressed by the
formula in which the diameter of the piston rod is FG001458
expressed by R, and the other two terms are the same Figure 7
as in the preceding expression.
π(D2-R2)
F2=Px
4
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.
π(D2) 1
Q1 = S x
4
π(D2-R2)
Q2 = S x
4
Q1 > Q2
FG001459
Figure 8

Seal of Cylinder
1. Assembly location and shape of seals
A. Rod cover seal
U-packing
Backup Ring
Retaining Ring
O-ring
Dust Wiper
Retaining Ring (DKBI Type)
Buffer Seal
DD(DU)-Bush
EX1301741
Figure 9
B. Piston seal
Dust Ring Dust Ring
Wear Ring Wear Ring

Piston Seal
Backup Ring
O-ring
EX1301742
Figure 10

2. Seal function
No Name Function Material

Seal the hydraulic oil between the piston and the Slipper Seal, Glyd Ring,
1 Piston Seal
inner surface of the tube. Compact Seal
Wear Ring Prevents scratch on the inner surface of the tube Phenol, Aramid
and the rod surface caused by foreign materials,
2 and eccentric center, and eccentric load,
and plays role bearing keeping stable friction
materials.
Contamination Protects the piston seal against the intrusion of Dust Ring, Slyd Ring
3 foreign material to keep the functions of the seal
intact.
Seals for preventing leak of hydraulic oil between
4 Rod Seal U-packing, V-packing
the friction material and the cover of the rod.
Prevents surge/shock applied directly to the rod
5 Buffer Seal seal to extent lifecycle of the seal on the system Step Seal
for high-pressure.
Dust Seal Prevents intrusion of foreign materials into the Single Lip, Double Lip
6 cylinder from outside environment to protect the
rod seal.
Prevents intrusion of foreign materials (e.g.,
rain and snow), and makes sealing between the
7 O-ring inner surface of the tube and the rod cover, and NBR
between the rod and the inner diameter of the
piston.
Prevents disengaging U-packing and O-ring
8 Backup Ring PTFE, Nylon
because of pressure and gap.

DISASSEMBLY
CAUTION
AVOID INJURY
Vent air from the hydraulic system before
disconnecting cylinder piping connections. Use the
lever on the reservoir, while the engine is running.
Discharge the hydraulic accumulator and vent residual
tank pressure after the engine is shut off. Pour
clean replacement hydraulic fluid into the system if
excessive fluid is lost.
1. F ollowing removal of cylinder from excavator

attachment, support cylinder on some type of sturdy
work platform and drain all oil. Rotate cylinder so
piping ports are on top, to allow trapped air to vent.
Figure 11
2. Position piston rod so it is extended approximately

one half meter (20”).
Figure 12

3. Remove bolts (27) on the end of cylinder.
NOTE: W
rap a cloth or other protective material
around piston rod, to avoid possibility of
accidentally scratching or scoring rod surface
while fasteners are being loosened and
removed.
Component parts (numbered in parentheses)
are keyed to Figure .
Figure 13
4. T ap 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 14
5. Begin withdrawing piston rod assembly, away from

cylinder. Attach a lifting support when final 1/3 of
rod is still inside barrel of cylinder. Prepare support
blocks for piston rod before it has been completely
withdrawn.
Figure 15
6. Lower piston rod to support blocks and detach wear

ring (outer surface) (19) from end of rod.
Figure 16

7. Immobilize piston rod by inserting a wooden or
other nonscoring, nonmetallic support through end
of rod.
Figure 17
8. Remove set screw using socket wrench.
HAOF340L
Figure 18
9. Fabricate or purchase a piston nut removal

wrench.
(Dimensions are called off at beginning of this
procedure.
This tool may also be ordered through your local
DOOSAN Parts distributor). Remove nut from end
of piston.
Figure 19
10. Use second piston tool described at beginning of

this procedure to separate piston. Detach cushion
ring (16), taking care not to damage cushion ring.
Figure 20

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 21
12. Use a dull, rounded tip tool to pry off O-ring (13)
and backup ring (14).
HAOF37OL
Figure 22
13. Find a screwdriver with an appropriate width tip to

facilitate removal of slipper seal (18), wear ring (19)
and slide ring (20) from piston (17).
Figure 23
14. Remove O-ring (21) and backup ring (22) from

cylinder head.
HAOF38OS
Figure 24

15. During disassembly of cylinder head, be careful
not to damage buffer seal (8) and U-packing (9).
HAOF39OL
Figure 25
16. Disassemble retaining ring (12) and dust wiper

(11).
Separate retaining ring (7) and rod bushing (6).
Figure 26
17. Force out pin bushing (2), (4) from body of

cylinder.
Figure 27

REASSEMBLY
IMPORTANT
Before reassembly:
● Inspect and replace damaged or excessively worn
parts.
● Clean parts and lubricate with clean hydraulic oil.
● Make sure work area is clean.
Replace any part that shows evidence of damage

or excessive wear. Replacement of all O-rings and
flexible seals is strongly recommended. Before
starting the cylinder reassembly procedure, all
parts must be thoroughly cleaned and dried, and/or
prelubricated with clean hydraulic fluid. Prepare the
work area beforehand to maintain cleanliness during
the reassembly procedure.
NOTE: R
eassemble the subassemblies of the cylinder
in the following order:
1. Body of the cylinder.
2. Piston rod.
3. Piston assembly.
4. Cylinder head assembly.
1. Reassemble pin bushing (2), (4) to piston rod and

body of cylinder.
Figure 28

2. F ollowing reassembly of rod cover components,
install the dust wiper (11) and rod bushing (6) to the
rod cover (5).
Insert retaining rings (7 and 12).
Figure 29
3. Prelubricate O-rings and seals before reassembly

(Figure 30).
Figure 30
4. B efore starting to rebuild piston assembly, heat

slipper seal for 5 minutes in an oil bath warmed to
150° - 180°C (302° - 356°F). Use special slipper
seal jig (third item in list of specialized tools at the
beginning of this procedure) to attach seal. Cool
seal by pushing a retracting jig against seal for
several minutes. Apply a strip of clean, see-through
sealing tape around slipper seal to keep it free of
dust. Figure 31

5. Immobilize piston rod on solid support blocks.
Assemble O-ring (21) and backup ring (22). Prepare
to attach rod cover assembly to piston rod. Push
rod cover by tightening piston nut (23).
Figure 32
6. A ssemble cushion ring (16) and attach piston

assembly to piston rod.
Figure 33
7. Use specially fabricate or factory sourced tool to

tighten piston nut (23).
Figure 34
8. Assemble wear ring (19), slide ring (20) and set

screw (24) to piston assembly.
Reference
Description
Number
1 Set Screw
Figure 35

9. Immobilize body of cylinder before reassembly.
Figure 36
Preapply fastener locking compound (Loctite #242

or #243 or an alternate manufacturer’s equivalent
product) to all end cover retaining bolts. Wrap
a protective cushion around end of rod while
tightening fasteners, to prevent possible damage to
polished surface of rod, should a wrench slip during
retightening.
Figure 37

TROUBLESHOOTING
Problem Possible Cause Remedy
Foreign material in U-packing. Remove foreign material.
Scratches in U-packing. Replace U-packing.
Damage to U-packing. Replace U-packing.
Foreign material in dust wiper. Remove foreign material.
Scratches to dust wiper. Replace dust wiper.
Damage to dust wiper. Replace dust wiper.
Oil leaking between
Foreign material in seal O-ring. Remove foreign material.
cylinder head and piston
Scratches in O-ring. Replace O-ring.
rod.
Damage to O-ring. Replace O-ring.
If scratches are not deep, hone with an
Scratches on sealing surface of piston
oil stone and lubricate. If scratches are
rod.
deep, replace piston rod.
Deep scratches on inner surface of
Replace bushing.
bushing.
Oil leaking between
cylinder head and cylinder Damage to O-rings. Replace O-rings.
tube.
Foreign material in dust wiper. Remove foreign material.
Scratches in dust wiper. Replace dust wiper.
Damage to dust wiper. Replace dust wiper.
Oil leaking between
Foreign material in O-ring. Remove foreign material.
cylinder head and piston
Scratches in O-ring. Replace O-ring.
rod.
Damage to O-ring. Replace O-ring.
If scratches are not deep, hone with an
Scratch on sealing surface of piston
oil stone and lubricate. If scratches are
rod.
deep, replace piston rod.
Deep scratches on inner surface of
Replace bushing
bushing.
Oil leaking between
cylinder head and cylinder Damage to O-rings. Replace O-rings.
tube.
Oil leaking from welded
Damage to welded area. Replace cylinder tube.
area of cylinder tube.
Light scratches on sealing surface of
Hone out scratches with oil stone.
cylinder tube.
Deep scratches on sealing surface of
Cylinder drops from pull of Replace cylinder tube.
cylinder tube.
gravity.
Deep scratches on sealing surface of
Replace O-rings.
piston O-rings.

Cylinder drops from pull of
Wear rings twisted. Replace wear rings.
gravity.
Wear rings scratched. Replace wear rings.
Wear rings have other damage. Replace wear rings.
Reduced oil flow due to dirty filter or
Disassemble and clean parts.
dirty intake line.
Air drawn into circuit through loose
Tighten intake connections.
connections.
Reservoir oil level too low. Fill reservoir to correct level.
Relief valve pressure setting incorrect. Adjust relief valve pressure.
Damaged pump shaft or pump drive
Replace damaged parts.
Slow bucket and boom sleeve.
movements. Pump worn or damaged internally. Replace worn or damaged parts.
Disassemble and inspect cartridge.
Relief valve sticking.
Clean or replace cartridge.
Perform cylinder bleeding procedure to
Air in pressure line. remove air. Tighten or replace pressure
line.
Damaged pipe or hose. Replace pipe or hose.
Worn cylinder seals. Replace worn parts.
Reduced oil flow due to dirty filter or
Disassemble and clean parts.
dirty intake line.
Reservoir oil level too low. Fill reservoir to correct level.
Relief valve pressure setting incorrect. Adjust relief valve pressure.
Pump worn or damaged internally. Replace worn or damaged parts.
Low-pressure, shown by
Disassemble and inspect cartridge.
weak upward movement Relief valve sticking.
Clean or replace cartridge.
of boom and bucket. Worn cylinder seals. Replace worn parts.
Low pump output due to dirty discharge Remove and clean pump discharge
pipes. pipes.
Relief valve spring is weak. Relief valve
Replace worn parts.
poppet worn.
Worn plunger in control valve. Replace plunger.
Stuck overload relief valve due to worn
Cylinder drops when Replace worn parts.
seat surface.
control valve is in neutral
Loose pipes or joints. Tighten parts.
Worn piston seal on hydraulic cylinder. Replace piston seal.
Excessive resistance in pump intake Inspect intake line and clean or replace
Vibration or excessive line. as necessary.
noise. Air being drawn into intake line. Inspect pipe joints and tighten.
Chattering relief valve. Change oil, replace valve.
Wrong type of operating oil. Drain and fill with proper type of oil.
Oil level too low. Raise to proper level.
Air bubbles in oil.
Perform cylinder bleeding procedure to
Air trapped in system
remove air.
System pressure too high. Adjust relief valve pressure.
Frequent rubber hose
Hoses breaking due to contact with
damage. Restrain hoses to prevent contact.
another machine parts.

Hydraulic System
Troubleshooting,
Testing and
Adjustment
DX140AF/DX140LCA Hydraulic System Troubleshooting, Testing and Adjustment 7-1

ＭＥＭＯ

Table of Contents
Hydraulic System Troubleshooting,

Testing and Adjustment
APPLICABLE MODELS.............................................. 5
HYDRAULIC SYSTEM - GENERAL NOTES.............. 6
HYDRAULIC SCHEMATIC.......................................... 7
General Notes..................................................... 7
OPERATION OF WORKING....................................... 9
COMPONENTS........................................................... 9
Boom Operating Circuit...................................... 9
Boom Up Circuit.................................................. 9
Boom Down Circuit............................................. 9
Arm Operating Circuit....................................... 10
Arm Crowd Circuit............................................. 10
Arm Dump Circuit............................................. 10
Bucket Operating Circuit................................... 11
Bucket Crowd Circuit........................................ 11
Bucket Dump Circuit......................................... 11
Swing Operating Circuit.................................... 11
Right Swing Operating Circuit........................... 12
Left Swing Operating Circuit............................. 12
Swing Relief Valve and Makeup Valve............. 12
Travel Operating Circuit.................................... 12
Forward Travel Circuit...................................... 13
Reverse Travel Circuit...................................... 13
PROCEDURAL TROUBLESHOOTING BASELINE
RECOMMENDATIONS........................................... ..14
Initial Checks and Tests to Establish Operating
Condition of the Excavator...................................... ..14

PILOT PRESSURE................................................... 16
Adjustment and Testing.................................... 16
POWER MODE VALVE............................................ 17
Current Signal and Hydraulic Pressure............ 17
Adjustments...................................................... 17
PRESSURE UP VALVE............................................ 18
Checks and Adjustments.................................. 18
PUMP INPUT POWER CONTROL........................... 20
Pump Regulator Adjustment............................. 20
FLOW METER AND FLOW METER KIT
INSTALLATION AND TESTING................................23
SWING SYSTEM....................................................... 25
TROUBLESHOOTING.............................................. 25
Precautions/Initial Checks......................................... 25
Swing Relief Valve Checking and Adjustment...26
TROUBLESHOOTING – SWING GEARBOX........... 28
TROUBLESHOOTING –HYDRAULIC PROBLEMS..29
TROUBLESHOOTING –CONTROL VALVE............. 31
TROUBLESHOOTING – TRAVELCONTROL
VALVE.......................................................................32
TROUBLESHOOTING –JOYSTICK CONTROL
VALVE..................................................................... ..33

SAFETY INSTRUCTIONS
WARNING
servicing cmachine. Read and understand the
Operation and Maintenance Manual and signs (decals)
APPLICABLE MODELS
The contents of this section apply to the following
models and serial number ranges.

HYDRAULIC SYSTEM - GENERAL
NOTES
Center
Joint
Travel Motor
FG019034
Travel Motor
Figure 1
The hydraulic system has several improvements

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

HYDRAULIC SCHEMATIC
The hydraulic schematic(s) is available in the
“Hydraulic and Electrical Schematic Shop Manual.”
This manual is a collection of diagrams and
schematics for several models.
General Notes
When referring to the schematic, refer to the following
items:
● A s s h o w n i n t h e s c h e m a t i c , t h e m a i n p u m p
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, supplied
by the left pump in the pump assembly, has

control spools for left travel, bucket, boom and arm
operation.
● Two-stage operation is a feature of boom and arm
function. All of these circuits can be operated using

the output of only one half of the hydraulic pump
assembly (one pump or the other), or – since both
halves of the
control valve have a spool and available circuit for
these functions – the output of both pumps can be
combined, allowing higher speed operation. Boom
up, arm crowd and dumping functions can operate
in any one of the two available power modes – the
standard or general duty mode, the high-speed/rapid
cycling mode.
● Whenever the right travel or left travel control spools
are shifted, output from the main pump assembly

flows through the center joint to one or both of the
axial piston motors driving the side frame crawler
tracks. A pilot valve connected to the swash plate
of each travel motor changes motor capacity (and
output) in direct proportion to the position of the
travel switch selected by the operator.

● The hydraulic reservoir return line has 10 micron
and the pilot circuit has 30 micron full flow filters.
The disposable elements in these two canister type
filters trap and remove impurities from the oil in the
system. An 80 mesh, 177 micron reservoir intake
strainer also helps maintain system cleanliness and
must be cleaned each time hydraulic fluid is drained
and replaced. An oil cooler in the hydraulic system
helps maintain the operating temperature of the
system at approximately 50°C (122°F).
● T h e a r m c y l i n d e r o p e r a t i n g c i r c u i t i n c l u d e s
anticavitation valves which protect the hydraulic

system from vacuum that could result from external
shocks or other unusual conditions. Boom, Arm,
and Bucket cylinder circuit are also protected by
overload relief valves. Whenever high-pressure is
generated because of a shock or overload, excess
pressure is dumped to the reservoir return circuit
through the relief valve.
A selection valve in the travel circuit can be used to
provide constant high torque/low speed travel, or
variable speed/ variable torque output for travel.
To prevent sliding during simultaneous travel and
boom/arm/bucket operation, select the high torque/
low speed travel position.

OPERATION OF WORKING
COMPONENTS
Boom Operating Circuit
The boom operating circuit includes the right and left
main hydraulic pumps (both halves of the main pump
assembly), both sides of the control valve and the
boom cylinder. The circuit operates in boom down
mode through the first shift position and through the
second shift position in boom up mode. Overload
relief valves set at 370 kg/cm2 (5,265 psi) protect the
hydraulic system from being damaged because of
overloads or shocks to the boom.
Boom Up Circuit
BOOM
When you pull the boom control lever backward, the CYLINDER
right side pilot valve generates secondary boom up

pilot pressure that is transmitted to the BOOM1 and BMD BM1 PILOT VALVE BM2
TL PL PR
BOOM2 spools of the control valve simultaneously. CONTROL
VALVE(L)
CONTROL
VALVE(R)
When secondary pilot pressure reaches 7 - 9 kg/cm2

(100 - 130 psi), boom control valve spools open and
PUMP(L) PUMP(R)
oil from both pumps goes to the boom cylinder. ARS1560L
Figure 2
Boom Down Circuit

When the boom control lever is pushed forward, the BOOM
CYLINDER
right side pilot valve generates secondary boom down
pilot pressure that is transmitted only to the BOOM1
PILOT VALVE BM1 BMD
spool of the control valve. PL TL

CONTROL
When secondary pilot pressure reaches 7 - 9 kg/cm2 VALVE(L)
(100 - 130 psi), the BOOM1 spool on the left side of

the control valve opens so oil from only one pump PUMP(L)
ARS1570L
(PUMP (L)) assembly goes to the boom cylinder for

Figure 3
boom lowering.

Arm Operating Circuit
The arm operating circuit includes both the right and
left hydraulic main pumps, the right and left halves of
the control valve, a slow return orifice, and the arm
cylinder. The circuit can be operated in the two-stage
speed control mode which works through both halves
of the control valve and doubles the volume of oil
flowing to the cylinder.
Overload relief valves set at 370 kg/cm2 (5,265 psi)
have been installed at the AM 1 and AMD 1 ports
on the right side of the control valve to protect the
circuit and system components from possible damage
caused by shocks and/or overload pressure.
Additional protection - to prevent cavitation of the
cylinder - is provided by a makeup valve and reservoir
return circuit, which ensures that volume of oil going to
the cylinder will not exceed the volume of oil coming
out.
Arm Crowd Circuit

When the arm control lever is put in the crowd mode,
the left side pilot valve generates secondary pressure
that is transmitted to the AM1 and AM2 spools of the ARM
CYLINDER
control valve simultaneously. REGENERATION VALVE
When secondary pilot pressure reaches 7 - 9 kg/cm2 AM2 PILOT VALVE AMD1 AM1
(100 - 130 psi), the arm control valve spools AM1 and
AM2 open.
PL TL PR
Output flow from both halves of the pump assembly is CONTROL CONTROL
VALVE(L) VALVE(R)
directed to the arm cylinder.
When working in the arm crowd mode, under certain PUMP(L) PUMP(R)
ARS1580L
conditions, oil in the arm cylinder could suddenly
be forced out by the weight of the arm and bucket. Figure 4
Insufficient oil flow to the cylinder could lead to
cavitation in the cylinder and/or surging or irregular
movement. This is prevented by a regeneration valve
attached to the control valve which maintains the
balance between oil flowing into the cylinder and oil
flowing out. ARM
CYLINDER
Arm Dump Circuit AM2 AMD2 PILOT VALVE AMD1 AM1
When the arm control lever is put in “dump” mode, the PL TL PR
left side pilot valve generates secondary pilot pressure CONTROL CONTROL
VALVE(L) VALVE(R)
that goes to both spools AM1 and AM2 of the control
valve simultaneously. PUMP(L) PUMP(R)
When pilot pressure reaches 7 - 9 kg/cm2 (100 - 130 ARS1590L
psi), the control spools open, allowing oil from PUMP

(L) and PUMP (R) to flow to the arm cylinder. Figure 5

Bucket Operating Circuit
The bucket operating circuit includes the left main
pump, the left half of the control valve and the bucket
cylinder. 370 kg/cm2 (5,265 psi) overload relief valves
at BKT and BKTD 1 ports of the control valve protect
the circuit and its components from being damaged.
Bucket Crowd Circuit

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

BUCKET
When the bucket control lever is put in the dump CYLINDER
mode, the bucket control valve spool in the left half of

the control valve opens to supply oil from the left main BKTD BKT PILOT VALVE
pump to the cylinder. CONTROL

TL PL
VALVE(L)
Swing Operating Circuit

The swing operating circuit consists of the right PUMP(L)
ARS1770L
main pump in the pump assembly, the right half of

Figure 7
the control valve and the swing motor. To keep the
upper works from coasting when the swing control
is in neutral, an electrical sensor in the control
circuit activates a valve to automatically engage a
mechanical brake.

Right Swing Operating Circuit
When the swing control lever is pushed to the right
CONTROL
swing position, pilot pressure from the left side pilot VALVE(L)
valve is directed to the right side pump regulator and SWD SW PILOT VALVE
right half of the control valve. TL PR

CONTROL
Output flow from the right pump is then directed

VALVE(R)
through the PR and SWR ports of the control valve to

the swing motor. PUMP(R) ARS1620L
Figure 8
Left Swing Operating Circuit

When the swing control lever is pushed to the left
swing position, the control valve spool at the right side CONTROL
VALVE(L)
of the control valve moves in the opposite direction SWD SW PILOT VALVE
and output flow from the right pump is directed TL PR

CONTROL
through the PR and SWL ports of the control valve to VALVE(R)
the swing motor.
Swing Relief Valve and Makeup Valve

PUMP(R)
ARS1610L
Whenever the spool is shifted to the neutral mode Figure 9

during swing operation, the possibility exists that surge
pressure in the circuit - caused by inertial momentum
of the upper structure works and correspondingly
reduced pressure at the opposite motor port - could
produce cavitation in the circuit. To keep that from
happening, a 270 kg/cm2 (3,840 psi) relief valve is
installed in the swing motor and a large capacity
makeup valve is connected to the entrance port of
the hydraulic reservoir, helping maintain acceptable
pressures on both sides of the circuit.
Travel Operating Circuit

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

Forward Travel Circuit
TRAVEL TRAVEL
When the right and left travel control levers are

MOTOR(L) MOTOR(R)
pushed forward, output from both of the main pumps CENTER JOINT
is directed through the PR, PL, TRRF, and TRLF ports

on the control valve, through the upper works center TRL TRLD PILOT VALVE TRRD TRR
PL TL PR
joint, to the travel motors on each side of the machine.
CONTROL CONTROL
VALVE(L) VALVE(R)
PUMP(L) PUMP(R)
ARS1630L
Figure 10
Reverse Travel Circuit

When the right and left travel control levers are TRAVEL TRAVEL
MOTOR(L) MOTOR(R)
pushed backward, output from both main pumps is

CENTER JOINT
directed through the PR, PL, TRRR, and TRLR ports
on the control valve, through the upper works center
TRL TRLD PILOT VALVE TRRD TRR
joint, to the travel motors. PL TL PR
CONTROL CONTROL
VALVE(L) VALVE(R)
PUMP(L) PUMP(R)
ARS1640L
Figure 11

PROCEDURAL
TROUBLESHOOTING BASELINE
RECOMMENDATIONS
Initial Checks and Tests to Establish

Operating Condition of the Excavator
Troubleshooting Recommendations
An excavator that fails to deliver designed
performance must be checked for the following:
●First hydraulic flow.
●Then hydraulic pressure in a specified order of
priority through different points of the system.

To verify adequate available hydraulic flow, before any
other tests are performed through the circuit:
Check engine operation -
●at 1,950 rpm with no load.
●at 1,950 rpm stall load.
If engine rpm drops excessively with a load or fails

to surpass rated speed (1,900 rpm), performance
problems may be because of inadequate hydraulic
flow caused by lagging rotational speed.
Note: Verify actual flow on the excavator against rated
performance, with a flow meter.
If engine tests meet specifications and adequate
torque and horsepower are available at the pump
drive flex coupling, pull out the electrical tray under the
operator’s seat to inspect the self-diagnostic display.

If the EPOS trouble code display is clear, check
hydraulic functions in the following sequence:
● Pilot pressure.
● Negacon, negative control pressure.
● Main relief pressure (front and rear pump)
● Swing pressure.
● Port relief pressure (individual control functions;
boom, arm, bucket, swing, and travel)

● Power boost circuit.
● Standard performance tests; cylinder speed,
hydraulic motor (travel and swing) speed, cylinder oil

tightness “permissible drift” test.
Note: System specification performance tests of
individual activator function are determined by
flow rate through the component or circuit, not
the control pressure or system pressure available
to the actuator. Poor flow through the individual
circuit may indicate that component is worn
beyond tolerance limits, while all other hydraulic
functions are adequate.
IMPORTANCE
It is suggested that 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.

PILOT PRESSURE
Adjustment and Testing
WARNING
This procedure must be done with two people. To reduce the
chance of accidental movement of the excavator, one person
must be properly seated at the operator’s controls stand while
checks and adjustments are made.
Vent hydraulic pressure from the reservoir before

breaking the seal on fittings to install two in-line
“T-style” adapters and test gauges (60 bar/1,000 psi)
at the gear pump outlet port, and at the joystick control
valve pilot line.
Start the engine and turn the engine speed control
dial to the maximum setting. After the excavator has
been operated long enough to reach normal operating
temperature, back off the engine control dial to
minimum rated rpm speed. With all controls in neutral,
make sure the left safety lever is in the up (UNLOCK)
position and check pressure at the gear pump outlet
port and at the joystick.
If gear pump pressure is outside the tolerance
specified in the table, adjust gear pump relief pressure
by loosening the locknut and turning the set screw in
(clockwise) to increase pressure, or turning it out to
decrease it.
IMPORTANCE
Refill the hydraulic fluid reservoir if there is any measurable loss
of hydraulic oil during test gauge and adapter fitting installation.
Engine rpm Pilot Pressure @ Pump Pilot Pressure - Joystick

2
Minimum Speed Setting (full left) 40 ±5 kg/cm 23.5 ±1.5 kg/cm2
on Speed Control Dial (569 ±71 psi) (334 ±21 psi)

POWER MODE VALVE
Current Signal and Hydraulic Pressure
Adjustments
WARNING
The electromagnetic pressure proportioning control

(EPPR) “power mode” valve is on the underside of the
pumps (not visible in the harness connections drawing,
because it is underneath the assembly), near the
engine/pump flexible coupling, adjacent to the pump
return line. To test and adjust power shift current and
pressure through the power mode valve a multilead
jumper harness is required. The jumper harness (which
is available through DOOSAN After Sales Service, or
could be spliced together from commonly available,
purchased parts) has extra leads so a VOM meter
can be connected to the circuit. To set up the testing
equipment, stop engine and disconnect the single
electrical lead from the power mode valve. Attach the
jumper harness to the terminal on the valve, connect
the test leads of the multimeter to the extra leads on
the harness and reconnect the valve electrical lead.
Vent the lever on top of the hydraulic tank to relieve
pressure and connect an in-line “T-style” adapter to
the valve pressure port. Install a 60 bar (1,000 psi) test
gauge in the adapter.
Restart the engine and increase engine rpm by
turning the speed control to the maximum speed
setting. Warm up the engine and hydraulic system
until hydraulic oil temperature is at least 45°C (113°F).
Select Power Mode on the Instrument Panel. Check
current readings (in milliamps) on the VOM meter and
hydraulic pressure gauge readings and make sure
both conform to the values in the table below.
Note: If recorded values do not conform to the specified
current or pressure in the table, back off the
locknut on the end of the valve, turn the adjusting
screw 1/4 turn and recheck current and pressure.
Repeat adjustment as required to obtain specified
performance and retighten the valve locknut.
Mode Engine rpm Current Pressure
Power Plus Mode High Idle: 150 ±15 - 600 ±60 mA Midrange value 1 . 6 - 3 2 . 8 k g / c m 2
1,950 (Auto Idle OFF) corresponding to engine rpm for both (22.9 - 466.5 psi)
1,850 (Auto Idle ON) current and hydraulic pressure readings.
Power Mode High Idle: 1,750 170 ±17 - 600 ±60 mA 3.8 - 32.8 kg/cm2
(54 - 466.5 psi)
Standard Mode High Idle: 1,700 200 ±20 - 600 ±60 mA 6.4 - 32.8 kg/cm2
(91 - 466.5 psi)
Economic Mode High Idle: 1,650 240 ±24 - 600 ±60 mA 10.6 - 32.8 kg/cm2
(150.8 - 466.5 psi)

PRESSURE UP VALVE
Checks and Adjustments
WARNING
AVOID INJURY OR DEATH
Read and understand the Operation & Maintenance Manual for
more information.
Refer to the "Operating Instructions" section of this manual for
detailed information regarding the work levers (joysticks) control
functions.
Vent hydraulic pressure from the reservoir to install an

in-line “T-style” adapter and test gauge (60 bar/1,000
psi) at the pilot pump signal port relief valve outlet.
Start the engine and turn the engine speed dial to
maximum.
When normal operating temperature is reached:
● Check pilot pressure and readjust it, if required:
● Select the Instrument Panel rear pump “pressure
display.”
● Select Power Mode.
● Stall the boom cylinder (towards the extend side).
● Read rear pump pressure on the Instrument Panel
display.
Repeat all tests with and without “pressure up”
selected through the console rocker switch and
joystick button.
If the two-stage main relief valve was not set correctly
and main relief high stage pressure (“pressure up”) is
outside the tolerance range, begin valve adjustment
by loosening the outside (widest diameter) locknut on
the relief valve. Turn the adjusting screw clockwise to
increase pressure, or counterclockwise to decrease it.
Pressure must be 370 kg/cm2 (5,263 psi), or up to 10
kg/cm2 (142 psi) higher.
Because one adjustment can affect the other, check
low stage main relief pressure by repeating the
cylinder stall test without “pressure up.” Readjust
standard relief pressure by turning the innermost
(smallest diameter) screw clockwise to increase the
setting, or counterclockwise to decrease it. Pressure
must be at least 350 kg/cm2 (4,975 psi), but less than
355 kg/cm2 (5,046 psi).
IMPORTANCE
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.

Pilot Pressure and
Power Mode Operation Main Pressure and Tolerance
Tolerance
40 ±10 kg/cm2
Power Mode Neutral, No Operation 20 - 40 kg/cm2 (285 - 570 psi)
(569 ±142 psi)
40 ±10 kg/cm2
Power Mode Cylinder Stall 330 ±5 kg/cm2 (4,693 ±71 psi)
(569 ±142 psi)
Power Mode W/ 40 ±10 kg/cm2
Cylinder Stall 350 ±10 kg/cm2 (4,978 ±142 psi)
Pressure Up (569 ±142 psi)
Note: The electrical pressure up (power boost) solenoid

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

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

flow meter is strongly recommended, as is consulting
the factory (before starting work) to validate the need
for making regulator adjustments. Vent hydraulic
pressure from the reservoir before breaking the seal
on fittings to install the flow meter kit. (Refer to “Flow
meter Installation and Testing” procedure.)
IMPORTANCE
Before starting this procedure or going onto make any changes
of adjustment settings:
● Verify engine output to the rated speed – 1,850 ±50 rpm.
● Permanently mark setscrew positions at the current regulator
control setting.
Use a scribe or other permanent marker to identify

a reference point on adjusting screws with a
corresponding reference on the body of the valve. The
adjustment process affects a complex balance and
could require some time to complete. If adjustment
has to be interrupted or postponed, reference marks
at the adjustment points allow immediate restoration
of original performance.
This adjustment procedure is normally performed:
● If the engine is being constantly overloaded (and
engine troubleshooting shows engine performance

to be at or above rated output).
● If reduced cylinder speed and diminished work
performance provide an indication that rated,

maximum pump flow may not be available (and all
other troubleshooting gives no indication of other
flaws or hydraulic system defects).
● If pump output is out of balance and one pump is
failing to keep up with the output flow of the other.

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

valve (Figure 12) for the location of adjustment screws
(1, 2 and 3). There are two different adjustments, with
the Negacon, negative control, adjustment screw (3,
directly below 1 and 2). Each one of the adjustment
procedures could affect the setting of the others.
Check and record the arm dump speed performance
test before and after input power adjustment, whether
or not a flow meter is used.

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

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

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

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

● Stop engine and operate controls to release
hydraulic pressure from the accumulator.

● Vent the reservoir to release all pressure from the
hydraulic system.
● Remove guard panels from around the main pump
assembly.
● Disconnect the main pump discharge output line.
Install the input flange of the flow meter on the pump

end of the output line.
● C a p o f f t h e u n u s e d ( i n p u t ) e n d o f t h e p u m p
discharge line with a blocking flange.

● Connect a premeasured length of hydraulic hose,
between the output end of the flow meter assembly

and the top of the reservoir. Use appropriate fittings
and adapter flanges to guarantee a pressure tight
seal.
Note: Be sure to maintain even tightening torque on
all flange fittings. Use Loctite brand “PST 545”
(or an alternate manufacturer’s hydraulic system
joint seal) if required, to give an airtight seal.
● An assistant – who must remain at the operator’s
control station always – should restart the engine
and run it long enough (at minimum rpm) to deaerate
the system and warm up the engine and hydraulic
system to operating temperature.

Record the values of all test results in three columns,
comparing 1) pump pressure (from the instrument
panel display) with 2) measured flow, in gallons or
liters per minute, from the installed flow meter. The
third column of test results should provide a record
of engine rpm measured during each of the following
tests – with the engine speed control dial set at
maximum, thepower mode selector at Power Mode
and the work mode selector at digging mode:
● Unloaded maximum engine speed baseline test (all
controls in neutral).
● Front pump test – operate “travel right” lever. Record
values at all specified pressures.

● Rear pump test – operate “travel left” lever. Record
values at all specified pressures.

Record the values for each of the three tests (neutral,
travel right and travel left) at the following pump
pressure levels, with travel speed control set at “high-
speed.”
Engine rpm Pressure Flow

100 ±5 kg/cm2 (1,422 psi)
150 ±5 kg/cm2 (2,133 psi)
200 ±5 kg/cm2 (2,844 psi)
300 ±5 kg/cm2 (4,267 psi)
350 ±5 kg/cm2 (4,975 psi)
*See below note.
Compare recorded values with output shown in the

P-Q curve in the specifications section of this book.
If test results do not meet specified values, pump
output tests can be repeated using different control
levers. Recheck front pump operation while stroking
the bucket cylinder out lever, and the rear pump by
actuating the swing control lever.

SWING SYSTEM
TROUBLESHOOTING
Precautions/Initial Checks
1. Stop work. Release all weight or any load safely
before proceeding. Avoid risking injury or adding to
damage.
2. Stop engine and disengage control functions until
initial tests are ready to be made.
WARNING
Stop operation and park excavator whenever these problems are
noticed:
1. Equipment breakdown.
2. Inadequate control response.
3. Erratic performance.
Stop the machine, put the boom and arm in the

inoperative (overnight park) position and begin by
making the fastest, simplest checks first:
● Check oil level.
● Check for overheating, oil leaks, external oil cooler
clogging or broken fan belt. Consult service record

for prior repair/service work.
● Drain some tank oil into a clean, clear container.
Look for metal shavings/grit, cloudiness/water or

foam/air bubbles in the oil.
Note: Dispose of drained fluids according to local
regulations.
● Check for wobble through the engine/pump flex
coupling.
Run engine with the pump input hydraulic power
control nut turned to the lowest power to check the
engine.
● Investigate unusual operating noises or vibration.
Check for loose bolts, connections.

Swing Relief Valve Checking and
Adjustment
Make a check of operating pressures through the
swing relief valve if:
● The swing motor fails to turn.
● Swings in one direction only.
● Swings but continues to coast.
● There is drifting on a slope.
1. Check operation by connecting:

A. Two 500 kg/cm2 (7,112 psi) pressure gauges to
the inlet and outlet measuring ports on top of the
swing motor.
Pressure must be between 265 and 275 kg/cm2
(3,769 psi and 3,911 psi), with both swing locks
engaged. With swing locks released, during
full acceleration and deceleration, pressure
should approach 270 kg/cm2 (3,840 psi) in each
direction.
B. Connect a 100 kg/cm2 (1,422 psi) pressure
gauge at the “SH” port of the hydraulic brake.
Pressure should always stay at or above 13 kg/
cm2 (185 psi) when operating swing, boom or
arm.
C. Connect a 10 kg/cm2 (142 psi) gauge at the
motor makeup valve.
Pressure should stay consistently above
2.5 kg/cm 2 (36 psi). If pressure drops below
the recommended minimum level, forceful
acceleration of the swing motor could lead to
cavitation of the circuit and stalling, slowed
rotation, noise and possible damage.
2. If main inlet and outlet pressures were off in the
preceding tests in Step 1, adjust swing relief valve
pressure.
Following adjustment, repeat the operating
pressure tests (with gauges connected to the inlet
and outlet test ports on top of the swing motor) and
check pressures with the swing locks engaged and
released.
If pressure adjustment fails to restore adequate
performance, proceed to the Troubleshooting –
Swing table.
3. If pressure tests were at recommended levels
through the main inlet and outlet ports, and through
the “SH” port of the swing brake, the causes of poor
swing performance could include a faulty swing
motor, drivetrain overloading or gearbox defect, or
a problem in the brake assembly or swing control
valve. Proceed to the troubleshooting information in
the next procedure.

If pressure through the “SH” port was tested below
the minimum 13 kg/cm2 (185 psi) level, check
the shuttle valve in the rear compartment behind
cabin. When pressure through the port is at the
recommended level, the brake release valve
should disengage the swing brake, allowing the
swing motor to rotate the excavator. If pressure
adjustment to the valve has been restored but the
brake still fails to release, the brake piston or friction
plate may be frozen, requiring disassembly of the
motor and parts repair/ replacement.
4. If pressure tested at the motor makeup valve
drops below recommended minimum level, and
consequent problems with cavitation, stalling and
surging are observed, check the restriction valve.
If pressure adjustment to the valve has been
restored but if problems with cavitation continues,
disassemble the upper swing motor housing and
clean or replace assembly components as required.
Note: I f a l l t e s t e d p r e s s u r e s a r e a t o r a b o v e
recommended levels, and there are no
mechanical problems in the drivetrain or in the
motor/brake assembly, the problem will require
further hydraulic troubleshooting. It’s also possible
that a defective joystick, an intermittent short
in an electrical control circuit or a problem in
the EPOS circuit is causing diminished swing
performance. Pull out the EPOS indicator panel
from underneath the operator’s seat and perform
the self-diagnostic test. Refer to the Electrical
section of this book for more information.

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

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

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

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

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

Irregular or uneven pressure. P o p p e t s e a t d a m a g e d o r p i l o t Clean/replace.
piston sticking to main poppet.
Loose locknut and adjusting screw. Readjust.
Components worn out, past wear Replace.
limits.
TROUBLESHOOTING – TRAVEL
CONTROL VALVE
Secondary pressure does not Low primary pressure. Check primary pressure.
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
(handle) subassembly. subassembly.
Secondary pressure too high. Dirt, other interference between Clean, repair or replace.
valve parts.
Return line pressure too high. Redirect return line.
Secondary pressure does not hold Dirt, other interference between Clean, repair or replace.
steady. valve parts, or worn spool sticking
intermittently.
Interference or binding on spool Clean, repair or replace.
return spring.
Interference, restriction or unsteady Repair or reroute tank return line.
pressure in tank return line.
Vent air, or repair leak.
NOTE: Look for evidence of leaking oil.

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

Main Pump
DX140AF/DX140LCA Main Pump 7-34

ＭＥＭＯ

Table of Contents
Main Pump
GENERAL DESCRIPTION........................................ 38
Gear (Pilot) Pump............................................. 40
Relief Valve....................................................... 40
Relief Valve Pump Regulator Description......... 41
Horsepower Control.......................................... 41
Power Shift Control........................................... 41
Negative Oil Discharge (Pump Bypass)
Control..............................................................42
Pump Regulator Operation............................... 42
Pump Output Decrease.................................... 43
Pump Discharge Decrease............................... 43
Pump Discharge Increase................................ 43
Horsepower Control.......................................... 44
Overload Protection.......................................... 44
Regulator Adjustment....................................... 44
Pump Input Power Control Adjustment............. 45
Part List............................................................. 47
Specifications.................................................... 51
Hydraulic Pump Performance .......................... 51
Characteristics.................................................. 51
TROUBLESHOOTING, TESTING AND
ADJUSTMENT........................................................ ..53
Main Pump........................................................ 53
Tools................................................................. 54
Tightening Torque............................................. 55
Removal............................................................ 56
DISASSEMBLY......................................................... 66
General Disassembly........................................ 66
Main Pump Disassembly.................................. 68
Pump Regulator Disassembly.......................... 69
CLEANING AND INSPECTION (WEAR LIMITS AND
TOLERANCES)....................................................... ..73
REASSEMBLY.......................................................... 75
Pump Regulator Reassembly........................... 75
Main Pump Reassembly................................... 79

SAFETY INSTRUCTIONS
WARNING

GENERAL DESCRIPTION
Figure 1
The main pump assembly contains two variable

displacement axial piston pumps connected in series,
driven through a flexible coupling off the back of the
engine. A regulator mounted on each pump controls
the flow output of that pump. A gear type pilot pump is
mounted on the second main pump (farther away from
the engine) and supplies oil to the two regulators and
the control valve.
The axial piston pumps in the main pump assembly
are units that incorporate three main functional
subassemblies:
● The rotary group includes a driveshaft, cylinder
block, piston, shoe, push plate, and spherical

bushing.
● The rotary group driveshaft is driven directly off the
engine and turns at the same rate as engine rpm.

The cylinder block and pistons revolve around the
driveshaft, producing oil flow through the pump
whenever the angle of the swash plate is tilted past
the 0 degree (vertical) angle. Whenever the pump
swash plate angle is at 0 degrees, piston stroke
length is reduced to 0, and there is no output from
the pump.
● The swash plate group includes the shoe plate,
swash plate support, and servo pistons.

● The pump regulator controls the tilt angle of the
swash plate. Increasing the swash plate tilt angle
increases the length of piston stroke, boosting both
the output flow and output pressure of the pump.
● The valve group consists of the valve block, valve
plate and plate pin, providing intake and exhaust

port assemblies for the pump.
● The pump cylinder block slides into the valve plate
whenever piston stroke is tilted past the “0” swash

plate angle, to allow flow of supply oil (input) and
positive discharge (output) through the pump.
Main Pump Output: 63 cc/rev. (3.84 in3/rev.) (1 pump)
Gear (Pilot) Pump Output: 15 cc/rev. (0.92 in3/rev.)
Pilot Pump Relief Valve: Relief pressure set at 40 kg/
cm2 (569
psi).
Figure 2

TO LEFT SIDE OF TO RIGHT SIDE OF
CONTROL VALVE CONTROL VALVE
Psv
A2 A1
Pz3
Q2 Q1
PRESS, SENSOR PRESS, SENSOR FRONT
Pz2
Pz1
Pi2 Pi1
REAR
DOOSAN
DB58
a3 100.6 PS /1,850 rpm
42 kg.m /1,400 rpm
A3 B3 B1 Dr
FG009798
Figure 3
Gear (Pilot) Pump

The pilot pump is a gear type pump, driven off the
output end of the second main pump. Gear rotation
inside the pump case produces oil flow from the intake
side of the pump to the output side of the pump.
The function of the pilot pump in the hydraulic circuit
is to maintain a flow of oil - independent of main pump
oil flow output - for the operation of control valves.
Figure 4
Relief Valve
When the discharge pressure of the pilot pump
exceeds 40 kg/ cm2 (569 psi), the ball and spool at the
top of the valve shift to the right - maintaining pressure
below the targeted 40 kg/cm 2 (569 psi) limit - as
excess oil returns to the drain port.
Figure 5

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

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

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

The relationship between Pump Displacement Flow
(Q on the vertical axis) and Pilot Pressure (Pi on the
horizontal axis). Pump output discharge is controlled
by increasing or decreasing pilot pump pressure
(Figure 7).
NOTE: Component parts (numbered in parentheses)
correspond to those in Figure 8.
Figure 7
Figure 8

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

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

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

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

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

loosening the large, thin nut (630) on the end of the
regulator. The larger (outer) adjusting screw (628)
affects adjustment of the outer return spring in the
regulator outer spool. Tightening the outer screw
approximately 1/4 turn increases compensator control
pressure approximately 18 kg/cm2 (256 psi), for a
torque increase of 4 kg•m (29 ft lb). Changing the
adjustment position of the outer screw (628) affects
the adjustment position of the inner screw (924),
which is the adjustment device for the inner spring of
the regulator outer spool. Loosen the inner screw and
back it out enough to compensate for the tightening
adjustment made to the outer screw, to maintain the
original setting.
Changing the adjustment position of the inner screw
1/4 turn affects the working resistance of the inner
spring. Increases in oil flow of approximately 10 l/
min (0.04 gpm) and about 4.8 kg•m (35 ft lb) of input
torque are the result.

The third adjustment screw on the side of the regulator
(924) can be repositioned after the smaller locknut
(801) is loosened.
Changing the position of the third adjustment screw
(924) affects pilot pressure. Turning the screw in 1/4
turn increases pilot pressure by 1.5 kg/cm2 (21 psi),
and consequently, because of the increase in pilot
pressure, the discharge flow from the main pump
assembly will increase by about 16 l/min (0.07 gpm)
Electric Proportional Reducing Valve

● Current/Pressure Operating
Characteristics
Condition: Primary Pressure 50 kg/cm2
Load discharge flow: 0 l/min
70 Hz, 400 - 600 mA
Figure 12

Part List
Main Pump
Figure 13

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

Pump Regulator
Figure 14

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

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

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

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

kg/ cm 2.
NOTE: Values in the graph marked “L” are flow, in Liters/
minute.

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

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

Tools
The tools necessary to disassemble/reassemble the
pump are shown in the following list.
Tool Name and Size Part Name

Necessary Tool Hex Socket Head PT Plug Hex Socket Head
Name B
Bolt (PT Thread) Setscrew
Allen wrench 4 O M5 BP-1/16 M8
5 O M6 BP-1/8 M10
6 O M8 BP-1/4 M12, M14
8 O M10 BP-3/8 M16, M18
10 M12 BP-1/2 M20
14 O M16, M18 BP-3/4
17 M20, M22 BP-1
Tool Name and Size Part Name

Necessary
VP Plug
Name B Tool Hex Headed Bolt
(PF Thread)
Double Ring Wrench, Socket 19 O M12 VP-1/4
Wrench, Double (Single) Open- 22 O VP-3/8
end Wrench.
24 O M16
27 O M18 VP-1/2
30 M20
36 VP-3/4
Adjustable Angle Wrench O Medium size, 1 set
Screwdriver O Minus type screwdriver, medium size, 2 set
Hammer O Plastic hammer, 1 set
Retaining Ring Pliers O For retaining ring, TSR-160
Steel Bar Steel bar of key material approximately 10 x 8 x
O
200
Torque Wrench O Capable of tightening with the specified torques

Tightening Torque
Tightening Torque Tool

Part Name Size
(kg.m) Size (mm) Name
M5 0.7 B=4
M6 1.2 5
M8 3 6 B
Hex Socket M10 5.8 8

Head Bolt M12 10 10
FG026934
(Material SCM435) M14 16 12
M16 24 14 Allen Wrench
M18 34 14
M20 44 17
NPTF 1/16 1.2 4
PT Plug
PT 1/16 0.7 4
(Material S45C)
PT 1/8 1.05 5
Wind Seal Tape Allen Wrench
PT 1/4 1.75 6
1.5 - 2 Turns
PT 3/8 3.5 8
Around the Plug.
PT 1/2 5.0 10
PF 1/4 3.0 6
PF 1/2 10 10
PF Plug PF 3/4 15 14
Allen Wrench
(Material S45C) PF 1 19 17
PF 1¼ 27 17
PF 1½ 28 17

Removal
WARNING
Contact with hydraulic fluid can harm your health. (e.g.
eye injuries, skin damage or poisoning, if inhaled).
● While performing removal and installation, wear
safety gloves, safety glasses and suitable working

clothes.
● If hydraulic fluid should come into contact with
your eyes or penetrate your skin, consult a doctor

immediately.
WARNING
FIRE CAN CAUSE SERIOUS INJURY OR DEATH
Hydraulic fluid is highly flammable.
● Keep open flames and ignition sources away from
the workplace.
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants,
grease, etc. must be disposed of in an environmentally
safe manner. Some regulations require that certain
spills and leaks on the ground must be cleaned in a
specific manner.
See local, state and federal regulations for the correct
disposal.
1. Park the machine on flat ground surface and stop

engine after swinging it for 15 ~ 20° to the right-
hand side as shown in the figure and placing the
bucket on the ground surface.
EX1301633
Figure 16

2. M ove safety lever on “RELEASED” (UNLOCK) O ACC
I
position.
LOCK
WARNING OFF OFF
ON
ON
If engine must be running while performing ON OFF
maintenance, always use extreme caution. Always EX1500510
have one person in the cabin at all times. Never leave
Figure 17
4. Operate the joystick levers and pedals several times

to release the remaining pressure in the hydraulic
piping.
5. Move safety lever to “LOCK” position.
starter switch.
7. Attach a maintenance warning tag on controls.
8. Turn battery disconnect switch to “OFF” position. ON
OFF
EX1500045
Figure 18

3
5 8
1 2
7 6
4
EX1401809
Figure 19

WARNING
Release any pressure in the hydraulic oil tank before
doing any work.
9. Loosen the oil tank air breather slowly to release

the pressure inside the hydraulic oil tank.
EX1500046
Pulling the breather cap upward, the check valve
(0.45 bar) opens, and the air is discharged to the Figure 20
atmosphere from the top of the hydraulic oil tank.
10. Oil drain method Suction Filter Cover
A. Remove cover (2 ea) on oil tank (bolt: 12 ea), Return Filter Cover
drain hydraulic oil using oil pump.
● Tool: 17 mm ( )
EX1500070
Figure 21
B. Drain hydraulic fluid using drain plug.

(without oil pump)
● Tool: 27 mm ( )
● Torque: 93.2 N.m (9.5 kg.m, 68.7 ft lb)
● Hydraulic oil tank capacity
– Approximately: 145 L (38.3 U.S. gal)

– Effective level: 97 L (25.6 U.S. gal)
C. Plug the filter cap to location of suction filter.
ltem Part Number

Filter Cap 2188-1008
EX1402349
Figure 23

Reference Number Description
1 Suction Filter 3
2 Nut
3 Rod
A
When installing
2
●Length (A): 647 mm
●Torque (2 nut): 49 N.m (5 kg.m, 36.2 ft lb)

1
11. Remove bolt (3, Figure ) (9 ea) and remove under
EX1402872
cover (1 and 2, Figure) under pump side.
● Tool: 19 mm ( ) Figure 24
● Cover weight 2
1
Reference Weight
Number kg lb
1,2 6 13
EX1500094
12. Open the right side door.
Figure 26
13. Remove bolts and washers (1, Figure) (4 ea) with

filter assembly (2).
Do not remove hoses (3, Figure 21).
● Tool: 17 mm ( )
Figure 27 Pump Room

14. Remove bolts (1,Figure)and remove baffle cover
(2,Figure) from pump room.
● Tool: 19 mm ( )
Figure 28
15. Remove bolts (1,Figure) (12 ea) with muffler cover

(2,Figure).
● Tool: 19 mm ( )
Figure 29
17. Remove bolts from pipe (1, Figure) and (2, Figure)
support.
● Tool: 19 mm ( )
Figure 30
Figure 31

18. Attach a lifting device onto lifting hole to support it.
19. Disconnect the connector of main harness from
EPPR valve and pressure sensor.
Figure 32
1
1
2
2
EX1500109
Figure 33
26. Remove bolts (4 ea) and remove suction pipe of

bottom of pump. Drain the hydraulic oil of suction
pipe to bowl.
● Tool: 10 mm ( )
Figure 34

27. Disconnect the hoses and adapters from bottom to
top of pump.
NOTE: Attach identification tags to the removed
hoses for reassembling After disconnecting
hoses from pump, plug them to prevent dirt or
dust from entering.
Figure 35
● Hoses and plugs ports

Plug/Flange Size Torque
Port Name
(Hose) (mm) (mm) N.m kg.m ft lb
A1 to Control Valve “P1” SAE 3/4”, D19 8 63.7 6.5 47.0
A2 to Control Valve “P2” SAE 3/4”, D19 8 63.7 6.5 47.0
to Pilot Filter
A3 UNF 13/16”-16-2B 24 55.9 5.7 41.2
(Gear Pump Delivery)
B3 Gear Pump Suction UNF 1 7/16”-12-2B 41 169.5 17.3 125.1
Dr1 to Oil Tank (Drain) UNF 1 3/16”-12-2B 36 124.5 12.7 91.9
Dr5 Gear Pump Drain UNF 13/16”-16-2B 24 55.9 5.7 41.2
Pi1 from Control Valve “ps1” UNF 9/16”-16-2B 19 25.5 2.6 18.8
Pi2 from Control Valve “ps2” UNF 9/16”-16-2B 19 25.5 2.6 18.8
from Pilot Filter “OUT”
Psv (Connect with Solenoid UNF 9/16”-16-2B 19 25.5 2.6 18.8
Valve “PO”)
a1,a2 Pressure Sensor PF 3/8” 27 6.0 0.6 4.4

Size Torque
Port Name
A B (C) (mm) N.m kg.m ft lb
A3 Adapter PF 1/2” UNF 13/16”-16 27 53 5.4 39
B3 Adapter PF 3/4” UNF 1 7/16”-12 41 73.5 7.5 54.2
Dr1 Elbow PF 1/2” UNF 1 3/16”-12 27 93.1 9.5 68.7
Dr5 Adapter PF 3/8” UNF 13/16”-16 27 31.4 3.2 23.1
PF 1/4”,
Pi1, Pi2 Tee PF 1/4” 19 39.2 4 28.9
UNF 9/16”-18
Psv Elbow PF 1/4” UNF 9/16”-18 19 39.2 4 28.9
DS2856002
A1, A2 Ring Seal (3/4”, ID:25.3,
OD:32.3, 1B)
A3 O-ring S8000185 (4D P18) S8030081 (1B F-08)

Size Torque
Port Name
2180-1026D31
B1 O-ring (ID:69.44, W:3.53,
Class1)
B3 O-ring S8000235 (4D P22.4) S8030165 (4D F-16)
Dr1 O-ring S8000235 (4D P22.4) S8030125 (4D F-12)
Dr5 O-ring S8000145 (4D P14) S8030081 (1B F-08)
Pi1,
2180-1216D11
Pi2, O-ring S8000115 (4D P11)
(ID:7.65, W:1.78, 1B)
Psv
* A: Opposite side of hose, B (C): Hose side
28. Remove bolts (10 ea) of pump without top bolts (2

ea).
● Tool: 17 mm ( )
EX1500112
Figure 36
29. A ttach a lifting device around pump. Raise the

lifting device until the pump is supported prior to
removing remaining bolts (2 ea).
● Main pump weight: about 91 kg (200.6 Ib) (with
cover and coupling
CAUTION
AVOID INJURY
Support the pump prior to removing remaining bolts to
EX1500113
prevent pump from falling.
Figure 37
30. Remove remaining bolts (2 ea).

● Tool: 17 mm ( )
Figure 38

31. Lift the pump from engine slowly and carefully.
32. Make sure there are no other electrical wires or
hoses connected to pump.
EX1500126
Figure 39
Installation
WARNING
INCORRECT INSTALLATION CAN CAUSE DEATH
OR SERIOUS INJURY
Any change in the connections will lead to
malfunctions (e.g. lift instead of lower).
● When connecting hydraulic components, observe
the specified piping according to the hydraulic

schematic diagram of the machine.
1. Perform installation in the reverse order to removal.

2. W hen installing the pump to engine, be careful
assembling pump shaft and drive coupling. Refer to
drive coupling installation.

Completing Work
1. If the hydraulic oil in the oil tank was removed, refill
the hydraulic oil tank.
IMPORTANT
Make sure the hydraulic oil tank is filled to an
appropriate level.
2. Stop the engine.

3. Remove drain plug. (Figure 40)
● Tool: 27 mm ( )
4. Keep pouring until the oil appears clean without gas Figure 40
bubbles; tighten the plug.
● Tool: 27 mm ( )

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

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

1. Loosen socket bolts (412, 413) to begin separation
of regulator valves from two pumps.
NOTE: See “Pump Regulator Disassembly” on page - 26
of this section for disassembly procedures.
2. Unbolt gear pump (rear pilot pump) at rear of main
pump assembly.
HDM3016P
Figure 41
3. When pilot pump and valve regulators have been

removed from assembly, the two pump cylinder
blocks (271) can be unbolted from center valve
support plate (251) and valve block (312). A total
of eight 17 mm Allen head hex bolts hold pump
assemblies together - four on each side.
4. Before unbolting eight pump block fasteners, flip
pump assembly top to bottom so regulator mounting
surfaces are facing down.
5. Unbolt all eight 17 mm hex bolts and separate both HDM3017L
pumps from center valve block, taking care not to Figure 42

damage O-rings (719) or lose or damage either one
of spring pins (886), between valve block and pump
casings.
NOTE: When pump assembly has been disassembled
to three main component sections (center
valve block, front pump and rear pump), the
procedure can be continued in either one of two
ways. Because both pumps, on either side of
the center valve block are identical, both can
be disassembled simultaneously, repeating the
same steps on opposite ends of the assembly at
the same time. If the rebuilding procedure is at all
unfamiliar, though, or there are any other reasons
to take a less aggressive approach, one pump
can be disassembled, rebuilt and completely
reassembled while the other pump is left for
reference, until rebuilding of the first pump has
been completed.

Main Pump Disassembly
1. Pull out cylinder block (141) from pump casing (271),
with all nine pistons (151), nine cylinder springs
(157) and nine shoes (152), including push plate
(153) and round bushing (156).
Figure 43
2. Unscrew two Allen head hex head bolts from front

seal cover plate (261). To separate cover plate
from rest of assembly, screw 6 mm cap screws
into threaded holes tapped into cover. Tighten all
four cap screws in a slow, staggered tightening
sequence, taking wrench off of each cap screw
after just a fraction of a turn and proceeding to next
- in regular rotation - until cover drops out.
HDM3019L
Figure 44
3. Separate pump casing (271) from support plate

(251) by tapping lightly with a plastic hammer. Be
careful not to damage either mating surface or
O-ring (717).
Figure 45
4. Withdraw driveshaft (111 and 113) on opposite

sides of center valve block) from swashplate
support and pull away valve plates (313 or 314).
Figure 46

NOTE: If a complete tear down and reassembly is being
performed, the only parts which should NOT
be loosened or removed are the hex nut (808)
spring pin servo piston stoppers in the swash
plate supports. (The preset discharge value would
require calibration if they were removed.) All other
remaining parts may be withdrawn from valve
block - needle bearing (124), spline coupling (114)
and pump casing - with stoppers (534, 535), servo
piston (532) and tilting pin (531) from the top of Figure 47
the pump casing.
IMPORTANT
Separation of servo pistons (532) and tilting pins (531)
must be done with a special fixture. Loctite #609 is
required for reassembly - on servo piston/tilting pin/
feedback pin (538).
NOTE: Do not disassemble the needle bearings (124).

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

1. Remove four Allen head bolts (412, 413) and pump
regulator assembly from pump body. Remove and
inspect O-ring gaskets (708, 724) found between
regulator casing and pump body.
NOTE: The regulator mounting bolts are uneven in length
and must be noted and replaced to the same
location.
Once regulator has been removed from pump, go to a
clean, well lighted, protected area for further Figure 48
disassembly. Use a rubber mat or other protective
covering on the workbench area to prevent damage or
scratching of any precision machined components.
2. Remove four Allen head bolts (436, 438) and pilot
cover (641) from regulator casing. Remove and
inspect O-rings (725, 730, 732, 734) found between
cover and regulator casing. Remove feedback lever
set spring (655) and adjusting screw bushing (647).
NOTE: These bolts are uneven in length and must be
noted and replaced to the same location. The pilot
cover is under pressure from feedback lever set
spring and care must be used when removing it. Figure 49

3. Remove retaining ring (814), spring seat (653) and
return spring (654) from feedback lever spool (652).
4. Remove pin (898) and Pf sleeve (631) from
compensator piston bore.
Figure 50
5. Remove four Allen head bolts (438) and pilot piston

lower cover (629) from regulator casing. Remove
and inspect O-rings (756, 763). Remove inner
spring (626), outer spring (625) and spring seat (624)
from Pf piston bore.
Figure 51
6. Remove adjusting ring (645) from bore by threading

a 4 mm x 50 mm bolt into center of adjusting ring
and gently pulling it out. Remove and inspect O-ring
(728). The shim (649), pilot spring (646) and spring
seat (644) will become loose and slide out of the
bore.
Figure 52

7. Remove four Allen head bolts (438) and cover (656)
from opposite side of portion and adjusting plugs.
Remove and inspect O-rings (722, 735).
Figure 53
8. R emove two retaining rings (858), portion plug

(614) and adjusting plug (615) from bore. A 4 mm
x 50 mm bolt can be threaded into these plugs and
gently pulled out, if they do not freely slide out of
the bore. Remove and inspect O-rings (755).
NOTE: The portion plug (614) and adjusting plug (615)
can be differentiated from each other by the pin
(875) at bottom of the portion plug (614).
Figure 54
9. Remove pilot piston (643) from bore.
Figure 55

10. Disassemble feedback lever (611) assembly by
separating side levers (612, 613). A 2 mm punch
can be used to drive out pins (875) from levers.
Figure 56
11. Remove piston case (622), compensator piston

(621) and piston rod (623) from piston bore.
Remove and inspect O-ring (733) from piston case
(622).
Figure 57
12. Remove spool (652) and sleeve (651) from bore

by driving out pin (874). This will release feedback
lever (611) from housing. Inspect retaining ring
(836) on sleeve.
Figure 58

(WEAR LIMITS AND
TOLERANCES)
NOTE: Inspect all components and precision surfaces
to confirm that they haven’t been worn beyond

service limits. Check the table below for
dimensional specifications.
All parts must be cleaned, air-dried and
relubricated with clean, approved type hydraulic
fluid, before final reassembly or as the final step
after the unit has been put back together again.
Replacement of all O-rings and oil seals with new
parts is generally recommended, unless pump has
had very few operating hours of use.
2
1
d D
5
4
3
H
h
a
t
HBOA230L
Figure 59
NOTE: Rounded bushings and push plates must always

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

Service Standards for Replacing Worn Parts
NOTE:When parts exceed the standard, replace them.
When there is conspicuous surface damage, it is always

safer to replace parts, whether standards are
exceeded or not.
Reference Standard Value Replacement

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

nicks, brittleness, softness or any other damage or
distortion, before final reassembly if any must be
reused.

