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Daewoo Solar 340LC-V, Shop Manual

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Daewoo Solar 340LC-V Shop Manual Download Page 528

S0709820K
Page 8

Travel Control Valve (With Damper)

TROUBLESHOOTING, TESTING AND ADJUSTMENT

At times pinpointing the source of the problem may be difficult. The following table lists some possible
problems, causes and remedies. Refer to this table for possible causes and remedies to help in correcting
problems.

The table only lists general problems, causes and 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 listed 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.

Problem

Possible Cause

Remedy

Secondary pressure will not 
increase.

Low primary pressure.

Adjust primary pressure.

Defective secondary pressure 
select spring.

Replace with new spring.

Gap between spool and casing is 
abnormally large.

Replace spool casing assembly.

Defective operating parts and 
components.

Disassemble/reassemble and 
replace defective parts.

Unstable secondary 
pressure.

Jamming of interconnected parts.

Repair/replace cause of jamming.

Unstable tank line pressure.

Install direct line to hydraulic tank.

Air in hydraulic lines.

Vent air from system.

Abnormally high secondary 
pressure.

High tank line pressure.

Install direct line to hydraulic tank.

Jamming of unconnected parts.

Repair/replace cause of jamming.

No damping.

Jamming of interconnected parts.

Repair/replace cause of jamming.

Worn damping piston and housing.

Replace damping piston and 
housing assembly.

Defective/damaged check valve.

Disassemble and examine check 
valve.

Worn damping piston orifice.

Replace damping piston.

Damping piston feels heavy.

Defective interconnected 
components.

Repair/replace defective parts.

Restricted movement of damping 
piston.

Repair/replace damaged piston.

Plugged orifice.

Replace related parts.

Summary of Contents for Solar 340LC-V

Page 1: ...nsumers periodically contact their distributors for recent documentation on purchased equipment This documentation may include attachments and optional equipment that is not available in your machine...

Page 2: ......

Page 3: ...Product Label Instructions Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine Solar 340LC V Serial Number 1001 and Up Pub No 023 00051E Pub No 023 00051E...

Page 4: ......

Page 5: ...tructure Cab S0402040K Counterweight S0403050K Fuel Tank S0405130K Fuel Transfer Pump S0405500 Swing Bearing S0407000 Swing Reduction Gearbox S0408030 Lower Structure and Chassis Track Assembly S05050...

Page 6: ...5K Main Control Valve Kayaba S0709401K Pilot Control Valve Work Lever Joystick S0709451K Travel Control Valve With Damper S0709820K Hydraulic Schematic S340LC V S0792190K Electrical System Electrical...

Page 7: ...1SAFETY...

Page 8: ......

Page 9: ...ng equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE Solar 130LC V 0001 and Up Solar 170LC V 1001 and Up Solar 220...

Page 10: ...l Safety Essentials 6 Location of Safety Labels 6 Summary of Safety Precautions for Lifting in Digging Mode 7 Unauthorized Modifications 8 General Hazard Information 8 Before Starting Engine 16 Machin...

Page 11: ...Mode on page 7 4 Unauthorized Modifications on page 8 5 General Hazard Information on page 8 6 Before Starting Engine on page 16 7 Machine Operation on page 19 8 Maintenance on page 26 9 Battery on p...

Page 12: ...ions given in this manual apply only to intended uses of the machine If you use your machine for any unintended uses that are not specifically prohibited you must be sure that it is safe for any other...

Page 13: ...out the safety of some procedures contact a DAEWOO distributor SAFETY ALERT SYMBOL Be Prepared Get To Know All Operating and Safety Instructions This is the Safety Alert Symbol Wherever it appears in...

Page 14: ...firm supporting surface with hooks and slings attached in approved configuration Loads must be balanced and supported evenly Use taglines to keep the load steady if wind conditions and large surface...

Page 15: ...work DANGER Unsafe use of the excavator while making rated lifts could cause serious potentially fatal injuries or extensive damage to the machine or nearby property Do not let anyone operate the mac...

Page 16: ...feeling well if you are taking medication that makes you feel sleepy if you have been drinking or if you are suffering from emotional problems These problems will interfere with your sense of judgemen...

Page 17: ...hine There is danger that this may lead to a serious accident When operating the machine do not put your hands or head out of the window When standing up from the operator s seat always place safety l...

Page 18: ...rious injury When getting on or off the machine always face the machine and maintain three point contact both feet and one hand or one foot and both hands with the handrails steps and track shoes to e...

Page 19: ...the fuel nozzle in constant contact with the neck of the fuel filling nozzle to provide a ground Keep fuel and other fluid reservoir caps tight and do not start the engine until caps have been secure...

Page 20: ...ible Always observe any rules and regulations related to the work site and working environment INJURY FROM WORK EQUIPMENT Do not enter or put your hand arm or any other part of your body between movab...

Page 21: ...the machine catches fire it may lead to serious personal injury or death If a fire occurs during operation escape from the machine as follows Turn the starter switch OFF and stop the engine If there i...

Page 22: ...e one way single acting and two way double acting piping valving auxiliary control kits Because Daewoo cannot anticipate identify or test all of the attachments that owners may wish to install on thei...

Page 23: ...windows doors or ductwork into which exhaust may be carried or blown by the wind exposing others to danger EMERGENCY EXIT This machine is equipped with a glass breaking tool It is behind the operator...

Page 24: ...and take other steps to prevent people from coming close to or entering the work site If people come close to a moving machine they may be hit or caught by the machine and this may lead to serious per...

Page 25: ...the head guard FOPS if working in areas where there is danger of falling rocks CHECKS BEFORE STARTING ENGINE Every day before starting the engine for the first time carry out the following checks If...

Page 26: ...after starting the engine it may result in a delay in discovering abnormalities in the machine and this may lead to personal injury or damage to the machine Carry out the checks in an open area where...

Page 27: ...of travel Sound the horn to warn people in the area Check that there is no one in the area around the machine There are blind spots behind the machine so if necessary swing the upper structure to che...

Page 28: ...ope or obstacle that causes the machine to tilt 10 degrees or more to the right or left or 30 degrees or more from front to rear Do not operate the steering suddenly The work equipment may hit the gro...

Page 29: ...r the bucket to the ground to help stop the machine Do not travel on grass fallen leaves or wet steel plates Even slight slopes may cause the machine to slip to the side so travel at low speed and mak...

