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Shop Manual: DX140W-5 / DX160W-5
Shop Manual: DX140W-5 / DX160W-5
December 2014
EXCAVATOR
Shop
Manual
DX140W-5 / DX160W-5
Serial Number 1001 and Up
Shop Manual
DX140W-5 / DX160W-5 EXCAVATOR
Copyright
OperationDOOSAN 2014
and Maintenance Manual Copyright Doosan 2011
Pub.No. 950106-01097 E
Serial Number 1001 and Up
DX140W-5 / DX160W-5
Product Label
Instructions
2 Specifications 1 Specifications
4 Engine 1 Engine
Table of Contents
Page I
6 Lower Structure and Chassis 1 Swing Bearing
2 Front Axle
3 Rear Axle
4 Center Joint
5 Travel Motor
6 Driveshaft
7 Transmission
Table of Contents
Page II
1Safety
Wheel Excavator
Maintenance
Safety
Edition 1
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
SAFETY MESSAGES
Replace with Safety Messages Section on pages III and IV in
the Doosan Operation & Maintenance Manual.
Pressurized Fluids
Pressurized air or fluids can cause debris and/or fluids to be
blown out. This could result in death or serious injury.
Immediately after operations are stopped, coolant, engine oil,
and hydraulic oil are at their highest temperatures and the
radiator and hydraulic tank are still under pressure. Always wait
for temperature to cool down. Follow specified procedures when
attempting to remove caps, drain oil or coolant, or replacing
filters. Always wait for temperature to cool down, and follow
specified procedures when performing these operations. Failure FG018457
to do so can result in death or serious injury. Figure 1
When pressurized air and/or pressurized water is used for
cleaning, wear protective clothing, protective shoes, and eye
protection. Eye protection includes goggles or a protective face
shield.
Pressure can be trapped in a hydraulic system and must be
relieved before maintenance is started.
Releasing trapped pressure can cause sudden machine
movement or attachment movement. Use caution if you
disconnect hydraulic lines or fittings.
HAOA100L
Figure 3
HDO1010L
Figure 5
To prevent hot oil or coolant from spraying out, stop engine, wait
for oil and coolant to cool. Using gloves, slowly loosen cap to
relieve pressure.
FG019096
Figure 7
Operation
Do not use machine where exhaust, arcs, sparks or hot
components can contact flammable material, explosive dust or
gases.
Do not operate machine near any flame.
Exhaust shields (if equipped) protect hot exhaust components
from oil spray or fuel spray in case of a break in a line, hose, or
seal. Exhaust shields must be correctly installed.
Hydraulic System
Check hydraulic tubes, hoses and fittings for damage, wear or
for leaks. Hydraulic lines and hoses must be properly routed and
have adequate support and secure clamps. Leaks can cause
fires. Never use a flame or bare skin to check for leaks.
Tighten or replace any parts that show leakage.
Check that all hose and tube clamps, guards, and cushions are
securely attached. If they are loose, they can vibrate during
operation and rub against other parts. This can cause damage
to hoses and cause high-pressure oil to spray on hot surfaces,
causing a fire and death or serious injury.
Always clean fluid spills. Do not use gasoline or diesel fuel for
cleaning parts. Use commercial nonflammable solvents.
EX1400129
Figure 10
FG018458
Figure 12
WE1400090
Figure 15
WARNING
AVOID DEATH OR SERIOUS INJURY
Never modify the operator cabin by welding, grinding,
drilling holes or adding attachments unless instructed in
writing by DOOSAN. Changes to the cabin can cause loss
of operator protection from rollover and falling objects, and
can result in death or serious injury.
FG020947
Figure 17
WARNING EX1300679
Figure 19
AVOID DEATH OR SERIOUS INJURY
Protect your eyes when breaking the glass.
Transporting Machine
When transporting machine on a trailer or truck, do the following:
• The weight, transportation height, and overall length of
machine may change depending on work equipment
attached to it. Always check the machine dimensions and
work equipment's dimensions before transporting.
• When passing over bridges or structures on private land,
check that structure is strong enough to support weight of
machine. Before traveling on public roads, check with
appropriate authorities and follow their instructions.
Machine Condition
Every day before starting engine for first time, perform the
following checks and repair machine before operating, as
necessary. If these checks are not properly done death or
serious injury could result.
• Check coolant, fuel, and hydraulic tank oil levels, and
check for clogged air cleaner and damage to electrical
wiring.
• Check operation of gauges, cameras (if equipped) and
angle of mirrors, and check that safety lever is in LOCKED
position.
• Check that work equipment and travel controls move
freely, and work controls return to "NEUTRAL" when
released.
• Check that attachment is properly attached and locked.
IMPORTANT
Only use Ultra Low Sulfur Diesel (ULSD) fuel and API CJ-4/
ACEA E9 grade engine oil with this machine.
WE1400092
Figure 22
EX1301113
Figure 23
Operator Station
Inspect condition of seat belt and mounting hardware. Replace
any parts that are worn or damaged. Do not use a seat belt
extension on a retractable seat belt.
Adjust seat so full pedal travel can be achieved with operator's
back against back of seat.
Keep all windows and doors closed on machine.
Adjust operator's seat to a position where it is easy to perform
operations, and check that there is no damage or excessive
wear to seat belt or mounting clamps.
Adjust and clean mirrors so area to rear of machine can be seen
clearly from operator's seat.
When standing up from operator's seat, always place safety lock
lever securely in "LOCK" position. If you accidentally move work
equipment levers when they are not locked, the machine could
suddenly move and cause damage, death or serious injury.
WARNING
AVOID DEATH OR SERIOUS INJURY
Failure to properly inspect and maintain seat belt and
seat belt system can cause lack of operator restraint
and can result in death or serious injury.
Before fastening seat belt, check that there is no
problem in belt mounting bracket. If it is worn or
damaged, replace seat belt. Fasten seat belt so it is not
twisted.
Always wear seat belt when operating machine.
WARNING
AVOID DEATH OR SERIOUS INJURY
Failure to check for and clear people from the surrounding
area of a machine can result in death or serious injury. The
operator should make sure that visual aids (mirrors and
camera(s)) are in proper working condition.
WARNING
AVOID DEATH OR SERIOUS INJURY
• Always lower outriggers so rear tires are slightly raised. WE1400013
Figure 27
• Do not suddenly lower, swing or stop work equipment.
Operate controls smoothly.
• Do not move bucket (or work tool) over other
personnel or work equipment. A load could fall or
attachment could hit other personnel or equipment
resulting in death or serious injury or property
damage.
• Keep bystanders away.
• Do not suddenly lower, swing or stop work equipment.
Operate controls smoothly.
• To prevent tipping or rollover when handling heavy loads,
the ram lock switch must be in the "LOCKED" position.
Engine Stop
Turn engine starter switch to "O" (OFF) position and remove
engine starter switch key.
Before lowering any equipment with engine stopped, clear area
around equipment of all personnel and bystanders. This
procedure will cause high-pressure air or hydraulic pressure to
be released to lower equipment.
Do not stop engine immediately after the machine has been
operated under load. This can cause overheating and
accelerated wear of engine components.
After the machine is parked, allow engine to run for five minutes
before stopping the engine. This allows hot areas of engine to
cool gradually.
• Do not leave operator's seat when there is a raised load.
WARNING
AVOID DEATH OR SERIOUS INJURY
• Before excavating, apply parking brake and depress
the service brake pedal and "ENGAGE" the latch
mechanism to lock the service brake in the applied
position.
• "LOWER" the dozer blade and outriggers to the
ground before working.
• When finishing work or parking the machine always
"RELEASE" the service brake pedal to prevent
damage caused by overheating.
• Before starting work, always check the condition of
the service brakes. Service as necessary.
WARNING
AVOID DEATH OR SERIOUS INJURY
Follow instructions before operating or servicing machine.
Read and understand the Operation & Maintenance Manual
and signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs,
adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and
failure to follow instructions can result in death or serious
injury.
Cleaning
Clean machine before performing inspection and maintenance.
If inspection and maintenance are done when machine is dirty, it
will become more difficult to locate problems, and you could slip
on steps and work platform areas and injure yourself.
When washing machine, do the following:
• Wear shoes with nonslip soles to prevent slipping and
EX1400134
falling.
Figure 35
• Wear safety goggles and protective clothing when washing
machine with high-pressure steam or water.
• Do not spray water directly on electrical components
(sensors, connectors). If water gets into electrical system,
it can cause operation problems.
• Pick up any tools or hammers that are laying in workplace.
Wipe up any grease or oil to prevent slippery substances,
that can cause tripping or slipping.
• When cleaning cabin top window which is made of
polycarbonate material, use tap water. Avoid use of
organic solvents for cleaning, such as benzene, toluene or
methanol. These solvents can cause a chemical reaction
that will dissolve and damage the window.
HDO1037L
Figure 36
Disassembling Precautions
When using a hammer to remove pins, pins can fly out or metal
particles may break off. Always do the following:
• Hitting hard metal pins, bucket teeth, cutting edges or
bearings with a hammer, can cause metal pieces to break
or fly off resulting in serious injury. Always wear safety
goggles and leather gloves. Keep other personnel away.
Use of Lighting
When checking fuel, oil, battery electrolyte, window washer fluid,
or coolant, always use proper lighting equipment to prevent arcs
or sparks that could cause a fire or explosion resulting in death
or serious injury.
HDO1040L
Figure 37
Burn Prevention
When checking radiator coolant level, stop engine, let engine
and radiator cool down, then check coolant recovery tank. If
coolant level in coolant recovery tank is near upper limit, there is
enough coolant in radiator.
Using gloves, loosen radiator cap slowly to release internal
pressure before removing radiator cap.
If coolant level in coolant recovery tank is below lower limit, add
coolant.
Cooling system conditioner contains alkali which can cause
personal injury. Do not allow alkali to contact skin, eyes, or
mouth.
Allow cooling system components to cool before draining
cooling system.
Hot oil and hot components can cause personal injury. Do not
allow hot oil or hot components to contact skin.
Vent hydraulic tank only after engine has been stopped and
hydraulic tank is cool. Using gloves, slowly tilt hydraulic tank air
breather to relieve pressure.
Relieve all pressure in hydraulic oil system, in fuel system, or in
cooling system before disconnecting any lines, hoses, fittings, or
related components.
Batteries give off flammable fumes that can explode and start a HAAE1980
fire. Figure 39
Do not smoke while you are checking battery electrolyte level.
Electrolyte is an acid. Electrolyte can cause personal injury. Do
not allow electrolyte to contact skin or eyes.
Always wear safety goggles and face protection when working
with batteries.
IMPORTANT
When disconnecting or connecting connectors between
ECU and engine, or connector between ECU and the
machine, always disconnect the battery to prevent damage
to ECU.
If you do not follow this procedure, the ECU will be
damaged and/or the engine will not operate properly.
WARNING
AVOID DEATH OR SERIOUS INJURY
Removal of the machine counterweight, front attachment or
any other part can affect the stability of the machine. This
could cause unexpected movement, and result in death or
serious injury.
Never remove counterweight or front attachment unless the
upper structure is in-line with the lower structure.
Never rotate the upper structure once the counterweight or
front attachment has been removed. Figure 41 WE1400011
Compressed Air
• When cleaning filters, radiator or other components with
compressed air, there is a hazard of flying particles that
can result in serious injury.
• Always wear safety goggles, dust mask, leather gloves,
and other protective devices.
WE1400031
Figure 47
Deep Digging
Do not perform deep digging under front of machine. The ground
under machine may collapse and cause machine to fall resulting
in death or serious injury.
Working heavy loads on loose, soft or uneven ground, can cause
side load conditions resulting in a tip over and injury. Traveling
without a load or a balanced load may also be hazardous.
Never rely on lift jacks or other inadequate supports when work
is being done. Block tires fore and aft to prevent any movement.
WE1400032
Use machine only for its intended purpose. Using it for other
Figure 48
purposes will cause failures.
• Do not perform demolition work under machine. There is a
hazard that the machine may become unstable and tip
over.
• When working on or from top of buildings or other
structures, check if structure can support weight of
machine and attachment. If a building structure collapses,
this can cause death or serious injury.
Poor Visibility
For good visibility, always do the following:
• When working in dark areas, attach working lights and
front lights to the machine. If necessary, set up additional
lighting at work site.
• Stop operations when visibility is poor, such as in fog, mist,
snow, and rain. Wait for visibility to improve before starting
operation.
To avoid hitting work equipment and damaging other property,
always do the following:
• When working in tunnels, on bridges, under electrical
wires, or when parking the machine or performing other
operations in places with limited height, be careful not to hit
and damage other equipment or property.
• To prevent hitting objects, operate machine at a slow
speed when working in confined spaces, indoors, or in
crowded areas.
• Do not swing bucket over the top of personnel or over
operator's cabin of dump truck.
High-voltage Cables
Do not travel or operate machine near electrical cables or
overhead power lines. There is a hazard of electric shock, which
can cause property damage and result in death or serious injury.
The bucket or other attachment does not have to make physical
contact with power lines for current to cause an electrocution.
Use a spotter and hand signals to stay away from power lines
not clearly visible to operator. On work sites where machine may
operate close to electrical cables, always do the following:
WE1400033
• Remember that electrical voltage determines what the
Figure 49
minimum distance is to stay away from the power line. See
the following table for minimum distances when working
near electrical power lines. Electrical flashover can occur
and damage machine and cause death or serious injury.
Working in Water
IMPORTANT
Do not exceed maximum permissible water depth. The
water level must not reach higher than bottom of the axle
housing.
WARNING
AVOID DEATH OR SERIOUS INJURY
Explosion of the battery can cause death or serious
injury. Never attempt to directly heat the battery with
open fire.
WARNING
AVOID DEATH OR SERIOUS INJURY
Explosion of the fuel tank can cause death or serious
injury. Never attempt to directly heat the fuel tank with
open fire.
IMPORTANT
Do not store acid type storage batteries near stacks of
tires. Acid fumes can damage rubber.
WARNING
AVOID DEATH OR SERIOUS INJURY
Wear goggles when using compressed air to prevent
face or eye injury.
Exhaust Ventilation
Engine exhaust gases can cause unconsciousness, loss of
alertness, judgment and motor control. This can result in death
or serious injury.
Make sure there is adequate ventilation before starting engine in
any enclosed area.
Check for and be aware of any open windows, doors or
ductwork where exhaust may be carried, or blown by wind,
exposing others to hazardous exhaust gases.
ARO1770L
Figure 52
Ventilation for Enclosed Area
If it is necessary to start engine within an enclosed area, or when
handling fuel, flushing oil, or paint; open doors and windows to
ensure that adequate ventilation is provided to prevent gas
poisoning.
Diesel engine exhaust contains products of combustion which
can be harmful to your health.
Always run engine in a well ventilated area. If you are in an
enclosed area, vent exhaust to outside.
WARNING
AVOID DEATH OR SERIOUS INJURY
Avoid exposure to dust containing asbestos as it can cause
death or serious injury to the lungs and other organs
(mesothelioma, lung and other cancers, and asbestosis).
WARNING
AVOID DEATH OR SERIOUS INJURY
Avoid exposure to dust containing crystalline silica
particles as it can cause serious injury to the lungs
(silicosis).
Sound
Sound Level Information: Hearing protection may be needed
when machine is operated with an open operator station for
extended periods or in a noisy environment.
Edition 1
DX140W-5/DX160W-5 Specifications
2-1-1
MEMO
Specifications DX140W-5/DX160W-5
2-1-2
Table of Contents
Specifications
Safety Instructions ..........................................2-1-5
General Description ........................................2-1-5
Component Locations.....................................2-1-6
Overall Dimensions ......................................2-1-10
One - Piece Boom ................................................... 2-1-10
Two - Piece Boom ................................................... 2-1-11
Working Range .............................................2-1-12
One - Piece Boom ................................................... 2-1-12
Two - Piece Boom ................................................... 2-1-14
General Specifications..................................2-1-16
DX140W-5............................................................... 2-1-16
DX160W-5............................................................... 2-1-18
Approximate Weight of Workload Materials ...2-1-19
Performance Tests .......................................2-1-21
Purpose of Performance Tests................................ 2-1-21
Kinds of Tests.......................................................... 2-1-21
Performance Standards .......................................... 2-1-21
Precautions for Evaluation of Test Data.................. 2-1-21
Definition of "Performance Standard"...................... 2-1-21
Preparation for Performance Tests ..............2-1-22
The Machine............................................................ 2-1-22
Test Area................................................................. 2-1-22
Precautions ............................................................. 2-1-22
Make Precise Measurement.................................... 2-1-22
Operational Performance Standard Table ....2-1-23
Operational Performance Test .....................2-1-26
Hydraulic Cylinder Cycle Time ................................ 2-1-26
Driveshaft Revolution Speed................................... 2-1-28
Swing Speed ........................................................... 2-1-29
Swing Function Drift Check ..................................... 2-1-30
DX140W-5/DX160W-5 Specifications
2-1-3
Specifications DX140W-5/DX160W-5
2-1-4
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL DESCRIPTION
The excavator has three main component sections:
• The Upper Structure
• The Lower Undercarriage and Chassis Frame
• The Excavator Front-end Attachment
The following illustration identifies main components and their
locations. (See Figure 1 on page -6.)
DX140W-5/DX160W-5 Specifications
2-1-5
COMPONENT LOCATIONS
20 21 1 2 3 4
11
10
15
17
18
19 5
16
13 6
14
12 9 8 7
Figure 1 WE1401228
Reference Reference
Description Description
Number Number
1 Cabin 12 Rim
2 Boom Cylinder 13 Wheel
3 Boom 14 Front Axle
4 Arm Cylinder 15 Rear Axle
5 Arm 16 Chocking Cylinder
6 Bucket Cylinder 17 Transmission
7 Guide Link 18 Travel Motor
8 Push Link 19 Driveshaft
9 Bucket 20 Counterweight
10 Side Cutter 21 Hood
11 Tooth Point
Specifications DX140W-5/DX160W-5
2-1-6
2
FR 1
ON
T
3
View A
A
Figure 2 WE1400164
Reference Reference
Description Description
Number Number
1 Engine 6 SCR Catalyst
2 Radiator 7 SCR Muffler
3 Precleaner 8 Urea Tank
4 Air Cleaner 9 DEF (AdBlue) Filter
5 Main Pump
DX140W-5/DX160W-5 Specifications
2-1-7
FR
ON
13 T
11
10
12 6
3
WE1401229
Figure 3
Reference Reference
Description Description
Number Number
1 Battery 8 Engine Oil Filter
2 Fuel Tank 9 Pilot Filter
3 Fuel Cap 10 Main Fuel Filter
4 Hydraulic Oil Tank 11 Gear Pump (Brake and Steering)
5 Air Breather 12 Gear Pump (Rotating)
6 Return Filter Water Separator & Pre fuel Filter
13
7 Suction Filter (Fuel Prefilter)
Specifications DX140W-5/DX160W-5
2-1-8
FR
ON
T
Engine
6
1
2
4
3
WE1401230
Figure 4
Reference Reference
Description Description
Number Number
1 Main Control Valve Solenoid Valve
5 (Ram Lock, Inching,
2 Swing Device Pilot Cut-off, Breaker)
3 Swing Bearing Solenoid Valve
6 (Forward, Backward,
4 Center Joint Power Boost, Cruise)
DX140W-5/DX160W-5 Specifications
2-1-9
OVERALL DIMENSIONS
I A
E
M
D
H
G
F
L J K
B
WE1400337
Figure 5
Specifications DX140W-5/DX160W-5
2-1-10
Two - Piece Boom
I A
E
D
C
H
G
F
L J K
FG023275
Figure 6
DX140W-5/DX160W-5 Specifications
2-1-11
WORKING RANGE
F
G
D
E
d
G.L
L
H J C
K 2,500 mm
A
WE1400340
Figure 7
Specifications DX140W-5/DX160W-5
2-1-12
Boom Type 4.4 m (14' 5") 4.6 m (15' 1")
DIM. Arm Type 2.1 m (6' 11") 2.5 m (8' 2") 2.1 m (6' 11")
Bucket Type (PCSA) 0.59 m3 (0.77 yd3) 0.45 m3 (0.59 yd3) 0.51 m3 (0.67 yd3)
A Max. Digging Reach 7,585 mm (24' 11") 8,235 mm (27' 0"') 7,765 mm (25' 6")
B Max. Digging Reach (Ground) 7,375 mm (24' 2") 8,040 mm (26' 5") 7,560 mm (24' 10")
C Max. Digging Depth 4,490 mm (14' 9") 5,020 mm (16' 6") 4,620 mm (15' 2")
D Max. Loading Height 5,905 mm (19' 4") 6,510 mm (21' 4") 6,060 mm (19' 11")
E Min. Loading Height 2,625 mm (8' 7") 2,465 mm (8' 1") 2,835 mm (9' 4")
F Max. Digging Height 8,195 mm (26' 11") 8,850 mm (29' 0") 8,340 mm (27' 4")
G Max. Bucket Pin Height 7,125 mm (23' 5") 7,730 mm (25' 4") 7,275 mm (23' 10")
H Max. Vertical Wall Depth 3,445 mm (11' 4") 4,265 mm (14' 0") 3,480 mm (11' 5")
I Max. Radius Vertical 5,480 mm (18' 0") 5,555 mm (18' 3") 5,695 mm (18' 8")
J Max. Depth to 2.5 m Line 4,215 mm (13' 10") 4,805 mm (15' 9") 4,345 mm (14' 3")
K Min Radius 2.5 m Line 2,105 mm (6' 11") 2,315 mm (7' 7") 2,240 mm (7' 4")
L Min. Digging Reach 455 mm (1' 6") 820 mm (2' 8") 885 mm (2' 11")
M Min Swing Radius 2,340 mm (7' 8") 2,665 mm (8' 9") 2,500 mm (8' 2")
d Bucket Angle 174° 174° 174°
DX140W-5/DX160W-5 Specifications
2-1-13
Two - Piece Boom
F
G
E
d
G.L
H J C
K 2,500 mm
A
WE1400341
Figure 8
Specifications DX140W-5/DX160W-5
2-1-14
Boom Type 4.987 m (16' 4")
DIM. Arm Type 2.5 m (8' 2") 2.1 m (6' 11")
Bucket Type (PCSA) 0.51 m3 (0.67 yd3) 0.59 m3 (0.77 yd3)
A Max. Digging Reach 8,670 mm (28' 5'') 8,210 mm (26' 11'')
B Max. Digging Reach (Ground) 8,490 mm (27' 10'') 8,020 mm (26' 4'')
C Max. Digging Depth 5,455 mm (17' 11'') 5,025 mm (16' 6'')
D Max. Loading Height 7,175 mm (23' 6'') 6,715 mm (22' 0')
E Min. Loading Height 3,015 mm (9' 11'') 3,365 mm (11' 0')
F Max. Digging Height 9,565 mm (31' 5'') 9,060 mm (29' 9'')
G Max. Bucket Pin Height 8,395 mm (27' 7'') 7,930 mm (26' 0'')
H Max. Vertical Wall Depth 4,410 mm (14' 6'') 3,840 mm (12' 7'')
I Max. Radius Vertical 5,680 mm (18' 8'') 5,825 mm (19' 1'')
J Max. Depth to 2.5 m Line 5,345 mm (17' 6'') 4,905 mm (16' 1'')
K Min. Radius 2.5 m Line 865 mm (2' 10'') 865 mm (2' 10'')
L Min. Digging Reach 1,565 mm (5' 2'') 1,760 mm (6' 5'')
M Min Swing Radius 2,850 mm (9' 4'') 2,650 mm (8' 8'')
d Bucket Angle 174° 174°
DX140W-5/DX160W-5 Specifications
2-1-15
GENERAL SPECIFICATIONS
DX140W-5
Shipping Weight 15,577 kg (34,341 lb)
Includes 10% fuel, 4,400 mm (14' 5"), 2,100 mm (6' 11") arm, 0.59 m3
(0.77 yd3) bucket and front stabilizer and rear stabilizer
Counterweight 2,200 kg (4,850 lb)
Upper Turntable 4,975 kg (10,968 lb)
Lower Turntable
4,832 kg (10,653 lb)
(Include Swing Bearing)
Operating Weight 15,819 kg (34,875 lb) with full fuel tank and operator
Major Component Weights One-Piece Boom (Short) 4,400 mm (14' 5") 738 kg (1,627 lb)
One-Piece Boom (Long) 4,600 mm (15' 1") 767 kg (1,691 lb)
Two-Piece Boom (Lower) 2,000 mm (6' 7") 384 kg (847 lb)
Two-Piece Boom (Upper) 3,350 mm (11' 0") 592 kg (1,305 lb)
Boom Cylinder 106 kg (234 lb) each
Long Arm 2,500 mm (8' 2") 418 kg (922 lb)
Short Arm 2,100 mm (6' 11") 375 kg (827 lb)
Arm Cylinder 151 kg (333 lb)
Bucket 0.59 m3 413 kg (910 lb)
Bucket Cylinder 87 kg (192 lb)
Dozer 672 kg (1,482 lb)
Dozer Cylinder 42 kg (93 lb) each
Outrigger 960 kg (2,116 lb)
Outrigger Cylinder 74 kg (163 lb) each
Digging Forces (At Power Boost, ISO)
Bucket Cylinder 90.5 kN or 9,228 kg (20,345 lb) with One-Piece Boom
100.2 kN or 10,218 kg (22,526 lb) with Two-Piece Boom
Arm Cylinder 77.2 kN or 7,872 kg (17,355 lb) with 2,100 mm (6' 11") Short Arm
65.7 kN or 6,700 kg (14,770 lb) with 2,500 mm (8' 2") Long Arm
Fuel Tank Capacity 280 L (73.9 U.S. gal.)
Hydraulic System Capacity 238 L (62.9 U.S. gal.)
Hydraulic Reservoir Capacity 148 L (39.1 U.S. gal.)
Bucket Heaped Capacity Range SAE 0.24 ~ 0.76 m3 (0.31 ~ 0.99 yd3)
NOTE: Refer to the Load Weight, Bucket and Arm Length Compatibility
Table for information on which bucket sizes are approved for which arm
length and workload material weights.
Undercarriage
Ground Clearance 347 mm (1' 2")
Wheel Base 2,800 mm (9' 2")
Overall Width 2,500 mm (8' 2")
Dozer Blade Width 2,500 mm (8' 2")
Tire Size (Std. Double) 8 x 10.00 - 20 -14PR
Specifications DX140W-5/DX160W-5
2-1-16
Shipping Dimensions
Overall Shipping Length 7,630 mm (25' 0")
Overall Shipping Width 2,500 mm (8' 2")
Overall Shipping Height 2,865 mm (9' 5")
Transport Loading Ramp
15° angle
Allowable Slope
When Transporting NOTE: Refer to Operation and Maintenance Manual for Recommended
Transportation Instructions.
DX140W-5/DX160W-5 Specifications
2-1-17
DX160W-5
Shipping Weight 16,728 kg (36,880 lb)
Includes 10% fuel, 4,988 mm (16' 4"), 2,500 mm (8' 2") arm, 0.51 m3
(0.67 yd3) bucket and front dozer blade and rear stabilizer
Counterweight 2,200 kg (4,850 lb)
Upper Turntable 4,975 kg (10,968 lb)
Lower Turntable
6,390 kg (14,088 lb)
(Include Swing Bearing)
Operating Weight 16,975 kg (37,423 lb) with full fuel tank and operator
Major Component Weights Two-Piece Boom (Lower) 2,000 mm (6' 7") 384 kg (847 lb)
Two-Piece Boom (Upper) 3,350 mm (11' 0") 592 kg (1,305 lb)
Boom Cylinder 106 kg (234 lb) each
Long Arm 2,500 mm (8' 2") 418 kg (922 lb)
Short Arm 2,100 mm (6' 11") 375 kg (827 lb)
Arm Cylinder 151 kg (333 lb)
Bucket 0.51 m3 393 kg (866 lb)
Bucket Cylinder 87 kg (192 lb)
Dozer 672 kg (1,482 lb)
Dozer Cylinder 42 kg (93 lb) each
Outrigger 960 kg (2,116 lb)
Outrigger Cylinder 74 kg (163 lb) each
Digging Forces (At Power Boost, ISO)
Bucket Cylinder 100.2 kN or 10,218 kg (22,526 lb) with Two-Piece Boom
Arm Cylinder 77.2 kN or 7,872 kg (17,355 lb) with 2,100 mm (6' 11") Short Arm
65.7 kN or 6,700 kg (14,770 lb) with 2,500 mm (8' 2") Long Arm
Fuel Tank Capacity 280 L (73.9 U.S. gal.)
Hydraulic System Capacity 238 L (62.9 U.S. gal.)
Hydraulic Reservoir Capacity 148 L (39.1 U.S. gal.)
Bucket Heaped Capacity Range SAE 0.24 ~ 0.76 m3 (0.31 ~ 0.99 yd3)
NOTE: Refer to the Load Weight, Bucket and Arm Length Compatibility
Table for information on which bucket sizes are approved for which arm
length and workload material weights.
Undercarriage
Ground Clearance 347 mm (1' 2")
Wheel Base 2,800 mm (9' 2")
Overall Width 2,500 mm (8' 2")
Dozer Blade Width 2,500 mm (8' 2")
Tire Size (Std. Double) 8 x 10.00 - 20 -14PR
Shipping Dimensions
Overall Shipping Length 7,630 mm (25' 0")
Overall Shipping Width 2,500 mm (8' 2")
Overall Shipping Height 2,865 mm (9' 5")
Transport Loading Ramp
15° angle
Allowable Slope
When Transporting NOTE: Refer to Operation and Maintenance Manual for Recommended
Transportation Instructions.
Specifications DX140W-5/DX160W-5
2-1-18
APPROXIMATE WEIGHT OF
WORKLOAD MATERIALS
IMPORTANT
Weights are approximations of estimated average volume
and mass. Exposure to rain, snow or groundwater; settling
or compaction because of overhead weight and chemical or
industrial processing or changes because of thermal or
chemical transformations could all increase value of
weights listed in table.
DX140W-5/DX160W-5 Specifications
2-1-19
Density Density Density Density
1,200 kg/m3 1,500 kg/m3 1,800 kg/m3 2,100 kg/m3
Material
(2,000 lb/yd3), (2,500 lb/yd3), (3,000 lb/yd3), (3,500 lb/yd3),
or less or less or less or less
1,522 kg/m3
Gypsum, crushed to 3 inch size - - -
(2,565 lb/yd3)
1,810 kg/m3
Gravel, DRY, packed fragments - - -
(3,051 lb/yd3)
1,922 kg/m3
Gravel, WET, packed fragments - - -
(3,240 lb/yd3)
1,282 kg/m3
Limestone, graded above 2 - - -
(2,160 lb/yd3)
1,362 kg/m3
Limestone, graded 1-1/2 or 2 - - -
(2,295 lb/yd3)
1,522 kg/m3
Limestone, crushed - - -
(2,565 lb/yd3)
1,602 kg/m3
Limestone, fine - - -
(2,705 lb/yd3)
1,282 kg/m3
Phosphate, rock - - -
(2,160 lb/yd3)
929 kg/m3
Salt - - -
(1,566 lb/yd3)
529 kg/m3
Snow, light density - - -
(891 lb/yd3)
1,522 kg/m3
Sand, DRY, loose - - -
(2,565 lb/yd3)
1,922 kg/m3
Sand, WET, packed - - -
(3,240 lb/yd3)
1,362 kg/m3
Shale, broken - - -
(2,295 lb/yd3)
529 kg/m3
Sulfur, broken - - -
(891 lb/yd3)
Specifications DX140W-5/DX160W-5
2-1-20
PERFORMANCE TESTS
Use operational performance test procedure to quantitatively
check all system and functions on the machine.
Kinds of Tests
1. Base machine performance test is to check the operational
performance of each system such as engine, travel, swing,
and hydraulic cylinders.
2. Hydraulic component unit test is to check the operational
performance of each component such as hydraulic pump,
motor, and various kinds of valves.
Performance Standards
"Performance Standard" is shown in tables to evaluate the
performance test data.
DX140W-5/DX160W-5 Specifications
2-1-21
PREPARATION FOR PERFORMANCE TESTS
Observe the following rules to perform performance tests
accurately and safety.
The Machine
1. Repair any defects and damage found, such as oil or water
leaks, loose bolts, cracks etc, before starting to test.
Test Area
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run straight
more than 20 m (65 ft 7 in), and to make a full swing with
the front attachment extended.
3. If required, rope off the test area and provide signboards to
keep unauthorized personnel away.
Precautions
1. Before starting to test, agree upon the signals to be
employed for communication among coworkers.
Once the test is started, be sure to communicate with each
other using these signals, and to follow them without fail.
2. Operate the machine carefully and always give first priority
to safety.
3. While testing, always take care to avoid accidents because
of landslides or contact with high voltage power lines. EX1302009
Always confirm there is sufficient space for full swings. Figure 9
Specifications DX140W-5/DX160W-5
2-1-22
OPERATIONAL PERFORMANCE STANDARD TABLE
Performance
Item Model Unit Measuring Conditions
Standard
Power Mode rpm - 2,100 ±25
Travel Mode
Standard Mode rpm - 1,700 ±25
rpm SPC Off 1,600 ±25
Power Plus Mode
rpm SPC On 1,500 ±25
rpm SPC Off 1,500 ±25
Power Mode
rpm SPC On 1,400 ±25
rpm SPC Off 1,450 ±25
Standard Mode
rpm SPC On 1,350 ±25
rpm SPC Off 1,400 ±25
Economy Mode
rpm SPC On 1,300 ±25
Lifting Mode rpm - 1,400 ±25
No Load Auto Warm Up On
Condition
Low Idle • Coolant Temperature 800 ±20
(Auto Warm Up Off) Below 15°C
Auto Warm Up Off
Condition
rpm
• Coolant Temperature
Engine Low Idle
Above 30°C
Speed (Auto Warm Up On)
• 10 minutes Spent After
• It may occur for a little 1,200 ±20
Startup
while after the engine
• The Dial on the rpm
starts up in winter.
Gauge Moved
Load 1 Pump Relief rpm above 1,600
(P+ SPC Off) 2 Pump Relief rpm above 1,600
Power Plus Mode rpm 1,600 ±25
Power Mode rpm 1,500 ±25
Revolution at Dial Max. SPC On
Standard Mode rpm 1,450 ±25
Boom Up
or Arm Dump Economy Mode rpm 1,400 ±25
Lifting Mode rpm Adjust Dial, SPC On 1,400 ±25
Low rpm Dial Min.
Above Ambient Temp.
rpm 800 ±20
10°C (50°F)
Auto Idle
Below Ambient Temp.
rpm 1,100 ±20
10°C (50°F)
Fan Revolution
High Idle rpm *Standard 1,750 ±50
Speed
DX140W-5/DX160W-5 Specifications
2-1-23
Performance
Item Model Unit Measuring Conditions
Standard
Power Mode mA Hill Up- Main Pump 240 ±30
Travel
Standard Mode mA Above 290 bar 240 ±30
Power Plus Mode mA 270 ±30
EPOS Power Mode mA SPC Off 300 ±30
(Pump Minimum Value at Arm
Standard Mode mA Crowd 320 ±30
Proportional
Current) Work Economy Mode mA 340 ±30
Lifting Mode mA 240 ±30
Auto Idle mA Idle 650 ±30
Low Idle mA 700 ±30
Relief bar 343 +10
*Standard
Relief Power Up bar 363 +10
Front
Idle P1 bar above 30
Idle P2 bar above 30
Relief (at Motor) bar 275 +10
Pressure Swing Motor *Standard
Relief (at Pump) bar 300 +10
Set
Travel Motor At Motor bar 363 +10
Max. Flow lpm 260 ±10
Relief (in Front of Valve) bar 350 ±25
Option
Relief (at Pump) bar 350 ±25
Proportional Current mA -
Up sec 3.3 ±0.4
Boom
Down sec 2.8 ±0.3
Crowd sec 2.8 ±0.3
Arm
Dump sec 2 ±0.3
Crowd sec 3.7 ±0.4
Bucket
Front Dump sec 2.1 ±0.3
Speed Up sec 6.3 ±0.5
Art Boom
Down sec 4.2 ±0.5
Up sec 1.6 ±0.3
Dozer
Down sec 1.8 ±0.3
Up sec 3.7 ±0.4
Outrigger
Down sec 4.7 ±0.5
Swing Single 3 *Standard, Swing Single
Swing sec 16.8 ±1.5
Revolution 3 Revolution
Swing Speed After 360° Swing, Empty
Swing
After 360° Swing mm Bucket, 607 ±20%
Coasting
Bearing Outer Race
Inching rpm 255 ±20
Jack-up 1st Speed rpm 830 ±40
Travel Speed
Speed 2nd Speed rpm 3,300 ±80
2nd (20km/hr) rpm 1,660 ±40
Specifications DX140W-5/DX160W-5
2-1-24
Performance
Item Model Unit Measuring Conditions
Standard
Weight Standard ton 1.0
Max. Reach Posture,
Boom Down mm/5min below 5
Bucket Crowd Posture,
Weight Bucket
Arm Crowd mm/5min (1.5 times of bucket below 5
capacity)
Bucket Dump mm/5min No settlement when Lock below 20
V/V is applied
Front Load Travel Posture,
Bucket Crowd Posture,
Cylinder Arm Dump mm/5min Weight Bucket below 20
(1.5 times bucket
capacity)
Dozer mm/5min below 5
Outrigger mm/5min below 5
Vertical Displacement in Max. Reach Posture,
mm/10min
Front Bucket's End Point Bucket Dump Posture
(Empty Boom Down mm/10min Recheck if bucket's end
Bucket) Arm Crowd mm/10min point fails in vertical
Bucket Crowd mm/10min displacement
DX140W-5/DX160W-5 Specifications
2-1-25
OPERATIONAL PERFORMANCE TEST
Summary
1. Check the overall operational performance of the front
attachment hydraulic system (between the hydraulic
pumps and each cylinder) by measuring the cycle time of
the boom, arm, bucket, and bucket dump (open/close)
cylinders with the empty bucket.
2. Bucket must be empty.
Preparation
1. Maintain the hydraulic oil temperature at 50 ±5 °C
(122 ±41 °F).
Specifications DX140W-5/DX160W-5
2-1-26
B. Arm cylinder
1) Arm crowd speed
Rapidly operate the arm while kept fully dumped
(extended), and measure the time it takes for
the arm to fold fully.
2) Arm dump speed
Rapidly operate the arm maintained in the fully
folded position, and measure the time it takes 0.5 m
for the arm to extend fully. WE1400778
3) Measuring available displacement of the Figure 11
cylinder: Measure and record the extension
length of the cylinder rod from the point at which
the arm cylinder is fully extended (crowded) to
the point at which the arm cylinder is fully folded
(dumped).
C. Bucket cylinder
1) Bucket crowd speed
Rapidly operate the bucket while fully dumped
(extended), and measure the time it takes for
the bucket to fold fully.
2) Bucket dump speed
Rapidly operate the bucket while fully folded,
and measure the time it takes for the bucket to
extend fully. 1m
WE1400779
3) Measuring available displacement of the Figure 12
cylinder: Measure and record the extension
length of the cylinder rod from the point at which
the bucket cylinder is fully extended (crowded)
to the point at which the bucket cylinder is fully
folded (dumped).
NOTE: Jack up the dozer of the wheel-type excavator and
mini-excavator pointing forward, and measure the
time taken to jack it up and to jack it back down.
Measure and record the operating time of the boom
swing (option) of the mini-excavator from right to left,
or from left to right.
NOTE: Record the details of any abnormal noise heard
during measurement, or any abnormal conditions
observed during operation, on a blank measurement
record sheet.
DX140W-5/DX160W-5 Specifications
2-1-27
Driveshaft Revolution Speed
Summary
Measure the drive shaft revolution cycle time with jack up
condition.
Preparation
1. Position the front attachment as described in Figure 13.
2. Jack up the machine with dozer and outrigger.
CAUTION
AVOID INJURY
Position the machine on firm and level ground not to
be tilted.
WE1400816
Figure 13
Measurement
1. Set the machine to correspond with measuring conditions.
2. Measure conditions are as below.
Specifications DX140W-5/DX160W-5
2-1-28
Swing Speed
Summary
Measure the time required to swing three complete turns.
Preparation
1. Check the lubrication of the swing gear and swing bearing.
2. Place the machine on flat, solid ground with ample space
lor swinging. Do not conduct this test on slopes.
3. With the bucket empty, position the front attachment as
follows.
With the arm cylinder fully retracted, and the bucket The height as the
cylinder fully extended, raise the boom so bucket pin boom foot pin height.
height is flush with the boom foot pin height.
WE1400780
NOTE: In case of no place to be measured, measure Figure 16
with the boom raised and the arm rolled-in.
4. Maintain the hydraulic oil temperature at 50 ±5°C
(122 ±41°F).
CAUTION
AVOID INJURY
Prevent personal injury. Always make sure that area is
clear and that co-workers are out of the swing area
before starting the measurement.
Measurement
1. Measurement conditions are as below.
Evaluation
Refer to "Operational Performance Standard Table" on page -23.
DX140W-5/DX160W-5 Specifications
2-1-29
Swing Function Drift Check
Summary
Measure the swing drift on the bearing outer circumference
when stopping after a 360° full-speed swing.
Preparation
1. Check the lubrication of the swing gear and swing bearing.
2. Place the machine on flat, solid ground with ample space
for swinging. Do not conduct this test on a slope.
3. With the bucket empty, position the front attachment as
follow.
With the arm cylinder fully retracted, and the bucket
cylinder fully extended, raise the boom so bucket pin
height is flush with the boom foot pin height. Two Matching Marks
WE1400781
4. Put the matching marks on the swing bearing and on the
Figure 17
track frame by using a tape, as illustrated.
5. Swing the upper structure 360°.
6. Maintain the hydraulic oil temperature at 50 ±5°C
(122 ±41°F).
CAUTION
AVOID INJURY
Prevent personal injury. Always make sure that area is
clear and that co-workers are out of the swing area WE1400782
before starting the measurement. Figure 18
Evaluation
Refer to "Operational Performance Standard Table" on page -23.
Specifications DX140W-5/DX160W-5
2-1-30
1General Maintenance
General
Maintenance
Instructions
Edition 1
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
WARNING
AVOID DEATH OR SERIOUS INJURY
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
AVOID DEATH OR SERIOUS INJURY
Structural elements of the machine may be built from a
variety of steels. These could contain unique alloys or may
have been heat-treated to obtain particular strength
characteristics. It is extremely important that welding
repairs on these types of steel are performed with the
proper procedures and equipment. If repairs are performed
incorrectly, structural weakening or other damage to the
machine (that is not always readily visible) could result.
Always consult DOOSAN After Sales Service before
welding on integral components (loader arm, frames, car
body, track frames, upper structure, attachment, etc.) of the
machine. It is possible that some types of structurally
critical repairs may require Magnetic Particle or Liquid
Penetrant testing, to make sure there are no hidden cracks
or damage, before the machine can be returned to service.
WARNING
AVOID DEATH OR SERIOUS INJURY
Always perform welding procedures with proper safety
equipment and adequate ventilation in a dry work area.
Keep a fire extinguisher near and wear personal protective
equipment.
HYDRAULIC SYSTEM -
GENERAL PRECAUTIONS
Always maintain oil level in the system at recommended levels.
Assemblies that operate under heavy loads, at high-speed, with
extremely precise tolerances between moving parts (e.g. pistons
and cylinders, or shoes and swash plates), can be severely
damaged if oil supply runs dry.
Assemblies can be run dry and damaged severely in a very
short time when piping or hoses are disconnected to repair leaks
and/or replace damaged components. Hoses that are
inadvertently switched during disassembly (inlet for outlet and
vice versa), air introduced into the system or assemblies that are
low on oil because of neglect or careless maintenance, could all
produce sufficient fluid loss to cause damage or improper
operation.
IMPORTANT
Hydraulic system operating conditions (repetitive cycling,
heavy workloads, fluid circulating under high-pressure)
make it extremely critical that dust, grit or any other
contamination be kept out of the system. Observe fluid and
filter change maintenance interval recommendations and
always preclean any exterior surface of the system before it
is exposed to air. For example, the reservoir fill cap and
neck area, hoses that have to be disassembled, and the
covers and external surfaces of filter canisters should all be
cleaned before disassembly.
General Precautions
Fluid level and condition should always be checked whenever
any other maintenance service or repair is being performed.
NOTE: If the unit is being used in an extreme temperature
environment (in subfreezing climates or in high
temperature, high humidity tropical conditions),
frequent purging of moisture condensation from the
hydraulic reservoir drain tap must be a regular and
frequent part of the operating routine. In more
moderate, temperate climates, draining reservoir
sediment and moisture may not be required more
than once or twice every few months.
Inspect drained oil and used filters for signs of abnormal coloring
or visible fluid contamination at every oil change. Abrasive grit or
dust particles will cause discoloration and darkening of the fluid.
Visible accumulations of dirt or grit could be an indication that
filters are overloaded (and will require more frequent
replacement) or that disintegrating bearings or other component
failures in the hydraulic circuit may be imminent or have already
occurred. Open the drain plugs on the main pump casings and
check and compare drain oil in the pumps. Look for evidence of
grit or metallic particles.
Vibration or unusual noise during operation could be an
indication of air leaking into the circuit (Refer to the appropriate
Troubleshooting section for component or unit for procedures.),
or it may be evidence of a defective pump. The gear type pilot
pump could be defective, causing low pilot pressure, or a main
pump broken shoe or piston could be responsible.
NOTE: If equipped, indicated operating pressure, as shown
on the multidisplay digital gauge on the Instrument
Panel ("F-Pump" and "R-Pump") will be reduced
because of a mechanical problem inside the pump.
However, pressure loss could also be because of
cavitation or air leakage, or other faults in the
hydraulic system.
Check the exterior case drain oil in the main pumps. If no
metallic particles are found, make sure there is no air in the
system. Unbolt and remove tank return drain line from the top
part of the swing motor, both travel motors and each main pump.
If there is air in any one of the drain lines, carefully prefill the
assembly before bolting together the drain line piping
connections. Run the system at low rpm.
IMPORTANT
Make sure that cleaning solvents will be compatible with
rubber materials used in the hydraulic system. Many
petroleum based compounds can cause swelling,
softening, or other deterioration of system sealing
elements, such as O-rings, caps and other seals.
Figure 1
General Instructions
All parts must be clean to permit an effective inspection. During
assembly, it is very important that no dirt or foreign material
enters unit being assembled. Even minute particles can cause
malfunction of close installed parts such as thrust bearing,
matched parts, etc.
WARNING
AVOID DEATH OR SERIOUS INJURY
Do not inhale vapors or allow solvent type cleaners to
contact skin. Keep solvent away from open flame, arcs or
sparks or other sources of ignition that could start a fire.
Bearing Inspection
The conditions of the bearing are vital to the smooth and
efficient operation of the machinery. When any component
containing bearings is disassembled, always carefully examine
the condition of the bearings and all of its components for wear
and damage.
Once the bearing is removed, clean all parts thoroughly using a
suitable cleaning solution. If the bearing is excessively dirty,
soak the bearing assembly in a light solution and move the
bearing around until all lubricants and/or foreign materials are
dissolved and the parts are thoroughly clean.
When drying bearings, moisture free compressed air can be
used. Be careful not to direct the air in a direction which will
force the bearing to dry spin while not being properly lubricated.
After the bearings have been cleaned and dried, carefully
inspect all bearing rollers, cages and cups for wear, chipping or
nicks. If the bearing cannot be removed and is to be inspected in
place, check for roughness of rotation, scoring, pitting, cracked
or chipped races. If any of these defects are found replace the
whole bearing assembly. NEVER replace the bearing alone
without replacing the mating cup or the cone at the same time.
Normal Bearing
Smooth even surfaces with no discoloration or marks.
Figure 2
Bent Cage
Cage damage because of improper handling or tool usage.
Figure 3
Figure 4
Galling
Metal smears on roller ends because of overheat, lubricant
failure or overload.
Replace bearing - check seals and check for proper lubrication.
Figure 5
Figure 6
Figure 7
Misalignment
Outer race misalignment because of foreign object.
Clean related parts and replace bearing. Make sure races are
properly seated.
Figure 8
Indentations
Surface depressions on race and rollers caused by hard
particles of foreign materials.
Clean all parts and housings, check seals and replace bearings
if rough or noisy.
Figure 9
Figure 10
Brinelling
Surface indentations in raceway caused by rollers either under
impact loading or vibration while the bearing is not rotating.
Replace bearing if rough or noisy.
Figure 11
Cage Wear
Wear around outside diameter of cage and roller pockets
caused by abrasive material and inefficient lubrication.
Replace bearings - check seals.
Figure 12
Figure 13
Figure 14
Smears
Smearing of metal because of slippage caused by poor
installation, lubrication, overheating, overloads or handling
damage.
Replace bearings, clean related parts and check for proper
installation and lubrication.
Replace shaft if damaged.
Figure 15
Figure 16
Heat Discoloration
Heat discoloration can range from faint yellow to dark blue
resulting from overload or incorrect lubrication.
Excessive heat can cause softening of races or rollers.
To check for loss of temper on races or rollers, a simple file test
may be made. A file drawn over a tempered part will grab and
cut metal, whereas a file drawn over a hard part will glide readily
with no metal cutting.
Replace bearing if overheating damage is indicated. Check
seals and other related parts for damage.
Figure 17
Stain Discoloration
Discoloration can range from light brown to black caused by
incorrect lubrication or moisture.
If the stain can be removed by light polishing or if no evidence of
overheating is visible, the bearing can be reused.
Check seals and other related parts for damage.
Figure 18
Edition 1
Standard Torques
Safety Instructions .........................................3-2-5
Torque Values for Standard Metric Fasteners 3-2-6
Torque Values for Standard U.S. Fasteners .3-2-7
Type 8 Phosphate Coated Hardware ............3-2-9
Torque Values for Hose Clamps .................3-2-10
ORFS Swivel Nut Recommended Torque ...3-2-10
Torque Values for Split Flanges ..................3-2-11
Torque Wrench Extension Tools .................3-2-12
Torque Multiplication .............................................. 3-2-12
Other Uses for Torque Wrench Extension Tools.... 3-2-13
Tightening Torque Specifications (Metric) .............. 3-2-14
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
Grade
Dia. x Pitch
(mm)
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
(4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M5 x Std.
(1.08) (1.15) (1.80) (1.59) (2.24) (2.02) (3.11) (3.47) (3.61) (5.42) (6.50)
0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.90 1.25 1.50
M6 x Std.
(2.02) (2.16) (3.25) (2.89) (3.97) (3.39) (5.56) (6.14) (6.50) (9.04) (10.84)
0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35
M7 x Std.
(3.11) (3.32) (5.06) (4.55) (6.00) (5.64) (8.67) (9.40) (10.12) (14.10) (16.99)
0.70 0.75 1.10 1.00 1.40 1.25 1.90 2.10 2.20 3.10 3.80
M8 x Std.
(5.06) (5.42) (7.95) (7.23) (10.12) (9.04) (13.74) (15.18) (15.91) (22.42) (27.48)
0.73 0.80 1.20 1.00 1.50 1.35 2.10 2.30 2.40 3.35 4.10
M8 x 1
(5.28) (5.78) (8.67) (7.23) (10.84) (9.76) (15.18) (16.63) (17.35) (24.23) (29.65)
1.35 1.40 2.20 1.90 2.70 2.35 3.70 4.20 4.40 6.20 7.20
M10 x Std.
(9.76) (10.12) (15.91) (13.74) (19.52) (19.99) (26.76) (30.37) (31.18) (44.84) (52.07)
1.50 1.60 2.50 2.10 3.10 2.80 4.30 4.90 5.00 7.00 8.40
M10 x 1.25
(10.84) (11.57) (18.08) (15.18) (22.42) (20.25) (31.10) (35.44) (36.16) (50.63) (60.75)
2.40 2.50 3.70 3.30 4.70 4.20 6.30 7.20 7.50 10.50 12.50
M12 x Std.
(17.35) (18.08) (26.76) (23.86) (33.99) (30.37) (45.56) (52.07) (54.24) (75.94) (90.41)
2.55 2.70 4.00 3.50 5.00 4.50 6.80 7.70 8.00 11.20 13.40
M12 x 1.25
(18.44) (19.52) (28.93) (25.31) (36.16) (32.54) (49.18) (55.69) (57.86) (81.00) (96.92)
3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00
M14 x Std.
(26.76) (28.20) (13.23) (37.61) (54.24) (50.63) (72.33) (83.17) (86.79) (122.96) (144.66)
4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M14 x 1.5
(29.65) (31.10) (47.73) (41.22) (60.03) (54.24) (80.28) (90.41) (94.02) (11.26) (158.12)
5.60 6.00 9.00 8.00 11.50 10.50 15.50 17.90 18.50 26.00 31.00
M16 x Std.
(40.50) (43.39) (65.09) (57.86) (83.17) (75.94) (112.11) (129.47) (133.81) (188.05) (224.22)
6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 35.50
M16 x 1.5
(44.84) (47.01) (70.16) (62.20) (90.41) (81.73) (122.96) (141.04) (144.66) (202.52) (256.77)
7.80 8.30 12.50 11.00 16.00 14.50 21.00 27.50 28.50 41.00 43.00
M18 x Std.
(56.41) (60.03) (90.41) (79.56) (115.72) (104.87) (151.89) (198.90) (206.14) (296.55) (311.01)
9.10 9.50 14.40 12.50 18.50 16.70 24.50 27.50 28.50 41.00 49.00
M18 x 1.5
(65.82) (68.71) (104.15) (90.41) (133.81) (120.79) (177.20) (198.90) (206.14) (296.55) (354.41)
11.50 12.00 18.00 16.00 22.00 19.00 31.50 35.00 36.00 51.00 60.00
M20 x Std.
(83.17) (86.79) (130.19) (115.72) (159.12) (137.42) (227.83) (253.15) (260.38) (368.88) (433.98)
12.80 13.50 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00
M20 x 1.5
(92.58) (97.64) (148.27) (130.19) (180.82) (162.74) (253.15) (285.70) (296.55) (419.51) (491.84)
15.50 16.00 24.50 21.00 30.00 26.00 42.00 46.00 49.00 67.00 75.00
M22 x Std.
(112.11) (115.72) (177.20) (151.89) (216.99) (188.05) (303.78) (332.71) (354.41) (484.61) (542.47)
17.00 18.50 28.00 24.00 34.00 29.00 47.00 52.00 56.00 75.00 85.00
M22 x 1.5
(122.96) (133.81) (202.52) (173.59) (245.92) (209.75) (339.95) (44.76) (405.04) (542.47) (614.80)
20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00
M24 x Std.
(148.27) (155.50) (238.68) (195.29) (289.32) (245.92) (397.81) (419.51) (455.67) (593.10) (655.43)
23.00 35.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.00
M24 x 2.0
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)
NOTE: Torque values listed throughout this manual are lubricated (wet) threads; values must be increased
1/3 for nonlubricated (dry) threads.
Heat-treated Material Grade 5 and Grade 8
Grade 5 Grade 8
Thread Size (3 Radial Dashes on Head) (6 Radial Dashes on Head)
Foot pounds Newton Meter Foot pounds Newton Meter
(ft lb) (Nm) (ft lb) (Nm)
1/4" - 20 6 8 9 12
1/4" - 28 7 9 11 15
5/16" - 18 13 18 18 24
5/16" - 24 15 20 21 28
3/8" - 16 24 33 34 46
3/8" - 24 27 37 38 52
7/16" - 14 38 52 54 73
7/16" - 20 42 57 60 81
1/2" - 13 58 79 82 111
1/2" - 20 65 88 90 122
9/16" - 12 84 114 120 163
9/16" - 18 93 126 132 179
5/8" - 11 115 156 165 224
5/8" - 18 130 176 185 251
3/4" - 10 205 278 290 393
3/4" - 16 240 312 320 434
7/8" - 9 305 414 455 617
7/8" - 14 334 454 515 698
1" - 8 455 617 695 942
1" - 14 510 691 785 1064
1 1/8" - 7 610 827 990 1342
1 1/8" - 12 685 929 1110 1505
1 1/4" - 7 860 1166 1400 1898
1 1/4" - 12 955 1295 1550 2102
1 3/8" - 6 1130 1532 1830 2481
1 3/8" - 12 1290 1749 2085 2827
1 1/2" - 6 1400 2034 2430 3295
1 1/2" - 12 1690 2291 2730 3701
1 3/4" - 5 2370 3213 3810 5166
2" - 4 1/2 3550 4813 5760 7810
NOTE: If any bolts and nuts are found loose or at values less
than what the chart states, it is recommended that
loose bolt and/or nut be replaced with a new one.
Torque
Radiator, Air Cleaner, Boots, Etc. Hydraulic System
Clamp Type and Size
Kilogram.meter Inch Pounds Kilogram.meter Inch Pounds
(kg.m) (in lb) (kg.m) (in lb)
"T" Bolt (Any Diameter) 0.68 - 0.72 59 - 63 ------- -------
Worm Drive - Under
44 mm (1-3/4 in) Open Diam- 0.2 - 0.3 20 - 30 0.5 - 0.6 40 - 50
eter
Worm Drive - Over 44 mm
0.5 - 0.6 40 - 50 ------- -------
(1-3/4 in) Open Diameter
Worm Drive - All "Ultra-Tite" 0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50
Bolt Torque
Flange Bolt
Size (*) Size Kilogram.meter Foot-pounds
(kg.m) (ft lb)
1/2" 5/16" 2.1 - 2.5 15 - 18
3/4" 3/8" 3.0 - 3.7 22 - 27
1" 3/8" 3.7 - 4.8 27 - 35
1 - 1/4" 7/16" 4.8 - 6.2 35 - 45
1 - 1/2" 1/2" 6.4 - 8.0 46 - 58
2" 1/2" 7.6 - 9.0 55 - 65
2 - 1/2" 1/2" 10.9 - 12.6 79 - 91
3" 5/8" 19.1 - 20.7 138 - 150
3 - 1/2" 5/8" 16.2 - 18.4 117 - 133
(*) - Inside diameter of flange on end of hydraulic tube or hose
fitting.
NOTE: Values stated in chart are for Standard Pressure
Series (Code 61) Split Flanges.
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
IMPORTANT
Disassembly, overhaul and replacement of components on
the machine, installation of new or replacement parts and/
or other service-related maintenance may require the use of
thread or flange sealing assembly compound.
Use the information on this page as a general guide in
selecting specific formulas that will meet the particular
requirements of individual assembly installations. DOOSAN
does not specifically approve a specific manufacturer or
brand name, but the following table of "Loctite"
applications is included for which cross-references to other
manufacturer's products should also be widely available.
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of
fastener adhesives, with Threadlocker sealers 222, 242/243,
262, 271, 272, or 277.
Breakaway Cure
Product Application Color Removal Strength (in lb) of
Sealer Alone
Low strength for 6 mm (1/4") or
222 Purple Hand tools 45
smaller fasteners.
Medium strength for 6 mm (1/4") and
242 or 243 Blue Hand tools 80
larger fasteners.
Heat/260°C (500°F)
High strength for high-grade fasteners
262 Red Remove HOT 160
subject to shock, stress and vibration.
(NO solvent)
Extra high strength for fine thread Heat/260°C (500°F)
271 Red 160
fasteners up to 25 mm (1") diameter. Remove HOT
High temperature/high strength for
Heat/316°C (600°F)
272 hostile environments to 232°C Red 180
Remove HOT
(450°F).
Extra high strength for coarse thread
Heat/260°C (500°F)
277 fasteners 25 mm (1") diameter and Red 210
Remove HOT
larger.
V. "Loctite" Adhesives
Edition 1
Engine DX140W-5/DX160W-5
4-1-1
MEMO
Engine DX140W-5/DX160W-5
4-1-2
Table of Contents
Engine
Safety Instructions ..........................................4-1-5
Overview.........................................................4-1-6
General Information ........................................4-1-7
General Description................................................... 4-1-7
Engine Maintenance................................................ 4-1-11
Inspection and Repair of the Engine ....................... 4-1-14
Engine Identification .....................................4-1-16
Engine Data Plate ................................................... 4-1-16
Engine Specification .....................................4-1-18
Engine Performance Curves ........................4-1-19
Special Tools ................................................4-1-20
Tightening Torques.......................................4-1-24
Major Parts Tightening Torque................................ 4-1-24
Tightening Torque for General Bolts ....................... 4-1-26
Tightening Torque of Plug Screw ............................ 4-1-27
Hollow Screw (4-Hole) Tightening Torque .............. 4-1-27
Engine Disassembly .....................................4-1-28
Engine Disassembly................................................ 4-1-28
Engine Assembly ..........................................4-1-44
Engine Assembly..................................................... 4-1-44
Cylinder ........................................................4-1-67
General Information................................................. 4-1-67
Cylinder Head.......................................................... 4-1-67
Cylinder Block ......................................................... 4-1-72
Valve Mechanism .................................................... 4-1-74
Actuating System..........................................4-1-86
Camshaft ................................................................. 4-1-86
Piston ...................................................................... 4-1-88
Connecting Rod....................................................... 4-1-92
Crankshaft ............................................................... 4-1-94
Timing Gear............................................................. 4-1-99
DX140W-5/DX160W-5 Engine
4-1-3
Lubrication system......................................4-1-100
General Information............................................... 4-1-100
Oil Pan................................................................... 4-1-104
Oil Pump................................................................ 4-1-106
Oil Filter ................................................................. 4-1-108
Exhaust System..........................................4-1-111
Turbocharger......................................................... 4-1-111
EGR (Exhaust Gas Recirculation) System ............ 4-1-123
DNOx System........................................................ 4-1-130
Cooling System ..........................................4-1-141
General information............................................... 4-1-141
Thermostat ............................................................ 4-1-142
Cooling fan ............................................................ 4-1-145
Fuel System................................................4-1-147
General Information............................................... 4-1-147
Fuel High-pressure System Components ............. 4-1-148
Injector................................................................... 4-1-149
Common Rail......................................................... 4-1-153
Fuel Injection Pump............................................... 4-1-158
Electrical System ........................................4-1-161
Electrical Parts ...................................................... 4-1-161
Switches and Sensors........................................... 4-1-162
ECU (Electronic Control Unit)................................ 4-1-166
Starter.................................................................... 4-1-168
Exhaust Gas Reduction......................................... 4-1-170
Circuit Diagram...................................................... 4-1-174
ECU Circuit .................................................4-1-179
Engine DX140W-5/DX160W-5
4-1-4
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
DX140W-5/DX160W-5 Engine
4-1-5
OVERVIEW
ONT
FR
WE1401123
Figure 1
Engine DX140W-5/DX160W-5
4-1-6
GENERAL INFORMATION
General Description
This manual provides the most efficient methods for engine
maintenance as well as quick, efficient methods to determine
the cause of engine faults to ensure that any actions taken by
professionally certified maintenance technicians are done in the
most efficient and efficient way possible. If maintenance is
performed by unskilled technicians, or maintenance without the
specified tools and facilities, serious bodily injury or critical faults
in engine performance may occur. Regular inspection and
maintenance are required to maintain long-term optimal engine
conditions and best performance. In the event that a part must
be replaced, only genuine parts as defined by the parts the list
(Parts Book) should be used. Doosan shall not be held liable for
any critical damage or faults which may be caused by the use of
unauthorized or remanufactured parts. The maintenance
methods stated in this Operation and Maintenance Manual are
the most efficient and safest work procedures. Some work
procedures require special tools.
For questions about genuine parts and special tools, please
contact us.
This manual includes 'Danger', 'Warning', and 'Caution' in order
to reduce possible injuries and engine faults which may occur
while performing maintenance. If workers do not follow the
instructions, critical faults in engine performance and operation
or serious bodily injury may occurred. 'Danger', 'Warning', and
'Caution' instructions must be followed. However, we inform you
that it is not possible to describe all possible and unexpected
dangers which may arise while performing engine maintenance.
DX140W-5/DX160W-5 Engine
4-1-7
Cautions for Inspection and Repair
1. Inspection and repair of engine should be performed only
when the engine is stopped. Otherwise, burns or safety
accidents may occur, so do not perform inspection or
repair while the engine is running.
2. If it is absolutely necessary to perform inspection or repair
on the operating engine, do not get close to the rotating
parts.
DANGER
AVOID DEATH
When accessories such as necklaces, rings, watches,
or gloves become stuck in rotating parts while the
engine is running, serious bodily injury may occur.
WARNING
AVOID DEATH OR SERIOUS INJURY
Do not exchange or disassemble a pipe or horse (from
the engine fuel circuit, engine oil circuit, coolant
circuit, or compressed air circuit) while the engine is
running. The leaked liquid may cause bodily injuries.
WARNING
AVOID DEATH OR SERIOUS INJURY
If the coolant cap is opened while the engine is still hot,
hot water will spurt out and may cause burns. Open the
engine coolant cap after fully cooling the engine.
WARNING
AVOID DEATH OR SERIOUS INJURY
Only refuel when the engine is stopped.
Engine DX140W-5/DX160W-5
4-1-8
6. Mark and separately manage the containers for storing
coolant from beverage containers for avoiding confusion.
See a doctor immediately in case of drinking coolant.
7. Follow the instructions provided by the battery
manufacturer when checking or handling batteries.
WARNING
AVOID DEATH OR SERIOUS INJURY
Battery fluid is corrosive and dangerous because of its
explosiveness and toxicity. Therefore, it should only
be handled by a skilled technician who specializes in
battery fluid.
General Repair
1. Wait until the engine is properly cooled down before starting
work, since you may get burned by the heated engine.
Before performing fuel line work, check the common rail
pressure and engine temperature by using the failure
diagnosis device.
2. Disconnect the battery ground wire from to prevent
damage of wires and sensors caused by a short circuit.
3. Engine oil and coolant may damage paint and should be
stored in a separate container and marked for safe
management.
4. Store the disassembled parts in a specified space to avoid
damage or pollution.
DX140W-5/DX160W-5 Engine
4-1-9
5. Use specified and special tools for efficient and safe repair.
6. If parts need to be replaced, use only genuine parts for
replacement. Using unauthorized or remanufactured parts
may cause critical damage and faults in engine
performance.
7. Replace parts such as cotter pins, gaskets, O-rings, seal
rings, oil seals, and washers with new ones during repairs.
Reuse of parts may be the cause of engine faults and
engine may not operate properly.
8. Group and store disassembled parts in disassembling
order. The strength, shape, and screw torque of bolts and
nuts are different according to their assembly position.
Please divide and store them accordingly to these
characteristics.
9. Clean disassembled parts to remove foreign substances
before inspecting or reassembling parts. Use compressed
air to clean the oil holes or holes.
10. Thinly spread oil or grease on rotating parts or parts
requiring lubrication, before assembling them.
11. If required, use a specified adhesive to assemble gaskets
to prevent water or oil from leaking.
12. Assemble bolts and nuts with the specified tightening
torque.
13. After completing repairs, conduct a final inspection and
perform a test operation to check if all works have been
successfully completed.
Engine DX140W-5/DX160W-5
4-1-10
8. Do Not work on rotating or running parts once the engine
has been started.
9. Discard oil according to the regulations set forth by the
relevant authorities.
10. If engine oil or fuel leaks on the floor or is improperly
discharged, serious environmental pollution of sea, river or
underground water may occur.
11. Discard the undiluted anticorrosive agent, antifreeze, filter
elements, and cartridges as special wastes.
12. Discard coolant and special waste according to the
regulations of the appropriate authorities.
WARNING
AVOID DEATH OR SERIOUS INJURY
Failure to observe the regulations of the relevant
authorities violates environmental pollution
regulations and may be subject to legal penalties.
Engine Maintenance
DX140W-5/DX160W-5 Engine
4-1-11
CAUTION
AVOID INJURY
Using inappropriate or unspecified fuel may cause
critical damage and faults in engine performance.
WARNING
AVOID DEATH OR SERIOUS INJURY
If the radiator cap is opened while the engine is still
hot, hot water will spurt out and may cause burns.
CAUTION
AVOID INJURY
Immediately replenish engine oil when the engine oil
level is below the lower limit of the engine oil gauge.
CAUTION
AVOID INJURY
Always use coolant mixed with antifreeze. If coolant
without antifreeze is used, the coolant may freeze
causing the coolant passage in the cylinder block to
freeze and damaging the engine.
Engine DX140W-5/DX160W-5
4-1-12
Prevention of Pollution
Consider the following to manage engine without causing
environmental pollution.
1. Discharge oil and coolant using collection containers.
2. Discard oil and coolant according to the regulations of the
relevant authorities.
3. Be careful not to let discharged oil and cooling water flow
into the ground or the sewer. Otherwise, serious pollution
of the drinking water source may occur.
4. Classify the oil, filters, and filter cartridges as
environmental pollution wastes and discards them
according to regulations.
5. Classify the antifreeze, cooling water, and anticorrosive
agent as hazardous wastes and discards them according
to the regulations.
WARNING
AVOID DEATH OR SERIOUS INJURY
Discard oil according to the regulations set forth by
the relevant authorities. Disposing of discharged oil
into the ground, sewers, drains, rivers, or the sea will
cause serious environmental pollution. Violation of
regulations regarding discard of engine oil without
observing the handling regulations, will be punished.
DX140W-5/DX160W-5 Engine
4-1-13
Inspection and Repair of the Engine
Intake Unit
Be careful when handling the air filter in the intake unit. If oil
level of the wet air filter is below the specified level, filtering
performance is degraded. On the other hand, if the oil level is
higher, oil may flow into the case, and it may become polluted. In
regards to the dry air filter, intake resistance should be small to
ensure the smooth intake of air.
Engine DX140W-5/DX160W-5
4-1-14
Exhaust Unit
If exhaust emission is leaked from the part connecting the
exhaust tube and the turbocharger, the supercharger efficiency
is lowered, causing degraded engine output and, if serious,
burning of related parts. As parts related to exhaust and
turbocharger are used at high temperature, be careful not to mix
the bolts and nuts with other parts when performing repair.
Lubrication System
Inspection and replacement of the lubrication system should be
performed according to the replacement schedule of oil and oil
filter. Overheated engine oil can affect not only the engine itself,
but also the engine performance.
DX140W-5/DX160W-5 Engine
4-1-15
ENGINE IDENTIFICATION
EX1403503
Figure 2
2 3 4
EX1403505
Figure 3
1. Engine Numbering
This decal indicates the model name and suffixes that ÿÿÿÿ ÿ ÿÿÿÿÿÿÿÿ
contain the engine’s information. (A) (B) (C) (D)
See Figure 2 for information on each set of numbers. A. Sales Model Name (4 ~ 7 digits)
B. Production Year (1digit)
C. Serial Number (5 digits)
D. Engine Suffix(2 digits)
EX1403504
Figure 4
Engine DX140W-5/DX160W-5
4-1-16
2. Quality Inspection Sticker
This decal displays a barcode for checking the engine’s
basic information and quality data. XXXX D
A
Reference B
Description
Number C
A Model
E
B Serial No.
C Option EX1403506
D Inspector Figure 5
E Barcode
3. Emission Label
This decal shows information on the region’s emission
regulations.
• NA
Reference
Description
Number
A Engine Displacement
B Engine Family
C Emission Control Device
EX1403507
D Useful Life Figure 6 NA
E Date of Manufacture
• EU
Reference
Description
Number
A Engine Displacement
B Engine Type
C Emission Control Device
D Useful Life
E Date of Manufacture
EX1403508
Figure 7 EU
4. Engine Oil
This decal specifies oil specification applicable to the
engine.
Figure 8 EX1403509
DX140W-5/DX160W-5 Engine
4-1-17
ENGINE SPECIFICATION
Items Specification
4-Cycle Water Cooled, Waste Gate
Type Turbocharge, Air to Air Intercooled Direct
Injection
Engine Emission US EPA Tier 4 Final (EU Stage IV)
Model DL 06P
Injection System Extra High-pressure Fuel Injection System
Rated Net Power 124 HP (126 PS) @ 2,000 rpm (SAE J1995)
Intake Valve 0.3 mm
Valve Clearance
Exhaust valve 0.4 mm
Number of Cylinders and Configuration 6, Straight
Rotating Direction (from Flywheel) Counterclockwise
Max. Permitted 6 bar (6.1 kg/cm2, 87 psi)
Oil Pressure
Min. Permitted at Idling Speed 1.5 bar (1.5 kg/cm2, 21.7 psi)
Using Lubrication Oil API CJ-4 or Higher
Oil Filter Paper Filter
Interval Between Oil Changes 500 h
Working Principle 4 Stoke Engine
Cylinder Diameter 100 mm
Piston Stroke 125 mm
Displacement 5,890 cc
Compression Ratio 17.4:1
Low Idle Speed 800 rpm
Max. Full Load Speed 2,080 rpm
Weight, without Coolant and Oil 644 kg (1,419.8 lb)
Volume,
10,600 cc
Excluding Radiator
Coolant Temperature 90 ~ 95°C (194 ~ 203°F)
Cooling System
Number of Thermostats 1
Thermostat,
83°C (181°F)
Opening Temperature
Type 1-pin, 24 V, DC
Starter Motor
1-pin, 24 V, 6 kW
Electrical System (Standard Equipment)
Alternator
1-pin, 24 V, 50 A
(Standard Equipment)
Engine DX140W-5/DX160W-5
4-1-18
ENGINE PERFORMANCE CURVES
80
70
Torque (kg.m)
60
50
180 40
160
Power Output (ps)
140
120
100
160
150
Revolution (rpm)
Figure 9
WE1401435
DX140W-5/DX160W-5 Engine
4-1-19
SPECIAL TOOLS
Number Designation Picture Tool Board
EX1403581
EX1403581
EX1403582
Cylinder Liner
EF.123-365A
Disassembly Tool
EX1403583
EX1403584
Engine DX140W-5/DX160W-5
4-1-20
Number Designation Picture Tool Board
EX1403585
EX1403586
EX1403587
EX1403588
EX1403589
DX140W-5/DX160W-5 Engine
4-1-21
Number Designation Picture Tool Board
EX1403590
EX1403591
EX1403592
Crankshaft Gear
EF.121-259
Inserting Jig
EX1403593
EX1403732
Engine DX140W-5/DX160W-5
4-1-22
Number Designation Picture Tool Board
EX1403595
EX1403597
14-pin Connector
860104-01047
(for Diagnostic Device)
EX1403596
USB
860104-01048
(for Diagnostic Device)
EX1403598
DX140W-5/DX160W-5 Engine
4-1-23
TIGHTENING TORQUES
Engine DX140W-5/DX160W-5
4-1-24
Size Tightening Torques
Major Parts
(Diameter x Pitch) N.m kg.m ft lb
21.6 2.2 15.9
Coolant Temperature Sensor M12 x 1.5
(Max. 24.5) (Max. 2.5) (Max. 18.1)
Engine Mounting Bracket M10 x 1.5 60.8 + 4.9 6.2 + 0.5 44.8 + 3.6
Fuel High-pressure Pump Gear Nut
M18 x 1.5 107.9 ±4.9 11 ±0.5 79.6 ±3.6
(CP Pump)
Fuel Injector Mounting Bracket Bolt M8 30.4 3.1 22.4
Fuel High-pressure Pump Mounting Bolt
M8 43.1 + 4.9 4.4 + 0.5 31.8 + 3.6
(Cylinder Block)
Fuel High-pressure Connector Nut M22 x 1.5 49 + 4.9 5 + 0.5 36.2 + 3.6
Common Rail Mounting Bolt M8 21.6 + 4.9 2.2 + 0.5 15.9 + 3.6
Fuel High-pressure Pipe - High-pressure
M14 x 1.5 27.5 + 4.9 2.8 + 0.5 20.3 + 3.6
Fuel Connector
Fuel High-pressure Pipe - Common Rail M14 x 1.5 24.5 + 4.9 2.5 + 0.5 18.1 + 3.6
Fuel High-pressure Pipe - Fuel High-
M14 x 1.5 20.6 + 4.9 2.1 + 0.5 15.2 + 3.6
pressure Pump
Fuel Filter Mounting Bolt M10 43.1 + 4.9 4.4 + 0.5 31.8 + 3.6
DX140W-5/DX160W-5 Engine
4-1-25
Tightening Torque for General Bolts
Keep the following torque values for bolts not specified in the
Tightening Torque for Major Parts table.
Hardness
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
Dia. x Pitch (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
(mm) Elastic Limit (kg/mm2)
20 24 32 30 40 36 46 54 64 90 106
Tightening Torque (kg.m)
0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M5
(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
(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
(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
(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
(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
(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
(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 1.5
(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
(26.76) (28.20) (13.23) (37.61) (54.24) (50.63) (72.33) (83.17) (86.79) (122.96) (144.66)
4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M14 x 1.5
(29.65) (31.10) (47.73) (41.22) (60.03) (54.24) (80.28) (90.41) (94.02) (11.26) (158.12)
5.60 6.00 9.00 8.00 11.50 10.50 15.50 17.90 18.50 26.00 31.00
M16
(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
(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
(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
(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
(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 1.5
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)
NOTE: The standard torque values specified above are based on 70% of a bolt's elastic limit.
The tensile force is calculated by multiplying the tensile strength by the cross-sectional area of a
screw. A special screw should be tightened to about 85% of the standard torque. For example, a screw
coated with MoS2 should be tightened to about 60% of the standard torque.
Engine DX140W-5/DX160W-5
4-1-26
Tightening Torque of Plug Screw
M10 M12 M14 M16 M18 M22 M24 M26 M30
5.0 5.0 8.0 8.0 10.0 10.0 12.0 12.0 15.0
DX140W-5/DX160W-5 Engine
4-1-27
ENGINE DISASSEMBLY
Engine Disassembly
CAUTION
AVOID INJURY
• Prepare the necessary tools and genuine parts before
engine disassembly.
• Prepare a shelf to keep removed parts.
• Keep the working area well lighted and clean.
• Keep your hands clean at all times during service.
• Keep parts removed from the engine in the removal
order.
• Make sure that removed parts are not mixed and do
not touch each other.
DANGER
AVOID DEATH 1
• Never open the radiator cap while the engine is hot.
If opening the radiator cap while the engine is still
hot, hot coolant may spurt, resulting in a severe
burn. Open the radiator cap after confirming that
the engine is sufficiently cooled down.
FG022450
• Put a label on the coolant container not to get
mixed with other containers. If you swallow coolant, Figure 11
seek professional medical help immediately.
Engine DX140W-5/DX160W-5
4-1-28
WARNING
AVOID DEATH OR SERIOUS INJURY
Used coolant should be discarded according to the
local regulations. Never discard used engine oil to the
ground, ditch, sewer, river, sea, etc. Such action can
pollute the environment. Discarding used engine oil
improperly can result in punishment due to violation of
the corresponding regulation.
CAUTION
AVOID INJURY
When changing coolant, make sure that it is not left on
any belt or electric part.
WARNING
AVOID DEATH OR SERIOUS INJURY
Used oil should be discarded according to the local
regulations. Never discard used engine oil to the
ground, ditch, sewer, river, sea, etc. Such action can
pollute the environment. Discarding used engine oil
improperly can result in punishment due to violation of
the corresponding regulation.
DX140W-5/DX160W-5 Engine
4-1-29
4. Remove the intercooler.
A. Remove all the hoses and air pipes from the Hot Air by
Turbo Charger
intercooler.
Compressor
B. Unscrew the intercooler mounting bolts to remove the Cooled Air to
intercooler. Intake Stake
Air Flow by
Cooling Fan
EX1404312
Figure 13
Cooling Fan
EX1404080
Figure 14
EX1403626
Figure 15
EX1403627
Figure 16
Engine DX140W-5/DX160W-5
4-1-30
10. Remove the breather.
A. Unscrew the mounting clamp screw to disconnect the
rubber hose.
B. Remove the breather valve assembly.
EX1403628
Figure 17
11. Disconnect the air pipe and remove the air heater.
A. Unscrew the mounting bolt to disconnect the air pipe
and remove the air heater.
CAUTION
AVOID INJURY
Never let foreign materials enter the turbocharger.
EX1403629
Figure 18
EX1403630
Figure 19
EX1403631
Figure 20
DX140W-5/DX160W-5 Engine
4-1-31
14. Separate the intake manifold.
A. Unscrew the intake manifold mounting bolts to
remove the intake manifold from the cylinder block.
B. Remove the gasket and clean the gasket mounting
surface thoroughly with a scraper.
EX1403632
Figure 21
CAUTION
AVOID INJURY EX1403633
Figure 22
• Seal the common rail thoroughly after removing it
to prevent foreign materials from entering it.
• Once the fuel high-pressure pipe is
disconnected, it cannot be reused.
EX1403634
Figure 23
Engine DX140W-5/DX160W-5
4-1-32
17. Remove the EGR valve.
A. Unscrew the EGR valve mounting bolts to remove
the EGR valve and exhaust manifold.
B. Unscrew the mounting bolts to remove the exhaust
pipe from the EGR cooler.
C. Disconnect the coolant pipe from the EGR valve.
CAUTION EX1403635
Figure 24
AVOID INJURY
Seal the EGR valve and exhaust pipe thoroughly after
removing them to prevent foreign materials from
entering them.
EX1403636
Figure 25
CAUTION
AVOID INJURY
EX1403637
Seal the EGR cooler thoroughly after removing it to Figure 26
prevent foreign materials from entering it.
EX1404191
Figure 27
DX140W-5/DX160W-5 Engine
4-1-33
20. Remove the turbocharger.
A. Disconnect the intake stake from the turbocharger.
B. Disconnect the coolant hose from the turbocharger.
C. Disconnect the oil feed pipe and oil drain pipe
between the cylinder block and turbocharger.
D. Unscrew the turbocharger mounting bolts to separate
the turbocharger from the exhaust manifold.
EX1404192
Figure 28
CAUTION
AVOID INJURY
Do not reuse the removed gasket.
EX1403642
Figure 29
CAUTION EX1403643
Figure 30
AVOID INJURY
Make sure that the gasket residual does not enter the
coolant passage.
Engine DX140W-5/DX160W-5
4-1-34
23. Remove the coolant pump.
A. Unscrew the bracket mounting bolts for the coolant
pump and oil cooler.
B. Unscrew the bolt (1 ea) for the oil cooler.
C. Unscrew the coolant pump mounting bolts to remove
the coolant pump.
D. Remove the O-ring for the coolant pump.
EX1403644
CAUTION Figure 31
AVOID INJURY
Do not reuse the O-ring.
EX1403645
Figure 32
EX1403646
Figure 33
Oil Filter
EX1403647
Figure 34
DX140W-5/DX160W-5 Engine
4-1-35
26. Remove the vibration damper.
A. Unscrew the mounting bolts of the vibration damper
and crank pulley in the reverse order to remove the
vibration damper assembly.
EX1403648
Figure 35
EX1403649
Figure 36
EX1403650
Figure 37
EX1403651
Figure 38
Engine DX140W-5/DX160W-5
4-1-36
30. Remove the fuel injector.
Injector Type Bolts
A. Unscrew the fuel high-pressure connector mounting
Fixing Bracket
bolts to disconnect the fuel high-pressure connector.
B. Remove the harness from the injector. O-ring
Seal Ring
C. Unscrew the injector mounting bracket bolts to
remove the injector.
CAUTION EX1403652
Figure 39
AVOID INJURY
Be careful not to damage the nozzle during removing
the injector.
D. Remove the seal ring from the nozzle hole from the
cylinder head.
CAUTION
AVOID INJURY
To remove the injector, unscrew the fuel high-pressure
connector mounting nut to disconnect the fuel high-
pressure connector completely. Then, unscrew the
caliper mounting bolt to remove the injector.
DX140W-5/DX160W-5 Engine
4-1-37
CAUTION
AVOID INJURY
Be careful not to damage the mating surface.
EX1403742
Figure 41
CAUTION
AVOID INJURY
Do not reuse the valve stem seal.
E. Remove valve.
F. Unscrew the mounting bolt of the lifting hook from the
cylinder block to remove the lifting hook.
EX1403743
Figure 42
EX1403653
Figure 43
Engine DX140W-5/DX160W-5
4-1-38
34. Remove the oil pan.
A. Unscrew the oil pan mounting bolts to remove the oil
pan.
B. Remove the oil pan gasket. Oil Pan Fixing Bolt
WE1401124
Figure 44
EX1403655
Figure 45
EX1403656
Figure 46
EX1403657
Figure 47
DX140W-5/DX160W-5 Engine
4-1-39
38. Flywheel housing
A. Unscrew the flywheel housing mounting bolts to
remove the flywheel housing.
B. Remove the flywheel housing oil seal.
EX1403658
Figure 48
EX1403659
Figure 49
EX1403660
Figure 50
Engine DX140W-5/DX160W-5
4-1-40
D. Keep the removed pistons in the corresponding
cylinder order and make sure that they are not hit by
each other.
E. Install the connecting rod caps to their corresponding
connecting rods loosely. Be careful not to mix them.
