Doosan DX340LC-5 DX350LC-5 Shop Manual Excavator 950106-01001E

Shop Manual
DX340LC-5/DX350LC-5
Excavator
Serial Number 10001 and Up
DOOSAN and the DOOSAN logo are registered

trademarks of DOOSAN Corporation in the United
States and various other countries around the 950106-01001E
world. April 2014
Copyright DOOSAN 2014 Original Instructions

1NOTICE
Date Contents Section No. Page
01/04/2014 1st Edition

1Table of Contents
1 Safety 1 Track Excavator Maintenance Safety
2 Specifications 1 Specifications
3 General Maintenance 1 General Maintenance Instructions
2 Standard Torques
4 Engine 1 Engine
2 Engine Coolant Heater (Option)
5 Upper Structure 1 Cabin
2 Counterweight
3 Hydraulic Oil Tank
4 Fuel Tank
5 Main Pump
6 Drive Coupling (Main Pump)
7 Main Control Valve
8 Swing Device
9 Fan Pump for Oil Cooler
10 Fan Motor for Oil Cooler
11 Gear Pump (Rotation)
12 Joystick Valve (Work Lever)
13 Travel Control Valve (with Damper)
14 Solenoid Valve
15 Accumulator
16 Two Pump
6 Lower Structure and Chassis 1 Swing Bearing
2 Center Joint
3 Travel Device
4 Track Assembly
Table of Contents
Page I
7 Front 1 Boom and Arm
2 Bucket
3 Cylinders
8 Hydraulic System 1 Hydraulic System
2 Hydraulic System Testing and Adjustment

3 Hydraulic System Troubleshooting
9 Electrical System 1 Electrical System
10 Options 1 One Way
2 Two-way
3 Rotating
4 Quick Coupler
11 Schematic 1 Hydraulic Schematic/Electrical Schematic
Table of Contents
Page II
1Safety
Track Excavator
Maintenance
Safety
Edition 1
DX340LC-5/DX350LC-5 Track Excavator Maintenance Safety

1-1-1
MEMO
Track Excavator Maintenance Safety DX340LC-5/DX350LC-5

1-1-2
Table of Contents
Track Excavator Maintenance Safety

Safety Instructions ..........................................1-1-5
Safety Messages ............................................1-1-5
General ...........................................................1-1-6
Transportation ..............................................1-1-19
Operation ......................................................1-1-21
Maintenance .................................................1-1-38
Environment and Circumstances..................1-1-55

1-1-3
MEMO

1-1-4
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.

1-1-5
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.
• Be sure that you understand the use and 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.
• Always check for and know the location of 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.

1-1-6
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 FG018457
to do so can result in death or serious injury. Figure 1
When pressurized air and/or pressurized water is used for
cleaning, wear protective clothing, protective 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.

1-1-7
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.
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. HAOA110L
Figure 2
To prevent personnel from being struck by flying objects, keep
personnel out of work area.
HAOA100L
Figure 3

1-1-8
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
HAOA020L
be required.
Figure 4
Wear a hard hat, safety shoes, safety goggles, mask, leather
gloves, earplugs and other protective equipment, as required.
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.

1-1-9
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 system,
lubrication system, fuel system, and cooling system, before any
lines, fittings or related items are disconnected. FG019095
Figure 6
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

1-1-10
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
Always observe the following:
Figure 8
• Add fuel, oil, antifreeze and hydraulic fluid to machine only

in a well ventilated area. Machine 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
Figure 9
Maintenance
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.

1-1-11
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

1-1-12
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
EX1400130
nozzle. In very cold, dry weather or other conditions that could
produce a static discharge, keep tip of fuel nozzle in constant Figure 11
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
Figure 12
Welding and Grinding

Always clean machine and attachment, set battery 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.

1-1-13
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.
• When using a fire extinguisher, always aim extinguisher at
base of fire. FG018459
• If an optional fire extinguishing system is in place, be Figure 13
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
HDO1009L
are 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.
EX1300678
Figure 15

1-1-14
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 roll-
over 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.

1-1-15
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.
Never modify the ROPS cabin. Replace the cabin and hardware EX1300529
if damaged. See your DOOSAN distributor for parts. Figure 16
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.

1-1-16
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 1
on the cabin.
For breaker operation, install a front guard (1, Figure 17) and
apply a laminated coating sheet to 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.
FG020947
Figure 17
When working in mines, quarries or other work sites where there

is a hazard of falling rocks, install Operator Protection Guard
(OPG) (2, Figure 18) and 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 2
reinforcement system, by drilling holes, welding, remounting or
relocating fasteners. Any 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 necessary FG018595
to add additional guards depending on operating Figure 18
conditions or local rules or regulations for the work
site. Always contact your DOOSAN distributor for
advice.

1-1-17
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.
WARNING EX1300679
Figure 19
Protect your eyes when breaking the glass.

1-1-18
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.

1-1-19
• 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.

1-1-20
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 CI-4/
ACEA E5, E7 or 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.

1-1-21
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 equipment to
maintain proper clearance when you operate machine or work DANGER
equipment near fences or near boundary obstacles. No Entry

EX1300680
Know appropriate work site hand signals and personnel that are Figure 20
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.

1-1-22
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. Maintain
three-point contact (both feet and one hand or one foot and both EX1301111
hands) with handrails, guardrails, steps, and track shoes to
Figure 21
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.
Do not carry tools or supplies when you mount or dismount the
machine.
EX1301112
Figure 22
EX1301113
Figure 23

1-1-23
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.

1-1-24
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.

1-1-25
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.

1-1-26
• 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.

1-1-27
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 leaks.
Figure 24
• 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
EX1301192
fire.
Figure 25
• When starting engine, sound horn as a warning to alert
personnel in the work area.
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.

1-1-28
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 death or serious
injury.
• 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 traveling in reverse. EX1400131
• When operating in areas with poor visibility, designate a Figure 26
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.

1-1-29
Never turn starter switch to "O" (OFF) position when traveling.
This can lead to a loss of steering control. Travel Position
Do not operate attachments while traveling.

Do not change selected travel mode (FAST/SLOW) while
traveling.
Never travel over obstacles or excessive slopes that 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 40 - 50 cm (16 - 20 in.)
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.
Always operate within permissible water depth. Permissible
water depth is up to centerline of upper track roller(s).
When passing over bridges or structures on private land, check EX1300681
that structure is strong enough to support weight of machine.
Figure 27
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.

1-1-30
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 death or serious injury.

1-1-31
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 machine
tipping, roll-over or sliding down the slope. Always fasten your 20 -
30 c
seat belt. m (8
- 12
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.
Do not travel on grass, fallen leaves, or wet steel plates. Even
slight slopes can cause machine to slide down a slope. Travel at
low speed and make sure that the machine is always traveling in)
12
directly up or down slope. 8-
cm(
Do not change travel direction on a slope. This could result in - 30
20
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.
In addition, lower bucket as far as possible, keep it pulled into
front, and keep swing speed as slow as possible.
EX1300691
Figure 28
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 equipment
to front to improve balance, keep work equipment EX1300682
approximately 20 - 30 cm (8 - 12 in) above ground, and Figure 29
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.

1-1-32
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 where slope is Towing Wire
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
• Make sure that towing eyes and towing devices are EX1400132
adequate for towing loads. Figure 30
• 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.

1-1-33
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, and can result in death or serious
injury.
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 can result in death or serious injury.
EX1400133
• When using a fork or grapple, do not attempt to pick up an
object with its tips. This could damage the machine or Figure 31
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 and can result in
death or serious injury.
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.
Wear appropriate personal protective equipment and follow the
established procedure in the Operation & Maintenance Manual.

1-1-34
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, 120
drop-offs and any area of 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 overnight support saddle. To Block
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 overnight storage
position and all switches and operating controls are in "OFF"
position, safety lever must be moved to "LOCK" position. This Unlock
will disable all pilot control functions.
Always close door of operator's cabin and lock all equipment to
prevent any unauthorized person from operating the machine. Lock EX1401035
Figure 32
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 running. EX1300684
Figure 33

1-1-35
Preservation/Storing Machine
Perform the following if storing excavator for more than one
month.
Conditions Maintenance Required

Cleaning Pressure wash undercarriage and track assemblies. Inspect for damage or
loose or missing parts.
Lubrication Perform all daily lubrication procedures.
Apply a coating of light oil to exposed plated metal surfaces, such as hydraulic
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.
Cooling System Inspect coolant recovery tank to make sure that antifreeze level in system is at
correct level.
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.
Hydraulic System Once a month, start engine and follow procedures in Operation & Maintenance
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. Park 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.
• Turning off electrical current with battery 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.

1-1-36
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.

1-1-37
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 can result in death or serious
injury.
• 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.

1-1-38
• 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.

1-1-39
• 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
• 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.

1-1-40
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 WARNING
chain or cable to keep the safety lever in the fully lowered
"LOCK" position, complies with OSHA's lockout requirements. DO NOT OPERATE
when performing inspection
or maintenance
950205-01451
FG018690
Figure 34
"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. 950205-01760
• If any other person starts engine, and operates control

FG018596
levers or control pedals while you are performing service or Figure 35
maintenance, it can result in death or serious injury.
Attach a "DO NOT OPERATE" warning tag to starter switch or to
controls before servicing or repairing equipment. Warning tags
(Special Instruction, SEHS7332) are available from your
DOOSAN distributor.

1-1-41
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
EX1400134
falling.
Figure 36
• Wear safety goggles and protective clothing when 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.

1-1-42
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.
Store oily rags and other flammable material in a protective
HDO1015I
container.
Figure 37
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 and hydraulic lines. FG018458
Figure 38

1-1-43
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.
Batteries give off flammable fumes that can explode and start a HAAE1980
fire. Figure 39
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.

1-1-44
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.

1-1-45
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.

1-1-46
Welding Repairs
When performing welding repairs, perform welding in a properly
equipped place. Repairs must be performed by a qualified
welder. Welding operations, can create potential hazards,
including generation of gas, fire, or electric shock. Never let an
unqualified welder do welding.
A qualified welder must do the following:
• To prevent battery explosion, turn battery disconnect
switch to "OFF" position.
• To prevent generation of gas, remove paint from location
of the weld.
• If hydraulic equipment, piping or component ports close to
them are heated, a flammable gas or mist could result in
an explosion or fire. To prevent this, protect and insulate
components from excessive heat.
• Do not weld on pipes or on tubes that contain flammable
fluids. Do not flame cut pipes or tubes that contain
flammable fluids. Before welding on pipes or tubes, or
before flaming cut pipes or tubes, clean them thoroughly
with a nonflammable solvent. Make sure pressure inside
pipes or tubes does not cause a rupture of the component
parts.
• If heat is applied directly to rubber hoses or piping under
pressure, they may suddenly break, so cover and insulate
them with a fireproof covering.
• Wear protective clothing.
• Make sure there is good ventilation.
• Remove all flammable objects and make sure a fire
extinguisher is available.
Preparation for Electrical Welding on Body Structure

To prevent damage by electrical welding, observe the following
procedures:
OFF
1. Turn battery disconnect switch to "OFF" position.
2. Proceed with welding.
3. Clean battery compartment.
4. Turn battery disconnect switch to "ON" position.
5. Close battery compartment door.
ON
EX1300827
Figure 40

1-1-47
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, and result in death or
serious injury.
Never remove counterweight or front attachment unless the
upper structure is in-line with the lower structure.
EX1401352
Never rotate the upper structure once the counterweight or Figure 41
front attachment has been removed.

1-1-48
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
ARO1380L
machine, use steps and handrails, and maintain a
Figure 42
three-point contact (both feet and one hand or both hands
and one foot) to support yourself.
• 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.

1-1-49
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 43
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 familiar with this injury.
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.

1-1-50
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 grease valve assembly.
HAOA110L
Keep your face and body away from grease valve. Refer to
Operation & Maintenance Manual, for proper procedure in this Figure 44
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 45

1-1-51
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 against
other parts, and excessive heat during operation.
EX1400129
• Replace hose or components if any of the following Figure 46
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.

1-1-52
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 familiar with
this injury.
• If you accidentally drink battery electrolyte, call a poison
prevention center immediately and get immediate medical
attention from a physician familiar with this injury.
• When cleaning top surface of battery, wipe it with a clean,
damp cloth. Never use gasoline, thinner, or any other EX1400136
organic solvent or detergent. Figure 47
• 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.

1-1-53
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.

1-1-54
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
Figure 48
Deep Digging
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. EX1300687
Figure 49
Use machine only for its intended purpose. Using it for other
purposes will cause failures.
• Do not perform demolition work under machine. There is a
hazard that the machine may become 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.

1-1-55
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:
• When working in dark areas, attach working lights and
front lights to the machine. If necessary, set up additional
lighting at work site.
• Stop operations when visibility is poor, such as in fog, mist,
snow, and rain. Wait for visibility to improve before starting
operation.
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 roll-
over.
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.

1-1-56
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 sites where machine may
operate close to electrical cables, always do the following:
EX1300688
• Remember that electrical voltage determines what the
Figure 50
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.

1-1-57
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 followed. Also check
which rules apply to ground personnel regarding exposing
cables, utilities and electrical lines. EX1300689
Consider all electrical cables as live. Figure 51
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 52).
After working in water, lubricate all lubrication points on 1 EX1300690

undercarriage, which have been underwater so water is Figure 52
removed. Check that no water has entered travel gearboxes and
undercarriage components.
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.

1-1-58
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 startup. Wait 3 - 4 seconds after
preheating until voltage of the battery returns, and then
actuate the key 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, effectiveness of the battery is reduced accordingly.
Insulation of the battery prevents this reduction, and
supports improvement of starting power of the starter.
WARNING
BATTERY EXPLOSION 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. Always keep the fuel tank fully filled after completion of
operation. 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 due to formation of wax
in fuel, make sure that wax formation point of fuel is lower
than atmospheric temperature.

1-1-59
6. Lubricate entire machine according to Operation &
Maintenance Manual, in this manual or lubrication chart on
machine.
WARNING
FUEL TANK EXPLOSION CAN CAUSE DEATH OR
SERIOUS INJURY
Never attempt to heat the fuel tank with an open flame.
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.
• Formation of scale and rust in cooling 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.

1-1-60
IMPORTANT
Do not store acid type storage batteries near stacks of
tires. Acid fumes can damage rubber.
3. Service 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. Use 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.

1-1-61
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. Lubricate 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. Check operating controls to ensure proper functionality
and that they return to "NEUTRAL" when released.

1-1-62
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 can result in death
or serious injury.
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.
ARO1770L
Figure 53
Ventilation for Enclosed Area
If it is necessary to start engine within an enclosed area, or when
handling fuel, flushing oil, or paint; open 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.

1-1-63
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.

1-1-64
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 FG009156
proof containers. Never drain oil directly onto ground. Figure 54
• 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.

1-1-65
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
Hands and Arms: The weighted root mean square acceleration
to which hands and arms are subjected, is less than 2.5 m/s2.
Whole Body: The weighted root mean square acceleration to
which whole body is subjected, is less than 0.5 m/s2.
Measurements are obtained on a representative machine, using
measuring procedures as described in the following standard:
ISO 2631/1. ISO 5349, and SAE J1166.
Recommendations for Reducing Vibrations:
1. Select proper machine, equipment and attachments for a
particular application.
2. Replace any damaged seat with a genuine DOOSAN seat.
Keep seat properly maintained and adjusted.
• Adjust seat and suspension for weight and size of
operator.
• Inspect and maintain suspension and adjustment
mechanisms for seat regularly.
3. Check that the machine is properly maintained.
4. Operate controls smoothly when; steering, accelerating,
slowing down, loading, or moving attachments.
5. Adjust machine speed and travel path to reduce vibration
level.
• Slow down when traveling over rough terrain or long
distances.
• Avoid obstacles and rough terrain.
6. Keep machine on and maintain designated travel path
when traveling.
• Remove any large rocks or obstacles.
• Fill any ditches and holes.
• Use other machines to maintain the travel path for the
excavator.

1-1-66
1Specifications
Specifications
Edition 1
DX340LC-5/DX350LC-5 Specifications
2-1-1
MEMO
Specifications DX340LC-5/DX350LC-5
2-1-2
Table of Contents
Specifications
General Description ........................................2-1-5
Component Locations.....................................2-1-6
General Dimensions .....................................2-1-10
One - Piece Boom ................................................... 2-1-10
Two - Piece Boom ................................................... 2-1-11
Working Range .............................................2-1-12
One - Piece Boom ................................................... 2-1-12
Two - Piece Boom ................................................... 2-1-14
General Specifications..................................2-1-16
Approximate Weight of Workload Materials..2-1-18
Performance Tests .......................................2-1-20
Purpose of Performance Tests................................ 2-1-20
Kinds of Tests.......................................................... 2-1-20
Performance Standards .......................................... 2-1-20
Precautions for Evaluation of Test Data.................. 2-1-20
Definition of "Performance Standard"...................... 2-1-21
Preparation for Performance Tests ..............2-1-21
The Machine............................................................ 2-1-21
Test Area................................................................. 2-1-21
Precautions ............................................................. 2-1-21
Make Precise Measurement.................................... 2-1-22
Operational Performance Standard Table ....2-1-23
Operational Performance Test .....................2-1-25
Hydraulic Cylinder Cycle Time ................................ 2-1-25
Travel Speed ........................................................... 2-1-27
Track Revolution Speed .......................................... 2-1-28
Mistrack Check........................................................ 2-1-30
Swing Speed ........................................................... 2-1-32
Swing Function Drift Check ..................................... 2-1-33
2-1-3
2-1-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL DESCRIPTION
The excavator has three main component sections:
• The Upper Structure
• The Lower Undercarriage and Track Frames
• The Excavator Front-end Attachment
The following illustration identifies main components and their
locations. (See Figure 1 on page -6.)
2-1-5
COMPONENT LOCATIONS
21
1 2 3 4
20
19
18 6
17
16 11
7
15
10
14
13
12 8
9
EX1400026
Figure 1
Reference Reference
Description Description
Number Number
1 Cabin 12 Track Link and Shoe
2 Boom Cylinder 13 Idler
3 Boom 14 Track Adjuster
4 Arm Cylinder 15 Track Guard
5 Arm 16 Upper Roller
6 Bucket Cylinder 17 Lower Roller
7 Guide Link 18 Sprocket
8 Push Link 19 Travel Motor
9 Bucket 20 Counterweight
10 Side Cutter 21 Hood
11 Tooth Point
2-1-6
2
1
11 4
10
8 7
EX1400027
Figure 2
Reference Reference
Number Number
1 Engine 7 Oil Centrifugal Cleaner
2 Radiator 8 Main Pump
3 Engine Oil Filter 9 DOC
4 Precleaner 10 Evaporator Module
5 Air Cleaner 11 SCR Catalyst
6 Oil Cooler
2-1-7
FR
1 ON
T
8
13 7
2
9
12
4
3
11
10
EX1400028
Figure 3
Reference Reference
Number Number
1 Battery 8 Air Breather
2 Fuel Tank 9 Return Filter
3 Fuel Cap 10 Suction Filter
4 DEF (AdBlue) Breather Filter 11 Fuel Prefilter
5 Urea Tank 12 Pilot Filter
6 DEF (AdBlue) Filter 13 Fuel Filter
7 Hydraulic Oil Tank
2-1-8
FR
ON
T
8 1
7 3
5
EX1400029
Figure 4
Reference Reference
Number Number
1 Solenoid Valve 5 Swing Device
2 Fan Motor 6 Control Valve
3 Center Joint 7 Gear Pump (Rotating)
4 Swing Bearing 8 Fan Pump
2-1-9
GENERAL DIMENSIONS
One - Piece Boom
G (G') A
H B
I
L F
N E
O
J C
K (K') D
EX1300752
Figure 5
6.5 m (21' 3") Boom

Dimension 3.2 m (10' 5") 2.6 m (8' 5") 3.95 m (13' 0")
STD Arm Arm Arm
A Shipping Length 11,315 mm (37' 1") 11,405 mm (37' 5") 11,345 mm (37' 3")
B Tail Swing Radius 3,530 mm (11' 7")
C Tumbler Distance 4,040 mm (13' 3")
D Track Length 4,940 mm (16' 2")
E Counterweight Clearance 1,195 mm (3' 11")
F
Shipping Height 3,255 mm (10' 8") 3,495 mm (11' 6") 3,420 mm (11' 3")
(Boom)
F
(Hose)
G Shipping Width (STD) 3,280 mm (10' 9")
G' Shipping Width (Narrow) 3,000 mm (9' 10")
H House Width 3,000 mm (9' 10")
I Cab Width 1,010 mm (3' 4")
J Shoe Width 600 mm (2')
K Undercarriage Width (STD) 3,280 mm (10' 9")
K' Undercarriage Width (Narrow) 3,000 mm (9' 10")
L Height Over Cab 3,080 mm (10' 1")
M Cab Height Above House 845 mm (2' 9")
N Track Height 1,048 mm (3' 5")
O Car Body Clearance 510 mm (1' 8")
2-1-10
Two - Piece Boom
G (G') A
H B
I
L F
N E
O
J C
K (K') D
EX1300753
Figure 6
6.52 m (21' 4") Boom

Dimension 3.2 m (10' 5") 2.6 m (8' 5") 3.95 m (13' 0")
STD Arm Arm Arm
A Shipping Length 11,350 mm (37' 3") 11,345 mm (37' 3") 11,280 mm (37')
B Tail Swing Radius 3,530 mm (11' 7")
C Tumbler Distance 4,040 mm (13' 3")
D Track Length 4,940 mm (16' 2")
E Counterweight Clearance 1,195 mm (3' 11")
F
(Boom)
F
(Hose)
G Shipping Width (STD) 3,280 mm (10' 9")
G' Shipping Width (Narrow) 3,000 mm (9' 10")
H House Width 3,000 mm (9' 10")
I Cab Width 1,010 mm (3' 4")
J Shoe Width 600 mm (2')
K Undercarriage Width (STD) 3,280 mm (10' 9")
K' Undercarriage Width (Narrow) 3,000 mm (9' 10")
L Height Over Cab 3,080 mm (10' 1")
M Cab Height Above House 845 mm (2' 9")
N Track Height 1,048 mm (3' 5")
O Car Body Clearance 510 mm (1' 8")
2-1-11
WORKING RANGE
WARNING
The Minimum Digging Reach or "L" dimension, depends on
the stability and support provided by ground conditions.
Digging too far underneath the excavator if soil conditions
are wet, loose or unstable can collapse ground support,
which could cause death or serious injury and/or
equipment damage.
One - Piece Boom

M
F
G
D
E
d
G.L 0
L
H J
C
K 2,500 mm
I
B
A
EX1401493
Figure 7
2-1-12
Boom 6.5 m (21' 3")
DIM. Arm 3.2 m (10' 5") STD 2.6 m (8' 5") 3.95 m (13' 0")
Bucket Type (PCSA) 1.49 m3 (1.95 yd3) 1.83 m3 (2.39 yd3) 1.25 m3 (1.63 yd3)
11,170 mm 10,585 mm 11,930 mm
A Max. Digging Reach
(36' 8") (34' 9") (39' 2")
10,970 mm 10,380 mm 11,745 mm
B Max. Digging Reach (Ground)
(35' 12") (34' 1") (38' 6")
7,535 mm 6,935 mm 8,290 mm
C Max. Digging Depth
(24' 9") (22' 9") (27' 2")
7,175 mm 6,865 mm 7,635 mm
D Max. Loading Height
(23' 6") (22' 6") (25' 1")
2,710 mm 3,315 mm 1,955 mm
E Min. Loading Height
(8' 11") (10' 11") (6' 5")
10,320 mm 9,970 mm 10,815 mm
F Max. Digging Height
(33' 10") (32' 8") (35' 6")
8,880 mm 8,570 mm 9,340 mm
G Max. Bucket Pin Height
(29' 2") (28' 1") (30' 8")
5,890 mm 5,090 mm 6,830 mm
H Max. Vertical Wall Depth
(19' 4") (16' 8") (22' 5")
7,720 mm 7,715 mm 7,785 mm
I Max. Radius Vertical
(25' 4") (25' 4") (25' 6")
7,345 mm 6,720 mm 8,155 mm
J Max. Depth to 2,500 mm Line
(24' 1") (22' 0") (26' 9")
3,320 mm 3,270 mm 3,395 mm
K Min. Radius 2,500 mm Line
(10' 11") (10' 9") (11' 2")
710 mm 2,175 mm -349 mm
L Min. Digging Reach
(2' 4") (7' 2") -(1' -2")
4,455 mm 4,480 mm 4,515 mm
M Min. Swing Radius
(14' 7") (14' 8") (14' 10")
d Bucket Angle 178° 178° 178°
2-1-13
Two - Piece Boom
F
G
D
E
d
G.L 0
L
H J
C
K 2,500 mm
I
B
A
EX1401494
Figure 8
2-1-14
Boom 6.52 m (21' 4")
DIM. Arm 3.2 m (10' 5") STD 2.6 m (8' 5") 3.95 m (13' 0")
Bucket Type (PCSA) 1.49 m3 (1.95 yd3) 1.83 m3 (2.39 yd3) 1.25 m3 (1.63 yd3)
11,380 mm 10,770 mm 12,150 mm
A Max. Digging Reach
(37' 4") (35' 4") (39' 10")
11,185 mm 10,565 mm 11,975 mm
B Max. Digging Reach (Ground)
(36' 8") (34' 8") (39' 3")
7,350 mm 6,740 mm 8,135 mm
C Max. Digging Depth
(24' 1") (22' 1") (26' 8")
9,065 mm 8,560 mm 9,900 mm
D Max. Loading Height
(29' 9") (28' 1") (32' 6")
3,645 mm 4,385 mm 3,005 mm
E Min. Loading Height
(11' 12") (14' 5") (9' 10")
12,455 mm 11,925 mm 13,305 mm
F Max. Digging Height
(40' 10") (39' 1") (43' 8")
10,765 mm 10,245 mm 11,605 mm
G Max. Bucket Pin Height
(35' 4") (33' 7") (38' 1")
5,935 mm 5,250 mm 6,750 mm
H Max. Vertical Wall Depth
(19' 6") (17' 3") (22' 2")
7,550 mm 7,510 mm 7,680 mm
I Max. Radius Vertical
(24' 9") (24' 8") (25' 2")
7,170 mm 6,540 mm 7,970 mm
J Max. Depth to 2,500 mm Line
(23' 6") (21' 5") (26' 2")
2,395 mm 2,430 mm 2,380 mm
K Min. Radius 2,500 mm Line
(7' 10") (7' 12") (7' 10")
1,780 mm 2,745 mm 1,005 mm
L Min. Digging Reach
(5' 10") (9' 0") (3' 4")
3,440 mm 3,635 mm 3,510 mm
M Min. Swing Radius
(11' 3") (11' 11") (11' 6")
d Bucket Angle 178° 178° 178°
2-1-15
GENERAL SPECIFICATIONS
Shipping Weight 34.9 tons (76,941 lb)
Includes 10% fuel, 6,500 mm (21' 3") boom, 3,200 mm (10' 5") arm,
1,410 mm (4' 6") backhoe bucket and standard shoes
Operating Weight Add weight of full fuel tank and operator.
Shipping Weights With Optional Add 380 kg (838 lb) for 700 mm (28") shoes
Track Shoes Add 760 kg (1,676 lb) for 800 mm (32") shoes
Add 945 kg (2,083 lb) for 850 mm (33.5") shoes
Add 1,140 kg (2,513 lb) for 900 mm (36") shoes
Add 526 kg (1,160 lb) for 600 mm (24") double grouser shoes
Major Component Weights Standard Boom 2,697 kg (5,946 lb)
2,600 mm (8' 5") Arm 1,121 kg (2,471 lb)
3,200 mm (10' 5") Arm 1,251 kg (2,758 lb)
3,950 mm (13' 0") Arm 1,470 kg (3,241 lb)
Boom Cylinders 290 kg (639 lb) each
Arm Cylinder 435 kg (959 lb)
Bucket Cylinder 260 kg (573 lb)
Counterweight 7,100 kg (15,700 lb)
Upper Structure 8,753 kg (19,297 lb)
Lower - below Swing Bearing 11,760 kg (25,926 lb)
Digging Forces (At Power Boost, ISO)
Bucket Cylinder 254 KN or 25,900 kg (57,100 lb) with Mono Boom/Articulated Boom + GP
Bucket
Arm Cylinder 185 KN or 18,865 kg (41,590 lb) with 3,200 mm (10' 5") Standard Arm
Fuel Tank Capacity 600 liters (158.5 U.S. gal)
Hydraulic System Capacity 450 liters (118.8 U.S. gal)
Hydraulic Reservoir Capacity 240 liters (63.4 U.S. gal)
Bucket Heaped Capacity Range SAE 1.25 - 2.01 m3 (1.63 - 2.63 yd3) Mono Boom/Articulated Boom
NOTE: Refer to the Load Weight, Bucket and Arm Length Compatibility
Table for information on which bucket sizes are approved with which arm
length and work load material weights.
Shoe Type Triple Grouser Double Grouser
Shoe Width and Optional Sizes 600 mm (24") - standard 600 mm (24") - optional
700 mm (28") - optional
850 mm (33.5") - optional
Ground Pressure Ratings:
Standard 600 mm (24") shoe 0.69 bar (0.69 kg/cm2, 9.85 psi)
Optional 700 mm (28") shoe 0.60 bar(0.60 kg/cm2, 8.57 psi)
Optional 850 mm (33.5") shoe 0.50 bar(0.50 kg/cm2, 7.17 psi)
Optional 600 mm (24")
0.71 bar(0.71 kg/cm2, 10.04 psi)
double grouser shoe
2-1-16
Transport Dimensions
Overall Shipping Length
11,285 mm (37'")
(standard boom and arm)
Overall Shipping Width
3,280 mm (10' 9")
(standard shoes)
Overall Shipping Height
3,390 mm (11' 1")
(to top of cylinder hose)
Track Shipping Length 4,940 mm (16' 2")
Transport Trailer Capacity 35 tons (38.6 short tons), minimum load capacity
Transport Loading Ramp
Allowable Slope When 15° angle
Transporting
NOTE: Refer to Operation and Maintenance Manual for Recommended
Transportation Instructions.
2-1-17
APPROXIMATE WEIGHT OF
WORKLOAD MATERIALS
IMPORTANT
Weights are approximations of estimated average volume
and mass. Exposure to rain, snow or groundwater; settling
or compaction because of overhead weight and chemical or
industrial processing or changes because of thermal or
chemical transformations could all increase value of
weights listed in table.
Density Density Density Density

1,200 kg/m3 1,500 kg/m3 1,800 kg/m3 2,100 kg/m3
Material
(2,000 lb/yd3), (2,500 lb/yd3), (3,000 lb/yd3), (3,500 lb/yd3),
or less or less or less or less
401 kg/m3
Charcoal - - -
(695 lb/yd3)
433 kg/m3
Coke, blast furnace size - - -
(729 lb/yd3)
449 kg/m3
Coke, foundry size - - -
(756 lb/yd3)
801 kg/m3
Coal, bituminous slack, piled - - -
(1,350 lb/yd3)
881 kg/m3
Coal, bituminous r. of m., piled - - -
(1,485 lb/yd3)
897 kg/m3
Coal, anthracite - - -
(1,512 lb/yd3)
1,009 kg/m3
Clay, DRY, in broken lumps - - -
(1,701 lb/yd3)
1,746 kg/m3
Clay, DAMP, natural bed - - -
(2,943 lb/yd3)
1,506 kg/m3
Cement, portland, DRY granular - - -
(2,583 lb/yd3)
1,362 kg/m3
Cement, portland, DRY clinkers - - -
(2,295 lb/yd3)
1,522 kg/m3
Dolomite, crushed - - -
(2,565 lb/yd3)
1,202 kg/m3
Earth, loamy, DRY, loose - - -
(2,025 lb/yd3)
1,522 kg/m3
Earth, DRY, packed - - -
(2,565 lb/yd3)
1,762 kg/m3
Earth, WET, muddy - - -
(2,970 lb/yd3)
Gypsum, calcined, (heated, 961 kg/m3
- - -
powder) (1,620 lb/yd3)
2-1-18
Density Density Density Density
1,200 kg/m3 1,500 kg/m3 1,800 kg/m3 2,100 kg/m3
Material
(2,000 lb/yd3), (2,500 lb/yd3), (3,000 lb/yd3), (3,500 lb/yd3),
or less or less or less or less
1,522 kg/m3
Gypsum, crushed to 3 inch size - - -
(2,565 lb/yd3)
1,810 kg/m3
Gravel, DRY, packed fragments - - -
(3,051 lb/yd3)
1,922 kg/m3
Gravel, WET, packed fragments - - -
(3,240 lb/yd3)
1,282 kg/m3
Limestone, graded above 2 - - -
(2,160 lb/yd3)
1,362 kg/m3
Limestone, graded 1-1/2 or 2 - - -
(2,295 lb/yd3)
1,522 kg/m3
Limestone, crushed - - -
(2,565 lb/yd3)
1,602 kg/m3
Limestone, fine - - -
(2,705 lb/yd3)
1,282 kg/m3
Phosphate, rock - - -
(2,160 lb/yd3)
929 kg/m3
Salt - - -
(1,566 lb/yd3)
529 kg/m3
Snow, light density - - -
(891 lb/yd3)
1,522 kg/m3
Sand, DRY, loose - - -
(2,565 lb/yd3)
1,922 kg/m3
Sand, WET, packed - - -
(3,240 lb/yd3)
1,362 kg/m3
Shale, broken - - -
(2,295 lb/yd3)
529 kg/m3
Sulfur, broken - - -
(891 lb/yd3)
2-1-19
PERFORMANCE TESTS
Use operational performance test procedure to quantitatively
check all system and functions on the machine.
Purpose of Performance Tests

1. To 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. Base 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

To evaluate not only that the test data is correct, but also in what
range the test data is, be 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.
2-1-20
Definition of "Performance Standard"
1. Operation speed values and dimensions of the new
machine.
2. Operational 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. Repair 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 travel
straight ahead more than 20 m (65 ft 7 in), and to make a
full swing with the front attachment extended.
3. If required, place cones or barricades around the test area
and post signs 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. Do not operate on soft ground, near drop-offs, around
electrical cables, or overhead power lines. Always confirm EX1302009
there is sufficient space for full swings. Figure 9
4. Use leak proof containers to catch drained or leaking oil.

Obey local laws and regulations when disposing of oil, fuel,
filters and batteries.
2-1-21
Make Precise Measurement
1. Accurately calibrate test instruments in advance to obtain
correct data.
2. Perform 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.
EX1302010
Figure 10
2-1-22
OPERATIONAL PERFORMANCE STANDARD TABLE
Performance Reference
Item Unit Remarks
Standard Page
Power Plus Mode rpm 1,900 ±25
Power Mode rpm 1,700 ±25
No Load Standard Mode rpm 1,600 ±25
Economy Mode rpm 1,500 ±25
Lifting Mode rpm 1,500 ±25
Power Plus Mode rpm 1,700 ±25 The rated engine
Power Mode rpm 1,600 ±25 speed is adjusted
No Load
to be lowered
(Smart Power Standard Mode rpm 1,500 ±25
down by 100 rpm
Control) Economy Mode rpm 1,500 ±25 if SPC is
Engine Speed Lifting Mode rpm 1,500 ±25 implemented.
Power Plus Mode mA -
The pump's
EPPR Valve Current Power Mode mA - pressure sensor
for Pump Torque
Standard Mode mA - must be removed
Control
to check the
(Power Shift Control) Economy Mode mA -
value.
Lifting Mode mA -
Low Idle rpm 800 ±20
Auto Idle rpm 850 ±20
1 Pump Relief rpm above 1,800
Power Plus Mode
2 Pump Relief rpm above 1,800
Power Plus Mode Standard bar 343 +10
(Auto Idle OFF)
Front Relief Power Boost bar 363 +10
Relief
Pressure Power Plus Mode at Pump bar 280 +10
(Auto Idle OFF)
Swing Relief at Swing Motor bar 280 +10
Up sec 3.6 ±0.4
Boom Down (Without LV) sec 2.8 ±0.3
Down (With LV*) sec 3.0 ±0.3
Front Single
Crowd sec 4.3 ±0.4 page -25
Speed Arm
Dump sec 3.6 ±0.3
Crowd sec 3.5 ±0.4
Bucket
Dump sec 2.7 ±0.3
Swing Speed Swing single 3 revolution sec 19.5 ±1.5 page -32
Low-speed sec 21.9 ±1.5
20 m Travel page -27
Travel Speed High-speed sec 13.8 ±1.0
on Flat Low-speed sec 34.1 ±2.0
Jack-up (3 Turns) page -28
High-speed sec 21.0 ±1.5
Swing 1,010 ±257
Swing BRG After 360° Swing mm page -33
Coasting (72 ±20°)
* LV: Lock Valve
2-1-23
Performance Reference
Item Unit Remarks
Standard Page
mm/
Boom below 20
5 min
Cylinder mm/
Front Arm below 20 page -39
Creeping 5 min
mm/
Bucket below 20
5 min
Travel Low-speed mm below 150
20 m Travel page -30
Deviation High-speed mm below 150
Fan Speed rpm 1,250 +50
Fan Max. Speed by
Fan Pump
Hydraulic Fan Control Pressure
bar 96 ±10
Control
Fan Control Value Fan Speed Control
Current mA 100 ±20
(Reference)
2-1-24
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
Power Plus Digging
High Idle OFF
Mode 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 it
takes for the bucket to reach the ground. EX1301781
3) Measuring available displacement of the Figure 11
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.
2-1-25
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 0.5 m
for the arm to extend fully. EX1301782
cylinder: Measure and record the extension
length of the cylinder rod from the point at 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 to
extend fully. 1m
EX1301783
cylinder: Measure and record the extension
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.
2-1-26
Travel Speed
Summary
Measure the time required for the excavator to travel a 20 m
(65.6 ft) test track.
Preparation
Arm Rolled-in, Bucket Rolled-in
1. Adjust the track sag on both side tracks equally. Bucket Height: 0.3 - 0.5 m
2. Prepare a flat and solid test track 20 m (65.6 ft) in length End
with extra length of 3 - 5 m (9.8 - 16 ft) on both ends for
machine acceleration and deceleration. Start
20 m
Deceleration
IMPORTANT
Zone 3 - 5 m
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 14
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. Measure 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
Power
Digging
Low Mode High Idle Plus OFF
Mode
Mode
Power
High Digging
High Idle Plus 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.
Evaluation
Refer to “Operational Performance Standard Table” on page -23.
2-1-27
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.
90 - 110
CAUTION
AVOID INJURY
5ecure support the raised track using wooden blocks. EX1300534
Figure 15
(122 ±41 °F).
Measurement
1. Measure the both tracks on forward and reverse directions
at each travel mode.
Travel Engine Power

Work Auto-idle
Mode Control Mode
Mode Switch
Switch Dial Switch
Power
Digging
Mode
Mode
Power
High Digging
High Idle Plus 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.
average values.
NOTE: Record the details of any abnormal noise heard
during measurement, or any abnormal conditions
2-1-28
observed during operation, on a blank measurement
record sheet.
Evaluation
NOTE: The 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.
2-1-29
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. If 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 ends for Max. Distance
machine acceleration and deceleration.
IMPORTANT
Acceleration
The bucket teeth will hit the boom if the bucket is Zone 3 - 5 m
m
rolled-in with the arm fully rolled-in.
20
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
the arm and bucket rolled-in.
(122 ±41 °C). EX1301768
Figure 16
Measurement
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
Power
Digging
Mode
Mode
Power
High Digging
High Idle Plus OFF
Mode Mode
Mode
3. Start traveling the machine in the acceleration zone with

the travel levers al full stroke.
2-1-30
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.
average values.
Evaluation
2-1-31
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 pin boom foot pin height.
height is flush with the boom foot pin height.
EX1301770
NOTE: In case of no place to be measured, measure Figure 17
with the boom raised and the arm rolled-in.
(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
Power Plus Digging
High Idle OFF
Mode 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.
average values.
Evaluation
2-1-32
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.
3. With the bucket empty, position the front attachment as
follow.
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. Two Matching Marks
EX1301772
4. Put the matching marks on the swing bearing and on the
Figure 18
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
clear and that co-workers are out of the swing area EX1301773
before starting the measurement. Figure 19
Measurement Measure Difference

Between Marks

Work Mode
Power Plus Digging
High Idle OFF
Mode Mode
Mark on Track Frame
2. Operate swing control lever fully and return it to the neutral
position when the mark on upper structure aligns with that Mark on Swing Bearing
on track frame after swinging 360°. EX1301774
Figure 20
3. Measure the time distance between the two marks.
4. Align the marks again, swing 360°, and then test in the
opposite direction.
average values.
Evaluation
2-1-33
2-1-34
1General Maintenance
General
Maintenance
Instructions
Edition 1
DX340LC-5/DX350LC-5 General Maintenance Instructions

3-1-1
MEMO
General Maintenance Instructions DX340LC-5/DX350LC-5

3-1-2
Table of Contents
General Maintenance Instructions

Safety Instructions3-1-5
Welding Precautions and Instructions3-1-6
Hydraulic System - General Precautions3-1-7
Maintenance Service and Repair Procedure3-1-9
General Precautions3-1-9
Hydraulic System Cleanliness and Oil Leaks3-1-10
Maintenance Precautions for Hydraulic System
Service3-1-10
Oil Leakage Precautions3-1-11
Cleaning and Inspection3-1-12
General Instructions3-1-12
Bearing Inspection3-1-13

3-1-3
3-1-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

3-1-5
WELDING PRECAUTIONS AND
INSTRUCTIONS
WARNING
To avoid accidents, personal injury and the possibility of
causing damage to the machine or to components, welding
must only be performed by properly trained and qualified
personnel, who possess the correct certification (when
required) for the specific welding fabrication or specialized
repair being performed.
WARNING
Structural elements of the machine may be built from a
variety of steels. These could contain unique alloys or may
have been heat-treated to obtain particular strength
characteristics. It is extremely important that welding
repairs on these types of steel are performed with the
proper procedures and equipment. If repairs are performed
incorrectly, structural weakening or other damage to the
machine (that is not always readily visible) could result.
Always consult DOOSAN After Sales Service before
welding on integral components (loader arm, frames, car
body, track frames, upper structure, attachment, etc.) of the
machine. It is possible that some types of structurally
critical repairs may require Magnetic Particle or Liquid
Penetrant testing, to make sure there are no hidden cracks
or damage, before the machine can be returned to service.
WARNING
Always perform welding procedures with proper safety
equipment and adequate ventilation in a dry work area.
Keep a fire extinguisher near and wear personal protective
equipment.

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

3-1-7
When starting the engine (particularly after long layoff or storage
intervals), make sure that all hydraulic controls and operating
circuits are in neutral, or "OFF". That will prevent pumps or other
components that may be temporarily oil starved from being run
under a load.
Replacement of any hydraulic system component could require
thorough cleaning, flushing, and some amount of prefilling with
fresh, clean oil if the protective seal on replacement parts has
obviously been broken or if seal integrity may have been
compromised. When protective seals are removed before
installation and reassembly, inspect all replacement parts
carefully, before they are installed. If the replacement part
shows no trace of factory prelube or has been contaminated by
dirt or by questionable oils, flushing and prefilling with clean
hydraulic fluid is recommended.
Vibration, irregular or difficult movement or unusual noise from
any part of the hydraulic system could be an indication of air in
the system (and many other types of problems). As a general
precaution (and to help lessen the risk of potential long-term
damage), allow the engine to run at no-load idle speed
immediately after initial start-up. Hydraulic fluid will circulate,
releasing any air that may have been trapped in the system
before load demands are imposed.
Before starting the machine, a daily walk-around safety
inspection, including a quick visual inspection for any exterior
evidence of leaking hydraulic fluid, can help extend the service
life of system components.
IMPORTANT
Hydraulic system operating conditions (repetitive cycling,
heavy workloads, fluid circulating under high-pressure)
make it extremely critical that dust, grit or any other
contamination be kept out of the system. Observe fluid and
filter change maintenance interval recommendations and
always preclean any exterior surface of the system before it
is exposed to air. For example, the reservoir fill cap and
neck area, hoses that have to be disassembled, and the
covers and external surfaces of filter canisters should all be
cleaned before disassembly.

3-1-8
MAINTENANCE SERVICE AND
REPAIR PROCEDURE
General Precautions
Fluid level and condition should always be checked whenever
any other maintenance service or repair is being performed.
NOTE: If the unit is being used in an extreme temperature
environment (in subfreezing climates or in high
temperature, high humidity tropical conditions),
frequent purging of moisture condensation from the
hydraulic reservoir drain tap must be a regular and
frequent part of the operating routine. In more
moderate, temperate climates, draining reservoir
sediment and moisture may not be required more
than once or twice every few months.
Inspect drained oil and used filters for signs of abnormal coloring
or visible fluid contamination at every oil change. Abrasive grit or
dust particles will cause discoloration and darkening of the fluid.
Visible accumulations of dirt or grit could be an indication that
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.

3-1-9
HYDRAULIC SYSTEM
CLEANLINESS AND OIL LEAKS
Maintenance Precautions for Hydraulic

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

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

3-1-11
CLEANING AND INSPECTION
General Instructions
All parts must be clean to permit an effective inspection. During
assembly, it is very important that no dirt or foreign material
enters unit being assembled. Even minute particles can cause
malfunction of close 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.

3-1-12
Be careful when installing sealing members, to avoid
cutting or scratching. Curling under of any seal lip will
seriously impair its efficiency. Apply a thin coat of Loctite
#120 to outer diameter of metal casing and on oil seals to
assure an oil tight install into retainer. Use extreme care
not to get Loctite on lips of oil seals. If this happens, that
portion of the seal will become brittle and allow leakage.
When replacing lip type seals, make sure spring loaded
side is towards oil to be sealed.
5. If available, use magna-flux or similar process for checking
for cracks that are not visible. Examine teeth on all gears
carefully for wear, pitting, chipping, nicks, cracks or scores.
Replace all gears showing cracks or spots where
case-hardening has worn through. Small nicks may be
removed with suitable hone. Inspect shafts and quills to
make certain they have not been sprung, bent, or no
twisted splines, and that shafts are true.
NOTE: Spline wear is not considered detrimental
except where it affects tightness of splined
parts.
Inspect thrust washers for distortion, scores, burs, and
wear. Replace thrust washer if defective or worn.
6. Inspect bores and bearing surfaces of cast parts and
machined surfaces for scratches, wear, grooves and dirt.
Remove any scratches and burrs with crocus cloth.
Remove foreign material. Replace any parts that are
deeply grooved or scratched which would affect their
operation.
Bearing Inspection
The conditions of the bearing are vital to the smooth and
efficient operation of the machinery. When any component
containing bearings is disassembled, always carefully examine
the condition of the bearings and all of its components for wear
and damage.
Once the bearing is removed, clean all parts thoroughly using a
suitable cleaning solution. If the bearing is excessively dirty,
soak the bearing assembly in a light solution and move the
bearing around until all lubricants and/or foreign materials are
dissolved and the parts are thoroughly clean.
When drying bearings, moisture free compressed air can be
used. Be careful not to direct the air in a direction which will
force the bearing to dry spin while not being properly lubricated.
After the bearings have been cleaned and dried, carefully
inspect all bearing rollers, cages and cups for wear, chipping or
nicks. If the bearing cannot be removed and is to be inspected in
place, check for roughness of rotation, scoring, pitting, cracked
or chipped races. If any of these defects are found replace the
whole bearing assembly. NEVER replace the bearing alone
without replacing the mating cup or the cone at the same time.

3-1-13
After inspection lightly coat the bearing and related parts with oil
and wrap in a clean lintless cloth or paper and protect them from
moisture and other foreign materials until installation.
It is also important to inspect the bearing housing and/or shaft
for grooved, galled or burred conditions that indicate the bearing
has been turning in its housing or on its shaft.
If available, use magna-flux or similar process for checking for
cracks that are not visible.
The following illustrations will aid in identifying and diagnosing
some of the bearing related problems.
NOTE: The illustrations will only show tapered roller
bearings, but the principles of identifying, diagnosing
and remedying the defects are common to all styles
and types of bearings.
Normal Bearing
Smooth even surfaces with no discoloration or marks.
Figure 2
Bent Cage
Cage damage because of improper handling or tool usage.
Figure 3

3-1-14
Replace bearing.
Figure 4
Galling
Metal smears on roller ends because of overheat, lubricant
failure or overload.
Replace bearing - check seals and check for proper lubrication.
Figure 5
Abrasive Step Wear

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

3-1-15
Etching
Bearing surfaces appear gray or grayish black in color with
related etching away of material usually at roller spacing.
Replace bearings - check seals and check for proper lubrication.
Figure 7
Misalignment
Outer race misalignment because of foreign object.
Clean related parts and replace bearing. Make sure races are
properly seated.
Figure 8
Indentations
Surface depressions on race and rollers caused by hard
particles of foreign materials.
Clean all parts and housings, check seals and replace bearings
if rough or noisy.
Figure 9

3-1-16
Fatigue Spalling
Flaking of surface metal resulting from fatigue.
Replace bearing - clean all related parts.
Figure 10
Brinelling
Surface indentations in raceway caused by rollers either under
impact loading or vibration while the bearing is not rotating.
Replace bearing if rough or noisy.
Figure 11
Cage Wear
Wear around outside diameter of cage and roller pockets
caused by abrasive material and inefficient lubrication.
Replace bearings - check seals.
Figure 12

3-1-17
Abrasive Roller Wear
Pattern on races and rollers caused by fine abrasives.
Clean all parts and housings, check seals and bearings and
replace if leaking, rough or noisy.
Figure 13
Cracked Inner Race

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

3-1-18
Frettage
Corrosion set up by small relative movement of parts with no
lubrication.
Replace bearing. Clean all related parts. Check seals and check
for proper lubrication.
Figure 16
Heat Discoloration
Heat discoloration can range from faint yellow to dark blue
resulting from overload or incorrect lubrication.
Excessive heat can cause softening of races or rollers.
To check for loss of temper on races or rollers, a simple file test
may be made. A file drawn over a tempered part will grab and
cut metal, whereas a file drawn over a hard part will glide readily
with no metal cutting.
Replace bearing if overheating damage is indicated. Check
seals and other related parts for damage.
Figure 17
Stain Discoloration
Discoloration can range from light brown to black caused by
incorrect lubrication or moisture.
If the stain can be removed by light polishing or if no evidence of
overheating is visible, the bearing can be reused.
Check seals and other related parts for damage.
Figure 18

3-1-19
3-1-20
Standard
Torques
Edition 1
DX340LC-5/DX350LC-5 Standard Torques

3-2-1
MEMO
Standard Torques DX340LC-5/DX350LC-5

3-2-2
Table of Contents
Standard Torques
Safety Instructions3-2-5
Torque Values for Standard Metric Fasteners3-2-6
Torque Values for Standard U.S. Fasteners3-2-7
Type 8 Phosphate Coated Hardware3-2-9
Torque Values for Hose Clamps3-2-10
ORFS Swivel Nut Recommended Torque3-2-10
Torque Values for Split Flanges3-2-11
Torque Wrench Extension Tools3-2-12
Torque Multiplication3-2-12
Other Uses for Torque Wrench Extension Tools3-2-13
Tightening Torque Specifications (Metric)3-2-14

3-2-3
3-2-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

3-2-5
TORQUE VALUES FOR STANDARD METRIC FASTENERS
NOTE: The units for the torque values are kg.m (ft lb).
Grade
Dia. x Pitch
(mm)
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
(4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M5 x Std.
(1.08) (1.15) (1.80) (1.59) (2.24) (2.02) (3.11) (3.47) (3.61) (5.42) (6.50)
0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.90 1.25 1.50
M6 x Std.
(2.02) (2.16) (3.25) (2.89) (3.97) (3.39) (5.56) (6.14) (6.50) (9.04) (10.84)
0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35
M7 x Std.
(3.11) (3.32) (5.06) (4.55) (6.00) (5.64) (8.67) (9.40) (10.12) (14.10) (16.99)
0.70 0.75 1.10 1.00 1.40 1.25 1.90 2.10 2.20 3.10 3.80
M8 x Std.
(5.06) (5.42) (7.95) (7.23) (10.12) (9.04) (13.74) (15.18) (15.91) (22.42) (27.48)
0.73 0.80 1.20 1.00 1.50 1.35 2.10 2.30 2.40 3.35 4.10
M8 x 1
(5.28) (5.78) (8.67) (7.23) (10.84) (9.76) (15.18) (16.63) (17.35) (24.23) (29.65)
1.35 1.40 2.20 1.90 2.70 2.35 3.70 4.20 4.40 6.20 7.20
M10 x Std.
(9.76) (10.12) (15.91) (13.74) (19.52) (19.99) (26.76) (30.37) (31.18) (44.84) (52.07)
1.50 1.60 2.50 2.10 3.10 2.80 4.30 4.90 5.00 7.00 8.40
M10 x 1.25
(10.84) (11.57) (18.08) (15.18) (22.42) (20.25) (31.10) (35.44) (36.16) (50.63) (60.75)
2.40 2.50 3.70 3.30 4.70 4.20 6.30 7.20 7.50 10.50 12.50
M12 x Std.
(17.35) (18.08) (26.76) (23.86) (33.99) (30.37) (45.56) (52.07) (54.24) (75.94) (90.41)
2.55 2.70 4.00 3.50 5.00 4.50 6.80 7.70 8.00 11.20 13.40
M12 x 1.25
(18.44) (19.52) (28.93) (25.31) (36.16) (32.54) (49.18) (55.69) (57.86) (81.00) (96.92)
3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00
M14 x Std.
(26.76) (28.20) (13.23) (37.61) (54.24) (50.63) (72.33) (83.17) (86.79) (122.96) (144.66)
4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M14 x 1.5
(29.65) (31.10) (47.73) (41.22) (60.03) (54.24) (80.28) (90.41) (94.02) (11.26) (158.12)
5.60 6.00 9.00 8.00 11.50 10.50 15.50 17.90 18.50 26.00 31.00
M16 x Std.
(40.50) (43.39) (65.09) (57.86) (83.17) (75.94) (112.11) (129.47) (133.81) (188.05) (224.22)
6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 35.50
M16 x 1.5
(44.84) (47.01) (70.16) (62.20) (90.41) (81.73) (122.96) (141.04) (144.66) (202.52) (256.77)
7.80 8.30 12.50 11.00 16.00 14.50 21.00 27.50 28.50 41.00 43.00
M18 x Std.
(56.41) (60.03) (90.41) (79.56) (115.72) (104.87) (151.89) (198.90) (206.14) (296.55) (311.01)
9.10 9.50 14.40 12.50 18.50 16.70 24.50 27.50 28.50 41.00 49.00
M18 x 1.5
(65.82) (68.71) (104.15) (90.41) (133.81) (120.79) (177.20) (198.90) (206.14) (296.55) (354.41)
11.50 12.00 18.00 16.00 22.00 19.00 31.50 35.00 36.00 51.00 60.00
M20 x Std.
(83.17) (86.79) (130.19) (115.72) (159.12) (137.42) (227.83) (253.15) (260.38) (368.88) (433.98)
12.80 13.50 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00
M20 x 1.5
(92.58) (97.64) (148.27) (130.19) (180.82) (162.74) (253.15) (285.70) (296.55) (419.51) (491.84)
15.50 16.00 24.50 21.00 30.00 26.00 42.00 46.00 49.00 67.00 75.00
M22 x Std.
(112.11) (115.72) (177.20) (151.89) (216.99) (188.05) (303.78) (332.71) (354.41) (484.61) (542.47)
17.00 18.50 28.00 24.00 34.00 29.00 47.00 52.00 56.00 75.00 85.00
M22 x 1.5
(122.96) (133.81) (202.52) (173.59) (245.92) (209.75) (339.95) (44.76) (405.04) (542.47) (614.80)
20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00
M24 x Std.
(148.27) (155.50) (238.68) (195.29) (289.32) (245.92) (397.81) (419.51) (455.67) (593.10) (655.43)
23.00 35.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.00
M24 x 2.0
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)

3-2-6
TORQUE VALUES FOR STANDARD U.S. FASTENERS
SAE Bolt Head
Type Description
Grade Marking
WILL HAVE NO MARKINGS IN THE CENTER OF THE HEAD.

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

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

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

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

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

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

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

3-2-9
TORQUE VALUES FOR HOSE CLAMPS
The following chart provides the tightening torques for hose
clamps used in all rubber applications (radiator, air cleaner,
operating lever boots, hydraulic system, etc.).
Torque
Radiator, Air Cleaner, Boots, Etc. Hydraulic System
Clamp Type and Size
Kilogram.meter Inch Pounds Kilogram.meter Inch Pounds
(kg.m) (in lb) (kg.m) (in lb)
"T" Bolt (Any Diameter) 0.68 - 0.72 59 - 63 ------- -------
Worm Drive - Under
44 mm (1-3/4 in) Open Diam- 0.2 - 0.3 20 - 30 0.5 - 0.6 40 - 50
eter
Worm Drive - Over 44 mm
0.5 - 0.6 40 - 50 ------- -------
(1-3/4 in) Open Diameter
Worm Drive - All "Ultra-Tite" 0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50
ORFS SWIVEL NUT RECOMMENDED TORQUE

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

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

3-2-11
TORQUE WRENCH EXTENSION TOOLS
Very large diameter, high-grade fasteners (nuts, bolts, cap
screws, etc.) require a great deal of turning force to achieve
recommended tightening torque values.
Common problems that could occur as a result are:
• Recommended torque exceeds the measuring capacity of
the torque wrench.
• Specialized sockets do not fit the adapter on the front end
(nose) of the torque wrench.
• Generating adequate force on the back end (handle) of the
wrench is difficult or impossible.
• Restricted access or an obstruction may make use of the
torque wrench impossible.
• A unique application requires fabrication of an adapter or
other special extension.
Most standard torque wrenches can be adapted to suit any one
of the proceeding needs or situations, if the right extension tool
is used or fabricated.
Torque Multiplication
A wrench extension tool can be used to increase the tightening
force on a high capacity nut or bolt.
For example, doubling the distance between the bolt and the
back (handle) end of the torque wrench doubles the tightening
force on the bolt. It also halves the indicated reading on the
scale or dial of the torque wrench. To accurately adjust or
convert indicated scale or dial readings, use the following
formula:
I = A x T/A + B where:
I = Indicated force shown on the torque wrench scale or dial.
T = Tightening force applied to the nut or bolt (actual Torque). Figure 1
A = Length of the torque wrench (between the center of the nut

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

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

3-2-12
NOTE: The formula assumes there is no added deflection or
"give" in the joint between the extension and torque
wrench. Readings may also be inaccurate:
• If the extension itself absorbs some of the tightening force
and starts to bend or bow out.
• If an extension has to be fabricated that is not perfectly
straight (for example, an extension made to go around an
obstruction, to allow access to a difficult to tighten
fastener), the materials and methods used must be solid
enough to transmit full tightening torque.
Other Uses for Torque Wrench Extension

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

3-2-13
Tightening Torque Specifications (Metric)
(For coated threads, prelubricated assemblies.)
IMPORTANT
Disassembly, overhaul and replacement of components on
the machine, installation of new or replacement parts and/
or other service-related maintenance may require the use of
thread or flange sealing assembly compound.
Use the information on this page as a general guide in
selecting specific formulas that will meet the particular
requirements of individual assembly installations. DOOSAN
does not specifically approve a specific manufacturer or
brand name, but the following table of "Loctite"
applications is included for which cross-references to other
manufacturer's products should also be widely available.
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of
fastener adhesives, with Threadlocker sealers 222, 242/243,
262, 271, 272, or 277.

3-2-14
I. "Loctite" Fastener Adhesives
Breakaway Cure
Product Application Color Removal Strength (in lb) of
Sealer Alone
Low strength for 6 mm (1/4") or
222 Purple Hand tools 45
smaller fasteners.
Medium strength for 6 mm (1/4") and
242 or 243 Blue Hand tools 80
larger fasteners.
Heat/260°C (500°F)
High strength for high-grade fasteners
262 Red Remove HOT 160
subject to shock, stress and vibration.
(NO solvent)
Extra high strength for fine thread Heat/260°C (500°F)
271 Red 160
fasteners up to 25 mm (1") diameter. Remove HOT
High temperature/high strength for
Heat/316°C (600°F)
272 hostile environments to 232°C Red 180
Remove HOT
(450°F).
Extra high strength for coarse thread
Heat/260°C (500°F)
277 fasteners 25 mm (1") diameter and Red 210
Remove HOT
larger.
II. "Loctite" Pipe Thread Sealant
Product Application Color Removal Required Setup

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

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

3-2-15
IV. "Loctite" retaining compounds

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

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

3-2-16
1Engine
Engine
Edition 1
Engine DX340LC-5/DX350LC-5
4-1-1
MEMO
4-1-2
Table of Contents
Engine
Overview.........................................................4-1-8
Inspection .......................................................4-1-9
Cleaning the Engine .................................................. 4-1-9
Special Tools ..................................................4-1-9
Mounting the Engine in a Universal Stand .............. 4-1-19
Engine Identification .....................................4-1-20
Engine Data Plate ................................................... 4-1-20
Engine Specification .....................................4-1-21
Engine Performance Curves ........................4-1-22
Tightening Torques.......................................4-1-24
Normal Tightening Torque....................................... 4-1-24
Special Tightening Torque ...................................... 4-1-28
Cylinder ........................................................4-1-56
Cylinder Head.......................................................... 4-1-56
Valve Mechanism .................................................... 4-1-74
Cylinder Block ......................................................... 4-1-77
Cylinder Liner .......................................................... 4-1-92
Flywheel Housing .................................................... 4-1-99
Front Cover ........................................................... 4-1-102
Oil Mist Separator.................................................. 4-1-104
Actuating System........................................4-1-110
Camshaft ............................................................... 4-1-110
Connecting Rod..................................................... 4-1-118
Crankshaft ............................................................. 4-1-120
Flywheel ................................................................ 4-1-129
Piston .................................................................... 4-1-134
Roller Tappet......................................................... 4-1-140
Intake Manifold ...................................................... 4-1-141
Power Take Off ..................................................... 4-1-141
Torsion Damper..................................................... 4-1-142
DX340LC-5/DX350LC-5 Engine
4-1-3
Belt Circuit ............................................................. 4-1-143
Balance Shaft Unit................................................. 4-1-150
Timing Gear........................................................... 4-1-155
Lubrication System .....................................4-1-161
General Information............................................... 4-1-161
Centrifugal Oil Cleaner .......................................... 4-1-163
Oil Cooler .............................................................. 4-1-168
Oil Filter ................................................................. 4-1-171
Oil Pump................................................................ 4-1-172
Oil Sump................................................................ 4-1-174
Oil Pressure Sensor .............................................. 4-1-175
Troubleshooting Chips Found in the Engine ......... 4-1-176
Troubleshooting the Lubrication System ............... 4-1-180
Lubrication Oil Consumption ................................. 4-1-181
Exhaust System..........................................4-1-184
T113, Exhaust Temperature Sensor before Catalytic
Converter............................................................... 4-1-200
T115, NOx Sensor................................................. 4-1-201
T131 NOx Sensor.................................................. 4-1-202
T116, Reductant Pick-up Unit ............................... 4-1-204
Evaporator............................................................. 4-1-209
V117 Reductant Doser .......................................... 4-1-209
V118, Coolant Valve for Heating the Reductant
System .................................................................. 4-1-216
V183 Reductant Pump .......................................... 4-1-218
H25, H26 Electrically Heated Reductant Hose...... 4-1-229
M4000 Electric Exhaust Brake .............................. 4-1-230
Reductant Tank ..................................................... 4-1-236
Oxidation Catalytic Converter................................ 4-1-243
Exhaust Manifold................................................... 4-1-245
Variable Geometry Turbocharger.......................... 4-1-253
EGR System.......................................................... 4-1-261
EGR Valve............................................................. 4-1-268
EGR Cooler ........................................................... 4-1-273
4-1-4
Cooling System ..........................................4-1-275
Internal Cleaning of Cooling System ..................... 4-1-278
Charge Air Cooler.................................................. 4-1-279
Charge Air Temperature Sensor ........................... 4-1-281
Charge Air Pressure Sensor ................................. 4-1-283
Coupling Coil for AC Compressor ......................... 4-1-284
Thermostat ............................................................ 4-1-285
Coolant Pump........................................................ 4-1-288
Coolant Temperature Sensor ................................ 4-1-289
Fuel System................................................4-1-291
Accumulator .......................................................... 4-1-296
Fuel Manifold......................................................... 4-1-297
Overflow Valve ...................................................... 4-1-306
Feed Pump............................................................ 4-1-309
Injector................................................................... 4-1-315
Fuel Filter .............................................................. 4-1-321
Fuel Heater............................................................ 4-1-325
Fuel System Troubleshooting................................ 4-1-326
Electrical System ........................................4-1-340
E44, Control Unit EMS .......................................... 4-1-340
Control Unit EEC ................................................... 4-1-356
Engine Speed Sensor ........................................... 4-1-361
T110 Oil Level Sensor........................................... 4-1-363
T111, Fuel Pressure Sensor ................................. 4-1-364
T125, Exhaust Back Pressure Sensor .................. 4-1-366
T135, Camshaft Position Sensor........................... 4-1-367
V109, Solenoid Valve for Charge Pressure........... 4-1-369
V120, Fuel Inlet Metering Valve ............................ 4-1-370
V142, V143, V144, V145, V146 Solenoid Valve for
Injector................................................................... 4-1-372
T8, Coolant Level Monitor ..................................... 4-1-373
P3, Alternator ........................................................ 4-1-374
M1, Starter Motor .................................................. 4-1-384
4-1-5
AC Compressor..................................................... 4-1-387
Electrical Parts ...................................................... 4-1-390
EMS S8 (1/2) ..............................................4-1-401
EMS S8 (2/2) ..............................................4-1-403
EEC, EEC3 Exhaust Emission Control
(9, 13 LITER Engines XPI) .........................4-1-405
4-1-6
SAFETY INSTRUCTIONS
WARNING
or serious injury.
4-1-7
OVERVIEW
O NT
FR
EX1301800
Figure 1
4-1-8
INSPECTION
Cleaning the Engine

The engine must be cleaned before starting work.
Clean with water and use a hot wash. Also use a degreasing
agent, if necessary.
Avoid spraying water on the engine control unit, see illustration.
Clean the components that are inside the marked area.
CAUTION FG020224
Figure 2
AVOID INJURY
Wear personal protective equipment (PPE) when cleaning
engine with hot pressurized water.
SPECIAL TOOLS
Number Designation Picture Tool Board
99 331
Fixture A
(Figure 4)
FG020229
587 692 99 612

Universal Stand
(Figure 4)
FG020230
98 094
Lifting Chain
(Figure 8)
FG020233
4-1-9
b
587 308
Lever Block D
(Figure 8) C
s FG020234
99 637
Lifting Eye
(Figure 8)
FG020235
99 322
(Figure 35), Drift D5
(Figure 36)
FG020257
99 322
Drift D5
(Figure 37)
FG020260
99 384
99 384
Drift D1-A3
(Figure 39)
FG020263
99 385
99 385
Shank D1-B1
(Figure 39)
FG020264
587 270
Kit with Puller
(Figure 39)
FG020265
4-1-10
99 574 Tool Kit (Guide, Drift

D7
(Figure 44) and Pilot Tap)
FG020270
99 397 Extension Piece with

C5, C6
(Figure 43) Threaded Shaft
FG020271
587 470
Pin Extractor
(Figure 47)
FG020274
99 015
Press Drift
(Figure 49)
FG020275
587 277
Valve Seat Cutter
(Figure 52)
FG020281
XX XX
XX XX
XX x
99 527 Cylinder Leakage

MC1
(Figure 70) Indicator
FG020287
99 309
(Figure 69)
Turning Tool D5
(Figure 281)
(Figure 288)
FG020288
4-1-11
99 109
Turning Tool
(Figure 48)
FG020296
588 179
Torque Screwdriver
(Figure 397)
FG020297
99 373 Tool for Replacing the

D5
(Figure 84) Camshaft Bearing
FG020302
99 003
Hydraulic Cylinder H1
(Figure 87)
FG020303
99 004 Air-operated Hydraulic

H1
(Figure 92) Pump
FG020304
87 198
Straight Edge
(Figure 96)
FG020318
98 075
Dial Gauge
(Figure 96)
FG020319
4-1-12
588 889 Tool for Machining the

(Figure 93) Cylinder Liner Guide
FG020321
588 866 Tool for Machining the

(Figure 116) Cylinder Liner Diameter
FG020333
587 512
Milling Cutter
(Figure 119)
FG020345
588 672
Extension
(Figure 118)
FG020346
99 066
Cylinder Liner Puller
(Figure 134)
FG020357
99 016
Compression Ring
(Figure 135)
FG020360
588 189
Air-operated Spray Gun
(Figure 148)
FG020368
4-1-13
99 148
Press Drift
(Figure 148)
FG020373
99 149
Press Drift
(Figure 159)
FG020379
587 110
Control Device
(Figure 191)
FG020400
87 368
Puller Bolts AM1, D3, B1, AD1
(Figure 225)
FG020411
Tool for Locking the

99 411
Flywheel on Engines D5
(Figure 226)
with Unit
FG020413
99 250
Drift D3, C4
(Figure 227)
FG020415
99 572 Piston Ring

(Figure 235) Compressor
FG020418
4-1-14
99 631 Adapter for Cylinder

(Figure 236) Liner with Scraper
FG020419
587 309
Piston Ring Expander D3
(Figure 239)
FG020423
98 290
Intermediate Piece G3
(Figure 264)
FG020437
99 132
Drift R2
(Figure 263)
FG020438
99 133
Drift R2
(Figure 266)
FG020439
99 135
Drift R2
(Figure 262)
FG020438
587 318
Puller Plate XA1
(Figure 267)
FG020446
4-1-15
587 319
Bearing Puller XA1
(Figure 267)
FG020447
98 575
Support Drift G2
(Figure 268)
FG020448
99 452
Drift AM3, D4
(Figure 269)
FG020449
99 074
Impact Drift D1
(Figure 283)
FG020455
587 526
Puller
(Figure 283)
FG020346
87 348
Drift AMI
(Figure 286)
FG020461
87 592
(Figure 286) Drift
(Figure 287)
FG020462
4-1-16
99 520
Socket Wrench
(Figure 308)
FG020469
99 362
Measuring Set
(Figure 313)
FG020474
USED OIL K GOOD
588 493 FLOSTICK

Viscosity Gauge NEW OIL
MOBIL
FG020478
99 405
(Figure 315) Clutch Bleeder
(Figure 471)
FG020484
99 484
Cover
(Figure 315)
FG020485
587 637 Maintenance

Sleeve
(Figure 321) Cabinet
FG020492
99 301
Adapter D5
(Figure 489)
FG020516
4-1-17
587 129 or
588 135 Coolant Tank
(Figure 489)
FG020517
99 633
(Figure 463) Assembly Tool
(Figure 476)
FG020534
99 475 Crow Bar for

(Figure 559) Removing Injectors
FG020551
99 695 Shank
Cutter for 51° Reducer

588 992
Chamfer
Cutter for 30° Reducer

587925
Chamfer
587 313 Gearbox Jack
4-1-18
Mounting the Engine in a Universal Stand
Preparations before commencing work:
• Remove engine from the machine.
2
3
1 4
FG020231
Figure 3
Reference Reference
Number Number
1 Engine Control Unit High-pressure Pump and Feed
3
2 Fuel Filter Pump
4 Starter Motor
1. Mount the engine in the universal stand.
Reference
Description
Number
1 Bolt M10 x 30 (8 off)
2 Nut M16 (4 off)
3 Bolt M16 x 50 (4 off) 2 3
1
99 331
FG020232
Figure 4
4-1-19
ENGINE IDENTIFICATION
Engine Data Plate

Reference
Description
Number
A Smoke Value
B Engine Type A
C Engine Serial Number
C FG020225
Figure 5
Figure 6
Reference
Description
Number
1 Warning! High Fuel Pressure
2 Important Engine Information
3 Valve Clearance
4 Engine Serial Number
5 Engine Power
Figure 7
4-1-20
ENGINE SPECIFICATION
Items Specification
4-Cycle Water Cooled, Waste Gate
Type Turbocharge, Air to Air Intercooled Direct
Injection
Engine Emission US EPA Tier 4 Final (EU Stage IV)
Model DC 9
Injection System Extra High-pressure Fuel Injection System
Rated Net Power 237 kW (318 HP) @ 1,800 rpm (SAE J1995)
Intake Valve 0.45 mm
Valve Clearance
Exhaust valve 0.70 mm
Number of Cylinders and Configuration 5, Straight
Rotating Direction (from Flywheel) Counterclockwise
Normal with the Engine at
Operating Temperature, 3.1 - 6.1 kg/cm2 (3 - 6 bar, 43.5 - 87 psi)
Oil Pressure Operating Speed
Min. Permitted at Idling
0.71 kg/cm2 (0.7 bar, 10.2 psi)
Speed
Crankcase Pressure with Closed
-5.4 - 2.0 bar
Crankcase Ventilation
ACEA-E5 or E7
Using Lubrication Oil
(for Fuel with Ultra Low Sulfur Content)
Oil Filter Paper Filter
Interval Between Oil Changes 500 h
Working Principle 4 Stoke Engine
Cylinder Diameter 130 mm
Piston Stroke 140 mm
Displacement 9,300 cc
Compression Ratio 17:1
Number of Teeth on the Flywheel 158
Low Idle Speed 800 rpm
Max. Full Load Speed 2,100 rpm
Weight, without Coolant and Oil 975 kg
Volume,
16,000 cc
Excluding Radiator
Coolant Temperature 90 - 95°C
Cooling System
Number of Thermostats 1
Thermostat,
80°C
Opening Temperature
Electrical System Type 1-pin, 24V, DC
Starter Motor
1-pin, 24V, 6 kW
(Standard Equipment)
Alternator
1-pin, 28V, 100 A
(Standard Equipment)
4-1-21
ENGINE PERFORMANCE CURVES
(kW) (hp)
240
320
230
220 300
210
280
200
190 260
180
240
170
160 220
150
200
140
130 180
1000 1200 1400 1600 1800 (rpm)
Power (kW x 1.36 = hp)
(N.m) (kpm)
1380
140
1330
135
1280 130
1230 125
1180 120
1000 1200 1400 1600 1800 (rpm)
Torque (N.m / 9.81 = kpm)

Figure 8 EX1400649
4-1-22
(g/kWh) (g/kWh)
Fuel Reductant
220 100
90
80
210
Fuel 70
60
200 50
40
30
190
Reductant 20
10
180 0
1000 1200 1400 1600 1800 (rpm)
Spec. Fuel and Reductant Consumption

(g/kWh / 1.36 = g/hph) EX1400650
Figure 9
Performance Condition SAE J 1995

Emission EU Stage IV and US Tier 4F
Power Output (Rated) 237 kW (318 HP) @ 1,800 rpm
Max. Torque 1,324 Nm @ 1,300 rpm
Fuel Consumption (Rated) 204 g/kWh
NOTE: Barometric Pressure: 760 mm (30") Mecury

Temperature: 20°C (68°F)
W/O Cooling Fan: Driven by hydraulic fan motor
Alternator: Not Installed
Exhaust System: Complete, attached
Air Cleaner, Installed
4-1-23
TIGHTENING TORQUES
Normal Tightening Torque

The specifications in the tables below show the normal
tightening torque for screws, nuts and unions. The values are to
be used unless other values are specified in the inspection
information. Always check whether there are special tightening
torques given in the descriptions for the respective areas in the
inspection information before using the general values for
normal and special tightening torques respectively.
The following conditions apply:
• A tolerance of ±15 % applies to all values unless otherwise
specified.
• All contact surfaces are to be clean and free of paint.
• Bolts and nuts are normally not lubricated regardless of
surface treatment. All exceptions are specified in the
inspection information.
Union Assemblies
The specified values apply with a tolerance of ±5 %. The values
apply to tightening with a counterhold.
Thread Inserts
The specified tightening torques also apply to bolted joints with a
thread insert (Heli-Coil).
Thread inserts often provide greater strength compared to a
directly screwed thread. This generates a stronger bolted joint in
aluminium or the like.
NOTE: When a damaged thread is repaired with a thread
insert, the normal screw and prescribed tightening
torque are to be maintained. Install the thread insert
as instructed in the inspection information.
4-1-24
Hexagonal Screws, Hexagon Socket Screws, Six-point Socket Screws, Hexagon Nuts
(Metric Thread, Course Pitch)
Strength Class 8.8/8
Thread
Tightening Torque (Nm)
M4 2.4
M5 5
M6 8
M8 20
M10 39
M12 70
M14 112
M16 180
M18 240 FG020238
M20 350
M22 490
M24 600
Flange Screws with Hexagonal Head and Hexagonal Flange Nuts
Strength Class 8.8/8
Thread
M5 5.4
M6 8.6
M8 22
M10 42
M12 77
M14 123
M16 184 FG020239
Thread Forming Six-point Socket Screws and Hexagon Screws with Captive Washer
(Modified Metric Thread, Course Pitch)
Class 8 Class 10
Thread
M4 2.9 -
M6 9.4 11
M8 24 26
M10 47 49
FG020240
M12 80 85
Thread Forming Six-point Socket Screws ST Thread
Thread Tightening Torque (Nm)
ST2.9 1.1
ST3.5 1.9
ST4.2 3.1
ST4.8 4.5
ST5.5 7.1
FG020241
ST6.3 9.7
4-1-25
Stud Tap End in Threaded Hole, Strength Class 8.8/8
Tightening the stud tap end in the threaded hole must be done so
the stud does not come loose when undoing the nut. To tighten the
stud in the threaded hole, the torque must just overcome the friction
in the thread and generate a preload. The torque for locking is 50%
of the normal torque for hexagonal screws, hexagon socket screws,
six-point socket screws, hexagon nuts.
FG020242
Union Nuts for Ferrule

Thread Tightening Torque ( ±15% Nm)
Plastic
Plastic
Pipe with
Steel Pipe Pipe with
Thread Brass
For Pipe with Steel
Ferrule and
Diameter Greased Ferrule and
Nut with
Steel Nut Brass or
Rubber
Steel Nut
Seal
M10x1 5 15 10 -
M12x1.5 6 20 10 -
M14x1.5 8 30 20 -
M16x1.5 10 40 25 15 FG020243
M18x1.5 12 50 30 20
M20x1.5 12 55 35 -
M24x1.5 16 60 50 40
M130x2 22 120 - -
Nuts for Lead-in Union
Thread Thread Tightening Torque ( ±15% Nm)
M12x1.5 20
M14x1.5 25
M16x1.5 35
M18x1.5 50
M24x1.5 70
M130x2 80 FG020244
Unions with Tapered Thread for Port Connection

Thread Tightening Torque Tightening Torque
Thread ( ±15% Nm) (Nm)
Straight Unions Elbow Unions
M10x1k 10 8
M12x1.5k 10 8
M14x1.5k 15 10
M16x1.5k 15 10
M18x1.5k 20 15
M20x1.5k 25 20 FG020245
M22x1.5k 25 20
M26x1.5k 45 40
4-1-26
Unions, Plugs and Banjo Screws with Cylindrical Threads for Seal with Flat Copper Gasket
M8x1 10
M10x1 20
M12x1.5 20
M14x1.5 25
M16x1.5 30
M18x1.5 35
M20x1.5 45
M22x1.5 50
M24x1.5 60
M26x1.5 70
M28x1.5 80
M30x1.5 110
M30x2 115
M32x1.5 115
M36x1.5 160
M38x1.5 170
M45x1.5 270
Plugs with Tapered Thread
M10x1k 15
M12x1.5k 20
M14x1.5k 20
M16x1.5k 25
M18x1.5k 40
M20x1.5k 40
M22x1.5k 40 FG020247
M26x1.5k 60
Insert Connections for Port Connection
M10x1k 18
M12x1.5k 24
M14x1.5k 28
M16x1.5k 35
M22x1.5k 40 FG020248
Insert Connections for Union Connection

Thread Tightening
Thread For pipe Diameter
Torque ( ±15% Nm)
M14x1.5k 4-8 10
M18x1.5k 12 15
M24x1.5k 16 25 FG020249
4-1-27
Special Tightening Torque
The specifications recommend values for special tightening
torques for certain threaded joints where there are strict
requirements on the distribution of prestressing force. The
distribution of the tightening torque is ±15% and the clamping
force then spread about ±30%.
Hexagonal Screws, Hexagon Socket Screws, Six-point Socket Screws, Hexagon Nuts.
Applies also with Captive Washer and Hexagon Screws with Thread Cleaning Thread.
(Metric Threads, Course Pitch)
Strength Class
Thread 8.8/8 10.9/10
M4 2.9 3.6
M5 6 7.5
M6 9.5 12
M8 24 30
M10 47 59
M12 84 105
M14 135 170
M16 210 270
FG020238
M18 290 360
M20 420 530
M22 580 730
M24 730 910
Hexagonal Screws, Hexagon Socket Screws, Six-point Socket Screws, Hexagon Nuts
Applies also with Captive Washer and Hexagon Screws with Thread Cleaning Thread
(Metric Thread, Fine Interval)
Thread Tightening Torque ( ±15% Nm)
Thread 8.8/8 10.9/10
M8x1 26 32
M10x1.25k 50 62
M12x1.25k 92 115
M14x1.5k 150 180
M16x1.5k 230 290
M18x1.5k 330 410
M20x1.5k 470 590 FG020238
M22x1.5k 640 800
M24x1.5k 830 1040
4-1-28
Flange Screws with Hexagonal Head and Hexagonal Flange Nuts
(Metric Threads, Course Pitch)
Thread Tightening Torque ( ±15 % Nm)
Thread 8.8/8 10.9/10
M5 6.7 8.1
M6 10.2 13
M8 26 32
M10 50 63
M12 92 115
M14 149 187
Tightening Torques for Hose Clamps

Specifications in the tables show tightening torque when
tightening by hand.
Tightening torque for new unfitted hose clamp is max 1 Nm.
A = Width (mm) Tightening Torque (±15 % Nm)

7.5 - 9 1.5
12 5
D
Figure 10 EX1301803

25 20
A EX1301804
Figure 11

20 10
25 20
A EX1301805
Figure 12
4-1-29
Tightening Torques for Engines
IMPORTANT
Tightening torques for threaded joints in engines.
If the tightening torque is not available in the table for each
engine, refer to the special and normal tightening torques
tables.
Engine Assembly
Cylinder Block
• Piston cooling nozzle: 23 Nm
Main Bearing Cap
NOTE: The screws can only be reused 3 times. Mark the
screws each time before fitting. 1 2 3 4
EX1301810
• Torx screw (M19): 110 Nm + 90°

• Hexagon screw (M19): 110 Nm + 90°
EX1301811
Connecting Rod Cap

EX1301810
4-1-30
• Torx screw: 50 Nm + 90°
• Check torque: 170 Nm
EX1302070
Flywheel Housing
• Lead-in union: 40 Nm ±6
Cylinder Head and Valve Package

Cylinder Head
EX1301810
Cylinder head bolt, tightened in four stages

1
• First stage: 60 Nm
• Second stage: 150 Nm
5
• Third stage: 250 Nm 3
• Fourth stage: 90°
4
6
2 FG020253
4-1-31
Rocker Cover
• Rocker cover, upper: 18 Nm
• Rocker cover, lower: 18 Nm
Valve Mechanism
• Adjusting screw nut on rocker arm: 35 Nm
4-1-32
• Screw for rocker arm shaft bearing retainer:
90 Nm + 60°
Roller Tappet Shaft
• Banjo screw for roller tappet shaft (engines produced

earlier): 33 Nm
• Slotted screw for roller tappet shaft (engines produced

later): 40 Nm
4-1-33
Crank Mechanism
Flywheel
• M18 flange screw: 180 Nm + 120°
Torsion Damper
• Torsion damper hub: 90 Nm + 30°
Timing Gear
• Intermediate gear: 50 Nm + 60°
• Camshaft gear: 20 Nm + 40°
EX1301830
Lubrication System
Oil sump
• Cylinder block, 8.8 screw: 26 Nm
• Cylinder block, 10.9 screw: 32 Nm
• Against cylinder block, 8.8 screw with spacer: 26 Nm
Oil Sump, Plastic

• Oil sump, spring screw: 20 Nm
4-1-34
Oil Plug
• Thread insert for oil plug: 320 Nm
• Magnetic oil plug, oiled seal: 80 Nm
• Magnetic oil plug, dry seal: 115 Nm
• Oil plug for filler connection in oil sump: 60 Nm

• Oil pump, 10.9 screw: 32 Nm
• Oil pump, 8.8 screw: 26 Nm
• Hose connection for cooling system: 85 Nm
• Oil filler pipe, retaining screw: 20 Nm
Oil Filter
• Element type filter, cover: 25 Nm
• Oil filter unit without loose filter element: Hand tighten
4-1-35
Oil Cooler
• Oil cooler core: 26 Nm
Centrifugal Oil Cleaner

• Nut for outer cover: 15 Nm
Oil Mist Separator

• Nut (M18 x 1.5): 35 ±5 Nm
Exhaust System
Exhaust Manifold
• Cylinder head hexagon screw: 40 Nm + 60°
• Cylinder head Torx screw: 60 Nm + 60°
• Turbocharger: 50 Nm
Exhaust pipe from Turbocharger
• Turbocharger (V-clamp): 20 Nm
EX1301840
Turbocharger Oil Pipe

• Turbocharger lubrication pipe: 40 ±1.2 Nm (±3 %)
• Nut for turbocharger lubrication pipe: 35 ±5 Nm
Turbocharger Coolant Pipe
• Water inlet, turbocharger: 40 Nm
• Water inlet, variable geometry turbocharger electric motor: 10 Nm
4-1-36
Variable Geometry Turbocharger, Electric Motor
• To be tightened crosswise in two stages (Screw 12.9): 3 Nm, 11 Nm
Silencer
• Exhaust pipe to and from silencer (V-clamp): 20 Nm
EX1301840
Reductant Doser
• Nut (M6): 10 Nm
Charge Air Cooler

• Pipe connection (V-clamp): 8 Nm
EX1301840
Fuel System
Injectors
• Nut for cable connection: 2 Nm
4-1-37
Tighten the Injector in Four Stages
• First stage, injector holder: 20 Nm
• Second stage, connection: 20 Nm
• Third stage, injector holder: 56 Nm
• Fourth stage, connection: 56 Nm
4-1-38
Pressure Pipe
• Nut (M20): 38 Nm
• Nut (M16): 38 Nm
• Nut (M18 x 1.5): 35 ±5 Nm
Accumulator
• End connection: 27 Nm + 90°
• Safety valve: 27 Nm + 90°
• Pressure sensor: 47 Nm
High Pressure Pump
• Pump gear: 300 Nm
• High pressure pump, cylinder head bolt: 68 Nm
• Screw for feed pump: 25 Nm
4-1-39
• Insert connection, feed pump: 35 Nm
• Plug for guide pin: 25 Nm
• Nipple, feed pump: 55 Nm
Overflow Valve
• Overflow valve: 55 Nm
4-1-40
Fuel Pipe
Banjo screw with copper gasket
• M8: 11 Nm
• M10: 15 Nm
• M12: 28 Nm
• M14: 45 Nm
• M16: 55 Nm
Fuel Manifold
• Straight joint (M16): 55 Nm
• Joint with check valve: 55 Nm
• End joint, inner: 30 Nm
• End joint, outer: 15 Nm
Fuel Filter
• Fuel filter, cover: 25 Nm
Auxiliary Equipment
Starter Motor
• Stud (M10): 24 Nm
• Connection 30: 20 Nm
4-1-41
Alternator 100A
• Pulley nut (M17): 139 Nm
• Connection B+: 12.5 Nm
Hydraulic Pump
Pump gear
Tightening to be carried out in two stages.
• 1 Stage: 70 Nm
Wait a short while.
• 2 Stage: 110 Nm
NOTE: After the second tightening, check that the nut has
rotated between 20° and 110°.
Belt Transmission
• Belt tensioner: 50 Nm
• Fan coupling, double nut (M14): 165 Nm
EX1301870
AC Compressor
Turnbuckle lock nuts: 200 ±10 Nm
4-1-42
Compressor
Compressor gear: 90 Nm + 60°
Disengageable Compressor
Gear wheel screw
Tightening to be carried out in 2 stages
• 1 Stage: 10 Nm ±1 Nm
• 2 Stage: 90° ±10°
Flange nut
• 2 Stage: 90° ±10°
Cylinder head screw (M8)

• 2 Stage: 90° ±10°/-5°
• 3 Stage: 90° ±10°/-5°
Cylinder head screw (M6)

• 2 Stage: 90° ±10°/-5°
Coolant pipe: 30 Nm
4-1-43
Intake System
Intake Manifold
• Intake manifold to cylinder head: 26 Nm
2 4 6 8 10 12 14 16 18 20
1 3 5 7 9 11 13 15 17 19
FG020255
Pneumatic Throttle
• Nipple on actuator: 11 Nm
Balance Axle
• Bearing cap screw (M10): 25 Nm + 45°
• Frame screw (M14): 90 Nm + 60°

• Gear: 50 Nm + 60°
4-1-44
EGR System
Water Pipe
• Hose clamps: 6.5 Nm
• Retaining strap for EGR cooler, screw (M6): 8 Nm
• Coolant pipe to actuator: 30 Nm
• Banjo screw, bleed pipe at the control cylinder
(M12 x 1.5): 30 Nm
4-1-45
Tightening Torques for Exhaust Gas Aftertreatment
IMPORTANT
Tightening torques for threaded joints in the system for
exhaust gas aftertreatment.
If the tightening torque is not in the table use the tightening
torque for normal tightening torques.
Tightening Torque
Sensor
• NOx sensor: 50 Nm
• Exhaust temperature sensor: 38 Nm
Attachment, Trucks
• Attachment, screw (M10): 59 Nm
4-1-46
Reductant Injection Nozzle
• Injector pipe: 20 Nm
SCR Main Unit

• Ventilating valve, screw 2 off: 6.5 Nm
• Pump, screw: 6.5 Nm
Main unit, screw 10 off

• First tighten 5.5 Nm, tighten back 100°, and then tighten
8.5 Nm.
4-1-47
Seals
IMPORTANT
Before starting work, check that the necessary seals are
available. Information is available in the workshop manual
and parts catalogue.
Seals to be Replaced When Joints are Undone

If a joint is torque tightened and then undone, always replace
seals of the following type.
Elastomer-coated Plate with Embossed Groove

The seal to be replaced when the joint has come undone.
The seal consists of a thin plate with an embossed groove which
is coated on both sides with a very thin layer of elastomer.
EX1301899
Figure 13
Fibre Seal
The fibre seal to be replaced when the joint has come undone.
The fibre seal consists, for example, of cellulose fibre or polymer
fibre, a polymer matrix and filling material. Make sure that you
have sufficient grip length on the screw in order to cope with the
compression that always occurs with a fibre seal.
EX1301900
Figure 14
O-ring
The O-ring to be replaced when the joint has come undone.
The O-ring is a ring-shaped gasket made of an elastic material
such as plastic or synthetic rubber. d1
d2
EX1301901
Figure 15
4-1-48
Wet Silicone
Before new wet silicon is sprayed onto the sealing surface, clean
the surfaces thoroughly since silicon seals by adhesion. With
good adhesion the sealing joint can cope with relatively large
movements.
Figure 16
Metal-bonded Rubber Profile

The seal consists of a metal which has elastomer bonded onto
the metal.
Figure 17
Graphite Seal
The graphite seal to be replaced when the joint has come
undone.
Examples of joints with graphite seal can be found in the SCR
system doser and in the joint between the cylinder head and the
exhaust manifold.
NOTE: If a graphite seal between a cylinder head and
exhaust manifold must be replaced due to leakage,
the seals between all cylinder heads and the exhaust
manifold must be replaced. EX1301904
Figure 18
Be careful not to confuse the different types of seals
for the same exhaust manifold. They have different
heights after tightening.
4-1-49
Seals to be Replaced in the Event of Damage or Leakage
In the event of damage to the seal or leakage, replace seals of
the following type.
CIPG
The CIPG seal should be replaced if it is damaged or leaking.
CIPG stands for Cured In Place Gasket. The seal consists of a
wet bead of silicone which is sprayed onto the sealing surface of
a casing, for example. The silicone is then vulcanised in an
oven, by UV light or similar.
Figure 19
Rubber Seal
The rubber seal should be replaced if it is damaged or leaking.
The rubber seal is a sealing joint in which the profile of the seal
consists of rubber.
Lubricating Points During Assembly
IMPORTANT
When assembling the engine, it is important for oil to be
applied to all contact surfaces with mechanical movement.
Apply engine oil to the lubricating points to reduce the risk
of engine damage when starting.
• Important lubricating points

• Contact surfaces on connecting rod bearings and main
bearings.
• Contact surfaces on axial bearings, bearing bushes and
bearing halves.
• Camshaft bearing surfaces and cams.
• Ball seats and bearing surfaces for roller tappets.
• Ball seats and ball pins on pushrods.
• Crankshaft bearing surfaces.
• Valve stem, valve stem cap and valve guide.
• Rocker arms, valve bridges and rocker arm shafts.
• Ball seats and adjusting screws on the rocker arms.
• Guide pins for the valve mechanism.
4-1-50
Replacing the Engine
NOTE: Replace coolant hoses if there is clear damage to the
coolant hoses which were
1. Drain the oil and coolant.
2. Remove air filter and inlet pipe between the turbocharger
and air filter. Cover the turbocharger inlet pipe.
3. Undo the connections for coolant, charge air pipes
between engine and charge air cooler, and bleed pipe for
the expansion tank.
FG020236
4. Undo the cable harness with clamping.
Figure 20
NOTE: The engine lifting eyes 99 637 are designed for
lifting the engine only, not the engine with
connected equipment (high voltage current
generator, gearbox, reverse gear, etc.) or
frame. All three lifting eyes must be used.
5. Fasten the lifting chain 98 094 to the rear lifting eyes 99
637.
6. Fasten the lever block 587 308 to the front lifting eye.
NOTE: The lifting eyes 99 637 are designed to manage max 30
a maximum inclination angle of 30° when lifting
an engine.
7. Undo the engine insulator bolts and lift away/out the
engine.
max 20
• Engine weight: about 950 kg FG020237
Figure 21
4-1-51
Removal the Engine
1. Depressurize the fuel system using checking tool.
IMPORTANT
The fuel system has a very high fuel pressure of up to
3,000 bars. The fuel system must be depressurised
using checking tool before any work is started.
Use checking tool to minimise the high pressure in the
fuel system.
The system should always be treated as pressurised,
even when the engine is switched off.
Wear protective gloves and goggles.
2. Disconnect the ground connection from the negative

terminal and disconnect the cable harness from the starter
motor.
NOTE: Help protect the environment. Avoid spillage
and use a suitable container.
3. Drain the coolant.
4. Undo the connections for coolant, charge air pipes
between engine and charge air cooler, and bleed pipe for
the expansion tank.
5. Remove the air filter and inlet pipe between the
turbocharger and air filter. Cover the turbocharger inlet
pipe.
6. Disconnect the fuel pipes to and from the engine. Mark the 2
pipes to make refitting easier and plug the connections.
7. Remove the coolant connections for SCR, to engine (1)
and from engine (2).
1
EX1301906
Figure22
4-1-52
8. Disconnect connectors C4001 (1) and C4002 (3) and
connector C4022 (4) to SCR.
1
• To be removed depending on the installation:
4
• Unit gearbox.
2
• Coolant level sensor.
3
• Protective casing on cooling package and fan.
• Depressurise the pneumatic system and remove the
connections.
EX1301907
• Power take-off. Figure 23
• Hydraulic pump.
• Disconnect the AC compressor and place it to one
side.
9. Fasten the lifting chain 98 094 to the rear lifting eyes 99
637.
lifting the engine only, not the engine together
with connected equipment (high-voltage current
10. Fasten the ratchet lever hoist 587 308 to the front lifting
eye.
NOTE: The lifting eyes 99 637 are designed to manage
a maximum inclination angle of 30° when lifting
an engine.
11. Check carefully that there is nothing that may be removed
with the engine or prevent lifting.
12. Undo the engine insulator screws and lift away/out the
engine.
4-1-53
Installing the Engine
1. Fasten the lifting chain 98 094 to the rear lifting eyes.
lifting the engine only, not the engine together
with connected equipment (high-voltage current
FG020236
Figure 24
2. Fasten the ratchet lever hoist 587 308 to the front lifting
eye.
max 30
EX1301876
Figure 25
3. Lift the engine, position it on the engine insulators and

screw it into place.
• If removed, refit:
• Unit gearbox.
• Coolant level sensor.
• Protective casing on cooling package and fan.
• Pneumatic system.
• Power take-off, see subgroup 01-55 Power take-off.
• Hydraulic pump, see subgroup 13-15 Hydraulic
pump.
• AC compressor, see subgroup 18-75 AC
compressor.
4-1-54
4. Connect connectors C4001 (1) and C4002 (3) and
connector C4022 (4) to SCR.
1
4
2
3
EX1301907
Figure 26
5. Install the coolant connections for SCR, to engine (1) and

from engine (2). 2
1
EX1301906
Figure27
6. Connect the fuel pipes to the high pressure pump and

hand pump.
7. Install the inlet pipe between the turbocharger and the air
filter.
8. Install the connections for coolant and the charge air pipes
between the engine and charge air cooler. Install the
expansion tank bleed pipe.
9. Fill with coolant.
10. Install the cable harness to the starter motor and the
ground connection to the negative terminal.
11. Start checking tool and check whether there are any fault
codes. Rectify the fault codes.
12. Clear inactive fault codes.
13. Test run the engine to check that no leakage occurs. Top
up with coolant if necessary.
4-1-55
CYLINDER
Cylinder Head
Specifications
Intake Valve
Oversize Valve Seat, Outer Diameter 46.254 - 46.265 mm
Valve Seat Position, Outer Diameter 46.200 - 46.216 mm
Valve Seat Position, Deep 11.25 - 11.35 mm
Exhaust Valve Seat
Oversize Valve Seat, Outer Diameter 44.281 - 44.292 mm
Valve Seat Position, Outer Diameter 44.200 - 44.216 mm
Valve Seat Position, Deep 11.25 - 11.35 mm
• Remove cylinder head according to the work description

for Removing the cylinder head.
• Remove inlet and exhaust valves according to the work
description for Removing the valves.
Overview
19
20
18
20 8
16 24 25
21 19 25A
25C
25B
8 14
17
30
13 31
11 25C
31C 31A
11
1D 31B 23
1D
1A 22
31C
36
1B
1 : 1A ~ 1F
1B
9
1C
10
1E
1F
15
12
Figure 28 EX1302147
4-1-56
Reference Reference
Number Number
1 Cylinder Head 18 Pin
1A Sleeve 19 Gasket
1B Core Plug 20 Bridge Valve
1C Rivet 21 Screw
1D Guide Valve 22 Bracket Assy
1E Seal 23 Rivet Plug
1F Seal 24 Screw
8 Pin 25 Intake RockerArm
9 Valve Stem Seal 26 Adjusting Screw
10 Intake Valve 27 Hex Nut
11 Intake Valve Spring 29 Rivet Plug
12 Collar Valve Spring 30 Retaining Ring
13 Exhaust Valve 31 Exhaust Arm Rocker
14 Outer Valve Spring 32 Adjusting Screw
15 Inner Valve Spring 33 Hex Nut
16 Collar Valve Spring 35 Rivet Plug
17 Collet Valve Spring 36 Retaining Ring
Removal Cylinder Head

1. Remove water-cooled EGR cooler as instructed in the
work description for Removing the water-cooled EGR
cooler.
Remove brackets for the water-cooled EGR cooler.
2. Remove bolts for the exhaust manifold on the relevant
cylinder and slacken the bolts on the adjacent cylinders so
the relevant part of the exhaust manifold comes loose.
3. Remove cooling system bleeder hose, separate the quick
release coupling at the front lifting eye.
4. Remove cable duct from the intake.
5. Remove cable ties for the cable harness from the engine
control unit.
IMPORTANT
The fuel system components are extremely sensitive
to dirt. Clean thoroughly before dismantling and plug
all connections with lint-free rags and tape.
4-1-57
6. Depressurize the fuel system and detach the fuel pipe (1, 1
Figure 29) running between the accumulator and fuel
manifold.
7. Detach the fuel manifold and remove bolts on the relevant
cylinder.
8. Detach the intake manifold and remove bolts on the
relevant cylinder. To remove fuel and intake manifold, see
"Fuel Manifold" and "Intake Manifold".
IMPORTANT EX1401040
Figure 29
All parts in the fuel injection system and valve
mechanism must be marked.
Everything must be reinstalled in the same position.
9. Remove injectors as instructed in the work description for

Removing the injectors.
Also remove high-pressure pipes and connection on the
cylinder head at the back viewed from the coolant pump.
IMPORTANT
If work is done on the 5th cylinder of an engine with an
EGR system, the EGR valve control cylinder must be
detached at the damper and removed.
10. Remove upper rocker cover and then the rocker arm
housing, valve bridges and pushrods. FG020251
Figure 30
11. Pull the cable harness out of the lower rocker cover and
remove it.
NOTE: Take care when pulling the cable harness out of
the rocker cover: the cable terminals can be
damaged which can cause the nut securing the
cable harness to the injector to come loose.
12. Work on the adjacent cylinders. Remove upper rocker
cover, release the cable harness and the lower rocker
cover so it can be moved.
13. Remove relevant cylinder head. Be careful with the FG020252
adjacent rocker covers. Figure 31
NOTE: Mark the cylinder heads if more than one is
being removed at the same time.
NOTE: If all cylinder heads are removed at the same
time, the turbocharger must be removed or
supported against the frame.
4-1-58
Installing Cylinder Head
1. Check the liner height as described in the work description
for Checking the liner height.
2. Clean the cylinder head and cylinder block. Lubricate the
threads and below the heads of the cylinder head bolts.
3. Install a new cylinder head gasket.
4. Install the cylinder head.
5. Tighten the cylinder head as shown in the illustration and
1
according to specification.
Cylinder head bolts can only be reused three times. Make
a mark with a center punch on the head of the bolt. If any of
5
the bolts already has three marks, it must be replaced. 3
4
6
2 FG020253
Figure 32
1 2 3 4
FG020254
Figure 33
6. Tighten the intake manifold. Use a new gasket. Tighten the

bolts in the order 1 - 20 as illustrated. Tighten the bolts in
the same order again.
2 4 6 8 10 12 14 16 18 20
1 3 5 7 9 11 13 15 17 19
FG020255
Figure 34
7. Tighten the intake manifold and the exhaust manifold. Use

new gaskets.
8. Install the cable bracket bolt in the lower rocker cover and
install the following parts:
• Lower rocker cover.
• Pushrods.
4-1-59
• Valve bridge.
• Rocker arm housing.
IMPORTANT
Lubricate the valve bridge and rocker arm housing
with engine oil.
9. Install the injector, high-pressure pipe connection and

high-pressure pipe as instructed in the work description.
10. Reset adjacent cylinders.
11. Adjust the valve clearance.
12. Install the upper rocker covers.
13. Install the cooling system vent
Install the brackets for the water-cooled EGR cooler.
Install the water-cooled EGR cooler as described in the
work description for Installing the water-cooled EGR cooler.
Removing and Installing Valves
WARNING
Wear protective goggles for eye protection.
1. Removing Valves
A. Remove split collets, valve spring collars, springs and 99 322
valves. Press down the spring using tool 99 322 in a
press so the collets can be removed.
B. Place the valves in a stand so they can be reinstalled
in the same position in the cylinder head.
FG020258
Figure 35
4-1-60
2. Installing Valves
NOTE: There are different versions of the combination 99 322
valve – valve spring collar – split collet. Parts
from the different versions must not be mixed
on the same valve.
A. Lubricate all parts well with engine oil before
assembly.
B. Insert the valve in the guide.
C. Install the valve springs and the valve spring collar. FG020259
D. Press together the springs in a press with tool 99 322 Figure 36
and install the collets. Ensure that collets are installed
in their correct positions.
Replacing a Valve Stem Seal

1. Remove valve according to the work description for
Removing valves.
2. Remove valve stem seal with a pair of pliers.
3. Install the valve.
FG020261
Figure 37
4. Carefully tap a new valve stem seal into place using tool 99
323 and a hammer.
99 323
FG020262
Figure 38
4-1-61
Replacing the Valve Seats
1. Remove valve seat inserts with an expanding sleeve from
the kit with puller 587 270 (1, Figure 39). 1
NOTE: Insert, for example, an aluminum sheet

2
between the cylinder head and counterhold to
protect against damage.
WARNING
FG020266
AVOID DEATH OR SERIOUS INJURY Figure 39
Wear protective goggles for eye protection from flying

metal parts.
2. Press in new valve seat inserts. Use drift 99 384 (2, Figure
39) and shank 99 385. Cool the drift and valve seat insert 99 385
to about -80°C with dry ice or liquid air. Pressing must be
done rapidly. 99 384
WARNING
Prevent frost injuries. Be careful when handling very
FG020267
cold parts and refrigerant.
Figure 40
Oversize valve seat inserts can be installed if the valve
seat insert position has been damaged.
The position is then machined using tool 587 277
according to the work description for Machining a valve
seat position.
Replacing the Valve Guides

1. Press out the valve guides using drift 99 383.
99 383
FG020268
Figure 41
4-1-62
2. Press in the new valve guides using drift 99 382. Press the
guide down as far as the drift allows, i.e. until it contacts 99 382
the spring seat in the cylinder head.
FG020269
Figure 42
Replacing the Injector Sleeves

The cylinder head must be removed when replacing the unit
injector sleeve. The valves do not need removing. The
illustrations show the cylinder head with valves removed to
demonstrate clearly the work described.
NOTE: Guide and pilot tap on extension piece 99 397.
FG020272
Figure 43
1. Thread the lower part of the sleeve using the pilot tap and
guide from tool kit 99 574.
2. Knock out the pilot tap and sleeve from underneath. Use a
100 mm long metal rod of diameter 9 mm.
3. Degrease and check the contact surfaces of the sleeve
and cylinder head. Smooth off any burrs and irregularities
that may score the sleeve.
4. Degrease the new injector sleeve and apply a thin film of
sealant 561 200 on the sleeve and cylinder head contact
surfaces. FG020273
Figure 44
5. Press in the sleeve using the drift and guide from tool kit 99
574.
4-1-63
Replacing the Valve Bridge Guide Pins
The cylinder head must be removed when replacing the guide
pins.
1. Remove Outlet valves and Intake valves.
2 1
Reference
Description
Number
1 Outlet Valves
2 Intake Valves
FG020276
Figure 45
2. Install shrink sleeve number 10 from tool kit 587 470.
FG020277
Figure 46
3. Use pin extractor 587 470 to remove guide pins.

587 470
FG020278
Figure 47
FG020279
Figure 48
4-1-64
4. Press in the new guide pins using drift 99 015. Maximum
press force 15 kN.
99 015
NOTE: Check before pressing in that tool is not
deformed.
Check after pressing in that valve bridge slides
easily on the guide pin.
5. Install all the parts in the cylinder head.
FG020280
Figure 49
Machining the Valve Seat Position

1. Check that contact surface on the cylinder head is level
and clean. Also check that magnetic stand on the valve
seat cutter is clean. Clean the valve guides.
2. Zero the micrometer.
FG020282
Figure 50
3. Assemble the micrometer with a suitable spindle on the

valve seat cutter and adjust the cutter. It is very important
that tip of the cutter is in the center of the micrometer
spindle.
FG020283
Figure 51
4-1-65
4. Select the largest control spindle that moves easily in the
valve guide. Install the valve seat cutter and turn the feed
screw to its upper position.
5. Turn off the magnet (position 2). Insert the guide spindle
into the valve guide. Adjust the pivot plate so the distance
between the cutter and the valve seat is approximately
1 mm.
Center the valve seat cutter precisely.
6. Turn on the magnet (position 1).
FG020284
Figure 52
7. Apply the quick-action lock. Make sure the crank can be

turned easily. If not, redo the centring.
FG020285
Figure 53
8. Machine the valve seat by cranking clockwise while turning

the screw clockwise. Lubricate with cutting oil while
machining.
IMPORTANT
The cutter must never be cranked counterclockwise.
9. When the surface of the valve seat has been machined,

reduce the cutting pressure by turning 2-3 revolutions
without any feed. Continue turning clockwise while turning
the screw counterclockwise until cutter is free. Disconnect FG020286
the solenoid by briefly pressing switch position 2. Figure 54
10. The valve seat cutter is now ready for the next valve seat.
4-1-66
Removing the Valve Seat Insert
1. Remove the cylinder head. See subgroup "Removing the
cylinder head".
2. Remove the intake and exhaust valves. See subgroup
"Removing and installing valves".
NOTE: Insert, for example, an aluminium sheet
between the cylinder head and counterhold to
protect against damage.
IMPORTANT
Wear protective goggles. There is a risk that loose
slivers of metal can cause personal injury when
pulling out the valve seats.
Remove the valve seat inserts with an expanding sleeve Figure 55

from the kit with puller 587 270.
Machining the Reducer Chamfer

1. Check that the contact surface on the cylinder head is level
and clean. Also check that the magnetic stand on the valve
2. Fit the cutting blade for a 51° reducer chamfer on the valve
seat cutter and set the distance to approximately 21 mm as
illustrated.
Figure 56
3. Select the largest control spindle that moves easily in the

valve guide. Fit the valve seat cutter and turn the feed
screw to its upper position.
Figure 57
4. Lubricate the control spindle and insert it in the valve

guide.
4-1-67
5. Adjust the pivot plate so that the distance between the
cutter and the reducer chamfer is approx. 1 mm. Centre
the valve seat cutter precisely.
Figure 58

Figure 59
IMPORTANT
The cutter must never be cranked anticlockwise.
8. Mill the reducer chamfer by cranking clockwise while

turning the feed screw clockwise. Make sure you do not
make the outer diameter of the reducer chamfer larger, as
shown in the illustration.
Figure 60
9. When the surface of the reducer chamfer has been machined,

reduce the cutting pressure by turning 2 - 3 revolutions without
any feed. Continue turning clockwise while turning the screw
counter clockwise until the cutter is free. Disconnect the
solenoid by briefly pressing switch position 2.
10. Continue with the next reducer chamfer as described in the
steps above.
4-1-68
Installing a New Valve Seat Insert
1. Clean the cylinder head.
2. Tap/press in new valve seat inserts. Use drift 99 384 and
shank 99 695. Cool the drift and valve seat insert to about -
80°C with dry ice or liquid air. The tapping/pressing in must
be done very rapidly.
WARNING
Be careful when handling the cold parts and
refrigerant mentioned above. Risk of frost injuries.
Oversize valve seat inserts can be fitted if the valve seat

insert position has been damaged. The position must then
be machined with tool 587 277, see subgroup 01-01 Figure 61
Machining a valve seat insert when fitting oversize valve
seat inserts.
Machining the Valve Seat Insert Sealing Surface

1. Check that the contact surface on the cylinder head is level
and clean. Also check that the magnetic stand on the valve
2. Fit the cutting blade for a 30° valve seat position on the
valve seat cutter and set the distance to approximately 17
mm as illustrated.
Figure 62
3. Lubricate the control spindle and insert it in the valve

guide.
4-1-69
4. Adjust the pivot plate so that the distance between the
cutter and the valve seat insert is approx. 1 mm. Centre the
valve seat cutter precisely.
Figure 63

Figure 64
IMPORTANT
The cutter must never be cranked anticlockwise.
7. Carry out minimal machining of the valve seat insert

sealing surface by cranking clockwise while turning the
feed screw clockwise. Continue until it can be seen that the
entire sealing surface is machined.
Figure 65
4-1-70
8. When the sealing surface of the valve seat insert has been
machined, reduce the cutting pressure by turning 2 - 3
revolutions without any feed. Continue turning clockwise
while turning the screw counter clockwise until the cutter is
free.
Disconnect the solenoid by briefly pressing switch position 2.
9. Continue with the next valve seat insert as described in the
steps above.
Height Check of Valve Seat Insert

1. Make sure that the cylinder head is clean.
NOTE: Use the same exhaust valve for the
measurement below to avoid measurement
errors.
2. Fit the exhaust valve in the first valve guide. Measure the
height of the exhaust valve.
Figure 66
3. Fit the same exhaust valve in the second valve guide.

Measure the height of the exhaust valve.
Figure 67
4. The height tolerance between exhaust valves is ±0.05 mm.

If the difference is greater, machine the valve seat insert
which is highest until the height tolerance is obtained.
Also check that the distance between the valve disc and
the bottom of the cylinder head is not less than 0.71 mm as
shown in the illustration.
Figure 68
4-1-71
Marking the Cylinder Head with 30° Exhaust Valve
1. Clean the cylinder head exhaust port.
2. Stamp E30 beside the exhaust port on the cylinder head.
The text height should be between 6 and 8 mm.
Figure 69
Checking the Cylinder Heads for Leaks
WARNING
Always wear eye protection. If crankshaft rotates, fuel in
cylinders or metal chips from damaged engine could cause
injury to eyes or face.
Leakage Equipment Calibration

1. Install the quick-release coupling (1, Figure 70) of the 2 4
measuring hose to the nipple on the aluminum block on the
back of the test equipment A. XX XX
XX XX
XX x
Reference
Description
Number
1 Quick-release Coupling 3
2 Nipple A
3 Pressure Regulator 1
4 Manometer Pointer
FG020289
Figure 70
2. Connect at least 6 bar (87 psi) of compressed air to the
connection nipple (3, Figure 70) of the test equipment.
3. Pull out the wheel on the pressure regulator (4, Figure 70)
and turn it until manometer pointer (5, Figure 70) indicates
23%. Press in the wheel and lock the regulator.
4. Disconnect the compressed air and remove quick-release
coupling (1, Figure 70) on the measuring hose from the
back of the test equipment (2, Figure 70).
4-1-72
Tolerance for Leakage Measurement
< 23% Engine is in good condition.

23 - 30% Engine is in acceptable condition.
Engine is worn and may have poorer
30 - 40%
performance than expected.
Engine is very worn.
40 - 50%
Consider reconditioning.
Engine is in poor condition and must be
> 50%
reconditioned.
If the leak cannot be located: remove cover on the expansion

tank and check whether bubbles appear, or measure the
pressure in the cooling system using adapter 99 312 and cooling
system tester 587 048.
If the pressure increases or bubbles appear, this may indicate a
cracked cylinder head or cylinder liner.
Integrity Check
1. Warm up the engine to operating temperature.
2. Remove all rocker arms and valve bridges.
3. Remove all injectors as instructed in the work description
for Removing the injectors.
4. Turn the engine with the turning tool 99 309 so cylinder
number 1 is at TDC.
5. Block the engine so the crankshaft does not begin to rotate
when the cylinder is pressurized by leaving the turning tool
in position with tommy bar, T-handle or ratchet handle.
If using a ratchet handle, set the ratchet handle direction
based on whether the engine is before or after TDC so the
ratchet handle blocks rotation.
6. Assemble the nozzle adapter.
Engines with fuel system 1 3
2
Reference
Description
Number
1 Copper Gasket 2
2 Nozzle Adapter 4
3 Guide Sleeve
4 Clamp
7. Install the nozzle adapter in the injector hole on cylinder as

shown in the illustrations for the respective engine type.
FG020292
Use the ordinary injector screw and clamp.
Figure 71
8. Install the nozzle adapter with the test adapter (5, Figure
73) for the test equipment and then with the quick-release
coupling (6, Figure 73) on the measuring hose.
4-1-73
Reference
Description 5
Number
5 Test Adapter 2
6 Quick-release Coupling
7 Nipple
FG020293
Figure 72
9. Connect at least 6 bar (87 psi) of compressed air to the 7

connection nipple (7, Figure 73) of the test equipment.
XX XX
Allow the air to blow for a short while until pressure has XX
XX
XX
stabilized.
10. Listen for leaking air in the crankcase. Air leakage
indicates worn or damaged piston rings or cylinder bore, or
cracked pistons.
11. Listen for leaking air in the exhaust pipe. If possible, 6
remove flexible pipe. Leaking air in the exhaust pipe
indicates exhaust valves that are not fully sealed. 5
FG020294
12. Detach the hose from the charge air cooler and listen for Figure 73
leaking air in the intake manifold. Leaking air indicates
intake valves that are not fully sealed.
If the value read is great, you can tap gently a few times on
the end of the valve stem using a small hammer. If the
value falls when the valve has settled, this indicates worn
valve guides.
13. Check the other cylinders for leaks. Rotate the crankshaft
120° in the direction of engine rotation to measure
cylinders 2 and 5, then a further 120° in the direction of
engine rotation to measure cylinders 3 and 4.
Valve Mechanism
Function
The valve mechanism consists of one or two camshafts, roller
tappets, pushrods, rocker arms and valve tappets.
Straight engines have one camshaft and V engines have two
camshafts, one for each cylinder line. In both cases the
camshaft is driven by the timing gears and rotates at half the
speed of the crankshaft.
The camshaft has two cams per cylinder, one for the intake
valves and one for the outlet valves.
One end of the push rod rests on the roller tappet, and the other
end acts on the rocker arm. At one end of the rocker arm there is EX1302148
an adjusting screw. The lower ball-shaped end of the screw Figure 74
rests in the pushrod, making the tappet adjust to the camshaft
movement.
4-1-74
The valve seat inserts are firmly pressed to a tight fit in the
cylinder head. The material in the seat inserts is very strong, so
the valve seats have a long service life. If required the valve seat
rings can be replaced.
EX1302149
Figure 75
With four valves per cylinder the valve area is greater, which
makes it easier to fill the cylinder with air. At the same time, less
energy is consumed in forcing out the exhaust fumes.
The effort required for gas flow is reduced and engine efficiency
is improved. This in turn leads to a reduction in fuel
consumption.
WARNING
Wear protective goggles to prevent injury to eyes.
Removing Valves
1. Remove split collets, valve spring collars, springs and 99 322
valves. Press down the spring using tool 99 322 in a press
so the collets can be removed.
2. Place the valves in a stand so they can be reinstalled in the
same position in the cylinder head.
FG020258
Figure 77
Installing Valves
NOTE: There are different versions of the combination valve 99 322
– valve spring collar – split collet. Parts from the
different versions must not be mixed on the same
valve.
1. Lubricate all parts well with engine oil before assembly.
2. Insert the valve in the guide.
3. Install the valve springs and the valve spring collar.
4. Press together the springs in a press with tool 99 322 and FG020259
install the collets. Ensure that collets are installed in their Figure 78
correct positions.
4-1-75
Checking the Valve
Intake Valve
Head Angle 19.5°
Minimum Measurement A 2.6 mm A
Outlet Valve
Head Angle 45.5°
Minimum Measurement 1.8 mm
Check dimension A on all valves. If the measurement does not

achieve the minimum permitted dimension, the valve must be
replaced. The valve should also be replaced if there are visible FG020295
defects on the intake valve surface. Figure 79
Checking and Adjusting the Valve Clearence
IMPORTANT
Remember to remove turning tool from the flywheel after
adjustment.
Check and adjust the valve play with the engine cold. Play for
the intake valves must be 0.45 mm and for the exhaust valves
0.70 mm.
Rotate the flywheel in the normal direction of rotation using
turning tool 99 309. Read the mark on the flywheel visible in the
lower window of the flywheel housing.
Engines equipped with flywheel with marking TDC Up: Fit
turning tool 99 109 in the holes of the upper hatch. Press the
pinion into the external ring gear and turn the flywheel with a
ratchet handle and a 14 mm socket. Read the mark on the FG020301
flywheel in the upper window of the flywheel housing. Figure 80
Dependent on equipment fitted, it may not be possible to use
turning tool 99 109 on certain buses.
Adjusting may be done in one of two ways. Either by setting the
TDC on the flywheel and the following the tables showing which
valves can be adjusted, or by the following the tables showing
which flywheel position to set to adjust all valves on a cylinder:
Adjust valves according to the table below. Follow the respective
column depending on whether the reading is in the lower or the
upper window. Start adjustment at the top of the table. Check
that there is no valve transition on cylinder 1.
NOTE: Valve transition occurs when the cylinder switches
from exhaust stroke to intake stroke. The exhaust 1 2 3 4 5
valve is closing while the intake valve is opening.
EX1302151
Figure 81
4-1-76
Cylinder configuration, 5 cylinder engines
Mark on Flywheel Adjust Intake and Mark on Flywheel

Valve Transition
Reading in the Revolution Exhaust Valves on Reading in the
on Cylinder
Lower Window Cylinder Upper Window
TDC Down 1 1 TDC Up
72/432 1 5 252/612
144/504 1 2 324/684
216/576 1 3 36/396
288/648 1 4 108/468
TDC Down 2 1 TDC Up
72/432 2 5 252/612
144/504 2 2 324/684
216/576 2 3 36/396
288/648 2 4 108/468
It is a good idea to mark the rocker arm with a pen after

adjustment to keep track of what has already been adjusted.
Cylinder Block
General Description
The cylinder block is cast in one piece, in compact graphite iron
(CGI) and each cylinder has a separate cylinder head. The
cylinder bores have wet liners.
Overview
Figure 82 EX1302152
Replacing the Camshaft Bearing

1. Remove camshaft as described in the work description
Removing the camshaft.
2. Remove cover for the camshaft at the front of the engine.
IMPORTANT
Wipe all around the edges of the old bearing seating
surfaces to avoid damaging contact surfaces when
installing the new bearings.
4-1-77
3. Wipe the bearing seat surfaces clean around the old
bearings.
NOTE: The recess in the bearing joint must be turned
towards the front of the engine. Place the new
bearings in the space between the bearing
seats for the camshaft.
FG020305
Figure 83
Reference
Description
Number 3
1 Threaded Stem with Flange Nuts
2 Press Drift
1
3 Flange 2
FG020306
Figure 84
4. Place the flange nuts on the threaded stem, part of tool 99

373, as illustrated.
1 2 3 4 5 6 7
8
164
328
492
656
820
984
FG020307
Figure 85
4-1-78
5. Take the threaded stem and insert the end with flange nut
number 1 from the rear of the engine past the rearmost
bearing seat.
Insert it further through the bearing seats and the new
bearings until flange nut 1 protrudes from the front of the
engine.
FG020308
Figure 86
6. Screw the flange part of tool 99 373 securely onto

hydraulic cylinder 99 003 with two M6x12 bolts. Press
together cylinder 99 003 if not already in neutral position.
99 003
8
FG020309
Figure 87
7. Screw on the flange with the hydraulic cylinder at the rear

of the engine with two M10x25 bolts.
8. Screw on flange nut 8, from tool 99 373, onto the threaded
stem.
9. Hang a new bearing on the stem at the front of the engine.
FG020310
Figure 88
NOTE: The recess in the bearing joint must be turned

towards the flange on the press drift. Secure the
bearing on the drift by placing the spring-loaded
ball in an oil way. The bearing is correctly
located on the drift when the ball and a marking
hole are centered on the bearing oil hole.
Place the press drift on the threaded stem and
place the bearing on the drift.
FG020311
Figure 89
4-1-79
10. Clean around the bearing contact surface.
NOTE: The marking on the drift must be uppermost and
vertical so the oil hole in the bearing will be
central to the oil ways.
FG020312
Figure 90
11. Hold the press drift with the new bearing against the old.
Secure the threaded stem between the press drift and
hydraulic cylinder 99 003 by tightening flange nut 8 on the
stem.
NOTE: Secure the threaded stem by tightening flange
nut 8.
The new bearing is in the correct position before
the old bearing is completely released. The new
bearing has the correct position when the 8
distance from the front Table for correctly
FG020313
located camshaft bearing edge of the cylinder
block to the front edge of the press drift has a Figure 91
permitted value according to the table. -12 mm
means that drift protrudes 12 mm from the
cylinder block.
Table for correctly located camshaft bearing
Camshaft Bearing No. Distance (mm)

1 -12 - -14
2 150 - 152
3 314 - 316
4 478 - 480
5 642 - 644
6 806 - 808
FG020314
Figure 92 Check measurement of bearing
12. Press in the new bearing at the same time as pressing out number 1.
the old bearing with hydraulic cylinder 99 003 and
hydraulic pump 99 004. Measure to check that bearing is
correctly positioned.
13. Remove press drift by detaching flange nut 8 and pushing
in the threaded stem.
4-1-80
NOTE: The seats for camshaft bearing numbers 2, 4
and 6 have two oil ways. The others only have
the lower one.
Check that bearing oil hole is central to the
cylinder block oil ways.
14. Repeat the procedure for the remaining bearings.
FG020315
Figure 93 Check measurement of bearing
number 2.
15. Carefully knock with a plastic hammer to release the old

bearings.
16. Clean the sealing surface, take a new gasket and install
the cover for the camshaft at the front of the engine.
17. Install the camshaft according to the section Installing the
Camshaft. Then perform a check on the camshaft setting.
FG020316
Figure 94
Measuring the Cylinder Liner Seat
Engines with Unmachined Liner Seats

Engines 0.15 - 0.30 mm
Engines with Machined Liner Seats

All Engines 0.20 - 0.30 mm
The maximum height difference between two sides of the same

liner is 0.02 mm. If the height difference is greater, the cylinder
bearing seat must be re-machined.
Figure 95
1. Remove any soot from the top of the cylinder block and the
edge of the cylinder liner.
2. Secure the cylinder liner with two diagonally positioned
tension lugs 98 515. Tighten the tension lug bolts.
3. Position the straight edge 87 198 with dial gauge 98 075
on the cylinder liner and reset the dial gauge against the
cylinder liner (A in illustration). D
C
C
4. Slide the straight edge from the cylinder liner (A) to the
cylinder block (B) and measure the height difference. B A
Measure the difference in the same way at four points, 90°
offset from each other. The maximum height difference
between the four points is 0.02 mm.
Figure 96 FG020320
4-1-81
Machining the Upper Cylinder Liner Guide
When replacing the cylinder liner, the sealing surface of the
cylinder liner's upper O-ring in the cylinder block only needs to
be machined enough to create a satisfactory sealing surface.
For this purpose, a number of oversized cylinder linders are
available as spare parts. The cylinder block is adapted to
different cylinder liner sizes by machining with tool 588 889.
Specifications for Checking and Adjusting the Cutting Blade and

Bevelling Blade
IMPORTANT
Measure the upper cylinder liner diameter to establish the
current measurement before starting machining.
Reference
Description EX1302072
Number Figure 97
A Cutting Blade
B Bevelling Blade
• Setting dimension for cutting blade A
Standard Dimensions for Setting Dimension for Cutting Blade A,

Piston Diameter Cylinder Liner in Cylinder Cylinder Liner Oversize
Block 0.5 mm 1 mm 1.5 mm 2 mm
130 mm 151 mm - 11.51 - -
FG020323
Figure 98
The reference measurement (TS) for the bevelling blade B is

specified on the plate in the tool box.
• Setting dimension for the bevelling blade B
Standard Dimensions for Setting Dimension for the Bevelling Blade B

Piston Diameter Cylinder Liner in Cylinder (B=TS ±X), Cylinder Liner Oversize
Block 0.5 mm 1 mm 1.5 mm 2 mm
130 mm 151 mm - TS + 0.50 - -
4-1-82
Checking and Adjusting the Cutter and Beveling Blade
To check the cutter, turn the feed screw until blade insert holder
is in its upper position.
To check the beveling blade, turn the feed screw until blade
insert holder is in its lower position.
1. Position the tool with the feed screw in the support block
and install the micrometer.
2. Carefully turn the base clockwise until blade is in the right
position.
3. Screw the micrometer in towards the blade and check the
setting dimension. The setting dimension for the beveling
blade is indicated on the plate in the tool box.
4. If the setting dimension is incorrect, adjust the blade by
loosening the two internal hexagon screws that hold it in
place.
EX1301922
Figure 99
NOTE: The blade is spring-loaded in the blade insert

holder.
FG020326
Figure 100
5. Set the micrometer with the right setting dimension and

tighten the internal hexagon screws that hold the blade in
place. Turn back the micrometer and tighten the internal
hexagon screws until blade is locked firmly in place. Check
the setting dimension of the blade and the micrometer.
FG020327
Figure 101
4-1-83
Installing the Swarf Collector
Install the swarf collector in the cylinder approximately 63 mm
from the upper face of the cylinder block.
FG020328
Figure 102
Machining the Upper Cylinder Liner Guide

1. Check that upper face of the cylinder block is clean and
free from damage.
2. Turn the feed screw of the tool until blade insert holder is in
its upper position.
3. Position the tool on the upper face of the cylinder block.
Make sure that guide pin ends up in the right position and
that tool contacts the cylinder block.
FG020329
Figure 103
4. Install the three internal hexagon screws and tighten them

with the internal hexagon key the comes in the kit.
5. Install the crank on the tool.
IMPORTANT
Do not crank the tool counterclockwise as this will
destroy the blade.
FG020330
• A suitable feed rate is approximately 25 cutter turns
Figure 104
per feed turn.
• Machine without stopping until feed screw is in its
lower position.
• Continue cranking clockwise will the feed screw
backs to its upper position.
4-1-84
6. Machine the upper cylinder liner guide on the cylinder
block with the tool.
7. Loosen the internal hexagon screws and remove tool.
FG020331
Figure105
Cleaning and Checking

1. Clean the swarf collector with a vacuum and then remove
it.
2. Remove burrs from the machined cylinder block edge with
abrasive paper, size 400.
3. Clean the cylinder block.
4. Check that cylinder liner can be inserted in the cylinder
block.
5. Clean the tool and return it to the box.
FG020332
Figure 106
4-1-85
Machining Lower Cylinder Liner Diameter
IMPORTANT
Measure the lower cylinder liner diameter to make sure the
cylinder liner mounted in the cylinder block is 139 mm
(5.47 in) or 140 mm (5.51 in).
Reference
Description
Number
1 Pin
2 Loose Stop Lug
FG020334
Figure 107
1. Check the fixture. Insert the gauge and check that

micrometer indicates 0.00 mm. The loose stop lug must be
removed to use the gauge. Install the loose stop lug after
checking and adjusting if required.
Reference
Description
Number 1
1 Gauge
2 Key 2
3 Loose Stop Lug

3
FG020335
Figure 108
2. Remove hexagon socket screw in the center of the cutting

head.
FG020336
Figure 109
4-1-86
3. Place the cutting head in the fixture. Center the cutting
head by turning it clockwise until it rests against the pin
and the cutter stops against the loose stop lug.
4. If this value is correct, install the cutting head on the tool
and tighten the hexagon socket screw. If the value needs
to be adjusted, proceed as follows:
• Cylinder liner diameter 139 mm
Check that cutter is set so the micrometer indicates
14.03 mm.
• Cylinder liner diameter 140 mm FG020337
Check that cutter is set so the micrometer indicates Figure 110
14.53 mm.
5. Hold the cutter against the lug and undo the hexagon
socket screw securing the cutter. The cutter is spring
loaded.
FG020338
Figure 111
6. Hold the cutting head with your hand and adjust the
micrometer.
• 14.03 mm gives the cutting head a diameter of
139.03 mm.
• 14.53 mm gives the cutting head a diameter of
140.03 mm.
FG020339
Figure 112
7. Lightly tighten the hexagon socket screw securing the

cutter.
FG020340
Figure 113
4-1-87
8. Back off the micrometer.
9. Tighten the hexagon socket screw securing the cutter.
10. Check the value again.
11. Install the cutting head on the tool, tighten the hexagon
socket screw in the center.
FG020341
Figure 114
Adjust the Diameter of the Cylinder Liner Seat 1

Diameter of lower liner seat
• 139.04 ±0.04 mm 2
• 140.04 ±0.04 mm 3
Reference
Description 4
Number
1 Crank Handle 5
2 Feed Screw
FG020342
3 Lever Figure 115
4 Guide Plate
5 Cutting Head
1. Check that upper surface of the upper liner seat on the

cylinder block is not damaged.
2. Turn the feed screw clockwise until cutting head is at the
top of the tool.
3. Lubricate the cutting head sliding surfaces with thin-bodied
oil.
4. Lower the tool into the cylinder block until guide plate
centers in the upper liner seat.
5. Secure the guide plate with the lever.
6. Install the crank handle and crank the cutter clockwise.
IMPORTANT
The cutter must never be cranked counterclockwise.
FG020343
Figure 116
4-1-88
7. Feed the cutting head right down until feed screw reaches
the guide plate by turning the feed screw counterclockwise.
A suitable feed rate is 15-20 cutter turns per feed turn.
8. Continue to crank the cutting head clockwise and feed it
backup by turning the feed screw clockwise all the way up.
9. Undo the lever on the guide plate and lift up the tool.
10. Clean the cylinder block and check that new cylinder liner
fits.
11. Clean the tool. FG020344
Figure 117
Machining the Cylinder Liner Seat

1. Shims must be used to adjust the liner to the correct
height. Shims are available in thicknesses of 0.2 mm,
0.3 mm and 0.4 mm. If the cylinder liner needs to be raised
by less than 0.2 mm, the bearing seat must be machined
until its height including the shim is correct.
Example of cutting depth calculation:
Height Required 0.25 mm

Current Cylinder Liner Height 0.16 mm
Raising the Cylinder Liner
0.09 mm
(0.25 mm - 0.16 mm)
Shim thickness 0.2 mm
Layer which must be Machined off
0.11 mm
(0.2 mm - 0.09 mm)
2. Clean the contact surface between the setting ring (which

is included in the extension kit) and the upper face of the
cylinder block.
NOTE: It is important for the surface to be cleaned
thoroughly; otherwise the cylinder liner seat
may be cut to the wrong depth or may be
slanted.
FG020347
Figure 118
4-1-89
3. Install extension 588 672 on the milling cutter 587 512.
FG020348
Figure 119
4. Set the depth of the extension to 206 mm.
206 mm
FG020349
Figure 120
5. Position the setting ring over the relevant cylinder and then
position the milling cutter. Energize the magnet on the
cutter by setting the switch to position 1.
6. Check that tool (cutter) does not touch the edge of the liner
seat when the milling cutter is installed in the setting ring.
Otherwise the vertical feed screw must be wound up until
cutter is free from the liner seat.
FG020350
Figure 121
7. Lift the rapid feeder ring and move the cutter by hand until
it is positioned above the liner seat surface without being in
contact with the cylinder block wall.
FG020351
Figure 122
4-1-90
8. Wind round and at the same time turn the vertical feed
screw clockwise until cutter just touches the liner seat.
9. Lift the rapid feed ring and move the cutter back so it is
within the liner seat surface.
10. Adjust the vertical feed screw to start machining. The
maximum feed per cut is 0.05 mm. If 0.05 mm is not
enough, several cuts may be required until required
position is reached.
FG020352
IMPORTANT
Figure 123
Never wind the milling cutter counterclockwise;
otherwise the cutter will break.
11. Wind clockwise with an even movement. Hold in the

horizontal feed screw with the other hand at the same time.
The cutter will be fed horizontally at 0.13 mm per turn.
Wind carefully when the cutter starts to approach the outer
edge of the liner seat.
Release the horizontal feed screw when the cutter has
gone over the edge so feeding stops.
FG020353
Figure124
12. Move the cutter back towards the center of the cylinder
bore by holding down the rapid feed ring at the same time
as the cutter is moved back by hand.
13. Repeat steps 10-12 if insufficient cutting depth has been
attained.
14. When the required depth has been attained, hold down the
rapid feed ring and move the cutter to the middle of the
cylinder bore. Change the switch on the milling cutter to
position 2 and lift out the entire tool. Then remove setting ring.
15. Clean any swarf from the liner seat. FG020351
Figure 125
16. Position the shim on the liner seat. The shim must be dry.
17. Position the cylinder liner.
18. Measure to ensure that height corresponds to the height
specified in the work description for measuring cylinder
liner height.
Adjusting the New Cylinder Block when Replacing

NOTE: New cylinder blocks are unmarked from the factory
and must be marked according to applicable
regulations before they are put into operation.
For marking, refer to section general engine
documents.
4-1-91
Cylinder Liner
Cylinder Liner Type

1. Clean the Cylinder Wear Ridge A B
It may be difficult to identify cylinder liner type when

extremely worn. Clean the cylinder wear ridge and check if
there are marks after honing.
FG020354
Figure 126
2. Identifying Cylinder Liner

1 A 1 B
Identifying cylinder liner without removing from the cylinder
block.
Check if there are any marks after honing 1.
Cylinder liner type A No honing on the cylinder wear ridge.
Cylinder liner type B Honing on the cylinder wear ridge.
Identifying cylinder liner removed from the cylinder block.
2 2
Check if there are signs of machining on the lower edge 2.
Cylinder liner type A No signs of machining on the lower
edge.
Cylinder liner type B Signs of machining on the lower edge.
FG020355
Figure 127
Function
The cylinder liners can be replaced. A steel gasket with
vulcanised rubber seals provides sealing between cylinder liner
and cylinder head. One gasket per cylinder.
The cylinder liner protrudes slightly above the cylinder block
surface and presses the gasket against the cylinder head, thus
making sure it seals.
The vulcanised rubber seals provide sealing against the coolant
and lubrication oil channels.
EX1302153
The temperature in and around the combustion chamber is Figure 128
extremely high. The cylinder liner has a low attachment which
enables cooling right up to the cylinder head. This reduces the
temperature of the piston rings which increases the service life
of both the piston rings and the cylinder liner. The low
attachment of the cylinder liner reduces the risk of the liner
sinking since the lower temperature reduces the material
fatigue.
4-1-92
Scraper Ring
The scraper ring (Figure 129) is located in a groove at the top of
the cylinder liner (Figure 132 and Figure 133). The scraper ring
removes build-up of carbon from the piston crown and reduces
wear on the cylinder liner.
EX1302154
Figure 129
EX1302155
Figure 130
Figure 131
4-1-93
Measuring Cylinder Liner
1. Check wear by measuring the cylinder wear ridge and
cylinder bore. A B
Measure the diameter of the cylinder wear ridge 2-8 mm

down the cylinder bore. (C, Figure 132)
Measure the diameter of the cylinder bore 10-12 mm down
the cylinder bore. (D, Figure 132)
2. Cylinder liner type A C C
D D
The difference between the diameter of cylinder wear ridge
C and the diameter of cylinder bore D must not exceed
0.06 mm.
Cylinder liner type B
The difference between the diameter of cylinder wear ridge
FG020356
C and the diameter of cylinder bore D must not exceed
Figure 132
0.06 mm.
Removing the Cylinder Liners

1. Mark the cylinder liners. The mark is necessary so the
liners can be reinstalled in the same place and position as
previously.
IMPORTANT
The mark must be made only on the surface indicated
in the illustration. Other surfaces are for sealing. If you
use a marker, you can mark anywhere.
FG020358
Figure 133
2. Remove cylinder liner using puller 99 066.

3. Remove sealing ring in the cylinder block. 99 003
99 066
FG020359
Figure 134
4-1-94
Installing the Cylinder Liner
IMPORTANT
Use only glycerol to lubricate the cylinder block, cylinder
liner and O-rings. Other lubricants may swell the O-rings.
IMPORTANT
The O-rings for the cylinder block and cylinder liner have
different thicknesses and diameters. The thinnest O-ring
with the smallest diameter fits on the cylinder liner.
1. Check the cylinder liner height according to the work

description for measuring cylinder liner height.
2. Make sure the interior of the cylinder block is clean. Clean
the O-ring surfaces.
3. Clean away any grease and dirt from compression ring 99
616.
4. Position the compression ring on the cylinder block. Check
that it does not make contact with the cylinder head guide
pins. If it does, tap down the guide pins further.
5. Set the compression ring to one side.
6. Lubricate the O-ring to be installed in the cylinder block
with glycerol and install it.
7. Carefully check the cylinder liner, both new and old, for FG020361
cracks which might have arisen during transport or Figure 135
careless handling.
Tap the liner carefully with a metal object. It should give a
clear metallic ring if it is intact. If it is cracked, there will be
no clear ringing sound.
8. Clean the O-ring groove of the cylinder liner.
9. Check the O-ring to be installed on the cylinder liner and
roll it into position using tool 99 656.
EX1301923
Figure 136
4-1-95
10. Lubricate the lower guide surface on the cylinder liner with
glycerol.
11. Thoroughly lubricate the compression ring 99 616 with
glycerol and install it in the cylinder block, centered over
the cylinder liner bore.
FG020362
Figure 137
12. Turn the liner with the stamped cylinder number facing
forward. If an old liner is being reinstalled, ensure that it is
reinstalled in the same place and position as before.
Position the cylinder liner in the cylinder block and press it
down past the first resistance. The cylinder liner should
protrude approximately 1 cm in the compression ring.
While the cylinder liner slides down, the compression ring
is centered automatically.
FG020363
Figure 138
13. Installing the cylinder liner by hand; see step 14.

Installing the cylinder liner using tools; see step 15.
14. Installing the cylinder liner by hand.
Grasp the cylinder liner with both hands and press it down
into place with a single, even movement. If the cylinder
liner does not go into place immediately, there is a great
risk that the upper O-ring is damaged.
FG020364
Figure 139
15. Fitting the cylinder liner using tools.

A. Fit tool 99 656 on the cylinder liner.
Figure 140
4-1-96
B. Screw in an M16 screw with eye into one of the screw
holes for the cylinder head.
Figure 141
C. Attach lifting arm 98 677 in the eye.

D. Press down the cylinder liner with an even
movement. If the cylinder liner does not go into place
immediately, there is a great risk that the upper O-
ring is damaged.
Figure 142
16. Check that the liner goes down completely.
FG020365
Figure143
4-1-97
Removing the Scraper Ring in the Cylinder Liner
1. Try to remove the scraper ring by hand.
If the scraper ring is so firmly seated that it cannot be
removed by hand, use the following method:
2. Turn the crankshaft so that the piston goes down far
enough so that there is enough room for plate 99 168
under the scraper ring.
3. If necessary, fit press tool 98 515 on the edge of the
cylinder liner in such a way that the liner will not be pulled
out of place.
4. Place the plate in tool 99 168 on the piston crown inside Figure 144
the cylinder.
5. Fit a compression ring below the scraper ring as illustrated.
During removal the plate in the dismantling tool will pull up
the compression ring, which will in turn pull up the scraper
ring.
6. Remove the bolt from slide hammer 99 074 and fit the
handle in tool 99 168 on the bolt. If it proves difficult to fit
the handle on the bolt, the bolt head can be ground down
slightly.
7. Fit the slide hammer 99 074 on the bolt.
Figure 145
8. Screw the bolt into the plate fitted in the cylinder.

9. Pull up the plate until it abuts against the compression ring.
10. Tap out the scraper ring and compression ring using the
slide hammer.
Figure 146
4-1-98
Flywheel Housing
Removing the Flywheel Housing

1. Remove oil sump, oil suction pipe.
2. Remove starter motor. Refer to work description for
removing the starter motor.
3. Remove flywheel. Refer to work description for removing
the flywheel.
4. Detach the hydraulic pump and move it aside.
5. Where appropriate, remove power take-off and units
connected to it.
6. Remove flywheel housing.
FG020367
Figure 147
Installing the Flywheel Housing

1. Remove all old sealant on the sealing surfaces of the
flywheel housing and timing gear plate. Clean off any oil
and grease using an alcohol based cleaning agent.
IMPORTANT
The sealing surfaces must be absolutely clean and
free from grease.
2. Using nozzle 584 118, apply sealant to the flywheel

housing on the side towards the timing gear plate. The
bead (X) must be approximately 1.5 mm wide. Follow the
pattern illustrated. Also apply sealant around the screw
holes marked with arrows.
IMPORTANT
The sealant must be applied inside the bolt holes, but
without allowing sealant into the crankcase. The
sealant may block channels and nozzles. This is =X
particularly important to bear in mind around oilways,
where the flow of oil to the air compressor and
injection pump can be blocked. FG020369
Figure 148
4-1-99
IMPORTANT
Assembly must be completed within 25 minutes of
starting to apply the sealant.
To facilitate assembly and avoid sealant getting into
the wrong places, make 2 guide pins which are
installed into the upper bolt holes on the flywheel
housing.
3. Install the flywheel housing against the timing gear plate. M10 x 30
4. Tighten the bolts.
NOTE: The bolts are of various sizes and lengths.
Ensure that they are installed in the correct
places.
M10 x 30 FG020370
Figure 149
M10 x 60 M12 x 100 M10 x 60
M10 x 60
M10 x 80 M12 x 100 FG020371

Figure 150
5. Where appropriate, install the power take-off and units

connected to it.
6. Install the hydraulic pump. M10 x 45
7. Install the flywheel. Refer to the work description for

installing the flywheel. M10 x 30
8. Install the starter motor. Refer the work description for
installing the starter motor.
9. Install the oil sump, oil suction pipe.
FG020372
Figure 151
4-1-100
Replacing the Rear Crankshaft Seal
1. Remove flywheel according to instructions.
2. Remove crankshaft seal using a screwdriver. Take care
not to scratch the sealing surfaces on the crankshaft and
the flywheel housing. Alternatively a self tapping screw can
be screwed into the crankshaft seal so the crankshaft seal
can be pulled out with a slide hammer.
FG020374
Figure152
NOTE: The crankshaft seal must be installed dry and

must not be lubricated. The sleeve in the seal
must be left in place. Do not touch the sealing
lip with your fingers.
FG020375
Figure 153
3. Install a new crankshaft seal using tool 99 148. Place the 99 148
crankshaft seal on the tool and fasten the tool with the
bolts.
4. Tighten the bolts alternately until tool stops against the
cover. Then remove tool and the protection ring of the
crankshaft seal.
5. Clean the flywheel sealing surface using degreasing agent
and wipe it dry before assembly.
6. Install the flywheel according to instructions.
FG020376
Figure 154
4-1-101
Front Cover
Removing the Front Cover

1. Switch off the main power supply.
2. Remove radiator if necessary. See the work description for
removing the radiator.
3. Remove fan ring, marking its position.
4. Remove fan electrical cable.
5. Remove fan. Maintain the fan upright.
6. Drain the oil from the oil sump.
7. Remove poly-V-belt(s).
8. Remove pulley and the hub.
9. Remove oil sump.
10. Remove 8 front cover bolts and remove front cover.
FG020377
Figure 155
11. Remove front cover and ladder frame gaskets. If the

surfaces have been sealed with silicone, it must be
washed away.
FG020378
Figure 156
4-1-102
Installing the Front Cover
1. Install the front cover.
FG020377
Figure 157
2. Install the ladder frame and oil sump.

3. Install the poly-V-belt(s). Replacing drive belts.
4. Install the fan.
5. Install the fan electrical cable.
6. Install the fan ring.
7. If the radiator was removed: Install the radiator.
8. Fill with engine oil.
9. Switch on the main power supply. FG020378
Figure 158
Replacing the front Crankshaft Seal

1. Remove cooling package and fan then release the belt
drive and loosen the pulley (pulley on engines with
geared-up fan) as described in the relevant work
description under cooling system.
2. Remove crankshaft seal with a screwdriver, take care not
to damage any sealing surfaces. Alternatively a
self-tapping screw can be screwed into the crankshaft seal
so the crankshaft seal can be pulled out with a slide
hammer.
3. Wipe around all surfaces.
4. Install the new crankshaft seal onto tool 99 149.
NOTE: The crankshaft seal must be installed dry and
on no account must it be lubricated. Do not
touch the sealing lip with your fingers. FG020380
Figure 159
4-1-103
NOTE: Note the installing direction of the seal.
5. Press the new seal into position with tool 99 149. The seal
is correctly installed when the tool is pressed home against
the front cover.
6. Install the pulley (pulley on engines with geared-up fan),
fan and cooling package as described in the relevant work
description under Cooling system.
99 149
FG020381
Figure 160
Oil Mist Separator
Overview
Intake and outlet on the oil mist separator
Reference
Description
Number
1 Crankcase Gases from the Engine
2 Cleaned Crankcase Gases
3 Oil Separated from the Crankcase Gases
Inlet for Oil which Drives the Oil Mist
4
Separator
Outlet for Oil which Drives the Oil Mist Figure 161
5
Separator
Function
The oil mist separator is driven by oil from the lubrication
system. The oil flows into the oil mist separator and is sprayed
onto the turbine located on the rotor shaft. The oil then flows out
and back to the oil sump.
The rotor consists of a number of tapered plastic plates which
are located on top of one another. There is a space for the
crankcase gases and oil particles between each plate.
The crankcase gases and oil particles flow into the oil mist
separator through the union in the top of the oil mist separator
housing. The oil particles stick to the rotating plates and the
centrifugal force causes the oil particles to be thrown against the
wall of the oil mist separator housing. The oil which has been
separated from the crankcase gases runs down along the walls
of the oil mist separator housing and then flows out of the oil
mist separator by the centrifugal oil cleaner to the oil sump. The
centrifugal oil cleaner contains an oil trap. The oil trap is there so
that oil from the oil sump is not drawn in the wrong direction.
4-1-104
Flow of crankcase gases (CCV)
Reference
Description
Number
1 Air Filter
2 Turbocharger
3 Charge Air Cooler
4 Air Compressor
5 Oil Mist Separator
6 Exhaust Brake
For engines with closed crankcase ventilation (CCV) the

cleaned crankcase gases flow out of the oil mist separator by a
diaphragm which acts as a pressure regulator. When the
vacuum downstream of the oil mist separator is too great, the
diaphragm will close the opening until the pressure has risen
again.
Figure 162
Removing the Oil Mist Separator

1. Drain coolant from the engine. Change - Coolant on
engines.
2. Remove the oxidation catalytic converter or the connection
to this.
3. Detach two coolant hoses from the exhaust brake.
4. Undo the V-clamp between the turbocharger and exhaust
brake.
5. Remove the exhaust brake.
6. In case of a compressor, remove its outlet pipe and inlet
pipe.
NOTE: Cover all inlets and outlets.
7. Detach the following components
• Undo the hose clamps for the lubrication oil return
6
pipe (4) and remove the hose.
• Remove the pressure pipe (5) for the oil mist
separator.
• Detach the inlet pipe (6) to the oil mist separator.
• Remove the oil mist separator outlet pipe (7).
• Remove the oil mist separator (8).
8 4 7 5 FG020382
Figure 163
4-1-105
Installing the Oil Mist Seperator
1. Install the following components:
• Install the oil mist separator (8) and the inlet pipe (6)
6
at the same time.
• Install the pressure pipe (5) and the oil mist separator
outlet pipe (7).
• Install the oil return pipe (4).
2. If a compressor is fitted, fit the outlet pipe and inlet pipe.
Replace damaged O-rings.
3. Install the exhaust brake to the turbocharger with a V- 8 4 7 5 FG020382
clamp. Figure 164
4. Install two coolant hoses on the exhaust brake.
5. Install the oxidation catalytic converter or the connection to
this.
IMPORTANT
After warming up the engine, tighten the Vclamps.
6. Fill with coolant. Change - Coolant on engines.
EX1301840
Figure 165
4-1-106
Disassembly
Remove oil mist separator from the engine before it is disassembled.
4
3
5
6
10 11
Figure 166 EX1302075
Reference Reference
Number Number
1 Separator Housing 7 Insert
2 Diaphragm 8 Turbine
3 Diaphragm Cover 9 Retaining Ring
4 Rotor Disk 10 Gasket
5 Retaining Ring 11 Turbine Housing
6 O-ring
4-1-107
WARNING
Follow the instructions in Procedures section for all work in
the workshop.
In addition, follow all local regulations for working with
ethanol.
1. Remove gasket (10) between the turbine housing (11) and

oil mist separator housing (1).
2. Lift the rotor assembly out of the oil mist separator housing.
If the rotor assembly is difficult to remove, use a rubber
mallet to carefully tap alternately on the three screw joints.
3. Remove turbine (8) from the rotor unit shaft. Press the
turbine downwards and release the retaining ring (9).
4. Detach the rotor disks by removing the retaining ring (5).
The magnets installed in the uppermost rotor disk can
easily be detached when the rotor disks are dismantled. FG020384
Figure 167
5. Remove diaphragm cover (3).
6. Remove diaphragm (2).
Assembly
IMPORTANT
New O-rings and gaskets must be used when the oil mist
separator is reassembled.
1. Install the rotor disks (4) on the rotor shaft and install the
retaining ring (5).
2. Install the rotor in the insert (7).
3. Install the turbine (8) on the rotor shaft and press on the
retaining ring (9).
4. Install a new O-ring (6).
5. Press the rotor assembly down into the oil mist separator
housing (1).
6. Install the diaphragm (2).
7. Install the diaphragm cover (3).
4-1-108
Measuring the Speed on the Oil Mist Separator
An angled ABS sensor must be used to measure the speed on
the oil mist separator. Cut the electrical cables and install two
connectors suitable for a multimeter which can measure Hz, see
illustration.
1. Start the engine and rev it up to 1000 rpm.
FG020385
Figure 168
2. Hold the sensor against the oil mist separator and read the
multimeter. The value must be at least 150 Hz at an engine
speed of 1000 rpm.
Cold Engine at Idling, Oil Temperature

120 ±50 Hz
of 20 - 50°C
Warm Engine at Engine Speed of
150 - 220 Hz
1,000 rpm
FG020387
Figure 169
4-1-109
ACTUATING SYSTEM
Camshaft
Description
The task of the camshaft is to control the opening and closing of
the intake and exhaust valves. On engines equipped with the
injection system, the camshaft also provides the movement
required to build up pressure in the injectors.
Camshaft Design
The camshaft has two or three cams per cylinder. There is
always one for intake valves and one for exhaust valves. In
some cases, there is also one for the injectors.
A cam can be described with the following terms; see picture:
Reference
Description
Number
1 Cam Profile
2 Base Circle Diameter
The Largest Lift of the Cam Profile,
3 Equivalent to the Maximum Movement of
the Roller Tappet.
Figure 170
Function
The camshaft rotates at half the speed of the crankshaft so that
each group of cams and actuate the valves of their cylinder
every other engine revolution during the exhaust stroke and
intake stroke. Where applicable, the injectors are actuated in
relation to injection timing.
Valve transition occurs at the arrow. This is when the exhaust
valves are closing and the intake valves are starting to open.
The time point when both the exhaust valves and the intake
valves are open simultaneously is called valve overlap.
When adjusting valve clearance, the valve transition of a Figure 171
cylinder is used to determine the position of the crankshaft. The
valves to be adjusted are then not actuated and the
corresponding roller tappet is on the camshaft base circle. The
adjustment order for each engine type can be found in tables in
Cylinder head.
Removing the Camshaft

1. Remove flywheel according to the work description
Removing the flywheel.
4-1-110
2. Remove flywheel housing according to the work
description Removing the flywheel housing.
3. Remove rocker arms, pushrods and valve bridges.
NOTE: Check the condition of the rocker arms, valve
bridges and pushrods. Replace damaged parts.
Mark the parts that are undamaged because
they must be reinstalled in their original
positions.
4. Remove camshaft gear.
5. Remove intermediate gear according to the work
description removing the intermediate gear and bolts for
the guide flange.
6. Remove timing gear plate.
7. Remove camshaft covers.
FG020391
Figure 172
8. Remove roller tappets.