Page 30: ...en terrain can cause dangerous side load conditions and possible tipover and injury Travel without a load or a balanced load may also be hazardous Never relay on lift jacks or other inadequate support...

Page 31: ...poor such as in fog mist snow and rain Wait for the visibility to improve to a level which causes no problems for the operation To avoid hitting the work equipment always do the following When workin...

Page 32: ...TE CAREFULLY ON SNOW ICE AND IN VERY COLD TEMPERATURES In icy cold weather avoid sudden travel movements and stay away from even slight slopes The machine could skid off to one side very easily Snow a...

Page 33: ...l water accumulation or runoff If parking on inclines is unavoidable block the crawler tracks to prevent movement Lower the bucket or other working attachment completely to the ground or to an overnig...

Page 34: ...o there is danger that you may get dirt or mud in your eyes or that you may slip and injure yourself When washing the machine do the following Wear shoes with non slip soles to prevent yourself from s...

Page 35: ...or fuel that is spilled onto hot surfaces or onto electrical components can cause a fire Store all fuels and all lubricants in properly marked containers and away from all unauthorized persons Store...

Page 36: ...to cool before you drain the cooling system Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Remove the hydraulic tank filter plug only...

Page 37: ...cut on pipes or on tubes that contain flammable fluids Before you weld on pipes or on tubes or before you flame cut on pipes or on tubes clean the pipes or tubes thoroughly with a nonflammable solvent...

Page 38: ...following Do not spill oil or grease Do not leave tools laying about Watch your step when walking Never jump down from the machine When getting on or off the machine use the steps and handrails and m...

Page 39: ...The loose retainer pin can injure personnel Make sure that the area is clear of people when you strike a retainer pin To avoid injury to your eyes wear protective glasses when you strike a retainer pi...

Page 40: ...om hydraulic hoses or pressurized components can be difficult to see but pressurized oil has enough force to pierce the skin and cause serious injury Always use a piece of wood or cardboard to check f...

Page 41: ...taminant and may only be disposed of at approved collection facilities To prevent pollution of the environment always do the following Never dump waste oil in a sewer system rivers etc Always put oil...

Page 42: ...ties of water and see a doctor at once If you accidentally drink battery electrolyte drink a large quantity of water or milk raw egg or vegetable oil Call a doctor or poison prevention center immediat...

Page 43: ...series connected twelve 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 m...

Page 44: ...ng rope to the left and right hooks and secure in position If the engine on the problem machine will not start or there is a failure in the brake system always contact your Daewoo distributor Never go...

Page 45: ...mation on partial disassembly Refer to the Transportation and Shipping section of this Operation and Maintenance Manual for information on loading unloading and towing LIFTING WITH SLING 1 Refer to Sp...

Page 46: ...S0102000 Page 38 Track Excavator Safety...

Page 47: ...1SPECIFICATIONS...

Page 48: ......

Page 49: ...and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capa...

Page 50: ...ange 8 General Specifications 10 Engine Performance Curves Per Ks r1004 Standard 12 Approximate Weight of Workload Materials 14 Performance Tests 17 Excavator Performance Standards 18 Test Conditions...

Page 51: ...AL DESCRIPTION The excavator has three main component sections The Upper Turntable The Lower Undercarriage and Track Frames The Excavator Front end Attachment The following illustration identifies mai...

Page 52: ...S0202110K Page 4 Specifications for Solar 340LC V COMPONENT LOCATIONS Figure 1...

Page 53: ...AIR CLEANER 11 CONTROL VALVES 12 ARM CYLINDER 13 BOOM 14 BOOM CYLINDER 15 CAB 16 SEAT 17 CENTER JOINT 18 SWING MOTOR 19 PRECLEANER 20 TRAVEL MOTOR 21 LOWER ROLLER 22 UPPER ROLLER 23 TRACK GUIDE 24 TR...

Page 54: ...S0202110K Page 6 Specifications for Solar 340LC V...

Page 55: ...6 11 320 mm 37 2 11 340 mm 37 2 B 3 500 mm 11 6 C 7 925 mm 26 0 7 820 mm 25 8 7 840 mm 25 9 D 4 010 mm 13 2 E 4 960 mm 16 3 F 1 195 mm 3 11 G 3 675 mm 12 1 3 550 mm 11 8 4 040 mm 13 3 H 2 990 mm 9 10...

Page 56: ...pends 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 inj...

Page 57: ...8 480 mm 27 10 D Max Loading Height 6 890 mm 22 7 7 270 mm 23 10 7 640 mm 25 1 F Max Digging Height 10 010 mm 32 10 10 440 mm 34 3 10 820 mm 35 6 G Max Bucket Pin Height 8 590 mm 28 2 8 960 mm 29 5 9...

Page 58: ...Bearing 11 630 kg 25 640 lb Digging Forces Bucket Cylinder 214 KN or 21 800 kg 48 060 lb with either 3 200 mm 10 5 or 2 600 mm 8 6 arm Arm Cylinder 171 KN or 17 400 kg 38 360 lb with 3 200 mm 10 5 sta...

Page 59: ...hipping Width standard shoes 3 280 mm 10 9 Overall Shipping Height to top of cylinder hose 3 550 mm 11 8 Track Shipping Length 4 960 mm 16 3 Transport Trailer Capacity 35 tons minimum load capacity Tr...

Page 60: ...Specifications for Solar 340LC V ENGINE PERFORMANCE CURVES PER KS R1004 STANDARD REVOLUTION rpm POWER OUTPUT ps 1000 200 2000 1500 FUEL CONSUMPTION g ps h 170 110 90 TORQUE kg m 160 100 300 100 150 A...

Page 61: ...ric Pressure 760 mmHg 20 C 68 F Cooling Fan 812 8 mm SUCKER 32 in Alternator 24V x 50A Air Cleaner Installed Muffler Installed Performance Standard KS R1004 Power 250 ps 1 900 rpm 246 58 hp 1 900 rpm...

Page 62: ...EDIUM WEIGHT OR DENSITY 1 600 KG M3 2 700 LB YD3 OR LESS HIGH WEIGHT OR DENSITY 2 000 KG M3 3 370 LB YD3 OR LESS Charcoal 401 kg m3 695 lb yd3 Coke blast furnace size 433 kg m3 729 lb yd3 Coke foundry...

