Doosan DX015 Service Manual

DX15 / DX18
Shop Manual
K1043970E
Serial Number 40001 and Up
DOOSAN reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine's package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
K1043970E Shop Manual Copyright 2008 DOOSAN

Pub.No. K1043970E
DX15 / DX18
Product Label
Instructions
Trim Out The Label Along

The Lines And Insert Into
Pocket On The Binder Spine
Pub. No. K1043970E

1Table of Contents
Safety
Track Excavator Safety......................................................................... SP001521
Specifications
Specification for DX15/DX18 ................................................................ SP001522
General Maintenance
General Maintenance Procedures ........................................................ SP000016
Standard Torques ................................................................................. SP000813
Upper Structure
Lower Structure and Chassis

Track Assembly .................................................................................... SP001523
Engine and Drive Train

Engine................................................................................................... SP001524
Hydraulics
Center Joint (Swivel)............................................................................. SP001525
Cylinders............................................................................................... SP001526
Swing Motor.......................................................................................... SP001527
Travel Motor (With Gear Box)............................................................... SP001528
Pilot Control Valve (Work Lever / Joystick)........................................... SP001529
Main Pump............................................................................................ SP001530
Main Control Valve ............................................................................... SP001531
Solenoid Valve...................................................................................... SP001532
Hydraulic Schematic (DX15/DX18)....................................................... SP001533
Table of Contents
Page I
Electrical System
Electrical System .................................................................................. SP001534
Electrical Schematic (DX15/DX18) ....................................................... SP001535
Attachments
Boom and Arm...................................................................................... SP001536
Bucket................................................................................................... SP001550
Table of Contents
Page II
1Safety
SP001521
TRACK EXCAVATOR SAFETYSP001521
Track
Excavator
Safety
Edition 1
Track Excavator Safety SP001521

Page 1
MEMO

Page 2
Table of Contents
Track Excavator Safety
Safety Precautions ............................................... 5

Applicable Models ................................................ 5
To the Operator of a DOOSAN Excavator............ 6
General Safety Essentials .................................... 8
Location of Safety Labels ..................................... 8
Unauthorized Modifications .................................. 8
Work Site Precautions .......................................... 9
Operation ............................................................ 13
Equipment .......................................................... 19
Maintenance ....................................................... 24
Shipping and Transportation .............................. 28

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
MODEL SERIAL NUMBER RANGE

DX15 40001 and Up
DX18 40001 and Up

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

own safety, and that of other people who may be affected by
your actions.
The safety information on the following pages is organized into
the following sections:
1. “General Safety Essentials” on page 1-8
2. “Location of Safety Labels” on page 1-8
3. “Work Site Precautions” on page 1-9
4. “Operation” on page 1-13
5. “Equipment” on page 1-19
6. “Maintenance” on page 1-24
7. “Shipping and Transportation” on page 1-28

Page 6
SAFETY ALERT SYMBOL
Be Prepared - Get To Know All Operating and Safety
Instructions.
This is the Safety Alert Symbol. Wherever it appears in this
manual or on safety signs on the machine you should be
alert to the potential for personal injury or accidents.
Always observe safety precautions and follow
recommended procedures.
Learn the Signal Words Used with the

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

Page 7
GENERAL SAFETY ESSENTIALS
Accessory Applications
The excavator has been primarily designed for moving earth
with a bucket.
Use of an accessory hydraulic hammer (breaker), work in rough
terrain, demolition applications or other hazardous operation
may require installation of additional protective structures to
safeguard the operator.
Never use machine for lifting.

The excavator is designed for excavating and loading only.
The excavator is not equipped for lifting and does not have
safety devices for lifting.
HKA1013L
Figure 1
LOCATION OF SAFETY LABELS

Location of safety labels (decals) can vary from unit to unit.
Refer to appropriate Operation and Maintenance Manual, and
parts manual for your unit.
Always replace damaged or faded decals.
UNAUTHORIZED MODIFICATIONS
Any modification made without authorization or written approval
from DOOSAN can create a safety hazard, for which the
machine owner must be held responsible.
For safety's sake, replace all OEM parts with the correct
authorized or genuine DOOSAN part. For example, not taking
the time to replace fasteners, bolts or nuts with the correct
replacement parts could lead to a condition in which the safety
of critical assemblies is dangerously compromised.

Page 8
WORK SITE PRECAUTIONS
Attachment Precautions
Options kits are available through your dealer. Contact
DOOSAN for information on available one-way (single-acting)
and two-way (double-acting) piping/valving/auxiliary control kits.
Because DOOSAN cannot anticipate, identify or test all of the
attachments that owners may wish to install on their machines,
please contact DOOSAN for authorization and approval of
attachments, and their compatibility with options kits.
Avoid High Voltage Cables

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

6.6 kV 3 m (9' 10")
HKA1012L
33.0 kV 4 m (13' 1")
Figure 2
66.0 kV 5 m (16' 5")
154.0 kV 8 m (26' 3")
275.0 kV 10 m (32' 10")
Use these minimum distances as a guideline only. Depending

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

Below ground hazards also include natural gas lines, electric
cables, water mains, tunnels and buried foundations. Know
what's underneath the work site before starting to dig.
HKA1009L
Figure 3

Page 9
Be Aware of Height Obstacles
Any type of object in the vicinity of the boom could represent a
potential hazard, or cause the operator to react suddenly and
cause an accident. Use a spotter or signal person working near
bridges, phone lines, work site scaffolds, or other obstructions.
Use Care on Loose Support

Working heavy loads over loose, soft ground or uneven, broken HKA1010L
terrain can cause dangerous side load conditions and possible Figure 4
tipover and injury. Travel without a load or balanced load may
also be hazardous.
If temperatures are changing, be cautious of dark and wet
patches when working or traveling over frozen ground. Stay
away from ditches, overhangs and all other weak support
surfaces. Halt work and install support mats or blocking if work is
required in an area of poor track support.
Use Solid Support Blocking

Never rely on lift jacks or other inadequate supports when work
is being done. Block tracks fore and aft to prevent any
movement.
Overhangs Are Dangerous

Digging the work face under an overhang - the work area
beneath a cliff or under the edge of a ditch - is dangerous. Know
the height and reach limits of the excavator and plan ahead
while working. Avoid creating dangerous situations by moving
around the work site while making excavations. Go onto another
digging area before steep overhangs are formed. Working
around deep pits or along high walls or trenching may require
support blocks, especially after heavy rainfalls or during spring
thaws. Park the excavator away from overhangs before work
HKA1006L
shut down.
Figure 5
Use Solid Support Blocking

Never rely on lift jacks or other inadequate supports when work
is being done. Block tracks fore and aft to prevent any
movement.

Page 10
Sloping Terrain Requires Caution
Dig evenly around the work site whenever possible, trying to
gradually level any existing slope. If it's not possible to level the
area or avoid working on a slope, reducing the size and cycling A
rate of the workload is recommended.
On sloping surfaces, use caution when positioning the excavator
before starting a work cycle. Stay alert for unstable situations to
avoid getting into them. For example, you should always avoid
working the bucket over downhill crawler tracks when parked
perpendicular to the slope. Slow all downhill swing movements
and avoid full extensions of the bucket in a downhill direction.
Lifting the bucket too high, too close to the machine, while the
excavator is turned uphill can also be hazardous.
• Raise bucket when encountering small obstacles.
• Keep bucket 20 - 30 cm (8 - 12") off ground when
driving on slopes. A
• If machine slips, lower bucket to ground and stop HKA1003L
immediately. Figure 6
• When traveling on level ground, bring front
attachment in and raise bucket 40 - 50 cm (15 - 20")
with teeth facing up.

Page 11
Stay Alert for People Moving through the
Work Area
When loading a truck you should always know where the driver is.
Avoid loading over the cab of a truck even if the driver is in a
safe spot. Someone else could have gone inside, for any
number of reasons. Avoid working where unseen passersby
might be.
Slow down the work cycle and use slower travel speeds in
congested or populated areas. Use a commonly understood HKA1002L
signal so that other members of the work crew can warn the Figure 7
operator to slow or halt work in an impending hazard situation.
Check for hazards in the work area before starting and moving.
• Use horn or other signal to warn others when you
start and move the machine.
• Use a signal man whenever the operator's vision is
obstructed in any way. Make sure the signal man is in
sight of the operator at all times.
• Agree on signals before operation.
• Keep bystanders and obstacles out of work area.
• Keep work areas well lighted at night.
BE AWARE OF AND CONFORM TO LOCAL REGULATIONS

Minimum levels of insurance coverage, work permits or
certification, physical barriers around the work site or restricted
hours of operation may be mandated by governing authorities.
There may also be guidelines, standards or restrictions on
equipment that may be used to perform certain kinds of work.
Check and follow all local requirements, which may also be
related to below ground hazards and power lines.

Page 12
OPERATION
Operate While Seated at the Operator's

Station ONLY
Never reach in through a window to work a control. Do not try to
operate the excavator unless you're in the command position
stay alert and focused on your work at all times but Do not twist
out of the seat if job activity behind you (or to the side) requires
your attention.
Use a spotter or signal person if you cannot see clearly and
something is happening behind you.
HAOA150L
Replace damaged safety labels and lost or damaged owner's
manuals. Figure 8
Do not let anyone operate the machine unless they've been fully
and completely trained, in safety and in operation of the machine.
Adjust seat
If the driver's seat is not adjusted correctly, the operator may
become easily fatigued and injury and/or damage could result.
• Be sure to adjust the driver's seat at the beginning of
each work period.
• Adjust driver's seat so that the operator can easily
reach the pedals while his back is firmly against the
lumbar support of the seat.
Before Starting the Engine

Do a "prestart" safety check:
• Walk around your machine before getting in the
operator's cab. Look for evidence of leaking fluid,
loose fasteners, misaligned assemblies or any other
indications of possible equipment hazard.
• All equipment covers and machinery safety guards
must be in place, to protect against injury while the
machine is being operated.
• Look around the work site area for potential hazards,
or people or property that could be at risk while
operation is in progress.
• NEVER start the engine if there is any indication that
maintenance or service work is in progress, or if a
warning tag is attached to controls in the cab.
• A machine that has not been used recently, or is being
operated in extremely cold temperatures, could require
a warm-up or maintenance service before start-up.
• Check gauges and monitor displays for normal
operation before starting the engine. Listen for
unusual noises and remain alert for other potentially
hazardous conditions at the start of the work cycle.

Page 13
Never Use Ether Starting Aids
An electric grid type manifold heater is used for cold starting.
The glowing heater element can cause ether or other starting
fluid to detonate, causing injury.
Figure 9
Mounting and Dismounting

NEVER get on or off a moving machine. Do not jump on/off. The
entry/egress path should be clear of mud, oil and spills and
mounting hardware must be kept tight and secure.
Always use handholds, steps or track shoes and maintain at
least 3-point contact of hands and feet. Never use controls as
handholds.
NEVER get up from the operator's seat or leave the operator's
station and dismount the machine if the engine is running.
Figure 10
Observe General Safety Rules

Only trained and authorized personnel, with a good knowledge
and awareness of safe procedures, may be allowed to operate
or perform maintenance or service on the excavator.
All personnel at the work site should be aware of assigned
individual responsibilities and tasks. Communication and hand
signals used should be understood by everyone.
Terrain and soil conditions at the work site, approaching traffic,
weather related hazards and any above or below ground
obstacles or hazards should be observed and monitored by all
work crew members.
Engine Ventilation
Engine exhaust gases can cause fatal accidents, and
unconsciousness, loss of alertness, judgement and motor
control and serious injury.
Make sure of adequate ventilation before starting the engine in
any enclosed area.
You should also be aware of open windows, doors or ductwork
into which exhaust may be carried, or blown by the wind,
exposing others to danger.
HAOA070L
Figure 11

Page 14
Asbestos Dust Hazard Prevention
Asbestos dust can be HAZARDOUS to your health if it is
inhaled. Materials containing asbestos fiber can be present on
work site. Breathing air that contains asbestos fiber can
ultimately cause serious or fatal lung damage. To prevent lung
damage from asbestos fiber, observe following precautions;
• Use a respirator that is approved for use in an
asbestos-laden atmosphere.
• Never use compressed air for cleaning.
ARO1770L
• Use water for cleaning to keep down the dust. Figure 12
• Work on the machine or component with the wind at
your back whenever possible.
• Always observe any rules and regulations related to
the work site and working environment.
Take Time to Provide Good Visibility

Halt work if visibility is poor. Strong rains, snow, fog and
extremely dusty conditions can all obscure visibility so badly that
it is best to wait for weather to change or dust to settle before
continuing operation.
Night work in areas of limited visibility should be halted if
installation of extra work lights on the machine (or work area) is
necessary.
Keep dirt and dust off of windows and off the lens surfaces of
work lights. Stop working if lights, windows or mirrors need
cleaning or adjustment.
Remove Coating Before Welding or Heating

Protect yourself from noxious smoke or dust.
Welding, soldering or heating with a welding torch directly on a
coated surface can produce noxious gases. Perform these
operations in an open or well ventilated area.
Remove coatings from surface before welding or heating.When
removing coating with a grinder, wear a welder's helmet to
prevent inhaling the dust.
When using a welding flux, wipe the face of the weld with soapy
or clear water. Do not store a welding flux near flame. Wait 15
minutes or more after removing coating before welding or heating.

Page 15
Do Not Heat Hydraulic System and Piping
Heating hydraulic components, piping or nearby areas can
produce flammable steam or gas. Take the following precautions:
• Clean flammable liquids out of piping using a
nonflammable solvent before welding.
• Never weld, solder or use a welding torch on
hydraulic components or nearby areas.
• Piping with hydraulic oil under pressure or rubber
hoses can burst if heated directly. Be sure to use fire HFB1039L
proof shields. Figure 13
Never Carry People In or On the Machine

Never transport other persons in or on the machine.
Riders restrict visibility, reduce concentration and may cause
and/or be subject to injury.
HKA1008L
Figure 14
Fuel, Oil and Hydraulic Fluid Fire Hazards

Add fuel, oil, antifreeze and hydraulic fluid to the machine only in
a well ventilated area. The machine must be parked with
controls, lights and switches turned off. The engine must be off
and any flames, glowing embers, auxiliary heating units or spark
causing equipment must be doused, turned off and/or kept well
clear of the machine.
Static electricity can produce dangerous sparks at the fuel filling
nozzle. In very cold, dry weather or other conditions that could
produce static discharge, keep the tip of the fuel nozzle in HAOA120L
constant contact with the neck of the fuel filling nozzle, to Figure 15
provide a ground.
Keep fuel and other fluid reservoir caps tight and do not start the
engine until caps have been secured.

Page 16
Boost Starting or Charging Engine Batteries
Turn off all electrical equipment before connecting leads to the
battery. This includes electrical switches on the battery charger
or boost starting equipment.
When boost starting from another machine or vehicle do not
allow the two machines to touch. Wear safety glasses or
goggles while required parallel battery connections - positive to
positive and negative to negative - are made.
24 volt battery units consisting of two series connected twelve volt
HAOA310L
batteries have a cable connecting one positive terminal on one of
Figure 16
the 12 volt batteries to a negative terminal on the other battery.
Booster or charger cable connections must be made between the
nonseries connected positive terminals and between the negative
terminal of the booster battery and the metal frame of the
machine being boosted or charged. Refer to the procedure and
illustration in Operation and Maintenance Manual.
Connect positive cable first when installing cables and disconnect
the negative cable first when removing them. The final cable
connection, at the metal frame of the machine being charged or
boost started, should be as far away from the batteries as possible.
Travel Controls May Produce Reversed

Operations
Before starting the machine you should always check to see
which end of the track frame is under the operator's cab. In the
normal travel configuration, track frame travel motors are at the
rear of the machine, under the engine and counterweight. If the
operator swings the cab 180°, travel motors will be underneath
the operator's cab, toward the front of the track frame and
operating travel will be reversed.
When traveling the excavator always keep lights on; make sure
that you are in compliance with all state and local regulations
concerning warning flags and signs and keep the operator's cab
positioned over the idler end of the track frame. That will keep
travel controls in their intended configuration and at the same
time, maintain the proper orientation of lights on the machine
and posted flags and signs.
KEEP "PINCH POINT" AREAS CLEAR - USE CAUTION IN

REVERSE AND SWING
Use a signal person in high traffic areas and whenever the
operator's view is not clear, such as when traveling in reverse.
Make sure that no one comes inside the swing radius of the
machine.
Anyone standing near the track frames, or working assemblies
of the attachment, is at risk of being caught between moving
parts of the machine.
Never allow anyone to ride on any part of the machine or HKA1005L
attachment, including any part of the turntable or operator's cab. Figure 17

Page 17
Travel Precautions
Attachment control levers should not be operated while traveling.
Do not change selected travel mode (FAST/SLOW) while
traveling.
Fold in work equipment so that the outer end of the boom is as
close to the machine as possible, and is 200 mm - 300 mm (8" -
12") above ground.
Never travel over obstacles or slopes that will cause the
machine to tilt severely. Travel around any slope or obstacle that
causes 10 degrees tilt, or more.
Operate Carefully on Snow and Ice and in

Very Cold Temperatures
In icy cold weather avoid sudden travel movements and stay
away from even very slight slopes. The machine could skid off to
one side very easily.
Snow accumulation could hide or obscure potential hazards. Use
care while operating or while using the machine to clear snow.
Warming up the engine for a short period may be necessary, to
avoid operating with sluggish or reduced working capacity. The
jolting shocks and impact loads caused by bumping or
bottoming the boom or attachment are more likely to cause
severe stress in very cold temperatures. Reducing work cycle
rate and work load may be necessary.
Parking Machine
Avoid making sudden stops or parking the machine wherever it
happens to be at the end of the work day. Plan ahead so that the
excavator will be on firm, level ground away from traffic and
away from high walls, cliff edges and any area of potential water
accumulation or runoff. If parking on inclines is unavoidable,
block the crawler tracks to prevent movement. Lower the bucket
or other working attachment completely to the ground, or to an
overnight support saddle. There should be no possibility of
unintended or accidental movement.
HKA1004L
Figure 18

Page 18
Shutdown Control Functions
After the machine has been lowered to the overnight storage
position and all switches and operating controls are in the "OFF"
position, the control stand lock lever must be engaged. Release
the left console to disable all pilot circuit control functions.
Insert the swing lock pin and engage all brakes and lock-down
security equipment that may have been installed on the machine.
IMPORTANT
When hydraulic system maintenance or service work must
be performed, you should be aware that an accumulator in
the system stores fluid under pressure after system lock
down, even after the control stand is raised. Release this
energy by working controls with the engine off, until
pressure in the pilot circuit has been completely bled away.
EQUIPMENT
Rough Operation May Require Use of

Certified Safety Equipment
Work in mines, tunnels, deep pits or on loose or wet surfaces
could produce danger of falling rock, roll over or hazardous
flying objects. Additional protection for the operator's cab could
be required in the form of a TOPS/Tip Over Protective Structure
reinforcement system.
HAOA110L
Figure 19
Any reinforcement system that is installed on the machine must

pass safety and certification standards and carry appropriate
labeling and rating information.
Never attempt to alter or modify any type of protective structure
reinforcement system, by drilling holes, welding or remounting or
relocating fasteners. Any serious impact or damage to the
system requires a complete integrity reevaluation.
Reinstallation, recertification and/or replacement of the system
may be necessary.
HAOA100L
Figure 20

Page 19
Install Additional Safety Equipment If
Conditions Require
When working with a breaker or in some shear work
applications, a front guard over the windshield may be required.
The windshield guard may or may not be OPS/certified,
depending upon the specific application and working situation.
Laminate glass protection for the front, side or rear windows
may also be recommended depending upon particular site
conditions.
Contact your DOOSAN distributor for available safety guards
and/or recommendations if there is any danger of getting hit by
objects that could strike the operator's cab. Make sure that all
other work site crew members are kept well away from the
excavator and safe from potential hazards.
Movement Alarms
If the excavator is equipped with an audible travel movement
alarm or visible swing movement alarm (strobe light), test the
alarm on a daily basis. The audible alarm should sound as soon
as the travel system is engaged. The strobe light should begin to
flash as soon as the swing system is engaged.
Protect Yourself From Flying or Falling

Objects
Wear safety glasses when operating in dusty or sandy
conditions or when rock fragments could be thrown up by
operation. Also wear protection when carrying out maintenance
such as removing or installing the bucket pin, etc.
HFB1025L
Figure 21
Keep a Fire Extinguisher at Hand

It is recommended that an appropriately sized (2.27 kg [5 lb] or
larger) multipurpose "A/B/C" fire extinguisher be mounted in the
cab. Check and service the fire extinguisher at regular intervals
and make sure that all work site crew members are adequately
trained in its use.
HAOA080L
Figure 22

Page 20
Maintain Standard Safety Equipment in
Good Condition
Machinery guards and body panel covers must be in place at all
times. Keep well clear of rotating parts. Pinch point hazards
such as cooling fan and alternator drive belts could catch hair,
jewelry or oversize or very loose clothing.
Safety labels must be replaced if they are damaged or become
unreadable. The information on labels gives work crew members
an important safety reminder exactly where it will do the most
good. Part numbers for each label and required mounting
locations are shown in Operation and Maintenance Manual.
Safety Critical Parts Must Be Replaced

Periodically
Replace the following fire related components as soon as they
begin to show any sign of wear, or at regular periodic intervals,
whether or not deterioration is visible:
• Fuel system flexible hoses, the tank overflow drain
hose and the fuel fill cap.
• Hydraulic system hoses, especially the pump outlet
lines and front and rear pump branch hoses.
• Keep mounting brackets and hose and cable routing
straps tight. Hose routing should have gradual bends.
Hydraulic Cylinder Seals Require Periodic

Replacement
Check cylinder drift rate at regular intervals. Maximum allowable
rates are included in the in this manual. Overhaul seal kits are
available through Doosan.
High-pressure Hydraulic Lines Can Store a

Great Deal of Energy
Exposed hydraulic hoses on the arm or boom could react with
explosive force if struck by a falling rock, overhead obstacle or
other work site hazard. Extra safety guards may be required.
NEVER allow hoses to be hit, bent or interfered with during
operation.
The Operator's Cab and Turntable Deck

Should Be Kept Clean
Cleaning off accumulations of grease and dirt helps extend
equipment service life. Cleaning also provides an opportunity to
inspect equipment. Minor damage can be repaired or corrected
before major problems result.
Keep the cab floor and consoles free of tools and personal items.

Page 21
Clothing and Personal Protective Items
Contain long hair, and avoid loose clothing and jewelry. They
can catch on controls or in protruding parts and cause serious
injury or death.
Do not wear oily clothes. They are highly flammable.
Full eye protection, a hard hat, safety shoes and gloves may be
required at the work site.
While working on the machine, never use inadequate tools.
They could break or slip, causing injury, or they may not HAOA020L
adequately perform intended functions. Figure 23
Breathing Masks, Ear Protection May Be

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

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

Page 22
Battery Electrolyte and Explosive Gases
Can Be Lethal
Flush eyes with water for 10 - 15 minutes if acid is splashed in
the face. Anyone who swallows acid must have immediate
medical aid. Call the Poison Control listing in the front cover of
the telephone directory. Water, a popsicle or ice cream are likely
better than old remedies that try to induce vomiting (which would
expose tissue to damage twice).
Explosive battery gas can be set off by sparks from incidental
HAOA150L
contact or static discharge. Turn off all switches and the engine
Figure 24
when working on batteries. Keep battery terminals tight. Contact
between a loose terminal and post can create an explosive spark.
Disconnect Batteries for Electrical Service

Before Electrical Welding
Remove cable to negative terminal first, when disconnecting
cable. Connect positive terminal cables first when installing
a battery.
Use Low Heat Portable Lighting

Hot surfaces on trouble lights or portable work lights can set off
fuel or battery explosive gases.

Page 23
MAINTENANCE
Keep Machine Clean at All Times

Keep machine free of oil and grease at all times.
Water will damage the electrical system. Never use water or
steam on the inside of the cab, in the engine compartment or in
any location where it may reach sensors, connectors or other
electrical components.
HFB1030L
Figure 25
Use Warning Tag Control Lockout

Procedures During Service
Alert others that service or maintenance is being performed and
tag operator's cab controls - and other machine areas if required
- with a warning notice. OSHA mandated control lever lockout WARNING
can be made with any OSHA certified lockout device and a
length of chain or cable to keep the left-hand control console in
the fully raised, nonactive position.
Warning tags for controls are available from DOOSAN HAOC920L
distributors.
Figure 26
Do not Run the Engine If Repairs or Work

Is Being Performed Alone
You should always have at least two people working together if
the engine must be run during service. One person needs to
remain in the operator's seat, ready to work the controls or stop
the machine and shut off the engine.
Always Use Adequate Equipment

Supports and Blocking
Do not allow weight or equipment loads to remain suspended.
Lower everything to the ground before leaving the operator's
seat. Do not use hollow, cracked or unsteady, wobbling weight
supports. Do not work under any equipment supported solely by 90 ~ 100
a lift jack. When inspecting or performing service under a
machine that is jacked up, keep boom at a 90°-100°angle to the
arm and chock tracks securely.
HBOH810L
Figure 27

Page 24
Warning for Counterweight and Front
Attachment Removal
DANGER X
DOOSAN warns any user, that the removal of the
counterweight from the machine, front attachment or any
other part, may affect the stability of the machine. This
could cause unexpected movement, resulting in death or
serious injuries. DOOSAN is not liable for any misuse. X
Never remove the counterweight or front attachment unless
the upper structure is in-line with the lower structure.
Never rotate the upper structure once the counterweight or
front attachment has been removed.
HAAD4060
Figure 28
Do not Work on Hot Engines or Hot

Cooling or Hydraulic Systems
Wait for the engine to cool off after normal operation. Park the
excavator on firm, level ground and lower all equipment before
shutting down and switching off controls. When engine lube oil,
gearbox lubricant or other fluids require change, wait for fluid
temperatures to decrease to a moderate level before removing
drain plugs.
NOTE: Oil will drain more quickly and completely if it is
warm. Do not drain fluids at 95°C (203°F)
temperatures but do not allow full cool down.
Cool Down Is Required Before Radiator or

Reservoir Checks
Shut down engine and allow heat to dissipate before performing
service on the engine radiator or hydraulic fluid reservoir. Both
assemblies have air vent levers at or near the fill cap for venting
built-up air pressure. Release the levers before trying to take off
fill caps and LOOSEN CAPS SLOWLY, before removal.
HAOA060L
Figure 29

Page 25
Precautions with High-pressure Line,
Tubes and Hoses
When inspecting or replacing high-pressure piping or hoses,
check that the pressure has been released from the circuit.
Failure to release the pressure may lead to serious injury.
Always do the following;
• Wear protective glasses and leather gloves.
• Fluid leaks from hydraulic hoses or pressurized
components can be difficult to see but pressurized oil
has enough force to pierce the skin and cause
serious injury. Always use a piece of wood or
cardboard to check for suspected hydraulic leaks.
Never use your hands or expose your fingers.
• Do not bend high-pressure lines. Do not strike
high-pressure lines. Do not install lines, tubes or
hoses that are bent or damaged.
• Make sure that all clamps, guards and heat shields are
installed correctly to prevent vibration, rubbing against
other parts, and excessive heat during operation.
– If any of the following conditions are found,
replace the part.
– Damage or leakage from hose end.
– Wear, damage, cutting of covering, or exposure
of strengthening wire layer.
– Cover portion is swollen in places.
– There is twisting or crushing at movable parts of
hose.
– Foreign material is embedded in the covering.
– Hose end is deformed.
NOTE: Refer to "Hose In-service Lifetime Limit
(European Standard ISO 8331 and
EN982 CEN)" in Operation and
Maintenance Manual, for additional
European regulations.
X X O
HAOA420L
Figure 30

Page 26
Obtain immediate medical attention if
pressurized oil pierces the skin
WARNING
Failure to obtain prompt medical assistance could result in
gangrene or other serious damage to tissue.
Use Correct Replacement Fasteners

Tightened to Proper Torque
Refer to the "General Maintenance" section of this manual for
information on tightening torques and recommended assembly
compounds and always use the correct part.
Poor or incorrect fastener connections can dangerously weaken
assemblies.
Dispose of All Petroleum Based Oils and

Fluids Properly X
Physical contact with used motor oil may pose a health risk.
Wipe oil from your hands promptly and wash off any remaining
residue.
Used motor oil is an environmental contaminant and may only
be disposed of at approved collection facilities. Never drain any
petroleum based product on the ground or dispose of old oil in
municipal waste collection containers, or in metropolitan sewer
HAOA470L
systems or rural landfills.
Figure 31
Check state and local regulations for other requirements.
Track Tension Adjustments Require Caution

NEVER turn out the track tension grease fitting nut. To release
pressure from the crawler frame track tension assembly, you
should NEVER attempt to disassemble the track adjuster or
attempt to remove the grease fitting or valve assembly.
Keep your face and body away from the valve. Refer to the track
adjustment procedure in the Operation and Maintenance
Manual or this manual.

Page 27
SHIPPING AND
TRANSPORTATION
Obey State and Local Over-the-Road

Regulations
Check state and local restrictions regarding weight, width and
length of a load before making any other preparation for
transport.
The hauling vehicle, trailer and load must all be in compliance
with local regulations governing the intended shipping route.
Partial disassembly or tear-down of the excavator may be
necessary to meet travel restrictions or particular conditions at
the work site. See this manual for information on partial
disassembly.
Refer to the Transportation and Shipping section of the
Operation and Maintenance Manual for information on loading,
unloading and towing.

Page 28
1Specifications
SP001522
SPECIFICATION FOR DX15/DX18SP001522
Specification
for DX15/DX18
Edition 1
Specification for DX15/DX18 SP001522

Page 1
MEMO

Page 2
Table of Contents
Specification for DX15/DX18

General Description .............................................. 7
Component Locations........................................... 8
General Dimensions ........................................... 10
Canopy Model ............................................................... 10
Cabin Model .................................................................. 12
Dimensions and Working Range ........................ 14
General Specifications........................................ 16
Engine Performance Curves
(ISO 3046 Standard) .......................................... 18
Engine RPM Standards (For a New Vehicle) ................ 19
Approximate Weight of Workload Materials........ 20
Performance Tests ............................................. 22
Excavator Performance Standards..................... 23
Test Conditions ............................................................. 23
Swing Speed Test ......................................................... 23
Boom Swing Test .......................................................... 24
Cylinder Performance Tests .......................................... 24
Travel Deviation ............................................................ 26
Swivel Turn Measurement............................................. 26
Amount of Drag When Swinging is Stopped ................. 26

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION
order.
handling load.
responsibility.
APPLICABLE MODELS

DX15 40001 and Up
DX18 40001 and Up

Page 5
Page 6
GENERAL DESCRIPTION
The excavator has three main component sections:
• The Upper Turntable
• The Lower Undercarriage and Track Frames
• The Excavator Front End Attachment
The following illustration identifies main components and their
locations. (See Figure 1 on page -8.)

Page 7
COMPONENT LOCATIONS
1
2
23
3
4
22
5
21
20
7
19
18
17 8
10
16
11
15 24 14 13 12 BTS0100L
Figure 1

Page 8
Reference Reference
Description Description
Number Number
1 Boom 13 Track Spring
2 Arm Cylinder 14 Idler
3 Canopy 15 Blade Cylinder
4 Work Levers (Joysticks) 16 Blade
5 Seat 17 Swing Bracket
6 Engine Hood 18 Boom Cylinder
7 Hood 19 Bucket
8 Counterweight 20 Dump (Push) Linkage
9 Main Frame 21 Bucket (Guide) Linkage
10 Travel Motor 22 Bucket Cylinder
11 Lower Track Roller 23 Arm
12 Rubber Track 24 Extension Cylinder

Page 9
GENERAL DIMENSIONS
Canopy Model
B F
C
A
M
P
G
T
U
S
O
H N
R L
I Q
J
FG012231
Figure 2

Page 10
Dimension Description Canopy Model
Model DX15 DX18
Boom Type (One Piece) 1,690 mm (66.53 in)
850 mm 1,100 mm 850 mm 1,100 mm
Arm Type
(33.46 in) (43.30 in) (33.46 in) (43.30 in)
Bucket Type (SAE) 0.04 m3
A Boom Offset 400 mm (15.75 in)
B Boom Offset 360 mm (14.17 in)
C Bucket Wide 450 mm (17.72 in)
D Boom Swing Angle 75°
E Boom Swing Angle 50°
F Tail Swing Radius 1,190 mm (46.85 in)
G Shipping Length 3,750 mm (147.64 in)
H Tumbler Distance 1,224 mm (48.19 in) 1,230 mm (48.43 in)
I Track Length 1,580 mm (62.2 in) 1,585 mm (62.40 in)
J Track Length (Dozer) 1,765 mm (69.46 in) 1,915 mm (75.39 in)
K Track Height 360 mm (14.17 in)
750 mm (29.53 in)~
L Track Gauge 1,070 mm (42.13 in)
1,070 mm (42.13 in)
980 mm (38.58 in)~
M Track Width 1,300 mm (51.18 in)
1,300 mm (51.18 in)
N Shoe Width 230 mm (9.06 in)
O Car Body Clearance 155 mm (6.10 in) 165 mm (6.50 in)
P Body Width 980 mm (38.58 in)
Q Shipping Width 1,300 mm (51.18 in) 980 mm (38.58 in)
980 mm (38.58 in)~
R Dozer Width 1,300 mm (51.18 in)
1,300 mm (51.18 in)
S Dozer Height 235 mm (9.25 in)
T Shipping Height 2,300 mm (90.55 in) 2,360 mm (92.91 in)
1,120 mm 1,250 mm 1,135 mm 1,265 mm
U Shipping Height (Boom)
(44.09 in) (49.21 in) (44.69 in) (49.80 in)

Page 11
Cabin Model
B
C
A
E
M
G P
T
U
S
O
H N
R L
I Q
J
FG012265
Figure 3

Page 12
Dimension Description Cabin Model
Model DX15 DX18
850 mm 1,100 mm 850 mm 1,100 mm
Arm Type
(33.46 in) (43.30 in) (33.46 in) (43.30 in)
A Boom Offset 400 mm (15.75 in)
B Boom Offset 360 mm (14.17 in)
C Bucket Wide 450 mm (17.72 in)
D Boom Swing Angle 75°
E Boom Swing Angle 50°
F Tail Swing Radius 1,190 mm (46.85 in)
G Shipping Length 3,750 mm (147.64 in)
H Tumbler Distance 1,224 mm (48.19 in) 1,230 mm (48.43 in)
I Track Length 1,580 mm (62.2 in) 1,585 mm (62.4 in)
J Track Length (Dozer) 1,765 mm (69.46 in) 1,915 mm (75.39 in)
K Track Height 360 mm (14.17 in)
750 mm (29.53 in)~
L Track Gauge 1,070 mm (42.13 in)
1,070 mm (42.13 in)
980 mm (38.58 in)~
M Track Width 1,300 mm (51.18 in)
1,300 mm (51.18 in)
N Shoe Width 230 mm (9.06 in)
O Car Body Clearance 155 mm (6.10 in) 165 mm (6.50 in)
P Body Width 980 mm (38.58 in)
Q Shipping Width 1,300 mm (51.18 in) 980 mm (38.58 in)
980 mm (38.58 in)~
R Dozer Width 1,300 mm (51.18 in)
1,300 mm (51.18 in)
S Dozer Height 235 mm (9.25 in)
T Shipping Height 2,260 mm (88.98 in) 2,320 mm (91.34 in)
1,120 mm 1,250 mm 1,135 mm 1,265 mm
U Shipping Height (Boom)
(44.09 in) (49.21 in) (44.69 in) (49.80 in)

Page 13
DIMENSIONS AND WORKING
RANGE
WARNING
The actual value for dimension "L" Digging Reach, depends
on the stability and support provided by ground conditions.
Digging too far underneath the excavator if soil conditions
are wet, loose or unstable can collapse ground support,
which could cause injury and/or equipment damage.
d
F
G
E
H
C
A
FG012252
Figure 4

Page 14
Reference Description Machine Type
DX15 DX18
850 mm 1,100 mm 850 mm 1,100 mm
Arm Type
(33.46 in) (43.30 in) (33.46 in) (43.30 in)
3,700 mm 3,920 mm 3,700 mm 3,920 mm
A Max. Digging Reach
(145.67 in) (153.62 in) (145.67 in) (153.62 in)
Max. Digging Reach 3,605 mm 3,850 mm 3,565 mm 3,595 mm
B
(Ground) (141.93 in) (151.57 in) (140.35 in) (141.54 in)
2,140 mm 2,385 mm 2,075 mm 2,325 mm
C Max. Digging Depth
(84.25 in) (93.90 in) (81.69 in) (91.53 in)
2,245 mm 2,420 mm 2,310 mm 2,485 mm
D Max. Loading Height
(88.39 in) (95.28 in) (90.95 in) (97.83 in)
1,225 mm 1,085 mm 1,285 mm 1,500 mm
E Min. Loading Height
(48.23 in) (42.72 in) (50.59 in) (59.06 in)
3,400 mm 3,560 mm 3,465 mm 3,625 mm
F Max. Digging Height
(133.86 in) (140.16 in) (136.42 in) (142.72 in)
2,830 mm 3,005 mm 2,870 mm 3,045 mm
G Max. Bucket Pin Height
(111.42 in) (118.31 in) (113.00 in) (119.89 in)
1,630 mm 1,845 mm 1,565 mm 1,780 mm
H Max. Vertical Wall Depth
(64.17 in) (72.64 in) (61.61 in) (70.08 in)
1,500 mm 1,670 mm 1,500 mm 1,670 mm
I Min. Swing Radius
(59.06 in) (65.75 in) (59.06 in) (65.75 in)
d Bucket Angle 159 ° 159 ° 159 ° 159 °

Page 15
GENERAL SPECIFICATIONS
DX15
Item Specification
Equipment Weight (Canopy / Cabin) 1,510 kg (3,329 lb) / 1,650 kg (3,637 lb)
Bucket CECE 0.04 m3 (0.05 yd3)
Capacity SAE 0.042 m3 (0.055 yd3)
Manufacturer and Model MITSUBISHI L3E
Piston Displacement 0.952 liters (58.09 in3)
Engine
Rated Output 17.2 ps (16.94 hp) @ 2,300 rpm
Torque 5.5 kg•m (39.78 ft lb) @ 2,100 rpm
Travel Speed (Low / High) 2.0 / 3.8 km/h (1.37 / 2.36 MPH)
Swing Speed 11 rpm
Speeds
Max. Grade 25°
Max. Digging Power 1,270 kg (2,800 lb)
Total Length 3,750 mm (12' 4")
Total Width 1,300 mm (4' 27")
Overall Total Height (Canopy / Cabin) 2,300 mm (7' 5") / 2,260 mm (7' 4")
Dimensions Width and Height 1,000 x 235 mm (39.37 x 9.25 in)
Dozer Blade Max Ground
155 mm (6.10 in)
Clearance
Ground Pressure (Canopy / Cabin) 0.24 kg/cm2 (3.41 psi) / 0.27 kg/cm2 (3.84 psi)
Travel Motor Type Piston
Track Assembly Material Rubber
Shoe Operating Control
Grease Cylinder Type
Type
Pump Type Piston Pump Gear Pump
P1 P2 P3 P4
Main Pressure kg/cm2 (psi) 210 210 165 40
Hydraulic (2,987) (2,987) (2,346) (569)
Output/Discharge Capacity - liters/min 16.3 16.3 10.4 11.7
(DBMS) (4.31) (4.31) (2.75) (3.09)
Hydraulic Oil Tank Capacity 26 liters (7 U.S. gal.)
Engine Oil Capacity 4.1 liters (1.1 U.S. gal.)
Miscellaneous
Fuel Tank Capacity 18.4 liters (4.86 U.S. gal.)
Fluid Capacities
Coolant Capacity 1.8 liters (0.48 U.S. gal.)