NOTE: Mark the roller tappets, as they must be
reinstalled in the same place.
9. Pull the camshaft backwards. Take care not to damage the
cams and bearings.
FG020392
Figure 173
Removing the Camshaft from the Front

If there is room, it is easiest to remove camshaft from the rear.
On many machines with bodywork this is not possible, so it
becomes necessary to remove it from the front. It is not
necessary to lift out the engine, but the cooling package needs
to be removed.
1. Remove gearbox as instructed in the work description
removing the gearbox.
2. Remove flywheel as instructed in the work description
removing the flywheel.
3. Remove flywheel housing as instructed in the work
5. Remove intermediate gear as instructed in the work
description removing the intermediate gear.
6. Remove timing gear plate.
4-1-111
7. Drain the cooling system as instructed in the work
description draining the cooling system.
8. Remove cooling package as instructed in the work
description Removing the radiator.
9. Working from the front with the cabin tilted: Remove fan
and drive belt as instructed in the work description 2
Replacing the drive belt. Remove both belts if the machine
3
is equipped with a geared-up fan.
10. Remove alternator (1, Figure 174), AC compressor (2), belt
tensioner for the outer belt (3) and idler roller (4). Leave the 1
belt tensioner lock in position while the belt tensioner is
removed. Keep the belt tensioner so there is no risk of the 4
lock coming loose.
IMPORTANT Figure 174

EX1400022
The belt tensioner can break if the lock comes loose.

Make sure the bolt or drill is pushed in properly.
11. Unscrew the front camshaft cover. The camshaft is then

exposed so it can be removed from the front.
FG020394
Figure 175
FG020395
Figure 176 Camshaft exposed
4-1-112
12. Lift off the rocker covers and remove rocker arms,
pushrods and valve bridges.
NOTE: Check the condition of the rocker arms, valve
bridges and pushrods. Replace damaged parts.
Mark the parts that are undamaged because
they must be reinstalled in their original
positions.
13. Release the camshaft covers so they can be unscrewed.
The high-pressure pump, fuel filter housing with holder,
engine control unit and AC compressor cooling coil must
be removed to access the covers.
IMPORTANT
Depressurize the fuel system before starting to work
on the high-pressure pump.
Use checking tool to minimize the high-pressure in the
fuel system.
14. Remove camshaft covers.
FG020391
Figure 177
15. Remove roller tappets.

NOTE: Mark the roller tappets, as they must be
reinstalled in the same place.
16. Remove guide flange with thrust washer in the rear end of
the camshaft.
17. Pull the camshaft out forwards. Take care not to damage
the cams and bearings.
FG020392
Figure 178
4-1-113
Installing the Camshaft
1. Install the camshaft. Take care not to damage the cams
and bearings.
NOTE: Lubricate the entire camshaft and the bearing
seats with engine oil before installing the
camshaft in the cylinder block.
2. Lubricate the valve tappets with engine oil and install them
in the same places as before they were removed.
Remember to lubricate the shells before installing the
pushrods. Tighten the screws.
3. Install the camshaft apertures. Tighten the screws.
4. Install the guide flange bolts.
Now the camshaft axial clearance can be checked:
• Install the camshaft gear temporarily.
• Measure the camshaft axial clearance using a dial
FG020392
gauge. The axial clearance must be between 0.05 -
0.35 mm. Figure 179
• If the clearance is outside the permitted range,

replace the thrust washer.
• Remove camshaft gear.
5. Remove all old sealing compound on the cylinder block
and the sealing surface on the timing gear plate. Clean off
any oil and grease from the sealing surfaces using an
alcohol based cleaning agent.
IMPORTANT
Clean thoroughly, as the sealing surfaces must be
completely free of grease.
6. Apply sealant to the timing gear plate using nozzle 584

118. The sealant must be placed outside the milled
grooves as illustrated. The diameter of the bead must be
approximately 4 mm.
IMPORTANT
Ensure that you apply sealant inside the screw holes,
but without allowing sealant into the crankcase. The
sealant may block channels and nozzles. This is
where the flow of oil to the air compressor or injection =4
pump can be blocked.

FG020396

4-1-114
7. Install the timing gear plate onto the cylinder block. Tighten
the screws.
8. Install the intermediate gear as described in the work
description Installing the intermediate gear.
9. Ensure that markings on the camshaft gear point towards
the center of the intermediate gear.
10. Install the camshaft gear and tighten the screws.
11. Install the flywheel housing as described in the work
description Installing the flywheel housing.
FG020397
12. Install the flywheel as described in the work description Figure 181
Installing the flywheel.
Installing - Camshaft from the Front

1. Install the camshaft. Take care not to damage the cams
and bearings.
NOTE: Lubricate the entire camshaft and the bearing
seats with engine oil before installing the
camshaft in the cylinder block.
2. Lubricate the valve tappets with engine oil and install them
in the same places as before they were removed.
Remember to lubricate the shells before installing the
pushrods. Tighten the screws. Install the rocker covers.
3. Install the camshaft covers. Tighten the screws.
4. Install the guide flange with thrust washer in the rear end of
the camshaft.
Now the camshaft axial clearance can be checked:
• Install the camshaft gear temporarily.
FG020392
• Measure the camshaft axial clearance using a dial Figure 182
gauge. The axial clearance must be between 0.05 -
0.35 mm.
• If the clearance is outside the permitted range,
replace the thrust washer.
• Remove camshaft gear.
and the sealing surface on the timing gear plate. Clean off
any oil and grease from the sealing surfaces using an
alcohol based detergent.
IMPORTANT
4-1-115
6. Apply sealant to the timing gear plate using nozzle 584
118. The sealant must be placed outside the milled
grooves as illustrated. The diameter of the bead must be
approximately 4 mm.
IMPORTANT
Ensure that you apply sealant inside the screw holes,
but without allowing sealant into the crankcase. The
sealant may block channels and nozzles. This is
where the flow of oil to the air compressor or injection =4
pump can be blocked.
FG020396

7. Install the timing gear plate onto the cylinder block. Tighten
the screws.
8. Install the intermediate gear as instructed in the work
description Installing the intermediate gear.
9. Ensure that markings on the camshaft gear point towards
the center of the intermediate gear.
description Installing the flywheel housing.
FG020397
12. Install the flywheel as described in the work description Figure 184
13. Install all components that were removed from the engine
side: High-pressure pump, fuel filter housing with holder,
engine control unit and cooling coil for AC compressor.
and the sealing surface on the front camshaft cover. Clean
off any oil and grease from the sealing surfaces using an
alcohol based detergent.
IMPORTANT
4-1-116
15. Apply sealant to the groove on the cover.
The diameter of the bead must be approximately 4 mm.
IMPORTANT
Make sure that you apply the sealant evenly along the
groove on the cover. Be particularly careful by the
oilway which is visible under the camshaft. Excess
sealant can block the channel.
FG020398
Figure 185
IMPORTANT
16. Install the camshaft cover. Tighten the screws.

17. Install the idler roller, belt tensioner with the lock still in
position, alternator and AC compressor.
FG020399
18. Install the drive belt and fan as described in the instructions Figure 186 Oilway under the camshaft.
Replacing the drive belt.
19. Install the cooling package as instructed in the work
description Installing the radiator. Fill the cooling system as
instructed in the work description Filling coolant.
20. Install the gearbox as instructed in the work description
Installing the gearbox.
4-1-117
Connecting Rod
Function
The upper part of the connecting rod is wedge shaped. This
allows for larger contact surfaces in piston and connecting rod.
EX1302079
Figure 187
The big end of the connecting rod is split diagonally, so that the
piston and the connecting rod can be pulled up through the
cylinder.
EX1302080
Figure 188
To prevent the connecting rod bearing cap and the connecting

rod from becoming offset, the contact surfaces have grooves
and pins, or they are unmachined fracture surfaces.
Figure 189
EX1302082
Figure 190
4-1-118
Checking Connecting Rod
Check the connecting rods using tool 587 110.
Make sure the gudgeon pin bushing is not damaged and then
proceed as below:
1. Install the connecting rod cap according to the markings
and tighten the screws to the correct torque according to
the table above.
2. Install the connecting rod in the tool using the expander
and put the corresponding gudgeon pin in the gudgeon pin
bushing.
3. Then apply the indicator to the gudgeon pin.
Check whether the connecting rod is twisted with the indicator
studs horizontal.
NOTE: Checking for twisted connecting rod.
FG020401
Figure 191
Check whether the connecting rod is bent with the indicator

studs vertical.
NOTE: Checking for bent connecting rod.
FG020402
Figure 192
4-1-119
The distance between the indicator studs on the tool illustrated
here is 75 mm. The distance between one of the indicator studs
and the measuring surface must be max. 0.1 mm when
measured using this tool. Check with a feeler gauge.
Check also whether the connecting rod is bent in an S-shape.
This is done by measuring the distance between the outside of
the connecting rod bushing and the level surface of the tool.
Turn the connecting rod around and measure the corresponding
distance. The deviation must not be greater than 0.6 mm.
NOTE: Checking whether the connecting rod is bent in an
S-shape.
FG020403
Figure 193
Crankshaft
Function
Each compression stroke acts to "slow down" the crankshaft and
each combustion stroke acts to increase its rotational speed.
The pistons and connecting rods change their direction of
motion twice per revolution.
The power impulses from the connecting rods cause torsional
oscillations in the crankshaft. These oscillations are strongest at
a specific engine speed.
Torsional oscillation is characterised as follows:
Imagine that the rear end of the crankshaft and the flywheel rotate
at a constant speed. In relation to the constant speed of the Figure 194
flywheel, the rotational speed of the front end of the crankshaft will
increase and decrease several times during each rotation.
The material is important for the crankshaft service life. Strict
requirements also apply to design and surface treatment. For
example, the surface finish of the shaft journals is vital in
preventing fatigue failure.
The bearing surfaces on the crankshaft are hardened to such a
depth that they can be reground in several stages.
The bearing shells of the main bearings and the con rod
bearings consist of three layers. The outer layer is steel, the mid
layer lead bronze, and the inner layer is lead and indium or lead,
tin and copper. The innermost layer is usually worn away during
the course of engine utilization.
Thrust washers are used for endways location of the crankshaft
at the rear main bearing. These thrust washers are available in
various thickness, keeping the axial clearance maintained after
grinding.
Figure 195
4-1-120
Removing the Crankshaft
1. Remove crankshaft gear as described in Removing the
crankshaft gear.
2. Remove crankshaft pulley as described in the work
description Removing the pulley.
3. Remove oil sump, oil pump suction pipe, ladder frame and
oil pump as described in the relevant work descriptions.
4. Remove pistons and connecting rods according to the
work description removing pistons.
5. Remove main bearing caps and main bearings.
NOTE: The main bearings and main bearing caps are
marked and must be reinstalled in the same
place.
6. Lift out the crankshaft.
FG020404
Figure 196
Checking Main Bearing Cap for M18 Main Bearing Screws

There have been instances where the heads of main bearing
cap screws break due to high load.
In case of any of these symptoms it is recommended that the
main bearing caps are checked. Remove the oil sump and
check carefully that all main bearing screws are secure. In some
cases, the screw head is in place but it has cracked and lost its
clamping force.
Replace the torsion damper when carrying out repairs as a
result of broken main bearing cap screws. The torsion damper
must be replaced because it often breaks down shortly after
replacing the main bearing cap screws.
1. Remove the main bearing caps.
NOTE: The main bearings and main bearing caps are
marked and must be refitted in the same
position.
4-1-121
2. Clamp the main bearing cap in a pillar drilling machine and
ensure that it sits straight in the vice. The complete cap
must be supported on one flat surface.
Figure 197
3. Machine the chamfer in the main bearing cap using tool A

588 971. The tool centres in the screw hole.
IMPORTANT
Ensure that the chamfer is centred. The chamfer may
be poorly centred from production.
Measure the chamfer upper diameter during machining to

avoid a chamfer which is too large.
Figure 198
Machine in small steps to the correct diameter,

23 ±0.2 mm.
Figure 199
4. Follow the description for fitting the main bearing caps.
Figure 200
4-1-122
Adjusting Main Bearing Cap for M19 Main Bearing Screws
There have been instances where the heads of main bearing
cap screws break due to high load.
In case of any of these symptoms it is recommended that the
main bearing caps are checked. Remove the oil sump and
check carefully that all main bearing screws are secure. In some
cases, the screw head is in place but it has cracked and lost its
clamping force.
Replace the torsion damper when carrying out repairs as a
result of broken main bearing cap screws. The torsion damper
must be replaced because it often breaks down shortly after
replacing the main bearing cap screws. However, this does not
apply to industrial and marine engines where the torsion damper
is fitted on the outside of the front cover.
A new improved M19 X 2.5 main bearing screw together with a
new chamfer of the holes in the main bearing caps can be used.
See illustration.
The new M19 x 2.5 Torx screws are marked by a circle.
A= Older screw head, B= New screw head
You can use the new screw with hexagonal head which is available
for the new type of main bearing cap if the new improved type of
screw with Torx head is at the end of its service life. Figure 201
Reference
Description
Number
A Old Main Bearing Cap.
B New Main Bearing Cap.
IMPORTANT
Different types of screws must not be mixed. Always use
screws of the same type and with the same length as other
main bearing cap screws in the engine. Figure 202
Replace all screws even if only one screw is broken.
1. Remove the main bearing caps.

2. Measure the chamfer upper diameter before starting
machining.
IMPORTANT
Be careful when machining the main bearing caps. A failed
and discarded main bearing cap results in renewal of the
complete cylinder block.
4-1-123
3. Clamp the main bearing cap in a pillar drilling machine and
ensure that it sits straight in the vice. The complete cap
must be supported on one flat surface.
Figure 203
4. Machine the chamfer in the main bearing cap using tool A

588 965. The tool centres in the screw hole.
IMPORTANT
Ensure that the chamfer is centred. The chamfer may
be poorly centred from production.
Figure 204
Figure 205
Measure the chamfer upper diameter during machining to

avoid a chamfer which is too large.
Machine in small steps to the correct diameter,
24 ±0.2 mm.
Figure206
4-1-124
5. Follow the description for fitting the main bearing caps.
Figure 207
Installing the Crankshaft

All parts must be cleaned before installing.
1. Place the bearing shells in the main bearing seats in the
cylinder block and in the main bearing caps. Then lubricate
the bearing surfaces with engine oil.
NOTE: The outside of the bearing shells must not be
lubricated.
2. Lift in the crankshaft.
FG020405
3. Lubricate the bolt thread and the surface of the main
bearing cap where the bolt is tightened, see illustration. Figure 208
FG020406
Figure 209
4-1-125
4. Install the main bearing caps.
NOTE: Install the main bearings and caps in the same
place as before removal.
5. Tighten the bolts for the main bearing caps.
IMPORTANT
The bolts can only be reused three (3) times.
FG020407
Check the number of punch marks on the head, if a
Figure 210
screw has three punch marks it must be replaced.
6. Mark the bolt heads with a punch mark whenever they are
tightened.
1 2 3 4
7. Install the pistons with connecting rods according to the
work description for Installing pistons.
8. Install the oil pump, oil pump suction pipe and finally the oil
sump as specified in the relevant work descriptions.
FG020408
Figure 211
Machining the Crankshaft

1. Measure the diameter of the crankshaft bearing journal
using a micrometer. Measure at several points around the
bearing journal.
If any of these diameters is lower than the minimum
indicated limit, regrinding of the crankshaft must be
considered. Refer to the dimensions under the tab
"Specification."
Oil pressure should also be checked, as it is affected by
such factors as wear in the main bearings and connecting FG020409
rod bearings. Figure 212
2. When regrinding, keep to the undersizes indicated in the

"Specification" tab. Suitable bearings are available for
these sizes.
It is important that fillet radius of the bearing journals is
correct. Use a template to check fillet radius.
3. After grinding the bearing journals, round off and polish the
oil hole openings on the bearing surfaces.
FG020410
Figure 213 Measure the Fillet Radius

Using a Gauge.
4-1-126
Removing the External Ring Gear for Balance Shaft Unit
1. Lift out the crankshaft as described.
2. Place the crankshaft in an upright position and carefully tap
with a hammer and a soft drift as illustrated. Tap all round
the ring gear so that it is not jammed.
The ring gear is fitted with a shrink fit. If the ring gear is
difficult to remove, it can be heated so that it becomes
larger and comes loose from the crankshaft.
The ring gear must not be used again but should be

scrapped.
Fitting the external ring gear for the balance shaft unit
3. Wipe clean the surface where the new ring gear will be
fitted.
IMPORTANT
The external ring gear must never become hotter than
180°C. If it becomes hotter, it must not be used.
4. Heat the ring gear on a heater plate. The external ring gear
should be heated to 160 - 170° so that it will be large
enough to fit on the crankshaft. Use an instrument to
measure the temperature.
WARNING
Remember that the ring gear will be very hot when it is
refitted on the crankshaft. Use suitable protective
equipment.
5. Fit the new ring gear on the crankshaft.

6. Refit the crankshaft according to the instructions.
4-1-127
Checking the External Ring Gear for Balance Shaft Unit
When a new external ring gear is fitted onto the crankshaft, its
mounting must be checked.
1. The crankshaft must be screwed tight when checking.
2. Fit a dial gauge as illustrated.
3. Rotate the crankshaft while checking that the external ring
gear axial run-out is not greater than 0.05 mm.
If the ring gear run-out is greater than allowed, it must be
removed and replaced with a new one.
Figure 215
Dimensions for Machining the Crankshaft
Connecting Rod Races Value (mm)

Standard, Diameter 86.978 - 87.000
Undersize 1, Diameter 86.728 - 86.750
Fillet Radius 4.8 - 5.2
Surface Quality (Ra) 0.25
Width, max. 56.05
Radial Clearance 0.051 - 0.114
Main Bearing Races Value (mm)

Standard, Diameter 107.978 - 108.000
Fillet Radius 4.8 - 5.2
Surface Quality (Ra) 0.25
Thrust Washers Value (mm)

Standard, Thickness 3.370 - 3.430
Oversize 1, Thickness 3.450 - 3.510
Axial Clearance 0.138 - 0.380
4-1-128
Flywheel
Instructions for Assembly and Adjustment of Lifting Tools

The lifting tools are secured to the component as follows.
All screws must be tightened according to standard tightening
torque, except the screws for locking the central brackets and
base bracket against the central beam. These should be
tightened to 30 Nm.
It is not permissible to use the lifting tools in any other way than
the ways set out in the following instructions.
Maintenance Instructions 30 Nm
EX1301942
Check lifting tools before use for damage, deformation and wear. Figure 216
• Test factor: 1.5 static.
WARNING
Never work or go under a vehicle not secured against
falling. There is a serious danger of crushing.
Both the chassis and moving axle suspension components
must be secured with stands to ensure absolute safety
when working under a raised vehicle.
The air bellows must be emptied before starting work.
Only move a loaded gearbox jack with the load in the lowest
possible position.
When lowering, make sure that the gearbox jack/unit or the
lifting tool goes clear of any obstructions to avoid any
damage.
Be aware of the risk of crushing when lowering the gearbox
jack and the lifting tool.
Reference
Description 2
Number 4
1 Front Sliding Bracket 7
1
2 Rear Sliding Bracket
3
3 Central Beam
4 Base Bracket
5 Supports 6
6 Adjustable Stay
7 Anti-slip Device 5 EX1301943
Figure 217
4-1-129
Preparations
A metal cover for a clutch is required in order to lift a flywheel.
Remove the pressure plate and spring from a used clutch. Save
the metal cover as a special tool for lifting the flywheel.
1. Screw the metal cover on the flywheel with its regular
screws.
2. Attach the base bracket on the gearbox jack 587 313 or
588 966.
3. Centre and tighten the central beam to the base bracket
with equal parts protruding at the front and at the back.
Figure 218
4. Attach the front sliding bracket edge-to-edge to the central

beam with the brake caliper lugs turned downwards. Push
the central beam so that the sliding bracket moves towards
the base bracket and attach the central beam to the base
bracket.
Figure 219
5. Install the left-hand and right-hand front adjustable stays

(the shorter model) on the front sliding bracket.
Pull up the stay so that the screw ends up in the groove
end and use 2 anti-slip devices on each stay.
Figure 220
4-1-130
6. Install the left-hand and right-hand rear adjustable stays
(the longer model) on the front sliding bracket. Use 2 anti-
slip devices on each stay.
Figure 221 Left-hand Rear Stay
Figure 222 Right-hand Rear Stay
7. Install the 2 upper rollers

Turn the narrow groove on the roller towards the clutch.
Install screws and support sleeves between the adjustable
stays.
Tighten the screws of the rollers and the rear adjustable
stays to the sliding bracket.
A. Turn the narrow groove on the roller towards the
clutch.
Figure 223
4-1-131
8. Slide the lift in towards the clutch so that the rollers fit
against the top edge of the clutch.
Position and adjust the lower rollers against the bottom
edge of the clutch.
Screw the lower rollers into place in the adjustable stays.
Figure 224
Removing the Flywheel

87 368
1. Remove engine speed sensor(s) in flywheel housing.
2. Remove flywheel screws.
3. Install lifting tool 99 646 and pull off the flywheel from
crankshaft using puller screws 87 368.
FG020412
Figure 225
Installing the Flywheel

1. Install two guide pins 99 478 in the crankshaft.
2. Install the flywheel on the crankshaft.
IMPORTANT
Use new hexagon screws and lubricate them with
engine oil before installing. 99 478
FG020414
3. Lock the flywheel with tool 99 411 on engines with unit Figure 226
injectors.
4. Install the engine speed sensor(s).
4-1-132
Replacing the External Ring Gear on the Flywheel
Replace the flywheel external ring gear if the gear teeth have
become so worn that starter pinion will not engage.
1. Grind a groove as deep as possible in the ring gear and
crack it open with a chisel.
Remove ring gear from the flywheel.
2. Clean the contact surfaces of the flywheel with a wire
brush.
3. Heat the new ring gear evenly around its circumference to
100°C - 150°C.
4. Lay the heated external ring gear on the flywheel so the
beveled side is facing the starter motor. Make sure the ring
gear is securely against the flywheel. If necessary, knock
down the ring gear with a plastic hammer.
5. The ring gear must not be cooled rapidly but be left to cool
in the open air.
Replacing Support Bearing

99 250
1. Remove retaining rings on both sides of the support
bearing.
2. Tap the support bearing out of the flywheel using drift 99
250.
3. Install the inner retaining ring and a new support bearing
using drift 99 250.
4. Install the outer retaining ring.
FG020416
Figure 227
Checking the Flywheel

Check the friction surface of the flywheel for heat damage.
If the friction surface of the flywheel has deep thermal cracks or
blueing that may sometimes be obvious as a movement of the
material, the flywheel should not be re-used.
Heat, caused by incorrect use of the clutch, will often lead to the
friction surface of the flywheel distorting and becoming concave. B
The concavity is not detrimental if the same flywheel and disk

are reinstalled. However, when replacing disks it is advisable to
check how deep this concavity is.
C D
If, by measuring as shown in the illustration, it is found that
dimension B is greater than 0.6 mm, there is an increased risk of
rapid disk wear in the future. A=C-D FG020417
If the distortion or wear, dimension A, is greater than Figure 228
approximately 1 mm, the flywheel must be replaced.
4-1-133
Piston
Function
There are two different types of pistons. Integrally cast
aluminium pistons and articulated pistons. Articulated pistons
are split and have an aluminium skirt and a steel crown.
One of the advantages of articulated pistons is that they
withstand more stress than conventional pistons. This allows for
a higher engine output.
EX1302085
Figure 229 Engine with Articulated piston
The combustion chamber is a recess in the piston crown. It is

bowl-shaped with a raised section in the centre.
The design of the combustion chamber affects the air rotation in
the combustion chamber.
EX1302086
Figure 230 Air Rotation in Combustion
Chamber
4-1-134
In order for the piston to run smoothly there must be a gap
between the piston and the cylinder wall. The piston therefore
has two compression rings which seal this gap and conduct the
heat from the piston.
FG020428
Figure 231 Piston Compression Rings on
Engines with Cylinder Block
The oil ring prevents lubrication oil from the crankcase getting
into the combustion chamber.
Inside the oil scraper ring there is an expander which presses
the ring against the cylinder wall. The expander is a coil spring.
The design of the piston and the piston rings is vital for the
reliability, lubrication, oil consumption and fuel consumption of
the engine.
FG020429
Figure 232 Piston Oil Scraper Ring
IMPORTANT
Mixing different piston types is not permitted. Check the
model and part number of the piston crown before fitting.
Figure 233
4-1-135
Removing the Piston
1. Remove cylinder head according to section Removing the
cylinder head.
2. On engines with scraper ring:
Remove scraper ring. "Cylinder block, Cylinder liner".
3. Drain the engine oil.
4. Remove clamp in the ladder frame for the oil level sensor
cable harness. Remove oil sump with oil level sensor.
5. Remove oil pump suction pipe. Keep the two O-rings
installed on the pipe.
6. Remove ladder frame if installed.
7. Remove piston cooling nozzle in the cylinder block on the
relevant cylinder.
IMPORTANT
Damaged piston cooling nozzles must not be
re-aligned, replace them instead. The oil jet must hit
the piston precisely. If it does not, the piston will
become overheated resulting in engine failure.
8. Remove connecting rod cap and connecting rod bearing

shells. Protect the oilway in the crankcase by winding tape
around it with the sticky side out.
Mark the piston before removing; the connecting rod is
marked. The parts must be reinstalled in the same place
and position. Lift out the piston and connecting rod.
NOTE: Always check the connecting rod as described
in Checking the connecting rod, if the cylinder
has seized, been filled with water or had a
broken valve. Bent connecting rods must not be
straightened.
Installing the Piston

1. Lubricate the piston, piston rings, cylinder liner and piston
ring compressor with engine oil.
2. Remove protection on the connecting rod race and
lubricate it.
3. Turn the piston rings so the gaps are distributed around the
piston.
Figure 234
4-1-136
4. Install the upper connecting rod bearing shell to the
connecting rod and lubricate the bearing surface.
5. Put the piston onto the connecting rod so the arrow marks
1
on the piston will face the front of the engine. Applies only
to aluminium pistons, steel pistons are symmetrical.
Place piston ring compressor 99 572 in position and push
the piston and connecting rod into the cylinder liner.
2
Reference
Description
Number FG020420
1 Piston Ring Compressor Figure 235
2 Adapter for Cylinder Liner with Scraper
If the cylinder liner has a scraper ring, adapter 99 631 must

be positioned between the cylinder liner and piston ring
compressor before the piston is slid down into the cylinder
liner. See illustration.
On an aluminum piston, the arrow on the piston must point
forward in the direction of the engine. The short end of the
connecting rod should face the engine intake manifold.
NOTE: The arrow must be facing the in the direction of
the engine (Figure 236).
6. Insert the connecting rod bearing shell in the connecting
rod cap, lubricate the bearing surface and install the
connecting rod cap the right way round. The number
markings on the connecting rod and on the connecting rod
cap must be on the same side.
7. Lubricate and screw on new connecting rod bolts. Figure 236
FG020421
8. Install the piston cooling nozzle.
IMPORTANT
Damaged piston cooling nozzles must not be
re-aligned, replace them instead. The oil jet must hit
the piston precisely. If it does not, the piston will
become overheated resulting in engine failure.
9. Install the ladder frame if applicable.

10. Install the oil pump pipe and suction pipe. Replace O-rings
on the pipe and check that no O-rings are left in the oil
pump or suction pipe.
11. Install the oil sump.
12. Install the clamp for the oil level sensor electrical cables in
the ladder frame.
13. Engines with scraper ring: Install the scraper ring in the
cylinder liner.
14. Install the cylinder head. Tighten the cylinder head bolts
according to work description.
Installing the cylinder head.
4-1-137
Replacing Piston on Connecting Rod, Replacing Piston Rings
1. Place the connecting rod in a vice with soft jaws. Remove
retaining rings for the gudgeon pin.
FG020424
Figure 237
2. Push out the gudgeon pin using drift 87 362.
87 362
FG020425
Figure 238
3. Remove piston rings using tool 587 309. Take care not to
587 309
scratch the piston skirt surface with the piston rings.
4. It is possible that graphite coating will disappear after
washing graphite coated pistons in an industrial washing
machine. This does not matter after they have been in use
for a while. However, new pistons must be washed with
some care with white spirit.
5. Clean the piston and its rings thoroughly without scratching
the sides of the ring grooves. Clean the oil holes in the
piston using a suitable drill bit. FG020426
6. Make sure the piston ring gaps do not exceed the Figure 239
permitted limit. Place the piston rings inside the cylinder
liner and measure the gap with a feeler gauge. Permitted
gap according to the table below.
Compression Ring 1 (upper) 0.9 mm

Compression Ring 2 (lower) 1.1 mm
Oil Scraper Ring 0.8 mm
4-1-138
7. Install the piston rings using tool 587 309.
Pistons rings marked with TOP must be turned with TOP
face up.
FG020428
Figure 240 Compression Rings on Engines
Figure 241 Oil Scraper Ring FG020429
8. Oil all bushings, gudgeon pinholes and the gudgeon pin

before assembling.
9. Install the piston skirt to the piston crown and install one of
the gudgeon pin retaining rings.
10. Put the piston onto the connecting rod so the arrow marks
on the piston will face the front of the engine. Applies to
aluminum pistons only, steel pistons are symmetrical.
NOTE: The arrow must be facing the front of the
engine. The short end of the connecting rod
must be on the left-hand side (Figure 242).
11. Insert the gudgeon pin using tool 87 362 and install the
second retaining ring for the gudgeon pin.
FG020421
Figure 242
4-1-139
Roller Tappet
Checking the Push Rod

NOTE: OId and new pushrods may be mixed on the same
cylinder head.
Identifying the Type of Pushrod.

Version 1 has a diameter of 10.15 mm at measuring point A.
Version 2 has a diameter of 11.10 mm at measuring point A. A
EX1301953
Figure 243
Installing the Roller Tappet
IMPORTANT
Lubricate the roller tappets with engine oil.
Check and Clean the Oil Way
EX1302088
Figure 244
4-1-140
Tightening Sequence on Engine
Figure 245
Intake Manifold
Installing Intake Manifold
Tightening Sequence
Intake manifold for engines 2 4 6 8 10 12 14 16 18 20
1 3 5 7 9 11 13 15 17 19
FG020255
Figure 246
Power Take Off
Overview 7
Reference
Description 3
Number
6
1 Gear Housing 1
2 Bolt
2
3 Roller Bearing
4 Nilos Ring
5 Nilos Ring
8
6 O-ring 5
7 Gear Assy
9 4
8 Bolt EX1302029
9 Flange Nut Figure 247
Use thread-locking fluid on the set screw (2).
4-1-141
Torsion Damper
Description
The torsion damper is a heavy disc which is positioned at the
very front of the crankshaft to dampen torsional vibrations.
Overview
Figure 248
Removing the Torsion Damper
Torsion Damper, Straight Engines with Geared-up Fan

1. Unscrew the shaft journal from the torsion damper so that
the outer pulley and shaft journal are removed as a unit.
The pulley and shaft journal do not need to be separated.
Figure 249
2. Lift the torsion damper off the crankshaft.
4-1-142
Belt Circuit
Description
The belt transmission is used to drive the coolant pump, AC
compressor, alternator and fan.
Function
Outer belt transmission for increased fan gear ratio. 2
Reference 3
Description
Number
1 Crankshaft Pulley 4
2 Fan Pulley
3 Idler Roller
1
4 Belt Tensioner
EX1302090
Figure 250
Reference 2 6
Description
Number
5
1 Crankshaft Pulley
2 Idler Roller
3 Alternator, 100 A 4
4 Belt Tensioner
5 Coolant Pump 3
6 Aircon Compressor
Replacing the Drive Belt 1

EX1302164
Figure 251
WARNING
Remember that engine is hot just after being turned off.
WARNING
Rotating pulleys and belts can cause entanglement hazard.
Keep hands,arms and tools away.
The automatic belt tensioner must never be readjusted, opened,

repaired or modified in any way. If the belt tensioner does not
provide sufficient tensioning of the poly-V-belt, it must be
replaced.
4-1-143
Removing the Drive Belt
1. Install a ratchet handle to the outer belt transmission belt
tensioner.
IMPORTANT
The belt tensioner should only be moved in the
direction which releases belt transmission tension.
The belt tensioner can be damaged if the belt
tensioner is tightened in the incorrect direction.
2. Release tension on the outer belt transmission poly-V belt. EX1302165

Make sure the belt tensioner does not stick or jerk by Figure 252
letting it return to its original position. Pull and release a
couple of times.
Replace the belt tensioner if it sticks or jerks.
3. Release the tension sufficiently so the belt tensioner can
be locked by inserting an 8 mm screw in the designated
hole.
IMPORTANT
The screw used to lock the belt tensioner in the
relieved position must be pressed in far enough that it FG020431
reaches the bottom of the belt tensioner. Figure 253
4. Make sure that belt tensioner is locked and that poly-V belt
has been released from tension.
5. Remove outer poly-V-belt.
6. Install a ratchet handle and relieve the tension on the
poly-V-belt of the inner belt transmission.
7. Carefully release the belt tensioner back into position and
remove ratchet handle.
Installing the Drive Belt
EX1302165
Figure 254
4-1-144
NOTE: Inner belt transmission with one alternator and
one AC compressor (Figure 251).
1. Check that rollers in the belt transmission rotate freely,
without jamming or making noise.
2. Slip the poly-V belts over the fan.
3. Inner belt transmission
NOTE: The inner belt is always longer than the outer one.
Install the inner belt transmission poly-V-belt onto its
pulleys; see Figure 255.
IMPORTANT
Make sure the drive belt is located correctly in all the
EX1302166
belt pulley grooves before starting to tighten belt.
Figure 255
4. Tighten the inner belt transmission carefully.
5. Outer belt transmission
NOTE: Check that poly-V-belt is correctly routed on all 2
pulleys and idler rollers.
3
Install the poly-V belt to the outer belt transmission pulleys
and idler rollers, see Figure 256.
4
6. Use the ratchet handle to relieve the tension from the
screw used to secure the belt tensioner. Keep hold of the
ratchet handle and pull out the screw. 1
7. Tighten the outer belt transmission carefully. EX1302090
Figure 256
IMPORTANT
Make sure the drive belt is located correctly in all the
belt pulley grooves before starting to tighten belt.
IMPORTANT
The belt tensioner should only be moved in the
direction which releases belt transmission tension.
The belt tensioner can be damaged if the belt
tensioner is tightened in the wrong direction.
8. Check that poly-V-belt is correctly routed on all pulleys and

idler rollers.
4-1-145
Checking the Poly-V-Belt
Check poly-V-belt for cracks and wear as follows:
FG020434
Figure 257
NOTE: The poly-V-belt has cracks and must be replaced.
FG020435
Figure 258
NOTE: Poly-V-belt beginning to show signs of wear. The

Poly-V-belt may be reinstalled.
FG020436
Figure 259
Remove Bearing in the Belt Pulley

1. Install the tommy bar to the outer belt transmission belt
tensioner.
2. Relieve the tension sufficiently so the belt tensioner can be
locked by inserting an 8 mm screw in the designated hole.
4-1-146
4. Install a ratchet handle to the inner belt transmission belt
tensioner.
5. Relieve the tension sufficiently so the belt tensioner can be
locked by inserting an 8 mm screw in the designated hole.
7. Lift the poly-V belts off the pulley.
FG020440
Figure 260
8. Undo the center screw and remove washer.

9. Detach the pulley from the engine. 99 135
FG020441
Figure 261
10. Remove shaft journal. Use special tool 99 135.
FG020442
Figure 262
11. Remove retaining ring. Use a retaining ring pliers.
99 132
IMPORTANT
The bearing must be pressed out with the screws
facing downwards and the flange upwards. Otherwise,
the pulley will be damaged.
12. Press out the bearing. Use special tool 99 132.

FG020443
Figure 263
4-1-147
Install the Bearing in the Belt Pulley
1. Install the new bearing. Use special tool 98 290.
98 290
FG020444
Figure 264
2. Install the retaining ring. Use a retaining ring pliers.
IMPORTANT
You must rotate the pulley as you press the shaft
journal on, or the bearing will be damaged. Rotate the
pulley approximately 20 turns.
FG020442
Figure 265
3. Install the shaft journal. Use special tool 99 133. Rotate the
pulley 20 times during installing.
99 133
4. Install the belt pulley on the engine. Tighten the screws.
x 20
5. Install the screw and washer. Rotate the pulley when the
screw is tightened.
FG020445
Figure 266
Replacing the Driver

1. Relieve the load on the outer belt transmission with the belt
tensioner.
2. Remove fan, belt pulley, spacer and screw from the driver.
3. Install pullers 587 318 and 587 319 as illustrated.
FG020450
Figure 267
4-1-148
4. Install support drift 98 575 in the center as illustrated.
5. Pull off the driver.
FG020451
Figure 268
6. Press a new driver with bearing onto the shaft.

7. Screw on a 110 mm long M14 screw with washers through
drift 99 452.
8. Tighten the screw so the driver is pressed onto the shaft.
FG020452
Figure 269
9. Switch to a 75 mm long M14 screw and tighten the driver

until it reaches the bottom of the shaft.
FG020453
Figure 270
10. Tighten the driver.

11. Install the pulley and spacer on the driver.
12. Install the outer belt transmission poly-V-belt.
13. Install the fan on the spacer.
FG020454
Figure 271
4-1-149
Balance Shaft Unit
Description
The balance shaft unit counteracts vibrations which arise in the
engine.
Location
The balancer shaft unit is mounted underneath the cylinder
block.
Figure 272
4-1-150
Overview
1C
1A
11 15
1B 1B 14
12
1
15
10
13
8
8A 11
10
1C
1C
1D
16
Reference Reference
Number Number
1 Balancer Shaft Frame 10 Bearing
1A Pin 11 Bearing
1B Plug 12 Thrust Bearing
1C Guide Sleeve 13 Gear
1D Screw 14 Gear
8 Balancer Shaft 15 Screw
8A Plug 16 Screw
4-1-151
Function
In an engine with five cylinders, three cylinders fire on one
rotation and two on the other rotation. This causes imbalance in
the engine, which generates vibration. To counteract this
vibration the engine has a balancer shaft unit.
The balancer shaft unit comprises, in simple terms, a balancer
shaft frame and two balancer shafts. The balancer shafts rotate
at double the crankshaft speed in opposite directions and they
are driven by an external ring gear which is fitted on the
crankshaft. When the shafts rotate they generate forces which
counteract the engine vibration.
The balance shafts are lubricated by a duct through the cylinder
block which connects the balance shaft unit to the rest of the
lubrication system.
It is important for the balancer shaft unit to be adjusted
according to the instructions. An incorrectly adjusted or
damaged balancer shaft can cause significant vibration in the
engine and vehicle. Vibration increases the load on the vehicle
and can damage the engine and vehicle. In addition, vibration is
very uncomfortable for the driver and passengers.
Removing the Balance Shaft Unit

Dismantling of the balance shaft unit can be facilitated by
loosening the bearing cap bolts before removing the balance shaft
unit from the engine. The bearing cap screws must not be totally
undone.
1. Remove the oil sump.
2. Remove the oil pump and the oil strainer.
3. Remove the balancer shaft unit.
There is no need to loosen the bearing cap screws if no
work is to be carried out on the balancer shaft unit.
The balancer shaft unit may get jammed on the guide pins.
Tap lightly with a rubber mallet to release the balancer
shaft unit.
WARNING
Remember that the balancer shaft unit is heavy.
Dismantling the Balance Shaft Unit

1. Remove the bearing caps and bearings.
If the bearings will be reused, they must be refitted in the
same place.
2. Remove the balancer shafts.
Mark the balance shafts so that they can be refitted in their
original positions.
4-1-152
Assembling Balance Shaft Unit
IMPORTANT
Make sure that the bearing surfaces are clean before the
balancer shafts are refitted.
When replacing balancer shaft bearings, all bearings
should be replaced at the same time.
IMPORTANT
When the balancer shaft unit is refitted, the bolts should be
bolted back in a specific order. It is important to observe
this to minimise the risk of stresses in the balancer shaft
unit.
NOTE: Check that the balancer shafts rotate easily after

tightening each bolt. Finish torque tightening all the
bolts before tightening the bracket.
NOTE: When replacing bearings, all bearings in the balancer
shaft unit should be replaced at the same time.
1. Check that the balancer shaft frame is level.
If the balance shaft frame is not level, the caps should only
be loosely fitted on the balance shaft frame. When the
balancer shaft frame is fitted to the engine, it will be
levelled and the caps can be tightened.
2. Fit the thrust bearings.
3. Fit the balancer shafts.
Make sure that the bearing surfaces are clean before they
are refitted.
4. Fit bearing caps and bearing halves. Figure274
IMPORTANT
The bolts must be tightened in the correct order, see
illustration. The caps are marked with L and R so that they
can be positioned correctly.
5. Check the balancer shafts.

There should be a slight axial play and the shafts must
rotate easily.
Permissible limits for bearing play:
• Axial: 0.18 - 0.30 mm
• Radial, both sides: 0.026 - 0.081 mm
4-1-153
Installing the Balance Shaft Unit
IMPORTANT
When the balancer shaft unit is refitted, the bolts should be
bolted back in a specific order. It is important to observe this
to minimise the risk of stresses in the balancer shaft unit.
1. Turn the engine so that TDC-Down is visible in the lower

inspection window.
2. Fit the balancer shaft unit and screw into place.
The balancer shaft unit has a number of guide pins which
should be fitted into the specified slots in the cylinder block.
Screw on the bolts in a specific order, see illustration A. If
they are screwed back in the wrong order, stresses may
occur in the balancer shaft unit which will cause the
balancer shafts to seize.
EX1301882
3. Remove the balancer shaft gears. Figure 275
Check how the balancer shaft gears are located before
removing them. These are marked L and R, and there is
corresponding marking on the bearing cap.
Tap carefully with a rubber mallet if they are jammed on.
4. Reset the balancer shafts.
Reset the balancer shafts by inserting a drift in the
resetting holes. Both balancer shafts must be reset at the
same time, see illustration B.
A suitable drift should be 150 mm long and have a
diameter of 6 mm.
5. Clean the tapered joints of the balancer shafts.
Wipe clean the surface where the balancer shaft gears
were fitted. EX1301883
Figure 276
6. Refit the balancer shaft gears.

Make sure that the balancer shaft gears are fitted correctly.
They are marked L and R, and the corresponding marking
can also be found on the bearing cap. See illustration C.
7. Remove the drift.
IMPORTANT
Do not forget to remove the drift from the resetting EX1301884
holes. Figure 277
8. Fit the oil pump and oil strainer.

9. Fit the oil sump.
4-1-154
Timing Gear
Overview
3 8
3B 8B 15
3A 8A
3C 8C
3D 8D
14
13
1
21
19 2
20 23
17 23D
23E
23A 23C
18
23B
22
29
31
37
36
31C
31D
31B
Figure 278 31A EX1302093
Reference Reference
Number Number
1 Camshaft 20 Washer
2 Pin 21 Flange Screw
3 Shaft Assy 22 Crank Shaft Gear
3A Roller Tappet 23 Intermediate Gear Assy
3B Sleeve 23A Gear
3C Retaining Ring 23B Shaft
3D Sleeve 23C Bearing
8 Shaft Assy 23D Snap Ring
8A Roller Tappet 23E Sleeve
8B Sleeve 29 Screw
8C Retaining Ring 31 Gear Assy
8D Sleeve 31A Shaft
13 Flange Screw 31B Bearing
14 Screw 31C Snap Ring
15 Pushrod 31D Sleeve
17 Camshaft Gear 36 Screw
18 Screw 37 Washer
19 Flange Guide
4-1-155
Function
The timing gears are located at the rear end of the engine.
Important components such as the unit injector and valve
mechanism require precise control. They are attached to the
rear end of the crankshaft, close to the flywheel, where the
crankshaft rotation is the smoothest.
The crankshaft gear drives two intermediate gears and the oil
6
pump gear. One intermediate gear drives the camshaft, fuel
pump and hydraulic pump. The other intermediate gear drives
the power take-off and air compressor. 5
The camshaft rotates at half the speed of the crankshaft. 7
4
Reference
Description
Number 3
1 Oil Pump Gear
2 Crankshaft Gear 2
3 Intermediate Gear
4 Hydraulic Pump Gear 1 8
5 Fuel Pump EX1302094
6 Camshaft Gear Figure 279
7 Power Take-off
8 Compressor Gear
To facilitate assembly, the gears have markings, either on a

tooth or in a tooth gap.
Figure 280
Removing the Intermediate Gear

The timing gears consist of one or two intermediate gears
depending on the design. The gears are removed in the same
way.
1. Turn the crankshaft so cylinder number 1 is close to TDC.
Use tool 99 309 and a locking bar on the flywheel starter
gear. 99 309
FG020456
Figure 281
4-1-156
Removing the flywheel. min 20

4. Manufacture a thread block according to the sketch. M10 15 - 20
Figure 282 FG020457
5. The shaft on which the gear is located has a groove. Install

puller 587 526, thread block and impact drift 99 074. Pull
off the gear and shaft.
587 526
99 074
IMPORTANT
After removing the intermediate gear, neither the
camshaft nor the crankshaft must be rotated. This can
damage the pistons and valves caused by
interference. Figure 283 FG020458
Installing Intermediate Gears

1. Check that cylinder number 1 is close to TDC. The
markings on the camshaft gear and crankshaft gear must
point towards the center of the intermediate gear.
Figure 284 FG020459
2. Install the intermediate gear against the camshaft gear and

the crankshaft gear so the markings point towards each
other.
3. Install the second intermediate gear.
4. Tighten the screws on the intermediate gears.
description installing the flywheel housing.
6. Install the flywheel as described in the work description
FG020460
Figure 285
4-1-157
Replacing the Bearing in the Intermediate Gear for the
Compressor
1. Remove retaining ring.
2. Press the bearing packet out of the gear.
3. Press the shaft journal out of the bearing.
4. Press the shaft journal into a new bearing using tool 87
348. Do not press on the outer race.
5. Press the ring on the shaft journal.
FG020463
6. Press the bearing packet into the intermediate gear. Use Figure 286
tool 87 592.
7. Install the retaining ring.
Replacing the Bearing in the Intermediate Gear for the

Camshaft
1. Press the shaft out of the bearing.
2. Press the bearing inner race shell from the shaft and
remove retaining ring.
3. Place the removed bearing inner race in the bearing and
press out the bearing using drift 87 348.
4. Press a new bearing onto the shaft journal using drift 87 87 592
348.
NOTE: Do not press on the outer race.
5. Press the bearing and shaft journal into the intermediate
gear using drift 87 592.
6. Install the retaining ring.
7. Press the spacing ring onto the shaft journal. Ensure that FG020464
shaft journal is on the press table. Figure 287
Removing the Camshaft Gear

gear.
99 309
Removing the flywheel.
4. Remove intermediate gear. FG020456
Figure 288
IMPORTANT
damage the pistons and valves caused by
interference.
4-1-158
FG020465
Figure 289
Installing the Camshaft Gear

1. Install the intermediate gear as described in the work
description Installing the intermediate gear on page -156.
3. Install the flywheel housing according to the section
Installing the flywheel housing.
4. Install the flywheel according to the section Installing the
flywheel.
FG020466
Figure 290
Removing the Crankshaft Gear

gear.
99 309
removing the flywheel.
description removing the flywheel housing.
4. Remove intermediate gear.
FG020456
Figure291
IMPORTANT
cause pistons and valves to collide and be damaged.
4-1-159
5. Remove crankshaft gear.
FG020467
Figure 292
Installing the Crankshaft Gear

1. Install the crankshaft gear.
2. Install the intermediate gear, refer to the work description
for Installing the intermediate gear on page -156.
description installing the flywheel housing.
4. Install the flywheel as described in the work description for
installing the flywheel.
FG020468
Figure 293
4-1-160
LUBRICATION SYSTEM
General Information
Components in the lubrication system
Reference
Description
Number
1 Oil Strainer
2 Oil Pump
3 Safety Valve (Located in the Oil Pump)
4 Oil Cooler
5 Centrifugal Oil Cleaner
Relief Valve
6
(Located in the Oil Cleaner Housing)
7 Oil Filter Figure 294
Piston Cooling Valve
8
(Located in the Oil Cooler Housing)
Oil Pressure Sensor
9
(Located in the Oil Filter Housing)
Schematic diagram of the oil circulation in the lubrication system
Reference
Description 2 3 D 4 8 B A7 9
Number
1 Oil Strainer
2 Oil Pump
3 Safety Valve
4 Oil Cooler 6
5
6 Relief Valve E
7 Oil Filter and Bypass Valve 1 EX1301997
8 Piston Cooling Valve Figure 295
9 Oil Pressure Sensor
Oil to Bearings, Turbocharger and for
A
Engine also Balance Shaft Unit
B Oil to Piston Cooling Nozzles
D Oil Filter Housing/Oil Cooler Housing
E Oil Cleaner Housing
4-1-161
The oil pump draws lubrication oil from the oil sump by the oil
strainer.
After the oil pump, the lubricating oil passes a safety valve. If the
oil pressure exceeds 9.5 bar, the safety valve opens and feeds
the lubricating oil back to the oil sump. If the oil pressure is too
high, the oil pump and other lubrication system components may
be exposed to severe stress.
The lubrication oil then passes through the oil cooler. Some of
the lubrication oil is passed through the centrifugal oil cleaner.
After cleaning, the oil is fed back to the oil sump.
The rest of the lubrication oil passes through a relief valve which
regulates the pressure in the oil system. Excess lubricating oil is
drained back to the oil sump.
EX1302096
The lubrication oil passes on to the oil filter for cleaning.
Figure 296
Lubrication oil reaches the camshaft bearings and crankshaft

main bearing by ducts in the cylinder block.
Ducts in the crankshaft lead the lubrication oil to the connecting
rod bearings.
A duct leading from the main duct takes lubrication oil to the
rocker arms.
The channel is constantly pressurised. The oil is fed to the roller
tappet shafts by grooves in the camshaft bearing. The roller
tappet shafts have drilled ducts for lubricating the roller tappets.
EX1302097
The pistons are cooled by the lubrication oil. Oil is sprayed up Figure 297
under the piston crown through special nozzles, one for each
cylinder.
The piston cooling valve opens at 1.7 - 2.2 bar.
There is no piston cooling at low speed (Idling).
EX1302098
Figure 298
4-1-162
Centrifugal Oil Cleaner
Location
EX1400557
Figure 299
Function
The centrifugal oil cleaner has a rotor which is made to rotate by
the force of the jet of lubrication oil spraying through two nozzles
in the bottom of the rotor.
Dirt particles are thrown against the rotor wall where they stick
and form a solid coating.
The centrifugal oil cleaner should be dismantled and cleaned in
accordance with the intervals specified.
A relief valve, regulating the pressure in the lubrication system,
is located in the centrifugal oil cleaner housing. Excess
lubricating oil is drained back to the oil sump.
Cleaning the Centrifugal Oil Cleaner

There must be a certain amount of deposited dirt in the rotor
bowl during cleaning of the centrifugal oil cleaner. If this is not
the case, this indicates that rotor may not be rotating.
The cause must be established immediately.
If the dirt deposit exceeds the permitted thickness of deposits at
the recommended intervals, the rotor bowl must be cleaned
more often.
1. Clean the cover unscrew the nut securing the outer cover.
2. Let the oil run out from the rotor.
3. Lift out the rotor. Wipe off the outside. Undo the rotor nut x 1.5
and screw it about one and a half turns to protect the
bearing.
FG020470
Figure 300
4-1-163
4. If the rotor nut is difficult to get loose, turn the rotor upside
down. Fasten the rotor nut in a vice. Turn the rotor one and
a half turns counterclockwise by hand or use an M20 bolt M20
as illustrated.
x1.5
IMPORTANT
The rotor must not be put in a vice. Never strike the
rotor bowl. This can cause additional damage
resulting in imbalance. FG019028
Figure 301
5. Remove rotor cover by holding the rotor in both hands and

tapping the rotor nut against the table. Never strike the
rotor directly as this can damage its bearings.
FG020471
Figure 302
6. Remove the strainer from the rotor cover. If the strainer is

stuck, insert a screwdriver between the rotor cover and
carefully prise them apart.
EX1301958
Figure 303
7. Remove the paper insert and scrape away the remaining

dirt deposits inside the rotor cover. If the deposits are
thicker than 28 mm, the centrifugal oil cleaner must be
cleaned more often.
EX1301959
Figure 304
4-1-164
8. Wash all parts.
Figure 305
9. Check the 2 nozzles on the rotor. Ensure that they are not
blocked or damaged. Replace any damaged nozzles. 1
10. Check that the bearings are undamaged.

11. Install a new paper insert on the inside of the rotor cover as
illustrated below.
2 3 4
EX1301989
Figure 306
12. Install the strainer onto the rotor.

13. Install a new O-ring by sliding it over the strainer.
Figure 307
4-1-165
14. Refit the rotor cover. Ensure that the O-ring is not outside
the cover.
15. Tighten the rotor nut by hand.
16. Check that the shaft is not loose. Secure with thread-
locking fluid 561 200 if it is loose. First clean thoroughly
using a suitable solvent. Then tighten the rotor shaft using
socket wrench 99 520.
17. Refit the rotor and rotate it by hand to make sure it rotates
easily.
EX1301991
Figure 308
18. Install a new O-ring in the cover. Refit the cover and
tighten the lock nut.
EX1301992
Figure 309
Operational Testing of the Centrifugal Oil Cleaner

Operational testing need only be carried out if there is a
suspicion that the centrifugal oil cleaner is not working properly.
For example, if there is an abnormally small amount of deposit in
the centrifugal oil cleaner in relation to the distance driven.
The rotor rotates very fast and should continue to turn when the
engine has stopped.
1. Run the engine until it reaches normal operating
temperature.
2. Stop the engine and listen for the rotor. Use your hand to
feel if the filter housing is vibrating.
EX1301993
Figure 310
3. If the filter housing is not vibrating, dismantle and check the

centrifugal oil cleaner.
Specification
Permitted thickness of deposits on the walls of the cover
Permitted thickness of deposits on the

28 mm
walls of the cover
4-1-166
Measuring the Oil Pressure
Oil Pressure
When Idling at least 1.5 bar (22 psi)
at 1000 rpm and Engine Warm at least 2.5 bar (36 psi)
at 1900 rpm and Engine Warm 5 ±1 bar (73 ±14 psi)
NOTE: Oil pressure is greatly affected by oil temperature.

The specified oil pressure values apply to a warmed-
up engine. It is not possible to give precise values
since an engine subject to heavy loading may have a
significantly higher oil temperature when running than
an engine with a low engine load that spends most of
its time idling. Also bear in mind that the coolant
temperature rises faster than the oil temperature
when warming up the engine.
1. Remove oil pressure sensor.
2. Install the measuring equipment with union and adapters
according to the illustrations.
3. Install the oil pressure sensor.
4. Start the engine and read off the oil pressure. If the oil OIL
M14x1.5
pressure deviates from the above specifications, check
that the engine has a normal operating temperature.
99 412
FG020475
Figure 311
14
OIL
Figure 312 FG020476
FG020477
Figure 313
4-1-167
Oil Cooler
Function
All the oil flows through the oil cooler and is cooled by the
coolant in the cooling system.
An opening valve for piston cooling is located in the oil cooler
housing on engines.
Principle drawing of the water and oil flows for oil coolers on
engines
EX1302100
Figure 314
Leak Testing the Oil Cooler

1. Remove oil cooler complete with cover from the engine.
2. Remove oil filter housing from the oil cooler cover.
3. Clean the oil cooler and the cover. Install special tool 99
484 with existing O-ring.
4. Connect special tool 99 405.
FG020486
Figure 315
5. Lower the oil cooler complete with the housing into a water
bath. Raise the pressure to 2 bar using the handle.
Maintain the pressure for at least one minute.
6. Where there is leakage, replace the parts which leak and
perform the test one more time.
7. Install the oil cooler.
8. Install the oil filter housing.
FG020487
Figure 316
4-1-168
Removing the Oil Cooler
2. Remove turbocharger and exhaust brake. 2
3. Remove hose and coolant pipe (1) from the water-cooled
EGR cooler.
5 1 3 4 WL1400046
Figure 317
4. Drain the oil filter Cover (2) by lifting out the filter.
5. Undo the clamp of the turbocharger cable harness (3).
6. Remove oil pressure sensor (4) and coolant temperature
sensor.
7. Remove oil filter housing (6). The turbocharger delivery
pipe will come with it.
8. Remove compressor hose and the lower coolant hose (7).
9. Remove engine oil cooler cover (8).
8 7 6
WL1400047
Figure 318
4-1-169
Installing the Oil Cooler
1. Clean the gasket faces on the cylinder block and oil cooler
cover.
2. Install the oil cooler cover (1) with a new gasket.
3. Install the lower coolant hose (2).
4. Install the oil filter housing (3) with a new gasket and new
oil filter.
1 2 3
WL1400048
Figure 319
5. Install the clamp of the turbocharger cable harness (4).

6. Install the oil pressure sensor (5) and the coolant
temperature sensor (6).
7. Install the hose and coolant pipe (7) on the water-cooled
EGR cooler.
8. Install the turbocharger.
9. Fill and bleed the cooling system.
6 7 4 5
WL1400049
Figure 320
4-1-170
Oil Filter
Replacing the Oil Filter
IMPORTANT
When replacing the oil filter, the centrifugal oil cleaner must
be cleaned.
If the centrifugal oil cleaner is not cleaned, the oil filter will
quickly plug up, increasing flow resistance in the filter. If
this happens, an overflow valve in the filter retainer will
open to let the oil bypass the filter without being cleaned.
1. Unscrew the filter cover with a closed tool with hexagon

driver socket 587 637.
IMPORTANT
Do not use an adjustable wrench or other open tool as
there is a risk of damaging the filter cover.
2. Lift out the filter housing cover with filter. The filter housing
will drain automatically once the filter has been removed. FG020493
Figure 321
3. Detach the old filter from the cover by holding the cover
and carefully tapping the entire filter against something
hard. Remember there will be oil splashes.
4. Assemble the new filter and tighten the filter cover.
FG020494
Figure 322
4-1-171
Oil Pump
Overview
7
3
9
1 6
4 FG020495
Figure 323
Reference Reference
Number Number
1 Oil Pump 6 Flange Bolt
2 Flange Bolt 7 Pipe
3 Guide Sleeve 8 O-ring
4 Flange Bolt 9 O-ring
5 Suction Pipe
Function
The oil pump is a gear pump driven by the crankshaft gear and
generates the pressure necessary for the lubricating oil to reach
all lubrication points.
The oil pressure must be high enough to ensure that each
lubrication point receives a sufficient amount of oil for lubrication
and cooling.
Oil Pump Engines
IMPORTANT
In the event of leakage or a fault with the oil pump, it must
not be overhauled but replaced completely.
4-1-172
Removing the Oil Pump 5
1. Drain the engine oil.
2. Remove the oil sump. 7
3
3. Remove the suction pipe (5). 9
1
Remove the oil pipe (7) between the oil pump and suction 6
pipe.
8
Remove the oil pump. 2
4 EX1302101
Figure 324
Installing the Oil Pump

NOTE: The washing water must be disposed of in
compliance with the relevant national or local
regulations.
IMPORTANT
Check and clean the suction strainer and oil pipe. Replace
all gaskets and O-rings.
1. Install the oil pump onto the cylinder block.

2. Install the oil pipe (7) between the oil pump and suction
strainer.
3. Install the suction pipe (5).
4. Install the oil pump.
5. Fill with engine oil.
4-1-173
Oil Sump
Parts List
6
7
3
2
8
EX1302001
Figure 325
Reference Reference
Description A Description A
Number Number
1 Oil Sump 1 5 Flange Screw 24
2 Thread Insert 1 6 Sealing Washer 1
3 Thread - Locked Fluid rq 7 Magnetic Plug 1
4 Gasket 1 8 Magnet 1
4-1-174
Tightening Sequence
11 7 3 1 5 9
15 13
22 17
23 21
19 20
18 16
14
16
10 6 2 4 8 12
EX1302003
Figure 326
Oil Pressure Sensor
Symbol
FG020502
Figure 327
Location
T5
FG020503
Figure 328
4-1-175
Function
The engine control unit reads the voltage from the sensor.
In the case of some faults when the signal voltage from the
sensor has been outside a certain range, the oil pressure gauge
will show 0 bar even though the oil pressure is higher than this.
The oil pressure lamp will not light up until the oil pressure has
moved outside the permitted pressure range.
The engine control unit expects a certain oil pressure depending
on the engine speed.
Below 1000 rpm, the oil pressure should be at a certain level.
Over 1000 rpm the oil pressure should be at a higher level in
order to provide sufficient oil pressure for piston cooling, etc. If
the oil pressure is below the permitted value, the oil pressure
lamp will light up. The oil pressure lamp therefore lights up at
different pressure levels depending on the engine speed.
NOTE: The bead of silicone should be approximately 10 mm
long when it covers two interfaces and approximately
5 mm long when it covers one interface, see
illustration.
Figure 329
Troubleshooting Chips Found in the Engine
Figure 330
4-1-176
Chips around the oilway for the cylinder head valve train
Figure 331
Cause
Possible Causes of Chips Inside the Engine

• Timing gear - gears and bearings
• Valve train - especially camshaft, rocker arms and roller
tappets
• Connecting rod bearings and main bearings - not
magnetic, so will not be found on the magnetic plug
• High pressure pump
• Connecting rod, axial wear
• Connecting rod, the smaller bearing bush at the end of the
connecting rod
Troubleshooting
If chips are discovered, for example, in the engine oil, oil sump,
engine oil filter, centrifugal oil cleaner or on the drain plug, there
is a fault in the engine. Chips act as an internal abrasive and will
ruin the engine. Always determine the cause of chips found
inside the engine. Clean the parts that are to be reused and
rectify any faults.
Magnetic chips are metal particles caused by excessive wear in,
for example, gears, shafts, pistons and cylinder liners.
Because chips from bearings are not magnetic, they do not get
caught by the magnetic drain plug.
A failed ceramic rod inside the high pressure pump will result in
white ceramic material appearing among the metal chips.
IMPORTANT
When checking the oil filter: Remove the complete oil filter
housing in order to stop any chips from entering the clean
side. Lift out the filter housing cover with filter element.
Detach the old filter and check for chips on the inside and
the outside of the filter. If there is only a small amount of
chips, clean the oil filter housing and fit a new oil filter.
4-1-177
See the components in the lubrication system in the illustration
below.
NOTE: Air compressor, high pressure fuel pump and
crankcase ventilation centrifugal oil separator are not
part of the illustration.
Reference
Description
Number
1 Oil Strainer
2 Oil Pump
3 Safety Valve (Located in the Oil Pump)
4 Oil Cooler
Relief Valve
6
(Located in the Oil Cleaner Housing)
7 Oil Filter Figure 332
Piston Cooling Valve
8
(Located in the Oil Cooler Housing)
Oil Pressure Sensor
9
(Located in the Oil Filter Housing)
Outline Diagram of the Oil Circulation in the Lubrication System

NOTE: Air compressor, high pressure fuel pump and
crankcase ventilation centrifugal oil separator are not
part of the illustration.
Reference
Description 2 3 D 4 8 B A7 9
Number
1 Oil Strainer
2 Oil Pump
3 Safety Valve
4 Oil Cooler 6
5
6 Relief Valve E
7 Oil Filter and Bypass Valve 1 EX1301997
8 Piston Cooling Valve Figure 333
9 Oil Pressure Sensor
Oil to Bearings, Turbocharger and for
A
Engine also Balance Shaft Unit
B Oil to Piston Cooling Nozzles
D Oil Filter Housing/Oil Cooler Housing
E Oil Cleaner Housing
4-1-178
Checking for Lubrication
1. Check for lubricating oil filter blockage. Does the filter
contain a small or large amount of chips?
2. Check the relief valve B under the cover of the lubricating
oil filter holder A. If the lubricating oil filter is blocked and
the relief valve has opened and allowed unfiltered oil to
flow through, the whole engine is contaminated by chips. If
it is determined that the lubricating oil filter has been
filtering the oil correctly, the oil sump, oil pump and
centrifugal oil cleaner must be cleaned and checked.
Reference
Description
Number
A Cover
B Valve Figure 334
C Spring
3. Check the centrifugal oil cleaner. Can the rotor rotate in the
rotor housing? Is the bearing bush round or oval (very
worn)? Is the relief valve stuck or is it fully functional?
4. Check the connecting rod bearings and crank pin. Are the
bearings worn (surface layer worn through and bearing
bronze visible)? Is the crank pin scratched?
Reference
Description
Number
A Normal Wear
B Scratches Caused by Chips
5. Check main bearings and crankshaft. Are the bearings

worn (surface layer worn through and bearing bronze
visible)? Is the crankshaft scratched? Figure 335
6. Detach the screws of the hydraulic pump and move it

aside. The inner surface of the flywheel housing is partially
shaped like a shelf. Check whether there are chips or other
metallic/ceramic material inside the hydraulic pump.
Figure 336
Action
Always determine the cause of chips found inside the engine.
If the connecting rod bearings, crank pins, main bearings or
crankshaft show wear or scratches, the whole engine is
contaminated by chips. The whole engine must then be
thoroughly checked and cleaned or replaced.
4-1-179
Troubleshooting the Lubrication System
Symptom Troubleshooting Action
Does the machine oil pressure gauge indicate
Check the oil pressure using tool 99 362.
the correct value?
Check the oil level and its viscosity using
Is the oil of the correct grade and viscosity?
tool 588 493.
Check that spring has not snapped and
Is the relief valve working?
that piston is not seizing.
Is the centrifugal oil cleaner correctly
Check the centrifugal oil cleaner.
assembled?
Sudden low oil
pressure. Check the O-rings and that line is properly
Are there any leaks from the oil pump?
installed.
Are there any leaks from the pressure side of
Check the O-rings.
the oil pump?
Is the oil pump driving gear loose? Check the oil pump driving gear.
Check the cover, housing and cold start
valve with spring. Also check to ensure that
Are all oil pump components in place?
pump wheel of the oil pump is not
damaged.
the correct value?
tool 588 493.
Gradually Is the oil filter clogged? Replace the oil filter.
dropping oil
Check that spring is not worn out and that
pressure. Is the relief valve working?
piston is not seizing.
Is the suction strainer clogged? Clean the suction strainer.
Is the oil pump worn out? Replace the oil pump.
Is the engine worn out? Check bearing wear.
the correct value?
tool 588 493.
High oil
Check that piston is not stuck in the closed
pressure Is the relief valve working?
position.
Check that piston is not stuck in the closed
Does the piston cooling valve work?
position.
Is the cold start valve in the oil pump stuck? Replace the oil pump.
4-1-180
Lubrication Oil Consumption
Introduction
Lubrication oil consumption refers to the lubrication oil that is
consumed through combustion in the engine.
Take into account the fuel consumption when assessing the
lubrication oil consumption. Both are affected by driving style
and operating conditions.
Lubrication oil consumption is usually higher while running in.
Lubricating oil consumption cannot be considered constant until
engine has been run for around 40,000 km or 600 operating
hours.
Oil consumption should not exceed 0.3% of fuel consumption.
Prolonged driving at high engine speeds (above the green zone
on the tachometer) with low power output or driving with heavy
loads, however, will increase lubrication oil consumption slightly
in relation to fuel consumption. In such conditions, the
lubrication oil consumption can be considered as acceptable
even if it exceeds 0.4% of fuel consumption.
Checking Lubricating Oil Consumption

To prevent taking measures prematurely, the engine must be
run with the crankcase ventilation open for at least 10,000 km or
150 hours while carefully the following the fuel and oil
consumption. The engine oil must be at operating temperature
when measuring the oil level.
If the follow-up shows that lubrication oil consumption is really
abnormally high, the engine must be inspected and repaired.
Instructions and Follow-up Documentation

Fuel consumption and lubrication oil consumption calculations
must be based on information that is as accurate as possible.
Start with the fuel tank full and the lubrication oil topped up to the
max limit on the dipstick.
Check the level on the dipstick with the machine or engine
standing level once all the lubricating oil has collected in the oil
sump.
The level can be checked on the dipstick three minutes after
stop when the engine is at operating temperature. Wait at least
five minutes after stopping before checking the level if the
engine has been started but not attained operating temperature.
Use the form "Driver's log-book for measuring oil consumption" MAX
to note when fuel and lubrication oil has been filled and the MIN
mileage or operating time during the follow-up period. FG020479
Figure 337
4-1-181
Example of Completed Driver's Log-book for Measuring Oil Consumption
Chassis Number Chassis Type Engine Serial Number Dealer Owner

No: 1 234 567 No:
Mileage (km) or
Lubrication Oil Main Type of Driving
Date Operating Time Filled Fuel
Consumption*, Liters Laden, Unladen
(hours)
090703 37,905 km 250 1
090705 38,477 km 250 2
090711 39,125 km 300 etc.
090714 39,845 km 275
090720 40,256 km etc.
090722 etc.
090723
Total: 3800 Total: 12
* Enter the amount of lubricating oil used to top up.
When changing oil, estimate how much oil has been consumed
before the oil is drained or measure how much oil is drained
from the engine.
Fuel consumed = 3800 liters
Oil consumed = 12 liters
Oil consumption in percent of fuel consumption: 12/ 3800 *
100% = 0.31
The consumption is slightly higher than recommended but is
acceptable if most of the driving has been on fast main roads
with low vehicle load.
Driver's Log-book for Measuring Oil Consumption
Chassis
Chassis Type Engine Serial Number Dealer Owner
Number
No: No:
Mileage (km) or Main Type of

Lubrication Oil
Date Operating Time Filled Driving Laden,
Consumption*, Liters
(hours) Unladen
Liters
Liters
Liters
Liters
Liters
Liters
Liters
* Enter the amount of oil used to top up.
4-1-182
Tips for Troubleshooting
The are several possible causes if the engine oil consumption is
too high. Here are some tips on possible faults that can cause
high oil consumption.
NOTE: First check that there are no external oil leaks.
NOTE: To prevent taking measures prematurely, the engine
must be run with the crankcase ventilation open for at
least 10,000 km or 150 hours while carefully the
following the fuel and oil consumption.
Oil Leak in the Turbocharger

If the turbocharger is damaged:
If the sealing ring on the turbine side is worn, the exhaust gases
will be blue when idling.
Check the return oil pipe from the turbocharger for blockage and
deformation. In these cases there is a risk that lubrication oil
pressure will force oil through the seals.
FG020480
Figure 338
Worn Piston Rings

Conduct a compression test on the engine as described in the
Workshop Manual for the respective engine type to check for
piston ring and cylinder liner wear.
98 249
FG020481
Figure 339
4-1-183
EXHAUST SYSTEM
General Information
Exhaust gas aftertreatment is made up of the electronic control
system for exhaust gas aftertreatment, EEC (Exhaust Emission
Control System), with sensors and electrical components such
as the reductant pump and reductant doser. Together with
components such as catalytic converters, reductant tank and
electrically heated reductant hoses, the exhaust gases are
cleaned to remove harmful substances.
Control System for Exhaust Gas Aftertreatment

The control system consists of a control unit, two NOx sensors,
temperature sensor for exhaust gases, reductant pump,
reductant doser, coolant valve and electrically heated reductant
hoses. Level, temperature and reductant quality sensors are
also fitted in the reductant tank.
Overview
6
4
7
2
3 2
Reference Reference
Number Number
1 Control Unit EEC 5 Reductant Pump
2 NOx Sensor 6 Reductant Doser
3 Temperature Sensor 7 Coolant Valve
Sensor for Level, Temperature Electrically Heated Reductant
4 8
and Reductant Quality Hoses
4-1-184
Control Unit EEC
The EEC control unit retrieves data from the system's sensors
and components. EEC communicates with the engine control
unit EMS. EMS decides on what measures are to be executed
what quantity of reductant is to be metered to the exhaust
gases, and notifies EEC. The EEC control unit is independently
responsible for the functions which supply reductant to the
exhaust gases. The EEC control unit is located on the reductant
tank bracket underneath the reductant tank.
Figure 341
NOx Sensor (T115 and T131)

There are two NOx sensors in the system. They are used to
measure the content of nitrogen oxide compounds in the
exhaust gases before and after exhaust gas aftertreatment. The
sensors report to EEC, which notifies EMS. The sensors are
electrically heated by EEC. The NOx sensors are located on the
exhaust outlet of the SCR catalytic converter (T115) and in the
exhaust brake housing (T131).
Figure 342
Temperature Sensor (T113)

There is a level and temperature sensor which measures the
fluid level and fluid temperature. This sensor reports to EEC and
is located in the reductant tank.
Figure 343
Sensor for Level, Temperature and Reductant Quality (T116)
Reference
Description
Number
1 Pipe for Coolant
2 Pipe for Reductant
3 Level Sensor
4 Temperature Sensor
5 Reductant Quality Sensor
There is a connection for reductant and coolant on the top of the Figure 344
reductant tank. A unit with sensors is fitted there which
measures the fluid level, fluid temperature and quality of the
reductant. The sensors report to EEC. The unit is available in
two different lengths. 490 mm for the smaller reductant tank and
630 mm for the larger reductant tank.
4-1-185
Reductant Pump (V183)
To achieve the right reductant pressure prior to metering in the
exhaust system, there is an electrically operated reductant pump
with variable speed control in the system which is monitored and
activated by EEC. The reductant pump reports pump speed to
EEC. The reductant pump is heated by the engine's coolant at
low outdoor temperatures. The reductant pump is located on the
reductant tank bracket underneath the reductant tank.
Figure 345
Reductant Doser EEC (V117)

To ensure that the correct quantity of reductant is metered to the
exhaust gases, there is an electrically operated reductant doser
in the system which is monitored and activated by EEC. The
reductant doser reports the pressure and temperature of the
reductant to EEC. The reductant doser is electrically heated and
located on the intake end plate/intake side of the evaporator.
Figure 346
Coolant Valve (V118)

There is an electrically controlled water valve for the coolant flow
from the engine's cooling system to the reductant tank. The
coolant heats the reductant in the reductant tank and the
reductant pump at low outdoor temperatures. The position of the
water valve varies according to the engine installation.
Figure 347
Electrically Heated Reductant Hoses (H25, H26)

The hoses designed for reductant are electrically heated in order
to prevent ice formation at low outdoor temperatures. Electrical
heating of the hoses is activated by EEC. The hoses run
between the connections on the reductant pump and to the
reductant doser and then to the reductant tank.
EX1302176
Figure 348
4-1-186
Components for Exhaust Gas Aftertreatment
Figure 349
Reference Reference
Number Number
1 Reductant Tank Evaporator with Reductant
3
Coolant Hoses for Heating Doser
2 Reductant Tank and Reductant SCR Catalytic Converter with
Pump 4 Ammonia Slip Catalytic
Converter
Evaporator
The evaporator is designed to evaporate the reductant and mix it
with the exhaust gases. A reductant doser (1) is also fitted on
the evaporator which injects the required quantity of reductant
into the evaporator.
Figure 350
4-1-187
Reductant Tank
4
Reference
Description
Number
1 Reductant Tank 1
2 Control Unit EEC
3 Reductant Pump 2
Sensor for Level, Temperature and
4 3
Reductant Quality
EX1302346
The reductant tank is available in two sizes: Usable volume is
Figure 351
38 litres. The reductant in the tank is heated by means of the
engine's coolant at low outdoor temperatures. The reductant
pump (3) and EEC control unit (2) are located on the same
bracket as the reductant tank. There is a connection (4) for
reductant and coolant on the top of the reductant tank. A unit
with sensors for level, temperature and reductant quality is fitted
in it. A reductant filter is also fitted on the unit.
SCR Catalytic Converter
Most reduction of hydrocarbons takes place in the SCR catalytic
converter by means of reductant injected in previously. NOx is
converted into water, carbon dioxide and ammonia. An ammonia
slip catalytic converter is also located in the SCR catalytic
converter. In a last step the exhaust gases pass an ammonia
slip catalytic converter that reduces any ammonia slip.
EX1302186
Figure 352
4-1-188
Function
Introduction
Selective catalytic reduction (SCR), recirculation of exhaust
gases (EGR) and controlled fuel injection with a fuel injection
system are used to effectively clean the exhaust gases and
remove harmful substances in them.
Figure 353
Reference
Description
Number
1 Reductant Tank
2 Electrically Heated Pressure Hose for Reductant
3 Electrically Heated Return Hose for Reductant
4 Coolant Valve
5 Coolant Hoses
6 Evaporator With Reductant Doser
7 Nox Sensors in the Exhaust Outlet (T115) of the SCR Catalytic Converter
8 Nox Sensor in the Exhaust Brake Housing (T131)
9 SCR Catalytic Converter
10 Temperature Sensor
11 Reductant Pump
12 Reductant Doser
13 Oxidation Catalytic Converter
4-1-189
Working Principle
The working principle for exhaust gas aftertreatment is divided
into three different operations:
• Starting
• Operation and reductant metering
• Shutdown
Starting
The reductant pump starts when the following has taken place:
The engine has started, the EEC control unit has carried out a
system check, the catalytic converters have started to heat up and
have reached the correct operating temperature (200 - 250°C)
and any heating of the reductant is finished. The reductant
pressure is built up to approximately 9 bar and is then injected into
the evaporator by the reductant doser.
Figure 354
• The EEC control unit monitors the values and functions of

all sensors.
• The engine is started.
• The reductant pump (11) starts and builds up the reductant
pressure to approximately 9 bar.
• When the temperature sensor (10) indicates that the
temperature of the exhaust gases.
• has reached 200 - 250°C, the EEC control unit activates
the reductant doser (12), which starts injecting reductant to
the evaporator (6). The dose is determined by the engine
control unit EMS based on the value from the NOx sensor
(8) and the combustion control mode in the engine
currently being operated by the engine control unit.
4-1-190
• The process to reduce the quantity of NOx starts in the
SCR catalytic converter (9).
• Starting when heating frozen reductant
• The EEC control unit monitors the values and functions of
all sensors.
• The engine is started.
• The EEC control unit opens the coolant valve (4) so that
the coolant can heat the reductant tank (1) and reductant
pump (11). The EEC control unit also activates
• electrical heating of the reductant hoses (2, 3) and the
electric heating in the reductant doser (12).
• The EEC control unit registers, by the temperature sensor
in the reductant tank (1) and the reductant doser (12),
when the reductant is at a temperature above -5°C, at
which the reductant pump (11) starts.
• When the temperature sensor (10) shows that the
temperature of the exhaust gases has reached 200 - 250°C
and the value at the NOx sensor (8) has been reported to
the engine control unit, the EEC control unit activates the
reductant doser (12). The reductant doser then starts
reductant injection into the evaporator (6). The dose is
determined by the engine control unit on the basis of the
combustion control in the engine which is currently being
operated by the engine control unit.
• The process to reduce the quantity of NOx starts in the
SCR catalytic converter (9).
4-1-191
Operation and Reductant Metering
Figure 355
• The exhaust gases are treated in a number of steps before

being released by the tailpipe. These steps are based on
the combustion control mode of the engine control unit.
• Through engine control unit (EMS) regulation, the exhaust
gases are monitored and treated in a number of steps
before being released by the end pipe. The concentration
of NOx is measured by the NOx sensor (8) and the EEC
control unit transmits the value to the engine control unit.
The exhaust gases then pass the oxidation catalytic
converter (13) where the NO2 rate of the exhaust gases
increases and any surplus diesel is burnt.
• The exhaust gases pass the evaporator (6), where
reductant is injected. In order for the process to work, the
exhaust gas temperature must have reached 200 - 250°C.
The exhaust gas temperature is measured by the
temperature sensor (10) and the value read by the EEC
control unit and sent to the engine control unit. If the
temperature is too low or too high the engine control unit
adjusts its combustion control mode.
• The EEC control unit controls the amount of reductant from
the reductant tank (1) by activating and indicating the
pump speed to the reductant pump (11) and the dose to
the reductant doser (12). The values from the NOx
sensors, exhaust gas temperature sensor and the
combustion control mode of the engine control unit form
the basis of the volume of reductant to be metered.
• When reductant has been mixed with the exhaust gases
(evaporation), the exhaust gases pass the SCR catalytic
converter (9), where the NOx is converted into water and
nitrogen. In a last step the exhaust gases pass an
4-1-192
ammonia slip catalytic converter (positioned in the SCR
catalytic converter) that reduces any ammonia slip.
• Before the exhaust gases are released the NOx
concentration is measured by NOx sensor (7). The value is
read off by the EEC control unit and transmitted to the engine
control unit. The value is compared to the NOx concentration
from NOx sensor (8) and forms the basis of the combustion
control mode of the engine control unit and any adjustment of
the exhaust temperature or reductant dose.
• Shutdown
• When the engine is switched off after being subject to
heavy loading and heat release, the reductant pump (11)
continues for a set period to deliver reductant to the
reductant doser (12). However, reductant is not injected
into the evaporator (6) but is returned to the reductant tank
(1) and has the purpose of cooling the reductant doser
(12). Do not switch off the battery master switch during
cooling, otherwise the reductant doser may be damaged
by the radiated heat from the exhaust system.
IMPORTANT
The SCR system may need up to 30 minutes to cool
the reductant doser in extreme conditions. The battery
master switch must not be switched off before then.
Exhaust Gas Aftertreatment with SCR and EGR

6 CO2
In order to reduce the concentrations of nitrogen oxide 2 H20
compounds (NOx), soot particles (PM), hydrocarbons (HC) and
N2
carbon monoxide (CO), catalytic converters and reductant
(32.5% urea and water) are used. The reductant is delivered into 7
the exhaust gases in the evaporator. When the exhaust gases 5
4
have been treated, water (H2O), carbon dioxide (CO2) and CO 3
nitrogen (N2) come out of the exhaust pipe. HC 1
NOX
The illustration is a principle drawing of the components carrying PM
out exhaust gas aftertreatment. EX1302188
Figure 356
Reference
Description
Number
1 Oxidation catalytic converter that reduces the amount of hydrocarbons.
2 Reductant pump for reductant.
3 Evaporator that mixes reductant with the exhaust gases.
4 SCR catalytic converter that converts nitrogen oxide into nitrogen and water.
Ammonia slip catalytic converter that oxidises the ammonia slip into N2 (nitrogen).
5
The ammonia slip catalytic converter is located in the SCR catalytic converter.
6 Reductant from the reductant tank.
Reductant doser which delivers reductant into the exhaust gases. The reductant doser is
7
located on the evaporator
4-1-193
Checking Reductant Quality
1. If refractometer 588981 is to be used when sampling and
you are not sure how it should be read, first perform a test
measurement with water and then a test measurement
with reductant of a known quality to see the difference in
the reading. Also take care to ensure that the refractometer
is at ambient temperature when the measurement is done.
2. Take a sample from the reductant tank and check with the
refractometer that the urea content in the water is between
31 and 34%. A higher content increases the risk of
blocking of the system due to crystals. A lower content
means that the system will not be able to lower the NOx
content to the correct level.
3. If the reductant must be changed. Take care to ensure that
the new reductant is pumped through the entire system by
disconnecting the hose from the pump, starting the pump
and leaving it running until the new reductant has been EX1302189
pumped through the entire system. Otherwise there is a Figure 357
risk of old reductant being left in the pump/pump module.
Checking Exhaust Gas Aftertreatment

Even though the reductant is not toxic, the following should be
taken into account when working on the SCR system.
• In case of eye contact, rinse immediately using an eye bath
and then seek medical attention.
• In case of contact with skin, rinse with water.
• Change immediately out of clothes which have spills on.
• If ammonia gas is inhaled, make sure that plenty of fresh
air is provided immediately.
WARNING
Use protective goggles and gloves if there is any risk
of splashing or spraying of reductant or coolant.
NOTE: Plug the connections and reductant hoses

again when they are detached so that no
contamination enters the reductant system.
IMPORTANT
When working on the reductant tank and SCR pump
when replacing hoses, connections must only be
lubricated with soapy water or distilled water with a 3%
urea mixture. Any other types of lubricants may block
and damage components in the SCR system.
4-1-194
Safety Precautions When Working on the SCR System
taken into account when working on the SCR system.
WARNING
Use goggles and protective gloves if there is any risk
WARNING
When the engine is running, the exhaust system parts
can reach such high temperatures that there is a risk of
personal injury. Make sure that the exhaust system
temperature has decreased to a suitable level before
starting work.
WARNING
The SCR system is heated by water from the engine
cooling system. The cooling system runs at
overpressure and when the engine is hot the coolant is
hot. Do not open any hoses without first stopping the
coolant flow in the hose.
IMPORTANT
When working on the SCR system when replacing
hoses for the reductant tank and SCR pump,
connections must only be lubricated with soapy water
or distilled water with a 3% urea mixture. Any other
types of lubricants may block and damage
components in the SCR system.
4-1-195
Handling Reductant
The reductant may dry and form crystals. The crystals may look
like white or greyish brown deposits. The crystals are sharp and
can cut through O-rings and other rubber seals. The crystals can
also block the system. The crystals normally dissolve very
rapidly in warm water, but more dense deposits may need to be
scraped off or heated to more than 500°C to remove them.
IMPORTANT
Make sure that you always clean the area when working on
the reductant system to prevent any spilt reductant from
drying and forming crystals which may get into the system.
Always fit new O-rings and clean thoroughly so that the
sealing surface is clean and free from crystals.
IMPORTANT
Protect connectors against reductant spillages. Reductant
is highly corrosive.
NOTE: Only use containers and collecting vessels

manufactured from material recommended for use
with reductant.
Safety Precautions for Work on the Reductant System

taken into account when working with the reductant system.
WARNING
4-1-196
WARNING
can reach such high temperatures that there is a risk
of personal injury. Make sure that the exhaust system
starting work.
WARNING
The reductant system is heated by water from the
engine cooling system. The cooling system runs at
WARNING
For reductant tanks manufactured after January 2007,
the bleed pipe has been eliminated. Bleeding is now
handled by the filler cap.
4-1-197
Troubleshooting
The information below indicates faults in other systems or
components which can cause a fault indication in EEC. It is
intended as an aid to prevent fault-free components from being
replaced.
• Blocked air filter.
• Oil level in engine too high.
• Blocked venting to fuel tank.
• Winter air intake connected during hot weather.
• Intake air leakage, which can deceive the mass flow
sensor so that the control unit uses the wrong mixture rate.
• Air leakage between intake manifold and cylinder heads.
• Incorrect or incorrectly calibrated mass flow sensor.
• Deposits on charge air pressure sensor, which can convey
incorrect information to the control unit.
• Defective temperature sensor or pressure sensor, which
can convey incorrect information to the control unit.
• The exhaust brake is not working correctly.
• The EGR valve is not regulating properly.
• Defective thermostat which is stuck in the open position so
that the engine does not get fully warmed up.
• Cracked charge air cooler which can result in air leaks.
• Contaminated charge air cooler which can reduce the
cooling effect.
• Cooling fan with too much slippage, which can result in
poor charge air cooling.
• Cooling fan with insufficient slippage, which can result in
the engine not getting fully warmed up in winter.
• Radiator grille fully or partly blocked so that the air flow can
be obstructed and thus cause a deterioration in cooling
capacity.
• If the vehicle has a cyclone cleaner which is defective, this
can affect the air flow going into the engine.
• Leaking or worn turbocharger.
• Fault on VGT section of turbocharger.
• Cracked plastic pipe between air filter and turbocharger.
• Plastic pipe between air filter and turbocharger collapses
onto itself during exhaust braking.
• Air leaks downstream of turbocharger due to cracked
compressor neck.
• Deposits in the turbocharger which can reduce the charge
air pressure by 0.2 bar.
4-1-198
• Exhaust gas leakage between exhaust manifold and
cylinder heads.
• Exhaust gas leakage in slip joints upstream of
turbocharger.
• Exhaust gas leakage at turbocharger gasket.
• Exhaust gas leakage in joint between turbocharger turbine
housing and bearing housing.
• Leakage at turbocharger turbine sealing rings during
exhaust braking, which can result in high oil carryover
levels.
• Worn engine components such as piston rings, cylinder
liner, valve guides, valve stem seals or leaking valves,
which can result in oily or sooty exhaust gases.
• Worn camshaft, which can result in insufficient valve lift on
one or more cylinders.
• Depleted, diluted or unsuitable engine oil which can result
in oily or sooty exhaust gases.
• Poorly performing injector (one or more) so that the fuel is
inadequately atomised, which in turn can result in sooty
exhaust gases.
• Incorrect diesel with a very high sulphur content or other
contamination.
• Incorrect crankcase ventilation.
• Suction leakage in the fuel system, which can cause air
bubbles which disrupt the fuel flow.
• Blocked fuel filter.
• Chip tuning.
• Bent connecting rods due to liquid slugging, caused by
condensation in the charge air cooler.
• Leakage in the exhaust system, which can result in an
incorrect back pressure.
• Silencer that has been dented, knocked or damaged in
some other way, which can result in an incorrect mixture
when reductant is injected.
• Incorrect reductant contaminated or diluted.
• Reductant residue in the silencer, which can result in
malfunctions in the mixing chamber.
• Air compressor that is worn or defective in some other way,
which can result in oily compressed air for reductant
injection.
4-1-199
T113, Exhaust Temperature Sensor before
Catalytic Converter
Overview
Figure 358
Symbol
EX1302190
Figure 359
Function
The exhaust temperature sensor detects the temperature of the
exhaust gases before the SCR catalytic converter. The sensor
informs the engine control unit of the exhaust gas temperature.
The engine control unit uses, for example, the exhaust
temperature to determine how much reductant should be
injected into the exhaust gases in order to obtain the required
emission level.
4-1-200
T115, NOx Sensor
Description
The NOx sensor measures the amount of nitrogen oxides in the
exhaust gases and sends the information to the engine control
unit.
Overview
Figure 360
Location
T115
EX1400083
Figure 361
Symbol
4
NOX
supply 1
3
NOX
can 2
EX1302192
Figure 362
4-1-201
Removal
IMPORTANT
When the NOx sensor has to be removed, it is important to
make sure that the cable harness between the sensor itself
and its control unit is not twisted. The nut on the sensor
may get stuck causing the cable harness to become
twisted. To avoid this, the control unit should be detached
from the vehicle so that it can follow the rotation when the
sensor is detached.
WARNING
The protective casing on the NOx sensor control unit is
thermally insulated and acts as a heat shield. It must not be
removed.
NOTE: The NOx sensor contains lead. Lead is harmful to

humans and the environment.
The NOx sensor must therefore be handled in
accordance with national regulations on
environmentally hazardous substances.
T131 NOx Sensor
General Description
The NOx sensor is located upstream of the catalytic converter
and measures how much nitrogen oxide the exhaust gases
coming directly from the engine contain. The NOx sensor sends
the information to the engine control unit which determines when
reductant should be metered into the catalytic converter and
how much.
Overview
Figure 363
4-1-202
Location
T131
EX1400084
Figure 364
Symbol
4
NOX
supply 1
3
NOX
can 2
EX1302192
Figure 365
Removing NOx Sensor
IMPORTANT
When the NOx sensor has to be removed, it is important to
make sure that the cable harness between the sensor itself
and its control unit is not twisted. The nut on the sensor
may get stuck causing the cable harness to become
twisted. To avoid this, the control unit should be detached
from the vehicle so that it can follow the rotation when the
sensor is detached.
WARNING
The protective casing on the NOx sensor control unit is
thermally insulated and acts as a heat shield. It must not be
removed.
NOTE: The NOx sensor contains lead. Lead is harmful to

humans and the environment. The NOx sensor must
therefore be handled in accordance with national
regulations on environmentally hazardous
substances.
4-1-203
T116, Reductant Pick-up Unit
Overview
The combined sensor T4002 is located in the reductant pick-up
unit. It comprises 3 integrated sensors which measure the
reductant level, temperature and quality.
EX1302196
Figure 366
Safety Precautions and Routines When Working with the

Reductant Circuit
taken into account when working with the reductant circuit.
WARNING
WARNING
starting work.
4-1-204
WARNING
The reductant system is heated by water from the engine
cooling system. The cooling system runs at overpressure
and when the engine is hot the coolant is hot. Do not open
any hoses without first stopping the coolant flow in the
hose.
IMPORTANT
Cleanliness is very important when working on the
reductant circuit. Clean thoroughly around all parts to be
dismantled to prevent dirt from entering the system.
IMPORTANT
Reductant causes certain metals to corrode. Always rinse
away any spillage on connections and other parts with
lukewarm water to prevent corrosion.
IMPORTANT
When working on the SCR system when replacing hoses for
the reductant tank and SCR pump, connections must only
be lubricated with soapy water or distilled water with a 3%
urea mixture. Any other types of lubricants may block and
damage components in the SCR system.
4-1-205
Function
The reductant pick-up unit has 4 functions.
Informs the driver about the reductant level in the reductant tank
There is a float in the reductant pick-up unit which floats on top
of the reductant. The float moves along a pipe from where it
sends signals about the reductant level in the reductant tank.
When the reductant pick-up unit signals that the reductant tank
is empty, there should still be some reductant remaining in the
tank in order to cool the reductant doser. When the vehicle is
moving, waves form on the surface of the reductant, which can
generate misleading signals about the level. Therefore, there is
a delayed function which filters out these.
Takes the reductant from the reductant tank to the reductant
doser
A pump takes the reductant from the reductant tank by the
reductant pick-up unit to the reductant doser to be injected into
the exhaust system. Part of the reductant is returned to the
reductant tank by the reductant doser in order to cool the
reductant doser.
Monitors the reductant temperature in the reductant tank
A temperature sensor is located at the bottom of the circuit
board in the reductant pick-up unit. The temperature in the
reductant tank is monitored and controlled by the SCR system.
Heats the reductant in the reductant tank
Coolant is routed from the engine to the reductant pick-up unit
and the reductant pump then back to the engine. When the
coolant passes the engine it is heated and then heats the
reductant hoses and the reductant in the reductant tank when it
is cold. The illustration shows the heated coolant being routed
through the reductant pick-up unit.
Monitors the reductant concentration in the tank
A sensor is located at the bottom of the reductant pick-up unit
that measures the concentration of reductant. This is done by an
ultrasonic sensor which uses the temperature to calculate the
reductant concentration. The SCR system then monitors to
ensure that the concentration is within permitted limits.
EX1302197
Figure 367
4-1-206
Replace Reductant Pick-up Unit
Pos. Comments
Clamp the coolant hose with pliers
Warning! The hose contains coolant from the engine.
1 at a suitable point so that the flow of
Open the coolant filler cap first to relieve any pressure.
coolant is stopped.
Detach the tank straps and bend
2
them backwards.
3 Detach the electrical connection.
Remove the hoses and the bleed
4
pipe from the reductant pick-up unit.
Remove the reductant tank, The reductant tank needs to be removed when it is not
5 if necessary. Refer to instructions possible to gain access to remove the reductant pick-up
for removing the reductant tank. unit because of bodywork, for example.
Use tool 99 568 with the handle

forming part of kit 99 397. Press the
6 tool down against the reductant
pick-up unit and turn anti-clockwise
until it stops, about 1/8 of a turn.
EX1302194
7 Lift out the reductant pick-up unit.

Refit the reductant pick-up unit by
8 pressing down and twisting it into Fit a new O-ring.
position using the tool.
NOTE: Remember to remove the pliers.
9 Refit all parts and remove the pliers. The screws for the tank straps should be
tightened at the bottom.
EX1302348
Figure 368
4-1-207
Checking Reductant Pick-up Unit
Method for checking the reductant pick-up unit.
Fault codes EMS 8255 (low level within limit)
1. Top up with reductant.
2. Go to the next step if a fault code is still registered.
Preparations to check other EMS fault codes (8252/8253/8285/
8284)
NOTE: Remember to shut off the recirculation of coolant
from the reductant pick-up unit before removal.
1. Remove the reductant pick-up unit from the tank.
2. Reconnect the cable harness.
Fault codes EMS 8252 or EMS 8253 (level outside limits)
1. Clean the float pipe of crystals.
2. Clean the suction pipe and the return pipe using
compressed air and lukewarm water.
IMPORTANT
It takes approximately 3 minutes before ICL indicates
the correct level. Wait for the value to stabilise. It is
possible to check the reductant level in checking tool.
3. Position the float in the lowest position (1) and check the
level on ICL or checking tool.
4. Position the float in the middle position (2) and check the
level on ICL or checking tool.
5. Position the float in the uppermost position (3) and check 3
the level on ICL or checking tool.
6. Replace the reductant pick-up unit if it shows the wrong
temperature.
2
Fault codes EMS 8285 or EMS 8284 (temperature outside

limits)
NOTE: Incorrect temperature in the reductant pick-up unit 1
can cause low consumption of urea.
EX1302195
NOTE: It is also possible to measure the resistance manually Figure 369
instead of using checking tool. Measure between pin
2 and pin 3 on sensor T116. The resistance should
be approximately 2.2 kohm at 20°.
1. Check that the temperature for T116 in checking tool is
stable.
2. Compare the temperature according to T116 with the
temperature according to T27 in checking tool.
3. Replace the reductant pick-up unit if it shows the wrong
temperature.
4-1-208
Evaporator
Overview
EX1400558
Figure 370
Function
The evaporator helps in the process by making ammonia from
the reductant (blue). The evaporator consists of an inlet where
the reductant doser is located, a port where the reductant
evaporates and mixes with the exhaust gases (green) and an
outlet where a rotator further mixes the ammonia with the
exhaust gases. The reductant pump supplies the reductant to
the flow of gas (yellow) by electrically heated hoses.
EX1302199
Figure 371
V117 Reductant Doser

Overview
EX1400560
Figure 372
4-1-209
Loction
V117
EX1400559
Figure 373

Reductant Circuit
WARNING
WARNING
When the engine is running, the exhaust system parts can
reach such high temperatures that there is a risk of
starting work.
4-1-210
WARNING
hose.
IMPORTANT
reductant circuit. Clean thoroughly around all parts to be
dismantled to prevent dirt from entering the system.
IMPORTANT
IMPORTANT
the reductant tank and SCR pump, connections must only
be lubricated with soapy water or distilled water with a 3%
urea mixture. Any other types of lubricants may block and
4-1-211
Function
2
The reductant doser meters out the quantity of reductant, which 1
3
the engine control unit indicates, to the evaporator in the
exhaust system.
Reference
Description
Number
1 Reductant Intake
2 Reductant Outlet
3 Connection for Electrical Connector EX1400561
Figure 374
The reductant doser is electrically heated to prevent the

reductant from freezing when the outdoor temperatures are low.
The reductant doser is also equipped with a reductant
temperature and pressure sensor and the measurements are
transmitted to the exhaust gas aftertreatment system.
Reference
Description
Number
1 Restriction Valve
2 Prefilter
3 Pressure and Temperature Sensor
4 Nozzle
5 Solenoid Valve
6 Heater Element
The reductant flows from the intake at a pressure of about 9-10

Figure 375
bar and first passes the prefilter (2), fills the ducts after which the
sensor (3) reads the pressure and temperature.
The dosage quantity is determined by the opening time of the
solenoid valve (5). It opens once per second and the amount of
time that the solenoid valve is open during that second
determines the dosage quantity. The opening time can vary from
5.95% of 1 second. The reductant is metered to the exhaust
gases by the nozzle (4).
After the engine has been switched off, the reductant pump
continues to pump reductant to the reductant doser to cool it.
Cooling stops when the temperature is not critical in the
reductant doser.
IMPORTANT
Do not switch off the main switch until cooling of the
reductant doser has finished. The reductant doser can be
damaged by too high a temperature.
4-1-212
A graphite gasket (1) is fitted on the reductant doser which seals
against the evaporator. It should be replaced if the reductant
doser has been removed. Also check the nozzle (2).
Figure 376
Replacing Reductant Doser
Pos. Comments
1 Remove the reductant tank. See the section Renewal - Reductant tank.
2 Clean around the reductant doser.
Detach the reductant doser hoses
Avoid reductant entering connectors.
3 and plug them with plugs 211 38 93
Wipe clean before detaching the connector.
and 211 38 94.
Detach the reductant doser.
Earlier version - use a 10 mm
Fit a new graphite gasket (1) between the evaporator and
4 socket with a jointed extension.
reductant doser when fitting the reductant doser.
Later version - use a Torx socket;
the nut is an M6 TORX TX8.
Disconnect the reductant doser
5
connectors.
IMPORTANT
Tighten the screws in stages when fitting and tightening the
reductant doser. This is to ensure that the reductant doser
is correctly located and does not damage the graphite
gasket.
Figure 377
4-1-213
Replacing Graphite Gasket for V117 New Reductant Doser
The graphite gasket (1) which is located between the evaporator
and the reductant doser must be replaced if the reductant doser was
removed from the evaporator. Clean the surface of the evaporator
and the reductant doser before refitting the reductant doser.
IMPORTANT
Tighten the screws in stages when fitting and tightening the
reductant doser. This is to ensure that the reductant doser is
correctly located and does not damage the graphite gasket.
Figure 378
Replacing Prefilter in V117 Reductant
IMPORTANT
Protect the connectors from reductant spills. Reductant is
highly corrosive.
1. Detach the reductant hoses from the reductant doser and

position them so that they do not leak reductant.
NOTE: Plug the connections so that no contamination
enters the reductant circuit.
2. Remove the reductant doser from the evaporator.
3. Disconnect the electrical cable from the reductant doser.
4. Remove the cover with the hose connections.
Figure 379
4-1-214
5. Replace the prefilter (1).
Figure 380
6. Check that the O-rings in the cover are undamaged.

7. Refit the cover.
8. Refit the reductant doser.
NOTE: Clean the surfaces of the evaporator and
reductant doser and replace the graphite gasket
before refitting the reductant doser.
IMPORTANT
Tighten the screws in stages when fitting and tightening
the reductant doser. This is to ensure that the reductant
doser is correctly located and does not damage the
graphite gasket.
4-1-215
V118, Coolant Valve for Heating the
Reductant System
Description
The coolant valve has the task of opening and releasing coolant
from the engine to heat up the SCR system if necessary. The
engine control unit determines when the coolant valve will open.
The coolant valve is open when voltage is supplied to it.
Overview
EX1302349
Figure 381
Location
EX1302350
Figure 382
Symbol
4-1-216
Safety Precautions for Work on the Reductant System
taken into account when working on the reductant system.
WARNING
Use protective goggles and gloves if there is any risk of
splashing or spraying of reductant or coolant.
WARNING
reach such high temperatures that there is a risk of personal
injury. Make sure that the exhaust system temperature has
decreased to a suitable level before starting work.
WARNING
any hoses without first stopping the coolant flow in the hose.
Pos. Comments
Clamp the hose using pliers to stop Warning! The hose contains coolant from the engine. Open
1
the coolant flow. the coolant filler cap first to relieve any pressure.
Detach the coolant hoses and the
2
electrical connection.
3 Replace the coolant valve.
4-1-217
V183 Reductant Pump
Description
The reductant pump pumps reductant from the tank to the
reductant doser.
Overview
EX1400562
Figure 384
Location
EX1302351
Figure 385
Symbol
Figure 386
4-1-218
Function
The reductant pump sucks reductant from the reductant tank, filters
and builds up pressure for the reductant which is then fed to the
reductant doser. The reductant pump is an electrically driven
diaphragm pump with a filter for cleaning the reductant. The
reductant pump is heated using the engine's coolant at low outdoor
temperatures in order to thaw frozen reductant or prevent it freezing.
Reference
Description
Number
1 Pump Unit
2 Valve Block 6 1 10 8
3 Reductant Filter 2 7
4 Cover 4
9
5 Connections for Coolant 5
3
6 Ventilation
7 Internal Hexagon Bolt EX1400563
8 Connection for Electrical Connector Figure 387
9 Connections for Reductant
10 Electric Motor for Diaphragm Pump
The illustration below shows a section through the valve block

viewed from below.
Reductant is sucked through the intake (1) and reductant filter in
the valve block (3) and then through a port (6) to the pump
chamber, where reductant pressure is built up. If the reductant
pressure exceeds 13 bar in the pump, the overflow valve (5) and
check valve (7) open, reducing the reductant pressure in the
pump. The amount of reductant pumped to the reductant doser
can be varied by regulating the speed of the electric motor
between 800 and 3500 revolutions per minute.
If the reductant freezes in the reductant pump at low outdoor
temperatures when it is nonoperational, which takes place at
approx. -11°C, there is a damping element (4) in the valve block
that is compressed when the reductant expands during freezing.
Reference
Description 3 4
Number
6
1 Intake, Reductant
2 Outlet, Reductant
3 Reductant Filter 7
4 Damping Element 2 5
5 Overflow Valve
6 Port to Pump Chamber 1
7 Check Valve
EX1302229
Figure 388
4-1-219
The illustration below shows a section through the valve block
viewed from the side.
Reductant is sucked in through the intake port (1) and by an
intake valve (2) to the pump chamber, where reductant pressure
is built up by means of the pump diaphragm (3). Pressurised
reductant passes through the outlet valve (4) and by the port (5)
to the reductant filter, which is located under the valve block. If
the pressure exceeds 13 bar, the overflow valve opens by the
port (6). Once the reductant has passed the reductant filter, it is
pumped out by the port (7) and outlet (8). The reductant
pressure has been reduced and is approx. 10 bar.
Reference
Description
Number Figure 389
Port from the Reductant Filter in the Valve
1
Block
2 Intake Valve
3 Pump Diaphragm
4 Outlet Valve
Port to the Reductant Filter Under the
5
Valve Block
6 Port to Overflow Valve
Port from the Reductant Filter Under the
7
Valve Block
8 Connection, Outlet for Reductant
Reductant Filter Retainer Under the Valve
9
Block
The reductant filter (1), which is located under the valve block,
must be replaced in accordance with the specified inspection
interval. If the reductant freezes in the reductant pump at low
outdoor temperatures when it is non-operational, which takes
place at approx. -11°C, there is a damping element (3) in the
filter retainer that is compressed when the reductant expands
during freezing. A sealing bladder (2) protects the damping
element from coming into contact with the reductant. The
damping element and the area around it are ventilated by a
diaphragm valve (4).
Reference
Description 1
Number
1 Reductant Filter
2 Sealing Bladder 2
3 Damping Element
4 Diaphragm Valve
3
EX1302231
Figure 390
4-1-220
Safety Precautions and Routines when Working with the
Reductant Circuit
WARNING
WARNING
starting work.
WARNING
The reductant system is heated by water from the
engine cooling system. The cooling system runs at
IMPORTANT
reductant circuit. Clean thoroughly around all parts to
be dismantled to prevent dirt from entering the system.
4-1-221
IMPORTANT
IMPORTANT
the reductant tank and SCR pump, connections must only be
lubricated with soapy water or distilled water with a 3% urea
mixture. Any other types of lubricants may block and
Replacing Reductant Pump
IMPORTANT
1. Open the cover on the expansion tank and release any

overpressure from the cooling system. Fit the cover again.
2. Clamp the coolant hoses to the reductant pick-up unit and
pump.
3. Remove the hoses and the electrical connection from the
pump.
Figure 391
4-1-222
4. Remove the pump.
IMPORTANT
Blow the new pump’s suction nipple with compressed
air (approx. 6 bar) for at least 3 seconds before fitting
the pump.
5. Fit a new pump.

6. Fit the electrical connection to the pump.
7. Fit the hoses to the pump. Use soapy water or distilled
water with a 3% urea mixture if required.
8. Remove the clamps from the coolant hoses.
9. Carry out a system check of the check tool system using Figure 392
checking tool to bleed and function test the system.
Replacing Reductant Filter
EX1302212
Figure 393
Figure 394
4-1-223
Reference
Description
Number
A Pump
B Filter
C Frost Protection Device
D O-ring
E Cover
Figure 395
1. Clean the pump.
2. Undo the cover.
EX1302216
Figure 397
3. Remove the cover and Oring.
A EX1302217
Figure 398
4-1-224
4. Remove the frost protection device and filter, collect any
reductant spillages in a container.
A EX1302218
Figure 399
5. Wipe the pump clean.
6. Check that the frost protection device and valve are

correctly fitted in the new cover.
Figure 401
7. Fit the filter.
Figure 402
4-1-225
8. Fit the frost protection device.
Figure 403
9. Lubricate the threads with the spray.
Figure 404
10. Fit the O-ring in the cover.
Figure 405
4-1-226
11. Fit the cover and tighten to 80 Nm.
Figure 406
Replacing Reductant Pump Prefilter
IMPORTANT
1. Detach the reductant hose (running from the reductant

tank) at the reductant pump connection.
NOTE: Plug the connections again so that no
2. Remove the connection on the reductant pump.
3. Replace the prefilter (1).
Figure 407
4-1-227
Replacing Overpressure Valve for Reductant Pump
IMPORTANT
1. Remove the reductant pump.

NOTE: Plug the connections again so that no
2. Clean the reductant pump. Use water.
3. Remove the plug outside of the overpressure valve (2)
using an internal hexagon key.
4. Remove the overpressure valve. Use a hexagon screw.
NOTE: The overpressure valve is damaged during
removal and must be replaced with a new one.
The old overpressure valve must not be refitted.
5. Fit a new overpressure valve (2) and the plug outside of it.
Figure 408
4-1-228
H25, H26 Electrically Heated Reductant Hose
Description
The hoses designed for reductant are electrically heated in order
to prevent ice formation at low outdoor temperatures. Electrical
heating is activated by EEC. H25 is a pressure hose from the
reductant pump to the reductant doser.
Electrical heating is activated by EEC. H26 is a return hose from
the reductant doser to the reductant tank.
Overview
EX1302232
Figure 409
Location
H26
H25
EX1302352
Figure 410
Function
H25 is an electrically heated pressure hose for reductant from
the reductant pump to the reductant doser.
4-1-229
M4000 Electric Exhaust Brake
Description
The exhaust brake is intended to enhance the engine braking
effect.
Overview
A : 1 ~ 23
24
9
22
20
4
3
9
1
23
10 2
6
7
12 15
8
16
25
11
16 14 13 14
17 15
18
5 EX1302353
Figure 411
4-1-230
Reference Reference
Number Number
1 Housing 13 Shaft
2 Bushing 14 Nut
3 Bushing 15 Lock Nut
4 Pin 16 Link
5 Bracket 17 Spring
6 Sleeve 18 Lock Nut
7 Screw 20 Pin
8 Bolt 22 Gasket
9 Screw 23 Exhaust Brake Sensor
10 Tube 24 Turbo Clamp
11 Electric Actuator 25 Clamp
12 Bolt
Location
Figure 412
Function
Industrial engines use an electrically controlled damper for the
exchange of gases. The exhaust brake bypass valve is
positioned downstream of the turbocharger near the exhaust
manifold.
By controlling the damper position, the exhaust gases are
restricted thus creating a back pressure. Apart from enhancing
the engine braking action, the back pressure created also
warms up the engine more rapidly and keeps the exhaust gas
aftertreatment system warm.
4-1-231
Removing Exhaust Brake
IMPORTANT
Risk of crush injuries. The actuator can be activated
automatically when supplied with voltage. Caution!

2. Remove the V-clamps, one on each side of the exhaust
brake.
3. Detach the 2 coolant hoses and the connector.
4. Remove the exhaust brake and actuator.
EX1400565
Figure 413
Installing Exhaust Brake
WARNING
1. Fit the exhaust brake and actuator.

2. Fit the 2 coolant hoses and connect the cable harness.
3. Fit both V-clamps, one on each side of the exhaust brake.
EX1400565
Figure 414
IMPORTANT
4. Fill with coolant
4-1-232
Replacing Exhaust Brake Actuator
Removing
1. Drain the cooling system.
Figure 416
2. Remove the 2 coolant hoses.

3. Remove the right nipple to access the retaining screw.
4. Remove the lock and nut from the link arm (A).
5. Remove the link arm.
6. Remove the actuator connection.
7. Remove the connector from the NOx sensor (B).
8. Remove 3 screws from the actuator (C).
9. Remove the actuator.
4-1-233
Installing
Figure 417
1. Fit the actuator with 3 screws.

2. Fit the link arm to the actuator and lock the nut.
3. Fit the right-hand coolant hose nipple.
4. Fit the 2 coolant hoses.
5. Fit the actuator connection with lock nut (A).
6. Fit the contact housing to the NOx sensor (B).
4-1-234
Adjusting Exhaust Brake
WARNING
Measurement between the screw holes on the adjustable link

arm. The illustrations shows a link arm on an engine.
There is a fixed and an adjustable version of the link arm. The
measurement between the screw holes on the adjustable link
arm should be:
142 ±2 mm
Low turbocharger 142 ±2mm
1. Calibrate the actuator using checking tool.
2. Clear any fault codes.
EX1302354
Figure 418
Checking Exhaust Brake

1. Activate the exhaust brake using checking tool.
2. Check that the control cylinder carries out the full stroke
between the open and closed position.
3. Check that the damper does not seize or get stuck.
4-1-235
Reductant Tank

Reductant Circuit
WARNING
Use goggles and protective gloves if there is any risk of
splashing or spraying of reductant or coolant.
WARNING
starting work.
WARNING
hose.
IMPORTANT
Cleanliness is very important when working on the reductant
circuit. Clean thoroughly around all parts to be dismantled to
prevent dirt from entering the system.
4-1-236
IMPORTANT
IMPORTANT
Reductant Tank Volume
Type Fill Volume

Normal 70 L
IMPORTANT
Do not top up the reductant tank to the top because
reductant freezes at -11°C and the tank could crack.
IMPORTANT
Clean on and around the filler cap before you open it so that
no water or dirt can enter the reductant tank.
The SCR system will be irreparably damaged if diesel gets
into the reductant tank.
NOTE: Help protect the environment! Avoid spillage and use

a suitable container.
4-1-237
Removing the Reductant Tank
1. If necessary, empty the reductant tank by sucking out the
fluid or opening the nipple.
EX1302359
Figure 419
2. Undo the screws and remove the straps.
EX1302355
Figure 420
3. Clamp the coolant hose using a welding clamp to stop the

coolant flow.
WARNING
The hose contains coolant from the engine. Open the
coolant filler cap first to relieve any pressure.
EX1302356
4. Pull out the hoses. These connections may be tight. Figure 421
5. Remove the reductant tank. If there is a lot of fluid in the

tank, to make it easier you can pull a strap through the
opening in the reductant tank and pull it out on a trolley.
Figure 422
4-1-238
Fitting the Tank
1. Position the tank.
2. Connect the hoses. Use soapy water or distilled water with
a 3% urea mixture if required.
3. Fit the strap and tighten the screws.
Removing the Reductant Pump

1. Remove the reductant tank as outlined in the description
above.
2. Remove the hoses and connector on the reductant pump.
Detach the connector last as there is less risk of reductant
entering the contact housing.
NOTE: Note that there is residual reductant in the
hoses.
EX1302357
Figure 423
EX1302356
Figure 424
3. Undo the four nuts (1) which secure the bracket to the
frame. Hold onto the bracket so that it does not fall out, and
cut off the cable ties (2) to the cable harness from the
control unit.
EX1302358
Figure 425
4-1-239
4. Remove the two screws securing the reductant pump.
EX1302360
Figure 426
Removing the Control Unit

1. Remove the reductant tank and reductant pump.
2. Remove the connectors for the control unit.
Figure 427
3. Cut off the cable ties which hold the cable harness from the
control unit. Hold onto the control unit, undo the screws
and remove the control unit.
Figure 428
4-1-240
Replacing the Filter
1. Unscrew the filter housing using a 46 mm socket.
NOTE: Note that there is residual reductant in the filter
housing.
EX1302358
Figure 429
2. Remove the filter and wipe around the filter housing to

ensure that dirt does not enter.
3. Fit new O-rings.
4. Fit a new filter and frost protection device. Use a 46 mm
socket and tighten the filter housing.
Replacing the Pump Prefilter
IMPORTANT
Undo the connection for reductant in. The filter (1) is secured by
the connection in the housing. Replace the filter.
1. Fit the connection for reductant and tighten the connection.
1 2 EX1302290
Figure 430
4-1-241
Replacing the Overpressure Valve on Pump
IMPORTANT
1. Remove the reductant pump.

2. Rinse the reductant pump clean with water.
3. Remove the plug using an internal hexagon key.
4. Remove the overpressure valve (2) using a hexagon screw
and fit a new valve.
NOTE: The overpressure valve is damaged during
removal and must be replaced with a new one
and must not be refitted.
5. Fit the plug and tighten.
4-1-242
Oxidation Catalytic Converter
Safety and Environmental

Safety precautions apply when opening the silencer.
WARNING
A P3 type respiratory protection/filter mask, protective
goggles and gloves should be used for any work where
there is a risk of exposure to harmful particles from the
oxidation catalytic converter.
You should not eat, drink or smoke while working.
Any dust particles from the oxidation catalytic converter
should be removed using a vacuum cleaner with microfilter
to minimise exposure.
Make sure you clean your hands after working with an
oxidation catalytic converter to avoid ingestion.
WARNING
starting work.
NOTE: The oxidation catalytic converter is made of precious

metal and should be processed in compliance with
local regulations.
However, if you come into contact with or inhale dust or powder,
the following symptoms may occur:
• Inhalation: Irritation of the airways, cough.
• Ingestion: Nausea and vomiting.
• Eyes: Irritation.
• Skin: Possible redness and irritation.
If symptoms arise, the following action should be taken:
• Inhalation: Move the patient from the area affected and
allow him to rest in the fresh air. Seek medical help if the
symptoms persist.
• Ingestion: Rinse mouth with clean water. Give milk or
water to drink. Seek medical help if the symptoms persist.
4-1-243
• Eyes: Rinse with water or isotonic salt solution for 5
minutes. Seek medical help if the symptoms persist.
• Skin: Wash the skin with soap and water. Seek medical
help if symptoms develop.
Removing Oxidation Catalytic Converter

1. Remove the V-clamp securing the oxidation catalytic
converter to the exhaust brake or exhaust bellows.
2. Remove the bracket securing the oxidation catalytic
converter.
3. Remove the oxidation catalytic converter.
Figure 431
Installing Oxidation Catalytic Converter

1. Fit the V-clamp securing the oxidation catalytic converter to
the exhaust brake or exhaust bellows.
2. Fit the oxidation catalytic converter and bracket.
Figure 432
4-1-244
Exhaust Manifold
Overview
13 14
10
1
12 2
4
6
7
8
3
5
15
EX1302167
Figure 433
Reference Reference
Number Number
1 Exhaust Manifold 8 Gasket
2 Exhaust Manifold 9 Bolt
3 Exhaust Manifold 10 Spacer Sleeve
4 Sealring 12 Gasket
5 Gasket 13 Bolt
6 Flange Screw 14 Plug, Screw
7 Spacer Sleeve 15 Turbo Charger
4-1-245
Replacing Sealing Rings on Exhaust Mainfold
Special tool 99715.99717 is included in tool kit 99718.
1. Remove the exhaust manifold.
2. Fit the exhaust manifold on the fixture with the
turbocharger connection facing you.
Screw the turbo manifold in the fixture using 4 screws.
Figure 434
3. Screw the puller onto the part of the exhaust manifold to be

removed. Fit the impact setting tool on the puller and tap
away the exhaust manifold from the turbo manifold.
Figure 435
4. Remove the old sealing ring, taking care not to damage the
sealing surface.
Figure 436
4-1-246
5. Clean the sealing surfaces and check that they are free
from unevenness; grind carefully with an emery cloth if
necessary.
Figure 437
Figure 438
6. Install the new sealing ring on the assembly tool and then
tap the sealing ring into place with a rubber/plastic mallet.
Figure 439
Figure 440
4-1-247
7. Install the impact setting tool on the puller and tap the
exhaust manifold back into place on the turbo manifold.
Take care to ensure the correct spacing is obtained
between the exhaust manifold parts; see below.
Figure 441
In general, the following distances apply:

• 164 mm between turbo manifold and left-hand
exhaust manifold.
• 132 mm between turbo manifold and right-hand
exhaust manifold.
Figure 442 Exhaust manifold of engine
8. Refit the exhaust manifold to the engine.
4-1-248
Replacing Exhaust mainfold
2. Remove the V-clamps, one on each side of the exhaust
brake.
Figure 443
3. Detach the 2 coolant hoses and the connector.

4. Remove the exhaust brake with its control cylinder.
5. Remove the charge air pipe connection towards the charge
air cooler.
6. Remove the screws and V-clamps for the charge air pipe.
7. Remove the charge air pipe.
Figure 444
The appearance of the exhaust manifold may differ but the

principle is the same.
8. Remove the exhaust gas temperature sensor (A).
9. Remove the screws to the exhaust manifold (B), the rear
V-clamp (C) and remove the EGR pipe.
10. Detach the hose to the dump valve.
Figure 445
4-1-249
11. Remove the screws towards the turbocharger.
Figure 446

12. Remove the exhaust gas temperature sensor from the
exhaust manifold (F).
13. Remove the coolant pipe bracket (E).
14. Remove the oil mist separator cover (D).
Figure 447

15. Remove the screws towards the cylinder heads.
16. Remove the exhaust manifold.
Figure 448
4-1-250
Installing Exhaust Mainfold
NOTE: Always use new gaskets.
NOTE: Cleanliness when fitting the gasket is essential for the
flange to be tight. Keep the surfaces around and on
the flange clean and free from dirt.
Figure 449

1. Install the exhaust manifold. Use new gaskets.
Figure 450

2. Install the turbocharger. Use new gaskets.
Figure 451

3. Install the exhaust gas temperature sensor (F). Use thread
seal tape.
4. Install the coolant pipe bracket (E).
5. Install the oil mist separator cover (D).
Figure 452
4-1-251
6. Install the EGR pipe (B). Use a new gasket.
7. Install the rear V-clamp to the EGR pipe (C).
8. Install the exhaust gas temperature sensor (A) to the
exhaust manifold. Use thread seal tape.
Figure 453
9. Install the charge air pipe using screws and V-clamps.

10. Install the connection to the charge air pipe.
Figure 454
11. Install the exhaust brake and its control cylinder.

12. Detach the 2 coolant hoses and connect the cable
harness.
13. Install both V-clamps, one on each side of the exhaust
brake.
EX1301840
Figure 455

15. Test run the engine.
4-1-252
Variable Geometry Turbocharger
Location
FG020504
Figure 456
Function
Variable geometry turbocharger
Like the fixed geometry turbocharger, the variable geometry
turbocharger consists of a turbine and a compressor. The
turbine is driven by the engine exhaust gases and the
compressor compresses the air going into the engine. The
compressor impeller and turbine wheel are located on the same
shaft. The bearing housing is situated between the compressor
and the turbine.
There is an axially moveable nozzle ring in the turbocharger
which is used to control the width in the turbine intake. When the
nozzle ring is moved so that the gap is reduced, a higher
exhaust back pressure is obtained. A higher exhaust back
pressure increases the speed of the exhaust gases, which
produces a higher turbine rotation speed and therefore a greater
air flow into the engine.
The movement of the nozzle ring is controlled by an electric
motor which is controlled by the engine control unit. The variable
geometry turbocharger then differs here from the conventional
one, in which the volume of air going into the engine is directly
dependent on the power output without any special regulating
system.
4-1-253
The electric motor changes the position of the nozzle ring after
receiving a CAN message from the engine control unit. There is
an electronic control unit in the electric motor that converts the
CAN message into a mechanical movement. The engine control
unit also receives information about the current position. If CAN
communication with the engine control unit is lost, the electric
motor places the nozzle ring in such a position that a preset
width is obtained.
The engine control unit provides supply voltage to the electric
motor. If the voltage supply disappears, the exhaust gases will
press the nozzle ring into its most open position, that is to say
maximum width, which means that the charge air pressure falls
and the engine loses power.
By adjusting the width in the turbine intake, the speed of the
3
exhaust gases is varied and therefore so is the volume of air
going into the engine. A
Reference
Description
Number
A Exhaust gases
1 Compressor
2 Turbine
2 1
3 Axially moveable nozzle ring
EX1302102
Figure 457
The turbocharger compressor and turbine wheels rotate very
rapidly. When the engine is running at full power, the rotational
speed may reach 100,000 rpm. At the same time the
temperature around the turbine wheel is above 600°C. This
places high demands on the rotating parts and on balancing,
cooling and lubrication. If the turbine wheel or compressor
impeller is damaged, the turbocharger must be replaced.
The shaft is mounted in two radial bearings and one thrust
bearing which rotates freely (in a thin oil film) in the bearing
housing. The bearing housing is sealed off from the turbine and
the compressor with sealing rings. A blocked air cleaner will
cause excessive vacuum in the intake pipe. There is then a risk
of oil mist being drawn from the bearing housing.
If the sealing ring on the turbine side is worn, the exhaust gases
will be blue when idling. Foreign bodies in the turbine or
compressor, such as a grain of sand or metal shavings, will ruin
the vanes. This will lead to imbalance and bearing wear. The
power output of the engine is reduced, and if the engine is kept
running the reduced air supply may cause the engine to
overheat, resulting in engine damage. This type of overheating
is not noticeable on the coolant temperature gauge.
Even small leaks in the pipe between the air filter and the
turbocharger will cause dirt to be deposited on the compressor
wheel. The charge air pressure is reduced, which results in an
increase in the exhaust gas temperature, smoke, and leads to a
reduction in the service life of the engine.
Leaks in the exhaust pipe between the cylinder head and the
turbocharger will result in a low charge air pressure.
4-1-254
Removing the Turbo Charger
NOTE: Make sure that you cover and protect all pipes,
connections and openings from dirt when the
turbocharger is removed.
2 3 5 4
2. Undo the V-clamp between the exhaust pipe and exhaust
brake. Move the exhaust pipe (2) out of the way.
3. Detach the exhaust brake and place to one side (3).
4. Remove the turbocharger inlet pipe and charge air pipe
(4).
5. Remove the coolant pipe on the variable geometry
turbocharger (5).
NOTE: Check that the inlet pipe rubber seal comes out
with the pipe.
6. Remove the coolant pipes to the electric motor.
EX1302103
Figure 458
7. Detach the coolant pipe from the variable geometry

turbocharger (6).
8. Undo the hose clamps for the oil hose (7).
9. Detach the pressure pipe at the variable geometry
8
turbocharger (8). 6
10. Undo the connectors for the rotational speed sensor and
electric motor. 7
11. Remove the variable geometry turbocharger.
Figure 460
4-1-255
Installing the Turbo Charger
NOTE: The joint between the turbocharger and turbo
manifold should be tightened using new parts: screw,
spacer, nut and gasket.
IMPORTANT
When the electric motor for the variable geometry
turbocharger has been removed, basic setting and
calibration of the electric motor must always be carried out
using checking tool. Also use checking tool to carry out a
condition test on the variable geometry turbocharger after
calibration.
NOTE: If the turbocharger caused oil carryover when it broke

down, the catalytic converter may have been
damaged. If the vehicle is equipped with SCR, run a
devalidation test with checking tool to check whether
the catalytic converter is working.
WARNING
If the turbocharger caused oil carryover, oil may have
entered the exhaust system and the catalytic converter may
have temporarily been ignited when the engine was under
load and a high level of heat was generated. Take care when
warming up for the first time after replacing the
turbocharger.
1. If studs are used in the joint, lubricate the stud threads with
heat resistant lubricant.
2. Clean the turbocharger and exhaust manifold sealing
surfaces.
3. Install the oil hose on the oil pipe and pull it up on the pipe.
Install the turbocharger with a new gasket.
4. Install the coolant pipes.
5. Install the oil hose.
6. Fill the turbocharger with engine oil and install the pressure
pipe.
7. Install the connectors for the rotational speed sensor and
electric motor.
8. Install the charge air cooler pipe and turbocharger inlet
pipe.
9. Check that the guide pins are in position in the
turbocharger. Install the exhaust brake and exhaust pipe
by the exhaust brake.
4-1-256
10. Tighten the V-clamp.
11. Refill the cooling system.
IMPORTANT

EX1301840
After warming up the engine, tighten the variable

geometry turbocharger retaining screws.
Removing the Turbocharger Electric Motor
IMPORTANT
calibration.
WARNING
Hot coolant can cause burns. Ethylene glycol can be fatal if
ingested. It has a toxic effect on the skin, particularly when
the coolant is hot. Wear protective gloves.

2. Remove the electric motor coolant pipes.
3. Detach the cable harness.
4. Undo and remove the screws securing the electric motor.
5. Remove the electric motor.
4-1-257
Installing the Turbocharger Electric Motor
IMPORTANT
calibration.
Check that the turbocharger lever can be moved to its end

positions. Lubricate the lever teeth with the grease contained in
the repair kit.
1. Transfer the nipples for the coolant connections to the
electric motor.
2. Set the lever in the correct position; check with the pin
included in the repair kit.
3. Connect checking tool to the vehicle. Fit the electric
motor's electrical connection and carry out a basic
calibration of the electric motor using checking tool. Leave
checking tool connected after the basic calibration.
4. Remove the pin holding the lever in position.
5. Install a new gasket.
Tip: When fitting the electric motor, it is easier if you use
studs. Temporarily fit 2 studs where the normal screws are Figure 462
fitted, fit the gasket and guide the electric motor onto the
studs. Then screw on 2 normal screws and remove the
studs.
6. Screw the electric motor onto the turbocharger. Use new
screws and tighten them diagonally.
7. Calibrate the electric motor using checking tool.
8. Connect the coolant pipes.
11. Start the engine and check that no new fault codes are
generated.
4-1-258
Checking the Turbo Charger
Carry out a condition test on the variable geometry turbocharger
in checking tool.
If the condition test in checking tool indicates that the movement
is restricted, carry out manual mechanical checking, see below.
1. Remove the electric motor M30.
2. Check that the lever can move freely between its end
positions by hand force alone:
In its left-hand end position the lever should touch hole B in
the bottom plate.
In its right-hand end position hole A in the lever should be
directly above hole C in the bottom plate.
Figure 464
3. If the lever cannot move freely between its end positions,

replace the turbocharger.
4. If the lever can move freely between its end positions:
• Carry out basic setting and calibration of the variable
geometry turbocharger using checking tool.
• Refit the electric motor M30.
• Carry out a condition test on the variable geometry
turbocharger in checking tool.
• If the condition test is a fail, replace the electric motor
M30.
• If the condition test is a pass for both the hot and cold
turbocharger, the fault code is probably due to
incorrect calibration of the electric motor or a
temporary malfunction, for example ice forming when
starting at low temperatures. No parts need to be
replaced.
4-1-259
NOTE: When calibrating the electric motor, the gear
adjusts itself automatically.
Figure 465
Checking the Action in Event of Mechanical Failure
IMPORTANT
The highest levels of cleanliness must be observed when
working on the turbocharger. Never leave the oil inlet and
outlet connections unprotected. Foreign bodies in the
bearing housing will soon lead to total breakdown.
Carry out the following:

1. Ensure that no leaks or loose particles are present in the
line between the air filter and the turbocharger.
2. Check that there are no loose particles in the exhaust or
intake manifolds.
3. Replace the charge air cooler.
4. Make sure all valves are intact.
5. Check that lubrication oil return pipe from the turbocharger
is not clogged or distorted.
6. Check that oil pressure pipe to the turbocharger is not
clogged or deformed and that it does not leak when
pressurized.
7. Replace the oil filter and clean the lubrication system.
4-1-260
EGR System
Description
The task of the EGR system is to return part of the exhaust
gases back to the engine.
When the exhaust gases are returned to the intake air, this
reduces the oxygen level. This leads to a reduction in the
combustion temperature and to fewer NOx emissions being
produced.
Location
Reference
Description 2 3
Number
1 Inlet Pipe
2 Liquid-cooled EGR Cooler
3 EGR Valve
4 Electric Actuator
1 4
EX1302035
Figure 466
Overview
Reference
Description
Number
1 Air Filter
2 Mass Flow Sensor
3 Turbocharger
4 Electrical Actuator for the Turbocharger
5 Turbocharger Rotational Speed Sensor
6 Inlet Pipe
7 Cylinders
8 Exhaust Manifold
9 Exhaust Back Pressure Sensor (T125)
10 EGR Valve
11 Electric Actuator For EGR Valve
12 Position Sensor for EGR Valve (T124)
13 Charge Air Temperature Sensor (T121)
14 Charge Air Pressure Sensor (T122)
15 Engine Control Unit (E44)
Figure 467
16 Charge Air Cooler
17 Liquid-cooled EGR Cooler
18 Electronic Exhaust Brake
19 Electric Actuator for Exhaust Brake (M4000)
4-1-261
Function
The EGR system is active between approx. 900 rpm and the
maximum engine speed with a positive torque and when the
coolant temperature exceeds approximately 50°C.
The principle of the EGR system is that some of the exhaust
gases are returned to the engine. The quantity of oxygen is
reduced by mixing the intake air with exhaust gases resulting in
a lower combustion temperature. In this way, the quantity of
nitrogen oxides.
NOx, in the exhaust gases is reduced.
The reduced nitrogen oxide emissions make it possible to meet Figure 468
emissions regulations and to optimise engine power and fuel
consumption.
Flow of air and exhaust gases
Part of the exhaust gases leaving the engine by the exhaust
manifold are led by the EGR valve through the EGR cooler,
where they are cooled.
The cooled exhaust gases are drawn back to the intake and
mixed with the intake air.
4-1-262
Controlling the flow
The engine control unit controls the flow of exhaust gases. The
control unit regulates EGR content, i.e. the volume of exhaust
gases that are returned to the engine. The level is measured in
percent 10% EGR content means that 10% of the total flow into
the engine is exhaust gas and 90% is air.
The mass flow sensor detects and informs the control unit of
how much air passes into the engine. The control unit also
receives information from the charge air pressure and
temperature sensors as well as the exhaust gas pressure
sensor. The control unit uses information from the sensors to
calculate the total volume of gas (air and exhaust gases) which
enter the cylinders. By measuring the total volume of gases and
subtracting from this the air flow from the mass flow sensor, the
control unit calculates the EGR content.
To increase measurement accuracy and to avoid incorrect
values, the control unit shuts the EGR valve for a preset time
interval, to avoid any gases flowing back to the cylinders. The
control unit compares the value from the mass flow sensor with
the calculated gas volume entering the cylinders. These two
values should be the same. If the values do not agree, the
control unit calibrates the mass flow sensor. The system is set in
motion when the engine is started and warmed up.
If a fault occurs in the system which results in the control unit not
being able to control the components as expected, fault codes
are generated and the control unit reduces the engine power
until the fault is rectified.
Cold engine
The EGR valve is closed until the engine has been warmed up.
No exhaust gases are then circulated.
Warm engine
Once the engine has been warmed up, the EGR valve is open
and exhaust gases then circulate in the EGR system. Where the
throttle is rapidly opened, the engine control unit reduces the EGR
content. This is intended to compensate for the shortage of
induction air that occurs before the turbocharger begins to charge.
Shut-off conditions
• The control unit shuts down the EGR system if:
• The charge air temperature falls below a specific value.
There is then a risk of freezing in the intake manifold.
• The engine is at such a high altitude that the air pressure
affects its performance.
• Coolant temperature is too high. At very high coolant
temperature, the control unit closes the EGR valve to avoid
loading the engine with additional heat from the EGR
cooler.
• The white smoke limiter is active.
• There is a risk of the EGR system freezing if the ambient
temperature is very low.
4-1-263
Properties
The EGR system is active between approximately 900 and the
highest engine rotation with a positive torque.
The EGR system is active when the coolant temperature
exceeds 50°C.
Checking EGR System

The work description includes a number of checks and a leak
test of the EGR cooler.
Leak test and functional inspection of the EGR system
components
It is normal to find a certain amount of soot coating in engines
with EGR systems.
Component How
Search for heavy soot accumulation. Check that the EGR valve is
EGR Valve properly closed. Check that the EGR valve springs back to the closed
position.
The Pipe between the EGR Valve and
Check that there is no abnormally large leakage.
the EGR Cooler
The Pipe between the Cooler and the
Inlet Pipe
Searching for leakage in the EGR cooler; see Leak testing the EGR
EGR Cooler
cooler.
The Hoses to and from the Air-cooled
EGR Cooler
Check using checking tool that the EGR valve control cylinder is
Control Cylinder to EGR Valve
working properly, see Checking the control cylinder.
If it does leak, the EGR components may need cleaning.
Checking the Control Cylinder

1. Connect checking tool.
2. Activate the control for the EGR valve control cylinder.
3. Check that the control cylinder moves unhindered between
the closed and open positions.
4. Check the valve in the closed position.
Make sure there is no play at the control cylinder.
5. Check the valve in the open position.
Check the integrity of the cylinder and that the valve opens
fully. In the fully open position, the rear end of the valve
shaft should lie against the mechanical stop.
4-1-264
Leak Testing the EGR Cooler
1. Remove the EGR cooler from the vehicle.
2. Seal the EGR cooler's coolant inlet and outlet.
Plug the hose connection with a rubber plug or similar and
with a plate on the end with a flange.
WARNING
It is important that the seals are securely fitted when
the EGR cooler is pressurised. There is otherwise a
risk of them coming loose.
3. Pressurise the EGR cooler by the bleed connection to 1.5

bar and lower it into a water bath. Use tool 99 405.
4. Leave the EGR cooler submerged for approximately 30
minutes to make sure that this really is leakage.
5. Once the leak test is complete, make sure that the EGR
cooler is depressurised before removing the seals.
Pressure Testing the EGR System
WARNING
Sulphuric acid can be formed in the pipe downstream of the
EGR cooler. Remember to use safety equipment!
• The text refers to: checking tool

1. Remove the inlet pipe from the intake of the turbocharger.
Figure 469
4-1-265
2. Clean the flange of the turbocharger inlet and the inside of
the rubber hose on tool 99 620.
3. Fit tool 99 620 to the intake of the turbocharger. Tighten
the hose clamp.
Figure 470
4. Turn the flywheel using tool 99 309 in the direction of

engine rotation until the "TDCDown" marking is visible in
the lower inspection hatch.
Figure 471
5. Connect tool 99 557 to tool 99 620.

Ensure to undo the valve (1) counterclockwise.
Figure 472
6. Connect checking tool and carry out the check "Leak

testing the EGR system" under "EMS".
7. Pressurise the system with 1.30 bar absolute pressure.
4-1-266
8. Close the valve (2) and read the air pressure in checking
tool
A pressure drop of 0.01 bar a second is acceptable. If the
change is greater than 0.01 bar a second, there may be a
leakage.
If there is leakage, check:
• that the EGR valve closes and seals properly.
• that no external air leaks can be heard between
connections and hoses, charge air cooler or inlet
pipe.
• use soapy water or leak detection spray to visually
check for air leaks.
Check the inlet side and charge air cooler
• Remove the EGR pipe which connects to the inlet
pipe. Plug the connection and pressure test the
system according to the method above.
• If leakage is detected. Separate the pipes
downstream of the charge air cooler.
• If the pressure drop is more than 0.01 bar a second,
even with the EGR system disconnected, continue
troubleshooting to check for any other faults.
Check the EGR Valve

Disassemble the joint upstream of the EGR damper and plug the
pipe. Pressure test the system according to the method above. If
the system is sealed with the plugged pipe, the EGR valve is
leaking and must be cleaned or replaced.
If the fault is rectified
Refit all components. Pressure test the system according to the
method above. Use checking tool to delete fault codes which
may have occurred while carrying out the work.
4-1-267
EGR Valve
Overview
Figure 473
Location
Figure 474
Function
The quantity of exhaust gases returned to the engine is
controlled by means of a damper in the EGR valve. The quantity
is determined by how far the damper is open. The damper is
actuated by an electronic actuator.
The actuator changes the position of the damper after receiving
a CAN message from the engine control unit. There is an
electronic control unit in the actuator that converts the CAN
message into a mechanical movement. If CAN communication
with the engine control unit is lost, the actuator places the
damper in such a position that a pre-set opening on the damper
is obtained.
The EGR actuator obtain voltage supply separately by the
customer interface. If the voltage supply disappears, the EGR
valve is switched off.
4-1-268
Removing the EGR Valve
WARNING

2. Remove the cable bracket (A).
3. Remove the contact housing (B).
Figure 475
4. Remove the nut on the rear to detach the link arm from the
actuator.
Figure 476
4-1-269
5. Remove the actuator.
6. Release the clamp securing.
Figure 477
7. Remove the screws on the holder for the rear coolant pipe
of the EGR cooler (7).
8. Remove the coolant pipe.
Figure 478
9. Slacken the screws holding the EGR valve to the cylinder

head.
10. Remove the EGR valve.
Figure 479
4-1-270
Installing the EGR Valve
1. Install the EGR valve.
2. Fasten the screws holding the EGR valve to the cylinder
head.
Figure 480
3. Position and tighten the screws of the holder to the EGR

cooler's rear coolant pipe (7).
4. Install the coolant pipe.
Figure 481
5. Fasten the clamp securing the control line to the bypass

valve.
6. Install the actuator.
WARNING
Figure 482
4-1-271
7. Install the link arm for the actuator with a nut. Lock the nut.
Figure 483
NOTE: There is a fixed and an adjustable version of the link

arm.
The measurement between the screw holes on the
adjustable link arm should be 202 ±2 mm.
Figure 484
8. Connect the actuator to the cable harness (B).

9. Fit the cable bracket (A).
10. Calibrate the actuator using checking tool.
Check for leaks.
Figure 485
4-1-272
EGR Cooler
Location
Figure 486
Function
The EGR cooler is a fluid-cooled cooler. The exhaust gases are
cooled using coolant from the cooling system.
Removing the EGR Cooler

1 2 3
NOTE: Work in an ergonomic position!
Remove the front wing liner to obtain a better working position.
1. Partly drain the cooling system.
2. Detach the coolant hose (1).
IMPORTANT
EX1400544
Use a new coolant hose when fitting the water-cooled Figure 487
EGR cooler.
3. Detach the retaining straps holding the EGR cooler in

place (2).
4. Detach the bleed pipe from the EGR cooler (3).
5. Remove the EGR cooler.
4-1-273
Installing the EGR Cooler
1 2 3
IMPORTANT
Always fit a new hose between the bypass valve and the
EGR cooler when you have removed it. This is because the
previous hose many have been damaged internally when it
was removed.
EX1400544
1. Install the EGR cooler.
Figure 488
2. Fasten the bleed pipe to the EGR cooler (3).
3. Fasten the straps holding the EGR cooler in place (2).
4. Attach the coolant pipe (1).
5. Fill the cooling system.
Cleaning the EGR Cooler

Following serious faults in the engine such as a leaking injector,
deposits can form in the water-cooled EGR cooler that can affect
its cooling capacity. The water-cooled EGR cooler can be
cleaned as follows:
1. Remove the water-cooled EGR cooler according to the
work description above.
2. Clean with a solvent.
3. Rinse with water.
4. Fit the water-cooled EGR cooler according to the work
description above.
4-1-274
COOLING SYSTEM
coolant hoses which were removed.
Draining the Coolant
WARNING
If the engine is at operating temperature, the coolant is very
hot and can cause burns.
IMPORTANT
It is not permissible to fill large amounts of coolant by the
expansion tank. Filling by the expansion tank leads to air
locks in the cooling system which can lead to damage to
the coolant pump shaft seal.
IMPORTANT
Do not start the engine until the correct coolant level has
been obtained. If the engine is started with a coolant level
that is too low, the coolant pump shaft seal may be
damaged, which can result in leaks.
NOTE: Avoid spillage and use a suitable container. Used

coolant must be disposed of as specified in national 99 301
and international law.
1. Carefully open the expansion tank cap. The cooling system
may be exposed to overpressure.
2. Remove the rubber plug protecting the drain and filler
nipple of the cooling system.
3. Connect adapter 99 301 to the drain nipple and use
coolant trolley 588 540 to drain and collect the coolant.
FG020518
Figure 489
4-1-275
Replacing Coolant
WARNING
If the engine is at operating temperature, the coolant is very
hot and can cause burns.
IMPORTANT
It is not permissible to fill large amounts of coolant by the
expansion tank. Filling by the expansion tank leads to air
locks in the cooling system which can lead to damage to
the coolant pump shaft seal.
IMPORTANT
Do not start the engine until the correct coolant level has
been obtained. If the engine is started with a coolant level
that is too low, the coolant pump shaft seal may be
damaged, which can result in leaks.
NOTE: Avoid spillage and use a suitable container. Used

coolant must be disposed of as specified in national 99 301
and international law.
1. Connect adapter 99 301 to the drain nipple on the right-
hand side of the engine as viewed from the rear (see
illustration). Use coolant trolley 588 540 to drain or top up
coolant.
IMPORTANT
FG020518
Figure 490
It is not permissible to fill large amounts of coolant by
the expansion tank. Filling by the expansion tank leads
to air locks in the cooling system which can lead to
damage to the coolant pump shaft seal.
Checking, Pressure Testing Cooling System

NOTE: The appearance of the expansion tanks may differ.
1. Remove the expansion tank cap.
2. Check the sealing surface on the filler pipe and the cap
seal for damage.
3. Check the coolant level. Top up if necessary.
4-1-276
The illustration shows the procedure on a truck however the
principle is the same for all engines.
4. Attach cooling system tester 587 048 with adapter 99 312
in place of the filler cap.
Figure 491
5. Pump up the pressure until the delivery valve opens. The

delivery valve should open within the approved opening
pressure, see table below. If the delivery valve does not
comply with this, it should be replaced.
Tolerance in Opening Pressure 0.8 - 1.1 bar
6. Stop pumping and allow the delivery valve to close. The

pressure remaining in the system must not fall below 0.5
bar. If this requirement is not met, this may be due to
external or internal leakage on the delivery valve, see
below.
Figure 492
Delivery Valve
Check the delivery valve, replace if required.
External Leakage
External leakage is indicated by coolant leaking out onto the
ground. First check all hose and pipe connections, including
those for the bus heating system.
Internal Leakage
Internal leakage in the engine can produce white exhaust gases
and coolant in the engine oil. Then engine conditioning is the
only solution.
Internal leakage in one of the bus oil coolers can lead to oil in the
cooling system or coolant in the oil. Replace the defective oil
cooler and clean the cooling system as described in 02:01-11
Cooling system, Cleaning.
4-1-277
Internal Cleaning of Cooling System
IMPORTANT
Do not use caustic soda as this could damage the
aluminium.
WARNING
To ensure proper handling of cooling system detergent,
study the warning text on the package.
NOTE: Use a container to avoid spills when changing the

coolant. Make sure that the coolant is disposed of in
compliance with national and international
regulations.
Removing Oil and Grease

1. Run the engine until it has reached operating temperature
and then drain the cooling system.
2. Remove the thermostats.
3. Fill the system with clean, hot water mixed with dishwasher
detergent intended for household machines. Concentration
1% (0.1/10 §¤).
4. Warm up the engine for approximately 20 - 30 minutes.

6. Fill the system with clean, hot water and run the engine for
about 20 - 30 minutes.
7. Drain the water from the cooling system.
8. Refit the thermostats.
9. Fill the cooling system with fresh coolant.
Removing Deposits
1. Run the engine until it has reached operating temperature
and then drain the cooling system.
2. Remove the thermostats.
3. Fill the system with clean, hot water mixed with some
commercially available radiator cleaning agent which is
based on sulphamic acid and contains dispersing agents.
Follow the manufacturer's instructions for the
concentration and cleaning period.
4. Run the engine for the specified time.
4-1-278
6. Fill the cooling system with clean, hot water and run the
engine for about 20 - 30 minutes.
7. Drain the water from the cooling system.
8. Refit the thermostats.
9. Fill the cooling system with fresh coolant.
Charge Air Cooler
Function
Maximum engine output depends among other things on the
amount of fuel that can be efficiently combusted in the engine.
Cold air has a higher density and contains more oxygen by
volume than heated air. The temperature of the intake air
increases when passing through the turbocharger. If the air then
is cooled, the air density increases and more oxygen is supplied
to the engine. This means that more fuel can be combusted.
If more fuel is combusted, this results in higher output, lower fuel
consumption and lower emissions. The cooled air lowers the EX1302113
combustion temperature as well as the temperature of the parts Figure 493
affected by the combustion, resulting in lower thermal stress in
spite of the increased engine output.
Intake system
The intake system consists of pipes that lead air from the
turbocharger to the charge air cooler. The charge air is cooled
by the air passing on the outside of the charge air cooler.
After being cooled down, the intake air is led to the intake
manifold, which distributes the air to the cylinders.
NOTE: Replacing coolant hoses if there is clear damage to
the coolant hoses which were removed.
WARNING
For ethanol-powered engines: Read the regulations for
ethanol in document 00:01-02 before starting work Follow
the instructions in the section Procedures for all work in the
workshop.
Comply with the rules on working with ethanol which have
been established locally for the workshop.
Test pressurising the charge air cooler
4-1-279
Connect test equipment
Figure 494
1. Remove the hose downstream and closest to the

turbocharger.
Figure 495
2. Install the cover and tighten the pipe clamps.

NOTE: Make sure the cover is firmly secured.
Figure496
3. Remove the hose nearest the intake manifold.

4. Install the cover with the air connection union and tighten
the pipe clamps.
NOTE: Make sure the cover is firmly secured.
5. Connect the measuring equipment to the cover.
Figure 497
4-1-280
Test Pressurisation
1. Apply compressed air to the test equipment and pressurise
the charge air cooler to 0.7 bar.
2. The pressure must not drop by more than 0.2 bar in 60
seconds.
If the pressure falls more, look for the cause and rectify the
fault.
Use leak detection spray when looking for leaks.
Check the pipes
Check that there are no cracks in those sections of the intake
system that cannot be test pressurised.
Charge Air Temperature Sensor
Symbol
EX1302114
Figure 498
Location
T121
EX1302115
Figure 499
Specification
Resistance at 20°C: 2,419 ±85Ω.
Temperature sensitivity: Between -40 and +120°C.
Description
The sensor informs the engine control unit of the current charge
air temperature.
4-1-281
Overview
EX1302117
Figure 500
Function
The charge air temperature sensor detects the temperature in
the inlet pipe between the turbocharger and the charge air
cooler.
The engine control unit uses the information from the sensor to
control the relationship between the intake air and EGR gases
going to the engine. The sensor also monitors the temperature
of the air coming into the charge air cooler so that it is not higher
than the temperature the charge air cooler material can
withstand.
When there is a high power output the turbocharger rotates at a
high speed. A high turbocharger speed means that the pressure
and thereby the temperature of the air coming into the charge air
cooler increases. If the temperature is higher than is permitted,
the engine control unit limits the power output by reducing the
quantity of fuel injected.
The sensor is of the NTC type, which means that its resistance
is temperature dependent.
If the temperature increases, the resistance in the sensor drops.
The engine control unit converts the sensor resistance to
voltage. If the voltage is outside a certain range, the engine
control unit will work to a pre-programmed temperature value,
and a fault code will be generated. The engine will then react
slower than normally during throttle application.
Removing and Fitting the Charge Air Temperature Sensor

Sensor protection 1 855 015 should be used when the sensor is
not fitted.
Figure 501
4-1-282
Charge Air Pressure Sensor
Symbol
EX1302118
Figure 502
Location
T122
EX1302119
Figure 503
Description
The sensor informs the engine control unit of the current charge
air pressure.
Overview
EX1302120
Figure 504
4-1-283
Function
The charge air pressure sensor detects the absolute pressure in
the intake manifold, i.e. the atmospheric pressure plus the
positive pressure provided by the turbocharger.
The signal from the sensor is directly proportional to the charge
air pressure. A high pressure gives a high voltage and vice
versa.
The engine control unit uses the information from the charge air
pressure sensor to control the relationship between the intake
air and EGR gases going to the engine.
Depending on the factors that requested the acceleration,
engine speed, engine acceleration and charge air temperature,
the engine control unit will expect a certain charge air pressure.
Should there be a fault in the signal, the engine control unit will
work to a preset pressure value. At the same time, the engine
torque will be limited and a fault code will be generated.
Coupling Coil for AC Compressor

Description
The coupling coil activates the AC compressor following a
request from the engine control unit.
Symbol
V2
2
1
Location
V2
EX1302122
Figure 506
4-1-284
Overview
Figure 507
Function
The coupling coil is electromagnetic and controlled by the
engine control unit. Request for the AC compressor is sent to
the engine control unit from the electronic control unit for
controlling air temperature, or if this is missing, from the control
system which reads the manually requested AC. The engine
control unit does not activate the AC compressor if the coolant
temperature is too high.
Thermostat
Description
The thermostat is used to regulate the amount of coolant which
passes through the radiator.
Location
FG020519
Figure 508

4-1-285
Overview
Reference
Description
Number
1 to the Coolant Pump
2 from Engine
3 to the Coolant Pump
Figure 509
Function
For engines with heat exchanger, there are also 2 thermostat
housings located at the front on the exhaust manifolds. For
engines with keel cooling, there is also a thermostat housing
located at the front on the right-hand exhaust manifold. The
thermostat is used to maintain the correct engine temperature
by regulating the amount of coolant passing through the heat
exchangers. When the coolant temperature is below the opening
temperature of the thermostat, coolant will just circulate in the
engine so that the engine heats up faster. Once operating
temperature has been attained, the thermostat will open to allow
the coolant to circulate through the heat exchanger.
Removing the Thermostat Housing

2. For generator set: Remove the fan guard on the right-hand
side to access the thermostat housing.
3. Remove turbocharger air hose, unscrew the outer part of
the thermostat housing and remove thermostat.
FG020520
Figure 510
4-1-286
Installing the Thermostat Housing
1. Clean the thermostat housing and check that nothing
obstructs the function of the thermostat.
FG020520
Figure 511
2. Install a new gasket, position the thermostat against the

cylinder block and install the thermostat housing. Tighten
the screws. Install the turbocharger air hose.
3. For generator set: Install the fan guard on the right-hand
side.
5. Start the engine and check that no leakage occurs. Check
the coolant level and top up if necessary.
Inspection of Thermostat Operation

1. Unscrew the thermostat housing bolts and remove
thermostat.
2. Submerge the thermostat in a vessel of boiling water. It
should hang freely without touching the sides and bottom
of the vessel.
3. Check that thermostat opens fully without jamming within
three minutes.
4. Check that thermostat closes fully when it has cooled
down.
5. If it does not work as described in points 3 and 4 or if it
jams, replace the thermostat.
4-1-287
Coolant Pump
Remove Coolant Pump

1. Drain the cooling system. See subgroup 02-00, Cooling
system.
2. Remove the fan, if fitted.
3. Remove the protective casing for the belt drive, if fitted.
EX1302165
Figure 512
4. Remove the outer and inner belt transmission.

