SM Dx480lca K Dx520lca K Shop Manual (950106 01846e) en

Shop Manual
DX480LCA-K/DX520LCA-K
Excavator
Serial Number 20001 and Up
DOOSAN and the DOOSAN logo are registered

trademarks of DOOSAN Corporation in the United
States and various other countries around the 950106-01846E
world. January 2018
Copyright DOOSAN 2018© Original Instructions

1Table of Contents
1 Safety 1 Track Excavator Maintenance Safety
2 Specifications 1 Specifications
3 General Maintenance 1 General Maintenance Instructions
2 Standard Torques
4 Engine* * Please refer to the DX12 Engine manual.
5 Upper Structure 1 Cabin (Non-Rops)
2 Cabin (Rops)
3 Counterweight
4 Hydraulic Oil Tank
5 Fuel Tank
6 Drive Coupling (Main Pump)
7 Gear Pump (Rotating)
6 Lower Structure and Chassis 1 Swing Bearing
2 Track Assembly
7 Front 1 Boom and Arm
2 Bucket
Table of Contents
Page I
8 Hydraulic System 1 Main Pump
2 Main Control Valve
3 Swing Device
4 Joystick Valve (Work Lever)
5 Travel Control Valve (with Damper)
6 Solenoid Valve
7 EPPR Valve
8 Accumulator
9 Center Joint
10 Travel Device
11 Cylinders
9 Electrical System 1 Electrical System
11 Schematic 1 Hydraulic Schematic/Electrical Schematic
Table of Contents
Page II
1Safety
1Track Excavator
Maintenance
Safety
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.
DX480LCA-K/DX520LCA-K Track Excavator Maintenance Safety

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

Safety Instructions ..........................................1-1-1
Safety Messages ............................................1-1-3
General ...........................................................1-1-3
Transportation...............................................1-1-16
Operation ......................................................1-1-18
Maintenance .................................................1-1-35
Environment and Circumstances..................1-1-50
Track Excavator Maintenance Safety DX480LCA-K/DX520LCA-K

1-1-2
SAFETY MESSAGES
Replace with Safety Messages Section on pages III and IV in
the Doosan Operation & Maintenance Manual.
GENERAL
Safe Operation is Operator's

Responsibility
Only trained and authorized personnel should operate and
maintain the machine.
Follow all safety rules, regulations and instructions when
operating or performing maintenance on machine.
• Do not operate machine if you are under the influence of
drugs or alcohol. An operator who is taking prescription
drugs must get medical advice to determine if he or she
can safely operate a machine.
• When working with other personnel on a work site, be sure
that all personnel know nature of work and understand all
hand signals that are to be used.
• Be sure that all guards and shields are installed in their
proper location. Have guards and shields repaired or
replaced immediately if damaged.
• Be sure that you understand the use and maintenance of
all safety features such as safety lever and seat belt. Use
them properly.
• Never remove, modify or disable any safety features.
Always keep them in good operating condition.
• Always check for and know the location of underground
and overhead utility lines before excavating.
• Failure to use and maintain safety features according to
instructions in this manual, Safety Manual and Shop
Manual can result in death or serious injury.
Know Your Machine

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

1-1-3
Proper Work Tools and Attachments
Only use work tools and attachments that are recommended by
DOOSAN for use on DOOSAN machines. When installing and
using optional attachments, read instruction manual for
attachment, and general information related to attachments in this
manual. Because DOOSAN cannot anticipate, identify or test all
attachments that owners may want to install on their machines,
contact DOOSAN for written authorization and approval of
attachments, and their compatibility with optional kits.
Attachments and attachment control systems that are
compatible with the machine are required for safe and reliable
machine operation. Do not exceed maximum operating weight
(machine weight plus attachment) that is listed on ROPS
certification plate.
Make sure that all guards and shields are in place on machine
and on work tool. Depending on type or combination of work
equipment, there is a potential that work equipment could
interfere with the cabin or other parts of machine. Before using
unfamiliar work equipment, check if there is any potential of
interference, and operate with caution.
While you are performing any maintenance, testing, or
adjustments to attachments, stay clear of the following areas:
cutting edges, pinch points, and crushing surfaces.
Never use attachment as a work platform or manlift.
Contact your DOOSAN distributor about auxiliary hydraulic kits
for attachments installation. If you are in doubt about
compatibility of a particular attachment with a machine, consult
your DOOSAN distributor.
Pressurized Fluids
Pressurized air or fluids can cause debris and/or fluids to be
blown out. This could result in death or serious injury.
Immediately after operations are stopped, coolant, engine oil,
and hydraulic oil are at their highest temperatures and the
radiator and hydraulic tank are still under pressure. Always wait
for temperature to cool down. Follow specified procedures when
attempting to remove caps, drain oil or coolant, or replacing
filters. Always wait for temperature to cool down, and follow
specified procedures when performing these operations. Failure FG018457
to do so can result in death or serious injury. Figure 1
When pressurized air and/or pressurized water is used for
cleaning, wear protective clothing, protective shoes, and eye
protection. Eye protection includes goggles or a protective face
shield.
Pressure can be trapped in a hydraulic system and must be
relieved before maintenance is started.
Releasing trapped pressure can cause sudden machine
movement or attachment movement. Use caution if you
disconnect hydraulic lines or fittings.

1-1-4
High-pressure oil that is released can cause a hose to whip or oil
to spray. Fluid penetration can result in death or serious injury. If
fluid enters skin or eyes, get immediate medical attention from a
physician familiar with this injury.
Obey all local laws and regulations for disposal of liquids.
To prevent hot coolant from spraying out, stop engine and wait
for coolant to cool. Using gloves, slowly loosen cap to relieve
pressure.
Flying or Falling Objects

On work sites where there is a potential hazard that flying or
falling objects can hit operator's cabin, select and use a guard to
match operating conditions for additional operator protection.
Working in mines, tunnels, deep pits, and loose or wet surfaces,
could produce hazard of falling rocks or flying objects. Additional
protection for operator's cabin could be required such as an
Operator Protection Guard (OPG) or window guards. Contact
your DOOSAN distributor for information on available protective
guards. HAOA110L
Figure 2
To prevent personnel from being struck by flying objects, keep
personnel out of work area.
HAOA100L
Figure 3

1-1-5
Personal Protective Equipment (PPE)
Do not wear loose clothing and accessories. Secure long hair.
These items can snag on controls or on other parts of
equipment.
Do not wear oily clothes. They are highly flammable.
Do not forget that some risks to your health may not be
immediately apparent. Exhaust gases and noise pollution may
not be visible, but these hazards can cause disabling or
permanent injuries. Breathing masks and/or ear protection may
HAOA020L
be required.
Figure 4
Wear a hard hat, safety shoes, safety goggles, mask, leather
gloves, earplugs and other protective equipment, as required.
While working on machine, never use inadequate tools. They
could break or slip, or they may not adequately perform intended
functions.
Correction of Machine Problems

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

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

1-1-6
Do not depend on hydraulic cylinders to support raised
equipment. Equipment can fall if a control is moved, or if a
hydraulic line breaks, is loosened or disconnected.
If it is necessary to remove guards to perform maintenance,
always install guards after maintenance is completed.
HDO1010L
Figure 5
Hot Coolant and Oils - Burn Prevention

Do not touch any part of an operating engine. Immediately after
operations are stopped, coolant, engine oil, and hydraulic oil are
at their highest temperatures. The radiator and hydraulic tank
are still under pressure. Always wait for temperature to cool
down. Attempting to remove caps, drain oil or coolant, or
replacing filters may lead to serious burns, if done when hot.
Relieve all pressure in air system, hydraulic oil system,
lubrication system, fuel system, and cooling system, before any
lines, fittings or related items are disconnected. FG019095
Figure 6
To prevent hot oil or coolant from spraying out, stop engine, wait
for oil and coolant to cool. Using gloves, slowly loosen cap to
relieve pressure.
FG019096
Figure 7

1-1-7
Fire and Explosion Prevention
All fuels, most lubricants and some coolant mixtures are
flammable and can cause a fire resulting in death or serious
injury, and property damage. Flammable fluids that are leaking
or spilled onto hot surfaces or onto electrical components can
cause fire.
Inspect for and remove all flammable materials such as spilled
fuel and oil, and debris from machine. Do not allow any
flammable materials to accumulate on machine.
HDO1015I
Always observe the following:
Figure 8
• Add fuel, oil, antifreeze and hydraulic fluid to machine only

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

1-1-8
Electrical
Check all electrical wiring and connections for damage daily.
Keep battery terminals clean and tight. Repair or replace any
damaged part or wires that are loose or frayed. Clean all
electrical connections and tighten all electrical connections.
Never check battery charge by placing a metal object across
terminal posts. Use a voltmeter or a hydrometer.
Battery gas can explode and can result in death or serious
injury. Follow procedures in this manual for connecting battery
and for jump-starting. Do not jump-start or charge a frozen or
damaged battery. Keep any flames or sparks away from
batteries. Do not smoke in battery charging area.
Improper jumper cable connections can cause an explosion that
can result in death or serious injury. Refer to Operation &
Maintenance Manual, for proper procedure.
Do not charge a frozen battery. This can cause an explosion.
After market radios or other electric operated equipment in cabin
must have a fuse in the electrical circuit.
Hydraulic System
Check hydraulic tubes, hoses and fittings for damage, wear or
for leaks. Hydraulic lines and hoses must be properly routed and
have adequate support and secure clamps. Leaks can cause
fires. Never use a flame or bare skin to check for leaks.
Tighten or replace any parts that show leakage.
Check that all hose and tube clamps, guards, and cushions are
securely attached. If they are loose, they can vibrate during
operation and rub against other parts. This can cause damage
to hoses and cause high-pressure oil to spray on hot surfaces,
causing a fire and death or serious injury.
Always clean fluid spills. Do not use gasoline or diesel fuel for
cleaning parts. Use commercial nonflammable solvents.
EX1400129
Figure 10

1-1-9
Fueling
Use caution when you are refueling a machine.
Fuel is flammable and can catch fire if it is brought close to a
flame.
Stop engine and let it cool before adding fuel. Do not smoke
while you are refueling a machine. Do not refuel a machine near
flames or sparks. Fill fuel tank outdoors.
Keep fuel and other fluid reservoir caps tight and do not start
engine until caps have been secured.
Store fuels and lubricants in properly marked containers away
from unauthorized personnel. Store oily rags and any flammable
materials in protective containers.
Static electricity can produce dangerous sparks at fuel filling
EX1400130
nozzle. In very cold, dry weather or other conditions that could
produce a static discharge, keep tip of fuel nozzle in constant Figure 11
contact with neck of fuel filling nozzle, to provide a ground.
Always place plastic fuel containers on the ground before filling.
Never Use Ether Starting Aids

Do not use ether or starting fluids on any engine that has glow
plugs, or an electric grid type manifold heater. These starting
aids can cause an explosion and result in death or serious
injury.
Use procedures in this manual for connecting battery and for
jump-starting.
FG018458
Figure 12
Welding and Grinding

Always clean machine and attachment, set battery disconnect
switch to "OFF" position, and disconnect wiring from electronic
controllers before welding. Cover rubber hoses, battery and all
other flammable parts. Keep a fire extinguisher near machine
when welding.
Toxic dust or gas can be produced when grinding or welding
painted parts. Grinding or welding painted parts must be done in
a well ventilated area. Wear dust mask when grinding painted
parts.
Dust generated from repairing nonmetallic parts such as hoods,
fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away from
flames or sparks.
Do not weld on lines or on tanks that contain flammable fluids.
Do not flame cut lines or tanks that contain flammable fluid.
Clean any such lines or tanks thoroughly with a nonflammable
solvent before welding or flame cutting.

1-1-10
If a Fire Occurs
If a fire occurs:
• Do not attempt to move machine or continue operations.
• Turn starter switch to "O" (OFF) position to stop engine.
• Use handrails, guardrails and steps to get off machine.
• Immediately call for help or fire station.
• When using a fire extinguisher, always aim extinguisher at
base of fire. FG018459
• If an optional fire extinguishing system is in place, be Figure 13
familiar with its operating procedures.
NOTE: Depending on job conditions, other procedures could
be necessary if a fire occurs.
Fire Extinguisher and First-aid Kit

(Emergency Medical Kit)
To be prepared in the event of a fire:
• Be sure that fire extinguishers have been provided and
read labels to ensure that you know how to use them. It is
recommended that an appropriately sized (2.27 kg [5 lb] or
larger) multipurpose A/B/C fire extinguisher be mounted in
cabin. Check and service fire extinguisher at regular
intervals and make sure that all work site crew members
HDO1009L
are adequately trained in its use.
Figure 14
• Inspect fire extinguisher and service fire extinguisher
regularly.
• Follow instructions on extinguisher instruction plate.
• Keep a first aid kit in storage compartment (Figure 15) and
keep another kit at work site. Check kit periodically and
keep it properly supplied.
• Keep emergency numbers for doctor, ambulance service,
hospital and fire department readily available.
EX1300678
Figure 15

1-1-11
Electrical System and Electrical Shock
Never short across starter terminals or across batteries.
Shorting could damage electrical system and engine neutral
start system.
When engine is running or immediately after it has stopped, high
voltage is generated at injector terminal and inside engine
controller, so there is a potential for an electrical shock. Never
touch injector terminal or inside of engine controller.
NOTE: If it is necessary to touch injector terminal or inside
engine controller, contact your DOOSAN distributor.
Roll-over Protective Structure (ROPS)

The operator's cabin is a ROPS certified structure for protecting
the seat-belted operator. It absorbs the impact energy of a
rollover impact. Do not allow machine weight (mass) to exceed
certified value on certification plate. If weight is exceeded, the
ROPS structure will not be able to fulfill its safety function.
Do not increase machine weight beyond certified value by
modifying machine or by installing attachments on machine. If
weight limit of protective equipment is exceeded, protective
equipment will not be able to protect operator, and operator may
suffer injury or death. Always observe the following:
• This machine is equipped with a protective structure. Do
not remove protective structure and carry out operations
without it.
• Never modify the operator’s cabin by welding, grinding,
drilling holes or adding attachments unless instructed by
DOOSAN. Changes to the cabin can cause loss of
operator protection from rollover and falling objects, and
operator may suffer serious injury or death.
• When protective structure is damaged or deformed by
falling objects or by rolling over, its strength will be reduced
and it will not be able to properly fulfill its function. In these
cases, always contact your DOOSAN distributor for advice.
Never repair a ROPS cabin.
• Always wear your seat belt when operating machine.

1-1-12
ROPS Certification
This DOOSAN excavator has an operator’s cabin that meets
ROPS requirements. The seat belt must be worn for rollover
protection.
The ROPS certification plate (Figure 16) is found on the left side
of the cabin on most models. It may vary slightly in its location
on some models.
Check the ROPS cabin, mounting, and hardware for damage.
Never modify the ROPS cabin. Replace the cabin and hardware EX1300529
if damaged. See your DOOSAN dealer for parts. Figure 16
ROPS  Roll-over Protective Structure complies with
ISO 12117-2:2008, EN 13531:2001.
WARNING
Never modify the operator cabin by welding, grinding,
DOOSAN. Changes to the cabin can cause loss of operator
protection from rollover and falling objects, and result in
serious injury or death.

1-1-13
Protecting Cabin from Flying or Falling Objects (Optional)
In a work site where additional operator protection is necessary
from falling or flying objects, install adequate protective guards 1
on the cabin.
For breaker operation, install a front guard (1, Figure 17) and
apply a laminated coating sheet to front glass. Contact your
DOOSAN distributor for recommendations.
When performing demolition or cutting operation, install a front
guard and top guard.
Apply a protective laminated coating sheet to outside of front
window. This will prevent glass from being scratched by dust
when cleaning it or running wipers.
FG020947
Figure 17
When working in mines, quarries or other work sites where there

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

1-1-14
Emergency Exit from Operator's Station
This machine is equipped with a glass breaking tool. It is found
on left pillar of cabin. This tool can be used to break the glass to
exit from cabin in an emergency. Grip handle firmly and use
sharp point to break glass.
• Be careful also not to slip on broken pieces of glass on
ground.
WARNING EX1300679
Figure 19
Protect your eyes when breaking the glass.

1-1-15
TRANSPORTATION
Obey State and Local Over-the-Road

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

To prevent machine tipping or roll-over when loading or
unloading machine, always do the following:
• Perform loading and unloading only on firm and level
ground. Maintain a safe distance from edge of road or
drop-off.
• Never use work equipment to load or unload machine. The
machine may fall or tip over.
• Always use loading ramps of adequate strength and
capacity. Be sure that ramps are wide, and long enough to
provide a safe loading slope. Take steps to prevent ramps
from moving out of position or coming off.
• Clean ramp surfaces so they are free of grease, oil, ice and
loose materials. Remove dirt from machine tracks and
undercarriage. On a rainy day, be careful since ramp
surfaces can be slippery.
• Turn auto idle switch "OFF".
• Run engine at low speed and travel slowly.
• When on ramps, do not operate any control lever except
for travel lever.
• Never correct your steering on ramps. If necessary, drive
off ramps, correct machine direction, then drive back onto
ramps.
• When driving up or down ramps, the center of gravity of
machine will change suddenly causing the tracks to drop
down to the ramps or trailer. This will occur at the joint
between the ramps and trailer. Travel slowly over this point.

1-1-16
• For machines equipped with a cabin, always lock door
after loading machine to prevent door from suddenly
opening during transportation.
Transporting Machine
When transporting machine on a trailer or truck, do the following:
• The weight, transportation height, and overall length of
machine may change depending on work equipment
attached to it. Always check the machine dimensions and
work equipment's dimensions before transporting.
• When passing over bridges or structures on private land,
check that structure is strong enough to support weight of
machine. Before traveling on public roads, check with
appropriate authorities and follow their instructions.

1-1-17
OPERATION
Always make sure that the machine is properly maintained.
Before Engine Starting
Machine Condition
Every day before starting engine for first time, perform the
following checks and repair machine before operating, as
necessary. If these checks are not properly done death or
serious injury could result.
• Check coolant, fuel, and hydraulic tank oil levels, and
check for clogged air cleaner and damage to electrical
wiring.
• Check operation of gauges, cameras (if equipped) and
angle of mirrors, and check that safety lever is in LOCKED
position.
• Check that work equipment and travel controls move
freely, and work controls return to "NEUTRAL" when
released.
• Check that attachment is properly attached and locked.
IMPORTANT
Only use Ultra Low Sulfur Diesel (ULSD) fuel and API CI-4/
ACEA E5, E7 or API CJ-4/ACEA E9 grade engine oil with
this machine.
Make sure that the machine is equipped with a lighting system

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

1-1-18
Work Site
Before starting operations, thoroughly check work area for any
hazards, such as underground utility lines, overhead electrical
lines, unstable ground, excessive slopes, etc.
Before starting engine and moving machine, make sure that no
one is underneath machine, around machine, or on machine.
Know width and length of your machine and work equipment to
maintain proper clearance when you operate machine or work DANGER
equipment near fences or near boundary obstacles. No Entry

EX1300680
Know appropriate work site hand signals and personnel that are Figure 20
authorized to give hand signals. Follow hand signals from only
one person.
If you need to operate on a street, protect pedestrians and cars
by designating a person for work site traffic duty or by erecting
fences and posting "No Entry" signs around work site.
Erect barricades or fences, post "No Entry" signs, and take other
steps to prevent people from coming close to or entering work
site. If people come too close to a moving machine, they may be
struck or caught by machine, and this can result in death or
serious injury.

1-1-19
Mounting/Dismounting
Before getting on or off machine, if there is any oil, grease, or
mud on handrails, guardrails, steps, or track shoes, wipe it off
immediately. Always keep these parts clean. Repair any
damage and tighten any loose bolts.
Never jump on or off machine. In particular, never get on or off a
moving machine. These actions can result in death or serious
injury.
When getting on or off machine, always face machine. Maintain
three-point contact (both feet and one hand or one foot and both
EX1301111
hands) with handrails, guardrails, steps, and track shoes to
ensure that you support yourself securely. Figure 21
Never hold onto any control levers when getting on or off

machine.
Securely latch door. If you grip handrail inside door when
moving on top of track shoes, and door latch is not securely
engaged, door may move and cause you to fall.
Use points marked by arrows in diagram when getting on or off
machine.
Do not carry tools or supplies when you mount or dismount the
machine.
EX1301112
Figure 22
DS1703811
Figure 23

1-1-20
Cleaning
Remove all straw, wood chips, leaves, grass, paper and other
flammable debris accumulated in engine compartment, mufflers
and around battery. Remove any dirt from window glass,
mirrors, handrails, and steps.
Do not leave tools or spare parts in operator's cabin. Vibration of
machine during operation can cause tools or spare parts to fall
and damage or break control levers or switches. Tools and
spare parts can also get caught in spaces between control
levers and cause accidental movement of work equipment
causing death or serious injury.
When entering operator's cabin, always remove all mud and oil
from your shoes. If you operate travel pedal with mud or oil stuck
to your shoes, your foot could slip off the control, or dirt and
debris may interfere with proper operation of control levers.
Clean window glass and working lights for good visibility.
Do not stick suction pads to window glass. Suction pads act as a
lens and can cause fire.
Never bring flammable or explosive items into operator's cabin.
Do not leave cigarette lighters laying around operator's cabin. If
temperature inside operator's cabin becomes too high, there is a
potential hazard that lighter could explode.
Secure all loose items such as lunch boxes, and other items that
are not a part of equipment.
Operator Station
Inspect condition of seat belt and mounting hardware. Replace
any parts that are worn or damaged. Do not use a seat belt
extension on a retractable seat belt.
Adjust seat so full pedal travel can be achieved with operator's
back against back of seat.
Keep all windows and doors closed on machine.
Adjust operator's seat to a position where it is easy to perform
operations, and check that there is no damage or excessive
wear to seat belt or mounting clamps.
Adjust and clean mirrors so area to rear of machine can be seen
clearly from operator's seat.
When standing up from operator's seat, always place safety lever
securely in "LOCK" position. If you accidentally move work
equipment levers when they are not locked, the machine could
suddenly move and cause damage, death or serious injury.
Seat Belt
Check seat belt daily for correct function.

1-1-21
Inspect seat belt system more often if machine is exposed to
severe environmental conditions or applications. Conduct the
following inspections and replace seat belt system as
necessary:
1. Check webbing. If system is equipped with a retractor, pull
webbing completely out and inspect full length of webbing.
Look for cuts, wear, fraying, dirt and stiffness.
2. Check buckle and latch for correct operation.
3. Make sure latch plate is not excessively worn, deformed or
buckle is not damaged or casing is broken.
4. Check retractor web storage device (if equipped) by
extending webbing and checking that it spools out and
retracts correctly.
5. Check webbing in areas exposed to ultraviolet (UV) rays
from sun or extreme dust or dirt. If original color of webbing
in these areas is extremely faded and/or webbing is
packed with dirt, webbing strength may be reduced.
NOTE: Contact your DOOSAN distributor for seat belt
system replacement parts.
WARNING
Failure to properly inspect and maintain seat belt and
seat belt system can cause lack of operator restraint
and can result in death or serious injury.
Before fastening seat belt, check that there is no
problem in belt mounting bracket. If it is worn or
damaged, replace seat belt. Fasten seat belt so it is not
twisted.
Always wear seat belt when operating machine.

1-1-22
Visibility Information
A rear view camera (if equipped) and mirrors provide the
operator with additional means to see the work area.
NOTE: These devices may vary from one region to another,
depending upon local and regional regulations. If a
machine is moved or sold into another region or
marketplace, it is the owner's responsibility to make
sure it complies with all applicable regulations.
WARNING
Failure to check for and clear people from the surrounding
area of a machine can result in death or serious injury. The
operator should make sure that visual aids (mirrors and
camera(s)) are in proper working condition.
Your machine may be equipped with visual aids such as mirrors

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

• If visibility cannot be sufficiently assured, use a flagman.
The operator should pay careful attention to signals and
follow instructions from flagman.
• Signals should only be given by one flagman.
• When working in dark places, turn "ON" work lights and
front lights on the machine. Set up additional lighting in
area.
• Stop operations if there is poor visibility, such as fog, snow,
rain, or sandstorms.

1-1-23
• Check mirrors and rear view camera (if equipped) on
machine before starting operations. Clean off any dirt and
adjust view for good visibility.
When operating or traveling during poor visibility conditions,
follow the preceding work site rules.
It may not be possible to adjust all visual aids to see all the way
around the machine. Therefore, additional precautions such as
flagman, barricades, etc., must be taken to keep other personnel
out of the work area.
Boost Starting or Charging Engine

Batteries
Follow these instructions to prevent an explosion or fire when
connecting booster cables to batteries:
• Turn "OFF" all electric equipment before connecting leads
to battery. This includes electric switches on battery
charger or battery booster equipment.
• When boost starting from another machine or vehicle do
not allow two machines to touch. Wear safety goggles and
gloves while battery connections are made.
• 24 volt battery units consisting of two series connected 12
volt batteries have a cable connecting one positive (+)
terminal on one of the 12 volt batteries to a negative (-)
terminal on the other battery. Booster or charger cable
connections must be made between the nonseries
connected positive (+) terminals and between the negative
(-) terminal of the booster battery and metal frame of the
machine being boosted or charged. The final booster cable
connection, at metal frame of the machine being charged
or boost started, must be as far away from the batteries as
possible. Refer to Operation & Maintenance Manual, for
proper procedure.
• Connect positive (+) cable first when installing cables and
disconnect negative (-) cable first when removing them.

1-1-24
Starting Engine
Only operate the machine from the operator's seat with your
seat belt fastened.
Only operate controls while engine is running.
Check for proper operation of all controls and all protective

devices while you operate the machine slowly in an open area.
• Read and understand control pattern before operating.
Check that movement of the machine matches display on
control pattern label. If it does not match, replace it
immediately with correct control pattern label.
• Check operation of work equipment, travel system and
swing system.
• Check for any problem with machine. Check for unusual
sounds, vibration, heat, odor, or improper readings from
gauges. Check for any oil or fuel leaks.
Figure 24
• If any problem is found, stop operation and perform repairs
immediately.
Do not use cellular telephones inside operator's cabin when
driving or operating the machine.
When operating the machine, do not extend your hands or head
out of window.
The boom and arm linkage can allow work tool or attachment to
contact undercarriage or cabin. Be aware of position of work
tool.
• Do not attempt to start engine by short-circuiting engine
starting circuit. This can result in death or serious injury, or 950205-03868A
fire.
DS1701748
• When starting engine, sound horn as a warning to alert Figure 25
personnel in the work area.
If there is a warning tag or "DO NOT OPERATE" tag hanging
from work levers (joysticks) or travel control levers, do not start
engine or move levers.
• Prevent personnel from walking or standing under raised
boom, unless it is properly supported.
NOTE: When starting engine in cold temperatures, "white
engine exhaust smoke" from the tail pipe can occur
until engine reaches normal operating temperatures.
Also, a white residue, because of water vapor inside
engine, can form at the engine oil fill location. These
conditions will not affect engine performance or
damage the engine or other exhaust system
components.

1-1-25
Swinging or Traveling
As a machine operator, you should know and follow local, state
and federal laws and regulations when operating on public roads
or highways.
It is important to keep in mind that the machine, in comparison
with the rest of traffic, is a slow moving and wide vehicle which
can cause traffic delays. Pay attention to traffic behind you and
allow traffic to pass you.
Before operating the machine or work equipment, always
observe the following precautions to prevent death or serious
injury.
• When changing travel direction from forward to reverse or
from reverse to forward, reduce speed and stop machine
before changing travel direction.
• Sound horn to alert people in area.
• Check that there is no one in area around machine. There
are restricted visibility areas behind machine so, if
necessary, swing upper structure slowly to check that there
is no one behind machine before traveling in reverse. EX1400131
• When operating in areas with poor visibility, designate a Figure 26
flagman to direct work site traffic.
• Keep unauthorized personnel away from turning radius or
travel path of the machine.
Be sure to observe above precautions even if a travel alarm or
mirrors are installed.
• Check that travel alarm works properly and that mirrors are
clean, not damaged and properly adjusted.
• Always latch door and windows of operator's cabin in
position (open or closed).
• On work sites where there is a hazard of flying or falling
objects, or of objects entering operator's cabin, check that
door and windows are securely closed. Install additional
guards, if work site application requires them.

1-1-26
Never turn starter switch to "O" (OFF) position when traveling.
This can lead to a loss of steering control. Travel Position
Do not operate attachments while traveling.

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

1-1-27
Lifting and Digging
The operator is responsible for any load carried when traveling
on public roads and while working with the machine.
• Keep loads secure so they do not fall off while operating.
• Do not exceed maximum load for the machine. Machine
operation will be affected when center of gravity changes,
caused by extended loads and different attachments.
To lift loads safely when in digging mode, the following must be
evaluated by the operator and work site crew.
• Condition of ground support.
• Excavator configuration and attachments.
• Weight, lifting height and swing radius.
• Safe rigging of load.
• Proper handling of suspended load.
Always watch load. Bring load close to the machine before
traveling any distances or swinging load.
Lifting capacity decreases as load is moved further from the
machine.
Set tracks at right angles to road shoulder or drop-off with
sprocket at rear when performing operations to make it easier to
move away from the work area.
Do not suddenly lower, swing, or stop work equipment.
• Do not move bucket over head of other personnel or over
the operator's seat of dump trucks or other hauling
equipment. The load may spill or bucket can hit dump truck
causing property damage or cause death or serious injury.

1-1-28
Operation on Slopes
If the machine has to be used on a slope, pile soil to make a
platform that will keep the machine as horizontal as possible.
Improper traveling on steep slopes could result in machine
tipping, roll-over or sliding down the slope. Always fasten your 20 -
30 c
seat belt. m (8
- 12
in)
When possible, operate machine up slopes and down slopes.
Avoid operating machine across slope.
On hills, banks or slopes, carry bucket approximately 20 - 30 cm
(8 - 12 in) above ground. In case of an emergency, quickly lower
bucket or work tool to ground to help stop machine.
Do not travel on grass, fallen leaves, or wet steel plates. Even
slight slopes can cause machine to slide down a slope. Travel at
low speed and make sure that the machine is always traveling in)
12
directly up or down slope. (8 -
cm
Do not change travel direction on a slope. This could result in - 30
20
tipping or sliding sideways of machine.
Improper operation when working on slopes can cause a tip
over. Use caution when swinging or operating work equipment
on slopes.
Do not swing work equipment from uphill side to downhill side
when bucket is loaded. This could cause machine to tip or roll-
over.
In addition, lower bucket as far as possible, keep it pulled into
front, and keep swing speed as slow as possible.
EX1300691
Figure 28
If the machine begins to slide down on a grade, immediately

dump load and turn the machine downhill.
Be careful to avoid any ground condition which could cause the
machine to tip. Tipping can occur when you work on hills, on
banks, or on slopes. Tipping can also occur when you cross
ditches, ridges, or travel over unexpected obstructions.
Keep the machine under control. Do not overload the machine
beyond capacity.
• When traveling up a steep slope, extend work equipment
to front to improve balance, keep work equipment EX1300682
approximately 20 ~ 30 cm (8 ~ 12 in) above ground, and Figure 29
travel at low speed.
• Do not turn on slopes or travel across slopes. Always go
down to a flat place to change position of the machine,
then travel backup the slope again.

1-1-29
Towing Cloth
To prevent death or serious injury when towing, always do the
following:
• Follow the instruction given in this manual.
• When performing preparation work for towing with two or
more personnel, determine signals to use and correctly
follow these signals. Towing Wire
• Always attach wire rope onto left and right hooks and
secure in position.
• If engine on problem machine will not start or there is a
failure in brake system, always contact your DOOSAN
distributor.
• Never go between towing machine and towed machine
during towing operation.
• Do not perform towing on steep slopes, so select a place
where slope is gradual. If there is no place where slope is Towing Wire
gradual, perform operations to reduce angle of slope
before starting towing operation.
• When towing a machine, always use a wire rope with a
sufficient towing capacity.
• Do not use a wire rope that is kinked or frayed, or a wire
rope with any loss of diameter. Wear leather gloves when
handling a wire rope.
• Do not use lightweight towing hook for towing another
machine.
Towing Wire
• Make sure that towing eyes and towing devices are EX1400132
adequate for towing loads. Figure 30
• Only connect wire rope to a drawbar or to a hitch.
• Operate the machine slowly and be careful not to apply
any sudden load to wire rope.

1-1-30
Attachment
Never let anyone ride on any work attachment, such as bucket,
crusher, grapple, or clamshell (grab bucket). This creates a
falling and crushing hazard, and can result in death or serious
injury.
The clamshell, grapple, or magnet can swing in all directions.
Move work levers (joysticks) in a continuous motion. Failure to
move work levers (joysticks) in a continuous motion can cause
clamshell, grapple, or magnet to swing into cabin or into a
person in work area. This can result in death or serious injury. EX1400133
Figure 31
• When using a fork or grapple, do not attempt to pick up an
object with its tips. This could damage the machine or
cause personal injury, if picked-up object slips off
attachment.
• Do not use impact force of work equipment for demolition
work. This could damage work equipment, cause broken
materials to fly off or tipping. This could result in death or
serious injury.
• Do not use work equipment or swing mechanism to pull
load in any direction. This could cause the work equipment
to move suddenly if the load releases and can result in
death or serious injury.
Equipment Lowering with Engine Stopped

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

1-1-31
Engine Stop
Turn engine starter switch to "O" (OFF) position and remove
engine starter switch key.
Before lowering any equipment with engine stopped, clear area
around equipment of all personnel and bystanders. This
procedure will cause high-pressure air or hydraulic pressure to
be released to lower equipment.
Do not stop engine immediately after the machine has been
operated under load. This can cause overheating and
accelerated wear of engine components.
After the machine is parked, allow engine to run for five minutes
before stopping the engine. This allows hot areas of engine to
cool gradually.
• Do not leave operator's seat when there is a raised load.
Parking Machine
Avoid making sudden stops, or parking machine wherever it
happens to be at end of workday. Park machine on firm and
level ground away from traffic and away from high walls, 120
drop-offs and any area of potential water accumulation or runoff. 
If parking on inclines is unavoidable, block crawler tracks to
prevent movement. Lower bucket or other working attachment
completely to ground, or to an overnight support saddle. To Block
prevent unintended or accidental movement.
When parking on public roads, provide fences, signs, flags, or
lights, and put up any other necessary signs to ensure that
passing traffic can see machine clearly. Park machine so
machine, flags, signs and fences do not obstruct traffic.
After front attachment has been lowered to an overnight storage
position and all switches and operating controls are in "OFF"
position, safety lever must be moved to "LOCK" position. This Unlock
will disable all pilot control functions.
Always close door of operator's cabin and lock all equipment to
prevent any unauthorized person from operating the machine. Lock EX1401035
Figure 32
The hydraulic system remains pressurized, provided

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

1-1-32
Preservation/Storing Machine
Perform the following if storing excavator for more than one
month.
Conditions Maintenance Required

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

2. Wash machine and touch up paint finish to avoid rusting.
3. Treat exposed parts with antirust agent, lubricate machine
thoroughly and apply grease to unpainted surfaces like
lifting and tilting cylinders etc.
4. Fill fuel tank and hydraulic oil tank to "FULL" marks.
5. Cover exhaust pipe (parking outside).
6. Make sure that coolant is at proper concentration for
expected lowest temperatures.
7. Park machine on level, firm ground where there is no risk
of freezing, landslide or flooding. Avoid parking machine on
a slope.
Keep in mind that theft and burglary risk can be minimized
by:
• Removing starter key when the machine is left
unattended.
• Locking doors and covers after working hours.
• Turning off electrical current with battery disconnect
switch.
• Park machine where risk of theft, burglary and
damage is minimized.
• Removing valuables from cabin such as cellular
phone, computer, radio and bags.
See Operation & Maintenance Manual, for more information.

1-1-33
Check After Long-term Parking
• All oil and fluid levels.
• Tension of all belts.
• Air pressure.
• Air cleaner.
• Batteries and electrical connections.
• Lubricate all greasing points.
• Wipe off grease from piston rods.
• Inspect for signs of nests (i.e. birds, rodents, etc.)
• Inspect safety labels (decals). Replace if damaged, worn,
or missing.

1-1-34
MAINTENANCE
Improper operation and maintenance can result in death or
serious injury. Read manual and safety decals before operating
or maintaining the machine. Follow all instructions and safety
messages.
WARNING
Follow instructions before operating or servicing machine.
Read and understand the Operation & Maintenance Manual
and signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs,
adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and
failure to follow instructions can result in death or serious
injury.
• Never service DOOSAN equipment without instructions.

• Always lower bucket and blade to ground before doing any
maintenance.
• Use correct procedure to lift and support excavator.
• Cleaning and maintenance are required daily.
• Welding or grinding painted parts must be done in well
ventilated areas.
• Wear a dust mask when grinding painted parts. Toxic dust
and gas can be produced.
• Vent exhaust to outside when engine must be running for
service.
• Exhaust system must be tightly sealed. Exhaust fumes are
hazardous and can cause death or serious injury.
• Stop and allow engine to cool and clean engine of
flammable materials before checking fluids.
• Never service or adjust machine with engine running
unless instructed to do so in this manual.
• Avoid contact with leaking hydraulic fluid or diesel fuel
under pressure. It can penetrate skin or eyes.
• Never fill fuel tank while engine running, while smoking, or
when near open flame.
• Keep body, jewelry and clothing away from moving parts,
electrical contact, hot parts and exhaust.
• Wear eye protection to guard from battery acid,
compressed springs, fluids under pressure and flying
debris when engines are running or tools are used. Use
eye protection approved for welding.

1-1-35
• Lead-acid batteries produce flammable and explosive
gases.
• Keep arcs, sparks, flames and lighted tobacco away from
batteries.
• Batteries contain acid which burns eyes or skin on contact.
• Wear protective clothing. If acid contacts body, flush well
with water. For eye contact flush well and get immediate
medical attention from a physician familiar with this injury.
• The maintenance procedures which are given in this
manual can be performed by the owner or operator without
any specific technical training. Maintenance procedures
which are not in this manual must be performed ONLY BY
QUALIFIED SERVICE PERSONNEL. Always use genuine
DOOSAN replacement parts.
• Only authorized personnel should service and repair the
machine. Do not allow unauthorized personnel into work
area.
• Lower work equipment and stop engine before performing
maintenance.
• Park machine on firm and level ground.
• Turn starter switch to "ON' position and keep safety lever in
"UNLOCK" position. Cycle work levers (joysticks) back and
forth, left and right at full stroke 2 to 3 times to eliminate
remaining internal pressure in hydraulic circuit. 
Then move safety lever to "LOCK" position.
• Check that battery relay is "OFF" and main power is shut
off. (Wait for approximately one minute after turning "OFF"
engine starter switch key and press horn switch. If horn
does not sound, the main power is shut off.)
• Put blocks under track to prevent the machine from
moving.
• To prevent injury, do not perform maintenance with engine
running. If maintenance must be done with engine running,
perform maintenance with at least two workers and do the
following:
– One worker must always sit in the operator's seat and
be ready to stop engine at any time. All workers must
maintain contact with other workers.
– When maintenance operations are near fan, fan belt,
or other rotating parts, there is a potential hazard of
being caught in rotating parts. Keep hands and tools
away.
• Never drop or insert tools or other objects into rotating fan
or fan belt. Parts can break off and hit someone.
• Do not touch any control levers or control pedals. If any
control levers or control pedals must be operated, always
give a signal to other workers and instruct them to move
away.

1-1-36
• When performing maintenance of engine and you are
exposed to engine noise for long periods of time, wear
hearing protection while working.
• If noise from the machine is too loud, it can cause
temporary or permanent hearing problems.
• Do not smoke when you service an air conditioner or if
refrigerant gas is present.
• Inhaling fumes either from a flame or gas from a cigarette
that has contacted air conditioner refrigerant can cause
death or serious injury.
• Never put maintenance fluids into glass containers.
Drain all liquids into a suitable containers.
• Unless instructed otherwise, perform maintenance with
equipment in servicing position. Refer to this manual for
procedure for placing equipment in servicing position.
Warning Tag
Alert others that service or maintenance is being performed by
attaching a "DO NOT OPERATE" warning tag to the operator's
cabin controls – and other machine areas, if required. Use of a
chain or cable to keep the safety lever in the fully lowered
"LOCK" position, complies with OSHA's lockout requirements.
"DO NOT OPERATE" warning tags, are available from your
DOOSAN distributor.
• Always attach "DO NOT OPERATE" warning tag to work
equipment control lever in the operator's cabin to alert EX1301177
Figure 34
others that you are performing service or maintenance on
the machine. Attach additional warning tags on the
machine, if necessary.
• Keep warning tags in tool box while it is not used. If there is
not tool box or in the owner manual storage pocket.
• If any other person starts engine, and operates control
levers or control pedals while you are performing service or
maintenance, it can result in death or serious injury.
Attach a "DO NOT OPERATE" warning tag to starter switch or to
controls before servicing or repairing equipment. Warning tags
(Special Instruction, SEHS7332) are available from your
DOOSAN distributor.

1-1-37
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.
Proper Tools and Clothing

Only use tools that are intended for the type of service to be
done. Metal pieces from low quality or damaged tools, such as
chisels or hammers, can break off and hit a service person in the
eyes or face causing serious injury.
Disassembling Precautions
When using a hammer to remove pins, pins can fly out or metal
particles may break off. Always do the following:
• Hitting hard metal pins, bucket teeth, cutting edges or
bearings with a hammer, can cause metal pieces to break
or fly off resulting in serious injury. Always wear safety
goggles and leather gloves. Keep other personnel away.
Use of Lighting
When checking fuel, oil, battery electrolyte, window washer fluid,
or coolant, always use proper lighting equipment to prevent arcs
or sparks that could cause a fire or explosion resulting in death
or serious injury.

1-1-38
Fire and Explosion Prevention
Fuels, most lubricants and some coolant mixtures are
flammable. Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a fire resulting
in property damage or death or serious injury.
Store all fuels and all lubricants in properly marked and
approved containers and keep away from all unauthorized
personnel.
Store oily rags and other flammable material in a protective
HDO1015I
container.
Figure 36
Tighten all fuel and oil caps.
Do not smoke while you refuel machine or while you are in a
refueling area.
Do not smoke in battery charging areas or in areas that contain
flammable material.
Clean all electrical connections and tighten all electrical
connections. Check electrical wires daily for wires that are loose
or frayed. Tighten all loose, and repair or replace all frayed,
electrical wires before operating machine.
Remove all flammable materials and debris from the engine
compartment, exhaust system components and hydraulic lines. FG018458
Figure 37

1-1-39
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 haae2090
fire. Figure 38
Do not smoke while you are checking battery electrolyte level.
Electrolyte is an acid. Electrolyte can cause personal injury. Do
not allow electrolyte to contact skin or eyes.
Always wear safety goggles and face protection when working
with batteries.

1-1-40
Rubber That Contains Fluorides
Observe extra great care when it is suspected that you may
have to handle rubber that contains fluorides.
Certain seals which have to withstand high operating
temperatures (e.g. in engines, transmissions, axles, hydraulic
motors and pumps) may be made from rubber that contains
fluorides, which, when exposed to high heat (fire), forms
hydrogen fluoride and hydrofluoric acid. This acid is very
corrosive and cannot be rinsed or washed off from the skin. It
causes very severe burns which take a long time to heal.
It usually means that damaged tissue must be surgically
removed. Several hours may pass after contact with the acid,
before any symptoms appear and therefore one is not given any
immediate warning. The acid may remain on the machine parts
for several years after a fire.
If swelling, redness or a stinging feeling appears and one
suspects that cause may be contact with heated rubber that
contains fluorides, contact a medical doctor immediately. If a
machine, or part of a machine, has been exposed to fire or
severe heat, it must be handled by specially trained personnel.
In all handling of machines after a fire, thick rubber gloves and
protective goggles must be used.
The area around a part which has been very hot and which may
be made of rubber that contains fluorides must be
decontaminated by thorough and ample washing with limewater
(a solution or suspension of calcium hydroxide, i.e. slaked lime
in water). After the work has been completed, the gloves must
be washed in limewater and then discarded.

1-1-41
Rubber and Plastics
Polymer materials when heated, can form compounds that
create a health hazard and can harm the environment.
Scrapped rubber and plastics must never be burned. Extra
precautions must be taken when servicing machines that have
been in a fire or exposed to extreme heat.
If gas cutting or welding is to be done near such materials, the
following safety instructions must be followed:
• Protect the material from heat.
• Use protective gloves, protective goggles and an approved
respirator.
Waste Hazardous to the Environment

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

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

1-1-42
Welding Repairs
When performing welding repairs, perform welding in a properly
equipped place. Repairs must be performed by a qualified
welder. Welding operations, can create potential hazards,
including generation of gas, fire, or electric shock. Never let an
unqualified welder do welding.
A qualified welder must do the following:
• To prevent battery explosion, turn battery disconnect
switch to "OFF" position.
• To prevent generation of gas, remove paint from location
of the weld.
• If hydraulic equipment, piping or component ports close to
them are heated, a flammable gas or mist could result in
an explosion or fire. To prevent this, protect and insulate
components from excessive heat.
• Do not weld on pipes or on tubes that contain flammable
fluids. Do not flame cut pipes or tubes that contain
flammable fluids. Before welding on pipes or tubes, or
before flaming cut pipes or tubes, clean them thoroughly
with a nonflammable solvent. Make sure pressure inside
pipes or tubes does not cause a rupture of the component
parts.
• If heat is applied directly to rubber hoses or piping under
pressure, they may suddenly break, so cover and insulate
them with a fireproof covering.
• Wear protective clothing.
• Make sure there is good ventilation.
• Remove all flammable objects and make sure a fire
extinguisher is available.
Preparation for Electrical Welding On Body Structure

1. Turn battery disconnect switch to "OFF" position.
2. Disconnect the negative (-) cable of battery. OFF ON
OFF OFF
3. Proceed with welding.

ON
ON
4. Connect the negative (-) cable of battery.

5. Clean battery compartment.
6. Turn battery disconnect switch to "ON" position.
EX1500481
7. Close battery compartment door.
Figure 39

1-1-43
Warning for Counterweight and Front
Attachment Removal
WARNING
Removal of the machine counterweight, front attachment or
any other part can affect the stability of the machine. This
could cause unexpected movement, and result in death or
serious injury.
Never remove counterweight or front attachment unless the
upper structure is in-line with the lower structure.
EX1401352
Never rotate the upper structure once the counterweight or Figure 40
front attachment has been removed.
Lock Inspection Covers

When performing maintenance with inspection cover open, use
lock bar to secure cover and prevent accidental lowering of the
cover caused by wind or movement of the machine.
Working on Machine
When performing maintenance operations on machine, prevent
tripping and falling by keeping area around your feet clean and
free of objects and debris. Always do the following:
• Do not spill oil or grease.
• Do not leave tools laying around.
• Watch your step when walking.
• Never jump down from machine. When getting on or off
ARO1380L
machine, use steps and handrails, and maintain a
Figure 41
three-point contact (both feet and one hand or both hands
and one foot) to support yourself.
• If job requires it, wear protective clothing.
• To prevent injury from slipping or falling, when working on
hood or covers, never stand or walk on areas except areas
equipped with nonslip pads.
• If it is necessary to work under raised equipment or the
machine, support work equipment and machine securely
with blocks and stands strong enough to support weight of
work equipment and machine.
• Do not work under the machine if track shoes are lifted off
ground and the machine is supported only with work
equipment. If any control levers are moved, or there is
damage to hydraulic system, work equipment or the
machine will suddenly drop causing death or serious injury.

1-1-44
Accumulator
The pilot control system is equipped with an accumulator. For a
short period of time after engine has been stopped, accumulator
will store a pressure charge that allow hydraulic controls to be
activated. Activation of any controls will allow selected functions
to operate under force of gravity.
When performing maintenance on pilot control system, release
hydraulic pressure in system as described in Operation &
Maintenance Manual.
The accumulator is charged with high-pressure nitrogen gas. If it
is improperly handled it can explode causing death or serious
injury. Always observe the following precautions:
• Do not drill or punch holes in accumulator or expose it to
any flames, fire or external heat source.
• Do not weld on accumulator.
EX1400135
• When performing disassembly or maintenance of Figure 42
accumulator, or when disposing of accumulator, charged
nitrogen gas must be properly released. Contact your
DOOSAN distributor for assistance.
• Wear safety goggles and leather gloves when working on
an accumulator. Hydraulic oil under pressure can
penetrate skin and result in death or serious injury. If fluid
enters skin or eyes, get immediate medical attention from a
physician familiar with this injury.
Compressed Air
• When cleaning filters, radiator or other components with
compressed air, there is a hazard of flying particles that
can result in serious injury.
• Always wear safety goggles, dust mask, leather gloves,
and other protective devices.

1-1-45
Track Tension Adjustments
Track adjusting systems use grease under high-pressure to
keep track under tension. Grease under high-pressure can
penetrate body and result in death or serious injury. Watch track
or track spring to see if track is being loosened.
NEVER LOOSEN track tension grease valve. To release
pressure from crawler frame track tension assembly, you should
NEVER attempt to disassemble track adjuster or attempt to
remove track tension grease valve assembly.
HAOA110L
Keep your face and body away from grease valve. Refer to
Operation & Maintenance Manual, for proper procedure in this Figure 43
manual.
Supports and Blocking for Work

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

1-1-46
High-pressure Lines, Tubes and Hoses
When inspecting or replacing high-pressure piping or hoses,
check to verify that pressure has been released from circuit.
Failure to release pressure can result in death or serious injury.
Release pressure as described in Operation & Maintenance
Manual. 
Always do the following:
• Wear eye protection and leather gloves.
• Fluid leaks from hydraulic hoses or pressurized
components can be difficult to see but has enough force to
pierce skin and can result in death or serious injury. Always
use a piece of wood or cardboard to check for suspected
hydraulic leaks. Never use your hands or expose your
fingers. Wear safety goggles.
• Do not bend high-pressure lines. Do not strike
high-pressure lines. Do not install lines, tubes or hoses that
are bent or damaged.
• Make sure that all clamps, guards and heat shields are
correctly installed to prevent vibration, rubbing against
other parts, and excessive heat during operation.
EX1400129
• Replace hose or components if any of the following
problems are found: Figure 45
– Damage or leakage from hose end fitting.

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

1-1-47
Battery
Battery Hazard Prevention

Battery electrolyte contains diluted sulfuric acid and generates
hydrogen gas. Hydrogen gas is highly explosive, and improper
handling can cause death or serious injury, or fire. Do not allow
electrolyte to contact skin or eyes. Always wear safety goggles
and protective clothing when servicing batteries. Wash hands
after touching batteries and connectors. Use of acid-resistant
gloves is recommended. Always observe the following
precautions.
• Do not smoke or bring any flame near battery.
• When working with batteries, Always wear safety goggles,
protective clothing, and acid-resistant gloves.
• If you spill battery electrolyte on yourself or your clothes,
immediately flush area with water.
• If battery electrolyte gets into your eyes, flush them
immediately with large quantities of water and get
immediate medical attention from a physician familiar with
this injury.
• If you accidentally drink battery electrolyte, call a poison
prevention center immediately and get immediate medical
attention from a physician familiar with this injury.
• When cleaning top surface of battery, wipe it with a clean,
damp cloth. Never use gasoline, thinner, or any other EX1400136
organic solvent or detergent. Figure 46
• Tighten battery caps.
• If battery electrolyte is frozen, do not charge battery or start
engine with power from another source. This could cause
the battery to explode and start a fire.
• When charging battery or starting with power from another
source, let battery electrolyte thaw and check that there is
no leakage of battery electrolyte before starting operation.
• Always remove battery from machine before charging.
• Do not use or charge battery if battery electrolyte level is
below LOW LEVEL line. This can cause an explosion.
Periodically check battery electrolyte level and add distilled
water to bring electrolyte level to FULL LEVEL line.
• Before maintaining or working with batteries, turn starter
switch to "O" (OFF) position.

1-1-48
Since there is a potential hazard that sparks could be generated,
always do the following:
• Do not let tools, rings or other metal objects make any
contact between battery terminals. Do not leave tools or
other metal objects lying near battery.
• When disconnecting battery terminals, wait for
approximately one minute after turning engine starter
switch key to "O" (OFF) position, and be sure to disconnect
grounding terminal; negative (-) terminal first. Conversely,
when connecting them, begin with positive (+) terminal and
then grounding (-) terminal, Make sure that all terminals
are connected securely.
• Flammable hydrogen gas is generated when battery is
charged. Remove battery from machine, take it to a well
ventilated place, and remove battery caps, before charging
it.
• After charging, tighten battery caps securely.
• After charging, secure battery back in machine.
When repairing or welding electrical system, wait for
approximately one minute after turning engine starter switch key
"OFF". Then disconnect negative (-) terminal of battery to stop
flow of electricity.

1-1-49
ENVIRONMENT AND
CIRCUMSTANCES
Work Site Areas Requiring Extra Caution

• Do not operate too close to edge of a quay, ramp, etc.
• Do not operate too close to edge of a steep slope or
drop-off. Take care when working in a place where
machine may tip over.
• Do not operate on soft ground or near riverbanks that could
collapse or where ground may not support weight of
excavator.
• Observe changes in ground and traction conditions after a
rain or other changes in weather.
Digging Under an Overhang

Do not dig work face under an overhang. This can cause
overhang to collapse and fall on top of the machine.
• Do not perform overhead demolition work. This can cause
broken objects and debris to fall on top of machine causing
death or serious injury, or property damage.
EX1300686
Figure 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 tracks fore and aft to prevent any
movement. EX1300687
Figure 48
Use machine only for its intended purpose. Using it for other
purposes will cause failures.
• Do not perform demolition work under machine. There is a
hazard that the machine may become unstable and tip
over.
• When working on or from top of buildings or other
structures, check if structure can support weight of
machine and attachment. If a building structure collapses,
this can cause death or serious injury.

1-1-50
Drop-off or Edge
When working at edge of an excavation or near a drop-off, the
machine could tip over, which can result in death or serious
injury. Always fasten your seat belt. Check ground conditions of
work site before operating to prevent the machine from falling or
roll-over, and to prevent ground, stockpiles, or banks from
collapsing.
Do not travel too close to edge of a drop-off.
Poor Visibility
For good visibility, always do the following:
• When working in dark areas, attach working lights and
front lights to the machine. If necessary, set up additional
lighting at work site.
• Stop operations when visibility is poor, such as in fog, mist,
snow, and rain. Wait for visibility to improve before starting
operation.
To avoid hitting work equipment and damaging other property,
always do the following:
• When working in tunnels, on bridges, under electrical
wires, or when parking the machine or performing other
operations in places with limited height, be careful not to hit
and damage other equipment or property.
• To prevent hitting objects, operate machine at a slow
speed when working in confined spaces, indoors, or in
crowded areas.
• Do not swing bucket over the top of personnel or over
operator's cabin of dump truck.
Loose or Soft Ground

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

1-1-51
Loose ground may easily give way under weight of the machine.
When working on loose or unstable ground, it is important not to
dig too deep and to carefully reposition the machine. Do not
panic and do not raise bucket, if ground should begin to
collapse. Lower work equipment to improve stability of machine.
Never dig under machine, if there is a potential of causing a
landslide.
High-voltage Cables
Do not travel or operate machine near electrical cables or
overhead power lines. There is a hazard of electric shock, which
can cause property damage and result in death or serious injury.
The bucket or other attachment does not have to make physical
contact with power lines for current to cause an electrocution.
Use a spotter and hand signals to stay away from power lines
not clearly visible to operator. On work sites where machine may
operate close to electrical cables, always do the following:
EX1300688
• Remember that electrical voltage determines what the
Figure 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.
Voltage Minimum Distance

6.6 kV 3 m (9' 10")
33.0 kV 4 m (13' 1")
66.0 kV 5 m (16' 5")
154.0 kV 8 m (26' 3")
275.0 kV 10 m (32' 10")
• Always contact the power company responsible before

beginning work near high voltage power lines.

1-1-52
Underground Operation
If excavation is in an underground location or in a building, make
sure there is adequate overhead clearance, and adequate
ventilation.
Special equipment and engines may be required in some
countries. Contact your DOOSAN distributor for more
information.
Check that there is sufficient room for machine and load.
Move slowly.
Make sure that authorities or companies responsible for
underground cables, utilities, and electrical lines have been
contacted and that their instructions are followed. Also check
which rules apply to ground personnel regarding exposing
cables, utilities and electrical lines. EX1300689
Consider all electrical cables as live. Figure 50
Working in Water
IMPORTANT
Do not exceed maximum permissible water depth. The
water level must not reach higher than centerline of upper
track roller(s) (1, Figure 51).
After working in water, lubricate all lubrication points on 1 EX1300690

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

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

1-1-53
Operation in Extreme Conditions
Operation In Extreme Cold

In extremely cold weather, avoid sudden travel movements and
stay away from even slight slopes. The machine could slide
down the slope.
Snow accumulation could hide potential hazards and slippery
surfaces.
Warming up engine for a short period may be necessary to
avoid operating with sluggish or reduced working capacity. The
jolting shocks and impact loads caused by bumping or
bottoming boom or attachment could cause severe stress in
very cold temperatures. Reducing work cycle rate and workload
may be necessary.
If machine is to be operated in extremely cold weather
temperatures, certain precautions must be taken. The following
paragraphs detail checks to be made to be certain machine is
capable of operating at these temperatures.
1. Preheat the engine before startup. Wait 3 ~ 4 seconds
after preheating until voltage of the battery returns, and
then actuate the key switch.
2. Keep batteries fully charged to prevent freezing. If distilled
water is added to batteries, run engine at least one hour to
mix electrolyte solution. When temperature drops below -
10°C, effectiveness of the battery is reduced accordingly.
Insulation of the battery prevents this reduction, and
supports improvement of starting power of the starter.
WARNING
BATTERY EXPLOSION CAN CAUSE DEATH OR
SERIOUS INJURY
Never attempt to directly heat the battery with open fire.
3. Keep engine in good mechanical condition for easy starting

and good performance during adverse weather.
4. Use engine oil with proper specifications for expected
temperatures. Refer to Operation & Maintenance Manual
or Shop Manual for details.
5. Always keep the fuel tank fully filled after completion of
operation. The fuel filter, if frozen, may interrupt the flow of
fuel. Periodically remove water from the fuel tank, drain
water from the filter, and replace the filter upon regular
basis.
To prevent fuel from being clogged due to formation of wax
in fuel, make sure that wax formation point of fuel is lower
than atmospheric temperature.

1-1-54
6. Lubricate entire machine according to Operation &
Maintenance Manual or lubrication chart on machine.
WARNING
FUEL TANK EXPLOSION CAN CAUSE DEATH OR
SERIOUS INJURY
Never attempt to heat the fuel tank with an open flame.
7. Start engine and allow it to reach normal operating

temperature before operating.
• If mud and ice collects and freezes on any of moving
parts while machine is idle, apply heat to thaw frozen
material before attempting to operate machine.
• Operate hydraulic units with care until they have
reached a temperature which enable them to operate
normally.
• Check all machine controls and functions to be sure
they are operating correctly.
8. An extra outer air filter must be kept in operator's cabin to
replace element that could become iced and cause
restricted airflow to engine.
9. Clean off all mud, snow and ice to prevent freezing. Cover
machine with a tarp if possible, keep ends of tarp from
freezing to ground.
Operation in Extreme Heat

Continuous operation of machine in high temperatures can
cause machine to overheat. Monitor engine and hydraulic
system temperatures and stop machine to let it cool, when
necessary.
1. Make frequent inspections and services of fan and
radiator. Check coolant level in radiator. Check grilles and
radiator fins for accumulation of dirt, debris and insects
which could block cooling passages.
• Formation of scale and rust in cooling system occurs
more rapidly in extremely high temperatures. Change
antifreeze each year to keep corrosion inhibitor at full
strength.
• If necessary, flush cooling system periodically to
keep passages clear. Avoid use of water with a high
alkali content which increases scale and rust
formation.

1-1-55
2. Check level of battery electrolyte daily. Keep electrolyte
above plates to prevent damage to batteries. Use a slightly
weaker electrolyte solution in hot climates. Batteries
self-discharge at a higher rate if left standing for long
periods at high temperatures. If machine is to stand for
several days, remove batteries and store in a cool place.
IMPORTANT
Do not store acid type storage batteries near stacks of
tires. Acid fumes can damage rubber.
3. Service fuel system as directed in "Check Fuel Level" on

page 4-27 and "Check for Leaks in Hydraulic System" on
page 4-27, of Operation & Maintenance Manual. Check for
water content before filling fuel tank. High temperatures
and cooling off cause condensation in storage drums.
4. Lubricate as specified in "Lubrication and Service Chart" on
page 4-15, in Operation & Maintenance Manual or
Lubrication Decal on machine.
5. Do not park machine in sun for long periods of time. If
possible, park machine under cover to protect it from sun,
dirt and dust.
A. Cover machine if no suitable shelter is available.
Protect engine compartment and hydraulics from dirt
and debris.
B. In hot, damp climates, corrosion will occur on all parts
of machine and will be accelerated during rainy
season. Rust and paint blisters will appear on metal
surfaces and fungus growth on other surfaces.
C. Protect all unfinished, exposed surfaces with a film of
preservative lubricating oil. Protect cables and
terminals with ignition insulation compound. Apply
paint or suitable rust preventive to damaged surfaces
to protect them from rust and corrosion.
Operation In Dusty and Sandy Areas

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

1-1-56
2. Use care when servicing fuel system to prevent dust and
sand from entering tank.
3. Service air cleaner at frequent intervals, check air
restriction indicator daily and keep dust cup and dust valve
clean. Prevent dust and sand from entering engine parts
and compartments as much as possible.
4. Lubricate and perform services outlined on current
lubrication chart on machine and Operation & Maintenance
Manual. Clean all lubrication fittings before applying
lubricant. Sand mixed with lubricant becomes very
abrasive and accelerates wear on parts.
5. Protect machine from dust and sand as much as possible.
Park machine under cover to keep dust and sand from
damaging unit.
Operation in Rainy or Humid Conditions

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

Saltwater and saltwater spray is very corrosive. When operating
in saltwater areas, or in or around snow, observe the following
precautions:
1. When exposed to saltwater, dry machine thoroughly and
rinse with freshwater, as soon as possible.
2. Keep all exposed surfaces coated with preservative
lubricating oil. Pay attention to damaged paint surfaces.
3. Keep all painted surfaces in good repair.
4. Lubricate machine as prescribed on lubrication chart on
machine or Operation & Maintenance Manual. Shorten
lubricating intervals for parts exposed to salt water.
5. Check operating controls to ensure proper functionality
and that they return to "NEUTRAL" when released.

1-1-57
Operation at High Altitudes
Operation instructions at high altitudes are the same as those
provided for extreme cold. Before operating at high altitudes,
engine fuel and air mixture may have to be adjusted according
to appropriate engine manual.
1. Check engine operating temperature for evidence of
overheating. The radiator cap must make a perfect seal to
maintain coolant pressure in cooling system.
• Perform warming-up operation thoroughly. If machine
is not thoroughly warmed up before control levers or
control pedals are operated, reaction of machine will
be slow.
• If battery electrolyte is frozen, do not charge battery
or start engine with a different power source. There is
a potential hazard that could cause a battery
explosion or fire.
• Before charging or starting engine with a different
power source, thaw battery electrolyte and check for
any leakage of electrolyte before starting.
Operation During Electrical Storms

During electrical storms, do not enter or exit machine.
• If you are off machine, keep away from machine until storm
passes.
• If you are in cabin, remain seated with machine stationary
until storm passes. Do not touch controls or anything
metal.
Exhaust Ventilation
Engine exhaust gases can cause unconsciousness, loss of
alertness, judgment and motor control. This can result in death
or serious injury.
Make sure there is adequate ventilation before starting engine in
any enclosed area.
Check for and be aware of any open windows, doors or
ductwork where exhaust may be carried, or blown by wind,
exposing others to hazardous exhaust gases.
ARO1770L
Figure 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.

1-1-58
Asbestos Information
WARNING
Avoid exposure to dust containing asbestos as it can cause
death or serious injury to the lungs and other organs
(mesothelioma, lung and other cancers, and asbestosis).
Asbestos dust can be HAZARDOUS to your health if it is inhaled.

Materials containing asbestos fiber can be present on work sites.
Breathing air that contains asbestos fiber can ultimately cause
serious or fatal lung damage or diseases such as mesothelioma,
lung and other cancers, and asbestosis. To prevent lung damage
from asbestos fiber, observe the following precautions:
• Use an approved respirator that is approved for use in an
asbestos-laden atmosphere.
• Use water for cleaning to keep down dust.
• Always observe any regulations related to work site and
working environment.
• Avoid brushing or grinding materials that contain asbestos.
• A vacuum cleaner that is equipped with a high efficiency
particulate air filter can also be used.
• Comply with applicable laws and regulations for workplace.
• Stay away from areas that might have asbestos particles in
air.
Silica Dust Information
WARNING
Avoid exposure to dust containing crystalline silica
particles as it can cause serious injury to the lungs
(silicosis).
Cutting or drilling concrete containing sand or rock containing

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

1-1-59
Disposal of Hazardous Materials
Physical contact with used motor oil or gear oil could create a
health risk. Wipe oil from your hands promptly and wash off any
remaining residue.
Used motor oil or gear oil is an environmental contaminant and
should only be disposed of at approved collection facilities. To
prevent pollution of environment, always do the following:
• Never dump waste oil in a sewer system, rivers, etc.
• Always put drained oil from your machine in approved, leak FG009156
proof containers. Never drain oil directly onto ground. Figure 53
• Obey appropriate laws and regulations when disposing of
harmful materials such as oil, fuel, solvent, filters, and
batteries.
Improperly disposing of waste can threaten environment.
Potentially harmful fluids must be disposed of according to local
regulations.
Use all cleaning solutions with care. Report all necessary
repairs.
Sound
Sound Level Information: Hearing protection may be required
when machine is operated with an open operator station for
extended periods or in a noisy environment.
Sound pressure level (LpA) at operator position

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

1-1-60
Vibration
Hands and Arms: The weighted root mean square acceleration
to which hands and arms are subjected, is less than 2.5 m/s2.
Whole Body: The weighted root mean square acceleration to
which whole body is subjected, is less than 0.5 m/s2.
Measurements are obtained on a representative machine, using
measuring procedures as described in the following standard:
ISO 2631/1. ISO 5349, and SAE J1166.
Recommendations for Reducing Vibrations:
1. Select proper machine, equipment and attachments for a
particular application.
2. Replace any damaged seat with a genuine DOOSAN seat.
Keep seat properly maintained and adjusted.
• Adjust seat and suspension for weight and size of
operator.
• Inspect and maintain suspension and adjustment
mechanisms for seat regularly.
3. Check that the machine is properly maintained.
4. Operate controls smoothly when; steering, accelerating,
slowing down, loading, or moving attachments.
5. Adjust machine speed and travel path to reduce vibration
level.
• Slow down when traveling over rough terrain or long
distances.
• Avoid obstacles and rough terrain.
6. Keep machine on and maintain designated travel path
when traveling.
• Remove any large rocks or obstacles.
• Fill any ditches and holes.
• Use other machines to maintain the travel path for the
excavator.

1-1-61
1-1-62
1Specifications
1Specifications
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Specifications
2-1-1
Table of Contents
Specifications
General ...........................................................2-1-3
General Description................................................... 2-1-3
Component Locations.....................................2-1-4
General Dimensions .......................................2-1-8
Working Range .............................................2-1-12
General Specifications..................................2-1-16
Engine Performance Curves.........................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......................2-1-25
Hydraulic Cylinder Cycle Time ................................ 2-1-25
Travel Speed ........................................................... 2-1-27
Track Revolution Speed .......................................... 2-1-28
Mistrack Check ........................................................ 2-1-30
Swing Speed ........................................................... 2-1-32
Swing Function Drift Check ..................................... 2-1-33
Specifications DX480LCA-K/DX520LCA-K
2-1-2
GENERAL
General Description
The excavator has three main component sections:
• The Upper Structure
• The Lower Undercarriage and Track Frames
• The Excavator Front-end Attachment
The following illustration identifies main components and their
locations. (See Figure 1 on page -4.)
2-1-3
COMPONENT LOCATIONS
1
5 3
2
7
19
20
18 8
12
17
13 9
16
14
15
11
10
DS1703891
Figure 1
Reference Reference
Description Description
Number Number
1 Hood 11 Bucket
2 Counterweight 12 Tooth Point
3 Cabin 13 Side Cutter
4 Boom Cylinder 14 Track Link and Shoe
5 Boom 15 Idler
6 Arm Cylinder 16 Track Adjuster
7 Arm 17 Lower Roller
8 Bucket Cylinder 18 Upper Roller
9 Guide Link 19 Travel Motor
10 Push Link 20 Sprocket
2-1-4
2
1 FR
ON
4 T
DS1703888
Figure 2
Reference Reference
Number Number
1 Engine 5 Air Cleaner
2 Radiator and Oil Cooler 6 Main Pump
3 Engine Oil Filter 7 Muffler
4 Precleaner
2-1-5
13
12 FR
ON
5 T
6
11
10
2
3
1
DS1703889
Figure 3
Reference Reference
Number Number
1 Battery 7 Hydraulic Oil Tank
2 Fuel Tank 8 Air Breather
3 Fuel Cap 9 Return Filter
4 Main Fuel Filter 10 Suction Filter
Water Separator & 11 Pilot Filter
5
Pre Fuel Filter 12 Surge Tank
6 Additional Water Separator 13 Cap (Coolant)
2-1-6
FR
5 ON
T
1
DS1703890
Figure 4
Reference Reference
Number Number
1 Swing Bearing 4 Solenoid Valve
2 Center Joint 5 Control Valve
3 Swing Device 6 Gear Pump
2-1-7
GENERAL DIMENSIONS
DX480LCA-K
G (G') A
H B
I
L F
N E
O
J C
K (K') D
EX1300752
Figure 5
2-1-8
6.3 m 7.1 m
7.1 m (23' 4")
(20' 8") (23' 4")
Boom
Boom Boom
Dimension
3.35 m 2.9 m 3.98 m 2.9 m 3.35 m
(11' 0") (9' 6") (13' 1") (9' 6") (11' 0")
Arm Arm Arm Arm Arm
Remarks Variable Fixed
13,130 mm 12,230 mm 12,210 mm 11,430 mm 12,180 mm
A Shipping Length
(43' 1") (40' 1") (40' 1") (37' 6") (39' 12")
3,700 mm
B Tail Swing Radius 3,700 mm (12' 2")
(12' 2")
C Tumbler Distance 4,470 mm (14' 8")
D Track Length 5,455 mm (17' 11")
1,275 mm
E Counterweight Clearance **1,426 mm (4' 8")
(4' 2")
F 3,580 mm 3,830 mm 3,840 mm 4,140 mm 3,570 mm
Shipping Height
(Boom) (11' 9") (12' 7") (12' 7") (13' 7") (11' 9")
F 3,730 mm 3,980 mm 3,990 mm 4,200 mm 3,720 mm
Shipping Height
(Hose) (12' 3") (13' 1") (13' 1") (13' 9") (12' 2")
3,350 mm
G Shipping Width (STD) 3,340 mm (10' 11")
(11' 0")
G' Shipping Width (Narrow) 3,070 mm (10' 1")/2,990 mm (9' 10") -
H House Width 2,990 mm (9' 10")
I Cab Width 1,010 mm (3' 4")
J Shoe Width 600 mm (1' 12")
3,350 mm
K(Std) Undercarriage Width * 3,900 mm (12' 10")/3,340 mm (11' 0") (Transport position)
(10' 12")
K' * 3,570 mm (11' 9")/3,070 mm (10' 1") (Transport position)

Undercarriage Width -
(Narrow) * 3,490 mm (11' 5")/2,990 mm (9' 10") (Transport position)
3,175 mm
L Height Over Cab ** 3,326 mm (10' 11")
(10' 5")
M Cab Height Above House 845 mm (2' 9")
1,069 mm
N Track Height **1,183 mm (3' 11")
(3' 6")
532 mm
O Car Body Clearance **725 mm (2' 5")
(1' 9")
* Retracted/Extended
** Without Grouser
2-1-9
DX520LCA-K
G (G') A
H B
I
L F
N E
O
J C
K (K') D
EX1300752
Figure 6
2-1-10
11.0 m
6.3 m (20' 8") 7.1 m (23' 4")
(36' 1")
Boom Boom
Boom
Dimension
2.9 m 2.4 m 8.0 m
3.35 m (11' 0")
(9' 6") (7' 10") (26' 3")
Arm
Arm Arm Arm
Remarks Variable Fixed
11,430 mm 11,620 mm 16,090 mm 12,130 mm 12,180 mm
A Shipping Length
(37' 6") (38' 1") (52' 9") (39' 10") (40' 0")
B Tail Swing Radius 3,700 mm (12' 2")
C Tumbler Distance 4,470 mm (14' 8")
D Track Length 5,455 mm (17' 11")
1,275 mm
E Counterweight Clearance **1,426 mm (4' 8")
(4' 2")
F 4,140 mm 4,010 mm 3,930 mm 3,990 mm 3,570 mm
Shipping Height
(Boom) (13' 7") (13' 2") (12' 11") (13' 1") (11' 9")
F 4,200 mm 4,100 mm 4,070 mm 4,125 mm 3,720 mm
Shipping Height
(Hose) (13' 9") (13' 5") (13' 4") (13' 6") (12' 2")
3,350 mm
G Shipping Width (STD) 3,340 mm (10' 11")
(11' 0")
G' Shipping Width (Narrow) 3,070 mm (10' 1")/2,990 mm (9' 10") -
H House Width 2,990 mm (9' 10")
I Cab Width 1,010 mm (3' 4")
J Shoe Width 600 mm (1' 12")
3,350 mm
K(Std) Undercarriage Width * 3,900 mm (12' 10")/3,340 mm (10' 11") (Transport Position)
(11' 0")
K' * 3,570 mm (11' 9")/3,070 mm (10' 1") (Transport position)

Undercarriage Width -
(Narrow) * 3,490 mm (11' 5")/2,990 mm (9' 10") (Transport position)
3,175 mm
L Height Over Cab ** 3,326 mm (10' 11")
(10' 5")
M Cab Height Above House 845 mm (2' 9")
1,069 mm
N Track Height **1,183 mm (3' 11")
(3' 6")
532 mm
O Car Body Clearance **725 mm (2' 5")
(1' 9")
* Retracted/Extended
** Without Grouser
2-1-11
WORKING RANGE
WARNING
The Minimum Digging Reach or "L" dimension, depends on
the stability and support provided by ground conditions.
Digging too far underneath the excavator if soil conditions
are wet, loose or unstable can collapse ground support,
which could cause death or serious injury and/or
equipment damage.
DX480LCA-K
F
G
D
E
d
G.L 0
L
H J
C
K 8'
I
B
A
EX1300965
Figure 7
2-1-12
6.3 m
Boom Type 7.1 m (23' 4")
(20' 8")
Dim.
3.35 m 2.9 m 3.98 m 3.35 m ** 3.35 m 2.9 m
Arm Type
(11' 0") (9' 6") (13' 1") (11' 0") (11' 0") (9' 6")
12,120 mm 11,720 mm 12,670 mm 12,150 mm 12,120 mm 10,770 mm
A Max. Digging Reach
(39' 9") (38' 5") (41' 7") (39' 10") (39' 9") (35' 4")
Max. Digging Reach 11,870 mm 11,460 mm 12,430 mm 11,900 mm 11,870 mm 10,480 mm
B
(Ground) (38' 11") (37' 7") (40' 9") (39' 1") (38' 11") (34' 5")
7,810 mm 7,360 mm 8,440 mm 7,850 mm 7,655 mm 6,810 mm
C Max. Digging Depth
(25' 7") (24' 2") (27' 8") (25' 9") (25' 1") (22' 4")
7,880 mm 7,730 mm 8,040 mm 7,850 mm 7,725 mm 6,595 mm
D Max. Loading Height
(25' 10") (25' 4") (26' 5") (25' 9") (25' 4") (21' 8")
3,125 mm 3,580 mm 2,500 mm 3,110 mm 2,970 mm 2,930 mm
E Min. Loading Height
(10' 3") (11' 9") (8' 2") (10' 2") (9' 9") (9' 7")
11,080 mm 10,940 mm 11,230 mm 10,930 mm 10,925 mm 9,720 mm
F Max. Digging Height
(36' 4") (35' 11") (36' 10") (35' 10") (35' 10") (31' 11")
9,705 mm 9,560 mm 9,850 mm 9,720 mm 9,550 mm 8,520 mm
G Max. Bucket Pin Height
(31' 10") (31' 4") (32' 4") (31' 11") (31' 4") (27' 11")
Max. Vertical Wall 4,410 mm 4,080 mm 4,965 mm 5,310 mm 4,255 mm 2,920 mm
H
Depth (14' 6") (13' 5") (16' 3") (17' 5") (14' 0") (9' 7")
9,970 mm 9,705 mm 10,235 mm 9,310 mm 9,970 mm 9,310 mm
I Max. Radius Vertical
(32' 9") (31' 10") (33' 7") (30' 7") (32' 9") (30' 7")
Max. Depth to 7,635 7,165 8,265 7,645 7,635 6,555
J
2,500 mm Line (25' 1") (23' 6") (27' 1") (25' 1") (25' 1") (21' 6")
Min. Radius  3,895 3,885 3,905 3,895 3,895 3,195
K
2,500 mm Line (12' 9") (12' 9") (12' 10") (12' 9") (12' 9") (10' 6")
880 mm 2,050 mm 80 mm 820 mm 880 mm 1,140 mm
L Min. Digging Reach
(2' 11") (6' 9") (0' 3") (2' 8") (2' 11") (3' 9")
5,170 mm 5,190 mm 5,140 mm 5,170 mm 5,170 mm 4,750 mm
M Min. Swing Radius
(17' 0") (17' 0") (16' 10") (17' 0") (17' 0") (15' 7")
d Bucket Angle 174° 174° 174° 174° 174° 176°
** Fixed Track
2-1-13
DX520LCA-K
F
G
D
E
d
G.L 0
L
H J
C
K 8'
I
B
A
EX1300965
Figure 8
2-1-14
11.0 m
Boom Type 6.3 m (20' 8") 7.1 m (23' 4")
(36' 1")
Dim.
2.9 m 2.4 m ** 2.9 m 3.35 m 2.4 m 8.0 m
Arm Type
(9' 6") (7' 10") (9' 6") (11' 0") (7' 10") (26' 3")
10,750 mm 10,330 mm 10,750 mm 12,120 mm 11,215 mm 19,610 mm
A Max. Digging Reach
(35' 3") (33' 11") (35' 3") (39' 9") (36' 10") (64' 4")
Max. Digging Reach 10,460 mm 10,030 mm 10,460 mm 11,870 mm 10,944 mm 19,460 mm
B
(Ground) (34' 4") (32' 11") (34' 4") (38' 11") (35' 11") (63' 10")
6,770 mm 6,270 mm 6,615 mm 7,810 mm 6,847 mm 15,130 mm
C Max. Digging Depth
(22' 3") (20' 7") (21' 8") (25' 7") (22' 6") (49' 8")
6,720 mm 6,620 mm 6,565 mm 7,880 mm 7,505 mm 11,950 mm
D Max. Loading Height
(22' 1") (21' 9") (21' 6") (25' 10") (24' 7") (39' 2")
2,950 mm 3,470 mm 2,795 mm 3,125 mm 4,155 mm 1,980 mm
E Min. Loading Height
(9' 8") (11' 5") (9' 2") (10' 3") (13' 8") (6' 6")
9,600 mm 9,460 mm 9,445 mm 11,080 mm 10,494 mm 14,520 mm
F Max. Digging Height
(31' 6") (31' 0") (31' 0") (36' 4") (34' 5") (47' 8")
8,520 mm 8,420 mm 8,365 mm 9,705 mm 9,311 mm 10,735 mm
G Max. Bucket Pin Height
(27' 11") (27' 7") (27' 5") (31' 10") (30' 7") (35' 3")
Max. Vertical Wall 1,190 mm 590 mm 1,035 mm 4,410 mm 1,380 mm 12,840 mm
H
Depth (3' 11") (1' 11") (3' 5") (14' 6") (4' 6") (42' 2")
10,100 mm 9,840 mm 10,100 mm 9,970 mm 10,536 mm 9,730 mm
I Max. Radius Vertical
(33' 2") (32' 3") (33' 2") (32' 9") (34' 7") (31' 11")
Max. Depth to 6,535 6,020 6,535 7,165 6,635 15,010
J
2,500 mm Line (21' 5") (19' 9") (21' 5") (23' 6") (21' 9") (49' 3")
Min. Radius  3,175 3,195 3,175 3,885 3,830 6,165
K
2,500 mm Line (10' 5") (10' 6") (10' 5") (12' 9") (12' 7") (20' 23")
1,240 mm 2,060 mm 1,240 mm 880 mm 3,263 mm 270 mm
L Min. Digging Reach
(4' 1") (6' 9") (4' 1") (2' 11") (10' 8") (0' 11")
4,750 mm 4,780 mm 4,750 mm 5,170 mm 5,170 mm 6,210 mm
M Min. Swing Radius
(15' 7") (15' 8") (15' 7") (17' 0") (17' 0") (20' 4")
d Bucket Angle 174° 176° 174° 174° 117° 178°
** Fixed Track
2-1-15
GENERAL SPECIFICATIONS
DX480LCA-K
Specification
Component
Metric English
Bucket CECE 1.89 m 3
2.47 yd3
Capacity SAE (PCSA) 2.14 m3 2.80 yd3
Operating Weight 49.3 metric tons 54.3 tons
Model DX12TI
Type Water COOLED - 6 Cylinders
Rated Output (Gross) 238 kW@2,000 rpm 319 HP (323 PS)@2,000 rpm
Engine
Rated Output (Net) 223 kW@2,000 rpm 299 HP (300 PS)@2,000 rpm
Maximum Torque 139 kg.m@1,300 rpm 1,005 ft lb@1,300 rpm
Fuel Tank Capacity 620 L 164 U.S. gal.
Type Axial Piston
Discharging Pressure 355 kg/cm2 5,049 psi
Hydraulic Maximum Discharge Quantity 2 x 387 L/min 2 x 102.2 U.S. gpm
Pump Tank Level 265 L 70 U.S. gal.
Hydraulic Oil
Full 390 L 103 U.S. gal.
Capacity
System 500 L 132.1 U.S. gal.
Digging Bucket (STD) 24.9/*27.2 metric tons 27.4/*30.0 tons
Capability (SAE) Arm (STD) 20.1/*22 metric tons 22.2/*24.2 tons
Capability (ISO) Arm (STD) 20.7/*22.6 metric tons 22.8/*24.9 tons
Swing Speed 8.7 rpm
Performance High-speed 5.7 km/h 3.54 MPH
Travel Speed
Low-speed 3.2 km/h 1.99 MPH
High-speed 20.7 metric tons 22.8 tons
Traction Force
Low-speed 36.4 metric tons 40.1 tons
Gradeability 35° (70% slope)
Ground pressure 0.85 kg/cm2 12.1 psi
Ground Clearance 770 mm 30.3 in
Track Shoe Width 600 mm 23.6 in
Upper Roller Qty. 3 per side
Bottom roller qty. 9 per side
2-1-16
DX520LCA-K
Specification
Component
Metric English
Bucket CECE 2.89 m 3
3.78 yd3
Capacity SAE (PCSA) 3.28 m3 4.29 yd3
Operating Weight 52.1 metric tons 57.4 tons
Model DX12TI
Type Water Cooled - 6 Cylinders
Rated Output (Gross) 238 kW@2,000 rpm 319 HP (323 PS)@2,000 rpm
Engine
Rated Output (Net) 223 kW@2,000 rpm 299 HP (300 PS)@2,000 rpm
Maximum Torque 139 kg.m@1,300 rpm 1,005 ft lb@1,300 rpm
Fuel Tank Capacity 620 L 164 U.S. gal.
Type Axial Piston
Discharging Pressure 355 kg/cm2 5,049 psi
Hydraulic Maximum Discharge Quantity 2 x 387 L/min 2 x 102.2 U.S. gpm
Pump Tank Level 265 L 70 U.S. gal.
Hydraulic Oil
Full 390 L 103 U.S. gal.
Capacity
System 500 L 132.1 U.S. gal.
Capability (SAE) Arm (STD) 23.2/*25.4 metric tons 25.8/*28.0 tons
Capability (ISO) Arm (STD) 23.6/*25.8 metric tons 26.0/*28.4 tons
Swing Speed 8.7 rpm
Performance High-speed 5.7 km/h 3.54 MPH
Travel Speed
Low-speed 3.2 km/h 1.99 MPH
High-speed 20.7 metric tons 22.8 tons
Traction Force
Low-speed 36.4 metric tons 40.1 tons
Gradeability 35° (70% slope)
Ground Pressure 0.9 kg/cm2 12.5 psi
Ground Clearance 770 mm 30.3 in
Track Shoe Width 600 mm 23.6 in
Upper Roller Qty. 3 per side
Bottom Roller Qty. 9 per side
2-1-17
ENGINE PERFORMANCE CURVES
340
320 180
Power Output (ps)
300 160
280 140
260 120
Torque (kg.m)
240 100
220 80
Fuel Consumption (g/ps.h)
200 60
180 40
160 20
140 0
1000 1200 1400 1600 1800 2000
Revolution (rpm)
DS1800049
Figure 9
Condition Specification
Engine Model DX12TI
Barometric Pressure 760 mmHg (20C (68°F))
Alternator Not Installed
Air Cleaner Installed
Muffler Installed
Cooling Fan Not Installed
Test Evaluation Standard KS-R0071

Engine Output (Rated) 323 PS/2,000 rpm
Torque (Max.) 1,363 N.m (139 kg.m, 1,005 ft lb)/1,300 rpm
Fuel Consumption (Max. Rated) 160 g/ps.hr
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.
Density Density Density Density

1,200 kg/m3 1,500 kg/m3 1,800 kg/m3 2,100 kg/m3
Material
(2,000 lb/yd3), (2,500 lb/yd3), (3,000 lb/yd3), (3,500 lb/yd3),
or less or less or less or less
401 kg/m3
Charcoal - - -
(695 lb/yd3)
433 kg/m3
Coke, blast furnace size - - -
(729 lb/yd3)
449 kg/m3
Coke, foundry size - - -
(756 lb/yd3)
801 kg/m3
Coal, bituminous slack, piled - - -
(1,350 lb/yd3)
881 kg/m3
Coal, bituminous r. of m., piled - - -
(1,485 lb/yd3)
897 kg/m3
Coal, anthracite - - -
(1,512 lb/yd3)
1,009 kg/m3
Clay, DRY, in broken lumps - - -
(1,701 lb/yd3)
1,746 kg/m3
Clay, DAMP, natural bed - - -
(2,943 lb/yd3)
1,506 kg/m3
Cement, portland, DRY granular - - -
(2,583 lb/yd3)
1,362 kg/m3
Cement, portland, DRY clinkers - - -
(2,295 lb/yd3)
1,522 kg/m3
Dolomite, crushed - - -
(2,565 lb/yd3)
1,202 kg/m3
Earth, loamy, DRY, loose - - -
(2,025 lb/yd3)
1,522 kg/m3
Earth, DRY, packed - - -
(2,565 lb/yd3)
1,762 kg/m3
Earth, WET, muddy - - -
(2,970 lb/yd3)
Gypsum, calcined, (heated, 961 kg/m3
- - -
powder) (1,620 lb/yd3)
2-1-19
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)
2-1-20
PERFORMANCE TESTS
Use operational performance test procedure to quantitatively
check all system and functions on the machine.
Purpose of Performance Tests

1. To comprehensively evaluate each operational function by
comparing the performance test data with the standard values.
2. According to the evaluation results, repair, adjust, or
replace parts or components as necessary to restore the
machine’s performance to the desired standard.
3. To economically operate the machine under optimal
conditions.
Kinds of Tests
1. Base machine performance test is to check the operational
performance of each system such as engine, travel, swing,
and hydraulic cylinders.
2. Hydraulic component unit test is to check the operational
performance of each component such as hydraulic pump,
motor, and various kinds of valves.
Performance Standards
"Performance Standard" is shown in tables to evaluate the
performance test data.
Precautions for Evaluation of Test Data

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

1. Operation speed values and dimensions of the new
machine.
2. Operational performance of new components adjusted to
specifications. Allowable errors will be indicated as
necessary.
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 travel
straight ahead more than 20 m (65 ft 7 in), and to make a
full swing with the front attachment extended.
3. If required, place cones or barricades around the test area
and post signs to keep unauthorized personnel away.
Precautions
1. Before starting to test, agree upon the signals to be
employed for communication among coworkers.
Once the test is started, be sure to communicate with each
other using these signals, and to follow them without fail.
2. Operate the machine carefully and always give first priority
to safety.
3. Do not operate on soft ground, near drop-offs, around
electrical cables, or overhead power lines. Always confirm EX1302009
there is sufficient space for full swings Figure 10
4. Use leak proof containers to catch drained or leaking oil.