Page 16
DX18
Item Specification
Equipment Weight (Canopy / Cabin) 1,650 kg (3,637 lb) / 1,790 kg (3,946 lb)
Bucket CECE 0.04 m3 (0.05 yd3)
Capacity SAE 0.042 m3 (0.055 yd 3)
Manufacturer and Model MITSUBISHI L3E
Piston Displacement 0.952 liters (58.09 in3)
Engine
Rated Output 17.2 ps (16.94 hp) @ 2,300 rpm
Torque 5.5 kg•m (39.78 ft lb) @ 2,100 rpm
Travel Speed (Low / High) 2.0 / 3.8 km/h (1.37 / 2.36 MPH)
Swing Speed 11 rpm
Speeds
Max. Grade 25°
Max. Digging Power 1,270 kg (2,800 lb)
Total Length 3,750 mm (12' 4")
Total Width 980 mm (3' 2") ~ 1,300 mm (4' 3")
Total Height (Canopy / Cabin) 2,360 mm (7' 7") / 2,320 mm (7' 6")
Overall
Dimensions 980 x 235 mm (38.58 x 9.25 in)
Width and Height
1,300 x 235 mm (51.18 x 9.25 in)
Dozer Blade
Max Ground
165 mm (6.49 in)
Clearance
Ground Pressure (Canopy / Cabin) 0.27 kg/cm2 (3.84 psi) / 0.29 kg/cm2 (4.12 psi)
Travel Motor Type Piston
Track Assembly Material Rubber
Shoe Operating Control
Grease Cylinder Type
Type
Pump Type Piston Pump Gear Pump
P1 P2 P3 P4
Main Pressure kg/cm2 (psi) 210 210 165 40
Hydraulic (2,987) (2,987) (2,346) (569)
Output/Discharge Capacity - liters/min 16.3 16.3 10.4 11.7
(DBMS) (4.31) (4.31) (2.75) (3.09)
Hydraulic Oil Tank Capacity 26 liters (7 U.S. gal.)
Engine Oil Capacity 4.1 liters (1.1 U.S. gal.)
Miscellaneous
Fuel Tank Capacity 18.4 liters (4.86 U.S. gal.)
Fluid Capacities
Coolant Capacity 1.8 liters (0.48 U.S. gal.)

Page 17
ENGINE PERFORMANCE
CURVES (ISO 3046 STANDARD)
WITHOUT FAN
Nm
60
55
50
TORQUE
45
40
20
kW
{ 17.5PS }
4
12.9kW/2300rpm
OUTPUT
10
FUEL CONSUMPTION g/kW h

320
310
300
290
280
0
1000 2000
ENGINE SPEED rpm
LOW IDLE
0
1350 + 25 rpm NL / 2550 -50 rpm
4
FG012253
Figure 5
NOTE: Barometric Pressure: 0.1 MPa (14.5 psi)

Temperature: 25°C (77°F)
Cooling Fan: ∅ 290 mm (11.42 in) sucker fan
Alternator: 12 V, 40 amp
Relative Humidity: 30%

Page 18
Specifications
Item
DX15/DX18
Model name L3E
Type Vertical 3-cylinder 4-cycle
No. of cylinders - bore x stroke 3 - 76 x 70 mm
(3 - 2.99 x 2.76 in)
Piston displacement 952 cc
(58.09 in3)
Firing order 1-3-2
Overall length 492 mm
(19.37 in)
Overall width 407 mm
(16.02 in)
Overall height 549 mm
(21.61 in)
Rated power 17.2 ps @ 2,300 rpm
(17.0 hp @ 2,300 rpm)
Maximum torque 5.50 kg•m @ 2,100 rpm
(40 ft lb @ 2,100 rpm)
Maximum rpm at no-load 0
2,550 -100 rpm
Minimum rpm at no-load Approx. 1,000 rpm
Fuel consumption 211 g/ps•h
(7.44 oz/hp•h)
Engine dry weight 80 kg (176 lb)
Fuel Light oil
Injection pump Bosch
Governor Mechanical centrifugal type
Alternator 12 V - 40A
Starter 12 V - 1.2 kW
ENGINE RPM STANDARDS (FOR A NEW VEHICLE)
Engine RPM
Conditions
DX15/DX18
Maximum rpm at no-load 2500 ±50 rpm
At 1-Pump Relief Above 2400 rpm
At 2-Pump Relief Above 2300 rpm

Page 19
APPROXIMATE WEIGHT OF
WORKLOAD MATERIALS
IMPORTANT
Weights are approximations of estimated average volume and mass. Exposure to rain, snow or
ground water; settling or compaction due to overhead weight, chemical or industrial processing
or changes due to thermal or chemical transformations could all increase the value of weights
listed in the table.
LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR

DENSITY DENSITY DENSITY
MATERIAL 1,100 KG/M3 1,600 KG/M3 2,000 KG/M3
(1,850 LB/YD 3), OR (2,700 LB/YD 3), OR (3,370 LB/YD3), OR
LESS LESS 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)

Page 20
LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR
DENSITY DENSITY DENSITY
MATERIAL 1,100 KG/M3 1,600 KG/M3 2,000 KG/M3
(1,850 LB/YD 3), OR (2,700 LB/YD 3), OR (3,370 LB/YD3), OR
LESS LESS LESS
Gypsum, calcined, (heated, 961 kg/m3

--------------------- ---------------------
powder) (1,620 lb/yd3)
1,522 kg/m3
Gypsum, crushed to 3 inch size --------------------- ---------------------
(2,565 lb/yd3)
Gravel, DRY, packed 1,810 kg/m3

--------------------- ---------------------
fragments (3,051 lb/yd3)
Gravel, WET, packed 1,922 kg/m3

--------------------- ---------------------
fragments (3,240 lb/yd3)
1,282 kg/m3
Limestone, graded above 2 --------------------- ---------------------
(2,160 lb/yd3)
Limestone, graded 1,362 kg/m3

--------------------- ---------------------
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
Sulphur, broken --------------------- ---------------------
(1,620 lb/yd3)

Page 21
PERFORMANCE TESTS
1. Main Relief Pressure
Working: 210 kg/cm2 (3,000 psi)
Travelling: 210 kg/cm2 (3,000 psi)
2. Actuator Speeds
Cycle Time
Operation Unit
S/N 40001 and up
Up sec. 1.9 ±0.3
Boom
Down sec. 1.5 ±0.3
Crowd sec. 2.2 ±0.3
Arm
Dump sec. 2.5 ±0.3
Crowd sec. 2.7 ±0.3
Bucket
Dump sec. 2.0 ±0.3
Swing (3 Revolutions) sec. 16.5 ±1.0
Up sec. 1.3 ±0.3
Dozer (Full)
Down sec. 1.2 ±0.3
Left sec. 5.3 ±0.3
Boom Swing
Right sec. 3.8 ±0.3
Jack-up Speed (3 Turns) sec. 9.5 ±1.0
2.1 / 3.8 km/h
Travel Speed Low / High
(1.30 / 2.36 MPH)
Travel Deviation 20 m (65.61 ft) Less Than 300 mm (0.98 ft)

Page 22
EXCAVATOR PERFORMANCE
STANDARDS
Evaluation of equipment performance and operating condition can
be made by running the excavator through a series of different
tests, and recording results with a stop watch and tape measure.
Compare results of performance tests against the specifications
and standards that follow, which are for equipment in new or
renewed condition.
Test Conditions
1. All tests should be performed on a flat, level, firmly
supporting ground surface.
2. All recommended, applicable maintenance and adjustment
service should be completed before testing.
3. Hydraulic fluid and engine oil should be of appropriate
viscosity for ambient weather conditions. Warm up
hydraulic oil to standard operating temperature, between
45° - 55°C (112° - 135°F).
4. Run all tests with the engine speed control set to maximum rpm.
Swing Speed Test

Extend the bucket cylinder completely and retract the arm
cylinder, as shown in Figure 6, to test swing speed. The lowest
point of the bucket will be approximately 1 m (3.3') off the ground.
Use paint marks at the same point on the turntable and
undercarriage, or select alternate measuring locations and use a
stopwatch to time 3 full 360° rotations. Measure the time it takes
for the turn table to swing 3 revolutions.
1 m (3.3')
AHS1290L
Figure 6
S/N 40001 and up

Swing (3 Revolutions) 16.5 ±1.0 sec.

Page 23
Boom Swing Test
With the boom, arm and bucket in the same position as for the
swing speed test with the boom evenly centered between the
side frames, pointing straight ahead. Use the controls to swing
75
the boom to one side then back to the center. Measure the time
it takes for the boom to swing to the maximum position (75° from
the center). Repeat the process for the other side.
S/N 40001 and up

Left 5.3 sec. 50
Right 3.8 sec.
AKS1300L
Figure 7
Cylinder Performance Tests

NOTE: All tests are performed with standard boom, arm and
bucket configuration. The bucket should be empty.
Boom Cylinders Test

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

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

Start with the boom up and the teeth of the bucket hanging
vertically, 500 mm (1.5' - 2') above the ground. Dump and crowd
the bucket several times, and average results.
Dozer Blade Cylinder

Start with the blade in the rest position on level ground. Test the
movement of the blade cylinder several times. Measure the times
it takes for the blade to move from the level ground rest position to
the up position and back down to the rest position on level ground.
Move the excavator to a spot where the blade can be moved up
and down through the full stroke. Start with the blade in the
lowest position. Test the movement of the blade cylinder several
times. Measure the times it takes for the blade to move through
the full stroke from the lowest position to the highest position
and back down to the lowest position.

Page 24
Cycle Time
Operation
S/N 40001 and up
Boom Up 1.9 ±0.3 sec.
Boom Down 1.5 ±0.3 sec.
Arm Crowd 2.2 ±0.3 sec.
Arm Dump 2.5 ±0.3 sec.
Bucket Crowd 2.7 ±0.3 sec.
Bucket Dump 2.0 ±0.3 sec.
Dozer Blade Up (1.3 ±0.3 sec. full stroke)
Dozer Blade Down (1.2 ±0.3 sec. full stroke)
Hydraulic Cylinder Natural Drop Test

To check boom and arm cylinder tightness against the specified
performance standard for new cylinders, put a full load of dirt in
the bucket and move the attachment cylinders so that the arm
cylinder is extended 20 - 50 mm (1" - 2") and boom cylinders are
retracted the same amount, 20 - 50 mm (1" - 2"). The top of the
bucket should be approximately 2 m (6' - 7') off the ground.
Turn off the engine and measure cylinder drop after 5 minutes.
Bucket arm and boom cylinders should not show more than
15 mm (0.59") change.
Cylinder Location Maximum Drop

Boom Cylinder Less Than 10 mm (0.39 in)
Arm Cylinder Less Than 10 mm (0.39 in)
Bucket Cylinder Less Than 10 mm (0.39 in)
Travel Motor Jack-up Test

Test travel motor operation on each side by painting or chalking
a mark on one crawler shoe, with a corresponding mark on the
travel frame. Use the attachment to jack up one side of the
machine and operate the raised travel motor. Record the
number of seconds it takes the crawler shoe to make 3 full
rotations, during both high speed and low speed operation.
Cycle Time
Operation
S/N 40001 and up
High Speed 9.5 ±1.0 sec.

Page 25
Travel Deviation
Travel deviation measurement.
Front
(Engine maximum rpm, no load, oil temperature:
Direction
50 ±5°C (122 ±41°F)
L
Running Distance (1) Deviation (2) 20m
20 m (65.61 ft) Less Than 300 mm (0.98 ft)
FG012254
Figure 8
Swivel Turn Measurement

1. Fill the bucket with approximately 60 kg (130 lb) of 12°
material.
2. Park the machine on an incline with an angle of 12° with
the hydraulic oil temperature at 50 ±5° C.
3. Fully extend the arm cylinder, position the boom cylinder
parallel to the surface of the incline and shut down engine.
4. Measure the amount of swing bearing outer race
movement after 3 minutes. HKA7043L
Figure 9
Model Standard Limit Weight
DX15/ 100 mm (4 in) 200 mm (8 in)
54 kg (119 lb)
DX18 or less or less
Amount of Drag When Swinging is Stopped

1. Position the machine on a level ground with high engine
rpm, oil temperature at 50°C ±5°C, and at maximum 1 2
operating radius as shown, and align the boom joint 1
parallel to the arm bucket coupling pin.
2. Apply a weight to the bucket tip, and measure angle with
the bucket tip as a basis after making a turn.
Bucket load: 54 kg
3
Moving angle: 40° or less HKA7044L
Figure 10

Page 26
1General Maintenance
SP000016
GENERAL MAINTENANCE PROCEDURES
SP000016
General
Maintenance
Procedures
Edition 1
General Maintenance Procedures SP000016

Page 1
MEMO

Page 2
Table of Contents
General Maintenance Procedures

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

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

ALL MODELS ALL RANGES

Page 5
WELDING PRECAUTIONS AND
GUIDELINES
IMPORTANT
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 be
caused. Always consult DOOSAN After Sales Service
before welding on integral components (loader arm, frames,
car body, track frames, turntable, attachment, etc.) of the
machine. It is possible that some types of structurally
critical repairs may require Magnetic Particle or Liquid
Penetrant testing, to make sure there are no hidden cracks
or damage, before the machine can be returned to service.
CAUTION!
Always perform welding procedures with the proper safety
equipment on hand. Adequate ventilation and a dry work
area are absolutely essential. Keep a fire extinguisher
nearby and always wear protective clothing and the
recommended type of eye protection.

Page 6
CAUTION!
Observe the following safety precautions:
1. Use extra caution and adequate safety shielding when
welding near fuel and oil tanks, batteries, hydraulic
piping lines or other fire hazards.
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 that could be damaged by weld
spatters, use adequate shielding protection in front of
the assembly.
5. During 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.
HYDRAULIC SYSTEM -
GENERAL PRECAUTIONS
Always maintain oil level in the system at recommended levels.
Assemblies that operate under heavy loads, at high speed, with
extremely precise dimensional tolerances between moving parts
- pistons and cylinders, or shoes and swash plates, for example
- can be severely damaged if oil supply runs dry.
Assemblies can be run dry and damaged severely in a very
short time when piping or hoses are disconnected to repair leaks
and/or replace damaged components. Hoses that are
inadvertently switched during disassembly (inlet for outlet and
vice versa), air introduced into the system or assemblies that are
low on oil due to neglect or careless maintenance, could all
produce sufficient fluid loss to cause damage.

Page 7
When starting the engine (particularly after long layoff or storage
intervals), make sure that all hydraulic controls and operating
circuits are in neutral, or "OFF." That will prevent pumps or other
components that may be temporarily oil starved from being run
under a load.
Replacement of any hydraulic system component could require
thorough cleaning, flushing, and some amount of prefilling with
fresh, clean oil if the protective seal on replacement parts has
obviously been broken or if seal integrity may have been
compromised. When protective seals are removed before
installation and reassembly, inspect all replacement parts
carefully, before they are installed. If the replacement part is
bone dry (with 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 minimize 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.
A daily walk-around prestart equipment safety inspection,
including a quick visual scan 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 work loads, fluid circulating under high-pressure)
make it extremely critical that dust, grit or any other type of
contamination be kept out of the system. Observe fluid and
filter change maintenance interval recommendations and
always preclean any exterior surface of the system before it
is exposed to air. For example, the reservoir fill cap and
neck area, hoses that have to be disassembled, and the
covers and external surfaces of filter canisters should all be
cleaned before disassembly.

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

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

System Service
Whenever maintenance, repairs or any other type of
troubleshooting or service is being performed, it's important to
remember that the 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 safe, noncombustible, evaporative type, low-
residue solvent and thoroughly clean exterior
surfaces of assemblies before any part of the circuit
is opened up or disassembled.
NOTE: It's just as important to clean the cap and
reservoir top before routine fluid changes
or quick checks as it is before major
repairs. (Accumulated dirt attracts
moisture, oil and other fluids - and more
dirt.)
• Keep dismantled parts covered during disassembly.
Use clean caps, plugs or tape to protect the
disconnected openings of flanges, manifolds and
piping.
• Do not allow cleaning solvents or other fluids to mix
with the oil in the system. Use clean oil to flush any
traces of solvent or other residue before reassembly.
• If metal or rubber fragments are found in the system,
flush and replace all fluid in the system and
troubleshoot the circuit to identify the source of
contamination.
IMPORTANT
Make sure that cleaning solvents will be compatible with
rubber materials used in the hydraulic system. Many
petroleum based compounds can cause swelling,
softening, or other deterioration of system sealing
elements, such as O-rings, caps and other seals.

Page 10
Oil Leakage Precautions
Oil that is visibly seeping from joints or seals should always
serve as a "red flag" alarm.
Leaks must alert the machine operator and maintenance crew
that air, water and dirt have an open, free passageway through
which to enter the circuit. Harsh, 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 very suddenly put a complete stop to
normal hydraulic function. You can prevent having to make
these types of repairs by following recommended assembly
procedures:
1. Use new O-rings and oil seals whenever hydraulic
assemblies are rebuilt.
2. Prepare joint surfaces before assembly by checking
alignment and flatness. Clean and repair corrosion or
any other damage.
3. Follow bolt torque recommendations and all other
assembly requirements.
NOTE: Grease lip seals before assembly.
Figure 1

Page 11
CLEANING AND INSPECTION
General Guidelines
All parts must be clean to permit an effective inspection. During
assembly, it is very important that no dirt or foreign material
enters unit being assembled. Even minute particles can cause
malfunction of close fitting parts such as thrust bearing, matched
parts, etc.
WARNING!
Care should be exercised to avoid inhalation of vapors,
exposure to skin and creating fire hazards when using
solvent type cleaners.
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 air stream 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 light weight oil and wrap in clean lintless cloth
or paper to protect them until installation.
For those bearings that are to be inspected in place;
inspect bearings for roughness of rotation, scoring, pitting,
cracked or chipped races. If any of these defects are
found, replace bearings. Also, inspect defective bearing
housing and/or shaft for grooved, galled or burred
conditions that indicate bearing has been turning in its
housing or on its shaft.
4. It is more economical to replace oil seals, O-rings, sealing
rings, gaskets and retaining rings when unit is
disassembled than waiting for premature failures; refer to
latest Micro Fiche and/or Parts Book for replacement
items. Be extremely careful when installing sealing
members, to avoid cutting or scratching.

Page 12
Curling under of any seal lip will seriously impair its
efficiency. Apply a thin coat of Loctite #120 to outer
diameter, of metal casing, on oil seals to assure an oil tight
fit 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 to the eye. 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 splines
twisted, 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 foe roughness of rotation, scoring, pitting, cracked
or chipped races. If any of these defects are found replace the
whole bearing assembly. NEVER replace the bearing alone
without replacing the mating cup or the cone at the same time.

Page 13
After inspection lightly coat the bearing and related parts with oil
and wrap in a clean lintless cloth or paper and protect them from
moisture and other foreign materials until installation.
It is also important to inspect the bearing housing and/or shaft
for grooved, galled or burred conditions that indicate that 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 to the naked eye.
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 due to improper handling or tool usage.
Figure 3

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

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

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

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

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

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

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

Page 19
Page 20
SP000813
STANDARD TORQUESSP000813
Standard
Torques
Edition 1
Standard Torques SP000813

Page 1
MEMO

Page 2
Table of Contents
Standard Torques

Torque Values for Standard Metric Fasteners...... 6
Torque Values for Standard U.S. Fasteners ........ 7
Type 8 Phosphate Coated Hardware ................... 9
Torque Values for Hose Clamps ........................ 10
Torque Values for Split Flanges ......................... 10
Torque Wrench Extension Tools ........................ 11
Torque Multiplication ..................................................... 11
Other Uses for Torque Wrench Extension Tools........... 12
Tightening Torque Specifications (Metric) ..................... 13

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

ALL MODELS ALL RANGES

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

Page 6
TORQUE VALUES FOR
STANDARD U.S. FASTENERS
S.A.E. 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.
0.90 When hardened surfaces are used under
the nut or bolt head.
NOTE: When reusing bolts and nuts in service, use
minimum torque values.

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

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

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

Page 9
TORQUE VALUES FOR HOSE
CLAMPS
The following chart provides the tightening torques for hose
clamps used in all rubber applications (radiator, air cleaner,
operating lever boots, hydraulic system, etc.).
Torque
Radiator, Air Cleaner, Boots, Etc. Hydraulic System
Clamp Type And Size
Kilogram Meter Inch Pounds Kilogram Meter Inch Pounds
(kg•m) (in lb) (kg•m) (in lb)
"T" Bolt (Any Diameter) 0.68 - 0.72 59 - 63 ------- ------
Worm Drive - Under
0.2 - 0.3 20 - 30 0.5 - 0.6 40 - 50
44 mm (1-3/4 in) Open Diameter
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
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 may cause leakage.
Bolt Torque
Flange Bolt
Kilogram Meter Foot Pounds
Size (*) Size
(kg•m) (ft lb)
1/2" 5/16" 2.1 - 2.5 15 - 18
3/4" 3/8" 3.0 - 3.7 22 - 27
1" 3/8" 3.7 - 4.8 27 - 35
1 - 1/4" 7/16" 4.8 - 6.2 35 - 45
1 - 1/2" 1/2" 6.4 - 8.0 46 - 58
2" 1/2" 7.6 - 9.0 55 - 65
2 - 1/2" 1/2" 10.9 - 12.6 79 - 91
3" 5/8" 19.1 - 20.7 138 - 150
3 - 1/2" 5/8" 16.2 - 18.4 117 - 133
(*) - Inside diameter of flange on end of hydraulic tube or hose

fitting.
NOTE: Values stated in chart are for Standard Pressure
Series (Code 61) Split Flanges.

Page 10
TORQUE WRENCH EXTENSION
TOOLS
Very large diameter, high grade fasteners (nuts, bolts, cap
screws, etc.) require a great deal of turning force to achieve
recommended tightening torque values.
Common problems that could occur as a result are:
• Recommended torque exceeds the measuring
capacity of the torque wrench.
• Specialized sockets do not fit the adapter on the front
end (nose) of the torque wrench.
• Generating adequate force on the back end (handle)
of the wrench is difficult or impossible.
• Restricted access or an obstruction may make use of
the torque wrench impossible.
• A unique application requires fabrication of an
adapter or other special extension.
Most standard torque wrenches can be adapted to suit any one
of the proceeding needs or situations, if the right extension tool
is used or fabricated.
Torque Multiplication
A wrench extension tool can be used to increase the tightening
force on a high capacity nut or bolt.
For example, doubling the distance between the bolt and the
back (handle) end of the torque wrench doubles the tightening
force on the bolt. It also halves the indicated reading on the
scale or dial of the torque wrench. To accurately adjust or
convert indicated scale or dial readings, use the following
formula:
I = A x T / A + B where:
I = Indicated force shown on the torque wrench scale or dial.
T = Tightening force applied to the nut or bolt (actual Torque). Figure 1
A = Length of the torque wrench (between the center of the nut

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

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

Page 11
NOTE: The formula assumes that there is no added
deflection or "give" in the joint between the extension
and torque wrench. Readings may also be
inaccurate:
• If the extension itself absorbs some of the tightening
force and starts to bend or bow out.
• If an extension has to be fabricated that is not
perfectly straight (for example, an extension made to
go around an obstruction, to allow access to a difficult
to tighten fastener), the materials and methods used
must be solid enough to transmit full tightening
torque.
Other Uses for Torque Wrench Extension

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

Page 12
Tightening Torque Specifications (Metric)
(For coated threads, prelubricated assemblies.)
CAUTION!
Disassembly, overhaul and replacement of components on
the machine, installation of new or replacement parts and/
or other service-related maintenance may require the use of
thread or flange sealing assembly compound.
Use the information on this page as a general guide in
selecting specific formulas that will meet the particular
requirements of individual assembly installations. DOOSAN
does not specifically endorse a specific manufacturer or
brand name but the following table of "Loctite" applications
is included for which cross-references to other makers'
products should also be widely available.
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of
fastener adhesives, with Thread locker sealers 222, 242/243,
262, 271, 272, or 277.

Page 13
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 Remove HOT
262 Red 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 high-
4 Hours (or 1/2
pressure hydraulic systems. Over
545 Purple Hand tools hour with Locquic
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 nonrigid Use Locquic "N" primer for faster (1/4 - 2
515 Purple
assemblies subject to shock, vibration hours) setup. Unprimed setup 1 - 12 hours.
or deflection.

Page 14
IV. "Loctite" retaining compounds

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

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

Page 15
Page 16
1Upper Structure
1Lower Structure and
Chassis
SP001523
TRACK ASSEMBLY SP001523
Track
Assembly
Edition 1
Track Assembly SP001523

Page 1
MEMO

Page 2
Table of Contents
Track Assembly

Track Tension ....................................................... 6
Cleaning and Inspection (Wear Limits and
Tolerances)........................................................... 8
Track Shoes and Links ....................................... 15
Interchanging Shoe Types.................................. 17
Front Idler Roller ................................................. 18
Lower Roller ....................................................... 20
Track Spring and Track Adjusting Cylinder ........ 22
Sprocket ............................................................. 25

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION
order.
handling load.
responsibility.
APPLICABLE MODELS

DX15 40001 and Up
DX18 40001 and Up

Page 5
GENERAL DESCRIPTION
The track assembly is composed of the following major
components:
1. Track
2. Front Idler Roller
3. Upper Roller
4. Lower Roller
5. Track Spring and Track Adjustment Cylinder
TRACK TENSION
WARNING
Safely measuring track tension requires two people. One
person must be in the operator's seat, running the controls
to keep one side frame in the air, while the other person
makes dimensional checks. Take all necessary precautions
to make sure the machine won't move or shift position
during service. Warm up the engine to prevent stalls, travel
the excavator to 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 pressure too suddenly. The
grease cylinder valve should never be backed off more than
1 complete turn from the fully tightened down position.
Bleed off pressure slowly and keep your body away from
the valve at all times.
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.
HKA1304L
Figure 1

Page 6
2. Measure the distance (A, Figure 2) between the rolling
surface of the track roller and the contact surface of the
crawler.
NOTE: This measurement can be thrown off if there is
too much mud or dirt or other material in the
track assembly. Clean off the tracks before
checking clearance.
Figure 2
A. For rubber crawlers

It is accepted if the distance between the rolling
surface of the track roller and the contact surface of
the crawler is 10 - 15 mm (0.39 - 0.59 in).
3. Too little sag in the crawler track can cause excessive
component wear. The recommended adjustment can also
be too tight causing accelerated stress and wear if ground
conditions are wet, marshy or muddy, or if the ground is
hard and full of rocks or gravel.
Figure 3
WARNING
The track adjusting mechanism is under very
high-pressure. NEVER release pressure too suddenly. The
grease cylinder valve should never be backed off more than
1 complete turn from the fully tightened down position.
Bleed off pressure slowly and keep your body away from
the valve at all times.
4. Track tension adjustments are made through the grease

fitting (1, Figure 4) in the middle of each side frame. Adding
grease increases the length of the adjustment cylinder.
The longer the adjustment cylinder, the greater the
pressure on the tension spring pushing the track idler
wheel outward.
5. If there isn't 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 thru hole
in adjustment cylinder.
6. After completing the tension adjustment, tighten the valve
Figure 4
securely.
NOTE: Cartridge tightening torque: 6 - 9 kg• m (43 -
65 ft lb).

Page 7
(WEAR LIMITS AND TOLERANCES)
CAUTION
Refer to the "Welding Precautions and Guidelines"
information in "General Maintenance Procedures" section for
general recommendations and specific safety precautions,
before starting any lower travel frame component rebuilding
procedure.
The tables that follow provide factory specified dimensional

limits (as new condition, recommended service and replacement
limit) for lower travel frame components.
Recommended maintenance to renew most listed components
requires welding on additional material and grinding off excess.
Some components must be replaced before the service limit is
exceeded. No maintenance or renewal is possible.
Compare the values in the tables with dimensions and profiles
shown in the following figures.
Rubber Tracks
20
B C
A
Wear Amount (mm)
15
10
0 5 00 1 000 1 500 2 000 2 500 3 000

Operating Hours HKA1313L
Figure 5
Reference Number Description

A Concrete Surface
B Normal Use
C Dirt
The amount of friction on the rubber track shoes determines the

limit of use. However, it is subject to change depending upon the
work condition and environment.

Page 8
A D
B E
F
HBOH840L
Figure 6
Reference Reference
Number Number
A 25.0 mm D 23.5 mm
(0.98 in) (0.93 in)
B 26.0 mm E 22.0 mm
(1.02 in) (0.87 in)
C 25.0 mm F 230.0 mm
(0.98 in) (9.06 in)
Reference
Description A
Number
A Pitch 96.0 mm (3.78 in)
Item DX15/DX18
4,410 ±12 mm
Distance Between Centers of Shoes
(173.62 ±0.47 in)
800 kg
Rigid HKA1315L
Scale Cord (1,764 lb)
Figure 7
No. of Coils 40 ±4 Coils
-25°C - 55°C
Operating Temperature Range
(-13°F - 131°F)
230 x 96 mm
Width x Pitch
(9.06 x 3.78 in)

Page 9
Track Frame Spring
HKA1312L
Figure 8
Item Limit Remarks

5.0 mm (0.20 in)
Bending
(Overall length of track frame)
Deformed Frame 10.0 mm (0.39 in) Bent
Distorted
(Distortion between left and right crawler frames)
Widened Idler 5.0 mm (0.20 in)
Recommended
Normal (New)
Item Limit for Remarks
Dimension
Maintenance
51.0 mm 56.0 mm Rebuild or
Track Frame
Gap between upper and lower (2.01 in) (2.20 in) Replace
sides of idler guide 50.0 mm 45.0 mm Rebuild or
Idler Frame
(1.97 in) (1.77 in) Replace
153.0 mm 158.0 mm Rebuild or
Track Frame
Gap between left and right of (6.02 in) (6.22 in) Replace
idler guide 150.0 ±1.0 mm 145.0 mm Rebuild or
Idler Support
(5.91 ±0.04 in) (5.71 in) Replace
Item Free Length Mounted Length Remarks

261.0 mm 223.0 mm
Track Spring Replace
(10.28 in) (8.78 in)

Page 10
Idler (For Steel Shoes)
B
C A
HKA1402L
Figure 9
No. Item Unit Standard Limits Remarks

Outside mm ø292.0 ø288.0
A Rebuild or Replace
Diameter (in) (11.49) (11.34)
mm ø277.18
B PCD - Rebuild or Replace
(in) (10.91)
Dedendum mm ø253.0
C - Rebuild or Replace
Diameter (in) (9.96)
mm 22.0
D Face Width - Rebuild or Replace
(in) (0.87)

Page 11
Track Roller
D
C E
G
F
B A
HKA1602L
Figure 10
No Item Unit Standard Limits Remarks

mm ø100.0
A Outside Diameter – Rebuild or Replace
(in) (3.94)
mm ø80.0 ø78.0
B Contact Surface Diameter Rebuild or Replace
(in) (3.15) (3.07)
mm 22.0 17.0
C Tab Width Rebuild or Replace
(in) (0.87) (0.67)
mm 80.0
D Overall Width – Rebuild or Replace
(in) (3.15)
mm 29.0
E Contact Width – Rebuild or Replace
(in) (1.15)
mm 0.2 ±0.1 1.5
F Side Clearance Replace Bushing
(in) (0.008 ±0.004) (0.059)
kg•m 21 kg•m
G Tightening Torque
(ft lb) (152 ft lb)

Page 12
Track Spring
O.D
P.C.D
I.D
L
L1
L0
HKA1503L
Figure 11
Designation Units Dimensions

No. of Active Coils ea. 7.5
Total No. of Coils ea. 9
kg/mm 23.03
Spring Constant
(lb/0.0394 in) (50.77)
kg 875
Set Load
(lb) (1929)
kg 4650
Compressive Load
(lb) (10,250)
mm 195.1
Minimum Closed Length (L)
(in) (7.68)
mm 261
Free Length (L0)
(in) (10.28)
mm 233.5
Set Length (L1)
(in) (9.19)
mm 78
Outside Diameter
(in) (3.07)
mm 63
Mean Diameter
(in) (2.48)
mm 48
Inside Diameter
(in) (1.89)
mm 15
Wire Diameter (D)
(in) (0.59)

Page 13
Sprocket
D
C
HKA1702L
Figure 12
No Item Unit Standard Limits Remarks

mm 22.0 16.0
A Sprocket Tooth Width Rebuild or Replace
(in) (0.87) (0.63)
mm ø253.0 ø240.0
B Sprocket Deddendum Diameter Rebuild or Replace
(in) (9.96) (9.45)
kg•m 6.5
C Mounting Bolt Tightening Torque M10
(ft lb) (47)
kg•m 6.5
D Motor Mounting Bolt Tightening Torque M10 x 1.5
(ft lb) (47)
mm ø140.0 mm
E Travel Motor Mounting Hole -
(in) (5.51 in)

Page 14
TRACK SHOES AND LINKS
Track Removal
1. Position machine on a smooth level surface with adequate
room for forward and reverse travel.
2. Relieve track tension. Refer to "Track Tension" in this
section for procedure.
3. Swing the front attachment to the side being serviced. Lift
the side by lowering the boom to the ground. Install jack
stands to support the weight of the equipment.
HKA1304L
Figure 13
Rubber Shoes
1. Loosen track tension cylinder nut and relieve all pressure
and be certain that the cylinder is completed retracted.
2. Use a steel bar for leverage and slide the rubber track
assembly over the idler assembly.
Figure 14

Page 15
Track Installation
Rubber Shoes
1. With upper structure at 90° to track frame. Use bucket and
boom to raise track frame off blocking.
2. Place rubber track assembly over idler and rollers.
HKA1304L
Figure 15
3. Use a steel bar for leverage and slide the rubber track
assembly over the idler assembly.
4. Apply track tension. Refer to "Track Tension" in this
section for procedure.
Figure 16

Page 16
INTERCHANGING SHOE TYPES
The steel and rubber track assemblies can be interchanged as
necessary depending on the application.
Changing to Rubber Track Assembly

1. Refer to "Track Removal" section to remove the track
assembly before proceeding to the following steps.
2. Remove steel track idler.
3. Remove steel track rollers.
Figure 17
4. Install rubber track rollers and tighten to specified torque.

NOTE: Steel tracks use a washer (1, Figure 18). 1
5. Install rubber track idler.
NOTE: Nut tightening torque: 21 kg•m (152 ft lb)
6. Refer to "Track Installation" section for track assembly
installation procedures.
Changing to Steel Track Assembly HKA1802S

Figure 18
2. Remove rubber track idler.
3. Remove rubber track rollers.
4. Install steel track rollers and tighten to specified torque.
5. Install steel track idler.
NOTE: Nut tightening torque: 21 kg•m (152 ft lb)

Page 17
FRONT IDLER ROLLER
Parts List
7
8 1
6
5
4
2
3
4
5
6
7
8
HKA1401L
Figure 19
Reference Reference
Number Number
1 Front Idler Assembly 5 Retaining Ring
2 Idler 6 Oil Seal
3 Shaft 7 Spring Pin
4 Bearing (BL-207) 8 Guide

Page 18
Removal and Disassembly
assembly before proceeding to the following steps. 2
3
2. Remove spring pin (7, Figure 20) from guide (8). 4
3. Remove guide (8, Figure 20) from shaft (3). 5
6
4. Remove oil seal (6, Figure 20) using a screw driver. 7
8
NOTE: Once removed, the oil seal should not be reused.
5. Remove retaining ring (5, Figure 20), bearing (4), and shaft
(3).
6. Repeat steps 2 - 5 for other side.
HBOH850L
Figure 20
Reassembly and Installation

1. Degrease, clean and dry all parts before reassembly.
2. Insert shaft (3, Figure 20) into idler gear (2).
3. Assemble bearing (4, Figure 20) onto shaft (3) and install
retaining ring (5)
4. Install new grease seal (6, Figure 20).
5. Install Shaft guide (8, Figure 20) and spring pin (7).
6. Repeat steps 1 - 5 for other side.