REASSEMBLY
Pump Regulator Reassembly
1. Install O-ring (733) and compensator piston
(621) to piston case (622). Insert assembly into
compensator bore.
2. Insert compensator piston rod (623) into piston
bore.
Figure 60
3. Assemble lever (612) to casing using pin (875).
Figure 61
4. Install retaining ring (836) onto spool sleeve (651)

and insert sleeve into spool bore. Insert spool (652)
into sleeve (already installed in block).
Figure 62

5. Attach feedback lever (611) to spool (652) using pin
(874).
Figure 63
NOTE: The notched portion of spool should face down

when mated into feedback lever for correct pin
alignment.(Figure 64)
1, 2 - Feedback lever (611)
3 - Spool (652)
3 2
HAOF220L
Figure 64
6. Insert pilot piston (643) into bore.
Figure 65

7. Assemble lever (613) onto feedback lever (611).
NOTE: Make certain pin (875) at the lower portion of
lever (613) is properly mated with groove in
piston (643).
Figure 66
8. Install O-rings (755) onto portion (614) and

adjusting (615) plugs. Insert pin (875) into portion
plug. Install both plugs into their proper bore and
secure with retaining rings (858).
NOTE: Be certain to install plugs into correct bore.
Feedback lever should move freely and not
bind up.
Figure 67
9. Install O-rings (722, 735) into cover and mount

cover (656) onto block using four Allen head bolts
(438).
Figure 68

10. Install O-ring (728) onto adjusting ring (645). Insert
spring seat (644), pilot spring (646) and adjusting
ring (645) into adjusting ring bore.
Figure 69
11. Insert spring seat (624), outer spring (625) and

inner spring (626) into Pf piston bore. Install
O-rings (756, 763) into pilot piston lower cover
(629). Mount cover onto regulator casing by using
four Allen head bolts (438).
Figure 70
12. I n s t a l l P f s l e e v e ( 6 3 1 ) a n d p i n ( 8 9 8 ) i n t o
compensator piston bore.
13. Install return spring (654), spring seat (653) and
retaining ring (814) onto feedback lever spool (652).
Insert feedback lever set spring (655) around
spool.
Figure 71

14. Insert adjusting screw bushing (647) into pilot
piston bore. Install O-rings (725, 730, 732, 734)
into their proper locations. Mount pilot cover (641)
onto regulator casing by using four Allen head bolts
(436, 438).
NOTE: Cover mounting bolts (436, 438) are uneven
in length and must be replaced to their proper
location.
Figure 72
15. Install O-rings (708, 724) to regulator casing base

and mount regulator to pump body using four Allen
head bolts (412, 413)
NOTE: The regulator mounting bolts (412, 413) are
uneven in length and must be replaced to their
proper location.
Figure 73
Main Pump Reassembly

NOTE: Reassembly must be done by reversing
disassembly steps.
1. Begin reassembly with servo piston (532), tilting pin
(531) and feedback pin (538) at top of pump case.
Use Loctite #609 to hold tilting pin and servo piston
if those parts have been disassembled.
2. Bolt swash plate support (251) to pump casing (271).
Tighten four Allen head mounting bolts.
3. Turn pump case upside down, with regulator
mounting surface on work surface. Insert tilting
bushing (214) of swash plate into tilting pin (531)
and assemble swash plate assembly (212/211) to Figure 74
support (251).
NOTE: Apply lubricant to all parts of swash plate
assembly to make assembly work easier. Use
both hands to check and verify complete free
movement of assembly after parts have been
reinstalled.

4. Subassemble driveshaft (111 or 113) with roller
bearing (123), bearing spacer (127) and retaining
ring (824). Install driveshaft into swash plate
support (251).
IMPORTANT
Do not use excessive force, hammer blows or other
tools to install the driveshaft. The subassembly can be
assembled using your hands.
Figure 75
5. Mount outer wheel of bearing on end of driveshaft

with plastic hammer. Use brass rod as a drift to
push outer wheel into final position. Install retaining
ring (824).
Figure 76
6. Grease O-ring (710) and oil seal (774) for

protection; then install seal cover (261) and tighten
mounting screws.
Figure 77
7. Assemble pistons (151) and shoes (152) and

cylinder parts push plate (153), round bushing
(156) and spacer (158) in cylinder (141) and install
assembly in pump casing. Mount valve plate (313
or 314) on valve block (312) and verify valve plate
inlet and outlet port alignment.
Figure 78

Figure 79
8. When both front and rear pump have been

completely reassembled, verify direction of valve
block. Install rear pump first.
Figure 80
9. Install regulators after pump assembly is bolted

together and replace case drain plugs.
Figure 81

Gear Pump
DX140AF/DX140LCA Gear Pump 7-82

ＭＥＭＯ

Table of Contents
Gear Pump
SINGLE GEAR PUMP............................................... 86
Disassembly......................................................... 86
Reassembly.......................................................... 88

SAFETY INSTRUCTIONS
WARNING

SINGLE GEAR PUMP
Disassembly
1. Clean exterior of pump.
FG001072
Figure 1
2. Remove clamp bolts.
FG001074
Figure 2
3. Cover sharp edges of driveshaft with adhesive tape

and coat shaft end extension with clean grease,
to avoid any damage to lip of shaft seal when
removing mounting flange.
FG001073
Figure 3

4. Remove mounting flange taking care to keep flange
as straight as possible during removal.
If mounting flange is stuck, tap around edge with
rubber mallet to break it away from body.
NOTE: Make sure that while removing mounting flange,
shaft and other components remain in position.
FG001075
Figure 4
5. Remove retaining ring, if replacement is necessary.
FG000834
Figure 5
6. Remove shaft seal taking care not to damage

surface of shaft hole, if replacement is necessary.
FG000835
Figure 6
7. Pull drive gear up to facilitate removal of front plate.
FG001076
Figure 7

8. Remove driving gear and driven gear, keeping
gears as straight as possible.
FG001077
Figure 8
9. Remove rear plate and end cover.
FG001078
Figure 9
Reassembly
1. Clean all components with care.
FG001078
Figure 10
2. Using a suitable driver, install shaft seal in

mounting flange.
FG000839
Figure 11

3. Install retaining ring in groove.
FG000840
Figure 12
4. Install O-ring on both sides of rear section of body.

NOTE: Coat O-rings with grease to hold O-rings in
body.
FG001079
Figure 13
5. Install rear section body on rear cover.
FG001080
Figure 14
6. Install seals in pressure plate(s) groove. Then Outlet Side

install backup ring in groove with seals. Coat seals
with grease.
NOTE: The front and rear pressure plates and seals
and backup rings are the same.
Inlet Side
FG001401
Figure 15

7. Insert pressure plate assembly into body while
keeping it straight.
NOTE: Seal side should face to rear cover, opposite
side of gears.
NOTE:Pay attention to installation direction of seal.
FG001081
Figure 16
8. Install drive gear and driven gear.
FG001082
Figure 17
9. Insert pressure plate into body in proper direction.
FG001083
Figure 18
10. Locate mounting flange in right position.
FG001084
Figure 19

11. Tighten bolts with washer in a crisscross pattern to
a torque value of 45 Nm.
FG001085
Figure 20
12. Check that pump rotates freely when driveshaft is

turned by hand. If not a pressure plate seal may be
pinched.
FG000851
Figure 21

Drive Coupling
(Main Pump)
DX140AF/DX140LCA Drive Coupling (Main Pump) 7-92

ＭＥＭＯ

Table of Contents
Drive Coupling (Main Pump)

GENERAL................................................................. 95
Specification..................................................... 95
Parts List................................................................... 96
SECTION VIEW........................................................ 98
Tools................................................................. 99
DISASSEMBLY....................................................... 100
REASSEMBLY........................................................ 101

SAFETY INSTRUCTIONS
WARNING
GENERAL
Specification
Condition in Use
Operation rpm Range 800 ~ 1,900 rpm
Max. Torque 1,570 N.m (160 kg.m, 1,158 ft lb)
Specification
Nominal Torque 785 N.m (80 kg.m, 579 ft lb)
Max. Torque 1,570 N.m (160 kg.m, 1,158 psi)
Max. Speed 1,900 rpm
Radial 0.4 mm (0.015 in)
Max. Permissible Displacements Angular 0.5°
Axial ±2 mm (±0.787 in)
Dynamic Torsion Spring Stiffness Cdyn 1.96 x 106 kg.cm/Rad
Mass Moment of Inertia 2.33 kg.cm. S
Allowable Environment Temperature -20 ~ +120°C

Parts List
10
11
9
8
8 3
4
7
5
2
6
6-5
6-3
6-5
6-7
6-4
6-2
6-6
6-1
6-8 : 6-2, 6-3, 6-4

6-7
EX1500006
Figure 1

Reference Reference
Number Number
1 Pump, Main 6-5 Socket Bolt Set (8 ea)
2 Cover 6-6 Bolt; Clamping M16 x 2.0 x 25
3 Bolt; Socket 6-7 Pin; Spring D5 x 10
4 Washer; Spring 6-8 Element Kit
5 Washer, Spring 7 Bolt
6 Coupling 8 Sensor; Pressure
6-1 Hub 9 Spacer
6-2 Element 10 Bolt
6-3 Insert (A) 11 Bracket; Pump
6-4 Insert (R)

SECTION VIEW
Whenever the drive coupling for main pump is
installed, the following mounting dimensions and
installation procedures must be observed.
NOTE: If these procedures are not followed, noise will
occur and/or the service life of drive coupling or
main pump will be reduced.
12
5 10
3
1
11
H
2
5
EX1500119
Figure 2 Drive Coupling Installation

Reference
Description Qty. Torque
Number
1 Hub 1
2 Element 1
3 Insert A 4
4 Insert R 4
5 Socket Bolt 8 206 ~ 226 N.m (21 ~ 23 kg.m, 152 ~ 166 ft lb)
7 Clamping Screw 2 98 ~ 118 N.m (10 ~ 12 kg.m, 72 ~ 87 ft lb)
8 Spring Pin 12
9 Support Plate 1
10 Bolt 4 264 N.m (27 kg.m, 195 ft lb)
11 Pump Shaft 1
12 Flywheel 1
Symbol Dimension Remarks

H 3.5 mm (0.14 in) Distance between from Pump Shaft to Coupling Hub
Tools
Name Description
Allen Wrench 8 mm, 14 mm, 17 mm
Plastic Hammer One Plastic Hammer

DISASSEMBLY
When the pump is removed from an engine, the hub
and insert would be attached on the pump.
1. After removing pump remove socket bolts (5, Figure
3) (4 ea) and remove insert (4) (4 ea).
● : 14 mm 5
6
2. Remove clamp screw (6, Figure 3) (2 ea) and
remove hub (1).
● : 8 mm
4
1
EX1500121
Figure 3
3. Remove socket bolts (5, Figure 4) (4 ea) and insert 3

(3, Figure 4) (4 ea) with element (2) and plate (9)
from flywheel. 5
● : 14 mm
2
EX1500122
Figure 4

REASSEMBLY 3
1. Place the plate (9, Figure 5) on flywheel.
Install insert (3, Figure 5) (4 ea) and spring pin
(7, Figure 6) (4 ea) with socket bolts (5) (4 ea) to 5
engine flywheel.
● : 14 mm 9
● Torque: 206 ~ 226 N.m (21 ~ 23 kg.m, 152 ~ 166
ft lb)
EX1500123
Figure 5
Flywheel Side
EX1500137
Figure 6
2. Assemble the insert (4, Figure 7) (4 ea) with socket

5
bolts (5) (4 ea) to hub (attached by spring pin) (7) (8 4
ea).
● Torque: 206 ~ 226 N.m (21 ~ 23 kg.m, 152 ~ 166
1
ft lb)
EX1500124
Figure 7

3. Slide hub into place on pump shaft (8, Figure 8).
Keep the dimension 3.5 mm between end of pump 8
shaft to hub and secure it in position with clamping 6
bolts (6).
● Torque: 98 ~ 118 N.m (10 ~ 12 kg.m, 72 ~ 87 ft
lb) 1
NOTE:Coat clamping bolts (6, Figure 8) with Loctite #262.
NOTE:Refer to “Dimension” of “H” on page -9.
EX1500135
Figure 8
4. Install element (2, Figure 9) inserts (3) on engine

3
flywheel.
5. Install main pump and hub (1) by pushing it softly 2
into element (2).
IMPORTANT
1. Bolts are coated against loosening with a bonding
compound. Do not use any additional bonding
EX1500136
compounds, oils or cleaning solvents on them.
2. Element (2, Figure 9) is not resistant to bonding Figure 9
compounds, oil or grease. Be careful not to expose
them to it.
3. Remove oil or dirt from flywheel cover and pump
shaft before assembly.
4. Misalignment between pump and engine must be
controlled to less than 0.6 mm (0.023 in).

Main Control Valve
DX140AF/DX140LCA Main Control Valve 7-103

ＭＥＭＯ

Table of Contents
Main Control Valve

SAFETY PRECAUTIONS........................................ 106
GENERAL............................................................... 106
Overview......................................................... 107
Parts List......................................................... 112
Cautions for Operation.................................... 136
PRECAUTION......................................................... 137
REMOVAL............................................................... 138
INSTALLATION....................................................... 152
COMPLETING WORK............................................. 152
DISASSEMBLY....................................................... 153
Cautions on Disassembly............................... 153
Sequence of Disassembly.............................. 154
CLEANING AND INSPECTION............................... 162
Cleaning.......................................................... 162
Inspection ...................................................... 162
REASSEMBLY........................................................ 163
Caution on Assembly...................................... 163
Sequence of Reassembly............................... 164
TROUBLESHOOTING AND ADJUSTMENT........... 174
Troubleshooting.............................................. 174
Adjusting Relief Valve..................................... 176

SAFETY PRECAUTIONS
WARNING
GENERAL
Specification
Control Method Negative Control

Rated Flow 160 L/min (30 L/min in neutral)
High 348 bar (350 kg/cm2, 4,978 psi) at 90 L/min
Main Relief Pressure
Low 323 bar (330 kg/cm2, 4,684 psi) at 90 L/min
Overload Relief Pressure 328 bar (365 kg/cm2, 5,192 psi) at 20 L/min
Max. Pressure of 1.5 MPa or Less
Permitted Back Pressure
Used Pressure of 0.5 MPa or Less
Normally -20 ~ +80°C
Permitted Use of Oil Temperature Highest 100°C
(Use of the Rubber for NBR)
OP2+OPT3 160 kg (353 lb)
Weight OPT3 146 kg (322 lb)
STD 133 kg (293 lb)

Overview
Figure 1

Port Name Size
AR1 Arti Boom Up
BR1 Option3
AR2 Option2
BR2 Option2
P3 P2 Pump High-pressure (Plugged)
P4 Two Pump Flow Valve (Option) PF 1/2
A3 Swing Motor Left
B3 Swing Motor Right
A7 Bucket Cylinder Tube Side
B7 Bucket Cylinder Rod Side
B8 Boom Cylinder Rod Side
P1 Pump High-pressure (A1)
P2 Pump High-pressure (A2)
A1 Travel Backward (LH)
B1 Travel Forward (LH)
A2 Option
B2 Option PF 3/4
A5 Arm Cylinder Rod Side
B5 Arm Cylinder Tube Side
A6 Travel Backward (RH)
B6 Travel Forward (RH)
A8 Boom Cylinder Tube Side
T1 Return Line 1 SAE 1 1/4”
T2 Return Line 2 SAE 1”
PP Pilot Pressure (40 bar)
PT Pressure Sensor Port
pc1 Lock Valve Pilot (Arm Crowd)
pc2 Lock Valve Pilot (Boom Down)
pc3 Drain Port
Swing Parking Brake Port (SH) and
PA
Pressure Sensor
PH Pressure Up
ps1 Negacon Pressure (Pi1) PF1/4
ps2 Negacon Pressure (Pi2)
DR Drain
pbu Drain Port
pcc Two Pump Signal
par1 Option3 Pilot
pbr1 Option3 Pilot
Par2 Option2 Pilot
Pbr2 Option2 Pilot

Port Name Size
pa1 Travel Backward (LH) Pilot
pa2 Option Pilot
pa3 Swing Left Pilot
pa4 Boom 2 Up Pilot
pa5 Arm 1 Dump Pilot
pa6 Travel Backward (RH) Pilot
pa7 Bucket Crowd Pilot
pa8 Boom 1 Up Pilot
pa9 Arm 2 Dump Pilot
PF3/8
pb1 Travel Forward (LH) Pilot
pb2 Option Pilot
pb3 Swing Right Pilot
pb4 Drain (Boom 2)
pb5 Arm 1 Crowd Pilot
pb6 Travel Forward (RH) Pilot
pb7 Bucket Dump Pilot
pb8 Boom 1 Down Pilot
pb9 Arm 2 Crowd Pilot

Tr4
BR2
AR2
pbr2 OPT3
358 bar@20L/min
par2
BR1
AR1
Pbu
pbr1 OPT2
358 bar@20L/min
par1 DR
8 T2 T1
Pi2 7
of Pump
ps2 ps1
9 pc1
pcc A5
6
pb9 ARM2 ARM1 B5
pb5
358 bar@20L/min
pa9
pc2 5 4 pa5
A8 pc3
B8 B4
pb8 BOOM1 BOOM2 pb4
pa8 pa4
358 bar@20L/min
B7 B3
A7 SWING A3
BUCKET
pb7 pb3
pa3
pa7 358 bar@20L/min
B2
B6 OPTION A2
A6 pb2
358 bar@20L/min P4
pb6 TRAVEL(R) pa2
pa6 B1
A1
3
TRAVEL(L) pb1
STRAIGHT pa1
TRAVEL Ts3
1 2 Ts5
Lo:328 bar@90L/min
VALVE(RIGHT) Hi:348 bar@90L/min VALVE(LEFT)
P2 P3 PH PA PP PT P1
EX1500144
Figure 2
Reference Reference
Number Number
1 Main Relief Valve 6 Arm Holding Valve
2 Orifice 7 Foot Relief Valve
3 Travel Straight Spool 8 Foot Relief Valve
4 Arm Regeneration Valve 9 Center Bypass Cut Valve
5 Boom Holding Valve

Left Side View
Arm Holding Valve

ps1
Arm Cylinder B5 A5 Arm 1
Boom 2
B3 A3 Swing
Swing Motor Option
B1 A1 Travel (LH)
Travel Motor (LH) P1 PH
Main Relief Valve

Negacon Signal
Main Pump
Right Side View
Dozer (OPT3)
Arti Boom (OPT2) AR2 BR2
AR1 BR1
Overload Relief Valve
Center Bypass Cut Valve
Boom Holding Valve
ps2 T2
Arm 2 Boom Cylinder
Boom 1 A8 B8
Bucket A7 B7 Bucket Cylinder
Travel (RH) A6 B6
Straight Travel
P2 Travel Motor (RH)
Negacon Signal
Main Pump
EX1500145
Figure 3

Parts List
74 72
77-8
73 71
32
63 77-7
77-8
77
68
77-7 61 39
63 38
37
77 36
63 63 33
56
32 35
63 34
32 32 19
59 18
58 55 16 17
60
60
57
19
1 18
69
63 26 17
21
21
63
22
63 53 18
54
27 28 53
29 31 30
52
70 51
17 16 50
18 69 67 49
19
90
47 66 55
24 63
46 25
18 16
23 21 17
81 32 16 18
17 19
16 18
17 19
18 69 27
66 13 42 19 28
90 29 62
65 21 20 63
31
67
30 7
89 63 8
88
9
ARM 2
65 BOOM 1 12 65
13 14
BUCKET
45
43 12 TRAVEL 11
44
43 ST. TRAVEL
48 6
45 10
43 5
44 2
43
41
65
15
ARM 1
2
3 BOOM 2
4 88 SWING
89
OPTION 1
12
11 TRAVEL
EX1500166
Figure 4

Reference Reference
Number Number
1 Housing; Valve 42 O-ring
2 Spool Assembly, Travel 43 Seat; Spring
3 Spool Assembly - Option 44 Spring
4 Spool Assembly, Swing 45 Spool End
5 Spool Assembly, Boom2 46 Cap
6 Spool Assembly, Arm1 47 Cap
7 Spool Assembly, Arm2 48 Spool
8 Spool Assembly, Boom1 49 Plug
9 Spool Assembly, Bucket 50 O-ring
Spool Assembly, Straight 51 Spring
10
Travel 52 Spool Assembly; Arm Regen
11 Cap 53 Ring; Backup
12 O-ring 54 O-ring
13 Cap 55 Valve; Relief
14 Cap 56 Plug; Orifice
15 Cap 57 Popet
16 Poppet 58 Spring
17 Spring 59 O-ring
18 O-ring 60 O-ring
19 Plug 61 Outlet Assembly
20 Plug Assembly 62 Valve, Main Relief
21 Plug 63 Valve; Relief
22 Plug 65 Bolt; Socket M8 x 1.25 x 25
23 Plug 66 Bolt; Socket
24 Poppet 67 Bolt; Socket
25 Spring 68 Socket-head Bolt
26 Poppet 69 Plug Assembly
27 Poppet 70 Plug Assembly
28 Spring 71 Rod,tie
29 Spacer Assembly 72 Nut
30 Valve Assembly; Anti Drift 73 Rod, Tie
31 O-ring 74 Nut
32 Plug Assembly 77 Block Assembly; Arti/Dozer
33 Sleeve 77-7 O-ring
34 Poppet 77-8 O-ring
35 Spring 81 Plug Assembly
36 Poppet 88 O-ring
37 Spring 89 Plug
38 O-ring 90 Plug Assembly
39 Flange
41 Spool

Theory of Operation
When All Spools are in Neutral
Neutral Passage
The oil supplied from the port (P1) enters into the tank
passage (Ta) through the orifice (L2) of negative relief
from the neutral passage (L1) and returns to ports (T1).
The oil supplied from the port (P2) passes the tank
passage (Ta) through orifice (R2) of negative relief
from the neutral passage (R1) and returns to port (T2).
The pressure of chambers (L2 and R2) flowing over
the negative relief, flows into pump from ports (ps1
and ps2), to control the volume of pump (P1) and (P2).
In addition, when excessive oil flows excessive into
the neutral passage, the negative relief operates to
prevent the abnormally high-pressure on ports (ps1
and ps2).

R1
DR
Ta
Center-Bypass Cut Valve
S5-8 T2 pbu ps2 pcc R2 Negacon Relief Valve (Rc1)

Orifice
L2 Negacon Relief Valve (Lc1)
ps1 Arm Regen Valve R

Tr4
L3
Ta
S5-2
pc3 L1
Lc9
R1
ps1
R3
L1
Arm 1 Arm 2
Boom 2 Boom 1
Swing Bucket
Option L3 R3 Travel (RH)
Travel (LH) Straight Travel
L1 R1
A P1 P2
L R
View A P1 Side P2 Side
EX1500146
Figure 5

Arm Regeneration Valve
pc3
pa5
pb5
Arm 1
pa4
pb4
Boom 2
pa3
pb3
Swing
pa2
pb2 Option
pa1
pb1
Travel (LH)
P1
Ts5
SECTION "L"
Main Pump EX1500147
Figure 6

Tr4
par2 pbr2
Dozer
pbr1
par1
Arti
Center-bypass Cut Valve

pcc pbu
DR ps2 T2
pb9
pa9 Arm 2
pb8
pa8
Boom 1
pb7
pa7 Bucket
pb6
pa6 Travel (RH)
Straight Travel
P1
PH P2
P1P
Ts3
Main Relief Valve

SECTION "R"
Main Pump
EX1500148
Figure 7

Single Operation
Boom Spool Shift
1. Boom neutral
This valve incorporates an antidrift valve on the
bottom of the cylinder of boom 1.
I n a neutral state, the poppet (AD1) is fully seated
by the pressure at port (A8) which is applied to
the spring chamber (AD5) through the path (AD2),
poppet (AD3), and path (AD4).
B4
L3 Ta Boom Cylinder
pb4 pa4
L1 Boom 2
DR
pb8 pa8
Ta Boom 1
R3
AD4
AD3
B8 A8
AD1 AD5 DR AD2
Boom Holding Valve
pc2
Boom Cylinder
DR1
pc2
A8
B8
B4
pb4 pb8
Boom 2 Boom 1
358bar@20L
pa4 pa8
P1 P2 EX1500149
Figure 8

2. Boom up (2-pump confluence)
When the boom 1 spool is moved by being
pressurized through the pilot port (pa8) of the boom
1 (Figure 9), the neutral path (R1) will be closed.
The oil supplied through port (P1) flows from the
parallel path (R3) to port (A8) by the load check
valve (S8- 1) and spool head.
When the boom 2 (Figure 9) spool is also moved
by being pressurized through the pilot port (pa4) of
boom 2, the neutral path (L1) will be closed. The oil
supplied through port (P1) joins in port (A8) by the
parallel path (L3), load check valve (S4-1), spool
head and path (7). Lubricant oil returns to the tank
path (Ta) from port (B8) by the spool head.
B4 S4-1
Ta Ta Boom Cylinder
L3
pb4 pa4
L1 Boom 2
R1 DR
7
pb8 pa8
R3
Ta Boom 1
AD4
AD3
B8 A8
S8-1 AD1 AD5 DR AD2
Boom Holding Valve
pc2
Boom Cylinder
DR1
pc2
A8
B8
B4
pb4 pb8
Boom 2 Boom 1
358bar@20L
pa4 pa8
P1 P2 EX1500150
Figure 9

3. Boom down (Regeneration)
When the boom 1 spool is moved by being
pressurized through the pilot port (pb8) of the
boom1, the neutral path (R1) will be closed. The oil
supplied through port (P2) flows from the parallel
path (R3) to port (B8) by the load check valve (S8-1)
and spool head.
At the same time, when the poppet (AD3) of the
antidrift valve is moved by pressurizing port (pc2) to
depressurize the spring chamber (AD5), the poppet
(AD1) will be opened, enabling the lubricant oil to
return from port (A8) to the tank path (Ta). A portion
of the lubricant oil pushes open the poppet (S8-3)
inside the boom 1 spool, flows through path (S8-2)
and joins at port (B8) to prevent cavitation on the
cylinder rod side.
B4
L3 Ta Boom Cylinder
Ta
pb4 pa4
L1 Boom 2
S8-3 R1 DR
pb8 pa8
R3
Ta Boom 1
S8-2 AD4
AD3
B8 A8
S8-1 AD1 AD5 DR AD2
Boom Holding Valve
pc2
Boom Cylinder
DR1
pc2
A8
B8
B4
pb4 pb8
Boom 2 358bar@20L Boom 1

pa4 pa8
P1 P2 EX1500151
Figure 10

Arm Spool Shift
1. Arm dump (2-speed convergence)
When the arm 1 spool is moved by being
pressurized through the pilot port (pa5) of the arm 1,
the oil supplied through the (P1) port flows from the
neutral path (R1)to the (A5) port by load the check
valve (S5- 1), path (S5-2) and spool head.
When the arm 2 spool is also moved by being
pressurized through the pilot port (pa9) of the arm 2,
the oil supplied through port (P2) flows from neutral
path (R1) to join at port (A5) by the load check
valve (S9-1) path (S9-2), spool head, and path (10).
At the same time, a portion of the oil from port (P2)
flows from path (R3) to port (A5) by the orifice (S9-3),
check valve (S9-4), path (S9-2) and path (10). The
lubricant oil returns to the tank path (Ta) from port
(B5) by the spool head of arm 1 at the same time,
it returns to the tank path (Ta) from path (11) by the
spool head of arm 2.
Arm Cylinder
pc1
Arm Holding Valve

DR
S5-1 S5-2 AD1 AD2
B5 A5
AD3
AD5
AD4
L3 S5-4
pb5 pa5
Ta L1 Ta
Arm 1
11 R1 10
pb9 pa9
Ta Arm 2
R3
RC6
Ta
S9-2 S9-4
Arm Cylinder
S9-3 S9-1
DR1
pc1
A5 Arm Lock
B5
pb5 pb9
Arm 1 Arm 2
358bar@20L
pa5 pa9
P1 P2 EX1500152
Figure 11

2. Arm crowd (2-speed confluence)
pressurized through the pilot port (pb5) of the arm
1, the oil supplied from port (P1) flows from the
parallel path (L1) to port (B5) by the load check
valve (S5-1), path (S5-2), and spool head.
pressurized through the pilot port (pb9) of the arm 2,
the oil supplied through the (P2) port will join at port
(B5) by the parallel path (R1), load check valve (S9-
1), path (S9-2), spool head, and path (11). At the
same time, a portion of the oil from port (P2) flows
to port (B5) through the path (R3), orifice (S9-3),
check valve (S9-4), path (S9-2), and path (11).
When the antidrift valve spool (AD3) is moved
by being pressurized through the (Pc1) port to
depressurize the spring chamber (AD5), the poppet
(AD1) will be opened and the lubricant oil in the (A5)
port will return to the tank path (Ta) by the spool
head, path (S5-3), and arm variable recycle orifice
(LC8).
A portion of the lubricant oil pushes the poppet (S5-
4) in the arm 1 spool open, flows through path (S5-
2) and joins at port (B5) to accelerate the cylinder,
preventing cavitation on the bottom side.
ps1
Ta Arm Regeneration Valve
S5-5 S5-6 Lc8 S5-3

Arm Cylinder
pc1
Arm Holding Valve

DR
S5-2 S5-1 AD1 AD2
B5 A5
AD3
AD5
AD4
L3 S5-4
pb5 pa5
11 L1 Ta
Ta Arm 1
R1 10
pb9 pa9
Ta Rc6 Arm 2
R3
Arm Cylinder Ta
S9-2 S9-4
S9-3 S9-1
DR1
pc1
A5 Arm Lock
B5
pb5 pb9
Arm 1 Arm 2
358bar@20L
pa5 pa9
P1 P2 EX1500153
Figure 12

3. Variable regeneration (at crowd control)
In arm crowd operation, the spool (S5-6) will stroke
according to the pressure in the path (S5-2) induced
through the path (S5-5), to change the position of
the arm variable recycle orifice (Lc8).
When the pressure in path (S5-2) is high, the
stroke of the spool (S5-6) will be increased, which
will increase the opening of the orifice (Lc8).
Conversely, if the pressure in the path (S5-2) is low,
the stroke of the spool (S5-6) will be decreased,
which will decrease the opening of the orifice (Lc8).
Therefore, the recycle oil volume varies according
to the head pressure of the arm cylinder.
ps1
Ta Arm Regeneration Valve
S5-6 Lc8
S5-5 S5-3
Arm Cylinder
pc1
Arm Holding Valve

DR
S5-2 S5-1 AD1 AD2
B5 A5
AD3
AD5
AD4
L3 S5-4
pb5 pa5
L1 Ta
Ta 11 Arm 1
R1 10
pb9 pa9
Ta Rc6 Arm 2
R3
Ta
S9-2 S9-4
S9-3 S9-1
pc3
Arm 1
S5-5
pb5 pa5
EX1500154
Figure 13

Parallel Orifice for Arm
In the arm parallel circuit of this valve, both arm 1 and
arm 2 are equipped with orifices, which control the
arm speed even in composite operation. The parallel
circuit of arm 2 is throttled at the orifice (Rc6) of the
sleeve (S9- 3) in the parallel path (R3), and connected
with path (S9-2) through the poppet (S9-4). (Figure
) The parallel circuit of the arm 1 pushes open the
poppet (S5-8) in the parallel path (L3), is throttled by
the orifice (Lc9) of the parallel variable orifice spool,
and connected with the path (S5-2).
The throttle volume of orifice (Lc9) can be controlled
by the pressure at the pilot port (Pc3).
S5-8
ps1
Negacon Relief Valve(Lc1)
L3
L2
Arm Regen Valve
Ta
S5-2
pc3
Lc9 R1
DR
Ta
Neutral Cut Spool(R)

R2
Negacon Relief Valve(Rc1)
T2 pbu ps2 pcc
pc3
Arm 1
S5-5
pb5 pa5
EX1500155
Figure 14

Bucket Spool Shift
When the bucket spool is moved by being pressurized
through the pilot port (pb7) (pa7) of the bucket the
neutral path (R1) will be closed.
parallel path (R3) to port (B7) (A7) by the load check
valve (S7- 1) path (S7-2) and spool head.
Lubricant oil returns to the tank path (Ta) from (A7) (B7)
by spool head.
S3-2 S3-1
B3 A3
Ta L3 Ta
pb3 pa3
L1 Swing
R1
pb7 pa7
Ta Ta Bucket
R3
B7 A7 Bucket Cylinder
S7-2 S7-1
Swing Motor
B3 B7
A3 A7
pb3 pb7
Swing 358bar@20L Bucket
pa3 pa7
P1 P2
EX1500156
Figure 15

Swing Spool Shift
When the swing spool is moved by being pressurized
through the pilot port (pb3) (pa3) of the swing, the
neutral path (L1) will be closed.
parallel path (L3), by the load check valve (S3-1), path
(S3-2), and the spool head to the (B3) (A3) port.
Lubricant oil returns to the tank path (Ta) from (A3) (B3)
by the spool head.
S3-2 S3-1
B3 A3
Ta L3 Ta
pb3 pa3
L1 Swing
R1
pb7 pa7
Ta Ta Bucket
R3
B7 A7 Bucket Cylinder
S7-2 S7-1
Swing Motor
B3 B7
A3 A7
pb3 pb7
Swing 358bar@20L Bucket
pa3 pa7
P1 P2 EX1500157
Figure 16

Option Spool Shift
When the spool is moved by being pressurized
through the pilot port (pb2) (pa2) of the option spool,
the neutral path (L1) will be closed. The oil supplied
through port (P1) flows through the parallel path (L3)
load check valve (S2-1), path (S2-2), and spool head
to port (B2) (A2).
Lubricant oil returns from (A2) (B2) to the tank path (Ta)
by the spool head.
This section makes use of the load check valve which
allows external joining at the (P4) port.
P4
S2-2 S2-1
B2 A2
L3
Ta Ta
pb2 pa2
L1
Option
pb6 pa6
Ta Ta Travel (RH)
R3
B6 A6
Arm 1 Arm 2
Boom 2 Boom 1
Swing Bucket Travel Motor
Breaker
B2 358bar@20L B6
A2 A6
pb2
P4 Option Travel(RH) pb6
pa2 pa6
P1 P2
EX1500158
Figure 17

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

Rc5 Rc3
pb6 pa6
Ta R1 Ta
S6-1 R3 Travel (RH)
S6-2
B6 A6 Lc6
B1 A1 PA PT Lc5
Lc3
PP
L3
L1
Ta Ta
pb1 pa1
R1 Lc7 Lc4 Travel (LH)

2
1 P1P P2
P1
Straight Travel
Arm 2 Arm 1
Travel Motor (RH) Travel Motor (LH)
Boom 1 Boom 2
Bucket Swing
Option
B6
Travel(R)
A6
pb6
B1
pa6 Travel(L) A1
pb1
pa1
Straight Travel
PP PT
P2 P1
EX1500159
Figure 18

Neutral Cut Spool Shift
This valve is equipped with a neutral cut spool at
the downstream end (upstream of the low-pressure
relief valve) of the neutral path (R1). When port (pcc)
is pressurized to move the neutral cut spool (R), the
neutral path (R1) will be closed.
Accordingly, the flow to the negacon relief valve (Rc1)
is shut-off, changing the pressure of the (ps2) signal.
In the meantime, the oil supplied through the (P2) port
joins into the path (S2-2) by (P4) with the external
device check as media and by the empty part of the
poppet (S2-1) of the option spool.
R1
DR
Ta
Center-Bypass Cut Valve(R)
Negacon Relief Valve(Rc1)
T2 pbu ps2 pcc R2

Orifice
EX1500160
Figure 19

Relief Valve
1. Main relief valve
The oil supplied through ports (P1) and (P2) is
guided to the main relief valve by the poppet (LP),
and by the poppet (RP) and path (3) respectively.
The maximum pressure of the (P1) and (P2) side
pumps is controlled by activation of the main relief
valve.
P1
LP
Ts5
Main Relief Valve
3
PH
Ts3
RP
P3 P2
WE1400939
Figure 20
2. Overload relief valve

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

Antidrift Valve (Holding Valve)
An antidrift valve is installed in the cylinder port on the
side of the arm rod (boom bottom) which prevents the
unwanted selflowering of the arm (boom) cylinder.
1. In the neutral state (Figure), cylinder port pressure pc1(pc2)
is guided to the spring chamber (AD5) through path Holding
(AD2), poppet (AD3) gap, and path (AD4). Valve
AD1 DR
The poppet (AD1) is fully seated by the differential A5(A8) AD2
B5
pressure generated by the spring force and the AD3
area difference of the poppet. AD4
AD5
WE1400940
Figure 21
2. I n arm dump (boom down) operation, the oil

pc1 (pc2)
supplied from the pump pushes the poppet (AD1)
Holding
open and flows into the cylinder port. Valve
AD1
B5 A5(A8)
Arm Dump
(Boom Down)
WE1400941
Figure 22
3. In the arm crowd operation (boom up), (pc1 (pc2))

is pressurized to move the poppet (AD3) to induce pc1 (pc2)
the oil in the spring chamber (AD5) to the drain path Holding
(DR) by the poppet (AD3) gap and spool (AD6) AD1 DR
Valve
AD6
gap; consequently, the poppet (AD1) is opened and B5 A5(A8)
the lubricant oil in the cylinder port flows to the tank
AD3
path (Ta) by the spool.
Arm Crowd AD5

(Boom Up)
WE1400942
Figure 23

Main Relief Valve Operation
2
1. T his relief valve is inserted between the neutral
path “HP” and the tank path “LP”. Oil is filled into “LP” B
the inner space (C) through the orifice of the main
poppet . A “HP” PH
The sleeve (2) and main poppet (1) are securely

seated by the areal difference between “A” and “B”.
1 C
WE1400943
Figure 24
2. When the pressure in the neutral path “HP” reaches E D

the preset pilot spring force, the pilot poppet (3) will
“LP”
be opened.
Oil flows around the pilot poppet (3), through the “HP” PH
drill hole (E) and circular gap (D), and is guided to
the tank path “LP”.
3
WE1400944
Figure 25
3. When the pilot poppet (3) is opened, the pressure in 3

the inner space (C) is decreased to open the main “LP”
poppet (1).
Therefore, the oil in “HP” flows directly through path A “HP” PH
“LP”.
1 C
WE1400945
Figure 26

Overload Relief Valve Operation
1. T his relief valve is inserted between the neutral K
"LP" B
path “HP” and tank path “LP”. Oil is filled in the
inner space (G) through the orifice of the piston (C).
The sleeve (K) and main poppet (D) are securely "HP"
A
seated by the areal difference between “A” and “B”.
EX1403985
C D G
Figure 27
2. W hen the pressure in the cylinder port “HP” "LP" E H

reaches the preset spring force of the pilot poppet,
the pilot poppet (E) will be opened.
Oil flows around the poppet, through the drill hole
"HP"
(H), and is guided to the low-pressure path “LP”.
EX1403986
Figure 28
3. T he pilot poppet (E) opens to make the oil flow "LP" I E

through the orifice (I) of piston (C), differential
pressure is generated between path “HP” and the
back side of the piston (C) to move the piston (C) to
"HP"
seat the poppet (E).
D C EX1403987
Figure 29
4. For the oil flow through the path “HP” and poppet C
"LP"
(D), the pressure difference increases because of
throttling by the poppet (D), circular gap of piston
(C), and orifice. The poppet (D) is opened by the
"HP"
differential pressure and oil flows directly through
path “LP”.
D F EX1403988
Figure 30

Absorption Operation
This relief valve is equipped with an antivoid unit in the K
"LP" B
cylinder port “HP”, which supplies oil when cavitation
occurs. In the low-pressure side “LP”, when the
pressure in the cylinder port “HP” is low, the sleeve
"HP"
A
(K) is opened by the differential pressure generated
by the areal difference between “A” and “B”. Oil flows
from the low-pressure side “LP” into the cylinder port
WE1400946
“HP” to prevent cavitation.
Figure 31
Negacon Relief Valve Operation

Generation of Signal Pressure E A B D
The oil supplied through the pump port (P1) flows to
ps1
the tank path through the neutral path (L1) and the
negacon orifice (D) at the neutral downstream path (A).
In this process, pressure is generated in the path
L1
(B) by the negacon orifice (D), and the pressure is
induced in the negacon signal pressure port (Ps1)
through path (E).
Poppet Tank Passage(Ta)
When the main spool that is upstream of the neutral
downstream path (A) is activated, the oil flow through WE1400947
the neutral downstream path (A) is decreased and the Figure 32

negacon signal pressure is reduced.
Relief Operation
A B D F C
In the event there is excessive oil flow in the neutral
downstream path (A), the pressure generated in path ps1
(B) by the negacon orifice (D) is induced to the back
chamber (C) of the poppet. The poppet is activated by
the differential pressure generated by the difference in L1
the hydraulic area between the path (B) and the back
chamber (C). When this poppet is activated, oil flows Poppet
to the tank path (Ta) through path (B) and the drill hole Tank Passage(Ta)
path (F) of the plug, preventing excessive pressure in
WE1400948
the negacon signal pressure port.
Figure 33

Cautions for Operation
1. B efore operating machine, make sure that oil
passages and hydraulic oil are clean.
2. Relief valve pressure should not be raised above
specified pressure setting.
3. The difference between main relief valve setting
pressure and overload relief valve setting pressure
should not be over 2.0 MPa (19.9 bar (290 psi)).
4. B efore operating machine, the hydraulic system
must be fully warmed up. If machine is operated
with cold hydraulic oil and valve, be careful of the
following, to prevent spool sticking because of heat
shock.
NOTE: D o not operate main relief valve or overload
relief valve suddenly and continuously. Cycle
oil through all actuators and warmed up cold
hydraulic oil in the lines and components
uniformly.
NOTE: Slight or compound work should not be
suddenly operated at cold weather because
heat is developed partly at all the orifices.

PRECAUTION
Lower the work equipment to the ground and stop
engine.
Operate the control levers and pedals several times to
release the remaining pressure in the hydraulic piping
Loosen the breather slowly to release the pressure
inside the hydraulic tank.
Escaping fluid under pressure can penetrate the skin
causing serious injury.
When pipes and hoses are disconnected, catch the oil
with an oil pan.

REMOVAL
WARNING

clothes.

immediately.
WARNING
the workplace.
IMPORTANT
specific manner.
disposal.
1. P ark the machine on firm and level ground and

lower the bucket as shown in Figure 34.
2. Stop engine
EX1300684
Figure 34

3. M ove safety lever to “RELEASED” (UNLOCK) O ACC
I
LOCK
WARNING OFF OFF
ON
ON
the cabin with engine running. Figure 35

starter switch.
(Figure 36)
ON
OFF
EX1500045
Figure 36
3
5 8
1 2
7 6
4
EX1401809
Figure 37

WARNING
doing any work.

EX1500046
11. Oil drain method Suction Filter Cover
NOTE: C heck the level on the oil level gauge Return Filter Cover
before draining the oil.
A. Remove cover on oil tank (bolt: 6 ea) and drain
hydraulic oil using oil pump. (Figure 39)
● Tool: 17 mm ( )
EX1500070
Figure 39
B. Drain hydraulic fluid using drain plug.

(without oil pump) (Figure 40)
● Tool: 27 mm ( )
● Torque: 93.1 N.m (9.5 kg.m, 68.7 ft lb)
● Hydraulic oil tank volume
– Approximately: 145 L (38.3 U.S. gal)

– Effective level: 97 L (25.6 U.S. gal)
C. Plug the filter cap to location of suction filter.
Item Part Number

Filter Cap 2188-1008
EX1402349
Figure 41

Reference
Description
Number 3
1 Suction Filter
A
2 Nut
3 Rod
2
When installing
● Length (A): 647 mm 1
● Torque (2 nut): 49 N.m (5 kg.m, 36.2 ft lb) EX1402872
Figure 42
12. Loosen the main control valve mounting bolts from

main frame bracket. (bolt: 4 ea) (Figure 43)
NOTE: D
o not remove bolts completely to hold the
position of control valve
● Tool: 24 mm ( )
EX1500072
Figure 43
13. O pen the engine cover and remove bolts and

washers (1, Figure 44) (4 ea) with cover (2).
● Tool: 19 mm ( )
● Cover weight: 9 kg (19.8 lb)
Figure 44
14. Disconnect the harness connector (3 ea).
Port Location 1 2
pc1, PT Left Side

pa8 Rear Side
EX1402294
Figure 45

15. Remove hoses, pipes and adapters from control
valve.
NOTE: A ttach identification tags to the removed
hoses for reassembling.
After disconnecting hoses from main control
valve, plug them to prevent dirt or dust from
entering.
Disconnect the hoses from the bottom to
top of control valve.
pbu
pcc
ps2
A8
pc2 B8
A7 B7
A6 B6
P2
Figure 46

Torque
Port Name Plug/Flange Size (Hose)
(mm) N.m kg.m ft lb
Travel Motor RH Backward
A6 UNF 1 3/16”-12-2B 36 124.5 12.7 91.8
(to Center Joint “4”)
Bucket Crowd
A7 UNF 1 3/16”-12-2B 36 124.5 12.7 91.8
(to Bucket Cylinder Head)
Boom Up
A8 UNF 1 3/16”-12 36 124.5 12.7 91.8
(to Boom Cylinder Head)
Travel Motor RH Forward
B6 UNF 1 3/16”-12-2B 36 124.5 12.7 91.8
Bucket Dump
B7 UNF 1 3/16”-12-2B 36 124.5 12.7 91.8
(to Bucket Cylinder Rod)
Boom Down
B8 UNF 1 3/16”-12 36 124.5 12.7 91.8
(to Boom Cylinder Rod)
P2 from Main Pump “A2” UNF 1 3/16”-12-2B 36 124.5 12.7 91.8
pc2 from Joint Sub Assembly “B1” UNF 11/16”-16-2B 22 38.2 3.9 28.2
ps2 to Main Pump “Pi2” UNF 9/16”-16-2B 19 25.5 2.6 18.8
pbu to Oil Tank UNF 9/16”-16-2B 19 25.5 2.6 18.8
pcc to Oil Tank UNF 9/16”-16-2B 19 25.5 2.6 18.8

● Fitting
Size Torque
Port Name
A6,A8,B6 Adapter PF 3/4” UNF 1 3/16”-12 36 176.4 18 130.1
A7, B7, B8 Adapter PF 1/2” UNF 1 3/16”-12 32 93.1 9.5 68.7
Adapter PF 3/4” UNF 1 3/16”-12 35 124.5 12.7 91.8
P2
Elbow UNF 1 3/16”-12 UNF 1 3/16”-12 19 39.2 4 28.9
pc2 Elbow PF 1/4” UNF 11/16”-16 19 39.2 4 28.9
ps2, pbu,
Adapter PF 1/4” UNF 9/16”-18
pcc
A6, A8, B6,
O-ring S8000241 (1B P24) S8030125 (4D F-12)
P2
A7, B7, B8 O-ring S8000185 (4D P18) S8030125 (4D F-12)
AR1, BR1 O-ring S8000185 (4D P18) S8030081 (1B F-08)
pc2 O-ring S8000115 (4D P11) S8030061 (1B F-06)
2180-1216D11
ps2, pbu,
O-ring S8000115 (4D P11) (ID:7.65, W:1.78,
pcc
1B)

pc3
pb9 pb5
pb8 pb4
pb3
pb7
pb6 pb2
pb1
Figure 47

Torque
(mm) N.m kg.m ft lb
pb1 from Pedal Valve “2” UNF 11/16”-16-2B 22 38.2 3.9 28.2
pb2 Connect with “pa2” UNF 9/16”-16-2B 19 25.5 2.6 18.2
pb3 from Joint Sub Assembly “B7” UNF 11/16”-16-2B 22 38.2 3.9 28.2
pb4 to Oil Tank UNF 11/16”-16-2B 22 38.2 3.9 28.2
from Joint Sub Assembly “B3”
pb5 UNF 11/16”-16-2B 22 38.2 3.9 28.2
(Connect with “pb9)
pb6 from Pedal Valve “4” UNF 11/16”-16-2B 22 38.2 3.9 28.2
pb9 Connect with “pb5” UNF 11/16”-16 22 38.2 3.9 28.2
pc3 to Oil Tank UNF 9/16”-16-2B 19 25.5 2.6 18.2

● Fitting
Size Torque
Port Name
pb1, pb6 Elbow PF 3/8” UNF 11/16”-16 22 49 5 36.2
pb2 Elbow PF 3/8” UNF 9/16”-18 22 49 5 36.2
pb3, pb4,
Adapter PF 3/8” UNF 11/16”-16 22 49 5 36.2
pb7, pb8
Tee PF 3/8” UNF 11/16”-16 22 49 5 36.2
pb5
Tube UNF 11/16”-16 UNF 11/16”-16 22 38.2 3.9 28.2
Adapter PF 3/8” UNF 11/16”-16 22 49 5 36.2
pb9
Tube UNF 11/16”-16 UNF 11/16”-16 22 38.2 3.9 28.2
pc3 Adapter PF 1/4” UNF 9/16”-18 19 39.2 4 28.9
pb1, pb3,
pb4, pb5,
O-ring S8000145 (4D P14) S8030061 (1B F-06)
pb6, pb7,
pb8, pb9
2180-1216D11
pb2 O-ring S8000145 (4D P14) (ID:7.65, W:1.78,
1B)
2180-1216D11
pc3, pbr1 O-ring S8000115 (4D P11) (ID:7.65, W:1.78,
1B)

ps1
A5
pc1
B5
B3 A3
A1
PT
B1
PA
P1
Figure 48

Torque
(mm) N.m kg.m ft lb
Travel Motor LH Backward
A1 UNF 1 3/16”-12-2B 36 125.5 12.7 91.8
A3 Left Swing (to Swing Device “B”) UNF 13/16”-16-2B 24 55.9 5.7 41.2
A5 Arm Dump (to Arm Cylinder Rod) UNF 1 3/16”-12-2B 36 124.5 12.7 91.8
Travel Motor LH forward
B1 UNF 1 3/16”-12-2B 36 124.5 12.7 91.8
B3 Right Swing (to Swing Device “A”) UNF 13/16”-16-2B 24 55.9 5.7 41.2
Arm Crowd
B5 UNF 1 3/16”-12-2B 36 124.5 12.7 91.8
(to Arm Cylinder head)
P1 from Main Pump “A1” UNF 1 3/16”-12-2B 36 124.5 12.7 91.8
PA to Swing Device “SH” UNF 9/16”-16-2B 19 25.5 2.6 18.2
PT Pressure Sensor PF 1/4” 27 6.0 0.6 4.4
from Joint Sub Assembly “B3” UNF 11/16”-16-2B 22 38.2 3.9 28.2
pc1
Pressure Sensor PF 1/4” 27 6.0 0.6 4.4
ps1 to Main Pump “Pi1” UNF 9/16”-16-2B 19 25.5 2.6 18.2

● Fitting
Size Torque
Port Name
A1, A5, B1,
Adapter PF 3/4” UNF 1 3/16”-12 36 176.4 18 130.1
B5
A3, B3 Adapter PF 1/2” UNF 13/16”-16 27 93.1 9.5 68.7
Adapter PF 3/4” UNF 1 3/16”-12 36 176.4 18 130.1
P1
Elbow UNF 1 3/16”-12 UNF 1 3/16”-12 35 124.5 12.7 91.8
PA Elbow PF 1/4” UNF 9/16”-18 19 39.2 4 28.9
PT Reducer PF 1/4” PF 1/4” 19 39.2 4 28.9
UNF 11/16”-16
Tee PF 1/4” 19 39.2 4 28.9
pc1 (with PF 1/4” Port)
Elbow PF 1/4” PF 1/4” 17 39.2 4 28.9
ps1 Elbow PF 1/4” UNF 9/16”-18 19 39.2 4 28.9
A1, A5, B1,
O-ring S8000241 (1B P24) S8030125 (4D F-12)
B5, P1
A3, B3 O-ring S8000185 (4D P18) S8030081 (1B F-08)
2180-1216D11
PA, O-ring S8000115 (4D P11) (ID:7.65, W:1.78,
1B)
PT O-ring S8000115 (4D P11)
S8000115 (4D P11),
pc1 O-ring S8000115 (4D P11)
S8030165 (4D F-16)
2180-1216D11
ps1 O-ring S8000115 (4D P11) (ID:7.65, W:1.78,
1B)

DR
pa5 pa9
pa4 pa8
pa3 pa7
pa2 pa6
pp
PH
pa1
Figure 49

Torque
(mm) N.m kg.m ft lb
pa1 from Pedal Valve “1” UNF 11/16”-16-2B 22 38.2 3.9 28.2
pa2 Connect with “pb2” UNF 9/16”-16-2B 19 25.5 2.6 18.2
pa3 from Joint Sub Assembly “B8” UNF 11/16”-16-2B 22 38.2 3.9 28.2
pa4
Connect with “pa8” UNF 11/16”-16 22 38.2 3.9 28.2
pa5
pa6 from Pedal Valve “3” UNF 11/16”-16-2B 22 38.2 3.9 28.2
pa7 from Joint Sub Assembly “B6” UNF 11/16”-16-2B 22 38.2 3.9 28.2
pa8
pa9 Connect with “pa5” UNF 11/16”-16 22 38.2 3.9 28.2
DR to Oil Tank UNF 9/16”-16-2B 19 25.5 2.6 18.2
to Swing Device “PG” UNF 9/16”-16-2B 19 25.5 2.6 18.2
PP
to Solenoid “P1” UNF 9/16”-16-2B 19 25.5 2.6 18.2
PH to Solenoid “PH” UNF 9/16”-16-2B 19 25.5 2.6 18.2

● Fitting
Size Torque
Port Name
pa1, pa6 Elbow PF 3/8” UNF 11/16”-16 22 49 5 36.2
pa2 Elbow PF 3/8” UNF 9/16”-18 22 49 5 36.2
pa3, pa7,
Adapter PF 3/8” UNF 11/16”-16 22 49 5 36.2
pa9
pa4, pa5 Tee PF 3/8” UNF 11/16”-16 22 49 5 36.2
UNF 11/16”-16
Tee PF 3/8” 22 49 5 36.2
pa8 (with PF 1/4” port)
Elbow PF 1/4” PF 1/4” 17 39.2 4 28.9
par1, DR,
Elbow PF 1/4” UNF 9/16”-18 19 39.2 4 28.9
PH
Adapter PF 1/4” PF 1/4” 19 39.2 4 28.9
PP
Tee PF 1/4” UNF 9/16”-18 19 39.2 4 28.9
pa1, pa3,
pa4,
O-ring S8000145 (4D P14) S8030061 (1B F-06)
pa5, pa6,
pa7, pa9
2180-1216D11
pa2 O-ring S8000145 (4D P14) (ID:7.65, W:1.78,
1B)
S8000115 (4D P11),
pa8 O-ring S8000145 (4D P14)
S8030061 (1B F-06)

T1
Figure 50

Torque
(mm) N.m kg.m ft lb
T1 to Oil Cooler SAE 1 1/4”, D31.8 10 107.9 11 79.6
● Fitting
Size
Port Name
A B
DS2856004
T1 Ring Seal
(1 1/4”, ID:38, OD:45, 1B)
* A: Opposite side of hose, B: Hose side

16. Install eyebolts (2 ea) to lift in threaded holes on
top of control valve. (Figure 51)
● Thread of hole: M10 x 1.5 (Depth 17 and 20
mm)
● Control valve weight: about 147 kg (324 lb)
Figure 51
17. Remove main control valve mounting bolts and

spacer from main frame bracket. (bolt: 4 ea) (Figure
52)
18. Lift the control valve by crane from frame slowly
and carefully.
Make sure there are no other electrical wires or
hoses connected to valve.
EX1500080
Figure 52

INSTALLATION
WARNING
OR SERIOUS INJURY

NOTE: F
irst, assemble the bolts and spacer (4 ea) of
main control valve mounting to main frame.
(Figure 53)
IMPORTANT
After completing the work, check the oil level. Start the
engine and check for any oil leaks. EX1500080
Figure 53
2. Be careful not to apply stress on control valve
when attaching piping and hoses. Unnecessary
stress can cause spools to bind and the control
valve from functioning properly.
3. Tighten the assembling bolts alternately and evenly
to the specified torque.
4. If welding procedures are being performed near the
control valve, the valve could be damaged by weld
spatter and heat. Use adequate shielding to protect
valve.
5. Valve ports must be covered with caps, plugs or
tape to protect them from dust and other foreign
materials, until pipe laying work is started.
COMPLETING WORK
1. If the hydraulic oil in the oil tank was removed, refill
the hydraulic oil tank.
2. S tart the engine and run at low idle for about 5
minutes.
3. Operate the joystick lever and actuate the hydraulic
cylinder 4 ~ 5 times very slowly, about 100 mm
before the end of stroke.
4. Operate the rod of cylinder to the end of stroke to
relieve the hydraulic piping.
(The air breather of oil tank is actuated to bleed the
air)

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

3. Clean the working place so no foreign material can
enter into the valve when disassembling.
4. Tag disassembled parts so they can be easily and
correctly identified for reassembling.
5. Replace all seals (O-rings, backup rings) with new
ones.