5. Remove the upper idler roller.
6. Remove the bracket of the fan pulley.
7. Remove centre idler roller.
8. Undo and remove the pump with its housing.
EX1400006
Figure 513
9. Remove the pump housing from the pump if the gasket

must be replaced.
FG020521
Figure 514
4-1-288
Install the Coolant Pump
1. Install the pump gasket.
2. Screw the pump to the housing.
3. Install the housing gasket.
4. Install the housing and pump to the engine.
5. Secure the belt transmission.
6. Fill with coolant according to the work description for filling
coolant.
Coolant Temperature Sensor
Description
The sensor measures the coolant temperature in the cylinder
block after the coolant has passed the combustion chamber.
Symbol
T33
FG020522
Figure 515
Location
T33
FG020523
Figure 516
NOTE: The O-ring can be replaced separately. Check the

O-ring, replace if necessary.
4-1-289
Overview
EX1302060
Figure 517
Function
The engine control unit uses the value from the coolant
temperature sensor to adjust the fuel quantity and injection
timing when starting the engine and when the engine is cold.
The coolant temperature also affects the idling speed and
maximum engine speed when the engine is cold and the engine
power when it is too warm. Directly after a cold start, the engine
control unit limits the engine speed to 1,000 rpm in order to
protect the engine, the idling speed is raised to 600 rpm. The
length of time engine speed limitation is engaged varies
depending on the coolant temperature.
Less than +10°C, approximately 40 seconds
More than +20°C, approximately 8 seconds
The idling speed returns to normal when the coolant has
reached 20 - 60°C (the temperature limit differs between engine
types). In certain engines, the engine power is limited when the
coolant temperature exceeds a certain temperature, between
116°C - 117°C depending on the engine type. The engine power
is limited so that the engine does not overheat, and a fault code
is generated at the same time. The sensor is of the NTC type,
which means that its resistance is temperature dependent. If the
temperature increases, the resistance in the sensor drops. The
engine control unit converts the sensor resistance to voltage. If
the voltage is outside a certain range a fault code will be
generated and the control unit will operate according to a preset
temperature value. The engine will then have poorer cold-start
characteristics and will emit more white smoke in cold weather.
Coolant temperature affect EGR, white smoke limiter and
adaptations.
4-1-290
FUEL SYSTEM
General Information
Overview
Fuel System Components 1 2 3 4 5

6
Reference 13
Description
Number 8
1 Connection
10
2 Injectors 12 7
3 Accumulator 9 11
4 Fuel Pressure Sensor
Remote
5 Safety Valve Fuelfilter
6 Bleed Nipple
EX1401013
7 High Pressure Pump
Figure 518
8 Fuel Inlet Metering Valve
9 Feed Pump
10 Hand Pump
11 Fuel Filter, 2 OFF
12 Fuel Manifold For Return Fuel
13 Overflow Valve
Schematic Diagram of the Fuel System

15
7 8 9 10
Reference
Description 12 16
Number
11 13
1 Fuel Tank
2 Hand Pump with Check Valves 6 14
3 Fuel Filter, Water Separating Suction Filter 17
18
4 Control Unit Cooler
5 3
5 Feed Pump 2
6 Fuel Filter, Pressure Filter 4
1
7 Fuel Inlet Metering Valve
8 Check Valve 19
9 High Pressure Pump EX1302126
10 Check Valve Figure 519
11 Venturi
12 Accumulator
13 Connection
14 Injectors
15 Fuel Pressure Sensor
16 Safety Valve
17 Fuel Manifold for Return Fuel
18 Return Pipe with Pressure Regulator
19 Venturi for Draining Water
4-1-291
WARNING
The fuel system has a very high fuel pressure of up to 3000
bars. The fuel system must be depressurised before any
work is started.
Minimize the high pressure in the fuel system.
The system should always be treated as pressurised, even
when the engine is switched off.
IMPORTANT
The fuel system is very sensitive to dirt. It is therefore very
important that everything is as clean as possible when work
is carried out on the fuel system.
When the fuel system has been opened, compressed air
must not be used to blow clean components.
When cleaning, rags or paper which shed fibres must not
be used. Use lint-free rags.
Clean tools before use.
Do not use worn chrome-plated tools as flakes of chrome
may come off.
Cover connections of removed components with a lint-free
cloth and tape.
Function 7 8 9 6
Reference
Description 10
Number
A High-pressure
B Low-pressure
C Return 3
1
The feed pump draws fuel from the fuel tank. The fuel is taken A 2
B 4
into connection 1 and drawn through the suction filter. From the 5
C
suction filter the fuel is drawn into the feed pump.
EX1401014
The feed pump builds up the fuel pressure to between 8 and 11 Figure 520
bar and forces the fuel through the pressure filter by the fuel pipe
3. The fuel flows from the pressure filter by the fuel pipe 4 on to
the fuel inlet metering valve fitted on the high pressure pump.
The fuel inlet metering valve controls how much fuel should be
led into the high pressure pump when requested to do so by the
engine control unit.
4-1-292
The high pressure pump builds up the fuel pressure to a
maximum of 3,000 bars. The fuel is taken on to the accumulator
by high pressure pipe 6.
A high pressure pipe 7 runs from the accumulator to each
connection bringing fuel to the injectors. When the solenoid
valve in the injector is supplied with voltage, the injector opens
and fuel is injected into the cylinder.
The fuel system works under high fuel pressure and it is
therefore important that there is no water in the fuel on the high
pressure side. Water causes corrosion and damage of the fuel
system components and the components will be damaged due
to the tight tolerances of the system. To prevent water in the
high pressure side of the fuel system, water is separated from
the fuel at the suction filter and taken back to the fuel tank by the
pipe 5.
There is a safety valve 8 on the accumulator that opens if there
is a fault in the fuel system, which results in the fuel pressure
becoming too high. The safety valve opens at a pressure of
3,000 bar and reduces the fuel pressure to 1,000 bar and then
regulates the fuel pressure so that it remains at 1,000 ±300 bar.
When the safety valve opens, the fuel is returned by the pipe 9.
Fuel which is taken out by the safety valve will heat up the pipe
after the safety valve.
Excess fuel from the injectors flows from the fuel manifold back
to the fuel tank by the pipe 10.
Fuel quantity and injection timing
Injection timing and the amount of fuel to be injected is
determined by the engine control unit. Injection duration and the
fuel pressure in the accumulator determine the amount of fuel
which is injected into the cylinder.
Fuel system adaptation
During adaptation, the engine idles hard with the exhaust brake
active.
Fuel manifold
Excess fuel from the injectors is routed to the fuel manifold and
then back to the fuel tank. The fuel manifold is pressurised to 0.7
bar.
Hand pump
The hand pump is used for the bleeding of the fuel system in
emergencies, such as engine stops.
Feed pump
On the engine, the feed pump, also called the low pressure
pump, is located on the high pressure pump and is driven by the
high pressure pump camshaft.
The feed pump draws fuel from the fuel tank and forces it
through the pressure filter to the high pressure pump. The fuel
pressure after the feed pump is between 9 and 12 bars.
4-1-293
The fuel pressure is governed by an internal pressure regulator
in the feed pump. Excess fuel is led back to the suction side of
the feed pump.
Safety valve
The safety valve on the accumulator opens if the fuel pressure
gets too high.
The safety valve has 2 stages. When the fuel pressure exceeds
3,000 bar the safety valve opens so that the fuel pressure drops
to approximately 1,000 bar. The safety valve regulates the fuel
pressure so that it remains at 1,000 bar ±300 bar. The engine
loses a great deal of output when the safety valve opens.
The safety valve is reset after the engine is switched off. The
high pressure pump will increase the fuel pressure again in the
accumulator to 2,400 bar unless there is a fault in the fuel
system which causes the safety valve to open.
Control unit cooler
The engine control unit is cooled by the fuel that passes through
the control unit cooler.
High pressure pump
The high pressure pump is driven by the engine crankshaft.
The high pressure pump has a fuel inlet metering valve which
regulates the fuel flow to it.
The pistons in the cylinders of the high pressure pump are
floating, which means that they only move when fuel is brought
into the high pressure pump.
When fuel is led into the high pressure pump, the pistons will be
pushed downwards by the fuel. When the high pressure pump
camshaft rotates, the pistons are pressed upwards pressing the
fuel out to the accumulator. When the high pressure pump does
not receive any fuel, during engine braking for example, the
pistons remain in their top positions until new fuel is introduced.
The high pressure pump has check valves which prevent the
fuel flowing the wrong way.
Water separating suction filter
The feed pump draws fuel from the fuel tank through the suction
filter. A first filtering of fuel and a separation of water takes place
in the suction filter.
Pressure filter
The pressure filter is located downstream of the feed pump and
performs a finer filtration than the suction filter.
4-1-294
Water separation
The fuel system is sensitive to water. Water must therefore be
separated from the fuel.
Water is separated from the fuel in the water separating suction
filter and is collected in the bottom of the fuel filter housing.
A proportion of the fuel from the pressure filter is led back to the
fuel tank, and on its way back the fuel passes a venturi. The
water is extracted from the water separating suction filter by
means of the venturi and travels with the return fuel.
The water is collected in the fuel tank and if necessary the fuel
tank should be drained of water.
Reference
Description
Number
1 Venturi
2 Fuel Tank
3 Water Separating Suction Filter
4 Fuel
5 Water
6 Draining
Figure 521
Measuring the Fuel Pressure

NOTE: The test connection for measuring fuel pressure is
located on the high-pressure pump (at the arrow to
the left in the illustration) and the fuel manifold (at the
arrow to the right in the illustration).
Measuring Supply Pressure FG020526

Figure 522
1. Connect pressure gauge 99 362 to the test connection on
the high-pressure pump and open the test connection.
2. Crank with the starter motor for approximately 20 seconds.
Read the pressure. The pressure must be more than 3 bar.
3. If the engine starts: Increase engine speed to 1,500 rpm.
Read the pressure. The pressure must be between 9 and
14 bar.
4. Switch off the engine, remove pressure gauge and close
the test connection.
4-1-295
Measuring Fuel Pressure at the Fuel Manifold When the
Engine Cannot be Started
the fuel manifold and open the test connection.
2. Start the engine. Read the pressure with the engine idling.
The pressure must be below 0.8 bar.
3. If the pressure is above 0.8 bar, proceed as follows:
• Remove overflow valve.
• Clean the overflow valve and check that it is not
blocked.
• Install the overflow valve.
• Bleed the fuel system by idling the engine for a while.
• Take a new reading.
If the pressure of the new reading exceeds 0.8 bar, there is
internal leakage in an injector.
Measuring Fuel Pressure at the Fuel Manifold When the

Engine Cannot be Started
the fuel manifold and open the test connection.
2. Crank with the starter motor for approximately 20 seconds.
Read the pressure. The value must be below 0.8 bar.
3. If no value can be read after 20 seconds: Allow the starter
motor to cool down and repeat step 2.
NOTE: If there is air in the filter housing, pressure
cannot build up. Bleed the filter housing and try
again.
4. Remove pressure gauge and close the test connection.
Accumulator
Description
The fuel is collected in the accumulator. The accumulator
ensures that the fuel pressure to the injectors is adequate. The
fuel pressure in the accumulator is approximately 2,400 bar.
Location
EX1401015
Figure 523
4-1-296
Fuel Manifold
Removing the Fuel Manifold
IMPORTANT
is done on the fuel system.
Do not use compressed air to blow components in the fuel
system clean.
may come off.
rag and tape.
EX1401016
Figure 524
1. Undo the brackets and move the electrical cables to one

side.
2. Remove return pipes 1 and 2.
3. Undo the fuel manifold bolts, marked with arrows in the
illustration, and pull out the fuel manifold towards the rear
end of the engine.
4-1-297
Installing the Fuel Manifold
EX1401016
Figure 525
1. Insert the bolt at the far left of the fuel manifold. Pull in the
fuel manifold from the rear end of the motor and screw in
all fuel manifold bolts; see the arrows.
2. Check that gaskets around the intake have not come
loose. The gaskets must protrude above the fuel manifold.
3. Install the return pipes 1 and 2.
4. Install the electrical cables by screwing in the brackets.
FG020528
Figure 526
4-1-298
Removing High-pressure Pipes and Connections
WARNING
3,000 bars (43,500 psi). The fuel system must be
depressurized before any work is started.
Minimize the high-pressure in the fuel system.
The system should always be treated as pressurized, even
IMPORTANT
may come off.
rag and tape.
To remove an injector from the cylinder head, its connection

must first be removed. 1
Reference
Description
Number
1 High-pressure Pipe
2 Connection
3 Injector
1. Start by depressurizing the fuel system. Minimize the

high-pressure in the fuel system. 2 3 FG020529
Figure 527
4-1-299
2. Place a rag over the high-pressure pipe cap nut 1 (at the 1
accumulator) of the cylinder in question. Then carefully
undo the nut. 2
3. Undo the cap nut in the other end of the high-pressure pipe
and remove pipe.
4. Undo the cap nut at connection 2. Hold tight so the
connection is not turned when the cap nut is undone.
There is a pin on the connection which can be damaged.

EX1401017
Make sure that it is clean around the connection

before it is drawn out from the engine. Dirt must not
enter the fuel system.
IMPORTANT
A high-pressure pipe that has been loosened or
removed, must never be reinstalled but must be
replaced by a new one.
5. Pull out the connection from the cylinder head. If it jams

and is difficult to pull out, you can replace the cap nut with
a nut with part number 812 889 and break carefully with a
crow bar.
EX1401018
Figure 529 When removing unions
and safety valve
Several unions and the safety valve in the system are sealed
with a sealing washer which must be replaced if the parts have
been disassembled. There is a plug at the accumulator end on 5
cylinder engines. This is sealed with the same type of washer.
The old washer is often stuck and can be difficult to remove
without damaging the sealing surface.
4-1-300
NOTE: Make a simple special tool using a standard 3-4 mm
hexagon key. Grind down the shorter end as
illustrated (12.7 mm) and use the tool to ease the
washer out of its spot.
FG020532
Figure 530
Installing High-pressure Pipes and Connections

1. Lubricate the new O-ring on the connection using engine
oil. Also check that pin is secure.
2. Press the connection into the cylinder head with the pin
facing upwards in the designated hole. Tighten the cap nut.
IMPORTANT
Make sure that high-pressure pipe is free of dirt before
it is installed to the engine.
3. Install the high-pressure pipe. Remove plugs and install

both ends of the high-pressure pipe before torque
tightening.
4-1-301
Removing the High-pressure Pump
WARNING
depressurized using checking tool before any work is
started.
IMPORTANT
A high-pressure pipe that has been loosened or removed,
must never be reinstalled but must be replaced by a new
one.
IMPORTANT
be used. Use lint-free rags. Clean tools before use.
may come off.
Plug or tape connections on components which are
removed.
IMPORTANT
must never be reinstalled and must be replaced by a new
one.
1. Start by depressurizing the fuel system.

Minimize the high-pressure in the fuel system.
Place a rag over the high-pressure pipe nut at the
accumulator. Then carefully undo the nut.
4-1-302
2. Remove fuel pipes. Mark the them to make installing
easier.
3. Separate the fuel metering valve cable harness.
4. Remove fuel filter housing.
5. Remove starter motor.
6. Unscrew the high-pressure pump and lift it out carefully.
Leave the bracket for the high-pressure pump behind. This
will make installing easier.
Installing the High-pressure Pump

1. Lift the high-pressure pump into position and screw into
place.
2. Undo the tapered joint which holds the high-pressure pump
bracket against the cylinder block, and then tighten it
again. This is done to remove any stresses.
1
5
3
6
2 4
Reference
Description
Number
1 Fuel filter housing.
2 Fuel line between the feed pump and the control unit cooler.
3 Fuel inlet line.
4 Fuel line between the fuel filter and the high-pressure pump.
5 Fuel line between the high-pressure pump and accumulator.
6 Return line between the high-pressure pump and the fuel filter.
7 Return line between the fuel manifold and the high-pressure pump.
4-1-303
Replacing the Cylinder Head for The High-pressure Pump
on Engines
WARNING
depressurized using checking tool before any work is
started.
IMPORTANT
Do not use compressed air to blow clean components in the
fuel system.
be used. Use lint-free rags. Clean tools before use.
may come off.
removed.
1 2
IMPORTANT
A high-pressure pipe that has been loosened or removed 3
must never be reinstalled and must be replaced with a new
one.
1. Tilt the cabin according to the instructions. 5 4

2. Remove mudguard according to the instructions.
3. Clean around the fuel system. EX1401020
4. Depressurize the fuel system. Minimize the pressure. Figure 532

Place a rag over the high-pressure line nut (1, Figure 532).
Then carefully undo the nut.
5. Undo the cable connection.
6. Remove high-pressure line (2, Figure 532) and install
clean plugs in the fuel connections.
NOTE: The high-pressure line must not be reused.
4-1-304
7. Undo the banjo unions on the high-pressure pump.
8. Remove fuel return line (3, Figure 532) and plug the fuel
manifold. Detach the lines (4 and 5, Figure 532) from the
cylinder head.
9. Undo the cylinder head screws alternately. Remove
cylinder head and gasket.
10. Remove protective plugs on the new cylinder head. Install
new springs, a new gasket and new screws.
11. Clean the pump surface that faces the cylinder head.
Check that guide pins under the roller tappets are straight
and that roller tappets are correctly positioned so they go
down completely in their seats; see illustration. Screw the
cylinder head into place alternately.
4-1-305
Overflow Valve
Description
The overflow valve controls the pressure downstream of the
injector in the fuel system.
Location
Overview
Figure 534
Function
The overflow valve controls the pressure downstream of the
injector in the fuel system.
The normal operating pressure downstream of the injector is
0.7 bar.
The overflow valve uses a channel in the fuel manifold to
recirculate return fuel to the fuel filter, which returns the fuel to
the fuel tank by a channel. Figure 535
4-1-306
Removing Overflow Valve
NOTE: The washing water must be disposed of in
compliance with the relevant national or local
regulations.
NOTE: Help protect the environment! Avoid spillage and use
a suitable container.
IMPORTANT
Protect all connections from dirt.
1. Wash the engine.

2. Remove the cap nut.
EX1401022
Figure 536
3. Remove the banjo screw and washers.
EX1401023
Figure 537
4. Remove the fuel pipe.
EX1401024
Figure 538
4-1-307
5. Remove the overflow valve.
EX1401025
Figure 539
Installing Overflow valve

1. Install the overflow valve.
EX1401025
Figure 540
2. Install the fuel pipe.
EX1401024
Figure 541
3. Install the banjo screw and washers.
EX1401023
Figure 542
4-1-308
4. Install the cap nut.
EX1401022
Figure 543
Feed Pump
Description
The feed pump supplies the engine's unit injectors with fuel.
Location
The feed pump is located at the rear of the compressor.
FG020558
Figure 544
Function
On the engines the feed pump is located on the high pressure
pump and is driven by the high pressure pump camshaft. The
feed pump draws fuel from the fuel tank and forces it through the
pressure filter to the high pressure pump. The fuel pressure after
the feed pump is between 9 and 12 bars. The fuel pressure is
governed by an internal pressure regulator in the feed pump.
Excess fuel is led back to the suction side of the feed pump.
4-1-309
Replacing the Pump Cylinder Head
IMPORTANT
A high pressure pipe that has been detached or removed
must never be refitted but must be replaced with a new one.
The illustration below shows the high pressure pump cylinder

head and its parts. The instructions refer to the numbered parts
on the illustration.
15 14
13
10
3 9
1 16
12
11
20
21
22
17
19
18
4
4-1-310
Reference Reference
Number Number
1 Fuel Pump 12 Flange Nut
2 O-ring 13 Fuel Inlet Metering Valve
3 O-ring 14 O-ring
4 Fuel Pump 15 O-ring
5 Seal 16 Screw
6 Fuel Pump 17 Union
7 Gasket 18 Straight Union
8 Screw 19 Sealing Washer
9 Union 20 Flange Screw
10 Seal 21 Stud
11 Gear 22 Lock Nut
Removing
1. Remove the high pressure pump.
1
2. Gradually slacken the screws on the cylinder head (8) in a
diagonal sequence as illustrated. The tension in the 3
4
springs can cause the cylinder head to stick if the screws
are not slackened off in this way. 2
3. Remove the cylinder head (6) with gasket (7).
EX1302068
Figure 546
Installing
4. If a new cylinder head is to be fitted: Remove the
protection plugs on the new cylinder head. Fit new springs,
a new gasket and new screws.
5. Clean the pump surface that faces against the cylinder
head. Check that the guide pins under the roller tappets
are straight and that the roller tappets are correctly
positioned so that they go down completely in their seats;
see illustration.
6. Install the gasket (7) on the high pressure pump (1).
7. Install the cylinder head (6).
8. Lubricate the cylinder head screws (8) and fit them on the
cylinder head. Figure 547
4-1-311
9. Gradually tighten the screws in a diagonal sequence as
illustrated. The tension in the springs can make it difficult to
screw on the cylinder head if the screws are not tightened 1
in this way.
3
10. Install the seal and high pressure pipe union (9) in the 4
cylinder head.
2
11. Lubricate and install the two O-rings on the valve (14, 15).
Then fit the valve in the cylinder head using the two
screws.
12. Install the high pressure pump.
EX1302068
Figure 548
Check
High pressure pump cylinder head.
Applies to engines with cylinder block generation 2.
NOTE: Observe strict cleanliness. Carry out the work in a
fume cupboard.
1. Remove the high pressure pump.
Removing the high pressure pump on the engines.
2. Remove the high pressure pump cylinder head.
Replacing the high pressure pump cylinder head on the
engines.
3. Turn the cylinder head so that the underside is facing
upwards.
4. Remove the springs.
Figure 549
5. Install 2 plugs 813 204.
4-1-312
6. Hold the 2 holes and carefully blow compressed air into the
third hole, see illustration. Blow until the 2 ceramic rods are
pushed out of the cylinders. Keep track of which cylinder
each ceramic rod belongs to and which direction it faces.
WARNING
Use goggles. If the check valve is in a poor condition,
the ceramic rods can be rapidly pushed out. Figure 550
7. Carefully refit the ceramic rods in the cylinders. It is

extremely important that the ceramic rods are refitted in the
same cylinder and in the same direction as before.
Figure 551
There are 2 different designs of ceramic rods. A is the earlier

design which is the same in both ends. B is the later design
where one end is more pointed. The pointed end must always
be turned towards the cylinder head and the flat end towards the
spring disc. A
EX1302066
Figure 552
8. Press down the ceramic rods. If they are fault free they
should spring up again. If the ceramic rods do not spring
up, the cylinder head should be replaced.
9. Remove the plugs and refit the springs.
10. Refit the cylinder head.
11. Replcing the high pressure pump cylinder head on the
engine.
12. Install the high pressure pump. Installing the high pressure
pump on the engine.
Figure 553
4-1-313
Removing Feed Pump
WARNING
3,000 bars (45,000 psi).
Use checking tool to minimize the high-pressure in the fuel
system.
IMPORTANT
Compressed air must not be used to blow components
clean if the fuel system is open.
may come off.
Cover connections of removed components with a lint free
cloth and tape.
1. The fuel pipes (1 and 2) must be removed before the feed

pump (A) can be removed. 1
Mark the feed pump and fuel pipes to make installing

easier.
2. Undo the feed pump and draw it out. A
3. Replace the O-ring.
2
4. Install the pump. Turn and carefully push in the pump until
pump coupling engages.
EX1401026
5. Make sure that feed pump is pressed all the way in against
Figure 554
the high-pressure pump before tightening the bolts.
Installing Feed Pump

1. Replace the O-ring and refit the pump. Turn and carefully
push in the pump until the pump coupling engages.
2. Make sure that the feed pump is pressed all the way in
against the high-pressure pump before tightening the
screws.
4-1-314
Injector
WARNING
The fuel system has a very high fuel pressure of up to 3,000
bar.
The system should always be treated as pressurised, even
IMPORTANT
is carried out on the fuel system.
Compressed air must not be used to blow components
clean if the fuel system is open.
When cleaning, cloths or paper which shed fibres must not
be used. Use lint-free cloths.
may come off.
cloth and tape.
IMPORTANT
The holes in the injection nozzles are very small and must
not be cleaned with any kind of cleaning tool because it will
damage them.
Function
There is one injector for each cylinder. The injector is controlled
electrically by the engine control unit.
The injector operates in two phases. One phase is when no
power is supplied to the injector and it is closed. The other
phase is when power is supplied to the injector and it is open.
The injector consists of a piston, injection nozzle needle, spring
and an electromagnetically controlled fuel valve.
The fuel enters the injector by the connection. The injector is
continuously pressurised to a maximum of 2,400 bar. When the
4-1-315
solenoid valve is supplied with power and opens, fuel is injected
into the cylinder.
Injection timing and the amount of fuel to be injected is
determined by the engine control unit. Injection duration and the
fuel pressure in the accumulator determine the amount of fuel
which is injected into the cylinder.
Phase 1, no power to the solenoid valve in the injector
No power is supplied to the injector solenoid valve and the
injector is closed. There is a fuel pressure of between 350 and a
maximum of 2,400 bar in the injector.
Figure 555
Phase 2, power to the solenoid valve in the injector

Power is supplied to the injector solenoid valve which then
opens, so that the fuel flows up into the valve part. The pressure
difference which arises in the injector means that the piston is
drawn upwards and fuel is injected into the cylinders.
When power is switched off to the solenoid valve, the fuel
pressure in the injector pushes the piston downwards and
closes the injector.
Figure 556
4-1-316
Removing Injector
Reference
Description
Number
8
1 Injector
2 O-ring
3 Seal
7
4 O-ring
5 High-pressure Connection Pipe 6
6 Nut
7 Holder 1 5
8 Screw 4
1. Start by depressurising the fuel system.

Minimize the high pressure in the fuel system.
2. Place a rag over the high pressure pipe nut at the
accumulator for the cylinder where the injector has to be
2
removed. Then carefully undo the nut.
3. Remove the upper rocker cover. 3 EX1302069
Figure 557
4. Undo the nuts for the injector electrical connections.
5. Remove the high pressure pipe. Undo the cap nut at the
connection to the injector.
IMPORTANT
Make sure that it is clean around the connection
before the connection is removed from the engine. Dirt
must not enter the fuel system.
IMPORTANT
A high pressure pipe that has been removed must
never be refitted but must be replaced with a new one.
Note: When working with the injector on cyl. 5, the
pipe for cyl. 6 must be replaced.
4-1-317
6. Plug the connections so that dirt cannot penetrate.
7. Undo the cap nut for the connection and pull the
connection upwards.
NOTE: If it is difficult to pull the connection upwards,
you can replace the cap nut with nut part
number 812 889 and break carefully with a crow
bar.
8. Plug the connections so dirt cannot penetrate.
9. Undo the injector holder screw.
IMPORTANT
The injector must be reinstalled to the same cylinder it FG020552
was removed from.
Figure 558
IMPORTANT
Do not pry into the valve part.
10. Undo the injector using the special tool by prising in the
groove on the injector sleeve. Check to ensure that the
sealing washer follows along up and does not remain in the
cylinder head.
11. Plug the injection part of the injector, as well as where the
connection is made, so that dirt cannot enter.
12. If several injectors are removed, number and place the
injectors in sequence so they are reinstalled on the same
cylinders.
FG020553
Figure 559
4-1-318
Installing Injectors
IMPORTANT
If one or more injectors are replaced, the engine control unit
must be programmed so the injector(s) injects (inject) the
correct amount.
IMPORTANT
must never be reinstalled and must be replaced by a new
one.
IMPORTANT
Check carefully that all parts that are reinstalled are clean. It
is very important that no dirt enters the fuel system.
IMPORTANT
The connectors on the injector are very susceptible to
damage.
1. Remove old washer by prying it off using a screwdriver.

Take care not to damage the injection nozzle tip.
Install a new sealing washer on the unit injector.
Cut a plastic pipe to approximately 50 mm, diameter
16 mm. Press the washer into position as far as it will go.
Then place the plastic pipe over the injection nozzle tip as
illustrated.
Hold the injector in one hand and the plastic pipe in the
other hand. Carefully tap the washer into place against a
workbench. Make sure that connectors are not subjected
to any knocks.
FG020554
Figure 560
4-1-319
2. Note the code which appears on the bottom line of text on
the injector; see the illustration. The code is needed later
when calibrating the injector. xx xxx x
xx xxx x
xx xxx x xx
xx xxx x x xx
3. Replace the O-ring on the injector and lubricate the O-ring

with engine oil.
IMPORTANT
The injector is carefully placed in position and
screwed into place using the holder.
4. Install the holder to the injector and place the injector

loosely in the groove.
5. Use the holder to make sure that injector is in the correct FG020555
position.
Figure 561
6. Screw on the holder.
7. Lubricate the new O-ring on the connection using engine
oil. Also check that pin is secure.
8. Press the connection into the cylinder head, with the pin
facing upwards, in the designated hole. Tighten the cap
nut.
9. Tighten the injector holder screw.
10. Tighten the connection cap nut.
11. Install the electrical connectors and the nuts.
12. Position the high-pressure pipe. Remove plugs and install
both ends of the high-pressure pipe before torque
tightening.
13. Install the rocker cover.
14. Enter the code for the new injector into the control unit.
15. Reset the adaptation of the fuel amount.
4-1-320
Fuel Filter
Location
2
Reference 1
Description
Number
1 Water Separating Suction Filter 3
2 Pressure Filter
3 Inlet, Fuel from the Fuel Tank 8
Fuel From the Suction Filter to the Control
4 4
6
Unit Cooler
5 Recirculation to Fuel Tank 5
7 EX1401027
Recirculation from the High Pressure
6 Figure 562
Pump and Injectors
Fuel from the Pressure Filter to the High
7
Pressure Pump
Fuel From the Feed Pump to the Pressure
8
Filter
9 Bleed Nipple
Removing Fuel Filter

NOTE: Use a suitable container. Used fuel must be disposed A B
of as specified in national and international laws and
regulations.
IMPORTANT
Always start with the water separating suction filter (A). Do
not open the pressure filter cover (B) until the filter housing
for the water separating filter (A) is completely drained.
EX1401028
Figure 563
1. Make a mark on the water separating suction filter cover A

(A). Unscrew the cover 3 to 4 turns, use socket 588 475.
IMPORTANT
Wait for at least 2 minutes to allow as much of the fuel as
possible to drain out of the filter housing.
2. Unscrew the filter cover (A) and lift it up slowly with the
EX1401029
filter element.
Figure 564
3. Make sure the suction tool is completely drained before
starting work. Draw out remaining fuel and any particles
using suction tool 588 793.
4-1-321
4. Keep the suction tool hose in the filter housing for the
water separating suction filter (A). A
EX1401030
Figure 565
5. Make a mark on the pressure filter cover (B). Unscrew the

B
cover 3 to 4 turns, use socket 588 475. Draw out fuel which
may drain into the water separating suction filter housing
when the pressure filter is detached.
IMPORTANT
Wait for at least 2 minutes to allow as much of the fuel
as possible to drain out of the filter housing.
EX1401031
Figure 566
6. Unscrew the pressure filter cover (B) and lift it up slowly

B
with the filter element. A
7. Fuel from the pressure filter housing (B) will flow into the
water separating suction filter housing (A). Leave the
suction tool in the water separating suction filter housing
(A) until it is completely drained of fuel.
EX1401032
Figure 567
8. Move the suction tool to the pressure filter housing (B).

B
Draw off remaining fuel and any particles.
IMPORTANT
It is important to remove remaining fuel and particles
from the filter housings to prevent fuel system
contamination.
9. Undo the old filter elements from the covers by carefully Figure 568
EX1401033
bending them to one side.
4-1-322
Installing Fuel Filter
1. Install a new O-ring to the cover. Lubricate the O-ring with
O-ring grease.
2. Press a filter element into the snap fastener on the cover.
3. Check that the filter housing is clean before fitting. Use lint-
free cloths.
IMPORTANT
Check that there is no remaining packaging material
stuck to the new filter elements.
IMPORTANT
Install the filter element to the filter cover before
positioning it in the fuel filter housing. The filter
element can otherwise be damaged.
IMPORTANT
In order to prevent back pressure in the filter housings
when the filter elements are screwed on, the bleed
nipple should be open.
4. Press down the filter element with the filter cover into the
fuel filter housing.
5. Screw down the filter cover until the cover seal lies against
the filter housing; use socket 588 475. There must be no
gap between the filter cover and the filter housing.
6. Tighten the filter cover to the correct torque.
7. Bleed the fuel system.
8. Start the engine and check that there is no fuel leakage
between the filter cover and filter housing.
If there is leakage, undo the filter cover and start again
from step 4.
4-1-323
Replacing Fuel Filter without Suction Tool
IMPORTANT
is carried
out on the fuel system.
system clean.
may come off.
removed.
1. Open the bleed nipple on the fuel filter housing to release

any remaining pressure. It may be difficult to unscrew the
filter cover if the fuel pressure has not fallen sufficiently.
NOTE: Fuel will come out of the bleed nipple. It should
be collected as specified in environmental
regulations.
IMPORTANT
Do not use an adjustable spanner or other open tool to
undo the filter cover, as this risks damaging the filter
cover.
2. To ensure that the filter housings are drained properly, the

filter covers must be removed as follows:
• On the pressure filter: Make a mark on the cover.
Unscrew the cover 3 to 4 turns, using a closed tool
with hexagon driver socket 588 475.
• On the water separating suction filter: Make a mark
on the cover. Unscrew the cover 3 to 4 turns.
• Wait at least 2 minutes to ensure the filter housings
have drained properly.
• On the pressure filter: Unscrew the filter cover and lift
it up slowly with the filter element.
• On the water separating suction filter: Unscrew the
filter cover and lift it up slowly with the filter element.
Remaining fuel will drain out of the fuel filter housing
automatically when the filter elements are lifted out. Figure 569
4-1-324
3. Check that no fuel or particles remain in the bottom of the
filter housing. Draw off remaining fuel and any particles.
IMPORTANT
It is important to remove remaining fuel and particles
from the filter housings to prevent contamination of
the fuel system.
4. Undo the old filter element from the cover by carefully

bending it to one side.
Fuel Heater
Location
H15
EX1401041
Figure 570
4-1-325
Fuel System Troubleshooting
EX1401034
Figure 571
4-1-326
A number of troubleshooting trees with their associated
descriptions are provided below.
IMPORTANT
Always wash the engine before starting work on the fuel
system.
Read the troubleshooting diagrams from left to right as

illustrated. 3
FG020603
Figure 572
4-1-327
M - Metal Shavings in the Engine
This can occur if the fuel system high-pressure pump is
defective and there are metal shavings in the oil sump and on
the magnetic plug.
M - Check of Metal Shavings in the Engine
D - Continue to O - Oil pump
B - Yes, there are metal shavings
A - Are there metal shavings on the magnetic plug and in

the oil sump?
C - No, there are no metal shavings
E - Continue to S - Start-up check
FG021460
Figure 573
O - Oil Pump
E - Have the engine overhauled at an

authorised workshop.
Troubleshooting is complete.
Yes
D - Remove the rocker covers and

the rocker arm housing Is there any
evidence of metal shavings at the
rocker arm housing?
Yes No
B - Remove the oil filter housing

assembly. Remove the oil filter Is there
F - Troubleshooting complete.
any evidence of metal shacings in the oil
fiter?
Yes No
A - Is the suction strainer G - Fit a new oil filter, clean the centrifugal oil
intact? cleaner and top up with oil. Troubleshooting is
No complete.
C - Check the oil pump Clean

if necessary. Continue
troubleshooting from B FG021461
Figure 574
4-1-328
S - Start-up Check
FG021464
Figure 575
FG021465
Figure 576
4-1-329
L - Low-Pressure Check
FG021462
Figure 577
FG021463
Figure 578
4-1-330
FG021466
Figure 579
4-1-331
L - Descriptions, Low-Pressure Check
L1 - Low-Pressure Check
1. Open the test connection on the high-pressure pump.
2. Pump using the hand pump. Check that fuel comes out of
3. Turn the engine over using the starter motor. Check that
fuel comes out of the test connection.
4. Close the test connection.
L2 - Checking the Suction Filter

NOTE: When replacing the suction filter, check the following
with the suction filter removed.
1. Pump with the hand pump and check that fuel free from
airflows out of the hole on the inside of the filter housing.
2. If no fuel comes out, check the suction strainer and all
joints on the suction pipe up to the fuel tank armature.
Replace the seals and check-tighten the connections.
3. If fuel comes out, install a new filter and bleed the fuel
system.
L3 - Checking the Feed Pump

1. Detach the outlet fuel pipe from the feed pump. Place a
container under the free end of the pipe.
2. Turn the engine over using the starter motor for about 20
seconds.
The feed pump provides about 1.2 lpm
The correct quantity for 20 seconds is 0.3-0.4 liters.
L4 - Checking the Feed Pump Drive

1. Remove feed pump from the high-pressure pump bracket.
2. Turn the feed pump by hand. Listen and touch.
3. Check that drive pins in the high-pressure pump are not
damaged.
4. Turn the engine over using the starter motor.
Check that feed pump drive in the high-pressure pump
rotates.
L5 - Checking the High-pressure Pump Drive

1. Remove high-pressure pump.
2. Turn the engine over using the starter motor. Check that
high-pressure pump drive rotates in the timing gear.
4-1-332
3. Replace the pump drive gear if it does not rotate or is
damaged. Check for resulting damage to the high-pressure
pump gear.
Damaged gears must be replaced.
4. If the pump drive gear in the timing gear rotates and is not
damaged, check that high-pressure pump gear is properly
seated on the shaft. If the gear is loose, the shaft may be
damaged. Do not tighten the gear.
Replace the high-pressure pump instead. If the gear is
jammed, the high-pressure pump is defective. If this is the
case, replace the high-pressure pump.
L6 - Checking the Supply Pressure at the Test Connection on

the High-pressure Pump
the high-pressure pump and open the test connection.
2. Turn the engine over using the starter motor. Read the
pressure after approximately 20 seconds. The pressure
must be more than 3 bar (46 psi).
3. If the engine starts, increase the engine speed to
1,500 rpm. Read the pressure. The pressure must be
between 9 and 14 bar (130 - 203 psi).
4. Close the test connection and remove pressure gauge.
H - High-pressure Check
Carry out a check on the safety

valve, see description H3
FG021467
Figure 580
4-1-333
Continue from high pressure below.
FG021468
Figure 581
FG021469
Figure 582
4-1-334
FG021470
Figure 583
H - Descriptions, High-pressure Check
H1 - Checking for Internal Leaks

1. Start the engine.
2. Start the test "Checking for internal leaks " in checking tool.
3. Switch off the engine. Read the pressure remaining in the
accumulator using checking tool. There must be some
pressure remaining. There are internal leaks if the
pressure approaches 0 bar within 1 min.
H2 - Checking the Return Fuel Pressure

the return fuel manifold and open the test connection.
2. Start the engine. Read the pressure with the engine idling.
The value must be below 0.8 bar. If the pressure exceeds
0.8 bar the overflow valve on the return fuel manifold must
be cleaned and visually inspected.
Start again from step 1.
NOTE: When the overflow valve is removed air will be
introduced, opposite the flow direction.
It will take some time for the system to bleed itself.
During this time the measurement is not reliable.
Leave the engine idling for a while before
repeating the test. If the pressure still exceeds
0.8 bar, there is internal leakage in an injector.
4-1-335
H3 - Checking the Safety Valve for Leaks
12 3
WARNING
The accumulator may be under high-pressure. Reduce the
pressure using checking tool before starting work.
Wear protective goggles.
There is a risk of burn injuries when the safety valve is
4 5 FG020605
open.
Figure 584
1. Remove return pipe 2 from the safety valve 1 to the return
fuel manifold 5.
2. Plug the connection in the return fuel manifold with cap nut
812 890 or 814 555 and sealing plug 813 878.
3. Install the return pipe at a slight angle to the engine.
Connect a transparent hose 4 to a union 3 - 366 082 on the
pipe. Pull the hose down into a can or similar.
4. Start the engine.
5. Start "Checking the safety valve for leaks" in checking tool.
Follow the instructions in the check.
6. Install the engine pipes. Torque tighten.
If the check failed:
Check that the following starting conditions have been met and
try again.
• The engine must be running.
• Parking brake activated.
• Gearbox in neutral.
• Clutch pedal released.
H4 - Checking Injectors Using SDPE3

1. Check cylinder balancing at idling speed using checking
tool. Note if any cylinder deviates.
2. Perform a cylinder output test using checking tool. Note
which cylinder deviates from the others by having a higher
output.
3. By comparing the two results with each other, a cylinder
with deviations in both tests can be identified. Continue
troubleshooting on the injector for that cylinder.
H5 - Verification of a Faulty Injector

1. Remove high-pressure pipe to the injector which has been
identified in H4.
4-1-336
2. Plug the outlet of the identified injector at the outlet port on
the fuel accumulator using tool 99 019. If the outlet port of
cylinder 1 has to be plugged, see the instructions in TI
03-08 01 28.
3. Start the engine and run it at idling speed for at least 15
seconds.
4. Switch off the engine. Read the pressure remaining in the
accumulator using checking tool.
If the pressure is more than 0 bar after 1 minute, the faulty
injector has been found and must be replaced. If the faulty
injector cannot be verified, continue troubleshooting
according to H6.
H6 - Checking for Internal Leaks
WARNING
Wear protective goggles. There is a risk of fuel splashing
from the high-pressure connections when pressurized.
A tool must be made to determine whether the fuel system is

leaking. A pressure regulator, a shutoff valve, two hose
couplings, hose clamps, hose and Tema quick release coupling
1100N for connection to the test connection are needed.
Assemble the parts as illustrated on the next page. It is vital that
all couplings and connections are tight.
1. Detach and remove all high-pressure pipes between the
accumulator and the high-pressure connections.
2. Connect the tool to the test connection on the return fuel
manifold and open the test connection.
IMPORTANT
Open the fuel fill cap so the pressure does not deform
the tank.
3. Pressurize the return fuel manifold. Slowly increase the

pressure. Listen for a bubbling noise in the tank. The
bubbling noise indicates at what pressure the overflow
valve opens. The pressure must be higher than 0.5 bar.
Then pressurize the manifold to max. 3 bar.
4. Listen for return leakage in the injectors by blocking one
high-pressure connection at a time and quickly removing
the obstacle. If there is internal leakage in the injector, a
hissing sound will be heard.
4-1-337
5. Replace the injector or injectors with internal leakage as
described above.
6. When replacing an injector, the tuning code of the new A B
injector must be programmed to the correct cylinder using
checking tool and basic setting of injector adaptation must
be performed.
Tools for test pressurizing the fuel system
Reference C
Description
Number
FG020606
A Shutoff Valve
Figure 585
B Pressure Regulator
Hose for Connection to the
C
Fuel System
H7 - Checking the Return Fuel Pressure

the return fuel manifold and open the test connection.
2. Turn the engine over using the starter motor. Read the
pressure after approximately 20 seconds. The value must
be below 0.8 bar.
3. If there is no detectable value after 20 seconds, let the
starter motor cool and repeat step 2.
NOTE: If there is air in the filter housing, pressure
cannot build up. Vent the filter housing and try
again.
4. Remove pressure gauge and close the test connection.
H8 - Checking the Safety Valve

12 3
WARNING
Wear protective goggles.
4 5 FG020605
1. Remove return pipe 2 from the safety valve 1 to the return Figure 586
fuel manifold 5.
2. Plug the connection in the return fuel manifold with cap nut
812 890 or 814 555 and sealing plug 813 878.
3. Install the return pipe at a slight angle to the engine.
Connect a transparent hose 4 to a union 3 - 366 082 on the
pipe. Pull the hose down into a can or similar.
4. Turn the engine over using the starter motor. If fuel leaks
out of the safety valve, it is faulty and must be replaced.
5. Install the engine pipes. Torque tighten.
4-1-338
H9 - Replacing the Cylinder Head on the High-pressure Pump
WARNING
3,000 bar (43,500 psi). The fuel system must be
depressurized before any work is started. Use checking tool
to minimize the high-pressure in the fuel system.
A jet of fuel at high-pressure can cut through the skin.
IMPORTANT
system clean.
may come off.
removed.
IMPORTANT
A high-pressure pipe that has been detached or removed
must never be reinstalled and must be replaced with a new
one.
4-1-339
ELECTRICAL SYSTEM
E44, Control Unit EMS

Description
Control system for engine functions.
Location
Engine Control Unit
EX1302340
Figure 587
Overview
Figure 588
4-1-340
Reference Reference
Number Number
T121, Charge Air Temperature T126, Intake Air Temperature
1 14
Sensor and Flow Sensor
T122, Charge Air Pressure 15 M42, Electric Throttle
2
Sensor T166, Pressure Sensor, Pressure
16
T33, Coolant Temperature for Electric Throttle
3
Sensor T162, Position Sensor for
17
4 T5, Oil Pressure Sensor Pneumatic Throttle
5 T74 Engine Speed Sensors T124, Position Sensor for the
18
6 T135, Camshaft Position Sensor EGR Valve
7 T110, Oil Level Sensor V107, Valve Block with a
19 Proportional Valve for the EGR
8 T111, Fuel Pressure Sensor
Valve and Exhaust Brake
9 V142-V146, Injectors
T123, Fan Rotational Speed
10 V120, Fuel Inlet Metering Valve 20
Sensor and Solenoid Valve
T125, Exhaust Back Pressure 21 M1, Starter Motor
11
Sensor
22 P3, Alternator
12 T120, Turbo Speed Sensor
V2, Coupling Coil for AC
M30, Electric Motor for 23
13 Compressor
Adjustable Turbocharger
4-1-341
1
2
EMS
4
5 7
6 8
9 11 12 13 10
14 15
EEC
16
17 18
Reference
Description
Number
1 Engine control
2 Combustion control
3 Exhaust gas monitoring
4 Diagnostic system for EMS
Regulation for work of oxidation catalytic converter (not used for industrial and marine
5
engines)
6 Checking reductant dosing
7 Regulation for work of particulate filter (not used for industrial and marine engines)
8 Checking soot particle regeneration (not used for industrial and marine engines)
9 Required reductant dosing
Required dosing of fuel to the exhaust gases during regeneration of the particulate filter (not
10
used for industrial and marine engines).
11 Temperature sensor values
12 NOx sensor values
13 Fault messages that trigger torque reduction
14 Checking and activation of reductant dosing
Checks and activates dosing of fuel to the exhaust gases during regeneration of the
15
particulate filter (not used for industrial and marine engines).
16 Diagnostic system for EEC
17 Diagnosis of reductant dosing and SCR catalytic converter
18 Diagnosis of particulate filter (not used for industrial and marine engines)
4-1-342
Introduction
The EMS has been developed to control the Engine system.
More components than before are controlled by the engine
control unit and the control of some components has been
extended.
• Rotational speed sensors (see also camshaft position
sensor below in new EMS components)
• Coolant temperature sensor
• Charge air pressure sensor
• Charge air temperature sensor
• Oil pressure sensor
• Starter motor
• Fan
• Exhaust brake proportional valve
• Control of fuel injection
• Control of alternator/alternators
• Oil level sensor (improved oil level display, see below in
new EMS components)
• Control of the EGR system and the variable geometry
turbocharger
• Solenoid valve for the AC compressor
• New EMS components
• Camshaft position sensor (the number of rotational speed
sensors is dependent on the combination of these and
camshaft position sensors)
• Electric throttle
• Pressure upstream of the throttle
• Position sensor on pneumatic throttle
• New oil level sensor which provides an improved oil level
display
• Rotational speed sensor and solenoid valve for the cooling
fan
General
The engine management system controls the fuel system, EGR
system, variable geometry turbocharger and a number of other
components such as the alternator, starter motor, AC
compressor and fan.
Electronic control of the fuel system provides increased control
over injection, allowing combustion to be optimised. Optimum
combustion results in turn in lower fuel consumption.
Electronic control of the fuel system is required to meet emission
requirements.
4-1-343
Electronic control of the fan ensures controlled cooling and
optimum operation.
Stricter requirements on emission levels also require more
efficient control of the air supply (throttle), recirculation of
exhaust gases (EGR) into the engine, exhaust gas
aftertreatment with SCR and/or DPF.
A brief description of the way in which the engine management
system and the components concerned work together follows. A
more detailed description of the components and their
interaction with the engine management system is provided
under the relevant component.
Fuel Injection
The engine control unit receives a message by CAN if
acceleration is requested. The engine control unit receives
information about the engine speed, fuel pressure, charge air
pressure and charge air temperature from the relevant sensors.
The engine control unit then controls the components in the fuel
system so that the correct amount of fuel is injected. The engine
control unit also takes into account information about the
turbocharger speed, air temperature and air flow to the engine in
order to supply fuel to the injectors.
Adaptation
Fuel injection is optimised through adaptation. In this case the
engine control unit adapts to each individual injector at regular
intervals in order to provide the best possible performance and
fuel economy.
During adaptation, the engine idles hard with the exhaust brake
active.
Alternator
The engine control unit determines when the alternator is to
charge. When charging is permitted, i.e. when the charging
conditions are met, the engine control unit sends a signal to the
alternator to charge.
The engine control unit receives a signal back from the
alternator when it is charging.
If a higher power supply is required during cold weather, the
engine control unit can request an increase in alternator
charging.
Starter Motor
The engine control unit activates the starter motor by sending a
control voltage to the relay on the starter motor.
The time limit for each attempt to start the engine is 35 seconds
to protect the starter motor.
4-1-344
AC Compressor
The engine control unit controls the activation of the AC
compressor. When the engine control unit receives a request to
activate the AC compressor, it sends a signal to the AC
compressor coupling coil.
EGR, throttle, Wastegate Valve and/or Variable/Fixed Geometry

Turbocharger
The engine control unit uses information from various sensors to
control the flow of air and exhaust gases into the engine. The
flow of air and exhaust gases into the engine is controlled by the
variable or fixed geometry turbocharger, throttle and/or EGR
valve.
You can read more about this process in the descriptions
covering these components.
Exhaust Brake
If the engine control unit receives a request for exhaust braking,
it sends a signal to the exhaust brake proportional valve. The
proportional valve then distributes compressed air to the
exhaust brake control cylinder. The control receives feedback on
the back pressure that the exhaust brake creates.
Industrial engines use an electrically controlled damper for the
exchange of gases. By controlling the damper position, the
exhaust gases are restricted thus creating a back pressure.
Apart from enhancing the engine braking action, the back
pressure created also warms up the engine more rapidly and
keeps the exhaust gas aftertreatment system warm.
Interaction with Other Systems

Functions involving the interaction of the engine control unit with
other systems are described below. A more detailed description
is provided under the relevant user function.
Request for Torque

The control units for the gearbox management system, GMS,
and brake management system, BMS, can, if necessary,
request torque by the engine control unit when changing gear
and for traction control. The system concerned may request
maximum torque for a short period, then the torque is limited to
approximately 70% for a further period. If the time limit is
exceeded, the engine control unit resumes control.
If both systems request control over torque at the same time, the
GMS request has the highest priority.
Request for Limited Torque

The control units for the gearbox management system, GMS,
and brake management system, BMS, can, if necessary,
request limited torque. The engine control unit then limits the
4-1-345
fuel volume according to the system which requests the lowest
torque. If required, the fuel injection can be switched off
completely. The function is not accessible under start. If the
torque is limited so much when idling that there is a risk of the
engine stopping, the idle speed control will intervene and
increase the fuel volume so that the engine speed is maintained.
Request for Cooling Fan

A higher fan speed may be required during retarder braking or
when using air conditioning. The control units for the climate
system, ACC, and gearbox management system, GMS, can, if
necessary, request increased fan speed by the engine control
unit.
Request for Control of AC Compressor

The AC compressor coupling coil is controlled by a signal from
the engine control unit when using ACC.
If the coolant temperature is above a certain level, the engine
control unit will not activate the AC compressor coupling coil.
Request for Exhaust Brake During Rapid Warm-up and When

Using the White Smoke Limiter
During rapid warm-up and when using the white smoke limiter,
the engine control unit receives a request from the coordinator
or ACC control unit for the exhaust brake. The level depends on
the engine speed and engine load. The exhaust brake is used
with both rapid warm-up and the white smoke limiter, even if the
engine control unit is supplying fuel. Normally, exhaust braking
is interrupted in order to protect the engine when fuel injection is
started. The request for the exhaust brake is rejected if the
engine temperature is above a certain level.
When fuel injection is at zero, the exhaust brake level requested
can be changed by any other function. It may either be a request
for a higher level or a request for limitation.
If a request for exhaust brake comes from EMS, GMS or BMS, it
has a higher priority.
Request for Exhaust Brake Control

The engine control unit may receive a request for exhaust brake
from other systems.
The following priority applies to exhaust brake control:
1. Overspeed protection and internal control unit functions -
EMS
2. Braking when changing gear - GMS
3. Braking - BMS
4. For the following, the request which is highest takes
precedence:
• Cruise control - EMS
4-1-346
• Retarder braking - GMS
• Braking - COO
A request for exhaust brake is rejected if there is fuel injection.
The request as described in point 4 above is rejected if the
engine speed is below a certain level, the clutch is depressed, or
if the torque converter is not locked.
The following can limit the exhaust brake, determined by the
system which requests the most limitation:
• Retarder braking - GMS
• Braking when changing gear - GMS
• Braking - BMS
Request for Raised Engine Speed

When changing gear, the gearbox management system, GMS,
requests a very high engine speed (2,700 rpm for a short period)
in order to carry out the gear change. The function can be
interrupted as follows:
• Limiting the engine speed when starting.
• A specific engine speed due to the generation of fault
codes.
Request for Engine Shut Down

The coordinator and bodywork control unit can send a signal to
the engine control unit to switch off the engine. The engine
control unit then carries out a controlled shutdown. The engine
then drops to a low idle until the speed is 7 km/h, when the
engine is switched off completely by shutting off the fuel supply.
Exhaust Gas Aftertreatment Systems SCR And DPF

The EEC control system carries out the control and diagnosis of
the SCR.
4-1-347
Connection
1
B1 A1
B2 A2
B3 A3
B4 A4
B5 A5
B6 A6
B7 A7
EX1302341
Figure 590
Control Unit
Task Signal Type Source/Destination
Pin
5 Cylinder Engine, 5 Cylinder Engine,
A1/1 +24V
Control of Injector, Cylinder 2 Injector (V143)
A1/2 +24V
A1/3 5 Cylinder Engine, Not Used +24V Not Used
A1/4 5 Cylinder Engine, Not Used +24V Not Used
A1/5 Not Used
5 Cylinder Engine, Grounding, Injector, 5 Cylinder Engine,
A1/6 Ground
Cylinder 2 Injector (V143)
A1/7 Ground
A1/8 5 Cylinder Engine, Not Used Not Used Not Used
A1/9 5 Cylinder Engine, Not Used Not Used Not Used
A1/10 Not Used
A2/1 Not Used
A2/2 Not Used
A2/3 Not Used
A2/4 Ground, Fuel Pressure Sensor Ground Fuel Pressure Sensor, (T111)
A2/5 Voltage Supply, Fuel Pressure Sensor +24V Fuel Pressure Sensor, (T111)
A2/6 Not Used
A2/7 Not Used
A2/8 Not Used
A2/9 Not Used
Analogue Input
A2/10 Control of the Fuel Pressure Sensor Fuel Pressure Sensor, (T111)
Signal
Digital Output
A3/1 Signal, Indication of Engine Operation Connector (C4007)
Signal
4-1-348
Control Unit
Pin
Frequency, Camshaft Position Sensor,
A3/2 Signal, Camshaft Position Sensor
Input Signal (T135)
Frequency, Camshaft Position Sensor,
A3/3 Signal, Camshaft Position Sensor
Input Signal (T135)
A3/4 Not Used
A3/5 Not Used
A3/6 Not Used
A3/7 Control of the Wastegate Valve. Ground Solenoid Valve (V109)
A3/8 Control of the Wastegate Valve. PWM Output Signal Solenoid Valve (V109)
A3/9 Not Used
A3/10 Not Used
A4/1 Not Used
A4/2 Not Used
A4/3 Not Used
A4/4 Ground, Coolant Level Sensor Ground Coolant Level Sensor (T8)
A4/5 Voltage Supply, Coolant Level Sensor +5V Coolant Level Sensor (T8)
A4/6 Not Used
A4/7 Not Used
A4/8 Not Used
A4/9 Not Used
Analogue Input
A4/10 Signal, Coolant Level Sensor Coolant Level Sensor (T8)
Signal
A5/1 Not Used
A5/2 Not Used
A5/3 Ground, Indication of Engine Operation Ground Connector (C4001-8)
Frequency,
A5/4 Signal from Engine Speed Sensor 1 Engine Speed Sensor (T74) 1
Input Signal
Frequency,
A5/5 Signal from Engine Speed Sensor 1 Engine Speed Sensor (T74) 1
Input Signal
A5/6 Not Used
A5/7 Not Used
A5/8 Not Used
A5/9 Not Used
A5/10 Not Used
A6/ 1 Not Used
A6/ 2 Not Used
A6/3 Not Used
A6/4 Ground, Redundant Gas Ground
A6/5 Voltage Supply, Redundant Gas +5V
A6/6 Not Used
A6/7 Not Used
A6/8 Not Used
A6/9 Not Used
Analogue Input
A6/10 Signal, Redundant Gas
Signal
A7/1 Not Used
A7/2 Grounding, Oil Pressure Sensor Ground Oil Pressure Sensor, (T5)
4-1-349
Control Unit
Pin
A7/3 Voltage Supply, Oil Pressure Sensor +5V Oil Pressure Sensor, (T5)
A7/4 Not Used
A7/5 Not Used
A7/6 Not Used
Voltage Supply, Outdoor Temperature
A7/7 +5V
Outdoor Temperature Sensor Sensor (T4000)
Analogue Input
A7/8 Signal, Oil Pressure Sensor Oil Pressure Sensor, (T5)
Signal
Voltage Supply, Coolant Temperature
A7/9 +5V
Coolant Temperature Sensor Sensor, (T33)
Grounding of Coolant Temperature Coolant Temperature
A7/10 Ground
Sensor Sensor, (T33)
B1/1 +24V
B1/2 +24V
B1/3 +24V
B1/4 5 Cylinder Engine, Not Used +24V Not Used
B1/5 Not Used
B1/6 Ground
B1/7 Ground
B1/8 Ground
B1/9 5 Cylinder Engine, Not Used Ground Not Used
B1/10 Not Used
B2/1 Not Used
B2/2 Not Used
B2/3 Not Used
Grounding of Charge Air Pressure Charge Air Pressure Sensor
B2/4 Ground
Sensor (T122)
Voltage Supply, Charge Air Pressure Sensor
B2/5 +5V
Charge Air Pressure Sensor (T122)
B2/6 Not Used
B2/7 Not Used
Grounding of Charge Air Temperature Charge Air Pressure Sensor
B2/8 Ground
Sensor (T121)
Voltage Supply. Charge Air Charge Air Temperature
B2/9 +5V
Temperature Sensor Sensor (T121)
Analogue Input Charge Air Pressure Sensor
B2/10 Signal, Charge Air Pressure Sensor
Signal (T122)
B3/1 Voltage Supply 2, Control Unit +24V Connector (C4001)
B3/2 Grounding 2, Control Unit Ground Connector (C4001)
B3/3 Signal by Starter Lock Digital Input Signal Connector (C4001)
B3/4 Not Used
B3/5 Not Used
4-1-350
Control Unit
Pin
B3/6 Voltage Supply 1, Control Unit +24V Connector (C4001)
B3/7 Grounding 1, Control Unit Ground Connector (C4001)
B3/8 Not Used
B3/9 CAN Red Bus CAN High Red CAN
B3/10 CAN Red Bus CAN Low Red CAN
B4/1 Not Used
B4/2 Not Used
B4/3 Not Used
B4/4 Not Used
B4/5 Not Used
B4/6 Not Used
B4/7 CAN Exhaust Gas Aftertreatment CAN High Connector (C4022-6)
B4/8 CAN Exhaust Gas Aftertreatment CAN Low Connector (C4022-7)
B4/9 Not Used
B4/10 Not Used
Digital Output
B5/1 Control of Starter Motor Starter Motor (Relay) M1
Signal
B5/2 SCR, Indication of Tank Level +24V Connector (C4008)
B5/3 Signal from Alternator 1 Digital Input Signal Alternator, (P3)
B5/4
Rotational Speed Sensor
Signal, Fan Rotational Speed Sensor
B5/5 PWM Input Signal and Solenoid Valve for the
And Solenoid Valve
Fan, (T123)
B5/6 SCR, Indication of Tank Level Connector (C4008)
Fuel Inlet Metering Valve,
B5/7 Grounding, Fuel Inlet Metering Valve Ground
(V120)
Fuel Inlet Metering Valve,
B5/8 Control of the Fuel Inlet Metering Valve PWM Output Signal
(V120)
B5/9 Control of Alternator 1 PWM Output Signal Alternator, (P3)
B5/10
Control of Fan Rotational Speed Sensor
B6/1 Pwm Output Signal and Solenoid Valve for the
and Solenoid Valve
Fan, (T123)
B6/2 Voltage Supply, Oil Level Sensor +5V Oil Level Sensor (T110)
B6/3 SCR, Fault Indication +24V
B6/4 SCR, Fault Indication Ground
Voltage Supply of Fan Rotational Speed
B6/5 +12V and Solenoid Valve for the
Fan, (T123)
Grounding of Fan Rotational Speed
B6/6 Ground and Solenoid Valve for the
Fan, (T123)
B6/7 Grounding of the Oil Level Sensor Ground Oil Level Sensor (T110)
Analogue Input
B6/8 Signal, Oil Level Sensor Oil Level Sensor (T110)
Signal
Grounding of Fan Rotational Speed
B6/9 and Solenoid Valve for the
Fan, (T123)
4-1-351
Control Unit
Pin
B6/10 Not Used
B7/1 Not Used
B7/2 Not Used
Atmospheric Pressure
B7/3 Ground, Atmospheric Pressure Ground
Sensor (T4000)
B7/4 Not Used
B7/5 Not Used
B7/6 Not Used
B7/7 Not Used
Atmospheric Pressure
B7/8 Voltage Supply, Atmospheric Pressure +5V
Sensor (T4000)
Analogue Input Atmospheric Pressure
B7/9 Signal, Atmospheric Pressure
Signal Sensor (T4000)
B7/10 Not Used
Removing Connectors on the Control Unit

You can make a removal tool from steel wire, see illustration, to 42
make it easier to remove connectors from the control unit. 2.5
60
15
FG020567
Figure 591
FG020568
Figure 592
4-1-352
Removing EMS
IMPORTANT
system clean.
may come off.
removed.
cloth and tape.
IMPORTANT
depressurized before any work is started.
Wear protective gloves and goggles. FG020569
Figure 593
1. Remove control unit cover.
FG020570
Figure 594
4-1-353
2. Remove control unit connectors.
EX1302342
Figure 595
3. Remove control unit.
FG020574
Figure 596
4. Remove control unit bracket.
FG020575
Figure 597
4-1-354
Installing EMS
WARNING
The fuel system has a very high fuel pressure of up to 3,000
bars. The fuel system must be depressurised using
checking tool before any work is started. Use checking tool
to minimise the high pressure in the fuel system. The
system should always be treated as pressurised, even
when the engine is switched off. Wear protective gloves
and goggles.
IMPORTANT
is carried out on the fuel system. Do not use compressed
air to blow components in the fuel system clean. When
cleaning, cloths or paper which shed fibres must not be
used. Use lint-free cloths.
may come off. Cover connections of removed components
with a lint-free cloth and tape.
1. Install the control unit bracket.
FG020575
Figure 598
2. Install the control unit.
FG020574
Figure 599
4-1-355
3. Install the control unit connectors.
EX1302342
Figure 600
4. Install the control unit cover.
FG020570
Figure 601
Control Unit EEC
Description
The EEC control unit controls the function of exhaust gas
aftertreatment components.
Location
EEC located on the reductant tank
4-1-356
Overview
46 44 42 40 38 36 34 32
30 28 26 24 22 20 18 16
15 13 11 9 7 5 3 1
29 26 23 20 17 14 11 8 5 3 1
30 27 24 21 18 15 12 9 6
31 28 25 22 19 16 13 10 7
4 2
EX1302295
Figure 602
4-1-357
Function
EEC control unit:
• Based on instructions from EMS, prepares and activates
reductant dosing during starting and operation.
• Monitors and activates components that participate in
reductant dosing during different operating conditions.
• Activates warnings and fault codes for components that
participate in reductant dosing.
• Monitors other sensors in the exhaust gas aftertreatment
system that send values to EMS by CAN.
Figure 603
• Participates in component and sensor diagnostics.
The EEC control unit transfers warnings and fault codes that
trigger torque reduction to EMS, which activates the measure.
• If there is a risk that system components will be damaged.
• If the fault makes it impossible to run exhaust gas
aftertreatment with full functionality.
Connection
Control Unit
Pin
A1
A2
Input Signal
A3 Voltage Supply for Control Unit Connector C4002
(U30, +24V)
Grounding
A4 Grounding the Control Unit Connector C4002
(U31, 0V)
A5
A6
A7
A8
A9
A10
A11
Wake-up Signal for Starting the Control Input Signal, Digital
A12 Connector C4002
Unit (U15)
A13
NOx Sensor Upstream of the
A14 Voltage Supply For The NOx Sensor 1 +24V Exhaust Gas Aftertreatment
(T131)
A15 Grounding NOx Sensor 1 Ground Exhaust Gas Aftertreatment
(T131)
A16
NOx Sensor Downstream of
A17 Measuring NOx CAN High the Exhaust Gas
Aftertreatment (T131)
A18 Measuring NOx CAN Low the Exhaust Gas
4-1-358
Control Unit
Pin
Communication With the Engine Control Engine Control Unit EMS
A19 CAN Low
Unit EMS (E44)
A20 Voltage Supply for the NOx Sensor +24V the Exhaust Gas
A21 Grounding NOx Sensor 2 Ground Exhaust Gas Aftertreatment
(T115)
Communication With the Engine Control
A22 CAN High Engine Control Unit EMS (E44)
Unit EMS
A23 Measuring NOx CAN High the Exhaust Gas
A24 Measuring NOx CAN Low the Exhaust Gas
A25
A26
A27
A28 Logging of Data by CAN CAN High
Sensor for Temperature,
Measuring the Temperature, Level and
Level and Quality of
A29 Quality of Reductant in the Reductant CAN High
Reductant (T4002)
Tank
Deviations may occur
Sensor for Temperature,
Measuring The Temperature, Level And
Level and Quality of
A30 Quality Of Reductant In The Reductant CAN Low
Reductant (T4002)
Tank
Deviations may occur
A31 Logging of Data by CAN CAN Low
B1 Voltage Supply for Reductant Pump +5V Reductant Pump (V183)
Output Signal,
B2 Regulation of Reductant Pump Speed Reductant Pump (V183)
PWM Signal
Output Signal, Reductant Injection Nozzle
B3 Injection of Reductant
PWM Signal (V117)
Analogue Input Reductant Injection Nozzle
B4 Signal Injection Nozzle for Reductant
Signal (V117)
B5 Supply Injection Nozzle for Reductant +5V
(V117)
Injection of Reductant, Reductant Injection Nozzle
B6 Input Signal
Reductant Temperature (V117)
Injection of Reductant, Reductant Injection Nozzle
B7 Input Signal
Reductant Pressure (V117)
B8 Injection of Reductant, Grounding Grounding (0V)
(V117)
B9
B10
B11
B12 Supply for the Reductant Pick-up Unit +24V Reductant Pick-up Unit
B13 Grounding of the Reductant Pick-up Unit Ground Reductant Pick-up Unit
B14
4-1-359
Control Unit
Pin
B15
B16 Grounding of Reductant Pump Grounding (0V) Reductant Pump (V183)
Input Signal,
B17 Reductant Pump Speed Reductant Pump (V183)
PWM Signal
B18
B19
B20
B21
B22
B23
B24
B25
B26
B27
B28
B29
Measuring the Exhaust Gas Temperature Sensor
B30 Temperature Downstream of the Grounding (0V) Downstream of the
Particulate Filter Particulate Filter (T113)
Measuring the Exhaust Gas Temperature Sensor
B31 Temperature Downstream of the Input Signal Downstream of the
Particulate Filter Particulate Filter (T113)
Output Signal, Reductant Injection Nozzle
B32 Heating the Reductant Injection Nozzle
PWM Signal (V117)
B33 Heating the Reductant Injection Nozzle Grounding (0V)
(V117)
B34
B35
Output Signal, Reductant Pick-up Unit
B36 Heating the Reductant Pickup Unit
PWM Signal (V118)
Reductant Pick-up Unit
B37 Heating the Reductant Pickup Unit Grounding (0V)
(V118)
The Reductant Tank Level
B38 Measuring Reductant Temperature Input Signal and Temperature Sensor
(T116) Deviations may occur
Measuring Reductant Temperature and
B39 Grounding (0V) and Temperature Sensor
Level
B40 Measuring Reductant Level Input Signal and Temperature Sensor
B41 Heating the Reductant Hose 1 (Option) Grounding (0V) Reductant Hose 1 (H25)
Output Signal,
B42 Heating the Reductant Hose 1 (Option) Reductant Hose 1 (H25)
PWM Signal
B43 Heating the Reductant Hose 2 (Option) Grounding (0V) Reductant Hose 2 (H26)
Output Signal,
B44 Heating the Reductant Hose 2 (Option) Reductant Hose 2 (H26)
PWM Signal
B45
B46
4-1-360
Engine Speed Sensor
Description
The sensor measures engine speed. The sensor is an inductive
sensor. In principle it consists of a coil wound around a
permanent magnet. The sensor reacts to varying magnetic
fields.
The resistance between the conductors must be 540 Ω ±10%.
Overview
FG020385
Figure 604
Location
T74
EX1400545
Figure 605
Function
There are two rotation speed sensors in the engine control
system, rotation speed sensor 1 and rotation speed sensor 2.
The sensors are inductive. This means that they only produce
signals when the engine is running. The signal strength varies
significantly, depending on the gap between the sensors and the
flywheel as well as on the engine speed. The engine
management system estimates the signal strength at different
engine speeds. If the signal strength becomes too low, a fault
code is generated.
Rotation speed sensor 1 and rotation speed sensor 2 both read
the position of the flywheel. This means that the engine
management system cannot determine which revolution the
engine is at, i.e. determine which cylinder is at firing position.
Every time the engine is stopped and the voltage cut off, the
4-1-361
engine position is stored. Next time the voltage is turned on, the
latest saved position is used so that the revolution the engine is
at is known. When the engine has started, a system check is
performed to verify that the stored position is correct.
The engine control unit receives signals from both rotation
speed sensors. If the engine control unit receives the wrong
signal or if the signal from any one of the rotation speed sensors
is missing, the engine torque will be limited for reasons of safety.
The engine will perform normally again as soon as the engine
control unit receives a correct signal.
If the engine control unit receives the wrong signals or if the
signals from both rotation speed sensors are missing, the
engine will not start. If the engine is running, it will be shut down.
The engine speed sensors detect the holes in the flywheel when
the flywheel rotates and send pulses to the control unit for each
hole. In this way, the engine control unit can calculate where the
engine is in the working cycle. The engine control unit detects
and compares the engine speed at combustion in each cylinder.
The engine control unit strives to maintain a constant
acceleration from each cylinder by compensating the fuel
quantity individually to each cylinder.
The interval between two of the holes is greater than the
intervals between the remaining holes. When the engine control
unit detects that the sensor has gone past the larger interval, it
knows that the flywheel is in a particular position in relation to
top dead centre (TDC UP).
4-1-362
T110 Oil Level Sensor
Description
The oil level sensor detects and informs the engine control unit
of the current oil level in the engine. The oil level is displayed in
the instrument cluster and if the oil level is too high or low, the
driver is warned by a warning lamp in the instrument cluster.
Location
T110
EX1302298
Figure 606
Overview
EX1302299
Figure 607
Symbol
Figure 608
4-1-363
Function
The oil level sensor measures the oil level in the oil sump. The oil
level is measured when the driver switches on the power with the
starter key. The measurement takes place before the engine is
started and before the oil pump starts pumping oil around the engine.
The information from the sensor is passed to the engine control
unit and then on to the instrument cluster by CAN. The oil level
value is saved and can be read off in the instrument cluster until
the engine has been started and the vehicle has been in motion
at over 10 km/h. To measure the oil level after the vehicle speed
has exceeded 10 km/h, you must switch off the engine and wait
until the oil has run back to the oil sump. The instrument cluster
shows how long of a waiting time is required before a new
measurement can be taken.
The time it takes for the oil to run back varies with the
temperature of the oil. Hot oil runs considerably faster than cold
oil. The control unit takes this into consideration when
calculating the waiting time. If the oil level is too high or too low,
a warning lamp will come on in the instrument cluster. The
warning stays on until it has been acknowledged or until the oil
level has been corrected. The warning does not come on when
moving, but comes on if it is activated before the engine starts
and has not been acknowledged.
The oil level sensor has a measuring range of approximately
10 cm. The sensor is a capacitive sensor. This means that
different levels in the measuring range correspond to a voltage
value which is sent to the control unit. The voltage values vary
between 0.5 - 4.5 V. If the voltage from the sensor is outside this
range, the control unit generates a fault code. If the vehicle is not
level, the oil level displayed in the instrument cluster will not be
correct. Nor will it correspond to the level that the dipstick is
showing, because the oil level sensor and dipstick are not
located in the same place.
T111, Fuel Pressure Sensor
Description
The fuel pressure sensor informs the engine control unit of the
current fuel pressure in the accumulator.
Location
T111
EX1302302
Figure 609
4-1-364
Overview
Symbol
EX1302300
Figure 611
Function
The fuel pressure sensor registers and informs the engine
control unit of the current fuel pressure in the accumulator.
The engine control unit compares the measured fuel pressure
with the fuel pressure requested and calculates how much fuel
the fuel inlet metering valve should convey to the high pressure
pump so that the correct fuel pressure is obtained in the
accumulator.
The engine control unit registers the voltage from the sensor.
The signal voltage is directly proportional to the fuel pressure. A
high pressure gives a high voltage and vice versa.
If there are any faults with the signal, the engine control unit will
operate according to a preset pressure value while at the same
time generating a fault code. As a safety measure, engine
torque is limited.
4-1-365
T125, Exhaust Back Pressure Sensor
Description
The sensor informs the engine control unit of the current exhaust
back pressure.
Location
EX1302303
Figure 612
Overview
EX1302304
Figure 613
Symbol
EX1302300
Figure 614
4-1-366
Function
With EGR
The exhaust back pressure sensor measures the pressure of
the exhaust gases coming out of the engine upstream of the
EGR valve. The engine control unit uses the exhaust back
pressure to control the damper in the EGR valve. When the
exhaust back pressure is high during throttle actuation, the
damper in the EGR valve is closed so that the engine does not
receive too much exhaust gas.
The engine control unit also uses information about the exhaust
back pressure when the exhaust brake is used. The damper in
the exhaust brake opens at a preset exhaust back pressure.
When a request for the exhaust brake comes, the damper
closes. The engine control unit then uses the sensor information
to control the damper in the exhaust brake so that the required
exhaust back pressure is obtained.
The sensor measures the absolute pressure, i.e. the
atmospheric pressure plus the exhaust pressure. If there are
any faults with the signal, the control unit will operate according
to a preset value while at the same time generating a fault code.
T135, Camshaft Position Sensor
Description
The sensor informs the engine control unit of the current exhaust
back pressure.
Location
T135
EX1400564
Figure 615
Overview
EX1302306
Figure 616
4-1-367
Symbol
Figure 617
Function
The camshaft position sensor is an inductive sensor that reacts
to a varying magnetic field. T135
The camshaft position sensor reads the rotation of the camshaft

and can thus record which position the engine has reached in its
working cycle. The camshaft gear on which the sensor should
be located is visible in the illustration below.
EX1400564
Figure 618
4-1-368
V109, Solenoid Valve for Charge Pressure
Description
The solenoid valve controls the turbocharger's wastegate valve.
Location
Figure 619
Overview
EX1302310
Figure 620
Symbol
Figure 621
Function
The turbocharger wastegate valve can be supplemented by a
solenoid valve (V109) that is controlled by PWM signals from the
The engine control unit controls the solenoid valve which in turn
controls the wastegate valve.
4-1-369
V120, Fuel Inlet Metering Valve
Description
The fuel inlet metering valve controls how much fuel is brought
into the high pressure pump.
Location
V120
EX1400566
Figure 622
Symbol
2 1
EX1302311
Figure 623
Specification
Resistance Value
Temperature °C Resistance ±0.5 ohms

-20 1.8
0 2.0
20 2.2
40 2.3
60 2.5
80 2.7
Function
The fuel inlet metering valve is located on the high pressure
pump. The fuel metering valve controls the fuel flow to the high
pressure pump and is controlled by a PWM signal from the
4-1-370
The engine control unit uses the signal from the fuel pressure
sensor on the accumulator to calculate how much fuel should be
supplied to the high pressure pump and then controls the fuel
metering valve so that it releases the required quantity of fuel.
If power to the fuel metering valve is cut, it will become fully
open and a fault code will be generated at the same time.
Removing Fuel Inlet Metering Valve

1. Separate the connector on the fuel inlet metering valve.
Figure 624
2. Remove the fuel inlet metering valve.
V120
EX1400566
Figure 625
3. Assemble in reverse order.

4. Refit all removed cable ties.
4-1-371
V142, V143, V144, V145, V146 Solenoid
Valve for Injector
Description
Solenoid valve which controls fuel supply to a unit injector.
Location
Figure 626
Symbol
B-1 A-1
EX1302315
Figure 627
Function
The solenoid valve is part of the injector. The solenoid valve
controls the fuel injection.
When the solenoid valve is not powered, the injector is closed.
When the solenoid valve is supplied with power, fuel is injected
into the cylinder. The opening time of the solenoid valve is
controlled by the engine control unit.
The amount of fuel injected into the cylinder is determined by the
opening time and the pressure in the accumulator.
The number of injections in each compression stroke can vary.
This leads to more efficient combustion, lower exhaust
emissions and quieter engine operation.
4-1-372
T8, Coolant Level Monitor
Description
The coolant level sensor ensures that the driver is alerted if the
coolant level is too low.
Location
T8
EX1400023
Figure 628
Symbol
Figure 629
Function
The coolant level monitor is located at the bottom of the
expansion tank and ensures that the instrument cluster's
indicator lamp for low coolant level comes on when the level is
too low.
The monitor sends an earthed signal to the coordinator, which
sends the information on to the instrument cluster.
4-1-373
P3, Alternator
Description
The alternator supplies components with current and charges
the batteries.
Location
P3
EX1302318
Figure 630
Specification
100 A
Designation 28V 40/100A
Power at 6,000 rpm 2,800 W
Resistance in rotor 8.5 ohm ±5%
Brush length > 1 mm
Engine speed (rpm) 100 A

500 40
600 60
800 80
1,500 100
Function
The engine control unit determines when the alternator is
activated. The engine speed must be sufficient, i.e.
approximately 400 rpm, to ensure that activation takes place.
The engine control unit receives signals from the alternator if it is
active and if charging is taking place. If the engine control unit
registers a fault in charging from the alternator, a fault code is
generated and the charging lamp on the instrument panel
comes on. After checking the cable harness and connectors, it is
advisable to carry out a check on the alternator.
The alternator is driven by the engine's poly-V-belt. When the
engine speed increases, the alternator speed also increases
resulting in a higher alternator voltage.
A charge regulator fitted on the alternator is used to ensure that
the alternator voltage does not become too high when the
engine speed increases. It is a transistor type charge regulato
and regulation takes place by grounding pin number 2 (L) on the
charge regulator.
4-1-374
Reference
Description 1 2 3 4 5
Number
1 Not Used
2 L
3 15
4 Not Used
5 Not Used
On the alternator the charge regulator is constructed as a single

unit with the carbon brushes.
The carbon brushes rest against the slip rings. The carbon
brushes must be a certain length in order for the alternator to
function.
If more power is required when the vehicle is stationary, the
EX1302334
engine speed can be increased by adjusting the idle speed. Figure 631
Removing Alternator
1. Cut the power using the battery master switch or by
disconnecting the battery terminals.
2. If necessary clear the area. It may be necessary to remove
the mudguard, hatch, catwalk etc. to gain access.
3. Take the load off the belt transmission.
Depending on the version, on engines with a 150 A
alternator, the idler roller/belt tensioner must be removed
before the screws securing the alternator are removed.
The illustration shows an 80 - 100A alternator.
4. Disconnect the positive cable 30 and the control cable.
5. Remove the alternator.
Figure 632
4-1-375
Installing Alternator
IMPORTANT
Check whether the poly-V-belt/belts with belt tensioners
and idler rollers are worn or damaged. Replace if
necessary.
The illustration shows an 80.100 A alternator

1. Fit the alternator.
2. Fit the positive cable 30 and the control cable.
3. Fit the belt transmission. See subgroup 01.15 Timing gear.
4. Fit the mudguard, hatch, catwalk etc.
5. Switch on the current with the battery master switch or
connect the cables to the battery terminals.
Figure 633
Checking Alternator
IMPORTANT
Make sure that you never run an alternator without the
batteries connected! This may cause the rectifiers and/or
charge regulator to be overloaded and damaged.
NOTE: To obtain a correct result, the alternator should be

kept at a temperature of 20 - 25°C. A higher
temperature may give a lower current.
When the engine control unit has generated fault codes for the
alternator, the following tests can be carried out.
• Output test
• Control voltage test
• Phase measurement
• Length of brushes
• Slip rings, rotor resistance and overcharging
4-1-376
Test Report
A more detailed explanation of the tests in the test report is
provided under the test concerned.
Test Check Values Acceptable Value Incorrect Value

Carry Out Control Voltage Carry Out Phase
Output Test 100A: > 45A and 28V
Test Measurement
Control Voltage Test 28 ±1.0V at 20°C Alternator OK Check the Brush Length
Phase Measurement < 250 mV Check the Brush Length. Replace Alternator
Brush length 100A: > 5.0 mm Check slip rings Replace Alternator
The surface should be Check the Rotor
Slip Rings Replace Alternator
smooth and bright Resistance
Rotor Resistance between Carry Out Overcharging
100A: 9.0 ±1.0 ohms Replace Alternator
the Slip Rings (at 20°C) Test
Measuring Overcharging
> 10 Mohm Replace Regulator Replace Alternator
Between
Output Test
1. Connect an ammeter and a voltmeter to the batteries as
illustrated.
Connection to batteries. Connection C41 at the starter
motor positive connection applies to DP
Figure 634
2. Start the engine and run it at idling speed for a few

minutes. Then note how much current is supplied from the
alternator to the batteries. Check at the same time that the
voltmeter does not fall below 27V. Run the engine at
approximately 500 rpm.
3. Connect the same equipment as before to the central
electric unit as illustrated.
Connection to central electric unit. Connection C41 at the
starter motor positive connection applies to DP
Figure 635
4-1-377
4. Hold the engine speed at 500 rpm and load the system by
using the vehicle's current consumers in accordance with
the test report, column Check value. See below for
examples of current consumers.
Add the current you read at the batteries to the sum of the
loads you are applying.
Example: If you obtained a value of 10 A at the batteries,
you only need to apply a load of 35 A to the alternator
instead of 45 A. 10 A + 35 A = 45 A
5. Run the engine for a time while you are applying the load.
Read the voltmeter again. It should still not show less than
27V.
Examples of current consumers:
Cab Fan at Maximum Approx. 10 A

Main Beam Approx. 6 A
Two Auxiliary Lamps Approx. 6 A
Seat Heater Approx. 2.5 A/seat
Electrically Heated Mirrors Approx. 2.5 A/mirror
Coolant-operated Cab
Approx. 6 A
Heater
Radio Approx. 1.5 A
4-1-378
Control Voltage Test
Carry out this test especially if you suspect there is
overcharging.
NOTE: The batteries should be fully charged to give good
results, i.e. maximum consumption at 10A.
1. Connect the ammeter and voltmeter to the central electric
unit as illustrated. Run the engine at approximately
500 rpm.
Connection to batteries. Connection C41 at the starter
motor positive connection applies to DP
2. Load the system with approximately 10-20A by using
various current consumers.
3. Allow the engine to run for a while. The control voltage on
the voltmeter should be 28V ±0.5V at 20°C.
Phase Measurement
Keep the voltmeter connected as it was for the voltage test, but Figure 636
reset it to the AC voltage position.
The voltmeter should be stable around 100 mV and at most 250
mV. If this performance is not achieved, the alternator is
defective and must be replaced.
Length of Brushes
Check that the length of the carbon brushes does not fall below
the permitted length, see specification.
Slip Rings/Rotor Resistance/Overcharging

The charge regulator must be removed in order to check the slip
rings.
1. Check that the surfaces of the slip rings are smooth and
bright. If the surfaces are not bright, this indicates poor
contact with the carbon brushes.
2. Measure the rotor resistance, see measurement
specification. See illustration.
EX1302322
Figure 637
4-1-379
3. Measure the insulation resistance between the slip rings
and alternator core (chassis earth). The ohmmeter must
show infinite resistance (at least 10 Mohm).
If one of the checks is not satisfactory, the alternator must
be replaced.
Replacing Bearing and Carbon Brushes on Alternator

1. Remove the cover washers for the carbon brushes.
Remove the screws holding the carbon brushes.
IMPORTANT
Mark the front housing against the rear housing to
make it easier when assembly the housings.
Figure 638
2. Remove the nut and pulley.
Figure 639
3. Remove the 4 screws which hold the alternator together.
Figure 640
4-1-380
4. Separate the alternator. The stator winding should remain
in the rear housing.
Figure 641
5. Remove the rotor from the rear housing as follows: Refit

the nut on the rotor shaft. Hold the rotor in the nut and
gently tap all around the housing until the rotor comes
loose.
IMPORTANT
Make sure that you do not damage the stator winding
and rotor.
Figure 642
6. Clamp the rotor in the vice.

NOTE: Use soft jaws on the vice so as not to damage
the rotor.
Remove the bearing on the rotor using puller
plate 587 517 and bearing puller 587 518.
Figure 643
4-1-381
7. Press on the new bearing.
Figure 644
8. Remove the screws and the washer securing the bearing

in the front housing.
Figure 645
9. Put a sleeve on the bearing and tap out the old bearing
from the front housing.
Figure 646
10. Fit a new bearing. Fit the front housing in the vice and
press it into position using a sleeve on the outer race.
Then refit the washer and tighten the 4 screws.
Figure 647
4-1-382
11. Assembly: Fit the rotor in the rear housing. Remember to fit
the spacing washer between the rotor and bearing in the
front housing.
Fit the front housing.
IMPORTANT
Check that the marks on the housings are aligned.
Figure 648
12. Screw on the housing and fit the carbon brushes.

13. Fit the nut and the pulley.
IMPORTANT
The pulley nut must be tightened to the correct torque,
otherwise there is a risk that it will come loose.
4-1-383
M1, Starter Motor
Overview
EX1302337
Figure 649
Location
M1
EX1302335
Figure 650
Connection
Tightening torque for the starter motor 105P70:
B+ (30) and control cable (50)
Figure 651
4-1-384
Reference
Description 5 6
Number 4
1 B+ from Battery (30)
2 Control Cable from EMS (50)
3 Control Cable from Pre-relay
4 B+ Supply to Pre-relay
5 Control Cable
1
6 Controlled Positive from Solenoid 2
3 FG020597
Figure 652
EX1302336
Figure 653
Function
Activating Start Motor

The starter motor is activated by control voltage from the engine
control unit and by battery voltage (30 supply).
When control voltage is activated, the starter relay (solenoid) in
the starter motor is powered up. When the control voltage is
interrupted, the solenoid switch is no longer powered.
EX1302338
Figure 654
Principle of Starting Procedure for Start Motor

1. When the starter key is turned to the start position, the
engine control unit sends voltage to the starter relay. When
the solenoid switch is supplied with voltage, it pulls the
engine starter ring gear using a control arm in the starter
motor pinion. The starter motor pinion can be slid on the
electric motor rotor shaft. In order to align the starter motor
pinion in the starter ring gear, the starter motor rotates
slowly until the starter motor pinion is in position.
2. When the pinion has become fully meshed with the engine
starter ring gear, a pair of connectors in the starter relay
are closed and supply full current to the starter motor.
4-1-385
3. When the engine has started, the starter pinion will prevent
the engine from driving the starter motor at a speed which
is too high (harmful) by a freewheel arrangement. The
starter motor pinion remains meshed with the starter ring
gear until voltage is no longer supplied to the starter relay.
The starter motor pinion is returned by a return spring in
the solenoid switch and the current to the starter motor is
interrupted.
The engine control unit monitors the starting procedure. Fault
codes will be generated, if the starting procedure is not carried
out normally.
The starter motor should be run for no more than 30 seconds to
prevent overheating. After that the starter motor must be rested
for at least 30 seconds. The starter motor may only be used 5
times in a row. After that it must be rested for 15 minutes.
Removing Start Motor

NOTE: On engines with a fuel heater located next to the
starter motor it may be necessary to first remove the
fuel heater.
1. Cut the power using the battery master switch or by
disconnecting the battery terminals.
2. Remove any noise shields.
3. Detach the positive cable 30 (B+) and the control cable 50.
4. Bend back the cables.
5. Undo the screws holding the starter motor in the flywheel
housing.
6. Carefully pull out the starter motor.
IMPORTANT
Check whether the starter pinion is damaged. If the
starter pinion is damaged, the entire starter ring gear
must be checked for damage.
Installing Start Motor
IMPORTANT
Check whether the starter pinion is damaged. If the starter
pinion is damaged, the entire starter ring gear must be
checked for damage.
1. Refit the starter motor.

2. Screw the starter motor onto the flywheel housing.
3. Tightening torque:
• M12 stud: 20 Nm
• M12 nut: 77 Nm
4-1-386
AC Compressor
Location
V2
EX1302339
Figure 655
Specification
Pressure Switches
• Safety valve opening pressure; 33.8 - 41 bar
• Low-pressure switch, closedown pressure; 1.96 bar
• High-pressure switch, closedown pressure; 31.4 bar
Tightening Torque
• Compressor oil plug; 10 Nm
• Compressor, valve plate; 34 Nm
• Pipe to compressor; 22 Nm
• Pipe to condenser; 8 Nm
• Pipe to evaporator; 8 Nm
• Centre nut; 30 Nm
Installing AC Compressor
If the compressor has broken in such a way that there a risk that
pieces of metal have entered the system, the entire system
between the compressor and filter should be cleaned. Thorough
cleaning or component renewal is necessary to prevent
subsequent faults and new problems.
Fit protection plugs to the compressor as well as the hose ends
to prevent moisture and dirt from entering the AC system.
• Fill up with compressor oil. To determine the correct
amount of oil for the system, see the relevant section in the
ACC system description.
• Fit the compressor.
• Fit new O-rings to the hose ends and lubricate the O-rings
with compressor oil.
4-1-387
• Replace the receiver dryer. See the receiver dryer work
description.
• Vacuum pump, check for leaks and fill up the AC system.
Refer to "Working with refrigerant, refilling".
Checking and Adjusting Distance Between Pulley and Rotor
Reference 6
Description
Number 5
1 Compressor Type C 4
3
2 Compressor Housing 2
3 Plug 1
4 Shaft Seal
5 Circlip
6 Coupling Coil
7 Circlip
8 Pulley
9 Circlip 11
10
10 Spacer 9
8
11 Rotor
7 EX1302343
12 Centre nut Figure 656
Use a feeler gauge to check/measure the distance between the
pulley (7 in the illustration) and rotor (10 in the illustration)
The distance should be between 0.4 mm (min) and 1.2 mm
(max).
If the distance is close to the upper tolerance limit, adjustment is
required.
If the distance between the pulley and rotor approaches the
upper tolerance, the shim (9 in the illustration) under the rotor
can be removed.
1. Remove the centre nut (No. 11 in illustration). Use special
tool 99 407 as a counterhold.
2. Remove the rotor (No. 10 in illustration).
3. Remove one shim (9 in the illustration).
4. Fit the rotor (No. 10 in illustration).
5. Using a feeler gauge, check that the distance between the
pulley (No. 7 in illustration) and rotor (No. 10 in illustration)
is between 0.4 and 0.8 mm. If the distance is still outside of
the tolerance range there is a reconditioning kit with loose
shims available as a spare part.
6. Fit the nut (No. 11 in illustration). Use special tool 99 407
as a counterhold.
• Tightening torque; 30 Nm.
4-1-388
Troubleshooting the AC Compressor
The compressor is sometimes indicated as the source of the
fault and replaceed unnecessarily, when the problem is usually
too little refrigerant in the system.
Note that the AC compressor disengages if engine temperature
becomes too high.
If the compressor rotates, clutch clearance is correct and the
clutch is operational, the compressor is normally not the
problem. Continue troubleshooting the rest of the system.
If the compressor rattles, it should be replaced.
• Check the following before replacing a compressor
• Rotate the compressor shaft and feel whether it can rotate.
Do so by manually rotating the compressor shaft clockwise
using a flexible ended wrench on the centre nut.
• Check the play in the compressor clutch and adjust if
necessary.
• Check that the pulley clutch is working. Method 1: Start the
engine and activate the AC. The compressor clutch should
follow the pulley. If it does not, continue by testing as
described in option 2 to rule out other possible faults.
Method 2: Fabricate an electrical cable so that you can
power up the clutch and ensure that it energises and locks
the pulley in place. Note that it is important that the current
is connected correctly.
• Simple check as to whether the pulley clutch always
follows and seems locked. (Welded clutch/may seize due
to rust).
• Use a spatula or similar tool to check whether there is a
space around the entire compressor clutch. If it is joined
anywhere, carefully tap in the spatula to release small
welds.
4-1-389
Electrical Parts
Connector C316
Overview
Figure 657
Connection
Source/Destination
Pin Signal SCR Reductant
Control Unit Doser V117,
E67, Pins Pins
1 PWM Input Signal B-32 4
2 Ground for Electric Heating B-33 3
Ground for Pressure and
3 B-8 7
Temperature Sensor
Temperature Sensor
4 B-6 6 Figure 658
Signal
5 Pressure Sensor Signal B-7 8
6 Voltage +5 V B-5 5
7 Input Signal, Analogue B-4 1
8 PWM Output Signal B-3 2
Location
C7
C4051
C316
C4011
C4012
EX1401042
Figure 659
4-1-390
Connector C4000
Overview
Figure 660
Connection
Pin Signal
1 Voltage U15 to the Engine Control Unit
2 U3, Ground 4 1
3 CAN Signal High
4 CAN Signal Low 2 3
WL1400025
Figure 661
Location
C4001
C4000 C4022
C4002
C4071
WL1400024
Figure 662
4-1-391
Connector C4001
Overview
Figure 663
Connection
Pin Signal
2 U31, Ground
5 U31, Ground
6 CAN Signal High
7 CAN Signal Low
8 Engine Running, + 24 V Figure 664
Location
C4001
C4000 C4022
C4002
C4071
WL1400024
Figure 665
4-1-392
Connector C4002
Overview
Figure 666
Connection
Customer interface to SCR control unit and EGR valve actuator
as well as exhaust brake actuator.
Pin Signal
1 U30 Voltage to the SCR Control Unit
2 U31, Ground
4 Not used
U31, Ground to EGR Valve Actuator and
5
Exhaust Brake Actuator Figure 667
U15 Voltage to EGR Valve Actuator and
6
Exhaust Brake Actuator
Location
C4001
C4000 C4022
C4002
C4071
WL1400024
Figure 668
4-1-393
Connector C4003, C4004, C4005, C4006
Location
C4000
C4001
C4003
E44 C4004
C4005
C4006
WL1400032
Figure 669
Connector C4007
Overview
Figure 670
Connection
Figure 671
Location
C4007 C4008
C4009 WL1400035
Figure 672
4-1-394
Connector C4008
Overview
Figure 673
Connection
Pin Signal ECU, Pin

Indicator Lamp for Level in Reductant
1 B5-2
Tank, SCR System
Indicator Lamp for Level in Reductant
2 B5-6
Tank, SCR System
Indicator Lamp for Active Fault Code,
3 B6-3
SCR System
Indicator Lamp for Active Fault Code,
4 B6-4
SCR System
Figure 674
Location
C4007 C4008
C4009 WL1400035
Figure 675
4-1-395
Connector C4009
Overview
Figure 676
Connection
Source/Destination
Pin Signal
E44, Pin T123, Pin
PWM Input Signal,
1 B5-5 3
T123 Fan Speed Sensor
Voltage +12 V,
2 B6-5 1
Fan Speed Sensor
3 Ground, Fan Speed Sensor B6-9 2
4 Not used
5 Ground, Fan Relay B6-6 4 Figure 677
PWM Output Signal,
6 B6-1 5
Fan Relay
Location
C4007 C4008
C4009 WL1400035
Figure 678
4-1-396
Connector C4011
Overview
Figure 679
Connection
Source/Destination
Pin Signal
E67, Pin T115, Pin
Voltage to NOx Sensor 4 1
1 A-20 1
T115
2 CAN Signal Low A-24 2 2 3
3 CAN Signal High A-23 3
4 Ground A-21 4
WL1400025
Figure 680
Location
C7
C4051
C316
C4011
C4012
EX1401042
Figure 681
4-1-397
Connector C4012
Overview
Figure 682
Connection
Source/Destination
Pin Signal
E67, Pin T113, Pin
Input Signal +5 V from
1 Exhaust Gas Temperature B-31 1
Sensor T113
2 Ground B-30 2
Figure 683
Location
C7
C4051
C316
C4011
C4012
EX1401042
Figure 684
4-1-398
Connector C4022
Overview
Figure 685
Connection
Pin Signal
2 U31, Ground
3 Not Used
4 Not Used
6 CAN Signal High
7 CAN Signal Low
Figure 686
Location
C4022
WL1400043
Figure 687
4-1-399
Connector C7
Overview
Figure 688
Connection
Pin Signal Source/Destination

U30 Voltage to the SCR
1 E67, pin A-3 M1/P3
Control Unit
2 Ground E67, pin A-4 G4000
3 Not Used
4 Not Used
U15 Voltage to the SCR
5 E67, pin A-12 C4002, pin 1
Control Unit
6 CAN Signal High E67, pin A-22 E44, pin B4-7 Figure 689
7 CAN Signal Low E67, pin A-19 E44, pin B4-8
Location
C7
C4051
C316
C4011
C4012
EX1401042
Figure 690
4-1-400
P500
A-1
EMS330.BK-1 (Digital Input Signal)
A-2
EMS331.RD-1 (PWM Output Signal)
A-3
A-4
G
EMS98.RD-50
B.1-1
Alternator
B.2-1
B.3-1
EMS S8 (1/2)
DX340LC-5/DX350LC-5
E44
P3
MCC_15
B5-4 T33
B5
A-1 B5-10 EMS229.WH-0.75 (+5 V)
A7
EMS201.BK-1 (Digital Input Signal) A7-9
1 2
A-2 B5-3 EMS230.BN-0.75 (Ground)

EMS202.RD-1 (PWM Output Signal) A7-10
Sensor
Coolant
A-3 B5-9
A-4
MCC_14
G
EMS99.RD-50 A7-1
B.1-1
Alternator
EMS231.RD-0.75 (+5 V)
A7-3
B.2-1 EMS232.BK-0.75 (Ground)
A7-2
T5 1 2 3
EMS233.GN-0.75 (Analogue Input Signal)

B.3-1 A7-8
P
Temperature Oil Press Sensor
EMS234.YE-1 (Analogue Input Signal)

(Oil Temp. Engine)
A7-7
POW EMS235.WH-1 (Analogue Input Signal)
B.2-1 A7-6
C35
B.1-1
M
EMS203.RD-1 (Digital Output Signal) EMS239.YE-1
Motor
Starter
A-1 B5-1 EMS240.WH-1
A6
A6-7
EMS236.RD-1 (+24 V) EMS241.RD-1
M1
A6-3
EMS237.BK-1 (Ground) EMS242.BK-1
MCC_13
A6-8
(Temp.)
T126 E D B C A
EMS204.RD-1 (PWM Output Signal) EMS238.GN-1 (Analogue Input Signal) EMS243.GN-1

6 5 1 2 4
B5-8 A6-9
1 2
EMS205.BK-1 (Ground)
Massflow Sensor
B5-7
Metering
MCC_3
Fuel Inlet
MCC_23
Solenoid Valve
Engine
MCC_12
V120
Component
C4072
C4071
C4008
EMS446.OG-2.5 EMS441.RD-1 EMS440.RD-1 (+24 V)
3
3
1
SCR LL B5-2 A6-10
B5-6 A6-5
MCC_8
MCC_7
B5-5
T123
A6-4
MCC_24
C4009
Frame
Frame
Frame
Engine
EMS468.YE-1 EMS208.YE-1 (PWM Input Signal)
EMS469.GN-1 EMS209.GN-1 (+12 V)
B6-5
B6
3 1 2
EMS470.BK-1 EMS210.BK-1 (Ground)
1 2 3
V
B6-9
A6-6
B6-10
EMS471.WH-1 EMS211.WH-1 (Ground) A6-2
B6-6
4 5
EMS472.RD-1 EMS212.RD-1 (PWM Output Signal) A6-1
5 6
/ Speed Sensor
B6-1
Cooling Fan Control

A7
A7-5
MCC-6
MCC_11
A7-4
Engine
Engine
C4072
C4071
C4008
T75
EMS447.BU-2.5 EMS443.BK-1 EMS442.BK-1 (+24 V)
4
4
SCR LF B6-3
B6-4 EMS244.WH-0.75 (Frequency Input Signal)
A3-4
A3
1 2
MCC_7
EMS245.BN-0.75 (Frequency Input Signal)
MCC_8
Speed
A3-5
MCC_24
Engine
Sensor 2
Frame
Frame
Frame
Engine
V
T110
EMS213.RD-1 (+5 V)
B6-2
V
EMS214.GN-1 (Analogue Input Signal)

B6-8 EMS344.BN-0.75 (Frequency Input Signal)
EMS215.BK-1 (Ground) A3-2
B6-7 EMS343.WH-0.75 (Frequency Input Signal)
Sensor
1 3 2 4
EMS347.YE-1 (Analogue Input Signal) A3-3
2 1
Sensor
Position
Camshaft
Engine Oil Level

A5-9
A5
MCC_9
C4001
C4008
A5-2
T135
EMS445.RD-1 EMS444.RD-1 (+24V / Digital Output Signal)
8
ER 3 A5-3
A3-10
MCC_10
MCC_27
EMS467.GN-1
A3-9
Frame
Engine
Engine
Engine
EMS466.YE-1
3 4
A3-8
EMS465.RD-1
1
A3-7
M
EMS464.BK-1
2
Motor (EGR 1)
A3-1
Electrical Actuator
MCC_21
T4000 P
B7-3 A3-6
B7
M28
EMS430.RD-1 (+5 V)
B7-8
Sensor
B7-9
2 1 3
Pressure
Atmosphere EMS463.GN-1
B7-10
MCC_18
EMS462.YE-1
B7-4
3 4
B7-5 EMS461.RD-1
1
Sensor
EMS460.BK-1
T120
2
MCC_22
Pressure Atmosphere
EMS224.RD-1 (Frequency Input Signal)

B7-1
1 2
EMS225.BK-1 (Frequency Input Signal)

B7-6
M4000
Speed
Turbine
V
Sensor 1
MCC_2
B7-2
B7-7
EMS219.RD-1 (+24 V)
1 2
EMS256.GN-1 (CAN High)

A4
A4-6
3 4
A5
EMS257.YE-1 (CAN Low)

Motor VGT
A4-7
C4073
C4002
C4050
Electrical Actuator
A4-1
MCC_19
EMS458.BK-1.5 EMS419.BN-2.5
5
5
MCC_1
A4-3 EGR/EXV 31
M30
A5-1
A4-2 EMS459.RD-1.5 EMS420.VT-2.5
6
6
A5-6 EGR/EXV 15
EMS428.BK-1 (+5 V) EMS457.GN-0.75 EMS421.BU-2.5
3
3
A4-5 EEC 15
EMS426.RD-1 (Ground)
A4-4 A5-10 EMS455.BK-2.5 EMS422.BK-2.5
C4049
2
2
A B C
EMS427.GN-1 (Analogue input signal) EEC 31

A4-10
A5-7 EMS456.RD-2.5 EMS423.OG-2.5
1
1
EEC 30
Coolant Level
Sensor Monitor
A5-8
MCC_5
A4-8
T8
MCC_28
MCC_17
A4-9 A5-4
A5-5
Frame
Frame
Frame
Engine
B2
B1
C4000
EMS401.GN-1
EMS 15
C4022
EMS400.BK-1
EMS 31
A2
A1
EMS402.RD-1 EEC 30
CAN1 H
EMS403.YE-1 EEC 31
1 2 3 4
CAN1 L
XPI 5-Cyl: See sheet 3
XPI 6-Cyl: See sheet 2
1 2 5
EEC 15
C4048
MCC_25
EMS451.BK-1 (CAN Low) EMS453.BK-1

7
B4-10 B4-8 CAN3 L

Frame
Engine
B4-9
EMS450.RD-1 (CAN High) EMS452.RD-1
6
B4
B4-5 B4-7 CAN3 H

B4-3 B4-1
MCC_4
MCC_16
B4-6
B4-4
C4047
B4-2
Frame
Engine
C4001
EMS410.GN-1.5 EMS406.GN-1 (Digital Input Signal)

3
EMS 15 B3-3
C4004 B3-5
EMS414.WH/BK-2.5 EMS411.BK-2.5 (Ground)
2
EMS 31 B3-2
C4001
MCC_26
EMS412.VT-2.5 (+24 V)
C4003 B3-6 EMS 30
EMS409.RD-0.75 EMS405.RD-1 (CAN High) EMS407.BK-2.5 (Ground)
B3
CAN1 H B3-9 B3-7 EMS 31

EMS413.WH/RD-2.5 (+24 V)
4 5 1
B3-1 EMS 30
C4005 EMS415.WH-2.5 (Ground)
EMS408.WH-0.75 EMS404.WH-1(CAN Low) B3-8
7
CAN1 L B3-10 EMS416.WH-2.5 (Ground)

B3-4
C4006
C4072
C4071
MCC_26
EMS417.RD-2.5
MCC_20
VGT 30
Frame
Engine
EMS418.GY-2.5
1 2
1 2
VGT 31
Cable Marking
MCC_24
Conductor Area (mm2)
Cable Colour (Orange)
Frame
Frame
Frame
Engine
Cable Designation
AWD35 . OG - 1
M4000
M4000.X
EMS436.GN-1
EMS435.YE-1
3 4
3 4
T8
T5
P3
M1
T75
T33
E44
C35
EMS434.RD-1
M30
M28
Des.
T135
T126
T123
T120
T110
V120
P500
T4000
C4073
C4072
C4071
C4050
C4049
C4048
C4047
C4022
C4009
C4008
C4006
C4005
C4004
C4003
C4002
C4001
C4000
M4000
M4000
EMS433.BK-1
1 2
M4000.X
1 2
F5
F7
F6
F8
F8
F5
F4
B7
B5
B7
B4
B6
B3
B8
B8
B4
B7
E4
E4
E3
E3
E3
B6
B7
B2
B2
B2
B2
E4
A2
A3
E7
C2
D8
MCC_29
Pos.
D 2, F 4
D 2, F 4
Engine
Engine
A 6, A 7, E 2
A 6, A 7, E 2
Cut cable
Cut cable
Alternator
Alternator
Description
Starter motor
Splice, 1-pole
Splice, 1-pole
Splice, 1-pole
Splice, 1-pole
Sensor, Phase
No Description
VT
PK
YE
BK
Sensor, Oil Level
Control unit, EMS
Connector, 7-pole
Connector, 6-pole
Connector, 6-pole
Connector, 4-pole
Cables
Motor, Exhaust Brake
Motor, Exhaust Brake
Monitor, Coolant Level
RD Red
Splice, 1-pole, Interface
Pink
BU Blue
GY Grey
Sensor, Engine Speed 2
Black
Sensor, Turbine Speed 1
Violet
WH White
Sensor, Massflow, Temp.
GN Green
BN Brown
Code Colour
Yellow
OG Orange
Connector, 4-pole, Interface
Sensor, Coolant Temperature
Solenoid Valve, Inlet Metering

Motor, Electrical Actuator VGT
Sensor, Pressure, Atmosphere

Connector, 4-pole, Diagnostics
Sensor, Fan Control, Fan Speed

Motor, Electrical Actuator EGR 1
Sensor, Oil Press, Oil Temp. Engine
Colour Code of Electric
EX1301797
4-1-401
Engine
EMS S8 (2/2)
Cable Designation Des. Pos. Description

C452-1 D2 Splice, Oil Protection
AWD35 . OG - 1
Fuel Pressure Exhaust Mainfold C453-1 D5 Splice, Oil Protection
Cable Marking
Sensor (Rail) Pressure Sensor Cable Colour (Orange) C456-1 D4 Splice, Oil Protection
T111 T125 Conductor Area (mm 2 ) C456-2 D4 Splice, Oil Protection
Turbo Charger
P P C457-1 D2 Splice, Oil Protection
Pressure Sensor C457-2 D2 Splice, Oil Protection
T122 P C458-1 D3 Splice, Oil Protection
Turbo Charger E44 A8 Control Unit, EMS
Temp. Sensor T111 F8 Sensor, Pressure, Rail
A B C 2 4 1 1 2 3
Fuel Actuator Solenoid Valve Fuel Actuator Solenoid Valve T121 E8 Sensor, Charger Temp
T121 T122 E7 Sensor, Charger Pressure
T125 F8 Sensor, Exhaust Manifold Pressure
(Cyl. 4) (Cyl. 5) (Cyl. 1) (Cyl. 2) (Cyl. 3) V141 E3 Solenoid Valve, Fuel Actuator
V144 V145 V141 V142 V143 V142 E3 Solenoid Valve, Fuel Actuator
V143 E2 Solenoid Valve, Fuel Actuator
2 1 V144 E5 Solenoid Valve, Fuel Actuator
A-1 B-1 A-1 B-1 A-1 B-1 A-1 B-1 A-1 B-1
MCC_8 MCC_1 V145 E5 Solenoid Valve, Fuel Actuator
Colour Code of
Electric Cables
Code Colour
BK Black
BN Brown
RD Red
OG Orange
YE Yellow
C452-2
C452-1
C453-2
C453-1
C456-2
C456-1
C458-2
C458-1
C457-2
C457-1
GN Green
BU Blue
VT Violet
GY Grey
EMS261.GN-0.75 (Analogue Input Signal)
WH White
PK Pink
MCC_2 MCC_3 MCC_5 MCC_6 MCC_7
EMS260.BK-0.75 (Ground)
EMS284.RD-1.5 (+24 V)
EMS276.RD-1.5 (+24 V)
EMS280.RD-1.5 (+24 V)
EMS263.WH-1 (Ground)
EMS259.RD-0.75 (+5 V)
EMS264.RD-1.5 (+24 V)
EMS268.RD-1.5 (+24 V)
EMS291.RD-1 (+5 V)
EMS288.RD-1 (+5 V)
EMS262.BN-1 (+5 V)
E44
B2-2
B2-5
B2-8
A2-2
A1-1
A1-6
B1-10
A2-10
A1-2
A1-9
A1-5
A2-5
A2-9
B2-9
A2-8
A2-3
B2-3
A1-3
A1-8
B1-1
B1-6
B1-2
B1-8
B1-5
B2-1
B2-6
A1-10
A2-4
B2-10
A1-4
B1-9
A2-1
A2-6
B2-4
B2-7
B1-7
B1-3
B1-4
A1-7
A2-7
A2 B2 A1 B1
A7 A5 A3 B4
A5-10
A3-10
B4-10
A7-10
A7-8
A7-7
A5-3
A5-2
A5-9
A5-7
A5-8
A5-5
A5-4
A5-1
A5-6
A3-5
A3-4
A3-3
A3-2
A3-1
A3-6
A3-9
A3-8
A3-7
B4-1
B4-6
B4-7
B4-8
B4-2
B4-3
B4-4
B4-9
B4-5
A7-3
A7-1
A7-2
A7-6
A7-5
A7-9
A7-4
EX1301798
4-1-403
E67
V117
C316
4
EEC438.GN-1 EEC430.GN-1 (Output Signal)
1
B-32
3
EEC439.YE-1 EEC431.YE-1 (Ground)
2
B-33
7
EEC440.BK-1 EEC432.BK-1 (Ground)
DX340LC-5/DX350LC-5
B-8
6
EEC441.BU-1 EEC433.BU-1 (Input Signal)
t
B-6
8
EEC442.WH-1 EEC434.WH-1 (Input Signal)
5
B-7
p
5
Dosing Unit
EEC443.RD-1 EEC435.RD-1 (+5 V)
6
B-5
1
EEC444.BN-1 EEC436.BN-1 (Analogue Input Signal)
7
B-4
2
EEC445.OG-1 EEC437.OG-1 (Output Signal)
8
B-3
M1
B-9 A-1
Component
Component
M
B-10 B.1-1
B.2-1
B-11
Start Motor
EEC409.WH-2.5
P3
A-1
A-18 A-2
A-3
A-17
Fuse Holder (SCR)
A-4
F4000
C4015
C4022
C7
G
1
2
A-14 EEC207.WH-2.5 EEC400.WH-2.5 EEC405.WH-2.5 EEC407.WH-2.5 EEC408.WH-2.5
1
1
A-3 B.1-1
A-15 (Input Signal (+24 V))
Alternator
B.2-1
B.3-1
G4000
1
T115
EEC208.WH-2.5 EEC401.WH-2.5 EEC406.BK-2.5
2
C4011
A-4
EEC450.YE-1 EEC446.YE-1 (CAN Low) (Grounding)
2
A-24
2
MCC_1
EEC447.GN-1 (CAN High)
CAN
NOX
EEC451.GN-1
Ground (SCR)
3
A-23
3
C4002
EEC452.RD-1 EEC448.RD-1 (+24 V)
1
A-20
1
EEC209.RD-1 EEC402.RD-1 EEC416.RD-1
5
1
A-12
NOX
EEC453.BK-1 EEC449.BK-1 (Ground)
Supply
4
A-21 (Digital Input Signal)
NOX Sensor (Exhaust Gas)

EEC210.GN-1 EEC403.GN-1 EEC417.RD-1
6
Component
Component
A-30 A-22
E44
(CAN High)
A-29
B4-7 B4-8
A-27
EEC211.BK-1 EEC404.BK-1 EEC418.BK-1
T113
7
A-26 A-19
C4012
(CAN Low)
Control Unit (EMS)
1
EEC456.RD-1 EEC454.BN-0.75 (CAN Low)
1
B-31
MCC_2
2
EEC457.BK-1 EEC455.BK-0.75 (CAN Low)
2
B-30
Frame
Frame
Frame
Component
B-46
C4008
B-45 EEC420.RD-1
3
Component
Component
Temp. Sensor (Exhaust Gas)

EEC421.YE-1
4
2
EEC, EEC3 EXHAUST EMISSION CONTROL (9, 13 LITER ENGINES XPI)
B-14 EEC422.GN-1
3
5
B-15
EEC423.BK-1
4
6
H25
Frame
Frame
Frame
Frame
EEC467.RD-1 (Output Signal)

B-42
2
EEC468.BK-1 (Ground)
B-41
H26
Hose Heater
1
EEC469.RD-1 (Output Signal)

B-44
2
Cable Marking
B-43
Cable Colour (Orange)
Cable Designation
Conductor Area (mm 2 )
A-13
V118
AWD35 . OG - 1
A-16
1
EEC458.BN-0.75 (Input Signal)

B-36
4
EEC459.BK-0.75 (Ground)
B-37
A-10
VT
PK
YE
BK
BU
BN
GY
RD
GN
OG
WH
A-7
Red
Pink
Blue
Grey
Water Valve (EEC)

Black
Violet
White
A-9
Green
Brown
Yellow
Code Colour
Electric Cables
Colour Code of
Orange
V183 2
EEC460.RD-1 (+5 V) A-6

B-1
4
B-16 A-5
3
EEC462.GN-1 (Output Signal)

B-2 A-8
P3
C7
C6
M1
1
E67
E44
H26
H25
EEC463.YE-1 (Input Signal)

Des.
T116
T115
T113
V183
V118
V117
C316
B-17 A-11
Pump Unit
F4000
C4015
C4014
C4013
C4012
C4011
C4008
C4002
G4000
F7
F7
F6
A2
A3
A8
A1
A6
A5
A3
A4
E6
E6
E5
E6
B5
B6
E4
B8
C8
C6
Pos.
V116
EEC464.BU-0.75 (Input Signal)

B-38
3
u
EEC465.BN-0.75 (Ground)
Alternator
Pump Unit
B-39
Description
2
Dosing Unit
Sensor, Nox
Starter Motor
Splice, 1-pole
No Description
EEC466.BK-0.75 (Input Signal)

Control Unit, EEC
Connector, 2-pole
Connector, 4-pole
Connector, 4-pole
Connector, 3-pole
Connector, 2-pole
Connector, 4-pole
Connector, 2-pole
Control Unit, EMS
Water Valve, EEC
B-40
1
u
Heater, Hose heater
Heater, Hose Heater
Ground, Engine, SCR
Sensor, Temp. Upstream
Sensor Unit (Temp./Level)

Fuse Holder, 1-pole, SCR
Sensor Unit, Temperature/Level
EX1301799
4-1-405
Engine
Engine Coolant
Heater (Option)
Edition 1
DX340LC-5/DX350LC-5 Engine Coolant Heater (Option)

4-2-1
MEMO
Engine Coolant Heater (Option) DX340LC-5/DX350LC-5

4-2-2
Table of Contents
Engine Coolant Heater (Option)

Disassembly and Assembly............................4-2-5
Changing the Circulating Pump................................. 4-2-5
Changing the Temperature Limiter............................ 4-2-7
Changing the Temperature Sensor ........................... 4-2-8
Changing the Combustion Air Fan .......................... 4-2-10
Changing the Burner, Flame Monitor and Glow Plug . 4-2-12
Changing the Burner Head...................................... 4-2-14
Changing the Heat Exchanger ................................ 4-2-16

4-2-3
MEMO

4-2-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DISASSEMBLY AND ASSEMBLY
Changing the Circulating Pump
Removal
1. Remove heater.
2. Disconnect the electrical connections.
3. Remove screws (4, Figure 1).
4. Remove clip (3, Figure 1) and circulating pump (2, Figure
1).
5. Complete the work on stripped-down components.
Installation
1. Apply acid-free grease to the sealing ring (1, Figure 1).
2. Place the circulating pump (2, Figure 1) in the assembly
position and attach with the clip (3, Figure 1) and screws
(4, Figure 1).
3. Tighten the screws (4, Figure 1) to 3 Nm ±10%.
4. Connect the electrical connections.
5. Install the heater.

4-2-5
1
4 FG018670
Figure 1 Changing the Circulating Pump
Reference Reference
Number Number
1 Sealing Ring 3 Clip
2 Circulating Pump 4 Screw (2)
NOTE: A Thermo 90 ST heater is shown. In the Thermo 90 S

heater, the control unit can also be arranged on the
combustion air fan without having any effect on
changing the circulating pump.

4-2-6
Changing the Temperature Limiter
Removal
NOTE: The temperature limiter only has to be removed if it is
being replaced with a new one.
The function must be checked in the installed
condition.
1. Remove heater.
3. Remove clip (2, Figure 2) and pull off the protective cap (1,
Figure 2).
4. Use a screwdriver to lever off the retaining spring and
remove temperature limiter (3, Figure 2).
NOTE: It is essential to install a new temperature limiter
to replace a removed one!
Installation
IMPORTANT
Incorrect installation will cause the heat exchanger to melt.
1. Insert the new temperature limiter (3, Figure 2) into the

heat exchanger (4, Figure 2) and press in the retaining
spring.
NOTE: You must be able to hear and feel the spring
clip into the groove. Only then is the
temperature limiter in the correct installation
position.
If you do not hear and feel the spring clip in:
• Clean the contact surface of the temperature limiter
on the heat exchanger
• Clean the groove in the heat exchanger
• Ensure that detent lugs are present on both sides of
the spring. Install a new temperature limiter if
necessary.
2. Put on the protective cap (1, Figure 2) and secure it with
the clip (2, Figure 2).
3. Tighten the clip to 1 Nm ± 10%.

4-2-7
Changing the Temperature Sensor
Removal
1. Remove heater.
WARNING
Leaking hot coolant can cause burns.
3. Unscrew and remove temperature sensor (6, Figure 2) and

remove it with the round sealing ring (5, Figure 2).
Installation
1. Apply acid-free grease (Vaseline) to the round sealing ring
(5, Figure 2).
2. Install the temperature sensor (6, Figure 2) with the round
sealing ring (5, Figure 2) and screw it into the heat
exchanger (4, Figure 2).
Tighten to 1.5 Nm ±10%.

4-2-8
1
2
6
3
5
FG018671
Figure 2 Changing the Temperature Limiter and Temperature Sensor
Reference Reference
Number Number
1 Protective Cap 4 Heat Exchanger
2 Clip 5 Round Sealing Ring
3 Temperature Limiter 6 Temperature Sensor
NOTE: A Thermo 90 ST heater is shown. In the Thermo 90 S

heater, the control unit can also be arranged on the
combustion air fan without having any effect on
changing the temperature sensor.

4-2-9
Changing the Combustion Air Fan
Removal
1. Remove heater.
3. Remove screws (2, Figure 3).
4. Pull the combustion air fan (1, Figure 3) off the burner head
(4, Figure 3) and remove with the shaped sealing ring (3,
Figure 3).
NOTE: Remove control unit if necessary from the
Thermo 90 S/Thermo 90 ST heater with flange
mounted control unit.
Installation
NOTE: Insert the shaped seal (3, Figure 3) correctly and
grease it (e.g. with Vaseline). Take care not to
squash it.
1. Install the new shaped sealing ring (3, Figure 3) onto the
combustion air fan (1, Figure 3). Bring the fan into the
assembly position and secure it with screws (2, Figure 3).
2. Tighten the screws (2, Figure 3) to 3 Nm ±10%.
NOTE: Install the control unit if necessary on the
Thermo 90 S/Thermo 90 ST heater with flange
mounted control unit.

4-2-10
Thermo 90 S
Control Unit 1
2 3
1
5
FG018672
Figure 3 Changing the Combustion Air Fan
Reference Reference
Number Number
1 Combustion Air Fan 4 Burner Head
2 Screw (2) 5 Control Unit
3 Shaped Sealing Ring
NOTE: A Thermo 90 ST heater is shown.

4-2-11
Changing the Burner, Flame Monitor and Glow Plug
Removal
1. Remove heater.
2. Remove combustion air fan.
3. Remove screw (5, Figure 5) and washer (4, Figure 5).
4. Remove nuts (10, Figure 5) and pull off the bar (8, Figure 5).
5. Pull the grommets (11 and 12, Figure 5) out of the slots in
the housing of the combustion pipe (3, Figure 5).
6. Pull the grommet (13, Figure 5) and burner (1, Figure 5)
out of the burner head and remove with the swirl orifice (2,
Figure 5).
7. Pull the flame monitor (7, Figure 5) and glow plug (6,
Figure 5) from the burner (1, Figure 5) and remove.
8. Perform a visual check for assessing the burner.
Installation
1. Place the swirl orifice (2, Figure 5) onto the burner (1,
Figure 5).
2. Carefully insert the flame monitor (7, Figure 5) and glow
plug (6, Figure 5) into the burner up to the stop and push
the grommets (11 and 12, Figure 5) into the slots in the
housing of the burner pipe (3, Figure 5).
3. Insert the burner (1, Figure 5) and grommet (13, Figure 5)
into the burner head (3, Figure 5).
IMPORTANT
During the following procedure, make sure that cables
of the flame monitor (7, Figure 5) and the glow plug (6,
Figure 5) are routed as shown in the figure.
4. Push the insulation (9, Figure 5) onto the bar (8, Figure 5)
and bring the bar into the assembly position. Flame Monitor
Glow Plug
NOTE: Route the cable of the flame monitor and the FG018673
glow plug as shown in the figure! Figure 4
5. Secure the bar (8, Figure 5) using the nuts (10, Figure 5).
Tighten the nuts to 3 Nm ±10%.
6. Secure the fuel line using the screw (5, Figure 5) and
washer (4, Figure 5). Tighten the screw to 3 Nm ±10%.
7. Install the combustion air fan.

4-2-12
1
13
12
11
7
8
10 9
4
5
3
FG018674
Figure 5 Changing the Burner, Flame Monitor and Glow Plug
Reference Reference
Number Number
1 Burner 8 Bar
2 Swirl Orifice 9 Insulation
3 Burner Head 10 Nut (2)
4 Washer 11 Grommet
5 Screw 12 Grommet
6 Glow Plug 13 Grommet
7 Flame Monitor
NOTE: A Thermo 90 ST heater is shown. The figure can also

be used for the Thermo 90 S heater.

4-2-13
Changing the Burner Head
Removal
1. Remove heater.
3. Remove burner, flame monitor and glow plug.
4. Remove mounting screw of the V-clamping collar (2,
Figure 6) and pull off the clamping collar.
5. Pull out and remove burner head (1, Figure 6) from the
heat exchanger (3, Figure 6).
Installation
NOTE: The burner head and exhaust outlet port can also be
aligned during installation in the machine.
1. Guide the burner head (1, Figure 6) into the heat
exchanger (3, Figure 6), align it if necessary and secure
with the V-clamping collar (2, Figure 6).
2. If necessary, tighten the mounting screw of the V-clamping
collar to 3 Nm ±10%.
3. Install the burner, flame monitor and glow plug.
4. Attach the combustion air fan.

4-2-14
3
2
FG018675
Figure 6 Changing the Burner Head
Reference Reference
Number Number
1 Burner Head 3 Heat Exchanger
2 V-clamping Collar
NOTE: A Thermo 90 ST heater is shown. The figure can also

be used for the Thermo 90 S heater.

4-2-15
Changing the Heat Exchanger
Removal
1. Remove heater.
2. Remove circulating pump.
3. Remove temperature limiter.
4. Remove temperature sensor.
6. Remove burner, flame monitor and glow plug.
7. Remove burner head.
8. Remove plug and connector housing.
Installation
1. Clip the connector housing onto the heat exchanger and
insert the plug into the connector housing.
2. Install the burner head.
3. Install the burner, flame monitor and glow plug.
4. Attach the combustion air fan.
5. Install the temperature sensor.
6. Install the temperature limiter.
7. Attach the circulating pump.

4-2-16
1Upper Structure
1Cabin
Edition 1
DX340LC-5/DX350LC-5 Cabin
5-1-1
MEMO
Cabin DX340LC-5/DX350LC-5
5-1-2
Table of Contents
Cabin
Cabin Identification .........................................5-1-5
Roll-over Protective Structure (ROPS)...................... 5-1-5
Removal .........................................................5-1-7
Installation ....................................................5-1-11
Dimensions of Cabin Glass ..........................5-1-14
Removal and Installation of Cabin Glass......5-1-18
Removal of Cabin Glass.......................................... 5-1-18
Installation of Cabin Glass....................................... 5-1-20
Installation of Upper Door Glass ............................. 5-1-25
Installation of Upper Front Glass............................. 5-1-25
5-1-3
5-1-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
CABIN IDENTIFICATION
Roll-over Protective Structure (ROPS)
General ROPS Instructions for ROPS Certified Cabins

The operator's cabin is a ROPS certified structure for protecting
the seat-belted operator. It absorbs the impact energy of a
rollover impact. Do not allow machine weight (mass) to exceed
certified value on certification plate. If weight is exceeded, the
ROPS structure will not be able to fulfill its safety function.
Do not increase machine weight beyond certified value by
modifying machine or by installing attachments on machine. If
weight limit of protective equipment is exceeded, protective
equipment will not be able to protect operator, and operator may
suffer 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,
DOOSAN. Changes to the cabin can cause loss of
operator protection from rollover and falling objects, and
operator may suffer 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 properly fulfill its function. In these
cases, always contact your DOOSAN distributor for advice.
Never repair a ROPS cabin.
• Always wear your seat belt when operating machine.
5-1-5
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 is found on the left side of the cabin
on most models. It may vary slightly in its location on some
models.
Check the ROPS cabin, mounting, and hardware for damage.
Never modify the ROPS cabin. Replace the cabin and hardware
if damaged. See your DOOSAN dealer for parts.
ROPS − Roll-over Protective Structure complies with
ISO 12117-2:2008, EN13531:2001.
WARNING
Never modify the operator cabin by welding, grinding,
DOOSAN. Changes to the cabin can cause loss of operator
protection from roll-over and falling objects, and result in
5-1-6
REMOVAL
1. Park on firm and level ground. O I
2. Lower front attachment (bucket) to ground.
3. Stop engine.
4. Move safety lever to "RELEASED" (UNLOCK) position. LOCK
5. Turn starter switch to "I" (ON) position.
WARNING
DO NOT OPERATE
WARNING or maintenance
190-00695A
ON OFF
EX1401036
If engine must be run while performing maintenance,
use extreme care. Always have one person in the
cabin at all times. Never leave the cabin with the
engine running.
6. To relieve pressure from accumulators, fully stroke work

levers in all directions. Movement can occur.
7. Move safety lever to "LOCK" position.
8. Turn key to "O" (OFF) position and remove from starter
switch.
9. Hang maintenance warning tag on controls.
10. Disconnect the battery cable from the negative (-) battery
terminal.
11. Prepare cabin shell for removal by disconnecting wiring
connectors for:
A. Cabin interior lighting.
B. External light wiring.
C. Radio antenna and connections.
D. Wiper/washer connections.
NOTE: Control console wiring harnesses and hydraulic
piping lines that pass through the floor of the
cabin do not need to be disassembled.
NOTE: If cabin is equipped with additional protective
guards over cabin openings, they must be
removed.
5-1-7
12. Remove mats from steps and floor.
13. Remove safety lever cover (1, Figure 2).
14. Remove two screws (2, Figure 2) in safety lever to remove
lever.
1
2 FG018676
Figure 2
15. Remove duct covers (1 and 2, Figure 3).
FG018677
Figure 3
16. Remove air ducts (1 thru 6, Figure 4) on right-hand side of

operator's cabin.
17. Disconnect monitor and sun sensor connectors. 2
1
18. Disconnect washer hose from floor plate.
5 6
4
3 EX1301627
Figure 4
19. Remove glove box pad (1, Figure 5), and two bolts under
pad.
20. Remove three caps (2, Figure 5) from top of rear cover. 2
Remove three bolts securing rear cover in place.
21. Remove two bolts (3, Figure 5) from bottom of rubber
mounts in rear cover. 1
22. Remove rear cover.

3
FG015887
Figure 5
5-1-8
23. Remove air ducts (1 thru 3, Figure 6). Remove
1 2
atmospheric air duct (4).
3
EX1301628
Figure 6
24. Remove all bolts fastening brackets (1 thru 3, Figure 7) to

separate brackets from body of operator cabin.
25. Disconnect connectors on interior lights, speakers and
antenna.
1
2
3
EX1301629
Figure 7
26. Remove four mounting nuts from four corners of cabin floor 2
2
(1, Figure 8).
• Tool: 24 mm ( )
27. Remove eleven bolts (2, Figure 8) on plate of floor in 1 2
operator's cabin.
2
Reference
Description Size Qty 2 2
Number
1 Nut M16 x 2.0 4
2 Bolt M12 x 1.75 x 35 11 EX1301630
Figure 8
28. Remove bolt which is fixing the plate to prevent loosening

of ROPS bolt (Figure 9).
• Tool: 19 mm ( )
• Torque: 88.3 N.m (9 kg.m, 65 ft lb)
EX1300970
Figure 9
5-1-9
29. Remove ROPS bolt (Figure 10).
• Tool: 60 mm ( )
EX1301632
Figure 10
30. Using a suitable lifting device, attach slings to four (4) lift
points on top of cabin (Figure 11, Figure 12).
• Cabin weight: approximately 485 kg (1,069 lb)
31. Lift cabin approximately 25 - 50 mm (1" - 2") above deck.
Check that all electrical connections have been
disconnected and all other items unbolted.
32. Continue lifting with crane to remove cabin shell. Lower
shell and rest on support.
NOTE: Lift operator's cabin slowly to prevent damaging EX1300971
controls covers and other components.
Figure 11
FG021964
Figure 12
5-1-10
INSTALLATION
1. Using a suitable lifting device, attach slings to four (4) lift
points on top of cabin (Figure 13, Figure 14).
• Cabin weight: approximately 485 kg (1,069 lb)
2. Lower cabin into position on cabin floor.
EX1300971
Figure 13
FG021964
Figure 14
3. Install four mounting nuts in four corners of cabin floor (1, 2

2
Figure 15).
• Tool: 60 mm ( )
• Torque: 206 N.m (21 kg.m, 152 ft lb) 1 2
4. Install eleven bolts (2, Figure 15) of floorplate in operator's 2
cabin.
2 2
Reference
Description Size Qty
Number
1 Nut M16 x 2.0 4 EX1301630
Figure 15
2 Bolt M12 x 1.75 x 35 11
5. Once cabin is mounted to floor, unhook lifting device.

6. Connect cabin ground cable.
7. Connect cabin light wiring connector.
8. Install stereo assembly with bolts (2, Figure 15) after
connecting speaker and antenna wires.
5-1-11
9. Install the bolt which is fixing the plate to prevent loosening
of ROPS bolt (Figure 16).
• Tool: 19 mm ( )
EX1300970
Figure 16
10. Install ROPS bolt (Figure 17).
• Tool: 60 mm ( )
EX1301632
Figure 17
11. Install air ducts (1 thru 5, Figure 18). Install atmospheric air 2
1
duct (6).
4 6
5
FG015893
Figure 18
12. Install brackets (1 thru 3, Figure 19) on body of operator's

cabin.
1
2
3
EX1301629
Figure 19
5-1-12
13. Install two bolts (2, Figure 20) and center bolts in center,
and three bolts on top to install dashboard cover. Install
cap (3, Figure 20) on top of dashboard cover.
3
14. Install glove box pad (1, Figure 20).
15. Connect washer hose at floor plate bottom.
1
FG015896
Figure 20
16. Install air ducts (1 thru 6, Figure 21) on right-hand side of

cabin.
17. Connect monitor, sun sensor connector, and washer hose. 2
1
5 6
4
3 EX1301627
Figure 21
18. Install duct covers (1 and 2, Figure 22).

19. Install safety lever. Apply Loctite on screws when installing
lever.
2
20. Install mats on steps and floor.
21. Connect negative (-) battery cable leading to frame from 1
battery.
FG018677
Figure 22
5-1-13
DIMENSIONS OF CABIN GLASS
Front Glass
816 7
Ceramic
19
2-R80
Coating
20.5 20.5
993
E-mark Position 100

86.5
105
3-R5 4-R5
40
12
Mark Smooth
2-R2
Detail A
824
A
4-R5
454.5
100
2-R75
E-mark Position
27.6
27.6
169.6
169.6
100
2-R100
7
58.3 707.4
EX1301291
Figure 23
NOTE: Unit: mm (1 mm = 0.039 in)
5-1-14
Left Glass
399.5 5 270.7 5
3-R5 3-R5 8
R6
786.4
786.4
R4344
.1
E-mark Position
E-mark Position 90 90
2- 8.5 Hole 2- 8.5 Hole
R68.1
32
R68
32
90
90
20.3
34 315.3 34
410.6 92
437.5 131.6 402.3
41 705
677.2
850.2 5 654.7
45
R22
R1
5-R46
32
R18
210.7
R5
4
341.2
R14
367
R4356.6 R1198.5
468.8
32
436.1
R2
0
R700
R14
Ceramic Coating
4
R1
R7
06
470
642.3
722.8
871.7
EX1301292
Figure 24
5-1-15
Rear Side Glass
43.3
5
Ceramic
32 32 Coating
601.2
E-mark
100
R125
100
4-R42.8 61.7
786.7
391.1 5
Ceramic
Coating
R3
5
30 R4024.6
R4062.1
1026.2
958.2
80
2-R
10
311
64
258.2
.2
5
E-mark
R3
452.9
EX1301293
Figure 25
5-1-16
Right Glass
1330.8 5
83.2
30
Ceramic
35
30 Coating
R2
48
527.5
957.1
R4435
1407.6
505.1
35
E-mark 37
419.7
306.6
150
90 97.9
30.8
918.7 207.9 163.3
1534.8
EX1301294
Figure 26
5-1-17
REMOVAL AND INSTALLATION OF CABIN GLASS
Removal of Cabin Glass

Procedures to remove right-hand glass (1, Figure 27), rear left,
glass, lower door glass and rear glass. 1
CAUTION
AVOID INJURY
When removing the broken or cracked glass, the glass EX1301295
shards can cause serious injury.
Figure 27
Before removing, use tape to hold the broken or cracked
glass together.
1. Remove resin panel, garnish or etc. around the glass.
Reference
Description
Number
3
1 Garnish
2 Lower Glass of Door
3 Rear Glass 1 4
4 Rear Left-hand Glass 5
2
5 Resin Panel
EX1301296
Figure 28
2. Prick a hole in the adhesive by using an awl (or cutter

knife). 1 2
Reference
Description 3
Number
1 Cabin
2 Cabin Glass
3 Awl
4 Adhesive
4
EX1301298
Figure 29
5-1-18
3. Pass a piano wire (1, Figure 30) (or a wire) through the
hole.
EX1301299
Figure 30
4. Wind both ends of the piano wire onto two screwdrivers.

Draw the wire back and forth to cut the adhesive (3, Figure Cabin Outside
31) between cabin (1) and glass (2). 1 2
Remove glass (2, Figure 31) 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 31
5-1-19
Installation of Cabin Glass
1
Procedures to install right-hand glass (1, Figure 33), rear, left-
hand glass, lower door glass and rear glass.
1. Cut off the remaining adhesive leaving a layer of old 2
adhesive 1 - 2 mm thick (Figure 32). The new adhesive
will bond to the remaining adhesive.
NOTE: Do not damage the cabin paint. Cut off Adhesive
by 1 - 2 mm Deep
Reference
Description EX1301302
Number
Figure 32
1 Cabin
2 Knife
EX1301295
Figure 33
2. Clean the remaining adhesive and metal surfaces with a

general purpose adhesive cleaner.
Reference
Description 3
Number
1 Garnish
2 Lower Glass of Door 1 4
3 Rear Glass
5
4 Rear Left-hand Glass 2
5 Resin Panel EX1301296

Figure 34
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).
5-1-20
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
A
Section A - A
EX1301354
Figure 35
Damper - Rear Glass
758
Adhesive Sides 5
573
A
Section A - A
EX1301355
Figure 36
5-1-21
Damper - Right-hand Glass
1,492
A
Adhesive Sides 5
1,376
7
Section A - A
EX1301356
Figure 37
Damper - Lower Glass of Door
800
7
184
329
R4,329 A
Adhesive Sides
429
5
R94
606 Section A - A
685
EX1301357
Figure 38
Damper - Rear Left-hand Glass
A
Adhesive Sides
5
Section A - A
EX1301358
Figure 39
5-1-22
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 step 1.
Wait for about 15 minutes to let it dry. 1
(Refer to position to apply primer (2, Figure 40).)
NOTE: The painting primer must be applied evenly to
2
leave no blemishes.
Reference 3
Description
Number
1 Cabin
EX1301303
2 Application Brush Figure 40
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. Remove 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 40).)
5-1-23
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 41

10. The 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
5-1-24
Installation of Upper Door Glass
1. Before installing the glass, remove garnish (2, Figure 42) 1
around sash assembly (1) from the cabin inside for easy
2
removal. Push the sash assembly by hands and remove
sash outside. 3
2. Install glass (3, Figure 42) and glass (4) into the sash 4
grooves.
3. Install the sash assembly, which the glass is installed on,
onto the door from the outside of cabin.
EX1301297
Secure the sash assembly at the inside of cabin by using Figure 42
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
4 Damper 1
Apply Silicone after 4
Fixing 2 (Seal)
Fill with Sealant

2
3
EX1301304
Figure 43
5-1-25
5-1-26
Counterweight
Edition 1
DX340LC-5/DX350LC-5 Counterweight
5-2-1
MEMO
Counterweight DX340LC-5/DX350LC-5
5-2-2
Table of Contents
Counterweight
General ...........................................................5-2-6
Warning for Counterweight and Front Attachment
Removal .................................................................... 5-2-6
Removal .........................................................5-2-8
Installation ......................................................5-2-9
5-2-3
5-2-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
5-2-5
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.
Never remove counterweight or front attachment unless the EX1401352
Figure 1
Never rotate the upper structure once the counterweight or
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 of Counterweight
7,100 kg (15,650 lb)
5-2-6
Responsibility must be assigned to one person to be in charge
of the lifting crew, and to verify that required safe lifting
precautions have been taken before each part of this procedure
has been started.
All members of the working crew should know and understand
the signals that will be used between the lifting leader, the assist
crane operator and the remainder of the work crew.
WARNING
If the 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
5-2-7
REMOVAL
O I
WARNING
LOCK
Death or serious injury can occur from a counterweight
falling during removal or installation. Do not allow WARNING
personnel under or around the counterweight during DO NOT OPERATE
removal or installation.
or maintenance
190-00695A
Use certified cables and shackles of adequate load rating. ON OFF

EX1401036
Improper lifting can allow the load to shift and cause death
Figure 4
or serious injury.
1. Park on firm and level ground.

3. Stop engine.
4. Move safety lever to "UNLOCK" position.
WARNING
If engine must be running while performing
maintenance, use extreme care. Always have one
person in the cabin at all times. Never leave the cabin
with the engine running.
6. Fully stroke work levers (joysticks) in all directions to 1

relieve any pressure from accumulators.
6
8. Turn key to "O" (OFF) position and remove from starter switch.
9. Attach a maintenance warning tag on controls.
11. Make sure all electrical and other items are disconnected.
12. Using a suitable lifting device capable of handling the
weight of the counterweight, partially support
counterweight from lifting holes (6, Figure 5),
5
counterweight (1) before loosening four bolts (2). Stop
lifting with assist crane as soon as lifting slings are taut. 4
13. Remove four bolts (2, Figure 5), washers (3) and shims (5)
from counterweight (1). 3
• Tool: 60 mm ( )
2
• Weight: 7,100 kg (15,650 lb)
Figure 5 EX1400040
NOTE: Heat bolts, if necessary, to free them.
5-2-8
14. When bolts (2, Figure 5), washers (3) and shims (5) 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
1. Using suitable lifting device capable of handling the weight

of the counterweight, support counterweight from lifting 6
holes (6, Figure 6). Raise counterweight (1, Figure 6) into
position just above support frame (4) leaving
counterweight suspended. Verify that counterweight 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.
5
2. Slide washers (3, Figure 6) onto bolts (2). Apply Loctite
#242 to mounting bolt threads. 4
3. Install four bolts (2, Figure 6) with washers (3) into
counterweight until washers contact support frame. Fully 3
lower counterweight onto support frame and finish
tightening bolts. 2
• Tool: 60 mm ( )
EX1400040
• Torque: 2,451 N.m (250 kg.m, 1,808 ft lb) Figure 6
NOTE: As assembling counterweight into main frame,
adjust the gap of height between counterweight
and side door assembly using shim (5, Figure 6)
suitably.
4. Remove lifting device from counterweight lifting holes (6,
Figure 6)
5. Make sure all electrical and other items are connected.
6. Turn disconnect switch to "ON" position.
5-2-9
5-2-10
Hydraulic Oil Tank
Edition 1
DX340LC-5/DX350LC-5 Hydraulic Oil Tank

5-3-1
MEMO
Hydraulic Oil Tank DX340LC-5/DX350LC-5

5-3-2
Table of Contents
Hydraulic Oil Tank

General ...........................................................5-3-5
Specification .............................................................. 5-3-5
Parts List ................................................................... 5-3-6
Air Breather ............................................................... 5-3-8
Removal .........................................................5-3-9
Installation ....................................................5-3-14
Completing Work ..........................................5-3-15

5-3-3
5-3-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specification
Volume (Full) 381 L (101 U.S. gal)
Optimum Volume 243 L (64 U.S. gal)
Tank Size 988 x 617 x 894
Tank Weight about 304 kg (Empty)
Size 10 μm, 1.6 m2 (ø150 x 415)
Operation Pressure 0 - 15.9 kg/cm2 (0 - 15 bar, 0 - 217.6 psi)
Return Filter (9, Figure 1)
Bypass Valve Setting 1.5 kg/cm2 at 40 L/min
Flow Rate 600 L/min (158.5 U.S. gpm)
Filter 10 μm, 270 cm2
Air Breather (20, Figure 1)
Cracking Pressure 0.04 - 0.05 kg/cm2 (0.39 - 0.49 bar, 0.57 - 0.71 psi)
Size 80 mesh, 5,400 cm2 (ø200 x 190)
Suction Filter (17, Figure 1) Resisting Pressure 1.5 kg/cm2 above
Flow Rate 850 L/min (224.6 U.S. gpm)
Actuation Pressure 1.5 kg/cm2 (1.5 bar, 21.8 psi)
Pressure Switch (26, Figure 1)
Rating 4 A Resistance at 24 V DC Max.

5-3-5
Parts List
24 20
20-2
FR
20-1 ON
28 T
28
28
5 12
5
13
6
15
7
27 14
25
9
17
19
26
3 23
23 2
18 21
2
22
16
11
10
EX1400096
Figure 1

5-3-6
Reference Reference
Number Number
1 Hydraulic Oil Tank 16 Hydraulic Pipe
2 Bolt 17 Suction Filter
3 Shim 18 O-ring
4 Shim 19 Level Gauge
5 Cover 20 Air Breather
6 O-ring 20-1 Gasket
7 Spring 20-2 Air Breather Element
8 By-pass Valve 21 O-ring
9 Filter Element 22 Plug
10 Bolt 23 Spacer
11 Spring Washer 24 Socket Bolt
12 Tank Cover 25 Nut
13 O-ring 26 Pressure Switch
14 Rod 27 By-pass Strainer
15 Compress Spring 28 Set Bolt

5-3-7
Air Breather
1. Structure of air breather
0.45 k 0.05 k 2
5
EX1301764
Figure 2
Reference Reference
Number Number
1 Housing 4 Flange
2 Element 5 Gasket
3 Body
2. Pressure release
Pulling the breather cap upward, the check valve 0.46 kg/cm2
(0.45 bar) opens, and the air is discharged to the atmosphere
from the top of the hydraulic oil tank.

5-3-8
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.

2. Front position: Extend the arm and dump the bucket until
both cylinders are fully retracted. Lower the boom until the
bucket rests on the ground. (Figure 3)
3. Stop engine.
EX1301745
Figure 3

5-3-9
4. Move safety lever to "RELEASED" (UNLOCK) position. O I
(Figure 4)
LOCK
WARNING
WARNING
DO NOT OPERATE
AVOID DEATH OR SERIOUS INJURY when performing inspection
or maintenance
If engine must be running while performing 190-00695A
ON OFF
maintenance, always use extreme caution. Always EX1401036
have one person in the cabin at all times. Never leave Figure 4
the cabin with engine running.
6. Fully stroke work levers (joysticks) in all directions to

7. Move safety lever to "LOCK" position. (Figure 4)
switch.
(Figure 5)
Figure 5
WARNING
Release any pressure in the hydraulic oil tank before
doing any work.
11. Loosen the oil tank air breather slowly to release the
pressure inside the hydraulic oil tank.
Pulling the breather cap upward, the check valve (0.45 bar)
Figure 6 EX1400156
opens, and the air is discharged to the atmosphere from
the top of the hydraulic oil tank.

5-3-10
12. Oil drain method.
NOTE: Check the level on the oil level gauge before
draining the oil.
EX1301746
Figure 7
A. Remove cover on oil tank (bolt: 6 ea), drain hydraulic

oil using oil pump. (Figure 8)
Also pump oil from the suction pipe.
• Tool: 14 mm ( )
• Torque: 63.7 N.m (6.5 kg.m, 47 ft lb)
Figure 8 EX1400160
B. Drain hydraulic fluid using drain plug. (without oil

pump) (Figure 9)
• Tool: 27 mm ( )
• Torque: 93.1 N.m (9.5 kg.m, 68.7 ft lb)
• Hydraulic oil tank volume
– Approximately: 381 L (101 U.S. gal)
– Effective level: 243 L (64 U.S. gal)
Figure 9 Oil Tank Bottom View EX1400161
13. Remove bolts and washers (1, Figure 10) (8 ea) with the
guardrail (2) (1 ea).
1
Remove bolts and washers (3, Figure 10) (4 ea) with cover 2
of control valve (4). 4
• Tool: 19 mm ( )
• Torque: 108 N.m (11 kg.m, 80 ft lb)
• Control valve cover weight: 20 kg (44 lb)
3
• Guardrail weight: 12 kg (26.5 lb)
Figure 10 EX1400162

5-3-11
14. Install eyebolts (2 ea) on the oil tank.
And tie the rope to the bolts to lift oil tank.
• Thread of hole: M10 x 1.5
Figure 11 EX1400163
15. Remove bolts and washers (1, Figure 12) (6 ea) under
cover (2) on bottom of main frame. Bottom of
1 2 Main Frame
• Tool: 19 mm ( )
• Torque: 107.8 N.m (11 kg.m, 79.5 ft lb)
• Under cover weight: 7.5 kg (16.5 lb)
EX1301751
Figure 12
16. Remove oil tank mounting bolts and spacers (1, Figure 13)
(6 ea) from the main frame.
• Tool: 24 mm ( )
2 1
17. Remove bolts (2, Figure 13) (6 ea) of suction pipe from the 1
oil tank.
• Tool: 17 mm ( )
18. Disconnect oil pressure switch harness. (10, Figure 14) Figure 13 Bottom of Main Frame EX1400164

5-3-12
19. Remove hoses (14 ea) and 2 pipes (8 and 9, Figure 14)
from the oil tank.
NOTE: Attach identification tag onto the removed
hoses for reassembly. Disconnect the hoses
from the bottom to top of oil tank. After
disconnecting hoses, plug them to prevent dirt
or dust from entering.
8
1 7
9
2
10
3
16 17
4 11
5
6 12
13 14
15
18 19
Figure 14 EX1400165
• Hoses and plugs ports
Plug/Flange Size Torque

Port Name
(Hose) (mm) (mm) (mm) N.m kg.m ft lb
1 from Control Valve L3 11/16"-16UN-2B 22 38.2 3.9 28.2
2 19 39.2 4 28.9
3 from Swing Device DB 13/16"-16UN-2B 24 55.9 5.7 41.2
4 from Center Joint G 1 3/16"-12UN-2B 36 124.5 12.7 91.9
5 22 49 5 36.2
6 22 49 5 36.2
7 41 205.9 21 151.9
SAE 1 1/4",
8 Oil Return Line 10 107.8 11 79.6
3,000 psi
SAE 1 1/4",
9 Oil Return Line 10 107.8 11 79.6
3,000 psi
10 Pressure Switch 41 205.9 21 151.9
from Control Valve Y 9/16"-18UNF-2B 19 25.5 2.6 18.8
11
from Fan Pump L1 11/16"-16UN-2B 22 38.2 3.9 28.2
12 from Fan Motor D 9/16"-16UN-2B 19 25.5 2.6 18.8
13 from PT Block T 13/16"-16UN-2B 24 55.9 5.7 41.2
14 from PT Block T 13/16"-16UN-2B 24 55.9 5.7 41.2
from Control Valve L2 11/16"-16UN-2B 22 38.2 3.9 28.2
15
from Solenoid Valve T 11/16"-16UN-2B 22 38.2 3.9 28.2
16 from Main Pump T1 1 3/16"-12UN-2B 36 124.5 12.7 91.9
17 from Main Pump T1 1 3/16"-12UN-2B 36 124.5 12.7 91.9
18 from Main Pump T2 9/16"-16UN-2B 19
19 from Main Pump R4 13/16"-16UN-2B 24

5-3-13
20. Using a crane, lift the hydraulic oil tank slowly.
• Oil tank weight: about 303 kg (668 lb)
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.
NOTE: First, assemble the bolts and spacers (6 ea) of oil

tank mounting to main frame. (Figure 15)
1. Install the oil tank with bolts and spacers (1, Figure 15)
(6 ea) to the main frame. 2 1
• Tool: 24 mm ( ) 1
2. Install the bolts (2, Figure 15) (6 ea) through suction pipe to
the oil tank.
Figure 15 Bottom of Main Frame EX1400164
• Tool: 17 mm ( )
3. Perform installation in the reverse order to remove.
4. If removed the level gauge, install level gauge as the
following torque.
5. When assembling rod to suction filter, adjust the
assembling length as Figure 16.
3
Reference
Description
606.5
Number
1 Suction Filter
2 Nut 2
3 Rod
1
• Torque (2 nut): 49 N.m (5 kg.m, 36.2 ft lb)
EX1400168
Figure 16

5-3-14
6. Location of air breather (1) must be as Figure 17 when
assembling cover (2). 2
EX1400166
Figure 17
COMPLETING WORK
1. Hydraulic oil tank volume:
• Approximately: 381 L (101 U.S. gal)
• Effective level: 243 L (64 U.S. gal)
2. Adjusting standard for hydraulic oil level
A. Front position: Extend the arm and dump the bucket
until both cylinders are fully retracted. Lower the
boom until the bucket rests on the ground.
B. Engine condition: Low idle
EX1301745
C. Fill hydraulic oil until fluid in level gauge is positioned
Figure 18
between low and high marks.
D. If hydraulic oil level is too high, drain excess hydraulic
oil from tank by removing drain plug located on
bottom of tank.