Page 19
LOWER ROLLER
Parts List
11 10
9 8
7
6
5
4 2
3
4
5
6
7
8
9
10
1 11
HKA1601L
Figure 21
Reference Reference
Number Number
1 Track Roller Assembly 7 Spacer
2 Track Roller 8 Retaining Ring
3 Shaft 9 Washer
4 Bearing (6205) 10 Spring Washer
5 Retaining Ring 11 Nut (M16)
6 Oil Seal

Page 20
2
1. Refer to "Track Removal" section to remove the track 3
4
2. Loosen the nut (11, Figure 22) from both inner and outer 5
side of track frame and remove roller from frame. 6
7
3. Remove nut (11, Figure 22), spring washer (10) and flat 8
washer (9). 9
10
11
4. Remove retaining ring (8, Figure 22) and spacer (7).
5. Use a screw driver to remove the oil seal (6, Figure 22).
NOTE: Once removed, the oil seal should not be HBOH860L
reused. Figure 22
6. Remove inner retaining ring (5, Figure 22) and bearing (4).
7. Repeat steps 2 - 6 for the other side.
8. Remove shaft (3, Figure 22) from roller (2)

1. Degrease, clean and dry all parts before reassembly.
2. Insert shaft (3, Figure 22) into roller body (2).
3. Insert bearing (4, Figure 22) onto shaft (3) and secure with
retaining ring (5).
4. Insert new oil seal (6, Figure 22) onto shaft.
5. Assemble spacer (7, Figure 22) and secure with outer
retaining ring (8).
6. Repeat steps 2 - 5 for the other side.
7. Place roller assembly into mounting grooves in track
frame.
8. Insert flat washer (9, Figure 22), lock washer (10) onto
shaft (3) and tighten with nut (11).
NOTE: Tightening Torque: 21 kg•m (152 ft lb)

Page 21
TRACK SPRING AND TRACK
ADJUSTING CYLINDER
Parts List
12 2 3 5 8 11
14 13 6 4 10
HKA1501L
Figure 23
1 2
12 4
13 10
11
9
14 8
7
5
6
HKA1502L
Figure 24

Page 22
Reference Reference
Number Number
1 Plate 8 Spacer
2 Cylinder 9 Retaining Ring
3 Track Spring 10 Cartridge Valve
4 Rod 11 Grease Fitting
5 O-ring 12 Castle Nut
6 Backup Ring 13 Cotter Pin
7 Dust Seal 14 Idler Yoke

2. Remove idler from track frame.
3. Remove the idler yoke (14, Figure 25) from track frame.
3
2
4. Use a press to relieve the spring force on plate (1, Figure 25).
5. Remove cotter pin (13, Figure 25) and castle nut (12).
6. Remove spring (3, Figure 25) from adjusting cylinder tube (2).
13
14
1
12
HBOH871L
Figure 25
7. Remove cartridge valve (10, Figure 26) and grease fitting

(11) together from the tension cylinder rod (4).
4 10
8. Remove cylinder rod (4, Figure 26) from tension cylinder 11
tube (2). 9
8
7
9. Remove retaining ring (9, Figure 26) and then remove 5
spacer (8), dust seal (7), backup ring (6) and O-ring (5). 6
HBOH872L
Figure 26

Page 23
1. Install O-ring (5), backup ring (6), dust seal (7) and spacer
(8) to cylinder tube (2). 10
NOTE: Coat grease to the O-ring and dust seal before 4 11
assembly
2. Assemble cylinder rod (4) to cylinder tube (2).
3. First, inject grease into cylinder tube (2).
4. Install cartridge valve (10) into tension adjusting cylinder
rod (4) until two threaded portions contact threaded hole,
and then assemble cylinder rod.
5. At this time, ensure that grease is drained from the grease 2
drain port and then tighten the cartridge valve. 9
8
NOTE: Cartridge valve tightening torque: 6 - 9 kg•m (43 7
- 65 ft lb). 5
6
HBOH873L
Figure 27
6. Use a press to compress the spring (3, Figure 28) and

assemble onto cylinder tube (2).
3
7. Assemble plate (1, Figure 28) and secure the spring in
place with castle nut (12).
8. Adjust the spring set length and bend the cotter pin (13,
2
Figure 28) completely.
NOTE: Spring set length: 233.5 mm (9.19 in)
NOTE: Release air from the cylinder tube completely
before assembly.Be sure to apply grease to the
piston area on the cylinder tube rod before
assembly.
14
9. Assemble idler yoke (14, Figure 28) idler assembly into
track frame. 1
10. Refer to "Track Installation" section for track assembly 12
installation procedures. 13
HBOH874L
Figure 28

Page 24
SPROCKET
Parts List
1 Bolt
2 Spring Washer
3 Sprocket
1
Removal 3
1. Refer to "Track Removal"section to remove the track 2

assembly before proceeding to the following steps. HKA1701L
2. Remove nine mounting bolts (1, Figure 29) and spring Figure 29
washers (3) from sprocket.
Installation
1. Place sprocket onto travel motor and align the holes.
2. Install washers, bolts and tighten to specified torque.
NOTE: Tightening torque: 11.5 kg•m (83 ft lb)
3. Refer to "Track Installation"section for track assembly

Page 25
Page 26
1Engine and Drive Train
SP001524
ENGINE SP001524
Engine
Edition 1
Engine SP001524
Page 1
MEMO
Engine SP001524
Page 2
Table of Contents
Engine

General................................................................. 7
Engine Model and Engine Number ................................. 7
Sectional Views ............................................................... 9
Features ........................................................................ 13
Performance Curves ..................................................... 14
Engine Specifications .................................................... 16
Maintenance .................................................................. 17
Troubleshooting............................................................. 27
Engine ................................................................ 34
Special Tools ................................................................. 34
Rocker Arms and Rocker Shaft..................................... 35
Cylinder Head................................................................ 37
Valve and Valve Spring ................................................. 41
Intake Manifold and Exhaust Manifold .......................... 44
Gear Case and Oil Pump .............................................. 46
Timing Gears ................................................................. 51
Camshafts (Valve and Pump) ....................................... 54
Piston and Connecting Rod........................................... 58
Crankshaft ..................................................................... 64
Cylinder Block ............................................................... 68
Lubricating System ............................................. 70
General.......................................................................... 70
Oil Filter and Oil Pressure Switch.................................. 71
Fuel System........................................................ 72
General.......................................................................... 72
Fuel Injection Pump....................................................... 74
Injection Nozzle ............................................................. 78
Governor System................................................ 82
General.......................................................................... 82
Torque Spring................................................................ 84
Engine SP001524
Page 3
Governor ....................................................................... 87
Cooling System .................................................. 89
General.......................................................................... 89
Fan and Fan Belt........................................................... 91
Water Pump .................................................................. 92
Thermostat .................................................................... 92
Engine Coolant Temperature Gauge Unit and Thermo
Switch ............................................................................ 93
Air Cleaner.......................................................... 94
Construction .................................................................. 94
Inspection ...................................................................... 95
Electrical System ................................................ 96
General.......................................................................... 96
Starter.......................................................................... 101
Alternator and Dynamo ............................................... 108
Glow Plug .................................................................... 116
Key OFF Stop System................................................. 116
Glow Plug Timer System............................................. 119
Periodic Service Chart ...................................... 120
Specifications and Standards ........................... 121
Engine ......................................................................... 121
Lubricating System...................................................... 125
Fuel System ................................................................ 126
Governor System ........................................................ 127
Cooling System ........................................................... 127
Electrical System......................................................... 129
Tightening Torque Chart and Sealant Chart ............... 132
Tightening Torque for Common Bolts and Nuts .......... 133
Tightening Torque for Common Plugs ........................ 134
Sealant Chart .............................................................. 134
Engine SP001524
Page 4
MEMO
Engine SP001524
Page 5
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DX15 40001 and Up
DX18 40001 and Up
Engine SP001524
Page 6
GENERAL
Engine Model and Engine Number
Model, Classification and Use

1. Engine model.
Model Application Use

L2A
11, 12 - Agricultural
L2C
L2E
31, 32 - Industrial
L3A
L3C
61, 62 - Export Only
L3E
2. The engine model number is broken down as follows.
L 3 C - 11 A
Subdivision of specification
Application
Cylinder bore (C:∅70)
Number of cyls
Name of series
(L:Lightweight engine)
Engine Model Embossment and Engine Number Stamp

1. Embossment of engine model and cylinder volume.
The engine model and cylinder volume are embossed on
side of injection pump mounting portion of cylinder block.
Figure 1 Engine Model and Cylinder

Volum
Engine SP001524
Page 7
2. Engine number stamp.
The engine number is stamped on injection pump
mounting portion of cylinder block (on upper side of tie rod
cover).
Figure 2 Engine Number
Engine SP001524
Page 8
Sectional Views
Longitudinal Section (L3C)
Figure 3
Engine SP001524
Page 9
Cross Section (L3C)
Figure 4
Engine SP001524
Page 10
Sectional Views of Governor (L3C)
Figure 5
Engine SP001524
Page 11
Oil Pump and Oil Filter
Figure 6
Engine SP001524
Page 12
Features
1. Small and lightweight engine.
The new series are 10 - 20% smaller in weight and 15 -
20% smaller in contour volume than the same class of
engines of competitors
2. Low noise and economical fuel consumption.
Low noise and economical fuel consumption are attained
by the well designed cylinder block construction (having
curved side faces), the rearranged combustion chambers,
and the small sized fuel Injection system.
3. Easy starting.
Figure 7 Injection Pump
The engine can be started instantly only by keeping the
starter switch key in the ON position for about 6 seconds to
allow automatic feeding of current to the glow plugs,
eliminating the necessity of setting the key to the HEAT
position. (For engines with the automatic glow plug
system.)
The new governor mechanism also contributes to easy
engine start, because it increases fuel injection and delays
injection timing for easy engine start without necessity of
moving the throttle lever to the "full throttle" position.
4. Multipurpose engine.
The L series engine can be equipped with various kinds of
optional devices.
• Key off stop system (Fuel cutoff valve).
• Torque spring.
• Manual stop lever.
Figure 8 Injection Pump
Engine SP001524
Page 13
Performance Curves
L2 Series Performance Curves
Figure 9
Engine SP001524
Page 14
L3 Series Performance Curves
Figure 10
Engine SP001524
Page 15
Engine Specifications
Item
Model
L2A L2C L2E L3A L3C L3E
Engine Type 4-cycle, Water Cooled, Vertical, Diesel
Firing Order 1-2 1-3-2
Compression Ratio 23:1
General
Combustion Chamber Swirl Chamber
61 kg 75 kg
Dry Weight
(134 lb) (165 lb)
Number of Cylinders 2 3
(2.56 x 2.76 in)
(2.56 x 2.76 in)

(2.76 - 2.76 in)
(2.99 - 2.76 in)
(2.76 - 2.76 in)
(2.99 - 2.76 in)

65 x 70 mm
70 x 70 mm
76 x 70 mm
65 x 70 mm
70 x 70 mm
76 x 70 mm
Bore x Stroke
Cylinders
464 cc 538 cc 635 cc 696 cc 808 cc 952 cc

Total Displacement (28.32 (32.83 (38.75 (42.47 (49.31 (58.09
in3) in3) in3) in3) in3) in3)
Maximum Power
Performance Maximum Torque See the engine performance curves.
Specific Fuel Consumption
In every direction 30° in a short time
List Ability 25° continuous
(to lower limit of oil level) (within 30 min.)
Injection Pump Bosch NC type
Fuel System Nozzle Throttle type
Fuel JIS No. 2 or No. 3 Diesel Fuel
Lubricating Method Forced Lubrication
Oil Filtration Paper Element Filter (Full-flow Type)
3.0/1.5 liters
Lubrication (0.79 - 0.40 U.S. gal.)
Oil Capacity
System Upper Limit/Lower Limit 2.4/1.4 liters 3.6/1.8 liters
(Excluding 0.5 liters (0.13 (0.63/0.37 U.S. gal.) (0.95 - 0.48 U.S. gal.)
U.S. gal.) for oil filter)
or 4.8/3.0 liters
(1.3 - 0.79 U.S. gal.)
Cooling Method Forced water circulation with pressurized radiator.
Cooling System Coolant Capacity
1.20 liters 1.80 liters
(Except Radiator and
(0.32 U.S. gal.) (0.48 U.S. gal.)
Hose)
Alternator 12 V @ 15 A or 12 V @ 40 A
Accessories Starting Motor 12 V @ 1.2 kW or 12 V @ 0.6 kW
Battery 45 Ah or more 60 Ah or more
Engine SP001524
Page 16
Maintenance
Engine Oil and Oil Filter

1. Checking and correcting the engine oil level.
A. Place the engine horizontally.
B. Check the oil level with oil level dipstick. If the oil level
has fallen to the lower limit, add oil up to the upper
limit.
C. Check the oil level before (everyday) operation of the
engine.
Figure 11 Checking Oil Level

CAUTION
Whenever oil is added, check the oil level again after
waiting for about 1 minute.
When adding oil, use only the same engine oil used in
the engine.
When checking the oil level in an engine which has
been long out of use, run the engine for several
minutes, shut down engine, and check the oil level
after a while.
2. Oil change intervals.

A. Change oil after first 50 hours of operation (on new
engine) and every 100 hours operation thereafter.
B. Replace oil filter after first 50 hours of operation (on a
new engine) and every 200 hours of operation
thereafter.
3. Engine oil to be used.
A. Engine oil must conform to the API classification and
viscosity number specified in the following table.
Figure 12 Checking Oil Level
API Classification Atm. Temperature Viscosity

Above 20°C SAE 30
(68°F)
Class CC or Better
(Class CD for 3000 or higher speed specification engine.) 5° - 20°C SAE 20
(41° - 68°F)
Below 5°C SAE 10W30
(41°F)
All seasons SAE 10W30
Engine SP001524
Page 17
4. When replacing oil filter, use only original equipment filter.
5. Changing oil.
A. To change oil, first warm up engine and remove drain
plug to let oil completely drain.
B. Install drain plug and fill oil pan with fresh engine oil
through oil fill cap.
NOTE: Oil pan drain plug tightening torque: 5.0 -
6.0 kg•m (36 - 43 ft lb).
NOTE: For oil capacity (Upper limit/Lower limit) see
“Engine Specifications” on page 1-16. Figure 13 Oil Filter
6. Replacing oil filter.

A. Remove oil filter with a filter wrench or similar device.
B. Thoroughly clean filter mounting surface of filter
bracket. Install new filter with O-ring coated with
engine oil and tighten securely by hand.
NOTE: Tightening torque 1.0 - 1.3 kg•m (7 - 10 ft lb)
CAUTION
Figure 14 Oil Filter Wrench
Be careful not to twist O-ring.
C. Run engine for several minutes and make sure that

no oil leaks.
D. After stopping engine, check oil level. If necessary,
add oil.
Retightening Cylinder Head Bolts

1. When retightening cylinder head bolts, draw out coolant,
loosen bolts slightly, and then tighten bolts to specified
torque in numerical order shown in Figure 15.
NOTE: Tightening torque:
M10 bolt 7.5 - 8.5 kg•m (54 - 61 ft lb).
M8 bolt 2.0 - 3.0 kg•m (14 - 21 ft lb).
Figure 15 Cylinder Head Bolt Tightening

Sequence (L2)
Engine SP001524
Page 18
2. The rocker assembly (the rocker arms, shaft, and stays) is
to be kept removed when cylinder head bolts are
retightened.
NOTE: Rocker stay tightening torque: M8 bolt 1.5 - 2.2
kg•m (11 - 16 ft lb).
Figure 16 Cylinder Head Bolt Tightening

Sequence (L3)
Adjusting Valve Clearance
CAUTION
Be sure to retighten cylinder head bolts before
adjusting valve clearance.
1. Set cylinder to be adjusted to top dead center of

compression stroke.
NOTE: Valve clearance: 0.25 mm (0.0098 in) (cold) for Figure 17 Adjusting Valve Clearance
both intake and exhaust valves.
2. The top dead center of compression stroke can be
obtained by aligning TDC (Top Dead Center) mark (notch)
on crankshaft pulley with mark on gear case.
3. First align TDC mark for No. 1 cylinder.
NOTE: Confirm that valves do not move up and down
when crankshaft is turned about 20° in normal
direction of rotation and in reverse direction.
4. When setting top dead center for No. 2 cylinder and that for
No. 3 cylinder, perform as follows:
A. L2 (Two cylinder engine)
From TDC (Top Dead Center) for No. 1 cylinder, turn
crankshaft 180° clockwise, and No. 2 cylinder is set
to TDC.
B. L3 (Three cylinder engine)
From TDC for No. 1 cylinder, turn crankshaft 240°
clockwise to set No. 3 cylinder TDC. Further, turn
crankshaft 240° clockwise, and No. 2 cylinder is set
to TDC.
Figure 18 Timing Mark
Engine SP001524
Page 19
Adjusting Fan Belt Tension
1. Move alternator so that belt can be deflected about 10 mm
(0.39 in) deep when depressed by thumb force (about 10
kg (22 lb) at a point midway between the alternator pulley
and crankshaft pulley.
Figure 19 Adjusting Fan Belt Tension
Bleeding Air From the Fuel System

1. Loosen the air vent screw on the fuel filter.
2. For the engine without fuel pump, in which fuel drops
spontaneously and enters fuel filter, wait for fuel to
overflow fuel filter. Then, tighten air vent screw.
3. For engine with electromagnetic fuel pump, turn starter
switch key to "ON" position to feed fuel to fuel filter. Loosen
air vent screw on filter and, after air escapes, tighten air
vent screw.
Figure 20 Fuel Filter Air Bleeding
4. Loosen air vent screw on fuel injection pump to let air

escape from fuel pipe and fuel injection pump.
5. Air in injection pipes and nozzles is driven out
automatically by cranking engine.
Figure 21 Fuel Injection Pump Air Bleeding
Replacing Fuel Filter

1. Cartridge type.
Replace cartridge type filter as an assembly if
accumulation of dust or water in its element is evident.
Regular replacement intervals every 400 hours of engine
operation. Check filter every 100 hours and, if necessary,
replace early.
2. Separate type filter with.
Close filter drain valve, remove ring nut, and take out
element from inside of filter. Clean or replace element.
Figure 22 CARTRIDGE TYPE FILTER
Engine SP001524
Page 20
3. Fuel pump.
The following three types of fuel pumps are available.
Which type of pumps is to be used for an engine depends
upon engine specification.
Figure 23 Plunger Type (Common) Fuel

Pump
A. Plunger type electromagnetic pump.

The plunger type pumps are classified as common,
large sized pump having a filter or as compact,
lightweight, low priced pump without filter.
Despite classification, check plunger type pump for
normal function and make sure that it does not leak
fuel. Only on pump with filter, remove cover and
clean or replace filter.
Figure 24 Plunger Type (Compact) Fuel

Pump
B. Diaphragm type electromagnetic pump.

The diaphragm type electromagnetic pump should
not be disassembled. Like compact plunger type
pump mentioned above, check that pump functions
normally and does not leak fuel.
Figure 25 Diaphragm Type Fuel Pump
C. Mechanical type fuel pump.

This type of fuel pump is installed with an adapter on
the rear end side of the fuel injection pump camshaft.
As the camshaft rotates, the fuel pump cam pushes
the tappet to actuate the diaphragm of the fuel pump.
This type of fuel pump is provided with a priming
lever to allow manual feed of fuel.
Check fuel pump for normal function and make sure
that it does not leak fuel or make abnormal sound.
Figure 26 Mechanical Type Fuel Pump
Engine SP001524
Page 21
Pump Type Delivery Flow Shutoff Pressure
Plunger Type (Common) 0.9 l/min 0.35 kg/cm2
(0.2378 gpm) or more (4.98 psi)
Plunger Type (Compact) 0.4 l/min 0.35 kg/cm2
(0.1057 gpm) or more (4.98 psi) or more
Diaphragm 0.37 l/min 0.15 kg/cm2
(0.0977 gpm) or more (2.13 psi)
Mechanical Type 0.225 l/min 0.2 kg/cm2
(0.0594 gpm) or more (2.84 psi)
At 12 V (electromagnetic pumps only) and at 20°C (68°F)
4. Draining water from water separator.

For engine provided with a water separator, remove filter
ring nut involved and take out cup. Wipe off water and dust
accumulated in cup.
Checking and Adjusting Injection Timing

To check and adjust injection timing, use following procedure:
1. Disconnect No. 1 injection pipe.
2. Remove No. 1 delivery valve from injection pump. Put back
valve holder only.
CAUTION
Be sure to shut off fuel feed pipe before removing
Figure 27 Removing Delivery Valve
delivery valve.
3. Remove tie-rod cover and disconnect tie-rod from control

rack.
4. Set control rack to a midway position in working range.
5. Open fuel feed pipe and make sure that fuel flows from
delivery valve holder.
6. Turn crankshaft in direction of normal rotation (clockwise)
and find an instant that fuel stops flowing from delivery
valve holder. This instant is the real injection timing.
CAUTION
The standard injection timing differs with engine
specification and engine speed.
Check to see whether, real injection timing, coincides
with standard injection timing (whether IT mark on
crankshaft pulley is in alignment with mark on gear
case).
Figure 28 Mechanical Type Fuel Pump
Engine SP001524
Page 22
7. If they do not coincide with each other, adjust thickness of
injection pump mounting shim.
Increasing or decreasing shim thickness by 0.1 mm
(0.0039 in) causes real injection timing to vary about 1°.
Figure 29 ADjusting Shim Thickness
8. To remove injection pump, first disconnect injection pipes

and fuel feed pipe from injection pump. Then, remove
tie-rod cover and tie rod. Dismount pump assembly.
Installation of pump is reversal of removal.
9. In dusty conditions or when engine is dirty, removal of a
delivery valve may cause intrusion of dust into injection
pump. Under such circumstances leave delivery valve
installed and check injection timing using the following
procedure:
A. Remove tie-rod cover and disconnect tie rod from
control rack. Figure 30 Removing Injection Pump
B. Set control rack to a midway position in working
range. Disconnect injection pipe from No. 1 nozzle.
Turn crankshaft gradually in direction of rotation until
swelling of fuel is found at open end of injection pipe.
This instant is real injection timing, which will come
approximately 1° after standard injection timing.
Model
RPM
L2 L3
Up to 2000 BTDC 15° ¨
Over 2000 - Under 3800 BTDC 17° ¨
Over 3800 BTDC 19° ¨
Engine SP001524
Page 23
Adjusting Engine Speeds
To adjust engine speed, remove cooling fan and install safety
cover over fan to prevent getting hurt.
1. The upper limit of engine speed can be adjusted with
HIGH-SPEED stopper bolt.
This stopper bolt has been set properly and sealed at
factory before shipping engine. Never tamper with seal
unless it is necessary.
2. Lower limit of engine speed can be adjusted with
LOW-SPEED stopper bolt.
3. Never remove sealing cap unnecessarily to adjust torque
spring setting. For proper disassembly procedure see
“Torque Spring” on page 1-84.
CAUTION
BWarm up engine (until coolant temperature rises up
to 50°C (122°F) or above) before adjusting engine
Figure 31 High Speed And Low Speed Set
speeds.
Bolts
4. While running engine for speed adjustment, check engine
for exhaust gas leak, water leak, oil leak, and fuel leak.
5. After adjustment, perform engine acceleration and
deceleration test to confirm that engine is free from hunting
and smoking.
Checking and Adjustment of Nozzles

To check and adjust injection nozzles, use following procedure:
1. Injection start pressure.
A. Remove nozzle assembly to be tested from cylinder
head and set nozzle on nozzle tester.
Perform air bleeding by moving tester hart file up and
down.
B. Operate handle at a speed of 60 rpm or more and
read gauge pressure of fuel injected from nozzle.
Figure 32 Testing Injection Start Pressure
NOTE: Injection start pressure: 140+10
-0 kg/cm2 (1,990
+140
-0 psi).
C. If reading of gauge pressure is not within specified

range, disassemble nozzle and vary thickness of
adjusting shim.
Increasing or decreasing shim thickness by 0.1 mm
(0.0039 in) will cause injection pressure to vary about
10 kg/cm2 (142 psi).
Engine SP001524
Page 24
D. When installing nozzle, use following values of
tightening torque:
NOTE: Nozzle tightening (to cylinder head) torque:
5.0 - 6.0 kg•m (36 - 43 ft lb).
NOTE: Nozzle retaining nut tightening torque: 3.5 -
4.0 kg•m (25 - 29 ft lb).
NOTE: Nozzle union collar tightening torque: 2.5 -
3.0 kg•m (18 - 22 ft lb).
Figure 33 Installing Nozzle Assembly
2. Chattering test.
Operate tester handle at a speed of about 1 stroke per
second.
A. Needle valve oscillation.
It is considered normal if nozzle injects fuel mist,
making intermittent sounds, and oscillations of
needle valve are transmitted to handle.
Figure 34 Chattering Test
B. State of fuel mist injection.

The nozzle should inject mist straight in direction of
its axis. A nozzle is defective if it does not inject
steadily or it injects fuel in several separate stripes.
A nozzle is defective if it spills fuel accumulated on
bottom of nozzle after chattering test. However, a
very small drop of fuel remaining on tip of nozzle after
chattering test may be regarded as normal.
3. Injection test.
Operate tester handle at a speed of 4 - 6 strokes per
Figure 35 After Spilling
second.
NOTE: A nozzle should inject fuel mist uniformly in
shape of a cone.
4. Checking compression pressure.
A. Make sure the following conditions exist:
1) All of the engine oil level, air cleaner, starting
motor, and battery are well conditioned.
2) The engine is preferably warmed up (to a
coolant temperature of 50°C (122°F) or more).
B. Measure compression pressure using the following
procedure:
1) Pull stop lever to "noninjection" position.
Figure 36 Testing Compression Pressure
Engine SP001524
Page 25
2) Remove glow plug from cylinder to be tested.
Set compression gauge adapter to that cylinder
and install gauge.
3) Crank engine with starting motor until a stable
reading of compression gauge is obtained.
4) After reading gauge, remove compression
gauge and adapter. Put back glow plug.
5) Check all cylinders using procedure described
above.
NOTE: Engine Speed: 250 - 280 rpm
Compression Pressure: 29 - 32 kg/cm2 (412 -

455 psi)
Pressure Difference Between Cylinders: Within
3 kg/cm2 (42.7 psi)
Engine SP001524
Page 26
Troubleshooting
Using Trouble Diagnosis Chart

As for diesel engines, trouble symptoms and causes are often
so complicated that it will be difficult to locate root cause by
judging from a trouble symptom. For example, trouble symptoms
caused by faulty injection pump, faulty injection nozzles, and
improper cylinder compression, respectively, will be much the
same. To pass judgment on such a case, very close
examination of the existing trouble symptom is necessary.
The trouble/diagnosis charts on the succeeding pages are
prepared in such a way of beginning with the most possible or
easiest to inspect item and then proceeding step wise to less
possible or more complicated items.
Before troubleshooting you should have a right understanding of
the following features about the construction and fuel
combustion in the diesel engines.
• Normal engine operation is accompanied by
combustion noise (diesel knocking sounds).
• A heavy loaded engine exhausts some black smoke.
• When operated singly an engine may vibration
because of high cylinder compression and large
output torque.
• When an engine is accelerated of decelerated
quickly, some hunting may occur.
CAUTION
Do not attempt to readjust or disassemble injection pump
for purpose of troubleshooting, without use of a pump
tester which is indispensable to measure injection quantity
for each cylinder.
To check whether state of combustion in a desired cylinder
is normal or not, loosen injection pipe to cut fuel feed to
that cylinder, and find resulting slowdown of engine.
Compare degree of slowdown by that cylinder with that by
another cylinder.
Engine SP001524
Page 27
Hard Starting
1. Items to be checked before diagnosis.
• Clogged air cleaner.
• Coagulation of engine oil.
• Use of poor quality fuel.
• Lowering of cranking speed.
2. Diagnosis.
Does preheating No Does current flow in glow plug No Inspect key switch,
system operating circuit as soon as key switch is wiring, and glow
normally? turned to "H" (ON). indicator
yes yes Inspect glow plug.
Is electric wiring normal? (Does fuel pump, of provided, No Inspect fuel pump
operate when key switch is turned to ON?) and / or wiring.
yes
Does fuel flow in fuel No Does fuel get out when fuel injection No Inspect fuel filter,
line? pump air vent screw is loosened? fuel pipe,
and fuel tank.
yes
Is engine put in order? No

Adjust engine properly.
(Injection timing and valve timing)
yes
Do injection nozzles operate normally? No

Inspect injection nozzles.
(State of fuel mist injection and injection start pressure)
yes
No Inspect valves,
Is cylinder compression normal? pistons, piston rings,
and cylinder head gasket.
Inspect injection pump.

AKS2560L
Figure 37
Engine SP001524
Page 28
Knocking
Diesel engines are usually accompanied by fuel combustion
noise (diesel knocking sounds) because of structural feature.
A problem should be suspected only when engine makes
abnormally loud sounds.
• Clogged air cleaner.
• Use of poor quality fuel (Small cetane number fuel
such as used for burning).
2. Diagnosis.
Is injection timing normal? No

(Ckeck for permature injection.) Adjust injection timing
yes
Do injection nozzles operate normally?

(Check for lowring of injection start pressure No Inspect injection nozzles.
and improper state of fuel mist injection.)
yes
No Inspect valves, pistons, piston rings,

Is cylinder compression normal?
and cylinder head gasket.
yes
Does injection pump operate normally?

(Check for uniformity of injection quantity.)
yes
Mechanical noise (Worn or damaged main moving parts)

AKS2570L
Figure 38
Engine SP001524
Page 29
Overheating
• Shortage of coolant and leakage.
• Clogged muffler.
• Loosening of fan belt.
• Shortage of engine oil and deterioration.
• Clogged radiator fins.
• Stagnation of cooling air.
• Too rich antifreeze solution.
• Defective thermostat.
2. Diagnosis.
Is engine operating condition moderate? No

(Check for overload continuous running.) Find the cause of overload.
yes
Is cooling system in good order?

(Check cylinder head gasket for blowing through, No
Repair cooling system.
water pump, water hose, and radiator fins for clogging,
and thermostat for malfunctining.)
yes
No Adjust injection timing.

Is injection timing is normal?
AKS2580L
Figure 39
NOTE: Overheating is mostly caused by mismatching a

load and an engine. If overheating arises only
when the engine drives a load, measure coolant
temperature under the working load condition
(full open thermostat) to see whether the
measurement exceeds a point 60°C higher than
atmospheric temperature. If so, it is advised to
check for mismatching of load, too.
Engine SP001524
Page 30
Black Smoky Exhaust
• Clogged air cleaner filter.
• Overload.
2. Diagnosis.
Is smoke set of injection pump is normal? No Adjust smoke set.
yes
Is engine put in order? No

(Check for excessive valve clearance and improper Adjust engine.
injection timing.)
yes
Do injection nozzle operate normally?

(Check for improper state of fuel mist injection and for No
Inspect injection nozzle.
excessively large injection start pressure.)
yes
No Inspect valves, cylinder head gasket,

Is cylinder compression normal?
piston, and piston rings.
yes

AKS2590L
Figure 40
Engine SP001524
Page 31
Unsteady Idling
• Faulty engine control system.
• Too high engine oil viscosity.
2. Diagnosis.
No
Is engine adjusted properly?
Adjust engine.
(Check for idling speed, valve clearance,
and injection timing.)
yes

(Check for state of fuel mist injection and injection start Inspect injection nozzle.
pressure.)
yes
Is cylinder compression normal? No Inspect valves, pistons,

(Check equality between cylinders.) and piston rings.
yes
Inspect injection pump

and governor system.
AKS2600L
Figure 41
Engine SP001524
Page 32
Low Output
• Seizing of engine moving parts.
• Clogged air cleaner filter.
• Too viscous engine oil.
• Clogged muffler.
• Malfunctioning of drive system.
2. Diagnosis.
Is sufficient fuel flow (Engine without fuel pump) is

in fuel line? spontaneous dropping of fuel No Inspect fuel filter,
normal? (engine with electromagnetic fuel pipe,
fuel pump) Does fuel pump feel and fuel tank.
fuel with key switch placed in ON?
yes
yes Inspect fuel pump.
Is engine adjusted properly? No

Adjust engine.
(Check for valve clearance and injection timing,.)
yes

Inspect injection nozzle.
(Check for state of fuel mist injection and injection start
pressure.)
yes
No Inspect valves, cylinder head gasket,

Is cylinder compression normal? piston, and piston rings.
yes

AKS2610L
Figure 42
Engine SP001524
Page 33
ENGINE
Special Tools
Use Tool Name Sketch Referential Page
Removal and installation Piston pin setting tool
of piston pin
ST332400
Measurement of cylinder Compression gauge

compression adapter
ST332270
Removal and installation Oil pressure switch

of oil pressure switch socket wrench (26)
MD998054
Repair of valve seat Valve seat cutter pilot
Valve seat cutter, 45°
Engine SP001524
Page 34
Rocker Arms and Rocker Shaft
Construction
Figure 43 Rocker System Component Parts
Reference Reference
Number Number
1 Oil Fill Cap 6 Rocker Spring
2 Breather Hose 7 Adjustment Screw
3 Rocker Cover 8 Rocker Arm
4 Rocker Cover Gasket 9 Rocker Stay
5 Rocker Shaft
Engine SP001524
Page 35
Removal and Installation
CAUTION
Be careful not to confuse proper direction of installation of
rocker shaft.
After installing rocker shaft, adjust valve clearance.
Figure 44 Installing Rocket Shaft and

Rocket Cover
Inspection
If any parts are found defective, replace them.
Figure 45 Inspecting Rocker Shaft and

Rocker Arms
Engine SP001524
Page 36
Cylinder Head
Construction
Figure 46 Cylinder Head Component Parts
Reference Reference
Number Number
1 Cylinder Head 6 Water Outlet Fitting
2 Valve Guide 7 Cylinder Head Gasket
3 Cylinder Head Bolt (Main Bolt) 8 Mouth Piece
4 Cylinder Head Bolt (Sub-bolt) 9 Thermostat
5 Seat Ring (3600 Rpm 10 Thermostat Fitting
Specification Engine)
Engine SP001524
Page 37
Removal
1. Remove injection pipe assembly.
CAUTION
When disconnection each injection pipe from injection
pump side delivery valve holder, grasp holder with a
wrench to prevent it from loosening.
After removing pipe assembly. Plug nozzle holders
and delivery valve holder to prevent intrusion of dust. Figure 47 Sequence For Loosening Cylinder
Head Bolts (L2)
2. Disconnect glow plug lead wire.

3. Loosen alternator bracket bolts and dismount alternator.
4. Disconnect air breather hose.
5. Remove rocker shaft assembly.
6. Remove rocker cover.
7. Loosen cylinder head mounting bolts in numerical order
(Figure 48) and remove cylinder head assembly (including
intake and exhaust manifold).
Figure 48 Sequence For Loosening Cylinder

Head Bolts (L3)
8. Remove cylinder head gasket. Clean cylinder head and

cylinder block surface from which gasket had been
removed.
9. Remove nozzle holder assemblies and glow plugs from
cylinder head.
10. Remove intake manifold and exhaust manifold from
cylinder head.
11. Remove valve retainers, valve spring, and valves from
cylinder head.
Figure 49 Removing Valves

CAUTION
When removing each valve retainer, depress retainer
against valve spring and remove retainer lock.
Identify each valve by putting a mark indication
number of cylinder from which valve is removed.
12. Remove valve stem seals.
Engine SP001524
Page 38
Inspection and Repair
Figure 50 Inspection of Cylinder Head
Replacement of Valve Guide

If a valve guide is found defective, replace it.
1. Removal.
Press guide at its upper end and pull it out of valve seat
side.
2. Installation (Press fitting).
Press fit guide from upper side of cylinder head to a height
of 14 ±0.5 mm (0.5512 ±0.0197 in) from valve spring seat
face.
Figure 51 Press Fitting Valve Guide
Engine SP001524
Page 39
Repair of Valve Seat
If a valve seat is found defective, reface it or replace cylinder
head.
Sinkage of Valve
Standard Service Limit
0.5 mm 1.5 mm
(0.0197 in) (0.0591 in)
Figure 52 Checking Valve Sinkage
CAUTION
When checking valve sinkage, valve guide must be in
normal condition.
Resurface valve seat so that it contacts middle portion of
valve face.
Installation
Installation of cylinder head is in reverse order of removal. Pay
attention to the following:
1. Replace cylinder head gasket. No application of sealant is
necessary. Marked on upper front of gasket, is engine
model number that gasket is applicable for. Be careful not
to confuse gasket with one for another model of engine.
2. Tighten cylinder head bolts in numerical order shown in
Figure 54 and Figure 55. Go through sequence order two
or three times. Tighten each bolt a little at a time until all
are tightened to specified torque. Figure 54 Sequence For Tightening Cylinder
Head Bolts (L2)
3. When connecting injection pipe assembly, loosen pipe

clamp.
NOTE: When tightening nut at each end of pipe, grip
nozzle holder or delivery valve holder with a
wrench to prevent it from being turned together
with nut.
NOTE: Also, take care not to allow dust to enter fuel
line.
Figure 55 Sequence For Tightening Cylinder

Head Bolts (L3)
Engine SP001524
Page 40
Valve and Valve Spring
Construction
Figure 56 Valve System Component Parts
Reference Reference
Number Number
1 Valve Stem Cap 4 Valve Stem Seal
2 Retainer Lock 5 Valve Spring
3 Valve Spring Retainer 6 Valve
Engine SP001524
Page 41
Removal
1. Dismount cylinder head assembly.
2. Depress valve retainer (to compress valve spring) and
remove retainer lock.
3. Remove valve.
Figure 57 Removing Valve and Valve

Spring
Inspection and Repair

If any parts are found defective, repair or replace them.
Figure 58 Inspection Of Valve and Valve

Spring
Valve Fatigue and Damage

Inspection Service
Standard
Item Limit
Free length 40.5 mm -1.0 mm
(1.5945 in) (-0.0394 in)
Load 5.94/35.5 -15%
kg/mm
(13.1 - 78.3
lb/0.0394 in)
Squareness 2" 3"
Margin 1.0 mm 0.5 mm Figure 59 Press Fitting Valve Guide
(0.0394 in) (0.0197 in)
Engine SP001524
Page 42
1. Repair of valve face.
If valve face is found worn down, resurface with a valve
refacer. If margin of resurfaced valve exceeds service limit,
replace valve.
2. Repair of valve stem end.
If valve stem end has been indented by wear, flatten with
an oil stone.
Figure 60 Inspecting Valve
Installation
1. Install valves and valves spring, referring to notes shown in
Figure 61.
2. Mount cylinder head assembly.
3. Adjust valve clearances.
Figure 61 Installation of Valve Spring
CAUTION
Be careful not to damage spring and stem seal by
excessively compressing spring when installing valve
spring.
Engine SP001524
Page 43
Intake Manifold and Exhaust Manifold
Construction
Figure 62 Manifold Component Parts
Reference Reference
Number Number
1 Intake Pipe 4 Intake Manifold Gasket
2 Intake Cover 5 Exhaust Manifold Gasket
3 Exhaust Manifold
Engine SP001524
Page 44
Inspection
Check following Item. If any defect is found, repair or replace
manifold.
1. Check mounting surfaces to cylinder head for flatness.
Surfaces must be flat within 0.150 mm (0.0059 in).
2. Check manifolds for corrosion, damage and cracks.
CAUTION
Check interior of intake manifold for dust and dirt. If
any dust is found, check air cleaner and intake pipe
connections for proper sealing.
Engine SP001524
Page 45
Gear Case and Oil Pump
Construction
Figure 63 Common To L2 And L3
Reference Reference
Number Number
1 Bushings 8 Oil Pump Outer Gear
2 Plug 9 Oil Pump Housing
3 Gear Case 10 Gear Case Gasket
4 Front Oil Seal 11 High-pressure Pump Gear
5 Relief Plunger Housing
6 Relief Spring 12 Housing Gasket
7 Oil Pump Inner Gear
Engine SP001524
Page 46
Removal
1. Remove crankshaft pulley.
2. Remove fan and fan belt.
3. Remove tie-rod cover from side face of injection pump.
4. Remove tie rod and tie rod and tie-rod spring. Be careful
not to let spring fall into case.
5. Remove governor cover assembly.
6. Remove water pump assembly.
7. Remove alternator.
8. Remove pump housing.
9. Remove gear case assembly.
Inspection
1. Check removed parts. If any parts are found defective,
repair or replace them.
Figure 64 Inspection Of Gear Case And Oil Pump
Engine SP001524
Page 47
Oil Pump Performance
Speed, rpm
Oil Pump Performance
1000 3000
2
Pressure 1.50 kg/cm 2.0 kg/cm2
(21.3 psi) (28.4 psi)
Discharge 3 liters 17 liters
Flow Rate (0.79 U.S. gal.) or (4.5 U.S. gal.) or more
more
3.0 kg/cm2 --------
Cracking Pressure
(42.7 psi)
Relief Valve
-------- 5.0 kg/cm2
Closing Pressure
(71.1 psi) or below
* Oil used: SEA 30, 100° ±5°C (212° ±41°F)
Replacement of Front Oil Seal

1. Remove front oil seal.
2. Press fit new front oil seal.
CAUTION
Apply thin coat of engine oil to circumference and lip
of oil seal.
Replacement of Governor Shaft Bushing

1. Remove expansion plug and draw bushings out.
2. Press fit new bushings into positions shown in Figure 65.
Figure 65 Press Fitting Governor Shaft

Bushing
Engine SP001524
Page 48
Inspection of Governor System
1. Check governor system parts. If you parts are found
defective, repair or replace them.
Figure 66 Check Weight For Wear and

Damage
Disassembly and Reassembly of Governor Levers

1. Removal of shaft.
A. Remove expansion plug, taking care not to scratch
gear case.
B. Pull out grooved pin.
2. Installation of shaft.
A. Install shaft in reverse order of removal.
B. After installing shaft, press fit expansion plug into
shaft hole in gear case. Figure 67 Installing Governor Shaft
Engine SP001524
Page 49
Installation of Gear Case Assembly
Figure 68 Gear Case Assembly
Figure 69 Installing Gear Case Assembly
Engine SP001524
Page 50
Timing Gears
Construction
Figure 70 Timing Gear Component Parts
Reference Reference
Number Number
1 Crankshaft Gear 3 Camshaft Gear
2 Idle Gear 4 Injection Pump Camshaft Gear
Engine SP001524
Page 51
Removal
1. Pry retaining ring out and remove idle gear.
Figure 71 Removing Delivery Valve
2. Remove valve camshaft and injection pump camshaft on

which the respective gears are press fitted. Remove gears
from shafts.
3. Remove crankshaft. Remove gear from crankshaft.
Figure 72 Removing Camshaft Gear
Inspection
Check removed gears. If any gear is found defective, replace it.
Idle Gear Bushing

Description Standard Value Service Limit
Clearance between 0.03 - 0.07 mm
0.20 mm
bushing and shaft. (0.0012 -
(0.0079 in)
0.0028 in)
Backlash Between Gears in Mesh

Standard Service
Description
Value Limit
Crankshaft - Idle 0.01 - 0.14 mm
0.30 mm
Idle - Camshaft (0.0004 -
(0.0118 in)
Idle - Fuel Pump Gear 0.0055 in)
Figure 73 Inspecting Timing Gears
Engine SP001524
Page 52
Installation of Timing Gears
1. Press fit crankshaft gear onto shaft.
2. Press fit valve camshaft gear and injection pump camshaft
gear onto respective shafts.
3. Install gears in following sequence.
A. Turn crankshaft to set No. 1 cylinder to top dead
center on compression stroke.
B. Install valve camshaft and injection pump camshaft.
C. Install idle gear so that timing marks on it are in
Figure 74 Timing Gears In Alignment With
alignment with marks on other gears.
Each Other
D. Confirm that timing gears are in alignment with each
other.
Engine SP001524
Page 53
Camshafts (Valve and Pump)
Construction
Figure 75 Camshaft Component Parts
Reference Reference
Number Number
1 Camshaft (Valve) 8 Tappet
2 Camshaft Gear 9 Push Rod
3 Ball Bearing 10 Camshaft (Injection Pump)
4 Woodruff Key 11 Camshaft Gear
5 Sunk Key 12 Ball Bearing (Rear)
6 Camshaft Stopper 13 Retaining Ring
7 Bolt
Engine SP001524
Page 54
Removal of Valves Camshaft
1. When it is necessary to remove only valve camshaft, use
following procedure:
A. Dismount cylinder head assembly.
B. Pull out push rods.
C. Pull out tappets.
D. Remove gear case assembly.
E. Remove camshaft stopper bolt.
F. Draw camshaft assembly out.
2. Removal of injection pump camshaft.
A. Disconnect injection pipes.
B. Remove injection pump assembly.
C. Remove rear case assembly.
D. Remove shaft rear cover.
E. Remove stopper bolt.
F. Pull out shaft to front side.
Figure 76 Removing Injection Pump

Camshaft
Engine SP001524
Page 55
Inspection
If any parts are found defective, repair or replace them.
Figure 77 Inspection of Camshafts
Major Diameter of Injection Pump Cam Major Diameter of Injection Pump Cam
30.0 mm 27.370 mm
Standard Valve Standard Valve
(1.1811 in) (1.0776 in)
-0.70 mm -1.0 mm
Service Limit Service Limit
(-0.0276 in) (-0.0394 in)
Engine SP001524
Page 56
Installation
When installing camshafts, pay attention to the following:
1. Coat bearing and cam lobes with oil.
2. Install camshafts in reverse order of removal.
3. Position timing marks on gears in alignment with marks on
idler gear. See “Timing Gears” on page -51.
4. After installation, check and adjust fuel injection timing and
valve clearances.
Figure 78 Installing Valve Camshaft
Engine SP001524
Page 57
Piston and Connecting Rod
Construction
Figure 79 Piston And Connecting Rod Component Parts
Reference Reference
Number Number
1 Piston Ring No. 1 6 Connecting Rod
2 Piston Ring No. 2 7 Connection Rod Bearing
3 Oil Ring 8 Connecting Rod Cap
4 Piston 9 Connecting Rod Bolt
5 Piston Pin 10 Connecting Rod Nut
Engine SP001524
Page 58
Removal
1. Remove cylinder head assembly.
2. Remove oil pan.
3. Remove oil screen.
4. Chalk cylinder number on side face of big end of each end
of each connecting rod to prevent confusion of connecting
rods.
Figure 80 Removing Connecting Rod and

Piston
5. Remove connecting rod cap from each piston and -rod

assembly, and draw assembly upward from cylinder.
Take care not to allow connecting rod to scratch crankshaft
pin and cylinder.
Keep removed parts (Connecting rod, rod cap, piston, etc.)
classified by cylinders.
6. Remove rings from each piston with piston ring pliers.
7. Using piston setting, pull out piston pin from each piston.
Engine SP001524
Page 59
Inspection
Inspect removed parts. If any parts are found defective, replace
or repair them.
Figure 82 Inspection of Piston and Connecting Rod
1. Inspection of piston ring gaps.