Sequence of Disassembly 1
12 65
Main Spool
1. R emove socket head bolt (65, Figure 54), and Arm 2
11
disassemble the long cap (11) and (15). Boom 1
Bucket
Take the O-ring (12) out from the groove of the Travel(RH)
valve housing. Straight
Travel
●Tool: 6 mm ( ) 65
Arm 1
Boom 2
Swing
12 Option
Travel(LH)
11 EX1500163
Figure 54
2. R emove socket head bolt (66, Figure 55), and 66

47
disassemble the cap (46) (47). 46
42
Take the O-ring (42) out from the cap.
●Tool: 5 mm ( )
3. Pull out each spool from the valve housing, keeping
66
it as a subassembly.
IMPORTANT
65
When extracting the spool, pull it out straight so as 13
12
to avoid any bruise or scratch. Bruises or scratches
on the spool may make a dent on the body hole, and WE1400950
the spool may not fit into the body hole at the time of Figure 55
reassembling.
Also, even if the spool fits into the body hole, it may
cause operational failure.
Each spool should be clearly marked with a tag so as
to avoid inserting a spool in a wrong position at the
time of re-assembling. Inserting a spool into a wrong
position will result in operational failure of the actuator
which is extremely dangerous.
4. R emove socket head bolt (65, Figure 55), and

disassemble the short cap (13).
Take the O-ring (12) out from the groove of the
valve housing.
●Tool: 6 mm ( )

5. Remove spool end of the spool (2 ~ 10, Figure 57), 7
and remove spring sheet and the spring. 8
Arm 2 9
●Tool: 6 mm ( ) Boom 1
Bucket
Travel(RH)
Straight
IMPORTANT Travel
6
10
5
When disassembling the spool assembly, pinch the 2
spool with a tightening wood, securing the whole thing Arm 1
Boom 2
in a vise while working on it, so as not to harm the 2 Swing
spool. When pinching the spool, pinch it at the end, i.e. 3 Option
4 Travel(LH)
as close to the spool end as possible, in order to avoid
EX1500164
bending the spool itself.
Figure 56
Adhesive agent is applied to the screw area of the
spool end. Heat the outer periphery of the spool at the
screw area with an industrial dryer until the spool end
can be easily tightened. (As a rough indication, the 30~40 3~6 30~40
heating temperature should be 200 ~ 250°C (392 ~
70~100
482°F).) In case the spool is excessively heated, it will
result in performance and durability degradation due
to heat-deformation of the spring, and therefore the
spring must be replaced with a new one. Also, be alert
that touching, with a bare hand, the heated spool
bearing a high temperature will result in a burn. FG001316
Figure 57

Sub Spool for Swing Priority and Center Bypass Cut 45
43
1. Remove spool end (45, Figure 58) of the spool (41) 48A 44
43
(48), and remove spring seat (43) and the spring 48
(44).
● Tool: 5 mm ( )
41A
2. As adhesive agent is applied to the spool and the
coupling screw part of the spool end, IMPORTANT
should be referred to when disassembling these
parts. 45
43
44
43
IMPORTANT 41
WE1400952
When disassembling the spool assembly, pinch the Figure 58

spool with a tightening wood, securing the whole thing
in a vise while working on it, so as not to harm the
spool. When pinching the spool, pinch it at the end, i.e.
as close to the spool end as possible, in order to avoid
bending the spool itself.
Adhesive agent is applied to the screw area of the
spool end. Heat the outer periphery of the spool at
the screw area with an industrial dryer until the spool
end can be easily tightened. (As a rough indication,
the heating temperature should be 200 ~ 250 °C (392
~ 482 °F).) In case the spool is excessively heated, it
will result in performance and durability degradation
due to heat-deformation of the spring, and therefore
the spring must be replaced with a new one. Also, be
alert that touching, with a bare hand, the heated spool
bearing a high temperature will result in a burn.
Sub Spool (Arm Regeneration Valve)

1. Remove plug (49, Figure 59) and remove O-ring
(50).
● Tool: 32 mm ( )
2. Remove spring (51, Figure 59) and pull out the 53
54
spool (52). 53
3. Hook, with a wire, the inner part of the side hole in 52

51
50
front of the sleeve (52, Figure 59), and pull it out.
At this point, the piston (52) can also be pulled out
together.
4. Take out the backup ring (53, Figure 59) and the 49
O-ring (54). WE1400953
Figure 59

Anti-drift Valve (Boom and Arm)
1. Remove socket head bolt (67, Figure 60), remove
body assembly (30), and remove O-ring (31) from
the groove of the valve housing. 27 29
28 31 30
● Tool: 6 mm ( )
67
IMPORTANT 27
28
29
When disassembling this part with the control valve 31
remained attached to the vehicle body, there is a 67
possibility that parts may jump out due to the internal
30
residual pressure. Remove socket head bolt (67) WE1400954
slowly, make sure there is no more resistance caused Figure 60
by the internal residual pressure, and then proceed
with disassembling.
2. Remove spacer assembly (29, Figure 60) using an

M6 x 1.0 screw, and take out the O-rings, and the
backup ring.
3. Remove spring (28, Figure 60) and the poppet (27).
4. S ecure the body assembly (30, Figure 60) with
a vise without harming the mating surface of the
O-ring (31) mounting side.
IMPORTANT
When disassembling this part with the control valve
remained attached to the vehicle body, there is
a possibility that parts may jump out due to the
internal residual pressure. Remove plug slowly,
make sure there is no more resistance caused by
the internal residual pressure, and then proceed with
disassembling.
Load Check Valve for Travel, Bucket, Boom 1, Boom 2,

Arm 1 and Swing
1. Remove plug (19, Figure 61) of the load check, and
remove O-ring (18) from the plug.
● Tool: 27 mm ( )
2. Take out the spring (17, Figure 61) and the poppet 19
(16). 16
17
18
19
WE1400955
Figure 61

Load Check Valve for Arm 2 39
38 68
1. Remove socket head bolt (68, Figure 62) and take 37
out the flange (39) from the main body. Take out
the O-ring (38)
from the grove of the valve housing. 36
33
●Tool: 8 mm ( ) 35
2. Take out the sleeve (33, Figure 62), the spring (35) 34
(37), and the poppet (34) (36).
IMPORTANT
WE1400956
At this point, take care not to drop the spring in the
Figure 62
passageway. Should the spring fall in the passageway,
a fragment taken into the spool sliding part could
possibly cause the spool to stick and cause the
actuator to go out of control, that is, it cannot be
stopped.
Merging Check Valve for Option

1. Remove plug (23, Figure 63) and remove O-ring (18)
from the plug.
● Tool: 32 mm ( )
25
(24). 18
23
3. Remove plug assembly (81, Figure 63) and remove
81
O-ring.
● Tool: 27 mm ( )
WE1400957
Figure 63
Common Check Valve 19

18
1. Remove plug (19, Figure 64) of the check and 16
17
remove Oring (18) from the plug.
● Tool: 27 mm ( )
16
(16). 17
18
19
WE1400958
Figure 64

Semi-parallel-check for Arm 1
32
1. Remove plug assembly (32, Figure 65) and remove
O-ring. 58
● Tool: 8 mm ( ) 57
2. Take out the spring (58, Figure 65) and the poppet
(57).
WE1400959
Figure 65
Relief Valve
1. Remove overload relief valve (63, Figure 66) from
the main body and the spool section of the add-on.
● Tool: 32 mm ( )
63
WE1400960
Figure 66
63
63
WE1400961
Figure 67

2. Remove main relief valve (62, Figure 68) from the
main body.
● Tool: 32 mm ( )
62
WE1400962
Figure 68
3. Take out the negative control relief valve (55, Figure

69) from the main body.
● Tool: 32 mm ( )
55
IMPORTANT
The relief valve itself is not meant for disassembling.
Please note that disassembling/assembling/adjusting
it will void the warranty. 55
WE1400963
Figure 69
Other Plugs
1. Disassemble the plug assembly (20, Figure 71) of 32
the (PP) port, and remove O-ring.
● Tool: 19 mm ( ) 21
2. Disassemble the PF1/8 sized plugging plug (21),

and remove O-ring.
● Tool: 5 mm ( )
3. Disassemble the PF3/8 sized plugging plug (32),
and remove O-ring. 69
● Tool: 8 mm ( )
4. Disassemble the PF1/2 sized plugging plug (69, 32
21
Figure 70), and remove O-ring. WE1400964
● Tool: 10 mm ( ) Figure 70

5. Disassemble the 7/8-14UN sized plugging plug (22,
Figure 71), and remove O-ring (18).
32
● Tool: 27 mm ( )
21
22
18
20
WE1400965
Figure 71
Add-on Section 74 72
1. Loosen and remove hexagonal nut (72, Figure 72)

73 71
and (74).
● Tool: 19 mm, 22 mm ( )
2. Pull out the outlet housing (61, Figure 72). 61
3. Remove main body mating surface O-rings (59) (60). 59
4. Remove tie rods (71) (73), and take it out from the 60
60
main body housing (1).
(Use a pipe wrench etc.) 1
IMPORTANT WE1400966
Figure 72
When pulling out the add-on section, take care not
to make a dent or a scratch on the mating surface. If
there is a dent or a scratch, oil leaking from the mating
surface could possibly cause operational malfunction.
Also take extreme care not to let the oil passage get
contaminated with foreign particles. Should it get
contaminated, a fragment taken into the spool sliding
part could possibly cause the spool to stick, and the
bad sheet of the load check could possibly cause
the actuator to go out of control, that is, it cannot be
stopped.

Cleaning
Thoroughly wash all the disassembled parts with clean
oil.
Dry all parts with compressed air, and place them on
clean pieces of sheet or vinyl in order to inspect them.
Inspection
Check each part to see if there is any burr, scratch, or
any other defect on all surfaces.
1. Check to see if there is any scratch or dent or dust
or cavity on the surface of the load check sheet
of the valve housing. If there is a small scratch,
remove it using an oilstone.
2. Check and make sure there is no scratch or dent on
the outer periphery of the spool. If there is a small
scratch, remove it using an oilstone.
3. A ll sliding parts must move smoothly, and there
must not be any foreign particle in all grooves and
passageways.
4. Change the spring if any of them is damaged or
excessively deformed or worn out.
5. W hen the relief valve does not function well,
follow “Adjusting Relief Valve” on page -5-7-78
(Maintenance guideline for the relief valve) to carry
out an inspection procedure.
6. All the O-rings and backup rings yielded from the
disassembled parts must be replaced with new
ones.
7. Check and make sure there is no paint fragment
remained around the body hole or around the plug
bearing surface after removing the cap or the plug.
(If paint fragments get inside the valve, it would
cause jamming or clogging which would result in
operational malfunction or oil leakage.)

REASSEMBLY
Caution on Assembly
Caution on Handling O-ring
1. D O N O T u s e t h e O - r i n g w h i c h h a s a c u t o r
hangnail.
2. Put grease on O-ring and the place which O-ring
attached enough to lubricate for reassembly.
3. D O NOT stretch O-ring as it changes original
shape.
4. Attach O-ring without twist.
Twisted O-ring may lose its seal function.
Caution on Handling Spool

1. Apply recommended torque on thread.
Excessive torque may cause the movement trouble.
2. Each part must be combined as it was.
Spreading Adhesive on Thread

1. Washing
Clean the thread in vapor wash by acetate rayon or
ether.
2. Dry
Dry the thread out by compressed air, to get firm
joint.
3. Adhesive application
Put proper quantity of adhesive “Loctite #638
equivalent” 2 or 3 rolls on near edge of external
thread.
Be careful that adhesive is not put on spring sheet.
CAUTION
AVOID INJURY
When working with Loctite, work in a place that is well
ventilated.
4. Interval of hardening
To get firm joint, leave tightened parts following
hours in the air.
● Atmosphere temperature 40°C: over 3 hours
IMPORTANT
Shortage of hardening interval may cause luck of joint
strength DO NOT use “Loctite Primer T”.
This leads less joint strength than normal dry.

Sequence of Reassembly 7
8
Arm 2 9
Main Spools Boom 1
12 65
1. A pply adhesive agent on the screw part of the Bucket
Travel(RH)
11
spools (2 ~ 10). Straight
Travel
Install the spring seat, the spring, and the spool 6 10
5
end, and pinch the spool with a tightening wood, 2
securing the whole thing in a vise, and tighten the 65
spool end. Arm 1

2 Boom 2
● Torque: 9.8 ~ 11.8 N.m (1 ~ 1.2 kg.m, 7.2 ~ 8.7 ft 3 4
Swing
lb) Option
12
11 Travel(LH)
IMPORTANT EX1500165
Figure 73
Take care not to let the adhesive agent drip out when
tightening the spool end with a lot of adhesive agent
applied on it. When working on the spool, pinch it at
the end, i.e. as close to the spool end as possible,
in order to avoid bending the spool itself with the
tightening torque. And, if the tightening torque is too
large, swelling of the spool could possibly cause the
spool to stick and cause the actuator to go out of
control, that is, it cannot be stopped.
From here on, refer to this note when using adhesive
agent.
IMPORTANT
Note that the springs for the boom 2 spool (5) and
the travelling straight spool (10) are different from
those for other parts. Combining a wrong spring to a
spool could possibly cause operational failure of the
actuator.
IMPORTANT
Watch out for the installing positions of the O-ring and
the backup ring. If they are installed in the opposite
positions, the O-ring could be cut, which could
possibly result in operational failure.

Sub Spool for Swing Priority and Center Bypass Cut 45
43
1. A pply adhesive agent on the screw part of the 48A 44
43
spools (41, Figure 74) (48). 48
2. Assemble the spring seat (43, Figure 74), the spring
(44), and the spool end (45), and then pinch the
spool with a tightening wood, securing the whole 41A
thing in a vise, and tighten the spool end (45).

● Tool: 5 mm ( )
● Torque: 19 ~ 22 N.m (1.9 ~ 2.2 kg.m, 14 ~ 16.2 ft
45
lb) 43
44
43
41
WE1400952
Figure 74
Sub Spool (Arm Regeneration Valve) 53

54
1. Install the backup ring (53, Figure 75) and the 53
O-ring (54) in the sleeve (52).
52
2. Install the piston (52, Figure 75) in the sleeve (52)
which has the seal installed in it.
3. Insert the spool (52, Figure 75) in the sleeve (52).
52A
WE1400967
Figure 75

Anti-drift Valve (Boom and Arm)
1. Install the O-ring (31, Figure 76) in the mating
surface.
2. Insert the poppet (27, Figure 76) in the valve 27 29
28 31 30
housing.
3. Push the spacer (29), which has the O-rings (31) 67
attached to it, into the valve housing along with the 27
28
spring (28). 29
31
67
IMPORTANT
30
WE1400954
Install the spacer carefully so that the spring can be
properly mounted on the locus of the spacer. Figure 76
If the spring is not properly mounted on the locus
on the spacer, the spring could be damaged by the
poppet, and the fragment could be circulated through
the flow path and could possibly result in operational
failure of each moving part.
4. I nstall the socket head bolt (67) in the body

assembly (30), and fasten it.
● Tool: 6 mm ( )
● Torque: 20 ~ 25 N.m
(2.0 ~ 2.6 kg.m, 14.8 ~ 18.4 ft lb)
Control Valve 74 72
Add-on Section
1. Attach the tie rods (71, Figure 77) (73) to the main 71
73
body valve housing (1).
IMPORTANT 61
59
Tighten the tie rod all the way to the effective 60
60
screwdepth.
If the screw part is not sufficiently fastened, oil could 1
leak from the mating surface, due to insufficient
clamping force on the add-on section, which could
WE1400966
Also, excessive load would be exerted on the screw Figure 77
thread which would damage the screw and could
2. Attach the O-rings (59, Figure) (60) on the main

body mating surface.

3. Install the outlet housing (61, Figure) on the valve
housing for the spool section using the tie rod as a
guide.
IMPORTANT
Since oil leakage from the mating surface could cause
operational failure, take care not to make a dent or
a scratch on the mating surface when installing the
addon section. Also watch out for foreign particles
getting inserted in the mating surface and the O-ring
falling off and sticking out.
IMPORTANT
When installing the add-on section, always install
the tie rod first and use it as a guide to determine
the mounting position. If the mounting position is
determined without using the tie rod, the O-ring of the
mating surface could stick out causing oil leakage
which, in turn, could possibly result in operational
failure.
4. Install hexagon nut (74) on the tie rod (73), and

fasten it.
● Tool: 22 mm ( )
● Torque: 152 ±7 N.m (15.5 ±0.7 kg.m, 112.1 ±5.16
ft lb)
Install hexagon nut (72) on the tie rod (71), and
fasten it.
● Tool: 19 mm ( )
● Torque: 93 ±4 N.m (9.5 ±0.4 kg.m, 68.6 ±3 ft lb)
IMPORTANT
The torque used for screwing the hexagonal nut
must be within the prescribed torque. If the tightening
torque is too small, oil could possibly leak out from the
mating surface due to insufficient clamping force. If,
on the other hand, the tightening torque is too large,
the spool could stick, due to deformation of the valve
housing for the spool section, which could possibly
cause the actuator to go out of control, that is, it
cannot be stopped.
The two pieces must be screwed in alternately so that
they can be evenly screwed in.

IMPORTANT
As for this control valve, the add-on section which is
normally supplied as a kit can be added later. For the
add-on section that is added afterwards, follow this
guideline on disassembling and assembling and pay
attention to each note when working on it.
Load Check Valve for Travel, Bucket, Boom 1, Boom 2,

19
Arm 1 and Swing 18
17
1. Insert the poppet (16, Figure 78) and the spring (17) 16
in the valve housing.

2. Screw in the plug (19, Figure 78) which has the
19
O-ring (18) attached to it, and fasten it. 16
17
● Tool: 27 mm ( ) 18
19
● Torque: 103 ~ 113 N.m
(10.5 ~ 11.5 kg.m, 76 ~ 83.4 ft lb)
WE1400958
Figure 78
Load Check Valve for Arm 2 39

38 68
1. Install the spring (35, Figure 79) and the poppet (34)
37
on the outer periphery of the sleeve (33), and then
insert the valve housing with the poppet (36) and
the spring (37) staying in the sleeve. 36
2. Install the O-ring (38, Figure 79) in the valve 33
housing groove, install the flange (39), and fasten 35
34
them with the socket head bolt (68).
● Tool: 8 mm ( )
● Torque: 39 ~ 44 N.m (4 ~ 4.5 kg.m, 28.8 ~ 32.5 ft
lb)
WE1400956
IMPORTANT Figure 79
When installing the flange (39), the spring (37) must

properly stay within the locus on the flange. If it does
not stay within the locus on the flange, the spring
could get damaged.
When tightening the socket head bolt (68), tighten the
two pieces alternately so that they can be tightened
evenly. From here on, refer to this note when
tightening flanges.

Merging Check Valve for Option
1. Insert the poppet (24, Figure 80) and the spring (25)
in the valve housing.
2. Install in the plug (23, Figure 80) which has the
O-ring (18) attached to it, and fasten it.
● Tool: 32 mm (
24
) 25
● Torque: 103 ~ 113 N.m
18
23
(10.5 ~ 11.5 kg.m, 76 ~ 83.4 ft lb) 81
3. Install in the plug assembly (81, Figure 80) which
has O-ring attached to it, and fasten it.
● Tool: 32 mm ( )
WE1400957
● Torque: 89 ~ 97 N.m (9.1 ~ 9.9 kg.m, 67.1 ~ 71.5
ft lb) Figure 80
Common Check Valve

1. Insert the poppet (16, Figure ) and the spring (17) in
the valve housing.
2. Screw in the plug (19, Figure ) which has the O-ring
(18) attached to it, and fasten it.
● Tool: 27 mm ( )
● Torque: 103 ~ 113 N.m 19
16
(10.5 ~ 11.5 kg.m, 76 ~ 83.4 ft lb) 17
18
19
WE1400955
Figure 81
Semi-parallel-check for Arm 1

1. Install the poppet (57, Figure 82) and the spring (58). 32
2. T ighten the plug (32, Figure 82) which has the
58
O-ring attached to it.
● Tool: 8 mm ( ) 57
● Torque: 73 ~ 79 N.m (7.4 ~ 8.1 kg.m, 53.8 ~ 58.3
ft lb)
WE1400959
Figure 82

Relief Valve
1. Screw in the overload relief valve (63), and fasten
it. There are 8 of these in total.
● Tool: 32 mm ( )
● Torque: 78 ~ 88 N.m (8 ~ 9 kg.m, 57.5 ~ 65 ft lb)
63
WE1400960
Figure 83
63
63
WE1400961
Figure 84
2. Screw in the main body main relief valve (62, Figure

85), and fasten it.
● Tool: 32 mm ( )
● Torque: 78 ~ 88 N.m (8 ~ 9 kg.m, 57.5 ~ 65 ft lb)
62
WE1400962
Figure 85

3. Screw in the negative control relief valve (55, Figure
86), and fasten it.
● Tool: 32 mm ( )
● Torque: 103 ~ 113 N.m
55
(10.5 ~ 11.5 kg.m, 76 ~ 83.4 ft lb)
55
WE1400963
Figure 86
Assembly Sub Spool for Swing Priority and Center 45

43
Bypass Cut 48A 44
43
1. Install the spool assembly (41, Figure 87) (48) 48
into the same position where it was before

disassembling.
41A
45
43
44
43
41
WE1400952
Figure 87
2. Install the cap (46, Figure 88) (47) which has the 47 66
O-ring (42) attached to it. 46
42
Insert the socket head bolt (66) in the cap, and
fasten it.
● Tool: 5 mm ( ) 66
● Torque: 8.8 ~ 10.5 N.m (0.9 ~ 1.1 kg.m, 6.5 ~ 7.7
ft lb)
65
IMPORTANT
13
12
The spool must be inserted slowly and straight with
respect to the direction of the hole. After the spool is WE1400950
inserted, slide the spool with a hand and make sure
there is no unsmoothness or raggedness. If the spool Figure 88
is inserted under an unsmooth and ragged condition, it
could possibly result in operational failure of the spool.
From here on, refer to this note when inserting spools.

Assembly Sub Spool (Arm Regeneration Valve)
1. Install the spool assembly (52, Figure 89) into the
same position where it was before disassembling.
2. Install the spring (51, Figure 89). 53
54
3. Screw in the plug (49, Figure 89) which has the 53
O-ring (50) attached to it, and fasten it. 52
51
● Tool: 32 mm ( ) 50
● Torque: 103 ~ 113 N.m
(10.5 ~ 11.5 kg.m, 76 ~ 83.4 ft lb)

49
WE1400953
Figure 89
Assembly of Main Spools 47 66

46
1. Install the O-ring (12, Figure 90) in the valve
housing (1). 13
42
2. Mount the short cap (13) on spools. 66
Insert the socket head bolt (65) in the short cap, 65 1
and fasten it.
● Tool: 6 mm ( )
● Torque: 20 ~ 25 N.m (2.0 ~ 2.6 kg.m, 14.8 ~ 18.4
ft lb)
65
13
12 WE1400970
Figure 90
3. Install the spools (2 ~ 10, Figure 91), that were

7
made “Subassembly”, in each spool hole, at 8
Arm 2 9
the same position where they were before Boom 1
12 65
Bucket
disassembling. Travel(RH)
11
Straight
4. Mount the long cap (11, Figure 91) on spools. Travel
Insert the socket head bolt (65) in the long cap, and 6 10
5
fasten it. 2
65
● Tool: 6 mm ( )
● Torque: 20 ~ 25 N.m (2.0 ~ 2.6 kg.m, 14.8 ~ 18.4 Arm 1
2 Boom 2
3 4
ft lb) Swing
Option
12
11 Travel(LH)
IMPORTANT EX1500165
Figure 91
When installing the cap, watch out for the mating
surface O-ring falling off.

Other Plugs
32
1. Tighten the plug assembly (32, Figure 92) which
has the O-ring mounted on it. 21
● Tool: 8 mm ( )
● Torque: 73 ~ 79 N.m (7.4 ~ 8.1 kg.m, 53.8 ~ 58.3
ft lb)
has the O-ring mounted on it.
● Tool: 5 mm ( ) 69
● Torque: 13.5 ~ 16.5 N.m

32
(1.4 ~ 1.7 kg.m, 10 ~ 12.2 ft lb) 21
WE1400964
has the O-ring mounted on it. Figure 92
● Tool: 27 mm ( )
● Torque: 103 ~ 113 N.m
(10.5 ~ 11.5 kg.m, 76 ~ 83.4 ft lb)

4. Tighten the plug assembly (69, Figure 92) (78-2)
32
which has the O-ring mounted on it.
● Tool: 10 mm ( )
● Torque: 116 ~ 128 N.m 21
(11.8 ~ 13.1 kg.m, 85.6 ~ 94.4 ft lb)
22
has the O-ring mounted on it. 18
● Tool: 19 mm ( )
● Torque: 49 ~ 59 N.m 20
(5 ~ 6 kg.m, 36.1 ~ 43.5 ft lb)
WE1400965
Figure 93
IMPORTANT
After assembling is completed, make sure there is no
part that was once disassembled that you forgot to
include in the assembling procedure. Also make sure
there is no screw that you forgot to fasten. If there is
an unfastened screw, loosened parts could cause oil
leakage.
All the prescribed torque values are meant for “Wet
Condition”, that is they are to be used under conditions
where hydraulic oil is applied to the mechanism.

TROUBLESHOOTING AND
ADJUSTMENT
Troubleshooting
Overall Control Valve

Remove part which becomes
Oil temp. is extraordinary high.
resitance in circuit.
Clean oil application, wash entire
Dirty oil.
circuit by flushing.
Excessive torque aoolied on joint. Check torque.
Housing distorted by mount bolt. Loosen mount bolt and check.
Pressure is extraordinary high. ConfIrm pressure of pump/cylinder.
Spool stuck Spool is bended. Replace main control valve.
Return spring breakdown. Replace damaged spring.
Dismantle and reassemble in correct
Spring/cap in incorrect position.
position.
Oil temp. in valve is not uniform. Warm up entire circuit.
Remove contamination and flush
Contamination inside valve.
entire circuit.
Insufficient pilot pressure. Check pilot pump/valve.
Oil leakage from cylinder. Check cylinder seal.
Oil leakage from spool. Check spool scratch.
Oil leakage from relief valve. Wash seat of housing/relief valve.
Impossible to hold the Dismantle anti-drift valve and wash

load at full lever seat of each part.
If scratch on seat, replace poppet or
Oil leakage from anti-drift valve.
calk poppet and seat.
If damage on internal spool, replace
pair of spool and sleeve.
Contamination on load check valve. Dismantle load check and wash.
Impossible to hold the
Replace poppet or calk poppet and
load at half lever Oil leakage from spool.
seat.

Relief Valve

No pressure boost Parts stuck, substance on seat.
Seat of pilot poppet is damaged.
Pressure is unstable Replace relief valve assembly.
Piston/main poppet stuck.
Seat wear by contamination.
Setting pressure is
Reset pressure and tighten lock nut
incorrect Adjuster/lock nut loose.
correctly
Damage on relief valve seat.
Replace relief valve.
Oil leakage Part stuck by contamination.
O-ring wear. Replace O-ring of adjuster/outer.
Hydraulic System

Check pressure, replace pump if
Pump failure.
necessary.
Relief valve failure. Replace relief valve assembly.
Cylinder failure. Repair or replace.
System failure nothing Pump pressure is too high. Check circuit.
moves Crack on main control valve. Replace main control valve.
Spool stops before full stroke. Confirm spool movement.
Oil shortage. Supply oil by normal level.
Clog on filter in circuit. Wash filter or replace.
Pipe/hose is restricted internally. Check pipe/hose.

Adjusting Relief Valve
Main Relief Valve
1. This part is designed for non-disassembly and is
not subject to readjustment. If pressure is adjusted,
we cannot guarantee its proper operation.
2. Install a precise pressure gauge at the circuit inlet.
3. Run the pump at the rated rpm.
4. M ove the spool in the control valve, read the
pressure gauge indication at the end of the cylinder
stroke.
IMPORTANT
Move the spool of the actuator. The set pressure of
the overload relief valve is higher than that of the main
relief valve actuator spool.
5. Turn the adjuster clockwise until desired pressure is

obtained.
17.8 MPa of pressure is increased by a turn of the
adjuster.
6. When the desired pressure is reached, and press
the adjuster so it does not rotate, then tighten the
locknut.
● Torque: 27 ~ 31 N.m (2.8 ~ 3.2 kg.m, 19.9 ~ 22.9
ft lb)
7. Raise the pressure again to check that specified
pressure is obtained.
Overload Relief Valve
IMPORTANT
If the set pressure is higher than that of the main relief
valve, it will be activated during the following
adjustment. It is not possible to adjust the overload
relief valve. Do not disassemble or adjust it. Replace
with a complete new set of assembled relief valves.
1. T his part is designed for non-disassembly and

should not be adjusted. Replace by assembly. If
the pressure has been adjusted, we cannot not
guarantee its proper operation.
2. Move the control valve spool, and read the pressure
gauge indication at the end of the cylinder stroke.

3. Turn the adjuster clockwise until desired pressure is
reached.
21.2 MPa of pressure is increased by each turn of
the adjuster.
4. W hen the specified pressure is reached, press
the adjuster so it does not rotate, and tighten the
locknut.
● Torque: 27 ~ 31 N.m (2.8 ~ 3.2 kg.m, 19.9 ~ 22.9
ft lb)
5. R aise the pressure again to check the rated
pressure has been obtained.

Swing Device
DX140AF/DX140LCA Swing Device 7-178

ＭＥＭＯ

Table of Contents
Swing Device
INSTRUCTION MANUAL........................................ 182
Indication of Type........................................... 182
Specifications.................................................. 183
Construction and Principles of Working.......... 184
Precaution in Use........................................... 191
Troubleshooting.............................................. 195
REMOVAL............................................................... 198
INSTALLATION....................................................... 203
COMPLETING WORK............................................. 203
MAINTENANCE MANUAL...................................... 204
Disassembling and Assembling...................... 204
Maintenance Standards.................................. 217

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 the load.
Remember, that ultimately safety is your own
responsibility.

INSTRUCTION MANUAL
Indication of Type
TSM 72 CH B 10 A -03 /270
Relief Valve
Setting Pre.
Design Code
Specification
A: Swing Specification
Shaft Geometry
10 : Male Spline
20 : Female Spline
Mechanical Brake Yes Or No

B : Brake Built-in
Valve Cover Code
Displacement
64 : 64 cc/rev
72 : 72 cc/rev
86 : 86 cc/rev
128 : 127.9 cc/rev
140 : 140.5 cc/rev
Motor Type

Specifications
Name TSM72CHB-10A-03/270-IRV
Displacement (cc•rev) 72
Pressure (kg•cm2) 270
Theoretical output torque (kgf•m) 30.9
Rated flow (min) 132
Maximum speed (rpm) 1,833
Brake torque (kgf•m) 36.8
Brake release pressure (kgf•cm2) 24
Weight (kgf) 41.3
NOTE: *1. The theoretical value at the rated pressure, not

including mechanical efficiency.
*2. The theoretical value at the rated pressure
and the max. speed.

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

111
303
401
made by
Tong Myung Heavy Industries Co.,Ltd
MFG. NO. :
PART NO. :
302
DAEWOO HEAVY IND. LTD.

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

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

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

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

FG007419
Figure 2 Diagram Showing the Working Explanation

Valve Casing Part
1. Anticavitation Check Valve
The motor can be rotated faster than supplied oil
flow because there is no counterbalancing valve to
prevent over speed ;
to prevent cavitation of the motor, oil compensation
insufficient flow is drawn through the anti-cavitation
check valve.
2. Relief Valve: KRD22EK10C (See Figure 4 on page
-12) We consider that port P is applied pressure by C Port
tank pressure.
Port P, R are affected by tank pressure at first, as
Control Valve
shown fig. 3-(1). The relief valve starts operating FG007421
when the force that is determined by multiply the Figure 3
pressure area (A1) of plunger (301) by pressure P1
is equal to the sum spring (321) force (Fsp) and the
force that is determined by multiply the pressure
area (A2) by pressure Pg of room ‘g’ in the plunger
(301).
Here, Pg is the pressure of room ‘g’ applied
pressure by passing oil through orifice m. If Pg
arrives at the pressure which is determined by
spring (321) pushing the piston (302), the piston
move to left side. when piston (302) move left
side, room ‘h’ operates as damping room because
of orifice (n) which is designed at the side of
adjustment plug (401) and piston (302). Because of
this mechanism, the pressure of room ‘g’ increases
smoothly while the piston (302) reaches end of
adjustment plug (401). (Figure 4-(2))
P1 × A1 = Fsp + Pg × A2
Fsp+PgxA2
P1=
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

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

(Pressure : Pg)
(2)
(3) Pressure : Ps
Pressure : Ps
Ps
(4)
P1
T FG007422
Figure 4

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

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

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

Precaution in Use
Inspection
Before installation of a new motor, inspect the
following items.
1. Inspect whether or not there is any damage during
transit, or if any parts are lost 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.
Anti-clockwise Clockwise (Attach a label M type)

FG007425
Figure 7 Brake Working Description
Revolutionary Direction of Shaft

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

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

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

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

3. Except Mineral Oil
Incase if using special fluid (phosphate ester
compounds, water-glycol, fluid fatly acid ester
compound, etc.), please consult us for instruction
before use.
Filter
If fine particles of dirt and metal are mixed with oil,
they enter into sliding surfaces and accelerate wear in
each part, and in the worst case seizure will be likely
to occur.
It is recommended, therefore, that 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.
Installation and Piping

1. When the motor is installed that its shaft turns
downside.
2. The motor should be installed that it is concentricity
below 0.05 mm.
3. The tightening torque of bolts for fixing the motor
to the bracket is shown in assembly drawing the
customer’s reference.
4. Since the casing inside is always kept filled with oil,
the drain must be returned to the tank through the
return pipe which is once raised higher tank that of
the motor itself as shown in Figure 9.
5. Motors will tolerate in the casing pressure up to
maximum 3 kg•cm2, but for common pressure, 2
kg•cm2 below should be kept.
6. Piping should be cleaned and flashing well. Figure 9
7. Be care to as the installation to piping.
8. Use the drain pipe bigger than the port size and
form shortly as possible as.

Oil Filling and Air Bleeder
1. Fill in the casing with oil using the drain port before
the operating.
In the motor, there are many kinds of high-speed
sliding surface like bearing, piston, shoe, spherical
bushing, and etc. So If there isn’t enough oil, can
make some problem like sticking or breaking in
those parts.
Air
Use the PF 1/4 port for venting air. Bleeder
2. All the air in the motor and circuit must be removed,
otherwise, it will be likely to be causes of imperfect
working or a damage of the motor.
Precaution in Starting Operations FG007427

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

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

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

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

established value
1. The volume of flowing is not

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

4. Brake torque is not sufficient.
1. Disassembly or inspection.
When it is worn better than standard,
1. Friction plates are worn.
replace it.
2. Brake piston is becoming stick.
Brake torque is not 2. Disassembly or inspection
3. Brake releasing pressure is not
sufficient 3. 1) Check for the circuit.
working.
2) Check for the brake valve
4. Spline of friction plates are damaged.
4. Disassembly or inspection.
1) Replace for damaged parts.
5. Motor is much slip

Investigates the DRAIN quantity for motor.
Normal: app. 200cc/min (TSM140:500cc/min)
1. Working defectiveness of relief valve

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

1. The lip is dirty or damaged.
2. Replace the driving shaft or defective
2. The shaft may be damaged or worn
centering of the driving shaft.
Oil leak from the oil out.
3. It repairs the drain piping which is
seal 3. The lib is damaged too high-pressure
closed up.
in the casing.
4. Disassemble, repair, and replace the
4. The shaft is rusty.
oil seal.
B. Oil leak from the blind and union
1. O-ring is not in. 1. Insert O-ring.

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

REMOVAL
WARNING

clothes.

immediately.
WARNING
the workplace.
IMPORTANT
specific manner.
disposal.
1. Park the machine on flat level ground.

2. Extend the boom and arm, as shown in Figure 11
and lower the boom until the attachment is 10 cm
above the ground.
3. Stop the engine.
10 cm
EX1301631
Figure 11

4. Move safety lever to “RELEASED” (UNLOCK) O ACC
I
LOCK
WARNING OFF OFF
ON
ON
ON OFF
EX1500510
maintenance, always use extreme caution. Always
6. Operate the joystick levers and pedals several

times to release the remaining pressure in the
hydraulic piping.
starter switch.
(Figure 13)
ON
OFF
EX1500045
Figure 13

3
5 8
1 2
7 6
4
EX1401809
Figure 14

WARNING
doing any work.

EX1500046
12. Remove hoses and adapters from swing device.

NOTE: Attach an identification tags to the removed
hoses for reassembling.
After disconnecting hoses, plug them to
prevent dirt or dust from entering.
Disconnect the hoses from the bottom to
top of swing device.
A
C
PG
Dr(RG)
B
N
DB
SH
Sgr
EX1500048
Figure 16

Plug/Flange Size Torque
Port Name
(Hose) (mm) (mm) N.m kg.m ft lb
A Main Port (from MCV “B3”) SAE 1/2”, D13 6 29.4 3 21.7
B Main Port (from MCV “A3”) SAE 1/2”, D13 6 29.4 3 21.7
C Make-up Port (from MCV “T1”) UNF 1 3/16”-12-2B 36 124.5 12.7 91.8
DB Drain Port (Connect with Center Joint) UNF 13/16”-16-2B 24 55.9 5.7 41.2
PG Brake Release Port (from MCV “PP”) UNF 9/16”-16-2B 19 25.5 2.6 18.8
Brake Release Signal
UNF 9/16”-16-2B 19 25.5 2.6 18.8
SH (from MCV “PA”)
Sgr Grease Inlet Port PF 1/4” 19 39.2 4 28.9
N Nut PF 1/2” 27 93.1 9.5 68.7
Dr(GR) Drain (Reduction Gear) PF 1/2” 27 93.1 9.5 68.7

● Fitting
Size Torque
Port Name
C Adapter PF 3/4” UNF 1 3/16”-12 36 166.6 17 122.9
DB Tee PF 3/8” UNF 13/16”-16 22 73.5 7.5 54.2
PG Adapter PF 1/4” UNF 9/16”-18 19 36.3 3.7 26.8
UNF 9/16”-18, PF
SH Tee PF 1/4” 19 36.3 3.7 26.8
1/4”
Reducer PF 1/4” PF 1/4” 19 39.2 4 28.9
Sgr Adapter PT 1/8” PF 1/4” 17 14.7 1.5 10.8
Dr(GB) Adapter PT 1/2” PF 1/2” 27 49.0 5 36.2
DS2856001
A,B Ring Seal
(1/2”, ID:18.9, OD:25.9, 1B)
C O-ring S8000235 (4D P22.4) S8030125 (4D F-12)
DB O-ring S8000145 (4D P14) S8030081 (1B F-08)
2180-1216D11
PG O-ring S8000115 (4D P11)
(ID:7.65, W:1.78, 1B)
2180-1216D11
SH O-ring S8000115 (4D P11)
(ID:7.65, W:1.78, 1B)
14. Install the eyebolts (M10 x 1.5 x DP18) (Figure

17).
15. Attach a nylon sling onto the eyebolt.
WE1401450
Figure 17

● Tool: 24 mm ( )
● Torque: 265 N.m (27 kg.m, 195 ft lb)
17. Remove plugs (2, Figure 18) (2 ea).

18. Install the back bolt to the plug position to ensure
that frame and swing device can be separated.
19. Hoist and remove swing device from the frame.
NOTE: W hen hoisting the swing device one part 1 2
of swing device will contact with the main WE1401451
frame. Figure 18
Hoist the swing device a little and push to
the front side while hoisting slowly.
20. Wind wire rope around the swing device, lift it up
with a crane and wash with flushing oil.
After washing, dry with compressed air.
● Weight: about 122 kg (269 lb)
WE1401452
Figure 19

INSTALLATION
WARNING
OR SERIOUS INJURY
When connecting hydraulic components, observe
●


2. When installing the hoses, install the drain hose
first.
3. When installing the swing device, slightly move the
end of bucket to align it with the swing bearing gear
if the swing device does not fit the gear.
COMPLETING WORK
IMPORTANT
If air is not vented from system, it will cause damage
to swing motor and bearings.
1. Disconnect drain hose and fill swing motor case

with hydraulic oil.
2. Connect drain hose.
3. Start engine and set throttle at “LOW IDLE” and EX1500049
swing upper structure slowly two full revolutions to Figure 20
left and right.
4. S top engine and check hydraulic oil level. Fill
hydraulic oil tank to “H” mark on sight gauge.
5. C heck for oil leaks and clean all fill and venting
locations.

MAINTENANCE MANUAL
Disassembling and Assembling
Tightening Torque of Bolts
In table 1. is shown tightening torque of bolts used
in motor. In case of reassembling, tighten accurately
each bolt in accordance with table 1.
Table 1 ( ) : TSM72
Tightening Torque
Bolt Size Name Part No.
(kg•cm)
M6 Hexagon Bolt 120 ± 20 400
M20 (M16) Hexagon Socket Bolt 4400 ± 660 (2400 ± 360) 109
M22 RO Plug 1100 ± 100 105
M36 (M24) RO Plug 2450 ± 250 (1300 ± 100) 105
PF 1/4 Plug 370 ± 20 111
M33 Relief Valve 1800 ± 100 105

Necessary Tools
In table 2, 3 Figure. is shown necessary tools for
disassembling and reassembling.
Table 2 ( ) : TSM72
Name Size 2-face width Application part Tool

Hexagon bolt M6 10 Brake valve Hexagon wrench socket wrench
Hexagon socket bolt M20 (M16) 17 (14) Hexagon wrench
Plug M22 10 RO plug Hexagon wrench
Plug M36 (M24) 17 (12) RO plug Hexagon wrench
Plug VP-1/4 19 VP plug Hexagon wrench socket wrench
36 Relief valve Hexagon wrench socket wrench
Table 3 etc. ( ) : TSM72
Spec.
Dimensions
Tool
Pliers (For lock ring) For ø65 axis (ø50)
Driver - Type 2EA
Steel rod About 10 x 8 x 200 1EA
Hammer One each of plastic hammer and metal hammer.
Torque range
• For 100 - 450 kg•cm
Torque wrench
• For 400 - 1,800 kg•cm
• For 1,200 - 4,800 kg•cm
Slide hammer bearing pliers

Special tool for removing the break piston 25page reference

2x 7
40
M10
(Effectiveness
Screw Length : 20)
100
250
11
M10
9 7 M10
136
169 (TSM140)
240
FG007428
Figure 21 Special Tool for Removing the Brake Piston

Procedures for Disassembly
Please use the following procedures for the inspection
and repair of the motor.
Numerals given in parentheses following the parts
names indicate the parts number shown by the
drawing in the instruction and maintenance manual.
1. Wind the wire rope at motor outside, lift up the
motor, and clean the motor with cleaning oil.
After cleaning, dry with compressed air.
2. Draw the oil out of the casing (301).
3. Mount on a suitable table for the driven-axis (201)
below.
Before disassembling make a match mark on motor
casing (301) and valve casing (101).
FG001856
Figure 22
4. Remove brake valve (400).
FG001857
Figure 23
5. Remove relief valve (107) from valve casing (101).
FG001858
Figure 24

6. Remove RO plug (102) and take out spring (103)
and plunger (104) from valve casing (101).
Figure 25
7. Remove swing reactionless valve ass’y (105) from

valve casing (101).
Figure 26
8. R e m o v e h e x s o c k e t b o l t s ( 1 0 9 , 1 1 0 ) a n d
disassemble valve casing (101) from casing (301)
(When loosening bolts, the valve casing will be
raised by brake springs (310). Remove valve plate
(213) from the valve casing (101).
Figure 27
9. Remove brake springs (310) from the brake piston

(309).
Figure 28

10. Disassemble brake piston (309) from casing (301)
by using the special tool for removing the brake
piston.
Lit it up straight by using the bolt hole in the brake
piston.
Figure 29
11. A fter placing the motor horizontally, take out

cylinder block (205) from casing (301).
Remove piston ass’y (203, 204), retainer (207),
spherical bushing (206), spacer (208).
When taking out the cylinder block, be careful not
to pull out roller (209).
Be careful not to damage the sliding parts of the
cylinder block, spherical bushing and shoe.
And washer (210, 2EA), spring (211), retaining ring
(212) are not disassemble at the disassembled
Figure 30
cylinder block.
12. Pull out friction plate (306, 2EA) and separation
plate (305, 3EA) from casing (301).
(TSM72 : friction plate : 3EA
separation plate : 4EA)
FG001865
Figure 31
13. Remove swash plate (202) and driveshaft with ball

bearing (303) from casing (301) Be careful not to
damage the ball bearing (303) and oil seal contact
surface.
If you beat a driveshaft end with plastic hammer, it
is easy to be disassembled.
Figure 32

14. Do next step if required.
A. Remove parallel pin (304) from casing (301).
FG001867
Figure 33
B. Remove ball bearing (303) with a press from

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

in the Inner Ring.
FG007429
Figure 34
C. Take out oil seal (302) from the casing (301)

with a using of tool. Press
Do not reuse the disassembling oil seal (302).

Drive Shaft
Ball Bearing
Press Table Hangs

in the Inner Ring.
FG007429
Figure 35
D. Take out ball bearing from the valve casing

(303).
15. Disassembling is finished, check each component
throughly.
FG001870
Figure 36

Procedures for Assembly
Following are caution to be specially borne in mind.
A. Rework damaged parts and before assembling,
prepare all parts to be replaced.
B. Clean all parts and dry with compressed air.
C. Coat the sliding parts and bearing with clean
hydraulic oil.
D. Replace O-ring, oil seal.
E. For the mounting of bolts to install the various parts,
please use a torque wrench, etc. and tighten the
bolts with the torque shown in table 1.
1. Place casing (301) on the work table with the valve
casing side downward.
FG001871
Figure 37
2. (It is necessary when oil seal was disassembled

from the casing.)
Insert oil seal (302) at the casing (301) with a using
of tool.
(Be careful to note the direction of oil seal. and
insert until fully seated at the casing end.)
FG001872
Figure 38
3. ( I t i s n e c e s s a r y w h e n b a l l b e a r i n g w a s
disassembled from the driveshaft.)
Ball bearing (303) is press fit by the heat to
driveshaft (201).
FG001873
Figure 39

4. Insert the driveshaft (101) complete with ball
bearing into casing (301).
Impact the outside surface of outer loop uniformly
till stop at casing section.
Coat the lip of the oil seal with grease and tape the
shaft spline for the protection of spline.
Tap evenly.
FG001874
Figure 40
5. (It is necessary when parallel pin was disassembled

from the casing.)
Assemble parallel pin (304) to casing (301).
FG001875
Figure 41
6. Assemble swash plate (202) to casing (301).

If casing is horizontal position from the bottom, It is
easy to work.
FG001876
Figure 42
7. Insert roller (209) to cylinder block (205).

Make sure that cylinder block is assembled with all
component.
(washer (210), spring (211), ring snap (212)) (Be
careful not to damage the sliding surface of the
cylinder block. Insert roller to each hole one by
one.)
FG001877
Figure 43

8. Place spacer (208), spherical bushing (206) to the
cylinder block (205).
FG001878
Figure 44
9. A s s e m b l e t h e r e t a i n e r w i t h t h e p i s t o n s u b
assembly (203, 204) unit to the cylinder block
(205).
FG001879
Figure 45
10. Insert cylinder block to driveshaft (101) aligning

the spline.
Figure 46
11. Place casing (301) downward and assemble

separation plate (305, 3EA) and friction plate (306,
2EA) in sequence.
Align 4 tangs to the notches.
Align cut the jaw and assemble that part.
(TSM72 : friction plate : 3EA
separation plate : 4EA)
FG001880
Figure 47

12. Mount O-ring (307, 308) to casing (301).
(Coat the O-rings with grease. O-ring can be
protected by grease.)
FG001881
Figure 48
13. Assemble brake piston (309) to casing (301).

The piston is difficult to assemble because of the
restriction of the O-ring; screw in two M8 bolts on
the brake piston and tap them gently with plastic
hammer.
FG001882
Figure 49
14. Assemble brake springs (310) into brake piston

(309).
Confirm the springs are fitted to the brake piston
completely.
FG001862
Figure 50
15. (It is necessary when ball bearing (108) was

disassembled from the valve casing.)
Assemble of ball bearing (108).
Insert it to valve casing (101) while tapping it
lightly.
Tap evenly on the outer diameter of the outer race
with a brass drift until it completely stops.
Do not use a steel punch or bar on the bearing
FG001884
since it can chip or crack the race.
Figure 51

16. Assemble valve plate (231) to valve casing (101)
and fit O-ring (113).
Be careful to note the direction of the valve plate.
Mount the valve plate with its round part toward
the opposite side of the flange.
Coat lightly with grease.
FG001885
Figure 52
17. Mount valve casing (101) to casing (301) and

tighten hex socket bolts (109, 110) to specification.
Be careful to note the mounting direction of the
valve casing.
(Reference to the drawing)
Be careful not to drop the valve plate or let the
brake springs pop out.
Tighten the bolts evenly.
FG001886
Figure 53
18. Install plunger (104) and spring (103) to valve

casing (101) and tighten RO plug (102) with O-ring
(106).
Confirm the smooth movement of the plunger
before installing the plug.
FG001887
Figure 54
19. Install swing reactionless valve ass’y (105) to

valve casing (101).
Confirm the spring in the swing reactionless valve
ass’y (105).
FG001888
Figure 55

20. Assemble relief valve (107) with O-ring to valve
casing (101).
FG001858
Figure 56
21. Assemble brake valve (400) to casing (301) and

tightening the hex socket bolts to specified torque.
22. The assembly is completed.
FG001856
Figure 57

Maintenance Standards
Standards for Replacement of Worn Parts If the
various parts of the motor have been worn out beyond
the following standard values, please replace them.
But this shall apply only to those cases when is no
remarkable outside damage.
Recommended
Standard
Item value for Remedy
dimension (mm)
replacement (mm)
Clearance between piston Replace piston or cylinder
0.025 (0.036) 0.055 (0.066)
and cylinder bore block.
Gap between piston and
0.05 0.2 Replace piston or shoe.
caulked part of shoe (δ)
Thickness of shoe (t) 4.5(6.5) 4.3 (6.2) Replace piston or shoe.
Assembled height of Replace sperical bushing
10.8 (13.0) 10.3 (12.5)
retainer (H-h) and 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).

Thickness of shoe (t) Assembled height of retainer (H-h)
Standard for Correcting Sliding Surfaces

If the surface roughness of the sliding surface of a part
exceeds the following standard, correct it or replace
the part.
Table 4 Revise standard
Item Surface roughness Roughness requiring correction

Shoe 0.8 - Z (Ra=0.2) (LAPPING) 3 - Z (Ra=0.8)
Swash Plate 0.4 - Z (Ra=0.1) (LAPPING) 3 - Z (Ra=0.8)
Cylinder Block 1.6 - Z (Ra=0.4) (LAPPING) 12.5 - Z (Ra=3.2)
Valve Plate 0.8 - Z (Ra=0.2) (LAPPING) 6.3 - Z (Ra=1.6)

Swing
Reduction Gear
DX140AF/DX140LCA Swing Reduction Gear 7-218

ＭＥＭＯ

Table of Contents
Swing Reduction Gear

SAFETY INSTRUCTIONS....................................... 221
APPLICABLE MODELS.......................................... 221
GENERAL DESCRIPTION...................................... 222
Theory of Operation........................................ 222
REASSEMBLY........................................................ 223
Parts List......................................................... 223
SHRINKAGE FITTING OF SHAFT AND FLEXIBLE
BEARING .............................................................. 225
REASSEMBLY OF CARRIER SUB........................ 227
ASSEMBLY OF THE MAIN.................................... 234
TEST....................................................................... 246
REASSEMBLY OF MOTOR.................................... 249

SAFETY INSTRUCTIONS
WARNING
APPLICABLE MODELS

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

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

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

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

Figure 2
FG005351
Figure 3
FG005352
Figure 4
FG005353
Figure 5

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

the air for 1 to 2 hours.
FG005355
Figure 7

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

insert it.
FG005358
Figure 10

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

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

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

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

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

FG005367
Figure 19
G. Install a retaining ring (ø30, C type, and for

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

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

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

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

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

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

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

runs smooth.
FG005381
Figure 33

ASSEMBLY OF THE MAIN
1. Washing of casing and other parts
Wash casing and other parts with steam to remove
remaining foreign substance after casting and
machining.
● Washing fluid: PK6540 (alkali)
● Concentration : 3-5%
● Temperature: 60 - 70°C
2. Assembly of shaft and bearing

A. Attach the washed casing on the turnover
machine and rotate the turnover machine so that
press fitting side of the shaft looks upward.
FG005382
Figure 34
FG005383
Figure 35
B. Place the driveshaft assembly where bearing

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

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

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

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

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

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

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

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

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

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

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

case.
FG005415
Figure 57
FG005416
Figure 58
FG005417
Figure 59

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

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

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

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

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

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

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

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

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

TEST
1. Pneumatic pressure test
A. After the reassembly of the carrier and the sun 2
4
6
10
8
assemblies, loosen bolts of the ring gear, place

the pneumatic test jig, and tighten 4 bolts again.
Now, make sure that pressure gauge is set to
zero.
FG005054
Figure 77
B. Supply air through valve until pressure gauge

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

10
0
FG005055
Figure 78
2. Noise and abnormal sound test

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

FG005436
Figure 80
B. S t a r t m o t o r i n t h e a d v a n c e a n d r e v e r s e
directions (1,875 ±90 rpm, no idle) and check for
any noise or abnormal sound carefully. (Standard
noise is 90dB at 30cm away.)
FG005437
Figure 81
Figure 82

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

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

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

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

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

FG005449
Figure 93
E. Seal the level gauge port of the motor with teflon

tape and use pipe wrench to tighten the level
gauge pipe.
CAUTION
AVOID INJURY
Do not insert the level gauge before filling gear oil. FG005450
Figure 94

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

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

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

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

Travel Device
DX140AF/DX140LCA Travel Device 7-256

ＭＥＭＯ

Table of Contents
Travel Device
PRODUCT OVERVIEW.......................................... 261
General Specifications.................................... 261
EXTERNAL DIMENSIONS...................................... 262
OPERATING DESCRIPTION.................................. 266
Reduction Gear............................................... 266
Hydraulic Drives.............................................. 267
PRECAUTIONS FOR USE...................................... 275
Installation (Refer to Diagram of External
Dimensions).................................................... 275
Tubing............................................................. 276
Fluid Selection................................................ 276
MAINTENANCE AND INSPECTION....................... 277
Daily Inspection.............................................. 277
Changing Fluid................................................ 278
Changing Lubrication...................................... 278
SEALS TABLE........................................................ 280
TROUBLESHOOTING............................................ 281
REMOVAL............................................................... 283
INSTALLATION....................................................... 289
COMPLETING WORK............................................. 289

OUTLINE OF MAINTENANCE................................ 290
Tools............................................................... 290
Bolts................................................................ 290
Equipments..................................................... 291
Fabricated Tools............................................. 291
Torque............................................................ 295
Weight Table................................................... 295
DISASSEMBLING................................................... 296
Work Preparation............................................ 296
General Precautions for Work........................ 296
Disassembling Order...................................... 297
MAINTENANCE STANDARDS............................... 314
Seals............................................................... 314
Maintenance Standards for Wearable Parts... 314
ASSEMBLING......................................................... 316
Preparation..................................................... 316
General Precautions for Assembling Work..... 316
Order of Assembling....................................... 317

SAFETY INSTRUCTIONS
WARNING

PRODUCT OVERVIEW
This product is a hydraulic driven rotary actuator.
The product contains a reduction gear, hydraulic
motor, brake valve and parking brake in one compact
unit. It has been developed for use as an actuator for
application requiring lowrpm, high torque operation
such as construction and marine machinery.
General Specifications
Item Units Spec
Rated Output Torque kgf•m 2,100
-1
Max. Speed min 60
Reduction Ratio 1/54.0
Max. Displacement cc/rev 82.8
-1
Max. Speed min 3,000
Hydraulic Motor 2
Max. Pressure kg/cm 355
2
2-speed Control Press kg/cm 20-70
Brake Torque (min) kg•m 50
Parking Brake 2
Brake Free Pressure kg/cm 7.7

EXTERNAL DIMENSIONS
Figure 1

GENERAL DESCRIPTION
Figure 2

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

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

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

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

Carrier (3)
Hub (1)
FG009760
Figure 3

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

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

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

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

Figure 6

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

3. High-low 2-speed switching mechanism
A. Low speed
When the pilot pressure is not supplied through
the port (P), the valve (363) is pushed up to the
upper position because of the spring (366) force
and pressurized oil through the port (A) or (B),
the pressurized oil is cut off at port (C), and oil in
the chamber (W) is released into the drain (motor
case)
through the valve (363).
Accordingly, the tilt angle of the swash plate
(103) becomes the maximumθ1 resulting the
maximum stroke volume and low speed rotation
of the hydraulic motor.
Figure 8

B. High-speed
When the pilot pressure is supplied through the
port (D), it defeats the spring (366) force and
pressurized oil through the port (A) or (B) to
push down the valve (363) to lower position, the
pressurized oil at the port (C) is led to the chamber
(P) through the valve (363), and the piston (161)
pushes the swash plate (103) up to the plane X
and maintain it at its position. At that time, the tilt
angle of the swash plate becomes the minimumθ2
resulting the minimum stroke volume and high-
speed rotation of the hydraulic motor.
Figure 9

PRECAUTIONS FOR USE
Installation (Refer to Diagram of External
Dimensions)
Before installation remove plugs from oil level
check ports, and confirm that reduction gear oil has
penetrated as far as the oil level check ports.
CAUTION
AVOID INJURY
When lifting a GM motor for transportation or
installation, never stand or work under the GM motor.
Figure 10
During installation, never hit the GM motor with a

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

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

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

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

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

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

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

Changing Fluid
The standard interval for changing hydraulic fluid is
every 1,000 hours or one year.
Hydraulic fluid may be changed within the standard
interval if there is significant reduction in volume,
subject to the following standards.
Test item Change standard
Viscosity change (40°C) ±10%
Total oxidation (mg KOH/ Consult oil supplier.
g) Additive types vary
according to manufacturer.
Water content (%) 0.1%
Impurities 10 mg/100ml
Impurities (%) 0.05%
Changing Lubrication
Reduction gear lubricating oil (gear oil) is added at
time of delivery.
1. Selecting gear oil - recommended grades
A. Use SAE 90 equivalent gear oil (API type GL-4
or higher) with ultra-high-pressure additives.
B. Recommended product names follow:
Supplier Product Name

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

A. First change (initial change after starting
operation) after 500 hours
B. Second and the following changes: after 1,000
hours or one year
C. Change standard
Test item Change standard
Viscosity change (40°C)
10% or less of new oil.
(mm2/s)
Water content (%) 0.2 % or less.

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

sure to confirm the cause and take appropriate
measures before filling with gear oil.
When removing gear oil, always dispose of old
oil in an approved container rather than on the
ground.
Also, take care to observe applicable laws and
regulations regarding disposal.
Oil may spray out when plugs are removed.
Turn the plug slowly and allow internal pressure
to escape before removing.
Figure 11
1. Stop the GM motor when the oil fill check port is at

the top and the oil drain port is at the bottom (Figure
11).
2. Place the waste oil receptacle below the GM motor.
3. To change oil, remove plugs on the 3 ports, and
drain the gear oil.
To fill oil, do not remove plugs from the drain ports.
● Tightening torque: 98.1 ±19.6 Nm (10.0 ±2.0
kg•m) After draining the oil, replace the plug on

the oil drain port.
kg•m)

4. Add gear oil to the oil fill port.
Stop filling just before the gear oil overflows at the
oil level check port.
5. Re-place the plugs on the oil fill ports and level
check port.
kg•m)
6. Re-place the plugs on the oil fill port.
kg•m)
SEALS TABLE
Handle sealing parts carefully.
Once disassembled, replace to the new parts even
though no damage is observed.
No. Name of Part Code Q’ty Remarks
3 31
1 O-ring JIS B 2401-P18-90 2 212
1 359
2 Floating Seal ES100-209-B-A-627 2 29
3 O-ring ARP568-261-70 1 32
4 O-ring JIS B 2401-P7-90 2 33
5 Oil Seal TCZ28 x 48 x 10 x 11.3 1 132
6 O-ring 50OD2039-00 1 135
7 O-ring 60OD2039-00 1 139
8 O-ring JIS B 2401-PIOA-90 2 207
2 209
9 O-ring JIS B 2401-P14-90
2 383
10 O-ring JIS B 2401-P11-90 2 211
11 O-ring JIS B 2401-P32-90 2 336
12 O-ring JIS B 2401-P8-90 3 358
13 Back up Ring JIS B 2407-T2-PIOA 4 208
14 Back up Ring JIS B 2407-T2-P14 4 210

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

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

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

REMOVAL
WARNING

clothes.

immediately.
WARNING
the workplace.
IMPORTANT
safe manner.
Some regulations require that certain spills and leaks
on the ground must be cleaned in a specific manner.
disposal.
1. Position machine on a smooth level surface with

adequate space. Move machine until master pin is
positioned at approximately 4 o’clock.
NOTE:
Regular Pin Master Pin

EX1400095 EX1500081
Figure 12
CAUTION
AVOID INJURY
Pressure of grease in adjuster cylinder is too high.
Take precautions in opening valve against valve
bounce or grease vent.

2. Loosen grease valve, and then slacken the tension
of track.
NOTE: S ince the inner pressure of the adjustment
cylinder is high, loosen the grease valve
slowly.
If the grease does not come out adequately, start
the engine and move the machine forwards and
backwards.
● Tool: 27 mm ( ) EX1500082

Figure 13
3. Remove master pin using jig or tool.
EX1500081
Figure 14
4. Jack up the machine, put two blocks under the track

to widen the gap between sprocket and lower track.
NOTE: The gap between sprocket and track link
must be over 50 mm (2 in).
EX1500083
Figure 15
5. Place travel device to the direction of the arrow

slowly and remove upper track.
EX1500084
Figure 16

6. Move safety lever to “RELEASED” (UNLOCK) O ACC
I
LOCK
WARNING OFF OFF
ON
ON
the cabin with engine running. Figure 17

times to release the remaining pressure in the
hydraulic piping.
starter switch.
(Figure 18)
ON
OFF
EX1500045
Figure 18

3
5 8
1 2
7 6
4
EX1401809
Figure 19

WARNING
doing any work.

EX1500046
14. R emove bolt (15 ea) with sprocket from travel

device (Figure 21).
● Tool: 22 mm ( )
● Torque: 294 N.m (30 kg.m, 217.0 ft lb)
● Sprocket weight: 35 kg (77.2 lb)
EX1500085
Figure 21
15. R emove bolts and washers (4 ea) with motor

cover from track frame (Figure 22).
● Tool: 19 mm ( )
● Weight: about 9 kg (19.8 lb)
Figure 22

16. Remove hoses and adapters from travel device in
sequence.
NOTE: Cap the open ends of hoses with plug. T
P1
Ps
P2
EX1500087
Figure 23

Torque
(mm) N.m kg.m ft lb
P1 Inlet, Outlet UNF 1 3/16”-12-2B 36 124.5 12.7 91.8
P2 Inlet, Outlet UNF 1 3/16”-12-2B 36 124.5 12.7 91.8
T Drain UNF 13/16”-16-2B 24 55.9 5.7 41.2
Ps Pilot UNF 9/16”-16-2B 19 25.5 2.6 18.8
● Fitting
Size Torque
Port Name
P1, P2 Adapter PF 3/4” UNF 1 3/16”-12 36 158.8 16.2 117.1
T Adapter PF 1/2” UNF 13/16”-16 27 84.3 8.6 67.2
Ps Elbow PF 1/4” UNF 9/16”-18 19 35.3 3.6 26.0
P1, P2 O-ring S8000241 (1B P24) S8030125 (4D F-12)
T O-ring S8000185 (4D P18) S8030081 (1B F-08)
2180-1216D11
Ps O-ring S8000115 (4D P11)
(ID:7.65, W:1.78, 1B)
* A: Opposite Side of Hose, B: Hose Side
17. Remove bolts (16 ea) from track frame except 4

bolts in the direction of 12 o’clock.
● Tool: 22 mm ( )
EX1500088
Figure 24

18. Install the sprocket bolts (2 ea) to travel device,
and tie the rope to the bolts to lift it.
EX1500089
Figure 25
19. R emove remaining bolts (4 ea) of track frame

side, and then hoist and remove travel device from
track frame very slowly.
● Weight: about 152 kg (335 lb)
EX1500090
Figure 26

INSTALLATION
WARNING
OR SERIOUS INJURY

IMPORTANT
When replace the travel device, both sides of travel
devices are same grades.

2. When installing the hoses, install the drain hose
first.
EX1500091
Figure 27
COMPLETING WORK
1. Air testing of reduction gear
Remove one of the plugs (28) of the reduction gear
and apply compressed air 2 bar (2 kg/cm2) through
the plug hole under water for two minutes. There
must be no observable air bubble.
→ Refill gear oil 2.2 L (SAE #90 equivalent, API
classification GL-4 Grade or better)
2. S tart the engine and run at low idle for about 5
minutes.

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

1 Long Hex-Bolt M12 (P1.5) x 40 mm 2

Equipments
Application
Name Type · Specification Q’ty
(Use or P/N)
Assembling and
Workbench 1
Disassembling
Washing
Wash Tank Washing·final washing 1
(product and parts)
24: press Cap. 9,800 (N) (1,000 (kgf)) min.
24, 104, 149 Press Workbench 104: press cap. 1,960 (N) (200 (kgf)) min. 1
149: press cap. 1,960 (N) (200 (kgf)) min.
Heating Cap: 100°C min
149 Heating Tank 1
Volume: 500 x 500 x 500 min
Drying after 0.29 - 0.49 (MPa)
Compressed Air 1
Washing 3 - 5 kg/cm2
Fabricated Tools
1. Workbench for travel motor
● For easy and safe work of disassembling and
assembling travel motor.
Figure 28
2. Pressing tool (Ⅰ)

● Used for inserting spring (114), washer (110), or
retaining ring (145) into the cylinder block (104).