42. Remove the piston.
A. Remove the snap ring of the piston pin using pliers.
EX1403662
Figure 52
EX1403663
Figure 53
EX1403664
Figure 54
DX140W-5/DX160W-5 Engine
4-1-41
43. Remove the bearing cap.
A. Unscrew the bearing cap mounting bolts in the
reverse order of their tightening to remove the
bearing cap.
NOTE: Unscrew these bolts with the same
method for the cylinder head bolts.
B. Keep the bearing caps in order.
EX1403665
Figure 55
CAUTION
AVOID INJURY
• Make sure that the main bearing and bearing
caps are not mixed.
• Fit the main bearings to their bearing caps
temporarily to prevent mixing.
EX1403667
Figure 57
Engine DX140W-5/DX160W-5
4-1-42
46. Remove the camshaft and tappet.
A. To prevent damage of the camshaft, pull it out while
turning it.
B. Store the removed camshaft on a safe special shelf
so that it is not deformed or damaged.
C. Remove the tappet.
CAUTION EX1403668
Figure 58
AVOID INJURY
Check for damage, scratch and wear. If any abnormal
condition is found, replace it.
EX1403669
Figure 59
DX140W-5/DX160W-5 Engine
4-1-43
ENGINE ASSEMBLY
Engine Assembly
CAUTION
AVOID INJURY
• Clean all the removed parts thoroughly. Especially,
clean the oil and coolant passages with compressed
air thoroughly to eliminate any restriction.
• Organize general tools and special service tools for
engine assembly.
• Prepare clean engine oil to apply onto moving parts.
• Prepare service parts, such as sealant and gasket.
• Replace any used gasket, seal ring and consumables
with new ones.
• Each bolt should to tightened to the specified torque
according to the tightening order. Never over-tighten it.
• After installing the engine components, check their
proper operation.
• After primary assembly, check if any bolt is loose.
• Keep your hands clean at all times during work.
Engine DX140W-5/DX160W-5
4-1-44
3. Install the oil spray nozzle.
A. Align the oil spray nozzle with the groove of the
cylinder block using the oil spray nozzle installing jig.
B. Install the relief valve.
C. Tighten the mounting bolt to 20.6 N.m (2.1 kg.m,
1 ft lb).
EX1403667
Figure 61
EX1403671
Figure 62
Key Groove
Oil Port and Passage
EX1403672
Figure 63
EX1403673
Figure 64
DX140W-5/DX160W-5 Engine
4-1-45
D. Fit the bolts to both sides of the crankshaft
temporarily. Then, place the crankshaft on the
cylinder block using the mounting bolts.
EX1403666
Figure 65
EX1403674
Figure 66
EX1403675
Figure 67
Engine DX140W-5/DX160W-5
4-1-46
– Step 3: Tighten it to 245.1 N.m (25 kg.m,
180.8 ft lb) with a torque wrench.
– Step 4: Tighten it to 294.1 N.m (30 kg.m,
217 ft lb) with a torque wrench for the
final time.
M. Tighten the bearing caps in the following order:
4 - 3 - 5 - 2 - 6 - 1 - 7.
N. Rotate the installed crankshaft for 2 ~ 3 turns to
check its free motion.
EX1403677
Figure 69
CAUTION
AVOID INJURY
When tightening the bolts, tighten the bolts on both
ends first and tighten the remaining bolts.
DX140W-5/DX160W-5 Engine
4-1-47
7. Install the fuel high-pressure pump.
A. Install the gear of the fuel high-pressure pump using its jig.
B. Tighten the gear nut to 107.9 N.m (11 kg.m, 79.6 ft lb).
C. Tighten the mounting bolt to 43.1 N.m (4.4 kg.m, 31.8 ft lb).
D. Install the fuel high-pressure pump to the timing gear
case on the back of the flywheel housing.
E. Tighten the flow screw to 29.4 N.m (3 kg.m, 21.7 ft lb).
F. Tighten the nipple to 43.1 N.m (4.4 kg.m, 31.8 ft lb).
EX1403634
G. Tighten the mounting bolts to the specified torque in
Figure 72
the correct order.
8. Install the gear system.
A. Install the thrust washer to the camshaft.
B. Install the cam gear, aligning it with the pin hole of the
camshaft.
C. Tighten the camshaft thrust washer to 9.8 N.m
(1 kg.m, 7.2 ft lb).
D. Tighten the camshaft gear mounting bolt to 30.4 N.m
(3.1 kg.m, 22.4 ft lb).
EX1403679
Figure 73
CAUTION
AVOID INJURY
When installing the gears, install the camshaft gear,
idle gear, fuel high-pressure pump idle gear and fuel
high-pressure pump in this order.
Crankshaft Gear -
"0" and "0"
Idle Gear (A) Fuel High Pressure
Camshaft
Camshaft Gear - Pump Idle Gear
"1" and "1" Gear
Idle Gear (B) Idle Gear (A, B)
Crankshaft Oil Pump Gear
F. Tighten the step idle gear to 60.8 N.m (6.2 kg.m, 44.8 ft lb). Gear
G. Tighten the fuel high-pressure pump idle gear to EX1403680
60.8 N.m (6.2 kg.m, 44.8 ft lb). Figure 74
Engine DX140W-5/DX160W-5
4-1-48
– End play
EX1403682
Figure 76
CAUTION
AVOID INJURY
• Make sure that the temperature of the ring gear
does not exceed 200°C. EX1403683
Figure 77
• When installing the wear ring, heat it to 150°C
with a heater, and apply loctite #262 to it, and use
an assembly jig to install it.
DX140W-5/DX160W-5 Engine
4-1-49
B. The front of the wear ring can be identified by the
mounting surface on the outer skirt.
C. Fit a guide bar into the crankshaft bolt hole.
D. Align the flywheel with the reference pin to install it
temporarily.
E. Apply adhesive (loctite #587) to the mounting bolt.
F. Fit the bolts that have no guide pin in their holes.
Then, remove the guide pin and fit the remaining bolt.
EX1403684
Figure 78
EX1403685
Figure 79
1
8 6
3 4
5 7
2
EX1403686
Figure 80
EX1403687
Figure 81
Engine DX140W-5/DX160W-5
4-1-50
B. When installing the piston and connecting rod, the
weight controlling section at the small end of the
connecting rod and the oil gallery inlet (big hole side)
of the piston should face the opposite direction.
C. Apply oil to the pin hole of the piston and align this
hole with the small end of the connecting rod. Then,
tap the piston pin with a rubber hammer gently to
install the connecting rod and piston.
EX1403663
Figure 82
CAUTION
AVOID INJURY
Direction of snap ring is assembling to be positioned
the opposite side.
EX1403688
E. Install the snap ring. Check its mounting condition. Figure 83
F. Use piston ring pliers to install the piston ring to the
piston.
2nd Ring
Oil Ring
EX1403689
Figure 84
"Y" or "TOP"
EX1403690
Figure 85
DX140W-5/DX160W-5 Engine
4-1-51
H. Adjust each piston ring connection angle to 120° and
fit a piston inserting jig into the piston.
2nd Ring Oil Ring
CAUTION
AVOID INJURY
The connection of the piston ring should not be in the Piston
same direction with the pin.
Piston
Top Ring EX1403691
Figure 86
AVOID INJURY
Make sure that the cylinder liner and piston are not
damaged.
L. Fit the bearing to the connecting rod cap and apply oil
on it. Install the Opening part of
the Retaining ring on the Opposite
M. Check that the manufacturing serial numbers Side of Upper/Lower Side
stamped on the connecting rod cap and connecting
rod big end are the same.
Engine DX140W-5/DX160W-5
4-1-52
N. Install the connecting rod cap while aligning it with the
reference pin.
O. Apply oil to the mounting bolt and install the bolt
loosely.
P. Tighten the bolts to the specified tightening torque in
the specified order using a torque wrench.
– Step 1: When tightening the connecting rod
bolt, tighten it with a hand until its head
touches the bolt seat of the connecting
rod. EX1403694
Figure 89
– Step 2: Tighten it to 39.2 ~ 58.8 N.m
(4 ~ 6 kg.m, 28.9 ~ 43.4 ft lb) with a
torque wrench.
– Step 3: Tighten it to 95.6 N.m (9.75 kg.m,
70.5 ft lb) with a torque wrench for the
final time.
Q. Shake the bearing cap with a hand. If it does not
move, loosen and tighten it again.
13. Install the oil pump and oil pipe.
A. Install the reference pin to the bearing cap No. 7.
B. Tap the oil pump with a urethane hammer gently to
install it.
C. Fit the washer and tighten the mounting bolt (M8) to
21.6 N.m (2.2 kg.m, 15.9 ft lb). Tighten the bolt (M10)
to 43.1 N.m (4.4 kg.m, 31.8 ft lb).
D. Connect the oil feed pipe to the oil pump with the bolt.
EX1403656
Figure 90
EX1403695
Figure 91
DX140W-5/DX160W-5 Engine
4-1-53
15. Install the oil pan.
A. Remove any protruded gasket on the timing gear
case, cover, cylinder block and flywheel housing
contact surface with a scraper thoroughly.
CAUTION
AVOID INJURY Oil Pan
Gasket
Make sure any gasket does not enter the engine during work. WE1401125
Figure 92
B. Apply silicon on the surfaces where the used gasket
was removed. Then, attach a new oil pan gasket.
C. Install the oil pan.
D. Tighten the bolts (4 ea) on both ends of the oil pan
first and tighten the remaining bolts.
E. Tighten the oil pan mounting bolt to 21.6 N.m
(2.2 kg.m, 15.9 ft lb).
CAUTION
AVOID INJURY
Align the bolt holes with the gasket holes before
tightening the bolts.
F. Tighten the drain plug to 98.1 N.m (10 kg.m, 72.3 ft lb).
16. Install the crankshaft pulley and vibration damper.
A. Install the vibration damper to the crankshaft pulley.
B. Tighten the bolts in the correct order.
C. Tighten the vibration damper to 60.8 N.m (6.2 kg.m,
44.8 ft lb).
D. Tighten the crankshaft pulley to 196.1 N.m (20 kg.m,
144.7 ft lb).
EX1403648
Figure 93
1
8 6
3 4
5 7
2
Engine DX140W-5/DX160W-5
4-1-54
17. Install the intake and exhaust valves.
A. Before installing the valve to the cylinder head, check
the marks "I" and "E" on the valve head surface.
Valve Marking Position
EX1403699
Figure 96
C. Align the new gasket bolt hole with the reference pin
on the cylinder block.
D. When installing the gasket, its mark on the right
should be upwards.
CAUTION
AVOID INJURY
Replace the gasket with a new one.
DX140W-5/DX160W-5 Engine
4-1-55
E. Check if there is any foreign material in the
combustion chamber. Head Bolt
F. Install the cylinder head by aligning it with the
retaining pin. Torque Wrench
CAUTION
AVOID INJURY
• Be careful not to damage the gasket. EX1403701
Figure 98
• If the pin hole cannot be aligned, lift the head and
then try to seat it again.
CAUTION
AVOID INJURY
All the bolts should be tightened according to the
above steps.
EX1403651
Figure 100
Engine DX140W-5/DX160W-5
4-1-56
20. Install the injector.
Injector Type Bolts
Fixing Bracket
CAUTION O-ring
Seal Ring
AVOID INJURY
• Clean all parts thoroughly and make sure that no
foreign material enters any part.
• Especially, the fuel line between the common rail
and injector is not equipped with a filtering EX1403652
function. Therefore, this section should be kept Figure 101
clean with care.
• Clean the drilling of the head for the fuel high-
pressure connector and the hole for the injector
thoroughly to remove any foreign materials from
them.
• If the injector is removed, the fuel high-pressure
connector should be replaced with a new one.
• If fuel collected in the fuel return line enters the
combustion chamber during injector
disassembly process, remove fuel by sucking it
out with a hand pump or by cranking the engine
with fuel flow blocked.
DX140W-5/DX160W-5 Engine
4-1-57
F. After tightening the injectors temporarily, unscrew the
bolts of the mounting brackets enough to move the Mount the High Pressure
injectors freely without load. Connector and Then
Assemble the Fixing Nut
G. Set the fuel high-pressure connector (3) with its balls
with Pre-tightening
set vertically.
3
Engine DX140W-5/DX160W-5
4-1-58
21. Install the rocker arm.
A. For rocker arm assembly, install the spring, rocker
arm, bracket, rocker arm, spring, washer and snap
ring in order.
CAUTION
AVOID INJURY
Install the rocker arm and bracket in the same EX1403707
direction. Figure 107
EX1403708
Figure 109
EX1403709
Figure 110
DX140W-5/DX160W-5 Engine
4-1-59
24. Install the oil cooler.
A. Install the oil cooler and gasket to the cylinder block.
CAUTION
AVOID INJURY
Make sure to install the gasket in the correct direction.
B. Tighten the bolt to 21.6 N.m (2.2 kg.m, 15.9 ft lb). EX1403710
Figure 111
CAUTION
Oil Filter
AVOID INJURY
The oil filter should be installed to the engine without
oil in it. Never fill the new oil filter with oil drained from EX1403647
the used oil filter. Figure 112
EX1403645
Figure 113
EX1403644
Figure 114
Engine DX140W-5/DX160W-5
4-1-60
27. Install the start motor.
A. Install the start motor to the stud bolt of the flywheel
housing.
B. Tighten the mounting nut to 78.5 N.m (8 kg.m,
57.9 ft lb).
EX1403711
Figure 115
CAUTION
AVOID INJURY
• Never reuse the fuel high-pressure pipe.
• Tighten the fuel high-pressure pipe to the
specified torque for a cylinder by cylinder.
EX1403632
Figure 117
DX140W-5/DX160W-5 Engine
4-1-61
30. Install the exhaust manifold.
A. Install the exhaust manifold gasket to the stud bolt of
the cylinder head.
B. \Align the gas outlet of the cylinder head with the Projection Face
gasket hole.
C. Install the exhaust manifold.
D. Tighten the mounting bolt to 49 N.m (5 kg.m,
36.2 ft lb).
EX1403712
Figure 118
EX1403642
Figure 119
EX1403643
Figure 121
Engine DX140W-5/DX160W-5
4-1-62
33. Install dosing module.
A. Install the dosing module to the UREA tank with the
mounting bolts.
B. Install the cover for the dosing module with the
mounting bolts.
C. Connect the dosing pipe.
EX1404191
Figure 122
CAUTION EX1403637
Figure 123
AVOID INJURY
Do not reuse the gasket.
EX1403713
Figure 124
DX140W-5/DX160W-5 Engine
4-1-63
35. Install the EGR valve.
A. Install the exhaust pipe to the EGR cooler with the
gasket and secure it with the mounting bolt.
B. Install the EGR valve to the exhaust pipe with the
gasket and secure it with the mounting bolt.
CAUTION
AVOID INJURY EX1403635
Figure 125
Do not reuse the gasket.
EX1403636
Figure 126
EX1403714
Figure 127
Engine DX140W-5/DX160W-5
4-1-64
38. Install the fuel filter.
A. Fuel needs to flow through the following components
in this order: fuel feed pump, fuel filter, fuel high-
pressure pump and common rail. Connect the fuel
feed pipe correctly according to the arrow direction
mark on the head of the fuel filter to ensure correct
fuel flow.
B. Tighten the fuel pipe to 29.4 N.m (3 kg.m, 21.7 ft lb).
C. Tighten the fuel temperature sensor to 21.6 N.m
(2.2 kg.m, 15.9 ft lb). EX1403715
Figure 129
D. Tighten the mounting bracket to 43.1 N.m (4.4 kg.m,
31.8 ft lb).
CAUTION
AVOID INJURY
A new fuel filter should be installed without fuel in it.
Never add fuel in the used fuel filter or fuel tank to a
new fuel filter.
40. Connect the air pipe and install the air heater.
A. Install the air pipe, air heater and throttle valve.
B. Tighten the mounting bolt to 21.6 N.m (2.2 kg.m,
15.9 ft lb).
CAUTION
AVOID INJURY
EX1403629
Never let foreign materials enter the turbocharger. Figure 131
DX140W-5/DX160W-5 Engine
4-1-65
41. Install the cooling fan.
A. Install the fan flange to the coolant pump pulley.
B. Install the cooling fan.
C. Tighten the cooling fan bolt to 21.6 N.m (2.2 kg.m,
15.9 ft lb).
D. Tighten the fan drive to 43.1 N.m (4.4 kg.m,
31.8 ft lb).
EX1403717
Figure 132
EX1403718
Figure 133
CAUTION
AVOID INJURY
Make sure to use the recommended genuine oil.
CAUTION
AVOID INJURY
Make sure to use the recommended coolant.
Engine DX140W-5/DX160W-5
4-1-66
CYLINDER
General Information
Doosan's diesel engine is an air-cooled electronic control diesel
engine that uses cooling fans, overhead valve, and
turbocharger.
The high-pressure fuel generated from the fuel high-pressure
pump is stored in the common rail. When a driver operates the
vehicle, fuel injection timing and optimum fuel amount are
decided based on the data set in the electronic control unit
(ECU) and the solenoid valve of the injector installed in each
engine cylinder is operated to inject fuel into the cylinder.
The cylinder block is made out of cast iron alloy and an anti-
vibration and anti-noise crank case is mounted. In addition, the
cylinder block and the timing gear case are designed as an
integral structure to reduce the engine length and improve
tightness. The cylinder head is an integral structure, too.
The forged crankshaft is an integral structure. The oil seals of
the crankshaft and the flywheel prevents oil from permeating
into the flywheel housing. The connecting rod is forged and its
big end part vertically separated. Like a piston, the connecting
rod can be disassembled through the upper side of the cylinder.
The alloy-type prefabricated bearing is used for the active part of
the crankshaft and the connecting rod.
Cylinder Head
General Description
The cylinder head is a cover mounted on top of the cylinder, and
it is bolted to the cylinder block with the head gasket in between,
forming the combustion chamber with other components,
including the pistons and cylinders. It has a oil passage for the
glow plug and lubrication and a coolant passage for reduction of
frictional heat. This cylinder head is integrated to each cylinder
and cannot be removed.
DX140W-5/DX160W-5 Engine
4-1-67
Parts List
1-6
1-7
1 : 1-1 ~ 1-8
1-8
1-4
1-5
1-1
4
1-5
2
1-5
1-2
1-3
EX1403599
Figure 134
Reference Reference
Description Description
Number Number
1 Head Assembly, Cylinder 1-7 Bush; INJ. Nozzle
1-1 Head, Cylinder 1-8 O-ring
1-2 Seat; Valve IN. 2 Pin
1-3 Seat; Valve EX. 3 Bolt; Head
1-4 Guide; Valve 4 Bolt; Stud
1-5 Core; Plug 5 Gasket; Cylinder Head
1-6 Plug; Core
Engine DX140W-5/DX160W-5
4-1-68
Disassembly
1. After disassembling the cylinder head, keep it on a shelf in
an organized way for later assembly.
2. Be careful not to damage the contact surface of the
cylinder head gasket.
3. Remove the valve cotter, spring and spring seat using a
valve spring compression tool.
4. Pull out the intake and exhaust valves.
5. Keep the removed parts in order.
6. Remove the valve stem seal. EX1403719
Figure 135
Assembly
1. Clean the cylinder head thoroughly.
2. Replace the valve stem seal with a new one.
3. Use a special service tool to install the stem seal to the
valve guide of the cylinder head.
4. Apply engine oil to the valve stem and valve guide, and
install the valve.
AVOID INJURY
Be careful not to damage the valve stem seal.
EX1403721
Figure 137
DX140W-5/DX160W-5 Engine
4-1-69
Inspection
CAUTION
AVOID INJURY
Be careful not to scratch the valve seat surface.
Bottom Distortion
C
1. Use a straightedge and feeler gauge to measure the (t) B D
distortion of the cylinder head in 6 directions. E
F
2. If any measured value is over the allowable service limit,
correct it with a fine sandpaper or grinder.
3. If it is over the allowable limit, replace the cylinder head. A
Allowable
Standard EX1403747
Limit
Figure 138
Cylinder Head
0.08 mm or
Bottom 0.15 mm
below
Flatness
Head Height: t 104.9 - 105.1 mm 104.4 mm
Flatness
1. Use a straightedge and feeler gauge to measure the
flatness of the intake/exhaust manifold mounting surface of
the cylinder head.
EX1403748
Figure 139
Engine DX140W-5/DX160W-5
4-1-70
DX140W-5/DX160W-5 Engine
4-1-71
Cylinder Block
General Description
This forms a base for the engine body, and component shapes, including the crankshaft's and head's, and bolt
holes are machined on it for their installation. It also has coolant and oil passage.
The cylinder block is cast in one piece, in compact graphite iron (CGI) and has all-in-one cylinder head. The
cylinder bores have wet liners.
Parts List
FRONT
1 : 1-1 ~ 1-11
2
1-1
3
REAR
1-7 1-8
4-1
4
4-2
1-10 REAR
1-5
1-6 CYL.6
CYL.5
CYL.4 1-8
1-9
CYL.3
CYL.2 1-11
CYL.1
FRONT
1-7
8
7
1-10
5 1-3B
6 1-3
1-3A
1-2B
1-2 NO.7
1-2A
NO.6
NO.5
1-4
NO.4
NO.3
NO.2
NO.1 EX1403600
Figure 140
Engine DX140W-5/DX160W-5
4-1-72
Reference Reference
Description Description
Number Number
1 Block Assembly, Cylinder 1-9 Plug; Core
1-1 Block, Cylinder 1-10 Plug; Core
1-2 Thrust Bearing Cap Assembly 1-11 Ball; Steel
1-2A Bearing Cap; Thrust 2 Plug Screw PT1/8
1-2B Ring; Stopper 3 Pin; Core
1-3 Bearing Cap Assembly 4 Relief Valve Assembly
1-3A Bearing Cap 4-1 O-ring
1-3B Ring; Stopper 4-2 Relief Valve
1-4 Bolt 5 Pin
1-5 Bush; Camshaft 6 Cover; Core Hole
1-6 Bush; Camshaft 7 Screw; Plug
1-7 Plug; Core 8 Seal; Ring
1-8 Plug; Core
Inspection
1. Cleanse the cylinder block and check if there is any
cracked or damaged part with naked eye.
2. Replace the cylinder block if it is seriously cracked or
damaged. Repair tiny cracks if existing.
3. Check if the oil path or coolant path is clogged or corroded.
4. Perform the hydrostatic test to check whether there is a
crank or an air leakage.
5. Block the discharging outlets of the cooling water path and
the oil path of the cylinder block and put pressure of 4 kg/cm2
(3.9 bar, 56.9 psi) on the inlet. Then sink the cylinder block in
the 70°C water for 1 minute and check if air leaks.
DX140W-5/DX160W-5 Engine
4-1-73
Valve Mechanism
General Description
The valve mechanism consists of one or two camshafts, roller
tappets, pushrods, rocker arms and valve tappets.
Straight engines have one camshaft and V engines have two
camshafts, one for each cylinder line. In both cases the
camshaft is driven by the timing gears and rotates at half the
speed of the crankshaft.
The camshaft has two cams per cylinder, one for the intake
valves and one for the outlet valves.
One end of the push rod rests on the roller tappet, and the other
end acts on the rocker arm. At one end of the rocker arm there is EX1302148
an adjusting screw. The lower ball-shaped end of the screw Figure 141
rests in the pushrod, making the tappet adjust to the camshaft
movement.
The valve seat inserts are firmly pressed to a tight fit in the
cylinder head. The material in the seat inserts is very strong, so
the valve seats have a long service life. If required the valve seat
rings can be replaced.
With four valves per cylinder the valve area is greater, which
makes it easier to fill the cylinder with air. At the same time, less
energy is consumed in forcing out the exhaust fumes.
The effort required for gas flow is reduced and engine efficiency
is improved. This in turn leads to a reduction in fuel
consumption. EX1302149
Figure 142
WARNING
AVOID DEATH OR SERIOUS INJURY
Wear protective goggles to prevent injury to eyes.
Engine DX140W-5/DX160W-5
4-1-74
Parts List
Valve
13 12
4 4
5 5
3 3
11 11
10 10
2 1
EXHAUST INTAKE
EX1403601
Figure 143
Reference Reference
Description Description
Number Number
1 Valve; Intake 10 Washer
2 Valve; Exhaust 11 Seal; Valve Stem
3 Spring; Valve 12 Caliper; Intake
4 Plate; Valve Spring 13 Caliper; Exhaust
5 Cotter; Valve
DX140W-5/DX160W-5 Engine
4-1-75
Rocker Arm
1-6
REAR
1-1
1-8
1-2
1-2
1-4 1-9
1-13
1-1 1-7
1-3
1-13
1-7
1-16 1-2
1-11
1-10
1-12
1-6 1-8
1-14
1-12
FRONT
1-9 1-15
EX1403602
Figure 144
Reference Reference
Description Description
Number Number
1 Rocker Arm Shaft Assembly 1-9 Ring; Snap
1-1 Rocker Arm; Intake 1-10 Bolt; Socket
1-2 Rocker Arm; Exhaust 1-11 Washer
1-3 Shaft; Rocker Arm 1-12 Screw; Adjust
1-4 Bracket; Rocker Arm 1-13 Nut
1-5 Bracket; Rocker Arm 1-14 Cap; Intake
1-6 Bracket; Rocker Arm 1-15 Cap; Exhaust
1-7 Spring; Compession 1-16 Bolt; Collared Hex.
1-8 Washer
Engine DX140W-5/DX160W-5
4-1-76
Valve Tappet and Push Rod
ROCKER ARM
EX1403603
Figure 145
Reference Reference
Description Description
Number Number
1 Tappet; Valve 2 Rod; Push
Valve Inspection
Wash the valve with clean engine oil and inspect it as follows:
DX140W-5/DX160W-5 Engine
4-1-77
Valve Seat Contact Surface
1. Check if the valve seat contact surface is scratched or
damaged.
2. If necessary, correct the surface with sandpaper. If
damage is severe, replace the seat.
Allowable
Standard
Limit
Intake Valve (A) 3.3 ~ 3.7 mm 2.8 mm or below A
Exhaust Valve (A) 3.3 ~ 3.7 mm 2.8 mm or below
EX1403750
Figure 147
more.
• Valve stem play
EX1403751
Allowable
Standard Figure 148
Limit
Intake Valve 0.023 ~ 0.052 mm 0.1 mm
Exhaust Valve 0.036 ~ 0.065 mm 0.15 mm
Engine DX140W-5/DX160W-5
4-1-78
– Valve step portion
Allowable
Standard Valve
Limit
Intake Valve (A) 0.35 ~ 0.65 mm 0.85 mm
Valve Seat
Exhaust Valve (A) 0.35 ~ 0.65 mm 0.85 mm
– Valve angle A
EX1403754
Figure 151
DX140W-5/DX160W-5 Engine
4-1-79
3. Check the squareness of the valve spring.
B
Reference
Description
Number
A Free Length
B Squareness
A
C Straightedge
Allowable
Specification
Limit
Valve Spring
1.4 mm or below 2.0 mm
Squareness
EX1403758
Figure 155
Engine DX140W-5/DX160W-5
4-1-80
Rocker Arm Installation
1. Install the rocker arm in the reverse order of its removal.
CAUTION
AVOID INJURY
• Check if there is any foreign material in the oil
feed hole of the rocker arm shaft. Wash it cleanly.
• Make sure to install the rocker arm in the correct
position in the correct order.
Visual Inspection
1. Visually check the surface of the adjusting screw cap
assembly which moves in contact with the valve stem.
Check if the surface is scratched or has worn layers.
2. If the wear level is small, grind the surface with an oily
whetstone or fine sandpaper. If the surface has severely
worn layers, replace the rocker arm.
Rocker Arm Bushing I.D.
1. Use a micrometer or vernier calipers to measure the inside
diameter of the rocker arm bushing.
2. Compare the measurement with the outside diameter of
the rocker arm shaft. If the clearance is over the allowable
limit, replace either the bushing or shaft which is worn
more.
DX140W-5/DX160W-5 Engine
4-1-81
Rocker Arm Shaft Inspection
Tappet Clearance
1. Measure the outside diameter of the tappet and the inside
diameter of the tappet hole of the cylinder block.
2. If the measurement is over the allowable limit, replace the
tappet.
Engine DX140W-5/DX160W-5
4-1-82
Tappet O.D.
1. Use a O.D. micrometer to measure the outside diameter of
the tappet.
2. If the measurement is over the allowable limit, replace the
tappet.
EX1403762
Figure 159
DX140W-5/DX160W-5 Engine
4-1-83
Valve Clearance
Adjust the valve clearance under the following conditions:
• When disassembling the engine or cylinder head,
• When loud noise is heard from the valve connection,
• When the fuel injection system is intact but the engine
operates abnormally.
1 2 3 4 5 6
Valve Seat
Valve Seat
Engine DX140W-5/DX160W-5
4-1-84
Method 1
1. Turn the crankshaft to set the piston of the cylinder No. 1 to
the TDC on the compression stroke.
NOTE: The cylinder No. 1 can be identified by the
cooling fan.
NOTE: When the cylinder No. 1 is at the TDC on the
compression stroke, valve overlap is occurred
at the cylinder No. 6.
2. Unscrew the rocker arm mounting nut at the cylinder No. 1.
3. Adjust the cylinder clearance with its adjusting nut. Then,
tighten the mounting nut.
Method 2
1. Turn the crankshaft to set the valves of the cylinder No. 6
overlapped.
NOTE: When the cylinder No. 1 is at the TDC on the
compression stroke, valve overlap is occurred
at the cylinder No. 6.
NOTE: The cylinder No. 1 can be identified by the
cooling fan.
2. Adjust the valve clearance marked with ' o ' in the table.
3. Rotate the engine for 1 turn (360°) in the engine rotating
direction to set the valves for the cylinder No. 1 overlapped.
NOTE: When the cylinder No. 6 is at the TDC on the
compression stroke, valve overlap is occurred
at the cylinder No. 1.
4. Adjust the valve clearance marked with ' x ' in the table.
5. Check the valve clearance again, and adjust it as
necessary.
Cylinder No. 1 2 3 4 5 6
Valve E I E I E I E I E I E I
No. 1 TDC o o o o o o
Turn 360° x x x x x x
DX140W-5/DX160W-5 Engine
4-1-85
ACTUATING SYSTEM
Camshaft
General Description
The task of the camshaft is to control the opening and closing of
the intake and exhaust valves. On engines equipped with the
injection system, the camshaft also provides the movement
required to build up pressure in the injectors.
Camshaft Design
The camshaft has two or three cams per cylinder. There is
always one for intake valves and one for exhaust valves. In
some cases, there is also one for the injectors.
A cam can be described with the following terms; see picture:
Reference
Description
Number
1 Cam Profile
2 Base Circle Diameter Figure 163
The Largest Lift of the Cam Profile,
3 Equivalent to the Maximum Movement of
the Roller Tappet.
Function
The camshaft rotates at half the speed of the crankshaft so each
group of cams can actuate the valves of their cylinder every
other engine revolution during the exhaust stroke and intake
stroke. Where applicable, the injectors are actuated in relation to
injection timing.
Valve transition occurs at the arrow. This is when the exhaust
valves are closing and the intake valves are starting to open.
The time point when both the exhaust valves and the intake
valves are open simultaneously is called valve overlap.
Figure 164
Camshaft Play
1. Move the camshaft gear to the opposite side of the cylinder
block.
2. Use a feeler gauge to measure the clearance between the
thrust plate and camshaft gear.
3. If the play is excessive, replace the thrust plate.
Engine DX140W-5/DX160W-5
4-1-86
Inspection
Allowable A
Standard
Limit C B B
Cam Lobe Intake 46.025 mm 45.73 mm
Height (C) D A EX1403767
Exhaust 47.782 mm 47.48 mm
Figure 166
Cam Journal Diameter ø55.92 ~
ø57.65 mm
(A and B) ø55.95 mm
Camshaft deflection
1. Place the camshaft on two V-blocks.
2. Use a dial gauge to check the deflection of the camshaft.
Correct it as necessary.
3. If its deflection is excessive and cannot be corrected,
replace it.
DX140W-5/DX160W-5 Engine
4-1-87
Piston
General Description
The piston moves in a reciprocating motion in the cylinder block
to receive high-pressure high-temperature gas in the
combustion stroke and produce rotating power for the crankshaft
through the connecting rod. Its head is designed to withstand hot
combustion gas and high pressure, and three to four piston rings
are fitting around its top to ensure its sealing and to prevent oil
entrance into the combustion chamber.
As it needs to move up and down in the cylinder at a high speed
repeatedly, it needs to be light and robust and have low thermal
expansion characteristic.
• The piston is an important component that receives higher
combustion pressure, So it is necessary to scrap it if the
head or pin hole part involves even a tiny scratch.
• Sometimes, the assembly can be done upside down since
the shapes of the top and bottom side are similar. So, the
assembly work requires attention.
• If the assembly is complete upside down, the piston may
run abnormally, which leads to higher consumption of oil,
increase of bypass gas, damage to the ring, and
sometimes even stand burn of the engine. Therefore, the
whole assembly process needs to take great care.
Parts List
2-1
2-2 2
2-3
Figure 169
Engine DX140W-5/DX160W-5
4-1-88
Reference Reference
Description Description
Number Number
1 Piston 2-3 Ring; Piston
2 Piston Ring Kit 5 Pin; Piston
2-1 Ring; Top 6 Ring; Lock
2-2 Ring; Second
Disassembly
Disassemble the piston according to the specified disassembly
steps.
Assembly
Assemble the piston according to the specified assembly steps.
Piston Inspection
Visual inspection
1. Visually inspect the piston for a crack, scratch and wear.
2. Especially, check if the ring groove is worn.
EX1403770
Figure 170
DX140W-5/DX160W-5 Engine
4-1-89
6. If this value is over the allowable limit, replace either the
piston or cylinder liner which is worn more.
Visual Inspection
If any worn or damaged piston ring is found during
disassembling the engine, replace it with a new one. Feeler Gauge
Allowable
Specification
Limit
Ring No. 1 0.30 ~ 0.45 mm 1.5 mm
Ring No. 2 0.60 ~ 0.80 mm 1.5 mm
Oil Ring 0.25 ~ 0.45 mm 1.5 mm
3. If the piston ring gap is over the allowable limit, replace the
piston ring with a new one.
Allowable
Standard
Limit
Ring No. 1 - -
Ring No. 2 0.05 ~ 0.09 mm 0.15 mm
Oil Ring 0.03 ~ 0.07 mm 0.15 mm
Engine DX140W-5/DX160W-5
4-1-90
Standard
Ring No. 1 1.47 ~ 2.21 kg
Ring No. 2 1.49 ~ 2.23 kg
Oil Ring 4.08 ~ 5.52 kg
EX1403773
Figure 173
EX1403774
Figure 174
IMPORTANT
If the piston needs to be replaced, replace the piston
pin as well.
EX1403775
Figure 175
DX140W-5/DX160W-5 Engine
4-1-91
Connecting Rod
General Description
The connecting rod is designed to convert the vertical
reciprocating motion of the piston into the rotating motion of the
crankshaft. As it is subject to powerful explosive force, it needs
to be rigid.
Its one end matched with the piston is called "small end" while
its the other end matched with the crankshaft is called "big end."
The big end is split in two parts which are put together with a
bolt. As the big end is connected to the rotating crankshaft, its
inner side is fitted with a replaceable metal bearing.
Parts List
2
1
1-1
3
1-3
CRANKSHAFT
Reference Reference
Description Description
Number Number
1 Connecting Rod Assembly 2 Metal; Con-rod
1-1 Rod; Connecting 3 Metal; Con-rod
1-3 Bolt; Connecting Rod
Engine DX140W-5/DX160W-5
4-1-92
Inspection
Distortion
1. Check the distortion of the connecting rod.
2. Fit the connecting rod to its measuring device and use a
feeler gauge to check its distortion. Feeler
Gauge
3. If the connecting rod is distorted, do not reuse it, but
replace it with a new one.
EX1403776
Figure 177
Hole Parallelization
1. Measure the parallelization of the small end bushing hole
and big end bearing hole of the connecting rod.
NOTE: Use the connecting rod measuring device and
feeler gauge for this measurement.
Wear
1. Install the connecting rod to the crankshaft.
2. Use a feeler gauge to measure the side clearance at the
big end of the connecting rod.
3. Install the connecting rod to the piston.
4. Measure the side clearance at the small end of the
connecting rod.
5. If the measurement is over the allowable limit, replace the
connecting rod.
DX140W-5/DX160W-5 Engine
4-1-93
Crankshaft
General Description
The crankshaft is used to convert power from the piston to
rotating torque through the connecting rod and transfer this
torque through the flywheel. Other than in the explosion stroke, it
transfers movement back to the piston, and it transfers rotating
torque to it to drive the oil pump, water pump and high-pressure
fuel pump.
Parts List
CRANKSHAFT
1
Reference Reference
Description Description
Number Number
1 Pulley; Crankshaft 3 Bolt; Socket
2 Washer; Plain
Inspection
Engine DX140W-5/DX160W-5
4-1-94
Wear Measurement
1. Use a O.D. micrometer to measure the journal and pin of
the crankshaft in the specified direction as illustrated to
check its wear amount.
2. If the wear amount is over the allowable limit, grind the
crankshaft to install an undersized bearing.
3. However, if the wear amount is within the allowable limit,
correct it with an oily whetstone or fine oily sandpaper.
NOTE: Use a sandpaper soaked in oil.
Allowable
Standard
Limit
ø79.905 ~
Journal O.D. ø78.905 mm
ø79.925 mm EX1403777
ø68.924 ~ Figure 179
Pin O.D. ø67.924 mm
ø68.944 mm
4. If the pin wear amount is over the allowable limit, grind the
crank journal and crank pin and use an undersized A
bearing.
NOTE: Use a sandpaper soaked in oil to grind the B B
crankshaft.
B B
5. There are four types of undersized bearings. The
crankshaft can be reused by grinding it according to the
undersized bearing to be used.
• Standard A
EX1403778
– 0.25 (I.D.: 0.25 mm smaller than standard) Figure 180
– 0.50 (I.D.: 0.50 mm smaller than standard)
– 0.75 (I.D.: 0.75 mm smaller than standard)
– 1.00 (I.D.: 1.00 mm smaller than standard)
6. Standard for section "R"
• Crank pin section "R": 3.5 ~ 4.0 "R"
IMPORTANT
When grinding the crankshaft, the section "R" at the
end of the bearing should be precisely ground. There Normal Abnormal Abnormal
should be no step or rough surface. EX1403779
Figure 181
DX140W-5/DX160W-5 Engine
4-1-95
Crankshaft Deflection
1. Place the crankshaft on two V-blocks.
2. Place a dial gauge on the surface plate. While turning the
crankshaft, measure the deflection of the crankshaft.
EX1403780
Figure 182
Visual Inspection
Visually check the crankshaft bearing and connecting rod
bearing for a scratch, abnormal wear or damage.
IMPORTANT 1
2
EX1403782
When tightening the connecting rod bolt, tighten it Figure 184
with a hand until its head touches the bolt seat of the
connecting rod. Then, tighten it finally with a torque
wrench.
Engine DX140W-5/DX160W-5
4-1-96
B. Compare the two values obtained from measurement
of the inside diameter of the connecting rod bearing
with the outside diameter of the crankshaft pin to
calculate the oil clearance.
EX1403784
Figure 186
OA OB
Spread = O A - O B
EX1403785
Figure 187
DX140W-5/DX160W-5 Engine
4-1-97
2. Bearing cap crush
A. Install the bearing and cap to the cylinder block.
B. Tighten the bolt to the specified tightening torque.
C. Unscrew one bolt completely and use a feeler gauge
to measure the clearance between the bearing cap
and cylinder block.
EX1403786
Figure 188
EX1403788
Figure 190
Engine DX140W-5/DX160W-5
4-1-98
Timing Gear
Overview
4-1
5
4
Function
The timing gears are located at the rear end of the engine.
Important components such as the unit injector and valve
mechanism require precise control. They are attached to the
rear end of the crankshaft, close to the flywheel, where the
crankshaft rotation is the smoothest.
The crankshaft gear drives intermediate gear. The intermediate
gear drives camshaft gear and high-pressure pump idle gear.
DX140W-5/DX160W-5 Engine
4-1-99
LUBRICATION SYSTEM
General Information
General Description
This engine is a forced lubrication type. Oil pressure is
generated and supplied by rotation of the oil pump gear which is
engaged with the crankshaft gear on the back of the cylinder
block. The oil pump receives oil from the oil pan through the
suction pipe to send it to the main passage of the cylinder block
through the oil filter and oil cooler. Then, it is distributed to the
crankshaft bearing, camshaft bearing and rocker arm for
lubrication. Also, as the turbocharger is connected to the engine
lubrication circuit, it receives oil for engine brake operation.
Lubricant is sprayed around the cylinder block and timing gear.
Each cylinder is equipped with its own oil spray nozzle to cool
down the internal section of the piston. Engine oil is filtered by
the oil filter.
Overview
Turbo Charger
Oil Cooler
Air Compressor
Oil Filter
(Bypass Valve 2.1 kg/cm2
(2.1 bar, 30.5 psi))
Camshaft Bush
Engine DX140W-5/DX160W-5
4-1-100
Purpose of Lubrication by Oil
1. Reduction of friction (Prevention of abrasion)
Lubrication maintains the least possible level of friction,
and forms a stronger oil film in a critical state to prevent the
surface friction on the perturbed section and subsequent
defacement.
2. Sealing function
Prevents the leak of gas under a high-pressure in
concurrence with the piston ring, just as in the cylinder
lubrication.
3. Cooling function
Regionally absorbs the heat from parts located on higher
spots, and discharge the heat again in a proper
temperature through the oil cooler and other units
4. Stress dispersing function
Provides momentarily and regionally a great pressure to
lubricated parts to destroy the oil film and raise adherence.
At this point, the lubricant disperses the local pressure
across the entire liquid
5. Anti-rust function
Forms a lubricant film to keep any moisture from infiltrating
into the lubricated surface to produce rust.
6. Oil purifying function
This absorbs alien materials such as carbon or metals
produced at lubricated parts and store them in the oil filter
DX140W-5/DX160W-5 Engine
4-1-101
Applicable Oil
Use only specified engine oil according to the environment and
condition of the area.
SAE 10 W-30
SAE 0 W-30
SAE 5 W-30
Ambient
Temperature
SAE 0 W-40
SAE 5 W-40
SAE 10 W-40
SAE 15 W-40
Capacity (L/U.S.gal.)
Oil Classification Oil Grade
Maximum Minimum Total
SAE 15W40 API CJ-4 or Higher 27/7 17/4.5 29/7.6
Engine DX140W-5/DX160W-5
4-1-102
Oil Lubricant Circuit
Return
Relief Valve
1 2 3 4
8 7 6 5
By Pass Valve
9
10A
10B
Figure 194
EX1403792
Reference Reference
Description Description
Number Number
1 Oil Pan 7 Oil Cooler
2 Strainer 8 Oil Filter
3 Oil Pump 9 Oil Cooler
4 Cylinder Block 10A Turbo Charger
5 Timing Gear Case 10B Cylinder Block
6 Cyliner Block
DX140W-5/DX160W-5 Engine
4-1-103
Oil Pan
Parts List
11
10
8-6
9 8-5 8-3
OIL PUMP
8 : 8-2 ~ 8-6
8-2
7
8-4
5
3
2
WE1401126
Figure 195
Reference Reference
Description Description
Number Number
1 Pan, Oil 8-2 Bracket; Oil Suct. Pipe
2 Joint; Drain 8-3 Clip; Pipe
3 Seal; Ring 8-4 Bolt M8 x 25
4 Gasket, Oil Pan 8-5 Washer
5 Bolt Assembly M8 x 45 8-6 Nut
6 Tube; Oil Level Gauge 9 Gasket
7 Gauge; Oil Level 10 Bolt Assembly M8 x 25
8 Oil Pipe Assembly 11 Bolt Assembly M8 x 40
Engine DX140W-5/DX160W-5
4-1-104
Tightening Sequence
13 9 5 1 3 7 11
17 15
21
19
22
20
16 18
12 8 4 2 6 10 14
WE1401127
Figure 196
DX140W-5/DX160W-5 Engine
4-1-105
Oil Pump
General Description
Engine oil is sucked from the oil pan by the gear type oil pump
and then all of the oil is forcibly delivered to the oil cooler and
filter for filtering. The filtered oil passes through the main oil path
of the cylinder block and lubricates bearing parts and the
turbocharger of the engine in order to maintain normal engine
performance.
Parts List
1-4
1-1
1 : 1-1 ~ 1-7
1-5
1-2
1-6
1-3
1-7
EX1403608
Figure 197
Reference Reference
Description Description
Number Number
1 Oil Pump Assembly 1-5 Pin; Dowel 6M6 x 10
1-1 Housing; Oil Pump 1-6 Cover; Oil Pump
1-2 Gear; Oil Pump 1-7 Bolt Assembly M8 x 22
1-3 Gear; Oil Pump 2 Pin; Dowel 6M6 x 12
1-4 Gear; Drive; Oil Pump 3 Bolt; Collared Hex.
Engine DX140W-5/DX160W-5
4-1-106
Disassembly
1. Remove the oil pump drive gear.
A. Loosen the screw to remove the oil relief valve.
B. Unfold the lock washer of the oil pump drive gear to
remove the mounting nut and washer.
C. Remove the drive gear.
2. Unscrew the mounting nut of the oil pump cover to remove
the oil pump cover.
NOTE: The oil pump cover is fixed to the body with 2 Cover Fixing Bolt
retaining pins. EX1403794
Figure 198
3. Remove the drive gear and driven gear.
Assembly
Assemble in the reverse order of disassembly.
Inspection
1. Use a steel ruler and feeler gauge to measure the axial
play of the oil pump gear. If the measurement is over the
allowable limit, replace it.
Steel Plate
Feeler Gauge
EX1403795
Figure 199
DX140W-5/DX160W-5 Engine
4-1-107
Oil Filter
General Description
As engine oil is sent from the oil pump to each part, it circulates in the engine for lubrication, rust prevention,
cooling, cleaning, sealing and stress dispersion. After it circulates in the engine, it may contain foreign materials.
Therefore, an oil filter is installed between the oil pan and cylinder or in the middle of the flow passage to remove
foreign materials from it.
Parts List
1-6
1-5
1-4
1 : 1-1 ~ 1-6 1-3
4
2
1-2 3 10
11
10 13
12
13 14
1-1
9
OIL COOLER
5
5 7
6 8
Reference Reference
Description Description
Number Number
1 Oil Filter Assembly 5 O-ring
1-1 Filter; Oil 6 Adapter
1-2 Head; Oil Filter 7 Adapter
1-3 Valve 8 O-ring
1-4 Spring 9 Hose; Oil Cooler
1-5 Seal; Ring 10 O-ring
1-6 Screw; Plug 11 Adapter
2 Washer; Spring 12 Adapter
3 Washer; Plain 13 O-ring
4 Bolt; Hex 14 Hose; Oil Cooler
Engine DX140W-5/DX160W-5
4-1-108
Replacing Oil Filter
1. Remove the oil filter using its service wrench.
2. Wipe the head and cartridge contact area of the oil filter
clean.
Oil Cooler
3. Seat the cartridge of the oil filter properly.
4. Apply a small amount of oil to the O-ring section of the
cartridge. Oil Filter
5. Fit a new oil filter loosely by screwing it with a hand.
6. Remove the oil filter using its service wrench.
EX1403647
Figure 202
IMPORTANT
• When replacing the cartridge of the oil filter,
make sure to use the specified genuine one.
• The oil filter should be installed to the engine
without oil in it. Never fill the new oil filter with oil
drained from the used oil filter.
DX140W-5/DX160W-5 Engine
4-1-109
Troubleshooting
Engine DX140W-5/DX160W-5
4-1-110
EXHAUST SYSTEM
Turbocharger
General Description
The turbocharger uses heat energy of exhaust gas in the engine
to draw in high density air into the cylinders to increase the
engine power.
Power of the engine is determined by the amount of fuel supply
and the engine's efficiency.
A sufficient amount of air should be supplied to the cylinders to
burn fuel completely and convert this energy to effective work.
Power of the engine is actually determined by the size of the
cylinders. The larger the cylinders are, the more the air is
delivered to burn more fuel, resulting in increase of engine
power.
Supercharging is a process to compress and supply air into the
engine's cylinders. The turbocharger is a device to supply extra
air for combustion with energy of exhaust gas in the combustion
chamber which is usually released and disappeared into the air.
Turbine Housing
Exhaust Gas Discharge
Exhaust Pipe
Fresh Air Inlet
Compressor Wheel
Oil Outlet
Intake Manifold
EX1403797
Figure 203
DX140W-5/DX160W-5 Engine
4-1-111
Function
1. Turbine:
As exhaust gas discharged from the combustion chamber
passes through the turbine housing, its energy is
transferred to the turbine blades to deliver the rotating
force to the turbine shaft. These series of motions are
occurred in a component called turbine. The turbine is
equipped with the seal ring and heat shield to prevent
exhaust gas from affecting its bearing.
2. Compressor:
As it is connected to the same shaft with the turbine, it
rotates together to receive rotating force from the turbine
shaft in order to receive, compress and send air to the
intake manifold. This is the basic principle of a compressor.
3. Bearings:
Thrust bearing: The turbine wheel is applied with axial
force. This axial force keeps the shaft from moving.
Journal bearing:
This bearing is a floating type and has double oil film on its
inside and outside so that it can rotate independently. As
its double oil film acts as a cushion, the sliding speed on
the bearing surface becomes lower than the rotating speed
of the shaft, ensuring dynamic stability.
4. Seal ring of compressor shaft:
The shaft is equipped with the seal plate and seal ring in a
dual structure to prevent leakage of compressed intake air
and lubricant.
Engine DX140W-5/DX160W-5
4-1-112
Parts List
EXHAUST MANIFOLD
A 5
2
6
15
11
A 7
10
9
10 13
12
8
14
13
CYLINDER BLOCK
EX1403610
Figure 204
Reference Reference
Description Description
Number Number
1 Charger Assembly, Turbo 9 Hose; Rubber
2 Gasket 10 Clamp
3 Nut 11 Gasket; Flange
4 Pipe; Oil Delivery 12 Gasket; Pipe-block
5 Ring; Seal 13 Bolt Assembly M8 x 22
6 Hollow Screw M12 x 1.5 14 Bolt Assembly M8 x 25
7 Pipe; Oil Return 15 Gasket; Exhaust Pipe
8 Pipe; Oil Return
DX140W-5/DX160W-5 Engine
4-1-113
Structure
1 2
3 D
A B
4
E
C
EX1403798
Figure 205
Reference Reference
Description Description
Number Number
1 Impeller Casing A Intake Air Inlet
2 Turbine Casing B Gas Outlet
3 Bearing Casing C Gas Inlet
4 Impeller D Oil Supply
5 Turbine E Oil Discharge
Engine DX140W-5/DX160W-5
4-1-114
Troubleshooting
DX140W-5/DX160W-5 Engine
4-1-115
Phenomenon Causes Troubleshooting
Leakage of gas from each part of the exhaust
Check or repair it
system
Clogged air filter element Replace or clean it
Contaminated or damaged turbocharger Repair or replace it
Leakage of air from the discharging part of
Check or repair it
the compressor shaft
Deformed or damaged intake unit hose Replace it
Poor clamping state Adjust and tighten the clamp
Replace and check if the impeller of the
Contaminated or damaged air filter
turbocharger is damaged
Poor turbo actuator operation Replace the turbocharger
Lowered Output
Leakage from the engine block and the
Check the engine
exhaust manifold
Contaminated blowby gas and abnormal oil Check the turbo impeller and the turbo intake
amount outlet
Large gap of the turbocharger wheel, causing Check if there is any sand or metallic foreign
interference with the wall substance
Check if there is any sand or metallic foreign
Damaged turbocharger wheel
substance
Damaged wheel and shaft of the Check if there is any sand or metallic foreign
turbocharger substance
Check if there is any sand or metallic foreign
Poor rotating force of the turbocharger wheel
substance
Deformed or damaged intake unit hose Replace it
Poor clamping state Adjust and tighten the clamp
Replace and check if the impeller of the
Contaminated or damaged air filter
Oil Leakage turbocharger is damaged
Leakage of coolant from the turbocharger or
Replace the hose and the gasket
oil from the oil hose
Poor turbo actuator operation Replace the turbocharger
Leakage from the engine block and the
Check the engine
exhaust manifold
Contaminated blowby gas and abnormal oil Check the turbo impeller and the turbo intake
amount outlet
Large gap of the turbocharger wheel, causing Check if there is any sand or metallic foreign
interference with the wall substance
Oil Leakage
Check if there is any sand or metallic foreign
Damaged turbocharger wheel
substance
Damaged wheel and shaft of the Check if there is any sand or metallic foreign
turbocharger substance
Check if there is any sand or metallic foreign
Poor rotating force of the turbocharger wheel
substance
Engine DX140W-5/DX160W-5
4-1-116
Phenomenon Causes Troubleshooting
Poor clamping state Adjust and tighten the clamp
Leakage of coolant from the turbocharger or
Replace the hose and the gasket
oil from the oil hose
Leakage from the engine block and the
Check the engine
exhaust manifold
Contaminated blowby gas and abnormal oil Check the turbo impeller and the turbo intake
amount outlet
Oil Consumption Large gap of the turbocharger wheel, causing Check if there is any sand or metallic foreign
interference with the wall substance
Check if there is any sand or metallic foreign
Damaged turbocharger wheel
substance
Damaged wheel and shaft of the Check if there is any sand or metallic foreign
turbocharger substance
Check if there is any sand or metallic foreign
Poor rotating force of the turbocharger wheel
substance
Deformed or damaged intake unit hose Replace it
Replace and check if the impeller of the
Contaminated or damaged air filter
turbocharger is damaged
Leakage of coolant from the turbocharger or
Replace the hose and the gasket
oil from the oil hose
Poor turbo actuator operation Replace the turbocharger
Contaminated blowby gas and abnormal oil Check the turbo impeller and the turbo intake
Black and White amount outlet
Emissions
Large gap of the turbocharger wheel, causing Check if there is any sand or metallic foreign
interference with the wall substance
Check if there is any sand or metallic foreign
Damaged turbocharger wheel
substance
Damaged wheel and shaft of the Check if there is any sand or metallic foreign
turbocharger substance
Check if there is any sand or metallic foreign
Poor rotating force of the turbocharger wheel
substance
Leakage from the engine block and the
Blue Emissions Check the engine
exhaust manifold
Oil leakage to the turbine or compressor Repair or replace it
Too much Fog Worn or damaged seal ring due to worn
Repair or replace it
bearing
Clogged air filter element Replace or clean it
Clogged air duct Check or repair it
Air leakage from the intake system Check or repair it
Too much
Exhaust The turbocharger cannot rotate because of
Repair or replace it
Emissions burning
A turbine blade or compression wing contacts
Repair or replace it
with the other one or is damaged
Deformed or clogged exhaust system pipe Check or repair it
DX140W-5/DX160W-5 Engine
4-1-117
How to Maintain Turbocharger
Engine DX140W-5/DX160W-5
4-1-118
Cautions for Maintenance
1. When the rpm is rapidly increased after starting the engine,
the journal bearings in the crankshaft is excessively
rotated, the crankshaft is rotated at excessive speed
before the journal bearing of the crankshaft is lubricated
fully. If the turbocharger rotates in this situation, bearings
are not smoothly cooled and lubricated, causing bearing
burn and damage of the related parts.
2. Please operate the engine for two minutes or more in order
to lubricate the turbocharger fully after replacing the engine
oil or oil filter.
3. If an engine has been operated at high speed for a long
period, fully operate the engine at idle and then stop the
engine. Otherwise, the turbine wheel continuously runs
without oil pressure in the turbocharger. Therefore, no oil
film is created on the center bearings and the journal
bearings of the turbocharger, causing bearing, wearing out
and shortening of the turbocharger lifetime.
4. If an engine is not operated for a long period during cold
weather or in areas with cold climate, operate the engine at
idle after starting the engine until the engine oil pressure is
normal.
5. The turbocharger turbine spins at high speed of 50,000 ~
200,000 rpm. Therefore, lubrication of bearings may
determine the turbocharger lifetime. Please use only
recommended genuine engine oil and check and replace
the engine oil periodically.
6. Prolonged usage of contaminated air cleaner may cause a
critical damage of the turbocharger. Regularly check and
replace the air cleaner.
7. A turbocharger is a very complex and precise part. Only
certified and skilled technicians should work on it.
8. If a turbocharger is operated without intake and exhaust
pipe, serious human injury may occur and critical faults of
the engine performance may occur. Please operate a
turbocharger only when all of parts are exactly mounted on
the specified position.
9. Do not lift up a turbocharger by grabbing the actuator. The
actuator may be damaged because of the weight of the
turbocharger.
10. The weight of a turbocharger is about 4.0 kg or more. To lift
up a turbocharger for installing or removing it, the worker
should lower the center of gravity or press his body close
to the turbocharger. Otherwise, worker may drop the
turbocharger, causing damage of the part and injury.
DX140W-5/DX160W-5 Engine
4-1-119
Inspection Items during Disassembly/Assembly of Turbocharger
Possible Problem
Consumption
Blue Smoke
Power Drop
Oil Leakage
White/black
No. Inspection Items Action
Smoke
Noise
Oil
Before Removal
1 Is the intake hose torn or deformed? ○ ○ ○ ○ Replace hose
2 Is the clamp tightened firmly? ○ ○ ○ ○ Tighten bolt/nut correctly
Replace air filter and check
3 Is the air filter intact? ○ ○ ○ ○ turbocharger impeller for
damage
4 Does turbocharger or oil hose leak? ○ ○ ○ ○ Replace hose and gasket
5 Is gas leaked from exhaust manifold gasket? ○ Replace nut and gasket
Replace solenoid and EGR
6 Do solenoid valve and EGR system intact? ○ ○ ○ valve
Does the turbocharger actuator operate
7
correctly? ○ ○ ○ ○ Replace turbocharger
During Removal
Is there a sign of leak between the engine block
1
and exhaust manifold? ○ ○ ○ ○ ○ Check engine
Inspection
Engine DX140W-5/DX160W-5
4-1-120
dry air filter should feature low possible intake air
restriction.
2. Exhaust system
If exhaust gas is leaked from the exhaust pipe or
turbocharger connection in the exhaust system, the
turbocharger's performance is deteriorated. Extra care is
needed to prevent a gas leak and seizure. A heat resisting
steel nut is used for parts, which can become hot during
driving, such as the turbine housing. Make sure not to mix
it with a general nut, and apply screw's anti-seize
compound to the specified mounting nut.
3. Lubrication system
In the lubrication system, the oil quality and the cartridge
replacement interval of the oil filter should be monitored
with care. Degraded engine oil can affect not only the
engine body, but also the turbocharger negatively.
C Turbine Compartment A
Move the Turbine Shaft in the Axial
D
Direction.
E Service Standard (0.038 ~ 0.093 mm) E (F)
EX1403799
F Wear Limit (0.24 mm) Figure 206
DX140W-5/DX160W-5 Engine
4-1-121
• Circumferential play of rotating part
B
Reference C
Description
Number A
A Oil Outlet
B Dial Gauge
C Magnet Vice D
Move the Turbine Shaft to the Left and
D F (G)
Right in the Circumferential Direction.
E
Standard Circumferential Play
E EX1403800
(0.326 ~ 0.496 mm) Figure 207
F Standard Wear (0.50 mm)
Engine DX140W-5/DX160W-5
4-1-122
EGR (Exhaust Gas Recirculation) System
General Description
The EGR (Exhaust Gas Recirculation) system recirculates a
portion of exhaust gas back to the intake system to cool it down
and supply it to the engine for re-combustion in order to reduce
NOx emission.
To reduce NOx and other emissions from the engine, it
circulates exhaust gas containing almost no oxygen toward the
intake system to decrease the density of oxygen supplied to the
engine and induce combustion at a low temperature. As a result,
a reduced amount of NOx is produced.
This system is equipped with the EGR cooler to reduce the
temperature of hot exhaust gas in order to reduce the amount of
NOx and enhance engine combustion efficiency.
1 3
EX1403801
Figure 208
Reference Reference
Description Description
Number Number
1 EGR Cooler 3 EGR Valve
2 Exhaust Pipe 4 Exhaust Manifold
DX140W-5/DX160W-5 Engine
4-1-123
Function
The EGR system is active between approximately 900 rpm and
the maximum engine speed with a positive torque and when the
coolant temperature exceeds approximately 50°C.
The principle of the EGR system is that some of the exhaust
gases are returned to the engine. The quantity of oxygen is
reduced by mixing the intake air with exhaust gases resulting in
a lower combustion temperature. In this way, the quantity of
nitrogen oxides.
NOx, in the exhaust gases is reduced.
The reduced nitrogen oxide emissions make it possible to meet Figure 209
emissions regulations and to optimize engine power and fuel
consumption.
Engine DX140W-5/DX160W-5
4-1-124
Cold Engine
The EGR valve is closed until engine has been warmed up. No
exhaust gases are then circulated.
Warm Engine
Once the engine has been warmed up, the EGR valve is open
and exhaust gases then circulate in the EGR system. Where the
throttle is rapidly opened, the engine control unit reduces the EGR
content. This is intended to compensate for the shortage of
induction air that occurs before the turbocharger begins to charge.
Shut-off Conditions
• The control unit shuts down the EGR system if:
• The charge air temperature falls below a specific value.
There is then a risk of freezing in the intake manifold.
• The engine is at such a high altitude that air pressure
affects its performance.
• Coolant temperature is too high. At very high coolant
temperature, the control unit closes the EGR valve to avoid
loading the engine with additional heat from the EGR
cooler.
• The white smoke limiter is active.
• There is a risk of the EGR system freezing if the ambient
temperature is very low.
DX140W-5/DX160W-5 Engine
4-1-125
Parts List
INTAKE STAKE
18
19
17
35
2
38
39
3 5 37
2
6 36
4
1
14
A
16 39
15
B
16 34
C 31
D 28
8
23 34
7
11 A
10 20
11 26 33
32
9 41
30 29
12
B
13
C 33
32
COOLING WATER PIPE
CONNECTION
D
40 42
EXHAUST MANIFOLD 30 29
25
24
25
22
WATER 21
PUMP 27
EX1403726
Figure 210
Engine DX140W-5/DX160W-5
4-1-126
Reference Reference
Description Description
Number Number
1 Cooler; EGR 22 Bolt Assembly M8 x 25
2 Gasket; EGR Cooler 23 Bolt Assembly M8 x 25
3 Adapter; Connector 24 Hose; Cooling Water
4 Seal; Ring 25 Clamp; Hose
5 Screw; Plug M10 x 1.5 26 Pipe Assembly; Cooling Water
6 Ring; Seal 27 Gasket; Water Pipe
7 Pipe Assembly; Cooling Water 28 Bolt Assembly M8 x 25
8 Gasket; Water Pipe 29 Adapter
9 Bolt Assembly M8 x 25 30 Ring; Seal
10 Hose; Rubber 31 Valve; EGR
11 Clamp; Hose 32 Adapter
12 Bracket 33 Ring; Seal
13 Bolt; Collared Hex. 34 Gasket; EGR Valve
14 Bolt Assembly M10 x 140 35 Exhaust Pipe Assembly
15 Hose; Rubber 36 Bolt; Stud
16 Clamp; Hose 37 Nut
17 Pipe Assembly; Exhaust 38 Pipe; Exhaust
18 Gasket; Manifold 39 Bolt; Hex.
19 Bolt Assembly M8 x 30 40 Pipe Assembly; Cooling Water
20 Gasket; Water Pipe 41 Pipe Assembly; Cooling Water
21 Pipe Assembly; Cooling Water 42 Bolt Assembly M8 x 18
Disassembly
1. Remove the EGR valve and disconnect the elbow pipe.
NOTE: Perform the process with the heat shield and
bellows pipe removed.
CAUTION
AVOID INJURY
As the EGR system is hot by exhaust gas, it should be
disassembled after it is sufficiently cooled down.
DX140W-5/DX160W-5 Engine
4-1-127
Assembly
Assemble in the reverse order of disassembly.
CAUTION
AVOID INJURY
Any used gasket should be replaced with a new one.
Disassembly
As the EGR system becomes hot by exhaust gas while the
engine is running, it should be disassembled after it is
sufficiently cooled down.
1. Disconnect the coolant inlet/outlet pipes and hoses.
2. Remove the gas pipe outlet and hose.
3. Remove the heat shield.
4. Disconnect the bellows pipe.
5. Remove the EGR cooler mounting bolts.
6. Remove the EGR cooler from the EGR bracket.
Assembly
Assemble in the reverse order of disassembly.
CAUTION
AVOID INJURY
Any used gasket should be replaced with a new one.
Engine DX140W-5/DX160W-5
4-1-128
Checking EGR System
Leak test and functional inspection of the EGR system
components
It is normal to find a certain amount of soot coating in engines
with EGR systems.
Component How
Search for heavy soot accumulation. Check that EGR valve is
EGR Valve properly closed. Check that EGR valve springs back to the closed
position.
The Pipe between the EGR Valve and
Check that there is no abnormally large leakage.
the EGR Cooler
The Pipe between the Cooler and the
Check that there is no abnormally large leakage.
Inlet Pipe
EGR Cooler Searching for leakage in the EGR cooler.
The Hoses to and from the Air-cooled
Check that there is no abnormally large leakage.
EGR Cooler
Check using checking tool that EGR valve control cylinder is working
Control Cylinder to EGR Valve
properly.
DX140W-5/DX160W-5 Engine
4-1-129
DNOx System
General Description
The Doosan engine is equipped with the DOC (Diesel Oxidation
Catalyst) and SCR (Selective Catalytic Reduction) systems in
order to comply with Tier 4 final (and stage IV) emission control.
This SCR system consists of the dosing module, supply module,
ECU (Engine Control Unit) and other components. The DEF
(Diesel Exhaust Fluid) is stored in the DEF tank. Once it is
needed, it is pressurized by the supply module and is delivered
to the dosing module under a certain level of pressure. The
dosing module is attached to the exhaust manifold to spray DEF
into the exhaust manifold in front of the SCR system.
EX1403802
Figure 211
Engine DX140W-5/DX160W-5
4-1-130
Aftertreatment Muffler and Catalyst
The aftertreatment muffler consists of the DOC muffler, SCR
muffler, mixer pipe and other pipes. The DOC muffler contains 3
DOC (Diesel Oxidation Catalyst) while the SCR muffler contains
SCR (Selective Catalytic Reduction).
Reference
Description
Number
1 DOC Converter
2 Mixer
2
3 SCR Muffler
1 EX1403803
Figure 212
DNOx2.2 System
The DNOx2.2 system is used to reduce NOx in emissions by
spraying urea into the SCR catalyst. It consists of the SM
(Supply Module), which functions as a pump, DM (Dosing
Module) to spray urea, DCU to control the overall system, urea
tank to store urea and urea/cooling water line.
Coolant Out
Coolant In
Coolant In
Urea
Back Line
Urea Tank
Coolant Out
Coolant Heat
SM
(Supply Module)
Electrical Heat
EX1403804
Figure 213
DX140W-5/DX160W-5 Engine
4-1-131
Urea Tank
The urea tank is used to store urea liquid. Connect lines to the
specified positions. Also, be careful not to apply impact to the
urea tank during its service.
3
12
13 6
1
7
14
11 8
2
9
5 10
4
15
EX1403805
Figure 214
Reference Reference
Description Description
Number Number
1 +24 V (Pin No. 1) 9 Coolant Inlet
2 Ground (Pin No. 2) 10 Level Indicator
3 CAN High (Pin No. 3) 11 Urea Tank Cap
4 CAN Low (Pin No. 4) 12 Inlet
5 Coolant Inlet 13 Backflow
6 Coolant Outlet 14 Outlet
7 Urea Outlet 15 Drain Plug
8 Urea Inlet
Engine DX140W-5/DX160W-5
4-1-132
Urea Filter Replacement
IMPORTANT
The replacement interval of the DEF (urea solution) filter is
different by the amount of foreign materials in DEF.
Make sure to use only the specified DEF and container and
keep the surrounding area of the tank clean to prevent
possible foreign materials.
Figure 215
Figure 216
Figure 217
DX140W-5/DX160W-5 Engine
4-1-133
4. Set the color of the mark on the end of the filter removing
tool in the same direction with the filter color section.
Figure 218
Figure 219
Figure 220
Figure 221
Engine DX140W-5/DX160W-5
4-1-134
8. Apply oil to the O-ring and install a new filter.
CAUTION
AVOID INJURY
Use Mobil Velocite No. 6 oil from Bosch.
Figure 222
Figure 223
CAUTION
AVOID INJURY
Check that filter surface is clean. It can be cleaned with
water only.
Figure 224
DX140W-5/DX160W-5 Engine
4-1-135
Supply Module
The supply module is used to pressurize DEF in the DEF tank to
a certain level and supply this pressurized DEF to the dosing
module.
Pin 8 Pin 2
7 Pin 12 Pin 6
2
6
3
5
4
EX1403806
Figure 225
Reference Reference
Description Description
Number Number
1 Connector 5 Cover Plate
2 Adblue Inlet 6 Detail Marking
3 Adblue Backflow Outlet 7 Filter Cover
4 Adblue Outlet
Engine DX140W-5/DX160W-5
4-1-136
Dosing Module
The dosing module is attached to the exhaust manifold in front
of the SCR system to receive DEF from the supply module and
spray it into the exhaust manifold.
1 2
7 4
EX1403807
Figure 226
Reference Reference
Description Description
Number Number
1 Coolant Outlet 5 Cooling Adapter
2 Coolant Inlet 6 Dosing Valve
3 Head Shield 7 Adblue Inlet
4 Protective Cap
DX140W-5/DX160W-5 Engine
4-1-137
Checking DNOx2.2 System
Dosing Module
Dosing Moduel fault is cause of the high temperature exposure
of nozzle tip injecting urea, electric harness contact failure, urea
hose line break or poor contacet, and more. Visual inspection of
dosing module failure are as follows.
1. When replacing dosing module, dosing module and bolts is
the leakage or damage caused by under tightening bolts or 1 2
over tightening.
3
2. Electric connector misassembly or debris contamination
inside of connector.
5
3. Urea leakage is caused by urea line misassembly.
4
4. Coolant leakage is caused by coolant line misassembly.
The high temperature exposure of dosing module is
caused by disconnected.
EX1403808
5. The high temperature exposure of dosing module is Figure 227
caused by gasket misassembly.
6. Urea leakage is caused by gasket reuse.
Supply Module
The supply module (SM) failure mode is associated with urea
line and electric connector damage and poor connection. When
replacing urea main filter regularly, supply module failure can
occur caused by disassembly.
CAUTION
AVOID INJURY
When replacing new filter, open the package on the verge of
replacement.
Engine DX140W-5/DX160W-5
4-1-138
Urea Tank
Urea Tank is keeping the urea solution. Assembly connected
line to correct location. When maintenance of urea tank, be
careful not to external impacts.
3
12
13 6
1
7
14
11 8
2
9
5 10
4
15
EX1403805
Figure 229
CAUTION
AVOID INJURY
Urea inlet hose is marked red color, backflow hose is
marked yellow color.
DX140W-5/DX160W-5 Engine
4-1-139
5. Make sure that the connection condition of urea line heater
(2-pin). Not running a heater in winter season there is a
danger of frost.
Engine DX140W-5/DX160W-5
4-1-140
COOLING SYSTEM
General information
General Description
This engine is a water-cooled type. Combustion heat from the
combustion chamber and heat from engine oil are absorbed by
coolant and dissipating them to the outside air to ensure
optimum engine operation.
In the cooling system, coolant supplied from the coolant pump is
sent to the oil cooler through the coolant pipe to absorb heat
from oil before it passes through the coolant jacket of the
cylinder block and through the cooling passage of the cylinder
head to absorb combustion heat.
After this coolant absorbs oil heat and combustion heat, it is led
to the thermostat through the coolant pipe. If the coolant
temperature is below the valve opening temperature of the
thermostat, the coolant flows into the coolant pump. If the
temperature is over the opening temperature, it flows into the
radiator. In the radiator, it releases heat and returns back to the
coolant pump in a low temperature condition again.
EGR
Cylinder Block EGR Valve
Cooler
HC Dosing
Water Pump Oil Cooler Injector
EX1403810
Figure 230
DX140W-5/DX160W-5 Engine
4-1-141
Thermostat
General Description
The thermostat maintains water temperature in the engine
consistently and prevents heat loss to improve heat efficiency of
the engine.
When the coolant temperature is below the normal temperature,
the thermostat is closed and the coolant is bypassed and directly
flows into the water pump. When the coolant temperature
reaches the normal temperature or is higher than the
temperature, the thermostat is fully open and the bypass circuit
is closed. So the coolant flows into the radiator.
CAUTION
AVOID INJURY
• The wax pellet type thermostat shows slower
response to the change of cooling water than the
bellows type thermostat. This happens because the
heat capacity of the wax pellet type thermostat is
larger than that of the bellows type thermostat.
Therefore, to prevent a rapid increase in the engine
coolant's temperature, you must first operate the
engine at idle until the engine is fully warmed up.
When the weather is very cold, do not operate the
engine in an overloaded condition or at a high speed
after starting the engine.
• When draining water from the engine cooler or
injecting water to the engine cooler, work slowly to
ensure that all air inside the cooler is expelled.
• When a defect is found in the thermostat, replace it
with a new one.
Reference
Description 1
Number
1 Heat Exchanger
2 Bypass Valve
3 Water Pump
4 Coolant Pipe
4 2
3
EX1403811
Figure 231
Engine DX140W-5/DX160W-5
4-1-142
Parts List
1 : 1-1 ~ 1-4
13
10
11
1-1
12
1-3
5
4 6
1-2
8
1-4 7
3
9
EX1403727
Figure 232
Reference Reference
Description Description
Number Number
1 Thermostat Assembly 6 Gasket
1-1 Housing; Thermostat 7 Connection
1-2 Thermostat 8 Bolt Assembly M8 x 60
1-3 O-ring 9 Bolt Assembly M8 x 45
1-4 Bolt; Hex 10 Outlet; Water
2 Gasket; Thermostat 11 Gasket; Water Pump
3 Bolt; Hex 12 Bolt Assembly M8 x 30
4 Washer; Spring 13 Connection; Screw
5 Washer; Plain
DX140W-5/DX160W-5 Engine
4-1-143
Cautions for Replacement and Handling of Thermostat
1. Cautions for handling
A wax pellet type thermostat features relatively slow
response for change in coolant temperature compared to a
bellows type. This is because the wax pellet type has
larger thermal capacity. Therefore, it needs to idle the
engine sufficiently before running it in order to prevent
surge of engine coolant temperature. In cold weather,
never overload the engine or speed drive.
2. When adding or draining coolant to/from the engine cooling
system, do it slowly to let air in the system escape.
3. Thermostat replacement
If any defect is found on the thermostat, replace it with a
new one.
Thermostat inspection
1. Check if the wax pellet and spring are damaged.
2. Put the thermostat into water and heat the water gradually
to check for operation of the thermostat. Ruler Thermometer
Engine DX140W-5/DX160W-5
4-1-144
Cooling fan
General Description
The speed of the cooling fan is controlled by the electronic fan
clutch in order to maintain its optimum speed. The electronic fan
clutch adjusts the cooling fan speed electrically according to the
coolant temperature, hydraulic oil temperature, CAC (Charge Air
Cooler) temperature and engine speed to reduce cooling fan
noise and obtain superior efficiency.
Specification
Parts List
10
2 7
4
3
5
Figure 234 1 EX1403728
Reference Reference
Description Description
Number Number
1 Fan Clutch Assembly 7 Pulley; Fan
2 Fan; Cooling 8 Fan Drive Assembly
3 Bolt Assembly M8 x 18 9 Bolt Assembly M10 x 40
4 Flange; Fan 10 V Belt
5 Bolt Assembly
DX140W-5/DX160W-5 Engine
4-1-145
Troubleshooting
Engine DX140W-5/DX160W-5
4-1-146
FUEL SYSTEM
General Information
This diesel engine compresses air delivered into its cylinders
and sprays fuel with its injection nozzles to burn fuel with
compression heat.
When the high-pressure pump produces high-pressure fuel, this
fuel is kept by the common rail and its injection timing and
injection amount are calculated by the ECU (Electronic Control
Unit). The ECU (Electronic Control Unit) operates the solenoid
valves of the injectors on each cylinder to inject fuel.
This common rail fuel injection system has the high-pressure
producing part and the fuel injection part separated. The ECU
determines the fuel injection amount, injection timing and
injection pressure according to the operating condition of the
engine before injecting fuel into the cylinders in order to ensure
optimum engine performance.
As the high-pressure pump produces high-pressure fuel, this
fuel is kept by the common rail. When a driver operates the
vehicle, the optimum fuel injection timing and injection amount
are determined by the ECU (Electronic Control Unit) based on
the preset data, vehicle speed and driving condition. Then the
ECU operates the solenoid valves of the injectors on each
cylinder to inject a proper amount of fuel into the cylinders.
The fuel tank should be made of non-corrosive material, and the
fuel low-pressure pump should not leak at twice the operating
pressure. Also, the pressure in the tank should not exceed
0.3 bar (0.3 kg/cm2, 4.4 psi).
Injector
Common Rail
Cylinder Head
Fuel Tank
DX140W-5/DX160W-5 Engine
4-1-147
Fuel High-pressure System Components
The common rail fuel injection system consist of the low-
pressure stage for low-pressure fuel delivery, high-pressure
stage for high-pressure fuel delivery, and electronic control unit.
1. Fuel high-pressure pump
The fuel high-pressure pump pressurizes fuel up to
approximately 1,835.5 kg/cm2 (1,800 bar, 26,106.8 psi)
and sends this pressurized fuel to the common rail (pipe
shape) through the high-pressure line.
2. Common rail
Even after the injector uses fuel from the common rail to
inject fuel, the fuel pressure in the common rail is still
maintained at a constant level. The common rail pressure
sensor detects the fuel pressure while the pressure control
valve maintains the fuel pressure at the desired level. The
fuel pressure in the common rail is controlled to max.
1,835.5 kg/cm2 (1,800 bar, 26,106.8 psi) by the pressure
control valve.
3. Injector
As the solenoid valve is operated, fuel flows to the injector
nozzle which then sprays fuel directly into the combustion
chamber. When the injector nozzle opens and sprays the
commanded amount of fuel, the excess fuel is returned to
the tank through the return line. Also, fuel returned from the
fuel pressure control valve and low-pressure stage and fuel
used to lubricate the high-pressure pump are returned
back to the fuel tank through the return line as well.
4. Fuel high-pressure pipe
The fuel high-pressure pipe carries high-pressure fuel at
1,835.5 kg/cm2 (1,800 bar, 26,106.8 psi). Therefore, this
pipe is made of special material to be able to withstand the
maximum pressure of the system and fluctuation of high
pressure occurred during fuel injection. The high-pressure
pipe has 8.0 mm of outside diameter and 3.5 mm of inside
diameter. Also, the fuel high-pressure pipes installed
between the common rail and injectors should be in the
same length and they are installed as short as possible.
Engine DX140W-5/DX160W-5
4-1-148
Injector
General Description
The injector uses the nozzle to inject fuel to the combustion
chamber directly. To control the injection, the solenoid valve is
used. Fuel is delivered as much as required from the open
injector nozzle and the remaining fuel is returned to the fuel tank
through the fuel return line. In addition, the fuel which has been
used to lubricate the high-pressure pump and returned from the
fuel pressure adjustment valve is returned to the fuel tank
through the return line.
The solenoid valve controls the fuel injection timing and amount.
The injector works instead of the nozzle and the nozzle holder
mounted on the existing engine. Fuel is delivered to the injector
through the high-pressure connector mounted on the cylinder
head and then delivered to the valve control chamber through
the delivery hole.
The valve control chamber is opened by the solenoid valve. It is
connected to the fuel return line via the discharge hole. The
hydraulic force which has been increased by the valve control
plunger with closed discharge hole exceeds the pressure value
of the nozzle needle. As a result, fuel delivery to the combustion
chamber is blocked by the force given to the contact surface of
the nozzle needle.
When the solenoid valve of the injector is pulled, the discharge
hole is opened. This lowers the pressure in the control chamber
and the hydraulic power given to the plunger. When hydraulic
force is lower than the force given to the nozzle needle pressure,
the nozzle needle is opened. Finally, fuel is injected to the
combustion chamber through the injection nozzle hole.
The reason that the nozzle needle is controlled by hydraulic
force is that the power required to open the needle quickly
cannot be directly generated from the solenoid valve. Fuel
control amount required to open the nozzle needle is added to
the fuel amount injected. The used fuel is discharged to the fuel
return line through the hole of the valve control chamber.
Fuel loss occurs on the nozzle needle, the valve plunger guide
as well as the valve control chamber. The control leakage fuel
and the fuel gathered from the line, which connects the over flow
valve, the high-pressure pump, and the pressure control valve,
is returned to the fuel tank through the fuel return line.
DX140W-5/DX160W-5 Engine
4-1-149
Parts List
1-2
CYLINDER HEAD
EX1403729
Figure 236
Reference Reference
Description Description
Number Number
1 Injector Assembly 3 Fixture
1-2 O-ring 4 Bolt; Collared Hex.
2 Ring; Seal
Engine DX140W-5/DX160W-5
4-1-150
How to Operate an Injector
Injector operation is classified into four operation stages to
operate the engine and create pressure in the high-pressure
pump.
• The injector is closed (high fuel pressure state)
• The injector is open (starting fuel injection).
• The injector is fully open (injecting fuel).
• The injector is closed (ending fuel injection). These
operation stages are decided by balancing the force given
to the injector components. If there is no pressure on the
common rail or the engine is stopped, the injector nozzle
does not work.
1. The injector is closed (pause state)
Under the pause state that no power is provided to the
solenoid valve of the injector, the injector does not operate.
The surface where the discharge hole exists is tightly
closed with the valve ball by the force from a valve spring
or magnet. High pressure in the common rail is kept by the
fuel control valve and the same pressure is generated in
the nozzle chamber of the injector. The common rail fuel
pressure, which is given to the end face of the valve control
chamber of the injector, and the injector nozzle spring
force are larger than the force to open the nozzle.
Therefore, the injector is closed.
2. The injector is open. (starting fuel injection)
When power is supplied while the injector solenoid valve is
closed, the fuel discharge hole is open by the pulling force
of the solenoid valve. Almost simultaneous with that, the
high current given to the solenoid valve is reduced to the
low current. This is because the air gap of the
electromagnet circuit gets smaller. Fuel in the valve control
chamber flows to the discharge valve hole on the upper
side and then goes into the fuel tank via the fuel return line.
The discharge hole completely breaks the pressure
balance and lowers the pressure in the valve control
chamber. As a result, the pressure in the valve control
chamber is lower than the nozzle chamber pressure which
has been equal to the common rail pressure. The lowered
pressure of the valve control chamber lowers the force
from the control plunger. So the nozzle needle is open and
fuel injection starts.
3. The injector is fully open. (injecting fuel)
The valve control plunger is stopped at the upper position
because fuel is full as fuel flows from the fuel delivery hole.
At this time, the injector nozzle is fully open and fuel is
injected to the combustion chamber at the pressure equal
to that of the common rail.
DX140W-5/DX160W-5 Engine
4-1-151
4. The injector is closed. (ending fuel injection)
As soon as the supply to the solenoid vale of the injector is
blocked, the valve spring applies force to the armature
downward and the valve ball closes the discharge hole.
The armature consists of two components. The armature
plate is guided by the driving shoulder and pressed
downward. However, in this case, an overspring is used. It
is a return spring that prevents the force from being applied
to the armature and the valve ball. As the discharge hole is
closed, fuel is delivered from the delivery hole and
generates pressure in the control chamber. This fuel
pressure is equal to the pressure of the common rail and
puts pressure on the valve control plunger through the end
face of the valve control plunger. As a result, the force of
the spring is added to the pressure exceeding the pressure
of the nozzle chamber. Therefore, the nozzle needle is
closed. The speed of closing the nozzle needle is decided
by the flow that passes through the delivery hole. As soon
as the nozzle needle is positioned to the stop position, fuel
injection is blocked.
Injector Protrusion
1. Insert the seal ring to the cylinder cylinder head, and install
the injector.
Cylinder Head
NOTE: Refer to the engine assembly instruction for Injector
installation steps.
2. Measure the protrusion of the injector from the cylinder
head, and adjust it as necessary.
Engine DX140W-5/DX160W-5
4-1-152
Common Rail
General Description
This common rail fuel injection system has the high-pressure
producing part and the fuel injection part separated.
The ECU determines the fuel injection amount, injection timing
and injection pressure according to the operating condition of
the engine before injecting fuel into the cylinders in order to
ensure optimum engine performance.
The common rail stores fuel under high pressure delivered from
the high-pressure fuel pump.