Page 63: ...mestone graded above 2 1 282 kg m3 2 160 lb yd3 Limestone graded 1 1 2 or 2 1 362 kg m3 2 295 lb yd3 Limestone crushed 1 522 kg m3 2 565 lb yd3 Limestone fine 1 602 kg m3 2 705 lb yd3 Phosphate rock 1...

Page 64: ...hale broken 1 362 kg m3 2 295 lb yd3 Sulphur broken 529 kg m3 1 620 lb yd3 MATERIAL LOW WEIGHT OR DENSITY 1 100 KG M3 1 850 LB YD3 OR LESS MEDIUM WEIGHT OR DENSITY 1 600 KG M3 2 700 LB YD3 OR LESS HIG...

Page 65: ...3 5 0 4 3 4 0 4 Down sec 2 9 0 3 2 9 0 3 Arm Dump sec 3 5 0 3 3 3 0 3 Crowd sec 4 9 0 4 4 8 0 4 Bucket Dump sec 3 1 0 3 3 1 0 3 Crowd sec 3 8 0 4 3 8 0 4 Swing 3 Revolutions sec 20 3 1 5 20 3 1 5 Jack...

Page 66: ...ts with the engine speed control set to maximum RPM 5 Repeat tests with Power Mode engine control settings at both Standard Mode standard work mode and Power Mode high speed mode Travel speed tests sh...

Page 67: ...ormity Deviation distance should always be measured at the 20 m 65 7 1 2 finish line Repeat the test in reverse to measure in both directions with starting point becoming the finish line and vice vers...

Page 68: ...With the boom arm and bucket in the same position as for the swing speed test rotate the turntable so that the boom is evenly centered between the side frames pointing straight ahead Locate the 90 re...

Page 69: ...d performance standard for new cylinders put a full load of dirt in the bucket and move the attachment cylinders so that the arm cylinder is extended 20 50 mm 1 2 and boom cylinders are retracted the...

Page 70: ...S0202110K Page 22 Specifications for Solar 340LC V...

Page 71: ...1GENERAL MAINTENANCE...

Page 72: ......

Page 73: ...recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoistin...

Page 74: ...ns and Guidelines 3 Hydraulic System General Precautions 4 Maintenance Service and Repair Procedure 5 General Precautions 5 Hydraulic System Cleanliness and Oil Leaks 6 Maintenance Precautions for Hyd...

Page 75: ...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 readi...

Page 76: ...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...

Page 77: ...tion 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 d...

Page 78: ...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 met...

Page 79: ...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 r...

Page 80: ...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 be...

Page 81: ...h even surfaces with no discoloration or marks Bent Cage Cage damage due to improper handling or tool usage Replace bearing Galling Metal smears on roller ends due to overheat lubricant failure or ove...

Page 82: ...ay or grayish black in color with related etching away of material usually at roller spacing Replace bearings check seals and check for proper lubrication Misalignment Outer race misalignment due to f...

Page 83: ...der impact loading or vibration while the bearing is not rotating Replace bearing if rough or noisy Cage Wear Wear around outside diameter of cage and roller pockets caused by abrasive material and in...

Page 84: ...e if leaking Smears Smearing of metal due to slippage caused by poor fitting lubrication overheating overloads or handling damage Replace bearings clean related parts and check for proper fit and lubr...

Page 85: ...made A file drawn over a tempered part will grab and cut metal whereas a file drawn over a hard part will glide readily with no metal cutting Replace bearing if over heating damage is indicated Check...

Page 86: ...S0302000 Page 14 General Maintenance Procedures Return to Master Table of Contents...

Page 87: ...s outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling...

Page 88: ...3 Torque Values for Standard U S Fasteners 4 Type 8 Phosphate Coated Hardware 6 Torque Values for Hose Clamps 7 Torque Values for Split Flanges 8 Torque Wrench Extension Tools 9 Torque Multiplication...

Page 89: ...00 86 79 17 00 122 96 20 00 144 66 M14 x 1 5 4 10 29 65 4 30 31 10 6 60 47 73 5 70 41 22 8 30 60 03 7 50 54 24 11 10 80 28 12 50 90 41 13 00 94 02 18 50 11 26 22 00 158 12 M16 x Std 5 60 40 50 6 00 4...

Page 90: ...ed 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...

Page 91: ...OT POUNDS ft lb NEWTON METER Nm FOOT POUNDS ft lb NEWTON METER Nm 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7 16 14 7 16 20 1 2 13 1 2 20 9 16 12 9 16 18 5 8 11 5 8 18 3 4 10 3 4 16 7 8 9 7 8 14 1 8...

Page 92: ...es 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 dist...

Page 93: ...boots hydraulic system etc CLAMP TYPE AND SIZE TORQUE RADIATOR AIR CLEANER BOOTS ETC HYDRAULIC SYSTEM KILOGRAM METER kg m INCH POUNDS in lb KILOGRAM METER kg m INCH POUNDS in lb T Bolt Any Diameter Wo...

Page 94: ...bolts will damage the flanges and or bolts which may cause leakage Inside diameter of flange on end of hydraulic tube or hose fitting NOTE Values stated in chart are for Standard Pressure Series Code...

Page 95: ...e 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 di...

Page 96: ...on 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 assemb...

Page 97: ...500 F Remove HOT 210 Product Application Color Removal Required Setup 545 No filler non clog formula for high pressure hydraulic systems Over application will not restrict or foul system components P...

Page 98: ...cold temperature applications 620 For high temperatures to 232 C 450 F Green Same as 609 above 680 For high strength bonds and tight clearance gaps to 0 00008 mm 0 002 Green Same as 609 above Product...

Page 99: ...1UPPER STRUCTURE...

Page 100: ......

Page 101: ...ction Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibilit...

Page 102: ...S0402040K Page 2 Cab TABLE OF CONTENTS Removal 3 Installation 6...

Page 103: ...disconnecting wiring connectors for A Cab interior lighting B External light wiring C Radio antenna and connections D Wiper washer connections NOTE Control console wiring harnesses and hydraulic pipi...

Page 104: ...located at right side of cab Disconnect duct wiring connector before removing duct 2 17 Disconnect washer hose located at floor plate bottom 18 Remove cover 5 Figure 4 on left side dash cover 3 and bo...

Page 105: ...ng a suitable lifting device attach slings to four lift points on top of cab Figure 7 NOTE Cab weighs approximately 290 kg 639 lb 28 Lift cab from 25 50 mm 1 2 above deck height Check that all electri...