● Used for removing the spring (114) from cylinder
block (104).
FG009805
Figure 29

3. Pressing tool (II)
● Used for removing the deep groove ball bearing
(149) from shaft (102).
FG009806
Figure 30
4. Oil seal inserter

● Used for pressure-inserting oil seal (132) into the
oil seal groove on the spindle (2).
FG009807
Figure 31
5. Lock washer inserter

● Used to insert lock washer (22) into the inlet of
the spindle (2).
FG009808
Figure 32
6. Main bearing inserter

● Used to insert angular ball bearing (24) into the
hub (1).
FG009809
Figure 33

7. Steel rod (I)
● Used to remove angular ball bearing (24) from the
hub.
FG009810
Figure 34
8. Long eyebolt
● Used to hang travel motor, spindle (2), and hub (1).
Use “A”
Hub M 16
Hub M 10
Spindle M 16
Travel Motor M 16
"A"
FG009811
Figure 35
FG009812
Figure 36
FG009813
Figure 37

11. Floating seal assembler (II)
● Use to assemble floating seal (29) with hub (1)
and spindle (2).
Figure 38
12. Floating seal assembler (III)

● Use to assemble floating seal (29) with spindle
(2).
FG009815
Figure 39

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

result in back injury.

DISASSEMBLING
Work Preparation
Prepare the following for disassembling;
1. Workbench
● Prepare the workbench for travel motor.
● The bench must be rigid enough for the
disassembling and reassembling the internal

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

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

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

3. Removing the lubricant
A. Lay down the travel motor (with the outlet port
pointing downward).
B. Loosen the plug (30) at the oiling port to release
the pressure in the reduction gear, and tighten
the plug lightly.
NOTE: If the reduction gear was not depressurized,
lubricant may eject out when the plug on the
discharge port is loosened.
C. Place a container at the end of the oil discharge
port, take the plug out slowly to discharge the
lubricant.
NOTE: The container must be large enough to
receive the lubricant in the reduction gear,
which is 2.1L.
D. If the lubricant does not come out smoothly,
remove plug on the oiling port slowly.
E. Remove O-ring (31) from the plug which was
taken out.
NOTE: Once disassembled, the O-ring (31) must be
replaced with a new one, to prevent oil leak.
4. Removing the cover
A. Turn the travel motor over (with the reduction
gear facing upwards)
B. Remove 12-M10 bolt (35).
C. Seal is applied on the fitting surfaces of the
cover (14) and hub (1). insert a metal rod on the
top of the cover, knock the rod to the upside of
the slope to remove cover.
CAUTION
Figure 40
AVOID INJURY
To prevent a foot injury, keep your feet away from
under the motor cover when removing the cover.

D. Mount eyebolts at the PF1/2 port, lift the cover
(14) up from the hub and move it.
Figure 41
5. Removing the thrust plate

A. Remove thrust plate (13).
Figure 42
6. Removing the 1st stage gears

A. Remove sun gear (1, 4).
NOTE: Take care not to drop the sun gear (1) down,
which is slippery with lubricant.
Figure 43
B. Mount eyebolts in the three M12 tabs on the

carrier (1, 3). lift the carrier assembly (1) with
crane and move it.
NOTE: When lifting the carrier (1) assembly up, align
the centerlines of the hub (1) and the carrier
assembly (1), and lift up slowly to prevent the
end of the planetary gear (1, 5) damaging the
teeth inside the hub.
Figure 44

7. Removing the coupling
A. Remove coupling (15) from the shaft (102).
Figure 45
8. Removing the 2nd stage gears

A. Mount eyebolts in the 3 (M12) tabs for lifting on
the 3 points of the carrier (2, 7). Lift the carrier
assembly (2) with crane and move it.
NOTE: When lifting the carrier assembly (2) up, align
the centerlines of the hub (1) and the carrier
assembly (2), and lift up slowly to prevent the
end of the planetary gear (2, 9) damaging the
teeth inside the hub.
B. Remove sun gear (2, 8).
Figure 46
NOTE: Take care not to drop the sun gear (2) down,
which is slippery with lubricant.
9. Removing the lock washer
A. Attach on the turn-over table using the M14 hole
of the hub (1).
Figure 47
B. Place (-) screw drive, or an equivalent tool, at the

skimmer of the 2 lock washers (22). Knock the
driver head with a hammer towards the bottom of
the slope to remove lock washer.
Figure 48

10. Removing the hub
A. Remove hex-groove bolt joining the hub and the
turnover table.
B. Mount eyebolts (M10) on the hub and lift it up
with crane.
WARNING
To prevent injury from falling or dropping parts.
Figure 49
● Always use an adequate lifting device to lift the Hub.
Do not Lift Hub at an angle. Lift Hub aligned with the

Spindle shaft.
● Lift Hub slowly and avoid using excessive force that
could damage lifting device.

● Use a press to remove Hub, if necessary.
11. Removing the floating seal

A. Exert force with hand on the inner side of the
floating seal (29) towards upside.
NOTE: Wear gloves to prevent cutting hand by the
edge of the floating seal.
If solidified with soil inside, remove it with (-)
screw drive or similar tools as leverage.
Figure 50
12. Removing the angular ball bearing

A. Place a pin punch on the edge of the outer ring
of the angular ball bearing (24) at 3 or 5 points
which divide the ring in equal intervals. Hammer
the punch to remove bearing small by small.
NOTE: Do not hammer the inner ring of the angular
ball bearing. if the inner ring is damaged,
the baring cannot be used.
Therefore, do not knock the inner ring,
unless the bearing is to be replaced.
Figure 51
When the outer ring of the ball bearing (24)
is out of the hub (1), the bearing falls down.
Place a pan covered with rubber mat to
receive the bearing.

13. Removing the rear flange
A. Turn the travel motor over (with motor side up).
NOTE: Following procedures are for removing the
Plug easily, when disassembling the inside
of the rear flange.
Loosen the plug so it can be removed with
hand.
Do not loosen the plug unless the rear
flange inside is to be disassembled.
B. Loosen the two plugs (324). Figure 52
NOTE: Following procedures are for removing the
plug easily, when disassembling the inside
of the rear flange.
Do not loosen the plug unless the rear
flange inside is to be disassembled.
When the plug (324) becomes loose, the
spring (328) can move easily. Therefore,
the plug (324) and the spring (328) may be
ejected out. Therefore, care must be taken
for this work.
C. Loosen the two plugs (380).
D. Loosen the two plugs (352).
E. Loosen the plug (357).
Figure 53
F. Loosen the two relief valve assemblies (including

203).
Figure 54

G. Remove two relief valve assemblies (including
203).
NOTE: Do not reuse the removed O-rings (207,
209, 212) and back-up rings (208, 210).
Figure 55
H. Unscrew the ten hex groove bolts (343) and

remove them from the rear flange (301).
I. Remove rear flange (301) from the spindle (2).
NOTE: Hold the rear flange with both hands, lift it
up carefully to remove it. It removed with
excessive force or by knocking, the timing
plate (109) may be fall down and damaged.
Care must be taken when removing the rear
flange.
Figure 56
J. Remove two parallel pins (34) from the spindle

(2).
Figure 57
K. Remove two O-rings (32, 33) from the spindle

(2).
NOTE:Do not reuse the removed O-rings (32, 33).
Figure 58

14. Disassembling the rear flange assembly
A. Place the rear flange (301) with the fitting
surface with the spindle (2) upside.
B. Remove timing plate (109) from the rear flange
(301).
NOTE:Removing the rear flange (301) may require
some force because of the oil on the fitting
surface. Insert a blade in the groove of
the fitting surface on the rear flange (301)
and lift the timing plate (109) up softly to Figure 59
remove it. Do not use sharp tools, such as
screwdriver, which may scratch the fitting
surface, resulting in oil leak.
C. Remove deep groove ball bearing (150) from
the rear flange (301).
Figure 60
D. Remove parallel pin (341) from the rear flange

(301).
Figure 61

15. Disassembling the brake valve parts in the rear
flange
A. Remove two plugs (324) from the rear flange
(301).
B. Remove washers (325) and springs (328), 2
each, from the rear flange (301).
Figure 62
C. Remove spool (323) from the rear flange (301).

NOTE: Tilt the plug port of the rear flange (301),
then the spool (323) will slide out. Take it by
lifting the front end.
Figure 63
D. Remove O-ring (336) from the plug (324).

NOTE:Do not reuse the removed O-ring (336).
Figure 64

16. Disassembling the 2-speed switching spool
A. From the rear flange (301), remove plug (357).
B. Remove O-ring (359) from the plug (357).
Figure 65
C. Remove spool (363) and spring (366) from the

rear flange (301).
Figure 66
17. Disassembling the piston

A. From the rear flange (301), remove two plugs
(380).
Figure 67
C. Remove piston (381) from the rear flange (301).
Figure 68

18. Disassembling the check valve ball
A. From the rear flange (301), remove two plugs
(352).
Figure 69
C. Remove steel ball (353) from the rear flange

(301).
NOTE: If it is difficult to remove steel ball, use a
magnet.
Figure 70
19. Disassembling the packing brake
CAUTION
AVOID INJURY
If compressed air is injected in rapidly, the piston (112)
may be ejected out from the spindle (2), resulting in
injury or damage. Cover the piston (112) to protect it.
A. Inject the compressed air into the hole in the

packing brake path of the spindle 2, and take Figure 71
the piston (112) out from the spindle 2.
B. Remove O-rings (135, 139) out from the piston
(112).
NOTE: Do not reuse the removed O-rings (135,
139).
Figure 72

20. Disassembling the hydraulic motor parts
NOTE: Oil will come out when the travel motor is
laid down. Place an oil pan under the travel
motor.
A. Lay the travel motor down at 90 degrees.
B. Remove oil in the travel motor.
C. Select the four opposite plates (116) and the
three friction plates (115).
Figure 73
D. Turn the cylinder block (104) by 2 - 3 rounds

with hands, and remove shoe (106) attached to
the swash plate (103).
NOTE: If the cylinder block (104) is removed in this
state, the shoe (106) remains in the swash
plate (103), and the parts (piston (105),
shoe (106) etc.) will be separated from
the cylinder block (104) and fall inside the
spindle (2). So care must be taken in this
state.
Figure 74
E. Remove cylinder block (104) from out of the

shaft (102).
F. Remove piston assembly (piston (105), shoe
(106)) and the retainer plate (107) from the
cylinder block (104).
NOTE: Remove piston assembly with the retainer
plate (107) by holding the retainer plate with
both hands.
The piston (105) and the shoe (106) are
jointed by being tightened on the spherical
Figure 75
surface of the piston. The shoe (106) cannot
be separated from the piston (105) without
damaging the shoe (106).
Therefore, if replacement is required,
replace them as a single unit (hereinafter,
will be referred to as the piston assembly.

G. From the retainer plate (107), take the piston
assemblies (105, 106) out (9 sets).
Figure 76
H. Remove thrust ball (108) from the cylinder block

(104).
Figure 77
I. Remove three collars (151) from the cylinder

block (104).
Figure 78
21. Removing the spring from the cylinder block

A. Place the cylinder block (104) on the press
workbench.
NOTE: Spring (114) must be taken out only for
replacement.
To remove spring (114), align the axes of
the press tool(•×) and the washer (110), to
prevent damage to the cylinder block (104)
by contact.
Cover the cylinder block (104) up with vinyl
sheet to prevent damage on the surface of Figure 79
the cylinder block (104).

B. Place the press tool (1) on the washer (110),
press the tool (1) strongly with a press, and
remove the retaining ring (145) out from the
retaining ring groove on the cylinder block (104)
with a retaining ring pliers.
CAUTION
AVOID INJURY
Release the press slowly to prevent the spring (114)
Figure 80
from being ejected and causing an injury.
Always wear proper face and eye protection.
C. From the cylinder block (104), remove the

retaining
ring (145), washer (110), spring (114), and washer
(110).
Figure 81
22. Removing the swash plate

A. Remove swash plate (103) from the shaft (102).
NOTE: Take care when removing the swash plate
(103), because the pivot (167) may be
attached to the swash plate (103).
Figure 82
B. Remove shaft (102) from the spindle (2).

At this time, the deep grooved ball bearing (149)
will be separated being attached on the shaft.
NOTE: Shaft (102) can be easily removed by
knocking the end of the shaft on the
reduction gear side with a plastic hammer.
Take care not to strike the shaft, or it may
bound.
C. Remove two (each) pivots (167) and parallel
pins (171) from the spindle (2).
Figure 83

D. Remove 2-speed switching piston assembly
and the spring (185) from the spindle (2).
Figure 84
23. Removing the deep grooved ball bearing

NOTE: Remove deep grooved ball bearing only for
replacement.
A. Place a press tool (II) on the press workbench,
and insert the shaft (102) in it.
B. Press the end of the shaft with the press to
remove inner ring (149) of the deep grooved
ball bearing from the shaft (102).
NOTE:Do not reuse the deep grooved ball bearing.
Figure 85
24. Removing the parts on the spindle

A. Remove seal (23) from the spindle (2).
Figure 86

B. Remove floating seal (29) from the spindle (2).
Figure 87
C. Remove oil seal 132 from the spindle (2).

NOTE: Do not reuse the removed floating seal (29)
and oil seal (132).
Figure 88
25. Washing the parts

A. Classify the hub (1), spindle (2), cover (14), rear
flange (301) and other pats.
B. Wash the hub (1) spindle (2) cove (14) rear
flange (301) in the wash tank.
NOTE: Remove soil on the surface carefully.
Kerosene used for washing is highly
inflammable. Be careful to prevent fire.
NOTE: if the parts are dirty, leave it in the solvent
for a while, until dust, soil, and grease are
Figure 89
separated and float up. Do not wash dirty
parts from the start, or the dirt may scratch
the surfaces.
C. Wash the other parts in a wash tank with
kerosene.

26. Final washing
A. P u t t h e p a r t s i n t h e f i n i s h w a s h i n g t a n k
containing kerosene. Rotate the parts slowly,
wash them clean to the inside.
Figure 90
B. Wipe the kerosene off the parts with clean

cloth.
NOTE: Dry the inside of the hub (1) and spindle (2)
with compressed air, where there is no dust
and moisture.
After drying, apply hydraulic oil on the
surface of the parts.
Leave the rear flange (301), hydraulic motor
parts, and gears in a place free from dust
and moisture to dry up. When dried, apply
Figure 91
hydraulic oil on their surfaces.

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

1. Any parts which show visible defect must be
replaced with new ones.
2. Replace the parts which show the following defects.
Part Allowable
Name Defect Description Standard Size
No. Range
● Any major visible defect.
1 Hub ● Pinching on the tooth of ring gear. - -
● Abnormal wear such as scratch.
● Any major visible defect.

2 Spindle - -
● Abnormal wear such as scratch.
3,7 Carrier Assembly ● Abnormal wear such as scratch. - -

4 Sun Gear 1
8 Sun Gear 2 ● Pinching on tooth.
- -
5 Planetary Gear 1 ● Breaking on the working surface of bearing.
9 Planetary Gear 2
● Dent.
24 Ball Bearing ● Breaking. - -
● Biased wear.
Scratch on the reciprocating surface between

301 Rear Flange - -
the Spools (323, 363) and Piston (381).
● Wear on the fitting surface with the Oil Seal
102 Shaft (132). - -

● Worn spline.
103 Swash Plate Sooting. - -

● Worn spline.
● Serious wear on the inside of the bore.
104 Cylinder Block - -
● Scratch or biased wear on the reciprocating
surface with the Timing Plate (109).

Piston Assembly ● Skimmer on the axial direction of the Piston
105 Skimmer Skimmer
Piston (105) and Shoe (106).
106 0.15 mm 0.15 mm
Shoe ● Abnormal, biased wear of Shoe (106).

Part Allowable
Name Defect Description Standard Size
No. Range
● Biased wear on the reciprocating surface
with the Shoe (106)
107 Retainer Plate - -
● Scratch or biased wear on the reciprocating
surface with the Thrust Ball (108).

● Biased wear on the spherical reciprocating
108 Thrust Ball - -
surface with the Retainer Plate (107).
● Sooting or biased wear on the reciprocating
109 Timing Plate - -
surface.
● Biased wear on both ends. Braking
Braking Torque
115 Friction Plate ● The torque is different from the specified Torque
206 Nm (21.0
116 Opposite Plate value. 206 Nm (21.0
kg•m), min.
● Sooting. kg•m), min.
105 Piston ● Scratch or dent on outer surface. - -
● Dent.
149 Deep Grooved Ball
● Breaking. - -
150 Bearing
● Wear.
2-Speed Piston Kit

161 ● Abnormal wear on outer surface.
Piston - -
162 ● Abnormal, biased wear on Shoe.
Shoe
323 ● Biased wear on outer surface.
Spool - -
363 ● Dent on outer surface.
381 Piston ● Scratch on outer surface. - -

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

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

Order of Assembling
When replacing and reassembling parts, prepressure
adjustment of ball bearing is required. Therefore,
make sure that parts below have been replaced before
assembling.
NOTE: Replacement parts for prepressure adjustment of
ball bearing. Hub (1), spindle (2), ball bearing (24)
NOTE: When replacing and reassembling the above listed
parts, make sure to use the pre-adjusted parts.
Otherwise, the travel motor may mal function
resulting in earlier damage.
1. Assembling the hub
A. Place the hub (1) on the press workbench.
B. Insert the ball bearing (24) into the hub (1). Place
the press fitting tool on the outer ring of the ball
bearing (24), press it with press to insert into the
hub (1).
C. Turn the hub (1) upside down.
D. Press fit the ball bearing (24) into the hub (1), in
the same method as B.
NOTE: Take care that ball bearing (24) is assembled
in the correct direction.
Figure 92
E. Apply grease on the O-ring of the floating seal (29).

insert the floating seal (29) into the groove on the
hub (1).
NOTE: When applying grease on the O-ring of the
floating seal (29), take the O-ring off of the
floating seal (29) and apply grease on the
whole surface of the O-ring, thin and evenly.
NOTE: To assemble the floating seal (29), place the
F/S assembling tool (I), floating seal (29),
and F/S assembling tool (II), in the listed Figure 93
order, and press until F/S assembling tool (II)
touches the F/S assembling tool (I). Remove
F/S assembling tools and confirm that end
surface of the hub is within 1 mm difference
with the floating seal surface.

2. Assembling the spindle part
A. Apply grease on the O-ring of the floating seal (29).
Insert the floating seal (29) into the floating seal
groove on the spindle (2).
NOTE: To assemble the floating seal (29), place the
F/S assembling tool (I), floating seal (29),
and F/S assembling tool (II), in the listed
order, and press until F/S assembling tool (II)
touches the F/S assembling tool (I). Remove
F/S assembling tools and confirm that end Figure 94
surface of the hub is within 1 mm difference
with the floating seal surface.
B. Join two eyebolts on the spindle (2) at symmetric
position.
C. Place the spindle (2) on the workbench with the
hexgroove bolts are on symmetric position.
CAUTION
AVOID INJURY
Tighten the hex-groove bolt securely to prevent the
Figure 95
travel motor from falling while servicing.

3. Adjusting the prepressure of the angular ball bearing
NOTE: When the hub (1), angular ball bearing (24) or
spindle (2) is replaced, perform prepressure
adjustment. If the prepressure is not appropriate,
the angular ball bearing may be fractured soon.
A. Insert the lock washer (22) in the spindle (2), and
measure size C.
B. Measure the width D of the angular ball bearing.
NOTE: Turn hub (1) and angular ball bearing (24)
by a few rounds to remove loose, before Figure 96
measuring the size.
C. Deduct size C with D. Select the seam (23) for
which the skimmer is +0.13 mm - +0.17 mm in the
table below.
Symbol T (mm)
A 0.9
B 1.0
C 1.1
D 1.2
E 1.3
F 1.4
G 1.5
H 1.6
I 1.7
J 1.8 Figure 97
K 1.9
L 2.0
D. Mount the seam (23) on the spindle (2).
Figure 98

4. Assembling the hub
A. Align the central axes of the hung hub (1) and
spindle (2) straight, lower the spindle (2) slowly
and insert into the angular ball bearing (24).
Figure 99
B. Tighten a lock hex-groove bolt in the ø14 hole of

the hub to fix with the workbench.
C. Place a metal rod on the inner ring of the angular
ball bearing (24) on the reduction gear side, knock
it lightly with a hammer to remove looseness of
the inner ring.
Figure 100
D. Place the lock washer (22) on the groove on the

spindle (2).
Figure 101
E. Insert the lock washer (22) into the spindle groove

with a tool.
NOTE: When assembling the carrier (2, 7), insert the
lock washer (22) fully into the groove to avoid
interference with the lock washer (22).
F. Remove lock hex-groove bolt which has been
connecting the hub (1) with the workbench.
G. Turn the hub (1) by 2 - 3 turns.
NOTE:Turning the hub (1) will settle the fitting surface
of the floating seal (29) to prevent leak.
H. Turn the workbench so motor faces upward. Figure 102

5. Assembling the motor parts in the spindle
A. Insert the oil seal (132) into the spindle (2) using
oil seal press-fitting tool and hammer
NOTE: When assembling the oil seal, apply lithium
grease on the oil seal lip Take care that
assembling direction of the oil seal (132) is
correct.
B. Assemble the two parallel pins (171) into the
pinholes of the spindle (2).
C. Apply lithium grease on the semi-spherical Figure 103
surface of the two pivots (167) and press fit them
into the parallel pins (171) which are inserted in
the spindle (2).
D. Apply grease on the spring (185) and assemble it
with the piston assembly piston (161), shoe (162).
E. Apply machine oil on the reciprocating surface of
the piston assembly and mount it into the piston
hole on the spindle (2).
F. Insert the two parallel pins (34) into the pin groove
on the fitting surface of the rear flange of the
spindle (2).
Figure 104
6. Assembling the shaft
CAUTION
AVOID INJURY
Wear leather gloves during the assembly work, to
prevent burns or other injuries to hands.
Figure 105
A. Put the deep grooved ball bearing (149) into the
heating tank, heat it for 10 minutes at 100 ±10°C,
and insert it onto the shaft (102).
B. Turn the travel motor by 90 degrees.
C. Insert the shaft (102) into the spindle (2).
NOTE: Insert the shaft (102) slowly into the spindle
(2) so lip of the oil seal (132) inserted into the
spindle is not damaged.
Damaged lip will cause oil leak, resulting in the
earlier failure of the travel motor.
Figure 106

D. Insert the swash plate (103) into the spindle (2).
NOTE: Apply grease on the fitting surface of the
swash plate (103) with the spindle (2).
Insert the swash plate (103) into the spindle (2)
by matching the pivot mounting grooves on
the swash plate (103) with the two pivots (167)
inserted onto the spindle (2).
Figure 107
7. Assembling the inner parts of the cylinder block
NOTE: Insert the THS retaining ring (145) with its sharp
edge facing the inlet.
Insert the washer (110) which contacts with
the fix ring (145) with its sharp edge facing the
fix ring (145).
A. Insert the washer (110), spring (114), washer
(110), and THS retaining ring, in the said order,
into the cylinder block (104).
B. Place the cylinder block (104) on the press
workbench.
Figure 108
CAUTION
AVOID INJURY
Take care to prevent the ejection of the fix ring which
can occur if the pliers tip slips out of the groove of the
fix ring, when assembling the THS retaining ring (145).
Always wear proper face and eye protection.
NOTE: The pressure of the spring (114) must be 112 N

(115 kgf) or more.
Protect the cylinder block (104) with a vinyl cover Figure 109
sheet to prevent damage on the contact surface
with the timing plate (109).
C. Place a press tool (I) on the washer (110), press
the tool with press, and assemble the THS
retaining ring (145) into the fix ring groove on the
cylinder block (104) using fix ring pliers.

8. Assembling the hydraulic motor parts
A. Insert the three needle-type collars (151) into the
groove on the cylinder block (104), and place the
thrust ball (108) on them.
Figure 110
B. Insert the nine piston assemblies into the retainer

plate (107).
NOTE:Soak the whole assembly in machine oil.
C. Assemble the retainer plate (107) and the nine
piston assemblies with the cylinder block (104).
NOTE: Align the retainer plate (107) and the spherical
surface of the thrust ball (108).
Figure 111
D. Insert the cylinder block (104) into the shaft (102).

NOTE: Align the splines on the cylinder block (104)
with those on the shaft (102).
Figure 112
E. After assembling the cylinder block (104), turn the

cylinder block (104) with hands to check if there is
any looseness or clicking.
If it clicks, check the assembly.
NOTE: The cylinder block (104) cannot be lifted up
after assembling.
If lifted up, the thrust ball (108) will be dropped,
unable to rotate normally.
Figure 113

9. Assembling the packing brake
NOTE: Soak the friction plate (115) in machine oil
before assembling.
A. Turn the workbench by 90 degrees.
B. On the cylinder block (104), assemble the four
opposite plates (116) and the three friction
plates in turns.
C. Apply grease thinly and insert the O-rings (135,
139) into the O-ring groove on the piston (112).
D. Assemble the piston (112) in the spindle (2). Figure 114
NOTE: If the piston (112) would not be inserted into
the spindle (2) because of the friction of the
O-rings (135, 139), knock the end of the
piston (112) lightly with a plastic hammer.
Take care to prevent scratch on the
O-ring when assembling the piston (112).
Figure 115
10. Assembling the 2-speed switching spool in the

rear flange
NOTE: Insert the spring (366) and spool (363) into
A. Assemble the O-ring (359) on the plug (357).
NOTE:Apply grease on the O-ring (359).
Figure 116
B. Insert the plug (357) into the rear flange (301).

C. Tighten the plug (357) with the rear flange (301)
using a hex-wrench, temporarily.
Figure 117

11. Assembling the check ball part
A. Assemble the two O-rings (358) with the two
plugs (352).
NOTE: Apply grease on the O-ring (358).
B. Insert the steel ball (353) into the rear flange
(301).
Figure 118

Figure 119
12. Assembling the piston

A. Assemble the two O-rings (383) with the two
plugs(380).
B. Insert the piston (381) into the rear flange (301).
Figure 120

Figure 121

13. Reassembling the brake valve
A. Insert the spool (323) into the rear flange (301).
NOTE: Apply machine oil on the spool (323) and
insert the spool (323) into the rear flange
(301).
Align the centerlines of the spool (323)
and the rear flange (301) to prevent the
damage on the inner surface of the rear
flange (301) and the outer surface of the
spool (323) by contact. Figure 122
If the groove of the rear flange (301)
or outer surface of the spool (301)
is damaged, internal leak can occur
after the reassembling, resulting in the
performance degradation of the travel
motor.
B. Assemble the O-ring (336) on the plug (324).
C. Insert washer (325) and spring (328) into the
plug (324).
Figure 123
D. Insert the two plugs (324) into the rear flange

(301).
NOTE: Take care when inserting the plug (324)
into the rear flange (301) to prevent the
deformation of the spring (328).
E. Tighten the two plugs (324) on the rear flange
(301) temporarily.
Figure 124

14. Assembling the rear flange components
A. Apply machine oil on the deep grooved ball
bearing (150) and insert the ball bearing (150)
into the rear flange (301).
B. Insert the parallel pin (341) into the pin groove
of the rear flange (301).
C. Apply grease on the fitting surface of the timing
plate (109) with the rear flange (301).
Figure 125
D. Assemble the timing plate (109) with the rear

flange (301) using the parallel pin (341) as the
guide.
NOTE: Mount the timing plate (109) until it contacts
with the rear flange (301). The contacting
will prevent the timing plate (109) from
being separated from the rear flange (301)
when mounting the rear flange (301) on the
spindle (2).
Figure 126
E. Mount the ten springs (113) on the rear flange

(301).
NOTE: A p p l y g r e a s e o n t h e s p r i n g s ( 1 1 3 )
sufficiently to prevent being separated from
Figure 127
15. Connecting between the rear flange and spindle

A. Insert the two O-rings (32, 33) into the O-ring
grooves on the spindle (2).
NOTE: Do not apply grease on the O-rings (32, 33).
If grease is applied, it may smear on the
fitting surface between the rear flange (301)
and spindle (2) during motor operation. The
smearing may be mistaken as the oil leak.
B. Pour 1.0 liter of hydraulic oil in the spindle (2).
Figure 128

C. Insert the rear flange (301) into the spindle (2),
aligning the pin groove on the rear flange (301)
and the two parallel pins inserted in the spindle
(2).
D. Tighten the ten hex-grooved bolts (343) to the
spindle (2) temporarily, using hex-wrench.
Figure 129
16. Tighten all parts by the specified torques.

A. Tighten the ten hex-grooved bolts (343) to the
spindle (2) by specified torque.
– Torque: 102 ±15.7 Nm (10.4 ±±1.6 kg•m)
Figure 130
B. Tighten the plug (324) by specified torque.

– Torque: 441 ±39.2 Nm (45.0 ±4.0 kg•m)
Figure 131
C. Tighten the plug (380) by specified torque.

– Torque: 58.8 ±9.81 Nm (6.0 ±1.0 kg•m)
Figure 132

D. Tighten the plug (352) by specified torque.
– Torque: 12.3 ±2.45 Nm (1.25 ±0.25 kg•m)
Figure 133
E. Tighten the plug (357) by specified torque.

– Torque: 98.1 ±19.6 Nm (10.0 ±2.0 kg•m)
Figure 134
17. Assembling the relief valve assembly

A. Mount the two relief valve assemblies (including
203).
Figure 135
B. T i g h t e n t h e t w o r e l i e f v a l v e a s s e m b l i e s
(including 203) by specified torque.
– Torque: 98.1 ±19.6 Nm (10.0 ±2.0 kg•m)
Figure 136

18. Assembling the 2-step gears
A. Turn the workbench so reduction gear faces
upwards.
B. Assemble the sun gear (2, 8) with the carrier (2,
7).
C. Install eyebolts in the three M12 tabs for
hanging on the carrier (2, 7), use a crane to
insert the carrier assembly (2).
NOTE: When inserting the carrier assembly (2),
align the centerlines of the hub (1) and Figure 137
the carrier assembly (2) so edge of the
planetary gear (2, 9) does not damage the
inner teeth of the hub (1), and insert the
carrier assembly slowly.
Arrange the planetary gear (2, 9) and the
rear flange (301) port as shown in the figure
on left.
Figure 138
19. Assembling the coupling

A. Assemble the coupling (15) to the shaft (102).
Figure 139
20. Assembling the 1st stage gears

A. Insert the carrier assembly (1) for hanging in the
Hub (1).
NOTE: When inserting the carrier assembly (1),
align the centerlines of the hub (1) and
the carrier assembly (1) so edge of the
planetary gear (1, 5) does not damage the
inner teeth of the hub (1), and insert the
carrier assembly slowly.
Figure 140

B. Insert the sun gear (1, 4) into the coupling (15),
aligning the splines.
NOTE: If the sun gear (1, 4) cannot be inserted
because the spline of the sun gear touches
the teeth end of the planetary gear, as the
gears are positioned such, slowly lift the
carrier assembly (1) up until sun gear (2, 8)
leaves the coupling, and then insert the sun
gear (1, 4).
Figure 141
C. Assemble the thrust plate (13) with the carrier (1,

3).
Figure 142
21. Assembling the cover

A. Apply locktite 515, which is a sealant, on the
fitting surface with the cover (14) of the hub (1).
NOTE:Apply the sealant without interval.
Figure 143
B. Mount eyebolts on the PF1/2 port, place the

cover (14) on the hub (1), matching the bolt
groove position
Figure 144

C. Apply locktite 242 on the tip of the hex-grooved
bolt (35), and tighten with specified torque.
– Torque: 66.7 ±3.92 Nm (6.8 ±0.4 kg•m)
Figure 145
22. Lubricant
A. Supply lubricant through the lubricating port.
NOTE:Supply 2.1 liter of lubricant.
Figure 146
B. Mount plug (30) on each port and tighten with

specified torque.
– Torque: 98.1 ±19.6 Nm (10.0 ±2.0 kg•m)
23. Removing the travel motor
A. Turn the travel motor upside down (with the
motor side facing upward).
B. Remove travel motor fixing bolts from the
workbench.
C. Tighten the eyebolt (M16) in the screw hole of
the spindle (2).
Figure 147
D. Join the hook and wire with the eyebolt, remove
Travel Motor from the workbench using a crane.

Performance Test
● When the maintenance work of the GM travel motor
has been completed, conduct performance testing

as follows.
1. Required instruments
Pressure Gauge 3.43 MPa
1 2
(35 kg/cm2)
2 Mass Cylinder (5 liter) 1
3 Stop Watch 1
2. Test procedures

Center Joint
DX140AF/DX140LCA Center Joint 7-334

ＭＥＭＯ

Table of Contents
Center Joint
GENERAL............................................................... 337
General Description........................................ 337
Overview......................................................... 338
Parts List......................................................... 339
SECTION VIEW...................................................... 340
REMOVAL............................................................... 341
INSTALLATION ...................................................... 346
COMPLETING WORK............................................. 346
DISASSEMBLY....................................................... 347
REASSEMBLY........................................................ 350
TROUBLESHOOTING, TESTING AND
ADJUSTMENT........................................................ 352
Inspection....................................................... 352
Testing............................................................ 352

SAFETY INSTRUCTIONS
WARNING
GENERAL
General Description
The center joint is designed to allow hydraulic oil from
the upper structure to flow to components in the lower
structure.
It is capable of allowing continuous 360° rotation of the
upper structure in relationship to the lower structure.

Overview
4 1
G
3 2 2
3
4
1
5
1
5
3
2
EX1301734
Figure 1
Size
Port Name
Body Spindle
1, 2 Traveling Right SAE 1” PF 3/4 O-ring
3, 4 Traveling Left SAE 1” PF 3/4 O-ring
5 Pilot PF 1/4 O-ring
G Drain PF 1/4 O-ring

Parts List
2-15
2-2
2-1
2-11
2-10
2-4
2-7
2-6
2-5
2-9
2-8
2-12
2-3
2-14
3: 2-6, 2-9, 2-10
2-13
EX1301306
Figure 2
Reference Reference
Number Number
2 Center Joint 2-9 O-ring
2-1 Hub 2-10 O-ring
2-2 Spindle 2-11 Shim
2-3 Cover 2-12 Shim
2-4 Spacer 2-13 Bolt
2-5 Retainer Ring 2-14 Spring Washer
2-6 O-ring 2-15 Plug
2-7 Dust Seal 3 Center Joint Seal Kit
2-8 Slipper Seal

SECTION VIEW
2-15
2-2 2-10
2-7
2-6
5
2-1
1
3
2-8
2
4
2-11
2-4
2-9
2-5
2-12 2-3 2-13, 2-14
EX1301738
Figure 3
Reference Reference
Number Number
2-1 Hub 2-9 O-ring
2-2 Spindle 2-10 O-ring
2-3 Cover 2-11 Shim
2-4 Spacer 2-12 Shim
2-5 Retainer Ring 2-13 Bolt
2-6 O-ring 2-14 Spring Washer
2-7 Dust Seal 2-15 Plug
2-8 Slipper Seal

REMOVAL
WARNING

clothes.

immediately.
WARNING
the workplace.
IMPORTANT
specific manner.
disposal.

2. Lower front attachment (bucket) to ground. (Figure 4)
3. Stop engine.
EX1300542
Figure 4

4. M ove safety lever to “RELEASED” (UNLOCK) O ACC
I
LOCK
WARNING OFF OFF
ON
ON

times to release the remaining pressure in the ON
hydraulic piping.
OFF
starter switch.
EX1500045
(Figure 6)
Figure 6
NOTE:Removal (installation) procedure of the bolts.

3
5 8
1 2
7 6
4
EX1401809
Figure 7
WARNING
doing any work.

EX1500046
Pulling the air breather cap upward, the check
valve (0.45 bar) opens, and the air is discharged Figure 8
to the atmosphere from the top of the hydraulic oil
tank.

12. Remove bolts (1, Figure 9) (4 ea) with under
covers (2) from frame.
●Tool: 19 mm ( )
●Torque: 107.9 N.m (11 kg.m, 79.6 ft lb) 1
●Under cover weight: about 9 kg (19.8 lb)
13. Remove hoses and adapters (Figure 10) from

center joint.
2
NOTE: Attach identification tags to the removed hoses for
EX1403118
reassembling.
After disconnecting hoses, plug them to prevent Figure 9 Bottom of Track Frame
dirt or dust from entering.
Disconnect the hoses from the bottom to top of 5
center joint.
3
1
4 0 2
EX1403119
Figure 10 Hub of Center Joint

Torque
(mm) (mm) N.m kg.m ft lb
UNF 13/16"-16-2B 24 55.9 5.7 41.2
0 Drain
UNF 13/16"-16-2B 24 55.9 5.7 41.2
1 to Travel Motor (LH) "P1" SAE 1", D24.5 10 107.9 11 79.6
2 to Travel Motor (LH) "P2" SAE 1", D24.5 10 107.9 11 79.6
3 to Travel Motor (RH) "P2" SAE 1", D24.5 10 107.9 11 79.6
4 to Travel Motor (RH) "P1" SAE 1", D24.5 10 107.9 11 79.6
UNF 9/16"-16-2B 19 25.5 2.6 18.8
5 Pilot (2-speed)
UNF 9/16"-16-2B 19 25.5 2.6 18.8
● Fitting
Size Torque
Port Name
0 Tee PF 1/2" UNF 13/16"-16 27 93.1 9.5 68.7
Tee UNF 9/16"-18 UNF 9/16"-18 19 25.5 2.6 18.8
5
Adapter PF 1/4" UNF 9/16"-18 19 39.2 4 28.9
0 O-ring S8000185 (4D P18) S8030081 (1B F-08)
DS2856003 (1", ID:33.2,
1, 2, 3, 4 Ring Seal
OD:40.2, 1B)
2180-1216D11 (ID:7.65,
5 O-ring S8000115 (4D P11)
W:1.78, 1B)

14. Remove bolt (1, Figure 11) and clamp (2).
1
● Tool: 30 mm, 8 mm ( )
● Torque (clamp): 6 N.m (0.6 kg.m, 4.4 ft lb)
15. Remove bolts (3, Figure 11) (6 ea) with plates (4) (2
ea) and lubber cover (5). 5
● Tool: 14 mm ( )
3
16. Remove hoses and adapters (Figure 12) from 4 2

center joint. EX1500068
NOTE: Attach identification tags to the removed hoses Figure 11 Spindle of Center Joint
for reassembling.
After disconnecting hoses, plug them to prevent 1
dirt or dust from entering. 0
Disconnect the hoses from the bottom to top of
3
center joint.
2
4
5
EX1500069
Figure 12 Spindle of Center Joint
Torque
Port Name Plug/Flange Size(Hose)
(mm) N.m kg.m ft lb
0 Drain UNF 13/16"-16-2B 24 55.9 5.7 41.2
1 from Control Valve "B1" UNF 1 3/16"-12-2B 36 124.5 12.7 91.8
2 from Control Valve "A1" UNF 1 3/16"-12-2B 36 124.5 12.7 91.8
3 from Control Valve "B6" UNF 1 3/16"-12-2B 36 124.5 12.7 91.8
4 from Control Valve "A6" UNF 1 3/16"-12-2B 36 124.5 12.7 91.8
5 from Solenoid Valve "TR2" UNF 9/16"-16-2B 19 25.5 2.6 18.2
● Fitting
Size Torque
Port Name
0 Adapter PF 1/2" UNF 13/16"-16 27 93.1 9.5 68.7
Elbow UNF 1 3/16"-12 UNF 1 3/16"-12 35 124.5 12.7 91.8
1, 2, 3, 4
Adapter PF 3/4" UNF 1 3/16"-12 36 176.4 18 130.1
5 Adapter PF 1/4" UNF 9/16"-18 19 39.2 4 28.9
0 O-ring S8000185 (4D P18) S8030081 (1B F-08)
1, 2, 3, 4 O-ring S8000235 (4D P22.4) S8030125 (4D F-12)
2180-1216D11 (ID:7.65,
5 O-ring S8000115 (4D P11)
W:1.78, 1B)

17. Install the eyebolts (PF 1/2) and tie with rope the
center joint to remove it (Figure 13).
EX1402386
Figure 13

● Tool: 19 mm ( )
1
EX1402387
Figure 14
19. Remove center joint from the frame slowly and

carefully.
● Center joint weight: about 36 kg (79 lb)
EX1402389
Figure 15

INSTALLATION
WARNING
OR SERIOUS INJURY


2. When installing the hoses, install the drain hose as
first action.
3. To prevent the water from penetrating, apply silicon
on the mounting part of center joint.
COMPLETING WORK
1. Start the engine and run at low idling for about 5
minutes.

DISASSEMBLY
IMPORTANT
Do not unbolt the center joint from the lower frame
until an adequate number of piping block off plates
are available, for disconnected piping lines. Be sure
that system pressure has been relieved - including
the hydraulic accumulator and tank reserve pressure -
before disassembly is started.
WARNING
Because of its weight, use a hoist or a similar device
to lift the assembly.
WARNING
The hydraulic oil will be hot after machine operation.
Allow the system to cool before attempting to service 13, 14 3
any of the hydraulic components.
1. Clean off the exterior of the swivel joint after it has

been removed.
2. Scribe or otherwise mark a line across the cover
and the body of the center joint, to allow reassembly
in the same configuration.
3. Remove oil remaining in each port with air. EX1402520
4. Use a 19 mm wrench to loosen cover bolts and
Figure 16
washers (13 and 14, Figure 16) and remove cover
(3).
9
5. Remove the shim (12, Figure 17) and O-ring (9).
12
EX1402521
Figure 17

6. U s e a p l i e r s t o r e m o v e r e t a i n i n g r i n g a n d 5
disassemble the spacer (4, Figure 18) and shim (11)

4
at the back of the retaining ring (5).
11
IMPORTANT
Care must be taken not to make a scratch or damage
the surface of the spindle when disassembling the
spindle of the hub.
EX1402522
Figure 18
7. Disassemble the spindle from the hub.

It can be disassembled easily by fixing the hub,
tightening at least 2 ~ 10 mm eyebolts on the
spindle, and lifting it with a hoist slowly. (Figure 19)
8. I f the spindle doesn’t separate easily when the
retaining ring are removed, use a wooden block and
hammer to drive it out of the housing.
3
4
FG013230
Figure 19
IMPORTANT
Care must be taken not to damage the inside
of the hub because it is likely to be damaged
when disassembling the slipper seal. It may be
FG021966
disassembled more easily with a screwdriver whose
tip is bent as shown in Figure 20. Figure 20

9. Remove the O-ring (10, Figure 21) (1 ea), dust 7 10
seal (7) (1 ea), O-ring (6) (1 ea) and slipper seal (8)
(7 ea) from the hub (1). 6
10. R e m o v e f o r e i g n s u b s t a n c e o n p i e c e s
disassembled and wash them out.
11. R eplace disassembled O-rings, dust seal and
1
slipper seals with new ones, for they cannot be
reused.
3
1
12. Clearance between the spindle and body of the 8
2
center joint must be tight. Replace or repair either
component if there is more than 0.1 mm (0.0039”)
4
of measurable wear.
EX1402523
Figure 21

REASSEMBLY
IMPORTANT
7 10
Apply a very light film of white grease inner surface of
the hub.
6
1. A ssemble the slipper seal (8, Figure 22) (7 ea),

O-ring (6) (1 ea), O-ring (6) (1 ea) and dust seal (7) (1
1
ea) into the hub.
3
CAUTION 1
8
2
AVOID INJURY
4
After assembling the slipper seal, a manual test must
be performed to ensure that every part is assembled
properly.
EX1402523
IMPORTANT Figure 22
For any slipper seal which is protruded, press it with

finger to seat it in its position. Care must be taken
when using a driver or a metal tool, which can cause
damage the seal.
2
IMPORTANT
1
Applying oil to the surface of the spindle will help

prevent damage to the slipper seal.
2. Fix the position of the spindle and press the hub

carefully into spindle with both being parallel each
other. (Figure 23)
3. Use a plastic (or rubber) hammer to tap the hub
until it is inserted completely.
IMPORTANT
Tap the Hub in a zigzag pattern so it does not tilt to FG013243
one side. Figure 23

4. Assemble the shim (11, Figure 24), spacer (4) and 5
install the retaining ring (5).
4
11
EX1402522
Figure 24
5. Apply the grease inner surface of cover (3, Figure 9

25) to fix the shim (12). And install the O-ring (9) to
hub. 12
EX1402521
Figure 25
6. Install the bolts and washers (13 and 14, Figure 26)
with cover (3) to hub. 13, 14 3
●Tool: 19 mm ( )
7. Prefill the center swivel with clean hydraulic fluid

before reassembly of high-pressure and drain line
piping. Clean and prefill piping line ends to reduce
the amount of air in the system. Bleed air from the
hydraulic system and check hydraulic tank fluid
level. EX1402520
Figure 26
IMPORTANT
After the completion of the assembly, a start-up and a
rotation torque test must be performed for the slipper
seal to seat in its place properly.

TROUBLESHOOTING, TESTING
AND ADJUSTMENT
Inspection
The center joint must be checked for evidence of
external oil leakage every 2,000 operating hours.
Leaking or defective O-rings are an indication that dirt
and other contaminants could be getting inside the
assembly, which will promote accelerated, abnormal
wear and can cause early failure of the assembly.
If internal seals or other sliding surface components
are worn and there is internal fluid leakage, complete
overhaul and repair or replacement of the center joint
may be required.
Pressure
Gauge
Testing
To check pressure through the center joint, make up a
test kit from the following equipment list: Swivel Joint
Body (Outer)
● 700 bar (10,000 psi) pressure gauge.
Swivel Joint
Stem (Inner)
● Adapters, connectors, piping and flange block off
plates conforming to those used in high-pressure

piping connections of the excavator.
● A high-pressure relief valve with a setting pressure Stop
Valve
1.5 times maximum system pressure.

● A stop valve. Manually-Operated
Changeover Valve
● A manually operated, in-line changeover valve.
Install the changeover valve upstream from one of Relief

Valve
the stem high-pressure ports. Connect the pressure (1.5x)
gauge downstream from one of the body ports. Install Tank

High Pressure
Pump
the stop valve between the changeover valve and the 0370
stem of the center joint. Other components must be
Figure 27
installed according to the layout in the block diagram.
The test kit is used to pressurize the center swivel
above normal working pressure and lock in the higher
pressure (as the stop valve is closed manually) for a
leak down test.
NOTE: The same type of kit can also be made up for the
drain port (return line) side of the center joint. Use
appropriate piping, connectors, test gauges, etc.,
and follow the same block diagram general layout
(Figure 27).

Accumulator
DX140AF/DX140LCA Accumulator 7-353

ＭＥＭＯ

Table of Contents
Accumulator

SAFETY PRECAUTIONS
CAUTION
working order.
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS

ＧＥＮＥＲＡＬ　ＤＥＳＣＲＩＰＴＩＯＮ
The accumulator is a gas-charged storage device 1
designed to hold a reserve quantity of hydraulic fluid
2
under pressure.
Accumulators are used in hydraulic circuits in much
the same way that condensers (or capacitors) are
used to 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 3
irregular operation are made up from the supply of
pressurized oil in the accumulator.
Reference Number Description
1 Screw Plug 4
2 Steel Pressure Vessel ARS1790L
3 Diaphragm
Figure 1
4 Fluid Valve
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
1. With no gas charge in the upper chamber 0 bar (0

psi, empty) and no oil in the bottom 0 bar (0 psi,
dry) the elastic diaphragm hangs loosely.
2. W hen the prepressure charge of gas (usually
nitrogen) is introduced through the port at the top
of the accumulator, the diaphragm expands to 1 2 3
maximum size.
The valve button in the center of the diaphragm
pushes into the fluid opening in the bottom
chamber, sealing off the lower valve. If the pressure
of the gas charge exceeds system oil pressure, no
fluid enters the accumulator. The button also keeps
the diaphragm from protruding into the lower valve 4 5 6
opening. ARS1800L
Note: Precharge pressure is referred to as the “P1” Figure 2

pressure. The accumulator manufacturer’s “P1”
rated pressure should be stamped or marked
on the accumulator’s rating plate. Annual
checks of actual precharge pressure should be
made by tapping a hydraulic pressure gauge
(and 3-way adapter coupling) into the valve on
the bottom of the accumulator.

When hydraulic fluid is pushed out the lower
valve opening by the pressure of the gas
charge on the other side of the diaphragm -
and there is no counterpressure from system
oil - the valve button on the bottom of the
diaphragm eventually seals off the lower oil
passage. Just after the needle on the gauge
reaches its highest point (when there is 0 bar (0
psi) resistance from hydraulic system pressure)
pressure on the gauge will drop sharply to zero,
as the accumulator is completely emptied of oil
and the diaphragm button closes.
Record the highest gauge reading and compare to
the “P1” rated precharge pressure on the accumulator
manufacturer’s data label. Repeat this test at least
once a year to verify proper functioning of the
accumulator.
3. A s h y d r a u l i c s y s t e m p r e s s u r e o v e r c o m e s
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. I f 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.

Remote Control
Valve (Work
Lever / Joystick)
DX140AF/DX140LCA Remote Control Valve (Work Lever / Joystick) 7-359

ＭＥＭＯ

Table of Contents
Remote Control Valve

(Work Lever / Joystick)
CAUTION................................................................ 362
Parts List......................................................... 364
Specifications.................................................. 366
Torques........................................................... 366
TOOLS AND MATERIALS...................................... 366
DISASSEMBLY....................................................... 367
TOLERANCES) REASSEMBLY............................. 371
START-UP PROCEDURES.................................... 377

SAFETY PRECAUTIONS
CAUTION
working order.
handling load.
responsibility.
APPLICABLE MODELS

GENERAL DESCRIPTION
Theory of Operation
Structure
The remote control valve contains four push rods,
spring holders, spools and return springs, which are
in the valve casing. The valve works as a pressure
reduction valve.
The housing has six ports, which include input port P,
tank port T, and four secondary pressure ports.
The electric horn button is installed in the valve
handle.
Gear pump pressure is used for operating control
spools.
Function
1. Neutral Position
When the lever is in neutral mode, the spool is
pushed upward by return spring. The force of
balancing spring, which determines the secondary
discharge pressure, is not transmitted to the spool.
The input port is closed and the pressure of the
output port is the same as the pressure of the tank
port T.
2. Control Switch
Pressing of the push rod starts to press the balance
spring, whose force is transferred to the spool to
connect the P and T ports, transferring the pilot
pressure. Output pressure acts on the bottom of
the spool and press the spool upwards until it is
balanced with the force of the balance spring.
In short, the second pressure (output pressure)
changes in proportion to the pressing force of the
balance spring.

Parts List
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
FG003938
Figure 1

Reference Reference
Number Number
1 Case 21 Joint Assembly
2 Plug 22 Swash Plate
3 Bushing 23 Nut
4 Spool 24 Nut
5 Shim Handle Assembly (L)
25
6 Spring Handle Assembly (R)
7 Spring Seat 25A Cap
8 Stopper 26 Handle Bar
9 Spring 27 Spring Pin
10 Stopper 28 Bellows
11 Spring 29 Bushing
12 Push Rod 30 Connector Assembly
13 Spring 32 Switch Assembly
14 Spring Seat 33 Spool Kit 1, 3
15 Stopper 34 Spool Kit 2, 4
16 Plug 35 Plug Kit 1, 3
17 O-ring 36 Plug Kit 2, 4
18 Rod Seal Handle Kit (Left)
19 Plate 37
Handle Kit (Right)
20 Boot

Specifications
Performance
Operating Torque (19.6)

PRESSURE (kgf/cm2)
PRESSURE (kgf/cm2)
(20)
TORQUE (kgf.cm)
TORQUE (kgf.cm)
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)
TOOLS AND MATERIALS

No. Tool Standard Remark
3 L Wrench 8 mm
19 Spanner 27 mm
20 Spanner 22 mm
22 Spanner 22 mm

DISASSEMBLY
1. Remove lead wire from bushing (29).
FG000804
Figure 3
2. Remove lever assembly from case (1).
FG000805
Figure 4
3. Remove hex nut (23) and swash plate (22) from

case.
FG000806
Figure 5
4. Remove joint assembly (21) from case.
FG000807
Figure 6

5. Remove plate (19) from case (1).
FG000808
Figure 7
6. Remove plug kit assembly, stopper (10), and spring

(11) from case (1).
FG000809
Figure 8
FG000810
Figure 9
FG000811
Figure 10

7. Remove four spool kit assemblies from case (1).
FG000812
Figure 11
FG000813
Figure 12
8. The bushing (3) and plug cannot be removed from

case (1).
FG000814
Figure 13
FG000815
Figure 14

FG000816
Figure 15
FG000817
Figure 16

(WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer
to “General Maintenance Procedures” section.
REASSEMBLY
1. Install four plugs (2) into case (1).
FG000815
Figure 17
FG000817
Figure 18
2. Install bushing (3) into case (1) using jig.
FG000814
Figure 19

FG000816
Figure 20
FG000818
Figure 21
3. Take care when assembling spool kit assemblies (1

and 3, 2 and 4). They should be assembled in same
way).
The assembly order is; spool (4), shim (5), spring (6),
spring seat (7), and stopper (8).
FG000819
Figure 22
FG000812
Figure 23

4. Install spring (9) into case (1).
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

7. Assemble four springs (11) and stoppers (10) and
insert assembled set in case (1) to form a plug kit
assembly.
Note: Pay attention to measurement specifications of
stoppers (1 and 3, 2 and 4).
FG000809
Figure 28
FG000811
Figure 29
FG000823
Figure 30
8. Install plate (19) into case (1).
FG000808
Figure 31

9. Install joint assembly (21) into case (1).
FG000807
Figure 32
10. Install wash plate (22) and hex nut (23) into case
(1).
FG000806
Figure 33
11. Insert bar and tighten it with a spanner to check

balance of joint assembly.
FG000824
Figure 34
12. Install boot (20) and bushing (29) into case (1).
FG000825
Figure 35

13. Install lever assembly into case (1).
FG000805
Figure 36
14. Put lead wire in bushing (29), tie it, and arrange
boot.
FG000826
Figure 37
FG000827
Figure 38
15. Install lead wire terminal into connector terminal

pressing them together.
FG001097
Figure 39

16. Assemble connector assembly (30), and connect
it to lead wire terminal, and properly route wiring.
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
3. Slowly cycle boom, arm, bucket cylinders and

swing motor about five times without a load to vent
air from pilot lines. Do this for five minutes.
ARO0470L
Figure 43

Travel Control
Valve (with
Damper)
DX140AF/DX140LCA Travel Control Valve (with Damper) 7-378

ＭＥＭＯ

Table of Contents
Travel Control Valve (With Damper)

Deceleration Valve.......................................... 383
Dampening Parts of the Control Section........ 384
CAUSES OF FAULTS AND MEASURES............... 386
Parts List......................................................... 387
Specifications.................................................. 388
Torques........................................................... 388
REMOVAL............................................................... 389
DISASSEMBLY....................................................... 390
TOLERANCES)....................................................... 393
ASSEMBLY............................................................. 394
INSTALLATION....................................................... 400
START-UP PROCEDURES.................................... 401

SAFETY PRECAUTIONS
CAUTION
working order.
handling load.
responsibility.
APPLICABLE MODELS

GENERAL DESCRIPTION
Theory of Operation
The damper valve is divided into two areas of
operation.
There is the pressure reducing valve (a) and the
damper mechanism (b). The following hydraulic circuit
is an example of a remotely located control valve.
5
6
P T
4
2
ARS1810L
Figure 1
Reference Reference
Number Number
1 Remote Control Valve 4 Control Valve
2 Pilot Pump 5 Hydraulic Motor
3 Main Pump 6 Hydraulic Cylinder

Deceleration Valve
1. In neutral position, the damper spool is pushed to
the neutral position by return spring which is seated
on the spring seat (and washer. As a result of the
damper spool’s switching function, the output port is
connected to port T and the pressure at the output
port and port T is the same.
2. When the cam of the remote control valve is
operated and moved from the neutral position to
the clockwise direction, the push rod and damper
spool of port 1 is moved down within the constraints
of washer 1, spring seat, secondary pressure select
spring, washer 2 and washer 3. As a result port
P and port 1 are connected and oil pressure from
the pilot pump flows through port 1, generating
pressure.
When the pressure of port 1 reaches the selected
pressure of the secondary pressure select spring,
the oil pressure and the spring set pressure will
equalize and the output pressure of port 1 is
maintained at a constant rate.
The damper spool in port 2 is in the neutral position,
oil returning from the control valve is discharged
through port T. In cases where the controls are
operated to the maximum position, the push rod
makes direct contact with the damper spool forcing
port P to make a direct path with the discharge port,
permitting the pressure to equalize at these ports.
40 160
SECONDARY PRESSURE (kg/cm2)
OPERATING TORQUE (kg.cm)
112.6
25 +
-1.5
Operating Torque 91.8
46.4
7.5 +
-1 Secondary Pressure
0 1+
-0.5 4.8 +
-0.5 5.5
PUSH-ROD STROKE (mm)

FG003924
Figure 2

Dampening Parts of the Control Section
1. In the neutral position, the push rod is pushed up to
its neutral position by the return spring and damper
spring.
2. When the cam is moved in the clockwise direction
from the neutral position, the push rod and damper
spool of port 1 are moved in a downward direction.
At this time, the pressurized oil in the damper spool
is discharged through the orifice and the dampening
pressure is generated. Meanwhile, the push rod in
port 2 moves up with the damper spring and the
damper spool between them. At the same time, the
oil from the oil tank passes through the check ball (3
positions)
consisting of a spring and steel ball, and flows out
through port T in the upper portion of the casing to
tank.
3. W hen the operating levers are moved to the
extreme opposite position: When the cam is moved
to the counterclockwise position from the clockwise
most
position, the push rod and piston in port 2 is moved
in the downward direction. As in the case described
above, the oil in the damping piston chamber is
discharged through the orifice and the dampening
pressure is generated in this chamber, providing
dampening force. In port 1, the push rod is moved
up by the action of the return spring and damper
spring.
At the same time, the oil from the oil tank passes
through the check ball (3 positions) consisting of a
spring and steel ball, and flows out through port T in
the upper portion of the casing to tank
The damping operation is effective in both operations,
when the levers are moved from the neutral position to
the maximum travel position and when the levers are
moved from the maximum travel position to the neutral
position as well.

A. When moving lever from the neutral position
Moving the lever from the neutral position to 1
the right forces oil in the right damper spool to

discharged through the orifice, generating pressure
2
that creates a dampening force.
Moving the lever in the opposite direction, causes 3
the left damper spool to assume the function of the
right spool. 4
Thus, a dampening force is generated at both ways.
HB4M033L-1
Figure 3
B. Operation of forward and reverse lever control 1

Oil outside the damper spool runs out through the
channel from the top of the casing to the port (T). 2
And oil in the damper spool is discharged through
orifice, generating pressure that creates a
dampening force.
HB4M032L-1
Figure 4

CAUSES OF FAULTS AND
MEASURES
At times it may be difficult to pinpoint the source of the
problem. The following table lists some of the possible
problems, possible causes and remedies. Refer to this
table for possible causes and remedies to assist in
correcting the sometimes difficult problems.
The table only lists some general problems, possible
causes and their remedies. In many cases the
problem is not caused by the failure of a single part
but, may be the result of a combination of problems
from related parts and their components. Possible
problems other than the ones list are not being
specified but that is not to say that these are the only
possible problems that can occur. The technician must
diagnose the problem, considering all possible causes
and repair the source of the malfunction.

Low primary pressure. Adjust primary pressure.
Defective secondary pressure
Replace with new spring.
Secondary pressure will not select spring.
Gap between damper spool and Replace damper spool casing
increase.
casing is abnormally large. assembly.
Defective operating parts and Disassemble/reassemble and
components. replace defective parts.
Jamming of interconnected parts. Repair/replace cause of jamming.
Unstable secondary pressure. Unstable tank line pressure. Install direct line to hydraulic tank.
Air in hydraulic lines. Vent air from system.
Abnormally high secondary High tank line pressure. Install direct line to hydraulic tank.
pressure. Jamming of interconnected parts. Repair/replace cause of jamming.
Air in piston chamber. Vent air from system.
Jamming of interconnected parts. Repair/replace cause of jamming.
Worn damper springs. Replace with new parts.
No dampening. Replace damper spool and housing
Worn damper spool and housing.
assembly.
Disassemble and examine check
Defective/damaged check valve.
valve.
Worn damper spool orifice. Replace damper spool.
Defective interconnected
Repair/replace defective parts.
components.
Damper spool feels heavy.
Restricted movement of damper
Repair/replace damaged piston.
spool.

Parts List
27 31 30 29 28 33
32 25,26
24
23
3
22
16 14,15
21 36
38 17
13 18
12 19
11 20
9
6
5
7
4 10
3 8
37 1 35 34 2
P T
1 2 3 4
FG003925
Figure 5

Reference Reference
Number Number
1 Body (1) 20 Retaining Ring
2 Body (2) 21 Plug
3 Plug 22 O-ring
4 Plug 23 Rod Seal
5 Spring Seat 24 Dust Seal
6 Damper Spring 25 Cover
7 Spring Seat 26 Hex Socket Head Bolt
8 Damper Spool 27 Cam
9 Stopper 28 Bushing
10 Return Spring 29 Camshaft
11 Rod Guide 30 Set Screw
12 O-ring 31 Set Screw
13 Retaining Ring 32 Hex Nut
14 Push Rod 33 Bellows
15 Spring Pin 34 Spacer
16 Seal 35 O-ring
17 Steel Ball 36 O-ring
18 Damper Spring 37 Hex Socket Head Bolt
19 Cam Plate 38 Piston
Specifications
Travel Control Valve Specification
Type Pilot Control (With Damper)
2
Pressure / Stroke 25 kg/cm @ 4.8 mm Stroke (356 psi @ 0.1890 in Stroke)
Weight 7.8 kg (17 lb)
Torques
Part Reference Number Bolt Size Tool Tightening Torque
26 M6 5 mm L-Wrench 88 kg•cm (6 ft lb)
32 M10 17 mm Spanner 440 kg•cm (32 ft lb)

REMOVAL O I

2. Lower front attachment (bucket) to ground.
3. Shut down engine.
4. Set safety lever on “RELEASED” position.
5. Turn starter switch to “I” (ON) position. WARNING
DON'T TOUCH WHEN

PERFORMING INSPECTION
OR MAINTENANCE
WARNING FG006745
Figure 6
If engine must be running while performing maintenance, always
use extreme caution. Always have one person in the cab at all
times. Never leave the cab with engine running.