Even after the injector uses fuel from the common rail to inject
fuel, the pressure pulse in the common rail is still maintained by
the volume of the rail to keep the fuel pressure at a constant
level.
The common rail pressure sensor detects the fuel pressure
while the pressure control valve maintains the fuel pressure at
the desired level. The fuel pressure in the common rail is
controlled to max. 1,835.5 kg/cm2 (1,800 bar, 26,106.8 psi) by
the pressure control valve.
EX1403815
Figure 238
DX140W-5/DX160W-5 Engine
4-1-153
The common rail fuel injection system consists of the following
main components:
1. ECU (Electronic Control Unit)
2. Crankshaft speed sensor
3. Camshaft speed sensor
4. Accelerator pedal sensor
5. Fuel temperature sensor
6. Boost pressure and temperature sensor, oil pressure and
temperature sensor
7. Common rail pressure sensor
8. Coolant temperature sensor
• As a driver depresses the accelerator pedal, the ECU
(Electronic Control Unit) receives information from
various sensors mentioned above to operate the
engine and vehicle according to the operating
condition instantly. Also, the ECU operates the open/
closed circuits and circulation circuit of the vehicle
and engine based on such information.
• The crankshaft speed sensor detects the engine
speed while information from the camshaft speed
sensor is used to determine the ignition order. The
potentiometer of the accelerator pedal sensor
produces an electric signal to inform the ECU of how
deep the pedal is depressed. Also, the turbocharger
and intake pressure sensor are installed, and the
intake pressure sensor is used to measure the intake
air pressure.
• When the engine temperature is low in cold weather,
the ECU receives information from the coolant
temperature sensor and air temperature sensor to
operate the engine ideally based on the current
operating condition.
Fuel Injection from the Injection Pump Common Rail Fuel Injection
Main Injection Pressure Max Injection Pressure Main Injection Pressure Common Rail Pressure
Time Time
EX1403816
Figure 239
Engine DX140W-5/DX160W-5
4-1-154
The common rail features the injection characteristics as follows:
1. Compared to the conventional system's injection
characteristics, the common rail manages the fuel injection
amount and injection pressure separately to satisfy with
any engine condition in order to ensure optimum fuel
injection.
2. In the initial fuel injection period, i.e. the ignition delay from
the beginning of fuel injection until the beginning of
combustion, the fuel injection amount should be adjusted
to a low level.
3. The common rail system is a modular type and has the
following major components for is injection characteristics:
A. Injector solenoid valve (installed to cylinder head)
B. Common rail
C. Fuel high-pressure pump
D. ECU (Electronic Control Unit)
E. Crankshaft speed sensor
DX140W-5/DX160W-5 Engine
4-1-155
Parts List
10
10-1
11
13
A
B
1
10-2A C
12 3
E
10-2
D
F 4
5
14
15
7
HIGH PRESS
PUMP
8
8-1
CYLINDER HEAD F
EX1403730
Figure 240
Engine DX140W-5/DX160W-5
4-1-156
Reference Reference
Description Description
Number Number
1 Pipe; Injection 10 Rail; Common
2 Pipe; Injection 10-1 Sensor; Pressure
3 Pipe; Injection 10-2 Valve; Pressure Limits
4 Pipe; Injection 10-2A O-ring
5 Pipe; Injection 11 Bracket; Common Rail
6 Pipe; Injection 12 Bolt Assembly M8 x 30
7 Pipe; Injection 13 Bolt Assembly M8 x 35
8 Connector; High Pressure 14 Clip; Pipe
8-1 O-ring 15 Bolt Assembly M8 x 12
9 Nut
DX140W-5/DX160W-5 Engine
4-1-157
Fuel Injection Pump
General Description
The fuel high-pressure pump uses a radial shaped piston pump
to produce high pressure. Pressure is independently generated
during the fuel injection process. The speed of the fuel high-
pressure pump is directly connected to the engine RPM,
regardless of the transmission's speed ratio. Compared to the
conventional injection system, the common rail injection system
delivers a certain amount of fuel constantly.
The injector is connected to the common rail with the high-
pressure pipe. It consists of the nozzle and solenoid valve which
is energized by the ECU when the ignition switch is operated.
When the ignition switch is blocked, the solenoid valve ends the
injection operation.
As the switching (opening/closing) operation of the injector's
solenoid valve is performed by high voltage and current, the
injectors' solenoid valves are operated in sequence according to
the preset value in the ECU. The crankshaft speed sensor and
camshaft speed sensor are used to detect the engine speed in
order to adjust the fuel injection timing and the beginning of fuel
injection correctly.
Eccentric Cam
Fuel
Inlet
Function
The fuel high-pressure pump has both low pressure stage and
high pressure stage. It carries high pressure fuel under any
operating circumstance during the service life of the vehicle.
Engine DX140W-5/DX160W-5
4-1-158
Also, it supplies a proper amount of fuel to the common rail to
handle any harsh condition, such as abrupt vehicle start or rapid
change of pressure in the common rail. The fuel high-pressure
pump produces the system pressure required in the common rail
constantly.
Operation
The fuel feed pump supplies fuel to the high-pressure pump
through the fuel inlet and safety valve. Then, this fuel is
transferred to the high-pressure pump's lubrication and cooling
circuits through the safety valve. The drive shaft is equipped with
the eccentric cam to move the pump's piston up and down
according to the shape of the cam.
If the fuel pressure delivered from the fuel feed pump exceeds
the fully open pressure of the safety valve, fuel moves the pump
piston downwards through the intake valve of the fuel high- EX1403818
pressure valve to the intake stroke position of the pumping Figure 242
chamber. When the pump piston passes the B.D.C., the valve is
closed. Then, as fuel cannot escape the pumping chamber, it is
compressed further over the delivered pressure.
As soon as the fuel pressure reaches the common rail pressure,
it opens the exhaust valve. Then, this compressed fuel enters
the high-pressure circuit. The pump piston continues to carry
fuel until it reaches the T.D.C. Then, as soon as the pressure
drops, the exhaust valve is closed. Then, fuel left in the pumping
chamber is depressurized and the pump piston moves
downwards again. When the pressure in the pumping chamber
drops below the pressure of the fuel feed pump, the intake valve
opens and the above steps are repeated.
Fuel Return
The fuel high-pressure pump is designed to supply a large
amount of fuel. While the engine is running at an idle speed or
with partial load, excess fuel is returned to the tank through the
pressure control valve.
DX140W-5/DX160W-5 Engine
4-1-159
pumping valve cannot be compressed during the delivery stroke.
As this fuel is returned to the low-pressure passage, no pressure
is produced. Since the pumping cut-off valve is operated only
with a small amount of force, it is possible to switch between the
delivery phase and cut-off phase at short intervals.
Parts List
4 5
4
1
4
5
1-1
2 1-3
1-4
1-2
EX1403731
Figure 243
Reference Reference
Description Description
Number Number
1 Injection Pump Assembly 2 Bolt Assembly M10 x 45
1-1 O-ring 3 Washer; Plain
1-2 Flow Meter; Fuel 4 Ring; Seal A14 x 20
1-3 O-ring 5 Nipple
1-4 O-ring 6 Adapter
1-5 Bolt
Engine DX140W-5/DX160W-5
4-1-160
ELECTRICAL SYSTEM
Electrical Parts
5
8
10
7
9
6
2
3
12
11
Figure 244 EX1403819
Reference Reference
Description Description
Number Number
EGR (Exhaust Gas Recirculation) Oil Pressure and Temperature
1 6
Motion Sensor Sensor (OPTS)
Boost Pressure and 7 Resistance Connector
2
Temperature Sensor (BPTS) 8 Rail Pressure Sensor (RPS)
Throttle Valve Position Sensor 9 Crankshaft Speed Sensor (CRS)
3
(TVA)
10 Camshaft Speed Sensor (CAM)
Coolant Temperature Sensor
4 11 Air Heater Relay
(CTS)
12 Fan Clutch
5 Injector Connector (INJ)
DX140W-5/DX160W-5 Engine
4-1-161
Switches and Sensors
FMU
1
2.58 2.83
2
2.29 2.05
Boot Press Temp Sensor 2.90 Boost Pressure/Temperature Sensor GND (G_R_BPS)
2.37 Boost Temperature Sensor SIG (I_A_BTS)
BPTS Boost Pressure/Temperature Sensor Voltage
2.07
2.90 2.37 2.07 2.86 (V_V_5VSS1A)
Engine DX140W-5/DX160W-5
4-1-162
Shape Symbol Pin No. Circuit name
EGR Valve
Vbat 24 V Battery Voltage (O_V_RH32)
GND Body GND
EGR
4
2.12 2.59
Resistance
2.18 CAN 2 Low (B_D_CAN2L)
1 2
2.17 2.18
DX140W-5/DX160W-5 Engine
4-1-163
Boost Pressure and Temperature Sensor
1. The boost pressure and temperature sensor is connected
to the intake manifold with the O-ring to measure the
absolute pressure and temperature in the intake manifold.
2. Its output signal is sent to the ECU which then calculates
the boost pressure based on the programmed
characteristic curve.
Electric Connections
Evaluation Circuit
Diaphragm
High Pressure
Connection
Mounting Thread
EX1403833
Figure 245
Engine DX140W-5/DX160W-5
4-1-164
Crankshaft Speed Sensor
The position of the pistons in the combustion chamber has a
major role in the fuel injection process.
All pistons in the engine are connected to the crankshaft by the
connecting rod.
The flywheel housing is equipped with the crankshaft speed
sensor to supply information for the position of all pistons.
This speed sensor detects the rotation per minute of the
crankshaft, and this information is used by the ECU (Electronic
Control Unit) for calculation as an important factor.
DX140W-5/DX160W-5 Engine
4-1-165
ECU (Electronic Control Unit)
1 2
Engine DX140W-5/DX160W-5
4-1-166
Operational Conditions of Electronic Control Unit (ECU)
Engine Start
1. Sets the reference temperature for determining preheat to
the lowest temperature among coolant temperature, fuel
temperature, intake air temperature, and oil temperature.
2. Sets the reference temperature for determining fuel
volume by setting the engine cooling temperature.
3. Determines the appropriate fuel volume to start the engine,
delivers the fuel to the engine, and measures the rpm
signal by using the crankshaft rev-count sensor.
Vehicle Driving
Calculates the required data for driving a vehicle, such as CAN
data and the rpm transferred from the vehicle control unit.
Limp Home
1. A function that allows drivers to drive their vehicle to the
repair center safely with the minimum conditions for driving
the vehicle when a fault code occurs.
2. Limp Home function is applied under the following
conditions.
• Accelerator pedal has failed: Regardless of pressing
the accelerator pedal, the vehicle is driven at a
consistent RPM.
• Sensor has failed: When sensors have failed, the
vehicle is driven with the consistent alternative
values.
• Output is limited: According to the fault type, the fuel
volume delivered to the engine is limited. The limit is
classified into four levels. The fuel volume is limited
according to the severity of the fault.
• Diagnosis Information display lamp: Provides
information of fault state to drivers for safe driving.
Failure Diagnosis
1. When a fault occurs, the failure diagnosis information
display lamp on the gauge board is turned on.
2. With the failure diagnosis information display lamp, drivers
can see the fault code.
NOTE: It can be checked from the failure diagnosis
information on the gauge board.
DX140W-5/DX160W-5 Engine
4-1-167
3. It can be diagnosed by connecting the diagnosis unit to the
check connector at the back of the driver's seat.
Driving Record
1. Writes the information related driving to the ECU.
2. The information on fuel consumption, engine use time, and
ECU use time is written in the ECU.
3. The information can be monitored with the ECU diagnosis
device.
Starter
General Description
The start motor is installed behind the flywheel housing. When
disassembling the engine, soak the start motor's pinion gear and
ring gear into fuel and clean them with a brush thoroughly. Then,
apply grease to them prevent their corrosion.
24V X 6.0kW
EX1403836
Figure 248
IMPORTANT
The start motor should always be protected from moisture
and humid condition.
Engine DX140W-5/DX160W-5
4-1-168
Circuit Diagram
Circuit Diagram
Battery Terminal
Solenoid Motor
Magnetic Switch
Solenoid Terminal
Switch Terminal
Ground Terminal
EX1403837
Figure 249
IMPORTANT
Before working on any electric system, make sure to
disconnect the negative battery cable in advance. Connect
the ground cable last after work to avoid a short circuit
during work.
DX140W-5/DX160W-5 Engine
4-1-169
Exhaust Gas Reduction
General Description
Connector
1
1. Mark by connector part 2 3
Reference
Description
Number
1 Wire Cover
2 Cable Tie
3 C/Tube 4
4 Tube (White) EX1403838
Figure 250
Symbol Description
2 Apply Manifold
Engine DX140W-5/DX160W-5
4-1-170
Circuit Diagram
EX1403845
Figure 252
Aftertreatment Connector
DX140W-5/DX160W-5 Engine
4-1-171
Switches and Sensors
NOX1
SCR1
SCR2
DOC1
NOX2
DOS
INT
EX1403846
Figure 253
1 2
1.23 1.96
EX1403850
Figure 254
5 1
EX1403851
Figure 255
Engine DX140W-5/DX160W-5
4-1-172
3. Secondary NOx sensor (NOx2)
5 1
EX1403852
Figure 256
1 2
1.09 300
EX1403853
Figure 257
1 2
1.32 1.43
EX1403854
Figure 258
1 2
1.16 1.18
EX1403855
Figure 259
DX140W-5/DX160W-5 Engine
4-1-173
7. Inter connector (INT)
7 12
1.09 301 302 304 303
EX1403856
Figure 260
Circuit Diagram
General Description
1. It is possible to identify the circuit number for the connector
and engine wire harness information.
2. The wiring colors can be identified as follows:
Symbol Color
B Black
Brn Brown
G Green
EX1403857
Gra Gray
Figure 261
L Blue
O Orange
P Purple
RW Red and White
W White
Y Yellow
Engine DX140W-5/DX160W-5
4-1-174
ECU (Engine Control Unit) Engine Connector
DX140W-5/DX160W-5 Engine
4-1-175
Wiring Wiring Wiring Wiring ECU Sensor
Circuit Name Remark
Label Size Color Type Pin No. Pin No.
Fuel Temperature/Coolant Tempera-
2.59 0.75 B a 59 Joint
ture Sensor GND
Shield Drain
2.69 0.75 B a Crankshaft/Camshaft Sensor Shield 69 3
(2.65/2.66, 2.67/2.68)
1.64 0.75 O a Fan Speed Sensor Output (FSS Out) 1 ICV PIN 11
4A 8.00 W a Alternator B
Engine DX140W-5/DX160W-5
4-1-176
Wiring Wiring Wiring Wiring ECU Sensor
Circuit Name Remark
Label Size Color Type Pin No. Pin No.
29B 0.75 W a Diode 4K INT 2 PIN 2
DX140W-5/DX160W-5 Engine
4-1-177
Engine DX140W-5/DX160W-5
4-1-178
ECU
ENGINE VEHICLE 1-03 99 0.85B
CONN CONN 99 0.85B
1-05
DX170W-5
1-28 99 0.85B
INJECTOR
1-29 99 0.85B 0.85B
SOLENOIDS
1-52 99 0.85B 99
2-49
INJECTOR1, BANK1 2-73 1-75 99 0.85B
1-76 99 0.85B
2-50
INJECTOR3, BANK1 2-74
ECU CIRCUIT
2-51
INJECTOR2, BANK1 2-75
INTER 2
2-25 CONN 2-1 SCR DOWNSTREAM
1 °t
INJECTOR5, BANK2 2-01 E30A 1-09 0.85Or E30B TEMPERATURE SENSOR
7 V
2-26 E28A 1-43 0.85RG E28B 2
6 SCR UPSTREAM
1 °t
INJECTOR6, BANK2 2-02 E29A 1-32 0.85Y E29B TEMPERATURE SENSOR
5 V
2-27 E27A 1-23 0.85G E27B 1
1 DOSING
INJECTOR4, BANK2 2-03 E26A 1-96 0.85GB E26B 2
2 VALVE
E32A 1-18 0.85Gr E32B 2
2-58 4
FUEL METERING °t DOC UPSTREAM(T4)
E31A 1-16 0.85GrR E31B 1
2-83 3 V TEMPERATURE SENSOR
UNIT(ZME)
TANK HEATING VALVE
2B
99
T1G 0.85Y
T2G 0.85YB
F11D 1.25RL
8 11 10 9
INTER
CONN 2-2
1
3
MASTER 4
96P
NOX SENSOR 5
2
CN1
4-1-179
Engine
1Upper Structure
1Cabin
Edition 1
DX140W-5/DX160W-5 Cabin
5-1-1
MEMO
Cabin DX140W-5/DX160W-5
5-1-2
Table of Contents
Cabin
Safety Instructions ..........................................5-1-5
Cabin Identification .........................................5-1-5
Roll-over Protective Structure (ROPS)...................... 5-1-5
Removal .........................................................5-1-7
Installation ....................................................5-1-12
Completing work ...........................................5-1-13
Dimensions of Cabin Glass ..........................5-1-14
Removal and Installation of Cabin Glass......5-1-18
Removal of Cabin Glass.......................................... 5-1-18
Installation of Cabin Glass....................................... 5-1-20
Installation of Upper Door Glass ............................. 5-1-25
Installation of Upper Front Glass............................. 5-1-25
DX140W-5/DX160W-5 Cabin
5-1-3
Cabin DX140W-5/DX160W-5
5-1-4
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
CABIN IDENTIFICATION
DX140W-5/DX160W-5 Cabin
5-1-5
ROPS Certification
This DOOSAN excavator has an operator's cabin that meets
ROPS requirements. The seat belt must be worn for roll-over
protection.
The ROPS certification plate is found on the left side of the cabin
on most models. It may vary slightly in its location on some
models.
Check the ROPS cabin, mounting, and hardware for damage.
Never modify the ROPS cabin. Replace the cabin and hardware
if damaged. See your DOOSAN dealer for parts.
ROPS − Roll-over Protective Structure complies with
ISO 12117-2:2008, EN13531:2001.
WARNING
AVOID DEATH OR SERIOUS INJURY
Never modify the operator cabin by welding, grinding,
drilling holes or adding attachments unless instructed by
DOOSAN. Changes to the cabin can cause loss of operator
protection from roll-over and falling objects, and result in
death or serious injury.
Cabin DX140W-5/DX160W-5
5-1-6
REMOVAL
1. Make the machine swing about 120° rightward on the flat
ground as shown in Figure 1 before lowering all the
attachments on the ground and then stop engine.
2. Set wheel chocks in front and behind each tire to prevent
the machine from moving.
WE1401487
Figure 1
LOCK
WARNING WARNING
DO NOT OPERATE
AVOID DEATH OR SERIOUS INJURY when performing inspection
or maintenance
WE1400464
Figure 3
DX140W-5/DX160W-5 Cabin
5-1-7
11. Turn battery disconnect switch to "OFF" position.
OFF
(Figure 4)
ON
Figure 4 EX1401760
12. Remove bolts and washers (1, Figure 5) (6 ea) with under
1
cover (2) on bottom of main frame.
• Tool: 19 mm ( ) 2
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
• Under cover weight: 9 kg (20 ft lb)
Figure 7 WE1400742
Cabin DX140W-5/DX160W-5
5-1-8
15. Remove cover (1, Figure 8), bolt and washer (2) with
safety lever assembly (3) from control stand.
• Tool: 4 mm ( )
1
3 2
EX1403564
Figure 8
1 2
Figure 9 WE1400435
WE1400436
Figure 10
4
1
Figure 11 WE1400437
DX140W-5/DX160W-5 Cabin
5-1-9
19. Remove glove box pad (1, Figure 12), and two bolts under
pad. 4
Remove caps and bolts (2, Figure 12) (3 ea) from top of
rear cover.
1 2
Remove bolts (3, Figure 12) (2 ea) from bottom of rubber
mounts in rear cover.
Remove rear cover (4, Figure 12).
3
WE1400438
Figure 12
20. Remove air ducts (1 thru 3, Figure 13) and atmospheric air
duct (4).
2 4
3
WE1400439
Figure 13
21. Remove all bolts (1, Figure 14) (17 ea) with brackets (2
thru 4) from body of operator cabin.
• Tool: 13 mm ( ) 2
3
• Torque: 19.6 N.m (2 kg.m, 14.5 ft lb)
1
4
WE1400440
Figure 14
Cabin DX140W-5/DX160W-5
5-1-10
22. Disconnect connectors of interior lights, speakers and
antenna.
WE1400441
Figure 15
WE1400442
Figure 16
24. Remove bolts and washers (1, Figure 17) (11 ea).
• Tool: 19 mm ( )
• Torque: 88.3 N.m (9 kg.m, 65.1 ft lb) 1 1
2 2
25. Remove nuts and washers (2) (4 ea) from cabin floor.
1 1
• Tool: 24 mm ( ) 2 1 2
1 1
• Torque: 205.9 N.m (21 kg.m, 151.9 ft lb)
WE1400443
Figure 17
DX140W-5/DX160W-5 Cabin
5-1-11
26. Remove bolts which is fixing the plate to prevent loosening
of ROPS bolt (1, Figure 18).
• Tool: 19 mm ( ) 2
• Tool: 60 mm ( )
1
• Torque: 127.5 N.m (13 kg.m, 94 ft lb)
WE1400444
Figure 18
IMPORTANT
Lift cabin approximately 25 ~ 50 mm (1" ~ 2") above
deck. Check that all electrical connections have been
disconnected and all other items unbolted.
Continue lifting with assist crane to remove cabin
shell. Lower shell to a prepared safe blocking support.
Do not rapidly lift operator's cabin: The bottom of
operator's cabin may come into contact with, and
scratch, control stand cover. Figure 19 WE1400445
INSTALLATION
1. Using a suitable lifting device, attach slings to four (4) lift
points on top of cabin (Figure 20).
• Cabin weight: 485 kg (1,069 lb)
2. Lower cabin into position on cabin floor.
Figure 20 WE1400445
• Tool: 24 mm ( )
• Torque: 205.9 N.m (21 kg.m, 151.9 ft lb)
Perform installation in the reverse order to removal.
Figure 21 WE1400446
Cabin DX140W-5/DX160W-5
5-1-12
COMPLETING WORK
1. Start the engine and run at low idle for about 5 minutes.
2. Perform the machine performance test.
DX140W-5/DX160W-5 Cabin
5-1-13
DIMENSIONS OF CABIN GLASS
Front Glass
816 7
993
824
454.5
27.6
27.6
169.6
169.6
7
58.3 707.4
EX1403138
Figure 22
Cabin DX140W-5/DX160W-5
5-1-14
Left Glass
399.5 5 270.7 5
786.4
786.4
20.3
410.6
437.5 131.6 402.3
850.2 5
210.7
367
468.8
436.1
470
642.3
722.8
871.7
EX1403139
Figure 23
NOTE: Unit: mm (1 mm = 0.039 in)
DX140W-5/DX160W-5 Cabin
5-1-15
Rear Side Glass
786.7 5
601.2
391.1
5
1026.2
958.2
452.9
EX1403140
Figure 24
Cabin DX140W-5/DX160W-5
5-1-16
Right Glass
1330.8 5
83.2
527.5
957.1
1407.6
505.1
419.7
306.6
30.8
918.7 207.9 163.3
1534.8
EX1403141
Figure 25
DX140W-5/DX160W-5 Cabin
5-1-17
REMOVAL AND INSTALLATION OF CABIN GLASS
CAUTION
AVOID INJURY
When removing the broken or cracked glass, the glass EX1301295
shards can cause serious injury.
Figure 26
Before removing, use tape to hold the broken or cracked
glass together.
Reference
Description
Number
3
1 Garnish
2 Lower Glass of Door
3 Rear Glass 1 4
4 Rear Left-hand Glass 5
2
5 Resin Panel
EX1301296
Figure 27
Reference
Description 3
Number
1 Cabin
2 Cabin Glass
3 Awl
4 Adhesive
4
EX1301298
Figure 28
Cabin DX140W-5/DX160W-5
5-1-18
3. Pass a piano wire (1, Figure 29) (or a wire) through the
hole.
EX1301299
Figure 29
Cabin Inside 3
EX1301300
Figure 30
DX140W-5/DX160W-5 Cabin
5-1-19
Installation of Cabin Glass
1
Procedures to install right-hand glass (1, Figure 32), rear, left-
hand glass, lower door glass and rear glass.
1. Cut off the remaining adhesive leaving a layer of old 2
adhesive 1 ~ 2 mm thick (Figure 31). The new adhesive
will bond to the remaining adhesive.
NOTE: Do not damage the cabin paint. Cut off Adhesive
by 1 - 2 mm Deep
Reference
Description EX1301302
Number
Figure 31
1 Cabin
2 Knife
EX1301295
Figure 32
Reference
Description 3
Number
1 Garnish
2 Lower Glass of Door 1 4
3 Rear Glass
5
4 Rear Left-hand Glass 2
IMPORTANT
Primer must be shaken for about 1 minute and mix
thoroughly before opening the cap.
After opening primer, apply primer as quickly as
possible and replace the cap immediately after using.
After opening primer, all the contents must be used
within 180 days (or 2 hours with the cap off).
Cabin DX140W-5/DX160W-5
5-1-20
Damper - Front Upper Glass
787
Adhesive Sides 5
975
5
A
Section A - A
EX1301354
Figure 34
758
Adhesive Sides 5
573
A
Section A - A
EX1301355
Figure 35
DX140W-5/DX160W-5 Cabin
5-1-21
Damper - Right-hand Glass
1,492
Length: about 4,712 mm
A
Adhesive Sides 5
1,376
7
Section A - A
EX1301356
Figure 36
800
7
184
329
R4,329 A
Adhesive Sides
429
5
R94
606 Section A - A
685
EX1301357
Figure 37
A
Adhesive Sides
5
Section A - A
EX1301358
Figure 38
Cabin DX140W-5/DX160W-5
5-1-22
4. Clean the mating edge of new glass by using clean rag and
ethylalcohol.
IMPORTANT
Primer (Sika Primer W06G+P) must be shaken for about
1 minute and mixed thoroughly before opening the cap.
After opening primer, apply primer as quickly as
possible and replace the cap immediately after using.
After opening primer, all the contents must be used
within 180 days (or 2 hours with the cap off).
Reference 3
Description
Number
1 Cabin
EX1301303
2 Application Brush Figure 39
3 Layer of Old Adhesive on Cabin
DX140W-5/DX160W-5 Cabin
5-1-23
Required
Application bead
should form
9 even triangle.
12 Remove Seal
Adhesive Cartridge
Panel
EX1401037
Figure 40
Painted Surface or
Glass Surface
Adhesive Surface
Adhesive Sika
Primer Sika Activator Primer Sika Primer
Tack-drive 310 ml
DM-1 250 ml Can 206G+P 30 ml Bottle
Cartridge
Upper Front Glass 310 ml 0.75 ml 0.67 ml
Lower Glass of Door 150 ml 0.50 ml 0.45 ml
Rear Left-hand Glass 250 ml 0.65 ml 0.60 ml
Rear Right-hand Glass 100 ml 1.00 ml 0.90 ml
Rear Glass 210 ml 0.50 ml 0.45 ml
Cabin DX140W-5/DX160W-5
5-1-24
Installation of Upper Door Glass
1. Before installing the glass, remove garnish (2, Figure 41) 1
around sash assembly (1) from the cabin inside for easy
2
removal. Push the sash assembly by hands and remove
sash outside. 3
2. Install glass (3, Figure 41) and glass (4) into the sash 4
grooves.
3. Install the sash assembly, which the glass is installed on,
onto the door from the outside of cabin.
EX1301297
Secure the sash assembly at the inside of cabin by using Figure 41
the garnish.
Reference
Description
Number
1 Upper Glass
2 Seal
3 Lower Glass
4 Damper 1
Apply Silicone after 4
Fixing 2 (Seal)
EX1301304
Figure 42
DX140W-5/DX160W-5 Cabin
5-1-25
Cabin DX140W-5/DX160W-5
5-1-26
Counterweight
Edition 1
DX140W-5/DX160W-5 Counterweight
5-2-1
MEMO
Counterweight DX140W-5/DX160W-5
5-2-2
Table of Contents
Counterweight
Safety Instructions ..........................................5-2-5
General ...........................................................5-2-6
Warning for Counterweight and Front Attachment
Removal .................................................................... 5-2-6
Removal .........................................................5-2-8
Installation ......................................................5-2-9
DX140W-5/DX160W-5 Counterweight
5-2-3
Counterweight DX140W-5/DX160W-5
5-2-4
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
DX140W-5/DX160W-5 Counterweight
5-2-5
GENERAL
WARNING
AVOID DEATH OR SERIOUS INJURY
DOOSAN warns any user, that removal of the counterweight
from the machine, front attachment (boom and arm) or any
other part, may affect the stability of the machine. This
could cause unexpected movement, resulting in death or
serious injuries.
Never remove counterweight or front attachment unless the
upper structure is in-line with the lower structure.
WE1401434
Never rotate the upper structure once the counterweight or Figure 1
front attachment has been removed.
WARNING
AVOID DEATH OR SERIOUS INJURY
The weight of counterweight is given in the following table.
Use only rated and approved slings and hardware when
removal or installation lifts are being made. Lifting slings,
shackles and all other hardware must be rigged safely. An
assist crane that is rated above weight capacity is required.
• Weight of counterweight:
– Standard: 2,150 kg (4,740 lb)
– Option: 2,450 kg (5,401 lb)
Counterweight DX140W-5/DX160W-5
5-2-6
Responsibility must be assigned to one person to be in charge
of the lifting crew, and to verify that required safe lifting
precautions have been taken before each part of this procedure
has been started.
All members of the working crew should know and understand
the signals that will be used between the lifting leader, the assist
crane operator and the remainder of the work crew.
WARNING
AVOID DEATH OR SERIOUS INJURY
If the upper structure deck has been unbalanced by
removal of weight from one end only, traveling with the
excavator, swinging the turntable, movement over bumps
or sloping and uneven surfaces could cause loss of control
resulting in tipping or rollover.
90 ~ 110
15
WE1400142
Figure 2
15
Figure 3 WE1400143
DX140W-5/DX160W-5 Counterweight
5-2-7
REMOVAL
O ACC
I
WARNING
AVOID DEATH OR SERIOUS INJURY
LOCK
Death or serious injury can occur from a counterweight
falling during removal or installation. Do not allow WARNING
personnel under or around the counterweight during DO NOT OPERATE
removal or installation. when performing inspection
or maintenance
190-00695A
ON OFF
Use certified cables and shackles of adequate load rating.
Improper lifting can allow the load to shift and cause death EX1403537
or serious injury. Figure 4
WARNING
AVOID DEATH OR SERIOUS INJURY
If engine must be running while performing
maintenance, use extreme care. Always have one
person in the cabin at all times. Never leave the cabin
with the engine running.
3 2
2
WE1401218
Figure 5
Counterweight DX140W-5/DX160W-5
5-2-8
13. Remove four bolts (2, Figure 5), spacers (3) and shims (4)
from counterweight (1).
• Tool: 46 mm ( )
• Weight:
– 2,150 kg (4,740 lb)
– 2,450 kg (5,401 lb)
NOTE: Heat bolts, if necessary, to free them.
14. When bolts (2, Figure 5), spacers (3) and shims (4) have
been removed, lift counterweight (1) a very short distance
above support frame (5) and stop. Check slings and make
sure counterweight is being supported evenly.
INSTALLATION 1
1. Using suitable lifting device capable of handling the weight
of the counterweight, support counterweight from lifting
holes (6, Figure 6). Raise counterweight (1) into position 6
just above support frame (5) leaving counterweight
suspended. Verify that counterweight is level and even.
NOTE: Leave counterweight (1, Figure 6) suspended
3 mm (0.125") above support frame (5) until all
four mounting bolts (2) are started in
counterweight mounting holes.
2. Align spacers (3) and shims (4, Figure 6) onto bolts (2). 4
Apply Loctite #242 to mounting bolt threads.
4
3. Install four bolts (2, Figure 6) with spacers (3) and shims (4) 5
into counterweight until washers contact support frame.
Fully lower counterweight onto support frame and finish 3
tightening bolts.
3 2
• Tool: 46 mm ( )
• Torque: 1,471 ±196 N.m 2
WE1401218
(150 ±20 kg.m, 1,085 ±145 ft lb) Figure 6
NOTE: As assembling counterweight into main frame,
adjust the gap of height between counterweight
and side door assembly using shim (4, Figure 6)
suitably.
4. Remove lifting device and lifting eyes from counterweight
lifting holes. (6, Figure 6)
5. Make sure all electrical lines and other items are connected.
6. Turn battery disconnect switch to "ON" position.
DX140W-5/DX160W-5 Counterweight
5-2-9
Counterweight DX140W-5/DX160W-5
5-2-10
Hydraulic Oil Tank
Edition 1
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
Specification
Volume (Full) 148 L (40 U.S. gal)
Optimum Volume 96 L (25 U.S. gal)
Tank Size 295 x 680 x 865
Tank Weight about 124 kg (Empty)
Size 10 μm, 1.6 m2 (ø150 x 415)
Operation Pressure 0 ~ 15 bar (0 ~ 15.9 kg/cm2, 0 ~ 217.6 psi)
Return Filter (26, Figure 1)
Bypass Valve Setting 1.5 bar (1.5 kg/cm2, 21 psi) at 40 L/min
Flow Rate 600 L/min (158.5 U.S. gpm)
Filter 10 μm, 270 cm2
Air Breather (5, Figure 1)
Cracking Pressure 0.39 ~ 0.49 bar (0.04 ~ 0.05 kg/cm2, 0.57 ~ 0.71 psi)
Size 80 mesh, 2,958 cm2 (ø150 x 142)
Suction Filter (3, Figure 1) Filtration Rating 177 μ
Flow Rate 750 L/min (198.1 U.S. gpm)
Actuation Pressure 1.5 kg/cm2 (1.5 bar, 21.3 psi)
Pressure Switch (101, Figure 1)
Rating 4 A Resistance at 24 V DC Max.
5 5-2
13 FR
5-1
ON
33 T
13
33 4
27
28
7
10
12
6
11
23
8
26
101
20
22
17
16
9
15
18 24 2
16 21
14
15 13 WE1400525
Figure 1
0.45 k 0.05 k 2
5
EX1301764
Figure 2
Reference Reference
Description Description
Number Number
1 Housing 4 Flange
2 Element 5 Gasket
3 Body
2. Pressure release
Pulling the breather cap upward, the check valve 0.46 kg/cm2
(0.45 bar) opens, and the air is discharged to the atmosphere
from the top of the hydraulic oil tank.
WARNING
AVOID DEATH OR SERIOUS INJURY
Contact with hydraulic fluid can harm your health. (e.g. eye
injuries, skin damage or poisoning, if inhaled).
• While performing removal and installation, wear safety
gloves, safety glasses and suitable working clothes.
• If hydraulic fluid should come into contact with your
eyes or penetrate your skin, consult a doctor
immediately.
WARNING
FIRE CAN CAUSE SERIOUS INJURY OR DEATH
Hydraulic fluid is highly flammable.
• Keep open flames and ignition sources away from the
workplace.
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants, grease,
etc. must be disposed of in an environmentally safe
manner. Some regulations require that certain spills and
leaks on the ground must be cleaned in a specific manner.
See local, state and federal regulations for the correct
disposal.
5. Set wheel chocks in front and behind each tire to prevent Figure 3
the machine from moving.
LOCK
WARNING WARNING
DO NOT OPERATE
AVOID DEATH OR SERIOUS INJURY when performing inspection
or maintenance
If engine must be running while performing 190-00695A
ON OFF
maintenance, always use extreme caution. Always EX1403537
have one person in the cabin at all times. Never leave Figure 4
the cabin with engine running.
WE1400464
Figure 5
ON
Figure 6 EX1401760
1 2
7 6
4
EX1401809
Figure 7
15. Loosen the oil tank air breather slowly to release the
pressure inside the hydraulic oil tank.
Pulling the breather cap upward, the check valve (0.45 bar) Figure 8 WE1400562
opens, and the air is discharged to the atmosphere from
the top of the hydraulic oil tank.
16. Oil drain method.
NOTE: Check the level on the oil level gauge before
draining the oil.
Figure 9 EX1402303
Figure 10 WE1400593
• Tool: 27 mm ( )
• Torque: 93.1 N.m (9.5 kg.m, 68.7 ft lb)
• Hydraulic oil tank volume
– Approximately: 148 L (39 U.S. gal)
– Effective level: 96 L (25.4 U.S. gal)
WE1400594
Figure 11 Bottom of Main Frame
Figure 12 WE1400835
Figure 13 WE1400836
19. Remove bolts (1, Figure 14) (10 ea) with air compressor
2
covert (2) and air compressor support (3).
• Tool: 19 mm ( )
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
• Support weight (with cover): 21 kg (46.3 lb) 3
Figure 14 WE1400837
20. Remove bolts (1, Figure 15) (2 ea) from fuel tank.
• Tool: 19 mm ( )
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
Figure 15 WE1400838
• Tool: 19 mm ( )
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
• Tank side cover weight: 14 kg (30.9 lb)
Figure 16 WE1400839
22. Remove bolts and washers (1, Figure 17) (8 ea) under
cover (2) on bottom of main frame.
• Tool: 19 mm ( )
1
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
• Under cover weight: 6 kg (13.2 lb)
2
23. Remove oil tank mounting bolts and spacers (1, Figure 18)
(4 ea) from the main frame.
2
• Tool: 24 mm ( )
• Torque: 264.6 N.m (27 kg.m, 195.2 ft lb)
1
24. Remove bolts (2, Figure 18) (6 ea) of suction pipe from the
oil tank.
• Tool: 17 mm ( )
• Torque: 63.7 N.m (6.5 kg.m, 47 ft lb)
• Tool: 12 mm ( )
• Torque: 29.4 N.m (3 kg.m, 21.7 ft lb)
1
Temperature 1
Sensor 2
Figure 19 WE1400842
27. Remove hoses, pipes and adapters (Figure 20) from the oil tank.
NOTE: Attach an identification tag onto the removed hoses for reassembly.
Disconnect the hoses from the bottom to top of oil tank.
After disconnecting hoses, plug them to prevent dirt or dust from entering.
2 3 4
5 6 7
8 9 10
11 12 13 14
15
Figure 20 WE1400843
• Fitting
Size Torque
Port Name
A B (mm) N.m kg.m ft lb
4 Adapter PF 3/8" UNF 11/16"-16 22 49 5 36.2
5, 6, 10 Elbow PF 3/8" UNF 11/16"-16 22 49 5 36.2
7 Elbow PF 3/8" UNF 9/16"-18 22 49 5 36.2
8, 9 Elbow PF 1/2" UNF 13/16"-16 27 93.1 9.5 68.7
12, 13 Elbow PF 1/4" UNF 9/16"-18 19 39.2 4 28.9
2180-1026D28
1 O-ring
(ID: 47.22, W: 3.53, 1B)
2, 3, 11 O-ring S8000145 (4D P14)
4, 5, 6, 10 O-ring S8000145 (4D P14) S8030061 (1B F-06)
2180-1216D11
7 O-ring S8000145 (4D P14)
(ID: 7.65, W: 1.78, 1B)
8, 9 O-ring S8000185 (4D P18) S8030081 (1B F-08)
2180-1216D11
12, 13 O-ring S8000115 (4D P11)
(ID: 7.65, W: 1.78, 1B)
14 O-ring S8000115 (4D P11)
*A: Opposite side of hose, B: Hose side
IMPORTANT
Make sure there are no other electrical wires or hoses
connected to tank.
INSTALLATION
WARNING
INCORRECT INSTALLATION CAN CAUSE DEATH OR
SERIOUS INJURY
Any change in the connections will lead to malfunctions
(e.g. lift instead of lower).
• When connecting hydraulic components, observe the
specified piping according to the hydraulic schematic
diagram of the machine.
• Tool: 24 mm ( ) 1
• Tool: 17 mm ( )
Figure 21 Bottom of Main Frame WE1400841
• Torque: 63.7 N.m (6.5 kg.m, 47 ft lb)
3. Perform installation in the reverse order to remove.
4. If removed the level gauge, install level gauge as the
following torque.
• Torque: 12.7 N.m (1.3 kg.m, 9.4 ft lb)
A
1 Suction Filter
2 Nut 2
3 Rod
1
• Length (A): 684 mm
EX1402872
• Torque (2 nut): 49 N.m (5 kg.m, 36.2 ft lb) Figure 22
Figure 23 WE1400844
COMPLETING WORK
1. Hydraulic oil tank volume:
• Approximately: 148 L (39 U.S. gal)
• Effective level: 96 L (25.4 U.S. gal)
2. Adjusting standard for hydraulic oil level
A. Front position: Extend the arm and dump the bucket
until both cylinders are fully retracted. Lower the
boom until the bucket rests on the ground. WE1401485
Figure 24
B. Engine condition: Low idle
C. Fill hydraulic oil until fluid in level gauge is positioned
between low and high marks. If hydraulic oil level is
too high, drain excess hydraulic oil from tank by
removing drain plug located on bottom of tank.
Edition 1
Fuel Tank
Safety Instructions ..........................................5-4-5
General ...........................................................5-4-5
Specification .............................................................. 5-4-5
Parts List ................................................................... 5-4-6
Removal .........................................................5-4-8
Installation ....................................................5-4-14
Completing Work ..........................................5-4-15
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
WARNING
AVOID DEATH OR SERIOUS INJURY
Diesel fuel is highly flammable and can be potentially
explosive. To prevent fires or explosion, keep arcs, sparks or
other ignition sources away from diesel fuel or fuel
containers.
Specification
Volume (Full) 280 L (74 U.S. gal)
Tank Size (mm) 600 x 700 x 990
Tank Weight about 121 kg (Empty)
Fuel Strainer Filter Filtration Ratio 24 mesh
(6, Figure 1) Working Oil Temperature -40 ~ 80°C (-40 ~ 176°F)
0.25 ~ 0.05 bar
Positive Pressure
Fuel Cap (0.25 ~ 0.05 kg/cm2 , 3.63 ~ 0.73 psi)
Check Valve
(10, Figure 1) below 0.035 bar
Negative Pressure
(0.035 kg/cm2, 0.51 psi)
Working Voltage V max. 48 V
Fuel Sensor
Working Current I max. 300 mA
(14, Figure 1)
Rating Power 125 mW
10
ONT
10-1
FR
13
13
14
101
102
12 1
11 8
11
7
2
3
5
4 WE1400526
Figure 1
WARNING
AVOID DEATH OR SERIOUS INJURY
Fire hazard!
Fuel is easily flammable.
• Keep open flames and ignition sources away from the
workplace.
EX1300964
Figure 2
WE1401484
Figure 3
EX1403537
Figure 4
AVOID DEATH OR SERIOUS INJURY
If engine must be running while performing
maintenance, use extreme care. Always have one
person in the cabin at all times. Never leave the cabin
with the engine running.
WE1400464
Figure 5
ON
Figure 6 EX1401760
1 2
7 6
4
EX1401809
Figure 7
15. Clean area around fuel tank fill cap. Open fuel cap.
Figure 8 WE1400845
Figure 9 WE1400846
17. Remove bolts and washers (1, Figure 10) (8 ea) with the
2
guardrail (2) (1 ea).
1
18. Remove bolts (3, Figure 10) (5 ea) and cover (4) from fuel
tank.
• Tool: 19 mm ( ) 3
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
• Tank cover weight: 4 kg (8.8 lb) 4
• Guardrail weight: 14 kg (30.9 lb)
Figure 10 WE1400847
19. Remove bolts and washers (1, Figure 11) (7 ea) with the
1 3
handrail (2) from fuel tank and frame.
5
20. Remove bolts (3, Figure 11) (4 ea) with the tank front cover 2
(4) from fuel tank.
21. Remove bolts (5, Figure 11) (6 ea) with air compressor
cover (6) from support.
• Tool: 19 mm ( ) 4
1
6
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
• Weight
WE1400848
Figure 11
Reference
Description kg (lb)
Number
2 Handrail 24 (52.9)
4 Tank Front Cover 4 (8.8)
6 Air Compressor Cover 6 (13.2)
• Tool: 19 mm ( )
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
• Support weight: 15 kg (33 lb)
Figure 12 WE1400849
Figure 13 WE1400850
2
1
EX1402326
Figure 14
2
1
Figure 15 WE1400851
Figure 16 WE1400852
27. Remove bolts (1, Figure 17) (2 ea) from fuel tank.
• Tool: 19 mm ( )
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
Figure 17 WE1400853
28. Open the right side door, remove bolts (2 ea) with tank side
cover (Figure 18).
• Tool: 19 mm ( )
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
• Tank cover weight: 14 kg (30.9 lb)
Figure 18 WE1400839
• Tool: 19 mm ( )
1
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
• Under cover weight: 6 kg (13.2 lb)
2
• Fitting
Size Torque
Port Name
A B (mm) N.m kg.m ft lb
S8030061
1 O-ring
(1B F-06)
S8030081
2 O-ring
(1B F-08)
* A: Opposite side of hose, B: Hose side
31. Remove fuel tank mounting bolts and spacers (3, Figure 20)
(4 ea) from the main frame.
• Tool: 24 mm ( )
• Torque: 264.6 N.m (27 kg.m, 195.2 ft lb)
IMPORTANT
Make sure there are no other electrical wires or hoses
connected to tank.
INSTALLATION
NOTE: First, assemble the bolts and spacers (4 ea) of fuel
tank mounting to main frame. (Figure 21)
1. Install the fuel tank with bolts and spacers (3, Figure 21) 3
(4 ea) to the main frame.
• Tool: 24 mm ( )
• Torque: 264.6 N.m (27 kg.m, 195.2 ft lb) 1
2. Connect fuel supply line (2, Figure 22) and drain valve line
(1) to fuel tank.
3. Perform installation in the reverse order to remove.
4. Make sure fuel tank drain valve (Figure 22) right side door
is closed.
5. Fill fuel tank and check for signs of leaks. Correct any
problems found.
6. Fuel tank capacity: 280 L (74 U.S. gal)
Figure 22 WE1400846
Figure 23 WE1400855
Edition 1
Main Pump
Safety Instructions ..........................................5-5-5
General ...........................................................5-5-5
Specifications ............................................................ 5-5-5
Overview ................................................................... 5-5-8
Hydraulic Circuit ........................................................ 5-5-9
Parts List ................................................................. 5-5-10
Theory of Operation ................................................ 5-5-14
Section View .................................................5-5-27
Removal .......................................................5-5-28
Installation ....................................................5-5-37
Completing Work ..........................................5-5-37
Assembly Guidelines for Tightening Torques ...5-5-38
Bolts ........................................................................ 5-5-38
Plugs with Internal Hexagon and Profile Seal Ring. 5-5-39
Seal-lock - Sealing Nuts .......................................... 5-5-39
Disassembly and Reassembly......................5-5-40
General Repair Guidelines ...................................... 5-5-40
Seal Kits and Subassemblies.................................. 5-5-42
Sealing the Driveshaft ............................................. 5-5-46
Gear Pump Sealing ................................................. 5-5-48
Removing Control Housing ..................................... 5-5-49
Control Module ........................................................ 5-5-52
Removing the Controller.......................................... 5-5-54
Valve Plate with Valves ........................................... 5-5-56
Remove Rotary Groups........................................... 5-5-57
Remove Intermediate Wheel................................... 5-5-60
Remove Auxiliary Drive ........................................... 5-5-62
Inspection ................................................................ 5-5-65
Assembling the Rotary Group ................................. 5-5-70
Pump Assembly ...................................................... 5-5-72
Hydraulic Component - Measurement "D" .............. 5-5-75
Installation of Control Housing ................................ 5-5-78
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
Specifications
Engine Power (P) 113 kW (154 PS) @ 2,000 rpm
Rated Speed (N) 2,000 rpm
High Idle (N) 2,100 rpm
Max. Flow (Q max.) 2 x 167 L/min @ 2,000 rpm & 35 bar
Min. Flow (Q min.) 2 x 16.5 L/min @ 2,000 rpm
Max. Displacement (V g max.) 85 cm3 / rev x 2
Weight 90 kg (200 lb)
Pilot Pressure (P) 39 ±2 bar (40 ±2 kg/cm2, 569 ±28 psi) @ 2,000 rpm
200
13 K
169 L 158 K
164 L
180 177 K
163 L
160
210 K
150 K 122 L
164 L
140 229 K
122 L
Q Flow (L/min)
120
64 K 202 K
127 L 123 L
100
350 K
78 L
80 350 K
71 L
350 K
60 69 L
40
20 350 K
23 L
A3
EPPR Valve
Input Current
R3 27.5
R1
25.0
M2 20.0
A2
17.5
15.0
10.0
7.5
M3 5.0
X3 2.5
Vg max Vg min
A1
M1
R2 S
WE1400528
Figure 2
Port
A3
X1
R3
M3
X1
M1
S
M2
A2
R1
A
A1
R2
View A
WE1400529
Figure 3
A3
EPPR Valve
R3
R1
M2
A2
Vg max Vg min X1
M3
X3
Vg max Vg min
X1
A1
M1
R2 S
EX1403145
Figure 4
Rotary Group
4
3
4B
4A
5
24
4D 4C
4E
23 2
8 25
27
7
25
22
21
20
2Ac
2Ad 2Ac2
2Ae 2Ac1
2Af 2Ab
2 2B 2Ba
2D
2Aa
2Be
2Ag
2Bb
2Bf
2Bc 2A
2Bd
3Ac
3Ad 3Ac2
3Ae 3Ac1
3 3Ab
3B 3Ba 3Af
3D
3Be 3Aa
3Bb 3Ag
3Bf
3Bc
3Bd
3A
Figure 5 EX1403163
2Aj
2Ai
2Ah
2Am
2Af
2Ag
2An
2A 2Af 2As
2Ao
2Aq
2Ar
2Aa
2Al 2Ad
2Ac 2A
2Ap
2Ab
2C
2Ae 2O
2Ak
2E
2D 2F 2N
49 46
2M
2B
18
50 2G
2I
48
2H
10 2
47 2L 2J
11
2K
44
43
42
15
42
14
13
12
17
16
37
26 EX1403164
Figure 6
6
2 A3 X1 Relief Valve (40 bar)
M3
Power Shift
Pressure
Pilot Ad2
Pump
8 EPPR Valve
3
4
5
Ad3
A1
P2
S
P1
P3
A2
Option
EX1403146
Figure 7
Reference Reference
Description Description
Number Number
1 Drive Shaft 7 Positioning Piston
2 Gear Pump (Pilot) 8 Positioning Trunnion
3 Piston S Suction Port
4 Cylinder A1, A2 High-pressure Delivery Port
5 Control Lens A3 Pilot Port
6 EPPR Valve
Piston
Control Lens
Driveshaft
Cylinder
EX1400245
Figure 8
A3
EPPR Valve
Input Current
R3
R1
M2
A2
X1
M3
X3
X1
A1
M1
R2 S
Pilot
Pump High System
Pressure
A3
EPPR Valve
Input Current
R3
R1
M2
A2
X1
M3
X3
X1
A1
M1
R2 S
Pilot
Pump Low System
Pressure
Input Current
R3
R1
M2 High Negacon
A2 Pressure
X1
M3
X3
X1
A1
M1
R2 S
High Negacon
Pressure
Pilot
Pump
A3
EPPR Valve
Input Current
R3
R1
M2 Low Negacon
A2 Pressure
X1
M3
X3
X1
A1
M1
R2 S
Low Negacon
Pressure
Pilot
Pump
A3
EPPR Valve
Input Current
R3 27.5
R1
25.0
Secondary Pressure (kg/cm2) 22.5
M2 20.0
A2
17.5
15.0
10.0
7.5
M3 5.0
X3 2.5
Vg max Vg min
A1
M1
R2 S
WE1400530
Figure 14
A3
EPPR Valve
Input Current
320 ~ 340 mA
R3
R1
M2
A2
X1
M3
X3
X1
A1
M1
R2 S WE1401531
Figure 15
320 ~ 340 mA
Check
Point
Pilot
Pump
WE1401532
Figure 16
A3
EPPR Valve
Input Current
240 ~ 300 mA
R3
R1
M2
A2
X1
M3
X3
X1
A1
M1
R2 S
240 ~ 300 mA
Pilot
Pump
WE1401533
Figure 17
To control flow, it needs more system pressure then standard mode pressure.
Ad1
Ad3
X1 (Pilot Nagative
Pressure)
A3
M3
Q Flow (L/min)
Pump
Ad1
Pi - Q Curve
Servo Piston
Figure 18 EX1403155
• Flow adjusting
– Ad1: Flow control adjust screw (The flow rate by pilot pressure adjusted)
– Ad2: Pressure control adjust screw (Pump input pressure adjust)
– Ad3: Max. flow adjust screw (Servo Piston Stroke Limitation)
• Measuring point
– M3: Power shift pressure check point (EPPR Valve 2nd pressure)
6
2 A3 X1 Relief Valve (40 bar)
M3
Power Shift
Pressure
Pilot Ad2
Pump
8 EPPR Valve
3
4
5
Ad3
A1
P2
S
P1
P3
A2
Option
EX1403146
Figure 19
Reference Reference
Description Description
Number Number
1 Drive Shaft 5 Control Lens
2 Gear Pump (Pilot) 6 EPPR Valve
3 Piston 7 Positioning Piston
4 Cylinder 8 Positioning Trunnion
WARNING
AVOID DEATH OR SERIOUS INJURY
Contact with hydraulic fluid can harm your health. (e.g. eye
injuries, skin damage or poisoning, if inhaled).
• While performing removal and installation, wear safety
gloves, safety glasses and suitable working clothes.
• If hydraulic fluid should come into contact with your
eyes or penetrate your skin, consult a doctor
immediately.
WARNING
FIRE CAN CAUSE SERIOUS INJURY OR DEATH
Hydraulic fluid is highly flammable.
• Keep open flames and ignition sources away from the
workplace.
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants, grease,
etc. must be disposed of in an environmentally safe
manner. Some regulations require that certain spills and
leaks on the ground must be cleaned in a specific manner.
See local, state and federal regulations for the correct
disposal.
WE1400569
Figure 20
LOCK
WARNING WARNING
DO NOT OPERATE
AVOID DEATH OR SERIOUS INJURY when performing inspection
or maintenance
WE1400464
Figure 22
ON
Figure 23 EX1401760
1 2
7 6
4
EX1401809
Figure 24
13. Loosen the oil tank air breather slowly to release the
pressure inside the hydraulic oil tank.
Pulling the breather cap upward, the check valve (0.45 bar) Figure 25 WE1400562
opens, and the air is discharged to the atmosphere from
the top of the hydraulic oil tank.
14. Oil drain method Suction Filter Cover
A. Remove cover (2 ea) on oil tank (bolt: 12 ea), drain
hydraulic oil using oil pump. (Figure 26) Return Filter Cover
• Tool: 17 mm ( )
• Torque: 63.7 N.m (6.5 kg.m, 47 ft lb)
Figure 26 WE1400593
• Tool: 27 mm ( )
• Hydraulic oil tank capacity
– Approximately: 148 L (39 U.S. gal)
– Effective level: 96 L (25.4 U.S. gal)
• Torque: 93.2 N.m (9.5 kg.m, 68.7 ft lb)
Figure 28 EX1402349
A
3 Rod
2
When installing
• Length (A): 684 mm 1
• Torque (2 nut): 49 N.m (5 kg.m, 36.2 ft lb) EX1402872
Figure 29
15. Remove bolt (1, Figure 30) (7 ea) and remove under cover
1
(2, Figure 30) under pump side.
• Tool: 19 mm ( ) 2
Figure 31 WE1400596
17. Remove bolts (3, Figure 32) (11 ea) and remove baffle
cover (1 and 2, Figure 32) from pump room.
• Tool: 19 mm ( )
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb) 3
2
• Cover weight 1
Reference Weight
Number kg lb
1 2 4.4
2 4 8.8 Figure 32 WE1400597
• Tool: 19 mm ( ) 1
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
• Cover weight: about 20 kg (44 lb) 3
Figure 33 WE1400598
19. Remove bolts (1, Figure 34) (3 ea) with support (2).
• Tool: 19 mm ( ) 1 2
Figure 34 WE1400599
Figure 35 WE1400600
22. Remove water hoses (1, Figure 36) (2 ea) and urea hose
(2) from Dosing module.
2
Figure 36 WE1400601
Figure 37 WE1400602
• Tool: 17 mm ( ) 2 2
• Tool: 19 mm ( ) 1
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
Figure 38 WE1400607
EX1402359
Figure 39
Figure 40 WE1400608
EX1404086
Figure 41
• Tool: 14 mm ( )
• Torque: 264.8 N.m (27 kg.m, 195.3 ft lb)
Figure 42 WE1400609
A2 S WE1400610
Figure 43
• Fitting
Size Torque
Port Name
A B (C) (mm) (mm) N.m kg.m ft lb
Block SAE 1", D25 PF 1" 10 176.4 18 130.1
A2Adapter PF 1" UNF 1 7/16"-12 41 205.8 21 151.8
Elbow UNF 1 7/16"-12 UNF 1 7/16"-12 41 169.5 17.3 125.1
A3 Adapter M18 x 1.5 UNF 13/16"-2A 24 40.2 4.1 29.6
X1 Adapter M14 x 1.5 UNF 9/16"-18 19 30.4 3.1 22.4
(F/R) Elbow UNF 9/16"-18 UNF 9/16"-18 17 25.5 2.6 18.8
M1, M2 Adapter UNF 9/16"-18 PF 3/8" 24 25.5 2.6 18.8
2180-1026D19
A1 O-ring
(ID: 32.92, W: 3.53, 1B)
2180-1026D19 S8000291 (1B P29),
A2 O-ring
(ID: 32.92, W: 3.53, 1B) S8030165 (4D F-16)
DS2851076
A3 O-ring S8030081 (1B F-08)
(ID: 15.3, W: 2.2, 1B)
2180-1216D11
X1 O-ring
(ID: 7.65, W: 1.78, 1B)
M1, M2 O-ring S8040061 (1B B-06)
2180-1026D32
S O-ring
(ID: 85.32, W: 3.53, Class1)
• Tool: 17 mm ( )
• Torque: 63.7 N.m (6.5 kg.m, 47 ft lb)
Figure 44 WE1400611
31. Attach a lifting device around pump. Raise the lifting device
until the pump is supported prior to removing remaining
bolts (2 ea).
• Main pump weight: about 90 kg (198 Ib)
CAUTION
AVOID INJURY
Support the pump prior to removing remaining bolts to
prevent pump from falling.
WE1400612
Figure 45
• Tool: 17 mm ( )
• Torque: 63.7 N.m (6.5 kg.m, 47 ft lb)
WE1400613
Figure 46
IMPORTANT
Make sure there are no other electrical wires or hoses
connected to main pump.
Figure 47 EX1403069
WARNING
INCORRECT INSTALLATION CAN CAUSE DEATH OR
SERIOUS INJURY
Any change in the connections will lead to malfunctions
(e.g. lift instead of lower).
• When connecting hydraulic components, observe the
specified piping according to the hydraulic schematic
diagram of the machine.
COMPLETING WORK
1. If the hydraulic oil in the oil tank was removed, refill the
hydraulic oil tank.
IMPORTANT
Make sure the hydraulic oil tank is filled to an
appropriate level.
• Tool: 6 mm ( )
4. Keep pouring until the oil appears clean without gas
bubbles; tighten the plug.
• Tool: 6 mm ( )
• Torque: 30 N.m (3.1 kg.m, 22 ft lb)
Bolts
Values stated are valid for bolts with metric ISO threads to DIN
13 part 13, and head areas to DIN 912 socked head cap screws,
DIN 931 hexagon bolt or DIN 933 hexagon bolts with threads up
to the head.
FG021156
Figure 49
WARNING
AVOID DEATH OR SERIOUS INJURY
Observe the following notices and instructions when
carrying out repairs on hydraulic units.
ASS1140L
Figure 52
HB7M3003
Figure 53
HB7M3004
Figure 54
IMPORTANT
Using abrasive materials on sliding surfaces can
damage the surface.
HB7M3005
Figure 55
ASS0060L
Figure 56
ASS0070L
Figure 57
ASS0080L
Figure 58
ASS0090L
Figure 59
ASS0100L
Figure 60
IMPORTANT
Adjustment is necessary.
Pay attention to direction of rotation.
ASS0110L
Figure 61
ASS0120L
Figure 62
ASS0130L
Figure 63
ASS0140L
Figure 64
ASS0150L
Figure 65
ASS0160L
Figure 66
ASS0170L
Figure 67
EX1401142
Figure 68
EX1401143
Figure 69
ASS0200L
Figure 70
ASS0210L
Figure 71
ASS0220L
Figure 72
ASS0230L
Figure 73
IMPORTANT
Take note of press-in depth. Install mark for press-in
depth of safety ring.
ASS0240L
Figure 74
Figure 75 EX1403156
1 ASS0260L
Figure 76
ASS0270L
Figure 77
Figure 78 EX1403157
Figure 79 ASS0290L
IMPORTANT
Mark installation position. Be careful, control lenses
can fall out.
Figure 80 ASS0300L
ASS0310L
Figure 81
1
1 ASS0320L
Figure 82
Reference
Description
Number
1 Setting Screw: Qmax
2 Setting Screw: Hydraulic Stroke Limitation
3 Setting Screw: Power Characteristic (Begin of Regulation)
X
ASS0330L
Figure 83
Control Module LR
ASS0340L
Figure 84
ASS0350L
Figure 85
ASS0360L
Figure 86
ASS0370L
Figure 87
Figure 88 EX1403158
1. Remove screws.
NOTE: Install control lens - torque support.
ASS0400L
Figure 89
ASS0410L
Figure 90
ASS0420L
Figure 91
ASS0430L
Figure 92
Figure 93 EX1401144
EX1403160
Figure 94
ASS0460L
Figure 95
ASS0470L
Figure 96
ASS0480L
Figure 97
2
Rotary Group 2
Rotary Group 1
ASS0490L
Figure 98
2
1
ASS0500L
Figure 99
A Adjustment of measurement D
*
1. Holding device
Drive shaft 2
Drive shaft 1
1. Holding device
*
A
Adjustment of measurement D
ASS0520L
Figure 101
2. Install sleeve.
NOTE: Press out bolt with a hydraulic press.
ASS0530L
Figure 102
ASS0540L
Figure 103
ASS0550L
Figure 104
ASS0560L
Figure 105
ASS0570L
Figure 106
ASS0580L
Figure 107
ASS0590L
Figure 108
ASS0600L
Figure 109
ASS0610L
Figure 110
ASS0620L
Figure 111
ASS0630L
Figure 112
ASS0640L
Figure 113
ASS0650L
Figure 114
2. Visually check:
To ensure that bearing seats are free of scores.
ASS0660L
Figure 115
3. Visually check:
Check to see that bearing bores are free of scores and
there is no evidence of wear.
ASS0670L
Figure 116
ASS0680L
Figure 117
ASS0690L
Figure 118
6. Piston:
Check to ensure that they are free of scores and there is
no pitting.
ASS0700L
Figure 119
7. Central pin:
Check to ensure that it is free of scores and there is no
pitting.
ASS071L
Figure 120
8. Retaining plate:
Check to ensure that it is free of scores and there is no
evidence of wear.
ASS0720L
Figure 121
ASS0730L
Figure 122
10. Check:
Control land (1, Figure 123), internal control drilling (2,
Figure 123) and pin cups (3, Figure 123).
ASS0740L
Figure 123
11. Check:
That sliding surfaces (1, Figure 124) are free of scores.
Seal (2, Figure 124).
ASS0750L
Figure 124
2
1
1
ASS0760L
Figure 125
*
*
*
*
ASS0770L
Figure 126
ASS0780L
Figure 127
ASS0790L
Figure 128
3. Insert spring plate (1, Figure 129) and cup springs (2,
Figure 129) into their correct position (and orientation)
using grease to hold them into place.
ASS0800L
Figure 129
ASS0810L
Figure 130
ASS0820L
Figure 131
ASS0830L
Figure 132
ASS0840L
Figure 133
ASS0850L
Figure 134
ASS0860L
Figure 135
Stop
D
A
A
D
Stop
ASS0870L
Figure 136
EX1403917
Figure 137
ASS0900L
Figure 138
ASS0890L
Figure 139
Figure 140
Figure 141
ASS0960L
Figure 142
Figure 143
EX1403161
Figure 144
* ASS1000L
Figure 145
ASS1010L
Figure 146
EX1403162
Figure 147
Pressure Pressure
side side
Suction side
ASS1030L
Figure 148
ASS1050L
Figure 150
2
ASS1060L
Figure 151
ASS1070L
Figure 152
EX1403159
Figure 153
IMPORTANT
Take note of press-in depth.
ASS1100L
Figure 155
Edition 1
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
Description
When installing the main pump on the engine, it is very
important to properly adjust clearance between the face of the
coupling hub and end of pump drive shaft to a specific value.
Specification
Nominal Torque 785 N.m (80 kg.m, 579 ft lb)
Max. Torque 1,560 N.m (160 kg.m, 1,157 ft lb)
Max. Speed 4,000 rpm
Radial 0.4 mm (0.015 in)
Max. Permissible Displacements Angular 0.5°
Axial ±2 mm (±0.08 in)
Dynamic Torsion Spring Stiffness Cdyn 1.96 x 106 kg.cm/Rad
Mass Moment of Inertia 2.33 kg.cm. S2
Allowable Environment Temperature -20 ~ 120°C (-20 ~ 248°F)
FR
ON
T
1-5
1-3
1-7
1-2
1-6
1-5
1-1
1-4
ENGINE
Reference Reference
Description Description
Number Number
1 Coupling; Pump 1-5 Socket Bolt Set (8 ea)
1-1 Hub 1-6 Bolt; Clamping
1-2 Element 1-7 Pin; Spring
1-3 Insert (A) 1-8 Element Kit
1-4 Insert (R)
10
7 Main Pump
H
11
EX1403313
Figure 2 Drive Coupling Installation
Tools
Name Description
Allen Wrench 8 mm, 14 mm
Plastic Hammer One Plastic Hammer
EX1403071
Figure 3
• : 14 mm
5
2
Figure 4 EX1403072
• : 14 mm
Figure 5 EX1403073
Flywheel Side
7
5
EX1403074
Figure 6
2. Assemble the insert (4, Figure 7) (4 ea) with socket bolts (5)
(4 ea) to hub (attached by spring pin) (7, Figure 6) (8 ea). 4
EX1404097
Figure 7
EX1403075
Figure 8
IMPORTANT
3
1. Bolts are coated against loosening with a
bonding compound. Do not use any additional
bonding compounds, oils or cleaning solvents on
them.
Figure 9 EX1403076
2. Element (2, Figure 9) is not resistant to bonding
compounds, oil or grease. Be careful not to
expose them to it.
3. Remove oil or dirt from flywheel cover and pump
shaft before assembly.
4. Misalignment between pump and engine must be
controlled to less than 0.6 mm (0.023 in).
Edition 1
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
Specification
Control Method Negative Control
Rated Flow 160 L/min (30 L/min in neutral)
High 363 bar (370 kg/cm2, 5,263 psi) at 90 L/min
Main Relief Pressure
Low 343 bar (350 kg/cm2, 4,978 psi) at 90 L/min
Overload Relief Pressure 373 bar (380 kg/cm2, 5,405 psi) at 20 L/min
Max. Pressure of 1.5 MPa or Less
Permitted Back Pressure
Used Pressure of 0.5 MPa or Less
Normally -20 ~ +80°C
Permitted Use of Oil Temperature Highest 100°C
(Use of the Rubber for NBR)
Weight 147 kg (324 lb)
T1
Top View
DR2
pcc
T2 ps1
ps2 pc3
A7 B7 pb7 pb3 B3 A3
A6 B6 pb6 A2
DRtp pb1 B1 A1 PT
PA
P2 P1
par1
DR1
pa5 pa9
pa4 pa8
pa3 pa7
pa6
PP pa1 ptp
PH
WE1400971
Figure 1
Tr4
par1
OPT 2
pbr1
DR2 AR1
DR1 373 bar@20L/min
373 bar@20L/min BR1
T1 T2
X(REAR)
ps1 5 of Pump
6 8 ps2
pc1 7
A5 pcc
B5
pb5 ARM 1 ARM 2 pb9
373 bar@20L/min
373 bar@20L/min 4 pa9
3 pc2
pa5 373 bar@20L/min
373 bar@20L/min
pc3 A8
B4 B8
pb4 BOOM 1 pb8
pa4 BOOM 2 pa8
B3 B7
A3
BUCKET A7
pb3 SWING pb7
pa3
pa7
B2 373 bar@20L/min
373 bar@20L/min 373 bar@20L/min
373 bar@20L/min
A2 OPT B6
pb2
P4 DOZER A6
pa2 pb6
B1
pb1 A1 pa6
TRAVEL
TRAVEL DRtp
pa1 -PRIORITY
Ts3
ptp
Ts5 Lo : 343 bar@90L/min
2 1 Hi : 363 bar@90L/min
VALVE(LEFT) VALVE(RIGHT)
P1 PT
PT PP PA PH P3 P2
PRESS.
SENSOR
50 bar
Figure 2 WE1401151
Reference Reference
Description Description
Number Number
1 Main Relief Valve 5 Arm Holding Valve
2 Orifice 6 Foot Relief Valve
3 Arm Regeneration Valve 7 Foot Relief Valve
4 Boom Holding Valve 8 Center Bypass Cut Valve
Boom 2
Option
P1 PH
Main Pump
Boom 1 A8 B8
Dozer / Outrigger A6 B6
Travel Priority
Dozer /
P2 Outrigger Cylinder
Negacon Signal
Main Pump
WE1400921
Figure 3
32 72 68
74 39
38
73 71 37
32 36
58 56 33
63 32
35
57 34
61 19
32
59 18
60 55 16 17
60
19
1 18
63 16 17
21
21
63
22
18
53
63 54
27 28 53
29 31 30 52
70 51
50
16 69 67 49
17
18
19 55
63
66 24
47 25
18 16
46 21 17
23 32 16 18
81 17 19
18
16 19
17 21
18 27
19 28
29 62
66 13
42 20 63
31
65 67
30
7
63 8
◾#5∷
ARM 2 9
Ḻ#4∷
BOOM 1
ᴮ##⾽ 12 65
BUCKET
65 ᑮ##⠺
13 DOZER
11
45 TRAVEL
43 12
PRIORITY
44
43 6 10
48
5
45 91
43 65
44
43
41
◾#4∷
ARM 1
2 Ḻ#5∷
3 BOOM 2
4 ⇊##㜶
SWING
⇊##ㆇ#4
12 OPTION 1
11 ⦦##㘳
TRAVEL
WE1401002
Figure 4
Neutral Passage
The oil supplied from the port (P1) enters into the tank passage
(Ta) through the orifice (L2) of negative relief from the neutral
passage (L1) and returns to ports (T1).
The oil supplied from the port (P2) passes the tank passage (Ta)
through orifice (R2) of negative relief from the neutral passage
(R1) and returns to port (T2).
The pressure of chambers (L2 and R2) flowing over the negative
relief, flows into pump from ports (ps1 and ps2), to control the
volume of pump (P1) and (P2).
In addition, when excessive oil flows excessive into the neutral
passage, the negative relief operates to prevent the abnormally
high-pressure on ports (ps1 and ps2).
DR1
Ta
Center-Bypass Cut Valve
Lc9
R1
ps1
R3
L1
Arm 1 Arm 2
Boom 2 Boom 1
Swing Bucket
Option L3 R3 Dozer
Outrigger
Travel
Travel
Priority
L1 R1
A P1 P2
L R
View A P1 Side P2 Side
WE1400924
Figure 5
pc3
pa5
pb5
Arm 1
pa4
pb4
Boom 2
pa3
pb3
Swing
pa2
pb2 Option
pa1
pb1
Travel
P1
Ts5
SECTION "L"
Main Pump WE1401436
Figure 6
par1 pbr1
pcc DR2
DR1 ps2 T2
pb9
pa9 Arm 2
pb8
pa8
Boom 1
pb7
pa7 Bucket
pb6
pa6 Dozer / Outrigger
DRtp
Ptp
Travel Priority
P1
PH P2
P1P
Ts3
B1 A1 PT
PP
L1 L3
Ta Ta
pb1 pa1
Travel
R1 P1
DRtp ptp
P1P P2 P1
R3 Travel Priority
B1
A1 DRtp
T C1 C2 C3 C4
pb1 Travel Travel Priority
pa1
ptp
PAR PBR PL TS
PT PP
P1 P2
WE1401481
Figure 8
B4
L3 Ta Boom Cylinder
pb4 pa4
L1 Boom 2
DR
pb8 pa8
Ta Boom 1
R3
AD4
AD3
B8 A8
AD1 AD5 DR AD2
pc2
Boom Cylinder
DR1
pc2
A8
B8
B4
pb4 pb8
Boom 2 Boom 1
373bar@20L
pa4 pa8
P1 P2 WE1401442
Figure 9
B4 S4-1
Ta Ta Boom Cylinder
L3
pb4 pa4
L1 Boom 2
R1 DR
7
pb8 pa8
R3
Ta Boom 1
AD4
AD3
B8 A8
S8-1 AD1 AD5 DR AD2
pc2
Boom Cylinder
DR1
pc2
A8
B8
B4
pb4 pb8
Boom 2 Boom 1
373bar@20L
pa4 pa8
P1 P2 WE1401444
Figure 10
B4
L3 Ta Boom Cylinder
Ta
pb4 pa4
L1 Boom 2
S8-3 R1 DR
pb8 pa8
R3
Ta Boom 1
S8-2 AD4
AD3
B8 A8
S8-1 AD1 AD5 DR AD2
pc2
Boom Cylinder
DR1
pc2
A8
B8
B4
pb4 pb8
P1 P2 WE1401443
Figure 11
Arm Cylinder
pc1
AD5
AD4
L3 S5-4
pb5 pa5
Ta L1 Ta
Arm 1
11 R1 10
pb9 pa9
Ta Arm 2
R3
RC6
Ta
S9-2 S9-4
Arm Cylinder
S9-3 S9-1
DR1
pc1
A5 Arm Lock
B5
pb5 pb9
Arm 1 Arm 2
373bar@20L
pa5 pa9
P1 P2 WE1401439
Figure 12
AD4
L3 S5-4
pb5 pa5
L1 Ta
Ta 11 Arm 1
R1 10
pb9 pa9
Ta Rc6 Arm 2
R3
Ta
Arm Cylinder
S9-2 S9-4
S9-3 S9-1
DR1
pc1
A5 Arm Lock
B5
pb5 pb9
Arm 1 Arm 2
373bar@20L
pa5 pa9
Figure 13 P1 P2 WE1401441
ps1
S5-6 Lc8
S5-5 S5-3
Arm Cylinder
pc1
AD4
L3 S5-4
pb5 pa5
L1 Ta
Ta 11 Arm 1
R1 10
pb9 pa9
Ta Rc6 Arm 2
R3
Ta
S9-2 S9-4
S9-3 S9-1
pc3
Arm 1
S5-5
pb5 pa5
WE1401440
Figure 14
S5-8
ps1
Negacon Relief Valve(Lc1)
L3
L2
Arm Regen Valve
Ta
S5-2
pc3
Lc9 R1
DR1
Ta
pc3
Arm 1
S5-5
pb5 pa5
WE1401445
Figure 15
S3-2 S3-1
B3 A3
Ta L3 Ta
pb3 pa3
L1 Swing
R1
pb7 pa7
Ta Ta Bucket
R3
B7 A7 Bucket Cylinder
S7-2 S7-1
Swing Motor
B3 B7
A3 A7
pb3 pb7
Swing 373bar@20L Bucket
pa3 pa7
P1 P2
WE1401446
Figure 16
S3-2 S3-1
B3 A3
Ta L3 Ta
pb3 pa3
L1 Swing
R1
pb7 pa7
Ta Ta Bucket
R3
B7 A7 Bucket Cylinder
S7-2 S7-1
Swing Motor
B3 B7
A3 A7
pb3 pb7
Swing 373bar@20L Bucket
pa3 pa7
P1 P2 WE1401447
Figure 17
P4
S2-2 S2-1
B2 A2
L3
Ta Ta
pb2 pa2
L1 Option
pb6 pa6
Ta Ta Dozer Stabilizer
R3
B6 A6
Arm 1 Arm 2
Boom 2 Boom 1
Swing Bucket
B2 373bar@20L B6
A2 A6
pb2
P4 Option Dozer pb6
Stabilizer
pa2 pa6
P1 P2
WE1401052
Figure 18
P4
S2-2 S2-1
B2 A2
L3
Ta Ta
pb2 pa2
L1
Option
pb6 pa6
Ta Ta Dozer Stabilizer
R3
B6 A6
Arm 1 Arm 2
Boom 2 Boom 1
Swing Bucket
Outrigger Cylinder
Breaker Dozer Cylinder
B2 373bar@20L B6
A2 A6
pb2
P4 Option Dozer pb6
Stabilizer
pa2 pa6
P1 P2
WE1401053
Figure 19
P4
S2-2 S2-1
B2 A2
L3
Ta Ta
pb2 pa2
L1
Option
pb6 pa6
Ta Ta Dozer Stabilizer
R3
B6 A6
Arm 1 Arm 2
Boom 2 Boom 1
Swing Bucket
Outrigger Cylinder
Breaker Dozer Cylinder
B2 373bar@20L B6
Dozer
A2 Stabilizer A6
pb2
P4 Option pb6
pa2 pa6
P1 P2
WE1401054
Figure 20
P4
S2-2 S2-1
B2 A2
L3
Ta Ta
pb2 pa2
L1
Option
pb6 pa6
Ta Ta Dozer Stabilizer
R3
B6 A6
Arm 1 Arm 2
Boom 2 Boom 1
Swing Bucket
B2 373bar@20L B6
A2 A6
pb2
P4 Option Dozer pb6
Stabilizer
pa2 pa6
P1 P2
WE1400936
Figure 21
R1
DR1
Ta
Center-Bypass Cut Valve
B1 A1 PT
PP
L1 L3
Ta Ta
pb1 pa1
Travel
R1 P1
ptp
DRtp
P1P P2 P1
R3 Travel Priority
Pilot Valve
A
Figure 22 WE1401438
ps2
Foot Relief
Valve
pcc
B1
A1 DRtp
T C1 C2 C3 C4
pb1 Travel Travel Priority
pa1 ptp
PAR PBR PL TS
PT PP
P1 P2
PI T
From “A” C1
Accelerator
Pedal Valve P
A Pilot Valve
WE1401051
Figure 23
Other Operations
When any other operation is activated, no signal is delivered to the port (ptp) of the travel priority spool and the
port (pcc) of the center bypass cut spool.
Therefore, oil from the main pump (P1) is supplied to the travel, option, swing, boom 2 and arm 1 spools while oil
from the main pump (P2) is delivered to the dozer, bucket, boom 1 and arm 2 spools.
R1
DR1
Ta
Center-Bypass Cut Valve(R)
S12-2 S12-1
BR1 AR1
G3
pbr1 par1
Pg
Ta Ta
Tr4
par1
Arti. Boom
pbr1
AR1
373bar@20L BR1
P2 WE1400938
Figure 25
P1
LP
Ts5
Main Relief Valve
3
PH
Ts3
RP
P3 P2
WE1400939
Figure 26
AD5
WE1400940
Figure 27
B5 A5(A8)
Arm Dump
(Boom Down)
WE1400941
Figure 28
AD3
1 C
WE1400943
Figure 30
Oil flows around the pilot poppet (3), through the drill hole
“LP”
(E) and circular gap (D), and is guided to the tank path
"LP". “HP” PH
3
Figure 31 WE1400944
A “HP” PH
1 C
WE1400945
Figure 32
A
The sleeve (K) and main poppet (D) are securely seated by
the areal difference between "A" and "B".
EX1403985
C D G
Figure 33
EX1403986
Figure 34
3. The pilot poppet (E) opens to make the oil flow through the
"LP" I E
orifice (I) of piston (C), differential pressure is generated
between path "HP" and the back side of the piston (C) to
move the piston (C) to seat the poppet (E).
"HP"
D C EX1403987
Figure 35
4. For the oil flow through the path "HP" and poppet (D), the
C
pressure difference increases because of throttling by the "LP"
poppet (D), circular gap of piston (C), and orifice. The
poppet (D) is opened by the differential pressure and oil
flows directly through path "LP".
"HP"
D F EX1403988
Figure 36
A
generated by the areal difference between "A" and "B". Oil flows
from the low-pressure side "LP" into the cylinder port "HP" to
prevent cavitation.
WE1400946
Figure 37
Relief Operation
A B D F C
In the event there is excessive oil flow in the neutral downstream
path (A), the pressure generated in path (B) by the negacon ps1
orifice (D) is induced to the back chamber (C) of the poppet. The
poppet is activated by the differential pressure generated by the
difference in the hydraulic area between the path (B) and the
back chamber (C). When this poppet is activated, oil flows to the L1
tank path (Ta) through path (B) and the drill hole path (F) of the
plug, preventing excessive pressure in the negacon signal Poppet
pressure port. Tank Passage(Ta)
WE1400948
Figure 39
PRECAUTION
Lower the work equipment to the ground and stop engine.
Operate the control levers and pedals several times to release
the remaining pressure in the hydraulic piping
Loosen the breather slowly to release the pressure inside the
hydraulic tank.
Escaping fluid under pressure can penetrate the skin causing
serious injury.
When pipes and hoses are disconnected, catch the oil with an
oil pan.
WARNING
AVOID DEATH OR SERIOUS INJURY
Contact with hydraulic fluid can harm your health. (e.g. eye
injuries, skin damage or poisoning, if inhaled).
• While performing removal and installation, wear safety
gloves, safety glasses and suitable working clothes.
• If hydraulic fluid should come into contact with your
eyes or penetrate your skin, consult a doctor
immediately.
WARNING
FIRE CAN CAUSE SERIOUS INJURY OR DEATH
Hydraulic fluid is highly flammable.
• Keep open flames and ignition sources away from the
workplace.
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants, grease,
etc. must be disposed of in an environmentally safe
manner. Some regulations require that certain spills and
leaks on the ground must be cleaned in a specific manner.
See local, state and federal regulations for the correct
disposal.
WE1400569
Figure 40
LOCK
WARNING WARNING
DO NOT OPERATE
AVOID DEATH OR SERIOUS INJURY when performing inspection
or maintenance
WE1400464
Figure 42
ON
Figure 43 EX1401760
1 2
7 6
4
EX1401809
Figure 44
13. Loosen the oil tank air breather slowly to release the
pressure inside the hydraulic oil tank.
Pulling the breather cap upward, the check valve (0.45 bar) Figure 45 WE1400562
opens, and the air is discharged to the atmosphere from
the top of the hydraulic oil tank.
14. Oil drain method
Suction Filter Cover
NOTE: Check the level on the oil level gauge before
draining the oil. Return Filter Cover
• Tool: 17 mm ( )
• Torque: 63.7 N.m (6.5 kg.m, 47 ft lb)
Figure 46 WE1400593
• Tool: 27 mm ( )
• Torque: 93.1 N.m (9.5 kg.m, 68.7 ft lb)
• Hydraulic oil tank volume
– Approximately: 148 L (39 U.S. gal)
– Effective level: 96 L (25.4 U.S. gal)
Figure 48 EX1402349
A
3 Rod
2
When installing
• Length (A): 684 mm 1
• Torque (2 nut): 49 N.m (5 kg.m, 36.2 ft lb) EX1402872
Figure 49
15. Loosen the main control valve mounting bolts from valve
mounting bracket. (bolt: 4 ea) (Figure 50)
NOTE: Do not remove bolts completely to hold the
position of control valve.
• Tool: 24 mm ( )
• Torque: 264.6 N.m (27 kg.m, 195.2 ft lb)
16. Open the engine cover and remove bolts and washers (1,
Figure 51) (4 ea) with cover (2).