Put each piston ring into cylinder bore and push ring with
piston to position ring in square with cylinder wall. Measure
ring gap with a feeler gauge.
If measurement exceeds service limit, replace piston ring.
• Measuring Ring Gap
Ring Standard Service

Limit
All Rings 0.15 - 0.40 mm 1.50 mm
(0.0059 - 0.0157 in) (0.0591 in) Figure 83 Measuring Ring Gap
CAUTION
When only replacement of rings is to be made, without
reboring (honing) of cylinder, position ring to be
measured at least worn place of cylinder skirt.
When replacing rings, install new rings having same
size as piston.
Piston rings available for servicing are sized into three
classes: STD, 0.25 mm OS, and 0.50 mm OS (0.0098 in
OS and 0.0197 in OS).
Engine SP001524
Page 60
2. Inspection of ring groove in piston.
Measure side clearance for each piston ring set in ring
groove in piston. If service limit is exceeded, replace ring
with new one.
If clearance still exceeds service limit, replace piston with
new one.
• Measuring Ring Side Clearance.
Service
Ring Standard
Limit
- 0.30 mm Figure 84 Measuring Ring Side Clearance
No. 1
(0.0118 in)
0.05 - 0.09 mm 0.20 mm
No. 2
(0.0020 - 0.0035 in) (0.0079 in)
0.03 - 0.07 mm 0.20 mm
Oil
(0.0012 - 0.0028 in) (0.0079 in)
NOTE: No. 1 ring is a semikeystone type.
Installation
When reassembling piston and connection rod, and installing
piston and rod assemblies in cylinder block, pay attention to the
following:
Figure 85 Installation of Piston and Connec

-tion Rod
1. Reassembling piston and connection rod. Using the Piston

Pin Setting Tool, press piston pin into set position.
Description Standard
Pin press fitting force 1000 ±500 kg
(at a normal temperature) (2,200 ±1,100 lb)
Engine SP001524
Page 61
Figure 86 Pressing In Piston Pin
2. Installation of piston rings.
Figure 87 Installation of Piston Rings and Connecting Rod Cap
Engine SP001524
Page 62
3. Set piston ring gaps to proper positions as shown in Figure
88, at ring. Coat rings and cylinder wall with oil.
4. Using a piston ring compressor to compress rings into
grooves, push piston and rod assembly down into cylinder.
Be careful not to break rings by excessively knocking head
of piston. Note that front marks on piston and connection
rod are toward front of engine.
Figure 88 Proper Arrangement of Ring Gaps
5. Coat bearing surface of connection rod caps with engine

oil. Fit each cap to connecting rod using match marks put
before removal as a guide. In case of a new rod, which
does not have such a match mark, position notches
(provided for preventing bearing from rotating) on same
side.
Figure 89 Fitting Cap to Connection Rod
Engine SP001524
Page 63
Crankshaft
Construction
Figure 90 Crankshaft Component Parts
Reference Reference
Number Number
1 Key 8 Flywheel
2 Crankshaft 9 Ring Gear
3 Crankshaft Gear 10 Rear Oil Seal
4 Crankshaft Pulley 11 Rear Oil Seal Case
5 Nut 12 Gasket
6 Washer 13 Flywheel Bolt
7 Spring Washer
Engine SP001524
Page 64
Removal
1. Loosen flywheel bolts and remove flywheel.
2. Loosen crankshaft pulley nut and remove pulley.
3. Remove rear oil seal case assembly.
4. Remove main bearing caps. Keep each set of bearing
removed together with its bearing cap.
5. Take out crankshaft.
Figure 91 Removing Main Bearing Cap
Inspection
Inspect removed parts. If any parts are found defective, repair or
replace them.
Figure 92 Inspection of Crankshaft and Flywheel
Engine SP001524
Page 65
1. Checking crankshaft for wear.
To check crankpins and main journals for tapering wear
and out of round wear, diameter of each crankpin or main
journal should be measured at two places along crankpin
or, main journal, into direction "A" and "B" each place, as
shown in Figure 93. If necessary, regrind crankpins and
main journals to next under size. If any crankpin or main
journal has been worn out beyond service limit, replace
crankshaft.
Figure 93 Checking Crankshaft for Wear
Diameter of Crankpin and Main Journal Under size (US) Diameters

Description Standard Service Limit Description Main Journal Crankpin
42.715 - 39.715 -
Main Journal 43.0 mm -0.70 mm 0.25 mm US 42.730 mm 39.730 mm
Dia. (1.6929 in) (-0.0276 in) (0.0098 in US) (1.6817 - (1.5636 -
1.6823 in) 1.5642 in)
42.465 - 39.465 -
40.0 mm -0.70 mm 0.50 mm US 42.480 mm 39.480 mm
Crankpin Dia.
(1.5748 in) (-0.0276 in) (0.0197 in US) (1.6719 - (1.5537 -
1.6724 in) 1.5543 in)
2. Inspection of crankshaft oil clearance.

Oil clearance is calculated by subtracting diameter of main
journal or crankpin from inside diameter of main bearing or
rod bearing. To check main bearing and rod rearing for
tapering wear and out of round wear, inside diameter of
each main bearing or rod bearing should be measured,
after its bearing cap is fastened to specified torque, at two
places along bearing, in two direction "A" and "B" each
place, as shown in Figure 99. If necessary, replace worn
bearing with new one.
If oil clearance still exceeds service limit, regrind
Figure 94 Measuring Main Bearing I.d.
crankshaft to next under size and replace bearing with one
of a corresponding under size.
CAUTION
A crankshaft which has been sized cannot be
reground to any under size.
Tightening Torque Oil Clearance

Description Standard Description Service Limit
5.0 - 5.5 kg•m 0.10 mm
Main Bearing Cap Bolt Main Bearing
(36 - 40 ft lb) (0.0039 in)
3.2 - 3.5 kg•m 0.15 mm
Rod Bearing Cap Nut Rod Bearing
(23 - 25 ft lb) (0.0059 in)
Engine SP001524
Page 66
Replacement of Crankshaft Rear Oil Seal
1. Pry oil seal out with a screwdriver.
2. Drive in a new oil seal to oil seal case.
Installation
When installing crankshaft, pay attention to notes given in
Figure 95.
Figure 95 Installing of Crankshaft
Engine SP001524
Page 67
Cylinder Block
Construction
Figure 96 Cylinder Block Component Parts
Reference Reference
Number Number
1 Cylinder Block 7 Rear Oil Seal
2 Front Plate 8 Oil Seal Case
3 Bearing Cap 9 Idler Gear Shaft
4 Cover 10 Oil Filter Shaft
5 Main Bearing 11 Oil Level Dipstick Guide
6 Starter Bracket
Engine SP001524
Page 68
Inspection
Inspect cylinder block. If it is found defective, repair or replace
block.
Cylinder Bore (mm)

Model Standard Service
Limit
L2A, L3A 65 +0.03 mm +0.20 mm
-0
+0.0012 (+0.0079 in
(2.5591 -0 in)
)
L2C, L3C 70 +0.03 mm +0.20 mm
-0 Figure 97 Measuring Cylinder Bore
(+0.0079 in
(2.7559 +0.0012
-0 in)
)
L2E, L3E +0.03
76-0 mm +0.20 mm
(+0.0079 in
(2.9921 +0.0012
-0 in)
)
Figure 98 Cylinder Bore Measuring Positions
Reboring of Cylinder
When reboring a cylinder, use following procedure:
1. Selecting a piston
Piston service size
0.25 mm OS or 0.50 mm OS
(0.0098 in OS or 0.0197 in OS)
2. Measure piston diameter.
3. Reboring finish dimension = [Piston OD] + [Clearance} -
[Honing allowance (0.020 mm (0.0008 in)]
NOTE: Clearance (between piston and cylinder) Figure 99 Measuring Piston Diameter
Standard: 0.71 - 0.84 mm (0.0280 - 0.0331 in)
(A - D)
CAUTION
When it is necessary for a cylinder to be rebored to
next over size, the remainders must also be rebored to
same over size.
Engine SP001524
Page 69
LUBRICATING SYSTEM
General
Specification
Description Specification
Lubricating system and filtering system Pressurized lubricating, full-flow filtering
Oil capacity (Upper limit/lower limit):
L2 : 2.4 / 1.4 l L3 : 3.0 / 1.5 l or 3.6 l / 1.8 l, 4.8 l/3.0 l
excluding 0.6 for oil filter
Gear type (Inner and outer gears in mesh) enclosed in
Type
Oil pump gear
Driving method Direct drive by crankshaft
Relief valve opening pressure 3.0 ±0.3 kg/cm2 @ 1000 rpm

(42.7 ±4.3 psi @ 1000 rpm)
Oil pressure switch closing pressure 0.5 ±0.1 kg/cm2

(7.1 ±1.4 psi)
Type Paper element cartridge type
Oil filter 1.0 ±0.2 kg/cm2
Relief valve opening pressure
(14.2 ±2.8 psi)
NOTE: For oil pump, which is enclosed in gear case.
Special Tools
Use Tool Name

Removal and installation oil pressure switch. Oil pressure switch wrench MD998054
Engine SP001524
Page 70
Oil Filter and Oil Pressure Switch
Construction
Reference
Description
Number
1 Oil Filter
2 Oil Pressure Switch
Figure 100 Oil Filter and Pressure

1. Coat O-ring with engine oil.
NOTE: Take care not to twist O-rings.
2. Coat threads with sealant (HERMESEAL HI or Three Bond
1314).
NOTE: Tightening torque 1.1 - 1.3 kg•m (8 - 9 ft lb) (Do
not use any wrench.).
Figure 101 Installing Pressure Switch
CAUTION
After installation, check for oil leak while engine is
running.
Figure 102 Installing Pressure Switch
Inspection
1. Inspect following:
A. Oil leak.
NOTE: Pressure switch ON pressure: 0.5 ±0.1 kg/cm2

(3.62 ±0.72 ft lb).
CAUTION
Check oil filter for dirtiness. If necessary, clean engine Figure 103 Inspecting Oil Filter and Switch
interior with flushing oil.
Engine SP001524
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FUEL SYSTEM
General
Inspection
Specification
Description
L2 L3
Type In-line type (Bosch NC)
Direction of rotation Clockwise (as viewed from driving side)
Injection order 1-1 1-3-2
Injection
Plunger diameter 6∅
Pump
Number of plungers 2 3
MS retard 4° (for crank)
Delivery valve Silt or Bosch
Type Thread Type
Type Throttle Type
Injection Nozzle
Number of jet See “Alternator and Dynamo” on page -108.
Nozzle
140 +10
0 kg/cm2
Injection Pressure
(1,990 +142
-0 psi)
Type Electromagnetic diaphragm type
Delivery 0.37 l/min (0.10 gpm) (12 V, at 20°C (68°F))
Type Electromagnetic plunger type
Fuel Pump
Delivery: Common type 0.9 l/min (0.24 U.S. gal.) (12 V, at 20°C (68°F))
(Optional)
Compact type 0.4 l/min (0.11 U.S. gal.) (12 V, at 20°C (68°F))
Type Mechanical drive type
Delivery 0.225 l/min (0.059 U.S. gal.)
Type Solenoid pull hold type
Rated current pull 55 A
hold 1.0 A
Fuel Cutoff Working voltage 12 V, DC
Valve Stroke 13.50 mm (0.5315 in)
Type Solenoid push out type
Coil Resistance 1.6 Ω ±10% (at 20°C (68°F))
Stroke 10.0 mm (0.3937 in)
Fuel Filter Paper Element Type
Engine SP001524
Page 72
Component Parts
Figure 104 Fuel System Component Parts
Reference Reference
Number Number
1 Injection Pump 5 Return Pipe
2 Adjustment Shim 6 Fuel Filter
3 Injection Pipe 7 Fuel Cutoff Solenoid
4 Injection Nozzle
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Page 73
Fuel Injection Pump
Construction
Figure 105 Injection Pump Component Parts
Reference Reference
Number Number
1 Union Collar 12 Plunger Barrel
2 Air Vent Screw Air Vent Screw 13 Sleeve
3 Delivery Valve Holder 14 Upper Seat
4 Valve Spring 15 Plunger Spring
5 Holder Stopper 16 Lower Sear
6 Housing 17 Adjusting Shim
7 O-ring 18 Tappet Roller
8 Delivery Valve 19 Pin
9 Gasket 20 Control Rack
10 Seat Valve 21 Stop Wire Bracket
11 Plunger Barrel
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Inspecting Injection Pump While It Is Mounted On Engine
Never attempt to disassemble pump unless it is necessary.
If pump is assumed defective, it is recommended to replace
pump assembly.
Inspection Inspection Procedure Criteria

Idling speed. Measure engine speed 900 rpm
Exhaust smoke color. 1) Quickly accelerate. No noticeable black Smoke
exhaust permitted.
Engine without load.
2) Apply load to engine.
Fuel cutoff solenoid. Turn starter switch on OFF from ON. A solenoid acting sound.
Removal
1. Disconnect fuel injection pipes.
2. Remove tie-rod clip cover.
3. Remove tie-rod clip and tie-rod.
4. Remove injection pump assembly.
Figure 106 Removing Injection Pump
Disassembly
1. Remove stopper plate.
2. Unscrew delivery holder. Take out delivery valve and valve
spring.
3. Remove tappet roller and stopper pin.
4. Remove tappet, plunger spring, etc.
CAUTION
When replacing plunger barrel, delivery valve, etc., do
not loosen adjusting screw and plate for each cylinder.
When those parts have been replaced, it is necessary
to measure fuel injection quantity by using a pump
tester and cam box.
All parts removed from pump should be kept classified
by cylinders and immersed in clean fuel.
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Inspection
Figure 107 Inspection of Injection Pump
Assembly
1. Insert plunger barrel into housing.
2. Install delivery valve and valve spring.
NOTE: Temporarily tighten holder.
3. Insert control rack.
4. Insert control pinion. Align match mark on rack with that on
pinion.
5. Install spring upper seat.
6. Insert plunger spring. Figure 108 Direction of Installation of
Plunger
7. Fit lower seat to plunger. Insert plunger into barrel side.
8. Depress tappet roller assembly and install stopper pin.
9. Tighten delivery holder
NOTE: Tightening torque 3.5 - 3.9 kg•m (25 - 28 ft lb).
Engine SP001524
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Installation
Install injection pump assembly in reverse order of removal.
CAUTION
When installing plunger barrel, engage dowel pin on
housing side with groove in barrel.
Position plunger so that part number stamp on its flange
faces direction opposite to rack side. (Engage feed hole
with plunger lead.)
After installation, check for proper injection timing.
Engine SP001524
Page 77
Injection Nozzle
Construction
Figure 109 Nozzle Holder Assembly Component Parts
Reference Reference
Number Number
1 Body Subassembly 5 Distance Piece
2 Shim Washer 6 Nozzle Assembly
3 Pressure Spring 7 Retaining Nut
4 Pin
Engine SP001524
Page 78
Removal
1. Disconnect injection pipe and fuel return pipe.
2. Remove injection nozzle assembly from cylinder head.
CAUTION
Attach an identification number tag to removed
injection nozzle.
Plug openings, from which pipes are disconnected
and nozzle is removed, to prevent intrusion of dust,
water, and other foreign particles into pipes and
combustion chamber.
Disassembly
If removed nozzle assembly is assumed defective, disassembly
assembly and repair or replace faulty parts.
1. Grip nozzle holder body in a vise. Loosen retaining nut. To
prevent deformation, never tightly grip retaining nut.
2. Take out shim washer, pressure spring, distance piece,
and nozzle assembly.
CAUTION
Scrape off carbon deposits with a wooden spatula.
Keep removed parts immersed in washing oil
(kerosene). Take special care not to scratch needle
valve in nozzle assembly.
Engine SP001524
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Inspection
Inspect removed parts. If any part is found defective, replace it.
Assembly
1. Insert nozzle assembly into retaining nut so that nozzle is
perfectly seated in nut.
2. Place distance piece, retaining pin, pressure spring, and
shim washer on nozzle assembly.
3. Tighten nozzle holder body fully by hand.
4. Grip nozzle holder in a vise. Tighten retaining nut to
specified torque.
NOTE: Tightening torque: 3.5 - 4.0 kg•m (25 - 29 ft lb).
Figure 110 Inspecting Nozzle
Adjustment
Adjust injection start pressure by increasing or decreasing
thickness of shim washer to be insert.
Varying shim thickness by 0.10 mm (0.0039 in) causes injection
start pressure to change 10.0 kg/cm2 (142 psi).
Available shims:
10 kinds of shims available from 1.25 - 1.7 mm (0.0492 -
0.0669 in) in thickness, 0.050 mm (0.0020 in) increments.
Figure 111 Assembling Nozzle
Injection Start Pressure

Standard 140 +10 kg/cm2
0
(1,990 +142
-0 psi)
Allowable limit 130.0 kg/cm2
(1,850 psi) or less
Figure 112 Testing Nozzle
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Page 80
Installation
1. Clean nozzle holder fitting surface of cylinder head. Install
nozzle holder with a gasket interposed.
NOTE: Tightening torque 5.0 - 6.0 kg•m (36 - 43 ft lb).
Figure 113 Installing Nozzle Holder
2. Connect fuel return pipe and injection pipe.

NOTE: Tightening torque:
Injection pipe 2.5 - 3.5 kg•m (18 - 25 ft lb).
Fuel return pipe 2.5 - 3.0 kg•m (18 - 22 ft lb).
Figure 114 Installing Injection Pipe
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Page 81
GOVERNOR SYSTEM
General
Specification
Governor type Centrifugal flyweight type
Construction
Figure 115 Governor System Component Parts
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Page 82
Reference Reference
Number Number
1 Sealing Metal 15 Start Spring
2 Sealing Wire 16 Governor Spring Lever
3 Low and High Speed 17 Speed Control Lever
4 Governor Spring 18 Cover Assembly
5 Sliding Shaft 19 Governor Cover Gasket
6 Stopper 20 Return Spring
7 Governor Spring 21 Stop Lever Assembly
8 Governor Shaft 22 O-ring
9 Governor Lever 23 Retaining Ring
10 Tie Rod 24 Stop Lever
11 Tie Rod Clip 25 Grooved Pin (3 x 20)
12 Tie Rod Cover 26 Grooved Pin (3 x 14)
13 Tie Rod Cover Gasket 27 Torque Spring Set
14 Tension Lever 28 Sealing Cap
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Torque Spring
Installation of Torque Spring Set

Install and adjust torque spring set using the following
procedure:
1. Set speed control lever to high idle speed position by
adjusting high-speed set bolt.
2. Turn in torque spring set until engine speed drops about 50
rpm from high idle speed.
3. From this position, turn back torque spring set by specified
number of turn (N.)
Lock torque spring set at that position with special nut.
4. Install torque spring set sealing cap and stake cap to
prevent loosening.
CAUTION
There are two types of torque spring sets; single
spring type and double spring type.
Since each torque spring set has been adjusted
Figure 116 Torque Spring Set
precisely during assembly, do not tamper with
adjustment screw unless it is necessary.
Number of Loosening Turns (N) Model

L2A-61A
2.4 L3A-61A
L3C-61A
2.5 L2C-61A
L2E-61A
2.8
L3E-61A
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Page 84
Assembling Torque Spring Set
When torque spring set has been disassembled or its
component parts have been replaced, reassemble and adjust
torque spring set using the following procedure:
1. Double spring type.
A. Assemble torque spring set as shown in Figure 117.
Using adjusting screw, adjust projection d of torque
spring stopper from spring case to get specified
projection.
Figure 117 Assembling Torque Spring Set
B. To measure projection "D." keep torque spring set in

vertical position as illustrated. Put dial gauge probe
against spring stopper at center of its end face using
a small dial gauge (have a sensitive probe which
does not compress torque spring when pushed
against spring stopper end).
C. Leaving dial gauge set condition unvaried, depress
stopper and slide torque spring set support spring
case. Read deflection of dial gauge which
corresponds to projection of spring stopper from
spring case. (measurement should be made two or
three times repeatedly to make sure of accurate Figure 118 Measuring Spring Stopper
measure.) For models which do not require any Projection "D"
torque spring action, set projection d to a value in
range of 0 - 0.4 mm (0 - 0.0016 in).
D. After adjustment, tighten nut to a torque of 0.8 - 1.2
kg•m (6 - 9 ft lb).
E. Check to see that spring stopper can be depressed
smoothly and that end face of stopper can become
flush with end face of spring case.
F. For purpose of identification of projection d, apply
paint of the color specified following table to surface
shown in Figure 117.
Identification
Model Part No. Projection "δ"
Color
L2E-31FS, 31SS 0.4 - 0.5 mm
MM435322 Black
L3C-31FS (0.0157 - 0.0197 in)
L2E-61WM
0 - 0.4 mm
L3C-61WM MM434977 White
(0 - 0.0157 in)
L3E-11A,12A-61WM
L3A-11C
0.2 - 0.3 mm
L3C-11A, 11C-11G MM434540
(0.0079 - 0.0118 in)
LE3-11C
Engine SP001524
Page 85
2. Single spring type.
When installing single spring type torque spring set, use
the following steps. Figure 119.
A. Lightly turn in adjustment screw (with a screw driver
operated by fingertips) until a resistance to screw
rotation is felt. Lightly lock screw at that position with
locknut.
B. Set scale to zero point. Turn in spring case until value
of load "A" shown in following table can be attained.
Lock spring case at that position with special nut.
C. Temporarily loosen adjustment screw until value of
load "A" is reduced by about 200.0 g (7.055 oz), and
then tighten screw until value of "B" is retained. Lock
screw at that position with locknut.
Figure 119 Setting Of Torque Spring
D. To inspect torque spring set for properly adjusted

spring load, use a testing arrangement such as
shown in Figure 120. Gradually push scale against
torque spring set until stopper is moved (or pointer of
dial gauge deflects). Check that load applied to
torque spring at that moment coincides with value of
load "C."
Figure 120 Inspection Torque Spring
Torque Adjusted Spring Load Identification

Spring Set A B C Color Code
MM436593 570
+10
g 570
+0
g 550
+20
g Green
-0
+0.353 +0 +0.705
(20.1 -0 oz) (20.1 oz) (19.4 oz)
MM435896 970
+10
g 970
+0
g 950
+20
g Yellow
-0
+0.353 +0 +0.705
(34.2 -0 oz) (34.2 oz) (33.5 oz)
MM436216 1,270 -0
+10
g 1,270
+0
g 1250
+20
g Purple
+0.353 +0 +0.705
(44.8 -0 oz) (44.8 oz) (44.0 oz)
MM435789 1,520
+10
g 1,520
+0
g 1500
+20
g Blue
-0
+0.353 +0 +0.705
(53.6 -0 oz) (53.6 oz) (52.9 oz)
Engine SP001524
Page 86
Checking
Replace gear case and inspect governor. When removing gear
case, be sure to remove tie-rod cover by side of fuel pump and
disconnect tie-rod from rack. If any parts are found defective,
replace them.
CAUTION
When governor is assumed to be malfunctioning, check
bearing on gear case side, too.
Governor
Inspection
Figure 121 Inspection Governor System Parts
Engine SP001524
Page 87
NOTE: Refer to “Gear Case and Oil Pump” on page 1-46.
1. Removing levers.
A. To remove levers, pull out grooved pins which have
been driven into governor lever, stop lever, and
speed control lever.
B. Loosen bolts fastening levers and shafts.
2. Installation.
Install levers and shafts, one after another, checking for
Figure 122 Installing Speed Control Lever
proper function of them.
CAUTION
After press fitting each grooved pin, check shaft for
smooth rotation.
Coat O-ring with oil before installing them.
No deflection exceeding 20.0 mm (0.7874 in) is
permitted for governor spring installed.
Install governor spring lever and speed control lever
so that play of angle between levers (standard: 5°) is
minimized.
Engine SP001524
Page 88
COOLING SYSTEM
General
Specifications
Fan belt Standard type for industrial application L2, 3 : LL HM type, length 905
Cooling fan L2: Standard type for industrial 4-blade, unequal pitch, suction
application type, 261∅
L3: Standard type for industrial 4-blade, unequal pitch, suction
application type, 291.0 mm (11.46 in)∅
Water pump Type Centrifugal impeller
Thermostat Type Wax type
Standard type
Valve cracking temperature 75 - 78°C (167- 172°F)
Full opening temperature 90°C (194°F) (Valve lift 8.0 mm
(0.3150 in))
Thermo switch Standard type
Switch ON temperature 108 - 114°C (226 - 237°F)
Temperature gauge Gauge specification 70°C (158°F) / 104 ±13.5 Ω
unit
115°C (239°F) / 23.8 ±2.5 Ω
Voltage used 12 volt DC
Engine SP001524
Page 89
Construction
Figure 123 Cooling System Component Parts
Reference Reference
Number Number
1 Cooling Fan 5 Thermostat
2 Water Pump Pulley 6 Thermostat Fitting
3 Water Pump Assembly 7 Thermo Switch
4 V-belt 8 Bypass Pipe
Engine SP001524
Page 90
Fan and Fan Belt
Fan Belt Inspection

See “Adjusting Fan Belt Tension” on page -20.
Figure 124 Inspecting Fan Belt
Fan Inspection
Check fan for cracks, damaged and deformation. If any replace
fan.
Figure 125 Inspecting Fan
Engine SP001524
Page 91
Water Pump

1. Remove fan and fan belt.
2. Remove water pump.
3. When installing water pump, reverse above mentioned
order of removal.
Inspection
Check water pump for water leak, rough rotation, and cracks. If
any, replace water pump assembly.
Figure 126 Removing Water Pump
Thermostat

NOTE: Pay attention to the following:
Never allow flange to protrude from faucet joint.
Replace gasket.
Figure 127 Installing Thermostat
Inspection
If thermostat does not operate properly, replace it.
Specification
Item
76.5 71
Valve cracking 75 - 78°C 71°C
temperature (167 - 172°F) (160°F)
Full open 88.5 - 91.5 95°C
temperature (Lift (191 - 197°F) (203°F)
8.0 mm (0.3150 in))
Figure 128 Inspecting Thermostat
Engine SP001524
Page 92
Engine Coolant Temperature Gauge Unit
and Thermo Switch
Inspection of Engine Coolant Temperature Gauge Unit

If gauge does not function properly, replace it.
CAUTION
Handle hot oil with special care not to cause a scald or a
fire.
Figure 129 Inspecting Temperature Gauge

Unit
Gauge Unit Part No. Specification

MD001380 70°C (158°F) / 104 ±13.5 Ω, 115°C (239°F) / 23.8 ±2.5 Ω
MM435133 80°C (176°F) / 118 ±6 Ω, 115°C (239°F) / 42 ±2.5 Ω
451510100 80°C (176°F) / 29.5 ±2.5 Ω, 106°C (223°F) / 14.3 ±0.5 Ω
Inspection of Thermo Switch

NOTE: Switch "ON" temperature 108 - 114°C (226 - 237°F).
CAUTION
Handle hot oil with special care not to cause a scald or a
fire.
Figure 130 Inspecting Thermo Switch
Engine SP001524
Page 93
AIR CLEANER
Construction
Figure 131 Air Cleaner Component Parts
Reference Reference
Number Number
1 Body Assembly 4 Bolt
2 Element Assembly 5 Partition Plate
3 Dust Pan Assembly
Engine SP001524
Page 94
Inspection
1. Check air cleaner body and cover for deformation,
corrosion, and damage. If any defect is found, repair or
replace.
2. If body and cover (element) are not airtight, dust would
intrude into engine, causing cylinders and pistons to wear
down early. Check interior of body for evidences of
intrusion of dust. If any, repair air leak part.
3. Check element and packing for damage and air leak. If
necessary, clean or replace element.
4. Check element for dirtiness, clogging, and damage. If
necessary, clean or replace element.
5. Check intake hose for damage and cracks. If necessary,
replace hose.
6. When installing air cleaner, properly position it so that air
inlet opening faces sideward or downward. Also, install
dust pan with arrow mark "TOP" indicating top.
Engine SP001524
Page 95
ELECTRICAL SYSTEM
General
Specification
Model M2T25381 M2T53085 M2T53681 M2T50285
Starter Type Solenoid shift type
Nominal output 12 V X 1.2 kW 12 V X 1.6 kW
Model M40793
Type Magnet type
Dynamo
Charging
performance 14 +10
0 A (at 14 V / 5200 rpm)
Model A0T25171 A0T25371 A0T24770
Alternator Type AC type with built-in IC regulator
Nominal output 12 V X 40 A 12 V X 35 A
Model RS 501 (For Dynamo, M40793)
Regulator and Type IC Type
Rectifier Regulated 14.5 V ± 0.5 V
voltage
Model Y - 145T
Type Sheath type, quick heating
Glow Plug
Regulated
10.5 V DC
voltage
Engine model L2 L3
Glow Plug Model DH-139 V-19 DH-139 V-29
Indicator Type Red hot type (Quick heat type)
Rated current 19 A 29 A
Model G71 SP
Glow Plug
Rated voltage 12 V DC
Relay
Coil resistance 13 Ω
Model YM-1 or YM-2
Control Timer
Input voltage 9 - 15 V DC
Unit
Load Solenoid (Coil resistance 1.7 Ω or more)
Type Push type
Voltage 10 - 15 V DC
Stroke 10 ±0.5 mm
(0.3937 ±0.0197 in)
Solenoid
Type Pull type
Voltage 12 V DC
Stroke 13.5 mm
(0.5315 in)
Engine SP001524
Page 96
Wiring Diagrams
Numeral on each wire is a "nominal size" according to JIS.
C-3406 low voltage electrical wiring for automobiles.
1. For standard type engines with alternator (with built-in IC
regulator) or AC dynamo.
Figure 132
Engine SP001524
Page 97
2. For L2 engines of "Key OFF stop" specification (with AC
dynamo)
Figure 133
3. For standard engines of "Key OFF stop" specification
Figure 134
Engine SP001524
Page 98
4. For L2, L3 engines with glow plug timer, Key OFF stop
specification
Figure 135
5. Three kinds of wiring diagrams for engines with "Key off

stop" system are shown in Figure 133 thru Figure 135.
Machines equipped with those engines may be in need of
wiring modification to match with those key off stop system
circuits. In such a case, careful attention should be paid to
the items mentioned below.
CAUTION
Wires G and R (I1 and I2) for the control timer unit are
to be minimized in wire resistance, with the necessary
consideration to prevent those wires from being
influenced by electric noises (caused by voltage
variations, etc.) from other electrical devices.
Be careful not to confuse the polarity of the diode (I3)
interposed between the starter switch and alternator
terminal " L" (If that diode is connected in reverse, it
will make the "Key OFF stop" system ineffective.)
Engine SP001524
Page 99
6. Combination of operations of components in "Key OFF
stop" (fuel cutoff solenoid) system circuit.
Injection
State of Starter Oil Pressure Fuel Output Pump
Function
Engine Switch Switch Solenoid Control Rack
Position
ON ON ON STOP
At start
START OFF OFF MS Cranking up
Normal
ON OFF OFF (SS)
running
Emergency
stop by an act
On the run
ON ON ON STOP of oil
pressure
switch
OFF OFF ON STOP Key OFF stop
7. Starter switch connection for automatic glow plug system

operations.
Starter Switch
Connection Remarks
Position
OFF B-OFF
Current flows in glow plug circuit (the indicator light is
ON B-ON turned "ON") for a fixed period of time (about 6
seconds).
Current flows in glow plug circuit the indicator light is
ST B-ST-ON
turned "ON") as long as key is in ST position.
Engine SP001524
Page 100
Starter
Construction
Figure 136 Start Component Parts
Reference Reference
Number Number
1 Front Bracket Assembly 8 Rear Bearing
2 Lever Assembly 9 Pinion
3 Spring Set 10 Pinion Shaft Assembly
4 Center Bracket Assembly 11 Gear
5 Switch Assembly 12 Yoke Assembly
6 Through Bolt 13 Brush Holder Assembly
7 Armature 14 Rear Bracket
Engine SP001524
Page 101
Inspection (Assembly)
If any abnormality is assumed by the following tests, adjust the
starter or disassemble and repair it.
1. Pinion gap inspection.
A. Interpose a battery (12 V) between starter terminal
"S" and starter body, and the pinion will protrude and
stop.
CAUTION
Never apply battery voltage for over 10 seconds
continuously.
Figure 137 Inspecting Pinion Gap
B. Lightly push pinion back and measure return stroke
(called pinion gap).
C. If pinion gap is not within standard range (0.5 -
2.0 mm (0.0197 - 0.0787 in), adjust it by increasing or
decreasing number of packings on magnetic switch.
The gap is decreased as the number of packings
increases.
2. No-load test.
A. Connect ammeter, voltmeter and battery to starter as
illustrated.
B. When switch is closed, pinion must protrude and
starter must run smoothly (at 3000 rpm or more). If
current or starter speed is out of specification,
disassemble starter and repair it.
CAUTION
Figure 138 No-load Test
Use the thick wires as far as possible for wiring and
tighten every terminal securely.
This is solenoid shift type starter which makes a
rotating sound larger than that of a direct drive type
starter.
When detecting starter rotation at pinion tip, take care
of protrusion of pinion.
Engine SP001524
Page 102
3. Magnetic switch.
Perform the following tests. If any test is not satisfied,
replace magnetic switch assembly.
A. Disconnect wire from terminal "M."
B. Attraction test.
Connect a battery to magnetic switch terminals "S"
and "M." Pinion must protrude.
CAUTION Figure 139 Attraction Text
Do not apply battery current for more than 10

seconds.
C. Holding test.
With a battery connected to magnetic switch terminal
"S" and to starter body, manually pull out pinion fully.
Pinion must remain at that position even when
released from holding by hand.
CAUTION
seconds.
Figure 140 Holding Test
D. Return test.
With a battery connected to magnetic switch terminal
"M" and to starter body, manually pull out pinion fully.
Pinion must return to its original position when
released from holding by hand.
CAUTION
seconds.
Figure 141 Return Text
Engine SP001524
Page 103
Disassembly
1. Disconnect wire from magnetic switch terminal "M."
2. Loosen two screws fastening magnetic switch. Remove
magnetic switch assembly.
3. Remove two through bolts and two screws fastening brush
holder. Remove rear bracket.
Figure 142 Removing Brush Holder

Assembly
4. With two brushes brought in floating state, remove yoke

and brush holder assembly. Then, pull armature out.
5. Remove cover and pry retaining ring out.
6. Unscrew bolts and remove center bracket. At same time,
washers for pinion shaft end play adjustment will come off.
7. Pull out reduction gear lever and lever spring from front
bracket.
8. On pinion side, pry retaining ring out, and pull out pinion
and pinion shaft.
9. At each end of armature, remove ball bearing with a Figure 143 Removing Reduction Gear
bearing puller.
It is impossible to replace ball bearing press fitted in front
bracket. If that bearing has worn off, replace front bracket
assembly.
Engine SP001524
Page 104
Inspection
Figure 144
Inspect the following:
Description Standard Service Limit

Depth of under cut 0.50 mm 0.20 mm
(0.0197 in) (0.0079 in)
Commutator O.D. 38.70 mm -1.0 mm
(1.5236 in) (-0.0394 in)
Height of brush 17.0 mm 6.0 mm
(0.6693 in) (0.2362 in)
Spring pressure 3.0 kg ----------
(6.61 lb)
Engine SP001524
Page 105
1. Inspecting magnetic switch.
Check magnetic switch for continuity between terminals
"S" and "M" and between terminals "S" and body. If zero
ohm is indicated (as an evidence of short circuit), replace
magnetic switch.
Figure 145
2. Inspecting armature.
A. Check armature with a growler tester. If short
circuited, replace armature. Also, check for insulation
between commutator and its shaft. If poorly insulated,
replace armature.
B. Measure commutator O.D. and depth of undercut.
Repair or replace if service limit is exceeded. Also,
check commutator outside surface for dirtiness and
roughness. If rough, polish commutator with fine
grain crocus cloth.
Figure 146 Checking Armature Coil
3. Brush holder inspection.

A. Check brushes. If worn out beyond service limit,
replace brushes.
B. Check brush spring tension. If decreased beyond
service limit, replace springs.
C. Check for insulation between positive brush holder
and holder base. If poorly insulated, replace holder
assembly. Also, check brush holders for proper
staking.
Figure 147 Checking Brush Holders
4. Field coil inspection.

A. Check for insulation between one end (brush) of coil
and yoke.
B. Check for continuity between both ends (brushes) of
coil.
C. Check poles and coil for tightness.
Figure 148 Checking Filed Coil
Engine SP001524
Page 106
Assembly and Adjustment
Reassemble starter assembly in reverse order of disassembly,
paying attention to the following:
1. Pinion shaft end play adjustment.
Set end play (thrust gap) to 0.50 mm (0.0197 in) or less by
inserting an adjusting washer between center bracket and
reduction gear.
A. Fit pinion shaft, reduction gear washer and retaining
ring to center bracket.
B. Measure end play by moving pinion shaft in axial Figure 149 Adjusting Pinion Shaft End Play
direction. If end play exceeds 0.50 mm (0.0197 in),
increase number of adjusting washers inserted.
2. Greasing.
Whenever starter has been overhauled, apply grease to
the following parts:
• Armature shaft gear and reduction gear.
• All bearings.
• Bearing shaft washers and retaining rings.
• Bearing sleeves.
• Pinion.
• Sliding portion of lever.
CAUTION
Never coat starter fitting surface, terminals, brushes,
and commutator with grease
Engine SP001524
Page 107
Alternator and Dynamo
Construction
Figure 150 Alternator Component Parts
Reference Reference
Number Number
1 Pulley 7 Terminal Set
2 Front Bracket Assembly 8 Regulator Assembly
3 Front Bearing 9 Rectifier Assembly
4 Rotor Assembly 10 Rear Bracket Assembly
5 Rear Bearing 11 Condenser Assembly
6 Stator
Engine SP001524
Page 108
Dynamo
The dynamo is used for so specified engines. This maintenance
free dynamo is a permanent magnet type, lightweight, compact,
single phase A/C generator. Alternating current generated by
the dynamo is rectified through a separate regulator and rectifier
unit. For dynamo inspection items, see end of this section.
On the Engine Inspection

1. Precautions for handling.
Erroneous handling possibly causes damage to charging
Figure 151 Dynamo
circuit and other troubles.
A. Never connect battery in reverse.
B. Do not use a merger and other high voltage testers.
C. When recharging battery, disconnect battery cable
from alternator.
D. Never disconnect lead wire from alternator terminal
"B" while running engine.
E. Never ground alternator terminal "B" to which battery
voltage is always terminal "L."
F. Never short circuit or ground terminal "L."
G. When using a steam cleaner, be careful not to direct
steam directly into alternator.
2. Checking for regulated voltage.
A. Interpose an ammeter between positive terminal of
battery and terminal "B" of alternator.
B. Ground alternator terminal "L" through a voltmeter.
C. Note that voltmeter indicates zero volt when starter
switch is in OFF position. A voltmeter will indicate a
voltage considerably lower than battery voltage when
starter switch is in ON position (while engine is
stopped).
D. Short circuit ammeter and start engine.
Figure 152 Checking For Regulated Voltage
E. Read voltmeter indication (regulated voltage) under
the following test conditions: Ammeter indication is
below 5 A; engine speed is at 1800 rpm and 2500
rpm; and lights are switched off. Regulated voltage
shows a tendency to decrease as alternator
temperature increases.
Engine SP001524
Page 109
3. Output inspection.
A. Disconnect grounding cable from battery.
B. Interpose an ammeter between battery and alternator
terminal "B." Ground terminal "B" through a
voltmeter.
C. Connect battery grounding cable.
D. Start engine.
E. Apply all load including lights.
F. Increase engine sped until normal alternator speed is
Figure 153 Return Text
attained. Read maximum indication of ammeter at
13.5 V of voltmeter indication. Output current must
conform to specification.
Description 12 V X 35 A 12 V X 40 A
7 A @ 1300 rpm ----------
Cold
30 A @ 2500 rpm ----------
Alternator Output at 13.5 V 3 A @ 1300 rpm ----------
Hot 23 A @ 2500 rpm 21 A @ 2500 rpm
36 A @ 5000 rpm 37 A @ 5000 rpm
Removal
1. Disconnect battery cable.
2. Disconnect lead wire from terminal "B" on back of
alternator.
3. Disconnect alternator connector.
4. Loosen alternator brace bolt and support bolt. Push
alternator toward engine and remove fan belt.
5. Demount alternator.
Figure 154 Removing Alternator
Engine SP001524
Page 110
Disassembly of Alternator
1. Remove three through bolts.
2. Heat rear bracket around rear bearing up to 50 - 60°C (122
- 140°F) (with a solder iron) and separate bracket from
stator coil.
CAUTION
Pry open alternator with a screw driver blade inserted
into clearance between stator cover and front bracket.
Be careful not to insert blade to deep.
3. Grip rotor in a vise, remove pulley nut, and pull out pulley,
fan and spacer.
4. Pull out rotor assembly from front bracket.
5. Unsolder stator coil lead wires. Remove stator assembly.
CAUTION
Never heat lead wires very long, to prevent damage to
diodes.
6. Disconnect capacitor from terminal "B."