7. Set safety lever on “LOCK” position.
starter switch.
9. Hang a maintenance warning tag on controls.
10. Disconnect negative (-) battery cable leading to
frame from battery.
11. Remove cabin under cover by loosening bolts.
12. Tag and disconnect hoses from pedal valve (1,
2
Figure 7). Plug and cap hoses and ports to prevent
contamination from entering hydraulic system or
component. 1
FG003016
Figure 7

DISASSEMBLY
1. Remove bellows (33).
ARS1870P
Figure 8
2. Remove set screw (30) from cam (27).
FG000985
Figure 9
3. Remove cam shaft (29) and cover (25) from cam

(27).
FG000986
Figure 10
4. Remove hex nut (32) and swash plate (31) from

cam.
FG000987
Figure 11

5. Remove hex socket head bolt (26) and cover (25)
from each body (1 and 2).
FG000988
Figure 12
FG000989
Figure 13
6. Remove push rod assembly from each body (1 and

2).
FG000990
Figure 14
7. Remove retaining ring (13).
FG000991
Figure 15

8. Remove rod guide (11) from each body (1 and 2).
FG000992
Figure 16
FG000993
Figure 17
9. Remove damper spool assembly and spring (10)

from each body (1 and 2).
FG000994
Figure 18
FG000995
Figure 19

10. Remove hex socket head bolt (37) from each body
(1 and 2). Disassemble each body (1 and 2) and
spacer (34). Remove plugs (3 and 4) and O rings
(35 and 36).
FG000996
Figure 20
FG000997
Figure 21
FG000998
Figure 22

(WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer
to “General Maintenance Procedures” section.

ASSEMBLY
1. Assemble plugs (3 and 4) and O rings (35 and 36)
into each body (1 and 2) and spacer (34). Install
hex socket head bolt (37) using torque wrench.
FG000996
Figure 23
FG000997
Figure 24
FG000998
Figure 25
2. Insert spring (10) into each body (1 and 2).
FG000995
Figure 26

3. Assemble in proper order, damper spool (8), shim
(7), spring (6), spring seat (5), and stopper (9).
FG000999
Figure 27
FG001000
Figure 28
4. Install damper spool assembly into each body (1

and 2).
FG000994
Figure 29
5. Install O-ring (12) on rod guide (11). Coat guide

assembly with grease, and slide it into each body (1
and 2).
FG000992
Figure 30

FG000993
Figure 31
6. I nstall retaining ring (13). Make sure that it is

properly seated.
FG000991
Figure 32
7. Assemble rod seal (23), dust seal (24), and O-ring

(22) into plug (21).
FG001001
Figure 33
FG001002
Figure 34

8. Assemble seal (16), piston (38), steel ball (17),
plate (19), spring (18), and retaining ring (20) into
push rod (14).
FG001003
Figure 35
FG001004
Figure 36
9. Assemble push rod and plug.
FG001005
Figure 37
10. Install push rod assembly into each body (1 and 2).
FG000990
Figure 38

11. Install bushing (28) in cover (25) using jig.
FG001006
Figure 39
12. Assemble cover (28) onto each body (1 and 2)

and install hex socket head bolt (26) using torque
wrench.
FG001007
Figure 40
FG000989
Figure 41
13. Install set screws (31) and hex nut (32) into cam
(27) and tighten it.
FG000987
Figure 42

14. Position cam (27) on cover (25), and insert cam
shaft (29) using hammer.
FG000986
Figure 43
15. Install set screw (30) in cam (27) and tighten it

using torque wrench.
FG000985
Figure 44
16. Check cam balance.
FG001009
Figure 45
17. Install bellows.
ARS2250P
Figure 46

INSTALLATION 2
1. Position pedal valve (1, Figure 47) on cabin floor
plate and install four bolts and washers (2). 1
FG003016
Figure 47
2. Install pedal brackets (3) and levers (4, Figure 48)
on pedal valve and install four bolts and washers (2).
3. Install rubber boots (1, Figure 48). 1
3
3
2
2
ARS2951L
Figure 48
4. Connect hoses as tagged during removal to pedal 2

valve (1, Figure 49).
5. Install cabin under cover by tightening bolts. 1
FG003016
Figure 49

START-UP PROCEDURES
1. Start engine and set throttle at “LOW IDLE.”
2. Set safety lever on “UNLOCK” position.
HAOB290L
Figure 50
3. Slowly push and pull both travel lever about five

times without a load to vent air from pilot lines.
HAOB903L
Figure 51

Electrical System
DX140AF/DX140LCA Electrical System 8-1

ＭＥＭＯ

Table of Contents
Electrical System
INTRODUCTION......................................................... 5
ELECTRICAL SUPPLY SYSTEM............................... 6
ENGINE STARTING CIRCUIT.................................... 8
Start Operation................................................... 8
After Start.......................................................... 10
ENGINE PREHEATING SYSTEM............................. 12
ENGINE STOP.......................................................... 13
CHARGING SYSTEM............................................... 14
MONITORING SYSTEM........................................... 15
Instrument Panel............................................... 16
Monitoring System Schematic.......................... 17
DISPLAY SCREEN................................................... 19
Standby interface.............................................. 19
WARNING AND INDICATOR.................................... 20
LIGHTS..................................................................... 20
Indication of Warning Lights...................................... 20
Indication of Multifunction Gauge and Letter
Information Area............................................. ..21
INITIAL OPERATION................................................ 23
MODE SELECTOR SWITCH.................................... 23
Power Mode Switch.......................................... 23
Power Mode Switch.......................................... 23
GRAPHIC INFORMATION AREA DISPLAY............. 24
Overview......................................................... 24
Main Menus for the Graphic Display Area...... 24
Menu Selector Buttons................................... 24
USER MENU............................................................. 25
User Menu - Access and Escape Methods....... 25
User Menu ....................................................... 25
SPECIAL MENU ....................................................... 41
Entering/Accessing and Exiting/Escaping........ 41
Menus............................................................... 41
Exiting/Escaping Menus................................... 42
Special Menu Selections.................................. 42
Graph................................................................ 46
FMIs (Failure Mode Identifier)........................... 51

ELECTRONIC HYDRAULIC CONTROL SYSTEM
(EPOS).................................................................... ..58
Control System Schematic............................... 58
POWER MODE CONTROL....................................... 60
Operation.......................................................... 62
POWER MODE CONTROL - CIRCUIT DIAGRAM �� 65
WORK MODE CONTROL......................................... 66
ENGINE CONTROL SYSTEM.................................. 67
ENGINE CONTROL DIAL......................................... 68
ENGINE CONTROL MOTOR.................................... 69
ENGINE CONTROL CIRCUIT................................... 70
DIAGRAM.................................................................. 70
AUTOMATIC DECELERATION................................ 71
CONTROL (AUTO IDLE CONTROL)........................ 71
ENGINE OVERHEAT................................................ 72
PROTECTION SYSTEM........................................... 72
POWER BOOST MODE............................................ 73
Operation.......................................................... 73
Power Boost Control - Circuit Diagram............. 74
AUTOMATIC TRAVEL SPEED................................. 75
CONTROL................................................................. 75
Automatic Travel Speed Control - Circuit......... 76
Diagram............................................................ 76
HOW TO ADJUST THE ENGINE.............................. 77
CONTROL DEVICE................................................... 77
ENGINE THROTTLE CONTROLLER....................... 79
SELF-DIAGNOSTIC FUNCTION.............................. 80
EPOS Controller........................................................ 80
OIL-WATER SEPARATOR ALARM.......................... 82
Running............................................................ 82
SELF-DIAGNOSTIC FUNCTION ............................. 83
EPOS controller ............................................... 83
Normal Operation Display................................. 84
Communication monitoring............................... 84
SOUND SYSTEM...................................................... 85
WIPER SYSTEM....................................................... 86
AIR CONDITIONING SYSTEM................................. 89
Basic working principle..................................... 89
Air Conditioning System Test........................... 93
Air Flow Diagram............................................ 102
Circuit of Air Conditioning System.................. 105
Air Conditioning Unit Components.................. 106
Automatic mode control.................................. 117

SAFETY INSTRUCTIONS
WARNING
Instructions are necessary before operating or servicing
machine. Read and understand the Operation & Maintenance
Manual and signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs, adjustments
or servicing. Check for correct function after adjustments repairs
or service. Untrained operators and failure to follow instructions
can cause death or serious injury.
INTRODUCTION
The electrical system for this equipment is DC 24
volts. The rated voltage for all electric components is
24 volts with the exception of the stereo and the air-
conditioning control actuator.
The system contains two 12 volt batteries connected
in series and a three phase AC generator with a
rectifier. The electric wiring used in the system is
easily identifiable by the insulator color. The color
symbols used in the electrical system are listed in the
following chart.
Electric Wire Color

Symbol Color
W White
G Green
Or Orange
B Black
L Blue
Lg Light green
R Red
Gr Grey
P Pink
Y Yellow
Br Brownness
V Purple
Note: RW: Red wire with White stripe
R - Base Color, W - Stripe Color
Note: 0.85G: Nominal sectional area of wire core less
insulator = 0.85 mm 2

ELECTRICAL SUPPLY SYSTEM
The electric power circuit supplies electric current
to each electric component. It consists of a battery,
battery relay, starter switch, circuit breaker, fusible link
and fuse box.
The negative terminal of the battery is grounded to the
vehicle body.
Even when the starter switch (5) is in the “OFF”
position, electric current is supplied to the following
components through battery (1) → fusible link (3)
→fuse box (6).
1. Terminal “5” of stereo
2. Terminal “B” of starter switch
3. Hour meter
4. Terminal “1” of TMS controller
5. Fuel feeder pump switch
6. Terminal “6” of wiper motor
7. Terminal “13” of wiper controller
8. Terminal “CN7-5, CN7-6” of instrument panel
9. Terminal “CN9-6” of air conditioner panel
10. Cabin light
11. Terminal “B” of engine stop motor
12. Terminal “4” of engine time delay
When the starter switch (5) is in the “ON or START”

positions, the current flows from the battery (1)
→fusible link (3) → fuse box (6) → “B” terminal of
starter switch (5) → “BR” terminal of starter switch (5)
→ “BR” terminal of battery relay (2) which activates
the coil of the battery relay and the electric supply
system is energized.
When the battery relay’s contacts are connected, all
electric devices can be operated.
While the engine is not running, the electric power for
all electric devices are supplied by the battery. Once
the engine is started the power is supplied from the
alternator (7).

ACC C
B
R2
5
BR
0.5G
R1
6
3
8
4 2
B A
BR
E
- + - +
12V 150AH 12V 150AH
R(I) B(B+) P(R)
Starter Switch Connection 1
PST TML B BR R1 R2 C ACC
OFF
SG
PREHEAT 7
ON
R
START F
E
EX1501508
Figure 1 Electric Power Circuit Diagram
Reference Reference
Description Component
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode

ENGINE STARTING CIRCUIT
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 2 (12) - “87a” terminal → “86” terminal of starter
relay 1 (8) - “85” terminal → “S” terminal of starter
controller (7) - “E” terminal → ground.
When the contact point “30” and “87” of starter relay 1
(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) → “B” terminal of the starter (9).
The starter motor is rotated and the engine is started.
If the instrument panel has the password function
activated , input number should match the set number,
otherwise the start circuit closes and the engine does
not start.
Note: If the security system is “LOCKED,” a four-digit Owner Password
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.
In the event the security system is locked,
current flows from battery (1) → fusible link (3) 3 4 5 6 7 8 9 : ; <
→ fuse box (6) → “B” terminal of starter switch Enter Owner Password
(5) →“ACC” terminal of starter switch (5) → “86”

terminal of starter relay (12) → “85” terminal of EX1301416
starter relay 2 (12) → “CN1-15” terminal of EPOS Figure 2
(13) → ground. This current flow causes the coil
in starter relay 2 (12) to be activated, opening
contacts at “87a” terminal. This prevents starter
relay (8) from functioning.

8
87a 9
30 S
87
7
N S 85 86
P
B E
B
87a
30 A
87
85 86 ACC
C
B 5
R2 BR
12
R1
3
CN1-15
6
4
B A
CN2-1
BR
13 E
11
Starter Switch Connection
R(I) B(B+) P(R) 2
OFF SG
PREHEAT 10 -
12V 150AH
+ - +
12V 150AH
ON R
F 1
START E
EX1501509
Figure 3 Starter Circuit (1) - While Starting
Reference Reference
Number Number
1 Battery 8 Starter Relay 1
2 Battery Relay 9 Starter
5 Starter Switch 12 Starter Relay 2
6 Fuse Box 13 EPOS Controller
7 Starter Controller

After Start
Once the engine has been started, the belt driven
alternator (10) generates a current.
The output generated by the alternator (10) is a
square wave pulse voltage through the “P” terminal
and the frequency of the pulse voltage is proportional
to the rotation of the alternator.
The starter controller (7) monitors the frequency of
the output current. Once the frequency is equivalent
to 500 rpm, it is sensed and the connection between
“S” and “E” terminals and the connection between “30”
and “87” terminals of starter relay 1 (8) are opened. As
a result the rotation of the starter (9) is stopped. Once
the engine is running, the starter (9) will not operate
even if the starter switch (5) is moved to the start
position, preventing possible damage to the starter.

Operation of the Start Circuit (2) - Immediately After
Start
8
87a 9
30 S
87
7
N S 85 86
P
B E
B
87a
30 A
87
85 86 ACC
C
B 5
R2 BR
12
R1
3
CN1-15
6
4
B A
CN2-1
BR
13 E
11
R(I) B(B+) P(R) 2
OFF SG
PREHEAT 10 -
12V 150AH
+ -
12V 150AH
+
ON R
F 1
START E
EX1501509
Figure 4 Operation of Start Circuit (2) - Immediately After Start
Reference Reference
Number Number
1 Battery 8 Starter Relay 1
2 Battery Relay 9 Starter
5 Starter Switch 12 Starter Relay 2
6 Fuse Box 13 EPOS Controller
7 Starter Controller

ENGINE PREHEATING SYSTEM
An air heater (8) is installed in the intake manifold of
the engine.
When the starter switch (5) is turned to “PREHEAT”
the current flows from the battery (1) → fusible link (3)
→ “B” terminal of starter switch (5) → “R1” terminal
of starter switch (5) → “C” terminal of preheat relay
(7) → ground. This current flow causes the coil in the
preheat relay (7) to be activated, closing contact.
When the contacts of the preheat relay (7) are closed,
the heating coils of the air heating device are heated
by current flowing from the battery (1) → battery relay
(2) → preheat relay (7) → air heater (8) → ground.
The duration of the heating time is approximately 20
seconds.
After 20 seconds later to start preheating, the preheat
indicator light will be turned “OFF” by the timer in the
EPOS controller.
If the starter switch (5) turns to “START”, the heating
process will go on because the current flows into the
coil in preheat relay (7) through “R2” terminal of starter
switch (5).
9 4
CN7-2, 16 2
ACC C B A
PREHEAT CN6-12, 13
L5 B 5
R2 BR
R1 BR E
10
CN4-4,5,6
CN2-13
CN2-1
- + - +
12V 150AH 12V 150AH
11 1
C B
-
200A

7 8 PST TML B BR R1 R2 C ACC
OFF
D A + PREHEAT
ON
START
EX1501511
Figure 5 Engine Preheat Circuit
Reference Reference
Number Number
1 Battery 7 Preheat Relay
2 Battery Relay 8 Air Heater
3 Fusible Link 9 Preheat Indicator Light
5 Starter Switch 11 EPOS Controller
6 Fuse Box

ENGINE STOP
Engine Stop circuit consists of starter switch (5),
engine stop motor (9), engine stop relay (8). The
current flowing into the “ACC” terminal of starter switch
allows the engine’s start and stop function.
The stop Motor is decelerated by the worm gear by
itself and converts the rotary motion into a back-and-
forth motion to pull and push the engine stop lever.
If the starter switch turns “ON”, the motor will stop
automatically after revolving 0° → 180°, and if the
starter switch turns “OFF”, the motor will stop at the
engine stop position by revolving 180° → 360°
A Starter Switch Connection

P1 87a TML
PST B BR R1 R2 C ACC
30
P2 87 OFF
A 85 86 PREHEAT
B
ON
E
START 10
1 4
8
9 2 3
6
3
ACC C
B 5
R2
BR
4 2
R1 B A
BR
E
7
- + - +
12V 150AH 12V 150AH
EX1501512
Figure 6 Engine Stop Circuit
Reference Reference
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 7 Diode
3 Fusible Link 8 Engine Stop Relay
4 Circuit Breaker 9 Engine Stop Motor
5 Starter Switch 10 Engine Time Delay

CHARGING SYSTEM
When the starter switch (5) is turned to the “ON”
position, an initial excited current flows to the field coil
of the alternator (7) through the battery relay (2) and
circuit breaker (4). When the engine is started from
this condition the alternator (7) starts charging. The
current flows from the “B(B+)” terminal of alternator (7)
→ circuit breaker (4) → battery relay (2) → battery (1).
The alternator also supplies electric current to other
electrical components. When the alternator (7) starts
to operate, a current flows from the “R(I)” terminal of
alternator → diode (8) → battery relay (2) coil securing
a path for the charging current to the battery (1). Thus
preventing the possibility of a high voltage build up
and possible damage to the electric system.
ACC C
B
R2
5
BR
0.5G
R1
6
3
8
4 2
B A
BR
E
- + - +
R(I) B(B+) 12V 150AH 12V 150AH
P(R)
Starter Switch Connection 1
OFF
SG
PREHEAT 7
ON
R
START F
E
EX1501513
Figure 7 Charging Circuit
Reference Reference
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box

MONITORING SYSTEM
Figure 8
S/N Component S/N Component

1 Instrument Panel Pump Discharge Pressure
9
2 Battery Sensor
Hydraulic Oil Temperature
3 Light Switch 10
Sensor
4 Return Filter Switch 11 Fuel Sensor
5 Pilot Filter Switch 12 Air Cleaner Indicator
6 EPOS Controller Engine Coolant Temperature
13
7 Alternator Sensor
8 Warning Buzzer 14 Engine Oil Pressure Switch
The monitoring system displays the various data

and warning signals onto the instrument panel by
processing the information gathered from the EPOS
controller. It displays information selected by the
operator.

Instrument Panel
Figure 9
Reference Reference
Number Number
1 Fuel Gauge 6 Digital Clock
Engine Coolant Temperature 7 Display Warning Symbols
2
Gauge 8 Warning Light
3 Hydraulic Oil Temperature Gauge
9 Function Buttons
Multifunction Gauge and Graphic
4 10 Selector Function Display
Information Area
5 Hour Meter
When the engine starter switch is turned to “I” (ON)

position, all gauge bands, switch/button indicator lights
and warning lights will turn “ON” and the alarm buzzer
will sound for about two seconds.
During this functional check, a LOGO will appear on
the multifunction gauge in the graphic information area
(3 and 4, Figure 9).

Monitoring System Schematic
19
CN7-16
3
CN6-4
ILL.
CN7-2 +
CN6-1 -
L1
L2 CN7-5
2
CN7-6
17
L3 4
L4 R2 B 16 B
CN7-3
L5
CN7-4 BR
L6 14 E
WARNING LAMP CN2-1 A

L1 : CHARGE
L2 : ENG OIL PRESS
L3 : W/T OVER HEAT
L4 : E/G WARNING 18
L5 : PREHEAT
L6 : WORK LAMP
+ CN5-7 15
CN3-1
5 SIG
CN3-2
9
LCD DISPLAY PANEL -
WATER TEMPERATURE CN2-17
FUEL LEVEL + 10
6 SIG CN3-3 CN2-18
GRAPHIC DISPLAY CN3-4
- 11
CN6-12 CN5-3
CN4-4
CN6-13
12
CN4-12 CAN A
CN4-6
CN3-7
GND
CN3-8 8
CN4-3
CN4-2 RxD
CN4-1 TxD CN3-9
CN3-10 7
1
2 CN5-13
3 CN5-14 21
4 20
5 CN5-15
6 CN5-16 22
14
CN5-5
R(I) CN2-14 23
13 EX1501515
Figure 10

S/N Component S/N Component
1 Instrument Panel 12 Return Filter Switch
2 Pilot Buzzer 13 Alternator
3 Light Switch 14 EPOS Controller
4 Starter Switch 15 Battery
5 Front Pump Pressure Sensor 16 Battery Relay
6 Rear Pump Pressure Sensor 17 Circuit Breaker
Hydraulic Oil Temperature 18 Fusible Link
7
Sensor 19 Fuse Box
8 Fuel Sensor
20 Check Connector
Pedal Pressure Switch
9 21 Coolant Temperature Sensor
(Optional)
10 Air Cleaner Indicator 22 Engine Speed Sensor
11 Pilot Filter Switch 23 Engine Oil Pressure Switch

DISPLAY SCREEN
Standby interface
Sensor Specification
Function Display
Input Terminal Input Specification
0% (34°C)
17% (46°C)
33% (59°C)
50% (72°C)
Coolant CN5-13 51% (86°C)
Temperature CN5-14 65% (90°C)
81% (96°C)
95 % (103°C)
98 % (107°C) (Warning Start)
100 % (110°C)
Fuel Level
CN3-7 1/10 LCD (Red Zone)

CN3-8 Blinking → over 5K ohms
FULL → under 525 ohms
0% (34°C)
17% (46°C)
33% (59°C)
50% (72°C)
Hydraulic Oil CN3-9 65% (85°C)
Temperature CN3-10 81% (91°C)
95% (97°C)
97% (98°C)
98% (99°C) (Warning Start)
100% (101°C)
CN5-15
Tachometer
CN5-16

WARNING AND INDICATOR
LIGHTS
Indication of Warning Lights
Input
Description Symbol Operation Remarks
Terminal
It lights in case of no
charge [voltage of
Normally, it lights
“R(I)” terminal is
CN2 - 14 when starting engine
Charge below 12 ±1V] or
CN1 - 8 (9) and is out after
overcharge [voltage
engine starts.
HAOA610L
of “R(I)” terminal is
above 33(V)].
After starting engine,

It lights when engine if engine oil pressure
Engine Oil CN5 - 5
oil pressure is below is insufficient after 8
Pressure CN1 - 8 (9)
the reference. seconds, a warning
buzzer will sound.
HAOA620L
It lights when engine

coolant temperature
Coolant CN5 - 13
sensor resistant is
Temperature CN5 - 14
below about 128
HAOD350L
ohms.
It lights during
preheating and turns
“OFF” after
CN2 - 13
Preheating completion of
CN1 - 8 (9)
preheating.
(After 20 sec
HAOA639L
preheating)
It lights when work

CN2 - 6
Work Light light turns “ON” (24V
CN1 - 8 (9)
applied).
HB4O2003

Indication of Multifunction Gauge and Letter
Information Area
Input
Terminal
When hydraulic oil

Hydraulic Oil CN3 - 9
temperature is above
Temperature CN3 - 10
about 96°C.
FG000056
Fuel CN3 - 7 When fuel is almost

Exhausted CN3 - 8 exhausted.
FG000057
CN2 - 17 When air cleaner is

Air Cleaner
CN1 - 8 (9) clogged.
FG000053
When return filter

CN5 - 3 pressure is above
Return Filter
CN1 - 8 (9) about 1.50 kg/cm²
(21 psi)
FG000054
When pilot filter

CN2 - 18 pressure is above
Pilot Filter
CN1 - 8 (9) about 1 kg/cm² (14
psi)
FG000055
Warning buzzer also

It flickers in case of
starts when boom
2.71V and above and
pressure sensor
Overload CN3-5 lights continuously in
output voltage is
Warning CN3-6 case of 2.8V and
about 2.7V while
above (and warning
overload warning
buzzer also starts).
switch is “ON”.

Input
Terminal
It lights when boost is

Boost CN2-2
selected.
FG000554
It lights when breaker

Breaker CN2-10
is selected.
It lights when shear is

Shear CN2-9
selected.
Lights up when quick

Quick Clamp CN2-11
clamp was release.
This symbol appears

when the water
separator is full.
Water CN3-19
This symbol appears
Separator CN3-20
when water separator
sensor output voltage
is about 1.5V below.

INITIAL OPERATION
Item Input (Terminal) Output (Operation and Initial Setting Mode)
Initial When “CN7-2” is applied ● Warning buzzer is activated and turned “OFF” after
Operation battery voltage (starter switch) about 3 seconds.
shifts from “OFF” to “ON” ● Power mode: When Fuel Saving Mode is disabled, the
power mode is the previous mode. When Fuel Saving

Mode is enable, the power mode is standard mode or
economy mode.
● Auto Idle: High Output (Activation).
● Display: Indicating coolant temperature, fuel level,
hydraulic oil temperature, engine speed.

● Clock: Current time display.
Note: Refer to method for setting clock in operation

manual for setting time.
MODE SELECTOR SWITCH

Power Mode Switch
EPOS Output
Operation Mode Electromagnetic Proportional Pressure Swing Priority 7-Segment
Reducing Valve (E.P.P.R Valve) Current (mA) Solenoid Valve Display
No-load: 150 ±20 mA
Power Mode Load: Variable output - 9x
(Max. current: 600 ±60 mA)
Power
Standard Mode Load: Variable output - 7x
Mode
Economy Mode Load: Variable output - 5x
Note: When the engine speed is below 1,000 rpm, the

output current of E.P.P.R valve is fixed to be 600
±60 mA.
Power Mode Switch

Operation Mode Output Check (Operation mode display LED)
Activation ON
Auto Idle
Cancellation OFF

GRAPHIC INFORMATION AREA
DISPLAY
Overview
Machine condition is displayed in the letter information
display department. The information display
department is divided into two menus. One is main
menu for the user and the other is a special menu for
the specialist. These menus can be changed from
normal display mode by the combination of selector
button.
Figure 11
Main Menus for the Graphic Display Area

1. User menu: Language setting, Time setting, Filter/
Oil information, Brightness adjustment, Password
2. Special menu: Information of machine status, fault
information, Information of machine operation.
Menu Selector Buttons

1. Proceed to the user menu using the menu/esc (1,
Figure 11) button on the front of the panel.
2. The ESC Button (1, Figure 11): Move a screen to
previous menu or main menu.

USER MENU
User Menu - Access and Escape Methods
Access Method
1. P roceed to the user menu using the menu/ESC
button on the front of the dashboard.
2. Select the user menu from the launch menu.
<Normal Indication Monitor> <Main Menu Monitor>
Figure 12
Escape Method
1. Press the ESC button to move to the normal display
screen.
2. If 20 seconds have passed without the operation
of the button, the normal display screen will be
displayed.
3. Turning “OFF” the starter switch to cut off power,
you will move to the normal display screen.
User Menu
Use the and buttons and move the cursor to see a
reversed display on the desired menu. Then, press the
button to select the menu.
Machine State ←
→ Machine Configuration ←
→ Gauge Panel
Configuration Press the ESC button to return to the
previous screen.
WARNING Figure 13

Do not use machine state menu when traveling or operating.

1. Machine State
This is used to check the current machine state,
filter/oil information, machine information, etc.
Use the and buttons and move the cursor to see
a reversed display on the desired menu. Then,
press the button to select the menu.
Monitoring ← → Filter/Oil Information ← → Machine
Information Press the ESC button to return to the
previous screen.
Figure 14
A. Monitoring
The monitoring screen displays the information
on machine pump pressure, voltage, fuel level,
etc.
At the machine state, if the cursor is placed on
Monitoring, press the button to display the
Monitoring screen.
Press the ESC button to return to the previous
screen.
Figure 15
B. Filter/Oil Information
The screen displays the information on filter/
oil use time, replacement period, and remaining
time.
the filter/oil information, press the button to
display the filter/oil information.
Figure 16

Reset Method/Replacement Period Change Method
Move the cursor over the filter/oil item you wish
to change using the and buttons on the front
of the dashboard and press the button on the
front of the dashboard. A window for resetting/
changing the filter/oil time will pop-up.
To reset the use time, move the cursor over
‘clear’ and press the button on the front of the
dashboard.
Use the and buttons to locate it at YES. Then, Figure 17
press the button to reset the operation hour.
Use the and buttons to locate it at NO. Then,
press the button to allow the pop-up window to
disappear without resetting the operation hour.
Figure 18
– The filter/oil use time shows the hours of

operation after initializing the engine. It begins
again with 0 hr after initialization the following
the replacement of filter/oil.
Figure 19
Figure 20

In order to change the filter/oil exchange period,
move the cursor over ‘change’ in the window for
resetting/changing the filter/oil time and press the
button on the front of the dashboard.
After the exchange period change screen
pops up, press the button on the front of the
dashboard and the exchange time will start
flashing.
Next, change the exchange period using the
and buttons on the front of the dashboard.
With the replacement period change being
Figure 21
completed, press the button to create a pop-
up window to select the period change.
Use the and buttons to locate it at YES. Then,
press the button to change the replacement
period.
Use the and buttons to locate it at NO. Then,
press the button to allow the pop-up window
to disappear without the replacement period not
being changed.
Filter/Oil Period Setup Table

Unit hour (Hr)
Replacement Period
Kind Minimum Available Change Value By
Basic Setup Value
Setup Value Step
Fuel Filter 500 100 50
Air Cleaner 2,000 1,000 50
Engine Oil Filter 500 100 50
Return Filter 1,000 100 50
Pilot Filter 500 100 50
Engine Oil 500 100 50
Hydraulic Oil 4,000 1,000 50
Coolant Water 2,000 1,000 50
Icon display
Filter/ ENG Oil Return Coolant

Fuel Filter Air Cleaner Filter Pilot Filter ENG Oil HYD. Oil
Oil Name Filter Water
Icon
EX1300858
Figure 22

If the remaining time for filter/oil replacement is
less than 10 hours, this pop-up window will be
created.
Press the ESC button or the button to allow
the pop-up window to disappear.
Figure 23
If the filter/oil replacement period is exceeded,

this pop-up window will be created. Press the
ESC button or the button to allow the pop-up
window to disappear.
WARNING
Do not use machine state menu when traveling or operating.
Figure 24
C. Machine Information
This is used to check the machine name, engine
type and attachment options.
the machine information, press the button to
access the machine information screen.
Click the ESC button to return to the previous
screen.
Figure 25
Figure 26

2. Machine Configuration
This is used when selecting the functions such as
attachment setting, camera setting.
Use the and buttons and move the cursor to see
a reversed display on the desired menu. Then,
press the button to select the menu.
Figure 27
Attachment Setting ←
→ Camera Setting
screen.
Figure 28
A. Attachment Setting (Optional)

In this menu, performance of the one way
and twoway can be set and set items can be
selected.
One Way Select ←
→ Two-way Select ←
→ One Way Setting
→Two-way Setting
←
screen.
Figure 29
How to Select Attachments (One Way/Two-way)

After proceeding to attachment setting items, one
way select and two-way select will appear.
Operate the and buttons to select one way/
twoway select. Then, press the button to move
the cursor to the selectable lists.
When the cursor is placed on the list, operate the
and buttons to move the cursor. Then, press
the button to select attachments to use.
Figure 30

When the selection is completed, the “Select
Complete!” pop-up window is displayed for 3
seconds, and the checkbox of the selected list is
updated.
The cursor can only be moved from the
selectable lists. The selectable list items at the
attachment setting are set as “Available” in the
use or non-use of attachments in the attachment
setting.
Figure 31
B. One Way Setting/Two-way Setting

The one way setting/two-way setting screen is
used to set up the use or non-use of attachments,
max.
engine limit, and max. attachment flow rate, etc.
At the machine configuration, when the cursor is
placed on attachment setting, press the button to
access the one way setting or two-way setting list
screen.
If the system is set up as the owner’s password Figure 32
locked, access the attachment setting list screen
by using owner’s password input screen. Owner Password
On the owner’s password input screen, press the

ESC button to return to the previous screen.
3 4 5 6 7 8 9 : ; <
Enter Owner Password
EX1301416
Figure 33
If you access the one way setting or two-way

setting list screen, the initial screen locates the
cursor at the top.
Figure 34

Operate the and buttons to select one way/
twoway.
Then, press the button on the list, operate the
the and buttons to move the cursor. Then,
press the button to select the attachments to
be set up and move to the attachment setting
screen.
On the attachment setting list screen, when
cursor is placed on the list, press the ESC button
to locate the cursor at one way/two-way at the
top. When the cursor is placed at one way/two-
way at the top, press the ESC button to return to Figure 35
the previous screen.
How to Set Up Attachments
Attachment setting items include attachment use,
max E/G limit, max flow (ATT), min flow (ATT),
and user setting max flow. Operate the and
buttons to locate the cursor. Then, press the
button to set up relevant items.
The cursor movement order goes like this:
1) One Way Setting
Attachment Use ← → Max E/G Limit ←→ Max Flow ←
→
Min Flow ←
→ User Setting Max Flow
2) Two-way Setting
Attachment Use ← → Max E/G Limit ←→ Max Flow ←
→ Figure 36
Min Flow ←
→ User Setting Max Flow
Attachment Use
The attachment use is designed to determine
whether relevant attachments are used or not.
If set up as enable, the relevant attachment can
be used.
If set up as disable, the relevant attachment
cannot be used.
Locate the cursor at the attachment use. Then,
press the button to set up enable/disable.
Note: If you select an attachment set up as disable, Figure 37
the pop-up window “Currently Selected
Item!” is displayed for three (3) seconds
disabling the setup.
Note: If an attachment is enabled it can be a
selectable attachment in the attachment
select.
Max Flow (Pump)
The max flow (pump) is the pump’s max. flow
rate discharged when using attachments. It
needs not to be set up by the user, and it is
automatically determined according to the max.
engine limit setup value.

Max Flow (ATT)/Min Flow (ATT)
The max flow (ATT) /min flow (ATT) can
be set up as the max/min flow rate value of
the attachment by the user according to the
attachment’s specifications.
For instance, if the relevant attachment’s use
capacity is 90 ~ 120 lpm (23.8 ~ 31.7 gpm), the
user can set up 120 lpm (31.7 gpm) for the max.
flow rate, and 90 lpm (23.8 gpm) for the min. flow
rate.
Operate the and buttons to move the cursor
to the max flow/min flow. Then, press the
button to convert into the editing mode.
At the editing mode, operate the and buttons
to determine the desired max flow/min flow.
Then, press the button to complete setup.
At the editing mode, press the ESC button to
disable the editing mode and the saving of the
setup value.
The change value by stage in the and buttons
operation is 10 lpm (2.6 gpm).
User Setting Max Flow
The user setting max flow is designed to set up
the flow rate segment of the attachment to be
used by the user.
Within the above setup max. flow rate (pump),
max.
flow rate (ATT), and min. flow rate (ATT) scope,
the user can set up the max. flow rate value of
the attachment to be used.
The setup method is the same as the above max
flow/min flow setup method. The change value by
stage in the and buttons operation is 10 lpm
(2.6 gpm).
When setting up all above items, the setup limits
are outlined as follows.

C. Camera Setting
The camera setting screen is designed to set up
various cameras “ON/OFF” and normal/mirror.
From the machine configuration, select camera
setting to access the camera setting list screen.
Figure 38
The camera setting list screen displays various

camera states (ON/OFF, NORMAL/MIRROR).
Select a camera and press the button to
access the relevant camera setting screen.
screen.
Figure 39
On the camera setting screen, set up the camera

state (ON/OFF, NORMAL/MIRROR).
Also, see the actual image of the currently
installed camera.
Figure 40
If a camera is not installed, the camera image

section is shown as a blue screen.
If the cursor is placed on “ON/OFF”, press the
button to set up “ON” ← → “OFF”.
Use the and buttons to locate the cursor at
normal/mirror. Then, press the button to set up
normal ← → mirror.
Figure 41

3. Gauge Panel Configuration
This menu is used to set up password, brightness,
default screen and time, and to input service phone
number. Use the and buttons and move the cursor
to see an reversed display on the desired menu.
Then, press the button to select the menu.
Password Setting ← → Brightness Setting ← → Default Screen
Setting ←→ Time Setting ← → Service Phone Number Setting
←→ Unit Setting ← → Notification Setting Press the ESC button
to return to previous screen. Figure 42
A. Password Setting
Password Setting
An owner passwords can be set.
By using the password setting function, you can
manage usage of operations and functions of the
machine.
Figure 43
1) Password entry Owner Password

When the password entry screen appears,
use the keypad to enter the password and
move to the settings screen.
The default password is “1111”.
How to enter the password 3 4 5 6 7 8 9 : ; <
Use the and buttons to select digits from Enter Owner Password
0 to 9 below, and press the button to input

the password. EX1301416
If the password is input incorrectly, use the
Figure 44
button on the lower right to delete the input
password.
IMPORTANT
If the password is input incorrectly three times in a row, you will
be redirected to the main screen and the system will not start for
the next 10 minutes.
Figure 45

2) Structure
Owner password settings include password
change, start-up restriction settings.
Figure 46
Password change
To change the owner password, select
password change with the keypad.
Figure 47
When the owner password has been

changed, “Password Set!” will pop-up.
Engine start-up setting Figure 48

By selecting “Engine Start-up” among item
settings the reentry time for password entry
upon start-up of the equipment can be set.
Note: No password for start-up of the equipment
is setby default.
a) Locked
Password is entered with each start-up.
b) 1 minute
If the system is started again within 1
minute from key-off after the password is
input, the password is not requested again.
c) 5 minutes
If the system is started again within 5 Figure 49
minutes from key-off after the password is
input, the password is not requested again.

B. Brightness Setting
On the Gauge Panel configuration screen, when
cursor is placed on brightness setting, press the
button to display the screen brightness setting
and camera brightness setting screen.
Figure 50
If you want to change the screen brightness,

select the screen brightness setting to display the
brightness adjustment screen.
Figure 51
Use the and buttons and adjust the brightness

of 0 - 100% at an interval of 10%.
The screen brightness when manufactured is set
as 80%.
screen.
Figure 52
If you want to change the camera screen

brightness, select the camera bri ghtness
setting to display the camera screen brightness
adjustment screen.
Figure 53

Use the and buttons to adjust the brightness
of 0 ~ 100% at an interval of 10%.
The camera screen brightness at the machine
release time is set as 80%.
screen.
Figure 54
C. Default Screen Setting

Sets the main screen display on the instrument
panel.
Figure 55
The initial screen shows basic information,

including the fuel level, coolant temperature and
hydraulic oil temperature.
Figure 56
Enter the “Default Screen Setting” menu and

select “Enable” for this function. Then, the main
screen shows the camera view next time the
starter switch is turned to the ON position.
Figure 57

Figure 58
D. Time Setting
cursor is placed on time setting, press the
button to access the time setting.
Use the and buttons and locate the cursor at
a target of change. Then, press the button to
change the target.
Figure 59
Use the and buttons to change numbers of

each item.
If the setup is completed, press the button to
store the setup details.
When the time setting is completed, locate cursor
to ‘SET’ and press the button.
If the SET button is not pressed, time setting
would not be completed.
screen. Figure 60
E. Service Phone Number Setting

On the Gauge Panel configuration screen,
when cursor is placed on service phone number
setting, press the button to access the service
phone number setting.
Figure 61

Use the and buttons and locate the cursor at
a desired number. Then, press the button to
input the number. If number input is completed,
press the key to enter the input phone
numbers.
Use the key and delete erroneously input
numbers.
Figure 62
When you input service phone numbers, if

warning/ alarm is issued, check the input phone
numbers in the pop-up window.
Figure 63
F. Unit Setting
cursor is placed on unit setting, press the button
to access the unit setting.
Figure 64
On the unit setting screen, change the units of

temperature, pressure, flow rate, and speed.
These figures at the machine release time are
set as below:
Temperature: °C
Pressure: bar
Flow rate: lpm
Speed: km/h
Figure 65

SPECIAL MENU
In this menu, many types of operating conditions and
functions can be accessed and displayed, including
the EPOS controller.
This menu is mainly used for machine testing and fault
diagnostics.
The special menu offers five submenus:
1. Monitoring.
2. Graph.
3. Failure Information.
4. Operating Hour Information.
5. Machine Configuration.
Entering/Accessing and Exiting/Escaping

Menus
Entering/Accessing Menus
When normal mode screen is displayed, if auto idle
selector button (1, Figure 66), up arrow button (2,
Figure 66) and camera mode selector button (3,
Figure 66) are pressed simultaneously for more than
3 seconds, normal mode screen (Figure 67) will be
changed to special menu screen (Figure 68).
Figure 66
Normal Mode Screen
Note: Normal mode screen display fuel gauge,

engine coolant temperature gauge, hydraulic oil
temperature gauge and engine speed (rpm).
Figure 67

Special Menu Screen
Note: Displayed language on the special menu screen

consists of Korean and English.
If any language except for Korean is selected
during language selection mode of main menu,
only English will be displayed on special menu
screen.
Figure 68
Exiting/Escaping Menus
1. If the ESC button is pressed the special menu
screen will be returned to the normal mode screen.
2. If this special menu is “ON” without any activity, for
more than 20 seconds, it will return to the normal
mode screen.
3. After the turning starter switch to “OFF” position,
turn it back to “ON” position, and the normal mode
screen displayed once again.
Special Menu Selections

Submenu Selection Method
Various submenus can be selected by use the and
buttons and moving the cursor to see a reversed
display on the desired menu. Then, click on the
button to select the menu.
Press the ESC button to return to the previous screen.
Entering Submenus: When cursor is located on
“Machine Info” of special menu screen, press the
button and the “Machine Info” will be displayed. Figure 69
Monitoring
1. Entering Submenus: When cursor is located on
“Monitoring” of special menu screen, press the
button and the “Monitoring” will be displayed.
2. Exiting Submenus: If the ESC button is pressed
display will be turned to previous screen.
Figure 70

Machine Analog Description
Analog Itemsl Display Remark

1. Front Pump Pressure MPa Front Pump Pressure
2. Rear Pump Pressure MPa Rear Pump Pressure
3. Boom Cylinder Pressure MPa Boom Cylinder Head Pressure
4. Alternator Voltage V Indicating Alternator Voltage
5. Battery Voltage V Indicating Battery Voltage
6. Engine Speed Control Dial Voltage mV Indicating Dial Voltage
7. WIF Sensor Voltage mV Indicating WIF Sensor Voltage
8. Fuel Level % Fuel Residual Quantity Radio of Fuel Tank
9. Hydraulic Oil Temperature °C Hydraulic Oil Temperature
10. TPS Voltage mV E/G Throttle Lever
11. Coolant Water Temperature °C Coolant Temperature
12. Power Shift P/V 1 mA Current in Pump Proportional Valve
13. Flow Control P/V mA Current in Flow Control Proportional Valve
Submenu Selections
Figure 71

Machine Digital Descriptions
Digital input item Mark Remarks

Lights up when output at alternator “R (I)” terminal is
1. Alternator
above 12 ±1 V.
Lights up when the boost button is “ON” with the work
2. Power Max Switch
mode selected to “BOOST”.
Lights up when the boost button is “ON” with the work
3. One Way Operator Switch
mode selected to “BREAKER”.
Lights up when the travel speed selector switch is set to “I”
4. Hi-Speed Select Switch-M
position.
Lights up when the travel speed selector switch is set to
5. Hi-Speed Select Switch-A
“II” position.
6. Working Lamp Switch Lights up when the light switch is set to “II” position.
7. One Way Select Switch Lights up when the selector switch is turned to “Breaker”.
8. Two Way Select Switch Lights up when the selector switch is turned to “Shear”.
9. Quick Coupler Lights up when the quick coupler switch is “ON”.
10. Pilot Cut Off Switch Lights up when the pilot cutoff switch is “ON”.
11. Air Cleaner Indicator Lights up when the air cleaner indicator contact is “ON”.
12. Pilot Filter ON / OFF Lights up when the pilot filter pressure switch is “ON”.
13. Return Filter Lights up when the return filter pressure switch is “ON”.
Lights up when the overload warning selector switch is
14. OWD Select Switch
“ON”.
15. Pedal Breaker Press Switch Lights up when the pedal pressure switch is “ON”.
16. Water in Fuel Lights up when WIF sensor is “ON”.
17. Preheating (Mechanical) Lights up when the preheting relay is “ON”.
18. Start up Switch Lights up when the starter switch is “START”.
19. Pressure Switch-Py Lights up when the pressure switch (Py) is “ON.”
20. Pressure Switch-Px Lights up when the pressure switch (Px) is “ON.”
21. Engine Oil Pressure Switch Light up when E/G oil pressure sensor is “ON”.
22. Relief Pressure S/V Lights up when the relief press up solenoid valve is “ON”.
23. High Speed S/V Lights up when the high-speed solenoid valve is “ON”.
24. Starter Relay Lights up when the starter relay is “ON”.

Submenu Selections
Figure 72

Graph
1. Entering Submenus: When a cursor is located in
“Graph” of special menu screen press the button
on panel and “Graph” screen is displayed.
2. Exiting Submenus: If the ESC button on panel is
pressed, this information screen will be returned to
previous screen.
Figure 73
Graph Data Monitoring

Real time monitoring of the selected data.
Figure 74
Figure 75
Graph Data Setting

User can be graph data setting.
The maximum limit of the graph data setting is 7.
Figure 76

Failure Information
“Failure Info” of special menu screen press the
button on panel and “Failure Info” Screen is
displayed.
2. Exiting Submenus: If the ESC button on panel is
previous screen.
Figure 77
* Real-time Failure: Current status of fault is

displayed.
* Failure Log: Memorized record of past fault is
displayed.
Figure 78
A. Current fault information

Current status of fault is displayed (Failure code,
fault contents).
When several faults are produced, fault information
can be checked on this information screen.
No: Number of currently occurring failure
Code: Display of current failure code
VXXyyy-zz: Method of displaying machine related
failure code
– V: Display of machine related failure code Figure 79
– XX: Display of failed part
– yyy: Serial number of failed part
– zz: FMI (Failure Mode Identifier) number
Eyyyyyy-zz: Method of displaying engine related
failure code
– E: Engine related failure code
– yyyyyy: Serial number of failed part
– zz: FMI (Failure Mode Identifier) number
* Method of displaying failed part of machine (VXX)
1) VCO: Communication related failure
2) VPV: EPPR valve related failure

3) VSV: Solenoid valve related failure
4) VRY: Relay related failure
5) VSP: Pressure sensor related failure
6) VSE: Sensor related failure except for pressure
sensor
7) VS5: 5V sensor related failure
8) VAL: Other failures.
Example)
VPV001-05: EPPR valve (A) current is lower than
normal current.
Description: Shows the description of the details of
machine failure.
Refer to the failure information code for unique
codes and FMI numbers.
This example shows one of two faults.
B. Past failure information

Memorized record of past failure is displayed
(Failure code, fault contents).
When several faults are produced, failure
information can be checked on this information
screen.
Note: “Count: xxx”: “xxx” means that totally counted

number of the same fault.
“Occurrence Time”: It indicates the period for
Figure 80
which machine has operated until a fault takes
place. (For more than two occurrences of the
same fault, until first occurrence time.)

Failure Code at Machine
GP Display GP Display Measurin Correct Value Severity
SPN Name FMI Remark
Code Description g Point Active Passive Level
Pump P/V (A) Pump P/V (A), CN1-10 Pump proportional
VPV001 05 3
Current Below Normal CN1-21 R= 13.5±2 Ω pressure reducing valve
Pump P/V (A) Pump P/V (A), CN1-10 (25°C (77°F)) Pump proportional
VPV001 06 3
Current Above Normal CN1-21 pressure reducing valve
Flow Control P/ Flow Control P/V (C), CN1-19 Flow control proportional
VPV007 05 3
V (C) Current Below Normal CN1-20 R= 13.5±2 Ω pressure reducing valve
Flow Control P/ Flow Control P/V (C), CN1-19 (25°C (77°F)) Flow control proportional
VPV007 06 3
V (C) Current Above Normal CN1-20 pressure reducing valve
Relief Press. Relief Press. Up S/V, Breaker/boost/ shear
UP S/V Current Below Normal selector switch has to be
CN1-1 selected as a boost
VSV002 05 3
CN1-11 function and the boost
switch on the right-hand
joystick is “ON” status
V = V_volt
Relief Press. Relief Press. Up S/V, Breaker/boost/ shear
UP S/V Current Above Normal selector switch has to be
CN1-1 selected as a boost
VSV002 06 3
CN1-11 function and the boost
switch on the right-hand
joystick is “ON” status.
Breaker Select Breaker Select S/V,
VSV013 05 3
S/V Current Below Normal CN2-8,
V = V_volt
Breaker Select Breaker Select S/V, CN1-8
VSV013 06 3
S/V Current Above Normal
B r e a k e r Breaker Operating S/V,
VSV001 05 3
Operating S/V Current Below Normal CN2-10,
V = V_volt
B r e a k e r Breaker Operating S/V, CN1-8
VSV001 06 3
Operating S/V Current Above Normal
Starter Relay Starter Relay, CN1-1 It has to be measured in
VRY007 05 3
Current Below Normal CN1-15 engine start up state.
V = V_volt
Starter Relay Starter Relay, CN1-1 It has to be measured in
VRY007 06 3
Current Above Normal CN1-15 engine start up state.
After Heat Relay After Heat Relay, CN1-16
VSV014 05 3
Current below normal CN1-04
V = V_volt
After Heat Relay After Heat Relay, CN1-16
VSV014 06 3
Current above normal CN1-04
Dial Dial,
VS5005 03 3
Voltage Above Normal CN3-16 V = 1.0 ±0.1 V
Dial Dial, CN3-17 V = 4.0 ±0.1 V
VS5005 04 3
Voltage Below Normal
E/G Control E/G Control Motor
VSE009 Motor Sensor 03 Sensor, Voltage 3
Above Normal CN3-13
E/G Control E/G Control Motor CN3-14
VSE009 Motor Sensor 04 Sensor, Voltage 3
Below Normal
Fuel Level Fuel Level Sensor,
VSE002 03 3
Sensor Voltage Above Normal CN3-7 Empty: 5±2 K Ω
Fuel Level Fuel Level Sensor, CN3-8 Full: 500 ±10 Ω
VSE002 04 3
Sensor Voltage Below Normal
Oil Temp. Oil Temp. Sensor,
VSE001 Sensor 00 Signal Above Normal 3
Range R = 2.45±0.25 k Ω
CN3-9 (25°C(77°F))
VSE001 03 CN3-10 R = 320±32Ω 3
Sensor Voltage Above Normal
(80°C(176°F))
VSE001 04 3
Water Temp. Water Temp. Sensor,
VSE010 Sensor 00 Signal Above Normal 3
Range
CN5-13
VSE010 03 CN5-14 3
Sensor Voltage Above Normal
VSE010 04 3
Engine Speed Engine Speed Sensor, CN5-15
VSE011 02 3
Sensor Incorrect Signal CN5-16

GP Display GP Display Measurin Correct Value Severity
SPN Name FMI Remark
Code Description g Point Active Passive Level
Front Pump
Front Pump Press.
VSP001 Press. 02 2
Sensor, Incorrect Signal
Sensor
Front Pump Front Pump Press.
CN3-1
VSP001 Press. 03 Sensor, Voltage Above V = IV 2
CN3-2
Sensor Normal
Front Pump Front Pump Press.
VSP001 Press. 04 Sensor, Voltage Below 2
Sensor Normal It has to be measured in
Rear Pump Rear Pump Press. engine stop state.
VSP002 Press. 02 Sensor, Incorrect 2
Sensor Signal
Rear Pump Rear Pump Press.
CN3-3
VSP002 Press. 03 Sensor, Voltage V = IV 2
CN3-4
Sensor Above Normal
Rear Pump Rear Pump Press.
VSP002 Press. 04 Sensor, Voltage 2
Sensor Below Normal
Alternator Alternator Potential,
VAL001 03 4
Potential Voltage Above Normal CN2-14 V = 27
Alternator Alternator Potential, CN1-8 ±0.1V
VAL001 04 4
Potential Voltage Below Normal
It is a compositeresistance
CN4-4 of CAN line. This value has
Gauge Panel Gauge Panel Comm.
VCO001 11 CN4-5 R = 60 ±5Ω 4 to be measured by
Communication Error
CN4-6 connected condition of
CAN line.
WIF Sensor, Signal
VSE004 WIF Sensor 01 3
Below Normal Range
WIF Sensor, CN3-19
Voltage Above Normal CN3-20
WIF Sensor,
Voltage Below Normal
Note:1. Active value: Starter switch has to be turned “ON”

Measuring points between component and wire
harness have to be connected.
2. Passive value: Starter switch has to be turned
“OFF” Measuring points between component and
wire harness have to be disconnected.
3. Measuring points are engine controller’s points
and passive value is each component’s value.
4. V_batt: Source power of equipment.

FMIs (Failure Mode Identifier)
FMI Description
0 Data Valid but Above Normal Operational Range - Most Severe Level
1 Data Valid but Below Normal Operational Range - Most Severe Level
2 Data Erratic, Intermittent or Incorrect
3 Voltage Above Normal, or Shorted to High Source
4 Voltage Below Normal, or Shorted to Low Source
5 Current Below Normal or Open Circuit
6 Current Above Normal or Grounded Circuit
7 Mechanical System Not Responding or Out of Adjustment
8 Abnormal Frequency or Pulse Width or Period
9 Abnormal Update Rate
10 Abnormal Rate of Change
11 Root Cause Not Known
12 Bad Intelligent Device or Component
13 Out of Calibration
14 Special Instructions
15 Data Valid but Above Normal Operating Range - Least Severe Level
16 Data Valid but Above Normal Operating Range - Moderately Severe Level
17 Data Valid but Below Normal Operating Range - Least Severe Level
18 Data Valid but Below Normal Operating Range - Moderately Severe Level
19 Received Network Data in Error
20 Data Drifted High
21 Data Drifted Low
31 Condition Exists

Information of Machine Operation
Accumulated operation hour of each mode and status
is displayed.
Operating Hour Information
“Operating Hrs” of special menu screen (Figure 81)
“Operating Hrs” screen will be displayed (Figure
82).
Figure 81
2. Operating Hours Screen
Figure 82
3. Exiting Submenus: If the ESC button (Figure 83) is

previous screen.
Figure 83

Information contents of operation hour
Items Information Contents Detection Method
Operation hours used Power Mode Power Mode status (Instrument panel)
Power Mode
are displayed. and Alternator signal (CN2-14) is “HI”.
Operation hours used standard Standard Mode status (Instrument panel)

Standard Mode
mode are displayed. and Alternator signal (CN2-14) is “HI”.
Economy Mode status (Instrument

Operation hours used economy
Economy Mode panel) and Alternator signal (CN2-14) is
mode are displayed.
“HI”.
Operation hours used auto idle Auto Idle Mode status (Instrument panel)
Auto Idle
status are displayed. and Alternator signal (CN2-14) is “HI”.
Operation hours used work mode is Work mode status (Instrument panel)
Working Mode
displayed and alternator signal (CN2-14) is “HI”.
Operation hours used travel mode Travel mode status (Instrument panel)
Travel Mode
is displayed and alternator signal (CN2-14) is “HI”.
Temperature of hydraulic oil is

classified 6 steps, and operation
hours of each step are displayed. The resistance delivered from
H y d r a u l i c O i l Under 30°C (87°F) temperature sensor of hydraulic oil is
Temperature 31 ~ 50°C (88 ~ 123°F) classified 6 steps, and operation hours of
Distribution (°C (°F)) 51 ~ 75°C (124 ~ 168°F) each step are displayed.
76 ~ 85°C (169 ~ 186°F) (Alternator output “HI” status)
86 ~ 95°C (187 ~ 203°F)
Over 96°C (204°F)
Temperature of coolant is classified
6 steps, and operation hours of
each step are displayed.
The resistance delivered from coolant
Under 40°C (105°F)
Coolant Temperature sensor is classified 6 steps, and
41 ~ 60°C (106 ~ 141°F)
Distribution (°C (°F)) operation hours of each step are
61 ~ 85°C (142 ~ 186°F)
displayed. (Alternator output “HI” status)
86 ~ 95°C (187 ~ 204°F)
96 ~ 104°C (205 ~ 221°F)
Over 105°C (222°F)

Example of Machine Operation Info Screen
Figure 84

Machine Configuration
1. Machine Configuration
A. Entering Submenus: When a cursor is located in
“Machine Configuration” of special menu screen
(Figure 85) press the button on panel and
“Machine Configuration” screen will be displayed
(Figure 87).
Figure 85
Entering service password is required when

accessing the menu.
Figure 86
B. Machine Configuration Screen (Figure 87).
Figure 87
2. Exiting Submenus: If the ESC button (Figure 88) is

previous screen.
Figure 88

Option Setting
“Option Setting” of special menu screen (Figure 89)
press the button on panel and “Option Setting
screen” will be displayed (Figure 90).
Figure 89
2. Option Setting
• Attachment Option
When a cursor is located in check box of one-
way or two-way, press the button on panel and
then, the check box light turns “ON”.
Figure 90
3. Program Update
Entering Submenus: When a cursor is located in
“Program Update” of special menu screen (Figure
91) press the button on panel and “Program
Update Screen” will be displayed (Figure 92).
Figure 91
Figure 92

4. Machine Information Delete
Entering Submenus: When a cursor is located
in “Machine Information Delete” of special menu
screen (Figure 93) press the button on panel
and “Machine Information Delete Screen” will be
displayed (Figure 94).
Note: When press the button on panel in the
selected menu the menu will be initialized.
- Delete Failure Log
- Reset Operation Hour Figure 93
- Gauge Panel Setting Reset
Figure 94
5. Version Information
Entering Submenus: When a cursor is located in
“Version Information” of special menu screen (Figure
95) press the button on panel and “Version
Information Screen” will be displayed (Figure 96).
Figure 95
Figure 96

E L E C T RO N I C H Y D R AU L I C
CONTROL SYSTEM (EPOS)
Control System Schematic
6 Main Relief V/V 6
7 11
12
3 8
P 14
13
4 5
N
9
17 10
P M
(Pump Control Signal)
(Potentiometer Signal)
(Engine Speed Sensor Signal)

(Drive Signal)
(Throttle Signal)
(Engine Throttle Control Signal)

15 2
20
(Throttle Command)
(Coolant Cater Temp. Signal)

(Switch Signal) 1
(Mode Select Signal)
AM
(Auto Idle Signal) H H
(Machine Information)
E F
C C
18
rpm
UP
WER
PO
S USB
21 (Sensor) 19
EX1501556
Figure 97

Reference Reference
Number Number
1 Instrument Panel 12 Solenoid Valve (Swing Priority)
2 EPOS Controller 13 Solenoid Valve (High Speed)
3 Engine 14 Travel Motor
4 Main Pump 15 Engine Throttle Controller
5 Aux Pump 16 Engine Control Dial
6 Control Valve 17 Engine Control Motor
7 Pressure Switch Breaker/Boost/Shear Selector
18
8 Pump Pressure Sensor Switch
19 Auto Travel Selector Switch
9 Engine Speed Sensor
Boost Switch
Electromagnetic Proportional 20
10 (Right Work Lever)
Pressure Reducing Valve
21 Sensor
11 Solenoid Valve (Boost)

POWER MODE CONTROL
6 6
P
4 5
9
17
10
3
15
16
FG021892
Figure 98
Reference Reference
Number Number
1 Power Mode Selector Button 9 9 Engine Speed Sensor
2 EPOS Controller Electromagnetic Proportional
10
3 Engine Pressure Reducing Valve
15 Engine Throttle Controller
4 Main Pump
16 Engine Control Dial
5 Aux Pump
17 Engine Control Motor
6 Control Valve

The power mode switch permits the selection of the
appropriate engine power depending on the working
condition. One of the two, Power Mode or Standard
Mode, setting can be selected.
When the engine start switch is turned “ON”, the
power mode is automatically defaulted to standard
mode. The desired mode can be selected by pressing
the select button on the instrument panel. When the
power mode is selected, the indicator lamp will turn
“ON” to display the selected mode.
The quantity of oil discharged by the pump and the
engine speed are determined by the mode selected by
the operator.
The pump output in each mode is determined by the
mode selection and is listed in the following table
Mode Economy Mode Standard Mode Power Mode

Output (%) Approximately 70% Approximately 85% 100%

Operation
1. Power Mode
This mode must 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 EPOS controller compares the target engine
speed with the actual engine speed and controls the POWER
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
FG015516
below the rated speed. When this occurs, the
controller senses this decrease and immediately Figure 99
reduces the 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 EPOS controller receives
engine speed signals from the engine control dial
and converts it to an operating signal current and is
then transferred to the pump’s E.P.P.R valve. Now
the E.P.P.R. valve converts the electric signal to the
corresponding control pressure and sends it to the
two pumps, adjusting the pump discharge volume
to the desired level.
A C
B D FG000580
Figure 100
Reference Reference
Number Number
A Engine Horsepower (hp) C Pump Discharge Volume (lpm)
B Engine Speed (rpm) Pump Discharge Pressure
D
(kg/cm2)

2. Standard Mode
Standard Mode is used for general work. When
this mode is selected it will reduce noise and fuel
consumption in comparison with Power Mode. The
EPOS controller compares the target engine speed
with the actual engine speed and controls the signal
to the E.P.P.R. valve which in turn varies the pump
output quantity and it is the same method with
power volume.
A C
D FG000581
Figure 101
Reference Reference
Number Number
D
(kg/cm2)
3. Economy Mode
Economy mode is used for light load work. When
this mode is selected, it will reduce noise and fuel
consumption in comparison with standard mode.
The current to the E.P.P.R. valve is shut off and
pump discharge volume is controlled by pump
regulator.
The EPOS controller compares the target engine
speed with the actual engine speed and controls FG013671
the signal to the E.P.P.R. valve which in turn varies

the pump output quantity and it is the same method Figure 102
with power volume.