Page 106: ...ll four hex bolts 3 Figure 9 in door side of cabin floor 5 Install two hex bolts 1 Figure 9 in right side of cabin floor and one bolt 4 in front of cab floor 6 Once cab is mounted to floor unhook lift...

Page 107: ...th bolts 1 Figure 10 Install two rubbers 2 Figure 11 12 Install cover 5 Figure 11 on left side dash cover 3 NOTE Connect speaker wire before installing cover 13 Connect washer hose located at floor pl...

Page 108: ...ness Install cover 3 Connect hour meter connector and cigar lighter connect of cover 2 17 Install cover 2 Figure 13 18 Install operator s seat 1 Figure 13 NOTE Be careful not to damage seat covering 1...

Page 109: ...r those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is...

Page 110: ...S0403050K Page 2 Counterweight Return to Master Table of Contents TABLE OF CONTENTS General 3 Removal 5 Installation 7...

Page 111: ...o warns any user that the removal of the counterweight from the machine front attachment or any other part may affect the stability of the machine This could cause unexpected movement resulting in dea...

Page 112: ...the swing lock if equipped to hold the deck in place and always go backwards up the loading ramp The counterweight end of the deck has to get on the trailer first while the cab is still going up the r...

Page 113: ...in all directions to relieve pressure from accumulators 7 Set safety lever on LOCK position 8 Turn key to OFF position and remove from starter switch 9 Hang maintenance warning tag on controls 10 Dis...

Page 114: ...lts 4 Stop lifting with assist crane as soon as lifting slings are taut 15 Remove four bolts 4 Figure 4 and washers 5 from counterweight 2 NOTE Heat bolts if necessary to free them 16 When bolts 4 Fig...

Page 115: ...mounting holes 3 Slide washers 5 Figure 5 onto bolts 4 Apply Loctite 242 to mounting bolt threads 4 Install four bolts 4 Figure 5 with washers 5 into counterweight until washers contact support frame...

Page 116: ...S0403050K Page 8 Counterweight Return to Master Table of Contents...

Page 117: ...f this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultim...

Page 118: ...S0405130K Page 2 Fuel Tank TABLE OF CONTENTS General Description 3 Parts List 4 Specifications 5 Removal 6 Installation 10 Start up Procedures 12...

Page 119: ...Fuel Tank GENERAL DESCRIPTION WARNING Engine fuel is highly flammable and potentially explosive To prevent possible injury and or damage to equipment extinguish or move to a safe distance all potenti...

Page 120: ...S0405130K Page 4 Fuel Tank PARTS LIST 12 11 1 13 16 26 14 35 35 33 33 19 20 23 10 9 8 3 7 5 6 4 ATS0700L Figure 1...

Page 121: ...M10x1 5x25 6 Spring Washer M10 7 Drain Valve 8 Bolt 9 Shim 10 Shim 11 Fuel Filter 12 Cap 2188 9004 13 SP Plug 14 Level Gauge 16 O ring 19 O ring 20 Plug 23 Spacer 26 Bolt 33 Bolt 35 Clip Reference Nu...

Page 122: ...representing 10 percent of total fuel supply 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 be...

Page 123: ...et safety lever on LOCK position 9 Turn key to OFF position and remove from starter switch 10 Hang maintenance warning tag on controls 11 Disconnect negative battery cable leading to frame from batter...

Page 124: ...supply line 1 Figure 7 and fuel return line 2 from fuel tank 3 and carefully drain remaining fuel from lines 15 Remove clamp 4 Figure 7 holding fuel return line 2 to tank 3 16 Tag and disconnect wire...

Page 125: ...rs 4 Figure 10 holding tank 3 to frame Lift tank 25 mm 1 and make sure it is balanced Make sure that there are no other electrical wires or hoses connected to tank Completely remove tank after inspect...

Page 126: ...level gauge on the side of the tank is easily damaged Be careful of obstacles and wind gusts 3 Install shims 5 Figure 11 as needed to prevent tank 3 from rocking or stress from mounting bolts 4 4 Tigh...

Page 127: ...l supply line 1 Figure 14 and fuel return line 2 to fuel tank 3 9 Install clamp 4 Figure 14 to hold fuel return line 2 to tank 3 10 Make sure fuel tank drain valve Figure 15 on bottom of tank is close...

Page 128: ...er head 2 Unscrew and pump the hand operated primer pump Figure 17 by the fuel injection pump Pump primer until fuel is present at plug hole in fuel filter head 3 Tighten plug in fuel filter head 4 Co...

Page 129: ...our own personal responsibility MODEL SERIAL NUMBER RANGE Mega 130 0001 and Up Mega 160 0001 and Up Mega 200 III 1001 and Up Mega 200 V 1001 and Up Mega 250 III 1001 and Up Mega 250 V 1001 and Up Mega...

Page 130: ...ment of Rear Cover 5 Replacement of Armature 6 Solar 250LC V 1001 and Up Solar 290LC V 0001 and Up Solar 290LL 1001 and Up Solar 300LC V 1001 and Up Solar 300LL 1001 and Up Solar 330LC V 1001 and Up S...

Page 131: ...EORY OF OPERATION Fuel pump consists of motor pump switch and hose assembly Figure 1 Reference Number Description 1 Motor 2 Pump 2 1 Pump Cover 2 2 Rotor and Vane 3 Inlet Hose 4 Outlet Hose 5 Check Va...

Page 132: ...or very close to zero the motor is bad and must be replaced On units equipped with a toggle switch check the resistance through the toggle switch while the switch is in the ON position If continuity...

Page 133: ...bly and a thermal limiter are installed in the rear cover If you find any damage replace them with new ones Remove the switch cover and screw M5 x L95 from the rear cover Remove cover At reassembly of...

Page 134: ...ver than remove the armature from the housing Remove the pump cover and remove the rotor and vane Insert a new armature into the housing Refer to Replacement of Rear Cover on page 5 for installation o...

Page 135: ...safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE Solar 130LC V 0001 and Up Solar 170LC V 1001 and Up Solar 220LC V 0001 and Up Solar 2...

Page 136: ...Swing Bearing TABLE OF CONTENTS Swing Bearing Maintenance 3 Operating Recommendation 3 Measuring Swing Bearing Axial Play 3 Measuring Bearing Lateral Play 3 Swing Bearing Basic Operation 4 Rebuilding...

Page 137: ...nts at 4 points 90 apart around the circumference of the bearing Figure 1 Record and keep all measurements Play in the bearing should increase minimally from one inspection to the next Eventually howe...