7. Loosen screws fixing rectifier and remove rectifier.
Engine SP001524
Page 111
Inspection
Inspect disassembled parts. If any part is found defective,
replace.
Figure 155 Inspection Of Alternator
1. Inspecting diodes.
Check each built-in diode in rectifier for continuity as
follows:
A. Connect a circuit tester (ohm meter) across lead wire
and case of diode to be test. Diode is considered
normal if its resistance is large in either direction and
small in the reverse direction.
B. If there is equal resistance in both directions, the
diode is suspected to be defective. Replace rectifier
assembly.
Figure 156 Checking Diodes
C. Check every diode for continuity.
Engine SP001524
Page 112
2. Inspecting field coil.
A. Check for continuity between slip rings. If there is no
continuity, field coil is suspected to be broken.
Replace field coil.
Figure 157 Checking Field Coil for

Continuity
B. Check for continuity between a slip ring and shaft (or

core). If any continuity is found, field coil is suspected
to be poor in insulation. Replace field coil.
Figure 158 Checking Field Coil for Insulation
3. Inspecting stator coil.

A. Check for continuity between lead wires of stator coil.
If there is no continuity, stator coil is suspected to be
broken. Replace stator coil.
Figure 159 Check Stator Coil for Insulation
B. Check for continuity between each lead wire and

stator core;. If any continuity is found, stator coil is
suspected to be poor in insulation. Replace stator
coil.
Figure 160 Check Stator Coil for Insulation
Engine SP001524
Page 113
Assembly of Alternator
Reassemble alternator assembly in reverse order of
disassembly, paying attention to the following:
1. The rear bearing has an eccentric groove.
Install retaining ring so that its projection fits in deepest
part of groove.
2. When installing a new rear bearing, press fit bearing with
its groove facing slip ring side.
3. When press fitting rear bearing into rear bracket, heat
bracket. Figure 161 Lifting Brushes
CAUTION
Press a wire through small hole in rear bracket to lift
brushes before installing rotor to rear bracket.
Remove wire after rotor is installed.
Installation
Install alternator in reverse order of removal.
1. Insertion of spacer.
A. When installing support bolts, insert spacer in place
using the following procedure:
1) Push in support bolts to normal position. (Leave
nuts removed from bolts)
2) Push alternator backward. Measure clearance
between alternator rear bracket and gear case
bracket to determine number of spacers to be Figure 162 Inserting Spacer
inserted into clearance (0.20 mm (0.0079 in)
maximum).
3) Reinstall alternator with necessary spacer
inserted in place. Tighten support bolt nuts
securely.
4) Perform belt tension adjustment.
Engine SP001524
Page 114
Dynamo, Regulator and Rectifier
1. Specifications.
See “Specification” on page -96.
2. Inspection.
A. Checking unit in service.
Measure battery voltage across terminals with a
circuit tester. It is considered normal if no-load
measurement is kept steady at about 15.0 V @ 5000
rpm or more of alternator speed.
Figure 163 Measuring Voltage Across
Battery Terminals
B. Checking regulator alone.

To judge whether a regulator is acceptable or not,
check regulator for normal continuity by connecting
circuit tester to lead wires as follows.
Figure 164 Lead Outlet Coupler
Lead to Be Tested If Abnormal Possible Cause of

Normal Measurement
Tester (+) Tester (-) Regulator Trouble
RED BLU 1
RED BLU 2
Continuity Broken diode
BLU 1 BLK
BLU 2 BLK
BLU 1 RED
noncontinuity Shorted diode
BLU 2 RED
BLK BLU 1
Shorted diode or thyristor
BLK BLU 2
NOTE: For testing, use circuit tester as an ohmmeter.

3. Installation.
Heat affects the regulator and rectifier. Position them in a
well ventilated place. Install the regulator in proper
direction so that the outlet of leads from the body faces
down.
Engine SP001524
Page 115
Glow Plug

NOTE: Glow plug tightening torque: 1.5 - 2.0 kg•m (11 -
14 ft lb).
Inspection
Check for continuity between glow plug terminal and body. If
plug is not conductive at all or shows a large resistance, replace
plug.
Figure 165 Checking Glow Plug
Key OFF Stop System
General
The function of this system is to actuate the fuel cutoff solenoid
when starter key is placed in OFF position. If also has the
emergency engine stop function by actuating the control timer in
case of abnormal lowering of oil pressure (and abnormal
increase of coolant temperature for special specification
engines).
Control Timer Unit
YM-1 YM-2
Model
(LWM80034) (LWM81025)
Voltage 9 - 15 V DC
Solenoid
Load
(Coil resistance 1.7Ω or more)
No. Wire Color Connect With

1 Blue Solenoid
2 Blue Solenoid
3 Red Battery (Starter Switch
"B")
4 Green Starter Switch "ON"
5 Red/White Starter (Starter Switch
"ST")
6 Yellow Oil pressure switch
7 Black (Ground)
Figure 166 Timer Unit
Engine SP001524
Page 116
Fuel Cutoff Solenoid (Push Type)
1. Specification.
Type Solenoid Push Type
Voltage 10 - 15 V DC
Coil 1.6 ±10% Ω
Resistance (at 20°C (68°F))
Stroke 10 ±0.5 mm
(0.3937 ±0.0197 in)
Figure 167 Fuel Cutoff Solenoid
(Push Type)
2. Solenoid installation procedure.

A. Temporarily fit solenoid (1, Figure 168) and nut (2) to
crank case. (Coat effective thread of solenoid with
THREE-BOND 1212 and 1211.)
B. Turn in solenoid so that clearance "C" becomes zero
at injection pump rack position "0 (stop position)."
C. Turn back solenoid 37° to 45° (the clearance
between rack and shaft will be 0.15 - 0.20 mm
(0.0059 - 0.0079 in)) and tighten locknut.
NOTE: Nut tightening torque: approximately 5.0 kg•m
(36 ft lb).
D. Start engine. Confirm that engine is stopped without
fail when solenoid shaft Is pushed In fully.
E. Install rubber cap with arrow mark to top side (water
drain hole side down).
CAUTION
Be careful not to allow detergent to intrude into Figure 168 Fuel Cutoff Solenoid
solenoid terminal and solenoid interior (cords and (Push Type)
shaft).
F. Care after engine assembly.

1) Make wiring properly for "key OFF stop"
system, according to foregoing wiling diagrams.
(See “General” on page -96.)
2) Start engine and confirm that solenoid comes
Into action to shut down engine when starter
switch is placed in OFF position.
3) Confirm that engine comes to a stop when oil
pressure switch terminal is short circuited to
switch body.
Engine SP001524
Page 117
Fuel Cutoff Solenoid (Pull Type)
1. Specification.
Type Pull type
Voltage 12 V DC
Rated Pull 55 A
Current
Rated Hold 1A
Current
Temperature -40 - +120°C Figure 169 Fuel Cutoff Solenoid (Pull Type)
Range (-40 - +248°F)
2. Solenoid installation.
In this solenoid, the solenoid shaft is pulled in when the
solenoid is excited and the shaft is returned (protruded)
when the switch key is turned to OFF. Install the solenoid
while it is not excited (shaft is protruding), using the same
procedure as mentioned before for the push type, so that
the specified clearance between the solenoid shaft and
injection pump rack can be obtained.
Engine SP001524
Page 118
Glow Plug Timer System
General
The glow plugs are used to help easy start of a cold engine by
preheating the combustion chamber.
In the standard specification engines, it is necessary to keep the
starter key at the "H" position 20 - 30 seconds by hand to heat
up the glow plugs.
The glow plug timer system eliminates the necessity of keeping
the starter switch at the "H" position and shortens the glow plug
heating time (6 seconds). This system remarkably simplifies the
glow plug operation.
Unlike the conventional glow plug circuit, this system applies
battery voltage directly to the glow plugs. Special care should be
taken to prevent short circuit by faulty wiring.
Glow Plug Timer
Model S8INJ
Rated Voltage 12 V DC
-40 - 85°C
Working Temperature
(-40 - +185°F)
Initial Performance (At
Normal Temperature,
6 ±0.7 sec (*)
Normal Humidity,
VCC: 12 V)
* Using test circuit shown in Figure 170,
measure time spent until glow plug relay trips
to ON after switch S1 is closed.
Figure 170 Glow Plug Timer System
Glow Plug Relay
Model G71SP
Rated Voltage 12 V DC
Continuous Rating 1 min
Coil Resistance 13 Ω
Inductance 24 mH (at 1 kHz)
Figure 171 Glow Plug Relay
Engine SP001524
Page 119
PERIODIC SERVICE CHART
: Check, adjust or replenish : Clean : Replace : Drain
storage
Before
400 hrs
Every
800 hrs
Every
operation
Before daily
50 hrs
After first
100 hrs
Every
Service interval
Remarks
Unit and point
Loose, damaged, or leaky parts

Exhaust, noise, and vibration
ENGINE
Retightening
Valve Clearance
Engine idling
Cylinder compression pressure
LUBRICATING
Engine oil
SYSTEM
Oil filter (Cartridge type)

Oil filter (Disassembly type) : Replace element.
Fuel
FUEL SYSTEM
Fuel tank
Fuel filter For cock type, replace element only.
Water sedimenter
Fuel pump Filter
Injection pump Adjust injection quantity.
Nozzle
Air cleaner
SYSTEM
INTAKE
(Paper-element type)
Air cleaner (Oil-bath type) : Change oil.
ELECTRICAL COOLING
When no antifree is used,

SYSTEM
Coolant
drain after daily operation.
Fan belt
Instruments (incl. pilot lamps)
SYSTEM
Starter, alternator, and regulator * *:Adjust for voltage and current

Glow plug
Solenoid switch Check for proper function.
AKS2720L
Figure 172
Engine SP001524
Page 120
SPECIFICATIONS AND
STANDARDS
Engine
Unit: mm
Description Specification or Standard Repair Limit Service Limit
About
28 kg/cm2 (400 psi) 25 kg/cm2
Cylinder Compression Pressure 22 kg/cm2
@ 280 rpm (355 psi)
(310 psi)
Difference Between Cylinders 2.50 kg/cm2 ---------- ----------
(Maximum) (35.6 psi)
Fuel Injection Order L2 : 1-2, L3 : 1-3-2 ---------- ----------
Cylinder Head
Within 0.50 mm 0.10 mm ----------
Bottom Surface Distortion
(0.0197 in) (0.0039 in)
6.60 mm ---------- ----------
Valve Guide I.D. (IN and EX)
(0.2598 in)
Valve Seat Angle (IN and EX) 45° ---------- ----------
1.3 - 1.8 mm 2.50 mm ----------
Valve Seat Width (IN and EX)
(0.0512 - 0.0709 in) (0.0984 in)
---------- ---------- -1.0 mm
Valve Seat Sinkage
(-0.0394 in)
Valve Clearance (IN and EX) 0.250 mm ---------- ----------
(0.0098 in) (Cold)
Valves
26.70 mm ---------- ----------
Valve Head Dia. (IN)
(1.0512 in)
24.70 mm ---------- ----------
(EX)
(0.9724 in)
94.0 mm ---------- ----------
Overall Length
(3.7008 in)
6.60 mm ---------- ----------
Stem O.D.
(0.2598 in)
---------- ---------- 0.10 mm
Stem To Guide Clearance (IN)
(0.0039 in)
---------- ---------- 0.150 mm
(EX)
(0.0059 in)
Valve Face Angle 45° ---------- ----------
Valve Head Thickness 1.0 mm ---------- 0.50 mm
(Margin Width) (0.0394 in) (0.0197 in)
Valve Head Sinkage 0.50 mm ---------- ----------
(From Cylinder Head Bottom Face) (0.0197 in)
Engine SP001524
Page 121
Unit: mm
Valve Spring
40.50 mm 39.30 mm ----------
Free Length
(1.5945 in) (1.5472 in)
5.94 kg / 35.5 mm ---------- -15%
(13.09 lb / 1.3976 in)
Preload / Installed Length
14.84 kg / 28 mm ---------- -15%
(32.71 lb / 1.1024 in)
Squareness 2° ---------- 3°
Rocker Arm
12.0 mm ---------- ----------
Rocker Arm I.D.
(0.4724 in)
---------- ---------- -0.20 mm
Rocker Are To Shaft Clearance
(-0.0079 in)
Cylinder Block Camshaft Hole
Dia.
42.0 mm ---------- ----------
Front (1.6535 in)
Ball bearing hole
34.0 mm ---------- ----------
No. 2
(1.3386 in)
33.0 mm ---------- ----------
No. 3
(1.2992 in) (L3)
33.0 mm ---------- ----------
Rear
(1.2992 in)
Cylinder Bore
65.0 mm +0.20 mm +0.70 mm
L2A, L3A
(2.5591 in) (+0.0079 in) (+0.0276 in)
70.0 mm +0.20 mm +0.70 mm
L2C, L3C
(2.7559 in) (+0.0079 in) (+0.0276 in)
76.0 mm +0.20 mm +0.70 mm
L2E, L3E
(2.9921 in) (+0.0079 in) (+0.0276 in)
0 - 0.30 mm ---------- ----------
Oversize Finish Tolerance (0 - 0.0118 in)
for each oversize
Within 0.010 mm ---------- ----------
Centricity
(0.0004 in)
Gasket Fitting and Surface Within 0.050 mm 0.10 mm ----------
Distortion (0.0020 in) (0.0039 in)
Engine SP001524
Page 122
Unit: mm
Piston
Type Solid type ---------- ----------
Material Aluminum alloy ---------- ----------
O.D. (Skirt End)
65.0 mm ---------- ----------
L2A, L3A
(2.5591 in)
70.0 mm ---------- ----------
L2C, L3C
(2.7559 in)
76.0 mm ---------- ----------
L2E, L3E
(2.9921 in)
Clearance To Cylinder ---------- ---------- 0.2
0.25, 0.50, 0.75 mm ---------- ----------
Oversize
(0.0098, 0.0197, 0.0295 in)
Protrusion From Cylinder Block Top 0.90 mm ---------- ----------
Surface (0.0354 in)
Piston Pin
Type Semifloating type ---------- ----------
18.0 mm ---------- ----------
O.D.
(0.7087 in)
---------- ---------- 0.080 mm
Piston Pin To Piston Clearance
(0.0031 in)
Press fit load: 1000 ±500 kg ---------- (Within
Piston Pin To Connecting Rod
(2,200 ±1,100 lb) standard
Clearance
range)
Piston Rings
Number of Rings
2 (No. 1: Chrome plated, ---------- ----------
Compression semikeystone type. No. 2:
Tapered.)
1 (Chrome plated ring with coil ---------- ----------
Oil
expander)
Ring Width
2.0 mm ---------- ----------
Compression (No. 2)
(0.0787 in)
3.0 mm ---------- ----------
Oil
(0.1181 in)
Ring Side Clearance
0.05 - 0.09 mm ---------- ----------
Compression No. 1
(0.0020 - 0.0035 in)
0.03 - 0.07 mm ---------- 0.20 mm
No. 2
(0.0012 - 0.0028 in) (0.0079 in)
0.15 - 0.40 mm ---------- 0.20 mm
Oil Ring
(0.0059 - 0.0157 in) (0.0079 in)
---------- ---------- 1.50 mm
Ring Gap
(0.0591 in)
Engine SP001524
Page 123
Unit: mm
Connecting Rod
Type Forged I-beam ---------- ----------
Within 0.050 mm ---------- 0.150 mm
Bend and Twist (0.0020 in) (0.0059 in)
Max.
0.1 - 0.35 mm ---------- 0.50 mm
Big and Thrust Clearance
(0.0039 - 0.0138 in) (0.0197 in)
Connecting Rod Bearing
Type Aluminum metal with back metal ---------- ----------
---------- ---------- 0.150 mm
Oil Clearance
(0.0059 in)
0.25, 0.50 mm ---------- ----------
Under Size
(0.0098, 0.0197 in)
Crankshaft
Type Fully counterbalanced ---------- ----------
Within 0.030 mm ---------- 0.050 mm
Bend
(0.0012 in) (0.0020 in)
0.05 - 0.175 mm ---------- ----------
End Play
(0.0020 - 0.0069 in)
43.0 mm -0.150 mm -0.70 mm
Journal O.D.
(1.6929 in) (-0.0059 in) (-0.0276 in)
40.0 mm -0.150 mm -0.70 mm
Pin O.D.
(1.5748 in) (-0.0059 in) (-0.0276 in)
Under Size Finishing
Journal U.S.
42.715 - 42.730 mm ---------- ----------
0.25
(1.6817 - 1.6823 in)
42.465 - 42.480 mm ---------- ----------
0.50
(1.6719 - 1.6724 in)
Pin U.S.
39.715 - 39.730 mm ---------- ----------
0.25
(1.5636 - 1.5642 in)
39.465 - 39.480 mm ---------- ----------
0.50
(1.5537 - 1.5543 in)
Main Bearing
Type Aluminum metal with back metal ---------- ----------
(No. 2: Flanged metal) ---------- 0.10 mm
Oil Clearance
(0.0039 in)
0.25, 0.50 mm ---------- ----------
Under Size
(0.0098, 0.0197 in)
Engine SP001524
Page 124
Unit: mm
Camshaft
Driving Method Gear drive ---------- ----------
Front Journal Ball bearing ---------- ----------
Journal To Cylinder Block Hole ---------- ---------- 0.150 mm
Clearance (0.0059 in)
27.370 mm ---------- -1.0 mm
Major Diameter of Cam (IN and EX)
(1.0776 in) (-0.0394 in)
---------- ---------- 0.150 mm
Oil Clearance
(0.0059 in)
Injection Pump Camshaft
Driving Method Gear drive ---------- ----------
Bearing Ball bearing (front and rear) ---------- ----------
30.0 mm ---------- -0.70 mm
Major Diameter of Cam
(1.1811 in) (-0.0276 in)
Tappet
19.0 mm ---------- ----------
O.D.
(0.7480 in)
---------- ---------- 0.150 mm
Tappet To Cylinder Block Clearance
(0.0059 in)
Push Rod
Within 0.30 mm ---------- ----------
Bend
(0.0118 in)
Lubricating System
Unit: mm
Oil Specification
API Service Classification Class CC or higher ---------- ----------
Viscosity
Above: 20°C (68°F) SAE 30 or low - 30 ---------- ----------
5 - 20°C (41 - 68°F) SAE 20 or low - 30 ---------- ----------
Below: 5°C (41°F) SAE 10W30 ---------- ----------
Engine SP001524
Page 125
Unit: mm
Oil Capacity
2.4/1.4 liters ---------- ----------
L2 (Standard) (0.63 - 0.37 U.S. gal.)
: Upper Limit/lower Limit (excludes 0.50 liters (0.13 U.S.
gal.) in oil filter)
3.0/1.5 liters ---------- ----------
L3 (Standard) (0.79 - 0.40 U.S. gal.)
3.6/1.8 liters ---------- ----------
L3 (Large) (0.95 - 0.48 U.S. gal.)
4.8/3.0 liters ---------- ----------
(1.3 - 0.79 U.S. gal.)
: Upper Limit/lower Limit
(excludes 0.50 liters (0.13 U.S.
Oil Pump
Type Gear type ---------- ----------
2
3 ±0.3 kg/cm @ 1000 rpm ---------- ----------
Check Valve Opening Pressure (0.79 ±0.08 U.S. gal. @1000
rpm)
0.100 - 0.196 mm 0.30 mm ----------
Outer Rotor To Housing Clearance
(0.0039 - 0.0077 in) (0.0118 in)
0.04 - 0.10 mm 0.250 mm ----------
Outer Rotor Thrust Clearance
(0.0016 - 0.0039 in) (0.0098 in)
Oil Pressure Switch
Contact Closing Pressure 0.50 kg/cm2 ---------- ----------
(Standard Type) (7.1 psi)
Fuel System
Unit: mm
Diesel fuel JIS No. 2 (JIS No. 3
Fuel Specification
in cold weather)
Fuel Filter
Type Paper element type ---------- ----------
Fuel Pump
Type Electromagnetic diaphragm type ---------- ----------
0.37 liters/min ---------- ----------
Delivery (0.10 U.S. gal.)
(12 V, at 20°C (68°F))
Engine SP001524
Page 126
Unit: mm
Fuel Pump
Type Electromagnetic plunger type ---------- ----------
0.90 liters/min ---------- ----------
Delivery: Common Type (0.24 gpm) or more
(12 V, at 20°C (68°F))
0.40 liters/min ---------- ----------
: Compact Type (0.11 gpm)
(12 V, at 20°C (68°F))
Fuel Pump
Type Electromagnetic drive type ---------- ----------
0.225 liters/min ---------- ----------
Delivery
(0.059 U.S. gal.)
Fuel Injection Pump For exclusive L2, L3 use model ---------- ----------
Type ND-PFR2NC or ND-PFR3NC ---------- ----------
Nozzle
Type Throttle type ---------- ----------
140.0 kg/cm 2 Within ----------
Injection Start Pressure (1,990 psi) standard
range
Governor System
Unit: mm
Governor
Type Centrifugal weight type ---------- ----------
Cooling System
Unit: mm
Cooling Fan
Type Uneven pitch, suction ---------- ----------
4-blade, 260 mm dia. ---------- ----------
L2: Standard
(10.24 in dia.)
4-blade, 260 mm dia. ---------- ----------
L3: Standard
(10.24 in dia.)
Fan Belt
Type HM type ---------- ----------
890 mm ---------- ----------
Length (Standard)
(35.0394 in)
Water Pump
Type Centrifugal impeller type ---------- ----------
Engine SP001524
Page 127
Unit: mm
Thermostat (76.5°C (170°F)
Specification)
Type Wax type ---------- ----------
75 - 78°C ---------- ----------
Valve Cracking Temperature
(167 - 172°F)
Full Opening Temperature at 8.0 mm 90°C ---------- ----------
(0.3150 in) valve lift (194°F)
Thermostat (71°C (160°F)
Specification)
Type Wax type ---------- ----------
71°C ---------- ----------
Valve Cracking Temperature
(160°F)
Full Opening Temperature at 95°C ---------- ----------
8.0 mm (0.3150 in) Valve Lift (203°F)
Thermo Switch
Type Bimetal type ---------- ----------
Model FW065102G220 (MM432104) ---------- ----------
108 - 114°C ---------- ----------
Contact Closing Temperature
(226 - 237°F)
Temperature Gauge Unit
Type Thermistor type ---------- ----------
Model (Part No.) A20-WEU (MD001380) ---------- ----------
70°C (158°F) / 104 ±13.5 Ω, ---------- ----------
Standard
115°C (239°F) / 23.8 ±2.5 Ω
Temperature Gauge Unit
Thermistor type ---------- ----------
Model (Part No.) YM-016-02-Wo=Tu
(MM435133)
35°C (95°F) / 670 Ω ---------- ----------
50°C (122°F) / 350 Ω ---------- ----------
80°C (176°F) / 118 ±6 Ω ---------- ----------
100°C (212°F) / 63.5 Ω ---------- ----------
Standard
105°C (221°F) / 54.5 Ω ---------- ----------
115°C (239°F) / 42 ±2.5 Ω ---------- ----------
120°C (248°F) / 36.2 Ω ---------- ----------
140°C (284°F) / 22 Ω ---------- ----------
Temperature Unit
Model (Part No.) 51400-K002-0 (0452510100) ---------- ----------
50°C (122°F) / 80 ±10 Ω ---------- ----------
60°C (140°F) / 56.3 ±5 Ω ---------- ----------
Standard 80°C (176°F) / 29.5 ±2.5 Ω ---------- ----------
100°C (212°F) / 16.5 ±2.5 Ω ---------- ----------
106°C (223°F) / 14.3 ±0.5 Ω ---------- ----------
Engine SP001524
Page 128
Electrical System
Unit: mm
Starter
Type Solenoid shift type ---------- ----------
M2T53681 (MM317604) ---------- ----------
Model M2T52381 (MM433174) ---------- ----------
M2T53085 (MD072585) ---------- ----------
Voltage Output 12V - 1.2 kW ---------- ----------
Clockwise as viewed from pinion ---------- ----------
Direction of Rotation
side
No-load Characteristics
Terminal Voltage 11.5 V ---------- ----------
Current 100 A or less ---------- ----------
Speed 3000 rpm or more ---------- ----------
Load Characteristics
Terminal Voltage 7.7 V ---------- 11.5 V
300 A (0.93 kg•m (6.73 ft lb) ---------- 0.70 kg•m
Current
or more) (5.06 ft lb)
Speed 850 rpm or more ---------- ----------
0.5 - 2.0 mm ---------- ----------
Pinion Gap
(0.0197 - 0.0787 in)
0.50 mm ---------- ----------
Thrust Gap
(0.0197 in) or less
Starter
Type Solenoid shift type ---------- ----------
Model (Part No.) M2T50285 (MM317602) ---------- ----------
Voltage - Output 12 V - 1.6 kW ---------- ----------
Clockwise as viewed from pinion ---------- ----------
side
No-load Characteristics
Current 100 A or less ---------- ----------
Speed 3000 rpm or more ---------- ----------
Load Characteristics
300 A (0.98 kg•m (7.09 ft lb) ---------- ----------
Current (Torque)
or more)
Speed 980 rpm or more ---------- ----------
0.5 - 2.0 mm ---------- ----------
Pinion Gap
(0.0197 - 0.0787 in)
0.50 mm ---------- ----------
Thrust Gap
(0.0197 in) or less
Engine SP001524
Page 129
Unit: mm
Dynamo
Type Magneto, AC type ---------- ----------
Model M40793 (MM403590) ---------- ----------
Charging Performance +10 ---------- ----------
14 0 A at 14 V, 5200 rpm
Clockwise as viewed from pulley ---------- ----------
side
Charging Start Speed 1800 rpm or less ---------- ----------
Alternator
A/C type with built-in IC ---------- ----------
Type
regulator
A0T25171 (MM432804) ---------- ----------
Model
A0T25371 (MM435752) ---------- ----------
Output 12 V - 40 A ---------- ----------
Clockwise as viewed from pulley ---------- ----------
side
Output Characteristics (Hot)
21 A @ 2500 rpm ---------- ----------
Current @ Speed
37 A @ 5000 rpm ---------- ----------
Regulated Voltage 14.7 ±0.3 V ---------- ----------
Alternator
Type AC type with built-in IC regulator ---------- ----------
Model AT24770 (MM409651) ---------- ----------
Output 12 V, 35 A ---------- ----------
Direction of Rotation Clockwise as viewed from pulley ---------- ----------
side
Output Characteristics 13.5 V ---------- ----------
Hot 3 A @ 1300 rpm ---------- ----------
Terminal Voltage 23 A @ 2500 rpm ---------- ----------
Current/speed 31 A @ 5000 rpm ---------- ----------
Cold 7 A @ 1300 rpm ---------- ----------
Terminal Voltage 30 A @ 2500 rpm ---------- ----------
Current/speed (36 A) @ 5000 rpm ---------- ----------
Regulated Voltage 14.4 ±0.3 V
Regulator
Type IC type ---------- ----------
Model (Part No.) RS5101 (MM403815) ---------- ----------
Regulated Voltage (Across Battery 14.5 ±0.5 V ---------- ----------
Terminals)
Battery Applicable To 12 V ---------- ----------
Light Applicable To 12 V, 3.4 W ---------- ----------
Engine SP001524
Page 130
Unit: mm
Glow Plug (Quick Heat Type)
Type Sheath type ---------- ----------
Model: T-145T (With hex. nut) ---------- ----------
Voltage - Current 10.5 V - 9.7 A ---------- ----------
Resistance 0.16 Ω ---------- ----------
Glow Plug Indicator (Quick Heat
Type) for L2
Type Red hot type ---------- ----------
Model DH-139V-19 ---------- ----------
Rated Current 19 A ---------- ----------
Voltage Across Terminals (at 19 A) 1.5 ±0.2 V ---------- ----------
Glow Plug Indicator (Quick Heat
Type) for L3
Type Red hot type ---------- ----------
Model DH-139V-29 ---------- ----------
Rated Current 29 A ---------- ----------
Voltage Across Terminals (at 29 A) 1.7 ±0.2 V ---------- ----------
Fuel Cutoff Solenoid
Type Electromagnetic push type ---------- ----------
Coil Resistance 1.6 ±10% Ω (20°C (68°F)) ---------- ----------
Working Voltage 10 - 15 V DC ---------- ----------
Stroke 10 ±0.5 ---------- ----------
-30° - +120°C ---------- ----------
Temperature Range
(-22° - +248°F)
Fuel Cutoff Solenoid
Type Electromagnetic push type ---------- ----------
Model 175IES ---------- ----------
Rated Voltage 12 - V DC ---------- ----------
Duty Cycle Continuous ---------- ----------
20°C ---------- ----------
Rated Temperature
(68°F)
-40° - +120°C ---------- ----------
Temperature Range
(-40° - +248°F)
Rated Pull Current 55 A ---------- ----------
Rated Hold Current 1A ---------- ----------
Control Timer
Model YM - 1 or YM - 2 ---------- ----------
Input Voltage 9 V - 15 V DC ---------- ----------
Solenoid (Coil resistance 1.7 W ---------- ----------
Load
or more)
-30° - +80°C ---------- ----------
Working Temperature
(-22° - +176°F)
Engine SP001524
Page 131
Unit: mm
Glow Plug Timer
Model S81NJ ---------- ----------
Rated Voltage 12 V DC ---------- ----------
-40°C - +85°C ---------- ----------
Working Temperature
(-40° - +185°F)
Initial Characteristic (Normal 6 ±0.7 sec ---------- ----------
Temperature, Humidity, VCC = 12 V)
Environmental Characteristic 6 ±1.3 sec ---------- ----------
(-30°C to 70°C, VCC = 7 - 15 V)
Glow Plug Relay
Model G71SP ---------- ----------
Rated Voltage 12 V DC ---------- ----------
Continuous Rating 1 minute ---------- ----------
Coil Resistance 13 Ω ---------- ----------
Inductance 24 mH (at 1 kHz) ---------- ----------
-40° - 100°C ---------- ----------
(-40° - 212°F)
Working Temperature (70° - 100°C (158° - 212°F)
for 20 sec or less continued
use)
Tightening Torque Chart and Sealant

Chart
Parts To Be Tightened SIze (Width Across Flat of Hex. Head) Tightening Torque (kg•m)
7.5 - 8.5 kg•m
Cylinder Head Bolts, Main M10 (14)
(54 - 61 ft lb)
2.0 - 3.0 kg•m
Cylinder Head Bolts, Sub M8 (12)
(14 - 22 ft lb)
3.2 - 3.5 kg•m
Connecting Rod Cap Nut M8 (14)
(23 - 25 ft lb)
8.5 - 9.5 kg•m
Flywheel Bolt M10 (17)
(61 - 69 ft lb)
10.0 - 12.0 kg•m
Crankshaft Pulley Nut M16 (24)
(72 - 87 ft lb)
5.0 - 5.5 kg•m
Main Bearing Cap Bolt M10 (17)
(36 - 40 ft lb)
1.5 - 2.2 kg•m
Rocker Stay Bolt M8 (12)
(11 - 16 ft lb)
0.5 - 0.7 kg•m
Rocker Cover Nut M6 (10)
(3.62 - 5.06 ft lb)
Nozzle Holder 5.0 - 6.0 kg•m
M20 (21)
(Fitting To Engine) (36 - 43 ft lb)
2.0 - 3.0 kg•m
Nozzle Union Color Fixing Nut M12 (17)
(14 - 22 ft lb)
Engine SP001524
Page 132
Parts To Be Tightened SIze (Width Across Flat of Hex. Head) Tightening Torque (kg•m)
3.5 - 4.0 kg•m
Nozzle Retaining Nut M16 (21)
(25 - 29 ft lb)
2.5 - 3.5 kg•m
Fuel Injection Pipe Nut M12 (17)
(18 - 25 ft lb)
3.5 - 3.9 kg•m
Delivery Valve Holder M16 (17)
(25 - 28 ft lb)
1.0 - 1.5 kg•m
Injection Pump Hollow Screw M10 (14)
(7 - 11 ft lb)
0.5 - 0.7 kg•m
Injection Pump Air Vent Screw M6 (10)
(3.62 - 5.06 ft lb)
4.0 - 5.0 kg•m
Solenoid Locknut M30 (36)
(29 - 36 ft lb)
2.0 - 3.0 kg•m
Coolant Temperature Gauge Joint M16 (23)
(14 - 22 ft lb)
1.9 - 2.7 kg•m
Thermo Switch M16 (19)
(14 - 19 ft lb)
1.9 - 2.7 kg•m
Thermo Gauge Unit M16 (17)
(14 - 19 ft lb)
1.1 - 1.3 kg•m
Oil Filter M20
(8.0 - 9 ft lb)
4.0 - 5.0 kg•m
Oil Relief Plug M18 (22)
(29 - 36 ft lb)
5.0 - 6.0 kg•m
Oil Drain Plug M18 (19)
(36 - 43 ft lb)
1.5 - 2.0 kg•m
Glow Plug M10 (12)
(11 - 14 ft lb)
0.1 - 0.15 kg•m
Glow Plug Lead Wire Fitting Nut M4 (7)
(0.72 - 1.08 ft lb)
Tightening Torque for Common Bolts and

Nuts
Head Mark
Designation of Screw Thread
4 7
0.3 - 0.5 kg•m 0.8 - 1.0 kg•m
M6
(2.17 - 3.62 ft lb) (5.79 - 7.23 ft lb)
1.0 - 1.3 kg•m 1.5 - 2.2 kg•m
M8
(7.23 - 9.4 ft lb) (11 - 16 ft lb)
1.8 - 2.5 kg•m 3.0 - 4.2 kg•m
M10
(13 - 18 ft lb) (22 - 30 ft lb)
3.0 - 4.2 kg•m 5.5 - 7.5 kg•m
M12
(22 - 30 ft lb) (40 - 54 ft lb)
5.0 - 7.0 kg•m 8.0 - 11.0 kg•m
M14
(36 - 51 ft lb) (58 - 80 ft lb)
Engine SP001524
Page 133
Tightening Torque for Common Plugs
Material of Plugged Part
Designation of Screw Thread
Aluminum Iron
--------------------- 0.8 - 1.2 kg•m
NPTF 1/16
(5.79 - 8.7 ft lb)
0.8 - 1.2 kg•m 1.5 - 2.2 kg•m
PT 1/8
(5.79 - 8.7 ft lb) (11 - 16 ft lb)
2.0 - 3.0 kg•m 3.5 - 4.5 kg•m
PT1/4, NPTF 1/4
(14 - 22 ft lb) (25 - 32 ft lb)
Sealant Chart
Where Sealant Coated
Parts Requiring Sealant Application Surface Sealant
Parts Are to Be Mounted
THREE-BOND
Fuel Cutoff Solenoid Cylinder Block
1212 or 1211
Threaded Water Drain Joint Effective Screw HERMESEAL Cylinder Block
Parts Oil Pressure Switch Threads HI or Gear Case
THREE-BOND
Taper Plug (NPTF 1/16) 1344 Cylinder Block
Cylinder Head and Cylinder
Sealing Cap
Press fit Periphery of HERMESEAL Block
Part Expansion Plug Press fit Part 52B
Cylinder Block
Oil Level Dipstick Guide
THREE-BOND
Side Seal Periphery
1212 or 1211
Other Cylinder Block
Contact Surface THREE-BOND
Bearing Cap
With Block 1212
Engine SP001524
Page 134
1Hydraulics
SP001525
CENTER JOINT (SWIVEL)SP001525
1Center Joint
(Swivel)
Edition 1
Center Joint (Swivel) SP001525

Page 1
MEMO

Page 2
Table of Contents
Center Joint (Swivel)

Parts List ....................................................................... 10
Troubleshooting, Testing and Adjustment .......... 12
Inspection ...................................................................... 12
Disassembly ....................................................... 13
Reassembly ........................................................ 13

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DX15 40001 and Up
DX18 40001 and Up

Page 5
GENERAL DESCRIPTION
The center joint (swivel) is designed to allow hydraulic oil from
the upper structure to flow to components in the lower structure.
It is capable of allowing continuous 360° rotation of the upper
structure in relationship to the lower structure.
a
A B
P
C D
c
d
P
F
E
e
D
C
B
A
T HKA9012L
Figure 1 DX15

Page 6
Reference Dimension
Description
Number Body Side Spindle Side
170 mm
a
(6.69 in)
40 mm
b
(1.57 in)
100 mm
c
(3.94 in)
75 mm
d
(2.95 in)
209 mm
e
(8.25 in)
A Right Travel Forward PF3/8 PF1/4
B Left Travel Reverse PF3/8 PF1/4
C Right Travel Reverse PF3/8 PF1/4
D Left Travel Forward PF3/8 PF1/4
E Blade Up PF1/4 PF1/4
F Blade Down PF1/4 PF1/4
P 2 Speed Travel PF1/4 PF1/8
T Drain PF1/4 PF1/8

Page 7
I
J
E
C J
I
C E
A
B a
A F D B
G
F D
G
b
d
c
H
G
I
e
J
F
E
D
C
H H
BTS0110L
Figure 2 DX18

Page 8
Reference Dimension
Description
Number Body Side Spindle Side
a 166 mm
(6.53 in)
b 36 mm
(1.42 in)
c 83 mm
(3.27 in)
d 95 mm
(3.74 in)
e 248.4 mm
(9.78 in)
A Track Extension PF1/4 PF1/4
B Track Decrease PF1/4 PF1/4
C Right Travel Reverse PF3/8 PF3/8
D Left Travel Reverse PF3/8 PF3/8
E Right Travel Forward PF3/8 PF3/8
F Left Travel Forward PF3/8 PF3/8
G 2 Speed Travel PF1/4 PF1/4
H Drain PF1/4 PF1/4
I Dozer Up PF1/4 PF1/4
J Dozer Down PF1/4 PF1/4

Page 9
Parts List
Figure 3 DX15
Reference Reference
Number Number
1 Center Joint Assembly 8 Thrust Plate
2 Body 9 Hex Head Bolt
3 Slipper Seal 10 O-ring
4 O-ring 11 Cover
5 Dust Wiper 12 Hex Head Bolt
6 Spindle 13 Spring Washer
7 Hex Head Plug 14 Pin

Page 10
H H
11
B I
5
8
G
I
I
1 B
J
2 J
A
13 F F
E E
D D
C C
4
9
7
12
10
3
BTS0120L
Figure 4 DX18
Reference Reference
Number Number
1 Hub 8 Backup Ring
2 Shaft 9 Ring - Retainer
3 Cover 10 Plug-PT
4 Spacer 11 Pin
5 Packing 12 Wrench Bolt
6 O-ring 13 Seal - Slipper
7 O-ring

Page 11
TROUBLESHOOTING, TESTING
AND ADJUSTMENT
Inspection
The center joint should be checked for evidence of external oil
leakage every 2,000 operating hours. Leaking or defective
O-rings are an indication that dirt and other contaminants could
be getting inside the assembly, which will promote accelerated,
abnormal wear and may cause early failure of the assembly.
If internal seals or other sliding surface components are worn
and there is internal fluid leakage, complete overhaul and repair
or replacement of the center joint may be required.