5-3-15
5-3-16
Fuel Tank
Edition 1
DX340LC-5/DX350LC-5 Fuel Tank

5-4-1
MEMO
Fuel Tank DX340LC-5/DX350LC-5

5-4-2
Table of Contents
Fuel Tank
General ...........................................................5-4-5
Specification .............................................................. 5-4-5
Parts List ................................................................... 5-4-6
Removal .........................................................5-4-8
Installation ....................................................5-4-12
Completing Work ..........................................5-4-13

5-4-3
5-4-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
WARNING
Diesel fuel is highly flammable and can be potentially
explosive. To prevent fires or explosion, keep arcs, sparks or
other ignition sources away from diesel fuel or fuel
containers.
Specification
Volume (Full) 600 L (158.5 U.S. gal)
Tank Size (mm) 995 x 970 x 900
Tank Weight about 323 kg (Empty)
Fuel Strainer Filter Filtration Ratio 24 mesh
(6, Figure 1) Working Oil Temp. -40 - +80°C
0.25 - 0.05 kg/cm2
Positive Pressure
Fuel Cap (0.25 -0.05 bar, 3.63 - 0.73 psi)
Check Valve
(10, Figure 1) below 0.035 kg/cm2
Negative Pressure
(0.035 bar, 0.51 psi)
Working Voltage V max. 48 V
Fuel Sensor
Working Current I max. 300 mA
(13, Figure 1)
Rating Power 125 mW

5-4-5
Parts List
15
11
T 14
N 11-1
F RO
2
10
53
54
55
51
13 52
9
MAIN FRAME 8
12
12
57 7
7
3
EX1400097
Figure 1

5-4-6
Reference Reference
Number Number
1 Fuel Tank 12 Spacer
2 Fuel Sensor 13 Level Gauge
3 O-ring 14 Fuel Sensor Cover
4 Tank Cover 15 Set Bolt
5 Bolt 51 O-ring
6 Spring Washer 52 Plug
7 Bolt 53 Cover
8 Shim 54 Spring Washer
9 Shim 55 Screw
10 Fuel Strainer Filter 56 Bolt
11 Fuel Cap 57 Clip
11-1 Element (Fuel Cap)

5-4-7
REMOVAL
WARNING
Fire hazard!
Fuel is easily flammable.
workplace.
1. Look at fuel level display (Figure 2) on instrument panel in

operator's cabin to see what it displays. The display is
divided into seven separated segments. Also, look at level
gauge on side of tank to estimate volume of fuel left in
tank.
NOTE: If possible, work excavator until available fuel
supply in tank has been run down as far as
possible. E F
E UREA
F
EX1300964
Figure 2
2. Park on firm and level ground and swing turntable to

approximately a 90° with respect to tracks. See Figure 3.
EX1300973
Figure 3
3. Lower front attachment (bucket) to ground. O I

4. Stop engine.
5. Move safety lever to "RELEASED" (UNLOCK) position.
6. Turn starter switch to "I" (ON) position. LOCK
WARNING
WARNING DO NOT OPERATE

or maintenance
190-00695A
AVOID DEATH OR SERIOUS INJURY ON OFF

EX1401036
If engine must be running while performing Figure 4
maintenance, use extreme care. Always have one
person in the cabin at all times. Never leave the cabin
with the engine running.

5-4-8
switch.
Figure 5
12. Clean area around fuel tank fill cap. Open fuel cap.
Figure 6 EX1400171
13. Open drain valve (Figure 7) right side door and carefully
drain.
• Fuel tank capacity: 600 L (158.5 U.S. gal)
Figure 7 EX1400172
1
guardrail (2) (1 ea).
2 4
15. Remove bolts (3, Figure 8) (8 ea) and cover (4) from fuel
tank.
• Tool: 19 mm ( ) 3
• Tank cover weight: 8 kg (17.6 lb)
• Guardrail weight: 12 kg (26.5 lb)
Figure 8 EX1400173

5-4-9
handrail (2) from fuel tank and frame. 3 2
17. Remove bolts (3, Figure 9) (4 ea) with the tank front cover 1
(4) from fuel tank.
4
• Tool: 17 mm ( )
1
• Weight
Reference
Description kg (lb)
Number EX1400174
Figure 9
2 Handrail 21 (46.3)
4 Tank Front Cover 5 (11)
18. Disconnect the connector of fuel sensor (1, Figure 10).

1
19. Remove bolts (2, Figure 10) (6 ea) and clips with harness
(3), and DEF breather filter. (4)
• Tool: 13 mm ( ) 2
• Torque: 29.4 N.m (3 kg.m, 21.7 ft lb) 3 4
Figure 10 EX1400175
20. Remove hose from fuel tank.

NOTE: Cap the open ends of hose with plug.
1
2
Figure 11 EX1400176

Port Name
(Hose) (mm) (mm) N.m kg.m ft lb
1 Return Line 13/16"-16UN 24 55.9 5.7 41.2
2 41 205.9 21 151.9

5-4-10
21. Install eyebolts (2 ea) on the fuel tank.
And tie the rope to the bolts to lift tank.
• Thread of hole: M12 x 1.75
• Fuel tank weight: 323 kg (712 lb)
Figure 12 EX1400177
22. Remove bolts and washers (1, Figure 13) (6 ea) with under
cover (2) on bottom of main frame.
• Tool: 19 mm ( )
1
• Under cover weight: 9.2 kg (20.3 lb)
2
Figure 13 EX1400178
23. Remove hose from fuel tank

NOTE: Cap the open ends of hose with plug.
2
1
EX1400179
Figure 14

Port Name
(Hose) (mm) N.m kg.m ft lb
1 to Drain Valve 11/16"-16UN 22 38.2 3.9 28.2
2 Supply Line 13/16"-16UN 24 55.9 5.7 41.2
24. Remove fuel tank mounting bolts and spacers (3, Figure
14) (6 ea) from the main frame.
• Tool: 24 mm ( )

5-4-11
25. Lift tank 25 mm and make sure it is balanced.
26. Make sure there are no other electrical wires or hoses
connected to tank.
27. Completely remove tank after inspection
• Fuel tank weight: 323 kg (712 lb)
NOTE: The clear level gauge on the side of the tank is
easily damaged. Be careful of obstacles and
wind gusts.
INSTALLATION
NOTE: First, assemble the bolts and spacers (6 ea) of fuel
tank mounting to main frame. (Figure 15)
1. Install the fuel tank with bolts and spacers (3, Figure 15)
(6 ea) to the main frame. 2
1
• Tool: 24 mm ( )
NOTE: The clear level gauge on the side of the tank is 3
easily damaged. Be careful of obstacles and
wind gusts.
Figure 15 EX1400179
2. Connect fuel supply line (2, Figure 15) and drain valve line
(1) to fuel tank.
4. Make sure fuel tank drain valve (Figure 16) right side door
is closed.
5. Fill fuel tank and check for signs of leaks. Correct any
problems found.
• Fuel tank capacity: 600 L (158.5 U.S. gal)
Figure 16 EX1400172

5-4-12
COMPLETING WORK
If engine does not start, the fuel system may need priming.
Prime the fuel system using the following procedure:
1. Turn key to "OFF" position.
2. Open right side door and locate fuel filter.
Figure 17 EX1400180
3. Attach a clear plastic hose to the bleed nipple (1, Figure 1

18) on the fuel filter housing. Place the end of the plastic
hose in a container that hose at least 3 L (0.8 U.S. gal.).
4. Loosen the hand pump handle (2, Figure 18).
5. Open the bleed nipple (1, Figure 18).
2
6. Pump (2, Figure 18) by hand until fuel comes out of the
hose. This may take around 100 pump strokes. Depending
on the installation, a significantly greater number of pump
strokes may be required before fuel comes out.
7. Close the bleed nipple (1, Figure 18). EX1302345
8. Start the engine and open the bleed nipple (1, Figure 18) Figure 18
carefully.
9. Check that fuel without air bubbles comes out of the hose.
Normally, about 3 liters of fuel must be drained before no
more air bubbles come through the hose.
10. Close the bleed nipple (1, Figure 18), remove hose and
tighten the hand pump handle (2).

5-4-13
5-4-14
1Main Pump
Edition 1
DX340LC-5/DX350LC-5 Main Pump

5-5-1
MEMO
Main Pump DX340LC-5/DX350LC-5

5-5-2
Table of Contents
Main Pump
General ...........................................................5-5-7
Specifications ............................................................ 5-5-7
ED Control (Electric Pressure Control with
Proportional Solenoid).......................................... 5-5-7
Pilot Pressure Pump Relief Valve ........................ 5-5-7
Angle Sensor........................................................ 5-5-7
Performance Curves ............................................ 5-5-8
Overview ................................................................. 5-5-10
Port..................................................................... 5-5-10
Hydraulic Circuit ...................................................... 5-5-11
Parts List ................................................................. 5-5-12
Rotary Group...................................................... 5-5-12
Control Part ........................................................ 5-5-14
Theory of Operation ................................................ 5-5-16
Increasing and Decreasing Flow Rate ............... 5-5-17
Pressure Control ................................................ 5-5-18
Pump Setting...................................................... 5-5-20
Pump Adjustment ............................................... 5-5-20
EPPR Valve (Electronic Proportional Pressure
Reduce).............................................................. 5-5-22
Emergency Operate ........................................... 5-5-23
Manual Override...................................................... 5-5-24
Angle Sensor........................................................... 5-5-26
Installation of Angle Sensor................................ 5-5-26
PPRV (Peak Pressure Reducing Valve).......5-5-27
PPRV’s Function ................................................ 5-5-27
Hydraulic Circuit ................................................. 5-5-28
Overview ............................................................ 5-5-28
Location.............................................................. 5-5-29
Section View....................................................... 5-5-30
Theory of Operation ........................................... 5-5-30
PPRV Adjustment............................................... 5-5-31

5-5-3
PPRV dP Measurement ..................................... 5-5-31
P PPRV and P Pump Correlation....................... 5-5-33
Installation ............................................................... 5-5-34
Hydraulic Oil ............................................................ 5-5-34
Guide for External Oil Leakage ............................... 5-5-34
Repair ...........................................................5-5-35
Necessary Tools and Jigs ....................................... 5-5-35
Tools................................................................... 5-5-35
Jigs ..................................................................... 5-5-35
Cautions During Disassembling and Assembling.... 5-5-36
Cautions for Disassembling................................ 5-5-36
Cautions for Assembling .................................... 5-5-36
Disassembling Procedure ....................................... 5-5-37
Exchange of O-ring (Surface of Pump Installation) . 5-5-37
Exchange of O-ring (Surface of Pilot Valve Assembly
Installation) ......................................................... 5-5-38
Exchange of O-ring and Backup Ring (Part of Main
Valve Assembly)................................................. 5-5-39
Disassembling Procedure of Pilot Valve Assembly
(Excluding Adjusting Screw Part) ....................... 5-5-40
Assembling Procedure ............................................ 5-5-40
Precaution ....................................................5-5-41
Tightening Torques ................................................. 5-5-41
Slotted Screws ........................................................ 5-5-41
Threaded Plugs ....................................................... 5-5-42
Sealing Nuts ............................................................ 5-5-43
Maintenance and Repair ..............................5-5-44
Cleaning and Care .................................................. 5-5-44
Inspection ................................................................ 5-5-45
Maintenance............................................................ 5-5-45
Repair...................................................................... 5-5-46
Spare Parts ............................................................. 5-5-46
Decommissioning .........................................5-5-47
Removal and Replacement ..........................5-5-47
Required Tools ........................................................ 5-5-47

5-5-4
Preparing for Removal ............................................ 5-5-47
Removing the Axial Piston Unit ............................... 5-5-48
Preparing the Components for Storage or Further Use.. 5-5-48
Troubleshooting ............................................5-5-49
How to Proceed for Troubleshooting....................... 5-5-49
Malfunction Table .................................................... 5-5-50
Section View............................................................ 5-5-52
Removal .......................................................5-5-53
Installation ....................................................5-5-62
Completing Work ..........................................5-5-62
Replacing Seals and Assembly Groups .......5-5-63
Replacing the Shaft Seal......................................... 5-5-64
Sealing or Replacing the Gear Pump...................... 5-5-67
Sealing the Cover of the Power Take-off ................ 5-5-69
Sealing the Port Plate with Valve ............................ 5-5-71
Sealing or Replacing the Pressure Reducing Valve ... 5-5-73
Replacing the Angle Position Sensor ...................... 5-5-75
Replacing Sealing Nuts ........................................... 5-5-77
D-Eco Power System ...................................5-5-78
Introduction of D-Eco Power System ...................... 5-5-78
Summary - Main Concept................................... 5-5-78
Total Diagram of D-Eco Power System.............. 5-5-79
Block Diagram of D-Eco Power Controller ......... 5-5-80
Flow Control ....................................................... 5-5-81
Power Shift Control ............................................ 5-5-83
Power Distribution Control.................................. 5-5-84
Other Controls .................................................... 5-5-86
Initialization of D-Eco Power System ...................... 5-5-88
Introduction......................................................... 5-5-88
Input Setting - Pilot Pressure Sensor ................. 5-5-89
Input Setting - Angle Sensor .............................. 5-5-93
Output Setting - Solenoid Valve ......................... 5-5-97
Output Setting - Pump EPPR Valve ................. 5-5-101
Etc. - Peak Pressure Reducing Valve .............. 5-5-110

5-5-5
D-Eco Power Diagnostic Tools Operation.....5-5-114
Program Start ........................................................ 5-5-114
D-Eco Power Diagnostic Tools Main Screen ........ 5-5-115
Contents and Function .......................................... 5-5-115
D-Eco Power Diagnostic Check List...................... 5-5-116
Joystick Check ................................................. 5-5-116
Angle Check ..................................................... 5-5-116
EPPR Valve Check .......................................... 5-5-116
Main Pressure Check ....................................... 5-5-116
D-Eco Power Diagnostic Tools Check........5-5-117
Joystick Check ...................................................... 5-5-117
Joystick Check Screen Description .................. 5-5-117
Settings Before the Joystick Check Test.......... 5-5-118
The Progress of the Joystick Check Test......... 5-5-119
Angle Check .......................................................... 5-5-130
Swash Plate Angle Check Screen Description. 5-5-130
Settings Before the Angle Check Test ............. 5-5-131
The Progress of the Angle Check Test ............ 5-5-132
EPPR V/V Check................................................... 5-5-134
EPPR V/V Check Screen Description .............. 5-5-134
Settings Before the EPPR V/V Check Test ...... 5-5-135
The Progress of the EPPR V/V Check Test ..... 5-5-136
Main Pump Check ................................................. 5-5-140
Main Pump Pressure Check Screen Description.. 5-5-140
Settings Before the Main Pump Pressure
Check Test ....................................................... 5-5-141
The Progress of the Main Pump Pressure Check. 5-5-142
Relief Pressure Check........................................... 5-5-146
Relief Pressure Check Screen Description ...... 5-5-146
Settings Before the Main Pump Pressure
Check Test ....................................................... 5-5-147
The Progress of the Main Pump Pressure
Check Test ....................................................... 5-5-148

5-5-6
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specifications
Engine Power (P) 322 PS (237 kW) @ 1,800 rpm
Rated Speed (N) 1,800 rpm
357 kg/cm2 (350 bar)
Rated Pressure
(Actual Relief Pressure, Controlled by EPPR Valve)
Max. Flow (Q max.) 2 x 350 L/min @ 1,800 rpm and 100 bar
Min. Flow (Q min.) 0 L/min @ 1,800 rpm
ED Control (Electric Pressure Control with Proportional Solenoid)
Control Pressure MHDRE (Ps) 28 ±3 bar @ 750 mA

Supply Voltage (V) 24 V
353.5 ±3.5 kg/cm @ 750 mA, 1,800 rpm, 17.5 L/min
2
Setting Priority No.1 (P)
(350 x 0.05: 5% Total System Leakage)
Test Priority No.2 (P) 275 ±5 bar @ 650 mA, 1,800 rpm
Test Priority No.3 (P) 46.5 ±7.5 bar @ 300 mA, 1,800 rpm
Pilot Pressure Pump Relief Valve
Pilot Pressure (P) 39 ±2 bar @ 1,800 rpm
Angle Sensor
Setting (U) 4.5 V @ 350 L/min (Vgmax.) and 1,800 rpm

5-5-7
Performance Curves
1. P - Q Curve
400
150 K
380 351 L 140 K
360 325 L
340 134 K
320 305 L
300
280
131 K
260 286 L Po
240 we
r
220 Po
Q Flow (L/min)
we 350 K
200 r 114 L 350 K
180 Sta
nd 133 L
ard
160
Ec
140 ono
mic
120
100
80 350 K
60 101 L 350 K
40 93 L
20
0
0 50 100 150 200 250 300 350
P Discharge Pressure (kg/cm 2 )
EX1400239
Figure 1
Input
rpm PS
Power+ Mode 1,800 258.2
Power Mode 1,700 223.8
Standard Mode 1,600 200.7
Economy Mode 1,500 183.3

5-5-8
2. P - I Curve
400
A3
T3
350
R3
R1
300 A2
M M2
Pump Pressure (bar)
250
Y3
Vgmax Vgmin M7
200 M6
EPPRV
Input Current
150
Vgmax Vgmin EPPRV
M5
100
50 M M1
A1
0 R2 R4 S
0 200 400 600 800 1000 1200
Controlled Current (mA)

EX1400240
Figure 2

5-5-9
Overview
The pump is a pressure-controlled type, structured in axle piston
variable dual pump system, provided with two slope piston
rotary groups designed with joint shafts for hydraulic drive. the
pump system further comprises: an EPPR valve that controls
the pump pressure; a regulator that controls the swivel angle of
the pump using the EPPR valve; an angle sensor that converts
the discharge flow rate of the pump into electrical signals to
provide inputs in addition to a pilot sensor; PTO for the gear
pump and option pump for pilot pressure; and a pump cover
coupled with the engine to attach the pump.
Port
Y3 T3 A3 R3 M2 R6 M6 M7
M5
R5
M1
R1
A1
R4
S
R2 A2 M
Figure 3 EX1400241
Port Description Size

A1, A2 Piston Pump Delivery Port 1 1/4 In
A3 Gear Pump Delivery Port (39 bar (40 kg/cm2)) M14 x 1.5
S Piston Pump Suction Port 5 In
T3 Gear Pump Drain Port M18 x 1.5
R1, R3 Air Bleed Port M22 x 1.5
R2 Drain Port Line M22 x 1.5
R4 Flushing Port 3/4-16UNF-2B
R5, R6 Air Bleed Port M10 x 1
M Measurement Port Servo Piston M12 x 1.5
M1 Measurement Port A1 M14 x 1.5
M2 Measurement Port A2 M14 x 1.5
M5, M6 Measurement Port PPRV M14 x 1.5
M7 Measurement Port Gear Pump (39 bar (40 kg/cm2)) M14 x 1.5
Y3 Gear Pump Pressure Port (39 bar (40 kg/cm2)) M14 x 1.5

5-5-10
Hydraulic Circuit
A3
T3
R3
R1
A2
P1
M
M2 R6
Vgmax Vgmin
M6
EPPRV
Y3
M7
EPPRV
Vgmax Vgmin
M5
M1 R5
M
P2
A1
R2 R4 S
EX1400242
Figure 4

5-5-11
Parts List
Rotary Group
8 25
27
7
25
3
24
5
4
24
23
4A
22
21
20
2Ac
2Ad 2Ac2
2Ae 2Ac1
2B 2Af 2Ab
2
2D
2Aa
2G
2Ag
2C
2H 2A
2E
2F
3Ac
3Ac2
3Ad
3 3Ae 3Ac1
3Af 3Ab
3B
3D
3G 3Aa
3C 3Ag
3H
3E 3A
3F
Figure 5 EX1400379

5-5-12
Reference Reference
Number Number
2 Rotary Group 3Ac2 Steel Sealing Ring
2A Rotary Group Section 3Ad Collar spring
2Aa Cylinder 3Ae Cup Spring
2Ab Center Pin 3Af Retaining Plate
2Ac Piston and Piston Rings 3Ag Pan Head Screw
2Ac1 Piston 3B Driveshaft
2Ac2 Steel Sealing Ring 3C Shim
2Ad Collar Spring 3D Left-hand Control Lens
2Ae Cup Spring 3E Backup Plate
2Af Retaining Plate 3F Retaining Ring
2Ag Pan Head Screw 3G Tapered-roller Bearing
2B Driveshaft 3H Tapered-roller Bearing
2C Shim 4 Gear Pump
2D Right-hand Control Lens 4A Socket Bolt
2E Backup Plate 5 Pump
2F Retaining Ring 7 Gear
2G Tapered-roller Bearing 8 Stub Shaft
2H Tapered-roller Bearing 20 Retaining Ring
3 Rotary Group 21 Oil Seal
3A Rotary Group Section 22 Shim
3Aa Cylinder 23 Locking Screw
3Ab Center Pin 24 Locking Screw
3Ac Piston and Piston Rings 25 Plain Roller Bearing
3Ac1 Piston 27 Key Shaft

5-5-13
Control Part
The exploded view of the pump shows the parts necessary for
internal repair and assembling and the parts available when
required.
2-48
2-50
2-41 2-19
2-47
2-30
2-3
2-20
2 2-30
2-25
2-1
2-46
2-24
2-32
2-22
2-43
2-42 2-27
11
10
43
44
42
K 13
1C 1E
1B 12
1A 17
1G 16
37
1F 1D
26
K EX1400243
Figure 6

5-5-14
Reference Reference
Number Number
1 Cover 2-41 Socket Bolt
1A Cover 2-42 Socket Bolt
1B O-ring 2-43 Socket Bolt
1C O-ring 2-46 Angle Sensor
1D Socket Head Screw 2-47 Filter
1E Screw 2-48 Reducing Valve
1F Threaded Pin 2-50 Orifice
1G Locknut 10 Control Housing
2 Control Module 11 Gasket
2-1 Control Housing 12 Positioning Piston
2-3 Control Piston 13 Positioning Trunnion
2-19 Pressure Spring 16 Piston
2-20 Pressure Spring 17 Threaded Pin
2-22 Pressure Spring 26 Screw
2-24 Ball Bearing 37 Square Ring
2-25 O-ring 42 Socket Screw
2-27 O-ring 43 Socket Bolt
2-30 O-ring 44 Cylinder Pin
2-32 O-ring

5-5-15
Theory of Operation
The axial piston variable double pump with two axial tapered
piston rotary groups with bent-axis design for open-circuit
hydrostatic drives. The axial piston variable double pump has a
common suction port (S) for both circuits and the auxiliary pump.
It generates two flows for supplying two separate circuits. Flow
is proportional to drive speed and displacement. By adjusting
the bent-axis rotary groups, the two flows can be steplessly
changed independent of one another. For axial piston units with
bent-axis design, the pistons (4) are arranged at an angle to the
driveshaft (1). When the driveshaft is turned, the cylinder (5) is
picked-up and set into motion cardan free by the pistons, which
are arranged in a ring on and flexibly connected to the driveshaft
flange. The cylinder then rotates over the spherical control lens
(8), in which two kidney-shaped control slots have been
incorporated. As they turn, each of the pistons moves from top
to bottom dead center and back, executing a stroke that
depends on the swivel angle. The driveshaft flange of both
rotary groups, which lie parallel next to one another, are
interlocked. The rotary group with the long driveshaft drives the
second rotary group by the interlocked driveshaft flange. On the
low-pressure side, fluid flows into the enlarging piston chamber.
At the same time, on the pressure side the fluid is pushed out of
the cylinder chamber into the hydraulic system by the pistons.
The pistons are braced against the driveshaft flange by the load
of the hydraulic pressure.
2 3 4 5 6 7
A3
A1
S
1
10
9
A2
8 2
Figure 7 EX1400244
Reference Reference
Number Number
1 Driveshaft 8 Control Lens
2 Gear Pump (Pilot) 9 Positioning Piston
3 Relief Valve 10 Positioning Trunnion
4 Piston S Suction Port
5 Cylinder A1, A2 High-pressure Delivery Port
6 Angle Sensor A3 Pilot Port
7 EPPR Valve

5-5-16
Engine torque is transferred to the shaft and the seven plungers,
causing the cylinder block to rotate while sliding along the valve
plate surface.
The plunger oscillates in the cylinder block bores and alternately
hydraulic oil is drawn and delivered.
Piston
Control Lens
Driveshaft
Cylinder
EX1400245
Figure 8
Increasing and Decreasing Flow Rate

Changing inclination of cylinder (5, Figure 7) causes the piston (4,
Figure 7) stroke to increase or decrease depending on the slant
angle to control the main pump flow rate. Up-down movement of
positioning piston (9, Figure 7) changes inclination of cylinder (5,
Figure 7). Positioning piston (9, Figure 7) is interlocked with
control lens (8, Figure 7) and positioning trunnion (10, Figure 7).
The one end of cylinder (5, Figure 7) is kept in contact with the
surface of control lens (8, Figure 7) and slides along it.
Maximum Displacement Angle: Minimum Displacement Angle (Operable Limit Angle):
Piston Swash Plate Cylinder Block Piston Swash Plate
Cylinder Block EX1400646

Figure 9

5-5-17
Pressure Control
Decrease of Pump Pressure

1. Decrease input pressure signal to EPPRV
2. ED regulator spool moves upward and connects the pump
pressure to head side of control piston.
3. Control piston moves right and decrease swash plate.
4. Decreasing flow rate decreases pump pressure.
A3
T3
R3
R1
A2 P Pump
P1
M
M2 R6
Vgmax Vgmin
M6
EPPRV
P EPPR
Y3
M7
EX1400246
Figure 10
P EPPR P EPPR
P Pump P Pump
EX1400247
Figure 11

5-5-18
Increase of Pump Pressure
1. Increase input pressure signal to EPPRV.
2. Regulator spool moves downward and connects head side
of control piston to drain.
3. Control piston moves left and increases swash plate.
4. Increasing flow rate increases pump pressure.
A3
T3
R3
R1
A2 P Pump
P1
M
M2 R6
Vgmax Vgmin
M6
EPPRV
P EPPR
Y3
M7
EX1400248
Figure 12
P EPPR P EPPR
P Pump
P Pump
EX1400261
Figure 13
• Control spool area ratio = 1: 12.25

5-5-19
Pump Setting
Max.Flowrate at Each Operations L/min @ 1,800 rpm

Idle Drive Total
Boom Up 360 210 570
Boom Down 85 85
Arm Crowd 259 360 619
Arm Dump 100 360 460
Bucket Crowd 360 360
Bucket Dump 360 360
Swing 350 350
Travel 325 325 325
Power Configuration
Working Mode rpm Torque Ratio (%) Power Ratio (%)
Power+ 1,800 100
Power 1,700 92
Standard 1,600 84.4
Economy 1,500 79.7
Pump Adjustment
Pressure Control
Flow Adjust Screw
Figure 14 EX1400262
As describe in the picture, fastening the bolts will lead to the

increase of initial spring force and increase of pump pressure
with respect to input current signal.

5-5-20
Pump pressure initial tuning
1. Turn on the engine, set the excavator at power mode, high
idle (750 mA)
2. Tighten the screw (1, Figure 15) at the top until pump
pressure reaches 353.5 kg/cm2 (347 bar).
1
Pump Pressure (kg/cm 2 )
353.5
45
300 750
Control Current (mA)
Figure 15 EX1400263
• Secondary pressure of EPPR valve - 3.94 kg/cm2 (3.86 bar)

and pump pressure - 45 kg/cm2 (44 bar) at current 300 mA.
• Secondary pressure of EPPR valve - 28.4 kg/cm2
(27.9 bar) and pump pressure - 353.5 kg/cm2 (347 bar) at
current 750 mA.

5-5-21
EPPR Valve (Electronic Proportional Pressure Reduce)
Symbol
A3
T3 P T
R3
R1
A2
P1
M
M2 R6
A
EPPRV
M6
EPPRV
Y3
M7
EPPRV
M1 R5
M
P2
A1
R2 R4 S
EX1400264
Figure 16
Pressure - Current Curve
400 40
Pump Pressure (kg/cm 2 )
Pilot Pressure (kg/cm 2 )

300 30
200 20
100 10
0 0
100 200 300 400 500 600 700 800 900
Current (mA)
Figure 17 EX1400265
I (mA) 300 350 400 500 600 650 700 750 785
P (bar) 47 75 104 169 238 275 309 347 362
Pi (bar) 3.86 6.53 9.19 14.52 19.85 22.51 25.18 27.8 29.7
Allowance ± (bar) 8 7.4 7 6 5 4.5 4 3.4 3.19

5-5-22
Emergency Operate
• High load (using 1 pump): 294 bar (650 mA)
• Low load: 196 bar (470 mA)

5-5-23
Manual Override
When power supply to the machine is interrupted, maximum
operating pressure can be established using a manual override
so the machine can be driven under its own power and relocated
to another work area.
IMPORTANT
Before actuating the manual override device of the system the
safety lever near the operator's seat must be activated.
Activate Manual Override

To activate the manual override:
1. Unplug the electrical connectors from both pressure
reducing valves (1, Figure 18).
2. Using a pointed tool, press both PINs (2, Figure 18) in up
to the stop. Both PINs must remain in the depressed
position.
2
1
FG020722
Figure 18
3. Remove both protective caps (3, Figure 19) on the covers

with a suitable tool (e.g. gripper).
IMPORTANT
The protective caps will be destroyed by the removal
process. When you require replacement protective
caps, contact your responsible Service partner or the
service department of the manufacturer's plant for the
3
axial piston unit; See “Spare Parts” on page 46. for FG020723
further information. Figure 19
4. On both Vg max-limiting threaded pins measure and record

the extension X to the SEAL LOCK®- nut.
5. Fix both Vg max-limiting threaded pins with hexagonal socket
wrench (wrench size M6). Loosen the SEAL LOCK® nuts
(wrench size M12).
6. Screw the Vg max-limiting threaded pins into the cover with a
hexagonal socket wrench (wrench size M6).
X
FG020724
Figure 20

5-5-24
IMPORTANT
Do not screw the Vg max limiting threaded pins
completely into the cover but rather leave the Vg max-
limiting threaded pins overhanging the SEAL LOCK®
nuts with an extension of X = 8 mm because otherwise
the Vg max limiting threaded pins will be less stable.
7. Tighten the SEAL LOCK® nuts with a torque of 69 N.m

(wrench size M12).
8. Move the safety lever, located next to the operator's seat,
to the "LOCK" position to prevent unintentional machine
movement.
9. Apply the manual override only briefly, e.g. to drive the
machine and relocate it to another area. If the power
supply to components of the main pump is defective,
contact your responsible Service partner or the service
department of the manufacturer's plant for the axial piston
unit; See “Spare Parts” on page 46. for further information.
Deactivate Manual Override

When the PINs are no longer depressed, manual override is
deactivated. To return the Vg max-limiting threaded pins to the
original setting, perform the operations 4-6 above in the reverse
order. Check the organization X to the SEAL LOCK® nuts
against your records.

5-5-25
Angle Sensor
The discharge flow from the pump is measured with an angle
sensor. Its angle is converted into electrical signals, which in
turn are converted to digital signals for use at an electric
controller as the pump discharge rate.
Installation of Angle Sensor

1. Ensure that ball pin is guided in the nut of the spring collar
in spring position.
(Install the angle sensor with the electrical connection to
the top.) 1
EX1400266
Figure 21
2. Center (rotate) the shaft of the swivel angle sensor

between the stoppers like the position on the Figure 22.
2
3. Check the groove/slot position of the sensor shaft in the
controller (must not be horizontal) and set (rotate) and
install the swivel angle sensor to groove/slot position.
4. Turn the angle sensor to adjust the signal of +4.5 V at the
Qmax position of the rotary group and install the screw with 4 3
the correct torque.
EX1400267
Figure 22
Voltage Characteristic
5 250 5000
4.5 4500 Angle Sensor Output (mA)
4 200 4000
Pump Pressure (bar)
3.5
3500
3 150
Voltage U (V)
3000
2.5
2500
2 100
2000
1.5
1 50 1500
0.5 1000
0 0 500
-50 -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 0 50 100 150 200 250 300 350 400
Angle ( ) Pump Flowrate (L/min)
EX1400268
Figure 23

5-5-26
PPRV (PEAK PRESSURE REDUCING VALVE)
PPRV’s Function
• Even though the front attachments stop suddenly, the
pump still needs time to reach minimum angle. Therefore,
the flow rates discharged from the pump during this period
will induce sudden peak of pump pressure.
• Because peak pressure will bring durability problems of
pump and piping system, PPRV (peak pressure reducing
valve) is required.
• PPRV will remove peak pressure by releasing oil to tank at
corresponding working conditions.
P PPRV
346 bar
(353 kg/cm2)
delP
T P Pump
44 bar
(45 kg/cm2)
P 300 mA 750 mA
EX1400269
Figure 24

5-5-27
Hydraulic Circuit
A3
T3 T1
PPR V/V T2
R3 X1 P2
R1 X2 P1
P P*
Drive
M2 M1 PHB X
Pump A2
M M2 R6 PHB
Vgmax Vgmin M6
M
EPPR V/V
Y3
M7
Vgmax Vgmin EPPR V/V T2 T1 P1
M5
Idle
Pump
M M1 R5
A1 M2 M1 PHB
R2 R4 S P P* P2
X2
X1
PPR V/V T2
T1
EX1400270
Figure 25
• X (X1, X2) port: Pump EPPR valve secondary pressure

(Pilot pressure)
• P1, P2 port: Piston pump pressure (High-pressure)
Overview
Port Size Description Remark

P1, P2 SAE 1 1/4 High-pressure Piston Pump Pressure
PHB SAE 1 High-pressure
M PF 1/4-13 High-pressure O-ring Type
T1 PF 3/4-18 Return Line O-ring Type
T2 PF 3/4-13 Return Line O-ring Type
X (X1, X2) PF 1/4-13 Pilot Pressure Secondary Pressure from EPPRV, O-ring Type

5-5-28
Location
Peak Pressure Reducing Valve (Idle)
Peak Reducing Valve (Drive)
EX1400277
Figure 26
Idle Side (PPRV)
T2
T2
PHB
M
PHB P2 X EX1400278
Figure 27
Drive Side (PPRV)
P1 T2
P2
P2 T1
PHB EX1400279
Figure 28

5-5-29
Section View
Pressure Sensor T1
EPPRV Pressure (X)
T2
Control Spool
Main Pump Pressure (P)

Figure 29 EX1400280
Theory of Operation
When the peak pressure of pump is higher than PPRV's
operating pressure, the control spool moves and causes flow
which induces pressure difference across the poppet. This
pressure difference opens the poppet and makes path to the
tank and finally reduces the pump pressure.
3
X
5
PHB
T2 T1 P1
1
EX1400281
Figure 30

5-5-30
PPRV Adjustment
• If you tighten the bolt to increase the initial spring force, dP
will be increased.
• If you are loosen the bolt to decrease the initial spring
force, dP will be decreased.
CCW: Unstable Movement
CW: High Peak Pressure

P PPRV
346 bar T1
(353 kg/cm2)
dP
P
44 bar
(45 kg/cm2)
300 mA 750 mA
P Pump
EX1400282
Figure 31
IMPORTANT
This valve has been set and inspected according to
specification. Readjustment of the adjusting portions
may lead to the loss of functions specified and may be
excluded from the scope of guarantee.
PPRV dP Measurement
1. Input forced current to EPPRV of both pumps to acquire
pump pressure's characteristics according to the input
current.
2. Connect X1 of idle pump to drive pump and connect X1 of
drive pump to idle pump. Input current signal to EPPRV of
idle pump. Gradually increase the current signal of drive
pump's EPPRV and observe the pump's plate angle.
The pressure at the instant when the pump's plate angle
changes is the PPRV's operating pressure.
3. Apply the same method to all 6 input current signals.
4. Apply same method to idle pump's case.
5. If adjusting dP is necessary, apply same methods to check
the performance.

5-5-31
Pump’s Characteristic Exp.
Pump Forced Input Current (mA)

Drive 300 400 500 600 700 750
Idle 300 400 500 600 700 750
Drive Pump’s PPRV dP Exp.
EPPRV Forced Input Current (mA)

↓ ↓ ↓ ↓ ↓ ↓
Drive 300 400 500 600 700 750
Idle 300 400 500 600 700 750
Idle Pump’s PPRV dP Exp.
EPPRV Forced Input Current (mA)

Drive 300 400 500 600 700 750
↓ ↓ ↓ ↓ ↓ ↓
Idle 300 400 500 600 700 750
A3
R3 T1
R1
X1
T2
X2
P P*
M2 M1 PHB
A2
M
Drive
Pump Y3
Vgmax Vgmin M7 X1 (Drive)
Engine M6
Vgmax Vgmin
X1 (Idle)
M5
Idle M1
M1
Pump
A1 M2 M1 PHB
R2 R4 S P P*
X2
T2
X1
T1
EX1400310
Figure 32

5-5-32
P PPRV and P Pump Correlation
Main pumps and PPRV controlled by same EPPR signal has
different pressure characteristic coming from different area ratio
of control piston.
Offset pressure is adjustable by changing initial spring force.
Adjust Screw Adjust Screw
T1
Pump ED Regulator PPRV

EX1400283
Figure 33
• ED regulator control piston area ratio = 1 : 12.75

• PPRV control piston area ratio = 1 : 10.12
abou
• P Pump = 12.75 x Px + C1 373 bar (380 kg
P PPRV = 10.12 x Px + C2
346 bar
P PPRV
Where, (353 kg/cm2)
Px = Pressure from EPPRV

about
C1, C2 = Offset pressure 98 bar (100 kg/cm2)
• What is offset:
44 bar
In proportional operations, the required output and actual (45 kg/cm2) P Pump
output are not always the same but leaves deviation.
This deviation is called offset. 300 mA 750 m
The reason that offset is generated is control deviation is EX14

required to change manipulation quantity. Figure 34

5-5-33
Installation
1. Use the high-pressure type flexible hoses for the ports P2,
PHB, X and T1.
2. When the valve is attached to pump, pay attention to the
following things.
• The surface of P1 port is not damaged.
• The O-ring is installed correctly to the O-ring groove.
3. After installation, pull out the air from the connecting hoses
of X port.
Hydraulic Oil
The hydraulic oil to be a general petroleum hydraulic oil or wear
resistant hydraulic oil.
(ISO 3448, VG32 - 56 or equivalent)
The applicable viscosity range is as follows:
• Maximum allowable viscosity: 1,000 mm2/s
• Minimum allowable viscosity: 10 mm2/s
Guide for External Oil Leakage

The probable cause check methods of external oil leakage and
countermeasures are summarized in the table in below. Refer to
below next page for disassembly and assembly procedure.
Symptom Cause Check Point Countermeasures

Oil leakage Damage to O-rings. Confirm the oil leaking Replace the O-rings.
point.
Loose plugs. Confirm the oil leaking Retighten or replace the
point. plugs.
Loose bolts. Confirm the oil leaking Retighten the bolts or
point. replace the O-rings.

5-5-34
REPAIR
WARNING
Bosch doesn't recommend exchange of the parts by
customer. If the customer disassembles and reassembles
the part, Bosch does not guarantee its performance.
Necessary Tools and Jigs

The following tools and jigs are necessary to disassemble and
assemble the valve.
Tools
Name Size (Nominal) Quantity

Hexagon Socket Screw Key 5, 6, 10 One Each
Grease Small Amount
Jigs
1. Disassemble and assemble for guide of pilot valve M4
assembly. (Socket Head screw or equivalent)
2. Disassemble for body of main valve assembly.
(The plate such as a ruler which thickness is about 2 - 3
mm. Material is not so hard, such as copper alloy and
aluminum)
20 - 30
FG021983
Figure 35

5-5-35
Cautions During Disassembling and Assembling
Cautions for Disassembling

1. Do not loosen adjusting screw unless absolutely
necessary.
2. Take utmost care during disassembly not to knock or drop
each part.
Figure 36
Cautions for Assembling

1. Wash each part thoroughly.
2. During assembling, take utmost care not to damage the
part or allow foreign materials to enter.
3. As a rule, the O-ring should not be reused.
4. Apply the grease when assemble O-ring.
5. In our assembly work, the torque wrench is used to control
the torque. Be sure to use the torque wrench.

5-5-36
Disassembling Procedure
Exchange of O-ring (Surface of Pump Installation)

1. Remove bolts (3, Figure 37) (4 places) and removes the
valve from pump. (Using tool: hexagon socket screw key,
size 10, tightening torque = 110 ±12 N.m)
2. Exchanges O-ring (4, Figure 37).
Figure 37

5-5-37
Exchange of O-ring (Surface of Pilot Valve Assembly Installation)
1. Remove bolt (12, Figure 38) (2 places) and remove pilot
valve assembly. (Using tool: hexagon socket screw key,
size 6, tightening torque = 32 ±3 N.m)
IMPORTANT
Be careful not to pull out main valve assembly parts.
(Refer to next page. Plunger (11, Figure 39), spring
sheet (12, Figure 39) and spring (13, Figure 39))
2. Exchanges the O-ring (13, Figure 38) (2 places).
Figure 38

5-5-38
Exchange of O-ring and Backup Ring (Part of Main Valve Assembly)
1. Remove pilot valve assembly. (See page -38)
2. Remove plunger (11), spring sheet (12) and spring (13).
3. Remove O-ring (16).
4. Insert the plate to O-ring groove and pull out to remove
body (10).
5. Exchange O-rings and backup rings.
Figure 39

5-5-39
Disassembling Procedure of Pilot Valve Assembly (Excluding Adjusting Screw Part)
1. Remove plug (7).
(Using tool: hexagon socket screw key, size 5, tightening
torque = 13 ±0.2 N.m)
2. Tighten jig (bolt, M4 x 20 - 30) on the end of guide (3) and
pull out to remove guide (3).
IMPORTANT
Be careful not to damage O-ring (14).
Be careful not to lose pin (6), and not to change the
inserting direction of pin (6).
Figure 40
3. Remove spool (2).

To remove spool (2), use a magnet stick.
IMPORTANT
Be careful not to pull out spring (15).
Assembling Procedure
Do the opposite procedure of disassembly.
When you insert sliding parts such as spool and, plunger, make
sure they slide smoothly.

5-5-40
PRECAUTION
Tightening Torques
You will find the tightening torques of the various screw types in
this chapter.
IMPORTANT
Make certain that threads are clean and dry.
Slotted Screws
The values apply for the following slotted screws:
1. With metric ISO threads according to DIN 13
2. With head seat dimensions according to
• DIN 912 socket head screw
• DIN 913 hexagon screws with shaft
• DIN 933 hexagon screws with thread to head
FG021156
Figure 41
Tightening Torque
Thread Size Strength Classes
8.8 10.9 12.9
M3 1.1 N.m 1.6 N.m 1.9 N.m
M4 3.1 N.m 4.5 N.m 5.3 N.m
M5 6.1 N.m 8.9 N.m 10.4 N.m
M6 10.4 N.m 15.5 N.m 18 N.m
M8 25 N.m 37 N.m 43 N.m
M10 51 N.m 75 N.m 87 N.m
M12 87 N.m 130 N.m 150 N.m
M14 140 N.m 205 N.m 240 N.m
M16 215 N.m 310 N.m 370 N.m
M18 300 N.m 430 N.m 510 N.m
M20 430 N.m 620 N.m 720 N.m
M22 580 N.m 830 N.m 970 N.m
M24 740 N.m 1,060 N.m 1,240 N.m

5-5-41
Threaded Plugs
Threaded Plug with Profile Sealing Ring
The values in the following table apply for threaded plugs with
profile sealing ring and metric thread according to DIN 3852.
FG021157
Figure 42
Threaded Plug with O-ring Seal

The values in the following table apply for threaded plugs with
O-ring and UNF- or UN thread according to ISO 11926.
FG021158
Figure 43

5-5-42
Thread Size Required Tightening Torque Hexagon Socket Size (WAF)
M10 x 1 DIN 3852 12 N.m 5 mm
M12 x 1.5 DIN 3852 25 N.m 6 mm
M14 x 1.5 DIN 3852 35 N.m 6 mm
M16 x 1.5 DIN 3852 50 N.m 8 mm
M18 x 1.5 DIN 3852 60 N.m 8 mm
M22 x 1.5 DIN 3852 80 N.m 10 mm
M26 x 1.5 DIN 3852 120 N.m 12 mm
M27 x 2 DIN 3852 135 N.m 12 mm
M33 x 2 DIN 3852 225 N.m 17 mm
M42 x 2 DIN 3852 360 N.m 22 mm
M48 x 2 DIN 3852 400 N.m 24 mm
5/16-24 UNF-2B ISO 11926 7 N.m 1/8 in
3/8-24 UNF-2B ISO 11926 7 N.m 5/32 in
7/16-20 UNF-2B ISO 11926 15 N.m 3/16 in
9/16-18 UNF-2B ISO 11926 25 N.m 1/4 in
3/4-16 UNF-2B ISO 11926 62 N.m 5/16 in
7/8-14 UNF-2B ISO 11926 127 N.m 3/8 in
1 1/16-12 UN-2B ISO 11926 147 N.m 9/16 in
1 5/16-12 UN-2B ISO 11926 198 N.m 5/8 in
1 5/8-12 UN-2B ISO 11926 320 N.m 3/4 in
1 7/8-12 UN-2B ISO 11926 390 N.m 3/4 in
Sealing Nuts
Required Hexagon Socket Size
Tightening Torque (WAF)
M6 10 N.m
M6 x 0.5 11 N.m
M8 22 N.m
M8 x 1 24 N.m
M10 40 N.m
FG021159
M10 x 1 44 N.m
Figure 44
M12 69 N.m
M12 x 1.5 72 N.m
M14 110 N.m
M14 x 1.5 120 N.m
M16 170 N.m
M16 x 1.5 180 N.m

5-5-43
MAINTENANCE AND REPAIR
Cleaning and Care
IMPORTANT
Prevent damage to the surface caused by solvents and
aggressive detergents!
Aggressive detergents can damage the seals on the axial
piston unit and reduce their service lift.
• Never use solvents or aggressive detergents.
IMPORTANT
Prevent damage to the hydraulic system and the seals!
A high-pressure cleaner's water pressure could damage the
electronics and the seals of the axial piston unit.
• Do not point the high-pressure cleaner at sensitive
components, e.g. shaft seal ring, electrical
connections and electrical components.
For cleaning and care of the axial piston unit, observe the
following:
1. Plug all openings with suitable protective caps/devices.
2. Check whether all seals and fittings on the connections are
securely seated to ensure that no moisture can penetrate
into the axial piston unit during cleaning.
3. Use only water and, if necessary, a mild detergent to clean
the axial piston unit.
4. Remove coarse dirt from the outside of the machine and
keep sensitive components such as solenoids, valves,
indicators and sensors clean.

5-5-44
Inspection
To enable long and reliable operation of the axial piston unit,
testing the hydraulic system and axial piston unit regularly and
document the following operating conditions:
Task to be Carried Out Interval

Hydraulic system Check level of hydraulic fluid in the reservoir. daily
Check the operating temperature (comparable load conditions) weekly
at the reservoir port and in the reservoir.
Analyze the hydraulic fluid: viscosity, aging, contamination. yearly or every 2,000 h
(whichever occurs first)
Axial piston unit Check axial piston unit for leakage. Early detection of hydraulic daily
fluid loss can help to identify and eliminate faults on the
machine or system. For this reason, recommends that axial
piston unit and system always be kept in a clean condition.
Check axial piston unit for noise development. daily
Check fasteners for tight seating. All fasteners have to be monthly
checked when the system is switched off, non-pressurized and
cooled down.
Maintenance
The axial piston unit is low maintenance when used as intended.
The service life of the axial piston unit is heavily dependent on
the quality of the hydraulic fluid. For this reason, we recommend
changing the hydraulic fluid at least once per year or every 2000
operating hours (whichever occurs first) or having it analyzed by
the hydraulic fluid manufacturer or a laboratory to determine its
suitability for further use.
The service life of the axial piston unit is limited by the service
life of the bearings installed. The service life can be requested
from the responsible Service partner, See “Spare Parts” on
page 46. for address. Based on these details, a maintenance
period is to be determined by the system manufacturer for the
replacement of the bearings and included in the maintenance
schedule of the hydraulic system.

5-5-45
Repair
Who or what offers a comprehensive range of services for the
repair of axial piston units.
Repairs to the axial piston unit may only be performed by
authorized, skilled and instructed personnel.
• Only use genuine spare parts from Doosan for repairing
the axial piston units.
Tested and pre-installed original assembly groups allow for
successful repair requiring only little time.
Spare Parts
CAUTION
AVOID INJURY
Prevent damage to persons and property because of faulty
spare parts!
Spare parts that do not meet the technical requirements
specified by Doosan can cause personal injury or property
damage.
• Use only original spare parts from Doosan.
The spare parts lists for axial piston units are order specific.
When ordering spare parts, quote the material and serial
number of the axial piston unit and the material numbers of the
spare parts.
Address all questions regarding spare parts to your responsible
Service partner or the service department of the manufacturer's
plant for the axial piston unit.

5-5-46
DECOMMISSIONING
The axial piston unit is a component that does not require
decommissioning.
For this reason, this chapter of the manual does not contain any
information.
For details about how to remove or replace your axial piston
unit, please refer to chapter "See “Removal and Replacement”
on page 47.".
REMOVAL AND REPLACEMENT
Required Tools
Removal can be performed using standard tools. No special
tools are necessary.
Preparing for Removal
WARNING
ELECTRICAL SYSTEMS OR COMPONENTS UNDER
PRESSURE CAN CAUSE DEATH OR SERIOUS INJURY
• Turn battery disconnect switch to the "OFF" position
and relieve system pressure before servicing or
disassembling.
1. Decommission the entire system as described in the

overall manual for the machine or system.
2. Protect the complete system against being energized.
3. Relieve the hydraulic system according to the instructions
of the machine or system manufacturer.

5-5-47
Removing the Axial Piston Unit
Proceed as follows to remove axial piston unit:
1. Make sure that hydraulic system is non-pressurized.
2. Check whether the axial piston unit has cooled down far
enough so it can be removed without causing injury.
3. For below-reservoir installation, before removing the axial
piston unit from the complete system, seal the connection
to the reservoir or drain the reservoir.
4. Place a drip tray under the axial piston unit to collect any
hydraulic fluid that may escape.
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.
5. To do this, loosen the lines and collect the escaping

hydraulic fluid in the drip tray.
6. Remove axial piston unit. Use a suitable lifting device.
7. Completely empty the axial piston unit.
8. Plug all openings.
Preparing the Components for Storage or

Further Use
Proceed as described in section See “Storing the Axial Piston
Unit” on page 16.

5-5-48
TROUBLESHOOTING
The following table may assist you in troubleshooting. The table
makes no claim for completeness.
In practical use, problems which are not listed here may also occur.
How to Proceed for Troubleshooting

1. Always act systematically and targeted, even under
pressure of time. Random and imprudent removal and
readjustment of settings could result in the inability to
ascertain the original error cause.
2. First obtain a general overview of how your product works
in conjunction with the entire system.
3. Try to determine whether the product worked properly in
conjunction with the entire system before the error
occurred.
4. Try to determine any changes of the entire system in which
the product is integrated.
• Were there any changes to the product's application
conditions or operating range?
• Were there any changes (conversions) or repairs on
the complete system (machine/system, electronics,
control) or on the product? If yes, which?
• Has the hydraulic fluid been changed?
• Was the product or machine operated as intended?
• How did the malfunction appear?
5. Try to get a clear idea of the error cause. Directly ask the
(machine) operator.
6. If you cannot rectify the error, contact one of the contact
addresses which can be found under:
www.doosaninfracore.co.kr

5-5-49
Malfunction Table
Fault Possible Cause Remedy
Unusual noises Drive speed too high. Machine or system manufacturer.
Wrong direction of rotation. Ensure correct direction of rotation.
Insufficient suction conditions, e.g. air in Machine or system manufacturer (e.g.
the suction line, inadequate diameter of optimize inlet conditions, use suitable
the suction line, viscosity of the hydraulic hydraulic fluid).
fluid too high, suction height too high, Completely air bleed the axial piston unit,
suction pressure too low, contaminants in fill the suction line with hydraulic fluid.
the suction line.
Remove contaminants from the suction line.
Improper installing of the axial piston unit. Check installation of the axial piston unit
according to the specifications of the
machine or system manufacturer.
Observe tightening torques.
Improper installing of the attachment Install attachment parts according to the
parts, e.g. coupling and hydraulic lines. information provided by the coupling or
fitting manufacturer.
Malfunction of the pressure relief valve of Bleeding the axial piston unit.
the axial piston unit (pressure cut-off). Check viscosity of the hydraulic fluid.
Contact our service.
Mechanical damage to the axial piston unit Exchange axial piston unit, contact our
(e.g. bearing damage). service.
No or Faulty mechanical drive (e.g. defective Machine or system manufacturer.
insufficient flow coupling).
Drive speed too low. Machine or system manufacturer.
the suction line.
Hydraulic fluid not in optimum viscosity Use suitable hydraulic fluid (machine or
range. system manufacturer).
External control of the control device Check external control (machine or
defective. system manufacturer).
Insufficient pilot pressure or control Check pilot pressure or control pressure,
pressure. contact our service.
Malfunction of the control device or Contact our service.
controller of the axial piston unit.
Wear of axial piston unit. Exchange axial piston unit, contact our
service.

5-5-50
Fault Possible Cause Remedy
No or Faulty mechanical drive (e.g. defective Machine or system manufacturer.
insufficient pressure coupling).
Drive power too low. Machine or system manufacturer.
the suction line.
Hydraulic fluid not in optimum viscosity Use suitable hydraulic fluid (machine or
range. system manufacturer).
External control of the control device Check external control (machine or
defective. system manufacturer).
pressure. contact our service.
Malfunction of the control device or Contact our service.
Wear of axial piston unit. Exchange axial piston unit, contact our
service.
Output unit defective (e.g. hydraulic motor Machine or system manufacturer.
or cylinder).
Pressure/ Axial piston unit and/or control unit not or Completely air bleed axial piston unit.
flow fluctuations insufficiently air bled. The pressure reducing valve must be
exchanged. Contact service.
the suction line.
Excessive Excessive inlet temperature at the axial Machine or system manufacturer:
hydraulic fluid and piston unit. Inspect system, e.g. malfunction of the
case temperature cooler, insufficient hydraulic fluid in the
reservoir.
Malfunction of the pressure control valves Contact Service.
(e.g. pressure cut-off, pressure controller).
Wear of axial piston unit. Exchange axial piston unit, contact
service.
Instability/vibrations Setpoint value not stable. Machine or system manufacturer.
Resonance in the reservoir line. Machine or system manufacturer.
Axial piston unit and/or control unit Completely air bleed axial piston unit.
insufficiently air bled. The pressure reducing valve must be
exchanged. Contact service.
Malfunction of the control devices or Contact service.
controller.

5-5-51
Section View
EX1400354
Figure 45

5-5-52
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.
1. Park the machine on firm, level 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 46

5-5-53
(Figure 47)
LOCK
WARNING
WARNING
DO NOT OPERATE
or maintenance
ON OFF

switch.
(Figure 48)
Figure 48
WARNING
doing any work.

Figure 49 EX1400156

5-5-54
10. Oil drain method
A. Remove cover on oil tank (bolt: 6 ea) and drain
hydraulic oil using oil pump.
• Tool: 14 mm ( )
EX1400160
Figure 50
B. Drain hydraulic fluid using drain plug. (without oil

pump)
• Tool: 27 mm ( )
• Hydraulic oil tank capacity
– Approximately: 381 L
– Effective level: 243 L
EX1400161
Figure 51 Oil Tank Bottom View
C. Plug the filter cap to location of suction filter.
Item Part Number

Filter Cap 2188-1011
EX1301534
Figure 52
Reference
Description
Number
3
1 Suction Filter
606.5
2 Nut
3 Rod
2
When installing
• Torque (2 nut): 49 N.m (5 kg.m, 36.2 ft lb) 1
EX1400168
Figure 53

5-5-55
11. Remove bolt (3, Figure 54) (12 ea) and remove under
cover (1 and 2, Figure 54) under pump side.
• Tool: 19 mm ( ) 1 2
• Cover weight
Reference Weight
Number kg lb
1 10.75 23.7 3
2 11.1 24.4
EX1400287
Figure 54
12. Remove bolt (6 ea) and remove engine cover of muffler

side.
• Tool: 19 mm ( )
EX1301536
Figure 55
13. Disconnect the harness from SCR catalyst.
• Tool: 24 mm ( )
EX1301538
Figure 56

5-5-56
• Tool: 22 mm ( )
EX1301539
Figure 57
14. Disconnect the harness from DOC (Diesel Oxidation

Catalyst) and hose connected UREA tank.
EX1301540
Figure 58
15. Open the clamp and remove SCR catalyst.
EX1301546
Figure 59

5-5-57
16. Open the clamp of DOC connected exhaust pipe.
EX1301547
Figure 60
17. Remove bolt (4 ea) of SCR muffler mounting bracket, and

then lift off all the parts assembled with muffler bracket.
• Tool: 10 mm ( )
• Weight: approximately 40 kg (88.2 lb)
EX1301548
Figure 61
18. Open the right side door.
EX1400288
Figure 62

5-5-58
19. Remove bolts (5, Figure 63) (26 ea), related baffles, covers
around pump and remove baffles and covers.
5 1
• Tool: 19 mm ( )
• Cover weight
Reference Weight
Number kg lb
1 6 14
2 2 4
EX1400289
3 2 4 Figure 63
4 1 2
3
2
Figure 64 EX1400290
20. Disconnect the connector of main harness from EPPR

valve and angle sensor.
Figure 65 EX1400291
21. Remove bolts (4 ea) and remove suction pipe on bottom of

pump. Drain the hydraulic oil of suction pipe to bowl.
• Tool: 14 mm ( )
Figure 66 EX1400292

5-5-59
22. Disconnect the hoses from bottom to top of pump.
NOTE: After disconnecting hoses from pump, plug
them to prevent dirt or dust from entering.
PPRV Idle PPRV Drive
R4 T2 P2
PHB P2
PHB
T1
X
T1
T3
A3 X
M5
T2
M6
Y3
Bottom View of Main Pump
EX1400293
Figure 67
• Thread of hoses
Torque
Port Name Plug/Flange Size (Hose)
(mm) (mm) N.m kg.m ft lb
R4 to Tank 13/16"-16UN-2B 24 55.9 5.7 41.2
A3 to Pilot Filter "IN" 13/16"-16UN-2B 24 55.9 5.7 41.2
T3 to Swing Device "C" 13/16"-16UN-2B 24 55.9 5.7 41.2
Y3 to Pilot Filter "OUT" 9/16"-18UN-2B 19 25.5 2.6 18.8
M5, M6 to PPRV "X" 9/16"-18UN-2B 19 25.5 2.6 18.8
P2 to Control Valve SAE 1 1/4 (High-pressure), D32 12 176.5 18 130.2
PHB to PPRV (Drive) SAE 1 (High-pressure), D25 10 107.9 11 79.6
PPRV
T1 Drain 1 3/16"-12UN-2B 36 124.5 12.7 91.9
Idle
T2 to Tank 9/16"-16UN-2B 19 25.5 2.6 18.8
X to Main Pump "M5" 9/16"-18UN-2B 19 25.5 2.6 18.8
P2 to Control Valve SAE 1 1/4 (High-pressure), D32 12 176.5 18 130.2
PHB to PPRV (Idle) SAE 1 (High-pressure), D25 10 107.9 11 79.6
PPRV
T1 Drain 1 3/16"-12UN-2B 36 124.5 12.7 91.9
Drive
T2 to Tank 9/16"-16UN-2B 19 25.5 2.6 18.8
X to Main Pump "M6" 9/16"-18UN-2B 19 25.5 2.6 18.8

5-5-60
23. Remove bolts (10 ea) of pump without top bolts (2 ea).
• Tool: 17 mm ( )
Figure 68 EX1400294
24. Attach a lifting device around pump to support it, remove

the slack from the lifting device when removing remaining
bolts (2 ea).
• Weight:
– Main pump: about 195 kg (430 Ib)
– PPRV drive: about 10 kg (22 Ib)
– PPRV idle: about 10 kg (22 Ib)
CAUTION
AVOID INJURY EX1400295
Figure 69
Support the pump prior to removing remaining bolts to
prevent pump from falling.
25. Remove remaining bolts (2 ea).
• Tool: 17 mm ( )
EX1400296
Figure 70
26. Lift the pump from engine slowly and carefully.
Figure 71 EX1400297

5-5-61
INSTALLATION
WARNING
SERIOUS INJURY

2. When 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
Fill the oil tank with oil and maintain the temporary
assembly condition of the adapter of the pump drain
port. (Figure 72)
EX1400298
If oil comes out of the pump drain port, fully assemble Figure 72
the adapter.
A. Start the engine and run at low idle.

B. Operate the joystick lever and actuate the hydraulic
cylinder 4 - 5 times very slowly, about 100 mm before
the end of stroke.
C. 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)

5-5-62
REPLACING SEALS AND
ASSEMBLY GROUPS
This chapter describes the replacement of assembly seals of the
axial piston unit.
The replacement of seals is described for the following
assembly groups:
1. Driveshaft.
2. Gear pump.
3. Cover of the power take-off.
4. Port plate with valve.
5. Pressure reducing valve.
6. Angle position sensor.
IMPORTANT
The cleanliness of the hydraulic fluid has a
considerable impact on the cleanliness and service life
of the hydraulic system. Any contamination of the
hydraulic fluid leads to wear and malfunctions. In
particular, contaminants, such as welding beads or
metal cuttings in the hydraulic lines, can damage the
axial piston unit.
• Absolute cleanliness is required.
• The axial piston unit must be installed in a clean
condition.
• Make sure that all ports, hydraulic lines and
add-on units (e.g. measuring equipment) are
clean.
• Make certain that no contaminants enter when
sealing the ports.
• Make certain that no detergents enter the
hydraulic system.
• Do not use any cotton waste or linty cloths for
cleaning.
• Do not use hemp as a sealant under any
circumstances.

5-5-63
Replacing the Shaft Seal
This section explains how to replace the shaft seal.
IMPORTANT
The material number of the required special tool can be
found in the special tool catalog RE 93010-02-S081.
3
2
1
4
5
FG020962
Figure 73
Reference Reference
Number Number
1 Retaining Ring 4 Driveshaft
2 Backup Plate 5 Case
3 Shaft Seal Ring

5-5-64
Procedure
To replace the shaft seal:
1. Mask the driveshaft (4) to prevent damage to the shaft seal.
4
WARNING
The retaining ring can suddenly release, causing
injury.
• Wear safety glasses or goggles to prevent injury.
FG020963
Figure 74
2. Remove retaining ring (1) and the backup plate (2) from
the case.
1
2
FG020964
Figure 75
3. Turn two tapping screws (6) into the rubber-filled holes of

the shaft seal (3). Pull the shaft seal out of the case with a 6
gripper (5).
FG020965
Figure 76

5-5-65
4. Inspect the driveshaft and the case for wear and
contaminants.
IMPORTANT
Leakage can occur if the shaft seal is damaged.
• Lightly grease the new shaft seal between the
sealing and dust lip to prevent dry running.
5. Press the new shaft seal (3) with the aid of the appropriate
mounting bushing (2.10) into the case (5) in the correct 6
2.10 2
position by turning a suitable socket head screw (6) into
the thread of the driveshaft.
6. Insert the backup plate (2). 3
WARNING
5
AVOID DEATH OR SERIOUS INJURY FG020966
The retaining ring can suddenly release, causing Figure 77
injury.
• Wear safety glasses or goggles to prevent injury.
7. Guide the retaining ring (1) into the case (5) so it engages
in the groove provided for this purpose. Inspect the seating
of the retaining ring in the groove. 1
8. Remove masking on the driveshaft.
5
FG020967
Figure 78

5-5-66
Sealing or Replacing the Gear Pump
This section explains how to seal or replace the gear pump.
The gear pump is sealed against the case with three O-rings.
IMPORTANT
No special tools are required for the following work steps.
FG020968
Figure 79
Reference Reference
Number Number
1 Gear Pump 3 O-rings
2 Fixing Screw

5-5-67
Procedure
To seal or replace the gear pump:
1. Remove two attaching screws (2) of the gear pump.
2. Detach the gear pump (1).
IMPORTANT
If the gear pump is defective, replace it with a new one.
Use a new seal set (3).
3. Remove old O-rings (3) and replace with new rings.

Inspect the recesses and the case of the gear pump for
contaminants.
4. Insert new O-rings (3) in the recesses and install the gear
pump.
5. Tighten the attaching screws (2) according to the
specifications in chapter See “Precaution” on page 41.
FG020969
Figure 80

5-5-68
Sealing the Cover of the Power Take-off
This section explains how to seal the cover of the power take-off.
The cover of the power take-off is sealed against the case with
an O-ring.
IMPORTANT
3 2
FG020970
Figure 81
Reference Reference
Number Number
1 Power Take-off Cover 3 O-rings
2 Attaching Screw

5-5-69
Procedure
To seal the cover of the power take-off.
1. Remove two attaching screws (2) of the cover (1) with an
Allen key (WAF 10). 1
2
FG020971
Figure 82
2. Turn the cover 45° and pull off the cover.

3. Remove old O-ring (3) and replace it with a new one.
Inspect the case and the groove. 3
FG020972
Figure 83
4. Insert the new O-ring in the recess in the cover and install
the cover.
5. Tighten the attaching screws (2) according to the
specifications in chapter “Precaution” on page 41. 2
FG020973
Figure 84

5-5-70
Sealing the Port Plate with Valve
This section explains how to seal the port plate with valve.
The port plate with valve is sealed against the case with two O-rings.
IMPORTANT
FG021147
Figure 85
Reference Reference
Number Number
1 Port Plate with Valve 3 O-rings
2 Attaching Screw

5-5-71
Procedure
To seal the port plate with valve:
1. Mark the position of the port plate with valve so you can
remount it in the correct position after sealing.
2. Remove two attaching screws (2) of the port plate with
valve (1).
3. Lift the port plate with valve upward.
4. Remove old O-rings (3). Inspect the recesses and the port
plate with valve for wear and contaminants.
5. Insert the new O-rings in the recesses provided for this
purpose.
6. Mount the port plate with valve.
7. Tighten the attaching screws according to the details in
chapter “Precaution” on page 41.

5-5-72
Sealing or Replacing the Pressure
Reducing Valve
This section explains how to seal or replace the pressure
reducing valve.
The pressure reducing valve is sealed against the case with
three O-rings.
IMPORTANT
FG021148
Figure 86
Reference Reference
Number Number
Pressure Reducing Valve, 2 O-rings
1
Electric

5-5-73
Procedure
To seal or replace the pressure reducing valve:
1. Use a ring wrench (WAF 30) to unscrew the pressure
reducing valve (1) from the control case.
2. Mask the thread of the pressure reducing valve to avoid
damaging the new O-rings.
3. Remove old O-rings (2) and replace with new rings.
Inspect the pressure reducing valve.
4. Remove masking on the thread of the pressure reducing
valve.
5. Screw in the pressure reducing valve with a tightening
torque MA = 12+5 N.m.

5-5-74
Replacing the Angle Position Sensor
This section explains how to replace the angle position sensor.
IMPORTANT
IMPORTANT
To replace and readjust the angle position sensor, the
rotary group of the variable pump must be set to Vg max.
FG021149
Figure 87
Reference Reference
Number Number
1 Angle Position Sensor 2 Attaching Screws

5-5-75
Procedure
To replace the angle position sensor:
1. Remove two attaching screws (2) of the angle position
sensor (1).
2. Remove angle position sensor.
To install the new angle position sensor:
1. Position the shaft (3) of the angle position sensor
horizontally between the stops.
3 FG021150
Figure 88
2. Inspect the groove of the sensor shaft (4) in the controller.
IMPORTANT
The groove of the sensor shaft in the controller must
not be horizontal.
4
FG021151
Figure 89
3. Install the angle position sensor (1) with the electric port
upward. Turn the angle position sensor so it fits into the
groove of the sensor shaft (4) and then press it into the
seat. 1
4. Adjustment: turn the angle position sensor until signal is at

+ 4.5 V.
The rotary groups of the pump are then set to Vg max.
5. Tighten the attaching screws with a tightening torque of
4
MA = 3.1 N.m.
FG021152
Figure 90

5-5-76
Replacing Sealing Nuts
This section explains how to replace the sealing nuts.
IMPORTANT
Procedure
To replace a sealing nut:
1. Remove protective cap.
IMPORTANT
The protective cap is destroyed when removing it. If
replacement protective caps are needed, contact your
responsible Doosan Service partner or the service
department of the manufacturer's plant for the axial
piston unit.
2. Measure and note the dimension X for the later installation

of the sealing nut (1).
3. Remove sealing nut.
1
FG021154
Figure 91
4. Screw in the new sealing nut according to the details in

chapter “Precaution” on page 41.
While tightening the sealing nut, secure the adjustment bolt
(2) with an Allen key. 2
5. Inspect dimension X after installing. 1
FG021155
Figure 92

5-5-77
D-ECO POWER SYSTEM
Introduction of D-Eco Power System
Summary - Main Concept

The electronic pump which has the implementation of a virtual
bypass flow rate of current negacon system is...
• Going with a load feeling like current negacon system
• No bypass/bleed off flow (only virtual)
→ Improving a fuel consumption
• Including a pressure control type pump than there is no
leakage in a relief operation.
→ Improving a fuel consumption
EPOS Controller receives joystick (lever) and pedal signals from
the pressure sensors, and pressure signals from the angle
sensor for pump discharge rate.
To eliminate the difference between the command for the
required flow rate from the joystick sensing pressure and the
actual discharge rate (measured with angle sensor), EPOS
controller outputs set-up current value to the EPPR valve of the
electronic pump to control the pump discharge rate by pressure.

5-5-78
Total Diagram of D-Eco Power System
Pilot System Actuator
**MCV
*PPRV
Angle
Pump
Pump ED
Regulator
Controller
Pump Flow Control

Pressure
Sensor Power Shift Control
Power Control ***EPPR Valve EPPR Valve
(Travel Straight)
Main Function Control
Relief Cut Off
By Pass Cut Valve
Swing Brake
Solenoid Valve
(Bypass Cut)
CAN Bus
Solenoid Valve
(Swing Brake)
Gauge Panel
Engine ECU EX1400307
Figure 93

5-5-79
Block Diagram of D-Eco Power Controller
Main Controller Pump Controller (Pump 1)

Main Function
T/Straigt PV
Control
Angle Convert to Qa Cut Off Cut Off P
Sensor Voltage Flow Rate Table Bypass SV
Qa
S/Brake SV
dQ Pi
Convert to
Joystick Qp
Virtual Stroke
Pressure Pump Model
Table Mapping Qb
VtrStr Flow Rate (Qp)
Convert to Current Pump EPPR
Ab 2 P P Min
Q Cd A EPPR Current Current
Pr Command
Table Mapping
(The Smaller Is
Bypass Area
Outputted)
(Ab)
Flow Controller
Max P
Wp1
State Set Self
Control Power
Pd
Pump 1 Power Max
by Wp1
GP Mode Mode Set Power For
Select Max VtrStr Pump Power Graph
Q Pi
Engine RPM Total Total Power Max Q Pd
ECU
PID Power Pump 2 Power P/Shift
Pump 2
Speed
Dial Power
Power Distribution
Power Shift Controller and Controller Max P P
* Only 1 Pump Side Is Expressed
EX1400308
Figure 94

5-5-80
Flow Control
Move Spool
Joystick
Controller Increase Pump Discharge Rate
Control Process
Sensing a pressure of joystick to calculate flow rate (Qp) and center
bypass area (Ab), VBO system control a pressure command of
electronic pump to have no difference with calculated flow rate and
actual flow rate (obtained by angle sensor).
Lever & Pedal
Pressure Sensor
4P
Close
Center
Controller
Angle Sensor
39 bar
(40 kg/cm2)
EPPR Valve
EX1400286
Figure 95
P Pump = (12.75 x Pi) + α

• P Pump: Pump Pressure
• 12.75: EPPR Valve Area Ratio
• Pi: Pump EPPR Secondary Input
• α: Spring Value (44 bar (45 kg/cm2))

5-5-81
Step
1. Calculating a required flow rate (Qpx) and a center bypass
area (Abx) of each operating spool.
2. Calculating a final output Qp (applied a special logic if
simultaneous operation occurs) and a equivalent Ab.
3. Calculating a center bypass flow rate (Qb) using a
equivalent Ab and current pressure command.
4. Calculating a deviation of flow rate between calculated and
actual. (dQ = Qp - Qb - Qa)
5. Calculating a pressure command by pump modeling.
6. For improving a pump stability, applying digital filters and
calculating a final pressure command of flow control.
Angle Convert to Qa
Sensor Voltage Flow Rate
Qa
dQ Pi
VtrStr
Convert to Qp
Joystick
Pressure Virtual Stroke
Pump Model
Table Mapping Qb
Flow Rate (Qp)
Q
Ab 2 P P
Max Q Q Cd A
Table Mapping
Bypass Area (Ab)
State
Flow Controller
Control
Max P P
EX1400309
Figure 96

5-5-82
Power Shift Control
Control Process
D-Eco power system is calculating a maximum pump power by
power shift control in the same way as NegaCon system.
To calculate a maximum power, joystick stroke and engine rpm
are entered in EPOS.
Step
1. Selecting a maximum value among joystick lever
pressures.
2. Calculating matched power of Pi-power map by maximum
Pi.
3. Limiting the increasing slope of power.
4. Applying a digital lead filter to engine rpm.
5. Executing PID control to control a target engine rpm.
6. Executing anti-windup.
7. Calculating a final required power that is summation of
initial power, PID control value and setting power by lever.
Convert to VtrStr
Joystick
Pressure Virtual Stroke
Mode
GP Mode Set Power for
Select Max VtrStr Total
Power
Pump Power Graph
Q
Engine RPM
PID Max Q
ECU
Dial
Reference Speed Power Shift Controller
Max P P
EX1400311
Figure 97
PID control: Proportional, Integral, and Differential processes

are done optimal combination to implement feedback control.
Feedback Control process can reduce error by comparing the
resultant values of control, more particularly, it measures output
of the target device, compare the measurement value with the
target value to calculate and minimize error.

5-5-83
Power Distribution Control
• Power of pump 1, 2 are controlled independently
→ Setting minimum assigned power of pump 1, 2 by mode.
• Able to using full power supplied from engine
→ If one pump uses less power, the other pump will use
the rest of power. (In case of NegaCon, workload is
decided by pump pressure not by power)
VBO Pump
Max Pressure
Inc 2 Pump
re
se
1P dP
Large um ow
Pump pR er
2 Regular eg
& ula
Pumps r
Small Pressure
Pump
Reduced Power
Qs max Qp max
Flow
Figure 98 EX1400314
Control Process
• NegaCon system is controlling a pump pressure to limit
power so maximum power of pump can be limited
regardless of flow rate.
• VBO system is calculating maximum power of each pump
independently and distributing a pump power at the ratio of
simultaneous operation.
• As a result the power efficiency can be improved.

5-5-84
Wp1
Qa
Set Self Power
Pump 1 Power
By Wp1 Max
Power Calculation Pd
Max Pressure From
Power
Total
Power
Total Power
Pump 2 Power
Pump 2
Power Distribution and Controller
Power
Pump 1
Q Max Power
Power Graph
Pump Power Graph
Wp1 Power (50%) Q
Max Q
Pd P1
Pump 2
Q Max Power
Power Graph
Wp1 Power (50%) Max P P
Total Power
P2
EX1400315
Figure 99
Step
1. Distributing total power by certain ratio (Wp1,%) to
calculate the maximum power for Pump 1.
2. Calculating the power of pump 2 using flow rate and pump
pressure command of pump 2.
3. Subtracting the power of pump 2 from total power.
4. Deciding on the maximum power between the maximum
power for pump 1 (1) and calculated power (3).
5. Dividing the maximum power by flow rate to calculate
pressure command for power distribution (Pd).

5-5-85
Other Controls
System Pressure Control

• Relief operation is not to be controlled by main Relief valve
and swing Relief valve, but to be controlled by pump
pressure.
→ Improving a fuel consumption by decreasing power loss.
Negacon D-Eco Power
Pump Pump
373 bar P Max ED 373 bar

(380 kg/cm 2 ) (380 kg/cm 2 )
System P Max. System P Max
Q Saving of Flow Loss

Q Q Q
Swing Qa Swing Qa
Relief Q
Relief Q
P Swing P Max t P Swing P Max t
In condition of relief, pump flow is fixed by In case of swing operation, pump flow In condition of relief, only leakage flow goes. In case of swing operation,
power limitation table. (Loss of flow is much) goes up to an exact value of table (about 7%) speed is increased by inertia and
immediatly. pump flow goes up to only supplied
value to swing motor.
EX1400463
Figure 100

5-5-86
Bypass Cut Valve Control
Bypass cut Solenoid Valve: ON (Close), OFF (Open)
Input Output
Coolant Swing Bypass Cut Note
Engine rpm Travel Straight
Temperature Cavitations S/V
< 500 - - - OFF
> 500 ON - - ON
> 500 OFF < 20° - OFF
> 500 OFF > 25° *1 ON OFF *2 OFF → ON
*1. If swing operation continues over 0.6 second and stops

*2. Turning off during 1 second and turning ON
Swing Brake Release Valve Control

Swing Brake Release Solenoid Valve: ON (Release), OFF (Lock)
Input Output
Swing Brake Note
Boom Arm Bucket Swing Travel L Travel R
Release S/V
ON - - - - - ON
- ON - - - - ON
- - ON - - - ON
- - - ON - - ON
OFF OFF OFF OFF OFF OFF OFF
OFF OFF OFF OFF OFF ON OFF
OFF OFF OFF OFF ON OFF OFF
OFF OFF OFF OFF ON ON OFF

5-5-87
Initialization of D-Eco Power System
Introduction
D-Eco power system is confirming an initial state of system for
normal control by checking inputs and outputs.
• Input: Pilot sensor, pump swivel angle sensor
• Output: Pump EPPR valve, travel straight EPPR valve,
bypass cut solenoid valve, swing brake release
solenoid valve.
Output Monitoring
Input
7. PPRV
3. EPPR Valve
(Pump)
1. Pilot Sensor Controller
4. EPPR Valve
• Pump Flow Control Gauge Panel
(Travel Straight)
• Power Shift Control

2. Angle Sensor
• Max Pressure Control 5. Solenoid Valve
(Bypass Cut)
• Main Function Control
6. Solenoid Valve * DMS

(Swing Brake)
CAN BUS
*DMS: Doosan Monitoring System
Engine ECU Gauge Panel

EX1400464
Figure 101

5-5-88
Input Setting - Pilot Pressure Sensor
D-Eco power system determines the pump flow rate by pressure
of joysticks and pedal as inputs.
If the pressure sensors of joystick and pedal malfunction,
system can't control the pump flow rate normally because of not
recognize inputs.
1. Converting pilot pressure which is entered by joysticks to
the electric signals. The values which is converted into
digital from the electric signals are used in the controller as
joystick strokes.
2. The values of pilot sensors must be minimum in neutral
position/be maximum in full stroke by setting.
o 25
42.5
64.5
16 6
2.7
Joystick
Main Control Valve
Section
o 14 0.1
Pressure Output (V)

Sensor Pump ED Pump
Regulator 5
(4.2) at: 25 °C
4
ADC
3
Controller EPPR V/V
2
(1.8)
1
0 10 20 30 40 50 P (kg/cm²)
Specification
EX1400465
Figure 102

5-5-89
Sequence of Setting
1. Checking static characteristic
A. Checking minimum pilot pressure
1) Set joysticks as neutral position → 0 bar
2) Check joystick pressures by monitoring
(normal: 0 bar+1)
B. Checking maximum pilot pressure
1) Set power mode as P+, set dial to max
→ maximum output of gear pump pressure
(overriding)
2) Set joysticks as full stroke
→ over 40 bar (gear pump pressure)
3) Check joystick pressures by monitoring
(normal: over 40 bar)
2. Checking dynamic characteristic
A. Checking reaction speed of pilot pressure.
1) Set joysticks as Neutral position → 0 bar
2) Add each joystick pressure data to graphic
monitoring and start monitoring.
3) Move each joystick to full stroke quickly
→ rising up to over 40 bar.
4) Check rising time from 0 - 30 bar
(normal: less 0.5 sec)
B. Checking point when the problem occurs.
1) Keep a constant value of pressure data
→ check a pressure sensor malfunction.
2) Reaction speed is over 0.5 sec
→ check an air addition in pilot line.

5-5-90
Joystick
Main Control Valve
Pressure
Sensor Pump
Pump ED
Regulator
ADC
Controller EPPR Valve
Check the Value of RS232

Pressure Sensor
DMS
EX1400473
Figure 103
1 VBO / Electronic Pump
Monitoring Arm Dump Pressure Boom-up Pressure
1 Basic
2 Digital I/O
Swing Pressure Swing Pressure Bucket Crowd Pressure Bucket Dump Pressure
3 Analog I/O
4 VBO / Electron
5 Engine Charac
Graph Output Arm Crowd Pressure Boom Down Pressure
Forced Drive
Self Diagnosis
History Managem Pump Proportional Pressure Pump Proportional Pressure

Front Pump Pressure Rear Pump Pressure
Reducing Valve 1 Reducing Valve 2
Parameter
Front Pump Swivel Angle Rear Pump Swivel Angle Right Travel Pressure Left Travel Pressure
EX1400474
Figure 104 Checking Pilot Pressure (Min/Max)

5-5-91
Monitoring
Boom-up Pressure
1 Basic Bucket Dump Pressure
2 Digital I/O Arm Crowd Pressure
Arm Dump Pressure
3 Analog I/O Bucket Crowd Pressure
Bucket Dump Pressure
4 VBO / Electron Right Travel Pressure
5 Engine Charac Swing Pressure
Graph Output
Forced Drive
Self Diagnosis
History Managem
Parameter
EX1400475
Figure 105 Checking Reaction speed of Pilot Pressure
Qa1
AD_cnt_Travel
30 bar
0 bar
(s)
Normal (0.24 sec)

AD_cnt_Travel
Qa1
30 bar
0 bar
(s)
Problem Occurs (0.92 sec) EX1400476

Figure 106

5-5-92
Input Setting - Angle Sensor
1. Converting angle values that angle sensors measure from
pump flow rate to electric signals.
The values which are converted into digital from the
electric signals, are used in the controller as current flow
rate.
2. The values of angle sensors must be minimum in minimum
angle/be maximum in maximum angle by setting.
Angle
Sensor
Angle
Pump
Pump ED
Regulator
ADC
Main Control Valve
Solenoid Valve
*ADC: Analog to Digital Converter (Bypass Cut)
EX1400477
Figure 107
Voltage Characteristic
45ȋ 45ȋ
37.9 0.5
Voltage (V)
22ȋ
37 0.2
50
Angle ( ȋG)
EX1400478
Figure 108

5-5-93
Sequence of Setting
1. Checking static characteristic
A. Checking minimum voltage of angle sensor
1) Turn on bypass cut solenoid valve
→ Closing the main control valve center bypass
line.
2) Put 0 mA (0 bar) by forced pump pressure
current → Set angle to minimum value.
3) Check voltage of angle sensor by monitoring
(normal: 0.5 V ±0.1)
B. Checking maximum voltage of angle sensor
1) Set power mode as P+, set dial to max → Angle
swivel can be moved maximum position.
2) Turn off bypass cut solenoid valve
→ Opening the main control valve center
bypass line.
3) Put 500 mA (170 bar) by forced pump pressure
current → Set angle to maximum value.
4) Check voltage of angle sensor by monitoring
(normal: 4.4 V ±0.1)
2. Checking dynamic characteristic
A. Checking reaction speed of pump angle swivel
1) Add each angle sensor data to graphic
monitoring and start monitoring.
2) Turn off bypass cut solenoid valve
→Opening the main control valve center bypass
line.
3) Put 500 mA (170 bar) after putting 0 mA (0 bar)
by forced pump pressure current
→ Set angle from minimum to maximum value.
4) Check rising time from 0.5 - 4.5 V
(normal: less 2 sec)

5-5-94
Angle
Sensor
Angle
Pump
Pump ED
Regulator
ADC
Checking Voltage RS232 Main Control Valve

of Angle Sensor
Solenoid Valve
DMS (Bypass Cut)
EX1400479
Figure 109
Forced Drive
Monitoring Pump 1 Proportional Pump 2 Proportional Cooling Fan Proportional
Pressure Reducing Valve Pressure Reducing Valve Pressure Reducing Valve
1 Basic
2 Digital I/O
Application Application Application
3 Analog I/O Pressure Relief Valve Straight Travel Proportional Engine Speed Command
Flow Control Pressure Reducing Valve
4 VBO / Electron
5 Engine Charac Application Application Application
Graph Output
Forced Drive
Self Diagnosis
History Managem
Parameter
VBO / Electronic Pump
Arm Crowd Pressure Boom Down Pressure
Pump Proportional Pressure Pump Proportional Pressure

EX1400480
Figure 110 Checking Voltage of Angle Sensor (Min/Max)

5-5-95
2 Graph Output
Monitoring
Front Pump Square Edition
1 Basic Rear Pump Square Edition
2 Digital I/O
3 Analog I/O
4 VBO / Electron
5 Engine Charac
Graph Output
Forced Drive
Self Diagnosis
History Managem
Parameter
EX1400481
Figure 111 Checking Reaction Speed of Pump Angle Swivel
4.5
5V
0.5
5V
Normal (1 sec)
EX1400482
Figure 112

5-5-96
Output Setting - Solenoid Valve
1. Solenoid valve are used in D-Eco power system.
A. Bypass cut solenoid valve: Center bypass line open/
close
B. Swing brake solenoid valve: Swing motor brake hold/
release
2. Checking the operation of solenoid valve whether it works
well or not in working conditions.
Controller Solenoid V/V

(Bypass Cut) Main Control Valve
• Pump Flow Control
Pump ED
Regulator
Pump
• Max Pressure Control
EPPR Valve
(Pump)
Solenoid Valve Swing Motor

(Swing Brake)
EX1400483
Figure 113

5-5-97
• Bypass Cut Solenoid Valve: ON (Close), OFF (Open)
Input Output
Travel Coolant Swing Bypass Cut Note
Engine rpm
Straight Temperature Cavitations S/V
< 500 - - - OFF
> 500 ON - - ON
> 500 OFF < 20° - OFF
> 500 OFF > 25° *1 ON OFF *2 OFF → ON
*1. If swing operation continues over 0.6 second and stops

*2. Turning off during 1 second and turning ON
• Swing Brake Release Solenoid Valve: ON (Release), OFF (Lock)
Input Output
*1.Swing Note
Boom Arm Bucket Swing Travel L Travel R Brake
Release S/V
ON - - - - - ON
- ON - - - - ON
- - ON - - - ON
- - - ON - - ON
OFF OFF OFF OFF OFF OFF OFF
OFF OFF OFF OFF OFF ON OFF
OFF OFF OFF OFF ON OFF OFF
OFF OFF OFF OFF ON ON OFF
*1. Swing Brake Release Solenoid Valve ON = Release/OFF = Lock

5-5-98
Sequence of Setting
1. Checking bypass solenoid valve
A. Set as neutral position of joystick
→ Bypass cut OFF: Check standby pump flow rate
(normal: less than 500 cc/sec)
Check reaction speed (normal: 500 ms ±15)
B. Set as neutral position of joystick
→ Bypass cut ON: Check maximum pump flow rate
(normal: over 4,000 cc/sec)
Check reaction speed (normal: 500 ms ±15)
2. Checking swing brake solenoid valve
A. Hold the condition of travel by one side
→ Swing brake will hold: Front must be held
B. Release the swing brake
→ Check the Initial position of front (changing)
C. Hold the swing brake
→ Check the Initial position of front (not changing)
Checking Solenoid Valve

Command
Controller Solenoid Valve

Pump ED
Regulator
Pump
EPPR Valve
(Pump)
RS232
DMS Solenoid Valve Swing Motor

(Swing Brake)
Figure 114
EX1400484

5-5-99
Pump 1 Proportional Pump 2 Proportional Cooling Fan Proportional
1 Monitoring
2 Graph Output
Forced Drive Pressure Relief Valve Straight Travel Proportional Engine Speed Command
Self Diagnosis
History Managem Application Application Application
Parameter
Application
Engine Injector Control
Application
EX1400485
Figure 115

5-5-100
Output Setting - Pump EPPR Valve
1. It is possible that an error occurred attempting to make
pump pressure from controller.
A. An error occurred mapping with current command of
controller and real current of current control.
B. An error occurred mapping with 2nd Pressure of ED
regulator and real pump pressure.
2. Because of above reason an error occurred between
pressure command of controller and real pump pressure.
An error in control range doesn't have any problems but
problem can be occurred in edge of control range (350 bar)
3. To make effect of error smaller, calibration of table can
work effective.
A. If an error occurred between real current and current
command, calibrate a table of current to current.
B. If an error occurred between ED regulator and real
pump pressure, calibrate a table of pressure
command to current.
Controller Solenoid Valve

Pump ED
Regulator
Pump
EPPR Valve
• Main Function Control (Pump)
EX1400491
Figure 116

5-5-101
Pressure Command An Error Real Pressure
Occurs!
Pump ED
Real Regulator
Pres
essure
Pressure Current Voltage
Command Command Command Current Pump
(bar) Pressure (mA) (V) (mA)
Convert to current
Pump Controller Command
Voltage control
to Current
EPPR Valve
(Pump)
Controller
Calibrate an Error Calibrate an Error an Error Occurred an Error Occurred

Pressure Command Current Command Between Between
> Real Pressure > Real Current Current Command Regulator Pi Pressure
> Real Current > Real Pressure
(Normal: ±10 mA) (Normal: ±50 mA)
Current Command vs Regulator Pi Pressure vs

Real Current Real Pressure
Real Pressure
(mA) (bar)
750 350 10 bar
20 mA
0 750 0 30
Current Command (mA) Pressure Command (bar)

EX1400492
Figure 117

5-5-102
4. Checking an error between real current from DAC and
current command from controller.
A. Checking an internal current command and a DA
output current command of controller.
1) Put the current command from 300 - 750 mA at
intervals of 100 mA by forced current command
in DMS.
2) Compare real current with current command by
monitoring.
Pump ED
Regulator
Pump
Pressure Current Real
Voltage Pilot Pressure
Command Command Command Current
Convert to Current
Voltage Control
to Current
EPPR Valve
(Pump)
Controller
EX1400493
Figure 118
Forced Drive
1 Basic
2 Digital I/O
4 VBO / Electron
Graph Output
Forced Drive
Self Diagnosis
History Managem
Parameter


5-5-103
2 Parameter Retouch
No. Name Current Value Corrected Value Unit Basic Value ROM Writing RAM Writing
Monitoring
Basic Value Application Application
1 Basic Basic Value Application Application
2 Digital I/O Basic Value Application Application
3 Analog I/O
4 VBO / Electron Basic Value Application Application
5 Engine Charac Application Application
Basic Value
Graph Output Basic Value Application Application
Forced Drive Basic Value Application Application
Self Diagnosis
History Managem Basic Value Application Application
Parameter Basic Value Application Application

5-5-104
5. Calibrate a table for DA converting as much as error of
current occurs.
A. Case of current error occurs
1) Error occurred over 25 mA
Hardware tuning required: An error range that
software tuning is not working.
2) Error occurred less 25 mA
Calibration of error required: Using parameter
change method to change DA converting table.
B. Internal current command → setting a table
converting DA output current command.
1) Converting table (8 point): Setting to make DA
output current equal to internal current
command.
2) Converting table = Standard value fixed in
specification + Offset (changing in parameter)
→ Refer to appendix
C. Control range of pump EPPR valve: 300 - 750 mA
→ Relevant point (300, 500, 700, 800) setting
Pump ED
Regulator
Pump
Real
Pressure Curr
rrent
Current Voltage Pilot Pressure
Command mmand
Comm
Command Command Current
Convert to Current
Voltage Control
to Current
EPPR Valve
(Pump)
Current to Voltage Current Command

Real Current vs Real Current
(V) (mA)
5 750
Calibrate a current to voltage

table if error occurred
between current output and
current command in current
control of controller.
0 750 (mA) 0 750
Current Command (mA)
Controller
EX1400496
Figure 121

5-5-105
6. Checking an error occurred between real pump pressure
and pressure command in controller.
A. Pressure command → Internal current command
1) Put the current command from 300 - 750 mA (in
control range) at intervals of 100 mA by Forced
current command in DMS.
2) Compare the pressure command with real
pump pressure by monitoring.
Compare Pressure Command and Real Pump Pressure
Real Pressure
(bar)
Pump ED
Regulator
Pump
Pressure Current Real
Voltage Pilot Pressure
Convert to Current
Voltage Control
to Current
EPPR Valve
(Pump)
Controller
EX1400502
Figure 122
Forced Drive
1 Basic
2 Digital I/O
4 VBO / Electron
Graph Output
Forced Drive
Self Diagnosis
History Managem
Parameter

Figure 123
EX1400503

5-5-106
2 Parameter Retouch
No. Name Current Value Corrected Value Unit Basic Value ROM Writing RAM Writing
Monitoring
1 Basic Basic Value Application Application
2 Digital I/O Basic Value Application Application
3 Analog I/O
4 VBO / Electron Basic Value Application Application
5 Engine Charac Application Application
Basic Value
Graph Output Basic Value Application Application
Forced Drive Basic Value Application Application
Self Diagnosis
History Managem Basic Value Application Application
Parameter Basic Value Application Application

5-5-107
7. Calibration by adding offset to pressure to current table as
much as error occurred in real pump pressure.
A. Case of pressure error occurs
1) Error occurred over 15 bar → Checking a pump
regulator required: an error range that software
tuning is not working.
2) Error occurred less 15 bar → Calibration of error
required: using parameter change method to
change pressure to current table.
B. Pressure command → Setting a table converting
internal current command.
1) Converting table (8 point): Setting to make
internal current command equal to pressure
command.
2) Converting table = Standard value fixed in
specification + Offset (changing in parameter)
→ Refer to appendix
C. Control range of pump EPPR valve: 45 - 370 bar
→ Relevant point (45, 100, 200, 250, 300, 350, 370)
setting.
Pump ED
Regulator
Pump
Real
Press
essure
Pressure Current Voltage Pilot Pressure
Convert to Current
Voltage Control
to Current
EPPR Valve
(Pump)
Pressure to Current Pressure Command

Real Pressure vs Real Pressure
(mA) (bar)
750 350
Calibrate a pressure to
current table if error occurred
between real pump pressure
and pressure command of
300 300 controller.
0 45 350 (bar) 0 45 350
Pressure Command (bar)

Controller EX1400505
Figure 125

5-5-108
mA bar (bar) P
0 0 400
300 45 350
381.1 100
300
528.7 200
250
602.5 250
676.2 300 200
750 350 150

790 370
100
50
0
200 300 400 500 600 700 800
(mA)

5-5-109
Etc. - Peak Pressure Reducing Valve
1. Decreasing a peak pressure involved in pressure control
pump.
2. Difference between the real pump pressure and pump ED
regulator is over delP → flow line is changed to tank:
decreasing a peak pressure.
3. Changing a cranking pressure (delP) by pump pressure
(refer to right graph)
A. PPPRV = 12.25 * Px + Offset 1
B. PPUMP = 12.75 * Px + Offset 2
C. delP = PPPRV - PPUMP
D. Calibrate Offset1 →delP will be changed
4. Cranking pressure high → difficult to control a peak
pressure cranking pressure low ⎯ hunting is occurred by
unintended operation of PPRV.
Main Control Valve
PPRV
Pump
Pump ED
Regulator
P PPRV
346 bar
(353 kg/cm 2 )
delP
P Pump
44 bar
(45 kg/cm 2 )
300 mA 750 mA
EX1400507
Figure 127

5-5-110
Sequence of Checking
1. Measuring real pump pressure and 2nd pressure of ED
regulator.
• 300 - 750 mA (in control range) at intervals of 100 mA
by Forced current command.
2. Holding 2nd pressure of ED regulator to PPRV
(for front PPRV)
A. Cross-connect pipe line for regulator of PPRV from
front to rear.
B. Put 300 mA to EPPR valve of rear pump by forced
current command.
3. Increasing a current to EPPR valve of front pump by forced
current command
• Checking an operation starting point of PPRV.
4. Calculating a cranking pressure (using 2nd pressure of
starting point and 2nd pressure measuring by Step 1.)
5. Repeating Step.2 - Step.4 (from 400 - 750 mA)
6. Calculating a cranking pressure of rear pump same as
above.
3
Forced Drive
1 Basic
2 Digital I/O
4 VBO / Electron
Graph Output
Forced Drive
Self Diagnosis
History Managem
Parameter

5-5-111
2
Original
Crossing
Front PPRV
Pump
ED
Front EPPR
Pump
ED Rear PPRV
Rear EPPR
EX1400509
Figure 129
3
3000 450
X1
400
30 X2 2500
Qa1 350
25 PPRV Starts Operation
Qa2 2000 300
20 P1
250
P2 1500
15 200
1000 150
10
100
500
5
50
0 0 0
10 20 30 40
EX1400351
Figure 130

5-5-112
P1 Differential
I Px 1 P1 Px 2 4 Idle
Relief Pressure 400
294 3.8 47 4 104 57 350
Pi Pump Pressure (kg/cm 2 )

395 8.7 108 8.7 165 57 300
P1 Relief
498 14.1 178 13.9 230 52 250
599 19.7 248 19.6 303 55 200
697 25.4 318 24.8 370 52 150
750 28.1 355 100
P1
50
0
0 50 10 15 20 25 30
PPRV Secondary Pressure (kg/cm 2 )

EX1400352
Figure 131
Calibration Method
1. Adjusting a PPRV pin (Using a calculated cranking
pressure) → Changing delP
2. PPRV pin is increasing/decreasing of 13 bar/cycle
(Increase: Clockwise, Decrease: Counterclockwise)
3. Monitoring a changed delP
(by DMS monitoring and Measuring system)
PPRV
Increase T1
M PHB
Decrease
Idle Idle
400 400
350 350
Pi Pump Pressure (bar)
Pi Pump Pressure (bar)
300 80 kg/cm2 300

P1 Relief P1 Relief 50 kg/cm2
250 250
200 200
150 150
P1 Del P is Decreasing P1
100 100
50 50
0 0
0 5 10 15 20 25 30 0 5 10 15 20 25 30
PPRV Secondary Pressure (kg/cm 2 ) PPRV Secondary Pressure (kg/cm 2 )

EX1400353
Figure 132

5-5-113
D-ECO POWER DIAGNOSTIC TOOLS OPERATION
Program Start
Click the "DMS-3.exe" file.
Click [Tools - D-Eco Power Diagnostic Tools] or press F4 for the D-Eco Power system diagnosis.
File View Connect Settings Tools Window Help

Download Program
Download Program Map for WheelLoader
Monitoring Login as Professional

D-Eco power Diagnostic tools F4
Graph Output Password Initialization
Force Operation
Diagnosis
History Data
Parameter

5-5-114
D-Eco Power Diagnostic Tools Main Screen
D-Eco Power Diagnosis
Help
Vehicle Number
1. Joystick 2. Swash Plate 3. EPPR Valve 4. Main Pump 5. Relief

Check Angle Check Check Pressure Check Pressure Check
Open Save Close
Contents and Function

1. Joystick check
• Check the pressure depending on joystick operation.
• Boom up, boom down, arm in, arm out, bucket crowd,
bucket dump, travel right, travel left, swing pressure
2. Angle check
• Swash plate angle check
• Front pump angle volt, rear pump angle volt
3. EPPR valve check
• EPPR valve check
• Power shift P/V 1, power shift P/V 2
4. Main pressure check
• Main pump pressure check
• Front pump pressure, rear pump pressure
5. Relief pressure check
• Relief pressure check
• Front pump pressure, rear pump pressure

5-5-115
D-Eco Power Diagnostic Check List
Joystick Check
Contents Reference Green Red

↓
Max. 30 bar (31 kg/cm ) 2 Reference ↓ Reference
↓
Min. 5 bar (5 kg/cm )
2 Reference ↓ Reference
Rising Time ↓
0.5 sec Reference ↓ Reference
(Min to Max.)
Falling Time ↓
0.5 sec Reference ↓ Reference
(Max to Min.)
Angle Check
Criteria Green Yellow Red

+20 mV
Max. (4,450 mV) ±10 mV > Yellow
-120 mV
+100 mV
Min. (600 mV) ±10 mV > Yellow
-140 mV
Rising Time
↓
(current (400 mA) 1.2 sec Reference ↓ Reference
to 4 V)
EPPR Valve Check
Reference Green Yellow Red

↓
100 ±5 mA ↓ ±25 mA ↓ ±25 mA
↓
200 ±5 mA ↓ ±25 mA ↓ ±25 mA
↓
300 ±3 mA ↓ ±20 mA ↓ ±20 mA
↓
500 ±3 mA ↓ ±20 mA ↓ ±20 mA
↓
700 ±3 mA ↓ ±20 mA ↓ ±20 mA
↓
800 ±5 mA ↓ ±25 mA ↓ ±25 mA
↓
850 ±5 mA ↓ ±25 mA ↓ ±25 mA
Main Pressure Check
Command Reference (kg/cm2)

(kg/cm2) Green Yellow Red
46 ±26
102 ±25
204 ±23
±3 > Yellow
255 ±22
306 ±21
357 ±20

5-5-116
D-ECO POWER DIAGNOSTIC TOOLS CHECK
Joystick Check
Joystick Check Screen Description
Joystick Check
1
Boom Up Pressure [F1] Boom Down Pressure [F2] Arm In Pressure [F3] Arm Out Pressure [F4]
Bucket Crowd Pressure [F5] Bucket Dump Pressure [F6] Travel Right Pressure [F7] Travel Left Pressure [F8]
Swing Pressure [F9] Arti Boom Up Pressure [F10] Arti Boom Down Pressure [F11]
1. Joystick
Check
Item Referance Data Measured Data Rem
Open Help
Engine RPM: Alternator Voltage: Hydraulic Oil Temp: Prev Next Close
3
No Name Function
1 Test Contents • Select the Joystick Operation Test
• The Graph Displays Real-time Operation
2 Graph
• Tests are Marked with Different Colors
• Display the Engine rpm, Battery Voltage, Hydraulic
3 Status Before the Test
Temp
• Status of the Results of the Operation
- Minimum Pressure, Maximum Pressure
4 Status and Results of Tests
- Up Time, Down Time.
- Coloring for Pass/Fail
Test Result
Contents Reference Green Red

↓
Max. 30 bar (31 kg/cm2) Reference ↓ Reference
↓
Min. 5 bar (5 kg/cm2) Reference ↓ Reference
↓
Up Time 0.5 sec Reference ↓ Reference
↓
Down Time 0.5 sec Reference ↓ Reference

5-5-117
Settings Before the Joystick Check Test
Settings Before the Test Pop-up creation if doesn't check the engine rpm, safety lever
1800
Over engine RPM 180 0 Engine RPM 1850
(Auto idle OFF)
OK
Put the safety lever up

(Bypass cut S/V OFF) Pop-up creation if the engine rpm is low
Read the current 1800

fault information,
check the pressure OK
sensor failure
Maintain the battery Battery Voltage:

Pop-up creation if doesn't check the safety lever
28.1
voltage is 27 V or more
Maintain the oil

temperature is Hydraulic Oil Temp.: 41
20 degrees or more OK
EX1400593
Figure 136

5-5-118
The Progress of the Joystick Check Test
Boom Up Pressure [F1]

1. Step 1 - Select the test
Click "Boom Up Pressure [F1]" or press F1
2. Step 2 - Tests performed actions
Joystick Lever Boom Up Quickly

Boom Down
Waiting One Second Return to Neutral
Boom Up
Joystick Lever EX1400594

Figure 137
3. Step 3 - Display test results and status
Joystick Check Display the Test Progress
Pressure (bar)
Criteria
Boom Up Pressure Minimum pressure: 5 bar ), maximum pressure: 30 bar
Quick operation (0.5 sec ), operating : 0 - 30 bar
Display the Status Test Results
Time (sec) Open Help

Boom Up Pressure
Boom Up Pressure Bucket Crowd Pressure

Boom Down Pressure Bucket Dump Pressure
Arm In Pressure Travel Right Pressure
Arm Out Pressure Travel Left Pressure
Swing Pressure Arti Boom Up Pressure Shown in Red on Fail
Arti Boom Down Pressure

EX1400595
Figure 138
4. Step 4 - Move the test menu

Click on "Close" at the end of the joystick check → Go to the D-Eco Power Diagnostic Tools Main Screen
To check the next test (Swash Plate Angle Check), click "Next" → Move to Swash Plate Angle Check
5. Etc.
A. Results unit indicates until second decimal point.
B. Sampling time is less than the 20 ms.
C. Test result data subsequently can use the TMS server transfer function.

5-5-119
Boom Down Pressure [F2]
Click "Boom Down Pressure [F2]" or press F2
Joystick Lever Boom Down Quickly
Boom Down
Boom Up
Return to neutral after waiting one second after
Joystick Lever joystick lever boom down quickly.
EX1400596
Figure 139
Pressure (bar)
Criteria
Minimum pressure: 5 bar ), maximum pressure: 30 bar




5-5-120
Arm in Pressure [F3]
Click "Arm in Pressure [F3]" or press F3
Joystick Lever Arm In Quickly

Arm Out
Arm In
Joystick Lever EX1400598

Figure 141
Pressure (bar)
Criteria




5-5-121
Arm Out Pressure [F4]
Click "Arm Out Pressure [F4]" or press F4
Joystick Lever Arm Out Quickly

Arm Out
Arm In
Joystick Lever
EX1400600
Figure 143
Pressure (bar)
Criteria




5-5-122
Bucket Crowd Pressure [F5]
Click "Bucket Crowd Pressure [F5]" or press F5
Joystick Lever Bucket Crowd Quickly

Bucket
Dump
Bucket
Crowd
Joystick Lever
EX1400607
Figure 145
Pressure (bar)
Criteria
Bucket Crowd Pressure
Bucket Crowd Pressure




5-5-123
Bucket Dump Pressure [F6]
Click "Bucket Dump Pressure [F6]" or press F6
Joystick Lever Bucket Dump Quickly

Bucket
Dump
Bucket
Crowd
Joystick Lever
EX1400609
Figure 147
Pressure (bar)
Criteria




5-5-124
Travel Right Pressure [F7]
Click "Travel Right Pressure [F7]" or press F7
Travel Left Travel Right

Operate Travel Lever (Pedal)
Travel Right Quickly
Travel Lever (Pedal)

EX1400611
Figure 149
Pressure (bar)
Criteria
Travel Right Pressure
Travel Right Pressure




5-5-125
Travel Left Pressure [F8]
Click "Travel Left Pressure [F8]" or press F8

Operate Travel Lever (Pedal)
Travel Left Quickly
Travel Lever (Pedal)

EX1400613
Figure 151
Pressure (bar)
Criteria
Travel Left Pressure
Travel Left Pressure




5-5-126
Swing Pressure [F9]
Click "Swing Pressure [F9]" or press F9
Joystick Lever Swing Quickly

Swing
Joystick Lever
EX1400615
Figure 153
Pressure (bar)
Criteria
Swing Pressure
Swing Pressure




5-5-127
Arti Boom Up Pressure [F10]
Click "Arti Boom Up Pressure [F10]" or press F10
Articulated
Boom Down Joystick Lever (Pedal)
Articulated Boom Up Quickly

Articulated
Boom Up
EX1400617
Figure 155
Pressure (bar)
Criteria




5-5-128
Arti Boom Down Pressure [F11]
Click "Arti Boom Down Pressure [F11]" or press F11
Articulated
Boom Down Joystick Lever (Pedal)
Articulated Boom Down Quickly

Articulated
Boom Up
EX1400619
Figure 157
Pressure (bar)
Criteria




5-5-129
Angle Check
Swash Plate Angle Check Screen Description
Swash Plate Angle Check
1
Front pump Angle volt [F1] Rear pump Angle volt [F2]
2. Swash Plate
Angle Check
Item Referance D Measured Data Save value
Help
Engine RPM: Alternator Voltage: Hydraulic Oil Temp:

3 Prev Next Close
No Name Function
1 Test Contents • Select the Angle Check Test
2 Graph
Temp
• Status of the Results of the Operation
- Minimum Pressure, Maximum Pressure
4 Status and Results of Tests - Up Time, Down Time.
- Coloring for Pass/Fail
• Shown in Red on Fail
Results
Min, Max Value (Refer Value), Conversion Time (Refer Time)
Criteria Green Yellow Red

Max +20 mV
±10 mV > Yellow
(4450 mV) -120 mV
Min +100 mV
±10 mV > Yellow
(600 mV) -140 mV

5-5-130
Settings Before the Angle Check Test
Pop-up creation if doesn't check the engine rpm, safety lever and
alternator voltage.
Settings Before the Test
OK
Joystick lever neutral
Pop-up creation if the engine rpm is low

Under engine rpm 1000 Engine RPM 800
(Auto idle OFF)
OK
voltage is 27 V or more 28.1
Pop -up creation if doesn't check the safety lever
Maintain the oil temperature Hydraulic Oil Temp.: 41

is 20 degrees or more
OK
Put the safety lever down
(Bypass cut S/V ON)
Pop-up creation if doesn't check the alternator voltage.
OK
EX1400622
Figure 160

5-5-131
The Progress of the Angle Check Test
Front Pump Angle Volt [F1]

Click "Front Pump Angle Volt [F1]" or press F1
5000
D-Eco power diagnostic program will automatically run the 4500
front pump angle volt

4000
3500
3000
Voltage (mV)
2500
2000
1500
1000
500
-500
0 5 10 15 20
Time (sec)
Swash Plate Angle Check Display the Test Progress
Front pump Angle volt Criteria

Min voltage: 0.43 - 0.7 V, max voltage: 4.33 - 4.47 V
Transition time (1.2sec, forced current (400 mA) -> 4.0 V))

Help Apply
Front pump Angle volt
Boom Up Pressure
Boom Down Pressure
Results
Min, max value (refer value), conversion time (refer time)
Criteria Green Y ellow Red
M ax +20 mV
(4450 mV) ±10 mV > Yellow
- 120 mV
M in +100 mV
- 140 mV

Click on "Close" at the end of the angle check → Go to the D-Eco Power Diagnostic Tools Main Screen
To check the next test (EPPR V/V Check), click "Next" → Move to EPPR V/V Check

5-5-132
Rear Pump Angle Volt [F2]
Click "Rear Pump Angle volt [F2]" or press F2
5000
4000
rear pump angle volt 3500
3000
Voltage (mV)
2500
2000
1500
1000
500
-500
0 5 10 15 20
Time (sec)
Swash Plate Angle Check Display the Test Progress
Rear pump Angle volt Criteria

Min voltage: 0.43 - 0.7 V, max voltage: 4.33 - 4.47 V
Transition time (1.2 sec, forced current (400 mA) -> 4.0 V))

Help Apply
Rear pump Angle volt
Boom Up Pressure
Boom Down Pressure
Results
Min, max value (refer value), conversion time (refer time)
Criteria Green Y ellow Red
M ax +20 mV
- 120 mV
M in +100 mV
- 140 mV

Click on "Close" at the end of the angle check → Go to the D-Eco Power Diagnostic Tools Main Screen
To check the next test (EPPR V/V Check), click "Next" → Move to EPPR V/V Check

5-5-133
EPPR V/V Check
EPPR V/V Check Screen Description
EPPR V/V Check
1
Power Shift P/V 1 [F1] Power Shift P/V 2 [F2]
3. EPPR V/V
Check
k Power Shift P/V 1
Command Output Relative Error Apply
Open Help
Engine RPM: Hydraulic Oil Temp:

3 Alternator Voltage: Prev Next Close
No Name Function
1 Test Contents • Select the EPPR V/V Check Test
2 Graph
Temp
Temp
- Display to command, output, error for each command
• Status
Status

↓
100 ±5 mA ↓ ±25 mA ↓ ±25 mA
↓
200 ±5 mA ↓ ±25 mA ↓ ±25 mA
↓
300 ±3 mA ↓ ±20 mA ↓ ±20 mA
↓
500 ±3 mA ↓ ±20 mA ↓ ±20 mA
↓
700 ±3 mA ↓ ±20 mA ↓ ±20 mA
↓
800 ±5 mA ↓ ±25 mA ↓ ±25 mA
↓
850 ±5 mA ↓ ±25 mA ↓ ±25 mA

5-5-134
Settings Before the EPPR V/V Check Test

OK
Over engine rpm 1800 Engine RPM 1850

(Start-up is ON) Pop-up creation if doesn't check the safety lever

voltage is 27 V or more 28.1
OK
Maintain the oil temperature Hydraulic Oil Temp.: 41

is 20 degrees or more
Put the safety lever down

(Bypass cut S/V ON)
EX1400627
Figure 166

5-5-135
The Progress of the EPPR V/V Check Test
Power Shift P/V 1 [F1]

Click "Power Shift P/V 1 [F1]" or press F1
2. Step 2 - Tests performed actions 1000
900
EPPR valve check 700
Current (mV)
600
500
400
300
200
100
0 5 10 15 20 25 30
Time (sec)
EX1400628
Figure 167
EPPR V/V Check Display the Test Progress
Power Shift P/V 1

Open Help apply
Power Shift P/V 1

Power Shift P/V 2
Force Operation Command
Results
Display to command, output, error for each command
Status
100 ± 5 mA ˨ ± 25 mA ˨ ± 25 mA ˦
200 ± 5 mA ˨ ± 25 mA ˨ ± 25 mA ˦
300 ± 3 mA ˨ ± 20 mA ˨ ± 20 mA ˦
500 ± 3 mA ˨ ± 20 mA ˨ ± 20 mA ˦
700 ± 3 mA ˨ ± 20 mA ˨ ± 20 mA ˦
800 ± 5 mA ˨ ± 25 mA ˨ ± 25 mA ˦
850 ± 5 mA ˨ ± 25 mA ˨ ± 25 mA ˦

5-5-136
4. Step 4 - Apply modified value
If you want to have to retake the modified values, click "apply"
Retest
YES NO YES NO
5. Step 5 - Retest results

Retested with the modified value (the test results confirmed changes)
Before Retest After Retest
Apply Modified
Value

Click on "Close" at the end of the EPPR v/v check → Go to the D-Eco Power Diagnostic Tools Main Screen
To check the next test (Main Pump Check), click "Next" → Move to Main Pump Check

5-5-137
Power Shift P/V 2 [F2]
Click "Power Shift P/V 2 [F2]" or press F2
900
EPPR valve check 700
600
Current (mV)
500
400
300
200
100
0 5 10 15 20 25 30
Time (sec)
EX1400632
Figure 171
EPPR V/V Check Display the Test Progress
Power Shift P/V2

Open Help apply
Power Shift P/V 1

Power Shift P/V 2
Force Operation Command
Results
Status
100 ± 5 mA ˨ ± 25 mA ˨ ± 25 mA ˦
200 ± 5 mA ˨ ± 25 mA ˨ ± 25 mA ˦
300 ± 3 mA ˨ ± 20 mA ˨ ± 20 mA ˦
500 ± 3 mA ˨ ± 20 mA ˨ ± 20 mA ˦
700 ± 3 mA ˨ ± 20 mA ˨ ± 20 mA ˦
800 ± 5 mA ˨ ± 25 mA ˨ ± 25 mA ˦
850 ± 5 mA ˨ ± 25 mA ˨ ± 25 mA ˦

5-5-138
Retest
YES NO YES NO
5. Step 5 - Retest results

Retested with the modified value (the test results confirmed changes)
Before Retest After Retest
Apply Modified
Value

Click on "Close" at the end of the EPPR v/v check → Go to the D-Eco Power Diagnostic Tools Main Screen
To check the next test (Main Pump Check), click "Next" → Move to Main Pump Check

5-5-139
Main Pump Check
Main Pump Pressure Check Screen Description
Main Pump Check
1
Front Pump Pressure [F1] Rear Pump Pressure [F2]
4. Main Pump
Pressure Check
Front Pump pressure
Open Help
3 Engine RPM: Alternator Voltage: Hydraulic Oil Temp: Prev Next Close
No Name Function
2 Graph
Temp
Temp
- Display to command, output, error for each command
• Status
1. Hyd. Temp: Pump pressure decreases by raising the temperature → A reference temperature set to 40°C.
2. Correction of error: Yellow (Complex tolerance of the vehicle. Set up to by each single pump tolerance)
Status

46 ±26
102 ±25
204 ±23
±3 > Yellow
255 ±22
306 ±21
357 ±20

5-5-140
Settings Before the Main Pump Pressure Check Test

OK
Over engine rpm 1800 Engine RPM:

1850
(Auto idle OFF) Pop-up creation if the engine rpm is low
Maintain the oil temperature Hydraulic Oil Temp:

41
is 40 degrees or more OK
Check Before the Test
Bypass Cut Valve Check

Solenoid Valve
Pump Pressure Sensor Check

Pressure Sensor
EX1400636
Figure 176

5-5-141
The Progress of the Main Pump Pressure Check
Front Pump Pressure [F1]

Click "Front Pump Pressure [F1]" or press F1
350
main pressure check 250
Pressure (bar)
200
150
100
50
-50
0 5 10 15 20 25 30
Time (sec)
EX1400637
Figure 177
Main Pump Check Display the Test Progress
Front Pump pressure

Open Help Apply
Front Pump Pressure

Rear Pump Pressure
Force Operation Command Results
Status

46 ±26
102 ±25
204 ±23
±3 > Yellow
255 ±22
306 ±21
357 ±20

5-5-142
Retest
YES NO YES NO
• Correction of error: Yellow (Complex tolerance of the vehicle. Set up to by each single pump tolerance)
Click on "Close" at the end of the main pump pressure check
→ Go to the D-Eco Power Diagnostic Tools Main Screen
To check the next test (Relief Pressure Check), click "Next"
→ Move to Relief Pressure Check

5-5-143
Rear Pump Pressure [F2]
Click "Rear Pump Pressure [F2]" or press F2
350
main pressure check 250
Pressure (bar)
200
150
100
50
-50
0 5 10 15 20 25 30
Time (sec)
EX1400637
Figure 180
Main Pump Check Display the Test Progress
Open Help Apply
Front Pump Pressure

Rear Pump Pressure
Force Operation Command Results
Status

46 ±26
102 ±25
204 ±23
±3 > Yellow
255 ±22
306 ±21
357 ±20

5-5-144
Retest
YES NO YES NO
• Correction of error: Yellow (Complex tolerance of the vehicle. Set up to by each single pump tolerance)
Click on "Close" at the end of the main pump pressure check
→ Go to the D-Eco Power Diagnostic Tools Main Screen
To check the next test (Relief Pressure Check), click "Next"
→ Move to Relief Pressure Check

5-5-145
Relief Pressure Check
Relief Pressure Check Screen Description
Relief Pressure Check
1
5. Relief
Pressure Checkk
Item Results Remarks
Open Help
3
No Name Function
2 Graph
Temp
• Status of the Test Operation
4 Status and Results of Tests - Reference 357 kg/cm2 (350 bar) Swash Plate Tilting
Angle, Leakage and Relief Pressure

5-5-146
Settings Before the Main Pump Pressure Check Test

OK
Over engine rpm 1800 Engine RPM:

1850
(Auto idle OFF) Pop-up creation if the engine rpm is low
Maintain the oil temperature Hydraulic Oil Temp:

41
is 40 degrees or more OK
Check Before the Test
Bypass Cut Valve Check

Solenoid Valve
Pump Pressure Sensor Check

Pressure Sensor
EX1400636
Figure 184

5-5-147
The Progress of the Main Pump Pressure Check Test
Front Pump Pressure [F1]

Click "Front Pump Pressure [F1]" or press F1
2. Step 2 - Tests performed actions 5000 500
4500 450
D-Eco power diagnostic program will automatically run the 4000 400
350
relief pressure check 3500
300
Pressure (bar)
Voltage (mV)
3000
250
2500
200
2000
150
1500
100
1000
50
500 0
0 -50
0 5 10 15 20 25 30
Time (sec)
EX1400641
Figure 185
Relief Pressure Check Display the Test Progress
Pressure Reference: Front Pump pressure
Pressure Reference: Front Pump pressure

Open Help
Front Pump Pressure

Rear Pump Pressure
Front Pump Swash-plate Angle Voltage Results
Reference 357 kg/cm2 (350 bar) Swash Plate Tilting Angle,
Rear Pump Swash-plate Angle Voltage Leakage and Relief Pressure
EX1400642
Figure 186

Click on "Close" at the end of the relief pressure check → Go to the D-Eco Power Diagnostic Tools Main Screen

5-5-148
Rear Pump Pressure [F2]
Click "Rear Pump Pressure [F2]" or press F2
2. Step 2 - Tests performed actions 5000 500
D-Eco power diagnostic program will automatically run the

4500 450
4000 400
relief pressure check 3500

350
300
3000
Pressure (bar)
Voltage (mV)
250
2500
200
2000
150
1500
100
1000
50
500
0
0 -50
40 42 44 46 48 50 52 54
Time (sec)
EX1400643
Figure 187
Relief Pressure Check Display the Test Progress
Pressure Reference: Rear Pump pressure

Open Help
Pressure Reference: Rear Pump pressure
Front Pump Pressure

Rear Pump Pressure
Front Pump Swash-plate Angle Voltage
Rear Pump Swash-plate Angle Voltage Results
Reference 357 kg/cm2 (350 bar) Swash Plate Tilting Angle,
Leakage and Relief Pressure

Click on "Close" at the end of the relief pressure check → Go to the D-Eco Power Diagnostic Tools Main Screen

5-5-149
5-5-150
Drive Coupling
(Main Pump)
Edition 1
DX340LC-5/DX350LC-5 Drive Coupling (Main Pump)

5-6-1
MEMO
Drive Coupling (Main Pump) DX340LC-5/DX350LC-5

5-6-2
Table of Contents
Drive Coupling (Main Pump)

General ...........................................................5-6-5
Specification .............................................................. 5-6-5
Parts List ................................................................... 5-6-6
Section View ...................................................5-6-8
Tools.......................................................................... 5-6-9
Disassembly .................................................5-6-10
Reassembly ..................................................5-6-10

5-6-3
5-6-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specification
Condition in Use
Operation rpm Range 800 - 1,800 rpm
Max. Torque 1,765 Nm/1,300 rpm
Max. Output 283 kW/1,800 rpm
Specification
Nominal Torque 3,432 N.m (350 kg.m, 2,531 psi)
Max. Torque 4,903 N.m (500 kg.m, 3,616 psi)
Alternating Torque ±1,471 N.m (±150 kg.m, ±1,084 psi)
Max. Speed 3,600 rpm
Radial 0.4 mm (0.015 in)
Max. Permissible Displacements Angular 0.5°
Axial ±2 mm (±0.08 in)
Dynamic Torsion Spring Stiffness Cdyn 1.79 x 106 kg.cm/Rad
Mass Moment of Inertia 8.46 kg.cm. S2
Allowable Environment Temperature -40 - +120 °C

5-6-5
Parts List
FR
ON
T
4
2
ENGINE
5
1 6
EX1400098
Figure 1
Reference Reference
Number Number
1 Hub 4 Insert
2 Clamping Bolt 5 Element
3 Socket Bolt 6 Flange

5-6-6
5-6-7
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.
I
H
10
5
3
11
EX1400102
Figure 2 Drive Coupling Installation

5-6-8
Reference
Description Qty. Torque
Number
1 Flange 1
2 Hub 1
3 Element 1
4 Clamping Screw 2 196.1 - 215.7 N.m (20 - 22 kg.m, 144.7 - 159.1 ft lb)
5 Spring Pin 8
6 Insert 4
7 Bolt 4 431.2 - 480.5 N.m (44 - 49 kg.m, 318.3 - 354.4 ft lb)
8 Socket Bolt 8 49 N.m (5 kg.m, 36.2 ft lb)
9 Retaining Ring 1
10 Pump Shaft 1
11 Flywheel 1
Symbol Dimension Remarks

40 mm
H Distance between from Pump Shaft to Coupling Hub
(1.57 in)
49 mm
I Distance between from Pump Shaft to Coupling Flange
(1.93 in)
Tools
Name Description
Allen Wrench 8 mm, 10 mm, 17 mm
Plastic Hammer One Plastic Hammer
Pliers One for Shaft and Hole Each

5-6-9
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 (1, Figure 3) (4

ea) and remove insert (2) (4 ea). 3
2
• : 17 mm
1
2. Remove clamp screw (3, Figure 3) (2 ea) and remove hub
(4). 4
• : 10 mm
Figure 3 EX1400107
3. Remove socket bolts (2, Figure 4) (8 ea) and remove

flange (1) and element (3).
• : 8 mm
NOTE: Be careful not to lose the location socket bolt (2,

Figure 4).
Figure 4
REASSEMBLY
1. Install flange (1, Figure 5) with socket bolts (2) (8 ea) to
engine flywheel.
• : 8 mm
• Torque: 49 N.m (5 kg.m, 36.2 ft lb)

NOTE: Careful assembling the bushing (3, Figure 5)
(8 ea).
Figure 5

5-6-10
2. Assemble the insert (2, Figure 6) (4 ea) with socket bolts
(3) (4 ea) to hub (attached by spring pin).
• Torque: 431.2 - 480.5 Nm
(44 - 49 kg.m, 318.3 - 354.4 ft lb)
Figure 6
3. Slide hub into place on pump shaft (1, Figure 7) until

retaining ring (2) in the hub touches the pump shaft (1) and
secure it in position with clamping bolts (3). 3
• Torque: 196.1 - 215.7 Nm

(20 - 22 kg.m, 144.7 - 159.1 ft lb) 2
NOTE: Coat clamping bolts (3, Figure 7) with Loctite
#262. 1
NOTE: Refer to “Dimension” on page -5-6-9 of "H", "I".
Figure 7 EX1400108
4. Install element (2, Figure 8) on the flange (1) on engine

flywheel.
5. Install main pump and hub (3, Figure 8) by pushing it softly
into element (2).
IMPORTANT
1. Bolts are coated against loosening with a
bonding compound. Do not use any additional
bonding compounds, oils or cleaning solvents on Figure 8
them.
2. Element (2, Figure 8) is not resistant to bonding
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 0.5 mm (0.019 in).

5-6-11
5-6-12
Main Control
Valve
Edition 1
DX340LC-5/DX350LC-5 Main Control Valve

5-7-1
MEMO
Main Control Valve DX340LC-5/DX350LC-5

5-7-2
Table of Contents
Main Control Valve

General ...........................................................5-7-5
Specification .............................................................. 5-7-5
Overview ................................................................... 5-7-6
Parts List ................................................................. 5-7-10
Removal .......................................................5-7-54
Installation ....................................................5-7-62
Completing Work ..........................................5-7-62
Disassembly .................................................5-7-63
General Repair Instructions..................................... 5-7-63
Repair Instructions .................................................. 5-7-64
Reassembly ..................................................5-7-83
Maintenance and Repair ......................................... 5-7-90
Troubleshooting, Testing and Adjustment............... 5-7-96
Start-up Procedures .....................................5-7-99
Commissioning........................................................ 5-7-99

5-7-3
5-7-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
The two-circuit positive control block is an enhancement of the
standard OC control, with improved functionality and reduced
energy consumption. With the PC principle, the pumps receive
the highest pilot pressure signal from the remote control valves
by a hydraulic logic; they then prepare the oil flow for the system
according to the pump characteristics. The hydraulically
controlled PC system is made up of the double pump, the mono
block with seven main axis and a shuttle valve block. With the
PC control block design, the remote control signals are
connected to the control pistons by the shuttle valve block. The
shuttle valve chain is also used to control pumps P1 and P2 and
to control other functions including summation, straight travel
etc.
Specification
Type Pilot Control
Spool Diameter ø 32 mm
Spool Arrangement Option, Bucket, Boom, Travel (L), Travel (R), Swing, Arm
Relief Valve Pressure 387.5 kg/cm2 (380 bar, 5,512 psi)
Port Relief Valve Pressure 387.5 kg/cm2 (380 bar, 5,512 psi)
Accessory Valve Boom and Arm Holding Valve
Weight 209 kg (461 Ib)

5-7-5
Overview
Throttle Check Valve
A1
Load Holding Valve A2
A3 B1
Throttle Check Valve A4 B2
Main Relief Valve
B3
A5
Load Check Valve
A6
B4
A7 B5
B6
B7 b1
b2
b3 PC1
BB
b4
L3
b5
b6
b7
Pi P1 P2
Y
K L1
T
Main Relief Vlave
S
L2
a1
a2
a3
AB
a4
a5 PC2
a6
a7
EX1400384
Figure 1

5-7-6
Port Name Size
P1 Drive Pump (1) High-pressure Port
P2 Idle Pump (2) High-pressure Port
B1 Arm Cylinder Tube Side Port
SAE 1 1/4, 6,000 psi
B5 Boom Cylinder Tube Port
T Return Port (to Tank)
K Return Port (to Oil Cooler)
A1 Arm Cylinder Rod Side Port
A2 Swing Motor Right Port
A3 Travel Forward (RH)
A4 Travel Forward (LH)
A5 Boom Cylinder Rod Side Port
A6 Bucket Cylinder Rod Side Port
SAE 1, 6,000 psi
A7 Two-way Option (LH) Port
B2 Swing Motor Left Port
B3 Travel Backward (RH)
B4 Travel Backward (LH)
B6 Bucket Cylinder Tube Port
B7 Two-way Option (RH) Port
L2 Drain Port (Arm)
L3 Drain Port (Boom)
PF 1/4
PC1 Bypass Cut Valve Port
PC2 Bypass Cut Valve Port

5-7-7
Port Name Size
AB Arm Summation Valve Port
BB Boom Summation Valve Port
a1 Arm Dump Pilot Port
a2 Swing Right Pilot Port
a3 Travel Forward Pilot Port (RH)
a4 Travel Forward Pilot Port (LH)
a5 Boom Down Pilot Port
a6 Bucket Dump Pilot Port
a7 Two-way Pilot (LH) Port
b1 Arm Crowd Pilot Port 9/16-18UNF
b2 Swing Left Pilot Port
b3 Travel Backward Pilot Port (RH)
b4 Travel Backward Pilot Port (LH)
b5 Boom Up Pilot Port
b6 Bucket Crowd Pilot Port
b7 Two-way Pilot (RH) Port
Pi Travel Straight Pilot Port (Backward)
L1 Drain Port (to Tank)
Y Drain Port (to Tank)
S Return Port 1 1/16-12UNF

5-7-8
Hydraulic Circuit
Bucket Boom Travel (L) Travel (R) Swing Arm
1 2 3
B7 A7 b7 B6 A6 b6 B5 A5 L3 b5 B4 A4 b4 AB pc2 b3 B3 A3 b2 B2 A2 b1 B1 A1
7 S13 8
NG26
PC14
ø0.6 ø2.5
NG25
PC21 S12
PC11 16
PC25
Boom Travel (L) Travel (R) Swing Arm

NG24
NG13
Option Bucket
S7 S6 S5 S4 9 NG14 10 S11 S3 S2 S1
14 15
S14
NG23 4 NG22 5 NG21 NG11 NG12 S18 6
NG20
NG15
NG10
ø0.8
PC24 380 ±5 bar PC23 380 ±5 bar PC22 PC21 PC13 PC12 13 380 ±5 bar
ø2.3
ø0.8
a7 a6 a5 a4 pc1 BB a3 a2 L2 a1
S10
380 ±5 bar
11
12
PR1 PR1
1 bar
3 bar
PR2
T Pi P2 L1P1 Y K S
EX1400409
Figure 2
Reference Reference
Number Number
1 Bucket Cylinder 10 Boom Summation Valve
2 Boom Cylinder 11 Travel Straight Valve
3 Arm Cylinder 12 Main Relief Valve
4 Bucket Relief Valve 13 Arm Brake Valve
5 Boom Relief Valve 14, 15 Holding Valves
6 Arm Relief Valve 16 Arm Regeneration Valve
7 Arm Summation Valve 17 Boom Regeneration Valve
8, 9 Bypass Cut Valves S1 - S7 Main Spools

5-7-9
Parts List
Control Block
120
221
113
220 222
221 222A 202
111 202A
136
202
161 202A
202 372
202A 130 210
210A
133
133 158
132 130
210 156
210A 150 158
152 160 175
130133 156
151
140 159 150
372 160
202
202A 100 133 170 159
163
135
141 158
237
236 a7 160
235 159
a6 187
156 186
151
152 a5 180
150
150 a4 152 189
156 151 182 159
171 A7
AB 167
158 b7 A6
B7 a3 PC2 158
150 b6 A5 160
B6 a2 159
156 b5 A4
234
233 B5
a1 156
159 b4
160 232
B4 150
BB A3 152
151 199
158 176 159 151 b3 A2
152 B3 197
160 A1 195
181 PC1 b2
B2
196
150
156 b1
158 186 B1
190
180
231
187 159
163 159 189
160
158
151
152
168 159 150
156
160 EX1301148
Figure 3

5-7-10
Reference Reference
Number Number
100 Valve Housing 181 Bypass Cut Spool
111 O-ring 182 Bypass Cut Spool
113 Plate 186 Cover
120 Socket Bolt 187 Socket Bolt
130 Plug 189 Hex Socket Bolt
132 Plug 190 Spool
133 O-ring 195 O-ring
135 Check Valve 196 O-ring
136 Check Valve 197 Cover
140 Check Valve 199 Socket Bolt
141 Check Valve 202 Anti Cavi Relief Valve
150 O-ring 202A Relief Valve Seal Kit
151 Spring Retainer 210 Pilot Control Valve
152 Pressure Spring 210A Seal Kit
156 Cover 220 Block Plate Assembly
158 Socket Bolt 221 Socket Bolt
159 Usit Ring 222 Main Relief Valve
160 Hex Socket Bolt 222A Seal Kit
161 Throttle Check Valve 231 Arm Spool
163 Throttle Check Valve 232 Swing Spool
167 Orifice 233 Travel Spool
168 Orifice 234 Travel Spool
170 Arm Summation Spool 235 Boom Spool
171 Boom Summation Spool 236 Bucket Spool
175 Orifice 237 Option Spool
176 Orifice 372 O-ring
180 O-ring * Seal Kit

5-7-11
Plate
MA = 330 Nm
13
20 12
11
21
5
10
42A
42
MA = 120 Nm
31
25
26
27
15 32
32
MA = 165 Nm 30
9
MA = 200 Nm
25
31
26
27
32
EX1301149
Figure 4
Reference Reference
Number Number
5 Valve Housing 25 Load Check Poppet
9 Plug 26 Pressure Spring
10 Straight Travel Spool 27 Check Valve
11 Spring Retainer 30 O-ring
12 Pressure Spring 31 O-ring
13 Plug Screw 32 Seal
15 Plug 42 Check Valve
20 Road Check Valve (1 Bar) 42A O-ring
21 Road Check Valve (3 Bar) * Seal Kit

5-7-12
Theory of Operation
General Description
Pump 1 (P1) supplies the travel (S3), slew (S2) and arm (S1)
sections. Pump 2 (P2) supplies the travel (S4), boom (S5) arm
(S6) and option 1 (S7) sections. Since the downstream
consumer sections can no longer be supplied by the neutral
gallery (NG) during simultaneous control of several sections,
parallel channels (PC) are integrated into the M9-25.
The boom (S5) is operated to full output, the bucket section (S6)
is supplied by the PC23 parallel channel. The same applies to
the slew (S2) and arm (S1) sections. To ensure the loaded
upstream and downstream sections are supplied with enough oil
even at different load pressures, orifices are assigned to the
parallel channels (PC).
The travel sections (S3) and (S4) boasts a special feature. The
axis are assigned in tandem to the downstream S2 and S1
respectively S5 and S6 to ensure the oil supply is provided
consistently (as a priority) for the travel section under different
working conditions. If the travel section (S3) is operated to full
output thus interrupting the P1 supply to sections S2 and S1, the
supply comes from pump 2 (P2) by the parallel channels PC13
and PC 12 over the straight travel valve (S10). If the travel
section (S4) is operated to full output thus interrupting the P2
supply to sections S5, S6 and S7 by NG21, the supply comes
from pump (P2) by the straight travel valve (S10) and the
parallel channels PC21, PC22, PC23 and PC24. At the same
time the travel section will be supplied by pump1 (P1) by the
straight travel valve.

5-7-13
Neutral Passage
When the spool is at the neutral position, the minimum
discharge flow from the pump is returned to the tank by the
center bypass line. (NGx →NGy →Tank)
When the spool is switched, the oil discharged from the pump
flows to the operator port by the load check valve and the
parallel channel, since the center bypass line is closed.
(The oil flows: NGx →NGy is cut off by the spool switching)
The oil returning after operating the actuator (cylinder and
motor) returns to the tank by the spool.
• NG: Neutral Gallery
• PC: Parallel Channel
Load Check Valve
A B
T T
NGa NGx NGy PCz
EX1400410
Figure 5 Neutral Spool Position

5-7-14
PC (Parallel Channel)
If no volumetric flow is needed, both pumps are the minimum
volumetric flow set (Qmin). The Qmin quantity now flows
through the "Neutral Gallery" (NG) of the main control valve
back to the tank. Pump (P1) flows for Qmin through the control
block by P1 →S3 →NG11 →S2 →NG12 →S1 →NG13 →S11 →
NG14 →NG15 into the tank channel. Qmin of pump 2 (P2) flows
through the control block by P2 →S10 →NG20 →S4 →NG21 →
S5 →NG22 →S6 →NG23 →S7 →NG24 →S13 →NG25 →S12 →
NG26 into the tank channel.
D-Eco Power
If no volumetric flow is needed, cut spools S12 and S14 are
switched by pilot pressure in PC1 and PC2 →NG15 and NG26
are closed, no connection to tank channel.
1 2 3
7 S13 8
NG26
PC14
ø0.6 ø2.5
NG25
PC21 S12
PC11 16
PC25
Boom Travel (L) Travel (R) Swing Arm

NG24
NG13
Option Bucket
S7 S6 S5 S4 9 NG14 10 S11 S3 S2 S1
14 15
S14
NG23 4 NG22 5 NG21 NG11 NG12 S18 6
NG20
NG15
NG10
ø0.8
PC24 380 ±5 bar PC23 380 ±5 bar PC22 PC21 PC13 PC12 13 380 ±5 bar
ø2.3
ø0.8
S10
380 ±5 bar
11
12
PR1 PR1
1 bar
3 bar
PR2
T Pi P2 L1P1 Y K S
EX1400409
Figure 6
Tank and Cooler Valves

The tank valve (4) and the cooler valve (5), which are described
in more detail in "Tank Line and Cooler Pre-tensioning", are
used to provide the necessary pre-load of the tank channel so
as to avoid cavitation in the consumers by the subsequent feed
function of the secondary valve. The spring value of the cooler
valve is selected at a lower level so as to ensure a permanent
through-flow of the oil cooler.

5-7-15
Summing and Cut Valves
The oil flow path from the P1 pump is as follows.
• P1 Pump → Travel (Right) Spool → Swing Spool → Arm
Spool →S11 (Boom Summation Valve) →S14 (Cut Valve)
→Tank
Cut Valve (S12) Cut Valve (S14)
NG26 NG25 NG14 NG15
T NG24 PC25 PC21 PC11 PC14 NG13 T
Arm Summation Valve Boom Summation Valve

(S13) (S11)
EX1400411
Figure 7
Two summing valves and two cut valves are integrated.

The summing valves enable summation of the pump volumes
when the boom is raised and the arm in or out. If the function of
raising the boom is activated, also the boom boost valve S11
(connection BB) must also be activated. When pump 1 (P1) is in
neutral, the connection between NG13 and NG14 on the S11
axis is open and the pump line is connected through the S14 cut
valve into the tank channel. (D-Eco Power: Cut spools S12 and
S14 are switched by pilot pressure in PC1 and PC2 →NG15 and
NG26 are closed, no connection to tank channel.)
So that pump volume 1 (P1) can flow directly into the boom
cylinder supply when the boom is being raised, the neutral
gallery on S11 is closed (connection between NG13 and NG14),
and the connection between NG13 and PC14 and the parallel
connection between PC11 and PC14 is opened.
The supply orifices NG13 →NG14, NG13 →PC14 and PC11 →
PC14 are integrated into the S11 summing piston for optimal
control of the boom. If the function of arm in or out is activated,
also the arm boost valve S13 (connection AB) must be
activated. When pump 2 (P2) is in neutral, the connection
between NG24 and NG25 on the S13 axis is open and the pump
volume flows through the S12 cut valve into the tank channel.
(D-Eco Power: cut spools S12 and S14 are switched by pilot
pressure in PC1 and PC2 → NG15 and NG26 are closed, no

5-7-16
connection to tank channel). So that pump volume 2 (P2) can
flow directly into the arm clip when the arm is operated, the
neutral gallery on S13 is closed (connection between NG24 and
NG25), and the connection between NG24 and PC25 and the
parallel connection between PC21 and PC25 is opened. The
supply orifices NG24 →NG25, NG24 →PC25 and PC21 →PC25
are integrated into the S13 summing piston for optimal control of
the arm.
A5 B5 L3 AB Pc2 B1 A1
S13 S12
NG24 NG25 NG26
PC21 PC25
Arm
Boom Travel (L) Travel (R)
S14 S11
NG15 NG14 NG13
PC14 PC11
Pc1 P2 L1 P1 BB T(K) L2
EX1400412
Figure 8
• AB: Arm Signal

• BB: Boom Up Signal
• Pc1, Pc2: Center Bypass Cut Off Signal

5-7-17
Schematics (Summing and Cut Valve Related)
A5 B5 L3 AB Pc2 B1 A1
S13 S12
Arm
Option Bucket Boom (L
Travel (L) Travel (R)
(R Swing
S14
S11
Pc1 BB L2
T Pi P2 L1 P1 Y K B
P
Safety Cut-off
a7
By-pass
High Speed
Operating
Cut-off Valve
Two-way
Hammer
(Empty)
Travel
Pedal
T
A
ACC P2 H0 TR2 PH BS
T
P
P2 P1 P0
P1 P3 P4
EX1400413
Figure 9

5-7-18
Straight Travel Valve
Travel Straight Operation

The straight travel spool (S10), which is integrated in the in-and
outlet valve ensures the separation of the pump circuits to
minimize the mutual interaction when the travel function is
operated at the same time as any working function. (arm, boom,
bucket and option).
During separation of the pump circuits pump 1 (P1) supplies the
travel section S3 and S4 and pump 2 (P2) supplies all other
functions.
The S3 axis (travel right) is assigned in tandem to the
downstream S2 and S1 to ensure the oil supply through pump 1
(P1) is provided consistently as a priority for the travel under the
different working conditions. In this way, the travel S3 is not
affected by the actuation of others.
Traveling straight is possible by additional "Travel Straight (TS)
Valve". Once the TS signal is on, P1 begins to control both two
travel motors at the same time, whereas P2 controls the rest of
functions. The purpose of this independent control is to preserve
steady straight movement of excavator when they are
performing various works.
Travel Straight Spool
P
P11
P
P2
2
PR
PR1 1 T
NG10 NG20 PC13 Pi 1

PC21
EX1400450
Figure 10

5-7-19
Travel Straight Valve - OFF
When the straight travel valve (S10) is in neutral, the connection
between P2 and NG20 is opened. The connection or feed by the
P2 pump for the parallel channel between PC13 and PC21 is
closed. If the travel S3 section is not actuated, the S1 and S2
sections are supplied by the neutral circulation of the S3 axis.
As soon as the S1 and/or S2 axis are actuated at the same time
as the S3 axis, the straight travel valve has to be switched on by
the Pi port.
Option Bucket Boom Travel (L) Travel (R) Swing Arm
S7 S6 S5 S4 S3 S2 S1
NG20 NG10
PC21 PC13
S10
380 ±5 bar
Pi P2 P1
EX1400451
Figure 11

5-7-20
Travel Straight Valve - ON
The S1 and S2 axis are then supplied by the P2 pump by the
PC13 channel during operation, so full pump volume from P1 is
available for driving the machine. The cut valve (S12) "Summing
and Cut Valves" must also be switched on in parallel so
necessary pressure is applied to pump 2 (P2).
The S4 axis (travel left) is assigned in tandem to the
downstream S5, S6 and S7 to ensure the oil supply through
pump 2 (P2) is provided consistently as a priority for the travel
under the different working conditions. In this way, the travel S4
is not affected by the actuation of others. When the straight
travel valve (S10) is in neutral, the connection between P2 and
NG20 is opened.
The connection or feed by the P2 pump for the parallel channel
between PC13 and PC21 is closed. If the travel S4 section is not
actuated, the S5, S6 and S7 consumer sections are supplied by
the neutral circulation of the S4 axis. As soon as the S5, S6 and/
or S7 axis are actuated at the same time as the S4 axis, the
straight travel valve has to be switched on by the Pi port.
The S5, S6 and S7 axis are then supplied by the P2 pump by the
PC21 channel during operation, so full pump volume from Pi is
available for driving the machine. The S14 cut valve "Summing
and Cut Valves" must also be switched on in parallel so
necessary pressure is applied to pump 2 (P2).
S7 S6 S5 S4 S3 S2 S1
NG20 NG10
PC21 PC13
S10
380 ±5 bar
Pi P2 P1
EX1400452
Figure 12

5-7-21
The Straight Traveling Valve Operating Conditions
• At the operation of the pilot EPPR valve (electric current supplied)
– Traveling straight (left and right traveling simultaneously)
→Less than 12 kg/cm2: 150 mA, 12 kg/cm2 or higher: 150 - 600 mA
– Traveling straight (left and right traveling simultaneously) + Front operation →150 - 600 mA
– Simultaneous traveling condition is judged by the condition that less value of the left and right traveling
exceeds 1/2 of the larger value.
– EPPR output is proportional to the front lever summation
Option BKT Boom Travel (L) Travel (R) Swing Arm
S10
380 ±5 bar
P
T
A
High-speed
Operating
a7
Two-way
Hammer
Cut-off
Safety
Travel
Pedal
ACC P2 H0 TR2 PH BS
T
P1 P2 P0
A3
P1 P3 P4
from Joystick (R) Button
EX1400453
Figure 13

5-7-22
Boom Spool Shift
Load holding valve and regeneration valve (boom down) is
installed on boom line.
A B
a5 b5
T T
NG24 NG22 NG21
Figure 14 EX1400454

5-7-23
Boom Up (2-pump Summation)
In single operation, the supply for raising the boom (S5) (B5
port) is provided by pump 2 (P2) by the NG20 and NG21 neutral
circulation. For the summation of both pump flows P1 and P2
form boom raising it is necessary to activate the boom
summation spool (S11) by the BB port (Summing and Cut
Valves) in parallel to the spool S5.
The oil from pump 1 (P1) is then added directly into the boom
bottom side by the NG10/NG11/NG12/NG13 neutral circulation
and the PC14 parallel channel.
The function of the pilot-controlled check valve is described in
"Check Function (Supply)". If other sections are actuated, which
are supplied by pump 1 (P1), at the same time as raising the
boom, the supply from NG13 to PC14 by the summing piston
(S11) is interrupted.
The parallel groove from PC11 to PC14 in the summing piston
(S11) can also be used to provide the boom raising function for
corresponding load pressures with an additional supply through
a partial flow from pump 1 (P1) by NG10/NG11/PC11 and the
PC14 parallel channel. If the travel section (S4) is proportionally
operated to full output at the same time as the boom section
(S5), the supply by the neutral gallery NG21 is reduced for
section S5.
In the opposite direction, the supply for S5 by the parallel
channel PC21 by pump 2 (P2) increases because the
connection between P2 and PC21 opens in proportion by the
straight travel valve (S10). At the same time the supply of
section S4 will be taken over by pump 1 (P1) through the
connection of P1 and NG20 which is opened by the straight
travel valve (S10). Also the necessary pressure in the pump
circuit (P1) is established by closing the cut valve (S14).
The pilot-controlled check valve (10) "Pilot-controlled Check
Valve (Antidrift Valve)" which is integrated into the boom supply,
ensures a leak-free boom shut-off against undesirable lowering
while the S5 piston is in neutral. Both the rod side (A) and the
piston side (B) are protected by a combined pressure
anticavitation valve.

5-7-24
Boom Cylinder Arm Cylinder
A5 B5 L3 b5 AB Pc2 B1 A1
S13 S12
Arm
Boom S14 Summation
S11
a5 BB L2
S10
380 ±5 bar
3 bar
Pc1
1 bar
Figure 15 T Pi P2 L1 P1 Y K EX1400455
Port Relief
Anti-cavitation Valve Load Check Valve Anti-drift Valve
Boom Spool
Input Pilot Pressure
Boom Summation Valve EX1400460

Figure 16

5-7-25
Boom Down (Regeneration)
In single operation, the supply for lowering the boom (S5) is
provided by pump 2 (P2) by the NG20 and NG21. Parallel to
this, the pilot controlled check valve (10) "Pilot-controlled Check
Valve (Antidrift Valve)" is activated so return oil can drain from
the cylinder (B5 port) to the tank. The function of the
pilot-controlled check valve is described in "Pilot controlled
Check Valve (Antidrift Valve)". The regeneration function
integrated into the boom piston enables high lowering speeds on
the boom without cavitation on the rod also for overlapped
movements, since some of the oil draining away from the base,
in addition to the available pump oil, is fed into the rod side of the
boom cylinder. If the travel section (S4) is proportionally
operated to full output at the same time as the boom section
(S5), the supply by the NG21 is reduced for section S5. In the
opposite direction, the supply for S5 by the parallel channel
PC21 by pump 2 (P2) increases because the connection
between P2 and PC21 opens in proportion by the straight travel
valve (S10). At the same time the supply of section S4 will be
taken over by pump 1 (P1) through the connection of P1 and
NG20 which is opened by the straight travel valve (S10). Also
the necessary pressure in the pump circuit (P1) is established by
closing the cut valve (S14).
A5 B5 L3 b5 AB Pc2 B1 A1
S13 S12
Boom
Arm
S14
S5 S4 S3 S1
NG20
NG21
S11
PC21
a5 BB L2
S10
380 ±5 bar
Pc1
3 bar
1 bar
T Pi P2 L1 P1 Y K
EX1400456
Figure 17

5-7-26
Load Check Valve Anti-drift Valve
Port Relief
Anti-cavitation Valve
Input Pilot
Pressure
Regeneration Unit Inside

Insid
EX1400461
Figure 18
Arm Spool Shift

Load holding valve and regeneration valve (arm crowd) is
installed on arm line.
Load Holding Valve (Main Poppet)
A B
a1 b1
T T
PC12 NG12 NG13
EX1400457
Figure 19

5-7-27
Arm In (Retraction, Crowd)
In single operation, the arm extension function (S1) is supplied
by the NG10, NG11 and NG12 neutral gallery by pump 1 (P1).
For the summation of both pump flows P1 and P2 form arm out it
is necessary to activate the arm summation spool (S13) by the
AB port in parallel to the spool S1.
The oil from pump 2 (P2) is then added into the clip of the arm
section by the NG20/NG21/NG22/NG23/NG24 neutral gallery
and the PC25 parallel channel. The clip (5) of the arm section
(S1) can also be supplied by an orifice within the parallel
channel PC12.
The PC12 parallel channel is fed from the NG11 neutral gallery
once the pressure in the NG11/NG12 circulation has reached
the respective arm load pressure. If the boom and/or bucket are
activated at the same time as the arm, the supply from NG24 to
PC25 by the summing piston (S13) is interrupted.
The parallel groove from PC21 to PC25 in the sum piston (S13)
can also be used to provide the arm function for corresponding
load pressures with an additional supply through a partial flow
from pump 2 (P2) by NG20/NG21/PC21 and the PC25 parallel
channel. If the travel section (S4) is at maximum control, no oil
can flow to the arm by the parallel nut in the summing piston
(S13). The function of the pilot-controlled check valve is
described in section "Check Function (Supply)".
Both the rod side (A) and the piston side (B) can be secured by a
combined pressure anticavitation valve. The check valve
"Pilot-controlled Check Valve (Antidrift Valve)", which is
integrated into the rod side feed from the arm ensures a leak-
free shut-off and prevents the arm being retracted at the neutral
position of the piston (S1).
When the arm is retracted, in addition to the piston (S1) being
activated by b1. The pilot-controlled check valve "Pilot-controlled
Check Valve (Antidrift Valve)" is controlled at the same time so
return oil can flow from the cylinder rod side to the tank.
The function of the pilot-controlled check valve is described in
section "Check Function (Supply)". Both the rod side and the
piston side can be secured by a combined pressure

5-7-28
A5 B5 L3 AB Pc2 b1 B1 A1
S13 S12
NG13
PC25
PC14
Boom Travel (L) Travel (R) Summation

S14 Arm
NG24
S5 S4 S3
S1
NG22, 23 NG21 NG11, 12
S11
NG20
NG10
BB a1 L2
380 ±5 bar
3 bar
1 bar
Pc1
T Pi P2 L1 P1 Y K
Arm Regeneration Unit
Figure 20
EX1400458
Port Relief Anti-drift Arm Load Port Relief

Anti-cavitation Valve Valve Spool Check Valve Anti-cavitation Valve
Arm Summation Valve
Input Pilot
Pressure
Regeneration Unit
Figure 21 Arm Holding Valve EX1400466

5-7-29
Arm Out (Extension, Dump)
In single operation, the arm extension function (S1) is supplied
by the NG10, NG11 and NG12 neutral gallery by pump 1 (P1).
For the summation of both pump flows P1 and P2 form arm out it
is necessary to activate the arm summation spool (S13) by the
AB port "Summing and Cut Valves" in parallel to the spool S1.
The oil from pump 2 (P2) is then added into the clip of the arm
section by the NG20/NG21/NG22/NG23/NG24 neutral gallery
and the PC25 parallel channel. The clip (5) of the arm section
(S1) can also be supplied by an orifice within the parallel
channel PC12. The PC12 parallel channel is fed from the NG11
neutral gallery once the pressure in the NG11/NG12 neutral
circulation has reached the respective arm load pressure. If the
boom and/or bucket are activated at the same time as the arm,
the supply from NG24 to PC25 by the summing piston (S13) is
interrupted. The parallel groove from PC21 to PC25 in the sum
piston (S13) can also be used to provide the arm function for
corresponding load pressures with an additional supply through
a partial flow from pump 2 (P2) by NG20/NG21/PC21 and the
PC25 channel. If the travel section (S4) is at maximum control,
no oil can flow to the arm by the parallel nut in the summing
piston (S13). The function of the pilot-controlled check valve is
described "Check Function (Supply)". Both the rod side and the
piston side can be secured by a combined pressure
A5 B5 L3 AB Pc2 b1 B1 A1
S13 S12
PC21
PC25
Arm
Boom Travel (L) Travel (R)

(R Summation
Summatio
NG24
S14 S1
S5 S4 S3
NG22, 23
2 NG21 NG11, 1
12
S11
NG10
NG20
PC13 PC12
BB a1 L2
380 ±5 bar
Pc1
3 bar
1 bar
Figure 22 T Pi P2 L1P1 Y K EX1400459

5-7-30
Regeneration Unit
Input Pilot Arm Summation Valve

Pressure
EX1400467
Figure 23

5-7-31
Bucket Compound Operation
The regeneration valve (bucket in) is installed on bucket line.
A B
a6 b6
T T
5 NG24 NG22 NG23 PC22
EX1400468
Figure 24
In single operation, the bucket section (S6) is supplied by pump

2 (P2) by the neutral gallery NG20, NG21 and NG22, the clip
channel (5) and parallel channel (PC22). The PC22 parallel
channel is fed by the NG21 neutral circulation as soon as the
necessary load pressure is established in the NG21/NG22
circulation by controlling the bucket piston (S6).
In single operation, the bucket section (S6) is supplied by pump
2 (P2) by the NG20, NG21 and NG22 neutral circulation, the clip
channel (5) and parallel channel (PC22).
The PC22 parallel channel is fed by the NG21 neutral circulation
as soon as the necessary load pressure is established in the
NG21/NG22 circulation by controlling the bucket piston (S6).
If the travel section (S4) is proportionally operated to full output
at the same time as the bucket section (S6), the supply from
pump 2 (P2) by NG21 is reduced for the S6 section. In the
opposite direction, the supply from pump 2 (P2) into the PC21/
PC22 by the straight travel valve increases. The connection
between P1 and NG20 opens in proportion by the straight travel
valve (S10) to supply the travel section S4.
The necessary pressure in the P2 pump circuit is established by
closing the cut valve (S14). Both the rod side and the head side
are protected by a combined pressure anticavitation valve.