Page 138: ...d 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 REBUILDING SWING BEARING 1 Remove tip of tapered pin 1 Fig...

Page 139: ...6 to remove steel balls 2 5 Turn inner ring and use wire 1 Figure 7 to remove retainers 2 6 Assemble in reverse order of disassembly and then adjust the gap between the steel balls and retainers using...

Page 140: ...S0407000 Page 6 Swing Bearing...

Page 141: ...he front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember...

Page 142: ...Return to Master Table of Contents TABLE OF CONTENTS General Description 3 Theory of Operation 3 Parts List 4 Special Tools 6 Specifications 7 Troubleshooting Testing and Adjustment 8 Removal 9 Disas...

Page 143: ...planet gears one sun gear and 2 step output reduction The planetary gear engages with the ring gear The pinion gear is connected with the output shaft and spline The gearbox reduces swing motor rpm t...

Page 144: ...S0408030 Page 4 Swing Reduction Gearbox Return to Master Table of Contents PARTS LIST Figure 1...

Page 145: ...Plate 2 7 Shaft For Pin 2 8 Bushing 2 9 Carrier 1 10 Sun Gear 1 11 Planetary Gear 1 12 Side Plate 1 13 Pin Assembly 14 Ring Gear 15 Thrust Plate 16 Cover 17 Lock Pin 18 Spacer 19 Collar 20 Plate 21 L...

Page 146: ...S0408030 Page 6 Swing Reduction Gearbox Return to Master Table of Contents SPECIAL TOOLS The special tools shown in Figure 2 can be fabricated to assist in gearbox assembly Figure 2...

Page 147: ...etary Gear Two Stage Planetary Gear Two Stage Planetary Gear Reduction Ratio 19 560 19 560 21 968 21 968 Maximum Output Speed 57 3 rpm 57 3 rpm 61 2 rpm 61 3 rpm Maximum Output Torque 2 100 kg m 15 18...

Page 148: ...damage to gearbox Repair replace broken or drive train faulty assemblies c Pressure at swing motor inlet shows Hydraulic pump or valve broken Troubleshoot hydraulic no increase but without irregular s...

Page 149: ...work levers joysticks in all directions to relieve pressure from accumulators 7 Set safety lever on LOCK position 8 Turn key to OFF position and remove from starter switch 9 Hang maintenance warning...

Page 150: ...ck 3 and hose fitting 7 from fill hole 13 Remove twelve bolts and washers 4 Figure 4 holding swing reduction gearbox 5 to frame 14 Using a suitable lifting device sling swing motor 1 Figure 4 and remo...

Page 151: ...lts and lift the planetary gears and the first planetary mounting plate out of the gearbox 5 Slide sun gear off the shaft and out of the gearbox 6 Thread an eye bolt into each of the three shafts that...

Page 152: ...slide the gear shaft out of the housing Use this method to remove the two remaining gear shafts gears and thrust plates Use the punch to drive the spring pins out of the shafts Use new spring pins wh...

Page 153: ...TE It is only necessary to disassemble the shaft when one of the shaft components is damaged bearing spacer etc and needs replacement 14 Set the shaft down into a metal pipe that has an inside diamete...

Page 154: ...n the shaft until the bearing is pressed into place Set the plate over the shaft spacer Press the shaft spacer onto the shaft 2 Apply 600 cc of grease to the roller area of bearing 3 Clean the oil fro...

Page 155: ...he eye bolts Lift the shaft assembly and guide it through the gear case Remove the Seal Protector 5 Install snap ring into the gear case 6 Position the gear case so that the input end is facing upward...

Page 156: ...side of the three planetary shafts Insert a planetary gear and thrust plate into the gear housing Slide a planetary shaft through the housing gear and plate 10 Use a hammer to tap a spring pin into th...

Page 157: ...e first planetary mounting plate assembly and set it down into the ring gear Slightly rotate the plate assembly so that the planetary gears mesh with the ring gear teeth This will allow the plate asse...

Page 158: ...ifting device sling swing motor 1 Figure 4 and position swing motor and reduction gearbox 5 as an assembly on unit 4 Install twelve bolts and washers 4 Figure 4 to secure swing reduction gearbox 5 to...

Page 159: ...1LOWER STRUCTURE AND CHASSIS...

Page 160: ......

Page 161: ...manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately...

Page 162: ...ont Idler Roller 12 Parts List 12 Front Idler Roller Disassembly 13 Front Idler Roller Reassembly 15 Lower Roller 16 Parts List 16 Lower Roller Removal 17 Lower Roller Disassembly 17 Lower Roller Reas...

Page 163: ...G Safely measuring track tension requires two people One person must be in the operator s seat running the controls to keep one side frame in the air while the other person makes dimensional checks Ta...

Page 164: ...is hard and full of rocks or gravel 4 The increased clearance recommended for muddy ground conditions is between distance D on below table The clearance should be approximately distance E on below ta...

Page 165: ...adjustment cylinder 2 The longer the adjustment cylinder the greater the pressure on the tension spring pushing the track idler wheel outward 6 If there is not enough slack or clearance in the tracks...

Page 166: ...general recommendations and specific safety precautions before starting any lower travel frame component rebuilding procedure Component Reference Dimensions Reference Normal New Dimension Recommended...

Page 167: ...1 741 42 3 mm 1 665 41 2 mm R 1 622 Master pin Lower roller axle A 75 mm 2 953 74 5 mm 2 933 74 2 mm R 2 921 Lower roller bushing A 75 5 mm 2 972 76 mm R 2 992 Axle bushing clearance 1 0 mm 0 039 1 8...

Page 168: ...r roller axle A 55 mm 2 165 54 5 mm 2 146 54 2 mm R 2 134 Upper roller bushing A 55 5 mm 2 185 56 mm R 2 205 Axle bushing clearance 1 0 mm 0 039 1 8 mm 0 071 Flange thickness bushing B 6 5 mm 0 256 5...

Page 169: ...ont idler bushing A 90 5 mm 3 563 91 mm R 3 583 Axle bushing clearance 1 0 mm 0 039 1 8 mm 0 071 Gap between bushing and side collar Total amount for both sides B 1 0 mm 0 039 1 5 mm 0 059 Front idler...

Page 170: ...o clock from top position on travel reduction gearbox 4 Remove four nuts and bolts 2 Figure 13 holding shoe to link Remove enough shoes to make access to lock pin easier NOTE Support track shoes with...