Page 12
DISASSEMBLY
Refer to the assembly drawing of the swivel joint for component
references (Figure 3).
IMPORTANT
Do not unbolt the center joint from the lower car body until
an adequate number of piping block off plates are available,
for disconnected piping lines. Be sure that system pressure
has been vented - including the hydraulic accumulator and
tank reserve pressure - before disassembly is started.
1. Clean off the exterior of the swivel joint after it has been
removed.
2. Remove bolts (12, Figure 3) and spring washer (13)
holding the cover from base of housing.
3. Remove the spindle (6, Figure 3) from the body (2) in the
upper direction.
4. To prevent damage of the O-ring, turn the spindle at
disassembly.
REASSEMBLY
1. Prelubricate O-rings with hydraulic oil, white grease or
petroleum jelly.
CAUTION!
Apply a very light film of white grease or petroleum jelly to
the lower rim of the stem and inner surface of the center
swivel body. Apply slow, evenhanded pressure, using both
hands, to slowly push the stem into the body. Seals may be
damaged if the stem is pushed in too quickly.
2. Thoroughly clean all other component surfaces of dirt or

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

Page 13
Page 14
SP001526
CYLINDERS SP001526
Cylinders
Edition 1
Cylinders SP001526
Page 1
MEMO
Cylinders SP001526
Page 2
Table of Contents
Cylinders

Theory of Operation ........................................................ 6
Specifications .................................................................. 7
Parts List ......................................................................... 8
Disassembly ....................................................... 10
Tolerances)......................................................... 13
Reassembly ........................................................ 14
Cylinders SP001526
Page 3
MEMO
Cylinders SP001526
Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DX15 40001 and Up
DX18 40001 and Up
Cylinders SP001526
Page 5
GENERAL DESCRIPTION
Theory of Operation
1 Piston
2 Oil Path A
3 Oil Path B
Cylinder piston rods are extended or retracted by oil flow to back

side of cylinder (shown as "oil path A") or to front of cylinder ("oil
path B").
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
oil pressure and the inside diameter of the cylinder is expressed
by B (Figure 1). Figure 1
F1 = P x πB2
4
(P: Pressure, π = 3.14, B: Cylinder Inside Diameter)

1 Cylinder Inside Diameter - B
2 Oil Path A
3 Oil Path B
4 Rod Diameter
When the cylinder rod is retracted, oil flow through the circuit Figure 2
from the pump to the front side of the cylinder generates a force
(F2) that can be expressed by the formula in which the diameter
of the piston rod is expressed by R, and the other two terms are
the same as in the preceding expression.
F2 = P x π(B2-R 2)
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 decrease cylinder stroke
length than it does to lengthen it.
Q1 = S x π(B2)
4
Figure 3
2 2
Q2 = S x π(B -R )
4
Q1 > Q 2
Cylinders SP001526
Page 6
Specifications
H, L K
A
C D
B
F
E
H, L J I
A
D C
B
F
K
E
G2
G1
HKA9001L
Figure 4
Boom Dozer Dozer

Item Cylinder Unit Boom Arm Bucket Variable
Swing Fixed Variable
Rod Pin mm ø30 ø30 ø30 ø30 ø30 ø25
A
Diameter (in) (1.18) (1.18) (1.18) (1.18) (1.18) (0.98)
Head Pin mm ø30 ø30 ø30 ø30 ø30 ø25
B
Diameter (in) (1.18) (1.18) (1.18) (1.18) (1.18) (0.98)
mm ø30 ø30 ø30 ø30 ø30 ø25
C Rod Diameter
(in) (1.18) (1.18) (1.18) (1.18) (1.18) (0.98)
mm ø55 ø55 ø55 ø60 ø60 ø50
D Cylinder Bore
(in) (2.17) (2.17) (2.17) (2.36) (2.36) (1.97)
Maximum
mm 1,005 1,010 830 985 550 670 771
Extended
(in) (39.57) (39.76) (32.68) (38.78) (21.65) (26.38) (30.35)
E Length
Minimum mm 620 620 530 635 450 548 551
Closed Length (in) (24.41) (24.41) (20.87) (25.0) (17.72) (21.57) (21.7)
mm 385 390 300 350 100 122 220
F Stroke
(in) (15.16) (15.35) (11.81) (13.78) (3.94) (4.80) (8.66)
mm 45 45 45 45 45 35
G1 Width
(in) (1.77) (1.77) (1.77) (1.77) (1.77) (1.38)
mm 45 45 45 45 45 35
G2 Width
(in) (1.77) (1.77) (1.77) (1.77) (1.77) (1.38)
kg 11 11 10 12 8 6
Weight
(lb) (24.25) (24.25) (22.05) (26.46) (17.64) (13.23)
Cylinders SP001526
Page 7
Parts List
Figure 5
Cylinders SP001526
Page 8
Reference Reference
Number Number
1 Cylinder Assembly 12 Backup Ring
2 Cylinder Tube Assembly 13 Piston
3 Piston Rod Assembly 14 Piston Packing
4 Rod Cover 15 Wear Ring
5 Bush 16 Cushion Plunger
6 Rod Packing 17 O-ring
7 Dust Seal 18 Set Screw
8 Retaining Ring 19 Bush
9 O-ring 20 Grease Fitting
10 O-ring 21 Grease Fitting
11 Backup Ring 22 Dust Seal
Cylinders SP001526
Page 9
DISASSEMBLY
CAUTION!
Vent air from the hydraulic system before disconnecting
cylinder piping connections. Use the lever on the reservoir,
while the engine is running. Discharge the hydraulic
accumulator and vent residual tank pressure after the
engine is shut off. Pour clean replacement fluid back into
the system if excessive fluid is lost.
1. Clamp the cylinder tube in a vise (1, Figure 6) using wood

blocks (2), so as not to damage the cylinder body. 2
1 A
2. Supply compressed air into the ports A and B to actuate
the cylinder rod to drain out the fluid from the cylinder. 1
3. Extract the cylinder rod about 1/3 of the length.
B HKA9003L
Figure 6
4. Using a screw driver, make the rod cover stopping capacity

even.
HKM9004L
Figure 7
5. With a rack wrench, turn the rod cover counterclockwise

from the cylinder tube to loosen it.
HKA9005L
Figure 8
Cylinders SP001526
Page 10
6. Slowly turn the cylinder rod assembly to remove it from the
tube.
NOTE: After disassembling the piston rod, take care
not to damage it.
HKA9006L
Figure 9
7. Install wood blocks (1, Figure 10) on the inside of the vise
as shown so that the piston rod will not be damaged and
clamp the rod for disassembly. 1
HKA9007L
Figure 10
8. Remove the nut from the piston rod assembly by turning

the nut slowly counterclockwise.
HKA9008L
Figure 11
9. Lay the piston rod assembly on the work bench on top of

wooden blocks (2, Figure 12). 2
10. Remove the rod cover by moving it back and forth.

1
11. Remove the backup ring and O-ring.
2
HKA9009L
Figure 12
Cylinders SP001526
Page 11
12. The bushing in the piston rod is pressed into the rod head,
use a press (1, Figure 13) to remove the bushing.
1
NOTE: Exercise care not to damage the cover or piston
groove.
HKA9010L
Figure 13
Cylinders SP001526
Page 12
(WEAR LIMITS AND
TOLERANCES)
Clean disassembled parts and dry thoroughly.
Clean O-rings, seals and packings with hydraulic oil.
Do not use a mixture of different type oils since service life of
parts may be shortened.
Clean the sliding surfaces, oil holes, and packing grooves
thoroughly.
If parts are not to be used immediately after cleaning or to be
stored, dip them in a suitable rust preventive compound or coat
them with liberal amount of oil. (Coating with hydraulic oil has
some rust-proofing effect.)
Inspect all the major parts and check that they are not damaged,
deformed, rusted, or scored.
Check each part for metal chips and other foreign materials.
Check the piston rod and sliding surfaces for signs of damage,
fretting, or discoloration.
Replace packings and seals with new ones.
For retainer ring and seal ring, note the installing direction.
Replace set pin with a new one.After assembling and fitting the
set pin, secure it by punching 2 places on the circumference so
that it may not be missed.
Strictly follow the specified tightening torque when tightening the
rod cover, piston, nut etc.
Cylinders SP001526
Page 13
REASSEMBLY
CAUTION!
Replace any part that shows evidence of damage or
excessive wear. Replacement of all O-rings and flexible
seals is strongly recommended. Before starting the cylinder
reassembly procedure, all parts should be thoroughly
cleaned and dried, and/or prelubricated with clean
hydraulic fluid. Prepare the work area beforehand to
maintain cleanliness during the reassembly procedure.
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 to piston rod and body of cylinder
by using a press (1, Figure 14).
1
HKA9010L
Figure 14
2. Lay the piston rod assembly on the work bench on top of

wooden blocks (2, Figure 15). 2
3. Reassemble the backup ring, O-ring and the rod cover.

1
2
HKA9009L
Figure 15
Cylinders SP001526
Page 14
4. Install wood blocks (1, Figure 16) on the inside of the vise
as shown so that the piston rod will not be damaged and
clamp the rod for reassembly. 1
HBOH900L
Figure 16
5. Verify the direction of the retaining ring (1, Figure 17) and
1 2
seal ring (2).
6. Use a new set pin and use a punch to set the new pin (3 3
and 4, Figure 17) into place so that it does not slip out.
HKA9011L
Figure 17
7. Install the nut to the piston rod assembly by turning the nut
slowly clockwise.
HBOH890L
Figure 18
Cylinders SP001526
Page 15
8. Install the piston rod assembly into the cylinder tube.
HKA9006L
Figure 19
9. Tighten rod cover by turning cover clockwise.

10. Move the piston rod to make sure it moves smoothly.
HBOH920L
Figure 20
Cylinders SP001526
Page 16
SP001527
SWING MOTOR SP001527
Swing Motor
Edition 1
Swing Motor SP001527

Page 1
MEMO

Page 2
Table of Contents
Swing Motor

Shockless Relief Valve Functions ................................... 8
Parts List ......................................................................... 9
Specifications ................................................................ 10
Special Tools and Materials ............................... 11
Recommended Tools .................................................... 11
Swivel Turn Measurement............................................. 12
Disassembly ....................................................... 13
Tolerances)......................................................... 17
Reassembly ........................................................ 18

Page 3
Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DX15 40001 and Up
DX18 40001 and Up

Page 5
GENERAL DESCRIPTION
Theory of Operation
The pressurized oil flowing in the motor flows past the disk valve
to the seat roller, the star of which does planetary motion to
rotate the main drive. At this time, the disk valve is driven by the
valve drive.
1 2
4
5
6
7
8
10 9 HKA7040L
Figure 1
Reference Reference
Number Number
1 Inlet 6 Valve Drive
2 Outlet 7 Valve Plate Port (7 Locations)
3 Taper Roller Bearing 8 External Drain Plug
4 Main Drive 9 Disk Valve (12 Ports)
5 Gerotor 10 Check Valve (2)
Hydraulic Motor Functions

The hydraulic motor is of a axial piston motor type, and converts
the pump fed hydraulic energy to rotational motion.

Page 6
Motor Construction and Principle of Operation
The pressurized oil flowing in through the hydraulic valve is
delivered to the valve plate. The pressurized oil delivered to port
A is fed to the cylinder port, in the cylinder barrel, corresponding
to the port A and pushes out the piston. This pushing force is
converted to rotational force using the swash plate.The return oil
within the cylinder port flows out through the port B of the valve
plate.In the case of reverse rotation, the pressurized oil flows in
from the port B and the return oil flows out to the tank through
the port A.
1
2
6
HKA7041L
Figure 2
Reference Reference
Number Number
1 Shaft 5 Port A
2 Piston 6 Port B
3 Cylinder Barrel 7 Swash Plate
4 Valve Plate

Page 7
Shockless Relief Valve Functions
The hydraulic motor, even at stationary, would continue to rotate
by inertia force although the port A shuts off hydraulic pressure.
Then, pressure generated within the port B pushes the relief
valve poppet open at the primary pressure P1.
Also, pressurized oil is induced at the piston section using the
poppet check, and as a result, the piston moves to the right side.
This motion increases the spring load to generate the secondary
pressure P and to control the pressure within the port B in the
manner as shown, and accordingly the hydraulic motor come to
a stop smoothly.
2 3
1
4
P1
8 7 6 5
HKA7042L
Figure 3
Reference Reference
Number Number
1 Suction Check Valve 6 Poppet
2 Port A 7 Check
3 Port B 8 Shockless Relief Valve
4 Suction Check Valve 9 Piston
5 Shockless Relief Valve

Page 8
Parts List
2 3
1
4
P1
8 7 6 5
HKA7042L
Figure 4
Reference Reference
Number Number
1. Bearing Housing 23. Spring
2. Pinion Gear 24. Inner Seal
3. Ball Bearing 25. Pin
4. Ball Bearing 26. Out Seal
5. Hex Plug 27. Shaft
6. X- Ring 28. Seat Roller
7. Retainer Ring 29. Valve Drive
8. O-ring 30. O-ring
16. Seal 31. Valve Housing
17. Wear Plate 32. Steel Ball
18. O-ring 33. Plug
19. Valve Plate 34. O-ring
20. O-ring 35. Spring
21. Valve 39. Hex Plug
22. Balance Plate

Page 9
Specifications
74
20 PF 3/8
T
45.7
A B
58
45 101 45
108
85
125
49
48
63.5 194 PF 3/8
HKA7001L
Figure 5
Item Specification
Displacement 158 cc
(9.64 in3)
Maximum rpm 68.7 rpm
Rated Flow Rate 16 l/min
(4.22 gpm)
Relief Set Pressure 150 kg/cm2
(2,134 psi)

Page 10
SPECIAL TOOLS AND
MATERIALS
Recommended Tools
Tool Description Remarks
Capacity
Torque Wrench 9 kg•m
(65 ft lb)
HKA7003L
Socket Wrench 9/16"
HKA7004L
Plier for φ 35
HKA7005L
Straight Screw Driver
HKA7006L
Plastic Hammer
HKA7007L
Capacity
Press 9 kg•m
(65 ft lb)

Page 11
AND ADJUSTMENT
Swivel Turn Measurement

1. Fill the bucket with approximately 60 kg (130 lb) of
material.
2. Park the machine on an incline with an angle of 12° with 12°
the hydraulic oil temperature at 50° ±5°C 50°C
(122° ±41°F)
3. Fully extend the arm cylinder, position the boom cylinder
parallel to the surface of the incline and shut down engine.
4. Measure the amount of swing bearing outer race
movement after 3 minutes.
HKA7043L
Model Standard Limit Weight Figure 6
100 mm (4 in) 200 mm (8 in)
DX15 60 kg (130 lb)
or less or less
AMOUNT OF DRAG WHEN SWINGING IS STOPPED

1. Position the machine on a level ground with high engine
rpm, oil temperature at 50°C ±5°C, and at maximum
operating radius as shown, and align the boom joint 1
parallel to the arm bucket coupling pin. 1 2
2. Apply a weight to the bucket tip, and measure the moving

length with the bucket tip as a basis after making a turn.
NOTE: Bucket load: 60 kg (132 lb)
3
HKA7044L
Figure 7

Page 12
DISASSEMBLY
1. Turn motor with pinion gear facing down and clamp into a
vice. Remove mounting bolts.
Figure 8
2. Remove valve housing.

NOTE: Be careful not to lose the spring pin.
Figure 9
3. Remove balance plate and valve.
Figure 10
4. Remove valve plate and valve drive.
Figure 11

Page 13
5. Remove seat roller and drive.
Figure 12
6. Remove plate.
Figure 13
7. Remove retaining ring.
Figure 14
8. Remove pinion gear using a plastic hammer or press.
Figure 15

Page 14
9. Detach X-ring from bearing housing.
Figure 16
10. Remove ball bearing by punching the inner face seal of

bearing with a lock pin punch.
Figure 17
11. Remove ball bearing from bearing housing.
Figure 18
12. Remove plug, spring and steel ball from valve housing.
Figure 19

Page 15
13. Disassembled Swing Motor
Figure 20

Page 16
(WEAR LIMITS AND TOLERANCES)
Inspect all components and precision surfaces, to confirm that
they haven't been worn beyond service limits. Refer to table
below for dimensional specifications.
All parts should be cleaned, air-dried and relubricated with
clean, approved type hydraulic fluid, before final reassembly or
as the final step after the unit has been put back together.
Replacement of all O-rings and oil seals with new parts is
generally recommended, unless motor has had minimal use.
Inspect O-rings and oil seals very carefully for cuts, nicks,
brittleness or softness, or any other type of damage or distortion,
before final reassembly.
NOTE: When parts exceed the standard, replace them.
When there is conspicuous surface damage, it is
always safer to replace parts, whether standards are
exceeded or not.

Page 17
REASSEMBLY
1. Assemble ball bearing to bearing housing using a plastic
hammer.
Figure 21
2. Assemble X-ring to bearing housing.
Figure 22
3. Insert pinion gear into bearing housing with a press.
Figure 23
4. Mount plunger in a vice, attach retaining ring to pinion

gear.
Figure 24

Page 18
5. Attach shaft face seal (1, Figure 26) to wear plate (2).
NOTE: Take note of the flat and rounded surfaces of
the seal and mount with the flat surface faced
down.
Figure 25
2 HKA2027L
Figure 26
6. Assemble drive to bearing housing. After assembling

O-ring to bearing housing, attach wear plate to bearing
housing.
Figure 27
7. After assembling O-rings (9022S-6, 9022S-12) to wear

plate, attach seat roller.
Figure 28

Page 19
8. Assemble valve drive to seat roller.
Figure 29
9. After attaching O-ring (9022S-12) (9022S-6) to valve plate,

assemble valve plate.
NOTE: When assembling, be careful to match up the
drain hole of valve plate and seat roller.
Figure 30
10. Assembly of the valve.

Because the assembly of valve is a important operation
1
which determine the rotating direction of motor, be careful
for the operation and refer to Figure 31.

1 Valve Drive Shaft
2 Valve
2
3 Z-rotor Star 4 3 15
4 Z-rotor Star and Valve Timing HKA7032L

Figure 31
11. Assemble plug, spring and steel ball to valve housing.
Figure 32

Page 20
12. Assemble spring and pin to valve housing.
Figure 33
13. Attach inner face seal (2, Figure 35) and outer face seal (1)
to balance plate (3).
Figure 34
Reference Number Description 2

1
1 Outer Seal
2 Inner Seal
3 Balance Plate
3 HKA7037L
Figure 35
14. After matching up the cutting face of balance plate (3,

Figure 36) to pin, assemble it to valve housing (1). 1
2
1 Valve Housing 3
2 Outer Seal
3 Balance Plate 4
4 Inner Seal
HKA7036L
Figure 36

Page 21
15. Attach O-ring to valve housing. After inserting a drive or
long thin rod into hole of port, assemble valve housing to
valve pressing not to be loosen the balance plate.
Assemble valve housing to valve matching up the drain
hole of valve housing and valve plate.
Figure 37
16. Attach hex bolt (4 pieces) using a socket wrench.

NOTE: Tightening Torque: 5 kg•m (36 ft lb).
Figure 38

Page 22
SP001528
TRAVEL MOTOR (WITH GEAR BOX)SP001528
Travel Motor
(With Gear Box)
Edition 1
Travel Motor (With Gear Box) SP001528

Page 1
MEMO

Page 2
Table of Contents
Travel Motor (With Gear Box)

Model / Type Description................................................. 6
Specifications .................................................................. 7
Cross Section Drawing .................................................... 8
Operating Principle Diagram ........................................... 9
Operation Description.................................................... 10
Handling ........................................................................ 14
Parts List ....................................................................... 16
Assembling Procedure ....................................... 21
General Attention .......................................................... 21
Hydraulic Motor Section ................................................ 22
Reduction Gear Section ................................................ 30

Page 3
Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DX15 40001 and Up
DX18 40001 and Up

Page 5
GENERAL DESCRIPTION
Model / Type Description
PHK- 120-37-1-8341A
Design Number
Painting Code
Gear Reduction Ratio
Nominal Output Torque
PHV series wheel motor

Page 6
Specifications
Item Specifications
Max. Output Torque 1225 Nm (125 kg•m (904 ft lb))
Speed Reducer Max. Output Shaft Speed 38.5/76.2 min-1
Gear Reduction Ratio 1 : 36.96
12.4/6.2 cc/rev
Displacement
(0.76/0.38 in3/rev)
Max. Operating Pressure 20.6 MPa (210 kg/cm2 (3,000 psi))
Max. Output Speed 1423/2816 min-1
Hydraulic Motor 18 liters/min
Max. Flow Rate
(4.8 gpm)
Parking Brake Static Friction Torque None
Parking Brake Releasing Pressure None
Speed Control Pressure None
Cracking Pressure None
Relief Valve
Setting Pressure None
458.3/229.2 cc/rev
Total Displacement
(27.97/13.99 in3/rev)
Hydraulic Oil ISO - VG 46
-20 - 100°C
Oil Temperature
(-4° - 212°F)
Filtering 10 μm
Etc.
SAE 30-CD
Reducer Lubricating Oil
Amount: 330 cc (11 oz)
17 kg
Weight
(37 lb)
Under coat: Red
Paint Color
Top coat: None

Page 7
Cross Section Drawing
Figure 1

Page 8
Operating Principle Diagram
Figure 2

Page 9
Operation Description
All PHK - series wheel motors consist of a fixed section, which is
made up of a hydraulic motor, a hydraulic valve unit, and a
rotary section. The rotary section is a simple planetary speed
reducer.
Speed Reducer
1. Function
The PHK - series wheel motor speed reducer is a double
reduction, planetary gear arrangement. The gearing
converts the high-speed rotary motion transmitted from the
hydraulic motor into low-speed high torque to obtain case/
sprocket rotation.
2. Principle of operation
The output shaft of the hydraulic motor has a spline
connected gear s2, of which the rotational speed is
reduced one step between gears a2, b2, and s2.
The one step reduced rotational speed is reduced another
step between gears a1, b1, and s1 that have been
connected to carrier 2 via a spline. The rotational speed
that has thus been reduced two step is transmitted through
gears a1, and a2 to the rotary section of the motor body to
drive the wheel motor.
The PHK - series swivel motor speed reducer is of a
double reduction, planetary gear arrangement. The
gearing converts the high-speed rotary motion transmitted
from the hydraulic motor into low-speed high torque to
obtain pinion shaft rotation.
Figure 3
A. In general, two-step simple plenary gear reduction
ratio R is expressed as:
Zs1 Zs2
R = ------------------------- ⋅ -------------------------
Zs1 + Za1 Zs2 + Za2
NOTE: Zs1 + Zs1: Number of teeth of gears s1 and s1,

respectively.
Za2 + Za2: Number of teeth of gears a2 and a2,
respectively.
B. Since the PHK - series swivel motor body itself
rotaries, gear reduction ratio R is expressed as
follows:
1
R′ = -------------------
1–1⁄R

Page 10
Hydraulic Motor
1. Function
The hydraulic motor used in this product is an axial piston
type (rotary cylinder swash plate type), and converts the
hydraulic energy supplied from the pump into a rotary
motion.
2. Construction of the motor and the principles of operation
The hydraulic oil flowing on through the hydraulic valve is
fed to valve plate 5. When hydraulic oil is fed to port A, this
oil flows into that cylinder port of cylinder barrel 4 that
corresponds to port A. This presses piston 6. This pressure
is converted into rotating force via swash plate 7, and then
taken out to shaft 3 connected to cylinder barrel 4 via a
spline. The return oil in the cylinder port flows out through
port B of valve plate 5.
For backward location, the hydraulic oil flows in from port B
and the return oil flows out from port A.
Figure 4

Page 11
3. Two Speed Motor Operation
The swash plate, which has two surfaces (I and II) on the
opposite side of sliding shoe surface. The swash is
supported by two pivot balls that are mounted in the motor
body 2. These two pivot balls allow the swash plate to tilt.
Since the two pivot balls are in an offset position from the
center line of the drive shaft and cylinder block, in the low
speed range, surface I is forced into contact with body 2,
by the supply oil pressure in the piston and the spring in
the cylinder barrel. The swash plate angle is α (Max.
capacity). This action causes the motor displacement
capacity is increased. This increase in displacement allows
the same volume of supply oil to rotate the motor at a
slower speed, but produces more torque.
When a speed change is made, the pressurized supply oil is
routed to the control chamber. The control chamber
contains a control piston. The control piston then presses
against surface I of the swash plate. The swash plate
moves/tilts until surface II contacts body 2, and the swash
plate angle becomes β. This action causes the motor
displacement capacity is decreased. This decrease in
displacement allows the same volume of supply oil to rotate
the motor at a higher speed, but produces less torque.
When a engine is stopped, the control chamber is
connected to the tank port and the swash plate returns to
the low speed position by the spring force. Starting position
is always the low speed.
Figure 5

Page 12
Hydraulic Valve
1. Structure
When pressurized supply oil is present at port A, the oil
opens check valve 3 and flows into the hydraulic motor
inlet port A. At the same time, a portion of the pressurized
oil passes through orifice C into chamber D, and moves
spool 2 to the right. Then the return oil from the hydraulic
motor, flows into port B, passing through area E, and
rotates the hydraulic motor. When the pressurized oil is
supplied to port B, the hydraulic motor rotates in the
opposite direction.
When the pressurized supply oil to port A is shut off, the
hydraulic motor continues to try and rotate due to inertia
force. When the pressurized supply oil to port A is shut off,
spool 2 tries to return to the left by the spring 4 force. At
this time, the oil in the chamber D tries to go out to port A
through the orifice C, but due to the throttle effect of orifice
C, the spool 2, speed is reduced. With the orifice and
notches on the spool, the returned oil is controlled
gradually and the hydraulic motor stops smoothly.
Figure 6

Page 13
Handling
Mounting
0
1. Sprocket pilot dimension A: 140h8-0.063
0
Sprocket pilot dimension B: 140h8-0.063
Figure 7
2. When installing the motor to the machine and/or attaching

the sprocket to the motor, do not force the sections and/or
strike them with a heavy object as damage may result. The
best method is to use the mounting bolts as a guide and
slowly slide it into place.
3. Use the specified bolts (equivalent grade 12.9 or higher)
for mounting the motor and the sprocket, and tighten using
the following torque.
Bolt Size Tightening Torque

49 - 64 Nm
M10
(5.0 - 6.5 kg•m)
Piping
1. The installation drawing shows the motor piping. Pay
attention to the rotating direction and piping.
2. When shipped, rubber plugs (or steel plugs for drain ports)
are attached to the piping ports. When piping, pay attention
as not to introduce dirt or welding scale into the ports.
3. One of two drain ports is used as a drain line. Use the
upper side port, and fill with 200 cc (7 oz) of hydraulic oil,
then connect the piping.
4. The permissible drain pressure is limited by the oil seal.
Therefore, pay attention to the size of drain piping so that
the drain pressure does not exceed the limit especially in
low temperature environment. The permissible pressure is
43 psi (3 kg/cm2) (Rated) and 143 psi (10 kg/cm2) (Peak).
5. Fine filtration prolongs the hydraulic system life and
ensures high reliability. Install a 10 μm filter, or better filter
in the circuit.

Page 14
Gear Lubricating Oil
1. Use diesel engine oil SAE 30-CD or equivalent as gear
lubricating oil. (when shipped, Idemitsu Apoloil Diesel
Motive S-330 is used.)
2. Any recommended gear oil can be used, but drain old oil
completely, and do not mix.
3. When shipped, gear box is prefilled. Take the following
steps to refill. All plugs are sealed by O-ring.
Figure 8
A. Remove the oil supply port plug and the level check
port plug.
B. Fill the oil from the oil supply port up to the "LEVEL."
C. Check the oil amount and install the oil supply port
plug and the level check port plug.
4. Gear oil amount: 330 cc (11 oz)
5. Gear oil change period
A. First change: 200 hours or 2 months
B. Second and after: 1,000 hours or 1 year
General Precautions
1. Always pay attention to oil leaks and loose bolts, and find
out these trouble as soon as possible to prevent damage to
the motor or machine.
2. Making a check sheet is recommended.

Page 15
Parts List
Reduction Gear
Figure 9

Page 16
Reference Reference
Number Number
101 Body 120 Bearing
102 Cover 121 Thrust Washer
104 Carrier 2 122 Retaining Ring
106 B1 Gear 123 Retaining Ring
107 B2 Gear 127 Spring Pin
108 S1 Gear 129 O-ring
109 S1 Gear 130 O-ring
111 B2 Pin 131 Plug
112 Seal Ring 132 Name Plate
113 O Retaining Ring 133 Hydraulic Motor
114 Thrust Plate 134 Thrust Washer
115 Slide Ring 135 Plug
116 Needle 136 O-ring
117 Needle 137 Retaining Ring
118 Floating Seal 138 Ring
119 O-ring 139 O-ring

Page 17
Hydraulic Motor
Figure 10

Page 18
Reference Reference
Number Number
202 Body 2 214 Retainer
203 Shaft 215 Bearing
204 Cylinder Barrel 216 Bearing
205 Valve Plate 217 O-ring
206 Piston 218 O-ring
207 Shoe 219 Oil Seal
208 Shoe Holder 220 Pivot Ball(s)
209 Barrel Holder 221 Retaining Ring
210 Swash Plate 222 Screw
211 Control Piston 223 Spring Pin
212 Pin 224 Pin
213 Spring C 225 Plug

Page 19
Figure 11
Reference Reference
Number Number
301 Body 1 313 Choke
302 Spool 314 Ring
303 Check Valve 315 Plug
304 Spring Guide 316 Plug
305 Spool 317 O-ring
306 Shuttle Spool 318 O-ring
307 Spring V1 319 O-ring
308 Spring V2 320 Choke
309 Spring V3 321 Needle
310 Plug 322 Plug
311 Plug 323 Choke
312 Plug

Page 20
ASSEMBLING PROCEDURE
General Attention
1. Clean each part with cleaning solvents before assembling
the parts.
2. Keep the parts free from foreign materials. Any foreign
materials trapped in the assembled parts may cause
seizure, galling, or other troubles.
3. Give special care to protect parts and seals such as
O-rings and oil seals from being damaged during
assembling or disassembling.
4. The disassembling procedure is in the opposite direction of
assembling. Please refer to the cross section drawing and
the parts list.
NOTE: Wheel motors include some parts which have
been assembled by press fitting. These parts
(for example, bearing and pin.) can not be
disassembled.

Page 21
Hydraulic Motor Section
1. Insert spool assembly, ring and spring into body 1.
2. Install plugs with new O-rings.
NOTE: a. The spool assembly can not be
disassembled.
b. Plugs tightening torque: 167 - 196 Nm. (123 -
145 in lb) (Both sides)
c. Hex size: 27 mm
Figure 12
Figure 13
Figure 14
Figure 15

Page 22
3. Press two-speed spool and spring into body 1. Secure
them in position with plug (each side) and O-ring.
NOTE: a. Tightening torque: 46 - 51 Nm (33 - 36 ft lb)
b. Hex size: 8 mm
c. Pay attention to installation direction of spool
and spring.
Figure 16
Figure 17
Figure 18
4. Press shuttle spool and ring into body 1. Secure them in

position with plug (each side).
NOTE: a. Tightening torque: 5.9 Nm (2 places) (4 ft lb)
b. Hex size: 5 mm
Figure 19

Page 23
Figure 20
Figure 21
5. Press bearing and spring pin into body 1.
Figure 22
6. Install O-rings (3 pcs) onto body 1.

NOTE: Apply a light coating of grease on O-rings to
help hold them in position.
Figure 23

Page 24
7. Press oil seal into body 2.
NOTE: a. Apply grease to O.D. of oil seal.
b. Pay attention to direction of oil seal lips. Make
sure that it is pressed in straight and is not
crocked.
Figure 24
Figure 25
8. Install pin into body 2.
Figure 26
9. Press bearing on shaft.
Figure 27

Page 25
10. Install control piston into body 2.
Figure 28
11. Install shaft into body 2.

NOTE: Be careful not to damage oil seal with shaft.
Figure 29
12. Install swash plate with ball into body 2.

NOTE: a. Apply oil to working face of swash plate.
b. Apply grease to back side of swash plate to
keep it from falling out.
Figure 30
Figure 31

Page 26
13. Install retainer, spring and retainer into cylinder barrel.
Secure them into place with retaining ring.
Figure 32
Figure 33
Figure 34

Page 27
14. Install three pins, barrel holder and shoe holder assembly
which piston shoe assemblies have been placed on shoe
holder to cylinder barrel to make up a cylinder barrel
assembly.
NOTE: Coat pistons and piston holes in cylinder barrel
with oil.
Figure 35
Figure 36
Figure 37
15. Coat swash plate with oil. Insert cylinder barrel assembly
into body 2 so that shoes contact swash plate.
NOTE: Fill body 2 with 100 cc (3.4 oz) of oil for initial
lubrication.
Figure 38

Page 28
16. Position valve plate onto body 1. Secure body 1 to body 2.
NOTE: a. The copper face of valve plate should be
facing up.
b. Apply oil to copper face of valve plate.
c. Apply grease to steel face of valve plate to
keep it from falling out.
Figure 39
Figure 40
17. Fasten body 1 to body 2 with hex socket head bolts.

NOTE: a. Tightening torque: 28.4 - 30.4 Nm (20 -
22 ft lb)
b. Hex size: 5 mm
c. If you hold motor in a vice, protect it with
aluminum plates or equivalent.
Figure 41

Page 29
Reduction Gear Section
1. Position floating seal with O-ring on motor.
NOTE: Apply grease to O-ring to aid installation, and
then wipe excess grease from seal surface.
Figure 42
2. Install inner race and bearing retainer with balls into

hydraulic motor (1 set)
NOTE: a. Pay attention to direction of inner race and
retainer. (See cross section drawing for
direction.)
b. Do not disassemble balls from retainer.
Figure 43
Figure 44
3. Position floating seal with O-ring on body.

NOTE: Apply grease to O-ring to aid installation, and
then wipe excess grease from seal surface.
Figure 45

Page 30
4. Position body on motor.
NOTE: a. Degrease surface of floating seal.
b. Hold speed reducer flange to motor flange with
C-clamps or a hydraulic press (see illustration).
Figure 46
Figure 47
5. Install bearing retainer with balls and inner race of bearing

into hydraulic motor (1 set).
NOTE: a. Pay attention to direction of inner race and
retainer. (See cross section drawing for
direction.)
b. Do not disassemble balls from retainer.
Figure 48
Figure 49

Page 31
6. Secure bearing in position with retaining ring.
NOTE: The preload for bearings is adjusted by
thickness of retaining ring.
Figure 50
7. Install four rings (1 pc / 1 pin), four thrust washers (1 pc / 1

pin) and sixty needles (15 pcs / 1 pin) into body 2.
Figure 51
Figure 52
Figure 53

Page 32
8. Press b2 pins and spring pins into carrier 2.
NOTE: These parts can not be disassembled.
Figure 54
9. Position S1 gear in carrier 2. Secure it in place with

retaining ring.
NOTE: a. Pay attention to direction of retaining ring.
The edged side should be facing up.
b. Pay attention not to open retaining ring too
much. The retaining ring which loses a tension
should be replaced.
Figure 55
10. Install three thrust washer (1 pc / 1 pin), three b2 gears (1

pc / 1 pin), thirty-nine needles (13 pcs / 1 pin) and three
thrust washers (1 pc / 1 pin) into carrier 2. Secure them in
position with three retaining rings.
NOTE: a. Pay attention to direction of retaining ring.
b. Do not open retaining ring too much. If
retaining ring loses tension, replace it.
Figure 56
Figure 57

Page 33
11. Insert thrust plate and secure it with retaining ring.
NOTE: a. The convex face of thrust plate should be
facing up.
b. Pay attention to direction of retaining ring.
c. Do not open retaining ring too much. If
retaining ring loses tension, replace it.
Figure 58
Figure 59
12. Install carrier 2 assembly in body, making sure that all

gears are properly engaging each other.
Figure 60
13. Install O-ring in body.

NOTE: Apply grease to O-ring.
Figure 61

Page 34
14. Position slide ring on cover.
NOTE: Apply grease to slide ring to prevent it dropping
out.
Figure 62
15. Fill body with 300 cc (10 oz) of gear oil before installing
cover.
NOTE: a. Do not to damage O-ring.
b. The vertical tapped hole should be located to
notches of body.
Figure 63
Figure 64
16. Install O-retaining ring in groove of body to secure cover in

position.
NOTE: Using a flat tipped punch, tap retaining ring, to
install it in groove. Do not damage housing.
Figure 65

Page 35
Figure 66
17. Screw two plugs (size: G 3/8) with O-ring into cover.
NOTE: a. Tightening torque: 46 - 51 Nm (34 - 38 ft lb)
b. Hex size: 8 mm
Figure 67

Page 36
SP001529
PILOT CONTROL VALVE (WORK LEVER /
JOYSTICK) SP001529
Pilot Control
Valve (Work
Lever / Joystick)
Edition 1
Pilot Control Valve (Work Lever / Joystick) SP001529

Page 1
MEMO

Page 2
Table of Contents
Pilot Control Valve (Work Lever / Joystick)

Parts List ....................................................................... 10
Performance .................................................................. 12

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DX15 40001 and Up
DX18 40001 and Up

Page 5
GENERAL DESCRIPTION
Theory of Operation
The pilot control valve contains four push rods, a spring holder
and return spring, which are in the valve casing. The valve
works as a pressure reduction valve. The housing has six ports,
which include input port "P," tank port "T" and four secondary
pressure ports.
The electric horn button is installed in the valve handle. Gear
pump pressure is used for operating control spools.
PUSH BUTTON PUSH BUTTON

SWITCH (L) SWITCH (R)
P T
19ƁSINGLE
25ƁDOUBLE
1 3 2 4
(267.9) HYDRAULIC SYMBOL
12.25
T
90
P
4 3 2 1
113
(131)
3 2
P
4 1
T 71
4- 7
6-PF1/4 O-RING PORT
27
71
98
BTS0030L
Figure 1
Maximum Primary Pressure 40 kg/cm2 (569 psi)

Permissible Exhaust Pressure 3 kg/cm2 (43 psi)
Rated Flow 20 liters (5.5 U.S. gal.)

Page 6
Figure 2
Reference Reference
Number Number
1 Body 8 Spring
2 Plug 9 Spring Seat
3 O-ring 10 Spool
4 Spring 11 Push Rod
5 Spring Seat 12 Plug
6 Spring Seat 13 O-ring
7 Stopper 14 Rod Seal

Page 7
Neutral Mode
The force of spring (2) setting up the output pressure of the pilot
valve does not act on the spool (1). Accordingly, the spool is
pushed upward by the spring (8) to reach the location of port B
in the diagram As a result, it indexes with the tank port T only
and the output port pressure becomes equal to tank pressure.
Control Mode
The spool moves downward according to the push rod (3)
stroke. Also, the port P is indexes with the port A so that the oil
fed from the pilot pump flows out to the port A to produce
pressure. If the pressure of port A increases up to that
corresponding to the spring force set by inclining the lever, the
hydraulic pressure and spring force becomes in a balanced
state. Furthermore, if the pressure of port A exceeds the set
pressure, the port A and P are closes, while A and T are
opened; if the pressure of port A goes down below the set
pressure, the port A and P are opened, while A and T are
closed. This principle of operation maintains the secondary
pressure stable.