5-7-32
Bucket Cylinder
B7 A7 b7 B6 A6 b6 B4 A4 b4 pc2 b3 B3 A3 b2 B2 A2
S12
Travel (L) Travel (R) Swing

NG24
Option
S14
Bucket
S7 S6 S4 S3 S2
NG23 NG21, 22
NG20
PC21
PC22
a7 Pc1 a6 a4 a2 a3
S10
380 ±5 bar
1 bar
3 bar
Bucket Regeneration Unit

T Pi P2 L1 P1 Y K
EX1400469
Figure 25

5-7-33
Swing Compound Operation
In single operation, the slew section (S2) is supplied by pump 1
(P1). The slew section (S2) and arm section (S1) are connected
in parallel to the pump (P1) by PC12. With an appropriately set
restrictor in PC12, the slewing gear retains the necessary
priority for acceleration in relation to the arm section (S1). If the
arm and blade sections are activated and supplied at the same
time. It is not possible to secure the (A) and (B) side by the
anticavitation valve or combined pressure/anticavitation valve
for the slew section (S2) because these are secured by the
slewing gear motor.
Pressure Relief & Swing Load Pressure Relief &

Anti-cavitation Valve Spool Check Valve Anti-cavitation Valve
A B
Input Pilot
a2 Pressure
T T
Swing Right
EX1400470
Figure 26

5-7-34
Swing Right/Left
Flowrate discharged from P1 is supplied to swing motor through
swing spool, whose opening area dependent on the swing pilot
signal. The direction of the swing motor rotation is dependent on
the pilot signal, right or left.
Swing Motor
S12
Option Bucket Travel (L) Travel (R) Swing
S14
S7 S6 S4 S3 S2
pc12
a7 Pc1 a6 a4 a2 a3
380 ±5 bar
3 bar
1 bar
T Pi P2 L1 P1 Y K
EX1400471
Figure 27

5-7-35
No Swing Signal with Swing Operation
1. Sudden fall of "Swing Signal Input" will lead to the
uppercarriage keep moving because of the inertia of huge
mass.
2. The bypass-cut valve must remain opened during this
operation to supply oil required for the makeup function.
3. Oil from tank reaches to the swing motor, actually working
as a swing pump, through makeup valve to avoid
cavitation.
SH
PG
DB
C
PA PB
Left A B Right
AB Pc2 b3 B3 A3 b2 B2 A2 b1 B1 A1
Travel (R) Swing Arm
Pc1 BB a3 a2 L2 a1
380 ±5 bar
3 bar
1 bar
T Pi P2 L1 P1 Y K
EX1400484
Figure 28

5-7-36
Swing Brake Release Operation (Condition)
At swing parking brake solenoid valve ON
(Any one or more of the boom, arm, bucket, and swing sensor is
1.5 V or higher)
• During swing operation (released by pilot pressure in swing
operation, shuttle valve SH signal pressure)
• Left and right simultaneous traveling (travel sensor value is
1.5 V or higher)
(from Swing Shuttle Block)

*SH
B
Pi
A
(Control Valve)
P
T
SH
(to Swing Motor)
Operating
Hammer
ACC P2 H0 TR2 PH BS
T
P0
P1 P3 P4
EX1400472
Figure 29

5-7-37
Travel Operation
Travel Right
In single operation, the travel section (S3) supply is provided
directly by pump 1 (P1). To ensure operation with maximum
volumetric flow is not affected by other consumers, pump 1 (P1)
is available exclusively for travel function when the travel section
(S3) is operated to full output. The travel section (S3) therefore
takes priority over the slew section (S2) and arm section (S1),
which are supplied by the straight travel valve (S10) and the
channels PC13 and PC12 by pump 2 (P2) in this case.
This priority is established by closing the NG11 neutral
circulation of the travel section (S3). A feed (anticavitation) valve
(2) can be attached to both the motor (A) and (B) side.
Travel (L) Motor Travel (R) Motor
S12
Travel ((R)
(R
Option Bucket Travel (L) Swing

S14
S7 S6 S4 S3 S2
NG11
PC13 PC12
a7 Pc1 a6 a4 a2 a3
S10
380 ±5 bar
3 bar
1 bar
T Pi P2 L1 P1 Y K
EX1400485
Figure 30

5-7-38
Travel Left
In single operation, the travel section (S4) supply is provided
directly by pump 2 (P2). To ensure operation with maximum
volumetric flow is not affected by other consumers, pump 2 (P2)
is available exclusively for travel function when the travel section
(S4) is operated to full output. The travel section (S4) therefore
takes priority over the boom section (S5), bucket section (S6)
and option section (S7). This priority is established by closing
the NG21 neutral gallery of the travel section (S4). As soon as
the boom, bucket or option section is operated in parallel with
the travel section S4 the travel section will be supplied by pump
1 (P1) and the following sections will be supplied by PC21,
PC22 and PC23 by pump 2 (P2) by the straight travel valve. A
feed (anticavitation) valve (2) can be attached to both the motor
(A) and (B) side.
Travel (L) Motor Travel (R) Motor
S12
S14
S7 S6 S4 S3 S2
NG21
PC21
PC23 PC22
a7 Pc1 a6 a4 a2 a3
S10
380 ±5 bar
1 bar
3 bar
T Pi P2 L1 P1 Y K
EX1400496
Figure 31

5-7-39
Travel Straight Operation
Valve". Once the TS signal is on, P1 begins to control both two
travel motors at the same time, whereas P2 controls the rest of
functions. The purpose of this independent control is to preserve
steady straight movement of excavator when they are
performing various works.
P1
P2
PR1 T
NG10 NG20 PC13 Pst P1

PC21
If TS signal on,
then spool’s movement generates
new flow path (red)
Figure 32 EX1400233

Forward Forward
to Tank 380 ±5 bar to Tank
3 bar
1 bar
T Pi P2 L1 P1 Y K S
Travel Straight Pump 1

Figure 33 Signal EX1400497

5-7-40
Option Spool Shift
Breaker and shear can be installed on option line.
The brake is one way and the shear is two-way.
The pump discharge rate related to option (spool) is set up at the
instrument panel.
A B
a7 b7
T T
NG24 NG23
Figure 34 EX1400481
In single operation, the option 1 section (S7) is supplied by

pump 2 (P2) by the neutral gallery NG20, NG21 and the parallel
channel PC22, PC23. If the travel section (S4) is proportionally
operated to full output at the same time as the option 1 section
(S7), the supply from pump 2 (P2) by NG21 is reduced for the
S7 section. In the opposite direction, the supply from pump 2
(P2) into the PC21/PC22/PC23 by the straight travel valve (S10)
increases. The connection between P1 and NG20 opens in
proportion by the straight travel valve (S10) to supply the travel
section S4. The necessary pressure in the P1 and P2 pump
circuit is established by closing the cut valve (S14). Both the rod
side (A) and the head side (B) are protected by a combined
pressure anticavitation valve.

5-7-41
S12

S14
S7 S6 S4 S3 S2
NG21
NG20
PC21, 22
PC23
a7 Pc1 a6 a4 a2 a3
S10 380 ±5 bar
3 bar
1 bar
T Pi P2 L1 P1 Y K
EX1400498
Figure 35

5-7-42
Main Relief Valve and Port Relief Valve
Main Relief Valve

The pilot-operated primary pressure relief valve is screwed into
the side of the control block, and limits the maximum pump
(system) pressure to the set value as a safety valve. Pressure
peaks in the pump line can occur if the volume flow requested by
the orifices is used up more quickly than the volume flow
requested by the pump or if an error occurs in the system.
When the system is delivered, the pressure setting is set
according to the project, and must not be changed.
Port Relief Valve

The pilot-controlled pressure anticavitation valves of the
individual consumer connections A and B are screwed into the
individual sections as valves in cartridge form above the control
piston. The valve protects the consumer circuit from overloading
or damage, e.g. from external forces or abrupt delays (control
piston in neutral position) by removing the pressure peak to the
tank. It limits the maximum pressure in the consumer as a safety
valve and sets the connection to the directional control valve to
the individually set value. When the system is delivered, the
pressure setting is set according to the project, and must not be
changed.
1 2 3 4 5 6
380 ±5 bar
P
P T
(A, B)
14 13 12 11 10 9 8 7
EX1400482
Figure 36

5-7-43
380 ±5 bar
3 bar
1 bar
T Pi P2 L1 P1 Y K S
Port Relief Valves Main Relief Valve

Relief Pressure: 380 ±5 bar Relief Pressure: 380 ±5 bar
EX1400499
Figure 37
Operation
The primary pressure relief valve and the secondary pressure
relief valves are identical in design and function. The system
pressure p is available by the restrictor D1 (1) in chamber C
(12). Since the A2 surface (4) is larger than A1 (14), the main
poppet remains closed. The spring 1 (2) in room C (12) ensures
a stable installation position. The valve remains closed as long
as the system pressure p is less than the value set by the
spindle (8) and compression spring (9). If the pressure p
exceeds the set value, the pilot poppet (10) opens and the oil
volume from room C (12) flows to the tank by the D2 restrictor
(5). The pressure in room C (12) drops because the supply by
the smaller section of the D1 restrictor (1) is less than the
outflow by the opened pilot poppet (10). The higher pressure p
on the surface A1 (14) opens the main poppet against the spring
1 (2), and connects the pump line/demand line to the tank. The
anticavitation (feed) function is not used on the primary side.

5-7-44
Retraction Valve (1 bar, 3 bar Check Valve)
The mono block has central cooling and tank connections K and
T which are integrated in the in- and outlet valve. These are
check valves and pre-tensioned by springs. The resulting
backlog in the outflow ensures oil feeds in the event of negative
external loads (e.g. lowering the boom, downhill travel or similar
movements creating extra demand) and avoids filling problems/
cavitation in the system.
The volume required for the post-feeds is fed from the demand
volume during consumer movements. If a consumer is delayed
abruptly, and the mass moment of inertia does not stop
immediately, e.g. slewing gear, the Qmin volume of pumps 1
(P1) and 2 (P2) ensure the required tank line volume in the
block. The lower pre-tensioning of the check valve on the K-
connection creates the priority of the non-return valve of the oil
by the cooler. With increasing volume flow, the resistance
increases in the cooler line, and a partial flow is fed in the
bypass by the T-connection to the tank.
380 ±5 bar
3 bar
1 bar
T Pi P2 L1 P1 Y K
EX1400483
Figure 38

5-7-45
Shockless Valve
The shockless valve (orifice, check valve) in the control valve
pilot line enables smooth control of the spool.
(Initial control of the spool)
• Total six valves are provided: swing and traveling (left, right).
A. Circuit diagram
Unrestricted Restricted
Figure 39 EX1400500
B. Normal assembly
A B
Figure 40 EX1400510
C. Abnormal (wrong) assembly
A B
Figure 41 EX1400511

5-7-46
Load Holding (Antidrift) Valve
In the boom lowering and crowd line, load holding valves (lock
valve) are installed to cut off cylinder oil flow when the spool is at
the neutral position. (Maintain the intrinsic settlement of the
cylinder at minimum value)
Holding Valve Operation - Cylinder Locking

Pilot Pressure
Pilot pressure is 0 bar
Cylinder pressure is restricted behind holding valve with
Spools
high-pressure. The check valve prevents the fluid from leaking.
Cylinder
Tank
EX1400234
Figure 42
380 ±5 bar
1 bar
3 bar
T Pi P2 L1 P1 Y K S
EX1400512
Figure 43

5-7-47
Neutral
Boom, Arm Cylinder
Control pistons (S2 and S5) in lock position (no pump pressure
on the pilot-controlled check valve) and any load pressure from
the consumer. PL1
L IN
The load-holding pressure of the consumer (actuator) is held in
the PL chamber, and is reported to the PL1 chamber by the
piston (1) of the pilot cartridge. This means the same pressure is PL
available in the PL and PL1 chambers. The surface conditions
are selected so primary poppet (3) is held in a closed state by
the spring force (2). The oil flow is avoided by seat of the (4) of Spool Pilot Signal EX1400538
the main poppet (3).
Figure 44
Figure 45
Reference Reference
Number Number
1 Pistons of the Pilot Cartridge 3 Main (Primary) Poppet
2 Spring 4 Seat

5-7-48
Boom Raise, Arm in
Boom, Arm Cylinder
Pump pressure on the pilot-controlled check valve and any load
pressure from the consumer.
PL1
As soon as the pump pressure (PL) is greater than the load L
pressure (PL1) plus the spring force (2), the primary poppet (3)
of the pilot-controlled check valve (antidrift valve) opens, and the
required volume flow can flow to the consumer. This balances PL
out the pressure in the PL and PL1 chambers by the pistons of
the pilot cartridge (1).
Spool Pilot Signal EX1400539
Figure 46
Figure 47
Reference Reference
Number Number
1 Pistons of the Pilot Cartridge 3 Primary Poppet
2 Spring 4 Seat

5-7-49
Holding Valve Operation - Cylinder Released
Pilot Pressure
Pilot pressure is given. When the pilot pressure rises, the
position of lock valve is changed, making the fluid inside of
cylinder rod released through the spool holding valve operation.
Spools
Cylinder
Tank
EX1400235
Figure 48
380 ±5 bar
1 bar
3 bar
T Pi P2 L1 P1 Y K S
EX1400512
Figure 49

5-7-50
Pilot-controlled Check Valve (Return Flow)
Boom, Arm Cylinder
The return pressure on the pilot-controlled check valve and
control of the pilot cartridge by pst.
When the piston of the pilot cartridge (1) is controlled by the pst PL1
pressure, the connection of the PL1 and PL chambers is L
separated, and the PL1 chamber to the drain connection L is
released. The main piston (3) can now be opened against the
spring (3) by the surface of the PL chamber with the pressure of PL
the return oil, and the return oil from the consumer can flow into
the tank by the control piston (S1 or S5). Spool Pilot Signal EX1400540
Figure 50
Figure 51
Reference Reference
Number Number
1 Pistons of the Pilot Cartridge 3 Primary Poppet
2 Spring 4 Seat

5-7-51
Bypass Cut Off Solenoid Valve
Bypass cut valve and bypass cut solenoid valve, which is
controlled by signal from electric controller, determine the
flowrate discharged from the main pump.
Bypass cut off solenoid valve always operates in normal
operation of the equipment.
(Solenoid valve: power on →center by pass line cut off)
The cases (conditions) when the bypass cut solenoid valve does
not operate (solenoid valve power cut off) are as follows:
• Engine speed is 500 rpm or below (not applicable to most
equipment)
• At engine starting-up (temporarily)
(At engine off, the pump swivel angle becomes maximum
→At engine start up, open the by pass line to reduce loss.)
• Coolant temperature is 20°C or below (prevent pump
vibration)
• Stop during swing (Swinging for 0.6 s or longer = Normal
swing operation) →prevent swing cavitation
• During left and right simultaneous traveling (straight
traveling valve operating) → prevent cavitation with travel
spool (traveling make up)
Bypass Cut
Solenoid Valve
Bypass Cut Valve

Signal from
Controller
Pilot Pump Main Pump Tank

EX1400197
Figure 52

5-7-52
380 ±5 bar
1 bar
3 bar
T Pi P2 L1 P1 Y K S
P
EX1400513
Figure 53

5-7-53
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.
1. Park the machine on firm, level ground and lower the

bucket as shown in Figure 54.
2. Stop engine.
EX1300684
Figure 54

5-7-54
(Figure 55)
LOCK
WARNING WARNING
DO NOT OPERATE
or maintenance
ON OFF

switch.
(Figure 56)
Figure 56
WARNING
doing any work.
Figure 57 EX1400156

5-7-55
11. Oil drain method
A. Remove cover on oil tank (bolt: 6 ea), drain hydraulic
oil using oil pump. (Figure 58)
• Tool: 14 mm ( )
Figure 58 EX1400160
B. Drain hydraulic fluid using drain plug.

(without oil pump) (Figure 59)
• Tool: 27 mm ( )
• Hydraulic oil tank volume
– Approximately: 381 L (101 U.S. gal)
– Effective level: 243 L (64 U.S. gal)
Figure 59 Oil Tank Bottom View EX1400161
C. Plug the filter cap to location of suction filter.
Item Part Number

Filter Cap 2188-1011
EX1301534
Figure 60
Reference
Description
Number
3
1 Suction Filter
606.5
2 Nut
3 Rod
2
When install
• Torque (2 nut): 49 N.m (5 kg.m, 36.2 ft lb) 1
EX1400168
Figure 61

5-7-56
12. Open the engine cover and remove bolts and washers (1,
Figure 62) (4 ea) with cover (2).
• Tool: 19 mm ( )
• Cover weight: 20 kg (44 lb) 1
1
2
Figure 62 EX1400009
13. Disconnect harness (2 ea) from control valve. (Figure 63)
Figure 63 EX1400271

5-7-57
14. Remove hoses from control valve.
NOTE: Attach 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.
1 2 3
7 6 5 4
Figure 64 Rear Side View EX1400272

No. Port Name
1 T to Tank SAE 1 1/4 3,000 psi 8 63.7 6.5 47
2 Pi to Pilot EPPR Valve "A" 9/16"-18UNF-2B 19 25.5 2.6 18.8
3 P2 Pump 2 SAE 1 1/4 6,000 psi 12 176.4 18 130.1
4 P1 Pump 1 SAE 1 1/4 6,000 psi 12 176.4 18 130.1
5 L1 to Pilot EPPR Valve "T" 11/16"-16UN-2B 22 38.2 3.9 28.2
6 Y to Tank 9/16"-18UNF-2B 19 25.5 2.6 18.8
7 K to Oil Cooler SAE 1 1/4 3,000 psi 8 63.7 6.5 47

5-7-58
8 9 10 11 12 13 14
7 6 5 4 3 2 1
Figure 65 Front Side View EX1400273

No. Port Name
1 A7 Option SAE 1 6,000 psi 10 107.8 11 79.5
2 A6 Bucket Cylinder Rod Side SAE 1 6,000 psi 10 107.8 11 79.5
3 A5 Boom Cylinder Rod Side SAE 1 6,000 psi 10 107.8 11 79.5
4 A4 Travel Backward (LH) SAE 1 6,000 psi 10 107.8 11 79.5
5 A3 Travel Backward (RH) SAE 1 6,000 psi 10 107.8 11 79.5
6 A2 Swing (Left) SAE 1 6,000 psi 10 107.8 11 79.5
7 A1 Arm Cylinder Rod Side SAE 1 6,000 psi 10 107.8 11 79.5
8 B1 Arm Cylinder Head Side SAE 1 1/4 6,000 psi 12 176.4 18 130.1
9 B2 Swing Right SAE 1 6,000 psi 10 107.8 11 79.5
10 B3 Travel Forward (RH) SAE 1 6,000 psi 10 107.8 11 79.5
11 B4 Travel Forward (LH) SAE 1 6,000 psi 10 107.8 11 79.5
12 B5 Boom Cylinder Head Side SAE 1 1/4 6,000 psi 12 176.4 18 130.1
13 B6 Bucket Cylinder Head Side SAE 1 6,000 psi 10 107.8 11 79.5
14 B7 Option SAE 1 6,000 psi 10 107.8 11 79.5

5-7-59
10 9 8 7 5 3 2 1
6 4
Top Side View

EX1400274
Figure 66

No. Port Name
1 b7 Option 9/16"-18UNF-2B 19 25.5 2.6 18.8
2 b6 Bucket Crowd 11/16"-16UN-2B 22 38.2 3.9 28.2
3 b5 Boom Up 11/16"-16UN-2B 22 38.2 3.9 28.2
4 L3 to Tank 11/16"-16UN-2B 22 38.2 3.9 28.2
5 b4 Travel (LH) Backward 11/16"-16UN-2B 22 38.2 3.9 28.2
6 PC1 Bypass Cut Valve 11/16"-16UN-2B 22 38.2 3.9 28.2
7 BB Combine Boom (to b5) 11/16"-16UN-2B 22 38.2 3.9 28.2
8 b3 Travel (RH) Backward 11/16"-16UN-2B 22 38.2 3.9 28.2
9 b2 Swing (Left) 11/16"-16UN-2B 22 38.2 3.9 28.2
10 b1 Arm Crowd 11/16"-16UN-2B 22 38.2 3.9 28.2

5-7-60
10 6
9 8 7 5 4 3 2 1
Bottom Side View

EX1400275
Figure 67

No. Port Name
1 a7 Option 9/16"-16UN-2B 19 25.5 2.6 18.8
2 a6 Bucket Dump 11/16"-16UN-2B 22 38.2 3.9 28.2
3 a5 Boom Down 9/16"-16UN-2B 19 25.5 2.6 18.8
4 a4 Travel (LH) Forward 9/16"-16UN-2B 19 25.5 2.6 18.8
5 AB Combine Arm 11/16"-16UN-2B 22 38.2 3.9 28.2
6 PC2 Bypass Cut Valve 11/16"-16UN-2B 22 38.2 3.9 28.2
7 a3 Travel (RH) Forward 11/16"-16UN-2B 22 38.2 3.9 28.2
8 a2 Swing (Right) 11/16"-16UN-2B 22 38.2 3.9 28.2
9 a1 Arm Dump 11/16"-16UN-2B 22 38.2 3.9 28.2
10 L2 to Tank 11/16"-16UN-2B 22 38.2 3.9 28.2
15. Tie with rope to the eyebolts to lift it and remove mounting
bolts (3 ea) from bracket. (Figure 68)
• Tool: 24 mm ( )
• Control valve weight: about 209 kg (261 lb)
16. Lift the control valve by crane from machine slowly and
carefully.
Figure 68 EX1400276

5-7-61
INSTALLATION
WARNING
SERIOUS INJURY
NOTE: First, assemble the bolts (3 ea) of main control valve

mounting to main frame. (Figure 68)
IMPORTANT
After completing the work, check the oil level. Start the
engine and check for any oil leaks.
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
hydraulic oil tank.
2. Start the engine and run at low idling 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)

5-7-62
DISASSEMBLY
General Repair Instructions
General instructions
After the decommissioning, there is still oil in the control block.
Leaking hydraulic fluid can cause damage to the environment
and pollution of the groundwater.
1. The national laws and provisions must always be
observed. In Germany, hydraulic vehicles and/or systems
are "Systems for handling water-polluting substances in
the sense of the Water Resources Act (WHG)". In this
connection, observe particularly 1 and °Þ19 WHG (°Þ19g,
19i, 19l).
2. Observe the information in the safety data sheet of the
hydraulic fluid and the vehicle/system manufacturer's
specifications.
Cleaning
1. Clean the control block from contamination and loose
foreign bodies.
2. Do not use cleaning agents that
• May attack plastics or change their properties
• May attack metals or react with them
• Can leave residues behind.
1. Suitable cleaning agents are plastic brushes and hydraulic
oil. Do not use metal brushes.
2. In case of contamination, clean bores using a brush tool
with plastic hair and hydraulic oil.
3. Do not clean the disassembled control block with a
pressure washer.
Housing and parts

1. You may only use original Doosan parts.
2. After disassembly, elastic seal elements must be
exchanged against new ones.
3. Housings and parts must be clean and undamaged.
4. Damaged housings and parts must no longer be used.
5. Any reprocessing of threads is not admissible.
6. Any reprocessing of bores is not admissible.
7. Protect the bores and threads against the deposition of
contamination.

5-7-63
Flange surfaces and sealing surfaces
1. Adhesion forces may act between the flange areas in the
disassembly.
2. Remove contamination using a whetstone and clean the
surface using an oil-soaked cleaning cloth.
3. Surfaces with punch marks or signs of wear in the sealing
surface must no longer be used.
4. Any reprocessing of the sealing surfaces is not admissible.
Bench vise
Protective brackets with hard rubber are to be used. Sealing and
flange surfaces must not be damaged.
Required tools
1. Oil-soaked cleaning cloth
2. Whetstone
3. You need only commercially available tools to mount the
control block.
Repair Instructions
Parts List Control Block
IMPORTANT
You can find the part numbers of the spare parts in the
specific spare part list according to the material number of
your control block.
Replace Load-holding Valve Spool (Item 130)

1. Required tools
• Hexagon wrench or socket wrench size 30
• Magnet gripper
• Torque wrench for 100 Nm with hexagon socket size 30

5-7-64
2. Load-holding valve consisting of:
• Poppet
• Pressure spring
• Plug screw
Figure 69
3. Removing load-holding valve

• Unscrew and remove plug screw with hexagon
wrench in counterclockwise direction.
• Remove pressure spring and poppet with magnet
gripper.
• Dispose the load-holding valve parts that have been
removed.
• Ensure that no contamination enters the bore.
Figure 70
4. Installing load-holding valve

• Check seals at the plug screw. The surfaces must be
clean and undamaged.
• Check the bore in the housing. If the bore is
damaged, the block must be replaced.
• Install load-holding valve by hand into the bore. Take
care, that spring has the right position inside the bore
of the poppet and the plug screw. Screw in plug
screw in clockwise direction.
• Tighten plug screw with torque wrench in clockwise
Figure 71
direction. Tightening torque MT = 100 Nm.
Replace Plug Screw (Item 132)

Follow the instructions according to See “Replace Load-holding
Valve Spool (Item 130)” on page -64..

5-7-65
Replace Throttle Check Valve (Item 135, 136) for Semi
Priority Boom Vs. Bucket and Swing Vs. Arm
1. Required tools
• Hexagon socket wrench size 24
• Magnet gripper
2. Throttle check consisting of
• Poppet
• Spring
• Plug screw
Figure 72
3. Removing throttle check valve

gripper.
• Dispose the throttle check valve parts that have been
removed.
Figure 73
4. Installing throttle check valve

• Check seal at the plug screw. The surfaces must be
• Install throttle check valve by hand into the bore.
Take care, that spring has the right position inside the
bore of the poppet and the plug screw. Screw in plug
screw in clockwise direction.
Figure 74

5-7-66
Replace Pilot Control Cartridge MHSL 5.5 (Item 210) for
Antidrift-valve Boom and Arm
1. Required tools
• Torque wrench for 100 Nm with hexagon wrench or
socket wrench size 27
2. Pilot control cartridge
Figure 75
3. Removing pilot control cartridge

• Unscrew and remove pilot control cartridge by turning
in counterclockwise direction.
• Dispose the pilot control cartridge that has been
removed.
Figure 76
4. Installing pilot control cartridge

• Check the seals at the pilot control cartridge. The
surfaces must be clean and undamaged.
• Install pilot control cartridge by hand into the bore.
• Tighten pilot control cartridge with torque wrench in
clockwise direction. Tightening torque MT = 100 Nm.
Figure 77

5-7-67
Replace Antidrift Valve (Item 140, 141)
1. Required tools
• Screw M6
• Tong
2. Removing antidrift valve
• Remove antidrift valve with screw M6 and tong by
turning in clockwise direction.
Figure 78
• Dispose the antidrift valve that has been removed.

Figure 79
3. Installing antidrift valve

• Check the seal at the antidrift valve. The surfaces
must be clean and undamaged.
• Install antidrift valve carefully by hand into the bore
without tilting.

5-7-68
Replace Secondary Pressure Relief Valve (Item 202, 208) /
Plug Screw (Item 200)
1. Required tools
• Hexagon wrench or socket wrench size 27 for item
200, 202 (hexagon socket size 30 for item 208)
socket wrench size 27 for item 200, 202 (120 Nm with
hexagon socket size 30 for item 208)
2. Removing secondary pressure relief valve
• Unscrew and remove pressure relief valve/plug
screw in counterclockwise direction.
• Dispose the pressure relief valve that has been
removed.
Figure 80
3. Installing secondary pressure relief valve
IMPORTANT
The pressure setting of the secondary valves can be
different on each axis. Ensure the correct installation
of the secondary valves to the valve axis.
• Check the seal at the thrust ring. The surfaces must

be clean and undamaged.
Figure 81
• Lubricate the pressure relief valve/plug screw and
screw it into the bore in clockwise direction.
• Tighten pressure relief valve/plug screw with torque
wrench.
Tightening torque MT = 100 Nm for item 200, 202.
Tightening torque MT = 120 Nm for item 208.
Figure 82

5-7-69
Replace Load-holding Valve Function Consisting of Poppet
(Item 205), Spring (Item 206) and Plug Screw (Item 207)
1. Required tools
• Magnet gripper
2. Removing load-holding valve
207
• Remove pressure relief valve (208) according to 206
Replace Antidrift Valve (Item 140, 141). 205
208
IMPORTANT
208
Pay attention that no parts fall into the bore of the
housing. 205
207 206
• Unscrew and remove plug screw (207) in FG021079
counterclockwise direction. Figure 83
• Remove spring (206) and poppet (205) with
magnet gripper.
205
T
207 206
FG021078
Figure 84
3. Installing load-holding valve
IMPORTANT
Pay attention that no parts fall into the bore of the
housing.
• Install poppet and spring by hand into the bore.
Take care, that spring has the right position
inside the bore of the poppet.
• Screw in plug screw in clockwise direction.
Tightening torque MT = 150 Nm.
• Install pressure relief valve (208) according to
Replace Antidrift Valve (Item 140, 141).

5-7-70
Replace Spool Boom Summation (Item 170, Similar With
Spool Arm Summation Item 171)
1. Required tools
2. Spool kit consisting of:
• Spool
• Spring retainer
• Pressure spring
• Spring retainer
Figure 85
3. Removing cover
• Unscrew and remove cylinder screw (158) on cover
(155) on side B with hexagon wrench in
counterclockwise direction. Take care, that cover
doesn't fall down.
• Remove cover and deposit it in a clean place.
• Protect cover and bore from contamination and
moisture.
Figure 86
4. Removing spool kit
• Remove pressure spring, spring retainer and spool
without tilting.
5. Installing spool kit
• Install pressure spring, spring retainer and spool by
hand into the bore.
• Install cover with hexagon wrench.
Figure 87

5-7-71
Replace Main Spool
1. Required tools
2. Removing cover
• Unscrew and remove cylinder screws (158) on cover
(155) on side A and B with hexagon wrench in
counterclockwise direction. Take care, that cover
doesn't fall down.
• Protect cover and bore from contamination and moisture.
Figure 88
3. Removing main spool

• Remove spring kit consisting of spring (152) and
spring retainer (151).
• Remove main spool without tilting Figure 89
4. Installing main spool
NOTE: Observe the installation position of the main
spool! The B-side of the main spool is marked
with a rill on the low end.
Figure 90
• Install main spool by hand into the bore without tilting.

• Install spring kit.
Figure 91

5-7-72
• Install cover (155) with hexagon wrench.
Figure 92
Replace Pilot Shuttle Valve (Item 163)

1. Required tools
• Screw tap 3 mm or 4 mm
• Magnet gripper
2. Removing pilot shuttle valve
• Screw in a screw tap into the pilot shuttle valve and
pull it out. According to mounting position use a
screw tap of 3 mm or 4 mm.
IMPORTANT
The pilot shuttle valve will be destroyed during
disassembly and must be replaced.
Take care to remove all parts of the pilot shuttle valve!

5-7-73
3. Installing pilot shuttle valve
• Install pilot shuttle valve by hand into the bore and
press in on block.
• Install cover (155) according to "Replace main spool"
on page -75
IMPORTANT
Note mounting position for main spool!
• Mounting position for main spool:

Pilot shuttle valve direction to port!
A B
FG021081
Figure 93
Figure 94
• Mounting position for spool boom summation, spool

arm summation or cut-valve spool:
Pilot shuttle valve direction to housing!
A B
FG021082
Figure 95

5-7-74
Replace Cut Spool (Item 182)
1. Required tools
• Torque wrench for 10.4 Nm with hexagon wrench
hexagon socket size 5
2. Cut spool consisting of:
• Spool
• Spring
• Spring retainer
• Retaining Ring
Figure 96
3. Removing cover on axis PC2

• Unscrew and remove cylinder screws (187) on cover
(186) with hexagon wrench in counterclockwise
direction. Take care, that cover doesn't fall down.
• Protect cover and bore from contamination and moisture.
Figure 97
4. Remove cut spool

• Remove cut spool (182) carefully.
• Dispose the cut spool that has been removed.
Figure 98
5. Installing cut valve spool

• Install cut spool by hand without tilting.
• Install cover with torque wrench.
Tightening torque MT = 10,4 Nm.

5-7-75
Replace End Plate (Item 113) and Directional Valve
(Item 101)
1. Required tools
• Hexagon socket wrench size 10
• Torque wrench for 100 Nm with hexagon socket size
10
• Oily cloth
• Dressing stone
2. Removing end plate and directional valve
• Unscrew and remove cylinder screws (120) in
counterclockwise direction. Take care, that end plate
and the directional valve don't fall down.
• Remove end plate and the directional valve from the
monoblock.
NOTE: Flange faces may stick together. Gently
pry components apart to disassemble.
• Remove O-rings (111) from the ports.
• Clean all flange faces of the monoblock, the end
element and of the directional valve with the dressing
stone if contaminated and wipe it down with an oily
cloth. Ensure that no contamination enters the bore
during cleanup.
• The sealing faces on the flange face and on the
recess of a flange face, and the sealing elements,
must be clean, dry and free from damage. If the
directional valve is damaged, it must be replaced!

5-7-76
111
111
FG021080
Figure 99
3. Installing end plate and directional valve

• Ensure that all sealing faces and sealing elements
are clean, dry and free from damage.
• Install O-rings (111).
• Bring the directional valve and the end plate into line
with the tightening bores of the monoblock.
• Install cylinder screws (120) by hand and tighten
crosswise with torque wrench.

5-7-77
Replace Inlet Section (Item 220)
1. Required tools
• Oily cloth
• Dressing stone
2. Removing inlet section
• Remove cylinder screws (221) of the plate with
socket wrench in counterclockwise direction.
• Lift and remove plate (220). Protect bores in plate
and monoblock from contamination and moisture.
NOTE: Flange faces may stick together. Gently
pry components apart to disassemble.
Figure 100
• Remove O-rings (30, 31, 32) from the ports.

• Clean all flange faces of the monoblock and of the
plate with the dressing stone if contaminated and
wipe it down with an oily cloth. Ensure that no
contamination enters the bore during cleanup.
• The sealing faces on the flange face and on the
recess of a flange face, and the sealing elements,
must be clean, dry and free from damage. If the plate
is damaged, it must be replaced!
Figure 101
3. Installing inlet section

• Install the plate (220) to the monoblock and bring the
bores into line.
• Install cylinder screws (221) by hand and tighten
crosswise with torque wrench.
FG021138
Figure 102

5-7-78
Replace Pre-load Valves (Item 20 and 21) for Tank Line and
Cooler Back Pressure
1. Required tools
• Screw M6
2. Removing pre-load valve
• Unscrew and remove pre-load valve with screw M6
by turning in clockwise direction.
• Dispose the pre-load valve parts that have been
removed.
Figure 103
3. Installing pre-load valve

NOTE: There are two different types of pre-load valves:
Two-piece valve consisting of poppet and
spring kit One-piece valve.
IMPORTANT
Both pre-load valves (20, 21) have a different spring
force and should not be inverted! The pre-load valve for
cooler back pressure always has the softer spring.
Figure 104
• Check the seal at the pre-load valve. The surfaces

must be clean and undamaged.
• Two-piece type: Install the poppet by hand into the
bore and press in carefully. Then press the spring kit
by hand into the bore on block.
• One-piece type: Install pre-load valve by hand into
the bore and press in carefully.
Figure 105

5-7-79
Replace Primary Pressure Relief Valve (Item 222)
1. Required tools
2. Removing primary pressure relief valve
• Unscrew and remove pressure relief valve MHDBN
22 K2-3X/... in counterclockwise direction.
• Dispose the pressure relief valve that has been
removed.
3. Installing primary pressure relief valve
• Check the seal and the thrust ring. The surfaces must
be clean and undamaged.
damaged, the inlet section must be replaced.
• Lubricate the pressure relief valve and screw it into
the bore in clockwise direction.
• Tighten pressure relief valve with torque wrench.
Figure 106

5-7-80
Replace Check Valves for Primary Pressure Relief (Item 42)
1. Required tools
• Magnet gripper
2. Check valve consisting of:
• Poppet
• Pressure spring
• Plug screw
Figure 107
3. Removing check valve

gripper.
• Dispose the check valve parts that have been
removed.
Figure 108
4. Installing check valve

• Check the bore in the plate. If the bore is damaged,
the plate must be replaced.
• Install check valve by hand into the bore. Take care,
that spring has the right position inside the bore of the
poppet and the plug screw. Screw in plug screw in
clockwise direction.

5-7-81
Replace Straight Travel Valve
1. Required tools
• Hexagon socket wrench size 22 for item 13
• Hexagon socket wrench size 12 for item 9
2. Straight travel valve consisting of:
• Plug screw (13)
• Pressure spring (12)
• Spring retainer (11)
• Spool (10)
• Plug screw (9) Figure 109
3. Removing straight travel valve

• Unscrew and remove plug screw (13) on side A with
hexagon socket wrench in counterclockwise
direction.
• Unscrew and remove plug screw (9) on side B with
hexagon socket wrench in counterclockwise
direction.
• Remove pressure spring, spring retainer and spool
from the bore without tilting. Push from the opposite
side if necessary.
Figure 110
4. Installing straight travel valve

• Check the bore in the plate. If the bore is damaged,
the plate must be replaced.
• Install plug screw (9) on side B by hand into the bore.
• Tighten the plug screw with torque wrench in
• Install spool, spring retainer and pressure spring by
hand into the bore and side A. Figure 111
• Install plug screw (13) on side A by hand into the
bore.
• Tighten the plug screw with torque wrench in

5-7-82
REASSEMBLY
WARNING
HIGH-PRESSURE OIL HAZARD
• Make sure the relevant system component is not under
pressure before assembling the product or when
connecting and disconnecting plugs.
• Protect system components against unintended
switching on.
ELECTRICAL SHOCK HAZARD

• Switch off power supply to the relevant system
component before assembling the product or when
connecting and disconnecting plug-in connectors.
• Connect control block solenoids only if no voltage is
applied.
• Protect the system component against unintended
switching on.
• Always connect the ground connections of the control
block with the appropriate ground system in your
installation.
• Only use a power pack with electrical isolation.
• Always comply with the applicable laws and
regulations.
TRIPPING HAZARD
• Lay the cables and lines so that they cannot be
damaged and no one can trip over them.
ACCIDENTAL MOVEMENT OF MACHINE

Avoid injury caused by incorrect assembly of pin
assignment or cable connections.
• Make sure that all pipes and/or hoses are applied at
the correct control block connection.
• After the completion of final assembly, you must
check the correct assembly of the cable plugs to each
control block solenoid.
NOTE: Noncompliance with protection class IP67 and risk of

short circuit because of missing seals and caps.
Fluids and foreign materials may penetrate into the
control block and destroy it.
– Before assembling make sure that all seals and
plugs of the plug-in connections are tight.

5-7-83
NOTE: Damage caused by incorrect assembly!
When assembling hydraulic lines and hoses under
mechanical stress, they are exposed to additional
mechanical forces during operation, which reduces
the service life of the control block and the complete
machine.
– Assemble hydraulic lines and hoses without
mechanical stress.
NOTE: Wear and malfunctions caused by contaminated
pressure fluid
The cleanliness of the hydraulic fluid has a
considerable impact on the cleanliness and service
life of the hydraulic system as a whole. Any pollution/
contamination of the hydraulic fluid will result in wear
and malfunctions. In particular, foreign bodies (e.g.
welding beads or metal cuttings) in the hydraulic lines
may damage the control block.
– Always ensure absolute cleanliness
– Assemble the control block free from any
pollution.
– Make sure that all connections, hydraulic lines
and add-on units (e.g. measuring instruments)
are clean.
– Ensure that no pollutants are able to penetrate
when sealing the connections.
– Ensure that no detergents are able to penetrate
the hydraulic system.
– Do not use cleaning rags/cotton waste or linty
cloth for cleaning.
– Only use suitable and permitted sealing
material for the seals.
– Possible oil residues from the factory check
must be completely removed.
– Remove possible resinifications caused be
incorrect storage.
NOTE: Functional impairment caused by wrong plug
connections!
Only use the plug connections listed in the "Technical
data sheet" for electrical connection.
– Observe the assembly instructions of the
manufacturer of the plug connections!
– Before commissioning, you must check the
power supply whether the voltage complies with
the details on the "Installation drawing" and
whether the total of the solenoid currents to be
expected is lower than or equals the capacity of
the power supply.

5-7-84
– The plug connections may only be contacted
when deenergized. The assembly process must
not be repeated more than 10 times.
NOTE: Incorrect connection wiring!
The control block must only be connected by a
specialized electrician or under supervision of the
same. The lines used have to be suitable for
operating temperatures of 20 °C...+100 °C.
– De-energize the connection line before
installation.
– Avoid sharp bends in the connection line and
the stranded wires, to avoid short-circuits and
interruptions.
– Route the connection line(s) using strain relief.
The first attachment point must be located at a
distance to the cable entry of 15 cm at most.
– Use fine-wired conductors with pressed-on wire
end sleeves only.
Unpacking
Dispose of the packaging according to the applicable laws and
regulations.
Coating the Control Block

If the control block is to be painted before being assembled,
please observe the following:
1. Protect the hydraulic ports against paint contamination by
screwing-in plastic threaded plugs beforehand.
2. Protect fastening threads against paint by screwing in
bolts.
3. Mask the flange surfaces of the control blocks and the
connection and end plates carefully before painting so no
dirt or paint may enter.
4. Avoid paint being applied to the contacts of the electrical
connections and make sure not to cause any damage to
the connector.
5. If you remove plastic screw-in plugs after painting you
must make sure that no paint chips enter the control block.
Nameplates are protected against the application of paint using
a foil which can be removed after coating.

5-7-85
Installation Conditions
When installing the product always observe the ambient
conditions specified in the technical data.
Installation position
If not indicated otherwise in the technical documents, the control
blocks can be installed in any position.
Required Tools
For mounting the control block, you only need commercial tools
suitable for the fastenings specified on the installation drawing.
Assembling the Control Block
Fastening the control block

For fastening, the control block is provided with fastening bores
which can be seen on the "Installation drawing". Please see the
"Installation drawing" for the position tolerances of the fastening
bores at the machine. Select the tightening torque according to
the usual standard values for each bore size and screw
tensioning class. Too much tightening torque might cause the
jamming of the valve spool. If this is the case, you must reduce
the tightening torque accordingly.
Observe the adequate residual clamping force of the screws.
1. Observe the requirements for the contact surface specified
in the "Installation drawing".
2. Check the smoothness of the flange surface in the
machine (tolerance: 0.5 mm)
3. Tighten mounting screws applying the tightening torque
specified in the standard.
4. Always mount the control block at the provided mounting
points and only use screws having the property class
according to EN ISO 4762 or EN ISO 4014 as specified.

5-7-86
We recommend screwing with the following parameters:
Series Dimensions Property Class Tightening Torque (Nm) Screw-in Depth (mm)
M1-16 M8 8.8/10.9 27/40 1
M1-25 M10 8.8/10.9 54/79 10

M1-32 M12 8.8/10.9 93/37 1
M4-12 M10 8.8/10.9 41/60 12...15

M4-15 M10 8.8/10.9 54/79 10
M4-22 M16 8.8/10.9 230/338 1
M6-15 M10 8.8/10.9 54/79 10

M6-22 M12 8.8/10.9 93/137 12
M7-20 M12 8.8/10.9 93/137 12
M7-22 M16 8.8/10.9 230/338 16
M8-16 M16 8.8/10.9 230/338 16
M8-18 M16 8.8/10.9 230/338 16
M8-22 M16 8.8/10.9 230/338 16
M8-25 M16 8.8/10.9 230/338 16
M8-32 M20 8.8/10.9 464/661 20
M8-35 M16 8.8/10.9 230/338 1
M9-20 M16 8.8/10.9 230/338 16

M9-25 M16 8.8/10.9 230/338 16
MO-10 M10 8.8/10.9 54/79 1
MO-16 M8 8.8/10.9 27/40 1
MO-22 M10 8.8/10.9 54/79 1
MO-32 M12 8.8/10.9 93/137 1
MO-40 M16 8.8/10.9 230/338 1
MO-52 M20 8.8/10.9 464/661 20

SP-08 M8 8.8/10.9 25/30 10...14; 1
SM 12 M8
SX 10 M8
SX 12 M8
SX 14 M10
SX 14 NGE M10
1
Through-holes in the housing; the screw-in depth depends on
the material of the nut thread.
Mechanically Connecting the Control Block

Please see the "Installation drawing" for the connection of the
actuating elements including. tolerances. Select the tightening
torque according to the actuating elements.
The actuation must be free of transverse forces!
1. Make sure before commissioning that switch is at zero
position (spool in center position).

5-7-87
Hydraulically Connecting the Control Block
The connecting system and the tightening torque required for
the hydraulic connection are specified on the "Installation
drawing" and the "Technical data sheet". The connection must
be designed according to the appropriate standard. The
standards are available at the distribution organizations which
are commissioned with the distribution of the standards by the
standard committee.
1. Use the provided seal for each hydraulic connection.
Installing the Electrical Supply

De-energize the relevant part of the system.
IMPORTANT
Information on the correct pin assignment are available in
the "Quotation/installation drawing".

5-7-88
Before First Commissioning
1. Make sure that interfaces of the machine and the
installation conditions allow for the safe operation of the
control block. In case of doubt, contact to us.
2. Check the operating instructions for the machine to find out
in which machine the control block must be installed, and
make a visual inspection to check whether the
commissioning of the hydraulics might result in
uncontrolled and dangerous motions. If necessary,
observe the risk analysis/risk evaluation of the machine.
3. Take according precautions if risks are to be expected, e.g.
make sure that cylinder piston rod can be extended without
any risks.
4. Secure the load to be lifted additionally with lifting gear/
load bearing equipment.
5. Check whether the electrical control of the machine allows
for the manual switching of the control block solenoids
during commissioning. If manual switching is not possible
or only under difficult conditions, you must prepare an
external control for the internal functional test of the
hydraulic system.
6. Develop a program for the commissioning process and file
it in the technical documents as annex to the operating
instructions.
7. Divide the functional circuit diagram in sub-circuits which
can be commissioned one after the other.
8. Read the functional circuit diagram and clarify ambiguous
facts and specifications.
9. Determine in which spool position the control blocks must
be switched and how they must be adjusted.
10. Apply important mandatory signs, prohibition signs,
information signs and check whether the meaning of these
signs is explained in the operating instructions.
11. Observe the following order for commissioning:
• Pump circuit
• Parts of the control: e.g. depressurization and switch-
over, free circulation, pressure reduction, etc.
12. Ensure that pipes and/or hoses are connected to all ports
and/or that ports are closed using plug screws.
13. Ensure that cap nuts and flanges are tightened properly on
pipe fittings and flanges.
14. Switch pressure and flow valves, pump controllers, and
sensors such as pressure switches, limit switches and
temperature controllers to the switching positions and set
values specified in the process program.

5-7-89
Maintenance and Repair
WARNING
• Regularly check the safety devices for correct
functionality.
• Adequately secure the maintenance area before
starting maintenance work.
• Pay attention to cleanliness in order to avoid
malfunctions caused by dirt. Paint residues on sealing
surfaces must be removed before assembly. Make
sure that paint residues do not enter block openings.
• Operate the hydraulic functions in maintenance mode.
If machine operation is required with protective covers
removed, do so with care. Switch off the hydraulic
functions and secure them against unintended
switching on.
• The user is not allowed to change the set values of
safety valves. New adjustments may only be
accomplished by authorized testing authorities.
• Wear protective goggles, protective gloves and safety
boots. Relieve hydraulic pressure in the system and
accumulators before performing maintenance.
• Let system sections and pressure lines which can be
opened cool down before starting commissioning
works.
• Slowly open segments which must still be
pressurized.
• Please observe that if there are check valves in the
pressure lines above the pumps, the hydraulic system
might still be pressurized after it has been
disconnected from the actual pressure supply. Move
all cylinders to the safe end position.
• Lower any load. Provide support devices if the load
cannot be lowered. Never conduct maintenance work
on raised components without using proper support
devices.
• Document date and type of maintenance performed.

5-7-90
WARNING
• Stop the engine and relieve any stored hydraulic
pressure.
• Support vertical cylinders mechanically against
sinking.
• Only new, structurally identical and tested
components, spare parts and lubricants in original
equipment quality are admitted for replacement/use.
• Make sure that all protective devices and functions
which could impair the safety shutdown system are
correctly installed and checked for functionality before
each re-commissioning.
• After the completion of all work, remove all tools and
devices used for maintenance from the machine.
Personal injuries caused by not functioning spare parts that
do not meet the technical requirements specified by
Doosan may cause personal injuries.
• Only use genuine spare parts from Doosan.
NOTE: Penetrating dirt and liquids will cause faults!

– Always ensure absolute cleanliness when working
on the control block.
– Cover all openings with the appropriate protective
equipment to prevent detergents from penetrating
the system.
– Check that all seals and plugs of the plug-in
connection are firmly Installed so no humidity
can penetrate the control block during cleaning.
– Dust accumulations on the control block have to
be removed at regular intervals.
NOTE: Damage to the surface from solvents and aggressive
cleaning agents!
Aggressive detergents can damage the seals on the
control block and let them age faster.
– Never use solvents or aggressive detergents.
– Only clean the control block using a damp,
lint-free cloth. Only use water to do this and, if
necessary, a mild detergent.

5-7-91
NOTE: Damage to the hydraulic system and seals!
The water pressure of a high-pressure cleaner can
damage the control block and seals of the hydraulic
power unit. The water displaces the oil from the
hydraulic system and seals.
– Do not use a high-pressure cleaner.
Definition
In accordance with DIN 31051: 2003-6 the term maintenance
means the combination of all technical and administrative
measures taken by management during the life cycle of an item
in order to maintain the functional condition or to return to the
same, so that item is able to meet the required function.
These measures can be classified into:
1. Maintenance (measures to delay the decrease of the
existing wear reserve).
2. Inspection (measures to determine and assess the actual
condition of an item, including the determination of the
cause of wear and the derivation of the required
consequences for a future use).
3. Repair (measures to return an item to a functional state,
except improvements).
4. Improvement (combination of all technical and
administrative measures and measures taken by the
management to increase the functional safety of an item,
without modifying the function required).
Inspection and Maintenance

The goal of inspection and maintenance is
1. to maintain the functionality of the system with its initial
parameters.
2. to ensure the permanent availability of the system.
3. to determine weak points.
4. to achieve the required service life of the system.
Basically we recommend to keep an inspection and
maintenance record where any system and site-specific works
and inspection and maintenance intervals are defined and
documented.
If the specified operating and ambient conditions are observed,
the control blocks are maintenance-free. Regular inspection and
maintenance work is therefore not required.
However, the following must be checked at least every three
years (from the manufacturer date of the control block):
1. The control block for leakage at the outside.
2. All screws and connections are firmly seated.

5-7-92
3. All connection lines for damages. If damage is visible,
replace the connection line.
IMPORTANT
Order information for seal kits is available in See “Spare
Parts” on page -95..
Pressure Fluids
The performance characteristics of pressure fluids deteriorate
with increased aging (chemical deterioration). Acids and resin
residues are formed which cause the bonding of mobile parts
inside the control block.
The following factors accelerate the aging process:
1. High temperatures
2. Air in the pressure fluid
3. Humidity
4. Water
5. Metallic catalysts
6. High operating pressure
7. Contamination
IMPORTANT
Observe the following general rule:
From a hydraulic fluid temperature of > 70 °C, aging
speed doubles with every 10 °C.
8. Further information on hydraulic fluids based on mineral oil

also applying for control blocks are available in our
technical data sheets.

5-7-93
Malfunction Caused by Contaminated Hydraulic Fluid
Contaminations of the hydraulic fluid not only result in increased
wear and reduced service life of the control block but also in
malfunctions. This could impair the safety and reliability of the
control block.
Therefore you should regularly perform the maintenance
measures specified in the operating instructions of the machine
and check cleanliness when working on the control block.
The following aspects might cause the contamination of the
hydraulic fluid:
1. Wear during the operation of the machine (metallic and
nonmetallic abrasion)
2. Leakages on the control block
3. Contamination during maintenance/repair
4. Use of contaminated (unfiltered) hydraulic fluid for
replacement.
Replenishing/Refilling
When replenishing/refilling your hydraulic system you must
make sure that you use admissible hydraulic fluid of the same
type and the same manufacturer.
In case of major contamination and/or premature aging of the
hydraulic fluid, the system including the tank must be cleaned
and rinsed before refilling. Before refilling, you must always filter
new hydraulic fluid according to the required cleanliness class
because it usually does not comply with the required cleanliness
class in its as-delivered state. Lines and hoses must be rinsed
before installation.
Use a filter aggregate when filling the hydraulic fluid tank. The
filter must be clean. Do not remove filter screens from the filler
neck or the filter insert of filters when filling the hydraulic fluid
tank.
IMPORTANT
The filter mesh must at least meet the required cleanliness
class of the entire system. If possible, it must even be finer.
The applied filter unit must meet the requirements about
functional safety and service life.
If possible, replenish the hydraulic fluid tank using a filling
coupling at the return filter.

5-7-94
Repair
IMPORTANT
Doosan offers a wide range of repair services for the control
block.
1. Only use genuine spare parts from Doosan for repairing

the Doosan.
2. The spare parts lists of the control blocks are
product-specific. Please indicate material and series
number of the control block and the material number of the
spare parts when ordering spare parts.
Instructions for Repair

For repair works, the control block may only be disassembled to
the extent described in the operating instructions.
Spare Parts
1. Order spare parts in writing. In urgent cases you can also
order by phone, but you are kindly requested to confirm
your order in writing (e.g. by fax).
2. Please send any enquiry to your nearest Doosan service
center or contact headquarters direct.
3. When ordering spare parts, please indicate the following
information from the product's nameplate:
• The material number of the control block.
4. Please indicate the following details from the spare parts list:
• Part number.
5. Additionally indicate:
• The desired number of spare parts.
• The desired type of dispatch (e.g. as parcel, freight,
air freight, by courier service, etc.).

5-7-95
TROUBLESHOOTING
Troubleshooting, Testing and Adjustment
How to Proceed for Troubleshooting

1. Always act systematically and targeted, even under
pressure of time. Random and imprudent disassembly and
readjustment of settings might result in the inability to
restore the original error cause.
2. First get a general idea of how the mobile control block
works in conjunction with the entire system.
3. Try to find out whether the mobile control block has worked
properly in conjunction with the entire system before the
troubles occurred first.
4. Try to determine any changes of the entire system in which
the mobile control block is integrated:
• Were there any changes to the mobile control block's
operating conditions or operating range?
• Were there any changes or repair works on the entire
system (machine/vehicle, electronics, control) or on
the mobile control block? If yes: which?
• Was the mobile control block or machine/vehicle
used as intended?
• How did the problem appear?
5. Try to get a clear idea of the error cause. Directly ask the
(machine) operator.

5-7-96
Malfunction Table
The control block is not susceptible to faults as long as the
specified conditions of use are complied with, in particular the
quality of the oil.
Problem Possible Cause Remedy

Pressure fluid escaping from the Control block housing leaking at Check seals, renew if necessary,
mobile control block the piston check tightening torques.
See "Installation Drawing" and
"Parts list"
Plug screws leaking Tighten plug screws, renew
sealing rings if necessary.
For O-ring seals:
Do not re-tighten the plug screw,
replace the seals and tighten the
plug screw with the specified torque
(see "Installation Drawing")
Control block housing leaking Remove control block and replace
it with a new one.
Connections leading to the Check seals, renew if necessary.
actuator leaking (Screw sockets, Check tightening torques,
screw connections) see "Installation Drawing"
Pressure fluid escaping from pipe or Pipe or hose lines damaged Renew pipe or hose lines
hose lines Pipe or hose lines have worked loose Tighten the screw connections and
fittings according to the assembly
instruction applicable to the fittings.
The corresponding assembly
instructions are available from the
manufacturer.
Pressure fluid leaking between the Seals in flange surface damaged Renew the seals, see "Installation
mobile control block modules Drawing"
Contamination entry upon Disassemble the control block,
assembly of the control block clean the flange surface,
see "Installation Drawing"
Mobile control block housing Renew damaged mobile control
leaking at flange surface block module.
Tightening torque of tie rods too low Check the tightening torques, see
"Installation Drawing"
Hydraulic function disturbed Air in the pressure fluid Vent hydraulic system.

5-7-97
Spool cannot Tie rods have been tightened with Loosen the nuts of the tie rods and
be mechanically too great a tightening torque tighten at the specified torque, see
displaced "Installation Drawing" of the
respective product.
Oil temperature too high and/or too Check cooler function, oil supply
great a temperature difference and pump pressure in neutral
between the pressure fluid and the position. Avoid temperature shock.
mobile control block, causing
blocking because of dissimilar heat
expansion of spool and mobile
control block
Contamination or foreign particles Visually inspect the connectors to
introduced during the assembly of the actuator, remove foreign
the connections leading to the particles with a magnet or
actuator are jamming the spool tweezers. In case of jammed
foreign particles, replace the control
block module with a new one.
Spool returns too slowly or not at all Spool jamming See "Spool cannot be
mechanically displaced" above in
the event of a malfunction.
Following a breakdown because of contamination, it is essential

to check the oil quality and if necessary to improve it by suitable
means, such as flushing or the additional building in of filters.

5-7-98
START-UP PROCEDURES
Commissioning
WARNING
Air enclosed in hydraulic systems can cause components
to vibrate during operation and cause unexpected
movements of the actuators:
• Depressurize the hydraulics before starting
commissioning and relieve accumulator pressure.
• Before commissioning you must make sure that
enclosed air is completely removed from the system.
This can be done by operating all machine functions at
low idle.
NOTE: Product damages resulting from a lack of pressure

fluid
If you commission the control block without or with
too little pressure fluid, the control block will be
immediately damaged or even destroyed.
– When commissioning or re-commissioning a
machine or system, you should ensure that
housing space, and the suction and work lines
of the control block are filled with pressure fluid
and that they remain filled with oil during
operation.

5-7-99
First Commissioning
1. Let the control block acclimate itself for several hours
before commissioning, otherwise water may condense in
the housing.
2. Make sure that all electrical and hydraulic connections are
either used or covered. Commission the control block only
if it is installed completely.
3. Avoid temperature shocks. Do not exceed temperature
differences of more than 20 °C between control block and
pressure fluid. Otherwise you risk jammed spools.
If temperatures are below-20 °C, the control block must be
warmed up.
Proceed as follows for the first commissioning of the control
block:
1. Completely fill the control block with permissible pressure
fluid.
2. Before commissioning, the housing of the control block
and, if available, the pre-control circuit must be completely
filled with pressure fluid and must be bled (see below).
3. Switch on hydraulic supply.
4. Activate the electrical supply.
5. Check electrical connections.
Before first or re-commissioning, have the electrical
connections checked for proper condition by a trained
electrician or under the direction and supervision of a
trained electrician.
IMPORTANT
Observe the operating instructions of the machine
where the control block is installed.
6. Bleed the hydraulic system.

Before the actual operation, you must switch the control
block several times under operating pressure in each
actuating direction and with reduced velocity. Thus, the
remaining air in the control block is pressed out.
Mechanical damage because of inadmissibly high
acceleration of the pressure fluid and the control block
spool is thus avoided and the control block's service life is
increased.

5-7-100
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do not
use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a doctor familiar with this injury.
7. Leakage test
Check whether during operation, hydraulic fluid leaks at
the control block and at the connections.
8. Perform a functional test ensuring that all controls function
as intended.
9. Commission control block.
IMPORTANT
Details for fine adjustment are available in the
operating instructions of each machine.
10. Check the operating temperature of the machine after

several hours of continuous operation. Too high operating
temperatures indicate errors which must be analyzed and
removed.
11. Have a pressure fluid sample analytically tested for the
required cleanliness class after first commissioning.
Replace the pressure fluid if the required cleanliness class
is not achieved. If the pressure fluid is not tested in the
laboratory after first commissioning, the following applies:
Replace the pressure fluid.
Re-commissioning
Proceed as follows to re-commission the control block:
1. Follow the instructions in See “First Commissioning” on
page -100.

5-7-101
5-7-102
Swing Device
Edition 1
DX340LC-5/DX350LC-5 Swing Device

5-8-1
MEMO
Swing Device DX340LC-5/DX350LC-5

5-8-2
Table of Contents
Swing Device
General ...........................................................5-8-5
Specification .............................................................. 5-8-5
Swing Motor ......................................................... 5-8-5
Swing Reduction Gear ......................................... 5-8-5
Pinion Gear .......................................................... 5-8-5
Parking Brake....................................................... 5-8-5
Overview ................................................................... 5-8-6
Hydraulics Circuit ...................................................... 5-8-7
Parts List ................................................................... 5-8-8
Swing Motor ......................................................... 5-8-8
Swing Reduction Gear ....................................... 5-8-10
Swing Device...................................................... 5-8-12
Hydraulic Motor .................................................. 5-8-13
Valve Casing ...................................................... 5-8-14
Schematic of Operation of Reactionless Valve .. 5-8-18
Brake Part .......................................................... 5-8-19
Cautions for Operation ............................................ 5-8-21
Inspection ........................................................... 5-8-21
Direction of Rotation........................................... 5-8-21
External Load at the End of Shaft ...................... 5-8-22
Hydraulic Oil and Temperature Range............... 5-8-22
Filter ................................................................... 5-8-23
Installation and Piping ........................................ 5-8-23
Oil Filling and Air Ventilation .............................. 5-8-24
Instructions before Starting to Operate .............. 5-8-24
Precaution ....................................................5-8-25
Tools for Disassembly and Assembly ..................... 5-8-25
Removal .......................................................5-8-27
Installation ....................................................5-8-31
Completing work ...........................................5-8-31

5-8-3
Disassembly and Reassembly......................5-8-32
Disassemble Swing Motor.................................. 5-8-32
Reassemble Swing Motor .................................. 5-8-36
Disassemble the Reduction Gear....................... 5-8-42
Reassemble the Reduction Gear ....................... 5-8-46
General Instructions ................................................ 5-8-53
Examination of Hydraulic Motor .............................. 5-8-53
Troubleshooting....................................................... 5-8-54
Maintenance Instructions..............................5-8-57
Replacement Standard of Worn Parts..................... 5-8-57
Standard of Sliding Surface Correction ................... 5-8-57

5-8-4
SAFETY INSTRUCTIONS
WARNING
machine. Read and understand the Operation and
or serious injury.
GENERAL
Specification
Swing Motor
Type Axial Piston

Displacement 260 cm3 (0.009 ft3)
Crossover Relief Valve Setting 300 kg/cm2 (294 bar)@315 L/min
Max. Supply Flow 315 L/min (83 U.S. gal)
Motor Shaft Speed 1,211 rpm
Motor Shaft Torque 1,216 Nm (124 kg.m, 897 ft lb)
Accessory Valves Swing Reactionless Valve
Weight 65.5 kg (144 lb)
Swing Reduction Gear
Drive Type 2 - Stage Planetary Gear

Reduction Ratio 19.565
Max. Output Speed 61.8 rpm
Max. Output Torque 22,221 N.m (2,266 kg.m, 16,390 ft lb)
Weight 343 kg (756 lb)
Pinion Gear
Type Spur Gear

Gear P.C.D D 196 mm
No. of Teeth 14
Module 14
Parking Brake
Spool Cracking 6 kg/cm2 (5.9 bar)

Time Delay 6.5 ±1.5 sec

5-8-5
Overview
Swing device consists of a swing motor and swing reduction
gear.
Swing motor includes a mechanical parking valve, relief valve,
makeup valve and time delay valve.
B A
C
SH PG
Pa
Air Breather
DB
Dr
Pb
Oil Level Gauge
EX1400019
Figure 1
Port Name Size

A High-pressure (Right) SAE 1"-6,000 psi
B High-pressure (Left) SAE 1"-6,000 psi
C Make Up PF 1 1/4, O-ring
DB Motor Drain PF 1/2, O-ring
SH Brake Signal PF 1/4, O-ring
PG Brake Release PF 1/4, O-ring
Pa Pressure Gauge PF 1/4, O-ring
Pb Pressure Gauge PF 1/4, O-ring
Air Breather PT 3/4
Oil Level Gauge PT 3/4
Dr Oil Drain PT 3/8

5-8-6
Hydraulics Circuit
RED
SH
PG
DB
C
PA PB
A B
EX1400020
Figure 2

5-8-7
Parts List
Swing Motor
R29
T11
T21 T28
T33 T8
T20 T31
T19 T39 T2
T39
T31
T10
T15
T19 T14
T20
T24 T33
37 T22
T18 T21
T5
T17 T7
T16
T25
T3
T13
T23
T4
T6
T12
T38
T30
T35
T34 T1
T36 EX1301131
Figure 3

5-8-8
Reference Reference
Number Number
T1 Casing T20 Spring
T2 Valve Casing T21 Plug
T3 Driveshaft T22 Pin
T4 Roller Bearing T23 O-ring
T5 Roller Bearing T24 O-ring
T6 Oil Seal T25 O-ring
T7 Shoe Plate T28 Socket Bolt
T8 Plate Retainer T29 Socket Bolt
T10 Piston Assembly T30 Socket Bolt
T11 Thrust Ball T31 Plug
T12 Cylinder Spring T33 O-ring
T13 Cylinder Block T34 Plug
T14 Friction Plate T35 O-ring
T15 Mating Plate T36 Retaining Ring
T16 Brake Piston T37 Relief Valve
T17 Brake Spring T38 Brake Valve
T18 Valve Plate T39 Swing Reactionless Valve
T19 Plunger

5-8-9
Swing Reduction Gear
R35-1
R37
R35 R30 R28
R4
R27 R5
R32
R35-2
R25
R24
R18 R26
R1
R23
R20 R26
R22
R12
R14
R21 R3
R16
R9
R20
R17
R19 R6
R31
R11 R33
R8
R23
R10
R13
R15
R29 R29
R19 R2
R7
R29
FG020711
Figure 4

5-8-10
Reference Reference
Number Number
R1 Casing R20 No.1 Thrust Washer
R2 Pinion Shaft R21 No.3 Thrust Washer
R3 Spherical Roller Bearing R22 Thrust Plate
R4 Cylinderical Roller Bearing R23 Screw
R5 Oil Seal R24 Case Cover
R6 Bearing Cover R25 Hex Socket Plug
R7 Ring Gear R26 Plug
R8 No.2 Carrier R27 Oil Level Gauge Pipe
R9 No.1 Carrier R28 Elevel Gaug
R10 Preload Plate R29 Pin
R11 Pin R30 Socket Bolt
R12 Inner Ring R31 Socket Bolt
R13 Bushing R32 Parallel Pin
R14 Needle Bearing R33 Bolt
R15 No.2 planetary gear R35 Air Breather Pipe
R16 No.1 planetary gear R35-1 Cap
R17 No.2 Sun Gear R35-2 Adapter
R18 No.1 Sun Gear R37 Socket Bolt
R19 No.2 Thrust Wa sher

5-8-11
Swing Device
R35
R37
R28
R30
FG021181
Figure 5
Reference Reference
Number Number
R28 Level Gauge Assembly R35 Air Breather Assembly
R30 Reduction Gear Socket Bolt R37 Swing Motor Socket Bolt

5-8-12
Theory of Operation
Hydraulic Motor
As shown in the figure below, the high-pressure oil entering the
cylinder block through valve plate (1) inlet side port exerts
pressure on the piston, generating axial force F. The force F is
divided into the two vectors of force F1 which is perpendicular to
the swash plate (3) and F2 which is perpendicular to the shaft,
with the shoe (2) as the medium. With the piston and the
medium, the force F2 is transmitted to the cylinder block (4) and
generates rotational torque to the output shaft. On the cylinder
block, 9 pistons are arranged equidistantly, and rotational torque
is transmitted to the output shaft by the multiple pistons
connected to the inlet side of the high-pressure oil in
consequences.
Reversing the direction of oil flow will reverse the direction of
rotation of the output shaft.
Theoretical output torque T is calculated with the formula below;
P×q
T=
2×π
P: effective differential pressure (kg/cm2)

q: volume per rotation (cc/rev)
Low Press. Oil High Press. Oil

Shoe Plate (3) Valve Plate (1)
Outlet Port Inlet Port
Shoe (2) Piston Cylinder Block (4)

FG018896
Figure 6 Operation Diagram of Motor

5-8-13
Valve Casing
1. Anticavitation check valve
Since the system using this type of motor has no valve
which has counterbalance function, the motor may rotate
exceeding the feed oil flow.
To prevent cavitation, suck in deficient oil through the
check valve.
Control Valve Control Valve
EX1301686
Figure 7
2. Relief valve
Lets assume that port P is pressurized from the tank
pressure. Initially, ports P and R are at tank pressure.
321 302 h g
R Port
P Port
A1 m 301 A2 n 401
EX1301621
Figure 8
When the two forces; the force defined by the product of

the area (A1) of plunger (301) receiving pressure and
pressure P1; and the force defined by the product of spring
(321) force (Fsp) and pressure-receiving area (A2) of
plunger (301) by the pressure Pg in the chamber g;
become the same, the relief valve starts to function.

5-8-14
Here, the Pg is the pressure in the chamber g which is
pressurized by the oil through the orifice m, and when it
reaches the pressure defined by the spring (321) pressing
the piston (302), the piston starts to move to the left.
P1 x A1 = Fsp + Pg x A2
Fsp + Pg x A2
P1 =
A1
321 g
R Port
P Port
A1 301 A2
Figure 9 EX1301687
3. Chamber h acts as a damping chamber by the orifice (n)

formed on the side of the piston (302).
By this, the pressure in the chamber g increases smoothly
until piston (302) reaches the end of the adjustment plug
(401).
321 302 h g
R Port
P Port
n 401
Figure 10 EX1301688

5-8-15
When the piston (302) reaches the end of the adjustment
plug (401), it cannot move further to the left, thus, the
pressure in chamber g becomes equal to Ps and the force
of the spring (321) becomes Fsp' (Figure 11).
Consequently, the pressure P varies as illustrated in
(Figure 11).
The pressure Ps at the final stage is expressed with the
equation below;
Ps x A1 = Fsp' + Ps x A2
Fsp'
Ps =
A1 - A2
302 g
R Port
P Port
Pressure: Ps 401
Pressure
Ps
P1
Time
Operational Diagram
EX1301689
Figure 11 Relief Valve

5-8-16
4. Reactionless valve
When the direction switching valve of swing motor I
switched, high-pressure oil is supplied to the port A (or port
B) of the hydraulic motor. Then, the poppet of the
reactionless valve moves to the right, blocks the bypass
route and drives the rotating body (1, Figure 12).
Then, when the direction switching valve returns to neutral
position, the ports at both sides of the hydraulic motor are
blocked, but the rotating body would maintain its rotation
because of inertia and the momentum of inertia is
transmitted to the hydraulic motor through the reduction
gear, generating brake pressure at the port B (or port A)
which stops the rotating body and tries to reverse the
direction of rotation.
By this brake pressure, the swing motor first stops and
then tries to reverse its direction of rotation and the
pressure at the port B tries to switch the poppet to the left,
but the action is delayed by the orifice at the port A. Now, a
bypass route is formed connecting the ports A and B
through which the high-pressure oil flows from port B to the
port A (2, Figure 12).
And, the poppet on the port B side moves to the left until it
blocks the bypass route (3, Figure 12).
As described above, in the process of reverse pressure
generation at the port B, the high-pressure oil is bypassed
to the port A to prevent reverse rotation and stop the swing
motor right away.
Motor Inlet
A Port Bypass Motor Outlet
B Port
(1)
Orifice Poppet Bypass
(2)
(3)
EX1301726
Figure 12 Principle of Operation of Reactionless Valve

5-8-17
Schematic of Operation of Reactionless Valve
1st 2nd

A B A B
Swing Swing Stop (Start of Stop)
3rd 4th
By Pass
A B A B
Swing Stop (before the Stop) Swing Stop (Complete of Stop)
EX1301690
Figure 13

5-8-18
Brake Part
The cylinder block (108) is connected with the driveshaft (102)
by spline joint, and rotation of the separation plate (110) in
circumferential direction is restricted by the circular arc grooved
on the casing (115). When the friction plate (109), engaged with
the outer circumference of the cylinder with gears, is pressed to
the casing (115) by the brake spring (118) with the separation
plate (110) and brake piston (119) as the media. Friction force is
generated between the friction plate and casing, separation
plate and brake piston. This friction force restricts and brakes
the driveshaft.
When brake release pressure is applied to the oil chamber
formed between the brake piston and casing and this pressure
overcomes the spring force, the brake piston moves and the
friction plate is separated from the casing, and the brake is
released.
Oil Pressure
Spring Force
118
119
Oil Chamber
110
109
Valve Casing
108
102
EX1400076
Figure 14 Operation Diagram of Brake

5-8-19
1. Parking brake operating
SH
PG
DB
PG SH
EX1400061
Figure 15
2. Parking brake release
SH
PG
DB
PG SH
EX1400062
Figure 16

5-8-20
Cautions for Operation
Inspection
Please check the followings before installing a new motor:
1. Check if there is any part damaged or missing (during
transportation).
2. Check if there is any loose joint.
3. Check that flange surfaces and the drain port cover are
properly assembled and there is no dust or other particle in
the motor.
Direction of Rotation
The relationship between the directions of oil flow and shaft
rotation is presented in Figure 17 and Table.
The direction of rotation differs by the direction of the slope of
casing.
Be careful for the direction of swing which is differentiated by the
shape of casing and direction of flange.
Normal Direction Reverse Direction

(Letter 'M' is Attached to the End of the Model Name)
EX1400021
Figure 17
Direction of the Rotation of the

Classification Inlet Outlet Shaft Seen at the End of the
Shaft
Normal Direction A B Right (Clockwise)
Reverse Direction B A Left (Counterclockwise)

5-8-21
External Load at the End of Shaft
In principle, the end of the motor shaft must be free of any
external radial or thrust load.
Hydraulic Oil and Temperature Range

1. Oil type
The recommended oil is mineral type hydraulic oil added
with extreme pressure additive, foam suppressor,
antioxidant, and desiccant, having high viscosity index.
2. Optimal viscosity and temperature range of hydraulic oil
(Figure 18)
Maximum viscosity range is 10 - 1000 cSt, however,
recommended range is 10 - 200 cSt to obtain optimal
efficiency.
Temperature range is restricted between -25 - 100°C to
protect oil seals and O-rings. The highest recommended
temperature is 60°C or lower to prevent degeneration of
the oil and seals.
Higher Limits of Viscosity

1000
750
500
400
300
Higher Temperature Limit

200
Low Temperature Limit
150
100
75
Viscosity in cSt
50
40
Optimum Working Range
30
25
20
15
10
9 Low Viscosity Limit
8
7
6
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 C
-20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 F FG018906
Figure 18 Optimum Viscosity and Temperature Range
3. Other types of oils than mineral oils

Please contact us to use phosphoric acid ester,
water-glycol, or fatty acid ester oils.

5-8-22
Filter
Dust or metal particles in hydraulic oil accelerate wear of sliding
surfaces or can cause sticking. Install 10 μm filter in the oil circuit
to remove particles from the oil.
Regarding contamination, NAS Class 9 or lower or 2 - 4 mg/
100 cc in Millipore Filter contamination rating is recommended.
Installation and Piping

1. In principle, the motor shaft should face downward.
2. The deviation of centerline from the driven part must be
0.05 mm or less.
3. The tightening torque of the bolts used in mounting the
motor to bracket must be according to the specifications on
the outline drawings.
4. The casing must be always filled with oil.
The position of the oil drain of the motor must be as shown
in (Figure 19) to allow the casing be full of oil.
5. The maximum allowable pressure in the casing is 3 bar,
however, 2 bar or less is recommended.
6. Clean the pipeline and perform flushing.
7. Avoid excessive force at pipe joints.
8. Drain pipe must be the same or larger than the port size of EX1400024
the motor, and as short as possible. Figure 19

5-8-23
Oil Filling and Air Ventilation
1. starting operation, fill the casing with oil through drain port.
In the hydraulic motor, there are high-speed sliding motion
parts, such as bearing, piston, shoe and spherical bushing.
If oil is not fully filled, these sliding parts can cause sticking
or damage.
The PF 1/4" port of the casing is for air vent. PF 1/4 Port
2. Air inside the hydraulic oil circuit or motor can cause

malfunction or damage, thus, must be removed
completely.
Instructions before Starting to Operate

EX1400025
1. Check if there is any loose joint or other trouble in the
pipeline. Figure 20
2. Check that direction of rotation is correct.

3. Check oil leaks from the hydraulic motor.
4. Check if abnormal vibration occurs during rotation or
operating direction switching valve.
5. Check if the oil temperature rise too fast.
6. Check that actual pressure is about the same as the
setting value.

5-8-24
PRECAUTION
Tools for Disassembly and Assembly

Tables 1 and 2 and Figure 21 presents the tools required for
disassembly and reassembly. Since different bolts and plugs are
used in different types, check and prepare necessary tools.
Table 1
Reference 2-face Application Tightening Torque

Name Size Tool
No. Width Part (kg.cm)
30 Socket Bolt M6 5 Brake Valve 120 ±20 L Wrench
Hex Socket Head
28, 29 M14 14 Valve Casing 1,790 ±180 L Wrench
Bolt
21 Plug M42 17 RO Plug 2,500 ±400 L Wrench
31 Plug PF 1/4 10 VP Plug 370 ±20 L Wrench
37 Relief Valve M30 41 Relief Valve 1,800 ±100 Socket Wrench
33 Hex Bolt M16 24 Pinion Shaft 2,700 Socket Wrench
Table 2
Specification
Size
Tools
for stop ring For ø55 shaft
Pliers For ø100 hole
for lock ring
For ø58 hole
Driver Flat tip, 2 pcs.
Steel Rod Approx. 10 x 8 x 200. 1 pc.
Hammer Plastic and metal hammers, 1 each
Torque adjustment rang
• for 100 - 450 kg.cm
Torque Wrench
• for 400 - 1,800 kg.cm
• for 1,200 - 4,800 kg.cm
Slide Hammer Bearing Pliers -
Brake Piston Puller See next page

5-8-25
2Xo9
2Xo7
40
M10
(effective screw for length : 20)
100
250
o10
M10
M10
123
205
240
FG021248
Figure 21 Tools for Brake Piston Disassembly

5-8-26
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.
1. Park the machine on flat level ground.

2. Extend the boom and arm, as shown in Figure 22 and
lower the boom until the attachment is 10 cm above the
ground.
3. Stop the engine.
10 cm
EX1301631
Figure 22

5-8-27
(Figure 23)
LOCK
WARNING
WARNING
DO NOT OPERATE
or maintenance
ON OFF
6. Operate the joystick levers and pedals several times to

release the remaining pressure in the hydraulic piping.
switch.
(Figure 24)
Figure 24
WARNING
doing any work.
Pulling the breather cap upward, the check valve (0.45 bar) Figure 25 EX1400156

5-8-28
13. Disconnect the hoses.
for reassembling.
After disconnecting hoses, plug them to prevent
dirt or dust from entering.
Disconnect the hoses from the bottom to
upward of swing device.
C1
C2
DB
B AGr
PG
A
SH
N
Figure 26 EX1400064

Port Name
A Main Hose SAE 1"-6000 psi 10 107.8 11 79.5
B Main Hose SAE 1"-6000 psi 10 107.8 11 79.5
C1 Make Up Line Hose 1 7/16"-12UN-2B 41 169.5 17.3 125.1
C2 Make Up Line Hose 13/16"-16UN-2B 24 55.9 5.7 41.2
DB Drain Line Hose 13/16"-16UN-2B 24 55.9 5.7 41.2
SH Pilot Line Hose 9/16"-16UN-2B 19 25.5 2.6 18.8
PG Brake Release Hose 9/16"-16UN-2B 19 25.5 2.6 18.8
Agr Lubrication Hose PF1/4 19 39.2 4 28.9
N Nut PF1/2 27 93.1 9.5 68.7

5-8-29
14. Install the eyebolts (M24 x 3.0) (Figure 27).
15. Attach a nylon sling onto the eyebolt.
Figure 27 EX1400065
16. Remove bolts and washers (1, Figure 28) (12 ea).
• Tool: 36 mm ( )
• Torque: 931.6 Nm (95 kg.m, 687.1 ft lb)
17. Remove plugs (2, Figure 28) (2 ea).
18. Install the back bolt to the plug position to ensure that 1
frame and swing device can be separated.
19. Hoist and remove swing device from the frame.
NOTE: When hoisting the swing device one part of
swing device will contact with the main frame.
2
Hoist the swing device a little and push to the
front side while hoisting slowly.
Figure 28 EX1400066
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 360 kg (794 lb)
EX1400067
Figure 29

5-8-30
INSTALLATION
WARNING
SERIOUS INJURY

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
hydraulic oil tank.
2. Start the engine and run at low idle for about 5 minutes.
3. Perform the machine performance test.

5-8-31
DISASSEMBLY AND REASSEMBLY
Disassemble Swing Motor
1. Wind wire rope around the motor, lift it up with a crane and
wash with flushing oil.
After washing, dry with compressed air.
2. Drain the casing (T1) through the drain port.
3. Point the end of the driveshaft downward and fix it on a T2
disassembly table for easy disassembling.
T30
Now, mark the joint position of the casing (T1) and valve
casing (T2) from the motor.
Remove brake switching valve (T38).
T38
T1
EX1301161
Figure 30
4. Unscrew the relief valve (T37) and remove it from the valve
casing (T2).
T37
T2
EX1301162
Figure 31
5. Remove RO plug (T42) from the casing (T1) and remove

check valve (T39).
T1
T42 T39
EX1301163
Figure 32

5-8-32
6. Separate the RO plug (T21) from the valve casing (T2) and T2
remove spring (T20) and plunger (T19).
T21 T20 T19
EX1301164
Figure 33
7. Unscrew the hex socket head bolt (T28) and remove it

from the valve casing (T2).
(Because of the brake spring (T17) force, valve casing is T28
separated from the casing automatically when the bolt is
removed.)
T2
EX1301165
Figure 34
8. Remove brake spring (T17) from the brake piston (T16).

T17 T16
FG021193
Figure 35
9. Using a jig, remove brake piston (T16) from the casing

(T1). T16
When using the bolt hole of the brake piston, pull it straight
upward.
FG021194
Figure 36

5-8-33
10. Place the motor horizontally, and remove cylinder block
(T13) from the driveshaft (T3).
T3
Then remove piston assembly (121, 122), retainer (123),
spherical bushing (113), spacer F (117), and shoe plate T13
(T7).
When taking out the cylinder block (T13), take care not do
drop the push rod (115).
Also take care not to damage the sliding surfaces of the
cylinder block (T13), spherical bushing (113) and shoe.
FG021195
Figure 37
11. Remove three friction plates (T14) and four separation

plates (T15) from the casing (T1). T15
T14
T1
FG021196
Figure 38
12. Remove retaining ring (T36) with pliers and remove

driveshaft from the casing (T1).
T36 T1 T3
FG021197
Figure 39
13. Remove shoe plate (T7) from the casing by hitting with a
steel rod on the cylindrical roller bearing (T4) side.
T7
T1
FG021198
Figure 40

5-8-34
14. Remove roller bearing (T4) from the casing (T1) by hitting
the casing (T1) lightly with a steel rod. T4
(You may hit the inner race of the roller bearing with a steel
rod, however, hit the inner race evenly to protect the
bearing. Do not reuse the bearing once removed.)
T1
FG021199
Figure 41
15. The work below must be conducted as necessary.

Remove oil seal (T6) from the casing (T1). (Hit the oil seal T6
lightly with a steel rod to remove seal. Do not reuse the oil
seal once removed.) T1
FG021200
Figure 42
16. Remove O-ring (T25, T23) from the valve casing (T2).
T25
T23
FG021201
Figure 43
17. Remove valve plate (T18) from the valve casing (T2).
T18
T2
FG021202
Figure 44

5-8-35
18. Remove cylindrical roller bearing (T5) from the valve
casing (T2) using a plastic hammer bearing pliers. Do not T5
reuse the removed bearing.
T2
FG021203
Figure 45
Reassemble Swing Motor

Reassembling is in reverse order of disassembling. Take care of
the following instructions.
1) After disassembly, make sure to repair damaged
parts and prepare the parts to be replaced.
2) Wash all the parts with wash fluid clean and dry with
compressed air.
3) Apply clean hydraulic oil on the sliding surfaces and
bearings.
4) Replace O-rings and oil seals, which is a principle.
5) Tighten screws, bolts and plugs at specified torque
using a torque wrench.
1. Place the casing (T1) on an appropriate place.
T1
FG021204
Figure 46
2. Install the oil seal (T6) at the casing (T1).

T6
T1
FG021200
Figure 47

5-8-36
3. Oil seal (T6) must be installed using a jig, taking care not to
damage the lip of the oil seal (T6).
Oil Seal Casing
FG021205
Figure 48
4. Oil seal (T6) must be installed using a jig, taking care not to
damage the lip of the oil seal (T6). T4
T1
FG021199
Figure 49
5. Install the roller bearing (T4) with the casing (T1) by hitting
the roller bearing (T4) lightly using a jig.
You may hit the inner race of the roller bearing with a steel
T7
rod, however, hit the inner race evenly to protect the
bearing. Do not reuse the bearing once removed.
T1
FG021198
Figure 50
6. Assemble the driveshaft (T3) with the casing (T1). After

assembly, install the retaining ring (T36) to the driveshaft
(T3) with pliers.
T36 T1 T3
FG021197
Figure 51

5-8-37
7. Insert the 9 cylinder block springs (T12) to the cylinder
block (T13).
T9, T10
Confirming that 9 cylinder block springs are assembled,
assemble the thrust call (T11). T8
After assembling the thrust ball (T11), assemble the
T11
retainer (T8) and piston assembly (T9, T10).
T12
T13
FG021206
Figure 52
8. Lay the motor horizontally and install the cylinder block

(T13), piston assembly (T9, T10), retainer (T8), thrust ball
(T11) and shoe plate (T7). T13, T9
T10, T8
During the assembly work, take care not to damage the T11, T7
sliding surfaces of the cylinder block (T13), thrust ball T1
(T11) and shoe.
FG021207
Figure 53
9. Install 3 friction plates (T14) and 4 separation plates (T15)

with the casing (T1). T15
T14
T1
FG021208
Figure 54
10. Apply grease to the O-rings (T25, T23) thinly and install
them with the valve casing (T2). T25
T23
FG021201
Figure 55

5-8-38
11. Assemble the brake piston (T16) with the casing (T1).
Install the brake piston (T16) by hitting it lightly with a T16
plastic hammer.
T1
FG021209
Figure 56
12. Assemble 24 brake springs (T17) with the brake piston

(T16). T17 T16
Take care that brake springs (T17) do not fall over.
FG021193
Figure 57
13. Install the oil seal (T6) into the casing (T1).
T22
T2
FG021210
Figure 58
14. Assemble the roller bearing (T5) with the valve casing (T2)
using a plastic hammer. T5
(Hit the bearing lightly with the plastic hammer to install it).
T2
FG021203
Figure 59

5-8-39
15. Apply grease thinly on the back of the valve plate (T18)
and assemble it with the valve casing (T2) aligning with pin T18
(T22) hole.
T22
Install the O-ring (T24) in the O-ring groove.
T2
T22
FG021211
Figure 60
16. Align the valve casing (T2) and the bolt hole of the casing
(T1), and tighten the socket bolts (T28, T29) by specified
torque.
T28
Take care not to damage the bearing when assembling it.
T29
T2
EX1301166
Figure 61
17. Move the plunger (T19) to fit with the valve casing (T2) by T2
2 - 3 times, and assemble the spring (T20) and RO plug
(T21) with the valve casing (T2).
T21 T20 T19
EX1301164
Figure 62
18. Assemble the check valve (T39) with the casing (T1) and
install the RO plug (T42) using an L-wrench.
T1
T42 T39
EX1301163
Figure 63

5-8-40
19. Assemble the relief valve (T37) with the valve casing (T2).
Before assembling, apply grease to the O-ring part of the
relief valve. (Tighten with the specified torque.) T37
T2
EX1301162
Figure 64
20. Assemble the brake valve (T38) with the casing (T1) using
socket bolts (T30).
T2
T30
CAUTION
AVOID INJURY
Do not assemble brake valve without the O-ring.
T38
T1
EX1301161
Figure 65
21. Wash the contact surface with the reduction gear with
flushing oil and dry it with compressed air.
EX1301167
Figure 66

5-8-41
Disassemble the Reduction Gear
The disassembling procedures of the reduction gear are as
follows.
The figure in the parenthesis after part name represents the
number in the assembly drawing.
1. Wind wire ropes around the reduction lift it up with a crane
and wash with flushing oil.
After washing, dry with compressed air
2. Disassemble the level gauge (R28) and the socket bolt
(R30) from the reduction gear.
R28
R30
FG021215
Figure 67
3. Remove case cover (R24) from the reduction gear.
R24
FG021216
Figure 68
4. Remove No.1 sun gear (R18) from the reduction gear. R18
FG021217
Figure 69

5-8-42
5. Remove No.1 carrier subassembly. Take care not to
damage the gear while taking out the gear.
Carrier No.1 Ass’y
FG021218
Figure 70
6. Remove No. 2 sun gear (R17).

Take care not to damage the gear while disassembling.
R17
FG021219
Figure 71
7. Remove hex bolts (R33).

R33
FG021220
Figure 72
8. Remove No. 2 carrier subassembly.
FG021221
Figure 73

5-8-43
9. Remove socket bolts (R31) to remove ring gear (R7).
R31
R7
FG021222
Figure 74
10. Install eyebolts in the two M10 bolt holes on top and
remove ring gear (R7).
R7
FG021223
Figure 75
11. Remove pin (R32).

R32
FG021224
Figure 76
12. Remove magnet (R23).
R23
FG021225
Figure 77

5-8-44
13. On a work table, press down the pinion shaft (R2) to
disassemble the shaft subassembly.
Shaft
Sub-assembly
R2
FG021226
Figure 78
14. Remove spherical roller bearing (R3) and cover (R6).

R3
R6
FG021227
Figure 79
15. Remove oil seal (R5).
R6
FG021228
Figure 80
Now, disassembling has been completed. Check that all the

parts are in good condition.

5-8-45
Reassemble the Reduction Gear
Reassembling is in reverse order of disassembling. Take care of
the following instructions.
1) After disassembly, make sure to repair damaged
parts and prepare the parts to be replaced.
2) Wash all the parts with wash fluid clean and dry with
compressed air.
3) Apply clean hydraulic oil on the sliding surfaces and
bearings.
4) Replace the oil seals, as a principle.
1. Place the casing (R1) with the flange downside, on a work
table.
R1
FG021229
Figure 81
2. Apply grease thinly on the outer circumference of the oil

seal (R5) and insert it using an assembly jig.
Take care not to damage the oil seal, and check correct
assembly by visual inspection.
FG021230
Figure 82
3. Insert cover (R6) into the pinion shaft (R2) and press fit the
spherical roller bearing (R3) using a press. R3
R6
R2
FG021231
Figure 83

5-8-46
4. Until the bearing is completely inserted by the press, press
fit the pinion shaft (R2) subassembly into the casing (R1).
Shaft
Sub-assembly
R2
FG021226
Figure 84
5. Assemble the hexagon socket head cap bolt (R23).
FG021232
Figure 85
6. Install the parallel pins (R32) at the casing (R1).

R32
FG021224
Figure 86
7. Apply sealant on the contacting part between the casing

(R1) and ring gear (R7). (Sealant specification: DOW
CORNING 780 RTV)
R1
FG021246
Figure 87

5-8-47
8. Checking the position pin (R31), assemble the ring gear
(R7) with the casing (R1).
R7
R1
FG021233
Figure 88
9. Tighten the hex socket head bolts (R31) (2 used).
• : 8 mm R31
• Torque: 6.5 kg•m (64 Nm, 47 Ib•ft)
R7
FG021222
Figure 89
10. Temporarily assemble the bushing (R13), planet gear

(R15) and washer (R19).
R19
R13
R15
FG021234
Figure 90
11. Install the thrust washer (R10) and then insert the
temporarily assembled planet gear (R15) into the carrier
No.2 (R8), and assemble No. 2 pin (R11). R11
R10
Through these procedures, assemble the 4 planet gears.
703
R29
FG021235
Figure 91

5-8-48
12. Install the No. 2 sun gear.
FG021221
Figure 92
13. Install the hex bolt (R33).

R33
FG021220
Figure 93
14. Install the No. 1 sun gear (R17).
R17
FG021219
Figure 94
15. Assemble the following with the NO.1 carrier (R9) in the
said order: R20
A. R21, Thrust washer No.3 R16

R9
B. R20, Thrust washer No.1
R14
C. R12, Inner ring
R21
D. R14, Needle bearing R12
E. R16, Planet gear R20
F. R20, Thrust washer No.1
FG021236
Figure 95

5-8-49
16. Place the thrust plate (R22) with tap aligned with the No.1
R23
carrier (R9), and tighten with flat head screws (R23).
R9
After tightening the screws, perform caulking.
R22
FG021238
Figure 96
17. Install the No. 2 sun gear.

Sub-assembly
FG021237
Figure 97
18. Install the sun gear (R18). R18
FG021217
Figure 98
19. Apply sealant to the case cover (R24) before assembling.

(Sealant specification: DOW CORNING 780 RTV)
FG021245
Figure 99

5-8-50
20. Install the case cover (R24) and level gauge port with their
directions aligned. R18
Level
Gage Port
FG021239
Figure 100
21. Apply locktite to socket bolts (R19). (Locktite specification:

locktite 638)
R19
FG021247
Figure 101
22. Assemble the case cover (R24) and ring gear (R7) using
the socket bolts (R19) applied with locktite.
R30
FG021240
Figure 102
23. Install the oil level gauge (R28) at the gauge port.
R28
FG021241
Figure 103

5-8-51
24. Assemble the retaining ring (T36) to the driveshaft (T3)
with pliers.
T36
FG021242
Figure 104
25. Assemble the motor driveshaft (T3) and No.1 sun gear
(R18), and tighten with the socket bolts (R37).
R37
EX1301168
Figure 105

5-8-52
TROUBLESHOOTING
General Instructions
This section provides the corrective actions against any
abnormality identified during hydraulic motor operation.
General instructions are as follows:
1. Think before taking action
Before taking any action, examine the characteristics of the
problem, and if there had been similar trouble before.
In addition, examine once again that cause of the problem
is the hydraulic motor.
2. Take care of foreign material
Foreign materials cause abnormal friction and wear. Take
care to avoid foreign materials during disassembly and
reassembly.
3. Parts handling
All the parts are precisely ground, thus, take utmost care
not to damage.
4. Take care not to damage O-rings and gasket surfaces.
It is highly recommended to replace with new O-rings after
disassembly.
Examination of Hydraulic Motor

It is very difficult to find out the cause of trouble in hydraulic oil circuit.
Check the items listed below, and examine the cause of the
hydraulic motor.
1. Check oil quality in the casing
Remove drain plug and check the oil in the casing.
If the oil contains many metal particles, the cause of
trouble may be a part in the hydraulic motor.
2. Abnormal noise
Check if the motor makes abnormal noise.
3. Pressure measurement of each parts
Before disassembly and inspection, measure the pressure
of each parts and examine the problem.
4. Measure the drain quantity of the motor
1) Lock the swing and supply high-pressure oil to the
motor, and normal drain quantity must be
approximately 25 LPM or less.
2) Normal drain quantity in normal swiveling must be 2
LPM of less.

5-8-53
Troubleshooting
1. Hydraulic motor fails to rotate
Symptom Possible Cause Corrective Action

Pressure does not rise 1. The setting of the relief 1. Set up with correct value
valve in the circuit is
incorrect.
2. Relief valve malfunction. 2.
1) Plunger sticks 1) Plunger sticks
2) Plunger orifice 2) Plunger orifice
clogged. clogged.
3. Plunger seat failure 3. Check the seat and replace
it if damaged.
Pressure rises up to normal level 1. Overloaded. 1. Remove load.
2. Sticking of moving parts 2. Check/repair piston, shoe,
cylinder block, and valve
plate.
3. Brake release pressure is 3.
not applied.
1) Check/repair the
circuit.
2) Check the brake
switching valve.
4. Brake piston is sticking. 4. Disassemble and check
5. Friction plate is sticking. 5. Disassemble and check
Replace the sticking part.
2. The direction of rotation is reverse.

Direction of rotation is reverse 1. Motor rotates in reverse 1. Referring to Figure 12,
direction. assemble correctly.
2. The inlet and outlet of 2. Correct the pipeline.
pipeline are reverse.

5-8-54
3. Rotating speed fails to reach setting value.

Rotating speed fails to reach 1. Insufficient incoming flow. 1. Check pump discharge
setting value rate, circuit to the motor.
2. Temperature is too high 2. Reduce the oil
and oil leaks too much. temperature.
3. Wear of damaged of sliding 3. Replace the damaged part.
parts
4. Insufficient brake torque

Insufficient brake torque 1. Friction plate is worn. 1. Disassemble and check.
Replace the part if
excessively worn.
2. Brake piston is sticking 2. Disassemble and check
3. Brake release pressure 3.
cannot be removed.
1) Check/repair the
circuit.
2) Check the brake
switching valve.
4. The spline of the friction 4. Disassemble and check
plate is damaged.
Replace the damaged part
5. Hydraulic motor slips excessively

Check the drain quantity of the motor.
Normal drain rate is 500 cc/min.

Excessive slip when external 1. Relief valve malfunction. 1. Same as subclause 1).
torque to drive the hydraulic
Same as subclause 1).
motor is applied.
2. Bad plunger seat 2. Replace the damaged part.

5-8-55
6. Oil leak
1) Leak at oil seal

Leak at oil seal 1. The lip is damaged by dust. 1. Replace the oil seal.
2. Worn or damaged shaft. 2. Change the relative
position of the lip and shaft,
or replace the lip.
3. Oil seal lip is overturned 3. Repair clogged pipeline.
because of excessively
high-pressure in the casing.
4. Rusted shaft. 4. Disassemble and correct it.
2) Oil leak at joint surface

Oil leak at joint surface 1. O-ring is missing. 1. Insert correctly and
reassemble
2. O-ring is damaged. 2. Replace.
3. Seal surface is damaged. 3. Disassemble and correct it
4. Loose or damaged bolt. 4. Tighten at specified torque
or replace the bolt

5-8-56
MAINTENANCE INSTRUCTIONS
Replacement Standard of Worn Parts

When a part is worn exceeding the criteria below, adjust or
replace the part. However, the criteria for parts with distinct
damage are not defined.
Standard Size Replacement

Item Corrective Action
(mm) Criteria (mm)
Clearance between the piston and Replace the piston or
0.028 0.058
cylinder block cylinder block
Clearance between the piston and Replace the piston or
0 0.3
shoe compressed part (δ) shoe assembly
Replace the piston or
Shoe thickness (t) 5.5 5.3
shoe assembly
Assembled height of the retainer Replace the retainer and
6.5 6
plate and spherical bushing (H-h) spherical bushing set
Friction plate thickness 4 3.6 Replace
h
H
t
Piston and shoe clearance between the piston and shoe ( ) Assembled height of the retainer and spherical bush (H-h)
Shoe thickness (t)
Figure 106 FG021244-1
Standard of Sliding Surface Correction

Correct or replace the part whose surface roughness of the
sliding face exceeds the following criteria.
Part Name Standard Roughness Roughness Requiring Correction

Shoe 0.8 - Z (Ra = 0.2) (Lapping) 3 - Z (Ra = 0.8)
Shoe Plate 0.4 - Z (Ra = 0.1) (Lapping) 3 - Z (Ra = 0.8)
Cylinder 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)
1)
NOTE: All the sliding surfaces must be lapped to make
the roughness below the standard roughness.
NOTE: 2) If the sliding surfaces of the retainer or

spherical bushing are excessively rough,
replace the parts by set unit.

5-8-57
5-8-58
Fan Pump for
Oil Cooler
Edition 1
DX340LC-5/DX350LC-5 Fan Pump for Oil Cooler

5-9-1
MEMO
Fan Pump for Oil Cooler DX340LC-5/DX350LC-5

5-9-2
Table of Contents
Fan Pump for Oil Cooler

General ...........................................................5-9-6
Specification .............................................................. 5-9-6
Overview ................................................................... 5-9-7
Parts List ................................................................... 5-9-8
Maintenance Guidelines ...............................5-9-15
Sealing Driveshaft ................................................... 5-9-16
Sealing Control Valve.............................................. 5-9-18
Tools........................................................................ 5-9-18
Removal .......................................................5-9-19
Installation ....................................................5-9-22
Completing Work ..........................................5-9-23
Section View .................................................5-9-24
EPPR Valve............................................................. 5-9-24
Disassembly .................................................5-9-25
Disassembly of Rotary Group ................................. 5-9-26
Disassembly of Control Device ............................... 5-9-27
Disassembly of Shaft/Bearings ............................... 5-9-28
Cleaning and Inspection ...............................5-9-29
Reassembly ..................................................5-9-32
Adjustment of Taper Roller Bearing ........................ 5-9-33

5-9-3
MEMO

5-9-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

5-9-5
GENERAL
Specification
Max. Input Speed 1,800 rpm
Max. Displacement 18 cc/rev
Max. Flow at Max 32 L/min (8.5 U.S. gal) (Theoretical Value)
Pressure Setting on EPPR Valve 122 kg/cm2 (120 bar, 1,740 psi)
Min. Pressure Setting on EPPR Valve 16 kg/cm2 (16 bar, 232 psi)

5-9-6
Overview
S
EX1301359
Figure 1
Port and Hydraulic Circuit
Stand by Pressure: 16 bar
Pressure Cut Off: 120 bar
Min.
18 cc Max.
S L1 L
EX1401186
Figure 2
Port Name Size

B Pressure SAE 3/4
S Suction SAE 1 1/4
L Case Drain 3/4-16UNF-2B

5-9-7
Parts List
40
43 41
53
52
42
15
20
14
25
21 1-12
1-10
1-7
1-11
1-9
5 1-2
1 1-4 1-6
1-1
7
18
10
17 31
27
24
33
16
12
EX1301310
Figure 3

5-9-8
Reference Reference
Number Number
1 Rotary Group 15 Taper Roller Bearing
1-1 Piston 16 Taper Roller Bearing
1-2 Cylinder Block 17 Bushing
1-4 Retainer Plate 18 Bushing
1-6 Spherical Bushing 20 Shaft Seal
1-7 Spring 21 O-ring
1-9 Pressure Pin 24 Seal
1-10 V Ring 25 Snap Ring
1-11 Backup Plate 27 Socket Bolt
1-12 Control Plate 31 Screw
5 Pump Housing 33 Cylinder Pin
6 Port Plate 40 Proportional Reducing Valve
7 Swash Plate 41 Control Valve
8 Driveshaft 42 Seal
10 Spring 43 Socket Bolt
12 Shim 52 Adjust Piston
14 Stop Ring 53 Plug

5-9-9
Theory of Operation
The (1, Figure 4) and (2) valves adjust the pump swivel angle in
order to maintain the electrically set pressure level.
When the cutoff pressure is controlled, the P-I curve also shifts
in response to the cutoff pressure (pressure measurement: X).
By controlling the discharge pressure according to the
characteristics of the fan drive, volume control can be performed
to control the speed of the fan.
• Stand by pressure: 16 bar
• Pressure cut off: 120 bar (at 0 mA)
Circuit
1 Stand by Pressure: 16 bar
2 Pressure Cut Off: 120 bar
Min.
18 cc Max.
S L1 L
EX1401187
Figure 4

5-9-10
Control Section
Stand by Pressure
Adjustment Screw: 16 bar
Pressure Cut Off (Max. P)

Pressure Adjustment
Screw: 120 bar
Figure 5 P A T EPPR Valve

EX1401188
Circuit Diagram Related to Fan Drive
from Control Valve
2.0 bar
19 cc Fan Motor
Min.
Fan Pump 18 cc Max.
S L1 L
EX1301362
Figure 6

5-9-11
Pump EPPR Valve
With the EPOS, the speed of the cooling fan can be controlled
according to the temperatures of the hydraulic oil and the engine
coolant.
The speed of the fan can be controlled by controlling the value of
current supplied to the EPPR valve (by changing the pressure).
Revolutions 1,200 ±50 rpm

Maximum Value
Pressure 82 ±10 bar
(Standard)
Electric current 160 ±20 mA
EPPR Valve
EPOS
EPPR Valve
Min.
18 cc Max.
S L1 L
EX1301363
Figure 7
Control Curve (Pressure/Flow Rate compared to the Current Value)

• ED: Pressure compared to the current value ED
Pressure (bar)
0
Electric Current (mA)
EX1401295
Figure 8

5-9-12
Control Curve (Pressure Compared to the Current Value)
140
120
100
Pressure (bar)
80
60
40
20
0 100 200 300 400 500 600
Electric Current (mA)

EX1401296
Figure 9

5-9-13
Current Value According to the Temperature
1. The EPOS receives information about operating oil
temperature from the sensor.
2. Then, the EPOS calculates the proper current value
through the proportional integral controller based on the
operating oil's temperature (target temperature: 80°C).
• Max./Min. current range: 600 ~ 0 mA
3. The calculated current value is sent to the control section
of the fan pump to adjust the discharge pressure of the fan
pump.
4. The fan's speed is adjusted according to the change in the
fan pump's discharge pressure.
Fan Motor
19 cc
Current
B
EPOS
Min. Target: 80°C

Limit
G Proportional
Oil G Integral
Fan Pump 18 cc Max.
Controller
Temperature
Sensor
S L1 L
Current (Min.): 0 mA
Current (Max.): 600 mA
EX1401298
Figure 10

5-9-14
MAINTENANCE GUIDELINES
1. Close off all openings of hydraulic unit.
ASS0030L
Figure 11
2. Replace all seals.

Use only original replacement parts
ASS0040L
Figure 12
3. Check all sealing and sliding surfaces for wear.

NOTE: Do not rework sliding surfaces using crocus
cloth or other similar materials. It can damage
the surface.
ASS0050L
Figure 13
4. Fill hydraulic unit with clean hydraulic oil before putting into
operation.
ASS0060L
Figure 14

5-9-15
Sealing Driveshaft
Reference
Description
Number
1 Retaining Ring
2 Shaft Seal 2
1
3 Ring
4 Bearing
EX1301961
Figure 15
1 2
3
4 FG024374
Figure 16
1. Protect driveshaft.
2. Remove retaining ring from pump body.
3. Remove shaft seal from front of pump body.
EX1301963
Figure 17
NOTE: Change shaft seal and check its sliding surface

(driveshaft) and housing. Grease sealing ring.
Check that shaft seal is properly seated in
housing.
EX1301962
Figure 18

5-9-16
4. Press sealing ring carefully down just below retaining ring
groove.
EX1301964
Figure 19
5. Install retaining ring in retaining ring groove.
EX1301963
Figure 20
NOTE: Make sure that retaining ring is properly seated

in groove.
EX1301964
Figure 21

5-9-17
Sealing Control Valve
NOTE: Remove control valve. Measure dimension and write
down.
1. Check sealing surface (1).
2. Check O-rings (2).
2
EX1301765
Figure 22
Tools
Loctite Types
• For all break-off plugs: #601
• For all other parts: #242
FG024423
Figure 23
• Bolt tensile strength grade: 8.8, 10.9, 12.9
FG024424
Figure 24

5-9-18
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

2. Lower front attachment (bucket) to ground. (Figure 25)
3. Stop engine.
EX1300542
Figure 25

5-9-19
(Figure 26)
LOCK
WARNING WARNING
DO NOT OPERATE
or maintenance
ON OFF

switch.
(Figure 27)
Figure 27
WARNING
doing any work.
Figure 28 EX1400156

5-9-20
12. Remove bolts and washers (1, Figure 29) (8 ea) with
under cover (2) from frame.
1
• Tool: 19 mm ( )
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb) 2
• Under cover weight: about 12 kg (27 lb)
Figure 29 Bottom of Frame EX1400081
13. Remove hoses (Figure 30) (3 ea) from fan pump.

for reassembling, and observe the assembly
angle of hoses.
NOTE: After disconnecting hoses, plug them to prevent
14. Disconnect the harness connector from EPPR Valve of fan
pump.
Figure 30
• Hoses ports

Port Name
S Outlet 1 7/16"-12UN-2B 41 169.7 17.3 125.1
B Inlet 1 3/16"-12UN-2B 36 124.5 12.7 91.9
L1 Drain 11/16"-16UN-2B 20 38.2 3.9 28.2

5-9-21
15. Tie pump with rope to lift it.
16. Remove set bolts (1, Figure 31) (2 ea) with fan pump (2)
from engine.
• Tool: 19 mm ( )
• Fan pump weight: about 12 kg (26.4 lb)
Figure 31
INSTALLATION
WARNING
SERIOUS INJURY

5-9-22
COMPLETING WORK
1. Start engine and set throttle at "LOW IDLE".
FG019382
Figure 32

5-9-23
SECTION VIEW
EX1301987
Figure 33
EPPR Valve
EX1301988
Figure 34

5-9-24
DISASSEMBLY
NOTE: Make alignment mark on connection plate and pump 1
housing (1).
EX1301965
Figure 35
1. Remove four screws, EPPR valve and three O-rings from

pump housing.
EX1301966
Figure 36
2. Remove four screws.
EX1301967
Figure 37
3. Remove connection plate, control plate and O-ring. Set

aside on a clean work area.
NOTE: Control plate can fall when removing connection
plate.
EX1301968
Figure 38

5-9-25
Disassembly of Rotary Group
1. Using a suitable puller, remove bearing from connection
plate.
NOTE: Do not damage sealing surface.
EX1301969
Figure 39
2. Remove bearing and shim.

NOTE: Do not damage sealing surface.
EX1301970
Figure 40
3. Remove rotary group from pump housing in a horizontal

position.
EX1301971
Figure 41

5-9-26
Disassembly of Control Device
1. Remove plug (1) from pump housing.
Remove control piston (2) from pump housing (flat
surface*) with tool. 1
2
3
EX1301972
Figure 42
2. Remove swash plate from pump housing.

NOTE: Turn swash plate (3, Figure 43) inside housing
slightly along Z-axis with tool.
Remove swash plate (3) from pump housing.
EX1301272
Figure 43
3. Remove bearing shells and bearing from pump housing.

NOTE: Note location of each bearing position in pump
for installation.
EX1301973
Figure 44

5-9-27
Disassembly of Shaft/Bearings
1. Remove driveshaft with bearing from pump housing.
EX1301974
Figure 45
2. Remove retaining ring and shaft seal from pump housing.
EX1301975
Figure 46
3. Using a suitable puller, remove outer race of tapered

bearing from housing press seat.
EX1301976
Figure 47
4. Remove shim from pump housing.
EX1301977
Figure 48

5-9-28
CLEANING AND INSPECTION
1. Replace all bearings and seals.
FG024394
Figure 49
Reference 5
Description 4
Number 1
2 3
1 Fretting Wear on Splines
1-1 Key Set
2 Driveshaft Seal Wear Grooves
3 Bearing Seat
1.1
4 Splines for Cylinder Drive
5 Bearing Seat
FG024395
Figure 50
2. Check that sliding surface is free of grooves.

NOTE: Check for freedom of connector movement.
FG024396
Figure 51
3. Check bearing surfaces.
FG024397
Figure 52

5-9-29
4. Check that retaining plate is free of grooves and there is no
wear in slipper pad area.
FG024398
Figure 53
5. Check to see there are no scratches or metal deposits on

sliding surface (1), and there is no axial play (2), (pistons 1
must only be replaced as a set).
2
FG024399
Figure 54
Reference
Description 2
Number
1 Cylinder Bores
2 Splines 1
FG024400
Figure 55
6. Grooves show no signs of wear.
FG024401
Figure 56

5-9-30
7. Cylinder sliding surface are free of grooves, no wear, no
embedded foreign particles. That there are no scratches
on control plate. (Only replace them as a set).
FG024402
Figure 57
8. Mounting surface - control plate is not damaged.
FG024403
Figure 58

5-9-31
REASSEMBLY
NOTE: Press in distance ring and outer racer with tool.
EX1301778
Figure 59
1. Assemble shaft in correct position in pump housing.

NOTE: Do not cut shaft seal!
EX1301779
Figure 60
2. Press in outer racer of rear bearing into connection plate.
FG024406
Figure 61
3. Align match marks to assemble connection plate on pump

housing.
NOTE: Install four socket screws. See “Tools” on
page -18.
4. Adjust the taper roller bearing set. See “Adjustment of
Taper Roller Bearing” on page -33.
NOTE: After adjustment, remove connection plate
again.
EX1301980
Figure 62

5-9-32
Adjustment of Taper Roller Bearing
Taper Roller Bearing Pretension
Pos.12
0 - 0.05
FG024408
Figure 63
Adjustment of taper roller bearing set

Preload of bearing from: 0 - 0.05 mm, grind Pos. 12 if necessary.
1. Install shaft seal. See “Sealing Driveshaft” on page -16.
EX1301981
Figure 64

5-9-33
2. Install bearing shells and spring in pump housing.
NOTE: Apply clean grease to help hold bearings in
position.
EX1301982
Figure 65
3. Assemble swash plate (3) in pump housing.

4. Install spring guide pin in correct position.
NOTE: Check for correct position of spring.
Z 3
EX1301273
Figure 66
5. Coat plug (1) with Loctite #242.

1
6. Assemble adjust piston (2) and plug (1) in pump housing. 2
• Torque (plug): 190 - 210 Nm 3
(19.4 - 21.4 kg.m, 140.1 - 154.9 ft lb)
EX1301983
Figure 67

5-9-34
7. Install pressure pins using an assembly aid.
FG024413
Figure 68
8. Compress spring using a suitable device.
FG024414
Figure 69
9. Assemble piston with retaining plate.

NOTE: Coat pistons and slipper pad with clean
hydraulic oil.
FG024415
Figure 70
FG024416
Figure 71

5-9-35
10. Install rotary group!
NOTE: Hold pistons by using an O-ring.
EX1301984
Figure 72
11. Install bearing and adjustment shim on shaft.
EX1301970
Figure 73
EX1301968
Figure 74

5-9-36
12. Align match marks, assemble connection plate on housing.
NOTE: Check for correct position on housing.
NOTE: Tighten screws to proper specification. See
“Tools” on page -18.
EX1301967
Figure 75
13. Install seal and EPPR valve on housing.
EX1301966
Figure 76
14. Finally assemble the pump.

NOTE: Double check alignment of match mark.
EX1301985
Figure 77
EX1301986
Figure 78

5-9-37
5-9-38
FAN MOTOR FOR OIL COOLERSP003246
Fan Motor for

Oil Cooler
Edition 1
DX340LC-5/DX350LC-5 Fan Motor for Oil Cooler

5-10-1
MEMO
Fan Motor for Oil Cooler DX340LC-5/DX350LC-5

5-10-2
Table of Contents
Fan Motor for Oil Cooler

Safety Instructions ........................................5-10-5
General .........................................................5-10-5
Specification ............................................................ 5-10-5
Overview ................................................................. 5-10-6
Parts List and Section View..................................... 5-10-7
Precaution ....................................................5-10-8
Tools........................................................................ 5-10-8
Removal .......................................................5-10-9
Installation ..................................................5-10-13
Completing Work ........................................5-10-13
Disassembly ...............................................5-10-14
Reassembly ................................................5-10-17
Reassembly........................................................... 5-10-17
Assembly............................................................... 5-10-18

5-10-3
5-10-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specification
Direction of Rotation (Looking on the Driveshaft) Reversible (R)
Displacement 19.09 cm3/rev
Max. Continuous Pressure P1 204 kg/cm2 (200 bar, 2,900 psi)
Max. Intermittent Pressure P2 224 kg/cm2 (220 bar, 3,190 psi)
Max. Peak Pressure P3 244 kg/cm2 (240 bar, 3,480 psi)
Max. Drain Line Pressure on the Reversible Rotation Motors 5 kg/cm2 (5 bar, 73 psi)
Min. P1 500 min-1
Speed
Max. P1 3,000 min-1
Weight 4 kg (8.8 lb)

5-10-5
Overview
D B
A
EX1301367
Figure 1
Port Name Size

A Inlet PF 1/2 A
B Pressure PF 1/2
D
D Drain PF 1/4
EX1301368
Figure 2

5-10-6
Parts List and Section View
A A
A
EX1301369
Figure 3
Reference
Item Part Number
Number
A Seal Kit for Motor 401107-01051

5-10-7
PRECAUTION
IMPORTANT
Check that spare parts have not been damaged in
shipment.
Always work in a clean environment.
Wash all components in solvent and blow dry with
compressed air before installing.
Do not damage rubber seals.
Avoid damaging precision machined surfaces.
Components should install into their housings without
excessive force. If force is necessary, this normally means
that component does not have correct tolerances or is
aligned incorrectly.
When hand pressure is insufficient, only use a press or
rubber hammer to install components.
Never strike components with metal hammers.
Steel bushing must be installed only with a suitable press.
Do not use hammers to install bearings.
Always respect direction of rotation when assembling
components.
Tools
Name Description
Wrench 22 mm
Allen Wrench 8 mm
Plastic Hammer One Plastic Hammer

5-10-8
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

2. Lower front attachment (bucket) to ground. (Figure 4)
3. Stop engine.
EX1300542
Figure 4

5-10-9
(Figure 5)
LOCK
WARNING
WARNING
DO NOT OPERATE
or maintenance
ON OFF

switch.
(Figure 6)
Figure 6
WARNING
doing any work.
Figure 7 EX1400156

5-10-10
12. Remove bolts and washers (1, Figure 8) (4 ea) with cover
(2).
• Tool: 19 mm ( )
1
• Cover weight: 20 kg (44 lb) 1
2
Figure 8 EX1400009
13. Remove bolts and washers (1, Figure 9) (6 ea) with cover
(2).
• Tool: 19 mm ( )
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb) 1 1
• Cover weight: 10 kg (22 lb)
Figure 9 EX1400010
14. Remove bolts (1, Figure 10) (4 ea) with fan guard (2) from
oil cooler.
1
• Tool: 13 mm ( )
2
Figure 10 EX1400011
15. Remove bolts (1, Figure 11) (6 ea) and nut (2) with fan (3)
from fan motor. (Input the hand into the fan)
16. Removed fan put in oil cooler shroud.
1
2
CAUTION 3
AVOID INJURY
Oil Cooler Side
Don’t damage the core of oil cooler by fan.
Figure 11 EX1400012
• Tool (Bolt): 13 mm ( )
• Tool (Nut): 22 mm ( )

5-10-11
17. Remove hoses (Figure 12) (3 ea) from fan motor.
for reassembling, and observe the assembly
angle of hoses.
Fan Motor
NOTE: After disconnecting hoses, plug them to prevent
A B
Figure 12 EX1400013
• Hoses

Port Name
A Inlet 13/16"-16UN-2B 24 55.9 5.7 41.2
B Outlet 13/16"-16UN-2B 24 55.9 5.7 41.2
D Drain 9/16"-16UN-2B 19 25.5 2.6 18.8
18. Remove bolts and washers (1, Figure 13) (4 ea) with fan
motor (2) from bracket. 1
• Tool: 13 mm ( )
2
• Motor weight: about 4 kg (8.8 lb)
Bracket
Figure 13 EX1400014

5-10-12
INSTALLATION
WARNING
SERIOUS INJURY
1. Perform installation in the reverse order to remove

normally.
2. The direction of plane of hub must be assembled towards
Bolt
fan motor direction.
Hub
Nut
Fan motor
Shaft
EX1301646
Figure 14 Fan Motor Section View
COMPLETING WORK
FG019382
Figure 15

5-10-13
DISASSEMBLY
Rear Cover
1. Remove locknut and washer, key from shaft.
Figure 16
2. Remove assembling bolts and washers from pump.
Figure 17
3. Remove valves from cover.

NOTE: Follow step 3 and 4 only when changing O-rings
on plugs or valves.
Figure 18

5-10-14
Mounting Flange
1. Remove mounting flange and O-ring. Be careful to keep it
as straight as possible during removal.
NOTE: Make sure when removing it, that driveshaft and
other components remain in position.
Figure 19
2. Remove retaining ring from flange.

3. Remove shaft seals with a screwdriver.
NOTE: Remove shaft seals only if required.
NOTE: Replace all shaft seals. Do not reuse them.
Figure 20
4. Remove 2nd flange and bearing assembly from working

section.
Figure 21
5. Remove bearing and shaft assembly from flange.

NOTE: Only when O-ring inside must be changed.
6. Remove retaining ring and bearing from rear of shaft.
NOTE: Follow this step only if replacing bearing or
shaft.
Figure 22

5-10-15
Working Section
1. Remove pressure plate with O-ring and backup ring from
working section.
2. Remove driving gear and driven gear as straight as
possible from working section.
Figure 23
3. Remove other pressure plate on rear side of working

section.
Figure 24

5-10-16
REASSEMBLY
Reassembly
Pressure Plates
1. Install O-ring into grove on aluminum pressure plate.
2. Install backup ring on O-ring.
3. Apply clean grease on O-ring and backup ring to hold them
in position.
Figure 25
Working Body
1. Apply clean grease on square rings to hold them in
position.
2. Install square rings into grooves of working section.
NOTE: Shape of square ring is different depending on
direction of body.
3. Install locator pins, if removed during disassembly.
Figure 26
Bearing Flange
1. Apply clean grease on O-ring and install in flange.
2. Install bearing and shaft assembly in flange.
NOTE: Be careful not to damage bearing.
Figure 27

5-10-17
Mounting Flange
1. Install shaft seal and backup washer in flange.
2. Install retaining ring in groove. Make sure retaining is
properly seated.
3. Install last shaft seal into flange facing out.
4. Apply clean grease on O-ring and install in flange.
Figure 28
Assembly
1. Install working body on rear cover.
Figure 29
2. Install pressure plate until it its face contacts rear cover.

3. Install driving gear and driven gear keeping them as
straight as possible during assembling.
NOTE: Coat gears and inside of housing with clean
hydraulic oil.
Figure 30
4. Install other pressure plates in working section.

5. Install shaft into driving gear.
Figure 31

5-10-18
6. Install reassembled bearing flange on working housing.
Figure 32
7. Install reassembled mounting flange on bearing flange.

NOTE: Apply clean grease on lips of shaft seals before
assembling.
Figure 33
8. Install bolts and tighten with in a crisscross pattern.

• Torque: 45 Nm (4.6 kg.m, 33.2 ft lb).
Figure 34
9. Install key on shaft.

10. Install washer and nut on shaft.
11. Check that pump rotates freely when driveshaft is turned
by hand. If not, a possible plate seal may be pinched.
Figure 35

5-10-19
5-10-20
Gear Pump
(Rotation)
Edition 1
DX340LC-5/DX350LC-5 Gear Pump (Rotation)

5-11-1
MEMO
Gear Pump (Rotation) DX340LC-5/DX350LC-5

5-11-2
Table of Contents
Gear Pump (Rotation)

General .........................................................5-11-5
Specification ............................................................ 5-11-5
Overview ................................................................. 5-11-6
Parts List ................................................................. 5-11-7

5-11-3
5-11-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specification
Direction of Rotation
Clockwise
(Looking on Driveshaft)
Displacement 26.7 cm3/rev
Inlet Pressure Range for Pump 0.7 - 3 kg/cm2 (0.7 - 3 bar, 10.1 - 43.5 psi)
Max. Continuous Pressure 286 kg/cm2 (280 bar, 4,061 psi)
Max. Intermittent Pressure 306 kg/cm2 (300 bar, 4,351 psi)
Max. Peak Pressure 316 kg/cm2 (310 bar, 4,496 psi)
Weight 13.7 kg (30.2 lb)

5-11-5
Overview
Out In
EX1400103
Figure 1

Inlet
Port Name Size
In Hydraulic Oil Inlet PF 1 O-ring
Out Hydraulic Oil Outlet PF 3/4 O-ring
Outlet
EX1301736
Figure 2

5-11-6
Parts List
5
7
14
9
12
2
3
2
13
10
15
14
13
8
4
8
12
6
13
1
11
EX1400104
Figure 3
Reference Reference
Number Number
1 Front Cover 9 Seal
2 Thrust Plate 10 Shaft Seal
3 Drive Shaft 11 Snap Ring
4 Driven Gear 12 Ring
5 Socket Bolt 13 Bush
6 Plug 14 Bush
7 Washer 15 Body
8 Seal * Gear Pump Seal Kit

5-11-7
5-11-8
Joystick Valve
(Work Lever)
Edition 1
DX340LC-5/DX350LC-5 Joystick Valve (Work Lever)

5-12-1
MEMO
Joystick Valve (Work Lever) DX340LC-5/DX350LC-5

5-12-2
Table of Contents
Joystick Valve (Work Lever)

General .........................................................5-12-5
Specifications .......................................................... 5-12-5
Overview ................................................................. 5-12-6
Parts List ................................................................. 5-12-8
Theory of Operation .............................................. 5-12-10
Tools and Torques ................................................ 5-12-11
Section View ...............................................5-12-12
Removal .....................................................5-12-14
Installation ..................................................5-12-19
Completing work .........................................5-12-19
Disassembly ...............................................5-12-20
Reassembly ................................................5-12-24

5-12-3
5-12-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specifications
Max. Primary Pressure 50 kg/cm2 (49 bar, 711.1 psi)
Max. Back Pressure 3 kg/cm2 (2.9 bar, 42.7 psi)
Rated Flow 20 L/min (5.3 U.S. gal)
Continuous Rated Current of Switch DC30 V x 6 A
Internal Leakage Oil Temperature 50 ±5°C
Neutrality 30 - 150 cc
At Work (15 kg/cm2) 30 - 400 cc
Performance
Port 1, 3 Port 2, 4
40 40
Secondary Pressure (kg/cm2)
Secondary Pressure (kg/cm2)

Operating Torque (kg.cm)
28 1.5 28 1.5
Single Operating Torque Single Operating Torque
(17.6) (17.9)
14.6 3 14.6 3
6.5 1 6.5 1
4.5 2 4.5 2
Secondary Pressure Secondary Pressure
0 1 2 3 4 5 6.5 7 0 1 2 3 4 5 6 7.5 8
Push Rod Stroke (mm) Push Rod Stroke (mm)
0 3 5 10 15 17.5 19 0 3.1 5 10 15 20 21.5

Operating Angle Operating Angle 21
Figure 1 EX1400109

5-12-5
Overview
The pilot valve is a valve that controls the spool stroke, direction,
etc of a main control valve.
This function is done by providing the spring at one end of the
main control valve spool and applying the output pressure
(secondary pressure) of the pilot valve to the other end.
P1
S3
P1
S1
S3
S2
S2
ingle
21.5 S
, 4)
(Port 2 S1
gle
19 Sin 25
, 3) Do
(Port 1 ubl
e
L.H R.H
P1 - Red P1 - Black P1 - Red P1 - Black

P1 - Blue P1 - Blue
S2 - Yellow S2 - Yellow S2 - Yellow S2 - Yellow
S3 - Green S3 - Green S1 - White S1 - White S3 - Green S3 - Green S1 - White S1 - White
4 4
1 P 1 P
T T
2 3 2 3
EX1301710
Figure 2

5-12-6
Switches
1. Push button switch
Switch 1 White White
Switch L.H R.H
Switch 2 Yellow Yellow
Breaker/booster
S1 Horn Button
Button Switch 3 Green Green
Intelligent Floating EX1301712
One Touch Figure 3
S2 Boom Temporary
Deceleration Button
Reset Bottom
S3 Spare Button Spare Button
2. Proportional switch
4 V (Right) Red ( 5 V)
Switch L.H R.H
Blue
P1 Rotating Switch Shear Switch (Signal)
1 V (Left) Black (Ground)

EX1301713
Figure 4
Ports
P T
Port L.H R.H Size

1 Left Swing Bucket Crowd
2 Arm Dump Boom Down
3 Right Swing Bucket Dump
PF 3/8
4 Arm Crowd Boom Up
P Pilot Oil Inlet Pilot Oil Inlet
1 3 2 4
T Pilot Oil Return Pilot Oil Return
EX1301711
Figure 5

5-12-7
Parts List
SPOOL
SPOOL
Figure 6

5-12-8
Reference Reference
Number Number
1 Case 20 Boot
2 Plug 21 Joint Assembly
3 Bushing 22 Swash Plate
4 Spool 23 Nut
5 Shim 24 Nut
6 Spring Joystick (LH)
25
7 Spring Seat Joystick (RH)
8 Stopper 25-1 Push Button Switch
9 Spring 25-2 Thumb Switch
10 Stopper 26 Handle Bar
11 Spring 28 Bellows
12 Push Rod 29 Bushing
13 Spring 30 Washer
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 37 Handle Kit (RH)
19 Plate 38 Handle Kit (LH)

5-12-9
Theory of Operation
Structure
The joystick valve contains four push rods, spring seat, spools
and return springs, which are in the valve casing. Moves the
spool of the main control valve by reducing the pressure of the
pilot pump from a first pressure to a second pressure.
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
1
When the joystick lever is in the neutral state, the spool is
pressed upward by the return spring and the spring seat.
The P-port is blocked by the lower part of the spool, and 2
the 4 operation ports are connected to the T-port by the
upperpart of the spool.
Reference 3
Description
Number
1 Swash Plate 4
2 Push Rod 5
3 Balance Spring
4 Return Spring
5 Spool
EX1301707
Figure 7
2. Half-operated state
When the joystick lever is moved, the push rod moves
downward, and the force thereof is transferred to the spool
through the spring seat and the control spring. When the
spool moves, the first pressure is transferred to the
operation ports through the spool.
When the lever spring stops in the halfway position, the
force of the compressed spring and the hydraulic pressure
caused by the second pressure applied upward because of
the difference in area of the upper and lower ends of the
spool create a state of equilibrium, and this pressure is
transferred to the spool of the control valve. That is, the
first pressure is transferred to the operation ports through
the spool as a hydraulic pressure (second pressure)
corresponding to the force of the compressed control
spring. EX1301708
Figure 8

5-12-10
3. Fully operated state
When the joystick lever is moved to its full extent, the lower
end of the push rod fully presses the spool seat to fully
compress the control spring.
The first pressure is transferred to the operation ports
through the spool, and the second pressure coming
through the spool overpowers the force of the control
spring, pushing the spool upward, and thus the spool is
restricted from movement by the push rod.
That is, when the joystick lever is fully pressed, the control
spring cannot perform its function and the spool is
restricted, making the first pressure and the second
pressure equal.
EX1301709
Figure 9
Tools and Torques
Reference Torque
Description Tool
Number Nm kg.m ft lb
2 Plug 36.3 3.7 27 PT1/8 ( )
22 Swash Plate 162.8 16.6 120 27 mm ( )
23 Hex Nut 162.8 16.6 120 22 mm ( )
24 Nut 162.8 16.6 120 22 mm ( )

5-12-11
SECTION VIEW
25-2
25-1
27
25
24 28
26
23
21
20
22 12
11
30
18
19
16
10 13
29 17
15
14 8
7
13
6
5
5
4 9
3
1
2 EX1301728
Figure 10

5-12-12
Reference Reference
Number Number
1 Case 17 O-ring
2 Plug 18 Rod Seal
3 Bushing 19 Plate
4 Spool 20 Boot
5 Shim 21 Joint Assembly
6 Spring 22 Swash Plate
7 Spring Seat 23 Nut
8 Stopper 24 Nut
9 Spring Joystick (LH)
25
10 Stopper Joystick (RH)
11 Spring 25-1 Push Button Switch
12 Push Rod 25-2 Thumb Switch
13 Spring 26 Handle Bar
14 Spring Seat 28 Bellows
15 Stopper 29 Bushing
16 Plug 30 Washer

5-12-13
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.
1. Make the machine swing about 15 ~ 20 degrees rightward

on the flat ground as shown in Figure 11 before lowering
the bucket on the ground and then stop engine.
EX1301714
Figure 11

5-12-14
(Figure 12)
LOCK
WARNING
WARNING
DO NOT OPERATE
or maintenance
ON OFF
4. Operate the joystick levers and pedals several times to

release the remaining pressure in the hydraulic piping.
switch.
(Figure 13)
Figure 13
WARNING
doing any work.
Figure 14 EX1400156

5-12-15
11. Remove bolts (3 ea) and washers (3 ea) and remove arm
rest from bracket. (Right side)
Left side is same.
• Tool: 13 mm ( )
EX1301715
Figure 15
12. Remove screw with arm rest cover.

Left side is same.
• Tool: Phillips screwdriver
EX1301716
Figure 16
13. Remove rubber and screws, remove cover (1, Figure 17)
from stand upper cover, and disconnect the connector of
harness which connect with switches.
Left side is same.
1
EX1301717
Figure 17 Stand RH
EX1301718
Figure 18 Stand LH

5-12-16
14. Remove screws (Figure 18) (4 ea), remove upper cover (1,
1
Figure 18) from bracket, and disconnect the connector of
harness which connect with switches.
Left side is same.
EX1301719
Figure 19 Stand RH
EX1301720
Figure 20 Stand LH
15. Remove screws (4, Figure 21) (2 ea), socket bolts and
washers (3) (4 ea) of joystick valve (1).
16. Remove bracket (2, Figure 21) from control stand bracket. 1
17. Separate joystick valve from control stand.

Left side is same. 2
• Tool: 5 mm ( ), phillips screwdriver 3
4
EX1301721
Figure 21 Stand RH
1
2
3
4
EX1301722
Figure 22 Stand LH

5-12-17
18. Remove hoses (6 ea) from joystick valve. (Figure 23)
6 hoses are the same thread and tool.
Left side is same.
• Tool: 22 mm ( )
• Hose size: 11/16"-16UN-2B
for reassembling. EX1301723
NOTE: Plug end of hoses to prevent dirt by oil or oil Figure 23

spilling onto ground.
19. Remove joystick valve from control stand. (Figure 24)
Left side is same.
EX1301724
Figure 24
20. Refer to bottom of joystick. (Figure 25)

Left Hand Right Hand
EX1301725
Figure 25

5-12-18
INSTALLATION
WARNING
SERIOUS INJURY

2. Keep the assembly angle when installing the hoses to
joystick valve.
COMPLETING WORK
FG019382
Figure 26
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.
FG018384
Figure 27

5-12-19
DISASSEMBLY
1. Remove lead wire from bushing (29).
FG013494
Figure 28
2. Remove lever assembly from case (1).
FG013495
Figure 29
3. Remove hex nut (23) and swash plate (22) from case (1).
FG013496
Figure 30
4. Remove joint assembly (21) from case (1).
FG013497
Figure 31

5-12-20
5. Remove plate (19) from case (1).
FG013498
Figure 32
6. Remove plug kit assembly, stopper and spring (11) from

case (1).
FG013499
Figure 33
FG013501
Figure 34
7. Remove 4 spool kit assemblies from case (1).
EX1301732
Figure 35

5-12-21
8. Remove spring (9) from (1).
FG013510
Figure 36
9. Remove bushing (3) from case (1).
FG013506
Figure 37
FG013508
Figure 38

5-12-22
10. Remove 4 plugs (2) from case (1).
FG013504
Figure 39
FG013507
Figure 40

5-12-23
REASSEMBLY
1. Install 4 plugs (2) into case (1).
FG013504
Figure 41
FG013507
Figure 42
2. Install bushing (3) into case (1) using jig.
FG013506
Figure 43
FG013508
Figure 44

5-12-24
3. Take care when assembling spool kit assemblies (1 and 3,
2 and 4). (They must be assembled in same way).
The assembly order is; spool (4), shim (5), spring (6),
spring seat (7), and stopper (8).
FG013509
Figure 45
FG013503
Figure 46
4. Install spring (9) into case (1).
FG013510
Figure 47
5. Install spool kit assembly into case (1). (The same way is
used for four parts.)
EX1301732
Figure 48

5-12-25
6. Assemble plug kit insert rod seal (18), O-ring (17), and
push rod (12) into plug (16) in proper order.
FG013511
Figure 49
FG013512
Figure 50
7. Install four springs (11) and stoppers and insert assembled

set in case (1) to form a plug kit assembly.
NOTE: Pay attention to measurement specifications of
stoppers (1 and 3, 2 and 4).
FG013499
Figure 51
FG013501
Figure 52

5-12-26
8. Install plate (19) into case (1).
FG013498
Figure 53
9. Install joint assembly (21) into case (1).
FG013497
Figure 54
10. Install boot and swash plate (22) and hex nut (23) into case
(1).
FG013513
Figure 55
FG013514
Figure 56

5-12-27
11. Insert bar and tighten it with a wrench to check balance of
joint assembly.
FG013515
Figure 57
12. Install bushing (29) into case (1).
FG013516
Figure 58
13. Install lever assembly into case (1).
FG013495
Figure 59
14. Put lead wire in bushing (29), tie it, and arrange boot.
FG013494
Figure 60

5-12-28
15. Assemble connector assembly (30), and connect it to lead
wire terminal, and properly route wiring.
FG013519
Figure 61
FG013520
Figure 62

5-12-29
5-12-30
Travel Control Valve
(with Damper)
Edition 1
DX340LC-5/DX350LC-5 Travel Control Valve (with Damper)

5-13-1
MEMO
Travel Control Valve (with Damper) DX340LC-5/DX350LC-5

5-13-2
Table of Contents
Travel Control Valve (with Damper)

General .........................................................5-13-6
Specification ............................................................ 5-13-6
Overview ................................................................. 5-13-7
Parts List ................................................................. 5-13-8
Theory of Operation .............................................. 5-13-10
Tools and Torques ................................................ 5-13-11
Section View ...............................................5-13-12
Removal .....................................................5-13-13
Installation ..................................................5-13-16
Completing Work ........................................5-13-19
Disassembly ...............................................5-13-20
Reassembly ................................................5-13-23
Troubleshooting ..........................................5-13-28

5-13-3
5-13-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

5-13-5
GENERAL
Specification
Type Pilot (with Damper)
7.4 - 25 bar
Pressure/Stroke Characteristic
(@1 - 4.3 mm Stroke)
Max. Primary Pressure 100 kg/cm2 (98 bar, 1,422 psi)
Max. Back Pressure 3 kg/cm2 (2.9 bar, 42.7 psi)
Rated Flow 20 L/min (5.3 U.S. gal)
Weight 7.8 kg (17.2 lb)
Performance
40 160
112.6
Secondary Pressure (kg/cm2 )
25 1.5

Operating Torque 91.8
46.4
7.5 1
Secondary Pressure
0 1 0.5 4.3 0.5 5.0
Rush Rod Stroke (mm)

EX1300984
Figure 1

5-13-6
Overview
The pilot valve is a valve that controls the spool stroke, direction,
etc of a main control valve.
This function is done by providing the spring at one end of the
main control valve spool and applying the output pressure
(secondary pressure) of the pilot valve to the other end.
P
T
2 1
4 3
EX1301730
Figure 2

P T
Port Name Size
1 Backward
2 Forward
3 Backward PF 1/4
4 Forward O-ring
P Pilot Oil Inlet
1 2 3 4
T Pilot Oil Return
EX1301731
Figure 3

5-13-7
Parts List
52
23
22
20 32
21
15
30
13
14
26
33
16
17
18
31
19
11 28
11 25
27
12
9 24
5
6 27
7
51
8 11
10
2
3
36 34
35
53: 12, 21, 22, 23, 34, 35

4
4 EX1301311
Figure 4

5-13-8
Reference Reference
Number Number
1 Body (1) 20 Plug
2 Body (2) 21 O-ring
3 Plug 22 Rod Seal
4 Plug 23 Dust Seal
5 Spring Seat 24 Cover Kit
6 Spring 25 Socket Bolt
7 Spring Seat 26 Cam Kit
8 Spool 27 DU Bushing
9 Stopper 28 Camshaft
10 Spring 30 Set Screw
11 Spring Pin 31 Nut
12 O-ring 32 Bellows
13 Push Rod 33 Piston
14 Spring Pin 34 O-ring
15 Seal 35 O-ring
16 Steel Ball 36 Expand
17 Spring 51 Spool Kit
18 Plate 52 Plug Kit
19 Snap Ring 53 Pedal Valve Seal Kit

5-13-9
Theory of Operation
Structure
The casing (spacer) has oil inlet port P (primary pressure), and
the oil outlet port T (tank). In addition the secondary pressure is
taken out through ports 1, 2, 3 and 4 provided at the bottom
face.
Pressure Reducing Valve

1. Neutral position
If pedal is in neutral, spool is pushed up by return spring
and spring seat. Port (P) is blocked by bottom part of spool
and four operating ports (left forward and backward, right
forward and backward) are connected to port (T) through
inner hole of spool.
2. Half-operated state
If pedal is moved, push rod moves down, and they transmit
this force through spring seat and control spring to spool. If
spool is moved, primary pressure is transmitted through an
inner hole of spool to operating port. If lever is stopped in
middle position, compressed control spring force and
secondary pressure transmitted through hole acts at
bottom part of spool, balance is maintained by hydraulic
force acted upward, and then this pressure is transmitted
to traveling spool of control valve. That is, primary pressure
is transmitted to operating port as secondary pressure
equivalent to control spring force compressed by spool.
3. Fully operated state
If pedal is moved to a maximum, bottom part of push rod
presses spool seat to a maximum, and compresses control
spring to a maximum. Primary pressure is transmitted
through inner hole of spool to operation port, secondary
pressure transmitted through spool overcomes control
spring force and pushes spool up, but spool is restricted by
push rod and does not move any more. That is, when
pedal lever is moved to a maximum, control spring does
not function, spool is restricted by push rod, and then
primary pressure equalizes to secondary pressure.
Damper Mechanism
1. Operation When Operating Lever
When pushing pedal, pushing force pushing push rod and
spool presses cylinder, return spring and hydraulic oil in
cylinder is compressed, piston coming down with push rod
compresses vibration prevention chamber of lower part, oil
of vibration prevention chamber of lower part is flowed
through orifice to oil pressure vibration prevention chamber
of upperpart of low-pressure, now, ball check valve
becomes closing condition because high-pressure
operates to vibration prevention chamber of lower part.

5-13-10
2. Operation When Operating Lever In Neutral Condition
Climbing restoring force acting on push rod, raises piston
in oil pressure prevention chamber and compresses upper
oil pressure prevention chamber. This compression
operation of upper oil pressure prevention chamber
prevents the push rod from quickly rising by restoring
spring, and the damping force is generated.
Neutral Maximum Operating

12.4
2
3
to Travel Spool
Figure 5 of Control Valve
EX1401585
Reference Reference
Number Number
1 Push Rod 4 Piston Chamber
2 Orifice 5 Plug
3 Piston
Tools and Torques

Reference Torque
Description Size Tool
Number Nm kg.m ft lb
25 Socket Bolt M6 29.4 3 6 5 mm ( )
31 Nut M10 43.1 4.4 32 17 mm ( )

5-13-11
SECTION VIEW
31 30 28 27 32
26
23
24
22
15 25
21
13
20 16
33 17
11
14 18
19
2
12 8
35
9 6
5
10 3
34
7
1
4
EX1401587
Figure 6
Reference Reference
Number Number
1 Body (1) 18 Plate
2 Body (2) 19 Snap Ring
3 Plug 20 Plug
4 Plug 21 O-ring
5 Spring Seat 22 Rod Seal
6 Spring 23 Dust Seal
7 Spring Seat 24 Cover
8 Spool 25 Socket Bolt
9 Stopper 26 Cam
10 Spring 27 Bushing
11 Spring Pin 28 Camshaft
12 O-ring 30 Set Screw
13 Push Rod 31 Hex Nut
14 Spring Pin 32 Bellows
15 Seal 33 Piston
16 Steel Ball 34 O-ring
17 Spring 35 O-ring

5-13-12
REMOVAL
3. Stop engine.
Figure 7 EX1300542

WARNING LOCK
WARNING
DO NOT OPERATE
If engine must be running while performing
or maintenance
maintenance, always use extreme caution. Always 190-00695A
ON OFF
have one person in the cabin at all times. Never leave EX1401036
the cabin with engine running. Figure 8

switch.
Figure 9

5-13-13
WARNING
doing any work.
Figure 10 EX1400156
12. Remove hex bolts (1) and washer.
Remove cover (2) from frame (3).
• Tool: 19 mm ( )
3 FG020150
Figure 11
13. Remove hoses (1) from travel control valve (2). Attach
identification tags to the removed hoses for reassembling.
• Tool: 17 mm, 22 mm ( )
1
2
1
EX1301757
Figure 12
14. Remove floor mat (1) from the cabin.
1
FG020151
Figure 13

5-13-14
15. Remove bolts (1) and washer.
Remove footrest (2) from floor plate (3).
• Tool: 17 mm ( )
1 2 1
3
FG020147
Figure 14
16. Remove bolts (1) and washer (2).

Remove travel pedal (3) from travel pedal bracket (4).
• Tool: 17 mm ( )
3
4
1, 2
FG020146
Figure 15
Remove socket bolts (1) and washer (2).

Remove travel pedal bracket (3) from travel control valve 3
(4).
• Tool: 8 mm ( )
1, 2
4
FG020148
Figure 16
Remove socket bolts (1) and washer (2).

Remove travel control valve (3) from floor plate (4).
• Tool: 8 mm ( ) 3
1, 2
FG020149
Figure 17

5-13-15
INSTALLATION
1. Position pedal valve (1, Figure 18) on cabin floor plate and 2
install four bolts and washers (2).
EX1301756
Figure 18
2. Install pedal brackets (3, Figure 19) on pedal valve and

install four bolts and washers (2).
3. Install plastic pedals (1).
2 3
FG019381
Figure 19
4. Connect hoses as tagged during removal to pedal valve (1,

2
Figure 20).
5. Install cabin under cover by tightening bolts.
EX1301756
Figure 20

5-13-16
6. Install travel control valve (3, Figure 21) to floor plate (4).
Install socket bolts (1) and washer (2).
• Tool: 8 mm ( ) 3
1, 2
FG020149
Figure 21
Install travel pedal bracket (3) to travel control valve (4).

Install socket bolts (1) and washer (2). 3
• Tool: 8 mm ( )
1, 2
4
FG020148
Figure 22
7. Install travel pedal (3) to travel pedal bracket (4).

Install bolts (1) and washer (2).
• Tool: 17 mm ( )
3
4
1, 2
FG020146
Figure 23
8. Install footrest (2) to floor plate (3).

Install bolts (1) and washer.
• Tool: 17 mm ( )
1 2 1
3
FG020147
Figure 24

5-13-17
9. Install floor mat (1) to the cabin.
1
FG020151
Figure 25
10. Detach identification tags from the removed hoses for

reassembling. Install hoses (1) to travel control valve (2).
• Tool: 17 mm, 22 mm ( )
1
2
1
EX1301757
Figure 26
11. Install cover (2) to frame (3).

Install hex bolts (1) and washer.
• Tool: 19 mm ( )
3 FG020150
Figure 27

5-13-18
COMPLETING WORK
FG019382
Figure 28
3. Slowly push and pull both travel lever about five times
without a load to vent air from pilot lines.
HAOB903L
Figure 29

5-13-19
DISASSEMBLY
1. Remove bellows (32).
FG013535
Figure 30
2. Remove set screw (29) from cam (26).
FG013536
Figure 31
3. Remove camshaft (28) from cam (26).
FG013537
Figure 32
4. Remove hex nut (31) and set screw (30) from cam (27).
FG013538
Figure 33

5-13-20
5. Remove hex socket head bolt (25) and cover (24) from
each body (1 and 2).
FG013539
Figure 34
FG013540
Figure 35
6. Remove push rod assembly from body (2).
FG013541
Figure 36
7. Remove body (2) from body (1).
FG013542
Figure 37

5-13-21
8. Remove damper spool assembly and spring (10) from
body (1).
FG013543
Figure 38
FG013544
Figure 39
9. Remove plug (3 and 4) and O-rings (12 and 34).
FG013545
Figure 40

5-13-22
REASSEMBLY
1. Insert spring (10) into body (1).
FG013544
Figure 41
2. Assemble in proper order, damper spool (8), shim (7),

spring (6), spring seat (5) and stopper (9).
FG013546
Figure 42
3. Install damper spool assembly into body (1).
FG013547
Figure 43
4. Assemble body (2) onto body (1).
FG013542
Figure 44

5-13-23
5. Assemble rod seal (22), dust seal (23) and O-ring (21) into
plug (20).
FG013548
Figure 45
FG013549
Figure 46
6. Assemble seal (15), piston (33), steel ball (16), plate (18),
spring (17) and retaining ring (19) into push rod (13).
FG013550
Figure 47
7. Assemble push rod and plug.
FG013551
Figure 48

5-13-24
8. Install push rod assembly into body (2).
FG013552
Figure 49
9. Install bushing (27) in cover (24) using jig.
FG013553
Figure 50
10. Assemble cover (24) onto each body (1 and 2) and install
hex socket head bolt (25) using torque wrench.
FG013554
Figure 51

5-13-25
11. Install set screws (30) and hex nut (31) into cam (26) and
tighten it.
FG013555
Figure 52
FG013556
Figure 53
12. Position cam (26) on cover (24) and insert camshaft (29)
using hammer.
FG013557
Figure 54
13. Install set screw (29) in cam (26) and tighten it using torque
wrench.
FG013558
Figure 55

5-13-26
14. Check cam balance.
FG013559
Figure 56
15. Install bellows.
FG013560
Figure 57
FG013561
Figure 58

5-13-27
TROUBLESHOOTING
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. Often the problem is not caused by the
failure of a single part but, may be the result of a combination of
problems from related parts and their components. Possible
problems other than the ones list are not being specified but that
is not to say that these are the only possible problems that can
occur. The technician must diagnose the problem, considering
all possible causes and repair the source of the malfunction.