Page 171: ...aise track frame off blocking 3 With blocking removed lower track frame onto track Make sure all rollers are properly positioned on track 4 Move unit backwards while feeding track up over front idler...

Page 172: ...S0505000 Page 12 Track Assembly FRONT IDLER ROLLER PARTS LIST Figure 18 Reference Number Description 1 Bearing 2 Plug 3 Pin 4 O ring 5 Axle 6 Group Seal 7 Idler 8 Bushing Reference Number Description...

Page 173: ...emove plug 2 Figure 19 and drain oil from roller assembly 1 2 Separate the pin 3 Figure 20 from the bearing 1 3 Use a press to remove the bearing from the axle Separate the O ring 4 Figure 21 from the...

Page 174: ...Detach the group seal 6 Figure 22 from the idler 7 and bearing 1 5 Use a press to separate the axle 5 Figure 23 O ring 4 and bearing 1 6 Remove bushing 8 Figure 24 with the press and special tool ST 1...

Page 175: ...ing 1 Figure 25 and axle 5 holes and pin 3 them together 4 Install group seal 6 Figure 26 inside the idler 7 and bearing 1 NOTE Apply clean engine oil to the joint side of the group seal Apply grease...

Page 176: ...S0505000 Page 16 Track Assembly LOWER ROLLER PARTS LIST Figure 28 Reference Number Description 1 Pin 2 O ring 3 Collar 4 Axle 5 Roller 6 Group Seal 7 Bushing 8 Plug Reference Number Description...

Page 177: ...rame There is an alignment pin on each end of lower roller assembly 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...

Page 178: ...tach collar 3 Figure 32 and O rings 2 from the axle using a press LOWER ROLLER REASSEMBLY 1 Degrease clean and dry all parts before reassembly Insert bushing 7 Figure 33 into roller 2 Apply grease to...

Page 179: ...e inside the roller 6 Install the collar 3 Figure 36 O ring 2 and pin 1 on the remaining side 7 Fill with clean engine oil with approximately 350 cc 3 4 pint LOWER ROLLER INSTALLATION 1 Install four b...

Page 180: ...rack Assembly UPPER ROLLER PARTS LIST Figure 38 Reference Number Description 1 Plug 2 Bolt 3 Cover 4 Bolt 5 Washer 6 Roller 7 Axle 8 Group Seal 9 Bracket 10 Bushing 11 O ring 12 Lock Washer Reference...

Page 181: ...ck on top of track frame and apply pressure to track shoe 3 Remove mounting hardware holding upper roller assembly to track frame UPPER ROLLER DISASSEMBLY 1 Remove the plug 1 Figure 40 from the cover...

Page 182: ...000 Page 22 Track Assembly 4 Separate the group seal 8 Figure 43 from the roller and bracket 9 5 Separate the bushing 10 Figure 44 from the roller with a press and special tool ST 1919 Figure 43 Figur...

Page 183: ...nto the roller 6 and bushing NOTE Apply clean engine oil to the joint side of the group seal Apply grease to the group seal O ring 3 Install the axle washer 5 Figure 47 and bolt 4 4 Attach group seal...

Page 184: ...S0505000 Page 24 Track Assembly 7 Tighten plug 1 Figure 48 Figure 48...

Page 185: ...S0505000 Page 25 Track Assembly TRACK SPRING AND TRACK ADJUSTING CYLINDER PARTS LIST Figure 49...

Page 186: ...mber Description 1 Piston Rod 2 Piston Ring 3 Backup Ring 4 Packing 5 Retaining Ring 6 Rod 7 O ring 8 Cylinder 9 Spring 10 Spacer 11 Flange 12 Nut 13 Valve 14 Bolt 15 Plate 16 Yoke 17 Socket Bolt 18 F...

Page 187: ...1ENGINE AND DRIVE TRAIN...

Page 188: ......

Page 189: ...ned within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own pers...

Page 190: ...ir Discharge According to Path Selection 10 Air conditioning System Circuit Diagram 12 Troubleshooting 14 Weight of R134a Gas Used In Machines 17 Refrigerant System Repairs 18 Refrigerant Safe Handlin...

Page 191: ...air filtration system which filters out dirt and dust particles from air being circulated into operator s cab This filter should be cleaned out every 500 hours NOTE In the event that the unit is being...

Page 192: ...e 3 and inspect for any damage 6 Use compressed air to clean filter element If filter element is very dirty use a mild soap or detergent and water to clean it NOTE If water was used to clean filter be...

Page 193: ...nditioner REFRIGERANT CIRCULATION 1 2 3 4 5 6 HDA6046L Figure 4 Reference Number Description 1 Evaporator 2 Expansion Valve 3 Condenser 4 Condenser Fan 5 Compressor 6 Blower Fan 7 Receiver Dryer Refer...

Page 194: ...ir surrounding the evaporator creating a cooling effect and changes from the gas to the liquid state The refrigerant once again flows into the compressor in the gaseous state and the process is repeat...

Page 195: ...UT CONTROL PANEL OUTPUT A C CONTROL PANEL DISPLAY LOW SPEED RELAY TEMPERATURE SENSOR MID SPEED RELAY HIGH SPEED RELAY BLOWER MOTOR VENT ACTUATOR DEF ACTUATOR INTAKE ACTUATOR COMP RELAY CONDENSER FAN R...

Page 196: ...consists of a 24 step variable selector The display uses 7 Green Red two color LEDs to display the selected temperature Blower Fan Speed Control OFF Switch LOW Switch MID Switch HI Switch Compressor C...

Page 197: ...Green 3 28 V 0 2 8 Red Red Green Green Green Green Green 3 11 V 0 2 9 Red Red Red Green Green Green Green 2 93 V 0 2 10 Red Red Red Green Green Green Green 2 76 V 0 2 11 Red Red Red Green Green Green...

Page 198: ...S0605060K Page 10 Air Conditioner AIR DISCHARGE ACCORDING TO PATH SELECTION Face Rear and Defroster Foot ARS1280L Figure 10 ARS1290L Figure 11...

Page 199: ...S0605060K Page 11 Air Conditioner Face and Defroster ARS1300L Figure 12...