Page 8
Page 9
Parts List
24
23
20
22
19 21
18 17
10 31
13
15 16
30
14
5 11
12
29
25 6
26
27
4
28
3 2 1 32 8
9
BTS0050L
Figure 3

Page 10
Reference Reference
Description Reference Description Reference
Number Number
1 Body 19 Hex Nut
2 Plug 20 Handle Bar
3 O-ring P8 21 Nut M14x2.0P
4 Spring 22 Boot
5 Spring Seat 23 Spring Pin ø5x28L
6 Stopper Handle
24
7 Spring Assembly
8 Spring Seat 25 Terminal
9 Spool 26 Seal Wire
10 Push Rod 27 Housing
11 Plug 28 Housing Rear
12 O-ring 4D-P20 29 Clip Band
13 Rod Seal DYR12 (H90) 30 Plate (B)
14 Plate (A) 31 Boot
15 Bushing 32 Plug PT3/8
16 Machine Screw M6x20 33 Spool Kit 5, 6, 7, 8, 9
17 Joint Assembly 34 Plug Kit 10, 11, 12, 13
18 Swash Plate 35 Handle Kit 20, 21, 22, 23, 24

Page 11
Performance
40
SECONDARY PRESSURE (kgf/cm)

36.7
OPERATING TORQUE (kgf.cm)

24.1 +
_2
OPERATING TORQUE
19.5 +
_ 1.5
6.7 +
_1
5+
_ 0.75 SECONDARY PRESSURE
7
0 1.1 6.5
PUSH-ROD STROKE(mm)
BTS0060L
Figure 4

Page 12
SP001530
MAIN PUMP SP001530
Main Pump
Edition 1
Main Pump SP001530

Page 1
MEMO
Main Pump SP001530

Page 2
Table of Contents
Main Pump

Pump Function ................................................................ 9
Special Tools and Materials ............................... 11
Special Tools ................................................................. 11
Lubricants and Sealants ................................................ 12
General.......................................................................... 13
Relief Valve ................................................................... 15
Overview of Set Torque Adjustment.............................. 16
Adjustment (Warranty) .................................................. 16
Procedures for Test Operation ...................................... 16
Disassembly ....................................................... 18
Precautions When Disassembling and Reassembling .. 18
Gear Pump Disassembly............................................... 18
Trochoid Pump Disassembly......................................... 19
Main Pump Disassembly............................................... 20
Shaft Disassembly......................................................... 23
Swash Plate .................................................................. 23
Cover Disassembly ....................................................... 24
Housing Disassembly .................................................... 25
Relief Valve Disassembly .............................................. 26
GeaR Pump (GSP2) Disassembly ................................ 27
Tolerances)......................................................... 29
Reassembly ........................................................ 31
Housing Reassembly .................................................... 31
Assembling Swash Plate ............................................... 33
Shaft Reassembly ......................................................... 34
Rotary Group Reassembly ............................................ 36
Main Pump SP001530

Page 3
Control Spring and Spring Washer Reassembly ........... 37
Cover Reassembly ........................................................ 37
Relief Valve Reassembly .............................................. 38
Cover Reassembly ........................................................ 39
Trochoid Pump .............................................................. 40
Mounting Gear Pump .................................................... 42
Gear Pump Reassembly ............................................... 43
Main Pump SP001530

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DX15 40001 and Up
DX18 40001 and Up
Main Pump SP001530

Page 5
GENERAL DESCRIPTION
This pump is a variable capacity double piston pump which
delivers equal amounts of oil to two places from a single cylinder
block. As a double pump, it is outstanding in its compactness
when performing the function of a single pump. Since this pump
has only one swash plate control, the angle of inclination of the
two pumps become identical. The pump's angle of inclination
varies depending upon the total pressure P1+P2 are the same.
In other words, output is controlled consistently so that the
relationship of delivery pressure and oil flow Q, (P1 + P2) x Q is
constant.
The 3rd pump or pilot pump can be linked to the same shaft with
a coupling placed in between them.
EXTERIOR, CIRCUIT DIAGRAM AND PORTS OF AP2D12-952
Figure 1
Main Pump SP001530

Page 6
Port Name Size / Standard
S1 Suction Port SAE 1 1/2 (Standard)
A1•A2 Delivery Port G1/2-17 (JIS B2351 O type)
A3 Delivery Port G1/2-17 (JIS B2351 O type)
A4 Pilot Port G38-13 (JIS B2351 O type)
R1 Air Bleeding Port M10x1.0 generic plug
R2 Air Bleeding Port M10x1.0 (Attached to bleeder pump)
Main Pump SP001530

Page 7
Theory of Operation
Figure 2
Reference Reference
Number Number
1 Drive Shaft 6 Gear Pump
2 Hanger 7 Housing
3 Rotary Group 8 Trochoid Pump
4 Cover 9 Relief Valve
5 Spring Seat 10 Control Spring(s)
The pump is a variable capacity double piston pump which

delivers equal amounts of oil to two places from a single cylinder
block. It is a single rotary group and thus there is only one
suction port. However, the control plate on the cover side
separates oil flow into two equal amounts, and delivers it to the
two delivery ports on the cover.
The 3rd pump or pilot pump can be linked to the same shaft with
the coupling placed in between them.
Main Pump SP001530

Page 8
Pump Function
Figure 3
The cylinder block is splined to the drive shaft. As the drive shaft
turns, the cylinder block is rotated.
The pistons inserted into the cylinder block, reciprocate along
the slide face on the swash plate.
During the cylinder block rotation, from bottom dead center to
top dead center, the pistons move, enlarging their intake
capacity, and thus draw oil into the cylinder block. Oil being
drawn into the cylinder block passes through the control plate on
the suction port side. (Suction stroke.)
During the cylinder block rotation, from top dead center to bottom
dead center, the pistons move, reducing their oil capacity, and
thus oil is delivered to the delivery port. (Delivery stroke.)
The inclination/angle of the swash plate (sliding face) can be
changed, so the pump's delivery capacity can be varied.
Oil taken from the inner port of the cylinder block is delivered
from the inner delivery port of the control plate.
Oil taken from the outer port of the cylinder block is delivered
from the outer delivery port of the control plate.
Main Pump SP001530

Page 9
Control Function
Figure 4
The piston slides on the swash plate, and is under the influence
of oil pressure caused by delivery pressures, P1 and P2, acting
on the swash plate.
Control springs are arranged, so that they counterbalance the
delivery pressure.
If oil pressure acting on the swash plate with the piston placed in
between is less than control spring mounting load, it is moved to
the maximum rotating position.
If oil pressure acting on the swash plate with the piston placed in
between is greater than control spring mounting load, the swash
plate rotates and the rotation continues at the point balancing
the oil pressure and control spring pressure. (Area A in the
slanting lines)
If P3 oil pressure acts on the shift piston, the control line diagram
moves.
Main Pump SP001530

Page 10
SPECIAL TOOLS AND
MATERIALS
Special Tools
Disassembling and reassembling pump requires the following
tools and jigs.
Tools
Name Quantity Size (nominal)

Hex-stem Spanner 1 each 4.8
Spanner 1 each 14, 24
Plastic Hammer 1 Medium size
Retaining Ring Pliers 1 For hole (for retaining ring 22)
Retaining Ring Pliers 1 For shaft (for retaining ring 18)
Something that can be tightened to a
Torque Wrench –
specified torque
Grease small
Adhesive small Loctite Hightech Sealant #98
Jig for Disassembly and Reassembly

This plate is used to position the pump, so that it faces
downward, and that the end of the shaft does not contact the
work surface.
Figure 5
Main Pump SP001530

Page 11
Cover Disassembly and Jig for Assembly
When disassembling or reassembling, a jig is needed to protect
the drive shaft.
When Disassembling - When the four hex socket bolts (M10) are
removed, the jig prevents the cover from being lifted obliquely by
the control spline.
When Reassembling - With the cover remaining horizontal,
mount it to the housing.
The right-hand figure shows the jig structure.
The jig is of such a structure that it pushed the machined leading
end (Note) of hex socket screw (M16x120) against the adjust
screw to press the cover.
NOTE: If hex socket screw is used, machine the part off
10 mm from the leading end to ø4.
Lubricants and Sealants Figure 6
For hydraulic oil, use general petroleum based fluid or hydraulic

fluid with resistance to wear (equivalent to ISO 3448, VG
32~56).
The viscosity range is as follows:
Maximum allowable viscosity: 1,000 mm2/s
Minimum allowable viscosity: 10 mm2/s

Recommended range of viscosity: 16 ~ 36 mm2/s
Main Pump SP001530

Page 12
AND ADJUSTMENT
General
The following shows the cause and corrective measures for
each complaint:
Countermeasures and
Complaints Cause Checks
Troubleshooting
Unusual 1. Entry of air caused by Check oil level of working oil. Add working oil.
noise low oil in hydraulic tank.
Check the filter. Clean or replace the element.
2. Increase in loss of
Check working oil Readjust RPM.
suction pressure due to
temperature and working oil
filter restriction. Replace sliding parts or pump.
type.
3. Increase in loss of Reset pressure.
Check the input shaft for RPM.
Flush the circuits.
increase in viscosity of Check pressure which is
working oil at low likely to cause overload. Change working oil.
temperature.
Measure contamination
4. RPM at the input shaft of working oil.
exceeds the specified
Check working oil for
value.
whitened turbidness
5. Mechanical damage to due to entry of moisture
bearings and so on. in working oil.
Main Pump SP001530

Page 13
Countermeasures and
Troubleshooting
Shortage of 1. Decrease in rpm at the Check the input shaft for Readjust RPM.
oil flow input shaft. RPM.
Stop operation, and check
2. Oil temperature is Check oil temperature. again if oil temperature falls.
abnormally high.
Check working oil type and oil Change old working oil to new
3. Viscosity is excessively temperature. oil with the specified viscosity.
high.
Check to see if it generates at Replace switching valve and
4. Increase in leakage a specific actuator. actuator.
from switching valve
Check to see if it generates at Replace the pump.
and actuator.
a specific pump.
Reset and lock.
5. Decrease in volumetric
Check lock nut for looseness.
efficiency of the pump. Add working oil.
Check working oil for oil level.
6. Loosening of adjust Clean or replace the element.
screw due to decrease Check filter.
Change old working oil to new
in horse power.
Check working oil type and oil oil with the specified viscosity
7. Entry of air due to temperature. and temperature.
lowered oil surface.
filter restriction.
increase in viscosity of
working oil at low
temperature.
Pressure 1. Decrease in relief valve Measure circuit pressure. Reset the relief valve.
wouldn't go settings.
Check to see if each actuator Replace the switching valve
up
2. Increase in leakage functions normally and there and actuator.
from switching valve is no heat at the piping
Replace the pump.
and actuator. located at the end of the tank.
3. Decrease in volumetric Check to see if it generates at
efficiency of the pump. a specific pump.
Overload at 1. Increase in pump horse Check the motor for Adjust with pliers or reset the
static power settings. temperature and working motor noise.
no-load speed.
2. Malfunction of Correct damage by
controller. Check to see if there is no engagement or replace.
foreign materials on each
3. Mechanical damage to Replace sliding parts or pump.
sliding part of the controller.
bearing and so on.
Check the housing around
bearing for unusual heat or
noise.
Main Pump SP001530

Page 14
Countermeasures and
Troubleshooting
Drop in rpm 1. Pick pressure Check the circuits for unusual Replace the relief valve.
at dynamic generated due to vibration and measure
Remove foreign
load decrease in reaction of pressure.
materials.
the relief valve.
Check the pilot lines for
Correct damage by
2. Decrease in reaction of foreign materials.
engagement or replace.
the controller.
Check each sliding part
on the controller for
foreign materials.
Unusual 1. Increase in leakage. Measure the actuator speed. Replace the pump.
heat
2. Mechanical damage to Check for where unusual Replace sliding parts or pump.
generation
bearing and so on. noise or heat is produced.
Replace sliding parts or pump.
3. Seized sliding parts. Check for where heat is
produced.
Oil leaks 1. Damaged O-ring and Check for location of oil leak Replace seal material.
packings. and check to see if unusual
Replace seal material.
pressure is produced.
2. Damaged oil seal.
Replace the input shaft or
Check for damage by foreign
3. Worn oil seal contact pump.
materials and check to see if
part on the input shaft.
unusual pressure is Retighten or replace the seal
4. Loosening of each produced. material.
plug.
Check for foreign materials
and check to see if unusual
pressure is produced.
Relief Valve
Cause for
Check items Results Cause Countermeasures
trouble
Malfunction Check relief valve. Set pressure is low. Faulty setup. Set to the preset value.
of valve. Spool defect. Spool damaged or Replace valve.
Oil doesn't worn.
flow.
Pressure is
unstable.
External Check the relief Relief guide Defective assembly. Tighten again to the
leakage. guide for tightening loosens. specified tightening
torque. torque.
Check the O-ring Bad O-ring and O-ring and packing Replace O-ring and
and packings. packings. damaged. packings.
Check the mounting Mounting surface Mounting surface Replace valve and
face of the O-ring damaged. damaged. cover.
and packings.
Main Pump SP001530

Page 15
Overview of Set Torque Adjustment
Figure 7
Overview of adjustment
1. Loosen the hex nut.
2. Set HP line diagram by tightening or loosening the adjust
screw.
Adjustment (Warranty)
This hydraulic pump has been set up by using a specified input
horse power and flow control pressure.
If the pump is readjusted, not only will each control function not
operate properly, the pump will not be in warranty. Never touch
the adjust screw.
Procedures for Test Operation

When starting the engine, check the following items and use
care:
1. Is the tank washed and clean?
2. Is the piping clean and mounted so that stress is not
applied to it?
3. Is the piping properly connected according to the piping
diagram (circuit diagram)?
4. Are joints or properly flanges tightened?
5. Are the motor and pump joints properly mounted?
6. Is the rotating direction of the motor in the same direction
as that of the pump?
Main Pump SP001530

Page 16
7. Is the specified working oil fed through the filter? Is the tank
filled with oil up to the indicated mark on the oil level gauge?
8. Does the filter have the specified filtering precision? (10
µm or less)
9. Is the filter properly mounted in relation to the flow direction?
10. Is the pump housing filled with fluid?
11. Is the control pump set to the bypass position?
12. Start the starting motor. If necessary, run it at low speed.
13. Do not apply any load to the system and check the
actuator for movement.
14. If the motor reaches traveling speed, apply load to the
actuator for checking.
15. If a monitoring device or measuring device is installed,
check it.
16. Keep an eye on the noise level.
17. Check the oil level in the tank, and add oil if necessary.
18. Apply load to the actuator and check the pressure control
valve for setting.
19. Check to see that there are no oil leaks at each part.
Correct leaks if necessary.
20. Stop the motor.
21. Tighten all the bolts and plugs again, if oil leaks are found.
(When retightening them, be sure to set the circuit
pressure to no-load.)
22. Check the tank for oil level.
23. Check functions of the pump and actuator.
24. Irregular movement of the actuator indicates that air is still
present in the circuits. If proper air bleeding of circuits is
properly carried out, all the parts should function normally,
without any irregular movements, and there is no
generation of air bubbles on the oil surface of the tank.
25. Check oil temperature.
26. Stop the motor.
27. Check the filter, and check the element for dirt.
28. If the element has been severely contaminated, flush the
entire hydraulic circuit.
NOTE: If you repair or replace an actuator or change
the working oil to prevent the pump from being
damaged, which is likely to allow air to enter the
piping or actuator, be sure to observe the
following items:
1. After filling oil, top off working oil in the pump housing.
2. Starting should be 1000 rpm or less, but use care not to
allow oil surface to go down below the low oil level mark on
the oil level gauge.
3. When performing air bleeding from the hydraulic circuits,
keep rpm at 1000 rpm or less, rotate each actuator for 3
cycles or more, and then idle them for 5 minutes or more.
Main Pump SP001530

Page 17
DISASSEMBLY
PRECAUTIONS WHEN DISASSEMBLING AND
REASSEMBLING
1. Precautions when disassembling.
A. Never adjust the adjust screw unless adjustment is
needed.
B. When disassembling, use care not to allow parts to
contact each other or fall.
2. Precautions when reassembling.
A. Be sure to clean each part.
B. When reassembling, use care not to damage parts or
to allow foreign materials enter them.
C. Do not reuse old O-ring, oil seal, or packing.
D. DOOSAN mechanic carries out reassembling
operation using torque wrench. You also must use
torque wrench.
Gear Pump Disassembly

1. Remove two hex socket bolts (M10x2).
NOTE: Hex-stem spanner (hex width across flat: 8 mm)
NOTE: Be careful not to damage two O-rings mounted
to housing.
Figure 8
2. Remove coupling.
Figure 9
Main Pump SP001530

Page 18
Trochoid Pump Disassembly
1. Remove three hex socket bolts (M5x12).
NOTE: Hex-stem spanner (hex width across flat: 4 mm)
Figure 10
2. Remove case, side plate (A), and gear.

NOTE: Use two bolts (M5x90).
Figure 11
3. Remove gear from case.
Figure 12
4. Remove side plate (A) from case.
Figure 13
Main Pump SP001530

Page 19
5. Remove side plate (B) from cover.
Figure 14
6. Remove shaft key.
Figure 15
Main Pump Disassembly

1. Cover disassembly.
The control spring is very strong, use a jig to press spring
and then remove hex socket bolts.
(M10x50 - 3 pieces)
(M10x40 - 1 piece)
Figure 16
Hex-stem spanner
(Hex width across flat; 8 mm)
Figure 17
Main Pump SP001530

Page 20
2. Cover disassembly.
Use a jig to keep cover horizontal, gently loosen hex
socket screw (for attaching) of jig, and then remove cover.
NOTE: Be careful of control plate mounted inside.
Figure 18
Hex socket screw for attaching.
Figure 19
3. Cover removed.
Figure 20
4. Remove packing.
Figure 21
Main Pump SP001530

Page 21
DISASSEMBLE CONTROL SPRING AND SPRING WASHER.
1. Remove two (2) control springs (inner and outer) and
guide.
Figure 22
2. Remove spring washer.
Figure 23
ROTARY GROUP DISASSEMBLY

1. Remove shim and then retaining ring (18 mm for shaft).
Retaining ring pliers (retaining ring for shaft 18 mm)
Figure 24
Figure 25
Main Pump SP001530

Page 22
2. Place pump horizontally to take out rotary group from
shaft.
Figure 26
3. Check to see if disassembled rotary group pin (ø3x17, 8x3

pieces) remains in housing.
Figure 27
Shaft Disassembly
1. Wrap protective tape around spline, and pull shaft straight
out so that oil seal is not damaged.
Figure 28
Swash Plate
1. Remove swash plate.
Figure 29
Main Pump SP001530

Page 23
2. Remove guide.
NOTE: Make match marks so that direction or right/left
is changed or reversed.
Figure 30
Figure 31
Cover Disassembly
1. Remove control plate.
Figure 32
2. Remove spring washer.
Figure 33
Main Pump SP001530

Page 24
Housing Disassembly
1. Remove piston, belleville spring, distance piece and shim.
Figure 34
2. Remove parallel pin and sleeve.
Figure 35
3. Disassemble minimum oil flow stopper.

Remove retaining ring (22 mm for hole).
Retaining ring pliers (retaining ring for hole, for 22 mm).
Figure 36
4. Remove guide, belleville spring, distance piece and shim.
Figure 37
Main Pump SP001530

Page 25
Relief Valve Disassembly
1. Remove hex nut.
NOTE: To set pressure, perform removal operation
only if disassembly is needed.
Spanner 24 mm
Figure 38
2. Remove adjust screw.

NOTE: Be careful of shim.
Figure 39
3. Remove spring.
Figure 40
4. Remove spool.
Figure 41
Main Pump SP001530

Page 26
GeaR Pump (GSP2) Disassembly
1. Remove four hex socket bolts (M10x20).
Hex-stem spanner (hex width across flat: 8 mm)
Figure 42
2. Remove cover.
Figure 43
3. Remove coupling.
Figure 44
4. Remove plate, guide and O-ring.
Figure 45
Main Pump SP001530

Page 27
5. Remove drive gear, idle gear and side plate.
Figure 46
Main Pump SP001530

Page 28
(WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to
"General Maintenance Procedures" section.
Clean and completely dry parts to be inspected.
Also, check major parts well, and replace any parts with unusual
wear exceeding allowance or harmful damage with new ones.
Replace any seal related parts, if they have manifest
deformation or damage.
1. Piston assembly and cylinder block.
Check exterior with naked eye.
There must be no damage, scratch, excessive wear.
(Particularly, on sliding parts.)
Check clearance between piston outer diameter and block
inner diameter.
D-d ð 0.06 mm.
Figure 47
2. Piston shoe and piston.

Check piston and shoe shaft direction for end play.
ε ð 0.2 mm.
Figure 48
3. Shaft.
Check oil seal mounting part for amount of wear.
Amount of wear ð 0.025 mm.
Figure 49
Main Pump SP001530

Page 29
4. Control plate.
Check sliding parts for damage. If it has been severely
damaged, replace it with a new one.
Figure 50
5. Guide and Retainer.

Check for scratches and stepped wear, and if it is
impossible to repair it, replace it.
Correct fine scratches and damage with lapping compound.
Lapping compound should be sufficiently washed.
Figure 51
Main Pump SP001530

Page 30
REASSEMBLY
Housing Reassembly
1. Reassembling minimum oil flow stopper.
Insert guide, belleville spring, distance piece and shim into
housing.
NOTE: Be careful of direction of belleville spring.
Figure 52
Figure 53
2. Reassemble retaining ring (22 mm for hole).

Retaining ring pliers (retaining ring for hole, for 22 mm)
Figure 54
Main Pump SP001530

Page 31
3. Assemble parallel pin and spring into housing.
Figure 55
4. Assemble piston, belleville spring, distance piece and shim

into housing.
NOTE: Be careful of direction of belleville spring.
Figure 56
Figure 57
Main Pump SP001530

Page 32
Assembling Swash Plate
1. Assemble guide into housing.
NOTE: Assemble it by noting position of match marks
made when disassembling.
Figure 58
Figure 59
2. Assemble swash plate.

NOTE: If bushing is damaged when disassembling,
assemble delivery side and suction side with
new parts.
Figure 60
Figure 61
Main Pump SP001530

Page 33
Shaft Reassembly
1. Wrap protective tape around spline so that oil seal will not
be damaged, and pull shaft straight out.
NOTE: Check to see if shim is assembled above
bearing.
Figure 62
Figure 63
ROTARY GROUP REASSEMBLY

1. Position ten pistons in retainer.
Figure 64
2. Coat grease on three parallel pins (ø3x17, 8) and

assemble it into splined hole of cylinder block.
Figure 65
Main Pump SP001530

Page 34
3. Grease round part of guide.
Figure 66
4. Carefully place guide on parallel pin and at same time,

assemble piston into hole of cylinder block.
NOTE: Grease shoe end.
Figure 67
Main Pump SP001530

Page 35
Rotary Group Reassembly
1. Align rotary group with shaft spline to assemble them.
Figure 68
2. Assemble retaining ring (18 mm for shaft) and then

assemble shim.
Retaining ring pliers (retaining ring for shaft, for 18 mm)
Shim, shaft, retaining ring, cylinder block.
Figure 69
Figure 70
Main Pump SP001530

Page 36
Control Spring and Spring Washer
Reassembly
1. Grease round part of spring washer before assembly.
Figure 71
2. Assemble two control springs (inner and outer) and guide.
Figure 72
Cover Reassembly
1. Grease inner side of spring washer (to prevent it from
falling out) and assemble it to cover.
Figure 73
2. Grease inner side of control plate (to prevent it from falling

out), align it with knock hole to assemble it to cover.
Figure 74
Main Pump SP001530

Page 37
Relief Valve Reassembly
1. Position spool into cover.
Figure 75
2. Assemble spring.
Figure 76
3. Assemble shim to adjust screw.
Figure 77
4. Assemble adjust screw.

Spanner 14 mm
Figure 78
Main Pump SP001530

Page 38
5. Tighten hex nut.
NOTE: After reassembling, set pressure and then
tighten again.
NOTE: Tightening torque: 9.8 Nm.
Spanner 24 mm
Figure 79
Cover Reassembly
1. Assemble packings.
Figure 80
2. Use a jig to keep cover horizontal, gently tighten hex

socket screw and then mount cover.
Figure 81
Figure 82
Main Pump SP001530

Page 39
3. Attach cover with hex socket bolt.
(M10x50 - 3 pieces)
(M10x40 - 1 piece)
NOTE: Tightening torque: 55 ~ 69 Nm.
Figure 83
Trochoid Pump
1. Assemble key to shaft.
Trochoid pump side, R part, Cover side.
When assembling key, make R side as trochoid pump.
Figure 84
Figure 85
2. Assemble side plate (B) to cover.
Figure 86
Main Pump SP001530

Page 40
3. Assemble gear (inner rotor) to shaft.
NOTE: Assemble it so that appropriate mating surface
contacts side of side plate (B).
Figure 87
Figure 88
4. Assemble side plate (A) to case.
Figure 89
5. Assemble gear (outer rotor) to case.

NOTE: Assemble it so that mating surface contacts
side of side plate (B).
Figure 90
Main Pump SP001530

Page 41
6. Mount case to cover.
Figure 91
7. Use three hex socket bolts (M5x12) to tighten.

NOTE: Tightening torque 6.9 ~ 8.3 Nm.
Figure 92
Mounting Gear Pump

1. Assemble coupling to shaft end at main pump side.
Figure 93
2. Connect main pump to gear pump.
Figure 94
Main Pump SP001530

Page 42
3. Use two hex socket bolts (M10x20) to attach gear pump.
Hex-stem spanner (hex width across flat: 8)
NOTE: Tightening torque: 55 ~ 69 Nm.
Figure 95
Gear Pump Reassembly

1. Gear pump (GSP2) reassembly.
Assemble coupling to side plate.
At this time, be careful of suction and delivery direction.
Figure 96
Figure 97
2. Insert drive gear and idle gear into side plate.
Figure 98
Main Pump SP001530

Page 43
3. Assemble to drive gear, idle gear and housing.
Figure 99
4. Insert O-ring into guide and then into plate.
Figure 100
Figure 101
5. Assemble plate, guide and O-ring.

At this time, be careful of suction and delivery direction.
Figure 102
Main Pump SP001530

Page 44
Figure 103
6. Assemble coupling.
Figure 104
7. Insert housing and cover.
Figure 105
8. Use four hex socket bolts (M10x21) to attach housing and

cover.
NOTE: Tightening torque 55 ~ 59 Nm.
Figure 106
Main Pump SP001530

Page 45
Main Pump SP001530
Page 46
SP001531
MAIN CONTROL VALVESP001531
Main Control
Valve
Edition 1
Main Control Valve SP001531

Page 1
MEMO

Page 2
Table of Contents
Main Control Valve

Operation......................................................................... 6
Parts List ....................................................................... 12
Specifications ................................................................ 18
Adjusting the Pressure for the Main Relief .................... 19
Disassembly and Reassembly............................ 20
To Replace the O-ring on the Mating Surface and Block
Assembly ....................................................................... 20
Replacement of O-ring on Spool ................................... 21
Removal of load check valve......................................... 22
Replacement of Relief Valve and O-ring ....................... 22
Installation .......................................................... 23
Handling ........................................................................ 23
Installation ..................................................................... 23
Start-up Procedures ........................................... 23
Operation....................................................................... 23

Page 3
Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DX15 40001 and Up
DX18 40001 and Up

Page 5
GENERAL DESCRIPTION
Operation
Arrangement
Figure 1

Page 6
Principle of Main Spool's Switchover Function
Figure 2
Operating the joy stick valve generates pilot pressure. This pilot
pressure generated at PA port will act on the right section of the
main spool, which overrides, in turn, the springs (A) and (B) and
moves to the left side.
Then, if the oil flowing through the port P is shut off from the port T,
oil pressure starts rising and the pressurized oil push up the load
check valve to allow the oil to flow into the port B, passing through
the main spool orifice A. If the joy stick valve which passes through
line hole A to the tank circuit is returned to the neutral position, the
pilot pressure is removed, which in turn, causes the spool to return
to the neutral position from the springs (A) and (B) to the right side.
Figure 3

Page 7
Principle of Relief Valve Operation
1. Main Relief Valve.
The primary pressure passes through the poppet, valve
seat, and orifice, presses the needle valve to the left side,
and at the same time, acts on the inside of the poppet to
push it to the right side. (The oil in the secondary pressure
chamber does this.)
As the primary pressure rises higher and higher, it pushes
out the spring in the rear of the needle valve, which in turn
is forced to move to the left side. Then, since the oil
pressure in the secondary pressure chamber returns to the
oil tank and the force pushing the poppet in the closed
direction (force pushing the poppet to the right side)
disappears, the poppet is pushed and opened by the
primary pressure, causing the oil to return to the tank.
As a decrease in the primary pressure makes the
secondary pressure decrease, the poppet is closed by the
spring force and the secondary pressure rises again to
push the poppet to the right side, with the result that the
relief condition is stopped.
Figure 4

Page 8
2. Combination Valve.
If the line pressure exceeds the set pressure, the poppet is
pushed to the right side to make the line pressure flow to
the tank.
Figure 5
The suction pressure activates the line pressure to make

the seat move to the left side, and oil flows in the line from
the tank. If the oil flows into the line to release the exhaust
pressure, the seat moves to the right side again and is
separated from the tank.
Figure 6

Page 9
3. Port Relief Valve.
In general, the poppet is pushed to the left side by the
spring force to shut off the line pressure and tank pressure.
Figure 7
If the line pressure exceeds the set value, the poppet is

pushed to the right side to make the line pressure flow to
the tank.
If the line pressure goes below the set value, the poppet is
pushed to the left side again by the spring force and shut
off the line pressure and tank pressure.
Figure 8

Page 10
Arm Regeneration Circuit
Figure 9
If the pressure (PB) of the arm cylinder rod side is higher

than the pressure (PA) of the cylinder head side, the
pressure of the rod side flows toward the head past the line
holes (A) (B) in order for (PA<PB) to actuate the piston (A)
to the right side at the pressure (PB) of the rod side.
Figure 10
If the pressure at the arm cylinder rod is lower than that at

the head side (PA>PB), the piston (A) is seated in the left
side by the pressure at the head and accordingly the return
oil flows straight into the tank port.
Figure 11

Page 11
Parts List
Construction of Blocks
Figure 12

Page 12
Reference Reference
Number Number
1 Control Valve Assembly 18 Main Relief Valve
2 Pump Block (P1) 19 O-ring
3 Travel Block (LH) 20 O-ring
4 Spare Block 21 Conflex Valve Block
5 Arm Block 22 O-ring
6 PTO Block 23 O-ring
7 Travel Block (RH) 24 Port Relief Valve
8 Bucket Block 25 O-ring
9 Boom Block 26 O-ring
10 Pump Block (P2) 27 Suction Check Valve
11 Swing Block 28 O-ring
12 Dozer Block 29 O-ring
13 Swing Block 30 Plug
14 Pump Block (P3) 31 Plug
15 O-ring 32 Tie Rod
16 O-ring 33 Nut
17 O-ring

Page 13
Detail Construction of Blocks
Figure 13

Page 14
Reference Reference
Number Number
1 Screw 13 Cover
2 Seal Holder 14 Bolt
3 Backup Ring 15 O-ring
4 O-ring 16 Spring Holder
5 Spring Holder 17 Spring
6 Spring 18 Spring
7 Socket Bolt 19 Spring
8 Spring Cover 20 Spool End
9 Plug 21 Spool End
10 O-ring 22 O-ring
11 Spring 23 Spring
12 Poppet 24 Piston

Page 15
Main Relief Valve
Location Tightening Torque

1.5 - 2.0 kg•m
Cap Nut Tightening Torque
(11 - 14 ft lb)
3.0 - 3.5 kg•m
Relief Valve Fixing Torque
(22 - 25 ft lb)
Figure 14
Reference Reference
Number Number
1 Cap Nut 8 Wire
2 Set Screw 9 O-ring
3 Gasket Ring 10 Valve Seat
4 Spring 11 Spring
5 Housing 12 Poppet
6 O-ring 13 O-ring
7 Needle Valve 14 Sleeve
Complex Valve

1.5 - 2.0 kg•m
Cap Nut Tightening Torque
(11 - 14 ft lb)
3.0 - 3.5 kg•m
(22 - 25 ft lb)
Figure 15
Reference Reference
Number Number
1 Cap Nut 6 Poppet
2 Set Screw 7 O-ring
3 Gasket Ring 8 Seat
4 Spring 9 O-ring
5 Relief Valve 10 Clip

Page 16
Port Relief Valve

3.0 kg•m
(22 ft lb)
Figure 16
Reference Reference
Number Number
1 Plug 6 O-ring
2 O-ring 7 Backup Ring
3 Body 8 Poppet
4 Spring 9 O-ring
5 O-ring

Page 17
Specifications
Figure 17
Port Size Port Size

P1, P2, P3, T1, T2 PF1/2 PA1, PA4, PA5, PA8 PF1/4
A1 - A9, B1 - B9 PF3/8 PB1, PB4, PB5, PB8 PF1/4
Locations Specifications
P1 Main Relief Pressure 210 kg/cm2 (3,000 psi)
A4, B4, A5, B5, A8, B8 Overload Relief Pressure 250 kg/cm2 (3,600 psi)

Page 18
AND ADJUSTMENT
Adjusting the Pressure for the Main Relief

1. Install a pressure gauge between the pump at a portion to
be measured and the control valve. (Use a pressure gauge
fitting of available.)
2. Raise the oil temperature up to 50 - 60°C (122 - 140°F) to
obtain the rated engine rpm.
3. Operate the control lever and check the pressure when the
cylinder reaches the end stroke.
4. When rasing the pressure, use a hex socket wrench to turn
the suction port to relief valve adjusting nut Figure 18
counterclockwise.
NOTE: Main relief valve: 100 kg/cm2 (1,420 psi) per turn
NOTE: Port relief valve: 100 kg/cm2 (1,420 psi) per turn
5. After adjusting to the specified pressure, securely tighten
the relief valve.

Page 19
DISASSEMBLY AND
REASSEMBLY
To Replace the O-ring on the Mating

Surface and Block Assembly
1. Disconnected the tie rod.
2. Remove each block. Take care not to damage the mating
surface for each block.
3. At disassembly, replace the O-ring on the mating surface if
possible.
4. Clean the mating surface to remove dust or dirt at
reassembly and install a new O-ring, then assemble them
by reversing the sequence as described above. (When
installing the O-ring, always coat it with grease.)
5. Tighten the tie rod nut. (Tightening torque: 2.4 kg•m)
(When tightening the nut, ensure that the spool of each
block should operate properly.)
Figure 19

Page 20
Replacement of O-ring on Spool
1. Replacement of lever.
A. Remove the O-ring holding bolt 1 from the block.
B. Remove the wiper 2 and O-ring 3.
C. When assembling the wiper, take care not to damage
the O-ring.
2. Replacement of cap.
A. Loosen the cap holding bolt 4 to remove the cap 5.
B. Remove the spool 6 and replace the O-ring 7.
C. Clean the spool, and then assemble it to the block body.
D. When assembling the spring cap, take care not to
damage the O-ring.
NOTE: Cap holding bolt tightening torque: 1.10 kg•m
(8.0 ft lb)
NOTE: Replace the spool and block as an assembly.
Figure 20

Page 21
Removal of load check valve
1. Remove the load check spring and load check valve from
the valve block.
2. Thoroughly clean them before reassembling them.
Replacement of Relief Valve and O-ring

1. Remove the suction assembly relief valve.
2. If necessary, replace the O-ring or relief valve.
3. Coat the O-ring with grease at installation.
4. When loosening the cap nut and hex head nut on the relief
set adjusting screw, always use a pressure gauge to check
for the relief setting pressure.
5. When removing the relief valve assembly, take care so that
the center hole of the relief piston may not be blocked by
foreign materials. Relief valve tightening torque: 7 kg•m
(51 ft lb).

Page 22
INSTALLATION
Handling
1. When handling or transporting the valve, take care not to
drop it so that it may not give impact to the spool tip and
cap area.
2. When storing the valve for an extended time, tighten plugs
to each portion to prevent the entry of dust or water.
Installation
1. When assembling valve fittings, use the specified
tightening torque. (Take care so that the pipe may not give
unnecessary stress over the valve.)
2. Install the control linkage so that the spool moves correctly
in the axial direction.
3. When welding near the valve, take care so that excessive
heat and welding sputter may not damage the O-ring and
dust seal.
4. In painting, prevent paint from being contacted with the
spool.
5. Do not leave plug unscrewed until doing piping works so
that dust or water may not enter each port.
START-UP PROCEDURES
Operation
1. Before operation, check to see that the hydraulic pipes and
hydraulic oil are clean.
2. Hydraulic oil for use should be at -20°C - 80°C (-4 - 176°F).
If the oil temperature is below 0°C (32°F), warm up the
engine.
3. Do not raise the set pressure for the main relief valve and
port relief valve above the specified one.

Page 23
Page 24
SP001532
SOLENOID VALVE SP001532
Solenoid Valve
Edition 1
Solenoid Valve SP001532

Page 1
MEMO

Page 2
Table of Contents
Solenoid Valve

Parts List ......................................................................... 9
Construction .................................................................. 11

Page 3
Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DX15 40001 and Up
DX18 40001 and Up

Page 5
GENERAL DESCRIPTION
Theory of Operation
The solenoid valve is designed to control the Pilot Control Valve
(Work Lever / Joystick) pilot pressure and travel second speed
pilot pressure.
The valve consists of a relief valve, unloading valve, lever lock,
and a travel second speed valve.
SOL2 SOL1
P
XG
Right-hand travel motor Right-hand joystick
Left-hand travel motor Left-hand joystick
BQS0060L
Figure 1
Item Description
SOL1 Limit switch (cutoff) attached to the right control stand.
SOL2 Limit switch for travel second speed control.

Page 6
Relief Valve
Poppet Spring
If the pressure of at port P increases above the relief valve T
spring pressure setting, the poppet is pushed to the right side to
make the port P indexed with the port T, with the result that the
pressure is relieved. P
<Relief state>
Poppet Spring
T
BQS0070L
Figure 2
Lever Lock Solenoid

If lever lock solenoid (A) is OFF, the spool does not allow oil in SOL(A) SOL(B)
port P to flow to port A.
If lever lock solenoid (A) is ON, the spool moves downward to
permit the passage for the port P and A to be opened.
T
A B
P
Spool (B)
ANS0210L
Figure 3

Page 7
Travel Motor High/Low Speed Shifting Solenoid
If travel motor speed shifting solenoid (B) is OFF, oil discharged SOL(A) SOL(B)
from port P is shut off from port B by spool (B), with the result
that the pilot pressure does not flow into port B.
If travel motor speed shifting solenoid (B) is ON, spool (B)
T
moves to allow ports P and A to be opened.
A B
P
Spool (B)
ANS0220L
Figure 4

Page 8
Parts List
14
14
5
17
4
17
11
7
15 19
11
3 9
12 2
15 2
6
3
12
16 16
16
18
8 13
ANS0190L
Figure 5

Page 9
Reference Reference
Number Number
1 Solenoid Valve Assembly 11 Spool
2 Shim 12 Stopper
3 Spring 13 Plug
4 Sleeve 14 Bolt
5 Solenoid 15 Washer
6 Plunger 16 Scale Ball
7 Stopper 17 O-ring
8 Body 18 O-ring
9 Spring 19 O-ring
10 Spool

Page 10
Construction
X X
Y A B Y
X-X Section
SOL2 SOL1
P
Y-Y Section
T
A B
BQS0050L
Figure 6

Page 11
Page 12
SP001533
HYDRAULIC SCHEMATIC (DX15/DX18)
SP001533
1Hydraulic
Schematic
(DX15/DX18)
Edition 1
Hydraulic Schematic (DX15/DX18) SP001533

Page 1
MEMO

Page 2
Table of Contents
Hydraulic Schematic
(DX15/DX18)
DX15/DX18........................................................... 7

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DX15 40001 and Up
DX18 40001 and Up

Page 5
Page 6
DX15/DX18
BREAKER
TRAVEL MOTOR(L) (OPTION) TRAVEL MOTOR(R)
RED RED SWING MOTOR

Dr 1 Dr 2 Dr 1 Dr 2
BUCKET BOOM BOOM SWING DOZER Dr.
ARM TO C/VALVE T1.
A T
(C/JOINT)
Two way
E F
A
B P
A B A B B A
(C/JOINT) T (C/JOINT)
P1 P2
B D A C
A9 B9 AP8 A8 B8 A7 B7 A6 B6 A5 B5 AP5 A4 B4 AP4 A3 B3 A2 B2 A1 B1 AP1
FORWARD
PTO
DOWN
DUMP
DUMP
RIGHT
LEFT
DOWN
REVERSE
P1
TO S/W MOTOR Dr. P3
210K
FORWARD
165K
REVERSE
CROWD
210K
CWD
RIGHT
LEFT
UP
UP
T1
T2
BP8 BP5 BP4 BP1
P2
P1 P2
P3
REMOTE CONTROL VALVE

ENG AP8 BP8 BP1 AP1 AP4 BP4 AP5 BP5
P1,P2 : 7.1 cc/rev 2 4 3 1 4 2 1 3
17.2ps/2300rpm
P3 : 4.5 cc/rev
P4 : 5.1 cc/rev T A B
RPP
S1 LPP P (L) T P (R) T
(C/JOINT)
Dr 1
T
Dr 2
AIR-BREATHER
0.05K 0.5K
HYD. OIL TANK
FG012259
Figure 1

7
1Electrical System
SP001534
ELECTRICAL SYSTEMSP001534
1Electrical
System
Edition 1
Electrical System SP001534

Page 1
MEMO

Page 2
Table of Contents
Electrical System

Troubleshooting - Electrical System ..................... 6
Overview............................................................... 6
Electrical Supply System ...................................... 7
Engine Starting Circuit .......................................... 8
Operation During Start Process ...................................... 8
Operation After Start Process ......................................... 9
Engine Preheating System ................................. 10
Principle of Operation .................................................... 10
Engine Stop System ........................................... 11
Operation in Engine Running Mode .............................. 11
Operation in Engine Stop Mode .................................... 12
Charging System ................................................ 13
Operation in Charging Mode ......................................... 13

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DX15 40001 and Up
DX18 40001 and Up

Page 5
TROUBLESHOOTING -
ELECTRICAL SYSTEM
Problem Possible Causes Remedies
Battery will not stay Internal battery short. Replace battery.
charge. Short in order part of circuit. Repair wiring or replace component.
Battery does not Battery worn out or defective. Replace battery.
charge. Defective alternator or belt. Repair or replace.
Cable connection loose or severely Repair or replace.
corrected. Circuit ground corroded or weak.
OVERVIEW
The electrical system for this equipment is DC 12 volts.
This rated voltage for all electric components is 12 volts. The
system contains a three phase AC generator with a rectifier. The
electric wiring used in the system is easily identifiable by the
insulator color. The color symbols used in the electrical system
are listed in the following chart.
Electric Wire Color
Symbol Color
W White
G Green
Or Orange
B Black
L Blue
Lg Light green
R Red
Gr Gray
P Pink
Y Yellow
Br Brown
V Violet
NOTE: RW: Red wire with white stripe.