2
• Tool: 19 mm ( )
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
• Cover weight: 9 kg (20 lb)
1
Figure 51 WE1400835
Figure 52 EX1404086
DR2
pcc
ps2 T2
A8
pc2 B8
A7
B7
A6
B6
P2
Right Side View
WE1401092
Figure 53
pb9
pb5
pb8
pb4
pb7
pb3
pb6
pb1
DRtp
Front View
WE1401093
Figure 54
pc1
B5
A3
B3
PT
B1 PA
A1
P1
Left Side View
WE1401094
Figure 55
pa9
pa4
pa8
pa3
pa7
pa6
PP
ptp
pa1
PH
Rear View
WE1401095
Figure 56
pa3 from Joint Plate Assembly "A7" UNF 11/16"-16-2B 22 38.2 3.9 28.2
from Joint Plate Assembly "A10" UNF 11/16"-16-2B 22 38.2 3.9 28.2
pa4
Connect with "pa8" UNF 11/16"-16 22 38.2 3.9 28.2
from Joint Plate Assembly "A8" UNF 11/16"-16-2B 22 38.2 3.9 28.2
pa5
Connect with "pa9" UNF 11/16"-16 22 38.2 3.9 28.2
pa6 from Joint Plate Assembly "A9" UNF 9/16"-16-2B 19 25.5 2.6 18.2
pa7 from Joint Plate Assembly "A6" UNF 11/16"-16-2B 22 38.2 3.9 28.2
Connect with Pilot Valve "T" UNF 11/16"-16-2B 22 38.2 3.9 28.2
DR1
to Oil Tank UNF 9/16"-16-2B 19 25.5 2.6 18.2
to Swing Device "PG" UNF 9/16"-16-2B 19 25.5 2.6 18.2
PP
to Solenoid "P2" UNF 9/16"-16-2B 19 25.5 2.6 18.2
PH to Solenoid "PL" UNF 9/16"-16-2B 19 25.5 2.6 18.2
Top View
WE1401096
Figure 57
• Fitting
Size
Port Name
A B
2180-1026D23
T1 O-ring
(ID: 37.69, W: 3.53, 1B)
* A: Opposite side of hose, B: Hose side
WE1401097
Figure 58
IMPORTANT
Make sure there are no other electrical wires or hoses
connected to valve.
WE1401098
Figure 59
WARNING
INCORRECT INSTALLATION CAN CAUSE DEATH OR
SERIOUS INJURY
Any change in the connections will lead to malfunctions
(e.g. lift instead of lower).
• When connecting hydraulic components, observe the
specified piping according to the hydraulic schematic
diagram of the machine.
IMPORTANT
After completing the work, check the oil level. Start the
engine and check for any oil leaks.
WE1401098
2. Be careful not to apply stress on control valve when Figure 60
attaching piping and hoses. Unnecessary stress can cause
spools to bind and the control valve from functioning
properly.
3. Tighten the assembling bolts alternately and evenly to the
specified torque.
4. If welding procedures are being performed near the control
valve, the valve could be damaged by weld spatter and
heat. Use adequate shielding to protect valve.
5. Valve ports must be covered with caps, plugs or tape to
protect them from dust and other foreign materials, until
pipe laying work is started.
COMPLETING WORK
1. If the hydraulic oil in the oil tank was removed, refill the
hydraulic oil tank.
2. Start the engine and run at low idle for about 5 minutes.
3. Operate the joystick lever and actuate the hydraulic
cylinder 4 ~ 5 times very slowly, about 100 mm before the
end of stroke.
4. Operate the rod of cylinder to the end of stroke to relieve
the hydraulic piping.
(The air breather of oil tank is actuated to bleed the air)
Cautions on Disassembly
1. On a level surface, place the main equipment on a level
surface and place all other working devices on the ground.
Ensure that neither the traveling nor the swing motion is
self-activated.
Stop engine and release the pressure from all actuators.
WARNING
AVOID DEATH OR SERIOUS INJURY
If the valve assembly is replaced or the valve is
disassembled under pressurized conditions, high-
pressure oil can be released suddenly or parts can be
ejected. When disassembling, fully lower bucket (or
attachment) and fully release all hydraulic oil pressure.
Main Spool
1
1. Remove socket head bolt (65, Figure 61), and disassemble 12 65
the long cap (11).
11
Take the O-ring (12) out from the groove of the valve Arm 2
housing. Boom 1
Bucket
• Tool: 6 mm ( ) Dozer
Travel
Priority
65
Arm 1
Boom 2
Swing
12 Option
Travel
11 WE1400949
Figure 61
• Tool: 5 mm ( )
3. Pull out each spool from the valve housing, keeping it as a
66
subassembly.
IMPORTANT
65
When extracting the spool, pull it out straight so as to 13
avoid any bruise or scratch. Bruises or scratches on 12
the spool may make a dent on the body hole, and the
spool may not fit into the body hole at the time of re- Figure 62 WE1400950
assembling. Also, even if the spool fits into the body
hole, it may cause operational failure.
Each spool should be clearly marked with a tag so as
to avoid inserting a spool in a wrong position at the
time of re-assembling. Inserting a spool into a wrong
position will result in operational failure of the actuator
which is extremely dangerous.
• Tool: 6 mm ( )
70~100
result in performance and durability degradation due
to heat-deformation of the spring, and therefore the
spring must be replaced with a new one. Also, be alert
that touching, with a bare hand, the heated spool
bearing a high temperature will result in a burn.
FG001316
Figure 64
IMPORTANT 45
43
44
When disassembling the spool assembly, pinch the 43
spool with a tightening wood, securing the whole thing 41
WE1400952
in a vise while working on it, so as not to harm the
Figure 65
spool. When pinching the spool, pinch it at the end, i.e.
as close to the spool end as possible, in order to avoid
bending the spool itself.
Adhesive agent is applied to the screw area of the
spool end. Heat the outer periphery of the spool at the
screw area with an industrial dryer until the spool end
can be easily tightened. (As a rough indication, the
heating temperature should be 200 ~ 250 °C (392 ~ 482
°F).) In case the spool is excessively heated, it will
result in performance and durability degradation due
to heat-deformation of the spring, and therefore the
spring must be replaced with a new one. Also, be alert
that touching, with a bare hand, the heated spool
bearing a high temperature will result in a burn.
49
WE1400953
Figure 66
67
IMPORTANT 27
28
29
When disassembling this part with the control valve 31
remained attached to the vehicle body, there is a 67
possibility that parts may jump out due to the internal
residual pressure. Remove socket head bolt (67)
30
slowly, make sure there is no more resistance caused WE1400954
by the internal residual pressure, and then proceed Figure 67
with disassembling.
IMPORTANT
When disassembling this part with the control valve
remained attached to the vehicle body, there is a
possibility that parts may jump out due to the internal
residual pressure. Remove plug slowly, make sure
there is no more resistance caused by the internal
residual pressure, and then proceed with
disassembling.
19
16
17
18
19
WE1400955
Figure 68
• Tool: 8 mm ( ) 36
2. Take out the sleeve (33, Figure 69), the spring (35) (37), 33
and the poppet (34) (36). 35
34
IMPORTANT
At this point, take care not to drop the spring in the
passageway. Should the spring fall in the passageway, WE1400956
a fragment taken into the spool sliding part could Figure 69
possibly cause the spool to stick and cause the
actuator to go out of control, that is, it cannot be
stopped.
Figure 70 WE1400957
• Tool: 27 mm ( )
2. Take out the spring (17, Figure 71) and the poppet (16).
19
16
17
18
19
WE1400958
Figure 71
WE1400959
Figure 72
Relief Valve
1. Remove overload relief valve (63, Figure 73) from the main
body and the spool section of the add-on.
• Tool: 32 mm ( )
63
WE1400960
Figure 73
63
63
WE1400961
Figure 74
62
WE1400962
Figure 75
3. Take out the negative control relief valve (55, Figure 76)
from the main body.
• Tool: 32 mm ( )
IMPORTANT
55
The relief valve itself is not meant for disassembling.
Please note that disassembling/assembling/adjusting
it will void the warranty.
55
WE1400963
Figure 76
Other Plugs
1. Disassemble the plug assembly (20, Figure 78) of the (PP) 32
port, and remove O-ring.
21
• Tool: 19 mm ( )
2. Disassemble the PF1/8 sized plugging plug (21), and
remove O-ring.
• Tool: 5 mm ( )
3. Disassemble the PF3/8 sized plugging plug (32), and
remove O-ring. 69
• Tool: 8 mm ( )
32
4. Disassemble the PF1/2 sized plugging plug (69, Figure 21
WE1400964
77), and remove O-ring.
Figure 77
• Tool: 10 mm ( )
21
22
18
20
WE1400965
Figure 78
Add-on Section
74 72
1. Loosen and remove hexagonal nut (72, Figure 79) and
(74).
73 71
• Tool: 19 mm, 22 mm ( )
2. Pull out the outlet housing (61, Figure 79).
61
3. Remove main body mating surface O-rings (59) (60).
59
4. Remove tie rods (71) (73), and take it out from the main 60
body housing (1). 60
(Use a pipe wrench etc.)
1
IMPORTANT
WE1400966
When pulling out the add-on section, take care not to Figure 79
make a dent or a scratch on the mating surface. If
there is a dent or a scratch, oil leaking from the mating
surface could possibly cause operational malfunction.
Also take extreme care not to let the oil passage get
contaminated with foreign particles. Should it get
contaminated, a fragment taken into the spool sliding
part could possibly cause the spool to stick, and the
bad sheet of the load check could possibly cause the
actuator to go out of control, that is, it cannot be
stopped.
Cleaning
Thoroughly wash all the disassembled parts with clean oil.
Dry all parts with compressed air, and place them on clean
pieces of sheet or vinyl in order to inspect them.
Inspection
Check each part to see if there is any burr, scratch, or any other
defect on all surfaces.
1. Check to see if there is any scratch or dent or dust or cavity
on the surface of the load check sheet of the valve
housing. If there is a small scratch, remove it using an
oilstone.
2. Check and make sure there is no scratch or dent on the
outer periphery of the spool. If there is a small scratch,
remove it using an oilstone.
3. All sliding parts must move smoothly, and there must not
be any foreign particle in all grooves and passageways.
4. Change the spring if any of them is damaged or
excessively deformed or worn out.
5. When the relief valve does not function well, follow
"Adjusting Relief Valve" on page -5-7-80 (Maintenance
guideline for the relief valve) to carry out an inspection
procedure.
6. All the O-rings and backup rings yielded from the
disassembled parts must be replaced with new ones.
7. Check and make sure there is no paint fragment remained
around the body hole or around the plug bearing surface
after removing the cap or the plug. (If paint fragments get
inside the valve, it would cause jamming or clogging which
would result in operational malfunction or oil leakage.)
Caution on Assembly
CAUTION
AVOID INJURY
When working with Loctite, work in a place that is well
ventilated.
4. Interval of hardening
To get firm joint, leave tightened parts following hours in the air.
• Atmosphere temperature 40°C: over 3 hours
• Atmosphere temperature 22°C: over 8 hours
• Atmosphere temperature 5°C: over 24 hours
IMPORTANT
Shortage of hardening interval may cause luck of joint
strength DO NOT use "Loctite Primer T".
This leads less joint strength than normal dry.
IMPORTANT 2
3 4
Arm 1
Boom 2
Swing
Take care not to let the adhesive agent drip out when 12 Option
tightening the spool end with a lot of adhesive agent 11 Travel
applied on it. When working on the spool, pinch it at WE1400969
the end, i.e. as close to the spool end as possible, in Figure 80
order to avoid bending the spool itself with the
tightening torque. And, if the tightening torque is too
large, swelling of the spool could possibly cause the
spool to stick and cause the actuator to go out of
control, that is, it cannot be stopped.
From here on, refer to this note when using adhesive
agent.
IMPORTANT
Note that the springs for the boom 2 spool (5) and the
travelling priority spool (10) are different from those
for other parts. Combining a wrong spring to a spool
could possibly cause operational failure of the
actuator.
IMPORTANT
Watch out for the installing positions of the O-ring and
the backup ring. If they are installed in the opposite
positions, the O-ring could be cut, which could
possibly result in operational failure.
• Tool: 5 mm ( )
• Torque: 19 ~ 22 N.m (1.9 ~ 2.2 kg.m, 14 ~ 16.2 ft lb)
45
43
44
43
41
WE1400952
Figure 81
52A
WE1400967
Figure 82
4. Install the socket head bolt (67) in the body assembly (30),
and fasten it.
• Tool: 6 mm ( )
• Torque: 20 ~ 25 N.m
(2.0 ~ 2.6 kg.m, 14.8 ~ 18.4 ft lb)
Control Valve
Add-on Section
74 72
1. Attach the tie rods (71, Figure 84) (73) to the main body
valve housing (1).
73 71
IMPORTANT
61
Tighten the tie rod all the way to the effective screw- 59
depth. If the screw part is not sufficiently fastened, oil 60
could leak from the mating surface, due to insufficient 60
clamping force on the add-on section, which could
possibly result in operational failure. 1
2. Attach the O-rings (59, Figure 84) (60) on the main body
mating surface.
IMPORTANT
Since oil leakage from the mating surface could cause
operational failure, take care not to make a dent or a
scratch on the mating surface when installing the add-
on section. Also watch out for foreign particles getting
inserted in the mating surface and the O-ring falling off
and sticking out.
IMPORTANT
When installing the add-on section, always install the
tie rod first and use it as a guide to determine the
mounting position. If the mounting position is
determined without using the tie rod, the O-ring of the
mating surface could stick out causing oil leakage
which, in turn, could possibly result in operational
failure.
4. Install hexagon nut (74) on the tie rod (73), and fasten it.
• Tool: 22 mm ( )
• Torque: 152 ±7 N.m (15.5 ±0.7 kg.m, 112.1 ±5.16 ft lb)
Install hexagon nut (72) on the tie rod (71), and fasten it.
• Tool: 19 mm ( )
• Torque: 93 ±4 N.m (9.5 ±0.4 kg.m, 68.6 ±3 ft lb)
IMPORTANT
The torque used for screwing the hexagonal nut must
be within the prescribed torque. If the tightening
torque is too small, oil could possibly leak out from the
mating surface due to insufficient clamping force. If,
on the other hand, the tightening torque is too large,
the spool could stick, due to deformation of the valve
housing for the spool section, which could possibly
cause the actuator to go out of control, that is, it
cannot be stopped.
The two pieces must be screwed in alternately so that
they can be evenly screwed in.
WE1400958
Figure 85
IMPORTANT WE1400956
Figure 86
When installing the flange (39), the spring (37) must
properly stay within the locus on the flange. If it does
not stay within the locus on the flange, the spring
could get damaged.
When tightening the socket head bolt (68), tighten the
two pieces alternately so that they can be tightened
evenly. From here on, refer to this note when
tightening flanges.
WE1400955
Figure 88
• Tool: 8 mm ( ) 57
WE1400959
Figure 89
63
WE1400960
Figure 90
63
63
WE1400961
Figure 91
2. Screw in the main body main relief valve (62, Figure 92),
and fasten it.
• Tool: 32 mm ( )
• Torque: 78 ~ 88 N.m (8 ~ 9 kg.m, 57.5 ~ 65 ft lb)
62
WE1400962
Figure 92
55
WE1400963
Figure 93
Assembly Sub Spool for Swing Priority and Center Bypass Cut
45
43
1. Install the spool assembly (41, Figure 94) (48) into the 48A 44
same position where it was before disassembling. 43
48
41A
45
43
44
43
41
WE1400952
Figure 94
2. Install the cap (46, Figure 95) (47) which has the O-ring 66
47
(42) attached to it. 46
Insert the socket head bolt (66) in the cap, and fasten it. 42
• Tool: 5 mm ( )
• Torque: 8.8 ~ 10.5 N.m (0.9 ~ 1.1 kg.m, 6.5 ~ 7.7 ft lb)
66
IMPORTANT
The spool must be inserted slowly and straight with 65
respect to the direction of the hole. After the spool is
13
inserted, slide the spool with a hand and make sure 12
there is no unsmoothness or raggedness. If the spool
is inserted under an unsmooth and ragged condition, WE1400950
it could possibly result in operational failure of the Figure 95
spool.
From here on, refer to this note when inserting spools.
49
WE1400953
Figure 96
65
13
12 WE1400970
Figure 97
• Tool: 5 mm ( )
69
• Torque: 13.5 ~ 16.5 N.m
(1.4 ~ 1.7 kg.m, 10 ~ 12.2 ft lb)
32
3. Tighten the plug assembly (22, Figure 100) which has the 21
WE1400964
O-ring mounted on it.
Figure 99
• Tool: 27 mm ( )
• Torque: 103 ~ 113 N.m
(10.5 ~ 11.5 kg.m, 76 ~ 83.4 ft lb)
4. Tighten the plug assembly (69, Figure 99) (78-2) which has
the O-ring mounted on it.
• Tool: 10 mm ( ) 32
IMPORTANT WE1400965
Figure 100
After assembling is completed, make sure there is no
part that was once disassembled that you forgot to
include in the assembling procedure. Also make sure
there is no screw that you forgot to fasten. If there is
an unfastened screw, loosened parts could cause oil
leakage.
All the prescribed torque values are meant for “Wet
Condition”, that is they are to be used under
conditions where hydraulic oil is applied to the
mechanism.
Troubleshooting
Relief Valve
IMPORTANT
Move the spool of the actuator. The set pressure of the
overload relief valve is higher than that of the main
relief valve actuator spool.
IMPORTANT
If the set pressure is higher than that of the main relief
valve, it will be activated during the following adjustment. It
is not possible to adjust the overload relief valve. Do not
disassemble or adjust it. Replace with a complete new set
of assembled relief valves.
Edition 1
Swing Device
Safety Instructions ..........................................5-8-5
General ...........................................................5-8-5
Specification .............................................................. 5-8-5
Overview ................................................................... 5-8-6
Parts List ................................................................... 5-8-8
Theory of Operation ................................................ 5-8-12
Cautions for Operation ............................................ 5-8-20
Removal .......................................................5-8-23
Installation ....................................................5-8-28
Completing work ...........................................5-8-28
Precaution ....................................................5-8-29
Tools for Disassembly and Assembly ..................... 5-8-29
Tightening Torque ................................................... 5-8-29
Disassembly .................................................5-8-31
Swing Device........................................................... 5-8-31
Swing Motor ............................................................ 5-8-32
Swing Reduction Gear ............................................ 5-8-37
Reassembly ..................................................5-8-41
Swing Motor ............................................................ 5-8-41
Swing Reduction Gear ............................................ 5-8-46
Troubleshooting ............................................5-8-51
General Instructions ................................................ 5-8-51
Examination of Hydraulic Motor .............................. 5-8-51
Troubleshooting....................................................... 5-8-52
Maintenance Instructions..............................5-8-55
Replacement Standard of Worn Parts..................... 5-8-55
Standard of Sliding Surface Correction ................... 5-8-55
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
Specification
Swing Motor
Pinion Gear
Parking Brake
DB C Pa Pb
Air Breather
B
PG
SH
Dr
WE1401361
Figure 1
RED
PG
DB
C
PA PB
A B
WE1401362
Figure 2
Swing Motor
30
31
39 33
2
25
24 17
23
37
13
26
23
28 24 9
25
5
12
22 11
21 8
20
29 7
27
4
3
19
18
6
36
16 35
15 14
38
34
32
1
Figure 3 WE1401432
*: 6, 27, 28, 29
28
29
18
5
20 25
23
26
19
12
27
14
16
19 1
27
24
9
3
19
17
6
15
24
11
21
8
13
19
WE1401433
Figure 4
Hydraulic Motor
As shown in the figure below, the high-pressure oil entering the
cylinder block through valve plate (112) inlet side port exerts
pressure on the piston, generating axial force F. The force F is
divided into the two vectors of force F1 which is perpendicular to
the swash plate (103) and F2 which is perpendicular to the shaft,
with the shoe (104-1) as the medium. With the piston and the
medium, the force F2 is transmitted to the cylinder block (108)
and generates rotational torque to the output shaft. On the
cylinder block, 9 pistons are arranged equidistantly, and
rotational torque is transmitted to the output shaft by the multiple
pistons connected to the inlet side of the high-pressure oil in
consequences.
Reversing the direction of oil flow will reverse the direction of
rotation of the output shaft.
Theoretical output torque T is calculated with the formula below;
Pxq
T=
2xπ
103 112
Low Pressure Hyd. Oil High Pressure Hyd. Oil
EX1301620
EX1301686
Figure 6
2. Relief valve
Lets assume that port P is pressurized from the tank
pressure. Initially, ports P and R are at tank pressure.
321 302 h g
R Port
P Port
A1 m 301 A2 n 401
EX1403242
Figure 7
Fsp + Pg x A2
P1 =
A1
321 g
R Port
P Port
A1 301 A2
Figure 8 EX1301687
321 302 h g
R Port
P Port
n 401
Figure 9 EX1403527
Fsp'
Ps =
A1 - A2
302 g
R Port
P Port
Pressure: Ps 401
Pressure
Ps
P1
Time
Operational Diagram
EX1403528
Figure 10 Relief Valve
Motor Inlet
A Port Bypass Motor Outlet
B Port
(1)
(2)
(3)
EX1301726
Figure 11 Principle of Operation of Reactionless Valve
1st 2nd
A B A B
Swing Swing Stop (Start of Stop)
3rd 4th
By Pass
A B A B
Swing Stop (before the Stop) Swing Stop (Complete of Stop)
EX1301690
Figure 12
Oil Pressure
Spring Force
21
20
Oil Chamber
19
18
3 17
WE1401363
Figure 13 Operation Diagram of Brake
Oil Chamber SH
PG
PG DB
Friction Plate
Separation
Plate
SH WE1401364
Figure 14
Oil Chamber SH
PG
PG DB
Friction Plate
Separation
Plate
SH WE1401365
Figure 15
Inspection
Please check the followings before installing a new motor:
1. Check if there is any part damaged or missing (during
transportation).
2. Check if there is any loose joint.
3. Check that flange surfaces and the drain port cover are
properly assembled and there is no dust or other particle in
the motor.
Direction of Rotation
The relationship between the directions of oil flow and shaft
rotation is presented in Figure 16 and Table.
The direction of rotation differs by the direction of the slope of
casing.
Be careful for the direction of swing which is differentiated by the
shape of casing and direction of flange.
750
500
400
300
150
100
75
Viscosity in cSt
50
40
Optimum Working Range
30
25
20
15
10
9 Low Viscosity Limit
8
7
6
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 C
-20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 F FG018906
Figure 17 Optimum Viscosity and Temperature Range
WARNING
AVOID DEATH OR SERIOUS INJURY
Contact with hydraulic fluid can harm your health. (e.g. eye
injuries, skin damage or poisoning, if inhaled).
• While performing removal and installation, wear safety
gloves, safety glasses and suitable working clothes.
• If hydraulic fluid should come into contact with your
eyes or penetrate your skin, consult a doctor
immediately.
WARNING
FIRE CAN CAUSE SERIOUS INJURY OR DEATH
Hydraulic fluid is highly flammable.
• Keep open flames and ignition sources away from the
workplace.
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants, grease,
etc. must be disposed of in an environmentally safe
manner. Some regulations require that certain spills and
leaks on the ground must be cleaned in a specific manner.
See local, state and federal regulations for the correct
disposal.
LOCK
WARNING WARNING
DO NOT OPERATE
AVOID DEATH OR SERIOUS INJURY when performing inspection
or maintenance
WE1400464
Figure 22
ON
Figure 23 EX1401760
1 2
7 6
4
EX1401809
Figure 24
WARNING
AVOID DEATH OR SERIOUS INJURY
Release any pressure in the hydraulic oil tank before
doing any work.
15. Loosen the oil tank air breather slowly to release the
pressure inside the hydraulic oil tank.
Pulling the breather cap upward, the check valve (0.45 bar) Figure 25 WE1400562
opens, and the air is discharged to the atmosphere from
the top of the hydraulic oil tank.
16. Disconnect harness from the swing device.
Figure 26 WE1401448
EX1402340
Figure 27
A
C
PG
Dr(RG)
B
DB N
SH
Sgr
Figure 28 WE1401449
• Fitting
Size Torque
Port Name
A B (C) (mm) N.m kg.m ft lb
C Adapter PF 3/4" UNF 1 3/16"-12 36 166.6 17 122.9
DB Tee PF 3/8" UNF 13/16"-16 22 73.5 7.5 54.2
PG Elbow PF 1/4" UNF 9/16"-18 19 36.3 3.7 26.8
Tee PF 1/4" UNF 9/16"-18, PF 1/4" 19 36.3 3.7 26.8
SH
Reducer PF 1/4" PF 1/4" 19 39.2 4 28.9
Sgr Adapter PT 1/8" PF 1/4" 17 14.7 1.5 10.8
Dr (RG) Adapter PT 1/2" PF 1/2" 27 49.0 5 36.2
2180-1026D30
A, B O-ring
(ID:18.64, W:3.53, 1B)
C O-ring S8000235 (4D P22.4) S8030125 (4D F-12)
DB O-ring S8000145 (4D P14) S8030081 (1B F-08)
2180-1216D11
PG O-ring S8000115 (4D P11)
(ID: 7.65, W: 1.78, 1B)
2180-1216D11,
SH O-ring S8000115 (4D P11)
S8000115 (4D P11)
* A: Opposite side of hose, B (C): Hose side
Figure 29 WE1401450
• Tool: 24 mm ( )
• Torque: 265 N.m (27 kg.m, 195 ft lb)
21. Remove plugs (2, Figure 30) (2 ea).
22. Install the back bolt to the plug position to ensure that
frame and swing device can be separated.
23. Hoist and remove swing device from the frame.
1 2
NOTE: When hoisting the swing device one part of
swing device will contact with the main frame. Figure 30 WE1401451
Hoist the swing device a little and push to the
front side while hoisting slowly.
24. Wind wire rope around the swing device, lift it up with a
crane and wash with flushing oil.
After washing, dry with compressed air.
• Weight: about 122 kg (269 lb)
WE1401452
Figure 31
WARNING
INCORRECT INSTALLATION CAN CAUSE DEATH OR
SERIOUS INJURY
Any change in the connections will lead to malfunctions
(e.g. lift instead of lower).
• When connecting hydraulic components, observe the
specified piping according to the hydraulic schematic
diagram of the machine.
COMPLETING WORK
IMPORTANT
If air is not vented from system, it will cause damage to
swing motor and bearings.
Table 2
Specification
Size
Tools
Pliers for stop ring For ø30 shaft
Driver Flat tip, 2 pcs.
Steel Rod Approximately 10 x 8 x 200. 1 pc.
Hammer Plastic and metal hammers, 1 each
Torque adjustment range
• for 100 ~ 450 kg.cm
Torque Wrench
• for 400 ~ 1,800 kg.cm
• for 1,200 ~ 4,800 kg.cm
Slide Hammer Bearing Pliers -
Brake Piston Puller See next page
Tightening Torque
Table 3 presents the tightening torque of the bolts used in the
hydraulic motor. Observe the specified torque when tightening
the bolts.
Table 3
2 x o7
40
M10
(Effectiveness Screw Length: 20)
100
250
o11
M10
o9 M10
o134
o240
WE1400556
Figure 33 Tools for Brake Piston Disassembly
Swing Device
Please use the following procedures for the inspection and
repair of the device.
Numerals given in parentheses following the parts names
indicate the parts number shown by the parts list.
1. Wind wire rope around the swing device, lift it up with a
crane and wash with flushing oil.
After washing, dry with compressed air.
FG026258
Figure 34
Reduction
Gear
WE1401368
Figure 35
WE1401369
Figure 36
37
WE1401370
Figure 37
• Tool: 12 mm ( )
25 24
23
WE1401371
Figure 38
• Tool: 10 mm ( ) 39
2
WE1401372
Figure 39
• Tool: 14 mm ( )
WE1401373
Figure 40
8. Remove brake springs (21) (22 ea) from the brake piston
21
(20).
20
WE1401374
Figure 41
WE1401375
Figure 42
17
WE1401376
Figure 43
17
WE1401398
Figure 44
11
12
13
17
WE1401397
Figure 45
12. Pull out friction plate (18) (3 ea) and separation plate
(19) (3 ea) from casing (1).
18
19
1
WE1401377
Figure 46
27
WE1401378
Figure 47
WE1401379
Figure 48
15. Fix the casing (1) flat, and extract the retaining ring (36)
from the driveshaft (3) with a pair of pliers.
1
36
3
WE1401380
Figure 49
WE1401382
Figure 51
WE1401383
Figure 52
WE1401384
Figure 53
26
WE1401385
Figure 54
26
WE1401386
Figure 55
WE1401387
Figure 56
FG026213
Figure 57
WE1401388
Figure 58
FG026215
Figure 59
WE1401389
Figure 60
8. Connect the eyebolts in the two M16 bolt holes on the top
to pull the ring gear (7) out. 7
WE1401390
Figure 61
WE1401391
Figure 62
WE1401392
Figure 63
21
WE1401393
Figure 64
Shaft subassembly
WE1401394
Figure 65
3 6
WE1401395
Figure 66
WE1401396
Figure 67
Swing Motor
Use care with the following instructions.
1) After disassembly, make sure to repair damaged
parts and prepare the parts to be replaced.
2) Wash all the parts with clean washing fluid and dry
with compressed air.
3) Apply clean hydraulic oil on the sliding surfaces and
bearings.
4) Replace O-rings and oil seals, which is a principle.
5) Tighten screws, bolts and plugs at specified torque
using a torque wrench.
1. Place casing (1) on the work table.
WE1401399
Figure 68
WE1401382
Figure 69
3. Insert the driveshaft (3), roller bearing (4) into casing (1).
1
WE1401381
Figure 70
36
3
WE1401380
Figure 71
WE1401379
Figure 72
17
WE1401397
Figure 73
17
WE1401398
Figure 74
17
WE1401376
Figure 75
19
1
WE1401377
Figure 76
27
WE1401378
Figure 77
WE1401375
Figure 78
20
WE1401374
Figure 79
13. Assemble the O-ring (28) and the spring pin (26) into the
casing (2).
28
Care shall be exercised to protect the casing (2) surface
from scratching when assembling the spring pin (26). 26
WE1401385
Figure 80
WE1401384
Figure 81
Mount the valve plate with its round part toward the
opposite side of the flange. 2
Coat lightly with grease.
WE1401383
Figure 82
• Tool: 14 mm ( ) 30
• Torque: 235 ±35 N.m (24 ±3.6 kg.m, 173 ±26 ft lb) 2
WE1401373
Figure 83
17. Insert the reactionless valve (39) into the valve casing (2),
and fasten the RO plug (39) with the specified torque.
• Tool: 10 mm ( ) 39
• Torque: 108 ±9.8 N.m (11 ±1 kg.m, 80 ±7 ft lb) 2
WE1401372
Figure 84
18. Insert the plunger (23) and the spring (24) into the valve
casing (2), and fasten the RO plug (25) with the specified 2
torque.
• Tool: 12 mm ( )
25 24
• Torque: 127 ±9.8 N.m (13 ±1 kg.m, 94 ±7 ft lb) 23
WE1401371
Figure 85
WE1401370
Figure 86
WE1401400
Figure 87
WE1401396
Figure 88
3. Insert cover (6) into the pinion shaft (2) and press fit the
spherical roller bearing (3) using a press.
3 6
WE1401395
Figure 89
Shaft subassembly
WE1401401
Figure 90
21
WE1401393
Figure 91
6. Insert the cylindrical roller bearing (4) into the casing (1)
using a press.
4
WE1401402
Figure 92
WE1401392
Figure 93
WE1401391
Figure 94
WE1401403
Figure 95
10. Checking the position pin (25), assemble the ring gear (7)
with the casing (1). 7
WE1401390
Figure 96
11. Tighten the hex socket bolts (28) from ring gear (7).
7
• Tool: 6 mm ( )
28
• Torque: 19.6 N.m (2 kg.m, 14.5 ft lb)
WE1401389
Figure 97
15
13
19
WE1401404
Figure 98
13. Install the planet gear (15) into the carrier No.2 (8), and
assemble No. 2 pin (11).
11
Through these procedures, assemble the 4 planet gears.
15
24
WE1401405
Figure 99
FG026215
Figure 100
WE1401388
Figure 101
24
WE1401406
Figure 102
FG026213
Figure 103
WE1401387
Figure 104
General Instructions
This section provides the corrective actions against any
abnormality identified during hydraulic motor operation.
General instructions are as follows:
1. Think before taking action
Before taking any action, examine the characteristics of the
problem, and if there had been similar trouble before.
In addition, examine once again that cause of the problem
is the hydraulic motor.
2. Take care of foreign material
Foreign materials cause abnormal friction and wear. Take
care to avoid foreign materials during disassembly and
reassembly.
3. Parts handling
All the parts are precisely ground, thus, take utmost care
not to damage.
4. Take care not to damage O-rings and gasket surfaces.
It is highly recommended to replace with new O-rings after
disassembly.
Standard Replacement
Item Corrective Action
Dimension (mm) Criteria (mm)
Clearance between the piston and Replace the piston or
0.028 0.058
cylinder block cylinder block
Clearance between the piston and Replace the piston or
0 0.3
shoe compressed part (δ) shoe assembly
Replace the piston or
Shoe thickness (t) 5.5 5.3
shoe assembly
Assembled height of the retainer Replace the retainer and
6.5 6
plate and spherical bushing (H-h) spherical bushing set
Friction plate thickness 4 3.6 Replace
H
h
t
Piston and shoe clearance between the piston and shoe ( ) Assembled height of the retainer and spherical bush (H-h)
Shoe thickness (t)
FG019002
Figure 105
Edition 1
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
Specifications
Max. Primary Pressure 49 bar (50 kg/cm2, 711.1 psi)
Max. Back Pressure 2.9 bar (3 kg/cm2, 42.7 psi)
Rated Flow 20 L/min (5.3 U.S. gal)
Continuous Rated Current of Switch DC30 V x 6 A
Internal Leakage Oil Temperature 50 ±5°C (122 ±41°F)
Neutrality 30 ~ 150 cc
At Work (15 kg/cm2) 30 ~ 400 cc
Performance
Port 1, 3 Port 2, 4
40 40
Secondary Pressure (kg/cm2)
28 1.5 28 1.5
Single Operating Torque Single Operating Torque
(17.6) (17.9)
14.6 3 14.6 3
6.5 1 6.5 1
4.5 2 4.5 2
Secondary Pressure Secondary Pressure
0 1 2 3 4 5 6.5 7 0 1 2 3 4 5 6 7.5 8
P1
S2
P1
S3
S2
S1
S1
ingle
21.5 S
, 4)
(Port 2 S3
gle
19 Sin 25
, 3) Do
(Port 1 ubl
e
4 4
1 P 1 P
T T
2 3 2 3
WE1400625
Figure 2
Switches
1. Push button switch
Switch 1 White White
Switch LH RH
Switch 2 Yellow Yellow
Breaker/Booster
S1 Horn Button Switch 3 Green Green
Button
Intelligent Floating EX1301712
One Touch Figure 3
S2 Boom Temporary
Deceleration Button
Reset Button
S3 Spare Button Spare Button
2. Proportional switch
4 V (Right) Red ( 5 V)
Switch LH RH
Blue
P1 Rotating Switch Shear Switch (Signal)
WE1400626
Figure 5
Ports
P T
Port LH RH Size
1 Left Swing Bucket Crowd
2 Arm Dump Boom Down
3 Right Swing Bucket Dump
PF 3/8
4 Arm Crowd Boom Up
P Pilot Oil Inlet Pilot Oil Inlet
1 3 2 4
T Pilot Oil Return Pilot Oil Return
EX1301711
Figure 6
Handle (Left)
SPOOL
Handle (Right)
SPOOL
EX1403268
Figure 7
Structure
The joystick valve contains four push rods, spring seat, spools
and return springs, which are in the valve casing. Moves the
spool of the main control valve by reducing the pressure of the
pilot pump from a first pressure to a second pressure.
The housing has six ports, which include input port P, tank port
T, and four secondary pressure ports.
The electric horn button is installed in the valve handle.
Gear pump pressure is used for operating control spools.
Function
1. Neutral position
1
When the joystick lever is in the neutral state, the spool is
pressed upward by the return spring and the spring seat.
The P-port is blocked by the lower part of the spool, and 2
the 4 operation ports are connected to the T-port by the
upperpart of the spool.
Reference 3
Description
Number
1 Swash Plate 4
2 Push Rod 5
3 Balance Spring
4 Return Spring
5 Spool
EX1301707
Figure 8
2. Half-operated state
When the joystick lever is moved, the push rod moves
downward, and the force thereof is transferred to the spool
through the spring seat and the control spring. When the
spool moves, the first pressure is transferred to the
operation ports through the spool.
When the lever spring stops in the halfway position, the
force of the compressed spring and the hydraulic pressure
caused by the second pressure applied upward because of
the difference in area of the upper and lower ends of the
spool create a state of equilibrium, and this pressure is
transferred to the spool of the control valve. That is, the
first pressure is transferred to the operation ports through
the spool as a hydraulic pressure (second pressure)
corresponding to the force of the compressed control
spring. EX1301708
Figure 9
EX1301709
Figure 10
Reference Torque
Description Tool
Number Nm kg.m ft lb
2 Plug 36.3 3.7 27 PT1/8 ( )
22 Swash Plate 162.8 16.6 120 27 mm ( )
23 Hex Nut 162.8 16.6 120 22 mm ( )
24 Nut 162.8 16.6 120 22 mm ( )
25-2
25-1
27
25
24 28
26
23
21
20
22 12
11
30
18
19
16
10 13
29 17
15
14 8
7
13
6
5
5
4 9
3
1
2 EX1403269
Figure 11
WARNING
AVOID DEATH OR SERIOUS INJURY
Contact with hydraulic fluid can harm your health. (e.g. eye
injuries, skin damage or poisoning, if inhaled).
• While performing removal and installation, wear safety
gloves, safety glasses and suitable working clothes.
• If hydraulic fluid should come into contact with your
eyes or penetrate your skin, consult a doctor
immediately.
WARNING
FIRE CAN CAUSE SERIOUS INJURY OR DEATH
Hydraulic fluid is highly flammable.
• Keep open flames and ignition sources away from the
workplace.
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants, grease,
etc. must be disposed of in an environmentally safe
manner. Some regulations require that certain spills and
leaks on the ground must be cleaned in a specific manner.
See local, state and federal regulations for the correct
disposal.
WE1401483
Figure 12
WARNING
LOCK
WARNING
AVOID DEATH OR SERIOUS INJURY DO NOT OPERATE
when performing inspection
WE1400464
Figure 14
ON
Figure 15 EX1401760
1 2
7 6
4
EX1401809
Figure 16
12. Loosen the oil tank air breather slowly to release the pressure
inside the hydraulic oil tank.
Pulling the breather cap upward, the check valve (0.45 bar)
Figure 17 WE1400562
opens, and the air is discharged to the atmosphere from
the top of the hydraulic oil tank.
13. Remove bolts (3 ea) and washers (3 ea) and remove arm
rest from bracket. (Right side)
Left side is same.
• Tool: 13 mm ( )
• Torque: 19.6 N.m (2 kg.m, 14.5 ft lb)
EX1301715
Figure 18
EX1301716
Figure 19
15. Remove rubber and screws, remove cover (1, Figure 20)
from stand upper cover, and disconnect the connector of
harness which connect with switches.
• Tool: Phillips screwdriver
1
EX1301717
Figure 20 Stand RH
1
4
Figure 21 Stand LH WE1400628
18. Remove screws (Figure 22) (4 ea), remove upper cover (1,
1
Figure 22) from bracket, and disconnect the connector of
harness which connect with switches.
Left side is same.
• Tool: Phillips screwdriver
EX1301719
Figure 22 Stand RH
EX1301720
Figure 23 Stand LH
4
EX1301721
Figure 24 Stand RH
1
2
3
4
EX1301722
Figure 25 Stand LH
4 4
P P
1 1
P
T T
2 3 2 3
2 1
• Fitting
Size Torque
Port Name
A B (mm) N.m kg.m ft lb
1, 2, 3, 4,
Adapter PF 3/8" UNF 11/16"-16 22 49 5 36.2
Left/Right P, T
Hand 1, 2, 3, 4, S8000145 S8030061
O-ring
P, T (4D P14) (1B F-06)
EX1403099
Figure 27
INSTALLATION
WARNING
INCORRECT INSTALLATION CAN CAUSE DEATH OR
SERIOUS INJURY
Any change in the connections will lead to malfunctions
(e.g. lift instead of lower).
• When connecting hydraulic components, observe the
specified piping according to the hydraulic schematic
diagram of the machine.
FG019382
Figure 28
FG018384
Figure 29
DISASSEMBLY
1. Remove lead wire from bushing (29).
FG000804
Figure 30
FG000805
Figure 31
FG000806
Figure 32
FG000807
Figure 33
FG000808
Figure 34
FG000809
Figure 35
FG000811
Figure 37
FG000812
Figure 38
FG000813
Figure 39
FG000814
Figure 40
FG000815
Figure 41
FG000816
Figure 42
FG000817
Figure 43
FG000815
Figure 44
FG000817
Figure 45
Figure 46 FG000814
FG000816
Figure 47
FG000819
Figure 49
FG000812
Figure 50
FG000820
Figure 51
FG000821
Figure 52
6. Assemble plug kit insert rod seal (18), O-ring (17), and
push rod (2) into plug (16) in proper order.
FG000822
Figure 53
FG000810
Figure 54
FG000809
Figure 55
FG000823
Figure 57
FG000808
Figure 58
FG000807
Figure 59
FG000806
Figure 60
FG000824
Figure 61
12. Install boot (20) and bushing (29) into case (1).
FG000825
Figure 62
FG000805
Figure 63
FG000826
Figure 64
FG000827
Figure 65
FG001097
Figure 66
FG000828
Figure 67
FG000829
Figure 68
Edition 1
Gear Pump
(Brake and Steering)
Safety Instructions ........................................5-10-5
General .........................................................5-10-5
General Description................................................. 5-10-5
Specification ............................................................ 5-10-5
Overview ................................................................. 5-10-6
Parts List ................................................................. 5-10-7
Removal .......................................................5-10-8
Installation ..................................................5-10-12
Completing Work ........................................5-10-13
Disassembly and Reassembly....................5-10-14
Disassembly .......................................................... 5-10-14
Reassembly........................................................... 5-10-16
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
General Description
This gear pump is installed onto the engine PTO (Power Take-
Off). It is driven by the engine to discharge oil.
This discharged oil is passed through the priority valve and is
delivered to the steering valve for steering operation. It is also
delivered to the brake supply valve, passing through the brake
filter for brake operation.
Also, as this pump is a fixed displacement type, not a variable
displacement type, it discharges a fixed amount of oil to the
brake side and steering side.
Specification
Brake Steering
Direction of Rotation
Clockwise
(Looking on Driveshaft)
Displacement 6.6 cc/rev 18.3 cc/rev
Inlet Pressure Range for Pump 0.7 ~ 3 bar (0.7 ~ 3 kg/cm2, 10.1 ~ 43.5 psi)
Max. Continuous Pressure (Rated) 250 bar (255 kg/cm , 3,626 psi)
2
200 bar (204 kg/cm2, 2,900 psi)
Max. Intermittent Pressure 280 bar (286 kg/cm2, 4,061 psi) 220 bar (224 kg/cm2, 3,190 psi)
Max. Peak Pressure 300 bar (306 kg/cm2, 4,351 psi) 240 bar (245 kg/cm2, 3,481 psi)
Weight 4.5 kg (9.9 lb)
Outlet (Brake)
WE1400629
Figure 1
Inlet WE1400630
Figure 2
1A
S
3 S
S 4
S : SEAL KIT
WE1400631
Figure 3
Reference Reference
Description Description
Number Number
1 Front; Section 3 Flange; Middle
1A Seal, Shaft 4 Bolt Set, Hex
2 Rear Assembly; Section S Seal Kit; Gear Pump
WARNING
AVOID DEATH OR SERIOUS INJURY
Contact with hydraulic fluid can harm your health. (e.g. eye
injuries, skin damage or poisoning, if inhaled).
• While performing removal and installation, wear safety
gloves, safety glasses and suitable working clothes.
• If hydraulic fluid should come into contact with your
eyes or penetrate your skin, consult a doctor
immediately.
WARNING
FIRE CAN CAUSE SERIOUS INJURY OR DEATH
Hydraulic fluid is highly flammable.
• Keep open flames and ignition sources away from the
workplace.
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants, grease,
etc. must be disposed of in an environmentally safe
manner. Some regulations require that certain spills and
leaks on the ground must be cleaned in a specific manner.
See local, state and federal regulations for the correct
disposal.
WE1400569
Figure 4
LOCK
WARNING WARNING
DO NOT OPERATE
AVOID DEATH OR SERIOUS INJURY when performing inspection
or maintenance
WE1400464
Figure 6
ON
Figure 7 EX1401760
1 2
7 6
4
EX1401809
Figure 8
12. Loosen the oil tank air breather slowly to release the
pressure inside the hydraulic oil tank.
Pulling the breather cap upward, the check valve (0.45 bar) Figure 9 WE1400562
opens, and the air is discharged to the atmosphere from
the top of the hydraulic oil tank.
13. Remove bolts and washers (1, Figure 10) (8 ea) with under
cover (2) on bottom of main frame.
1
• Tool: 19 mm ( )
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
2
• Under cover weight: 8 kg (17.6 lb)
Figure 11 WE1400709
• Fitting
Size Torque
Port Name
A B (C) (mm) N.m kg.m ft lb
P1 Adapter PF 1/2" UNF 13/16"-16 27 50.0 5.1 36.9
Adapter PF 1/2" UNF 13/16"-16 27 50.0 5.1 36.9
P2
Tee UNF 13/16"-16 UNF 13/16"-16 29 55.9 5.7 41.2
2180-1026D19
Inlet O-ring (ID: 32.92,
W: 3.53, 1B)
S8000185 S8030081
P1, P2 O-ring
(4D P18) (1B F-08)
15. Remove bolts (1, Figure 12) (2 ea) and washers with gear
pump (2) from engine.
• Tool: 8 mm ( )
Figure 12 WE1400710
WE1400711
Figure 13
INSTALLATION
WARNING
INCORRECT INSTALLATION CAN CAUSE DEATH OR
SERIOUS INJURY
Any change in the connections will lead to malfunctions
(e.g. lift instead of lower).
• When connecting hydraulic components, observe the
specified piping according to the hydraulic schematic
diagram of the machine.
WE1401482
Figure 14
FG019382
Figure 15
Figure 16 WE1400713
WE1400714
Figure 17
Disassembly
1. Clean exterior of pump.
FG000830
Figure 18
FG000831
Figure 19
FG000832
Figure 20
FG000833
Figure 21
FG000834
Figure 22
FG000835
Figure 23
FG000836
Figure 24
FG000837
Figure 25
FG000838
Figure 26
Reassembly
1. Clean all components with care.
FG000838
Figure 27
FG000839
Figure 28
FG000840
Figure 29
FG000841
Figure 30
FG000842
Figure 31
Inlet Side
FG001401
Figure 32
FG000844
Figure 33
FG000845
Figure 34
FG000846
Figure 35
FG000847
Figure 36
FG000848
Figure 37
FG000849
Figure 38
FG000850
Figure 39
FG000851
Figure 40
Edition 1
Brake System
Safety Instructions ........................................5-11-5
General .........................................................5-11-6
General Description................................................. 5-11-6
Hydraulic Circuit ...................................................... 5-11-7
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
General Description
Oil from the gear pump, which is connected to the engine, passes
through the brake filter and is supplied to the brake supply valve.
This oil is also collected in the accumulator and is also supplied to
the brake pedal valve to build up the brake operating pressure.
When an operator operates the brake pedal valve during machine
operation, pressure already built in the brake pedal valve is
transferred to the shuttle valve which then passes it to the front
axle and rear axle through the center joints (ports 6 and 7) in
order to apply it to the brake system for braking and stopping the
machine.
Engine
Center Joint
Rear Axle
WE1401489
Figure 1
1 2
Engine 4
7
Chock
9 3 3 1 1 3 3 1 1 3 3 1 3 1 8
8 8 1 1 2 2 8 8 4 4 8 8 2 4 4
4 5 13 14 10 11 8 9 3 15 7 6 1 12 2
Steer
Cylinder
Chock
WE1400633
Figure 2
Reference Reference
Description Description
Number Number
1 Gear Pump 6 Shuttle Valve
2 Brake Filter 7 Center Joint
3 Brake Supply Valve 8 Front Axle
4 Accumulator 9 Rear Axle
5 Brake Pedal Valve 10 Engine
Edition 1
Brake Filter
Safety Instructions ........................................5-12-5
General .........................................................5-12-5
General Description................................................. 5-12-5
Specification ............................................................ 5-12-5
Overview ................................................................. 5-12-6
Parts List ................................................................. 5-12-6
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
General Description
This filter is to remove foreign materials in oil in the brake piping
in order to prevent deterioration of the brake operation
performance due to foreign materials.
Specification
160 bar
Max. Working Pressure
(163 kg/cm2, 2,364 psi)
Temperature Range -20 ~ 120°C
Bypass Setting Pressure 3.5 bar (3.5 kg/cm2, 50.8 psi)
Weight 1.3 kg (2.9 lb)
Filtration Rating 10 μm
Element Replacement Interval 1,000 hr
Outlet
WE1400330
Figure 1
Parts List
Reference
Description
Number
4
1 Element, Brake Filter
2 O-ring
3 O-ring 3
4 By-pass Valve
2 1
WE1400331
Figure 2
Edition 1
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
General Description
This valve receives hydraulic oil from the brake gear pump to
build up certain pressure in the accumulator and pass oil to the
brake pedal valve.
Also, if pressure built in the gear pump is over the preset level
(157 bar (160 kg/cm2, 2,276 psi)), high-pressure oil is drained
and returned to the tank.
Specification
Max Working Pressure 206 bar (210 kg/cm2, 2,987 psi)
Rated Flow 16.5 L/min (4.4 U.S. gal/min)
Relief Setting Pressure 157 ±2 bar (160 ±2 kg/cm2, 2,276 ±28 psi)
Cut in - 101 bar (103 kg/cm2, 1,465 psi)
Unloading Pressure
Cut out - 123 bar(125 kg/cm2, 1,778 psi)
Weight 4 kg (9 lb)
3
2
4
WE1400685
Figure 1
P1 In (Brake Pump) AC
PF 1/2 ACC A ACC B
T Out (Tank) C4 C5
C3
ACC A Accumulator GP G1
160 bar
ACC B Accumulator P1
PF 3/8 C1 C6 C2
AB to Front Axle
AC to Rear Axle 103 bar
125 bar
T
PSD Pressure Switch PF 1/4
WE1400687
Figure 2
3
2
4
WE1400685
Figure 3
Reference Reference
Description Description
Number Number
1 Body 4 Check Valve
2 Logic Valve 5 Unloading Valve
3 Relief Valve
Functions
This brake supply valve assembly package has functions as
below:
1. Prevents overload on brake pump saving energy.
2. Performs a function as a safety device of the brake control
device.
3. Supplies brake control pressure.
Set Pressure
Oil Flow
Cut-in Cut-out
16.5 L/min 101 ±3 bar (103 ±3 kg/cm 1,465 ±42 psi)
2, 123 ±3 bar (125 ±3 kg/cm2, 1,778 ±42 psi)
4
Disassembly
1
2
Assembly
WE1400686
Figure 4
WARNING
AVOID DEATH OR SERIOUS INJURY
Contact with hydraulic fluid can harm your health. (e.g. eye
injuries, skin damage or poisoning, if inhaled).
• While performing removal and installation, wear safety
gloves, safety glasses and suitable working clothes.
• If hydraulic fluid should come into contact with your
eyes or penetrate your skin, consult a doctor
immediately.
WARNING
FIRE CAN CAUSE SERIOUS INJURY OR DEATH
Hydraulic fluid is highly flammable.
• Keep open flames and ignition sources away from the
workplace.
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants, grease,
etc. must be disposed of in an environmentally safe
manner. Some regulations require that certain spills and
leaks on the ground must be cleaned in a specific manner.
See local, state and federal regulations for the correct
disposal.
WE1401487
Figure 5
LOCK
WARNING WARNING
DO NOT OPERATE
AVOID DEATH OR SERIOUS INJURY when performing inspection
or maintenance
WE1400464
Figure 7
ON
Figure 8 EX1401760
1 2
7 6
4
EX1401809
Figure 9
12. Loosen the oil tank air breather slowly to release the
pressure inside the hydraulic oil tank.
Pulling the breather cap upward, the check valve (0.45 bar) Figure 10 WE1400562
opens, and the air is discharged to the atmosphere from
the top of the hydraulic oil tank.
13. Open the left side door.
Figure 11 WE1400716
Figure 12 WE1400717
• Fitting
Size Torque
Port Name
A B (mm) N.m kg.m ft lb
T Adapter PF 1/2" UNF 13/16"-16 27 93.1 9.5 68.7
P1 Elbow PF 1/2" UNF 13/16"-16 27 93.1 9.5 68.7
AB Elbow PF 3/8" UNF 11/16"-16 22 49.0 5 36.2
AC Elbow PF 3/8" UNF 11/16"-16 22 49.0 5 36.2
T, P1 O-ring S8000185 (4D P18) S8030081 (1B F-08)
AB, AC O-ring S8000145 (4D P14) S8030061 (1B F-06)
ACC A,
O-ring S8000145 (4D P14)
ACC B
• Tool: 17 mm ( )
• Torque: 63.7 N.m (6.5 kg.m, 47 ft lb)
Figure 14 WE1400719
WE1400720
Figure 15
INSTALLATION
WARNING
INCORRECT INSTALLATION CAN CAUSE DEATH OR
SERIOUS INJURY
Any change in the connections will lead to malfunctions
(e.g. lift instead of lower).
• When connecting hydraulic components, observe the
specified piping according to the hydraulic schematic
diagram of the machine.
FG019382
Figure 16
Figure 17 WE1400713
Edition 1
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
General Description
This pedal valve is designed for heavy-duty brake pedal valve of
driving excavator.
It is hydraulic operated and contains an operation brake function
to fix pedal with ratch while the machine stops.
Specification
103 ±2 ~ 125 ±2 bar
Supply Pressure (105 ±2 ~ 127 ±2 kg/cm2,
1,494 ±29 ~ 1,813 ±29 psi)
Flow Rate 13.6 L/min (3.6 U.S. gpm)
60 bar
Secondary Pressure
(61 ±3 kg/cm2, 870 ±21.7 psi)
Operation Angle 20°
Weight 4 kg (8.8 lb)
T1 BL1
P1
BR1
T2
BL2
P2
BR2
WE1400364
Figure 1
Hydraulic Circuit
Port Size
T1, T2, P1, P2, BL1, BL2,
PF 3/8
BR1, BR2
BL1
BR1 T1
P1
BL2
T2
BR2
P2
WE1400366
Figure 2
T1
BL1
P1
BL2
BR1
T2
BR2
P2
WE1400369
Figure 3
2. During Operation
BL1
A. Operation of pedal causes action of main spring (13) T1
BR1
and spool (3). The load of spring (13) generates P1
pressure B port seating pressure.
B. P and BR ports are connected and pressure is 13
generated, which moves to orifice to act pilot 3
pressure to the floor of spool (3).
T1 BL2
BL1 T2
C. If pilot pressure is higher than pressure set to spring BR2
P2
(13), spool (3) moves up and pressure decreases.
P1
D. If pilot pressure is lower than pressure set to spring BR1
(13), spool (3) moves down to close T port and
pressure increases.
E. Operation angle of pedal changes load of spring (13) WE1400370
and thus the second pressure of BR port. Figure 4
2 4 6 8 10 12 14 16 18 20 22
Operation Angles
Figure 5 WE1400773
T1
BL1
P1
BR1
T2
BL2
P2
BR2
WE1400368
Figure 6
WARNING
AVOID DEATH OR SERIOUS INJURY
Contact with hydraulic fluid can harm your health. (e.g. eye
injuries, skin damage or poisoning, if inhaled).
• While performing removal and installation, wear safety
gloves, safety glasses and suitable working clothes.
• If hydraulic fluid should come into contact with your
eyes or penetrate your skin, consult a doctor
immediately.
WARNING
FIRE CAN CAUSE SERIOUS INJURY OR DEATH
Hydraulic fluid is highly flammable.
• Keep open flames and ignition sources away from the
workplace.
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants, grease,
etc. must be disposed of in an environmentally safe
manner. Some regulations require that certain spills and
leaks on the ground must be cleaned in a specific manner.
See local, state and federal regulations for the correct
disposal.
WE1401488
Figure 7
LOCK
WARNING WARNING
DO NOT OPERATE
AVOID DEATH OR SERIOUS INJURY when performing inspection
or maintenance
IMPORTANT
Operate the joystick levers and brake pedal valve
several times to release the remaining pressure in the
hydraulic piping.
WE1400464
Figure 9
ON
Figure 10 EX1401760
1 2
7 6
4
EX1401809
Figure 11
WARNING
AVOID DEATH OR SERIOUS INJURY
Release any pressure in the hydraulic oil tank before
doing any work.
11. Loosen the oil tank air breather slowly to release the
pressure inside the hydraulic oil tank.
Pulling the breather cap upward, the check valve (0.45 bar) Figure 12 WE1400562
opens, and the air is discharged to the atmosphere from
the top of the hydraulic oil tank.
12. Stow the front upper window (1, Figure 13) in the cabin
ceiling.
1
13. Remove lower window (2) from cabin in direction of the
arrow.
WARNING
AVOID DEATH OR SERIOUS INJURY 2
Never have wet hands when handling a window. Never
drop window or let it come into contact with other Figure 13 WE1400774
parts of machine.
Figure 14 WE1400742
• Tool: 19 mm ( ) 2
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
• Under cover weight: 9 kg (20 lb)
WE1400741
Figure 15 Bottom of Main Frame
WE1400775
Figure 16
WE1400426
Figure 17
• Fitting
Size Torque
Port Name
A B (mm) N.m kg.m ft lb
T1, T2,
Adapter PF 3/8" UNF 11/16"-16 22 30.8 3.14 22.7
P1, P2
BR1, BR2 Elbow PF 3/8" UNF 11/16"-16 22 30.8 3.14 22.7
BL1, BL2 Reducer PF 3/8" UNF 1/2-20"-2A 22 30.8 3.14 22.7
T1, T2,
S8000145 S8030061
P1, P2, O-ring
(4D P14) (1B F-06)
BR1, BR2
S8000145
BL1, BL2 O-ring
(4D P14)
• Tool: 13 mm ( )
• Torque: 29.4 N.m (3 kg.m, 21.7 ft lb)
2
WE1400428
Figure 19
WE1400429
Figure 20
INSTALLATION
WARNING
INCORRECT INSTALLATION CAN CAUSE DEATH OR
SERIOUS INJURY
Any change in the connections will lead to malfunctions
(e.g. lift instead of lower).
• When connecting hydraulic components, observe the
specified piping according to the hydraulic schematic
diagram of the machine.
FG019382
Figure 21
Figure 22 WE1400713
REASSEMBLY
4 3 2 1 5 6 7
FG003651
Figure 23
Reference Reference
Description Description
Number Number
1 Lower Part 5 O-ring
2 Spool 6 Spring Guide
3 Lower Spring 7 Upper Spring
4 Plug
1. Insert spool (2) and lower spring (3) in lower part (1).
CAUTION
AVOID INJURY
Take care to prevent dust or foreign substances
entering valves after washing.
FG003652
Figure 24
• Tool: 19 mm ( )
• Torque: 137.3 ~ 161.8 N.m
(14 ~ 16.5 kg.m, 101.3 ~ 119.3 ft lb)
FG003653
Figure 25
FG003654
Figure 26
FG003655
Figure 27
1 2 3 4 5
6 7 8 9 10
FG003656
Figure 28
Reference Reference
Description Description
Number Number
1 Upper Part 6 Spool
2 Oil Seat 7 Spring Retainer
3 Plain Washer 8 Main Spring
4 Retaining Ring 9 Holder
5 Drive Bearing 10 Rubber Cover
1. Install oil seal (2), plain washer (3), retaining ring (4), and
drive bearing on lower part (1).
Tools: Drive bearing jig and retaining ring pliers.
CAUTION
AVOID INJURY
Use a jig to press and push bearing.
Never remove the dry bearing.
FG003657
Figure 29
CAUTION
AVOID INJURY
Take care to prevent dust or foreign substances
entering valves after washing.
FG003658
Figure 30
CAUTION
AVOID INJURY
Do not forget to install O-ring.
FG003659
Figure 31
• Tool: 6 mm ( )
FG003560
Figure 32
FG003662
Figure 33
FG003663
Figure 34
FG003664
Figure 35
1 2 3 4
5 6 7 8 9 10 11 12 10
Figure 36 FG003665
Reference Reference
Description Description
Number Number
1 Rubber Pedal 7 Ratch Lock Pin
2 Lock Plate 8 Retaining Ring
3 Pedal 9 Pedal Lock Pin
4 Retaining Ring 10 Hexagon Bolt
5 Ratch 11 Pedal Plate
6 Ratch Spring 12 Double Torsion Spring
• Tool: 6 mm ( )
FG003666
Figure 37
FG003667
Figure 38
3. Install the lock pin retaining ring at the end of lock pin (9).
• Tools: Shaft retaining ring flyer
CAUTION
AVOID INJURY
When removing lock pin, remove the retaining ring
first.
FG003668
Figure 39
CAUTION
AVOID INJURY
Apply grease to the inside of ratch spring.
FG003669
Figure 40
5. Use ratch lock pin (7) to install the ratch assembly in pedal
plate (11).
CAUTION
AVOID INJURY
When removing lock pin, remove the retaining ring
first. (Damage to pedal plate)
FG003670
Figure 41
FG003671
Figure 42
FG003673
Figure 44
FG003674
Figure 45
FG003676
Figure 47
• Tool: 13 mm ( )
• Torque: 19.6 N.m (2.0 kg.m, 14.5 ft lb)
FG003677
Figure 48
FG003678
Figure 49
Edition 1
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
Specification
Supply Pressure 40 bar (40 kg/cm2, 569 psi)
Flow Rate 8 ~ 27 L/min (2 ~ 7 U.S. gpm)
12 ~ 40 bar
Secondary Pressure
(12 ~ 40 kg/cm2, 171 ~ 569 psi)
Weight 2 kg (4.4 lb)
P
T
A WE1400785
Figure 1
Hydraulic Circuit
Port Size
P, T, A PF 1/4
T
A
P
Figure 2 WE1400472
Function
It is used to reduce the primary pressure delivered from the pilot gear pump to the secondary pressure level to
control the control valve travel spool.
1. Neutral position
While the accelerator valve is in the neutral position, the spring seat (6), spool (3) and push rod (12) have
been pushed upwards by the spring (8).
The oil with the primary pressure flowed into the accelerator valve through the port (P).
Keeps blocked by the spool (3).
The operating port (A) are connected to the port (T).
12
T
A
8 P
T Port
P Port
3
A Port
WE1400786
Figure 3
12
T
5 A
P
T Port
P Port
3
A Port
WE1400787
Figure 4
3. Full control
Moving the pedal to the full forces the push rod (12) to move downwards and the moving rod pushes down
the spring seat (6), spring (5) and spool (3), by which the spring (5) is fully compressed.
The primary pressure is delivered to the operating port (A) through the spool (3) while the delivered
secondary pressure pushes up the spool (3). However, as the spool (3) is fixed to the push rod (12) and thus
cannot move.
12
6
T
A
5 P
T Port
P Port
3
A Port
WE1400788
Figure 5
II-13 II-10
II-9
II-12
II-11
I-6
I-7
I-5 2
I-4
I-3 1
EX1400789
Figure 6
Reference Reference
Description Description
Number Number
1 Body 8 Spring
2 Plug II Plug Kit
I Spool Kit II-9 Plug
I-3 Spool II-10 Seal
I-4 Spring Seat II-11 O-ring
I-5 Spring II-12 Push Rod
I-6 Spring Seat II-13 Dust Seal
I-7 Stopper
WARNING
AVOID DEATH OR SERIOUS INJURY
Contact with hydraulic fluid can harm your health. (e.g. eye
injuries, skin damage or poisoning, if inhaled).
• While performing removal and installation, wear safety
gloves, safety glasses and suitable working clothes.
• If hydraulic fluid should come into contact with your
eyes or penetrate your skin, consult a doctor
immediately.
WARNING
FIRE CAN CAUSE SERIOUS INJURY OR DEATH
Hydraulic fluid is highly flammable.
• Keep open flames and ignition sources away from the
workplace.
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants, grease,
etc. must be disposed of in an environmentally safe
manner. Some regulations require that certain spills and
leaks on the ground must be cleaned in a specific manner.
See local, state and federal regulations for the correct
disposal.
WE1401487
Figure 7
LOCK
WARNING WARNING
DO NOT OPERATE
AVOID DEATH OR SERIOUS INJURY when performing inspection
or maintenance
WE1400464
Figure 9
ON
Figure 10 EX1401760
1 2
7 6
4
EX1401809
Figure 11
12. Loosen the oil tank air breather slowly to release the
pressure inside the hydraulic oil tank.
Pulling the breather cap upward, the check valve (0.45 bar) Figure 12 WE1400562
opens, and the air is discharged to the atmosphere from
the top of the hydraulic oil tank.
13. Stow the front upper window (1, Figure 13) in the cabin
ceiling.
1
14. Remove lower window (2) from cabin in direction of the
arrow.
WARNING
AVOID DEATH OR SERIOUS INJURY 2
Never have wet hands when handling a window. Never
drop window or let it come into contact with other Figure 13 WE1400774
parts of machine.
Figure 14 WE1400742
16. Remove bolts and washers (1, Figure 14) (6 ea) with under
1
cover (2) on bottom of main frame.
• Tool: 19 mm ( ) 2
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
• Under cover weight: 9 kg (20 lb)
Figure 16 WE1400794
• Fitting
Size Torque
Port Name
A B (mm) N.m kg.m ft lb
A Elbow PF 1/4" UNF 9/16"-18 19 39.2 4 28.9
P, T Adapter PF 1/4" UNF 9/16"-18 19 39.2 4 28.9
S8000115 2180-1216D11
A, P, T O-ring
(4D P11) (ID: 7.65, W: 1.78, 1B)
• Tool: 5 mm ( )
• Torque: 12.7 N.m (1.3 kg.m, 9.4 ft lb)
1
2
Figure 18 WE1400792
Figure 19 WE1400793
INSTALLATION
WARNING
INCORRECT INSTALLATION CAN CAUSE DEATH OR
SERIOUS INJURY
Any change in the connections will lead to malfunctions
(e.g. lift instead of lower).
• When connecting hydraulic components, observe the
specified piping according to the hydraulic schematic
diagram of the machine.
FG019382
Figure 20
Figure 21 WE1400795
DISASSEMBLY
1. Remove bolts (49) (2 ea) and washers (54) (2 ea).
(Figure 22)
• Tool: 5 mm ( )
49, 54
WE1400790
Figure 22
FG007509
Figure 23
FG007510
Figure 24
FG007511
Figure 25
FG007512
Figure 26
FG007513
Figure 27
FG007512
Figure 28
Figure 29
FG007511
Figure 30
Figure 31
FG007510
Figure 32
FG007509
Figure 33
• Tool: 5 mm ( )
49, 54
WE1400790
Figure 34
Edition 1
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
General Description
The accumulator is a gas-charged storage device designed to
hold a reserve quantity of hydraulic fluid under pressure. 1
Accumulators are used in hydraulic circuits in much the same
way that condensers (or capacitors) are used to collect, store 2
and maintain electrical charge in a circuit.
In a hydraulic circuit, minor variations or lags in pump output that
might otherwise cause unsteady or irregular operation are made
up from the supply of pressurized oil in the accumulator.
Reference 3
Description
Number
1 Screw Plug
2 Steel Pressure Vessel
3 Diaphragm 4
4 Fluid Valve
ARS1790L
Specifications
System Charge Pressure Working Pressure Volume
10 bar 80 bar
Pilot
(10 kg/cm2, 145 psi) (82 kg/cm2, 1,160 psi) 750 cc
30 bar 210 bar (45.77 in3)
Brake
(31 kg/cm2, 435 psi) (214 kg/cm2, 3,046 psi)
Edition 1
Steering System
Safety Instructions ........................................5-17-5
General .........................................................5-17-6
General Description................................................. 5-17-6
Hydraulic Circuit ...................................................... 5-17-7
Theory of Operation ................................................ 5-17-8
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
General Description
Turning the steering wheel causes hydraulic oil to be sent from
the steering gear type pump to the steering valve which directs
oil to the steering cylinders.
Front Axle
LS
L
R
T
P
Center Joint
Gear Pump
Steering Valve
CF LS
EF
P
Tank Priority Valve
WE1400812
Figure 1
3 3 1 1 1 1 3 3 1 1 3 3 1 3 1
8 8 2 2 8 8 4 4 8 8 2 4 4
4 5 13 14 10 11 8 9 3 15 7 6 1 12 2
1 Chock
Front Axle
Chock
P T LS
3 bar 4 6
2 CF EF Engine
LS
P
WE1400813
Figure 2
Reference Reference
Description Description
Number Number
1 Steering Valve 4 Gear Pump
2 Priority Valve 5 Front Axle
3 Center Joint 6 Engine
L R
235 ~ 255 bar
LS
Priority Valve
LS Connected to Tank P T LS
T P
Neutral Position
WE1400814
Figure 3
• Function : To feed oil from the steering gear pump to the steering cylinder of front axle for steering
operation.
• Configuration: Pump, priority valve, steering unit (neutral position spring, spool and sleeve, gerotor,
makeup check, etc.).
Operation
When handle is not operated, the spool and sleeve are stopped by the neutrally-positioned spring.
The oil passage of the spool and sleeve blocks the pump, cylinder in/out and gerotor in/out.
LS pressure transmits the steering load to the priority valve and the pressure is transferred to the T-port by
the internal oil passage.
When the LS pressure joins the T-port, the pressure of the pump activates the spool of the priority valve to
switch over to the left, and then the pump oil joins the front.
L R
235 ~ 255 bar
CF
175 ~ 185 bar
LS
Priority Valve
P P T LS
T
Steering Position
WE1400815
Figure 4
Operation
When the steering wheel turns, the neutrally-positioned spring connecting the spool and the sleeve is
depressed downwards and begins to turn, creating a rotational angle.
The difference in the rotational angles between the spool and the sleeve serves to connect the oil passage
of the LS to the pump, which transfers the priority spool to the right.
This in turn blocks the oil flow from joining the front, and the oil is carried to the steering unit.
The pump oil of the steering unit joins the entry of the gerotor by the internal oil passage of the spool and sleeve.
Then, the oil from the gerotor is carried to the cylinder by the internal oil passage of the spool and sleeve for
steering operation.
Oil returned from the steering cylinder is carried to the tank by the oil passage of the spool and sleeve.
Edition 1
Steering Valve
Safety Instructions ........................................5-18-5
General .........................................................5-18-6
General Description................................................. 5-18-6
Specifications .......................................................... 5-18-8
Overview ................................................................. 5-18-9
Theory of Operation .............................................. 5-18-10
Gerotor Operation ................................................. 5-18-11
Relief Valve ........................................................... 5-18-11
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
General Description
This steering unit is a load sensing steering unit consisting of a
rotary valve, a changeover valve and two rotary meters.
The rotary meters are mechanically connected so the oil flow to
the steering cylinders is proportional to the angular movement of
the steering wheel.
When the pump pressure on the steering unit exceeds 7 bar
(7 kg/cm2, 101.5 psi) the oil flow from both rotary meters is
available for steering.
When the pump pressure is less than 4 bar (4 kg/cm2, 58 psi),
the oil flow for steering is available from only one of the rotary
meters.
This makes high manual steering pressure possible.
This steering unit gives the following facilities:
• Manual steering without emergency steering pump.
• Large displacement for working functions.
• Small displacement for driving on roads.
There is always a precise ratio between the metered oil quantity
and the angular movement of the steering wheel.
When the gear pump supplies sufficient oil flow to the steering
unit, operator can steer the vehicle with steering wheel.
However if the oil flow from the gear pump is too small, the
steering unit functions automatically in manual steering mode.
The steering system is sized so that manual steering only comes
into effect for short-lived manoeuvring of the vehicle in the event
of sudden gear pump pressure drop.
This is taken as the maximum steering wheel torque a driver of
average strength is able to exert.
The steering unit consists of the direction control section (A,
Figure 1) and the pump or oil control section (B).
These two sections operate together to forward hydraulic oil to
the steering cylinder of front axle.
The hydraulic oil from the priority valve flows into the direction
control section of the steering unit.
When the steering wheel is activated, the hydraulic oil in the
direction control section is channeled to the steering cylinder.
The oil control section is fitted with a small hydraulic pump which
controls the hydraulic oil fed to the steering cylinder.
When the steering wheel turns rapidly, more hydraulic oil is fed
to the steering cylinder.
Figure 1
Section (B)
Oil Control
WE1400590
Operating Condition
Max. Pump Discharge Flow 36.6 L/min (9.6 U.S. gpm) @ 2,000 rpm
Max. Pump Pressure 200 bar (204 kg/cm² (2,900 psi))
Hydraulic Oil ISO VG 46 WR or SIMILAR
Hydraulic Oil Temperature -20 ~ 90°C (-4 ~ 194°F)
LS
L R
T P
WE1400591
Figure 2
Spline Specification
Dia. Pitch 16/32
NO of Teeth 12
Pitch Dia. ø19.05
Pressure Angle 30 Degree
Over Pin Dia. Max. 15.128
Pin Dia. ø3
P T LS
Figure 3 WE1400592
Neutral Operation
Figure 4
Right Turn
The spool (2, Figure 4) is engaged with the spline of the steering
shaft. When the steering wheel is turned to the right, the spool
turns. The sleeve (1) is connected to the spool (2) by centering
springs (3). When spool turns, the sleeve turns. The sleeve
turning angle is about 10° less than the spool turning angle.
This allows the longitudinal slots in the spool to align with the
ports in the sleeve. Oil from port P on the steering unit travels
through the control spool and is directed to port R which directs
the oil to the steering cylinders. The amount of flow metered to
port R is controlled by the amount of steering wheel rotation.
Excess oil flow through port P that is not metered to port R, is
directed by the spool to port T and is then directed through the
oil cooler and into the tank.
Left Turn
The spool (2, Figure 4) is engaged with the spline of the steering
shaft. When the steering wheel is connected to the spool (2) by
centering springs (3). When the spool turns, the sleeve turns.
The sleeve turning angle is about 10° less than the spool turning
angle. This allows the longitudinal slots in the spool to align with
the ports in the sleeve. When the steering wheel is turned to the
left, oil from port P on the steering unit is directed through the
control spool in the steering unit, out port L and into the steering
cylinders. The amount of oil flow metered to port L is controlled
by the amount of steering wheel rotation. Excess oil flow through
port P that is not metered to port L, is directed by the spool to
port T and is then directed through the oil cooler and into the
tank.
Relief Valve
The main relief valve is built into the steering valve. When
abnormal pressure is generated during steering operation, the
pump oil is returned to the tank line by the relief valve to prevent
failure or breakdown of the hydraulic pump.
Figure 6
Edition 1
Priority Valve
Safety Instructions ........................................5-19-5
General .........................................................5-19-6
Overview ................................................................. 5-19-6
Hydraulic Circuit ...................................................... 5-19-6
Theory of Operation ................................................ 5-19-7
Removal .......................................................5-19-8
Installation ..................................................5-19-12
Completing Work ........................................5-19-13
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
Overview
CF
EF P LS
WE1400387
Figure 1
Hydraulic Circuit
to Steering Valve to Oil Tank
CF EF
LS
WE1400388
Figure 2
LS
EF CF
WE1400386
Figure 3
WARNING
AVOID DEATH OR SERIOUS INJURY
Contact with hydraulic fluid can harm your health. (e.g. eye
injuries, skin damage or poisoning, if inhaled).
• While performing removal and installation, wear safety
gloves, safety glasses and suitable working clothes.
• If hydraulic fluid should come into contact with your
eyes or penetrate your skin, consult a doctor
immediately.
WARNING
FIRE CAN CAUSE SERIOUS INJURY OR DEATH
Hydraulic fluid is highly flammable.
• Keep open flames and ignition sources away from the
workplace.
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants, grease,
etc. must be disposed of in an environmentally safe
manner. Some regulations require that certain spills and
leaks on the ground must be cleaned in a specific manner.
See local, state and federal regulations for the correct
disposal.
WE1400569
Figure 4
LOCK
WARNING WARNING
DO NOT OPERATE
AVOID DEATH OR SERIOUS INJURY when performing inspection
or maintenance
WE1400464
Figure 6
ON
Figure 7 EX1401760
1 2
7 6
4
EX1401809
Figure 8
WARNING
AVOID DEATH OR SERIOUS INJURY
Release any pressure in the hydraulic oil tank before
doing any work.
12. Loosen the oil tank air breather slowly to release the
pressure inside the hydraulic oil tank.
Pulling the breather cap upward, the check valve (0.45 bar) Figure 9 WE1400562
opens, and the air is discharged to the atmosphere from
the top of the hydraulic oil tank.
13. Remove bolts and washers (1, Figure 10) (7 ea) with under
cover (2) on bottom of main frame. 1 2
• Tool: 19 mm ( )
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
• Under cover weight: 4 kg (8.8 lb)
WE1401055
Figure 10 Bottom of Main Frame
LS
WE1401056
Figure 11
• Fitting
Size Torque
Port Name
A B (mm) N.m kg.m ft lb
P, EF, CF Adapter PF 1/2" UNF 13/16"-16 27 93.1 9.5 68.7
LS Elbow PF 1/4" UNF 9/16"-18 19 39.2 4 28.9
S8000185 S8030081
P, EF, CF O-ring
(4D P18) (1B F-08)
S8000115 2180-1216D11
LS O-ring
(4D P11) (ID:7.65, W:1.78, 1B)
15. Remove bolt (1, Figure 12) and washer with priority valve
(2) from bracket.
1
2
• Tool: 13 mm ( )
• Torque: 29.4 N.m (3 kg.m, 21.7 ft lb)
Figure 12 WE1401057
WE1400412
Figure 13
INSTALLATION
WARNING
INCORRECT INSTALLATION CAN CAUSE DEATH OR
SERIOUS INJURY
Any change in the connections will lead to malfunctions
(e.g. lift instead of lower).
• When connecting hydraulic components, observe the
specified piping according to the hydraulic schematic
diagram of the machine.
FG019382
Figure 14
3. Slowly turn the steering wheel to the right and left about
five times without a load to vent air from pilot lines.
WE1400714
Figure 15
Edition 1
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
Specifications
Supply Pressure 40 bar (40 kg/cm2, 569 psi)
Rated Flow 20 L/min (5.3 U.S. gal)
Oil Temperature -20 ~ +90°C
Performance
28 + 30
Operating Torque (kg.cm)
Secondary Pressure
Secondary Pressure
(kg/cm2)
(kg/cm2)
16.6促3
15
M10 x 1.25
P
1 2
EX1403271
Figure 2
Port Size
1, 2, P, T PF 1/4 O-ring
1 2
FG007451
Figure 3
23
20
22
16
21
14
19
15
18
17
5-5
6-1
5-1 6-4
6
6-2
5 5-4
6-3
4
5-3
5-2 2
3 1
Figure 4 EX1403272
Reference Reference
Description Description
Number Number
1 Body 6-3 O-ring
2 Plug 6-4 Rod; Push
3 O-ring 14 Cover
4 Spring 15 Bolt
5 Spool Kit 16 Guide
5-1 Seat; Spring 17 Pin
5-2 Spool 18 Bolt
5-3 Seat; Spring 19 Nut
5-4 Spring 20 Lever
5-5 Stopper 21 Pin; Spring
6 Plug Kit 22 Boot
6-1 Plug 23 Bushing
6-2 Seal; Rod * Seal Kit; Dozer Joystick
*: 3, 6-3
Function
It is used to reduce the primary pressure delivered from the pilot
gear pump to the secondary pressure level to control the control
valve dozer spool.
1. Neutral position
While the dozer valve is in the neutral position, the spring
seat (5-1), spool (5-2) and push rod (6-4) have been
pushed upwards by the spring (4).
The oil with the primary pressure flowed into the dozer
valve through the port P.
Keeps blocked by the spool (5-2).
The operating ports (1 and 2) are connected to the port T.
T P
6-4
5-1
T
4
1 2
5-2 P
1 2
Figure 5 EX1403273
20
T P
6-4
5-1
T
5-3
1 2
5-2 P
1 2
EX1403274
Figure 6
20
T P
6-4
5-1
T
5-3
1 2
P
5-2
1 2
EX1403275
Figure 7
TOOLS
Reference
Description Tool
Number
2 Plug 10 mm ( )
15 Socket Bolt 5 mm ( )
18 Bolt 2.5 mm ( )
19 Nut 8 mm ( )
WARNING
AVOID DEATH OR SERIOUS INJURY
Contact with hydraulic fluid can harm your health. (e.g. eye
injuries, skin damage or poisoning, if inhaled).
• While performing removal and installation, wear safety
gloves, safety glasses and suitable working clothes.
• If hydraulic fluid should come into contact with your
eyes or penetrate your skin, consult a doctor
immediately.
WARNING
FIRE CAN CAUSE SERIOUS INJURY OR DEATH
Hydraulic fluid is highly flammable.
• Keep open flames and ignition sources away from the
workplace.
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants, grease,
etc. must be disposed of in an environmentally safe
manner. Some regulations require that certain spills and
leaks on the ground must be cleaned in a specific manner.
See local, state and federal regulations for the correct
disposal.
WE1401483
Figure 8
LOCK
WARNING WARNING
DO NOT OPERATE
AVOID DEATH OR SERIOUS INJURY when performing inspection
or maintenance
Figure 10 WE1400464
ON
Figure 11 EX1401760
1 2
7 6
4
EX1401809
Figure 12
12. Loosen the oil tank air breather slowly to release the
pressure inside the hydraulic oil tank.
Pulling the breather cap upward, the check valve (0.45 bar)
Figure 13 WE1400562
opens, and the air is discharged to the atmosphere from
the top of the hydraulic oil tank.
13. Remove bolts (3 ea) and washers (3 ea) and remove arm
rest from bracket.
• Tool: 13 mm ( )
• Torque: 19.6 N.m (2 kg.m, 14.5 ft lb)
15. Remove socket bolt (1, Figure 16) with grip (2).
2
16. Remove screw (3) with cover (4) from stand upper cover,
and disconnect the connector of harness which connect
with switches. 3
1
4
WE1400628
Figure 16 Stand LH
• Tool: 10 mm ( )
• Torque: 9.8 N.m (1 kg.m, 7.2 ft lb)
Figure 17 EX1403104
2
1
WE1401058
Figure 18
• Fitting
Size Torque
Port Name
A B (mm) N.m kg.m ft lb
1, P, T Adapter PF 1/4" UNF 9/16"-18 19 39.2 4 28.9
2 Elbow PF 1/4" UNF 9/16"-18 19 39.2 4 28.9
S8000115 2180-1216D11
1, 2, P, T O-ring
(4D P11) (ID:7.65, W:1.78, 1B)
EX1403106
Figure 19
INSTALLATION
WARNING
INCORRECT INSTALLATION CAN CAUSE DEATH OR
SERIOUS INJURY
Any change in the connections will lead to malfunctions
(e.g. lift instead of lower).
• When connecting hydraulic components, observe the
specified piping according to the hydraulic schematic
diagram of the machine.
FG019382
Figure 20
Figure 21 EX1403107
Figure 22
FG003783
Figure 23
FG003786-1
Figure 24
Figure 25
FG003787
Figure 27
FG003788
Figure 28
FG003789
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
FG003789
Figure 34
FG003791
Figure 35
FG003788
Figure 36
FG003792
Figure 37
FG003787
Figure 38
Figure 39
Figure 40
FG003786-1
Figure 41
FG007458
Figure 42
FG003794
Figure 43
FG003794-1
Figure 44
FG003783
Figure 45
FG003795
Figure 46
Figure 47
FG003781-1
Figure 48
Edition 1
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
General Description
This 4-solenoid valve has functions as below.
1. Cuts off pilot pressure.
2. Controls driving speed. (Inching Mode)
3. Performs a ram lock function. (Locking chocking cylinder)
4. Supplies presssure to breaker (shear) operation.
Specification
Pressure (Max.) 69 bar (70 kg/cm2, 996 psi)
Flow (Max.) 23 L/min (6.1 U.S. gal)
Leakage below 40 ml/min
Solenoid Coil
Rated Voltage DC 24 V
Operation Voltage Range 20 ~ 30 V
Surge Absorber Built in
C5
C4
C3
C2
C6
PB
HO
P3
CT
S
PS P2
P
IC
C7
CH
T
SD
WE1401104
Figure 1
Reference Reference
Description Description
Number Number
C2 Ram Lock C4 Pilot Cut-off
C3 Inching Mode C5 Breaker (Shear)
SD CH IC PB PS HO
T
C7
C6
C1 C2 C3 C4 C5
P1
P2 P3 GTS
WE1401105
Figure 2
C4
C3
C2
C5
C4
C3
C2
C6
PB
HO
P3
CT
S
1
PS P2
P
IC
C7
3
CH
T
SD
3
Figure 3
WE1401106
Reference Reference
Description Description
Number Number
1 Body 3 Check Valve
2 Spool, Solenoid 4 Coil 24 V
2-1
Disassembly
2-2
Assembly
2-3
C5
C4
C3
C2
C6
PB
HO
P3
CT
1
S
PS P2
P
IC
C7
CH
3 T
SD
Figure 4 3
WE1401107
Torque
No. Part Name Screw Spec Tools
N.m kg.m ft lb
Torque Wrench/19 mm
2-1 Coil Lock Nut UNF1/2-20" 2.9 ±0.2 0.6 ±0.02 4.3 ±0.14
Hex. Socket
Torque Wrench/1"
2-3 Solenoid Valve UNF7/8-14" 19.6 ±2.5 2 ±0.25 14.5 ±1.8
Hex. Socket
Torque Wrench/1"
3 Check Valve UNF7/8-14" 19.6 ±2.5 2 ±0.25 14.5 ±1.8
Hex. Socket
CAUTION
AVOID INJURY
Do not damage the tube and retainer of Solenoid
Valve when disassembling the coil lock nut.