Obey local laws and regulations when disposing of oil, fuel,
filters and batteries.
Make Precise Measurement

1. Accurately calibrate test instruments in advance to obtain
correct data.
2. Perform tests under the exact test conditions prescribed for
each test item
3. Repeat the same test and confirm that test data obtained
can be produced repeatedly. Use mean values of
measurements if necessary.
EX1302010
Figure 11
2-1-22
OPERATIONAL PERFORMANCE STANDARD TABLE
Measuring Performance
Item Model Unit
Conditions Standard
Power Mode rpm *Standard 2,050 +50
Standard Mode rpm *Standard, S Mode 1,900 +50
No Load Economy Mode rpm *Standard, E Mode 1,900 +50
Auto Idle rpm *Standard 1,200 ±50
Low Idle rpm Dial Min. 980 ±50
1 Pump Relief rpm above 1,900
Engine  Load *Standard
Speed 2 Pump Relief rpm above 1,900
Power Mode rpm above 1,900
*Standard. Decrease
Standard Mode rpm the rpm from Max. above 1,750
Revolution at 
Economy Mode rpm using the dial, and find above 1,750
Boom Up 
1300 rpm rpm the lowest rpm that above 1,200
or Arm Dump
remains constant for
Should not stop
Low rpm more than 1 second.
engine
Power Mode mA 200 ±30
Minimum Value at Arm
Standard Mode mA 260 ±30
EPPR Valve Current Crowd
EPOS Economy Mode mA 310 ±30
for Pump
Auto Idle mA 650 ±30
Idle
Low Idle mA 650 ±30
Relief bar 319 +10
Main *Standard
Relief Power Up bar 348 +10
Swing Relief (at Motor) bar *Standard 294 +10
Pressure Set
Rotating Relief bar *Standard, at Pipe Room 80 ±25
Option 1 Way Relief bar *Standard, Max rpm, 222 ±25
2 Way Relief bar Flow rate gauge: middle 319 +10
Up sec 3.8 ±0.4
Boom Down sec 2.6 ±0.3
Down (Lock Valve) sec *Standard, sudden 3.1 ±0.3
Front Crowd sec 4.1 ±0.4
command, up to just
Speed
Arm Crowd (Lock Valve) sec before the cushion 4.6 ±0.4
Dump sec section 3.1 ±0.3
Crowd sec 3.0 ±0.4
Bucket
Dump sec 3.1 ±0.3
*Standard, Swing
Swing Speed Swing Speed sec 21.4 ±1.5
Single 3 Revolution
Swing After 180° Swing,
Swing Coasting Swing Coasting mm Empty Bucket, 1,470(100°) ±200
Bearing Outer Race
2-1-23
Measuring Performance
Item Model Unit
Conditions Standard
mm/ Max. reach posture,
Boom Down below 5
5 min bucket crowd posture,
mm/ weight bucket (1.5
Front  Arm Crowd below 5
Settlement 5 min times of bucket
(Weight Bucket)
capacity) should not
mm/ be natural lowering at
Bucket Dump below 20
5 min lock valve
Track Sag Track Sag mm Jack Up Posture 395 ±15
Travel Speed on Flat 1st Gear sec 22 ±1.5
*Standard
(20 m) 2nd Gear sec 12.9 ±1.0
Travel 1st Gear sec 38.4 ±2.0
Jack-up (3 turns) *Standard
2nd Gear sec 21.1 ±1.5
1st Gear mm *Standard below 150
Travel Deviation (20 m)
2nd Gear mm Forward/Reverse Each below 150
• Standard Condition: P Mode, Engine Dial Max. A/I Off, A/C Off, Digging Mode, Oil 50 ±5°C, Coolant 80 +10°C
2-1-24
OPERATIONAL PERFORMANCE TEST
Hydraulic Cylinder Cycle Time
Summary
1. Check the overall operational performance of the front
attachment hydraulic system (between the hydraulic
pumps and each cylinder) by measuring the cycle time of
the boom, arm, bucket, and bucket dump (open/close)
cylinders with the empty bucket.
2. Bucket must be empty.
Preparation
1. Maintain the hydraulic oil temperature at 50 ±5°C
(122 ±41°F).
Engine Power Mode Auto-idle

Work Mode
Control Dial Switch Switch
Digging
High Idle Power Mode OFF
Mode
2. Position the front attachment as described in the following.

Then, measure the operating time until cylinder reaches
the stroke end by fully moving the control lever.
A. Boom cylinder
1) Boom up speed
Rapidly operate the bucket from the ground,
and measure the time it takes for the boom to
reach the end point.
2) Boom down speed
Rapidly operate the bucket with the boom
reached the end point, and measure the time it
takes for the bucket to reach the ground. EX1301781
3) Measuring available displacement of the Figure 12
cylinder: Measure and record the extension of
the cylinder rod from when the bucket is resting
on the ground to when the boom cylinder is
extended to its maximum length.
2-1-25
B. Arm cylinder
1) Arm crowd speed
Rapidly operate the arm while kept fully dumped
(extended), and measure the time it takes for
the arm to fold fully.
2) Arm dump speed
Rapidly operate the arm maintained in the fully
folded position, and measure the time it takes 0.5 m
for the arm to extend fully. EX1301782
cylinder: Measure and record the extension
length of the cylinder rod from the point at which
the arm cylinder is fully extended (crowded) to
the point at which the arm cylinder is fully folded
(dumped).
C. Bucket cylinder
1) Bucket crowd speed
Rapidly operate the bucket while fully dumped
(extended), and measure the time it takes for
the bucket to fold fully.
2) Bucket dump speed
Rapidly operate the bucket while fully folded,
and measure the time it takes for the bucket to
extend fully. 1m
EX1301783
cylinder: Measure and record the extension
length of the cylinder rod from the point at which
the bucket cylinder is fully extended (crowded)
to the point at which the bucket cylinder is fully
folded (dumped).
NOTE: Jack up the dozer of the wheel-type excavator and
mini-excavator pointing forward, and measure the
time taken to jack it up and to jack it back down.
Measure and record the operating time of the boom
swing (option) of the mini-excavator from right to left,
or from left to right.
NOTE: Record the details of any abnormal noise heard
during measurement, or any abnormal conditions
observed during operation, on a blank measurement
record sheet.
2-1-26
Travel Speed
Summary
Measure the time required for the excavator to travel a 20 m
(65.6 ft) test track.
Preparation
Arm Rolled-in, Bucket Rolled-in
1. Adjust the track sag on both side tracks equally. Bucket Height: 0.3 - 0.5 m
2. Prepare a flat and solid test track 20 m (65.6 ft) in length End
with extra length of 3 ~ 5 m (9.8 ~ 16 ft) on both ends for
machine acceleration and deceleration. Start
20 m
Deceleration
IMPORTANT
Zone 3 - 5 m
Acceleration
Zone 3 - 5 m
The bucket teeth will hit the boom if the bucket is EX1301767
rolled-in with the arm fully rolled-in. Figure 15
As for this condition: arm fully rolled-in + bucket fully
rolled-in, set the bucket at fully rolled-in and a perform
arm roll-in operation.
3. Hold the bucket 0.3 - 0.5 m (12 - 20 in) above the ground
with the arm and bucket rolled-in.
4. Maintain the hydraulic oil temperature at 50 ±5 °C
(122 ±41 °F).
Measurement
1. Measure both the slow and fast speeds of the machine.
2. Measurement conditions are as below.
Travel Engine Power

Work Auto-idle
Mode Control Mode
Mode Switch
Switch Dial Switch
Power Digging
Low Mode High Idle OFF
Mode Mode
High Power Digging
High Idle OFF
Mode Mode Mode
3. Start traveling the machine in the acceleration zone with

the travel levers to full stroke.
4. Measure the time required to travel 20 m (65.6 ft)
5. After measuring the forward travel speed, turn the upper
structure 180° and measure the reverse travel speed.
6. Perform the measurement three times and calculate the
average values.
Evaluation
Refer to "Operational Performance Standard Table" on page 1-23.
2-1-27
Track Revolution Speed
Summary
Measure the track revolution cycle time with the track raised off
ground.
Preparation
1. Adjust the track sag of both side tracks to be equal.
2. Put the mark on the track to be measured, by using a piece
of chalk.
3. Swing the upper structure 90° and lower the bucket to
raise the track off ground. Keep the boom-arm angle
between 90 - 110° as shown place blocks under the
machine frame.
90 - 110
CAUTION
AVOID INJURY
Secure support the raised track using wooden blocks. EX1300534
Figure 16
(122 ±41 °F).
Measurement
1. Measure the both tracks on forward and reverse directions
at each travel mode.
Travel Engine Power

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

stroke.
4. Measure the time required for 3 revolutions in both
directions after a constant track revolution speed is
obtained.
average values.
NOTE: Record the details of any abnormal noise heard
during measurement, or any abnormal conditions
observed during operation, on a blank measurement
record sheet.
2-1-28
Evaluation
NOTE: The measurement data obtained through the raised
track revolution test may have wide variations.
Therefore, the evaluation based on the results
obtained from the 20 m travel speed check described
before is more recommendable.
2-1-29
Mistrack Check
Summary
1. Allow the machine to travel 20 m (65.6 ft). Measure the
maximum tread deviation from the tread chord line drawn
between the travel start and end points to check the
performance equilibrium between both sides of the travel
device systems (from the main pump to the travel motor).
2. If measured on a concrete surface, the tread deviation has
a trend to decrease.
Preparation
Front Zone
1. Adjust the track sag of both tracks to be equal.
2. Provide a flat, solid test yard 20 m (65.6 ft) in length, with
extra length of 3 - 5 m (9.8 - 16 ft) on both ends for Max. Distance
machine acceleration and deceleration.
IMPORTANT
Acceleration
The bucket teeth will hit the boom if the bucket is Zone 3 - 5 m
m
rolled-in with the arm fully rolled-in.
20
As for this condition: arm fully rolled-in + bucket fully
rolled-in, set the bucket at fully rolled-in and a perform
arm roll-In operation.
3. Hold the bucket 0.3 - 0.5 m (12 - 20 in) above the ground
the arm and bucket rolled-in.
(122 ±41 °C). EX1301768
Figure 17
Measurement
1. Measure the amount of mistracking in both fast, and slow
travel speeds.
Travel Engine Power

Work Auto-idle
Mode Control Mode
Mode Switch
Switch Dial Switch
Power Digging
Mode Mode
High Power Digging
High Idle OFF
Mode Mode Mode
3. Start traveling the machine in the acceleration zone with

the travel levers full stroke.
4. Measure the maximum distance between a straight 20 m
(65.6 ft) tread chord line and the tread made by the
machine.
2-1-30
5. After measuring the tracking in forward travel, turn the
upper structure 180° and measure in reverse travel.
average values.
Evaluation
2-1-31
Swing Speed
Summary
Measure the time required to swing three complete turns.
Preparation
1. Check the lubrication of the swing gear and swing bearing.
2. Place the machine on flat, solid ground with ample space
lor swinging. Do not conduct this test on slopes.
3. With the bucket empty, position the front attachment as
follows.
With the arm cylinder fully retracted, and the bucket The height as the
cylinder fully extended, raise the boom so bucket pin boom foot pin height.
height is flush with the boom foot pin height.
EX1301770
NOTE: In case of no place to be measured, measure Figure 18
with the boom raised and the arm rolled-in.
(122 ±41 °F).
CAUTION
AVOID INJURY
Prevent personal injury. Always make sure that area is
clear and that co-workers are out of the swing area
before starting the measurement.
Measurement

Work Mode
Digging
Mode
2. Operate swing control lever fully.

3. Measure the time required to swing 3 turns in one
direction. (Record the stopwatch measurement to the
second decimal place.)
4. Operate swing control lever fully in the opposite direction
and measure the time required for 3 turns.
average values.
Evaluation
2-1-32
Swing Function Drift Check
Summary
Measure the swing drift on the bearing outer circumference
when stopping after a 360° full-speed swing.
Preparation
1. Check the lubrication of the swing gear and swing bearing.
2. Place the machine on flat, solid ground with ample space
for swinging. Do not conduct this test on a slope.
3. With the bucket empty, position the front attachment as
follow.
With the arm cylinder fully retracted, and the bucket
cylinder fully extended, raise the boom so bucket pin
height is flush with the boom foot pin height. Two Matching Marks
EX1301772
4. Put the matching marks on the swing bearing and on the
Figure 19
track frame by using a tape, as illustrated.
5. Swing the upper structure 360°.
(122 ±41 °F).
CAUTION
AVOID INJURY
Prevent personal injury. Always make sure that area is
clear and that co-workers are out of the swing area EX1301773
before starting the measurement. Figure 20
Measurement Measure Difference

Between Marks

Work Mode
Digging
Mode
Mark on Track Frame
2. Operate swing control lever fully and return it to the neutral
position when the mark on upper structure aligns with that Mark on Swing Bearing
on track frame after swinging 360°. EX1301774
Figure 21
3. Measure the time distance between the two marks.
4. Align the marks again, swing 360°, and then test in the
opposite direction.
average values.
Evaluation
2-1-33
2-1-34
1General Maintenance
1General Maintenance
Instructions
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K General Maintenance Instructions

3-1-1
Table of Contents
General Maintenance Instructions

Welding Precautions and Instructions ............3-1-3
Hydraulic System - General Precautions........3-1-4
Maintenance Service and Repair Procedure ..3-1-6
General Precautions.................................................. 3-1-6
Hydraulic System Cleanliness and Oil Leaks .3-1-7
Maintenance Precautions for Hydraulic System 
Service ...................................................................... 3-1-7
Oil Leakage Precautions ........................................... 3-1-8
Cleaning and Inspection .................................3-1-9
General Instructions .................................................. 3-1-9
Bearing Inspection................................................... 3-1-10
General Maintenance Instructions DX480LCA-K/DX520LCA-K

3-1-2
WELDING PRECAUTIONS AND
INSTRUCTIONS
WARNING
To avoid accidents, personal injury and the possibility of
causing damage to the machine or to components, welding
must only be performed by properly trained and qualified
personnel, who possess the correct certification (when
required) for the specific welding fabrication or specialized
repair being performed.
WARNING
Structural elements of the machine may be built from a
variety of steels. These could contain unique alloys or may
have been heat-treated to obtain particular strength
characteristics. It is extremely important that welding
repairs on these types of steel are performed with the
proper procedures and equipment. If repairs are performed
incorrectly, structural weakening or other damage to the
machine (that is not always readily visible) could result.
Always consult DOOSAN After Sales Service before
welding on integral components (loader arm, frames, car
body, track frames, upper structure, attachment, etc.) of the
machine. It is possible that some types of structurally
critical repairs may require Magnetic Particle or Liquid
Penetrant testing, to make sure there are no hidden cracks
or damage, before the machine can be returned to service.
WARNING
Always perform welding procedures with proper safety
equipment and adequate ventilation in a dry work area.
Keep a fire extinguisher near and wear personal protective
equipment.

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

3-1-4
When starting the engine (particularly after long layoff or storage
intervals), make sure that all hydraulic controls and operating
circuits are in neutral, or "OFF". That will prevent pumps or other
components that may be temporarily oil starved from being run
under a load.
Replacement of any hydraulic system component could require
thorough cleaning, flushing, and some amount of prefilling with
fresh, clean oil if the protective seal on replacement parts has
obviously been broken or if seal integrity may have been
compromised. When protective seals are removed before
installation and reassembly, inspect all replacement parts
carefully, before they are installed. If the replacement part
shows no trace of factory prelube or has been contaminated by
dirt or by questionable oils, flushing and prefilling with clean
hydraulic fluid is recommended.
Vibration, irregular or difficult movement or unusual noise from
any part of the hydraulic system could be an indication of air in
the system (and many other types of problems). As a general
precaution (and to help lessen the risk of potential long-term
damage), allow the engine to run at no-load idle speed
immediately after initial start-up. Hydraulic fluid will circulate,
releasing any air that may have been trapped in the system
before load demands are imposed.
Before starting the machine, a daily walk-around safety
inspection, including a quick visual inspection for any exterior
evidence of leaking hydraulic fluid, can help extend the service
life of system components.
IMPORTANT
Hydraulic system operating conditions (repetitive cycling,
heavy workloads, fluid circulating under high-pressure)
make it extremely critical that dust, grit or any other
contamination be kept out of the system. Observe fluid and
filter change maintenance interval recommendations and
always preclean any exterior surface of the system before it
is exposed to air. For example, the reservoir fill cap and
neck area, hoses that have to be disassembled, and the
covers and external surfaces of filter canisters should all be
cleaned before disassembly.

3-1-5
MAINTENANCE SERVICE AND
REPAIR PROCEDURE
General Precautions
Fluid level and condition should always be checked whenever
any other maintenance service or repair is being performed.
NOTE: If the unit is being used in an extreme temperature
environment (in subfreezing climates or in high
temperature, high humidity tropical conditions),
frequent purging of moisture condensation from the
hydraulic reservoir drain tap must be a regular and
frequent part of the operating routine. In more
moderate, temperate climates, draining reservoir
sediment and moisture may not be required more
than once or twice every few months.
Inspect drained oil and used filters for signs of abnormal coloring
or visible fluid contamination at every oil change. Abrasive grit or
dust particles will cause discoloration and darkening of the fluid.
Visible accumulations of dirt or grit could be an indication that
filters are overloaded (and will require more frequent
replacement) or that disintegrating bearings or other component
failures in the hydraulic circuit may be imminent or have already
occurred. Open the drain plugs on the main pump casings and
check and compare drain oil in the pumps. Look for evidence of
grit or metallic particles.
Vibration or unusual noise during operation could be an
indication of air leaking into the circuit (Refer to the appropriate
Troubleshooting section for component or unit for procedures.),
or it may be evidence of a defective pump. The gear type pilot
pump could be defective, causing low pilot pressure, or a main
pump broken shoe or piston could be responsible.
NOTE: If equipped, indicated operating pressure, as shown
on the multidisplay digital gauge on the Instrument
Panel ("F-Pump" and "R-Pump") will be reduced
because of a mechanical problem inside the pump.
However, pressure loss could also be because of
cavitation or air leakage, or other faults in the
hydraulic system.
Check the exterior case’s oil drain line in the main pumps. If no
metallic particles are found, make sure there is no air in the
system. Unbolt and remove tank return drain line from the top
part of the swing motor, both travel motors and each main pump.
If there is air in any one of the drain lines, carefully prefill the
assembly before bolting together the drain line piping
connections. Run the system at low rpm.

3-1-6
HYDRAULIC SYSTEM
CLEANLINESS AND OIL LEAKS
Maintenance Precautions for Hydraulic

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

3-1-7
Oil Leakage Precautions
Oil that is visibly seeping from joints or seals should always
serve as a "red flag" alarm.
Leaks must alert the machine operator and maintenance crew
that air, water and dirt have an open, free passageway through
which to enter the circuit. Corrosive salt air, freezing and thawing
condensation cycles and working environments that are full of
fine dust are especially hazardous. Clogging of valve spools or
external piping (especially pilot circuit piping) can gradually
diminish or suddenly put a stop to normal hydraulic function. You
can prevent having to make these types of repairs by the
following recommended assembly procedures:
1. Use new O-rings and oil seals whenever hydraulic
assemblies are rebuilt.
2. Prepare joint surfaces before assembly by checking
alignment and flatness. Clean and repair corrosion or any
other damage.
3. Follow bolt torque recommendations and all other
assembly requirements.
NOTE: Grease lip seals before assembly.
Figure 1

3-1-8
CLEANING AND INSPECTION
General Instructions
All parts must be clean to permit an effective inspection. During
assembly, it is very important that no dirt or foreign material
enters unit being assembled. Even minute particles can cause
malfunction of close installed parts such as thrust bearing,
matched parts, etc.
WARNING
Do not inhale vapors or allow solvent type cleaners to
contact skin. Keep solvent away from open flame, arcs or
sparks or other sources of ignition that could start a fire.
1. Clean all metal parts thoroughly using a suitable cleaning

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

3-1-9
Be careful when installing sealing members, to avoid
cutting or scratching. Curling under of any seal lip will
seriously impair its efficiency. Apply a thin coat of Loctite
#120 to outer diameter of metal casing and on oil seals to
assure an oil tight install into retainer. Use extreme care
not to get Loctite on lips of oil seals. If this happens, that
portion of the seal will become brittle and allow leakage.
When replacing lip type seals, make sure spring loaded
side is towards oil to be sealed.
5. If available, use magna-flux or similar process for checking
for cracks that are not visible. Examine teeth on all gears
carefully for wear, pitting, chipping, nicks, cracks or scores.
Replace all gears showing cracks or spots where
case-hardening has worn through. Small nicks may be
removed with suitable hone. Inspect shafts and quills to
make certain they have not been sprung, bent, or no
twisted splines, and that shafts are normal condition.
NOTE: Spline wear is not considered detrimental
except where it affects tightness of splined
parts.
Inspect thrust washers for distortion, scores, burs, and
wear. Replace thrust washer if defective or worn.
6. Inspect bores and bearing surfaces of cast parts and
machined surfaces for scratches, wear, grooves and dirt.
Remove any scratches and burrs with crocus cloth.
Remove foreign material. Replace any parts that are
deeply grooved or scratched which would affect their
operation.
Bearing Inspection
The conditions of the bearing are vital to the smooth and
efficient operation of the machinery. When any component
containing bearings is disassembled, always carefully examine
the condition of the bearings and all of its components for wear
and damage.
Once the bearing is removed, clean all parts thoroughly using a
suitable cleaning solution. If the bearing is excessively dirty,
soak the bearing assembly in a light solution and move the
bearing around until all lubricants and/or foreign materials are
dissolved and the parts are thoroughly clean.
When drying bearings, moisture free compressed air can be
used. Be careful not to direct the air in a direction which will
force the bearing to dry spin while not being properly lubricated.
After the bearings have been cleaned and dried, carefully
inspect all bearing rollers, cages and cups for wear, chipping or
nicks. If the bearing cannot be removed and is to be inspected in
place, check for roughness of rotation, scoring, pitting, cracked
or chipped races. If any of these defects are found replace the
whole bearing assembly. NEVER replace the bearing alone
without replacing the mating cup or the cone at the same time.

3-1-10
After inspection lightly coat the bearing and related parts with oil
and wrap in a clean lintless cloth or paper and protect them from
moisture and other foreign materials until installation.
It is also important to inspect the bearing housing and/or shaft
for grooved, galled or burred conditions that indicate the bearing
has been turning in its housing or on its shaft.
If available, use magna-flux or similar process for checking for
cracks that are not visible.
The following illustrations will aid in identifying and diagnosing
some of the bearing related problems.
NOTE: The illustrations will only show tapered roller
bearings, but the principles of identifying, diagnosing
and remedying the defects are common to all styles
and types of bearings.
Normal Bearing
Smooth even surfaces with no discoloration or marks.
Figure 2
Bent Cage
Cage damage because of improper handling or tool usage.
Figure 3

3-1-11
Replace bearing.
Figure 4
Galling
Metal smears on roller ends because of overheat, lubricant
failure or overload.
Replace bearing - check seals and check for proper lubrication.
Figure 5
Abrasive Step Wear

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

3-1-12
Etching
Bearing surfaces appear gray or grayish black in color with
related etching away of material usually at roller spacing.
Replace bearings - check seals and check for proper lubrication.
Figure 7
Misalignment
Outer race misalignment because of foreign object.
Clean related parts and replace bearing. Make sure races are
properly seated.
Figure 8
Indentations
Surface depressions on race and rollers caused by hard
particles of foreign materials.
Clean all parts and housings, check seals and replace bearings
if rough or noisy.
Figure 9

3-1-13
Fatigue Spalling
Flaking of surface metal resulting from fatigue.
Replace bearing - clean all related parts.
Figure 10
Brinelling
Surface indentations in raceway caused by rollers either under
impact loading or vibration while the bearing is not rotating.
Replace bearing if rough or noisy.
Figure 11
Cage Wear
Wear around outside diameter of cage and roller pockets
caused by abrasive material and inefficient lubrication.
Replace bearings - check seals.
Figure 12

3-1-14
Abrasive Roller Wear
Pattern on races and rollers caused by fine abrasives.
Clean all parts and housings, check seals and bearings and
replace if leaking, rough or noisy.
Figure 13
Cracked Inner Race

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

3-1-15
Frettage
Corrosion set up by small relative movement of parts with no
lubrication.
Replace bearing. Clean all related parts. Check seals and check
for proper lubrication.
Figure 16
Heat Discoloration
Heat discoloration can range from faint yellow to dark blue
resulting from overload or incorrect lubrication.
Excessive heat can cause softening of races or rollers.
To check for loss of temper on races or rollers, a simple file test
may be made. A file drawn over a tempered part will grab and
cut metal, whereas a file drawn over a hard part will glide readily
with no metal cutting.
Replace bearing if overheating damage is indicated. Check
seals and other related parts for damage.
Figure 17
Stain Discoloration
Discoloration can range from light brown to black caused by
incorrect lubrication or moisture.
If the stain can be removed by light polishing or if no evidence of
overheating is visible, the bearing can be reused.
Check seals and other related parts for damage.
Figure 18

3-1-16
1Standard Torques
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Standard Torques

3-2-1
Table of Contents
Standard Torques
Torque Values for Standard Metric Fasteners...3-2-3
Torque Values for Standard U.S. Fasteners...3-2-4
Type 8 Phosphate Coated Hardware .............3-2-6
Torque Values for Hose Clamps.....................3-2-7
ORFS Swivel Nut Recommended Torque ......3-2-7
Torque Values for Split Flanges .....................3-2-8
Torque Wrench Extension Tools ....................3-2-9
Torque Multiplication ................................................. 3-2-9
Other Uses for Torque Wrench Extension Tools..... 3-2-10
Tightening Torque Specifications (Metric) ............... 3-2-11
Standard Torques DX480LCA-K/DX520LCA-K

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

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

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

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

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

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

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

3-2-5
TYPE 8 PHOSPHATE COATED HARDWARE
This chart provides tightening torque for general purpose
applications using original equipment standard hardware as
listed in the Parts Manual for the machine involved. DO NOT
SUBSTITUTE. In most cases, original equipment standard
hardware is defined as Type 8, coarse thread bolts, nuts and
thru hardened flat washers (Rockwell "C" 38 - 45), all phosphate
coated and assembled without supplemental lubrication (as
received) condition.
The torques shown below also apply to the following:
1. Phosphate coated bolts used in tapped holes in steel or
gray iron.
2. Phosphate coated bolts used with phosphate coated
prevailing torque nuts (nuts with distorted threads or plastic
inserts).
3. Phosphate coated bolts used with copper plated weld nuts.
Markings on bolt heads or nuts indicate material grade ONLY
and are NOT to be used to determine required torque.
Standard Torque ±10%

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

3-2-6
TORQUE VALUES FOR HOSE CLAMPS
The following chart provides the tightening torques for hose
clamps used in all rubber applications (radiator, air cleaner,
operating lever boots, hydraulic system, etc.).
Torque
Radiator, Air Cleaner, Boots, Etc. Hydraulic System
Clamp Type and Size
Kilogram.meter Inch Pounds Kilogram.meter Inch Pounds
(kg.m) (in lb) (kg.m) (in lb)
"T" Bolt (Any Diameter) 0.68 - 0.72 59 - 63 ------- -------
Worm Drive - Under 
44 mm (1-3/4 in) Open Diam- 0.2 - 0.3 20 - 30 0.5 - 0.6 40 - 50
eter
Worm Drive - Over 44 mm
0.5 - 0.6 40 - 50 ------- -------
(1-3/4 in) Open Diameter
Worm Drive - All "Ultra-Tite" 0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50
ORFS SWIVEL NUT RECOMMENDED TORQUE

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

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

3-2-8
TORQUE WRENCH EXTENSION TOOLS
Very large diameter, high-grade fasteners (nuts, bolts, cap
screws, etc.) require a great deal of turning force to achieve
recommended tightening torque values.
Common problems that could occur as a result are:
• Recommended torque exceeds the measuring capacity of
the torque wrench.
• Specialized sockets do not fit the adapter on the front end
(nose) of the torque wrench.
• Generating adequate force on the back end (handle) of the
wrench is difficult or impossible.
• Restricted access or an obstruction may make use of the
torque wrench impossible.
• A unique application requires fabrication of an adapter or
other special extension.
Most standard torque wrenches can be adapted to suit any one
of the proceeding needs or situations, if the right extension tool
is used or fabricated.
Torque Multiplication
A wrench extension tool can be used to increase the tightening
force on a high capacity nut or bolt.
For example, doubling the distance between the bolt and the
back (handle) end of the torque wrench doubles the tightening
force on the bolt. It also halves the indicated reading on the
scale or dial of the torque wrench. To accurately adjust or
convert indicated scale or dial readings, use the following
formula:
I = A x T/A + B where:
I = Indicated force shown on the torque wrench scale or dial.
T = Tightening force applied to the nut or bolt (actual Torque). Figure 1
A = Length of the torque wrench (between the center of the nut

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

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

3-2-9
NOTE: The formula assumes there is no added deflection or
"give" in the joint between the extension and torque
wrench. Readings may also be inaccurate:
• If the extension itself absorbs some of the tightening force
and starts to bend or bow out.
• If an extension has to be fabricated that is not perfectly
straight (for example, an extension made to go around an
obstruction, to allow access to a difficult to tighten
fastener), the materials and methods used must be solid
enough to transmit full tightening torque.
Other Uses for Torque Wrench Extension

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

3-2-10
Tightening Torque Specifications (Metric)
(For coated threads, prelubricated assemblies.)
IMPORTANT
Disassembly, overhaul and replacement of components on
the machine, installation of new or replacement parts and/
or other service-related maintenance may require the use of
thread or flange sealing assembly compound.
Use the information on this page as a general guide in
selecting specific formulas that will meet the particular
requirements of individual assembly installations. DOOSAN
does not specifically approve a specific manufacturer or
brand name, but the following table of "Loctite"
applications is included for which cross-references to other
manufacturer's products should also be widely available.
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of
fastener adhesives, with Threadlocker sealers 222, 242/243,
262, 271, 272, or 277.

3-2-11
I. "Loctite" Fastener Adhesives
Breakaway Cure
Product Application Color Removal Strength (in lb) of
Sealer Alone
Low strength for 6 mm (1/4") or
222 Purple Hand tools 45
smaller fasteners.
Medium strength for 6 mm (1/4") and
242 or 243 Blue Hand tools 80
larger fasteners.
Heat/260°C (500°F)
High strength for high-grade fasteners
262 Red Remove HOT 160
subject to shock, stress and vibration.
(NO solvent)
Extra high strength for fine thread Heat/260°C (500°F)
271 Red 160
fasteners up to 25 mm (1") diameter. Remove HOT
High temperature/high strength for
Heat/316°C (600°F)
272 hostile environments to 232°C Red 180
Remove HOT
(450°F).
Extra high strength for coarse thread
Heat/260°C (500°F)
277 fasteners 25 mm (1") diameter and Red 210
Remove HOT
larger.
II. "Loctite" Pipe Thread Sealant
Product Application Color Removal Required Setup

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

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

3-2-12
IV. "Loctite" retaining compounds

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

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

3-2-13
3-2-14
1Upper Structure
1Cabin (Non-Rops)
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Cabin (Non-Rops)

5-1-1
Table of Contents
Cabin (Non-Rops)
Removal..........................................................5-1-3
Installation.......................................................5-1-7
Completing work .............................................5-1-7
Dimensions of Cabin Glass ............................5-1-8
Removal and Installation of Cabin Glass......5-1-12
Removal of Cabin Glass.......................................... 5-1-12
Installation of Cabin Glass....................................... 5-1-14
Installation of Upper Door Glass.............................. 5-1-19
Installation of Upper Front Glass ............................. 5-1-19
Cabin (Non-Rops) DX480LCA-K/DX520LCA-K

5-1-2
REMOVAL
1. Make the machine swing about 15 ~ 20° rightward on the
flat ground as shown in Figure 1 before lowering the bucket
on the ground and then stop engine.
EX1301714
Figure 1
2. Move safety lever to "RELEASED" (UNLOCK) position. O ACC

(Figure 2) I
3. Turn starter switch to "I" (ON) position. Unlock
WARNING OFF
Lock
OFF
ON
ON
If engine must be running while performing ON OFF
maintenance, always use extreme caution. Always EX1504472
have one person in the cabin at all times. Never leave Figure 2
the cabin with engine running.
4. To relieve pressure from accumulators, fully stroke work

levers in all directions. Movement can occur.
5. Move safety lever to "LOCK" position. (Figure 2)
6. Turn key to "O" (OFF) position and remove from starter
switch.
7. Attach maintenance warning tag on controls.
8. Turn battery disconnect switch to "OFF" position.
(Figure 3) FRONT OFF
ON
OFF
ON
DS1704238
Figure 3

5-1-3
9. Remove bolts and washers (1, Figure 4) (6 ea) with 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: 9.5 kg (20.9 ft lb)
EX1403184
Figure 4 Bottom of Main Frame
10. Disconnect washer hose.
Figure 5 Bottom of Cabin WE1400432
11. Remove floor mat from the cabin.
Figure 6 EX1502130
12. Remove cup holder (1, Figure 7).

6 7
Remove front covers (2 and 3, Figure 7) and side covers (4
and 5). 4
Before removing front cover (2, Figure 7) disconnect hour
meter connector.
NOTE: Don't remove monitor panel (6, Figure 7) and
switch panel (7).
1
3 2 5
WE1400448
Figure 7

5-1-4
13. After removing rear mat (1, Figure 8), remove rear center
cover (2), cassette cover (3), rear side covers (4 thru 6) 4 5
and rear cover (7).
3
7 6
2
WE1400449
Figure 8
14. Remove fuse box bracket (1, Figure 9) from left sidewall
without disassembly harness connector.
1
Remove cassette bracket (2, Figure 9) and disconnect
antenna and speaker wire.
Remove EPOS controller (3, Figure 9) without disassembly 3
harness connectors.
NOTE: Be careful not to let water get into electrical
components (sensor, connectors). 
If water gets into electrical system, this will
cause an electrical short circuit and result in 2
improper machine operation. Figure 9
WE1400450
15. Remove air ducts (1 thru 4, Figure 10) from cabin rear
panel.
Remove across bar (5, Figure 10) between left and right
side of cabin.
2
1 3
4
5
WE1400451
Figure 10
16. Disconnect cabin wiring connectors from main harness.

NOTE: Control console wiring harnesses and hydraulic
piping lines that pass through the floor of the
cabin do not need to be disassembled.
NOTE: If cabin is equipped with additional protective
guards over cabin openings, they must be
removed.
WE1400452
Figure 11

5-1-5
17. Remove air ducts (1 thru 6, Figure 12) at the right side of
cabin sequently from the front duct. 6
5
3
1
Figure 12 WE1400453
18. Using a suitable lifting device, attach slings to four lift

points on top of cabin (Figure 13).
• Lifting hole size: M12 x 1.75, depth: 15 mm
• Cabin weight: about 315 kg (695 lb)
Figure 13 WE1400454
19. Remove bolts and washers (1 and 2, Figure 14) (6 ea).
Torque
No.
(mm) N.m kg.m ft lb
1 1
1 19 88.2 9 65.1 3
3
2 17 63.7 6.5 47
3 2 3
20. Remove nuts and washers (3, Figure 14) (4 ea) from cabin 2 1
floor.
• Tool: 24 mm ( )
WE1400455
Figure 14
IMPORTANT
Continue lifting with assist crane to remove cabin
shell. Lower shell to a prepared safe blocking support.
• Support size: about 2,000 x 2,800 mm
Check that all electrical connections have been
disconnected and all other items unbolted.
Do not rapidly lift operator's cabin: The bottom of
operator's cabin can come into contact with, and
WE1400456
scratch, control stand cover. Figure 15

5-1-6
INSTALLATION
1. Using a suitable lifting device, attach slings to four (4) lift
• Cabin weight: 315 kg (695 lb)
2. Lower cabin into position on cabin floor.
WE1400456
Figure 16
3. Install mounting nuts (Figure 17) (4 ea) and washers in four

corners of cabin floor.
When install the nut, apply Loctite (#262) to nut.
• Tool: 24 mm ( )
Perform installation in the reverse order to removal.
WE1400457
Figure 17
COMPLETING WORK
1. Start the engine and run at low idle for about 5 minutes.
2. Perform the machine performance test.

5-1-7
DIMENSIONS OF CABIN GLASS
Front Glass
26.1
848
2-R64 Ceramic
Coating
R2896.4
1033.8
31
100 E-mark Position 2-R54
R7
43.2
.5
100
96 96 4-R5
20
854
2-R5
423.6
R1673.5
427.1
100 E-mark Position

2-R165
100
DS1800179
Figure 18
NOTE: Unit: mm (1 mm = 0.039 in)

5-1-8
Left Glass
358.8 353.2 5 280.2 5
0.2
R2
206.3
R7
60
197.6
.2
R1 R3
00
00
R2
828
760.4
761
.5
567.3
554.1
24.5
2- 13 Hole
40
E-mark Position
(100)
0 .2
11 R7
170
R 0.
(100)
2
367.1 194.1 150.8 525.5 93.6
895.8
575.2
43.2 5
Ceramic
R5
118.3
R56
Coating
5.5
R6 37
R2
329.1
R
65 R1 2-
4
.5 0
681.6
R21
100
412.6
85.5
R2734
2
0. E-mark Position
R3
R85
100
.8
0
94.6
4.9
R9
5
85.1
R2
901.7
EX1401714
Figure 19

5-1-9
Rear Side Glass
100
4-
R7
2
529
778
37.4
311.7 5
Ceramic
R6 Coating
4.2
R1394.3
4.2
R6
28.3
R12
36.9
R799.1
1108
E-mark Position
100
100
0
165
R6
459.2
4.2
R6
EX1401715
Figure 20

5-1-10
Right Glass
Ceramic
Coating
1199.9
E-mark Position
1533.4
EX1501739
Figure 21

5-1-11
REMOVAL AND INSTALLATION OF CABIN GLASS
Removal of Cabin Glass

Procedures to remove right-hand glass (1, Figure 22), rear left,
glass, lower door glass and rear glass. 1
CAUTION
AVOID INJURY
When removing the broken or cracked glass, the glass EX1401717
shards can cause serious injury. Figure 22
Before removing, use tape to hold the broken or cracked
glass together.
1. Remove resin panel, garnish or etc. around the glass.
Reference
Description
Number
1 Garnish 3
2 Lower Glass of Door

3 Rear Glass 1 4
4 Rear Left-hand Glass 5
2
5 Resin Panel
EX1401718
Figure 23
2. Prick a hole in the adhesive by using an awl (or cutter

knife). 1 2
Reference
Description 3
Number
1 Cabin
2 Cabin Glass
3 Awl
4 Adhesive
4
EX1301298
Figure 24

5-1-12
3. Pass a piano wire (1, Figure 25) (or a wire) through the
hole.
EX1301299
Figure 25
4. Wind both ends of the piano wire onto two screwdrivers.

Draw the wire back and forth to cut the adhesive (3, Figure Cabin Outside
26) between cabin (1) and glass (2). 1 2
Remove glass (2, Figure 26) from the cabin (1).

NOTE: Piano wire is easily broken. If a part of the piano
wire turns hot, change the position of the wire
and continue cutting the adhesive.
Cabin Inside 3
EX1301300
Figure 26

5-1-13
Installation of Cabin Glass
1
Procedures to install right-hand glass (1, Figure 28), 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 27). 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 27
1 Cabin
2 Knife
EX1401717
Figure 28
2. Clean the remaining adhesive and metal surfaces with a

general purpose adhesive cleaner.
Reference
Description
Number 3
1 Garnish
2 Lower Glass of Door 1 4
3 Rear Glass 5
2
4 Rear Left-hand Glass
5 Resin Panel EX1401718
Figure 29
IMPORTANT
Primer must be shaken for about 1 minute and mix
thoroughly before opening the cap.
After opening primer, apply primer as quickly as
possible and replace the cap immediately after using.
After opening primer, all the contents must be used
within 180 days (or 2 hours with the cap off).

5-1-14
3. Apply the damper on cabin body before applying adhesive.
Damper - Front Upper Glass
A
Length: about 3,600 mm
7
Section A - A
EX1401719
Figure 30
Damper - Rear Glass
787
8
538.1
Section A - A
EX1401720
Figure 31

5-1-15
Damper - Right-hand Glass
A
7
5
Section A - A
EX1401721
Figure 32
Damper - Lower Glass of Door
716
7
94
5
A
324
Section A - A
Figure 33
EX1402138
Damper - Rear Left-hand Glass
7
5
Section A - A
EX1401722
Figure 34

5-1-16
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.
5. Using application brush, apply primer for glass (Sika

Primer W06G+P) to the layer of old adhesive from step 1.
Wait for about 15 minutes to let it dry.  1
(Refer to position to apply primer (2, Figure 35).)
NOTE: The painting primer must be applied evenly to
2
leave no blemishes.
Reference 3
Description
Number
1 Cabin
EX1301303
2 Application Brush Figure 35
3 Layer of Old Adhesive on Cabin
6. Cut off the nozzle of adhesive cartridge (Sika Tack-Drive)

into V-shaped by using a knife. (Refer to page -15.)
7. Remove seal of cartridge. Install the V-shaped nozzle.
8. Install the cartridge to the manual caulking gun.
9. Apply adhesive to the adhesive position at cabin side so
bead triangle will be even. 
(Refer to position to apply adhesive (3, Figure 35).)

5-1-17
Required
Cut Nozzle Required

End into
V-shaped
Adhesive
Apply Bead Here
Application bead
should form
9 even triangle.
12 Remove Seal
Adhesive Cartridge
Panel
EX1401037
Figure 36

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

5-1-18
Installation of Upper Door Glass
1. Before installing the glass, remove garnish (2, Figure 37) 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 37) 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.
EX1401723
Secure the sash assembly at the inside of cabin by using Figure 37
the garnish.
Installation of Upper Front Glass

1. Stick seal to the lower side of front upper glass by using
Cemedine SIKAFLEX 255 ultrafast.
Stick and secure both right and left ends (the thicker part)
of seal to the glass by using Cemedine SIKAFLEX 255
ultrafast.
Stick the mating surface of seal and the glass by using
Cemedine SIKAFLEX 255 ultrafast so no visible undulation
or boss can be found.
NOTE: Cemedine SIKAFLEX 255 ultrafast Glue-state
adhesive, tubed.
Reference
Description
Number
1 Upper Glass
2 Weather Strip
3 Lower Glass
1
4 Damper 4
2
3
EX1401724
Figure 38

5-1-19
5-1-20
1Cabin (Rops)
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Cabin (Rops)

5-2-1
Table of Contents
Cabin (Rops)
Cabin Identification .........................................5-2-3
Roll Over Protective Structure (ROPS) 
When Required by Local Regulations ....................... 5-2-3
Removal..........................................................5-2-5
Installation.....................................................5-2-10
Completing work ...........................................5-2-10
Dimensions of Cabin Glass ..........................5-2-11
Removal and Installation of Cabin Glass......5-2-15
Removal of Cabin Glass.......................................... 5-2-15
Installation of Cabin Glass....................................... 5-2-17
Installation of Upper Door Glass.............................. 5-2-22
Installation of Upper Front Glass ............................. 5-2-22
Cabin (Rops) DX480LCA-K/DX520LCA-K

5-2-2
CABIN IDENTIFICATION
The excavator could be equipped with either a ROPS or NON-
ROPS cab.
Figure 1, shows a NON-ROPS cabin (1) and a ROPS cabin (2).
When servicing your cabin use the correct section.
1 2
EX1501740
Figure 1
Reference Reference
Number Number
1 Non-Rops Cabin 2 Rops Cabin
Roll Over Protective Structure (ROPS) 

When Required by Local Regulations
Global markets may or may not require a Roll Over Protective
Structure (ROPS). Always comply with all regional and
governmental regulations that apply to your market. The
following information is for a ROPS cabin.
General ROPS Guidelines for ROPS Certified Cabins

The operator's cabin is a ROPS certified structure for protecting
the seat-belted operator. It absorbs the impact energy of a
rollover impact. Do not allow machine weight (mass) to exceed
certified value on certification plate. If weight is exceeded, the
ROPS structure will not be able to fulfill its safety function.
Do not increase machine weight beyond certified value by
modifying machine or by installing attachments on machine. If
weight limit of protective equipment is exceeded, protective

5-2-3
equipment will not be able to protect operator, and operator may
suffer serious injury or death. Always observe the following:
• This machine is equipped with a protective structure. Do
not remove protective structure and carry out operations
without it.
• Never modify the operator’s cabin by welding, grinding,
DOOSAN. Changes to the cabin can cause loss of
operator protection from rollover and falling objects, and
operator may suffer serious injury or death.
• When protective structure is damaged or deformed by
falling objects or by rolling over, its strength will be reduced
and it will not be able to properly fulfill its function. In these
cases, always contact your DOOSAN distributor for advice.
Never repair a ROPS cabin.
• Always wear your seat belt when operating machine.
ROPS Certification
This DOOSAN excavator has an operator’s cabin that meets
ROPS requirements. The seat belt must be worn for rollover
protection.
The ROPS certification plate (Figure 2) 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. EX1300529
Figure 2 Left Side of Rops Cabin (Inside)
ROPS  Roll-over Protective Structure complies with
ISO 12117-2:2008, EN13531:2001.
WARNING
Never modify the operator cabin by welding, grinding,
DOOSAN. Changes to the cabin can cause loss of operator
protection from rollover and falling objects, and result in
serious injury or death.

5-2-4
REMOVAL
flat ground as shown in Figure 3 before lowering the bucket
on the ground and then stop engine.
EX1301714
Figure 3

(Figure 4) I
WARNING OFF
Lock
OFF
ON
ON
4. To relieve pressure from accumulators, fully stroke work

levers in all directions. Movement can occur.
switch.
7. Attach maintenance warning tag on controls.
ON
OFF
ON
DS1704238
Figure 5

5-2-5
• Tool: 19 mm ( ) 1
• Under cover weight: 9.5 kg (20.9 ft lb)
EX1403184
10. Disconnect washer hose.
Figure 7 Bottom of Cabin WE1400432
Figure 8 DS1701906
12. Remove screw with cover (1, Figure 9), bolt and washer (2)
with safety lever assembly (3) from control stand.
• Tool: Screwdriver
1
2
Figure 9 DS1701907

5-2-6
13. Remove duct covers (1 and 2, Figure 10).
1 2
Figure 10 WE1400435
14. Disconnect wiper, monitor, sun sensor and hour meter

connectors.
NOTE: Control console wiring harnesses and hydraulic
piping lines that pass through the floor of the
cabin do not need to be disassembled.
NOTE: If cabin is equipped with additional protective
guards over cabin openings, they must be
removed.
WE1400436
Figure 11
15. Remove air ducts (1 thru 6, Figure 12) on right-hand side

of operator's cabin. 5
3
4
1
Figure 12 WE1400437
16. Remove glove box pad (1, Figure 13), and two bolts under
pad. 4
Remove caps and bolts (2, Figure 13) (3 ea) from top of
rear cover.
1 2
Remove bolts (3, Figure 13) (2 ea) from bottom of rubber
mounts in rear cover.
Remove rear cover (4, Figure 13).
3
WE1400438
Figure 13

5-2-7
17. Remove air ducts (1 thru 3, Figure 14) and atmospheric air
duct (4).
2 4
3
WE1400439
Figure 14
18. Remove all bolts (1, Figure 15) (17 ea) with brackets (2
thru 4) from body of operator cabin.
• Tool: 13 mm ( ) 2
3
1
4
WE1400440
Figure 15
19. Disconnect connectors of interior lights, speakers and

antenna.
cause an electrical short circuit and result in
improper machine operation.
WE1400441
Figure 16

5-2-8
20. Using a suitable lifting device, attach slings to four lift
points on top of cabin (Figure 17)
• Lifting hole size: M12 x 1.75, depth: 15 mm
• Cabin weight: about 485 kg (1,069 lb)
WE1400442
Figure 17
21. Remove bolts and washers (1, Figure 18) (11 ea).
• Tool: 19 mm ( )
• Torque: 88.3 N.m (9 kg.m, 65.1 ft lb) 1 1
2
22. Remove nuts and washers (2) (4 ea) from cabin floor. 2
1 1
• Tool: 24 mm ( ) 2 1 2
1 1
WE1400443
Figure 18
23. Remove bolts which is fixing the plate to prevent loosening

of ROPS bolt (1, Figure 19).
• Tool: 19 mm ( ) 2
24. Remove ROPS bolt (2, Figure 19).
• Tool: 60 mm ( )
1
• Torque: 127.5 N.m (13 kg.m, 94 ft lb)
WE1400444
Figure 19
IMPORTANT
Continue lifting with assist crane to remove cabin
shell. Lower shell to a prepared safe blocking support.
• Support size: about 2,000 x 2,800 mm
Check that all electrical connections have been
disconnected and all other items unbolted.
Do not rapidly lift operator's cabin: The bottom of
operator's cabin can come into contact with, and WE1400445
scratch, control stand cover. Figure 20

5-2-9
INSTALLATION
1. Using a suitable lifting device, attach slings to four (4) lift
• Cabin weight: 485 kg (1,069 lb)
2. Lower cabin into position on cabin floor.
WE1400445
Figure 21
3. Install mounting nuts (Figure 22) (4 ea) and washers in four

corners of cabin floor.
When install the nut, apply Loctite (#262) to nut.
• Tool: 24 mm ( )
Perform installation in the reverse order to removal.
WE1400446
Figure 22
COMPLETING WORK

5-2-10
DIMENSIONS OF CABIN GLASS
Front Glass
816 7
993
86.5
40
824
454.5
27.6
169.6
7
58.3 707.4
EX1501741
Figure 23

5-2-11
Left Glass
399.5 5 270.7 5
786.4
410.6 402.3
437.5 131.6
850.2 5
210.7
367
468.8
436.1
642.3
722.8
871.7
EX1501742
Figure 24

5-2-12
Rear Side Glass
786.7 5
601.2
391.1 5
1026.2
958.2
258.2
452.9
EX1501743
Figure 25

5-2-13
Right Glass
1330.8 5
83.2
527.5
957.1
1407.6
505.1
419.7
306.6
97.9
30.8
918.7 207.9 163.3
1534.8
EX1501744
Figure 26

5-2-14
REMOVAL AND INSTALLATION OF CABIN GLASS
Removal of Cabin Glass

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

knife). 1 2
Reference
Description 3
Number
1 Cabin
2 Cabin Glass
3 Awl
4 Adhesive
4
EX1301298
Figure 29

5-2-15
3. Pass a piano wire (1, Figure 30) (or a wire) through the
hole.
EX1301299
Figure 30
4. Wind both ends of the piano wire onto two screwdrivers.

Draw the wire back and forth to cut the adhesive (3, Figure Cabin Outside
31) between cabin (1) and glass (2). 1 2
Remove glass (2, Figure 31) from the cabin (1).

NOTE: Piano wire is easily broken. If a part of the piano
wire turns hot, change the position of the wire
and continue cutting the adhesive.
Cabin Inside 3
EX1301300
Figure 31

5-2-16
Installation of Cabin Glass
1
Procedures to install right-hand glass (1, Figure 33), rear, left-
hand glass, lower door glass and rear glass.
1. Cut off the remaining adhesive leaving a layer of old 2
adhesive 1 ~ 2 mm thick (Figure 32). The new adhesive
will bond to the remaining adhesive.
NOTE: Do not damage the cabin paint. Cut off Adhesive
by 1 - 2 mm Deep
Reference
Description EX1301302
Number
Figure 32
1 Cabin
2 Knife
EX1301295
Figure 33
2. Clean the remaining adhesive and metal surfaces with a

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

Figure 34
IMPORTANT
Primer must be shaken for about 1 minute and mix
thoroughly before opening the cap.

5-2-17
3. Apply the damper on cabin body before applying adhesive.
Damper - Front Upper Glass
787
Adhesive Sides 5
975
5
A
Section A - A
EX1301354
Figure 35
Damper - Rear Glass
758
Adhesive Sides 5
573
A
Section A - A
EX1301355
Figure 36

5-2-18
Damper - Right-hand Glass
1,492
A
Adhesive Sides 5
1,376
7
Section A - A
EX1301356
Figure 37
Damper - Lower Glass of Door
800
7
184
329
A
Adhesive Sides
429
5
606 Section A - A
685
EX1301357
Figure 38
Damper - Rear Left-hand Glass
A
Adhesive Sides
5
Section A - A
EX1301358
Figure 39

5-2-19
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.
5. Using application brush, apply primer for glass (Sika

Primer W06G+P) to the layer of old adhesive from step 1.
Wait for about 15 minutes to let it dry.  1
(Refer to position to apply primer (2, Figure 40).)
NOTE: The painting primer must be applied evenly to
2
leave no blemishes.
Reference 3
Description
Number
1 Cabin
EX1301303
2 Application Brush Figure 40
3 Layer of Old Adhesive on Cabin
6. Cut off the nozzle of adhesive cartridge (Sika Tack-Drive)

into V-shaped by using a knife. (Refer to page -18.)
7. Remove seal of cartridge. Install the V-shaped nozzle.
8. Install the cartridge to the manual caulking gun.
9. Apply adhesive to the adhesive position at cabin side so
bead triangle will be even. 
(Refer to position to apply adhesive (3, Figure 40).)

5-2-20
Required
Cut Nozzle Required

End into
V-shaped
Adhesive
Apply Bead Here
Application bead
should form
9 even triangle.
12 Remove Seal
Adhesive Cartridge
Panel
EX1401037
Figure 41

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

5-2-21
Installation of Upper Door Glass
1. Before installing the glass, remove garnish (2, Figure 42) 1
around sash assembly (1) from the cabin inside for easy
2
removal. Push the sash assembly by hands and remove
sash outside. 3
2. Install glass (3, Figure 42) and glass (4) into the sash 4
grooves.
3. Install the sash assembly, which the glass is installed on,
onto the door from the outside of cabin.
EX1301297
Secure the sash assembly at the inside of cabin by using Figure 42
the garnish.
Installation of Upper Front Glass

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

2
3
EX1301304
Figure 43

5-2-22
1Counterweight
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Counterweight
5-3-1
Table of Contents
Counterweight
General ...........................................................5-3-3
Warning for Counterweight and Front Attachment 
Removal .................................................................... 5-3-3
Removal..........................................................5-3-5
Installation.......................................................5-3-6
Counterweight DX480LCA-K/DX520LCA-K
5-3-2
GENERAL
Warning for Counterweight and Front

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

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

8,506 kg (18,753 lb)
DX480LCA-K
9,006 kg (19,855 lb)
DX520LCA-K 11,105 kg (24,482 lb)
5-3-3
Responsibility must be assigned to one person to be in charge
of the lifting crew, and to verify that required safe lifting
precautions have been taken before each part of this procedure
has been started.
All members of the working crew should know and understand
the signals that will be used between the lifting leader, the assist
crane operator and the remainder of the work crew.
WARNING
If the upper structure deck has been unbalanced by
removal of weight from one end only, traveling with the
excavator, swinging the turntable, movement over bumps
or sloping and uneven surfaces could cause loss of control
resulting in tipping or rollover.
To maintain stability the counterweight must be removed only

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

trailer for transport after the front attachment has been removed,
always go backwards up the loading ramp with the
counterweight uphill (Figure 3).
15
EX1300747
Figure 3
5-3-4
REMOVAL
O ACC
I
WARNING Unlock

Lock
Death or serious injury can occur from a counterweight
falling during removal or installation. Do not allow OFF OFF
ON
ON
personnel under or around the counterweight during
removal or installation.
ON OFF
Use certified cables and shackles of adequate load rating.
Improper lifting can allow the load to shift and cause death EX1504472
or serious injury. Figure 4
1. Park on firm and level ground.

2. Lower front attachment (bucket) to ground.
3. Stop engine.
4. Move safety lever to "UNLOCK" position.
5. Turn starter switch to "I" (ON) position.
WARNING
If engine must be running while performing
maintenance, use extreme care. Always have one
person in the cabin at all times. Never leave the cabin
with the engine running.
6. Fully stroke work levers (joysticks) in all directions to

relieve any pressure from accumulators.
7. Move safety lever to "LOCK" position. 5
8. Turn key to "O" (OFF) position and remove from starter 1
switch.
9. Attach a maintenance warning tag on controls.
10. Turn battery disconnect switch to "OFF" position.
11. Make sure all electrical and other items are disconnected.
12. Install the eye bolts.
NOTE: Thread: M48 x 5.0
13. Using a suitable lifting device capable of handling the
weight of the counterweight, partially support
counterweight from lifting eye bolts (5, Figure 5),
counterweight (1) before loosening six bolts (2). Stop lifting
with assist crane as soon as lifting slings are taut. 3
4
2 DS1800071
Figure 5
5-3-5
14. Remove bolts (2, Figure 5) and washers (3) from
counterweight (1).
• Tool: 60 mm ( )
– DX480LCA-K: 8,506 kg (18,753 lb)
9,006 kg (19,855 lb)
– DX520LCA-K: 11,105 kg (24,482 lb)
NOTE: Heat bolts, if necessary, to free them.
15. When bolts (2, Figure 5) and washers (3) have been
removed, lift counterweight (1) a very short distance above
support frame (4) and stop. Check slings and make sure
counterweight is being supported evenly.
INSTALLATION
1. Using suitable lifting device capable of handling the weight
of the counterweight, support counterweight from lifting eye 5
bolts (5, Figure 6). Raise counterweight (1, Figure 6) into 1
position just above support frame (4) leaving
counterweight suspended. Verify that counterweight is
level and even.
NOTE: Leave counterweight (1, Figure 6) suspended
3 mm (0.125") above support frame (4) until all
mounting bolts (2) are started in counterweight
mounting holes.
2. Slide washers (3, Figure 6) onto bolts (2). Apply Loctite
#242 to mounting bolt threads.
3. Install bolts (2, Figure 6) with washers (3) into
counterweight until washers contact support frame. Fully
lower counterweight onto support frame and finish
3
tightening bolts. 4
• Tool: 60 mm ( ) 2 DS1800071
• Torque: 2,451 N.m (250 kg.m, 1,808 ft lb) Figure 6
4. Remove lifting device from counterweight lifting eye bolts

(5, Figure 6)
5. Make sure all electrical and other items are connected.
6. Turn battery disconnect switch to "ON" position.
5-3-6
1Hydraulic Oil Tank
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Hydraulic Oil Tank

5-4-1
Table of Contents
Hydraulic Oil Tank

General ...........................................................5-4-3
Specification .............................................................. 5-4-3
Parts List ................................................................... 5-4-4
Air Breather ............................................................... 5-4-6
Removal..........................................................5-4-7
Installation.....................................................5-4-16
Completing Work ..........................................5-4-17
Hydraulic Oil Tank DX480LCA-K/DX520LCA-K

5-4-2
GENERAL
Specification
Volume (Full) 390 L (103 U.S. gal)
Optimum Volume 265 L (70 U.S. gal)
Tank Size 851 x 700 x 894 mm
Tank Weight about 274 kg (604 lb) (Empty)
Size 10 m, 2.79 m2 (ø172 x 415)
Operation Pressure 0 ~ 15 bar (0 ~ 15.9 kg/cm2, 0 ~ 217.6 psi)
Return Filter (9, Figure 1)
Bypass Valve Setting 1.5 bar (1.5 kg/cm2) at 40 L/min
Flow Rate 880 L/min (232.5 U.S. gpm)
Filter 10 m, 590 cm2
Vacuum Relief 0.039 ~ 0.049 bar
Air Breather (21, Figure 1)
Pressure (0.04 ~ 0.05 kg/cm2, 0.57 ~ 0.71 psi) at 1 L/min
Cracking Pressure 0.45 bar (0.46 kg/cm2, 6.5 psi) at 1 L/min
Suction Filter (17, Figure 1) Size 80 mesh, 5,400 cm2 (ø200 x 190)
Pressure Switch (28, Figure 1) Actuation Pressure 1.5 bar (1.5 kg/cm2, 21.7 psi)

5-4-3
Parts List
25
30 21-2 21
32
FR
ON 30 21-1
T 5 30
32
32
5
6 12
6 13
7
15
7
8
8 14
29
29
26
9
9
17
20
28
19
18
31
3
4
24 24
19 22
2 18
16 2
11
10
DS1800072
Figure 1

5-4-4
Reference Reference
Number Number
1 Tank, Oil 17 Filter, Suction
2 Bolt 18 Plug
3 Shim 19 O-ring
4 Shim 20 Gauge, Level
5 Cover 21 Breather, Air
6 O-ring 21-1 Gasket
7 Spring 21-2 Element, Air Breather
8 Valve, By-pass 22 O-ring
9 Element, Filter 24 Spacer
10 Bolt 25 Bolt
11 Washer 26 Nut
12 Cover, Tank 28 Switch, Oil Pressure
13 O-ring 29 Strainer, By-pass
14 Rod 30 Bolt
15 Spring, Compress 31 Sensor
16 Pipe 32 Washer, Hard

5-4-5
Air Breather
1. Structure of air breather
0.46 k 0.05 k 2
5
DS1800180
Figure 2
Reference Reference
Number Number
1 Housing 4 Flange
2 Element 5 Gasket
3 Body
2. Pressure release
Pulling the breather cap upward, the check valve 0.46 kg/cm2
(0.45 bar) opens, and the air is discharged to the atmosphere
from the top of the hydraulic oil tank.

5-4-6
REMOVAL
WARNING
Contact with hydraulic fluid can harm your health. (e.g. eye
injuries, skin damage or poisoning, if inhaled).
• While performing removal and installation, wear safety
gloves, safety glasses and suitable working clothes.
• If hydraulic fluid should come into contact with your
eyes or penetrate your skin, consult a doctor
immediately.
WARNING
FIRE CAN CAUSE SERIOUS INJURY OR DEATH
Hydraulic fluid is highly flammable.
• Keep open flames and ignition sources away from the
workplace.
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants, grease,
etc. must be disposed of in an environmentally safe
manner. Some regulations require that certain spills and
leaks on the ground must be cleaned in a specific manner.
See local, state and federal regulations for the correct
disposal.
1. Make the machine swing about 30° rightward on the flat

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

5-4-7
(Figure 4) I
WARNING OFF
Lock
OFF
ON
ON

7. Move safety lever on "LOCK" position. (Figure 4)
switch.
ON
OFF
ON
DS1704238
Figure 5
NOTE: Removal (installation) procedure of the bolts.

3
5 8
1 2
7 6
4
EX1401809
Figure 6

5-4-8
WARNING
Release any pressure in the hydraulic oil tank before doing
any work.
11. Loosen the oil tank air breather slowly to release the
pressure inside the hydraulic oil tank.
When the breather cap is pulled upward, the check valve
Figure 7 DS1601105
(0.45 bar) opens, and the air is discharged to the
atmosphere from the top of the hydraulic oil tank.
12. Drain the hydraulic tank, as follows:
NOTE: Check the level on the oil level gauge before
draining the oil.
Figure 8 EX1400737
A. Remove bolts (1, Figure 9) (12 ea). Remove suction

1
filter cover (2) and return filter cover (3). Then drain
hydraulic oil with an oil pump. 3
• Tool: 17 mm ( )
• Torque: 63.7 N.m (6.5 kg.m, 47 ft lb)
DS1704244
Figure 9
B. Remove bolts (1, Figure 10) (6 ea). Then remove the

under cover (2) at the bottom of main frame.
• Tool: 19 mm ( ) 1 2
• Weight: 12 kg (26 lb)
DS1704239
Figure 10

5-4-9
Drain hydraulic oil using drain plug.
(without oil pump) (Figure 11)
FRONT
• Tool: 27 mm ( )
• Torque: 93.2 N.m (9.5 kg.m, 68.7 ft lb)
• Hydraulic oil tank capacity
– Approximately: 390 L (103 U.S. gal)
– Effective level: 265 L (70 U.S. gal)
DS1704245
C. Remove the suction filter and plug its hole in the tank
with a filter cap.
Item Part Number

Filter Cap 2188-1011
DS1601106
Figure 12
Reference
Description
Number
3
1 Suction Filter
2 Nut
A
3 Rod
2
When installing
• Length (A): 606.5 mm 1
• Torque (2 nut): 49 N.m (5 kg.m, 36.2 ft lb) EX1402872
Figure 13
13. Remove bolts (Figure 14) (6 ea) and remove engine cover
of the muffler side.
• Tool: 19 mm ( )
DS1704240
Figure 14

5-4-10
14. Open engine bonnet.
DS1704241
Figure 15
15. Remove bolts and washers (1, Figure 16) (4 ea) with main
control valve cover (2). 1
• Tool: 19 mm ( )
Engine Cover
DS1704242
Figure 16
16. Open right side door.
DS1704243
Figure 17
17. Install eyebolts (2 ea) on the oil tank. (Figure 18)

And tie the rope to the bolts to lift oil tank.
• Thread of hole: M10 x 1.5
DS1704259
Figure 18

5-4-11
18. Remove bolts (1, Figure 19) (3 ea) and clips with harness.
• Tool: 12 mm ( )
A
19. Disconnect oil pressure switch connector and oil
temperature sensor connector. (Figure 19 ~ Figure 21).
components (sensor, connectors). If water gets
into electrical system, this will cause an B
electrical short circuit and result in improper 1
machine operation. DS1800073
Figure 19
A. Oil pressure switch

Pressure
Switch
1
2
DS1800074
Figure 20
B. Oil temperature sensor

1 Push
Temperature
Sensor 2
Figure 21 DS1704261
20. Remove bolts with clips (1, Figure 22) (2 ea) and bolts (2,
Figure) (2 ea) on the rear side of oil tank.
2
• Bolt 1:
– Tool: 12 mm ( )
– Torque: 29.4 N.m (2 kg.m, 21.7 ft lb) 1
• Bolt 2:
– Tool: 19 mm ( )
– Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
DS1704262
Figure 22

5-4-12
21. When the hose is disconnected, oil left in the hose can flow
out. Therefore, place the end of the hose into a suitable
container to prevent contamination of the ground and
environment.
EX1504170
Figure 23

5-4-13
22. Remove hoses and adapters from the oil tank.
NOTE: Attach identification tags on the removed hoses for reassembly. 
Disconnect the hoses in order from bottom to top of oil tank. After the hoses are disconnected,
plug and cap them to prevent dirt or dust from entering.
5
6
7
1
8
9
2 3 4
10
11
12
DS1704263
Figure 24
• Hoses and plugs ports
Plug/Flange Size Torque

Port Name
(Hose) (mm) (mm) N.m kg.m ft lb
1 from radiator SAE 2 1/2", 3000 psi 10 107.9 11.0 79.6
2 from Swing Device "DB" PF 1/2" 27 93.1 9.5 68.7
3 from Swing Device "DB" PF 1/2" 27 93.1 9.5 68.7
4 from Center Joint "0" UNF 1 3/16"-12-2B 36 176.4 18.0 130.1
5 Plug PF 1/4" 19 39.2 4.0 28.9
6 Plug PF 1/4" 19 39.2 4.0 28.9
7 from Solenoid Valve "PH" PF 1/2" 27 93.1 9.5 68.7
8 Plug PF 3/8" 22 49.0 5.0 36.2
from Main Control Valve
9 PF 3/8" 22 49.0 5.0 36.2
"DR2"
from Main Control Valve
10 PF 3/8" 22 49.0 5.0 36.2
"DR1"
11 from Main Control Valve "pb3" PF 3/8" 22 49.0 5.0 36.2
12 from Main Pump "R4" PF 1/2" 27 93.1 9.5 68.7

5-4-14
• Fitting
Size Torque
Port Name
A B (C) (mm) N.m kg.m ft lb
2 PF 1/2" PF 1/2" 27 93.1 9.5 68.7
3 Elbow PF 1/2" PF 1/2" 27 93.1 9.5 68.7
4 PF 3/4" UNF 1 3/16"-12 36 176.4 18.0 130.1
7 PF 1/2" PF 1/2" 27 93.1 9.5 68.7
Adapter
9 PF 3/8" PF 3/8" 22 49.0 5.0 36.2
10 Tee PF 3/8" PF 3/8" 22 49.0 5.0 36.2
11 PF 3/8" PF 3/8" 22 49.0 5.0 36.2
Adapter
12 PF 1/2" PF 1/2" 27 93.1 9.5 68.7
2180-1026D31
1
(ID:69.44, W:3.53, Class1)
2, 3, 7, 12 S8000185 (4D P18)
4 O-ring S8000235 (4D P22.4) S8030125 (4D F-12)
5, 6 S8000115 (4D P11)
8, 9, 10,
S8000145 (4D P14)
11
* A: Opposite side of hose, B (C): Hose side
23. Remove oil tank mounting bolts and spacers (1, Figure 25)
(6 ea) from the main frame.
• Tool: 24 mm ( )
1
24. Remove bolts (2, Figure 25) (6 ea) of suction pipe from the
oil tank. 2
• Tool: 17 mm ( )
DS1704260
25. Lift up the oil tank 25 mm and make it is balanced.
Move it sideways to remove in order to avoid damaging the
exhaust pipe.
• Oil tank weight: about 274 kg (604 lb)

5-4-15
INSTALLATION
WARNING
INCORRECT INSTALLATION CAN CAUSE DEATH OR
SERIOUS INJURY
Any change in the connections will lead to malfunctions.
• When connecting hydraulic components, observe the
specified piping according to the hydraulic schematic
diagram of the machine.
NOTE: First, assemble the bolts and spacers (6 ea) of oil

tank mounting to main frame. (Figure 26)
1. Install the oil tank with bolts and spacers (1, Figure 26)
(6 ea) to the main frame. 1
• Tool: 24 mm ( )
• Torque: 264.6 N.m (27 kg.m, 195.2 ft lb) 2
2. Install the bolts (2, Figure 26) (6 ea) with suction pipe from
the oil tank.
• Tool: 17 mm ( ) DS1704260
3. Perform installation in the reverse order of removal.
4. If the level gauge is removed, install it with the following
torque. Make sure to add small amount of grease to the O-
Ring when installing the level gauge.
5. When assembling rod to suction filter, adjust the
assembling length as Figure 27.
3
Reference
Description
Number
A
1 Suction Filter
2 Nut 2
3 Rod
1
When installing
EX1402872
• Length (A): 606.5 mm Figure 27
• Torque (2 nut): 49 N.m (5 kg.m, 36.2 ft lb)

5-4-16
6. Location of air breather (1) must be as Figure 28 when
assembling cover (2).
DS1601264
Figure 28
COMPLETING WORK
1. Hydraulic oil tank volume:
• Approximately: 390 L (103 U.S. gal)
• Effective level: 265 L (70 U.S. gal)
2. Adjusting standard for hydraulic oil level
A. Front position: Extend the arm and dump the bucket
until both cylinders are fully retracted. Lower the
boom until the bucket rests on the ground.
B. Engine condition: Low idle
EX1301745
C. Fill hydraulic oil until fluid in level gauge is positioned
Figure 29
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.

