Mounting instruction for EX200(EX120)-2,3 Conversion Kit

1.Key points for mounting on control valve side

Disassemble control valve bonnet, disassemble valve plug and valve as shown in the
following picture, assemble fittings and hoses for all types

EX200/220-2,3

EX100/120-2,3

Fix the hose with cable tie attached to prevent hose damage from vibration
Re-assemble the control valve bonnet when confirmed free of leakage
2.Key points for subassembly of flow controller
Assemble two O-Rings on the valve sleeve [Picture 1]

Assemble the spring (4466356) on valve stem in the valve assembly [Picture 2]

Apply grease on the valve stem mounted with spring,Mount non-slip material into the
valve.
Upper part of servo piston provided with two bore diameters, φ 12 and φ 17.
Apply valve element and shim with right diameter.
※ Shims A and B are applicable to two types of valve element. Shims C and D shall
be selected based on bore diameter.

※ Quantity of shim shall be increased based on condition of engine. Absorbed

torque of the pump may be increased to be above typical torque.

※ The engine may occasionally shut down in case too many shims are added.

※ Location of flow controller valve plug shall be dependent on type of engine.

Mounting of valve plug shall follow the picture shown below.

3. Key points for mounting on pump side

Remove high-speed solenoid valve, pipeline, stopper and clamp.

Seal the pump oil inlet/outlet with tape to prevent dust and paint

Remove paint with scraper in the pump.

[Solenoid valve part]
[Stopper part]

Place O-Ring on each hole. Note direction of block and it with hexagon socket screw.

※ Please refer to the next page for mounting direction.

Please note the direction during mounting of sub-assembled stopper assembly.

And mount O-Ring.

Mount valve sleeve assembly and spring(4466217)

Mount flow controller assembly. No spring falling is allowed. Fix with hexagon socket
screw.

Remove stopper beneath the pump. Please note hydraulic oil flow.

When the stopper is removed, mount the O-Ring on the stopper and fix it onto the
pump with hexagon socket screw.

No direction needs to be considered during mounting (please refer to Page 8)

Flow controller
※ Note: Mounting position of plug numbered 29 depends on type of engine. (Please
refer to Page 5.)

※ Note: Quantity of shims numbered 38, 40, and 41 to be mounted depends on

type of engine. (Please refer to Page 4)

4. Key points for fitting and hose mounting

Perform mounting as per the following picture.

EX100/120-2,3
EX200/220-2
※ Plug numbered 09 is not required in case of type 2.
EX200/220-3
5. Key points for valve cover mounting

Mount the valve cover on main conductor bundle originally connected with solenoid
valve.
6. Precautions

※ Please note that shapes of valve somehow show differently since pictures of them
are from trial products.

※ Apply anti-corrosive paint in case of any scraping indication after flow controller
mounting.

※ Never allow hose to contact metal parts or knives during hose assembly.

※ Pumps must be vented and hydraulic oil shall be added in case of insufficient
amount.