In case the tube and retainer gets damaged
(dented, deformed), solenoid valve will not work.
CAUTION
AVOID INJURY
Excessive use of torque will result in defects on
solenoid valve.
Edition 1
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
General Description
This 4-solenoid valve has functions as below.
1. Drives forward.
2. Drives backward.
3. Boosts main pressure.
4. Controls cruise driving.
Specification
Pressure (Max.) 69 bar (70 kg/cm2, 996 psi)
Flow (Max.) 23 L/min (6.1 U.S. gal)
Leakage below 40 ml/min
Solenoid Coil
Rated Voltage DC 24 V
Operation Voltage Range 20 ~ 30 V
Surge Absorber Built in
P3 TS
PL
P2 R
PB
R
PA
T P1
WE1401108
Figure 1
Reference Reference
Description Description
Number Number
C1 Drive Forward C3 Main Pressure Boost
C2 Drive Backward C4 Cruise Control
P3
T
C1 C2 C3 C4 P2
P1
PAR PBR PL TS
WE1401109
Figure 2
C4
C3
1
C2
C1
P3 TS
PL
P2
R
PB
R
PA
T P1
Figure 3 WE1401110
Reference Reference
Description Description
Number Number
1 Body 3 Coil 24 V
2 Spool, Solenoid
2-1
Disassembly
2-2
Assembly
2-3
C3
C4
C2
C1
P3 TS
PL
P2 R
PB
R
PA
T P1
WE1401111
Figure 4
Torque
No. Part Name Screw Spec Tools
N.m kg.m ft lb
Torque Wrench/19 mm
2-1 Coil Lock Nut UNF1/2-20" 2.9 ±0.2 0.6 ±0.02 4.3 ±0.14
Hex. Socket
Torque Wrench/1"
2-3 Solenoid Valve UNF7/8-14" 19.6 ±2.5 2 ±0.25 14.5 ±1.8
Hex. Socket
CAUTION
AVOID INJURY
Do not damage the tube and retainer of Solenoid
Valve when disassembling the coil lock nut.
In case the tube and retainer gets damaged
(dented, deformed), solenoid valve will not work.
CAUTION
AVOID INJURY
Excessive use of torque will result in defects on
solenoid valve.
Edition 1
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
Specification
Direction of Rotation
Clockwise
(Looking on Driveshaft)
Displacement 14.53 cm3/rev
Inlet Pressure Range for Pump -0.2 bar (-0.2 kg/cm2, -2.9 psi)
Max. Continuous Pressure (Rated) 250 bar (255 kg/cm2, 3,626 psi)
Max. Intermittent Pressure 280 bar (286 kg/cm2, 4,061 psi)
Max. Peak Pressure 300 bar (306 kg/cm2, 4,351 psi)
Weight 3 kg (6.6 lb)
In WE1401112
Figure 1
Outlet
Figure 2 EX1301736
Location
Disassembly
1. Clean exterior of pump.
FG001072
Figure 4
FG001074
Figure 5
FG001073
Figure 6
FG001075
Figure 7
FG000834
Figure 8
FG000835
Figure 9
FG001076
Figure 10
FG001077
Figure 11
FG001078
Figure 12
Reassembly
1. Clean all components with care.
FG001078
Figure 13
FG000839
Figure 14
FG000840
Figure 15
FG001079
Figure 16
FG001080
Figure 17
Inlet Side
FG001401
Figure 18
FG001081
Figure 19
FG001082
Figure 20
FG001083
Figure 21
FG001084
Figure 22
FG001085
Figure 23
FG000851
Figure 24
Edition 1
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation and
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
Specification
Rated Pressure 83 bar (85 kg/cm2, 1,209 psi)
Rated Flow 50 L/min (13 U.S. gal)
Internal Leakage 100 cc/min at 68 bar (69 kg/cm2, 986 psi)
Main Relief Pressure Setting 78 bar (80 kg/cm2, 1,131 psi)
Overload Relief Pressure Setting 98 bar (100 kg/cm2, 1,421 psi)
4 1
5 T P 2
pa A B pb
Reference Reference
Description Description
Number Number
1 Inlet Block 4 Main Relief Valve
2 Work Block 5 Overload Relief Valve
3 T Block
EX1403308
Figure 2
A B T
pa pb
pa pb A
B
EX1403309
Figure 3
Spool Operation
1. When Pilot Pressure "Pa" is impressed
When pilot pressure is impressed at the "Pa" port, the
pressured oil flowed from the P port is to be discharged to
the A port through the load check poppet and the spool, as
the hydraulic oil passage for bypass is blocked.
P
A B T
pa pa pb
pb
A
B
EX1403310
Figure 4
P
A B T
pb pa pb
pa
A
B
EX1403311
Figure 5
General Cautions
It is the principle that disassembly and assembly of this valve
should carried out by the manufacturer. In case disassembly
and assembly is inevitably required elsewhere, the following
cautions must be observed.
1. This valve is precisely processed and the gaps among
each part are extremely tiny. This, disassembly and
assembly should be performed very carefully so that any
foreign material such as dust or sand can not intrude into
the valve.
2. For disassembly, a technician should start disassembly
after fully understanding the structure of the valve with
structural drawings and reference drawings.
3. When the valve needs to be removed from a machine, be
sure to put caps on each port and to wash the exterior of
the assembly after checking the caps on each port again
before assembling.
4. In case the disassembled parts need to be placed
unassembled for a while, they must be treated with rust
prevent oil and sealed to prevent rusting.
5. Do not hold a pilot cap, a relief valve and a overload relief
valve when this valve needs to be moved.
6. Even in case disassembly and assembly is not peformed
smoothly, do not hit or treat any part of the product roughly.
7. After disassembly, attach ID tags to each part for accurate
assembly.
8. For O-rings and back up-rings, it is the principle to use the
new ones. And be sure not to damage one during
assembly. (Apply a small portion of grease on the parts for
smooth assembly.)
9. Fasten bolts, overload relief valves and main relief valves
with the specified standard torque.
10. As various tests (relief characteristics test, leakage test,
operational test, etc.) are essential after disassembly and
assembly, do not disassemble this valve if those tests are
not available.
11. Be careful not to damage the O-ring contacting parts of this
valve for preventing oil leakage.
12. Be cautious about safety during operation as this valve
assembly is heavy.
CAUTION
AVOID INJURY
For replacement of a spool, it must be replaced with a sub-
assembly of spool.
CAUTION
AVOID INJURY
During assembly operation of a spool sub-assembly, be
careful so that a foreign material can not intrude into the
sub-assembly.
Figure 6
Figure 7
Figure 8
3. Assembling Spool
Insert the spool into the fixed main body. (Overloaded
force may damage the main body or the spool. When the
spool is stuck, pull it back and press it smoothly while
rotating it.)
Check the direction of the mark, identified during the
disassembly operation.
Assemble the spring seat and the spring.
Figure 9
Figure 10
Figure 11
CAUTION
AVOID INJURY
Be careful not to damage the seat of the removed main
relief valve.
CAUTION
AVOID INJURY
As the main relief valve is a very important part, related to
performance and safety, and hard to be set for the pressure
again, be sure to replace it with an assembly if needed, not
disassembling it.
CAUTION
AVOID INJURY
During assembly of a main relief valve, be careful so that a
foreign material cannot intrude into the main frame.
Figure 12
Figure 13
Figure 14
CAUTION
AVOID INJURY
As the removed overload relief valves may have different
setting values for each position, identify them for the
original position with tags for accurate assembly.
CAUTION
AVOID INJURY
As the overload relief valve is a precision part, be cautious
about damage or intrusion of foreign materials.
CAUTION
AVOID INJURY
As the overload relief valve is a very important part, related
to performance and safety, and hard to be set for the
pressure again, be sure to replace it with an assembly if
needed, not disassembling it.
CAUTION
AVOID INJURY
During disassembly of a overload relief valve, be careful not
to damage the return cap by the spanner.
Figure 15
Figure 16
Figure 17
CAUTION
AVOID INJURY
During assembly of the sub-block assembly, be careful so
that a foreign material cannot intrude into the main body.
Figure 18
Figure 19
Figure 20
Figure 21
Edition 1
Swing Bearing
Safety Instructions ..........................................6-1-5
General ...........................................................6-1-6
General Description................................................... 6-1-6
Parts List ................................................................... 6-1-6
Maintenance Guidelines .................................6-1-7
Disassembly ...................................................6-1-8
Reassembly ..................................................6-1-10
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
General Description
The swing bearing, which connects the upper structure with the
lower structure, consists of a inner ring, outer ring and ball
bearings. During swing movement, power from the swing motor
is transferred to the pinion by planetary gears connected to
gears on the inner ring, which is fixed in the undercarriage. Ball
bearings turn the outer ring.
Parts List
2 6
FG1301305
Figure 1
Reference Reference
Description Description
Number Number
1 Outer Ring 5 Ball
2 Inner Ring 6 Retainer
3 Tapered Pin 7 Seal
4 Plug
Figure 5
Figure 6
3. Lift outer ring and check that inner ring can move freely.
See Figure 7, if not, replace seal (7, Figure 8).
• Weight: 205 kg (452 lb)
Figure 7 WE1401490
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
3. Top plug (4) into outer race (1) and then, drive pin (3) into
the pinhole.
Caulk the head of pin (3) with a punch.
Fill grease through the grease fitting.
Figure 13
Edition 1
Front Axle
Safety Instructions ..........................................6-2-5
General ...........................................................6-2-5
Specification .............................................................. 6-2-5
Parts List ................................................................... 6-2-6
DX140W-5............................................................ 6-2-6
DX160W-5............................................................ 6-2-7
Lubrication and Maintenance .........................6-2-8
Oil Change ........................................................... 6-2-8
Oil Change Interval............................................... 6-2-9
Oil Level Check .................................................... 6-2-9
Brake .................................................................... 6-2-9
Brake Wear Measurement............................6-2-10
Lining Wear Measurement of Multi-disc Brake... 6-2-11
Disassembly .................................................6-2-12
Steering ................................................................... 6-2-12
Output...................................................................... 6-2-15
Planetary Carrier ................................................ 6-2-16
Brake/Hub .......................................................... 6-2-16
Knuckle Housing ................................................ 6-2-20
Input ........................................................................ 6-2-22
Differential ............................................................... 6-2-25
Reassembly ..................................................6-2-28
Differential ............................................................... 6-2-28
Input ........................................................................ 6-2-30
Determine Thickness of the Shim to Obtain a
Correct Contact Pattern...................................... 6-2-30
Adjust Rolling Moment of Drive Pinion Bearing.. 6-2-32
Determine Shim for Setting the Bearing Rolling Torque
(Differential Bearing) and Backlash
(Bevel Gear Set)................................................. 6-2-33
Check the Contact Pattern of the Bevel Gear Set . 6-2-34
Input Flange ............................................................ 6-2-36
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
Specification
DX140W-5 DX160W-5
Type Fully Floating Planetary Drive
Overall Reduction Ratio 16 : 1
Differential Oil Volume 9 L (2.4 U.S. gal.) 10.5 L (2.8 U.S. gal.)
Hub Oil Volume Per Each 2.4 L (0.63 U.S. gal.)
Circle Diameter 335 mm
Wheel Bolt
No. of Bolt/Thread 10 ea/M22 x 1.5
Type Wet Disc
Brake
Operating Pressure 60 bar (61 kg/cm2, 870 psi)
Travelling 10,000 kg (22,046 lb) 12,850 kg (28,329 lb)
Axle Loading
Working 25,000 kg (55,115 lb) 33,350 kg (73,524 lb)
Rated Pressure 170 bar (173 kg/cm2, 2,466 psi)
Steering
Relief Pressure 225 bar (229 kg/cm2, 3,263 psi)
Weight 560 kg (1,235 lb) 655 kg (1,444 lb)
DX140W-5
285
280
135
120
40
80 90
30
10 270
130
510
320
160
630 205 390-2 501
540 502
Reference Reference
Description Description
Number Number
10 Seal; Shaft 150.15 x 178-13 285 Disc; I. Clutch S = 2.0
30 Bearing; Roller 285 Disc; I. Clutch S = 2.5
40 Bearing; Roller 285 Disc; I. Clutch S = 3.0
80 Hub 320 Washer; Thrust S = 1.5
90 Ring, O 320 Washer; Thrust S = 2.0
120 Carrier, Disk 320 Washer, Thrust S = 5.0
130 Ring, O 320 Washer; Thrust S = 3.0
135 Ring, O 320 Washer; Thrust S = 1.7
160 Gear, Ring 320 Washer; Thrust S = 2.2
200 Piston 320 Washer; Thrust S = 2.7
205 Pin; Cylindrical 390 Carrier Assembly; Planetary Gear
210 U-ring 390-1 Carrier; Planet
214 Ring; Support 390-2 Gear, Planetary
230 U-ring 390-3 Bearing, Roller
232 Ring; Support 390-5 Ring, Retaining
238 Spring; Compression 501 Plug; Screw
239 Spring; Compression 502 O-ring
256 Screw 510 Screw; Hex
258 Sleeve; Spring 540 Bolt, Wheel; M22 x 1.5 x 55
270 Disc, Clutch; Outer 630 Screw; Cap
280 Disc; I. Clutch S = 2.5
270
90
80 30
540 60 280
275
130 501
393
30 502
630 205
10
Reference Reference
Description Description
Number Number
10 Seal; Shaft 167.8 x 198 280 Disc; I. Clutch A = 2.0
30 Bearing; Roller 280 Disc; I. Clutch A = 3.0
60 Bush 280 Disc; I. Clutch A = 2.5
80 Hub 320 Washer; Thrust S = 1.5
90 Ring, O 320 Washer; Thrust S = 1.7
120 Carrier, Disk 320 Washer; Thrust S = 2.0
130 O-ring 320 Washer; Thrust S = 2.2
135 O-ring 320 Washer, Thrust S = 5.0
160 Ring; Gear 320 Washer; Thrust S = 2.7
200 Piston 320 Washer; Thrust S = 3.0
205 Pin; Cylindrical 390 Carrier Assembly; Planetary Gear
210 U-ring 391 Carrier; Planet
214 Ring; Support 392 Gear; Planet
230 U-ring 393 Bearing; Roller
232 Ring; Support 396 Ring; Retaining
238 Spring; Compression 501 Plug; Screw
239 Spring; Compression 502 O-ring
256 Screw 510 Screw; Cap
258 Sleeve; Spring 630 Screw; Cap
270 Disc; O. Clutch 540 Bolt, Wheel; M22 x 1.5 x 48
275 Disc; I. Clutch A = 2.5
4 DX160W-5
5 4 DX140W-5
3
1
2
Figure 3 WE1401492
Reference Reference
Description Description
Number Number
Oil Drain Hole Oil Filler/Oil Check Hole
1 3
(M36 x 1.5 Axle Drive Housing) (M36 x 1.5 Axle Drive Housing)
Oil Drain/Oil Filler Hole 4 Brake Connection Pipe
2
(M36 x 1.5 Output Units) 5 Brake Breather Valve
WARNING
AVOID DEATH OR SERIOUS INJURY
To avoid injury when opening the oil drain and oil filler
plug (2), due to a possible pressure build-up in the oil
system of the planetary carrier, bring drain hole to
topmost position (12 o’clock) and carefully unscrew oil
drain and oil filler plug (2).
Then bring drain hole to lowermost position (6 o’clock)
and drain oil from outputs.
Brake
The following oils are admissible for the pneumo-hydraulic
operated or accumulator operated brake actuation
1. Motor oils SAE 10 W acc. to specification MIL-L 2104 C,
MIL-L 46152, API-CC, CD, SC, SD, SE
2. ATF. oils type A, Suffix A, Dexron von II D
WARNING
AVOID DEATH OR SERIOUS INJURY
The measurement of wear on the multi-disc brake only
gives limited information on the total state of the plate pack.
Without disassembling the output.
CAUTION
AVOID INJURY
To avoid injury when opening the oil drain/oil filler plug (1),
due to a possible pressure build-up in the planetary carrier
bring drain hole to topmost position (12 o’clock) and
carefully unscrew oil drain and filler plug (1).
4 5 6 7
WE1401344
Figure 5
• Take limit value of piston stroke (at max. wear) from the
chart below. WE1401345
Figure 6
Lined Piston Stroke Limit Value of Piston
Model
Discs with New Discs Stroke (X) at Max. Wear
DX140W-5 8 pcs. 0.7 ... 1.3 mm 7.0 mm
DX160W-5 6 pcs. 0.7 ... 1.3 mm 6.0 mm
WARNING
AVOID DEATH OR SERIOUS INJURY
Secure axle by means of a support (arrow).
Figure 7
Steering
1. Loosen hex nuts on both tie rods.
Figure 8 WE1401261
WARNING
AVOID DEATH OR SERIOUS INJURY
Drive out tie rod from bevel seat.
Use suitable mandrel (brass/aluminium).
Figure 9 WE1401262
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Output
1. Loosen screw plug and drain oil from the axle.
IMPORTANT
Use suitable collecting basin - environmental
protection!
IMPORTANT
To avoid injury due to a possible pressure build-up in
the oil system of the planetary carrier, bring oil filler
and control plug to 12 o’clock position and carefully
unscrew! use suitable mandrel (brass/aluminium).
Then bring drain hole to 6 o’clock position and drain the
oil!
Use suitable collecting basin - environmental Figure 22
protection!
Figure 23
Figure 24
Figure 25
Brake/Hub
1. Unsnap retaining ring and remove both thrust washers.
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
9. Remove O-ring (arrow) and lift-off disc carrier from the joint
housing.
Figure 34
IMPORTANT
Pay attention to the releasing bearing inner ring.
Figure 35 WE1401263
11. Lift-off shaft seal (arrow) with lever and remove both
bearing outer rings from hub.
Figure 36
Figure 37
Figure 38
Reference
Description
Number
1 Bearing Pin 6
3
2 Knuckle Housing
2 5
3 Axle Housing
4 Shim (Only on Lower Bearing Pin) 4
1
FG002333
5 O-ring
Figure 39
6 Sealing Cap
7 Taper Roller Bearing
IMPORTANT
Remove lower bearing pin - by means of lifting device/
see Figure 41 - not before securing the knuckle
housing.
Figure 40
IMPORTANT
Pay attention to releasing O-ring.
Figure 41
4. Remove bearing inner ring (7), O-ring (5), sealing cap (6)
and brake connection screw neck (8) from bearing pin (1).
Figure 42
IMPORTANT
Pay attention to seal ring in the axle housing - risk of
damage.
Figure 43
IMPORTANT
Pay attention to seal ring in the axle housing - risk of
damage.
Figure 44
7. Pull out seal ring and afterwards the bushing behind from
the knuckle housing.
Figure 45
8. Pull out seal ring and afterwards the bushing behind from
the axle housing.
Figure 46
Figure 47
Input
1. Support axle to axle drive housing (see arrow).
Then secure axle housing (crown wheel side) by means of
lifting tackle and loosen threaded joint.
Then separate axle housing from axle drive housing.
IMPORTANT
Pay attention to possibly releasing differential. Figure 48
2. Remove bearing outer ring (1, Figure 49) and the shim
behind as well as O-ring (2) from axle housing.
IMPORTANT
Mark shim (regarding position/bearing allocation) -
assembly aid.
Figure 49
Figure 50
Figure 51
5. Legend to Figure 52 10
1
Reference
Description
Number
1 Input Pinion
2 Hex. Nut 9
3 Washer 7
4 Input Flange 8
5 Screen Sheet 5
6
6 Seal Ring 3 4
7 Taper Roller Bearing
8 Spacer Ring (Bearing Rolling Moment) 2
FG002353
9 Shim (Contact Pattern) Figure 52
10 Input Housing
IMPORTANT
Hexagon nut is installed with Loctite (# 262).
Figure 53
7. Remove flange.
If required. remove screen sheet from output flange.
Figure 54
Figure 55
IMPORTANT
Use plastic hammer!
If taper roller bearings should not be replaced, pay
attention that the outside bearing inner ring - with all
its rolls - is in contact with bearing outer ring when
driving out the input pinion.
Figure 56
Figure 57
11. Pull off outer bearing outer ring from bearing hole.
(S) Internal extractor 5870 300 019
(S) Counter support 5870 300 020
Figure 58
IMPORTANT
Mark shim (reg. position/bearing allocation) -
assembly aid.
Figure 59
13. If required:
Then remove bushing from hole.
NOTE: Bushings are destroyed by this.
Figure 60
Differential
1. Constant spacers (a).
a
WE1401264
Figure 61
WE1401265
Figure 62
Figure 63 WE1401266
Figure 64 WE1401267
WE1401268
Figure 65
WE1401269
Figure 66
WE1401271
Figure 68
WE1401272
Figure 69
Differential
1. Constant spacers (a).
a
WE1401264
Figure 70
Legend to Figure 71
3
Reference 2
Description
Number 1
1 Axle Bevel Gear
2 Pressure Disk
3 Constant Ring
WE1401273
Figure 71
IMPORTANT
4
WE1401276
Figure 73
Figure 75 WE1401279
Figure 76 WE1401280
Figure 77 WE1401281
IMPORTANT
Use an appropriate support (arrow) - differential may
not be supported on the bearing cage.
Figure 78 WE1401282
Input
WE1400298
Figure 79
IMPORTANT
Make sure that the rollers are located without any play
(rotate bearing inner ring several times in both
directions roller setting).
WE1400301
Figure 82
Figure 83
Figure 84
Figure 85
Figure 86
Figure 87
Figure 88
IMPORTANT 70
WE1401283
Figure 89
Test dimension "70" is stamped into the crown wheel rear.
Without + or - deviation specification, this corresponds to
test dimension/Actual value "70" in the table below.
According to this value the necessary shims are allocated
in the table below!
In case of + or - deviation of the test dimension for
production reasons, it is additionally signed on the
crown wheel rear (e.g. -20 or -10. 10 or 20).
In accordance with this deviation the necessary shims
are allocated in the below table!
Legend to Figure 90
1
Reference 2
Description
Number
3 4
1 Crown Wheel
2 Differential Carrier
3 Shim (Crown Wheel Side)
5 6
4 Shim (Differential Carrier Side)
5 Axle Housing
6 Axle Housing
8
7 Axle Drive Housing 7
8 Input Pinion WE1401284
Figure 90
WE1401285
Figure 91
WE1401286
Figure 92
Figure 93 WE1401287
IMPORTANT
Then bring axle into horizontal position and
reassemble the second clamping angle (S).
Figure 94
IMPORTANT
In case of a contact pattern deviation a measuring WE1401289
mistake was made when determining the shim Figure 95
(Figure 82), which must be absolutely corrected.
Figure 96
Figure 97
WE1401291
Figure 98
Legend to Figure 99
1
Reference 2
Description
Number
1 Input Pinion
2 Axle Drive Housing 3
2. Mount shaft seal ring with the seal lip showing to the oil
chamber.
(S) Driver tool 5870 048 286
IMPORTANT
Use of the specified driver tool (S) ensures the exact
installation position of the shaft seal ring.
Just before fitting, wet contact face shaft seal ring/axle WE1401293
drive housing with lubricant. Figure 100
Apply grease on seal and dust lip of the shaft seal ring.
IMPORTANT
Wet thread of the hexagon nut with Loctite # 262.
WE1401294
Figure 101
Reference 2
Description
Number
1 Axle Housing B
Y
2 Bushing
B Installation Dimension 1.0 ±0.3 mm
Installation Position/Lubrication
Y
Groove Outlet of Bushing (Top View)
WE1401295
Figure 103
IMPORTANT
Lubrication groove outlet (V-point) must be mounted
in 6 o'clock position (bottom) and showing to the oil
chamber side.
Use of the specified driver tool (S) ensures the exact
installation depth of the bushing.
2. Flush-mount seal ring with the seal lip showing to the oil
chamber (see sketch below) into the axle housing hole.
DX140W-5
(S) Driver tool 5870 055 081
(S) Handle 5870 260 002
DX160W-5
(S) Driver tool 5870 055 090
(S) Handle 5870 260 002
Figure 104
Reference 1
Description
Number 4
3
1 Axle Housing
2
2 Shaft Seal Ring
Y
3 Bushing
4
4 Bearing Outer Rings (Pivot Bearing)
Lubrication Groove Outlet
Y (V-point-in 6 o'clock Position and on WE1401296
Oil Chamber Side) Figure 105
3. Insert both bearing outer rings into the pivot bearing holes
of the axle housing.
DX140W-5
(S) Driver tool 5870 058 058
(S) Handle 5870 260 002
DX160W-5
(S) Driver tool 5870 058 022
(S) Handle 5870 260 002
Figure 106
4. Install the u-joint shaft-by inserting the u-joint shaft into the
axle bevel gear teeth.
IMPORTANT
Pay attention to shaft seal ring in the axle housing -
risk of damage.
IMPORTANT
Operation is only required when using a new knuckle
housing. WE1401298
Figure 108
Reference 1
Description
Number B
1 Knuckle Housing
2
2 Bushing
Installation Dimension
B DX140W-5 1 ±0.2 mm
DX160W-5 2 ±0.2 mm
Installation Position/Lubrication Groove Y WE1401300
Y Figure 110
Outlet of the Bushing
IMPORTANT
Lubrication groove outlet (V-point) must be mounted
in 6 o'clock position (bottom) and showing to the oil
chamber side (referred to the axle fitted into the
vehicle).
Use of the specified driver tool (S) ensures the exact
installation depth of the bushing.
IMPORTANT
Use of the specified driver tool (S) ensures the exact
installation position of the shaft seal ring.
Just before fitting wet contact face shaft seal ring/
knuckle housing with sealing agent.
Apply grease on seal and dust lip of the seal ring.
Reference 1
Description
Number
2
1 Knuckle Housing
2 Shaft Seal Ring W
3 Bushing
Installation Dimension - Shaft Seal Ring Y 3
W DX140W-5 2 ±0.2 mm
DX160W-5 3.5 ±0.2 mm WE1401302
Lubrication Groove Outlet (V-point) Must Figure 112
Be Mounted in 6 o'clock Position and
Y Showing to the Oil Chamber Side
(Referred to the Axle Fitted Into the
Vehicle)
WE1401303
Figure 113
WE1401304
Figure 114
IMPORTANT WE1401305
Figure 115
Pay attention to shaft seal ring in the knuckle housing
- risk of danger.
IMPORTANT
Pay attention to installation position - mount bearing
pin with lubrication nipple showing to axle centre.
Use of "new" locking screw is imperative. (DX140W-5)
WE1401306
Figure 116
WE1401307
Figure 117
IMPORTANT
Observe installation position - mount bearing pin with
oil supply holes showing to axle centre.
Figure 118
IMPORTANT
Use of new locking screws is imperative. Figure 119
WE1401493
Figure 120 DX140W-5
WE1401343
Figure 121 DX160W-5
3
WE1401308
Figure 122
IMPORTANT
Use of the specified driver tool (S) ensures the exact
installation position of the shaft seal ring.
Wet the outer diameter of the shaft seal ring with
Loctite # 574. Figure 123 WE1401309
WE1401311
Figure 125
WE1401312
Figure 126
IMPORTANT
Just before fitting wet the seal lips of the shaft seal
ring with lubricant.
WE1401313
Figure 127
6. Oil O-ring and insert it into the annular groove (see arrow)
of the knuckle housing.
Then install disk carrier.
WE1401314
Figure 128
WE1401315
Figure 129
IMPORTANT
While tightening the slotted nut rotate hub in both
directions several times - roller setting. WE1401316
Figure 130
Apply lubricant (Molycote Paste 1,000) to thread
knuckle housing/slotted nut.
IMPORTANT
Take the actually required disk fitting/arrangement
from the corresponding spare parts list.
Bring inner clutch disks in a position where one of the
tooth recesses (see arrow) is in 6 o'clock position - WE1401318
with axle being installed in the vehicle. Figure 132
WE1401319
Figure 133
IMPORTANT
Observe installation position, see Figure 135.
WE1401320
Figure 134
Figure 136
Figure 137
IMPORTANT
Use hexagon screws just once.
WE1401322
Figure 138
WE1400307
Figure 139
IMPORTANT
Ensure exact toothing position of oil supply holes .
knuckle housing/ring gear (pressure oil supply to
brake piston).
WE1401323
Figure 140
WE1401324
Figure 141
IMPORTANT
WE1401325
Breathe brake completely before starting the test. Figure 143
• Test media:
Motor oils SAE-lO W correspond to, MIL-L 2104 C,
MIL-L 46152, API-CC, CD, SC, SD, SE, ATF-oils
type A, Suffix A Dexron of II D
• High-pressure test:
Build up test pressure p = 100 bar (101.9 kg/
cm2, 1,469.5 psi) and close locking valve of HP pump.
A pressure drop by max. 3 bar (3 kg/cm2, 43.5 psi) is
permissible during a 5-minute test duration.
• Low pressure test:
Reduce test pressure to p = 5 bar (5 kg/cm2, 72.5 psi)
and close locking valve.
No pressure drop is allowed during a 5-minute testing
duration.
WE1401326
IMPORTANT Figure 144
Figure 145 X
WE1401327
Calculation Example: 1 2 3
Dimension "A" 83.10 mm
Dimension "B" - 82.10 mm
Difference = Piston stroke = 1.00 mm B
IMPORTANT
If the required piston stroke (0.7 ... 1.3 mm) is not
achieved, correct it with the corresponding inner
Figure 146 WE1401328
clutch disk(s) - refer to corresponding spare parts list.
Reference
Description
Number
1 Ring Gear
2 Measuring Hole
3 Piston
X Piston Stroke/Disk Clearance
WE1401329
Figure 147
IMPORTANT
Observe installation position - ensure that both lugs of
the thrust washer are engaged each in a spare fixing
hole of the slotted nut.
WE1401330
Figure 148
WE1401331
Figure 149
WE1401332
Figure 150
IMPORTANT
4
IMPORTANT
Mount bearing inner ring with large radius, showing to
the planetary carrier (downwards).
WE1401337
Figure 155
Pivot Bearing
Heat pivot bearing hole by means of hot-air blower and insert
super-cooled bushing(s).
IMPORTANT
Observe installation position for bushing version with slot,
insert bushings - with slot in 12 o’clock position.
Figure 156
Steering
Figure 157
Reference Reference
Description Description
Number Number
Steering Cylinder 7 Rod Wiper
1
(Cylinder Tube with Brake Head) 8 Dual Ring
2 Brake Head 9 Retaining Ring
3 Piston Rod 10 O-ring
4a O-ring 11 Retaining Ring
Piston Sealing
4b Form Seal Ring 12 Flange
5 Guide Ring 13 Retaining Ring
6 U-ring 14 Wrench Socket (Piston Rod)
1. Mount U-ring (6) and wiper (7) in the steering cylinder (1).
IMPORTANT
Observe installation position - in this connection see
detailed sketch.
Figure 158
Detailed sketch:
Figure 159
Figure 160
3. Install form seal ring (4a) and press with inner installer (S2)
into annular groove (arrow) of piston (3).
Figure 161
Figure 162
Figure 163
IMPORTANT
Observe installation position - insert piston rod (3)
with wrench point of attach (14 - Figure 157) showing
in direction of arrow.
Figure 164
IMPORTANT
Slightly oil all sealing elements before installing the
piston rod.
7. Insert u-ring (6), rod wiper (7) and dual ring (8) in brake
head (2).
Observe installation position - in this connection refer to
detailed sketch.
Figure 165
Detailed Sketch:
Figure 166
IMPORTANT
Slightly oil all sealing elements before inserting the
brake head.
Figure 167
Figure 168
10. Bring the inserted brake head (8) into contact position
(arrow) on the snapped circlip (9).
Oil O-ring (10) and insert into recess.
Figure 169
Figure 170
IMPORTANT
Observe installation position of flange - chamfer
(circlip contact arrow) to show towards circlip.
Figure 171
Figure 172
Figure 173
15. Bolt hexagon nut (2) and ball joint (3) to axial joint (1).
IMPORTANT 3
2
1
Do not tighten hexagon nut before setting the track.
IMPORTANT
Wet thread of the axial joint with Loctite (# 243).
WE1401339
Figure 175
17. Install tie rod into knuckle housing and fix with "new"
locking nut.
• Torque (M27 x 1.5): 600 N.m (61.2 kg.m, 443 ft lb)
IMPORTANT
Use locking screws just once.
WE1401340
Figure 176
A2
5 5
Y
1
4 4
3 X
3
2 A1
1 1
WE1400605
Figure 177
Reference Reference
Description Description
Number Number
1 Straightedge Installation Dimension
X
2 Measuring Device (Central Position - Piston Rod)
3 Nut Distance - Wheel Center to Rim
Y
Flange
4 Stop Screw with Nut (Internal)
5 Stop Screw (Outer)
IMPORTANT
Do not change axial position of piston rod any more
during track setting.
IMPORTANT
For a toe-in and toe-out setting, which might be
required, stick to the vehicle manufacturer's
specification.
Make setting on both output sides.
IMPORTANT
When track setting is required, steering angle setting may
only be carried out after track setting has been completed.
5 5
4 4
3 X
3
2
1
WE1400606
Figure 178
IMPORTANT
Take the value of the steering angle to be set from the
vehicle manufacturer's specifications.
IMPORTANT
Make setting on both output sides.
FG003411
Figure 180
3. Mount oil drain, oil filler plug (1) - fitted with "new" O-ring -
in both outputs.
• Torque (M 36 x 1.5): 50 N.m (5 kg.m, 36.9 ft lb)
• Oil volume: about 2.4 L (0.6 U.S. gal)
1
IMPORTANT
Prior to putting the axle into operation fill it with oil in
accordance with the corresponding lubrication and WE1401342
maintenance instructions. Figure 181
Edition 1
Rear Axle
Safety Instructions ..........................................6-3-5
General ...........................................................6-3-5
Specification .............................................................. 6-3-5
Parts List ................................................................... 6-3-6
DX140W-5............................................................ 6-3-6
DX160W-5............................................................ 6-3-7
Lubrication and Maintenance .........................6-3-8
Oil Change ........................................................... 6-3-8
Oil Change Interval............................................... 6-3-9
Oil Level Check .................................................... 6-3-9
Brake .................................................................... 6-3-9
Brake Wear Measurement............................6-3-10
Lining Wear Measurement of Multi - Disc Brake.. 6-3-11
Disassembly .................................................6-3-12
Output...................................................................... 6-3-12
Brake ....................................................................... 6-3-14
Input - Transmission................................................ 6-3-17
Differential ............................................................... 6-3-19
Reassembly ..................................................6-3-22
Differential ............................................................... 6-3-22
Input ........................................................................ 6-3-24
Determine Shim for Setting the Bearing Rolling Torque
(Differential Bearing) and Backlash
(Bevel Gear Set)................................................. 6-3-24
Check the Contact Pattern of the Bevel Gear Set... 6-3-25
Output...................................................................... 6-3-27
Hub Carrier/Hub ................................................. 6-3-27
Multi Disk Brake ................................................. 6-3-31
Planetary Carrier ................................................ 6-3-36
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
Specification
DX140W-5 DX160W-5
Type Fully Floating Planetary Drive
Overall Reduction Ratio 16 : 1
Oil Volume 11.2 L (2.9 U.S. gal.) 14 L (3.7 U.S. gal.)
Differential Hub
Oil Volume Per Each 2.4 L (0.6 U.S. gal.)
Circle Diameter 335 mm
Wheel Bolt
No. of Bolt/Thread 10 ea/M22 x 1.5
Type Wet Disc
Brake
Operating Pressure 60 bar (61 kg/cm2, 870 psi)
Travelling 10,000 kg (22,046 lb) 12,850 kg (28,329 lb)
Axle Loading
Working 25,000 kg (55,115 lb) 33,350 kg (73,524 lb)
Weight 573 kg (1,263 lb) 652 kg (1,437 lb)
DX140W-5
285
280
135
120
40
80 90
30
10 270
130
510
320
160
630 205 390-2 501
540 502
Reference Reference
Description Description
Number Number
10 Seal; Shaft 150.15 x 178-13 285 Disc; I. Clutch S = 2.0
30 Bearing; Roller 285 Disc; I. Clutch S = 2.5
40 Bearing; Roller 285 Disc; I. Clutch S = 3.0
80 Hub 320 Washer; Thrust S = 1.5
90 Ring, O 320 Washer; Thrust S = 2.0
120 Carrier, Disk 320 Washer, Thrust S = 5.0
130 Ring, O 320 Washer; Thrust S = 3.0
135 Ring, O 320 Washer; Thrust S = 1.7
160 Gear, Ring 320 Washer; Thrust S = 2.2
200 Piston 320 Washer; Thrust S = 2.7
205 Pin; Cylindrical 390 Carrier Assembly; Planetary Gear
210 U-ring 390-1 Carrier; Planet
214 Ring; Support 390-2 Gear, Planetary
230 U-ring 390-3 Bearing, Roller
232 Ring; Support 390-5 Ring, Retaining
238 Spring; Compression 501 Plug; Screw
239 Spring; Compression 502 O-ring
256 Screw 510 Screw; Cap
258 Sleeve; Spring 540 Bolt, Wheel; M22 x 1.5 x 55
270 Disc, Clutch; Outer 630 Screw; Cap
280 Disc; I. Clutch S = 2.5
280
270
90
30
80
540 60
10 275
130 390-1
502 501
130 320
30 390-5
205
630
230
232 510
390-2
238 390-3
256
120 390
135
160
214
258 239 210
200 WE1400638
Figure 2
Reference Reference
Description Description
Number Number
10 Seal; Shaft 167.8 x 198 280 Disc; I. Clutch A = 2.0
30 Bearing; Roller 280 Disc; I. Clutch A = 3.0
60 Bush 280 Disc; I. Clutch A = 2.5
80 Hub 320 Washer; Thrust S = 1.5
90 O-ring 320 Washer; Thrust S = 1.7
120 Carrier; Disk 320 Washer; Thrust S = 2.0
130 O-ring 320 Washer; Thrust S = 2.2
135 O-ring 320 Washer, Thrust S = 5.0
160 Ring; Gear 320 Washer; Thrust S = 2.7
200 Piston 320 Washer; Thrust S = 3.0
205 Pin; Cylindrical 390 Carrier Assembly; Planet
210 U-ring 390 Carrier Assembly; Planetary Gear
214 Ring; Support 390-1 Carrier; Planet
230 U-ring 390-2 Gear; Planet
232 Ring; Support 390-3 Bearing; Roller
238 Spring; Compression 390-5 Ring; Retaining
239 Spring; Compression 501 Plug; Screw
256 Screw 502 O-ring
258 Sleeve; Spring 510 Screw; Cap
270 Disc; O.Clutch 540 Bolt, Wheel; M22 x 1.5 x 48
275 Disc; I. Clutch A = 2.5 630 Screw; Cap
3
1
WE1400639
Figure 3
Reference Reference
Description Description
Number Number
Oil Drain Hole Oil Filler/Oil Check Hole
1 3
(M36 x 1.5 Axle Drive Housing) (M36 x 1.5 Axle Drive Housing)
Oil Drain/Oil Filler Hole 4 Brake Connection Pipe
2
(M36 x 1.5 Output Units) 5 Brake Breather Valve
WARNING
AVOID DEATH OR SERIOUS INJURY
To avoid injury when opening the oil drain and oil filler
plug (2), due to a possible pressure build-up in the oil
system of the planetary carrier, bring drain hole to
topmost position (12 o’clock) and carefully unscrew oil
drain and oil filler plug (2).
Then bring drain hole to lowermost position (6 o’clock)
and drain oil from outputs.
Brake
The following oils are admissible for the pneum. hydraulic
operated or accumulator operated brake actuation:
1. Motor oils SAE 10 W acc. to specification MIL-L 2104 C,
MIL-L 46152, API-CC, CD, SC, SD, SE
2. ATF. oils type A, Suffix A, Dexron of II D
WARNING
AVOID DEATH OR SERIOUS INJURY
The measurement of wear on the multi-disc brake only
gives limited information on the total state of the plate pack
- without disassembly of output.
CAUTION
AVOID INJURY
To avoid injury when opening the oil drain/oil filler plug (1),
due to a possible pressure build-up in the planetary carrier
bring drain hole to topmost position (12 o’clock) and
carefully unscrew oil drain and oil filler plug (1).
Oil Stand
FG006855
Figure 4
Reference
Description
Number
1 Oil Filler - Oil Drain Hole
2 Gauge Hole (ø = 10 mm) in Ring Gear
3 Dial Indicator with Magnetic Stand 4 5 6 7
4 Planetary Carrier
5 Ring Gear WE1401344
6 Piston Figure 5
7 Disc Package
X Piston Stroke
• Take limit value of piston stroke (at max. wear) from the
chart below. WE1401345
Figure 6
Lined Piston Stroke Limit Value of Piston
Model
Discs with New Discs Stroke (X) at Max. Wear
DX140W-5 8 pcs. 0.7 ... 1.3 mm 7.0 mm
DX160W-5 6 pcs. 0.7 ... 1.3 mm 6.0 mm
Output
1. Mount the axle to the assembly truck.
Figure 7
2. Loosen oil drain plug and drain oil from the axle - use
suitable collecting basin.
Figure 8
IMPORTANT
To avoid injury when opening the oil drain and oil filler
plug, due to a possible pressure build-up in the oil
system of the planetary carrier - bring drain hole to
topmost position (12 o’clock) and carefully unscrew oil
drain and oil filler plug.
Then bring drain hole to lowermost position (6 o’clock)
and drain oil from outputs - use suitable collecting
basin! Then bring drain hole to 6 o’clock position and Figure 9
drain the oil.
Figure 10
Figure 11
Figure 12
Figure 13
WE1400311
Figure 14
Brake
1. Remove slotted nut mount (cylinder screw).
Figure 15
Figure 16
Figure 17
IMPORTANT
Pay attention to the releasing O-ring (arrow).
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
10. Secure hub by means of lifting bracket, pull hub from hub
carrier by means of pressure piece and two-armed puller.
IMPORTANT
Pay attention to the releasing bearing inner ring.
Figure 24
11. Lift-off shaft seal (arrow) with lever and remove both
bearing outer rings from hub.
Figure 25
Figure 26
Figure 27
Figure 28
Input - Transmission
1. Fix transmission by means of a lifting strap and loosen
threaded connection. (Transmission/axle drive housing).
Figure 29
IMPORTANT
For assembly and disassembly of the transmission
stick to section.
Figure 30
Figure 31
IMPORTANT
Secure axle by means of a support (arrow).
IMPORTANT
Pay attention to releasing differential.
Figure 32
IMPORTANT
Mark shim (installation position/bearing allocation) -
assembly aid!
Figure 33
Figure 34
IMPORTANT
Mark shim (installation position/bearing allocation) -
assembly aid.
Figure 35
Differential
1. Constant spacers (a).
a
WE1401264
Figure 36
WE1401265
Figure 37
Figure 38 WE1401266
Figure 39 WE1401267
WE1401268
Figure 40
WE1401269
Figure 41
WE1401271
Figure 43
WE1401272
Figure 44
Differential
1. Constant spacers (a).
a
WE1401264
Figure 45
Legend to Figure 46
3
Reference 2
Description
Number 1
1 Axle Bevel Gear
2 Pressure Disk
3 Constant Ring
WE1401273
Figure 46
IMPORTANT
4
WE1401276
Figure 48
Figure 50 WE1401279
Figure 51 WE1401280
Figure 52 WE1401281
IMPORTANT
Use an appropriate support (arrow) - differential may
not be supported on the bearing cage.
Figure 53 WE1401282
Input
IMPORTANT 70
WE1401283
Figure 54
Test dimension "70" is stamped into the crown wheel rear.
Without + or - deviation specification, this corresponds to
test dimension/Actual value "70" in the table below.
According to this value the necessary shims are allocated
in the table below!
In case of + or - deviation of the test dimension for
production reasons, it is additionally signed on the
crown wheel rear (e.g. -20 or -10. 10 or 20).
In accordance with this deviation the necessary shims
are allocated in the below table!
Legend to Figure 55
1
Reference 2
Description
Number
3 4
1 Crown Wheel
2 Differential Carrier
3 Shim (Crown Wheel Side)
5 6
4 Shim (Differential Carrier Side)
5 Axle Housing
6 Axle Housing
8
7 Axle Drive Housing 7
8 Input Pinion WE1401284
Figure 55
WE1401285
Figure 56
WE1401286
Figure 57
WE1401346
Figure 58
IMPORTANT
Preliminarily fix axle housing without O-ring!
WE1401347
Figure 59
Figure 60
5. By rotating the input flange, roll crown wheel over the input
pinion in both directions several times.
Then remove transmission and axle housing and lift
differential out of the axle drive housing.
Compare the obtained contact pattern with contact pattern.
WE1401348
Figure 61
Figure 62
Figure 63
Figure 64
Output
Hub Carrier/Hub
1. Grease O-ring (1) and mount it to hub carrier.
The following operation is only required when fitting a new
hub carrier:
Seal machining openings (arrows) of oil supply holes with
plugs.
(S) Lever riveting tongs 5870 320 016
Figure 65
IMPORTANT
Ensure radial installation position! Stamped circle (see
arrow) must be in uppermost (12 o'clock) position.
Figure 66
Figure 67
Figure 68
5. Insert both bearing outer rings (1) of the hub bearing until
contact position is obtained.
2
Press wheel bolts (2) into the hub until contact position is
obtained. 1
3
WE1401308
Figure 69
IMPORTANT
Use of the specified driver tool (S) ensures the exact
installation position of the shaft seal ring.
Wet the outer diameter of the shaft seal ring with
Loctite # 574. Figure 70 WE1401309
Legend to Figure 71
1 X 2
Reference
Description
Number
1 Hub
2 Shaft Seal Ring
Installation Dimension -
X
Shaft Seal Ring 0 ~ 0.3 mm
Figure 71 WE1401310
IMPORTANT
Just before fitting wet the seal lips of the shaft seal
ring with lubricant.
Figure 72
8. Oil O-ring and insert it into the annular groove (see arrow)
of the knuckle housing.
Then install disk carrier.
Figure 73
Figure 74
10. Insert stub shaft and sun gear shaft for supporting the
socket wrench (Figure 76).
Figure 75
11. Bring hub bearing into contact position - for this purpose
tighten slotted nut.
(S) Socket wrench 5870 656 097
• Torque: 1,400 N.m (143 kg.m, 1,033 ft lb)
IMPORTANT
While tightening the slotted nut rotate hub in both Figure 76
directions several times - roller setting.
Apply lubricant (Molycote Paste 1,000) to thread
knuckle housing/slotted nut.
Figure 77 WE1401317
IMPORTANT
Take the actually required disk fitting/arrangement
from the corresponding spare parts list.
Bring inner clutch disks in a position where one of the
tooth recesses (see arrow) is in 6 o'clock position - WE1401318
with axle being installed in the vehicle. Figure 78
WE1401319
Figure 79
3. Oil U-ring and support rings and insert them into the
annular grooves of the ring gear.
IMPORTANT
Observe installation position, see Figure 81.
WE1401320
Figure 80
Legend to Figure 81
1
Reference
Description 2
Number
1 Ring Gear 3
2 Support Ring 4
3 U-ring 5
4 U-ring
5 Support Ring WE1401321
Figure 81
Figure 82
Figure 83
IMPORTANT
Use hexagon screws just once.
WE1401322
Figure 84
Legend to Figure 85
1
Reference 2
Description
Number 3
1 Hexagon Screw 4
2 Spring Sleeve
3 Compression Spring (Outer)
4 Compression Spring (Inner)
WE1400307
Figure 85
IMPORTANT
Ensure exact toothing position of oil supply holes .
knuckle housing/ring gear (pressure oil supply to
brake piston).
Figure 86 WE1401349
IMPORTANT 2
Figure 87 WE1401350
IMPORTANT
First tighten slotted nut with 1,400 N.m, then retighten
slotted nut until a fixing hole overlaps a threaded hole
in the knuckle housing.
While tightening the slotted nut rotate hub in both
directions several times - roller setting.
Wet thread - knuckle housing/slotted nut - with
lubricant.
IMPORTANT
Breathe brake completely before starting the test. Figure 89
• Test media:
Motor oils SAE-lO W correspond to, MIL-L 2104 C,
MIL-L 46152, API-CC, CD, SC, SD, SE, ATF-oils
type A, Suffix A Dexron of II D
• High-pressure test:
Build up test pressure p = 100 bar (101.9 kg/
cm2, 1,469.5 psi) and close locking valve of HP pump.
A pressure drop by max. 3 bar (3 kg/cm2, 43.5 psi) is
permissible during a 5-minute test duration.
• Low pressure test:
Reduce test pressure to p = 5 bar (5 kg/cm2, 72.5 psi)
and close locking valve.
No pressure drop is allowed during a 5-minute testing
duration.
IMPORTANT Figure 90
Figure 91 X
WE1401327
Calculation Example: 1 2 3
Dimension "A" 83.10 mm
Dimension "B" - 82.10 mm
Difference = Piston stroke = 1.00 mm B
IMPORTANT
If the required piston stroke (0.7 ... 1.3 mm) is not
achieved, correct it with the corresponding inner
Figure 92 WE1401328
clutch disk(s) - refer to corresponding spare parts list.
Reference
Description
Number
1 Ring Gear
2 Measuring Hole
3 Piston
X Piston Stroke/Disk Clearance
Figure 93
Figure 94 WE1401333
IMPORTANT
4
IMPORTANT
Mount bearing inner ring with large radius, showing to
the planetary carrier (downwards).
Figure 96 WE1401335
Figure 97 WE1401336
WE1401351
Figure 98
Figure 99
Edition 1
Center Joint
Safety Instructions ..........................................6-4-5
General ...........................................................6-4-5
General Description................................................... 6-4-5
Overview ................................................................... 6-4-6
Parts List ................................................................... 6-4-7
Removal .........................................................6-4-8
Installation ....................................................6-4-17
Completing Work ..........................................6-4-17
Disassembly .................................................6-4-18
Reassembly ..................................................6-4-21
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
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.
9 8 14
13
15 6 11
10
5 4 12
1 2
7 3
2
4
3
5
6
7
12
10
8
11
9
15
1
WE1400395
Figure 1
18 15
1
2
6 5
7 4
9
3
11
12
10
14
Figure 2 13
WE1400396
Reference Reference
Description Description
Number Number
1 Spindle Assembly 11 Shim
2 Body 12 O-ring
3 Seal; Rotary 110 x 120 x 4.8 13 Bolt
4 O-ring 14 Washer; Spring
5 O-ring 15 Plug; PT
6 Shim 16 Plug; PT
7 Plate; Thrust 17 Plug; Hex. Socket
8 Ring; Retaining 18 Plug
9 O-ring 19 Plug
10 Cover * Seal Kit; Center Joint
*: 3, 4, 5, 9, 12
WARNING
AVOID DEATH OR SERIOUS INJURY
Contact with hydraulic fluid can harm your health. (e.g. eye
injuries, skin damage or poisoning, if inhaled).
• While performing removal and installation, wear safety
gloves, safety glasses and suitable working clothes.
• If hydraulic fluid should come into contact with your
eyes or penetrate your skin, consult a doctor
immediately.
WARNING
FIRE CAN CAUSE SERIOUS INJURY OR DEATH
Hydraulic fluid is highly flammable.
• Keep open flames and ignition sources away from the
workplace.
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants, grease,
etc. must be disposed of in an environmentally safe
manner. Some regulations require that certain spills and
leaks on the ground must be cleaned in a specific manner.
See local, state and federal regulations for the correct
disposal.
WARNING
LOCK
WARNING
AVOID DEATH OR SERIOUS INJURY DO NOT OPERATE
when performing inspection
WE1400464
Figure 5
ON
Figure 6 EX1401760
1 2
7 6
4
Figure 7 EX1401809
14. Loosen the oil tank air breather slowly to release the
pressure inside the hydraulic oil tank.
Pulling the air breather cap upward, the check valve
(0.45 bar (0.5 kg/cm2, 6.5 psi)) opens, and the air is Figure 8 WE1400647
discharged to the atmosphere from the top of the hydraulic
oil tank.
15. Remove bolts and nuts (Figure 9) (8 ea) from center
propeller shaft.
• Tool: 14 mm ( )
• Torque: 68.6 N.m (7 kg.m, 50.6 ft lb)
WE1401458
Figure 9 Bottom of Chassis Frame
16. Losen the center joint mounting nuts (Figure 9) (4 ea) from
chassis frame.
NOTE: Do not remove nuts completely to hold the
position of center joint.
• Tool: 19 mm ( )
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
WE1401459
Figure 10 Bottom of Chassis Frame
FR 2 RE 4
ON AR
T
5
3 6
12
7
9 10
11
1
14 15
13
WE1401460
Figure 11 Hub of Center Joint
WE1400651
Figure 12
19. Remove bolts (1, Figure 13) (2 ea) with plate (2).
• Tool: 24 mm ( )
• Torque: 264.6 N.m (27 kg.m, 195.2 ft lb)
2
WE1400650
Figure 13
Rear Front
6 11
1
12
15
8
3
7
4
14 9
10
5 13 2
WE1400652
Figure 14 Spindle of Center Joint
WE1400405
Figure 15
WE1400653
Figure 16
24. Remove center joint from the frame slowly and carefully.
• Center joint weight: about 90 kg (198 lb)
IMPORTANT
Make sure there are no other electrical wires or hoses
connected to center joint.
WE1400654
Figure 17
WARNING
INCORRECT INSTALLATION CAN CAUSE DEATH OR
SERIOUS INJURY
Any change in the connections will lead to malfunctions
(e.g. lift instead of lower).
• When connecting hydraulic components, observe the
specified piping according to the hydraulic schematic
diagram of the machine.
COMPLETING WORK
1. Start the engine and run at low idling for about 5 minutes.
2. Perform the machine performance test.
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.
Figure 18 WE1400397
2. Remove cover.
• Remove the bolts and washers using a spanner
(wrench) or air impact.
• Remove the cover.
– Tool: 17 mm ( )
– Torque: 63.7 N.m (6.5 kg.m, 47 ft lb)
FG003767
Figure 19
FG003769
Figure 20
FG003770
Figure 21
Reference
Description
Number
1 Plastic Hammer
FG003771
Figure 22
Reference
Description
Number
1 Plastic Hammer
2 Jig
Figure 23
CAUTION
AVOID INJURY
O-rings and seals should be replaced whenever the
assembly is being overhauled or re-assemble.
Figure 24
CAUTION
AVOID INJURY
Be sure to check for any dent-like scratches in the
direction of operation.
WE1400398
Figure 25
CAUTION
AVOID INJURY
Apply a very light film of white grease or petroleum
jelly to the lower rim of the stem and inner surface of
the center swivel body. Apply slow, even-handed
pressure, using both hands, to slowly push the stem
into the body. Seals may be damaged if the stem is
pushed in too quickly.
Edition 1
Travel Motor
Safety Instructions ..........................................6-5-5
General ...........................................................6-5-5
General Description................................................... 6-5-5
Specification .............................................................. 6-5-6
Overview ................................................................... 6-5-7
Schematic.................................................................. 6-5-9
Control.................................................................. 6-5-9
Counter Balance Group...................................... 6-5-10
Parts List ................................................................. 6-5-11
Travel Motor ....................................................... 6-5-11
Counter Balance Valve....................................... 6-5-12
Theory of Operation ................................................ 6-5-14
Torque Control ................................................... 6-5-14
Retarding Function ............................................. 6-5-19
Circuit Operation ..................................................... 6-5-20
During Forward (Reverse) High-speed (3rd Gear)
Driving (Vg min. (28 cc) - Vg max. (107 cc)) ...... 6-5-20
Accelerator Pedal Released During Forward Driving
at High Speed (Vg Retarding: 56 cc).................. 6-5-21
Accelerator Pedal Released During Reverse Driving
at High Speed (3rd Gear) (Vg min.: 28 cc)......... 6-5-23
During Forward (Reverse) Driving at Low Speed
(2nd Gear) (Vg min. (28 cc) - Vg max. (107 cc)) 6-5-24
Accelerator Pedal Released During
Forward (Reverse) Driving at Low Speed (2nd Gear)
(Vg ret1: 28 cc)................................................... 6-5-25
During Driving at Inching Speed (1st Gear)
(Vg max.: 107 cc Maintained)............................. 6-5-26
Motor Pressure over 290 bar (296 kg/cm2, 4,206 psi)
(Vg max.: 107 cc Maintained)............................. 6-5-27
Driving Performance Curve of Travel Motor ............ 6-5-31
Beginning of Regualtion ..................................... 6-5-31
Switch Pressure ................................................. 6-5-31
Removal .......................................................6-5-32
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation and
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
General Description
This travel motor is bent-axis piston motor, with the function to
control the traveling torque automatically which is corresponding
to the traveling resistance.
Also, it is equipped with the motion control valve as the
prevention against the over-speed.
X1 (IC)
U T1 MB G ext
B (FWD)
Q max
Q min S
T2
A (REV)
MA
M3
M2
X2
WE1401408
Figure 1
A
X1
U T
MB
S
G
WE1401409
Figure 2
Control
X1 (IC)
Torque Control
U T1 MB G ext
B (FWD)
Servo Piston
T2
A (REV)
MA
M3
M2
Q min. Stopper
Servo Piston
Relief Valve
Check Valve
Q max. Stopper
Counter Balance Block
X1 (IC)
U T1 MB G ext
T2
A
MA
M3
M2
X2
B Ge x t S A
Check Valve
Relief Valve
WE1401411
Figure 4
Travel Motor
17 18 1 12
8 13
5 51
10
11
9
WE1400255
Figure 5
Reference Reference
Description Description
Number Number
1 Rotary Group 11 Shim
2 Control Group 12 O-ring
5 Housing; Pump 13 Plug
8 Plug 17 Bolt; Stud
9 Ring; Retaining 18 Nut; Lock
10 Seal; Oil 51 Counter Balance Valve
1-11 20
24
1-11
27
25 22
24
11
23
28
2
27
21
6 26
23
10
WE1401519
Figure 6
Torque Control
WE1400257
Figure 7
Servo Piston
Small Chamber
Minimum Displacement
(High Speed, Low Torque)
Torque Control Block
Maximum Displacement
(Low Speed, High Torque) Adjustment Screw
WE1401412
Figure 8
A B
PB
Max. Min.
(X)
G
Vg min. Vg max.
HA Curve
T (T1)
- Automatic Control
Regulating Valve Adjusting Cylinder - High-pressure Related
(Adjusting Piston)
- PB: Operating Pressure
with Setting Spring - Vg: Displacement (Motor Speed)
WE1400259
Figure 9
1. Provided that the pump flow and high-pressure remain constant, then
• Reducing displacement gives higher speed and lower torque
• Increasing displacement does higher torque and lower speed
2. The displacement is set "Automatically" dependent on operating pressure.
Small Chamber
Large Chamber
U B X M1
A
Servo Piston
Q Min.
Q Max.
Spring
Tank Load Secondary Port
A G T
Primary Port
X1
G
PB
U T1 MB G ext
S
Max.
290 bar
T2
B
Vg min. Vg max.
MA
M3
M2 Increased Displacement
- High Torque, Low Speed
X2
WE1401413
Figure 11
X1 (IC)
U T1 MB G ext
Q Max.
S
Q Min.
A
T2
B
MA
M3
M2
X2
WE1400262
Figure 12
X1
G Set Pressure
PB
U T1 MB G ext
S
Min.
290 bar
T2
B
MA Vg min. Vg max.
M3
M2
Decreased Displacement
- High Speed, Low Torque
X2
WE1401414
Figure 13
WE1400264
Figure 14
P P
Start Retarding
A B
A Traveling
Stop
B
Time
WE1401415
Figure 15
During Forward (Reverse) High-speed (3rd Gear) Driving (Vg min. (28 cc) - Vg max. (107 cc))
• In running at port (B) pressurized (Figure 16), the pressure at port (MA) becomes a high-pressure at the brake.
• The stroke limiter piston is operated once by the forward driving pressure.
(Vg retarding (28 cc) →Vg min. (42 cc))
• The motor's swivel angle is changed by the pressure of the driving motor.
P1 P2
G
B (FWD)
T2 A (REV)
J M
MA
M3
M2
300 bar
X2
- Min. Travel Displacement
WE1401416
Figure 16
P1 P2
G
B (FWD)
T2 A (REV)
J M
MA
Switching Valve 1 M3
M2
X2 300 bar
- Min. Hold Displacement
Switching Valve 2
WE1401417
Figure 17
X2
X2
M2
M3
M3
M2
300 bar
X2
WE1401418
Figure 18
P1 P2
G
B (FWD)
T2 A (REV)
J M
MA
M3
M2
X2 300 bar
- Min. Travel Displacement
WE1401419
Figure 19
P1 P2
G
B (FWD)
T2 A (REV)
J M
MA
M3
M2
300 bar
X2
- Min. Travel Displacement
WE1401420
Figure 20
P1 P2
G
B (FWD)
T2 A (REV)
J M
MA
Switching Valve 1 M3
M2
300 bar
X2
- Very Smallest Displacement
Switching Valve 2
Figure 21 WE1401421
P1 P2
G
B (FWD)
T2 A (REV)
J M
MA
M3
M2
300 bar
X2
PB
Vg min. Vg max.
WE1401422
Figure 22
Torque Control
Transmission
(High) (Low) X1 (IC)
P1 P2
G
B (FWD)
T2 A (REV)
J M
MA
M3
M2
300 bar
X2
PB PB
Motor Pressure: over 290 bar Motor Pressure: below 290 bar
WE1401423
Figure 23
Q min. Stopper
Servo Piston
WE1401424
Figure 24
Q min. Stopper
Servo Piston
Q max. Stopper
Counter Balance Block
WE1401425
Figure 25
- Adjustment
WE1401429
Adjustment Screw
Figure 26 WE1401426
Adjustment
1. Increase of torque PB
Vg min. Vg max.
Figure 27 WE1400281
2. Decrease of torque
PB
290 bar
Vg min. Vg max.
Figure 28 WE1401427
120
42 107 q (cc)
WE1401428
Figure 29
Switch Pressure
PMA (bar)
• 0 bar (306 kg/cm , 4,351 psi)
Setting Pressure: 300 -+30 2
300
28 56 q (cc)
WE1401429
Figure 30
WARNING
AVOID DEATH OR SERIOUS INJURY
Contact with hydraulic fluid can harm your health. (e.g. eye
injuries, skin damage or poisoning, if inhaled).
• While performing removal and installation, wear safety
gloves, safety glasses and suitable working clothes.
• If hydraulic fluid should come into contact with your
eyes or penetrate your skin, consult a doctor
immediately.
WARNING
FIRE CAN CAUSE SERIOUS INJURY OR DEATH
Hydraulic fluid is highly flammable.
• Keep open flames and ignition sources away from the
workplace.
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants, grease,
etc. must be disposed of in an environmentally safe
manner. Some regulations require that certain spills and
leaks on the ground must be cleaned in a specific manner.
See local, state and federal regulations for the correct
disposal.
WE1401484
Figure 31
WARNING
LOCK
WARNING
AVOID DEATH OR SERIOUS INJURY DO NOT OPERATE
when performing inspection
WE1400464
Figure 33
ON
Figure 34 EX1401760
1 2
7 6
4
EX1401809
Figure 35
14. Loosen the oil tank air breather slowly to release the
pressure inside the hydraulic oil tank.
Pulling the air breather cap upward, the check valve
(0.45 bar) opens, and the air is discharged to the Figure 36 WE1400647
atmosphere from the top of the hydraulic oil tank.
15. Remove nuts (1, Figure 37) (16 ea) with rear propeller
shaft (2). 1 1
• Tool: 14 mm ( )
• Torque: 68.6 N.m (7 kg.m, 50.1 ft lb)
• Rear propeller shaft weight: about 17 kg (37.5 lb)
Transmission
WE1401468
Figure 37 Bottom of Chassis Frame
16. Remove hoses and adapters (Figure 38) from travel motor.
X2
NOTE: Attach identification tags to the removed hoses X
for reassembling.
A T2
After disconnecting hoses, plug them to prevent
dirt or dust from entering.
Disconnect the hoses from the bottom to top of
travel motor.
G
B S WE1401469
Figure 38
• Fitting
Size Torque
Port Name
A B (mm) N.m kg.m ft lb
S Adapter M22 x 1.5 UNF 1 3/16"-12 36 59.8 6.1 44.1
X Adapter M14 x 1.5 UNF 9/16"-18 19 30.4 3.1 22.4
X2 Adapter M14 x 1.5 UNF 9/16"-18 19 30.4 3.1 22.4
G Adapter M14 x 1.5 UNF 9/16"-18 19 30.4 3.1 22.4
T2 Adapter M18 x 1.5 UNF 13/16"-16 24 40.2 4.1 29.6
2180-1026D19
A, B O-ring
(ID:32.92, W:3.53, 1B)
S O-ring S8030125 (4D F-12)
DS2851078 2180-1216D11
X2 O-ring
(ID:11.3, W:2.2, 1B) (ID:7.65, W:1.78, 1B)
WE1401470
Figure 39
• Tool: 14 mm ( )
• Torque: 265 N.m (27 kg.m, 195 ft lb)
3
WE1401471
Figure 40
WE1401472
Figure 41
INSTALLATION
WARNING
INCORRECT INSTALLATION CAN CAUSE DEATH OR
SERIOUS INJURY
Any change in the connections will lead to malfunctions
(e.g. lift instead of lower).
• When connecting hydraulic components, observe the
specified piping according to the hydraulic schematic
diagram of the machine.
Figure 42 WE1401473
COMPLETING WORK
1. Start the engine and run at low idling for about 5 minutes.
2. Perform the machine performance test.
G ext
MA G T
M2
M3
MB MA
G
X1
Figure 43 WE1401430
CAUTION
AVOID INJURY
Observe the following notices when carrying out repair
work at hydraulic aggregates.
HB7M3002
Figure 44
HB7M3003
Figure 45
HB7M3004
Figure 46
CAUTION
AVOID INJURY
Rework of sealing area f. ex. with abrasive paper can
damage surface.
HB7M3005
Figure 47
HB7M3006
Figure 48
HB7M3007
Figure 49
HB7M3008
Figure 50
3. Housing
HB7M3009
Figure 51
HB7M3010
Figure 52
HB7M3011
Figure 53
6. Counter-balance Valve
HB7M3012
Figure 54
Figure 55
HB7M3014
Figure 56
HB7M3015
Figure 57
HB7M3016
Figure 58
HB7M3017
Figure 59
HB7M3018
Figure 60
CAUTION
AVOID INJURY
Pay attention to pressing depth
CAUTION Figure 61
AVOID INJURY
Mark for pressing depth.
Assemble retaining ring.
Figure 62 HB7M3020
4. Disassembly position:
Pos. 1
Remove cover pos. 1
Figure 63 FG007441
CAUTION
3 HB7M3022
AVOID INJURY Figure 64
Installation position differs according to the control
components
Reference
Description 1
Number
5
1 Input Flow of Oil Control
2 High-pressure/Low-pressure 2 3
3 High-pressure/Low-pressure
4 Leakage Oil
5 Control Piston 4
HB7M3023
Figure 65
HB7M3024
Figure 66
CAUTION
AVOID INJURY
X
Attention! Spring load.
Reference
Description
Number 1
1 Check of O-ring
HB7M3026
Figure 68
Reference
Description
Number 1
O-ring/High Pressure - Small Control 2
1
Piston Side
2 O-ring/Control Pressure 4
HB7M3027
Figure 69
HB7M3028
Figure 70
2. Inspect!
O-ring
Figure 71
HB7M3030
Figure 72
1-11 20
24
1-11
27
25 22
24
11
23
28
2
27
21
6 26
23
10
WE1401519
Figure 73
Reference
Description
Number
1 Brake Piston
2 Valve Bushing
3 Throttle Pin
4 Valve Screw
5 Bolt
Figure 74
6 Spring Collar
11 Pressure Spring
HB7M3033
Figure 75
CAUTION
AVOID INJURY
For disassembly of the port plate, swivel always rotary
group to zero position.
Piston rings to hang out of the cylinder boring.
Figure 76
HB7M3035
Figure 77
3. Check O-ring.
CAUTION
AVOID INJURY
Stick new O-ring with some grease.
Do not swivel rotary group.
Piston rings to hang out from the cylinder boring. HB7M3036
Figure 78
HB7M3037
Figure 79
HB7M3038
Figure 80
HB7M3039
Figure 81
CAUTION
AVOID INJURY
Use new screw.
Precote coating.
Note tightening torque!
Figure 82
CAUTION
AVOID INJURY
Stick control lens in sliding surface with grease.
Assembly in reversal order.
Mount port plate.
HB7M3041
CAUTION Figure 83
AVOID INJURY
Rotary group vertical.
HB7M3042
Figure 84
HB7M3043
Figure 85
CAUTION
AVOID INJURY
If the bearings are used again do not hit on the drive
shaft.
HB7M3044
Figure 86
CAUTION
AVOID INJURY
Setting of hydraulic part necessary.
HB7M3010
Figure 87
1. Rotary group
A. Mechanical part: Adjust drive shaft with bearing.
B. Hydraulic part:
CAUTION
AVOID INJURY
Adjustment necessary.
FG003029
Figure 88
HB7M3047
Figure 89
CAUTION
AVOID INJURY
Screws are glued.
Use Torx-tools.
HB7M3048
Figure 90
Inspection Notes
1. Free of corrosion, erosion or fretting; no damage to splines
or keyways.
HB7M3049
Figure 91
HB7M3050
Figure 92
3. Center pin
No scoring and no pittings. 1 2
HB7M3051
Figure 93
4. Retaining plate
No scoring and no evidence of wear
HB7M3052
Figure 94
HB7M3053
Figure 95
HB7M3054
Figure 96
7. Visual check:
Bearing areas free of scoring and no evidence of wear.
HB7M3055
Figure 97
Figure 98
Figure 99
HB7M3058
Figure 100
Figure 101
Figure 102
Figure 103
2. * Disc
Figure 104
HB7M3063
Figure 105
Figure 106
5. Check dimension X.
Figure 107
CAUTION
AVOID INJURY
Take care of assembly design.
Tighten fixing screws with torque.
Figure 108
HB7M3067
Figure 109
FG007441
Figure 110
CAUTION
AVOID INJURY
Take care of press-in depth.
Figure 111
WE1400221
Figure 112
Edition 1
DX140W-5/DX160W-5 Driveshaft
6-6-1
MEMO
Driveshaft DX140W-5/DX160W-5
6-6-2
Table of Contents
Driveshaft
Safety Instructions ..........................................6-6-5
General ...........................................................6-6-5
Specification .............................................................. 6-6-5
Overview ................................................................... 6-6-6
Front/Rear Driveshaft ........................................... 6-6-6
Center Driveshaft ................................................. 6-6-6
Removal (Front Driveshaft).............................6-6-7
Installation
(Front Driveshaft)............................................6-6-9
Removal (Center Driveshaft) ........................6-6-10
Installation
(Center Driveshaft) .......................................6-6-12
Removal (Rear Driveshaft) ...........................6-6-13
Installation
(Rear Driveshaft) ..........................................6-6-15
DX140W-5/DX160W-5 Driveshaft
6-6-3
Driveshaft DX140W-5/DX160W-5
6-6-4
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
Specification
Weight Installation Length Closed Length
No. Description
(kg (lb)) (mm) (mm)
1 Front Driveshaft 16 (37.3) - 878 ±3
2 Center Driveshaft 16 (37.3) 342.4 -
3 Rear Driveshaft 16 (37.3) - 878 ±3
DX140W-5/DX160W-5 Driveshaft
6-6-5
Overview
Chassis Frame
1 2 3
Front Axle Rear Axle
Figure 1 Transmission WE1401431
Reference Reference
Description Description
Number Number
1 Front Driveshaft 3 Rear Driveshaft
2 Center Driveshaft
Front/Rear Driveshaft
3 1 2 3
Figure 2 WE1400235
Reference Reference
Description Description
Number Number
1 Grease Nipple 3 Universal Joint
2 Grease Nipple
Center Driveshaft
2
Figure 3 1 WE1400236
Reference Reference
Description Description
Number Number
1 Grease Nipple 2 Bearing Unit
Driveshaft DX140W-5/DX160W-5
6-6-6
REMOVAL (FRONT DRIVESHAFT)
1. Park on firm and level ground.
2. Lower all the attachments to ground. (Figure 4)
3. Stop engine.
4. Set wheel chocks in front and behind each tire to prevent
the machine from moving.
WE1401484
Figure 4
WARNING
LOCK
WARNING
AVOID DEATH OR SERIOUS INJURY DO NOT OPERATE
when performing inspection
WE1400464
Figure 6
ON
Figure 7 EX1401760
DX140W-5/DX160W-5 Driveshaft
6-6-7
NOTE: Removal (installation) procedure of the bolts.
3
5 8
1 2
7 6
4
Figure 8 EX1401809
14. Remove bolts and nuts (Figure 9) (8 ea) from front axle.
• Tool: 14 mm ( )
• Torque: 68.6 N.m (7 kg.m, 50.6 ft lb)
Front Axle
WE1400237
Figure 9 Bottom of Chassis Frame
15. Remove bolts and nuts (Figure 10) (8 ea) from center
propeller shaft.
• Tool: 14 mm ( )
• Torque: 68.6 N.m (7 kg.m, 50.6 ft lb)
WE1401101
Figure 10 Bottom of Chassis Frame
WE1401461
Figure 11 Bottom of Chassis Frame
Driveshaft DX140W-5/DX160W-5
6-6-8
INSTALLATION
(FRONT DRIVESHAFT)
1. Perform installation in the reverse order to removal
normally.
NOTE: Apply the loctite #262 to threaded area.
After assembling, pour grease to grease nipple of universal joint
(Figure 12).
WE1401462
Figure 12 Bottom of Chassis Frame
DX140W-5/DX160W-5 Driveshaft
6-6-9
REMOVAL (CENTER DRIVESHAFT)
1. Park on firm and level ground.
2. Lower all the attachments to ground. (Figure 13)
3. Stop engine.
4. Set wheel chocks in front and behind each tire to prevent
the machine from moving.
WE1401484
Figure 13
WARNING
LOCK
WARNING
AVOID DEATH OR SERIOUS INJURY DO NOT OPERATE
when performing inspection
WE1400464
Figure 15
ON
Figure 16 EX1401760
Driveshaft DX140W-5/DX160W-5
6-6-10
NOTE: Removal (installation) procedure of the bolts.
3
5 8
1 2
7 6
4
Figure 17 EX1401809
14. Remove bolts and washers (1, Figure 18) (4 ea) with cover
(2) from bracket. FRONT
• Tool: 19 mm ( )
1
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
2
• Cover weight: 8 kg (17.6 lb)
WE1401463
Figure 18 Bottom of Chassis Frame
15. Remove bolts and nuts (Figure 19) (16 ea) from propeller
shaft. FRONT
• Tool: 14 mm ( )
• Torque: 68.6 N.m (7 kg.m, 50.6 ft lb)
WE1401464
Figure 19 Bottom of Chassis Frame
16. Remove bolts and washers (1, Figure 20) (4 ea) from
bracket. FRONT
• Tool: 24 mm ( )
• Torque: 264.8 N.m (27 kg.m, 195.3 ft lb)
1
17. Remove center propeller shaft (2, Figure 20) slowly and
carefully. 2
• Propeller shaft weight: about 16 kg (35.3 lb)
WE1401465
Figure 20 Bottom of Chassis Frame
DX140W-5/DX160W-5 Driveshaft
6-6-11
INSTALLATION
FRONT
(CENTER DRIVESHAFT)
1. Perform installation in the reverse order to removal
normally.
NOTE: Apply the loctite #262 to threaded area.
When assembling, make the same direction of grease nipples
as shown in Figure 21.
After assembling, pour grease to grease nipple of bearing
WE1401466
(Figure 21). Figure 21 Bottom of Chassis Frame
Driveshaft DX140W-5/DX160W-5
6-6-12
REMOVAL (REAR DRIVESHAFT)
1. Park on firm and level ground.
2. Lower all the attachments to ground. (Figure 22)
3. Stop engine.
4. Set wheel chocks in front and behind each tire to prevent
the machine from moving.
WE1401484
Figure 22
WARNING
LOCK
WARNING
AVOID DEATH OR SERIOUS INJURY DO NOT OPERATE
when performing inspection
WE1400464
Figure 24
ON
Figure 25 EX1401760
DX140W-5/DX160W-5 Driveshaft
6-6-13
NOTE: Removal (installation) procedure of the bolts.
3
5 8
1 2
7 6
4
Figure 26 EX1401809
• Tool: 14 mm ( )
• Torque: 63.7 N.m (6.5 kg.m, 47 ft lb)
Transmission
Figure 27 WE1400245
15. Remove bolts and nuts (Figure 28) (8 ea) from center
propeller shaft.
• Tool: 14 mm ( )
• Torque: 68.6 N.m (7 kg.m, 50.6 ft lb)
WE1401467
Figure 28 Bottom of Chassis Frame
WE1401158
Figure 29 Bottom of Chassis Frame
Driveshaft DX140W-5/DX160W-5
6-6-14
INSTALLATION
(REAR DRIVESHAFT)
1. Perform installation in the reverse order to removal
normally.
NOTE: Apply the loctite #262 to threaded area.
After assembling, pour grease to grease nipple of universal joint
(Figure 30).
WE1401159
Figure 30 Bottom of Chassis Frame
DX140W-5/DX160W-5 Driveshaft
6-6-15
Driveshaft DX140W-5/DX160W-5
6-6-16
1Transmission
Edition 1
DX140W-5/DX160W-5 Transmission
6-7-1
MEMO
Transmission DX140W-5/DX160W-5
6-7-2
Table of Contents
Transmission
Safety Instructions ..........................................6-7-5
General ...........................................................6-7-5
General Description................................................... 6-7-5
Specification .............................................................. 6-7-6
Overview ................................................................... 6-7-6
Hydraulic Circuit ........................................................ 6-7-7
Theory of Operation .................................................. 6-7-8
Transmission Solenoid Valve (Gear Shift) ........... 6-7-8
Parking Brake....................................................... 6-7-9
Towing.................................................................. 6-7-9
Gear Shift Mechanism........................................ 6-7-11
Section View .................................................6-7-13
Separate the Transmission from the Axle.....6-7-14
Disassembly - Brake/Clutch/Planet Carrier .....6-7-15
Downshift Interlock .................................................. 6-7-15
Speed Transmitter................................................... 6-7-18
Emergency Release (Parking Brake) ...................... 6-7-19
Input Housing and Modulation Valve....................... 6-7-20
Brake/Clutch............................................................ 6-7-22
Planet Carrier .......................................................... 6-7-27
Disassembly - Output ...................................6-7-30
Reassembly - Output ....................................6-7-34
Axle Attachment ...................................................... 6-7-34
Determine Adjusting Shim for Pinion Gap.......... 6-7-37
Determine the Adjusting Ring for Rolling Moment/
Pinion Bearing .................................................... 6-7-41
Check the Rolling Moment of the Pinion Bearing .. 6-7-43
Shaft Seal/Output Flange ................................... 6-7-43
Check the Pinion Gap ........................................ 6-7-45
Reassembly - Brake/Clutch/Planet Carrier ...6-7-46
Planet Carrier .......................................................... 6-7-46
Brake/Clutch............................................................ 6-7-52
DX140W-5/DX160W-5 Transmission
6-7-3
Disc Components Brake and Clutch .................. 6-7-54
Adjust and Check the Disc Clearance/
Piston Stroke of Brake and Clutch ..................... 6-7-56
Modulation Valve and Input Housing....................... 6-7-64
Emergency Release (Parking Brake) ...................... 6-7-66
Check the Emergency Release for
Leak Tightness .................................................. 6-7-67
Check the Multi-Disc Brake and Multi-Disc Clutch
for Leak Tightness as well as Closing Pressure.... 6-7-68
Speed Transmitter................................................... 6-7-69
Reassembly - Downshift Interlock ................6-7-70
Downshift Interlock .................................................. 6-7-70
Attach the Transmission to the Axle .............6-7-78
Transmission DX140W-5/DX160W-5
6-7-4
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
General Description
This transmission is a 2-speed powershift transmission.
The transmission consists of the rotating multi-disc clutch and
multi-disc brake, which is fixed to the transmission body.
The disc brake is held by force of the spring (for parking brake
function), but it is released by hydraulic pressure during
activation.
The downshift interlock (transmission governor) function is to
maintain the high speed (3rd gear) driving condition until the
driving speed reaches the low speed (2nd gear) when attempting
to shift to the low (2nd) gear from the high (3rd) gear (driving at
10 km/h or higher).
When the driving speed reaches the low speed (2nd gear), which
is called "Downshift Point", the transmission is shifted from the
high speed (3rd gear) to the low speed (2nd gear).
(The downshift operation is performed when the driving speed is
reduced to approximately 70% of the full speed from the high
(3rd) gear.)
The gear shift operation is performed between 2-speeds while
there are 3 driving speeds for an actual machine.
• 1st speed driving
(inching solenoid valve and low speed solenoid valve)
• 2nd speed driving (low-speed solenoid valve)
• 3rd speed driving (high-speed solenoid valve)
DX140W-5/DX160W-5 Transmission
6-7-5
Specification
Gear Ratio 1st: 4.87, 2nd: 1.2
Pilot Pressure 30 ~ 35 bar (30.6 ~ 35.7 kg/cm2, 435.1 ~ 507.6 psi)
Volume of Oil 2.5 L (0.6 U.S. gal)
Mounting Type Direct Mounting to Axle
Overview
5
EN
EN 8 7 UN PN
UN
12
WE1400249
Figure 1
Reference Reference
Description Description
Number Number
1 Lubrication Pressure 8 Road Speed (Brake)
2 Shift Interlock 12 Oil Drain Plug (M24 x 1.5)
3 Brake Pressure Relief Valve (Emergency
UN
4 Clutch Actuation Parking Brake)
Speed Transmitter Bleed Valve (Emergency
5 EN
(Output Speed) Actuation Parking Brake)
7 Off-Load Speed (Clutch) PN Grease Nipple
Transmission DX140W-5/DX160W-5
6-7-6
Hydraulic Circuit
Valve Block
P
Pressure Valve
K B
Rotary Upper Chassis
/Undercarriage
S
K B
M
J Gear Shift Piston
Check
EB Valve
EK
Nab Change-over
LB Check Valve
Leakage Check
Valve
UN Output Output
PN S
EN Transmission
WE1400250
Figure 2
DX140W-5/DX160W-5 Transmission
6-7-7
Theory of Operation
M2 M1 P M2 M1 B K T
M T DV P M
WE1400272
Figure 3
Reference Reference
Description Description
Number Number
M1 Solenoid Valve (Off-road Speed) B Brake (Road Speed)
M2 Solenoid Valve (Road Speed) P Pilot Pressure Input
DV Pressure Valve T Tank
K Clutch (Off-road Speed) M Measuring Point System Pressure
Transmission DX140W-5/DX160W-5
6-7-8
Parking Brake
The parking brake is put into function by actuation of the parking
brake switch.
The parking brake position of the gearshift valve in the Solenoid
Valve block is shifted by not applying any current to both of the
solenoids (M1) and (M2).
This means in case of a power failure, the parking brake is
engaged automatically.
Towing
The emergency power cut-off system cuts off power flow
between the input and output of the transmission. It applies
grease (10) with the grease gun to disengage the disc brake and
clutch simultaneously until the pressure reaches the relief valve
setting pressure.
This device is designed to draft an implement effectively.
In this case, as the transmission cannot be lubricated separately, EN
the specified draft speed and distance should be maintained.
PN
• Towing speed: Max. 10 km/h
UN
• Towing distance: Max. 5 km
1. Activate the emergency actuation
WE1400273
A. Engine stop. Figure 4
B. Grease with grease gun on the grease nipple (PN)
until it comes visibly out at the pressure relief valve
(EN) of the emergency actuation.
2. Deactivate the emergency actuation
To deactivate the emergency power cut-off system, open
the emergency activation bleeder (EN) and set the shift
lever to the road speed (2nd gear) position.
Then, grease is drained through the bleeder (EN).
After draining grease as mentioned above, close the
bleeder (EN).
DX140W-5/DX160W-5 Transmission
6-7-9
Emergency Actuation Deactivated Emergency Actuation Activated
1 2 3
4 5 6 7 8 9 10 11
WE1400274
Figure 5
Reference Reference
Description Description
Number Number
Set of Springs (Plate Spring) for Pressure Ring for the Emergency
1 7
Multi-plate Clutch Actuation
2 Clutch Piston 8 Ring for the Emergency Actuation
3 Multi-plate clutch 9 Multi-plate Brake
Set of Springs (Plate Spring) for 10 Grease
4
Multi-plate Brake 11 Grease Nipple
5 Brake Piston
6 Pin
IMPORTANT
No gear must be selected if the emergency control is
activated - apply parking brake.