5-4-17
5-4-18
1Fuel Tank
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Fuel Tank

5-5-1
Table of Contents
Fuel Tank
General ...........................................................5-5-3
Specification .............................................................. 5-5-3
Parts List ................................................................... 5-5-4
Removal..........................................................5-5-6
Installation.....................................................5-5-12
Completing Work ..........................................5-5-13
Fuel Tank DX480LCA-K/DX520LCA-K

5-5-2
GENERAL
WARNING
Diesel fuel is highly flammable and can be potentially
explosive. To prevent fires or explosion, keep arcs, sparks or
other ignition sources away from diesel fuel or fuel
containers.
Specification
Volume (Full) about 620 L (164 U.S. gal)
Tank Size 1,050 x 826 x 916 mm
Tank Weight about 294 kg (648 lb) (Empty)
Fuel Strainer Filter  Filtration Ratio 24 mesh
(11, Figure 1) Working Oil Temp. -40 ~ +80°C
0.25 ~ 0.05 bar
Positive Pressure
Fuel Cap (0.25 ~ 0.05 kg/cm2, 3.63 ~ 0.73 psi)
Check Valve
(12, Figure 1) below 0.035 bar
Negative Pressure
(0.035 kg/cm2 , 0.51 psi)
Working Voltage DC 20 ~ 32 V
Fuel Sensor Working Temperature -40 ~ +80 Celsius Degrees
(2, Figure 1) Float F 3/4 1/2 1/4 E
Resistance
Resistance (k) 0.5 1.2 2.68 3.94 5.0

5-5-3
Parts List
FR 12
ON
T
12-1
11
21 20
19
16
15
2
9
13
8
10
13
3
8
6
5
DS1800075
Figure 1

5-5-4
Reference Reference
Number Number
1 Fuel Tank 11 Fuel Strainer Filter
2 Fuel Sensor 12 Fuel Cap
3 O-ring 12-1 Fuel Cap Element
4 Tank Cover 13 Spacer
5 Bolt 15 Washer
6 Washer 16 Screw
8 Bolt 19 Bracket, Housing
9 Shim 20 Washer
10 Shim 21 Screw

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

operator's cabin to see what it displays. The display is
divided into seven separated segments. Also, look at level
gauge on side of tank to estimate volume of fuel left in
tank.
NOTE: If possible, work excavator until available fuel
supply in tank has been run down as far as
possible. E F
EX1401618
Figure 2
2. Make the machine swing about 60° rightward on the flat

ground as shown in (Figure 3) before lowering all the
attachments on the ground.
3. Stop engine.
DS1600544
Figure 3

I
5. Turn starter switch to "I" (ON) position.
Unlock
WARNING Lock
OFF OFF

ON
ON
If engine must be running while performing

maintenance, use extreme care. Always have one ON OFF
person in the cabin at all times. Never leave the cabin EX1504472
with the engine running. Figure 4

5-5-6
switch.
10. Turn battery disconnect switch to "OFF" position. (Figure 5)
FRONT OFF
ON
OFF
ON
DS1704238
Figure 5

3
5 8
1 2
7 6
4
EX1401809
Figure 6
11. Clean area around fuel tank fill cap. Open fuel cap.
DS1800076
Figure 7

5-5-7
12. Open right side door and carefully drain using the drain
valve.
• Fuel tank capacity: 620 L (164 U.S. gal)
Figure 8 DS1800077
13. Remove bolts (1, Figure 9) (8 ea) and cover (2) from fuel
tank. 2
• Tool: 19 mm ( )
• Tank cover weight: 11 kg (24 lb)
DS1800078
Figure 9
14. Remove bolts (1, Figure 10) (4 ea) with the tank front cover
(2) from fuel tank. 3
2
15. Remove bolts and washers (3, Figure 10 and Figure 11)
(10 ea) with the handrail (4) from fuel tank and frame.
3
• Bolt (1)
– Tool: 17 mm ( ) 4
– Torque: 63.7 N.m (6.5 kg.m, 47 ft lb)
• Bolt (3) 1
– Tool: 19 mm ( ) DS1800079
Figure 10
• Weight
Reference
Description kg (lb)
Number
2 Tank Front Cover 10 (22)
4 Handrail 20 (44)
DS1800080
Figure 11

5-5-8
16. Disconnect the connector of fuel sensor (1, Figure 12).
If water gets into electrical system, this will 1
17. Remove bolt (2, Figure 12) and clip with harness. 2
• Tool: 12 mm ( )
DS1701216
Figure 12
How to disconnect the harness connector.

1
Figure 13 WE1400196
18. Remove bolt (1, Figure 14) and clip (2) with hose.
• Bolt (1) 2
– Tool: 12 mm ( )
• Clip (2) 3
– Tool: Driver 1
Figure 14 DS1800081

Port Name
(Hose) (mm) N.m kg.m ft lb
3 Plug PF 1" 41 205.8 21.0 151.8
• O-ring
Size
Port Name
A B
3 O-ring S8000291 (1B P29)
* A: Opposite side of hose, B: Hose side

5-5-9
19. Install eyebolts (2 ea) on the fuel tank.
And tie the rope to the bolts to lift tank.
• Thread of hole: M12 x 1.75
• Fuel tank weight: 294 kg (648 lb)
Figure 15 DS1800082
cover (2) on bottom of main frame. FRONT
• Tool: 19 mm ( )
2
• Under cover weight: 6 kg (13 lb)
Figure 16 Bottom of Main Frame DS1800083
21. When the hose is disconnected, diesel fuel left in the hose
can flow out. Therefore, place the end of the hose into a
suitable container to prevent contamination of the ground
and environment.
EX1504170
Figure 17

5-5-10
22. Remove hose from fuel tank
FRONT
NOTE: Cap the open ends of hose with plug.
DS1800084
Figure 18 Bottom of Fuel Tank

Port Name
1 to Drain Valve UNF 11/16"-16 22 38.2 3.9 28.2
2 Supply Line UNF 13/16"-16 24 55.9 5.7 41.2
23. Remove fuel tank mounting bolts and spacers (3, Figure 18)
(6 ea) from the main frame.
• Tool: 24 mm ( )
24. Lift tank about 40 mm and make sure it is balanced.
25. Make sure there are no other electrical wires or hoses
connected to tank.
26. Completely remove tank after inspection
• Fuel tank weight: 294 kg (648 lb)
NOTE: The clear level gauge on the side of the tank is
easily damaged. Be careful of obstacles and
wind gusts.

5-5-11
INSTALLATION
NOTE: First, assemble the bolts and spacers (6 ea) of fuel
tank mounting to main frame. (Figure 19) FRONT
1. Install the fuel tank with bolts and spacers (3, Figure 19)
(6 ea) to the main frame.
3
• Tool: 24 mm ( )
NOTE: The clear level gauge on the side of the tank is
easily damaged. Be careful of obstacles and 1
wind gusts.
DS1800084
2. Connect fuel supply line (2, Figure 19) and drain valve line Figure 19 Bottom of Fuel Tank
(1) to fuel tank.
4. Make sure fuel tank drain valve (Figure 20) inside the right
side door is closed.
5. Fill fuel tank and check for signs of leaks. Correct any
problems found.
6. Fuel tank capacity: 620 L (164 U.S. gal)
Figure 20 DS1800077

5-5-12
COMPLETING WORK
If air remains in the fuel inlet line to the engine, it can cause the
engine to run in an abnormal condition. Air can impact the
starting capability of the engine, and can also result in surging
engine speeds.
Bleeding Fuel System (Optional)

If air remains in the fuel inlet line to the engine, it can cause the
engine to run in an abnormal condition. Air can impact the
starting capability of the engine, and can also result in surging
engine speeds.
If the machine happens to have run out of fuel, or if the fuel filter
has been replaced, air can need to be bleed using the following
procedure:
Electric Transfer Pump (ETP)

1. Stop engine.
2. Loosen plug (1, Figure 21) on the pre fuel filter head.
1
• Tool: 10 mm ( )
3. Turn electric transfer pump switch (3, Figure 21) to "I"(ON)

2
position.
4. When pure fuel falls from tap (2, Figure 21) on the pre fuel
filter head, turn electric transfer pump switch (3, Figure 21)
to "O" (OFF) position. 3
5. Tighten plug (1, Figure 21) on the pre fuel filter head.
DS1701377
• Plug tightening torque: 8 ±2 N.m (0.8 ±0.2 kg.m, 5.9 Figure 21
±1.5 ft lb)
6. Loosen plug (1, Figure 22) on the main fuel filter head.
1
• Tool: 17 mm ( )

position.
8. When the fuel comes out from the plug (1, Figure 22) hole
on the main fuel filter head, turn electric transfer pump
switch (3, Figure 21) to "O" (OFF) position.
9. Tighten plug (1, Figure 22) on the main fuel filter head.
DS1800143
• Plug tightening torque: 2 ±0.5 N.m (0.2 ±0.05 kg.m, Figure 22
1.5 ±0.4 ft lb)
position for about 1minutes.
11. Start engine and look for signs of leaks.
12. If the engine does not start after approximately fifteen
seconds of cranking, repeat step 10 to 11.

5-5-13
Priming Hand Pump
1. Stop engine.
2. Loosen plug (1, Figure 23) on the pre fuel filter head.
2
• Tool: 10 mm ( )
1
3. Pump the hand operated primer pump (2, Figure 23) on the
pre fuel filter. Pump primer until fuel is present at plug hole
in pre fuel filter head (1, Figure 23).
4. Tighten plug (1, Figure 23) on the pre fuel filter head.
• Plug tightening torque: 6.5 ±1.6 N.m (0.7 ±0.2 kg.m, DS1704068
4.8 ±1.2 ft lb) Figure 23
5. Loosen plug (1, Figure 24) on the main fuel filter head.
1
• Tool: 17 mm ( )
6. Pump the hand operated primer pump (2, Figure 23) on the
pre fuel filter. Pump primer until the fuel comes out from
the plug hole on main fuel filter head (1, Figure 24).
7. Tighten plug (1, Figure 24) on the main fuel filter head.
• Plug tightening torque: 2 ±0.5 N.m (0.2 ±0.05 kg.m,
1.5 ±0.4 ft lb)
DS1800143
8. Continue to pump primer pump until a strong resistance is Figure 24
felt.
9. Start engine and look for signs of leaks.
10. If the engine does not start after approximately fifteen
seconds of cranking, repeat step 8 to 9.

5-5-14
1Drive Coupling
(Main Pump)
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Drive Coupling (Main Pump)

5-6-1
Table of Contents
Drive Coupling (Main Pump)

General ...........................................................5-6-3
Description ................................................................ 5-6-3
Specification .............................................................. 5-6-3
Parts List ................................................................... 5-6-4
Section View ...................................................5-6-6
Tools.......................................................................... 5-6-7
Disassembly ...................................................5-6-8
Reassembly ....................................................5-6-9
Drive Coupling (Main Pump) DX480LCA-K/DX520LCA-K

5-6-2
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 1,618 N.m (165 kg.m, 1,193 ft lb)
Max. Torque 3,138 N.m (320 kg.m, 2,314 ft lb)
Max. Speed 3,600 rpm
Radial 0.4 mm (0.015 in)
Max. Permissible Displacements Angular 0.5°
Axial ±2 mm (±0.08 in)
Dynamic Torsion Spring Stiffness Cdyn 6.98 x 106 kg.cm/Rad
Mass Moment of Inertia 0.9 kg.cm. S2
Allowable Environment Temperature -40 ~ +120°C

5-6-3
Parts List
FR
ON
T
4
3
2 : 2A ~ 2H
2H : 2B, 2C, 2D
2E
2C
2G 1
2B
2F 2E
2D
4
3
2A 2G
DS1701050
Figure 1
Reference Reference
Number Number
1 Pump, Main 2E Socket Bolt Set (8 ea)
2 Coupling 2F Bolt; Clamping M20 x 2.5 x 25
2A Hub 2G Pin; Spring D8x16
2B Element 2H Element Kit
2C Insert (A) 3 Washer
2D Insert (R) 4 Bolt

5-6-4
5-6-5
SECTION VIEW
Whenever the drive coupling for main pump is installed, the
following mounting dimensions and installation procedures must
be observed.
NOTE: If these procedures are not followed, noise will occur
and/or the service life of drive coupling or main pump
will be reduced.
10
12
Main Pump
11
DS1701051
Figure 2 Drive Coupling Installation

5-6-6
Reference
Description Qty. Torque
Number
1 Spring Pin 4
2 Insert 4
3 Socket Bolt M20 x 65 4 432 ~ 481 N.m (44 ~ 49 kg.m, 318 ~ 354 ft lb)
4 Flywheel 1
5 Spring Pin 8
6 Insert 4
7 Hub 1
8 Socket Bolt M20 x 60 4 432 ~ 481 N.m (44 ~ 49 kg.m, 318 ~ 354 ft lb)
9 Pump Shaft 1
10 Clamping Screw M20 x 25 2 196 ~ 216 N.m (20 ~ 22 kg.m, 145 ~ 159 ft lb)
11 Element 1
12 Snap Ring 1
Tools
Name Description
Allen Wrench 8 mm, 16 mm
Plastic Hammer One Plastic Hammer
Pliers One for Shaft and Hole Each

5-6-7
DISASSEMBLY
When the pump is removed from an engine, the hub and insert
would be attached on the pump.
1. After removing pump remove socket bolts (5, Figure 3)
6
(4 ea) and remove insert (4) (4 ea). 4
• Tool: 17 mm ( )
5
2. Remove clamp screw (6, Figure 3) (2 ea) and remove hub
(1).
• Tool: 10 mm ( )
1
DS1701298
Figure 3
3. Remove socket bolts (5, Figure 4) (4 ea) and insert (3,

Figure 4) (4 ea) with element (2) from flywheel. 3
• Tool: 17 mm ( ) 2
DS1701299
Figure 4

5-6-8
REASSEMBLY
1. Install insert (3, Figure 5) (4 ea) and spring pin (7, Figure 6)
(4 ea) with socket bolts (5) (4 ea) to engine flywheel.
• Tool: 17 mm ( )
• Torque: 431.2 ~ 480.5 N.m

5
(44 ~ 49 kg.m, 318.3 ~ 354.4 ft lb)
DS1701300
Figure 5
Flywheel Side
DS1701301
Figure 6
2. Assemble the insert (4, Figure 7) (4 ea) with socket bolts

(5) (4 ea) to hub (attached by spring pin) (7) (8 ea).
• Torque: 431.2 ~ 480.5 N.m
(44 ~ 49 kg.m, 318.3 ~ 354.4 ft lb) 5
1
DS1701302
Figure 7

5-6-9
3. Install hub (1, Figure 8) to the pump shaft such that snap
ring (12) contacts the shaft, and then tighten clamping 8
6
bolts (6).
• Torque: 196.1 ~ 215.7 N.m
(20 ~ 22 kg.m, 144.7 ~ 159.1 ft lb)
NOTE: Coat clamping bolts (6, Figure 8) with Loctite
#262.
1
DS1701303
Figure 8
4. Install element (2, Figure 9) to inserts (3) on engine flywheel.

5. Install main pump and hub (1, Figure 8) by pushing it softly 3
into element (2).
2
IMPORTANT
1. Bolts are coated against loosening with a
bonding compound. Do not use any additional
bonding compounds, oils or cleaning solvents on
them. DS1701304
2. Element (2, Figure 9) is not resistant to bonding Figure 9

compounds, oil or grease. Be careful not to
expose them to it.
3. Remove oil or dirt from flywheel cover and pump
shaft before assembly.
4. Misalignment between pump and engine must be
controlled to less than 0.6 mm (0.023 in).

5-6-10
1GearPump
(Rotating)
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Gear Pump (Rotating)

5-7-1
Table of Contents
Gear Pump (Rotating)

General ...........................................................5-7-3
Specification .............................................................. 5-7-3
Overview ................................................................... 5-7-3
Location ..................................................................... 5-7-4
Parts List ................................................................... 5-7-5
Disassembly ...................................................5-7-6
Single Gear Pump (Opt) ............................................ 5-7-6
Reassembly ....................................................5-7-9
Single Gear Pump (Opt) ............................................ 5-7-9
Gear Pump (Rotating) DX480LCA-K/DX520LCA-K

5-7-2
GENERAL
Specification
Direction of Rotation
Clockwise
(Looking on Driveshaft)
Displacement 26.7 cm3/rev
Inlet Pressure Range for Pump 0.7 ~ 3 bar (0.7 ~ 3 kg/cm2, 10.1 ~ 43.5 psi)
Max. Continuous Pressure 280 bar (286 kg/cm2, 4,061 psi)
Max. Intermittent Pressure 300 bar (306 kg/cm2, 4,351 psi)
Max. Peak Pressure 310 bar (316 kg/cm2, 4,496 psi)
Weight 13.7 kg (30.2 lb)
Overview
Out In
EX1400103
Figure 1
Port and Hydraulic Circuit

Inlet
Port Name Size
In Hydraulic Oil Inlet PF 1" O-ring
Out Hydraulic Oil Outlet PF 3/4" O-ring
Outlet
EX1301736
Figure 2

5-7-3
Location
Main Pump
PTO Gear Pump

DS1701070
Figure 3

5-7-4
Parts List
5
7
14
9
12
2
3
2
13
10
15
14
13
8
4
8
12
6
13
1
11
EX1400104
Figure 4
Reference Reference
Number Number
1 Front Cover 9 Seal
2 Thrust Plate 10 Shaft Seal
3 Drive Shaft 11 Snap Ring
4 Driven Gear 12 Ring
5 Socket Bolt 13 Bush
6 Plug 14 Bush
7 Washer 15 Body
8 Seal * Gear Pump Seal Kit

5-7-5
DISASSEMBLY
Single Gear Pump (Opt)

1. Clean the pump externally with care
Figure 5
2. Loosen and remove the clamp bolts
Figure 6
3. Coat the sharp edges of the drive shaft with adhesive tape
and smear a clean grease on the shaft end extension to
avoid any damaging lip of the shaft seal when removing
the mounting flange.
Figure 7

5-7-6
4. Remove the mounting flange taking care to keep the flange
as straight as possible during removal.
If mounting flange is stuck, tap around the edge with
rubber mallet in order to break away from the body.
NOTE: Ensure that while removing mounting flange,
shaft and other components remain position.
Figure 8
Figure 9
5. Remove snap ring with proper tool, (only when it is needed

to replace shaft seal)
Figure 10
6. Remove the shaft seal taking care not to give any damage
on the surface of shaft hole.(only when it is needed to
replace shaft seal)
Figure 11

5-7-7
7. Ease the drive gear up to facilitate removal the front plate.
Figure 12
8. Remove driving gear, driven gear, keeping gears as

straight as possible. And rear plate.
Figure 13

5-7-8
REASSEMBLY
Single Gear Pump (Opt)

1. Clean all components externally with care
Figure 14
2. Insert the shaft seal carefully and fit it inside of mounting

flange with proper tool.
Figure 15
3. Fit the snap ring in pre-arranged position with proper tool.
Figure 16

5-7-9
4. Fit the o-ring on the body.
Smear clean grease on the o-rings to avoid drifting away of
o-ring from the body.
Figure 17
5. Locate the seals on the groove pre-arranged on the

pressure plates.
Then, locate back-up ring on the groove pre-arranged on
the seals.
Smear clean grease on the seals.
(The front and rear pressure plates and seals and back-up
rings are same).
Figure 18
6. Insert the complete pressure plate into body while keeping

the plate straight.
NOTE: Seal side should face to the inside, opposite
side of gears.
NOTE: Pay attention to the direction of seal.
Figure 19
7. Locate drive gear and driven gear.
Figure 20

5-7-10
8. Insert the pressure plate in to body with attention to the
direction.
Figure 21
9. Locate mounting flange in right position.

Tap around mounting flange with rubber mallet.
Figure 22
10. Tighten the bolts with washer in a crisscross pattern to

torque value of 140 Nm.
Figure 23
11. Check that the pump rotate freely when the drive shaft is
turned by hand. If not a pressure plate seal can be
pinched.
Figure 24

5-7-11
5-7-12
1Lower Structure and
Chassis
1Swing Bearing
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Swing Bearing

6-1-1
Table of Contents
Swing Bearing
General ...........................................................6-1-3
Parts List ................................................................... 6-1-3
Maintenance Guidelines .................................6-1-4
Disassembly ...................................................6-1-5
Reassembly ....................................................6-1-7
Swing Bearing DX480LCA-K/DX520LCA-K

6-1-2
GENERAL
General Description
The swing bearing, which connects the upper structure with the
lower structure, consists of a inner ring, outer ring and ball
bearings. During swing movement, power from the swing motor
is transferred to the pinion by planetary gears connected to
gears on the inner ring, which is fixed in the undercarriage. Ball
bearings turn the outer ring.
Parts List
2 6
FG1301305
Figure 1
Reference Reference
Number Number
1 Outer Ring 5 Ball
2 Inner Ring 6 Retainer
3 Tapered Pin 7 Seal
4 Plug

6-1-3
MAINTENANCE GUIDELINES
Operating Recommendation
The service life of the swing bearing may be extended if a daily
effort is made to equalize usage over both ends of the
excavator. If the excavator is used in the same operating
configuration day in and day out (for example, with the travel
motors always under the counterweight, or with the attachment
over one side of the machine more than the other), the bearing's
service life could be reduced. Repositioning the excavator
during the work shift, to work the opposite end of the bearing,
will provide a more even and gradual rate of wear and extended
service life. EX1302041
Figure 2
Measuring Swing Bearing Axial Play

Regular checks of bearing displacement must be made at least
twice a year. Use a dial indicator. With the arm cylinders fully
retracted and the bucket cylinders fully extended, position the
arm tip pin height is flush with the boom foot pin height. 
(Figure 3)
Push the attachment against the ground to lift up the excavator
The height as the
above the ground and take measurements at 4 points, 90° apart, boom foot pin height.
around the circumference of the bearing.
Record and keep all measurements. Play in the bearing should EX1301770
increase minimally from one inspection to the next. Figure 3 Measurement (h1)
Eventually, however, as the bearing begins to approach the limit

of its service life, clearance increases become much more
pronounced and the actual measured play in the bearing could
exceed twice the value that was measured when the machine
was new.
Measuring Bearing Lateral Play

When vertical checks are made, the side to side play in the EX1301780
bearing can be checked by fully retracting the arm and bucket Figure 4 Measurement (h2)
cylinders and extending the tip of the bucket as far forward as it
will go. With the excavator parked on a flat, level surface and the
bucket tip just off the ground, push against the bucket sideways
to take up all the lateral clearance in the bearing. (Less than 100
lb of force must be required to move the bucket over all the
way.) Check lateral play in both directions and record the values.
When the bearing is beginning to approach the end of its service
life, the measured lateral clearance should start to show
increase in value.

6-1-4
DISASSEMBLY
1. Remove tip of tapered pin (3, Figure 5) using grinder and
tap lightly to remove debris.
Figure 5
2. Remove plug (4, Figure 6) using a M10 x P 1.5 bolt.
Figure 6
3. Lift outer ring and check that inner ring can move freely.
See Figure 7, if not, replace seal (7, Figure 8).
• Weight: 653 kg (1,440 lb)
Figure 7 WE1401490
4. Turn inner ring and use magnet bar (C, Figure 8) to

remove steel balls (5).
Figure 8

6-1-5
5. Turn inner ring and use wire (D, Figure 9) to remove
retainers (6).
Figure 9

6-1-6
REASSEMBLY
1. Clean (degrease) the seal groove for the outer and inner
seals (7, Figure 10).
Apply instant glue to seal (7).
Install both seals respectively into position.
Figure 10
2. Hoist the outer race by crane horizontally and match it with

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

6-1-7
6-1-8
1Track Assembly
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Track Assembly

6-2-1
Table of Contents
Track Assembly
General ...........................................................6-2-3
Track Tension .................................................6-2-4
Track Shoes and Links ...................................6-2-6
Parts List ................................................................... 6-2-6
Track Removal .......................................................... 6-2-7
Track Installation ....................................................... 6-2-9
Wear Limits and Tolerances.................................... 6-2-10
Sprocket........................................................6-2-12
Wear Limits and Tolerances.................................... 6-2-12
Front Idler .....................................................6-2-13
Overview ................................................................. 6-2-13
Parts List ................................................................. 6-2-14
Front Idler Disassembly........................................... 6-2-15
Front Idler Reassembly ........................................... 6-2-17
Upper Roller..................................................6-2-18
Overview ................................................................. 6-2-18
Parts List ................................................................. 6-2-19
Upper Roller Removal ............................................. 6-2-20
Upper Roller Installation .......................................... 6-2-20
Upper Roller Disassembly ....................................... 6-2-20
Upper Roller Reassembly........................................ 6-2-22
Lower Roller..................................................6-2-23
Overview ................................................................. 6-2-23
Parts List ................................................................. 6-2-24
Lower Roller Removal ............................................. 6-2-25
Lower Roller Installation .......................................... 6-2-25
Lower Roller Disassembly ....................................... 6-2-25
Lower Roller Reassembly........................................ 6-2-26
Track Adjuster...............................................6-2-28
Parts List ................................................................. 6-2-28
Disassembly ............................................................ 6-2-29
Assembly ................................................................. 6-2-30
Track Assembly DX480LCA-K/DX520LCA-K

6-2-2
GENERAL
The track assembly is composed of the following major
components:
1. Track
2. Front Idler
3. Upper Roller
4. Lower Roller
5. Track Adjuster

6-2-3
TRACK TENSION
WARNING
Measuring track tension requires two people. One person
must be in the operator's seat, operating the controls while
the other person makes dimensional checks. Block frame to
make sure the machine won't move or shift position during
service. Warm up the engine to prevent stalls, park the
excavator in an area that provides level, uniform ground
support and/or use support blocks when necessary.
Track shoe link pins and bushings wear with normal usage,
reducing track tension. Periodic adjustment is necessary to
compensate for wear and it can also be required by working
conditions.
1. Track tension is checked by jacking up one side of the
excavator. See Figure 1. Place blocking under frame while
taking measurement.
Turn the track backward 1 ~ 2 turns.
90 - 110
EX1300534
Figure 1
2. Measuring the distance (A, Figure 2) between the bottom

of the side frame and the top of the lowest crawler shoe.
Recommended tension for operation over most types of
terrain is distance "B" on below table.
NOTE: Clean off the tracks before checking clearance
for accurate measurements.
A
3. Too little sag in the crawler track (less than clearance
distance "B" on below table) can cause excessive
component wear. The recommended adjustment can also
be too tight causing accelerated stress and wear if ground
FG000223
conditions are wet, marshy or muddy.
Figure 2
4. The increased clearance recommended for muddy, sandy
or snowy ground conditions is between distance "C" on
below table.
Terrain Type Distance "A"

380 ~ 410 mm
Normal "B"
(14.96 ~ 16.14 in)
410 ~ 460 mm
Muddy, Sandy or Snowy "C"
(16.14 ~ 18.11 in)

6-2-4
WARNING
The track adjusting mechanism is under very
high-pressure. NEVER release grease pressure too
fast. The track tension grease valve should never be
loosened more than one (1) complete turn from the
fully tightened down position. Bleed off grease
pressure slowly. Keep your body away from the valve
always. Always wear eye and face protection when
adjusting track tension.
5. Track tension adjustments are made through the grease

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

6-2-5
TRACK SHOES AND LINKS
Parts List
1
1-1
1-1A 1-1D
1-1B 1-1A
1-1H
1-1F
1-1H
1-3
1-1G
1-1E
1-1G
1-1B
1-3 1-1C
1-4
1-2
FR
ON
2 T
4
3
TRACK FRAME
Figure 4 EX1401291

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

approximately 4 o'clock from top position on front idle
roller.
3. Put a wooden block under track shoes, as shown.
1
2
4
EX1400787
Figure 6
4. Loosen valve (1, Figure 7) for track adjuster to drain

grease out. Use socket wrench 27 mm
NOTE: Loosen carefully, keeping face, hands, body
away from the valve and nipple. Do not loosen
valve Quickly.
5. Remove four nuts and bolts (1 and 2, Figure 6) holding 1
shoe to link. Remove enough shoes to make access to
master pin.
6. Remove master pin from link by hammer or press. Remove
pin after detaching shoe.
EX1401292
Figure 7

6-2-7
7. Move unit forward until entire track is laying on ground.
NOTE: Do not drive unit off track.
FG003911
Figure 8
8. Rotate upper structure to 90° from track. Use bucket and

boom to raise track frame off track.
9. Position blocking under frame.
90 - 110
EX1300534
Figure 9

6-2-8
Track Installation
1. Lay rebuilt or new track into position under track frame.
End of track must be positioned under drive sprocket.
90 - 110
2. With upper structure at 90° to track frame. Use bucket and
boom to raise track frame off blocking.
3. With blocking removed, lower track frame onto track. Make
sure all rollers are properly positioned on track.
EX1300534
Figure 10
4. Move unit forward while feeding track up over drive

sprocket. Continue to pull track back until it engages front
idle roller.
5. Align links and install master pin.
6. Install four nuts and bolts (to fix track shoe).
7. Apply track tension. Refer to "Track Tension" on page 2-4"
in this section for procedure.
FG003912
Figure 11

6-2-9
Wear Limits and Tolerances
H J
G G
B B
I K
A
C
F
D E EX1400789
Figure 12

6-2-10
Limit for Use
Recommended Limit
No. Check Item Standard Dimension (Repair - P or
for Maintenance
Replace - R)
215.9 mm
A Link Pitch
(8.50")
Bushing Outside 71.0 mm 68.0 mm 66.0 mm (R)
B
Diameter (2.80") (2.68") (2.60")
129 mm 126 mm 122 mm (P)
C Link Height
(5.08") (4.96") (4.80")
24 mm
D Length at Tip
(0.94")
18 mm
E Length at Tip
(0.71")
36 mm 32 mm 30 mm
F Height
(1.42") (1.26") (1.18")
Standard Tolerance Standard Tolerance Standard Repair
Interference Tolerance
Dimension Shaft Dimension Hole Interference Limit
G between
bushing and link 71.4 mm +0.05 71.0 mm +0.074 +0.45 0.326 -
(2.81") 0.0 (2.80") 0.0 0.326 0.45
H between regular
pin and link 47.0 mm +0.285 46.8 mm 0.062 +0.485 0.273 -
(1.85") +0.135 (1.84") 0.0 0.273 0.485
Clearance Tolerance
I between regular
pin and bushing 47.0 mm +0.285 47.9 mm +0.5 +1.265 0.615 -
(1.85") +0.135 (1.89") 0.0 0.615 1.265
J between master
pin and link 47.0 mm +0.11 46.8 mm +0.062 +0.31 0.218 -
(1.85") +0.08 (1.84") 0 0.218 0.31
Clearance Tolerance
K between master
pin and bushing 47.0 mm +0.11 47.9 mm +0.5 +1.32
0.79 - 1.32
(1.85") +0.08 (1.89") 0.0 +0.79

6-2-11
SPROCKET
Wear Limits and Tolerances
A E
D
C
B
Travel Device
EX1401293
Figure 13
Standard Allowable Limit Limit for Use

No. Check Item
Dimension for Maintenance (Repair - P or Replace - R)
89 mm
A Tooth Width - -
(3.504")
123 mm 119 mm 117 mm (R)
B Tooth Bottom Surface
(4.843") (4.685") (4.606")
159 mm
C Pitch Circle Dimension - -
(6.260")
167 mm 164 mm 162 mm (R)
D Tooth Top Land
(6.575") (6.457") (6.378")
216 mm
E Accumulated Pitch Tolerance - -
(8.504")

6-2-12
FRONT IDLER
Overview
310
203 205
102 145
110
682
630
290
360 4 - M20 x P2.5 64

420 140
EX1401300
Figure 14


6-2-13
Parts List
1
1-5
1-6
1-8
1-2
1-1 1-4
1-7
1-3
1-7
1-4
1-8
1-5
1-6
1-2
4
3
2
EX1400791
Figure 15
Reference Reference
Number Number
1 Idler Assembly 1-6 Plug
1-1 Body 1-7 O-ring
1-2 Support 1-8 Floating Seal
1-3 Shaft 2 Track Spring
1-4 Bushing 3 Bolt
1-5 Pin 4 Spring Washer

6-2-14
Front Idler Disassembly
1. Remove plug (9, Figure 16) from idler assembly (1), and
drain oil into a suitable container.
FG003914
Figure 16
2. Separate the pin (6, Figure 17) from the bearing (3).
3
FG003915
Figure 17
3. Use a press to remove bearing from the axle (4). Separate

4
the O-ring (8, Figure 18) from the axle.
3
8
FG001482
Figure 18
4. Detach the floating seal (7, Figure 19) from the idler (2)
3
and bearing (3).
7
2
3 FG001483
Figure 19

6-2-15
5. Use a press to separate the axle (4, Figure 20), O-ring (8)
and bearing (3).
8
FG001484
Figure 20
6. Remove bushing (5, Figure 21) with the press.
10
5 2
FG001485
Figure 21

6-2-16
Front Idler Reassembly 4
3
1. Degrease, clean and dry all parts before reassembly.
8
Insert bushing (5, Figure 21) into the idler (2). 6
2. Grease O-ring (8, Figure 22) and insert it into the axle.
3. Align the bearing (3, Figure 22) and axle (4) holes and pin
(6) them together.
8
FG001486
Figure 22
4. Install floating seal (7, Figure 23) inside the idler (2) and
3
bearing (3).
NOTE: Apply clean engine oil to the joint side of the 7
floating seal. Apply grease to the floating seal 2
O-ring.
3 FG001483
Figure 23
5. Install idler (2, Figure 24) on the axle.

6. Install bearing (3, Figure 24) and pin (6) to the axle.
NOTE: Fill the idler assembly with new gear oil (ISO VG
6
220 EP/VI 130) with approximately 470 cc
(15.9 oz). 2
3
7. Install plug (9, Figure 24) on the bearing.
FG001488
Figure 24

6-2-17
UPPER ROLLER
Overview
316.5
205
95
200105-00002C
180
210
60
93
EX1400792
Figure 25

• Weight: 38 kg (83.8 lb)

6-2-18
Parts List
6
12
9
8
9 7
8
11
10
5 EX1400793
Figure 26
Reference Reference
Number Number
1 Body 7 Washer
2 Upper Roller Shaft 8 Bolt
3 Roller Bushing 9 Spring Washer
4 Roller Bushing 10 Plug
5 Cover 11 O-ring
6 Thrust Washer 12 Floating Seal

6-2-19
Upper Roller Removal
1. Relieve track tension. This will allow track to be raised so
links clear top of roller.
2. Position a bottle jack on top of track frame and apply
pressure to track shoe.
3. Remove mounting hardware holding upper roller assembly
to track frame.
WARNING Figure 27
EX1401301

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

EX1401301
Figure 28
Upper Roller Disassembly

1. Remove plug (10, Figure 29) from the cover and drain oil.
10
EX1400796
Figure 29

6-2-20
2. Remove bolts (8, Figure 30) and cover (5). Detach bolts (8)
and washer (7).
8
7
EX1400795
Figure 30
3. Separate the roller (1, Figure 31) from the shaft (2).
2
1
FG001497
Figure 31
4. Separate the floating seal (12, Figure 32) from the roller. 1
5. Separate the thrust washer (6) from the shaft (2).
12
EX1400808
Figure 32
6. Separate the bushing (3 and 4, Figure 33) from the roller

with a press.
EX1400809
Figure 33

6-2-21
Upper Roller Reassembly 4
1
Insert bushing (3 and 4, Figure 34) into the roller (1).
EX1400797
Figure 34
2. Insert floating seal (12, Figure 35) into the roller (1) and 1
bushing.
NOTE: Apply clean engine oil to the joint side of the
floating seal. Apply grease to the floating seal 2
O-ring.
12
3. Install the shaft (2) and thrust washer (6).
6
EX1400808
Figure 35
4. Install washer (7, Figure 36) and bolt (8).

5. Insert the O-ring (11, Figure 36) to the cover (5). Attach
8
cover (5) and bolt (8) to the roller.
6. Fill with gear oil (ISO VG 220 EP/VI 130) with 5
approximately 600 ±30 cc (20 ±1 oz).
8
7. Tighten plug (10, Figure 36).
7
11
10 EX1400810
Figure 36

6-2-22
LOWER ROLLER
Overview
290 125
280
210
76.5
200
250
85
C
7
00
00
2 0 010 4 -
4- 23.5
400 (Bolt Hole Pitch)

445
EX1400811
Figure 37


6-2-23
Parts List
5
2 8
6
5 7
7
8
2
FG019395
Figure 38
Reference Reference
Number Number
1 Roller 6 Floating Seal
2 Collar 7 O-ring
3 Shaft 8 Plug
4 Bushing 9 Bolt
5 Pin

6-2-24
Lower Roller Removal
1. Relieve track tension. Refer to "Track Tension" in this
section for procedure.
90 - 110
2. Swing upper structure at 90° to frame.
3. Using bucket raise track off ground and place blocking
under frame.
4. Remove four bolts and lower roller assembly from track
frame. There is an alignment pin on each end of lower
roller assembly. EX1300534
Figure 39
NOTE: To gain access to some rollers the link guard
may have to be removed. Remove four spring
washers and bolts to remove guard.
NOTE: If additional track clearance is required, remove
upper rollers before raising track.
Lower Roller Installation

1. Install four bolts to hold lower roller assembly to track
frame.
90 - 110
NOTE: To gain access to some rollers a link guard may
have to be removed. Remove four spring
washers and bolts to remove guard.
EX1300534
Figure 40
Lower Roller Disassembly

5
1. Remove plug (8, Figure 41) from the collar and drain oil.
2. Pull the pin (5, Figure 41) from the collar.
FG001489
Figure 41

6-2-25
3. Separate the collar (2, Figure 42) from the axle, using
press.
2
FG001490
Figure 42
4. Detach O-rings (7, Figure 43) from the axle.

1
5. Separate floating seals (6, Figure 43) from the collar and 6
roller (1).
2
6. Detach collar (2, Figure 43) and O-rings (7) from the axle,
using press.
2
7 6 FG001493
Figure 43
Lower Roller Reassembly

Insert bushing (4, Figure 44) into roller.
4
FG019396
Figure 44

6-2-26
2. Apply grease to the O-rings (7, Figure 44) and insert into
axle. 5
3. Align collar (2, Figure 45) and axle (3) pinholes and pin (5)
the collar. 3 7 2
FG001492
Figure 45
4. Insert floating seals (6, Figure 46) into the roller (1) and
1
collar (2).
6
NOTE: Apply clean gear oil to the joint side of the
2
floating seal. Apply grease to the floating seal
O-ring.
5. Slide the axle inside the roller.
2
7 6 FG001493
Figure 46
6. Install the collar (2, Figure 47), O-ring (7), and pin (5) on
the remaining side. 5
7. Fill with clean gear oil (ISO VG 220 EP/VI 130) with
approximately 485 cc (16.4 oz).
8. Install plug (8, Figure 47) on the collar.
8
2 FG001487
Figure 47

6-2-27
TRACK ADJUSTER
Parts List
9
11
8
7
10
17
16
12
13
15
14
Seal Kit
2
20
Figure 48 EX1401302

6-2-28
Reference Reference
Number Number
1 Body 11 Spring Washer
2 Rod 12 Packing
3 Bracket 13 Back Up Ring
4 Stopper 14 Dust Seal
5 Shaft 15 Piston Ring
6 Spring 16 Retaining Ring
7 Lock Nut 17 Body Assembly
8 Lock Plate 20 Grease Valve
9 Bolt * Seal Kit
10 Spring Pin
Disassembly
1. Apply pressure on spring (6, Figure 49) with a press. Press Press
NOTE: The spring is under a large installed load. 
This is dangerous, so be sure to set properly. 9, 11
• Spring set load: 28,039 kg (61,815 lb) 8
7
2. Remove bolt (9, Figure 49), spring washer (11) and lock
plate (8). 3
6
3. Remove lock nut (7, Figure 49).
NOTE: Take enough notice so that the press which
pushes down the spring, should not be slipped
out in its operation.
4. Tighten the press load slowly and remove bracket (3,
Figure 49) and spring (6).
EX1400069
Figure 49
5. Remove piston rod (2, Figure 50) from body (1).

1 2
6. Remove grease valve (20, Figure 50) from piston rod (2).
20
EX1400092
Figure 50

6-2-29
7. Remove dust seal (14, Figure 51) from body (1).
14
1
EX1400071
Figure 51
8. Remove stop ring (16, Figure 52), backup ring (13),

packing (12) and piston ring (15) from piston rod (2).
16 12 13 15
EX1400093
Figure 52
Assembly
1. Install piston ring (15, Figure 53), packing (12), backup ring
(13) and stop ring (16) to piston rod (2).
16 12 13 15
EX1400093
Figure 53
2. Install dust seal (14, Figure 54) to body (1).

NOTE: When installing piston ring (15), packing (12),
dust seal (14) take full care as not to damage
the lip. 14
1
EX1400071
Figure 54

6-2-30
3. Grease into body (1, Figure 55), then push in piston rod (2)
1
by hand.
NOTE: Fill up "B" part with grease. Press fit the piston
rod (2, Figure 55) by maximum to *100 mm.
Remove air in the "B" part and the piston rod
and install the grease valve (20).
B 20 2
NOTE: If air letting is not sufficient, it can be difficult to
EX1400094
adjust the tension of crawler.
Figure 55
• Tool: 27 mm ( )
• Grease valve torque: 137 N.m (14 kg.m, 101 ft lb)
4. Install piston rod (2, Figure 56) to body, and assemble 3 5 4 10
spacer (4) with the shaft (5) after assembling the shaft (5)
with spring pin (10).
5. Install spring (6, Figure 56) and bracket (3) to body.
6. Apply pressure to spring (6, Figure 56) with a press and
tighten lock nut (7). 2
NOTE: Apply sealant before assembling. 7 6 EX1400074
NOTE: During the operation, pay attention specially to Figure 56
prevent the press from slipping out.
7. Tighten the press load and confirm the set length of spring 6
(6, Figure 57).
• Length A: 683 mm (26.9 in)
A
EX1400075
Figure 57
8. After the setting of spring (6, Figure 58), install lock plate Press Press
(8), spring washer (11) and bolt (9).
NOTE: Apply loctite on bolt (9, Figure 58). 9, 11
• Torque: 177 N.m (18 kg.m, 130 ft lb) 8
7
3
6
EX1400069
Figure 58

6-2-31
9. Install the bolt (3, Figure 59) and washer (4).
• Torque: 539 N.m (55 kg.m, 398 ft lb)
4 3
EX1400813
Figure 59

6-2-32
1Front
1Boom and Arm
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Boom and Arm

7-1-1
Table of Contents
Boom and Arm

Specifications..................................................7-1-3
Removal..........................................................7-1-4
Arm Removal............................................................. 7-1-4
Boom Removal .......................................................... 7-1-6
Installation.......................................................7-1-7
Arm Installation.......................................................... 7-1-7
Boom Installation ....................................................... 7-1-7
Completing Work ............................................7-1-7
Boom and Arm DX480LCA-K/DX520LCA-K

7-1-2
SPECIFICATIONS
The table below has a complete listing of dimensional specifications for all mounting pins used on the front
attachment.
NOTE: Some mounting pins must be drilled and tapped for lubrication fittings and piping, or may have other
required specifications. Consult DOOSAN After Sales Service for information on wear tolerances and
replacement limits for mounting pins.
A B C E
D
F
K J I H G EX1300988
Figure 1
Criteria
Mark Measuring Part Standard Tolerance Standard Clearance Remedy
Size Pin Hole Clearance Limit
125 mm -0.10 +0.18
A Boom Foot 0.28 ~ 0.38 1.5
(4.92") -0.15 +0.23
110 mm -0.10 +0.16
B Boom Cylinder Head 0.26 ~ 0.36 1.5
(4.33") -0.15 +0.21
120 mm -0.10 +0.18
C Boom Center 0.28 ~ 0.38 1.5
(4.72") -0.15 +0.23
125 mm -0.10 +0.18
D Boom End 0.28 ~ 0.38 1.5
(4.92") -0.15 +0.23
120 mm -0.10 0
E Arm Cylinder Head 0.10 ~ 0.204 1.5
(4.72") -0.15 +0.054
120 mm -0.10 0
F Arm Cylinder Rod 0.10 ~ 0.204 1.5 Replace
(4.72") -0.15 +0.054
110 mm -0.10 0
G Bucket Cylinder Head 0.10 ~ 0.204 1.5
(4.33") -0.15 +0.054
100 mm -0.10 +0.16
H Arm Link 0.26 ~ 0.36 2.0
(3.94") -0.15 +0.21
120 mm -0.10 +0.18
I Arm End 0.28 ~ 0.38 2.0
(4.72") -0.15 +0.23
110 mm -0.10 +0.16
J Bucket Cylinder Rod 0.26 ~ 0.36 2.0
(4.33") -0.15 +0.21
120 mm -0.10 +0.18
K Push Link to Bucket 0.28 ~ 0.38 2.0
(4.72") -0.15 +0.23

7-1-3
REMOVAL
DANGER
AVOID DEATH
DOOSAN warns any user, that removal of the counterweight
from the machine, front attachment or any other part, can
affect the stability of the machine. This could cause
unexpected movement, resulting in death or serious injuries.
Never remove counterweight or front attachment unless the
Never rotate the upper structure once the counterweight or
EX1401352
Figure 2
IMPORTANT
Always break down the front attachment by removing
outermost sections first - the bucket before the arm, the
arm before the boom. Reinstallation of the attachment must
begin with the boom and end with the bucket.
Refer to the appropriate Bucket section for its removal and

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

two bucket linkage pins and the bucket cylinder mounting pin, on
the arm. Use an assist crane or hoist to lift the cylinder and
relieve weight on mounting pins.
Park the excavator away from obstructions and all traffic on
clear, flat, level ground. Extend the arm cylinder and crowd the

7-1-4
arm into the boom. Partially retract the boom cylinder so the
boom is stretched out in front of the excavator, as low to the
ground as possible, with the arm crowded under the boom.
The tip of the arm point must be lowered to secure blocking that
will safely support the weight of the arm. Place the blocking
directly in front of the excavator and make sure that it will not be
unbalanced with an initial weight load that is all to one end,
under the arm point.
Shut off the engine and release hydraulic system pressure -
move any of the control levers with the engine off to release
pressure built up in the accumulator. Manually vent residual
hydraulic pressure in the tank by moving the lever near the cap,
on top of the reservoir.
WARNING
Secure the swing lock and tag and lock out controls in the
operator's cabin to keep anyone from moving or
inadvertently starting the engine. Restrict access to the
work site while sections of the attachment are in the air, or
while they are being supported by the assist crane. The safe
lifting capacity of the assist crane or hoist that is used must
exceed the weight of the heaviest section of the attachment,
the boom (approximately 3,825 kg (8,433 lb), not including
the weight of accessories or fixtures).
Before beginning the disassembly of attachment mounting pins,

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

7-1-5
IMPORTANT
To make sure that polished surfaces of cylinder rod ends
are not damaged during disassembly or removal
procedures, wrap exposed rod surfaces (especially those of
boom cylinders) with a protective covering material.
Immediately the following disassembly and removal,
cylinder rods should always be fully retracted. This eases
handling problems and avoids possible damage.
Remove retainers on the end of the mounting pin for the arm
cylinder rod end. Use the assist crane to relieve the weight load
and withdraw the pin. Lower the arm down to the blocking
support for any continued disassembly procedures.
Boom Removal
NOTE: Boom removal may be simplified if the shell of the
operator's cabin is taken off the turntable deck first.
Refer to the Operator's Cabin Removal procedure
before continuing, if both components are to be
removed from the excavator.
After the bucket, arm and arm cylinder have been removed,
lower the end of the boom to a stable, secure blocking support.
Attach the assist crane sling to the body of either boom cylinder,
break the mounting pin connection to the boom by tapping
through the pin from the same side of the boom and repeat for
the opposite cylinder.
Release hydraulic pressure and disconnect line couplings as
previously outlined in the Arm Removal Procedure, observing
the same precautions.
Disconnect wiring for work light assemblies and any other
accessory lines or connections. Locate the sling of the assist crane
near the center of gravity, optimum lift point for the boom, and use
the crane to take pressure off the boom foot pin. Drive out the pin
after disassembling retainers and carefully lift away the boom.
WARNING
If either the front attachment or counterweight has been
removed, stability of the excavator will be affected. Never
travel with the excavator, swing the turntable or drive over
uneven or sloping terrain if one of these components have
been removed. Tipping or a rollover could result in death or
serious injury.
To maintain stability, the counterweight must be removed

whenever the front attachment is taken off the machine.

7-1-6
INSTALLATION
Arm Installation
Reattach the base of the arm cylinder to the mounting point on
top of the boom.
WARNING
Before assembling the front attachment, make sure that
individual boom, arm and bucket sections are all
compatible for work intended. Refer to the General Safety
Pages, Lift Ratings, Working Range Diagrams and Weights
of Materials sections in the Operation & Maintenance
Manual. Consult your dealer or DOOSAN After Sales
Service for more information if you have any questions.
Begin with the arm securely supported on blocking in front of the

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

7-1-7
7-1-8
1Bucket
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Bucket
7-2-1
Table of Contents
Bucket
Bucket Tooth Inspection and Replacement ....7-2-3
Bucket O-ring Replacement............................7-2-4
Bucket Replacement and Reversal ................7-2-5
Replacement ............................................................. 7-2-6
Reversal .................................................................... 7-2-7
Bucket DX480LCA-K/DX520LCA-K
7-2-2
BUCKET TOOTH INSPECTION
AND REPLACEMENT
There are several different types of attachment methods for
replaceable bucket tooth. Some of the most common types are
shown in the following drawings.
Bucket tooth are usually replaced in sets but it may sometimes
be necessary to replace individual teeth.
Look for the following indications of wear or damage:
• Lock pins protrude unevenly on one side.
• Lock pins have been worn down so far that they no longer
make full contact through the length of the pinhole.
• Lock washers or pins show obvious damage or weakness.
• Wear points on the working surfaces of tooth points - pits,
cracks, chips or craters - are larger than 8 mm to 10 mm
(1/3" to 1/2") across.
FG004607
Figure 1
HDO5057I-1
Figure 2
1. On a routine basis, inspect the bucket tooth to make sure

that tooth wear or breakage has not developed. Do not
allow the replaceable bucket tooth to wear down to the
point that bucket adapter is exposed. See Figure 1.
2. To replace a tooth (1, Figure 3), use a hammer and punch
to drive the locking pin (2) and lock washer (3) out of the
tooth adapter (4).
3. Once the worn tooth has been removed, use a putty knife 4
to scrape the adapter as clean as possible.
3
4. Slide the new tooth into position and insert the lock
1
washer.
2
5. Insert the locking pin into the tooth and with a hammer, EX1401304
drive the pin in until lock washer seats in the locking Figure 3
groove.
7-2-3
BUCKET O-RING
REPLACEMENT
WARNING
Due to possibility of flying metal objects, always wear
safety helmet, protective gloves and eye protection when
changing pins.
1. Inspect bucket O-rings on a routine basis. If worn or

damaged, replacement is necessary.
2. Roll old O-ring (1, Figure 4) onto boss (2) around bucket
pin (3). Remove bucket pin and move arm or bucket link
(4) out of way. 1
2 4
DS1703949
Figure 4
3. Remove old O-ring and temporarily install new O-ring (1,

Figure 5) onto bucket boss (2). Make sure that O-ring
groove on both bucket link (4) and boss have been
cleaned.
4. Realign arm or link with bucket pinhole and insert bucket
pin (3, Figure 4).
1
2 3 4
DS1703950
Figure 5
5. Roll new O-ring (1, Figure 6) into O-ring groove.
DS1703951
Figure 6
7-2-4
BUCKET REPLACEMENT AND
REVERSAL
WARNING
When pins are knocked in with a hammer, pieces of metal
can fly and cause serious injury.
When performing this operation, always wear goggles, hard
hat, gloves, and other protective equipment.
When the bucket is removed, place it in a stable condition.
If pins are hit with a strong force, there is a hazard that pin
can fly out and injure people in the surrounding area. Make
sure there is no one in the surrounding area before starting
the operation.
When removing the pins, do not stand behind the bucket. In
addition, be careful not to put your foot under the bucket
while standing at the side for the work.
When removing or inserting pins, be careful not to get your
fingers caught.
Never insert your fingers into the pinholes when aligning
the holes.
Stop the machine on a firm and flat surface and do the work.
When performing joint work, appoint a leader and follow that
person's instructions and signals.
7-2-5
Replacement
5
1. Place the bucket in contact with a flat surface.
A
6
IMPORTANT
When removing the pins, place the bucket so it is in
light contact with the ground.
B
If the bucket is lowered strongly to the ground, the FG018431
resistance will be increased and it will be difficult to
remove pins. Figure 7
After removing the pins, make sure that mud or sand

does not get on them. Dust seals are installed at both
ends of the bushings, be careful not to damage them.
2. Remove double nut on the stopper bolt for arm pin (A) and
2
link pin (B), remove bolt, pull out arm pin (A) and link pin
(B), and then remove bucket. 1
3. Align the arm (5) with holes (1) of the replacement bucket
and the link (6) with holes (2), then insert grease-coated
pins (A) and (B) into hole (1) and hole (2) respectively.
EX1401305
Figure 8
4. When installing the bucket, for arm pin portion (A), install
O-ring (3) to bucket (4) in the position shown in the
diagram on the right. After inserting the pin, install it in the
standard groove.
5. Install the stopper bolts and nuts for each pins.
6. Lubricate with grease thoroughly until grease comes out
from the end face.
IMPORTANT
4 3 5 3
FG018592
When replacing the bucket, replace the dust seal if it
Figure 9
has been damaged. If a damaged seal is used without
being replaced, sand and dirt can enter the pin portion
and cause abnormal wear of the pin.
7-2-6
Reversal
5
1. Place the bucket in contact with a flat surface.
A
6
IMPORTANT
When removing the pins, place the bucket so it is in
light contact with the ground. If the bucket is lowered
B
strongly to the ground, the resistance will be
increased and it will be difficult to remove pins. FG018431
After removing the pins, make sure that mud or sand Figure 10
does not get on them.
Dust seals are installed at both ends of the bushings,
be careful not to damage them.
2. Remove double nut on the stopper bolt for arm pin (A) and
link pin (B), remove bolt, pull out arm pin (A) and link pin
(B), and then remove bucket.
2
1
FG018433
Figure 11
3. After removing the bucket, reverse it.

4. Align arm (5) with replacement bucket hole (1), then align
link (6) with hole (2), then insert greased-coated pins (A)
and (B) into hole (1) and hole (2) respectively.
IMPORTANT 2
1
When reversing, do not install an O-ring. Keep the

O-ring in a safe place until using it next. FG018434
Figure 12
5. Install the stopper bolts and nuts for each pin.
6. Lubricate with grease thoroughly until grease comes out
from the end face.
IMPORTANT
When replacing the bucket, replace the dust seal if it
has been damaged. If a damaged seal is used without
being replaced, sand and dirt can enter the pin portion
and cause abnormal wear of the pin.
7-2-7
7-2-8
1Hydraulic System
1Main Pump
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Main Pump

8-1-1
Table of Contents
Main Pump
General ...........................................................8-1-3
Specifications ............................................................ 8-1-3
Overview ................................................................... 8-1-6
Hydraulic Circuit ........................................................ 8-1-7
Parts List ................................................................... 8-1-8
Theory of Operation ................................................ 8-1-12
Section View .................................................8-1-25
Removal........................................................8-1-26
Installation.....................................................8-1-36
Completing Work ..........................................8-1-36
Disassembly and Reassembly......................8-1-37
General Repair Guidelines ...................................... 8-1-37
Seal Kits and Subassemblies .................................. 8-1-39
Sealing the Driveshaft ............................................. 8-1-43
Gear Pump Sealing ................................................. 8-1-45
Removing Control Housing...................................... 8-1-46
Control Module ........................................................ 8-1-49
Removing the Controller.......................................... 8-1-51
Valve Plate with Valves ........................................... 8-1-53
Remove Rotary Groups........................................... 8-1-54
Remove Intermediate Wheel ................................... 8-1-57
Remove Auxiliary Drive ........................................... 8-1-59
Inspection ................................................................ 8-1-62
Assembling the Rotary Group ................................. 8-1-67
Pump Assembly ...................................................... 8-1-69
Hydraulic Component - Measurement "D"............... 8-1-72
Installation of Control Housing ................................ 8-1-75
Assembly of Intermediate Wheel............................. 8-1-78
Installation of Gear Pump ........................................ 8-1-79
Installation of Cover/Auxiliary Drive......................... 8-1-80
Troubleshooting ............................................8-1-81
How to Proceed for Troubleshooting ....................... 8-1-81
Malfunction Table .................................................... 8-1-82
Main Pump DX480LCA-K/DX520LCA-K

8-1-2
GENERAL
Specifications
Quantity 2
Displacement 186 x 2 cc/rev
Rated Flow Rate 2 x 342 L/min @ 1,900 rpm & 50 bar
Max. Flow Rate 2 x 387 L/min @ 2,150 rpm & 50 bar (Travel)
Weight 195 kg (430 lb)

8-1-3
Performance Curves
1. P - Q Curve
147 k 157 k
310 L 336 L
35 0
30 0 9k I=
340 L 20
I= 0m
26 A
137 k I= 0 m 232 k
25 0 311 L 31 A 208 L 242 k
0m 226 L
A
14 k
Q Flow (L/min)
20 0 235 L
221 k 350 k
15 0 209 L 147 L
350 k
129 L
10 0 350 k
123 L
50
31 k
48 L
0 50 10 0 15 0 20 0 25 0 30 0 35 0
P Discharge Pressure (kg/cm 2)
0 10 20 30
Pilot Pressure (kg/cm 2)
Figure 1 DS1800113
Input Input Current

Mode Remarks
(rpm) (mA)
Power 1,900 200
Standard 1,750 260 Variable
Economy 1,600 310

8-1-4
2. P - I Curve
Reduced Pressure VS Current Characteristic

Reduced Pressure Port 2 to Port 1
(24 V Coil), 150 Hz PWM
464 (32.0)
Pressure psi (bar)
5% Max
Hysteresis
174 (12.0)
0 0.35 0.60
Current Ampere
EX1300985
Figure 2

8-1-5
Overview
This pump is a pressure control type which has an axial piston
variable double pump structure equipped with two axial piston
rotary groups in a joint shaft design for hydraulic drive. It
consists of the EPPR valve to control the pump's pressure,
regulator to control the swivel angle of the pump, pilot sensor to
convert the pump displacement flow into an electric signal, gear
pump for pilot pressure, PTO for an optional pump, and pump
cover to be engaged with the engine to fix the pump.
Port
R4
X1
A1
M
S
M1
X1
A3
R3 M3 M2 A2 R2
EX1401340
Figure 3
Port Description Size

S Suction Port 5"
A1 Piston Pump Delivery Port SAE 1 1/4", D31.8
A2 Piston Pump Delivery Port SAE 1 1/4", D31.8
A3 Gear Pump Delivery Port (39 bar (40 kg/cm2)) M18 x 1.5
X1 Control Pressure Ports for Negative Control (ps1 and ps2) M14 x 1.5
M Measurement Port M12 x 1.5
M1 Measurement Port A1 UNF 9/16"-16-2B
M2 Measurement Port A2 UNF 9/16"-16-2B
M3 Measurement Port for Power Override M14 x 1.5
R1 Air Bleed Port M22 x 1.5
R2 Drain port M22 x 1.5
R3 Air Bleed Port M22 x 1.5
R4 Flushing port UNF 3/4"-16-2B

8-1-6
Hydraulic Circuit
A3
EPPR Valve
R3 R1
X1
A2
M2
M1
A1
M3
X1
R4 R2
DS1602351
Figure 4

8-1-7
Parts List
The exploded view of the pump shows the parts necessary for
internal repair and assembling and the parts available when
required.
Rotary Group
25
7 27 8
25
3
24
9 2
28 5
23
4A
22
21
20
2Ac
2Ad 2Ac2
2Ae 2Ac1
2 2Af 2Ab
2B
2D
2Aa
2G
2Ag
2C 2A
2H
2E
2F
3Ac
3Ad 3Ac2
3Ae 3Ac1
3
3B 3Af 3Ab
3D
3G 3Aa
3C 3Ag
3H 3A
3E
3F
Figure 5 EX1401125

8-1-8
Reference Reference
Number Number
2 Rotary Group 2H Bearing; Tapered-roller
20 Ring; Retaining 3 Rotary Group
21 Seal; Oil 3A Rotary Group; Section
22 Shim 3Aa Cylinder
23 Screw; Locking 3Ab Pin; Center
24 Screw; Locking 3Ac Piston & Piston Rings
25 Bearing; Plain Roller 3Ac1 Piston
27 Shaft; Key 3Ac2 Ring; Steel Sealing
28 O-ring 3Ad Collar; Spring
2A Rotary Group; Section 3Ae Cup Spring
2Aa Cylinder 3Af Plate; Retaining
2Ab Pin; Center 3Ag Screw; Pan Head
2Ac Piston & Piston Rings 3B Shaft; Drive
2Ac1 Piston 3C Shim
2Ac2 Ring; Steel Sealing 3D Control Lens; Left-hand
2Ad Collar; Spring 3E Plate; Back-up
2Ae Cup Spring 3F Ring; Retaining
2Af Plate; Retaining 3G Bearing; Unit Tapered-roller
2Ag Screw; Pan Head 3H Bearing; Tapered-roller
2B Shaft; Drive 4 Pump; Gear
2C Shim 4A Bolt; Socket M10 x 20
2D Control Lens; Right-hand 5 Housing; Pump
2E Plate; Back-up 7 Gear
2F Ring; Retaining 8 Shaft; Stub
2G Bearing; Unit Tapered-roller 9 Stud; Connect

8-1-9
Control Part
2Al
2Ai
2Ah
2Ao 2Ap
2Ag 2Af
2Af
2Aq
2Au
2A
2
2At
2As
2An 2Ad
2Aa
2Ac 2Ar
2A
2Ab
2Ae 2C 2S
2Am
2E
2D
2U
2B
2F 2R
2P
2G
2I
2H
10 2
2O 2J
11
2N
43
44
42
15
1
14
K 13
1B 1C 1E
12
17
1A
1G 16
37
1F 1D
26
K
EX1401126
Figure 6

8-1-10
Reference Reference
Number Number
1 Cover 2B Housing; Control
1A Cover 2C Piston; Control
1B O-ring 2D Bush; Spring
1C O-ring 2E Spring; Pressure
1D Screw; Socket-head 2F Pin; Threaded
1E Screw 2G Collar; Spring
1F Pin; Threaded 2H Collar; Spring
1G Nut; Lock 2I Spring, Pressure
2 Module Assy, Control 2J Spring, Pressure
2A Module, Control 2N O-ring
2Aa Housing; Control 2O O-ring
2Ab Piston, Control 2P Screw; Locking
2Ac Bushing; Control 2R Nut; Seal Lock
2Ad Piston; Positioning 2S Screw; Socket-head
2Ae Pin 2U Screw
2Af Collar; Spring 10 Housing; Control
2Ag Spring; Pressure 11 Gasket
2Ah Screw; Locking 12 Piston; Positioning
2Ai Pin; Threaded 13 Trunnion; Positioning
2Al Nut; Seal Lock 14 Collar; Spring
2Am O-ring 15 Spring; Pressure
2An O-ring 16 Piston
2Ao O-ring 17 Pin; Threaded
2Ap Screw; Socket-head 26 Screw; Hex
2Aq Pin; Double Break-off 37 Ring; Square
2Ar Pin; Cylinder 42 Screw; Socket M16 x 60
2As Pin; Double Break-off 43 Bolt; Socket M16 x 90
2At Plug 44 Pin; Cylinder
2Au Screw; Locking

8-1-11
Theory of Operation
The axial piston variable double pump with two axial tapered
piston rotary groups with bent-axis design for open-circuit
hydrostatic drives. The axial piston variable double pump has a
common suction port (S) for both circuits and the auxiliary pump.
It generates two flows for supplying two separate circuits. 
Flow is proportional to drive speed and displacement. 
By adjusting the bent-axis rotary groups, the two flows can be
steplessly changed independent of one another. For axial piston
units with bent-axis design, the pistons (3) are arranged at an
angle to the driveshaft (1). When the driveshaft is turned, the
cylinder (4) is picked-up and set into motion cardan free by the
pistons, which are arranged in a ring on and flexibly connected
to the driveshaft flange. The cylinder then rotates over the
spherical control lens (5), in which two kidney-shaped control
slots have been incorporated. As they turn, each of the pistons
moves from top to bottom dead center and back, executing a
stroke that depends on the swivel angle. The driveshaft flange of
both rotary groups, which lie parallel next to one another, are
interlocked. The rotary group with the long driveshaft drives the
second rotary group by way of the interlocked drive-shaft flange.
On the low-pressure side, fluid flows into the enlarging piston
chamber. At the same time, on the pressure side the fluid is
pushed out of the cylinder chamber into the hydraulic system by
the pistons. The pistons are braced against the driveshaft flange
by the load of the hydraulic pressure.

8-1-12
Ad1
6
2 A3 X1 Relief Valve (40 bar)
M3
Power Shift
Pressure
Pilot Ad2
Pump
Servo Piston (7)
8 EPPR Valve
3
4
5
M2
Ad3
A1
P2
S
P1
P3
A2
Option
EX1401127
Figure 7
Reference Reference
Number Number
1 Drive Shaft 7 Positioning Piston
2 Gear Pump (Pilot) 8 Positioning Turnnion
3 Piston S Suction Port
4 Cylinder A1, A2 High-pressure Delivery Port
5 Control Lens A3 Pilot Port
6 EPPR Valve

8-1-13
Engine torque is transferred to the shaft and the seven plungers,
causes the cylinder block to rotate while sliding along the valve
plate surface.
The plunger oscillates in the cylinder block bores and alternately
hydraulic oil is drawn and delivered.
Piston
Control Lens
Driveshaft
Cylinder
EX1400245
Figure 8
Increasing and Decreasing Flow Rate

Changing inclination of cylinder (4, Figure 7) causes the piston (3,
Figure 7) stroke to increase or decrease depending on the slant
angle in order to control the main pump flow rate. 
Up-down movement of positioning piston (7, Figure 7) changes
inclination of cylinder (4, Figure 7). 
Positioning piston (7, Figure 7) is interlocked with control lens (5,
Figure 7) positioning pin (8, Figure 7). 
The one end of cylinder (4, Figure 7) is kept in contact with the
surface of control lens (5, Figure 7) and slides along it.
Maximum Displacement Angle: Minimum Displacement Angle (Operable Limit Angle):
Piston Swash Plate Cylinder Block Piston Swash Plate
Cylinder Block EX1400646

Figure 9

8-1-14
Pressure Control
As the magnetic pump discharge pressure A1 and the relative
pump pressure A2 rise, the pump's swivel angle (discharge flow
rate) is automatically decreased to limit the input torque under a
certain level. (While the RPM is constant, the input power (HP)
is constant as well.)
As the system is operated with the combined load pressure of
double pumps in parallel, the regulator for each pump is
controlled with the same swivel angle (discharge flow rate)
during power control.
This mechanism prevents overload of the motor regardless of
load application on two pumps.
• Pump Input Pressure (PS) = (P x Q)/450
P: External System or Load Pressure, (P1 + P2)/2
Q: Pump Discharge Flow Rate

8-1-15
Decrease of Pump Pressure
1. Decrease input pressure signal to EPPRV.
2. Regulator spool moves upward and connect the pump
pressure to head side of control piston.
3. Control piston moves right and decrease swash plate.
4. Decreasing flow rate decreases pump pressure.
A3
R3 R1
X1
A2
M2
M1
A1
M3
X1
R4 R2
Pilot
Pump High System
Pressure
Minimum Flow Position

DS1602352
Figure 10

8-1-16
Increase of Pump Pressure
1. Increase input pressure signal to EPPRV.
2. Regulator spool moves downward and connect head side
of control piston to drain.
3. Control piston moves left and increase swash plate.
4. Increasing flow rate increases pump pressure.
A3
R3 R1
X1
A2
M2
M1
A1
M3
X1
R4 R2
Pilot
Pump Low System
Pressure
Maximum Flow Position

DS1602353
Figure 11

8-1-17
Flow Control
As shown in the figure below, the pump's discharge flow rate is
arbitrarily controlled according to change in the pilot pressure.
The servo valve is a negative flow control type to decrease the
main pump's discharge flow rate according to increase of the
pilot pressure.
Therefore, fuel consumption can be decreased during operation
by discharging only the required amount of oil with pilot
pressure.

8-1-18
Decrease Oil Flow
When receiving high negacon pressure through the port ps1 or
ps2 from the control valve by the operating signal (neutral
position), pressure in the large-diameter chamber is increased.
Even though pressure is always built in the small-diameter
chamber, their volumetric difference pushes the servo piston,
decreasing the angle of the swash plate and reducing the
discharge flow rate of the pump. As the pump's discharge flow
rate is minimized, power loss and heat by excessive oil flow from
cut-out valve are prevented.
A3
High Negacon
Pressure
R3 R1
X1
A2
M2
M1
A1
M3
X1
R4 R2
High Negacon
Pressure
Pilot
Pump
Minimum Flow Position

DS1602354
Figure 12

8-1-19
Increase Oil Flow
When receiving low negacon pressure through the port ps1/ps2
by operation of each spool of the control valve through the pilot
line, oil flows to the large-diameter chamber, control piston and
drain port, so pressure in the large-diameter chamber is
decreased. As the small-diameter chamber is always applied
with discharge pressure, the swivel angle is increased to push
the servo piston. Then, the angle of the swash plate is increased
to maximize the pump's discharge flow rate, making an efficient
operating condition.
A3
Low Negacon
Pressure
R3 R1
X1
A2
M2
M1
A1
M3
X1
R4 R2
Low Negacon
Pressure
Pilot
Pump
Maximum Flow Position

DS1602355
Figure 13

8-1-20
Power Shift
The power shift function controls the setting power of the pump
by changing current of the EPPR (Electronic Proportional
Pressure Reducing) valve which is attached to the pump.
The power shift EPPR valve sends its secondary pressure to the
power control section of each pump regulator through the
internal passage of the pump to change power to the same
level. With this mechanism, power of the pump can be arbitrarily
adjusted in order to obtain optimum level of power suitable for
various operating conditions.
A3
ps2
R3 R1
X1
A2
M2
M1
A1
M3
ps1
X1
R4 R2 DS1602356
Figure 14

8-1-21
Power Shift (STD Mode/Economy Mode: 3.5 ~ 5.5 bar)
A3
290 - 330 mA
R3 R1
X1
A2
M2
S
M1
A1
M3
X1
R4 R2
DS1601680
Figure 15
Power shift pressure helps moving power control spool easily

with low system pressure.
290 - 330 mA
Check
Point
Pilot
Pump
DS1601681
Figure 16

8-1-22
Power Shift (Power Mode: 1.7 bar)
A3
250 mA
R3 R1
X1
A2
M2
S
M1
A1
M3
X1
R4 R2
250 mA
Pilot
Pump
DS1601682
Figure 17
To control flow, it needs more system pressure then standard mode pressure.

8-1-23
Adjusting and Measuring Point
Ad1 9k 157 k
340 L Ad3 336 L
X1 (Pilot Nagative 350

A3 Pressure)
M3 300
Power Shift 242 k

Pressure 250 226 L
Ad2
Pilot
Q Flow (L/min)
Ad2
Pump 200
14 k
150 235 L Ad1
100 350 k
147 L
Servo Piston 50
31 k
48 L
0 50 100 150 200 250 300 350
P Dischage Pressure (kg/cm ) 2
M2
Ad3
0 10 20 30 40
X1 Pilot Pressure (kg/cm 2)
Figure 18 DS1704265
• 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
– M2: Servo piston large chamber pressure check point
– M3: Power shift pressure check point (EPPR Valve 2nd pressure)

8-1-24
SECTION VIEW
Ad1
6
2 A3 X1 Relief Valve (40 bar)
M3
Power Shift
Pressure
Pilot Ad2
Pump
Servo Piston (7)
8 EPPR Valve
3
4
5
M2
Ad3
A1
P2
S
P1
P3
A2
Option
EX1401127
Figure 19
Reference Reference
Number Number
1 Drive Shaft 5 Control Lens
2 Gear Pump (Pilot) 6 EPPR Valve
3 Piston 7 Positioning Piston
4 Cylinder 8 Positioning Turnnion

8-1-25
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

flat ground as shown in (Figure 20) before lowering the all
the attachments on the ground and then stop engine.
EX1301633
Figure 20

8-1-26
(Figure 21) I
WARNING OFF
Lock
OFF
ON
ON

switch.
ON
OFF
ON
DS1704238
Figure 22

3
5 8
1 2
7 6
4
EX1401809
Figure 23

8-1-27
WARNING
any work.

Figure 24 DS1601105
draining the oil.
Figure 25 EX1400737

1
filter cover (2) and return filter cover (3). Then drain
hydraulic oil with an oil pump. 3
• Tool: 17 mm ( )
DS1704244
Figure 26
B. Remove bolts (1, Figure 27) (6 ea). Then remove the

under cover (2) at the bottom of main frame.
• Tool: 19 mm ( ) 1 2
DS1704239
Figure 27

8-1-28
Drain hydraulic oil using drain plug.
FRONT
• Tool: 27 mm ( )
DS1704245
with a filter cap.
Item Part Number

DS1601106
Figure 29
Reference
Description
Number
3
1 Suction Filter
2 Nut
A
3 Rod
2
When installing
• Length (A): 606.5 mm 1
Figure 30
11. Remove bolt (3, Figure 31) (11 ea) and remove under
1
cover (1 and 2, Figure 31) under pump side.
• Tool: 19 mm ( ) 2

• Cover weight
Reference Weight
Number kg lb
1 6 13.2 3
2 7 15.4 DS1704246
Figure 31

8-1-29
12. Remove bolt (Figure 32) (6 ea) and remove engine cover
of muffler side.
• Tool: 19 mm ( )
• Weight: approximately 20 kg (44 lb)
DS1704240
Figure 32
13. Open right side door.

Remove bolts and washers (1, Figure 33) (8 ea) with cover (2).
• Tool: 19 mm ( )
Muffler Assy
Right Side Door
1 2
DS1704247
Figure 33
14. Attach a lifting device around muffler assembly. 

And tie the rope to lift muffler assembly.
Remove bolts and washers (1, Figure 34) (5 ea).
• Tool: 10 mm ( )
DS1704248
Figure 34

8-1-30
15. Remove bolts (1, Figure 35) (2 ea) with clamp (2). Then
remove bolts (3) (4 ea) on both sides of muffler. Then 2
remove the muffler from the engine.
• Tool: 19 mm ( ) 1
• Muffler assembly weight: 74 kg (163 lb) Muffler Assy
3
DS1704249
Figure 35
16. Remove bolts (1, Figure 36) (23 ea) of baffles and covers
around pump. Then remove the baffles and covers.
1
• Tool: 19 mm ( )
3
• Cover weight
Reference Weight
Number kg lb 5
2 4 8.8
3, 4 2 4.4
4
5 3 6.6
DS1704251
Figure 36

8-1-31
17. Disconnect the connector of main harness from main
pump. B
into electrical system, this will cause an
electrical short circuit and result in improper
machine operation.
DS1704252
Figure 37
DS1704253
Figure 38
How to disconnect the harness connector.

A. EPPR valve
2
Figure 39 EX1401509
B. Pressure sensor
DS1600646
Figure 40

8-1-32
environment.
EX1504170
Figure 41
19. Remove bolts (Figure 42) (4 ea) and remove suction pipe
of pump. Drain the hydraulic oil of suction pipe to bowl.
• Tool: 14 mm ( )
DS1704254
Figure 42

8-1-33
20. Remove hoses and adapters from the main pump.
Discharge Block
NOTE: Attach identification tags on the removed hoses R4
for reassembly. Disconnect the hoses in order
from bottom to top of oil tank. After the hoses
are disconnected, plug and cap them to prevent X1 A1
dirt or dust from entering.
S
X1
A3 A2
Discharge Block
DS1704255
Figure 43

Port Name
R4 to Oil Tank (Flushing Port) PF 1/2" 27 93.1 9.5 68.7
A3 to Pilot Filter "IN" PF 1/2" 27 93.1 9.5 68.7
X1 from Control Valve "ps2"
PF 1/4" 19 39.2 4.0 28.9
(Upper) (Control Pressure Port)
X1 from Control Valve "ps1"
PF 1/4" 19 39.2 4.0 28.9
(Lower) (Control Pressure Port)
to Control Valve "P2" SAE 1", D25.4 8 63.7 6.5 47.0
A1
Dummy SAE 1", D25.4 10 107.9 11.0 79.6
to Control Valve "P1" SAE 1", D25.4 10 107.9 11.0 79.6
A2
Dummy SAE 1 1/4", D31.8 10 107.9 11.0 79.6
• Fitting
Size Torque
Port Name
R4 UNF 3/4"-16 PF 1/2" 24 70.0 7.1 51.0
A3 Adapter M18 x 1.5 PF 1/2" 27 70.0 7.1 51.0
X1 M14 x 1.5 PF 1/4" 19 45.0 4.6 33.0
2180-1026D35
S
(ID:136.12, W:3.53, Class1)
2180-1026D13
R4
(ID:16.36, W:2.21, 1B)
O-ring DS2856004 DS2856003
A1
(1 1/4", ID:38, OD:45, 1B) (1", ID:33.2, OD:40.2, 1B)
DS2856003
DS2856004 (1", ID:33.2, OD:40.2, 1B),
A2
(1 1/4", ID:38, OD:45, 1B) DS2856004
(1 1/4", ID:38, OD:45, 1B)

8-1-34
21. Remove bolts (10 ea) of pump without top bolts (2 ea).
• Tool: 17 mm ( )
DS1704256
Figure 44
22. Attach a lifting device around pump. Raise the lifting device
until the pump is supported prior to removing remaining
bolts (2 ea).
• Weight:
– Main pump: about 180 kg (397 Ib)
– Discharge block: about 12 kg (26.5 Ib) (2 ea)
DS1704258
Figure 45
23. Remove remaining bolts (2 ea).
• Tool: 17 mm ( )
CAUTION
AVOID INJURY
Support the pump prior to removing remaining bolts to
prevent pump from falling. DS1704257
Figure 46
24. Lift the pump from engine slowly and carefully.
EX1400969
Figure 47

8-1-35
INSTALLATION
WARNING
SERIOUS INJURY
1. Perform installation in the reverse order to removal.

2. When installing the pump to engine, be careful assembling
pump shaft and drive coupling. Refer to drive coupling
installation.
COMPLETING WORK
NOTE: If pump is run without sufficient oil in the main
hydraulic pump, damage can occur. Always vent
pump of air after draining hydraulic system.
1. With the engine stopped, remove vent plug (Figure 48) to
see if any oil is present.
2. If oil is not present, fill oil tank with oil.
3. Install vent plug (Figure 48) first.
4. Slowly loosen vent plug (Figure 48) several turns, until
hydraulic oil flows out of plug. This shows that air has been EX1401260
released.
Figure 48
5. Tighten the plug (Figure 48).

8-1-36
DISASSEMBLY AND REASSEMBLY
General Repair Guidelines

NOTE: Observe the following cautions when performing
repairs on hydraulic units.
WARNING
Observe the following notices and instructions when
carrying out repairs on hydraulic units.
ASS1140L
Figure 49
1. Close off all openings of hydraulic unit.
ASS0030L
Figure 50
2. Replace all seals.

Use only original spare parts
ASS0040L
Figure 51

8-1-37
3. Check all sealing and sliding surfaces for wear.
IMPORTANT
Using abrasive materials on sliding surfaces can
damage the surface.
ASS0050L
Figure 52
4. Fill hydraulic unit with hydraulic oil before putting into

operation.
ASS0060L
Figure 53

8-1-38
Seal Kits and Subassemblies
1. Seal kit for driveshaft.
ASS0070L
Figure 54
2. Peripheral seal kit.
ASS0080L
Figure 55
3. Rotary group 1, ready to install.
ASS0090L
Figure 56
4. Rotary group 2, ready to install.
ASS0100L
Figure 57

8-1-39
5. Rotary group, hydraulic component (order rotary groups 1
and 2 separately).
IMPORTANT
Adjustment is necessary. 
Pay attention to direction of rotation.
ASS0110L
Figure 58
6. Rotary group 1, mechanical section, ready to install.
ASS0120L
Figure 59
7. Rotary group 2, mechanical section, ready to install.
ASS0130L
Figure 60

8-1-40
8. Control, pre-adjusted.
ASS0140L
Figure 61
9. Gear pump, complete.
ASS0150L
Figure 62
10. Intermediate gear.
ASS0160L
Figure 63

8-1-41
11. Auxiliary drive.
ASS0170L
Figure 64
12. Valve plate with valves.
EX1401142
Figure 65
13. Pipe, complete with fittings.
EX1401143
Figure 66

8-1-42
Sealing the Driveshaft
ASS0200L
Figure 67
1. Protect driveshaft. (e.g. with tape).
ASS0210L
Figure 68
2. Remove retaining ring and shim.
ASS0220L
Figure 69

8-1-43
3. Screw sheet metal screw(s) into holes fitted with rubber.
Pull out seal with pliers.
ASS0230L
Figure 70
4. Press in shaft seal ring and shim with bushing to stop.
IMPORTANT
Take note of press-in depth. Install mark for press-in
depth of safety ring.
ASS0240L
Figure 71

8-1-44
Gear Pump Sealing
Figure 72 ASS0250L
Remove gear pump.