Page 200: ...HRS 26P 14 9 2 7 15 9 26 16 CN5 16 2 1 4 15 4 5 6 1 2 COOL 15 CN5 AMP MIC 13P 13 6 12 11 4 5 10 9 3 7 8 2 1 15 8 M 15 1 87 9 87a 87 M 85 8 87a 7 10 30 BLOWER SPEED TEMP CONTROL RECIRCLE FRESH AIR MOD...

Page 201: ...elay 10 Foot Defrost Control Actuator 11 Receiver Dryer Low High Pressure Cut Off Switch 12 Diode 13 Compressor 14 A C Control Panel 15 A C Unit 15 1 Blower Motor 15 2 Resister 15 3 High Speed Relay 1...

Page 202: ...y 1 Check for traces of refrigerant oil Yes Reassemble using correct tightening torque No Go to next step 2 Using a leak detection device or soapy water check for refrigerant leakage at all major comp...

Page 203: ...3 46 9 psi Yes Moisture in system replace receiver dryer No Contaminated system replace expansion valve Replace evaporator core assembly 5 High Pressure Over 6 18 kg cm2 85 256 psi Low Pressure 500 m...

Page 204: ...r Conditioner 7 High Pressure Over 7 0 11 0 kg cm2 100 156 psi Low Pressure 4 0 6 0 kg cm2 57 85 psi Possible Cause Low refrigerant pressure due to poor compressor compression Inspect and replace comp...

Page 205: ...Solar 170LC V 850 20 grams 30 0 7 oz Solar 170W III 1100 20 grams 38 0 7 oz Solar 200W III 1100 20 grams 38 0 7 oz Solar 200W V 850 20 grams 30 0 7 oz Solar 220LC III 950 20 grams 33 0 7 oz Solar 220L...

Page 206: ...em standards require new tools equipment and parts DO NOT attempt to use equipment use in servicing the old refrigerant system WARNING Always wear protective glasses and gloves when handling refrigera...

Page 207: ...efrigerant 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 pr...

Page 208: ...R AIR LEAKAGE 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...

Page 209: ...uge dials indicates 0 kg cm2 0 psi VACUUMING REFRIGERANT SYSTEM 1 Vacuuming Procedure NOTE When the A C system has been exposed to the air it must be vacuumed out Perform vacuum process for 30 minutes...

Page 210: ...he mounting disk is in the raised position B Attach the manifold gauge center hose to the valve assembly C Turn the disc in the clockwise direction and securely mount valve onto refrigerant container...

Page 211: ...e engine running When exchanging refrigerant containers press the manifold gauge low side valve to eliminate air from the charging hose 2 Charge the system by opening the manifold gauge low side valve...

Page 212: ...from vehicle 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 Gauge Dial Stand...

Page 213: ...sor 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 magnet...

Page 214: ...S0605060K Page 26 Air Conditioner...

Page 215: ...those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is...

Page 216: ...S0609010K Page 2 Drive Coupling Main Pump TABLE OF CONTENTS Drive Coupling 3 Special Tools 4 Drive Coupling Installation 6 Installation Procedure 8...

Page 217: ...it is very important to properly adjust clearance between the face of the coupling hub and end of pump drive shaft Measurement H shown in the following procedure to a specific value Figure 1 thru Fig...

Page 218: ...d Figure 5 This distance will be referred to as Measurement H in the installation instructions that follow NOTE In manufacturing drawings Figure 4 dimension A and B equal the Measurement H The two too...

Page 219: ...Dimension Measurement Models A 6 0 1 mm 0 2362 0 0039 in S300LC V S300LL B 7 0 1 mm 0 2756 0 0039 in S340LC V S420LC V S470LC V C 20 0 mm 0 787 in D 7 0 mm 0 275 in E 18 0 mm 0 708 in Radius F 22 0 m...

Page 220: ...ive 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 lif...

Page 221: ...Pin 4 2 Insert 4 3 Bolt 4 Ta 4 Flywheel 1 5 Spring Pin 8 6 Insert 4 7 Hub 1 8 Bolt 4 Ta 9 Pump shaft 1 10 Clamping screw 2 Tb 11 Element 1 Table 2 Specification for Measurement H and Torque Refer to...

Page 222: ...ews 10 NOTE Tighten clamping screws to value Tb in the tables NOTE Coat clamping screws 10 with Loctite 262 5 Install element 11 between inserts 2 on engine flywheel 4 6 Install main pump and hub 7 by...

Page 223: ...1HYDRAULICS...

Page 224: ......

Page 225: ...Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use...

Page 226: ...rcuit 8 Swing Operating Circuit 8 Right Swing Operating Circuit 9 Left Swing Operating Circuit 9 Swing Relief Valve and Make up Valve 9 Travel Operating Circuit 9 Forward Travel Circuit 10 Reverse Tra...

Page 227: ...and Flow Meter Kit Installation and Testing 20 Swing System Troubleshooting 22 Precautions Initial Checks 22 Swing Relief Valve Checking and Adjustment 22 Troubleshooting Swing Gearbox 24 Troubleshoot...

Page 228: ...t efficiency The system features an electronically controlled output optimization system which allows the operator to choose between two distinctly different power modes high output rapid cycling maxi...

Page 229: ...cuit for these functions the output of both pumps can be combined allowing higher speed operation Boom up arm crowd and dumping functions can operate in any one of the two available power modes the st...

Page 230: ...ondary boom up pilot pressure that is transmitted to the right and left sides of the control valve simultaneously When secondary pilot pressure reaches 7 9 kg cm2 101 130 psi boom control valve spools...

Page 231: ...of the control valve simultaneously When secondary pilot pressure reaches 7 9 kg cm2 101 130 psi the arm control valve spool on the right and left sides of the control valve opens Output flow from bot...

Page 232: ...ump flows to the bucket cylinder BUCKET DUMP CIRCUIT When the bucket control lever is put in the dump mode the bucket control valve spool in the left half of the control valve opens to supply oil from...

Page 233: ...LVE AND MAKE UP VALVE Whenever the spool is shifted to the neutral mode during swing operation the possibility exists that surge pressure in the circuit caused by inertial momentum of the upper works...

Page 234: ...achine REVERSE TRAVEL CIRCUIT When the right and left travel control levers are pushed backward output from both main pumps is directed through the PR PL TRRR and TRLR ports on the control valve throu...

Page 235: ...at the pump drive flex coupling pull out the electrical tray under the operator s seat to inspect the self diagnostic display If the EPOS trouble code display is clear check hydraulic functions in th...