If the emergency actuation device is deactivated
incorrectly, the transmission will be damaged during
operation.
Transmission DX140W-5/DX160W-5
6-7-10
Gear Shift Mechanism
1. 1st speed operation
When placing the gear shift lever in the 1st gear position, an electric signal is sent to the solenoid on the
valve block (M1) side.
This electric signal switches the solenoid valve of the valve block to open the port (K).
Then, the pilot pressure in the port K is led into the chamber (CK) in the transmission.
When this pressure overcomes the force of the cup spring (KS), the piston (KP) is pushed to the left.
As a result, the piston (KP) is separated from the disc (A), resulting in rotation of the drive shaft at the 1st
gear speed.
Travel Motor
P
Control Pressure Valve (32 bar)
Orifice “K”
K B
Disc (A)
KS
KP
Shaft
Figure 6 WE1400285
DX140W-5/DX160W-5 Transmission
6-7-11
2. 2nd speed operation
When placing the gear shift lever in the 2nd gear position, an electric signal is sent to the solenoid on the
valve block (M2) side.
This electric signal switches the solenoid valve of the valve block to open the port (B).
Then, the pilot pressure in the port (B) is led into the chamber "CB" in the transmission.
When this pressure overcomes the force of the cup spring "BS", the piston "BP" is pushed to the left.
As a result, the piston "BP" is separated from the disc (B), resulting in rotation of the drive shaft at the 2nd
gear speed.
Travel Motor
P
Control Pressure Valve (32 bar)
Orifice “K”
K B
Disc (A)
KS
KP
Shaft
Figure 7 WE1400286
Transmission DX140W-5/DX160W-5
6-7-12
SECTION VIEW
1 2 3 4 5 6
Input
10
Output Output
9 8
WE1400271
Figure 8
Reference Reference
Description Description
Number Number
Cup Springs for Multi-disk Brake 6 Lube Oil Pump
1
and Multi-disk Clutch 7 Spur Gear Drive
2 Input Shaft Output Pinion -
8
3 Multi-disk Brake Rear Axle Direct Attachment
4 Multi-disk Clutch 9 Output Flange - Front Axle
5 Planetary Drive 10 Travel Motor Mounting
DX140W-5/DX160W-5 Transmission
6-7-13
SEPARATE THE TRANSMISSION FROM THE AXLE
1. Drain oil from the axle casing.
use a suitable collector.
Figure 9
Figure 10
Transmission DX140W-5/DX160W-5
6-7-14
DISASSEMBLY - BRAKE/CLUTCH/PLANET CARRIER
1. Mount the transmission to the assembly truck.
Figure 11
2. Loosen the screw plug and drain the oil - use a suitable
collector.
Figure 12
Downshift Interlock
1. Disassemble both oil tubes.
Figure 13
Figure 14
DX140W-5/DX160W-5 Transmission
6-7-15
3. Loosen the cover bolt connection, remove cover and flat
gasket (also see Figure 16).
Figure 15
Figure 16
Figure 17
CAUTION
AVOID INJURY
Keep pump to contact and rotate it by 180° -
disassembly aid.
Transmission DX140W-5/DX160W-5
6-7-16
7. Remove outer (1) and internal rotor (2) and take the
released ball [(3) driver] out of the control housing (4).
Outer, internal rotor and control housing = rotor set
Figure 19
Figure 20
Figure 21
10. Pull the cpl. pump shaft out of the pump cover.
Figure 22
DX140W-5/DX160W-5 Transmission
6-7-17
11. Unsnap the retaining ring and press the ball bearing from
the shaft.
Figure 23
Figure 24
Reference
Description
Number
1 Housing
2 O-rings
3 Check Valve (010)
4 G.shift Piston
5 Check Valve (009)
6 Check Valve (008)
7 Pressure Limiting Valve
Figure 25
13. Remove O-rings and all single parts/valves.
Speed Transmitter
Loosen the screw and pull off the speed transmitter.
Figure 26
Transmission DX140W-5/DX160W-5
6-7-18
Emergency Release (Parking Brake)
CAUTION
AVOID INJURY
Position of the single connection or bleeder valves/
lubrication nipples etc.
Figure 27
1. Remove bleeder.
2. Remove compression spring and the ball.
Figure 28
Figure 29
Figure 30
DX140W-5/DX160W-5 Transmission
6-7-19
Input Housing and Modulation Valve
CAUTION
AVOID INJURY
Loosen the bolt connection of the input housing equally -
the input housing is subject to a cup spring and
compression spring preload.
Figure 31
Figure 32
2. Modulation valve:
Remove compression spring and the O-ring (arrow).
Figure 33
Transmission DX140W-5/DX160W-5
6-7-20
3. Pull the complete piston out of the bore.
Figure 34
DX140W-5/DX160W-5 Transmission
6-7-21
Brake/Clutch
1. Remove cup springs from the brake.
Figure 35
Figure 36
3. Remove piston.
Figure 37
Figure 38
Transmission DX140W-5/DX160W-5
6-7-22
WARNING
AVOID DEATH OR SERIOUS INJURY
Attach 2 (two) eyebolts and pull the piston cautiously
out of the housing - risk of damage.
Figure 39
Figure 40
Figure 41
Figure 42
DX140W-5/DX160W-5 Transmission
6-7-23
WARNING
AVOID DEATH OR SERIOUS INJURY
Remove pressure ring with ring - also Figure 44 -
cautiously by means of lever action - risk of damaging
the sealing surfaces.
CAUTION Figure 43
AVOID INJURY
Ring can also remain in the housing - disassemble the
ring separately.
WARNING
AVOID DEATH OR SERIOUS INJURY
Remove pressure ring from the ring cautiously by
means of lever action - risk of damaging the sealing
surfaces.
Figure 44
Figure 45
9. Take the disc set of the brake with end shim(s) out of the
housing.
Figure 46
Transmission DX140W-5/DX160W-5
6-7-24
10. Unsnap the retaining ring.
Figure 47
Figure 48
12. Take the disc set of the clutch (with end shim/s) out of the
internal gear.
Figure 49
13. Remove assembly input shaft with internal gear from the
housing.
Figure 50
DX140W-5/DX160W-5 Transmission
6-7-25
14. Unsnap the retaining ring.
Figure 51
15. Press the input shaft out of the ball bearing/internal gear.
Figure 52
Figure 53
CAUTION
AVOID INJURY
In case of an extremely fixed seat - heat the centering
disc - disassembly aid.
Figure 54
Transmission DX140W-5/DX160W-5
6-7-26
18. Unsnap the retaining ring and remove ball bearing.
Figure 55
Planet Carrier
1. Remove axial needle cage with both thrust washers.
Figure 56
Figure 57
CAUTION
AVOID INJURY
Pay attention to the released planet carrier and the
bearing innerring.
Figure 58
DX140W-5/DX160W-5 Transmission
6-7-27
4. Pull the second bearing inner ring from the planet carrier.
Figure 59
CAUTION
AVOID INJURY
If the taper roller bearings are reused - pay attention to
the bearing location, i.e. respective bearing inner ring
to bearing outer ring.
Figure 60
Figure 61
Figure 62
Transmission DX140W-5/DX160W-5
6-7-28
8. Pull off the bearing inner ring in case of an extremely fixed
seat heat the bearing inner ring.
Figure 63
Figure 64
10. Remove screen sheet (2) from the planet carrier (1).
Figure 65
DX140W-5/DX160W-5 Transmission
6-7-29
DISASSEMBLY - OUTPUT
1. Loosen the bolt connection, remove cover and the O-ring.
Figure 66
Figure 67
Figure 68
CAUTION
AVOID INJURY
Pay attention to the released bearing inner ring and
the adjusting ring (rolling moment/pinion bearing)
behind it.
Figure 69
Transmission DX140W-5/DX160W-5
6-7-30
5. Remove O-ring (arrow) and the bush from the pinion.
Figure 70
6. Pull off and press off respectively the bearing inner ring.
Figure 71
CAUTION
AVOID INJURY
Pay attention to the shim behind it (pinion gap setting).
Figure 72
DX140W-5/DX160W-5 Transmission
6-7-31
8. Pull off the bearing cover.
Figure 73
Figure 74
Figure 75
11. Lift the output gear with oil baffle plate out of the housing.
Remove oil baffle plate from the output gear.
Figure 76
Transmission DX140W-5/DX160W-5
6-7-32
12. Remove screen sheet.
Figure 77
13. Expel the bearing outer ring from the housing bore (arrow).
Figure 78
Figure 79
DX140W-5/DX160W-5 Transmission
6-7-33
REASSEMBLY - OUTPUT
Only when a new housing is installed (Figure 80):
Seal the finished holes (8x) of the oil supply bores with screw
plugs.
Figure 80
Axle Attachment
1. Install the stud bolts.
CAUTION
AVOID INJURY
Observe the installation position. Figure 81.
Figure 82
Figure 83
Transmission DX140W-5/DX160W-5
6-7-34
4. Position the screen sheet - with slotted pin (Figure 83) into
the fixing bore (arrow).
CAUTION
AVOID INJURY
Observe the installation position - slotted pin = radial
fixing of the screen sheet.
Figure 84
Figure 85
CAUTION
AVOID INJURY
Installation position of the shaft seal - Sealing lip Figure 86
showing to the oil sump (Figure 87).
CAUTION
AVOID INJURY
Install the shaft seal (1) considering the required
installation position (Dim. "X" - Figure 87).
DX140W-5/DX160W-5 Transmission
6-7-35
CAUTION
AVOID INJURY
Grease the shaft seal in the area around the sealing
and dust lip.
Reference
Description
Number
1 Shaft seal
2 Bearing cover
X Installation Dimension → 69.5 - 0.5 mm
Figure 87
Transmission DX140W-5/DX160W-5
6-7-36
Determine Adjusting Shim for Pinion Gap
Reference
Description
Number
1 Pinion
2 Roller Bearing
3 Bearing Cover
4 Ball (ø = 7 mm)
A Auxiliary Dimension
B Bearing Width
C Reference Dimension
Contact Surface/Bearing Cover to
D
Contact/Bearing Bore
E 73.0 mm (Constant Value)
Pinion Dimension
X
(Engraved on the Pinion)
189.0 mm (Contact Surface/Bearing
Z
Cover to Center/Axle Casing)
CAUTION Figure 88
AVOID INJURY
For a correct installation and positioning of the pinion, the
following steps are to be carried out as exactly as possible.
CAUTION
AVOID INJURY
Auxiliary dimension "A" is obligatory to determine the
reference dimension "C" - on the installed pinion
(Figure 115).
Figure 89
DX140W-5/DX160W-5 Transmission
6-7-37
2. Read pinion dim. "X" on the pinion (see arrow) or measure
it in case of manufacturing-specific + or - deviation from the
pinion dim. (relating value is marked by hand on the pinion
e.g. + 0.1).
Pinion dim. "X" (without + or - deviation) = 116.0 mm
Figure 90
CAUTION
AVOID INJURY
Since the installed roller bearing is subject to a
preload, deducting an empirical value of - 0.1 mm is to Figure 91
be considered.
Figure 93
Transmission DX140W-5/DX160W-5
6-7-38
6. Oil the O-rings (arrows) and insert them into the ring
grooves of the bearing cover.
Figure 94
7. Bend the edges of the fixing straps of the oil baffle plate
slightly - assembly aid (sheet is fixed to the bearing cover -
Figure 96).
Figure 95
CAUTION
AVOID INJURY
Observe the installation position - locate the fixing lug
of the oil baffle plate into the recess of the bearing
cover (see arrow).
Figure 96
Figure 97
DX140W-5/DX160W-5 Transmission
6-7-39
10. Mount the heated bearing inner ring until contact and after
cooling-down install it subsequently until contact is
obtained.
Figure 98
11. Mount the bush, oil the O-ring (arrow) and put it into the
ring groove.
Figure 99
Figure 100
Transmission DX140W-5/DX160W-5
6-7-40
13. Fasten the pinion by means of the clamping bar.
Figure 101
CAUTION
AVOID INJURY
It is recommended to reinstall the adjusting ring (e.g. s Figure 102
= 1.35 mm) from the disassembly, if however the
required rolling moment of 1.5 ~ 3.0 N.m (without shaft
seal) is not obtained - see bearing rolling moment
check Figure 107 - the bearing rolling moment is to be
corrected with an adequate adjusting ring.
Figure 103
DX140W-5/DX160W-5 Transmission
6-7-41
3. Mount the flange.
Figure 104
CAUTION
AVOID INJURY
Rotate the pinion - when tightening - in both directions
(aligning of rollers) several times.
Figure 106
Transmission DX140W-5/DX160W-5
6-7-42
Check the Rolling Moment of the Pinion Bearing
1. Bearing rolling moment (without shaft seal) 1.5 ~ 3.0 N.m
(When using new roller bearings - upper value should be
achieved)
CAUTION
AVOID INJURY
If the required rolling moment deviates, it is to be
corrected with an adequate adjusting ring (Figure 102).
Figure 107
Figure 108
CAUTION
AVOID INJURY
Installation position of the shaft seal. Sealing lip
showing to the oil sump (Figure 110).
DX140W-5/DX160W-5 Transmission
6-7-43
Legend to the sketch:
Reference
Description
Number
1 Shaft Seal
2 Screen Sheet
3 Flange
4 Roller Bearing
5 Bearing Cover
M Installation Dimension → 17.6 - 0.5 mm
Figure 110
N Installation Dimension → 27.5 + 0.3 mm
Figure 111
Figure 112
4. Mount the preassembled flange and put the O-ring into the
recess.
Figure 113
Transmission DX140W-5/DX160W-5
6-7-44
5. Place the washer and fasten it by means of hexagon
screws.
• Tightening torque (M10/8.8)
MA = 46 N.m (4.7 kg.m, 34 ft lb)
Figure 114
CAUTION
AVOID INJURY
If the constant value of Dim. "E" = 73.00 ±0.05 mm is
not achieved, it is to be corrected with an adequate
shim/pinion gap (Figure 93).
DX140W-5/DX160W-5 Transmission
6-7-45
REASSEMBLY - BRAKE/CLUTCH/PLANET CARRIER
Planet Carrier
1. Illustration shows the "Axle Attachment".
Install the bearing outer ring until contact.
CAUTION
AVOID INJURY
Observe the bearing location - bearing inner ring to
bearing outer ring - also see instructions for Figure 116
disassembly page -28, Figure 60.
CAUTION
AVOID INJURY
Observe the bearing location - bearing inner ring to
bearing outer ring - also see instructions for
disassembly page -28, Figure 60.
Figure 117
3
1
Figure 118
Reference
Description
Number 1
1 Planet Carrier 2 X
3
2 Screen Sheet
Contact Surface - Axial Needle Cage/
3
axial Washer
X Install. Dim. 1.5 - 0.5 mm
Figure 119
Transmission DX140W-5/DX160W-5
6-7-46
4. Insert the slotted pins (6x), considering the installation
dimension "X" = 28.0 - 1.0 mm and the installation position -
Figure 121 (slot is showing to the center).
CAUTION
AVOID INJURY
Prior to installation grease the slotted pin - assembly X
aid.
Figure 120
Figure 121
Reference
Description
Number
1 Bearing Inner Ring with Cylinder Rollers
1a Packing Sleeve + Assembly Aid
2 Planetary Gear
3 Cylinder Rollers
3a Packing Sleeve + Assembly Aid
4 Shim
Figure 122
DX140W-5/DX160W-5 Transmission
6-7-47
5. Position the planetary gear (2) - with the marking showing
downwards.
Put the bearing inner ring (1) onto the planetary gear (2)
and press it until contact is obtained.
Then remove loose packing sleeve (1a).
CAUTION
AVOID INJURY
Figure 123
Keep the bearing inner ring to contact and rotate the
planetary gear by 180°.
6. Position the cylinder rollers (3) onto the planetary gear (2).
Figure 124
Figure 125
Transmission DX140W-5/DX160W-5
6-7-48
CAUTION
AVOID INJURY
Keep the bearing inner ring with cylinder rollers to
contact - and mount the preassembled the planetary
gear to the planet carrier pin.
Figure 126
Figure 127
CAUTION
AVOID INJURY
Install the retaining ring subsequently until contact at
the groove base is obtained.
10. Press the bearing inner ring onto the planet carrier until
contact ist obtained.
Figure 129
DX140W-5/DX160W-5 Transmission
6-7-49
11. Insert the preassembled planet carrier.
Figure 130
Figure 131
Figure 132
Transmission DX140W-5/DX160W-5
6-7-50
14. Mount the heated bearing inner ring until contact.
Figure 133
15. Position the shim and attach the hexagon screws by hand
(fixing of the planet carrier).
Then remove clamping bar - Figure 131.
Figure 134
CAUTION
AVOID INJURY
Tighten the hexagon screws equally - risk of
distortion.
WARNING
AVOID DEATH OR SERIOUS INJURY
When tightening the hexagon bolts rotate the planet
carriers - into both directions. several times (aligning
of rollers).
DX140W-5/DX160W-5 Transmission
6-7-51
Brake/Clutch
1. Mount the heated centering disc and press it until contact
is obtained.
Figure 136
Figure 137
3. Insert the ball bearing into the internal gear and fasten it by
means of the retaining ring.
Figure 138
Transmission DX140W-5/DX160W-5
6-7-52
4. Heat the bearing inner ring of the ball bearing.
Figure 139
Figure 140
Figure 141
CAUTION
AVOID INJURY
Fix the axial needle cage and the thrust washers by
means of grease centrically - assembly aid. Figure 142
DX140W-5/DX160W-5 Transmission
6-7-53
8. Mount the preassembled input shaft (with internal gear).
Figure 143
Reference
Description
Number
Upper Ring Groove
B
(Retaining. Ring -1)
1 Retaining Ring
2 End Shim / Brake (1 Pc.)
3 Outer Disc / Brake (6 Pcs.)
4 Inner Disc / Brake (6 Pcs.)
5 End Shim / Clutch (1 Pc.)
Figure 144
6 Inner Disc / Clutch (10 Pcs.)
7 Inner Disc / Clutch (9 Pcs.)
8 Transmission Housing
9 Disc Carrier / Internal Gear
1. Brake
Snap the retaining ring (1) into the ring groove (A).
CAUTION
AVOID INJURY
Observe the installation position of the retaining ring
(1) - ring groove (A).
Figure 145
Transmission DX140W-5/DX160W-5
6-7-54
2. Insert the end shim (2).
Figure 146
CAUTION
AVOID INJURY
Position the outer disc (1 pc.) s = variable 2.8 ~ 3.7 mm,
in the disc set on the top (piston-side).
With outer disc s = variable, the disc clearance/piston
stroke will be adjusted - Figure 160. Figure 147
4. Clutch:
Insert the disc set (outer/inner discs) - beginning with an
outer disc - alternately.
CAUTION
AVOID INJURY
Position the outer disc (1 pc.) s = variable 1.2 ~ 1.6 mm,
in the disc set on the top (piston side).
Figure 148
With outer disc s = variable, the disc clearance/piston
stroke will be adjusted - Figure 159.
DX140W-5/DX160W-5 Transmission
6-7-55
Adjust and Check the Disc Clearance/Piston Stroke of
Brake and Clutch
1. Mount the pressure piece (without compression spring).
Figure 149
2. Oil the axial roller cage and mount it with both thrust
washers (1x each, positioned underneath and onto the
axial needle cage respectively).
Figure 150
Figure 151
Figure 152
Transmission DX140W-5/DX160W-5
6-7-56
5. Insert both cup springs/clutch.
Fix the cup springs by means of grease and position them
centrically. assembly aid.
CAUTION
AVOID INJURY
Observe the installation position - also see Figure 155.
Figure 153
CAUTION
AVOID INJURY
Observe the installation position - also see Figure 155.
Figure 154
Reference l ll lll
Description
Number
1 Measuring Fixture 5
D C B A
2 Piston/Clutch 3 X
Y
3 Cup Springs/Clutch 4
2
4 Piston/Brake 6
5 Cup Springs/Brake
6 Transmission Housing FG002838
Figure 155
I Measuring Bore (Disc Clearance/Clutch)
II Measuring Bore (Disc Clearance/Brake)
A Mounting Face/Housing - Face/Piston
Mounting Face/Housing -
B
Piston Contact/Housing
C Mounting Face/Housing - Face/Piston
Mounting Face/Housing -
D
Piston Contact/Housing
DX140W-5/DX160W-5 Transmission
6-7-57
CAUTION
AVOID INJURY
Locate the measuring fixture with hexagon screws
equally (risk of breakage) until contact is obtained.
Figure 157
Figure 158
Transmission DX140W-5/DX160W-5
6-7-58
WARNING
AVOID DEATH OR SERIOUS INJURY
If the required disc clearance (piston stroke) is not
obtained, this is to be corrected with a suitable outer
disc - Figure 148.
WARNING
AVOID DEATH OR SERIOUS INJURY
If the required disc clearance (piston stroke) is not
obtained, this is to be corrected with a suitable outer
disc n see Figure 147.
Figure 161
12. Insert the oil baffle plate into the disc carrier and fix it with
the snap ring.
Figure 162
DX140W-5/DX160W-5 Transmission
6-7-59
13. Oil the sealing faces and the O-ring.
Insert the O-ring (arrow) into the groove and insert the ring.
CAUTION
AVOID INJURY
Observe the installation position - Figure 163.
Figure 163
14. By means of the mounting tool locate the ring until contact
is obtained.
Figure 164
Figure 165
16. Insert the seal (1) with the sealing lip showing to the oil
sump. also see detail sketch.
Put both O-rings (2) into the ring grooves of the pressure
ring (3) and insert the preassembled pressure ring -
observe the installation position.
Figure 166
Transmission DX140W-5/DX160W-5
6-7-60
17. By means of the mounting tool locate the pressure ring
until contact.
Figure 167
Figure 168
Figure 169
DX140W-5/DX160W-5 Transmission
6-7-61
20. Oil the axial roller cage and mount it with both thrust
washers (1x each to be positioned underneath and onto
the axial needle cage respectively).
Figure 170
Figure 171
Reference
Description
Number
1 Housing
2 Seal (With Sealing Lip)
3 Seal
4 Piston/Brake
5 Seal (With Sealing Lip)
6 Seal (With Sealing Lip)
7 Piston/Clutch
Figure 172
Figure 173
Transmission DX140W-5/DX160W-5
6-7-62
24. Insert the preassembled piston/brake until contact is
obtained.
CAUTION
AVOID INJURY
Piston is to be positioned that the oil supply bore
(arrow) - with the transmission installed into the
vehicle - is at 12 o’clock position.
Figure 174
Figure 175
Figure 176
Figure 177
DX140W-5/DX160W-5 Transmission
6-7-63
28. Press the piston axially, contrary to the compression spring
preload, and seal the pressure oil supply bore by means of
screw plug/sealing ring (arrow) - thus the piston is kept in
axial position - assembly aid for input housing assembly
(Figure 184 and 213).
Figure 178
CAUTION
AVOID INJURY
Observe the installation position - Figure 179 and also
Figure 155 respectively.
Figure 179
CAUTION
AVOID INJURY
Observe the installation position -Figure 180 and also
Figure 155.
Figure 180
Figure 181
Transmission DX140W-5/DX160W-5
6-7-64
2. Place the O-ring (arrow) and insert the compression
spring.
Figure 182
3. Input housing:
Oil the O-ring and put it into the ring groove of the input
housing.
Figure 183
Figure 184
WARNING
AVOID DEATH OR SERIOUS INJURY
Locate the input housing with hexagon screws equally
(risk of breakage) until contact is obtained.
DX140W-5/DX160W-5 Transmission
6-7-65
Emergency Release (Parking Brake)
Legend to Figure 186:
Reference
Description
Number
1 Input Housing
2 Housing
3 O-ring
4 Threaded Element (Orifice)
5 Ball
6 Compression Spring
7 O-ring
8 Bleeder Figure 186
9 Lubrication Nipple
Figure 187
Figure 188
Figure 189
Transmission DX140W-5/DX160W-5
6-7-66
Check the Emergency Release for Leak Tightness
1. Install the bleeder valve (1), screw plugs (2) with O-ring
screw plug (3) with O-ring and compressed air connection
piece (4).
• Tightening torque
– Bleeder valve (M10 x 1)
MA = 22 N.m (2.2 kg.m, 16.2 ft lb)
– Screw plug (M10 x 1 with O-ring)
MA = 25 N.m (2.5 kg.m, 18.4 ft lb)
– Screw plug (M18 x 1.5 with O-ring)
MA = 35 N.m (2.2 kg.m, 16.2 ft lb)
• Compr.air connect. piece (M10 x 1) w. seal. ring)
MA = 15 N.m (1.5 kg.m, 11.1 ft lb)
Figure 190
Figure 191
Figure 192
DX140W-5/DX160W-5 Transmission
6-7-67
3. Remove screw plug and the compressed air connection
piece (Figure 191).
Install the bleeder (3) with O-ring and lubrication nipple (4).
• Tightening torque
– Lubrication nipple (M10 x 1)
MA = 22 N.m (2.2 kg.m, 16.2 ft lb)
– Bleeder (M18 x 1.5)
MA = 22 N.m (2.2 kg.m, 16.2 ft lb)
Figure 193
Reference
Description
Number
1 Transmission Housing
2 Input Housing
AB Pressure Oil Connection - Multi-disc Brake
AK Pressure Oil Connection - Multi-disc Clutch
EB Bleeder Valve - Multi-disc Brake
EK Bleeder Valve - Multi-disc Clutch
Figure 194
1. Multi-disc brake:
Connect the HP-Pump ("AB" - Figure 194 and Figure 193),
Build up a pressure of p = 30 ... max. 35 bar
- Bleed the pressure chamber (several times).
Close the shut-off valve.
During a test duration of 3 minutes no measurable
pressure drop is allowed!
Figure 195
Transmission DX140W-5/DX160W-5
6-7-68
2. Closing pressure test (Cup spring preloading force):
When measuring the closing pressure the valve block is
not allowed to be attached to the transmission due to the
by-pass function between brake and clutch.
Connection "AK" (See Figure 194 respectively) open (not
closed and tank connection respectively).
Reduce the pressure slowly, when pressure range 11 ~ 9
bar (closing pressure) is reached, the input shaft has to be
locked at a tightening torque of 50 ±5 N.m.
Figure 196
3. Multi-disc clutch:
Connect the HP-Pump ("AK" - See Figure 194), build up a
pressure of p = 30 ... max. 35 bar
- Bleed the pressure chamber (several times).
Close the shut-off valve.
During a test duration of 3 minutes no measurable
pressure drop is allowed.
Test medium:
According to the "Table of recommended lubricants" of Figure 197
operation manual.
Speed Transmitter
Install the speed transmitter with O-ring.
• Tightening torque (M 8/8.8)
MA = 23 N.m (2.3 kg.m, 17 ft lb)
Figure 198
DX140W-5/DX160W-5 Transmission
6-7-69
REASSEMBLY - DOWNSHIFT INTERLOCK
Downshift Interlock
Legend to Figure 199:
Reference
Description
Number
1 Housing
2 G.shift Piston
3 Pressure Limiting Valve
4 Check Valve (008)
5 Check Valve (009)
6 Check Valve (010) Figure 199
7 Filter
8 Lube Oil Pump
Figure 200
Figure 201
Transmission DX140W-5/DX160W-5
6-7-70
3. Insert the compression spring, oil and mount the
preassembled piston.
Figure 202
Figure 203
CAUTION
AVOID INJURY
Observe the installation position of the different check
valves.
Oil the single parts acc. to the "Table of
Recommended Lubricants" pages of operation
manual. Figure 204
Reference Torque
Description
Number N.m kg.m ft lb
1 Pressure Limiting Valve (Cpl.) 10 1 7.4
2 Check Valve (Cpl.) 10 1 7.4
3 Check Valve (Cpl.) 10 1 7.4
4 Check Valve (Cpl.) 10 1 7.4
DX140W-5/DX160W-5 Transmission
6-7-71
6. Secure the check valves and the pressure limiting valve by
two blows each with the center punch.
Figure 205
CAUTION
AVOID INJURY
Insert the needle sleeve to installation dimension "X".
CAUTION
AVOID INJURY
The exact installation position is ensured by use of the
specified mounting tool.
CAUTION
AVOID INJURY
Insert the needle sleeve with marked face showing
upwards.
8. Mount the ball bearing onto the shaft and fasten it with the
retaining ring.
Figure 207
Transmission DX140W-5/DX160W-5
6-7-72
9. Press the preassembled pump shaft into the pump cover
and fasten it with the retaining ring.
Figure 208
10. Insert the compression springs (1) and ball (2) into the
bores (see arrows - 3x).
WARNING
AVOID DEATH OR SERIOUS INJURY
Prior to installation oil single parts of the pump/rotor
set (control housing, internal and outer rotor) - use oil
acc. to the "Table of Recommended Lubricants" pages
of operation manual. Figure 209
CAUTION
AVOID INJURY
Keep the pump shaft/cover in "Vertical" position - pay
attention to the position of the inserted balls/
compression springs - Figure 209 ~ Figure 214).
Figure 210
DX140W-5/DX160W-5 Transmission
6-7-73
12. Position the ball - see arrow -(drive for internal rotor) with
grease (assembly aid) into the recess of the pump shaft.
Figure 211
CAUTION
AVOID INJURY
Place the groove of the internal rotor over the driving
ball (see arrows).
Figure 212
Figure 213
Figure 214
Transmission DX140W-5/DX160W-5
6-7-74
CAUTION
AVOID INJURY
Keep the assembled pump to contact and rotate the
housing by 180°.
Figure 216
Figure 217
CAUTION
AVOID INJURY
Pay attention to different screw length.
DX140W-5/DX160W-5 Transmission
6-7-75
19. Oil both O-rings (arrows) and put them into the ring
grooves of the housing.
Figure 219
CAUTION
AVOID INJURY
Pay attention to different screw length.
21. Install both screw-in sleeves and the screw plug (see
arrows) - with O-rings.
• Tightening torque
– Screw-in sleeve (M16 x 1.5)
MA = 23 N.m (2.3 kg.m, 17 ft lb)
– Screw plug (M18 x 1.5)
MA = 35 N.m (3.6 kg.m, 25.8 ft lb)
Figure 221
Reference
Description
Number
1 Oil Tube
2 Union Screw (M16 x 1.5)
3 Sealing Ring
4 Union Screw (M14 x 1.5)
5 Sealing Ring
Figure 222
Transmission DX140W-5/DX160W-5
6-7-76
22. Install both oil tubes.
• Tightening torque
– Union screw (M14 x1.5)
MA = 25 N.m (2.5 kg.m, 18.4 ft lb)
– Union screw (M16 x1.5)
MA = 45 N.m (4.6 kg.m, 33.2 ft lb)
Figure 223
DX140W-5/DX160W-5 Transmission
6-7-77
ATTACH THE TRANSMISSION TO THE AXLE
1. Position the assembly transmission to the axle.
Figure 224
WARNING
AVOID DEATH OR SERIOUS INJURY
Prior to put the unit into operation the specifications
and regulations respectively as well as the Figure 225
instructions of the transmission operating and
maintenance instructions.
Transmission DX140W-5/DX160W-5
6-7-78
1Front
Boom and Arm
Edition 1
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
A B C E
F
D
K J I H
WE1401520
Figure 1
A L C M E D F
B K I J H
WE1401521
Figure 2
DANGER
AVOID DEATH
DOOSAN warns any user, that removal of the counterweight
from the machine, front attachment or any other part, may
affect the stability of the machine. This could cause
unexpected movement, resulting in death or serious injuries.
Never remove counterweight or front attachment unless the
upper structure is in-line with the lower structure.
Never rotate the upper structure once the counterweight or
front attachment has been removed.
IMPORTANT
WE1401434
Figure 3
Arm Removal
WARNING
AVOID DEATH OR SERIOUS INJURY
This procedure is intended for routine removal or
replacement of the attachment by ONLY authorized and
trained service persons. Call you local Doosan distributor
for assistance.
DO NOT allow other personnel to go under the boom, arm
or attachment sections, if not properly supported.
Keep away from pressurized hydraulic lines to prevent
death or serious injury from high-pressure oil.
WARNING
AVOID DEATH OR SERIOUS INJURY
Secure the swing lock and tag and lock out controls in the
operator's cabin to keep anyone from moving or
inadvertently starting the engine. Restrict access to the
work site while sections of the attachment are in the air, or
while they are being supported by the assist crane. The safe
lifting capacity of the assist crane or hoist that is used must
exceed the weight of the heaviest section of the attachment,
the boom (approximately 770 kg (1,698 lb), not including the
weight of accessories or fixtures).
Remove retainers on the end of the mounting pin for the arm
cylinder rod end. Use the assist crane to relieve the weight load
and withdraw the pin. Lower the arm down to the blocking
support for any continued disassembly procedures.
Boom Removal
NOTE: Boom removal may be simplified if the shell of the
operator's cabin is taken off the turntable deck first.
Refer to the Operator's Cabin Removal procedure
before continuing, if both components are to be
removed from the excavator.
After the bucket, arm and arm cylinder have been removed,
lower the end of the boom to a stable, secure blocking support.
Attach the assist crane sling to the body of either boom cylinder,
break the mounting pin connection to the boom by tapping
through the pin from the same side of the boom and repeat for
the opposite cylinder.
Release hydraulic pressure and disconnect line couplings as
previously outlined in the Arm Removal Procedure, observing
the same precautions.
Disconnect wiring for work light assemblies and any other
accessory lines or connections. Locate the sling of the assist crane
near the center of gravity, optimum lift point for the boom, and use
the crane to take pressure off the boom foot pin. Drive out the pin
after disassembling retainers and carefully lift away the boom.
WARNING
AVOID DEATH OR SERIOUS INJURY
If either the front attachment or counterweight has been
removed, stability of the excavator will be affected. Never
travel with the excavator, swing the turntable or drive over
uneven or sloping terrain if one of these components have
been removed. Tipping or a rollover could result in death or
serious injury.
Arm Installation
Reattach the base of the arm cylinder to the mounting point on
top of the boom.
WARNING
AVOID DEATH OR SERIOUS INJURY
Before assembling the front attachment, make sure that
individual boom, arm and bucket sections are all
compatible for work intended. Refer to the General Safety
Pages, Lift Ratings, Working Range Diagrams and Weights
of Materials sections in the Operation & Maintenance
Manual. Consult your dealer or DOOSAN After Sales
Service for more information if you have any questions.
Boom Installation
Before reassembling the attachment, make sure to inspect all
bushings and pivot points of each section. To avoid damaging
the seats, bushings should never be hammered or chiseled out
of their seats.
Installation is otherwise a reversal of the removal procedures.
COMPLETING WORK
Once the boom has been serviced, it must be lubricated as
outlined in the initial start-up procedures of the operation
manual. Refer to the appropriate Operation & Maintenance
Manual for unit.
Edition 1
DX140W-5/DX160W-5 Bucket
7-2-1
MEMO
Bucket DX140W-5/DX160W-5
7-2-2
Table of Contents
Bucket
Safety Instructions ..........................................7-2-5
Bucket Tooth Inspection and Replacement ....7-2-6
Bucket O-ring Replacement ...........................7-2-7
Installation ................................................................. 7-2-8
Bucket Detaching and Reversal .....................7-2-9
Detaching .................................................................. 7-2-9
Reversal .................................................................... 7-2-9
DX140W-5/DX160W-5 Bucket
7-2-3
Bucket DX140W-5/DX160W-5
7-2-4
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
DX140W-5/DX160W-5 Bucket
7-2-5
BUCKET TOOTH INSPECTION
AND REPLACEMENT
There are several different types of attachment methods for
replaceable bucket tooth. Some of the most common types are
shown in the following drawings.
Bucket tooth are usually replaced in sets but it may sometimes
be necessary to replace individual teeth.
Look for the following indications of wear or damage:
• Lock pins protrude unevenly on one side.
• Lock pins have been worn down so far that they no longer
make full contact through the length of the pinhole.
• Lock washers or pins show obvious damage or weakness.
• Wear points on the working surfaces of tooth points - pits,
cracks, chips or craters - are larger than 8 mm to 10 mm
(1/3" to 1/2") across.
FG004607
Figure 1
HDO5057I-1
Figure 2
Bucket DX140W-5/DX160W-5
7-2-6
BUCKET O-RING REPLACEMENT
WARNING
AVOID DEATH OR SERIOUS INJURY
Due to possibility of flying metal objects, always wear
safety helmet, protective gloves and eye protection when
changing pins.
1 1
EX1404393
Figure 4
• Tool: 24 mm ( )
1
• Torque: 196.1 N.m (20 kg.m, 144.7 ft lb)
WE1401454
Figure 5
WE1401455
Figure 6
DX140W-5/DX160W-5 Bucket
7-2-7
4. Separate the arm from the bucket and remove the O-ring
(1, Figure 7).
1
WE1401456
Figure 7
Installation
1. Perform installation in the reverse order to remove.
NOTE: Assemble double nut like Figure 9.
WE1401457
Figure 8
1 ~ 2 mm
EX1404398
Figure 9
Bucket DX140W-5/DX160W-5
7-2-8
BUCKET DETACHING AND REVERSAL
Detaching
Park the excavator away from obstructions on clear, flat, level
ground. Lower the bucket carefully to preassembled blocking on
the ground. Brace the bucket so that there is no load weight on
the pin connecting the bucket and arm. Disassemble the
fasteners on the end of the bucket pin and pull out the pin.
If the pin sticks and resists normal withdrawal, there may be a
load on it. Raise and lower the arm slightly until an unstressed
pin position is located.
CAUTION
AVOID INJURY
Use care pulling out the pin to avoid damaging the dust
seals on either end of the arm.
When the pin has been withdrawn, move the operating joystick
slightly to take weight off the remaining link pin. Disassemble the
link pin end retainers and pull out the pin.
Lift the arm away from the bucket so that the bucket can be
carried away or another end attachment can be put on the
excavator.
Reversal
Follow instructions for "Detaching" and remove both the bucket
and link pins. Rotate the bucket 180° to change bucket
configuration. This procedure is greatly simplified if some type of
rotating or swiveling support can be used, on the ground
underneath the bucket. Follow instructions for "Bucket
Attachment" to replace pins.
WARNING
AVOID DEATH OR SERIOUS INJURY
Bucket curl and dump levers must be used in opposite
directions, after the bucket has been reversed.
DX140W-5/DX160W-5 Bucket
7-2-9
Bucket DX140W-5/DX160W-5
7-2-10
Cylinders
Edition 1
DX140W-5/DX160W-5 Cylinders
7-3-1
MEMO
Cylinders DX140W-5/DX160W-5
7-3-2
Table of Contents
Cylinders
Safety Instructions ..........................................7-3-5
General ...........................................................7-3-5
General Description................................................... 7-3-5
Specification .............................................................. 7-3-5
Parts List ................................................................... 7-3-6
Boom Cylinder (LH).............................................. 7-3-6
Boom Cylinder (RH) ............................................. 7-3-8
Arm Cylinder....................................................... 7-3-10
Bucket Cylinder .................................................. 7-3-12
Arti Boom Cylinder ............................................. 7-3-14
Dozer Cylinder (LH)............................................ 7-3-16
Dozer Cylinder (RH) ........................................... 7-3-18
Outrigger Cylinder (LH) ...................................... 7-3-20
Outrigger Cylinder (RH)...................................... 7-3-22
Theory of Operation ................................................ 7-3-24
Seal of Cylinder ....................................................... 7-3-25
Special Tools and Materials .........................7-3-27
Piston Nut................................................................ 7-3-27
Piston Jig................................................................. 7-3-28
Steel Bushing Jig..................................................... 7-3-29
Dust Wiper Jig ......................................................... 7-3-30
Slipper Seal Jig ....................................................... 7-3-31
Slipper Seal Straightening Jig ................................. 7-3-32
Rod Bushing (DD-bushing) Pushing-in Jig.............. 7-3-33
Disassembly .................................................7-3-34
Reassembly ..................................................7-3-39
Troubleshooting ............................................7-3-43
DX140W-5/DX160W-5 Cylinders
7-3-3
Cylinders DX140W-5/DX160W-5
7-3-4
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation & Maintenance
Manual and signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs, adjustments
or servicing. Check for correct function after adjustments
repairs or service. Untrained operators and failure to follow
instructions can cause death or serious injury.
GENERAL
General Description
Two essentially similar types of hydraulic cylinders are used on
the excavator. The cylinder that is used to operate the excavator
boom or bucket is equipped with a rod stopper, which acts as a
cushion only when the cylinder rod is fully retracted (and the
bucket is pulled close to the arm). This type of cylinder is shown
in the below drawing. Arm cylinders have a cushion or stopper
for operation in both directions.
Specification
Rod O.D
Tube I.D
Stroke
Closed Length
Figure 1 EX1400068
DX140W-5/DX160W-5 Cylinders
7-3-5
Parts List
The following parts list is component Parts List.
32
33
36
26
29
28
A B
1 27
37
24
23
38
39
24
17
22
21
19
18
19
20
16
25 14
13
15
7
6
5
8 A
9
10
11
12
WE1401495
Figure 2
Cylinders DX140W-5/DX160W-5
7-3-6
Reference Reference
Description Description
Number Number
1 Tube Assemby 21 O-ring
2 Bushing, Sintering 22 Ring; Backup
3 Rod, Cylinder 23 Nut, Piston
4 Bushing, Sintering 24 Screw; Set
5 Cover, Rod 25 Bolt; Socket
6 DD-bush 26 Band Assembly, Pipe
7 Ring; Retaining 27 Band, Pipe
8 Seal; Buffer 28 Washer; Spring
9 U-packing 29 Bolt
10 Ring; Backup 30 Pipe Assembly; (LH)
11 Wiper; Dust 31 O-ring
12 Ring; Retaining 32 Washer; Spring
13 O-ring 33 Bolt; Socket
14 Ring; Backup 34 Washer; Spring
15 O-ring 35 Bolt
16 Ring; Cushion 36 Pipe Assembly; (LH)
17 Piston 37 O-ring
18 Seal; Slipper 38 Washer
19 Ring; Wear 39 Bolt; Socket
20 Ring; Dust * Seal Kit
DX140W-5/DX160W-5 Cylinders
7-3-7
Boom Cylinder (RH)
29
27
28 B
31
35 30 32
B
34 33
35
1
34
26
36 24
23
A
37
24
38
39 17
22
21
19
18
19
20
16
25 14
13
15
7
6
A 5
8
9
10
11
12
3
WE1401496
Figure 3
Cylinders DX140W-5/DX160W-5
7-3-8
Reference Reference
Description Description
Number Number
1 Tube Assembly 21 O-ring
2 Bushing, Sintering 22 Ring; Backup
3 Rod, Cylinder 23 Nut, Piston
4 Bushing, Sintering 24 Screw; Set
5 Cover, Rod 25 Bolt; Socket
6 DD-bush 26 Band Assembly, Pipe
7 Ring; Retaining 27 Band, Pipe
8 Seal; Buffer 28 Washer; Spring
9 U-packing 29 Bolt
10 Ring; Backup 30 Pipe Assembly; (RH)
11 Wiper; Dust 31 O-ring
12 Ring; Retaining 32 Washer; Spring
13 O-ring 33 Bolt; Socket
14 Ring; Backup 34 Washer; Spring
15 O-ring 35 Bolt
16 Ring; Cushion 36 Pipe Assembly; (RH)
17 Piston 37 O-ring
18 Seal; Slipper 38 Washer
19 Ring; Wear 39 Bolt; Socket
20 Ring; Dust * Seal Kit
DX140W-5/DX160W-5 Cylinders
7-3-9
Arm Cylinder
43
36 35 42
41
34
28 33
29
30
31
1 32
24
37
23
A 38 24
17
20
39 19
40 18
19
20
21
22
16
14
27 13
15
7
A 6
5
8
3
9
10
11
12
WE1401497
Figure 4
Cylinders DX140W-5/DX160W-5
7-3-10
Reference Reference
Description Description
Number Number
1 Tube Assembly 22 Ring; Backup
2 Bushing, Sintering 23 Nut, Piston
3 Rod, Cylinder 24 Screw; Set
4 Bushing, Sintering 27 Bolt; Socket
5 Cover, Rod 28 Valve; Check
6 DD-bush 29 Spring
7 Ring; Retaining 30 Support; Spring
8 Seal; Buffer 31 O-ring
9 U-packing 32 Plug
10 Ring; Backup 33 Band Assembly, Pipe
11 Wiper; Dust 34 Band, Pipe
12 Ring; Retaining 35 Washer; Spring
13 O-ring 36 Bolt
14 Ring; Backup 37 Pipe Assembly
15 O-ring 38 O-ring
16 Ring; Cushion 39 Washer; Spring
17 Piston 40 Bolt; Socket
18 Seal; Slipper 41 Clamp, Pipe
19 Ring; Wear 42 Washer, Spring
20 Ring; Dust 43 Bolt
21 O-ring * Seal Kit
DX140W-5/DX160W-5 Cylinders
7-3-11
Bucket Cylinder
33
32
31
30
26
38
39
2
40
1
28
29
27
26
23 24
27
28
29 24
38
39
A
40 17
34
35 22
21
20
19
36 18
37 19
20
16
25
14
13
15
7
A 6
8
9
10
11
3
12
WE1401498
Figure 5
Cylinders DX140W-5/DX160W-5
7-3-12
Reference Reference
Description Description
Number Number
1 Tube Assembly 22 Backup Ring
2 Bushing, Sintering 23 Nut, Piston
3 Rod, Cylinder 24 Screw; Set
4 Bushing, Carburizing 25 Bolt
5 Cover, Rod 26 Band Assembly, Pipe
6 DD-bush 27 Band, Pipe
7 Ring; Retaining 28 Washer; Spring
8 Seal; Buffer 29 Bolt
9 U-packing 30 Pipe Assembly
10 Ring, Backup 31 O-ring
11 Wiper; Dust 32 Washer
12 Ring; Retaining 33 Bolt; Socket
13 O-ring 34 Pipe Assembly
14 Ring; Backup 35 O-ring
15 O-ring 36 Washer
16 Ring; Cushion 37 Bolt; Socket
17 Piston 38 Clamp, Pipe
18 Seal; Slipper 39 Washer; Spring
19 Ring; Wear 40 Bolt M10 x 1.5 x 45
20 Ring; Dust * Seal Kit
21 O-ring
DX140W-5/DX160W-5 Cylinders
7-3-13
Arti Boom Cylinder
32
31
39 39 29
38 38 30
37 37
36
35
2
33
34 25
25
1
23
26
26 22
27
28
23
16
18
17
5 19
21
20
24 21
14
13
15
7
6
8
9
10
11
12 3
WE1401499
Figure 6
Cylinders DX140W-5/DX160W-5
7-3-14
Reference Reference
Description Description
Number Number
1 Tube Assembly 21 Ring; Backup
2 Bushing, Sintering 22 Nut, Piston
3 Rod Assembly, Cylinder 23 Screw; Set
4 Bushing, Sintering 24 Bolt
5 Cover, Rod 25 Clamp, Pipe
6 DD-bush 26 Band, Pipe
7 Ring; Retaining 27 Washer; Spring
8 Seal; Buffer 28 Bolt M10 x 1.5 x 40
9 U-packing 29 Pipe Assembly
10 Ring; Backup 30 O-ring
11 Wiper; Dust 31 Washer; Spring
12 Ring; Retaining 32 Bolt; Socket M10 x 1.5 x 45
13 O-ring 33 Pipe, Cylinder; R
14 Ring; Backup 34 O-ring
15 O-ring 35 Washer; Spring
16 Piston 36 Bolt; Socket
17 Seal; Slipper 37 Clamp, Pipe
18 Ring; Wear 38 Washer, Spring
19 Ring; Dust 39 Bolt
20 O-ring * Seal Kit; Arti Boom
DX140W-5/DX160W-5 Cylinders
7-3-15
Dozer Cylinder (LH)
23
22 23
21 24
17
16
25
18 1
15
19 20
12
13
14
7
9
3
10
11
4
WE1401500
Figure 7
Cylinders DX140W-5/DX160W-5
7-3-16
Reference Reference
Description Description
Number Number
1 Tube Assembly 14 O-ring
2 Bush; Rolled 15 Piston
3 Rod Assembly 16 Seal; Slipper
4 Bush; Rolled 17 Ring, Wear
5 Cover; Rod 18 Ring, Dust
6 Bush 19 O-ring
7 Ring, Retaining 20 Backup Ring
8 Seal, Buffer 21 Nut, Piston
9 U-packing 22 Screw; Set
10 Dust Wiper 23 O-ring
11 Ring, Retaining 24 Valve, Double Check; LH
12 O-ring 25 Bolt, Socket
13 Backup Ring * Seal Kit; Dozer
DX140W-5/DX160W-5 Cylinders
7-3-17
Dozer Cylinder (RH)
22
21
17 23
16
23
18
24
15 25
19 20
12
13
14
7
9
3
10
11
4
WE1401501
Figure 8
Cylinders DX140W-5/DX160W-5
7-3-18
Reference Reference
Description Description
Number Number
1 Tube Assembly 14 O-ring
2 Bush; Rolled 15 Piston
3 Rod Assembly 16 Seal; Slipper
4 Bush; Rolled 17 Ring, Wear
5 Cover; Rod 18 Ring, Dust
6 Bush 19 O-ring
7 Ring, Retaining 20 Backup Ring
8 Seal, Buffer 21 Nut, Piston
9 U-packing 22 Screw; Set
10 Dust Wiper 23 O-ring
11 Ring, Retaining 24 Valve, Double Check; RH
12 O-ring 25 Bolt, Socket
13 Backup Ring * Seal Kit; Dozer
DX140W-5/DX160W-5 Cylinders
7-3-19
Outrigger Cylinder (LH)
24
2
25
23
21
27
26
21
20
17
22
16
15
14
18 19
11
12
13
1
7
9
3
10
4
WE1401502
Figure 9
Cylinders DX140W-5/DX160W-5
7-3-20
Reference Reference
Description Description
Number Number
1 Tube Assembly 15 Seal; Slipper
2 Bush; Steel 16 Ring; Wear
3 Rod, Cylinder 17 Ring; Dust
4 Bush; Steel 18 O-ring
5 Cover, Rod 19 Ring; Backup
6 Bush; DD 20 Nut, Piston
7 Ring, Retaining 21 Screw; Set
8 Seal; Buffer 22 Pipe Assembly; (LH)
9 U-packing 23 O-ring
10 Wiper; Dust 24 Valve Assembly (LH)
11 O-ring 25 Bolt, Socket
12 Ring; Backup 26 Bolt; Hex. Socket
13 O-ring 27 Washer
14 Piston * Seal Kit
DX140W-5/DX160W-5 Cylinders
7-3-21
Outrigger Cylinder (RH)
2 25
26
27
21
23
21 24
20
17
22
16
15
14
18 19
11
12
13
1
7
9
3
10
4
WE1401503
Figure 10
Cylinders DX140W-5/DX160W-5
7-3-22
Reference Reference
Description Description
Number Number
1 Tube Assembly 15 Seal; Slipper
2 Bush; Steel 16 Ring; Wear
3 Rod, Cylinder 17 Ring; Dust
4 Bush; Steel 18 O-ring
5 Cover, Rod 19 Ring; Backup
6 Bush; DD 20 Nut, Piston
7 Ring, Retaining 21 Screw; Set
8 Seal; Buffer 22 Pipe Assembly; (RH)
9 U-packing 23 O-ring
10 Wiper; Dust 24 Valve Assembly (RH)
11 O-ring 25 Bolt, Socket
12 Ring; Backup 26 Bolt; Hex. Socket
13 O-ring 27 Washer
14 Piston * Seal Kit
DX140W-5/DX160W-5 Cylinders
7-3-23
Theory of Operation
1 Piston
2 Oil Path A 1
3 Oil Path B D
F1 = P x πD2
4
Q1 = S x π(D2)
4
Q2 = S x π(D2-R2)
4
Q1 > Q2 FG001459
Figure 13
Cylinders DX140W-5/DX160W-5
7-3-24
Seal of Cylinder
1. Assembly location and shape of seals
A. Rod cover seal
U-packing
Backup Ring
Retaining Ring
O-ring
Dust Wiper
Retaining Ring (DKBI Type)
Buffer Seal
DD(DU)-Bush
EX1301741
Figure 14
B. Piston seal
O-ring
EX1301742
Figure 15
DX140W-5/DX160W-5 Cylinders
7-3-25
2. Seal function
Cylinders DX140W-5/DX160W-5
7-3-26
SPECIAL TOOLS AND
MATERIALS
Piston Nut
( )
A
35
350
Figure 16 FG018703
Cylinder A
81.0 mm
Boom
(3.19 in)
81.0 mm
Arm
(3.19 in)
71.0 mm
Bucket
(2.80 in)
91.0 mm
Arti Boom
(3.58 in)
81.0 mm
Outrigger
(3.19 in)
71.0 mm
Dozer
(2.80 in)
DX140W-5/DX160W-5 Cylinders
7-3-27
Piston Jig
( )
15
2-∅"B"
)
F/2
∅8 Through Hole
R(
"
"D
∅
"A"
∅"
C"
35
R(R15~20)
5
R
4-
30
ARS4740L
Figure 17
Material SM45C (AISI 1045)
Rockwell Hardened from 22 ~ 27
Oil Quench
Cylinder A (±0.1) øB øC øD
80.0 mm 12.0 mm 70.0 mm 110.0 mm
Boom
(3.15 in) (0.47 in) (2.76 in) (4.33 in)
90.0 mm 12.0 mm 75.0 mm 115.0 mm
Arm
(3.54 in) (0.47 in) (2.95 in) (4.53 in)
70.0 mm 12.0 mm 60.0 mm 95.0 mm
Bucket
(2.76 in) (0.47 in) (2.36 in) (3.74 in)
110.0 mm 14.0 mm 80.0 mm 135.0 mm
Arti Boom
(4.33 in) (0.55 in) (3.15 in) (5.31 in)
80.0 mm 12.0 mm 70.0 mm 110.0 mm
Outrigger
(3.15 in) (0.47 in) (2.76 in) (4.33 in)
70.0 mm 12.0 mm 60.0 mm 100.0 mm
Dozer
(2.76 in) (0.47 in) (2.36 in) (3.94 in)
Cylinders DX140W-5/DX160W-5
7-3-28
Steel Bushing Jig
(5)
"B" + 40
"A" - 20
∅ "B"
∅"A"
(∅20)
15 F E
G
ARS4750L
Figure 18
Material: SM45C which is done thermal refining <QT> HRC 22 ~ 28
Undefined Chamfer C/R = 0.5 Max.
1 Place: Finally work to used DNMG Tip <Nose R0.4>
Cylinder øA-0.05
-0.15
øB (±0.1) E F+0.05
0
70.5 mm 85.0 mm 30.0 mm 6.5 mm
Boom
(2.78 in) (3.35 in) (1.18 in) (0.26 in)
70.5 mm 85.0 mm 30.0 mm 6.5 mm
Arm
(2.78 in) (3.35 in) (1.18 in) (0.26 in)
Bucket 64.5 mm 79.0 mm 30.0 mm 6.5 mm
(Rod side) (2.54 in) (3.11 in) (1.18 in) (0.26 in)
Bucket 64.5 mm 79.0 mm 30.0 mm 7.0 mm
(Head side) (2.54 in) (3.11 in) (1.18 in) (0.28 in)
79.5 mm 94.0 mm 30.0 mm 7.0 mm
Arti Boom
(3.13 in) (3.70 in) (1.18 in) (0.28 in)
59.5 mm 74.0 mm 30.0 mm 6.5 mm
Outrigger
(2.34 in) (2.91 in) (1.18 in) (0.26 in)
59.5 mm 69.0 mm 30.0 mm 6.5 mm
Dozer
(2.34 in) (2.72 in) (1.18 in) (0.26 in)
DX140W-5/DX160W-5 Cylinders
7-3-29
Dust Wiper Jig
.5
C1
3-
R0.2
DIA. (B+40)
DIA. (A-20)
DIA. A
DIA. B
15 C D
ARS4760L
Figure 19
Material: SM45C which is done thermal refining <QT> HRC 22 ~ 28
Undefined Chamfer C/R = 0.5 Max.
1 Place: Finally work to used DNMG Tip <Nose R0.4>
Cylinder øA-0.2
-0.3 øB -0.2
-0.3 C 0-0.1 D
73.0 mm 89.0 mm 5.5 mm 10.0 mm
Boom
(2.87 in) (3.50 in) (0.22 in) (0.39 in)
79.0 mm 94.0 mm 5.5 mm 10.0 mm
Arm
(3.11 in) (3.70 in) (0.22 in) (0.39 in)
64.0 mm 79.0 mm 5.5 mm 10.0 mm
Bucket
(2.52 in) (3.11 in) (0.22 in) (0.39 in)
84.0 mm 99.0 mm 5.5 mm 10.0 mm
Arti Boom
(3.31 in) (3.90 in) (0.22 in) (0.39 in)
69.0 mm 84.0 mm 5.5 mm 10.0 mm
Outrigger
(2.72 in) (3.31 in) (0.22 in) (0.39 in)
59.0 mm 74.0 mm 5.0 mm 10.0 mm
Dozer
(2.32 in) (2.91 in) (0.20 in) (0.39 in)
Cylinders DX140W-5/DX160W-5
7-3-30
Slipper Seal Jig
0
R1
R1
∅(A+2)
∅A
∅(A-14)
10°
B
(B+40)
ARS4770L
Figure 20
Cylinder øA+0.2
+0.1 B+0.2
+0.1
110.0 mm 25.0 mm
Boom
(4.33 in) (0.98 in)
115.0 mm 26.0 mm
Arm
(4.53 in) (1.02 in)
95.0 mm 26.0 mm
Bucket
(3.74 in) (1.02 in)
140.0 mm 20.0 mm
Arti Boom
(5.51 in) (0.79 in)
110.0 mm 31.0 mm
Outrigger
(4.33 in) (1.22in)
100.0 mm 31.0 mm
Dozer
(3.94 in) (1.22in)
DX140W-5/DX160W-5 Cylinders
7-3-31
Slipper Seal Straightening Jig
C2
∅20
1
2 -C
4
R
2-5
15
20
∅(A+15)
∅A
1
2-R
100
25
50
ARS4780L
Figure 21
Cylinder øA+0.2
+0.1
110.5 mm
Boom
(4.35 in)
115.5 mm
Arm
(4.55 in)
95.5 mm
Bucket
(3.76 in)
140.5 mm
Arti Boom
(5.53 in)
110.5 mm
Outrigger
(4.35 in)
100.5 mm
Dozer
(3.96 in)
Cylinders DX140W-5/DX160W-5
7-3-32
Rod Bushing (DD-bushing) Pushing-in Jig
C1
A1
B
C1
C D
EX1301743
Figure 22
Cylinder øA+0.2
-0.1 øB (±0.1) C D E
74.0 mm 79.0 mm 30.0 mm 66.0 mm 96.0 mm
Boom
(2.91 in) (3.11 in) (1.18 in) (2.60 in) (3.78 in)
79.0 mm 84.0 mm 30.0 mm 66.0 mm 96.0 mm
Arm
(3.11 in) (3.31 in) (1.18 in) (2.60 in) (3.78 in)
64.0 mm 69.0 mm 30.0 mm 94.0 mm 124.0 mm
Bucket
(2.52 in) (2.72 in) (1.18 in) (3.70 in) (4.88 in)
84.0 mm 89.0 mm 30.0 mm 46.0 mm 76.0 mm
Arti Boom
(3.31 in) (3.50 in) (1.18 in) (1.81 in) (2.99 in)
69.0 mm 74.0 mm 35.0 mm 46.0 mm 81.0 mm
Outrigger
(2.72 in) (2.91 in) (1.38 in) (1.81 in) (3.19 in)
59.0 mm 64.0 mm 30.0 mm 37.0 mm 67.0 mm
Dozer
(2.32 in) (2.52 in) (1.18 in) (1.46 in) (2.64 in)
DX140W-5/DX160W-5 Cylinders
7-3-33
DISASSEMBLY
CAUTION
AVOID INJURY
Vent air from the hydraulic system before disconnecting
cylinder piping connections. Use the lever on the reservoir,
while the engine is running. Discharge the hydraulic
accumulator and vent residual tank pressure after the
engine is shut off. Pour clean replacement hydraulic fluid
into the system if excessive fluid is lost.
Figure 23
Figure 24
Cylinders DX140W-5/DX160W-5
7-3-34
3. Remove bolts (27) on the end of cylinder.
NOTE: Wrap a cloth or other protective material around
piston rod, to avoid possibility of accidentally
scratching or scoring rod surface while
fasteners are being loosened and removed.
Component parts (numbered in parentheses)
are keyed to Figure 4.
Figure 25
Figure 26
Figure 27
Figure 28
DX140W-5/DX160W-5 Cylinders
7-3-35
7. Immobilize piston rod by inserting a wooden or other
nonscoring, nonmetallic support through end of rod.
Figure 29
HAOF340L
Figure 30
Figure 31
Figure 32
Cylinders DX140W-5/DX160W-5
7-3-36
11. Use a plastic hammer to evenly pull off rod cover (5) from
end of piston rod. Be careful not to damage rod bushing (6)
and dust wiper, U-packing and other seals.
Figure 33
12. Use a dull, rounded tip tool to pry off O-ring (13) and
backup ring (14).
HAOF37OL
Figure 34
Figure 35
14. Remove O-ring (21) and backup ring (22) from cylinder
head.
HAOF38OS
Figure 36
DX140W-5/DX160W-5 Cylinders
7-3-37
15. During disassembly of cylinder head, be careful not to
damage buffer seal (8) and U-packing (9).
HAOF39OL
Figure 37
Figure 38
17. Force out pin bushing (2), (4) from body of cylinder.
Figure 39
Cylinders DX140W-5/DX160W-5
7-3-38
REASSEMBLY
IMPORTANT
Before reassembly:
• Inspect and replace damaged or excessively worn
parts.
• Clean parts and lubricate with clean hydraulic oil.
• Make sure work area is clean.
Replace any part that shows evidence of damage or
excessive wear. Replacement of all O-rings and flexible
seals is strongly recommended. Before starting the cylinder
reassembly procedure, all parts must be thoroughly
cleaned and dried, and/or prelubricated with clean
hydraulic fluid. Prepare the work area beforehand to
maintain cleanliness during the reassembly procedure.
Figure 40
DX140W-5/DX160W-5 Cylinders
7-3-39
2. Following reassembly of rod cover components, install the
dust wiper (11) and rod bushing (6) to the rod cover (5).
Insert retaining rings (7 and 12).
Figure 41
Figure 42
Figure 43
Cylinders DX140W-5/DX160W-5
7-3-40
5. Immobilize piston rod on solid support blocks. Assemble
O-ring (21) and backup ring (22). Prepare to attach rod
cover assembly to piston rod. Push rod cover by tightening
piston nut (23).
Figure 44
Figure 45
Figure 46
8. Assemble wear ring (19), slide ring (20) and set screw (24)
to piston assembly.
Reference
Description
Number
1 Set Screw
Figure 47
DX140W-5/DX160W-5 Cylinders
7-3-41
9. Immobilize body of cylinder before reassembly.
Figure 48
Figure 49
Cylinders DX140W-5/DX160W-5
7-3-42
TROUBLESHOOTING
Problem Possible Cause Remedy
Oil leaking between Foreign material in U-packing. Remove foreign material.
cylinder head and piston Scratches in U-packing. Replace U-packing.
rod. Damage to U-packing. Replace U-packing.
Foreign material in dust wiper. Remove foreign material.
Scratches to dust wiper. Replace dust wiper.
Damage to dust wiper. Replace dust wiper.
Foreign material in seal O-ring. Remove foreign material.
Scratches in O-ring. Replace O-ring.
Damage to O-ring. Replace O-ring.
Scratches on sealing surface of piston If scratches are not deep, hone with an
rod. oil stone and lubricate.
If scratches are deep, replace piston
rod.
Deep scratches on inner surface of Replace bushing.
bushing.
Oil leaking between Damage to O-rings. Replace O-rings.
cylinder head and cylinder
tube.
Oil leaking from welded Damage to welded area. Replace cylinder tube.
area of cylinder tube.
Oil leaking between Foreign material in U-packing. Remove foreign material.
cylinder head and piston Scratches in U-packing. Replace U-packing.
rod. Damage to U-packing. Replace U-packing.
Foreign material in dust wiper. Remove foreign material.
Scratches in dust wiper. Replace dust wiper.
Damage to dust wiper. Replace dust wiper.
Foreign material in O-ring. Remove foreign material.
Scratches in O-ring. Replace O-ring.
Damage to O-ring. Replace O-ring.
Scratch on sealing surface of piston If scratches are not deep, hone with an
rod. oil stone and lubricate.
If scratches are deep, replace piston
rod.
Deep scratches on inner surface of Replace bushing
bushing.
Oil leaking between Damage to O-rings. Replace O-rings.
cylinder head and cylinder
tube.
Oil leaking from welded Damage to welded area. Replace cylinder tube.
area of cylinder tube.
Cylinder drops from pull of Light scratches on sealing surface of Hone out scratches with oil stone.
gravity. cylinder tube.
Deep scratches on sealing surface of Replace cylinder tube.
cylinder tube.
Deep scratches on sealing surface of Replace O-rings.
piston O-rings.
Foreign material in U-packing. Remove foreign material.
DX140W-5/DX160W-5 Cylinders
7-3-43
Problem Possible Cause Remedy
Cylinder drops from pull of Scratches in U-packing. Replace U-packing.
gravity. Damage to U-packing. Replace U-packing.
Wear rings twisted. Replace wear rings.
Wear rings scratched. Replace wear rings.
Wear rings have other damage. Replace wear rings.
Slow bucket and boom Reduced oil flow due to dirty filter or Disassemble and clean parts.
movements. dirty intake line.
Air drawn into circuit through loose Tighten intake connections.
connections.
Reservoir oil level too low. Fill reservoir to correct level.
Relief valve pressure setting incorrect. Adjust relief valve pressure.
Damaged pump shaft or pump drive Replace damaged parts.
sleeve.
Pump worn or damaged internally. Replace worn or damaged parts.
Relief valve sticking. Disassemble and inspect cartridge.
Clean or replace cartridge.
Air in pressure line. Perform cylinder bleeding procedure to
remove air. Tighten or replace
pressure line.
Damaged pipe or hose. Replace pipe or hose.
Worn cylinder seals. Replace worn parts.
Low-pressure, shown by Reduced oil flow due to dirty filter or Disassemble and clean parts.
weak upward movement dirty intake line.
of boom and bucket. Reservoir oil level too low. Fill reservoir to correct level.
Relief valve pressure setting incorrect. Adjust relief valve pressure.
Pump worn or damaged internally. Replace worn or damaged parts.
Relief valve sticking. Disassemble and inspect cartridge.
Clean or replace cartridge.
Worn cylinder seals. Replace worn parts.
Low pump output due to dirty Remove and clean pump discharge
discharge pipes. pipes.
Relief valve spring is weak. Relief Replace worn parts.
valve poppet worn.
Cylinder drops when Worn plunger in control valve. Replace plunger.
control valve is in neutral Stuck overload relief valve due to worn Replace worn parts.
seat surface.
Loose pipes or joints. Tighten parts.
Worn piston seal on hydraulic cylinder. Replace piston seal.
Vibration or excessive Excessive resistance in pump intake Inspect intake line and clean or replace
noise. line. as necessary.
Air being drawn into intake line. Inspect pipe joints and tighten.
Chattering relief valve. Change oil, replace valve.
Air bubbles in oil. Wrong type of operating oil. Drain and fill with proper type of oil.
Oil level too low. Raise to proper level.
Air trapped in system Perform cylinder bleeding procedure to
remove air.
Frequent rubber hose System pressure too high. Adjust relief valve pressure.
damage. Hoses breaking due to contact with Restrain hoses to prevent contact.
another machine parts.
Cylinders DX140W-5/DX160W-5
7-3-44
1Hydraulic System
1Hydraulic
System
Edition 1
Hydraulic System
Safety Instructions ..........................................8-1-5
Hydraulic System............................................8-1-5
General Description................................................... 8-1-5
Hydraulic Schematic .......................................8-1-6
General Notes ........................................................... 8-1-6
Hydraulic Component and Oil Flow ................8-1-8
Hydraulic Components .............................................. 8-1-8
Main Oil Circuit ........................................................ 8-1-10
Pilot Oil Circuit......................................................... 8-1-11
Return Oil Circuit ..................................................... 8-1-12
Safety Cutoff Valve Operation ......................8-1-13
Power Up Valve Operation ...........................8-1-14
Swing Brake Release Operation ..................8-1-16
Travel Forward and Backward Operation .....8-1-18
Steering Operation .......................................8-1-19
Boom Up Operation ......................................8-1-20
Boom Down Operation .................................8-1-22
Arm Dump Operation....................................8-1-24
Arm Crowd Operation ...................................8-1-26
Bucket Dump Operation ...............................8-1-28
Bucket Crowd Operation ..............................8-1-30
Combined Swing and Travel Operation........8-1-32
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
HYDRAULIC SYSTEM
General Description
The hydraulic system has several improvements over
conventional hydraulic systems - including cross sensing total
horsepower control - to maximize output efficiency.
The system features an electronically controlled output
optimization system, which allows the operator to choose
between two, distinctly different power modes: high output/rapid
cycling maximum speed power mode, and a standard power
mode for most types of general operation.
Electronic management of hydraulic control valves assists in
optimizing the application speed and overall operator control of
hydraulic actuators and functions.
General Notes
When referring to the schematic, refer to the following items:
• As shown in the schematic, the main pump assembly is
driven by the engine. Mechanical energy is converted to
hydraulic power, generating the required hydraulic flow
which drives the system. Two main pumps (a drive side
pump and a idle side pump) make up the main pump
assembly.
• Hydraulic output from the drive side pump is transmitted to
the right side of the control valve. Output from the idle side
pump is transmitted to the left side of the control valve.
Hydraulic output from the pilot pump is used to control the
pump and to operate pilot and solenoid valves.
• The right half of the hydraulic control valve, supplied by the
drive side pump in the pump, operates spools for travel
priority, dozer, bucket, boom 1 and arm 2 functions. The
amount of oil flow to the actuators at the output end of each
of those circuits is regulated through the movement of
each individual valve spool.
• The left half of the hydraulic control valve, fed by the idle
side pump in the pump, operates spools for travel, option,
swing, boom 2 and arm 1 operation.
• Two-stage operation is a feature of boom and arm
function. All of these circuits can be operated using the
output of only one half of the hydraulic pump (one pump or
the other), or – since both halves of the control valve have
a spool and available circuit for these functions – the
output of both pumps can be combined, allowing higher
speed operation. Boom up, arm crowd and dumping
functions can operate in any one of the two available
power modes – the standard or general duty mode, the
high speed/rapid cycling mode.
• Whenever the travel control spools are shifted, output from
the main pump passes through the center joint to the travel
motor driving the wheel.
• The transmission control valve is a 3-position type,
consisting of low speed, high speed and neutral positions.
This valve is switched to the neutral position to protect the
transmission when the parking brake is applied or when
the pilot supply pressure is dropped below the preset level.
Hydraulic Components
pil
1 pil 56 A
C2 T 275 bar MAIN CIRCUIT
T T
54 Ø0.4
B
PC
PC from C/V B2
P3 (#19)
B(#64) pa pb RETURN CIRCUIT
T P1 RH B A(#64)
Ø1.0
A
RH A B Tr4
21 21
PA par1 2(#60)
PB
OPT 2 HO(#04)
C 50 bar
PRESS. DR2
pbr1 1(#60) 23 55 P
pa2
60 T P
pb(#63)
P
pa(#63) 59 T P
AR1 UP A B
270 bar 270 bar SENSOR LH
DR1 373 bar@20L/min BR1 DOWN T1
T1 T2 70 2(#59) A B 1(#59) 2 RH-HI LH-HI 2
RH-HI LH-HI
ps1 E
X(REAR)
of Pump T2
C2 C2 (CLOSE)
T
(OPEN)
1 T
64 1 OPT. PEDAL
DB
PG
F ps2
P E E
ARTI. PEDAL
RH (PE3C)
2
pc1 G H A(#43) T1 from JOYSTICK(R) PPC
1
DOWN UP
2
from JOYSTICK(L) PPC
1
pcc
prb1 pra1
SH
DUMP A5
CROWD B5 ARM 1 ARM 2
CROWD
pb9
70
T2 Pi1 Pi1
Shear Select operating
B(#55) A(#55)
A3(#18) T T
PRESS. A3(#18) pb5 P
SENSOR
pa9 C 373 bar@20L/min D pa9 DUMP
pa5 52 V2 V2
52 17 A 69
50 bar pc2 P-T BLOCK
A8(#18) pa5 373 bar@20L/min A1(#18)
pc3 A8 T
TS(#06) P3(#06)
LH
pa8
B4
pb4 BOOM 1 pb8 DOWN
B8
16 P(#43)
A P P
P pc2 pb7 pa6 pa4 pb5 pa7 pb6 pa5 pb3 pa3
P-T BLOCK
P(#68) pb9
T
175-185 bar
P P 43 PI T
0.75 L
3 10 bar
A(#55)
5 A(#17)
C1
8 P T LS
P-T BLOCK P
pb2(#19)
2 4 SD CH IC PB PS HO 3 bar
IN OUT ptp(#19) A
T
C7 pcc(#19)
P(#61)
A3 C6 T B(HIGH) K(LOW)
ps1 C1 C2 C3 C4 C5
P1 CF EF
X(REAR)
of Pump
P2 P3 GTS
A 26 bar
53 PRESSURE
PRESS.
TRANSMISSION SENSOR
3 3 1 1 3 3 1 1 3 3 1 3 1 30 47±4 bar
10 LS
WARNING 8 8 1 1 2 2 8 8 4 4 8 8 2 4 4 AUTO RAM P
R3 4 5 14 13 11 10 8 9 3 15 7 6 1 12 2 OPERATE 9
R1 P T
3.5 bar
24 26 65 P(#63)
GP
GEAR PUMP B(HIGH)
35
M2 PRESS. SENSOR 490 bar 32 K(LOW) 5 bar
2x0.75L
65 bar
LOW
A2 CHOCK 30 bar PRESSURE
2.5 bar 25 M
RELEASE
CRUISE
WARNING
(REAR) G
X(IC)
BL1
12 AB PSA PSD
AC 12
1.51 bar ACC'B
28 Vgmax
X1 U T1 MB GEXT 4.6 bar
BR1 T1 ACC'A
27 ENGINE
DL06
Vgmin GP
GP J
M
B
(FWD) 40
Pi BL DOZER
P1 GP
C3 C4 C5
G1
P1 160 bar
S STEER C2
10u
7 Ma
qmax
qmin
A Y BR
CYLINDER
RELEASE
CRUISE
C1 C6
T
T
Ø0.5
A 39
WE1401474
Figure 1
pil
1 pil 56 A
C2 T 275 bar
T T
54 Ø0.4
B
PC P3 (#19) pa pb
PC from C/V B2 B(#64)
T P1 RH B A(#64)
Ø1.0
A
RH A B Tr4
21 21
PA par1 2(#60)
PB
OPT 2 HO(#04)
C 50 bar
PRESS. DR2
pbr1 1(#60) 23 55 P
pa2
60 T P
pb(#63)
P
pa(#63) 59 T P
AR1 UP A B
270 bar 270 bar SENSOR LH
DR1 373 bar@20L/min BR1 DOWN T1
T1 T2 70 2(#59) A B 1(#59) 2 RH-HI LH-HI 2
RH-HI LH-HI
ps1 E
X(REAR)
of Pump T2
C2 C2 (CLOSE)
T
(OPEN)
1 T
64 1 OPT. PEDAL
DB
PG
F ps2
P E E
ARTI. PEDAL
RH (PE3C)
2
pc1 G H A(#43) T1 from JOYSTICK(R) PPC
1
DOWN UP
2
from JOYSTICK(L) PPC
1
pcc
prb1 pra1
SH
DUMP A5
CROWD B5 ARM 1 ARM 2
CROWD
pb9
70
T2 Pi1 Pi1
Shear Select operating
B(#55) A(#55)
A3(#18) T T
PRESS. A3(#18) pb5 P
SENSOR
pa9 C 373 bar@20L/min D pa9 DUMP
pa5 52 V2 V2
52 17 A 69
50 bar pc2 P-T BLOCK
A8(#18) pa5 373 bar@20L/min A1(#18)
pc3 A8 T
TS(#06) P3(#06)
LH
pa8 pb4
B4 B8
BOOM 1 pb8 DOWN
16 P(#43)
A P P
P pc2 pb7 pa6 pa4 pb5 pa7 pb6 pa5 pb3 pa3
P-T BLOCK
P(#68) pb9
T
175-185 bar
P P 43 PI T
0.75 L
3 10 bar
A(#55)
5 A(#17)
C1
8 P T LS
P-T BLOCK P
pb2(#19)
2 4 SD CH IC PB PS HO 3 bar
IN OUT ptp(#19) A
T
C7 pcc(#19)
P(#61)
A3 C6 T B(HIGH) K(LOW)
ps1 C1 C2 C3 C4 C5
P1 CF EF
X(REAR)
of Pump
P2 P3 GTS
A 26 bar
53 PRESSURE
PRESS.
TRANSMISSION SENSOR
3 3 1 1 3 3 1 1 3 3 1 3 1 30 47±4 bar
10 LS
WARNING 8 8 1 1 2 2 8 8 4 4 8 8 2 4 4 AUTO RAM P
R3 4 5 14 13 11 10 8 9 3 15 7 6 1 12 2 OPERATE 9
R1 P T
3.5 bar
24 26 65 P(#63)
GP
GEAR PUMP B(HIGH)
35
M2 PRESS. SENSOR 490 bar 32 K(LOW) 5 bar
2x0.75L
65 bar
LOW
A2 CHOCK 30 bar PRESSURE
2.5 bar 25 M
RELEASE
CRUISE
WARNING
(REAR) G
X(IC)
BL1
12 AB PSA PSD
AC 12
1.51 bar ACC'B
28 Vgmax
X1 U T1 MB GEXT 4.6 bar
BR1 T1 ACC'A
27 ENGINE
DL06
Vgmin GP
GP J
M
B
(FWD) 40
Pi BL DOZER
P1 GP
C3 C4 C5
G1
P1 160 bar
S STEER C2
10u
7 Ma
qmax
qmin
A Y BR
CYLINDER
RELEASE
CRUISE
C1 C6
T
T
Ø0.5
A 39
WE1401475
Figure 2
pil
1 pil 56 A
C2 T 275 bar
T T
54 Ø0.4
B
PC P3 (#19) pa pb
PC from C/V B2 B(#64)
T P1 RH B A(#64)
Ø1.0
A
RH A B Tr4
21 21
PA par1 2(#60)
PB
OPT 2 HO(#04)
C 50 bar
PRESS. DR2
pbr1 1(#60) 23 55 P
pa2
60 T P
pb(#63)
P
pa(#63) 59 T P
AR1 UP A B
270 bar 270 bar SENSOR LH
DR1 373 bar@20L/min BR1 DOWN T1 2 2
T1 T2 70 2(#59)
RH-HI
A B
LH-HI
1(#59) RH-HI LH-HI
ps1 E
X(REAR)
of Pump T2
C2 C2 (CLOSE)
T
(OPEN)
1 T
64 1 OPT. PEDAL
DB
PG
F ps2
P E E
ARTI. PEDAL
RH (PE3C)
2
pc1 G H A(#43) T1 from JOYSTICK(R) PPC
1
DOWN UP
2
from JOYSTICK(L) PPC
1
pcc
prb1 pra1
SH
DUMP A5
CROWD B5 ARM 1 ARM 2
CROWD
pb9
70
T2 Pi1 Pi1
Shear Select operating
B(#55) A(#55)
A3(#18) T T
PRESS. A3(#18) pb5 P
SENSOR
pa9 C 373 bar@20L/min D pa9 DUMP
pa5 52 V2 V2
52 17 A 69
50 bar pc2 P-T BLOCK
A8(#18) pa5 373 bar@20L/min A1(#18)
pc3 A8 T
TS(#06) P3(#06)
LH
pa8 pb4
B4
BOOM 1 pb8 DOWN
B8
16 P(#43)
A P P
P pc2 pb7 pa6 pa4 pb5 pa7 pb6 pa5 pb3 pa3
P-T BLOCK
P(#68) pb9
T
175-185 bar
P P 43 PI T
0.75 L
3 10 bar
A(#55)
5 A(#17)
C1
8 P T LS
P-T BLOCK P
pb2(#19)
2 4 SD CH IC PB PS HO 3 bar
IN OUT ptp(#19) A
T
C7 pcc(#19)
P(#61)
A3 C6 T B(HIGH) K(LOW)
ps1 C1 C2 C3 C4 C5
P1 CF EF
X(REAR)
of Pump
P2 P3 GTS
A 26 bar
53 PRESSURE
PRESS.
TRANSMISSION SENSOR
3 3 1 1 3 3 1 1 3 3 1 3 1 30 47±4 bar
10 LS
WARNING 8 8 1 1 2 2 8 8 4 4 8 8 2 4 4 AUTO RAM P
R3 4 5 14 13 11 10 8 9 3 15 7 6 1 12 2 OPERATE 9
R1 P T
3.5 bar
24 26 65 P(#63)
GP
GEAR PUMP B(HIGH)
35
M2 PRESS. SENSOR 490 bar 32 K(LOW) 5 bar
2x0.75L
65 bar
LOW
A2 CHOCK 30 bar PRESSURE
2.5 bar 25 M
RELEASE
CRUISE
WARNING
(REAR) G
X(IC)
BL1
12 AB PSA PSD
AC 12
1.51 bar ACC'B
28 Vgmax
X1 U T1 MB GEXT 4.6 bar
BR1 T1 ACC'A
27 ENGINE
DL06
Vgmin GP
GP J
M
B
(FWD) 40
Pi BL DOZER
P1 GP
C3 C4 C5
G1
P1 160 bar
S STEER C2
10u
7 Ma
qmax
qmin
A Y BR
CYLINDER
RELEASE
CRUISE
C1 C6
T
T
Ø0.5
A 39
WE1401476
Figure 3
pil
1 pil 56 A
C2 T 275 bar
T T
54 Ø0.4
B
PC P3 (#19) pa pb
PC from C/V B2 B(#64)
T P1 RH B A(#64)
Ø1.0
A
RH A B Tr4
21 21
PA par1 2(#60)
PB
OPT 2 HO(#04)
C 50 bar
PRESS. DR2
pbr1 1(#60) 23 55 P pa2 60 T P
pb(#63)
P
pa(#63) 59 T P
AR1 UP A B
270 bar 270 bar SENSOR LH
DR1 373 bar@20L/min BR1 DOWN T1 2 2
T1 T2 70 2(#59)
RH-HI
A B
LH-HI
1(#59) RH-HI LH-HI
ps1 E
X(REAR)
of Pump T2
C2 C2 (CLOSE)
T
(OPEN)
1 T
64 1 OPT. PEDAL
DB
PG
F ps2
P E E
ARTI. PEDAL
RH (PE3C)
2
pc1 G H A(#43) T1 from JOYSTICK(R) PPC
1
DOWN UP
2
from JOYSTICK(L) PPC
1
pcc
prb1 pra1
SH
DUMP A5
CROWD B5 ARM 1 ARM 2
CROWD
pb9
70
T2 Pi1 Pi1
Shear Select operating
B(#55) A(#55)
A3(#18) T T
PRESS. A3(#18) pb5 P
SENSOR
pa9 C 373 bar@20L/min D pa9 DUMP
pa5 52 V2 V2
52 17 A 69
50 bar pc2 P-T BLOCK
A8(#18) pa5 373 bar@20L/min A1(#18)
pc3 A8 T
TS(#06) P3(#06)
LH
pa8
B4
pb4 BOOM 1 pb8 DOWN
B8
16 P(#43)
A P P
P pc2 pb7 pa6 pa4 pb5 pa7 pb6 pa5 pb3 pa3
P-T BLOCK
P(#68) pb9
T
175-185 bar
P P 43 PI T
0.75 L
3 10 bar
A(#55)
5 A(#17)
C1
8 P T LS
P-T BLOCK P
pb2(#19)
2 4 SD CH IC PB PS HO 3 bar
IN OUT ptp(#19) A
T
C7 pcc(#19)
P(#61)
A3 C6 T B(HIGH) K(LOW)
ps1 C1 C2 C3 C4 C5
P1 CF EF
X(REAR)
of Pump
P2 P3 GTS
A 26 bar
53 PRESSURE
PRESS.