Visually check
1. O-ring (1, Figure 73).
1 ASS0260L
Figure 73
2. Sealing surface of housing (2, Figure 74).
ASS0270L
Figure 74

8-1-45
Removing Control Housing
Figure 75 EX1402519
1. Place pump into a disassembly / assembly device with a

crane and secure it into position.
Figure 76 ASS0290L

8-1-46
2. Remove screws holding port plate.
3. Using a suitable lifting device, remove port plate.
IMPORTANT
Mark installation position. Be careful, control lenses
can fall out.
Figure 77 ASS0300L
4. Remove paper seal, and clean sealing surface.
ASS0310L
Figure 78

8-1-47
2
2
1
1 ASS0320L
Figure 79
Reference
Description
Number
1 Setting Screw: Qmax
2 Setting Screw: Hydraulic Stroke Limitation
3 Setting Screw: Power Characteristic (Begin of Regulation)
NOTE: Before performing setting or disassembly of

regulator, measure distance "X" of adjustment screw
and record value.
X
ASS0330L
Figure 80

8-1-48
Control Module
Control Module LR
ASS0340L
Figure 81
Remove and disassemble control module LR.

* *
ASS0350L
Figure 82

8-1-49
Control Module H
ASS0360L
Figure 83
Remove and disassemble control module H.
ASS0370L
Figure 84

8-1-50
Removing the Controller
(1)
ASS0380L
Figure 85
1. Remove cover.
NOTE: Do not change the setting of adjustment screw
(1, Figure 85).
ASS0390L
Figure 86

8-1-51
2. Remove screws.
NOTE: Install control lens - torque support.
ASS0400L
Figure 87
3. Remove locking screw and replace with a new one.

NOTE: Loosen adhesive with a "gentle" flame
(approximately 120°C).
ASS0410L
Figure 88
ASS0420L
Figure 89
4. Remove swivel pin.
ASS0430L
Figure 90

8-1-52
Valve Plate with Valves
Figure 91 EX1401144
1. Pressure relief valve.

2. Electro- proportional pressure reducing valve (EPPR).

8-1-53
Remove Rotary Groups
EX1401145
Figure 92
1. Keep cylinder with device (Remove it completely with

driveshaft).
ASS0460L
Figure 93
2. Remove cylinder (remove driveshaft without cylinder).
ASS0470L
Figure 94

8-1-54
3. Remove cup springs 1 and spring cup 2.
ASS0480L
Figure 95
4. Note disassembly position: (1, 2 and 3, Figure 96). I

3
2
Rotary Group 2
Rotary Group 1
ASS0490L
Figure 96
5. Press out rotary group with an appropriate device. I
2
1
ASS0500L
Figure 97

8-1-55
Fixing screws are glued
A Adjustment of measurement D
*
1. Holding device
Drive shaft 2
Drive shaft 1
1. Holding device
*
A
Adjustment of measurement D
Fixing screws are glued

ASS0510L
Figure 98
NOTE: 1) Position (*) driveshafts with bearing set

are the smallest assembly group.
2) The assembly group is adjusted to
measurement A.
3) The tapered roller bearings are adjusted to
the specified through-torque.
NOTE: 1) Fixing screw - Retaining device.
2) Removal of screws is only possible if
driveshaft is warmed up to a temperature
of approximately 120°C for 1/2 hour in an
oil bath or heat air furnace.
3) Remove screw quickly.

8-1-56
Remove Intermediate Wheel
1. Press bolt (*, Figure 99) into gear wheel. (Installed
pressing fit).
NOTE: Can only be disassembled with a hydraulic
press. *
ASS0520L
Figure 99
2. Install sleeve.
NOTE: Press out bolt with a hydraulic press.
ASS0530L
Figure 100

8-1-57
3. Remove gear wheel through side drive opening.
ASS0540L
Figure 101
4. Remove bearing with extraction device.
ASS0550L
Figure 102

8-1-58
Remove Auxiliary Drive
ASS0560L
Figure 103
1. Remove screws and auxiliary drive.
ASS0570L
Figure 104
2. Press off bearing cap.
ASS0580L
Figure 105

8-1-59
3. In the event of oil leakage, visually check O-ring, housing
and groove.
ASS0590L
Figure 106
4. Install extractor device.
ASS0600L
Figure 107
5. Pull out output pinion.
ASS0610L
Figure 108
6. Install bearing extractor device.
ASS0620L
Figure 109

8-1-60
7. Completely mount device and pull out bearing.
ASS0630L
Figure 110
8. Pull out pinion bearing.
ASS0640L
Figure 111

8-1-61
Inspection
1. Check to see that bearing bore is free of scores and there
is no evidence of wear.
ASS0650L
Figure 112
2. Visually check:
To ensure that bearing seats are free of scores.
ASS0660L
Figure 113
3. Visually check:
Check to see that bearing bores are free of scores and
there is no evidence of wear.
ASS0670L
Figure 114
4. Axial piston play:

Checked with retaining plate installed.
ASS0680L
Figure 115

8-1-62
5. Driveshafts:
Check to ensure that cups are free of scores and there is
no pitting (1, Figure 116).
Check to see there is no evidence of corrosion and wear
steps (2, Figure 116).
ASS0690L
Figure 116
6. Piston:
Check to ensure that they are free of scores and there is
no pitting.
ASS0700L
Figure 117
7. Central pin:
Check to ensure that it is free of scores and there is no
pitting.
ASS071L
Figure 118
8. Retaining plate:
Check to ensure that it is free of scores and there is no
evidence of wear.
ASS0720L
Figure 119

8-1-63
9. Check cylinder block / control lens.
Bores (1, Figure 120) are free of scores, no evidence of
wear.
Faces (2, Figure 120) are even, there are no cracks, no
scores.
Side guides (3, Figure 120) show no evidence of wear, free
of scores.
ASS0730L
Figure 120
10. Check:
Control land (1, Figure 121), internal control drilling (2,
Figure 121) and pin cups (3, Figure 121).
ASS0740L
Figure 121
11. Check:
That sliding surfaces (1, Figure 122) are free of scores.
Seal (2, Figure 122).
ASS0750L
Figure 122

8-1-64
12. Complete rotary group.
NOTE: Adjustment of the hydraulic component is
necessary.
Mechanical component: driveshaft is adjusted with the
bearing (1, Figure 123).
Hydraulic component (2, Figure 123): Adjustment is
necessary (*, Figure 123).
2
1
1
ASS0760L
Figure 123

8-1-65
13. Rotary group: All of the components.
* Adjustment (Figure 124).
For adjustment values and torque values, see service
information.
*
*
*
*
ASS0770L
Figure 124

8-1-66
Assembling the Rotary Group
1. Threads must be free of oil, grease, dust or any other
contaminants which can impair locking of screws.
ASS0780L
Figure 125
2. Assemble retaining plate with pistons and center pin in

position. Use screws that have a precoat coating.
NOTE: For tightening torques, see service information.
ASS0790L
Figure 126
3. Insert spring plate (1, Figure 127) and cup springs (2,
Figure 127) into their correct position (and orientation)
using grease to hold them into place.
ASS0800L
Figure 127
4. Ensure that all parts are assembled in correct order and

orientation.
ASS0810L
Figure 128

8-1-67
5. Insert pistons into cylinder. Using a soft surface as a
support to prevent sliding surfaces from being damaged.
Preassemble both rotary groups in this manor.
ASS0820L
Figure 129

8-1-68
Pump Assembly
1. Warm up housing to approximately 80°C.
ASS0830L
Figure 130
2. Insert pre assembled rotary group 2, being sure to align

gear tooth marks.
ASS0840L
Figure 131
3. Insert rotary group 1. Align the marked gear teeth.
ASS0850L
Figure 132
4. Gear tooth marks must align with each other.
ASS0860L
Figure 133

8-1-69
5. Adjustment of measurement D.
NOTE: Hydraulic control portion.
Stop
D
A
A
D
Stop
ASS0870L
Figure 134
NOTE: Driveshafts with bearing set.

The assembly group is adjusted to dimension
(A). The tapered roller bearings are adjusted to
the stipulated breakaway torque.

8-1-70
Assembly Guideline
Retaining force:
After rotary group has been installed into housing, it has to be
pressed in until end stop is reached. Allow housing to cool down
from its assembly temperature (approximately 80°C) to room
temperature.
Adjustment of the Hydraulic Component of the Rotary Group

The adjustment of dimension "D" is done using spring plates of
differing thickness, so correct clearance is achieved between the
rotary group which is installed in housing and center pin, and
spring plates.
NOTE: Dimension (D) = 0.4 ±0.1 mm.
After assembling complete unit, the breakaway torque of the
rotary group has to be checked with a torque wrench.

8-1-71
Hydraulic Component - Measurement "D"
Measuring Device - Hydraulic Component
EX1401146
Figure 135
Measuring Centering Intermediate Intermediate

Size Shim (5) S.H.C.S (6)
Device (*) Device (1) Ring (4) Plate (7)
1x 2x 2x 2x 2x
200 9452269 9452025 9452015 9083279 9083134 2775187

8-1-72
Mounting Position
NOTE: Be sure that correct mounting position is used. The
numbers on the top of the measuring device (*,
Figure 135) refer to the piston diameter.
ASS0900L
Figure 136
Size Mounting Position

200 28
ASS0890L
Figure 137
1. Install intermediate ring or plates onto the housing. 

(Figure 138)
ASS0920L
Figure 138
2. Zero adjustment - measuring device.

Turn using the hand wheel until stop is reached. Set dial
gauge to zero. (Figure 139)
Figure 139

8-1-73
Measuring Procedure
1. Turn down by 4 turns on the dial gauge. (Figure 140)
Check: 2 mm clearance, set dial gauge to "Zero."
NOTE: Clearance: Size 28 - 160 0.4 mm ±0.1.
ASS0960L
Figure 140
2. Turn down, using the hand wheel, until resistance is met.

Read the measured value. (Figure 141)
NOTE: Do not use excessive force.
Figure 141

8-1-74
Installation of Control Housing
ASS0990L
Figure 142
1. Install swivel pin into correct position and orientation. Take

hardening time and tightening torque into account.
NOTE: Tightening Torques (*):
M6 = 8.5 N.m (0.87 kg.m (6.27 ft lb))
M8 = 14 N.m (1.43 kg.m (10.33 ft lb))
M10 = 35 N.m (3.57 kg.m (25.81 ft lb))
M12 = 69 N.m (7.04 kg.m (50.89 ft lb))
* ASS1000L
Figure 143

8-1-75
2. Push on piston ring by hand. Install adjustment piston.
Take the tightening torques into account.
ASS1010L
Figure 144
3. Install control housing.
ASS1020L
Figure 145
4. Install control lens in their correct position using grease to

hold them in place. Direction of rotation Direction of rotation
counterclockwise clockwise
Pressure Pressure
side side
Suction side
ASS1030L
Figure 146

8-1-76
ASS1040L
Figure 147
5. Install seal and controller.
ASS1050L
Figure 148

8-1-77
Assembly of Intermediate Wheel
1. Press bearing (1, Figure 149) into housing.
2. Install and align intermediate wheel (2, Figure 149) through 1
side drive opening. New Assembly
Position 3
3. Cool down bolt (3, Figure 149) with nitrogen and install it.
4. Press in bearing (4, Figure 149).
2
ASS1060L
Figure 149
5. Press bearing into housing.
ASS1070L
Figure 150

8-1-78
Installation of Gear Pump
ASS1080L
Figure 151
1. Assemble shaft seal, disk and safety ring. Press-in with

assemble sleeve.
IMPORTANT
Take note of press-in depth.
ASS1090L
Figure 152

8-1-79
Installation of Cover/Auxiliary Drive
ASS1100L
Figure 153

8-1-80
TROUBLESHOOTING
The following table can assist you in troubleshooting. The table
makes no claim for completeness.
In practical use, problems which are not listed here may also occur.
How to Proceed for Troubleshooting

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

8-1-81
Malfunction Table
Fault Possible cause Remedy
Unusual noises Drive speed too high. Machine or system manufacturer.
Wrong direction of rotation. Ensure correct direction of rotation.
Insufficient suction conditions, e.g. air in Machine or system manufacturer (e.g.
the suction line, inadequate diameter of optimize inlet conditions, use suitable
the suction line, viscosity of the hydraulic hydraulic fluid).
fluid too high, suction height too high, Completely air bleed the axial piston unit,
suction pressure too low, contaminants in fill the suction line with hydraulic fluid.
the suction line.
Remove contaminants from the suction line.
Improper fixing of the axial piston unit. Check fixing of the axial piston unit
according to the specifications of the
machine or system manufacturer.
Observe tightening torques.
Improper fixing of the attachment parts, Fix attachment parts according to the
e.g. coupling and hydraulic lines. information provided by the coupling or
fitting manufacturer.
Malfunction of the pressure relief valve of Bleeding the axial piston unit.
the axial piston unit (pressure cut-off). Check viscosity of the hydraulic fluid.
Contact our service.
Mechanical damage to the axial piston unit Exchange axial piston unit, contact our
(e.g. bearing damage). service.
No or Faulty mechanical drive (e.g. defective Machine or system manufacturer.
insufficient flow coupling).
Drive speed too low. Machine or system manufacturer.
the suction line.
Hydraulic fluid not in optimum viscosity Use suitable hydraulic fluid (machine or
range. system manufacturer).
External control of the control device Check external control (machine or
defective. system manufacturer).
Insufficient pilot pressure or control Check pilot pressure or control pressure,
pressure. contact our service.
Malfunction of the control device or Contact our service.
controller of the axial piston unit.
Wear of axial piston unit. Exchange axial piston unit, contact our
service.

8-1-82
Fault Possible cause Remedy
No or Faulty mechanical drive (e.g. defective Machine or system manufacturer.
insufficient pressure coupling).
Drive power too low. Machine or system manufacturer.
the suction line.
Hydraulic fluid not in optimum viscosity Use suitable hydraulic fluid (machine or
range. system manufacturer).
External control of the control device Check external control (machine or
defective. system manufacturer).
Insufficient pilot pressure or control Check pilot pressure or control pressure,
pressure. contact our service.
Malfunction of the control device or Contact our service.
controller of the axial piston unit.
Wear of axial piston unit. Exchange axial piston unit, contact our
service.
Output unit defective (e.g. hydraulic motor Machine or system manufacturer.
or cylinder).
Pressure/ Axial piston unit and/or control unit not or Completely air bleed axial piston unit. 
flow fluctuations insufficiently air bled. The pressure reducing valve must be
exchanged. contact service.
the suction line.
Excessive Excessive inlet temperature at the axial Machine or system manufacturer:
hydraulic fluid and piston unit. Inspect system, e.g. malfunction of the
case temperature cooler, insufficient hydraulic fluid in the
reservoir.
Malfunction of the pressure control valves Contact Service.
(e.g. pressure cut-off, pressure controller).
Wear of axial piston unit. Exchange axial piston unit, contact
service.
Instability/vibrations Setpoint value not stable. Machine or system manufacturer.
Resonance in the reservoir line. Machine or system manufacturer.
Axial piston unit and/or control unit not Completely air bleed axial piston unit.
insufficiently air bled. The pressure reducing valve must be
exchanged. Contact service.
Malfunction of the control devices or Contact service.
controller.

8-1-83
8-1-84
1Main Control Valve
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Main Control Valve

8-2-1
Table of Contents
Main Control Valve

General Description ........................................8-2-4
When All Spools are in Neutral.................................. 8-2-4
Single Operation........................................................ 8-2-8
Combined Operation ............................................... 8-2-20
Anti Drift Valve......................................................... 8-2-23
Main Relief Valve .................................................... 8-2-23
Overload Relief Valve.............................................. 8-2-24
Low Pressure Relief Valve ...................................... 8-2-26
Parts List ................................................................. 8-2-27
Specifications .......................................................... 8-2-36
Troubleshooting, Testing and Adjustment ....8-2-37
General.................................................................... 8-2-37
Relief Valve ............................................................. 8-2-38
Hydraulic System .................................................... 8-2-38
Adjustment of Relief Valve ...................................... 8-2-39
Removal........................................................8-2-40
Installation.....................................................8-2-54
Completing Work ..........................................8-2-54
Disassembly .................................................8-2-55
General Instructions for Disassembly...................... 8-2-55
Disassembly of Main Spool (3) ~ (11) ..................... 8-2-55
Disassembly of Subspool (24)................................. 8-2-56
Disassembly of Subspool (20)................................. 8-2-57
Disassembly of Anti Drift Valve of Boom and Arm .. 8-2-57
Disassembly of Swing Load Check ......................... 8-2-58
Disassembly of Load Check .................................... 8-2-58
Disassembly of Other Check Valves ....................... 8-2-58
Disassembly of Flange ............................................ 8-2-59
Disassembly of Relief Valve .................................... 8-2-59
Disassembly of Other Flange .................................. 8-2-59
Disassembly of Main Relief Valve ........................... 8-2-60
Disassembly of Overload Relief Valve .................... 8-2-61
Disassembly of Low Pressure Relief Valve ............. 8-2-61
Main Control Valve DX480LCA-K/DX520LCA-K

8-2-2
Cleaning and Inspection 
(Wear Limits and Tolerances) ......................8-2-62
Cleaning .................................................................. 8-2-62
Inspection ................................................................ 8-2-62
Reassembly..................................................8-2-63
Subassembly........................................................... 8-2-63
Reassembly of Control Valve .................................. 8-2-65

8-2-3
GENERAL DESCRIPTION
When All Spools are in Neutral
Neutral Passage (Figure 1 and Figure 2)

1. Oil supplied to port (P1) flows through neutral passage (L1)
to low pressure relief valve throttle (Lc1), to tank passage
(Ta), and returns to ports (T1 and T3).
2. Oil supplied to port (P2) flows through neutral passage
(R1), to low pressure relief valve throttle (Rc1), to tank
passage (Ta), and returns to ports (T1 and T3).
3. The pressures of low pressure relief valve chambers (L2
and R2) reach through ports (Ps1 and Ps2) to pumps, and
control displacement of pumps (P1 and P2).
4. If too much oil flows into neutral passages, low pressure
relief valves are activated, and protect ports (Ps1 and Ps2)
from rising pressures.

8-2-4
Figure 1

8-2-5
Signal Passage (Figure 2)
1. Oil supplied to port (PP, Figure 2), after passing through
orifice (Lc3), is divided into two flows. One flow is sent to
port (PT), and the other flows through land (Lc4) and
passage (5) to land (Rc3) and into tank passage (Ta).
2. The same oil supplied from port (PP), after passing
through orifice (Lc5), flows partly to port (PA) and passes
partly through passages (L4), (8) and (R4), to boom spool
1 land (Rc4) and flows into tank passage (Ta).
3. The oil passing through orifice (Lc6) flows partly from land
(Lc7), to tank passage (Ta), and passes partly through
passage (4) to travel spool land (Rc5) and flows into tank
passage (Ta).

8-2-6
Figure 2

8-2-7
Single Operation
Travel Spool Shifting (Figure 3 and Figure 4)

1. When shifting travel spool by increasing pressure of travel
(section 1) pilot port (Pb1 (Pa1)), oil supplied to port (P1)
flows through neutral passage (L1), to spool, and flows to
port (B1 (A1)). Return oil flows through port (A1 (B1)) to
spool and returns to tank passage (Ta).
2. When shifting travel spool by increasing pressure of travel
(section 6) pilot port (Pb6 (Pa6)), oil supplied to port (P2)
flows through neutral passage (R1), and spool, to passage
(S6-1) and flows to port (B6 (A6)). At this time poppet (S6-
2) is not opened because parallel passage (R3) pressure
equals passage pressure (S6-1). Return oil flows through
port (A6 (b6)) to spool and returns to tank passage (Ta).
3. When shifting either spool (section 1 or 6), land (Lc4) or
(Rc3) is closed. Oil supplied from port (PP) does not flow
into tank passage, so that pressure at port (PT) rises.

8-2-8
Figure 3

8-2-9
Swing Spool Shifting (Figure 4)
1. When shifting swing spool by increasing pressure of swing
(section 2) pilot port (Pb2 (Pa2)), neutral port (L1) is
closed. Oil supplied to port (P1) flows through, parallel
passage (L3), load check valve (S2-1), and spool to port
(B2 (A2)). Return oil flows through port (A2 (B2)), to spool,
and returns to tank passage (Ta).
Figure 4

8-2-10
Boom Spool Shifting
1. Neutral (Figure 5)
This valve also works with anti drift valves that are installed
on the bottom side of each boom cylinder.
When in neutral, poppet (AD1) is closed by pressure from
port (A7), that is sent through passage (AD2), spool (AD3),
and passage (AD4) to poppet (AD1).
Figure 5 Neutral Condition

8-2-11
2. Boom up (2 speed junction) (Figure 6)
When boom spool 1 (section 7) is shifted by increasing
pressure of boom 1 pilot port (Pa7), neutral passage (R1)
is closed. Oil supplied to port (P2) flows through parallel
passage (R3), and load check valve (S7-1), to spool and
flows into port (A7). When boom 2 (section 3) spool is
shifted by increasing pressure of boom 2 pilot port (Pa3)
also, neutral passage (L1) is closed. Oil supplied to port
(P1) flows through parallel passage (L3), load check valve
(S3-1), and spool to passage (6) and it then joins at port
(A7). Return oil flows through port (B7) to spool and returns
to tank passage (Ta).
Figure 6 Boom Up

8-2-12
3. Boom down (regeneration) (Figure 7)
When boom spool 1 (section 7) is shifted by increasing
pressure of boom 1 pilot port (Pb7), neutral passage (R1)
is closed. Oil supplied to port (P2), flows through parallel
passage (R3), and load check valve (S7-1), to spool, and
flows into port (B7). When spool (AD3) of anti drift valve is
shifted by increasing pressure of port (Pc2) also, poppet
(AD1) is opened by decreasing of pressure in spring
chamber (AD5), and return oil from port (B7) returns to
tank passage. Some return oil opens poppet (S7-3), in
boom 1 spool, flows through passage (S7-2), it then joins
with port (B7), and prevents cavitation on cylinder rod side.
Figure 7 Boom Down

8-2-13
Spare Spool Shifting (Figure 8)
1. When spare spool is shifted by increasing pressure of
spare (section 4) pilot port (Pb4 (Pa4)), neutral passage
(L1) is closed. Oil supplied to port (P1) flows through,
parallel passage (L3), load check valve (S4-1), passage
(S4-2), and spool, into port (B4 (A4)). When neutral-cut
spool (R) is shifted by increasing pressure of port (pa10)
(Figure 1) also, oil supplied from port (P2) flows through
passage (11), and poppet (S4-3), it then joins with passage
(S4-2). Return oil returns through port (A4 (B4)) and spool
Bucket Spool Shifting (Figure 8)

1. When bucket spool is shifted by increasing pressure of
bucket (section 8) pilot port (Pb8 (Pa8)), neutral passage
(R1) is closed. Oil supplied to port (P2), flows through,
parallel passage (R3), load check valve (S8-1), passage
(S8-2), and spool, into port (B8 (A8)). When neutral-cut
spool (L) is shifted by increasing pressure of port (Pa11)
(Figure 1) also, oil supplied from port (P1) flows through
passage (7) and poppet (S8-3), it then joins with passage
(S8-2). Return oil returns through port (A8 (B8)) and spool
Figure 8

8-2-14
Arm Spool Shifting
1. Arm dump (2 speed junction) (Figure 9)
When arm spool 1 is shifted by increasing pressure of arm
1 (section 5) pilot port (Pb5), oil supplied from port (P1)
flows through, neutral passage (L1), load check valve (S5-
1), passage (S5-2), and spool, into port (B5). When arm 2
spool is shifted by increasing pressure of arm 2 (section 9)
pilot port (pb9) also, oil supplied from port (P2) flows
through neutral passage (R1), load check valve (S9-1),
passage (S9-2), spool, and passage (10), it then joins with
port (B5). Return oil returns through port (A5) and spool to
tank passage (Ta).
Figure 9 Dump

8-2-15
2. Arm crowd (2 speed junction)
When arm spool 1 is shifted by increasing pressure of arm
1 (section 5) pilot port (Pa5), oil supplied from port (P1)
flows through, neutral passage (L1), load check valve (S5-
1), passage (S5-2), and spool, into port (A5). When arm 2
spool is shifted by increasing pressure of arm 2 (section 9)
pilot port (pa9) also, oil supplied from port (P2) flows
through neutral passage (R1), load check valve (S9-1),
passage (S9-2), spool and passage (9), it then joins with
port (A5). When spool (AD3) of anti drift valve is shifted by
increasing pressure of port (pc1) also, poppet (AD1) is
opened by decreasing of pressure of spring chamber
(AD5), and return oil from port (B5) returned through spool,
passage (S5-3) and arm variable regeneration throttle
(Lc8) to tank passage (Ta). Some of return oil open poppet
(S5-4) in boom 1 spool, flows through passage (S5-2), it
then joins with port (A5), increases cylinder speed, and
then prevents cavitation on cylinder bottom side.
3. Variable regeneration (when crowding) (Figure 10)
When crowding arm, spool (S5-6) is stroked according to
pressure of passage (S5-2) connected to passage (S5-5),
and opening size of arm variable regeneration throttle
(Lc8) varies. When pressure of passage (S5-2) is high,
stroke of spool (S5-6) is increased, so that opening size of
throttle (Lc8) is increased. In contrary, when pressure of
passage (S5-2) is low, stroke of spool (S5-6) is decreased,
so that opening size of throttle (Lc8) is decreased.
Therefore regeneration flow varies according to pressure
of bottom of arm cylinder.

8-2-16
Figure 10

8-2-17
Neutral-cut Spool Shifting (Figure 11)
1. This valve has a neutral-cut spool that is installed in lowest
flow side (the upper flow side of low pressure relief valve).
When spool (L (R)) is shifted by increasing pressure of port
(pa10 (pa11)), neutral passage (L1 (R1)) is closed. Oil
supplied to port (P1) flows through passage (7) and poppet
(S8-3, Figure 8), it then joins with bucket (section 8)
passage (S8-2, Figure 8). Oil supplied to port (P2) flows
through passage (11) and poppet (S4-3, Figure 8), it then
joins with spare (section 4) passage (S4-2, Figure 8).
Parallel Throttle for Arm (Figure 11)

1. The throttle, that is installed in the parallel circuit for arm of
this valve, one in each of arm 1 (section 5) and the arm 2
(section 9) prevents the arm speed from increasing during
combined operation.
2. The parallel circuit of arm 2 (section 9), after narrowing at
the throttle (Rc6) in poppet (S9-3) allows oil from parallel
passage (R3), to join with oil in passage (S9-2, Figure 11).
3. The parallel circuit of arm 1 (section 5), after narrowing at
the throttle (Lc9) in poppet (S5-8) allows oil from parallel
passage (L3), to join with oil in passage (S5-2, Figure 10).
Figure 11

8-2-18
Relief Valve
1. Main relief valve (Figure 12)
Oil supplied to port (P1) flows through poppet (LP), oil
supplied from port (P2), flows through poppet (RP), and
passage (3) also, it then joins with the main relief valve.
The highest pressure of pump (P1) and (P2) is controlled
by actuating of main relief valve.
2. Over load relief valve
The over load relief valve, that is installed in each cylinder
port of boom 1, arm 1 and bucket, prevent the actuator
pressure from increasing to extremely high pressures by
external forces.
This relief valve, when pressure of cylinder port is a
negative pressure, also has the function to prevent
cavitation by drawing oil from the tank.
Figure 12

8-2-19
Combined Operation
Travel Combined Operation (Figure 13)

1. When applying simultaneously the operation except travel
while travel left and right simultaneous operating (while
forward traveling, backward traveling, or pivot turning) or
when applying travel left and right simultaneous operating
while applying the operation except travel, oil supplied from
port (PP) is disconnected with the tank passage (Ta) at the
signal land part of section of exception of travel shifted with
the land (Lc4) (Lc7) (Rc3) (Rc5), and the pressure of signal
passage increases up to the relief setting pressure of
pressure source for signal.
By increasing of signal pressure, the travel straight spool is
shifted and the pressures of ports (PT) and (PA) increase.
When travel straight spool is shifted, oil supplied from port
(P1) flows through neutral passage (L1), to travel (section
1), and simultaneously flows through, passage (2), travel
straight spool, and passage (R1), into travel (section 6). Oil
supplied to port (P2) flows through, travel straight spool
and passage (1) into parallel passage (L3).
If the section load pressure except the travel is higher than
the travel (section 6) load pressure, some oil supplied from
port (P2) opens poppet (S6-2), it then joins through throttle
in head of poppet with passage (S6-1).
Because travel (section 1 and 6) is activated by oil supplied
from port (P1) and the implement except the travel is
activated by oil supplied from port (P2), when applying the
combined operation with the travel left and right
simultaneous operation and the implement operation
except the travel, the travel is prevented from veering.

8-2-20
Figure 13

8-2-21
Swing Combined Operation (Figure 14)
1. When applying the combined operation with the swing and
another implement, poppet (S2-1) is fixed by increasing
port (pc6) pressure, poppet (S2-3) is opened, and pressure
supplied to port (L3) is increased through throttle (S2-4).
Accordingly, even in the case that the swing load pressure
is low, the simultaneous operation character with the other
implement can be secured.
Figure 14

8-2-22
Anti Drift Valve
1. The anti drift valve is installed in the cylinder port of arm
rod (boom bottom) side to prevent the arm (boom) cylinder
from natural lowering.
In neutral condition (Figure 15), cylinder port pressure is
sent through passage (AD2), spool (AD3), and passage
(AD4) to spring chamber (AD5).
Poppet (AD1) is completely closed by spring strength or
pressure differential due to difference of poppet sizes.
Figure 15
When arm dumping (boom up) (Figure 16) oil supplied

from pump opens poppet (AD1) it allows oil to flow to
cylinder port.
Figure 16
When crowding arm (boom down) (Figure 17), spool (AD3)

is shifted by increasing pressure of port (pc1 (pc2)), and oil
in spring chamber (AD5) is allowed to flow through,
passage (AD6) to drain port (DR1' (DR2')) This allows
poppet (AD1) to open and let return oil flow into tank
passage (Ta).
Figure 17
Main Relief Valve

1. The main relief valve is located between neutral oil
passage (HP, Figure 18) and low pressure oil passage
(LP). Pressurized oil flows into neutral oil passage (HP)
through orifice in the main poppet (C) to fill internal cavity
(D). Due to the difference in areas between (A) and (B), on
which hydraulic pressure acts, main poppet (C) seats on
sleeve (E).
Figure 18

8-2-23
2. When pressure in neutral oil passage (HP) rises and
exceeds relief valve setting, pilot poppet (F) opens.
Pressurized oil flows through pilot poppet (F) into low
pressure oil passage (LP), passing through hole (G).
Figure 19
3. As pilot poppet (F) opens, pressure in internal cavity (D)

lowers to move main poppet (C) so that pressurized oil
flows into neutral oil passage (HP) and directly into low
pressure oil passage (LP).
Figure 20
4. Pressure up operation
When pressure at pilot port (Pi) is increased, piston (H)
moves to the pressure setting position of plug (I) so that
the force of spring increases, thus increasing pressure in
the neutral oil passage (HP).
Figure 21
Overload Relief Valve

1. The overload relief valve is located between cylinder port
(HP) and low pressure oil passage (LP). Pressurized oil at
cylinder port (HP), flows through an orifice in piston (C), to
fill internal cavity (G). Due to the difference in area
between (A) and (B) on which the hydraulic pressure acts,
main poppet (D) seats on sleeve (K).
Figure 22

8-2-24
2. When pressure in cylinder port (HP) rises and exceeds the
relief valve setting, pilot poppet (E) opens. Pressurized oil
then flows through pilot poppet (E) into low pressure oil
passage (LP), passing through hole (H).
Figure 23
3. As pilot poppet (E) opens, pressurized oil flows through

orifice (I) so that pressure on back of piston (C) lowers to
move piston (C). As a result, piston (C) seats on pilot
poppet (E).
Figure 24
4. Pressurized oil in passage (HP) flows through orifice (F) in

piston (C) so that pressure on back of main poppet (D)
moves main poppet (D). Pressurized oil then flows into
passage (HP) and directly into passage (LP).
Figure 25
5. Sucking operation
An anti void unit is installed in cylinder port (HP) to prevent
the development of cavitation. If pressure at cylinder port
(HP) becomes lower than that of oil passage (LP), sleeve
(K) moves so that oil is supplied from the low pressure oil
passage (LP) to cylinder port (HP) to eliminate cavitation.
Figure 26

8-2-25
Low Pressure Relief Valve
1. When oil does not pass
Figure 27
2. When spool is in neutral

Oil in neutral oil passage (HP) flows through signal orifice
(A) into low pressure oil passage (LP). The pressure of the
signal port (4Ps (5Ps)) increases by the negacon signal
orifice (A).
Figure 28
3. Low pressure relief valve operation

When the excessive quantities of oil in the neutral oil
passage (HP) flow, pressure in neutral oil passage (HP)
exceeds spring setting pressure (C). This causes poppet
(B) to open. Oil then flows from neutral oil passage (HP)
into low pressure oil passage (LP) so excessive pressure
is prevented in neutral oil passage (HP).
Figure 29

8-2-26
Parts List
Figure 30

8-2-27
Figure 31

8-2-28
Figure 32

8-2-29
Reference Reference
Number Number
1 Valve Housing 41 Backup Ring
2 Valve Housing 42 Body
3 Spool Assembly (Arm-2) 43 Piston
4 Spool Assembly (Bucket) 44 Flange
5 Spool Assembly (Boom 1) 45 O-ring
6 Spool Assembly (Travel) 46 Poppet
7 Spool Assembly (Straight Travel) 47 Body Assembly
8 Spool Assembly (Arm-1) 48 Relief Valve Assembly
9 Spool Assembly (Service) 49 Relief Valve Assembly
10 Spool Assembly (Boom 2) 50 Relief Valve Assembly
11 Spool Assembly (Swing) 51 Plug Assembly
12 Cap 52 Poppet
13 Cap 53 Spring
14 O-ring 54 Plug
15 Poppet 55 O-ring
16 Spring 56 Flange
17 Spacer 57 O-ring
18 O-ring 58 Plug Assembly
19 Backup Ring 59 Plug Assembly
20 Spool Assembly 60 Plug Assembly
21 Spring Seat (A) 61 Plug Assembly
22 Spring 62 Plug Assembly
23 Plug 63 Socket-Head Bolt
24 Spool Assembly 64 Socket-Head Bolt
25 Spring 65 Socket-Head Bolt
26 O-ring 66 Name Plate
27 Plug 67 Drive Screw
28 Poppet 68 Socket-Head Bolt
29 Spring 69 O-ring
30 Poppet 70 O-ring
31 Poppet 71 O-ring
32 Poppet 72 O-ring
33 Spring 73 Cap
34 Flange 74 Cap
35 O-ring 75 Steel Ball
36 Poppet Assembly 76 Flange Cap
37 Spring 77 Socket-Head Bolt
38 Sleeve 78 O-ring
39 Piston 79 Poppet
40 O-ring

8-2-30
Spool Assembly (4, Bucket)
Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
Figure 33
Spool Assembly (5, Boom)
Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
6 Poppet
7 Spring Figure 34
8 Plug
9 O-ring
10 Backup Ring
Spool Assembly (6, Travel)
Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
Figure 35

8-2-31
Spool Assembly (7, Straight Travel)
Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
Figure 36
Spool Assembly (8, Arm1)
Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
6 Poppet
7 Spring Figure 37
8 Plug
9 O-ring
10 Backup Ring
Spool Assembly (9, Service)
Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
Figure 38

8-2-32
Spool Assembly (10, Boom 2)
Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
Figure 39
Spool Assembly (11, Swing)
Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
Figure 40
Spool Assembly (3, Arm 2)
Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
Figure 41
Spool Assembly (20, Arm Regeneration Release Valve
Reference
Description
Number
1 Spool
2 Sleeve
3 Sleeve
4 Piston
5 O-ring
6 Backup Ring
7 O-ring Figure 42
8 Backup Ring

8-2-33
Spool Assembly (24)
Reference
Description
Number
1 Spool
2 Spool End
Figure 43
Poppet Assembly (36)
Reference
Description
Number
1 Poppet
2 Poppet
3 Spring
4 Plug
Figure 44
Plug Assembly (51)
Reference
Description
Number
1 Plug
2 O-ring
3 O-ring
4 O-ring
Figure 45
Plug Assembly (58)
Reference
Description
Number
1 Plug
2 O-ring
3 O-ring
4 Backup Ring
Figure 46

8-2-34
Relief Valve Assembly (48)
Figure 47
Item Specification
Serial No. 1001 thru 1050 1051 and Up
Hi: 34.3 ±0.5 MPa Hi: 34.3 ±0.5 MPa
Relief Valve Pressure
Low: 31.4±0.5 MPa Low: 31.4±0.3 MPa
Flow 250 L/min. 150 L/min.
Reference
Description
Number
1 O-ring
2 O-ring
3 O-ring
4 Backup Ring
5 O-ring
6 Backup Ring
7 O-ring Figure 48
Item Specification
Relief Valve
35.3 ±0.5 MPa
Pressure
Flow 20 L/min.

8-2-35
Reference
Description
Number
1 Plug
2 Spring
3 Poppet
4 Sleeve
5 O-ring
6 O-ring
Figure 49
Specifications
Component Name Specification
Rated Flow 400 liter/min.
500 liter.min at Neutral
Max. Pressure 31.9 MPa
Allowable Back Pressure Peak Pressure: Below 1.5 MPa
Normal Pressure: Below 0.5 MPa
Allowable Working Temperature Range -20 ~ 90C

8-2-36
TROUBLESHOOTING, TESTING
AND ADJUSTMENT
General
Problem Possible Cause Remedy
Spool does not stroke. Hydraulic oil excessively hot. Remove blockage in oil piping.
Hydraulic oil contaminated. Change oil and clean oil passages.
Overtightened piping port fittings. Check torque.
Valve housing deformed when Remove assembling bolts and

assembling. check.
Pressure too high. Check pump port pressure and
cylinder port pressure with pressure
gauge.
Spool bent. Replace valve assembly.
Return spring damaged. Replace damaged parts.
Spring or cap crisscrossed. Remove and center cap.
Valve temperature uneven. Warm up entire system.
Dirt in valve. Clean valve.
Lack of pilot pressure. Check pilot valve and pilot relief

pressure.
Fails to bear load Leaky cylinder. Check seal parts of cylinder.
Leaky spool. Check spool.
Leaky overload relief valve. Clean valve housing and relief valve
seat parts.
Leaky anti drift valve. Remove anti drift valve and clean
every seat parts.
If seat parts are damaged, replace
poppet or lap poppet and seat parts.
If drift valve is out of order, replace
spool and sleeve at the same time.
Load drops when changing Dirt in load check valve. Remove and clean check valve.
the spool from neutral to up.
Poppet or seat parts in check valve Remove poppet or lap poppet and
damaged. seat parts.

8-2-37
Relief Valve
Pressure does not rise. Pressure does not rise. Replace relief valve.
Pressure unstable Pressure unstable
Relief pressure is incorrect. Seat parts worn due to dirt.
Lock nut and adjuster deformed. Reset pressure and tighten lock nut
in rated torque.
Oil leaks Relief valve seat parts damaged. Replace relief valve.
Every parts stuck due to dirt.
O-ring worn. Replace adjuster or O-ring.
Hydraulic System
Hydraulic system is poor or Hydraulic pump failed. Check pressure or replace pump.
none of the controls function
Relief valve failed. Replace pump.
Some kinds of cylinders failed. Repair or replace.
Pump load pressure too high. Check circuit pressure.
Valve cracked. Replace valve assembly.
Spool does not fully stroke. Check spool operation.
Hydraulic oil level in tank too low. Add hydraulic oil.
Filter in circuit plugged. Clean or replace filter.
Circuit piping snarled. Check piping.

8-2-38
Adjustment of Relief Valve
Main Relief Valve

1. Connect an accurate pressure gauge to inlet port.
2. Start engine and maintain rated pump speed.
3. Shift control valve spool and read pressure gauge from
stroke end of cylinder.
NOTE: Shift a spool that the actuator pressure setting
of the over load relief valve is higher than the
pressure of the main relief valve.
4. High pressure adjustment (See Figure 74 on page -60).
A. Loosen lock nut (5) and tighten plug (6) until piston
contacts the end (* mark) of plug (4). Plug (6) should
be torqued below 2 kg.m (15 ft lb). While plug (6) is
tightened, plug (4) should not be turned. The distance
A (See Figure 18 on page -23) should be more than
15 mm (0.59 in). Tighten lock nut (5).
B. Loosen lock nut (3) and turn adjusting plug (4)
clockwise to raise relief pressure at the condition of
step A. Turn adjusting plug (4) counterclockwise to
lower relief pressure. One turn varies pressure by
approximately 25.7 MPa. Tighten lock nut (3) after
pressure has been adjusted.
5. Low pressure adjustment
A. Loosen lock nut (5) and turn adjusting plug (6)
counterclockwise to lower relief pressure at step 4.
One turn varies pressure by approximately
21.3 MPa.Tighten lock nut (5) after pressure has
been adjusted.
B. Recheck the setting pressure by raising pressure.
Over Load Relief Valve
IMPORTANT
If pressure of main relief valve is higher than the specified
pressure for it, change main relief valve assembly setting
without adjusting over load relief valve.
1. Shift the control valve spool and read the pressure gauge
from the stroke end of the cylinder.
2. Loosen lock nut (3) and turn adjusting plug clockwise to
raise pressure. One turn varies pressure by approximately
21.2 MPa.
3. Tighten lock nut (3) after pressure has been adjusted. Lock
nut (3) should be torqued to 2.80 ~ 3.2 kg.m (20 ~ 23 ft lb).
4. Recheck the pressure setting again.

8-2-39
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

2. Lower front attachment (bucket) to ground.
3. Stop engine.
EX1300684
Figure 50

8-2-40
(Figure 51) I
WARNING OFF
Lock
OFF
ON
ON

switch.
ON
OFF
ON
DS1704238
Figure 52

3
5 8
1 2
7 6
4
EX1401809
Figure 53

8-2-41
WARNING
any work.
Figure 54 DS1601105
draining the oil.
Figure 55 EX1400737

1
filter cover (2, Figure 56) and return filter cover (3,
Figure 56). Then drain hydraulic oil with an oil pump. 3
• Tool: 17 mm ( )
DS1704244
Figure 56
B. Drain hydraulic oil using drain plug.

FRONT
• Tool: 27 mm ( )
DS1704245

8-2-42
with a filter cap.
Item Part Number

DS1601106
Figure 58
Reference
Description
Number
3
1 Suction Filter
2 Nut
A
3 Rod
2
When installing
• Length (A): 606.5 mm 1
Figure 59
13. Remove bolts and washers (1, Figure 60) (6 ea) under
cover (2) from bottom of main frame.
FRONT
• Tool: 19 mm ( )
• Under cover weight: 7 kg (15 lb)
2
1
DS1800093
14. Loosen the main control valve mounting bolts from main
frame bracket. (bolt: 4 ea) (Figure 61)
FRONT
NOTE: Do not remove bolts completely to hold the
position of control valve.
• Tool: 30 mm ( )
• Torque: 539 N.m (55 kg.m, 397.7 ft lb)
DS1800104

8-2-43
15. Open the engine cover and remove bolts and washers (1,
Figure 62) (4 ea) with cover (2). Engine Cover
1 2
• Tool: 19 mm ( )
• Cover weight: 25 kg (55 lb)
DS1800105
Figure 62
16. Disconnect the harness connector (2 ea).

NOTE: Be careful not to let water get into electrical 2
into electrical system, this will cause an
electrical short circuit and result in improper
machine operation.
Port Location
PA, PT Right Side
1
Figure 63 EX1401453
environment.
EX1504170
Figure 64

8-2-44
18. Remove hoses and adapters from the main control valve.
NOTE: Attach identification tags to the removed hoses for reassembly. After the hoses are disconnected
from the main control valve, plug and cap them to prevent dirt or dust from entering. 
Disconnect the hoses from the bottom to top of main control valve.
B5 A5
DR1
A4
B4
pc6
A2
B2 PA
B1 PT
A1
P1
Right Side View
DS1800106
Figure 65

Port Name
P1 from Main Pump "A2" SAE 1", D25.4 10 107.9 11.0 79.6
Connect with "DR3" PF 1/4" 19 39.2 4.0 28.9
DR1
to Oil Tank PF 3/8" 22 49.0 5.0 36.2
A1 to Center Joint "3" SAE 1", D25.4 10 107.9 11.0 79.6
A2 to Swing Device "B" SAE 1", D25.4 10 107.9 11.0 79.6
A4 Option (1/2way) SAE 1", D25.4 10 107.9 11.0 79.6
A5 to Arm Cylinder "Head" SAE 1 1/4", D31.8 12 176.4 18 130.1
B1 to Center Joint "2" SAE 1", D25.4 10 107.9 11.0 79.6
B2 to Swing Device "A" SAE 1", D25.4 10 107.9 11.0 79.6
B4 Option (1/2way) SAE 1", D25.4 10 107.9 11.0 79.6
B5 to Arm Cylinder "Rod" SAE 1 1/4", D31.8 12 176.4 18.0 130.1
to Swing Device "SH" PF 1/4" 19 39.2 4.0 28.9
PA
Pressure Sensor PF 1/4" 19 39.2 4.0 28.9
PT Pressure Sensor PF 1/4" 19 39.2 4.0 28.9
pc6 Connect with "pa7" PF 3/8" 22 49.0 5.0 36.2

8-2-45
• Fitting
Size Torque
Port Name
DR1 Tee PF 1/4" PF 1/4", PF 3/8" 17 34.3 3.5 25.3
Tee PF 1/4" PF 1/4" 17 34.3 3.5 25.3
PA
Reducer PF 1/4" 19 39.2 4.0 28.9
PT Reducer PF 1/4" 19 34.3 3.5 25.3
pc6 Elbow PF 1/4" PF 3/8" 19 34.3 3.5 25.3
P1, A1,
DS2856003
A2, A4,
(1", ID:33.2, OD:40.2, 1B)
B1, B2, B4
O-ring DS2856004
A5, B5
(1 1/4", ID:38, OD:45, 1B)
DR1, PA,
S8000115 (4D P11)
PT, pc6

8-2-46
pa5 pa9
pa8
pa4
pa7
pa3
pa2 pc2
PP pa6
pa1
PH
Front View
Figure 66 DS1800107

Port Name
PH from Solenoid Valve "PH" PF 1/4" 19 39.2 4.0 28.9
from Solenoid Valve "P1" PF 1/4" 19 39.2 4.0 28.9
PP
to Swing Device "PG" PF 1/4" 19 39.2 4.0 28.9
pa1 from Pedal Valve "3" PF 1/4" 19 39.2 4.0 28.9
from Joint Sub Assembly "B1"
pa2 PF 3/8" 22 49.0 5.0 36.2
(from Joystick Valve LH "1")
pa3 PF 3/8" 22 49.0 5.0 36.2
(from Joystick Valve RH "4")
pa4 Connect with "pb4" PF 1/4" 19 39.2 4.0 28.9
PF 3/8" 22 49.0 5.0 36.2
pa5 (from Joystick Valve LH "4")
Connect with "pc1" PF 3/8" 22 49.0 5.0 36.2
pa6 from Pedal Valve "1" PF 1/4" 19 39.2 4.0 28.9
PF 3/8" 22 49.0 5.0 36.2
pa7 (from Joystick Valve RH "4")
pa8 PF 3/8" 22 49.0 5.0 36.2
(from Joystick Valve RH "3")
pa9 PF 3/8" 22 49.0 5.0 36.2
pc2 Connect with "pb7" PF 3/8" 22 49.0 5.0 36.2

8-2-47
• Fitting
Size Torque
Port Name
PH Elbow PF 1/4" PF 1/4" 19 34.3 3.5 25.3
PP Tee PF 1/4" PF 1/4" 19 34.3 3.5 25.3
pa1, pa4, pa6 PF 3/8" PF 1/4" 22 44.1 4.5 32.5
Elbow
pa2, pa8, pa9 PF 3/8" PF 3/8" 22 44.1 4.5 32.5
pa3, pa5 PF 3/8" PF 3/8" 22 44.1 4.5 32.5
Tee
pa7 PF 3/8" PF 3/8" 21 44.1 4.5 32.5
pc2 Elbow PF 1/4" PF 3/8" 19 34.3 3.5 25.3
PH, PP, pc2 S8000115 (4D P11)
O-ring
pa1 ~ pa9 S8000145 (4D P14)

8-2-48
T2
A8
B8
DR2 B7
A7
B6
A6
P2
Left Side View

DS1800108
Figure 67

Port Name
P2 from Main Pump "A1" SAE 1", D25.4 10 107.9 11.0 79.6
T2 to Oil Cooler SAE 2 1/2", D63.5 10 107.9 11.0 79.6
DR2 to Oil Tank PF 3/8" 22 49.0 5.0 36.2
A6 to Center Joint "1" SAE 1", D25.4 10 107.9 11.0 79.6
A7 to Boom Cylinder "Head' SAE 1 1/4", D31.8 12 176.4 18.0 130.1
A8 to Bucket Cylinder "Rod" SAE 1 1/4", D31.8 12 176.4 18.0 130.1
B6 to Center Joint "4" SAE 1", D25.4 10 107.9 11.0 79.6
B7 to Boom Cylinder "Rod' SAE 1 1/4", D31.8 12 176.4 18.0 130.1
B8 to Bucket Cylinder "Head" SAE 1 1/4", D31.8 12 176.4 18.0 130.1
• Fitting
Size Torque
Port Name
DR2 Elbow PF 1/4" PF 3/8" 19 34.3 3.5 25.3
P2, A6, DS2856003
B6 (1", ID:33.2, OD:40.2, 1B)
2180-1026D31
T2
O-ring (ID:69.44, W:3.53, Class1)
DR2 S8000115 (4D P11)
A7, A8, DS2856004
B7, B8 (1 1/4", ID:38, OD:45, 1B)

8-2-49
pb5
pb9
pc1
pb8
pb4
pb7 pb3
pb6 pb2
pb1
Rear View
DS1800109
Figure 68

Port Name
pb1 from Pedal Valve "4" PF 1/4" 19 39.2 4.0 28.9
pb2 PF 3/8" 22 49.0 5.0 36.2
pb3 to Oil Tank PF 3/8" 22 49.0 5.0 36.2
pb4 Connect with "pa4" PF 1/4" 19 39.2 4.0 28.9
PF 3/8" 22 49.0 5.0 36.2
pb5 (from Joystick Valve LH "2")
Connect with "pb9" PF 3/8" 22 49.0 5.0 36.2
pb6 from Pedal Valve "2" PF 1/4" 19 39.2 4.0 28.9
PF 3/8" 22 49.0 5.0 36.2
pb7 (from Joystick Valve RH "2")
PF 3/8" 22 49.0 5.0 36.2
pb8 (from Joystick Valve RH "1")
Connect with "pa11" PF 1/4" 19 39.2 4.0 28.9
pb9 Connect with "pb5" PF 3/8" 22 49.0 5.0 36.2
pc1 Connect with "pa5" PF 3/8" 22 49.0 5.0 36.2

8-2-50
• Fitting
Size Torque
Port Name
pb1, pb6 Elbow PF 3/8" PF 1/4" 22 44.1 4.5 32.5
pb2 Adapter PF 3/8" PF 3/8" 22 44.1 4.5 32.5
pb3, pb9 Elbow PF 3/8" PF 3/8" 22 44.1 4.5 32.5
pb4 Adapter PF 3/8" PF 1/4" 22 44.1 4.5 32.5
pb5, pb7 PF 3/8" PF 3/8" 22 44.1 4.5 32.5
Tee
pb8 PF 3/8" PF 3/8", PF 1/4" 22 44.1 4.5 32.5
pc1 Elbow PF 1/4" PF 3/8" 19 34.3 3.5 25.3
pc1 S8000115 (4D P11)
O-ring
pb1 ~ pb9 S8000145 (4D P14)

8-2-51
ps2
pa10
pa11
ps1
Top View
DS1800110
Figure 69

Port Name
pa10 to Oil Tank PF 1/4" 19 39.2 4.0 28.9
pa11 connect with "pb8" PF 1/4" 19 39.2 4.0 28.9
ps1 to Main Pump "X1" (Lower) PF 1/4" 19 39.2 4.0 28.9
ps2 to Main Pump "X1" (Upper) PF 1/4" 19 39.2 4.0 28.9
• Fitting
Size Torque
Port Name
pa10, ps1,
Elbow PF 1/4" PF 1/4" 17 34.3 3.5 25.3
ps2
pa11 Adapter PF 1/4" PF 1/4" 19 34.3 3.5 25.3
pa10, pa11,
O-ring S8000115 (4D P11)
ps1, ps2

8-2-52
19. Install eyebolts (2 ea) to lift in threaded holes on top of
control valve. (Figure 70)
• Thread of hole: M12 x 1.75 (Depth 18 mm)
• Control valve weight: about 422 kg (930 lb)
DS1800111
Figure 70
20. Remove main control valve mounting bolts from main

frame bracket. (bolt: 4 ea) (Figure 71)
FRONT
21. Lift the control valve by crane from frame slowly and
carefully.
DS1800112
Figure 71

8-2-53
INSTALLATION
WARNING
SERIOUS INJURY
NOTE: First, assemble the bolts (4 ea) of main control valve

mounting to main frame. (Figure 72)
FRONT
IMPORTANT
After completing the work, check the oil level. Start the
engine and check for any oil leaks.
2. Be careful not to apply stress on control valve when Figure 72 DS1800112

attaching piping and hoses. Unnecessary stress can cause
spools to bind and the control valve can not function
properly.
3. Tighten the assembling bolts alternately and evenly in
accordance with 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 tapes to
protect the ports from dust and other foreign materials until
they are reassembled.
COMPLETING WORK
1. If the hydraulic oil in the oil tank was removed, refill the
hydraulic oil tank.
3. Operate the joystick lever and actuate the hydraulic
cylinder 4 ~ 5 times very slowly, without fully reaching the
stroke (leave about 100 mm).
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)

8-2-54
DISASSEMBLY
General Instructions for Disassembly

1. Stop engine at low actuator pressure.
It is dangerous to disassemble control valve while it is
under pressure. High pressure oil can squirt out or
components can spring out. When partially disassembling
control valve that is on machine, be careful to follow the
following caution.
CAUTION
AVOID INJURY
When disassembling assembly, when pressure is not
fully released, or bucket is not lowered to ground, it is
very dangerous. A poppet in an antidrift valve can
spring out and drop the bucket at the same time.
Always lower bucket to ground and fully release
pressure before disassembling.
2. Vent pressurized air from hydraulic oil tank.

3. Clean all exterior surfaces of valve before to disassembly
and protect it from dirt and foreign materials.
4. Match mark the disassembled parts to ensure proper
reassembling position.
5. Replace all sealing parts such as O-rings and backup rings
with a new ones.
6. Do not replace spools, they are matched with valve
housing and sleeve.
NOTE: The further part numbers of an assembly part
are shown as (assembly part number - further
part number).
Disassembly of Main Spool (3) ~ (11)

1. Remove socket head bolt (63, width across flats: 10 mm)
and long cap (12 and 73). Remove O-ring (14) from valve
housing.
2. Remove all spool subassemblies from valve housing.

8-2-55
WARNING
When removing spool, be careful not to damage it.
Attach label to each spool in order to install it in the
correct position when reassembling.
3. Remove socket head bolts (63) and short cap (13 and 74).
Remove O-ring from valve housing.
4. Remove spool end (further part number - 5, width across
flats: 22 mm) of spool (3, 4, 6, 7, 9 10 and 11), spring seat
(further part number - 2) and spring (further part number - 3
and 4).
5. Remove spool end (5-5, width across flats: 22 mm) of
spool (5), spring seat (5-2) and spring (5-3,4). Remove
plug (5-8: groove width; 3 mm), O-ring (5-9) and backup
ring (5-10).
6. Remove spool end (8-5, width across flats: 22 mm) of
spool (8), spring seat (8-2) and spring (8-3,4). Remove
plug (8-8: groove width; 3 mm), spring (8-7) and poppet (8-
6).
7. Disassembly of spool
IMPORTANT
Work with spool gripped in vise with wood (see Figure
73) not to scratch outside diameter of spool.
Because Loctite is applied to threaded portion of spool
end, heat outside surface of spool with industrial drier
to release Loctite.
Heat spool until spool end is easily loosened, and Figure 73
remove immediately after heating it to 200 ~ 250C.
If it is over heated, change spring to new one.
Disassembly of Subspool (24)

1. Remove plug (27, width across flats: 36 mm), spring (25),
spring seat (21), and spool (24). Remove the other spool in
a similar manner.
2. Remove O-ring (26) from plug.
3. Spool (24-1) and spool end (24-2) are secured with Loctite.
Heat spool end to loosen it (Heating temperature: 200 ~
250C) to prevent damage of thread.

8-2-56
Disassembly of Subspool (20)
1. Remove plug (23, width across flats: 32 mm) and O-ring
(72).
2. Remove spring (22), spring seat (21) and spool (20-1).
3. Pull off sleeve (20-2,3) and piston (20-4).
Disassembly of Anti Drift Valve of Boom

and Arm
1. Remove socket head bolt (63) and body assembly (47)
and O-ring (35 and 70).
WARNING
Removing antidrift valve seat, when pressure is not
fully released, or bucket is not lowered to ground, is
very dangerous. A part in the valve can spring out and
drop the bucket at the same time. Always lower bucket
to ground and fully release pressure before
disassembling.
2. Remove spring (33) and poppet (46).

3. Grip body assembly (47, width across flats: 8 mm) in vise
taking care not to scratch O-ring (35 and 70) surface.
4. Remove plug (47-5) and O-ring (47-10).
5. Remove spring (47-4), spool (47-2) and O-ring (47-3).
6. Remove plug assembly (47-7, width across flats: 6 mm)
and O-ring.
IMPORTANT
The filter in plug assembly (47-7) is pressed into place
and can not be removed. If filter replacement is
necessary, replace it with a new plug assembly.
7. Remove plug (47-8, width across flats: 8 mm) and O-ring.

8. Remove plug (47-9, width across flats: 5 mm) and O-ring.
NOTE: Steel ball (75) should not be disassembled
since it is a press fit.

8-2-57
Disassembly of Swing Load Check
1. Remove socket head bolt (68, width across flats: 10 mm)
and flange (44).
2. Remove body (42), piston (43) and O-ring (45).
3. Pull off sleeve (38) and remove spring (37) and piston (39).
4. Remove O-ring (40, 35) and backup ring (41).
5. Remove poppet assembly (36).
6. Grip plug (36-4, width across flats: 12 mm) in vise and
remove poppet (36-1), spring (36-3) and poppet (36-2).
Disassembly of Load Check

1. Remove travel semi parallel check from port P2. Remove
plug (54, width across flats: 27 mm). Remove O-ring (54)
from plug. Remove spring (53) and poppet (52).
WARNING
At this time, be careful not to drop spring into
passage. If valve is operated with spring in passage, a
broken piece can penetrated in main spool sliding
surface and a serious accident can occur by a
runaway or not being able to stop.
2. Remove travel load check from port P1. Remove socket

head bolt (63, width across flats: 10 mm) and flange (34).
Remove poppet (32), spring (33) and O-ring (35).
3. Remove the remaining load check. Remove socket head
bolt (63, width across flats: 10 mm) and flange (34).
Remove poppet (31), spring (33) and O-ring (35).
Disassembly of Other Check Valves

1. Remove two common check valves from main relief valve.
Remove socket head bolt (64, width across flats: 8 mm)
and flange (56). Pull off collar from spacer (17). Remove
O-ring (18) and backup ring (19). Remove spring (16) and
poppet (15).
2. Remove parallel check valve from spare junction, bucket
junction and arm one. Remove plug (61, width across flats:
10 mm) and O-ring.
3. Remove spring (29) and poppet (28).
4. Remove semi parallel check valve from arm two. Remove
plug (61, width across flats: 10 mm) and O-ring. Remove
spring (29) and poppet (30).

8-2-58
Disassembly of Flange
1. Remove flange from spare port. Remove socket head bolt
(77, width across flats: 10 mm) and flange (76) and O-ring
(78).
2. Remove flange from boom two. Remove socket head bolt
(64, width across flats: 8 mm) and flange (56) and O-ring
(57).
Disassembly of Relief Valve

1. Remove eight overload relief valves (49, (8 places, width
across flats: 32 mm)).
2. Remove main relief valve (48, width across flats: 41 mm).
3. Remove two negacon relief valves (50, width across flats:
46 mm).
Disassembly of Other Flange

1. Remove plug assemblies (60, 61, 62, 58, 52, 59) and O-
rings.
Reference
Size Quantity
Number
60 6 mm 5
61 10 mm 17
62 12 mm 6
58 24 mm 1
52 27 mm
59 8 mm
NOTE: Valve housings (1 and 2) should not be

disassembled because O-rings and housings
can be deformed and mating surfaces can be
crisscrossed when reassembling them.
Steel ball (75) should not be disassembled
since it is a press fit.

8-2-59
Disassembly of Main Relief Valve
1. This relief valve should be replaced as an assembly. When
replacing it, loosen cap (8, width across flats: 41) and O-
ring (1, Figure 74). If oil leaks from nut (3), remove nut (3)
and plug (4) and replace O-ring and backup ring.
Figure 74

8-2-60
Disassembly of Overload Relief Valve
1. This relief valve should be replaced as an assembly. When
replacing it, loosen cap (1, width across flats: 31.75 mm)
and O-ring (2). If oil leaks from nut (3), remove adjusting kit
and replace O-ring (4).
NOTE: When disassembling adjusting kit, be careful
not to allow components to spring out by force
of spring or to lose the poppet.
Figure 75
Disassembly of Low Pressure Relief Valve

1. This relief valve is a press fit at area (D) making it a non-
serviceable item, that should be replaced as a whole
assembly.
Figure 76

8-2-61
CLEANING AND INSPECTION
(WEAR LIMITS AND
TOLERANCES)
Cleaning
Clean all parts thoroughly using a suitable cleaning fluid and dry
them with moisture free compressed air. Put them on a clean
paper or a vinyl surface for inspection.
Inspection
Inspect all parts for scratches, notches and the other defects.
1. Inspect load check seat surface of valve housing for
scratches, scores, dirt, notches and corrosion. Remove
small scratches with oilstone.
2. Inspect exterior surface of spool for scratches and notches.
Remove small scratches with oilstone.
3. Inspect all grooves and passages of sliding parts for
foreign materials.
4. Replace any springs that are damaged, heavy deformed or
worn.
5. If relief valve malfunctions, inspect it by using relief valve
procedure (see page).
6. Replace all O-rings and backup rings with new ones.
7. After disassembling cap or plug, check whether there are
paint chips around valve body hole or plug. If paint chips
penetrate into valve, they can cause malfunction or leaks
to occur.

8-2-62
REASSEMBLY
NOTE: Before reassembling, confirm number of
components, reassembling position, tools and etc.
Subassembly
Before reassembling valve housing, subassemble parts as
needed.
Main Spool (3) ~ (11)

1. Apply Loctite to threads of spools (3, 4, 6, 7, 9, 10 and 11).
Assemble spring seat (above parts numbers - 2), spring
(above parts numbers - 3, 4) and spool end (above parts
numbers - 5), and assemble spool end in spool that is
gripped in vise with wood.
• Torque: 24 ~ 26 N.m (2.45 ~ 2.65 kg.m, 18 ~ 19 ft lb)
IMPORTANT
Be careful not to get Loctite into spool by over
applying it.
Be careful that spool operation does become
deteriorated by over torquing spool end.
2. After assembling poppet (above parts numbers - 6) and

spring (above parts numbers - 7) in middle hole of spool
(5), apply Loctite to thread of spool. Grip spool in vise with
wood. Assemble plug (5-8) into which O-ring (5-9) and
backup ring (5-10) are inserted.
Assemble spring seat (5-2), spring (5-3, 4) and spool end
(5-5) and tighten spool end.
3. Assemble poppet (8-6) and spring (8-7) in middle hole of
spool (8). Apply Loctite to thread of spool and assemble
plug (8-8).
Apply Loctite to thread of spool. Grip spool in vise with
wood. Assemble spring seat (8-2), spring (8-3, 4) and
spool end (8-5) and tighten spool end.

8-2-63
Subspool (20)
1. Assemble backup ring (20-8) and O-ring (20-7) in sleeve
(20-3). Assemble backup ring (20-6) and O-ring (20-5) in
sleeve (20-2).
2. Assemble piston (20-4) in sleeve (20-3) with O-ring.
3. Assemble piston in sleeve (20-2).
Subspool (24)
1. Apply Loctite to thread of spool (24-1).
IMPORTANT
Be careful not to get Loctite into spool by over
applying it. Be careful that spool operation does
become deteriorated by over torquing spool end.
2. Tighten spool end (24-2) in spool (24-1).

Boom, Arm Anti Drift Valve

1. Grip body in vise, taking care not to scratch O-ring (35 and
70) surface of body (47-1).
2. Insert spring seat (47-3) in spool (47-2), and insert spool in
body (47-1) hole.
3. Assemble spring (47-4).
4. Tighten plug (47-5) with O-ring (47-10) in body (47-1).
5. Tighten plug (47-9) with O-ring to body (47-1).
Tighten plug (47-8) with O-ring in body (47-1).
6. Tighten plug (47-7) with O-ring and filter in body (47-1).
Swing Load Check

1. Insert poppet (36-2) and spring (36-3) in poppet (36-1),
and tighten plug (36-4).

8-2-64
IMPORTANT
Insert spring into poppet. Large end of spring should
be facing the poppet. If spring is not inserted properly,
it can break.
Reassembly of Control Valve
Reassembly of Load Check Valve

1. Assemble travel semiparallel check for P2 port. Assemble
poppet (52) and spring (53), and fasten plug (54) with O-
ring (55).
2. Assemble travel load check for P1 port. Assemble poppet
(32), spring (33) and O-ring (35), and fasten flange (34)
with socket head bolt (63).
IMPORTANT
When fastening flange, spring (33) should be inserted
into flange. If it is not properly installed, the spring can
be broken. When tightening socket head bolts, they
should be tightened evenly.
3. Assemble remaining load check. Assemble poppet (31),

spring (33) and O-ring, and fasten flange (34) with socket
head bolts (63).
Reassembly of Swing Load Check

1. Install O-ring (40) and backup ring (41) on sleeve (38).
2. Install piston (39), spring (37) and poppet assembly (36) in
sleeve (38).
3. Install sleeve assembly in body. Install O-ring (35) on body.
4. Install piston (43) and O-ring (45) in body (42).
5. Install body assembly in sleeve (38).
6. Fasten flange (44) and body (42) with socket head bolt
(68).

8-2-65
Reassembly of Other Check Valve
1. Assemble two common check valves of main relief valve.
Install poppet (15) and spring (16). Insert spacer (17) with
O-ring (18) and backup ring (19). Fasten flange (56) with
socket head bolts (64).
IMPORTANT
When fastening flange, spring (33) should be inserted
into flange. If it is not properly installed, the spring can
be broken. When tightening socket head bolts, they
should be tightened evenly.
2. Assemble parallel check valve for spare junction, bucket

junction and arm one. Install poppet (28) and spring (29),
and tighten plug (61) with O-ring.
• Torque: 116 ~ 128 N.m (11.83 ~13.05 kg.m, 86 ~ 94 ft lb)
3. Assemble arm two semiparallel check valve. Install poppet
(28) and spring (29), and tighten plug (61) with O- ring.
• Torque: 116 ~ 128 N.m (11.83 ~13.05 kg.m, 86 ~ 94 ft lb)
Reassembly of Flange
1. Assemble flange for spare port. Install O-ring (78) on
flange (76), and fasten flange with socket head bolts (77).
2. Assemble flange for boom two. Install O-ring (57) on valve
housing, and fasten flange (56) with socket head bolt (64).
The good surface of flange should be facing the O-ring
side.
Reassembly of Boom and Arm Anti Drift Valve

1. Install poppet (46) and spring (57), and fasten body
assembly (47) with socket head bolt (63).
IMPORTANT
When installing body assembly (47), spring (33)
should be completely installed in spring position of
body assembly.

8-2-66
Reassembly of Relief Valve
1. Tighten eight over load relief valves (49).
2. Tighten main load relief valve (48).
3. Tighten negacon relief valve (50).
Reassembly of Subspool (24)

1. Install spool (24) in valve hole it was removed from during
disassembly.
2. Install spring seat (24) and spring (25).
3. Tighten plug (27) with O-ring.
IMPORTANT
Insert spool in hole perpendicularly. Make sure that
spool is in correct position. If it is not in correct
position, a malfunction can occur.
Reassembly of Subspool (20)

1. Install spool assembly in valve hole it was removed from
during disassembly.
2. Install spring seat (21) and spring (22).
3. Tighten plug (23) with O-ring (72).

8-2-67
Reassembly of Main Spool (3) ~ (11)
1. Install O-ring on valve housing (1,2).
2. Fasten short cap (74) with socket head bolt (63) for travel
straight spool (7). Fasten short cap (13) with socket head
bolt (63) for the other travel straight spools.
3. Install spools (3 ~ 11) in valve holes they were removed
from during disassembly.
4. Fasten long cap (73) with socket head bolt (63) on travel
straight spool (7). Fasten long cap (12) with socket head
bolt (63) on other travel straight spools.
IMPORTANT
When assembling, be careful not to drop O-ring from
mating surface.
Reassembly of Other Plugs

1. Tighten plug assembly (60) with O-ring.
4. Tighten plug assembly (58) with O-ring and backup ring.
IMPORTANT
After reassembly is completed, recheck tightening
torque of all components. If they are not properly
tightened, an oil leak can occur. The torque values are
based on the threads being lubricated.

8-2-68
Reassembly of Main Relief Valve
Check whether there is dirt or paint chips around plug (4, Figure
77) and nut (3). Reassemble with new O-rings. Clean the
installation portion of relief valve and install it. Tighten cap (8:
Width across flats 41).
When adjusting the position of port (Pi), adjust it before adjusting
pressure and tightening plug (2, Width across flats 41 mm). After
adjusting plug (2), move cap (7, Width across flats 54 mm).
If plugs are disassembled, Adjust pressure by referring to "Main
Relief Valve" on page 2-39.
NOTE: The torque values are based on the threads being
lubricated.
Figure 77

8-2-69
Reassembly of Overload Relief Valve
Check whether there is dirt or paint chips around cap (1, width
across flats: 31.75 mm) and reassemble with a new O-ring.
Clean the installing part of relief valve and install it.
If adjusting kit is disassembled, clean around threads and adjust
pressure by referring to "Over Load Relief Valve" on page 2-39.
lubricated.
Figure 78
Reassembly of Low Pressure Relief Valve

Check whether there is dirt or paint chips around plug (1, width
across flats: 46 mm) and reassemble it with new O-rings (3 and
4).
lubricated.
Figure 79

8-2-70
1Swing Device
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Swing Device

8-3-1
Table of Contents
Swing Device
General ...........................................................8-3-3
Specification .............................................................. 8-3-3
Overview ................................................................... 8-3-4
Hydraulics Circuit....................................................... 8-3-5
Parts List ................................................................... 8-3-6
Theory of Operation ................................................ 8-3-11
Cautions for Operation..................................8-3-19
Precaution.....................................................8-3-23
Tools for Disassembly and Assembly...................... 8-3-23
Removal........................................................8-3-25
Installation.....................................................8-3-30
Completing work ...........................................8-3-30
Disassembly and Reassembly......................8-3-31
Disassemble Swing Motor ....................................... 8-3-31
Reassemble Swing Motor........................................ 8-3-36
Disassemble the Reduction Gear............................ 8-3-42
Reassemble the Reduction Gear ............................ 8-3-46
General Instructions ................................................ 8-3-53
Examination of Hydraulic Motor............................... 8-3-53
Troubleshooting....................................................... 8-3-54
Maintenance Instructions..............................8-3-57
Replacement Standard of Worn Parts..................... 8-3-57
Standard of Sliding Surface Correction ................... 8-3-57
Swing Device DX480LCA-K/DX520LCA-K

8-3-2
GENERAL
Specification
Swing Motor
Type Axial Piston

Displacement 132 cm3 (0.005 ft3)
Crossover Relief Valve Setting 300 kg/cm2 (294 bar, 4,267 psi)
Max. Supply Flow 185 L/min (49 U.S. gal)
Motor Shaft Speed 1,401 rpm
Motor Shaft Torque 618 N.m (63 kg.m, 456 ft lb)
Accessory Valves Swing Reactionless Valve
Weight 63.5 kg (140 lb)
Swing Reduction Gear
Drive Type 2 - Stage Planetary Gear

Reduction Ratio 21.6
Max. Output Speed 65 rpm
Max. Output Torque 13,337 N.m (1,360 kg.m, 9,837 ft lb)
Weight 190 kg (419 lb)
Pinion Gear
Type Spur Gear

Gear P.C.D D 180 mm
No. of Teeth 15
Module 12
Parking Brake
Spool Cracking 13 kg/cm2 (12.7 bar)

Time Delay 5 ±3 sec

8-3-3
Overview
Swing device consists of a swing motor and swing reduction
gear. And there are two swing devices in this machine.
Swing motor includes a mechanical parking valve, relief valve,
makeup valve and time delay valve.
PA C PB DB
Air Breather B
Oil Level Gauge

PG
SH
Dr
EX1401267
Figure 1
Port Name Size

A High-pressure (Right) SAE 3/4"-6,000 psi
B High-pressure (Left) SAE 3/4"-6,000 psi
C Make Up PF 1", O-ring
DB Motor Drain PF 1/2", O-ring
SH Brake Signal PF 1/4", O-ring
PG Brake Release PF 1/4", O-ring
Pa Pressure Gauge PF 1/4", O-ring
Pb Pressure Gauge PF 1/4", O-ring
Air Breather PT 1/2"
Oil Level Gauge PT 1/4"
Dr Oil Drain PT 1/2"

8-3-4
Hydraulics Circuit
RED
SH
PG
DB
294 bar
294 bar C
PA
A B
DS1600856
Figure 2

8-3-5
Parts List
Swing Motor
55
30
31
28 6
29
55 10
27
11
22
12
27
29 13
26 28
24 25 14
32
23
21 5
20
19
4
18
16 3
17
91-1 2
91 90
9
7
87
8
88
51
1
Figure 3 DS1800114

8-3-6
Reference Reference
Number Number
1 Case 22 Casing; Valve
2 Seal, Oil 23 Pin, Spring
3 Bearing; Roller 24 Bearing, Ball
4 Shaft, Drive 25 Plate, Valve
5 Plate; Shoe
26 O-ring
6 Block, Cylinder
27 Plunger
7 Washer
28 Plug
8 Spring
29 Spring
9 Ring,snap
10 Roller 30 Plug
11 Collar 31 Bolt
12 Ball, Thrust 32 Valve, Relief
13 Plate, Retainer 51 Valve, Brake
14 Piston & Shoe Assembly 55 Valve
16 Plate, Separation 87 Bolt, Socket
17 Plate, Friction 88 Gauge Assembly, Level
18 O-ring 90 Ring, Snap
19 O-ring 91 Pipe, Breather; Air
20 Piston, Brake 91-1 Cap
21 Spring, Brake * Seal Kit; Swing Motor
*; 2, 18, 19, 26

8-3-7
Swing Reduction Gear
600
608 602
708
607 802
606
604
601 605
603 801
606
510
504
702
511
509 505
512
508
700 501
704
511
705
503
707
706
701 506
703
706
507
502
EX1401270
Figure 4

8-3-8
Reference Reference
Number Number
501 Case, Gear 604 Ring, Inner
502 Shaft, Pinion 605 Bearing, Needle
503 Bearing, Roller; Spherical 606 Washer, Thrust; No.1
504 Bearing, Roller; Spherical 607 Plate; Thrust
505 Seal, Oil 608 Screw
506 Cover 700 Carrier Assy; No.2
507 Screw 701 Carrier; No.2
508 Washer, Thrust; No.3 702 Gear, Sun; No.2
509 Bolt, Hex 703 Gear, Planetary; No.2
510 Plug; PT 704 Pin; No.2
511 Plug 705 Bushing
512 Pin, Parallel 706 Washer, Thrust; No.2
600 Carrier Assy; No.1 707 Pin, Spring
601 Carrier; No.1 708 Washer, Thrust
602 Gear, Sun; No.1 801 Gear, Ring
603 Gear, Planetary; No.1 802 Bolt, Socket

8-3-9
Swing Device
35
28
37
30
EX1401271
Figure 5
Reference Reference
Number Number
28 Level Gauge Assembly 35 Air Breather Assembly
30 Pinion Gear 37 Swing Motor Socket Bolt

8-3-10
Theory of Operation
Hydraulic Motor
As shown in the figure below, the high-pressure oil entering the
cylinder block through valve plate (1) inlet side port exerts
pressure on the piston, generating axial force F. The force F is
divided into the two vectors of force F1 which is perpendicular to
the swash plate (3) and F2 which is perpendicular to the shaft,
with the shoe (2) as the medium. With the piston and the
medium, the force F2 is transmitted to the cylinder block (4) and
generates rotational torque to the output shaft. On the cylinder
block, 9 pistons are arranged equidistantly, and rotational torque
is transmitted to the output shaft by the multiple pistons
connected to the inlet side of the high-pressure oil in
consequences.
Reversing the direction of oil flow will reverse the direction of
rotation of the output shaft.
Theoretical output torque T is calculated with the formula below;
P×q
T=
2×
P: effective differential pressure (kg/cm2)

q: volume per rotation (cc/rev)
Low Press. Oil High Press. Oil

Shoe Plate (3) Valve Plate (1)
Outlet Port Inlet Port
Shoe (2) Piston Cylinder Block (4)

FG018896
Figure 6 Operation Diagram of Motor

8-3-11
Valve Casing
1. Anticavitation check valve
Since the system using this type of motor has no valve
which has counterbalance function, the motor may rotate
exceeding the feed oil flow.
To prevent cavitation, suck in deficient oil through the
check valve.
Control Valve Control Valve
EX1301686
Figure 7
2. Relief valve
Lets assume that port P is pressurized from the tank
pressure. Initially, ports P and R are at tank pressure.
321 302 h g
R Port
P Port
A1 m 301 A2 n 401
EX1301621
Figure 8
When the two forces; the force defined by the product of

the area (A1) of plunger (301) receiving pressure and
pressure P1; and the force defined by the product of spring
(321) force (Fsp) and pressure-receiving area (A2) of
plunger (301) by the pressure Pg in the chamber g;
become the same, the relief valve starts to function.