Secondary pressure will not Low primary pressure. Adjust primary pressure.
increase. Defective secondary pressure
Replace with new spring.
select spring.
Gap between damper spool and
Replace damper spool casing assembly.
casing is abnormally large.
Defective operating parts and Disassemble/reassemble and replace
components. defective parts.
Unstable secondary Jamming of interconnected parts. Repair/replace cause of jamming.
pressure. Unstable tank line pressure. Install direct line to hydraulic tank.
Air in hydraulic lines. Vent air from system.
Abnormally high secondary High tank line pressure. Install direct line to hydraulic tank.
pressure. Jamming of interconnected parts. Repair/replace cause of jamming.
No dampening. Air in piston chamber. Vent air from system.
Jamming of interconnected parts. Repair/replace cause of jamming.
Worn damper springs. Replace with new parts.
Worn damper spool and housing. Replace damper spool and housing
assembly.
Defective/damaged check valve. Disassemble and examine check valve.
Worn damper spool orifice. Replace damper spool.
Damper spool feels heavy. Defective interconnected
Repair/replace defective parts.
components.
Restricted movement of damper
Repair/replace damaged piston.
spool.

5-13-28
1Solenoid Valve
Edition 1
DX340LC-5/DX350LC-5 Solenoid Valve

5-14-1
MEMO
Solenoid Valve DX340LC-5/DX350LC-5

5-14-2
Table of Contents
Solenoid Valve
General .........................................................5-14-5
Specification ............................................................ 5-14-5
Overview ................................................................. 5-14-6
Parts List ................................................................. 5-14-8
Disassembly and Reassembly....................5-14-10

5-14-3
5-14-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specification
Pressure (Max.) 70 kg/cm2 (69 bar, 996 psi)
Flow (Max.) 23 L/min (6.1 U.S. gal)
Leakage 40 ml/min
Solenoid Coil
Rated Voltage DC 24 V
Operation Voltage Range 20 - 30 V
Surge Absorber Built in
Connector Type Deutsch DT-02 Series
Housing Series: DT04-2P-Type molded
Deutsch Terminals: Pin 1060-16-0122
Test 49 bar at 20 L/min

5-14-5
Overview
C4
P4
C3
P3
C2
BS
C1
PH
ACC
TR2
T
P2
H0
P0 P1 EX1400105
Figure 1
P4 P3 ACC
P1
BS PH TR2 H0 P2
P0
T
EX1400106
Figure 2

5-14-6
2-Solenoid Valve
BS PH TR2 H0 P2 P0
P1
C6
C5 C4 C3 C2 C1
Figure 3 P4 P3 ACC
EX1400110
3-Solenoid Valve
BS PH TR2 H0 P2 P0
P1
C6
C5 C4 C3 C2 C1
Figure 4 P4 P3 ACC
EX1400111
4-Solenoid Valve
BS PH TR2 H0 P2 P0
P1
C6
C5 C4 C3 C2 C1
Figure 5 P4 P3 ACC
EX1301277
Port Name Size

P0 Pilot Filter PF 1/2, O-ring
P1 Pilot Inlet Pressure PF 1/4, O-ring
P2 Safety Cut-off PF 1/2, O-ring
P3 Safety Cut-off PF 1/4, O-ring
P4 Plugged PF 1/4, O-ring
T Pilot Outlet Pressure PF 3/8, O-ring
ACC Accumulator PF 1/2, O-ring
BS Plugged PF 1/4, O-ring
PH Pressure Up PF 1/4, O-ring
TR2 Travel High/low Speed PF 1/4, O-ring
H0 Breaker Pressure Supply PF 1/4, O-ring

5-14-7
Parts List
2-1
2-2
4
5
1
EX1400112
Figure 6
Reference
Description Size Torque (kg.m) Tool
Number
2 Solenoid Valve UNF7/8 - 14" 3.5 ±0.25 Torque Wrench/1", Hex
2-1 Coil Locknut UNF1/2 - 20" 0.6 Torque Wrench/19 mm, Hex
2-2 Coil
3 Check Valve UNF7/8 - 14" 3.5 ±0.25 Torque Wrench/1", Hex
4 Plug PF 1/4 2.5 ±0.25 Torque Wrench/19 mm, Hex
5 Plug PF 1/8 0.1 ±0.25 Torque Wrench/5 mm, Socket

5-14-8
Theory of Operation
C4
C3
C2 2
C1 2-1
C6
1 EX1400113
Figure 7
Reference
Description Quantity Remarks
Number
1 Block Body 1
2 Solenoid Valve 4 C1 - C4
2-1 Coil (Deutsch Type) 4 C1 - C4
3 Check Valve 1 C6
4 Plug 3 P3, P4, H0
5 Plug 6
Reference
Function Operations Remarks
Number
Provides pressurized oil coming from the pilot pump for
C1 Pilot Cut-off the pilot pressure supply solenoid valve to operate each
work system.
Supplies pilot pressure for the pedal valve assembly and
C2 Breaker Pressure Supply Optional
shuttle valve.
Sets low and high travel speed. Shifts speed between
C3 High/Low Travel Speed both depending on the state of the solenoid valve or a
signal detected in the EPOS controller.
C4 Two Way Pedal Supplies pilot pressure for the two way pedal valve. Optional

5-14-9
DISASSEMBLY AND REASSEMBLY
1. Choose a work area for disassembly.
NOTE: (1) Choose a clean work area.
(2) Use a rubber mat or other protective
covering on the workbench area to
prevent damage or scratching of any
precision machined components.
2. For disassembly and reassembly, use torques and tools
listed in tables.
3. The directions of disassembly and reassembly are same as
the "Disassembly Direction" and "Reassembly Direction" as
shown in Figure 6.
4. Disassembly and reassembly of the solenoid valve
A. Remove coil locknut (2-1) from solenoid valve (2).
IMPORTANT
Take care not to damage the solenoid valve (2)
when removing the coil locknut.
If the solenoid valve (2) is damaged (bent or
deformed), the solenoid valve may not operate.
B. Remove coil (2-2) by hand.

C. Remove solenoid valve (2).
D. Check disassembled components for damage, and
reassemble them in the reverse order of the
disassembly.
E. Do not use excessive torque when assembling he
solenoid valve and coil.
IMPORTANT
Excessive torque can damage the solenoid valve.
5. Do not allow any contamination to enter the valve during

disassembly and reassembly procedures.
6. Every component must be washed out before reassembly.

5-14-10
TROUBLESHOOTING
Symptoms Causes How to Check Solutions
Foreign sub- Disassemble the solenoid valve and check if Remove contami-
stance, dirt and there is any contamination such as a foreign sub- nant, wash, and
dust in solenoid stance and sludge between the case and the assemble compo-
valve. spool. nents.
Tube or retainer Disassemble the solenoid valve and check if Replace solenoid
of solenoid valve there is any deformation (bending or reduction) in valve.
damaged. the tube or the retainer.
Malfunction Coil broken, Disassemble the solenoid valve and check the Replace coil.
of solenoid short, or burned. coil resistance.
valve Spec: 26.7Ω @ 20°C
Disconnection: ∞
Short: Low or excessive resistance
Disassemble the solenoid valve and check the
outside of the coil to see if its casing is burned
and melted.
Connector termi- Check if the connector (valve side) and housing Replace coil or
nal ground defect. (where harness is attached) are grounded properly. housing.
Pilot pressure. Remove plug of the "P5" port, install a pressure Refer to "Causes"
gauge, and check the pilot pressure discharged and "How to Check"
from the pilot pump when operating the pilot cut- of the solenoid valve
off valve (C1). above.
Pilot relief valve. Check if the relief valve installed in the pilot line Remove foreign
Pilot pres- operates properly. substance, reas-
sure fails to semble, and replace
• Check if pressure is bypassing because of
generate; the relief valve.
the presence of foreign substance.
Pilot pump. Check if the pilot pump works properly. Replace the pilot
pump.
Pilot filter. Check if the mesh screen of the pilot filter is con- Wash, reassemble,
taminated by foreign substance. and replace the fil-
ter.
Pilot system. Check any defect of the pilot system considering Repair defect(s)
findings from "Pilot pressure fails to generate;" accordingly.
category.
Solenoid valve. Install a pressure gauge at each outlet port of the Refer to "Causes"
Poor Actua- solenoid valve (H0, TR2, PH, and BS ports) and and "How to Check"
tor Perfor- check the pressure value discharged from the of the solenoid valve
mance pilot pump when operating the solenoid valve. above.
Main control Check if main control valve of each component Repair according to
valve. works properly. findings.
Other compo- Check if each component works properly. Repair according to
nents. findings.

5-14-11
5-14-12
Accumulator
Edition 1
DX340LC-5/DX350LC-5 Accumulator
5-15-1
MEMO
Accumulator DX340LC-5/DX350LC-5
5-15-2
Table of Contents
Accumulator
General .........................................................5-15-5
Specifications .......................................................... 5-15-7
5-15-3
5-15-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
The accumulator is a gas-charged storage device designed to 1
hold a reserve quantity of hydraulic fluid under pressure.
Accumulators are used in hydraulic circuits in much the same 2
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 irregular operation are made
up from the supply of pressurized oil in the accumulator.
Reference
Description
Number
3
1 Screw Plug
2 Steel Pressure Vessel
4
3 Diaphragm
4 Fluid Valve
ARS1790L
Accumulators are solidly constructed to resist the high operating Figure 1
pressures of the fluids they contain. There are only three main
moving parts: a plug at the top allows precharging or expelling
gas from the compressible, precharged upper chamber; a valve
assembly at the bottom of the accumulator for passing hydraulic
fluid in and out, and an elastic diaphragm to separate the two
chambers. The flexible diaphragm changes shape to conform to
the changing pressures and volumes of the two fluids in the
upper and lower chambers.
5-15-5
There are six possible positions the diaphragm can be in and
they are as follows: Pressure Fluid Nitrogen
1. With no gas charge in the upper chamber 0 bar (0 psi,

empty) and no oil in the bottom 0 bar (0 psi, dry) the elastic
diaphragm hangs loosely.
2. When the prepressure charge of gas (usually nitrogen) is
introduced through the port at the top of the accumulator, the
diaphragm expands to maximum size. The valve button in the 1 2 3
center of the diaphragm pushes into the fluid opening in the
bottom chamber, sealing off the lower valve. If the pressure of
the gas charge exceeds system oil pressure, no fluid enters
the accumulator. The button also keeps the diaphragm from
protruding into the lower valve opening.
NOTE: Precharge pressure is referred to as the "P1"
pressure. The accumulator manufacturer's "P1"
rated pressure must be stamped or marked on 4 5 6
ARS1800L
the accumulator's rating plate. Annual checks of
actual precharge pressure must be made by Figure 2
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 "P1"
rated precharge pressure on the accumulator
manufacturer's data label. Repeat this test at least once a
year to verify proper functioning of the accumulator.
3. As hydraulic system pressure overcomes accumulator
precharge pressure, the flexible diaphragm begins to
retract upward.
4. When system oil is at highest working pressure and the
accumulator fills to maximum reserve capacity, the flexible
diaphragm is pushed up into the top of the upper chamber.
The highest working pressure is sometimes referred to as
the "P3" pressure and can also be referenced on the
manufacturer's data label on the exterior of the
accumulator.
5. If system oil pressure begins to fall off or is momentarily
checked or interrupted, the energy stored on the other side
of the diaphragm, in the form of compressed gas, pushes
oil back out of the lower chamber, maintaining oil pressure
of the circuit.
5-15-6
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.
Specifications
System Charge Pressure Volume
10 kg/cm2 320 cc
Pilot
(9.8 bar, 142 psi) (19.53 in3)
5-15-7
5-15-8
Two Pump
Edition 1
DX340LC-5/DX350LC-5 Two Pump

5-16-1
MEMO
Two Pump DX340LC-5/DX350LC-5

5-16-2
Table of Contents
Two Pump
General .........................................................5-16-5
Layout...................................................................... 5-16-7

5-16-3
5-16-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Theory of Operation
When a set flow rate of an attachment is 1 pump (about 240 L/min)
or greater:

5-16-5
Hydraulic Circuit
5
Attachment Option
b7
BKT Boom Travel (L) Travel (R) Swing Arm
B7
A7
a7
P1
P2
387 ±5 kg/cm2 387 ±5 kg/cm2
(380 ±5 bar) Pi (380 ±5 bar)
Relief V/V
3
A
4
P
T
A
Two-way Pedal
High-speed
a7
Operating
2
Hammer
P
Cut-off
Safety
Travel
ACC P2 H0 TR2 PH BS
T
1
P1 P2 P0
A3
P1 P3 P4
from Joystick (RH) Button

EX1400203
Figure 1

5-16-6
Reference Reference
Number Number
1 Main Pump EPPR and Solenoid Package
4
2 Solenoid Valve Valve
3 Bypass Cutoff Valve 5 Control Valve
Layout
By-pass Cut Off Valve
EPPR & Sol. Package Valve
Figure 2 EX1400192

5-16-7
5-16-8
1Lower Structure and
Chassis
Swing Bearing
Edition 1
DX340LC-5/DX350LC-5 Swing Bearing

6-1-1
MEMO
Swing Bearing DX340LC-5/DX350LC-5

6-1-2
Table of Contents
Swing Bearing
General ...........................................................6-1-6
General Description................................................... 6-1-6
Parts List ................................................................... 6-1-6
Maintenance Guidelines .................................6-1-7
Disassembly ...................................................6-1-8
Reassembly ..................................................6-1-10

6-1-3
6-1-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

6-1-5
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
2 6
FG1301305
Figure 1
Reference Reference
Number Number
1 Outer Ring 5 Ball
2 Inner Ring 6 Retainer
3 Tapered Pin 7 Seal
4 Plug

6-1-6
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 gradual rate of wear and extended
service life. EX1302041
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
The height as the
above the ground and take measurements at 4 points, 90° apart, boom foot pin height.
around the circumference of the bearing.
Record and keep all measurements. Play in the bearing should EX1301770
increase minimally from one inspection 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 EX1301780
bearing can be checked by fully retracting the arm and bucket Figure 4 Measurement (h2)
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 take up all the lateral clearance in the bearing. (Less than 100
lb of force must be required to move the bucket over all the
way.) Check lateral play in both directions and record the values.
When the bearing is beginning to approach the end of its service
life, the measured lateral clearance should start to show
increase in value.

6-1-7
DISASSEMBLY
1. Remove 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).
Figure 7
4. Turn inner ring and use magnet bar (C, Figure 8) to

remove steel balls (5).
Figure 8

6-1-8
5. Turn inner ring and use wire (D, Figure 9) to remove
retainers (6).
Figure 9

6-1-9
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

6-1-10
1Center Joint
Edition 1
DX340LC-5/DX350LC-5 Center Joint

6-2-1
MEMO
Center Joint DX340LC-5/DX350LC-5

6-2-2
Table of Contents
Center Joint
General ...........................................................6-2-5
Overview ................................................................... 6-2-6
Parts List ................................................................... 6-2-7
Section View ...................................................6-2-8
Disassembly ...................................................6-2-9
Reassembly ..................................................6-2-12
Troubleshooting, Testing and Adjustment ....6-2-14
Inspection ................................................................ 6-2-14
Testing..................................................................... 6-2-14

6-2-3
MEMO

6-2-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
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.

6-2-5
Overview
2
1
4
3
5
2
1
4 3
5
EX1400114
Figure 1
Size
Port Name
Body Spindle
1, 2, 3, 4 Travel Motor SAE 1 1/4" SAE 1
5 Pilot PF 3/8 O-ring
G Drain PF 3/4 O-ring

6-2-6
Parts List
13
14
7
3
10
15
16
9
12
8 4
17
5
1
2
11 EX1400115
Figure 2
Reference Reference
Number Number
1 Body 11 Plug
2 Spindle Assembly 12 Plug
3 Cover 13 Bolt
4 Spacer 14 Spring Washer
5 Shim 15 Bolt
7 Seal 16 Spring Washer
8 O-ring 17 Dust Seal
9 O-ring * Center Joint Seal Kit
10 O-ring

6-2-7
SECTION VIEW
15, 16 12 13, 14
3
10
1
7
4
3
5
17
2
5
11 EX1400116
Figure 3
Reference Reference
Number Number
1 Body 10 O-ring
2 Spindle Assembly 11 Plug
3 Cover 12 Plug
4 Spacer 13 Bolt
5 Shim 14 Spring Washer
7 Seal 15 Bolt
8 O-ring 16 Spring Washer
9 O-ring 17 Dust Seal

6-2-8
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 any of the
hydraulic components.
1. Set PF3/4 eyebolts on the cover drain port and use a hoist
to move it to a workplace.
2. Remove active oil remaining on each port with air.
3. Use a 19 mm wrench to loosen spacer bolts and remove
cover and O-rings (1BG120).
Cover Bolt (M12)
EX1400117
Figure 4

6-2-9
4. Use a 17 mm wrench to disassemble the spacer and the
shim.
IMPORTANT
Spacer
Care must be taken not to make a flaw on the surface Bolt (M10)
of the shaft when disassembling the body of the shaft
assembly.
EX1400118
Figure 5
5. Disassemble the body from the spindle assembly.

A. It can be disassembled easily by fixing the spindle
assembly, tightening at least 2 - 12 mm eyebolts on
the body, and lifting it with a hoist slowly.
B. Or, it may be disassembled by setting the continuous
thread studs on the spindle drain port as shown in the
figure.
EX1400119
Figure 6
6. Separate the body into 6 slipper seals, 1 wear ring, and 1

O-ring.
IMPORTANT
Care must be taken not to damage the inside of the
body because it is likely to be damaged when
disassembling the slipper seal. It may be
disassembled more easily with a screwdriver whose
tip is bent as shown in Figure 7.
EX1400120
7. Remove PT and PF plugs sealing the shaft. Figure 7
• Internal sealing PF 3/4: 12 mm wrench.

• External sealing PT 3/8: 8 mm Wrench.

6-2-10
8. Remove foreign substance on pieces disassembled and PF 3/4 Plug
wash them out.
9. Replace disassembled O-rings and slipper seals with new
ones, for they cannot be reused.
IMPORTANT
The inside of the hub must be air washed and
rustproof treated after washing it to prevent rusting.
PT 3/8 Plug EX1400121

Figure 8

6-2-11
REASSEMBLY
CAUTION
AVOID INJURY
Apply active oil to every functional (moving) part before
assembly to reduce any assembly friction as much as
possible.
1. Wrap the Teflon tape around the PT3/8 about 6 times. PF 3/4 Plug
2. Assemble the PT and PF plugs into the washed shaft.
Internal Sealing PF 3/4: External Sealing PT 3/8:

12 mm wrench 8 mm wrench
Engagement Torque: Engagement Torque:
147 ±9.8 N.m 44 - 93 N.m
(15 ±1.0 kg.m) (4.5 - 9.5 kg.m)
3. Assemble the slipper seal, the wear ring, and the O-ring
into the body.
PT 3/8 Plug EX1400121

Figure 9
4. Assemble the 1AP120 O-ring the outside of the body.
CAUTION
AVOID INJURY
After assembling the slipper seal, a manual test must
be performed to ensure that every part is assembled
properly. 1AP120
EX1400122
IMPORTANT Figure 10
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 to the seal.

6-2-12
IMPORTANT
Applying oil to the surface of the shaft will help
prevent damage to the slipper seal.
5. Fix the position of the shaft and press the body carefully
into shaft with both being parallel each other.
6. Use a plastic (or rubber) hammer to tap the body until it is
inserted completely.
IMPORTANT
Tap the hub in a zigzag pattern so it does not tilt to one
side.
Figure 11
7. Install the shim, the spacer, and the spacer bolts on the top
of the shaft.
8. Use a torque wrench to tighten spacer bolts at 49 - 59 N.m
(5 - 6 kg.m).
Spacer
Bolt (M10)
EX1400118
Figure 12
9. Set the O-ring (1BG120) in its place and assemble the

cover in the direction as shown in the figure.
10. Tighten the cover bolt (M12) at torque of 98 - 123 N.m
(10 - 12.5 kg.m).
11. Return the O-ring (1AP120) assembled to the outside of Cover Bolt (M12)
the body to its original position.
IMPORTANT
After the completion of the assembly, a start-up and a
rotation torque tests must be performed for the slipper
seal to seat in its place properly.
Figure 13 EX1400117

6-2-13
TROUBLESHOOTING, TESTING
AND ADJUSTMENT
Inspection
The center joint must be checked for evidence of external oil
leakage every 2,000 operating hours. Leaking or defective
O-rings are an indication that dirt and other contaminants could
be getting inside the assembly, which will promote accelerated,
abnormal wear and can cause early failure of the assembly.
If internal seals or other sliding surface components are worn
and there is internal fluid leakage, complete overhaul and repair
or replacement of the center joint may be required.
Testing
Pressure
To check pressure through the center joint, make up a test kit Gauge
from the following equipment list:

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

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

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

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

Pump
block diagram. The test kit is used to pressurize the center Tank
swivel above normal working pressure and lock in the higher 0370
pressure (as the stop valve is closed manually) for a leak down Figure 14
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
14).

6-2-14
Travel Device
Edition 1
DX340LC-5/DX350LC-5 Travel Device

6-3-1
MEMO
Travel Device DX340LC-5/DX350LC-5

6-3-2
Table of Contents
Travel Device
General ...........................................................6-3-5
Specification .............................................................. 6-3-5
Overview ................................................................... 6-3-6
Parts List ................................................................... 6-3-8
Travel Motor ......................................................... 6-3-8
Travel Reduction Gear ....................................... 6-3-10
Hydraulic Motor (Brake Valve, Parking Brake,
High-Low 2-Stage Switching Mechanism).......... 6-3-12
Reduction Gear .................................................. 6-3-20
Cautions for Operation ............................................ 6-3-22
Installation Method (refer to the Outline Drawing) ... 6-3-22
Pipeline............................................................... 6-3-22
Hydraulic Oil ....................................................... 6-3-23
Lubricant............................................................. 6-3-24
Maintenance/Service.......................................... 6-3-25
Precaution ....................................................6-3-26
Tools for Disassembly and Assembly ..................... 6-3-26
Hydraulic Motor .................................................. 6-3-26
Reduction Gear .................................................. 6-3-27
Tightening Torque ................................................... 6-3-28
Removal .......................................................6-3-29
Installation ....................................................6-3-34
Completing Work ..........................................6-3-35
Section View .................................................6-3-36
Disassembly .................................................6-3-38
Cautions on Disassembly........................................ 6-3-38
Disassembly Sequence........................................... 6-3-38
Disassembly of Reduction Gear......................... 6-3-38
Disassembly of Hydraulic Motor......................... 6-3-43
Reassembly ..................................................6-3-48

6-3-3
Cautions on Assembly............................................. 6-3-48
Assembly Sequence................................................ 6-3-48
Assembly of Hydraulic Motor.............................. 6-3-48
Assembly of Reduction Gear.............................. 6-3-59
Performance Test .........................................6-3-65

6-3-4
SAFETY INSTRUCTIONS
WARNING
machine. Read and understand the Operation and
or serious injury.
GENERAL
Specification
1 Speed 2 Speed
Travel Motor Type Axial Piston 2-speed
Displacement 269.9 cc/rev 165 cc/rev
Crossover Relief Valve Setting 343 bar @25 L/min
Max. Supply Flow 280 L/min (74 U.S. gpm)
Motor Shaft Speed 1,163.4 rpm 1,903 rpm
1,474 N.m 901 N.m
Motor Shaft Torque
(150.3 kg.m, 1,087 ft lb) (91.9 kg.m, 665 ft lb)
Reduction Gear Type 2 - Stage Planetary Gear
Reduction Gear Ratio 46.12
Max. Output Speed 25.2 rpm 41.3 rpm
67,999 N.m 41,570 N.m
Max. Output Torque
(6,934 kg.m, 50,154 ft lb) (4,239 kg.m, 30,661 ft lb)
Weight 360 kg (Included Motor)
Traveling Traveling Speed 3.3 km/hr 5.2 km/hr
Performance
Traction Force 37.85 ton 23.14 ton
Traction Force (EFF. = 85% / 75%) 32.17 ton 17.35 ton
Grade ability 70%
Parking Brake Control Type Main Pressure, Mechanical
Brake Torque 853 N.m (87 kg.m, 629 ft lb) (min)
Brake Release Pressure 8 ±1.5 bar

6-3-5
Overview
Travel device consists of a travel motor and gearbox.
Travel motor includes brake valve, parking brake and high/low
speed changeover mechanism.
Fill
D
P1
A
Level
B
Drain
P2
P
EX1301697
Figure 1
Port Name Size

A Inlet, Outlet SAE 1", 6000 psi, ø25, 27.8 x 57.2
B Inlet, Outlet SAE 1", 6000 psi, ø25, 27.8 x 57.2
D Drain PF 1/2, O-ring
P Pilot (High-speed) PF 1/4, O-ring
P1. P2 Gauge PF 1/4, O-ring
Fill PF 1/2, O-ring
Level PF 1/2, O-ring
Drain PF 1/2, O-ring

6-3-6
D D
Reduction Gear
HIGH
LOW
Hydraulic Motor
P
Parking Valve
Parking Brake
P1 P2
High, Low Change Unit
Control Valve
A B
Pump
EX1400154
Figure 2

6-3-7
Parts List
Travel Motor
267
231
230
233
210
260
232
237 200
249
203
236
201
208 207
214
204
215
71 216
202 215
14 26 216
12 215
216
13 215
8 1 54 50
6 213
7 41 212
209
52
74
68
502
74
52
73
56 72
54 2
56 7
6
8
13
12
66 500
65 14
43 501 502
83
82 75
54 54
FG018748
Figure 3

6-3-8
Reference Reference
Number Number
1 Rear Flange 201 Piston Assembly
2 C.B Spool Assembly 202 Driveshaft
6 Main Spring 203 Swash Plate
7 Washer 204 Cylinder Block
8 Seat 207 Plate Retainer
12 Cap 208 Thrust Ball
13 O-ring 209 Mating Plate
14 Socket Bolt 210 Spring
26 O-ring 212 Parking Piston
41 Pin 213 Spring
43 Socket Bolt 214 Cylinder Spring
50 Needle Bearing 215 Friction Plate
52 Plug 216 Mating Plate
54 Plug 230 O-ring
56 Plug 231 O-ring
65 2 Speed Spool 232 Oil Seal
66 Spring 233 O-ring
68 Steel Ball 236 Lock Ring
71 Orifice 237 Retaining Ring
72 Orifice 249 Roller Bearing
73 Orifice 260 2 Speed Piston Kit
74 O-ring 267 Pivot
75 Orifice 500 Reducing Valve
82 Plug 501 Cover
83 O-ring 502 Relief Valve Assembly
200 Cylinder Block Kit

6-3-9
Travel Reduction Gear
182
183
182
146 183
141 142
185
143 182
146 183
181
112 180
145 170
160
130
140
135
136
132
134
131
133
136 110
105
102
105
109
103
101
EX1301132
Figure 4

6-3-10
Reference Reference
Number Number
101 Spindle 140 Carrier No 1
102 Hub 141 Planetary Gear No 1
103 Floating Seal 142 Needle Cage
105 Angular Bearing 143 Bearing Shaft (R)
109 Distance Piece 145 Spring Pin
110 Shim Plate 146 Thrust Washer
112 Thrust Plate 160 Sun Gear
130 Carrier No 2 170 Drive Gear
131 Planetary Gear No 2 180 Cover
132 Needle Cage 181 Thrust Washer
133 Bearing Shaft (F) 182 Plug
134 Floating Bushing 183 O-ring
135 Spring Pin 185 Socket Bolt
136 Thrust Washer

6-3-11
Theory of Operation
Hydraulic Motor (Brake Valve, Parking Brake, High-Low

2-Stage Switching Mechanism)
Function
1. Function of the hydraulic motor
The hydraulic motor is a swash plate type axial piston
motor, which converts the power of the pressurized oil from
the pump into rotational motion.
2. Function of brake valve
The brake valve included in the hydraulic motor performs
four functions as follows:
A. When the motor stops, brake the motor to control the
moment of inertia and stop the motor smoothly.
B. The function of a check valve is to prevent cavitation
of hydraulic motor.
C. To function as a relief valve which controls the brake
pressure of the hydraulic motor and anticavitation
valve to prevent cavitation.
D. While the travel motor operates, it opens the port
which releases the parking brake, and when the
motor stops, it close the port.
3. Function of high-low speed 2-stage switching mechanism:
Using the switching valve and control piston, the swivel
angle of the swash plate can be switched between
high-speed low torque and low-speed high torque stages.
4. Function of parking brake
The parking brake stops the excavator from a when parked
on a slope by using friction plate type brake mechanism.
The brake is integrated with the hydraulic motor.

6-3-12
Theory and Description of Operation
1. Hydraulic motor
(Y1)
W1
Cylinder Block (204)
ri
F1 F1’
A P
W1
N1
Piston (205)
Swash Plate (203)

Low Press. High Press.
(Y2) FG018751
Figure 5
The high-pressure oil from the hydraulic pump flows

through the rear flange (RF1) of the hydraulic motor, timing
plate (209), and into the cylinder block (204). The
high-pressure oil enters the cylinder through one side of
the line Y1 - Y2 which connects the top-bottom dead points
of the piston (205) stroke.
In the Figure 5 above, the high oil pressure is applied on
the piston (205), pushing the swash plate (203) with force
F1' (F1' = P x A, P: oil pressure, A: area), generating
reaction F1. The reaction force F1 is divided into thrust
component N1 and radial component W1 by the swash
plate (203) having swivel angle of α. W1 is illustrated in the
above figure, and generated torque T = W1 x r1 in relation
to the line Y1 - Y2 which connects the top-bottom dead
points of the piston (205).
This torque which is the resultant torque ∑(W1 x r1) x i of
the torques generated by the pistons (4 or 5) on one side
where high-pressure oil has passed, rotates the cylinder
block (204) connected to the piston (205), and the cylinder
block (204) transmits rotational torque to the driveshaft
(202) connected by spline shaft.

6-3-13
2. Relief valve operation
The relief valve performs the following functions.
Chamber D Chamber C Poppet A
Chamber A
Chamber B
A1
Piston Chamber g Poppet A
A2
FG018752
Figure 6
A. The high-pressure oil entering chamber A by

counterbalance valve flows into chamber B in the
seat (See Figure 6). In the chamber B, the oil exerts
F1 = A1 x P1 of force on the cross-section A1 of
poppet A to push the poppet A to the left and the oil
flows from chamber A → chamber B → chamber D.
While the poppet A is pushed to the left, the oil flows
from chamber B to chamber C through the orifice of
the poppet A. This high-pressure oil then pushes the
piston to the right through the orifice in the relief valve
body. When the piston reaches the end of the right
side (stroke end) by the oil, the oil is blocked from
chamber g to the spring chamber in the body. As the
resultant force of the oil pushing the area A2 of the
poppet A, which is F2 = A2 x P2, and the spring force
becomes higher than the force F1 = A1 x P1 exerted
on the area A1 of the poppet A, the poppet A and
seat are closed, and the oil flow through chamber A →
chamber B →chamber D is stopped.
B. When the relief valve on the left is closed, the
pressure of the oil in the chamber A further increases.
This oil pressure is applied to the poppet B of the
relief valve on the right side. Since the force (F4 =
A4 x P3) applied on the area A4 of the poppet B
becomes larger than the force (F3 = A3 x P3) on the
area A3, the poppet B moves to the right and opens,
and the oil flows; chamber A →chamber E →chamber
D to operate the motor.
By controlling the pressure in chamber D in 2-stages,
the brake of the hydraulic motor is released smoothly
and the motor starts to run.

6-3-14
C. Brake operation
RF1 213 212 101 202
CB
500
71 216 215 204
Counter Balance Spool (CB)
P1 D
Position 1
HIGH
A
LOW
B
Position 2
Position 3
P2 P D
Pressure Reducing Brake Piston Orifice (71)

Figure 7 Valve (500) Chamber EX1400155
When releasing the brake, the high-pressure oil

opens the counterbalance spool (CB) assembled with
the rear flange (RF1), and apply pressure on the
brake piston (212) to release the brake. When oil
does not exert pressure on the piston, brake force is
maintained by brake spring.
Brake force is generated by the spindle (101) and the
mating plate (216) assembled to the spindle (101),
brake piston (212) and the friction plate (215) coupled
with cylinder block (204) using spline. Reducing Valve
EX1400604
When pressure is not applied, the brake piston, by
the force of the brake spring (213), pushes the friction Figure 8 Parking Brake Release
plate and mating plate assembled with the spindle to
generate friction force. This friction force restrains the
driveshaft (202) which is coupled with the cylinder
block using spline to activate the brake.

6-3-15
(Counterbalance spool is in travel state (position 1 or 3))
The pressure of the oil entered through the A or B port is
reduced in the pressure reduction valve and enters the
brake piston chamber.
Here, although a small amount of oil is drained through
the orifice B (71), because high-pressure oil is supplied
from the counterbalance valve, the pressure in the
brake piston chamber overcomes the spring force and
releases the brake.
(Counterbalance spool is in neutral state (position 2))
Because high-pressure oil is not supplied, the
pressure in the brake piston chamber is low and the
brake spring force overcomes the pressure in the
brake piston chamber, and the brake is applied. Now,
because the oil in the brake piston chamber is
drained through the orifice B (71), the spool returns to
neutral position, and delays braking until motor stops
to prevent damage to the friction plates.
D. How to release brake
Brake can be released by the following procedures
without supplying release pressure.
WARNING
To prevent excavator from accidental rolling or
movement, always block excavator tracks (or
wheels) before releasing brake before servicing
brake.
Remove 2 plugs (45) from the rear flange (RF1).

Insert an M10 x 135L bolt and join with the threaded
part of the brake piston to release the brake.
Now, the condition is the same as when brake
release pressure is supplied, and the brake is
released.
– Socket Wrench: 6 mm, 8 mm
NOTE: If the hydraulic motor fails to rotate after
releasing the brake, the cause can be
failure to generate operating pressure
because of a pump problem.
To tow the system without disassembling
the hydraulic motor, connect short hoses
to the ports P1 and P2 of the pressure
measure ports and then tow the system at
low speed.

6-3-16
E. Counterbalance valve operation
AM P BM
L K
D C’
N
DH CH M
1’ 1
F DV CV E
G’ G
AV BV FG018754
Figure 9
The BV port and AV port are connected to the

hydraulic pump and tank, respectively. The oil from
the hydraulic pump flows from BV to CV, then
through C' to push the counterbalance poppet, then
through K to BM port into hydraulic motor and rotates
the hydraulic motor.
When the oil discharge pressure of the pump rises,
the high-pressure oil through passage G flow through
spring chamber E and ball check valve, and into
damping chamber M. When the pressure in the
chambers E and M surpasses the force of the spring
which maintains the spool at neutral position, the
spool moves from the right to the left. The hydraulic
oil in chamber N flows into chamber F by orifice 1',
and the oil in chamber F flows through G' and AV and
drained into the tank. When the spool moves from the
right to the left, path L - DH - D' - DEVICE is provided
in addition to path CV - H - P, increasing the opening
area of the spool.
When the pump discharge pressure becomes lower,
the pressure in chambers E and M also become
lower and the spool moves from the left to the right by
the spring in chamber F. Since the hydraulic oil in
chamber M flows into chamber E by orifice 1, and the
oil in chamber E flows to port BV by path G, the spool
moves from the left to the right.

6-3-17
When the pressure at the port BV is lowered down to
the tank pressure, the pressure in chambers E and F
also are lowered to the tank pressure, and the spool
returns to neutral position.
F. Operation of the swivel switching mechanism
Shoe (262) supports swiveling swash plate (203),
and the hemispherical pivots (267) at the both ends
of the shoe bear the load transmitted through the
swash plate stopper.
For capacity change, the swivel angle of the swash
plate is controlled. The control mechanism opens the
swivel piston (261) at the swash plate stopper part
and controls the hydraulic oil into and out of the
piston chamber with swivel control valve, which leads
to control the swivel angle of the swash plate in 2
positions of large and small.
Low speed - less than pilot pressure (20 bar)
A B
Pilot o1 X
Pressure (D)
267
65
A
B 66
203 262 261
Drain Chamber P
EX1400601
Figure 10
When pilot pressure is not supplied, by the force of

the 2-speed spring (66) of the 2-speed spool (65) and
the oil pressure of port (A) or port (B), the 2-speed
spool is pushed up and the oil at port (C) is cut-off.
The high-pressure oil in chamber (P) is drained into
motor case by the 2-speed spool (65).
Consequently, the swash plate (203) has the
maximum swivel angle θ1 and the displacement of
the hydraulic motor piston becomes maximum,
resulting in low speed rotation.
– Torque: High
– Speed: Low

6-3-18
At high-speed
A B
Pilot
Pressure (D) o2
65 X
A
B 66
203
261
C
Drain
Chamber P
EX1400602
Figure 11
When pilot pressure is supplied through port D

(pressure: bar), the pressure overcomes the force of
the 2-speed spring (66) and the oil pressure of port
(A) or port (B), pushing down the 2-speed spool and
the oil at port (C) flows into chamber (P) by 2-speed
spool (65). The high-pressure oil entered the
chamber (P) pushes the 2-speed piston (261) until
swash plate (203) contacts surface X.
Consequently, the swash plate (203) has the
minimum swivel angle θ2 and the displacement of the
hydraulic motor piston becomes minimum, resulting
in high-speed rotation.
– Torque: Low
– Speed: High

6-3-19
Reduction Gear
1. Planetary gear mechanism
Reduction unit slows down the rotating speed of motor and
converts motor torque to strong rotating force.
This reduction unit utilizes two stages, planetary reduction
system.
Planetary reduction system consists of sun gear, planetary
gears, carriers and hub.
When the sun gear is driven through input shaft, planetary
gear, rotating on their center, also move, meshing with
fixed hub, around sun gear.
This movement is transferred to carrier and deliver the
torque.
This mechanism is planetary gear mechanism.
Hub
Fixed Hub
Carrier
Planetary Gear Carrier
Sun Gear
Input Output
Sun Gear
Planetary Gear
EX1301696
Figure 12

6-3-20
2. 2-stage reduction gear
Hub (102) Drive Gear (170) Hub (102)

Sun Gear (160)
Carrier No. 2
Carrier No. 1
Planetary Gear (F)

Planetary Gear (R) (141)
1st Stage 2nd Stage EX1301695

Figure 13
The rotational torque output from the shaft of the hydraulic

motor is transmitted to the drive gear which becomes a
driveshaft and rotates planetary gear (F).
Here, the planetary gear (F) both rotates and revolves at
the same time.
That is, the carrier No. 1 which acts as the fixed shaft of the
planetary gear (F) rotates, and this rotation is transmitted
to the sun gear connected to the carrier, and the sun gear
acts as the driver shaft that rotates planetary gear (R). The
planetary gear (R) driven by the sun gear should both
rotate and revolve, same as the planetary gear (F), but
cannot revolve because the fixed shaft of the planetary
gear (R) is fixed to the spindle and rotates hub.
No. of hub teeth No. of hub teeth

Speed reduction ratio (I) = ( +1) ( +1) - 1
Drive gear Sun gear

6-3-21
Cautions for Operation
Installation Method (refer to the Outline Drawing)
Frame Mount
Sprocket Mount
EX1301762
Figure 14
Tightening torque of mounting bolts
Tightening Torque
Classification Qty Bolt Size
Nm kg.m ft lb
Frame Mount 30 M20 x 2.5 x 75 539 55 398
Sprocket Mount 28 M20 x 2.5 x 60 539 55 398
NOTE: The bolts must be JIS Strength Class 10.9 equivalent

or better.
When assembling, do not hit the travel motor with
hammer, etc., but use bolt holes.
Take care not to damage the assembling part of the
gearbox.
Pipeline
• Connect the pipeline after confirming the direction of
rotation of the motor (see outline drawing).
• At the time of shipping, pipeline ports (brake valve port,
motor drain port) are plugged and capped. The plugs and
caps are provided to protect the line from dust or welding
scale, to not remove them until connecting the pipeline.
• Make sure to fill the motor case with hydraulic oil before
starting the motor.
• Determine the pipeline diameter so the back pressure at
the motor drain port is less than 2 bar (or less than 5 bar at
peak).

6-3-22
Hydraulic Oil
Because the hydraulic motor case is drained at the time of
shipping, make sure to fill up the case with hydraulic oil before
operation.
Selecting Hydraulic Oil

Take the followings into consideration when selecting the
hydraulic oil for travel motor:
1. Use VG32-VG56 grade or equivalent.
2. Use wear resistant hydraulic oil.
3. Please contact us when hydraulic oil other than the one in
the table below is to be used;
Viscosity (40°C) 32CST 46CST

Grade
ISO VG VG32 VG46
Inspection, Replacement of Hydraulic Oil

The standard replacement period of hydraulic oil is as follows
(may vary by operating condition);
The table below shows the standard replacement period of
hydraulic oil.
• Replacement period: 1,000 hr or 1 year
• Replacement criteria
Test Item Replacement Criteria

Viscosity Change (40°C) ±10%
Oxidation (mgKQH/g) *
Moisture (%) 0.1%
Foreign Matter 10 mg/100 m§¤
Suspended Solids (%) 0.05%

Color Changes greatly
* For further details, contact us, since above criteria varies

greatly by the type of oil and manufacturer.

6-3-23
Lubricant
The reduction gear is filled with lubricant (gear oil) at the time of
shipping, however, check the oil level before operation.
1. Selecting gear oil
Use the gear oil with SAE #90 of equivalent extreme
pressure additive (API Classification GL-4 Grade or
better).
2. Replacement period of gear oil
A. First replacement (first time after starting operation):
500 hr
B. Second and later replacement: 1,000 hr or 1 year
However, if gear oil reduces fast than normal, find out
and correct the cause before refilling oil.
3. Replacement volume of gear oil: 7 L (1.85 U.S. gal)
4. Replacement method of gear oil
Port's of Gear Oil

Inlet
G1/2 (PF1/2)
Level Check
G1/2 (PF1/2)
Drain
G1/2 (PF1/2)
EX1301763
Figure 15
Added or replaced oil must be of the same kind. Do not mix

with a different type or grade of oil.
A. Let the oil refill port and drain port be perpendicular to
the horizontal plane.
B. For replacement, unplug the two ports and drain the
gear oil.
C. Refill gear oil until oil overflows from oil level check
port.
D. Wind Teflon or thread tape on the plug before
plugging the ports again.

6-3-24
Maintenance/Service
Check the following items while operating the travel motor.
1. Stop the product before service or inspection except when
checking the noise level of clause 3 below. Otherwise, you
may get physical injury including burn.
A. Oil leak (hydraulic oil, gear oil)
B. Loose bolt
C. Abnormal noise
D. Abnormally high case temperature
(Standard external surface temperature of case
during continuous operation: 80°C max.)
E. Replacement period of gear oil (See “Lubricant” on
page -24.)
F. Hydraulic motor allowable drain: 0.5 lpm (pressure
50 K max., at 25 rpm)
2. The case may be very hot right after operation. Measure
the temperature with a contact type thermometer.

6-3-25
PRECAUTION
Tools for Disassembly and Assembly
Hydraulic Motor
Tool B Size Applicable Part

Hex Wrench 2 Orifice (71)
4 Plug (54), Orifice (71)
6 PT Plug (45), PF Plug (52)
10 Socket Bolt (14)
17 Socket Bolt (43)
Socket Wrench 19 VP Plug (56)
Wrench 22.4 Reducing Valve (500)
41 Relief Valve (RV1)
Pliers (for holes TPR-90) For retaining rings (236)
Pliers (for shafts) For retaining rings (237)
Hammer, Plastic Hammer
Copper Rod, Approx. 7 x 7 x 200 mm Bearing (50, 249)
Monkey Wrench
Torque Wrench
Driver (JISB 4609)
Jig for Oil Seal Insertion
Bearing
Seal Tape
B B
B Size (rear side width) FG018759

Figure 16

6-3-26
Reduction Gear
Tool B Size Applicable Part

Hex Wrench (JIS B 4686) 10 Plug (182)
8 Socket Bolt (185)
Eyebolt (M10) No.1 Carrier (140), No.2 Carrier (130)
Eyebolt (M20) Hub (102), Spindle (101)
Hammer, Plastic Hammer Wood hammer also applicable
Driver (θ) To disassemble floating seal
Press (1 ton) Angular Bearing (105)
Punch For caulking spring pins and set screws
Torque Wrench
Oil Grind stone Finishing
B B

Figure 17

6-3-27
Tightening Torque
Tightening Torque
Classification Symbol Name Size (mm) B Size
Nm kg.m ft lb
Socket
14 M12 x 45 10 98.1 10 72.3
Bolt
Socket
43 M20 x 45 17 431.5 44 318.2
Bolt
54 Plug NPTF 1/16 4 9.8 1 7.2
Hydraulic Motor 45 Plug PT 1/2 6 21.6 2.2 15.9
56 VP Plug PF 1/4 19 36.3 3.7 26.8
52 Plug PF 1/4 6 36.3 3.7 26.8
71 Orifice M4 x 0.7 2 3.5 0.36 2.6
82 Plug PF 1/2 10 107.9 11 79.6
182 Plug PF 1/2 10 98.1 10 72.3
Reduction Gear Socket
185 M10 x 35 8 57.9 5.9 42.7
Bolt
B B

Figure 18

6-3-28
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.
CAUTION
AVOID INJURY
Pressure of grease in adjuster cylinder is too high. Take
precautions in opening valve against valve bounce or
grease vent.

6-3-29
1. Loosen grease valve, and then slacken the tension of
track.
NOTE: Since 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 ( )
• Torque: 137 N.m (14 kg.m, 101 ft lb)
Figure 19
2. Position the master pin in the direction of 4 o'clock and

then remove master pin using hydraulic press.
NOTE:
Regular Pin Master Pin Figure 20

EX1400095
3. Put two blocks under the track below to widen the gap
between sprocket and lower track.
NOTE: The gap between sprocket and track link must
be over 50 mm.
Figure 21
4. Turn off the travel device to the direction of an arrow slowly

and remove upper track.
Figure 22

6-3-30
5. Turn the upper structure 90° and jack up the machine.
NOTE: Jack up the machine until the track is slightly off
the ground.
90 - 110
Set the angle between boom and arm in 90 - 110° and
support the machine by using a block.
EX1300534
Figure 23

(Figure 24)
LOCK
WARNING WARNING
DO NOT OPERATE
or maintenance
ON OFF

switch.
(Figure 25)
Figure 25

6-3-31
WARNING
doing any work.
Pulling the breather cap upward, the check valve (0.45 bar) Figure 26 EX1400156
14. Remove bolt (28 ea) with sprocket from travel device
(Figure 27).
• Tool: 30 mm ( )
• Sprocket weight: 82 kg (181 lb)
Figure 27
15. Remove cover from track frame (bolt: 4 ea, washer: 4 ea).
• Tool: 19 mm ( )
Figure 28

6-3-32
16. Remove hoses from travel device in sequence.
D
NOTE: Cap the open ends of hoses with plug.
• Tool: 19 mm, 24 mm ( )
• Tool: 10 mm ( )
A
P B
Figure 29 EX1400157
• Thread of hoses and plug
Torque
Port Name Plug/Flange Size (Hose)
(mm) (mm) N.m kg.m ft lb
A Inlet, Outlet SAE 1", 6000 psi, D25 10 107.8 11 79.5
B Inlet, Outlet SAE 1", 6000 psi, D25 10 107.8 11 79.5
D Drain 13/16"-16UN-2B 24 55.8 5.7 41.2
P Pilot 9/16"-16UN-2B 19 25.4 2.6 18.8
17. Remove bolts (26 ea) from track frame except 4 bolts in
the direction of 12 o'clock
• Tool: 30 mm ( )
Figure 30 EX1400158
18. Install the sprocket bolts (2 ea) to travel device, and tie the
rope to the bolts to lift it.
Figure 31

6-3-33
19. Remove remaining bolts (4 ea) of track frame side, and
then hoist and remove travel device from track frame very
slowly.
EX1301601
Figure 32
INSTALLATION
WARNING
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.
Figure 33 EX1400159

6-3-34
COMPLETING WORK
1. Air testing of reduction gear
Remove one of the plugs (182) of the reduction gear and
apply compressed air (0.3 bar) through the plug hole under
water for two minutes. There must be no observable air
bubble.
→ Refill gear oil 7 L (SAE #90 equivalent, API classification
GL-4 Grade or better)
2. Air testing of hydraulic motor
Seal all the pipe ports of the hydraulic motor except one
through which compressed air 3 bar) is injected under
water for two minutes. There must be no observable air
bubble.
→ Hydraulic oil refill 2.5 L
3. Start the engine and run at low idling for about 5 minutes.

6-3-35
SECTION VIEW
10 9 13 6 7 1 2 3 4 5
11
14
8
12
56
43
412 402
500
413
405 406 407 409 408 414 403 401 404, 405 501
216 215 207 206 101 103 109 203 105 110 130 267 102 133
135
212
145
204
146
213
143
205
142
208
160
41 141
98, 99 170
209 181
50 180
214 112
82, 83 140
65
134
66 136
182,182
75
26 233 230 202 185
71 72,73 231 236 249 262 237 261 210 131 132 232 EX1301699
Figure 34

6-3-36
Reference Reference
Number Number
1 Rear Flange 145 Spring Pin
2 C.B Spool Assembly 146 Thrust Washer (R)
3 Poppet 160 Sun Gear
4 Plug 170 Drive Gear
5 Spring 180 Cover
6 Main Spring 181 Thrust Washer (R)
7 Washer 182 Plug
8 Seat 183 O-ring
9 Steel Ball 185 Socket Bolt
10 Spring 202 Driveshaft
11 Screw 203 Swash Plate
12 Cap 204 Cylinder Block
13 O-ring 205 Piston
14 Socket Bolt 206 Shoe
26 O-ring 207 Retainer Plate
41 Pin 208 Thrust Ball
43 Socket Bolt 209 Timing Plate
50 Needle Bearing 210 Spring
56 Plug 212 Piston
65 Spool 213 Spring
66 Spring 214 Shoe
71 Orifice 215 Friction Plate
72 Orifice 216 Mating Plate
82 Plug 232 Oil Seal
83 O-ring 233 O-ring
98 Nameplate 236 Retaining Ring
99 Rivet Screw 237 Retaining Ring
101 Spindle 249 Roller Bearing
102 Hub 261 Piston
103 Floating Seal 262 Shoe
105 Angular Bearing 267 Pivot
109 Distance Piece 401 Plunger
110 Shim Plate 402 Seat
112 Thrust Plate (R) 403 Body
130 Carrier No.2 404 Backup Ring
131 Planetary Gear (F) 405 O-ring
132 Needle Bearing 406 O-ring
133 Shaft Bearing (F) 407 Spring Retainer
134 Floating Bushing 408 Spring
135 Spring Pin 409 Piston
136 Thrust Washer (F) 412 Adjust Plug
140 Carrier No.1 413 Locknut
141 Planetary Gear (R) 414 Shim
142 Needle Bearing 500 Reducing Valve
143 Shaft Bearing (R) 501 Cover

6-3-37
DISASSEMBLY
Cautions on Disassembly
1. Take care not to damage the contact surfaces of the seals
(O-rings, oil seals) and gears, pins and bearings, and other
sliding surfaces.
2. When disassembling the hydraulic motor as mounted on
the equipment, take care to prevent dust and other foreign
materials from entering.
3. The number in the parenthesis after the part name
indicates the part number in the assembly drawing.
4. The motor's inlet pipeline side and output side are defined
to be rear and front sides, respectively.
Disassembly Sequence
The procedures of disassembly are as follows. In the order of
disassembly, A: Reduction Gear is followed by B: Motor
Disassembly of Reduction Gear

1. Select appropriate space for disassembling.
NOTE: Select a clean space.
Put rubber blanket on the work table to protect
the parts.
2. Remove dust and foreign materials from the reduction
gear.
3. Drain the gear oil.
NOTE: Put the drained oil in a clean container to check
the purity of the oil. Do not reuse the gear oil.
4. With the cover (180) facing upward, disassemble the
socket bolt (185).
NOTE: Do not reuse the thrust washer (M) of the cover.
FG018760
Figure 35

6-3-38
5. Disassemble the driver gear (170).
FG018761
Figure 36
6. Disassemble the carrier No. 1 assembly.

NOTE: Carrier No. 1 consists of planetary gear (R)
(141), needle bearing (142), shaft bearing (R)
(143). carrier No. 1 (140), thrust washer (R)
(146), and spring pin (145).
NOTE: Install M10 eyebolts and disassemble it using a
crane.
FG018762
Figure 37
7. Disassemble the spring pin (145) in the shaft bearing (R)

(145).
NOTE: Do not disassemble unless repair is required.
NOTE: Do not reuse the spring pin (145).
FG018763
Figure 38
FG018764
Figure 39

6-3-39
8. Disassemble shaft bearing (R) (143), planetary gear (R)
(141), thrust washer (R) (146), needle bearing (142), and
thrust washer (R) (146) in the said order.
FG018765
Figure 40
9. Disassemble the sun gear (160).
FG018767
Figure 41
10. Disassemble the carrier No. 2 assembly.

NOTE: Install M10 eyebolts and disassemble it using a
crane.
FG018768
Figure 42
11. Disassemble the spring pin (135) in the shaft bearing (F)
(133).
NOTE: Do not reuse the spring pin (135).
FG018763
Figure 43

6-3-40
FG018769
Figure 44
12. Disassemble the shaft bearing (F) (133) (4 ea).
FG018770
Figure 45
13. Disassemble thrust washer (F) (136), planetary gear (F)

(131), needle bearing (132), and floating bushing (134)
from the carrier No. 2 (130) in the said order.
FG018771
Figure 46
14. Put a tool on the separated surface and hit the tool with a
hammer to remove shim plate (110).
FG018772
Figure 47

6-3-41
15. Disassemble the hub (102) from the spindle (101).
NOTE: Install M10 eyebolts on the hub (102) and
disassemble it using a crane.
FG018773
Figure 48
16. Disassemble the distance piece (109) from the spindle

(101).
FG018774
Figure 49
17. Disassemble the floating seal (103) from the hub (102) and
spindle (101).
NOTE: Use a flat tip driver.
FG018775
Figure 50
18. On the hub (102), angular bearings (105) (2 ea) are

assembled in addition to the floating seal (103).
NOTE: Do not disassemble unless necessary.
NOTE: When disassembling, use aluminum rod and
hammer to protect the parts from being
damaged.
FG018776
Figure 51

6-3-42
Disassembly of Hydraulic Motor
1. Disassemble the reducing valve assembly.
FG018777
Figure 52
2. Disassemble the two relief valves (RV1).
FG018778
Figure 53
3. Remove two plugs (45), install M10 x 135 L socket bolts to

join with the brake piston (212).
FG018779
Figure 54
4. Disassemble the eight socket bolts (43).
FG018780
Figure 55

6-3-43
5. Remove bolt for forced brake release, and disassemble the
brake piston (212) and rear flange (RF1).
FG018781
Figure 56
6. Disassemble the brake spring (213) and timing plate (209).

NOTE: Removing the timing plate (209) may be difficult
if it is adhered to the rear flange (1) by oil.
In such case, disassemble it by inserting a steel
rod into the cast hole of the rear flange.
NOTE: Using a sharp tool can damage the contact
surface, leading to oil leak.
FG018782
Figure 57
7. Disassemble the plug (56), swivel spring (66) and swivel

spool (65).
FG018783
Figure 58
8. Disassemble the socket bolt (14), cover (12), and

counterbalance spool assembly.
NOTE: If the counterbalance spool or counterbalance
spring are damaged, replace with a
counterbalance spool assembly.
FG018784
Figure 59

6-3-44
9. Disassemble the friction plat (215) (4 ea) and mating plate
(216) (3 ea).
NOTE: While performing this job, keep the motor in
horizontal position.
FG018785
Figure 60
10. Disassemble the cylinder block kit.

FG018786
Figure 61
11. From the cylinder block (204), remove piston assembly

assembled with the retainer plate (207).
FG018787
Figure 62
12. Disassemble the piston assembly from the retainer plate

(207).
FG018789
Figure 63

6-3-45
13. Disassemble the thrust ball (208) and cylinder block spring
(214) (9 ea).
FG018790
Figure 64
14. Disassemble the swash plate (203).

FG018791
Figure 65
15. Disassemble the swivel piston assembly and two pivots

(267).
FG018792
Figure 66
16. Disassemble the retaining ring (236). Remove driveshaft

(202) from the spindle by hitting the front-side end with a
plastic hammer.
NOTE: Do not disassemble the roller bearing (102)
unless necessary.
FG018834
Figure 67

6-3-46
17. Using a retaining ring pliers, disassemble the retaining ring
(237) and roller bearing (249).
FG018835
Figure 68
18. Remove oil seal (232) from the spindle (101).

NOTE: Oil seal (491) cannot be reused. Assemble with
a new one.
Now, disassembly has been completed. Do not disassemble the
pin (41, for timing plate positioning) press fitted in the rear
flange.
FG018836
Figure 69

6-3-47
REASSEMBLY
Cautions on Assembly
Wash all the parts clean with clean flushing oil and dry them with
compressed air. Avoid using oilcloth, however, if necessary, use
a clean cloth and take care to avoid dust, etc.
Bolts and plugs must be tightened at the torque specified in
Table 5, using a torque wrench.
If a hammer is required, use a plastic hammer and hit the parts
lightly. As in the disassembly procedures, the number in the
parenthesis after the part name indicates the part number in the
assembly drawing.
Assembly Sequence
The procedures of assembly of the motor are as follows. This
assembly instruction presumes that all the parts are new.
The assembly sequence is A: Reduction Gear followed by B:
Hydraulic Motor
Assembly of Hydraulic Motor

1. Assemble the oil seal (232) with the spindle (101).
NOTE: Take care not to damage the oil seal (232).
NOTE: Apply grease thinly on the assembly part of the
spindle (101).
FG018793
Figure 70
2. Assemble the shaft (202) with the spindle (101).

NOTE: Apply grease thinly on the oil seal lip (232). (To
protect the oil seal).
FG018794
Figure 71

6-3-48
3. Assemble the retaining ring (236) using pliers.
FG018834
Figure 72
4. Assemble the two pivots (267).
FG018792
Figure 73
5. Assemble the swivel piston (261) and shoe assembly

(262).
FG018837
Figure 74
6. Apply grease on the rear side of the swash plate (203) and
assemble it with the spindle (101).
NOTE: Check that swash plate moves smoothly.
FG018838
Figure 75

6-3-49
7. Assemble nine cylinder springs (214) with the cylinder
block (204).
FG018790
Figure 76
8. Assemble the cylinder block (204) with the thrust ball

(208).
NOTE: Arrange the assembly positions of the cylinder
and spherical busy spline.
FG018795
Figure 77
9. Insert piston (261) and shoe assembly (262) (9 sets) into

the retainer plate (207).
FG018789
Figure 78
10. Assemble them with the cylinder block (204).
FG018787
Figure 79

6-3-50
11. Assemble the spindle (101) and cylinder block sub (CB1).
NOTE: Apply appropriate quantity of hydraulic oil to the
swash plate (203) and shoe (262).
FG018796
Figure 80
12. Assemble the friction plate (215) (4 ea) and mating plate
(216) (3 ea) with the spindle (101) and cylinder block (204).
FG018797
Figure 81
FG018798
Figure 82
13. Assemble the O-ring (233) (P8) with the spindle (101).
NOTE: Use new O-rings when reassembling after
disassembly.
FG018799
Figure 83

6-3-51
14. Assemble the O-ring (231) (WG48) with the spindle (101).
disassembly.
FG018800
Figure 84
15. Assemble the O-ring (230) (WG52) with the spindle (101).
disassembly.
FG018800
Figure 85
16. Assemble seven plugs (54) to the rear flange (01) at

specified torque.
• Torque (Plug (54)): 9.8 N.m (1 kg.m, 7.2 ft lb)
FG018802
Figure 86
17. Assemble the two plugs (56) at specified torque.

• Torque (Plug (56)): 36.3 N.m (3.7 kg.m, 26.8 ft lb)
FG018803
Figure 87

6-3-52
18. Assemble the 2-speed spring (66) and 2-speed spool (65)
in the said order.
NOTE: Apply grease to the O-ring (46).
NOTE: When assembling the spool (65) with the rear
flange (1), apply hydraulic oil to the spool (65).
NOTE: Take care not to damage the bore of the rear
flange (1) and circumference of the spool (65).
Otherwise, internal oil leak may be increased
resulting in the degeneration of the travel motor
performance. FG018783
Figure 88
NOTE: Since the clearance is very small, arrange the
centerlines of the shaft and hole. This is to
prevent damage to the bore of the rear flange
(1) and circumference of the spool (65) and to
make assembly work easier.
19. Assemble the plug (82) at specified torque.
• Torque (Plug (82)): 107.9 N.m (11 kg.m, 79.6 ft lb)
FG018804
Figure 89
20. Insert the steel ball (68) and perform caulking.
FG018805
Figure 90

6-3-53
21. Assemble the plug (52) at specified torque.
FG018806
Figure 91
22. Assemble the orifice (71) at specified torque.

• Torque (Orifice (71)): 3.5 N.m (0.4 kg.m, 2.6 ft lb)
FG018807
Figure 92
23. Assemble the counterbalance spool (2) and washer (7) to

the rear flange (1).
FG018808
Figure 93
24. Assemble the O-ring (13) (P44).
FG018809
Figure 94

6-3-54
25. Assemble the main spring (6).
FG018810
Figure 95
26. Assemble the counterbalance spool (2), washer (7), main

spring (6) and seat in the said order.
FG018784
Figure 96
27. Assemble the cover (12) with socket bolts (14).

• Torque (Socket bolt (14)): 98.1 Nm
(10 kg.m, 72.3 ft lb)
FG018811
Figure 97
28. Press fit the pin (41).
FG018812
Figure 98

6-3-55
29. Press fit the needle bearing (50) (For new assembly).
NOTE: Do not disassemble this bearing when
disassembling.
FG018813
Figure 99
30. Assemble the sub of rear flange (1) with the timing plate
(209).
NOTE: Apply grease to the rear side of the timing plate
to prevent the timing plate from falling off during
assembling.
FG018782
Figure 100
31. Assemble the sub of the rear flange (1) with the O-ring (26)
(WG51).
FG018814
Figure 101
32. Assemble the sub of the rear flange (1) with 14 brake
springs (213).
NOTE: Apply grease to the springs to prevent them
from falling off during assembling.
FG018815
Figure 102

6-3-56
33. Assemble the orifice (71) with the brake piston (212).
FG018716
Figure 103
34. Insert two M10 x 135 L socket bolts in the forced brake
release hole of the rear flange (303) and assemble the sub.
NOTE: After assembling, remove M10 x 135 L socket
bolts (2 ea).
FG018781
Figure 104
35. Assemble the sub of the rear flange (1) with the spindle
(101).
NOTE: Apply grease to the needle bearing (50)
press-fitted into the rear flange (1).
FG018817
Figure 105
36. Assemble rear flange (1) sub with eight socket bolts at
specified torque.
• Torque (Socket bolt (43)): 431.5 Nm
(44 kg.m, 318.2 ft lb)
FG018780
Figure 106

6-3-57
37. Remove M10 x 135 socket bolts from the forced brake
release hole of the rear flange (1), and install tow plugs
(45) at specified torque.
FG018779
Figure 107
38. Assemble rear flange (1) sub with relief valve (RV1) (2
sets) at specified torque.
• Torque (Relief valve (RV1)): 245.2 Nm
(25 kg.m, 180.8 ft lb)
FG018778
Figure 108
39. Assemble the sub of rear flange (1) with the reducing valve
(500) (1 set) at specified torque.
• Torque (Reducing valve (500)): 44.1 Nm
(4.5 kg.m, 32.5 ft lb)
FG018777
Figure 109
40. Assemble the sub of rear flange (1) with the reducing valve
cover (501).
FG018818
Figure 110

6-3-58
Assembly of Reduction Gear
1. Insert the angular bearing (105) into the hub (102) by press Hammer
fitting. Press Jig
NOTE: Take care that inserting direction is correct.
A/Ball Bearing
Hub
FG018819
Figure 111
2. Assemble the floating seal (103) to the spindle (101) and

hub (102).
FG018820
Figure 112
NOTE: Apply grease to the floating seal (103).
Floating Seal
Spindle Floating Seal
FG018821
Figure 113
3. Assemble the distance piece (109) with the spindle.
FG018774
Figure 114

6-3-59
4. Assemble the spindle (101) with the hub assembly.
FG018773
Figure 115
5. Using a press, press down the inner race of the bearing

(105) to the deepest position allowed for the press.
6. While pressing the spindle (101) flange, assemble the shim
plate (110) in the groove.
FG018822
Figure 116
7. Assemble thrust washer (F) (136), planetary gear (F)

(131), needle bearing (132), and floating bushing (134) to
the carrier No. 2.
FG018771
Figure 117
8. Assemble the shaft bearing (133) to the carrier No. 2.
FG018770
Figure 118

6-3-60
9. Assemble the spring pin (135) to the carrier No. 2 (130).
FG018763
Figure 119
FG018769
Figure 120
10. Assemble the carrier No. 2 assembly to the hub (102).

NOTE: Install M10 eyebolts and assemble it using a
crane.
FG018768
Figure 121
11. Assemble the sun gear (160).
FG018767
Figure 122

6-3-61
12. Assemble thrust washer (R) (146), planetary gear (R)
(141), needle bearing (142), and shaft bearing (R) (143) to
the carrier No. 1.
FG018765
Figure 123
13. Assemble the spring pin (145) to the carrier No. 1 (140).
FG018763
Figure 124
FG018764
Figure 125
14. Assemble the carrier No. 1 assembly to the hub (102).

NOTE: Install M10 eyebolts and assemble it using a
crane.
FG018762
Figure 126

6-3-62
15. Assemble the drive gear (170) to the carrier No. 1
assembly.
FG018761
Figure 127
16. Assemble the thrust plate (112) with the cover (180).
NOTE: Apply grease to the thrust plate (112) before
assembling.
FG018824
Figure 128
17. Assemble the thrust washer (M) (181) with the cover (180).
NOTE: Apply grease to the thrust washer (M) (181)
before assembling.
FG018825
Figure 129
18. Apply sealant to the surface of the cover contacting the

hub (102).
• Sealant: silicon rubber (780-RTV)
FG018826
Figure 130

6-3-63
19. Assemble the cover (180) to the hub (102).
FG018827
Figure 131
20. Tighten the socket bolts (185) at specified torque.

• Torque: 57.9 ±9.8 N.m (5.9 ±1 kg.m, 42.7 ±7.2 ft lb)
FG018760
Figure 132
21. Assemble the O-ring (183) with the plug (182).

22. Tighten the plug (182) with the cover (180) at specified
torque.
FG018829
Figure 133

6-3-64
PERFORMANCE TEST
Make sure to fill up the spindle with hydraulic oil before
performance test. Conduct performance test as follows after
completing the maintenance of travel motor.
1. With testing apparatus: If an internal part or parts have
been replaced, conduct performance test according to the
following conditions before commissioning.
• Conditions for preparatory operation
1) Unloaded operation at 20 rpm, left and right
directions for one minute
2) Operate left and right at 10 rpm with 196 bar for
one minute
directions for one minute
• Test Condition
1) Hydraulic oil: wear resistant hydraulic oil ISO
VG #46 or equivalent
2) Lubricant: gear oil
3) Temperature:
Ambient temperature → room temperature
Oil operating temperature → 50 ±5°C
Reduction gear case temperature → 40 - 80°C
4) Oil drain pressure: 0.8 bar or less

6-3-65
A. Efficiency test (at 1st speed)
Volumetric Efficiency Mechanical Efficiency External Drain Rate

90% or above 82% or above (See reference)
Differential pressure: 196 bar
3.0 lpm or less
Speed: 8 rpm
B. Volumetric efficiency test at 2nd speed
Switched to 2nd Speed Volumetric Efficiency

Differential pressure: 78 bar
94% or above
Speed: 18 rpm
C. Operating test of 2nd speed parts

In the above (A, B) preparatory operating conditions,
at unloaded test, check that motor is switched from
low speed to high-speed when high-pressure oil
(29 bar or above) is applied to the 2nd speed
switching pilot port (Port D).
In addition, check that motor is switched to low speed
at the pressure lower than 20 bar.
2. Performance test in the field without testing apparatus
Install the travel motor on the equipment. Connect
pipelines without attaching the shoe. Conduct testing after
the preparatory operation under the following conditions.
• Preparatory operating condition
directions for one minute.
directions for one minute.
• Test condition
1) Temperature: Hydraulic oil → 50 ±5°C
Case → 40 - 80°C
A. Unloaded drive pressure (differential pressure)
1st Speed 10 rpm 20 bar

2nd Speed 20 rpm 29 bar
B. Motor drain rate
1st and 2nd

At 10 rpm 3 lpm or less
Speed

6-3-66
TROUBLESHOOTING
Problem Cause Correction
Cannot start-up Without pressure Relief setting pressure is too Set up correct pressure
low
Pump failure Check moving parts
excluding travel parts, and
repair as necessary
Steering valve failure Check the spool and repair it
if necessary
With pressure Brake valve failure Replace sticking spool or
valve, repair other problems.
Hydraulic motor failure Replace the motor, or check
the hydraulic oil and replace
it as necessary
Damaged gear Replace the reduction gear
(reduction gear)
Overloaded Release the load
Oil leak Contact surface Flaw on contact surface Correct with crocus cloth
Loose bolt Tighten and recheck
Casing Loose plug Tighten
Damaged by stone, etc. Replace the reduction gear
Floating seal Worn sliding surface Replace the reduction gear
Damaged O-ring Replace floating seal
Hydraulic motor Loose bolt Tighten
Damaged O-ring Replace the O-ring
Flaw on seal Correct with crocus cloth
Sliding on slope Poor volumetric efficiency of the motor Replace the hydraulic motor
Increase of leak in brake valve Replace the brake valve
(Replace rear flange)
Parking brake fails to function
• Damaged spring • Replace the spring
• Worn friction plate • Replace friction plate
and mating plate
Reduction gear case Low gear oil level Refill up to proper level
too hot Bearing is not fixed Replace the reduction gear
Hydraulic oil enters gear case Replace the oil seal

6-3-67
Problem Cause Correction
Travels sideways At low-pressure
• Discharge volume differs by left and right • Repair
• Drain volume differs from left and right • Replace the hydraulic
motor motor
At high-pressure
• Discharge volume differs by left and right • Replace the pump and
regulator
• Drain volume differs from left and right • Replace the hydraulic
motor motor
• Left and right motions of the brake valve • Replace the brake
are not the same valve
(Replace rear flange)
• Relief valve too low on the left or right side • Set up pressure
of the control valve correctly. Replace the
relief valve
Speed is too low Pump discharge volume is too low.
• Pump regulator does not work correctly • Repair the regulator
• Too much external drain from the pump • Repair/replace the
pump
Too much external oil leak from the motor Repair/replace the motor
Abnormal noise Damaged motor or reduction gear Repair/replace the motor or
reduction gear
Vibration in piping Clamp the pipeline

6-3-68
Track
Assembly
Edition 1
DX340LC-5/DX350LC-5 Track Assembly

6-4-1
MEMO
Track Assembly DX340LC-5/DX350LC-5

6-4-2
Table of Contents
Track Assembly
General ...........................................................6-4-5
Track Tension .................................................6-4-6
Track Shoes and Links ...................................6-4-8
Parts List ................................................................... 6-4-8
Track Removal .......................................................... 6-4-9
Track Installation ..................................................... 6-4-11
Wear Limits and Tolerances.................................... 6-4-12
Sprocket .......................................................6-4-14
Wear Limits and Tolerances.................................... 6-4-14
Front Idler .....................................................6-4-15
Overview ................................................................. 6-4-15
Parts List ................................................................. 6-4-16
Front Idler Disassembly........................................... 6-4-17
Front Idler Reassembly ........................................... 6-4-19
Upper Roller .................................................6-4-20
Overview ................................................................. 6-4-20
Parts List ................................................................. 6-4-21
Upper Roller Removal ............................................. 6-4-22
Upper Roller Installation .......................................... 6-4-22
Upper Roller Disassembly....................................... 6-4-22
Upper Roller Reassembly ....................................... 6-4-24
Lower Roller .................................................6-4-25
Overview ................................................................. 6-4-25
Parts List ................................................................. 6-4-26
Lower Roller Removal ............................................. 6-4-27
Lower Roller Installation .......................................... 6-4-27
Lower Roller Disassembly....................................... 6-4-27
Lower Roller Reassembly ....................................... 6-4-28
Track Adjuster ..............................................6-4-30
Parts List ................................................................. 6-4-30

6-4-3
Disassembly ............................................................ 6-4-31
Assembly................................................................. 6-4-32

6-4-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
The track assembly is composed of the following major
components:
1. Track
2. Front Idler
3. Upper Roller
4. Lower Roller
5. Track Adjuster

6-4-5
TRACK TENSION
WARNING
Measuring track tension requires two people. One person
must be in the operator's seat, operating the controls while
the other person makes dimensional checks. Block frame to
make sure the machine won't move or shift position during
service. Warm up the engine to prevent stalls, park the
excavator in an area that provides level, uniform ground
support and/or use support blocks when necessary.
The track adjusting mechanism is under very
high-pressure. NEVER release grease pressure too fast.
The track tension grease valve should never be loosened
more than one (1) complete turn from the fully tightened
down position. Bleed off grease pressure slowly. Keep your
body away from the valve always. Always wear eye and face
protection when adjusting track tension.
Track shoe link pins and bushings wear with normal usage,
reducing track tension. Periodic adjustment is necessary to
compensate for wear and it may also be required by working
conditions.
1. Track tension is checked by jacking up one side of the
excavator. See Figure 1. Place blocking under frame while
taking measurement.
Turn the track backward 1 - 2 turns.
90 - 110
EX1300534
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: Clean off the tracks before checking clearance
for accurate measurements.
A
3. Too little sag in the crawler track (less than clearance
distance "B" on below table) can cause excessive
component wear. The recommended adjustment can also
be too tight causing accelerated stress and wear if ground
FG000223
conditions are wet, marshy or muddy.
Figure 2

6-4-6
4. The increased clearance recommended for muddy, sandy
or snowy ground conditions is between distance "C" on
below table.
Terrain Type Distance "A"

320 - 340 mm
Normal "B"
(12.60 - 13.39 in)
340 - 370 mm
Muddy, Sandy or Snowy "C"
(13.39 - 14.57 in)
WARNING
The track adjusting mechanism is under very
high-pressure. NEVER release grease pressure too
fast. The track tension grease valve should never be
loosened more than one (1) complete turn from the
fully tightened down position. Bleed off grease
pressure slowly. Keep your body away from the valve
always. Always wear eye and face protection when
adjusting track tension.
5. Track tension adjustments are made through the grease

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

6-4-7
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
1-1C
1-1B
1-4
FR
ON
T
1-2
TRACK FRAME
2
3
Figure 4 4 EX1301740

6-4-8
Reference Reference
Number Number
1 Track Shoe Assembly 1-1G Dust Seal
1-1 Track Link Assembly 1-1H Spacer
1-1A Track Link (RH) 1-2 Track Bolt
1-1B Track Link (LH) 1-3 Nut
1-1C Track Pin 1-4 Track Shoe
1-1D Master Pin 2 Step
1-1E Regular Bushing 3 Spring Washer
1-1F Master Bushing 4 Bolt
Track Removal
1. Position machine on a smooth level surface with adequate
room for forward and reverse travel.
EX1301081
Figure 5
2. Move machine until master link (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.
2
1
4
FG004355
Figure 6
4. Loosen valve (1, Figure 7) for track adjuster to drain

grease out. Use socket wrench 27 mm
NOTE: Loosen carefully, keeping face, hands, body
away from the valve and nipple. Do not loosen
1
valve Quickly.
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 press.
Remove pin after detaching shoe. FG004356
Figure 7

6-4-9
7. Move unit forward until entire track is laying on ground.
NOTE: Do not drive unit off track.
FG003911
Figure 8
8. Rotate upper structure to 90° from track. Use bucket and

boom to raise track frame off track.
9. Position blocking under frame.
90 - 110
EX1300534
Figure 9

6-4-10
Track Installation
1. Lay rebuilt or new track into position under track frame.
End of track must be positioned under drive sprocket.
90 - 110
2. With upper structure at 90° to track frame. Use bucket and
boom to raise track frame off blocking.
3. With blocking removed, lower track frame onto track. Make
sure all rollers are properly positioned on track.
EX1300534
Figure 10
4. Move 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 “Track Tension” on page -6"
in this section for procedure.
FG003912
Figure 11

6-4-11
Wear Limits and Tolerances
H J
G G
B B
I K
A
C
F
D E EX1401012
Figure 12

6-4-12
Limit for Use
Recommended Limit
No. Check Item Standard Dimension (Repair - P or
for Maintenance
Replace - R)
216 mm
A Link Pitch
(8.504")
Bushing Outside Diam- 66.5 mm 62.5 mm 59 mm (R)
B
eter (2.618") (2.461") (2.323")
116 mm 108 mm 103 mm (P)
C Link Height
(4.567") (4.252") (4.055")
24 mm
D Length at Tip
(0.945")
18 mm
E Length at Tip
(0.709")
36 mm 30 mm 26 mm
F Height
(1.417") (1.181") (1.024")
Standard Repair
Bushing Tolerance Link Tolerance
Interference between Interference Limit
G
bushing and link 66.50 mm 0.46 66.5 mm +0.074 0.336 -
(2.618") 0.41 (2.618") 0.0 0.460
Regular Standard Repair
Tolerance Link Tolerance
Interference between Pin Interference Limit
H
regular pin and link 44.75 mm +0.05 44.75 mm -0.35 0.35
(1.762") 0.0 (1.762") -0.40 0.45
Regular Standard Repair
Tolerance Bushing Tolerance
Clearance between reg- Pin Clearance Limit
I
ular pin and bushing 44.75 mm +0.050 44.75 mm 1.2 0.65
(1.762") 0.0 (1.762") 0.7 1.20
Standard Repair
Master Pin Tolerance Link Tolerance
Interference between Interference Limit
J
master pin and link 44.6 mm +0.03 44.6 mm -0.20 0.20
(1.756") 0.0 (1.756") -0.25 0.28
Standard Repair
Master Pin Tolerance Bushing Tolerance
Clearance between Clearance Limit
K
master pin and bushing 44.6 mm -0.25 44.6 mm 1.35 1.1
(1.756") -0.35 (1.756") 0.85 1.7

6-4-13
SPROCKET
Wear Limits and Tolerances
A E
D
C
B
Travel Device
EX1301737
Figure 13
Standard Allowable Limit Limit for Use

No. Check Item
Dimension for Maintenance (Repair - P or Replace - R)
84 mm
A Tooth Width - -
(3.307")
108 mm 105 mm 104 mm (R)
B Tooth Bottom Surface
(3.307") (4.134") (4.094")
141.4 mm
C Pitch Circle Dimension - -
(5.567")
146 mm 143 mm 141 mm (R)
D Tooth Top Land
(5.748") (5.630") (5.551")
216 mm
E Accumulated Pitch Tolerance - -
(8.504")

6-4-14
FRONT IDLER
Overview
235 172
102
94.5
580
630
289.5
316 4 - M16 x P2.0 65

366 110
EX1400085
Figure 14
• Weight: 187 kg (412 lb)

6-4-15
Parts List
9
8
7
2
4
5
6
7
8
EX1301268
Figure 15
Reference Reference
Number Number
1 Idler Assembly 6 Pin
2 Idler 7 Floating Seal
3 Support 8 O-ring
4 Shaft 9 Plug
5 Bushing

6-4-16
Front Idler Disassembly
1. Remove plug (9, Figure 16) from idler assembly (1), and
drain oil into a suitable container.
FG003914
Figure 16
2. Separate the pin (6, Figure 17) from the bearing (3).
3
FG003915
Figure 17
3. Use a press to remove bearing from the axle (4). Separate

4
the O-ring (8, Figure 18) from the axle.
3
8
FG001482
Figure 18
4. Detach the floating seal (7, Figure 19) from the idler (2)
3
and bearing (3).
7
2
3 FG001483
Figure 19

6-4-17
5. Use a press to separate the axle (4, Figure 20), O-ring (8)
and bearing (3).
8
FG001484
Figure 20
6. Remove bushing (5, Figure 21) with the press and special
tool (10, ST-1909).
10
5 2
FG001485
Figure 21

6-4-18
Front Idler Reassembly 4
3
1. Degrease, clean and dry all parts before reassembly.
8
Insert bushing (5, Figure 21) into the idler (2). 6
2. Grease O-ring (8, Figure 22) and insert it into the axle.
3. Align the bearing (3, Figure 22) and axle (4) holes and pin
(6) them together.
8
FG001486
Figure 22
4. Install floating seal (7, Figure 23) inside the idler (2) and
3
bearing (3).
NOTE: Apply clean engine oil to the joint side of the 7
floating seal. Apply grease to the floating seal 2
O-ring.
3 FG001483
Figure 23
5. Install idler (2, Figure 24) on the axle.

6. Install bearing (3, Figure 24) and pin (6) to the axle.
NOTE: Fill the idler assembly with new gear oil (ISO VG
6
220 EP/VI 130) with approximately 420 cc (14.2
oz). 2
3
7. Install plug (9, Figure 43) on the bearing.
FG001488
Figure 24

6-4-19
UPPER ROLLER
Overview
319
214
98
200105-00003B
142
175
83
EX1400086
Figure 25
• Weight: 26.4 kg (58.2 lb)

6-4-20
Parts List
Track Frame
5
10
13
11
7
9
14
12
8
EX1400087
Figure 26
Reference Reference
Number Number
1 Roller 8 Plug
2 Shaft 9 Cover
3 Thrust Ring 10 Washer
4 Bushing 11 Bolt
5 Bushing 12 Blot
6 Floating Seal 13 Spring Washer

6-4-21
Upper Roller Removal
1. Relieve track tension. This will allow track to be raised so
links clear top of roller.
2. Position a bottle jack on top of track frame and apply
pressure to track shoe.
3. Remove mounting hardware holding upper roller assembly
to track frame.
FG000524
WARNING Figure 27

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

1. Perform installation in the reverse order of removal.
FG000524
Figure 28
Upper Roller Disassembly

1. Remove plug (9, Figure 29) from the cover and drain oil.
9
FG001494
Figure 29

6-4-22
2. Remove bolts (13, Figure 30) and cover (10). Detach bolts
(12) and washer (11).
11
12
10
13
FG001495
Figure 30
3. Separate the roller (1, Figure 31) from the axle (2).
2
1
FG001497
Figure 31
4. Separate the floating seal (6, Figure 32) from the roller. 1
5. Separate the thrust ring (3) from the axle.
6
3
EX1400088
Figure 32
6. Separate the bushing (4 and 5, Figure 33) from the roller

with a press and special tool (ST-1919).
FG019397
Figure 33

6-4-23
Upper Roller Reassembly
4
1. Degrease, clean and dry all parts before reassembly. 1
Insert bushing (4 and 5, Figure 34) into the roller (1). 5
FG003917
Figure 34
2. Insert floating seal (6, Figure 35) into the roller (1) and 1
bushing.
NOTE: Apply clean engine oil to the joint side of the
floating seal. Apply grease to the floating seal 2
O-ring.
6
3. Install the axle (2) and thrust ring (3).
3
EX1400088
Figure 35
4. Install washer (11, Figure 36) and bolt (12).

5. Insert the O-ring (7, Figure 36) to the cover (10). Attach
11
cover (10) and bolt (13) to the roller.
12
6. Fill with engine oil, 200 cc. 7
10
7. Tighten plug (9, Figure 36).
13
9 FG001501
Figure 36

6-4-24
LOWER ROLLER
Overview
290 114.3
272
200
67
180
214
A
1
00
00
2 0 010 4 -
4- 22
368.4 (Bolt Hole Pitch)

407
EX1400090
Figure 37

6-4-25
Parts List
5
2 8
6
5 7
7
8
2
FG019395
Figure 38
Reference Reference
Number Number
1 Roller 6 Floating Seal
2 Collar 7 O-ring
3 Shaft 8 Plug
4 Bushing 9 Bolt
5 Pin

6-4-26
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. Using bucket raise track off ground and place blocking
under frame.
4. Remove four bolts and lower roller assembly from track
frame. There is an alignment pin on each end of lower
roller assembly. EX1300534
Figure 39
NOTE: To gain access to some rollers the link guard
may have to be removed. Remove four spring
washers and bolts to remove guard.
NOTE: If additional track clearance is required, remove
upper rollers before raising track.
Lower Roller 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.
EX1300534
Figure 40
Lower Roller Disassembly

5
1. Remove plug (8, Figure 41) from the collar and drain oil.
2. Pull the pin (5, Figure 41) from the collar.
FG001489
Figure 41

6-4-27
3. Separate the collar (2, Figure 42) from the axle, using
press.
2
FG001490
Figure 42
4. Detach O-rings (7, Figure 43) from the axle.

1
5. Separate floating seals (6, Figure 43) from the collar and 6
roller (1).
2
6. Detach collar (2, Figure 43) and O-rings (7) from the axle,
using press.
2
7 6 FG001493
Figure 43
Lower Roller Reassembly

1. Degrease, clean and dry all parts before reassembly.
Insert bushing (4, Figure 44) into roller.
4
FG019396
Figure 44

6-4-28
2. Apply grease to the O-rings (7, Figure 44) and insert into
axle. 5
3. Align collar (2, Figure 45) and axle (3) pinholes and pin (5)
the collar. 3 7 2
FG001492
Figure 45
4. Insert floating seals (6, Figure 46) into the roller (1) and
1
collar (2).
6
NOTE: Apply clean gear oil to the joint side of the
2
floating seal. Apply grease to the floating seal
O-ring.
5. Slide the axle inside the roller.
2
7 6 FG001493
Figure 46
6. Install the collar (2, Figure 47), O-ring (7), and pin (5) on
the remaining side. 5
7. Fill with clean gear oil (ISO VG 220 EP/VI 130) with
approximately 485 cc (16.4 oz).
8. Install plug (8, Figure 47) on the collar.
8
2 FG001487
Figure 47

6-4-29
TRACK ADJUSTER
Parts List
21
9
19
11
18
8
7
5
3
4
10
17 : 1, 5, 10
1 16
12
13
15
14
2
20
EX1400091
Figure 48

6-4-30
Reference Reference
Number Number
1 Cylinder Body 12 U-ring Packing
2 Piston Rod 13 Backup Ring
3 Bracket 14 Dust Seal
4 Spacer 15 Piston Ring
5 Shaft 16 Stop Ring
6 Spring 17 Cylinder Assembly
7 Locknut 18 Bolt
8 Lock Plate 19 Washer
9 Bolt 20 Grease Valve
10 Spring Pin 21 Cap
11 Spring Washer
Disassembly
1. Apply pressure on spring (6, Figure 49) with a press. Press Press
NOTE: The spring is under a large installed load.
This is dangerous, so be sure to set properly. 9, 11
• Spring set load: 22,825 kg (50,321 lb) 8
7
2. Remove bolt (9, Figure 49), spring washer (11) and lock
plate (8). 3
6
3. Remove lock nut (7, Figure 49).
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 49) and spring (6).
EX1400069
Figure 49
5. Remove piston rod (2, Figure 50) from body (1).

1 2
6. Remove grease valve (20, Figure 50) from piston rod (2).
20
EX1400092
Figure 50

6-4-31
7. Remove dust seal (14, Figure 51) from body (1).
14
1
EX1400071
Figure 51
8. Remove stop ring (16, Figure 52), backup ring (13),

packing (12) and piston ring (15) from piston rod (2).
16 12 13 15
EX1400093
Figure 52
Assembly
1. Install piston ring (15, Figure 53), packing (12), backup ring
(13) and stop ring (16) to piston rod (2).
16 12 13 15
EX1400093
Figure 53
2. Install dust seal (14, Figure 54) to body (1).

NOTE: When installing piston ring (15), packing (12),
dust seal (14) take full care as not to damage
the lip. 14
1
EX1400071
Figure 54

6-4-32
3. Grease into body (1, Figure 55), then push in piston rod (2)
1
by hand.
NOTE: Fill up "B" part with grease. Press fit the piston
rod (2, Figure 55) by maximum to *95 mm.
Remove air in the "B" part and the piston rod
and install the grease valve (20).
B 20 2
NOTE: If air letting is not sufficient, it may be difficult to
EX1400094
adjust the tension of crawler.
Figure 55
• Tool: 27 mm ( )
• Grease valve torque: 137 N.m (14 kg.m, 101 ft lb)
4. Install piston rod (2, Figure 56) to body, and assemble 3 5 4 10
spacer (4) with the shaft (5) after assembling the shaft (5)
with spring pin (10).
5. Install spring (6, Figure 56) and bracket (3) to body.
6. Apply pressure to spring (6, Figure 56) with a press and
tighten lock nut (7). 2
NOTE: Apply sealant before assembling. 7 6 EX1400074
NOTE: During the operation, pay attention specially to Figure 56
prevent the press from slipping out.
7. Tighten the press load and confirm the set length of spring 6
(6, Figure 57).
• Length A: 600 mm (23.6 in)
A
EX1400075
Figure 57
8. After the setting of spring (6, Figure 58), install lock plate Press Press
(8), spring washer (11) and bolt (9).
NOTE: Apply loctite on bolt (9, Figure 58). 9, 11
8
7
3
6
EX1400069
Figure 58

6-4-33
6-4-34
1Front
Boom and Arm
Edition 1
DX340LC-5/DX350LC-5 Boom and Arm

7-1-1
MEMO
Boom and Arm DX340LC-5/DX350LC-5

7-1-2
Table of Contents
Boom and Arm

Specifications .................................................7-1-6
One - Piece Boom ..................................................... 7-1-6
Two - Piece Boom ..................................................... 7-1-8
Removal .......................................................7-1-10
Arm Removal........................................................... 7-1-10
Boom Removal........................................................ 7-1-12
Installation ....................................................7-1-13
Arm Installation........................................................ 7-1-13
Boom Installation..................................................... 7-1-13
Completing Work ..........................................7-1-14

7-1-3
7-1-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

7-1-5
SPECIFICATIONS
The table below has a complete listing of dimensional
specifications for all mounting pins used on the front attachment.
NOTE: Some mounting pins must be drilled and tapped for
lubrication fittings and piping, or may have other
required specifications. Consult DOOSAN After Sales
Service for information on wear tolerances and
replacement limits for mounting pins.
One - Piece Boom
A B C E
D
F
K J I H G EX1300988
Figure 1

7-1-6
Criteria
Mark Measuring Part Standard Tolerance Standard Clearance Remedy
Size Pin Hole Clearance Limit
110 mm -0.10 +0.18
A Boom Foot 0.13 ~ 0.33 1.5
(4.331") -0.15 +0.03
105 mm -0.10 +0.18
B Boom Cylinder Head 0.13 ~ 0.33 1.5
(4.134") -0.15 +0.03
100 mm -0.10 +0.18
C Boom Center 0.13 ~ 0.33 1.5
(3.937") -0.15 +0.03
110 mm -0.10 +0.18
D Boom End 0.13 ~ 0.33 1.5
(4.331") -0.15 +0.03
100 mm -0.10 +0.18
E Arm Cylinder Head 0.13 ~ 0.33 1.5
(3.937") -0.15 +0.03
100 mm -0.10 +0.18
F Arm Cylinder Rod 0.13 ~ 0.33 1.5 Replace
(3.937") -0.15 +0.03
100 mm -0.10 +0.18
G Bucket Cylinder Head 0.13 ~ 0.33 1.5
(3.937") -0.15 +0.03
90 mm -0.06 +0.18
H Arm Link 0.09 ~ 0.29 2.0
(3.543") -0.11 +0.03
100 mm -0.10 +0.18
I Arm End 0.13 ~ 0.33 2.0
(3.937") -0.15 +0.03
100 mm -0.10 +0.18
J Bucket Cylinder Rod 0.13 ~ 0.33 2.0
(3.937") -0.15 +0.03
100 mm -0.10 +0.18
K Push Link to Bucket 0.13 ~ 0.33 2.0
(3.937") -0.15 +0.03

7-1-7
Two - Piece Boom
A L M C E N
D F
B K J H G I
EX1401277
Figure 2

7-1-8
Criteria
Mark Measuring Part Standard Tolerance Standard Clearance Remedy
Size Pin Hole Clearance Limit
110 mm -0.10 +0.18
A Boom Foot 0.13 - 0.33 1.5
(4.330") -0.15 +0.03
105 mm -0.10 +0.18
B Boom Cylinder Head 0.13 - 0.33 1.5
(4.134") -0.15 +0.03
100 mm -0.10 +0.18
C Boom Center 0.13 - 0.33 1.5
(3.937") -0.15 +0.03
110 mm -0.10 +0.18
D Boom End 0.13 - 0.33 1.5
(4.330") -0.15 +0.03
100 mm -0.10 +0.18
E Arm Cylinder Head 0.13 - 0.33 1.5
(3.937") -0.15 +0.03
100 mm -0.10 +0.18
F Arm Cylinder Rod 0.13 - 0.33 1.5
(3.937") -0.15 +0.03
90 mm -0.06 +0.18
G Arm Link 0.09 - 0.29 2.0
(3.543") -0.11 +0.03
Replace
100 mm -0.10 +0.18
H Arm End 0.13 - 0.33 2.0
(3.937") -0.15 +0.03
100 mm -0.10 +0.18
I Bucket Cylinder Head 0.13 - 0.33 1.5
(3.937") -0.15 +0.03
100 mm -0.10 +0.18
J Bucket Cylinder Rod 0.13 - 0.33 2.0
(3.937") -0.15 +0.03
100 mm -0.10 +0.18
K Push Link to Bucket 0.13 - 0.33 2.0
(3.937") -0.15 +0.03
110 mm -0.10 +0.18
L Arti Cylinder Head 0.13 - 0.33 1.5
(4.330") -0.15 +0.03
110 mm -0.10 +0.18
M Arti Cylinder Rod 0.13 - 0.33 1.5
(4.330") -0.15 +0.03
110 mm -0.10 +0.18
N Upper Boom Center 0.13 - 0.33 1.5
(4.330") -0.15 +0.03

7-1-9
REMOVAL
DANGER
AVOID DEATH
DOOSAN warns any user, that removal of the counterweight
from the machine, front attachment or any other part, may
affect the stability of the machine. This could cause
unexpected movement, resulting in death or serious injuries.
Never remove counterweight or front attachment unless the
Never rotate the upper structure once the counterweight or
EX1401352
Figure 3
IMPORTANT
Always break down the front attachment by removing
outermost sections first - the bucket before the arm, the
arm before the boom. Reinstallation of the attachment must
begin with the boom and end with the bucket.
Refer to the appropriate Bucket section for its removal and

installation procedure before going onto the initial step of the
front attachment removal or installation procedure.
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

7-1-10
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 2,697 kg (5,946 lb), not including
the weight of accessories or fixtures).
Before beginning the disassembly of attachment mounting pins,

disconnect the arm cylinder hydraulic hose couplings and put a
clean plug in the end of each one. Use any 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.

7-1-11
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.

7-1-12
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.

7-1-13
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.

7-1-14
1Bucket
Edition 1
DX340LC-5/DX350LC-5 Bucket
7-2-1
MEMO
Bucket DX340LC-5/DX350LC-5
7-2-2
Table of Contents
Bucket
Bucket Tooth Inspection and Replacement ....7-2-6
Bucket O-ring Replacement ...........................7-2-7
Bucket Shimming Procedures ........................7-2-8
New Bucket Installation ............................................. 7-2-8
Bucket Replacement and Reversal ..............7-2-10
Replacement ........................................................... 7-2-11
Reversal .................................................................. 7-2-12
7-2-3
7-2-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
7-2-5
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.
• Wear points on the working surfaces of tooth points - pits,
cracks, chips or craters - are larger than 8 mm to 10 mm
(1/3" to 1/2") across.
FG004607
Figure 1
HDO5057I-1
Figure 2
1. On 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. Once the worn tooth has been removed, use a putty knife 3
to scrape the adapter as clean as possible.
4. Slide the new tooth into position and insert the lock 2 1 FG000346
washer. Figure 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.
7-2-6
BUCKET O-RING
REPLACEMENT
WARNING
Prevent injury from flying metal objects. Always wear safety
helmet, protective gloves and eye protection when
changing pins.
FG018706
1. Inspect the bucket O-rings on a routine basis. If worn or Figure 4

damaged, replacement is necessary.
2. Roll the old O-ring (1, Figure 5) onto the boss (2) around
the bucket pin (3). Remove bucket pin and move the arm 1 4
2
or bucket link (4) out of the way.
FG019071
Figure 5
3. Remove old O-ring and temporarily install the new O-ring

(1, Figure 6) onto the bucket boss (2). Make sure that O- 1 4
ring groove on both the bucket link (4) and boss have been 2
cleaned.
4. Realign the arm or link with the bucket pinhole and insert
the bucket pin (3, Figure 5).
FG019074
Figure 6
5. Roll the new O-ring (1, Figure 7) into the O-ring groove.
1
FG019075
Figure 7
7-2-7
BUCKET SHIMMING
PROCEDURES
New Bucket Installation
WARNING
When performing this adjustment, put the safety lever in the
LOCKED position and stop engine.
Improperly adjusted clearance could cause galling on the
contact surfaces of the bucket and arm, resulting in
excessive noise and damaged O-ring.
3
1 2 8 7
5 10
9 4 6
FG000415
Figure 8
Reference Reference
Number Number
1 No Gap 6 Stopper
2 Arm Boss 7 Bolt
3 Bucket Clearance 8 Hard Washer
4 Shim 9 Flange
5 Pin 10 Bucket Boss
7-2-8
Shimming Procedures for Installed Bucket
The clearance of the bucket linkage on this machine can be
adjusted by shimming. If the gap between the bucket and the
arm becomes excessive, adjust bucket clearance to 1.0 mm.
The thickness of the shims are 1.0 mm (0.04 in)
1. Position the machine on a level surface and lower the
bucket to the ground.
2. Slowly operate the swing control lever until arm boss (2)
and the bucket boss (10) are in full face contact at no gap
(1).
3. Place the safety lever in the LOCKED position and stop
engine.
4. Measure bucket clearance (3), determine the number of
shims (4) that need to be removed by using the following
calculation;
Subtract 1 mm from bucket clearance (3).
5. Remove appropriate number of shim at location (9) to meet
the above thickness. To remove shim, detach stopper (6)
and bolts (7) from bucket.
6. After correcting the number of shim, install stopper (6) and
tighten bolts (7).
• Torque (bolt): 265 N.m (27 kg.m, 195 ft lb)
NOTE: Apply loctite on bolt (7, Figure 8).
7. After installation, make sure that bucket clearance (3) is
still correct.
7-2-9
BUCKET REPLACEMENT AND
REVERSAL
WARNING
When pins are knocked in with a hammer, pieces of metal
may fly and cause serious injury.
When performing this operation, always wear goggles, hard
hat, gloves, and other protective equipment.
When the bucket is removed, place it in a stable condition.
If pins are hit with a strong force, there is a hazard that pin
can fly out and injure people in the surrounding area. Make
sure there is no one in the surrounding area before starting
the operation.
When removing the pins, do not stand behind the bucket. In
addition, be careful not to put your foot under the bucket
while standing at the side for the work.
When removing or inserting pins, be careful not to get your
fingers caught.
Never insert your fingers into the pinholes when aligning
the holes.
Stop the machine on a firm and flat surface and do the work.
When performing joint work, appoint a leader and follow that
person's instructions and signals.
7-2-10
Replacement
5
1. Place the bucket in contact with a flat surface.
A
6
IMPORTANT
When removing the pins, place the bucket so it is in
light contact with the ground.
B
If the bucket is lowered strongly to the ground, the FG018431
resistance will be increased and it will be difficult to
remove pins. Figure 9
After removing the pins, make sure that mud or sand

does not get on them. Dust seals are installed at both
ends of the bushings, be careful not to damage them.
2. Remove double nut on the stopper bolt for arm pin (A) and
1
link pin (B), remove bolt, pull out arm pin (A) and link pin
(B), and then remove bucket. 2
3. Align the arm (5) with holes (1) of the replacement bucket
and the link (6) with holes (2), then insert grease-coated
pins (A) and (B) into hole (1) and hole (2) respectively.
FG018432
Figure 10
4. When installing the bucket, for arm pin portion (A), install
O-ring (3) to bucket (4) in the position shown in the
diagram on the right. After inserting the pin, install it in the
standard groove.
5. Install the stopper bolts and nuts for each pins.
6. Lubricate with grease thoroughly until grease comes out
from the end face.
IMPORTANT
4 3 5 3
FG018592
When replacing the bucket, replace the dust seal if it
has been damaged. If a damaged seal is used without Figure 11
being replaced, sand and dirt may enter the pin portion
and cause abnormal wear of the pin.
7-2-11
Reversal
5
1. Place the bucket in contact with a flat surface.
A
6
IMPORTANT
When removing the pins, place the bucket so it is in
light contact with the ground. If the bucket is lowered
B
strongly to the ground, the resistance will be
increased and it will be difficult to remove pins. FG018431
After removing the pins, make sure that mud or sand Figure 12
does not get on them.
Dust seals are installed at both ends of the bushings,
be careful not to damage them.
2. Remove double nut on the stopper bolt for arm pin (A) and
link pin (B), remove bolt, pull out arm pin (A) and link pin
(B), and then remove bucket.
2
1
FG018433
Figure 13
3. After removing the bucket, reverse it.

4. Align arm (5) with replacement bucket hole (1), then align
link (6) with hole (2), then insert greased-coated pins (A)
and (B) into hole (1) and hole (2) respectively.
IMPORTANT 2
1
When reversing, do not install an O-ring. Keep the

O-ring in a safe place until using it next. FG018434
Figure 14
5. Install the stopper bolts and nuts for each pin.
6. Lubricate with grease thoroughly until grease comes out
from the end face.
IMPORTANT
When replacing the bucket, replace the dust seal if it
has been damaged. If a damaged seal is used without
being replaced, sand and dirt may enter the pin portion
and cause abnormal wear of the pin.
7-2-12
Cylinders
Edition 1
DX340LC-5/DX350LC-5 Cylinders
7-3-1
MEMO
Cylinders DX340LC-5/DX350LC-5
7-3-2
Table of Contents
Cylinders
General ...........................................................7-3-5
Specification .............................................................. 7-3-5
Parts List ................................................................... 7-3-6
Boom Cylinder (LH).............................................. 7-3-6
Boom Cylinder (RH) ............................................. 7-3-8
Arm Cylinder....................................................... 7-3-10
Bucket Cylinder .................................................. 7-3-12
Seal of Cylinder ....................................................... 7-3-15
Special Tools and Materials .........................7-3-17
Piston Nut................................................................ 7-3-17
Piston Jig................................................................. 7-3-18
Steel Bushing Jig..................................................... 7-3-19
Dust Wiper Jig ......................................................... 7-3-20
Slipper Seal Jig ....................................................... 7-3-21
Slipper Seal Straightening Jig ................................. 7-3-22
Rod Bushing (DD-bushing) Pushing-in Jig.............. 7-3-23
Disassembly .................................................7-3-24
Reassembly ..................................................7-3-29
7-3-3
7-3-4
SAFETY INSTRUCTIONS
WARNING
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.
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 lower drawing. Arm cylinders have a cushion or stopper
for operation in both directions. This type of cylinder is shown in
the upper drawing.
Specification
Rod O.D
Tube I.D
Stroke
Closed Length
Figure 1 EX1400068
Boom Arm Bucket

Quantity 2 1 1
Tube I.D ø150 ø170 ø150
Rod O.D ø100 ø120 ø100
Stroke (mm) 1,450 1,805 1,300
Closed Length (mm) 2,100 2,415 1,870
Head End Cushion X O X
Rod End Cushion O O O
Remarks
7-3-5
Parts List
The following parts list is a partial listing only; for complete parts
list information, refer to the Hydraulic Equipment Component
Parts List.
The bucket and boom cylinders are identical and differ only in
the attached pipes.
Boom Cylinder (LH)

2
29 30
39
28
40
32
41
27
1 33
25
34
24
31
23
36 17
35 22
21
20
37
19
18
38 19
20
16
26 14
13
15
7
6
5
8
9
10
11 3
12
Figure 2
EX1400152
7-3-6
Reference Reference
Number Number
1 Cylinder Tube Assembly 22 Backup Ring
2 Bushing 23 Piston Nut
3 Cylinder Rod Assembly 24 Steel Ball
4 Bushing 25 Set Screw
5 Rod Cover 26 Hex Socket Bolt
6 Dd-bushing 27 Pipe Band Assembly
7 Retaining Ring 28 Pipe Band
8 Buffer Seal 29 Spring Washer
9 U-packing 30 Bolt
10 Backup Ring 31 H Pipe Assembly (LH)
11 Dust Wiper 32 O-ring
12 Retaining Ring 33 Spring Washer
13 O-ring 34 Socket Bolt
14 Backup Ring 35 R Pipe Assembly (LH)
15 O-ring 36 O-ring
16 Cushion Ring 37 Spring Washer
17 Piston 38 Socket Bolt
18 Slipper Seal 39 Pipe Clamp
19 Wear Ring 40 Spring Washer
20 Slyd Ring 41 Bolt
21 O-ring * Bucket/Boom Seal Kit
7-3-7
Boom Cylinder (RH)
30
28 29
32
27
1
33
34
25
31 24
39
40
36 41 23
35
17
22
21
37
20
19
38 18
19
20
16
26 14
13
15
7
6
5
8
9 3
10
11
12
4
EX1400153
Figure 3
7-3-8
Reference Reference
Number Number
6 Dd-bushing 27 Pipe Band Assembly
8 Buffer Seal 29 Spring Washer
9 U-packing 30 Bolt
10 Backup Ring 31 H Pipe Assembly (RH)
11 Dust Wiper 32 O-ring
13 O-ring 34 Socket Bolt
14 Backup Ring 35 R Pipe Assembly (RH)
15 O-ring 36 O-ring
16 Cushion Ring 37 Spring Washer
17 Piston 38 Socket Bolt
18 Slipper Seal 39 Pipe Clamp
19 Wear Ring 40 Spring Washer
20 Slyd Ring 41 Bolt
21 O-ring * Bucket/Boom Seal Kit
7-3-9
Arm Cylinder
37
34 36
35 46 2
47
41
48
40
38
39
29
1
36 30
37 31
32 25 26
33 24
40
49 50 27
41
51 23
24
25
42 17
A 20
19
44 18
43 45 19
20
21
22
28 16
14
13
15
7
6
A
5 3
8
9
10
11
12 4
EX1400124
Figure 4
7-3-10
Reference Reference
Number Number
1 Cylinder Tube Assembly 28 Socket Bolt
2 Bushing 29 Check Valve
3 Cylinder Rod Assembly 30 Spring
4 Bushing 31 Spring Support
5 Rod Cover 32 O-ring
6 DD-bushing 33 Plug
7 Retaining Ring 34 Pipe Band Assembly
8 Buffer Seal 35 Pipe Band
9 U Packing 36 Spring Washer
10 Backup Ring 37 Hex Bolt
11 Dust Wiper 38 Pipe Band Assembly - R
14 Backup Ring 41 Hex Bolt
15 O-ring 42 Pipe Assembly - R
16 Cushion Ring 43 O-ring
17 Piston 44 Spring Washer
18 Slipper Seal 45 Socket Bolt
19 Wear Ring 46 U-bolt
20 Slyd Ring 47 Spring Washer
21 O-ring 48 Nut
22 Backup Ring 49 Pipe Clamp
23 Piston Nut 50 Spring Washer
24 Steel Ball 51 Bolt
25 Set Screw * Arm Cylinder Seal Kit
7-3-11
Bucket Cylinder
33
32
38
31
30
29
2
28
27
40
39 39
40
27
1
28
29
25
38 23 24
24
34 25
17
20
19
A
18
19
36 20
35
37 21
22
16
26 14
13
15
7
6
A
5
8
3
9
10
11
4
12
EX1400169
Figure 5
7-3-12
Reference Reference
Number Number
6 DD-bushing 27 Pipe Band Assembly
8 Buffer Seal 29 Hex Bolt
9 U-packing 30 Pipe Assembly - H
10 Backup Ring 31 O-ring
11 Dust Wiper 32 Spring Washer
12 Retaining Ring 33 Socket Bolt
13 O-ring 34 Pipe Assembly - R
14 Backup Ring 35 O-ring
16 Cushion Ring 37 Socket Bolt
17 Piston 38 U-bolt
18 Slipper Seal 39 Spring Washer
19 Wear Ring 40 Nut
20 Slyd Ring * Bucket/Boom Seal Kit
21 O-ring
7-3-13
Theory of Operation
1 Piston
2 Oil Path A 1
3 Oil Path B D
Cylinder piston rods are extended or retracted by oil flow to the

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

2 Oil Path A
4
3 Oil Path B
4 Rod Diameter - R
1
When the cylinder rod is retracted, oil flow through the circuit
from the pump to the front side of the cylinder generates a force 2
(F2) that can be expressed by the formula in which the diameter
3
of the piston rod is expressed by R, and the other two terms are
the same as in the preceding expression. FG001458
F2 = P x π(D2-R2) Figure 7
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. 1
Q1 = S x π(D2)
4
Q2 = S x π(D2-R2)
4
Q1 > Q2 FG001459
Figure 8
7-3-14
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
7-3-15
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
and the rod surface caused by foreign materials,
2 and eccentric center, and eccentric load, and Phenol, Aramid
(DU-bushing) plays role bearing keeping stable friction
materials.
Contamination Protects the piston seal against the intrusion of
3 foreign material to keep the functions of the seal Dust Ring, Slyd Ring
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
6 cylinder from outside environment to protect the Single Lip, Double Lip
(Dust Wiper) rod seal.
Prevents intrusion of foreign materials (e.g., rain
and snow), and makes sealing between the inner
7 O-ring 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.
7-3-16
SPECIAL TOOLS AND
MATERIALS
Piston Nut
( )
A
35
350
FG018703
Figure 11
Material SM45C (AISI 1045)
Rockwell Hardened from 22 ~ 27
Oil Quench
Cylinder A
111 mm
Boom
(4.37 in)
131 mm
Arm
(5.16 in)
111 mm
Bucket
(4.37 in)
7-3-17
Piston Jig
( )
15
2-∅"B"
)
F/2
∅8 Through Hole
R(
"
"D
∅
"A"
∅"
C"
35
R(R15~20)
5
R
4-
30
ARS4740L
Figure 12
Material SM45C (AISI 1045)
Rockwell Hardened from 22 ~ 27
Oil Quench
Cylinder A (±0.1) øB øC øD
120.0 mm 14.0 mm 80.0 mm 150.0 mm
Boom
(4.72 in) (0.55 in) (3.15 in) (5.91 in)
135.0 mm 14.0 mm 102.0 mm 170.0 mm
Arm
(5.31 in) (0.55 in) (4.02 in) (6.70 in)
120.0 mm 14.0 mm 80.0 mm 150.0 mm
Bucket
(4.72 in) (0.55 in) (3.15 in) (5.91 in)
7-3-18
Steel Bushing Jig
(5)
"B" + 40
"A" - 20
∅ "B"
∅"A"
(∅20)
15 F E
G
ARS4750L
Figure 13
Material: SM45C which is done thermal refining <QT> HRC 22 ~ 28
Undefined Chamfer C/R = 0.5 Max.
1 Place: Finally work to used DNMG Tip <Nose R0.4>
Cylinder øA-0.05
-0.15
øB (±0.1) E F+0.05
0
Remark
105.0 mm 118.0 mm 30.0 mm 7.5 mm
Head Side
(4.13 in) (4.65 in) (1.18 in) (0.30 in)
Boom
100.0 mm 113.0 mm 30.0 mm 7.5 mm
Rod Side
(3.94 in) (4.45 in) (1.18 in) (0.30 in)
100.0 mm 113.0 mm 30.0 mm 7.5 mm
Arm
(3.94 in) (4.45 in) (1.18 in) (0.30 in)
100.0 mm 113.0 mm 30.0 mm 7.5 mm
Bucket
(3.94 in) (4.45 in) (1.18 in) (0.30 in)
7-3-19
Dust Wiper Jig
5
C 1.
3-
R0.2
DIA. (B+40)
DIA. (A-20)
DIA. A
DIA. B
15 C D
ARS4760L
Figure 14
Material: SM45C which is done thermal refining <QT> HRC 22 ~ 28
Undefined Chamfer C/R = 0.5 Max.
1 Place: Finally work to used DNMG Tip <Nose R0.4>
Cylinder øA-0.2
-0.3 øB -0.2
-0.3 C 0-0.1 D
98.0 mm 114.0 mm 6.0 mm 10.0 mm
Boom
(3.86 in) (4.49 in) (0.24 in) (0.39 in)
118.0 mm 136.0 mm 6.0 mm 10.0 mm
Arm
(4.65 in) (5.35 in) (0.24 in) (0.39 in)
98.0 mm 114.0 mm 6.0 mm 10.0 mm
Bucket
(3.86 in) (4.49 in) (0.24 in) (0.39 in)
7-3-20
Slipper Seal Jig
0
R1
R1
∅(A+2)
∅A
∅(A-14)
10°
B
(B+40)
ARS4770L
Figure 15
Cylinder øA+0.2
+0.1 B+0.2
+0.1
150.0 mm 28.5 mm
Boom
(5.91 in) (1.12 in)
170.0 mm 34.0 mm
Arm
(6.69 in) (1.34 in)
150.0 mm 28.5 mm
Bucket
(5.91 in) (1.12 in)
7-3-21
Slipper Seal Straightening Jig
C2
∅20
1
2 -C
4
R
2-5
15
20
∅(A+15)
∅A
1
2-R
100
25
50
ARS4780L
Figure 16
Cylinder øA+0.2
+0.1
150.7 mm
Boom
(5.93 in)
170.7 mm
Arm
(6.72 in)
150.7 mm
Bucket
(5.93 in)
7-3-22
Rod Bushing (DD-bushing) Pushing-in Jig
C1
A1
B
C1
C D
EX1301743
Figure 17
Inner diameter (A1): "A"-20 (no machining required on the inner

diameter)
Cylinder øA+0.2
-0.1 øB (±0.1) C D E
99 mm 104 mm 30 mm 75 mm 105 mm
Boom
(3.90 in) (4.09 in) (1.18 in) (2.95 in) (4.13 in)
119 mm 124 mm 50 mm 76.5 mm 126.5 mm
Arm
(4.69 in) (4.88 in) (1.97 in) (3.01 in) (4.98 in)
99 mm 104 mm 30 mm 75 mm 105 mm
Bucket
(3.90 in) (4.09 in) (1.18 in) (2.95 in) (4.13 in)
1. Assemble the rod bushing with the exclusive jig (if

disassembled).
Push in the rod bushing in true vertical direction to prevent
inclining of the bushing.
Apply small volume of operating oil on inner surface of the
rod cover for facilitating pushing in.
2. Remove all of pushing-in residues generated during the
pushing-in process.
3. Mount the retaining ring on the rod cover groove at the end
of the rod bushing after cleaning to prevent disengagement
of the rod bushing.
(Mount the retaining ring manually with pliers, and check if
the ring is securely mounted.)
7-3-23
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. Following 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 18
2. Position piston rod so it is extended approximately one half

meter (20").
Figure 19
3. Remove bolts (27) on the end of cylinder.

NOTE: Wrap a cloth or other protective material around
piston rod, to avoid possibility of accidentally
scratching or scoring rod surface while
fasteners are being loosened and removed.
Component parts (numbered in parentheses)
are keyed to Figure 4.
Figure 20
7-3-24
4. Tap two bolts into cover of cylinder head, 180° apart.
Tighten them in a staggered, even sequence, to back off
piston rod end cover from edge of cylinder wall. Look for
adequate clearance between cover and end of cylinder
wall before using a plastic or other soft faced hammer for
final disassembly.
Figure 21
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 22
6. Lower piston rod to support blocks and detach wear ring

(outer surface) (19) from end of rod.
Figure 23
7. Immobilize piston rod by inserting a wooden or other

nonscoring, nonmetallic support through end of rod.
Figure 24
7-3-25
8. Remove set screw using socket wrench.
HAOF340L
Figure 25
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 26
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 27
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 28
7-3-26
12. Use a dull, rounded tip tool to pry off O-ring (13) and
backup ring (14).
HAOF37OL
Figure 29
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 30
14. Remove O-ring (21) and backup ring (22) from cylinder
head.
HAOF38OS
Figure 31
15. During disassembly of cylinder head, be careful not to

damage buffer seal (8) and U-packing (9).
HAOF39OL
Figure 32
7-3-27
16. Disassemble retaining ring (12) and dust wiper (11).
Separate retaining ring (7) and rod bushing (6).
Figure 33
17. Force out pin bushing (2), (4) from body of cylinder.
Figure 34
7-3-28
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: Reassemble the subassemblies of the cylinder in the

following order:
1. Body of the cylinder.
2. Piston rod.
3. Piston assembly.
4. Cylinder head assembly.
1. Reassemble pin bushing (2), (4) to piston rod and body of
cylinder.
Figure 35
7-3-29
2. Following reassembly of rod cover components, install the
dust wiper (11) and rod bushing (6) to the rod cover (5).
Insert retaining rings (7 and 12).
Figure 36
3. Prelubricate O-rings and seals before reassembly (Figure

37).
Figure 37
4. Before starting to rebuild piston assembly, heat slipper seal

for 5 minutes in an oil bath warmed to 150° - 180°C (302° -
356°F). Use special slipper seal jig (third item in list of
specialized tools at the beginning of this procedure) to
attach seal. Cool seal by pushing a retracting jig against
seal for several minutes. Apply a strip of clean,
see-through sealing tape around slipper seal to keep it free
of dust.
Figure 38
7-3-30
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 39
6. Assemble cushion ring (16) and attach piston assembly to

piston rod.
Figure 40
7. Use specially fabricate or factory sourced tool to tighten

piston nut (23).
Figure 41
8. Assemble wear ring (19), slide ring (20) and set screw (24)
to piston assembly.
Reference
Description
Number
1 Set Screw
Figure 42
7-3-31
9. Immobilize body of cylinder before reassembly.
Figure 43
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 44
7-3-32
TROUBLESHOOTING
Oil leaking between Foreign material in U-packing. Remove foreign material.
cylinder head and piston Scratches in U-packing. Replace U-packing.
rod. 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.
Foreign material in seal O-ring. Remove foreign material.
Scratches in O-ring. Replace O-ring.
Damage to O-ring. Replace O-ring.
Scratches on sealing surface of piston If scratches are not deep, hone with an
rod. oil stone and lubricate.
If scratches are deep, replace piston
rod.
Deep scratches on inner surface of Replace bushing.
bushing.
Oil leaking between Damage to O-rings. Replace O-rings.
cylinder head and cylinder
tube.
Oil leaking from welded Damage to welded area. Replace cylinder tube.
area of cylinder tube.
Oil leaking between Foreign material in U-packing. Remove foreign material.
cylinder head and piston Scratches in U-packing. Replace U-packing.
rod. Damage to U-packing. Replace U-packing.
Foreign material in dust wiper. Remove foreign material.
Scratches in dust wiper. Replace dust wiper.
Damage to dust wiper. Replace dust wiper.
Foreign material in O-ring. Remove foreign material.
Scratches in O-ring. Replace O-ring.
Damage to O-ring. Replace O-ring.
Scratch on sealing surface of piston If scratches are not deep, hone with an
rod. oil stone and lubricate.
If scratches are deep, replace piston
rod.
Deep scratches on inner surface of Replace bushing
bushing.
Oil leaking between Damage to O-rings. Replace O-rings.
cylinder head and cylinder
tube.
Oil leaking from welded Damage to welded area. Replace cylinder tube.
area of cylinder tube.
Cylinder drops from pull of Light scratches on sealing surface of Hone out scratches with oil stone.
gravity. cylinder tube.
Deep scratches on sealing surface of Replace cylinder tube.
cylinder tube.
Deep scratches on sealing surface of Replace O-rings.
piston O-rings.
Foreign material in U-packing. Remove foreign material.
7-3-33
Cylinder drops from pull of Scratches in U-packing. Replace U-packing.
gravity. Damage to U-packing. Replace U-packing.
Wear rings twisted. Replace wear rings.
Wear rings scratched. Replace wear rings.
Wear rings have other damage. Replace wear rings.
Slow bucket and boom Reduced oil flow due to dirty filter or Disassemble and clean parts.
movements. 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.
sleeve.
Pump worn or damaged internally. Replace worn or damaged parts.
Relief valve sticking. Disassemble and inspect cartridge.
Clean or replace cartridge.
Air in pressure line. Perform cylinder bleeding procedure to
remove air. Tighten or replace
pressure line.
Damaged pipe or hose. Replace pipe or hose.
Worn cylinder seals. Replace worn parts.
Low-pressure, shown by Reduced oil flow due to dirty filter or Disassemble and clean parts.
weak upward movement dirty intake line.
of boom and bucket. 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.
Relief valve sticking. Disassemble and inspect cartridge.
Clean or replace cartridge.
Worn cylinder seals. Replace worn parts.
Low pump output due to dirty Remove and clean pump discharge
discharge pipes. pipes.
Relief valve spring is weak. Relief Replace worn parts.
valve poppet worn.
Cylinder drops when Worn plunger in control valve. Replace plunger.
control valve is in neutral Stuck overload relief valve due to worn Replace worn parts.
seat surface.
Loose pipes or joints. Tighten parts.
Worn piston seal on hydraulic cylinder. Replace piston seal.
Vibration or excessive Excessive resistance in pump intake Inspect intake line and clean or replace
noise. line. as necessary.
Air being drawn into intake line. Inspect pipe joints and tighten.
Chattering relief valve. Change oil, replace valve.
Air bubbles in oil. Wrong type of operating oil. Drain and fill with proper type of oil.
Oil level too low. Raise to proper level.
Air trapped in system Perform cylinder bleeding procedure to
remove air.
Frequent rubber hose System pressure too high. Adjust relief valve pressure.
damage. Hoses breaking due to contact with Restrain hoses to prevent contact.
another machine parts.
7-3-34
1Hydraulic System
1Hydraulic
System
Edition 1
DX340LC-5/DX350LC-5 Hydraulic System

8-1-1
MEMO
Hydraulic System DX340LC-5/DX350LC-5

8-1-2
Table of Contents
Hydraulic System
General Description ........................................8-1-5
Hydraulic Schematic .......................................8-1-6
Hydraulic Component .....................................8-1-8
Boom Up Operation ......................................8-1-10
Boom Down Operation .................................8-1-12
Easy Boom Operation ..................................8-1-14
Arm Crowd Operation ...................................8-1-16
Arm Dump Operation....................................8-1-18
Bucket Crowd Operation ..............................8-1-20
Bucket Dump Operation ...............................8-1-22
Swing Operation ...........................................8-1-24
ON Swing Signal ..................................................... 8-1-24
OFF Swing Signal ................................................... 8-1-25
Travel Operation ...........................................8-1-26
Travel Straight Operation .............................8-1-28
Holding Valve Operation - Cylinder Locking
(Pilot Pressure Is 0 bar) ................................8-1-30
Holding Valve Operation - Cylinder Released
(Pilot Pressure Is Given)...............................8-1-31
Main Relief Valve and Port Relief Valve
Operation ......................................................8-1-32
Bypass Cut Valve and Bypass Cut Solenoid Valve
Operation ......................................................8-1-33

8-1-3
8-1-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL DESCRIPTION
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.

8-1-5
HYDRAULIC SCHEMATIC
The hydraulic schematic(s) is available in the "Hydraulic
Schematic Shop Manual". This manual is a collection of
diagrams explanation and schematics.
General Description
When referring to the schematic, refer to the following items:
• As shown in the schematic, the main pump assembly is
driven by the engine. Mechanical energy is converted to
hydraulic power, generating the required hydraulic flow
which drives the system. Two main pumps (a P1 pump and
a P2 pump) make up the main pump assembly.
• The right half of the hydraulic control valve, supplied by the
P1 pump in the pump assembly, operates valve spools for
right travel, swing 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
P2 pump in the pump assembly, has control spools for left
travel, bucket, boom and option operation.
• Two-stage operation is a feature of boom and arm
function. All of these circuits can be operated using the
output of only one half of the hydraulic pump assembly
(one pump or the other), or – since both halves of the
control valve have a spool and available circuit for these
functions – the output of both pumps can be combined,
allowing higher speed operation. Boom up, arm crowd and
dumping functions can operate in any one of the two
available power modes – the standard or general duty
mode, the high-speed/rapid cycling mode.
• Whenever the right travel or left travel control spools are
shifted, output from the main pump assembly flows through
the center joint to one or both of the axial piston motors
driving the side frame crawler tracks. A pilot valve
connected to the swash plate of each travel motor changes
motor capacity (and output) in direct proportion to the
position of the travel switch selected by the operator.
• The hydraulic reservoir return line and the pilot circuit both
have 10 micron full flow filters. The disposable elements in
these two canister type filters trap and remove impurities
from the oil in the system. An 80 mesh, 177 micron
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).

8-1-6
• The arm cylinder operating circuit includes anticavitation
valves which protect the hydraulic system from vacuum
that could result from external shocks or other unusual
conditions. Boom, Arm, and Bucket cylinder circuit are also
protected by overload relief valves. Whenever
high-pressure is generated 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.

8-1-7
HYDRAULIC COMPONENT
3
4 4 SH
B(#17)
Pilot Oil Flow Line
BACKWARD B
D P P2 P2 P D
FORWARD B
DB PG
P1(#16)
Main Oil Flow Line
Return Oil Line
LOW
LOW
C
PA
T3(#01)
Signal Oil Flow Line
A BACKWARD
PB
A FORWARD
HIGH
HIGH
4 2 5 0 3 1
D
P1 P1 D LEFT A B RIGHT
TRAVEL MOTOR (L) 5 TRAVEL MOTOR (R)

255
250kg/cm
bar
38 A P1
P2(#02)
2
PH(#16)
A B 6 6 B
L.H 280 bar
1 T P T(#25) 38 255 kg/cm T
A B P2
37 R.H 35 33
TWO-WAY
PEDAL(R.H)
B A
C2 C2 B A 29 QUICK COUPLER B6(#02)
2 1 T1
P2
LH-HIGH
RH-HIGH
36
E E
E Pi1
30
SENSOR
SENSOR
#25
HO(#16)
P3 7 46 2
b7(#02) P T 8 Pi1
T
Pi1
T C2
E
1 T P
39 V2 V2
C2 47
A
RH-HI
B
LH-HI
28 28 C
a5(#02) E T V2
(CLOSE) T (OPEN) V2 T Pi1 E

2 2 4
ARTI.PEDAL(L.H)
#25 T P1
from JOYSTICK(R) PPC
2 DOWN UP 1
1 T P 32 1 T P 3 13
TWO WAY OPTION B8(#23) 45
SENSOR
SENSOR
a8(#44)
ST TRAVEL
PEDAL(L.H) L.TRAVEL R.TRAVEL
B6(#23) B1(#24) a8(#44) b8(#44) 2 1 2 FORWARD 1 4 FORWARD 3
T1 34 1(#47) A(#36) P2(#33) B11(#23)
AB(#24)
B12(#23) B7(#23) B4(#24)
FORWARD
BACKWARD
BB(#02) ARTI. BOOM BACKWARD BACKWARD
B8 A8 b8 B7 A7 b7 B6 A6 b6 B5 L3 b5 B4 A4 b4 AB Pc2 b3 B3 A3 b2 B2 A2 b1 B1 A1
T A
ø1.2
1.2
/ø2.0
2.0 ø0.6 204 205 ø1.2
/ø2.0
211 213
ARTI. OPTION BKT TRAVE(L) TRAVE(R) SWING ARM
BOOM 212
A B
L.H 201 202 206 207 210 203 T(#37)
38 25 T(#36)
A B 380 ±5 bar 380 ±5 bar 380 ±5 bar 380 ±5 bar 380 ±5 bar
R.H P(#43) P(#36)
38 ø1.2
/ø2.0 ø0.8
0.8
ø1.2
/ø2.0
T(#43)
a8 7M9-25 a7 a6 a5 a4 Pc1 BB a3 a2 L2 a1
Pi1(#46) 208
39 44 2(#47) 2 HO(#16) B9(#23) C(#29) B10(#23)
380 ±5 bar
B5(#23) A2(#24) B3(#24)
209 b5(#02)
3 bar
2 2
11 T P T P 12
ONE WAY OPTION 1 3 1 3
500 bar 4 4
SENSOR
A(#17) 500 bar
SENSOR
P1(#33)
SWING ARM BOOM BUCKET
1 3 2 4 2 4 1 3
LEFT DUMP DOWN CROWD
RIGHT CROWD UP DUMP
31 A2 B2 C2 D2
10 RH-HI
(CCW)
LH-HI
(CW) P(#40)
ISO BHL
18
Pi(#02) 17 T
*SH(#24) A1 B1 C1 D1
19 T B 42 P T
ø0.3
0.3 80 bar
C(#03) A
A ø0.6
41 P(#42)
P 40 26 0.6
P pa pb
SH(#03)
1 P A 100 bar
A1 A3 A2 A4 A5 A7 A6 A8 A9 A11 A10 A12 23
S b(#36)
A2 15 B 100 bar
Two way Pedal
Hammer Operating
M M2 R6 a7(#02)
P(#37)
9
high speed
Safety Cut-off
DRIVE PUMP B1 B3 B2 B4 B5 B7 B6 B8 B9 B11 B10 B12

B
SENSOR
SENSOR
SENSOR
SENSOR
SENSOR
SENSOR
SENSOR
SENSOR
SENSOR
Travel
Vgmax Vgmin
ENGINE
21 DC9 ACC P2 HO TR2 PH BS
#25 43
TIER-4F T P
20 Vgmax Vgmin a3 b3 b5 P1(#29) a6 b6 a4 b4
A1 A3 A2 A4
22 1.5 ±0.2 bar
L1L2 S IDLE PUMP
P1
A B
M1 R5 PG(#03)
10u A1 M2 M1 PHB RH-HI T LH-HI
177u R2 R4 S
X2
P P* P0 P3 P4 16 ROTATING
(CCW) #25 (CW) B1
b1
B3
AB
a1
B2
a2
B4
*SH
b2
24
T2
X1 from JOYSTICK(R) BOTTON OPTION
14 Hammer Select
27 T1
EX1400137
Figure 1

8-1-8
Reference Reference
Number Number
1 Main Pump 31 Pattern Change Valve
2 Main Control Valve 32 Straight Travel Pedal Valve
3 Swing Device 33 Quick Coupler Valve
4 Travel Device 34 One-way PPR Valve
5 Center Joint 35 Two-way PPR Valve
6 Boom Cylinder 36 Two-way EPPR Valve
7 Arm Cylinder 37 Two-way Pedal Valve
8 Bucket Cylinder 38 Stop Valve
9 Fan Drive Pump 39 High-pressure Return Filter
10 Fan Drive Motor 40 Gear Pump for Rotating
11 Joystick Valve (LH) 41 Power Take-off
12 Joystick Valve (RH) 42 Rotating Control Valve
13 Pedal Valve 43 Rotating EPPR Valve
14 Pilot Filter 44 Main Control Valve (Arti.)
15 Accumulator 45 Arti. Boom Cylinder
16 Solenoid Valve 46 Arti. Boom Lock Valve
17 EPPR and Solenoid Valve 47 Arti. Boom Pedal Valve
18 Bypass Valve 201 Bucket Relief Valve
19 Oil Cooler 202 Boom Relief Valve
20 Full Flow Filter 203 Arm Relief Valve
21 Air Breather 204 Arm Summation Valve
22 Hydraulic Tank 205 Bypass Cut Valve
23 Joint Plate (Primary) 206 Bypass Cut Valve
24 Joint Plate (Secondary) 207 Boom Summation Valve
25 PT Block 208 Travel Straight Valve
26 Pump Peak Reducing Valve (Drive) 209 Main Relief Valve
27 Pump Peak Reducing Valve (Idle) 210 Arm Brake Valve
28 Boom Lock Valve 211 Holding Valve
29 Boom Floating Valve 212 Holding Valve
30 Arm Lock Valve 213 Arm Regeneration Valve

8-1-9
BOOM UP OPERATION
3
B(#17)
4 4 SH
D P P2 P2 P D
BACKWARD B
FORWARD B
P1(#16)
DB PG
LOW
LOW
C
PA
A FORWARD
PB
A BACKWARD
HIGH
HIGH
4 2 5 0 3 1
D P1 5 P1 D LEFT A B RIGHT
TRAVEL MOTOR (L) TRAVEL MOTOR (R)
6 6
B A 29
C2 C2
P2
E E
E Pi1 30
P3 7
8 Pi1
T
Pi1
T C2
V2 V2
28 28 C a5(#02) E T V2
T P1
B8(#23)
AB(#24)
B6(#23) B1(#24)
1(#47) A(#36) P2(#33) B11(#23) B12(#23) B7(#23) B4(#24)
BB(#02)
204 205
ø1.2
ø0.6 ø1.2
/ø2.0
2.0
/ø2.0
213
TRAVE(L)
ARTI. OPTION BKT TRAVE(R) SWING ARM
211 BOOM 212
202 206 207 210 203
380 ±5 bar 380 ±5 bar 380 ±5 bar 380 ±5 bar 2 380 ±5 bar
ø1.2 ø0.8 ø1.2 ø1.2 ø2.5 380 ±5 bar

/ø2.0 /ø2.0 /ø2.0
a8 7M9-25 a7 a6 a5 a4 Pc1 208 BB a3 a2 L2 a1

44 Pi1(#46) 2 HO(#16) B9(#23) C(#29) B10(#23)
380 ±5 bar
B5(#23) A2(#24) B3(#24)
2(#47)
b5(#02)
3 bar
209
500 bar
SENSOR
A(#17) 500 bar
SENSOR
P1(#33)
EX1400139
Figure 2
Boom spool and boom summation valve are switched to a

location, proportional to the input pilot pressure.
Oil from 2 pumps goes to boom cylinder through passage
described above. (Once the summation valve shifted, oil from
P1 and P2 together goes into boom cylinders)
EX1400194
Figure 3

8-1-10
Port Relief
Anti-cavitation Valve Load Check Valve Anti-drift Valve
Boom Spool
Input Pilot Pressure
Boom Cylinder Boom Summation Valve
Boom Summation Valve

Travel (R) Spools
Arm Spools
Boom Spool
Pilot Pressure
(Signal)
P2 P1
EX1400193
Figure 4

8-1-11
BOOM DOWN OPERATION
3
B(#17)
4 4 SH
D P P2 P2 P D
BACKWARD B
FORWARD B
P1(#16)
DB PG
LOW
LOW
C
PA
A FORWARD
PB
A BACKWARD
HIGH
HIGH
4 2 5 0 3 1
6 6
B A 29
C2 C2
E E P2
P3 E Pi1 30
8 Pi1
T
Pi1
T
7
V2 V2
C2
28 28 C a5(#02)
E T V2
T P1
B8(#23)
AB(#24)
B6(#23) B1(#24)
1(#47) A(#36) P2(#33) B11(#23) B12(#23) B7(#23) B4(#24)
BB(#02)
204 205
ø1.2
ø0.6 ø1.2
/ø2.0
2.0
/ø2.0
213
TRAVE(L)
ARTI. OPTION BKT BOOM TRAVE(R) SWING ARM
211 212
206 207 210 203
380 ±5 bar 380 ±5 bar 380 ±5 bar 380 ±5 bar

380 ±5 bar
ø1.2 ø0.8 ø1.2 ø1.2 ø2.5

/ø2.0 /ø2.0 /ø2.0
a8 7M9-25 a7 a6 a5 a4 Pc1 208 BB a3 a2 L2 a1

44 Pi1(#46) 2
380 ±5 bar
HO(#16) B9(#23) C(#29) B10(#23) B5(#23) A2(#24) B3(#24)
2(#47)
b5(#02)
3 bar
209
500 bar
SENSOR
A(#17) 500 bar
SENSOR
P1(#33)
EX1400138
Figure 5
Oil from two pumps goes to the arm spool through main spools
and arm summation valve.
As a result, high-pressure is exerted on arm rod area and
pushes the cylinder to "dump" direction. Flowrate from head
returns to tank.
EX1400195
Figure 6

8-1-12
Load Check Valve Anti-drift Valve
Port Relief
Anti-cavitation Valve
Input Pilot
Pressure
Regeneration Unit Inside

Insid
Boom Cylinder
Boom
Regeneration
Boom Spool
Pilot Pressure
(Signal)
Tank P2
EX1400196
Figure 7

8-1-13
EASY BOOM OPERATION
3
B(#17)
4 4 SH
D P P2 P2 P D
BACKWARD B
FORWARD B
P1(#16)
DB PG
LOW
LOW
C
PA
A FORWARD
PB
A BACKWARD
HIGH
HIGH
4 2 5 0 3 1
6 6
B A 29
C2 C2
P2
E E
E Pi1 30
P3 7
8 Pi1
T
Pi1
T C2
V2 V2
28 28 C a5(#02) E T V2
T P1
B8(#23)
AB(#24)
B6(#23) B1(#24)
1(#47) A(#36) P2(#33) B11(#23) B12(#23) B7(#23) B4(#24)
BB(#02)
204 205
ø1.2
ø0.6 ø1.2
/ø2.0
2.0
/ø2.0
213
TRAVE(L)
211 212
202 206 207 210 203
380 ±5 bar 380 ±5 bar 380 ±5 bar 380 ±5 bar

380 ±5 bar
ø1.2 ø0.8 ø1.2 ø1.2 ø2.5

/ø2.0 /ø2.0 /ø2.0
a8 7M9-25 a7 a6 a5 a4 Pc1 208 BB a3 a2 L2 a1

44 Pi1(#46) 2 HO(#16) B9(#23) C(#29) B10(#23)
380 ±5 bar
B5(#23) A2(#24) B3(#24)
2(#47)
b5(#02)
3 bar
209
500 bar
SENSOR
A(#17) 500 bar
SENSOR
P1(#33)
EX1400140
Figure 8
Easy boom operation is utilized for ease of use when bucket or

hydraulic breaker is used.
If boom floating mode is switched on, boom cylinder (6, Figure 8)
head side oil passage is connected to tank side oil passage, and
boom descends depending on the condition of ground surface.
If boom breaker mode is switched on, boom cylinder (6, Figure 8)
head side oil passage is connected to tank side oil passage and,
as a result, boom naturally descends when breaker is hit.
However, boom cylinder (6, Figure 8) rod side blocks oil
passage at the time of breaker operation by taking boom
reaction into account, and the constraint condition is maintained.
All these actions take place when boom descends.

8-1-14
OFF Signal
Floating Mode
T2 B T1 P1 T2
A8
Main
B A B8 Control
pb8 Valve
P2 P2
T1 T2 P1 ON Signal
Boom Down
Pilot Signal
T2 B T1 P1 T2
P2
Breaker Mode
A8
Main
20
B A B8 Control
Pilot Pressure (kg/cm2)
pb8 Valve
P2
15
10
C 7
5
T1 T2 P1
Boom Down 1
Pilot Signal 1 3 5 7 9 11 12
Spool Movement (mm)

EX1400911
Figure 9

8-1-15
ARM CROWD OPERATION
3
B(#17)
4 4 SH
D P P2 P2 P D
BACKWARD B
FORWARD B
P1(#16)
DB PG
LOW
LOW
C
PA
A FORWARD
PB
A BACKWARD
HIGH
HIGH
4 2 5 0 3 1
6 6
B A 29
C2 C2
P2
E E
E Pi1 30
P3 7
8 Pi1
T
Pi1
T C2
V2 V2
28 28 C a5(#02) E T V2
T P1
B8(#23)
AB(#24)
B6(#23) B1(#24)
1(#47) A(#36) P2(#33) B11(#23) B12(#23) B7(#23) B4(#24)
BB(#02)
ø1.2 205 ø1.2

/ø2.0
2.0 ø0.6 204 /ø2.0
213
ARTI. OPTION BKT BOOM TRAVE(L) TRAVE(R) SWING ARM
211 212
207 210 203

206
380 ±5 bar 380 ±5 bar 380 ±5 bar 380 ±5 bar
380 ±5 bar
ø1.2 ø0.8 ø1.2 ø1.2 ø2.5

/ø2.0 /ø2.0 /ø2.0
a8 7M9-25 a7 a6 a5 a4 Pc1 208 BB a3 a2 L2 a1

44 Pi1(#46) 2
380 ±5 bar
HO(#16) B9(#23) C(#29) B10(#23) B5(#23) A2(#24) B3(#24)
2(#47)
b5(#02)
3 bar
209
500 bar
SENSOR
A(#17) 500 bar
SENSOR
P1(#33)
EX1400141
Figure 10
High-pressure oil from arm cylinder rod chamber goes to head

chamber through a check valve located in arm spool.
(Return oil line is restricted by arm regeneration valve.)
EX1400198
Figure 11

8-1-16
Arm Summation Valve
Input Pilot
Pressure
Regeneration Unit
Arm Holding Valve
Pilot Pressure (Arm Crowd)
Arm
Regeneration
Arm Summation
Valve
Spools
Arm Cylinder
Spools
Arm Spool
Arm Holding
Valve
P2 P1 Tank
EX1400199
Figure 12

8-1-17
ARM DUMP OPERATION
3
B(#17)
4 4 SH
D P P2 P2 P D
BACKWARD B
FORWARD B
P1(#16)
DB PG
LOW
LOW
C
PA
A FORWARD
PB
A BACKWARD
HIGH
HIGH
4 2 5 0 3 1
6 6
B A 29
C2 C2
P2
E E
E Pi1 30
P3 7
8 Pi1
T
Pi1
T C2
V2 V2
28 28 C a5(#02) E T V2
T P1
B8(#23)
AB(#24)
B6(#23) B1(#24)
1(#47) A(#36) P2(#33) B11(#23) B12(#23) B7(#23) B4(#24)
BB(#02)
204 205
ø1.2
ø0.6 ø1.2
/ø2.0
2.0
/ø2.0
213
ARTI. OPTION BKT BOOM TRAVE(L) TRAVE(R) SWING ARM
211 212
207 210 203

206
380 ±5 bar 380 ±5 bar 380 ±5 bar 380 ±5 bar 380 ±5 bar
ø1.2 ø0.8 ø1.2 ø1.2 ø2.5

/ø2.0 /ø2.0 /ø2.0
a8 7M9-25 a7 a6 a5 a4 Pc1 208 BB a3 a2 L2 a1

44 Pi1(#46) 2
380 ±5 bar
HO(#16) B9(#23) C(#29) B10(#23) B5(#23) A2(#24) B3(#24)
2(#47)
b5(#02)
3 bar
209
500 bar
SENSOR
A(#17) 500 bar
SENSOR
P1(#33)
EX1400142
Figure 13
Oil from two pumps goes to the arm spool through main spools
and arm summation valve.
As a result, high-pressure is exerted on arm rod area and
pushes the cylinder to "dump" direction. Flowrate from head
returns to tank.
EX1400200
Figure 14

8-1-18
Regeneration Unit
Input Pilot Arm Summation Valve

Pressure
Arm Spool
Pilot Pressure
“AB”
Arm Cylinder
Arm Summation
Valve
Pilot Pressure
Spools
Spools
(Arm Dump)
P2 P1 Tank
EX1400201
Figure 15

8-1-19
BUCKET CROWD OPERATION
3
B(#17)
4 4 SH
D P P2 P2 P D
BACKWARD B
FORWARD B
P1(#16)
DB PG
LOW
LOW
C
PA
A FORWARD
PB
A BACKWARD
HIGH
HIGH
4 2 5 0 3 1
6 6
B A 29
C2 C2
P2
E E
E Pi1 30
P3 7
8 Pi1
T
Pi1
T C2
V2 V2
28 28 C a5(#02) E T V2
T P1
B8(#23)
AB(#24)
B6(#23) B1(#24)
1(#47) A(#36) P2(#33) B11(#23) B12(#23) B7(#23) B4(#24)
BB(#02)
204 205
ø1.2
ø0.6 ø1.2
/ø2.0
2.0
/ø2.0
213
TRAVE(L)
211 212
206 207 210 203
ø1.2 ø0.8 ø1.2 ø1.2 ø2.5

/ø2.0 /ø2.0 /ø2.0
a8 7M9-25 a7 a6 a5 a4 Pc1 208 BB a3 a2 L2 a1

44 Pi1(#46) 2
380 ±5 bar
HO(#16) B9(#23) C(#29) B10(#23) B5(#23) A2(#24) B3(#24)
2(#47)
b5(#02)
3 bar
209
500 bar
SENSOR
A(#17) 500 bar
SENSOR
P1(#33)
EX1400143
Figure 16
Bucket spool is switched to a location proportional to the input

pilot pressure.
Oil from one pump goes to bucket cylinder head through
passage described above.
Oil from bucket cylinder rod returns to tank reservoir through
bucket spool.
EX1400202
Figure 17

8-1-20
Port Relief Bucket Load Port Relief
Input Pilot
Pressure
Pilot Pressure
(Bucket Crowd) Spools
Bucket Cylinder
Bucket Spool Tank P2

EX1400226
Figure 18

8-1-21
BUCKET DUMP OPERATION
3
B(#17)
4 4 SH
D P P2 P2 P D
BACKWARD B
FORWARD B
P1(#16)
DB PG
LOW
LOW
C
PA
A FORWARD
PB
A BACKWARD
HIGH
HIGH
4 2 5 0 3 1
6 6
B A 29
C2 C2
P2
E E
E Pi1 30
P3 7
8 Pi1
T
Pi1
T C2
V2 V2
28 28 C a5(#02) E T V2
T P1
B8(#23)
AB(#24)
B6(#23) B1(#24)
1(#47) A(#36) P2(#33) B11(#23) B12(#23) B7(#23) B4(#24)
BB(#02)
204 205
ø1.2
ø0.6 ø1.2
/ø2.0
2.0
/ø2.0
213
TRAVE(L)
211 212
206 207 210 203
ø1.2 ø0.8 ø1.2 ø1.2 ø2.5

/ø2.0 /ø2.0 /ø2.0
a8 7M9-25 a7 a6 a5 a4 Pc1 208 BB a3 a2 L2 a1

44 Pi1(#46) 2 HO(#16) B9(#23) C(#29) B10(#23)
380 ±5 bar
B5(#23) A2(#24) B3(#24)
2(#47)
b5(#02)
3 bar
209
500 bar
SENSOR
A(#17) 500 bar
SENSOR
P1(#33)
EX1400144
Figure 19
Bucket spool is switched to a location proportional to the input

pilot pressure.
Oil from one pump goes to bucket cylinder rod through passage
described above.
Oil from bucket cylinder head returns to tank reservoir through
bucket spool.
EX1400227
Figure 20

8-1-22
Port Relief Bucket Load Port Relief
Input Pilot
Pressure
Bucket Spool
Spools
Bucket Cylinder
Pilot Pressure
(Bucket Dump)
Tank P2
EX1400228
Figure 21

8-1-23
SWING OPERATION
ON Swing Signal
Flowrate discharged from pump is supplied to swing motor
through swing spool, whose opening area dependent on the
swing pilot signal.
The direction of the swing motor rotation is dependent on the
pilot signal, right or left.
EX1400229
Figure 22
Port Relief Swing Load Port Relief

Input Pilot
Pressure
EX1400230
Figure 23

8-1-24
OFF Swing Signal
1. Sudden fall of "Swing Signal Input" will lead the
uppercarriage to keep moving because of the inertia of
huge mass.
2. Oil from tank reaches the swing motor, actually working as
a swing pump, through makeup valve to avoid cavitation.
3. The bypass-cut valve (206) must remain opened during
this operation to supply oil required for the makeup
function.
3
B(#17)
4 4 SH
D P P2 P2 P D
BACKWARD B
FORWARD B
P1(#16)
DB PG
LOW
LOW
PA
A FORWARD
PB
A BACKWARD
HIGH
HIGH
4 2 5 0 3 1
6 6
B A 29
C2 C2
P2
E E
E Pi1 30
P3 7
8 Pi1
T
Pi1
T C2
V2 V2
28 28 C a5(#02) E T V2
T P1
B8(#23)
AB(#24)
B6(#23) B1(#24)
1(#47) A(#36) P2(#33) B11(#23) B12(#23) B7(#23) B4(#24)
BB(#02)
204 205
ø1.2
ø0.6 ø1.2
/ø2.0
2.0
/ø2.0
213
TRAVE(L)
211 212
206 207 210 203
ø1.2 ø0.8 ø1.2 ø1.2 ø2.5

/ø2.0 /ø2.0 /ø2.0
a8 a7 a6 a5 a4 Pc1 208 BB a3 a2 L2 a1
44 Pi1(#46) 2 380 ±5 bar
2(#47) HO(#16) B9(#23) C(#29) B10(#23) B5(#23) A2(#24) B3(#24)
b5(#02)
3 bar
209
500 bar
SENSOR
A(#17) 500 bar
SENSOR
P1(#33)
EX1400145
Figure 24

8-1-25
TRAVEL OPERATION
3
B(#17)
4 4 SH
D P P2 P2 P D
BACKWARD B
FORWARD B
P1(#16)
DB PG
LOW
LOW
C
PA
A FORWARD
PB
A BACKWARD
HIGH
HIGH
4 2 5 0 3 1
6 6
B A 29
C2 C2
P2
E E
E Pi1 30
P3 7
8 Pi1
T
Pi1
T C2
V2 V2
28 28 C
a5(#02) E T V2
T P1
B8(#23)
AB(#24)
B6(#23) B1(#24)
1(#47) A(#36) P2(#33) B11(#23) B12(#23) B7(#23) B4(#24)
BB(#02)
204 205
ø1.2
ø0.6 ø1.2
/ø2.0
2.0
/ø2.0
213
TRAVE(L)
211 212
201 202 206 207 210 203
ø1.2 ø0.8 ø1.2 ø1.2 ø2.5

/ø2.0 /ø2.0 /ø2.0
a8 7M9-25 a7 a6 a5 a4 Pc1 208 BB a3 a2 L2 a1

44 Pi1(#46) 2
380 ±5 bar
HO(#16) B9(#23) C(#29) B10(#23) B5(#23) A2(#24) B3(#24)
2(#47)
b5(#02)
3 bar
209
500 bar
SENSOR
A(#17) 500 bar
SENSOR
P1(#33)
WL1400146
Figure 25
Flowrate discharged from pump is supplied to travel motor

through travel spool (right or left), whose opening area is
dependent on the travel pilot signal.
Left (right) motor determines the direction of left (right) side,
forward or backward. All of those movement has the same
mechanism described above.
Right Side
EX1400231
Figure 26

8-1-26
Travel Spool
A B
Input Pilot
a3 Pressure
b3
T PC25 NG10 NG11 NG13 T
Travel Right: Forward

EX1400232
Figure 27

8-1-27
TRAVEL STRAIGHT OPERATION
3
B(#17)
4 4 SH
D P P2 P2 P D
BACKWARD B
FORWARD B
P1(#16)
DB PG
LOW
LOW
C
PA
A FORWARD
PB
A BACKWARD
HIGH
HIGH
4 2 5 0 3 1
6 6
B A 29
C2 C2
P2
E E
E Pi1 30
P3 7
8 Pi1
T
Pi1
T C2
V2 V2
28 28 C a5(#02) E T V2
T P1
B8(#23)
AB(#24)
B6(#23) B1(#24)
1(#47) A(#36) P2(#33) B11(#23) B12(#23) B7(#23) B4(#24)
BB(#02)
204 205
ø1.2
ø0.6 ø1.2
/ø2.0
2.0
/ø2.0
213
TRAVE(L)
211 212
201 202 206 207 210 203
ø1.2 ø0.8 ø1.2 ø1.2 ø2.5

/ø2.0 /ø2.0 /ø2.0
a8 7M9-25 a7 a6 a5 a4 Pc1 208 BB a3 a2 L2 a1

44 Pi1(#46) 2
380 ±5 bar
HO(#16) B9(#23) C(#29) B10(#23) B5(#23) A2(#24) B3(#24)
2(#47)
b5(#02)
3 bar
209
500 bar
SENSOR
A(#17) 500 bar
SENSOR
P1(#33)
EX1400147
Figure 28

valve".
Once the TS signal is on, P1 begins to control both two travel
motors at the same time, whereas P2 controls the rest of
functions.
The purpose of this independent control is to preserve steady
straight movement of excavator when they are performing
various works.