A C
B D FG021897
Figure 103
Reference Reference
Number Number
D
(kg/cm2)
4 Operation in Case of Failure in the Control System (Aux Mode

Operation)
Though it is impossible to control current of the
E.P.P.R (Electromagnetic Proportional Pressure
Reducing) Valve controlling the discharge volume
of pump due to fault in control system, the machine
can be operated in the aux mode.
Upon turning “ON” the aux mode switch, the E.P.P.R
Valve controlling the discharge volume of pump
comes into contact with the aux mode resistor to let
current of a certain value flow. Now, the discharge
volume of pump follow the control by the pump
regulator, nearly at quantity roughly similar to that in
the standard mode.

P OW E R M O D E C O N T RO L -
CIRCUIT DIAGRAM
1
15A
CN7-2
CN7-16
26
CN7-3
2 26 15A 26 10A 26 10A
25
CN7-4
CN1-1
CN6-12 CN4-4 CN1-2
CN6-13 CN4-5 CAN
CN6-* CN4-6
CN5-15
30 CN5-16
CN1-8
24
29 CN1-9
15 CN1-3 II
10 CN1-4 A/I
23
14 CN1-5 W/M
17 CN1-6 O/H 22
12 CN1-10 1 10
5
P/V-(A)
4 P4 2
(+)
CN1-21 3
M 6
(-) 5 P5 4
(+) 8 P3 RETRACT
7 P2
16
1
(-)
6 P1 CW LOW
SIG CN3-16 2
CN3-13 GND CN3-17 3
CN3-14 HIGH
1
+(5V)
2
SIG
3
GND
9
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) FG002102
Figure 104
Reference Reference
Number Number
1 Instrument Panel 23 Aux Mode Resistor
2 EPOS Controller 24 Battery
E.P.P.R. Valve 25 Battery Relay
10 (ElectromagneticProportional 26 Fuse
Pressure Reducing)
16 16 Engine Control Dial
30 Engine Speed Sensor
22 22 Aux Mode Switch

WORK MODE CONTROL
6 6
3 12
P
4 5
17
15
16
FG021893
Figure 105
Reference Reference
Number Number
1 ECO Mode Selector Switch 6 Control Valve
2 Mode Selector Switch 12 Solenoid Valve
3 Engine 15 Engine Throttle Controller
4 Main Pump 16 Engine Control Dial
5 Aux Pump 17 Engine Control Motor
Depending on the working condition, ECO mode, can

be selected from the instrument panel.
When the engine starter switch is turned “ON”, the
work mode is automatically defaulted to digging mode.
Depending on the trenching mode selected, the control
valve solenoid adjusts the assignment of hydraulic oil
flow to each device on the equipment.

ENGINE CONTROL SYSTEM
(Feedback Signal)
16
P 2
3
15 M
(Command Signal) (Drive Signal)
10A
BATT. RELAY
9
10 AUTO IDLE COMMAND
5 4
17 OVER HEAT e-EPOS Controller

M
5 5 BATTERY
RETRACT 3 8 (+) 5V 1 1
5V (+) CW LOW
2 7 SIG 2 2
SIG
1 6 3 3
(-) (-) HIGH
12
17
15 FG014301
Figure 106
Reference Reference
Number Number
2 Engine Control Motor 15 Engine Throttle Controller
3 Engine 16 Engine Control Dial
When the engine control dial is moved, the output

voltage changes according to the dial position, and
this signal enters the engine throttle controller. The
engine throttle controller drives the motor according
to the dial command position by comparing the value
of dial voltage and the value of potentiometer voltage
which is used to observe the motor position (Feedback
signal) contained within the engine control motor.
The throttle controller stops the motor by cutting off
the motor drive current when dial command signal and
feedback signal are the same.
A cable is attached to the engine control motor and
the end of this cable is connected with the lever which
adjusts fuel injection of engine. Thus, this lever is
always driven with motor, so the speed of the engine
is controlled.

ENGINE CONTROL DIAL
1st STEP 7th STEP 13th STEP
( 10 ) ( 10 )
STOP STOP
(V)
5
4.0V
4
3 2.5V
2
2 1.0V
1
0 SETUP
1ST 2nd 7th 12th 13th
STOP STOP
VIEW ( POTENTIOMETER BOTTOM)

1 2 3
FG000866
Figure 107
Reference Reference
Number Number
1 Knob Potentiometer
2
(Variable Resistor)
The engine control dial has a built in potentiometer.

When the control knob is moved the output voltage
(through “2 and 3” terminals) will vary from the 5 V
supplied from the EPOS controller as shown in the
graph.

ENGINE CONTROL MOTOR
1 2 3
Circuit Diagram
P4
(GREEN)
P1(Gr) P2(P) P3(L) M

P5
(YELLOW)
(RETRACT) (GRAY) P1
ACCEL
(PINK) P2
P4(G) P5(Y) +
-
Vs
(5.0V)
(BLUE) P3 Vp
DECEL
(EXTEND)
FG014302
Figure 108
The engine control motor uses the DC motor and has

a potentiometer (a variable resistor) that is used to
observe the position within it. When the engine control
motor has unusual loads (in case of aging of control
cable or folded cable), the engine throttle controller
shuts off current to the engine control motor for
protecting the system in the event the engine control
motor does not drive. In this situation, it can drive
normally if the start switch is moved from OFF position
to ON position after removing the cause of unusual
loads.
Note: Change or Adjust the engine control motor in
accordance with adjustment way of engine control
device. Wrong adjustment causes unexpected
performance of the equipment.

ENGINE CONTROL CIRCUIT
DIAGRAM
1
15A
CN7-2
CN7-16
26
CN7-3
2 26 15A 26 10A
CN7-4
CN1-1 25
CN6-12 CN4-4 CN1-2
CN6-13 CN4-5 CAN
CN6-* CN4-6
CN1-8 24
15 CN1-9
15 CN1-3 II
10 CN1-4 A/I
14 CN1-5 W/M
17 CN1-6 O/H
12
17 31
4 P4 Py
(+)
CN2-15
M
(-) 5 P5 Px
CN2-16
(+) 8 P3 RETRACT
7 P2 32 16
1
(-)
6 P1 CW LOW
SIG CN3-16 2
CN3-13 GND CN3-17 3
CN3-14 HIGH
1
+(5V)
2
SIG
3
GND
9
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)
FG002106
Figure 109
Reference Reference
Number Number
1 Instrument Panel 24 Battery
2 EPOS Controller 25 Battery Relay
15 Engine Throttle Controller 26 Fuse
16 Engine Control Dial 31 Pressure Switch (Py)
17 Engine Control Motor 32 Pressure Switch (Px)

AUTOMATIC DECELERATION
CONTROL (AUTO IDLE CONTROL)
16 15
3
1
31
32
FG021894
Figure 110
Reference Reference
Number Number
1 Auto Idle Switch 15 Engine Throttle Controller
2 EPOS Controller 16 Engine Control Dial
3 Engine 31 Pressure Switch
32 Pressure Switch
If the machine is idling without the controls being

operated or is waiting for a dump truck the engine
speed is automatically lowered. Once the controls are
operated and work is being started the machine will
be restored to the previous settings. As a result, noise
and fuel consumption will be reduced. This function
can be selected or cancelled through the Auto Idle
Selector Switch on the instrument panel.
The initial setting at start-up is with this switch in the
select position. Approximately 4 seconds after this
function is selected, if all work levers are in the neutral
position, the EPOS controller compares the automatic
reduction signal with the signal set by engine control
dial. The lower of the two signals is selected, the
EPOS controller sends a signal to the engine controller
to control the engine speed.
The neutral status of the machine is detected by the
two pressure switches in the control valve. When the
work levers are in the neutral position, the switch is in
the “OFF” position.

ENGINE OVERHEAT
PROTECTION SYSTEM
Engine
6 6
4 4
1
1 2
AM 5 7
H H 8
33
4
E F
C H C H
E F
10
C C
9
3
rpm
s 1 2 3 4 5
USB
10
6 7 8 9 0
11
12
EX1300989
FG021895
Figure 111
Reference Reference
Number Number
1 Instrument Panel E.P.P.R. Valve
2 EPOS Controller 10 (Electromagnetic Proportional
Pressure Reducing Valve)
3 Main Pump
4 Aux Pump
33 Warning Buzzer
6 Control Valve
When the engine coolant temperature increases to

over 107°C (225°F), the gauge panel detects it from
the sensor mounted in the coolant line of engine and
send a signal to the EPOS controller and turns on the
buzzer simultaneously.
The EPOS controller returns an overheat signal to
the engine throttle controller and changes from power
mode to standard mode. The engine speed is then set
to a low speed by the engine throttle controller. That
is, when the engine coolant temperature increases, a
warning buzzer turns on, power mode is changed to
standard mode and engine speed set to a low speed.
When coolant temperature falls below 95°C (203°F),
normal operation will resume.

POWER BOOST MODE
Operation
6 6
Main Relief v/v
11
4 4
5
2
20
(Button Signal)
1
1 2
AM 5 7
H
E F
H 8 4
C H C H
UP
WER E F
PO C C
9
3
rpm
18
USB
FG021896
1 2 3 4 5
10
6 7 8 9 0
6
11
Figure 112 12
EX1300989
Reference Reference
Number Number
1 Instrument Panel 11 Solenoid Valve (Boost)
2 EPOS Controller Breaker/Boost/Shear Selector
18
4 Main Pump Switch
Power Boost Switch
5 Aux Pump 20
(Top of Right Work Lever)
6 Control Valve
The Power Boost function is used to temporarily

increase the main relief pressure to enhance
excavation ability. When the breaker/boost/shear
selector switch is set to “BOOST” and the power
boost button on the center of the right-hand work
lever (joystick) is pressed during work, the EPOS
controller will activate the power boost solenoid valve
and increase the relief valve pressure from 330 - 350
kg/cm2 (4,700 - 5,000 psi). The excavation ability is
increased by approximately 6%.
When the power boost function is in activated, a power
boost symbol appears on the information display
department of instrument panel.
Note: Do not use this switch for more than 10 seconds.

Power Boost Control - Circuit Diagram
1
15A
CN7-2
CN7-16
26
2 26 15A 26 20A
CN7-3 25
CN7-4
CN1-1 18
CN7-4 CN4-4 CN1-2
CN7-5 CN4-5 CAN
CN7-6 CN4-6 PST SHEAR PRESS BREAKER
TML 1 0 2
24
11 10
3
(C4) 14
CN1-11
13
6
CN2-2 (POWER MAX)
16
CN1-8 12
CN1-9
6 3
(Center)
(POWER MAX / BREAKER)
20
(CN2) (CN1)
FG000586
Figure 113
Reference Reference
Number Number
1 Instrument Panel Power Boost Switch
20
2 EPOS Controller (Top of Right Work Lever)
24 Battery
11 Solenoid Valve (Pressure Up)
Breaker/Boost/Shear Selector 25 Battery Relay
18
Switch 26 Fuse

AUTOMATIC TRAVEL SPEED
CONTROL
6 6
7
3
8 8
14
13
5
4 4
2
16
19
FG002110
Figure 114
Reference Reference
Number Number
1 EPOS Controller 8 Pump Pressure Sensor
3 Engine 13 Solenoid Valve (High speed)
4 Main Pump 14 Travel Motor
5 Aux Pump 16 Engine Control Dial
6 Control Valve Selector Switch For
19
7 Pressure Switch (Py Port) AutomaticTravel
If the automatic travel speed control switch is set to

the “OFF” position, the travel motor will run in the
I-speed (low speed) range. If the selector switch is
set to the “I” position, the travel motor will run in the II-
speed (high speed) range. If the selector switch is set
to the “II” position, the EPOS controller will monitor
the main pump discharge pressure and automatically
select the “ON” - “OFF” status of the II - speed travel
solenoid valve based on the travel load. The travel
speed is changed between the I-speed and the II-
speed mode.
The travel load is monitored by the two pressure
sensors in the discharge lines of the front (upper)
and rear (lower) pumps. When the travel load is high
(pressure over 300 kg/cm2 (4,300 psi) the solenoid
valve is turned “OFF” and I-speed (low) is selected. In
the case when the travel load is low (pressure under
160 kg/cm2 (2,280 psi), the solenoid valve will be
turned “ON” and the II-speed will be selected. But,
if the engine speed control switch dial is set below
approximately 1400 rpm, the travel speed will be set
to I-speed mode.

Automatic Travel Speed Control - Circuit
Diagram
26
15A
2 26 15A
26 15A
26 10A
CN1-8
CN1-9 CN1-1
+ CN1-2 25
8 SIG CN3-1
CN3-2
- 13
+
(C3) 24
CN1-12
9 SIG CN3-3
CN3-4
15 -
19
0
15 CN1-3 3 2
CN2-4 I
10 CN1-4 II
14 CN1-5 0
I 5
17 CN1-6
CN2-5 6 II
12
7 8
4 P4
(+)
M
(-) 5 P5
(+) 8 P3 RETRACT
7 P2 16
(-)
6 P1 CW LOW
CN3-16 2
SIG
CN3-13 CN3-17
GND 3
CN3-14 HIGH
1
+(5V)
2
SIG
3
GND
9
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)
FG002111
Figure 115
Reference Reference
Number Number
2 EPOS Controller Selector Switch for Automatic
19
8 Pressure Sensor (Front Pump) Travel
24 Battery
9 Pressure Sensor (Rear Pump)
25 Battery Relay
13 Solenoid Valve (High speed)
26 Fuse
16 Engine Control Dial

HOW TO ADJUST THE ENGINE
CONTROL DEVICE
The engine speed adjustment is done following order.
1. High Idle speed adjustment
A. Set to the H-mode by pushing the power mode
switch after turning the start switch ON.
B. Set the engine control dial to MAX position to
make #01 motor cable pulled up initially.
C. Adjust #01 motor cable in #32 bracket to make
the
engine governor lever reach the high stopper.
2. Low Idle speed adjustment
A. Set the engine control dial to MIN position to
make #01 motor cable lengthened maximum.
Now, the stroke of cable is approximately 37mm.
B. Check whether the engine governor reaches
to the low stopper and the cable hang down
properly.
C. If the lever doesn’t reach the low stopper, move
the #01 cable to the hole located one step down
at the lever. In contrast, if the cable hangs down
too much, move the #01 cable to the hole which
is located on step up at the lever and repeat 1), 2)
D. After doing above action, turn the adjustment nut
of #01 motor cable 2/3~1 rotate and make it pull
up 1~1,025mm and finish the adjustment.
3. Adjustment speed of automatic deceleration and
standard mode
A. Adjust the regulation speed with the following
adjusting method (or opposite direction) after
removing the rub bushing attached to the cover
of engine throttle controller. (clockwise →
increase speed, counterclockwise → decrease
speed)
B. Let the engine control dial be in max position, set
up the select condition of power mode and auto
idle following chart, respectively and set speed
by adjusting screws of variable resistors (VR1,
VR2).
The established speed is written on the name
plate attached on the cover of throttle controller.
Dial position and set the mode

Variable
Section Power mode Auto Regulated engine speed
Resistor Dial
Switch Idle
Set auto MAX speed ON (Select the Written on the name plate
VR1 ON
deceleration speed position power mode) of throttle controller
Set standard mode MAX speed OFF (select the Written on the name plate
VR2 OFF
speed position standard mode) of throttle controller

1 2
VR1
MOTOR
VR2 SIGNAL STATUS R G Y VOLTAGE
VR3
VR4
R G
Y
- ENGINE RPM SETTING -
RPM VR1
ENGINE THROTTLE CONTROLLER
RPM VR2
PART NO. K1003111
RPM VR3 SERIAL NO.
VR4
RPM WHEEL
TYPE
ONLY
FG002112
Figure 116
Reference Reference
Number Number
VR1 (set auto deceleration 3 Name plate
1
speed)
2 VR2 (set Power mode speed)

ENGINE THROTTLE CONTROLLER
When the rub cap on the upper part of controller is
removed, three LED are shown in it.
LED works following chart with the condition of
equipment (start switch is OFF).
Input signal of LED sign Control motor terminal

State
throttle controller Red Green Yellow voltage
Dial voltage < motor Control motor is working on
X ◎ ○ Approximately + 24(V)
potentiometer voltage (RPM is increasing)
Dial voltage > motor Control motor is working on
◎ X ○ Approximately - 24(V)
potentiometer voltage (RPM is increasing)
Dial voltage = motor
Stop state ○ ○ ○ 0 (V)
potentiometer voltage
Motor overload
- X X ○ 0 (V)
(cut off current)
Error on controller voltage
- X X X 0 (V)
source (is low or no input)
WARNING
1. “ ◎ ” turn on brightly, “○” turn on, “X” turn off.
2. Measured terminal of motor voltage, 4(+), 5(-) terminal of
throttle controller.
3. Yellow LED is used to show the Power on.
4. In motor overload current cut off mode, remove the cause
of overload, and turn the start switch off and then on normal
work should resume.

SELF-DIAGNOSTIC FUNCTION
EPOS Controller
The system operation status and malfunction codes
can be checked through the display on top of the
EPOS controller box the rear cover behind the
operator’s seat.
1 2
4 3
FG000588
Figure 117
Reference Reference
Number Number
1 Upper Digit Power Monitor (Stays “ON”
2 Lower Digit 4 While Power Is In Normal
Engine Speed Monitor LED Range,)
3 (Flash Interval Increases With
Engine Speed.)
1. Power Monitor
This LED is turned “OFF” when the input voltage to
the EPOS controller is below 18.5 ± 1 V or above
32.5 ± 1 V. Stays “ON” while in normal range.
2. Engine Speed Monitor
This LED light flashes according to the engine
speed. The flashing interval is proportional to the
engine speed.
3. Normal Operation Display Readout
Display Readout
Mode Selection Operation Status
Upper Digit Lower Digit
Normal Operation
Power Mode
Power Mode
HAOH340L HAOH370L
Normal Operation
Power Mode Standard Mode
Standard Mode
HAOH350L HAOH370L
Normal Operation
Economy Mode
Economy Mode
FG013637 HAOH370L

4. Communication Monitor
What are shown in the 7-SEGMENT LED are same
as those in the Error Codes.
Error Code Indication Code Fault Location

V201 01 Communication error in instrument panel.
V202 02 Communication error in engine controller.

OIL-WATER SEPARATOR ALARM
Running
Equip with oil-water separator and oil-water separator
sensor. This sensor can effectively monitor the water
level of filter element and instrument board will alarm
when the water level is too high, to remind customers
Figure 118
of drainage and maintenance to protect the fuel
system and engine not being damaged.
1. Working principle: This sensor is installed on the
lower part of the oil-water separator. When moisture 24V
of fuel oil of oil-water separator sensor reaches the

height of two-electrode, the two-electrode will occur Out
电子判断
short circuit by using the conductivity of water. At 传感器

EPOS
this time, the EOPS receives the voltage signal GND
corresponding to sensor and controls the instrument

电极
board to make water level warning lamp be on.

2. Warning conditions:
PIN A and C: 24V
Figure 119
PIN B and C: 0.9-1.1V no-alarm: 3.0-3.8V
PIN C: 0V
When meeting the above conditions, the instrument
board alarm lights will be on, and buzzer will give
an alarm.
3. Reference of detection method:
- Key switch is in ON position, inspect whether the
alarm condition voltage is satisfied.
- S e n s o r B a n d C t e r m i n a l s ’ r e s i s t a n c e
measurement (normal value: 27 KΩ).
- Unplug the two electrodes connecting the sensor
terminal. It will be alarmed under the normal
condition.
Ｎｏｔｅ： Special menu of instrument board can be taken Figure 120
the sensor voltage value Please use the above
benchmark data for the actual fault phenomena.

SELF-DIAGNOSTIC FUNCTION
EPOS controller
Operational status and fault code of system can be
inquired through the displayer on the top of the EPOS
controller box at the rear cover behind the driver’s
seat.
1 2
4 3
Figure 121 FG000588
S/N Description
1 Up digit
2 Down digit
3 Monitor of engine speed
4 Power supply monitor
5 Information transfer indicator
● Power supply monitor

The light is on when the input voltage of EPOS
controller reaches 18.5±1~ 32.5±1V, and the light is
off under other circumstances.
● Monitor of engine speed
The higher the value /1042 (HZ) reflecting the

engine speed sensor is, the faster the engine speed
is, and the faster the lower light flashes, which is a
proportional relation. When the engine stops, the
light is still on but not flashes any more.
● Information transfer indicator
When the information transfer between instrument

boards is normal, the light will flash.

Normal Operation Display
Display
Mode Operation conditions
High level Low level
Normal operation
P
Power mode
HAOH340L FG018940
Normal operation
Power Mode S
Standard mode
FG018938 FG018940
Normal operation
E
FG018940
Economic mode
HAOH350L
Normal operation
Excavation
Mining mode
FG018940 HAOH370L
Working mode
Lifting Normal operation
(Optional) Lifting mode
FG018940 FG018939
Communication monitoring
EPOS LED window code is consistent with the fault
code of instrument board. Please refer to the fault
code of instrument board. For example:
Fault code EPOS code Reason

Communication error of
V201 01
instrument board
Error of ECU
V202 02
communication

SOUND SYSTEM
Add USB socket in the sound system. Users can
choose MP3 audio function, and USB is set at the
right control console.
Note: U S B c a n b e u s e d f o r t h e u p g r a d i n g o f
instrument board. For maintenance, please
contact Doosan PS department in advance.
Figure 122
Switch Test terminal Measured value Action

Power supply button 4.36 士 0.2V Audio on
1.24 士 0.2V Volume up
3-4
0 ± 0.2V Volume down
Option button 2.49 ± 0.2V Selected waveband

WIPER SYSTEM
(Continuous mode)
(Intermittent gear mode)
(Intermittent gear 2 mode)
(Cleaning mode)
Socket number
(Wiper motor)
Figure 123
1. Storage battery 2. Storage battery relay 3. Safety device

4. Safety case 5. Wiper motor 6. Wiper controller
7. Wiper control panel 8. Cleaner 9. Wiper cut-off switch
10. Light switch

1. Successive action
● Action of wiper motor
Press and hold the switch on wiper control

panel (7), the voltage of No. 5 terminal of wiper
controller (6) drops from about 5.5±0.5V to
0±0.5V. Meanwhile, the current flows through
No. 3 terminal of wiper controller(5)-No. 2 and
No. 4 terminals of wiper motor (6)-No. 4 terminal
of wiper controller, and wiper motor (5) acts
continuously. (Action angle of wiper: 80°)
● Wiper motor stops.
Press the successive action switch of wiper

control panel (7) again, the voltage of No. 5
terminal of wiper controller (6) rises from (0±0.5V)
to about (5.5±0.5V).
However, after No. 6 and No. 5 terminals of wiper
motor (5) contact with each other, No. 6 terminal
of wiper controller (6) is power supply voltage
and wiper controller (6) makes wiper motor (5)
act successively. After No. 6 and No. 1 terminals
contact with each other, and if the No. 7 terminal
voltage of wiper controller (6) is recognized, the
current of wiper controller (6) flows through No.
4 terminal of wiper controller - No. 4 and No. 2
terminals of wiper motor (5) - No. 3 terminal of
wiper controller (6), which drive wiper motor (5)
rotate in an opposite direction.
Wiper motor (5) rotates in an opposite direction,
connect the cam switch joint on No. 6 terminal of
wiper motor (5), enter into the isolation area of
cam board, No. 6 and No. 5 terminals of wiper
motor (5) are disconnected, and wiper motor (5)
stops.
When wiper motor (5) stops, move the connection
rod of wiper motor (5) and the wiper, the stop
switch on the right side of cab is started. (Action
angle of wiper: 90°)
2. Intermittent action
● Intermittent gear 1 (interval 3 seconds)
Press No. 1 intermittent action switch of wiper

control panel (7), the voltage of No. 8 terminal of
wiper controller (6) drops from about 5.5±0.5V
to 0±0.5V. Meanwhile, the current flows through
No. 3 terminal of wiper controller (6) - No. 2 and
No. 4 terminals of wiper motor (5) - No. 4 terminal
of wiper controller (6), and wiper motor (5) stops
for 3 seconds after one action. This mode is
repeated.

● Intermittence gear 2 (interval 6 seconds)
Press No. 2 intermittent action switch of wiper
control panel (7), the voltage of No. 10 terminal
of wiper controller (6) drops from about 5.5±0.5V
to 0±0.5V. Meanwhile, the current flows through
No. 3 terminal of wiper controller (6) - No. 2 and
No. 4 terminals of wiper motor (5) - No. 4 terminal
of wiper controller (6), and wiper motor (5) stops
for 6 seconds after one action. This mode is
repeated.
● Intermittence actions stop
Press No. 3 intermittence action switch of wiper

control panel (7), and the wiper motor stop when
the action finishes.
Note: When the wiper cut-off switch is in the position
of ON, wiper system does not work.

AIR CONDITIONING SYSTEM
Basic working principle
Definition of air conditioning
Air conditioning on the excavator combines heating
and cooling, with the functions of adjusting air humidity
and fresh air.
Main components include: Ventilation device for
circulating air, heater for heating, evaporator for
cooling and dehumidification, and filter for purifying
air.
Controlling temperature
The air blown out from the blower fan flows through
the evaporator generating cold air and the heater
generating warm air by engine warm water, by which
the temperature can be adjusted.
Interior and exterior air switch
The re-cycle of indoor air cycle and fresh air from
outdoor air is controlled by the switch air door at the
entrance of fan, which mixes them and makes them
act with each other.
1. Re-cycle: Use it when the room temperature needs
to be decreased or increased rapidly, or when the
outdoor air has unpleasant smells.
2 Fresh air: Use it when outdoor fresh air is needed
(ventilation) or when fog is formed on windows due
to heating air.
Temperature control
Air conditioning can maintain a certain level of room
temperature, avoid fog, expel humidity and ensure
room comfort.

Basic Structure
Figure 124
1. Air conditioning unit (cooling/heating) 7. High-pressure pipe (1)

2. Condenser 8. High-pressure pipe (2)
3. Compressor 9. Ambient temperature sensor
4. Drying bottle 10. Sun load sensor
5. High-pressure pipe 11. Air conditioning control panel
6. Low-pressure pipe

Principle of Cooling Cycle Action
Figure 125
High-pressure and high-temperature gas 1 . Evaporator

Mixture of high-pressure and high-temperature gas and liquid 2. Expansion valve
3. Condenser
High-pressure and medium temperature gas 4. Condenser fan
Mixture of low-pressure and low-temperature liquid and gas 5. Compressor
Low-pressure and low-temperature gas 6. Air blower
7. Drying bottle

Electrical System 8-92
Name of
product Compressor Condenser Expansion valve Evaporator
Items
Condense low-temperature and Heat dissipates and
Pressure drops, and
low-pressure gas refrigerant temperature drops, pressure
Function temperature drops Absorb heat, status changes
into high-temperature and keeps unchanged, status
accordingly
high-pressure gas changes
Liquid Liquid
Gas Gas Gas Liquid Liquid Gas
gas gas
Refrigerant status
Thermo-compression Isobaric change Thermal expansion Isobaric change
Hot air Expansion valve
Cold air (for cab)
Cycle
composition Evaporator
Drying
bottle
Condenser
Temperature
change
Blower fan
(Isobaric
DX140AF/DX140LCA
change)
Pressure (Isobaric
change change)
Air Conditioning System Test
Filter element position and inspection
To ensure the air freshness in cab, the air conditioning
filter element is installed.
Filter element is cleaned once for 500 hours.
1. Inspection key points of filter element for internal
circulating air.
It is installed behind the cab. Press the right and
left button on the top of filter element, and push it
Figure 126
forward, it will be opened.
2. Inspection key points of filter element for external

circulating air.
Open the knob behind the left door of cab, and
open the cover.
Figure 127
Dismantle the filter element installed on the cover, and

clean with compressed air. Close the outer cover, twist
on the knob finally.
Figure 128

Inspection Methods of Each Part of Air Conditioning
1. Drying bottle
After the air conditioning is started for five minutes,
touch the drying bottle with hands.
If the whole drying bottle is at the same temperature, it
means a normal work.
If a part of drying bottle is cold, while the other part
is hot, it means refrigerant is muddy and blocked.
(Replace with new products)
2. Inspection methods of electromagnetic clutch
Disconnect the line between switch and
electromagnetic clutch.
When connecting the positive (+) of storage battery to
clutch with a long wire, it is normal if the clutch makes
a sound of “Chuu”.
3. Inspection methods of blower motor
Disconnect the wire connecting plug via motor,
connect the ampere meter (-) to one end of wire of
motor, and connect the other end of wire to power
supply (+).
The reason is that the disconnected wire has
resistance, which will drive the motor to rotate
backward slowly.
4. Inspection methods of evaporator
If the evaporator outlet does not expel air out, the
motor may be malfunctioning, or there is no input of
power supply. If the wind is strong, but not cold, it
might be due to the refrigerant cycle.
● When the elevator is frozen
confirm whether there is frosting, or whether the
refrigerant is not enough, or whether the filter
element is blocked.

Linkage Inspection and Maintenance Guideline of Air
Conditioning and Compressor
1. Features of compressor
When the compressor runs at a high speed, the
compression action generates, which will thus cause
noise and vibration. With the increase of engine
speed, the noise will become larger.
2. Precautions at refrigerant recycle/addition
● During the recycle/addition, the high and low
hose connections of double meter valve shall be
connected correctly.
● During the addition, the vacuum status shall be
maintained sufficiently.
● During the addition, condensed engine oil needs
to be added - addition amount 20~30g

3. Precautions at replacement of compressor
● Compressor cannot be placed upside down:
Oil will flow out, and at the emergent operation,

overflow valve will be damaged, and its duration
will be influenced.
● Before installing high and low hose, manually
twist the clutch for 5-6 times, and lubricate the

compressor inside with engine oil to make it start
easier.
● When replacing the compressor, it can be
replaced after fully confirmation: In case of

abnormalities at any other parts, the compressor
may be replaced.
4. When the air conditioning makes a noise during the
operation
● Confirm whether the noise will become larger with
the increase of vehicle load during the operation

of air conditioning.
● Confirm whether the amount of refrigerant is not
sufficient or overmuch, the compressor may make

a noise.
● When replacing the air conditioning accessories,
the engine oil must be refilled for 20~30g.

● After recycling the refrigerant and re-adding it,
a full vacuum status must be maintained before

filling the engine oil.
(When replacing a compressor, there is no need to
refill the compressor engine oil. When the compressor
is accepted to the warehouse, the inside has been
sealed into engine oil. )

System Vacuumization
If the refrigerant in the device is not sufficient, requiring
refilling of refrigerant, the air conditioning system must
keep a vacuum status.
Vacuum work is to remove air and humidity in the
unit. After all parts have been replaced, the vacuum
pumping must be lasted for at least 15 minutes.
After system maintenance or parts disassembly and
inspection, the vacuum work must be lasted for at
least 30 minutes.
1. When the engine stops, make the vacuum pump
work and open the high and low valve of double
meter valve.
2. After 10 minutes, confirm whether the scale value
of low pressure gauge is lower than Okg/ cm2. If it
is not a negative value, it must be system leakage,
and it must be maintained according to the following
procedures.
● Fill appropriate quantity of refrigerant to the
system with refrigerant filler.
● Inspect the leakage status of exhaust with
leakage detector to find the leakage parts and

repair.
● Discharge the refrigerant again and vacuumize
the system. If the leakage parts cannot be found,

continue to vacuum the system.
● Restart the vacuum pump.
● Maintain the scale of double meter valve at a
vacuum status of Okg/cm2.

● To maintain the low pressure gauge scale of
double meter valve at Okg/cm2, vacuumize the

system for about 15 minutes.
● After 15 minutes of vacuum work, close the
pressure valve at both sides. Maintain this status

before filling the refrigerant.

Inspection and fault determination of air conditioning
1. Fault cases of air conditioning
● No cold air or bad refrigeration effect.
● Noisy or abnormal noise.
● Unpleasant smell at the air outlet.
2. General inspection conditions

● Engine operates 2-3 minutes at the maximum
speed (about 1,800-2,000rmp).

● When the fan is at the maximum speed, switch on
the air conditioner.

● Adjust the temperature to the minimum, and
operate for more than 20 minutes.

Absorption test content:
1) Whether the compressor works normally.
2) Whether the fan works. If there is no abnormalities,
determine the air temperature at outlet and high
and low pressure of double meter valve.
3. Inspection methods of refrigerant status
Air conditioning conditions Normal Slightly abnormal Quite abnormal

High-pressure hot, low- High-pressure warm, low- No temperature difference
High and low pressure
pressure cold, large pressure slightly cold, little between high pressure
hose connection
temperature difference temperature difference and low pressure
Partially severely
Connecting pipe status Normal, no damages Partially damaged
damaged

4. Reasons for poor Refrigeration Effect
Phenomena Reason Judgment

Small air volume or no air volume Fan motor is normal. 1) Air filter is contaminated.
Low air volume 2) Air vent pipe falls off
3) Evaporator freeze
●Fault of control panel
●Insufficient refrigerant
●Air volume insufficient
Fan motor does not work. 1) Motor is disconnected.

2) Control module is of poor contact.
3) Resistance short-circuit
4) Fuse short-circuit
Normal air volume Condenser operates normally. 1) Confirm refrigerant volume
2) Normal pressures of high and low
pressure
High pressure: 15-17kg/cm2
●
Low pressure: 1.3-2.0kg/cm2

●
● External air temperature: 30-35℃
● Engine 1500RPM
Compressor does not work 1) Circuit break

normally. 2) Pressure switch does not work
normally
3) The compressor clutch is burne

5. H igh and low pressure test of air conditioning
system
● Normal conditions
The cold air recycles normally; the pressure
displayed on the double meter valve inhales air at
a temperature of 30~35℃ by the fan; the engine
speed is 2,000rpm, the most cold gear; under the
fast speed of fan, the low pressure side is about
1.5-2.0kg/cm2, and the high pressure side is
about 14.5-15kg/cm2.
● Insufficient refrigerant
● Low pressure: 0.8kg/cm2 (low)

A Pressure 2
● High pressure: 8-9kg/cm (low)
● Insufficient cold air (air outlet is almost not cold)

B Condition
●Refrigerant leakage in air conditioning system
C Reason ● Expansion valve is blocked
● Drying bottle is blocked
● Refrigerant is not sufficient or leaked

D Judgment
● Repair the leakage part of refrigerant, or refill refrigerant
E Handling method
● Repair or replace expansion valve and drying bottle
● Excessive refrigerant
● Low pressure: 2.5kg/cm2 (high)
A Pressure 2
● High pressure: 20kg/cm (height)
● Poor status of refrigerant

B Condition
C Reason
● Poor cooling performance of condenser
D Judgment ● Poor cooling performance of condenser: Condenser block or condenser
fan fault

● Air sneaks into the air conditioning system.
● Low pressure: 2.5kg/cm2 (high)
A Pressure 2
● High pressure: 23kg/cm (height)
● Poor refrigeration effect (low pressure pipe is not cold)

B Condition
C Reason ● Air sneaks into the air conditioning system.
D Judgment ● Vacuumization in the air conditioning system is not complete.
● Replace drying bottle
E Measures ● Inspect the oil quantity of compressor refrigerant oil
● Vacuumize again and fill refrigerant
● Water flows into the air conditioning system

● Low pressure: 50cmHg~1.5kg/cm2 (slight or severe vibration)
A Pressure
● High pressure: 7-15kg/cm2 (slight or severe vibration)
● Periodically cold or not cold at the state of cold air
B Condition ● The pressure of double meter valve reduces slightly to the normal
pressure.
● Water flows into the air conditioning system, and the expansion valve
C Reason
freezes occasionally.
● The dyer is at the excessive saturation status.
D Judgment
● Water freezes the expansion valve.
● Replace dryer
E Measures ● Vacuumize again and fill refrigerant

● When the refrigerant in the air conditioning system does not circulate
● Low pressure: Negative pressure (very low)
A Pressure 2
● High pressure: 63kg/cm (very high)
● Poor refrigeration effect (not cold)

B Condition
C Reason ● Expansion valve holes are blocked (frozen or blocked by foreign matters)
D Judgment ● Expansion valve hole is blocked
● Remove water: Vacuumize again and fill refrigerant
● Clear the foreign matters: Disassemble the expansion valve, remove or
E Measures replace by compressed air
● Replace dryer
● Replace the expansion valve

Air Flow Diagram
Figure 129
Based on the different air direction modes, the

directions and blown-out air vary.
Mode
Air outlet

Diagram of Air-out of Air Unit
Figure 130
Air volume mode is related to the degree of opening of air door. (Unit %)
Air-out mode
Air-vent
Up Up, down Bottom Defrosting/bottom Defrosting
Up 100 60 0 0 0
Bottom 0 40 100 80 60
Defrosting 0 0 0 20 40

Component Characteristics
Distinction Remarks
1) Full automatic temperature control (adjust temperature freely)
Control panel
2) Liquid-crystal display (status display)
1) Capacity of cold/heating air increases
Air conditioning unit 2) To realize full automatic temperature control, install indoor temperature sensor
3) Install component to control fan speed
Condenser 1) Remove electric fan (move the water tank)
Ambient temperature 1) Full automatic temperature control, install indoor temperature sensor (left chassis,
sensor bottom of cab)
1) It is used for supplementary control based on different sunshine amount (behind
Sun load sensor
the switch panel)
※ Models of drying bottle and compressor are different from the previous ones. Fungibility

Circuit of Air Conditioning System
Figure 131
Note: The compressor is equipped for Scania engine.

Air Conditioning Unit Components
Figure 132

Component description
Compressor
Compressor absorbs gas refrigerant evaporated by
the evaporator, and discharges it by the condenser.
The refrigerant changes in a cycle of liquid-gas-liquid.
Condenser cools down the gas refrigerant provided
by the compressor and converts them into high-
temperature and high-pressure liquid.
Note: For the specific specification and structure of
Scania compressor, refer to the air conditioning
Figure 133
part in the section “Assembly and disassembly
of engine”.
Condenser
Condenser is used to dissipate the heat and
liquefy the high-temperature and high-pressure gas
refrigerant generated by the condenser through water
tank fan of engine or condenser fan.
The amount of heat dissipated by the condenser
depends on the heat inhalation of evaporator and the
heat generated by the compression of refrigerant.
When the condenser is not cooled down sufficiently,
the refrigerant cycle circuit pressure may rise, causing
overload and reducing the refrigeration capacity. The
rotation status of cold fan shall be noted, or inspect
whether the condenser surface is blocked.

Dryer
Function
1. According to the change of refrigerant circulation
quantity, in order to ensure the smooth operation of
the refrigerant circulation circuit, a proper amount of
refrigerant is stored.
2. T he liquid refrigerant from the condenser is
mixed with the air bubble, namely gas refrigerant.
Refrigerant containing bubbles to the expansion
valve will significantly reduce the cooling capacity,
therefore, the bubble must be separated from the
liquid, only transport the liquid refrigerant to the
expansion valve.
3. The moisture contained in the refrigerant is removed Figure 134
by a desiccant, and the impurities are removed by
the filter element.
4. W h e n t h e t e m p e r a t u r e a n d p r e s s u r e i n t h e
refrigerant circuit become high, the observation hole
will melt and the refrigerant will be discharged into
the atmosphere.
(Protect refrigerant circuit)
5. In the absence of refrigerant, in order to prevent the
compressor work, install low-voltage switch.
6. Confirm refrigerant quantity with observation hole.
(Old refrigerant limited)
2
●High/low pressure switch illustration (unit: kg/cm )

Expansion valve
The expansion valve is installed at the inlet of the
evaporator, and the high pressure liquid refrigerant
output from the dryer is converted into a low pressure
liquid refrigerant to the evaporator under the action of
the expansion valve.
Evaporator
Evaporator is evaporated through expansion under
the low pressure. When the liquid flows through the
evaporator pipe, the hot air blown out by the blower
causes the steam to evaporate into gas. At the same
time, according to the vaporization heat, it will become
cool to make indoor air cool. In addition, the vapor
in the air cools into water, and is exhausted with
dust, etc. to the outdoor through the lower conduit of
the cab. Similarly, the heat exchange between the
refrigerant and the air is achieved through a conduit
and a heat sink instead of water or dust.
When the evaporator freezes or frost occurs in the

heat sink. If the hot and humid air is in contact with the
heat sink, it will be accompanied by a drop of water
when it cools below the dew point temperature.
At this point, if the temperature of the heat sink cools
to below 0℃, the water drops attached will form ice, and
the vapor in the air will form frost, and will significantly
reduce its cooling function.

Electrical parts
1. Control unit
Automatic button LCD Air conditioning button
Temperature button Blower button
OFF switch
Option button
Air-out mode button
Figure 135 Air-in type button Defrost button
开关控制
Input Output
Action characteristic
Button State Display symbol
The following items are automatically controlled
with different setting temperature
- Air door position of temperature control
Automatic - Air-out direction
- Air-in type
- Fan speed
- Compressor stop operation
- It will rise 0.5℃ per press

- In the fully automatic state, set the maximum
(Up)
temperature of 32℃
Air blower
It will drop 0.51℃ per press
- In the fully automatic state, set the minimum
(Down) temperature of 17℃
- Running of the compressor

Air
conditioning Not displayed - Compressor stops

Input Output
Action characteristic
Button State Display symbol
- Top and bottom air-out
- Bottom air-out
Air-out mode
- Bottom and defrost mouth air-out
- Top air-out
- Rise one grid per press (below 1 second)

(Up) - It will rise continuously when pressing it continuously
- Drop one grid per press (below 1 second)

(Down) - It will drop continuously when pressing it continuously
- Defrost mouth air-out

Defrosting
- Defrost mouth no-air-out
- Indoor air circulation

- Output OFF after 40 seconds
Air-in type
- Outdoor air-in
- Output OFF after 40 seconds
- ℃→℉, ℉→℃, the temperature unit shall change per press

- When the “SEL” and “MODE” buttons are pressed for more than 3
Select seconds at the same time, the outdoor air temperature is displayed
- When the “SEL” and “AC” buttons are pressed for more than 3
seconds at the same time, enter the self-diagnostic mode
- Blower: Stop running

- Air mixing air door: Stationary
- Air-out mode: Fixed top air-out mode
OFF
- Air-in mode: Fixed indoor circulation mode

2. Temperature actuator
● Air conditioning was equipped with single
temperature actuator and air-out mode actuator.
According to the regulation temperature control
button, change the temperature control air door
position, adjust the output of air temperature.
● Detection
Connect the power supply positive electrode

with the P1 terminal, and connect the negative Figure 136
electrode with the P2 terminal to confirm whether
the actuator is driven by warm air direction.
In turn, confirm whether the actuator is driven by
cold air direction.
Setting temperature Output terminal Voltage

Maximum cold air C ( + ) : CN10-9 0.5 ± 0.2V
Maximum warm air B (-) : CN10-4 4.5 ± 0.2V
3. Air-out mode actuator

● According to the selection of air-out mode to
change the air outlet position

● Air outlet position: Change according to the
order of up, up and down → bottom → bottom/

defrosting → defrosting
Air-out mode Output terminal Voltage

Up 0.5V ± 0.2V
Up, down C (+ ): CN10-10 1.3V ± 0.2V
Bottom B (-): CN10-4 2.45V±0.2V
Bottom/Defrosting 3.5V±0.2V
Defrosting 4.5V ± 0.2V

4. Intake type actuator
● When the action is controlled, the input value
of each sensor is calculated, and the indoor /

outdoor air is automatically converted.
● Test: Connect the power supply positive electrode
with the P1 terminal, and connect the negative

electrode with the P2 terminal to confirm whether Figure 137
the actuator is driven to the outdoor air intake
(FRE) direction, and, in turn, confirm whether
there is the formation of an inverse drive.
Selection mode Output terminal Output

Fresh air P1 ( + ) , P2 (-) Fresh air option switch air door movement
Re-cycle P1 ( - ) , P2 ( + ) Re-cycle option switch air door movement
5. Air volume control module

● GATE- rotational speed of control voltage and
blower motor
Figure 138
Air volume Output terminal Output

1 10±0.5V
2 12.5V±0.5V
3 15V±0.5V
4 CN11-2 CN10-1 17.5V±0.5V
5 20.0V±0.5V
6 22.0V±0.5V
7 25V±0.5V

6. Blower relay: Power supply for blower when using
air conditioning system.
※ 1) The above figure represents PI: CN11-1, P2:
CN10-8,
A: CN10-1, B: CN11-2
2) Rated voltage 24V, rated current: 20A Figure 139
7. Compressor relay: Power supply of electromagnetic

clutch for compressor.
※ Rated voltage: 24V, rated current: 10A
Figure 140
8. Water temperature sensor: The sensor is installed

below water tank, which senses the cooling water
temperature flowing in radiator.
Figure 141
Temporary (℃) Resistance value (kΩΩ)

-10 55.8 ±1.7
0 32.9 ±0.9
15 15.76 ±0.5
25 10.0 ±0.3
35 6.5 ±0.2

9. The central temperature sensor (DUCT SENSOR)
of the evaporator is installed on the central conduit
of the evaporator, which can sense the temperature
of the central part of evaporator and be played to
prevent the evaporator from freezing. The sensor
is composed of potentiometer with negative
Figure 142
characteristics. When the temperature falls, the
resistance value becomes large, or vice versa.

0 11.36 ±0.1
2 10.39 ±0.2
2.5 10.17±0.2
3 9.73 ±0.2
3.5 9.52 ± 0.2
4 9.52 ± 0.2
5 9.12 ±0.2
10 7.36 ±0.15
25 4.02 ± 0.08
30 3.33 ± 0.07
10. Indoor temperature sensor

Indoor air import parts installed in the blower
unit can sense the indoor temperature, control
outlet temperature, protect sensor and control
temperature control air door, rotational speed of
Figure 143
blower motor, air conditioning automatic operation
or starting of cold/warm air, etc.

-15 218.2±3.43%
0 97.83 ±2.61%
15 47.12 ±1.45%
25 30.0 ± 1.20%
35 19.60 ±1.44%
60 7.478 ± 2.82%

11.Ambient temperature sensor
● Install under the driver’s seat, it can perceive the
outdoor temperature.
● C ontrol the outlet temperature, protect the
sensor, control the temperature control air outlet

and rotational speed of blower motor and control
the multi-air outlet.
※ Under the condition of automatic operation, when
the outdoor temperature falls below -3℃, the
Figure 144
compressor is automatically stopped to protect the
compressor.

-10 163 ±4.9
0 96.9 ±2.9
10 59.4 ±1.8
20 37.4 ±1.1
25 30 ± 0.9
30 24.2 ± 0.7
12. Sun load sensor is installed next to the standby

power supply socket in the cab, with a built-in triode,
which can be induced by the amount of sunlight of
cab. According to the ratio of light and heat, electricity
is generated, which is communicated to the air
conditioning control panel, to achieve the effect of
supplementary air volume and output temperature.
(Specific flow graph of sunshine amount, output
voltage 0.5~4.5V)
Output voltage (mV)
LUX (Lumen and light unit)（x10,1000）

Figure 145

Automatic mode control
● Outline
Input the information sensed by the various sensors
(outdoor temperature sensor, indoor temperature
sensor, sun load sensor, central temperature sensor
of evaporator) to the air conditioning control panel,
automatically control air-out temperature, air volume,
compressor operation / stop, air entrance type
conversion, etc. through microcomputer calculation,
to maintain comfortable indoor air environment.
● Function
(1) Automatically control indoor temperature

According to the setting temperature,
automatically adjust the indoor temperature.
Change according to the outdoor temperature,
quantity of illumination and heat change
discharged by the driver.
(2) Maximum cold/warm air function
The temperature switch is set at 17℃, which is
the lowest temperature, and is set at 32℃, which
is the highest temperature.
When the blower switch is in automatic mode,
the cold air temperature is the lowest, and the
warm air temperature is the highest .
(3) Automatic control of air volume
When the blower switch is in automatic mode,
it will automatically adjust the rotational speed
of blower motor with the change of temperature
control air door.
(4) Air-out mode control
In the automatic mode, the air-out mode actuator
is automatically adjusted to the up air-out, up
and down air-out and bottom air-out mode
according to the data of each sensor.
(5) Compressor control
According to the data of each sensor, control the
operation/stop of compressor.
In the automatic mode, even if the compressor
button is closed and set to 17℃ (coldest), the
compressor is also forced to operate.
(6) Intake type control
In the automatic mode, the fresh air and re-cycle
will be automatically converted through the data
of each sensor.
(7) Cold air start control
Indoor temperature is high in summer, and when
the air conditioning system has just begun to
work, the system will slow down air volume to a
certain time to air temperature down to the driver
to prevent the sudden blow of hot air to the
driver.
(8) Warm air start control
Indoor temperature is low in winter, and when
the air conditioning system has just begun to
work, the system will delay air volume to a
certain time to air temperature rise to prevent
the output of the cold air suddenly blow to the
driver,. Previously, the air-out mode control air
door maintains on defrosting air outlet.

(Input/output case)
Distinction Items Distinction

Indoor temperature
R25=30KΩ ± 1.2%, B ( 0/50 ) =3887K± 1%
sensor
Ambient temperature
R25=30.0KΩ ±3%, B ( 0/50 ) =3880K±2%
sensor
Central temperature
R0=11.36KΩ ± 1 %, B ( 0/50 ) =3422K ± 2%
sensor of evaporator
Input item Sun load sensor VSH=2V ( at 1000W/m2 )
Water temperature
R25=10KΩ ±3%, B ( 0/50 ) =3950K±2%
sensor
Temperature actuator 3.0KΩ ± 30%B features
Air-out actuator 3.0KΩ ± 30%B features
Touch-type button (9
AUTO, OFF, TEMP, SEL, MODE, INTAKE, BLOWER, A/C, DEF
kinds)
Air-out actuator motor Rated current: Less than 0.1A (12V), when locking: Less than 0.4A
Air-in type actuator
↑
motor
Temperature actuator
Output item ↑
motor
P/MOSFET IRFP 260N
Blower motor Electricity consumption = less than 280W (24V, below 12A)
Display screen LCD form
Indoor temperature sensor = 25℃, outdoor temperature sensor = 25℃,
central temperature sensor of evaporator = -2℃
When sensor is out Temperature actuator = setting temperature 17 ~ 24.5℃: Fixed for
Others of order, guarantee minimum 17℃ setting temperature 25~32℃: Fixed for maximum 32 ℃
measures Air-out actuator = selection of up air-out: Fixed for the up air-out,
selection of other forms except for up air-out: The fixation is defrosting
Illumination intensity = no guarantee

(Control Logic)

Temperature setting 1. Automatically adjust the indoor temperature according to the
Indoor air temperature setting temperature, and control it according to the following items
sensor ● Temperature / air-out / inner/ outer inlet conversion / air volume /
Outdoor air compressor AUTO mode

AUTO
temperature sensor 2. In addition to the temperature adjustment button, manually operate
Water temperature any other button, and relieve AUTO mode.
sensor 3. When the AUTO mode is relieved, manually select the function
Sun load sensor other than the switch automatic control
1. When an sensor occurs an error, the system handles it according
to the following procedures.
● Indoor temperature sensor: 25℃
Temperature setting
● Ambient temperature sensor: 25℃
Indoor air temperature
● Central temperature sensor of evaporator: -2℃
sensor
Sensor ● Temperature actuator
Outdoor temperature
guarantee Setting temperature 17-24.5℃: Maximum cold air
sensor
Setting temperature 25~32℃ (maximum warm air)
Water temperature
● Air-out actuator
sensor
Up: Fixed up air-out
Mode other than top The fixation is defrosting
※ Sun load sensor does not guarantee.
1. Temperature setting 32℃: Maximum warm air
2. Temperature setting 17℃: Maximum cold air
Maximum cold air Maximum warm air
(17℃) (32℃)
Temperature The coldest The hottest
actuator
Air volume Maximum Maximum
Maximum
Compressor Force run Stop
cold/warm Air-in type Re-cycle Fresh air
Automatic setting
air automatic Air-out mode Up Bottom
control setting
※ Control the maximum cold/warm air only in automatic mode.
When the maximum warm air is relieved, control logic.
1. When the maximum warm air setting time is too long and under
the indoor temperature rising state, even if the setting temperature
drops 0.5℃, it will converse in accordance with A/CON, re-cycle,
up air-out mode, and not sense there are significant changes in the
temperature.

1. In the hot summer, make the output of the temperature drop, to
prevent hot air output
2. Entry conditions
(1) A/C ON (auto or manual)
(2) The sensing temperature of evaporator temperature sensor is
above 30℃
(3) Air volume: Automatic mode
3. Once the engine is turned off, the restart mode will be canceled,
Automatic mode which need to be reset.
Cold air 4. After the start of the engine, within 5 seconds, and under manual
evaporator
control (AC OFF and air volume control) state, when the AUTO switch is
Temperature sensor ON, control the cold air start.
5. Cold air start control is prior to maximum cold air
6. Release conditions
(1) AC OFF
(2) Air volume: Manual control
(3) Under the manual control of cold air, to stop the system which
has just started, just need to press the “OFF” switch after 12
seconds Within 12 seconds, the “OFF” switch does not work
1. Entry condition (AND condition)

(1) In AUTO mode or manual control mode, the air-out mode is as
follows
●Up and down, bottom or bottom/defrosting
(2) The water temperature sensor is normal, the water temperature

is <731
(3) Air volume: Automatic mode
(4) Setting temperature > indoor temperature +3C
※ When the automatic mode is relieved, the air volume is reduced
from the largest to smaller within 12 seconds
Temperature sensor 2. Under the manual control of cold air, to stop the system which has
Outdoor temperature just started, just need to press the “OFF” switch after 12 seconds
Within 12 seconds, the “OFF” switch does not work
Warm wind sensor
3. Warm air start control is prior to maximum warm air
control (1) Indoor temperature
4. Manual control of up and down, bottom, bottom/defrosting of air-
sensor out mode
Automatic mode 5. When entering, control it through the water temperature sensor
6. During control, when the water temperature sensor has faults, the
control mode is warm air control (2)
7. Action release
(1) Manually select the air volume, only relieve the air volume
(2) When operating the air-out mode switch, only relieve the
wind direction, and the air volume is implemented during the
remaining time in the warm air start control.
(3) When selecting the maximum cold air (171)
(4) Water temperature sensor >73t

1. Entry conditions
(1) Automatic air-out mode
(2) Outdoor temperature <5℃, indoor temperature-outdoor
temperature ≤5℃
(3) Fault of water temperature sensor
2. Under the manual control of cold air, to stop the system which has
just started, just need to press the “OFF” switch after 12 seconds
Within 12 seconds, the “OFF” switch does not work
Temperature sensor 3. Warm air start control is prior to maximum warm air
Outdoor temperature 4. Action release
Warm wind sensor (1) Air volume: Manually select air volume
control (2) Indoor temperature (2) When operating the air-out mode switch, only relieve the
sensor wind direction, and the air volume is implemented during the
remaining time in the warm air start control.
Automatic mode
(3) Indoor temperature-outdoor temperature >15℃
(4) When selecting the maximum cold air (17℃)
5.Exceptional condition
In initial condition, when the operation time is within the warm air
control time, if meeting 1 time of entry condition, implement the
warm air start control in the remaining time.
※ When entering the exceptional conditions, the air volume is
reduced from the largest to smaller within 12 seconds
1. Function: When the compressor works, to prevent the evaporator
from freezing, the electromagnetic clutch of the compressor
is switched on / off with the change of the temperature of the
Temperature sensor evaporator temperature sensor.
Outdoor air 2. Control chart:
temperature sensor
Indoor air temperature
sensor
Automatic mode
Compressor
control
1. Function: Protection compressor in winter
2. Control chart:
Outdoor temperature
sensor
※ Only in automatic operation mode

(Self-diagnostic)
● Entry method of self-diagnostic
Start switch ON
Temperature setting 25℃ Temperature setting 77 ℉
Press the A/S button for 5 seconds, press option

button more than 3 times.
All scenes on LCD flashes 2 times in a cycle of 0.5

seconds, the remaining diagnostic will be started.
When the relevant code is flashing in a cycle of

0.5 seconds, and there are more than 2 faults, the
associated code displays that the representation after
2 times is the next.
Normally, display “EO” when a fault occurs, and

display the first code.
When there are 2 or more errors, if the temperature

regulation switch is selected up / down, and the fault
code is indicated by up / down (normally, only display
“EO”)
Press the A/S button for 5 seconds, press

option switch more than 3 times.
Diagnostic mode is carried out in 30

seconds, and if not operating any
button, it is returned to the initial state.
Before entering self-diagnostic, restore the
state

(Error code)
CODE Error content CODE Error content

E0 Normal E7 Sun load sensor short circuit
Indoor temperature sensor short
E1 E8 Sun load sensor broken circuit
circuit
Indoor temperature sensor broken
E2 E9 Water temperature sensor short circuit
circuit
Ambient temperature sensor short Water temperature sensor broken
E3 E10
circuit circuit
Ambient temperature sensor broken High and low voltage switch broken
E4 E11
circuit circuit
Temperature sensor of evaporator
E5 E12 Actuator position error of air-out mode
short circuit
Temperature sensor of evaporator
E6 E13 Temperature actuator position error
broken circuit
Note: 1. The actuator position error refers to not reach

the specified location within 40 seconds
2. Under the condition of no sunshine, the sun
load sensor displays more than E8 3.2

Engine
DX140AF/DX140LCA General information 9-1

ＭＥＭＯ

Table of Contents
Engine
GENERAL INFORMATION......................................... 5
Engine specifications.............................................. 5
Engine power......................................................... 6
Performance curve................................................. 7
Engine assembly.................................................. 11
Safety regulations................................................. 17
TECHNICAL INFORMATION.................................... 23
Engine model and serial number.......................... 23
Engine type.......................................................... 24
Engine timing........................................................ 25
Valves................................................................... 26
Lubrication system............................................... 26
Air cleaner............................................................ 29
Fuel system.......................................................... 29
Cooling system..................................................... 32
V-belt tension check and adjust........................... 36
Intercooler (Air to air)............................................ 36
Valve clearance and adjustment.......................... 37
Cylinder compression pressure............................ 38
Injection nozzle..................................................... 39
Battery.................................................................. 39
Starting motor....................................................... 40
Diagnosis and remedy.......................................... 41
Engine inspection................................................. 50
MAINTENANCE........................................................ 52
Engine Disassembly............................................. 52
Engine Inspection................................................. 73
Engine Reassembly............................................. 98
Electrical Equipments......................................... 118

COMMISSIONING AND OPERATION.................... 125
Preparation......................................................... 125
Starting and operation........................................ 127
Inspections after starting.................................... 129
Operation in winter time..................................... 130
Maintenance and care........................................ 132
Cooling system................................................... 134
Valve clearance and adjustment........................ 136
Injection timing................................................... 138
Tightening the cylinder head bolts...................... 141
Fuel injection pump............................................ 141
Feed pump strainer............................................ 142
Separator (Add if necessary).............................. 142
Air bleeding........................................................ 142
Belts................................................................... 143
MAINTENANCE OF MAJOR COMPONENTS........ 146
Lubrication system............................................. 146
Cooling system................................................... 149
Fuel system........................................................ 154
Turbocharger...................................................... 194
Air Intake System............................................... 205
SPECIAL TOOL LlST.............................................. 207
Appendix................................................................. 209

GENERAL INFORMATION
Engine specifications

Engine power

Performance curve
Performance curve (0858)
Figure 1
Performance DIN 6270B DIN 6270A

Output (rated) 96 kW(130PS)/2,800 rpm 85 kW(115PS)/2,800 rpm
Torque (min) 370 N.m(38.0 kg.m)/1 ,600 rpm
Fuel consumption (min) 218 g/kW.h(160 g/PS.h)

Performance curve (DB58T)
Figure 2

Torque (min) 450 N.m(46.0 kg.m)/1 ,600 rpm

Performance curve (DB58TI)
Figure 3

Torque (min) 539 N.m(55.0 kg.m)/1,600 rpm

Performance curve (DB58TIS)
Figure 3
Performance DIN 6270B

Output (rated) 126.5 kW(172PS)/2,200 rpm
Torque (min) 696 N.m(71 kg.m)/1,4 00 rpm
Fuel consumption (min) 217.5 g/kW.h(160 g/PS.h)

Engine assembly
Engine sectional view (DB58TIJTIS : air to water type)
Figure 4
No. Name No. Name

1 Oil spray nozzle 18 Piston pin
2 Connecting rod 19 Thermostat
3 Cylinder liner 20 Intake valve
4 Oil cooler 21 Exhaust valve
5 Piston 22 Breather
6 Swirl chamber 23 Inter cooler
7 Fuel injection pipe 24 Rocker arm
8 Fuel injection nozzle 25 Oil filler cap
9 Valve cotter 26 Cylinder head cover
10 Valve spring 27 Cylinder head
11 Valve stem seal 28 Push rod
12 Valve guide 29 Vibration damper
13 Oil pan 30 Oil drain plug
14 Oil pump strainer 31 Crank shaft
15 Oil pump 32 Cam shaft
16 Cooling water pump 33 Tappet
17 Cooling water pump pulley

Engine sectional view (DB58TIS : air to air type)
Figure 5
No. Name No. Name

1 Oil spray nozzle 17 Cooling water pump pulley
2 Connecting rod 18 Piston pin
3 Cylinder liner 19 Therπlostat
4 Oil cooler 20 Intake valve
5 Piston 21 Exhaust valve
6 Swirl chamber 22 Breather
7 Fuel injection pipe 23 Rocker arm
8 Fuel injection nozzle 24 Oil filler cap
9 Valve cotter 25 Cylinder head cover
10 Valve spring 26 Cylinder head
11 Valve stem1 seal 27 Push rod
12 Valve guide 28 Vibration damper
13 Oil pan 29 Oil drain plug
14 Oil pump strainer 30 Crank shaft
15 Oil pump 31 Cam shaft
16 Cooling water pump 32 Tappet

Engine assembly views
D858
Figure 6
No. Name No. Name

1 Oil filter 14 Cooling water pump
2 Lifting hook 15 Alternator
3 Oil cooler 16 Fan drive mounting
4 Intake manifold 17 Oil level gauge
5 Priming pump 18 Exhaust manifold
6 Fuel injection pump 19 Push rod chamber cover
7 Fuel injection pipe 20 Flywheel housing
8 Water outlet 21 Fly wheel
9 Cooling fan 22 Oil pan
10 Cooling fan idler 23 Starter
11 Crank shaft pulley 24 Cylinder head cover
12 Vibration damper 25 Fuel injection nozzle
13 Oil drain plug 26 Fuel filter

DB58T
Figure 7
No. Name No. Name

1 Engine pick-up sensor 15 Cooling water pump
2 Lifting hook 16 Alternator
3 Oil cooler 17 Breather
4 Intake manifold 18 Turbo charger
5 Priming pump 19 Exhaust manifold
6 Fuel injection pump 20 Oil filler cap
7 Fuel injection pipe 21 Push rod chamber cover
8 Water outlet 22 Flywheel housing
9 Cooling fan 23 Fly wheel
10 Crank shaft pulley 24 Oil pan
11 Vibration damper 25 Starter
12 Oil filter 26 Oil level gauge
13 Oil drain plug 27 Cylinder head cover
Air pipe(turbo charger to intake 28 Fuel injection nozzle
14
manifold) 29 Fuel filter

DB58TI/TIS
Figure 8
No. Name No. Name

1 Fuel filter 14 Alternator
2 Oil cooler 15 Water outlet
3 Intake manifold 16 Exhaust manifold
4 Priming pump 17 Oil filler cap
5 Fuel injection pump 18 Push rod chamlber cover
6 Fuel injection pipe 19 Flywheel housing
7 Cooling fan 20 Fly wheel
8 Crank shaft pulley 21 Starter
9 Vibration damper 22 Turbo charger
10 Oil filter 23 Oil level gauge
11 Oil pan Air pipe(turbo charger to
24
12 Oil drain plug intercooler)
13 Cooling water pump 25 Fuel injection nozzle
26 Intercooler

DB58TIS
Figure 9
No. Name No. Name

1 Flywheel housing 15 Cooling water pump
2 Lifting hook 16 Air heater
3 Oil filler cap 17 Thermostat housing
4 Fuel filter 18 Water pump pulley
5 Intake manifold 19 Alternator
6 Air pipe(intercooler to manifold) 20 Water outlet
7 Breather Air pipe(turbocharger to
21
8 Cooling fan intercooler)
9 Oil filter 22 Turbo charger
10 Oil pan 23 Exhaust manifold
11 Oil drain plug 24 Crank shaft pulley
12 Fuel injection pump 25 Starter
13 Fuel feed pump 26 Push rod chamlber cover
14 Priming pump 27 Oil level gauge
28 Fuel injection pipe

Safety regulations
General notes
Oay-to-day use of power engines and the service
products necessary for running them presents
noproblems if the persons occupied with their
operation , maintenance and care are given suitable
trainingand think as they work.
This summary is a compilation of the most important
regulations. These are broken down into main sections
which contain the information necessary for preventing
injury to persons, damage to property andpollution.
In addition to these regulations those dictated by the
type of engine and its site are to beobserved also.
IMPORTANT
If, despite all precautions, an accident occurs, in
particular through contact with caustic acids,fuel
penetrating the skin, scalding from oil, antifreeze being
splashed in the eyes etc., consulta doctor immediately.
Regulations designed to prevent accidents

1. Ouring commissioning, starting and operationBefore
putting the engine into operation for the first
time , read the operating instructions carefully
andfamiliarize yourself with the “critical” points. If
you are unsure, ask your OAEWOO representative.
● For reasons of safety we recommend you
attach a notice to the door of the engine room

prohibitingthe access of unauthorized persons
and that you draw the attention of the operating
personalto the fact that they are responsible for
the safety of persons who enter the engine room.
● The engine must be started and operated
only by authorized personnel. Ensure that

the enginecannot be started by unauthorized
persons.
● When the engine is running , do not get too close
to the rotating parts. Wear close-fitting clothing.