8-3-12
Here, the Pg is the pressure in the chamber g which is
pressurized by the oil through the orifice m, and when it
reaches the pressure defined by the spring (321) pressing
the piston (302), the piston starts to move to the left.
P1 x A1 = Fsp + Pg x A2
Fsp + Pg x A2
P1 =
A1
321 g
R Port
P Port
A1 301 A2
Figure 9 EX1301687
3. Chamber h acts as a damping chamber by the orifice (n)

formed on the side of the piston (302).
By this, the pressure in the chamber g increases smoothly
until piston (302) reaches the end of the adjustment plug
(401).
321 302 h g
R Port
P Port
n 401
Figure 10 EX1301688

8-3-13
When the piston (302) reaches the end of the adjustment
plug (401), it cannot move further to the left, thus, the
pressure in chamber g becomes equal to Ps and the force
of the spring (321) becomes Fsp' (Figure 11).
Consequently, the pressure P varies as illustrated in
(Figure 11).
The pressure Ps at the final stage is expressed with the
equation below;
Ps x A1 = Fsp' + Ps x A2
Fsp'
Ps =
A1 - A2
302 g
R Port
P Port
Pressure: Ps 401
Pressure
Ps
P1
Time
Operational Diagram
EX1301689
Figure 11 Relief Valve

8-3-14
4. Reactionless valve
When the direction switching valve of swing motor I
switched, high-pressure oil is supplied to the port A (or port
B) of the hydraulic motor. Then, the poppet of the
reactionless valve moves to the right, blocks the bypass
route and drives the rotating body (1, Figure 12).
Then, when the direction switching valve returns to neutral
position, the ports at both sides of the hydraulic motor are
blocked, but the rotating body would maintain its rotation
because of inertia and the momentum of inertia is
transmitted to the hydraulic motor through the reduction
gear, generating brake pressure at the port B (or port A)
which stops the rotating body and tries to reverse the
direction of rotation.
By this brake pressure, the swing motor first stops and
then tries to reverse its direction of rotation and the
pressure at the port B tries to switch the poppet to the left,
but the action is delayed by the orifice at the port A. Now, a
bypass route is formed connecting the ports A and B
through which the high-pressure oil flows from port B to the
port A (2, Figure 12).
And, the poppet on the port B side moves to the left until it
blocks the bypass route (3, Figure 12).
As described above, in the process of reverse pressure
generation at the port B, the high-pressure oil is bypassed
to the port A to prevent reverse rotation and stop the swing
motor right away.
Motor Inlet
A Port Bypass Motor Outlet
B Port
(1)
Orifice Poppet Bypass
(2)
(3)
EX1301726
Figure 12 Principle of Operation of Reactionless Valve

8-3-15
Schematic of Operation of Reactionless Valve
1st 2nd

A B A B
Swing Swing Stop (Start of Stop)
3rd 4th
By Pass
A B A B
Swing Stop (before the Stop) Swing Stop (Complete of Stop)
EX1301690
Figure 13

8-3-16
Brake Part
The cylinder block (108) is connected with the driveshaft (102)
by spline joint, and rotation of the separation plate (110) in
circumferential direction is restricted by the circular arc grooved
on the casing (115). When the friction plate (109), engaged with
the outer circumference of the cylinder with gears, is pressed to
the casing (115) by the brake spring (118) with the separation
plate (110) and brake piston (119) as the media. Friction force is
generated between the friction plate and casing, separation
plate and brake piston. This friction force restricts and brakes
the driveshaft.
When brake release pressure is applied to the oil chamber
formed between the brake piston and casing and this pressure
overcomes the spring force, the brake piston moves and the
friction plate is separated from the casing, and the brake is
released.
Oil Pressure
Spring Force
118
119
Oil Chamber
Valve Casing
110
109 108
102
EX1401272
Figure 14 Operation Diagram of Brake

8-3-17
1. Parking brake operating
Parking Brake Spring
Parking Brake Piston

SH
Oil Chamber
PG
Separation Plate PG DB
Friction Plate
SH
EX1401273
Figure 15
2. Parking brake release
Parking Brake Spring
Parking Brake Piston

SH
Oil Chamber
PG
Separation Plate PG DB
Friction Plate
SH
EX1401274
Figure 16

8-3-18
CAUTIONS FOR OPERATION
Inspection
Please check the followings before installing a new motor:
1. Check if there is any part damaged or missing (during
transportation).
2. Check if there is any loose joint.
3. Check that flange surfaces and the drain port cover are
properly assembled and there is no dust or other particle in
the motor.
Direction of Rotation
The relationship between the directions of oil flow and shaft
rotation is presented in Figure 17 and Table.
The direction of rotation differs by the direction of the slope of
casing.
Be careful for the direction of swing which is differentiated by the
shape of casing and direction of flange.
Normal Direction Reverse Direction

EX1401275
Figure 17
Direction of the Rotation of the

Classification Inlet Outlet Shaft Seen at the End of the
Shaft
Normal Direction A B Right (Clockwise)
Reverse Direction B A Left (Counterclockwise)

8-3-19
External Load at the End of Shaft
In principle, the end of the motor shaft must be free of any
external radial or thrust load.
Hydraulic Oil and Temperature Range

1. Oil type
The recommended oil is mineral type hydraulic oil added
with extreme pressure additive, foam suppressor,
antioxidant, and desiccant, having high viscosity index.
2. Optimal viscosity and temperature range of hydraulic oil
(Figure 18)
Maximum viscosity range is 10 - 1000 cSt, however,
recommended range is 10 - 200 cSt to obtain optimal
efficiency.
Temperature range is restricted between -25 - 100°C to
protect oil seals and O-rings. The highest recommended
temperature is 60°C or lower to prevent degeneration of
the oil and seals.
Higher Limits of Viscosity

1000
750
500
400
300 Higher Temperature Limit

200
Low Temperature Limit
150
100
75
Viscosity in cSt
50
40
Optimum Working Range
30
25
20
15
10
9 Low Viscosity Limit
8
7
6
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 C
-20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 F FG018906
Figure 18 Optimum Viscosity and Temperature Range
3. Other types of oils than mineral oils

Please contact us to use phosphoric acid ester,
water-glycol, or fatty acid ester oils.

8-3-20
Filter
Dust or metal particles in hydraulic oil accelerate wear of sliding
surfaces or can cause sticking. Install 10 m filter in the oil
circuit to remove particles from the oil.
Regarding contamination, NAS Class 9 or lower or 2 - 4 mg/
100 cc in Millipore Filter contamination rating is recommended.
Installation and Piping

1. In principle, the motor shaft should face downward.
2. The deviation of centerline from the driven part must be
0.05 mm or less.
3. The tightening torque of the bolts used in mounting the
motor to bracket must be according to the specifications on
the outline drawings.
4. The casing must be always filled with oil.
The position of the oil drain of the motor must be as shown
in (Figure 19) to allow the casing be full of oil.
5. The maximum allowable pressure in the casing is 3 kg/
cm2, however, 2 kg/cm2 or less is recommended.
6. Clean the pipeline and perform flushing. EX1401278
Figure 19
7. Avoid excessive force at pipe joints.
8. Drain pipe must be the same or larger than the port size of
the motor, and as short as possible.

8-3-21
Oil Filling and Air Ventilation
1. Starting operation, fill the casing with oil through drain port.
In the hydraulic motor, there are high-speed sliding motion
parts, such as bearing, piston, shoe and spherical bushing.
If oil is not fully filled, these sliding parts can cause sticking
or damage.
2. Air inside the hydraulic oil circuit or motor can cause Air Breather Port
malfunction or damage, thus, must be removed
completely.
Instructions before Starting to Operate

1. Check if there is any loose joint or other trouble in the DS1704266
pipeline. Figure 20
2. Check that direction of rotation is correct.
3. Check oil leaks from the hydraulic motor.
4. Check if abnormal vibration occurs during rotation or
operating direction switching valve.
5. Check if the oil temperature rise too fast.
6. Check that actual pressure is about the same as the
setting value.

8-3-22
PRECAUTION
Tools for Disassembly and Assembly

Tables 1 and 2 and Figure 21 presents the tools required for
disassembly and reassembly. Since different bolts and plugs are
used in different types, check and prepare necessary tools.
Table 1
Reference 2-face Application Tightening Torque

Name Size Tool
No. Width Part (kg.cm)
26,28 Plug M36 10 RO Plug 2,450 ±250 L Wrench
30 Plug PF 1/4" 19 VP Plug 370 ±20 Hex Wrench
31 Hex Socket Head Bolt M20 17 Valve Casing 4,400 ±660 L Wrench
32 Relief Valve M30 41 Relief Valve 1,800 ±100 Socket Wrench
51 Bolt M6 10 Brake Valve 120 ±20 Hex Wrench
509 Hex Bolt M16 24 Pinion Shaft 2,850 ±300 Socket Wrench
510 Plug PT 1/2" PT Plug 660 ±50
511 Plug PT 1/4" PT Plug -
Table 2
Specification
Size
Tools
for stop ring For ø55 shaft
Pliers For ø100 hole
for lock ring
For ø58 hole
Driver Flat tip, 2 pcs.
Steel Rod 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

8-3-23
2Xo9
2Xo7
40
M10
(effective screw for length : 20)
100
250
o10
M10
M10
123
205
240
FG021248
Figure 21 Tools for Brake Piston Disassembly

8-3-24
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.
1. Park the machine on flat level ground.

2. Extend the boom and arm, as shown in Figure 22 and
lower the boom until the attachment is 10 cm above the
ground.
3. Stop the engine.
10 cm
EX1301631
Figure 22

8-3-25
(Figure 23) I
WARNING OFF
Lock
OFF
ON
ON

switch.
ON
OFF
ON
DS1704238
Figure 24

3
5 8
1 2
7 6
4
EX1401809
Figure 25

8-3-26
WARNING
any work.
Figure 26 DS1601105
environment.
EX1504170
Figure 27

8-3-27
13. Remove hoses and adapters from the swing device.
NOTE: Attach identification tags on the removed hoses for reassembly. Disconnect the hoses in order
from bottom to top of oil tank. After the hoses are disconnected, plug and cap them to prevent dirt
or dust from entering.
DB
C DB
B
N
B PG
PG
C Sgr
A
A SH
SH
DS1800085
Figure 28
Plug/Flange Size| Torque

Port Name
SAE 3/4", D20,
A from Control Valve "B2" 8 63.7 6.5 47.0
SAE 1", D25
SAE 3/4", D20,
B from Control Valve "A2" 8 63.7 6.5 47.0
SAE 1", D25
DB to Oil Tank PF 1/2" 27 93.1 9.5 68.7
C from Control Valve "T2" PF 1 1/4" 50 343.0 35.0 253.1
PG from Control Valve "PP" PF 1/4" 19 39.2 4.0 28.9
SH from Control Valve "PA" PF 1/4" 19 39.2 4.0 28.9
Sgr Lubrication Hose PF 1/4" 19 39.2 4.0 28.9
N Nut PF 1/2" 27 93.1 9.5 68.7
• Fitting
Size Torque
Port Name
C Adapter PF 1" PF 1 1/4" 50 205.8 21.0 151.8
DB Elbow PF 1/2" PF 1/2" 27 93.1 9.5 68.7
Elbow PF 1/4" PF 1/4" 17 39.2 4.0 28.9
PG
Tee PF 1/4" PF 1/4" 19 39.2 4.0 28.9
Adapter PF 1/4" PF 1/4" 19 39.2 4.0 28.9
SH
Tee PF 1/4" PF 1/4" 19 39.2 4.0 28.9
Sgr Adapter PT 1/4" PF 1/4" 19 19.6 2.0 14.5
DS2856002
DS2856002 (3/4", ID:25.3, OD:32.3, 1B),
A, B
(3/4", ID:25.3, OD:32.3, 1B) DS2856003
O-ring (1", ID:33.2, OD:40.2, 1B)
C S8000291 (1B P29)
DB S8000185 (4D P18)
PG, SH S8000115 (4D P11)

8-3-28
14. Install the eyebolts (M10 x 1.5, DP18) (Figure 29).
15. Attach a nylon sling onto the eyebolt.
Figure 29 DS1800086
16. Remove bolts and washers (1, Figure 30) (2 x 13 ea).
• Tool: 30 mm ( )
• Torque: 539 N.m (55 kg.m, 397.7 ft lb)
17. Remove plugs (2, Figure 30) (2 x 2 ea).
18. Install the back bolt to the plug position to ensure that
frame and swing device can be separated.
1
1
19. Hoist and remove swing device from the frame.
2
NOTE: When hoisting the swing device, a part of swing 1
device can come in touch with the main frame. Figure 30 2 DS1800087
While hoisting the swing device, push towards
the front side.
20. Wind wire rope around the swing device, lift it up with a
crane and wash with flushing oil.
After washing, dry with compressed air.
• Weight: about 2 x 250 kg (2 x 551 lb)
DS1800088
Figure 31

8-3-29
INSTALLATION
WARNING
SERIOUS INJURY

2. When installing the hoses, install the drain hose first.
3. When installing the swing device, slightly move the end of
bucket to align it with the swing bearing gear if the swing
device does not fit the gear.
• Gear oil volume: 2 x 5 L
COMPLETING WORK
IMPORTANT
If the air is not vented from the system, it will cause damage
to the swing motor and bearings.
NOTE: Perform this only when oil has been drained from
swing motor.
DS1800089
1. Stop engine. Figure 32
2. Disconnect drain hose and fill swing motor case with
hydraulic oil.
3. Connect the drain hose.
4. Start engine and set throttle at "LOW IDLE" and swing
upper structure slowly two full revolutions to the left and
right.
5. Stop engine and check hydraulic oil level. Fill hydraulic oil
tank to "H" mark on sight gauge.
6. Check for leaks and clean all fill and venting locations.

8-3-30
DISASSEMBLY AND REASSEMBLY
Disassemble Swing Motor

Please use the following procedures for the inspection and
repair of the motor.
Numbers given in parentheses the following the parts names
indicate the parts number shown by the drawing in the
instruction and maintenance manual.
1. Completely remove dirt and dust adhering to the outside.
Discharge all hydraulic fluid in the motor casing and the
port oil passage.
Use a clean, dust-free work area.
Handle parts with care to prevent dirt and dust from
adhering.
Do not over - disassemble.
2. Separate swing device, air bleeder assembly and level
gauge assembly.
Air Breather
FG024710
Figure 33
3. Remove bolts and motor from swing reduction case.

The motor must be separated without damage or any
foreign substance.
FG024738
Figure 34

8-3-31
4. Wind the wire rope around the outside of the motor, Lift up
the motor, and clean the motor with cleaning oil. After 101
cleaning, dry with compressed air.
5. Drain the oil out of the casing (101).
6. Mount a motor on a suitable table for the driveshaft below.
Before disassembling make a match mark on motor casing
(301) and valve casing (101).
301
FG024736
Figure 35
7. Separate the brake valve (400).
400 115
FG024745
Figure 36
8. Remove relief valve (107) from the casing (101).
107
101
FG024746
Figure 37
9. Separate the plug (102) from the valve casing (101) and
disassemble the spring (103) and the plunger (104).
101
102 104
103
FG024739
Figure 38

8-3-32
10. Disassemble the S/R V/V assembly (105) from the valve
casing (101).
105 101
FG024740
Figure 39
11. Loosen and remove hexagon socket head cap bolts (109,
110) from the valve casing (101). 109
NOTE: Upon removing the bolts with the force of the

brake spring (310), the valve casing is 101
separated from the casing automatically.)
Separate the valve plate (213) from the valve casing (101).
310
FG024744
Figure 40
12. Remove brake spring (310) from the brake piston (309).
310
309
FG024747
Figure 41
13. Use a tool to remove brake piston (309) from the casing.
To use a hole of bolt, pull it upward straight.
309
301
FG024748
Figure 42

8-3-33
14. Put the motor horizontally and separate the cylinder block
(205) from the driving shaft (201).
Then, remove piston assemblies (203, 204), the retainer
(207), the thrust ball (206), and the collar roller (209). Care
must be taken when taking out the cylinder block (205), as 201
it can fall off. Also sliding parts of the cylinder block, the
thrust ball, shoes, etc. should not be damaged.
NOTE: Do not remove 2 washers (210), the spring
(211), and the retaining ring (212). 205
FG024749
Figure 43
15. Separate 2 friction plates (306) and 3 separation plates

(305) from the casing (301). 305
306
FG024750
Figure 44
16. Use a plastic hammer to tap the face of the casing shaft to
disassemble the driving shaft (201) consisting of the swash
303
plate (202) and the ball bearing (303). Care must be taken
not to damage sliding parts of the oil seal when separating 201
the driving shaft from the casing.
FG024751
Figure 45
17. Perform the following procedures as necessary.

1) Remove parallel pin (304) from the casing. 304
FG024753
Figure 46

8-3-34
2) Remove ball bearing (303) from the driving shaft
(201). Do not reuse the removed bearing. Press
Drive Shaft
Ball Bearing
Hang bearing inner

race on the base
of press.
FG024770
Figure 47
3) Use a tool to separate from the casing (301) the oil

seal (302), which should not be reused. PRESS Oil Seal
Rod Casing
FG022415
Figure 48
4) Remove ball bearing (108) and timing plate (213)

from the valve casing. 108
Now, disassembly is done.
213
Check every component carefully to see if there are any defects.
FG024752
Figure 49

8-3-35
Reassemble Swing Motor
Assembly must be done in the reverse order of disassembly
described above, taking into consideration the following points:
1) Parts damaged during disassembly must be repaired
without fail and spare parts must be prepared in
advance.
2) Every part must be cleaned well with cleaning oil and
dried with compressed air before starting assembly.
3) Sliding parts and bearings must be applied clean
active oil before their assembly.
4) Seal parts like O-rings and the oil seals must be
replaced according to the standards.
5) Use a torque wrench to tighten or engage bolts and
plugs according to reference "Tools for Disassembly
and Assembly" on page-23.
1. Put the casing (301) on a proper place.
301
FG024754
Figure 50
2. This procedure is necessary when the oil seal is separated

from the casing. 302
Use a tool to insert the oil seal (302) in the casing (301).
NOTE: Be careful to note the direction of oil seal and
insert until fully seated in the casing. 301
IMPORTANT
Do not reuse oil seal! FG024759
Figure 51

8-3-36
3. This procedure is necessary when the ball bearing was
separated from the driveshaft.
Install the ball bearing (303) in the driveshaft (201) by
shrinkage fitting.
201
303
FG024760
Figure 52
4. Insert the driving shaft (201) with the ball bearing (303) in
the casing (301) with its output shaft facing upward and
use a hammer to tap the surface of the ball bearing into the 201
casing. At this point, apply grease to the lip of the oil seal
lightly and then insert it carefully so it can not be damaged.
303
NOTE: Wrap a tape around the spline of the driving
shaft to prevent the damage of the spline
because of the lip.
Tap the surface of the external circumference
evenly until it reaches the end completely.
FG024761
Figure 53
5. This procedure is necessary when the parallel pin was

removed from the casing. 304
Insert the parallel pin (304) in the casing (301).
301
FG024762
Figure 54

8-3-37
6. Assemble the swash plate (202) in the casing (301).
NOTE: It is easy to assembly when the casing is put 301
horizontally.
202
FG024763
Figure 55
7. Insert the roller (209) in the cylinder block (205).

209
NOTE: Check if the cylinder block has the washer
(210), the spring (211),and the retaining ring
(212).
Sliding parts of the cylinder block should not be
damaged.
205
FG022420
Figure 56
8. Assemble the collar (208) and the thrust ball (206) in

cylinder block (205).
206
208
205 FG022421
Figure 57
9. Assemble the piston assembly (203, 204) assembled in the

203,204
retainer (207) in the cylinder block (205).
207
205
FG022422
Figure 58

8-3-38
10. Assemble the cylinder block (205) in the driving shaft
(201). At this point, arrange phases of the thrust ball and
the cylinder block so it can be inserted on the driving shaft
more easily.
201
205
FG024749
Figure 59
11. Insert the separation plate (305) and then the friction plate
(306) in the casing (301). 3 separation plates and 2 friction 305
plates shall be assembled. 306
NOTE: To assemble them, the friction should have the
same phase for its parts where 4 gears are cut
face up and down, and so does the separation
plate for its parts where 4 jaws are cut.
301
FG024764
Figure 60
12. Insert the O-rings (307, 308) in the casing (301).

308
NOTE: Apply grease to the O-rings light to prevent their
breakage when inserting them in the brake 307
piston.
301
FG024765
Figure 61
13. Assemble the brake piston in the casing (301). If does not
inserted well because of the resistance of the O-ring,
engage a hex M8 bolt to the brake piston and use a plastic
hammer to tap its surface evenly.
309
301
FG024748
Figure 62

8-3-39
14. Assemble the brake spring (310) in the brake piston (309).
Make sure that spring take the seat of the brake piston 310
firmly.
309
FG024747
Figure 63
15. This procedure is necessary when the ball bearing (108)

was disassembled.
108
Use a hammer tied to a steel bar to tap the surface of the
ball bearing into the valve casing (101).
101
FG024766
Figure 64
16. Assemble the valve plate (213) in the valve casing (101)
and insert the O-ring (112). Apply grease to the ngaging 213
part of the valve plate light (to prevent its falling off).
101
112
FG024767
Figure 65
17. Mount the valve casing (101) on the casing (301) and
connect them with hex socket head cap bolts (109). 109
Pay attention to the mounting direction of the valve casing

(and its external measures). 101
Care must be taken not to have the valve plate fall off and
the brake spring fall down. Tighten hex socket head cap
bolts uniformly.
301
FG024768
Figure 66

8-3-40
18. Insert the plunger (104) and the spring (103) in the valve
casing (101) and engage the plug (102) with the O-ring
(106) to the valve casing (101). Make sure that plunger
moves smooth.
101
102 104
103
FG024739
Figure 67
19. Assemble the S/R V/V assembly (105) in the valve casing
(101). Check the spring in the S/R V/V assembly.
105 101
FG024740
Figure 68
20. Apply grease to O-ring on the relief valve (107) and insert it
in the valve casing (101).
107
101
FG024746
Figure 69
21. Use hex socket head cap bolts(115) to connect the brake
valve (400) and the casing (301).
400 115
FG024745
Figure 70

8-3-41
22. The assembly is completed.
FG024769
Figure 71
Disassemble the Reduction Gear

Please use the following procedures for the inspection and
repair of the reduction gear.
Numbers given in parentheses the following the parts names
indicate the part number shown by the drawing in the instruction
and maintenance manual.
1. Wind the wire rope around the outside of the reduction
gear. Lift it up with a crane and clean the reduction gear
with cleaning oil. After cleaning, dry with compressed air.
2. Remove PT plug (510) and drain out gear oil.
510
FG024737
Figure 72
3. Remove No. 1 sun gear (602) from No. 1 carrier

subassembly. 602
No. 1 Carrier
FG024735
Figure 73

8-3-42
4. Remove No. 1 carrier subassembly.
No. 1 Carrier
sub - assembly
FG024713
Figure 74
5. Remove No. 2 sun gear (702) from No. 2 carrier

subassembly.
702
FG024714
Figure 75
6. Remove bolt (509) in No. 2 carrier.
509
FG024715
Figure 76
7. Remove No.2 carrier subassembly from ring gear.

Carrier No. 2
Sub-assembly
FG024716
Figure 77

8-3-43
8. Remove bolt (314) in ring gear.
314
FG024717
Figure 78
9. Remove ring gear (801) from casing (501).

801
501
FG024734
Figure 79
10. Remove pins (512) from casing (501).

512
501
FG024719
Figure 80
11. Remove bolts (507) from casing (501).
501
507
FG024733
Figure 81

8-3-44
12. Use a rollover machine to turn case over and place a jig on
JIG
driveshaft. Use a press to remove pinion shaft from case 501
(501).
FG022457
Figure 82
13. Remove bearing (504) from case (501). 50
FG022458
Figure 83
14. Remove pinion shaft (502) from casing.
502
FG024732
Figure 84
15. Remove oil seal (505).

505
IMPORTANT
Do not reuse oil seal!
Disassembling is finished, check each component thoroughly.
FG024731
Figure 85

8-3-45
Reassemble the Reduction Gear
Assembly must be done in the reverse order of disassembly
described above, taking into consideration the following points:
1) Parts damaged during disassembly must be repaired
without fail and spare parts must be prepared in
advance.
2) Every part must be cleaned well with cleaning oil and
3) Sliding parts and bearings must be applied clean
hydraulic oil before their assembly.
4) Seal parts of the O-ring and the oil seal must be
replaced according to the standards.
5) Use a torque wrench to tighten or engage bolts and
plugs in according to "Tools for Disassembly and
Assembly" on page-23.
1. Install the bearing cover (506) and the taper roller bearing
(503) on the pinion shaft (502).
503
506
502
FG022461
Figure 86
2. Install the pinion shaft (502) and other associated parts.
IMPORTANT
Before assembling the pinion shaft, etc.
501
Apply grease slightly on the lip surface to prevent any
scratch when installing.
502
FG024730
Figure 87

8-3-46
3. Tighten screws (507) to assemble cover (506).
506
507
FG024729
Figure 88
4. Mount a casing (501) on a suitable work table or jig.
501
FG024728
Figure 89
5. Press to insert oil seal (505) into casing (501) by using

pressing jig after spreading grease oil around the outside 505
ring of the oil seal.
IMPORTANT
501
Do not reuse oil seal!
FG024727
Figure 90
6. Install the taper roller bearing (504) with a using of tool.

504
501
FG024720
Figure 91

8-3-47
7. Assemble pins (512) with casing (501).
512
501
FG024719
Figure 92
8. Apply sealant evenly to ring gear assembly of casing.
FG022467
Figure 93
9. Lift ring gear (801) with hoist, wipe its mating surface clean
with cloth, match and align holes after checking its 801
assembling direction.
FG024718
Figure 94
10. Press assembled parts firmly by tightening special bolts

(802) on which no Loctite has been applied.
802
EX1402255
Figure 95

8-3-48
11. Assemble bushing (705) and the washer (706) onto planet
gear No.2 (703) and arrange it on the pinhole of the carrier 706
No.2.
705
703
706
EX1402253
Figure 96
12. Turn over gear assembly (703, 705, 706) and insert it and
thrust washer (508) into No. 2 carrier.
704
Align bushing hole with carrier holes.
NOTE: Thrust washer (606) must be on both sides of
508
gear.
Align spring pinhole in pin No.2 (704) with spring pinhole of
No. 2 carrier.
703
Insert no.2 pin (704) into carrier and No. 2 bushing.
NOTE: Pin No.2 can be gently tapped with a soft faced 707 EX1402256
hammer. Figure 97
After all four No.2 pin (704) are installed, align spring pin
(707) with carrier hole and drive it into position using a
hammer.
13. Using a suitable lifting device, lower No. 2 carrier
subassembly into ring gear, making sure that planetary Carrier No. 2
Sub-assembly
gears are engaged. Continue to lower carrier and engaging
it onto splines of pinion shaft.
Make sure that carrier is resting on bearing.
NOTE: Make sure that carrier and driveshaft can rotate.
FG024716
Figure 98
14. After tightening the bolt (509), to attach carrier assembly 2

and use a torque wrench to tighten it up to the standard
509
torque.
• Tool: 24 mm ( )
• Torque : 279.5 N.m (28.5 kg.m, 206 ft lb)
FG024715
Figure 99

8-3-49
15. Install No. 2 sun gear (702) in No. 2 carrier.
702
FG024714
Figure 100
16. Assemble the following parts on the carrier No.1.

606
Reference 603
Description
Number 605
502 Thrust Washer 604
603 Planet Gear 606
604 Innerring
502
605 Needle Bearing
606 Thrust Washer No.1
FG022471
Figure 101
17. Assemble the following parts.

608
Reference
Description
Number
607 Thrust Plate
608 Screw
607
FG022472
Figure 102
18. Install the carrier No.1 subassembly. Lift the carrier No.1
subassembly and turn it clockwise or counterclockwise No. 1 Carrier
gently for it to engage with the spline of the No.2 sun gear sub - assembly
(702) and the ring gear (801).
FG024713
Figure 103

8-3-50
19. Install No. 1 sun gear (602) in No. 1 carrier.
602
FG024712
Figure 104
20. Use a hoist to lift the prepared motor, wipe out the
assembly, and install the retaining ring (214) on the shaft
(201).
201
214 FG024711
Figure 105
21. Apply sealant evenly to ring gear assembly of motor.
FG022475
Figure 106
22. Put the motor on the reduction gear carefully as shown in

the figure.
The level gauge port and hole in the ring gear must be
alligned.
Assemble the motor by turning it clockwise or Lavel
counterclockwise gently so splines of the shaft shall be guage
engaged with the No.1 sun gear. port
FG024709
Figure 107

8-3-51
23. Apply Loctite to 16 socket bolts (314).
314
FG022498
Figure 108
24. Insert bolt (314) into holes,and tighten with an impact

wrench.
314
FG024708
Figure 109
25. Engage the level gauge pipe sealed with teflon tape to the
level gauge port of the port with a pipe wrench.
Install air breather assembly to motor. Air Breather
After filling with oil, stick the level gauge into tank and
check the oil level.
Assembly is done.
FG024710
Figure 110

8-3-52
TROUBLESHOOTING
General Instructions
This section provides the corrective actions against any
abnormality identified during hydraulic motor operation.
General instructions are as follows:
1. Think before taking action
Before taking any action, examine the characteristics of the
problem, and if there had been similar trouble before.
In addition, examine once again that cause of the problem
is the hydraulic motor.
2. Take care of foreign material
Foreign materials cause abnormal friction and wear. Take
care to avoid foreign materials during disassembly and
reassembly.
3. Parts handling
All the parts are precisely ground, thus, take utmost care
not to damage.
4. Take care not to damage O-rings and gasket surfaces.
It is highly recommended to replace with new O-rings after
disassembly.
Examination of Hydraulic Motor

It is very difficult to find out the cause of trouble in hydraulic oil circuit.
Check the items listed below, and examine the cause of the
hydraulic motor.
1. Check oil quality in the casing
Remove drain plug and check the oil in the casing.
If the oil contains many metal particles, the cause of
trouble can be a part in the hydraulic motor.
2. Abnormal noise
Check if the motor makes abnormal noise.
3. Pressure measurement of each parts
Before disassembly and inspection, measure the pressure
of each parts and examine the problem.
4. Measure the drain quantity of the motor
1) Lock the swing and supply high-pressure oil to the
motor, and normal drain quantity must be
approximately 25 LPM or less.
2) Normal drain quantity in normal swiveling must be 2
LPM of less.

8-3-53
Troubleshooting
1. Hydraulic motor fails to rotate
Symptom Possible Cause Corrective Action

Pressure does not rise 1. The setting of the relief 1. Set up with correct value
valve in the circuit is 
incorrect.
2. Relief valve malfunction. 2.
1) Plunger sticks 1) Plunger sticks
2) Plunger orifice 2) Plunger orifice
clogged. clogged.
3. Plunger seat failure 3. Check the seat and replace
it if damaged.
Pressure rises up to normal level 1. Overloaded. 1. Remove load.
2. Sticking of moving parts 2. Check/repair piston, shoe,
 cylinder block, and valve
plate.
3. Brake release pressure is 3.
not applied.
1) Check/repair the

circuit.

 2) Check the brake
switching valve.
4. Brake piston is sticking. 4. Disassemble and check
5. Friction plate is sticking. 5. Disassemble and check
Replace the sticking part.
2. The direction of rotation is reverse.

Direction of rotation is reverse 1. Motor rotates in reverse 1. Referring to Figure 12,
direction. assemble correctly.
2. The inlet and outlet of 2. Correct the pipeline.
pipeline are reverse.

8-3-54
3. Rotating speed fails to reach setting value.

Rotating speed fails to reach 1. Insufficient incoming flow. 1. Check pump discharge
setting value rate, circuit to the motor.
2. Temperature is too high 2. Reduce the oil
and oil leaks too much. temperature.
3. Wear of damaged of sliding 3. Replace the damaged part.
parts
4. Insufficient brake torque

Insufficient brake torque 1. Friction plate is worn. 1. Disassemble and check.
 Replace the part if
excessively worn.
2. Brake piston is sticking 2. Disassemble and check
3. Brake release pressure 3.
cannot be removed.
1) Check/repair the

circuit.

 2) Check the brake
switching valve.
4. The spline of the friction 4. Disassemble and check
plate is damaged.
Replace the damaged part
5. Hydraulic motor slips excessively

Check the drain quantity of the motor.
Normal drain rate is 500 cc/min.

Excessive slip when external 1. Relief valve malfunction. 1. Same as subclause 1).
torque to drive the hydraulic
Same as subclause 1).
motor is applied.
2. Bad plunger seat 2. Replace the damaged part.

8-3-55
6. Oil leak
1) Leak at oil seal

Leak at oil seal 1. The lip is damaged by dust. 1. Replace the oil seal.
2. Worn or damaged shaft. 2. Change the relative
 position of the lip and shaft,
or replace the lip.
3. Oil seal lip is overturned 3. Repair clogged pipeline.
because of excessively 
high-pressure in the casing.
4. Rusted shaft. 4. Disassemble and correct it.
2) Oil leak at joint surface

Oil leak at joint surface 1. O-ring is missing. 1. Insert correctly and
reassemble
2. O-ring is damaged. 2. Replace.
3. Seal surface is damaged. 3. Disassemble and correct it
4. Loose or damaged bolt. 4. Tighten at specified torque
or replace the bolt

8-3-56
MAINTENANCE INSTRUCTIONS
Replacement Standard of Worn Parts

When a part is worn exceeding the criteria below, adjust or
replace the part. However, the criteria for parts with distinct
damage are not defined.
Standard Size Replacement

Item Corrective Action
(mm) Criteria (mm)
Clearance between the piston and Replace the piston or
0.025 0.055
cylinder block cylinder block
Clearance between the piston and Replace the piston or
0.05 0.2
shoe compressed part () shoe assembly
Replace the piston or
Shoe thickness (t) 4.5 4.3
shoe assembly
Assembled height of the retainer Replace the retainer and
10.8 10.3
plate and spherical bushing (H-h) spherical bushing set
Friction plate thickness 3.5 3.1 Replace
h
H
Ⱦ
Clearance between the piston and the shoe ( ) Height of the assembled retainer plate
Figure 111 Thickness of shoe (t) and the thrust ball (H-h)
EX1401279
Standard of Sliding Surface Correction

Correct or replace the part whose surface roughness of the
sliding face exceeds the following criteria.
Part Name Standard Roughness Roughness Requiring Correction

Shoe 0.8 - Z (Ra = 0.2) (Lapping) 3 - Z (Ra = 0.8)
Shoe Plate 0.4 - Z (Ra = 0.1) (Lapping) 3 - Z (Ra = 0.8)
Cylinder 1.6 - Z (Ra = 0.4) (Lapping) 12.5 - Z (Ra = 3.2)
Valve Plate 0.8 - Z (Ra = 0.2) (Lapping) 6.3 - Z (Ra = 1.6)
NOTE: 1)All the sliding surfaces must be lapped to make

the roughness below the standard roughness.
2)
NOTE: If the sliding surfaces of the retainer or
spherical bushing are excessively rough,
replace the parts by set unit.

8-3-57
8-3-58
1Joystick Valve
(Work Lever)
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Joystick Valve (Work Lever)

8-4-1
Table of Contents
Joystick Valve (Work Lever)

General ...........................................................8-4-3
Specifications ............................................................ 8-4-3
Overview ................................................................... 8-4-4
Parts List ................................................................... 8-4-6
Theory of Operation .................................................. 8-4-8
Tools and Torques .................................................... 8-4-9
Section View .................................................8-4-10
Removal........................................................8-4-12
Installation.....................................................8-4-18
Completing work ...........................................8-4-18
Disassembly .................................................8-4-19
Reassembly ..................................................8-4-23
Joystick Valve (Work Lever) DX480LCA-K/DX520LCA-K

8-4-2
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)
Internal Leakage Oil Temperature Range -20 ~ 90°C (-4 ~ 194°F)
Neutrality Max. 300 cc/min
At Work (14.7 bar (15 kg/cm , 213.3 psi) 2 Max. 500 cc/min
Performance
40
Secondary Pressure (kg/cm2)
Operating Torque (kg.cm)

28 1
Single Operating Torque
(17.6)
14.6 3
7 0.5
4.5 2
Secondary Pressure
0 1 2 3 4 5 6.5 7
Push Rod Stroke (mm)
0 3 5 10 15 17.3 19
Operating Angle
DS1702136
Figure 1

8-4-3
Overview
The remote control valve contains four push rods, spring
holders, spools and return springs, which are in the valve
casing. The valve works as a pressure reduction valve.
The housing has six ports, which include input port P, tank port
T, and four secondary pressure ports.
The electric horn button is installed in the valve handle.
Gear pump pressure is used for operating control spools.
S2 S2
S1 S1
S3 S3
gle
19° Sin 25°
19° Do
ubl
e
A A
4 4
1 P 1 P
T T
2 3 2 3
LH RH
Push Button Switch

3 2 1 LH RH Center
6 5 4
1 - Gray 2 - Blue 3 - Red
4 - Gray 5 - Blue 6 - Red
View A
DS1702137
Figure 2

8-4-4
Push Button Switch

(LH)
Button LH RH 1 Gray 4 Gray
S1 - Shear Close (RH)
S2 - Shear Open 2 Blue 5 Blue
S3 Horn Button Breaker Button (Center)
3 Red 6 Red
DS1702138
Figure 3
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 4

8-4-5
Parts List
A
25
22
21
18
17
㘢#ᖎ+❚⻋,#
JOYSTICK GRIP 12
14 9
52
11
23
26
10
24 16
7
A 6
51
15
5
13
19 SPOOL
1
2
3
DS1702135
Figure 5

8-4-6
Reference Reference
Number Number
1 Case 15 Spacer
2 Plug 16 Joint Assembly
3 Bushing 17 Plate, Swash
4 Spool 18 Nut
5 Shim 19 Bushing
6 Spring 21 Nut
7 Seat, Spring 22 Joystick (LH)
8 Spring 22 Joystick (RH)
9 Plug 23 Bar, Handle
10 Rod, Push 24 Pin, Spring
11 O-ring 25 Bellows
12 Seal, Rod 26 Connector Assembly
13 Plate 51 Spool Kit
14 Boot 52 Plug Kit

8-4-7
Theory of Operation
Structure
The joystick valve contains four push rods, spring seat, spools
and return springs, which are in the valve casing. Moves the
spool of the main control valve by reducing the pressure of the
pilot pump from a first pressure to a second pressure.
The housing has six ports, which include input port P, tank port
T, and four secondary pressure ports.
The electric horn button is installed in the valve handle.
Gear pump pressure is used for operating control spools.
Function
1. Neutral position
When the joystick lever is in the neutral state, the spool is 1
pressed upward by the return spring and the spring seat.
The P-port is blocked by the lower part of the spool, and
the 4 operation ports are connected to the T-port by the 2
upperpart of the spool.
3
Reference
Description
Number
4
1 Swash Plate
2 Push Rod
3 Balance Spring
4 Return Spring 5
5 Spool DS1602148
Figure 6
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 DS1602149
spring.
Figure 7

8-4-8
3. Fully operated state
When the joystick lever is moved to its full extent, the lower
end of the push rod fully presses the spool seat to fully
compress the control spring.
The first pressure is transferred to the operation ports
through the spool, and the second pressure coming
through the spool overpowers the force of the control
spring, pushing the spool upward, and thus the spool is
restricted from movement by the push rod.
That is, when the joystick lever is fully pressed, the control
spring cannot perform its function and the spool is
restricted, making the first pressure and the second
pressure equal.
DS1602150
Figure 8
Tools and Torques
Reference Torque
Description Tool
Number N.m kg.m ft lb
2 Plug 36.3 3.7 27 PT 1/8" ( )
17 Swash Plate 162.8 16.6 120 27 mm ( )
18 Hex Nut 162.8 16.6 120 22 mm ( )
21 Nut 162.8 16.6 120 22 mm ( )

8-4-9
SECTION VIEW
21
20
14
18
16 10
17
15 12
9
13
19
11
8
4
22
1 3
DS1702139
Figure 9

8-4-10
Reference Reference
Number Number
1 Case 13 Plate
2 Plug 14 Inner Boots
3 Bushing 15 Spacer
4 Spool 16 Joint Assembly
5 Shim 17 Swash Plate
6 Spring 18 Hex Nut
7 Spring Seat 19 Bushing
8 Spring 20 Nut
9 Plug Handle Assembly (LH)
21
10 Push Rod Handle Assembly (RH)
11 O-ring 22 Connector Assembly
12 Rod Seal

8-4-11
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

EX1301633
Figure 10

8-4-12
(Figure 11) I
WARNING OFF
Lock
OFF
ON
ON

switch.
ON
OFF
ON
DS1704238
Figure 12

3
5 8
1 2
7 6
4
EX1401809
Figure 13

8-4-13
WARNING
any work.

DS1601105
(0.45 bar) opens, and the air is discharged to the Figure 14
10. Remove bolts (3 ea) and washers (3 ea) and remove arm
rest from bracket. (Right side)
Left side is the same.
• Tool: 13 mm ( )
EX1301715
Figure 15
11. Remove screw with arm rest cover.

• Tool: Phillips screwdriver
EX1301716
Figure 16
12. Remove rubber and screws, remove cover (1, Figure 17)
from stand upper cover, and disconnect the harness
connectors that are connected with switches.
components (sensor, connectors).  1
• Tool: Phillips screwdriver EX1301717
Figure 17 Stand RH

8-4-14
1
EX1301718
Figure 18 Stand LH
13. Remove screws (Figure 19) (4 ea) and remove upper

cover (1, Figure 19) from bracket, and disconnect the
harness connectors that are connected with switches. 1

• Tool: Screwdriver
DS1604168
Figure 19 Stand RH
DS1702140
Figure 20 Stand LH
14. Remove screws (4, Figure 21) (2 ea), socket bolts and
washers (3) (4 ea) of joystick valve (1).
1
15. Remove bracket (2, Figure 21) from control stand bracket.
16. Separate joystick valve from control stand.
3
• Tool: 5 mm ( ), Phillips screwdriver
4 2
DS1602344
Figure 21 Stand RH

8-4-15
1
2
DS1702141
Figure 22 Stand LH
17. Remove hoses and adapters from joystick valve.

NOTE: Attach identification tags on the removed hoses for reassembly. Disconnect the hoses in order
from bottom to top of oil tank. After the hoses are disconnected, plug and cap them to prevent dirt
or dust from entering.
4 4
P P
1 1
P
T T
2 3 2 3
2
1
Left Hand Right Hand

DS1602345
Figure 23
•
Hoses and plugs ports

Port Name
to Joint Plate Assy "A1"
1 PF 3/8" 22 49.0 5.0 36.2
(to Control Valve "pa2")
2 PF 3/8" 22 49.0 5.0 36.2
(to Control Valve "pb5")
Left to Joint Plate Assy "A2"
3 PF 3/8" 22 49.0 5.0 36.2
Hand (to Control Valve "pb2")
4 PF 3/8" 22 49.0 5.0 36.2
P from P Block PF 3/8" 22 49.0 5.0 36.2
T to T Block (Drain) PF 3/8" 22 49.0 5.0 36.2

8-4-16
Port Name
1 PF 3/8" 22 49.0 5.0 36.2
2 PF 3/8" 22 49.0 5.0 36.2
Right to Joint Plate Assy "A6"
3 PF 3/8" 22 49.0 5.0 36.2
Hand (to Control Valve "pa8")
4 PF 3/8" 22 49.0 5.0 36.2
P from P Block PF 3/8" 22 49.0 5.0 36.2
T to T Block (Drain) PF 3/8" 22 49.0 5.0 36.2
• Fitting
Size Torque
Port Name
A B (mm) N.m kg.m ft lb
1, 2, 3, 4,
Adapter PF 3/8" PF 3/8" 22 40.2 4.1 29.6
Left/Right P, T
Hand 1, 2, 3, 4, S8000145
O-ring
P, T (4D, P14)
* A: Opposite side of hose, B: Hose side
18. Remove joystick valve from control stand.
DS1702142
Figure 24

8-4-17
INSTALLATION
WARNING
SERIOUS INJURY

2. Keep the assembly angle when installing the hoses to
joystick valve.
COMPLETING WORK
1. Start engine and set throttle at "LOW IDLE".
FG018152
Figure 25
3. Slowly cycle boom, arm, bucket cylinders and swing motor

about five times without a load to vent air from pilot lines.
Do this for five minutes.
FG018384
Figure 26

8-4-18
DISASSEMBLY
1. Remove lead wire from bushing (19).
FG013494
Figure 27
2. Remove lever assembly from case (1).
FG013495
Figure 28
3. Remove hex nut (18) and swash plate (17) from case (1).
FG013496
Figure 29
4. Remove joint assembly (16) from case (1).
FG013497
Figure 30

8-4-19
5. Remove plate (13) from case (1).
FG013498
Figure 31
6. Remove plug kit assembly (52), spool kit assembly (51)

from case (1).
FG013499
Figure 32
FG013501
Figure 33
7. Remove 4 spool kit assemblies from case (1).
EX1301732
Figure 34

8-4-20
8. Remove spring (8) from case (1).
FG013510
Figure 35
9. Remove bushing (3) from case (1).
FG013506
Figure 36
FG013508
Figure 37

8-4-21
10. Remove 4 plugs (2) from case (1).
FG013504
Figure 38
FG013507
Figure 39

8-4-22
REASSEMBLY
1. Install 4 plugs (2) into case (1).
FG013504
Figure 40
FG013507
Figure 41
2. Install bushing (3) into case (1) using jig.
FG013506
Figure 42
FG013508
Figure 43

8-4-23
3. Take care when assembling spool kit assemblies (1 and 3,
2 and 4). (They must be assembled in same way).
The assembly order is; spool (4), shim (5), spring (6),
spring seat (7).
FG013509
Figure 44
FG013503
Figure 45
4. Install spring (8) into case (1).
FG013510
Figure 46
5. Install spool kit assembly into case (1). (The same way is
used for four parts.)
EX1301732
Figure 47

8-4-24
6. Assemble plug kit insert rod seal (12), O-ring (11), and
push rod (10) into plug (9) in proper order.
FG013511
Figure 48
FG013512
Figure 49
7. Install four springs and stoppers and insert assembled set

in case (1) to form a plug kit assembly.
NOTE: Pay attention to measurement specifications of
stoppers (1 and 3, 2 and 4).
FG013499
Figure 50
FG013501
Figure 51

8-4-25
8. Install plate (13) into case (1).
FG013498
Figure 52
9. Install joint assembly (16) into case (1).
FG013497
Figure 53
10. Install boot and swash plate (17) and hex nut (18) into case
(1).
FG013513
Figure 54
FG013514
Figure 55

8-4-26
11. Insert bar and tighten it with a wrench to check balance of
joint assembly.
FG013515
Figure 56
12. Install bushing (19) into case (1).
FG013516
Figure 57
13. Install lever assembly into case (1).
FG013495
Figure 58
14. Put lead wire in bushing (19), tie it, and arrange boot.
FG013494
Figure 59

8-4-27
15. Assemble connector assembly (26), and connect it to lead
wire terminal, and properly route wiring.
FG013519
Figure 60
FG013520
Figure 61

8-4-28
1Travel Control Valve
(with Damper)
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Travel Control Valve (with Damper)

8-5-1
Table of Contents
Travel Control Valve (with Damper)

General ...........................................................8-5-3
Specification .............................................................. 8-5-3
Overview ................................................................... 8-5-4
Parts List ................................................................... 8-5-6
Tools and Torques .................................................... 8-5-9
Section View .................................................8-5-10
Removal........................................................8-5-11
Installation.....................................................8-5-16
Completing Work ..........................................8-5-17
Disassembly .................................................8-5-18
Reassembly ..................................................8-5-21
Travel Control Valve (with Damper) DX480LCA-K/DX520LCA-K

8-5-2
GENERAL
Specification
Type Pilot (with Damper)
7.5 ~ 25 kg/cm2
Pressure/Stroke Characteristic
(@1 ~ 4.3 mm Stroke)
Max. Primary Pressure 100 kg/cm2 (98 bar, 1,422 psi)
Max. Back Pressure 3 kg/cm2 (2.9 bar, 42.7 psi)
Rated Flow 20 L/min (5.3 U.S. gal)
Weight 7.8 kg (17.2 lb)
Performance
40 160
112.6
Secondary Pressure (kg/cm2 )
25 1.5
Operating Torque (kg.cm)

Operating Torque 91.8
46.4
7.5 1
Secondary Pressure
0 1 0.5 4.3 0.5 5.0
Rush Rod Stroke (mm)

EX1300984
Figure 1

8-5-3
Overview
The pilot valve is a valve that controls the spool stroke, direction,
etc. of a main control valve.
This function is done by providing the spring at one end of the
main control valve spool and applying the output pressure
(secondary pressure) of the pilot valve to the other end.
P
T
2 1
4 3
EX1301730
Figure 2

P T
Port Name Size
1 Backward
2 Forward
3 Backward PF 1/4"
4 Forward O-ring
P Pilot Oil Inlet
1 2 3 4
T Pilot Oil Return
EX1301731
Figure 3

8-5-4
8-5-5
Parts List
32
54
11 28
25
53-1
53
52
12 53-1
51
11
10
34 3
35
DS1800115
Figure 4

8-5-6
Reference Reference
Number Number
3 Plug 34 O-ring
4 Plug 35 O-ring
10 Spring 51 Kit, Spool
11 Pin, Spring 52 Kit; Plug
12 O-ring 53 Kit; Cover
25 Bolt 53-1 Bush
28 Shaft; Cam 54 Kit; Cam
32 Bellows

8-5-7
Theory of Operation
Structure
The casing (spacer) has oil inlet port P (primary pressure), and
the oil outlet port T (tank). In addition the secondary pressure is
taken out through ports 1, 2, 3 and 4 provided at the bottom
face.
Pressure Reducing Valve

1. Neutral position
If pedal is in neutral, spool is pushed up by return spring
and spring seat. Port (P) is blocked by bottom part of spool
and four operating ports (left forward and backward, right
forward and backward) are connected to port (T) through
inner hole of spool.
2. Half-operated state
If pedal is moved, push rod moves down, and they transmit
this force through spring seat and control spring to spool. If
spool is moved, primary pressure is transmitted through an
inner hole of spool to operating port. If lever is stopped in
middle position, compressed control spring force and
secondary pressure transmitted through hole acts at
bottom part of spool, balance is maintained by hydraulic
force acted upward, and then this pressure is transmitted
to traveling spool of control valve. That is, primary pressure
is transmitted to operating port as secondary pressure
equivalent to control spring force compressed by spool.
3. Fully operated state
If pedal is moved to a maximum, bottom part of push rod
presses spool seat to a maximum, and compresses control
spring to a maximum. Primary pressure is transmitted
through inner hole of spool to operation port, secondary
pressure transmitted through spool overcomes control
spring force and pushes spool up, but spool is restricted by
push rod and does not move any more. That is, when
pedal lever is moved to a maximum, control spring does
not function, spool is restricted by push rod, and then
primary pressure equalizes to secondary pressure.
Damper Mechanism
1. Operation When Operating Lever
When pushing pedal, pushing force pushing push rod and
spool presses cylinder, return spring and hydraulic oil in
cylinder is compressed, piston coming down with push rod
compresses vibration prevention chamber of lower part, oil
of vibration prevention chamber of lower part is flowed
through orifice to oil pressure vibration prevention chamber
of upperpart of low-pressure, now, ball check valve
becomes closing condition because high-pressure
operates to vibration prevention chamber of lower part.

8-5-8
2. Operation When Operating Lever In Neutral Condition
Climbing restoring force acting on push rod, raises piston
in oil pressure prevention chamber and compresses upper
oil pressure prevention chamber. This compression
operation of upper oil pressure prevention chamber
prevents the push rod from quickly rising by restoring
spring, and the damping force is generated.
Neutral Maximum Operating

12.4
2
3
to Travel Spool
Figure 5 of Control Valve
EX1401585
Reference Reference
Number Number
1 Push Rod 4 Piston Chamber
2 Orifice 5 Plug
3 Piston
Tools and Torques

Reference Torque
Description Size Tool
Number Nm kg.m ft lb
25 Socket Bolt M6 29.4 3 6 5 mm ( )
31 Nut M10 43.1 4.4 32 17 mm ( )

8-5-9
SECTION VIEW
31 30 28 27 32
26
23
24
22
15 25
21
13
20 16
33 17
11
14 18
19
2
12 8
35
9 6
5
10 3
34
7
1
4
EX1401587
Figure 6
Reference Reference
Number Number
1 Body (1) 18 Plate
2 Body (2) 19 Snap Ring
3 Plug 20 Plug
4 Plug 21 O-ring
5 Spring Seat 22 Rod Seal
6 Spring 23 Dust Seal
7 Spring Seat 24 Cover
8 Spool 25 Socket Bolt
9 Stopper 26 Cam
10 Spring 27 Bushing
11 Spring Pin 28 Camshaft
12 O-ring 30 Set Screw
13 Push Rod 31 Hex Nut
14 Spring Pin 32 Bellows
15 Seal 33 Piston
16 Steel Ball 34 O-ring
17 Spring 35 O-ring

8-5-10
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

EX1301633
Figure 7

8-5-11
(Figure 8) I
WARNING OFF
Lock
OFF
ON
ON

switch.
ON
OFF
ON
DS1704238
Figure 9

3
5 8
1 2
7 6
4
EX1401809
Figure 10

8-5-12
WARNING
any work.

DS1601105
(0.45 bar) opens, and the air is discharged to the Figure 11
10. Remove bolts and washers (1, Figure 12) (6 ea) under
• Tool: 19 mm ( ) 1
• Under cover weight: 12.6 kg (27.8 lb)
EX1403184
environment.
EX1504170
Figure 13

8-5-13
12. Remove hoses and adapters from travel control valve.
NOTE: Attach identification tags on the removed hoses T
1
for reassembly. After the hoses are
disconnected, plug and cap them to prevent dirt
2
or dust from entering. 
4
3
EX1402015
Figure 14 Bottom of Cabin

Port Name
1 to Control Valve "pa6" UNF 11/16"-16-2B 22 38.2 3.9 28.2
2 to Control Valve "pb6" UNF 11/16"-16-2B 22 38.2 3.9 28.2
3 to Control Valve "pa1" UNF 11/16"-16-2B 22 38.2 3.9 28.2
4 to Control Valve "pb1" UNF 11/16"-16-2B 22 38.2 3.9 28.2
P from PT Block UNF 9/16"-16-2B 19 25.5 2.6 18.8
T to PT Block (Drain) UNF 9/16"-16-2B 19 25.5 2.6 18.8
• Fitting
Size Torque
Port Name
1, 2, 3, 4 Elbow PF 1/4" UNF 11/16"-16 19 36.3 3.7 26.8
P, T Adapter PF 1/4" UNF 9/16"-18 19 36.3 3.7 26.8
1, 2, 3, 4 B1, P11 (S8000111)
O-ring
P, T B1, P11 (S8000111)
DS1701906
Figure 15

8-5-14
14. Remove bolts (1, Figure 16) (4 ea) and washers with foot
rests (2) (2 ea) from floor plate.
• Tool: 17 mm ( )
1
2
DS1602754
Figure 16
15. Remove bolts (1, Figure 17) (4 ea) and washers with travel
pedals (2) (2 ea) from travel pedal bracket.
• Tool: 17 mm ( )
1
2
EX1402317
Figure 17
pedal brackets (2) (2 ea) from travel control valve.
• Tool: 8 mm ( )
1
EX1402318
Figure 18
control valve (2) from floor plate.
• Tool: 8 mm ( )
Figure 19 EX1402319

8-5-15
18. Remove travel control valve from floor plate.
• Valve weight: about 8 kg (17.6 lb)
Figure 20 EX1402320
INSTALLATION
WARNING
SERIOUS INJURY

2. When installing the hose, install the drain hose first.

8-5-16
COMPLETING WORK
1. Start engine and set throttle at "LOW IDLE".
FG018152
Figure 21
3. Slowly push and pull both travel lever about five times
without any load to vent air from pilot lines.
HAOB903L
Figure 22

8-5-17
DISASSEMBLY
1. Remove bellows (32).
FG013535
Figure 23
2. Remove set screw (29) from cam (26).
FG013536
Figure 24
3. Remove camshaft (28) from cam (26).
FG013537
Figure 25
4. Remove hex nut (31) and set screw (30) from cam (27).
FG013538
Figure 26

8-5-18
5. Remove hex socket head bolt (25) and cover (24) from
each body (1 and 2).
FG013539
Figure 27
FG013540
Figure 28
6. Remove push rod assembly from body (2).
FG013541
Figure 29
7. Remove body (2) from body (1).
FG013542
Figure 30

8-5-19
8. Remove damper spool assembly and spring (10) from
body (1).
FG013543
Figure 31
FG013544
Figure 32
9. Remove plug (3 and 4) and O-rings (12 and 34).
FG013545
Figure 33

8-5-20
REASSEMBLY
1. Insert spring (10) into body (1).
FG013544
Figure 34
2. Assemble in proper order, damper spool (8), shim (7),

spring (6), spring seat (5) and stopper (9).
FG013546
Figure 35
3. Install damper spool assembly into body (1).
FG013547
Figure 36
4. Assemble body (2) onto body (1).
FG013542
Figure 37

8-5-21
5. Assemble rod seal (22), dust seal (23) and O-ring (21) into
plug (20).
FG013548
Figure 38
FG013549
Figure 39
6. Assemble seal (15), piston (33), steel ball (16), plate (18),
spring (17) and retaining ring (19) into push rod (13).
FG013550
Figure 40
7. Assemble push rod and plug.
FG013551
Figure 41

8-5-22
8. Install push rod assembly into body (2).
FG013552
Figure 42
9. Install bushing (27) in cover (24) using jig.
FG013553
Figure 43
10. Assemble cover (24) onto each body (1 and 2) and install
hex socket head bolt (25) using torque wrench.
FG013554
Figure 44

8-5-23
11. Install set screws (30) and hex nut (31) into cam (26) and
tighten it.
FG013555
Figure 45
FG013556
Figure 46
12. Position cam (26) on cover (24) and insert camshaft (29)
using hammer.
FG013557
Figure 47
13. Install set screw (29) in cam (26) and tighten it using torque
wrench.
FG013558
Figure 48

8-5-24
14. Check cam balance.
FG013559
Figure 49
15. Install bellows.
FG013560
Figure 50
FG013561
Figure 51

8-5-25
TROUBLESHOOTING
At times it may be difficult to pinpoint the source of the problem.
The following table lists some of the possible problems, possible
causes and remedies. Refer to this table for possible causes
and remedies to assist in correcting the sometimes difficult
problems.
The table only lists some general problems, possible causes
and their remedies. Often the problem is not caused by the
failure of a single part but, may be the result of a combination of
problems from related parts and their components. Possible
problems other than the ones list are not being specified but that
is not to say that these are the only possible problems that can
occur. The technician must diagnose the problem, considering
all possible causes and repair the source of the malfunction.

Secondary pressure will not Low primary pressure. Adjust primary pressure.
increase. Defective secondary pressure
Replace with new spring.
select spring.
Gap between damper spool and
Replace damper spool casing assembly.
casing is abnormally large.
Defective operating parts and Disassemble/reassemble and replace
components. defective parts.
Unstable secondary Jamming of interconnected parts. Repair/replace cause of jamming.
pressure. Unstable tank line pressure. Install direct line to hydraulic tank.
Air in hydraulic lines. Vent air from system.
Abnormally high secondary High tank line pressure. Install direct line to hydraulic tank.
pressure. Jamming of interconnected parts. Repair/replace cause of jamming.
No dampening. Air in piston chamber. Vent air from system.
Jamming of interconnected parts. Repair/replace cause of jamming.
Worn damper springs. Replace with new parts.
Worn damper spool and housing. Replace damper spool and housing
assembly.
Defective/damaged check valve. Disassemble and examine check valve.
Worn damper spool orifice. Replace damper spool.
Damper spool feels heavy. Defective interconnected
Repair/replace defective parts.
components.
Restricted movement of damper
Repair/replace damaged piston.
spool.

8-5-26
1Solenoid Valve
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-5K/DX520LCA-5K Solenoid Valve

8-6-1
Table of Contents
Solenoid Valve
General ...........................................................8-6-3
Specification .............................................................. 8-6-3
Overview ................................................................... 8-6-4
Parts List ................................................................... 8-6-7
Functions of Solenoid Valve ...................................... 8-6-9
Solenoid Valve DX480LCA-5K/DX520LCA-5K

8-6-2
GENERAL
Specification
Pressure (Max.) 69 bar (70 kg/cm2, 996 psi)
Flow (Max.) 23 L/min (6.1 U.S. gal)
Leakage 30 cc/min
Test 39 bar (40 kg/cm2) at 15 L/min
Solenoid Coil
Rated Voltage DC 24 V
Operation Voltage Range 20 ~ 30 V

8-6-3
Overview
3-Solenoid Valve
P4
TR2
PH
ACC
C4
T P2
C3
HO P1
P3 C1
PO
DS1603227
Figure 1
4-Solenoid Valve
P4
TR2
PH
ACC
P2 C4
T
C3
P1 C2
HO
C1
P3
PO
DS1603228
Figure 2

8-6-4
5-Solenoid Valve
BS PH
ACC
TR2 C5
C4
T
P2 C3
P4
HO C2
P3
C1
PO P1
DS1603229
Figure 3
P4
BS PH P3 P1
TR2 ACC
H0 P2
T P0
EX1401847
Figure 4

8-6-5
3-Solenoid Valve
PH TR2 HO P2 PO
P1
C6
C4 C3 C2 C1
Figure 5 P4 P3 ACC DS1603230
4-Solenoid Valve
PH TR2 HO P2 PO
P1
C6
C4 C3 C2 C1
Figure 6 P4 P3 ACC
DS1603231
5-Solenoid Valve
BS PH TR2 HO P2 PO
P1
C6
C5 C4 C3 C2 C1
Figure 7 P4 P3 ACC
DS1603232
Port Name Size

PO Pilot Filter
P2 Safety Cut-off PF 1/2", O-ring
ACC Accumulator
P1 Pilot Inlet Pressure
Pilot Pressure
P3
(Two Way EPPR Valve)
Pilot Pressure
P4
(Rotating EPPR Valve) PF 1/4", O-ring
BS Two Way Mode
PH Pressure Up
TR2 Travel High Speed
HO Breaker Pressure Supply
T Drain PF 3/8", O-ring

8-6-6
Parts List
2-1
2-2
4 5
EX1401848
Figure 8
Reference
Description Size Torque (kg.m) Tool (mm)
Number
1 Block
2 Solenoid Valve UNF 7/8" - 14 2 ±0.25 (25)
2-1 Coil Locknut UNF 1/2" - 20" 0.6 (19)
2-2 Coil
3 Check Valve UNF 7/8" - 14" 4 ±0.2 (24)
4 Plug PF 1/4" 2.5 ±0.25 (19)
5 Plug PF 1/8" 0.1 ±0.25 (5)

8-6-7
Theory of Operation
C5
C4
C3
2
C2
C1 2-1
C6
1 EX1401849
Figure 9
Reference
Description Quantity Remarks
Number
1 Block Body 1
2 Solenoid Valve 5 C1 ~ C5
2-1 Coil 5 C1 ~ C5
3 Check Valve 1 C6
4 Plug 3 P3, P4, H0
5 Plug 6

8-6-8
Functions of Solenoid Valve
The solenoid valve assembly controls the following functions.
1. Pilot Cut-off
2. Breaker Pressure Supply
3. High/Low Travel Speed
4. Main Pressure (Power Boost) Increase
5. Breaker/Shear Mode Selection
Functions and Operations of Solenoid Valves
Reference
Function Operations Remarks
Number
Provides pressurized oil coming from the pilot pump for
C1 Pilot Cut-off the pilot pressure supply solenoid valve to operate each
work system.
Supplies pilot pressure for the pedal valve assembly and
C2 Breaker Pressure Supply Option
shuttle valve.
Sets low and high travel speed. Shifts speed between
C3 High/Low Travel Speed both depending on the state of the solenoid valve or a
signal detected in the EPOS controller.
Main Pressure (Power Temporally increases the pressure setting of the main
C4
Boost) Increase relief valve, to increase the excavation power.
Supplies pilot pressure to shear valve that controls the
Breaker/Shear Mode
C5 front option attachment so it is ready to work in the Option
Selection
breaker mode.
Detailed Functions and Operations of Solenoid Valves

1. Pilot Cut-off Solenoid Valve (C1)
It provides pressurized oil coming from the pilot pump to the;
• Breaker solenoid valve (C2)
• High/low travel speed solenoid valve (C3)
• Main pressure (power boost) increase solenoid valve
(C4)
• Breaker/shear mode selection solenoid valve (C5)
NOTE: Port "P3" from 5-solenoid valve assembly, is
connected to a 2-solenoid valve assembly that
is used to control a shear.
Pulling up the safety lever, located on the left side of the
operator's seat, allows the electrical power from the pilot
cutoff switch to activate the pilot cutoff solenoid valve. The
pilot cutoff solenoid valve then supplies pressurized oil to
each of the other solenoid valves.

8-6-9
2. Breaker Pressure Supply Solenoid (C2)
Pressing the breaker switch on the joystick operates the
breaker solenoid valve (C2). This supplies pilot pressure to
the option valve in the main control valve. The pilot
pressure shifts the option valve spool, which then allows
pressurized oil from the main pump to flow to the breaker
system for operation.
3. High/Low Travel Speed Solenoid (C3)
When the travel speed selector switch is moved to the "O"
position, the travel speed is set to low speed. The solenoid
valve is not activated.
When the travel speed selector switch is moved to the "I"
position the travel speed is set to high-speed. The solenoid
valve is activated.
When the travel speed selector switch is moved to the "II"
position, the travel speed switches to automatic.
NOTE: Turning the automatic travel switch to the "II"
position, the EPOS controller detects the
discharge pressure from the main pump, and
automatically turns the high travel speed control
"ON" or "OFF" depending on if the travel load is
high or low to switch the travel speed to speed
"I" or "II". The travel load is detected by two
pressure sensors located on the discharge line
of the front and rear pumps.
If the load is high (pressure about 294 bar
(300 kg/cm2, 4,264 psi)), the solenoid valve
turns "OFF" for travel at low speed.
If the load is low (pressure about 157 bar
(160 kg/cm2, 2,277 psi)), the solenoid valve
turns "ON" for the travel at high-speed.
If the engine control dial is set to 1,400 rpm or
below, however, the solenoid valve always
turns "ON" for the travel at low, though the
automatic travel switch is set to the automatic
travel (2nd place).
4. Main Pressure (Power Boost) Increase Solenoid (C4)
Pressing the power boost button on the work lever sends a
signal from the EPOS controller to activate the pressure
increase solenoid valve. This temporally increases the
pressure setting of the main relief valve to increase the
hydraulic power. When it is activate, the pressure setting of
the main relief valve increases from 331 bar (337 kg/cm2,
4,801 psi) to 348 bar (355 kg/cm2, 5,047 psi), which in turn
increases the hydraulic power.

8-6-10
5. Breaker/Shear Mode Selection Solenoid (C5)
The breaker/shear switch activates the solenoid valve
when the front option attachment is changed from shear to
breaker.
When the switch is set to breaker, pilot pressure is
supplied to shear valve shifting the spool inside. with the
pressurized oil from the main pump supplied to breaker.

8-6-11
8-6-12
1EPPR Valve
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K EPPR Valve

8-7-1
Table of Contents
EPPR Valve
General ...........................................................8-7-3
Structure .................................................................... 8-7-3
Functions and Operation ................................8-7-4
Cautions for Operation....................................8-7-4
Maintenance Instructions................................8-7-5
Maintenance .............................................................. 8-7-5
Disassembly .............................................................. 8-7-6
Assembly ................................................................... 8-7-7
EPPR Valve DX480LCA-K/DX520LCA-K

8-7-2
GENERAL
Structure
Figure 1
Reference Reference
Number Number
1 Solenoid 5 Pin
2 Valve casing 6 Spring
3 Sleeve 7 O-ring
4 Spool 8 O-ring

8-7-3
FUNCTIONS AND OPERATION
The proportional reducing valve shall be adjusted that its
reduced pressure is proportional to the current of the solenoid.
The proportional solenoid shall be changed with pressure
proportional to the electrical input signal. Flow increases
corresponding to the force of the solenoid. As the solenoid (1)
receives pressure, the spool (4) opens and oil flows from P to A.
Pressure of the port A influences the top surface of the pin (5).
When it reaches the valve set of the solenoid, the spool starts to
move and oil flow from P to A decreases.
CAUTIONS FOR OPERATION

1. Wiring of the solenoid
• The solenoid has no polarity.
2. Input electricity
• Do not supply electric current more than 0.7A to the
solenoid coil.
3. Adjustment screw
• It was adjusted to the standard.
• The pressure of the port A increases when turning
the adjustment screw clockwise.
4. Symptoms and Solutions of Problems
Symptoms Causes Solutions

Poor wiring Fix wiring
Pressure does not Solenoid damaged Replace the solenoid
increase nor change Piston or spool sticked Fix, or clean and grind
Amplifier damaged Repair or replace the amplifier
Poor opening space
Unnatural pressure Too wide Readjust
change Too narrow
Piston or spool sticked Fix, or clean and grind
Poor opening space
Unnatural pressure Too wide Readjust
Too narrow
Slow reaction Low pressure supplied Readjust

8-7-4
MAINTENANCE INSTRUCTIONS
Maintenance
Bolt Tightening Torque

Table 1 shows torques used to tighten bolts of the motor.
Make sure that assembly work should be done according to
Table 1.
Used Torques
Bolt Sizes Name
(kg.cm)
M 35 Hex bolt 450 ±50
M 10 Hex bolt 200 ±20
NPTF 1/16 Plug 90
Tools Used for Disassembly and Assembly

Table 2 shows tools necessary for disassembly and assembly.
As bolts and plugs to be used depend on types, they should be
checked accordingly in advance.
For Sizes Used Torques Used Tools

Solenoid M 35 450 ±50 Spanner
Sleeve M 10 200 ±20 Hex bar spanner
NPTF plug 1/16 90 Hex bar spanner

8-7-5
Disassembly
1. Determine a place for disassembly.
• It should be clean.
• Lay a rubber board or a cloth on the table and take
care not to damage parts.
2. Remove dust and rust of the proportional pressure
reducing valve with cleansing oil.
3. Disassemble the solenoid
• Take care not to damage O-rings of the solenoid.
FG003690
Figure 2
4. Disassemble the spool, the spring, and the pin.
FG003691
Figure 3
5. Disassemble the sleeve.

• Take care not to damage O-rings of the sleeve.
FG003692
Figure 4

8-7-6
Assembly
Assembly shall be done in the reverse order of disassembly
described above, taking into consideration the following points.
• Parts damaged during disassembly should be repaired
without fail and spare parts should be prepared in
advance.
• Every part should be cleaned enough with cleaning oil and
• Sliding parts and bearings should be applied clean active
oil before their assembly.
• Basically, parts of the O-ring and the oil seal should be
replaced.
• Use a torque wrench to tighten or engage bolts and plugs
in accordance with reference torques as described in
Maintenance Guide.
1. Assemble the sleeve.
FG003693
Figure 5
• Take care not to damage O-rings of the sleeve.
FG003694
Figure 6

8-7-7
2. Assemble the spool, the spring, and the pin.
FG003695
Figure 7
• The spring and the pin should not be fell off.
FG003696
Figure 8

8-7-8
3. Assemble the solenoid correctly.
PART No.: 426-00266

SERIAL No.:
FG003697
Figure 9
• Take care not to damage O-rings of the solenoid.
FG003698
Figure 10

8-7-9
8-7-10
1Accumulator
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Accumulator
8-8-1
Table of Contents
Accumulator
General ...........................................................8-8-3
Specifications ............................................................ 8-8-4
Accumulator DX480LCA-K/DX520LCA-K
8-8-2
GENERAL
The accumulator is a gas-charged storage device designed to 1
hold a reserve quantity of hydraulic fluid under pressure.
Accumulators are used in hydraulic circuits in much the same 2
way that condensers (or capacitors) are used to collect, store
and maintain electrical charge in a circuit.
In a hydraulic circuit, minor variations or lags in pump output that
might otherwise cause unsteady or irregular operation are made
up from the supply of pressurized oil in the accumulator.
Reference
Description
Number
3
1 Screw Plug
2 Steel Pressure Vessel
4
3 Diaphragm
4 Fluid Valve
ARS1790L
Accumulators are solidly constructed to resist the high operating Figure 1
pressures of the fluids they contain. There are only three main
moving parts: a plug at the top allows precharging or expelling
gas from the compressible, precharged upper chamber; a valve
assembly at the bottom of the accumulator for passing hydraulic
fluid in and out, and an elastic diaphragm to separate the two
chambers. The flexible diaphragm changes shape to conform to
the changing pressures and volumes of the two fluids in the
upper and lower chambers.
There are six possible positions the diaphragm can be in and
they are as follows: Pressure Fluid Nitrogen
1. With no gas charge in the upper chamber 0 bar (0 psi,

empty) and no oil in the bottom 0 bar (0 psi, dry) the elastic
diaphragm hangs loosely.
2. When the prepressure charge of gas (usually nitrogen) is
introduced through the port at the top of the accumulator, the
diaphragm expands to maximum size. The valve button in the 1 2 3
center of the diaphragm pushes into the fluid opening in the
bottom chamber, sealing off the lower valve. If the pressure of
the gas charge exceeds system oil pressure, no fluid enters
the accumulator. The button also keeps the diaphragm from
protruding into the lower valve opening.
NOTE: Precharge pressure is referred to as the "P1"
pressure. The accumulator manufacturer's "P1"
rated pressure must be stamped or marked on 4 5 6
ARS1800L
the accumulator's rating plate. Annual checks of
actual precharge pressure must be made by Figure 2
tapping a hydraulic pressure gauge (and 3-way
adapter coupling) into the valve on the bottom
of the accumulator.
When hydraulic fluid is pushed out the lower
valve opening by the pressure of the gas charge
on the other side of the diaphragm - and there is
no counterpressure from system oil - the valve
DX480LCA-K/DX520LCA-K Accumulator
8-8-3
button on the bottom of the diaphragm
eventually seals off the lower oil passage. Just
after the needle on the gauge reaches its
highest point (when there is 0 bar (0 psi)
resistance from hydraulic system pressure)
pressure on the gauge will drop sharply to zero,
as the accumulator is completely emptied of oil
and the diaphragm button closes.
Record the highest gauge reading and compare to "P1"
rated precharge pressure on the accumulator
manufacturer's data label. Repeat this test at least once a
year to verify proper functioning of the accumulator.
3. As hydraulic system pressure overcomes accumulator
precharge pressure, the flexible diaphragm begins to
retract upward.
4. When system oil is at highest working pressure and the
accumulator fills to maximum reserve capacity, the flexible
diaphragm is pushed up into the top of the upper chamber.
The highest working pressure is sometimes referred to as
the "P3" pressure and can also be referenced on the
manufacturer's data label on the exterior of the
accumulator.
5. If system oil pressure begins to fall off or is momentarily
checked or interrupted, the energy stored on the other side
of the diaphragm, in the form of compressed gas, pushes
oil back out of the lower chamber, maintaining oil pressure
of the circuit.
6. With minimal system pressure, an equilibrium point may be
reached in which accumulator precharge pressure and
hydraulic system oil pressure achieve a rough balance. In
this condition a minimal amount of oil is stored in the
accumulator.
Specifications
System Charge Pressure Volume
10 kg/cm 2 320 cc
Pilot
(9.8 bar, 142 psi) (19.53 in3)
Accumulator DX480LCA-K/DX520LCA-K
8-8-4
1Center Joint
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Center Joint

8-9-1
Table of Contents
Center Joint
General ...........................................................8-9-3
Overview ................................................................... 8-9-3
Section View ...................................................8-9-5
Removal..........................................................8-9-6
Installation.....................................................8-9-12
Completing Work ..........................................8-9-12
Disassembly .................................................8-9-13
Reassembly ..................................................8-9-16
Troubleshooting, Testing and Adjustment ....8-9-19
Inspection ................................................................ 8-9-19
Testing..................................................................... 8-9-19
Center Joint DX480LCA-K/DX520LCA-K

8-9-2
GENERAL
General Description
The center joint is designed to allow hydraulic oil from the upper
structure to flow to components in the lower structure.
It is capable of allowing continuous 360° rotation of the upper
structure in relationship to the lower structure.
Overview
2
1
4
3
5
2
1
4 3
5
EX1400114
Figure 1
Size
Port Name
Body Spindle
1, 2, 3, 4 Travel Motor SAE 1 1/4" SAE 1
5 Pilot PF 3/8" O-ring
G Drain PF 3/4" O-ring

8-9-3
Parts List
13
14
7
9 10
15
8 16
17 4
12
5
2
1
11 EX1402541
Figure 2
Reference Reference
Number Number
1 Body 11 Plug
2 Spindle Assembly 12 Plug
3 Cover 13 Bolt
4 Spacer 14 Spring Washer
5 Shim 15 Bolt
7 Seal 16 Spring Washer
8 O-ring 17 Dust Seal
9 O-ring * Center Joint Seal Kit
10 O-ring

8-9-4
SECTION VIEW
15, 16 12 13, 14
3
10
1
7
4
3
5
17
2
5
11 EX1400116
Figure 3
Reference Reference
Number Number
1 Body 10 O-ring
2 Spindle Assembly 11 Plug
3 Cover 12 Plug
4 Spacer 13 Bolt
5 Shim 14 Spring Washer
7 Seal 15 Bolt
8 O-ring 16 Spring Washer
9 O-ring 17 Dust Seal

8-9-5
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

2. Lower front attachment (bucket) to ground. (Figure 4)
3. Stop engine.
10 cm
EX1301631
Figure 4

8-9-6
(Figure 5) I
WARNING OFF
Lock
OFF
ON
ON

switch.
ON
OFF
ON
DS1704238
Figure 6

3
5 8
1 2
7 6
4
EX1401809
Figure 7

8-9-7
WARNING
any work.
Figure 8 DS1601105
covers (2) (2 ea) from frame. 1
• Tool: 24 mm ( )
• Under cover weight: about 10 kg (31 lb) (per 1 ea)
2
EX1401444
Figure 9 Bottom of Track Frame
environment.
EX1504170
Figure 10

8-9-8
14. Remove hoses and adapters from center joint.
5
NOTE: Attach identification tags on the removed hoses
for reassembly. Disconnect the hoses in order 3
4
are disconnected, plug and cap them to prevent
dirt or dust from entering.
2 1
DS1601510
Figure 11 Spindle of Center Joint
• Thread of hoses and plugs

Port Name
UNF 13/16"-16-2B 24 55.9 5.7 41.2
0 Drain
UNF 13/16"-16-2B 24 55.9 5.7 41.2
1 to Travel Motor (RH) "A" SAE 1", D24 10 107.9 11.0 79.6
2 to Travel Motor (LH) "B" SAE 1", D24 10 107.9 11.0 79.6
3 to Travel Motor (RH) "B" SAE 1", D24 10 107.9 11.0 79.6
4 to Travel Motor (LH) "A" SAE 1", D24 10 107.9 11.0 79.6
UNF 9/16"-18-2B 19 25.5 2.6 18.8
5 Pilot (2-speed)
UNF 9/16"-18-2B 19 25.5 2.6 18.8
• Fitting
Size Torque
Port Name
0 PF 3/4" UNF 13/16"-16 32 176.4 18.0 130.1
Tee
5 PF 3/8" UNF 9/16"-18 22 49.0 5.0 36.2
0 S8000241 (1B P24) S8030081 (1B F-08)
1, 2, 3, 4 DS2856003 (1", ID:33.2, OD:40.2, 1B)
O-ring
2180-1216D11
5 S8000145 (4D P14)
(ID:7.65, W:1.78, 1B)

8-9-9
15. Remove bolt (1, Figure 12) and bracket (2).
• Tool: 24 mm ( ) 1

2
EX1403171
Figure 12 Hub of Center Joint
16. Remove hoses and adapters (Figure 13) from center joint.
0
NOTE: Attach identification tags on the removed hoses
for reassembly. Disconnect the hoses in order
2 1
are disconnected, plug and cap them to prevent
dirt or dust from entering. Disconnect the hoses
from the bottom to top of center joint.
4 5 3
EX1403172
Figure 13 Hub of Center Joint
• Thread of hoses and plugs

Port Name
0 Drain UNF 1 3/16"-12-2B 36 124.5 12.7 91.8
1 from Control Valve "A6" SAE 1 1/4", D30 12 176.4 18.0 130.1
2 from Control Valve "B1" SAE 1 1/4", D30 12 176.4 18.0 130.1
3 from Control Valve "A1" SAE 1 1/4", D30 12 176.4 18.0 130.1
4 from Control Valve "B6" SAE 1 1/4", D30 12 176.4 18.0 130.1
5 from Solenoid Valve "TR2" UNF 9/16"-18-2B 19 25.5 2.6 18.8
• Fitting
Size Torque
Port Name
0 PF 3/4" UNF 1 3/16"-12 32 176.4 18.0 130.1
Adapter
5 PF 3/8" UNF 9/16"-18 22 49.0 5.0 36.2
0 S8000235 (4D P22.4) S8030125 (4D F-12)
1, 2, 3, 4 2180-1026D23 (ID:37.69, W:3.53, 1B)
O-ring
2180-1216D11
5 S8000145 (4D P14)
(ID:7.65, W:1.78, 1B)

8-9-10
17. Install the eyebolts (PF 3/4") (Figure 14).
Attach a nylon sling onto the eyebolt.
EX1400946
Figure 14
18. Remove bolts and washers (1, Figure 15) (3 ea).
• Tool: 24 mm ( )
EX1400947
Figure 15
19. Lift the center joint by crane slowly and carefully.

• Center joint weight: about 55 kg (121 lb)
EX1400948
Figure 16

8-9-11
INSTALLATION
WARNING
SERIOUS INJURY
Any change in the connections will lead to malfunctions
(e.g. lift instead of lower).

3. To prevent the raindrops from penetrating, apply silicon on
the mounting part of center joint.
COMPLETING WORK
1. Start the engine and run at low idling for about 5 minutes.

8-9-12
DISASSEMBLY
IMPORTANT
Do not unbolt the center joint from the lower frame until an
adequate number of piping block off plates are available,
for disconnected piping lines. Be sure that system pressure
has been relieved - including the hydraulic accumulator and
tank reserve pressure - before disassembly is started.
WARNING
Because of its weight, use a hoist or a similar device to lift
the assembly.
WARNING
The hydraulic oil will be hot after machine operation. Allow
the system to cool before attempting to service any of the
hydraulic components.
1. Remove active oil remaining on each port with air.