8-1-28
P1
P2
PR1 T
NG10 NG20 PC13 Pst P1

PC21
If TS signal on,
then spool’s movement generates
new flow path (red)
EX1400233
Figure 29

8-1-29
HOLDING VALVE OPERATION - CYLINDER LOCKING
(PILOT PRESSURE IS 0 BAR)
3
B(#17)
4 4 SH
D P P2 P2 P D
BACKWARD B
FORWARD B
P1(#16)
DB PG
LOW
LOW
C
PA
A FORWARD
PB
A BACKWARD
HIGH
HIGH
4 2 5 0 3 1
6 6
B A 29
C2 C2
P2
E E
E Pi1 30
P3 7
8 Pi1
T
Pi1
T C2
V2 V2
28 28 C a5(#02) E T V2
T P1
B8(#23)
AB(#24)
B6(#23) B1(#24)
1(#47) A(#36) P2(#33) B11(#23) B12(#23) B7(#23) B4(#24)
BB(#02)
204 205
ø1.2
ø0.6 ø1.2
/ø2.0
2.0
/ø2.0
213
TRAVE(L)
211 212
201 202 206 207 210 203
ø1.2 ø0.8 ø1.2 ø1.2 ø2.5

/ø2.0 /ø2.0 /ø2.0
a8 7M9-25 a7 a6 a5 a4 Pc1 208 BB a3 a2 L2 a1

44 Pi1(#46) 2
380 ±5 bar
HO(#16) B9(#23) C(#29) B10(#23) B5(#23) A2(#24) B3(#24)
2(#47)
b5(#02)
3 bar
209
500 bar
SENSOR
A(#17) 500 bar
SENSOR
P1(#33)
EX1400148
Figure 30
Cylinder pressure is restricted behind holding valve with high-

pressure. The check valve is preventing the fluid from leaking. Pilot Pressure
Spools
Cylinder
Tank
EX1400234
Figure 31

8-1-30
HOLDING VALVE OPERATION - CYLINDER RELEASED
(PILOT PRESSURE IS GIVEN)
3
B(#17)
4 4 SH
D P P2 P2 P D
BACKWARD B
FORWARD B
P1(#16)
DB PG
LOW
LOW
C
PA
A FORWARD
PB
A BACKWARD
HIGH
HIGH
4 2 5 0 3 1
6 6
B A 29
C2 C2
P2
E E
E Pi1 30
P3 7
8 Pi1
T
Pi1
T C2
V2 V2
28 28 C a5(#02) E T V2
T P1
B8(#23)
AB(#24)
B6(#23) B1(#24)
1(#47) A(#36) P2(#33) B11(#23) B12(#23) B7(#23) B4(#24)
BB(#02)
204 205
ø1.2
ø0.6 ø1.2
/ø2.0
2.0
/ø2.0
213
TRAVE(L)
211 212
201 202 206 207 210 203
ø1.2 ø0.8 ø1.2 ø1.2 ø2.5

/ø2.0 /ø2.0 /ø2.0
a8 7M9-25 a7 a6 a5 a4 Pc1 208 BB a3 a2 L2 a1

44 Pi1(#46) 2 HO(#16) B9(#23) C(#29) B10(#23)
380 ±5 bar
B5(#23) A2(#24) B3(#24)
2(#47)
b5(#02)
3 bar
209
500 bar
SENSOR
A(#17) 500 bar
SENSOR
P1(#33)
EX1400149
Figure 32
When the pilot pressure rises, the position of lock valve is

changed, making the fluid inside of cylinder rod released Pilot Pressure
through the spool.
Spools
Cylinder
Tank
EX1400235
Figure 33

8-1-31
MAIN RELIEF VALVE AND PORT RELIEF VALVE OPERATION
3
B(#17)
4 4 SH
D P P2 P2 P D
BACKWARD B
FORWARD B
P1(#16)
DB PG
LOW
LOW
C
PA
A FORWARD
PB
A BACKWARD
HIGH
HIGH
4 2 5 0 3 1
6 6
B A 29
C2 C2
P2
E E
E Pi1 30
P3 7
8 Pi1
T
Pi1
T C2
V2 V2
28 28 C a5(#02) E T V2
T P1
B8(#23)
AB(#24)
B6(#23) B1(#24)
1(#47) A(#36) P2(#33) B11(#23) B12(#23) B7(#23) B4(#24)
BB(#02)
204 205
ø1.2
ø0.6 ø1.2
/ø2.0
2.0
/ø2.0
213
TRAVE(L)
211 212
201 202 206 207 210 203
ø1.2 ø0.8 ø1.2 ø1.2 ø2.5

/ø2.0 /ø2.0 /ø2.0
a8 7M9-25 a7 a6 a5 a4 Pc1 208 BB a3 a2 L2 a1

44 Pi1(#46) 2
380 ±5 bar
HO(#16) B9(#23) C(#29) B10(#23) B5(#23) A2(#24) B3(#24)
2(#47)
b5(#02)
3 bar
209
500 bar
SENSOR
A(#17) 500 bar
SENSOR
P1(#33)
EX1400150
Figure 34
EX1400236
Figure 35

8-1-32
BYPASS CUT VALVE AND BYPASS CUT SOLENOID
VALVE OPERATION
3
B(#17)
4 4 SH
D P P2 P2 P D
BACKWARD B
FORWARD B
P1(#16)
DB PG
LOW
LOW
C
A FORWARD PA PB
A BACKWARD
HIGH
HIGH
4 2 5 0 3 1
6 6
B A 29
C2 C2
P2
E E
E Pi1 30
P3 7
8 Pi1
T
Pi1
T C2
V2 V2
28 28 C a5(#02) E T V2
T P1
B8(#23)
AB(#24)
B6(#23) B1(#24)
1(#47) A(#36) P2(#33) B11(#23) B12(#23) B7(#23) B4(#24)
BB(#02)
204 205
ø1.2
ø0.6 ø1.2
/ø2.0
2.0
/ø2.0
213
TRAVE(L)
211 212
201 202 206 207 210 203
ø1.2 ø0.8 ø1.2 ø1.2 ø2.5

/ø2.0 /ø2.0 /ø2.0
a8 7M9-25 a7 a6 a5 a4 Pc1 208 BB a3 a2 L2 a1

44 Pi1(#46) 2 HO(#16) B9(#23) C(#29) B10(#23)
380 ±5 bar
B5(#23) A2(#24) B3(#24)
2(#47)
b5(#02)
3 bar
209
500 bar
SENSOR
A(#17) 500 bar
SENSOR
P1(#33)
EX1400151
Figure 36
Bypass cut valve and bypass cut solenoid valve, which is

controlled by signal from electric controller, determine the
flowrate discharged from the main pump.

8-1-33
Bypass Cut
Solenoid Valve
Bypass Cut Valve

Signal from
Controller
Pilot Pump Main Pump Tank

EX1400197
Figure 37

8-1-34
1Hydraulic
System Testing
and Adjustment
Edition 1
DX340LC-5/DX350LC-5 Hydraulic System Testing and Adjustment

8-2-1
MEMO
Hydraulic System Testing and Adjustment DX340LC-5/DX350LC-5

8-2-2
Table of Contents
Hydraulic System Testing and Adjustment

Procedural Troubleshooting Baseline
Recommendations..........................................8-2-6
Initial Checks and Tests to Establish Operating Condition
of the Excavator ........................................................ 8-2-6
Pilot Pressure .................................................8-2-7
Adjustment and Testing............................................. 8-2-7
Pump Swash Plate .........................................8-2-8
Pump EPPRV .................................................8-2-9
Pump Pressure .............................................8-2-10
Adjustment and Testing........................................... 8-2-10
Pump Regulator............................................8-2-11
Adjustment and Testing........................................... 8-2-11
Installation and Testing of Flow Meter and Flow
Meter Kit .......................................................8-2-13
Installation and Testing Procedures ........................ 8-2-13
Swing System Troubleshooting ....................8-2-14
Precautions/Initial Checks ....................................... 8-2-14
Swing Relief Valve Checking and Adjustment ........ 8-2-15

8-2-3
8-2-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

8-2-5
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 should
be checked for the following:
• First, check the hydraulic pressure and flow at various
points of the hydraulic system.
• Check engine operation at Power + mode (1,890 rpm). If
engine rpm drops excessively with a load or fails to
surpass the rated speed (1,800 rpm), the performance
problem may be due to lagging rotational speed.
Take out the self-diagnosis display from beneath the operator’s
seat to start checking.
Check the EPOS failure code display, and perform the diagnosis
program in accordance with the DMS diagnosis manual.
• Pilot pressure
• Pump swash plate tilting angle
• Pump EPPRV
• Pump pressure
In accordance with the standard test procedures,
• Check the cylinder speed, hydraulic motor (travel and
swivel) speed, and allowable cylinder descent.
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.
IMPORTANT
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.

8-2-6
PILOT PRESSURE
Adjustment and Testing
WARNING
This procedure should be done with two people. To reduce
the chance of accidental movement of the excavator, one
person should be properly seated at the operator's controls
while checks and adjustments are made.
With the DMS diagnosis program, check the joystick pressure of

each actuator.
First, check that signal from the pilot pressure sensor is OK with
the EPOS failure code display.
If the pressure sensor is abnormal, replace the harness and the
pressure sensor.
Start the engine and turn the engine speed control dial to the
maximum setpoint. Warm-up the engine so that excavator
reaches the normal operating temperature.
For each actuator, check the joystick pressure and pressure
rise/drop time.
Normal pressure and pressure rise/drop time are as follows;
Engine rpm Joystick Pressure at Max. Stroke Joystick Ascend/Descend Time

Max. or 1,500 rpm or above > 36 kg/cm (> 35 bar)
2 < 0.5 sec
If the joystick pressure and ascend/descend time at a specific

operation fail to meet the above criteria, inspect the joystick and
joystick line.
If the joystick pressure fails to meet the above specification at all
operations, inspect the gear pump.
Release the hydraulic pressure from the tank, insert a "t-type"
inline adapter into the discharge port of the gear pump, and
connect a pressure gauge (60 bar/1,000 psi).
Set the engine control dial to the maximum rated rpm.
Set all the controls at neutral, and check the pressure at the gear
pump discharge port.
Engine rpm Gear Pump Pressure

Max. Rating 41 +2 kg/cm2 (40 +2 bar)
If the gear pump pressure fails to meet the specified tolerance,

replace the gear pump relief valve.

8-2-7
NOTE: Be aware that serial number changes and variation in
the joystick assemblies used on different excavators
could produce slight change in actual performance
characteristics. Comparison of part numbers to serial
numbers stamped on your assembly may be
required, if questions or doubt exists.
IMPORTANT
Refill the hydraulic fluid reservoir if there is any measurable
loss of hydraulic oil during test gauge and adapter fitting
installation.
PUMP SWASH PLATE

WARNING
With the DMS diagnosis program, check the pump swash plate
tilting angle signal.
First, check that pump swash plate tilting angle signal is OK with
the EPOS failure code display. If the pump swash plate tilting
angle signal is abnormal, replace the harness and the swash
plate tilting angle sensor.
maximum setpoint. Warm-up the engine so that excavator
reaches the normal operating temperature.
Check the swash plate tilting angle signals of the pumps (idle
and drive). The swash plate tilting angle signals should be within
the range in the table below;
Engine rpm Min. Max.

Max. or 1,500 rpm or above 0.5 - 0.1V 4.5 - 0.1V
Swash plate tilting angle sensor should be tuned at the time of

installation. Under the maximum swash plate tilting angle driving
condition, fine-tune the mounting angle of the swash plate tilting
angle sensor so that signal come within the range shown in the
table above. After the tuning, if the signal fails to meet the
minimum value at the minimum swash plate tilting angle driving
condition, the pump regulator needs adjustment or replacement.

8-2-8
PUMP EPPRV
WARNING
With the DMS diagnosis program, check the current supplied to

the EPPRV.
First, check if there is open or short-circuit failure in the circuit,
with the EPOS failure code display. If open/short-circuit problem
is identified, replace the harness and/or EPPRV.
Warm-up the engine so that excavator reaches the normal
operating temperature.
With the DMS diagnosis program, check the difference (error)
between the current instruction and actual measured value.
The error range which can be calibrated is as follows;
Engine rpm Current Error

Min. or 700 rpm or above ± 20 mA or less
If the error comes under the range which allows calibration,

perform calibration. If the error exceeds the range which allows
calibration, adjust or replace the current driver of the EPOS.

8-2-9
PUMP PRESSURE
WARNING
maximum setpoint. When the engine reaches the standard
operating temperature;
• Select the Power Plus mode.
• Fully extend the boom cylinder until movement stops.
• Read the pump pressure in the instrument panel display.
• Repeat the test by selecting and deselecting "Pressure Up"
with the joystick.
The normal pump pressures are as follow;
Mode Operation Pump Pressure

Power Plus Mode Cylinder Stall 357 +10 kg/cm2 (350 +10 bar)
Power Plus Mode with "Raise Up" Cylinder Stall 377 +10 kg/cm2 (370 +10 bar)
If the pump pressures fail to meet the above specification, the

pump pressure should be adjusted.
With the DMS diagnosis program, perform pump pressure
diagnosis.
With the DMS diagnosis program, check the difference (error)
between the pump pressure instruction and actual pressure. The
error range which can be calibrated is as follows;
Engine rpm Pump Pressure Error

Max. or 1,500 rpm or above ± 18 mA or less
If the error comes under the range which allows calibration,

perform calibration.
If the error exceeds the range which allows calibration, repair or
replace the pump regulator.

8-2-10
PUMP REGULATOR
WARNING
If the pump swash plate tilting angle and/or pump control

pressure is out of the range which allows calibration, the pump
regulator needs adjustment.
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 in fittings to install the flow meter kit. (Refer to
the "Flow Meter Installation and Testing" procedure.)
IMPORTANT
Before starting this procedure or going onto make any
changes of adjustment settings;
• Verify that engine speed is above the rated speed of
1,800 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.
The 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 problems).

8-2-11
• If the 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, drive 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.
In the Figure 1, refer to the location of adjustment screws (1) and 2
(2).
There are two different adjustments which are maximum flow
and Pi pressure-pump pressure relationship.
Each one of the adjustment procedures could affect the setting
of the other.
Check and record the arm dump speed for comparison before
and after the adjustment.
NOTE: Regulator adjustments affect total cumulative
horsepower.
This is because each regulator compensates for the output of
the other.
It is not necessary to adjust both regulators at the same time, but 1
after checking or adjusting one of them, the remaining unit
should also be checked. FG022502
Start the engine and turn the engine speed dial to the maximum. Figure 1
When normal operating temperature is reached, loosen the
largest diameter locknut around the adjustment screw (2) for the
outer regulator spring. Tightening the screw reduces maximum
pump capacity (swash plate tilting angle) and consequently, the
flow rate. On the contrary, loosening the screw increases
maximum pump capacity (swash plate tilting angle) and
consequently, the flow rate.
With the flow meter, adjust the maximum pump capacity and the
mounting angle of the swash plate tilting angle sensor.
To adjust the pump pressure, turn the regulator adjustment
screw (2) slowly.
Loosening and tightening the adjustment screw (2) decreases
and increases the maximum pump pressure, respectively.
Adjust the pump pressure at the following conditions;
Mode Operation Pump Pressure

357 +10 kg/cm2
Power Plus Mode Cylinder Stall
(350 +10 bar)
After adjusting the maximum pressure, perform calibration again

through the DMS diagnosis program.

8-2-12
INSTALLATION AND TESTING OF FLOW METER AND
FLOW METER KIT
To adjust and evaluate the maximum displacement of the idle
and drive pumps, flow meter needs to be installed.
If you prefer self-testing, our after service department can assist
you with these tests, with hoses and a fitting kit (or the
specifications of the hoses and fittings) required for installing
flow meter on the main pump assembly.
Installation and Testing Procedures

• Stop engine and operate the joystick to release the
hydraulic pressure from the accumulator.
• Vent the reservoir to release all pressure from the
hydraulic system.
• Remove the guard panel from around the main pump
assembly.
• Disconnect the main pump discharge output line. Install the
input flange of the flow meter on the pump end of the
output line.
• Cap off the unused (input) end of the pump discharge line
with a blocking flange.
NOTE: 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
• Be sure to maintain even tightening torque on all flange
fittings. Use Locktite brand PST 54 (or an alternate
manufacturer's hydraulic system joint seal) if required to
give an airtight seal.
• An assistant (who must remain at the operator's control
station at all times) should restart the engine and run is
long enough (at minimum rpm) to derate the system and
warm up the engine and hydraulic system to operating
temperature.

8-2-13
SWING SYSTEM
TROUBLESHOOTING
Precautions/Initial Checks
1. Stop work. Release all weight or any type of load safely
before proceeding. Avoid risking injury or adding to
damage.
2. Shut down 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.

8-2-14
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 490 bar (7,112 psi) pressure gauges to the inlet
and outlet measuring ports on top of the swing motor.
Pressure should be between 284 and 294 bar
(4,124 psi and 4,267 psi), with both swing locks
engaged. With swing locks released, during full
acceleration and deceleration, pressure should
approach 289 bar (4,196 psi) in each direction.
B. Connect a 98 bar (1,422 psi) pressure gauge at the
"SH" port of the hydraulic brake.
Pressure should always stay at or above 13 bar (185
psi) when operating swing, boom or arm.
C. Connect a 10 bar (142 psi) gauge at the motor
makeup valve.
Pressure should stay consistently above 2.5 bar (36
psi). If pressure falls below the recommended
minimum level, forceful acceleration of the swing
motor could lead to cavitation of the circuit and
stalling, slowed rotation, noise and possible damage.
2. If main inlet and outlet pressures were off in the preceding
tests in Step 1, adjust swing relief valve pressure.
Following adjustment, repeat the operating pressure tests
(with gauges connected to the inlet and outlet test ports on
top of the swing motor) and check pressures with the swing
locks engaged and released.
If pressure adjustment fails to restore adequate
performance, proceed to the Troubleshooting – Swing table.
3. If pressure tests were at recommended levels through the
main inlet and outlet ports, and through the "SH" port of the
swing brake, the causes of poor swing performance could
include a faulty swing motor, 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 bar (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.

8-2-15
4. If pressure tested at the motor makeup valve falls below
recommended minimum level, and consequent problems
with cavitation, stalling and surging are observed, check
the restriction valve. If pressure adjustment to the valve
has been restored but if problems with cavitation
continues, disassemble the upper swing motor housing
and clean or replace assembly components as required.
NOTE: If all tested pressures are at or above
recommended levels, and there are no
mechanical problems in the 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.

8-2-16
1Hydraulic
System
Troubleshooting
Edition 1
DX340LC-5/DX350LC-5 Hydraulic System Troubleshooting

8-3-1
MEMO
Hydraulic System Troubleshooting DX340LC-5/DX350LC-5

8-3-2
Table of Contents
Hydraulic System Troubleshooting

Hydraulic System............................................8-3-5
Unusual Noise Comes Out from Pump Connection .. 8-3-5
Engine Starts but Machine Does Not Operate .......... 8-3-6
Hydraulic Oil is Cloudy .............................................. 8-3-7
Hydraulic Oil Overheated .......................................... 8-3-7
Hydraulic Pump Cavitation ........................................ 8-3-8
Hydraulic Oil is Contaminated ................................... 8-3-8
Attachment Cylinders, Swing and Travel Motors are All
Operable.
But Speed Is Lower and Power Lacks. ..................... 8-3-9
Travel Left, Bucket are Inoperable.
But Boom Up and Arm are Slower Than Normal
Operation................................................................. 8-3-10
Travel Right, Swing are Inoperable.
But Boom Up and Arm are Slower Than Normal
Operation................................................................. 8-3-11
Attachment Cylinders, Swing and Travel Motors are All
Operable.
But Fine Operation Is Difficult and Loud Noises are
Heard....................................................................... 8-3-12
Arm-in Is Unstable................................................... 8-3-13
Travel Right Motor are Inoperable or Operable in One
Direction Only.......................................................... 8-3-13
Travel Left Motor are Inoperable or Operable in One
Direction Only.......................................................... 8-3-14
Swing Motor are Inoperable or Operable in One Direction
Only. ........................................................................ 8-3-14
Arm Is Operable but Slower in One Direction. ........ 8-3-15
Two Pump (Breaker etc.) Becomes Slower. ........... 8-3-15
Machine Cannot Travel Straight During Combined
Operation of Travel and Front. ................................ 8-3-16
Machine Cannot Travel Straight During Travel
Operation................................................................. 8-3-16
Considerable Flow at Pump with Neutral Lever
Position.................................................................... 8-3-17
Troubleshooting – Swing Gearbox ...............8-3-18

8-3-3
Troubleshooting – Hydraulic Problems.........8-3-19
Troubleshooting – Main Pump......................8-3-22
Troubleshooting – Control Valve ..................8-3-24
Troubleshooting – Travel Control Valve .......8-3-26
Troubleshooting – Joystick Control Valve.....8-3-26

8-3-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
HYDRAULIC SYSTEM
Unusual Noise Comes Out from Pump Connection
Remove dust plug under engine YES

flywheel and check if rubber pieces Coupling element is broken.
or particles are not.
NO
YES Replace the coupling or retighten
Coupling hub spline is worn or hub the screw.
fastening screw is loose.
If hydraulic pump or engine is

NO suspected, Refer to the service
manual on hydraulic pump and
engine.

8-3-5
Engine Starts but Machine Does Not Operate
Is oil level correct in hydraulic NO Replenish oil to the standard

oil tank? level.
YES
Do not hydraulic pump and pump YES Abnormal noise comes out of YES
Hydraulic pump is broken.
connections make abnormal noise. hydraulic pump.
YES
NO Abnormal noise comes out of YES See refer to “Unusual noise comes
pump connection. out from pump connection”.
YES Is pilot line clogged or oil YES Need clean the pilot piping
Is pilot pump pressure OK?
leakage on pilot line? interior or repair pilot line.
NO Remote control valve or safety

NO solenoid valve is failure.
Pilot relief valve is failure or less

YES
Is gear pump discharging the oil? pressure. Disassemble and repair
or resetting pilot pressure.
NO
Gear pump is broken.

8-3-6
Hydraulic Oil is Cloudy
Has keep the oil change interval NO Need observance of oil change
maintenance? interval.
YES
Drop hydraulic oil sample on a hot YES Water is mixed.

plate and check if it foams come up. Replace the oil.
NO
Is the hydraulic oil with another YES Must be used one kind brand oil.
oil brand? Replace with Doosan genuine oil.
NO
The hydraulic system has YES Clean the cooler and check of
overheated. the hydraulic system.
Oil is aerated. Check suction line

NO
and return line and eliminate
the air intruding source.
Hydraulic Oil Overheated
NO Replenish specified oil to the

Is hydraulic oil level correct?
corrected level.
YES
Is not oil cooler clogged and is YES Clean oil cooler.

anything blocking air circulation? Secure air circulation route.
NO
NO
Is fan drive motor normal? Repair fan drive motor.
YES
NO
Is fan drive pump normal? Repair fan drive pump.
YES
YES Check the EPOS controller

Is fan EPPR current normal?
or electric wire.
NO
Repair the fan EPPR valve.

8-3-7
Hydraulic Pump Cavitation
NO Replenish specified oil to the

Is hydraulic oil level correct?
corrected level.
YES
Is not viscosity of hydraulic oil too YES Replace oil with proper
high? viscosity.
NO
YES
Is the suction strainer clogged? Replace suction strainer.
NO
YES Check for air intrusion in suction

Is air intruding at pump suction line?
line and retighten or replace parts.
Hydraulic Oil is Contaminated
Has not hydraulic oil passed YES Replace hydraulic oil and filter.
specified replacement hours? Clean the hydraulic system.
NO
Has return filter been replaced at NO Replace hydraulic oil and replace
proper intervals? return filter.

8-3-8
Attachment Cylinders, Swing and Travel Motors are All Operable.
But Speed Is Lower and Power Lacks.
1 2 5
EX1400181
NO
Is PPRV in main pump normal? Replace the PPRV in main pump.
2 YES
Is bypass-cut spool move smoothly NO Clean or replace the bypass-cut

by handy? spool in control valve.
5 YES
NO Repair or replace the bypass-cut

Is bypass-cut solenoid valve normal?
solenoid valve.

8-3-9
Travel Left, Bucket are Inoperable.
But Boom Up and Arm are Slower Than Normal Operation.
Main Pump
EX1400182
NO Repair or replace the ED

Is ED regulator in idle pump normal?
regulator in idle pump.
4 YES
NO Replace the EPPR valve in idle

Is EPPR valve in idle pump normal?
pump.
YES
Is harness connection with idle NO Repair or replace the harness

pump EPPR valve normal? for EPPR valve.

8-3-10
Travel Right, Swing are Inoperable.
But Boom Up and Arm are Slower Than Normal Operation.
Main Pump
EX1400182
3
NO Repair or replace the ED
Is ED regulator in drive pump normal?
regulator in drive pump.
4 YES
NO Replace the EPPR valve in idle

Is EPPR valve in drive pump normal?
pump.
YES
Is harness connection with drive NO Repair or replace the harness

pump EPPR valve normal? for EPPR valve.

8-3-11
Attachment Cylinders, Swing and Travel Motors are All Operable.
But Fine Operation Is Difficult and Loud Noises are Heard.
Main Pump
EX1400183
NO Replace the lever pressure

Is lever pressure sensor normal?
sensor.
YES
Is harness connection with lever NO Repair or replace the harness

pressure sensor normal? with lever pressure sensor.
2 YES
NO Replace the angle sensor of

Is pump angle sensor normal?
pump.
YES
Is harness connection with pump NO Repair or replace the harness

angle sensor normal? with pump angle sensor.

8-3-12
Arm-in Is Unstable.
a7 b1 B1 A1
a6
a5 2.5
A7 a4
b7 A6 3
Arm
AB
b6
6
a3
b5
5
a2
b4
a1
380 5.1 bar
BB
B
b3
2.3
b2
2
b1 L2 a1
1
Main Control Valve EX1400184
Is arm brake valve in main control NO Replace the arm brake valve in
valve normal? main control valve.
Travel Right Motor are Inoperable or Operable in One Direction Only.
4
EX1400185
NO
Is travel right motor normal? Replace the right travel motor.
4 YES
Is joint sub ass'y in pilot pressure NO Replace the shuttle valve in

sensor block normal? pilot pressure sensor block.

8-3-13
Travel Left Motor are Inoperable or Operable in One Direction Only.
EX1400186
NO
Is travel left motor normal? Replace the left travel motor.
YES

Swing Motor are Inoperable or Operable in One Direction Only.
EX1400187
NO
Is swing motor normal? Replace the swing motor.
YES


8-3-14
Arm Is Operable but Slower in One Direction.
Arm Dump
Arm Crowd EX1400188

sensor block normal? joint sub ass'y.
Two Pump (Breaker etc.) Becomes Slower.
1 4
EX1400189

by handly? spool.
4 YES
Is bypass-cut solenoid valve NO Repair or replace the bypass-cut

normal? solenoid valve.

8-3-15
Machine Cannot Travel Straight During Combined Operation of Travel and Front.
2 5
Travel Straight Valve EX1400190
Is EPPRV for travel straight valve NO Replace the EPPRV for travel
normal? straight valve.
2 YES
Is travel straight valve spool NO Repair or replace the travel

move smoothly by handly or straight valve.
spring breakaway?
Machine Cannot Travel Straight During Travel Operation.

3
EX1400191
NO Replace the PPRV in main

Is PPRV in main pump normal?
pump.

8-3-16
Considerable Flow at Pump with Neutral Lever Position.
1 2 5
EX1400181
NO
Is PPRV in main pump normal? Replace the PPRV in main pump.
2 YES

by handy? spool in control valve.
5 YES
NO Repair or replace the bypass-cut

Is bypass-cut solenoid valve normal?
solenoid valve.

8-3-17
TROUBLESHOOTING – SWING GEARBOX
Swing motor fails to operate and:
Three pressure tests at Swing relief valve defective. Brake Adjust pressure to recommended range
motor, brake or makeup release valve defective. Motor in affected valve.
valve show low reading(s). makeup valve defective.
OR
Disassemble and clean valve assembly.
Replace all valve components that show
damage.
All three pressure checks Exchange front and rear pump inlet If swing and left travel are restored but
are OK but left travel also and outlet hoses to test pump right travel stops working, replace or
fails to run. function. repair P1 pump.
All three pressure tests are Brake assembly or motor friction Check for binding. Disassemble and
OK, but machine fails to plate failing to release. repair.
swing at all. Pilot (control) pressure low or swing Disassemble / Repair pilot pressure
control valve stuck. swing spool (305) and / or swing control
valve.
Swing motor defective. Test motor drain rate. Replace / Repair
motor.
Gear train defective. Refer to "Swing Gear Troubleshooting"
procedure.
Swing functions but only at Causes listed above could also Check above list; then replace oil, test
reduced rpm. produce dragging swing, OR hot or motor drain rate and check for "03"
wrong oil OR worn-out parts. reading (e-EPOS self-test).
Left travel speed is also Low output at P1 pump or external Clean and repair piping or repair or
reduced. pilot piping leaks/is clogged. replace pump P1.
Swing control movement is Inlet / outlet piping reversed. Reset controls or reverse piping.
reversed.
Machine swings but Swing control valve spool not Replace return spring; clean/ repair
continues moving past centered. valve piston and spool.
stopping point. Pilot pressure may be outside Disassemble, clean or replace pilot relief
range. valve or pilot valve.
Swing relief valve may be faulty. Repair/Replace swing relief valve.
Swing movement is in one Check to see that pilot pressure is If pilot pressure is unequal, clean or
direction only. the same right and left. repair piping or repair/replace valve.
Swing control valve spool may be Repair/Replace the swing control valve.
stuck.
Swing relief valve may be faulty. Repair/Replace the swing relief valve.
No rotation and:
Pressure at swing motor Swing brake not releasing. Check brake engagement and
inlet increases. disengagement; check release pressure.
Internal damage to gearbox Replace broken gears and drivetrain
drivetrain. assemblies.
Overload. Reduce load weight.

8-3-18
Pressure at swing motor Swing motor driveshaft damage. Replace swing motor.
inlet shows no increase, Internal damage to gearbox Repair/Replace broken or faulty
and the swing motor is drivetrain. assemblies.
making irregular noises.
Pressure at swing motor Hydraulic pump or valve problem. Troubleshoot hydraulic system.
inlet shown no increase, but
without irregular noises
from the swing motor.
Oil Leakage:
From driveshaft or from Oil seal damaged. Assembly Replace oil seal Disassemble and check
bolted connections or other compound (joint sealer) old and not mating surfaces. Reapply Loctite; torque
assembled surfaces. sealing, bolt not tight or flange bolts to specifications.
warped.
Excess heat:
Gearbox casing becomes Low oil level. Replace oil; refill to specified level.
excessively hot, with or Bearings or gears worn, but not Repair or replace gearbox.
without irregular noise (s), completely inoperative.
during operation.
TROUBLESHOOTING – HYDRAULIC PROBLEMS

Attachment cylinders, swing Main pump(s) malfunction. Repair or replace.
and travel motors are all Low oil level in hydraulic system. Refill.
inoperable. Loud noises are
Main pump inlet (oil supply) piping Repair or replace.
heard from main pump
or hose damaged.
assembly.
Attachment cylinders, swing Pilot pump malfunction. Repair or replace.
and travel motors are all Pilot cutoff solenoid stuck. Repair or replace.
inoperable. No usual or loud
Pilot cutoff switch faulty. Repair or replace.
noises can be heard.
Engine/pump flex coupling Replace flex coupling.
damaged.
Attachment cylinders, swing PPRV failed. Repair or replace.
and travel motors are all Bypass-cut spool stuck open. Clean/replace.
operable. But speed is
Bypass-cut solenoid valve failed. Repair or replace.
lower and power lacks.
Travel left, bucket are Idle pump ED regulator failed. Repair or replace.
inoperable. But boom up Idle pump EPPR valve failed. Replace.
and arm are slower than
Wrong harness connection with idle Repair or replace.
normal operation.
pump EPPR valve.
Travel right, swing are Drive pump ED regulator failed. Repair or replace.
inoperable. But boom up Drive pump EPPR valve failed. Replace.
and arm are slower than
Wrong harness connection with Repair or replace.
normal operation.
drive pump EPPR valve.

8-3-19
Attachment cylinders, swing Lever pressure sensor failed. Replace.
and travel motors are all (Safety mode)
operable. But loud noises Wrong harness connection with Repair or replace.
can be heard at neutral lever pressure sensor. (Safety
lever position. mode)
Pump angle sensor failed. Replace.
(Safety mode)
Wrong harness connection with Repair or replace.
pump angle sensor. (Safety mode)
Arm-in is unstable Arm Brake valve failed. Replace.
Travel right motor are Travel right motor failed. Repair or replace.
inoperable or operable in Shuttle valve failed in pilot pressure Repair or replace.
one direction only. sensor block.
Travel left motor are Travel left motor failed. Repair or replace.
inoperable or operable in Shuttle valve failed in pilot pressure Repair or replace.
one direction only. sensor block.
Swing motor are inoperable Shuttle valve failed in pilot pressure Repair or replace.
or operable in one direction sensor block.
only.
Arm is operable but slower Shuttle valve failed in pilot pressure Repair or replace.
in one direction. sensor block.
2 pump option (breaker Bypass-cut spool stuck open. Clean/replace.
etc.) becomes slower. Bypass-cut solenoid valve failed. Repair or replace.
Machine cannot travel EPPRV for Travel straight valve Replace.
straight during combined failed.
operation of Travel and Travel straight valve spool stuck or Repair or replace.
Front spring breakaway.
Machine cannot travel PPRV failed. Repair or replace.
straight during travel
operation.
Sluggish performance of all Main pump(s) damaged or worn. Repair or replace.
hydraulic functions - Main relief valve pressure off. Readjust pressure.
attachment, swing and
Low oil level in hydraulic system. Refill.
travel.
Hydraulic reservoir intake strainer Clean.
clogged.
Pump inlet (supply side) piping or Tighten connection.
hose allowing air into hydraulic
system.
Pump PRV failed. Repair or replace.
Considerable flow at pump Pump PRV failed. Repair or replace.
with neutral lever position. Bypass-cut spool stuck open. Clean/replace.
Bypass-cut solenoid valve failed. Repair or replace.

8-3-20
Oil temperature abnormally Oil cooler clogged or air circulation Clean.
high. to cooler blocked.
Cooling fan belt tension too loose. Readjust belt tension.
Relief valve set too low. Readjust valve.
Relief valve in constant use. Reduce or slow workload or cycling rate.
Hydraulic oil severely neglected or Replace oil.
incorrect for application.
One circuit in hydraulic Overload relief valve malfunction. Readjust or replace.
system inoperable. Oil leak at makeup valve. Clean, repair.
Control valve spool damaged. Repair or replace.
Dirt in control valve spool. Clean or replace.
Actuator (joystick, foot pedal) Repair or replace.
damaged or worn.
Internal seal leak in cylinder. Repair or replace.
Cylinder rod damaged. Repair or replace.
Pilot valve or piping malfunction. Repair or replace.
Mechanical linkage frozen, loose or Repair or replace.
damaged.
Lever pressure sensor failed Replace.
(no safety mode)
Travel motors inoperable. Center joint damaged. Repair or replace.
Parking brake not releasing. Repair or replace.
Travel lever pressure sensor failed. Replace.
Travel motor worn or damaged. Repair or replace.
Travel motor pilot piping damaged. Repair or replace.
Travel motors operate very Track tension poorly adjusted Low Readjust tension Refill.
slowly. oil in idlers or rollers.
Travel brake dragging. Repair.
PPRV failed. Repair or replace.
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.
Swing lever pressure sensor failed. Replace.
Pilot piping damaged. Repair or replace.
Swing motor operates Swing gear, bearing or mounting Repair or replace.
unevenly. loose or worn.
Lubricant worn away, inadequate. Grease.
Swing relief valve may be faulty. Repair/Replace the swing relief valve.

8-3-21
TROUBLESHOOTING – MAIN PUMP
Unusual noises. Drive speed too high. Repair.
Insufficient suction conditions, e.g. Completely air bleed the axial piston unit,
air in the suction line, viscosity of fill the suction line with hydraulic fluid.
the hydraulic fluid too high, low oil Remove contaminants from the suction
level, contaminants in the suction line.
line.
Improper fixing of the axial piston Repair. Observe tightening torques.
unit.
Improper fixing of the attachment Repair.
parts, e.g. coupling and hydraulic
lines.
Malfunction of the pressure relief Bleeding the axial piston unit. Check
valve of the axial piston unit viscosity of the hydraulic fluid. Replace.
(pressure cutoff).
Mechanical damage to the axial Exchange axial piston unit.
piston unit (e.g. bearing damage).
No or insufficient flow. Faulty mechanical drive (e.g. Repair or Replace.
defective coupling).
Drive speed too low. Repair.
line.
Hydraulic fluid not in optimum Replace.
viscosity range.
External control of the control Check external control, Repair or
device defective. Replace.
pressure. Repair or Replace.
Malfunction of the control device or Repair or Replace.
Wear of axial piston unit. Exchange axial piston unit.

8-3-22
No or insufficient pressure. Faulty mechanical drive (e.g. Repair or Replace.
defective coupling).
Drive power too low. Repair.
line.
Hydraulic fluid not in optimum Use suitable hydraulic fluid (machine or
viscosity range. system manufacturer).
External control of the control Check external control.
device defective.
Insufficient pilot pressure or control Check pilot pressure or control pressure.
pressure.
Malfunction of the control device or Repair or Replace.
Wear of axial piston unit. Exchange axial piston unit.
Pressure/flow fluctuations. Axial piston unit and/or control unit Completely air bleed axial piston unit.
not or insufficiently air bled. The pressure reducing valve must be
exchanged.
line.
Excessive hydraulic fluid Excessive inlet temperature at the Inspect system, e.g. malfunction of the
and case temperature. axial piston unit. cooler, insufficient hydraulic fluid in the
reservoir.
Malfunction of the pressure control Repair or Replace
valves (e.g. pressure cutoff,
pressure controller).
Wear of axial piston unit. Exchange axial piston unit
Instability/vibrations. Axial piston unit and/or control unit Completely air bleed axial piston unit.
not or insufficiently air bled. The pressure reducing valve must be
exchanged.
Malfunction of the control devices Repair or replace.
or the controller.

8-3-23
TROUBLESHOOTING – CONTROL VALVE
Check control valve problems only after other hydraulic circuit
operational tests have been made. Refer to the
"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.

Pressure fluid escaping Control block housing leaking at the Check seals, replace if necessary, check
from the mobile control piston. tightening torques.
block. Plug screws leaking. Tighten plug screws, renew sealing rings
if necessary. For O-ring seals: Do not re-
tighten the plug screw, replace the seals
and tighten the plug screw with the
specified torque.
Control block housing leaking. Remove the control block and replace it
with a new one.
Connections leading to the actuator Check seals, renew if necessary. Check
leaking (Screw sockets, screw tightening torques.
connections).
Pressure fluid leaking Seals in flange surface damaged Replace the seals.
between the mobile control Contamination entry upon Disassemble the control block, clean the
block modules. assembly of the control block flange surface.
Mobile control block housing Renew damaged mobile control block
leaking at flange surface module.
Tightening torque of tie rods too low Check the tightening torques.
Hydraulic function Air in the pressure fluid Vent hydraulic system.
disturbed.
Spool cannot be Tie rods have been tightened with Loosen the nuts of the tie rods and
mechanically displaced. too great a tightening torque. tighten at the specified torque.
Oil temperature too high and/or too Check cooler function, oil supply and
great a temperature difference pump pressure in neutral position. Avoid
between the pressure fluid and the temperature shock.
mobile control block, causing
blocking due to dissimilar heat
expansion of spool and mobile
control block.
Contamination or foreign particles Visually inspect the connectors to the
introduced during the assembly of actuator, remove foreign particles with a
the connections leading to the magnet or tweezers. In case of jammed
actuator are jamming the spool. foreign particles, replace the control
block module with a new one.
Spool returns too slowly or Spool jamming. See "Spool cannot be mechanically
not at all. displaced" above in the event of a
malfunction.

8-3-24
Main relief valve. Particulate contamination. Disassemble, clean main poppet.
Broken or damaged spring. Replace.
Adjusting screw loose. Readjust.
Main poppet sticking. Repair/replace.
Components worn out, past wear Replace.
limits.
Cylinder goes down in spool Excessive clearance between Replace spool or casing.
neutral. casing and spool.
Spool jamming. See "Spool cannot be mechanically
displaced" above.
Main relief or port relief not See "Main relief valve" above.
operating properly.
Cylinder drops before start Rod check valve damaged or Clean/replace.
at boom up operation. clogged.
Poppet sticking. Clean/replace.
Slow operation or response. Excessive clearance between spool Replace spool or casing.
or casing.
Spool jamming. See "Spool cannot be mechanically
displaced" above.
Main or port relief valve damaged. See "Main relief valve" above.
Boom and arm cylinders do Summation spool sticking. See "Spool cannot be mechanically
not perform normally in displaced" above.
combined operation. Broken or deformed spring. Replace.
Clogged spool passage. Clean/replace, replace filter.

8-3-25
TROUBLESHOOTING – TRAVEL CONTROL VALVE
Secondary pressure does Low primary pressure. Check primary pressure.
not increase. Broken spring. Replace spring.
Spool sticking. Clean, repair or replace.
Excess spool to casing clearance. Replace spool casing.
Worn or loose universal joint Repair or replace U-joint subassembly.
(handle) subassembly.
Secondary pressure too Dirt, other interference between Clean, repair or replace.
high. valve parts.
Return line pressure too high. Redirect return line.
Secondary pressure does Dirt, other interference between Clean, repair or replace.
not hold steady. valve parts, or worn spool sticking
intermittently.
Interference or binding on spool Clean, repair or replace.
return spring.
Interference, restriction or unsteady Repair or reroute tank return line.
pressure in tank return line.
Air bubbles in piping (temporary) or Vent air, or repair leak.
air leak.
NOTE: Look for evidence of leaking oil.
TROUBLESHOOTING – JOYSTICK CONTROL VALVE

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

8-3-26
1Electrical System
Electrical
System
Edition 1
DX340LC-5/DX350LC-5 Electrical System

9-1-1
MEMO
Electrical System DX340LC-5/DX350LC-5

9-1-2
Table of Contents
Electrical System
Introduction .....................................................9-1-7
Electrical Supply System ................................9-1-8
Engine Starting Circuit ..................................9-1-10
Start Operation ........................................................ 9-1-10
After Start ................................................................ 9-1-12
Engine Stop ..................................................9-1-13
Charging System ..........................................9-1-15
Monitoring System ........................................9-1-16
Instrument Panel ..................................................... 9-1-17
Functional Check..................................................... 9-1-17
Monitoring System Schematic................................. 9-1-18
Operation ......................................................9-1-20
Instruments.............................................................. 9-1-20
Warning and Indicator Lights ........................9-1-22
Indication of Warning Lights .................................... 9-1-22
Indication of Multifunction Gauge ............................ 9-1-26
Initial Operation ............................................9-1-28
Graphic Information Area Display.................9-1-29
Overview ................................................................. 9-1-29
Main Menus for the Graphic Display Area............... 9-1-29
Menu Selector Buttons ............................................ 9-1-29
User Menu ....................................................9-1-30
User Menu - Access and Escape Methods ............. 9-1-30
Special Menu ................................................9-1-62
Entering/Accessing and Exiting/Escaping Menus ... 9-1-62
Special Menu Selections ......................................... 9-1-63
Electronic Hydraulic Control System (EPOS)....9-1-92
Control System Schematic ...................................... 9-1-92
Power Plus Mode Control .............................9-1-94

9-1-3
Operation................................................................. 9-1-96
Power Mode Control .....................................9-1-98
Smart Power Control (SPC)........................9-1-100
Operation............................................................... 9-1-100
Engine Control System ...............................9-1-103
Engine Control Dial.....................................9-1-104
Engine Control ............................................9-1-106
Automatic Deceleration Control
(Auto Idle Control) ......................................9-1-108
Engine Overheat Protection System ..........9-1-110
Power Boost Mode .....................................9-1-113
Operation............................................................... 9-1-113
Power Boost Control ............................................. 9-1-114
Automatic Travel Speed Control.................9-1-116
Automatic Travel Speed Control ........................... 9-1-118
Water in Fuel Warning System ...................9-1-119
Operation............................................................... 9-1-119
Self-diagnostic Function .............................9-1-120
EPOS Controller.................................................... 9-1-120
Air Conditioner System ...............................9-1-122
Outline ................................................................... 9-1-122
Internal and External Filters .................................. 9-1-123
Air-Conditioning System Layout ............................ 9-1-124
Air Conditioner/Heater Circuit Diagram ................. 9-1-125
Air Conditioner/Heater Unit ................................... 9-1-126
Ambient Air Temperature Sensor.......................... 9-1-131
Sun Sensor............................................................ 9-1-132
Control Panel......................................................... 9-1-132
Receiver Dryer ...................................................... 9-1-140
Refrigerant System Repairs .......................9-1-143
Refrigerant Safe Handling Procedures.................. 9-1-143

9-1-4
Repair and Replacement Procedure ..................... 9-1-144
Refrigerant Recovery ............................................ 9-1-146
Vacuuming Refrigerant System............................. 9-1-146
Leakage Check ..................................................... 9-1-148
Refrigerant Charging ............................................. 9-1-148
Inspecting System For Leakage............................ 9-1-150
Wiper System .............................................9-1-151
Wiper Circuit.......................................................... 9-1-151
Wiper Operation .................................................... 9-1-152
Lighting System ..........................................9-1-154
Lighting System Circuit Diagram ........................... 9-1-154
Kind of Light .......................................................... 9-1-155
Operation............................................................... 9-1-155
Overload Warning Device...........................9-1-156
Overload Warning Device Circuit Diagram............ 9-1-156
Audio Controller ..........................................9-1-157
Audio Controller Circuit Diagram........................... 9-1-157

9-1-5
9-1-6
SAFETY INSTRUCTIONS
WARNING
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 electrical
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.
Electrical Wire Color
Symbol Color
W White
G Green
Or Orange
B Black
L Blue
Lg Light green
R Red
Gr Gray
P Pink
Y Yellow
Br Brown
V Violet
NOTE: RW: Red wire with White stripe

R - Base Color, W - Stripe Color
NOTE: 0.85G: Nominal sectional area of wire core less
insulator = 0.85 mm2

9-1-7
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 machine
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. Engine controller. (ECU + SCU)
5. Terminal "2" of fuel auto shutoff controller.
6. Terminal "6" of wiper motor.
7. Terminal "13" of wiper controller.
8. Terminal "CN7-5, CN7-6" of instrument panel controller.
9. Terminal "CN9-6" of air conditioner panel.
10. Cabin light
11. Terminal "11" of diesel heater timer.
12. Terminal "12" of diesel heater.
13. Terminal "1" of TMS controller.
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).

9-1-8
STARTER SWITCH CONNECTION
PST TML B BR R1 R2 C ACC

OFF C
ON
B
START
ACC C
B 5 A
R2 R1
BR
60B
10
8
6
3
4
B
A
W L 15 S DF
B+
BR
2.2 uF
E
8 2
1 2
7
- + - +
FIELD
12V 200AH 12V 200AH
REGULATOR 1
9
EX1301079
Figure 1 Electric Power Circuit Diagram
Reference Reference
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 7 Alternator
3 Fusible Link 8 Diode
4 Circuit Breaker 9 Engine Controller
5 Starter Switch 10 Starter

9-1-9
ENGINE STARTING CIRCUIT
Start Operation
When the starter switch is turned to "START" position, the start
signal is transferred to "1-69" of EPOS(11). Then, EPOS (11)
transfers the start signal to ECU (9) using CAN communication
and ECU (9) drives "starter (10)" when it receives the start
signal. The start signal is transferred in the following order;
battery (1) -> fuse blink fusible link (3) -> fuse box (6) -> terminal
"B" of starter switch (5) -> terminal "C" of starter switch (5) ->
terminal "2" of emergency starter switch (12) -> terminal "3" of
emergency starter switch (12) -> terminal "1-58" of EPOS (11).
Thereafter, the signal is further transferred as follows: CAN
communication line of EPOS (11) -> CAN communication line of
ECU (9) -> terminal "B-1" of ECU (9)" -> terminal "C" of starter
(10).
When the start signal is transferred to terminal "C" of starter
(10), the pinion gear of the starter (10) is pushed forward,
making connection to the flywheel gear, and, as a result, the
internal contacts of starter (10) are connected. Thereafter, the
current flows as follows: battery (1) -> terminal "A" of battery
relay (2) -> terminal "B" of battery relay (2) -> terminal "B" of
starter (10).
The starter motor is rotated and the engine is started.
If the instrument panel has the password function activated, the
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.
If the security system is locked, EPOS (11) cannot
transfer the start signal to ECU (9). This prevents the
starter (10) from functioning. 3 4 5 6 7 8 9 : ; <
The default password is "1111". Enter Owner Password
For details, See “Password Setting” on page -52.

NOTE: If EPOS controller (11) goes wrong and doesn't send EX1301416
the "START" signal at engine controller, you can use Figure 2
emergency starter switch to do an emergency start.
WARNING
When you use emergency starting, machine cannot use
starter over run protection.

9-1-10

87a
OFF 30
87
PREHEAT
86 85
ON
C
START 11
13
B
ACC
C
B 2 A
R2 R1 3
1
BR
5 12 10
8
6
3
4
B
A
W L 15 S DF
B+
BR
2.2 uF
E
8 2
1 2
- + - +
FIELD
12V 200AH 12V 200AH
1
REGULATOR
7 9
EX1301080
Figure 3 Starter Circuit (1) - While Starting
Reference Reference
Number Number
1 Battery 8 Diode
2 Battery Relay 9 Engine Controller
3 Fusible Link 10 Starter
4 Circuit Breaker 11 EPOS Controller
5 Starter Switch 12 Emergency Starter Switch
6 Fuse Box 13 Emergency Starting Relay
7 Alternator

9-1-11
After Start
The EPOS controller (11) monitors the engine rpm.
Once the engine has been started, the belt driven alternator (7)
generates a current.
After the engine start, engine running signal is outputted from
terminal "C4001-8" of ECU (9) and inputted to terminal "BR" of
battery relay (2), which makes it possible for the contact points
"A" and "B" of the battery relay (2) to make contact.
Operation of the Start Circuit (2) - Immediately After Start

87a
OFF 30
87
PREHEAT
86 85
ON
C
START 11
13
B
ACC
C
B 2 A
R2 R1 3
1
BR
5 12 10
8
6
3
4
B
A
W L 15 S DF
B+
BR
2.2 uF
E
8 2
1 2
- + - +
FIELD
12V 200AH 12V 200AH
1
REGULATOR
7 9
EX1301080
Figure 4 Operation of Start Circuit (2) - Immediately After Start
Reference Reference
Number Number
1 Battery 8 Diode
2 Battery Relay 9 Engine Controller
3 Fusible Link 10 Starter
4 Circuit Breaker 11 EPOS Controller
5 Starter Switch 12 Emergency Starter Switch
6 Fuse Box 13 Emergency Starting Relay
7 Alternator

9-1-12
ENGINE STOP
When starter switch (5) is turned "ON" the engine controller (9)
is activated. The engine controller monitors and controls the
engine including the injector solenoid (15). It controls the fuel
deliver rate and the injection timing for each cylinder.
NOTE: There is an individual injector solenoid (15) for each
of the five cylinders. Only one solenoid is shown in
Figure 6.
When starter switch (5) is turned "OFF", the engine controller
stops suppling power to the injector solenoid (15). This stops
fuel from being injected into the engine cylinder, thus stopping
the engine.
If the engine cannot be shut down using the starter switch (5), an
emergency stop switch (14) is provided to stop engine. To
activate the emergency stop switch, move it to "I"
(EMERGENCY STOP) position.
I
The emergency stop switch (14) is in its "O" (OFF) position O
during normal operation. The switch must be moved and held in
the "I" (EMERGENCY STOP) position until engine stops.
EX1300828
Figure 5 Engine Emergency Stop Switch

9-1-13

87a
OFF 30
87
PREHEAT
86 85
ON
C
START 11
13
B
ACC C
B 2
R2 R1
A
1 3
BR
5 12 10
8
6
3
4
B
A
W L 15 S DF
B+
3 1 BR
2.2 uF
E
14 8
2 2
1 2
- + - +
FIELD
12V 200AH 12V 200AH
1
REGULATOR
7 15
9 EX1301110
Figure 6 Engine Stop Circuit
Reference Reference
Number Number
1 Battery 9 Engine Controller
2 Battery Relay 10 Starter
3 Fusible Link 11 EPOS Controller
4 Circuit Breaker 12 Emergency Starter Switch
5 Starter Switch 13 Emergency Starting Relay
6 Fuse Box 14 Emergency Stop Switch
7 Alternator 15 Injector Solenoid
8 Diode

9-1-14
CHARGING SYSTEM
When the engine is started from this condition the alternator (7)
starts charging. The current flows from the "B (B+)" terminal of
alternator (7) the "B" terminal of starter (10) →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 engine controller (9) →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 electrical system.

OFF C
ON
B
START
ACC C
B 5 A
R2 R1
BR
60B
10
8
6
3
4
B
A
W L 15 S DF
B+
BR
2.2 uF
E
8 2
1 2
7
- + - +
FIELD
12V 200AH 12V 200AH
REGULATOR 1
9
EX1301079
Figure 7 Charging Circuit
Reference Reference
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 7 Alternator
3 Fusible Link 8 Diode
4 Circuit Breaker 9 Engine Controller
5 Starter Switch 10 Starter

9-1-15
MONITORING SYSTEM
1 2
PM 5 7
H H 8 4
E F
C C
E F
9
TRIP
3
/h rpm ECO
Min Max
SPC
S USB
10
6
11
12
14 13 EX1300989
Figure 8
Reference Reference
Number Number
1 Instrument Panel Pump Discharge Pressure
9
2 Battery Sensor
3 Light Switch Hydraulic Oil Temperature
10
Sensor
4 Return Filter Switch
11 Fuel Sensor
5 Pilot Filter Switch
12 Air Cleaner Indicator
6 EPOS Controller
13 Engine Controller
7 Alternator
14 Jog Switch Control Panel
8 Warning Buzzer
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.

9-1-16
Instrument Panel
10
9 8
AM 12
1
H H
3 4
E F
2 C E F C
TRIP 5
rpm ECO
7 /h Min Max
s
SPC
USB 13
15 14 16
6
11
EX1300990
Figure 9
Reference Reference
Number Number
1 Fuel Gauge 9 Display Warning Symbols
2 DEF (AdBlue) Level Gauge 10 Warning Light
Engine Coolant Temperature 11 Function Buttons
3
Gauge 12 Mode Selector Buttons
Hydraulic Oil Temperature 13 Selector Function Display
4
Gauge
14 Jog Switch
Multifunction Gauge and Graphic
5 Camera Mode Selector/
Information Area 15
ESC Button
6 ECO Gauge
16 Multimedia Selector Button
7 Trip Rate
8 Digital Clock
Functional Check
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 three (3)
seconds.
During this functional check, a LOGO will appear on the
multifunction gauge in the graphic information area (3 and 4,
Figure 9).

9-1-17
Monitoring System Schematic
1 19
3
7-2
22
1
2
3 7-8 17
4 7-18
4
1
C B 16 B
7-5
2
7-6 BR
3 7-9 + 2
4 7-19
14 E
6-1 -
7-3
22 1 7-7 7-4
1-58 A
2 7-17
7-1
3 7-10
4 7-20 18
+ 15
1-19
5 SIG
1-37
-
+
SIG 1-18
6 1-36
-
6-12 1-77 2-92

6-13 1-78
10
CAN A
1-59 1-46
11
1-61 GND
1-64
21 1-62 RxD 12
1-81 TxD
1-14
1
2
1-32 8
3
C4001-6
C4001-7
4 20 1-15
5 1-33 7
6
14
1-2
13 R(I)
+
5-10
23 SIG
5-20
-
+
+
5-4 SIG
24 SIG 5-9
5-14 29
5-19 -
-
+ +
4-1 5-3
25 SIG
4-7 5-13
SIG
30
- -
+ +
4-2 5-2 SIG
26 SIG
4-8 5-12 31
- -
+ +
4-3 5-1 SIG
27 SIG
4-9 5-11 32
- -
+ +
4-4 4-5 SIG
28 SIG
4-10 4-11 33
- -
EX1400238
Figure 10

9-1-18
Reference Reference
Number Number
1 Instrument Panel 18 Fusible Link
2 Pilot Buzzer 19 Fuse Box
3 Light Switch 20 Check Connector
4 Starter Switch 21 Engine Controller
5 Front Pump Pressure Sensor 22 Rearview Camera
6 Rear Pump Pressure Sensor 23 Front Pump Angle Sensor
7 Hydraulic Oil Temperature Sensor 24 Rear Pump Angle Sensor
8 Fuel Sensor 25 Arm In Pilot Pressure Sensor
9 Pedal Pressure Switch (Optional) 26 Arm Out Pilot Pressure Sensor
10 Air Cleaner Indicator 27 Travel LH Pilot Pressure Sensor
11 Pilot Filter Switch 28 Travel RH Pilot Pressure Sensor
12 Return Filter Switch 29 Boom Up Pilot Pressure Sensor
13 Alternator 30 Bucket Crowd Pilot Pressure Sensor
14 EPOS Controller 31 Boom Down Pilot Pressure Sensor
15 Battery 32 Bucket Dump Pilot Pressure Sensor
16 Battery Relay 33 Swing Pilot Pressure Sensor
17 Circuit Breaker

9-1-19
OPERATION
Instruments
Sensor Specification
Function Display
Input Terminal Input Specification
17% (46°C)
97% 100% 33% (59°C)
81% 50% (72°C)

H
65% 65% (93°C)
Coolant ECU-CAN
81% (101°C)
Temperature 50% Communication
95% (110°C) (Tropical Zone Mode)
33% C 97 % (112°C)
17% EX1300991 98 % (113°C) (Warning Start)
100 % (110°C)
White
1/10 LCD (Red Zone) Blinking →

CN1-14 over 5K ohms
Fuel Level
1/10 CN1-32
Red Full
FULL →under 525 ohms
E F
EX1301123
17% (46°C)
100% 97% 33% (59°C)
81% 50% (72°C)
H
65% 65% (85°C)
Hydraulic Oil CN1-15
81% (90°C)
Temperature 50% CN1-33
95% (97°C) (Tropical Zone Mode)
C 33% 97% (98°C)
17%
EX1300992 98% (99°C) (Warning Start)
100% (101°C)

9-1-20
Sensor Specification
Function Display
Input Terminal Input Specification
5% →Min.
DEF (AdBlue) ECU-CAN
20% →Red Zone
Level Gauge E F Communication
100% →Max.
EX1300993
ECU-CAN
Tachometer rpm Communication
EX1301378
ECO symbol: The instant workload

- Green: Normal operation
- Amber: Idling operation
Green/Amber/Red/Gray
- Red: Heavy loading operation
EPOS-CAN - Gray: ECO symbol off
ECO Gauge ECO
ECO Communication
Min Max ECO gauge: The average fuel
efficiency for 1 minute
Green Amber Red
- Green: Fuel efficiency is good
EX1300994
- Amber: Fuel efficiency is normal
- Red: Fuel efficiency is not good
Amount of fuel use (ℓ)

TRIP
EPOS-CAN Operating hours (hr)
Trip Meter
Communication Average fuel efficiency (ℓ/hr)
/h
Daily average fuel efficiency (ℓ/hr)
EX1300995

9-1-21
WARNING AND INDICATOR
LIGHTS
Indication of Warning Lights

Input
Description Symbol Operation Remarks
Terminal
This symbol appears
in case of no charge
[voltage of engine
controller engine
Normally, it lights
running terminal
when starting engine
Charge CN1-2 (C4001-8) is below or
and is out after engine
overcharge] [voltage
starts.
of engine controller
HAOA610L engine running
terminal (C4001-8) is
above 33 (V)].
After starting engine,

This symbol appears
ECU-CAN if engine oil pressure
Engine Oil when engine oil
Communic- is insufficient after 8
Pressure pressure is below the
ation seconds, a warning
reference.
buzzer will sound.
HAOA620L
ECU-CAN This symbol appears

Engine
CHECK Communic- in case of fault in
Check
ation engine system.
FG000045
This symbol appears

ECU-CAN when engine coolant
Coolant
Communic- temperature sensor
Temperature
ation resistant is above
about 112°C.
HAOD350L
EPOS-CAN Preheating period

Communic- depends on coolant
This symbol appears temperature.
Preheating ation
during preheating.
(CN2-96 20 sec preheating at
CN2-106) 5°C.
HAOA639L

9-1-22
Input
Terminal
The WIF sensor

voltage is under
Water CN1-21
1.5 ±0.5 V, because
Separator CN1-39
moisture is detected
in fuel.
FG013744
Europe:
20%: Light on
0%: Flashes every
2 seconds
ECU-CAN
DEF America:
Communic-
(AdBlue) Low 20%: Light on
ation
10%: Flashes every
2 seconds
FG019175
0%: Flashes every
0.5 second
Alarm notifying
abnormal operation
at the post
ECU-CAN processing side of
SCR Fault Communic- the SCR system.
ation Check the ECU
malfunction from the
FG019176 current malfunction
information.
ECU-CAN This symbol appears

Engine Stop STOP Communic- in case of fault in the
ation engine system.
FG019003
The warning buzzer

This symbol appears sounds
Quick
CN1-72 when quick coupler is simultaneously when
Coupler
unlocked. quick coupler is
unlocked.
EX1301541
EPOS-CAN This symbol appears

Vehicle
Communic- when a breakdown
Check
ation occurs to the vehicle.
EX1301542

9-1-23
Input
Terminal
This symbol appears

EPOS-CAN
Vehicle when there is an
Communic-
STOP irregularity in the
ation
vehicle.
EX1301543
When hydraulic oil

Hydraulic Oil CN1-15
temperature is above
Temperature CN1-33
about 98°C.
FG000056
Fuel CN1-14 When fuel is almost

Exhausted CN1-32 exhausted.
FG000057
When air cleaner is

Air Cleaner CN2-92
clogged.
FG000053
When return filter

pressure is above
Return Filter CN1-64
about 1.50 bar
(21 psi)
FG000054
When pilot filter

Pilot Filter CN1-46 pressure is above
about 1 bar (14 psi)
FG000055

9-1-24
Input
Terminal
Warning buzzer also

It flashes in case of
starts when boom
2.68 V and above and
pressure sensor
Overload CN1-20 lights continuously in
output voltage is
Warning CN1-38 case of 2.77 V and
about 2.68 V while
above (and warning
overload warning
buzzer also starts).
FG000253 switch is "ON".
This symbol appears

Work Light CN1-74 when work light turns
"ON" (24 V applied).
HB4O2003
01 Emergency operation
Pump Angle This symbol appears
5-9, 5-10, mode select pop up
Sensor in case of failure in
5-19, 5-20 appears at the same
Failure
SENSOR pump angle sensor.
time.
FG020681
4-1, 4-2,
4-3, 4-4,
Pilot 02 4-5, 4-7,
Emergency operation
4-8, 4-9, This symbol appears
Pressure mode select pop up
4-10, 4-11, in case of failure in
Sensor appears at the same
Failure SENSOR 5-1, 5-2,
5-3, 5-4,
pilot pressure sensor.
time.
FG020682 5-11, 5-12,
5-13, 5-14,
2-114, This symbol appears

Pump EPPR
2-119, in case of failure in
V/V Failure
EPPR 3-8, 3-16 pump EPPR V/V.
FG020683

9-1-25
Indication of Multifunction Gauge
Input
Terminal
Low-speed
Basic run mode
Travel
EX1301575
It only operates when

the auto idle pressure
This symbol appears
is 10.5 bar or more
High-speed when high-speed run
CN1-75 during running and
Travel mode switch is
the high-speed run
operated.
solenoid valve is
EX1301577 operated.
When the auto idle

pressure is 10.5 bar
or more, dial voltage
This symbol appears
is less than 2.5 V and
Automatic CN1-56 when the automatic
pump pressure is
Travel CN1-75 run mode switch is
153.7 bar during
operated.
running, the high-
EX1301577 speed run solenoid
valve is operated.
This symbol appears

Intelligent
when the Intelligent
Floating CN1-48
floating boom switch
Boom
is operated.
EX1301578
If the Voltage step-up

This symbol appears
switch is operated or
when the voltage
Voltage step- the lift mode is
CN1-76 step-up switch is
up selected, the voltage
operated or the lift
step-up solenoid
mode is selected.
valve is operated.
FG000554
Jog Switch
This symbol appears
Excavation CAN
when the excavation
mode Communic-
mode is selected.
ation
EX1301579

9-1-26
Input
Terminal
Jog Switch
This symbol appears
CAN
Lift Mode when the lift mode is
LIFT Communic-
ation
selected.
EX1301580
Jog Switch
This symbol appears
Breaker CAN
when the breaker
Mode Communic-
mode is selected.
ation
EX1301581
Jog Switch
Breaker This symbol appears It appears only for the
CAN
Mode when the breaker vehicle with PE3C
Communic-
(Option) mode is selected. option.
ation
EX1301582
Jog Switch
This symbol appears
Two-Way CAN
when the two-way
Mode Communic-
mode is selected.
ation
EX1301583
Jog Switch
Two-Way This symbol appears It appears only for the
CAN
Mode when the two-way vehicle with PE3C
Communic-
(Option) mode is selected. option.
ation
EX1301584
This symbol appears It appears only for the

ISO Mode CN2-90 when the ISO mode vehicle with pattern
is selected. change option.
EX1301585

9-1-27
Input
Terminal
This symbol appears It appears only for the

BHL Mode CN2-83 when BHL mode is vehicle with pattern
selected. change option.
EX1301586
INITIAL OPERATION
Item Input (Terminal) Output (Operation and Initial Setting Mode)
• Warning buzzer is activated and turned "OFF" after
about 3 seconds.
• Power mode: When Fuel Saving Mode is disabled,
the power mode is the previous mode. When Fuel
When "CN7-2" is applied Saving Mode is enable, the power mode is standard
Initial
battery voltage (starter switch) mode or economy mode.
Operation
shifts from "OFF" to "ON" • Auto Idle: High Output (Activation).
• Display: Indicating coolant temperature, fuel level,
hydraulic oil temperature, engine speed, DEF
(AdBlue) level, trip meter.
• Clock: Current time display.
NOTE: Refer to method for setting clock in operation manual

for setting time.

9-1-28
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 jog switch.
PM
H H
E F
C E F C
TRIP
/h rpm ECO
Min Max
3
SPC
S USB
2 1
EX1300996
Figure 11
Selector Buttons Graphic Display Area

1. Jog Switch 3. Letter Information Display Department
2. Escape Button
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. Jog Switch (1 on Figure 11): Move cursor and set menu.
2. Escape Button (ESC, 2 on Figure 11): Move a screen to
previous menu or main menu.

9-1-29
USER MENU
User Menu - Access and Escape Methods
Access Method
1. On the normal display screen, click on the jog switch to
access the user menu screen.
2. Proceed to the user menu using the menu/esc button on
the front of the dashboard.
3. Select the user menu from the launch menu.
PM PM
User Menu
H H
E F
C E F C Vehicle GP
TRIP Vehicle State Configuration Entertainment Configuration
/h rpm ECO
Min Max
SPC SPC
S USB S USB
<Normal Indication Monitor> <Main Menu Monitor>

EX1301029
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
PM
Turn the jog switch and move the cursor to see a reversed User Menu
display on the desired menu. Then, click on the jog switch to
select the menu.
Vehicle State ↔ Vehicle Configuration ↔ Entertainment ↔
GP Configuration
Vehicle GP
Vehicle State Configuration Entertainment Configuration
Press the ESC button to return to the previous screen.
SPC
S USB
WARNING Figure 13
EX1301030

Do not use vehicle state menu when traveling or operating.

9-1-30
1. Vehicle State
PM
This is used to check the current vehicle state, filter/oil Vehicle State
information, vehicle information, etc.
Monitoring
Turn the jog switch and move the cursor to see a reversed
Filter/Oil Information
display on the desired menu. Then, click on the jog switch
to select the menu. Vehicle Information
Monitoring ↔ Filter/Oil Information ↔ Vehicle

Information SPC
S USB
Press the ESC button to return to the previous screen. EX1301031

Figure 14
A. Monitoring
Monitoring
The monitoring screen displays the information on Front Pump Pressure Rear Pump Pressure Battery Voltage
vehicle pump pressure, voltage, fuel level, etc.
bar bar bar
At the vehicle state, if the cursor is placed on 0 500 0 500 0 500
Monitoring, click on the jog switch to display the Engine Dial Voltage Fuel Level Engine Speed
Monitoring screen.
bar v %
Press the ESC button to return to the previous 0 50 0 40 0 100
screen.
FG018483
Figure 15
B. Filter/Oil Information
PM
The screen displays the information on filter/oil use Vehicle State
time, replacement period, and remaining time.
Monitoring
At the vehicle state, if the cursor is placed on the
filter/oil information, click on the jog switch to display Filter/Oil Information
the filter/oil information. Vehicle Information
SPC
S USB
EX1301032
Figure 16

9-1-31
Reset Method/Replacement Period Change Method
Move the cursor over the filter/oil item you wish to Fuel Filter
change using the jog switch or the and buttons TIME: 40hr
REMAIN: 1960hr
CHANGE: 2000hr
2 %
on the front of the dashboard and click the jog switch Air Cleaner
or press the 'Enter' button on the front of the TIME: 0 hr
REMAIN: 2000hr
CHANGE: 2000hr
0 %
dashboard. A window for resetting/changing the filter/ Engine Oil Filter

oil time will pop-up. TIME: 0 hr
REMAIN: 100hr
CHANGE: 100hr
0 %
To reset the use time, move the cursor over 'clear' Return Filter
and click the jog switch or press the 'Enter' button on TIME: 41 hr
REMAIN: 1359hr
CHANGE: 1400hr
2 %
the front of the dashboard.

EX1301406
Turn the jog switch to locate it at YES. Then, click on Figure 17
the jog switch to reset the operation hour.
Turn the jog switch to locate it at NO. Then, click on
the jog switch to allow the pop-up window to
disappear without resetting the operation hour. TIME: 40hr
Fuel Filter
CHANGE: 2000hr
REMAIN: 1960hr 2 %
Air Cleaner
Fuel Filter
TIME: 0 hr CHANGE: 2000hr
REMAIN: 2000hr 0 %
TIME: 40 Engine CHANGE:

Oil Filter 2000
TIME:CLEAR
0 hr CHANGE
CHANGE: 100hr
REMAIN: 100hr 0 %
Return Filter
REMAIN: 1359hr 2 %
EX1301407
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 TIME: 40hr
Fuel Filter
CHANGE: 2000hr
the replacement of filter/oil. REMAIN: 1960hr 2 %
Air Cleaner
Reset Operation
TIME: 0 hr
Hour?
CHANGE: 2000hr
REMAIN: 2000hr 0 %
Engine Oil Filter

TIME: 0 hr \HV QR
CHANGE: 100hr
REMAIN: 100hr 0 %
Return Filter
REMAIN: 1359hr 2 %
EX1301408
Figure 19
Fuel Filter
TIME: 40hr CHANGE: 2000hr
REMAIN: 1960hr 2 %
Air Cleaner
Fuel Filter
CHANGE:
REMAIN: 2000hr 2000 hr 0 %
Engine Oil Filter

1000 hr
TIME: CHANGE: 2000hr
100hr
REMAIN: 100hr 0 %
Return Filter
REMAIN: 1359hr 2 %
EX1301409
Figure 20

9-1-32
To change the filter/oil exchange period, move the
cursor over 'change' in the window for resetting/
changing the filter/oil time and click the jog switch or TIME: 40hr
Fuel Filter
CHANGE: 2000hr
press the 'Enter' button on the front of the dashboard. REMAIN: 1960hr 2 %
Air Cleaner
Change Period?
After the exchange period change screen pops up, TIME: 0 hrCHANGE: 2000hr
REMAIN: 2000hr 0 %
click the jog switch or press the 'Enter' button on the Engine Oil Filter
front of the dashboard and the exchange time will TIME: 0 hr \HV QR
CHANGE: 100hr
REMAIN: 100hr 0 %
start flashing. Return Filter
Next, change the exchange period using the jog REMAIN: 1359hr 2 %
switch or the and buttons on the front of the EX1301410

dashboard. Figure 21
Then, turn the jog switch counterclockwise to reduce
the period. Turn clockwise to extend the period.
With the replacement period change being
completed, click on the jog switch to create a pop-up
window to select the period change.
Turn the jog switch to locate it at YES. Then, click on
the jog switch to change the replacement period.
Turn the jog switch to locate it at NO. Then, click on
the jog switch to allow the pop-up window to
disappear without the replacement period not being
changed.
Filter/Oil Period Setup Table Unit: time (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 1,000 100 50
Engine Oil 500 100 50
Hydraulic Oil 2,000 1,000 50
Coolant Water 6,000 1,000 50
Symbol Description
Filter/ ENG Oil Return Coolant

Fuel Filter Air Cleaner Pilot Filter ENG Oil HYD. Oil
Oil Name Filter Filter Water
Icon
EX1300858
Figure 22

9-1-33
If the remaining time for filter/oil replacement is less
than 10 hours, this pop-up window will be created. PM
Press the ESC button or the jog switch to allow the H Caution H
pop-up window to disappear.
Return Filter
F
E period starts!
Replacement
C E F C
TRIP
/h rpm ECO
Min Max
SPC
S USB
EX1301047
Figure 23
If the filter/oil replacement period is exceeded, this

pop-up window will be created. Press the ESC button PM
or the jog switch to allow the pop-up window to H Caution H

disappear.
Return Filter
WARNING TRIP
C E
F
E period is exceeded!
Replacement
F C
/h rpm ECO
Min Max
AVOID DEATH OR SERIOUS INJURY SPC
S USB
Do not use vehicle state menu when traveling or EX1301048

operating.
Figure 24
C. Vehicle Information
PM
This is used to check the vehicle name, engine type Vehicle State
and attachment options.
Monitoring
At the vehicle state, if the cursor is placed on the
vehicle information, click the jog switch to access the Filter/Oil Information
vehicle information screen. Vehicle Information
Click the ESC button to return to the previous screen.

SPC
S USB
EX1301033
Figure 25
Vehicle Information
Engine
Attachment Option Not Available
Vehicle Number 001001
EX1301411
Figure 26

9-1-34
2. Vehicle Configuration
PM
This is used when selecting the functions such as User Menu
attachment setting, camera setting, forced dial input, auto
shut-off setting and option motion setting.
Turn the jog switch and move the cursor to see an
reversed display on the desired menu. Then, click the jog
Vehicle GP
switch to select the menu. Vehicle State Configuration Entertainment Configuration
SPC
S USB
EX1301034
Figure 27
Attachment Setting ↔ Camera Setting ↔ Forced Dial

Input ↔ Auto Shut-off Setting ↔ Option Motion Setting PM
Vehicle Configuration
Press the ESC button to return to the previous screen.
Attachment Setting
Camera Setting
Forced Dial Input
Auto Shut-off Setting
Option Motion Setting
SPC
S USB
EX1301035
Figure 28
A. Attachment Setting (Optional)

PM
In this menu, performance of the breaker and Attachment Setting
two-way can be set and set items can be selected.
Breaker Select
Breaker Select ↔ Two-way Select ↔ Breaker
Two Way Select
Setting ↔ Two-way Setting
Breaker Setting
Press the ESC button to return to the previous
Two way Setting
screen.
SPC
S USB
EX1301412
Figure 29
How to Select Attachments (Breaker/Two-way)

Breaker Select
After proceeding to attachment setting items, breaker 1. 1800 rpm 95 lpm 140 bar
select and two-way select will appear. 2. 1800 rpm 95 lpm 140 bar
Operate the jog switch clockwise/counterclockwise to 3. Not in Use
select breaker/two-way select. Then, click on the jog 4. Not in Use
switch to move the cursor to the selectable lists. 5. Not in Use
When the cursor is placed on the list, operate the jog

switch clockwise/counterclockwise to move the
cursor. Then, click on the jog switch to select
attachments to use. EX1301413
Figure 30

9-1-35
When the selection is completed, the "Select
Breaker Select
Complete!" pop-up window is displayed for 3
seconds, and the checkbox of the selected list is 1. 1800 rpm 95 lpm 140 bar
updated. 2. 1800 rpm 95 lpm 140 bar

3. Not in Use
The cursor can only be moved from the selectable 4. Not in Use
Select Complete!
lists. The selectable list items at the attachment 5. Not in Use
setting are set as "Available" in the use or non-use of
attachments in the attachment setting.
EX1301414
Figure 31
B. Breaker Setting/Two-way Setting

PM
The breaker setting/two-way setting screen is used to Attachment Setting
set up the use or non-use of attachments, max.
engine limit, and max. attachment flow rate, etc. Breaker Select
Two Way Select

At the vehicle configuration, when the cursor is
placed on attachment setting, click on the jog switch Breaker Setting
to access the Breaker setting or Two-way setting list Two way Setting
screen.
SPC
If the system is set up as the owner's password S USB
locked, access the attachment setting list screen by EX1301415

using owner's password input screen. Figure 32
On the owner's password input screen, press the

Owner Password
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 breaker setting or two-way setting

Breaker Setting
list screen, the initial screen locates the cursor at the
top. 1. 1800 rpm 95 lpm 140 bar
2. 1800 rpm 95 lpm 250 bar
3. 1800 rpm 95 lpm 140 bar
4. 1800 rpm 95 lpm 140 bar
5. 1800 rpm 95 lpm 140 bar
EX1301417
Figure 34

9-1-36
Operate the jog switch clockwise/counterclockwise to
Two Way Setting
select breaker/two-way. Then, click on the jog switch
on the list, operate the jog switch clockwise/ 1. 1800 rpm 95 lpm 250 bar
counterclockwise to move the cursor. Then, click on 2. 1800 rpm 95 lpm 340 bar
the jog switch to select the attachments to be set up 3. 1800 rpm 95 lpm 250 bar
and move to the attachment setting screen. 4. 1800 rpm 95 lpm 250 bar
5. 1800 rpm 95 lpm 250 bar
On the attachment setting list screen, when cursor is
placed on the list, press the ESC button to locate the
cursor at breaker/two-way at the top. When the
cursor is placed at breaker/two-way at the top, press
the ESC button to return to the previous screen. EX1301418
Figure 35
How to Set Up Attachments

Breaker 1 Setting
Attachment setting items include attachment use,
Attachment Use Dydlodeoh Button Type Wrjjoh
max E/G limit, max pressure (ATT), max flow (ATT), Max E/G Limit 4;33 usp Max Press.(ATT) 473 edu
min flow (ATT), and user setting max flow. Operate Max Flow(Pump) 7<3 osp Max Flow(ATT) 573 osp
the jog switch clockwise/counterclockwise to locate 2 Pump Option Dydlodeoh Min Flow(ATT) 63 osp
the cursor. Then, click on the jog switch to set up
relevant items. User Setting Max Flow <8 osp
0 .
The cursor movement order goes like this: 63 573
1) Breaker Setting
EX1301419
Attachment Use ↔ Toggle ↔ Max E/G Limit
Figure 36
↔ Max Pressure ↔ Max Flow ↔ Min Flow ↔
User Setting Max Flow
2) Two-way Setting
Attachment Use ↔ Max E/G Limit ↔ Max
Pressure ↔ Max Flow ↔ Min Flow ↔ User
Setting Max Flow
Attachment Use
Breaker 1 Setting
The attachment use is designed to determine Attachment Use Dydlodeoh Button Type Wrjjoh
whether relevant attachments are used or not. Max E/G Limit 4;33 usp Max Press.(ATT) 473 edu
If set up as enable, the relevant attachment can be Max Flow(Pump) 7<3 osp Max Flow(ATT) 573 osp
2 Pump Option Dydlodeoh Min Flow(ATT) 63 osp
used. Currently Selected Item!
If set up as disable, the relevant attachment cannot User Setting Max Flow <8 osp
be used. 0
63 573
.
Locate the cursor at the attachment use. Then, click

on the jog switch to set up enable/disable. EX1301420
NOTE: If you select an attachment set up as Figure 37
disable, 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.

9-1-37
Toggle
This item sets the applicability of the toggle of the
breaker button.
If toggle is selected, the breaker will continue
operation when the breaker button is pressed once,
and reset when pressed again.
If the toggle is released, the breaker is actuated while
the breaker button is being pressed.
Max E/G Limit
The max E/G Limit is set up to define the flow rate
limit discharged when using attachments.
Operate the jog switch to move the cursor to the max
E/G limit. Then, click on the jog switch to convert into
the editing mode.
At the editing mode, operate the jog switch clockwise/
counterclockwise to determine the desired max.
engine limit. Then, click the jog switch 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 jog switch
operation is 100 rpm.
Max Pressure (ATT)
The max pressure (ATT) can be set up as the max
pressure of the attachment by the user according to
the attachment's specifications.
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.
The setup method is the same as the above max.
engine limit setup method. The change value by
stage in the jog switch operation is 10 lpm (2.6 gpm).

9-1-38
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.
engine limit setup method. The change value by
stage in the jog switch operation is 10 lpm (2.6 gpm).
When setting up all above items, the setup limits are
outlined as follows.
• Breaker Setting
Max. Limit Min. Limit

Max. E/G Limit 1,800 rpm 1,200 rpm
Max. Flow (Pump) Conforms to the max. engine limit Conforms to the max. engine limit
Max. Flow (ATT) 240 lpm (62.4 gpm) 140 lpm (36.4 gpm)
Min. Flow (ATT) 80 lpm (20.8 gpm) 30 lpm (7.8 gpm)
Max. Press. (ATT) 280 bar 140 bar
• Two-way Setting
Max. Limit Min. Limit

Max. E/G Limit 1,800 rpm 1,200 rpm
Max. Flow (Pump) Conforms to the max. engine limit Conforms to the max. engine limit
Max. Flow (ATT) 240 lpm (62.4 gpm) 100 lpm (26 gpm)
Min. Flow (ATT) 80 lpm (20.8 gpm) 30 lpm (7.8 gpm)
Max. Press. (ATT) 340 bar 140 bar

9-1-39
C. Camera Setting
PM
The camera setting screen is designed to set up Vehicle Configuration
various cameras "ON/OFF" and normal/mirror.
Attachment Setting
From the vehicle configuration, select camera setting
Camera Setting
to access the camera setting list screen.
Forced Dial Input
Auto Shut-off Setting
SPC
S USB
EX1301037
Figure 38
The camera setting list screen displays various

PM
camera states (ON/OFF, NORMAL/MIRROR).
Camera Setting
Select a camera and click the jog switch to access
the relevant camera setting screen. No 1 Camera
Press the ESC button to return to the previous No 2 Camera
screen. No 3 Camera
SPC
S USB
EX1301038
Figure 39
On the camera setting screen, set up the camera

No 1 Camera
state (ON/OFF, NORMAL/MIRROR).
Also, see the actual image of the currently installed No 1 Camera
camera.
On Off
Normal Mirror
EX1301421
Figure 40
If a camera is not installed, the camera image section

No 1 Camera
is shown as a blue screen.
If the cursor is placed on "ON/OFF", click on the jog No 1 Camera
switch to set up "ON" ↔ "OFF".
On Off
Turn the jog switch to locate the cursor at normal/ Normal Mirror
mirror. Then, click on the jog switch to set up normal
↔ mirror.
EX1301422
Figure 41

9-1-40
D. Forced Dial Input
PM
The forced dial input screen provides a method Vehicle Configuration
whereby to use the gauge panel's jog switch and
control the engine rpm, replacing the engine control Attachment Setting
dial. Camera Setting

Forced Dial Input
From the vehicle configuration, select the jog shuttle Auto Shut-off Setting
for dial to access it. Option Motion Setting
SPC
S USB
EX1301039
Figure 42
If you access the jog shuttle for dial screen, the initial
# Input
Forced Dial
cursor is located at the using jog shuttle for dial.
If the using jog shuttle for dial is shown as disable,
Using Jog Shuttle for Dial Available
the cursor cannot be moved.
Current Engine Speed 0
40 %
Setting RPM Dial
EX1301423
Figure 43
When the cursor is placed at the using jog shuttle for

# Input
Forced Dial
dial, if you click on the jog switch, a pop-up window
will be created, saying "Do you want to use manual
Dial Control for Engine rpm?". Using Jog Shuttle for Dial Available
Do you want to use
Operate the jog switch and select "YES/NO" to manual Dial Control for
Current Engine Speed
RPM? 0
determine whether to use jog shuttle for dial. Engine
\HV QR
0%
If you select "YES", then using jog shuttle for dial is Setting RPM Dial
enabled, causing the pop-up window to disappear.
If you select "NO", then using jog shuttle for dial
remains disabled, causing the pop-up window to EX1301424
disappear. Figure 44
If the using jog shuttle for dial is shown as enable,

# Input
Forced Dial
operate the jog switch clockwise and move the cursor
to the setting rpm dial. When the cursor is placed at
the setting rpm dial, click on the jog switch to cause Using Jog Shuttle for Dial Available
the cursor to flicker, changing into an editing mode to
set up the rpm dial. When the cursor is placed at the Current Engine Speed 0
editing mode, operate the jog switch clockwise/
40 %
counterclockwise, thus setting up the engine rpm. Setting RPM Dial
When the cursor is at the editing mode, press the

ESC button to disable the editing mode. When the
cursor is not at the editing mode, press the ESC EX1301425
button to return to the previous screen. Figure 45
Before keying off the gauge panel or disabling the
using jog shuttle for dial, control the engine rpm only
with the shuttle of the gauge panel's jog shuttle.

9-1-41
E. Auto Shut-off Setting
PM
In the auto shut-off setting screen, the engine of the Vehicle Configuration
equipment can be set to shut off automatically when
the equipment is not operated for a preset time. Attachment Setting
Camera Setting
Select auto shut-off setting in the vehicle settings and Forced Dial Input
proceed to the setting screen. Auto Shut-off Setting
SPC
S USB
EX1301426
Figure 46
In the auto shut-off setting screen, the cursor will

Auto Shut-off# Setting
initially be over auto shut-off function in use.
NOTE: This feature is off in factory defaults. Auto Shut-off Function in
Available
Use
To use the feature, place the cursor over auto shut-
off function in use and click the jog switch to select Auto Shut-off Time Setting 5 Min
the feature. 3 60
The engine can be set to shut off automatically after a

maximum of 60 minutes to a minimum of 3 minutes.
In factory defaults, the time is set to 5 minutes. EX1301427
Further, this feature is off in factory defaults. Figure 47
The following conditions must be met if this feature is
to be used.
Auto Shut-off (ASD) Active Condition
Input
Pilot Cut-
Auto Idle off S/W Engine Coolant Fluid Output
GP Menu Dial Status Time
S/W (Crawler rpm Temp. Temp.
Type Only)
More than More than at Setting Engine
Active ON ON ON Low rpm
50 °C 20 °C Time Stop Signal
Time Count
Deactive Except Above Condition
Reset
When this feature is activated and the above

conditions are met, "Engine will shut off" will pop up 1
minute before the engine shuts off.
Further, 10 seconds before the engine shuts off, the
pilot buzzer will be activated to alert the user.

9-1-42
F. Option Motion Setting (Option)
PM
When the PE3C option is installed, the motion input Vehicle Configuration
signal of the attachment can be set to be used
through either the joystick or the hydraulic pedal in Attachment Setting
the option motion setting screen. Camera Setting

Forced Dial Input
Select option motion setting in the vehicle settings Auto Shut-off Setting
and proceed to the settings screen. Option Motion Setting
SPC
S USB
EX1301428
Figure 48
'Joystick Thumb Wheel' and 'Option Pedal' can be

# Setting
Option Motion
selected in option motion settings.
Joystick Thumb Wheel
Joystick Thumb Wheel
The breaker/two-way motion signal can be input as a Option Motion
Option Pedal
joystick manipulation signal.
If this item is selected in a vehicle in which a hydraulic
pedal is installed, the hydraulic pedal will be
deactivated.
Option Pedal (Option) EX1301429
This option is available only in vehicles with the PE3C Figure 49
option with a hydraulic pedal installed.
The breaker/two-way motion signal can be input as a
hydraulic pedal manipulation signal.
If this item is selected, the input signal of the joystick
thumb wheel is deactivated.

9-1-43
3. Entertainment
PM
This menu is used to replay videos and MP3. User Menu
Turn the jog switch and move the cursor to see a reversed
to select the menu.
Vehicle GP
Vehicle State Configuration Entertainment Configuration
SPC
S USB
EX1301040
Figure 50
Video ↔ MP3
PM
Press the ESC button to return to the previous screen. Entertainment
Video
MP3
SPC
S USB
EX1301041
Figure 51
If the use of entertainment is limited, this pop-up window

PM
will be created.
Entertainment
To lift the use limits, you should change the limit setup in
the GP configuration.
Video The entertainment
The pop-up window will automatically disappear in 3 MP3
use is restricted!
seconds. Press the ESC button or the jog switch to remove
pop-up window.
For details, See “GP Configuration” on page -51. SPC
S USB
EX1301042
Figure 52
If the use of entertainment is not limited, this pop-up

PM
window will be created. The pop-up window will
Entertainment
automatically disappear in 3 seconds.
Press the ESC button or the jog switch to remove pop-up Be careful playing
Video
window. entertainment menu on
MP3 travel or operating!
SPC
S USB
EX1301043
Figure 53

9-1-44
WARNING
Listening to entertainment clips, such as video, music,
etc., can cause an accident, resulting in death or
serious injury.
Do not play entertainment files when operating the
machine.
A. Video
PM
From the entertainment screen, select video to Entertainment
access it.
Video
MP3
SPC
S USB
EX1301041
Figure 54
When there is no USB storage system, a pop-up

PM
window is displayed for 3 seconds, saying "USB"
Entertainment
Storage is not installed". and the video is not played.
Video USB Storage is not

MP3 installed.
SPC
S USB
EX1301044
Figure 55
When initially accessing the video player, the USB

Video
storage system file tree is displayed on the screen.
Operate the jog switch clockwise/counterclockwise to Hard Disk MOVIE
select and play a video. ..(3)
If there is a video file that played last, it will Video(1).avi
automatically be replayed. Video(2).avi

Video(3).avi
Video(4).avi
FG018511
Figure 56

9-1-45
If the format is not supported, a pop-up window is 33=33=59
displayed for 3 seconds, saying "This file is not 33=36=7<
available!" and the video is not played.
This file is not available!
EX1301451
Figure 57
Formats that can be supported are given below.
Formats that can be supported

File Type AVI, MP4, MKV, MOV
Supported Resolution 720*480, 720*384, 720*304, 704*448, 704*304, 640*480, 640*360,
640*272, 640*352, 672*288, 512*384, 576*432, 480*320, 480*360,
320*240
Supported Video Codec H.264, MPEG4, Xvid, MPEG1/2
Supported Audio Codec MP3
Supported File Size Under 1.7 GB
Supported USB Format FAT32
The screen composition of the video player is given 33=33=59
below. 33=36=7<
The top section displays the current playing time of

the total playing time.
The screen center shows the video being played.
The bottom displays the video player function
operation symbol and cursor.
The video player function operation symbol and jog
switch are operated in the following order. EX1301452
Play/Pause ↔ Replay the Previous File ↔ Video Figure 58
Progress Bar ↔ Replay the Next File ↔ Video
Files List
If no operation continues for more than 5 seconds,
the video will automatically be converted into the
whole screen.
On the whole screen, click on the jog switch or the
ESC button to remove whole screen.
FG018214
Figure 59

9-1-46
Play/Pause 33=33=59
33=36=7<
Locate the cursor on the play/pause symbol and click

on the jog switch to execute the video's play/pause
functions.
With the play being on, click on the jog switch to
display the pause symbol at the center of the screen,
thus allowing the video to pause.
With the pause being on, click on the jog switch to
cause the pause symbol at the center of the screen to
disappear, resuming the video playing. EX1301453
Figure 60
Replay the Previous File 33=33=59

33=36=7<
Locate the cursor at the replay the previous file

symbol and click on the jog switch to replay the
previous file.
EX1301454
Figure 61
Locate the cursor at the video progress bar and click 33=33=59
on the jog switch to convert into the fast forward/ 33=36=7<
rewinding mode.
On the fast forward/rewinding mode, operate the jog
switch clockwise/counterclockwise to conduct fast
forward/rewinding.
Fast forward/rewinding can be conducted at an
interval of 30 seconds per click during which the jog
switch is turned.
On the fast forward/rewinding mode, press the ESC EX1301455
button to disable the fast forward/rewinding mode. Figure 62
Replay the Next File 33=33=59

33=36=7<
Locate the cursor at the replay the next file symbol

and click on the jog switch to replay the next file.
EX1301456
Figure 63

9-1-47
Video Files List 33=33=59
33=36=7<
Locate the cursor at the video files list symbol and

click on the jog switch to move to the video file list
screen.
EX1301457
Figure 64
Select and replay a video.

Video
Hard Disk MOVIE
..(3)
Video(1).avi
Video(2).avi
Video(3).avi
Video(4).avi
FG018557
Figure 65
B. MP3
PM
From the entertainment screen, select MP3 to access Entertainment
it.
Video
MP3
SPC
S USB
EX1301053
Figure 66
If there is no USB storage system, a pop-up window

PM
is displayed for 3 seconds, saying "USB Storage is
Entertainment
not installed". and the MP3 player is not run.
Video USB Storage is not

installed.
MP3
SPC
S USB
EX1301054
Figure 67

9-1-48
When initially accessing the MP3 player, the file tree
screen of USB storage system is displayed. Operate
Hard Disk MP3
the jog switch clockwise/counterclockwise to select
and play an MP3 file. ..(0)
If there is an MP3 file played last, the file will Music(1) .mp3
automatically be played. Music(2) .mp3

Music(3) .mp3
Music(4) .mp3
FG018560
Figure 68
The screen composition of MP3 player is given

Singer - Title
below.
The top section displays the name of the file being
played and the current playing time of the total Title
playing time.
The screen center shows the album image of the file
being played, the album name, the song name and Next
the name of the next file to be played.
The bottom displays the MP3 player function
operation symbol and cursor. FG020124
Figure 69
The MP3 player function operation symbol and jog
switch are operated in the following order.
Play/Pause ↔ Replay the Previous File ↔ MP3
Progress Bar ↔ Replay the Next File ↔ MP3 Files
List ↔ Background MP3 Play
Play/Pause
Singer - Title
Locate the cursor at the play/pause symbol and click
on the jog switch to execute the MP3 play/pause
functions. Title
With play being on, click the jog switch to display the
pause symbol at the center of the screen, causing the
MP3 to pause. Next
With pause being on, click on the jog switch to cause

the pause symbol at the center of the screen to
disappear, resuming the MP3 playing. FG020125
Figure 70

9-1-49
Replay the Previous File
Singer - Title
symbol, and click on the jog switch to replay the
previous file. Title
Next
FG020126
Figure 71
Fast Forward/Rewinding
Singer - Title
Locate the cursor at the video progress bar and click
on the jog switch to convert into the fast forward/
rewinding mode. Title
On the fast forward/rewinding mode, operate the jog
switch clockwise/counterclockwise to conduct fast
forward/rewinding. Next
Fast forward/rewinding can be conducted at an

interval of 30 seconds per click during which the jog
switch is turned. FG020127
Figure 72
On the fast forward/rewinding mode, press the ESC
button to disable the fast forward/rewinding mode.
Replay the Next File
Singer - Title
symbol and click on the jog switch to replay the next
file. Title
Next
FG020128
Figure 73
MP3 Files List

Singer - Title
Locate the cursor at the MP3 files list symbol and
click on the jog to move to the file list screen.
Title
Next
FG020129
Figure 74

9-1-50
Select a file and replay the MP3.
Hard Disk MP3
..(0)
Music(1) .mp3
Music(2) .mp3
Music(3) .mp3
Music(4) .mp3
FG018560
Figure 75
Background MP3 Play

Singer - Title
Position the cursor on the "HOME" button and
pressing the jog switch, MP3 is played by the initial
screen. Title
Next
FG020130
Figure 76
PM
H H
E F
C E F C
TRIP
/h rpm ECO
Min Max
SPC
S PLAY
EX1301432
Figure 77
4. GP Configuration
PM
This menu is used to set up password, brightness, default User Menu
screen and time, and to input service phone number. Turn
the jog switch and move the cursor to see an reversed
to select the menu.
Vehicle GP
Password Setting ↔ Brightness Setting ↔ Default Vehicle State Configuration Entertainment Configuration
Power Mode Setting ↔ Time Setting ↔ Service Phone
Number Setting ↔ Unit Setting ↔ Notification Setting
SPC
S USB
↔ Entertainment Use Setting

EX1301052
Press the ESC button to return to previous screen. Figure 78

9-1-51
A. Password Setting
PM
Password Setting GP Configuration
An owner passwords and user passwords can be set Password Setting
(Only the owner password is selected in the default Brightness Setting
shipment state). Default Power Mode Setting
By using the password setting function, you can Time Setting
manage usage of operations and functions of the Service Phone Number Setting
vehicle. SPC
S USB
EX1301070
Figure 79
Owner Password Setting

PM
1) Selection Password Setting
An owner password can be set for managing Owner Password Setting
functions of equipment and use privileges of the
User Password Seeting
equipment for different users.
To set an owner password, place the cursor
over Owner Password Setting in the settings
screen and click the jog switch (or press "Enter" SPC
on the keypad). S USB
EX1301055
Figure 80
2) Password entry
Owner Password
When the password entry screen appears, use
the jog switch (or 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 : ; <
Rotate the jog switch to select digits from 0 to 9 Enter Owner Password
below, and click Enter on the jog switch to input
the password.
If the password is input incorrectly, use the EX1301416
button on the lower right to delete the input Figure 81
password.
Owner Password
IMPORTANT
If the password is input incorrectly three
times in a row, you will be redirected to the Password Error!
main screen and the system will not start for
the next 10 minutes. 3 4 5 6 7 8 9 : ; <
Enter Owner Password
EX1301433
Figure 82

9-1-52
3) Structure
Password Setting
Owner password settings include password
change, start-up restriction settings, function Password Change
item settings, user password use settings, and Owner Engine Startup Lock has not been set!
user password change.
Item Setting
Use
User
Password Change
EX1301434
Figure 83
Password change
Owner Password Change
To change the owner password, select
password change with the jog switch (or the
keypad).
3 4 5 6 7 8 9 : ; <
Enter Password
EX1301435
Figure 84
When the owner password has been changed,

Password Setting
"Password Set!" will pop-up.
Password Change
Owner Engine Startup Lock has not been set!

Password
Item Setting Set!
Use
User
Password Change
EX1301436
Figure 85
Item setting
Item Setting
User privileges and settings for engine start-up,
attachment settings, and entertainment use Item Use Permission
settings can be set.
Engine Startup
NOTE: Permission, which gives certain
Attachment Setting
users permission touse certain
features, can only be checked when Entertainment Use Setting
use ischecked.
In this case, the user has the same
privileges as the owner, and the
EX1301437
user's settings take precedence in
equipment settings. Figure 86
NOTE: This setting is off by default.

9-1-53
a) Engine startup
Setting of password input upon operation
of equipment.
b) Attachment setting
Setting of password input for attachment
setting.
c) Entertainment use setting
Setting of password input for
entertainment (video/MP3) use setting.
Engine start-up setting
Password Setting
By selecting "Engine Start-up" among item
settings, the reentry time for password entry Password Change
upon start-up of the equipment can be set. Owner Always 1min 5min
NOTE: No password for start-up of the Item Setting

equipment is setby default. Use
User
a) Always Password Change
Password is entered with each start-up.

b) 1 min EX1301438
If the system is started again within 1
Figure 87
minute from key-off after the password is
input, the password is not requested
again.
c) 5 min
minutes from key-off after the password is
again.
User password setting
Password Setting
a) User password use setting
Sets use of the user password. Password Change
b) User password change Owner Engine Startup Lock has not been set!
After setting use privileges for the user Item Setting

password, the owner can change the user Use
password. User
Password Change
EX1301439
Figure 88

9-1-54
User Password Setting
PM
1) Selection Password Setting
If the owner checks user password use in owner Owner Password Setting
password setting, user password setting will User Password Seeting
appear in the password setting screen so user
password can be set. (refer to “Owner
Password Setting” on page -52).
To set a user password, place the cursor over SPC
User Password Setting in the Password Setting S USB
screen and click the jog switch (or press "Enter" EX1301440
on the keypad). Figure 89
2) Password entry
When the password input screen appears, input
the password with the jog switch (or keypad)
and move to the settings screen. (refer to
"Owner Password Setting 2" on page 2-71.)
The default password is "1111".
3) Structure
Password Setting
User password settings include password
change, start-up restriction settings, and Password Change
function item settings. User Always 1min 5min
Item Setting
EX1301441
Figure 90
Password change
User Password Change
To change the user password, select password
change, and change the user password using
the jog switch (or keypad).
3 4 5 6 7 8 9 : ; <
Enter Password
EX1301442
Figure 91

9-1-55
When the user password is changed,"Password
Password Setting
Set!" will pop-up.
Password Change
Owner Engine Startup Lock has not been set!

Password
Item Setting Set!
Use
User
Password Change
EX1301436
Figure 92
Item setting
Item Setting
Use of engine start-up, attachment setting, and
entertainment use setting can be set. Item Use
NOTE: This is only possible when permitted Engine Startup

by the owner.
Attachment Setting
a) Engine startup Entertainment Use Setting
Setting of password input upon operation
of equipment.
b) Attachment setting EX1301443
Setting of password input for attachment
Figure 93
setting.
c) Entertainment use setting
Setting of password input for
entertainment (video/MP3) use setting.
Engine start-up setting
Password Setting
By selecting "Engine Start-up" among item
settings the reentry time for password entry Password Change
upon start-up of the equipment can be set. User Always 1min 5min
a) Always Item Setting

Password is entered with each start-up.
b) 1 min
minute from key-off after the password is
input, the password is not requested EX1301444
again. Figure 94
c) 5 min
minutes from key-off after the password is
again.
NOTE: If the owner uses the engine start-up
feature but does not permit the user
to use it, the user cannot select
whether to use the feature, but can
select the password reentry time.

9-1-56
B. Brightness Setting
PM
On the GP configuration screen, when cursor is GP Configuration
placed on brightness setting, click on the jog switch to
Password Setting
display the screen brightness setting and camera
Brightness Setting
brightness setting screen.
Default Power Mode Setting
Time Setting
Service Phone Number Setting
SPC
S USB
EX1301071
Figure 95
If you want to change the screen brightness, select

PM
the screen brightness setting to display the
Brightness Setting
brightness adjustment screen.
Screen Brightness Setting
Camera Brightness Setting
SPC
S USB
EX1301056
Figure 96
Turn the jog switch and adjust the brightness of 0 -

100% at an interval of 10%. Screen Brightness Setting
The screen brightness when manufactured is set as H H
60%.
60 %
screen. C
E
E F
F
C
EX1301057
Figure 97
If you want to change the camera screen brightness,

PM
select the camera brightness setting to display the
Brightness Setting
camera screen brightness adjustment screen.
Screen Brightness Setting
Camera Brightness Setting
S USB
EX1301058
Figure 98

9-1-57
Turn the jog switch to adjust the brightness of 0 -
100% at an interval of 10%.
The camera screen brightness at the vehicle release
time is set as 60%. 60 %

screen.
EX1301445
Figure 99
C. Default Power Mode Setting

PM
placed on default power mode setting, click on the jog
switch to access the default power mode setting. Password Setting
Brightness Setting
Fuel Saving Mode is Enable Default Power Mode Setting
Time Setting
ON OFF ON
P+ P+ SPC
PWR+ PWR+ S USB
P P EX1301073
PWR PWR
Figure 100
S S
STD STD
E E Default Power Mode Setting

ECO ECO
Fuel Saving Mode Enable

Fuel Saving Mode is Disable
Smart Power Control Enable
ON OFF ON
P+ P+
PWR+ PWR+
P P
PWR PWR
EX1301446
S S
STD STD
Figure 101
E E
ECO ECO
D. Time Setting
PM
placed on time setting, click the jog switch to access
the time setting. Password Setting
Brightness Setting
Turn the jog switch and locate the cursor at a target Default Power Mode Setting
of change. Then, click on the jog switch to change the Time Setting
target. Service Phone Number Setting
SPC
S USB
EX1301074
Figure 102

9-1-58
Turn the jog switch to change numbers of each item.
Time Setting
If the setup is completed, click on the jog switch to
store the setup details.
TIME 09 : 47 : 24 PM
When the time setting is completed, locate cursor to
'SET' and press the job switch. DATE 2013 / 10 / 29 SET
If the SET button is not pressed, time setting would

not be completed.
screen. EX1301447
Figure 103
E. Service Phone Number Setting

PM
placed on service phone number setting, click on the
jog switch to access the service phone number Password Setting
setting. Brightness Setting

Time Setting
SPC
S USB
EX1301075
Figure 104
Turn the jog switch and locate the cursor at a desired

number. Then, click on the jog switch to input the
number. If number input is completed, press the 1 2 3
Current Phone Number is
key to enter the input phone numbers.
4 5 6
Use the key and delete erroneously input Enter Phone Number if you want
to Change. 7 8 9
numbers. 000-0000-0000
0
EX1301448
Figure 105
When you input service phone numbers, if warning/

alarm is issued, check the input phone numbers in PM
the pop-up window. H Warning H

000-0000-0000
Hydraulic Oil
Hydraulic oil overheat. Please check after the
hydraulic oil is cooled off completely. In times of
E F
an emergency situation, turn off the engine after
C
gradually cooling Ethe engine. F C
TRIP
/h rpm ECO
Min Max
SPC
S USB
EX1301064
Figure 106

9-1-59
F. Unit Setting
PM
placed on unit setting, click the jog switch to access
the unit setting. Brightness Setting
Time Setting
Unit Setting
SPC
S USB
EX1301076
Figure 107
On the unit setting screen, change the units of

Unit Setting
temperature, pressure, flow rate, and speed. These
figures at the vehicle release time are set as below:
Temperature 䮎䯘
Temperature: °C
Pressure edu nji2 䶫 svl PSd
Pressure: bar
Flux osp jsp
Flow rate: gpm
Speed np2k psk
Speed: km/h
EX1301449
Figure 108
G. Language Setting
PM
placed on language setting, click on the jog switch to
access the language setting. Default Power Mode Setting
Time Setting
Unit Setting
Language Setting
SPC
S USB
EX1301046
Figure 109
On the language selection screen, turn the jog switch

Language Setting
and move the cursor to select a language. Then, click
on the jog switch to adopt the selected language.
screen.
Language
Korean, English, Chinese, Persian, Turkish,
Indonesian, Polish, Arabic, Russian, Thai, Hindi,
Japanese, French, German, Nederlands, Italian,
Portuguese, Spanish, Finnish, Swedish, EX1301062
Norwegian, Danish, Vietnamese, Greek Figure 110

9-1-60
H. Notification Setting
PM
placed on notification setting, click on the jog switch
to access the notification setting. Time Setting
Unit Setting
Language Setting
Notification Setting
SPC
S USB
EX1301060
Figure 111
Depending on the notification setting screen details,

pop-ups are created on the main screen when
warning/alarm is issued, when the switch is operated,
and when the supplies replacement period expires. Warning Alarm Pop up Avalible
On the notification setting screen, turn the jog switch

Maintenance Notification Pop up Avalible
and move the cursor to a desired location. Then, click
on the jog switch to select enable or disable.
All notice items at the vehicle release time are set as
Enable.
EX1301450
Figure 112
I. Entertainment Use Setting

PM
placed on entertainment use setting, click on the jog
switch to access the entertainment use setting. Service Phone Number Setting
Unit Setting
Language Setting
Entertainment Use Setting
SPC
S USB
EX1301061
Figure 113
Depending on the entertainment use setting details,

Entertainment Use Setting
the use of video and MP3 is limited.
Prohibition on Engine Running
Prohibition on Working or Travel
EX1301063
Figure 114

9-1-61
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. Vehicle Configuration.
Entering/Accessing and Exiting/Escaping

Menus
Entering/Accessing Menus
2
When normal mode screen is displayed, if jog switch (1, Figure
115), power mode selector button (2, Figure 115) and
multimedia button are pressed simultaneously for more than 3
seconds, normal mode screen (Figure 116) will be changed to
special menu screen (Figure 117).
4 3
1 FG018857
Figure 115
Normal Mode Screen

NOTE: Normal mode screen display fuel gauge, engine
H H
coolant temperature gauge, hydraulic oil temperature
gauge, ECO gauge and engine speed (rpm), DEF
(AdBlue) gauge, trip meter.
E F
C E F C
TRIP
/h rpm ECO
Min Max
EX1301002
Figure 116

9-1-62
Special Menu Screen
PM
NOTE: Displayed language on the special menu screen Service Menu
consists of Korean and English.
Monitoring
If any language except for Korean is selected during Graph
language selection mode of main menu, only English Failure Information
will be displayed on special menu screen. Operationg Hour Information
SPC
S USB
EX1301082
Figure 117
Exiting/Escaping Menus
1. If escape button (ESC, 4 on Figure 115) 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
PM
Various submenus can be selected by turning the jog switch and Service Menu
moving the cursor to see a reversed display on the desired
Monitoring
menu. Then, click on the jog switch to select the menu.
Graph
Press the ESC button to return to the previous screen. Failure Information
Entering Submenus: When cursor is located on "Machine Info" Operationg Hour Information
of special menu screen, press "Enter ( , 3 on Figure 115)" Vehicle Configuration
button and the "Machine Info" will be displayed. SPC
S USB
EX1301082
Figure 118
Monitoring
PM
1. Entering Submenus: When cursor is located on Monitoring
"Monitoring" of special menu screen, press the jog switch
Vehicle Analog
and the "Monitoring" will be displayed.
Vehicle Digital
2. Exiting Submenus: If escape button (ESC, 4 on Figure Engine Signal
115) is pressed display will be turned to previous screen. User Selection Signal
Doosan Connect Information
SPC
S USB
EX1301083
Figure 119

9-1-63
Vehicle Analog Description
Analog Items Display Remark

1. Front Pump Pressure bar Front pump pressure.
2. Rear Pump Pressure bar Rear pump pressure.
3. Boom Cylinder Pressure bar 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 Current in WIF sensor voltage.
8. Flow Control Lever LH Voltage mV Indicating LH joystick thumb wheel switch voltage.
9. Flow Control Lever RH Voltage mV Indicating RH joystick thumb wheel switch voltage.
10. Fuel Level % Fuel residual quantity radio of fuel tank.
11. Hydraulic Oil Temperature °C Hydraulic oil temperature.
12. Boom Up Pressure bar Boom up pilot pressure.
13. Boom Down Pressure bar Boom down pilot pressure.
14. Arm In Pressure bar Arm in pilot pressure.
15. Arm Out Pressure bar Arm out pilot pressure.
16. Bucket Crowd Pressure bar Bucket crowd pilot pressure.
17. Bucket Dump Pressure bar Bucket dump pilot pressure.
18. Travel Pressure (RH) bar Travel pilot pressure (RH).
19. Travel Pressure (LH) bar Travel pilot pressure (LH).
20. Swing Pressure bar Swing pilot pressure.
21. Option 1 Pressure bar Option 1 pilot pressure.
24. Front Pump Angle Voltage mV Indicating front pump angle sensor voltage.
25. Rear Pump Angle Voltage mV Indicating rear pump angle sensor voltage.
26. Power Shift P/V 1 mA Current in front pump proportional valve.
27. Power Shift P/V 2 mA Current in rear pump proportional valve.
28. Coolant Fan Control P/V mA Current in coolant fan control proportional valve.
29. 2-Way P/V (Open) mA Current in two-way (open) flow control proportional valve.
30. 2-Way P/V (Close) mA Current in two-way (close) flow control proportional valve.
31. Rotating P/V (CW) mA Current in rotating (CW) flow control proportional valve.
32. Rotating P/V (CCW) mA Current in rotating (CCW) flow control proportional valve.
33. Pressure Control P/V 1 mA Current in 1 way pressure proportional valve.
34. Pressure Control P/V 2 mA Current in 2 way pressure proportional valve.
35. Travel Straight P/V mA Current in travel straight flow control proportional valve.

9-1-64
Submenu Selections
Vehicle Analog Vehicle Analog

Front Pump Pressure 0 bar Flow Control Lever RH Voltage 2381 mV
Rear Pump Pressure 0 bar Fuel Level 76 %
Boom Cylinder Pressure 0 bar Hydraulic Oil Temperature 13
Alternator Voltage 0.0 V Boom Up Pressure 0 bar
Battery Voltage 28.3 V Boom Down Pressure 0 bar
Engine Speed Control Dial Voltage 1036 mV Arm In Pressure 0 bar
WIF Sensor Voltage 3604 mV Arm Out Pressure 0 bar
Flow Control Lever LH Voltage 2583 mV Bucket Crowd Pressure 0 bar
Vehicle Analog Vehicle Analog

Rear Pump Angle Voltage 2226 mV Bucket Dump Pressure 0 bar
Power Shift P/V 1 0 mA Travel Pressure (RH) 0 bar
Power Shift P/V 2 0 mA Travel Pressure (LH) 0 bar
Coolant Fan Control P/V 0 mA Swing Pressure 0 bar
2-Way P/V (Open) 0 mA Option 1 Pressure 0 bar
2-Way P/V (Close) 0 mA Option 2 Pressure 0 bar
Rotating P/V (CW) 0 mA Option 3 Pressure 0 bar
Rotating P/V (CCW) 0 mA Front Pump Angle Voltage 2270 mV
Vehicle Analog
Pressure Control P/V 1 0 mA
Pressure Control P/V 2 0 mA
Travel Straight P/V 0 mA
EX1400249
Figure 120

9-1-65
Vehicle Digital Descriptions
Digital Items Mark Remark

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
2. Power Max Switch
work mode selected to "BOOST".
3. One Way Operator Switch Lights up when the one way operator switch is "ON".
Lights up when the travel speed selector switch is set
4. Hi-Speed Selector Switch-M
to "I" position.
Lights up when the travel speed selector switch is set
5. Hi-Speed Selector Switch-A
to "II" position.
6. Working Lamp Switch Lights up when the light switch is set to "II" position.
7. Quick Coupler Lights up when the quick coupler switch is "ON".
Lights up when the air-conditioning relay in the
8. Air Conditioner Switch
air-conditioning unit is "ON".
Lights up when the one touches deceleration button
9. One Touch Deceleration Switch
is "ON".
Lights up when the intelligent floating boom switch is
10. Intelligent Floating Boom Switch
set to "I" position or the "II" position.
11. Pilot Cut Off Switch Lights up when the pilot cutoff switch is "ON".
12. Air Cleaner Indicator ON/OFF Lights up when the air cleaner indicator contact is "ON".
13. Pilot Filter Lights up when the pilot filter pressure switch is "ON".
14. Return Filter Lights up when the return filter pressure switch is "ON".
Lights up when the overload warning selector switch
15. OWD Selector Switch
is "ON".
16. Swing Pressure Switch Lights up when the swing pressure switch is "ON".
17. Water in Fuel Lights up when WIF sensor is "ON".
18. Preheating (Electrical) Lights up when the preheating (electrical) is "ON".
19. Start up Switch Lights up when the starter switch is "START"
20. Swing Alarm Select Switch Lights up when the swing alarm selector switch is "ON".
21. Travel Alarm Select Switch Lights up when the travel alarm selector switch is "ON".
22. SPC Switch Lights up when the SPC switch is "ON".
Lights up when the emergency engine stop switch is
23. Emergency Engine Stop Switch
"ON".
24. One Way S/V Lights up when the one way solenoid valve is "ON".
Lights up when the relief pressure solenoid valve is
25. Relief Pressure S/V
"ON".
26. High Speed S/V Lights up when the high-speed solenoid valve is "ON".
27. Bypass Cut Off S/V Lights up when bypass cut off solenoid valve is "ON".
Lights up when the swing brake release solenoid
28. Swing Brake Release S/V
valve is "ON".
29. Back Buzzer Relay Lights up when the back buzzer relay is "ON".
30. Core TMS Status Lights up when the core TMS status is "ON".
31. Preheat Relay Lights up when the preheat relay is "ON".
32. Preheat Solenoid Lights up when the preheat solenoid is "ON".

9-1-66
Submenu Selections
Alternator One Touch Deceleration Switch

Power Max Switch Intelligent Floating Boom Switch
One Way Operator Switch Pilot Cut Off Switch
Hi-Speed Selector Switch-M Air Cleaner Indicator
Hi-Speed Selector Switch-A Pilot Filter
Working Lamp Switch Return Filter
Quick Coupler OWD Selector Switch
Air Conditioner Switch Swing Pressure Switch
Relief Pressure S/V Water in Fuel

High Speed S/V Preheating (Electrical)
Bypass Cut Off S/V Start up Switch
Swing Brake Release S/V Swing Alarm Select Switch
Back Buzzer Relay Travel Alarm Select Switch
Core TMS Status SPC Switch
Preheat Relay Emergency Engine Stop Switch
Preheat Solenoid One Way S/V
EX1400250
Figure 121

9-1-67
Engine Signal Description
Analog Items Display Remark

1. Engine Speed rpm Engine Speed
2. Throttle Position % Throttle Position
3. % Load at Current Speed % Current load ratio of equipment
4. Actual Engine Percent Torque %
5. Fuel Rate L/h Fuel Rate
6. Boost Pressure bar Pump pressure for boost
7. Engine Oil Pressure bar Engine Oil Pressure
8. Fuel Temperature °C Fuel Temperature
9. Engine Oil Temperature °C Engine Oil Temperature
10. Coolant Water Temperature °C Coolant Coolant Temperature Gauge
11. Intake Manifold Temperature °C Intake Manifold Temperature
12. Total Fuel Used L Total Fuel Used
13. App Command % App Command
14. DEF Level %
Submenu Selections
Engine Signal Engine Signal

Engine Speed 0 rpm Engine Oil Temperature. -273
Throttle Position 0 % Coolant Water Temperature. -40
% Load at Current Speed 0 % Intake Manifold Temperature. -40
Actual Engine Percent Torque -125 % App Command 0 L
Fuel Rate 0.0 L/h Total Fuel Used 0 %
Boost Pressure 0 bar DEF Level 0 %
Engine Oil Pressure 0 bar
Fuel Temperature -40
EX1400251
Figure 122
User Selection Signal

User can select signals of all monitoring items.
Front Pump Press.
The maximum limit of monitoring signal is 8. Rear Pump Press.
Boom Cylinder Press.
Px Pressure
Py Pressure
Alternator Voltage
Battery Voltage
Engine Dial Volt.
EX1301613
Figure 123

9-1-68
Rear Pump Press. Front Pump Press. 0 bar
Boom Cylinder Press. 0 bar
Px Pressure Boom Cylinder Press. 0 bar
Py Pressure You canPxselect up to 8
Pressure 0 bar
Alternator Voltage items!
Py Pressure 0 bar
Battery Voltage Alternator Voltage 1V
Engine Dial Volt. Battery Voltage 24.7 V
Flow Ctrl Lever LH Volt. Engine Dial Volt. 215 mV
Flow Ctrl Lever LH Volt.
EX1301614
Figure 124
Graph
PM
1. Entering Submenus: When a cursor is located in "Graph" Service Menu
of special menu screen press enter jog switch (1 on Figure
Monitoring
115) and "Graph" screen is displayed.
Graph
2. Exiting Submenus: If escape button (ESC, 4 on Figure Failure Information
115) is pressed, this information screen will be returned to Operationg Hour Information
previous screen. Vehicle Configuration
SPC
S USB
EX1301615
Figure 125
Graph Data Monitoring

PM
Real time monitoring of the selected data. Service Menu
Graph Data Setting
SPC
S USB
EX1301084
Figure 126

Battery Voltage V Current Value : 24.7
40.0
Engine Dial Volt.
Rotating P/V (CCW)
0
1 19 Sec
EX1301616
Figure 127

9-1-69
Graph Data Setting
Graph Data Setting
User can be graph data setting. Front Pump Press.
The maximum limit of the graph data setting is 7. Rear Pump Press.
Boom Cylinder Press.
Px Pressure You can select up to 7
Py Pressure items!
Alternator Voltage
Battery Voltage
Engine Dial Volt.
EX1301617
Figure 128
Failure Information
PM
1. Entering Submenus: When a cursor is located in "Failure Service Menu
Info" of special menu screen, press jog switch (1 on Figure
Monitoring
115) and "Failure Info" screen is displayed.
Graph
2. Exiting Submenus: If escape button (ESC, 4 on Figure Failure Information
115) is pressed, this information screen will be returned to Operationg Hour Information
previous screen. Vehicle Configuration
SPC
S USB
EX1301086
Figure 129
* Real-time Failure: Current status of fault is displayed.

PM
* Failure Log: Memorized record of past fault is displayed. Failure Information
Real Time Failure Information
Failure Log Information
SPC
S USB
EX1301087
Figure 130
A. Current failure information

Real Time Failure Information
Current status of fault is displayed (Failure code, fault NO Code Description
contents). 1 VCO002-11 THUMB WHEEL (LH)
2 VPV001-05 PUMP P/V (A), Current below normal
When several faults are produced, fault information 3 VPV010-05 FLOW CONTROL P/V (F) ROTATIN.
can be checked using the jog switch (1, Figure 115). 4 VSV001-05 BREAKER OPERATING S/V, Curen.
5 VSP011-04 ARM OUT PRESS. SENSOR, Voltag
No: Number of currently occurring failure 6 VSP008-04 BOOM DOWN PRESS. SENSOR, Vo
Description
Code: Display of current failure code Pump P/V (A), Current below normal
VXXyyy-zz: Method of displaying machine related

failure code EX1301618
Figure 131
– V: Display of machine related failure code
– XX: Display of failed part

9-1-70
– 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
Failure Log Information
Memorized record of past failure is displayed (Failure NO Code Count Occurrence Time
code, fault contents). 5 VPV007-05 9 21 Hr 20 Min
6 VCO002-11 25 21 Hr 27 Min
When several faults are produced, failure information 7 VSP011-04 2 21 Hr 56 Min
can be checked using the jog switch (1, Figure 115). 8 VSP008-04 1 21 Hr 56 Min
9 VSV001-05 4 21 Hr 56 Min
NOTE: "Count: xxx": "xxx" means that totally 10 VPV001-05 15 21 Hr 56 Min
Description
counted number of the same fault.
BREAKER OPERATING S/V, Current below normal
"Occurrence Time": It indicates the period
for which machine has operated until a EX1301619
fault takes place. (For more than two Figure 132
occurrences of the same fault, until first
occurrence time.)

9-1-71
Failure Code at Machine
GP Correct Value
Measuring Severity
Display SPN Name FMI GP Display Description Remark
Point Active Passive Level
Code
It is a composite
Gauge Panel 6-12/ resistance of
VCO001 CAN (Gauge Panel) 11 4
Communication Error 6-13 CAN
line. This value
R = 60 ±5 Ω has to be
measured by
E-ECU Communication 1-72/ connected
VCO002 CAN (ECU) 11 4
Error 1-78 condition of CAN
line.
Pump P/V (A), Current
5
Below Normal 2-119/ R = 13.5 ±2 Ω
VPV001 Pump P/V (A) 3
Pump P/V (A), Current 2-114 (25°C (77°F))
6
Above Normal
Pump P/V (B), Current
5
Below Normal 3-16/ R = 13.5 ±2 Ω
VPV002 Pump P/V (B) 3
Pump P/V (B), Current 3-8 (25°C (77°F))
6
Above Normal
Fan Control P/V (J), Current
5
Below Normal 2-116/ R = 22.5 ±2 Ω
VPV004 Fan Control P/V (J) 3
Fan Control P/V (J), Current 2-121 (25°C (77°F))
6
Above Normal
Press. Control 1 P/V (H),
5
Current Below Normal 2-111/ R = 9.5 ±2 Ω
VPV005 Press. Control 1 P/V (H) 3
Press. Control 1 P/V (H), 2-112 (25°C (77°F))
6
Current Above Normal
Press. Control 2 P/V (I),
5
Current Below Normal 2-109/ R = 9.5 ±2 Ω
VPV006 Press. Control 2 P/V (I) 3
Press. Control 2 P/V (I), 2-110 (25°C (77°F))
6
Flow Control P/V (C) 2-way
5 RH-open, Current Below
Flow Control P/V (C) Normal 2-89/ R = 18 ±2 Ω
VPV007 3
2-way RH-open Flow Control P/V (C) 2-way 2-97 (25°C (77°F))
6 RH-open, Current Above
Normal
Flow Control P/V (D) 2-way
5 RH-close, Current Below
Flow Control P/V (D) 2- Normal 2-88/ R = 18 ±2 Ω
VPV008 3
way RH-close Flow Control P/V (D) 2-way 2-95 (25°C (77°F))
6 RH-close, Current Above
Normal
Flow Control P/V (E)
5 Rotating CW, Current Below
Flow Control P/V (E) Normal 2-103/ R = 18 ±2 Ω
VPV009 3
Rotating CW Flow Control P/V (E) 2-104 (25°C (77°F))
6 Rotating CW, Current Above
Normal
Flow Control P/V (F)
5 Rotating CCW, Current
Flow Control P/V (F) Below Normal 2-105/ R = 18 ±2 Ω
VPV010 3
Rotating CCW Flow Control P/V (F) 2-113 (25°C (77°F))
6 Rotating CCW, Current
Above Normal
Travel Straight P/V (L),
5
Current Below Normal 3-7/ R = 18 ±2 Ω
VPV012 Travel Straight P/V (L) 4
Travel Straight P/V (L), 3-15 (25°C (77°F))
6
Breaker Operating S/V,
5
Current Below Normal 1-1/ V = V_volt
VSV001 Breaker Operating S/V 3
Breaker Operating S/V, 1-25 (Note 4)
6

9-1-72
GP Correct Value
Measuring Severity
Code
High-speed S/V (C), Current
5
Below Normal 1-1/
VSV003 High-speed S/V (C) V = V_volt 3
High-speed S/V (C), Current 1-7
6
Above Normal
Swing Brake Release S/V
5
Swing Brake Release S/V (K), Current Below Normal 1-1/
VSV006 V = V_volt 4
(K) Swing Brake Release S/V 3-12
6
(K), Current Above Normal
Option Safety S/V, Current
5
Below Normal 1-1/
VSV007 Option Safety S/V V = V_volt 3
Option Safety S/V, Current 2-87
6
Above Normal
Bypass Cut Off S/V (J),
5
Current Below Normal 1-1/
VSV012 Bypass Cut Off S/V (J) V = V_volt 3
Bypass Cut Off S/V (J), 3-4
6
Glow Plug Relay, Current
5
Below Normal 1-1/
VRY001 Glow Plug Relay V = V_volt 3
Glow Plug Relay, Current 2-96
6
Above Normal
Alarm Relay, Current Below
5
Normal 1-1/
VRY002 Alarm Relay V = V_volt 3
Alarm Relay, Current Above 2-99
6
Normal
Front Pump Press. Sensor,

2
Incorrect Signal
It has to be
Front Pump Press. Front Pump Press. Sensor, 1-19/
VSP001 3 V=1V 2 measured in
Sensor Voltage Above Normal 1-37
engine stop state
Front Pump Press. Sensor,

4
Voltage Below Normal
Rear Pump Press. Sensor,

2
Incorrect Signal
It has to be
Rear Pump Press. Rear Pump Press. Sensor, 1-18/
VSP002 3 V=1V 2 measured in
Sensor Voltage Above Normal 1-36
engine stop state
Rear Pump Press. Sensor,

4
OWD Press. Sensor,

2
Incorrect Signal
It has to be
OWD Press. Sensor, 1-20/
VSP003 OWD Press. Sensor 3 V=1V 2 measured in
Voltage Above Normal 1-38
engine stop state
PRESS. Sensor, Voltage
4
Below Normal
Boom Up Press. Sensor,
3 It has to be
Voltage Above Normal 1-65/
VSP006 Boom Up Press. Sensor V=1V 2 measured in
Boom Up Press. Sensor, 1-29
4 engine stop state
Bucket Crowd Press.
3 Sensor, Voltage Above
Normal It has to be
Bucket Crowd Press. 5-3/
VSP007 V=1V 2 measured in
Sensor Bucket Crowd Press. 5-13
engine stop state
4 Sensor, Voltage Below
Normal
Boom Down Press. Sensor,
3 It has to be
Boom Down Press. Voltage Above Normal 5-2/
Sensor Boom Down Press. Sensor, 5-12
4 engine stop state

9-1-73
GP Correct Value
Measuring Severity
Code
Bucktet Dump Press.
Normal It has to be
Bucktet Dump Press. 5-1/
Sensor Bucktet Dump Press. 5-11
engine stop state
Normal
Arm In Press. Sensor,
3 It has to be
VSP010 Arm In Press. Sensor V=1V 2 measured in
Arm In Press. Sensor, 4-7
4 engine stop state
Arm Out Press. Sensor,
3 It has to be
VSP011 Arm Out Press. Sensor V=1V 2 measured in
Arm Out Press. Sensor, 4-8
4 engine stop state
Travel Press. Sensor (LH),
3 It has to be
Travel Press. Sensor Voltage Above Normal 4-3/
(LH) Travel Press. Sensor (LH), 4-9
4 engine stop state
Travel Press. Sensor (RH),
3 It has to be
Travel Press. Sensor Voltage Above Normal 4-4/
(RH) Travel Press. Sensor (RH), 4-10
4 engine stop state
Swing Press. Sensor,
3 It has to be
VSP014 Swing Press. Sensor V=1V 2 measured in
Swing Press. Sensor, 4-11
4 engine stop state
Att (Option) Press. Sensor,
3 It has to be
Att (Option) Press. Voltage Above Normal 4-6/
Sensor Att (Option) Press. Sensor, 4-12
4 engine stop state
Attachment 2 Press. Sensor,
3 It has to be
Attachment 2 Press. Voltage Above Normal 3-1/
Sensor Attachment 2 Press. Sensor, 3-9
4 engine stop state
Option Pedal 1 Press.
Normal It has to be
Option Pedal 1 Press. 5-8/
Sensor Option Pedal 1 Press. 5-18
engine stop state
Normal
Option Pedal 1 Press.
Normal It has to be
Option Pedal 1 Press. 5-7/
Sensor Option Pedal 1 Press. 5-17
engine stop state
Normal
Oil Temp. Sensor, Signal
0
Above Normal Range
R = 2.45 ±0.25 Ω
Oil Temp. Sensor, Voltage 1-15/ (25°C (77°F))
VSE001 Oil Temp. Sensor 3 3
Above Normal 1-33 R = 320 ±32 Ω
(80°C (176°F))
Oil Temp. Sensor, Voltage
4
Below Normal
Fuel Sensor, Voltage Above
3
Normal 1-14/ Empty: 5 ±0.2 Ω
VSE002 Fuel Sensor 3
Fuel Sensor, Voltage Below 1-32 Full: 500 ±10 Ω
4
Normal
WIF Sensor, Signal Below
1
Normal Range
WIF Sensor, Voltage Above 1-21/
VSE004 WIF Sensor 3 3
Normal 1-39
WIF Sensor, Voltage Below
4
Normal

9-1-74
GP Correct Value
Measuring Severity
Code
Angle Sensor (A), Voltage
3 V = 0.5 V excess
Above Normal 5-10/
VSE007 Angle Sensor (A) V = 4.5 V less 3
Angle Sensor (A), Voltage 5-20
4 than
Below Normal
Angle Sensor (B), Voltage
3 V = 0.5 V excess
Above Normal 5-9/
VSE008 Angle Sensor (B) V = 4.5 V less 3
Angle Sensor (B), Voltage 5-19
4 than
Below Normal
Thumb Wheel (RH) Voltage V = 1.0 ±0.1 V
3
Above Normal 1-11/ V = 2.5 ±0.2 V
VS5001 Thumb Wheel (RH) 3
Thumb Wheel (RH) Voltage 1-30 neutral
4 V = 4.0 ±0.1 V
Below Normal
Thumb Wheel (LH) Voltage V = 1.0 ±0.1 V
3
Above Normal 1-12/ V = 2.5 ±0.2 V
VS5002 Thumb Wheel (LH) 3
Thumb Wheel (LH) Voltage 1-31 neutral
4 V = 4.0 ±0.1 V
Below Normal
3 Dial, Voltage Above Normal

1-16/ V = 1.0 ±0.1 V
VS5005 Dial 3
1-34 V = 4.0 ±0.1 V
4 Dial, Voltage Below Normal
Alternator Potential, Voltage

3
Above Normal
VAL001 Alternator Potential 1-2 V = 27 ±0.1 V 4
Alternator Potential, Voltage
4
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.

9-1-75
Failure Code at Engine
GP (Graphic Panel): Code displays on Panel Gauge
SPN (Suspect Parameter Number), FMI (Failure Mode Identifier): Code displays on DMS
DTC (Diagnostic Trouble Code): Code displays on Scania Diagnostic tool
HEX: Hexadecimal, DEC: Decimal number
GP Scania DTC
SPN Code Light
Display SPN Name FMI GP Display Description Remarks
Code Status
Code HEX DEC
2123 8483 3 Throttle position sensor 1, short circuit to battery. Yellow
2122 8482 4 Throttle position sensor 1, short circuit to ground Yellow
Adapted throttle position sensor voltage, at closed end position,
2121 8481 7 Yellow
E000051 51 Engine Throttle Position is outside permitted range.
Adapted throttle position sensor voltage, at open end position, is
1091 4241 8 None
outside permitted range.
2138 8504 9 Throttle position sensor(s) bad performance, correlation error. Yellow
E000094 94 Engine Fuel Delivery Pressure 1100 4352 0 Accumulator pressure is too high Yellow
250A 9482 2 Oil level sensor (L_Oil), faulty None
250D 9485 3 Oil level sensor (L_Oil), short circuit to +24 V None
E000098 98 Engine Oil Level
250C 9484 4 Oil level sensor (L_Oil), short circuit to ground or open load None
1715 5909 10 Oil level sensor stuck (T110) None
0524 1316 1 Oil press sensor, pressure too low Red
0521 1313 2 Oil press sensor (P_Oil), faulty Yellow
0523 1315 3 Oil press sensor (P_Oil), short circuit to +24 V Yellow
0522 1314 4 Oil press sensor (P_Oil), short circuit to ground or open load Yellow
E000100 100 Engine Oil Pressure 1522 5410 13 Oil press sensor (T5) Yellow
1520 5408 16 Oil press sensor, press above normal Yellow
Indicates low oil pressure, will optionally result in engine
134F 4943 17 None
protective action
1521 5409 18 Oil press sensor, press below normal Yellow
0234 564 0 Boost pressure higher than reference Yellow
0299 665 1 Boost pressure lower than reference Yellow
0108 264 3 Boost press sensor (P_Boost), short circuit to +24 V Yellow
Boost press sensor (P_Boost), short circuit to ground or open
0107 263 4 Yellow
load
Turbocharger/supercharger boost pressure not detected -
2262 8802 7 Yellow
mechanical
Engine Intake Manifold #1 1081 4225 8 Boost pressure (T122) not plausible None
E000102 102
Pressure
107C 4220 9 Boost pressure (T122) not plausible None
006C 108 10 Correlation error, map higher than intercooler pressure None
006B 107 15 Correlation error, map higher than exp None
1234 4660 16 Boost pressure higher than reference at part load Yellow
1299 4761 18 Boost pressure lower than reference at part load Yellow
1066 4198 20 Plausibility error, map too high Yellow
1067 4199 21 Plausibility error, map too low Yellow
16EA 5866 0 Boost temperature sensor excessive high Yellow
16EB 5867 1 Boost temperature sensor excessive low Yellow
0096 150 2 Boost temp sensor (T_Boost), faulty Yellow
0098 152 3 Boost temp sensor (T_Boost), short circuit to +24 V or open load Yellow
0097 151 4 Boost temp sensor (T_Boost), short circuit to ground Yellow
Boost temperature sensor above normal, plausibility test during
16EE 5870 9 None
low load and no EGR
Engine Intake Manifold 1
E000105 105
Temperature 16F3 5875 15 Boost temperature (T121) high Yellow
16C3 5827 16 High boost temp. Yellow
Boost temperature sensor below normal, plausibility test during
16EF 5871 17 None
low load and no EGR
Boost temperature sensor above normal, plausibility test when
16F0 5872 20 None
EGR active
Boost temperature sensor below normal, plausibility test when
16F1 5873 21 None
EGR active

9-1-76
GP Scania DTC
SPN Code Light
Code Status
Code HEX DEC
Engine Air Filter 1 Differential 1422 5154 1 Air filter clogged. None
E000107 107
Pressure 1423 5155 2 Air filter control switch broken. Yellow
2226 8742 2 Ambient pressure sensor error (by CAN) None
16DB 5851 3 Ambient pressure sensor, SCB. Yellow
16DA 5850 4 Ambient pressure sensor engines, SCG. Yellow
E000108 108 Barometric Pressure 106C 4204 15 Correlation error, AAP higher than EXP None
006D 109 16 Correlation error, AAP higher than intercooler pressure None
1064 4196 20 Plausibility error, AAP too high Yellow
1065 4197 21 Plausibility error, AAP too low Yellow
1133 4403 0 Engine coolant water temperature excessive high. None
1128 4392 1 Coolant temperature (T33) too low None
1136 4406 2 Coolant temperature sensor fault (T33) None
0118 280 3 Engine temp sensor 1 (T_ENG1), short circuit to battery or open load Yellow
0117 279 4 Engine temp sensor 1 (T_ENG1), short circuit to ground Yellow
0115 277 8 Engine temperature sensor stuck Yellow
0116 278 9 Engine temp sensor 1 (T_ENG1), faulty Yellow
E000110 110 Engine Coolant Temperature
1135 4405 10 Engine coolant temperature (T33) is not plausible. Yellow
1132 4402 16 Engine coolant water temperature too high. None
Engine temp sensor 1 (T_ENG1), temp below normal or
1130 4400 17 Yellow
VGT-temp above normal.
Engine temp sensor 1 (T_ENG1), temp above normal or VGT-
1131 4401 18 Yellow
temp below normal.
0217 535 20 Engine coolant water temperature too high. No action. Yellow
0128 296 21 Coolant temperature below thermostat regulating temperature None
2560 9568 1 Engine coolant level too low. No action. Yellow
2556 9558 3 Engines coolant level sensor, short circuit to battery None
E000111 111 Engine Coolant Level
Engine coolant level sensor/switch circuit low, short circuit to
2558 9560 4 Yellow
ground
0088 136 0 Fuel rail pressure is excessively above command Yellow
0087 135 1 Fuel rail pressure is excessively below command with engine on Yellow
0191 401 2 Fuel rail press sensor (P_Rail), faulty Yellow
Fuel rail press sensor (P_Rail), short circuit to +24 V or open
Engine Injector Timing Rail 1 0193 403 3 Yellow
E000156 156 load
Pressure
0192 402 4 Fuel rail press sensor (P_Rail), short circuit to ground Yellow
0190 400 8 Fuel rail press sensor (P_Rail), stuck Yellow
1090 4240 9 Fuel rail pressure is lagging. None
1087 4231 18 Fuel rail pressure is too low during cranking Yellow
1060 4192 2 Alternator actuator (altU15Act), faulty Yellow
1063 4195 3 Alternator actuator (altU15Act), Short Circuit to +24V Yellow
Charging System Potential 1062 4194 4 Alternator actuator (altU15Act), short circuit high to ground Yellow
E000167 167
(Voltage) 1061 4193 5 Alternator actuator (altU15Act), open load Yellow
063A 1594 9 Alternator 1 - no signal or not plausible signal Yellow
160B 5643 10 Alternator 2 - no signal or not plausible signal Yellow
1565 5477 0 Battery voltage > 47 V for 1 s Red
1564 5476 1 Battery voltage < 9 V for 0.5 s Yellow
1507 5383 4 Supply voltage 1 for engine control unit approximately 0 V Yellow
1509 5385 5 Supply voltage 2 for engine control unit approximately 0 V Yellow
E000168 168 Battery Potential / Power Input 1
2064 8292 15 SCR - external battery voltage too high. Yellow
0563 1379 16 Battery voltage > 32 V for 5 s Yellow
2063 8291 17 SCR - external battery voltage too low. Yellow
0562 1378 18 Battery voltage < 21 V (not below 400 rpm) for 5 s Yellow
Ambient temperature sensors correlation error. AAT1 higher
1074 4212 0 Yellow
E000171 171 Ambient Air Temperature than AAT2.
1271 4721 1 Ambient temperature (T27) low or boost temperature (T121) high Yellow

9-1-77
GP Scania DTC
SPN Code Light
Code Status
Code HEX DEC
11B0 4528 2 Ambient temperature sensor, faulty. Yellow
1073 4211 3 Electrical fault on AAT2 (by CAN) None
1075 4213 4 Electrical fault on AAT2 (by CAN) None
1077 4215 7 Ambient temperature sensor stuck/manipulated None
D104 53508 9 CAN message (ambient condition) from coordinator time out None
Ambient temperature sensors correlation error. AAT1 higher
1076 4214 15 Yellow
than AAT3.
Ambient temperature (T27) high or boost temperature (T121)
1270 4720 16 None
E000171 171 Ambient Air Temperature low
Ambient temperature sensors correlation error, AAT1 shows
1071 4209 17 Yellow
lower value than AAT3.
Ambient temperature sensors correlation error, AAT1 shows
1072 4210 18 Yellow
lower value than AAT2.
1070 4208 19 Ambient temperature sensor signal defect (by CAN) None
Temperature sensor before compressor low or ambient
0070 112 20 Yellow
temperature sensor high
Temperature sensor before compressor high or ambient
0071 113 21 Yellow
temperature sensor low
1205 4613 0 Severe overspeed has occurred Red
1201 4609 10 Over speed protection, fast over speed None
E000190 190 Engine Speed 1321 4897 15 Engine speed has been above the limit, DTC for information. None
1202 4610 16 Over speed protection, over speed Yellow
0219 537 20 Engine overspeed, value to high None
D107 53511 2 Kick-down signal defect (by CAN) None
Accelerator Pedal Kick-down
E000559 559 1550 5456 9 Accelerator pedal kick-down CAN message, faulty Yellow
Switch
D418 54296 10 Accelerator pedal/kick-down switch, EMS and coordinator don't agree Yellow
Engine Idle Shutdown Timer
E000590 590 - - 2 None
State
1214 4628 1 Camshaft sensor (T135) fault or not connected Yellow
0344 836 2 Camshaft position sensor, intermittent fault Yellow
0343 835 3 Camshaft position sensor, short circuit to battery Yellow
0342 834 4 Camshaft position sensor, short circuit to ground Yellow
E000636 636 Engine Position Sensor
0340 832 5 Camshaft position sensor, open circuit. Yellow
Engine speed detected by engine speed sensor, but no signal
0016 22 7 Yellow
from camshaft position sensor
0341 833 8 Camshaft pulse pattern, gap or sync error or other fault. Yellow
11A1 4513 1 Two or more injectors with the same trim code, injector cyl. 1 Yellow
1178 4472 2 Injector trim code. Barcode or checksum error, injector cyl. 1 Yellow
0261 609 4 Injector 1 cable short circuit to ground Yellow
0201 513 5 Injector cyl. 1 cable/injector open load Yellow
115F 4447 6 Injector cyl. 1 cable/injector short circuit Yellow
1150 4432 7 Injection error, physical cylinder 1 Yellow
118F 4495 8 Injector cyl. 1, over or under fueling Yellow
E000651 651 Engine Injector Cylinder #01 Fault with sensors/actuators that monitor/control the particulate
12C0 4800 10 Red
filter
1199 4505 13 Injector trim code version error, injector cyl. 1 Yellow
11E0 4576 15 Cylinder 1 torque error None
11D0 4560 16 Cylinder 1 (V141) injector fault None
0263 611 20 Cylinder 1 balancing min or max. None
11E8 4584 21 Fault in injector for short diagnosis None
1179 4473 2 Injector trim code. Barcode or checksum error, injector cyl. 2 Yellow
E000652 652 Engine Injector Cylinder #02

9-1-78
GP Scania DTC
SPN Code Light
Code Status
Code HEX DEC
1161 4449 6 Injector cyl. 2 cable/injector short circuit Yellow
1190 4496 8 Injector cyl. 2, over or under fueling Yellow
Fault with sensors/actuators that monitor/control the particulate
12C1 4801 10 Yellow
filter
119A 4506 13 Injector trim code version error, injector cyl. 2 Yellow
0266 614 20 Cylinder 2 balancing min or max None
117A 4474 2 Injector trim code. Barcode or checksum error, injector cyl. 3 Yellow
12C2 4802 10 Red
filter
119B 4507 13 Injector trim code version error, injector cyl. 3 Yellow
11DA 4570 18 Cylinder 3 (V143) injector fault None
117B 4475 2 Injector trim code. Barcode or checksum error, injector cyl. 4 Yellow
0204 516 5 Injector cyl. 4 cable/injector open load. Yellow
E000654 654 Engine Injector Cylinder #04 1167 4455 6 Injector cyl. 4 cable/injector short circuit Yellow
12C3 4803 10 Fault with sensors/actuators that monitor/control the particulate filter Yellow
119C 4508 13 Injector trim code version error, injector cyl. 4 Yellow
11DB 4571 18 Cylinder 4 (V144) injector fault None
117C 4476 2 Injector trim code. Barcode or checksum error, injector cyl. 5 Yellow
116E 4462 6 Injector cyl. 5 cable/injector short circuit Yellow
12C4 4804 10 Yellow
filter
119D 4509 13 Injector trim code version error, injector cyl. 5 Yellow
11DC 4572 18 Cylinder 5 (V145) injector fault None
117D 4477 2 Injector trim code. Barcode or checksum error, injector cyl. 6 Yellow
1171 4465 6 Injector cyl. 6 cable/injector short circuit. Yellow

9-1-79
GP Scania DTC
SPN Code Light
Code Status
Code HEX DEC
119E 4510 13 Injector trim code version error, injector cyl. 6 Yellow
E000656 656 Engine Injector Cylinder #06 11E5 4581 15 Cylinder 6 torque error None
11DD 4573 18 Cylinder 6 (V146) injector fault None
0278 632 20 Cylinder 6 balancing min or max Yellow
117E 4478 2 Injector trim code. Barcode or checksum error, injector cyl. 7 Yellow
119F 4511 13 Injector trim code version error, injector cyl. 7 Yellow
E000657 657 Engine Injector Cylinder #07 11DE 4574 18 Cylinder 7 (V147) injector fault None
Two or more many injectors with the same trim code, injector
11A8 4520 1 Yellow
cyl. 8
117F 4479 2 Injector trim code. Barcode or checksum error, injector cyl. 8 Yellow
11A0 4512 13 Injector trim code version error, injector cyl. 8 Yellow
11DF 4575 18 Cylinder 8 (V148) injector fault None
0284 644 20 Cylinder 8 balancing min or max Yellow
160D 5645 0 Unintentional starter activation while moving or idling. Yellow
160C 5644 2 Starter actuator (starter), faulty. Yellow
1645 5701 3 Starter actuator (starter), short circuit to +24 V Yellow
E000677 677 Engine Starter Motor Relay 1646 5702 4 Starter actuator (starter), short circuit high to ground Yellow
0512 1298 5 Starter actuator (starter), open load Yellow
1670 5744 7 Starter actuator blind start None
D108 53512 19 Starter motor demand defect (by CAN) None
1602 5634 2 Fan actuator (fanAct), faulty. Yellow
0692 1682 3 Fan actuator (fanAct), short circuit to +24 V Yellow
E000986 986 Requested Percent Fan Speed 0691 1681 4 Fan actuator (fanAct), short circuit high to ground Yellow
0480 1152 5 Fan actuator (fanAct), open load Yellow
1603 5635 7 Fan coupling unit, bad performance Yellow
Engine Protection System has
E001110 1110 16BF 5823 14 Engine stop because of other fault. Red
Shutdown Engine
E001239 1239 Engine Fuel Leakage 1 0094 148 7 Fuel rail pressure, small volume leak Yellow
Engine Misfire for Multiple
E001322 1322 0300 768 7 Random/multiple cylinder misfire detected None
Cylinders
E001323 1323 Engine Misfire Cylinder #1 0301 769 7 Cylinder 1 misfire detected None
E001328 1328 Engine Misfire Cylinder #6 - - 7 Cylinder 6 misfire detected None

9-1-80
GP Scania DTC
SPN Code Light
Code Status
Code HEX DEC
1183 4483 2 Inlet metering valve 1 (IMV1), Faulty. Red
1184 4484 3 Inlet metering valve 1 (IMV1), short circuit high to +24 V Red
Inlet metering valve 1 (IMV1), SCB on low side or OL or SCG on
1182 4482 5 Yellow
E001442 1442 Engine Fuel Valve 1 Position high side
11B8 4536 7 IMV (V120) malfunction None
11B1 4529 8 Plausible leakage in the inlet metering valve Yellow
118E 4494 10 Calculated IMV resistance not ok Yellow
1605 5637
1606 5638 2 EMS memory error. None
1610 5648
1607 5639
Source Address of Controlling 8 EMS memory or TPU error Red
E001483 1483 160F 5647
Device for Engine Control
16D7 5847 9 Camshaft TPU supervision error. Yellow
160A 5642 11 Software watchdog reset Yellow
1604 5636 12 Hardware watchdog error Red
E001632 1632 Engine Torque Limit Feature - - 2 Engine torque limit feature None
16F9 5881 3 Fan/WPC speed sensor, short circuit to battery Yellow
E001639 1639 Fan Speed 0526 1318 4 Fan/WPC speed sensor supply too low Yellow
0528 1320 8 Fan speed sensor circuit (T123) no signal Yellow
1704 5892 1 Reductant tank empty Yellow
203C 8252 2 Reductant tank level sensor, short circuit. Yellow
Aftertreatment 1 SCR Catalyst
E001761 1761 203A 8250 3 Reductant tank level sensor, short circuit to battery. Yellow
Tank Level
203D 8253 5 Reductant tank level sensor, open circuit. Yellow
203F 8255 18 Low reductant level in the tank, tank empty Yellow
115D 4445 2 Group A - short to other bank Yellow
115C 4444 3 Group A - short circuit battery Yellow
115B 4443 4 Group A - short circuit ground Yellow
E002797 2797 Engine Injector Group 1 11A9 4521
5 GAS: power stage relay (R651) Yellow
1692 5778
115A 4442 5 Injector drive voltage Yellow
116D 4461 8 Injection error, group A Yellow
116C 4460 2 Group B - short to other bank Yellow
116B 4459 3 Group B - short circuit battery Yellow
E002798 2798 Engine Injector Group 2 11AA 4522 4 Group B - short circuit ground Yellow
116A 4458 5 GAS: Power stage relay (R652) Yellow
1608 5640 8 Injection error, group B Yellow
E003031 3031 1038 4152 0 SCR - Main Unit, high temperature low limit exceedence. Yellow
Tank Temperature
2202 8706 4 NOx downstream sensor, short circuit to ground. Yellow
2200 8704 5 NOx downstream sensor, open circuit. Yellow
NOx sensor circuit range/performance, downstream NOx-
2201 8705 7 Yellow
sensor
12C9 4809 8 NOx downstream sensor error on CAN Yellow
100F 4111 9 SCR - NOx sensor not ready, downstream NOx-sensor Yellow
. 3226 Aftertreatment 1 Outlet Nox 16CE 5838 10 SCR - NOx downstream sensor is stuck Yellow
Downstream NOx-sensor has low sensitivity compared to
16F2 5874 17 None
engine out NOx-model.
Downstream NOx-sensor has low sensitivity compared to
16D9 5849 18 None
upstream NOx-sensor.
100A 4106 19 NOx downstream sensor, CAN error. Yellow
16FB 5883 20 Downstream NOx-sensor has large NOx bias fault. None

9-1-81
GP Scania DTC
SPN Code Light
Code Status
Code HEX DEC
0426 1062 2 Exhaust gas temperature sensor before the SCR catalyst (T113) Yellow
Upstream catalyst temperature sensor not plausible.
104D 4173 3 None
Temperature is above normal.
0427 1063 4 Exhaust gas temperature sensor before the SCR catalyst (T113) None
Aftertreatment 1 Exhaust Gas
E003241 3241
Temperature 1 0425 1061 5 Exhaust gas temperature sensor before the SCR catalyst (T113) None
104F 4175 8 Exhaust gas temperature sensor before the SCR catalyst (T113) Yellow
16CD 5837 10 Exhaust gas temperature sensor before the SCR catalyst (T113) Yellow
20ED 8429 16 Upstream SCR temperature sensor (T113) - too high Red
Aftertreatment 1 Exhaust Gas 104E 4174 18 Exhaust gas temperature sensor before the SCR catalyst (T113) None
E003241 3241
Temperature 1 16FF 5887 19 CAN error on all three sensors on can triple temperature sensor Yellow
16DD 5853 0 SCR control max limit, STAD None
16DE 5854 1 SCR control min limit, STAD None
The EEC3 System has demanded "SCR Hazardous major
12C7 4807 2 Red
functional failure" actions.
20A3 8355 3 SCR - Main unit, ventilation valve test, short to battery. Yellow
1033 4147 4 SCR - Main unit, internal supply voltage low Yellow
20A0 8352 5 Main unit, ventilation valve test, open load. Yellow
Aftertreatment 1 SCR Catalyst 1047 4167 6 EEC system voltage error Yellow
E003360 3360
Tank Controller
1022 4130 7 SCR - Ignition switch, plausible error. Yellow
The EEC3 has demanded "SCR Major functional failure
12C6 4806 9 Yellow
reductant dosing stopped" actions.
The EEC3 system has demanded "SCR minor functional failure"
12C8 4808 10 Yellow
actions.
16AA 5802 12 SCR - Main unit, error Yellow
1032 4146 16 SCR - Main unit, internal supply voltage high Yellow
100C 4108 19 Communication with the SCR control unit error. Yellow
2049 8265 3 SCR - Reductant dosing valve, short circuit to battery. Yellow
E003361 3361 2047 8263 5 SCR - Reductant dosing valve, open circuit. Yellow
Dosing Unit
208E 8334 10 SCR - Injection valve for reductant Yellow
20C0 8384 0 SCR - Main unit, reductant heater main unit control circuit high Yellow
SCR - Main unit, reductant heater main unit heater control
20BD 8381 2 Yellow
circuit/open
20C4 8388 3 SCR - Main unit, internal heating pump, short circuit battery Yellow
2044 8260 4 SCR - Main unit, reductant temperature sensor circuit low Yellow
Aftertreatment 1 SCR Catalyst 20C1 8385 5 SCR - Main unit, internal heating pump, open load. Yellow
E003363 3363
Tank Heater SCR - Main unit, reductant heater main unit control circuit
20BE 8382 8 Yellow
performance
1054 4180 15 SCR - Reagent tank temperature too high None
101A 4122 16 SCR - Main unit, high temperature high limit exceeded. Yellow
209F 8351 17 SCR - Reductant tank heater Yellow
2045 8261 18 SCR - Main unit, low temperature limit exceeded. Yellow
1049 4169 0 SCR system Yellow
NOx limits exceeded, root
E004090 4090 2BAD 11181 11 NOx exceedence - Root cause unknown None
cause unknown
20EE 8430 16 SCR system Yellow
NOx limits exceeded because
E004095 4095 2BA8 11176 2 NOx exceedence - Interruption of reagent dosing activity None
of Interrupted Reagent Dosing
NOx limits exceeded because
E004096 4096 2BA7 11175 2 NOx exceedence - Empty reagent tank None
of Empty Reagent Tank
1040 4160 0 SCR - Reductant pressure Yellow
The EEC3 has demanded "SCR Hazardous Minor Functional
12C5 4805 1 Yellow
Failure reductant pump stopped" actions.
Aftertreatment 1 SCR Dosing 103D 4157 2 Urea pressure sensor, plausible error during start-up Yellow
E004334 4334
Reagent Absolute Pressure
204D 8269 3 Urea pressure sensor, SRC high Yellow
204C 8268 4 Urea pressure sensor, SRC low Yellow
204B 8267 8 Urea pressure sensor, pressure to high, not plausible Yellow
Aftertreatment 1 SCR Dosing
E001483 4337 N/A None
Reagent Temperature

9-1-82
GP Scania DTC
SPN Code Light
Code Status
Code HEX DEC
E004341 4341 Reagent Line Heater 1 N/A None
Preliminary FMI
Aftertreatment 1 SCR Catalyst 1031 4145 0 SCR - Main unit, reductant pump fault, pump speed too high Yellow
E004374 4374
Reagent Pump Motor Speed 1030 4144 1 SCR - Main unit, reductant pump fault, pump speed too low. Yellow
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

9-1-83
Information of Machine Operation
Accumulated operation hour of each mode and status is
displayed.
Operating Hour Information
PM
1. Entering Submenus: When a cursor is located in Service Menu
"Operating Hrs" of special menu screen (Figure 133) press
Monitoring
jog switch (1 on Figure 115) and "Operating Hrs" screen
will be displayed (Figure 134). Graph
Failure Information
Operationg Hour Information
SPC
S USB
EX1301088
Figure 133
2. Operating Hours Screen

Operationg Hour Information
4 hr
0 hr
14 hr
0 hr
0 hr
0 hr
0 hr
0 hr
EX1301626
Figure 134
3. Exiting Submenus: If escape button (ESC, 4 on Figure

115) is pressed for more than 1 second, this information
screen will be returned to previous screen.