● Do not touch the engine with bare hands when it
is warm from operation risk of burns.

● Exhaust gases are toxic. Comply with the
installation instructions for the installation
of OAEWOOdiesel engines which are to be
operated in enclosed spaces. Ensure that there is
adequate ventilationand air extraction.
● Keep vicinity of engine, ladders and stairways
free of oil and grease.

Accidents caused by slipping can have serious
consequences.
2. During maintenance and care

● Always carry out maintenance work when the
engine is switched off. If the engine has to

bemaintained while it is running , e.g. changing
the elements of change-over filters, remember
that there is a risk of scalding. 00 not get too
close to rotating parts.
● Change the oil when the engine is warm from
operation.
CAUTION
There is a risk of burns and scalding. 00 not touch oil
drain valve or oil filters with bare hands.
● Take into account the amount of oil in the sump.

Use a vessel of sufficient size to ensure that the
oil will not overflow.
● Open the coolant circuit only when the engine has
cooled down. If opening while the engine is still

warm is unavoidable, comply with the instructions
In the chapter entitled“Cooling”.
● Neither tighten up nor open pipes and hoses
(Iube oil circuit, coolant circuit and any additional

hydraulic oil circuit) during the operation. The fluid
which flow out can cause injury.
● Fuel is inflammable. Do not smoke or use naked
lights in its vicinity. The tank must be filled only

when the engine is switched off.
● Keep service products (anti-freeze) only in
containers which can not be confused with drinks

containers
● Comply with the manufacturer’s instructions when
handling batteries.

CAUTION
Accumulator acid is toxic and caustic. Battery gases
are explosive.
3. When carrying out checking, setting and repair work

● Checking, setting and repair work must be carried
out by authorized personnel only.

● Use only tools which are in satisfactory condition.
Slip caused by the worn open-end wrench could

lead to Injury.
● When the engine is hanging on a crane , no-one
must be allowed to stand or pass under it. Keep

lifting gear in good condition.
• When checking injectors, do not put your hands
under the jet of fuel.
Do not inhale at atomized fue l.
● When working on the electrical system disconnect
the battery earht cable first. Connect it up again

last in prevent short circuits.
Regulations designed to prevent damage to engine and

premature wear
(1) Never demand more of the engine than it was
designed to yield for its intended purpose Oetailed
information on this can be found in the sales
literature. The injection pump must not be adjusted
without prior written permission of OAEWOO.
(2) If faults occur, find the cause immediately and
have it eliminate in order to prevent more serious
of damage.
(3) U s e o n l y g e n u i n e O A E W O O s p a r e p a r t s .
OAEWOO will accept no responsibility for damage
result-ing from the installation of other parts which
are supposedly “just as good”.
(4) In addition to the above, note the following points.
● Never let the engine run when dry, i.e. without
lube oil or coolant. Use only OAEWOO-approved

service products. (engine oil , anti-freeze and
anticorrosion agent)
● Pay attention to cleanliness. The Oiesel fuel must
be free of water. See “Maintenance and care”.

●Have the engine maintained at the specified
intervals
●Do not switch off the engine immediately when
it is warm, but let it run without load for about 5

minutes so that temperature equalization can
take place.
● Never put cold coolant into an overheated
engine. See “Maintenance and care”.

● Do not add so much engine oil that the oil level
rises above the max. marking on the dipstick.

● Do not exceed the maximum permissible tilt of
the engine. Serious damage to the engine may

result if these instructions are not adhered to.
● Always ensure that the testing and monitoring
equipment (for battery charge, oil pressure, and

coolant temperature) function satisfactorily
● Comply with instructions for operation of the
alternator. See “Commissioning and operation”

● Do not let the water pump run dry. If there is a
risk of frost, drain the water when the engine

switched off.
Regulations designed to prevent pollution

a) Engine oil, filter element, fuel filter
● Take old oil only to an oil collection point. Take
strict precautions to ensure that oil does not get

into the drains or into the ground.
● The drinking water supply may be contaminated.
● Oil and fuel filter elements are classed as
dangerous waste and must be treated as such.

b) Coolant
● Treat undiluted anti-corrosion agent and / or
antifreeze as dangerous waste.

● When disposing of spent coolant comply with the
regulations of the relevant local authorities.

Notes on safety in handling used engine oil
Prolonged or repeated contact between the skin and
any kind of engine oil decreases the skin.
Orying, irritation or inflammation of the skin may
therefore occur. Used engine oil also contains
dangerous substances which have caused skin cancer
in animal experiments. If the basic rules of hygiene
and health and safety at work are observed, health
risks are not to the expected as a result of handling
used engine oi l.
health precautions
● Avoid prolonged or repeated skin contact with used
engine oil.
● Protect your skin by means of suitable agents
(creams etc.) or wear protective gloves.

● Clean skin which has been in contact with engine oil
- Wash thoroughly with soap and water, A nailbrush

is an effective aid.
- Certain products make it easier to clean your
hands.
- Do not use petrol , Oiesel fuel , gas oil , thinners or
solvents as washing agents.
● After washing apply a fatty skin cream to the skin.
● Change oil-soaked clothing and shoes.
● Do not put oily rags into your pockets.
Ensure that used engine oil is disposed of properly.

- Engine oil can endanger the water supply -
For this reason do not let engine oil get into the
ground, waterways, the drains or the sewers.
Violations are punishable. Collect and dispose of used
engine oil carefully.
For information on collection points please contact the
seller, the supplier or the local authorities.

General repair instructions
1. Before performing service operation, disconnect
the grounding cable from the battery for reducing
the chance of cable damage and burning due to
short-circuiting.
2. Use covers for preventing the components from
damage or pollution.3. Engine oil and anti-freeze
solution must be handled with reasonable care as
they cause paint damage.
4. The use of proper tools and special tools where
specified is important to efficient and reliable
service operation.
5. Use genuine DOOSAN parts necessarily.
6. Used cotter pins, gaskets, O-rings, oil seals, lock
washer, self-Iock nuts and rubber coated seal ring
etc. should be discarded and new ones should
be prepared for installation as normal function of
the parts can not be maintained if these parts are
reused.
7. To facilitate proper and smooth reassemble
operation, keep disassembled parts neatly in
groups.
Keeping fixing bolts and nut separately is very
important as they vary in hardness and design
depending on position of installation.
8. Clean the parts before inspection or reassembly.
Also clean oil ports, etc. using compressed air to
make certain they are free from restrictions.
9. Lubricate rotating and sliding faces of parts with oil
or grease before installation.
10. When necessary, use sealer on gaskets to prevent
leakage.
11. Carefully observe all torque specifications for bolts
and nuts.
12. When service operation is completed, make a final
check to be sure service has been done properly.

TECHNICAL INFORMATION
Engine model and serial number
The engine model and serial number is located on
the engine as illustrated. These numbers are required
when requesting warranty and ordering parts. They
are also referred to as engine model and serial
number because of their location.
● Engine serial No. (example 1 : DB58)

DB58 3 00001 FA
Figure 10
Engine suffix(EARFA)
Serial no.
Production year(2003)
Engine model
● Engine serial No. (example 2 : DB58S)

DB58S 3 00001 FA
Engine suffix(ECRFA)
Serial no.
Engine model Figure 11
● Engine serial No. (example 3 : DB58T)

DB58T 3 00001 FA
Engine suffix(EATEA)
Serial no.
Engine model
● Engine serial No. (example 4 : DB58TI)

DB58TI 3 00001 FA
Engine suffix(EAOEB)
Serial no.
Engine model
DX140AF/DX140LCA Technical information 9-23

● Engine serial No. (example 5 : DB58TIS)
DB58TIS 3 00001 FA
Engine suffix(ECOEC)
Serial no.
Engine model
Engine type
The Engines OB58, OB588, OB58T, OB58TI,
OB58TI8 are in-line vertical , water-cooled , 6-cylinder
four stroke diesel engines with direct injection. OB58
is natural aspiration , OB58T is turbo-charged ,
OB58TI,
OB58TI8 are turbo-charged and inter-cooled engine.
Cylinder block
The cylinder block is a single piece of alloy cast iron.
To increase its stiffness, it is extended to a level below
the crankshaft center line. The engine has replaceable
dry cylinder liners and common cylinder heads with
struck-in valve seat rings and replaceable valve
guides,
Piston con-rod I crankshaft

The forged crankshaft is a integrate type
(Counterweight is integrated with crank shaft body).
Radial oil seal on crankshaft and flywheel are provided
to seal the flywheel housing inside penetrations.
The con-rods (connecting rods) are die-forged and
can be removed through the top of the cylinders
together with the pistons. Crankshaft and connecting
rods run in steel-backed lead bronze ready-to fit type
bearings.

Engine timing
Camshaft, oil pump, PTO(power take off) pump and
injection pump are driven by a gear train arranged at
the front end.
Figure 12

Valves
The overhead valves are actuated via chilled cast iron
tappets, push rods and rocker arms from the
camshaft.
Lubrication system
The engine is equipped with force-feed lubrication.
The pressure is produced by a gear pump whose
drive gear is in direct mesh with the camshaft gear at
the middle of cylinder block.
The oil pump draws the oil from the oil sump and
delivers it through the oil cooler and oil filter to the
main distributor gallery and from there to the main
bearings, big-end bearings and camshaft bearings as
well as to the small-end bearings and the rocker arms.
The injection pump and turbo charger are also
connected to the engine lubricating system.
The cylinder block walls and timing gears are splash-
Iubricated.
The lube oil is cleaned in a full-flow oil filter.
Figure 13

Recommend of lubricating oil
Initial factory fill is high quality break-in oil for API
Service. During the break-in period (50 hours) ,
frequently check the oil level. Somewhat higher oil
consumption is normal until piston rings are seated
The oil level should be maintained in the safe range
between the Min. and Max. marks on the dipstick
The safe range between the marks represents
approximately 3 liters. To obtain the best engine
performance and engine life, grade of engine oil
is recommended. Engine oils are specified by API
Service, letter designations and SAE viscosity
numbers. If the specified motor oil is not available, use
a reputable brand of engine oil labeled for API Service
CH-4 and SAE viscosity 30 or 15W40. Refer to oil
identification symbol on the container.
● Engine oil should be changed at the specified

intervals.
Oil filter cartridge should be changed simultaneously.
- First oil change : 50 hr operating
First oil change After 50hr operation

DB58
DB58T every 200 Hour
Construction equipments DB58TI
DB58S
every 250 Hour
DB58TIS
●The following oils are also recommended
Engine oil capacity Recommend oil
Engine model Oil pan

Total(Iiter) SAE No. API No.
Max.(Iiter) Min.(Iiter)
DB58 Fork lift 13 11 14.5
DB58T SAE 15W40 above CD or CE
DB58TI Excavator 19 16 20.5
DB58S Fork lift 13 11 14.5 SAE10W40 ACEA-E2 or ACEA-E3

DB58TIS Excavator 19 16 20.5 SAE15W40 (API CH-4)

* If long oil change intervals are to be used, ACEA-E3
oil must be used.
Figure 14
Oil cooler
An oil cooler is provided between the oil filter and
the cylinder block. This cooler is a flat tube type with
turbulence inserts and operated by the coolant
Oil filter
● Check for oil pressure and oil leaks, and repair or
replace the oil filter if necessary.

● Change the oil filter cartridge simultaneously at
every replacement of engine oil.
Figure 15

Figure 16
Air cleaner
In case that elements are deformed, damaged or if the
air cleaner has a crack, replace it.
By the definite interval , the elements must be cleaned
and replaced.
Fuel system
The fuel is delivered by the fuel feed pump via the
fuel filter to the injection pump and from there to the
injection nozzles. Figure 17
Figure 18

The fuel is sprayed into the cylinders through nozzles
fitted in screw-fit injection nozzle holders in the
cylinder heads.
Excessively delivered fuel and leak fuel from the
nozzle flow through the return pipe back to the tank.
A strainer is arranged ahead of the fuel feed pump.
Injection pump
The in-line injection pump is driven via gears from the
crankshaft. It is connected to the force feed lubricating
system of the engine and consequently maintenance-
free. The governor flange-mounted on the pump
casing is a variable range governor designed to keep
the speed set of varying load.
Figure 19
Fuel filter
● This fuel filter has two functions not only oil filtering
but also water separating.

● Before entering the suction chamber of the injection
pump, the fuel is cleaned in a strainer of fuel feed

pump and a fuel filter.
● Drain water in filter with loosening the drain plug
under filter manually from time to time.

● The fuel filter element should be replaced at every
200 hours.
Figure 20
Fuel requirements
DAEWOO diesel engines was designed to use
Number 2-D diesel fuel or equivalent that meets
specification DIN 51601-DK. For maximum fuel
economy, Number 2-D fuel whenever possible. When
temperatures are below -7 oC (20 OF) , use Number
1-D fuel. If Number 1-D fuel is not available, the
mixture of one kerosene to two gallons of Number 2-D
fuel can be used. Once kerosene has been added, the
engine should be run for several minutes to mix the
fuel.

How to select fuel oil
Fuel quality is an important factor in obtaining
satisfactory engine performance, long engine life, and
acceptable exhaust emission levels. DAEWOO
engines are designed to operate on most diesel fuels
marketed today. In general, fuels meeting the
properties of ASTM Designation D975 (grades 1-D
and 2-D) have provided satisfactory performance.
The ASTM 975 specification , however, does not in
itself adequately define the fuel characteristics needed
for assurance of fuel quality.
The properties listed in the fuel oil selection chat
below have provided optimum engine performance.
Grade 2-D fuel is normally available for generator
service. Grade 1-D fuel should not be used in pleasure
craft engines, except in an emergency.
Fuel Selection Chart
#) Not specified In ASTM D 975

+) Differs from ASTM D 975
NOTE: 1) The cloud point should be 6 oC (10 OF) below
the lowest expected fuel temperature to prevent
clogging of fuel fitters by crystals.

Cooling system
The engine has a liquid-cooling system. The fresh
water pump is a maintenance-free by V-belt from the
crankshaft pulley.
Depending on the agreed extent of delivery and
the design of the engine, the coolant circuit can be
equipped with temperature monitors which , in the
event of loss of coolant, shut the engine down.
● Check the coolant level of the expansion tank by
removing the expansion tank filler cap, and add

coolant if necessary.
● When injecting antifreeze solution , first drain out the
old coolant from the cylinder block and radiator, and

then clean them with cleaning solution.
● Be sure to mix soft water with antifreeze solution.
Cooling system (type-1)
Figure 21

Cooling system (type-2)
Figure 22
Coolant pressure cap

Check the pressure valve opening pressure using
a expansion tank cap tester. Replace the filler cap
assembly if the measured valve does not reach the
specified limit. (pressure valve opening pressure : 0.9
kg/cm2 )
NOTE: Because it is dangerous to open the pressure

cap quickly when coolant is hot, after lowering the
inside pressure of the tank by slow-opening at first
open it fully.
Figure 23

Anti-freeze
The anti-freeze, 50% of the whole coolant, is always
to be used to prevent the cooling system from the
corrosion. And in winter the amount of anti-freeze
shown in the following table should be used in
accordance with the ambient temperature.
Ambient Temperature (oC) Cooling water (%) Anti-freeze (%)

Over -10 85 15
-10 80 20
-15 73 27
-20 67 33
-25 60 40
-30 56 44
-40 50 50
As the individual freezing points corresponding to

the propotions of antifreeze in the table are subject
to change slightly according to the kind of antifreeze ,
you must follow the specifications provided by the
antifreeze manufacturer.
As the ratio of antifreeze in the mixture decrease each
time new coolant is added to make up for the loss
coolant resulting from engine operation , Check the
mix ratio with every replenishment of coolant, and top
up as necessary.
Cooling water
● Regarding the engine cooling water, the hard water
must be used (Do not use the soft water).
● The engine cooling water can be used diluting it with
antifreezing solution 40% and the additive for rust

prevention (DCA4) 3 - 5 %.
● The density of above solution and additive must be
inspected every 500 hours to maintain it properly.

NOTE: The proper density control of antifreezing solution
and rust preventing additive will be able to prevent
the rusting effectively and maintain the stable
quality of engine.
For the improper control might give the fatal
damage to the cooling water pump and cylinder
liners, detail care is needed.
● Since DB58 cylinder liner is dry type, paticularly the
cooling water control should be applied thoroughly.
● The density of antifreezing solution and additive
for rust prevention is able to be confirmed by the

cooling water test kit. (Fleetguard CC2602M)
● How to use the cooling water test kit
(1) When the cooling water temp. of engine is in the

range of 10 - 55 oC, loosen the plug for cooling
water discharge and fill the plastic cup about a
half.
NOTE: In taking the coling water sample,if the water in

auxiliary tank were taken,it is hard to measure
sure the accurate density. Take the cooling water
sample necessarily loosening the cooling water
discharge plug.
(2) At the state of a test paper soaked in the sampled
water, after taking the paper out through water
agitation , shake off the water.
(3) Wait for about 45 sec. till the color change of test
paper.
NOTE: However, it should not elapse longer than 75 sec,
and if it did, the hue would change.
(4) Make the numerical value by comparing the test
paper which hue has changed with the color list of
label on storage bottle.
(5) By comparing the hue changed into yellowish green
or so with the green color indication of test paper
storage bottle, confirm the density. (Then , the density
indication must be in the hue range of 33%o 50%) .
(6) The brown at the middle of test paper and the lower
pink color indication represent the additive state for
rust prevention , and the proper range is that the
meeting numerical value of brown (vertical) and pink
color (horizontal) locates in the range of 0.3 to 0.8 at
the color list of label on the test paper storage bottle.
(7) In case of less than 0.3, replenish the additive for
rust prevention (DCA4), and in case of more than
0.8, pour out the cooling water about 50% and then
readjust the density after refilling with clean fresh
water.

V-belt tension check and adjust
●V-Belt
By the finger-pressure the belt is pressed by 10mm
- 15mm between the fan pulley and the alternator
pulley in normal condition. For the adjustment of the
tension , loosen the adjusting bolts which support
the alternator, adjust the tension and tighten the
bolts agaln.
Figure 24
● Poly belt
Poly belt will be properly tensioned if the deflection
force “F” is applied midway between the belt’s tangent
points with the pulley
T = 0.015 x 8 (about 1.5mm per 100mm)
Figure 25
Intercooler (Air to air)
The intercooler is air to air type and has a large
cooling fan capacity. The intercooler life and perfor
mance depends on the intake air condition greatly.
Fouled air pollutes and clogs the air fins of intercooler.
As a result of this, the engine output is decreased and
engine malfunction is occurred. 80 you always check
whether the intake air systems like air filter element
are worn or polluted.
Figure 26

Valve clearance and adjustment
NOTE: The cylinder head bolts were previously tightened
with the torque wrench.
Therefore it is not necessary to retighten the
cylinder head bolts before adjusting the valve
clearance.
Rocker arm screw
2.6 :t 0.5kg.m
lock nut torque
Figure 27
● After letting the #1 cylinder’s piston come at
the compression top dead center by turning the
crankshaft, adjust the valve clearances.
● Loosen the lock nuts of rocker arm adjusting screws
and push the feeler gauge of specified value

between a rocker arm and a valve stem and adjust
the clearance with adjusting screw respectively and
then tighten with the lock nut.
● As for the valve clearance, adjust it when in cold, as
follows.
Model Intake Valve Exhaust Valve Figure 28

DB58
DB58S
DB58T 0.4 mm 0.4 mm
DB58TI
DB58TIS
1) Rotate the crankshaft to overlap the intake and the

exhaust valves of #6, then #1 cylinder become the
compression state of top dead center.
2) Therefore adjust the valve clearance corresponding
to“ ” of lower figure. At this time there are no force
on the push rods of #1 cylinder.
3) Rotating the crankshaft by one revolution , #6
cylinder become the compression state of top dead
center.
4) T h e r e a f t e r a d j u s t t h e v a l v e c l e a r a n c e s
corresponding to “ ” of lower figure.
5) After reinsuring the valve clearances, retighten if
necessary.

● No. 1 cylinder is located at the side where flywheel
was installed.
Figure 29
Cylinder compression pressure

● Stop the engine after warming up, and take out
preheating plug and injection plpe.
● Install the special tool(compression gauge adapter)

at the preheating plug hole, and connect the
compression pressure gauge there.
Figure 30
● Check the compression pressure at gauge several

times until highest compression reading is reached.
Standard value 28kg/cm2 over

Limit value 24kg/cm2
Difference between
Within :t 10%
each cylinder
● Condition : Water temperature 750℃.
Figure 31

Injection nozzle
Figure 32
● Install a nozzle on the nozzle tester.

● If the inspection pressure is less than the specified
value, adjust using the adjusting shims.
Engine model Injection nozzle pressure

DB58, DB588, DB58T 220 kg/cm2
EAOENB/C/D, EAOLNB 185 kg/cm2
DB58TI
EAOEF 200 kg/cm2
ECOLA 185 kg/cm2
DB58TI8
ECOENB/C/D/E/F/G, ECOLB 190 kg/cm2
● Check the atomizing state and replace it if abnormal.
Battery
● Inspect for any leakage of electrolytic solution owing
to battery crack, and replace the battery in case of
poor condition.
● Inspect for amount of electrolytic solution , and
replenish if insufficient.
● Measure the gravity of electrolytic solution, if less
than specified value (1.12~1.28), replenish.

Starting motor
In case of engine maintenance,clean ponion and
ring gear thoroughly putting in the fuel,and coat
them with grease.
Also, in case of washing engine room and so forth ,
inspect the wiring state being careful for water not to
get in.
Figure 33

Diagnosis and remedy
● The following description summarizes the probable
cause of and remedy for general failure by item.
● Immediate countermeasures should be taken before
a failure is inflamed if any symptom is detected.

Engine inspection
Stopping engine
After checking the engine for any unusual condition at
the idling speed, then turn the key switch to the stop
the engine.
General engine inspection cycle
In order to insure maximum, trouble-free engine
performance at all times, regular inspection,
adjustment and maintenance are vital
● Daily inspections in below figure should be checked
every day.
● The following maintenance details should be
executed thoroughly at regular internals.

Use of original parts for repair and replacement
For engine is being mechanically harmonized with
many parts, only when the original parts that the
manufacture recommends to use is used, the engine
trouble would be preventively maintained and
capable to keep up the maximum performances.
For the analogous parts not the original parts are poor
in qualities and gives ill performance, it may
rather bring early engine failure.

MAINTENANCE
Engine Disassembly
Major part fixing nuts and bolts
1.Cylinder head cover
(Unit : kg.m)
Figure 34
DX140AF/DX140LCA Maintenance 9-52

2.Cylinder block
(Unit : kg.m)
Figure 35

3.Oil pan and lecel gauge
(Unit : kg.m)
Figure 36

4.Camshaft and rocker arm
(Unit : kg.m)
Figure 37

5.Crankshaft,piston and flywheel
(Unit : kg.m)
Figure 38

6.Thermostat and housing
(Unit : kg.m)
Figure 39

7.Intake and exhaust manifold
(Unit : kg.m)
Figure 40

8.Intake and exhaust manifold
(Unit : kg.m)
Figure 41

9.Intaek and exhause manifold
(Unit : kg.m)
Figure 42

10.Timing gear case and flywheel housing
(Unit : kg.m)
Figure 43

11.Oil cooler,oil fillter and oil pump
(Unit : kg.m)
Figure 44

12.Fuel system
(Unit : kg.m)
Figure 45

13.Engine repair parts
Figure 46
No. Name No. Name

1 Cover to timing gear case gasket 12 Oil filter cover gasket
2 Gear case to cylinder block gasket 13 Oil cooler gasket
3 Timing gear case oil seal 14 Intake manifold gasket
4 Flywheel housing gasket 15 Oil pan gasket
5 Crank shaft rear oil seal 16 Turbocharger gasket
6 Cylinder head gasket 17 Turbocharger outlet gasket
7 Cylinder head cover gasket 18 Water pump gasket
8 Valve guide oil seal 19 Water pump housing gasket
9 Tappet chamber cover gasket 20 Exhaust manifold gasket
10 Air heater gasket 21 Thermostat gasket
11 Thermostat housing gasket 22 Oil pump hole cover gasket

Main structure parts (1)
Figure 47
No. Name No. Name

1 Rubber hose (Coolant by-pass) 9 Oil pump driving pinion
▲2 Rocker arm shaft assembly 10 Nut
3 Push rod ▲11 Crankshaft pulley and dust cover
4 Cylinder head bolt ▲12 Taper bushing
▲5 Cylinder head assembly 13 Timing gear cover
6 Cylinder head gasket 14 Oil thrower
7 Coolant pump assembly ▲15 Fly wheel
8 Tappet chamber cover
2) Rocker arm shaft

Loosen the rocker arm shaft fixing bolts a little in
numerical sequence as specified.
Figure 48

5) Cylinder head
Loosen the cylinder head bolts a little in the
numerical order shown in the figure.
Figure 49
11) Crankshaft pulley

Use an appropriate wrench (54 mm) to remove the
crankshaft pulley nut.
Figure 50
12) Taper bushing

Use the taper bushing remover to remove the
crankshaft end taper bushIng.
Figure 51
15) Flywheel
Loosen the flywheeI bolts a little in the numencal
order as specified.
Figure 52

Main structure parts (2)
Figure 53
No. Name No. Name

1 Oil cooler 9 Timing gear case
2 Oil pan 10 Idler gear shaft
3 Oil pump and coupling ▲11 Crank shaft bearing cap
4 Flywheel housing 12 Crank shaft bearing (Iower part)
5 Piston and connecting rod 13 Thrust bearing
▲6 Idler gear 14 Crank shaft
▲7 Cam shaft 15 Crank shaft bearing (upper part)
8 Tappet

6) Idler gear
Measure the following points before disas-sembly.
<Idler gear end play>
Standard Limllt
0.058 - 0.115 mm 0.2 mm
Figure 54
<Timing gear back lash>
Standard Limllt
0.10 - 0.17 mm 0.3 mm
Includes the crankshaft gear, the camshaft gear

and the idler gear.
Figure 55
7) Camshaft
Measure the following points before disas sembly.
<Cam Gear End Play>

Standard Limllt
0.050 - 0.114 mm 0.2 mm
Figure 56
11) Crankshaft bearing cap

Measure the crankshaft endplay at the thrust
bearing (center main bearing) before disassembly.
<Crankshaft End Play>
Standard Limllt
0.15 - 0.33 mm 0.4 mm
Figure 57

Rocker arm disassembly
Figure 58
No. Name No. Name

1 Bracket 3 Spring
2 Rocker arm 4 Rocker arm shaft

Cylinder head disassembly
Figure 59
No. Name No. Name

1 Exhaust manifold and gasket 7 Spring seat(upper)
2 Intake manifold and gasket 8 Valve spring
3 Coolant outlet pipe 9 Spring seat(upper)
4 Thmostat 10 Valve
5 Thermostat housing and gasket 11 Valve sterm oil seal
▲6 Valve cotter

IMPORTANT
6)Valve cotter
Use the valve spring compressor to remove the valve
cotter.
Figure 60
Piston and connecting rod disassembly
Figure 61
No. Name No. Name

1 Piston rings 4 Spring
2 Snap ring 5 Connecting rod bearing
3 Piston pin and connecting rod

IMPORTANT
Remove any carbon deposits from the upper part of
the cylinder bore.
This will prevent damage to the piston and the piston
rings when they are removed fron the cylinder bore.
Figure 62
1. Piston rings
Use a piston ring remover to remove the pis-ton
rings.
Do not attempt to use other tools. Stretching piston
ring will result in reduced piston ring tension.
Figure 63
2. Snap ring
Use a pair of snap ring pliers to remove the snap
ring.
Figure 64
3. Piston pin
Tap the poston pon out with a hammer and brass
bar.
Figure 65

Engine Inspection
Cylinder block
● Clean the cylinder block thoroughly and make a
visual inspection for cracks or damage.

● Replace if cracked or severely damaged, and
correct if slightly damaged.

● Check oil and water flow lines for restriction or
corrosion.
● Make a hydraulic test to check for any cracks or air
leaks.
(Hydraulic test) :
Stop up each outlet port of water/oil passages in the
cylinder block, apply air pressure of about 5kg/cm2
against the inlet ports then immerse the cylinder block
in water for about 3 minute to check any leaks. (Water
temperature : 70 C)
Cylinder block
1) Inspection
● Carefully remove carbon from the lower lace of
the cylinder head using nonmetallic material to

prevent scratching of the valve seat faces.
● Check the entire cylinder head for very fine
cracks or damage invisible to ordinary sight using

a hydraulic tester or a magnetic flaw detector.
2) Distortion at the lower face
● Measure the amount of distortion using a straight
edge and a feeler gauge at six positions (A - F) as

shown in the right figure.
● If the measured value exceeds the standard
value, retrace the head with grinding paper of fine

grain size to correct such defect.
● If the measured value exceeds the maximum
allowable limit, replace the cylinder head. Figure 66
<Lower face warpage and height>
Standard Limit
Warpage 0.2 mm or less 0.3mm
Thickness : t 89.95- 90.05 mm 89.65mm
Figure 67

3) Flatness
Measure flatness of the intake/exhaust manifolds
fitting surfaces on the cylinder head using a straight
edge and a feeler gauge.
Standard Limit
0.05 mm 0.2mm
4) Hydraulic test
Hydraulic test method for the cylinder head is same
as that for cylinder block.
Figure 68
Valve stem and valve guide clearance

1)Measuring method - I
● After install dial gauge needle on the inserted
valve stem , set up calibrator to “0”. (as shown in

figure)
● Move valve head from side to side.
Record total dial indicator reading.

This valve is the clearance between the valve
stem and valve guide.
● Valve and guide set must be replaced if measured
value exceed the specified limit
<Valve stem clearance (T. I.R)> Figure 69
Standard Limit
Intake side 0.039 - 0.071mm 0.20mm
Exhaust side 0.064 - 0.096mm 0.25mm

2) Measuring method - 11
● Measure valve stem outside diameter.
● Measure valve guide inside diameter by using of
caliper calibrator of telescoping gauge.

● The difference between the valve stem outside
diameter and the valve guide inside diameter is

the valve stem clearance.
Figure 70
3) Valve guide replacement

● Removal of valve guide.
● Pull out the valve guide, by using hammer and
valve guide remover, from bottom of cylinder

head.
Figure 71
● Install of valve guide.

● The height from the bottom of the cylinder head to
the edge of valve guide top
4) Valve depression
● Install the valve ①to the cylinder head②.
Figure 72
● Measure valve depression by using the depth
gauge or calibrator from the bottom of cylinder

head.
● Seat insert and valve must be replaced if the
measured value exceed the specified limit.

● If the valve is replaced , the valve guide must be
also replaced.
Standard Limit
I ntake and exhaust
1.0mm 2.5mm
valve depression
Figure 73

5) Valve contact width
● Inspect the valve contact faces for the roughness
and unevenness.
Make valve contact surfaces smooth.
● Measure the width of valve contact.
Limit
V’alve contact width, Intake 2.4mm
Valve contact width , Exhaust 1.6mm
Figure 74
6) Valve seat replacement

● Arc weld entire inside circumference①of the valve
seat②(see figure)
● Cool valve seat for a few minutes. This will make
removal of the valve seat easler.

● Pull out the valve seat by using the inner extractor
● Carefully remove the carbon and other foreign
material from the cylinder head insert bore.
Figure 75
7) Valve seat installation

● Carefully place Jig①
CAUTION
The smooth face of jig must contact the valve seat.
● Assemble valve insert by slowly pressing it Figure 76

against the jig with the bench press.
(The amount of needed pressure is more than
2,500kg.)
IMPORTANT
Do not press the valve seat excessively with the
bench press.
It may damage the valve seat.

8) Valve seat correction
● Remove the carbon deposits from the valve seat
surface.
● Remove the rough areas by using valve cutter.
(30°, 90°or 150°)

Do not cut the valve seat too much.
Angle Location Standard
Intake valve seat 90°
Exhaust valve seat 90°
Figure 77
IMPORTANT
Use an adjustable valve cutter pilot.
Do not allow the cutter pilot to wobble inside the valve
guide.
Figure 78
● Spread compound on the surface of valve seat.

● Insert valve into valve guide.
● Lap the valve and valve seat with the lapping tool.
● Check that valve contact width is correct.
Figure 79
● Check that the entire surface of valve seat is in

contact with the valve.
Figure 80

Valve spring
1) Valve spring free length
● Measure the valve spnng with the vernier caliper.
● Replace the spring if the measured value is less
than the specified limit.

Standard Limit
Exhaust and intake valve
53.65mm 52mm
spring free length
Figure 81
2) Valve spring inclination

● Measure the valve spring inclination by the using
of square.
● Replace the valve spring if the mea-sured value
exceed the specified limit.
Standard Limit
Valve spring Inclination 2.5mm 3.5mm
Figure 82
3) Valve spring tension

● Measure the valve tension by using spring tester.
● Replace the valve spring if the measured value
Standard Limit
Valve spring tension at
22.5kg 20.0kg
44mm set length
Figure 83

Tappet
● Check the valve tappets for excessive wear,
damage or abnormalities.
Figure 84
● Measure the outside diameter of tappet with the

micrometer.
Standard Limit
Tappet outside
N27.96~N29.98mm N27.92mm
diamleter
Figure 85
● Measure the clearance between tappets and

cylinder motion parts by the using dialindicator.
Standard Limit
Tappet and tappet
0.020~0.054mm 0.1mm
bore clearance
Figure 86
Push rod
● Measure the run out of push rod with the feeler
gauge.
● Roll the push rod along a smooth flat surfcace as
shown in the figure.
Limit
Push rod of run-out 0.2mm
Figure 87

Rocker arm correction
● Check the valve stem contact part of rocker arm.
● Grind contact surface with an oil stone il it is
irregularly contacted.
● Replace the rocker arm il it is extremely damaged.
Figure 88
1) Rocker arm and shaft

● Check the disassembled parts lor wear, damage
and abnormalities.
Figure 89
2) Rocker arm shaft outside diameter

● Measure the outside diameter 01 rocker arm with
the micrometer.
● Replace shaft il measured value exceed the
specilied limit.
Standard Limit
Diameter of
N18.98~N19.00mm N18.85mm
rocker arm shaft
Figure 90
3) Rocker arm and shaft clearance

● Measure the inside diameter of rocker arm
bushing with the vernier caliper.
● Measure the out side diameter of rocker arm
shaft.
Standard Limit
Diameter of rocker
N19.02~N19.05mm N19.07mm
arm bushing
Figure 91

Standard Limit
Rocker arm
bushing and
0.02~0.07mm 0.2mm
rocker arm shaft
clearance
● Check the rocker arm oil port whether alien
substance is in it or not.
● Clean the rocker arm oil port with compressed air il
necessary. Figure 92
Idler gear and shaft

● Replace the idler gear shaft if measured value
exceeds the specified limit.

Standard Limit
Diameter of
N44.945~N44.975mm N44.9mm
idler gear shaft
Figure 93
● Measure the inside diameter of idler gear with the

dial indicator.
Standard Limit
Clearance of idle
0.045~0.105mm 0.2mm
gear and shaft
Figure 94
Camshaft
● Use the jig to install or overhaul camshaft bearing in
cylinder block.
● Measure the clearance between the cam journal and
the camshaft bearing.
Figure 95

Standard Limit
Clearance of cam
joumal and cam 0.03~0.09mm 0.15mm
bearing
Figure 96
● Align the camshaft bearing oil port with the mating

oil port (machined on the cylinder block).
Figure 97
● Measure the cam lobe with the micrometer.

Replace the camshaft if the measured values
Standard Limit
Cam lobe height (C-D), In 7.44mm 6.94mm
Cam lobe height (C-D), Ex 7.71mm 7.21mm
Cam journal diameter N56.0mm N55.6mm
Figure 98
● Set up the camshaft on a measuring stand.

Measure the run out of camshaft woth the dial
indicator.
Record the measured value (T.I.R)
Replace the camshaft if the measured value
Limit
Camshaft run-out 0.12mm
Figure 99

Cylinder liner
1) Cylinder liner bore measurement
● Measure the bore at measuring position ①in line
with the crankshaft③and across the crankshaft②.
Figure 100
● Measured position: 20 mm from the top of liner. (max.

wear portion)
● Replace the cylinder liner if the measured value
exceeds specified limit.

Standard Limit
Diameter of
cylinder liner N102.017~N102.046mm N102.20mm
bore
CAUTION
Figure 101
The casting liner is specially honed without the chrome
plating inside,so that chrome ting (top ring and oil ring)
must be used.
2) Cylinder liner inspection

● Set up the straight square along the top edge of
cylinder liner.
● Measure liner projection with the feeler gauge.
Standard
Cylinder liner Cast liner 0.02~0.07mm
projection Steel liner 0.015~0.115mm
● The difference in the liner projection height between

any two adjacent cylinders must NOT exceed 0.3mm Figure 102

3) Cylinder liner replacement
● Set the cylinder liner remover to the cylinder liner.
● Check that cylinder liner remover shaft bottom
edge.
● Slowly turn the remover shaft handle counter-
clockwise to pull the cylinder liner free.
IMPORTANT
Take care not to damage the cylinder body upper face
when remove the cylinder liner. Figure 103
Cylinder block
1) Grade selection of cylinder liner
● Select a grade from the outside diameter of
the cylinder liner and inside diameter of block

combination.
● Determine a grade of the cylinder liner after
measuring the inside diameter of the cylinder

block.
● Loose fitting cylinder liners (the liner is too small
for the cylinder bore) will adversely affect engine

cooling efficiency and may lead to serious engine
damage. Cylinder liners which are too large for Figure 104
the cylinder bore will be difficult to install.
2) Cylinder block bore measurement

● M e a s u r e a t m e a s u r i n g p o i n t ①a c r o s s t h e
positions W- W, X-X, Y-Y and Z-Z.

Measuring point diameter : 115 mm
● Calculate average value of four measurements to
determine the correct cylinder liner grade.
Figure 105

Grade marking Cylinder block bore diameter
1 N105.090 - N106.000 mm
2 N106.000 - N1 06.01 0 mm
Figure 106
3) Cylinder liner outside diameter

● Measure the liner outside diameter at①,②and③
measunng pOlnt across X-X, Y-Y.

Measuring Points :
①20.0 mm
②105.0 mm
③185.0 mm
● Calculate the average value of 6 measurements
to determine the correct cylinder liner grade.

● Combination of the cylinder bore and the cylinder
liner outside diameter. Figure 107
Steel liner(tightness) Cast iron liner(clearance)

Cylinder liner fitting clearance 0.001 - 0.019mm 0.005 - 0.026mm
<Cylinder bore and liner outside diameter>

(A) Steel cylinder liner
Grade Cylinder bore Cylinder liner outside diameter

1 N105.001 - N1 05.01 Omm N105.011 - N105.020mm
2 N105.011 - N105.020mm N105.021 - N105.030mm
3 N105.021 - N105.030mm N105.031 - N105.040mm
(B) Cast iron cylinder liner
Cylinder liner diameter Grade marking

② position ①,③position
N102.020 - N1 02.031 mm N1 02.017 - N102.035mm 1
ND(Inner diameter)
N102.031 - N1 02.042mm N102.028 - N102.046mm 2
N105.973 - N1 05.984mm N105.970 - N105.988mm A
NE(Outer diameter)
N1 05.984 - N1 05.995mm N105.981 - N105.999mm B

Part no 01 cylinder Cylinder liner diameter
Marking
liner grade Outer Inner
65.01201-0068 1 A 1A
65.01201-0069 1 A 1B
65.01201-0070 2 B 2A
65.01201-0071 2 B 2B
4) Cylinder liner assembly

● Carefully wipe away any foreign material from the
cylinder liner inside and outside surfaces and the Figure 108
cylinder bore.
● Cleanly wash cylinder liner and bore surfaces with
new kerosene or diesel oil.

● Use a clean rag to remove all traces of kerosene
or diesel oil from cylinder liner and bore surfaces.

● Insert the cylinder liner into cylinder block from
the top of the cylinder block.

● Set the cylinder liner installer to the top of the
cylinder liner.
● Position the cylinder body so that the installer
Figure 109
center is directly beneath the bench press shaft
center.
● Check that the cylinder liner is set perpendicular
to the cylinder.
● Use the bench press to apply an initial seating
force of 500kg to the cylinder liner.

● Use the bench press to apply a final seating force
of 2,500kg to fully seat the cylinder liner.

● After installing the cylinder liner, measure the
cylinder liner projection.
5) Piston grade selection Figure 110

● “Piston grade” refers to the piston diameter and
the cylinder liner bore combination.

● Selection of the proper piston grade will ensure
efficient engine operation, free from cylinder liner

and piston problems.
● Measure the cylinder liner bore after installing the
cylinder liner.
● Determine the appropriate piston grade after
measuring cylinder liner bore

6) Cylinder liner bore measurement
● Loacte the two measuring points.
Cylinder liner measuring point

-①:20mm
-②: 105mm
● M e a s u r e c y l i n d e r l i n e r b o r e a t m e a s u r i n g
points①and②in four different directions (X-X,Y-

Y,W-W and Z-Z)
● Calculate the average value of the 8
measurements. Figure 111

Standard
Cylinder liner bore N1 02.020 - N1 02.042 mm
CAUTION
It is most important to use correct piston- liner
combination. Incorrect combination will result in piston
seizure.
Always measure the cylinder bore and select the
appropriate piston grade.
Figure 112
Piston
1) Piston outside diameter
● Piston outside diameter vary depending on the
piston type to be used.

● Measure the piston outside diameter② (see
figure).
<Piston grade>
Grade Limit
A N101.953 - N101.967 mm
B N101.963 - N101.977 mm
Figure 113

<Cylinder liner bore and piston>
Clearance 0.053 - 0.077 mm
CAUTION
The cylinder liner-piston kit clearances are preset.
However, the cylinder liner installation procedure may
result in slight decreases in the cylinder liner bore
Figure 114
clearances.
Always measure the cylinder liner bore clearance after
installation to be sure that it is correct.
2) Piston ring and piston groove clearance

● Measure the piston ring and the piston ring
groove clearance with a feeler gauge.

● Measure it at several points around the piston.
● Replace the piston ring If the measured value

<Piston ring and piston groove clearance>
Standard Limit
Top ring 0.070 - 0.120 mm 0.20
2nd ring 0.050 - 0.085 mm 0.15
Oil ring 0.030 - 0.070 mm 0.15 Figure 115
3) Piston ring gap

● Insert the piston ring horizontally (in the position
it will assume if it were installed to the piston) into
the cylinder liner.
● Push the piston ring with an inverted piston
into the cylinder liner until it reaches measuring

point①or ②The cylinder liner diameter is the
smallest at these two points.
Do not allow the piston ring to slant to one side or
the other. It must be perfectly horizontal.
Cylinder liner measuring point
Figure 116
-①: 10mm
-②: 130mm

● Measure piston ring gap with a feeler gauge.
● The piston ring must be replaced if the measured
value exceeds the specified limit.
Standard Limit
Top ring 0.25-0.45 mm 1.50 mm
2nd ring 0.40-0.60 mm 1.50 mm
Oil ring 0.20-0.40 mm 1.50 mm
4) Piston pin
● Measure piston pin outside diameter with
micrometer at several points.

● Replace the piston pin if the measured value

Standard Limit
Piston pin outside
N35.000-N35.005mm N34.95mm
diameter
Figure 117
5) Piston pin hole

● Measure diameter of the piston pin hole with
inside dial gauge.
Standard
Piston pin and piston
N35.010 - N35.018 mm
clearance
Figure 118
6) Piston pin and piston pin hole clearance

● Determine the clearance between the piston
pin and the piston pin hole by calculating the

difference between the piston pin hole diameter
and the piston pin outside diameter.
Limit
Piston pin and piston pin
0.005 - 0.018 mm
hole clearance
Figure 119

● If an inside dial indicator is not available, use the
following procedure to check the piston pin fi t.
(1) Heat piston to approximately 60C with the piston
heater.
(2) Push strongly against the piston pin with your
thumb. The piston pin fitting should feel tight.
Maintenance of cylinder block, cylinder liner and piston Figure 120

To maintain the engine in optimum condition and
retain maximum performance for a long time, the
cylinder block, cylinder liner and piston which have
the same grade marking number (the same size
tolerance) should be assembled. The marking number
(the part’s grade) and marking position is as follows.
● Cylinder block
a) Marking number ; 1 or 2
(Size grade for of cylinder bore diameter)
b) Marking position ; Top of the cylinder
block side surface
Figure 121
● Cylinder liner
a) Marking number; 1 A, 1 B, 2A or 2B
1A
Can used the poston Agrade

Can used the cylinder block 1 grade
b) Marking position ; Cylinder liner lower surface.
●Piston
a) Marking number ; A or B Figure 122
(Size grade for piston outer diameter)
b) Marking position ; Center of the piston upper
surface

● Assembly process of cylinder block, cylinder liner
and piston.
(1) Check the marking number (1 or 2) of cylinder
block. (Top of side surface)
(2) Then assemble the liner whose first digit of the
marking (1 A, 1 B, 2A, 2B) is just the same with it
on the cylinder block.
(3) Assemble the piston whose marking is just same
with the second digit (A or B) of the assembled
cylinder liner’s marking.
Connecting rod
1) Connecting rod alignment
● Measure the parallelism between the connecting
rod big end hole and small end hole with a

connecting rod aligner.
● Replace the connecting rod if the measured value

Standard Limit
Connecting rod
0.05mm or less 0.20mm
parallelism
Figure 123
2) Piston pin and bush clearance
● Measure an inside of connecting rod bushing and
outside of piston pin with the caliper gauge and

micrometer.
● Replace a connecting rod bush or piston pin if the
measured value exceeds the specified.

Standard Limit
Piston pin and
0.012-0.030mm 0.05mm
bushing clearance
Figure 124
3) Connecting rod bush replacement
● Connecting rod bush removal.
(1) Clamp the connecting rod in a vise.
(2) Pull out connecting rod bush by using a brass
bar with a bench press or a hammer.
● Connecting rod bush assembly.
(1) Use special jig to assemble the connecting rod

bush.
IMPORTANT
Alige the connecting rod bush oil hole with the
Figure 125
connecting rod oil hole.

(2) Use a piston pin hole grinder ①fitted with a
reamer ②or an adjustable pilot reamer to ream
the piston pin hole.
Standard
Connecting rod bush
N35.017 - N35.030mm
inside diameter
Figure 126
4) Connecting rod bearing Inspection

● Fit the connecting bearing lower half into the
connecting rod bearing cap.
● Check the tension of the connecting rod bearing
lower half.
If the tension is insufficient, the bearing must be
replaced.
● Tighten the connecting rod and the bearing cap to
the specified torque.

A type B type Figure 127
Connecting rod
12.5±0.25kg.m 9.75±0.25kg.m
bolt torque
● Measure the inside diameter of the connecting rod

bearing with an inside dial gauge.
Standard
Connecting rod
N63.974 - N64.005mm
bearing diameter
Figure 128

Crankshaft
1) Crankshaft and bearing inspection
● Check the crankshaft journal surfaces and pin
surfaces for excessive wear and damage.

● Check oil seal fitting surfaces of the crankshaft
front and rear ends for excessive wear and

damage.
● Replace or repair the crankshaft if any excessive
wear or damage is discovered.

● Check the crankshaft oil ports for obstructions
● Clean oil port with high pressure air if necessary.
2) Crankshaft journal and pin diameter

● Measure the crankshaft journal outside diameter
with the micrometer across ①-① and ②-②.

● Measure crankshaft journal outside diameter at
two points③and ④by using the micrometer.

● Repeat step 1 and 2 to measure the crankshaft
outside diamleter.
The crankshaft must be reground if the measured
value of the crank pin outside diameter and/or
crankshaft journal diameter exceeds the specified
Figure 129
limit
Standard
Crankshaft journal
N79.905 - N79.925mm
outside diameter
Standard
Crankshaft pin
N63.924 - N63.944mm
outside diameter
● Measure the crankshaft journal outside diameter

(and/or crankshaft pin outside diameter) and
bearing inside diameter to determine the bearing
clearance.
3) Crankshaft journal and bearing clearance
● If the bearing clearance exceeds the specified
limit, the crankshaft must be reground and/or the

bearing must be replaced.
Standard Limit
Main bearing
0.025-0.090mm 0.11mm
clearance

Standard Limit
Rod bearing
0.03-0.073mm 0.10mm
clearance
4) Crankshaft bearing diameter

● Install the main bearing cap with bearings to the
cylinder block with the specified torque and facing

the arrow mark on the bearing cap toward front.
Place them in order of punched cylinder numbers.
● Measure the main bearing diameter with an inside
dial gauge
Main bearing cap torque 24.1±1kg.m
Main bearing diameter N80mm

Figure 130
5) Crankshaft run-out
● Mount the crankshaft on a set of Vblocks.
● Set the dial gauge to the center of the crankshaft
journal.
● Gently rotate the crankshaft in the normal
direction of engine rotation.

● Read the dial indicator (TIR) as you turn the
crankshaft.
● The crankshaft must be replaced if the measured
value exceeds the specified limit.
Standard Limit
Crankshaft run- Figure 131
0.05mm 0.40mm
out
● If the repaired crankshaft generated a crack,

replace it.

6) Main bearing and con-rod bearing tension
● Check to see if the bearing has enough tension ,
and set bearing into its regular position with the

finger pressure.
Figure 132
7) Crankshaft regrinding
● Pay close attention to the following steps in order
to ensure the reground-crankshaft reliability.
Undersize bearing
0.25mm 0.50mm
Availability
<Crankshaft regrinding procedure>

(1) Grind the crankshaft journal part and pin part.
(2) Fillet the crankshaft journal and crank pin radius to
a minimum of R3.5:t0.2.
There must be no stepping around the fillet area.
(3) Finish the crankshaft journal , crank pin and oil
hole corners to a smooth surface having a chamfer
radius of 1mm.
Figure 133
Crankshaft Journal and
0 .4μor less
crank pin roughness
(4) Measure the clearance between crankshaft journal

and crank pin.
(5) Measure the crankshaft run-out.
8) Crankshaft grinding limit

Limit
Crank journal outside N79.419 Diameter N79.419
Crank pin outside Diameter N63.424
● Undersize bearings (0.25 and 0.5 mm) are

available to compensate for excessive clearance
between the crankshaft journal bearing and the
crankshaft. Regrinding of the crankshaft to fit the
undersize bearings is required.

Standard Limit
Main bearing
0.039-0.098mm 0.11mm
clearance
Standard Limit
Connecting rod
0.03-0.073mm 0.10mm
bearing
9) Crankshaft gear replacement

● Visually inspect the crankshaft gear.
● Replace the crankshaft gear as following steps if
excessive wear or damage is discovered.

(1) Disassemble the crankshaft gear by using the
crankshaft remover.
Figure 134
(2) Replace new part.

(3) Heat the crankshaft gear for at least 10 minutes
to 120C.
(4) Use the crankshaft gear installer to install the
crankshaft gear.
Figure 135

Flywheel and flywheel housing
1) Ring gear inspection
● Inspect the ring gear.
● If the ring gear teeth are broken or excessively
worn the ring gear must be replaced.
Figure 136
2) Ring gear replacement
● Strike around the edges of the ring gear with a
hammer and chisel to remove it.

3) Ring gear installation
● Heat the ring gear evenly with a gas burner to
invite thermal expansion.

Pay attention that temperature of ring gear is not
exceeded 200C.
● Use a hammer to install the ring gear when it is
sufficiently heated
Figure 137
4) Oil seal replacement (rear)

● Use a pry bar to remove the flywheel housing oil
seal.
● Assemble the oil seal to flywheel housing by
using the oil seal assemble jig.
Figure 138
5) Oil seal replacement (front)

● Use an adapter and a hammer to remove the
crankshaft front end oil seal.

● Assemble the oil seal to flywheel housing by
using the oil seal assemble jig
Figure 139

Engine Reassembly
Piston and connecting rod assembly
Figure 140
No. Name No. Name

▲1 Piston ▲4 Piston ring
▲2 Piston pin and connecting rod ▲5 Connecting rod bearing
▲3 Snap ring 6 Connecting rod bolt
1) Piston
● Use a piston heater to heat piston to
approximately 60C.
Figure 141

2) Connecting rod
● Install the piston and connecting rod with setting
the marks as illustrated

● Assemble the piston pin into the piston and
connecting rod bushing.
Figure 142
3) Snap ring
● Assemble the snap rings by using snap ring flyer.
● Check that the piston moves smoothly on the
piston pin.
Figure 143
4) Piston ring
● Assemble the piston ring by using piston ring
assembly jig.
● Systematically assemble piston rings as follows:
(1) Oil ring

(2) 2nd compression ring
(3) 1 st compression ring
Rightly assemble the 1 st and 2nd compression
rings that the marked side must be facing “up”.
Oil ring may be assembled any way because it is Figure 144
not indicated.
● Lubricate the surface of piston ring with engine
oil.
● Check it whether piston rings are smoothly
rotating in the piston ring grooves.

5) Connecting rod bearing
● Assemble the connecting rod bearing to the big
end and the cap.
● Lubricate the bearing with engine oi l.
● Assemble the connecting rod and connecting
rod bearing, and tighten cap bolt as the specified

torque.

Cylinder head assembly parts
Figure 145
No. Name No. Name

▲1 Valve stem oil seal 7 Thermostat housing and gasket
▲2 Intake and exhaust valve 8 Thermostat
3 Spring seat (Iower) 9 Cooling water outlet
▲4 Intake and exhaust valve spring ▲10 Intake manifold and gasket
▲5 Spring seat (upper) ▲11 Exhaust manifold and gasket
▲6 Valve cotter
1) Valve stem oil seal

● Lubricate the oil seals and valve stem sealing
area with engine oil.
● Assemble the valve stem oil seal by using oil seal
installer.
Figure 146

2) Intake and exhaust valves
● Place the cylinder head on a flat wooden surface.
● Lubricate valve stem with the engine oil
● Assemble the valves to the intake or exhaust
valve guides.
Figure 147
4) Intake and exhaust valve springs

● Assemble the valve spring with their painted end
facing top
Figure 148
5) Spring seat
6) Valve cotter
● Use a spring compressor to push the valve spring
into position.
● Install the spring seat split collar.
Figure 149
● Set the spring seat split collar by tapping lightly

around the head of the collar with a rubber
hammer.
Figure 150

10) Intake manifold and gasket
● Assembly the intake manifold gasket.
The intake manifold gasket must be installed

with its unchamfered corner facing “up” and to
the front of the englne.
Figure 151
● Assemble the intake manifold.

● Tighten the intake manifold bolts to the specified
torque a little at a time in the numerical order.
(see figure)
Intake manifold bolt rque 2.2
Figure 152
11) Exhaust manifold and gasket

● Install the exhaust manifold gasket.
● The “TOP” mark must be facing up.
Figure 153
● Install the exhaust manifold

● Tighten the exhaust manifold bolts to the
specified torque a little at a time in the numerical
order. (see figure)
Exhaust manifold bolt torque 2.2
Figure 154

Rocker arm and shaft assembly
Figure 155
No. Name No. Name

▲1 Rocker arm shaft 3 Rocker arm
▲2 Spring 4 Bracket
1) Rocker arm shaft

● The rocker arm shaft must be installed with the oil
holes facing up.

Main components
Figure 156
No. Name No. Name

▲2 Crankshaft bearing (Iower) ▲9 Idler gear shaft
▲3 Crank shaft ▲10 Idler gear
▲4 Thrust washer ▲11 Piston and connection rod
▲5 Crank shaft bearing (upper) and cap ▲12 Oil pump and coupling
▲6 Timing gear case ▲13 Flywheel housing
7 Tappet ▲14 Oil pan
▲8 Camshaft ▲15 Oil cooler
* The tappet must be installed before the camshaft

installation.

2) Crankshaft bearing (Iower)
● There is no oil hole and oil groove on the lower
bearing. But opposite upper bearing has oil hole

and oil groove.
Figure 157
3) Crankshaft
● Assemble the crankshaft gear in front side.
CAUTION
Make sure the part number of crankshaft because its
counterweight size may be different depending upon
engines.
Figure 158
4) Thrust washer
● Assemble thrust washer with the oil groove side
facing the crankshaft sliding face.
Figure 159
5) Crankshaft bearing cap

● Lubricate the bearing cap bolts with engine oil
● Assemble the bearing caps to the crankshaft.
The arrow mark must be pointing to the front of

the engine.
Figure 160

● Tighten the bearing cap bolts to the specified
torque a little at a time in the numerical order. (see
figure)
Crankshaft bearing
24.0±1 kg.m
cap bolt torque
● Check that the crankshaft turns smoothly by
manually rotating it
Figure 161
6) Timing gear case

● Tighten timing gear case bolt to the specified
torque
Timing gear case bolt torque 2.2
● Apply silicon to the indicated area. (see figure)
Figure 162
8) Camshaft
● Tighten thrust plate bolt through the camshaft
gear hole.
Thrust plate bolt torque 2.2
Camshaft gear bolt torque 13
Figure 163
9) Idler gear shaft

● Assemble an idler gear shaft by using the thrust
collar fixing bolt as a guide.

● The oil hole must be facing the camshaft.
● Lubricate the idle gear shaft with engine oi l.
Figure 164

10) Idler gear
● Assemble the idle gear.
Set the timing marks “A” , “B” , and “C” as shown

in the figure.
● Tighten the idle gear bolts seating the thrust
collar to the specified torque.

● The thrust collar must be installed with the
chamfered side facing the front of the engine.

Idle gear bolt torque 2.2
Figure 165
11) Piston and connecting rod

● Set the piston ring gaps as shown in the figure.
● Lubricate the piston , the piston ring and the
connecting rod bearings with engine oil.
Figure 166
● Position the piston front mark towards the front of

the engine.
● Use the piston ring compressor to compress the
piston rings.
● Push the piston in until it makes contact with the
crank pin by using a hammer gnp.