2. Use a 19 mm wrench to loosen bolts and washers (13 and 13
14, Figure 17) and remove cover (3) and O-rings (10).
14
10
EX1402538
Figure 17

8-9-13
3. Use a 17 mm wrench to disassemble the bolts and 15
washers (15 and 16, Figure 18), spacer (4) and the shim
(5). 16
IMPORTANT 4
Care must be taken not to make a flaw on the surface 5

of the spindle when disassembling the body of the
spindle assembly.
EX1402539
Figure 18
4. Disassemble the body from the spindle assembly.

A. It can be disassembled easily by fixing the spindle
assembly, tightening eyebolts on the hub, and lifting it
with a hoist slowly.
B. Or, it can be disassembled by setting the continuous
thread studs on the spindle drain port as shown in the
figure.
EX1402540
Figure 19

8-9-14
12
IMPORTANT
2
7
Care must be taken not to damage the inside of the
1
body because it is likely to be damaged when
disassembling the slipper seal. It can be disassembled
4
more easily with a screwdriver whose tip is bent as 1
3
shown in Figure 20.
9
5. Remove the slipper seals (7, Figure 20) (7 ea), O-ring (9) 17
(1 ea), dust seal (17) (1 ea) and O-ring (8) (1 ea) from the
8 EX1402542
hub (1).
Figure 20
6. Remove foreign substance on pieces disassembled and PF 3/4 Plug

wash them out.
7. Replace disassembled O-rings and slipper seals with new
ones, for they cannot be reused.
PT 3/8 Plug EX1400121

Figure 21

8-9-15
REASSEMBLY
IMPORTANT
Apply a very light film of white grease inner surface of the
hub.
1. Assemble the slipper seals (7, Figure 22) (7 ea), O-ring (9)
(1 ea), dust seal (17) (1 ea) and O-ring (8) (1 ea) into the
hub (1).
2. Assemble the O-ring (8, Figure 22) the outside of the hub. 12
CAUTION
2
7
1
AVOID INJURY
4
After assembling the slipper seal, a manual test must 1
3
be performed to ensure that every part is assembled
properly. 9
17
8
IMPORTANT
EX1402542
Figure 22
For any slipper seal which is protruded, press it with

finger to seat it in its position. Care must be taken
when using a driver or a metal tool, which can cause
damage to the seal.
IMPORTANT
Applying oil to the surface of the shaft will help
prevent damage to the slipper seal.

8-9-16
3. Fix the position of the spindle and press the body carefully
into shaft with both being parallel each other.
4. Use a plastic (or rubber) hammer to tap the body until it is
inserted completely.
IMPORTANT
Tap the hub in a zigzag pattern so it does not tilt to one
side.
EX1402543
Figure 23
5. Install the shim (5, Figure 24), the spacer (4), and the 15
spacer bolts (15) on the top of the spindle.
16
• Tool: 17 mm ( )
• Torque: 49 ~ 59 N.m (5 ~ 6 kg.m, 36 ~ 43 ft lb)
4
EX1402539
Figure 24

8-9-17
6. Set the O-ring (10, Figure 25) in its place of the cover.  13
Install the cover (3, Figure 25) with bolts and washer (13
and 14).
14
• Tool: 19 mm ( )
• Torque: 98 ~ 123 N.m (10 ~ 12.5 kg.m, 72 ~ 90 ft lb) 3
IMPORTANT
10
After the completion of the assembly, a start-up and a
rotation torque tests must be performed for the slipper
seal to seat in its place properly.
EX1402538
Figure 25

8-9-18
TROUBLESHOOTING, TESTING
AND ADJUSTMENT
Inspection
The center joint must be checked for evidence of external oil
leakage every 2,000 operating hours. Leaking or defective
O-rings are an indication that dirt and other contaminants could
be getting inside the assembly, which will promote accelerated,
abnormal wear and can cause early failure of the assembly.
If internal seals or other sliding surface components are worn
and there is internal fluid leakage, complete overhaul and repair
or replacement of the center joint can be required.
Testing
Pressure
To check pressure through the center joint, make up a test kit Gauge
from the following equipment list:

• 700 bar (10,000 psi) pressure gauge.
• Adapters, connectors, piping and flange block off plates
Swivel Joint
Body (Outer)
conforming to those used in high-pressure piping Swivel Joint

Stem (Inner)
connections of the excavator.
• A high-pressure relief valve with a setting pressure 1.5
times maximum system pressure.
• A stop valve.
Stop
Valve
• A manually operated, in-line changeover valve.

Manually-Operated
Install the changeover valve upstream from one of the stem Changeover Valve
high-pressure ports. Connect the pressure gauge downstream

from one of the body ports. Install the stop valve between the Relief
Valve
changeover valve and the stem of the center joint. Other (1.5x)
components must be installed according to the layout in the High Pressure

Pump
block diagram. The test kit is used to pressurize the center Tank
swivel above normal working pressure and lock in the higher 0370
pressure (as the stop valve is closed manually) for a leak down Figure 26
test.
The same type of kit can also be made up for the drain port
(return line) side of the center joint. Use appropriate piping,
connectors, test gauges, etc., and follow the same block
diagram general layout (Figure 26).

8-9-19
8-9-20
1Travel Device
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Travel Device

8-10-1
Table of Contents
Travel Device
Safety Instructions ........................................8-10-1
General .........................................................8-10-3
Specification ............................................................ 8-10-3
Overview ................................................................. 8-10-4
Parts List ................................................................. 8-10-6
Theory of Operation .............................................. 8-10-10
Cautions for Operation .......................................... 8-10-20
Precaution...................................................8-10-23
Tools for Disassembly and Assembly.................... 8-10-23
Tightening Torque ................................................. 8-10-25
Removal......................................................8-10-26
Installation...................................................8-10-32
Completing Work ........................................8-10-32
Section View ...............................................8-10-33
Disassembly ...............................................8-10-36
Cautions on Disassembly ...................................... 8-10-36
Disassembly Sequence ......................................... 8-10-36
Reassembly ................................................8-10-46
Cautions on Assembly........................................... 8-10-46
Assembly Sequence.............................................. 8-10-46
Performance Test .......................................8-10-65
Troubleshooting ..........................................8-10-67
Travel Device DX480LCA-K/DX520LCA-K

8-10-2
GENERAL
Specification
1 Speed 2 Speed
Travel Motor Type Axial Piston 2-speed
Displacement 255 cc/rev 145 cc/rev
Crossover Relief Valve Setting 343 bar (350 kg/cm2)@25 L/min
Max. Supply Flow 380 L/min (100 U.S. gpm)
Motor Shaft Speed 1,490 rpm 2,621 rpm
1,393 N.m 794 N.m
Motor Shaft Torque
(142 kg.m, 1,027 ft lb) (81 kg.m, 586 ft lb)
Reduction Gear Type 3 - Stage Planetary Gear
Reduction Gear Ratio 68.23
Output Speed 21.8 rpm 38.4 rpm
95,046 N.m 54,044 N.m
Output Torque
(9,692 kg.m, 70,102 ft lb) (5,511 kg.m, 39,861 ft lb)
Weight 562 kg (Included Motor)
Traveling Traveling Speed 3.0 km/hr 5.3 km/hr
Performance
Traction Force 45.7 ton 26 ton
Traction Force (EFF. = 81%) 37 ton 21 ton
Grade ability 35° (70%)
Parking Brake Control Type Main Pressure, Mechanical
Brake Torque 853 N.m (87 kg.m, 629 ft lb) (min)
Brake Release Pressure 8 ±1.5 bar (8.2 ±1.5 kg/cm2)
Weight 562 kg (1,239 lb)

8-10-3
Overview
Travel device consists of a travel motor and gearbox.
Travel motor includes brake valve, parking brake and high/low
speed changeover mechanism.
Fill
D
A
Level
B
P1
Drain
P2
P
EX1401283
Figure 1
Port Name Size

A Inlet, Outlet SAE 1 1/4", 5000 psi, ø32, 66.7 x 31.8
B Inlet, Outlet SAE 1 1/4", 5000 psi, ø32, 66.7 x 31.8
D Drain PF 1/2", O-ring
P Pilot (High-speed) PF 1/4", O-ring
P1. P2 Gauge PF 1/4", O-ring
Fill PF 1/2", O-ring
Level PF 1/2", O-ring
Drain PF 1/2", O-ring

8-10-4
Reduction Gear
D D
Hydraulic Motor
HIGH
Parking Valve LOW
Parking Brake
P
High, Low Change Unit
P1 P2
Control Valve
Pump
A B
EX1401284
Figure 2

8-10-5
Parts List
Travel Motor
267
231
230
233
210
260
232
237
249
236
200
203
201
208 207
214
204
202
215
71 216
215
26 216
14 215
12 216
215
13 54 50
1
6
7 41 212
213
209
52
74
68
502
74
52
73
45 72
54 2
45 7
6
13
12
66 500 14
65 501 502
83 43
82 75
54 54
Figure 3 EX1401285

8-10-6
Reference Reference
Number Number
1 Rear Flange 201 Piston Assembly
2 C.B Spool Assembly 202 Driveshaft
6 Main Spring 203 Swash Plate
7 Washer 204 Cylinder Block
12 Cap 207 Plate Retainer
13 O-ring 208 Thrust Ball
14 Socket Bolt 209 Mating Plate
26 O-ring 210 Spring
41 Pin 212 Parking Piston
43 Socket Bolt 213 Spring
45 Plug 214 Cylinder Spring
50 Needle Bearing 215 Friction Plate
52 Plug 216 Mating Plate
54 Plug 230 O-ring
65 2 Speed Spool 231 O-ring
66 Spring 232 Oil Seal
68 Steel Ball 233 O-ring
71 Orifice 236 Lock Ring
72 Orifice 237 Retaining Ring
73 Orifice 249 Roller Bearing
74 O-ring 260 2 Speed Piston Kit
75 Orifice 267 Pivot
82 Plug 500 Reducing Valve
83 O-ring 501 Cover
200 Cylinder Block Kit 502 Relief Valve Assembly

8-10-7
Travel Reduction Gear
182
183
131 135
132
133 185
135 186
141
152 113
151 115
150
125 181 180 184
170
145 120
144
142
143
144
140
151
162
160
130
127
126
121
122
123
101 114 124
126
108
111
110
109
105
102
107
105
112 103
EX1401286
Figure 4

8-10-8
Reference Reference
Number Number
101 Spindle 131 Gear; Planetary No 2
101 Spindle 132 Bearing, Needle
102 Hub 133 Shaft; No 2
103 Seal, Floating 135 Washer, Thrust; 2.5T
105 Bearing; Angular 140 Carrier; No 1
107 Bolt, Socket M20 x 2.5 x 90 141 Gear; Planetary No 1
108 Ring, O 142 Cage; Needle
109 Piece, Distance 143 Ring; Inner
110 Coupling 144 Plate; Side E
111 Bolt, Socket M16 x 2.0 x 35 145 Ring; Snap
112 Plate; Thrust 150 Gear, Sun; No 3
113 Coupling, Drive 151 Ring; Thrust 90
114 Gear, Ring 152 Ring
115 Ring 160 Gear, Sun; No 2
120 Carrier; No 3 162 Ring
121 Gear; Planetary No 3 170 Gear, Drive
122 Bearing, Needle 180 Cover
123 Bushing 181 Washer; Thrust
124 Shaft; No 3 182 Plug
125 Pin; Spring 183 O-ring
126 Washer, Thrust; 3T 185 Bolt M12 x 1.75 x 40
127 Pin 186 Washer; Spring
130 Carrier; No 2 184 Ring, Thrust

8-10-9
Theory of Operation
Hydraulic Motor (Brake Valve, Parking Brake, High-Low

2-Stage Switching Mechanism)
Function
1. Function of the hydraulic motor
The hydraulic motor is a swash plate type axial piston
motor, which converts the power of the pressurized oil from
the pump into rotational motion.
2. Function of brake valve
The brake valve included in the hydraulic motor performs
four functions as follows:
A. When the motor stops, brake the motor to control the
moment of inertia and stop the motor smoothly.
B. The function of a check valve is to prevent cavitation
of hydraulic motor.
C. To function as a relief valve which controls the brake
pressure of the hydraulic motor and anticavitation
valve to prevent cavitation.
D. While the travel motor operates, it opens the port
which releases the parking brake, and when the
motor stops, it close the port.
3. Function of high-low speed 2-stage switching mechanism:
Using the switching valve and control piston, the swivel
angle of the swash plate can be switched between
high-speed low torque and low-speed high torque stages.
4. Function of parking brake
The parking brake stops the excavator from a when parked
on a slope by using friction plate type brake mechanism.
The brake is integrated with the hydraulic motor.

8-10-10
Operation of the Hydraulic Motor
1. Hydraulic motor
(Y1)
W1
Cylinder Block (204)
ri
F1 F1’
A P
W1
N1
Piston (205)
Swash Plate (203)

Low Press. High Press.
(Y2) FG018751
Figure 5
The high-pressure oil from the hydraulic pump flows

through the rear flange (RF1) of the hydraulic motor, timing
plate (209), and into the cylinder block (204). The
high-pressure oil enters the cylinder through one side of
the line Y1 - Y2 which connects the top-bottom dead points
of the piston (205) stroke.
In the Figure 5 above, the high oil pressure is applied on
the piston (205), pushing the swash plate (203) with force
F1' (F1' = P x A, P: oil pressure, A: area), generating
reaction F1. The reaction force F1 is divided into thrust
component N1 and radial component W1 by the swash
plate (203) having swivel angle of . W1 is illustrated in the
above figure, and generated torque T = W1 x r1 in relation
to the line Y1 - Y2 which connects the top-bottom dead
points of the piston (205).
This torque which is the resultant torque (W1 x r1) x i of
the torques generated by the pistons (4 or 5) on one side
where high-pressure oil has passed, rotates the cylinder
block (204) connected to the piston (205), and the cylinder
block (204) transmits rotational torque to the driveshaft
(202) connected by spline shaft.

8-10-11
2. Relief valve operation
The relief valve performs the following functions.
Chamber D Chamber C Poppet A
Chamber A
Chamber B
A1
Piston Chamber g Poppet A
A2
FG018752
Figure 6
A. The high-pressure oil entering chamber A by

counterbalance valve flows into chamber B in the
seat (See Figure 6). In the chamber B, the oil exerts
F1 = A1 x P1 of force on the cross-section A1 of
poppet A to push the poppet A to the left and the oil
flows from chamber A chamber B  chamber D.
While the poppet A is pushed to the left, the oil flows
from chamber B to chamber C through the orifice of
the poppet A. This high-pressure oil then pushes the
piston to the right through the orifice in the relief valve
body. When the piston reaches the end of the right
side (stroke end) by the oil, the oil is blocked from
chamber g to the spring chamber in the body. As the
resultant force of the oil pushing the area A2 of the
poppet A, which is F2 = A2 x P2, and the spring force
becomes higher than the force F1 = A1 x P1 exerted
on the area A1 of the poppet A, the poppet A and
seat are closed, and the oil flow through chamber A
chamber B  chamber D is stopped.
B. When the relief valve on the left is closed, the
pressure of the oil in the chamber A further increases.
This oil pressure is applied to the poppet B of the
relief valve on the right side. Since the force (F4 =
A4 x P3) applied on the area A4 of the poppet B
becomes larger than the force (F3 = A3 x P3) on the
area A3, the poppet B moves to the right and opens,
and the oil flows; chamber A  chamber E 
chamber D to operate the motor.
By controlling the pressure in chamber D in 2-stages,
the brake of the hydraulic motor is released smoothly
and the motor starts to run.

8-10-12
3. Brake operation
RF1 213 212 101 202
CB
500
71 216 215 204
Counter Balance Spool (CB)
P1 D
Position 1
HIGH
A
LOW
B
Position 2
Position 3
P2 P D
Pressure Reducing Brake Piston Orifice (71)

Figure 7 Valve (500) Chamber EX1401287
When releasing the brake, the high-pressure oil opens the

counterbalance spool (CB) assembled with the rear flange
(RF1), and apply pressure on the brake piston (212) to
release the brake. When oil does not exert pressure on the
piston, brake force is maintained by brake spring.
Brake force is generated by the spindle (101) and the
mating plate (216) assembled to the spindle (101), brake
piston (212) and the friction plate (215) coupled with
cylinder block (204) using spline.
When pressure is not applied, the brake piston, by the Reducing Valve
EX1400604
force of the brake spring (213), pushes the friction plate
and mating plate assembled with the spindle to generate Figure 8 Parking Brake Release
friction force. This friction force restrains the driveshaft
(202) which is coupled with the cylinder block using spline
to activate the brake.

8-10-13
(Counterbalance spool is in travel state (position 1 or 3))
The pressure of the oil entered through the A or B port is
reduced in the pressure reduction valve and enters the
brake piston chamber.
Here, although a small amount of oil is drained through the
orifice B (71), because high-pressure oil is supplied from
the counterbalance valve, the pressure in the brake piston
chamber overcomes the spring force and releases the
brake.
(Counterbalance spool is in neutral state (position 2))
Because high-pressure oil is not supplied, the pressure in
the brake piston chamber is low and the brake spring force
overcomes the pressure in the brake piston chamber, and
the brake is applied. Now, because the oil in the brake
piston chamber is drained through the orifice B (71), the
spool returns to neutral position, and delays braking until
motor stops to prevent damage to the friction plates.
4. How to release brake
Brake can be released by the following procedures without
supplying release pressure.
WARNING
To prevent excavator from accidental rolling or
movement, always block excavator tracks (or wheels)
before releasing brake before servicing brake.
Remove 2 plugs (45) from the rear flange (RF1). Insert an

M10 x 135L bolt and join with the threaded part of the
brake piston to release the brake.
Now, the condition is the same as when brake release
pressure is supplied, and the brake is released.
• Socket Wrench: 6 mm, 8 mm
NOTE: If the hydraulic motor fails to rotate after
releasing the brake, the cause can be failure to
generate operating pressure because of a
pump problem.
To tow the system without disassembling the
hydraulic motor, connect short hoses to the
ports P1 and P2 of the pressure measure ports
and then tow the system at low speed.

8-10-14
5. Operation of counterbalance valve
Port (BV) is connected to hydraulic pump, while port (AV)
is connected to tank. Pressurized oil from hydraulic pump
passes through (BV) to (CV), from (CV) to (C), opening
check valve poppet and supplying to hydraulic motor
through (BM) port and then rotate the motor.
Also, if hydraulic pressure delivered from pump is
increased, pressurized oil flowing from gallery (G) passes
spring chamber (E), ball check valve, and then reaches
damping chamber (M).
If pressure in chambers (E) and (M) overpowers spring
(362) force which is designed to maintain neutral position
of spool, spool moves in Right Left direction. 
Working oil in (N) chamber flows through orifice (Q) to (F)
chamber, while working oil in chamber (F) passes (G) to
(AV) and then is drained to tank.
If hydraulic pressure delivered from pump is lowered,
pressure in (E) and (M) chambers also is lowered. 
As a result, spool is returned in direction Left Right by
spring (362) of chamber (F). 
Working oil in (M) chamber passes orifice (R) and is
delivered to (E) chamber, while working oil in (E) chamber
is delivered from path (G) to (BV) port. As a result, spool
moves in direction of Left Right.
If pressure in (BV) port is lowered down to tank pressure,
pressure in (E) and (F) chambers also becomes same as
tank pressure. As a result, spool returns to neutral position.

8-10-15
AV BV
H G
F E
Q R
DV CV
362
AM BM E
D
CheckValve
Check ValvePoppet
Poppet
C
AV BV
H
G
F
E
DV CV
R
362
AM BM
D
E
Check Valve Poppet

Figure 9 EX1402196

8-10-16
6. Operation of the swivel switching mechanism
Shoe (262) supports swiveling swash plate (203), and the
hemispherical pivots (267) at the both ends of the shoe
bear the load transmitted through the swash plate stopper.
For capacity change, the swivel angle of the swash plate is
controlled. The control mechanism opens the swivel piston
(261) at the swash plate stopper part and controls the
hydraulic oil into and out of the piston chamber with swivel
control valve, which leads to control the swivel angle of the
swash plate in 2 positions of large and small.
Low speed - less than pilot pressure (19.6 bar)
A B
Pilot o1 X
Pressure (D)
267
65
A
B 66
203 262 261
Drain Chamber P
EX1400601
Figure 10
When pilot pressure is not supplied, by the force of the

2-speed spring (66) of the 2-speed spool (65) and the oil
pressure of port (A) or port (B), the 2-speed spool is
pushed up and the oil at port (C) is cut-off.
The high-pressure oil in chamber (P) is drained into motor
case by the 2-speed spool (65).
Consequently, the swash plate (203) has the maximum
swivel angle 1 and the displacement of the hydraulic
motor piston becomes maximum, resulting in low speed
rotation.
• Torque: High
• Speed: Low

8-10-17
At high-speed
A B
Pilot
Pressure (D) o2
65 X
A
B 66
203
261
C
Drain
Chamber P
EX1400602
Figure 11
When pilot pressure is supplied through port D

(pressure: kg/cm2), the pressure overcomes the force of
the 2-speed spring (66) and the oil pressure of port (A) or
port (B), pushing down the 2-speed spool and the oil at
port (C) flows into chamber (P) by 2-speed spool (65). The
high-pressure oil entered the chamber (P) pushes the
2-speed piston (261) until swash plate (203) contacts
surface X.
Consequently, the swash plate (203) has the minimum
swivel angle 2 and the displacement of the hydraulic
motor piston becomes minimum, resulting in high-speed
rotation.
• Torque: Low
• Speed: High

8-10-18
Operation of the Reduction Gear
The reduction gear consists of 3-stage planetary and differential
mechanism, as illustrated in the figure above.
Since the sun gear is designed in a floating structure, the life
span of the gear depends upon the accuracies of the gear teeth Input (Output of hydraulic motor)
and the carrier pinholes.
The rotational power of the hydraulic motor is transmitted to the
drive gear (D) which drives the No. 1 planetary gear (P1). The
No. 1 planetary gear (P1) transmits rotatory force to the cover
gear (C) in the direction of the tangential force of the drive gear AUS0610L
(D). As the cover gear (C) is fixed, the reaction force of the Figure 12
rotatory force is generated and rotates the No. 1 carrier (C1).
That is, the No. 1 planetary gear (P1) revolves, not rotates. The
rotation of the No. 1 carrier (C1) is transmitted to the No. 2 sun
gear (S2) as 1-stage output. (the No. 1 carrier and the No. 2 sun
gear are coupled with splines.)
In the above described principle, the revolution of the No. 2
planetary gear (P2) is transmitted to the No. 3 sun gear (S3) by
the No. 2 carrier (C2). Hear, since the No. 3 pin supporting the
No. 3 planetary gear (P3) is fixed, the No. 3 planetary (P3)
drives the ring gear (R) by both revolution and rotation.
Consequently, the rotating drum is driven by the resultant power
of the cover gear and ring gear.
The reduction gear ratio is as follows
(ZD + ZC) (ZS2 + ZR) (ZS3 + ZR)

i= -1
ZD x ZS2 x ZS3
ZD : number of the teeth of the drive gear

ZC : number of the teeth of the cover gear
ZS2: number of the teeth of the No. 2 sun gear
ZS3: number of the teeth of the No. 3 sun gear
ZR : number of the teeth of the ring gear
The direction of rotation is opposite to that of the input shaft.

8-10-19
Cautions for Operation
Installation Method (refer to the Outline Drawing)
Frame Mount
Sprocket Mount
EX1401288
Figure 13
Tightening torque of mounting bolts
Tightening Torque
Classification Qty Bolt Size
N.m kg.m ft lb
Frame Mount 26 M24 x 3.0 x 90 932 95 687
Sprocket Mount 36 M20 x 2.5 x 65 588 60 434
NOTE: The bolts must be Strength Class 10.9 equivalent or

better.
When assembling, do not hit the travel motor with
hammer, etc., but use bolt holes.
Take care not to damage the assembling part of the
gearbox.
Pipeline
• Connect the pipeline after confirming the direction of
rotation of the motor (see outline drawing).
• At the time of shipping, pipeline ports (brake valve port,
motor drain port) are plugged and capped. The plugs and
caps are provided to protect the line from dust or welding
scale, to not remove them until connecting the pipeline.
• Make sure to fill the motor case with hydraulic oil before
starting the motor.
• Determine the pipeline diameter so the back pressure at
the motor drain port is less than 3 bar (3 kg/cm2) (or less
than 3 bar at peak).

8-10-20
Hydraulic Oil
Because the hydraulic motor case is drained at the time of shipping,
make sure to fill up the case with hydraulic oil before operation.
Selecting Hydraulic Oil

Take the followings into consideration when selecting the
hydraulic oil for travel motor:
1. Use VG32-VG56 grade or equivalent.
2. Use wear resistant hydraulic oil.
3. Please contact us when hydraulic oil other than the one in
the table below is to be used;
Viscosity (40°C) 32CST 46CST

Grade
ISO VG VG32 VG46
Inspection, Replacement of Hydraulic Oil

The standard replacement period of hydraulic oil is as follows
(may vary by operating condition);
The table below shows the standard replacement period of
hydraulic oil.
• Replacement period: 1,000 hr or 1 year
• Replacement criteria
Test Item Replacement Criteria

Viscosity Change (40°C) ±10%
Oxidation (mgKQH/g) *
Moisture (%) 0.1%
Foreign Matter 10 mg/100 m ℓ
Suspended Solids (%) 0.05%
Color Changes greatly
* For further details, contact us, since above criteria varies

greatly by the type of oil and manufacturer.
Lubricant
The reduction gear is filled with lubricant (gear oil) at the time of
shipping, however, check the oil level before operation.
1. Selecting gear oil
Use the gear oil with SAE #90 of equivalent extreme
pressure additive (API Classification GL-4 Grade or
better).
2. Replacement period of gear oil
A. First replacement (first time after starting operation):
500 hr
B. Second and later replacement: 1,000 hr or 1 year

8-10-21
However, if gear oil reduces fast than normal, find out
and correct the cause before refilling oil.
3. Replacement volume of gear oil: 10 L (2.6 U.S. gal)
4. Replacement method of gear oil
Port's of Gear Oil

Inlet
G1/2 (PF1/2)
Level Check
G1/2 (PF1/2)
Drain
Figure 14 G1/2 (PF1/2) EX1401289
Added or replaced oil must be of the same kind. Do not mix

with a different type or grade of oil.
A. Let the oil refill port and drain port be perpendicular to
the horizontal plane.
B. For replacement, unplug the two ports and drain the
gear oil.
C. Refill gear oil until oil overflows from oil level check
port.
D. Wind Teflon or thread tape on the plug before
plugging the ports again.
Maintenance/Service
Check the following items while operating the travel motor.
1. Stop the product before service or inspection except when
checking the noise level of clause 3 below. Otherwise, you
may get physical injury including burn.
A. Oil leak (hydraulic oil, gear oil)
B. Loose bolt
C. Abnormal noise
D. Abnormally high case temperature 
(Standard external surface temperature of case
during continuous operation: 80°C max.)

8-10-22
E. Replacement period of gear oil (See ?$paratext>? on
page -21.)
F. Hydraulic motor allowable drain: 0.5 lpm (pressure
50 K max., at 25 rpm)
2. The case may be very hot right after operation. Measure
the temperature with a contact type thermometer.
PRECAUTION
Tools for Disassembly and Assembly
Hydraulic Motor
Tool B Size Applicable Part

2 Orifice (71)
4 Plug (54), Orifice (71)
Allen Wrench 6 PT Plug (45), PF Plug (52)
10 Socket Bolt (14)
17 Socket Bolt (43)
22.4 Reducing Valve (500)
Socket Wrench
41 Relief Valve (RV1)
Pliers (for holes TPR-90) For retaining rings (236)
Pliers (for shafts) For retaining rings (237)
Hammer, Plastic Hammer
Copper Rod, Approximately 7 x 7 x 200 mm Bearing (50, 249)
Monkey Wrench
Torque Wrench
Driver (JISB 4609)
Jig for Oil Seal Insertion
Bearing
Seal Tape
B B
Figure 15 B Size (rear side width) FG018759

8-10-23
Reduction Gear
Tool B Size Applicable Part

Allen Wrench 10 Plug (182)
Hex Wrench 19 Hex Bolt (185)
Eyebolt (M10) No.1 Carrier (140), No.2 Carrier (130)
Eyebolt (M20) Hub (102), Spindle (101)
Hammer, Plastic Hammer Wood hammer also applicable
Driver () To disassemble floating seal
Press (1 ton) Angular Bearing (105)
Punch For caulking spring pins and set screws
Torque Wrench
Oil Grind stone Finishing
B B
B Size (rear side width) FG018759

Figure 16

8-10-24
Tightening Torque
Tightening Torque
Classification Symbol Name Size (mm) B Size
N.m kg.m ft lb
Socket
14 M12 x 45 10 98.1 10 72.3
Bolt
Socket
43 M20 x 45 17 431.5 44 318.2
Bolt
Hydraulic Motor 54 Plug NPTF 1/16 4 9.8 1 7.2

45 Plug PT 1/2 6 21.6 2.2 15.9
52 Plug PF 1/4 6 36.3 3.7 26.8
71 Orifice M4 x 0.7 2 3.5 0.36 2.6
82 Plug PF 1/2 10 107.9 11 79.6
Socket
107 M20 x 90 17 431.5 44 318.2
Bolt
Reduction Gear
182 Plug PF 1/2 10 98.1 10 72.3
185 Hex Bolt M12 x 40 19 88 9 65
B B
B Size (rear side width) FG018759

Figure 17

8-10-25
REMOVAL
WARNING
• If hydraulic fluid should come into contact with your eyes
or penetrate your skin, consult a doctor immediately.
WARNING
workplace.
IMPORTANT
etc. must be disposed of in an environmentally safe manner.
Some regulations require that certain spills and leaks on the
ground must be cleaned in a specific manner. See local, state
and federal regulations for the correct disposal.
1. Position machine on a smooth level surface with adequate

space. Move machine until master pin is positioned at
approximately 4 o'clock.
NOTE:
EX1401463
Figure 18
Regular Pin Master Pin
EX1400095
CAUTION
AVOID INJURY
Pressure of grease in adjuster cylinder is too high.
Take precautions in opening valve against valve
bounce or grease vent.

8-10-26
2. Loosen grease valve, and then slacken the tension of
track.
NOTE: Since the inner pressure of the adjustment
cylinder is high, loosen the grease valve slowly.
If the grease does not come out adequately, start the
engine and move the machine back and forth.
• Tool: 27 mm ( )
Figure 19 EX1401462
3. Remove master pin using jig or tool.
EX1401463
Figure 20
4. Put blocks at two different positions under the track to

widen the gap between sprocket and lower track.
NOTE: The gap between sprocket and track link must
be over 50 mm (2 in).
Figure 21 EX1401464
5. Place travel device in the direction of the arrow slowly and

remove upper track.
EX1401465
Figure 22

8-10-27
6. Set the angle between boom and arm in 90 ~ 110° and
support the machine by using a block. Swing the upper
structure and jack up the machine.
NOTE: Jack up the machine until the track is slightly off 90 - 110
the ground.
7. Stop engine.
Figure 23
EX1300534

(Figure 24) I
WARNING OFF
Lock
OFF
ON
ON

switch.
ON
OFF
ON
DS1704238
Figure 25

8-10-28
3
5 8
1 2
7 6
4
EX1401809
Figure 26
WARNING
any work.
Pulling the breather cap upward, the check valve (0.45 bar)
Figure 27 DS1601105
opens, and the air is discharged to the atmosphere from
the top of the hydraulic oil tank.
16. Remove bolt (36 ea) with sprocket from travel device
(Figure 28).
• Tool: 30 mm ( )
• Sprocket weight: 105 kg (231 lb)
EX1401466
Figure 28
17. Remove cover from track frame (bolt: 5 ea, washer: 5 ea).
• Tool: 19 mm ( )
• Weight: about 17 kg (37.5 lb)
EX1401467
Figure 29

8-10-29
18. When disconnecting the hose, oil left in the hose can flow
environment.
EX1504170
Figure 30
19. Remove hoses and adapters from travel device.

NOTE: Attach identification tags to the removed hoses
for reassembling. D
After disconnecting hoses, plug them to prevent
dirt or dust from entering. A
Disconnect the hoses from the bottom to top of
travel device.
P
B
EX1401468
Figure 31

Port Name
A Inlet, Outlet SAE 1 1/4", 5000 psi, D32 12 176.4 18.0 130.1
B Inlet, Outlet SAE 1 1/4", 5000 psi, D32 12 176.4 18.0 130.1
D Drain UNF 13/16"-16-2B 24 55.9 5.7 41.2
P Pilot UNF 9/16"-18-2B 19 25.5 2.6 18.8
• Fitting
Size Torque
Port Name
D PF 1/2" UNF 13/16"-16 27 83.4 8.5 61.5
Adapter
P PF 1/4" UNF 9/16"-18 19 34.3 3.5 25.3
DS2856004
A, B
(1 1/4", ID:38, OD:45, 1B)
D O-ring S8000185 (4D P18) S8030081 (1B F-08)
2180-1216D11
P S8000115 (4D P11)
(ID:7.65, W:1.78, 1B)

8-10-30
20. Remove bolts (22 ea) from track frame except 4 bolts in
the direction of 12 o'clock
• Tool: 36 mm ( )
EX1401469
Figure 32
21. Install the sprocket bolts (2 ea) to travel device, and tie the
rope to the bolts to lift it.
EX1401470
Figure 33
22. Remove remaining bolts (4 ea) of track frame side, and

then hoist and remove travel device from track frame very
slowly.
• Weight: about 562 kg (1,239 lb)
EX1401471
Figure 34

8-10-31
INSTALLATION
WARNING
SERIOUS INJURY
Any change in the connections will lead to malfunctions
(e.g. lift instead of lower).
IMPORTANT
When replace the travel device, both sides of travel devices
are same grades.
1. Perform installation in the reverse order to remove.

Figure 35 EX1401472
COMPLETING WORK
1. Air testing of reduction gear
Remove one of the plugs (182) of the reduction gear and
apply compressed air 0.3 bar (0.3 kg/cm2) through the plug
hole under water for two minutes. There must be no
observable air bubble.
 Refill gear oil 10 L (SAE 80W90 equivalent, API
classification GL-4 Grade or better)
2. Air testing of hydraulic motor
Seal all the pipe ports of the hydraulic motor except one
through which compressed air 3 bar (3 kg/cm2) is injected
under water for two minutes. There must be no observable
air bubble.
 Hydraulic oil refill 2.5 L
3. Start the engine and run at low idling for about 5 minutes.

8-10-32
SECTION VIEW
59 54 56 53 60 58 57 49 50 52 51 55 62 61 80
72 67 68 71
121
A A
Section A -A
113
115
114
106
109 116 110 107 108 111 118 103 104 81 82 117 112 105 69 123 122
101 100 99 96 98 92 1 3 84 11 4 6 7 8 12 16 15 14 17 30 28 22 15
95 27
93 29
76 35
97 32
74 36
39
37
94 38
41
73
75 40
102 21
66 31
65 33
64
63 21
70 26
124 42
79 43
78
34
77 47 48 46 87 88 86 90 5 85 83 89 91 2 9 18 13 19 23 24 10 20 44 45 25 EX1401290
Figure 36

8-10-33
Reference Reference
Number Number
1 Spindle 48 O-ring
2 NPTF Plug 49 Rear Flange
3 Floating Seal 50 C.B Spool
4 Hub 51 Plug
5 Angular Ball Bearing 52 Poppet
6 O-ring 53 Steel Ball. 3/16"
7 Distance Piece 54 Screw
8 Coupling (B) 55 Spring (Check)
9 Socket Bolt 56 Spring
10 Ring Gear 57 Washer
11 Socket Bolt 58 Spring (Main)
12 Carrier No. 3 59 Seat
13 Thrust Washer (3.0) 60 O-ring
14 Floating Bush 61 Cover (C.B)
15 Needle Bearing 62 Socket Bolt
16 Planetary Gear No. 3 63 Spring (2 Speed)
17 Shaft (Bearing) No. 3 64 Spool (2P)
18 Spring Pin 65 RO Plug
19 Thrust Plate (R) 66 O-ring
20 Sun Gear No. 3 67 RO Plug
21 Thrust Ring 90 68 O-ring
22 Thrust Ring 209 69 PT Plug
23 Coupling 70 Orifice
24 Snap Ring (R) 71 NPTF Plug
25 Carrier No. 2 72 Steel Ball (YSS)
26 Clip. WR145 73 Needle Bearing
27 Thrust Washer (2.0) 74 Parallel Pin
28 Planetary Gear No. 2 75 Timing Plate
29 Shaft (Bearing) No. 2 76 Spring
30 Spring Pin 77 Orifice
31 Sun Gear No. 2 78 Orifice
32 Carrier No. 1 79 O-ring WG
33 Clip. WR135 80 Socket Bolt
34 Cover 81 Reducing Valve
35 Side Plate E 82 Cover
36 Ring Inner (NSK) 83 Oil Seal
37 Needle Bearing 84 Pivot
38 Planetary Gear No. 1 85 Snap Ring (S)
39 Snap Ring (S) 86 Bearing Roller
40 Drive Gear 87 Drive Shaft
41 Thrust Washer (M) 88 Snap Ring (R)
42 RO Plug 89 Piston (2 Speed)
43 O-ring 90 Shoe (2 Speed)
44 Spring Washer 91 Spring (2 Speed Piston)
45 Hex Bolt 92 Swash Plate
46 O-ring WG 93 Cylinder Block
47 O-ring WG 94 Spring (Cylinder Block)

8-10-34
Reference Reference
Number Number
95 Thrust Ball 109 Piston
96 Retainer Plate 110 Sleeve
97 Piston 111 Spring Seat
98 Shoe 112 Spring
99 Friction Plate 113 Plug
100 Mating Plate 114 O-ring
101 Piston (Parking) 115 Back Up Ring
102 Orifice 116 Lock Nut
103 Body 117 Back Up Ring
104 Seat 118 O-ring
105 Plunger 121 Dust Plug
106 Adjust Plug 122 RO Plug
107 Back Up Ring 123 O-ring
108 O-ring 124 Dust Plug

8-10-35
DISASSEMBLY
Cautions on Disassembly
1. Take care not to damage the contact surfaces of the seals
(O-rings, oil seals) and gears, pins and bearings, and other
sliding surfaces.
2. When disassembling the hydraulic motor as mounted on
the equipment, take care to prevent dust and other foreign
materials from entering.
3. The number in the parenthesis after the part name
indicates the part number in the assembly drawing.
4. The motor's inlet pipeline side and output side are defined
to be rear and front sides, respectively.
Disassembly Sequence
The procedures of disassembly are as follows. In the order of
disassembly, A: Reduction Gear is followed by B: Motor
Reduction Gear
1. Select appropriate workplace.
NOTE: Select a clean place.
Cover the floor with rubber mat, etc., to protect
the parts.
2. Clear the reduction gear surface of dust and other foreign
material.
3. Drain the gear oil.
NOTE: Put the drained gear oil in a clean container to
check its clearness. Do not reuse the drained
gear oil.
4. Put down the cover (180) facing upward, and remove
socket bolt (185).
NOTE: Do not reuse the thrust washer (M) of the cover.
Figure 37

8-10-36
5. Remove drive gear (170), and remove No.1 carrier (140)
with the No.1 planetary gear (141) and No.2 sun gear
(160).
Figure 38
6. Remove retaining ring (145), and remove planet E (144),

No.1 planetary gear (141) and the needle bearing (142).
Figure 39
7. Remove clip (162), and remove No.1 carrier (140) from

No.2 sun gear (160).
Figure 40
8. From the sun gear No.2 (160), remove thrust ring 90 (151).
Figure 41

8-10-37
9. Remove No.2 carrier (006), spring pin (125), and remove
No.2 shaft bearing (133) from No.2 carrier (130).
NOTE: Before disassembly work, check followings and
proceed with the disassembly if there is any
problem.
Inspect the planetary gear tooth surface if there
is flaking or pitting.
Rotate the planetary gear lightly to check
abnormal noise and/or eccentricity.
Figure 42
10. From No.2 carrier (130), remove thrust washer (135), No.2
planetary gear (131), and the needle bearing (132).
Figure 43
11. From the sun gear No.3 (150), remove thrust ring 90 (151)
and clip (152), and remove No.2 carrier (130) from No.3
sun gear (150).
Figure 44

8-10-38
12. Remove thrust ring (209) (184) from No.3 carrier (120).
Figure 45
13. Remove No.3 carrier (120) with No.3 planetary gear (121)
being assembled.
NOTE: Attach two M10 eyebolts and lift it up with a
crane.
Figure 46
14. Remove spring pin (127), and remove No.3 shaft bearing
(124) from No.3 carrier (120).
NOTE: On the rear side of the No.3 carrier, remove
No.3 shaft bearing.
Figure 47

8-10-39
15. Remove No.3 planetary gear (121), the needle bearing
(122), the floating bushing (123), and the thrust washer
(126) from the No.3 carrier.
Figure 48
16. Remove thrust plate R (112) and the coupling B (110), and
then remove distance piece (109).
crane.
Figure 49
17. Disassemble the hub (102) and ring gear (114) assembly,
and remove floating seal (103).
crane.
Figure 50
18. Remove socket bolt (107), and disassemble the hub (102)
and ring gear (114).
Figure 51

8-10-40
19. Remove two angular bearings (105) from the hub (102).
NOTE: In principle, do not reuse the bearing once
disassembled.
Figure 52
Disassembling Hydraulic Motor

1. Disassemble the pressure reducing valve assembly.
Figure 53
2. Disassemble the two relief valves (RV1).
Figure 54
3. Remove two plugs (45), install M10 x 135L socket bolt and
assemble them with the brake piston (212).
Figure 55

8-10-41
4. Remove eight socket bolts (43).
Figure 56
5. Remove bolts for forced brake reset, and remove brake

piston (212) and rear flange (RF1).
Figure 57
6. Remove brake spring (213) and timing plate (209).
Figure 58
7. Remove plug (56), swivel spring (66), and swivel spool

(65).
Figure 59

8-10-42
8. Remove socket bolt (14), and disassemble the cover (12)
and counterbalance spool assembly.
NOTE: If the counterbalance spool or counterbalance
spring is defective, replace the whole
counterbalance spool assembly.
Figure 60
9. Disassemble four friction plates (215) and three mating

plates (216)
NOTE: Hold the motor in vertical position during the
work.
Figure 61
10. Disassemble the cylinder block kit.

work.
Figure 62
11. Remove piston assembly assembled with the retainer plate

(207) from the cylinder block (204).
Figure 63

8-10-43
12. Remove piston assembly from the retainer plate (207).
Figure 64
13. Remove thrust ball (208) and 9 cylinder block springs

(214).
Figure 65
14. Remove swash plate (203).

work.
Figure 66
15. Remove swivel piston (261) and shoe assembly (262).
Figure 67

8-10-44
16. Remove 2-speed spring (210) from the swivel piston (261)
and shoe assembly (262).
Figure 68
17. Remove swivel piston assembly and 2 pivots (262).
Figure 69
18. Remove retaining ring (236). Remove front end of

driveshaft (202) from the spindle (101) by striking it with a
plastic hammer.
NOTE: Do not remove roller bearing (102) unless it is
defective.
Figure 70
19. Using retaining ring pliers, remove retaining ring (237) and
roller bearing (249).
Figure 71

8-10-45
20. Remove oil seal (232) from the spindle (101).
NOTE: The oil seal (491) cannot be reused.
Replace it with a new one.
Figure 72
Through above procedures, disassembly work is completed. Do

not remove pin (41: for fixing timing plate position) press-fitted
with the rear flange.
REASSEMBLY
Cautions on Assembly
Wash all the parts clean with clean flushing oil and dry them with
compressed air. Avoid using oilcloth, however, if necessary, use
a clean cloth and take care to avoid dust, etc.
Bolts and plugs must be tightened at the torque specified in
Table 5, using a torque wrench.
If a hammer is required, use a plastic hammer and hit the parts
lightly. As in the disassembly procedures, the number in the
parenthesis after the part name indicates the part number in the
assembly drawing.
Assembly Sequence
The procedures of assembly of the motor are as follows. This
assembly instruction presumes that all the parts are new.
The assembly sequence is A: Reduction Gear followed by B:
Hydraulic Motor

8-10-46
Reduction Gear
1. Assemble the side plate E (144) and inner race (143) with
carrier No. 1 (140) in that order.
Figure 73
2. Assemble the needle bearing (142).
Figure 74
3. Assemble carrier No.1 with sun gear No.2 and the clip
(162).
Figure 75
4. Assemble planetary gear No. 1 (141) and the side plate

(144) in that order.
Figure 76

8-10-47
5. Assemble the retaining ring (145) using retaining ring
pliers.
Figure 77
6. Assemble carrier No.2 with sun gear No.3 and the clip
(150) in that order.
Figure 78
7. Assemble No.2 planetary gear (131) with the thrust washer

(135), needle bearing (132), and thrust washer (135) in
that order.
Figure 79
8. Assemble carrier No.2 (130) with the above assembly and

shaft bearing No.2 (133).
Figure 80

8-10-48
9. Insert the spring pin (125) into the pinhole of the carrier
No.2 (130).
NOTE: Align the centers of the carrier pin and planetary
gear.
Figure 81
10. Assemble No.3 planetary gear (121) with the needle

bearing (122) and floating bushing (123), put thrust
washers (126) on both sides and insert the assembly into
the NO.3 carrier (120).
Figure 82
11. Insert shaft bearing No.3 (124).
Figure 83
12. Insert the spring pin (127) into the pinhole of the carrier
No.3 (120).
NOTE: Align the centers of the carrier pin and planetary
gear.
Figure 84

8-10-49
13. Assemble the angular bearing (105) into the hub (102).
Figure 85
14. Assemble the angular bearing (105) into the other side of
the hub (102).
Figure 86
15. Assemble the hub (102) with the ring gear (114), tighten
with socket bolt (107).
• Socket bolt (107) tightening torque: 5,030 kg.cm
Figure 87
16. Assemble the hub (102) and ring gear (114) assembly with
the spindle (101).
Figure 88

8-10-50
17. Place the coupling B (110) and tighten with hex bolt (111)
at specified torque.
• Hex bolt (111) tightening torque: 2,570 kg.cm
Figure 89
18. Insert carrier No.3 sub into the ring gear (114).
Figure 90
19. Assemble thrust ring 209 (184) with No.3 carrier (120).
Figure 91

8-10-51
20. Insert carrier No.2 sub into the ring gear (114).
Figure 92
21. Insert carrier No.1 sub into the ring gear (114) and
assemble thrust ring 90 (151).
Figure 93
22. Assemble the drive gear (170).
Figure 94
23. Press Fit the thrust washer M (181) into the cover (180).
Figure 95

8-10-52
24. Apply sealant to the contact face of the ring gear (114)
cover (180) and assemble the cover (180) using socket
bolt (185).
Figure 96
25. Refill reduction gear oil.

• Reduction gear oil volume: 10 L (2.6 U.S.gal)
Figure 97
26. Install the plug (182) in the reduction gear oil inlet.
• Plug (182) tightening torque: 1,000 kg.cm
Figure 98
Assembling Hydraulic Motor

1. Install 7 plugs (54) with the rear flange (1) at specified
torque.
• Plug (54) tightening torque: 100 kg.cm
Figure 99

8-10-53
2. Assemble 2 plugs (56) at specified torque.
Figure 100
3. Assemble the 2-speed spring (66) and 2-speed spool (65)

in that order.
Figure 101
4. Assemble the plug (82) at specified torque.

• Plug (82) tightening torque: 1,100 kg.cm
Figure 102
5. Insert the steel ball (68) and perform caulking.
Figure 103

8-10-54
6. Assemble the plug (52) at specified torque.
Figure 104
7. Assemble the orifice (71) at specified torque.

• Orifice (71) tightening torque: 36 kg.cm
Figure 105
8. Assemble the counterbalance spool (2) and washer (7)

with the rear flange (1).
Figure 106
9. Assemble the O-ring (13) (P44).
Figure 107

8-10-55
10. Assemble the main spring (6).
Figure 108
11. Assemble the counterbalance spool (2), washer (7), main

spring (6) and seat (8) in that order.
Figure 109
12. Assemble the cover (12) using socket bolt (14).

Figure 110
13. Press Fit the pin (41).
Figure 111

8-10-56
14. Press Fit the needle bearing (50). (For the first assembling)
NOTE: Do not disassemble this in the disassembly
procedures.
Figure 112
15. Assemble the rear flange (1) sub with the timing plate
(209).
NOTE: Apply grease on the rear side of the timing plate
to prevent it from falling down.
Figure 113
16. Assemble the rear flange (1) sub with the O-ring (26)
(WG51).
Figure 114
17. Assemble the rear flange (1) sub with 4 brake springs
(213).
NOTE: Apply grease to the springs to prevent them
from falling down.
Figure 115

8-10-57
18. Assemble orifice (71) with the brake piston (212).
• Tightening torque: 36 kg.cm
Figure 116
19. Insert M10 x 135 socket bolt into the hole for forced brake
release of the rear flange (303) and assemble the sub-
subassembly.
NOTE: When the assembly has been completed,
remove 2 M10 x 135L socket bolts.
Figure 117
20. Assemble the cylinder block (204) with 9 springs (214).
Figure 118
21. Assemble thrust ball (208) with the cylinder block (204).
NOTE: Align the cylinder and the splines on the
spherical bushing.
Figure 119

8-10-58
22. Insert the piston (261) and 9 sets of shoe assembly (262)
assembly into the retainer plate (207).
Figure 120
23. Assemble the subassembly with the cylinder block (204).
Figure 121
24. Assemble the roller bearing (249) on the driveshaft (202).

25. Assemble the retaining ring (236) using retaining ring
pliers.
NOTE: Take care not to damage the oil seal sliding
surface of the driveshaft.
Take care not to confuse the direction of the
retaining ring.
Figure 122
26. Assemble the oil seal (232) on the spindle (101) using an
oil seal assembly jig.
Figure 123

8-10-59
27. Assemble the driveshaft (202) with the spindle (101), and
assemble the retaining ring (236) using pliers.
Figure 124
28. Assemble the pivot (267).
Figure 125
29. Assemble the 2-speed spring (210) with the swivel piston
(261) and shoe assembly (262).
Figure 126
30. Assemble the swivel piston (261) and shoe assembly

(262).
Figure 127

8-10-60
31. Apply grease on the back side of the swash plate (203)
and assemble it with the spindle.
NOTE: Check that swash plate moves smoothly.
Figure 128
32. Assemble the spindle (101) cylinder block subassembly

(CB1).
NOTE: Apply hydraulic oil to the swash plate (203) and
shoe (262).
Figure 129
33. Assemble four friction plates (215) and three mating plates
(216) on the spindle (101) and cylinder block (204).
Figure 130
Figure 131

8-10-61
34. Assemble the O-ring (233) (P8) on the spindle (101).
NOTE: Do not reuse the O-ring.
Figure 132
35. Assemble the O-ring (231) (WG48) on the spindle (101).

Figure 133
36. Assemble the O-ring (230) (WG52) on the spindle (101).

Figure 134
37. Assemble the rear flange (1) sub with the spindle (101).
NOTE: Apply grease to the needle bearing (50) press-
fitted into the rear flange (50).
Figure 135

8-10-62
38. Tighten 8 socket bolts (43) with the rear flange (1) sub at
specified torque.
Figure 136
39. In the brake forced release hole of the rear flange (1),
disassemble M10 x 135L socket bolt, and tighten 2 plugs
at specified torque.
Figure 137
40. Tighten the 2 sets of relief valve (RV1) to the rear flange
(1) sub at specified torque.
• Relief valve (RV1) tightening torque: 2,500 kg.cm
Figure 138
41. Tighten the 1 sets of reducing valve (500) to the rear flange
(1) sub at specified torque.
• Reducing valve (500) tightening torque: 450 kg.cm
Figure 139

8-10-63
42. Assemble the rear flange (1) sub with the reducing valve
cover (501).
Figure 140

8-10-64
PERFORMANCE TEST
Make sure to fill up the spindle with hydraulic oil before
performance test. Conduct performance test as follows after
completing the maintenance of travel motor.
1. With testing apparatus: If an internal part or parts have
been replaced, conduct performance test according to the
following conditions before commissioning.
• Conditions for preparatory operation
1) Unloaded operation at 20 rpm, left and right
directions for one minute
2) Operate left and right at 10 rpm with 196 bar
(200 kg/cm2) for one minute
directions for one minute
• Test Condition
1) Hydraulic oil: wear resistant hydraulic oil ISO
VG #46 or equivalent
2) Lubricant: gear oil
3) Temperature:
Ambient temperature  room temperature
Oil operating temperature 50 ± 5°C
Reduction gear case temperature 40 - 80°C
4) Oil drain pressure: 0.8 bar (0.8 kg/cm2) or less

8-10-65
A. Efficiency test (at 1st speed)
Volumetric Efficiency Mechanical Efficiency External Drain Rate

90% or above 82% or above (See reference)
Differential pressure: 196 bar (200 kg/cm )2
3.0 lpm or less
Speed: 8 rpm
B. Volumetric efficiency test at 2nd speed
Switched to 2nd Speed Volumetric Efficiency

Differential pressure: 78.5 bar (80 kg/cm2)
94% or above
Speed: 18 rpm
C. Operating test of 2nd speed parts

In the above (A, B) preparatory operating conditions,
at unloaded test, check that motor is switched from
low speed to high-speed when high-pressure oil
(29 bar (30 kg/cm2) or above) is applied to the 2nd
speed switching pilot port (Port D).
In addition, check that motor is switched to low speed
at the pressure lower than 20 bar (20 kg/cm2).
2. Performance test in the field without testing apparatus
Install the travel motor on the equipment. Connect
pipelines without attaching the shoe. Conduct testing after
the preparatory operation under the following conditions.
• Preparatory operating condition
directions for one minute.
directions for one minute.
• Test condition
1) Temperature: Hydraulic oil 50 ± 5°C
Case  40 ~ 80°C
A. Unloaded drive pressure (differential pressure)
1st Speed 10 rpm 20 bar (20 kg/cm2)

2nd Speed 20 rpm 29 bar (30 kg/cm2)
B. Motor drain rate
1st and 2nd

At 10 rpm 3 lpm or less
Speed

8-10-66
TROUBLESHOOTING
Problem Cause Correction
Cannot start-up Without pressure Relief setting pressure is too Set up correct pressure
low
Pump failure Check moving parts
excluding travel parts, and
repair as necessary
Steering valve failure Check the spool and repair it
if necessary
With pressure Brake valve failure Replace sticking spool or
valve, repair other problems.
Hydraulic motor failure Replace the motor, or check
the hydraulic oil and replace
it as necessary
Damaged gear Replace the reduction gear
(reduction gear)
Overloaded Release the load
Oil leak Contact surface Flaw on contact surface Correct with crocus cloth
Loose bolt Tighten and recheck
Casing Loose plug Tighten
Damaged by stone, etc. Replace the reduction gear
Floating seal Worn sliding surface Replace the reduction gear
Damaged O-ring Replace floating seal
Hydraulic motor Loose bolt Tighten
Damaged O-ring Replace the O-ring
Flaw on seal Correct with crocus cloth
Sliding on slope Poor volumetric efficiency of the motor Replace the hydraulic motor
Increase of leak in brake valve Replace the brake valve
(Replace rear flange)
Parking brake fails to function
• Damaged spring • Replace the spring
• Worn friction plate • Replace friction plate
and mating plate
Reduction gear case Low gear oil level Refill up to proper level
too hot Bearing is not fixed Replace the reduction gear
Hydraulic oil enters gear case Replace the oil seal

8-10-67
Problem Cause Correction
Travels sideways At low-pressure
• Discharge volume differs by left and right • Repair
• Drain volume differs from left and right • Replace the hydraulic
motor motor
At high-pressure
• Discharge volume differs by left and right • Replace the pump and
regulator
• Drain volume differs from left and right • Replace the hydraulic
motor motor
• Left and right motions of the brake valve • Replace the brake
are not the same valve
(Replace rear flange)
• Relief valve too low on the left or right side • Set up pressure
of the control valve correctly. Replace the
relief valve
Speed is too low Pump discharge volume is too low.
• Pump regulator does not work correctly • Repair the regulator
• Too much external drain from the pump • Repair/replace the
pump
Too much external oil leak from the motor Repair/replace the motor
Abnormal noise Damaged motor or reduction gear Repair/replace the motor or
reduction gear
Vibration in piping Clamp the pipeline

8-10-68
1Cylinders
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Cylinders
8-11-1
Table of Contents
Cylinders
Safety Instructions ........................................8-11-1
General .........................................................8-11-3
General Description................................................. 8-11-3
Specification ............................................................ 8-11-3
Parts List ................................................................. 8-11-4
Theory of Operation .............................................. 8-11-12
Seal of Cylinder ..................................................... 8-11-13
Special Tools and Materials........................8-11-15
Piston Nut .............................................................. 8-11-15
Piston Jig ............................................................... 8-11-16
Steel Bushing Jig................................................... 8-11-17
Dust Wiper Jig ....................................................... 8-11-18
Slipper Seal Jig ..................................................... 8-11-19
Slipper Seal Straightening Jig ............................... 8-11-20
Rod Bushing (DD-bushing) Pushing-in Jig ............ 8-11-21
Disassembly ...............................................8-11-22
Reassembly ................................................8-11-27
Troubleshooting ..........................................8-11-31
Cylinders DX480LCA-K/DX520LCA-K
8-11-2
GENERAL
General Description
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). 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
Boom Arm Bucket

Quantity 2 1 1 1 1
Tube I.D ø170 ø190 ø190 ø170 ø120
Rod O.D ø115 ø130 ø130 ø115 ø80
Stroke (mm) 1,610 1,980 1,805 1,341 1,060
Closed Length (mm) 2,290 2,780 2,530 2,041 1,630
Head End Cushion X O O X X
Rod End Cushion O O O O O
Weight (kg/lb) 412/908 612/1,350 570/1,256 368/811 368/811
Remarks for 7.1 m Boom for 6.3 m Boom
8-11-3
Parts List
The following parts list is a partial listing only; for complete parts
list information, refer to the Hydraulic Equipment Component
Parts List.
Boom Cylinder (LH)
33
32
29
30
31
41
28
35
40
34
2
27
26
24
23
24
37
17
36 22
21
38
20
19
39 18
19
20
16
14
25 13
15
7
6
5
8
9
10 3
11
12
4
DS1800091
Figure 2
8-11-4
Reference Reference
Number Number
1 Tube, Cylinder 22 Ring, Backup
2 Bushing 23 Nut, Piston
3 Rod, Cylinder 24 Screw, Set
4 Bushing 25 Bolt, Socket
5 Cover, Rod 26 Band, Pipe (LH)
6 Bush, DU 27 Band, Pipe
7 Ring, Retaining 28 Washer, Spring
8 Seal, Buffer 29 Bolt M12 x 1.75 x 40
9 U-packing 30 Pipe Assembly, H (LH)
10 Ring, Backup 31 O-ring
11 Wiper, Dust 32 Washer, Spring
12 Ring, Retaining 33 Bolt, Socket
13 O-ring 34 Washer, Spring
14 Ring, Backup 35 Bolt; M12 x 1.75 x 25
15 O-ring 36 Pipe Assembly, R (LH)
16 Ring, Cushion 37 O-ring
17 Piston 38 Washer, Spring
18 Seal, Slipper 39 Bolt, Socket
19 Ring, Wear 40 Washer, Spring
20 Ring, Slyd 41 Bolt M12 x 1.75 x 30
21 O-ring * Seal Kit
*: 8, 9, 10, 11, 13, 14, 15, 18, 19, 20, 21, 22
8-11-5
Boom Cylinder (RH)
33
2 32
30
31
29
28
26
1 35
27 41
40
34
24
23
37 24
36
17
38 22
21
39
20
19
18
19
20
16
14
25
13
15
7
6
3
5
8
9
10
11
12
4
DS1800050
Figure 3
8-11-6
Reference Reference
Number Number
1 Tube, Cylinder 22 Ring, Backup
2 Bushing 23 Nut, Piston
3 Rod, Cylinder 24 Screw, Set
4 Bushing 25 Bolt, Socket
5 Cover, Rod 26 Band, Pipe (RH)
6 Bush, DU 27 Band, Pipe
9 U-packing 30 Pipe Assembly, H (RH)
11 Wiper, Dust 32 Washer, Spring
12 Ring, Retaining 33 Bolt, Socket
13 O-ring 34 Washer, Spring
14 Ring, Backup 35 Bolt; M12 x 1.75 x 25
15 O-ring 36 Pipe Assembly (RH)
16 Ring, Cushion 37 O-ring
17 Piston 38 Washer, Spring
18 Seal, Slipper 39 Bolt, Socket
19 Ring, Wear 40 Washer, Spring
20 Ring, Slyd 41 Bolt M12 x 1.75 x 30
21 O-ring * Seal Kit
*: 8, 9, 10, 11, 13, 14, 15, 18, 19, 20, 21, 22
8-11-7
Arm Cylinder - Boom 7.1 m
53
45
46
44
53
37 43
42
36
49
2
54
55
38 34
54 47
52
55 48
51 29
30 25
A 31
35 24
50 32
33 26
27
39
23
40 24
41 25
1
17
20
19
18
19
20
16 21
A 22
14
28 13
7 15
6
3
5
8
9
10
11
4
12
EX1401308
Figure 4
8-11-8
Reference Reference
Number Number
1 Tube, Cylinder 29 Valve; Check
2 Bushing, Carburizing 30 Spring
3 Rod, Cylinder 31 Support; Spring
4 Bushing, Carburizing 32 O-ring
5 Cover, Rod 33 Plug
6 Bushing, DU 34 Pipe Band Ass'y - H
7 Ring; Retaining 35 Band; Pipe
8 Seal; Buffer 36 Washer; Spring
9 Packing; U 37 Bolt; Hex
10 Ring; Back Up 38 Pipe Band Ass'y - B
11 Wiper; Dust 39 Band; Pipe
12 Ring, Retaining 40 Washer; Spring
13 O-ring 41 Bolt; Hex
14 Ring; Back Up 42 Pipe Assy; H
15 O-ring 43 O-ring
16 Ring; Cushion 44 Washer; Spring
17 Piston 45 Bolt; Hex. Socket
18 Seal; Buffer 46 Bolt; U
19 Ring; Wear 47 Washer; Spring
20 Ring; Slyd 48 Nut
21 O-ring 49 Pipe Assy; R
22 Ring; Back Up 50 O-ring
23 Nut, Piston 51 Washer; Spring
24 Ball, Steel 52 Bolt; Hex. Socket
25 Screw, Set 53 Bolt; U
26 Plunger, Cushion 54 Washer; Spring
27 Ring, Stop 55 Nut
28 Bolt; Hex Socket * Seal Kit; Arm Cylinder
*: 8, 9, 10, 11, 13, 14, 15, 18, 19, 20, 21, 22
8-11-9
Bucket Cylinder - Arm 3.35 m
32
31
29
30
39 26 27 28 2
38 37
37
38 24
39
33
36 23
35
24
17
1 20
34 A 19
18
19
20
22
21
22
A 16
14
13
25
15
7
6
5 3
8
9
10
11
12
DS1800092
Figure 5
8-11-10
Reference Reference
Number Number
1 Tube, Bucket Cylinder 21 O-ring
2 Bushing 22 Ring, Backup
3 Rod, Cylinder 23 Nut, Piston
4 Bushing 24 Screw, Set
5 Cover; Rod 25 Bolt, Socket
6 Bush, DU 26 Band Assembly, Pipe
9 U-packing 29 Pipe Assembly
11 Wiper, Dust 31 Washer
12 Ring, Retaining 32 Bolt
13 O-ring 33 Pipe Assembly
15 O-ring 35 Washer
16 Ring, Cushion 36 Bolt
17 Piston 37 U-bolt
18 Seal, Slipper 38 Washer, Spring
19 Ring, Wear 39 Nut, Hex
20 Ring, Slyd * Seal Kit
* 8, 9, 10, 11, 13, 14, 15, 18, 19, 20, 21, 22
8-11-11
Theory of Operation
1 Piston
2 Oil Path A 1
3 Oil Path B D
Cylinder piston rods are extended or retracted by oil flow to the
back side of the cylinder (shown as ("oil path A") or to the front of 3
the cylinder ("oil path B"). 2
The cylinder rod is extended as oil flow is pumped through the
circuit to the back side of the piston. The force (F1) of the piston
stroke can be expressed by the formula below, where P = circuit FG001456
oil pressure and the inside diameter of the cylinder is expressed Figure 6
by D (Figure 6).
F1 = P x D2
4
(P: Pressure, = 3.14, D: Cylinder Inside Diameter)
1 Cylinder Inside Diameter - D

2 Oil Path A
4
3 Oil Path B
4 Rod Diameter - R
1
When the cylinder rod is retracted, oil flow through the circuit
from the pump to the front side of the cylinder generates a force 2
(F2) that can be expressed by the formula in which the diameter
3
of the piston rod is expressed by R, and the other two terms are
the same as in the preceding expression. FG001458
F2 = P x (D2-R2) Figure 7
4
Because the volume of oil needed to lengthen the cylinder rod

(Q1) is greater than the volume of oil required to retract the
cylinder rod, it takes more time to extend a cylinder than it does
to retract it. 1
Q1 = S x (D2)
4
Q2 = S x (D2-R2)
4
Q1 > Q2 FG001459
Figure 8
8-11-12
Seal of Cylinder
1. Assembly location and shape of seals
A. Rod cover seal
U-packing
Backup Ring
Retaining Ring
O-ring
Dust Wiper
Retaining Ring (DKBI Type)
Buffer Seal
DD(DU)-Bush
EX1301741
Figure 9
B. Piston seal
Dust Ring Dust Ring
Wear Ring Wear Ring

Piston Seal
Backup Ring
O-ring
EX1301742
Figure 10
8-11-13
2. Seal function
No Name Function Material

Seal the hydraulic oil between the piston and the Slipper Seal, Glyd Ring,
1 Piston Seal inner surface of the tube. Compact Seal
Wear Ring Prevents scratch on the inner surface of the tube
and the rod surface caused by foreign materials,
2 and eccentric center, and eccentric load, and Phenol, Aramid
(DU-bushing) plays role bearing keeping stable friction
materials.
Contamination Protects the piston seal against the intrusion of
3 foreign material to keep the functions of the seal Dust Ring, Slyd Ring
Seal intact.
Seals for preventing leak of hydraulic oil between
4 Rod Seal U-packing, V-packing
the friction material and the cover of the rod.
Prevents surge/shock applied directly to the rod
5 Buffer Seal seal to extent lifecycle of the seal on the system Step Seal
for high-pressure.
Dust Seal Prevents intrusion of foreign materials into the
6 cylinder from outside environment to protect the Single Lip, Double Lip
(Dust Wiper) rod seal.
Prevents intrusion of foreign materials (e.g., rain
and snow), and makes sealing between the inner
7 O-ring surface of the tube and the rod cover, and NBR
between the rod and the inner diameter of the
piston.
Prevents disengaging U-packing and O-ring
8 Backup Ring PTFE, Nylon
because of pressure and gap.
8-11-14
SPECIAL TOOLS AND MATERIALS
Piston Nut
( )
A
35
350
FG018703
Figure 11
Material SM45C (AISI 1045)
Rockwell Hardened from 22 - 27
Oil Quench
Cylinder A
130.0 mm
Boom
(5.1 in)
140.0 mm
Arm
(5.5 in)
130.0 mm
Bucket
(5.1 in)
8-11-15
Piston Jig
( )
15
2-∅"B"
)
F/2
∅8 Through Hole
R(
"
"D
∅
"A"
∅"
C" 35
R(R15~20)
R5
4-
30
ARS4740L
Figure 12
Material SM45C (AISI 1045)
Rockwell Hardened from 22 - 27
Oil Quench
Cylinder A (±0.1) øB øC øD
135.0 mm 13.0 mm 105.0 mm 170.0 mm
Boom
(5.3 in) (0.51 in) (4.13 in) (6.7 in)
150.0 mm 13.0 mm 110.0 mm 190.0 mm
Arm
(5.9 in) (0.51 in) (4.33 in) (7.5 in)
135.0 mm 13.0 mm 105.0 mm 170.0 mm
Bucket
(5.3 in) (0.51 in) (4.13 in) (6.7 in)
8-11-16
Steel Bushing Jig
(5)
"B" + 40
"A" - 20
∅ "B"
∅"A"
(∅20)
15 F E
G
ARS4750L
Figure 13
Material: SM45C which is done thermal refining <QT> HRC 22 - 28
Undefined Chamfer C/R = 0.5 Max.
1 Place: Final work to used DNMG Tip <Nose R0.4>
Cylinder øA-0.05
-0.15
øB (±0.1) E F+0.05
0
Remark
110.0 mm 130.0 mm 50.0 mm 11 mm
Head Side
(4.33 in) (5.12 in) (1.97 in) (0.43 in)
Boom
120.0 mm 140.0 mm 50.0 mm 11 mm
Rod Side
(4.72 in) (5.51 in) (1.97 in) (0.43 in)
120.0 mm 140.0 mm 50.0 mm 11 mm
Arm
(4.72 in) (5.51 in) (1.97 in) (0.43 in)
110.0 mm 130.0 mm 50.0 mm 11 mm
Bucket
(4.33 in) (5.12 in) (1.97 in) (0.43 in)
8-11-17
Dust Wiper Jig
.5
C1
3-
R0.2
DIA. (B+40)
DIA. (A-20)
DIA. A
DIA. B
15 C D
ARS4760L
Figure 14
Material: SM45C which is done thermal refining <QT> HRC 22 - 28
Undefined Chamfer C/R = 0.5 Max.
1 Place: Final work to used DNMG Tip <Nose R0.4>
Cylinder øA-0.2
-0.3 øB -0.2
-0.3 C 0
-0.1
D
115.0 mm 131.0 mm 6.0 mm 7.0 mm
Boom
(4.53 in) (5.16 in) (0.24 in) (0.28 in)
130.0 mm 136.0 mm 6.0 mm 7.0 mm
Arm
(5.12 in) (5.35 in) (0.24 in) (0.28 in)
115.0 mm 131.0 mm 6.0 mm 7.0 mm
Bucket
(4.53 in) (5.16 in) (0.24 in) (0.28 in)
8-11-18
Slipper Seal Jig
0
R1
R1
∅(A+2)
∅A
∅(A-14)
10°
B
(B+40)
ARS4770L
Figure 15
Cylinder øA+0.2
+0.1 B+0.2
+0.1
170.0 mm 34.5 mm
Boom
(6.69 in) (1.36 in)
190.0 mm 41.5 mm
Arm
(7.48 in) (1.63 in)
170.0 mm 34.5 mm
Bucket
(6.69 in) (1.36 in)
8-11-19
Slipper Seal Straightening Jig
C2
∅20
1
2-C
4
R
2-5
15
20
∅(A+15)
∅A
1
2-R
100
25
50
ARS4780L
Figure 16
Cylinder øA+0.2
+0.1
170 mm
Boom
(6.69 in)
190 mm
Arm
(7.48 in)
170 mm
Bucket
(6.69 in)
8-11-20
Rod Bushing (DD-bushing) Pushing-in Jig
C1
A1
B
C1
C D
EX1301743
Figure 17
Inner diameter (A1) : "A"-20 (no machining required on the inner

diameter)
Cylinder øA+0.2
-0.1 øB (±0.1) C D E
115 mm 119.5 mm 45 mm 85 mm 130 mm
Boom
(4.53 in) (4.70 in) (1.77 in) (3.35 in) (5.12 in)
130 mm 134.5 mm 60 mm 90 mm 150 mm
Arm
(5.12 in) (5.30 in) (2.36 in) (3.54 in) (5.91 in)
115 mm 119.5 mm 45 mm 85 mm 130 mm
Bucket
(4.53 in) (4.70 in) (1.77 in) (3.35 in) (5.12 in)
1. Assemble the rod bushing with the exclusive jig (if

disassembled).
Push in the rod bushing in true vertical direction to prevent
inclining of the bushing.
Apply small volume of operating oil on inner surface of the
rod cover for facilitating pushing in.
2. Remove all of pushing-in residues generated during the
pushing-in process.
3. Mount the retaining ring on the rod cover groove at the end
of the rod bushing after cleaning to prevent disengagement
of the rod bushing.
(Mount the retaining ring manually with pliers, and check if
the ring is securely mounted.)
8-11-21
DISASSEMBLY
CAUTION
AVOID INJURY
Vent air from the hydraulic system before disconnecting
cylinder piping connections. Use the lever on the reservoir,
while the engine is running. Discharge the hydraulic
accumulator and vent residual tank pressure after the
engine is shut off. Pour clean replacement hydraulic fluid
into the system if excessive fluid is lost.
1. Following removal of cylinder from excavator attachment,

support cylinder on some type of sturdy work platform and
drain all oil. Rotate cylinder so piping ports are on top, to
allow trapped air to vent.
Figure 18
2. Position piston rod so it is extended approximately one half

meter (20").
Figure 19
3. Remove bolts (27) on the end of cylinder.

NOTE: Wrap a cloth or other protective material around
piston rod, to avoid possibility of accidentally
scratching or scoring rod surface while
fasteners are being loosened and removed.
Component parts (numbered in parentheses)
are keyed to Figure 4.
Figure 20
8-11-22
4. Tap two bolts into cover of cylinder head, 180° apart.
Tighten them in a staggered, even sequence, to back off
piston rod end cover from edge of cylinder wall. Look for
adequate clearance between cover and end of cylinder
wall before using a plastic or other soft faced hammer for
final disassembly.
Figure 21
5. Begin withdrawing piston rod assembly, away from

cylinder. Attach a lifting support when final 1/3 of rod is still
inside barrel of cylinder. Prepare support blocks for piston
rod before it has been completely withdrawn.
Figure 22
6. Lower piston rod to support blocks and detach wear ring

(outer surface) (19) from end of rod.
Figure 23
7. Immobilize piston rod by inserting a wooden or other

nonscoring, nonmetallic support through end of rod.
Figure 24
8-11-23
8. Remove set screw using socket wrench.
HAOF340L
Figure 25
9. Fabricate or purchase a piston nut removal wrench.

(Dimensions are called off at beginning of this procedure.
This tool can also be ordered through your local DOOSAN
Parts distributor). Remove nut from end of piston.
Figure 26
10. Use second piston tool described at beginning of this

procedure to separate piston. Detach cushion ring (16),
taking care not to damage cushion ring.
Figure 27
11. Use a plastic hammer to evenly pull off rod cover (5) from
end of piston rod. Be careful not to damage rod bushing (6)
and dust wiper, U-packing and other seals.
Figure 28
8-11-24
12. Use a dull, rounded tip tool to pry off O-ring (13) and
backup ring (14).
HAOF37OL
Figure 29
13. Find a screwdriver with an appropriate width tip to facilitate

removal of slipper seal (18), wear ring (19) and slide ring
(20) from piston (17).
Figure 30
14. Remove O-ring (21) and backup ring (22) from cylinder
head.
HAOF38OS
Figure 31
15. During disassembly of cylinder head, be careful not to

damage buffer seal (8) and U-packing (9).
HAOF39OL
Figure 32
8-11-25
16. Disassemble retaining ring (12) and dust wiper (11).
Separate retaining ring (7) and rod bushing (6).
Figure 33
17. Force out pin bushing (2), (4) from body of cylinder.
Figure 34
8-11-26
REASSEMBLY
IMPORTANT
Before reassembly:
• Inspect and replace damaged or excessively worn
parts.
• Clean parts and lubricate with clean hydraulic oil.
• Make sure work area is clean.
Replace any part that shows evidence of damage or
excessive wear. Replacement of all O-rings and flexible
seals is strongly recommended. Before starting the cylinder
reassembly procedure, all parts must be thoroughly
cleaned and dried, and/or prelubricated with clean
hydraulic fluid. Prepare the work area beforehand to
maintain cleanliness during the reassembly procedure.
NOTE: Reassemble the subassemblies of the cylinder in the

following order:
1. Body of the cylinder.
2. Piston rod.
3. Piston assembly.
4. Cylinder head assembly.
1. Reassemble pin bushing (2), (4) to piston rod and body of
cylinder.
Figure 35
8-11-27
2. Following reassembly of rod cover components, install the
dust wiper (11) and rod bushing (6) to the rod cover (5).
Insert retaining rings (7 and 12).
Figure 36
3. Prelubricate O-rings and seals before reassembly (Figure

37).
Figure 37
4. Before starting to rebuild piston assembly, heat slipper seal

for 5 minutes in an oil bath warmed to 150° - 180°C (302° -
356°F). Use special slipper seal jig (third item in list of
specialized tools at the beginning of this procedure) to
attach seal. Cool seal by pushing a retracting jig against
seal for several minutes. Apply a strip of clean,
see-through sealing tape around slipper seal to keep it free
of dust.
Figure 38
8-11-28
5. Immobilize piston rod on solid support blocks. Assemble
O-ring (21) and backup ring (22). Prepare to attach rod
cover assembly to piston rod. Push rod cover by tightening
piston nut (23).
Figure 39
6. Assemble cushion ring (16) and attach piston assembly to

piston rod.
Figure 40
7. Use specially fabricate or factory sourced tool to tighten

piston nut (23).
Figure 41
8. Assemble wear ring (19), slide ring (20) and set screw (24)
to piston assembly.
Reference
Description
Number
1 Set Screw
Figure 42
8-11-29
9. Immobilize body of cylinder before reassembly.
Figure 43
Preapply fastener locking compound (Loctite #242 or #243 or an

alternate manufacturer's equivalent product) to all end cover
retaining bolts. Wrap a protective cushion around end of rod
while tightening fasteners, to prevent possible damage to
polished surface of rod, should a wrench slip during retightening.
Figure 44
8-11-30
TROUBLESHOOTING
Oil leaking between Foreign material in U-packing. Remove foreign material.
cylinder head and piston Scratches in U-packing. Replace U-packing.
rod. Damage to U-packing. Replace U-packing.
Foreign material in dust wiper. Remove foreign material.
Scratches to dust wiper. Replace dust wiper.
Damage to dust wiper. Replace dust wiper.
Foreign material in seal O-ring. Remove foreign material.
Scratches in O-ring. Replace O-ring.
Damage to O-ring. Replace O-ring.
Scratches on sealing surface of piston If scratches are not deep, hone with an
rod. oil stone and lubricate.
If scratches are deep, replace piston
rod.
Deep scratches on inner surface of Replace bushing.
bushing.
Oil leaking between Damage to O-rings. Replace O-rings.
cylinder head and cylinder
tube.
Oil leaking from welded Damage to welded area. Replace cylinder tube.
area of cylinder tube.
Oil leaking between Foreign material in U-packing. Remove foreign material.
cylinder head and piston Scratches in U-packing. Replace U-packing.
rod. Damage to U-packing. Replace U-packing.
Foreign material in dust wiper. Remove foreign material.
Scratches in dust wiper. Replace dust wiper.
Damage to dust wiper. Replace dust wiper.
Foreign material in O-ring. Remove foreign material.
Scratches in O-ring. Replace O-ring.
Damage to O-ring. Replace O-ring.
Scratch on sealing surface of piston If scratches are not deep, hone with an
rod. oil stone and lubricate.
If scratches are deep, replace piston
rod.
Deep scratches on inner surface of Replace bushing
bushing.
Oil leaking between Damage to O-rings. Replace O-rings.
cylinder head and cylinder
tube.
Oil leaking from welded Damage to welded area. Replace cylinder tube.
area of cylinder tube.
Cylinder drops from pull of Light scratches on sealing surface of Hone out scratches with oil stone.
gravity. cylinder tube.
Deep scratches on sealing surface of Replace cylinder tube.
cylinder tube.
Deep scratches on sealing surface of Replace O-rings.
piston O-rings.
Foreign material in U-packing. Remove foreign material.
8-11-31
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.
8-11-32
1Electrical System
1Electrical
System
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX480LCA-K/DX520LCA-K Electrical System

9-1-1
Table of Contents
Electrical System
Introduction .....................................................9-1-5
Electrical Supply System ................................9-1-6
Engine Starting Circuit ....................................9-1-8
Start Operation .......................................................... 9-1-8
After Start ................................................................ 9-1-10
Engine Preheating System ...........................9-1-12
Engine Stop ..................................................9-1-14
Charging System ..........................................9-1-15
Monitoring System ........................................9-1-16
Instrument Panel ..................................................... 9-1-17
Monitoring System Schematic ................................. 9-1-18
Operation ......................................................9-1-20
Instruments.............................................................. 9-1-20
Warning and Indicator Lights ........................9-1-21
Indication of Warning Lights .................................... 9-1-21
Indication of Multifunction Gauge ............................ 9-1-22
Initial Operation.............................................9-1-24
Mode Selector Switch ...................................9-1-24
Graphic Information Area Display.................9-1-25
Overview ................................................................. 9-1-25
Main Menus for the Graphic Display Area............... 9-1-25
Menu Selector Buttons ............................................ 9-1-25
User Menu ....................................................9-1-26
User Menu - Access and Escape Methods ............. 9-1-26
Special Menu ................................................9-1-46
Entering/Accessing and Exiting/Escaping Menus ... 9-1-46
Special Menu Selections ......................................... 9-1-47
Electronic Hydraulic Control System (EPOS) ..9-1-64
Control System Schematic ...................................... 9-1-64
Power Mode Control .....................................9-1-66
Operation................................................................. 9-1-68
Electrical System DX480LCA-K/DX520LCA-K

9-1-2
Power Mode Control - Circuit Diagram.................... 9-1-71
Work Mode Control.......................................9-1-72
Work Mode Control - Circuit Diagram ..................... 9-1-73
Engine Control System.................................9-1-74
Engine Control Dial ................................................. 9-1-75
Engine Control Motor .............................................. 9-1-76
Engine Control Circuit Diagram............................... 9-1-77
Automatic Deceleration Control 
(Auto Idle Control) ........................................9-1-78
Engine Overheat Protection System ............9-1-79
Power Boost Mode .......................................9-1-80
Operation................................................................. 9-1-80
Power Boost Control - Circuit Diagram ................... 9-1-81
Breaker Mode ...............................................9-1-82
Operation................................................................. 9-1-82
Breaker Control - Circuit Diagram ........................... 9-1-84
Automatic Travel Speed Control...................9-1-85
Automatic Travel Speed Control - Circuit Diagram . 9-1-86
Self-diagnostic Function ...............................9-1-87
EPOS Controller...................................................... 9-1-87
Air Conditioner System.................................9-1-89
Outline ..................................................................... 9-1-89
Internal and External Filters .................................... 9-1-90
Air-Conditioning System Layout .............................. 9-1-92
Air Conditioner/Heater Circuit Diagram ................... 9-1-93
Air Conditioner/Heater Unit ..................................... 9-1-94
Ambient Air Temperature Sensor............................ 9-1-99
Sun Sensor............................................................ 9-1-100
Control Panel......................................................... 9-1-100
Compressor........................................................... 9-1-107
Receiver Dryer ...................................................... 9-1-107
Troubleshooting..........................................9-1-108
Refrigerant System Repairs .......................9-1-110
Refrigerant Safe Handling Procedures.................. 9-1-110
Repair and Replacement Procedure ..................... 9-1-111
Refrigerant Recovery ............................................ 9-1-113
Vacuuming Refrigerant System............................. 9-1-113
Leakage Check ..................................................... 9-1-115

9-1-3
Refrigerant Charging ............................................. 9-1-115
Inspecting System For Leakage ............................ 9-1-117
Wiper System .............................................9-1-118
Wiper Circuit .......................................................... 9-1-118
Wiper Operation .................................................... 9-1-119
Lighting System ..........................................9-1-120
Lighting System Circuit Diagram ........................... 9-1-120
Kind of Light .......................................................... 9-1-121
Operation............................................................... 9-1-121
Overload Warning Device...........................9-1-122
Overload Warning Device Circuit Diagram............ 9-1-122
Audio Controller ..........................................9-1-123
Audio Controller Circuit Diagram ........................... 9-1-123

9-1-4
INTRODUCTION
The electrical system for this equipment is DC 24 volts. The
rated voltage for all electric components is 24 volts with the
exception of the stereo and the air-conditioning control actuator.
The system contains two 12 volt batteries connected in series
and a three phase AC generator with a rectifier. The electric
wiring used in the system is easily identifiable by the insulator
color. The color symbols used in the electrical system are listed
in the following chart.
Electric Wire Color
Symbol Color
W White
G Green
Or Orange
B Black
L Blue
Lg Light green
R Red
Gr Gray
P Pink
Y Yellow
Br Brown
V Violet
NOTE: RW: Red wire with White stripe

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

9-1-5
ELECTRICAL SUPPLY SYSTEM
The electric power circuit supplies electric current to each
electric component. It consists of a battery, battery relay, starter
switch, circuit breaker and fuse box.
The negative terminal of the battery is grounded to the vehicle
body.
Even when the starter switch (5) is in the "OFF" position, electric
current is supplied to the following components through battery
(1)  circuit breaker (3)  fuse box (6).
1. Terminal "1" of DC-DC converter
2. Terminal "B" of starter switch
3. Hour meter
4. Engine controller
5. Fuel feeder pump switch
6. Terminal "6" of wiper motor
7. Terminal "13" of wiper controller
8. Terminal "CN7-5, CN7-6" of instrument panel
9. Terminal "CN9-6" of air conditioner panel
10. Cabin light
When the starter switch (5) is in the "ON or START" positions,
the current flows from the battery (1)  circuit breaker (3) 
fuse box (6) "B" terminal of starter switch (5)  "BR" terminal
of starter switch (5)  "BR" terminal of battery relay (2) which
activates the coil of the battery relay and the electric supply
system is energized.
When the battery relay's contacts are connected, all electric
devices can be operated.
While the engine is not running, the electric power for all electric
devices are supplied by the battery. Once the engine is started
the power is supplied from the alternator (7).