9-1-84
Information contents of operation hour
Item Information Contents Detection Method

Power Plus Mode Operation hours used Power Plus Power Plus Mode status (Instrument
Mode are displayed. panel) and Alternator signal (CN1-2) is
"HI"
Power Mode Operation hours used Power Mode Power Mode status (Instrument panel)
are displayed. and Alternator signal (CN1-2) is "HI"
Standard Mode Operation hours used standard Standard Mode status (Instrument panel)
mode are displayed. and Alternator signal (CN1-2) is "HI".
Economy Mode Operation hours used economy Economy Mode status (Instrument
mode are displayed. panel) and Alternator signal (CN1-2) is
"HI"
Auto Idle Operation hours used auto idle Auto Idle Mode status (Instrument panel)
status are displayed. and Alternator signal (CN1-2) is "HI"
The operation hours for Lift Mode
Lift Mode
are displayed.
The operation hours for Breaker
Breaker Mode
Mode are displayed.
The operation hours for Two-way
Two-way Mode
Mode are displayed.
Hydraulic Oil Temperature Temperature of hydraulic oil is The resistance delivered from
Distribution (°C (°F)) classified 6 steps, and operation temperature sensor of hydraulic oil is
hours of each step are displayed classified 6 steps, and operation hours of
each step are displayed.
Under 30°C (87°F)
(Alternator output HI status)
31 - 50°C (88 - 123°F)
51 - 75°C (124 - 168°F)
76 - 85°C (169 - 186°F)
86 - 95°C (187 - 203°F)
Over 96°C (204°F)
Coolant Temperature Temperature of coolant is classified The resistance delivered from coolant
Distribution (°C (°F)) 6 steps, and operation hours of sensor is classified 6 steps, and
each step are displayed. operation hours of each step are
displayed. (Alternator output HI status)
Under 40°C (105°F)
41 - 60°C (106 - 141°F)
61 - 85°C (142 - 186°F)
86 - 95°C (187 - 204°F)
96 - 104°C (205 - 221°F)
Over 105°C (222°F)

9-1-85
Example of Machine Operation Info Screen
Operationg Hour Information Operationg Hour Information

4 hr Lift Mode 0 hr
0 hr Breaker Mode 0 hr
14 hr Two Way Mode 0 hr
0 hr
0 hr
0 hr
0 hr
0 hr
Operationg Hour Information Operationg Hour Information

17 hr 0 hr
1 hr 0 hr
1 hr 0 hr
1 hr 0 hr
0 hr 0 hr
0 hr 20 hr
EX1301077
Figure 135

9-1-86
1. Vehicle Configuration
PM
A. Entering Submenus: When a cursor is located in Service Menu
"Vehicle Configuration" of special menu screen
Monitoring
(Figure 136) press jog switch (1 on Figure 115) and
Graph
"Vehicle Configuration" screen will be displayed
(Figure 138). Failure Information
Operation Hour Information
SPC
S USB
EX1301089
Figure 136
Entering service password is required when

Service Password
accessing the menu.
Q Q
3 4 5 6 7 8 9 : ; <
Enter Service Password
EX1301634
Figure 137
B. Vehicle Configuration Screen (Figure 138).

Option Setting
Program Update
Vehicle Serial Number
Vehicle Information Delete
Version Information
SPC
S USB
EX1301090
Figure 138
C. Exiting Submenus: If escape button (ESC, 4 on

Figure 115) is pressed, this information screen will be
returned to previous screen.

9-1-87
Option Setting
1. Entering Submenus: When a cursor is located in "Option Vehicle Configuration
Setting" of special menu screen (Figure 139) press jog
switch (1 on Figure 115) and "Option Setting screen" will Option Setting
be displayed (Figure 140) Program Update

Version Information
SPC
S USB
EX1301090
Figure 139
2. Option Setting
• Attachment Option Vehicle Configuration
When a cursor is located in check box of breaker or Option Setting
two-way, press jog switch (1 on Figure 115) and then, Program Update
the check box light turns "ON". Vehicle Serial Number
Version Information
SPC
S USB
EX1301090
Figure 140
• Two Pump Option

Option Setting
When a cursor is located in check box of two pump
option, press jog switch (1 on Figure 115) and then
the check box light turns "ON". Attachment Option Breaker Two Way
• Two-way Option Pedal Two Pump Option Enable
Place the cursor on the check box for the two-way Two Way Option Pedal Enable
option pedal and select a function by pressing the jog
switch.
NOTE: Option setting can only be made for those
EX1301635
vehicles with the option in question.
Selecting a vehicle without the option can Figure 141
cause a problem in terms of performance
and safety.

9-1-88
3. Program Update
Entering Submenus: When a cursor is located in "Program Vehicle Configuration
Update" of special menu screen (Figure 142) press jog
Option Setting
switch (1 on Figure 115) and "Program Update Screen" will
be displayed (Figure 143). Program Update
NOTE: When USB memory is installed in USB port, Vehicle Information Delete
program update can be updated. Version Information
SPC
S USB
EX1301091
Figure 142
Program Update
Be careful not to remove USB or shut down GP. It may

Seriously damage the equipment.
Current Version V 0100 [2013.10.23]
Update Version No Available Update Files!
Insert USB for update!
EX1301636
Figure 143
4. Vehicle Serial Number

Entering Submenus: When a cursor is located in "Vehicle Vehicle Configuration
Serial Number" of special menu screen (Figure 144) press
Option Setting
jog switch (1 on Figure 115) and "Vehicle Serial Number
Program Update
Screen" will be displayed (Figure 145).
Vehicle serial number can be input by turning the jog Vehicle Information Delete
switch and pressing the jog switch. Version Information
SPC
S USB
EX1301092
Figure 144
3 4 5 6 7 8 9 : ; <
Enter Serial Number
EX1301638
Figure 145

9-1-89
5. Vehicle Information Delete
Entering Submenus: When a cursor is located in "Vehicle Vehicle Configuration
Information Delete" of special menu screen (Figure 146)
Option Setting
press jog switch (1 on Figure 115) and "Vehicle Information
Delete Screen" will be displayed (Figure 147) Program Update
NOTE: When press jog switch (1 on Figure 115) in the Vehicle Information Delete
selected menu the menu will be initialized. Version Information
- Delete Failure Log SPC
S USB
- Reset Operation Hour EX1301093

- GP Setting Reset Figure 146

Delete Failure Log
Reset Operation Hour
GP Setting Reset
EX1301094
Figure 147
6. Version Information
Entering Submenus: When a cursor is located in "Version Vehicle Configuration
Information" of special menu screen (Figure 148) press jog
Option Setting
switch (1 on Figure 115) and "Version Information Screen"
Program Update
will be displayed (Figure 149).
Vehicle Information
S USB
EX1301096
Figure 148
Version Information
EPOS S/W Version V 0100 [2013.10.11]
GP S/W Version V 0110 [2013.10.23]
GP OS Version V 0081 [2013.03.25]
EX1301637
Figure 149

9-1-90
9-1-91
ELECTRONIC HYDRAULIC CONTROL SYSTEM (EPOS)
Control System Schematic
15
6 6
7 7 11 13
8
8
12
14
33 33
E/G
4 4
5
3
21
22
9 10
PM
E/G speed order H H
E F
C E F C
TRIP
/h rpm ECO
Min Max
SPC
S USB
17 16 20 18 19 EX1400252
Figure 150

9-1-92
Reference Reference
Number Number
1 Instrument Panel 11 Solenoid Valve (Boost)
2 EPOS Controller 12 Solenoid Valve (High-speed)
3 Engine Controller (ECU) 13 Solenoid Valve (Breaker)
4 Main Pump 14 Travel Motor
5 Aux Pump 15 Main Relief Valve
6 Control Valve 16 Engine Control Dial
7 Pressure Switch 17 Jog Switch Control Panel
8 Pump Pressure Sensor 18 Auto Travel Selector Switch
Electromagnetic Proportional 19 Boost Switch (Right Work Lever)
9 Pressure Reducing Valve 20 Sensor
(Attachment)
21 Aux Mode Switch
Electromagnetic Proportional
22 Aux Mode Resistor
10 Pressure Reducing Valve
(Mode Control) 33 Pump Angle Sensor

9-1-93
POWER PLUS MODE CONTROL
6 6
33 33
E/G
5
4 4
3
10 10
23
2
22
32 17
1
PM
H H
E F
C E F C
TRIP
/h rpm ECO
Min Max
SPC
S USB
EX1400253
Figure 151
Reference Reference
Number Number
Instrument Panel 17 Engine Control Dial
1
(Power Mode Selector Switch) 22 Aux Mode Switch
2 EPOS Controller 23 Aux Mode Resistor
3 Engine Controller (ECU) 32 Jog Switch Control Panel
4 Main Pump 33 Pump Angle Sensor
5 Aux Pump
6 Control Valve
Electromagnetic Proportional
10 Pressure Reducing Valve
(Mode Control)

9-1-94
The Jog Switch Control Panel permits the selection of the
appropriate engine power depending on the working condition.
One of the four. Power Plus Mode, Power Mode, Standard Mode
or Economy Mode setting can be selected. When the engine
starter switch is turned "ON", the power mode is automatically
defaulted to standard mode. The desired mode can be selected
by pressing the jog switch on the jog switch control panel. When
the power mode is selected, the indicator light will turn "ON" to
display the selected mode.
The quantity of oil discharged by the pump and the engine
speed are determined by the mode selected by the operator.
The pump output in each mode is determined by the mode
selection and is listed in the following table
Mode Power Plus Mode Power Mode Standard Mode Economy Mode
Output (%) 100% Approximately 90% Approximately 80% Approximately 75%

9-1-95
Operation
1. Power Plus Mode

This mode must be selected for high-speed work. In this
mode the engine output is most efficiently utilized because
of the discharged oil volume being controlled based on the
equivalent horsepower curve at various loaded pressures.
The EPOS controller compares the target engine speed
with the actual engine speed and controls the signal to the
EPPR (Electromagnetic Proportional Pressure Reducing)
valve which in turn varies the pump output quantity.
If the load increases, the engine speed will fall below the
rated speed. When this occurs, the controller senses this
decrease and immediately reduces the pump discharge FG018900
volume to maintain the engine speed at the rated level. Figure 152
On the other hand, if the load is decreased the controller

increases the discharge volume of the pump to maintain PM
the engine speed at the rated level. H H
By repeating these control operations, the engine speed is Power Mode

maintained at the rated speed so maximum power can be
generated. P+E P SF E
C C
E F
In Power Mode, the EPOS controller receives engine TRIP
speed signals from the engine control dial and the engine /h rpm ECO
Min Max
s
SPC
controller (ECU) and converts it to an operating signal USB
current and is then transferred to the pump's EPPR valve. EX1301028

Now the EPPR valve converts the electric signal to the Figure 153
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 154
Reference Reference
Number Number
A Engine Horsepower (hp) Pump Discharge Pressure
D
B Engine Speed (rpm) (bar)
C Pump Discharge Volume (lpm)

9-1-96
2. Power Mode, Standard Mode, Economy Mode
Power Mode, Standard Mode or Economy Mode is
selected on the work type. When the standard/economy
mode is selected it will reduce noise and fuel consumption
in comparison with Power Plus Mode. The EPOS controller
compares the target engine speed with the actual engine
speed and controls the signal to the EPPR valve which in
turn varies the pump output quantity and it is the same
method with power volume.
A C
Power Plus Mode

Power Mode
Standard Mode
Economy Mode
B D FG018902
Figure 155
Reference Reference
Number Number
A Engine Horsepower (hp) C Pump Discharge Volume (lpm)
B Engine Speed (rpm) D Pump Discharge Pressure (bar)

9-1-97
POWER MODE CONTROL
15A
26
4 26 26 34
+
5-10
35 SIG
5-20
15A 10A
- B
1
BR
+ 1-1
35 SIG
5-9 1-3 E 25
5-19
-
7-5
7-6
7-2
24
7-4
7-3 27
7-1
6-12 1-77
6-13 1-78 CAN A
1-59
23
22
1-61 GND 2-119 1
2
3
1-62 RxD
4
23
1-81 TxD 2-114
5
6
7
3-16
8 23
9
3-8 10
36
11 87a
12 30
87
85 86
22
1
2
3
3 1
5
4
2 6
3 3-15 7
C4001-6 8
4 9
C4001-7
5 3-7 10
11
6 12
C4001-2
32 3 4
14
C4001-5 23
C4002-2 2
C4002-5
C4071-2 1 GND 1-34 3
17
CW HIGH
C4002-1 SIG 1-16 2
C4071-1 (+5V) 1-13 1
LOW
C4002-6
1-4
C4001-1
1-5
C4001-4
10A 26
C4002-3 10A 26
C4001-3
10A 26
10A 26
15A 26
1
ACC B 10A 26
2 3
28
33
AMP 040 MK2 36P
1 8
1 6 1 4
2 7 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6
5
2 5 2 1 4 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 106 107 108 109 110 111 112 113 119 120 121
6 4 5
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
3 6 98 99 100 101 102 103 104 105
3 7 2 3 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 117 118
3 4 3
90 91 92 93 94 95 96 97
81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 16 15 14 13 12 11 10 9
4 5 20 19 18 17 16 15 14 13 12 11
1 2 82 83 84 85 86 87 88 89 114 115 116
EPOS (CN2) GAUGE (CN7) GAUGE (CN6)

ECU (C4001) ECU (C4002) ECU (C4022) ECU (C4071) EPOS (CN1)
EX1400254
Figure 156

9-1-98
Reference Reference
Number Number
1 Instrument Panel 25 Battery Relay
3 Engine Controller 26 Fuse
4 EPOS Controller 27 Fusible Link
10 EPPR Valve (Electromagnetic 28 Starter Switch
Proportional Pressure Reducing) 32 Jog Switch Control Panel
17 Engine Control Dial 33 Engine Emergency Stop Switch
22 Aux Mode Switch 34 Circuit Breaker
23 Aux Mode Resistor 35 Pump Angle Sensor
24 Battery 36 Aux Mode Relay

9-1-99
SMART POWER CONTROL (SPC)
The SPC (Smart Power Control) function controls engine speed
to reduce fuel consumption by determining high and low load
during excavation operation.
When SPC mode is selected, the engine rpm is reduced by
100 rpm from the working mode. In excavation work, the load at
boom-up and arm-in is detected to increase engine power to
operate the equipment at high power.
The selection and release of the SPC function can be made with
the SPC switch on the R.H stand.
When the start-up switch is turned on, the power mode is
automatically set to SPC Standard of SPC Mode. In this status,
use the button switch on the instrument panel or jog switch to
select SPC Power Plus Mode, SPC Power Mode, SPC Standard
Mode, or SPC Economy Mode. When a mode is selected, the
corresponding symbol appears at the bottom left of the
instrument panel.
Operation
1. Smart Engine Speed Control

This function controls engine speed according to the
workload which is determined with the actual torque of the
engine and high load (boom-up, arm crowd) pilot pressure.
The engine speed is classified into Heavy load mode and
Light load mode and matched automatically according to
the workload. The variable range of the engine speed is set
by 100 rpm that does not cause any problem in operation
sequence. The workload is determined with the actual
torque information of the engine and the joystick
information.

9-1-100
Engine Actual Torque Condtion “Smart Engine Speed Control”
All the engine speed to match automatically
Engine Actual Torque
depend on working load condition (joystick

lever & the engine auctual torque condition.)
100 % Engine Speed

80 %
Rated rpm Heavy Load Mode
50 %
100 rpm
Light Load Mode
Engine rpm
Rated rpm
300 rpm
Joystick Lever Condition

(Heavy Load Condition)
Low Idle
Boom Up (Pilot 20 bar )

Engine Control
Dial Position
Arm Crowd
(Pilot 20 bar )
EX1301792
Figure 157
If the joystick lever condition meets the heavy load condition and the
Entering actual torque of the engine meets the heavy load area condition, the
Condition engine speed is shifted from light load mode to heavy load mode to set
Heavy Load the hydraulic power to the maximum working performance level.
Condition
If the joystick lever condition meets any one of the heavy load condition
Maintenance
and 50 % or above of the engine actual torque, the engine speed is
Condition
maintained at heavy load mode.
When the engine actual torque is reduced to less than 50% and the
Entering joystick lover condition meets all the conditions other than the heavy
Condition load condition, the engine speed is shifted to light load mode to improve
Light Load fuel efficiency.
Condition
If the joystick lever condition meets any condition other than the heavy
Maintenance
load condition or the engine actual torque is in the light load area (0 -
Condition
80 %), the engine speed is maintained at light load mode.

9-1-101
2. Smart Pump Torque Control
This function controls the pump torque according to the
limitation applied to the engine by turbocharger lag time
and smoke limit. The engine limitation information is
obtained from the engine actual torque. In the fuel
economy mode, the pump responsibility is lowered than
that of the engine torque slightly for smooth operation of
the equipment.
Torque Control
Mode
%
Actual Torque Ramp Start Power
Total Power
Power
100
40
Torque Control
Lamp Determined Limiter
Power Limiter
Power Output Value Using
Ramp and Power
Pump Torque Engine Torque Pump Torque Engine Torque

Torque
Torque
T T
Engine rpm
Engine rpm
10 11 12 10 11 12
T T
EX1301793
Figure 158

9-1-102
ENGINE CONTROL SYSTEM
4 17
(Drive Signal) (Command Signal)
FG000584
Figure 159
Reference Reference
Number Number
3 Engine Controller 17 Engine Control Dial
4 EPOS Controller
When the engine control dial is moved, the output voltage

changes according to the dial position.
The EPOS controller converts this output voltage of dial to digital
signal and sends it to the engine controller by CAN line.
According to the dial command, the quantity of fuel injection is
adjusted.
Power Output Value Using Ramp and Power

9-1-103
ENGINE CONTROL DIAL
1st Step 7th Step 13th Step
CCW CW
Mechanical Mechanical
Stop Stop
5
4.0V
4
Output Voltage (V)
3 2.5V
2
1.0V
1
0 Step
1st 2nd ...... 7th ...... 12th 13th
CCW CW
Stop Stop
1 2 3
FG018941
Figure 160
Reference Reference
Number Number
1 Knob 2 Hall Effect Sensor
The engine control dial has a built in potentiometer. When the

control knob is moved, the output voltage (through "2 and 3"
terminals) will vary from the 5 V supplied from the EPOS
controller as shown in the graph.

9-1-104
9-1-105
ENGINE CONTROL
4
26 26 34
15A 10A
B
1
BR
E 25
7-5
7-6
7-2
1-1 24
7-4 1-3
7-3
7-1
6-12 1-77 36
6-13 1-78 1-76 (BREAKER) 8 4
CAN A
1-59 (RS1)
1-61 GND
1-62 RxD
1-81 TxD
3 1
2
3
17
GND 1-34 3
C4001-6 CW HIGH
4
C4001-7 SIG 1-16 2
5 1-13 1
(+5V)
6 LOW
C4001-2 14
32 3 4
1-4
C4001-5
1-5 27
C4002-2 2
C4002-5
C4071-2 1
C4002-1
C4071-1
C4002-6
C4001-1 10A 26
C4001-4
10A 26
10A 26
C4002-3 10A 26
C4001-3 15A 26
ACC B 10A 26
1
2 3
28
33
AMP 040 MK2 36P
1 8
1 6 1 4
2 7 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6
5
2 5 2 1 4 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 106 107 108 109 110 111 112 113 119 120 121
6 4 5
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
3 6 98 99 100 101 102 103 104 105
3 7 2 3 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 117 118
3 4 3
90 91 92 93 94 95 96 97
81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 16 15 14 13 12 11 10 9
4 5 20 19 18 17 16 15 14 13 12 11
1 2 82 83 84 85 86 87 88 89 114 115 116

EX1400255
Figure 161

9-1-106
Reference Reference
Number Number
1 Instrument Panel 26 Fuse
3 Engine Controller 27 Fusible Link
4 EPOS Controller 28 Starter Switch
EPPR Valve (Electromagnetic 32 Jog Switch Control Panel
10
Proportional Pressure Reducing) 33 Engine Emergency Stop Switch
17 Engine Control Dial 34 Circuit Breaker
24 Battery 36 Power Boost Switch
25 Battery Relay

9-1-107
AUTOMATIC DECELERATION CONTROL
(AUTO IDLE CONTROL)
E/G
3 4
1
5 5
FG018916
Figure 162
Reference Reference
Number Number
1 Jog Switch Control Panel 3 Engine Controller
(Auto Idle Switch) 4 Engine Control Dial
2 EPOS Controller 5 Pressure Sensor

9-1-108
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 canceled 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 sensors in the control valve. When the work levers are
in the neutral position, the sensor is below 15.5 bar.

9-1-109
ENGINE OVERHEAT PROTECTION SYSTEM
6 6
E/G
4 4 5
3
31
7 7
(Pump Control Signal)

2
1
(E/G Overheating Signal) PM
H H
E F
C E F C
TRIP
/h rpm ECO
Min Max
(E/G Overheating Signal)

SPC
S USB
EX1400256
Figure 163
Reference Reference
Number Number
1 Instrument Panel 6 Control Valve
2 EPOS Controller EPPR Valve
3 Engine Controller 7 (Electromagnetic Proportional
Pressure Reducing Valve)
4 Main Pump
31 Warning Buzzer
5 Aux Pump
When the engine coolant temperature increases to over 107°C

(225°F), the engine controller detects it from the sensor
mounted in the coolant line and will send a signal to the EPOS
controller. The EPOS controller sends a overheat signal to the
instrument panel turning "ON" the warning light and buzzer
simultaneously.
Also, the EPOS controller returns an overheat signal to the engine
controller and changes power mode to standard mode. The engine
speed is then set to a low speed by the engine controller.
When coolant temperature falls below 95°C (203°F), normal
operation will resume.

9-1-110
1. Coolant Overheat Prevention System
The engine controller detects the engine coolant
temperature with the temperature sensor in the coolant
line. If the coolant is overheated, the engine controller send
the overheat signal to the EPOS controller which conveys
the signal to the instrument panel.
If the coolant is overheated, the pump output is reduced to
prevent engine overheat.
When the coolant temperature reaches about 110 °C
(230 °F), the pump output is reduced to 85% into the
Tropical mode. A pop-up screen appears on the instrument
panel to inform the operator of the mode shift.
If the coolant temperature exceeds 113 °C (235.4 °F), the
engine controller sends coolant overheat signal to the
EPOS controller which conveys the signal to the
instrument panel.
Receiving the engine overheat signal, the instrument panel
turns on the warning light and triggers the buzzer for
warning.
In addition, the EPOS controller sends a signal back to the
engine controller and shifts the power mode to the
standard mode.
The engine controller controls the engine speed to low
speed range.
In summary, in case of engine coolant overheat, the
system selects tropical mode, triggers warning buzzer,
shifts to standard power mode, reduce engine speed, and
reduces pump output.
When the coolant temperature is lowered to 104 °C
(219.2 °F) or below, the system resumes normal operating
condition.

9-1-111
2. Hydraulic Oil Overheat Prevention System
During operation, the EPOS controller monitors the
hydraulic oil temperature with the hydraulic oil temperature
sensor. If the hydraulic oil is overheated, the EPOS
controller sends the overheat signal to the instrument
panel.
When the hydraulic oil is overheated, the pump output is
reduced to prevent engine overheat.
When the hydraulic oil temperature reaches about 97 °C
(206.6 °F), the pump output is reduced to 85% into the
Tropical mode. A pop-up screen appears on the instrument
panel to inform the operator of the mode shift.
If the hydraulic oil temperature exceeds 99 °C (210.2 °F),
the EPOS controller sends hydraulic oil overheat signal to
the instrument panel.
Receiving the hydraulic oil overheat signal, the instrument
panel turns on the warning light and triggers the buzzer for
warning.
In addition, the EPOS controller sends a signal back to the
engine controller and shifts the power mode to the
standard mode.
The engine controller controls the engine speed to low
speed range.
In summary, in case of hydraulic oil overheat, the system
selects tropical mode, triggers warning buzzer, shifts to
standard power mode, reduce engine speed, and reduces
pump output.
When the hydraulic oil temperature is lowered to 104 °C
(201.2 °F) or below, the system resumes normal operating
condition

9-1-112
POWER BOOST MODE
Operation
16
6 6
11
E/G
4 4 5
3
7 7
1
PM
H H
E F
C E F C
TRIP
/h rpm ECO
Min Max
SPC
S USB
20
18
EX1400257
Figure 164
Reference Reference
Number Number
1 Instrument Panel EPPR Valve
2 EPOS Controller 7 (Electromagnetic Proportional
3 Engine Controller Pressure Reducing Valve)
4 Main Pump 11 Solenoid Valve (Boost)
5 Aux Pump 16 Main Relief Valve
6 Control Valve 18 Jog Switch Control Panel
Power Boost Switch
20
(Top of Right Work Lever)
The Power Boost function is used to temporarily increase the main

relief pressure to enhance excavation ability. When the Work Mode
is set to "BOOST" by the jog switch control panel and the power
boost button on 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 350 to
363 bar (4,980 - 5,260 psi) for 7 seconds. 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.

9-1-113
Power Boost Control
15A
26
4 26 26 26 34
+
5-10
35 SIG
5-20
15A 10A 10A
- B
1
BR
+ 1-1
35 SIG
5-9 1-3 E 25
5-19
-
7-5
7-6
7-2
24
7-4
7-3 27
7-1
37
6-12 1-77
1-76 (BREAKER) 8 4
6-13 1-78 CAN A (RS1)
1-59
23
22
1-61 GND 2-119 1
2
3
1-62 RxD
4
23
1-81 TxD 2-114
5
6
7
3-16
8 23
9
3-8 10
36
11 87a
12 30
87
85 86
22
1
2
3
3 1
5
4
2 6
3 3-15 7
C4001-6 8
4 9
C4001-7
5 3-7 10
11
6 12
C4001-2
32 3 4
14
C4001-5
23
C4002-2 2
C4002-5
C4071-2 1 GND 1-34 3
17
CW HIGH
C4002-1 SIG 1-16 2
C4071-1 (+5V) 1-13 1
LOW
C4002-6
1-4
C4001-1
1-5
C4001-4
10A 26
C4002-3 10A 26
C4001-3
10A 26
10A 26
15A 26
1
ACC B 10A 26
2 3
28
33
AMP 040 MK2 36P
1 8
1 6 1 4
2 7 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6
5
2 5 2 1 4 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 106 107 108 109 110 111 112 113 119 120 121
6 4 5
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
3 6 98 99 100 101 102 103 104 105
3 7 2 3 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 117 118
3 4 3
90 91 92 93 94 95 96 97
81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 16 15 14 13 12 11 10 9
4 5 20 19 18 17 16 15 14 13 12 11
1 2 82 83 84 85 86 87 88 89 114 115 116

EX1400258
Figure 165

9-1-114
Reference Reference
Number Number
1 Instrument Panel 28 Starter Switch
3 Engine Controller 32 Jog Switch Control Panel
4 EPOS Controller 33 Engine Emergency Stop Switch
17 Engine Control Dial 34 Circuit Breaker
24 Battery 35 Pump Angle Sensor
25 Battery Relay 36 Aux Mode Relay
26 Fuse Power Boost Switch
37
27 Fusible Link (Top of Right Work Lever)

9-1-115
AUTOMATIC TRAVEL SPEED CONTROL
6 6
13
E/G 8
15
4 4 5
3
17 2 19
FG016914
Figure 166
Reference Reference
Number Number
2 EPOS Controller 8 Pump Pressure Sensor
3 Engine Controller 13 Solenoid Valve (High-speed)
4 Main Pump 15 Travel Motor
5 Aux Pump 17 Engine Control Dial
6 Control Valve Selector Switch For Automatic
19
7 Pressure Switch Travel

9-1-116
If the automatic travel speed control switch is set to "OFF"
position, the travel motor will run in the I-speed (low speed)
range. If the selector switch is set to "I" position, the travel motor
will run in the II-speed (high-speed) range. If the selector switch
is set to "II" position, the EPOS controller will monitor the main
pump discharge pressure and automatically select the "ON" -
"OFF" status of the II-speed travel solenoid valve based on the
travel load. The travel speed is changed between the I-speed
and the II-speed mode.
The travel load is monitored by the two pressure sensors in the
discharge lines of the front (upper) and rear (lower) pumps.
When the travel load is high-pressure over 294 bar (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 157 bar
(2,280 psi), the solenoid valve will be turned "ON" and the
II-speed will be selected. But, if the engine speed control switch
dial is set below approximately 1,400 rpm, the travel speed will
be set to I-speed mode.

9-1-117
Automatic Travel Speed Control
15A
26
2 26 15A 26 15A
25
8 1-1
+ 1-3
SIG 1-19
1-37
- 13
(C3) 24
+ 1-7
SIG 1-18
1-36
- 19
9 0
1-75 3 I 2
II
0
I 5
1-56 6 II
7 8
17
1-4 +(5V) 1-13 1
CW LOW
1-5 SIG 1-16 2
GND 1-34 3
HIGH
AMP 040 MK2 36P
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6
43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 106 107 108 109 110 111 112 113 119 120 121
4 5 8 7 6 5 4 3 2 1
98 99 100 101 102 103 104 105 10 9 8 7 6 5 4 3 2 1
62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 117 118
3
81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 90 91 92 93 94 95 96 97 16 15 14 13 12 11 10 9
20 19 18 17 16 15 14 13 12 11
1 2 82 83 84 85 86 87 88 89 114 115 116
EPOS (CN1) EPOS (CN2) GAUGE (CN7) GAUGE (CN6)
EX1400259
Figure 167
Reference Reference
Number Number
2 EPOS Controller Selector Switch for Automatic
19
8 Pressure Sensor (Front Pump) Travel
9 Pressure Sensor (Rear Pump) 24 Battery
13 Solenoid Valve (High-speed) 25 Battery Relay
17 Engine Control Dial 26 Fuse

9-1-118
WATER IN FUEL WARNING SYSTEM
Operation
If the fuel contains a significant concentration of water, it can
cause engine performance deterioration and shorten the service
life of the engine, after a long time operation.
To protect the engine in case that operator ignores "Water In
Fuel (WIF)" warning and keeps operating the equipment, which
can deteriorate the engine, a sound warning system is added to
induce the operator to remove water in the fuel.
1. Buzzer Sound at WIF Warning

If the fuel contains significant ratio of water, the WIF sensor
of the water-oil separator sends a signal to the EPOS
controller which relays the signal to the instrument panel.
The instrument panel turns on the warning light and pop-up
window on the screen, and triggers the buzzer so operator
can remove water from the fuel.
If the operator resets the warning pop-up and buzzer
without removing the water from the fuel, the warning pop-
up window reappears on the instrument panel screen and
the buzzer sounds again after 30 seconds from the reset.
2. Power Output Reduction by Water in Fuel

If the operator fails to remove water from the fuel for one
hour from the first WIF warning, the power of the
equipment is reduced so operator must remove water from
the fuel.
Restricted
Engine Speed Pump Output
Function
Limited 1,200 rpm 70%

9-1-119
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 168
Reference Reference
Number Number
1 Upper Digit Power Monitor (Stays "ON"
2 Lower Digit 4 While Power Is In Normal
Range,)
Engine Speed Monitor LED
3 (Flash Interval Increases With
Engine Speed.)
1. Power Monitor
This LED is turned "OFF" when the input voltage to the
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.

9-1-120
3. Normal Operation Display Readout
Display System
Mode
Higher Digit Lower Digit Condition
Normal Operation
P+, P
Power Mode
HAOH340L
HAOH340L FG018940
Normal Operation
Power Mode S
Standard Mode
FG018938 FG018940
Normal Operation
E
Economy Mode
HAOH350L FG018940
Normal Operation
Digging
Digging Mode
FG018940 HAOH370L
Work Mode
Normal Operation
Lift
Lift Mode
FG018940 FG018939
4. Communication Monitor
What are shown in the 7-SEGMENT LED are same as
those in the Error Codes.
Error Code Indication Code Fault Location

Communication error in instrument
V201 01
panel.
Communication error in engine
V202 02
controller.

9-1-121
AIR CONDITIONER SYSTEM
Outline
EX1301100
Figure 169
Solid-type heater and air conditioner are installed in the cover

behind the operator's seat.
Temperature of the operator's cabin is adjusted automatically to
the temperature set by operator.
(Please refer to the Operation & Maintenance Manual for
detailed full automatic control.
Vent mode selects the direction of discharged air.
Outlets by vent modes
Modes
Outlets A A+B B B+C C

9-1-122
Internal and External Filters
Internal and external air purification filters are installed for the
operator's room.
Filters must be cleaned every 500 hours.
If machine operates in an excessively contaminated
environment, filters must be cleaned more frequently and if
necessary, replaced with new ones.
How to Check Internal Air Filter

1. Press both levers on the left and right side at the top of the
filter installed at the rear of the operator's seat.
EX1300823
Figure 170
How to Check External Air Filter

1. Open the door at the left side of machine and loosen four
marked bolts to remove cover.
EX1300825
Figure 171
2. Turn marked knobs at the rear side of the cabin to open the
cover.
3. Remove filter attached to the cover and clean the
contaminated filter using compressed air.
4. Close the cover, replace the knobs, and secure the cover
to the support with butterfly bolts.
EX1300826
Figure 172

9-1-123
Air-Conditioning System Layout
10
11
2
5
6
5
7
4
1
6
8
9 FG016941
Figure 173
Reference Reference
Number Number
1 Air Conditioner/heater Unit 7 Liquid Hose (1)
2 Condenser 8 Liquid Hose (2)
3 Compressor 9 Ambient Temperature Sensor
4 Receiver Dryer 10 Sun Sensor
5 Discharge Hose 11 Control Panel
6 Suction Hose

9-1-124
Air Conditioner/Heater Circuit Diagram
0.5RW
FUSIBLE LINK
LAMP SWITCH
20A STARTER SWITCH

BATTERY RELAY
A/C CONTROL PANEL AIRCON UNIT BATT.

1.25LR CN11-2 42C 24V
LED 1~12 130C CN9-6
0.85LR CN10-8 42D
54E CN9-11 0.5WR
CN10-18 46B
ILL 42B CN9-5 1.25LR
0.85BW
0.85LR
RECEIVER DRIER
BLOWER A/C
42E 46A
RELAY RELAY
COMPRESSOR
168B CN8-10 0.5LG CN10-16 168A
A/C THERMO (LOW) 105B CN9-8 0.5LB CN10-5 105A CN11-4 0.85LW 47C
106B CN8-11 CN10-6 106A 47A 47B

0.5LY
FET
DIODE 4
1.25B CN11-1 99 - +
M
107B CN8-12 0.5LW CN10-1 107A 0.85B 0.85B
BLOWER
108A CN9-13 0.5GrG CN10-2 108B FRE (P1)

INTAKE
109A CN9-12 0.5GrY CN10-20 109B REC (P2) ACTUATOR
M
110A CN9-15 0.5OrR CN10-12 110B DEF (P1)

111A CN9-14 0.5OrW CN10-13 111B VENT (P2)
M
MODE
43A CN9-16 0.5YB CN10-11 43B Vref MODE
ACTUATOR
44A CN9-17 0.5YW CN10-10 44B MODE F/BACK
99 CN9-10 1.25B
112A CN9-1 0.5LgW

g CN10-19 112B WARM (P1)
113A CN9-18 0.5LgB
g CN10-3 113B COOL (P2)
M
114A CN9-3 0.5YR CN10-7 114B Vref MIX Temp. Control
115A CN9-4 0.5YW CN10-9 115B MIX F/BACK ACTUATOR
167C CN9-2 1.25BL CN10-4 167A GND
116A CN8-2 0.5OrB CN10-15 116B

DUCT
SENSOR
45A CN8-1 0.5LgR

g CN10-14 45B
WATER
SENSOR
2
48A CN8-5 0.5LY CN10-17 48B 1 INCAR
SENSOR
SUN LOAD SENSOR
0.5Lg 2 - + 1 CN10 AMP 20P CN11 KET 4P

142A CN8-3
142B 0.5YR
114C 0.85BL 167B 2
49A CN8-4 0.85YG 0.85YG 49B 1 AMBIENT TEMP
SENSOR
CN8 CN9
AMP 18P + 12P
AMP 040-III 20P

KET 4P AMP 070 18P AMP 070 12P
2 1 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 10
4 3 18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
(CN11) (CN10) (CN9) (CN8) FG001463

Figure 174

9-1-125
Air Conditioner/Heater Unit
Airflow Diagram
External Air Inlet
Internal Air Inlet
External Air
VENT
COOL
DOOR
-INTAKE
DOOR
DEF -MIX
Internal Air
WARM
Evaporator Fan
Heater
FOOT Core
FG016942
Figure 175

9-1-126
Door Open by Vent Modes
Mode
Door
Vent Bi-level Foot Def/foot Def
Vent 100 60 0 0 0
Foot 0 40 100 80 60
Def 0 0 0 20 40
Main Components
Internal
Air Sensor
Blower
Motor
Actuator
- Internal/external
Air Exchanger
Internal
Air Filter
FG016943
Figure 176

9-1-127
Actuator - Airflow Direction Control
Change of discharged airflow according to selected airflow
direction mode
Change of airflow direction: Direction changes in the order of
VENT→ BI-LEVEL → FOOT → FOOT/DEF → VENT.
Actuator - Temperature Control

Change of discharged air temperature by controlling the position
of temperature control door.
N P2
c
b
e
P2 P1
b c e
FG001361
Figure 177
Actuator - Airflow Direction Control
Airflow Direction Mode Output Terminal Voltage

Vent 0.5 ±0.2V
Bi-level 1.3 ±0.2V
c (+): CN10-10
Foot 2.45 ±0.2V
b (-): CN10-4
Foot/def 3.5 ±0.2V
Def 4.5 ±0.2V
Actuator - Temperature Control
Set Temperature Output Terminal Voltage

Max cooling c (+): CN10-9 Below 0.4V
Max heating b (-): CN10-4 Above 4.5V

9-1-128
Actuator - Internal/External Air Exchange
N P2
P1
CN10-20 CN10-2
P2 P1
c e
FG001055
Figure 178
Mode Output Terminal Output

Moving of exchange door
Intake P1 (+), P2 (-)
by selecting intake.
Moving of exchange door
Recirculate P1 (-), P2 (+)
by selecting recirculate.
Airflow Control Module

Airflow is controlled through the control of voltage between
GATE and SOURCE.
DRAIN
(CN10-1)
SOURCE GATE
(CN11-1) (CN10-6)
FG001056
Figure 179
Airflow Output Terminal Output

1st 10 ±0.5V
2nd 12.5 ±0.5V
3rd 15 ±0.5V
4th CN11-2 CN10-1 17.5 ±0.5V
5th 20.0 ±0.5V
6th 22.0 ±0.5V
7th More than 25V
Input voltage is 27.5V.

The airflow is based on manual set.

9-1-129
Relay - Blower: Power is supplied to the blower motor when the
system is turned "ON".
87 85(-)
Specifications
87
Rated voltage 24V 86 85
Rated current 20A
30
30 86(+)
FG001057
Figure 180
Relay - A/C: Power is supplied to the magnetic clutch of the

compressor.
Specifications
Rated voltage 24V L S1 (+)
Rated current 10A
B S2
(-)
FG001058
Figure 181
Duct Sensor: It is inserted in the core of the evaporator to

prevent freezing of the evaporator.
The sensor consist of negative characteristic thermistor that
resistant value increases and decreases when the temperature
rises and falls, respectively.
Temperature (°C) Resistance (KΩ)

0 11.36 ±0.1
2 10.39 ±0.2
2.5 10.17 ±0.2
3 9.95 ±0.2 Figure 182
3.5 9.73 ±0.2
4 9.52 ±0.2
5 9.12 ±0.2
10 7.36 ±0.15
25 4.02 ±0.08
30 3.33 ±0.07

9-1-130
Coolant Temperature Gauge Sensor: It senses the
temperature of coolant water in the heater core.

-10 55.8 ±1.7
0 32.9 ± 0.9
15 15.76 ±0.5
25 10.0 ±0.3
35 6.5 ±0.2
Figure 183
Internal Air Temperature Sensor: Built in the internal air filter,

it senses the internal temperature.

-15 218.2 ±7.5
0 97.83 ±0.9
15 47.12 ±0.7
25 30.0 ±0.36
35 19.60 ±0.3
Figure 184
Ambient Air Temperature Sensor

Built at the bottom of the cockpit, it senses the temperature of
external air.

-10 163 ±4.9
0 96.9 ±2.9
10 59.4 ± 1.8
20 37.4 ±1.1
FG001064
25 30 ±0.9
Figure 185
30 24.2 ±0.7

9-1-131
Sun Sensor
Built beside the socket of spare power, it senses the quantity of
the sun radiation to regulate discharge temperature and airflow
as set by operator.
83.7
OUTPUT VOLTAGE(mV)
76.2
67.7
58.8
46.6
36.0
21.4
1.0 2.0 3.0 4.0 5.0 6.0 7.0

LUX(x10,000)
FG001062
Figure 186
Control Panel
Appearance and Terminal Arrangement
A/C OUTSIDE
AUTO A/C
AUTO MAX
TEMP
OFF
SEL MODE
AMP 070 18P AMP 070 12P

8 7 6 5 4 3 2 1 5 4 3 2 1
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
(CN9) (CN8) FG001063

Figure 187
Refer to "Air Conditioner and Heater" of operation manual.

9-1-132
Terminal Terms
CN Term No. Terms CN Term No. Terms

Temperature control Coolant temperature
1 1
(warm) gauge sensor
2 Sensor ground 2 Duct sensor
Temperature control
3 3 Sun sensor
Power (5V)
Ambient air temperature
4 Mix feedback 4
sensor
Internal air temperature
5 Power (KEY "ON") 5
CN8 sensor
6 Backup 6 -
7 - 7 -
8 A/C output (LOW) 8 -
9 - 9 -
10 Ground 10 D.P.S CHECK
CN9 11 Illumination 11 Airflow module (gate)
Intake/Recirculate
12 12 Blower motor (feedback)
(Recirculate)
Intake/Recirculate
13
(Intake)
Airflow direction control
14
(VENT)
15
(DEF.)
16
Power (5V)
17
(feedback)
Temperature control
18
(cool)

9-1-133
Control Logic
Categories Inputs System Operation

AUTO Set temperature 1. Automatically adjust room temperature as set and then
next items.
sensor Temperature, airflow direction, Recirculate/Intake, Airflow,
Compressor
sensor 2. Auto mode is released when manually setting any switch
except, Temperature Control switch in Auto mode.
Coolant temperature
gauge sensor 3. Upon the releasing of Auto mode, all of functions except
selected switch are controlled automatically.
Sun sensor
Sensor Set temperature 1. In case of sensor fault, the following defaults are applied:
compensation
Internal air temperature Internal air temperature sensor: 25°C, Ambient air
sensor temperature sensor: 25°C, Duct sensor: -2°C
Ambient air temperature Temperature control actuator:
sensor
- Set Temperature 17 - 24.5°C: Max cooling, Set
Coolant temperature Temperature 25 - 32°C: Max heating
gauge sensor
Airflow direction mode actuator
- VENT: VENT fix, modes other than VENT: Fixed to DEF
* Sun sensor is not compensated.
Max cooling/ Auto Setting 1. Set Temperature 32°C: Max heating
heating control
2. Set Temperature 17°C: Max cooling
Max Cooling (17 C) Max Heating (32 C)
Temp Control
FULL COOL FULL HOT
Actuator
Air Flow MAX HI AUTO HI
Compressor Forced ON OFF
Intake/Recircle Recircle Intake
Wind Direction Mode VENT FOOT
* Max cooling/heating control is possible only in Auto mode.

9-1-134
Starting Auto mode 1. Prevention of discharge of hot air before discharge
Control of temperature drops enough in hot summer weather
Duct sensor
Cooling
2. Start conditions (AND condition)
A. A/C on (AUTO or manual)
B. Temperature sensed by the duct sensor is above
30°C
C. Airflow: Auto mode
3. One time control in the cycle of engine OFF →engine run
4. Initial cooling control is executed when the Auto switch is
"ON" in the manual status (A/C "OFF" and manual control
of airflow) in 5 seconds after engine run.
5. Initial cooling control must be before max cooling.
6. Release condition (OR condition)
A. A/C "OFF"
B. Airflow: Manual control
C. Release is possible with the "OFF" switch but not
allowed within 12 seconds (after Start "ON") while
the system is off using the "OFF" switch and during
the time of initial cooling control.

9-1-135
1. Start condition (AND condition)
A. When airflow direction mode is one of the following
modes in the Auto or manual control mode
- BI-LEVEL, FOOT or FOOT/DEF
B. The coolant temperature gauge sensor is stable and
the coolant temperature gauge < 73°C
C. Airflow: Auto mode
D. Set temperature > Internal air temperature + 3°C
* Airflow falls gradually up to 12 seconds when operation
released.
Coolant temperature 2. One time control in the cycle of engine OFF →engine run
gauge sensor 3. Initial heating control must be before max heating.
Starting Internal air temperature
control of 4. Airflow is controlled only when the airflow direction is in the
sensor manual mode and BI-LEVEL, FOOT, or FOOT/DEF is set.
heating (1)
Auto mode 5. Control through the coolant temperature gauge sensor for
Set Temperature start.
6. Starting control of heating (2) starts in case of fault of the
coolant temperature gauge sensor during controlling.
7. Operation release (OR condition)
A. Only airflow is released if it is selected manually.
B. When handling the airflow direction mode switch,
only airflow direction is released but the airflow
control is performed only for the remaining period of
the starting control of heater.
C. When Max Cooling (17°C) is selected.
D. Coolant temperature gauge sensor > 73°C.

9-1-136
Starting Coolant temperature 1. Entry condition (AND condition)
control of gauge sensor
A. Auto Mode
heating (2)
B. Ambient air temperature < 5°C and difference
sensor
between ambient and internal air temperature ≤5°C
sensor C. Failure of coolant temperature gauge sensor
Auto mode 2. Only one time of engine OFF →engine run

3. Starting control of heating is before max heating.
4. Operation release (OR condition)
A. Airflow: Manual selection
B. When handling the airflow direction mode switch,
only airflow direction is released but the airflow
control is performed only for the remaining period of
the starting control of heater.
C. Difference between internal and ambient air
temperature>15°C
D. When Max Cooling (17°C) is selected.
5. Exceptional case
Starting control of heating is performed only once during
the remaining period if the entry condition is satisfied
within the starting control period that is the accumulation
of initial start times.
(Inclusive of Auto mode "ON" case within the period of
starting control of heater.)
* Airflow must be reduced slowly for up to 12 seconds in
case of exceptional entry case.
Duct sensor 1. Function: Magnetic clutch of compressor is turned "ON/
OFF" depending on temperature of the duct sensor to
prevent the freezing of the evaporator with A/C being
"ON".
2. Control pattern.
Compressor 2.0 0.5 C 3.5 0.5 C

control
External temperature 1. Function: Prevention of compressor in winter.
sensor
2. Control pattern.
*Only for Auto mode.

9-1-137
Self-diagnosis
How to start self-diagnosis
Starter Switch ON
Set temp to 25 C Set temp to 77 F
Press the SEL switch more than 3 times in

5 secs while pressing the A/C switch
Auto diagnosis starts after every graphic

in LCD displays twice every 0.5 sec.
A code concerned blinks in the cycle of 0.5-sec ON

and 0.5-sec OFF. In case of two or more errors, codes
concerned blink twice at a time.
For normal, E0 lights; for error, the first

error code is indicated.
For 2 or more error, error codes are indicated

upstreams/downstreams if the temp control switch is
set to up/down. (For normal condition, only EO lights.)
Press the SEL switch more than 3 times in

5 secs while pressing the A/C switch. Return to default status if no switch
operated for 30 secs in diagnosis mode.
Return to position before auto diagnosis

starts.
FG001367
Figure 188

9-1-138
Error codes
Code Description
E0 Normal
E1 Internal air temperature sensor short
E2 Internal air temperature sensor open
E3 Ambient air temperature sensor short
E4 Ambient air temperature sensor open
E5 Duct sensor short
E6 Duct sensor open
E7 Sun sensor short
E8 Sun sensor open
E9 Coolant temperature gauge sensor short
E10 Coolant temperature gauge sensor open
E11 D.P.S open
E12 Position error of airflow direction actuator
E13 Position error of temperature control actuator
NOTE: The position error means that it fails to move to

designated place in 40 seconds.
Sun sensor displays E8 in case of no sunlight. E1 E1 E2 E2 E3
2 and more fails: Codes concerned blinks twice at a

time.
0.5 0.5
FG001067
Figure 189
Ambient Temperature Display

Selection of both the SEL and MODE switch for more than 3
seconds indicates the ambient temperature in the set
temperature display department.
- Range of temperature display: -40 - +60°C
NOTE: Display of ambient temperature may be released in
the same way for its entry way.
It returns automatically to default mode 5 seconds
after entering the ambient air temperature display
mode.

9-1-139
Receiver Dryer
The receiver dryer reserves refrigerant enough to ensure High/Low Pressure Switch
smooth freezing cycle responding immediately to the change of
level in the freezing cycle.
As liquid refrigerant from the condenser may contain refrigerant
gas with bubbles whose presence in the expansion valve
decreases the freezing power excessively, it separates liquid
and gas and sends liquid only to the expansion valve.
Water in refrigerant shall be eliminated with dryer and through
filter.
• Weight of refrigerant:800 ±20 grams FG001366
Figure 190
MAX. 0.25 bar

31 2 bar
2.0 0.2 bar 6 2 bar
FG001462
Figure 191

9-1-140
TROUBLESHOOTING
Refrigerant Pressure Check
1. Open all doors and windows.
2. Install manifold gauge set.
3. Start engine and maintain engine speed at 1,800 -
2,000 rpm.
LO HI
Figure 192
4. Check high/low-pressure of refrigerant.
High-pressure: 8.0 - 10.0 bar (114 - 142 psi)

1
Low-pressure: Approximately 1.0 bar (14 psi)
Possible Cause: Low Refrigerant Level
Step Inspection Item Remedy
Reassemble using correct tightening
Yes
1 Check for traces of refrigerant oil. torque.
No Go to next step.
Using a leak detection device or soapy water Yes Repair leaking component.
2 check for refrigerant leakage at all major No Recharge system to correct
components and joints. pressure.
High-pressure: Over 23 bar (327 psi)

2
Low-pressure: Approximately 2.5 - 3.0 bar (36 - 43 psi)
Possible Cause: Overcharge, Frost on condenser
Check for condenser pin damage or Yes Clean, repair or replace condenser.
1
contamination. No Refrigerant overcharge.
High-pressure: Approximately 20 - 25 bar (285 - 356 psi)

3
Low-pressure: Approximately 2.5 - 3.5 bar (36 - 50 psi)
Possible Cause: Air in system.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long time, replace the receiver dryer.

9-1-141
High-pressure: Over 6 bar (85 psi)
4
Low-pressure: Approximately 760 mmHg (Negative Pressure)
Possible Cause: Refrigerant does not circulate
1. Connect manifold gauge and start engine.
2. Turn on air conditioner. Moisture in system, replace receiver
Yes
dryer.
3. Set blower switch to HIGH position.
4. Turn air conditioner OFF and wait 10
1
minutes.
Contaminated system, replace
5. Recheck high/low-pressure readings. expansion valve.
No
High-pressure: 13.0 - 19.0 bar (185 - 270 psi) (Replace evaporator core assembly.)
Low-pressure: 1.5 - 3.3 bar (21.3 - 46.9 psi)
High-pressure: Over 6 - 18 bar (85 - 256 psi)

5
Low-pressure: 500 mmHg (Negative Pressure) - Dial indicator needle unstable.
Possible Cause: Moisture in system has iced up the expansion valve.
NOTE: When the absorbed moisture freezes the pressure readings may look normal. Careful readings
must be made to determine whether pressure is in normal range.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long time, replace the receiver dryer.
High-pressure: Over 22.0 - 23 bar (313 - 327 psi)

6
Low-pressure: 2.5 bar (36 psi)
Possible Cause: Refrigerant pressure problem because of defective expansion valve or temperature sensor.
Inspect whether the temperature sensor is Yes Replace expansion valve.
1
installed properly. No Exchange duct sensor.
High-pressure: Over 7.0 - 11.0 bar (100 - 156 psi)

7
Low-pressure: 4.0 - 6.0 bar (57 - 85 psi)
Possible Cause: Low refrigerant pressure because of poor compressor compression.
Inspect and replace compressor if necessary.

9-1-142
REFRIGERANT SYSTEM REPAIRS
WARNING
Always wear safety goggles and gloves when handling
refrigerant. If refrigerant comes in contact with the skin or
eyes, immediately flush with clean, running water and
consult a physician.
Select a clean and well ventilated area to work.
The refrigerant container is under high-pressure and must
be stored below 40°C (104°F). Be careful not to drop the
container from a high location.
The contents are under high-pressure and should not be
used with compressed air or near an open flame.
Refrigerant Safe Handling Procedures
UNION NUT
TORQUE WRENCH
CORRECT WRONG
WRONG
WRONG
CORRECT
O - RING POSITION
CAP & PLUG CORRECT WRONG WRONG
HDA6066L
Figure 193
The following procedures must be observed for safe handling of

refrigerant during vacuum and charging process.
1. Use an approved recovery/charging device which can
safely perform vacuum and charge work simultaneously.
2. The new refrigerant has improved cooling characteristics
than the old type and care must be used not to overcharge
the system.

9-1-143
3. Do not over tighten connections when working on
refrigerant system.
4. The new refrigerant system standards require new tools,
equipment and parts. DO NOT attempt to use equipment
use in servicing the old refrigerant system.
5. The new refrigerant oil (PAG type) has a high moisture
absorption characteristic. When the refrigerant system
vacuum seal has been broken, immediately plug up all
openings to prevent moisture from entering the system.
6. When joining unions which use O-ring seals, lightly coat
O-rings with refrigerant oil. Be careful not to drip oil on the
threads of the nut.
7. Be certain the O-rings are seated properly on the
refrigerant line lip. Always use new O-rings when
reassembling parts. Do not reuse old O-rings.
8. Use a vacuum pump to evacuate refrigerant system of air.
9. When charging the refrigerant system with the engine
running, do not open the high-pressure valve on the
manifold gauge as the reverse flow of high-pressure
refrigerant will rupture the hose.
10. When releasing the high-pressure hose after completing
the charging process, quickly disconnect the hose to
minimize refrigerant released to the air.
Repair and Replacement Procedure

1. Work Procedure
A. Before repairing or replacing any refrigerant
components first, return all refrigerant oil to the
compressor and perform recovery procedures.
2. Operating Condition
A. Run engine at maximum engine speed.
B. Select 'HI' blower fan speed and select A/C switch to
'ON'.
C. Set the temperature control switch for maximum
cooling and leave running for approximately 20
minutes.
NOTE: The manifold gauge dial pointer can vary
depending on the outdoor temperatures.

9-1-144
INSTALL REPAIR TOOL
RECOVER REFRIGERANT
REPAIR / REPLACE DEFECTIVE PARTS
VACUUM SYSTEM (OVER 5 MINUTES)
CHECK SYSTEM FOR AIR LEAKAGE REPAIR
VACUUM SYSTEM (OVER 20 MINUTES)
CHARGE SYSTEM (APPROXIMATELY 100 g)
CHECK SYSTEM FOR REFRIGERANT LEAKAGE
CHARGE SYSTEM TO PROPER LEVEL

(Standard Capacity less Initial Charge)
CHECK SYSTEM FOR REFRIGERANT LEAKAGE
CHECK FOR PROPER REFRIGERANT LEVEL
RUN SYSTEM
RECOVER REFRIGERANT IN CHARGING HOSE
REMOVE REPAIR TOOLS

HDA6067L
Figure 194

9-1-145
Refrigerant Recovery
Reference
Description 2 3
Number
1 4
1 To Compressor
2 Low-pressure Side
3 High-pressure Side
4 From Receiver
5 Refrigerant Recovery Tank
1. Attach the manifold gauges and the refrigerant recovery 5

unit to the refrigerant lines as shown. HDA6067L
Figure 195
NOTE: Be careful not to switch the connections for the
low and high-pressure valves.
2. Open the high-pressure valve slowly to release the
refrigerant to the recovery unit.
NOTE: Open the valve slowly, while checking to see
that refrigerant is not leaking out.
3. When the manifold gauge dial falls below 3.5 bar (50 psi),
slowly open the low-pressure valve.
4. Open both the high and low-pressure valves slowly until
manifold gauge dials indicates 0 bar (0 psi).
Vacuuming Refrigerant System

2 3
Reference 1 4
Description
Number
1 To Compressor
2 Low-pressure Side
4 From Receiver
5 Vacuum Pump 5
HDA6068L
1. Vacuuming Procedure Figure 196
NOTE: When the A/C system has been exposed to the
air, it must be vacuumed out. Perform vacuum
process for 30 minutes for complete moisture
and air evacuation.
A. Attach the manifold gauges and vacuum pump to the
refrigerant system as shown.
B. Turn on the vacuum pump and open both valves.
C. When the low-pressure gauge shows approximately
710 mmHg, close both valves and turn off vacuum
pump.

9-1-146
2. Check system for vacuum leak.
Allow system to sit for 10 minutes and check whether the
system is holding the pressure. If the pressure has
dropped, it must be repaired before proceeding to the next
step.
3. Vacuuming Procedure
If the system is holding the pressure and it has not
changed for 10 minutes, vacuum out the system for an
additional 20 minutes.
HDA6069L
A. Turn on the vacuum pump and slowly open both
Figure 197
valves.
B. Allow vacuum pump to run for additional 20 minutes
until low-pressure gauge dial reads approximately
750 mmHg.
C. Close both valves and stop the vacuum pump.
4. Installation of Refrigerant Container
Reference 1
Description
Number
1 Handle
2 Hose Connection
2
3 Mounting Disk
3
A. Before mounting valve on the container, make sure
the handle is in the counterclockwise most position,
with the puncture pin retracted and the mounting disk HDA6070L
is in the raised position. Figure 198
B. Attach the manifold gauge center hose to the valve
assembly.
C. Turn the disk in the clockwise direction and securely
mount valve onto refrigerant container.
D. Turn the valve handle in the clockwise direction and
puncture the container seal with the pin.
E. Once the can has been punctured, turn the handle in
the counterclockwise direction so the refrigerant can
flow into the manifold gauge center hose. Now, do
not open the low and high-pressure valves of the
manifold gauge.
F. Press the manifold gauge low side valve to eliminate
the trapped air in the hose.

9-1-147
Leakage Check
NOTE: Perform the leakage check after completing
vacuuming process.
1. After attaching the manifold gauge, open the high side
valve.
2. Charge system until low side gauge dial indicates a
pressure of 1 bar (14 psi) and close the high side valve.
3. Using a refrigerant leak detector or soapy water check
each joint for leakage. 1
Reference
Description
Number
1 Refrigerant Leak Detection Device
4. If a leak is detected, check for O-ring damage or correct

tightening torque and replace or repair as necessary.
5. If no leaks are detected, proceed with the charging
process.
HDA6071L
Figure 199
WARNING
For accurate refrigerant leak detection, perform leak
detection procedure in a well ventilated area.
Refrigerant Charging
1. Perform the vacuuming procedure, vacuum holding and
leaking tests as described in the proceeding headings.
NOTE: First charge the refrigerant system with 100g
(3.5 ounces) of refrigerant with the engine off.
Then using the manifold gauges as a guide fully
charge the system with the engine running.
When exchanging refrigerant containers, press
the manifold gauge low side valve to eliminate
air from the charging hose.
Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low-pressure Side
4 From Receiver
5 Refrigerant Supply Container
2. Charge the system by opening the manifold gauge low

5
side valve. HDA6072L
Figure 200
Initial charge amount: 100 g (3.5 ounces).

9-1-148
3. If refrigerant does not flow freely into system, try starting
engine first before operating air conditioner.
• Temperature control switch setting: Maximum
Cooling
Blower Speed Setting: Hi (3 step)
Engine Speed: 1,300 - 1,500 rpm
WARNING
When charging refrigerant system with the engine
running:
• Always keep refrigerant supply container in the
upright position.
• Never open the high side pressure valve.
4. Open the manifold gauge low side valve and charge

system to standard capacity.
Gauge Dial Standard Reading

13 - 20 bar
High Side Gauge
(185 - 285 psi)
1.5 - 3.5 bar
Low Side Gauge
(22 - 50 psi)
NOTE: These standards are for outside temperatures

between 30° - 35°C (86° - 95°F). The gauge
readings may vary for extreme temperature
conditions.
IMPORTANT
• When outside temperature is low, warm the
refrigerant supply container with warm water not
exceeding 40°C (104°F). Do not allow water to
come in contact with the charging adapter valve
handle.
• When outside temperature is high, cool off
refrigerant supply container and condenser to aid
the refrigerant charging process.
5. Close low-pressure side valve.

6. Shut off engine and close refrigerant supply container
adapter valve. Disconnect manifold gauge hoses from
machine.

9-1-149
Inspecting System For Leakage
After completing charging procedures, clean all joints and
connections with a clean dry cloth. Using a refrigerant leak
detecting device or soapy water, inspect system for leaks
2
starting from the high-pressure side.
1
NOTE: When the refrigerant circulation has been stopped
the high-pressure will start to decrease and the
low-pressure will start to increase until they are
equalized. Starting the inspection from the high side 3
will result in an accurate test.
Reference 4
Description HDA6073L
Number Figure 201
1 Pressure
2 High-pressure
3 Low-pressure
4 Compressor Stop
Inspection Procedure
1. High-pressure Side
Compressor outlet →condenser inlet →receiver dryer inlet
→air conditioner unit inlet.
2. Low-pressure side
Compressor inlet →air conditioner unit outlet.
3. Compressor
Compressor shaft area, bolt hole area and magnetic clutch
area.
4. Receiver dryer
Pressure switch and plug area.
5. Connection valve area
Inspect all valve areas.
Verify all valves are capped to prevent leaking.
Check for foreign material inside of valve cap.
6. Interior of air-conditioning unit.
After stopping engine, insert detector probe into drain
hose. (Leave inserted for 10 seconds minimum.)
NOTE: When inspecting leakage from the
air-conditioning unit, perform the inspection in a
well ventilated area.

9-1-150
WIPER SYSTEM
Wiper Circuit
5 6 7
- 2 3 5 (Continuous mode) 3
+
M
8 (Intermittent 1 mode) 4
4 4
10 (Intermittent 2 mode) 5
5 6 11 (Washer mode) 6
1 7 8
12 - + 1
P
1
6 9 13 2
9 2 8
AMP MIC 13P
CN12 CN13 KET 8P
15A 10A 10A 15A

4
10
2
3
AMP MIC 13P 1
3 4 4 6
7 8 9 11 13 9 5
(CN12) (CN13) (Wiper Motor)
FG000589
Figure 202
Reference Reference
Number Number
1 Battery 6 Wiper Controller
2 Battery Relay 7 Wiper Switch Panel
3 Fusible Link 8 Window Washer
4 Fuse Box 9 Wiper Cutoff Switch
5 Wiper Motor 10 Light Switch

9-1-151
Wiper Operation
Continuous operation
- Operation of wiper motor
Pressing the successive operation switch on the wiper switch
panel (7) changes the voltage of the "5" terminal of the wiper
controller (6) from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and
current flows by the "3" terminal of the wiper controller (6) → the
"2" and "4" terminals of the wiper motor (5) → the "4" terminal of
the wiper controller (6) to run the wiper motor (5) continuously.
- Stop of wiper motor
Pressing again the successive operation switch on the wiper
switch panel (7) changes the voltage of the "5" terminal of the
wiper controller (6) from LOW (0+0.5V) to HIGH (about
5.5 ±0.5V). As the "5" and "6" terminals of the wiper motor are
connected still that power is supplied to "6" terminal of the wiper
controller (6),
However, the controller (6) runs the wiper motor continuously
and then rotates the motor reversely by letting current flow by the
"4" terminal of the wiper controller (6) → the "2" and "4" terminals
of the wiper motor (5) → the "3" terminal of he wiper controller (6)
when the "1" and "6" terminals of he wiper motor (5) are
connected and thus power voltage is supplied to "7" terminal of
the wiper controller (6).
The Wiper motor (5) stops reverse revolution when the contact of
a cam switch connected to "6" terminal of the wiper motor (5)
moves to an insulation area of the cam plate to disconnect the "5"
and "6" terminals of the wiper motor (5).
When the wiper motor (5) stops, arm and blade connected to it
move to the stop positions of the right pole in the cabin.

9-1-152
Intermittent operation
- Intermittent 1st (3-second)
Pressing once the Intermittent switch in the switch panel (7)
changes voltage of the "8" terminal in the wiper controller (6)
from HIGH (about 5.5 ±0.5 V) to LOW (0+0.5 V) and current
flows through the "3" terminal in the wiper controller (6) → the "2"
and "4" terminals in the wiper motor (5) → the "4" terminal in the
wiper controller (6) to start the cycle that wiper stops 3 seconds
after every operation.
- Intermittent 2nd (6-second)
Pressing twice the Intermittent switch in the switch panel (7)
changes voltage of the "10" terminal in the wiper controller (6)
from HIGH (about 5.5 ±0.5 V) to LOW (0+0.5 V) and current
flows through the "3" terminal in the wiper controller (6) → the
"2" and "4" terminals in the wiper motor (5) → the "4" terminal in
the wiper controller (6) to start the cycle that wiper stops 6
seconds after every operation.
- Stopping the intermittent action
Pressing three times the Intermittent switch in the switch panel
(7) while the wiper is operating stops the action of the wiper
motor.
NOTE: The wiper system does not work when the wiper
cutoff switch (9) is "ON".

9-1-153
LIGHTING SYSTEM
Lighting System Circuit Diagram
7
13 87a
30
87
*15 85 86
*16
*9
87a
6
30
*14 87
87
30
85 86
85 86
12
*8
87
30 *5
0 0
85 86 3 I 2 2 I 3
II II
0
I 5 5
0
I
4
6 II II 6
7 8 8 7
20A
15A
10 30A
6-9 15A
6-10 15A
6-11
11
L6 6-12 3
1-74
6-4 1-77
2
6-5 1-78 CAN
1-59 1-1
1-3
1-4
1
1-5
FG018942
Figure 203

9-1-154
Reference Reference
Number Number
1 Battery Front Cabin Light /
9
2 Battery Relay Rear Work Light Relay
3 Fuse Box 10 Instrument Panel
4 Light Switch 11 EPOS Controller
5 Cabin Light Switch 12 Headlight (2 ea.)
Headlight Relay (Work Light 13 Work Light (2 ea.)
6
Indicate Light) 14 Front Cabin Light (4 ea.)
7 Work Light Relay 15 Rear Cabin Light (2 ea.)
8 Front Cabin Light Relay 16 Rear Work Light (1 ea.)
NOTE: The "*" mark are optional parts.
Kind of Light
The lighting system is consists of headlights, work lights, cabin
lights (optional), relays and switches.
Operation
Connected Terminal
Switch Position Activated Relay Lit Light
of switch
1 "2-3" Terminal - Illumination Light of Switch
"2-3" Terminal - Illumination Light of Switch
Light Switch Headlight Relay Headlight (2 ea.)
2
"5-6" Terminal Work Light (2 ea.)
Work Relay
Symbol Light of Work Light
Front Cabin Light (2 ea.) or
1 "2-3" Terminal Front Cabin Light Relay
Front Cabin Light (4 ea.)
Cabin Light Front Cabin Light (2 ea.) or
"2-3" Terminal Front Cabin Light Relay
Switch Front Cabin Light (4 ea.)
2
Rear Cabin Light Relay/ Rear Cabin Light (2 ea.) and
"5-6" Terminal
Rear Work Light Relay Rear Work Light (1 ea.)

9-1-155
OVERLOAD WARNING DEVICE
Overload Warning Device Circuit Diagram
10A 20A
4 1
5 1-1
1 0 1-3
2 1-45
3 I
7 8 1-4
1-5
+
1-20
6 SIG
- 1-38
EX1400260
Figure 204
Reference Reference
Number Number
1 Battery 4 EPOS Controller
2 Battery Relay 5 OWD Selector Switch
3 Fuse Box 6 Pressure Sensor

9-1-156
AUDIO CONTROLLER
Audio Controller Circuit Diagram
8
14
10
4
2
7 Stereo ANT.
3
2 15 5
Vcc(+5V)
3 16
MICOM 4
0.5WR 1
4 13
3 11
3 10A 10A 15A

9
(RH) (LH)
5
- + - + 9 17
7 1 6 4 2
2 3
17
10 4
12
13
1 11
1
9 10 11 12 13 14 15 16 17 18
1 2 3 4 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 78 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8
(Audio Control Panel) (Stereo) (Handsfree Unit)

FG018951
Figure 205
Reference Reference
Number Number
1 Battery 7 Audio Control Panel
2 Battery Relay 8 Stereo
3 Fuse Box 9 Speaker
4 Fusible Link 10 Antenna Module
5 Hands-free Unit 11 Light Switch
Operations by Audio Control Panel
Connected Terminal of
Switch Measured values Operations
switch
PWR 4.36 ±0.2V Stereo ON, OFF
1.24 ±0.2V Volume up
"3-4"
0 + 0.2V Volume down
SCAN 2.49 ±0.2V Frequency selection

9-1-157
9-1-158
1Options
One Way
Edition 1
DX340LC-5/DX350LC-5 One Way

10-1-1
MEMO
One Way DX340LC-5/DX350LC-5

10-1-2
Table of Contents
One Way
General .........................................................10-1-5
General Description................................................. 10-1-5
Caution for Installation............................................. 10-1-7
Installation Procedure ...................................10-1-8
Main Piping - One or Two-way ................................ 10-1-8
Main Piping - One Way ......................................... 10-1-10
Pilot Piping - One Way .......................................... 10-1-12
Boom Piping - One and Two-way.......................... 10-1-14
Arm Piping - One and Two-way ............................ 10-1-16
After Installation Precautions................................. 10-1-17
Air Bleeding ........................................................... 10-1-17
Completing Work ........................................10-1-18

10-1-3
10-1-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
General Description
The following description is of the installation of a pipe to
operate an attachment such as a breaker.
This description explains how to install a new pipe on a machine
in which a breaker operating pipe is not installed.
Figure 1 EX1301482
Theory of Operation
When a breaker (hammer) switch located at a right side joystick
lever is operated, an OPT spool will move to the maximum
extent possible through a hammer-operated solenoid valve.
Oil from the front (P1) pump is connected to a high-pressure line
from the breaker through the OPT spool, and the pressure is
controlled by a PPR valve connected to the high-pressure line
(the variable pressure being controlled according to a current
value).
EX1301342
The low-pressure oil of a breaker return line is returned to the
Figure 2
tank through a return filter and an oil cooler.
The flow rate through the front (P1) pump is controlled by an
instrument panel.

10-1-5
Hydraulic Circuit
T1
4
T A B A L.H
A7 B7 B A
Option R.H
b7
BKT Boom Travel (L) 5
P2
2
387 ±5 kg/cm2
(380 ±5 bar)
387 ±5 kg/cm2
(380 ±5 bar)
Relief V/V
a7
6 Two-way Pedal
High-speed
Operating
Hammer
3
Cut-off
Safety
Travel
T
A
ACC P2 H0 TR2 PH BS
T
P
P1 P2
1
P0
A3
P1 P3 P4
Figure 3 from Joystick (RH) Button EX1400204
Reference Reference
Number Number
1 Main Pump 4 Pressure Proportional Relief V/V
2 Control Valve 5 Stop Valve
3 Solenoid Valve 6 By-pass Cut Off Valve

10-1-6
Caution for Installation
• When you install piping, make sure there is no foreign
substance inside piping sub-parts such as hoses, pipes,
valves and fittings.
• Prior to installing piping:
A. Park on firm and level ground.
B. Lower front attachment (bucket) to ground.
C. Stop engine.
D. Move safety lever to "RELEASED" (UNLOCKED)
position.
E. Turn starter switch to "I" (ON) position.
F. Fully stroke work levers (joysticks) in all directions to
G. Move safety lever to "LOCK" position.
H. Turn key to "O" (OFF) position and remove from
starter switch.
I. Attach a maintenance warning tag on controls.
CAUTION
AVOID INJURY
Release any pressure in the hydraulic oil tank before work.
IMPORTANT
Contact your DOOSAN distributor about proper size of
hydrualic pipes for installation.

10-1-7
INSTALLATION PROCEDURE
Install the parts as below pictures and needed parts refer to parts book.
Main Piping - One or Two-way
FR
54 ON
T
54
51
51
53 12
14
BOOM
52
8
54
16 4
8 13 7
1
16 13
7
11 2
53 15
16
52 14
54 8 14
14 1 12 10
12 6
16
3
8 7 5
13
12
14
13
7
15
18
9 A7
17
CONTROL VALVE
MAIN FRAME
Figure 4 EX1400205

10-1-8
Reference Reference
Number Number
1 Att. Discharge Block 12 Bolt
2 Eppr Valve Bracket 13 Socket Bolt
3 Block Bracket (LH) 14 Washer
4 Block Bracket (RH) 15 O-ring
5 Hose Assembly 16 O-ring
6 Clip 17 O-ring
7 Split Flange 18 O-ring
8 Plug 51 Hose Assembly
9 Adapter 52 Split Flange
10 Bolt 53 Socket Bolt
11 Bolt 54 O-ring

10-1-9
Main Piping - One Way
FR
ON
T
BOOM
1
1-1
1-2
4 11
52
9 1-3
11
14
6 5
14
13 13
OIL TANK
1 A
10 T
8
2
51
15
12
14 7
9
4
11
B7
MAIN FRAME
CONTROL VALVE
EX1400206
Figure 5

10-1-10
Reference Reference
Number Number
1 Relief Valve 8 Bolt
1-1 Eppr Valve 9 Socket Bolt
1-2 Coil 10 Plain Washer
1-3 Flow Control Valve 11 O-ring
4 Flange 14 O-ring
5 Adapter 15 1 Way Joint Harness
6 Elbow 51 Hose Assembly
7 Elbow 52 O-ring

10-1-11
Pilot Piping - One Way
FR 8
ON 4
T 7
T1
1 7
6
8
8
5
9
b7
OIL TANK
2 8
CONTROL VALVE 4
7
a7 HO
9
5 10
EX1400207
Figure 6

10-1-12
Reference Reference
Number Number
1 Hose Assembly 6 Tee
4 Adapter 9 O-ring
5 Adapter 10 Solenoid Valve

10-1-13
Boom Piping - One and Two-way
NOTE: This is for STD Boom (6.5 m).
FR
ON
T
A
12
7
3 8
7
A
8
BOOM
1
2
A B
5 A
6
4 9
7
5 6
5
6 9
4
7
5 6
EX1400208
Figure 7

10-1-14
Reference Reference
Number Number
1 Pipe 6 Clamp
2 Pipe 7 Socket Bolt
3 Pipe 8 O-ring
4 Rubber 9 Split Flange
5 Clamp 12 Pipe

10-1-15
Arm Piping - One and Two-way
NOTE: This is for STD Arm (3.2 m).
FR
ON
T
2 10
20
3
10
20
3
10
10
20
20 3 BOOM
3
4
5
6
6
6
6 1
5
4
13
1 13 18
17
3
3 52
51
52-1
51-1
52-2 52-7
17 52-3 52-6
51-2 51-7
18 51-6
51-3 52-5
51-5 52-4
51-4
ARM
EX1400209
Figure 8

10-1-16
Reference Reference
Number Number
1 Pipe 51-3 Adapter
2 Hose 51-4 Cap
3 O-ring 51-5 O-ring
4 Bolt 51-6 Plug
5 Washer 51-7 O-ring
6 Clamp 52 Stop Valve Assembly (RH)
10 Socket Bolt 52-1 Stop Valve (RH)
13 Socket Bolt 52-2 O-ring
17 Spring Washer 52-3 Adapter
18 Socket Bolt 52-4 Cap
20 Split Flange 52-5 O-ring
51 Stop Valve Assembly (LH) 52-6 Plug
51-1 Stop Valve (LH) 52-7 O-ring
51-2 O-ring
After Installation Precautions

• After finishing installation of piping, connect 'P' and 'T' line Bucket Cylinder
directly to each other without connecting the breaker and
Stop Valve
do flushing process a few minutes to make hydraulic oil
Breaker Cap
clean before connecting the hoses to the attachments.
• Connect hydraulic hoses as shown in Figure 9. Make sure
that 'Pressure' and 'Tank' lines are not reversed.
When connecting the hoses, make it sure that no foreign
substances get into the hoses.
Dirt and sand can cause serious damage to the
attachments. EX1301485
• Arrange the connecting hoses so they are not twisted or Figure 9
excessively bent.
Air Bleeding
1. Start the engine and run at low idle.
cylinder 4 - 5 times very slowly about 100 mm before the
end of stroke.
(The air breather of oil tank is actuated to bleed the air.)

10-1-17
COMPLETING WORK
Breaker line overload relief valve can be changed from the
monitor (range 142.8 - 255 kg/cm2 (140 - 250 bar)).
Set to 255 kg/cm2 (250 bar). Check the pressure at maximum
flow.
(If maximum control pressure is out of tolerance, check EPPR
current)
How to Set Up Attachments

Breaker 1 Setting
Attachment setting items include attachment use, max E/G limit,
Attachment Use Dydlodeoh Button Type Wrjjoh
max pressure (ATT), max flow (ATT), min flow (ATT), and user Max E/G Limit 4;33 usp Max Press.(ATT) 473 edu
setting max flow. Operate the jog switch clockwise/ Max Flow(Pump) 7<3 osp Max Flow(ATT) 573 osp
counterclockwise to locate the cursor. Then, click on the jog 2 Pump Option Dydlodeoh Min Flow(ATT) 63 osp
switch to set up relevant items.
User Setting Max Flow <8 osp
The cursor movement order goes like this: 0 .
63 573
1. Breaker Setting
Attachment Use ↔ Toggle ↔ Max E/G Limit ↔ Max EX1301419
Pressure ↔ Max Flow ↔ Min Flow ↔ User Setting Max
Figure 10
Flow
2. Two-way Setting
Attachment Use ↔ Max E/G Limit ↔ Max Pressure ↔
Max Flow ↔ Min Flow ↔ User Setting Max Flow
For details, See “Attachment Setting (Optional)” on page -34,
Electrical System Section in this manual.

10-1-18
Two-way
Edition 1
DX340LC-5/DX350LC-5 Two-way
10-2-1
MEMO
Two-way DX340LC-5/DX350LC-5
10-2-2
Table of Contents
Two-way
General .........................................................10-2-5
Structure.................................................................. 10-2-6
Installation Procedure .................................10-2-10
Main Piping - One or Two-way .............................. 10-2-10
Main Piping - Two-way .......................................... 10-2-12
Pilot Piping - Two-way........................................... 10-2-14
Pilot Piping - Two-way (Pedal) .............................. 10-2-16
Boom Piping - One and Two-way.......................... 10-2-18
Arm Piping - One and Two-way ............................ 10-2-20
Floor Mat - Two-way (Pedal) ................................. 10-2-22
Air Bleeding ........................................................... 10-2-23
Completing Work ........................................10-2-23
10-2-3
10-2-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
General Description
The following description is for the installation of a pipe for use of
an attachment such as a crusher or shear in which hydraulic
pressure operates in both directions.
The description explains how to install a new pipe on a machine
in which an attachment-operating pipe is not installed.
EX1301486
Figure 1
Theory of Operation
When a thumb wheel (variable) switch located at a right side
joystick lever is operated, an output signal (1.0 - 4.0 V) of the
switch supplies a current value to a two-way EPPR valve
through an EPOS controller to variably control (move) an OPT
spool of a main control valve.
A shear operation pressure is controlled by a PPR valve
connected to a line. (the variable pressure is controlled
according to a current value)
EX1301283
The two-way PPR valve is used in the shear (two-way).
Figure 2
10-2-5
Structure
Main Control Valve (OPT Spool)

b7 a7
P (40 bar)
A B
Current
EPOS Controller
Voltage
Joystick
(Right-hand)
EX1400210
Figure 3
10-2-6
Hydraulic Circuit
Button Type
L.H
B A
B A
A7 B7
R.H
Option B A
b7
BKT Boom Travel (L) T1 5
4
P2
2
387 ±5 kg/cm2
a7 (380 ±5 bar)
from Joystick (R)
T
7
A B
P
Two-way Pedal
High-speed
6
Operating
Hammer
Cut-off
Safety
Travel
T
A
ACC P2 H0 TR2 PH BS
P T
P1 P2
1
A3 P0
P1 P3 P4
Figure 4 3
EX1400211
Reference Reference
Number Number
1 Main Pump 5 Stop Valve
2 Control Valve 6 By-pass Cut Off Valve
3 Solenoid Valve 7 EPPR Valve (Two-way)
4 Pressure Proportional Relief V/V
10-2-7
Pedal Type
L.H
B A
B A
A7 B7
R.H
Option B A
b7
BKT Boom Travel (L) T1 5
4
P2
2
387 ±5 kg/cm2
a7 (380 ±5 bar)
T P
from Joystick (R)
T 7
PE3C Pedal A B
2 1
LH-high
RH-high
P
6
Two-way Pedal
High-speed
Operating
T
Hammer
A
Cut-off
Safety
Travel
P ACC P2 H0 TR2 PH BS
P1 P2
1
A3 P0
P1 P3 P4
3
EX1400212
Figure 5
10-2-8
Reference Reference
Number Number
1 Main Pump 5 Stop Valve
2 Control Valve 6 By-pass Cut Off Valve
3 Solenoid Valve 7 EPPR Valve (Two-way)
4 Pressure Proportional Relief V/V 8 Two-way Pedal Valve

C. Stop engine.
position.
starter switch.
CAUTION
AVOID INJURY
10-2-9
Main Piping - One or Two-way
FR
54 ON
T
54
51
51
53 12
14
BOOM
52
8
54
16 4
8 13 7
1
16 13
7
11 2
53 15
16
52 14
54 8 14
14 1 12 10
12 6
16
3
8 7 5
13
12
14
13
7
15
18
9 A7
17
CONTROL VALVE
MAIN FRAME
Figure 6 EX1400205
10-2-10
Reference Reference
Number Number
1 Att. Discharge Block 12 Bolt
2 Eppr Valve Bracket 13 Socket Bolt
3 Block Bracket (LH) 14 Washer
4 Block Bracket (RH) 15 O-ring
6 Clip 17 O-ring
9 Adapter 52 Split Flange
10 Bolt 53 Socket Bolt
11 Bolt 54 O-ring
10-2-11
Main Piping - Two-way
FR
ON
T
BOOM
6 14
14
1
12
1-3
1-1
1-2
2
4
1-1
14
1-2
3 1-3
17
9
15 OIL TANK
1
17 A
9 B
16
13 16
11 T
51
8
18
19
15
7
12
6
14
B7
MAIN FRAME
EX1400213
Figure 7
10-2-12
Reference Reference
Number Number
1 Relief Valve 11 Bolt
1-1 EPPR Valve 12 Socket Bolt
1-2 Coil 13 Plain Washer
1-3 Flow Control Valve 14 O-ring
7 Plug 19 Joint Harness
8 Adapter 51 Hose Assembly
9 Adapter
10-2-13
Pilot Piping - Two-way
MAIN FRAME
FR
101 ON
T
101-1
213
FLOOR PLATE
203
208 OIL TANK
205
211 209 209 205 211 RELIEF VALVE
T P
106
101
105 A B
209 209
8
206 3 T1 8
206 9 3
211
9
201
211 202
211
204
209 212 102 2
108 207
T T
109
P 104
210
107
103
9
BLOCK 6
( 103 ) 10
b7
CONTROL VALVE
9
5
7
7-1 ( 102 )
a7 7
10
7-1 4
HO
9
7-2
1
53
EX1400214
Figure 8
10-2-14
Reference Reference
Number Number
1 Hose Assembly 105 Bolt
2 Hose Assembly 106 Spring Washer
3 Adapter 107 O-ring
5 Elbow 109 O-ring
6 Elbow 201 Hose
7 Shuttle Valve Tee 202 Hose Assembly
7-1 O-ring 203 Clip
7-2 O-ring 204 Plug
8 O-ring 205 Adapter
9 O-ring 206 Elbow
10 O-ring 207 Tee
53 Solenoid Valve 208 Bolt
101 EPPR Valve 209 O-ring
101-1 EPPR Valve 210 O-ring
104 Tee 213 Two-way Joint Harness
10-2-15
Pilot Piping - Two-way (Pedal)
6 FR
ON
T
26
4 23 29
2 27
7 MAIN FRAME
28
24
25 5
3
29 15
34
EPPR 22
1 19 30 VALVE
30 30 16 32
T 16
P 32 T
9 32 P 21
30 21-1
17 21-1
A B
32 34
14 21-2
21
11
12
13
10
32 20
30
32 T T 33
P 18
31 8
BLOCK
53 51
52
PH
54
EX1400215
Figure 9
10-2-16
Reference Reference
Number Number
1 Pedal Valve 21 Shuttle Valve Tee
2 Pedal Bracket 21-1 O-ring
3 Foot Rest 21-2 O-ring
4 Plate 22 Bolt
5 Lock 23 Bolt
6 Pedal Rubber (RH) 24 Bolt
7 Pedal Rubber 25 Socket Bolt
8 Hose 26 Socket Bolt
9 Hose 27 Spring Washer
14 Pressure Sensor 32 O-ring
15 Clip 33 O-ring
16 Adapter 34 Harness
17 Adapter 51 Elbow
19 Elbow 53 O-ring
20 Tee 54 4-sol Solenoid Valve
10-2-17
Boom Piping - One and Two-way
FR
ON
T
A
12
7
3 8
7
A
8
BOOM
1
2
A B
5 A
6
4 9
7
5 6
5
6 9
4
7
5 6
EX1400208
Figure 10
10-2-18
Reference Reference
Number Number
1 Pipe 6 Clamp
2 Pipe 7 Socket Bolt
3 Pipe 8 O-ring
4 Rubber 9 Split Flange
5 Clamp 12 Pipe
10-2-19
Arm Piping - One and Two-way
FR
ON
T
2 10
20
3
10
20
3
10
10
20
20 3 BOOM
3
4
5
6
6
6
6 1
5
4
13
1 13 18
17
3
3 52
51
52-1
51-1
52-2 52-7
17 52-3 52-6
51-2 51-7
18 51-6
51-3 52-5
51-5 52-4
51-4
ARM
EX1400209
Figure 11
10-2-20
Reference Reference
Number Number
1 Pipe 51-3 Adapter
2 Hose 51-4 Cap
3 O-ring 51-5 O-ring
4 Bolt 51-6 Plug
5 Washer 51-7 O-ring
6 Clamp 52 Stop Valve Assembly (RH)
10 Socket Bolt 52-1 Stop Valve (RH)
13 Socket Bolt 52-2 O-ring
17 Spring Washer 52-3 Adapter
18 Socket Bolt 52-4 Cap
20 Split Flange 52-5 O-ring
51 Stop Valve Assembly (LH) 52-6 Plug
51-1 Stop Valve (LH) 52-7 O-ring
51-2 O-ring
10-2-21
Floor Mat - Two-way (Pedal)
FR
ON
T
PEDAL VALVE
PEDAL VALVE
FLOOR PLATE
EX1400216
Figure 12
Reference
Description
Number
1 Floor Mat - Option Pedal (L)
10-2-22
• After finishing installation of piping, connect 'P' and 'T' line
directly to each other without connecting the attachments
and do flushing process for a few minutes to make
hydraulic oil clean before connecting the hoses to the
attachments.
• When connecting hydraulic hoses, make it sure that
'Pressure' and 'Tank' lines are not reversed.
When connecting the hoses, make it sure that no foreign
attachments.
• Arrange the connecting hoses so they are not twisted or
excessively bent.
Air Bleeding
end of stroke.
COMPLETING WORK
Two way line overload relief valve can be changed from the
monitor (range 255 - 346.7 kg/cm2 (250 - 340 bar)).
Set to 346.7 kg/cm2 (340 bar). Check the pressure at maximum
flow.
(If maximum control pressure is out of tolerance, check EPPR
current)
• Flow setting valve (EPPR valve): 250 L/min (66 U.S. gal)
• EPPR valve set: 312 mA
• Pilot pressure: 10 kg/cm2 (9.8 bar)
10-2-23
10-2-24
Rotating
Edition 1
DX340LC-5/DX350LC-5 Rotating
10-3-1
MEMO
Rotating DX340LC-5/DX350LC-5
10-3-2
Table of Contents
Rotating
General .........................................................10-3-5
Structure.................................................................. 10-3-6
Main Piping - Rotating ........................................... 10-3-10
Pilot Piping - Rotating............................................ 10-3-12
Boom Piping - Rotating ......................................... 10-3-14
Arm Piping - Rotating ............................................ 10-3-16
Air Bleeding ........................................................... 10-3-17
Completing Work ........................................10-3-17
10-3-3
10-3-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
General Description
When an attachment such as a crusher or a shear is used, an
optional rotating mechanism is provided according to the task
needed to be performed with the attachment.
EX1301491
Figure 1
Theory of Operation
When a thumbwheel switch located on the left joystick lever is
moved, the switch output signal (1.0 V - 4.0 V) supplies a current
to the rotating EPPR valve through the EPOS controller and a
control valve for rotating is controlled.
Moving the thumb wheel to the right rotates the attachment
clockwise. Moving the thumb wheel to the left rotates the
attachment counterclockwise.
Thumbwheel switch voltage output → EPOS controller input → EX1301284
EPOS controller current output → rotating EPPR valve current Figure 2
supply → control valve spool variable supply.
10-3-5
Structure
Rotating Control Valve

pa pb
P (40 bar)
A B
Current
EPOS Controller
Voltage
Joystick
(Left-hand)
EX1301492
Figure 3
10-3-6
Hydraulic Circuit
Attachment
L.H R.H
from Joystick (L)

B
100 k
3 T
A
100 k
A B Pa Pb
P
2
80 k
P T
Main Pump 1
EX1400217
Figure 4
Reference Reference
Number Number
1 Gear Pump (Rotating) 3 EPPR Valve
2 Control Valve (One Spool)
10-3-7
C. Stop engine.
position.
starter switch.
CAUTION
AVOID INJURY
10-3-8
10-3-9
Main Piping - Rotating
FR
ON
T
BOOM
51
52
OIL TANK
MAIN PUMP
24
5
32 ( 8) 1 29
32 18
14
14 27 2 32
23 16 32 20
27 25 26 31
A 13 32
B pa 19
3 32
26 28
12 pb 22 T
31 P 30
9 15
21 4 33
22
22 8
10
11
7
28 13 30
32 15
33 6
OIL COOLER
PIPING
MAIN FRAME
EX1400218
Figure 5
10-3-10
Reference Reference
Number Number
1 Gear Pump 19 Elbow
2 Power Take Off 20 Elbow
3 One Spool Valve 21 Set Bolt
4 Bracket 22 Bolt
5 Spacer 23 Bolt
6 Hose 24 Socket Bolt
9 Clip 27 O-ring
10 Clip 28 O-ring
11 Clip 29 O-ring
16 Elbow 51 Hose
18 Elbow 52 Hose
10-3-11
Pilot Piping - Rotating
FR
ON
T
1
FLOOR PLATE
1-1
8 15
13
P 1
2
12 159 14 BLOCK
T
11 B T P
13 A 13 17
6 7 7 14 4
15 9
15 5 16
10
MAIN FRAME
pa
pb
ONE SPOOL
VALVE
EX1400219
Figure 6
10-3-12
Reference Reference
Number Number
1 EPPR Valve 9 Tee
1-1 EPPR Valve 10 Bolt
2 Hose Assembly 11 Bolt
6 Clip 15 O-ring
7 Adapter 16 O-ring
8 Elbow 17 Joint Harness
10-3-13
Boom Piping - Rotating
FR
ON
T
3
b
10
9
2
b
10
9
1
1
b
BOOM
10
9
10
9
e
c
12
a b
20 9 8
7
5
22
6 13 d
4 7
5
7 4
8
11
9 20 7
22 6
8
18 7
BOOM 5
14
18
15
19
19 7 16 12
20
20 6 17
21 21 13
7 5
8
c d e
Figure 7 EX1400220
10-3-14
Reference Reference
Number Number
1 Pipe 12 Pipe
2 Pipe 13 Pipe
3 Pipe 14 Plate
4 Plate 15 Bolt
5 Pipe Clamp 16 Spring Washer
6 Bolt 17 Pipe Clamp
7 Spring Washer 18 Bolt
8 Bolt 19 Hardened Washer
9 O-ring 20 Pipe Clamp
10 Socket Bolt 21 Pipe Clamp
11 O-ring 22 Bolt
10-3-15
Arm Piping - Rotating
T
ON
FR 3
2
3
BOOM
1
2
5 3
6
1
4
6
5
4
ARM
5
6
4
16 6
5
4
15 16
13
12
15
11 51
14
52 51
12 52
54
53 11 54
53
Figure 8 EX1400221
10-3-16
Reference Reference
Number Number
1 Pipe 13 Switch Valve (RH)
2 Hose Assembly 14 Switch Valve (LH)
3 O-ring 15 O-ring
4 Pipe Clamp 16 Socket Bolt
5 Bolt 51 O-ring
6 Spring Washer 52 Elbow
11 Bolt 53 Cap
12 Spring Washer 54 O-ring

and do flushing process for a few minutes to clean
hydraulic oil before connecting the hoses to the
attachments.
• When connecting hydraulic hoses, making sure that
When connecting the hoses, make sure that no foreign
attachments.
excessively bent.
Air Bleeding
end of stroke.
COMPLETING WORK
• Control valve (rotating) pressure check (main relief):
81.6 kg/cm2 (80 bar)
• Left joystick pilot pressure check: 31.6 kg/cm2 (31 bar)
10-3-17
10-3-18
Quick Coupler
Edition 1
DX340LC-5/DX350LC-5 Quick Coupler

10-4-1
MEMO
Quick Coupler DX340LC-5/DX350LC-5

10-4-2
Table of Contents
Quick Coupler
General .........................................................10-4-5
Quick Coupler Operation ..............................10-4-8
To Engage Attachment............................................ 10-4-8
To Release Attachment......................................... 10-4-11
Main Piping - Quick Coupler.................................. 10-4-14
Electric Parts - Quick Coupler ............................... 10-4-15
Boom Piping - Quick Coupler ................................ 10-4-16
Arm Piping - Quick Coupler................................... 10-4-18
Air Bleeding ........................................................... 10-4-19
Completing Work ........................................10-4-19

10-4-3
10-4-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
General Description
Quick Couplers are attachments installed at the outer end of the
work equipment of various types of construction and earth-
moving machines. They facilitate the shorter time exchange of
working tools, buckets and etc.
Figure 1
Theory of Operation
1. LOCK
When the quick coupler switch on the right control stand is
operated, a flow path will form according to the movement
of the spool on the quick coupler solenoid valve, and
pressure from the pump will be applied to the cylinder of
the quick coupler, moving the quick coupler in a locking
direction.
2. UNLOCK
When the quick coupler switch of the right control stand is EX1301517
operated, a flow path will form because of the movement of Figure 2
the spool of the quick coupler solenoid valve, and pressure
from the pump will be applied to the cylinder of the quick
coupler, moving the quick coupler in an unlocking direction.
Quick coupler only operates over 280 bar pressure of
bucket crowd.

10-4-5
Hydraulic Circuit
b6
4
B6
3
A6
a6
B A B A
2 2
250k 250k
280k 280k
P2 P2
T P1 T P1
P1 P2
1 A3
EX1400222
Figure 3
Reference Reference
Number Number
1 Main Pump 3 Bucket Cylinder
2 Quick Coupler Solenoid Valve 4 Control Valve (Bucket Spool)

10-4-6
CAUTION
AVOID INJURY

C. Stop engine.
position.
starter switch.

10-4-7
QUICK COUPLER OPERATION
NOTE: The quick coupler installed on your machine may be
different than the one shown in this manual. Always
read and follow the manufacturer's Quick Coupler
Owner's Manual for more instructions.
To Engage Attachment
WARNING
The following safety instructions are for your safety, the
safety of bystanders, and to prevent property damage. Read
the instructions before using the machine and make sure
you are familiar with all safety messages and decals.
Hydraulic quick couplers must be installed, operated,
inspected, serviced, maintained and repaired by properly
trained and experienced people.
• Do not operate the machine if there are other workers
or people in the work area. Also, never allow people to
stand or walk under the work tool or attachment while
operating.
• Do not start or perform any work unless you are
properly trained. You should understand how to use
the quick coupler according to the instructions.
• Make sure that quick coupler is "FULLY ENGAGED
AND LOCKED" every time after you change work tools
or attachments.
• Perform the recommended daily inspection and
maintenance for proper operation.
• Attachments used with the machine should not exceed
the rated capacity and load limits of the excavator.
• Check for changes to load radius, maximum operating
capacity and read and follow load rating charts before
lifting loads or objects.
WARNING
Never use attachments or buckets which are not approved
by DOOSAN. Buckets and attachments for safe loads of
specified densities are approved for each model.
Unapproved attachments can cause death or serious injury.

10-4-8
1. Park the excavator and attachment on firm and level
ground. O I
2. Move quick coupler switch to "I" (UNLOCKED) position
(Figure 4).
NOTE: Refer to the Operating Controls Section of this
manual for further information.
When the quick coupler switch is in the "I" (UNLOCKED)
position, a warning message will appear on the
multifunction display screen and a warning buzzer will
sound in the cabin. EX1301101
NOTE: To retract quick coupler lock, fully extend the Figure 4

bucket cylinder (bucket crowd) and maintain
hydraulic relief condition for 5 seconds or more
with switch in the "I" (UNLOCKED) position.
NOTE: Whenever the quick coupler switch is moved to
the "I" (UNLOCKED) position, a quick coupler PM
release system activated symbol and a warning H H
message will appear on the display screen and
a warning buzzer will sound. When moving
switch to "O (LOCKED) position, the symbol
and warning message will disappear and E F
C C
buzzer will stop.
E F
TRIP
/h rpm ECO
Min Max
EX1301023
Figure 5
3. Retract the bucket cylinder. Align the quick coupler with

attachment mounting pins or interface.
WARNING
Keep attachment close to ground during engaging or
releasing attachment. Attachment can fall off without
warning if not "FULLY ENGAGED AND LOCKED" EX1300731
causing death or serious injury. Figure 6
4. Move the arm (1, Figure 7) and raise it until hook (2)
engages the upper pin or interface of attachment.
1
2
EX1300732
Figure 7

10-4-9
5. Extend the bucket cylinder (bucket crowd) to engage quick
coupler to lower attachment pin or interface.
EX1400299
Figure 8
6. Set quick coupler switch to "O" (LOCKED) position.

7. Fully extend the bucket cylinder (bucket crowd) to fully
engage and lock quick coupler to attachment.
NOTE: To engage the quick coupler lock, fully extend
the bucket cylinder (bucket crowd) maintain <UNLOCK>
hydraulic relief condition for 10 seconds with O I
the quick coupler switch moved in the "O"
(LOCKED) position.
EX1300733
Figure 9
8. Shake the attachment vigorously and lower the boom to

the ground and apply down pressure to the quick coupler
and attachment to check that attachment is fully engaged
and locked to the quick coupler (Figure 10).
<LOCK>
O I
EX1300734
Figure 10

10-4-10
9. Visually check that quick coupler is fully engaged and
locked before operating the machine and attachment.
Push Type
WARNING
Failure to visually check that quick coupler is "FULLY Pull Type
ENGAGED AND LOCKED" before operating can allow
the attachment to fall off causing death or serious injury. EX1300735
Figure 11
WARNING
The attachment swing radius is increased when the
quick coupler is installed.
Operate quick coupler and attachment through its full
range of motion to check for interference between
attachment and machine that could damage the cabin,
boom, coupler or attachment.
WARNING
Never use quick coupler or attachment to transport or
lift persons. Always use quick coupler and attachment
according to the instructions provided by the
manufacturer.
To Release Attachment
1. Park the excavator and attachment on firm and level
ground.
2. Move quick coupler switch to "I" (UNLOCKED) position. <UNLOCK>
When the quick coupler switch is in the "I" (UNLOCKED) O I
position, a warning message will appear on the
multifunction display screen and a warning buzzer will
sound in the cabin.
NOTE: To retract quick coupler lock, fully extend the EX1300736
bucket cylinder (bucket crowd) and maintain Figure 12
hydraulic relief condition for 5 seconds or more
in bucket crowd position, with the switch in the
"I" (UNLOCKED) position.

10-4-11
NOTE: Whenever the quick coupler switch is moved to
the "I" (UNLOCKED) position, a quick coupler PM
release system activated symbol and a warning H H
message will appear on the display screen and
a warning buzzer will sound. When moving
switch to "O (LOCKED) position, the symbol
and warning message will disappear and E F
C C
buzzer will stop.
E F
TRIP
/h rpm ECO
Min Max
EX1301023
Figure 13
3. Retract the bucket cylinder to move the quick coupler

toward the machine (Figure 14).
EX1300737
Figure 14
4. Move quick coupler switch to "O" (LOCKED) position.

Lower and move arm away from attachment and toward
the machine.
<LOCK>
O I
EX1300738
Figure 15

10-4-12
10-4-13
Main Piping - Quick Coupler

1
1-2
FR
ON
BOOM
T
1-1
1-3
52
OIL TANK
54
51 15 9
17 19
T 20
P2
20 9 19 B
53 P1 A
( 6) 19 10 21
( 7)
1
4
( 5)
13 23 16 20
5 11
20
19
9 12
19 7
22 2
18 20
B6
3
18 9 19
20
8
14
CONTROL VALVE
MAIN FRAME
Figure 16 EX1400223

10-4-14
Reference Reference
Number Number
1 Quick-fit Valve 14 Bolt
1-1 Solenoid Valve 15 Bolt
1-2 Reducing Valve 16 Socket Bolt
1-3 Coil 17 Spring Washer
2 Bucket Pipe 18 O-ring
3 Spacer Block 19 O-ring
4 Quick Fit Valve Bracket 20 O-ring
7 Hose Assembly 23 Joint Harness
8 Clip 24 Adapter, Filter
9 Adapter 51 Hose Assembly
10 Adapter, Filter 52 Hose Assembly
11 Elbow 53 Hose Assembly
12 Tee 54 O-ring
13 Set Bolt
Electric Parts - Quick Coupler
CONTROL STAND (R.H)
Figure 17
EX1301559
Reference Reference
Number Number
1 Lockout Toggle Switch 3 Quick Coupler Decal
2 Joint Harness

10-4-15
Boom Piping - Quick Coupler
5
13
12
13
6 FR
8 13 ON
T
(1 )
4 7
(2 )
a
1
a
2
a a
10
11
BOOM a
(1 )
13
(2 )
13 3
3 13
13
6 5
7 9
8
Figure 18 EX1400224

10-4-16
Reference Reference
Number Number
1 Hose 8 Nut
2 Hose Assembly 9 Bracket
3 Connector Adapter 10 Bolt
4 Bracket 11 Clip
5 Bolt 12 Adapter
6 Hardened Washer 13 O-ring
7 Plate

10-4-17
Arm Piping - Quick Coupler
T
ON
FR
8
a 3
BOOM
8
9
1
a 2
ARM
7
6
5
4
8 4
8 a
Figure 19 EX1400225

10-4-18
Reference Reference
Number Number
1 Pipe 6 Spring Washer
2 Pipe 7 Pipe Clamp
5 Bolt

and do flushing process for a few minutes to clean the
hydraulic oil before connecting the hoses to the
attachments.
• When connecting hydraulic hoses, making sure that
When connecting the hoses, make sure that no foreign
attachments.
excessively bent.
Air Bleeding
end of stroke.
COMPLETING WORK
• The quick coupler switch and the installation state of the
pipes can be verified with the eye.
• High-pressure can be checked using the push/pull type
quick coupler.

10-4-19
10-4-20
1Schematic
1Hydraulic Schematic
/ Electrical Schematic
Edition 1
DX340LC-5/DX350LC-5 Hydraulic Schematic / Electrical Schematic

11-1-1
MEMO
Hydraulic Schematic / Electrical Schematic DX340LC-5/DX350LC-5

11-1-2
DX340LC-5 / DX350LC-5
B(#17)
OPTION
ONE-WAY ; JOYSTICK BOTTON(R.H)
APPLIED PART
34 38 BREAKER
Hydraulic Schematic
3 SH 36 38 FILTER 39
D P P2 P2 P D ONE/TWO-WAY ; JOYSTICK PPC(R.H) 35 PEDAL 37
BACKWARD B
P1(#16)
FORWARD B
DB PG ROTATING ; JOYSTICK PPC(L.H) 40 41 42 43
28. BOOM LOCK VALVE 01. MAIN PUMP
QUICK COUPLER 33 29. BOOM FLOATING VALVE 02. MAIN CONTROL VALVE(STD)
BOOM LOCK VALVE/ARM LOCK VALVE 28 / 30 30. ARM LOCK VALVE 03. SWING DEVICE
31. PATTERN CHANGE VALVE 04. TRAVEL DEVICE
LOW
C
LOW
T3(#01) PATTERN CHANGE VALVE (ISO BHL) 31 32. STRAIGHT TRAVEL PEDAL VALVE 05. CENTER JOINT
PA PB
A BACKWARD
A FORWARD
33. QUICK COUPLER VALVE 06. BOOM CYLINDER
STRAIGHT TRAVEL PEDAL 32 34. ONE-WAY PPR VALVE 07. ARM CYLINDER
HIGH
HIGH
35. TWO-WAY PPR VALVE 08. BUCKET CYLINDER
4 2 5 0 3 1 INTELLIGENT BOOM 29 36. TWO-WAY EPPR VALVE 09. FAN DRIVE PUMP
37. TWO WAY PEDAL VALVE 10. FAN DRIVE MOTOR
ARTI. BOOM 44 45 PEDAL 47 LOCK VALVE 46
D
P1 P1 D LEFT A B RIGHT 38. STOP VALVE 11. JOYSTICK VALVE(L.H)
O 39. HIGH PRESSURE RETURN FILTER 12. JOYSTICK VALVE(R.H)
4 TRAVEL MOTOR (L) 5 TRAVEL MOTOR (R) 4 P 40. GEAR PUMP FOR ROTATING
S
T
13. PEDAL VALVE
T 41. POWER TAKE-OFF D 14. PILOT FILTER
42. ROTATING CONTROL VALVE 15. ACCUMULATOR
250 bar
43. ROTATING EPPR VALVE 16. SOLENOID PACKAGE VALVE
A P1 44. MAIN CONTROL VALVE(ARTI) 17. EPPR&SOL. PACKAGE VALVE
38 P2(#02) 45. ARTI. BOOM CYLINDER 18. BY-PASS CUT OFF VALVE
A B B 46. ARTI. BOOM LOCK VALVE 19. OIL COOLER
2
PH(#16) 6 6 47. ARTI. BOOM PEDAL VALVE 20. FULL FLOW FILTER
L.H 280 bar
21. AIR BREATHER
1 T P T(#25) 38 33 T
22. HYDRAULIC TANK
A B P2 23. JOINT PLATE(PRIMARY)
37 R.H 35 24. JOINT PLATE(SECONDARY)
B A 25. PT BLOCK
TWO-WAY
PEDAL(R.H) C2 C2 B A QUICK COUPLER B6(#02) 26. PUMP PEAK REDUCING V/V(DRIVE)
2 1 T1 30 27. PUMP PEAK REDUCING V/V(IDLE)
LH-HIGH E E
P2
RH-HIGH
36 7 E Pi1
SENSOR
SENSOR
46 2
#25 P3
HO(#16) P b7(#02) E 47
T 8 Pi1
T
Pi1
T C2 1 T P
V2 V2
C2
A B 28 28 a5(#02) E T V2
RH-HI LH-HI
C
(CLOSE) T (OPEN) 2 2 4
#25
39 T P1
29 V2 T Pi1 E ARTI.PEDAL(L.H) 32 13
2 DOWN UP 1
from JOYSTICK(R) PPC 45 1 T P 1 T P 3
TWO WAY OPTION B8(#23)
SENSOR
SENSOR
a8(#44)
ST TRAVEL
PEDAL(L.H) L.TRAVEL R.TRAVEL
B6(#23) AB(#24) B1(#24) a8(#44) b8(#44) 2 1 2 FORWARD 1 4 FORWARD 3
T1 FORWARD
1(#47) B(#36) P2(#33) B11(#23) B12(#23) B7(#23) B4(#24) BACKWARD
BB(#02)
ARTI. BOOM BACKWARD BACKWARD
34 B8 A8 b8 B7 A7 b7 B6 A6 b6 B5 L3 b5 B4 A4 b4 AB Pc2 b3 B3 A3 b2 B2 A2 b1 B1 A1
ø1.2 ø1.2
ø0.6 ø1.2 ø2.5
T A /ø2.0 /ø2.0 /ø2.0
ARTI. OPTION BKT BOOM TRAVEL(L) TRAVEL(R) SWING ARM
A B 25
L.H T(#37)
ø0.8
38 T(#36)
A B 380 ±5 bar 380 ±5 bar 380 ±5 bar 380 ±5 bar 380 ±5 bar
R.H P(#43) P(#36)
ø1.2 ø1.2 ø1.2 T(#43)
/ø2.0 ø0.8 ø2.3
/ø2.0 /ø2.0
a8 7M9-25 a7 a6 a5 a4 Pc1 BB a3 a2 L2 a1
39 Pi1(#46) HO(#16) B9(#23) C(#29) B10(#23)
380 ±5 bar
B5(#23) A2(#24) B3(#24)
2(#47)
44 2 b5(#02)
3 bar
2 2
1bar
3 T P T P 3
ONE WAY OPTION T Pi P2 L1 P1500 bar Y K
S 1 1
SENSOR
4 4
A(#17) 500 bar
P1(#33) SENSOR 11 12
SWING ARM BOOM BUCKET
1 3 2 4 2 4 1 3
LEFT DUMP DOWN CROWD
RIGHT CROWD UP DUMP
A2 B2 C2 D2
RH-HI LH-HI
31
(CCW) (CW) P(#40)
ISO BHL
Pi(#02) *SH(#24) A1 B1 C1 D1
T 42
T B P T
ø0.3 80 bar
C(#03) A
P(#42) 26 A ø0.6
41 P 18 17 P pa pb
10 40 SH(#03)
19 23
P A 100 bar
A1 A3 A2 A4 A5 A7 A6 A8 A9 A11 A10 A12
1 S 15
A2 A(#36)
a7(#02) B 100 bar
Two way Pedal
Hammer Operating
M M2 R6
P(#37)
high speed
Safety Cut-off
DRIVE PUMP B1 B3 B2 B4 B5 B7 B6 B8 B9 B11 B10 B12

B
SENSOR
SENSOR
SENSOR
SENSOR
SENSOR
SENSOR
SENSOR
SENSOR
SENSOR
Travel
Vgmax Vgmin
21 ENGINE
DC9 ACC P2 HO TR2 PH BS
#25
P
TIER-4F T
20 Vgmax Vgmin a3 b3 b5 P1(#29) a6 b6 a4 b4
22 9 IDLE PUMP
A B A1 A3 A2 A4
L1 L2 S
P1
1.5 ± 0.2 bar
M1 R5 PG(#03) RH-HI T LH-HI
10u M2 M1 PHB (CCW) #25 (CW)
A1 P0 P3 B1 B3 B2 B4
177u P P* P4
R2 R4 S
X2 16 from JOYSTICK(L) PPC
b1
AB
a1 a2
*SH
b2 24
T2
X1 27 14 from JOYSTICK(R) BOTTON ROTATING OPTION
T1 When Operating Hammer Select EX1400681

11-1-3
DX340LC-5 / DX350LC-5
6-LAMP ASS'Y (OPT)
WORKING LAMP
(301005-00132)x2
185B
1.25RG
87a
30 F24D ROTATING BEACON (OPT)
Electrical Schematic(1/2)
2RY
TERMINAL NO (RH) 1.25B 2RG 185A 87 ROTATING
1.25RG 0.85RG 66C 0.5B 85 86 0.5RG
TELESCOPIC BEACON
BEACON SWITCH LOWER WIPER (OPT)
(RR) (549-00101/K1056645) WIPER
AMP 040 MK2 36P 0.85B 185C 68C ROTATING BEACON SWITCH PANEL
87a 1.25RG
FRONT CABIN LAMP 30 F15G 1.25RB (300705-00037) 1 0 (543-00095)
(K1055454 )x(2 or 4) (REAR) (LH) 2 F2B 0.85RG
1 8 66A 87 0.85RG 66D 1.25B WORKING LAMP RELAY 186B 0.85Or 186A 3 I 196B 3 0.5LR (CONT) 5 196A 200A 3 0.85LW 2 200B -
192B L
+
1 6
12 1
0.85R 0.85LR M
2 7
1 4 1 4 11 2 65B 0.85RG 86 64B 0.5RG (RL) (301202-00042) CONT. 197B 4 0.5LY (INT-1) 8
2
5 0.5B 85 0.85B 0.85B 0.5B 7 8 80E 0.5WR 197A
2 5 6 2 3
10 3
REAR 193A 1 201B 4 0.85LB 4 201A
3 6
3 7 9 4 (FR) 0.85B 184C 0.85RW 0 INT 198B 5 0.5LG (INT-2) 10 198A
3 4 GAUGE (CN7) GAUGE (CN6) 1.25B 2 192A
4 5 8 5 REAR CABIN LAMP WORKING LAMP +
WASHER
7 6 STOP RUN B F3B 0.85BR F3C 3 I 6 0.5L (WASHER) 11 199A
(K1055454 )x2 0.85B (K1055454) 199B
AMP 070 18P AMP 070 12P 65C 0.85RG LAMP SWITCH (549-00103/K1056625)
CABIN LAMP RELAY 2 F19C M 0.5B 7 8 80F (K1000789)
ECU (C4002) ECU (C4022) ECU (C4071) CABIN LAMP SWITCH 87a 1 202B
ECU (C4001) 8 7 6 5 4 3 2 1 5 4 3 2 1
TMS (FMR) (K1053326) HEAD LAMP WINDOW WASHER 202A 7 0.85WL
0.85B (549-00103/301401-00009) 30 1.25Y 0 S 193B 0.85G 0.5WR
(K1055454 )x2 184B 2 F24B
-
+ 5
0.85RW 1.25RW 184A 87 0.85WR 80A 3 I 0.85RY LOWER WIPER SW F4E 1 0.85L - 0.85RB 12 195A 203A 6 0.85WB 203B
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6 2B 0 F23B E 0.85B P
87a II (549-00101/301401-000022) F4D 195C 6 F28E
(FRONT) 0.5WR 63A 3 I 2 0.5RL (RH) 0.85B 0.5B 85 86 0.5RG WIPER
A/C PANEL (CN9) A/C PANEL (CN8) 30 F23D 2RL
DIODE ARRAY DIODE ARRAY 65D 0.85RG 87 II 0 0.5L 0.5RB CONTROLLER 0.85WR
2RG 65A 184D 68B I 5 F24C 0.85RY
AMP MIC 9P (300611-00271) WIPER MOTOR
AMP 040-III 20P F23C LOWER WIPER MOTOR F4C 195B
KET D/L 4P HANDSFREE UNIT (FML) 85 86 63B 0.5WR 0 0.85RW 0.5RG 68A 6 II CN5 DIODE 4 (300512-00010)
5 6 7 8 3 4 0.85B 0.5B (538-00012 )
I 5 0.5RL (LH) HEAD LAMP RELAY 1
2 1 0.85B 0.5B 7 8 80C 0.5WR 0.85L 0.85L F4B
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 0.5RG 64A 6 II (K1053326) 80G
WIPER CUT SW
65E 0.85RG 2 0.5WR 0.5Or 13 F21E (549-00086 )
4 3
20 19 18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18 19 20
0.5B 7 8 0.5WR 0.5WR
1 2 3 4 1 2 CABIN LAMP RELAY 1 8 0.5B 0.85B 2 99 194A 9 0.85Lg 0.85B
(FL) 0.85B 2RY
A/C UNIT (CN11) A/C UNIT (CN10) 80B AMP MIC 13P 194B
(301202-00042)
21 22 23 24 2RL CN4
2B 3RL 0.5WR
25 26 27 28
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 FUEL HEATER (OPT) AUTO SHUTOFF FUEL PUMP (OPT)

43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 106 107 108 109 110 111 112 113 119 120 121
4 5
98 99 100 101 102 103 104 105 AUTO SHUTOFF UNIT FUEL PUMP 0.85L
3
62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44
117 118 87a (300609-00005)
81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 90 91 92 93 94 95 96 97 FUEL HEATER 1 30 F25C 0.5RG (401-00527 ) 0.85WR
MOLEX 4P 3RG
1 2 82 83 84 85 86 87 88 89 114 115 116
(K1004716 ) 3R 71A 87 5 189B (-)
1 0 1.25WR F28B 2 0.5Or
1
1 2 P
EPOS (CN1)
3 71B 85 86
EPOS (CN2) 1 2 3 4
2
0.5RY 70A 3 I 189A (+) 190A 2 25A 2R 12V POWER 12V POWER SOCKET(OPT)
2 3 0.5B F25B 1 START STOP 6 DC/DC
PRESS. SENSOR 70B 7 8 0.5WR 1.25B 2LR 1
(CN13) 0.5B SOCKET
9 5
4
5 TRAVEL/SWING ALARM ASS'Y (OPT) SWITCH SWITCH
190B F5B
CONVERTER 1 3 25B +
(K1053423) 2 27A 2L
AMP 070 16P AMP 040 12P AMP 040 20P 8 4 6
80D (300612-00001A) 2RY 1 DC/DC
FUEL HEATER FUEL HEATER 187A 3 4 188A 99 + 12V POWER
7 + 173C 0.85RY - CONVERTER 2 3 27B
ALARM RELAY RELAY 1 F6B SOCKET
3 12 6 8 SWITCH 0.85LR 0.85BY 12V POWER SOCKET(OPT) (300612-00001A)
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 (K1053326) (K1053326) 2B
DIODE 3
4 1 173B (549-00101/K1056653) FUEL LEVEL 99 - (K1053423)
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 87a F15B 2RY
7 2 3 2 ALARM SWITCH 30 0.85RB 87a 187B 188B SWITCH
16 15 14 13 12 11 10 9 7 1 - 2.5B 2B
30 F17B (301412-00004) 0.85Or F21C
6 1 (549-00103/301401-00010)
0.85B 0.85RY 173A 87 3LB
EPOS (CN3) EPOS (CN4) EPOS (CN5) JOG SWITCH JACK ASS'Y CALL SWITCH ALARM BUZZER 0
3RY 461A 87 AUXILIARY MODE
MICRO PHONE (516-00011 ) 0.5P 174A 3 I 2 F15D 0.5LB 172B 85 86 0.5RB 461B 85 86 70C
0.85BR F3D
MICRO PHONE(OPT)
II 0.85R F27J GAUGE PANEL
STARTER SWITCH CONNECTION F15C 0.5B 0.5RY
80K AMPLIFIER
0 0.5WR CIRCUIT
LAN
(800201-00050A) CABLE MIC
TML B BR R1 R2 C ACC I 5 F15E 0.85RB 1.25WR 0.85GBr F20C
PST SPEAKER
0.5W 175A 6 II
FUEL HEATER REFER TO PAGE 2 1.25YB 5 F10B
(300652-00002A)
OFF 0.85RY RELAY 2 8
8 0.5WR CIGAR LIGHTER 0.85YB F10C 401A 0.5GrL 401B +
7 (K1053326) 7E
ON (300730-00006) 1 402B
0.5B 80J 1.25B 402A 0.5BW -
FUEL HEATER 2 0.85WR
START 2.5B
6P
(K1004716 )
1.25B F1B
1.25WR
0.85RG
0.5WR
0.85BR
1.25W
3RG
2RY
0.85R
0.85L
2RL
2RY
3R
AUXILIARY MODE 0.5Br
2LR
2RL
0.85R
SCR CONTROL UNIT GPS ANTENNA
GAUGE PANEL 1.25RB F23A F24A F25A F26A F27A F28A F1A F2A F3A F4A F5A F6A F7A Glow plug 30 F10G 2.0YB
ENGINE VEHICLE PR1B
0.85RY F8A 2.0OrR PR1A 87 EMERGNECY STARTING RELAY
CONN CONN CIRCUIT 9 10 11 12 13 14 1 2 3 4 5 6 7 8 1.25WR (K1053326)
CONTROLLER 20A 20A 30A 20A 10A 15A 10A 10A 10A 10A 10A 10A 20A 10A 0.5BY PR3B 85 86 6F 87a
4 B-32 HORN 1 HORN 2
REFER TO PAGE 2 OVER LOAD ( 300611-00477 ) H.F L.F 1.25WR 2WR ST1C 30 C4002-4 Including in Engine Harness
3 (300726-00002) (300726-00003) 87 1.25R ECU (B-1)
B-33 SATELLITE ANT. 17 18 B2E 15 16
WARNING (OPT) 172A 2-99 B4D B4B B2C
0.5LR
0.85B
95G
96G
7 B-8 97B 96B 95B (300703-00002) 246B 246D 0.85B ST3A
0.85RY 0.85RY 5W 5W GLOW PLUG RELAY ST2B 86 85
8 9 STARTER SWITCH C STARTER
6 B-6 OVER LOAD WARNING SWITCH FUSE BOX 2 FUSE BOX 1 (301202-00042)
SHIELD
DOSING 1 F21B 0.85LR (301419-00006)

0.85Or 5W 5W
0.5YB
(549-00102/301401-00006)
0.5Y
UNIT 8 B-7 87a 6A

1 0 TxD 169A 1-80 0.5GL 0.5GL 169A 5 3 9F 0.85RW 30 F15H 0.85RG
5 2 86B 0.5BrY 1-45 TMS B4E B2D B4C B
B-5 86A
1-79 246A 87 15R 212A B
RxD 168A 0.5GW 168B 6 4 F13F 18 B2B ACC C ST1A 0.5BG
+5V
0.5B 3 I 0.5GW CONTROLLER 15 16 2WR 17 2WR 87a

1 B-4 245A 85 86 F15H 0.5RG 6E 30
0.5B 7 8 167A 1-43 0.5LR 0.5RG 98B 7 2 ST1B
0.85RL
80L 0.5WR 1-28 175B 30A 20A 30A 10A 15A 10A 10A 15A 30A 20A 10A 15A 15A 20A 1.25WR 2 87 PR2B
2 B-3 9 10 11 12 13 14 B 0.85LR
1-9 174B GPS ANTENNA GPS ANT. HORN RELAY 1 2 3 4 5 6 7 8 EMERGNECY
F8B R1
HIGH SPEED SWITCH (K1053326) F15A F16A F17A F18A F19A F20A F21A F22A F9A F10A F11A F12A F13A F14A
STARTING
1 3 6D 86 85 PR4B
F27D 0.85R (549-00103/301401-00008) 0 R2 BR Glow plug
2RG
2R
2WR
+ 0.5G
1.25YB
1.25RB
1.25LB
1.25RL
1.25RB
1.25LR
2
0.85GBr
A-24 SWITCH 0.5LR
1.25Y
0.85Or
3LB
2 F13C 0.5RL S/V
0.85BrR
PRESSURE SENSOR 87B 0.85BrW 1-20 87A 3 I ROOM LAMP 7A A
(549-00093) ST2A
CAN
NOX
3 A-23 (OWD) SIG II (534-00079 ) 0.85Br

NOX 88B 0.85WB 1-38 88A 166B
1 (2547-9045 ) - OFF PREHEATING S/V RELAY
SENSOR A-20 0 10W
166A 1-75 0.5BrB (MANUAL) 147A (K1053326)
5 F13B 0.5B E DR B+ 0.5WR 60B
SUPPLY
4 A-21 F27E 0.85R I 0.5RL

NOX
+ 165B 6 100R FUSIBLE LINK

165A 1-56 0.5BrW (AUTO) II 0.5BR
PRESSURE SENSOR(A) 89B 0.85GR 1-19 89A ON F22B (2527-1023A)
SIG 0.5B 7 8 80M 0.5WR 3LB
(FRONT PUMP)
1 B-31 90B 0.85W 1-37 90A
-
SENSOR t° (2547-9045 ) 0.85Y 2WR 2WR 2WR 2R
TEMP. UPSTREAM 2 B-30
V +
F27F 0.85R 68D 1-74 0.5RG 0.85GBr 0.85WR F8C 1 Including in Engine Harness B2A B1B
PRESSURE SENSOR(B) 0.5G
1 91B 0.85GY 1-18 91A PR4A 2-106 0.5BR PREHEAT(GLOW PLUG S/V) 0.85Or 0.85Or 0.85RW 9C 3 HOUR 2 0.5B
B-42 (REAR PUMP) SIG DA1-2 BATTERY RELAY
HOSE HEATER 1 2 (2547-9045 ) 92B 0.85WL 1-36 92A 147B 1-58 0.5BG KEY SW 'START' 0.5BG 0.5BG 7B 8A CIRCUIT BREAKER (2544-9024 ) 2R
B-41 - HOUR METER 2 4 0.85BrW
0.5BY PREHEAT(GLOW PLUG) 0.85LR 0.85LR (2528-9040 ) (300708-00016) B1A
PR3A 2-96
F27G 0.85R B
1 F13E 0.85RL 0.85WR 8W 8W 8W 8W A
B-44 1-1
WIF SENSOR 93B 0.85LgR 1-21 93A
HOSE HEATER 2 2 F13D 0.85RL 1.25RL 2RL B4A B3B B3A
B-43 (K1046350) - 94B 0.85LgB 1-3
1-39 94A
9E 1-2 0.5RW ALT 'I' 0.85RW 0.85RW 0.85RW 0.85BrW 8C BR
1 B-38 0.5Y 0.5Y 1-77 95A
53B 1-47 0.85YG 0.85YG 53A NO 2WR
0.85Y
WATER VALVE 0.85WR E
4 B-37 0.5YB 0.5YB 1-78 96A CAN COM F19B
NC 1.25B
SHIELD SHIELD 1-59 97A 0.85YG 53D PILOT CUT-OFF SWITCH
(P2) (549-00089 ) 2R MASTER SWITCH 100R
2 B-1 0.85R 999 1-4 0.85B 53C
+5V
0.5RG 0.5RG 1-61 98A GND 5 PILOT 0.85RY 0.85GBr (K1057605)

4 B-16 DA2-1
POWER AUTO IDLE 999 1-5 0.85B CUT OFF 100B 1
0.5GW 0.5GW 1-62 100A RxD 1
0.85B 000 2 100B 100R
PUMP UNIT
3 B-2 RS-232 REMOVAL COUNTWEIGHT(U38 OPT) DA5-2 1.25RB F12B 1.25B SEAT HEATER 8B
0.5GL 101A TxD 0.85RL 0.85RL F13Ø (HO) 0.85Br 316D
I SPEED II/III SPEED CAMERA 1-81 Fixed 1 173D (0000000)
1 B-17 2 0.85BrR 0.85BrR C1
6 F13P 3
DA1-1
3 4 2 1 CHECK CONN F27M 0.85R 999 Earth of Controller DA2-2 0.5Br 0.85Br Open 3 1 316A 316B 2 4
Jog Switch + BREAKER F18C F18B
95F 96F F27L 0.5GL 101B 45A 1-25 3 316C 1
1.25LR
45B 2 45C
(410113-00071) 0.85BR 0.85BR
0.5RW
1.25RB
1 282B 0.85GR 5-10 282A 50B 50A
DA5-1
3 B-38 50C - + - +
t° 0.5GW 100B SIG ANGLE SENSOR REMOVAL COUNTWEIGHT SW 1 F12C 1.25B
SEAT AIR
SENSOR UNIT V 2 B-39 2
-
283B 0.85W 5-20 283A (PUMP) 0.85RL 0.85RL F13J (TR2) DIODE 2 QUICK CLAMP SW
(549-00212 ) P SUSPENSION 9B 12V 200AH 12V 200AH
TEMP./LEVEL 0.5RG 98B 7 F13H (549-00092 ) 0.85B SOL-VALVE (00000000)
1 B-40 3 DA2-3 HIGH
F27N 0.85V
V 0.5Y 0.5Y 95E 4 + 44A 1-7 0.85Gr 44B 3 0.85Gr 44C SPEED SOL-VALVE 0.85B
0.5WR
B(+) C4022-1 A-3 0.5YB 0.5YB 96E 5 SIG
284B 0.85GY 5-9 284A ANGLE SENSOR
0.85RL 0.85RL (PH)
QUICK CLAMP(OPT) 0.5RW
285B 0.85WL 5-19 285A (PUMP)
(KEY ON) -BR C4022-5 A-12 SHIELD 97E 6 - 5 F13S 2 WAY 0.85BrR 15R
DA3-1 3R
F27O 0.85R PEDAL 0.85RW
CAN H C4022-6 A-22 7 + 460A 2-87 0.85GrW 460B 1 0.85GrW 460C 0.5RL F9B 1.25LR
80Q CN9-11 0.5LR CN11-2
390A (OPTION)
CAN L C4022-7 A-19 0.85BrR 5-8 390A
8 SIG TWO-WAY PEDAL
OPTION 3
0.5RL
ILL F21D CN9-6 0.5Or
0.5LR CN10-8 F9C DIESEL HEATER (OPT)
C4022-2 A-4 9 391A 0.85GrB 5-18 391A 0 AT ECU
- PT-12 2 CN10-18 30B 4A
LED 1~12 F9E CN9-5 1.25LR DIAGNOSIS 0.5WR W L 15 S DF
(CONN.2) (CONN.1) CN15 F27P 0.85R 700A 1-55 0.5G 0.5G 700B 3 I 0.5BW B+
F13V CONNECTOR
0.85WR
0.85R F27N + RECEIVER DRIER 0.85GBr
12 0.5B 7 8 0.5WR A/C CONTROL PANEL 0.85LR 1 2 2.2 uF
392A 0.85BrW 5-7
2RL
SIG 392A TWO-WAY PEDAL (543-00107 ) (2204-6039A )
ECU 0.5B 80W BLOWER 0.85WR
13 393A 0.85Gr 5-17 393A OPTION 4 0.85BrR F18D F9D 30A
- PT-13 CN8 CN9 RELAY
219B
220B
0.5B 106A ECO MODE
F28D
F20B
ENGINE VEHICLE
80R
14 6 F18E F7B
DA3-2 SWITCH AMP 12P + 18P
CONN CONN CN4-7 1-60 106B
43A 3-4 0.85GrW 43B 2 0.85GrW 43C (K1056448/301401-00033) 225A 225B 2 12 11 10 1
CN8-10 0.5LG CN10-16
0.85YB
0.85Y
LEVER PATTERN BYPASS CUT OFF A/C
CAN H B4-7 226A CN9-8 0.5LB CN10-5 226B RELAY CN11-4 1 219A 3 215A 0.85LB 215B 2
CHANGE SWITCH 1 2 108B (ISO) 0.85LR 2-90 108A 50D 1-72 0.5Br (QUICK CLAMP) 0.5Br A/C THERMO (LOW) HEATER
DIESEL
CAN L B4-8 (301411-00002) 29A 8 220A 4 216A 0.85W 216B 8 TIMER
3 4 109B (BHL) 0.85L 2-83 109A 227A CN8-11 0.5LY CN10-6 227B HEATER (300739-00014)
C4002-3 0.85B FET
2.5B 9 (440207-00019) FIELD
C4002-1 1.25B CN11-1 99 - +
M 4 12
110B 0.85YR 1-14 110A AIRCON UNIT
FUEL SENSOR 228A CN8-12 0.5LW CN10-1 228B (440205-00033) 1 2 0.85B
BLOWER 217A 218A REGULATOR
0.85BrR
111B 0.85BR 1-32 111A SWING BREAK
0.85LW
0.85LB
0.5WR
F13R
0.85LR
1 B5-8 (301316-00004) 0.85RL 0.85RL SWING BREAK 1.25L 1.25Br
2WR
0.5G
2RL
SOLENOID VALVE RELEASE S/V
RELEASE SWITCH
2R
3R
2 B5-7
7 F13Q 217B 218B
INLET METERING DA3-3 JOYSTICK LEVER SWITCH 229A CN9-13 0.5GrG CN10-2 229B FRE (P1) 1 2 ALTERNATOR
(301421-00026) INTAKE
112B 0.85LgR 1-15 112A 315A 3-12 0.85LgW 3 315B 0.85LgW 315C 1 (190201-00045A)
230A CN9-12 0.5GrY CN10-20 230B REC (P2) ACTUATOR
1 A3-7 OIL TEMP SENSOR (ON JOYSTICK L.H) M
SOLENOID VALVE 113B 0.85LgW 1-33 113A 315D 2-94 0.85LgW 0.85LgW 315E 2 3 0.85B
2 A3-8 999 Earth of Controller (K1003296) 0.5B 8 4 245B 0.5G
WASTEGATE
231A CN9-15 0.5OrR CN10-12 231B DEF (P1)
B3-8 999 C4071-2(VGT) 2B (LS1) HORN(301412-00287)
INDICATOR 0.85B 115B 0.85BW 2-92 115A 232A CN9-14 0.5OrW CN10-13 232B VENT (P2) METERING PUMP
1 B6-2 0.5BrB 150B 7 3 F18F 0.5BrR M
O EGR 999 C4002-5(EGR) 2B (170-00004) MODE (400909-00056)
SENSOR 3 B6-8 233A CN9-16 0.5YB CN10-11 233B Vref MODE
C4022-2 999 C4002-2(SCR) 2B (LS2) ONE TOUCH DECELATION ACTUATOR
OIL LEVEL PILOT FILTER SW 0.85B 116B 0.85BG 1-46 116A (301412-00287) 234A CN9-17 0.5YW CN10-10 234B MODE F/BACK
V 2 B6-7 C4001-2(ECU) 148A 1-34 0.5G 148B 3 5V1B
3R
B3-2 999 2B (471-00075A) CW HIGH 1 CW CW COMPRESSOR
149A 149A 2 ENGINE CONTROL 99 CN9-10 1.25B
B3-7 999 C4001-5(ECU) 2B 0.85B 117B 0.85RB 1-64 117A 1-16 0.5GB 152B 2 ROTATING (K1057338)
RETURN FILTER SW DIAL
1 A7-9 (549-00095 ) 0.5GR 5V1D 1 SWITCH (OPT)
SENSOR t° 2B 1.5bar (ONE TOUCH DECELERATION)
(300661-00004) 153B 5 MAGNET
2 150A 1-67 0.5BrB LOW 0.5BrB CCW(301405-00117) 235A CN9-1 0.5LgW CN10-19 235B WARM (P1)
COOLANT TEMP. V A7-10 118B 0.85GB 1-44 118A 0.85LW 29C CLUTCH
5V1A 1-13 0.5GR 0.5GR 236A CN9-18 0.5LgB CN10-3 236B COOL (P2)
M 29B
1 A5-4 152A 1-12 0.5YB 0.5YB 0.5GR 5V1C 1 237A CN9-3 0.5YR CN10-7 237B Vref MIX
SENSOR t° CW OPEN MIX
DIODE 1
C4022-1 F7D C4002-1(SCR) 2RL 118C 2WAY
ENGINE SPEED 1 2 A5-5 153A 1-31 0.5Y 0.5Y 0.5LB 154B 2 238A CN9-4 0.5YW CN10-9 238B MIX F/BACK ACTUATOR
V B3-9 95D C4001-6(CAN H) 0.5Y SWITCH (OPT)
154A 1-11 0.5LB 0.5LB 0.5L 155B 5 239A CN9-2 1.25BL CN10-4 239B GND
1 A3-4 96D C4001-7(CAN L) 0.5YB 0.85P 1-65 144E CLOSE (301405-00117) 0.85B
SENSOR t° 155A 1-30 0.5L 0.5L
0.85RW
AIR COMPRESSOR (OPT)
ENGINE SPEED 2 2 A3-5 119B 0.85Lg 2-116 119A 240A CN8-2 0.5OrB CN10-15 240B AIRCOMP RELAY AIR COMPRESSOR
V B3-10 36C 1-76 0.5GY (BREAKER) 0.5GY 0.5GY 36A 8 4 F18G 0.5BrR DUCT
0.85RW (400102-00148A)
OIL FAN CONTROL 00
PROPORTIONAL V/V 120B 0.85LgB 2-121 120A SENSOR BLOCK (XXXXXX-XXXXX ) + (K1057340)X9 ARTI (OPT) (RS1) PRESSURE UP (301412-00287) SENSOR
0.5WR 3R F26D 30
4
PURGE V/V
1 A7-3
O 121B 0.85W 2-112 121A BUCKET Cr BUCKET DUMP (K1057340)X2 0.5RY 35A 7 3 32C 0.85BrW 241A CN8-1 0.5LgR CN10-14 241B AIR COMP. CONTROLLER
87 333A 3W
SENSOR 2 A7-2 B3-4 F22C 2WR ATT. PRESS. CONTROL WATER 3R
C4071-1(VGT) PROPORTIONAL V/V BOOM UP BOOM DOWN ARM IN ARM OUT TRAVEL LH TRAVEL RH SWING ARTI-1 ARTI-2 BOOM FLOATING TEMPORARY RESET (300611-00146)
OIL PRESS. TEMP. 122B 0.85WB 2-111 122A (PT-5) (PT-10) (PT-11) (RS2) SENSOR 323B 86 85
V 3 A7-8 EGR F16B 2RG SCR Single FUSE(KEY ON Singnal) (ONE-WAY) (PT-1) (PT-2) (PT-3) (PT-4) (PT-6) (PT-7) (PT-8) (PT-9) (301412-00287)
C4002-6(EGR) 2 Relay Unit
123B 0.85WR JOYSTICK LEVER SWITCH AIR COMP.SWITCH
ATT. PRESS. CONTROL 2-110 123A - SIG - SIG - SIG - SIG - SIG - SIG - SIG - SIG - SIG - SIG - SIG
B3-1 F14B C4001-1(ECU) 2R 242A CN8-5 0.5LY CN10-17 242B 1 INCAR
+
+
+
+
+
PROPORTIONAL V/V (190201-00047A) (301423-00002/300701-00027) AIR COMP. MOTOR

1 (TWO-WAY) SENSOR 6 323A
A7-3 333B 1
124B 0.85WL (ON JOYSTICK R.H) + -
B3-6 F14C C4001-4(ECU) 2R P/V-(C) 2-109 124A 0.85R F26B 1 3W B5.2
O SUN LOAD SENSOR P
0.85LB F11M
F11G
0.85LB F11C
0.85LB F11H
0.85LB F11D
0.5GY 36D F18H

0.85LB F11N
F11B
0.85LB F11E
0.85LB F11K
SENSOR 2 A7-2 CN10 AMP 20P CN11 KET 4P

0.85LB F11F
0.85LB F11J
0.85WOr 303B
0.85WLg 304B
305B
0.85RB 306B
307B
0.85RW 308B
0.85RY 309B
0.85RG 310B
0.85YOr 295B
0.85YLg 296B
297B
0.85WB 298B
0.85WL 299B
0.85WR 300B
0.85WY 301B
0.85WG 302B
318B
0.85YB 319B
0.85YL 320B
0.85YR 321B
0.85YW 293B
0.85YG 294B
C4022-5 144C C4002-3(SCR) 0.85P FLOW CONTROL 156B 0.85Gr 2-88 156A 0.5BrR (547-00023A) 2
PRESS. PROPORTIONAL V/V 0 1 0.85W 311B
3 A7-8 243A CN8-3 0.5Lg 2 - + 1 STOP PRESSURE S/W
ATMOSPHERE B3-3 144D C4001-3(ECU) 0.85P (JOYSTICK RH-CLOSE)
PEDAL SWITCH 239D 0.85R F26C 2 5 324A 0.85YW
157B 0.85GrB 157A 324B 3
0.85RL
2
0.85LB
0.85LB
2-95 0.85BL
0.85W
P/V-(C)
0.85R
0.85Y
4 A7-8 TERMINAL 0.5RY 243B 237C AMBIENT TEMP I 3 0.85WL 312B 3

V A5-3 9A C4001-8(E/G RUNNING)
FLOW CONTROL 158B 0.85GrR 2-89 158A 244A CN8-4 0.85YG 244B 1 SENSOR 0.5WR 80AA 8
START
4 0.85B 3B 2
0.85RW 7
PROPORTIONAL V/V 0.85LB 0.85LB (547-00024A)
STARTER (C) B-1 (JOYSTICK RH-OPEN) 159B 0.85GrL 2-97 159A
P/V-(C) 0.85LB
0.85LW
160B 0.85Or 2-103 160A
(CONN.2) (CONN.1) FLOW CONTROL
318A 5-14
320A 5-13
293A 5-12
295A 5-11
303A 4-10
305A 4-11
307A 4-12
0.85RW
319A 5-4
321A 5-3
294A 5-2
296A 5-1
4-7
4-1
4-8
4-2
4-9
4-3
304A 4-4
306A 4-5
308A 4-6
3-9
3-1
PROPORTIONAL V/V
(JOYSTICK LH-CW) 161B 0.85OrB 2-104 161A 0.85RW
INTELLIGENT FLOATING BOOM SWITCH
0.85P P/V-(C)
309A
310A
297A
298A
299A
300A
301A
302A
162B 0.85OrR 2-105 162A 29D 1-50 0.5LW (301423-00040/300701-00020) 0.85LB INTELLIGENT FLOATING BOOM RELAY
FLOW CONTROL (K1053326)
PROPORTIONAL V/V 163B 0.85OrL CN5 34G 1-48 0.5LB 80K 10 9
(JOYSTICK LH-CCW) 2-113 163A CN2 AMP 40P + AMP 81P CN3 AMP 040 20P CN4 AMP 040 12P AMP 070 16P 87a 0.85LY 33B 34A 34B
3 7 0.85LB PILOT S/V
0 1 32A (BOOM FLOAT) 0.85BrW 32B 30
0.85BrR F18J 2 87 33A 34C 5
DA4-1
E/G EMERGENCY 2RG 3 34D DA4-3
I (BREAKER FLOAT)
STOP SWITCH 35B 86 85 0.5B
1
0.85B 99
2WR 0.5WR 80S 8 7
0.85P
(301421-00032)

1 2R 2R 99 0.85LY 33C SMART MAIN S/V
144A 2 3 6B 0.85LR 0.5LB 0.5LB 8 4 33D 33E 6
DA4-2
0.85BrW 34H
0.85RW DA4-4
2
0.85B 99
0.85RW 0.5RY
EX1400682

11-1-5
0.85B 14
CAR STEREO 453B STEREO ANT. DX340LC-5 / DX350LC-5
Electrical Schematic(2/2)
(300654-00040)-RADIO
(300637-00014)-MP3
AUDIO
CONTROL PANEL
(543-00096)
2 5V3B 0.5WG 5V3A 15 F21G 5 0.85Or
Vcc(+5V)
3 205B 0.5W 205A 16 F3E 4 0.85BR
80H 0.85BR
0.5WR 1 MICOM
4 206B 0.5BL 206A 13
UNIFIED
0.85BR GP DISPLAY
CN13 MOLEX 4P
Vcc(+5V) 0.5WR (300426-00130)
0.5WR 3 80I
403B 18 0.5Y 0.5Y 7-13 403A SPKR
404B 8 0.5YB 0.5YB 7-14 404A SPKL
SPEAKER
405A 6 SHIELD SHIELD 7-15 405A GND
(2541-9020 )x2
12
STEREO ANT.
(RH) 407B 11 1.25BL 6-3 407A Mute Control
(LH)
- + - + 408B 9 0.5WG 17 408A
449B 448B 209B 208B 0.5GrR 7 409B 1 0.5W 6 409A HANDSFREE
208A
210A 2 0.5GrL 3 210B (300609-00041A)
0.5BY 17 209A
211A 10 0.5BW 4 211B
0.5GrL 0.5GrL 12 448A
0.5BW 0.5BW 13 449A 2 453A
0.85BR 1 F3F 4 452A GPS ANT.
UNIFIED ANTENNA
(300703-00009A) 3 451A DMB ANT.
410B 1 0.5LG 16 410A
411B 2 0.5LB 18 411A
1 F3D
412B 6 0.5LY 15 412A GND 11
413B 7 0.5LW 9 413A
0.85BR
414B 8 0.5GrG 20 414A
20P
8P
80S 4 0.5WR 0.5GrY 7 415A
8P 5 0.5OrR 5 416A 419B 28 0.5GL 6-10 419A TxD
0.5OrW 19 417A 420B 24 0.5GW 6-9 420A RxD Bluetooth
CALL SWITCH 0.5YB 8 418A 421B 26 0.5RG 6-11 421A GND 0.85BR
(301405-00061A) FUSE BOX 1(3)
JACK ASSY DMB ANT. GPS ANT.
(300619-01179A) Use the USB CABLE
ILL. 80K 6-4 0.85WR 0.85WR ILLUMINATION
0.5YB 5 418B 5V2B 4 0.5WR 6-5 5V2A
0.5OrW 6 417B 423B 2 0.85GBr 6-7 423A F21C 7-6 0.85Or
0.5OrR 9 416B 424B 3 0.5G 6-6 424A F21F 7-5 0.85Or 0.85Or FUSE BOX 2(7)
0.5GrY 10 415B 425B 1 0.85BrR 6-8 425A
0.5WR 11 80T 12
12P
7E 7-2 0.5Br 0.5Br KEW SW(BR)
CCD CAMERA 3 0.85R

1 9V1D 0.5Y FUSE BOX 2(13)
0.85R F27J +
2 177D 0.5YB PILOT BUZZER
83B 6-1 0.5WB 83A - (2516-1116 )
3 183B 0.5P 7-8 183A Vedio Sig
95B 6-12 0.5Y 0.5Y
4 182B 0.5PB 7-18 182A Sig Gnd
REAR VIEW 6-13 FUSE BOX 2(6)
96B 0.5YB 0.5YB 0.85GBr
CAMERA (OPT) CCD CAMERA 2 CAN
1 9V1C 0.5Y SHIELD SHIELD
2 177C 0.5YB
3 181B 0.5Or 7-9 181A Vedio Sig
4 180B 0.5OrB 7-19 180A Sig Gnd
CCD CAMERA 1
1 9V1B 0.5Y 7-7 9V1A V+ 9V
REAR VIEW 2 177B 0.5YB 7-17 177A V- e-EPOS
CAMERA CONTROLLER
3 178B 0.5YL 7-10 178A Vedio Sig
(301102-00021) (300611-00014)
4 179B 0.5YW 7-20 179A Sig Gnd
WORK MODE RESISTOR
(300645-00017,41Ω)
AUXILIARY MODE SW 0.85Y 325B F20R 0.85GBr
(301421-00004) PUMP
59B 2-119 0.85Or 0.85Or 59A 1 PROPORTIONAL V/V
2 56A 0.85LgR 56B TRAVEL MODE RESISTOR
0.85BrB 55B 3 P/V-(A) (300645-00018,28Ω)
58B 2-114 0.85OrB 0.85OrB 58A 4 0.85YW 326B F20S
5 57B 0.85LgW 57A
0.85B 6
WORK MODE RESISTOR
PUMP
286A 3-16 0.85OrL 0.85OrL 286B 7 (300645-00017,41Ω)
0.85GBr
8 316A 0.85LgB 316B PROPORTIONAL V/V
0.85BrR 287A 9 P/V-(B) 0.85LgY 327B F20T
288A 3-8 0.85OrR 0.85OrR 288B 10
11 317A 0.85LgY 87a
317B 30 F20U
0.85B 12
332B 87
328B 85 86 F20V
AUXILIARY MODE SELECT SW
0.85YOr
0.85YW
(301421-00004)
0.85YB
0.85YL
0.85Y
1 325A 0.85Y Working
0.85BrR 287B 2
3 326A 0.85YW Travel AUXI MODE RELAY
(K1053326)
4 327A 0.85YL
0.85BrB 55A 5
6 328A 0.85YB
313A 3-15 0.85LgR 0.85LgR 313B 7
8 329A 0.85LgG 329B TRAVEL STRAIGHT
0.85YG 331A 9 PROPORTIONAL V/V
P/V-(B)
314A 3-7 0.85LgB 0.85LgB 314B 10
11 330A 0.85Lg 330B
0.85B 12
999 7-4 0.85B

0.85YG 331B 332A 0.85YOr
999 7-3 0.85B
TRAVEL MODE RESISTOR
(300645-00018,28Ω)
99 7-1 0.85B 999 Earth of Controller Serial Number 10001 and Up
EX1400683

11-1-7

Doosan DX340LC-5 DX350LC-5 Shop Manual Excavator 950106-01001E

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Doosan DX340LC-5 DX350LC-5 Shop Manual Excavator 950106-01001E

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Available Formats

Shop Manual

Serial Number 10001 and Up

DOOSAN and the DOOSAN logo are registered

Copyright DOOSAN 2014 Original Instructions

01/04/2014 1st Edition

3 General Maintenance 1 General Maintenance Instructions

2 Engine Coolant Heater (Option)

5 Upper Structure 1 Cabin

6 Lower Structure and Chassis 1 Swing Bearing

8 Hydraulic System 1 Hydraulic System

2 Hydraulic System Testing and Adjustment

9 Electrical System 1 Electrical System

10 Options 1 One Way

11 Schematic 1 Hydraulic Schematic/Electrical Schematic

DX340LC-5/DX350LC-5 Track Excavator Maintenance Safety

Track Excavator Maintenance Safety DX340LC-5/DX350LC-5

Track Excavator Maintenance Safety

DX340LC-5/DX350LC-5 Track Excavator Maintenance Safety

Track Excavator Maintenance Safety DX340LC-5/DX350LC-5

DX340LC-5/DX350LC-5 Track Excavator Maintenance Safety

Safe Operation is Operator's

Know Your Machine

Track Excavator Maintenance Safety DX340LC-5/DX350LC-5

DX340LC-5/DX350LC-5 Track Excavator Maintenance Safety

Flying or Falling Objects

Track Excavator Maintenance Safety DX340LC-5/DX350LC-5

Correction of Machine Problems

Crushing and Cutting

DX340LC-5/DX350LC-5 Track Excavator Maintenance Safety

Hot Coolant and Oils - Burn Prevention

Track Excavator Maintenance Safety DX340LC-5/DX350LC-5

• Add fuel, oil, antifreeze and hydraulic fluid to machine only

DX340LC-5/DX350LC-5 Track Excavator Maintenance Safety

Track Excavator Maintenance Safety DX340LC-5/DX350LC-5

Never Use Ether Starting Aids

Welding and Grinding

DX340LC-5/DX350LC-5 Track Excavator Maintenance Safety

Fire Extinguisher and First-aid Kit

Track Excavator Maintenance Safety DX340LC-5/DX350LC-5

Roll-over Protective Structure (ROPS)

DX340LC-5/DX350LC-5 Track Excavator Maintenance Safety

Track Excavator Maintenance Safety DX340LC-5/DX350LC-5

When working in mines, quarries or other work sites where there

DX340LC-5/DX350LC-5 Track Excavator Maintenance Safety

Track Excavator Maintenance Safety DX340LC-5/DX350LC-5

Obey State and Local Over-the-Road

Loading and Unloading

DX340LC-5/DX350LC-5 Track Excavator Maintenance Safety

Track Excavator Maintenance Safety DX340LC-5/DX350LC-5

Before Engine Starting

Make sure that the machine is equipped with a lighting system

DX340LC-5/DX350LC-5 Track Excavator Maintenance Safety

equipment near fences or near boundary obstacles. No Entry

Track Excavator Maintenance Safety DX340LC-5/DX350LC-5

Never hold onto any control levers when getting on or off

DX340LC-5/DX350LC-5 Track Excavator Maintenance Safety

Track Excavator Maintenance Safety DX340LC-5/DX350LC-5

DX340LC-5/DX350LC-5 Track Excavator Maintenance Safety

Your machine may be equipped with visual aids such as mirrors