TRANSMISSION SENSOR
3 3 1 1 3 3 1 1 3 3 1 3 1 30 47±4 bar
10 LS
WARNING 8 8 1 1 2 2 8 8 4 4 8 8 2 4 4 AUTO RAM P
R3 4 5 14 13 11 10 8 9 3 15 7 6 1 12 2 OPERATE 9
R1 P T
3.5 bar
24 26 65 P(#63)
GP
GEAR PUMP B(HIGH)
35
M2 PRESS. SENSOR 490 bar 32 K(LOW) 5 bar
2x0.75L
65 bar
LOW
A2 CHOCK 30 bar PRESSURE
2.5 bar 25 M
RELEASE
CRUISE
WARNING
(REAR) G
X(IC)
BL1
12 AB PSA PSD
AC 12
1.51 bar ACC'B
28 Vgmax
X1 U T1 MB GEXT 4.6 bar
BR1 T1 ACC'A
27 ENGINE
DL06
Vgmin GP
GP J
M
B
(FWD) 40
Pi BL DOZER
P1 GP
C3 C4 C5
G1
P1 160 bar
S STEER C2
10u
7 Ma
qmax
qmin
A Y BR
CYLINDER
RELEASE
CRUISE
C1 C6
T
T
Ø0.5
A 39
WE1401477
Figure 4
Tr4
par1
OPT 2
DR2 pbr1
DR1
AR1
BR1
17
373 bar@20L/min
T1 T2
T
A
ps1 E F ps2 P
pc1 G H pcc
Accelerator
Pedal Valve
A5 P-T BLOCK
B5
ARM 1 ARM 2
pb5 pb9
373 bar@20L/min D pa9
C
pc2
pa5 373 bar@20L/min
pc3 A8
B4 B8
BOOM 1 pb8
pb4
pa4 BOOM 2 pa8
B3 14 15
A3 B7 T P T P
BUCKET A7
pb3 pb7
SWING pa7
pa3
B2 373 bar@20L/min 373 bar@20L/min
A2
pb2
OPT B6
A6
P4 DOZER pb6 SWING ARM BOOM BUCKET
pa2
pa6 1 3 2 4 2 4 1 3
B1
A1 2 2
DRtp
Safety Cut-off
pb1 TRAVEL 1 3 1 3
pa1 TRAVEL -PRIORITY ptp 4 4
Ts3 0.75 L
Ts5 19 10 bar
3
VALVE(LEFT)
B A LoHi :: 343 bar@90L/min
363 bar@90L/min VALVE(RIGHT)
P1 PT PP PA PH P3 P2 4 SD CH IC PB PS HO
T
A3 C7
C6
2 C4 C5
IN OUT P1 C1 C2 C3
P2 P3 GTS
R3
R1
65 P(#63)
GEAR PUMP
M2 PRESS. SENSOR 490 bar
A2
M
(REAR)
Vgmax
X1
ENGINE Vgmin
DL06
28
27 7 Ma
10u
X3
Vgmax
TANK Vgmin
ps2
177u to C/V
29 X1
(FRONT)
M
A1
1 M1
PRESS. SENSOR 490 bar
R2 S
WE1401136
Figure 5
Tr4
par1
OPT 2
DR2 pbr1
AR1
DR1 BR1
373 bar@20L/min
T1 T2 15
ps1 E F ps2
pc1 G H pcc
A5
B5
ARM 1 ARM 2
pb5 pb9
373 bar@20L/min D pa9
C
pc2
pa5 373 bar@20L/min
pc3 A8
B4 B8
BOOM 1 pb8
pb4
pa4 BOOM 2 pa8
B3 P3
A3 B7
A7 T C1 C2 C3 C4 P2
pb3 BUCKET pb7
SWING pa7
pa3 P1
B2 373 bar@20L/min 373 bar@20L/min
A2
pb2
OPT B6
A6
P4 DOZER pb6 6
pa2 PAR PBR PL TS
B1 pa6
A1
DRtp
pb1 TRAVEL
pa1 TRAVEL -PRIORITY ptp
Ts3
Ts5 0.75 L 3
19 B Lo : 343 bar@90L/min
VALVE(LEFT) A Hi : 363 bar@90L/min VALVE(RIGHT) 10 bar
P1 PT PP PA PH P3 P2
4 SD CH IC PB PS HO
T
A3 C7
C6
2 C4 C5
IN OUT P1 C1 C2 C3
P2 P3 GTS
R3
R1
65 P(#63)
GEAR PUMP
M2 PRESS. SENSOR 490 bar
A2
M
(REAR)
Vgmax
X1
ENGINE Vgmin
DL06
28
27 7 Ma
10u
X3
Vgmax
TANK Vgmin
ps2
177u to C/V
29 X1
(FRONT)
M
A1
1 M1
PRESS. SENSOR 490 bar
R2 S
WE1401137
Figure 6
H EX1402243
Figure 7
Tr4
par1
OPT 2
pbr1
DR2
AR1
DR1 BR1
373 bar@20L/min
T1 T2
P-T BLOCK
ps1 E F ps2
pc1
G H pcc
A5
B5
ARM 1 ARM 2
pb5 pb9
Safety Cut-off
SH
PRESS.
3
0.75 L
SENSOR A3 10 bar
50 bar
4 SD CH IC PB PS HO
T
C7
C6
2
IN OUT C1 C2 C3
C4 C5
P1
R3
R1
P2 P3 GTS
65 P(#63)
GEAR PUMP
M2 PRESS. SENSOR 490 bar
A2
M
(REAR)
Vgmax
ENGINE Vgmin X1
28 DL06
27
7 Ma
10u
X3
Vgmax
TANK 177u Vgmin
29 X1
(FRONT)
M
A1
1 M1
PRESS. SENSOR 490 bar
R2 S
WE1401478
Figure 8
Ta L3 Ta
pb3 pa3
L1 Swing
R1
pb7 pa7
Ta Ta Bucket
R3
B7 A7 Bucket Cylinder
S7-2 S7-1
Swing Motor
B3 B7
A3 A7
pb3 pb7
Swing 373bar@20L Bucket
pa3 pa7
P1 P2 WE1401447
Figure 9
Tr4
par1
OPT 2
DR2 pbr1
AR1
DR1 BR1
373 bar@20L/min
T1 T2
ps1 E F ps2
Forward
pc1 G H pcc Neutral
A5
B5 Backward
ARM 1 ARM 2
pb5 pb9
C
C
373 bar@20L/min D pa9
A3
2
IN OUT
R3
R1
32
24 26 65 P(#63)
GEAR PUMP
X(IC)
M2 PRESS. SENSOR 490 bar G
A2 MB GEXT
U T1
M
J B
(REAR)
M (FWD)
7 Vgmax
Vgmin X1
28 ENGINE qmax
S
27 DL06 qmin
A
10u Ma (REV)
T2 MA
X3
Vgmax M3
TANK 177u Vgmin M2
X2
29 X1 (TU) 31
(FRONT)
M
A1
1 M1
PRESS. SENSOR 490 bar
R2 S
WE1401139
Figure 10
L R
235-255 bar
R3
R1
65 P(#63)
GEAR PUMP
M2 PRESS. SENSOR 490 bar
A2
M 175-185 bar
(REAR)
7 Vgmax
X1
ENGINE Vgmin
28 DL06 8
27 P T LS
Ma
10u
X3
Vgmax
TANK Vgmin
177u
29 X1
CF EF
(FRONT)
M
A1
1 M1
PRESS. SENSOR 490 bar LS
R2 S P
9
3 3 1 1 3 3 1 1 3 3 1 3 1
8 8 1 1 2 2 8 8 4 4 8 8 2 4 4
30
4 5 14 13 11 10 8 9 3 15 7 6 1 12 2
B(HIGH) GP
K(LOW) 5 bar
35
32
CHOCK
X(IC)
G
U T1 MB GEXT
GP J Pi BL
GP B DOZER
M (FWD) 40
qmax S Steering
qmin Cylinder
A Y BR
(REV)
CHOCK
MA
T2 M3
M2
X2 GP
REAR AXLE (TU) 31
BRAKE FRONT AXLE
C BRAKE
C
36
A
38
37 34 Ø0.5
Ø0.5
33
T
T
Ø0.5
A 39
Figure 11
WE1401140
Tr4 21 21
par1
OPT 2
DR2 pbr1
AR1
DR1 BR1
373 bar@20L/min
T1 T2
C2 C2
ps1 E F ps2 E E
pc1 G H pcc
A5
Pi1 Pi1
B5 ARM 2 T T
ARM 1 pb9
pb5 V2 V2
373 bar@20L/min D pa9 52 52
C pc2
373 bar@20L/min A1(#18)
pa5 A8
pc3 B8
B4
pb4 pb8
pa4 BOOM 2 BOOM 1 pa8 UP P-T BLOCK
B3 B7
A3
pb3 BUCKET A7
pb7
SWING PRESS.
pa7 SENSOR
pa3
373 bar@20L/min 373 bar@20L/min
B2 50 bar
A2 OPT B6
pb2 A6
P4 DOZER pb6
pa2
T P 15
pa6
B1
A1
pb1 DRtp
TRAVEL 2
pa1 TRAVEL
-PRIORITY ptp 1 3
Ts3 BOOM BUCKET
Ts5 19 Lo : 343 bar@90L/min 2 4
4 3
VALVE(LEFT) B A Hi : 363 bar@90L/min VALVE(RIGHT) DOWN
1
CROWD
UP DUMP
P1 PT PP PA PH P3 P2
18 B1 B2 B9 B10 B3 B6 B4 B8 B5 B7
A3
A1 A2 A9 A10 A3 A6 A4 A8 A5 A7
65 P(#63)
GEAR PUMP 0.75 L 3
10u 10 bar
490 bar
M2 PRESS. SENSOR
TANK A2 4 SD CH IC PB PS HO
177u
M T
29 (REAR) C7
Vgmax C6
Vgmin X1
ENGINE C4 C5
C1 C2 C3
DL06 P1
7 P2 P3 GTS
Ma
X3
Vgmax
Vgmin
X1
(FRONT)
M
A1
1 M1
PRESS. SENSOR 490 bar
R2 S
WE1401141
Figure 12
Ta Ta Boom Cylinder
L3
pb4 pa4
L1 Boom 2
R1 DR
7
pb8 pa8
R3
Ta Boom 1
AD4
AD3
B8 A8
S8-1 AD1 AD5 DR AD2
pc2
Boom Cylinder
DR1
pc2
A8
B8
B4
pb4 pb8
Boom 2 Boom 1
373bar@20L
pa4 pa8
P1 P2 WE1401444
Figure 13
Tr4
21 21
par1
OPT 2
DR2 pbr1
AR1
DR1 BR1
373 bar@20L/min
T1 T2
C2 C2
ps1 E F ps2 E E
pc1 G H pcc
A5
B5 ARM 2 Pi1 Pi1
ARM 1 pb9
pb5 T T
D V2 V2
C 373 bar@20L/min pa9 52 52
pc2
pa5 373 bar@20L/min
A8
pc3 B8
B4
BOOM 1 pb8 DOWN
pb4 B A 68
pa4 BOOM 2 pa8
B3 B7
A3
pb3 BUCKET A7
pb7
SWING
pa3 pa7
373 bar@20L/min 373 bar@20L/min
B2 C
A2 OPT B6
pb2 A6
P4 DOZER pb6
pa2 41 T1 T2 P
pa6
B1
A1
pb1 DRtp
TRAVEL
pa1 TRAVEL
-PRIORITY ptp
Ts3
Ts5 19 P-T BLOCK
Lo : 343 bar@90L/min
VALVE(LEFT) B A Hi : 363 bar@90L/min VALVE(RIGHT)
P1 PT PP PA PH P3 P2
A3
T P 15
2
2 1 3
BOOM BUCKET
IN OUT
R3 2 4 1 3 4
DOWN CROWD
R1 UP DUMP
28
27 65 P(#63)
18
B1 B2 B9 B10 B3 B6 B4 B8 B5 B7
GEAR PUMP
10u
M2 PRESS. 490 bar
A2 SENSOR
TANK 177u
A1 A2 A9 A10 A3 A6 A4 A8 A5 A7
M
29 (REAR) pb7 pa6 pa4 pb5 pa7 pb6 pa5 pb3 pa3
pb9
Vgmax
Vgmin X1
ENGINE
Safety Cut-off
DL06
7 0.75 L 3
Ma 10 bar
X3
Vgmax
4 SD CH IC PB PS HO
Vgmin T
C7
X1
C6
(FRONT) C1 C2 C4 C5
P1 C3
M
A1 P2 P3 GTS
1 M1
PRESS. SENSOR 490 bar
R2 S
WE1401142
Figure 14
L3 Ta Boom Cylinder
Ta
pb4 pa4
L1 Boom 2
S8-3 R1 DR
pb8 pa8
R3
Ta Boom 1
S8-2 AD4
AD3
B8 A8
S8-1 AD1 AD5 DR AD2
pc2
Boom Cylinder
DR1
pc2
A8
B8
B4
pb4 pb8
P1 P2 WE1401443
Figure 15
Tr4
par1
OPT 2
DR2 pbr1
AR1
PA 51 DR1
373 bar@20L/min
BR1
E E T1 T2
22 2 P-T BLOCK
1
ps1 E F ps2
pil
pil
T T
pc1 G H pcc
PC
PC A5 DUMP
B5
pb5 pb9
ARM 1 373 bar@20L/min ARM 2 pa9
C 14 T P
pa5 pc2
373 bar@20L/min
A8
pc3
B4 D B8
pb4 BOOM 1 pb8 2
pa4 BOOM 2 pa8 1 3 SWING ARM
B3 B7 4 1 3 2 4
A3 A7 LEFT
pb3 BUCKET DUMP
pb7 RIGHT CROWD
SWING pa7
pa3
373 bar@20L/min 373 bar@20L/min
B2
A2
pb2
OPT B6
A6
42
P4 DOZER pb6
pa2
pa6
18 B1 B2 B9 B10 B3 B6 B4 B8 B5 B7
B1
A1
pb1 DRtp
TRAVEL
pa1 TRAVEL -PRIORITY ptp
Ts3 A1 A2 A9 A10 A3 A6 A4 A8 A5 A7
Ts5 19 B A
Lo : 343 bar@90L/min
Hi : 363 bar@90L/min
pc2 pb7 pa6 pa4 pb5 pa7 pb6 pb3 pa3
VALVE(LEFT) VALVE(RIGHT) P(#68) pb9
P1 PT PP PA PH P3 P2
Safety Cut-off
A3 0.75 L
3
10 bar
4 SD CH IC PB PS HO
T
C7
C6
R3
2 C1 C4 C5
IN OUT P1 C2 C3
R1
P2 P3
65 P(#63)
GEAR PUMP
M2 PRESS. SENSOR 490 bar
24 26 A2
M
(REAR)
Vgmax
Vgmin X1
ENGINE
28 DL06
27
7 Ma
10u
X3
Vgmax
TANK Vgmin
177u
29 X1
(FRONT)
M
A1
1 M1
PRESS. SENSOR 490 bar
R2 S
WE1401143
Figure 16
AD5
AD4
L3 S5-4
pb5 pa5
Ta L1 Ta
Arm 1
11 R1 10
pb9 pa9
Ta Arm 2
R3
RC6
Ta
S9-2 S9-4
Arm Cylinder
S9-3 S9-1
DR1
pc1
A5 Arm Lock
B5
pb5 pb9
Arm 1 Arm 2
373bar@20L
pa5 pa9
P1 P2 WE1401439
Figure 17
Tr4
par1
OPT 2
DR2 pbr1
PA 51 DR1
AR1
BR1
E E 373 bar@20L/min
22 2 50 bar
T1 T2 P-T BLOCK
PRESS.
SENSOR ps1 E F ps2
1 pil
pil
T
pc1 G H pcc
T
PC A5
PC CROWD
CROWD B5 ARM 1 ARM 2 pb9
pb5
373 bar@20L/min D 14 T P
C pa9
pc2
pa5 373 bar@20L/min
pc3 A8
B4 B8 2
pb4 BOOM 1 pb8 1 3 SWING ARM
pa4 BOOM 2 pa8 4 1 3 2 4
B3 LEFT DUMP
B7
A3 RIGHT
pb3 BUCKET A7 CROWD
pb7
SWING pa7
pa3
B2
373 bar@20L/min 373 bar@20L/min 42
A2 OPT B6
pb2 A6
P4 DOZER pb6 18B1 B2 B9 B10 B3 B6 B4 B8 B5 B7
pa2
B1 pa6
A1
pb1 DRtp
TRAVEL A1 A2 A9 A10 A3 A6 A4 A8 A5 A7
pa1 TRAVEL
-PRIORITY ptp
Ts3 pc2 pb7 pa6 pa4 pa7 pb6 pa5 pb3 pa3
Ts5 19 B Lo : 343 bar@90L/min
A Hi : 363 bar@90L/min P(#68)
VALVE(LEFT) VALVE(RIGHT)
P1 PT PP PA PH P3 P2
Safety Cut-off
A3
0.75 L
3
10 bar
4 SD CH IC PB PS HO
T
C7
C6
R3
2
C1 C2 C4 C5
IN OUT P1 C3
R1
P2 P3
65 P(#63)
GEAR PUMP
M2 PRESS. SENSOR 490 bar
24 26 A2
M
(REAR)
Vgmax
ENGINE Vgmin X1
28 DL06
27 7
Ma
10u
X3
Vgmax
TANK Vgmin
177u
29 X1
(FRONT)
M
A1
1 M1
PRESS. SENSOR 490 bar
R2 S
WE1401144
Figure 18
AD4
L3 S5-4
pb5 pa5
L1 Ta
Ta 11 Arm 1
R1 10
pb9 pa9
Ta Rc6 Arm 2
R3
Ta
Arm Cylinder
S9-2 S9-4
S9-3 S9-1
DR1
pc1
A5 Arm Lock
B5
pb5 pb9
Arm 1 Arm 2
373bar@20L
pa5 pa9
P1 P2 WE1401441
Figure 19
Tr4
par1
OPT 2
DR2 pbr1
AR1
DR1 BR1
373 bar@20L/min
T1 T2
ps1 E F ps2 23
pc1 G H pcc T1
A5 70
B5 ARM 2
ARM 1 pb9 T2
pb5 P
C 373 bar@20L/min D pa9
pc2 T1
pa5 373 bar@20L/min
pc3 A8 70
B4 B8 T2
P
pb4 pb8
pa4 BOOM 2 BOOM 1 pa8 P-T BLOCK
B3 B7 P2(#66)
A3
pb3 BUCKET A7
SWING DUMP pb7
pa3 pa7
373 bar@20L/min 373 bar@20L/min
B2
A2 OPT B6
pb2 A6
P4 DOZER pb6
pa2
T P 15
pa6
B1
A1
pb1 DRtp
TRAVEL 2
pa1 TRAVEL
-PRIORITY ptp 1 3
Ts3 BOOM BUCKET
Ts5 19 Lo : 343 bar@90L/min 2 4 4
VALVE(LEFT) B A Hi : 363 bar@90L/min VALVE(RIGHT) DOWN
1
CROWD
3
UP DUMP
P1 PT PP PA PH P3 P2
18 B1 B2 B9 B10 B3 B6 B4 B8 B5 B7
A3
A1 A2 A9 A10 A3 A6 A4 A8 A5 A7
65 P(#63)
GEAR PUMP 0.75 L 3
10u 10 bar
490 bar
M2 PRESS. SENSOR
TANK A2 4 SD CH IC PB PS HO
177u
M T
29 (REAR) C7
Vgmax C6
Vgmin X1
ENGINE C4 C5
C1 C2 C3
DL06 P1
7 P2 P3 GTS
Ma
X3
Vgmax
Vgmin
X1
(FRONT)
M
A1
1 M1
PRESS. SENSOR 490 bar
R2 S
WE1401145
Figure 20
Ta L3 Ta
pb3 pa3
L1 Swing
R1
pb7 pa7
Ta Ta Bucket
R3
B7 A7 Bucket Cylinder
S7-2 S7-1
Swing Motor
B3 B7
A3 A7
pb3 pb7
Swing 373bar@20L Bucket
pa3 pa7
P1 P2
WE1401446
Figure 21
Tr4
par1
OPT 2
DR2 pbr1
AR1
DR1 BR1
373 bar@20L/min
T1 T2
ps1 E F ps2
23
pc1 G H pcc T1
A5
70
B5 ARM 2
ARM 1 pb9 T2
pb5 P
C 373 bar@20L/min D pa9
pc2 T1
373 bar@20L/min
pa5
pc3 A8 70
B8 T2
B4 P
pb4 pb8
pa4 BOOM 2 BOOM 1 pa8
P-T BLOCK
B3 B7 P2(#66)
A3
pb3 A7
SWING pb7
BUCKET
pa3 CROWD pa7
373 bar@20L/min 373 bar@20L/min
B2
A2 OPT B6
pb2 A6
P4 DOZER pb6
pa2
T P 15
pa6
B1
A1
pb1 DRtp
TRAVEL 2
pa1 TRAVEL
-PRIORITY ptp 1 3
Ts3 BOOM BUCKET
Ts5 19 Lo : 343 bar@90L/min 2 4 4
3
VALVE(LEFT) B A Hi : 363 bar@90L/min VALVE(RIGHT) DOWN
1
CROWD
UP DUMP
P1 PT PP PA PH P3 P2
18 B1 B2 B9 B10 B3 B6 B4 B8 B5 B7
A3
A1 A2 A9 A10 A3 A6 A4 A8 A5 A7
65 P(#63)
GEAR PUMP 0.75 L 3
10u 10 bar
490 bar
M2 PRESS. SENSOR
TANK A2 4 SD CH IC PB PS HO
177u
M T
29 (REAR) C7
Vgmax C6
Vgmin X1
ENGINE C4 C5
C1 C2 C3
DL06 P1
7 P2 P3 GTS
Ma
X3
Vgmax
Vgmin
X1
(FRONT)
M
A1
1 M1
PRESS. SENSOR 490 bar
R2 S
WE1401146
Figure 1
22
Ta L3 Ta
pb3 pa3
L1 Swing
R1
pb7 pa7
Ta Ta Bucket
R3
B7 A7 Bucket Cylinder
S7-2 S7-1
Swing Motor
B3 B7
A3 A7
pb3 pb7
Swing 373bar@20L Bucket
pa3 pa7
P1 P2
WE1401522
Figure 23
Tr4
par1
P-T BLOCK
DR2
OPT2 17 T
pbr1
DR1 AR1 A P
373 bar@20L/min BR1
T1 T2 Accelerator
Pedal Valve
ps1 E F ps2
14 T P
pc1 G H pcc
A5 2
B5 ARM2
ARM1 pb9 1 3
pb5 SWING ARM
DB
VALVE(LEFT) 363 bar@90L/min VALVE(RIGHT) 6
P1 PT PP PA PH P3 P2 PAR PBR PL TS
PG (FWD) (REV)
Safety Cut-off
pa1
SH
PRESS. 0.75 L
3
SENSOR 10 bar
50 bar
4 SD CH IC PB PS HO
2 T
IN OUT C7
A3
C6
C1 C2 C4 C5
P1 C3
P2 P3 GTS
R3
R1
65 P(#63)
GEAR PUMP
32
M2 PRESS. SENSOR 490 bar
A2
M
(REAR) X(IC)
7 Vgmax
Vgmin X1
G
U T1 MB GEXT
28 ENGINE
27 DL06 J B
M (FWD)
10u Ma qmax
S
X3 qmin
Vgmax
TANK 177u Vgmin
A
29 X1 T2 MA
(REV)
M3
(FRONT) M2
X2
M
A1 (TU) 31
1 M1
PRESS. SENSOR 490 bar
R2 S
WE1401479
Figure 24
Edition 1
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
Troubleshooting Recommendations
An excavator that fails to deliver designed performance must be
checked for the following:
• First hydraulic flow.
• Then hydraulic pressure in a specified order of priority
through different points of the system.
To verify adequate available hydraulic flow, before any other
tests are performed through the circuit:
Check engine operation - (Power plus mode without SPC)
• at 1,700 rpm with no load.
• at 1,700 rpm stall load.
If engine rpm drops excessively with a load or fails to surpass
rated speed (1,700 rpm), performance problems may be
because of inadequate hydraulic flow caused by lagging
rotational speed.
NOTE: Verify actual flow on the excavator against rated
performance, with a flow meter.
If engine tests meet specifications and adequate torque and
horsepower are available at the pump drive flex coupling, pull
out the electrical tray under the operator's seat to inspect the
self-diagnostic display.
If the EPOS trouble code display is clear, check hydraulic
functions in the following sequence:
• Pilot pressure.
• Negacon, negative control pressure.
• Main relief pressure (drive side and idle side pump)
• Swing pressure.
• Port relief pressure (individual control functions; boom,
arm, bucket, swing, and travel)
• Power boost circuit.
• Standard performance tests; cylinder speed, hydraulic
motor (travel and swing) speed, cylinder oil tightness
"permissible drift" test.
NOTE: System specification performance tests of
individual activator function are determined by
flow rate through the component or circuit, not
the control pressure or system pressure
IMPORTANT
It is suggested that troubleshooter maintain the testing
sequence of the preceding list. Checks and adjustments
nearer the middle or the end of the list may depend on
adequate functioning of systems tested nearer the top of
the list.
WARNING
AVOID DEATH OR SERIOUS INJURY
This procedure must be done with two people. To reduce
the chance of accidental movement of the excavator, one
person should properly seated at the operator's control
stand while checks and adjustments are made.
IMPORTANT
Refill the hydraulic fluid reservoir if there is any measurable
loss of hydraulic oil during test gauge and adapter fitting
installation.
WARNING
AVOID DEATH OR SERIOUS INJURY
This procedure must be done with two people. To reduce
the chance of accidental movement of the excavator, one
person should properly seated at the operator's control
stand while checks and adjustments are made.
WARNING
AVOID DEATH OR SERIOUS INJURY
This procedure must be done with two people. To reduce
the chance of accidental movement of the excavator, one
person should properly seated at the operator's control
stand while checks and adjustments are made.
IMPORTANT
Pressure adjustments and checks cannot be made if pilot
pressure is outside the specified range. Refer to the pilot
pump adjustment procedure if required, then proceed with
any necessary adjustments to main relief pressure settings.
WARNING
AVOID DEATH OR SERIOUS INJURY
This procedure must be done with two people. To reduce
the chance of accidental movement of the excavator, one
person should properly seated at the operator's control
stand while checks and adjustments are made.
IMPORTANT
Before starting this procedure or going onto make any
changes of adjustment settings:
• Verify engine output to the rated speed –
2,000 ±50 rpm.
• Permanently mark setscrew positions at the current
regulator control setting.
1
Figure 1 1 EX1403918
Start the engine and turn the engine speed dial to maximum.
When normal operating temperature is reached, loosen the
largest diameter locknut around the adjustment screw for the
outer regulator spring. Tightening the screw shifts the P/Q
(Pressure/Flow) control curve to the right, and increases
compensating control pressure.
On the other hand, if the persistent cause of performance
problems is engine overloading, decreasing the adjustment by
turning the larger diameter adjusting screw out will decrease
pump input horsepower. 1/4 turn on the adjusting screw is equal
to approximately 17 horsepower.
Figure 2
IMPORTANT
Because changing the position of adjusting screw also
affects the setting of the adjustment for the inner spring,
the smaller diameter adjusting screw, turn in the inner
screw 198° (slightly more than 1/2 turn, 180°) before screw
is backed out 1/4 turn (90°).
Figure 3
The adjusting screw (Figure 1) affects the delivery rate (Q) of the
pump. Tightening the adjusting screw decreases the maximum
cut flow (as shown in Figure 4) while backing out the screw
increases cut flow delivery rate.
Balance both pumps for equal output.
Q
P
HDA3008L
Figure 4
Precautions/Initial Checks
1. Stop work. Release all weight or any load safely before
proceeding. Avoid risking injury or adding to damage.
2. Stop engine and disengage control functions until initial
tests are ready to be made.
WARNING
AVOID DEATH OR SERIOUS INJURY
Stop operation and park excavator whenever these
problems are noticed:
1. Equipment breakdown.
2. Inadequate control response.
3. Erratic performance.
Stop the machine, put the boom and arm in the inoperative
(overnight park) position and begin by making the fastest,
simplest checks first:
• Check oil level.
• Check for overheating, oil leaks, external oil cooler
clogging or broken fan belt. Consult service record for
prior repair/service work.
• Drain some tank oil into a clean, clear container. Look
for metal shavings/grit, cloudiness/water or foam/air
bubbles in the oil.
NOTE: Dispose of drained fluids in compliance
with all applicable environmental laws and
regulations.
• Check for wobble through the engine/pump flex
coupling. Run engine with the pump input hydraulic
power control nut turned to the lowest power to check
the engine.
• Investigate unusual operating noises or vibration.
Check for loose bolts, connections.
Edition 1
Electrical System
Safety Instructions ..........................................9-1-7
Introduction .....................................................9-1-7
Electrical Supply System ................................9-1-8
Engine Starting Circuit ..................................9-1-10
Start Operation ........................................................ 9-1-10
After Start ................................................................ 9-1-12
Engine Preheating System ...........................9-1-14
Engine Stop ..................................................9-1-16
Charging System ..........................................9-1-18
Monitoring System ........................................9-1-19
Display Monitor........................................................ 9-1-20
Functional Check..................................................... 9-1-20
Monitoring System Schematic................................. 9-1-22
Operation ......................................................9-1-24
Instruments.............................................................. 9-1-24
Warning and Indicator Lights ........................9-1-26
Indication of Warning Lights .................................... 9-1-26
Indication of Multifunction Gauge ............................ 9-1-30
Initial Operation ............................................9-1-31
Graphic Information Area Display.................9-1-32
Overview ................................................................. 9-1-32
Main Menus for the Graphic Display Area............... 9-1-32
Menu Selector Buttons ............................................ 9-1-32
User Menu ....................................................9-1-33
User Menu - Access and Escape Methods ............. 9-1-33
Special Menu ................................................9-1-71
Entering/Accessing and Exiting/Escaping Menus ... 9-1-71
Special Menu Selections ......................................... 9-1-72
Failure Code .................................................9-1-88
Failure Code at Machine ......................................... 9-1-88
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
INTRODUCTION
The electrical system for this equipment is DC 24 volts. The
rated voltage for all electric components is 24 volts with the
exception of the stereo and the air-conditioning control actuator.
The system contains two 12 volt batteries connected in series
and a three phase AC generator with a rectifier. The electrical
wiring used in the system is easily identifiable by the insulator
color. The color symbols used in the electrical system are listed
in the following chart.
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
8
4 2
B A
BR
E
- + - +
12V 150AH 12V 150AH
1
STARTER SWITCH CONNECTION P(R) B(B+) R(I)
E ALTERNATOR
8B
WE1400660
Figure 1 Electric Power Circuit Diagram
Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Circuit Breaker 1 7 Alternator
4 Circuit Breaker 2 8 Diode
Start Operation
When the starter switch is turned to "START" position, the "S"
and "E" terminals of the starter controller (7) are connected. Now
the contacts in the starter relay 1 (8) are closed by the current
flow from the battery (1) → circuit breaker 1 (3) → fuse box (6)
→ "B" terminal of starter switch (5) → "C" terminal of starter
switch (5) → "30" terminal of starter relay 2 (12) - "87a" terminal
→ "86" terminal of starter relay 1 (8) - "85" terminal → "S"
terminal of starter controller (7) - "E" terminal → ground.
When the contact point "30" and "87" of starter relay 1 (8) are
connected, the pinion gear of the starter (9) is pushed forward
and contacts the ring gear of the flywheel and the internal
contacts of the starter are connected. The current flows from the
battery (1) → "A" terminal of the battery relay (2) → "B" terminal
of the battery relay (2) → "B" terminal of the starter (9).
The starter motor is rotated and the engine is started.
If the instrument panel has the password function activated, the
input number should match the set number, otherwise the start
circuit closes and the engine does not start.
NOTE: If the security system is "LOCKED," a four-digit
Owner Password
password will be required to start the engine. If the
system is "UNLOCKED," no password will be
required and this display screen will not appear.
If the security system is locked, current flows from
battery (1) → circuit breaker 1 (3) → fuse box (6) →
"B" terminal of starter switch (5) → BR" terminal of 3 4 5 6 7 8 9 : ; <
starter switch (5) → "86" terminal of starter relay 2 (12) Enter Owner Password
→ "85" terminal of starter relay 2 (12) → "2-115"
terminal of EPOS (13) → ground.
This current flow causes the coil in starter relay 2 (12) EX1301416
to be activated, opening contacts at "87a" terminal. Figure 2
This prevents starter relay 1 (8) from functioning.
87a 8
30
87 A
85 86 ACC
C
B 5
R2 BR
12
3
2-115
6
4
B A
1-69
BR
13 E
11
2
STARTER SWITCH CONNECTION P(R) B(B+) R(I)
ON R 1
F
START E
E ALTERNATOR
8B
WE1400661
Figure 3 Starter Circuit (1) - While Starting
Reference Reference
Description Description
Number Number
1 Battery 8 Starter Relay 1
2 Battery Relay 9 Starter
3 Circuit Breaker 1 10 Alternator
4 Circuit Breaker 2 11 Diode
5 Starter Switch 12 Starter Relay 2
6 Fuse Box 13 EPOS Controller
7 Starter Controller
87a 8
30
87 A
85 86 ACC
C
B 5
R2 BR
12
3
2-115
6
4
B A
1-69
BR
13 E
11
2
STARTER SWITCH CONNECTION P(R) B(B+) R(I)
ON R 1
F
START E
E ALTERNATOR
8B
WE1400661
Figure 4 Operation of Start Circuit (2) - Immediately After Start
Reference Reference
Description Description
Number Number
1 Battery 8 Starter Relay 1
2 Battery Relay 9 Starter
3 Circuit Breaker 1 10 Alternator
4 Circuit Breaker 2 11 Diode
5 Starter Switch 12 Starter Relay 2
6 Fuse Box 13 EPOS Controller
7 Starter Controller
9 4
CN7-5, 6 2
ACC C B A
CN6-12, 13
B 5
R2 BR
BR E
10
CN1-39, 40, 21
CN1-69
- + - +
12V 150AH 12V 150AH
11 1
C B
- +
200A
13
STARTER SWITCH CONNECTION
1-46, 47, 10
7 TML
1-69 PST B BR R2 C ACC
(1) (2)
1-74 OFF
D H
1-83
+
8 -
ACC
ON
START
12
WE1400663
Figure 5 Engine Preheat Circuit
Reference Reference
Description Description
Number Number
1 Battery 8 Air Heater
2 Battery Relay 9 Preheat Indicator Light
3 Circuit Breaker 1 10 Diode
4 Circuit Breaker 2 11 EPOS Controller
5 Starter Switch 12 Engine Controller
6 Fuse Box 13 Preheat Relay Fuse
7 Preheat Relay
EX1403563
ACC C
10 B 5
1
1-11 2 3
R2
BR
4 2
B A
1-74
1-69 BR
E
7
9
- + - +
12V 150AH 12V 150AH
1
WE1400664
Reference Reference
Description Description
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 7 Diode
3 Circuit Breaker 1 8 Engine Controller
4 Circuit Breaker 2 9 Injector Solenoid
5 Starter Switch 10 Engine Emergency Stop Switch
ACC C
B 5
R2
BR 3
8
4 2
B A
BR
E
- + - +
12V 150AH 12V 150AH
P(R) B(B+) R(I)
STARTER SWITCH CONNECTION
1
PST TML B BR R2 C ACC
OFF SG
7
ACC
R
ON F
E
START
E ALTERNATOR
8B
WE1400675
Figure 8 Charging Circuit
Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Circuit Breaker 1 7 Alternator
4 Circuit Breaker 2 8 Diode
1
2 5 7
4
AM
H H 8 3 9
17
C
E
E F
F
C 10
TRIP
/h rpm ECO
Min Max 16
s
SPC
USB
11
6
21
12
18
20 15
14
22
19 13
WE1400676
Figure 9
Reference Reference
Description Description
Number Number
1 Instrument Panel 12 Air Cleaner Indicator
2 Battery 13 Engine Controller Unit
3 Light Switch 14 Parking Brake Sensor
4 Return Filter Switch 15 Brake Oil Pressure Switch
5 Pilot Filter Switch 16 Travel Speed Select Switch
6 EPOS Controller 17 Parking Brake Switch
7 Alternator 18 Steering Console
8 Warning Buzzer 19 FNR Select Switch
Pump Discharge Pressure 20 Left Side Combination Switch
9
Sensor 21 Ram Lock Switch
10 Oil Temperature Sensor 22 Jog Switch Control Panel
11 Fuel Sensor
10
9 8
AM 12
1
H H
3 4
E F
2 C E F C
TRIP 5
rpm ECO
7 /h Min Max
s
SPC
USB 13
15 14 16
6
11
EX1300990
Figure 10
Reference Reference
Description Description
Number Number
1 Fuel Gauge 9 Display Warning Symbols
2 DEF (AdBlue) Level Gauge 10 Warning Light
Engine Coolant Temperature 11 Function Buttons
3
Gauge 12 Mode Selector Buttons
Hydraulic Oil Temperature 13 Selector Function Display
4
Gauge
14 Jog Switch
Multifunction Gauge and Graphic
5 Camera Mode Selector/
Information Area 15
ESC Button
6 ECO Gauge
16 Multimedia Selector Button
7 Trip Meter
8 Digital Clock
Functional Check
When the engine starter switch is turned to "I" (ON) position, all
gauge bands, switch/button indicator lights and warning lights
will turn "ON" and the alarm buzzer will sound for about two (2)
seconds.
During this functional check, a LOGO will appear on the
multifunction gauge in the graphic information area (3 and 4,
Figure 10).
1 2
CN6-1
22
CN7-5
CN7-6
3
3 2
CN6-4
33
LAMP SWITCH 4
1
2 CN7-4
3 CN7-3 20
4
19
1
2
3
4 17
34
1 1-69
21
18
2 1-34
3
5 1-10
4
1-10
6
2-85 10 PEDAL BRAEKER
CN6-12 1-39 PRESSURE SW 1 (OPT)
CN6-13 1-40
1-21
2-103 11 PEDAL BRAEKER
PRESSURE SW 2 (OPT)
1-23
1-50
12
32 1-24
INDICATOR
1-43
23 1-37
1-49 13
1-46
PILOT FILTER SW
1-47
7 1-48 14
1-10 RETURN FILTER SW
12
8
16 1-28
1-2
9
36 24 1-19
PARKING BRAKE
1-13
25 35 1-11
SENSOR
CN17-2 26
CN17-1 27
28
29
(RAM LOCK) 1-72
(BEAM) 1-53
31 (PARKING) 1-74
WE1400677
Figure 11
Instruments
Sensor Specification
Function Display
Input Terminal Input Specification
17% (46°C)
97% 100% 33% (59°C)
White
EX1301123
17% (46°C)
100% 97% 33% (59°C)
5% → Min.
DEF (AdBlue) ECU-CAN
20% → Red Zone
Level Gauge E F Communication
100% → Max.
EX1300993
ECU-CAN
Tachometer rpm Communication
EX1301378
EX1300995
FG000045
Preheating period
depends on coolant
This symbol appears temperature.
Preheating 2-101
during preheating.
20 sec preheating at
5°C.
HAOA639L
Europe:
20%: Light on
10%: Flashes every
2 seconds
5%: Flashes every
ECU-CAN
DEF 0.5 seconds
Communic
(AdBlue) Low America:
ation
20%: Light on
10%: Flashes every
FG019175 2 seconds
5%: Flashes every
0.5 second
Alarm notifying
abnormal operation
at the post
ECU-CAN processing side of
SCR Fault Communic the SCR system.
ation Check the ECU
malfunction from the
FG019176 current malfunction
information.
FG019003
EX1301542
FG000056
FG000057
FG000053
FG000055
HB4O2003
Jog Switch
This symbol appears
Excavation CAN
when the excavation
mode Communic
mode is selected.
ation
EX1301579
Jog Switch
This symbol appears
CAN
Lift Mode when the lift mode is
LIFT Communic
ation
selected.
EX1301580
Jog Switch
This symbol appears
Breaker CAN
when the breaker
Mode Communic
mode is selected.
ation
EX1301581
Jog Switch
Breaker This symbol appears It appears only for the
CAN
Mode when the breaker vehicle with PE3C
Communic
(Option) mode is selected. option.
ation
EX1301582
Jog Switch
Two-Way This symbol appears It appears only for the
CAN
Mode when the two-way vehicle with PE3C
Communic
(Option) mode is selected. option.
ation
EX1301584
INITIAL OPERATION
Item Input (Terminal) Output (Operation and Initial Setting Mode)
• Warning buzzer is activated and turned "OFF" after
about 3 seconds.
• Power mode: When Fuel Saving Mode is disabled,
the power mode is the previous mode. When Fuel
When "CN7-2" is applied Saving Mode is enable, the power mode is standard
Initial
battery voltage (starter switch) mode or economy mode.
Operation
shifts from "OFF" to "ON" • Auto Idle: High Output (Activation).
• Display: Indicating coolant temperature, fuel level,
hydraulic oil temperature, engine speed, DEF
(AdBlue) level, trip meter.
• Clock: Current time display.
Overview
Machine condition is displayed in the letter information display
department. The information display department is divided into
two menus. One is main menu for the user and the other is a
special menu for the specialist. These menus can be changed
from normal display mode by the jog switch.
PM
H H
E F
C E F C
TRIP
/h rpm ECO
Min Max
3
SPC
S USB
2 1
EX1300996
Figure 12
Access Method
1. On the normal display screen, click on the jog switch to
access the user menu screen.
2. Proceed to the user menu using the menu/esc button on
the front of the dashboard.
3. Select the user menu from the launch menu.
PM PM
User Menu
H H
E F
C E F C Vehicle GP
TRIP Vehicle State Configuration Entertainment Configuration
/h rpm ECO
Min Max
SPC SPC
S USB S USB
Escape Method
1. Press the ESC button to move to the normal display screen.
2. If 20 seconds have passed without the operation of the
button, the normal display screen will be displayed.
3. Turning "OFF" the starter switch to cut off power, you will
move to the normal display screen.
User Menu
PM
Turn the jog switch and move the cursor to see a reversed User Menu
display on the desired menu. Then, click on the jog switch to
select the menu.
Vehicle State ↔ Vehicle Configuration ↔ Entertainment ↔
GP Configuration
Vehicle GP
Vehicle State Configuration Entertainment Configuration
Press the ESC button to return to the previous screen.
SPC
S USB
WARNING Figure 14
EX1301030
S USB
A. Monitoring
Monitoring
The monitoring screen displays the information on Front Pump Pressure Rear Pump Pressure Battery Voltage
vehicle pump pressure, voltage, fuel level, etc.
bar bar bar
Monitoring, click on the jog switch to display the Engine Dial Voltage Fuel Level Engine Speed
Monitoring screen.
bar v %
screen.
FG018483
Figure 16
B. Filter/Oil Information
PM
The screen displays the information on filter/oil use Vehicle State
time, replacement period, and remaining time.
Monitoring
At the vehicle state, if the cursor is placed on the
filter/oil information, click on the jog switch to display Filter/Oil Information
SPC
S USB
EX1402167
Figure 17
on the front of the dashboard and click the jog switch Air Cleaner
or press the 'Enter' button on the front of the TIME: 0 hr
REMAIN: 2000hr
CHANGE: 2000hr
0 %
To reset the use time, move the cursor over 'clear' Return Filter
and click the jog switch or press the 'Enter' button on TIME: 41 hr
REMAIN: 1359hr
CHANGE: 1400hr
2 %
Air Cleaner
Fuel Filter
TIME: 0 hr CHANGE: 2000hr
REMAIN: 2000hr 0 %
Return Filter
TIME: 41 hr CHANGE: 1400hr
REMAIN: 1359hr 2 %
EX1301407
Figure 19
Air Cleaner
Reset Operation
TIME: 0 hr
Hour?
CHANGE: 2000hr
REMAIN: 2000hr 0 %
Return Filter
TIME: 41 hr CHANGE: 1400hr
REMAIN: 1359hr 2 %
EX1301408
Figure 20
Filter/Oil Information
Fuel Filter
TIME: 40hr CHANGE: 2000hr
REMAIN: 1960hr 2 %
Air Cleaner
Fuel Filter
TIME: 0 hr CHANGE: 2000hr
CHANGE:
REMAIN: 2000hr 2000 hr 0 %
Return Filter
TIME: 41 hr CHANGE: 1400hr
REMAIN: 1359hr 2 %
EX1301409
Figure 21
press the 'Enter' button on the front of the dashboard. REMAIN: 1960hr 2 %
Air Cleaner
Change Period?
After the exchange period change screen pops up, TIME: 0 hrCHANGE: 2000hr
REMAIN: 2000hr 0 %
click the jog switch or press the 'Enter' button on the Engine Oil Filter
front of the dashboard and the exchange time will TIME: 0 hr \HV QR
CHANGE: 100hr
REMAIN: 100hr 0 %
start flashing. Return Filter
TIME: 41 hr CHANGE: 1400hr
Next, change the exchange period using the jog REMAIN: 1359hr 2 %
Replacement Period
Kind Minimum Available Change Value By
Basic Setup Value
Setup Value Step
Fuel Filter 500 100 50
Air Cleaner 2,000 1,000 50
Engine Oil Filter 500 100 50
Return Filter 1,000 100 50
Pilot Filter 1,000 100 50
Engine Oil 500 100 50
Hydraulic Oil 2,000 1,000 50
Coolant Water 2,000 1,000 50
Symbol Description
Icon
EX1300858
Figure 23
Press the ESC button or the jog switch to allow the H Caution H
pop-up window to disappear.
Return Filter
F
E period starts!
Replacement
C E F C
TRIP
/h rpm ECO
Min Max
SPC
S USB
EX1301047
Figure 24
WARNING TRIP
C E
F
E period is exceeded!
Replacement
F C
/h rpm ECO
Min Max
S USB
C. Vehicle Information
PM
This is used to check the vehicle name, engine type Vehicle State
and attachment options.
Monitoring
At the vehicle state, if the cursor is placed on the
vehicle information, click the jog switch to access the Filter/Oil Information
Click the ESC button to return to the previous screen. Fuel Efficiency Data
SPC
S USB
EX1402168
Figure 26
Vehicle Information
Engine
EX1301411
Figure 27
SPC
S USB
EX1402169
Figure 28
90 18
60 12
30 6
0 0
7 6 5 4 3 2 1
Days Before
EX1402170
Figure 29
8.0
6.0
4.0
2.0
0.0
12 11 10 9 8 7 6 5 4 3 2 1
Hours Before
EX1402171
Figure 30
EX1402172
Figure 31
EX1402173
Figure 32
2. Vehicle Configuration
PM
This is used when selecting the functions such as User Menu
attachment setting, camera setting, forced dial input, auto
shut-off setting and option motion setting.
Turn the jog switch and move the cursor to see an
reversed display on the desired menu. Then, click the jog
Vehicle GP
switch to select the menu. Vehicle State Configuration Entertainment Configuration
SPC
S USB
EX1301034
Figure 33
Press the ESC button to return to the previous screen. Attachment Setting
Camera Setting
Forced Dial Input
Auto Shut-off Setting
Option Motion Setting
SPC
S USB
EX1301035
Figure 34
SPC
S USB
WE1400332
Figure 35
WE1400345
Figure 38
3 4 5 6 7 8 9 : ; <
Enter Owner Password
EX1301416
Figure 39
Min : Max :
30 400
WE1400346
Figure 40
Button Type
This item sets the applicability of the toggle of the
breaker button when the breaker button is pressed
once, and reset when pressed again.
If toggle is not selected, the breaker is only actuated
while the breaker button is being pressed and held.
2 Pump Option
2 pump option is displayed as long as it is enabled in
the option setting in the service menu.
If the user setting max flow is below 1 pump flow, the
light is turned off and the caption is displayed as not
enable.
– If the user setting max flow is 1 pump flow or
over, the light is turned on and the caption is
displayed as enable.
Max Pressure
The maximum pressure of the breaker can be set.
The configurable max. pressure range is different by
equipment. For details, refer to the EPOS
specifications.
The maximum pressure indication/setting resolution
is 10 bar (10.2 kg/cm2, 145 psi)..
When the cursor is placed on the list, operate 1 Set 240 lpm 140 bar
Then, click on the jog switch to select breaker 4 Set 30 lpm 30 bar
When the selection is completed, the "Select No Select Setting Flow Pressure
Complete!" pop-up window is displayed for 3 1 Set 240 lpm 140 bar
seconds, and the checkbox of the selected list 2 Set 30 lpm 30 bar
is updated.
3 Set 30 lpm 30 bar
Select Complete!
4 Set 30 lpm 30 bar
WE1400348
Figure 42
4) Two-way Setting
Two Way Setting
The two-way setting screen is used to set up the
max flow, the use or non-use of button type, 2 No Select Setting Flow Pressure
pump option. 1 Set 240 lpm 140 bar
WE1400349
Figure 43
3 4 5 6 7 8 9 : ; <
Enter Owner Password
EX1301416
Figure 44
• Two-way Setting
Max. Limit Min. Limit
Max. E/G Limit 1,700 rpm -
Max. Press. (ATT) 340 bar 140 bar
SPC
S USB
EX1301037
Figure 46
screen. No 3 Camera
SPC
S USB
EX1301038
Figure 47
camera.
On Off
Normal Mirror
EX1301421
Figure 48
EX1301422
Figure 49
SPC
S USB
EX1301039
Figure 50
If you access the jog shuttle for dial screen, the initial
# Input
Forced Dial
cursor is located at the using jog shuttle for dial.
If the using jog shuttle for dial is shown as disable,
Using Jog Shuttle for Dial Available
the cursor cannot be moved.
Current Engine Speed 0
40 %
Setting RPM Dial
EX1301423
Figure 51
Select auto shut-off setting in the vehicle settings and Option Motion Setting
S USB
EX1301426
Figure 54
Input Output
DeSOx Switch
Auto Idle Pilot Cutoff Engine Coolant Hydraulic
GP Menu (SCR Regen Signal) Dial Status Time Signal Pop-up Alarm
Mode Switch rpm Temp. Temp.
(DL06 Engine Only)
1 minute 10 seconds
More than More than at Setting Engine
Active ON ON OFF OFF 10 rpm Normal before before
50°C 20°C Time Stop Signal
stopping stopping
Deactive Except Above Condition Time Count Reset
WARNING
AVOID DEATH OR SERIOUS INJURY
When the auto shut-off feature is used, the engine
shuts off automatically after the preset time, and
thus particular care must be taken that no safety
problems occur when it is used.
SPC
S USB
EX1301428
Figure 56
SPC
S USB
EX1402174
Figure 58
EX1402175
Figure 59
SPC
S USB
EX1301040
Figure 60
Video ↔ MP3
PM
Press the ESC button to return to the previous screen. Entertainment
Video
MP3
SPC
S USB
EX1301041
Figure 61
S USB
EX1301042
Figure 62
WARNING
SPC
EX1301043
Listening to entertainment clips, such as video, music, Figure 63
etc., can cause an accident, resulting in death or
serious injury. Do not play entertainment files when
operating the machine.
MP3
SPC
S USB
EX1301041
Figure 64
SPC
S USB
EX1301044
Figure 65
FG018511
Figure 66
EX1301451
Figure 67
FG018214
Figure 69
Play/Pause 33=33=59
33=36=7<
EX1301454
Figure 71
Locate the cursor at the video progress bar and click 33=33=59
on the jog switch to convert into the fast forward/ 33=36=7<
rewinding mode.
On the fast forward/rewinding mode, operate the jog
switch clockwise/counterclockwise to conduct fast
forward/rewinding.
Fast forward/rewinding can be conducted at an
interval of 30 seconds per click during which the jog
switch is turned.
On the fast forward/rewinding mode, press the ESC EX1301455
button to disable the fast forward/rewinding mode. Figure 72
EX1301456
Figure 73
EX1301457
Figure 74
..(3)
Video(1).avi
Video(2).avi
Video(3).avi
Video(4).avi
FG018557
Figure 75
B. MP3
PM
From the entertainment screen, select MP3 to access Entertainment
it.
Video
MP3
SPC
S USB
EX1301053
Figure 76
SPC
S USB
EX1301054
Figure 77
If there is an MP3 file played last, the file will Music(1) .mp3
FG018560
Figure 78
Next
FG020126
Figure 81
Next
FG020128
Figure 83
Next
FG020129
Figure 84
..(0)
Music(1) .mp3
Music(2) .mp3
Music(3) .mp3
Music(4) .mp3
FG018560
Figure 85
Next
FG020130
Figure 86
PM
H H
E F
C E F C
TRIP
/h rpm ECO
Min Max
SPC
S PLAY
EX1301432
Figure 87
4. GP Configuration
PM
This menu is used to set up password, brightness, default User Menu
screen and time, and to input service phone number. Turn
the jog switch and move the cursor to see an reversed
display on the desired menu. Then, click on the jog switch
to select the menu.
Vehicle GP
Password Setting ↔ Brightness Setting ↔ Default Vehicle State Configuration Entertainment Configuration
Power Mode Setting ↔ Default Screen Setting ↔ Time
Setting ↔ Service Phone Number Setting ↔ Unit
SPC
S USB
By using the password setting function, you can Default Screen Setting
manage usage of operations and functions of the Time Setting
vehicle. SPC
S USB
EX1402178
Figure 89
EX1301055
Figure 90
2) Password entry
Owner Password
When the password entry screen appears, use
the jog switch (or the keypad) to enter the
password and move to the settings screen.
The default password is "1111".
How to enter the password 3 4 5 6 7 8 9 : ; <
Rotate the jog switch to select digits from 0 to 9 Enter Owner Password
below, and click Enter on the jog switch to input
the password.
If the password is input incorrectly, use the EX1301416
button on the lower right to delete the input Figure 91
password.
Owner Password
IMPORTANT
If the password is input incorrectly three
times in a row, you will be redirected to the Password Error!
main screen and the system will not start for
the next 10 minutes. 3 4 5 6 7 8 9 : ; <
Enter Owner Password
EX1301433
Figure 92
3) Structure
Password Setting
Owner password settings include password
change, start-up restriction settings, function Password Change
item settings, user password use settings, and Owner Engine Startup Lock has not been set!
user password change.
Item Setting
Use
User
Password Change
EX1301434
Figure 93
3 4 5 6 7 8 9 : ; <
Enter Password
EX1301435
Figure 94
Password Change
EX1301436
Figure 95
Item setting
Item Setting
User privileges and settings for engine start-up,
attachment settings, and entertainment use Item Use Permission
settings can be set.
Engine Startup
NOTE: Permission, which gives certain
Attachment Setting
users permission touse certain
features, can only be checked when Entertainment Use Setting
use ischecked.
In this case, the user has the same
privileges as the owner, and the
EX1301437
user’s settings take precedence in
equipment settings. Figure 96
b) User password change Owner Engine Startup Lock has not been set!
EX1301439
Figure 98
If the owner checks user password use in owner Owner Password Setting
password setting, user password setting will User Password Seeting
appear in the password setting screen so user
password can be set. (refer to “Owner
Password Setting” on page -59).
To set a user password, place the cursor over SPC
screen and click the jog switch (or press "Enter" EX1301440
on the keypad). Figure 99
2) Password entry
When the password input screen appears, input
the password with the jog switch (or keypad)
and move to the settings screen. (refer to
"Owner Password Setting 2" on page 2-71.)
The default password is "1111".
Item Setting
EX1301441
Figure 100
Password change
User Password Change
To change the user password, select password
change, and change the user password using
the jog switch (or keypad).
3 4 5 6 7 8 9 : ; <
Enter Password
EX1301442
Figure 101
EX1301436
Figure 102
Item setting
Item Setting
Use of engine start-up, attachment setting, and
entertainment use setting can be set. Item Use
S USB
EX1402179
Figure 105
SPC
S USB
EX1301056
Figure 106
60%.
60 %
Press the ESC button to return to the previous
screen. C
E
E F
F
C
EX1301057
Figure 107
S USB
EX1301058
Figure 108
EX1301445
Figure 109
P P EX1402180
PWR PWR
Figure 110
S S
STD STD
P+ P+
PWR+ PWR+
P P
PWR PWR
EX1301446
S S
STD STD
Figure 111
E E
ECO ECO
ON OFF ON
SPC
Mode
SPC
Mode
STD
Mode
ON OFF ON
SPC SPC
Mode Mode
STD STD
Mode Mode
S
SPC
USB
EX1402181
Figure 112
E F
C E F C
TRIP
/h rpm ECO
Min Max
S
SPC
PLAY
EX1301432
Figure 113
EX1402182
Figure 114
rpm
S
SPC
EX1402183
Figure 115
S USB
EX1403722
Figure 116
S USB
EX1403723
Figure 118
EX1301448
Figure 119
Hydraulic Oil
Hydraulic oil overheat. Please check after the
hydraulic oil is cooled off completely. In times of
E F
an emergency situation, turn off the engine after
C
gradually cooling Ethe engine. F C
TRIP
/h rpm ECO
Min Max
SPC
S USB
EX1301064
Figure 120
G. Unit Setting
PM
On the GP configuration screen, when cursor is GP Configuration
placed on unit setting, click the jog switch to access
the unit setting. Default Power Mode Setting
Default Screen Setting
Time Setting
Service Phone Number Setting
Unit Setting
SPC
S USB
EX1403724
Figure 121
Temperature: °C
Pressure edu nji2 䶫 svl PSd
Pressure: bar
Flux osp jsp
Flow rate: lpm
Speed np2k psk
Speed: km/h
EX1301449
Figure 122
H. Language Setting
PM
On the GP configuration screen, when cursor is GP Configuration
placed on language setting, click on the jog switch to
access the language setting. Default Screen Setting
Time Setting
Service Phone Number Setting
Unit Setting
Language Setting
SPC
S USB
EX1403725
Figure 123
Language
Korean, English, Chinese, Persian, Turkish,
Indonesian, Polish, Arabic, Russian, Thai, Hindi,
Japanese, French, German, Nederlands, Italian,
Portuguese, Spanish, Finnish, Swedish, EX1301062
Norwegian, Danish, Vietnamese, Greek Figure 124
I. Notification Setting
PM
On the GP configuration screen, when cursor is GP Configuration
placed on notification setting, click on the jog switch
to access the notification setting. Time Setting
Service Phone Number Setting
Unit Setting
Language Setting
Notification Setting
SPC
S USB
EX1301060
Figure 125
SPC
S USB
EX1301061
Figure 127
EX1301063
Figure 128
Entering/Accessing Menus
2
When normal mode screen is displayed, if jog switch (1, Figure
129), power mode selector button (2, Figure 129) and
multimedia button are pressed simultaneously for more than 3
seconds, normal mode screen (Figure 130) will be changed to
special menu screen (Figure 131).
4 3
1 FG018857
Figure 129
/h rpm ECO
Min Max
EX1301002
Figure 130
S USB
EX1301082
Figure 131
Exiting/Escaping Menus
1. If escape button (ESC, 4 on Figure 129) is pressed the
special menu screen will be returned to the normal mode
screen.
2. If this special menu is "ON" without any activity, for more
than 20 seconds, it will return to the normal mode screen.
3. After the turning starter switch to "OFF" position, turn it
back to "ON" position, and the normal mode screen
displayed once again.
Entering Submenus: When cursor is located on "Machine Info" Operating Hour Information
S USB
EX1301082
Figure 132
Monitoring
PM
1. Entering Submenus: When cursor is located on Monitoring
"Monitoring" of special menu screen, press the jog switch
Vehicle Analog
and the "Monitoring" will be displayed.
Vehicle Digital
2. Exiting Submenus: If escape button (ESC, 4 on Figure Engine Signal
129) is pressed display will be turned to previous screen. User Selection Signal
Doosan Connect Information
SPC
S USB
EX1301083
Figure 133
Submenu Selections
Vehicle Analog
EX1300997
Figure 135
Submenu Selections
Engine Signal
Engine Speed 770 rpm
Throttle Position 0 %
% Load at Current Speed 0 %
Fuel Rate 0.0 L/H
Boost Pressure 0 bar
Engine Oil Pressure 0 bar
Engine Signal
Fuel Temperature -40 C
Engine Oil Temperature -273 C Coolant Water Temperature -40 C
DOC Intake Temperature -273 C
Intake Manifold Temperature -40 C
APP Command 0.0 %
Total Fuel Used 0 L
SCR Upsteam Temperature -273 C
Engine Signal SCR Downsteam Temperature -273 C
DEF Temperature -40 C DEF Level 0 %
EX1403137
Figure 136
EX1301613
Figure 137
Graph
PM
1. Entering Submenus: When a cursor is located in "Graph" Service Menu
of special menu screen press enter jog switch (1 on Figure
Monitoring
129) and "Graph" screen is displayed.
Graph
2. Exiting Submenus: If escape button (ESC, 4 on Figure Failure Information
129) is pressed, this information screen will be returned to Operating Hour Information
previous screen. Vehicle Configuration
SPC
S USB
EX1301615
Figure 139
SPC
S USB
EX1301084
Figure 140
0
1 19 Sec
EX1301616
Figure 141
The maximum limit of the graph data setting is 7. Rear Pump Press.
Boom Cylinder Press.
Px Pressure You can select up to 7
Py Pressure items!
Alternator Voltage
Battery Voltage
Engine Dial Volt.
EX1301617
Figure 142
Failure Information
PM
1. Entering Submenus: When a cursor is located in "Failure Service Menu
Info" of special menu screen press jog switch (1 on Figure
Monitoring
129) and "Failure Info" screen is displayed.
Graph
2. Exiting Submenus: If escape button (ESC, 4 on Figure Failure Information
129) is pressed, this information screen will be returned to Operating Hour Information
previous screen. Vehicle Configuration
SPC
S USB
EX1301086
Figure 143
SPC
S USB
EX1301087
Figure 144
S USB
EX1301088
Figure 147
EX1301626
Figure 148
EX1301077
Figure 149
S USB
EX1301089
Figure 150
Q Q
3 4 5 6 7 8 9 : ; <
Enter Service Password
EX1301634
Figure 151
Option Setting
Program Update
Vehicle Serial Number
Vehicle Information Delete
Version Information
SPC
S USB
EX1301090
Figure 152
S USB
EX1301090
Figure 153
2. Option Setting
• Attachment Option Vehicle Configuration
When a cursor is located in check box of breaker or Option Setting
two-way, press jog switch (1 on Figure 129) and then, Program Update
the check box light turns "ON". Vehicle Serial Number
Vehicle Information Delete
Version Information
SPC
S USB
EX1301090
Figure 154
Place the cursor on the check box for the two-way Two Way Option Pedal Enable
option pedal and select a function by pressing the jog
switch.
NOTE: Option setting can only be made for those
EX1301635
vehicles with the option in question.
Selecting a vehicle without the option can Figure 155
cause a problem in terms of performance
and safety.
S USB
EX1301091
Figure 156
Program Update
EX1301636
Figure 157
S USB
EX1301092
Figure 158
3 4 5 6 7 8 9 : ; <
Enter Serial Number
EX1301638
Figure 159
S USB
GP Setting Reset
EX1301094
Figure 161
6. Version Information
Entering Submenus: When a cursor is located in "Version Vehicle Configuration
Information" of special menu screen (Figure 162) press jog
Option Setting
switch (1 on Figure 129) and "Version Information Screen"
Program Update
will be displayed (Figure 163).
Vehicle Serial Number
Vehicle Information Delete
Vehicle Information
S USB
EX1301096
Figure 162
Version Information
FG018893
Figure 163
GP Correct Value
Measuring Severity
Display SPN Name FMI GP Display Description
Point Active Passive Level
Code
6-12/
VCO001 Can (Gauge Panel) 11 Gauge Panel Communication Error
6-13
R = 60 ±5Ω 4
1-39/
VCO002 Can (ECU) 11 E-ECU Communication Error
1-40
VPV001 05 Current of Pump P/V (A) is Below Normal 2-98/ R = 13.5 ±2Ω
Pump P/V (A) 4
VPV001 06 Current of Pump P/V (A) Is Above Normal 2-99 (25°C (77°F))
VPV003 05 Current of Flow Control P/V (C) is Below Normal 2-108/ R = 13.5 ±2Ω
Flow Control P/V ( C) 3
VPV003 06 Current of Flow Control P/V (C) is Above Normal 2-109 (25°C (77°F))
VPV005 05 Current of Press. Control 1 P/V (H) is Below Normal 1-26/ R = 9.5 ±2Ω
Press. Control 1 P/V (H) 3
VPV005 06 Current of Press. Control 1 P/V (H) is Above Normal 1-27 (25°C (77°F))
VPV006 05 Current of Press. Control 2 P/V (I) is Below Normal 1-44/ R = 9.5 ±2Ω
Press. Control 2 P/V (I) 3
VPV006 06 Current of Press. Control 2 P/V (I) is Above Normal 1-63 (25°C (77°F))
Current of Flow Control P/V (C) 2-way RH-open is
VPV007 05
Flow Control P/V (C) Below Normal 1-6/ R = 18 ±2Ω
3
2-way RH-open Current of Flow Control P/V (C) 2-way RH-open is 1-25 (25°C (77°F))
VPV007 06
Above Normal
Current of Flow Control P/V (D) 2-way RH-close is
VPV008 05
Flow Control P/V (D) Below Normal 2-82/ R = 18 ±2Ω
3
2-way RH-close Current of Flow Control P/V (D) 2-way RH-close is 2-83 (25°C (77°F))
VPV008 06
Above Normal
Current of Flow Control P/V (E) Rotating CW is Below
VPV009 05
Flow Control P/V (E) Normal 1-7/ R = 18 ±2Ω
3
Rotating CW Current of Flow Control P/V (E) Rotating CW is 1-8 (25°C (77°F))
VPV009 06
Above Normal
Current of Flow Control P/V (F) Rotating CCW is
VPV010 05
Flow Control P/V (F) Below Normal 2-90/ R = 18 ±2Ω
3
Rotating CCW Current of Flow Control P/V (F) Rotating CCW is 2-91 (25°C (77°F))
VPV010 06
Above Normal
VSV001 05 Current of Breaker Operating S/V is Below Normal 1-1/ V = V_volt
Breaker Operating S/V 3
VSV001 06 Current of Breaker Operating S/V is Above Normal 2-97 (Note 4)
VSV002 05 Current of Relief Press. Up S/V (B) is Below Normal 1-1/
Relief Press. Up S/V (B) V = V_volt 3
VSV002 06 Current of Relief Press. Up S/V (B) is Above Normal 2-96
VSV007 05 Current of Option Safety S/V is Below Normal 1-1/
Option Safety S/V V = V_volt 3
VSV007 06 Current of Option Safety S/V is Above Normal 2-116
VSV008 05 Current of Cruise S/V (F), Current Below Normal 1-1/
CRUISE S/V V = V_volt 3
VSV008 06 Current of Cruise S/V (F), Current Above Normal 2-113
VSV009 05 Current of Forward S/V (G), Current Below Normal
FORWARD S/V 2-112 V = V_volt 3
VSV009 06 Current of Forward S/V (G), Current Above Normal
VSV010 05 Current of Reverse S/V (H), Current Below Normal
REVERSE S/V 2-105 V = V_volt 3
VSV010 06 Current of Reverse S/V (H), Current Above Normal
VSV011 05 Current of 2 Pump Select S/V (I) is Below Normal 1-1/
2 Pump Select S/V (I) V = V_volt 3
VSV011 06 Current of 2 Pump Select S/V (I) is Above Normal 2-104
VRY002 05 Current of Alarm Relay is Below Normal 1-1/
Alarm Relay V = V_volt 3
VRY002 06 Current of Alarm Relay is Above Normal 2-119
VRY003 05 Backup Lamp Relay, Current Below Normal
Backup Lamp Relay 2-117 V = V_volt 3
VRY003 06 Backup Lamp Relay, Current Above Normal
VSV013 05 Inching S/V, Current Below Normal
Inching S/V 2-89 V = V_volt 3
VSV013 06 Inching S/V, Current Above Normal
VSV014 05 Low Speed S/V, Current Below Normal
Low-speed S/V 2-88 V = V_volt 3
VSV014 06 Low Speed S/V, Current Above Normal
VSV015 05 High Speed S/V, Current Below Normal
High-speed S/V 2-114 V = V_volt 3
VSV015 06 High Speed S/V, Current Above Normal
DTC Code
P Code
GP Display Code FMI GP Display Description Severity Remarks
DTC
HEX DEC
H H
C C
Min Max
16
6 6
7 7
11 14
8
8
13 15
E/G
4 4 5
3
9 10
Power Mode
Work Mode
Auto Idle Mode
2 Machine Information
25
E/G Speed
PM
H H
Order E F
C E F C
TRIP
/h rpm ECO
Min Max
SPC
S USB
24 23
1
21 19 22
17 20
WE1400678
Figure 164
6 6
E/G
4 4
3
25
10
2
PM
H H
24 C
E
E F
F
C
TRIP
/h rpm ECO
Min Max
SPC
S USB
19 23 22 1
17
WE1400679
Figure 165
Reference Reference
Description Description
Number Number
Electromagnetic Proportional
Instrument Panel
1 10 Pressure Reducing Valve
(Power Mode Selector Switch)
(Mode Control)
2 EPOS Controller 17 Engine Control Dial
3 Engine Controller (ECU) 19 Work/Travel Selector Switch
4 Main Pump 22 Aux Mode Switch
5 Aux Pump 23 Aux Mode Resistor
6 Control Valve 24 Accelerator Pedal
25 Jog Switch Control Panel
Mode Power Plus Mode Power Mode Standard Mode Economy Mode
Output (%) 100% Approximately 90% Approximately 80% Approximately 75%
C C
In Power Mode, the EPOS controller receives engine Speed
speed signals from the engine control dial and the engine 0 25 (mph) Min Max
A C
B D FG000580
Figure 168
Reference Reference
Description Description
Number Number
A Engine Horsepower (hp) Pump Discharge Pressure
D
B Engine Speed (rpm) (kg/cm2)
C Pump Discharge Volume (lpm)
A C
B D FG018902
Figure 169
Reference Reference
Description Description
Number Number
A Engine Horsepower (hp) C Pump Discharge Volume (lpm)
B Engine Speed (rpm) D Pump Discharge Pressure (kg/cm2)
34
26 15A 10A
B
1
BR
4
E 25
7-2
Starter Switch (ACC) A
7-5
7-6
24
7-4
7-3
1-1
7-1
1-3
6-12 1-39
6-13
23
1-40 CAN A
1-21
22
2-98 1
5
1-23 GND 2 10
1-24 RxD 2-99 3
6
1-43 TxD 4
3 1
17
2 GND 1-11 3 HIGH
CW
3 SIG 1-31 2
1-46
4 (+5V) 1-19 1
1-47 LOW
5
1-10
6 1-4 35
1-03 14
1-05 32 3 4
1-5 Position Idle
1-28 Sensor Validation 27
1-29 2
1-52
P1
1-75
1-76 1
1-25 A B C E F D
1-20
1-01 Starter
Switch 1-12
1-26 (ACC) 1-29
1-49
33 2-93
1-73 1
1-11 2 3 26
1-74 10A
15A
1-69 BR B 10A
28
ECU (CN1)
WE1400680
Figure 170
Operation
Arm Crowd
(Pilot 15 bar )
EX1403306
Figure 171
If the joystick lever condition meets the heavy load condition and the
Entering actual torque of the engine meets the heavy load area condition, the
Condition engine speed is shifted from light load mode to heavy load mode to set
Heavy Load the hydraulic power to the maximum working performance level.
Condition
If the joystick lever condition meets any one of the heavy load condition
Maintenance
and 50 % or above of the engine actual torque, the engine speed is
Condition
maintained at heavy load mode.
When the engine actual torque is reduced to less than 50% and the
Entering joystick lover condition meets all the conditions other than the heavy
Condition load condition, the engine speed is shifted to light load mode to improve
Light Load fuel efficiency.
Condition
If the joystick lever condition meets any condition other than the heavy
Maintenance
load condition or the engine actual torque is in the light load area (0 ~
Condition
80 %), the engine speed is maintained at light load mode.
Torque Control
Mode
%
Actual Torque Ramp Start Power
Total Power
Power
100
40
Torque Control
Lamp Determined Limiter
Power Limiter
Power Output Value Using
Ramp and Power
Torque
T T
Engine rpm
Engine rpm
10 11 12 10 11 12
T T
EX1301793
Figure 172
24
(Command Signal)
4 17
(Drive Signal)
WE1500076
Figure 173
Reference Reference
Description Description
Number Number
3 Engine Controller 17 Engine Control Dial
4 EPOS Controller 24 Accelerator Pedal
CCW CW
Mechanical Mechanical
Stop Stop
3
4
2
5
4.0V
4
Output Voltage (V)
3 2.5V
2
1.0V
1
0 Step
1st 2nd ...... 7th ...... 12th 13th
CCW CW
Stop Stop
1 2 3
WE1400656
Figure 174
Reference Reference
Description Description
Number Number
1 Knob 3 Magnetic
2 Hall Effect Sensor 4 Gear
POSITION B 1-12
SENSOR
C 1-29
IDLE E 2-93
VALIDATION
F
D
Foot Pedal
Stroke 17.5
Detail A
PIN
A LOCATION DESCRIPTION COLOR CONNECTOR
B A APS SIGNAL BLACK 2 1 6
C B APS GRAND WHITE 1
D 2 5
C APS SUPPLY RED 3
E
D THROTTLE ACTIVE GREEN 5 3 4
F
E IDLE ACTIVE BLUE 6
Pedal Sensor F IVS SUPPLY ORANGE 4
WE1400681
Figure 175
4
26 34
15A 15A
B
1
BR
E 25
7-2
Starter Switch (ACC)
A
7-5
7-6
1-1 24
7-4 1-3
7-3 35
5
7-1 2-96 1
6-12 1-39 36
6-13 1-40 1-81 (BREAKER)
CAN A
1-21 (RS1)
1-23 GND 17
GND 1-11 3
1-24 RxD CW HIGH
1-43 TxD SIG 1-31 2
(+5V) 1-19 1
LOW
3 1
1-4
2 27
3
1-5 37
1-46 Position Idle
4
1-47 Sensor Validation
5
1-10
6 P1
1-03 14
1-05 32 3 4
1-28
1-20 A B C E F D
1-29 2
1-52 1-12
1-75
1 1-29
1-76
1-25 2-93
1-01 Starter
Switch
1-26 (ACC)
1-49
1-73
26
10A
15A
1-69 BR B 10A
28
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
GAUGE (CN7) GAUGE (CN6)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
EPOS (CN1) EPOS (CN2)
ECU (CN1)
WE1400682
Figure 176
E/G
3 4
1
5 5
WE1500077
Figure 177
Reference Reference
Description Description
Number Number
1 Jog Switch Control Panel 3 Engine Controller
(Auto Idle Switch) 4 Engine Control Dial
2 EPOS Controller 5 Pressure Sensor
6 6
E/G
4 4 5
3
31
7
(Pump control signal)
2
1
(E/G overheating signal) PM
H H
E F
C E F C
TRIP
rpm ECO
S USB
WE1400683
Figure 178
Reference Reference
Description Description
Number Number
1 Instrument Panel 6 Control Valve
2 EPOS Controller EPPR Valve (Electromagnetic
3 Engine Controller 7 Proportional Pressure Reducing
Valve)
4 Main Pump
31 Warning Buzzer
5 Aux Pump
Operation
16
6 6
11
E/G
4 4 5
3
PM
H H
E F
C E F C
TRIP
/h rpm ECO
Min Max
SPC
S USB
20 18
WE1400684
Figure 179
Reference Reference
Description Description
Number Number
1 Instrument Panel 11 Solenoid Valve (Boost)
2 EPOS Controller 16 Main Relief Valve
3 Engine Controller 18 Jog Switch Control Panel
4 Main Pump Power Boost Switch
20
5 Aux Pump (Top of Right Work Lever)
6 Control Valve
4
26 34
15A 15A
B
1
BR
E 25
7-2
Starter Switch (ACC)
A
7-5
7-6
1-1 24
7-4 1-3
7-3 35
5
7-1 2-96 1
6-12 1-39 36
6-13 1-40 1-81 (BREAKER)
CAN A
1-21 (RS1)
1-23 GND
1-24 RxD
1-43 TxD
3 1
2
3
17
GND 1-11 3
1-46 CW HIGH
4
1-47 SIG 1-31 2
5 1-19 1
1-10 (+5V)
6 LOW
1-03 14
1-05 32 3 4
1-4
1-28 1-5 27
1-29 2
1-52
1-75
1
1-76
1-25
1-01 Starter
Switch
1-26 (ACC)
1-49
1-73
26
10A
15A
1-69 BR B 10A
28
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
GAUGE (CN7) GAUGE (CN6)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
EPOS (CN1) EPOS (CN2)
ECU (CN1)
WE1400689
Figure 180
Operation
40
6
3
35 36
4 4
15 32
38
39
24 17
WE1400690
Figure 181
Reference Reference
Description Description
Number Number
3 Engine Controller (ECU) 32 Pressure Switch (Py)
4 Main Pump 35 Cruise Solenoid Valve
5 Aux Pump 36 Forward Solenoid Valve
6 Control Valve 38 Cruise Switch
15 EPOS Controller 39 Brake Pedal
17 Engine Control Dial 40 Travel Motor
24 Accelerator Pedal
2. Cancel
When the brake is applied the cruise control will be O
canceled.
Bring the forward/reverse switch back to neutral (N), will
I
also cancel the cruise control.
If the engine is running at an excessive rpm when the
cruise control is canceled, reduce the engine rpm setting.
NOTE: If the auto idle is "ON" when the cruise control is
canceled, the engine will return to idle in FG022343
approximately four seconds. When the cruise Figure 183
control is turned back "ON" the engine will
return to the rpm setting control by the engine
speed control dial.
3. Cruise Operation
5
4
1-61
11 3 2
+
1-14 B A
SIG. 1-1
1-28
- 1-3 BR
12 E
A 1-20
B 1-12
C 1-29
E 2-93
F
D
- + - +
7
13 2-112 12V 150AH 12V 150AH
1-19
+
1-13
SIG. 1
-
1-11
2-113
8
14
1 1-4
2 1-31
3 1-5
CW
9
0 1
1-80 3
I 2
1-58 9 10
(F)
1-76 13 10
(R)
1-57 12 10
(N)
10
WE1500078
Figure 184
Reference Reference
Description Description
Number Number
1 Battery 8 Cruise Solenoid Valve
2 Battery Relay 9 Cruise Switch
3 Circuit Breaker 10 Forward/Reverse Switch
4 Fuse 11 Auto Idle Sensor (Py)
5 Stop Light Switch 12 Accelerator Pedal
6 EPOS Controller 13 Parking Brake Sensor
7 Forward Solenoid Valve 14 Engine Control Dial
EPOS Controller
The system operation status and malfunction codes can be
checked through the display on top of the EPOS controller box
the rear cover behind the operator's seat.
1 2
4 3
FG000588
Figure 185
Reference Reference
Description Description
Number Number
1 Upper Digit Power Monitor (Stays "ON"
2 Lower Digit 4 While Power Is In Normal
Range,)
Engine Speed Monitor LED
3 (Flash Interval Increases With
Engine Speed.)
1. Power Monitor
This LED is turned "OFF" when the input voltage to the
EPOS controller is below 18.5 ±1 V or above 32.5 ±1 V.
Stays "ON" while in normal range.
2. Engine Speed Monitor
This LED light flashes according to the engine speed. The
flashing interval is proportional to the engine speed.
Display System
Mode
Higher Digit Lower Digit Condition
Normal Operation
P+, P
Power Mode
HAOH340L
HAOH340L FG018940
Normal Operation
Power Mode S
Standard Mode
FG018938 FG018940
Normal Operation
E
Economy Mode
HAOH350L FG018940
Normal Operation
Digging
Digging Mode
FG018940 HAOH370L
Work Mode
Normal Operation
Lift
Lift Mode
FG018940 FG018939
4. Communication Monitor
What are shown in the 7-SEGMENT LED are same as
those in the Error Codes.
Outline
C B
Modes
EX1300822
Figure 187
FG016045
Figure 188
FG016043
Figure 189
2. Turn marked knobs at the rear side of the cabin to open the
cover.
3. Remove filter attached to the cover and clean the
contaminated filter using compressed air.
4. Close the cover, replace the knobs, and secure the cover
to the support with butterfly bolts.
FG016044
Figure 190
11
3
10
2
1
5
7
4
8
6
8
9
WE1400657
Figure 191
Reference Reference
Description Description
Number Number
1 Air Conditioner/heater Unit 7 Liquid Hose (1)
2 Condenser 8 Liquid Hose (2)
3 Compressor 9 Ambient Temperature Sensor
4 Receiver Dryer 10 Sun Sensor
5 Discharge Hose 11 Control Panel
6 Suction Hose
CIRCUIT BREAKER
LAMP SWITCH
CN11-2 24V
LED 1~12 CN9-6
CN10-8
CN9-11
CN10-18
ILL CN9-5
RECEIVER DRIER
BLOWER A/C
RELAY RELAY
COMPRESSOR
CN8-10 CN10-16
CN8-11 CN10-6
FET
DIODE 4
1.25B CN11-1 - +
M
CN8-12 CN10-1 BLOWER
CN8-2 CN10-15
DUCT
SENSOR
CN8-1 CN10-14
WATER
SENSOR
2
CN8-5 CN10-17 1 INCAR
SENSOR
SUN LOAD SENSOR
2
CN8-4 1 AMBIENT TEMP
SENSOR
CN8 CN9
AMP 18P + 12P
20 19 18 17 16 15 14 13 12 11 10
4 3 18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
Airflow Diagram
External Air
VENT
COOL
DOOR
-INTAKE
DOOR
DEF -MIX
Internal Air
WARM
Evaporator Fan
Heater
FOOT Core
FG016942
Figure 193
Mode
Door
Vent Bi-level Foot Def/foot Def
Vent 100 60 0 0 0
Foot 0 40 100 80 60
Def 0 0 0 20 40
Main Components
Internal
Air Sensor
Blower
Motor
Actuator
- Internal/external
Air Exchanger
Internal
Air Filter
FG016943
Figure 194
N P2
c
b
a
P2 P1
a c b
WE1400658
Figure 195
N P2
P1
CN10-20 CN10-2
P2 P1
c e
FG001055
Figure 196
DRAIN
(CN10-1)
SOURCE GATE
(CN11-1) (CN10-6)
FG001056
Figure 197
30 86(+)
WE1400659
Figure 198
Specifications
Rated voltage 24V L S1 (+)
Rated current 10A
B S2
(-)
FG001058
Figure 199
Figure 201
83.7
OUTPUT VOLTAGE(mV)
76.2
67.7
58.8
46.6
36.0
21.4
Control Panel
A/C OUTSIDE
AUTO A/C
AUTO MAX
TEMP
OFF
SEL MODE
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
Temp Control
FULL COOL FULL HOT
Actuator
Starter Switch ON
Code Description
E0 Normal
E1 Internal air temperature sensor short
E2 Internal air temperature sensor open
E3 Ambient air temperature sensor short
E4 Ambient air temperature sensor open
E5 Duct sensor short
E6 Duct sensor open
E7 Sun sensor short
E8 Sun sensor open
E9 Coolant temperature gauge sensor short
E10 Coolant temperature gauge sensor open
E11 D.P.S open
E12 Position error of airflow direction actuator
E13 Position error of temperature control actuator
0.5 0.5
FG001067
Figure 207
Receiver Dryer
The receiver dryer reserves refrigerant enough to ensure High/Low Pressure Switch
smooth freezing cycle responding immediately to the change of
level in the freezing cycle.
As liquid refrigerant from the condenser may contain refrigerant
gas with bubbles whose presence in the expansion valve
decreases the freezing power excessively, it separates liquid
and gas and sends liquid only to the expansion valve.
Water in refrigerant shall be eliminated with dryer and through
filter.
• Weight of refrigerant: 800 ±20 grams FG001366
Figure 209
FG001462
Figure 210
Figure 211
WARNING
AVOID DEATH OR SERIOUS INJURY
Always wear safety goggles and gloves when handling
refrigerant. If refrigerant comes in contact with the skin or
eyes, immediately flush with clean, running water and
consult a physician.
Select a clean and well ventilated area to work.
The refrigerant container is under high-pressure and must
be stored below 40°C (104°F). Be careful not to drop the
container from a high location.
The contents are under high-pressure and should not be
used with compressed air or near an open flame.
UNION NUT
TORQUE WRENCH
CORRECT WRONG
WRONG
WRONG
CORRECT
O - RING POSITION
HDA6066L
Figure 212
RECOVER REFRIGERANT
RUN SYSTEM
Reference 1
Description
Number
1 Handle
2 Hose Connection
2
3 Mounting Disk
3
A. Before mounting valve on the container, make sure
the handle is in the counterclockwise most position,
with the puncture pin retracted and the mounting disk HDA6070L
is in the raised position. Figure 217
B. Attach the manifold gauge center hose to the valve
assembly.