9-1-6
6 C
B 5
ACC R2
BR
4 2
B A
8
BR
2
E
1
P(R) B(B+) R(I)
Starter Switch Connection SG

TML B - + - +
PST BR R2 C ACC
OFF
7 12V 150AH 12V 150AH
ACC R 1
F
ON
E
START
E
DS1800031
Figure 1 Electric Power Circuit Diagram
Reference Reference
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Circuit Breaker 7 Alternator
4 Circuit Breaker 8 Diode

9-1-7
ENGINE STARTING CIRCUIT
Start Operation
When the starter switch is turned to the "START" position.
The pinion gear of the starter (9) is pushed forward and makes
contact with the ring gear of the flywheel and the internal
contacts of the starter are connected. The current flows from the
battery (1)  "B" terminal of the starter (9). The starter motor
activates the engine to start.
If the instrument panel has the password function activated,
input number should match the set number, otherwise the start
circuit closes and the engine does not start.
NOTE: If the security system is "LOCKED," a four-digit
Owner Password
password will be required to start the engine. If the
system is "UNLOCKED," no password will be
required and this display screen will not appear.
In the event the security system is locked, current
flows from battery (1)  circuit breaker (3)  fuse
box (6)  "B" terminal of starter switch (5)  "BR" 3 4 5 6 7 8 9 : ; <
terminal of starter switch (5)  "86" terminal of starter Enter Owner Password
relay (8)  "CN1-15" terminal of EPOS (12) 
ground. This current flow causes the coil in starter
relay (8) to be activated, opening contacts at "87a" EX1301416
terminal. This prevents starter relay (8) from Figure 2
functioning.

9-1-8
8
87a
30
87
9
86 85
6 C
B 5
ACC R2 CN2-1 CN1-15
BR CN5-15 A
CN5-16
12 13
11
3
4 2
B A
11
BR
2
E
1
P(R) B(B+) R(I)

- + - +
PST TML B BR R2 C ACC 10
12V 150AH 12V 150AH
OFF
ACC R 1
F
ON
E
START
E
DS1704267
Figure 3 Starter Circuit (1) - While Starting
Reference Reference
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
5 Starter Switch 12 EPOS Controller
6 Fuse Box 13 Speed Sensor

9-1-9
After Start
Once the engine has been started, the belt driven alternator (10)
generates a current.
If EPOS senses the frequency is over 450 rpm via Speed
sensor, current flows from battery (1)  fuse box (6)  "B"
terminal of starter switch (5)  "BR" terminal of starter switch (5)
 "86" terminal of starter relay (8)  "CN1-15" terminal of
EPOS (12)  ground.
This current flow causes the coil in starter relay (8) to be activated,
opening contacts at "87a" terminal.
As a result the rotation of the starter (9) is stopped. Once the
engine is running, the starter (9) will not operate even if the
starter switch (5) is moved to the start position, preventing
possible damage to the starter.

9-1-10
Operation of the Start Circuit (2) - Immediately After Start
8
87a
30
87 9
86 85
6 C
B 5
ACC R2 CN2-1 CN1-15
BR
A
12
11
3
4 2
B A
11
BR
2
E
1
P(R) B(B+) R(I)

- + - +
12V 150AH 12V 150AH
OFF
ACC R 1
F
ON
E
START
E
DS1800033
Figure 4 Operation of Start Circuit (2) - Immediately After Start
Reference Reference
Number Number
1 Battery 7 Starter Controller
2 Battery Relay 8 Starter Relay
3 Circuit Breaker 9 Starter
5 Starter Switch 11 Diode
6 Fuse Box 12 EPOS Controller

9-1-11
ENGINE PREHEATING SYSTEM
An air heater (8) is installed in the intake manifold of the engine.
When the starter switch (5) is turned "ON" the current flows from
the battery (1)  circuit breaker (3)  "C" terminal of preheat
relay (7)  "CN1-16" EPOS ground. This current flow causes
the coil in the preheat relay (7) to be activated, closing contact.
When the contacts of the preheat relay (7) are closed, the
heating coils of the air heating device are heated by current
flowing from the battery (1)  preheat relay (7)  air heater (8)
 ground.
The duration of the heating time is approximately 20 seconds.
After 20 seconds later to start preheating, the preheat indicator
light will be turned "OFF" by the timer in the EPOS controller.

9-1-12
9
C B
- -
200A
7 8
(1) (2)
B
D H + +
C
B 5
ACC R2
BR 12
A
CN1-16
CN2-1
11
6 3
4 2
B A
11
BR
2
E
1
P(R) B(B+) R(I)

- + - +
12V 150AH 12V 150AH
OFF
ACC R 1
F
ON
E
START
E
DS1800034
Figure 5 Engine Preheat Circuit
Reference Reference
Number Number
1 Battery 7 Preheat Relay
2 Battery Relay 8 Air Heater
3 Circuit Breaker 9 Starter
5 Starter Switch 11 Diode
6 Fuse Box 12 EPOS Controller

9-1-13
ENGINE STOP
Engine Stop circuit consists of starter switch (5), engine stop
solenoid (9) and timer (8). The current flowing into the "ACC"
terminal of starter switch allows the engine’s start and stop
function.
When the key switch is "ON", the HOLD coil is energized, and
the PULL coil is energized for 1 second through timer. After 1
second, the power supply to the PULL coil is stopped, but the
PULL coil remains pulled by the magnetic field of the HOLD coil.
This is a state in which the engine can operate.
When the key switch is "OFF", the HOLD coil stops supplying
power and returns to its original position, the PULL coil also
returns to its original position.
At this moment the fuel supply to the engine is cut off and the
engine is turned off.
8 9
1 4 1 PULL
3 2 2 HOLD 3
C
B 5
ACC R2
7
BR
7
6 3
2
4
B A
BR
2
E
1
Starter Switch Connection

PST TML B BR R2 C ACC
OFF
ACC
ON - + - +
START 12V 150AH 12V 150AH
1
Figure 6 Engine Stop Circuit DS1800035
Reference Reference
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 7 Diode
3 Circuit Breaker 8 Timer
4 Circuit Breaker 9 Engine Stop Solenoid
5 Starter Switch

9-1-14
CHARGING SYSTEM
When the starter switch (5) is turned to the "ON" position, an
initial excited current flows to the field coil of the alternator (7)
through the battery relay (2) and circuit breaker (4). When the
engine is started from this condition the alternator (7) starts
charging. The current flows from the "B(B+)" terminal of
alternator (7)  circuit breaker (4)  battery relay (2) battery
(1).
The alternator also supplies electric current to other electrical
components. When the alternator (7) starts to operate, a current
flows from the "R(I)" terminal of alternator  diode (8)  battery
relay (2) coil securing a path for the charging current to the
battery (1). Thus preventing the possibility of a high voltage build
up and possible damage to the electric system.
6 C
B 5
ACC R2
BR
4 2
B A
8
BR
2
E
1
P(R) B(B+) R(I)

TML B - + - +
PST BR R2 C ACC
OFF
7 12V 150AH 12V 150AH
ACC R 1
F
ON
E
START
E
DS1800031
Figure 7 Charging Circuit
Reference Reference
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box

9-1-15
MONITORING SYSTEM
+
2
-
1
8 5 7
AM
H H 4 R
E F E
C C
3
rpm 9
S USB
10
6
11
14
12
13 DS1800041
Figure 8
Reference Reference
Number Number
1 Instrument Panel 8 Warning Buzzer
2 Battery 9 Pump Discharge Pressure Sensor
3 Light Switch 10 Hydraulic Oil Temperature Sensor
4 Return Filter Switch 11 Fuel Sensor
5 Pilot Filter Switch 12 Air Cleaner Indicator
6 EPOS Controller 13 Engine Coolant Temperature Sensor
7 Alternator 14 Engine Oil Pressure Switch
The monitoring system displays the various data and warning

signals onto the instrument panel by processing the information
gathered from the EPOS controller. It displays information
selected by the operator.

9-1-16
Instrument Panel
7 6
5 1
AM
1
H H
3
2
E F
< Connector and Terminal No.>
C C 4
AMP 040 28P
rpm
S USB 6 5 4 3 2 1 8 7 6 5 4 3 2 1
10 12 11 10 9 8 7 16 15 14 13 12 11 10 9
9 (CN7) (CN6)
EX1501576
Figure 9
Reference Reference
Number Number
1 Fuel Gauge 5 Hour Meter
Engine Coolant Temperature 6 Digital Clock
2
Gauge 7 Display Warning Symbols
Hydraulic Oil Temperature 8 Warning Light
3
Gauge
9 Function Buttons
Multifunction Gauge and Graphic
4 10 Selector Function Display
Information Area
When the engine starter switch is turned to "I" (ON) position, all
gauge bands, switch/button indicator lights and warning lights
will turn "ON" and the alarm buzzer will sound for about two
seconds.
During this functional check, a LOGO will appear on the
multifunction gauge in the graphic information area (3 and 4,
Figure 9).

9-1-17
Monitoring System Schematic
19
CN6-1
3
CN6-3
CN6-2 +
CN6-12 -
CN6-11
2
17
4
R2 B 16 B
CN6-9
CN6-10 BR
14 E
CN2-1 A
18
+ CN5-7 15
CN3-1
5 SIG
CN3-2
9
LCD DISPLAY PANEL -
WATER TEMPERATURE CN2-17
FUEL LEVEL + 10
CN3-3
6 SIG CN2-18
GRAPHIC DISPLAY CN3-4
- 11
CN7-4 CN5-3
CN4-4
CN7-5
12
CN4-12 CAN A
CN7-6 CN4-6
CN3-7
GND
CN3-8 8
CN4-3
CN4-2 RxD
CN4-1 TxD CN3-9
CN3-10 7
1
2 CN5-13
3 CN5-14 21
4 20
5 CN5-15
6 CN5-16 22
14
CN5-5
R(I) CN2-14 23
13 FG021890
Figure 10

9-1-18
Reference Reference
Number Number
1 Instrument Panel 12 Return Filter Switch
2 Pilot Buzzer 13 Alternator
3 Light Switch 14 EPOS Controller
4 Starter Switch 15 Battery
5 Front Pump Pressure Sensor 16 Battery Relay
6 Rear Pump Pressure Sensor 17 Circuit Breaker
Hydraulic Oil Temperature 18 Fusible Link
7
Sensor 19 Fuse Box
8 Fuel Sensor 20 Check Connector
9 Pedal Pressure Switch (Optional) 21 Coolant Temperature Sensor
10 Air Cleaner Indicator 22 Engine Speed Sensor
11 Pilot Filter Switch 23 Engine Oil Pressure Switch

9-1-19
OPERATION
Instruments
Sensor Specification
Function Display
Input Terminal Input Specification
0% (34°C)
98% 100% 17% (46°C)

33% (59°C)
81%
H 50% (72°C)
65%
Coolant CN5-13 51% (86°C)
Temperature 50% CN5-14 65% (90°C)
33% 81% (96°C)

C
17% 95 % (103°C)
0% WE1401047 98 % (107°C) (Warning Start)
100 % (110°C)
White
1/10 LCD (Red Zone)

CN3-7 Blinking  over 5K ohms
Fuel Level
11% CN3-8
Red Full
FULL  under 525 ohms
E F
WE1401048
0% (34°C)
100% 98% 17% (46°C)
81% 33% (59°C)

H
50% (72°C)
65%
Hydraulic Oil CN3-9 65% (85°C)
50%
Temperature CN3-10 81% (91°C)
C 33% 95% (97°C)

17% 97% (98°C)
WE1401049 98% (99°C) (Warning Start)
100% (101°C)
CN5-15
Tachometer rpm CN5-16
EX1301378

9-1-20
WARNING AND INDICATOR LIGHTS
Indication of Warning Lights

Input
Description Symbol Operation Remarks
Terminal
It lights in case of no
charge [voltage of
Normally, it lights
"R(I)" terminal is below
CN2-14 when starting engine
Charge 12 ±1V] or overcharge
CN1-8(9) and is out after
[voltage of "R(I)"
engine starts.
terminal is above
HAOA610L 33(V)].
After starting engine,

It lights when engine if engine oil pressure
Engine Oil CN5-5
oil pressure is below is insufficient after 8
Pressure CN1-8(9)
the reference. seconds, a warning
buzzer will sound.
HAOA620L
It lights when engine

coolant temperature
Coolant CN5-13
sensor resistant is
Temperature CN5-14
below about
128 ohms.
HAOD350L
It lights during
preheating and turns
CN2-13
Preheating "OFF" after completion
CN1-8(9)
of preheating. 
(After 20 sec preheating)
It lights when work

Work Light CN2-6 light turns "ON" (24 V
applied).
HB4O2003

9-1-21
Indication of Multifunction Gauge
Input
Terminal
When hydraulic oil

Hydraulic Oil CN3-9
temperature is above
Temperature CN3-10
about 96°C.
FG000056
Fuel CN3-7 When fuel is almost

Exhausted CN3-8 exhausted.
FG000057
CN2-17 When air cleaner is

Air Cleaner
CN1-8(9) clogged.
FG000053
When return filter

pressure is above
Return Filter CN5-3
about 1.50 kg/cm²
(21 psi)
FG000054
When pilot filter

CN2-18 pressure is above
Pilot Filter
CN1-8(9) about 1 kg/cm²
(14 psi)
FG000055
Warning buzzer also

It flickers in case of
starts when boom
2.71V and above and
CN3-5 pressure sensor
Overload lights continuously in
output voltage is
Warning CN3-6 case of 2.8V and
about 2.7V while
above (and warning
overload warning
buzzer also starts).
FG000253 switch is "ON".

9-1-22
Input
Terminal
It lights when boost is

Boost CN2-2
selected.
FG000554
It lights when breaker

Breaker CN2-10
is selected.
FG001470
It lights when shear is

Shear CN2-9
selected.
FG001471
It lights when the

water separator is
full.
Water CN3-19
Separator CN3-20 It lights when water
separator sensor
output voltage is
DS1800181 about 1.5V below.

9-1-23
INITIAL OPERATION
Item Input (Terminal) Output (Operation and initial setting mode)
• LCD, all of LED and warning lights are turned "ON"
and turned "OFF" after about 2 seconds.
• Warning buzzer is activated and turned "OFF" after
about 2 seconds.
When "CN6-1,2" is applied
Initial • Power mode: Standard mode.
battery voltage (starter switch
Operation
shifts from "OFF" to "ON" • Auto Idle: High Output (Activation).
• Display: Indicating coolant temperature, Fuel level,
Hydraulic oil temperature, Engine speed.
• Clock: Current time display.
NOTE: Refer to method for setting clock in operation manual

for setting time.
MODE SELECTOR SWITCH

Power Mode Switch
EPOS Output
Operation Mode Electromagnetic Proportional Pressure
Swing Priority 7-Segment
Reducing Valve (E.P.P.R Valve)
Solenoid Valve Display
Current (mA)
No-load: 150 ±20 mA
Power Mode Load: Variable output - 9x
(Max. current: 600 ±60 mA)
Power
Standard Mode Load: Variable output - 7x
Mode
Economy Mode Load: Variable output - 5x
NOTE: When the engine speed is below 1,000 rpm, the

output current of E.P.P.R valve is fixed to be
600 ±60 mA.
Auto Idle Switch
Operation Mode Output Check (Operation Mode Display LED)

Activation ON
Auto Idle
Cancellation OFF

9-1-24
GRAPHIC INFORMATION AREA
DISPLAY
Overview
Many kinds of condition of machine are displayed on the letter
information display department. The information display
department is divided into two menus. One is main menu for
user and the other is special menu for specialist. These menus
can be moved from normal display mode by the combination of
selector buttons.
AM
H H
E F
C C
rpm
S USB
1
EX1501577
Figure 11
Main Menus for the Graphic Display Area

1. User menu: Language setting, Time setting, Filter/Oil
information, Brightness adjustment, Password
2. Special menu: Information of machine status, fault
information, Information of machine operation.
Menu Selector Buttons

1. Proceed to the user menu using the menu/ESC (1, Figure
11) button on the front of the panel.
2. The ESC Button (1, Figure 11): Move a screen to previous
menu or main menu.

9-1-25
USER MENU
User Menu - Access and Escape Methods
Access Method
1. Proceed to the user menu using the menu/esc button on
the front of the dashboard.
2. Select the user menu from the launch menu.
PM PM
User Menu
H H
E F
C C Machine State Machine Gauge Panel
Configuration Configuration
rpm
S USB S USB
<Normal Indication Monitor> <Main Menu Monitor>

EX1402098
Figure 12
Escape Method
1. Press the ESC button to move to the normal display screen.
2. If 20 seconds have passed without the operation of the
button, the normal display screen will be displayed.
3. Turning "OFF" the starter switch to cut off power, you will
move to the normal display screen.
User Menu
PM
Use the and buttons and move the cursor to see a User Menu
reversed display on the desired menu. Then, press the
button to select the menu.
Machine State  Machine Configuration  Gauge Panel
Configuration Machine State Machine Gauge Panel
Press the ESC button to return to the previous screen.
S USB
WARNING
EX1402099
Figure 13

Do not use vehicle state menu when traveling or operating.

9-1-26
1. Machine State
PM
This is used to check the current vehicle state, filter/oil Machine State
information, vehicle information, etc.
Monitoring
Use the and buttons and move the cursor to see a
Filter/Oil Information
Machine Information
Monitoring  Filter/Oil Information  Machine
Information S USB
Press the ESC button to return to the previous screen. EX1402086

Figure 14
A. Monitoring
Monitoring
The monitoring screen displays the information on Front Pump Pressure Rear Pump Pressure Battery Voltage
machine pump pressure, voltage, fuel level, etc.
bar bar bar
At the machine state, if the cursor is placed on 0 500 0 500 0 500
Monitoring, press the button to display the Engine Dial Voltage Fuel Level Engine Speed
Monitoring screen.
bar v %
Press the ESC button to return to the previous 0 50 0 40 0 100
screen.
FG018483
Figure 15
B. Filter/Oil Information
PM
The screen displays the information on filter/oil use Machine State
time, replacement period, and remaining time.
Monitoring
At the machine state, if the cursor is placed on the
filter/oil information, press the button to display
the filter/oil information. Machine Information
S USB
EX1402087
Figure 16

9-1-27
Reset Method/Replacement Period Change Method
Move the cursor over the filter/oil item you wish to Fuel Filter
change using the and buttons on the front of TIME: 40hr
REMAIN: 1960hr
CHANGE: 2000hr
2 %
the dashboard and press the button on the front Air Cleaner
TIME: 0 hr CHANGE: 2000hr
of the dashboard. A window for resetting/changing REMAIN: 2000hr 0 %
the filter/oil time will pop-up.  Engine Oil Filter

To reset the use time, move the cursor over 'clear' REMAIN: 100hr 0 %
and press the button on the front of the TIME: 41 hr

Return Filter
CHANGE: 1400hr
dashboard. REMAIN: 1359hr 2 %
Use the and buttons to locate it at YES. Then, EX1301406
press the button to reset the operation hour. Figure 17
Use the and buttons to locate it at NO. Then,

press the button to allow the pop-up window to
Fuel Filter
disappear without resetting the operation hour. TIME: 40hr CHANGE: 2000hr
REMAIN: 1960hr 2 %
Air Cleaner
Fuel Filter
REMAIN: 2000hr 0 %
TIME: 40 Engine CHANGE:

Oil Filter 2000
TIME:CLEAR
0 hr CHANGE
CHANGE: 100hr
REMAIN: 100hr 0 %
Return Filter
REMAIN: 1359hr 2 %
EX1301407
Figure 18
– The filter/oil use time shows the hours of

operation after initializing the engine. It begins
again with 0 hr after initialization the following TIME: 40hr
Fuel Filter
CHANGE: 2000hr
the replacement of filter/oil. REMAIN: 1960hr 2 %
Air Cleaner
Reset Operation
TIME: 0 hr
Hour?
CHANGE: 2000hr
REMAIN: 2000hr 0 %
Engine Oil Filter

TIME: 0 hr \HV QR
CHANGE: 100hr
REMAIN: 100hr 0 %
Return Filter
REMAIN: 1359hr 2 %
EX1301408
Figure 19
Fuel Filter
TIME: 40hr CHANGE: 2000hr
REMAIN: 1960hr 2 %
Air Cleaner
Fuel Filter
CHANGE:
REMAIN: 2000hr 2000 hr 0 %
Engine Oil Filter

1000 hr
TIME: CHANGE: 2000hr
100hr
REMAIN: 100hr 0 %
Return Filter
REMAIN: 1359hr 2 %
EX1301409
Figure 20

9-1-28
In order to change the filter/oil exchange period,
move the cursor over 'change' in the window for
Fuel Filter
resetting/changing the filter/oil time and press the TIME: 40hr CHANGE: 2000hr
button on the front of the dashboard.

REMAIN: 1960hr 2 %
Air Cleaner
Change Period?
After the exchange period change screen pops up,
REMAIN: 2000hr 0 %
press the button on the front of the dashboard Engine Oil Filter
\HV QR
and the exchange time will start flashing. REMAIN: 100hr 0 %
Return Filter
Next, change the exchange period using the and TIME: 41 hr
REMAIN: 1359hr
CHANGE: 1400hr
2 %
buttons on the front of the dashboard.
EX1301410
With the replacement period change being
Figure 21
completed, press the button to create a pop-up
window to select the period change.
Use the and buttons to locate it at YES. Then,
press the button to change the replacement
period.
Use the and buttons to locate it at NO. Then,
press the button to allow the pop-up window to
disappear without the replacement period not being
changed.
Filter/Oil Period Setup Table Unit: time (hr)
Replacement Period
Kind Minimum Available Change Value By
Basic Setup Value
Setup Value Step
Fuel Filter 500 100 50
Air Cleaner 2,000 1,000 50
Engine Oil Filter 500 100 50
Return Filter 1,000 100 50
Pilot Filter 1,000 100 50
Engine Oil 500 100 50
Hydraulic Oil 2,000 1,000 50
Coolant Water 2,000 1,000 50
Symbol Description
Filter/ ENG Oil Return Coolant

Fuel Filter Air Cleaner Pilot Filter ENG Oil HYD. Oil
Oil Name Filter Filter Water
Icon
EX1300858
Figure 22

9-1-29
If the remaining time for filter/oil replacement is less
than 10 hours, this pop-up window will be created. PM
Press the ESC button or the button to allow the H Caution H

pop-up window to disappear.
Return Filter
F
E period starts!
Replacement
C E F C
rpm
S USB
EX1402088
Figure 23
If the filter/oil replacement period is exceeded, this

pop-up window will be created. Press the ESC button PM
or the button to allow the pop-up window to H Caution H

disappear.
Return Filter
WARNING
F
E period is exceeded!
Replacement
C E F C
rpm
AVOID DEATH OR SERIOUS INJURY S USB
Do not use vehicle state menu when traveling or EX1402089

operating. Figure 24
C. Machine Information
PM
This is used to check the machine name, engine type Machine State
and attachment options.
Monitoring
At the machine state, if the cursor is placed on the
machine information, press the button to access
the machine information screen. Machine Information
Click the ESC button to return to the previous screen.

S USB
EX1402090
Figure 25
Machine Information
Engine
Attachment Option One Way/Two Way
EX1402091
Figure 26

9-1-30
2. Machine Configuration
PM
This is used when selecting the functions such as User Menu
attachment setting, camera setting.
Use the and buttons and move the cursor to see a
button to select the menu. Machine State Machine Gauge Panel
S USB
EX1402100
Figure 27
Attachment Setting  Camera Setting  Breaker

Operation Time Setting  TPS Auto Calibration  PM
Emergency Code (TMS) Machine Configuration
Press the ESC button to return to the previous screen. Attachment Setting
Camera Setting
Breaker Operation Time Setting
TPS Auto Calibration
Emergency Code (TMS)
S USB
Figure 28 DS1704098
A. Attachment Setting (Optional)

PM
In this menu, performance of the one way and two- Attachment Setting
way can be set and set items can be selected.
One Way Select
One Way Select  Two-way Select  One Way
Two Way Select
Setting Two-way Setting
One Way Setting
Press the ESC button to return to the previous
Two Way Setting
screen.
S USB
EX1402093
Figure 29
How to Select Attachments (One Way/Two-way)

One Way Select
After proceeding to attachment setting items, one 1. 1800 rpm 95 lpm 140 bar
way select and two-way select will appear. 2. 1800 rpm 95 lpm 140 bar
Operate the and buttons to select one way/two- 3. Not in Use

4. Not in Use
way select. Then, press the button to move the 5. Not in Use
cursor to the selectable lists.
When the cursor is placed on the list, operate the
and buttons to move the cursor. Then, press the
button to select attachments to use. EX1402094
Figure 30

9-1-31
When the selection is completed, the "Select
One Way Select
Complete!" pop-up window is displayed for 3
seconds, and the checkbox of the selected list is 1. 1800 rpm 95 lpm 140 bar
updated. 2. 1800 rpm 95 lpm 140 bar

3. Not in Use
The cursor can only be moved from the selectable 4. Not in Use
Select Complete!
lists. The selectable list items at the attachment 5. Not in Use
setting are set as "Available" in the use or non-use of
attachments in the attachment setting.
EX1402095
Figure 31
One Way Setting/Two-way Setting

PM
The one way setting/two-way setting screen is used Attachment Setting
to set up the use or non-use of attachments, max.
engine limit, and max. attachment flow rate, etc. One Way Select
Two Way Select

At the machine configuration, when the cursor is
One Way Setting
placed on attachment setting, press the button to
access the one way setting or two-way setting list Two Way Setting
screen.
If the system is set up as the owner's password
S USB
EX1402096
locked, access the attachment setting list screen by
using owner's password input screen. Figure 32
On the owner's password input screen, press the

Owner Password
ESC button to return to the previous screen.
3 4 5 6 7 8 9 : ; <
Enter Owner Password
EX1301416
Figure 33
If you access the one way setting or two-way setting

One Way Setting
list screen, the initial screen locates the cursor at the
top. 1. 1800 rpm 95 lpm 140 bar
2. 1800 rpm 95 lpm 250 bar
3. 1800 rpm 95 lpm 140 bar
4. 1800 rpm 95 lpm 140 bar
5. 1800 rpm 95 lpm 140 bar
EX1402097
Figure 34

9-1-32
Operate the and buttons to select one way/two-
Two Way Setting
way. Then, press the button on the list, operate
the the and buttons to move the cursor. Then, 1. 1800 rpm 95 lpm 250 bar
2. 1800 rpm 95 lpm 340 bar
press the button to select the attachments to be
3. 1800 rpm 95 lpm 250 bar
set up and move to the attachment setting screen. 4. 1800 rpm 95 lpm 250 bar
On the attachment setting list screen, when cursor is 5. 1800 rpm 95 lpm 250 bar
placed on the list, press the ESC button to locate the

cursor at one way/two-way at the top. When the
cursor is placed at one way/two-way at the top, press
the ESC button to return to the previous screen.
Figure 35 EX1301418
How to Set Up Attachments

One Way Setting 3
Attachment setting items include attachment use,
Attachment Use Hqdeohg Button Type Qrw#Xvh
max E/G limit, max flow (ATT), min flow (ATT), and Max E/G Limit 5333 usp Max Press(ATT) Qrw#Xvh
user setting max flow. Operate the and buttons Max Flow(Pump) 573 osp Max Flow(ATT) 453 osp
to locate the cursor. Then, press the button to set 2 Pump Option Qrw#Xvh Min Flow(ATT) 53 osp
up relevant items.
User Setting Max Flow 78 osp
The cursor movement order goes like this: 0 .
53 453
1) One Way Setting
Attachment Use  Max E/G Limit  Max EX1402101
Flow  Min Flow  User Setting Max Flow Figure 36
2) Two-way Setting
Attachment Use  Max E/G Limit  Max
Flow  Min Flow  User Setting Max Flow
Attachment Use
One Way Setting 1
The attachment use is designed to determine Hqdeohg Button Type
Attachment Use Qrw#Xvh
whether relevant attachments are used or not. Max E/G Limit 5333 usp Max Press(ATT) Qrw#Xvh
If set up as enable, the relevant attachment can be Max Flow(Pump) 573 osp Max Flow(ATT) 453 osp
2 Pump Option Qrw#Xvh Min Flow(ATT)
used. Currently Selected Item! 53 osp
If set up as disable, the relevant attachment cannot User Setting Max Flow 78 osp
be used. 0
63 673
.
Locate the cursor at the attachment use. Then, press

the button to set up enable/disable. EX1402102
NOTE: If you select an attachment set up as Figure 37

disable, the pop-up window "Currently
Selected Item!" is displayed for three (3)
seconds disabling the setup.
NOTE: If an attachment is enabled it can be a
selectable attachment in the attachment
select.
Max Flow (Pump)
The max flow (pump) is the pump's max. flow rate
discharged when using attachments. It needs not to
be set up by the user, and it is automatically
determined according to the max. engine limit setup
value.

9-1-33
Max Flow (ATT)/Min Flow (ATT)
The max flow (ATT) /min flow (ATT) can be set up as
the max/min flow rate value of the attachment by the
user according to the attachment's specifications.
For instance, if the relevant attachment's use
capacity is 90 ~ 120 lpm (23.8 ~ 31.7 gpm), the user
can set up 120 lpm (31.7 gpm) for the max. flow rate,
and 90 lpm (23.8 gpm) for the min. flow rate.
Operate the and buttons to move the cursor to
the max flow/min flow. Then, press the button to
convert into the editing mode.
At the editing mode, operate the and buttons to
determine the desired max flow/min flow. Then, press
the button to complete setup.
At the editing mode, press the ESC button to disable
the editing mode and the saving of the setup value.
The change value by stage in the and buttons
operation is 10 lpm (2.6 gpm).
User Setting Max Flow
The user setting max flow is designed to set up the flow
rate segment of the attachment to be used by the user.
Within the above setup max. flow rate (pump), max.
flow rate (ATT), and min. flow rate (ATT) scope, the
user can set up the max. flow rate value of the
attachment to be used.
The setup method is the same as the above max
flow/min flow setup method. The change value by
stage in the and buttons operation is 10 lpm
(2.6 gpm).
When setting up all above items, the setup limits are
outlined as follows.
• One Way Setting
Max. Limit
Max. E/G Limit User Setting Value
Conforms to the Max. Engine
Max. Flow (Pump)
Limit
Max. Flow (ATT) 350 lpm (91 gpm)
Min. Flow (ATT) 50 lpm (13 gpm)
• Two-way Setting
Max. Limit
Max. E/G Limit User Setting Value
Conforms to the Max. Engine
Max. Flow (Pump)
Limit
Max. Flow (ATT) 70 lpm (18.2 gpm)
Min. Flow (ATT) 50 lpm (13 gpm)

9-1-34
B. Camera Setting
PM
The camera setting screen is designed to set up Machine Configuration
various cameras "ON/OFF" and normal/mirror.
Attachment Setting
From the vehicle configuration, select camera setting Camera Setting
to access the camera setting list screen. Breaker Operation Time Setting
S USB
Figure 38 DS1704099
The camera setting list screen displays various

PM
camera states (ON/OFF, NORMAL/MIRROR).
Camera Setting
Select a camera and press the button to access
the relevant camera setting screen. No 1 Camera
No 2 Camera
screen. No 3 Camera
S USB
EX1402104
Figure 39
On the camera setting screen, set up the camera

No 1 Camera
state (ON/OFF, NORMAL/MIRROR).
Also, see the actual image of the currently installed No 1 Camera
camera.
On Off
Normal Mirror
EX1301421
Figure 40
If a camera is not installed, the camera image section

No 1 Camera
is shown as a blue screen.
If the cursor is placed on "ON/OFF", press the No 1 Camera
button to set up "ON"  "OFF".

On Off
Use the and buttons to locate the cursor at Normal Mirror
normal/mirror. Then, press the button to set up

normal  mirror.
EX1301422
Figure 41

9-1-35
C. Breaker Operation Time Setting
PM
This machine limits the continuous operation time of Machine Configuration
the breaker in order to prevent damages to its
components. Attachment Setting
Camera Setting
S USB
Figure 42 DS1704100
You can adjust this time limit in the page of Breaker

Operation Time Setting. Breaker Operation Time Setting
• Setting Time Range: 10 ~ 60 sec

Breaker Operation Time 15 Sec
• Default Time: 15 sec
10 60
DS1601788
Figure 43
D. TPS Auto Calibration

PM
This menu enables TPS calibration. Machine Configuration
Attachment Setting
Camera Setting
S USB
Figure 44 DS1704101
Conditions to be met for TPS calibration:

• Engine speed control dial is in the max position
Engine Control Dial Max
• Pilot cutoff lever is on
Pilot Cut Off Switch
• Engine is running Engine Startup
• Speed sensor, TPS sensor, and engine speed Sensor normal

control dial are under normal condition
Ready for correction. To execute the calibration, Press
the "YES".
DS1704126
Figure 45

9-1-36
Engine Control Dial Max
Pilot Cut Off Switch
Engine Startup
Sensor normal
Correction is not possible. Please check the condition

for correction.
DS1704127
Figure 46
E. Emergency Code (TMS)

PM
This menu enables authorized personnel to Machine Configuration
temporarily unlock those machines that have been
locked by the TMS server (Ignition lock or RPM Attachment Setting
limitation) but are currently located where they cannot Camera Setting
receive an unlocking command from the server. Breaker Operation Time Setting
S USB
DS1704125
Figure 47
Emergency Code(TMS)
3 4 5 6 7 8 9 : ; < D EFGHI
Enter Password
DS1701751
Figure 48
If you enter the menu when the machine is not

Emergency Code(TMS)
locked, the screen will be shown as in Figure 49.
Vehicle Operation is not locked.
DS1701752
Figure 49

9-1-37
Pressing the Enter key without a 8-digit password
Emergency Code(TMS)
typed in will prompt a pop-up as shown in Figure 50.
Please enter all 8 digits

of password!
3 4 5 6 7 8 9 : ; < D EFGHI
Enter Password
DS1701753
Figure 50
If you type in a 8-digit password and press Enter and

Emergency Code(TMS)
that results in "Unlock Success" data from the TMS
server, then a pop-up will appear as shown in Figure
51.
Vehicle is unlocked now.

3 4 5 6 7 8 9 : ; < D EFGHI
Enter Password
DS1701754
Figure 51
If you type in a 8-digit password and press Enter and

Emergency Code(TMS)
that results in "Unlock Fail" data from the TMS server,
then a "Password Error" pop-up will appear as shown
in Figure 52.
Password Error!
3 4 5 6 7 8 9 : ; < D EFGHI
Enter Password
DS1701781
Figure 52
3. Gauge Panel Configuration

PM
This menu is used to set up password, brightness, default User Menu
screen and time, and to input service phone number. Use
the and buttons and move the cursor to see an
Machine State Machine Gauge Panel
Password Setting  Brightness Setting  Default Configuration Configuration
Screen Setting  Time Setting  Service Phone

Number Setting  Unit Setting Notification Setting S USB
EX1402105
Press the ESC button to return to previous screen.
Figure 53

9-1-38
A. Password Setting
PM
Password Setting Gauge Panel Configuration
An owner passwords can be set. Password Setting
By using the password setting function, you can Brightness Setting
manage usage of operations and functions of the Default Screen Setting
vehicle. Time Setting

Service Phone Number Setting
S USB
EX1402106
Figure 54
1) Password entry
Owner Password
When the password entry screen appears, use
the keypad to enter the password and move to
the settings screen.
The default password is "1111".
How to enter the password 3 4 5 6 7 8 9 : ; <
Use the and buttons to select digits from 0 Enter Owner Password
to 9 below, and press the button to input the
password.
EX1301416
If the password is input incorrectly, use the
Figure 55
button on the lower right to delete the input
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 56
2) Structure
Password Setting
Owner password settings include password
change, start-up restriction settings. Locked
Unlocked
Engine Startup
1 Minute
5 Minute
Password Change
Figure 57 EX1402107

9-1-39
Password change
Owner Password Change
To change the owner password, select
password change with the keypad.
3 4 5 6 7 8 9 : ; <
Enter Password
EX1301435
Figure 58
When the owner password has been changed,

Password Setting
"Password Set!" will pop-up.
Locked
Unlocked
Engine Startup
Password Set
1 Minute
5 Minute
Password Change
EX1402108
Figure 59
Engine start-up setting

Password Setting
By selecting "Engine Start-up" among item
settings the reentry time for password entry Locked
upon start-up of the equipment can be set. Unlocked
Engine Startup
NOTE: No password for start-up of the 1 Minute
equipment is setby default. 5 Minute
a) Locked Password Change
Password is entered with each start-up.

b) 1 minute EX1402107
If the system is started again within 1 Figure 60
minute from key-off after the password is
input, the password is not requested again.
c) 5 minutes
If the system is started again within 5
minutes from key-off after the password is
input, the password is not requested again.

9-1-40
B. Brightness Setting
PM
On the Gauge Panel configuration screen, when Gauge Panel Configuration
cursor is placed on brightness setting, press the
Password Setting
button to display the screen brightness setting and
Brightness Setting
camera brightness setting screen.
Default Screen Setting
Time Setting
S USB
EX1402109
Figure 61
If you want to change the screen brightness, select

PM
the screen brightness setting to display the
brightness adjustment screen. Brightness Setting
Screen Brightness Setting
Camera Brightness Setting
S USB
EX1402194
Figure 62
Use the and buttons and adjust the brightness

of 0 ~ 100% at an interval of 10%. Screen Brightness Setting
The screen brightness when manufactured is set as H H
80%.
80 %
screen. C
E F
C
EX1404972
Figure 63
If you want to change the camera screen brightness,

PM
select the camera brightness setting to display the
camera screen brightness adjustment screen. Brightness Setting
Screen Brightness Setting
Camera Brightness Setting
S USB
EX1402110
Figure 64

9-1-41
Use the and buttons to adjust the brightness of
0 ~ 100% at an interval of 10%.
The camera screen brightness at the vehicle release
time is set as 80%. 80 %

screen.
EX1404851
Figure 65
C. Default Screen Setting

PM
Sets the main screen display on the display monitor. Gauge Panel Configuration
Password Setting
Brightness Setting
Time Setting
S USB
EX1404973
Figure 66
The initial screen shows basic information, including

the fuel level, coolant temperature and hydraulic oil PM
temperature. H H
E F
C C
rpm
S PLAY
EX1404974
Figure 67
Enter the "Default Screen Setting" menu and select

"Enable" for this function. Then, the main screen
shows the camera view next time the starter switch is
turned to the ON position. Move the Camera Screen at Enabled
Boot Time
EX1402182
Figure 68

9-1-42
rpm
S
EX1404975
Figure 69
D. Time Setting
PM
On the GP configuration screen, when cursor is Gauge Panel Configuration
placed on time setting, press the button to access
Password Setting
the time setting.
Brightness Setting
Use the and buttons and locate the cursor at a Default Screen Setting
target of change. Then, press the button to Time Setting
change the target. Service Phone Number Setting
S USB
EX1402106
Figure 70
Use the and buttons to change numbers of

Time Setting
each item.
If the setup is completed, press the button to
store the setup details. TIME 09 : 47 : 24 PM
When the time setting is completed, locate cursor to DATE 2014 / 10 / 29 SET
'SET' and press the button.

If the SET button is not pressed, time setting would
not be completed.
Press the ESC button to return to the previous EX1402111
screen. Figure 71
E. Service Phone Number Setting

PM
placed on service phone number setting, press the
Password Setting
button to access the service phone number
Brightness Setting
setting.
Time Setting
S USB
EX1402112
Figure 72

9-1-43
Use the and buttons and locate the cursor at a
desired number. Then, press the button to input
the number. If number input is completed, press the 1 2 3
Current Phone Number is
key to enter the input phone numbers. 4 5 6
Use the key and delete erroneously input
Enter Phone Number if you want
to Change. 7 8 9
numbers. 000-0000-0000
0
EX1301448
Figure 73
When you input service phone numbers, if warning/

P
alarm is issued, check the input phone numbers in AM
the pop-up window. H Caution H

000-0000-0000
P Pilot Filter
Service Pilot Filter

E F
C E F C
rpm
S USB
EX1402113
Figure 74
F. Unit Setting
PM
placed on unit setting, press the button to access
Brightness Setting
the unit setting.
Default Power Mode Setting
Time Setting
Unit Setting
S USB
EX1402114
Figure 75
On the unit setting screen, change the units of

Unit Setting
temperature, pressure, flow rate, and speed. These
figures at the vehicle release time are set as below:
Temperature 䮎䯘
Temperature: °C
Pressure edu nji2 䶫 svl PSd
Pressure: bar
Flux osp jsp
Flow rate: lpm
Speed np2k psk
Speed: km/h
EX1301449
Figure 76

9-1-44
G. Language Setting
PM
placed on language setting, press the button to
Default Power Mode Setting
access the language setting.
Time Setting
Unit Setting
Language Setting
S USB
EX1402115
Figure 77
On the language selection screen, use the and

Language Setting
buttons and move the cursor to select a language.
Then, press the button to adopt the selected
language.
screen.
Language
Korean, English, Chinese, Persian, Turkish,
Indonesian, Polish, Arabic, Russian, Thai, Hindi,
EX1301062
Japanese, French, German, Nederlands, Italian,
Portuguese, Spanish, Finnish, Swedish, Figure 78
Norwegian, Danish, Vietnamese, Greek
H. Notification Setting
PM
placed on notification setting, press the button to
Time Setting
access the notification setting.
Unit Setting
Language Setting
Notification Setting
S USB
EX1402116
Figure 79
Depending on the notification setting screen details,

Notification Setting
pop-ups are created on the main screen when
warning/alarm is issued, when the switch is operated,
and when the supplies replacement period expires. Warning Alarm Pop up Avalible
On the notification setting screen, use the and Maintenance Notification Pop up Avalible
buttons and move the cursor to a desired location.
Then, press the button to select enable or
disable.
All notice items at the vehicle release time are set as
Enable. EX1301450
Figure 80

9-1-45
SPECIAL MENU
In this menu, many types of operating conditions and functions
can be accessed and displayed, including the EPOS controller.
This menu is mainly used for machine testing and fault
diagnostics.
The special menu offers five submenus:
1. Monitoring.
2. Graph.
3. Failure Information.
4. Operating Hour Information.
5. Machine Configuration.
Entering/Accessing and Exiting/Escaping

Menus
Entering/Accessing Menus
When normal mode screen is displayed, if auto idle selector
button (1, Figure 81), up arrow button (2, Figure 81) and camera
mode selector button (3, Figure 81) are pressed simultaneously
for more than 3 seconds, normal mode screen (Figure 82) will AM
be changed to special menu screen (Figure 83). H H
E F
C C
rpm
S USB
1 2 3
EX1501516
Figure 81
Normal Mode Screen

NOTE: Normal mode screen display fuel gauge, engine
H H
coolant temperature gauge, hydraulic oil temperature
gauge and engine speed (rpm).
E F
C C
rpm
WE1400701
Figure 82

9-1-46
Special Menu Screen
PM
NOTE: Displayed language on the special menu screen Service Menu
consists of Korean and English.
Monitoring
If any language except for Korean is selected during Graph
language selection mode of main menu, only English Failure Information
will be displayed on special menu screen. Operating Hour Information
Machine Configuration
S USB
EX1501519
Figure 83
Exiting/Escaping Menus
1. If the ESC button is pressed the special menu screen will
be returned to the normal mode screen.
2. If this special menu is "ON" without any activity, for more
than 20 seconds, it will return to the normal mode screen.
3. After the turning starter switch to "OFF" position, turn it
back to "ON" position, and the normal mode screen
displayed once again.
Special Menu Selections

Submenu Selection Method
PM
Various submenus can be selected by use the and Service Menu
buttons and moving the cursor to see a reversed display on the
Monitoring
desired menu. Then, click on the button to select the menu.
Graph
Press the ESC button to return to the previous screen. Failure Information
Operating Hour Information
Entering Submenus: When cursor is located on "Machine Info"
of special menu screen, press the button and the "Machine
Info" will be displayed. S USB
EX1501520
Figure 84
Monitoring
PM
1. Entering Submenus: When cursor is located on Monitoring
"Monitoring" of special menu screen, press the button
Machine Analog
and the "Monitoring" will be displayed.
Machine Digital
2. Exiting Submenus: If the ESC button is pressed display will User Selection Signal
be turned to previous screen.
S USB
EX1501521
Figure 85

9-1-47
Machine Analog Description
Analog Items Display Remark

1. Front Pump Pressure MPa Front Pump Pressure
2. Rear Pump Pressure MPa Rear Pump Pressure
3. Boom Cylinder Pressure MPa Boom Cylinder Head Pressure
4. Alternator Voltage V Indicating Alternator Voltage
5. Battery Voltage V Indicating Battery Voltage
6. Engine Speed Control Dial Voltage mV Indicating Dial Voltage
7. WIF Sensor Voltage mV Indicating WIF Sensor Voltage
8. Fuel Level % Fuel Residual Quantity Radio of Fuel Tank
9. Hydraulic Oil Temperature °C Hydraulic Oil Temperature
10. TPS Voltage mV E/G Throttle Lever
11. Coolant Water Temperature °C Coolant Temperature
12. Power Shift P/V 1 mA Current in Pump Proportional Valve
13. Flow Control P/V mA Current in Flow Control Proportional Valve
Submenu Selections
Machine Analog Machine Analog

Front Pump Pressure 0 MPa Hydraulic Oil Temperature -40 C
Rear Pump Pressure 0 MPa TPS Voltage mV
Boom Cylinder Pressure 0 MPa Coolant Water Temperature C
Alternator Voltage 24.7 V Power Shift P/V 1 0 mA
Battery Voltage 21.6 V Flow Control P/V 0 mA
Engine Speed Control Dial Voltage 216 mV
WIF Sensor Voltage mV
Fuel Level 0%
EX1501522
Figure 86

9-1-48
Machine Digital Descriptions
Digital Items Mark Remark

Lights up when output at alternator "R (I)" terminal is
1. Alternator
above 12 ±1 V.
Lights up when the boost button is "ON" with the work
2. Power Max Switch
mode selected to "BOOST".
Lights up when the boost button is "ON" with the work
3. One Way Operator Switch
mode selected to "BREAKER".
Lights up when the travel speed selector switch is set
4. Hi-Speed Select Switch-M
to "I" position.
Lights up when the travel speed selector switch is set
5. Hi-Speed Select Switch-A
to "II" position.
6. Working Lamp Switch Lights up when the light switch is set to "II" position.
Lights up when the selector switch is turned to
7. One Way Select Switch
"Breaker".
Lights up when the selector switch is turned to
8. Two Way Select Switch
"Shear".
9. Quick Coupler Lights up when the quick coupler switch is "ON".
10. Pilot Cut Off Switch Lights up when the pilot cutoff switch is "ON".
Lights up when the air cleaner indicator contact is
11. Air Cleaner Indicator
ON/OFF "ON".
12. Pilot Filter Lights up when the pilot filter pressure switch is "ON".
Lights up when the return filter pressure switch is
13. Return Filter
"ON".
Lights up when the overload warning selector switch
14. OWD Select Switch
is "ON".
15. Pedal Breaker Press Switch Lights up when the pedal pressure switch is "ON".
16. Water in Fuel Lights up when WIF sensor is "ON".
17. Preheating (Mechanical) Lights up when the preheting relay is "ON".
18. Start up Switch Lights up when the starter switch is "START".
19. Pressure Switch-Py Lights up when the pressure switch (Py) is "ON."
20. Pressure Switch-Px Lights up when the pressure switch (Px) is "ON."
21. Engine Oil Pressure Switch Light up when E/G oil pressure sensor is "ON".
Lights up when the relief press up solenoid valve is
22. Relief Pressure S/V
"ON".
Lights up when the high-speed solenoid valve is
23. High Speed S/V
"ON".
24. Starter Relay Lights up when the starter relay is "ON".

9-1-49
Submenu Selections
Machine Digital Machine Digital

Alternator Quick Coupler
Power Max Switch Pilot Cut Off Switch
One Way Operator Switch Air Cleaner Indicator
Hi-Speed Select Switch-M Pilot Filter
Hi-Speed Select Switch-A Return Filter
Working Lamp Switch OWD Select Switch
One Way Select Switch Pedal Breaker Press Switch
Two Way Select Switch Water in Fuel
Machine Digital
Preheating (Mechanical)
Start up Switch
Pressure Switch-Py
Pressure Switch-Px
Engine Oil Pressure Switch
Relief Pressure S/V
High Speed S/V
Starter Relay
EX1501523
Figure 87

9-1-50
Graph
PM
1. Entering Submenus: When a cursor is located in "Graph" Service Menu
of special menu screen press the button on panel and Monitoring
"Graph" screen is displayed. Graph
2. Exiting Submenus: If the ESC button on panel is pressed, Failure Information
this information screen will be returned to previous screen. Operating Hour Information
S USB
EX1501524
Figure 88
Graph Data Monitoring

PM
Real time monitoring of the selected data. Service Menu
Graph Data Setting
S USB
EX1501578
Figure 89

Battery Voltage V Current Value : 24.7
40.0
Engine Dial Volt.
Rotating P/V (CCW)
0
1 19 Sec
EX1301616
Figure 90
Graph Data Setting

Graph Data Setting
User can be graph data setting. Front Pump Press.
The maximum limit of the graph data setting is 7. Rear Pump Press.
Boom Cylinder Press.
Px Pressure You can select up to 7
Py Pressure items!
Alternator Voltage
Battery Voltage
Engine Dial Volt.
EX1301617
Figure 91

9-1-51
Failure Information
PM
1. Entering Submenus: When a cursor is located in "Failure Service Menu
Info" of special menu screen press the button on panel
Monitoring
and "Failure Info" Screen is displayed.
Graph
2. Exiting Submenus: If the ESC button on panel is pressed, Failure Information
this information screen will be returned to previous screen. Operating Hour Information
S USB
EX1501579
Figure 92
* Real-time Failure: Current status of fault is displayed.

PM
* Failure Log: Memorized record of past fault is displayed. Failure Information
Real Time Failure Information
Failure Log Information
S USB
EX1501580
Figure 93
A. Current fault information

Real Time Failure Information
Current status of fault is displayed (Failure code, fault NO Code Description
contents). 1 VCO002-11 THUMB WHEEL (LH)
2 VPV001-05 PUMP P/V (A), Current below normal
When several faults are produced, fault information 3 VPV010-05 FLOW CONTROL P/V (F) ROTATIN.
can be checked on this information screen. 4 VSV001-05 BREAKER OPERATING S/V, Curen.
5 VSP011-04 ARM OUT PRESS. SENSOR, Voltag
No: Number of currently occurring failure 6 VSP008-04 BOOM DOWN PRESS. SENSOR, Vo
Description
Code: Display of current failure code Pump P/V (A), Current below normal
VXXyyy-zz: Method of displaying machine related

failure code EX1301618
Figure 94
– V: Display of machine related failure code
– XX: Display of failed part
– yyy: Serial number of failed part
– zz: FMI (Failure Mode Identifier) number
Eyyyyyy-zz: Method of displaying engine related
failure code
– E: Engine related failure code
– yyyyyy: Serial number of failed part
– zz: FMI (Failure Mode Identifier) number
* Method of displaying failed part of machine (VXX)
1) VCO: Communication related failure
2) VPV: EPPR valve related failure

9-1-52
3) VSV: Solenoid valve related failure
4) VRY: Relay related failure
5) VSP: Pressure sensor related failure
6) VSE: Sensor related failure except for pressure
sensor
7) VS5: 5V sensor related failure
8) VAL: Other failures.
Example)
VPV001-05: EPPR valve (A) current is lower than
normal current.
Description: Shows the description of the details of
machine failure.
Refer to the failure information code for unique codes
and FMI numbers.
This example shows one of two faults.
B. Past failure information
Failure Log Information
Memorized record of past failure is displayed (Failure NO Code Count Occurrence Time
code, fault contents). 5 VPV007-05 9 21 Hr 20 Min
6 VCO002-11 25 21 Hr 27 Min
When several faults are produced, failure information 7 VSP011-04 2 21 Hr 56 Min
can be checked on this information screen. 8 VSP008-04 1 21 Hr 56 Min
9 VSV001-05 4 21 Hr 56 Min
NOTE: "Count: xxx": "xxx" means that totally 10 VPV001-05 15 21 Hr 56 Min
Description
counted number of the same fault.
BREAKER OPERATING S/V, Current below normal
"Occurrence Time": It indicates the period
for which machine has operated until a EX1301619
fault takes place. (For more than two Figure 95
occurrences of the same fault, until first
occurrence time.)

9-1-53
Failure Code at Machine
GP Display GP Display Measurin Correct Value Severity

SPN Name FMI Remark
Code Description g Point Active Passive Level
Pump P/V (A),  CN1-10 Pump proportional

VPV001 Pump P/V (A) 05 3
Current Below Normal CN1-21 R = 13.5 ±2  pressure reducing valve
Pump P/V (A),  CN1-10 (25°C (77°F)) Pump proportional
VPV001 Pump P/V (A) 06 3
Current Above Normal CN1-21 pressure reducing valve
Flow Control P/V (C), CN1-19 Flow control proportional
VPV007 Flow Control P/V (C) 05 3
Current Below Normal CN1-20 R = 13.5 ±2  pressure reducing valve
Flow Control P/V (C), CN1-19 (25°C (77°F)) Flow control proportional
VPV007 Flow Control P/V (C) 06 3
Current Above Normal CN1-20 pressure reducing valve
Breaker/boost/ shear
selector switch has to be
Relief Press. Up S/V, CN1-1 selected as a boost
VSV002 Relief Press. UP S/V 05 3
Current Below Normal CN1-11 function and the boost
switch on the right-hand
joystick is "ON" status
V = V_volt
Breaker/boost/ shear
selector switch has to be
Relief Press. Up S/V, CN1-1 selected as a boost
VSV002 Relief Press. UP S/V 06 3
Current Above Normal CN1-11 function and the boost
switch on the right-hand
joystick is "ON" status.
Breaker Select S/V,
VSV013 Breaker Select S/V 05 3
Current Below Normal CN2-8,
V = V_volt
Breaker Select S/V, CN1-8
VSV013 Breaker Select S/V 06 3
Current Above Normal
Breaker Operating S/V,
VSV001 Breaker Operating S/V 05 3
Current Below Normal CN2-10,
V = V_volt
Breaker Operating S/V, CN1-8
VSV001 Breaker Operating S/V 06 3
Current Above Normal
Starter Relay,  CN1-1 It has to be measured in
VRY007 Starter Relay 05 3
Current Below Normal CN1-15 engine start up state.
V = V_volt
Starter Relay,  CN1-1 It has to be measured in
VRY007 Starter Relay 06 3
Current Above Normal CN1-15 engine start up state.
After Heat Relay, CN1-16
VSV014 After Heat Relay 05 3
Current below normal CN1-04
V = V_volt
After Heat Relay, CN1-16
VSV014 After Heat Relay 06 3
Current above normal CN1-04
Dial, 
VS5005 Dial 03 3
Voltage Above Normal CN3-16 V = 1.0 ±0.1 V
Dial,  CN3-17 V = 4.0 ±0.1 V
VS5005 Dial 04 3
Voltage Below Normal
E/G Control Motor
E/G Control Motor
VSE009 03 Sensor, Voltage 3
Sensor
Above Normal CN3-13
E/G Control Motor CN3-14
E/G Control Motor
VSE009 04 Sensor, Voltage 3
Sensor
Below Normal
Fuel Level Sensor,
VSE002 Fuel Level Sensor 03 3
Voltage Above Normal CN3-7 Empty: 5 ±0.2 k
Fuel Level Sensor, CN3-8 Full: 500 ±10 
VSE002 Fuel Level Sensor 04 3
Oil Temp. Sensor,
VSE001 Oil Temp. Sensor 00 Signal Above Normal 3
Range R = 2.45 ±0.25 k
CN3-9 (25°C (77°F))
Oil Temp. Sensor,
VSE001 Oil Temp. Sensor 03 CN3-10 R = 320 ±32  3
Voltage Above Normal
(80°C (176°F))
Oil Temp. Sensor,
VSE001 Oil Temp. Sensor 04 3
Water Temp. Sensor,
VSE010 Water Temp. Sensor 00 Signal Above Normal 3
Range
CN5-13
Water Temp. Sensor,
VSE010 Water Temp. Sensor 03 CN5-14 3
Voltage Above Normal
Water Temp. Sensor,
VSE010 Water Temp. Sensor 04 3
Engine Speed Sensor, CN5-15
VSE011 Engine Speed Sensor 02 3
Incorrect Signal CN5-16

9-1-54
GP Display GP Display Measurin Correct Value Severity
SPN Name FMI Remark
Code Description g Point Active Passive Level
Front Pump Press.

Front Pump Press.
VSP001 02 Sensor, Incorrect 2
Sensor
Signal
Front Pump Press.
Front Pump Press. CN3-1
VSP001 03 Sensor, Voltage V = IV 2
Sensor CN3-2
Above Normal
Front Pump Press.
Front Pump Press.
VSP001 04 Sensor, Voltage 2
Sensor
Below Normal It has to be measured in
Rear Pump Press. engine stop state.
Rear Pump Press.
VSP002 02 Sensor, Incorrect 2
Sensor
Signal
Rear Pump Press.
Rear Pump Press. CN3-3
VSP002 03 Sensor, Voltage V = IV 2
Sensor CN3-4
Above Normal
Rear Pump Press.
Rear Pump Press.
VSP002 04 Sensor, Voltage 2
Sensor
Below Normal
Alternator Potential,
VAL001 Alternator Potential 03 4
Voltage Above Normal CN2-14
V = 27 ±0.1V
Alternator Potential, CN1-8
VAL001 Alternator Potential 04 4
It is a compositeresistance
CN4-4 of CAN line. This value has
Gauge Panel Gauge Panel Comm.
VCO001 11 CN4-5 R = 60 ±5  4 to be measured by
Communication Error
CN4-6 connected condition of
CAN line.
WIF Sensor, Signal
VSE004 WIF Sensor 01 3
Below Normal Range
WIF Sensor, CN3-19
Voltage Above Normal CN3-20
WIF Sensor,
NOTE: 1. Active value: Starter switch has to be turned "ON"

Measuring points between component and wire harness have to be connected.
2. Passive value: Starter switch has to be turned "OFF"
Measuring points between component and wire harness have to be disconnected.
3. Measuring points are engine controller's points and passive value is each component's value.
4. V_batt: Source power of equipment.

9-1-55
FMIs (Failure Mode Identifier)
FMI Description
0 Data Valid but Above Normal Operational Range - Most Severe Level
1 Data Valid but Below Normal Operational Range - Most Severe Level
2 Data Erratic, Intermittent or Incorrect
3 Voltage Above Normal, or Shorted to High Source
4 Voltage Below Normal, or Shorted to Low Source
5 Current Below Normal or Open Circuit
6 Current Above Normal or Grounded Circuit
7 Mechanical System Not Responding or Out of Adjustment
8 Abnormal Frequency or Pulse Width or Period
9 Abnormal Update Rate
10 Abnormal Rate of Change
11 Root Cause Not Known
12 Bad Intelligent Device or Component
13 Out of Calibration
14 Special Instructions
15 Data Valid but Above Normal Operating Range - Least Severe Level
16 Data Valid but Above Normal Operating Range - Moderately Severe Level
17 Data Valid but Below Normal Operating Range - Least Severe Level
18 Data Valid but Below Normal Operating Range - Moderately Severe Level
19 Received Network Data in Error
20 Data Drifted High
21 Data Drifted Low
31 Condition Exists

9-1-56
Information of Machine Operation
Accumulated operation hour of each mode and status is
displayed.
PM
1. Entering Submenus: When a cursor is located in Service Menu
"Operating Hrs" of special menu screen (Figure 96)
Monitoring
"Operating Hrs" screen will be displayed (Figure 97).
Graph
Failure Information
Operation Hour Information
S USB
DS1602040
Figure 96
2. Operating Hours Screen

0 hr
14 hr
0 hr
0 hr
Working Mode 0 hr
Travel Mode 0 hr
DS1602041
Figure 97
3. Exiting Submenus: If the ESC button (Figure 98) is

pressed, this information screen will be returned to
previous screen.
WE1400760
Figure 98

9-1-57
Information contents of operation hour
Item Information Contents Detection Method

Power Mode Operation hours used Power Mode Power Mode status (Instrument panel)
are displayed. and Alternator signal (CN2-14) is "HI".
Standard Mode Operation hours used standard Standard Mode status (Instrument panel)
mode are displayed. and Alternator signal (CN2-14) is "HI".
Economy Mode Operation hours used economy Economy Mode status (Instrument
mode are displayed. panel) and Alternator signal (CN2-14) is
"HI".
Auto Idle Operation hours used auto idle Auto Idle Mode status (Instrument panel)
status are displayed. and Alternator signal (CN2-14) is "HI".
Operation hours used work mode is Work mode status (Instrument panel)
Working Mode
displayed and alternator signal (CN2-14) is "HI".
Operation hours used travel mode Travel mode status (Instrument panel)
Travel Mode
is displayed and alternator signal (CN2-14) is "HI".
Hydraulic Oil Temperature Temperature of hydraulic oil is The resistance delivered from
Distribution (°C (°F)) classified 6 steps, and operation temperature sensor of hydraulic oil is
hours of each step are displayed. classified 6 steps, and operation hours of
each step are displayed. 
Under 30°C (87°F)
(Alternator output "HI" status)
31 ~ 50°C (88 ~ 123°F)
51 ~ 75°C (124 ~ 168°F)
76 ~ 85°C (169 ~ 186°F)
86 ~ 95°C (187 ~ 203°F)
Over 96°C (204°F)
Coolant Temperature Temperature of coolant is classified The resistance delivered from coolant
Distribution (°C (°F)) 6 steps, and operation hours of sensor is classified 6 steps, and
each step are displayed. operation hours of each step are
displayed. (Alternator output "HI" status)
Under 40°C (105°F)
41 ~ 60°C (106 ~ 141°F)
61 ~ 85°C (142 ~ 186°F)
86 ~ 95°C (187 ~ 204°F)
96 ~ 104°C (205 ~ 221°F)
Over 105°C (222°F)

9-1-58
Example of Machine Operation Info Screen
Operating Hour Information Operating Hour Information

Power Mode 0 hr 0 hr
Standard Mode 0 hr 0 hr
Economy Mode 0 hr 0 hr
Auto Idle 0 hr 0 hr
Working Mode 0 hr 86 ~ (Overheat-1) 0 hr
Travel Mode 0 hr Above Overheat 20 hr

17 hr
1 hr
1 hr
1 hr
96 ~ (Overheat-1) 0 hr
Above Overheat 0 hr
EX1501528
Figure 99

9-1-59
1. Machine Configuration
PM
A. Entering Submenus: When a cursor is located in Service Menu
"Machine Configuration" of special menu screen
Monitoring
(Figure 100) press the button on panel and
Graph
"Machine Configuration" screen will be displayed
Failure Information
(Figure 102).
S USB
EX1501529
Figure 100
Entering service password is required when

Service Password
accessing the menu.
Q Q
3 4 5 6 7 8 9 : ; <
Enter Service Password
EX1301634
Figure 101
B. Machine Configuration Screen (Figure 102).

Option Setting
Program Update
Machine Information Delete
Version Information
S USB
EX1501530
Figure 102
2. Exiting Submenus: If the ESC button (Figure 103) is

pressed, this information screen will be returned to
previous screen.
WE1400760
Figure 103

9-1-60
Option Setting
1. Entering Submenus: When a cursor is located in "Option Machine Configuration
Setting" of special menu screen (Figure 104) press the
Option Setting
button on panel and "Option Setting screen" will be
Program Update
displayed (Figure 105).
Version Information
S USB
EX1501531
Figure 104
2. Option Setting
Option Setting
• Attachment Option
When a cursor is located in check box of one-way or Attachment Option One Way Two Way
two-way, press the button on panel and then, the
check box light turns "ON". Two Pump Option Not Use
EX1501550
Figure 105
3. Program Update
Entering Submenus: When a cursor is located in "Program Machine Configuration
Update" of special menu screen (Figure 106) press the Option Setting
button on panel and "Program Update Screen" will be Program Update
displayed (Figure 107).
Version Information
S USB
EX1501551
Figure 106
Program Update
Be careful not to remove USB or shut down gauge

panel. It may Seriously damage the equipment.
Current Version V 0100 [2013.10.23]
Update Version No Available Update Files!
Insert USB for update!
WE1500394
Figure 107

9-1-61
4. Machine Information Delete
Entering Submenus: When a cursor is located in "Machine Machine Configuration
Information Delete" of special menu screen (Figure 108)
Option Setting
press the button on panel and "Machine Information
Program Update
Delete Screen" will be displayed (Figure 109).
NOTE: When press the button on panel in the Version Information
selected menu the menu will be initialized.
- Delete Failure Log S USB
- Reset Operation Hour EX1501552
- Gauge Panel Setting Reset Figure 108

Delete Failure Log
Reset Operation Hour
Gauge Panel Setting Reset
EX1501553
Figure 109
5. Version Information
Entering Submenus: When a cursor is located in "Version Machine Configuration
Information" of special menu screen (Figure 110) press the
Option Setting
button on panel and "Version Information Screen" will
Program Update
be displayed (Figure 111).
Version Information
S USB
EX1501554
Figure 110
Version Information
EPOS S/W Version V 0100 [2014.10.11]
Gauge Panel S/W Version V 0110 [2014.10.23]
Gauge Panel OS Version V 0081 [2014.03.25]
EX1501555
Figure 111

9-1-62
9-1-63
ELECTRONIC HYDRAULIC CONTROL SYSTEM (EPOS)
Control System Schematic
6 Main Relief V/V 6
7 11
12
3 8
P 14
13
4 5
N
9
17 10
P M
(Pump Control Signal)
(Potentiometer Signal)
(Drive Signal)
(Engine Speed Sensor Signal)
(Throttle Signal)
(Engine Throttle Control Signal)

15 2
20
(Throttle Command)
(Switch Signal) 1
(Coolant Cater Temp. Signal)
(Mode Select Signal)
AM
(Auto Idle Signal) H H
(Machine Information)
E F
C C
rpm
18 S USB
21 (Sensor) 19
DS1800036
Figure 112

9-1-64
Reference Reference
Number Number
1 Instrument Panel 12 Solenoid Valve (Swing Priority)
2 EPOS Controller 13 Solenoid Valve (High Speed)
3 Engine 14 Travel Motor
4 Main Pump 15 Engine Throttle Controller
5 Aux Pump 16 Engine Control Dial
6 Control Valve 17 Engine Control Motor
7 Pressure Switch Breaker/Boost/Shear Selector
18
8 Pump Pressure Sensor Switch
9 Engine Speed Sensor 19 Auto Travel Selector Switch
Electromagnetic Proportional 20 Boost Switch (Right Work Lever)
10
Pressure Reducing Valve 21 Sensor
11 Solenoid Valve (Boost)

9-1-65
POWER MODE CONTROL
6 6
P
4 5
9
17
10
3
15
16
DS1800037
Figure 113
Reference Reference
Number Number
1 Power Mode Selector Switch Electromagnetic Proportional
10
2 EPOS Controller Pressure Reducing Valve
3 Engine 15 Engine Throttle Controller
4 Main Pump 16 Engine Control Dial
5 Aux Pump 17 Engine Control Motor
6 Control Valve
9 Engine Speed Sensor

9-1-66
The power mode switch permits the selection of the appropriate
engine power depending on the working condition. One of the
two, Power Mode or Standard Mode, setting can be selected.
When the engine start switch is turned "ON," the power mode is
automatically defaulted to standard mode. The desired mode
can be selected by pressing the select button on the instrument
panel. When the power mode is selected, the indicator lamp will
turn "ON" to display the selected mode.
The quantity of oil discharged by the pump and the engine
speed are determined by the mode selected by the operator.
The pump output in each mode is determined by the mode
selection and is listed in the following table
Mode Economy Mode Standard Mode Power Mode

Output (%) Approximately 70% Approximately 85% 100%

9-1-67
Operation
1. Power Mode
This mode should be selected for high speed work. In this
mode the engine output is most efficiently utilized due to
the discharged oil volume being controlled based on the
equivalent horsepower curve at various loaded pressures.
The EPOS controller compares the target engine speed POWER
with the actual engine speed and controls the signal to the
E.P.P.R. (Electromagnetic Proportional Pressure
Reducing) valve which in turn varies the pump output
quantity.
FG015516
If the load increases, the engine speed will fall below the
rated speed. When this occurs, the controller senses this Figure 114
decrease and immediately reduces the pump discharge
volume to maintain the engine speed at the rated level.
On the other hand, if the load is decreased the controller
increases the discharge volume of the pump to maintain
the engine speed at the rated level.
By repeating these control operations, the engine speed is
maintained at the rated speed so that maximum power can
be generated.
In Power Mode, the EPOS controller receives engine
speed signals from the engine control dial and converts it
to an operating signal current and is then transferred to the
pump's E.P.P.R valve. At this time the E.P.P.R. valve
converts the electric signal to the corresponding control
pressure and sends it to the two pumps, adjusting the
pump discharge volume to the desired level.
A C
B D FG000580
Figure 115
Reference Reference
Number Number
A Engine Horsepower (hp) C Pump Discharge Volume (lpm)
B Engine Speed (rpm) D Pump Discharge Pressure (kg/cm2)

9-1-68
2. Standard Mode
Standard Mode is used for general work. When this mode
is selected it will reduce noise and fuel consumption in
comparison with Power Mode. The EPOS controller
compares the target engine speed with the actual engine
speed and controls the signal to the E.P.P.R. valve which
in turn varies the pump output quantity and it is the same
method with power volume.
A C
B D FG000581
Figure 116
Reference Reference
Number Number

9-1-69
3. Economy Mode
Economy mode is used for light load work. When this
mode is selected, it will reduce noise and fuel consumption
in comparison with standard mode. The current to the
E.P.P.R. valve is shut off and pump discharge volume is
controlled by pump regulator.
The EPOS controller compares the target engine speed
with the actual engine speed and controls the signal to the
E.P.P.R. valve which in turn varies the pump output
quantity and it is the same method with power volume.
FG013671
Figure 117
A C
B D FG021897
Figure 118
Reference Reference
Number Number
4 Operation in Case of Failure in the Control System

(Aux Mode Operation)
Though it is impossible to control current of the E.P.P.R
(Electromagnetic Proportional Pressure Reducing) Valve
controlling the discharge volume of pump due to fault in
control system, the machine can be operated in the aux
mode.
Upon turning "ON" the aux mode switch, the E.P.P.R Valve
controlling the discharge volume of pump comes into
contact with the aux mode resistor to let current of a certain
value flow. At this time, the discharge volume of pump
follow the control by the pump regulator, nearly at quantity
roughly similar to that in the standard mode.

9-1-70
Power Mode Control - Circuit Diagram
B
26 15A
2 26 10A 26 10A BR
CN1-1 E 25
CN1-2
A
CN5-15
30 CN5-16
29 CN1-8
16 CN3-18 CN1-9
ECO
15 CN1-3 STD 24
10 CN1-4
23
A/I
14 CN1-5 W/M
17 CN1-6 O/H 22
12 CN1-10 1 10
3 5
P/V-(A)
4 P4 2
(+)
CN1-21 3
M 6
(-) 5 P5 4 31
(+) 8 P3 RETRACT 2
CN5-2
7 P2 3
(-)
6 P1 16
SIG 1
CW LOW
CN3-13 GND CN3-16 2
CN3-14 CN3-17 3
HIGH
1
+(5V)
2
SIG
3
GND
9
AMP 070 16P AMP 040 12P AMP 040 20P AMP 070 18P AMP MIC 21P
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
AMP 040 28P
6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
(CN7) (CN6)
EX1501558
Figure 119
Reference Reference
Number Number
2 EPOS Controller 24 Battery
3 Engine Control Motor 25 Battery Relay
E.P.P.R. Valve (Electromagnetic 26 Fuse
10
Proportional Pressure Reducing) 29 Engine Throttle Controller
16 Engine Control Dial 30 Engine Speed Sensor
22 Aux Mode Switch 31 Power Mode Switch
23 Aux Mode Resistor

9-1-71
WORK MODE CONTROL
6 6
3 12
P
4 5
17 H H
AM
E F
C C
rpm
S USB
18
15
16
DS1800038
Figure 120
Reference Reference
Number Number
1 Instrument Panel 12 Solenoid Valve
2 EPOS Controller 15 Engine Throttle Controller
3 Engine 16 Engine Control Dial
4 Main Pump 17 Engine Control Motor
5 Aux Pump 18 Power Mode Switch
6 Control Valve

9-1-72
Work Mode Control - Circuit Diagram
15A
CN7-2
CN7-16
26
B
2 26 15A BR
CN7-3 25 E
CN7-4
CN1-1
CN6-12 A
CN4-4 CN1-2
CN6-13 CN4-5 CAN
CN4-6
24
12
(C5)
CN1-13
18
CN5-2
CN1-8
CN1-9
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
AMP 040 28P
6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
(CN7) (CN6)
EX1501560
Figure 121
Reference Reference
Number Number
1 Instrument Panel 24 Battery
2 EPOS Controller 25 Battery Relay
12 Solenoid Valve (Swing Priority) 26 Fuse
18 Power Mode Switch

9-1-73
ENGINE CONTROL SYSTEM
(Feedback Signal)
16
P 2
3
15 M
(Command Signal) (Drive Signal)
10A
BATT. RELAY
9
10 AUTO IDLE COMMAND
5 4
17 OVER HEAT e-EPOS Controller

M
5 5 BATTERY
RETRACT 3 8 (+) 5V 1 1
5V (+) CW LOW
2 7 SIG 2 2
SIG
1 6 3 3
(-) (-) HIGH
12
17
15 DS1800040
Figure 122
Reference Reference
Number Number
2 Engine Control Motor 15 Engine Throttle Controller
3 Engine 16 Engine Control Dial
When the engine control dial is moved, the output voltage

changes according to the dial position, and this signal enters the
engine throttle controller. The engine throttle controller drives
the motor according to the dial command position by comparing
the value of dial voltage and the value of potentiometer voltage
which is used to observe the motor position (Feedback signal)
contained within the engine control motor.
The throttle controller stops the motor by cutting off the motor
drive current when dial command signal and feedback signal are
the same.
A cable is attached to the engine control motor and the end of
this cable is connected with the lever which adjusts fuel injection
of engine. Thus, this lever is always driven with motor, so the
speed of the engine is controlled.

9-1-74
Engine Control Dial
10 x 12 Step = 120 ±1
1th Step 7th Step 13th Step
CCW (10 ) (10 ) CW

Mechanical Mechanical
Stop Stop
2 - Ø4.5
54 ±2
78.5
Knob
(V)
5
4.0V
Output Voltage
3 2.5V
2
1.0V
1
0 Step
1st 2nd 7th 12th 13th
CCW CW
Stop Stop
WE1400771
Figure 123
Output Specification
Knob Location Output

2nd Step 80 ±5%
7th Step 50 ±10%
12th Step 20 ±5%
When the control knob is moved the output voltage (through "2
and 3" terminals) will vary from the 5 V supplied from the EPOS
controller as shown in the graph.

9-1-75
Engine Control Motor
1 2 3
Circuit Diagram
P4
(GREEN)
P1(Gr) P2(P) P3(L) M

P5
(YELLOW)
(RETRACT) (GRAY) P1
ACCEL
(PINK) P2
P4(G) P5(Y) +
-
Vs
(5.0V)
(BLUE) P3 Vp
DECEL
(EXTEND)
FG014302
Figure 124
The engine control motor uses the DC motor and has a

potentiometer (a variable resistor) that is used to observe the
position within it. When the engine control motor has unusual
loads (in case of aging of control cable or folded cable), the
engine throttle controller shuts off current to the engine control
motor for protecting the system in the event the engine control
motor does not drive. In this situation, it can drive normally if the
start switch is moved from OFF position to ON position after
removing the cause of unusual loads.
NOTE: Change or Adjust the engine control motor in
accordance with adjustment way of engine control
device. Wrong adjustment causes unexpected
performance of the equipment.