R - Base color, W - Stripe color.
NOTE: 0.85 G: Nominal sectional area of wire core less
insulator = 0.85 mm2.

Page 6
ELECTRICAL SUPPLY SYSTEM
The electric power circuit supplies electric current to each
electric component. It consists of a battery, fusible link, starter
switch, and fuse box.
The negative terminal of the battery is grounded of the vehicle
body.
Even when the starter switch (5) is in the "OFF" position, electric
current is supplied to the following components through battery
(1) → fusible link (2) → fuse box (4).
1. Inside light
2. "B" terminal of starter switch
When the starter switch (5) is in the "PREHEAT," "ON" and
"START" position, the current flows from the battery (1) →
fusible link (2) → starter switch "B" terminal (5) / starter switch
"BR" terminal (5) → fuse box (4) and all electric devices can be
operated.
While the engine is not running, the battery (1) supplies the
electric power for all electric devices. Once the engine is started
the power is supplied from the alternator.
FG012318
Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM
Reference Number Description Reference Number Description
1 Battery 4 Fuse Box
2 Fusible Link 5 Starter Switch
3 Alternator 6 Starter

Page 7
ENGINE STARTING CIRCUIT
Operation During Start Process

When the starter switch (5) is turned to the "START" position, the
contacts in the starter relay (4) are closed by the current flow from
the battery (1) → fusible link (2) → terminal "B" of starter switch (4)
→ terminal "ACC" of starter switch (4) → terminal "4" of E/G stop
timer (5) → terminal "2" of E/G stop timer (5) → terminal "86" of E/G
stop relay (6) → terminal "85" of E/G stop relay. So, current flows
from the battery (1) → fusible link (2) → terminal "30" of E/G stop
relay (6) → terminal "87" of E/G stop relay (6) → terminal "P" of
stop solenoid (3) → terminal "COM" of stop solenoid (3) → ground.
When the contact point "B" and "PP" of starter relay (4) are
closed, the pinion gear of starter is pushed forward and makes
contact with the ring gear of the flywheel and the internal
contacts of the starter are connected.
The current flows from the battery (1) → terminal "B" of the
starter (6). The starter motor is rotated, and the engine is started.
The warning light (8) goes out when the engine is started..
FG012319
Figure 2 STARTER SWITCH (1) - WHILE STARTING

1 Battery 5 Starter Switch
2 Fusible Link 6 Starter
3 Alternator 7 Diode
4 Starter Relay 8 Warning Light

Page 8
Operation After Start Process
Once the engine has been started, the belt driven alternator (3)
generates a current.
The output generated by alternator (3) "L" terminal will produce
voltage (equal to charge voltage). This will turn "OFF" the
warning light (8).
NOTE: After engine has started, starter switch (5) is not
turned to "START" position.
Operation of Starting Circuit (2) - Immediately After Start
FG012321
Figure 3 STARTER SWITCH (1) - WHILE STARTING

2 Fusible Link 6 Starter
3 Alternator 7 Diode
4 Starter Relay 8 Warning Light

Page 9
ENGINE PREHEATING SYSTEM
Principle of Operation
Cylinder preheat plugs are installed into each cylinder of the
engine.
When the starter switch (5) is turned to the "PREHEAT" position,
the contacts in the preheat relay (3) are closed by the battery (1)
→ fusible link (2) → terminal "B" of starter switch (5) → terminal
"R1" of starter switch (5) → terminal "C" of preheat relay (3) →
terminal "D" of preheat relay (3) → ground and preheat timer (6)
will activate.
When the contact point "B" and "PP" of preheat relay (3) are
closed, the glow plug (4) heated by current flowing from the
battery (1) → fusible link (2) → preheat relay (3) → glow plugs (4)
→ ground.
The time of preheat is approximately 6 seconds and when
preheating is completed, the warning light (7) comes "ON."
FG012323
Figure 4
2 Fusible Link 6 Preheat Timer
3 Preheat Relay 7 Warning Light
4 Glow Plugs 8•9 Diode

Page 10
ENGINE STOP SYSTEM
The engine stop circuit consists of a starter switch (4) and
engine stop solenoid (3). There are two modes of operation;
engine running and engine stop.
Operation in Engine Running Mode

When the starter switch (4) is turning to "START" position, the current
flows from the battery (1) → fusible link (2) → terminal "B" of starter
switch (4) → terminal "ACC" of starter switch (4) → terminal "4" of E/G
stop timer (5) → terminal "2" of E/G stop timer (5) → terminal "86" of
E/G stop relay (6) → terminal "85" of E/G stop relay. So, current flows
from the battery (1) → fusible link (2) → terminal "30" of E/G stop relay
(6) → terminal "87" of E/G stop relay (6) → terminal "P" of stop
solenoid (3) → terminal "COM" of stop solenoid (3) → ground.
When the coil of the stop solenoid (3) is excited, the solenoid
shaft is pulled in, so that specified clearance between the
solenoid shaft and injection pump rack can be obtained.
After engine has started, starter switch (4) will return to "ON"
position, at this time, the current flows from the battery (1) →
fusible link (2) → terminal "B" of starter switch (4) → terminal
"ACC" of starter switch (4) → terminal "H" of stop solenoid (3) →
terminal "COM" of stop solenoid (3) → ground.
When the coil of the stop solenoid (3) is excited, the solenoid
shaft is held in.
S
ACC H
HOLD
B C COM
PULL
R2 P
BR
R1
1 87 3
4 4
85
RESISTOR
2
86
3 30
6
5
+ -
1 FG012327
Figure 5
1 Battery 4 Starter
2 Fusible Link 5 E/G Stop Timer
3 Stop Solenoid 6 E/G Stop Relay

Page 11
Operation in Engine Stop Mode
When the starter switch (4) is turning to "OFF" position, the
electric current flow to the coil of the engine stop solenoid (3) is
shut off and the stop solenoid shaft is returned.
ACC H
HOLD
B C COM
PULL
R2 P
BR
R1
1 87 3
4 4
85
RESISTOR
2
86
3 30
6
5
+ -
1 FG012327
Figure 6 ENGINE STOP CIRCUIT - STOP MODE

1 Battery 4 Starter
2 Fusible Link 5 E/G Stop Timer
3 Stop Solenoid 6 E/G Stop Relay

Page 12
CHARGING SYSTEM
Operation in Charging Mode

When the starter switch (5) is turned to the "ON" position, an
initial excited current flows to the field coil of the alternator (3)
through the fusible link (2), starter switch (5), and fuse box (4).
When the engine is started from this condition the alternator (3)
starts charging. The current flows from the terminal "B" of
alternator (3) → fusible link (2) → battery (1).
The alternator (3) also supplies electric current to other electrical
components.
FG012318
Figure 7 CHARGING CIRCUIT

1 Battery 4 Fuse Box
2 Fusible Link 5 Starter Switch
3 Alternator 6 Starter

Page 13
Page 14
SP001535
ELECTRICAL SCHEMATIC (DX15/DX18)
SP001535
1Electrical
Schematic
(DX15/DX18)
Edition 1
Electrical Schematic (DX15/DX18) SP001535

Page 1
MEMO

Page 2
Table of Contents
Electrical Schematic
(DX15/DX18)
DX15/DX18........................................................... 7

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DX15 40001 and Up
DX18 40001 and Up

Page 5
Page 6
DX15/DX18
CABIN (OPTION)
AVX 5W
WIPER MOTOR
0 ROTATING BEACON (OPTION)
(538-00005)
2 34B 0.85LW 34A 6 I 2 11C 0.85LR
0 7
B 12E 35A 3 II 0.85RG 10B 5 B 2F
0.85Or 37C S
AVX 5Y
+ P 38B 1 I 1 37B
99 10 9 21B 0.5WR
M 0.5WR 21B 9 10 99 0.85B P S 4B
S 31C 0.5B 0.5uF
M 0.5B 20R
99 4 3 35B 0.85LY HEATER SWITCH 99 T
E 99 (549-00040) ROTATING
-
0.85B (-) +(2190-2584D5) BEACON SWITCH ROTATING BEACON L 24A AVX 1.25WG
0.85LW
0.85Y
0.85L
0.85B
HEATER (2549-9115) (2RL006846-001)
(920-00119) CIGAR LIGHTER HELLA B 1A
+(2190-2036D10) R 9B
(545-00002)
AVX 1.25RB
WINDOW WASHER
WIPER & WASHER SWITCH AVX 0.85L 23A
M
(2916-9002A) 0.85LB -
(2549-9114)
DA3-3
DA3-2
2 7
+(2190-2036D14) 1.25B 99 ILL 21K 0.5WR WATER TEMP.SENSOR E 99
33C ALTERNATOR
33D - 6 3
4 II AVX 3B 99
DA3-1
1 31A 2 99 0.85B 12V/40A STARTER
P 5
0.85Y 6 0 + AVX 0.85YB 26A 12V/1.2KW
32A
12D + 12C 7 99
1.25W
5 0.85B
16C
33A I 99 E 10W B 8B WATER TEMP.SWITCH
0.85LB 10
0.85WR
0.5B 99 9 21B 0.5WR 0.85B AVX 0.85BY 27A
0.85L ROOM LAMP
(2534-9068) E/G OIL PRESS. SW 99 (-) (+) 1.25R AVX 1.25R H AVX 5BW
48C 48D
(+) (-) 1.25B HOLD
AVX 0.85BW AVX 0.85B AVX 3B COM
FUEL PUMP
10 13C 0.85R 28A 99
99 PULL 3B
INDICATOR P
U 3
DA2-3
W/T GAUGE + 6 23C 0.85L (2170-1003) 47A
W 7
FUEL SENSOR GLOW PLUG
- 47B ENGINE STOP
22A (S) (547-00020) SOLENOID
U 12 22C AVX 3RW
FUEL GAUGE + 1.25R
F 0.85YR 99 (-)
- 3BY 0.85BY
(L) 85 87 4A AVX 5Y
ILLUMINATION 3 21J 25A
6E
RESISTOR
0.5WR 1.25BW 6F
L7 L8
DA1-1
5
4 99 0.85B 0.85B 30 2J 5W
0.85YW
6G 1
99 86
0.85R
8
DA1-4
99
7D 0.85B STARTER RELAY
HOUR METER (2) 99 7
4
(K1023526)
DA1-3
H 39A
0.5B 3
+ (1) 8D E/G STOP TIMER E/G STOP RELAY
0.5WR
AVX 3RW
39C
(K1043647) (K1023526 )
(3) 24C 0.85WG 1 0.85Y 85 87 0.85BG 0.85BG 85 87 3A AVX 5BW
4 48B 45C 47C 39E
RESISTOR
RESISTOR
45E 45D
ENG OIL PRESS 7 27C 0.85BY 2 0.85RW 2 39D
L1 6
DA1-2
46C 6 86 3W 0.85B 30 2H 5W
2
WATER TEMP 11 26C 0.85YB 3 99 46E 30 2K 99 86
L3 1.25B 46D 99
DA2-2 0.85B PREHEAT RELAY
AIR CLEANER 5 28C 0.85BW (K1023526)
L4
FUEL 2 25C 0.85YW

L5
AVX 5W
PREHEAT 9 29C 0.85LB
L6
CHARGE 8 24D 0.85WG

L2
5W
5W 5W 1B 5WR
2A 60A
GAUGE PANEL
(K1043760) 20R
(539-00063) FUSIBLE LINK
HIGH SPEED SWITCH
(2549-9115) +(2190-2036D13) 20B
7 0 5 17D
0.85Y
0.85YR 40B 1 I WORKING
9 21C + -
0.85RW
40D 40C 0.5B 10 87a LAMP SWITCH STARTER SWITCH CONNECTION
30 14B (2549-9115) 12V 45AH
B BR R1 R2 C ACC
0.5WR
21F 0.85RG 21A 87 +(2190-2036D5)

1.25RW
AVX 1.25RB
0.85B OFF (2506-9011)
0.5WR
0.85B 0.85RG 0 7 HEAT BATTERY
0.85B 86 20B 20B 5
0.85WR
DIODE 6 85
0.85RG
0.85LR
0.85R
1.25R
0.85Y
1 14D ON
0.85L
HIGH SPEED DOZER & 99 0.5B 99 0.5YB I

SOLENOID VALVE VARIABLE TRACK SWTICH WORKING LAMP 99 10 START
9 21D
(2549-9115)+ (534-00029)
0.5B
41A
13A
12A
17A
10A
48A
WORKING LAMP RELAY

9A
8A
(2190-2584D7,190-01151)
(2544-9032) DIODE ARRAY
0.85RB 43B 7 0 1 2 3 4 5 6 7 8 19C (-)
5 0.85LR 0.85B 0.85RY
3W
43D 43C NOTE. 1. DIODE PART NO.

5
1 I 10A 10A 10A 10A 10A 10A 10A 10A 99 19D 15B (+) PILOT CUT OFF S/W(2) 5 6 7 8
41C
DA2-1 9 0.5WR ACC 5D 3WR HORN (549-00041)+(2190-2036D17) DIODE 6 ~ 7 : 2548-1027
10
3WR
1 HORN SWITCH
15 16 17 0.85RB (516-00009) DA1 ~ DA3 : K1000815
0.85B 21F (ON JOSTICK L.H) 1
0.85B 5G 2WR 44B
2D B C 6D 3BY 1 2 3 4
2E 2W 0.85YG 5 I
VARIABLE TRACK FUSE BOX 9
SOLENOID VALVE (2510-1008) 5E 2WR 10 30A 21E 0.5WR
3WR R2 6C 3BY DA1 ~ DA3
0.5B 99
5C BR 5F 2WR PILOT CUT
0.85RL
R1 7B OFF SWITCH
1.25BW
0.85YG
1.25BW 7C 3 18 19 20 (549-00046)
1 11B 0.85LR
PREHEAT STARTER SWITCH 87a 30 14B
15A 15A 15A 15A 20A 20A 0.85RL NO
TIMER 4 29A 0.85LB (2549-1152) 0.85YG 30F 87 C 17C
44A
(537-00030) 30D NC 0.85Y
9 10 11 12 13 14 30E
1.25W
0.85LR
86 30G
DIODE 7
99 85
2 99
14A
11A
16A
15A
1.25B 0.85B
1.25RW/0.85RY 0.85B 99 0.85YG
0.85B
0.85RB
PILOT CUT OFF
PILOT CUT OFF RELAY
SOLENOID VALVE
(2544-9032)
FG012260
Figure 1

7
1Attachments
SP001536
BOOM AND ARM SP001536
Boom and Arm
Edition 1
Boom and Arm SP001536

Page 1
MEMO

Page 2
Table of Contents
Boom and Arm

Front Attachment Pin Specifications..................... 6
Front Attachment - Removal and Installation........ 7
Arm Removal Procedure ................................................. 7
Boom Removal Procedure .............................................. 9
Tolerances)......................................................... 10
Installation .......................................................... 14
Arm Installation Procedure ............................................ 14
Boom Installation Procedure ......................................... 14
Start-up Procedures ........................................... 14

Page 3
Page 4
SAFETY PRECAUTIONS
CAUTION
order.
handling load.
responsibility.
APPLICABLE MODELS

DX15 40001 and Up
DX18 40001 and Up

Page 5
FRONT ATTACHMENT PIN
SPECIFICATIONS
The table below has a complete listing of dimensional
specifications for all mounting pins used on the front attachment.
NOTE: Some mounting pins must be drilled and tapped for
lubrication fittings and piping, or may have other
required specifications. Consult DOOSAN After Sales
Service for information on wear tolerances and
replacement limits for mounting pins
Mounting Pin Diameter, mm (In) Length, mm (In)

A 30 mm (1.18 in) 172 mm (6.77 in)
B 30 mm (1.18 in) 172 mm (6.77 in)
C 30 mm (1.18 in) 165 mm (6.50 in)
D 30 mm (1.18 in) 172 mm (6.77 in)
E 30 mm (1.18 in) 104 mm (4.09 in)
F 30 mm (1.18 in) 104 mm (4.09 in)
G 30 mm (1.18 in) 167 mm (6.57 in)
H 35 mm (1.38 in) 225 mm (8.86 in)
I 40 mm (1.57 in) 94 mm (3.70 in)
J 40 mm (1.57 in) 94 mm (3.70 in)
K 30 mm (1.18 in) 220 mm (8.66 in)
L 30 mm (1.18 in) 104 mm (4.09 in)
M 30 mm (1.18 in) 195 mm (7.68 in)
G
H I
F
E
B
L
A M
K
J
AKS1960L
Figure 1

Page 6
FRONT ATTACHMENT -
REMOVAL AND INSTALLATION
DANGER X
DOOSAN warns any user, that the removal of the
counterweight from the machine, front attachment or any
other part, may affect the stability of the machine. This
could cause unexpected movement, resulting in death or
serious injuries. DOOSAN is not liable for any misuse. X
Never remove the counterweight or front attachment unless
the upper structure is in-line with the lower structure.
Never rotate the upper structure once the counterweight or
front attachment has been removed.
HAAD4060
Figure 2
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
should 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 Procedure
WARNING
This procedure is only intended for routine removal or
replacement of the attachment, while working under
normal, safe operating conditions. In the event of a major
structural collapse of some part of the attachment, an
accident or complete loss of attachment hydraulic function,
Do not proceed with attachment disassembly unless you
are completely sure of what you are doing. Please call your
local DOOSAN distributor or DOOSAN After Sales Service
for assistance. Do not allow personnel to stand underneath
a weakened or only partially supported attachment section.
Keep clear of hydraulic lines that may have fluid escaping
at high-pressure – it can cause severe or even fatal injuries.
Complete the bucket end removal procedure by pulling out the

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

Page 7
Park the excavator away from obstructions and all traffic on
clear, flat, level ground. Extend the arm cylinder and crowd the
arm into the boom. Partially retract the boom cylinder so that the
boom is stretched out in front of the excavator, as low to the
ground as possible, with the arm crowded under the boom.
The tip of the arm point should 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 cab 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,
not including the weight of accessories or fixtures).
Before beginning the disassembly of attachment mounting pins,

disconnect the arm cylinder hydraulic hose couplings and put a
clean plug in the end of each one. Use any and all reasonable
precautions necessary to avoid introducing dirt or other
contaminants into the hydraulic system. Wipe down coupling
points before disconnecting hydraulic lines and use evaporative
type solvent spray cleaner. Tag and mark hoses for reassembly,
if necessary.
Place a sling under the arm cylinder (the cylinder used to extend
and retract the attachment arm, pinned to the top of the boom).
Lift the sling so that the weight load on the rod end of the arm
cylinder (pinned to the ears on the inner end of the arm) is
released. Prepare blocking under the arm that will securely
support the weight of the arm and arm cylinder.
CAUTION
To make sure that the polished surfaces of cylinder rod ends
will not suffer accidental damage during disassembly or
removal procedures, wrap exposed rod surfaces (especially
those of boom cylinders) with a protective covering material.
Immediately following disassembly and removal, cylinder
rods should always be fully retracted. This eases handling
problems and also avoids possible damage.
Remove retainers on the end of the mounting pin for the arm
cylinder rod end. Use the assist crane to relieve the weight load
and withdraw the pin. Lower the arm down to the blocking
support for any continued disassembly procedures.

Page 8
Boom Removal Procedure
NOTE: Boom removal may be simplified if the shell of the
operator's cab is taken off the turntable deck first.
Refer to the Operator's Cab Removal procedure
before continuing, if both components are to be
removed from the excavator.
After the bucket, arm and arm cylinder have been removed,
lower the end of the boom to a stable, secure blocking support.
Attach the assist crane sling to the body of either boom cylinder,
break the mounting pin connection to the boom by tapping
through the pin from the same side of the boom and repeat for
the opposite cylinder.
Release hydraulic pressure and disconnect line couplings as
previously outlined in the Arm Removal Procedure, observing
the same precautions.
Disconnect wiring for work light assemblies and any other
accessory lines or connections. Locate the sling of the assist
crane near the center of gravity, optimum lift point for the boom,
and use the crane to take pressure off the boom foot pin. Drive
out the pin after disassembling retainers and carefully lift away
the boom.
WARNING
Traveling the excavator, swinging the turntable or
movement over bumps or sloping, uneven surfaces could
all produce loss of control and possible accidents or
injuries, if the turntable deck has been unbalanced by
removal of weight from one end only.
To maintain stability, the counterweight should be removed

whenever the front attachment is taken off the machine.

Page 9
(WEAR LIMITS AND
TOLERANCES)
8
9
10
13
6
11
1
14
2
12 5
3
4 AKS1970L
Figure 3

1 Swing Cylinder Head 8 Arm Cylinder Rod
2 Swing Cylinder Rod 9 Boom, Arm
3 Swing Post 10 Bucket Cylinder
4 Boom Joint 11 Bucket Cylinder Rod
5 Boom Cylinder Head 12 Bucket Dump Link
6 Boom Cylinder Rod 13 Arm, Bucket Link
7 Arm Cylinder Head 14 Arm, Bucket

Page 10
1 2
b
a
b
a
B
A
3
4 a
b
D
a
6 b
5 a
b
F
E
HKA3002L
Figure 4

Page 11
a
7 8 a
b
b
H
a
b
9 a 10
b
K
J
I
a
11 b
12 a
b
L
M
N
O
a
a
13 b 14 b
S
Q
HKA3003L
Figure 5

Page 12
Reference Dimension
Description
Number a b Clearance
47.0 mm 45.0 mm 2.0 - 3.5 mm
1 Swing cylinder head and head bracket
(1.85 in) (1.77 in) (0.079 - 0.138 in)
47.0 mm 45.0 mm 2.0 - 3.5 mm
2 Swing cylinder rod and swing post
(1.85 in) (1.77 in) (0.079 - 0.138 in)
160.0 mm 158.0 mm 0.5 - 2.5 mm
3 Swing post
(6.30 in) (6.22 in) (0.002 - 0.098 in)
160.0 mm 158.0 mm 0.5 - 2.5 mm
4 Boom Joint
(6.30 in) (6.22 in) (0.002 - 0.098 in)
47.0 mm 45.0 mm 1.5 - 2.0 mm
5 Boom cylinder head and boom
(1.85 in) (1.77 in) (0.059 - 0.079 in)
47.0 mm 45.0 mm 1.0 - 2.5 mm
6 Boom cylinder rod and boom
(1.85 in) (1.77 in) (0.039 - 0.098 in)
47.0 mm 45.0 mm 1.0 - 2.5 mm
7 Arm cylinder head and boom
(1.85 in) (1.77 in) (0.039 - 0.098 in)
47.0 mm 45.0 mm 1.0 - 2.5 mm
8 Arm cylinder rod and arm
(1.85 in) (1.77 in) (0.039 - 0.098 in)
130.0 mm 129.0 mm 0.5 - 1.7 mm
9 Boom and arm
(5.12 in) (5.08 in) (0.002 - 0.067 in)
47.0 mm 45.0 mm 1.5 - 2.5 mm
10 Bucket cylinder head and arm
(1.85 in) (1.77 in) (0.059 - 0.098 in)
46.50 mm 45.0 mm 1.0 - 2.5 mm
11 Bucket cylinder rod and dump linkage
(1.83 in) (1.77 in) (0.039 - 0.098 in)
105.0 mm 104.5 mm 0 - 2.0 mm
12 Dump linkage and bucket
(4.13 in) (4.11 in) (0 - 0.079 in)
105.0 mm 104.5 mm 0.3 - 2.7 mm
13 Arm and bucket linkages
(4.13 in) (4.11 in) (0.012 - 0.106 in)
105.0 mm 104.5 mm 0.3 - 2.7 mm
14 Arm and bucket
(4.13 in) (4.11 in) (0.012 - 0.106 in)

Page 13
INSTALLATION
Arm Installation Procedure

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

excavator. Pregrease the mounting pin for the rod end of the
arm cylinder and push it through the ears on the end of the arm.
Attach a sling around that mounting pin and lift the arm with an
assist crane until it is in position for the boom arm pin connection
to be made.
Relieve hydraulic pressure from all points of the system before
any hydraulic lines are opened, then carefully assemble
hydraulic connections to the arm cylinder.
Remove the sling from around the rod end arm cylinder pin,
withdraw the pin and lift the body of the arm cylinder to repin the
mounting connection.
Boom Installation Procedure

Before reassembling the attachment, make sure to inspect all
bushings and pivot points of each section. To avoid damaging
the seats, bushings should never be hammered or chiseled out
of their seats.
Installation is otherwise a reversal of the removal procedures.
START-UP PROCEDURES
Once the boom has been serviced, it should be lubricated as
outlined in the initial start-up procedures of the operation
manual. Refer to the appropriate operation and maintenance
manual for unit.

Page 14
SP001550
BUCKET SP001550
Bucket
Edition 1
Bucket SP001550
Page 1
MEMO
Bucket SP001550
Page 2
Table of Contents
Bucket

Bucket Tooth Inspection and Replacement .......... 6
Type 1 ............................................................................. 6
Type 2 ............................................................................. 7
Type 3 ............................................................................. 8
Bucket O-ring Replacement ............................... 10
Type 1 ........................................................................... 10
Type 2 ........................................................................... 11
Bucket Shimming Procedures ............................ 13
New Bucket Installation ................................................. 13
Type 1 ........................................................................... 13
Type 2 ........................................................................... 14
Bucket Attachment, Removal and Reversal ....... 15
Detaching the Bucket .................................................... 15
Attaching the bucket...................................................... 15
Reversing the Bucket .................................................... 16
Bucket SP001550
Page 3
Bucket SP001550
Page 4
SAFETY PRECAUTIONS
CAUTION
order.
handling load.
responsibility.
APPLICABLE MODELS

DX15 40001 and Up
DX18 40001 and Up
Bucket SP001550
Page 5
BUCKET TOOTH INSPECTION
AND REPLACEMENT
There are several different types of attachment methods for
replaceable bucket teeth. Some of the most common types are
shown in the following drawings.
Bucket teeth are usually replaced in sets but it may sometimes
be necessary to replace individual teeth.
Type 1
Look for the following indications of wear or damage:
• Lock pins protrude unevenly on one side.
• Lock pins have been worn down so far that they no
longer make full contact through the length of the pin
hole.
• Lock washers or pins show obvious damage or
weakness.
• Wear points on the working surfaces of tooth points -
pits, cracks, chips or craters - are larger than 8 -
10 mm (1/3" - 1/2") across.
HAOC680L
Figure 1
1. On a routine basis, inspect the bucket teeth to make sure

that tooth wear or breakage has not developed. Do not
allow the replaceable bucket teeth to wear down to the
point that the bucket adapter is exposed. See Figure 7.
2. To replace a tooth (1, Figure 4), use a hammer and punch
to drive the locking pin (2) and lock washer (3) out of the
tooth adapter (4).
3. Once the worn tooth has been removed, use a putty knife
to scrape the adapter as clean as possible.
4. Slide the new tooth into position and insert the lock
washer. Figure 2
5. Insert the locking pin into the tooth and with a hammer,
drive the pin in until the lock washer seats in the locking
groove.
Bucket SP001550
Page 6
Type 2
WARNING
Due to the possibility of flying metal objects, always wear
safety helmet, protective gloves and eye protection when
changing bucket teeth.
Curl the bucket upwards and place the round rear surface of
the bucket firmly on the ground. Shut the engine off and lock
out the hydraulic controls before working on the bucket.
NOTE: These instructions are only for DOOSAN OEM

buckets. If you are using other manufacturers
buckets, refer to their specific instructions.
Figure 3
1. On a routine basis, inspect the bucket teeth to make sure

that tooth wear or breakage has not developed. Do not
allow the replaceable bucket teeth to wear down to the
point that the bucket is exposed. See Figure 3.
2. To replace a tooth, remove bolts, lock washers and plain
washers from seat. Remove tooth and shim(s) from
bucket. See Figure 4.
to scrape bucket as clean as possible.
Figure 4
4. Slide the new tooth into position and insert shims. Shim
tooth until gap is less than "X" [0.5 mm (0.020 in)]. See
Figure 5.
5. Secure tooth and shim into position with seat, plain
washers, lock washers and bolts.
Figure 5
Bucket SP001550
Page 7
Type 3
WARNING
Due to the possibility of flying metal objects, always wear
changing bucket teeth.
Curl the bucket upwards and place the round rear surface
of the bucket firmly on the ground. Place wooden blocks
under front of bucket. Shut the engine off and lock out the
hydraulic controls before working on the bucket.
Inspect locking pin assembly and replace it if the following

conditions exist;
1. The locking pin is too short when both surfaces are
aligned.
2. The rubber has been torn and bosses of the steel balls are
liable to slip off.
3. Pressing steel ball causes the boss to go inside.
X 1/3T X X
T
HAOE380L
Figure 6
HAOC680L
Figure 7
Bucket SP001550
Page 8
1. On a routine basis, inspect bucket teeth to make sure that
tooth wear or breakage has not developed. Do not allow
replaceable bucket teeth to wear down to a point that
bucket adapter is exposed. See Figure 7. 1
2. To replace a tooth, use a hammer (1, Figure 8) and punch
(2) to drive locking pin assembly out of tooth and tooth 2
adapter.
to scrape adapter as clean as possible.
4. Slide new tooth into position and insert locking pin HAOE370L
assembly. Figure 8
Bucket SP001550
Page 9
BUCKET O-RING REPLACEMENT
Type 1
WARNING
Due to possibility of flying metal objects, always wear
changing pins.
1. Inspect the bucket O-rings on a routine basis. If worn or

damaged, replacement is necessary.
HAOH640I
Figure 9
2. Roll the old O-ring (1, Figure 10) onto the boss (2) around
the bucket pin (3). Remove the bucket pin and move the 4
1
arm or bucket link (4) out of the way. 2
HAOC710L
Figure 10
3. Remove the old O-ring and temporarily install the new

O-ring (1, Figure 11) onto the bucket boss (2). Make sure 4
1
that the O-ring groove on both the bucket link (4) and boss 2
have been cleaned.
4. Realign the arm or link with the bucket pin hole and insert
the bucket pin (3, Figure 10).
HAOC701L
Figure 11
Bucket SP001550
Page 10
5. Roll the new O-ring (1, Figure 12) into the O-ring groove.
1
HAOC720L
Figure 12
Type 2
WARNING
Due to possibility of flying metal objects, always wear
changing pins.
1. Inspect the bucket O-rings on a routine basis. If worn or

damaged, replacement is necessary.
HAOE360L
Figure 13
2. Roll the old O-ring (1, Figure 10) onto the bushing (2)
around the bucket pin (3). Remove the bucket pin and 4
1
move the arm or bucket link (4) out of the way. 2
HAOC710L
Figure 14
Bucket SP001550
Page 11
3. Remove the old O-ring and temporarily install the new
O-ring (1, Figure 11) onto the bucket bushing (2). Make
1 3
sure that the O-ring groove on both the bucket link (3) and 2
bushing have been cleaned.
4. Realign the arm or link with the bucket pin hole and insert
the bucket pin (3, Figure 10).
HAOC700L
Figure 15
5. Roll the new O-ring (1, Figure 12) into the O-ring groove.
1
HAOC720L
Figure 16
Bucket SP001550
Page 12
BUCKET SHIMMING
PROCEDURES
New Bucket Installation

1. If a new bucket is being installed on the excavator,
measure the inside dimension between the bucket ears
and the outside dimension across the arm mounting boss.
2. Subtract the clearance on both sides from the difference of
the two and shim accordingly, before assembly.
WARNING
To check end play (side-to-side) clearance at bucket
attachment point, the bucket must be free to move but at all
other times lower it to the ground or use support blocks to
immobilize this assembly. Shut off engine and tag and lock
out controls to prevent movement during this procedure.
Type 1
Shimming Procedures for Installed Bucket

1. With bucket attached, curl bucket and arm outward and
lower boom so that bucket teeth are pointing away from
excavator, just a few inches off ground. This position
provides easy accessibility for dimensional measurements.
2. Force bucket to one side and check for end play
(side-to-side) clearance under O-rings at attachment point.
Total clearance should be 1 mm (0.04 in) between side
face of boss and inside edge of ear bushing (Y, Figure 17).
Too tight a fit (less than 1 mm (0.04 in)) can cause
excessive wear while too much clearance may produce
excessive noise and potentially hazardous slack control.
3. Recheck end play by forcing bucket towards opposite side
and repeating clearance measurements.
4. If an adjustment is required, remove two jam nuts (1,
Figure 17) and bolt (2) from pin (3). Add or remove shims
(4) as required. Use equal amount of shims on each side.
Install bolt (2) and two jam nuts (1). Jam nuts must clear
boss by 1 - 2 mm (0.04 - 0.08 in) at point (X).
Figure 17
Bucket SP001550
Page 13
Type 2
Shimming Procedures for Installed Bucket

1. With bucket attached, curl bucket and arm outward and
lower boom so that bucket teeth are pointing away from
excavator, just a few inches off ground. This position
provides easy accessibility for dimensional measurements.
2. Force bucket to one side and check for end play
(side-to-side) clearance under O-rings at attachment point.
Clearance should be between 0.2 - 0.7 mm (0.0078 -
0.0275 in) on each end of arm boss, between side face of
boss and inside edge of ear bushing. Too tight a fit can
cause excessive wear while too much clearance may
produce excessive noise and potentially hazardous slack
control.
3. Recheck end play by forcing bucket towards opposite side
and repeating clearance measurements.
HAOE361L
4. If an adjustment is required, remove bolt (Figure 17) and
Figure 18
pin. Add or remove shims as required. Install pin and bolt.
Torque bolts to 42 Nm / 4.3 kg•m (31 ft lb).
Bucket SP001550
Page 14
BUCKET ATTACHMENT,
REMOVAL AND REVERSAL
Detaching the Bucket

Park the excavator away from obstructions on clear, flat, level
ground. Lower the bucket carefully to preassembled blocking on
the ground. Brace the bucket so that there is no load weight on
the pin connecting the bucket and arm. Disassemble the
fasteners on the end of the bucket pin and pull out the pin.
If the pin sticks and resists normal withdrawal, there may be a
load on it. Raise and lower the arm slightly until the unstressed
pin position is located.
CAUTION
Use care pulling out the pin to avoid damaging the dust
seals on either end of the arm.
When the pin has been withdrawn, move the operating joystick
slightly to take weight off the remaining link pin. Disassemble the
link pin end retainers and pull out the pin.
Lift the arm away from the bucket so that the bucket can be carried
away or another end attachment can be put on the excavator.
Attaching the bucket

Carefully inspect all parts before reassembling the bucket
linkage. Look for cracks or any other evidence of physical
damage and replace any seal or O-ring that is not in like new
condition. Prelube linkage pins before assembly.
Use an old cylinder rod, a long breaker bar or a similar, relatively
thin diameter support bar for making the first (temporary) pin
connection, between the bucket and arm. If the support bar is
straight, the arm can be raised and the bucket will hang level,
allowing direct insertion of the bucket ear-attachment linkage
pin.
Figure 19
Bucket SP001550
Page 15
When the link pin has been installed, withdraw the temporary
support rod from the bucket pin holes, lower and raise the arm
and boom and install the bucket pin.
WARNING
When making linkage alignments, never insert fingers into
pin holes. The attachment or bucket could shift position
and cause a severe injury. Match holes by visually lining
them up. Use the sharp tipped, soft point of a pencil or a
similar tool to check for high spots or irregularities.
Reversing the Bucket

Follow instructions for "Detaching the Bucket" and remove both
the bucket and link pins. Rotate the bucket 180° to change
bucket configuration. This procedure is greatly simplified if some
type of rotating or swiveling support can be used, on the ground
underneath the bucket. Follow instructions for "Bucket
Attachment" to replace pins.
WARNING
Figure 20
Bucket curl and dump levers must be used in opposite
directions, after the bucket has been reversed.
Bucket SP001550
Page 16

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DX15 / DX18

K1043970E Shop Manual Copyright 2008 DOOSAN

Trim Out The Label Along

Pub. No. K1043970E

Lower Structure and Chassis

Engine and Drive Train

Track Excavator Safety SP001521

Track Excavator Safety SP001521

Track Excavator Safety

Safety Precautions ............................................... 5

Track Excavator Safety SP001521

Track Excavator Safety SP001521

MODEL SERIAL NUMBER RANGE

Track Excavator Safety SP001521

Please respect the importance of taking responsibility for your

Track Excavator Safety SP001521

Learn the Signal Words Used with the

Track Excavator Safety SP001521

Never use machine for lifting.

LOCATION OF SAFETY LABELS

Track Excavator Safety SP001521

Avoid High Voltage Cables

Voltage Minimum Safe Distance

Use these minimum distances as a guideline only. Depending

Before Starting to Dig, Contact Authorities

Track Excavator Safety SP001521

Use Care on Loose Support

Use Solid Support Blocking

Overhangs Are Dangerous

Use Solid Support Blocking

Track Excavator Safety SP001521

Track Excavator Safety SP001521

BE AWARE OF AND CONFORM TO LOCAL REGULATIONS

Track Excavator Safety SP001521

Operate While Seated at the Operator's

Before Starting the Engine

Track Excavator Safety SP001521

Mounting and Dismounting

Observe General Safety Rules

Track Excavator Safety SP001521

Take Time to Provide Good Visibility

Remove Coating Before Welding or Heating

Track Excavator Safety SP001521

Never Carry People In or On the Machine

Fuel, Oil and Hydraulic Fluid Fire Hazards

Track Excavator Safety SP001521

Travel Controls May Produce Reversed

KEEP "PINCH POINT" AREAS CLEAR - USE CAUTION IN

attachment, including any part of the turntable or operator's cab. Figure 17

Track Excavator Safety SP001521

Operate Carefully on Snow and Ice and in

Track Excavator Safety SP001521

Rough Operation May Require Use of

Any reinforcement system that is installed on the machine must

Track Excavator Safety SP001521

Protect Yourself From Flying or Falling

Keep a Fire Extinguisher at Hand

Track Excavator Safety SP001521

Safety Critical Parts Must Be Replaced

Hydraulic Cylinder Seals Require Periodic

High-pressure Hydraulic Lines Can Store a

The Operator's Cab and Turntable Deck

Track Excavator Safety SP001521

Breathing Masks, Ear Protection May Be