At the same time, rotate the crankshaft until the
crank pin reaches its highest point.
Figure 167
● Set the bearing cap cylinder number marks and

the connecting rod cylinder number marks.
● Lubricate the connecting rod cap bolt threads
and setting face with MOS2 grease.

● Tighten the connecting rod cap bolts to the
specified torque.
Refer to the following table.
Figure 168

Figure 169
12) Oil pump assembled

● Lubricate the oil pump with the specified engine
oil.
● Install the oil pump with the coupling.
● Tighten the oil pump bolts to the specified torque.
Oil pump bolt torque 5.0
Figure 170
13) Flywheel housing

● Apply silicon to the shaded area. (see figure)
● Install the flywheel housing.
Tighten the flywheel housing bolts to the

specified torque.
M14 x 1.5 13
M16 x 1.5 16
Figure 171
14) Oil pan

● Apply liquid gasket to the area indicated by the
arrows in the figure.

● Install the gasket and oil pan.
● Tighten the oil pan bolts to the specified torque.
Oil pan bolt torque 2.2
Figure 172

15) Oil cooler
● Assemble the oil cooler with gasket after applying
sealant to the oil cooler gasket

● Tighten the oil cooler bolts to the specified
torque. in the numerical order (see figure)
Figure 173

Major component assembly
Figure 174
No. Name No. Name

▲1 Flywheel 9 Oil pump driving pinion
▲2 Crankshaft pulley nut 10 Push rod
▲3 Tappet chamber cover 11 Taper bushing
▲4 Water pump 12 Crankshaft pulley and dust cover
▲5 Cylinder head gasket 13 Timing gear cover
▲6 Cylinder head bolt 14 Oil thrower
▲7 Cylinder head 15 Rubber hose
▲8 Rocker arm shaft Assembly

1) Flywheel
● Lubricate the flywheel bolt with engine oil.
● Install the flywheel.
Tighten the flywheel bolts to the specified torque

in the numerical order. (see figure)
Flywheel bolt torque 18
Figure 175
2) Injection pump
● Align the injection pump gear “C” timing mark with
the idler gear “C” timing mark.
Figure 176
● Tighten the injection pump bolts to the specified

torque.
Injection pump bolt torque 2.2
Figure 177
3) Crankshaft pulley nut

● Tighten the crankshaft pulley nut to the specified
torque by using a wrench.
Crankshaft pulley nut torque 60
Figure 178

3) Tappet chamber cover
● Apply silicon to the tappet chamber cover gasket.
● Assemble the tappet chamber cover and tighten
the bolts to the specified torque.

Tappet chamber cover bolt torque 2.2
Figure 179
4) Water pump
● Apply silicon to the pump gasket before installing
the water pump.
Figure 180
5) Cylinder head gasket

● The gasket “TOP” mark should be faced up and
“FRONT” mark is towards the front of the engine.
Figure 181
6) Cylinder head bolts

7) Cylinder head
● Carefully place the cylinder head on the cylinder
block.
● Tighten the cylinder head bolts to the specified
steps and torque in the numerical order as figure

and following table.
Figure 182

Bolt type Torque
1 st step : 7.0kg.m
hexagonal bolt
2nd step: 11.5+0.5kg.m
1 st step : 4.4kg.m
Dodecagonal bolt 2nd step : 90°
3rd step : 90°
<12-gonal bolt limited value>
8tandard(mm) Limit(mm)
105 116.2
102 103.2
● Apply engine oil to the cylinder head bolts threads

and setting faces.
8) Rocker arm shaft assembly

● Tighten the rocker arm bolts to the specified
torque a little at a time in the numerical order. (see

figure)
Rocker arm shaft

3.1
bracket bolt torque
Figure 183
● Lubricate the rocker arm and the rocker arm shaft
with engine oil.
● Adjust valve clearance.

External parts
Figure 184
No. Name No. Name

1 Flywheel housing 15 Cooling water pump
2 Lifting hook 16 Air heater
3 Oil filler cap 17 Thermostat housing
4 Fuel filter 18 Water pump pulley
5 Intake manifold 19 Alternator
▲6 Air pipe(intercooler to manifold) 20 Water outlet
7 Breather 21 Air pipe(turbocharger to intercooler)
8 Cooling fan 22 Turbo charger
▲9 Oil filter 23 Exhaust manifold
10 Oil pan 24 Crank shaft pulley
11 Oil drain plug 25 Starter
12 Fuel injection pump 26 Push rod chamber cover
13 Fuel feed pump 27 Oillevel gauge
14 Priming pump 28 Fuel injection nozzle

1) Cylinder head cover
● Tighten the cylinder head cover bolts to the
specified torque a little at a time in the sequence.

(see figure)
Cylinder head cover bolt torque 2.2
Fan belt
●Adjust the fan belt tension.
Figure 185
2) Starter
●Tighten the starter bolts to the specified torque
after install the starter to the flywheel housing.

Starter fixing nuts torque 8 .4kg.m
Figure 186
3) Injection nozzle
● Install the injection nozzle with the injection
nozzle gaskets.
Injection nozzle nuts torque 2.2
● Be careful not to damage the nozzle tips.
Figure 187
4) Fuel injection pipe

● Install the fuel injection pipes ①and tighten the
bolts to the specified torque.

Injection pipe torque 3.0
● Carefully position and set the clips②It is very

important that each clip be positioned correctly.
Figure 188

An improperly positioned clip will result in
objectionable fuel pulsing noise and injection pipe
breakage.
● Install the fuel return pipes③
5) Oil filter
● Install the oil filter assembly with tightening the
bolts securely.
Oil filter assembly mounting
5.0
bolts torque
Figure 189
Figure 190
6) Fuel pipe
● Install the fuel pipe and tighten the fuel pipe joint
bolts to the specified torque.

Take care not to interchange the check valves
and joint bolts.
Fuel pipe joint bolt

1.7
torque
7) Fuel hose
● Install the fuel filter hoses and tighten the hollow
screws to the specified torque.

Fuel filter hose bolts torque 4.2 kg.m
Figure 191

8) Intake pipe
● Install the intake pipe and tighten the intake pipe
flange bolts to the specified torque.
Figure 192

Electrical Equipments
Wiring circuit
a) Glow plug system (type - 1)
Figure 193
b) Glow plug system (type - 2)
Figure 194

c) Air heater system (type - 3)
Figure 195
Starting of winter
CAUTION
1. Preheating devices are attached to the engine for
improving the starting abilities at extremely low
temperature.
2. Do not actuate the starter for longer than 10
seconds. If starting fails regardless of the
preheating, start the preheating again after 30
seconds.
Operation 1 : Turn the key switch to the HEAT position,

then the pilot lamp lights up for about
20 seconds When the pilot lamp is
extinguished, do operation 2
Behavior - When the coolant temperature is below 10 C
in cold weather, you’d better operate the pre-
heating system (Air heater)
- If the pre-heating is not necessary, the pre-
heating system is not operated with the pilot
lamp.
Operation 2 : After checking the pilot lamp, turn the key
switch to the START position to crank the
engine, at once.
Behavior - When the key switch is placed in the START
position , air heater is continuously heated to
facilitate starting operation and to reduce white
smoke during 30 seconds automatically.
- If the coolant temperature is above 15 C , air
eater needs not be heated.

Operation 3 : After the engine is cranked, convert the key
switch to the ON position.
Behavior - As the engine is cranked, air heater is heated
for 30 seconds (after-heating) to reduce and to
element quickly white smoke.
Alternator
The alternator is fitted with integral silicon rectifiers. A
transistorized regulator mounted on the alternator
body interior limits the alternator voltage. The
alternator should not be operated except with the
regulator
and battery connected in circuit to avoid damage to
the rectifier and regulator.
a) 24V x 45A Alternator
Figure 196
The alternator is maintenance-free, nevertheless, it

must be protected against dust and, above all, against
moisture and water.
Figure 197

NOTE
Operate the alternator according to the instructions
given in the chapter.
Figure 198
No. Name No. Name

1 Hex nut 13 Frame
2 Pulley 14 Bushing
3 Fan 15 Needle bearing
4 Collar 16 Rectipier
5 Bearing ass’y 17 Screw
6 Rotor ass’y 18 Regulator
7 Stator ass’y 19 Brush set ass’y
8 Cover 20 Brush holder
9 Pin 21 Spring
10 Stud bolt 22 Brush
11 Insulator 23 Brush
12 Bolt 24 Baffle

b) 24V x 60A Alternator
Figure 199
Figure 200

Starting motor
The sliding-gear starter motor is flanged to the rear of
the flywheel housing on the left-hand side. As parts of
every engine overhaul, the starter pinion and ring gear
should be cleaned with a brush dipped in fuel and
then a coat of grease should be applied again
Figure 201
Figure 202
Always protect starter motor against moisture.
WARNING
Always disconnect the battery earth cable before
starting work on the electrical system.
Connect Up the earth cable last, as there is otherwise
a risk of short-circuits.

Figure 203
No. Name No. Name

1 Yoke assembly 14 Coil spring
2 Bush holder assembly 15 Pinion starter
3 End frame 16 Pinion stop nut
4 Through bolt 17 Snap ring
5 Armature assembly 18 Snap ring
6 snap retainer 19 Snap retainer
7 Idle gear 20 Coil spring
8 Clutch roller 21 Housing
9 Retainer 22 Terminal cap
10 Coil spring 23 Screw
11 Steel ball 24 Cover
12 Clutch assembly 25 Through bolt
13 Clutch shaft 26 Magnet switch assembly

COMMISSIONING AND
OPERATION
Preparation
At the time of initial commissioning of a new or
overhauled engine make sure to have observed the
“Technical Information for the installation DAEWOO
generator engines”.
● Oil filler neck on cylinder head cover
Before daily starting of the engine, check the fuel,

coolant and oil level, replenish if necessary The
notches in the dipstick indicate the highest and
lowest permissible oil levels.
The oil required in the sump is specified in the
“Engine Specification”.
NOTE
The oil required to fill the oil fillers and pipes depends
upon the engine and use and must be determined
individually at the time of initial commissioning. (Make
the Max and Min. marks of the determined quantity on
the oil level gauge.)
● Cleanliness
Ensure outmost cleanliness when handling fuels,
lubricants and coolants
Starting
For engine starting please confer the instruction.
NOTE
1.Preheating devices are attached to the engine
for improving the starting abilities at extremely low
temperature.
2. Do not actuate the starter for longer than 10
seconds. If starting fails regardless of the preheating,
start the preheating again after 30 seconds.
DX140AF/DX140LCA Commissioning and operation 9-125

Operation 1 : Turn the key switch to the HEAT position,
then the pilot lamp lights up for about
20 seconds When the pilot lamp is
extinguished, do operation 2.
Behavior When the coolant temperature is below 10 C
in cold weather, you’d better operate the pre-
heating system (Glow plug)
- If the pre-heating is not necessary, the pre-
heating system is not operated with the pilot
lamp.
Operation 2 : After checking the pilot lamp, turn the key
switch to the START position to crank the
engine, at once.
Behavior - When the key switch is placed in the START
position, glow plug is continuously heated to
facilitate starting operation
- If the coolant temperature is above 10 C , glow
plug needs not be heated.
Operation 3 : After the engine is cranked, convert the key
switch to the ON position.
b) Audible Alarm
The generator gauge panel for DB58 series engine is
equipped with an audible alarm to alert the
operator to the following:
* Low engine oil pressure
* Engine coolant overheat
The alarm horn will sound when the ignition is turned
on and continue to sound until the engine is
started and minimum oil pressure is obtained. This
provides a functional test of warning system.
Should engine coolant overheat occur, the alarm horn
will sound and the engine is stopped by stop
solenoid at the same time automatically. Proceed as
follows:
First, quickly observe the coolant temperature gauge
for engine coolant overheat and/or needle
oscillation indicating low coolant. If the temperature
gauge indicates engine coolant overheat, throttle
back to idle speed IMMEDIATELY and cut 0仔the main
circuit breaker of the generator control
panel. Do not restart engine until cause for the alarm
has been found and corrected. Refer t。
“Diagnosis and remedy” in Trouble Shooting Chart. If
the coolant temperature gauge indicates low
coolant, add some amount of required coolant to fill
radiator. If cause for the alarm cannot be found,
contact your DAEWOO dealer.

Starting and operation
Operation of a new engine (Break-In)
Because the sliding surfaces of a new engine are not
lapped enough, the oil film can be destroyed easily by
overload or overspeed and the engine life-time may
be shortened.
Therefore the following things must be obeyed by all
means.
Up to the first 150 hours (2,000km)
● Engine should be run at fast idling until the
temperature of the engine becomes normal

operating condition.
● Overload or continuous high speed operation should
be avoided.
● High speed operation with no load should be
prevented.
● Abrupt start and stop of the engine should be
avoided.
● Engine speed must be under 70% of its maximum
speed.
● Maintenance and inspection must be accomplished
thoroughly.
Check points for break-in
During the break-in (the initial running of the engine)
period, be particularly observant as follows:
a) Check engine oillevel frequently. Maintain oillevel in
the safe range, between the “min.” and “max.”
marks on dipstick.
NOTE
If you have a problem getting a good oil level reading
on dipstick, rotate dipstick 1800 and reinsert for check.
When adding engine oil , refer to Lubrication Section.

b) Watch the oil pressure warning lamp. If the lamp
blinks, it may be the oil pick-up screen is not
covered with oil. Check oil dipstick. Add oil to the
oil pan, if required. Do not overfil l. If level is correct
and the status still exists, see your DEALER for
possible switch or oil pump and line malfunction.
NOTE
Oil pressure will rise as RPM increases,and fall as
RPM decreases. In addition, cold oil generally show
higher oil pressure for any specific RPM than hot
oi l. 80th of these conditions reflect normal engine
operation.
c) Watch the engine water temperature gauge and be

sure there is proper water circulation. The water
temperature gauge needle will fluctuate if water
level in expansion tank is too low.
At the end of the break-in period, remove break-
in oil and replace the oil filter element. Fill oil pan
with recommended engine oi l. Refer to Lubricating
System.
● Engine oil should be changed at the specified

intervals.
Oil filter cartridge should be changed simultaneously.
- First oil change : 50 hr operating.
First oil change After 50hr operation
DB58
DB58T every 200 Hour
Construction
DB58TI
equipments
DB58S
every 250 Hour
DB58TIS
● The following oils are also recommended

* If long oil change intervals are to be used,
ACEA-E3 oil must be used.
Engine model Recomm engine oil

SAE No. API No.
DB58
DB58TI
DB58S SAE15W40 ACEA-E2 or ACEA-E3
DB58TIS SAE10W40 (API CH-4)

Inspections after starting
● It is advisable to operate an engine at idling until the
engine reaches up to normal operating temperature.
● Engine should be stopped if the color, the noise or
the odor of exhaust gas is not normal.

● Confirm the following things through warning lamps
and gauge panel.

- Pressure of lubricating oil
The normal pressure comes up to 100 kPa (1.0
bar) at idling and 300 - 480 kPa (3.0 - 4.8 bar) at
maximum speed. If the pressure fluctuates at idling
or does not reach up to the expected level at high
speed, shut down the engine immediately and
check the oil level and the leakage.
- Temperature of cooling water
The cooling water temperature should be 80 -
95 C in normal operating conditions. Abnormally
high cooling water temperature could cause the
overheating of engine and the sticking of cylinder
components.
And excessively low cooling water temperature
increases the fuel consumption, accelerates the
wears of cylinder liners and shortens the engine
life-time.
NOTE
When engine is overheated, do not stop the engine
immediately. Lower the engine load and run
the engine and its cooling systems continuously.

Operation in winter time
Pay special attention to the freezing of cooling water
and the viscosity of lubricating oil.
Prevention against the freeze of cooling water

When not using anti-freeze, completely discharge the
whole cooling water after engine running. The freeze
of cooling water causes the fatal damages of the
engine. Because the anti-freeze is used to prevent
cooling water from freeze, consult “The amount of
anti-freeze”.
Prevention against excessive cooling

Drop of thermal efficiency caused by excessive
cooling increases fuel consumption, therefore prevent Figure 204
the engine from excessive cooling. If the temperature
of coolant does not reach to normal condition (80 - 95
C) after continuous operation, examine the thermostat
or the other cooling lines.
Lubricating oil
As cold weather leads to the rise of oil viscosity,
engine speed becomes unstable after starting.
Therefore the lubricating oil for winter should be used
to prevent this unstability. Refer to Lubrication System
section.

Starting of engine in winter
It is necessary to preheat engine satisfactorily under
10 oC (50 OF) in winter. Refer to Starting.
Tuning the engine

The purpose of an engine tune-up is to restore power
and performance that’s been lost through wear,
corrosion or deterioration of one or more parts or
components. In the normal operation of an engine,
these changes can take place gradually at a number
of points, so that it’s seldom advisable to attempt an
improvement in performance by correction of one or
two items only. Time will be saved and more lasting
results will be obtained by following a definite and
thorough procedure of analysis and correction of all
items affecting power and performance.
Economical, trouble-free operation can better be
ensured if a complete tune-up is performed once
every years, preferably in the spring. Components that
affect power and performance to be checked are:
● Components affecting fuel injection ;
Nozzle, delivery valve, fuel filter, water separator,

etc.
● Components affecting Intake & exhaust ;
Air filter, inter-cooler, turbo, silencer, etc.

● Components affecting lubrication & cooling ;
Air & oil filter, antifreeze, etc.

Maintenance and care
4.5.1. Periodical inspection and maintenance
In order to insure maximum, trouble-free engine
performance at all times, regular inspection,
adjustment
and maintenance are vital.
• Daily inspections in below figure should be checked
every day.
• The maintenance should be executed thoroughly at
regular internals.
(refer to appendix “General Engine Inspection Cycle”.)
Exchanging 01 lubrication oil

Engine oil and the oil filter are important factors
affecting engine life. They affect ease of starting, fuel
economy, combustion chamber deposits and engine
wear. Refill and drain oil pan every 200 hours of
operation or 6 months whichever occurs first. At the
end of the break-in period (50 hours), change the oil
sump oil and replace the oil filter.
Oil level
Check the oil level in the engine sump daily with a
dipstick
● The notches in dipstick must indicate the oil level
between the max. and the min. permissible

● The oil level should be checked with the engine
horizontal and only after it has been shut down for

about 5 minutes.
● Examining the viscosity and the contamination of
the oil smeared at the dipstick replace the engine oil

if necessary. Figure 205
IMPORTANT
Do not add so much engine oil that the oil level rises
above the max.marking on the dipstick. Over lifting will
result in damage to the engine.

Oil exchange procedure
While the oil is still hot, exchange oil as follows:
● Take out the oil dip dipstick.
● Remove the drain valve from oil pan, then drain out
the engine oil into a container.
Figure 206
● Refill with new engine oil at the oil filler neck on the
head cover and the lubricating oil in accordance
with the oil capacity of the engine through oil filler.
Be careful about the mixing of dust or contaminator
during the supplement of oi l. Then confirm that oil
level gauge indicates the vicinity of its maximum
level.
● For a few minutes, operate the engine at idling in
order to circulate oil through lubrication system.

● Thereafter shut down the engine. After waiting for
about 10 minutes measure the quantity of oil and Figure 207

refill the additional oil if necessary.
Replacement of oil filter cartridge

At the same times of oil exchanges, replace the oil
filter cartridge.
IMPORTANT
Don’t forget tightening the drain valve after having
drained engine oil.
● Loosen the oil filter by turning it counterclockwise

with a filter wrench.
● With a rag wipe clean the fitting face of the filter body
and the oil filter body so that new oil filter cartridge
can be seated properly. Figure 208
● Lightly oil the O-ring and turn the oil filter until
sealing face is fitted against the O- ring. Turn 1-1/4

turns further with the filter wrench.

IMPORTANT
It is strongly advisable to use DAEWOO genuine oil
filter cartridge for replacement.
Figure 209
Cooling system
The coolant must be changed at intervals of 1,200
hours operation or six months whichever comes first.
If the coolant is being fouled greatly, it will lead
an engine overheat or coolant blow off from the
expansion tank.
Coolant draining
● Remove the pressure cap.
● Open the drain valve at the radiator lower part to
drain the coolant as the right figure.

● Loosen the coolant drain plug of the cylinder block
and oil cooler
Figure 210
CAUTION
When removing the pressure filler cap while the
engine is still hot, cover the cap with a rag, then turn
it slowly to release the internal steam pressure This
will prevent a person from scalding with hot steam
spouted out from the filler port.
Figure 211

Cleaning 01 the cooling inside system circuit
(by authorized specialist personnel)
When the cooling system circuit are fouled with water
scales or sludge particles, the cooling efficiency will
be lowered.
Investigations have shown that in many cases the
poor condition of the coolant and /or the cooling
system accounts for damage to the water pump
mechanical seal, The poor condition of the cooling
system is normally due to use of unsuitable or no
anti-freezing agents and corrosion inhibitor or defect,
not early enough replaced covers for filler neck and
working valves.
If twice in a short time the water pump of an engine
develops leases or the coolant is heavily contaminated
(dull, brown, mechanically contaminated, grey or black
sings of a leakage on the water pump casing) clean
the cooling system prior to removing that water pump
as follows.
1. Orain coolant.
2. Remove thermostats, so that the whole cooling
system is immediately flown through when
cleaned.
3. Fill the cooling system with a mixture of potable
water and 1.5% by volume of cleaner. (Henkel
P3T5175)
4. Warm up engine under load. After a temperature
of 60∞C is reached, run engine for a further 15
minutes.
5. Orain cleaning fluid.
6. Repeat steps c) and d).
7. Flush cooling system.
8. Replace drain plug by drain plug with a bore of
8mm diameter
9. Fill cooling system with hot water.
10. Run engine at idle for 30 minutes. At the same
time continuously replenish the water leaking from
the bore in drain plug by adding fresh water.
CAUTION
Periodically clean the circuit interior with a cleaner.

Valve clearance and adjustment
NOTE
The cylinder head bolts were previously tightened with
the torque wrench.
Therefore it is not necessary to retighten the cylinder
head bolts before adjusting the valve clearance.
Rocker arm screw

2.6
lock nut torque
Figure 212
● After letting the #1cylinder’s piston come at the

compression top dead center by turning the
crankshaft,adjust the valve clearances.
● Loosen the lock nuts of rocker arm adjusting screws
and push the feeler gauge of specified value

between a rocker arm and a valve stem and adjust
the clearance with adjusting screw respectively and
then tighten with the lock nut.
● As for the valve clearance, adjust it when in cold, as
follows.
Figure 213
Model Intake Valve Exhaust Valve
OB58
OB58S
OB58T 0.4 mm 0.4 mm
OB58TI
OB58TIS
1) Rotate the crankshaft to overlap the intake and the

exhaust valves of #6, then #1 cylinder become the
compression state of top dead center.
2) Therefore adjust the valve clearance corresponding
to “ ”11 of lower figure. At this time there are no
force on the push rods of #1 cylinder.
3) Rotating the crankshaft by one revolution, #6
cylinder become the compression state of top dead
center.
4) T h e r e a f t e r a d j u s t t h e v a l v e c l e a r a n c e s
corresponding to“ ”of lower figure.
5) After reinsuring the valve clearances, retighten if
necessary.

● No. 1 cylinder is located at the side where flywheel
was installed.
Figure 214

Injection timing
CAUTION
Take care to avoid entry of dust or foreign particles
into the pump interior when the timing adjustment is
made.
<Check procedure>
● Align the crankshaft pulley TDC mark with the
pointer.
● Remove the inspection hole cover at the front of the
injection pump on the timing gear case cover.
Figure 215
● Check the alignment between the pointer④on the

injection pump gear nut lock plate and the projection
area mark③on the injection pump gear case.
● If it is in misalignment, recheck with turning the
crankshaft pulley one more turn to repeat the

foregoing procedure to mark sure that it is in
alignment
● Check the alignment of the notched

lines①and②(These notched lines were aligned at
the factory to set the injection pump body and the
mounting flange.) Next, inspect the crank angle
position of the injection timing.
Figure 216

<Check procedure>
● Turn the crankshaft pulley counterclockwise about
300 crank angle.

● Disconnect the injection pipe from the No.1 plunger.
This will allow you to visually check the full injection

starting flow at No. 1 plunger.
Figure 217
● Remove the delivery valve holder ①, thevalve seat

②, valve spring ③, and the delivery valve④from the
No.1 plunger.
● Assemble the delivery holder ① and tighten it to the
specified torque.
Do not reassemble the delivery valve, the delivery
valve spring and the valve seat.
These parts will be reassembled later.
Figure 218
● Hold the fuel control lever at the fully open position

● Slowly turn the crankshaft pulley clockwise, at the
same time, continue to feed the fuel with pumping
the priming pump.
When the fuel stop to flow out from the No.1 delivery
valve holder, stop the pump instantaneously.
This crank angle position is the injection starting of
the engine.
Figure 219
● Observe and make sure that mark (injection starting

angle line a°) on the crank-shaft pulley is aligning
with the pointer.
Blow out the remaining fuel from the delivery valve
holder.
Make sure that there is no fuel being delivered from
the priming pump.
Figure 220

●Fuel injection timing angle
Fuel injection DB58/DB588 DB58T DB58TI DB58TI8

timing (BTDC) α° α° α° α°
- Refer to the 1.2. Engine power
● Remove the delivery valve holder from the No.1

plunger.
● Reassemble the delivery valve internal parts to the
delivery valve holder.

● Reassemble the delivery valve holder assembly
to the No.1 plunger and tighten it to the specified

toque.
Delivery valve holder
4.25
torque
● Assemble the No.1 cylinder injection pipe and Figure 221

tighten it to the specified torque.
Injection pope nut torque 3.1
INPORTANT
1) Do not overtighten the injection pump body.The
injection pump body is made of aluminum.
2) Overtighten will distort the injection pump body
shape and adversely affect control rack operation.
<Adjusting procedure>
● Align the pointer the specified timing mark on the
crank pulley.
● Perform the steps of “checking procedure” of
Injection Timing.
● Loosen the 4 injection pump fixing nuts.
● Timing adjustment
To advance the timing

Pivot the injection pump at the pump drive shaft
toward out.
To retard the timina
Pivot the injection pump at the pump drive shaft
toward in. (toward the cylinder block)
INPORTANT
Figure 222
The 1 mm misalignment between the two setting mark
lines corresponds to about 2° in crank angle.

● Do a fine injection pump position adjustment, while
continue the pumping operation to feed the fuel, and
stop to pivot the injection pump when the fuel stop to
flow out from the No. 1 delivery valve holder.
● Tighten the four injection pump fixing nuts.
● Once remove the No. 1 delivery valve holder, and
reassemble the delivery valve, spring and the valve

holder with the specified torque
● Install the No.1 injection pipe and tighten it to the
specified torque.
Tightening the cylinder head bolts

● The cylinders head bolts are to be tightened in the
sequence shown in the illustrations.
First tighten the bolts slightly, then slightly more
again and finally tighten with a torque wrench as
follows.
● The tightening by excessive torque may cause the
damages of the cylinder head gaskets, the flanges of

Figure 223
cylinder liners and the cylinder head bolts, therefore
obey the regular torque.
80lt type Torque

1st step : 7.0kg.m
hexagonal bolt
2nd step: 11.5+0.5kg.m
1st step: 4.4kg.m
dodecagonal bolt 2nd step : 90°
3rd step : 90°
<Dodecagonal bolt limited value>
8tandard(mm) Limit(mm)
115 116.2
102 103.2 Figure 224
Fuel injection pump

● Check the housing crack, damage etc.
and replace it if abnormal.
● Check if the idle operation and speed regulating
lever’s sealing is removed.

● The adjustment and testing of fuel injection pump
should necessarily be done at the test bench.
Figure 225

Feed pump strainer
● Remove the strainer with a screwdriver and wash
the strainer with clean diesel fuel.
Figure 226
Separator (Add if necessary)

● Check water level of the separator.
● Release the plug at the bottom to eliminate water
when water level (floating) reaches the warning

point.
Elimination plug torque 1.2
Air bleeding
Figure 227
● Loosen the priming pump cap(1) on the Injection
pump.
● Loosen the hollow screw for air bleed(2).
● Operate the priming pump until there are no more
bubbles visible in the fuel being discharged from the

fuel filter fuel return eye bolt.
● Retighten the hollow screw.
● Operate the priming pump several times and check
for fuel leakage around the injection pump and the

fuel filter.
NOTE
Figure 228
Removing the seal when bleeding the fuel system
replace it with a new one.

Belts
The tension of the belts should be checked after every
2,000 hours of operation.
1) Change the belts if necessary
If in the case of a multiple belt drive, wear or differing
tensions are found, always replace the complete set
of belts.
2) Checking condition
Check belts for cracks, oil, overheating and wear.
3) Testing by hand
● V-belt
By the finger-pressure the belt is pressed by 10-

15mm between the pulleys in normal condition.
(Pressed mid-way between the belt pulleys)
A more precise check of the V-belt tension is
possible only by using a V-belt tension tester.
Figure 229
● Poly belt
Poly belt will be properly tensioned if the
deflection force “F” is applied mid-way between
the belt’s tangent points with the pulley.
T = 0.015 x 8(about 1.5mm per 100mm)
T = 0.015 x *8 (mm)
(T : Deflection , 8 : 8pan)
(D-d)2
*S= C2- mm
2 Figure 230
C : Distance of pulleys (mm),

D : Large pulley diameter (mm),
d : 8mall pulley diameter (mm)
Commissioning

4) Measuring tension
①Lower indicator arm (1) into the scale.
• Apply tester to belt at a point midway between two
pulleys so that edge of contact surface (2) is flush
with the V- belt.
• Slowly depress pad (3) until the spring can be heard
to disengage. This will cause the indicator to move
upwards. Figure 231
If pressure is maintained after the spring has
disengaged a false reading will be obtained!
②Reading of tension
• Read of the tensioning force of the belt at the

point where the top surface of the indicator arm (1)
intersects with the scale.
• Before taking readings make ensure that the
indicator arm remains in its position.
Figure 232
●V-belt tension
Tensioning forces on the tester

Type Drive belt width new installation When servicing after
Installation After 10 min. running time long running time
M 9.5 mm 50kg 45kg 40kg
A 11.8 mm 55kg 50kg 45kg
B 15.5 m m 75kg 70kg 60kg
C 20.2 mm 75kg 70kg 60kg
● Poly belt tension
No of rib (PK type) Force(kgf)

3 20-27
4 27-36
5 34-45
6 41-57
7 48-66
8 59-73
Figure 233

5) Tensioning and changing belts
● Loosen fixing bolts and nuts.
● Adjust the alternator until belts have correct
tensions.
● Retighten fixing bolts and nuts.
● To change the belts loosen fixing bolts and nuts.
Then push the alternator toward water pump

pulley by hand.
Figure 234

MAINTENANCE OF MAJOR
COMPONENTS
Lubrication system
Oil pump
1) Disassembly
Figure 235
No. Name No. Name

1 Oil suction pipe 4 Pinion Gear
2 Cover and dowel 5 Pinion gear shaft
3 Drive shaft and gear
DX140AF/DX140LCA Maintenance of major components 9-146

2) Inspection
● Visually inspect the disassembled parts for the
excessive wear and damage.

● Correct or replace the parts if the wear or damage
is discovered during inspection.
Figure 236
3) Oil Pump Drive Gear
● Use a feeler gauge to measure the clearance
between the oil pump cover (oil pump case)

inside surface and the drive gear.
● If the clearance exceeds the specified limit, the
drive gear and/or the oil pump cover must be

replaced.
Limit
Oil pump cover and
0.18 mm
drive gear clearance
Figure 237
4) Oil pump pinion gear

between the oil pump case cover inside surface

and the pinion gear.
● If the clearance exceeds the specified limit, the
pinion gear and/or the oil pump cover must be

replaced.
Limit
Oil pump cover and
0.12 mm
pinion gear clearance Figure 238
5) Oil pump reassembly

● To assemble, follow the disassembly procedures
in reverse order.

Oil cooler
1) Disassembly
Figure 239
No. Name No. Name

1 Oil cooler element 4 O-ring
2 Gasket 5 By-pass valve spring
3 By-pass plug 6 By-pass valve
2) Inspection
● Correct or replace the part if the wear or damage
is discovered during inspection.
3) Oil cooler element
● Install the oil cooler element to the oil cooler, then
tighten the oil cooler element fixing bolts to the

specified torque.
Limit
Oil cooler element
2.2
fixing bolts torque
4) Oil cooler reassembly

● To assemble, follow the disassembly procedures
in reverse order. Figure 240

Cooling system
Water pump
1) Disassembly
Figure 241
No. Name No. Name

1 Pulley flange ▲5 Impeller
▲2 Snap ring 6 Pump housing
▲3 Unit bearing 7 Cover
4 Mechanical seal 8 Gasket
(1) Impeller
●Remove the impeller by using the jig.
Figure 242

(2) Unit bearing
● Remove the unit bearing by using a bench
press and a suitable remover.
Figure 243
(3) Mechanical seal

● Remove the mechanical seal by using a
suitable remover.
Figure 244
(4) Hub
● Remove the hub by using a bench press and a
suitable rod.
Figure 245
(5) Snap ring

● Remove the snap ring by using a pair of the
snap ring plier.
Figure 246

2) Inspection
(1) Unit bearing
● Correct or replace the part if the wear,
defect or other damage is discovered during

inspection.
Figure 247
3) Water pump reassembly

(1) Unit bearing
● Lubricate the bearing with multipurpose
grease.
● Use a bench press to assemble the unit
bearing at the pump.
Figure 248
2) snap Ring
● use a pair of anap ring plier to install the snap
ring.
Figure 249
(3) Hub
● Use a bench press and a bar to install the hub.
Figure 250

(4) Mechanical seal
● Apply sealant to the seal unit outer periphery
before installation.
Figure 251
● Use a bench press and a bar to install the seal

unit into the pump body.
Figure 252
(5) Impeller
● Use a bench press to install the impeller to the
shaft.
between the impeller and the pump body.
Clearance between
0.3 - 0.8mm
impeller and pump body
Figure 253
(6) Pulley
● Install the pulley and tighten the pulley bolts to
the specified torque.
Pulley fixing bolts
2.2
torque
Figure 254

Thermostat
● Correct or replace thermostat if the wear,defect or
other damage is discovered during inspection.
Valve Temperature Lift

Close 71℃ 82℃
Standard 85℃ 95℃ 10mm
Maximum 110℃ 110℃ less 16mm
Figure 255

Fuel system
Fuel filter
1) Cartridge type
Figure 256
2) Paper element type
Figure 257
No. Name No. Name

1 Drain plug 5 Fuel filter element
2 Center bolt 6 Spring seat
3 Fuel filter body 7 Spring
4 Body coer gasker

3) Inspection
● Make the necessary adjustments, repairs and
part replacements if excessive wear or damage is

discovered during inspection.
4) Fuel filter reassembly
● T o r e a s s e m b l e t h e f u e l f i l t e r , f o l l o w t h e
disassembly procedure in the reverse order.
Injection nozzle
1) Disassembly
Figure 258
No. Name No. Name

1 Nozzle holder body 7 Push rod spring
2 Seal ring 8 Spring seat
3 Injection pipe connector 9 Nozzle adjusting screw
▲4 Injection nozzle 10 Cap nut gasket
5 Retaining nut 11 Nozzle holder cap nut
6 Nozzle holder push rod
2) Injection nozzle
Remove the nozzle assembly from the nozzle body.
Keep the parts separately to maintain the proper
needle valve to body combination.
3) Inspection
Make the necessary adjustments, repairs and
parts replacements if excessive wear or damage is
discovered during inspection.

(1) Push rod spring
● Check the push rod spring for wear, weakness
and corrosion.
Figure 259
(2) Nozzle holder push rod

● Check the nozzle holder push rod curvature.
● Check the nozzle holder push rod and needle
valve contact surface for excessive wear and

poor contact.
Figure 260
(3) Injection nozzle

● Check the injection nozzle needle valve, the
valve seat, and the injection nozzle hole for

carbon deposits.
If carbon deposits are present, the injection
nozzle and the needle valve must be replaced.
● Hold the nozzle body vertically.
Pull the needle valve about one-third of the

way out of the nozzle body.
Release the needle valve Check that the
Figure 261
needle valve falls back into the nozzle body as
far as the valve seat.
If the needle does not fall back into the nozzle
body as far as the valve seat, the injection
nozzle and the needle valve must be replaced.

4) Reassembly
(1) Injection pipe connector
Injection pipe
5.5
connector torque
Figure 262
(2) Injection nozzle

● There must be no oil on the contact surface
of the injection nozzle and the injectio nozzle

holder.
Clean these contact surface with diesel fuel
before installation.
● The nozzle dowel pin must be with the dowel
hole in the nozzle holder body.
Figure 263
(3) Retaining nut

● Clamp the injection nozzle in a vise.
● Tighten the retaining nut to the specified
torque by using a wrench.

Nozzle retaining nut
7
Torque
Figure 264
(4) Nozzle holder cap nut

● Clamp the injection nozzle in a vise.
● Tighten the nozzle holder cap nut to the
specified torque by using a wrench.

Nozzle holder cap nut torque 4.5
Figure 265

(5) Nozzle adjusting screw (injection starting
pressure check)
● Attach the injection nozzle holder to the
injection nozzle tester.
Figure 266
● Loosen the adjustment screw①.
Figure 267
● Check the injection nozzle starting presI.

sure and the spray condition by operating
the injection tester.
<spray condition check>
Operate the injection nozzle tester
hand lever 4 to 6 times while looking for
abnormal injection nozzle spray conditions.
(See figure)
(1) Correct (Good) Figure 268
(2) Incorrect (Bad - orifice)
(3) Incorrect (Bad - dripping)
● Adjust the injection nozzle starting pres
sure.
Turn the adjusting screw clockwise while
operating the injection nozzle tester handle.
CAUTION
Keep away your skin from the tester because pressure
of nozzle tester is very high when inject.

Parts no 01 injection system
1) Injection pump assembly
2) Injection nozzle assembly
3) Injection pipe assembly

Injection pump calibration
1) 0858 engine
(1) Injection pump assembly : 65.11101-7380 (101605-996F DOOWON)
- Injection pump : KP-PES6A95C410RS2000 (101062-8300)
- Governor : KP-EP/RSV200-1450AQ43A311 (105419-1340)
- Plunger and barrel : 131151-3200, 131100-7900
- Delivery valve : 131160-1120
- Feed pump : KP-FP/KS-A (105220-6290)
- Prestroke : 3.6±0.05mm
- Coupling : 156639-9820
(2) Nozzle holder assembly : 65.10101-7295 (105160-4650 DOOWON)
(3) Nozzle : 65.10102-6044 (1 05025-138A DOOWON)
(4) Injection pipe : 65.10301-6144
(5) Injection order :1-5-3-6-2-4

(6) Rack diagram and setting valve at each point
a) 0858 : EAROA
b) 0858 : EAREA
c) 0858 : EARE8IRFE/RFI/RFJ/RFH
d) 0858 : EARFF
e) 0858 : EARLAl8
f) 0858 : EARLC

(7) R a c k c u r v e o f s t a n d a r d i n j e c t i o n p u m p
(65.11101-7380)
Figure 269

2) D858 engine (EARFG/EARFK)
(1) Injection pump assembly : 65.11101-7398 (1 01605-996G DOOWON)
- Injection pump :KP-PES6A95C410RS2000 (101062-8300)
- Governor :KP-EP/RSV200-1450AQ43A311 (105419-134A)
- Plunger and barrel :131151-3200, 131100-7900
- Delivery valve :1 311 60-11 20
- Feed pump :KP-FP/KS-A (105220-6290)
- Prestroke :3.6±0.05mm
- Coupling :156639-9820
(2) Nozzle holder assembly :65.10101-7295 (105160-4650 DOOWON)
(3) Nozzle : 65.10102-6044 (1 05025-138A DOOWON)
(4) Injection pipe :65.10301-6144

(65.11101-7380)
Figure 270

3) DB58S engine (ECRFA/B/C)
(1) Injection pump assembly : 65.11101-7399 (1 01605-996X DOOWON)
- Injection pump : KP-PES6A95C410RS2000 (101 062-830A)
- Governor : KP-EP/RSV200-1450AQ43A311 (105419-1340)
- Prestroke : 3.6±0.05 mm
- Coupling : 156639-9820
(3) Nozzle : 65.10102-6044 (1 05025-138A DOOWON)
(4) Injection pipe : 65.10301-6144

(65.11101-7399)
a) DB58S : ECRFA
b) DB58S : ECRFB
c) DB58S : ECRFC
Figure 271

4) DB58T engine (EATE A/B//D/LA)
(1) Injection pump assembly : 65.11101-7655 (101605-9760 DOOWON)
- Injection pump :KP-PES6A95C410RS2000 (101062-9040)
- Governor :KP-EP/RSV200-1350AQ49A311 (1 05411-1820)
- Plunger and barrel :131151-3200, 131100-7900
- Delivery valve :131110-4320
- Feed pump :KP-FP/KS-A (105220-6410)
- Prestroke :3.6±0.05 mm
- Coupling :156639-4220
(3) Nozzle :65.10102-6044 (1 05025-138A DOOWON)
(4) Injection pipe :65.10301-6289

a) DB58T: EATEA
b) DB58T : EATEB
c) DB58T : EATED
d) DB58T: EATLA

(7) Rack curve and boost pressure of standard
injection pump(65.111 01-7655)
Figure 272
Figure 273

5) DB58T engine (EATEE/F/G/H/I/EATLB)
(1) Injection pump assembly : 65.11101-7375 (101605-9720 DOOWON
- Injection pump : KP-PES6A95C410RS2000 (101062-8250)
- Governor : KP-EP/RSV200-1350AQ49A311 (1 05411-1940)
- Delivery valve : 13111 0-4320
- Coupling : 156639-7620
(3) Nozzle : 65.10102-6044 (1 05025-138A DOOWON)
(4) Injection pipe : 65.10301-6289
(5) Injection order : 1-5-3-6-2-4

a) OB58 : EATEEfTEHfTLB
b) OB58 : EATEF
c) OB58 : EATEG
d) DB58:EATEI

Figure 274
Figure 275

6) DB58TI engine (EAOEA/D/E/F)
- Injection pump :KP-PES6AD1 00B41 OR (101062-8260)
- Plunger and barrel :1311 50-2600, 1311 00-8600
- Delivery valve :131110-5520
- Feed pump :KP-FPIKS-AD (105220-6490)
- Prestroke :3.8±0.05mm
- Coupling :156639-8820
(2) Nozzle holder assembly :65.10101-7058 (10 5160-466A DOOWON) : EAOEAlD/E
65.10101-7092 (105160-5420 DOOWON): EAOEF
(3) Nozzle :65.10102-6054 (1 05025-139A DOOWON) : EAOEAlD/E
65.10102-6064 (105025-4200 DOOWON) : EAOEF
(4) Injection pipe :65.10301-6072

a) DB58TI : EAOEAlOED
b) DB58TI : EAOEE
c) R a c k c u r v e o f s t a n d a r d i n j e c t i o n
pump(65.11101-7374)
Figure 276

7) DB58TI engine (EAOEB/OEC)
(1) Injection pump assembly : 65.11101-7374 (101605-983X DOOWON)
- Injection pump : KP-PES6AD1 00B41 OR (101062-8260)
- Feed pump : KP-FPIKS-AD (105220-6490)
- Coupling : 156639-8820
(2) Nozzle holder assembly : 65.10101-7058 (1 05160-466A DOOWON)
(3) Nozzle : 65.10102-6054 (1 05025-139A DOOWON)
(4) Injection pipe : 65.10301-6072

a) DB58TI : EAOEB
b) DB58TI : EAOEC
c) Rack curve and boost pressure of standard

injection pump (65.11101-7374)
Figure 277

Figure 278

8) DB58TI engine (EAOLA/OLB)
- Feed pump : KP-FP/KS-AD (105220-6490)
- Coupling : 156639-8820
(2) Nozzle holder assembly : 65.10101-7058 (1 05160-466A DOOWON)
(3) Nozzle : 65.10102-6054 (1 05025-139A DOOWON)
(4) Injection pipe : 65.10301-6072

a) DB58TIS : EAOLAlOLB

Figure 279

Figure 280

9) DB58TIS engine (ECOEA/OEB)
(1) Injection pump assembly : 65.11101-7391 (1 01605-830A DOOWON)
- Injection pump :KP-PES6AD1 00B41 OR (101 062-826A)
- Plunger and barrel :1311 50-2600 131100-8600
- Delivery valve :1311 60-3620
- Feed pump :KP-FPIKS-AD (105220-6490)
- Prestroke :3.8±0.05 mm
- Coupling :156639-882C
(3) Nozzle :65.10102-6064 (105025-4200 DOOWON)
(4) Injection pipe :65.10301-6088, 65.10301-6089

a) DB58TIS : ECOEA
b) DB58TIS : ECOEB

Figure 281

Figure 282

10) DB58TIS engine (ECOEC/D/E/F/G)
(1) Injection pump assembly : 65.11101-7389 (101605-810ADOOWON)
- Injection pump : KP-PES6AD1 00B41 OR (101 062-826A)
- Feed pump : KP-FP/KS-AD (105220-6490)
- Coupling : 156639-882C
(3) Nozzle : 65.10102-6061 (105025-4000 DOOWON)
(4) Injection pipe : 65.10301-6088, 65.10301-6089

a) DB58TIS : ECOEC
b) DB58TIS : ECOED
c) DB58TIS : ECOEE
d) DB58TIS : ECOEF
e) DB58TIS : ECOEG

Figure 283
Figure 284

11) DB58TIS engine (ECOLA)
- Injection pump : KP-PES6AD1 05B41 ORS2 (101 061-882B)
- Governor : KP-EP/RSV200-1350AQ49A311 (1 05411-224A)
- Plunger and barrel : 131151-2700131100-7800
- Feed pump : KP-FP/KS-ADS (105210-5280)
- Coupling : 156639-8820
(3) Nozzle : 65.10102-6064 (105025-4200 DOOWON)
(4) Injection pipe : 65.10301-6088, 65.10301-6089

(6) Rack curve
a) Rack curve and boost pressure of standard
injection pump(65. 111 01-7392)
Figure 285
Figure 286

12) DB58TIS engine (ECOLB)
- Feed pump : KP-FPIKS-AD (105220-6490)
- Coupling : 156639-882C
(3) Nozzle : 65.10102-6061 (105025-4000 DOOWON)
(4) Injection pipe : 65.10301-6088, 65.10301-6089

Figure 287
Figure 288

13) Injection pump
Figure 289
No. Name No. Name

1 Pump housing 90 Camshaft
2 Cover assembly 91,91a Taper roller bearing
3 Bolt, cover 92.92a Camshaft ring
4 O-ring 93.93a Shim
5 Gasket 95 Center bearing
16 Screw, plug 101 a Bearing cover
18 Bolt, stud 104a Bolt
20 Spring washer 112a Woodruf key
21 Nut 196 Nut
23 O-ring 117a Connection bolt
30 Plunger 118a Gasket
36 Delivery valve 121 Plug screw
37 Delivery valve spring 122 Gasket
40 Delivery valve holder 130 Connect
45 Lock plate assembly 130a Adapter
49 O-ring 131a Bolt
55 Tappet 132a Gasket
115a. Adapter 133a Gasket
56 Shim 145 Plug screw
61 Plunger spring 146 Gasket
62 Seat, spring(upper) 152 Connection bolt
63 Seat, spring(lower) 154 Packing
67 Control rack 191 Bracket
68 Stop bolt 192 O-ring
76 Pinion 194 Washer
77 Sleeve 195 Spring washer
78 Bolt

14) Governor
Figure 290

No. Name No. Name
1 Governor housing 136 Nut
4 Plate 137 Gasket
6 Adapter 138 Cap
7 Bolt 140 Idle spring
8 Spring 141 Nut
10 Bolt 150 Speed setting lever
13 Nut 170 Guide lever
19 Adapter 173 Split pin
20 Bolt 174 Floating lever link
21 Gasket 181 Tension lever
35 Governor cover 182 Lever shaft
38 Tension lever bolt 183 Collar
39 Nut 190 Control lever
44 Stop bolt 192 Nut
46 Cap 195 Return spring
47 Plug 198 Spring washer
48 Adjusting bolt 201 O-ring
49 Nut 202 Bush
50 Stop bolt 203 Shim
51 Bolt 205 Shaft lever
52 Bolt 207 Support lever
80 Cover 211 Snap ring
82 Bolt 220 Damper spring
83 Bolt 236 Gasket
100 Fly wheel 239 Gasket
101 Woodruf key 240 Lead seal
102 Spring washer 241 Wire, lead seal
103 Nut 255 Bracket
117 Sleeve 331 Angleich spring
118 Shim 332 Connection nut
130 Governor spring
132 Starting spring

Turbocharger
Main data and specifications
1) Main data and specifications
2) Construction
Figure 291
No. Name No. Name

1 Impeller casing A Air inlet
2 Turbine casing B Gas outlet
3 Bearing casing C Gas inlet
4 lmpeller D Oil supply
5 Turbine E Oil return

3) Construction
Figure 292

No. Name No. Name
4 Bearing housing 43 Oil seal plate
5 Turbine housing 46 Gasket
6 Turbine wheel ass’y 57 Hex bolt
7 Compressor wheel 61 Lock nut
8 Compressor housing 64 Snap ring
11 Journal bearing 67 Hex bolt
12 Thrust bearing 74 Actuator ass’y
13 Piston ring seal(turbine) 75 Hose clamp
16 Piston ring seal 77 Actuator clip
22 Retainer ring 80 Cover plate
31 Oil stopper 81 Hose
32 32.0-ring 82 Elbow
33 Oil baffle 83 Hex nut
34 Inlet baffle 88 Clamp plate
36 Thrust coliar 91 Retaining ring
38 Heat protector cover

4) Operating principle
The turbocharger is a system designed to make use
of the engine exhaust gas energy to charge high-
density air into the cylinders, thereby to increase
the engine output.
Figure 293

General descriptions
The engine output is determined by the fuel delivery
volume and engine efficiency.
To burn the supplied fuel completely to change into
effective power for the engine, the volume of air
enough to burn the fuel completely should be supplied
into the cylinders.
Therefore, the engine output is determined
substantially by the cylinder capacity, and a greater
volume of compressed air is charged into cylinders
of given capacity, the greater engine output can be
obtained as a greater volume of air charged into the
cylinders burns so much more fuel.
As explained, the compressing of air to supply into the
cylinders is called 18upercharging” and the making
use of the energy of exhaust gas discharged from the
combustion chamber to charge the compressed air
into the cylinders is called “Turbocharging”.

Functions
1) Turbine
Exhaust gas discharged from the combustion
chamber distributes its own energy to the turbine
blades while passing the inside of the turbine
housing, with the result that the turbine shaft can
get rotating force. This is the operating principle of
‘turbine’, which is mounted with seal rings and heat
protector to prevent exhaust gas from affecting the
bearings adversely.
2) Compressor
The compressor, which is connected to the turbine
over the one and same shaft to form a rotating
body, takes in and compresses ambient air with
rotating force transmitted from the turbine shaft.
Then, the compressed air is delivered to the
intake stake. This is the operating principle of the
compressor.
3) Bearings
(1) Thrust bearing
The turbine wheel creates thrust force.
Therefore, exercise care so that the shaft is not
deviated from its the original position due to this
thrust
(2) Journal bearing
This journal bearing of floating type forms a
dual oil film on both the inside and outside
of the bearing so that the bearing can rotate
independently. As the dual oil film plays a role
as a damper,
the sliding speed of the bearing surface
becomes lower than the rotating speed of the
shaft, resulting in assurance of stability in its
movement.
4) Sealing-compressor shaft
The compressor is of a dual construction type
composed of seal plate and seal ring to prevent the
leak of compressed air or lubricating oil.

Precautions for operation
1) Precautions for operation of engine
The following precautions should be observed when
starting,operating, or stopping the engine:

Walk-around check and servicing
As the condition of turbocharger depends greatly on
how well the engine is serviced, it is very important to
maintain the engine in accordance with the specified
maintenance procedure.
1) Intake system
Pay particular attention to the air cleaner when
servicing the intake system.
In the case of wet-type air cleaner, if the level of oil
surface is lower than specified, cleaning effect is
poor; if too high, the cleaner draws in oil to foul the
case.
Especially, if the rotor is fouled, the sophisticatedly-
tuned balance is broken to create vibration and to
cause seizure and unusual wear to the bearing.
Therefore, it is very important to use a good quality
air cleaner all the time.
In the case of dry-type air cleaner, it is essential
to clean it to reduce intake resistance as much as
possible.
2) Exhaust system
Pay particular attention to prevent gas leaks
and seizure when servicing the exhaust system
because leakage of exhaust gas from discharge
pipes, turbocharger fixing portions, etc. lowers
charging effect As such components as turbine
chamber that becomes red-hot during operation use
heat resisting steel nuts, do not interchange these
nuts with ordinary steel nuts. In addition, apply anti-
seizure coating to fixing nuts on the portions as
designated.
3) Lubricating system
Pay particular attention to oil quality and oil filter
change intervals when servicing the lubricating
system.
Deteriorated engine oil affects adversely not only
the engine but torso the turbocharger.
Suggested engine oils for the turbocharger-
mounted engine are as follows:
Engine model Recommend oil

SAE No. API No.
DB58
DB58TI
DB58S SAE15W40 ACEA-E2 or ACEA-E3
DB58TIS SAE10W40 (API CH-4)

Periodical checking and servicing
Make it a rule to check the turbocharger assembly for
condition and contamination periodically.
1) Guide for checking the rotor for rotating condition
The inspection of the rotor assembly for rotating
condition should be performed by the degree of
unusual sound. If a sound detecting bar is used,
install its tip on the turbocharger housing and
increase the engine revolutions slowlμIf a high-
pitch sound is heard continuously, it means that the
rotor assembly is not normal. In this case, as the
metal bearing and rotor are likely to be in abnormal
conditions, the turbocharger should be replaced or
repaired.
2) Guide for checking rotor end play
Disassemble the turbocharger from the engine,
then check the rotor axial play and radial play.
When disassembling the turbocharger, be sure to
plug the oil inlet and outlet ports with taps, etc.
(1) Rotor axial play
Figure 294
(2) Rotor radial play
Figure 295

(3) If the measured axial and radial plays are
beyond the limit of wear, replace or repair the
turbocharger.
3) Guide for disassembling/cleaning and checking the
turbocharger First, disassemble the turbocharger
from the engine and clean/check it with the oil inlet
and outlet plugged with tape and so on.
4) Precautions for reassembling the turbocharger onto
the engine For reassembly of the turbocharger or
handling it after reassembly operation, be sure to
observe the following precautions:
Especially, exercise extreme care to prevent
foreign matters from entering the inside of the
turbocharger.
(1) Lubricating system
● Before reassembling the turbocharger onto the
engine, inject new oil in the oil inlet port and
lubricate the journal and thrust bearings by
rotating them with hand .
● Clean not only the pipes installed between the
engine and oil inlet port but also the oil outlet
pipe and check them for damage or foreign
matters.
● Assemble each joint on oil pipes securely to
prevent oil leaks.

(2) Intake system
● Check the inside of the intake system for
foreign matters.
● Assemble each joint on the intake duct and air
cleaner securely to prevent air leaks.

(3) Exhaust system
● Check the inside of the exhaust system for
foreign matters.
● Be sure to use heat resisting steel bolts
and nuts. Do not interchange them with

ordinary steel bolts and nuts when performing
reassembly operation. Apply anti-seizure
coating to the bolts and nuts
● Assemble each joint on the exhaust pipes
securely to prevent gas leaks.

Diagnostics and troubleshooting

Air Intake System
Maintenance
(only when engine is switched 011)
Empty the dust bowl (7) regularly. The bowl should
never be filled more than halfway with dust.
On slipping off the two clamps (3), the dust bowl can
be removed. Take off the cover (6) of the dust bowl
and empty.
Be careful to assemble cover and bowl correctly There
is a recess in the cover rim and a lug on the collector
which should register. Where the filter is installed
horizontally, watch for “top” mark on cleaner bowl.
Figure 296
Changing 1ilter element

● On removing the hexagon nut, take out the dirty
cartridge and renew or clean.

● Wipe the cleaner housing with a damp cloth, in
particular the sealing surface for the element.
NOTE
Do not allow dirt to get into the clean air end.
Figure 297

Cleaning filter elements
●By compressed air (wear goggles)
- For the purpose, the air gun should be fitted

with a nozzle extension which is bent 900 at the
discharge end and which is long enough to reach
down inside to the bottom of the element.
- Moving the air gun up and down, blow out the
element from the inside (maximum 500kPa - 5 bar)
until no more dust comes out of the filter pleats.
Figure 298
●By washing
- Before washing, the element should be precleaned
by means of compressed air, as described above.
- Then allow the element to soak in lukewarm
washing solvent for 10 minutes, and then move it
to and for in the solvent for about 5 minutes.
- Rinse thoroughly in clean water, shake out and
allow drying at room temperature. The cartridge
must be dry before it is reinstalled.
- Never use steam sprayers, petrol (gasoline) ,
alkalis or hot liquids etc. to clean the filter elements.
●Knocking out dirt by hand
- In emergencies, when no compressed air or Figure 299

cleaning agent is available, it is possible to clean
the filter cartridge provisionally by hitting the end
disk of the cartridge with the ball of one’s thumb.
- Under no circumstances should the element be
hit with a hard object or knocked against a hard
surface to loosen dirt deposits.
●Checking the filter cartridge
- Before reinstalling the cartridge, it must be checked

for damage e.g. to the paper pleats and rubber
gaskets, or for bulges and dents etc. in the metal
jacket.
- Cracks and holes in the paper pleating can be
established by inspecting the cartridge with a
flashlight.
- Damaged cartridges should not be reused under
any circumstances. In cases of doubt, discard the
cartridge and install a new one. Figure 300

SPECIAL TOOL LlST
DX140AF/DX140LCA Special tool list 9-207

DX140AF/DX140LCA Special tool list 9-208
Appendix
1) Tightening torque for major parts
2) Tightening torque for fuel injection pump system
DX140AF/DX140LCA Appendix 9-209

3) Tightening torque for hollow screw(4-hole)
★: Adopted in DAEWOO engine: Adopted in DAEWOO engine

4) Standard bolt tightening torque table
Refer to the following table for bolts other then
described above.
Others:
1. The above torque rating have been determined to
70% or so of the limit value for bolt elasticity.
2. Tension is calculated by multiplying tensile strength
by cross section of thread.
3. 8pecial screws should be tightened to 85% or so
of the standard value For example, a screw coated
with M082 should be tightened to 60% or so of the
standard value.
DX140AF/DX140LCA Appendix 9-210

Drawing
DX140AF/DX140LCA Drawing 4-1

ＭＥＭＯ

Table of Contents
Drawing
DX140AF/DX140LCA Hydraulic Drawing....................4
DX140AF/DX140LCA Electrical Drawing....................5


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Maintenance Manual

Service Technology Division of DICC PS Department

1）Track Excavator Maintenance Safety........1-3

1）General Maintenance Instructions..............3-1

1）Boom and Arm...........................................6-3

1）DX140AF/ DX140LC AHydraulic Drawing.....4

DX140AF/DX140LCA Track Excavator Maintenance Safety 1-3

DX140AF/DX140LCA Track Excavator Maintenance Safety 1-4

Track Excavator Maintenance Safety

DX140AF/DX140LCA Track Excavator Maintenance Safety 1-5

DX140AF/DX140LCA Track Excavator Maintenance Safety 1-6

influence of drugs or alcohol. An operator who is

be sure that all personnel know nature of work and

in their proper location. Have guards and shields

maintenance of all safety features such as safety

Always keep them in good operating condition.

underground and overhead utility lines before

to instructions in this manual, Safety Manual and

Know Your Machine

DX140AF/DX140LCA Track Excavator Maintenance Safety 1-7

DX140AF/DX140LCA Track Excavator Maintenance Safety 1-8

DX140AF/DX140LCA Track Excavator Maintenance Safety 1-9

Correction of Machine Problems

Crushing and Cutting

DX140AF/DX140LCA Track Excavator Maintenance Safety 1-10

Hot Coolant and Oils - Burn Prevention

To prevent hot oil or coolant from spraying out, stop

DX140AF/DX140LCA Track Excavator Maintenance Safety 1-11

machine only in a well ventilated area. Machine Figure 8

nonmetallic hoods or nonmetallic fenders can

DX140AF/DX140LCA Track Excavator Maintenance Safety 1-12

DX140AF/DX140LCA Track Excavator Maintenance Safety 1-13

Never Use Ether Starting Aids

DX140AF/DX140LCA Track Excavator Maintenance Safety 1-14

extinguisher at base of fire. Figure 13

be familiar with its operating procedures.

Fire Extinguisher and First-aid Kit

and read labels to ensure that you know how to

adequately trained in its use. Figure 14

● Keep a first aid kit in storage compartment (Figure

15) and keep another kit at work site. Check kit

service, hospital and fire department readily

DX140AF/DX140LCA Track Excavator Maintenance Safety 1-15

Roll-over Protective Structure (ROPS)

Do not remove protective structure and perform

grinding, drilling holes or adding attachments unless

by falling objects or by rolling over, its strength will

DX140AF/DX140LCA Track Excavator Maintenance Safety 1-16

DX140AF/DX140LCA Track Excavator Maintenance Safety 1-17

When working in mines, quarries or other work

necessary to add additional guards depending on

DX140AF/DX140LCA Track Excavator Maintenance Safety 1-18

DX140AF/DX140LCA Track Excavator Maintenance Safety 1-19

Loading and Unloading

level ground. Maintain a safe distance from edge of

machine. The machine may fall or tip over.

capacity. Be sure that ramps are wide, and long

ice and loose materials. Remove dirt from machine

● Run engine at low speed and travel slowly.

● When on ramps, do not operate any control lever

except for travel lever.

drive off ramps, correct machine direction, then drive

gravity of machine will change suddenly causing