9-1-76
Engine Control Circuit Diagram
1
15A
CN7-2
CN7-16
26
25 B
CN7-3
2 26 15A 26 10A BR
CN7-4 E
CN1-1
CN6-12 CN4-4 CN1-2 A
CN6-13 CN4-5 CAN
CN4-6
15 CN1-8
16 CN3-18 ECO CN1-9
15 CN1-3 STD
24
10 CN1-4 A/I
14 CN1-5 W/M
17 CN1-6 O/H
12
17 31
4 P4 Py
(+)
CN2-15
M
(-) 5 P5 Px
CN2-16
(+) 8 P3 RETRACT
P2 32
7 16
1
(-)
6 P1 CW LOW
SIG CN3-16 2
CN3-13 GND CN3-17 3
CN3-14 HIGH
1
+(5V)
2
SIG
3
GND
9
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
AMP 040 28P
6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
(CN7) (CN6) EX1501561

Figure 125
Reference Reference
Number Number
1 Instrument Panel 24 Battery
2 EPOS Controller 25 Battery Relay
15 Engine Throttle Controller 26 Fuse
16 Engine Control Dial 31 Pressure Switch (Py)
17 Engine Control Motor 32 Pressure Switch (Px)

9-1-77
AUTOMATIC DECELERATION CONTROL 
(AUTO IDLE CONTROL)
16 15
3
31
1
2
32
DS1800039
Figure 126
Reference Reference
Number Number
Instrument Panel 15 Engine Throttle Controller
1
(Auto Idle Selector Button) 16 Engine Control Dial
2 EPOS Controller 31 Pressure Switch
3 Engine 32 Pressure Switch
If the machine is idling without the controls being operated or is

waiting for a dump truck the engine speed is automatically
lowered. Once the controls are operated and work is being
started the machine will be restored to the previous settings. As
a result, noise and fuel consumption will be reduced. This
function can be selected or cancelled through the Auto Idle
Selector Switch on the instrument panel.
The initial setting at start-up is with this switch in the select
position. Approximately 4 seconds after this function is selected,
if all work levers are in the neutral position, the EPOS controller
compares the automatic reduction signal with the signal set by
engine control dial. The lower of the two signals is selected, the
EPOS controller sends a signal to the engine controller to
control the engine speed.
The neutral status of the machine is detected by the two
pressure switches in the control valve. When the work levers are
in the neutral position, the switch is in the "OFF" position.

9-1-78
ENGINE OVERHEAT PROTECTION SYSTEM
Engine
6 6
4 4
1
AM
H H
S
C
E F
rpm
C
USB
33
10
15
2
DS1800042
Figure 127
Reference Reference
Number Number
1 Instrument Panel E.P.P.R. Valve
2 EPOS Controller 10 (Electromagnetic Proportional
Pressure Reducing Valve)
3 Main Pump
15 Engine Throttle Controller
4 Aux Pump
33 Warning Buzzer
6 Control Valve
When the engine coolant temperature increases to over 107°C

(225°F), the gauge panel detects it from the sensor mounted in
the coolant line of engine and send a signal to the EPOS
controller and turns on the buzzer simultaneously.
The EPOS controller returns an overheat signal to the engine
throttle controller and changes from power mode to standard
mode. The engine speed is then set to a low speed by the engine
throttle controller. That is, when the engine coolant temperature
increases, a warning buzzer turns on, power mode is changed to
standard mode and engine speed set to a low speed.
When coolant temperature falls below 95°C (203°F), normal
operation will resume.

9-1-79
POWER BOOST MODE
Operation
6 6
Main Relief v/v
11
4 4
5
2
20
(Button Signal)
1
AM
H H
E F
C C
rpm
S USB
18
DS1800043
Figure 128
Reference Reference
Number Number
1 Instrument Panel 11 Solenoid Valve (Boost)
2 EPOS Controller Breaker/Boost/Shear Selector
18
4 Main Pump Switch
5 Aux Pump Break/Booster Button
20
(Top of Right Work Lever)
6 Control Valve
The Power Boost function is used to temporarily increase the

main relief pressure to enhance excavation ability. When the
breaker/boost/shear selector switch is set to "BOOST" and the
power boost button on the center of the right-hand work lever
(joystick) is pressed during work, the EPOS controller will
activate the power boost solenoid valve and increase the relief
valve pressure from 330 ~ 350 kg/cm2 (4,700 ~ 5,000 psi). The
excavation ability is increased by approximately 6%.
When the power boost function is in activated, a power boost symbol
appears on the information display department of instrument panel.
NOTE: Do not use this switch for more than 10 seconds.

9-1-80
Power Boost Control - Circuit Diagram
1
10A
CN7-6
CN7-5
26 25
B
CN7-3
2 26 15A 26 20A BR
CN7-4 E
CN1-1
CN6-12 CN4-4 CN1-2 PST SHEAR PRESS BREAKER
CN6-13 CN4-5 UP A
CAN
CN4-6 TML 1 0 2
9
10
11 3
24
(C2) 14 18
CN1-11 13
11
6
CN2-2 (Power Max.) 16
15
CN1-8 12
CN1-9
6 3
(Power Max. / Breaker) (Center)
20
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
AMP 040 28P
6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
(CN7) (CN6)
EX1501562
Figure 129
Reference Reference
Number Number
1 Instrument Panel Power Boost Switch
20
2 EPOS Controller (Top of Right Work Lever)
11 Solenoid Valve (Pressure Up) 24 Battery
Breaker/Boost/Shear Selector 25 Battery Relay
18
Switch 26 Fuse

9-1-81
BREAKER MODE
Operation
20 10
6 6
(Electric Signal)
11
Engine
4 4
5
2
18
DS1800044
Figure 130
Reference Reference
Number Number
2 EPOS Controller 11 Solenoid Valve (Breaker)
4 Main Pump Breaker/Boost/Shear Selector
18
5 Gear Pump (Pilot) Switch
6 Control Valve Break/Booster Button
20
(Top of Right Work Lever)
10 Pedal Switch (Breaker)

9-1-82
Electric Breaker Pedal
• How to use the electric breaker pedal
To operate the breaker, select the breaker mode and then
press the electric breaker pedal.
NOTE: Note: The use of the electrical breaker pedal is
an option. You can use the joystick’s breaker
button alternatively since both commanding
devices are parallel-wired to the breaker.
• How the electric breaker pedal works
Once the working mode switch is shifted to the breaker
mode, the EPOS is accordingly signaled at pin CN2-8 so
that it enters the breaker mode.
When pressed in this mode, the electric breaker pedal lets
the 24V power from the fuse be sent through the working
mode switch to the breaker solenoid valve.
At the same time, the EPOS receives a signal demanding
the operation of the breaker at pin CN2-10 and in turn
stops its 24V power supply from pin CN2-10 to the breaker
solenoid valve.
As a result, the breaker solenoid valve is powered to opens
due to this 24V potential difference.

9-1-83
Breaker Control - Circuit Diagram
25
B
2 26 15A 26 20A BR
E
CN1-1
CN1-2 PST SHEAR PRESS BREAKER
UP A
TML 1 0 2
9
10
11 3
24
(C2) 14 18
CN1-17 13
3
CN2-10 11
6
CN2-2 (Power Max.)
16
15
CN1-8 12
CN1-9 10
6 3
(Power Max. / Breaker) (Center)
20
AMP 070 18P AMP MIC 21P

8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
(CN2) (CN1)
DS1603313
Figure 131
Reference Reference
Number Number
2 EPOS Controller Breaker Switch
20
3 Diode (Top of Right Work Lever)
10 Pedal Switch (Breaker) 24 Battery
11 Solenoid Valve (Breaker) 25 Battery Relay
Breaker/Boost/Shear Selector 26 Fuse
18
Switch

9-1-84
AUTOMATIC TRAVEL SPEED CONTROL
6 6
7
3
8 8
14
13
5
4 4
16
19
FG002110
Figure 132
Reference Reference
Number Number
2 EPOS Controller 8 Pump Pressure Sensor
3 Engine 13 Solenoid Valve (High speed)
4 Main Pump 14 Travel Motor
5 Aux Pump 16 Engine Control Dial
6 Control Valve Selector Switch for Automatic
19
7 Pressure Switch (Py Port) Travel
If the automatic travel speed control switch is set to the "OFF"

position, the travel motor will run in the I-speed (low speed)
range. If the selector switch is set to the "I" position, the travel
motor will run in the II-speed (high speed) range. If the selector
switch is set to the "II" position, the EPOS controller will monitor
the main pump discharge pressure and automatically select the
"ON" - "OFF" status of the II - speed travel solenoid valve based
on the travel load. The travel speed is changed between the
I-speed and the II-speed mode.
The travel load is monitored by the two pressure sensors in the
discharge lines of the front (upper) and rear (lower) pumps.
When the travel load is high (pressure over 300 kg/cm2 (4,300
psi) the solenoid valve is turned "OFF" and I-speed (low) is
selected. In the case when the travel load is low (pressure under
160 kg/cm2 (2,280 psi), the solenoid valve will be turned "ON"
and the II-speed will be selected. But, if the engine speed control
switch dial is set below approximately 1,400 rpm, the travel
speed will be set to I-speed mode.

9-1-85
Automatic Travel Speed Control - Circuit Diagram
15A
26
25 B
2 26 15A
26 10A
BR
CN1-8 E
CN1-9 CN1-1
+ CN1-2
A
8 SIG
CN3-1
CN3-2
- 13
(C3)
+ CN1-12
CN3-3
9 SIG
-
CN3-4 24
15
16 CN3-18 19
0
15 CN1-3 3 2
CN2-4 I
10 CN1-4 II
14 CN1-5 0
I 5
17 CN1-6
CN2-5 6 II
12
7 8
4 P4
(+)
M
(-) 5 P5
(+) 8 P3 RETRACT
7 P2 16
1
(-)
6 P1 CW LOW
CN3-16 2
SIG
CN3-13 CN3-17
GND 3
CN3-14 HIGH
1
+(5V)
2
SIG
3
GND
9
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
AMP 040 28P
6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
(CN7) (CN6)
EX1501563
Figure 133
Reference Reference
Number Number
2 EPOS Controller Selector Switch for Automatic
19
8 Pressure Sensor (Front Pump) Travel
9 Pressure Sensor (Rear Pump) 24 Battery
13 Solenoid Valve (High speed) 25 Battery Relay
15 Engine Throttle Controller 26 Fuse
16 Engine Control Dial

9-1-86
SELF-DIAGNOSTIC FUNCTION
EPOS Controller
The system operation status and malfunction codes can be
checked through the display on top of the EPOS controller box
the rear cover behind the operator's seat.
1 2
4 3
FG000588
Figure 134
Reference Reference
Number Number
1 Upper Digit Power Monitor (Stays "ON" While
4
2 Lower Digit 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.
3. Normal Operation Display Readout
Display Readout Operation

Mode Selection
Upper Digit Lower Digit Status
Normal Operation
Power Mode
Power Mode
HAOH340L HAOH370L
Normal Operation
Power Mode Standard Mode
Standard Mode
HAOH350L HAOH370L
Normal Operation
Economy Mode
Economy Mode
FG013637 HAOH370L

9-1-87
4. Communication Monitor
What are shown in the 7-SEGMENT LED are same as
those in the Error Codes.
Error Code Indication Code Fault Location

V201 01 Communication error in instrument panel.
V202 02 Communication error in engine controller.

9-1-88
AIR CONDITIONER SYSTEM
Outline
EX1301100
Figure 135
Solid-type heater and air conditioner are installed in the cover

behind the operator's seat.
Temperature of the operator's room is adjusted automatically to
the temperature set by operator. (Please refer to the Operation
Manual for detailed full automatic control.)
Vent mode selects the direction of discharged air.
Outlets by vent modes
Modes
Outlets A A+B B B+C C

9-1-89
Internal and External Filters
Internal and external air purification filters are installed for the
operator's room.
Filters should be cleaned every 500 hours.
If machine operates in an excessively contaminated
environment, filters should be cleaned more frequently and if
necessary, replaced with new ones.
How to Check Internal Air Filter

1. Press both levers on the left and right side at the top of the
filter installed at the rear of the operator's seat.
FG000422
Figure 136
How to Check External Air Filter

1. Open the door at the left side of machine and loosen four
marked bolts to remove the cover (1, Figure 137).
1
TOP
Donaldson.
FG000440
Figure 137
2. Turn marked knobs (1, Figure 138) at the rear side of the
cabin to open the cover.
FG000441
Figure 138

9-1-90
3. Remove the 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.
FG000342
Figure 139

9-1-91
Air-Conditioning System Layout
8
9
1
6
5 7
6
DS1800046
Figure 140
Reference Reference
Number Number
1 Air Conditioner/Heater Unit 6 Liquid Hose
2 Condenser 7 Ambient Temperature Sensor
3 Compressor 8 Sun Sensor
4 Discharge Hose 9 Control Panel
5 Suction Hose

9-1-92
Air Conditioner/Heater Circuit Diagram
10A
LAMP SWITCH 15A

CIRCUIT BREAKER BATTERY RELAY
20A B A
BR
2
E
MASTER SWITCH
AIRCON UNIT
1
A/C CONTROL PANEL
1.25LR CN11-2 42C
LED 1~12 130C CN9-6
0.85LR CN10-8 42D
54E CN9-11 0.5WR BATTERY
CN10-18 46B
ILL 42B CN9-5 1.25LR
0.85BW
0.85LR
DPS SENSOR
BLOWER A/C
42E 46A
RELAY RELAY
COMPRESSOR
168B CN8-10 0.5LG CN10-16 168A
A/C THERMO (LOW) 105B CN9-8 0.5LB CN10-5 105A CN11-4 0.85LW 47C
106B CN8-11 CN10-6 106A 47A 47B

0.5LY
FET
DIODE 4
1.25B CN11-1 99 - +
M
107B CN8-12 0.5LW CN10-1 107A 0.85B 0.85B
BLOWER
108A CN9-13 0.5GrG CN10-2 108B FRE (P1)

INTAKE
109A CN9-12 0.5GrY CN10-20 109B REC (P2) ACTUATOR
M
110A CN9-15 0.5OrR CN10-12 110B DEF (P1)

111A CN9-14 0.5OrW CN10-13 111B VENT (P2)
M
MODE
43A CN9-16 0.5YB CN10-11 43B Vref MODE
ACTUATOR
44A CN9-17 0.5YW CN10-10 44B MODE F/BACK
99 CN9-10 1.25B
112A CN9-1 0.5LgW CN10-19 112B WARM (P1)

113A CN9-18 0.5LgB CN10-3 113B COOL (P2)
M
114A CN9-3 0.5YR CN10-7 114B Vref MIX Temp. Control
115A CN9-4 0.5YW CN10-9 115B MIX F/BACK ACTUATOR
167C CN9-2 1.25BL CN10-4 167A GND
116A CN8-2 0.5OrB CN10-15 116B

DUCT
SENSOR
2
48A CN8-5 0.5LY CN10-17 48B 1 INCAR
SENSOR
SUN LOAD SENSOR
0.5Lg 2 - + 1 CN10 AMP 20P CN11 KET 4P

142A CN8-3
142B 0.5YR
114C 0.85BL 167B 2
49A CN8-4 0.85YG 0.85YG 49B 1 AMBIENT TEMP
SENSOR
CN8 CN9
AMP 18P + 12P
AMP 040-III 20P
KET 4P AMP 070 18P AMP 070 12P
2 1 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 10
4 3 18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
(CN11) (CN10) (CN9) (CN8)

DS1800182
Figure 141

9-1-93
Air Conditioner/Heater Unit
Air Flow Diagram
External Air Inlet
Vent Rear Cold Box Internal Air Inlet

Outlet Outlet
Vent
Front
Outlet
Foot
DEF Outlet
Outlet
External Air
Internal Air
Evaporator Fan
Heater
Core
FG001359
Figure 142

9-1-94
Door Open by Vent Modes
Mode
Door
Vent Bi-level Foot Def/foot Def
Vent 100 60 0 0 0
Foot 0 40 100 80 60
Def 0 0 0 20 40
Main Components
Actuator
- Temp A/C
Control Relay Blower
Relay
Duct
Sensor
Air Flow
Control
Module
Actuator
Blower
-Wind Direction
Motor
Control
Actuator
Evaporator - Internal/External
Air Exchanger
Internal
Internal Air Sensor
Air Filter DS1800183
Figure 143

9-1-95
Actuator - Wind Direction Control
Change of discharged air flow according to selected wind
direction mode
Change of wind direction: Direction changes in the order of
VENT BI-LEVEL  FOOT  FOOT/DEF  VENT.
Actuator - Temperature Control

Change of discharged air temperature by controlling the position
of temperature control door.
N P2
c
b
e
P2 P1
b c e
FG001361
Figure 144
Actuator - Wind Direction Control
Wind Direction Mode Output Terminal Voltage

Vent 0.5 ±0.2 V
Bi-level 1.3 ±0.2 V
c(+): CN10-10
Foot 2.45 ±0.2 V
b(-): CN10-4
Foot/def 3.5 ±0.2 V
Def 4.5 ±0.2 V
Actuator - Temperature Control
Set Temperature Output Terminal Voltage

Max cooling c(+): CN10-9 Below 0.4 V
Max heating b(-): CN10-4 Above 4.5 V

9-1-96
Actuator - Internal/External Air Exchange
N P2
P1
CN10-20 CN10-2
P2 P1
c e
FG001055
Figure 145
Mode Output Terminal Output

Moving of exchange door
Intake P1(+), P2(-)
by selecting intake.
Moving of exchange door
Recirculate P1(-), P2(+)
by selecting recirculate.
Air Flow Control Module

Air flow is controlled through the control of voltage between
GATE and SOURCE.
DRAIN
(CN10-1)
SOURCE GATE
(CN11-1) (CN10-6)
FG001056
Figure 146
Air flow Output Terminal Output

1st 10 ±0.5 V
2nd 12.5 ±0.5 V
3rd 15 ±0.5 V
4th CN11-2 CN10-1 17.5 ±0.5 V
5th 20.0 ±0.5 V
6th 22.0 ±0.5 V
7th More than 25 V
Input voltage is 27.5 V.

The air flow is based on manual set.

9-1-97
Relay - Blower: Power is supplied to the blower motor when the
system is turned "ON."
87 85(-)
Specifications
87
Rated voltage 24 V
86 85
Rated current 20 A
30
30 86(+)
FG001057
Figure 147
Relay - A/C: Power is supplied to the magnetic clutch of the

compressor.
Specifications
Rated voltage 24 V L S1 (+)
Rated current 10 A
B S2
(-)
FG001058
Figure 148
Duct Sensor: It is inserted in the core of the evaporator to

prevent freezing of the evaporator.
The sensor consist of negative characteristic thermistor that
resistant value increases and decreases when the temperature
rises and falls, respectively.
Temperature (°C) Resistance (k)

0 11.36 ±0.1
2 10.39 ±0.2
2.5 10.17 ±0.2
3 9.95 ±0.2 Figure 149
3.5 9.73 ±0.2
4 9.52 ±0.2
5 9.12 ±0.2
10 7.36 ±0.15
25 4.02 ±0.08
30 3.33 ±0.07

9-1-98
Internal Air Temperature Sensor: Built in the internal air filter,
it senses the internal temperature.

-15 218.2 ±7.5
0 97.83 ±0.9
15 47.12 ±0.7
25 30.0 ±0.36
35 19.60 ±0.3
Figure 150
Ambient Air Temperature Sensor

Built at the bottom of the cockpit, it senses the temperature of
external air.

-10 163 ±4.9
0 96.9 ±2.9
10 59.4 ±1.8
20 37.4 ±1.1
FG001064
25 30 ±0.9
Figure 151
30 24.2 ±0.7

9-1-99
Sun Sensor
Built beside the socket of spare power, it senses the quantity of
the sun radiation to optimize discharge temperature and air flow
as set by operator.
83.7
OUTPUT VOLTAGE(mV)
76.2
67.7
58.8
46.6
36.0
21.4
1.0 2.0 3.0 4.0 5.0 6.0 7.0

LUX(x10,000)
FG001062
Figure 152
Control Panel
Appearance and Terminal Arrangement
A/C OUTSIDE
AUTO A/C
AUTO MAX
TEMP
OFF
SEL MODE
AMP 070 18P AMP 070 12P

8 7 6 5 4 3 2 1 5 4 3 2 1
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
(CN9) (CN8) FG001063

Figure 153
Refer to "Air Conditioner and Heater" of operation manual.

9-1-100
Terminal Terms
CN Term No. Terms CN Term No. Terms

Temperature Control
1 1 Duct Sensor
(Warm)
2 Sensor Ground 2 Sun Sensor
Temperature Control Ambient Air
3 3
Power (5V) Temperature Sensor
Internal Air Temperature
4 Mix Feedback 4
Sensor
5 Power (KEY "ON") CN8 5 -
6 Backup 6 -
7 - 7 -
8 A/C Output (LOW) 8 -
9 - 9 D.P.S Check
10 Ground 10 Air Flow Module (Gate)
Blower Motor
CN9 11 Illumination 11
(Feedback)
Intake/Recirculate
12
(Recirculate)
Intake/Recirculate
13
(Intake)
Wind Direction Control
14
(VENT)
15
(DEF.)
16
Power (5V)
17
(Feedback)
Temperature Control
18
(Cool)
Control Logic
Categories Inputs System Operation

AUTO Set temperature 1. Automatically adjust room temperature as set and then
next items.
Internal air temperature
sensor Temperature, Wind direction, Recirculate/Intake, Air flow,
Compressor
Ambient air temperature
sensor 2. Auto mode is released when manually setting any switch
except, Temperature Control switch in Auto mode.
Sun sensor
3. Upon the releasing of Auto mode, all of functions except
selected switch are controlled automatically.

9-1-101
Sensor Set temperature 1. In case of sensor failure, following defaults are applied:
compensation
Internal air temperature Internal air temperature sensor: 25°C, Ambient air
sensor temperature sensor: 25°C, Duct sensor: -2°C
Ambient air temperature Temperature control actuator:
sensor
- Set Temperature 17 ~ 24.5°C: Max cooling, Set
Temperature 25 ~ 32°C: Max heating
Wind direction mode actuator
- VENT: VENT fix, modes other than VENT: Fixed to DEF
* Sun sensor is not compensated.
Max cooling/ Auto Setting 1. Set Temperature 32°C: Max heating
heating control
2. Set Temperature 17°C: Max cooling
Max Cooling (17 C) Max Heating (32 C)
Temp Control
FULL COOL FULL HOT
Actuator
Air Flow MAX HI AUTO HI
Compressor Forced ON OFF
Intake/Recircle Recircle Intake
Wind Direction Mode VENT FOOT
* Max cooling/heating control is possible only in Auto mode.

Starting Auto mode 1. Prevention of discharge of hot air before discharge
Control of temperature drops enough in hot summer weather
Duct sensor
Cooling
2. Start conditions (AND condition)
(1) A/C on (AUTO or manual)
(2) Temperature sensed by the duct sensor is above 30°C
(3) Air flow: Auto mode
3. One time control in the cycle of engine OFF  engine run
4. Initial cooling control is executed when the Auto switch is
"ON" in the manual status (A/C "OFF" and manual control
of air flow) in 5 seconds after engine run.
5. Initial cooling control should be before max cooling.
6. Release condition (OR condition)
(1) A/C "OFF"
(2) Air flow: Manual control
(3) Release is possible with the "OFF" switch but not
allowed within 12 seconds (after Start "ON") while the
system is off using the "OFF" switch and during the time of
initial cooling control.

9-1-102
1. Start condition (and condition)
(1) When wind direction mode is one of the following
modes in the Auto or manual control mode
- BI-LEVEL, FOOT or FOOT/DEF
(2) Air flow: Auto mode
(3) Set temperature > Internal air temperature + 3°C
* Air flow falls gradually up to 12 seconds when operation
Internal air temperature released.
Starting sensor 2. One time control in the cycle of engine OFF  engine run
control of 3. Initial heating control should be before max heating.
Auto mode
heating (1)
Set Temperature 4. Air flow is controlled only when the wind direction is in the
manual mode and BI-LEVEL, FOOT, or FOOT/DEF is set.
5. Operation release (or condition)
(1) Only air flow is released if it is selected manually.
(2) When handling the wind direction mode switch, only
wind direction is released but the air flow control is
performed only for the remaining period of the starting
control of heater.
(3) When Max Cooling (17°C) is selected.
Starting Ambient air temperature 1. Entry condition (and condition)
control of sensor
(1) Auto Mode
heating (2)
Internal air temperature
(2) Ambient air temperature < 5°C and difference between
sensor ambient and internal air temperature  5°C
Auto mode 2. Only one time of engine OFF  engine run
3. Starting control of heating is before max heating.
4. Operation release (or condition)
(1) Air flow: Manual selection
(2) When handling the wind direction mode switch, only
wind direction is released but the air flow control is
performed only for the remaining period of the starting
control of heater.
(3) Difference between internal and ambient air
temperature >15°C
(4) When Max Cooling (17°C) is selected.
5. Exceptional case
Starting control of heating is performed only once during
the remaining period if the entry condition is satisfied
within the starting control period that is the accumulation
of initial start times.
(Inclusive of Auto mode "ON" case within the period of
starting control of heater.)
* Air flow should be reduced slowly for up to 12 seconds in
case of exceptional entry case.

9-1-103
Duct sensor 1. Function: Magnetic clutch of compressor is turned "ON/
OFF" depending on temperature of the duct sensor to
prevent the freezing of the evaporator with A/C being
"ON."
2. Control pattern.
2.0 0.5 C 3.5 0.5 C

Compressor
control
External temperature 1. Function: Prevention of compressor in winter.
sensor
2. Control pattern.
*Only for Auto mode.

9-1-104
Self Diagnosis
How to start self diagnosis
Starter Switch ON
Set temp to 25 C Set temp to 77 F
Press the SEL switch more than 3 times in

5 secs while pressing the auto switch
Auto diagnosis starts after every graphic

in LCD displays twice every 0.5 sec.
A code concerned blinks in the cycle of 0.5-sec ON

and 0.5-sec OFF. In case of two or more errors, codes
concerned blink twice at a time.
For normal, E0 lights; for error, the first

error code is indicated.
For 2 or more error, error codes are indicated

upstreams/downstreams if the temp control switch is
set to up/down. (For normal condition, only EO lights.)
Press the SEL switch more than 3 times in

5 secs while pressing the auto switch Return to default status if no switch
operated for 30 secs in diagnosis mode.
Return to position before auto diagnosis

starts.
DS1704264
Figure 154

9-1-105
Error codes
Code Description
E0 Normal
E1 Internal Air Temperature Sensor Short
E2 Internal Air Temperature Sensor Open
E3 Ambient Air Temperature Sensor Short
E4 Ambient Air Temperature Sensor Open
E5 Duct Sensor Short
E6 Duct Sensor Open
E7 Sun Sensor Short
E8 Sun Sensor Open
E11 D.P.S Open
E12 Position Error of Wind Direction Actuator
E13 Position Error of Temperature Control Actuator
NOTE: The position error means that it fails to move to

designated place in 40 seconds.
Sun sensor displays E8 in case of no sunlight. E1 E1 E2 E2 E3
2 and more fails: Codes concerned blinks twice at a

time.
0.5 0.5
FG001067
Figure 155
Ambient Temperature Display

Selection of both the SEL and MODE switch for more than 3
seconds indicates the ambient temperature in the set
temperature display department.
• Range of temperature display: -40 ~ 60°C
NOTE: Display of ambient temperature may be released in
the same way for its entry way.
It returns automatically to default mode 5 seconds
after entering the ambient air temperature display
mode.

9-1-106
Compressor
Categories Specifications Relief Valve
Output 155.3 cc/rev
Oil Level 120 cc (ND-OIL8)
Refrigerant R134a
Rated Voltage 24V
Open: 35 ~ 42.2 kg/cm2G
Relief Valve
Close: 28.1 kg/cm2G
Compressor sucks in refrigerant which evaporates completely in

FG001365
the evaporator and discharges it to the condenser.
Figure 156
Refrigerant undergoes repeated status change in the order of
liquid, gas, and liquid in the freezing cycle, and the compressor
makes evaporated refrigerant a high temperature and
high-pressured gas to freeze it in the condenser.
Receiver Dryer
The receiver dryer reserves refrigerant enough to ensure
smooth freezing cycle responding immediately to the change of
level in the freezing cycle.
As liquid refrigerant from the condenser may contain refrigerant
Receiver
gas with bubbles whose presence in the expansion valve Dryer
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
Dual Pressure Switch

DS1800048
Figure 157
MAX. 0.25 kg/cm2

32 2 kg/cm2
2.0 0.2 kg/cm2 6 2 kg/cm2
FG001462
Figure 158

9-1-107
TROUBLESHOOTING
Refrigerant Pressure Check
1. Open all doors and windows.
2. Install manifold gauge set to the low pressure and high
pressure side of the compressor.
3. Connect the center filler hose to the refrigerant canister.
4. Open (1/2 turn) and close each pressure valve to release LO HI
the air from the hoses and gauge set.

5. Start the engine and idle at approx. 1,500 rpm for about 10
minutes to stabilize the system. HDA6074L
Figure 159
6. Turn on the air conditioning switch and select the
temperature selection switch to maximum cooling at
maximum fan speed.
7. Open all system vents for maximum air distribution.
8. After 5 minutes, check high/low pressure of refrigerant.
See the table below.
9. After checking, stop the engine, and then remove the
gauge set.
High-pressure: 8 ~ 10 bar (8 ~ 10 kg/cm2, 114 ~ 142 psi)

1
Low-pressure: Approximately 1 bar (1 kg/cm2, 14 psi)
Possible Cause: Low Refrigerant Level
Step Inspection Item Remedy
Reassemble using correct tightening
Yes
1 Check for traces of refrigerant oil. torque.
No Go to next step.
Using a leak detection device or soapy water Yes Repair leaking component.
2 check for refrigerant leakage at all major Recharge system to correct
components and joints. No
pressure.
High-pressure: Over 23 bar (23 kg/cm2, 327 psi)

2
Low-pressure: Approximately 2.5 ~ 3 bar (2.5 ~ 3 kg/cm2, 36 ~ 43 psi)
Possible Cause: Overcharge, Frost on condenser
Check for condenser pin damage or Yes Clean, repair or replace condenser.
1
contamination. No Refrigerant overcharge.

9-1-108

High-pressure: Approximately 20 ~ 25 bar (20 ~ 25 kg/cm2, 285 ~ 356 psi)
3
Low-pressure: Approximately 2.5 ~ 3.4 bar (2.5 ~ 3.5 kg/cm2, 36 ~ 50 psi)
Possible Cause: Air in system.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long time, replace the receiver dryer.
High-pressure: Over 6 bar (6 kg/cm2, 85 psi)

4
Low-pressure: Approximately 760 mmHg (Negative Pressure)
Possible Cause: Refrigerant does not circulate
1. Connect manifold gauge and start engine.
2. Turn on air conditioner. Moisture in system, replace receiver
Yes
dryer.
3. Set blower switch to HIGH position.
4. Turn air conditioner OFF and wait 10
1
minutes.
Contaminated system, replace
5. Recheck high/low-pressure readings.
No expansion valve.
High-pressure: 13.0 ~ 19.0 kg/cm2 (185 ~ 270 psi) (Replace evaporator core assembly.)
Low-pressure: 1.5 ~ 3.3 kg/cm (21.3 ~ 46.9 psi)
2
High-pressure: Over 6 ~ 18 bar (6 ~ 18 kg/cm2, 85 ~ 256 psi)

5
Low-pressure: 500 mmHg (Negative Pressure) - Dial indicator needle unstable.
Possible Cause: Moisture in system has iced up the expansion valve.
NOTE: When the absorbed moisture freezes the pressure readings may look normal. Careful readings
must be made to determine whether pressure is in normal range.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long time, replace the receiver dryer.

6
Low-pressure: 2.5 bar (2.5 kg/cm2, 36 psi)
Possible Cause: Refrigerant pressure problem because of defective expansion valve or temperature sensor.
Inspect whether the temperature sensor is Yes Replace expansion valve.
1
installed properly. No Exchange duct sensor.

7
Low-pressure: 4 ~ 6 bar (4 ~ 6 kg/cm2, 57 ~ 85 psi)
Possible Cause: Low refrigerant pressure because of poor compressor compression.
Inspect and replace compressor if necessary.

9-1-109
REFRIGERANT SYSTEM REPAIRS
WARNING
Always wear protective glasses 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
should be stored below 40°C (104°F). Be careful not to drop
the container from a high location.
The contents are under high-pressure and should not be
used with compressed air or near an open flame.
Refrigerant Safe Handling Procedures
UNION NUT
TORQUE WRENCH
CORRECT WRONG
WRONG
WRONG
CORRECT
O - RING POSITION
CAP & PLUG CORRECT WRONG WRONG
HDA6066L
Figure 160
The following procedures should be observed for safe handling

of refrigerant during vacuum and charging process.
1. Use an approved recovery / charging device which can
safely perform vacuum and charge work simultaneously.
2. The new refrigerant has improved cooling characteristics
than the old type and care should be used not to
overcharge the system.

9-1-110
3. Do not over tighten connections when working on
refrigerant system.
4. The new refrigerant system standards require new tools,
equipment and parts. DO NOT attempt to use equipment
use in servicing the old refrigerant system.
5. The new refrigerant oil (PAG type) has a high moisture
absorption characteristic. When the refrigerant system
vacuum seal has been broken, immediately plug up all
openings to prevent moisture from entering into the
system.
6. When joining unions which use O-ring seals, lightly coat O-
rings with refrigerant oil. Be careful not to drip oil on the
threads of the nut.
7. Be certain the O-rings are seated properly on the
refrigerant line lip. Always use new O-rings when
reassembling parts. Do not reuse old O-rings.
8. Use a vacuum pump to evacuate refrigerant system of air.
9. When charging the refrigerant system with the engine
running, do not open the high-pressure valve on the
manifold gauge as the reverse flow of high-pressure
refrigerant will rupture the hose.
10. When releasing the high-pressure hose after completing
the charging process, quickly disconnect the hose to
minimize refrigerant released to the air.
Repair and Replacement Procedure

1. Work Procedure
A. Before repairing or replacing any refrigerant
components first, return all refrigerant oil to the
compressor and perform recovery procedures.
2. Operating Condition
A. Run engine at maximum engine speed.
B. Select 'HI' blower fan speed and select A/C switch to
'ON'.
C. Set the temperature control switch for maximum
cooling and leave running for approximately 20
minutes.
NOTE: The manifold gauge dial pointer can vary
depending on the outdoor temperatures.

9-1-111
INSTALL REPAIR TOOL
RECOVER REFRIGERANT
REPAIR / REPLACE DEFECTIVE PARTS
VACUUM SYSTEM (OVER 5 MINUTES)
CHECK SYSTEM FOR AIR LEAKAGE REPAIR
VACUUM SYSTEM (OVER 20 MINUTES)
CHARGE SYSTEM (APPROXIMATELY 100 g)
CHECK SYSTEM FOR REFRIGERANT LEAKAGE
CHARGE SYSTEM TO PROPER LEVEL

(Standard Capacity less Initial Charge)
CHECK SYSTEM FOR REFRIGERANT LEAKAGE
CHECK FOR PROPER REFRIGERANT LEVEL
RUN SYSTEM
RECOVER REFRIGERANT IN CHARGING HOSE
REMOVE REPAIR TOOLS

HDA6067L
Figure 161

9-1-112
Refrigerant Recovery
Reference
Description 2 3
Number
1 4
1 To Compressor
2 Low-pressure Side
3 High-pressure Side
4 From Receiver
5 Refrigerant Recovery Tank
1. Attach the manifold gauges and the refrigerant recovery 5

unit to the refrigerant lines as shown. HDA6067L
Figure 162
NOTE: Be careful not to switch the connections for the
low and high-pressure valves.
2. Open the high-pressure valve slowly to release the
refrigerant to the recovery unit.
NOTE: Open the valve slowly, while checking to see
that refrigerant is not leaking out.
3. When the manifold gauge dial falls below 3.5 kg/cm2
(50 psi), slowly open the low-pressure valve.
4. Open both the high and low-pressure valves slowly until
the manifold gauge dials indicates 0 kg/cm2 (0 psi).
Vacuuming Refrigerant System

2 3
Reference
Description 1 4
Number
1 To Compressor
2 Low-pressure Side
4 From Receiver
5 Vacuum Pump 5
HDA6068L
1. Vacuuming Procedure Figure 163
NOTE: When the A/C system has been exposed to the
air, it must be vacuumed out. Perform vacuum
process for 30 minutes for complete moisture
and air evacuation.
A. Attach the manifold gauges and vacuum pump to the
refrigerant system as shown.
B. Turn on the vacuum pump and open both valves.
C. When the low-pressure gauge shows approximately
710 mmHg, close both valves and turn off vacuum
pump.

9-1-113
2. Check system for vacuum leak.
Allow system to sit for 10 minutes and check whether the
system is holding the pressure. If the pressure has
dropped, it must be repaired before proceeding to the next
step.
3. Vacuuming Procedure
If the system is holding the pressure and it has not
changed for 10 minutes, vacuum out the system for an
additional 20 minutes.
HDA6069L
A. Turn on the vacuum pump and slowly open both
Figure 164
valves.
B. Allow vacuum pump to run for additional 20 minutes
until the low-pressure gauge dial reads approximately
750 mmHg.
C. Close both valves and stop the vacuum pump.
4. Installation of Refrigerant Container
Reference 1
Description
Number
1 Handle
2 Hose Connection
2
3 Mounting Disk
3
A. Before mounting valve on the container, make sure
the handle is in the counterclockwise most position,
with the puncture pin retracted and the mounting disk HDA6070L
is in the raised position. Figure 165
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. At this time,
do not open the low and high-pressure valves of the
manifold gauge.
F. Press the manifold gauge low side valve to eliminate
the trapped air in the hose.

9-1-114
Leakage Check
NOTE: Perform the leakage check after completing
vacuuming process.
1. After attaching the manifold gauge, open the high side
valve.
2. Charge system until the low side gauge dial indicates a
pressure of 1 kg/cm2 (14 psi) and close the high side valve.
3. Using a refrigerant leak detector or soapy water check
each joint for leakage.
1
Reference
Description
Number
1 Refrigerant Leak Detection Device
4. If a leak is detected, check for O-ring damage or correct

tightening torque and replace or repair as necessary.
5. If no leaks are detected, proceed with the charging
process. HDA6071L
Figure 166
WARNING
For accurate refrigerant leak detection, perform leak
detection procedure in a well ventilated area.
Refrigerant Charging
1. Perform the vacuuming procedure, vacuum holding and
leaking tests as described in the proceeding headings.
NOTE: First charge the refrigerant system with 100g
(3.5 ounces) of refrigerant with the engine off.
Then using the manifold gauges as a guide fully
charge the system with the engine running.
When exchanging refrigerant containers, press
the manifold gauge low side valve to eliminate
air from the charging hose.
Reference
Description 2 3
Number
1 4
1 To Compressor
2 Low-pressure Side
4 From Receiver
5 Refrigerant Supply Container
2. Charge the system by opening the manifold gauge low 5

side valve. HDA6072L
Figure 167
Initial charge amount: 100 g (3.5 ounces).

9-1-115
3. If refrigerant does not flow freely into system, try starting
engine first before operating air conditioner.
• Temperature control switch setting: Maximum
Cooling
Blower Speed Setting: Hi (3 step)
Engine Speed: 1,300 ~ 1,500 rpm
WARNING
When charging refrigerant system with the engine
running:
• Always keep refrigerant supply container in
the upright position.
• Never open the high side pressure valve.
4. Open the manifold gauge low side valve and charge

system to standard capacity.
Gauge Dial Standard Reading

13 ~ 20 bar
High Side Gauge
(13 ~ 20 kg/cm2, 185 ~ 285 psi)
Low Side Gauge 1.5 ~ 3.4 bar

(1.5 ~ 3.5 kg/cm2, 22 ~ 50 psi)
NOTE: These standards are for outside temperatures

between 30 ~ 35°C (86 ~ 95°F). The gauge
readings can vary for extreme temperature
conditions.
WARNING
• When outside temperature is low, warm the
refrigerant supply container with warm
water not exceeding 40°C (104°F). Do not
allow water to come in contact with the
charging adapter valve handle.
• When outside temperature is high, cool off
refrigerant supply container and condenser
to aid the refrigerant charging process.
5. Close low-pressure side valve.

6. Shut off engine and close refrigerant supply container
adapter valve. Disconnect manifold gauge hoses from
vehicle.

9-1-116
Inspecting System For Leakage
After completing charging procedures, clean all joints and
connections with a clean dry cloth. Using a refrigerant leak
detecting device or soapy water, inspect system for leaks
2
starting from the high-pressure side.
1
NOTE: When the refrigerant circulation has been stopped
the high-pressure will start to decrease and the low-
pressure will start to increase until they are
equalized. Starting the inspection from the high side 3
will result in a accurate test.
Reference 4
Description HDA6073L
Number Figure 168
1 Pressure
2 High-pressure
3 Low-pressure
4 Compressor Stop
Inspection Procedure
1. High-pressure Side
Compressor outlet  condenser inlet  receiver dryer
inlet  air conditioner unit inlet.
2. Low-pressure side
Compressor inlet  air conditioner unit outlet.
3. Compressor
Compressor shaft area, bolt hole area and magnetic clutch
area.
4. Receiver dryer
Pressure switch and plug area.
5. Connection valve area
Inspect all valve areas.
Verify all valves are capped to prevent leaking.
Check for foreign material inside of valve cap.
6. Interior of air-conditioning unit.
After stopping engine, insert detector probe into drain
hose. (Leave inserted for 10 seconds minimum.)
NOTE: When inspecting leakage from the air-
conditioning unit, perform the inspection in a
well ventilated area.

9-1-117
WIPER SYSTEM
Wiper Circuit
5 6 7
- 2 3 5 (Continuous mode) 3
+
M
8 (Intermittent 1 mode) 4
4 4
10 (Intermittent 2 mode) 5
5 6 11 (Washer mode) 6
1 7 8
12 - + 1
P
1
6 9 13 2
9 2 8
AMP MIC 13P
CN12 CN13 KET 8P
15A 10A 10A 15A

4
10
2
3
AMP MIC 13P 1
3 4 4 6
7 8 9 11 13 9 5
(CN12) (CN13) (Wiper Motor)
FG000589
Figure 169
Reference Reference
Number Number
1 Battery 6 Wiper Controller
2 Battery Relay 7 Wiper Switch Panel
3 Fusible Link 8 Window Washer
4 Fuse Box 9 Wiper Cutoff Switch
5 Wiper Motor 10 Light Switch

9-1-118
Wiper Operation
Continuous Operation
- Operation of wiper motor
Pressing the successive operation switch on the wiper switch
panel (7) changes the voltage of the "5" terminal of the wiper
controller (6) from HIGH (about 5.5 ± 0.5V) to LOW (0+0.5V) and
also current flows via 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 the "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 via
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 the "7"
terminal of the wiper controller (6).
The Wiper motor (5) stops reverse revolution when the contact
of a cam switch connected to the "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.
Intermittent operation
- Intermittent 1st (3-second)
Pressing once the Intermittent switch in the switch panel (7)
changes voltage of the "8" terminal in the wiper controller (6)
from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and current flows
through the "3" terminal in the wiper controller (6)  the "2" and
"4" terminals in the wiper motor (5)  the "4" terminal in the
wiper controller (6) to start the cycle that wiper stops 3 seconds
after every operation.
- Intermittent 2nd (6-second)
Pressing twice the Intermittent switch in the switch panel (7)
changes voltage of the "10" terminal in the wiper controller (6)
from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and current flows
through the "3" terminal in the wiper controller (6)  the "2" and
"4" terminals in the wiper motor (5)  the "4" terminal in the
wiper controller (6) to start the cycle that wiper stops 6 seconds
after every operation.
- Stopping the intermittent action
Pressing three times the Intermittent switch in the switch panel (7)
while the wiper is operating stops the action of the wiper motor.
NOTE: The wiper system does not work when the wiper
cutoff switch (9) is "ON."

9-1-119
LIGHTING SYSTEM
Lighting System Circuit Diagram
7
13 87a
30
87
*15 85 86
*16
*9
87a
6
30 87a
*14 87
87
30
85 86
85 86
12
*8
87a
87
30 *5
0 0
86 3 2 2 3
II II
I 5 5 I
4
6 6
7 8 8 7
20A
10 30A
CN6-1 15A
CN6-2
CN6-9
11
L6 CN6-10 3
CN2-6
CN7-4 CN4-4
2
CN7-5 CN4-5 CAN
CN7-6 CN4-6 CN1-1
CN1-2
CN1-8
1
CN1-9
FG000590
Figure 170

9-1-120
Reference Reference
Number Number
1 Battery Front Cabin Light /
9
2 Battery Relay Rear Work Light Relay
3 Fuse Box 10 Instrument Panel
4 Light Switch 11 EPOS Controller
5 Cabin Light Switch 12 Headlight (2 ea.)
Headlight Relay (Work Light 13 Work Light (2 ea.)
6
Indicate Light) 14 Front Cabin Light (4 ea.)
7 Work Light Relay 15 Rear Cabin Light (2 ea.)
8 Front Cabin Light Relay 16 Rear Work Light (1 ea.)
NOTE: The "*" mark are optional parts.
Kind of Light
The lighting system is consists of headlights, work lights, cabin
lights (optional), relays and switches.
Operation
Connected Terminal
Switch Position Activated Relay Lit Light
of switch
1 "2-3" Terminal - Illumination Light of Switch
"2-3" Terminal - Illumination Light of Switch
Light Switch Headlight Relay Headlight (2 Ea.)
2
"5-6" Terminal Work Light (2 Ea.)
Work Relay
Symbol Light of Work Light
Front Cabin Light (2 Ea.) or
1 "2-3" Terminal Front Cabin Light Relay
Front Cabin Light (4 Ea.)
Cabin Light Front Cabin Light (2 Ea.) or
"2-3" Terminal Front Cabin Light Relay
Switch Front Cabin Light (4 Ea.)
2
Rear Cabin Light Relay / Rear Cabin Light (2 Ea.) and
"5-6" Terminal
Rear Work Light Relay Rear Work Light (1 Ea.)

9-1-121
OVERLOAD WARNING DEVICE
Overload Warning Device Circuit Diagram
3 2
B A
15A 15A BR
4
5 CN1-1
1 0 CN1-2
2 CN5-4
0.5B 3 I
0.5B 7 8
CN1-8
CN1-9
+
CN3-5
SIG
6 CN3-6
-
CN4
CN1 CN2 CN3
DS1800184
Figure 171
Reference Reference
Number Number
1 Battery 4 EPOS Controller
2 Battery Relay 5 OWD Selector Switch
3 Fuse Box 6 Pressure Sensor

9-1-122
AUDIO CONTROLLER
Audio Controller Circuit Diagram

7
ANTENNA
10 8
MODULE
2 15
Vcc(+5V) 9
3 16 (LH) (RH)
1 MICOM
4 13
+ - + -
3 Vcc(+5V)
7
5 17
2
C
10
14
B 6 11
ACC R2
BR
4
11
4
3
5
B A
BR
2
E
Starter Switch Connection 2 1
PST TML B BR R2 C ACC

OFF
ACC
ON - + - +
START 12V 150AH 12V 150AH
1
DS1800047
Figure 172
Reference Reference
Number Number
1 Battery 7 Audio Control Panel
2 Battery Relay 8 Stereo
3 Fuse Box 9 Speaker
4 Circuit Breaker 10 Antenna Module
6 Starter Switch

9-1-123
Operations Via Audio Control Panel
Connected Terminal of
Switch Measured values Operations
switch
PWR 4.36 ±0.2 V Stereo ON, OFF
1.24 ±0.2 V Volume up
"3-4"
0 +0.2 V Volume down
SCAN 2.49 ±0.2 V Frequency selection

9-1-124
1Schematic
1Hydraulic Schematic /
Electrical Schematic
DX480LCA-K/DX520LCA-K Hydraulic Schematic / Electrical Schematic

11-1-1
Hydraulic Schematic / Electrical Schematic DX480LCA-K/DX520LCA-K
11-1-2
DX480LCA-K / DX520LCA-K
Hydraulic Schematic
Option Applied Part 1. Main Pump
Two Breaker 2. Pilot Filter
One-way; Joystick Button 22
pump Filter 3. Accumulator
11 Two-way; Joystick Button/Pedal 22 25 26 27 32 36 34 23 4. Solenoid Valve (Package)
5. Joystick Valve (L)
Rotating; Joystick Button/Pedal 28 29 30 31
6. Joystick Valve (R)
V2 T E Quick Coupler 33
to X1(A2) of Pump to X1(A1) of Pump 7. Pedal Valve
Pattern Change Valve (ISO BHL) 35 8. Control Valve
ps2 T4 T2 T1 T3 ps1 C2 9. Boom Cylinder
Boom Lock Valve/Arm Lock Valve 21 S
10. Arm Cylinder
T
BC
Foot Relief Foot Relief
BC
21 D 11. Bucket Cylinder
12. Swing Device
Pi1 of Arm Lock Valve (Opt.) Pi1 E
pa9 of C/V P2 P Dr 13. Travel Device
pa11
pa10
DR1' 10 13 14. Center Joint
9 9
A Backward
DR1 15. Restriction Valve
Arm Lock pc1 16. Restriction Valve
17. Oil Cooler
B5 L.H R.H 18. Return Filter
B9
19. Air Breather
36 36 20. Hydraulic Tank
Forward B
A9
A5
pb9 Arm 2 Arm 1 pb5 21. Lock Valve
22. EPPR Valve for 1/2 Way
C2 C2
360bar@20L/min Regen. pa5 A 25 23. Breaker Return Filter
E E 25. 1/2 Way Select Valve
pa9 X P1 26. Opt. Pedal Valve for 2 Way
27. Shuttle Valve for Opt.
Pi1 Pi1 P2 P Dr O 28. Additional Gear Pump
B8 B4 L C B
T T 13 P 29. Solenoid Valve for Rotating
A Backward
360bar@20L/min T 30. Rotating Valve
V2 V2 A8 A4
31. Opt. Pedal Valve for Rotating
21 21 pb8 Bucket Option pb4
32. Solenoid Valve for 2 Way
pa8 360bar@20L/min
33. Quick Clamp Valve
DR2' 34. Solenoid Valve for 2-pump
23 35. Pattern Change Valve
Forward B
DR2 pa4
33 pc2 Boom Lock A3
36. Stop Valve
A P A7
B3 SH
Boom 2 DB
pb3
B7 360bar@20L/min PG P1
B 250K 413250
2 2 4 2
pb7 Boom 1 pa3
B2
300K 14
T 413250
C PA
pa7
A2 1 1 3 1
B6 Swing PB
pb2
A6
Travel DR3 12 31 T P T P 7 T P 26
pb6
30 Pa A B pa2
B LEFT RIGHT A
FP pc6
pa6
B1
Travel Straight A1
Travel Opt. Pedal 1 Opt. Pedal 1
P pb1
L.Travel R.Travel
pa1
SH 2 1 2 1 4 3 2 1
from #28
CW CCW Forward Forward
DB
80K pr1 PG Backward Backward
#30 Pb #30 Pa
Main Relief Pb6 Pa6 Pb1 Pa1
325bar@150L/min 300K
T
LEFT 355bar@150L/min RIGHT
100K C
P2 P3 PH PA PP PT P1 P1 PA
8 PB
Pb
T P 5 T P 6
from #31 from #31 12
B LEFT RIGHT A 2 2
1 3 1 3
29 A B 4 4
Swing Arm Boom Bucket
T A3 pa10 1 3 2 4 2 4 3 1
T Left Dump Down Up Dump
22 Right Crowd Crowd
A1 C1
from #4 P4 ps1 35 B1 D1
P1 ISO A2 C2 BHL
CCW CW to #30 P
34
B2 D2
from Joystick(L) Switch 15 40k@24L

X1
Pcr=3.0K P1
28 2 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10
ps2 27
17 R3 R1
Hammer Operating
16 Pcr=2.0K X1 3 B1 B2 B3 B4 B5 B6 B7 B8 B9 S1 B10
Hammer/Shear
19
Safety Cut-off
10u
PH
Pressure up
high speed
0.5k 0.05k pa2 pb2 pa5 pb7 pa8 pa7 pb8 pa4 pb4
pa9 pb5 pa3
Travel
Select
A1
ACC P2 TR2 PH HO
10u 1.05k ±0.2k
Engine T
Doosan DX12 S
18 1.5k 1.5k
LH-HI
(CLOSE)
RH-HI
(OPEN)
177u
A B
20 A2
T
P1
4 Main Circuit
P0 P3 P4
M3 Pilot Circuit
ps1 #29 P1
1 X1 P1
32 Return Circuit
R4 R2 From Joystick(R) Button
From Joystick(R) Switch
DX480LCA-K / DX520LCA-K Hydraulic Schematic / Electrical Schematic

11-1-3
DX480LCA-K / DX520LCA-K
Electrical Schematic
0.85R
L 36B 0.85R 37B 1 0
2 36A
88B 3 I
+
STOP RUN B 88H 0.85BR 0.85G 7 8 54L
M 0.5WR
S 37A 0.85G 0.85G 0.5B LOWER WIPER SW
WIPER WIPER AUDIO
6-LAMP ASS'Y (OPT)
-
CONTROLLER SWITCH PANEL
50B
E 0.85B 0.85BR 0.85BR CONTROL PANEL
87a - 155B 2 0.85LW 3 155A 159A 5 (CONT) 0.5LR 3 159B
30
+
WORKING LAMP 2RY M
129B 0.85RG 1.25RG 0.85RG 129C 51B 1.25RG 2RG 51A 87 ROTATING BEACON (OPT) LOWER WIPER MOTOR 156A 4 4 156B
160A 8 (INT-1) 0.5LY 4 160B CONT. POWER
(RR) 0.85LB
0.85B 0.85B (RH) 1.25B 0.5B 85 86 0.5RG 161A 10 (INT-2) 0.5LG 5 161B INT SEEK ANTENNA
(REAR) ROTATING LOWER WIPER (OPT) 162A 11 (WASHER) 0.5L 6 162B
WASHER VOL.
REAR WORKING LAMP 87a 0.85RG 129D 55C
BEACON SWITCH
30 125E 1.25RL 51C 1 CAR STEREO
1.25RG 129A 87 (RL) 1.25RG 124B 157B 0.85WL 7 157A MODULE
0.85B WORKING LAMP RELAY ROTATING BEACON 1 0 WINDOW WASHER
(LH) 2 0.85RG 158B 5 0.85WB 6 158A 35C 12 0.85RB - + 0.85L 1 34E
0.5B 85 86 128B 0.5RG 1.25B 1.25B 33B 0.85Or 33A 3
127B 0.85RG CABIN LAMP I P
63C 6 35A 34C 2 121B 0.5WG 121A 15
0.85B 0.5B 7 8 0.5WR Vcc(+5V) SPEAKER
(FR) 0.85B 0.85RL 0.5RB 0.5L
3 123B 0.5W 123A 16 (LH) (RH)
52D 54K WIPER MOTOR 35B 34D 0.5WR 1 54D MICOM
CABIN LAMP RELAY 2 87a DIODE 5
127C 0.85RG HEAD LAMP 30 1.25R 4 169A 0.5BL 169B 13
53B 34B 1 0.85L 0.85L
0.85RW 1.25RW 53A 87 + - + -
(FMR) 0.85B CABIN LAMP SWITCH 130B 13 0.5RW 0.5WR 2 54C
(RH) 0.85B 0.5B 85 86 0.5RG LAMP SWITCH CN14 MOLEX 4P 117B 118B 119B 120B
Vcc(+5V)
2B 0 125B 0 0.85B 0.85Lg 9 138A 99 2 0.85B 0.5B 8
87a 2 55B 2 52B 3 54I 117A 7 0.5GrR
(FRONT) 0.5WR 126A 3 I 0.5RL 0.85WR 54A 3 I 0.85R 138B AMP MIC 13P 0.5WR
30 125D 3RL 17
II 53C II WIPER CUT SW CN12 CN13 KET 8P 118A 0.5BY
127D 0.85RG 3RG 127A 87 0.85RW HEAD LAMP RELAY FUEL PUMP (OPT)
125C 0 119A 2 0.5GrL
(FML) 0.85B 0.5B 85 86 126B 0
(LH) 5 52C
0.85BR 0.85WR 5 19D
I 5 0.5RL 0.85B I 0.5R 120A 10 0.5BW
0.5WR 0.5WR 0.85B 14
0.5RG 128A 6 II 0.5RG 55A 6 II
99 11 0.5B
127E 0.85RG 0.5B 7 8 0.5WR 0.5B 7 8 54G 0.5WR
CABIN LAMP RELAY 1 0.85R 132A 2
(FL) 0.85B 54F FUEL PUMP
SEAT HEATER (OPT) 1.25R
FUEL PUMP SW
12V POWER + 132B 3
DC/DC 1 0.85LR 0.85LR 4 13B
2B 3RL 1.25B 64B 1.25WL 64A 1 2 63B 1.25RL SOCKET CONVERTER 131B
CABIN LAMP 2RY P
1 0 - 99
2 143B 1.25RB
1.25B 144B 1.25R 144A 3 I 0.85B 3WL 231B 1 4 232A 3W 232B 1 PULL
8 54Q
LCD GAUGE PANEL REAR VIEW CAMERA 0.5B 7
SEAT AIR SUSPENSION (OPT) 1.25RB 1.25RB
SEAT HEATER 7D 3 2 0.85Br 7E 2 HOLD 3 3B
V+ 9V 195A CN7-7 0.5Or 195B 1.25R
SEAT HEATER SWITCH AIR SUSPENSION
196A CN7-17 196B 2RY
0.85WR
V- 0.5OrB
0.85BR
TIMER
0.85Br
0.5RW
E/G STOP S/V
0.85L
1.25B 143C 1.25RB
3WL
Sig 197A CN7-10 0.5YL 197B P 0.85RG 0.85RG
Sig Gnd 198A CN7-20 0.5YW 198B 0.5RG
ILL. 54B CN6-4 0.5WR 0.5WR 0.5WR CIGAR LIGHTER
0.85Br STARTER RELAY
KEY ON 28B CN7-2 0.5R 0.85R 0.85R
3WL 87a 0.85BL
ACC 28C CN7-16 0.5R 3RL 3RL
1.25B 62B 1.25W 0.5RW 0.85BY 30
FUEL HEATER (OPT) 87 5A
PILOT BUZZER 1.25RB 11B
+
TRAVEL/SWING ALARM ASS'Y (OPT)
0.85BL
0.5R 28D 0.5Br 86 85 0.5GB
59B 0.85RY
29B CN6-1 0.5WB 29A - 7C 89A
1.25R 0.85LR STARTER
+ 31B 0.85RY 0.85RY
130D CN7-5 0.5RW ALARM BUZZER 0.5GB 5B 24V 7KW
BACK UP
0.85WR
0.85RG
0.85BR
- 0.85B
0.85RY
1.25R
0.85LR
0.85R
1.25W
/0.85LR
(516-00011 ) 0
0.85L
2RY
3RL
3R
130G CN7-6 0.5RW
2RL
0.5P 3 I 2 0.5W 87a 30B
99 CN7-3 II 30 0.85RG
0.5B 104C 32B 31A 87 125A 50A 59A 28A 52A 63A 124A 179A 62A 131A 34A 88A 19A 1.25WR
99 CN7-4 0.5B 0 99 FUEL HEATER
5 0.5W 9 10 11 12 13 14 1 2 3 4 5 6 7 8 6A
I 0.5W 85 86 0.5RG 3B
0.85B 122B 0.85V 122A 6 II 30A 20A 20A 15A 15A 15A 10A 10A 10A 10A 10A 10A 10A 10A
32C 32A
1.25WR
ETP (OPT)
0.85LR
0.85BY
30C 1.25WR 2WR
OVER LOAD WARNING (OPT) 5bar
7 8 0.5WR
4G
17 18 2E
4D
15
2B
16
11A
54M ALARM RELAY 15R 98A B
SWING PRESS SW E-PUMP E-PUMP SW
ALARM SWITCH 5W 5W ACC C
ONLY SWING (OPT) 0.5B FUSE BOX 2 FUSE BOX 1
OVER LOAD 1.25B 233B 1.25WL 233A 1 2 220B 1.25R 13A
P 5W 5W
WARNING SWITCH B
0.5BW BR
2RL
4F 2D 4E 10A 6B 0.85Br
1 0
2 140B
0.5RG 0.85LB 15 16 2WR 17 18 2C 2WR R2
7A
0.5BrY 57B 0.85RY
0.5B 3 I 0.5RW 0.5RW A
HORN 1 H.F 10A 10A 10A 10A 10A 10A 10A 10A 30A 20A 15A 15A 15A 10A STARTER SWITCH
0.85B
0.5B 7 8 54P 0.5WR 0.5WR 0.5WR HORN RELAY
1 2 3 4 5 6 7 8 9 10 11 12 13 14
87a 60B
1.25RB
0.85RY
UNIFIED GP DISPLAY
0.5RW
0.5WR
0.5GB
0.5BG
0 30 56B 0.85RB 56A 66A 30A 93A 177A 40A 130A 83A 231A 42A 133A 143A 21A 220A
3WL
(NEW) 194B 0.85R B2 CN5-4 140A 141A 3 I 2 21B 0.5RL 57C 0.85RY 0.85RY 57A 87
+
0.85WR
1.25RB
60R
1.25R
0.85RB
1.25RL
0.85RG
0.85LB
0.85RL
0.85RB
0.85Y
0.5RW
0.85BrR
PRESSURE SENSOR 139B CN3-5 II HORN 2 L.F
3WL
0.85BrW 139A 0.85B 58A 85 86 56C 0.5RB
2LR
SIG 55D CN2-6 0.5RG 0.5G CIRCUIT BREAKER
(OWD) CN3-6 0
- 145A 0.85W 145B 141B CN2-4 0.5BrB (MANUAL) 5 21L
I 0.5RL 0.85LB 2WR 2WR 2WR 2R
CN3-15 194A +5V 22B CN2-5 0.5BrW (AUTO) 22A 6 II
0.85RG 0.85RG 0.85Br 2A 1B
194C 0.85R 0.5B 7 8 54H 0.5WR
PRESSURE SENSOR(A) + 0.5BW 7B
SIG 74B 0.85GR CN3-1 74A 178B CN1-16 0.85LB PREHEAT
(FRONT PUMP) 0.85LB 0.85Y 0.85RY
75A 0.85W CN3-2 75B HIGH SPEED SWITCH DA(Z)-2
UPDATE CONN. - 10B CN2-1 0.5BG KEY SW 'START' 0.5BG 0.5BG 0.5BG 2R
5V1A CN6-5 0.5WR 4 5V1B
CIRCUIT BREAKER
BATTERY RELAY
194D 0.85R 89B CN1-15 0.5GB START RELAY 0.5GB 0.5GB 0.5GB 8A 1A
U1A CN6-7 0.5Y 2 U1B + PT 0.85BrR 8W 8W 8W
B
A 15W
AUTO IDLE (1) 0.5G
76B 0.85GY CN3-3 76A 104A 104B
U2A CN6-6 0.5YB 3 U2B PRESSURE SENSOR(B) SIG CN2-15 0.85P 0.85B
/ TRAVEL SW 4B 3B 3A
(REAR PUMP) 77A 0.85WL CN3-4 77B 17bar 0.5RW 0.5RW 0.5RW
U3A CN6-8 0.5BrR 1 U3B -
0.85RL
1.25BrW 8C BR
21C CN1-1 0.5WR 0.5WR 1.25BrW
21D CN1-2 0.85RL 1.25RL 1.25RL 1.25RL 1.25RL
0.5GBr 192B E
CN4-8
9C CN2-14 0.5RW ALT 'I' 0.5RW 0.5RW 0.5RW 1.25B
CN4-12 192A 8B
120 0.5RW 187B NC 0.85RL 3WL
COM 40B 0.85Y
CN1-8 0.85B 0.85YG 41A NO 0.85RB MASTER SWITCH
CN6-12 80A 80B 99 HOUR METER 6C
0.5Y CN4-4 SOL-VALVE ASS'Y DA(Z)-1 60B 60R 15W 1
15R
1 2
0.85RY
CAN H
CN6-13 81B 99 CN1-9 0.85B 0.5RW 9D 3
81A 0.5YB CN4-5 0.85YG 41B PILOT CUT-OFF SWITCH HOUR 2 0.5B
CAN L (C1) OFF 10W
SHIELD 82B CN4-6 3 41C PILOT DR B+ 9B
DA4-1
CUT OFF
1
135B 0.5GL 135A CN4-1 187A CN5-1 0.5RW 1 0.85B 99 0.85B E ON 83B - + - +
2
136B 0.5GW 136A CN4-2 TxD 0.85YL 0.85YL 61C (C2) QUICK CLAMP(OPT) 12V 12V
137B 0.5RG 137A RxD 61B ROOM LAMP
CN4-3 RS-232 4
DIAGNOSTIC
3 DA4-2 BREAKER PREHEAT FUSE BATTERY

CN7 CN6 80C GND (고정) 1 0.5RW
0.5Y 235A CN1-17 0.85GrB 2 235C 0.85GrB 235B
200A
CONN
AMP 040 16P+20P 4 2 0.85LB 0.85RB 12A 98B AVX 8W

81C 0.85RB
0.5YB NOTE 2. 0.85RL 0.85RL 21F 0.5Br 0.85Br (풀림) 3
5 (C3) 66B 0.85LB
82C 0.85LB
SHIELD CONTROLLER 6 21J HIGH 84B 84A
6 DA1-2 84C 0.5RW 0.5RW AVX
SPEED 0.85RY 2RW
24C CN1-12 0.85Gr 24B 2 0.85Gr 24A QUICK CLAMP SW
0.85BrR
0.85RB
0.85RL
CN1 AMP MIC 21P
CN4 AMP 040 12P
~ 185A DIODE 6 0.5WR
0.5G
0.5B CN4-7 185B 0.85RL 0.85RL 21E AIRCON UNIT 4A 9A
14 (C4)
15W
28G 0.85R 21H 0.5RW 177C P(R) B(B+) R(I)
SATELLITE CN15 DA1-1
5
RELIEF SOL-VALVE 1.25LR CN11-2 42C 12B 15B
WIF SENSOR 202A 0.85LgR 202C LED 1~12 130C CN9-6
ANT. CN3-19 23C CN1-11 0.85GrW 23B 1 0.85GrW 23A PRESS UP 0.85B C B
54E 0.5LR CN10-8 42D
203A 0.85LgB CN3-20 203C CN9-11 0.5WR 177D - -
0.85RL 150F (C5) CN10-18 46B
0.5RW ILL 42B CN9-5 1.25LR
DIODE 11
150K BREAKER
GPS ANT. 9 8
0.85RL
DA1-3 5
0.5BW SG
99 SELECT DIODE 9
81F 80F 1 0.85B 99 0.85LR
0.85YL 0.85GY DPS SENSOR
7 1 0.5RG BLOWER A/C
137C 130E 84D CN2-11 0.5Br (QUICK CLAMP) 0.5Br 61D 71A 0.85BrR 42E 46A 0.85B
0.5GR CN4-10 400A RELAY RELAY (1) (2)
5 3
400B 9E CN4-11 401A 0.85RL D H R
6 4
0.5G
(POWER MAX) 168B CN8-10 0.5LG CN10-16 168A 178A 15L + +
F PST TML B BR R2 C ACC
401B 21N 0.7bar 60B CN2-2 0.5BrW 0.5BrW
0.85LB E OFF
TMS 2,12 ENG OIL PRESS SWITCH 97B 0.85BY CN5-5 97A 71B CN2-10 0.5GY (BREAKER) 0.5GY A/C THERMO (LOW) 105B CN9-8 0.5LB CN10-5 105A 100A 100B
CN2 AMP 070 18P
BREAKER SHEAR SELECT SW PREHEAT RELAY AIR HEATER

ACC
CONTROLLER 150E CN2-8 0.5RL (1-WAY) 0.85RL 106B CN8-11 0.5LY CN10-6 106A E ON
(2-WAY) 0.5B FET 99
181B 0.85GrL CN5-15 181A 151C CN2-9 0.5RY 0.5RY PST SHEAR PRESS BREAKER START
ENG SPEED SENSOR 1.25B 8B
UP CN11-1 99 - + 0.5L
182B 0.85GrR CN5-16 182A 186B CN5-2 0.5WOr 0.5WOr 1 0 2 M COMPRESSOR
TML
SHIELD AUXI MODE RESISTOR 99 107B CN8-12 0.5LW CN10-1 107A
9 BLOWER MAGNET
0.85BrB 94A 93B 0.85RL
0.85BrR
0.5WR 54J CN11-4 0.85LW 47C CLUTCH
0.85RB
0.85RY
0.5WR
0.5RW
10
0.5G
TERMINAL NO
2RL
183B 0.85YL CN5-13 183A 0.85RY 151A 108A CN9-13 0.5GrG CN10-2 108B FRE (P1) 47A 47B
3 INTAKE
W/TEMP SENSOR 1 0
184B CN5-14 184A 101A CN1-10 0.85Or 101B 1 2 186A 0.5WOr 0.85BrR 133G 109A CN9-12 0.5GrY CN10-20 109B REC (P2) ACTUATOR
DIODE 4
TERMINAL NO 0.85BL 5 0.85LgR 14 M
94B 2
P/V-(A) 0.5B 3 I 0.85BrR 133H
95A 95B 13
7 8 54N 0.5WR 110A CN9-15 0.5OrR CN10-12 110B DEF (P1) 0.85B 0.85B AMP 070 18P AMP MIC 21P
72B 72A 102B CN1-21 0.85OrB 102A 3 0.85RL 150A
0.85YR CN3-7 6 11
FUEL SENSOR 0.85LgW 111A CN9-14 0.5OrW CN10-13 111B VENT (P2) 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
KET 118 9P DIAGNOSTIC CONN. 14P 73B 0.85BR CN3-8 73A 0.85B 4 M MODE
96B 96A PUMP 6 43A CN9-16 43B Vref MODE DIESEL HEATER (OPT)
4 3 2 1 POWER MODE SW 0.5BrW 60A 0.5YB CN10-11 ACTUATOR 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
PROPORTIONAL V/V 16 0.5RW
AUXILIARY MODE SW 0.85BrL 134B 44A CN9-17 0.5YW CN10-10 44B MODE F/BACK
130H (CN2) (CN1)
9 8 7 6 5 3 2 1 26B 0.85LgR CN3-9 26A 15
OIL TEMP SENSOR 0.85YL 61A 99 CN9-10 1.25B 3
(CN13) 7 6 5 4
27B 0.85LgW CN3-10 27A 78A CN1-19 78B 12 0.5W 216B 1 4
0.85Lg HEATER AMP 040-III 20P AMP 040 28P
11 10 9 8
P/V-(C) (OPTION) 0.5LB 215B 2 TIMER KET D/L 4P
14 13 12 JOYSTICK LEVER SWITCH 112A CN9-1 0.5LgW CN10-19 112B WARM (P1)
FLOW CONTROL
MOLEX 4P 79B CN1-20 0.85LgB 79A 9 8 7 6 5 4 3 2 1 2 1 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 201B 0.5LG CN3-18 201A ECO PROPORTIONAL V/V 113A CN9-18 0.5LgB CN10-3 113B COOL (P2)
M
0.5RW 0.5B 99 6 3 58B 0.5G 20 19 18 17 16 15 14 13 12 11 10 12 11 10 9 8 7 16 15 14 13 12 11 10 9
15 163B CN1-3 163A STD PA 114A CN9-3 0.5YR CN10-7 114B Vref MIX MIX 4 3
ROTATING S/V (OPT) (HORN) (C)
AMP MIC 17P
1 2 3 4 (CN15) 103A CN2-16 0.85V 103B 0.85B AUTO IDLE (2) SW ACTUATOR
10 164B 0.5WG CN1-4 164A A/I 115A CN9-4 0.5YW CN10-9 115B MIX F/BACK (CN10) (CN11) (CN7) (CN6)
(CN14) 17bar 146C 146B 1 0.85OrB 0.85OrB 146A 4 1 133B 0.85BrR 2RL
14 165B 0.5YL CN1-5 165A W/M CCW 167C CN9-2 1.25BL CN10-4 167A GND 63G
3 (ROTATE-CCW) (L) 3
17 166B 0.5LG CN1-6 166A O/H 67A CN2-17 0.85BW 67B 0.85B INDICATOR DA5-1 1 216A 0.5W AMP 070 18P AMP 070 12P AMP MIC 13P
AMP MIC 17P (A)
0.85RY
0.5WR
0.85RB
116A CN8-2 CN10-15 116B

0.5RW
64mbar 1 0.85OrR 147A 5 2 133C 0.85BrR 0.5OrB DUCT
12 0.85B DIESEL 2 215A 0.5LB 1 2 3 4 5 6
2RL
ENG CONTROL MOTOR 8 7 6 5 4 3 2 1 5 4 3 2 1

CN16
8 7 6 5 4 3 2 1
(ROTATE-CW) (R) SENSOR HEATER 5 217A 1.25Br
AMP 070 16P
4 153A 0.85GW 153B P4 147C 147B 2 0.85OrR 2B 6

17 16 15 14 13 12 11 10 9 CW (ON JOYSTICK L.H) 4 218A 1.25L
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6 7 8 9 10 11 12 13
(+) 4
(CN9) (CN8) (CN12) WIPER CONT.
AMP MIC 17P
(CN16) (B) DA5-2

M 69A CN5-3 0.85RB 69B 0.85B 2 3 0.85B PEDAL SWITCH
(-) 5 154B 0.85Y 154A P5 RETURN FILTER SW 0.85BrL 134C 133J 0.85BrR 2
1.5bar
48A CN8-5 0.5LY CN10-17 48B 1 INCAR
8 85A 0.85L 85B P3 RETRACT AMP 070 16P AMP 040 12P AMP 040 20P
CN5
DIODE ARRAY (+) 70A CN5-7 0.85GB 70B PEDAL BRAEKER (OPTION)
0.85B SHEAR S/V (OPT) - E3C SENSOR 1.25Br 217B
AMP 040 20P
86B P2 PRESSURE SW (OPTION) 1

86A 7 0.85Or 5bar SUN LOAD SENSOR
DA6-1 1 0.85OrY 8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
5 6 7 8 3 4 87B 6 0.85Gr P1 100C CN2-13 0.5L 0.85BrL 134A 6 3 133D 0.85BrR
148C 148B 1 5 71C 4 0.85GY 142A CN8-3 0.5Lg 2 - + 1 CN10 AMP 20P CN11 KET 4P 1.25L 218B 12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11
(-) 87A (CLOSE) (BREAKER/POWER MAX) (C) 16 15 14 13 12 11 10 9
0.85Or CN3-13 86C 90B 1 142B 0.5YR 2
CW LOW 7 148D
71D (CN5) (CN4) (CN3)
CN3-14 SIG 91A CN3-16 0.5G 91B 2 0.85OrY 148A 4 1 151J 0.85RY 114C 0.85BL 167B 2 METERING PUMP
0.85Gr 87C DA6-3 AMBIENT TEMP
CN3
1 2 3 4 1 2 3 6
(SHEAR-CLOSE) (L) 49A CN8-4
GND 92B CN3-17 0.5GB 92A 3 0.85YG 0.85YG 49B 1 SENSOR
(426-00263 ) 2
DA1 DA4 ~ DA6 HIGH 149C 149B DA6-2 2 0.85Or 0.85Or 149A 5 2 151K 0.85RY
(OPEN) CN8 CN9
ENGINE CONTROL DIAL (SHEAR-OPEN) (R)
8
DA6-4 149D AMP 12P + 18P
1 90A 0.5GR
3 4 +(5V)
2 91C 0.5G
0.5GR 4 3 0.85B JOYSTICK LEVER SWITCH A/C CONTROL PANEL 2-PUMP CONTROL (OPTION)
0.5G 0.5WR 2-PUMP SWITCH
SIG 0 1
3 92C 0.5GB 0.5GB (ON JOYSTICK R.H) 0.85RY 179B 2
GND
0.5RW
3 180A 0.85BrW 180F 0.85BrW 180C 2-PUMP S/V
2RL
1 2 9 177B 0.85RB 0.85RB 0.85RB 0.85RB I
0.5WR 54R 8 7 0.5B DIODE 8
DA(Z) NOTE3. 70F 0.85GB 70C
THROTTLE CONTROLLER
0.5L 0.5L 0.5L
2RL 2RL
0.85GB 0.85GB 0.85GB 0.85GB
0.5RW 0.5RW
DX480LCA-K / DX520LCA-K Hydraulic Schematic / Electrical Schematic

11-1-5

SM Dx480lca K Dx520lca K Shop Manual (950106 01846e) en

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SM Dx480lca K Dx520lca K Shop Manual (950106 01846e) en

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Shop Manual

Serial Number 20001 and Up

DOOSAN and the DOOSAN logo are registered

Copyright DOOSAN 2018© Original Instructions

3 General Maintenance 1 General Maintenance Instructions

4 Engine* * Please refer to the DX12 Engine manual.

5 Upper Structure 1 Cabin (Non-Rops)

4 Hydraulic Oil Tank

6 Drive Coupling (Main Pump)

7 Gear Pump (Rotating)

6 Lower Structure and Chassis 1 Swing Bearing

7 Front 1 Boom and Arm

2 Main Control Valve

4 Joystick Valve (Work Lever)

5 Travel Control Valve (with Damper)

9 Electrical System 1 Electrical System

11 Schematic 1 Hydraulic Schematic/Electrical Schematic

DX480LCA-K/DX520LCA-K Track Excavator Maintenance Safety

Track Excavator Maintenance Safety

Track Excavator Maintenance Safety DX480LCA-K/DX520LCA-K

Safe Operation is Operator's

Know Your Machine

DX480LCA-K/DX520LCA-K Track Excavator Maintenance Safety

Track Excavator Maintenance Safety DX480LCA-K/DX520LCA-K

Flying or Falling Objects

DX480LCA-K/DX520LCA-K Track Excavator Maintenance Safety

Correction of Machine Problems

Crushing and Cutting

Track Excavator Maintenance Safety DX480LCA-K/DX520LCA-K

Hot Coolant and Oils - Burn Prevention

DX480LCA-K/DX520LCA-K Track Excavator Maintenance Safety

• Add fuel, oil, antifreeze and hydraulic fluid to machine only

Track Excavator Maintenance Safety DX480LCA-K/DX520LCA-K

DX480LCA-K/DX520LCA-K Track Excavator Maintenance Safety

Never Use Ether Starting Aids

Welding and Grinding

Track Excavator Maintenance Safety DX480LCA-K/DX520LCA-K

Fire Extinguisher and First-aid Kit

DX480LCA-K/DX520LCA-K Track Excavator Maintenance Safety

Roll-over Protective Structure (ROPS)

Track Excavator Maintenance Safety DX480LCA-K/DX520LCA-K

DX480LCA-K/DX520LCA-K Track Excavator Maintenance Safety

When working in mines, quarries or other work sites where there

Track Excavator Maintenance Safety DX480LCA-K/DX520LCA-K

DX480LCA-K/DX520LCA-K Track Excavator Maintenance Safety

Obey State and Local Over-the-Road

Loading and Unloading

Track Excavator Maintenance Safety DX480LCA-K/DX520LCA-K

DX480LCA-K/DX520LCA-K Track Excavator Maintenance Safety

Before Engine Starting

Make sure that the machine is equipped with a lighting system

Track Excavator Maintenance Safety DX480LCA-K/DX520LCA-K

equipment near fences or near boundary obstacles. No Entry

DX480LCA-K/DX520LCA-K Track Excavator Maintenance Safety

Never hold onto any control levers when getting on or off

Track Excavator Maintenance Safety DX480LCA-K/DX520LCA-K

DX480LCA-K/DX520LCA-K Track Excavator Maintenance Safety

Track Excavator Maintenance Safety DX480LCA-K/DX520LCA-K

Your machine may be equipped with visual aids such as mirrors

Work Site Rules

DX480LCA-K/DX520LCA-K Track Excavator Maintenance Safety

Boost Starting or Charging Engine

Track Excavator Maintenance Safety DX480LCA-K/DX520LCA-K