C. Turn the disk in the clockwise direction and securely
mount valve onto refrigerant container.
D. Turn the valve handle in the clockwise direction and
puncture the container seal with the pin.
E. Once the can has been punctured, turn the handle in
the counterclockwise direction so the refrigerant can
flow into the manifold gauge center hose. Now, do
not open the low and high-pressure valves of the
manifold gauge.
F. Press the manifold gauge low side valve to eliminate
the trapped air in the hose.
WARNING
AVOID DEATH OR SERIOUS INJURY
For accurate refrigerant leak detection, perform leak
detection procedure in a well ventilated area.
Refrigerant Charging
1. Perform the vacuuming procedure, vacuum holding and
leaking tests as described in the proceeding headings.
NOTE: First charge the refrigerant system with 100g
(3.5 ounces) of refrigerant with the engine off.
Then using the manifold gauges as a guide fully
charge the system with the engine running.
When exchanging refrigerant containers, press
the manifold gauge low side valve to eliminate
air from the charging hose.
Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low-pressure Side
3 High-pressure Side
4 From Receiver
5 Refrigerant Supply Container
WARNING
AVOID DEATH OR SERIOUS INJURY
When charging refrigerant system with the engine
running:
• Always keep refrigerant supply container in the
upright position.
• Never open the high side pressure valve.
IMPORTANT
• When outside temperature is low, warm the
refrigerant supply container with warm water not
exceeding 40°C (104°F). Do not allow water to
come in contact with the charging adapter valve
handle.
• When outside temperature is high, cool off
refrigerant supply container and condenser to aid
the refrigerant charging process.
Inspection Procedure
1. High-pressure Side
Compressor outlet → condenser inlet → receiver dryer
inlet → air conditioner unit inlet.
2. Low-pressure side
Compressor inlet → air conditioner unit outlet.
3. Compressor
Compressor shaft area, bolt hole area and magnetic clutch
area.
4. Receiver dryer
Pressure switch and plug area.
5. Connection valve area
Inspect all valve areas.
Verify all valves are capped to prevent leaking.
Check for foreign material inside of valve cap.
6. Interior of air-conditioning unit.
After stopping engine, insert detector probe into drain
hose. (Leave inserted for 10 seconds minimum.)
NOTE: When inspecting leakage from the
air-conditioning unit, perform the inspection in a
well ventilated area.
Wiper Circuit
5 6 7
- 2 3 5 (Continuous mode) CN16-10
+
M
8 (Intermittent 1 mode) CN15-9
4 4
10 (Intermittent 2 mode) CN15-10
5 6 11 (Washer mode) CN16-11
1 7 8
12 - + CN16-2
P
1
6 13
8
9
9 2 7
AMP MIC 13P
CN12 CN13 KET 8P
4
10
2
B A
BR
3 E
7 8 9 10 11 12 13 9 8 7 6 5
Reference Reference
Description Description
Number Number
1 Battery 6 Wiper Controller
2 Battery Relay 7 Wiper Switch Panel
3 Circuit Breaker 8 Window Washer
4 Fuse Box 9 Wiper Cutoff Switch
5 Wiper Motor 10 Light Switch
Continuous operation
- Operation of wiper motor
Pressing the successive operation switch on the wiper switch
panel (7) changes the voltage of the "5" terminal of the wiper
controller (6) from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and
current flows by the "3" terminal of the wiper controller (6) → the
"2" and "4" terminals of the wiper motor (5) → the "4" terminal of
the wiper controller (6) to run the wiper motor (5) continuously.
- Stop of wiper motor
Pressing again the successive operation switch on the wiper
switch panel (7) changes the voltage of the "5" terminal of the
wiper controller (6) from LOW (0+0.5V) to HIGH (about
5.5 ±0.5V). As the "5" and "6" terminals of the wiper motor are
connected still that power is supplied to "6" terminal of the wiper
controller (6),
However, the controller (6) runs the wiper motor continuously
and then rotates the motor reversely by letting current flow by the
"4" terminal of the wiper controller (6) → the "2" and "4" terminals
of the wiper motor (5) → the "3" terminal of he wiper controller (6)
when the "1" and "6" terminals of he wiper motor (5) are
connected and thus power voltage is supplied to "7" terminal of
the wiper controller (6).
The Wiper motor (5) stops reverse revolution when the contact of
a cam switch connected to "6" terminal of the wiper motor (5)
moves to an insulation area of the cam plate to disconnect the "5"
and "6" terminals of the wiper motor (5).
When the wiper motor (5) stops, arm and blade connected to it
move to the stop positions of the right pole in the cabin.
10A
4
10A
4
30A
20A
7
2 B 5
BR 9
3 E 10
6
12
1
4 13 21
10A
2-117
10A 8
1-61
1-53
18 14 14 18
*
* 20 20
19 19
11
15 16 17 16 15 WE1400694
Figure 222
Type
Lighting system consists of headlight, work lights, cabin light
(optional), and S/W devices and relays to control them.
Operation
Connected Activated Relay/
Switch Position Lit Light
Terminal of Switch Operated Switch
Illumination Light of Switch/
Position Light of Headlight/
1st "2-3" Terminals - Position LIght of Rear
Light Switch (5) Combination Light
Position Light of Arm
"2-3" Terminals - "
2nd
"5-6" Terminals Headlight Relay (10) Low Beam of Headlight (2 ea.)
Operated Light Switch
"56-56b" Terminals Low Beam of Headlight (2 ea.)
(2nd)
Operated Light Switch
"56-56a" Terminals High Beam of Headlight (2 ea.)
(2nd)
"30-56a" Terminals - High Beam of Headlight (2 ea.)
Combination
Switch (6) Front Turn Signal Light (LH)
"49a-L" Terminals - Side Turn Signal Light (LH)
Rear Combination Light (LH)
Front Turn Signal Light (RH)
"49a-R" Terminals - Side Turn Signal Light (RH)
Rear Combination Light (RH)
FNR Switch
(Reverse Position) ON EPOS Controller Backup Light Relay Backup Light (2 ea.)
(8)
Stoplight Switch Stoplight of Rear Combination
ON ON -
(9) Light (2 ea.)
2 B
BR
4
A
5 1-1
1 0 1-3
2 2-84
3 I
7 8
1
1-4
1-5
+
1-32
6 SIG
- 1-10
WE1400695
Figure 223
Reference Reference
Description Description
Number Number
1 Battery 4 EPOS Controller
2 Battery Relay 5 OWD Selector Switch
3 Fuse Box 6 Pressure Sensor
8
14
10
4
2
7 Stereo ANT.
3
2 15 5
Vcc(+5V)
3 16
MICOM 4
0.5WR 1
4 13
3
11
5
- + - + 9 17
7 1 6
B 2
2 3
17
10 4 BR
12 4 E
13
1 11
A
9 10 11 12 13 14 15 16 17 18
1 2 3 4 1 2 3 4 5 6 7 8 9 1
1 2 3 4 5 6 78 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8
Reference Reference
Description Description
Number Number
1 Battery 7 Audio Control Panel
2 Battery Relay 8 Stereo
3 Fuse Box 9 Speaker
4 Circuit Breaker 10 Antenna Module
5 Hands-free Unit 11 Light Switch
Connected Terminal of
Switch Measured values Operations
switch
PWR 4.36 ±0.2V Stereo ON, OFF
1.24 ±0.2V Volume up
"3-4"
0 + 0.2V Volume down
SCAN 2.49 ±0.2V Frequency selection
3 4
Parking Brake Switch Work/Travel Switch
5 1-72
9 7
O (P) 1 Ram Lock SW
2 0 (T) 3 CN17-9 Ram Lock
I 3 CN17-10 2 314A 1 5
BR
E 2
WE1400696
Figure 225
Reference Reference
Description Description
Number Number
1 Battery 6 Ram Lock Pressure Switch
2 Battery Relay 7 Ram Lock Solenoid Valve
3 Parking Brake Switch 8 EPOS Controller
4 Work/Travel Switch 9 Diode
5 Ram Lock Switch 10 Fuse
Edition 1
One Way
Safety Instructions ........................................10-1-5
General .........................................................10-1-5
General Description................................................. 10-1-5
Theory of Operation ................................................ 10-1-5
Hydraulic Circuit ...................................................... 10-1-6
Caution for Installation............................................. 10-1-7
Installation Procedure ...................................10-1-8
Main Piping - One or Two-way ................................ 10-1-8
Main Piping - One Way ......................................... 10-1-10
Pilot Piping - One or Two-way............................... 10-1-12
Pilot Piping - One Way .......................................... 10-1-14
Boom Piping - One or Two-way ............................ 10-1-15
Arm Piping - One or Two-way ............................... 10-1-16
After Installation Precautions................................. 10-1-17
Air Bleeding ........................................................... 10-1-17
Completing Work ........................................10-1-18
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
General Description
The following description is of the installation of a pipe to
operate an attachment such as a breaker.
This description explains how to install a new pipe in equipment
in which a breaker operating pipe is not installed.
Figure 1 EX1301482
Theory of Operation
When a breaker (hammer) switch located at a right side joystick
lever is operated, an OPT spool will move to the maximum
extent possible through a hammer-operated solenoid valve.
Oil ejected from the front (P1) pump is connected to a
high-pressure line from the breaker through the OPT spool, and
the pressure thereof is controlled by a PPR valve connected to
the high-pressure line (the variable pressure being controlled
according to a current value).
EX1403214
The low-pressure oil of a breaker return line is returned to the
Figure 2
tank through a return filter and an oil cooler.
The flow rate through the front (P1) pump is controlled by an
instrument panel.
5
2
A2 B2 T A L.H
4
pb2
P4 Option 373bar@20L/min B A
R.H
P1 pa2 5
6
1
A3 A2
Ram Lock
Operating
A
Hammer
ps1 T
Inching
Cut-off
Pilot
P
X1 SD CH IC PB PS HO
T
C7
X3 C6
X1 C1 C2 C3 C4 C5
P1
A1 P2 P3 GTS
3
from JOYSTICK(R) BOTTON
WE1401117
Figure 3
Reference Reference
Description Description
Number Number
1 Main Pump 4 Pressure Proportional Relief V/V
2 Control Valve 5 Stop Valve
3 Solenoid Valve 6 EPPR Valve
CAUTION
AVOID INJURY
Release any pressure in the hydraulic oil tank before work.
IMPORTANT
Contact your DOOSAN distributor about proper size of
hydraulic pipes for installation.
FR
ON
T
BOOM
1-2
1-1
13
7
13
12
3
A
1 13 4
8
MAIN FRAME 10
9
13
T
12
6
OIL COOLER PIPE
13
B2
11
5
13
CONTROL VALVE
WE1401527
Figure 4
FR
ON
T
BOOM
52
51
22
3
6
5
4
6
23 a
A 2
MAIN FRAME
T
21
B2
A2
1
CONTROL VALVE
WE1401504
Figure 5
FR
OIL TANK ON
T
21
11
23
CONTROL VALVE
X1 MAIN PUMP
5
(6 )
pb2 ps1
16
22 OUT
24
8 14
23
13
23
(4 )
(5 )
3 2
6 9 2-1
MAIN FRAME 17 23
19 A
T
CONTROL VALVE 12
21
(Port pb2) P
(7) 15
18 21 2
1 10
HO
20 23
1
1-2
1-2
1-1
1-3
MAIN FRAME
WE1401505
Figure 6
FR
ON
T
OIL TANK
6
10
CONTROL VALVE
8
10
2
5
10 9
7
pb2 3
9
pa2 5
10
1
10
HO 4
8
MAIN FRAME
SOLENOID VALVE
WE1401506
Figure 7
Reference Reference
Description Description
Number Number
1 Hose Assembly, Hydraulic 6 Tee
2 Hose Assembly, Hydraulic 7 Bolt
3 Clip 8 O-ring
4 Elbow 9 O-ring
5 Elbow 10 O-ring
4 FR
8 ON
7 T
3 6
7
6 15
A
15 6
7
6 1
A 7
13
14
2
13 12
Ḻ#
14 5 BOOM A
12 11
5
8
11
WE1401507
Figure 8
Reference Reference
Description Description
Number Number
1 Pipe 8 O-ring
2 Pipe 11 Clamp, Pipe
3 Pipe 12 Clamp, Pipe
4 Pipe 13 Bolt
5 Rubber; Pipe 14 Washer; Spring
6 O-ring 15 Pipe
7 Bolt; Socket
FR
ON
T
4
5 9
5
3 BOOM
1
7
8
5 10
9 5
4 6
52
52-6
1
52-1
52-2 52-7
7
52-3
6 52-5
51
52-4
51-1
10
51-2 51-7
8 51-6
51-3
51-5
51-4 ARM
WE1401508
Figure 9
Air Bleeding
1. Start the engine and run at low idle.
2. Operate the joystick lever and actuate the hydraulic
cylinder 4 ~ 5 times very slowly about 100 mm before the
end of stroke.
3. Operate the rod of cylinder to the end of stroke to relieve
the hydraulic piping.
(The air breather of oil tank is actuated to bleed the air.)
SPC
S USB
WE1400332
Figure 11
When turning the jog switch counterclockwise or pressing the 4 Set 30 lpm 30 bar
Edition 1
DX140W-5/DX160W-5 Two-way
10-2-1
MEMO
Two-way DX140W-5/DX160W-5
10-2-2
Table of Contents
Two-way
Safety Instructions ........................................10-2-5
General .........................................................10-2-5
General Description................................................. 10-2-5
Theory of Operation ................................................ 10-2-5
Structure.................................................................. 10-2-6
Hydraulic Circuit ...................................................... 10-2-7
Caution for Installation............................................. 10-2-9
Installation Procedure .................................10-2-10
Main Piping - One or Two-way .............................. 10-2-10
Main Piping - Two-way .......................................... 10-2-12
Pilot Piping - One or Two-way............................... 10-2-14
Pilot Piping - Two-way........................................... 10-2-16
Pilot Piping - Two-way (Pedal) .............................. 10-2-18
Boom Piping - One or Two-way ............................ 10-2-20
Arm Piping - One or Two-way ............................... 10-2-22
After Installation Precautions................................. 10-2-23
Air Bleeding ........................................................... 10-2-23
Completing Work ........................................10-2-24
DX140W-5/DX160W-5 Two-way
10-2-3
Two-way DX140W-5/DX160W-5
10-2-4
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
General Description
The following description is of the installation of a pipe for use as
an attachment such as a crusher or shear in which hydraulic
pressure operates in both directions.
The description explains how to install a new pipe in equipment
in which a corresponding attachment-operating pipe is not
installed.
EX1301486
Figure 1
Theory of Operation
When a thumb wheel (variable) switch located at a right side
joystick lever is operated, an output signal (1.0 ~ 4.0 V) of the
switch supplies a current value to a two-way EPPR valve
through an EPOS controller to variably control (move) an OPT
spool of a main control valve.
A shear operation pressure is controlled by a PPR valve
connected to a line. (the variable pressure is controlled
according to a current value)
EX1403216
The two-way PPR valve is used in the shear (two-way).
Figure 2
DX140W-5/DX160W-5 Two-way
10-2-5
Structure
P (40 bar)
A B
RH-HI LH-HI
T
Current
EPOS Controller
Voltage
Joystick
(Right-hand)
WE1401064
Figure 3
Two-way DX140W-5/DX160W-5
10-2-6
Hydraulic Circuit
Button Type
2 4 5
A2 B2
T A L.H
pb2
T A
P4 Option 373bar@20L/min R.H
4 5
P1 pa2
6 A B
RH-HI LH-HI
ps1
A
T
7 T
P
from Joystick (R) PPC
1 Shear Select operating
A3 A2
Ram Lock
Operating
Hammer
Inching
Cut-off
3
Pilot
X1 SD CH IC PB PS HO
T
C7
X3 C6
X1 C1 C2 C3 C4 C5
P1
A1 P2 P3 GTS
Reference Reference
Description Description
Number Number
1 Main Pump 5 Stop Valve
2 Control Valve 6 EPPR Valve
3 Solenoid Valve 7 EPPR Valve (Two-way)
4 Pressure Proportional Relief V/V
DX140W-5/DX160W-5 Two-way
10-2-7
Pedal Type
2 4 5
A2 B2
T A L.H
pb2
T A
P4 Option 373bar@20L/min R.H
P1 pa2
4 5
8
P
T P
A B
RH-HI LH-HI
2way Pedal T
1 2 7
LH-high from Joystick (R) PPC
RH-high
Shear Select operating
A P
1
A3 A2
Ram Lock
Operating
A
Hammer
ps1 T
Inching
Cut-off
3
P Pilot
X1 SD CH IC PB PS HO
T
C7
6
X3 C6
X1 C1 C2 C3 C4 C5
P1
A1 P2 P3 GTS
Reference Reference
Description Description
Number Number
1 Main Pump 6 EPPR Valve
2 Control Valve 7 EPPR Valve (Two-way)
3 Solenoid Valve 8 Two-way Pedal Valve
4 Pressure Proportional Relief V/V 9 Two-way Pedal Safety Valve
5 Stop Valve
Two-way DX140W-5/DX160W-5
10-2-8
Caution for Installation
• When you install piping, make sure there is no foreign
substance inside piping sub-parts such as hoses, pipes,
valves and fittings.
• Prior to installing piping:
A. Park on firm and level ground.
B. Lower front attachment (bucket) to ground.
C. Stop engine.
D. Move safety lever to "RELEASED" (UNLOCKED)
position.
E. Turn starter switch to "I" (ON) position.
F. Fully stroke work levers (joysticks) in all directions to
relieve any pressure from accumulators.
G. Move safety lever to "LOCK" position.
H. Turn key to "O" (OFF) position and remove from
starter switch.
I. Attach a maintenance warning tag on controls.
CAUTION
AVOID INJURY
Release any pressure in the hydraulic oil tank before work.
DX140W-5/DX160W-5 Two-way
10-2-9
INSTALLATION PROCEDURE
Install the parts as below pictures and needed parts refer to parts book.
FR
ON
T
BOOM
1-2
1-1
13
7
13
12
3
A
1 13 4
8
MAIN FRAME 10
9
13
T
12
6
OIL COOLER PIPE
13
B2
11
5
13
CONTROL VALVE
WE1401527
Figure 6
Two-way DX140W-5/DX160W-5
10-2-10
Reference Reference
Description Description
Number Number
1 Valve, Relief; Proportional 7 Tee
1-1 Valve, Relief; Proportional 8 Bolt M10 x 1.5 x 75
1-1 Coil; 24 V 9 Washer, Spring
2 Hose Assembly, Hydraulic 10 O-ring
3 Hose 11 O-ring
4 Adapter 12 O-ring
5 Adapter 13 O-ring
6 Tee
DX140W-5/DX160W-5 Two-way
10-2-11
Main Piping - Two-way
FR
ON
T
BOOM
1-2
51
1-1
11
51 6
11
10
1 A 21
8 a
7
T
22
11
10
A a
4
MAIN FRAME
T 2
21
22
A2
9
5
11 CONTROL VALVE
WE1401509
Figure 7
Two-way DX140W-5/DX160W-5
10-2-12
Reference Reference
Description Description
Number Number
1 Valve, Relief; Proportional 7 Bolt M10 x 1.5 x 75
1-1 Valve, Relief; Proportional 8 Washer, Spring
1-2 Coil; 24V 9 O-ring
2 Hose 10 O-ring
3 Hose Assembly, Hydraulic 11 O-ring
4 Adapter 21 Plate, Mounting; Mono
5 Adapter 22 Bolt; Set
6 Tee 51 Hose
DX140W-5/DX160W-5 Two-way
10-2-13
Pilot Piping - One or Two-way
FR
OIL TANK ON
T
21
11
23
CONTROL VALVE
X1 MAIN PUMP
5
(6 )
pb2 ps1
16
22 OUT
24
8 14
23
13
23
(4 )
(5 )
3 2
6 9 2-1
MAIN FRAME 17 23
19 A
T
CONTROL VALVE 12
21
(Port pb2) P
(7) 15
18 21 2
1 10
HO
20 23
1
1-2
1-2
1-1
1-3
MAIN FRAME
WE1401505
Figure 8
Two-way DX140W-5/DX160W-5
10-2-14
Reference Reference
Description Description
Number Number
1 Valve, Solenoid; (4-sol) 11 Adapter
1-1 Spool, Solenoid 12 Elbow
1-2 Check 13 Elbow (90)
1-3 Coil 24V 14 Tee
2 Valve, EPPR 15 Bolt; Set
2-1 Valve; EPPR 16 Bolt
3 Bracket 17 Bolt
4 Hose Assembly, Hydraulic 18 Bolt
5 Hose 19 Washer, Spring
6 Hose Assembly, Hydraulic 20 Washer, Spring
7 Hose Assembly, Hydraulic 21 O-ring
8 Clip 22 O-ring
9 Valve, Shuttle; (Orifice 0.9) 23 O-ring
10 Adapter, Filter 24 O-ring
DX140W-5/DX160W-5 Two-way
10-2-15
Pilot Piping - Two-way
FR OIL TANK
ON
T
5
ACCEL 10
PEDAL VALVE 12
65
T 58
67
3
8
53
CONTROL VALVE
67
58 55
65
51 6
62 67 58 11
P 12
61 57
65 65 65 Pb2
60
T T
B T 2
A 67 P
67 59 66
64 65 52
11
58 6
PT BLOCK Pa2
63 67
54
12
12
56 1
4
51
HO 51-1
7
4-SOLENOID VALVE
WE1401510
Figure 9
Two-way DX140W-5/DX160W-5
10-2-16
Reference Reference
Description Description
Number Number
1 Hose Assembly, Hydraulic 53 Hose Assembly, Hydraulic
2 Hose Assembly, Hydraulic 54 Hose Assembly, Hydraulic
3 Clip 55 Hose Assembly, Hydraulic
4 Adapter, Connector 56 Hose Assembly, Hydraulic
5 Elbow 57 Plug
6 Elbow 58 Adapter
7 Tee, Shuttle Valve 59 Adapter
8 Bolt 60 Elbow
9 Nut 61 Elbow
10 O-ring 62 Elbow (90)
11 O-ring 63 Bolt
12 O-ring 64 Washer, Spring
51 Valve, EPPR; Dual 65 O-ring
51-1 Valve, EPPR 66 O-ring
52 Hose Assembly, Hydraulic 67 O-ring
DX140W-5/DX160W-5 Two-way
10-2-17
Pilot Piping - Two-way (Pedal)
5
FR
4 7
ON
T
31
37
14
37
32 40
ACCEL 23
30
PEDAL VALVE
36 38 T
3 T 26 23 38 38
6 1 1
FLOOR 33 P
PLATE 34
37 A
38 21 40 40 38
40 28 21
T 1-2
P 40
13
8 38 1-1
41 19
21
38 40 17
20 18
11 40 2
19 40 21 40
41 8 38 40
42 16 21 2-1
P 27 38
24
39 T
38 2 40 P
23 T 21 38
35 AB 25 T
40 22 P
40 39
11
29
10 PT BLOCK
9
12
CONTROL VALVE
15
Pb2
Pa2
4-SOLENOID VALVE
WE1401511
Figure 10
Two-way DX140W-5/DX160W-5
10-2-18
Reference Reference
Description Description
Number Number
1 Valve, Solenoid 21 Adapter
1-1 Spool, Solenoid 22 Adapter
1-2 Coil 24V 23 Elbow
2 Valve, EPPR; Dual 24 Elbow
2-1 Valve, EPPR 25 Tee, Shuttle Valve
3 Valve, Pedal 26 Tee
4 Bracket 27 Tee
5 Rubber; Pedal 28 Bolt M8 x 1.25 x 60
6 Plate, Lock 29 Bolt
7 Plate 30 Bolt; Socket M8 x 1.25 x 25
8 Switch; Pressure 31 Bolt; Socket
9 Hose Assy, Hydraulic 32 Bolt; Socket
10 Hose Assy, Hydraulic 33 Bolt; Socket M10 x 1.5 x 30
11 Hose Assy, Hydraulic 34 Washer, Spring
12 Hose Assy, Hydraulic 35 Washer, Spring
13 Hose Assy, Hydraulic 36 Washer; Spring
14 Hose Assy, Hydraulic 37 Washer; Spring
15 Hose Assy, Hydraulic 38 O-ring
16 Hose Assy, Hydraulic 39 O-ring
17 Hose Assy, Hydraulic 40 O-ring
18 Hose Assy, Hydraulic 41 Harness
19 Reducer 42 Tie, Cable; Coupler
20 Adapter
DX140W-5/DX160W-5 Two-way
10-2-19
Boom Piping - One or Two-way
NOTE: This is for Boom 4.4 m.
4 FR
8 ON
7 T
3 6
7
6 15
A
15 6
7
6 1
A 7
13
14
2
13 12
Ḻ#
14 5 BOOM A
12 11
5
8
11
WE1401507
Figure 11
Two-way DX140W-5/DX160W-5
10-2-20
Reference Reference
Description Description
Number Number
1 Pipe 8 O-ring
2 Pipe 11 Clamp, Pipe
3 Pipe 12 Clamp, Pipe
4 Pipe 13 Bolt
5 Rubber; Pipe 14 Washer; Spring
6 O-ring 15 Pipe
7 Bolt; Socket
DX140W-5/DX160W-5 Two-way
10-2-21
Arm Piping - One or Two-way
NOTE: Tihis is for Arm 2.1 m.
FR
ON
T
4
5 9
5
3 BOOM
1
7
8
5 10
9 5
4 6
52
52-6
1
52-1
52-2 52-7
7
52-3
6 52-5
51
52-4
51-1
10
51-2 51-7
8 51-6
51-3
51-5
51-4 ARM
WE1401508
Figure 12
Two-way DX140W-5/DX160W-5
10-2-22
Reference Reference
Description Description
Number Number
1 Pipe Assembly, Hydraulic 51-3 Adapter
2 Hose 51-4 Cap
3 O-ring 51-5 O-ring
4 Bolt 51-6 Plug
5 Clamp; Pipe 51-7 O-ring
6 O-ring 52 Valve Assembly, Stop; (RH)
7 Bolt; Socket 52-1 Valve, Stop; (RH)
8 Bolt; Socket 52-2 O-ring
9 Washer; Hardened 52-3 Adapter
10 Washer; Spring 52-4 Cap
51 Valve Assembly, Stop; (LH) 52-5 O-ring
51-1 Valve, Stop; (LH) 52-6 Plug
51-2 O-ring 52-7 O-ring
Air Bleeding
1. Start the engine and run at low idle.
2. Operate the joystick lever and actuate the hydraulic
cylinder 4 ~ 5 times very slowly about 100 mm before the
end of stroke.
3. Operate the rod of cylinder to the end of stroke to relieve
the hydraulic piping.
(The air breather of oil tank is actuated to bleed the air.)
DX140W-5/DX160W-5 Two-way
10-2-23
COMPLETING WORK
Two way line overload relief valve can be changed from the
monitor (range 250 ~ 350 bar (255 ~ 356 kg/cm2)).
Set to 350 bar (356 kg/cm2). Check the pressure at maximum
flow.
(If maximum control pressure is out of tolerance, check EPPR
current)
• Flow setting valve (EPPR valve): 260 ±10 L/min (69 ±2.6 U.S. gal)
• EPPR valve set: 315 mA
Two-way DX140W-5/DX160W-5
10-2-24
Rotating
Edition 1
DX140W-5/DX160W-5 Rotating
10-3-1
MEMO
Rotating DX140W-5/DX160W-5
10-3-2
Table of Contents
Rotating
Safety Instructions ........................................10-3-5
General .........................................................10-3-5
General Description................................................. 10-3-5
Theory of Operation ................................................ 10-3-5
Structure.................................................................. 10-3-6
Hydraulic Circuit ...................................................... 10-3-7
Caution for Installation............................................. 10-3-8
Installation Procedure .................................10-3-10
Main Piping - Rotating ........................................... 10-3-10
Pilot Piping - Rotating............................................ 10-3-12
Boom Piping - Rotating ......................................... 10-3-14
Arm Piping - Rotating ............................................ 10-3-16
After Installation Precautions................................. 10-3-17
Air Bleeding ........................................................... 10-3-17
Completing Work ........................................10-3-17
DX140W-5/DX160W-5 Rotating
10-3-3
Rotating DX140W-5/DX160W-5
10-3-4
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
General Description
When an attachment such as a crusher or a shear is used, an
optional rotating mechanism is provided according to the task
needed to be performed with the attachment.
EX1301491
Figure 1
Theory of Operation
When a thumbwheel switch located on the left joystick lever is
moved, the switch output signal (1.0 V ~ 4.0 V) supplies a
current to the rotating EPPR valve through the EPOS controller
and a control valve for rotating is controlled.
Moving thumb wheel right side is for clockwise rotation and
moving thumb wheel left side is for counterclockwise rotation.
Thumbwheel switch voltage output → EPOS controller input →
EPOS controller current output → rotating EPPR valve current EX1403215
supply → control valve spool variable supply. Figure 2
DX140W-5/DX160W-5 Rotating
10-3-5
Structure
P (40 bar)
A B
RH-HI LH-HI
T
Current
EPOS Controller
Voltage
Joystick
(Left-hand)
WE1401067
Figure 3
Rotating DX140W-5/DX160W-5
10-3-6
Hydraulic Circuit
Attachment
L.H R.H
A
100 bar
3 B
P
100 bar
A B pb pa
RH-HI LH-HI
T
2
80 bar
from Joystick (L) PPC
P T
Main Pump
1
WE1401068
Figure 4
Reference Reference
Description Description
Number Number
1 Gear Pump (Rotating) 3 EPPR Valve
2 Control Valve (One Spool)
DX140W-5/DX160W-5 Rotating
10-3-7
Caution for Installation
• When you install piping, make sure there is no foreign
substance inside piping sub-parts such as hoses, pipes,
valves and fittings.
• Prior to installing piping:
A. Park on firm and level ground.
B. Lower front attachment (bucket) to ground.
C. Stop engine.
D. Move safety lever to "RELEASED" (UNLOCKED)
position.
E. Turn starter switch to "I" (ON) position.
F. Fully stroke work levers (joysticks) in all directions to
relieve any pressure from accumulators.
G. Move safety lever to "LOCK" position.
H. Turn key to "O" (OFF) position and remove from
starter switch.
I. Attach a maintenance warning tag on controls.
CAUTION
AVOID INJURY
Release any pressure in the hydraulic oil tank before work.
Rotating DX140W-5/DX160W-5
10-3-8
DX140W-5/DX160W-5 Rotating
10-3-9
INSTALLATION PROCEDURE
Install the parts as below pictures and needed parts refer to parts book.
FR
ON
T
BOOM
16 33
29 23
25
1
3
101
101
30
OIL COOLER PIPE
MAIN PUMP 12
34
2 9
7 21
27
17 pa 10
24
22 21
6 10
31
8 B A
T P
28
29
16
8
32 18
14 33
33
FRAME
WE1401512
Figure 5
Rotating DX140W-5/DX160W-5
10-3-10
Reference Reference
Description Description
Number Number
1 Pump, Gear 19 Bolt; Set
2 Valve; One Spool 20 Bolt; Set
3 Power Take Off 21 Bolt
4 Bracket 22 Bolt; Socket M8 x 1.25 x 25
5 Bracket, Support; One Spool 23 Bolt; Socket M10 x 1.5 x 30
6 Hose 24 Washer, Spring
7 Hose Assembly, Hydraulic 25 Washer, Hard; M10
8 Hose 26 Nut
9 Hose 27 O-ring
10 Clip 28 O-ring
11 Adapter; Connector 29 O-ring
12 Adapter 30 O-ring
14 Adapter 31 O-ring
15 Adapter 32 O-ring
16 Elbow 33 O-ring
17 Elbow 34 O-ring
18 Elbow 101 Hose
DX140W-5/DX160W-5 Rotating
10-3-11
Pilot Piping - Rotating
FR
ON
T
FLOOR PLATE
15 8
13
T
12
P 11
1 A B
13 13
13 7
6 15
6
2 15
15
1
1-1
15 10 3
15
14
T
P
9 16
14
PT BLOCK
5
pb
pa
ONE SPOOL VALVE
Figure 6
WE1401526
Rotating DX140W-5/DX160W-5
10-3-12
Reference Reference
Description Description
Number Number
1 Valve, EPPR; Dual 9 Tee
1-1 Valve, EPPR 10 Tee
2 Hose Assembly, Hydraulic 11 Bolt
3 Hose Assembly, Hydraulic 12 Washer, Spring
4 Hose Assembly, Hydraulic 13 O-ring
5 Hose Assembly, Hydraulic 14 O-ring
6 Adapter 15 O-ring
7 Adapter 16 O-ring
8 Elbow
DX140W-5/DX160W-5 Rotating
10-3-13
Boom Piping - Rotating
NOTE: This is for Boom 4.4 m.
FR
ON
T
9
a
9
a
b
3
b 7 8
b
4 b
7
b
8
b 2
BOOM
a b c
c
6
10 5
14
5 11
12 5
13
WE1401513
Figure 7
Rotating DX140W-5/DX160W-5
10-3-14
Reference Reference
Description Description
Number Number
1 Pipe Assembly, Hydraulic 8 Bolt; Socket M8 x 1.25 x 45
2 Pipe Assembly, Hydraulic 9 O-ring
3 Pipe Assembly, Hydraulic 10 Clamp, Pipe
4 Pipe Assembly, Hydraulic 11 Clamp; Pipe
5 Washer; Spring 12 Bolt
6 Bolt 13 Bolt
7 O-ring 14 Clamp; Pipe
DX140W-5/DX160W-5 Rotating
10-3-15
Arm Piping - Rotating
NOTE: This is for Arm 2.1 m.
T
ON
FR
BOOM
2
2
3
4
6
1
5 5 6
4
1
ARM
12
11 12
9
8
7 11
10
101
8
102 7
104 101
103 102
104
103
Figure 8 WE1401040
Rotating DX140W-5/DX160W-5
10-3-16
Reference Reference
Description Description
Number Number
1 Pipe Assembly, Hydraulic 9 Valve; Switch (RH)
2 Hose 10 Valve; Switch (LH)
3 O-ring 11 O-ring
4 Bolt 12 Bolt; Socket
5 Clamp; Pipe 101 O-ring
6 Washer; Spring 102 Elbow
7 Bolt 103 Cap
8 Washer, Spring 104 O-ring
Air Bleeding
1. Start the engine and run at low idle.
2. Operate the joystick lever and actuate the hydraulic
cylinder 4 ~ 5 times very slowly about 100 mm before the
end of stroke.
3. Operate the rod of cylinder to the end of stroke to relieve
the hydraulic piping.
(The air breather of oil tank is actuated to bleed the air.)
COMPLETING WORK
• Control valve (rotating) pressure check (main relief): 80 bar
(81.6 kg/cm2)
• Left joystick pilot pressure check: 31 bar (31.6 kg/cm2)
DX140W-5/DX160W-5 Rotating
10-3-17
Rotating DX140W-5/DX160W-5
10-3-18
Quick Coupler
Edition 1
Quick Coupler
Safety Instructions ........................................10-4-5
General .........................................................10-4-5
General Description................................................. 10-4-5
Theory of Operation ................................................ 10-4-5
Hydraulic Circuit ...................................................... 10-4-6
Caution for Installation............................................. 10-4-7
Quick Coupler Operation ..............................10-4-8
Securing Work Tool................................................. 10-4-8
Attaching Quick Coupler to Excavator..................... 10-4-8
Releasing the Work Tool ....................................... 10-4-10
Installation Procedure .................................10-4-12
Main Piping - Quick Coupler.................................. 10-4-12
Electric Parts - Quick Coupler ............................... 10-4-13
Boom Piping - Quick Coupler ................................ 10-4-14
Arm Piping - Quick Coupler................................... 10-4-16
After Installation Precautions................................. 10-4-17
Air Bleeding ........................................................... 10-4-17
Completing Work ........................................10-4-17
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
General Description
Quick Couplers are attachments installed at the outer end of the
work equipment of various types of construction and earth-
moving machines. They facilitate the shorter time exchange of
working tools, buckets and etc.
Figure 1
Theory of Operation
1. LOCK
When the quick coupler switch on the right control stand is
operated, a flow path will form according to the movement
of the spool on the quick coupler solenoid valve, and
pressure from the pump will be applied to the cylinder of
the quick coupler, moving the quick coupler in a locking
direction.
2. UNLOCK
When the quick coupler switch of the right control stand is EX1301517
operated, a flow path will form because of the movement of Figure 2
the spool of the quick coupler solenoid valve, and pressure
from the pump will be applied to the cylinder of the quick
coupler, moving the quick coupler in an unlocking direction.
Quick coupler only operate over 280 bar pressure of bucket
crowd.
B7 3
B2
A2 A7
pb2 pa2 pa7 pb7
P4 Option Bucket
P1 P3 P2
2 2 1
B A B A
A3 A2
245bar 245bar X1
274bar 274bar
P2 P2
X3
X1
T P1 T P1 A1
WE1401120
Figure 3
Reference Reference
Description Description
Number Number
1 Main Pump 3 Bucket Cylinder
2 Quick Coupler Solenoid Valve 4 Control Valve
CAUTION
AVOID INJURY
Release any pressure in the hydraulic oil tank before work.
WARNING
AVOID DEATH OR SERIOUS INJURY
The following safety instructions are for your safety, the
safety of bystanders, and to prevent property damage. Read
the descriptions before using the machine and make sure
you are familiar with all safety notices.
Hydraulic quick couplers must be installed, operated,
inspected, serviced, maintained and repaired by qualified,
appropriately trained and experienced people only.
Ensure that work tool or bucket is not carrying a load. If
work tool or bucket is on unstable position or carrying a
load, it can cause serious accident.
The buzzer will sound unless the coupler is not locked.
Perform physical test by dragging the attachment on the
ground to confirm the coupler pins are engaged.
• Do not operate the machine if there are other workers
or people in the work area. Also, never allow people to
stand or pass under the bucket or attachment for any
reason.
• Do not start or perform any work unless you are
property trained. You should understand how to use
the device according to the instructions.
• Make sure that device is correctly and securely
engaged every time you change working tools or
attachments.
• Perform the recommend daily check for safe
operation.
EX1300731
Figure 4
1
2
EX1300732
Figure 5
EX1300734
Figure 7
Push Type
Pull Type
EX1300735
Figure 8
EX1300737
Figure 10
<LOCK>
O I
EX1300738
Figure 11
BOOM FR
ON
T
(6 )
51 CONTROL VALVE
105 106
103
104
23 20
17 A7
P3
11 101 105
23 17
102
104
( 101)
16 8
2 13 24 8
23 21
P1 T 23 OIL COOLER PIPE
P2
1 15
9 21 14
6 4
1-2
B 19 18
3 22
A
12
1 24
21
10 23
17 CONTROL VALVE
1-1 SUPPORT
7
1-3
MAIN FRAME
WE1401514
Figure 12
T 1
N
FRO 3
CONTROL STAND(R.H)
Figure 13 WE1401042
Reference Reference
Description Description
Number Number
1 Switch; Lockout Toggle 3 Name Plate; Quick Clamp
2 Harness; Joint
10 FR
7 8 10 ON
T
2
10 7
5 8 10
1
16
14 16
14
16
14
1 14
BOOM
14
14
1 10
3
10
3
4
6
13
12 6
10
WE1401515
Figure 14
O NT
FR
BOOM
7
8 3
5
4
7
9
8
5
4
8
5
4
1
ARM
2
6
7 6
7
5
4
Figure 15 WE1401516
Air Bleeding
1. Start the engine and run at low idle.
2. Operate the joystick lever and actuate the hydraulic
cylinder 4 ~ 5 times very slowly about 100 mm before the
end of stroke.
3. Operate the rod of cylinder to the end of stroke to relieve
the hydraulic piping.
(The air breather of oil tank is actuated to bleed the air.)
COMPLETING WORK
• The quick coupler switch and the installation state of the
pipes can be verified with the eye.
• High-pressure can be checked using the push/pull type
quick coupler.
Edition 1
Two Pump
Safety Instructions ........................................10-5-5
General .........................................................10-5-5
General Description................................................. 10-5-5
Theory of Operation ................................................ 10-5-5
Hydraulic Circuit ...................................................... 10-5-6
Caution for Installation............................................. 10-5-7
Installation Procedure ...................................10-5-8
Main Piping - Two Pump ......................................... 10-5-8
Pilot Piping - Two Pump ........................................ 10-5-10
After Installation Precautions................................. 10-5-11
Air Bleeding ........................................................... 10-5-11
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
GENERAL
General Description
To prevent decreases in operational speed because of an
insufficient flow rate when an attachment such as a crusher is
used, a two-pump system in which an additional valve is
installed and lines drive side and idle side which can be
(optionally) supplied to supplement an insufficient flow rate.
Theory of Operation
When a set flow rate of an attachment is 1 pump (about 167 L/min)
or greater:
The two-pump solenoid valve is moved, and thus the drive side
pump's oil flows through the two-pump flow valve to join the idle
side pump's oil in the OPT spool.
Attachment
A2 B2
T2
5
ps2
pcc
Option Arm 2
P4
P1 P3 P2
3
B
T P
A
6
A
4
P
T
A3 A2
Ram Lock
Operating
Hammer
Inching
Cut-off
Pilot
X1 SD CH IC PB PS HO
1
C7
X3 C6 2
X1 C1 C2 C3 C4 C5
P1
A1 P2 P3 GTS
Reference Reference
Description Description
Number Number
1 Main Pump 4 Solenoid Valve (Two Pump)
2 Solenoid Valve 5 Control Valve
3 Two Pump Flow Valve 6 Shuttle Valve
CAUTION
AVOID INJURY
Release any pressure in the hydraulic oil tank before work.
FR
ON
T
OIL COOLER PIPE
102 108
103
107
104
108
107
105
101
11
7
5
13 2
13
8
13
A
6
12
3
10
12
9
6
13
Figure 2 WE1401517
FR
ON
T
1-2
20
15
1-1 21
13
CONTROL VALVE 21
21
53
52 pcc
P 54
PT BLOCK
DR1
PILOT
VALVE OIL TANK
3
A
4
7
9 8
21 21 21
17 10 15 16
51 21
18 20
19 14 A 21
T 20
20 20
21 10
19 21 P
JOINT SUB ASS’Y P 2
1
11
21 STOP VALVE
5 6
T
20
12
21
Figure 3
WE1401518
Air Bleeding
1. Start the engine and run at low idle.
2. Operate the joystick lever and actuate the hydraulic
cylinder 4 ~ 5 times very slowly about 100 mm before the
end of stroke.
3. Operate the rod of cylinder to the end of stroke to relieve
the hydraulic piping.
(The air breather of oil tank is actuated to bleed the air.)
Edition 1
Ø1.0
A
EASY BOOM 68
A RIGHT LEFT B 245 bar 98 bar
LH A
20 from C/V A2 ONE-WAY 53 54 56 59
T
98 bar
TWO-WAY 53 54 55 56 59
RH A B Tr4
21 ROTATING 63 64 65
PA PB
par1 2(#60) 55 60
C 50 bar
OPT 2 23 HO(#04)
pa2 pb(#63) pa(#63) 59 QUICK COUPLER 66 67
pbr1 1(#60) P T P P T P
PRESS. DR2 AR1 UP A B ARTI. BOOM 57 58 60
270 bar 270 bar SENSOR LH
DR1 373 bar@20L/min BR1 DOWN T1 2 2
2(#59) A B 1(#59) RH-HI LH-HI TWO PUMP
T1 T2 61 62
RH-HI LH-HI
X(REAR) C2 C2 (CLOSE) (OPEN)
DB
ps1 of Pump T2
P
T 1 ARTI. PEDAL T 64 1
RH
OPT. PEDAL
(PE3C)
PG ps2 E E 1 1 2
2
pc1 70 from JOYSTICK(R) PPC DOWN UP from JOYSTICK(L) PPC
A(#43) T1
pcc 70 Shear Select operating prb1 pra1
DUMP A5 CROWD B(#55) A(#55)
SH ARM 2 Pi1 Pi1
CROWD B5 ARM 1 pb9 T2 1. MAIN PUMP
A3(#18) T T
pb5 P
PRESS.
SENSOR
A3(#18)
373 bar@20L/min pa9 DUMP 52 V2 V2 69 2. PILOT FILTER
pa9 pa5 17 A 3. ACCUMULATOR (for PILOT)
50 bar
A8(#18) pa5 373 bar@20L/min
pc2
A1(#18) 52 P-T BLOCK
4. 4-SOLENOID VALVE
pc3 A8
B8
16 TS(#06)
A
T
P3(#06) P
5. SOLENOID VALVE (for TM)
LH B4 P
pa8 pb4 BOOM 1 pb8 DOWN 68 P(#43) 6. 4-SOLENOID VALVE
A10(#18)
B A Accelerator T 7. STEERING & BRAKE PUMP
pa4 BOOM 2 pa8 UP
pa4 Pedal Valve 8. STEERING UNIT
A B3 B7 P2(#66) (DOWN) 1 14
9. PRIORITY VALVE
56 54 A5(#18) pb3 A3 BUCKET A7
A2(#18)
T P P(#62) PS(#04) T P
15
SWING pb7 DUMP 10. BRAKE FILTER
A7(#18) pa3 A6(#18) (UP) 2
pa7 CROWD 11. BRAKE SUPPLY VALVE
T B2 373 bar@20L/min 373 bar@20L/min
PRESS. C 12. ACCUMULATOR (for BRAKE)
HO(#04) A2 B6 DOWN SENSOR 2 2
OPT 1 P T 2 13. BRAKE PEDAL
T pb2 DOZER A6 UP 50 bar 1 3 1 3 L R
P4 A7(#18)
SWING ARM BOOM BUCKET
235-255 bar
14. JOYSTICK VALVE (LH)
56 54 B(#55) pa2 pb6
41
T1 T2 P 4 1 3 2 4 2 4 1 3 4 15. JOYSTICK VALVE (RH)
FWD B1 A9(#18) LEFT DUMP DOWN CROWD
pa6 A1(#18) RIGHT CROWD UP DUMP 16. JOYSTICK VALVE (DOZER)
REV A1
A PAR(#6) pb1 TRAVEL DRtp 17. ACCELERATOR PEDAL VALVE
RH
PBR(#6) pa1 TRAVEL -PRIORITY 18. JOINT PLATE
Ts3 A(#43)
19. CONTROL VALVE
Ts5 19 Lo : 343 bar@90L/min
ptp
42 20. SWING DEVICE
P(#17)
STANDARD
B VALVE(LEFT) Hi : 363 bar@90L/min VALVE(RIGHT) P3
61 P1 PT PP PA PH P3 P2
T C1 C2 C3 C4 21. BOOM CYLINDER
P P2 22. ARM CYLINDER
T
A(#43) PRESS. P1 23. BUCKET CYLINDER
SENSOR B1 B2 B9 B10 B3 B6 B4 B8 B5 B7
A 50 bar P1(#66)
24. OIL COOLER
pcc(#19) 6 18 25. RESTRICTION VALVE
A PAR PBR PL TS 26. RESTRICTION VALVE
FWD REV
62 pb1 pa1 A(#17)
A1 A2 A9 A10 A3 A6 A4 A8 A5 A7
27. RETURN FILTER
P pc2 pb7 pa6 pa4 pb5 pa7 pb6 pa5 pb3 pa3 28. AIR BREATHER
P-T BLOCK
P(#68) pb9 29. HYDRAULIC OIL TANK
T
30. CENTER JOINT
175-185 bar
31. TRAVEL MOTOR
43 32. TRANSMISSION
P P
8 33. FRONT AXLE
PI T
0.75 L A(#55) C1
34. REAR AXLE
3
10 bar 5 35. CHOCKING CYLINDER
A(#17) P T LS
36. DOZER BLADE (FRONT)
2 P-T BLOCK pb2(#19) P
4 SD CH IC PB PS HO 3 bar 37. STABILIZER(REAR)
IN OUT ptp(#19) A 38. 1-SOLENOID VALVE (for FR-DZ.)
T
C7 pcc(#19) 39. 2-SOLENOID VALVE (for RE-OR.)
C6
P(#61) 40. CHOCKING VALVE
A3 T B(HIGH) K(LOW) 41. SHOCKLESS VALVE (for BOOM DOWN)
ps1 C1 C2 C3 C4 C5 42. SHOCKLESS VALVE (for ARM DUMP)
P1 CF EF
X(REAR) 43. PILOT VALVE
of Pump
P2 GTS
A
P3
26 bar PRESS. 10
53 TRANSMISSION SENSOR
PRESSURE 3 3 1 1 3 3 1 1 3 3 1 3 1 30 47±4 bar LS 51. LOCK VALVE(for ARM)
WARNING 8 8 1 1 2 2 8 8 4 4 8 8 2 4 4 AUTO RAM P 52. LOCK VALVE(for BOOM)
R3 4 5 14 13 11 10 8 9 3 15 7 6 1 12 2 OPERATE 9 53. PROPORTIONAL VALVE(for OPT FLOW CONTROL)
R1 P T 35 54. PROPORTIONAL VALVE
26 65 3.5 bar 55. PROPORTIONAL VALVE(for PE3C)
24 P(#63) 56. STOP VALVE
GEAR PUMP B(HIGH) GP 57. ARTI. BOOM CYLINDER
25 32 58. LOCK VALVE(for ARTI. BOOM)
M2 PRESS. SENSOR 490 bar
K(LOW) 5 bar
13 2x0.75L
65 bar
LOW 59. PEDAL VALVE(for PE3C)
CHOCK
OPTION
A2 RELEASE 30 bar PRESSURE
2.5 bar WARNING 60. PEDAL VALVE(for ARTI. BOOM)
M CRUISE AB PSA PSD
(REAR) X(IC) 12 AC
61. TWO PUMP FLOW VALVE
28 1.51 bar Vgmax
G
U T1 MB GEXT 4.6 bar
BL1
ACC'B 62. 1-SOLENOID V/V(for TWO PUMP)
27 ENGINE Vgmin
X1 GP Pi BL BR1 T1 ACC'A C4 C5 63. ROTATING VALVE
GP J B DOZER C3
DL06 M (FWD) P1 GP G1 64. PROPORTIONAL V/V(for PERO)
P1 160 bar
65. ROTATING PUMP
10u qmax
qmin
S STEER
CYLINDER
RELEASE C1 C6 C2 11 66. QUICK COUPLER VALVE
29 7 Ma A
(REV)
Y BR CRUISE
67. QUICK COUPLER
X3 BL2 103 bar BRAKE
CHOCK 4.6 bar T 125 bar SUPPLY 68. EASY BOOM VALVE
177u Vgmax MA T2
T2 M3 BR2 VALVE
Vgmin
ps2 M2 40 P2
69. 1-SOLENOID V/V(for OPT.PEDAL)
1 to C/V
X2 31 GP 70. SWITCH VALVE(for CLAMSHELL)
REAR AXLE (TU)
X1 BRAKE FRONT AXLE
(FRONT) C BRAKE
C
M 38
A1 A
PRESS. SENSOR 490 bar
M1 Ø0.5
33 36
R2 S
37 34 Ø0.5
T
T Serial Number 1001 and Up
Ø0.5
A 39 WE1401480
0.5RG
206A 13 EPOS 48N
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Vcc(+5V) 15D 5 0.85RL
DA2-2
5
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
64B 0.85RG 1.25WR 1.25WR 1
205A 16
14 0.85RG 64C 451C
MICOM EPOS
(RR) 0.85LgY 451B
LAMP SWITCH
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
DA3-1
RADIO ANT. REAR WORKING LAMP 1 2
DA3-2
DMS ANT. 5 TURN SIGNAL (L) 1 338C CN17-1 PILOT CUT OFF SW 1
Vcc(+5V) ( ) 3 4 L1 87a 1.25WR II 327A 4
ECU (CN1) (RL) 17CC NC 327C 0.85Y 3 325C 0.85YG 0.85YG 325A DOZER STAB
0.85BrB
0.85B 30 67C 0.85YG
370B 18 CN7-13(29) 370A LineR CN17 AMP SEAL 12P 184A 87 0 0.85RW COM 325B
66A 66B 0.85WY 0.85WY 2 1 5 (C1)
1.25RG
371B 8 CN7-14(30) 371A 1.25B 0.85RG I 5 0.85RW 328A N0 DA2-1
9 5 1 7 1 LineL 0.5RB REAR CABIN LAMP 1
65B 0.85RG 0.85GY 0.5B 85 86 440B 440A 6 II 310B
17DD
8 2
10 6 2 9 3 372B 6 CN7-15(31) 372A GND
1.25WR PARKING BRAKE SWITCH (OPT)
0.5WR 0.5GrW 0.85WL 310A
0.5RW
11 7 3
(FR) ARM POSITION LAMP(L) FRONT FRONT ARM POSITION LAMP(R) 0.5WR 8 7 0.5B WORK/TRAVEL SWITCH
10 4
11 5
374A 11 CN6-3(3) 374B Ext_Mute Off Control 0.85B HEAD LAMP(L) HEAD LAMP(R) COBO AA1 O(P) 1 315C 0.85BrW 0.85BrB DA6-4
RAM LOCK SW
12 8 4
SPEAKER 87a (OPT) T/S LAMP(L) T/S LAMP(R) (OPT) 1 0.5B 0.85RB 2 0 (T) 3 313B CN17-9 313A 1 5 312C 0.85YG 311A
12 6
HANDSFREE 30 17J 3W 75/70W 75/70W 3W 2 335B 80GG 314A 0.85YG RAM LOCK
21W 21W 3 314B CN17-10 2
2LR
1.25RW 18Y 0.85WR 19Y HEAD LAMP RELAY I
ECU JOINT UREA SUPPLY MODULE 1 24H 65C 0.85RG 80AB 87 0.85WL 0.85LY 339A 3 CN17-7 81B PST Release LOCK 6 311B
(C2)
(LH) IGN+
CABIN LAMP SWITCH 8 I(W) 1 328C CN17-8 328B 312B DA1-3
TML AUTO
3 7
0.85GY 7 0.5B
0.85WY
- + 2
0.85RG
0.85GY
0.5GrR 9 17 406A (FMR) 0.85RW RAM LOCK PRESS. SW
TEL MUTE GND SPEAKER 0.85B 0.5B 85 86 66C 80YY 4
5 340A CN17-11 8 80AA 7 99 0.85B
0.85L
DA9-3 NC 6,12,15,16
0.85OrR
209B 208B 1 6 407A 339D 339C 80HH 311H
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 7 208A
TEL MUTE
0 62B 338D 340E CN17-12 317A 0.85Br 317B
43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
2 210A' 210B (RH)
2B 339B 6 335A 3
4 5
210A 210B' 3 0.5WR 63A 3 2
0.85WL
F L AUDIO+ (FRONT) I 0.5RL 0.5B
0.85RW
0.85RW
0.85WR
312A
0.85WL
0.85GR
0.5BY 17
0.85GL
SIDE T/S LAMP (LH) 1 2 L
DA9-2
209A CN17-6
DA9-1
- + SIDE T/S LAMP (RH)
2RG
COMBINATION SWITCH (LH)
0.85R
0.85R
0.85B
0.85B
0.85B
0.85B
0.85B
62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44
0.85B
3
211A 10 211A' 211B' 4 211B F L AUDIO- 65D 0.85RG II 7 8 14
0.5WR 0.85YG
81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63
20P
HOMOLOGATION RELAY 338E 0.85GL 0.85GR 340D
3 4 311G 0.85Y
1 2
409A' 409B 408B
80I 3
0.5LW (FML) 0.85B 0 62C 0.5B 340B 0.85B E 13
EPOS (CN1) 0.5GrL 409B' 87a 5 0.85B 0.85B 338B 340B SW TURN SIGNAL HEAD LAMP 0.85OrR 0.85OrR 314N
I 1.25RL 11 INCHING
(turn sig)
HAZARD SWITCH
(turn sig)
408A 12 408B'
0.85GR
F L SPK+
30 62D 80BF
0.85GL
1.25RG 64A 6 18Z 342B 341C 342C 341B 19Z
(clearanc)
(clearanc)
2RL II TML N 314L 8 314M
409A 13 2RG 65A 87 10 DA1-2 (C3)
F L SPK- 65E 0.85RG 8 0.85WR 0.85GY 335C CN16-7 17F B 0.5B 3
(high)
(high)
7 0.5WR
(low)
4 0.85G
0.5B 49a DA5-3 0.85G
(low)
106 107 108 109 110 111 112 113 119 120 121
408A' 0.5BW 9
98 99 100 101 102 103 104 105
Signal 411B 1 16 411A SIGNAL(SW) (FL) 0.85B 0.5B 85 86 63B 0.85GR 0.85GR 340A CN16-3 BLINKER UNIT 7
329B
329C
117 118
80B R 322C
90 91 92 93 94 95 96 97
82 83 84 85 86 87 88 89 114 115 116 Signal GND 412B 2 18 412A SIGNAL GND(SW) 0.85GL 0.85GL 338A CN16-1 0.85RW 0.85YG 0.85YG 325A PILOT CUT OFF
2B 2RL L 7 325B
IND+ 413B 6 15 413A IND+ 99 11 FRONT CABIN LAMP (C4)
EPOS (CN2) 0.85WL 0.85WY 184B CN16-4 DA1-1
Mic+ 414B 7 9 414A MIC+ CABIN LAMP RELAY 1 56 3
8P
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 ILL+ 80L 4 7 416A 0.85WL 0.85R 0.85R 0.85R 342D CN16-6 FUSE 2 (3) 0.85LB 48Z BREAKER
GND(Jack) 56a 0.85OrR
2019 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9 ILL- 99 5 5 417A Cable Tx/S RxD 375B 8' CN6-10(10) 375A TxD 0.85WR 0.5WR 0.85RG 67B CN16-8 DA8-1 3 48Y (C1)
21E 21J 1.25RG 1 30 CAR STEREO 4, COMMON ANTENNA, HANSFREE 1
0.85OrR
8P 19 418A Cable Rx TxD 376B 4' CN6-9(9) 376A RxD Bluetooth 1.25RG 0.85GW 0.85B 0 CN16-9 12V POWER 1
45C
15 0.85B 45B
GAUGE (CN7) GAUGE (CN6) 8 419A Cable Tx GND 377B 6' CN6-11(11) 377A GND 5 DA5-1 OUTRIGGER(FL) SOCKET 2R 25A 2 ACC RELAY
CN16-12
0.85GW
CALL SWITCH 0.85RY 0.85B 0 DC/DC 87a
1 1.25W 2 0.85W 343A 1 0 15/1 30 700B
+
(turn sig)
0.85GW
2 21C
(clearanc)
(clearanc)
3 CONVERTER 1
(stop)
8 7 6 5 4 3 2 1 5 4 3 2 1
0.85BR 199B CN16-11 25B
0.85GW
0.5BR
0.85WR
(back up)
0.85RY
0.85B
0.85RY
0.85B
0.85GL
0.85WL
0.85GR
(turn sig)
(back up)
FRONT L 343D 1 2LR 2LR 87
(stop)
JACK ASS'Y 343F 310C 3 I 53c 0.85OrB
0.85WR
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
AUDIO DIODE 38 0.85G 245Z CN16-2 24B 24A 86 85
1.25RW
0.5B 7 8 80S 0.5WR H - 99 0.85OrB 322F 0.85OrB 322G 322A
0.5WR
6 418B Cable Rx 379B 2 CN6-7(7) 379A USB D+ 21F
21K 1.25RG C A B E F D D F E B A C DA5-2 DA5-1
0.5WG 204B 2 0.85LG 198B CN15-10 53b 0.85GrL 2
0.85GrL 1
0.85GrL HI
+
1 176D 0.5Y 3 1.25RY 4 0.85RY 345A 1 0 (1) M 196A 0.85LR 0.85LR 0.85LR 0.85R L 1.25RW 2.5WR
2 21E 0.85BW 165B 48W 2.5R 31B 30 4
11 10 9 8 AUDIO CONTROL PANEL REAR R 345D 345F 10 (INT-2) 87 299A PURGE V/V
2 177D 0.5YB
0.5RG
14 13 12 201B 4 0.85LB 4 201A 198A 0.85LG 1 193A 0.85G 192B
(CN13) 3 I 0
CN7-8(24) 183A Vedio Sig DIODE 40 165C 48X 8 (INT-1) 192A 2 0.85BrW
3 183B 0.5P 7 8 80U 0.5WR 197A 0.85LY +
AIR COMP. CONTROLLER 298C 86 85 0.85BL
3 22E 0.85L 0.85L B RUN STOP
CAMERA (OPT)
0.85GBr
(2) I
4 182B 0.5PB CN7-18(34) 182A Sig Gnd
REAR VIEW
1.25RW
0.5B 195A 12 0.85RB - + 0.85L BEACON SWITCH 26C 0.85RY STOP
SPC SENSOR(1) 488A 0.85GR WIPER MOTOR ROTATING BEACON 0.5BrR 2 296B 4 0.85B 2.5B 2
1 2 3 4
(ARM CROWD) SIG
EPOS CN 1-46 P LOWER WIPER MOTOR 3 0.85YL 696A 3
195C 23D 0.85Or 1 0
SPEED SENSOR
88NA 0.85W I
- EPOS CN 1-10 21N 1.25RG 0.85B OUTRIGGER(RL) WIPER CONTROLLER 2 21B START 2.5B
DIODE ARRAY CCD CAMERA 1 + 0.5WR 8 7
WHEEL
0.5RB 0.5L 186B 186A 3 I GAUGE PANEL CN7-2/JOG SHUTTLE 1 AIR COMP. ASS'Y
1 176B 0.5Y CN7-7(23) 176A V+ 9V 348A 6 0.85RG
82NB 0.85R SIG 0.5RG 195B 23C 80U
+ REAR VIEW 2 177B 0.5YB CN7-17(33) 177A V- 99 0.85B 0.5B 7 8 80E AIR COMP.SWITCH
SPC SENSOR(2) 489A 0.85GR 99 CN7-4(20) 0.5B 0.5RW DIODE 5
3 4 EPOS CN 1-65 CAMERA -
(BOOM UP) SIG 3 178B 0.5YL CN7-10(26) 178A Vedio Sig 99 CN7-3(19) 0.5B
88NB 0.85W
- (K1045037) 0.5WR
4 179B 0.5YW CN7-20(36) 179A Sig Gnd ILL.
1 2
SPC SWITCH 80K
CN6-4(4) 0.5WR
12V POWER SOCKET(OPT) 2RG
O 1 0.5WR
0.85RB 2 69B
DIODE ARRAY FUSE BOX 1-13 0.85Br CN7-16(32) 7G 6G CN7-2(18) 0.85GBr 0.85R 12V POWER
41C I 3 800B 0.85GrR EPOS CN 1-70 START SW (BR/Key-on) START SW (ACC) 2 27A 2L
2RY 1 DC/DC
8 7 0.5B 17GG CN7-6(22) 0.5RW CONVERTER 2 27B + SOCKET
FUSE BOX 2-16 26B 3
4 5 6 7 8 9
80SP 17G CN7-5(21) 0.5RW
1 2 3
10 11 12 13 14 15 16 17 18 19 20
99 -
2B
ALARM RELAY 1
CN7 CN6 87a ALARM RELAY 2
309A 0.85RL
308B 30 0.5WL 308A 87a 2.0B
21 22 23 24
AMP 040 12P+16P 0.5RG
25 26 2728 HANDSFREE UNIT
ECU 87
0.5WB 83A 87
30
1-68 348B 165A 1-61
AUTO IDLE (1)
SENSOR (TRAVEL)
illumination
INJECTOR 80Zxx 86 0.85LgY 2-118 451A 342A 1-53 (BEAM)
0.5Br
85
SOLENOIDS ENGINE VEHICLE 1-03 99 0.85B 0.5B 85 86
TRAVEL 2 PUMP CONTROLLER 0.85R 82B + FUEL HEATER (OPT)
2-49 CONN CONN 171A 1-14
1
2
1-05 99 0.85B 83B CN6-1(1) 7Z 0.85P 171B SIG Py
6 1 INJECTOR1, BANK1 2-73 0.85BL 362V
0.85BrW
99
1.25RW
1-28 0.85B STARTER CONTROLLER
1.25RG
3
0.85BR
-
1.25RW
1.25W
7 2 CN6-12(12)
95B - 309B 0.5BW
0.85R
0.85L
1.25RB
0.5RG
4
0.5RG
2RG
307B 2-117
2RY
2RY
2RL
99
2RL
1-29 0.85B 0.85B PILOT BUZZER HORN 1 HORN 2 472B N S 0.85BW
3 5
6
2-50
99
96B CN6-13(13) 17xxx 0.5RW 1.25B 20B 1.25W STARTER RELAY 1
8 4 INJECTOR2, BANK1 1-52 99 0.85B BACK UP RELAY 62A 67A 69A 81A 82A 17A 20A 21A 22A 23A 26A 700A 15A 12B 87a
7 2-74 97B 1.25RW +
87a H.F L.F
9 5 8
1-75 99 0.85B 9 10 11 12 13 14 1 2 3 4 5 6 7 8 5A 1.25WR 0.85B E 30 0.85Y S
Px 0.85Y 52E 30 87
AUTO IDLE(2)
82C 0.85R 14B 7D
0.85GBr
2-51 + 87 337A 246B 0.85B 246D 0.85B CIGAR LIGHTER 13A 13B
1-76 99 0.85B COMM. ANT. GPS ANT. 0.85RY
30A 20A 20A 15A 15A 30A 10A 10A 10A 10A 10A 30A 10A 10A
85 86
INJECTOR3, BANK1 84B 0.85V 1-33 84A 1.25WR 2WR B P
SENSOR
MICRO PHONE CALL SWITCH 2-75 OVER LOAD WARNING SWITCH SIG
INTER 0.85Y 52xxx 86 85 307A 17 18 2E 15 16
7F
2 362V 0.85BW 1-28 362A 4E 4C 2C 12A 11B
2-25 CONN 2-1 - 87a
INJECTOR1, BANK2 143A 1-09 0.85Or 143B 1 °t SCR DOWNSTREAM 1 0
2 86B 0.5BrY 2-84
ANALOG GND
0.5Y 95C 8 TMS
246A 87
30 334E 0.85RG
5W 5W
0.85Br
V TEMPERATURE SENSOR 86A STARTER RELAY 2
1.25WG
6 5 4 3 2 1
2-01 7
12 11 10 9 8 7 4 1
0.5B 3 I 0.5YB 96C 9
CONTROLLER 1 15X 0.85RL FUSE BOX 2 5W 5W FUSE BOX 1 6A
ACC 87a 0.85BL
3 2
2-26 136A 1-43 0.85RG 136B 2 7 8 3 9F 0.85RW 245A 85 86 334F 0.5RG 15R 212A B
0.5B 80L 0.5WR C 0.85BY
JACK ASS'Y JOG SWITCH INJECTOR2, BANK2 2-02 142A 1-32 0.85Y 142B
6
1 °t SCR UPSTREAM 0.5G 0.5RG 98C 7
4 41F 4F 80AX 4D STARTER
SWITCH
30
87 11A
5 V TEMPERATURE SENSOR TxD 169A 1-42 0.5GL 0.5GL 169A 5 HORN RELAY 15 16 1.25WR 17 18 2B 2WR 1.25WR 10A 10B
139B 82D 0.85R 2 99 0.5G B 86 85 0.5GB
2-27 139A 1-23 0.85G 1 + RxD 168A 1-41 0.5GW 0.5GW 168B 6 20A 20A 10A 10A 10A 10A 10A 10A 30A 20A 20A 20A 30A 30A 147A
1 PRESSURE SENSOR 1-32 0.85B 5B R1
DOSING 87B 0.85BrW 87A 7E 164B
INJECTOR2, BANK2 2-03 138A 1-96 0.85GB 138B 2 VALVE (OWD) SIG 313C 1-62 (TRAVEL SELECT) 0.5BG R2
2 88B 0.85WB ROOM LAMP 1 2 3 4 5 6 7 8 9 10 11 12 13 14
141B - 45A 2-97 (BREAKER OPERATING) (534-00079 ) BR 7A A
141A 1-18 0.85Gr 2 46A 47A 48A 334A 52A 54A 19A 18A 28A 31A 51A 40A 41A 16A 0.85Br
2-58
FUEL METERING
4
°t DOC UPSTREAM(T4) 82E 0.85R 311C (RAM LOCK) OFF 10W
GAUGE PANEL CN7-16
0.5RG
1-72
0.85WR
2.0RG
0.85GrR 140B
2.0RG
+
0.85WL
0.85BrR
0.85RL
140A 1
0.85LB
1-16
0.85Y
0.85BrR
V
2R
2-83 OVER LOAD 0.5B E DR B+ 0.5WL
1.25RB
1.25LR
1.25RL
1.25RL
3 TEMPERATURE SENSOR 89B 0.85GR 89A
UNIT(ZME)
111A 1-62 0.85L
PRESSURE SENSOR(A) SIG 1-34 315A 1-74 (PARKING) STARTER 60B
WIPER MOTOR
2 111B WARNING (OPT) (FRONT PUMP)
- 88PA 0.85W 1-10 88A 329A 2-89 0.85G (INCHING) ON 5X
0.85Br DIODE 2 1.25WG
60R
TANK HEATING
ANALOG GND 330A 2-88 0.85GrR (LOW SPEED) 7B 8A 0.85BrW FUSIBLE LINK
4 3 2 1
VALVE + 82F 0.85R 320A 0.85GrL (HIGH SPEED)
2-114 2WR 2R
PRESSURE SENSOR(B) 91B 0.85GY 91A 2WR
2-11 1 145P SIG 1-15
9 8 6 5
P 363B 3.0bar 0.85WR 5C 2A 1B
7
2-36 0.85WR JOG SHUTTLE
(REAR PUMP) 88PB 0.85WL 363A 2-100 EMERGENCY STEERING PRESS SW 1
0.5G
WIPER SWITCH PANEL RAIL PRESS. -
9C 3 HOUR 2 0.5B
0.85WL 0.85Br 0.85RW
SENSOR V 2-60 UREA SUPPLY MOUDLE POWER AUTO IDLE WORK 82G 0.85R 147B 1-69 0.5BG (KEY SW 'START')
BATTERY RELAY
0.5BG 0.5BG 2R
137A 1-68 0.85RW 137B 2 HOUR METER CIRCUIT BREAKER
1 2 3
135A 1-07 0.85Y 135B 3
P REDUCTION AGENT
WIF SENSOR 93B 0.85LgR 1-38 93A 164A 2-115 0.5GB (START RELAY) 0.5GB 0.5GB
B
1A
4 5 6 2-31 CAMERA DMB - 362V 0.85LgB 8W 8W A
41E 0.85RL
P& 2-35 134A 1-39 0.85L 134B 4 V PRESSURE SENSOR 1-1
OIL PRESS. 41D 1-3 0.85RL 1.25RL 4B 3B 3A
AIR COMP. CONTROLLER SENSOR t° 2-06
95F 3 4 2 1 6D
0.85GBr
133A 1-50 0.85WR 0.85WR 133B 9 96F 99BH START SW (ACC) 9E 1-2 0.5RW ALT 'I' 0.85RW 0.85RW 0.85RW 0.85BrW 8C BR
(ODFT) 0.5Y 0.5Y 1-39 95A
2-13 0.85G 132B 10
V 132A 1-84
M
REDUCTION
0.5YB 0.5YB 1-40
325H 1-55 0.85YG (PILOT CUT-OFF SWITCH) E
AGENT PUMP 96A CAN 0.85Or 0.85Or
2 3
2-07 131A 1-89 0.85BW 131B 8 99 1-4 0.85B
471A
0.85Br 8B 1.25B
4 1
P& 130B 12
SHIELD SHIELD 1-21 97A
99 1-5 0.85B DA7-4
314P 3
2 353A
SOL-VALVE ASS'Y MASTER SWITCH 60R
BOOST PRESS. 2-86 130A 1-85 0.85W 0.85RL 353B
DIODE 1
98A GND 314Q 1 FORWARD(PAR) 0.85BrR
SENSOR t° 2-90 0.85WR 133D 11
UREA 0.5RG 1-23
4 353C
2R
(LDF 6T) REVERTING VALVE 0.5GW 1-24 100A RxD 349A 2-112 0.85BR (FORWARD) 350C 349B 6 DA4-2 60B 1 2 60B 60R
UREA TANK 6 0.85R 5 354A 354C (Fix) 1
2-37 129A 1-02 0.85B 129B 5 2 0.85BR 354B 2 0.85LB
V SUPPLY MODULE 0.5GL 1-43 101A TxD
Fwd.
3 350B 350A 4
0.85Br (Release) 3
481E HEATER 0.5Br 48B 9B
CHECK CONN FUEL SENSOR RS-232 2 0.85L
0.85Or 314R 9 (PBR) 50A
1 8 355A 50B 1
LAN
2-05 0.5GL 101B 471C 0.85RL 355B 50C CABLE
187B 3 314S 7 REVERSE MIC
1 8 THROTTLE PLATE 128A 1-04 0.85BY 128B 1 2 481D
0.85R 1 110B 0.85YR 1-37 110A 1 352B 355C QUICK CLAMP SW
5 40E AMPLIFIER SPEAKER - + - +
2 7
ACTUATOR 2-29 PRESSURE LINE HEATER 0.5GW 100B Rev. 351B 12 DA1-2
6 DIODE 6
M 2 188B 4 88F 0.85BR DA7-1 1.25LR 8 28T 430A 2 0.5GrL 430B + 12V 150AH 12V 150AH
3 6
127B 1 2 481C 0.85R 11 356A 356C 2 0.85Gr 356B
3P
2-34 127A 1-48 0.85LW 0.5RG 98B SOL-VALVE
AUXILIARY F N R SW 352A 10
2P
4 5
SUCTION LINE HEATER 3 352C 0.85LR 0.85B 1 99FR 431A 6 0.5BW 431B - 2RW
THROTTLE POSITION 2-15
126A 1-72 0.85L 0.85L 126B 1 2 481B 0.85R 0.5Y 95E 4 2 351A 2-105 0.85Gr
AUXILIARY TRAVEL SW
(PL)
RELIEF
QUICK CLAMP(OPT) 0.5WR 8W
INTER CONN 1 FEEDBACK SENSOR 2-40 BACK FLOW LINE HEATER 96E (REVERSE) 0.85RL 41L
0.5YB 5 OIL TEMP SENSOR PRESS UP
2R 0.85LB 1.25WG
A/C CONTROL PANEL
0.85WR
DIODE 3
0.5YW 290B 7 43A 2-96 0.85GrW 43B 1
UREA HEATING 362V (OPTION) 28B
1.25RW
4 9
DA4-3
CN10-18 30B
5 8
BARGWARNER N 2-94 AUTO SHUTOFF UNIT 151E 1-20 151Z 357A 2-113 0.85BrB (CRUISE) 357C 3 0.85BrB 357B 28E CN9-5 1.25LR
A
6 7
TURBINE WHEEL 2 CN15 0.5BW
POSITION
SPEED SENSOR 2-78 12 0.85LR RECEIVER DRIER 1.25RB 40C 1.25B SEAT AIR
3 187A 0.85LR 153E 153Z (OPTION) P
INTER CONN 2 0.5B
13 1-29 CN8 CN9
28D 30A
BLOWER SUSPENSION SG
CAN H2 2-17 85 87 360B 360A 50D 1-77 0.5Br (QUICK CLAMP) 0.5Br TRAVEL SPEED SELECT SWITCH AMP 12P + 18P
1.25B 1 START STOP 4 188A 0.85BY 0.5B 106A 14 2-93 RELAY
E
VALIDATION
321B 47C SWITCH SWITCH 49A 2-104 0.85YW (2 PUMP SELECT) 0.85YW 473A 3 0.5L 7 473B
CONTROLLER AREA CAN L2 2-18
F
2 1
441B 1-60 0.5YB (INCHING SPEED SELECT) 0.5YB 441A 9 225A CN8-10 0.5LG CN10-16 225B
IDLE
1 81D CN11-4 R
INTER CONN 3 16E 1-01 0.85R FUEL PUMP
442B 1-78 0.5WB (LOW SPEED SELECT) 0.5WB 442A 2 0.85RB A/C THERMO (LOW) 226A CN9-8 0.5LB CN10-5 226B RELAY
F
2RG
CAMSHAFT SPEED SENSOR 2-43 16G 1-73 0.85R 359D 1-19 PUMP
SENSOR
TEMPERATURE
t ° 2-59 97D 1-10 SHIELD SHIELD
1 359C FLOW CONTROL 0.85B 4
6 57B 0.85LgW 57A - +
V LOW 231A CN9-15 0.5OrR CN10-12 231B DEF (P1)
200A
SENSOR 290A 1-71 0.5YW CAN H1 PROPORTIONAL V/V 0.5RG
2 149A 0.5GB 1-31 149A 60A 2-108 0.85LgR 60B P/V-(B) 232A CN9-14 0.5OrW CN10-13 232B VENT (P2)
2-39 291A 1-95 0.5YL CAN L1 JOYSTICK LEVER SWITCH WORKING LAMP RELAY M
COOLANT t° 3 148B 0.5B 8 4 245B 0.5G
87a 233A CN9-16 0.5YB CN10-11 233B Vref MODE
MODE
TEMPERATURE
V SHIELD HIGH CW 0.5G (ON JOYSTICK L.H) (2) (LS1) (1) 46B 30 2RY ACTUATOR
SENSOR BRAKE OIL 61B 2-109 0.85LgW 61A 0.5Y 0.85RG 185B 2RG 185A 87 234A CN9-17 0.5YW CN10-10 234B MODE F/BACK COMPRESSOR
2-69 1-06 0.85LW PREHEAT SIGNAL 452C 0.85V 2-92 452A 150B 7 3 52F (1) (2)
107B PRESS SW 0.85B
150A 1-73 (ONE TOUCH DECELERATION) (4) (LS2) (3) ROTATING 0.85B 68C 86 85 99 CN9-10 1.25B MAGNET D H 213A
7C 1-69 0.85Br KEY-ON 65bar 0.5BrB 0.5BrB + -
1 2-66 0.5B 0.85LW 29C CLUTCH 146A 15L 213B 15B
115B 0.85BW 1-50 115A 151A 1-20 151B SWITCH (OPT) 185C 0.5RG
N INDICATOR 0.85B 0.5GR 0.5GR 1
0.85BL
2 CW CCW 0.85RG
2-65 1 51E 1.25Br 235A CN9-1 0.5LgW CN10-19 235B WARM (P1) 29B PREHEAT RELAY
CRANKSHAFT SPEED SENSOR 152A 1-66 0.5YB 0.5YB 152B 2 0.85B
V
DIODE 4
SHIELD TANK TANK 4 96D2 0.5YB PILOT FILTER SW 0.85B 116B 0.85BG 1-49 116A 153A 1-29 0.5Y (ANALOG GROUND) 0.5Y 153B 5
1 0 46C 2 236A CN9-18 0.5LgB CN10-3 236B COOL (P2)
M AIR HEATER
LEVEL TEMP 3 95D2 0.5Y CW 0.5RY
154A 1-30 68B 3 I 237A CN9-3 0.5YR CN10-7 237B Vref MIX MIX
0.5LB WORKING LAMP
2 2-68 SIGNAL SIGNAL 2 99 0.85B 117B 0.85RB 1-48 117A 7 80XX 8 0.5WR 238A CN9-4 0.5YW CN10-9 238B MIX F/BACK ACTUATOR 0.85B
RETURN FILTER SW
96D1 0.85YB
N
95D1 0.85Y
0.5B
51F 1.25Br
1 2-67
2B 1.5bar 0.5GR 151C 1 CW OPEN 239A CN9-2 1.25BL CN10-4 239B GND
CAMSHAFT SPEED SENSOR 36C 1-81 0.5GY (BREAKER)
V UREA TANK 2B PEDAL BRAEKER 0.85B 118B 0.85GB 2-85 118A 0.5LB 154B 2 WORKING LAMP SWITCH
SHIELD 99 PRESSURE SW 1 (OPT) CRUISE SWITCH 0.5Y 153C 5
240A CN8-2 0.5OrB CN10-15 240B
DUCT
INTER 0 1 CLOSE
8 11 10 9 PEDAL BRAEKER 0.85B 114B 0.85GR 2-103 114A 444A 3 SENSOR
CONN 2-2 444B 1-80 (CRUISE) 0.5GY 36A 8 4 52G 0.5Y
1 PRESSURE SW 2 (OPT) 0.85RG I 2
0.85RG
(RS1) 241A CN8-1 0.5LgR CN10-14 241B
3 0.5WR 80EK 8 7 0.5B 0.5RY 35A 7 WATER
119B 0.85Lg 2-110 119A 3 32C 0.5BrW
+ 306C 0.85RY SENSOR
2
AMP 40P
NOX SENSOR PROPORTIONAL V/V 302B 1-58 0.5LY (FORWARD TRAVEL) 0.5LY 302A 9 10 52H 0.5Y - 0.85B 306B
5 120B 0.85LgB 2-111 120A 4 52B 242A CN8-5 0.5LY CN10-17 242B 1 INCAR
87a
303B 1-76 0.5Or (REVERSE TRAVEL) (F) 30 0.85RB SENSOR
2 TRAVEL 2 SUN LOAD SENSOR
121B 0.85W 1-26 121A 0.5Or 303A 13 10 52I 0.5Y ALARM BUZZER 306A 87 CN10 AMP 20P CN11 KET 4P
ATT. PRESS. CONTROL 301B 1-57 0.5WR (NEUTRAL)
BOSCH 96P
(R)
CN2
0
254C ATT. PRESS. CONTROL 161A 1-8 0.85OrB 161B PROPORTIONAL V/V (ON JOYSTICK R.H) 2 0.85RB 244A CN8-4 0.85YG 244B 1 SENSOR
3 254A 0.85Br 2-30 NOX SENSOR 5 (JOYSTICK LH-CW)
PEDAL SWITCH TERMINAL
PROPORTIONAL V/V 304A 3
1 TML
CN1
36D 52K I
124B 0.85WL 1-63 124A 162A 2-90 162B B BR R2 C ACC
4 252A 0.85BrY 252C
2
2-38 2 (TWO-WAY) 0.85OrR P/V-(C) 0.5B 7 8 80ZZ 0.5WR PST
AIR FLOW METER 1 253A 0.85BrW 253C 2-54 P/V-(C) 156B 0.85Gr 1-6 156A FLOW CONTROL 0.5OrL
251C
3
FLOW CONTROL 163A 2-91 0.85OrL 163B PROPORTIONAL V/V OFF
2 251A 0.85B
4
2-34
PROPORTIONAL V/V (JOYSTICK LH-CCW) SMART BOOM SWITCH
368C 1-58 0.5BrR Inhibit 0.5BrR E/G EMERGENCY STOP SWITCH 157B 0.85GrB 1-25 157A SMART BOOM RELAY
0.85RL 51B
6
1
BORGWARNER 1-59 0.5BrW Regen 1
(JOYSTICK RH-CLOSE) 304B 1-52 (TRAVEL ALARM SWITCH)
0.5LW 80S 10 9 99 0.5B 87a 0.85LY 33B 34A 0.85LB 34B PILOT S/V
ACC
369C 0.5BrW
2-119 (TRAVEL ALARM RELAY)
3 7
99 2 P/V-(C) 158B 0.85GrR 2-82 158A 305B 0.5LY 0 32A (BOOM FLOAT) 0.85BrW 32B 30
EGR
0.85B 10 144B 1-11 0.85R 0.5R 144A 2 3 145B 0.85W FLOW CONTROL 29D 1-56 0.5LW (AIRCON SIGNAL) 0.5WR
0.85BrR 54E 2
I 3 34D (BREAKER FLOAT)
87 33A
DA7-3 34C 5
DA7-1 ON
145A 1-74 0.85W PROPORTIONAL V/V 35B 86 85 0.5B
1
0.85B 99
159B 0.85GrL 2-83 159A 1-54 0.5LY 0.5WR 80S 8
0.85W 145E 8
4
+ 146C 1-83 0.85BW PREHEAT RELAY
(JOYSTICK RH-OPEN) 34G
0.5WR
0.5BG 7 99 0.5B
99
START
0.85LY 33C SMART MAIN S/V
0.85WB 370B 12
3 1-38 0.85LW A/C REQUIST 0.85Br
- 29XX 2R 6 4 33E 6
DA7-2
0.85WL 125B 5 370A 1-87 0.85WB 2R
7 + FAN 0.85BrW 34H 33D 2
0.85B 99
0.85WR 371B 1 DA7-4
CLUTCH 125A 1-67 0.85WL KEY START 0.5BG 0.5RY
11 SIG
0.85WG 372B 2 371A 1-64 0.85WR 0.85W 0.85W
5 -
372A 1-65 0.85WG 0.85BL 0.85BL
147C 1-63 0.85BG AIRCON SIGNAL
0.5BrR 368C
DeSOx REGEN SWITCH
9 10 80DE 0.5WR
0.85RL (POWER : EGR/VTG)
WE1401530
7 8 80DD 0.5WR 0.5WR
99