Page 236: ...e specified in the table adjust gear pump relief pressure by loosening the lock nut and turning the set screw in clockwise to increase pressure or turning it out to decrease it NOTE Be aware that seri...

Page 237: ...tank to relieve pressure and connect an in line t style adapter to the valve pressure port Install a 60 bar 1 000 psi test gauge in the adapter Restart the engine and increase engine RPM by turning th...

Page 238: ...uid back into the system if excessive fluid was lost To verify operation of the swing priority solenoid valve connect test equipment and begin testing with the work mode switch set to digging the stat...

Page 239: ...it Pressure must be 350 bars 5075 psi or up to 10 bars 145 psi higher Because one adjustment can affect the other check low stage main relief pressure by repeating the cylinder stall test without pre...

Page 240: ...tment NOTE The electrical pressure up power boost solenoid valve located alongside the swing priority solenoid and arm speed control solenoid in compartment rear of the operator s cab must be operatin...

Page 241: ...tently overloaded and engine troubleshooting shows engine performance to be at or above rated output If reduced cylinder speed and diminished work performance provide an indication that rated maximum...

Page 242: ...ustment procedures could affect the setting of the others Check and record the arm dump speed performance test before and after input power adjustment whether or not a flow meter is used NOTE Regulato...

Page 243: ...quare tipped adjusting screw should be turned in the opposite direction turns to avoid changing inner spring adjustment Pump input power adjustments are normally made in small increments 1 4 turn 90 o...

Page 244: ...te fittings and adapter flanges to guarantee a pressure tight seal NOTE Be sure to maintain even tightening torque on all flange fittings Use Loctite brand PST 545 or an alternate manufacturer s hydra...

Page 245: ...book If test results do not measure up to specified values pump output tests can be repeated using different control levers Recheck front pump operation while stroking the bucket cylinder out lever a...

Page 246: ...power to check the engine Investigate unusual operating noises or vibration Check for loose bolts connections SWING RELIEF VALVE CHECKING AND ADJUSTMENT Make a check of operating pressures through th...

Page 247: ...compartment behind cabin When pressure through the port is at the recommended level the brake release valve should disengage the swing brake allowing the swing motor to rotate the excavator If pressu...

Page 248: ...motor drain rate Replace Repair motor Gear train defective Refer to Swing Gear Troubleshooting procedure Swing functions but only at reduced RPM Causes listed above could also produce dragging swing O...

Page 249: ...al damaged Assembly compound joint sealer old and not sealing bolt not tight or flange warped Replace oil seal Disassemble and check mating surfaces Reapply Loctite torque bolts to specifications Exce...

Page 250: ...valve malfunction Readjust or replace Oil leak at make up valve Clean repair Control valve spool damaged Repair or replace Dirt in control valve spool Clean or replace Actuator joystick foot pedal dam...

Page 251: ...contamination Disassemble clean main poppet Broken or damaged spring Replace Adjusting screw loose Readjust Main poppet sticking Repair replace Clogged orifice in pilot passage to control valve Clean...

Page 252: ...ents worn out past wear limits Replace Problem Possible Causes Remedies Secondary pressure does not increase Low primary pressure Check primary pressure Broken spring Replace spring Spool sticking Cle...

Page 253: ...sembly Secondary pressure too high Dirt other interference between valve parts Clean repair or replace Return line pressure too high Redirect return line Secondary pressure does not hold steady Dirt o...

Page 254: ...S0702180K Page 30 Hydraulic System Troubleshooting Testing and Adjustment...

Page 255: ...thin this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal r...

Page 256: ...S0703010K Page 2 Accumulator TABLE OF CONTENTS General Description 3 Specifications 4...

Page 257: ...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 T...

Page 258: ...ge 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 i...

Page 259: ...S0703010K Page 5 Accumulator Solar 470LC V S N 1001 thru 1049 Pilot Travel 10 kg cm2 140 psi 320 cc 19 53 in3 S N 1050 and Up 750 cc 45 77 in3 Model Serial Number System Charge Pressure Volume...

Page 260: ...S0703010K Page 6 Accumulator...

Page 261: ...tained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own p...

Page 262: ...S0704030 Page 2 Center Joint Swivel TABLE OF CONTENTS General Description 3 Parts List 4 Troubleshooting Testing and Adjustment 5 Inspection 5 Testing 5 Disassembly 6 Reassembly 7...

Page 263: ...RIPTION The center joint swivel is designed to allow hydraulic oil from the upper structure to flow to components in the lower structure It is capable of allowing continuous 360 rotation of the upper...

Page 264: ...PARTS LIST Figure 1 Reference Number Description 10A Center Joint Body 10B Spindle 10C O ring 10D Slipper Seal 10E O ring 10F Cover 10G Hex Bolt 10H Spring Washer 10I Plug 10J Plug 25 Spring Washer 3...

Page 265: ...of the excavator A high pressure relief valve with a setting pressure 1 5 times maximum system pressure A stop valve A manually operated in line change over valve Install the change over valve upstre...

Page 266: ...g overhauled or rebuilt For repair procedures or emergency teardown use a thin but rounded tip smooth edge scraper or spatula to remove O rings or seals to avoid causing damage to those that must be r...

Page 267: ...r swivel with clean hydraulic fluid before reassembly of high pressure and drain line piping Clean and pre fill piping line ends to reduce the amount of air in the system Bleed air from the hydraulic...

Page 268: ...S0704030 Page 8 Center Joint Swivel...

Page 269: ...Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE Solar 130LC V 0001 and Up Solar 130W V 0001 and Up Solar 170LC V 1001 and Up Solar 170W V 1001 and Up Sol...

Page 270: ...TENTS General Description 3 Theory of Operation 3 Parts List 4 Special Tools and Materials 6 Piston Nut 6 Piston Jig 10 Steel bush Jig 14 Dust Wiper Jig 18 Slipper Seal Jig 22 Slipper Seal Straighteni...

Page 271: ...shown as oil path A or to the front of the cylinder oil path B The cylinder rod is extended as oil flow is pumped through the circuit to the back side of the piston The force F1 of the piston stroke c...

Page 272: ...it does to lengthen it Q1 Q2 PARTS LIST The following parts list is a partial listing only for full and complete parts list information refer to the Hydraulic Equipment Component Parts List Cross sect...

Page 273: ...t 8 Retaining Ring 9 Rod Cover 10 O ring 11 O ring 12 Backup Ring 13 Piston Rod 14 Cylinder Tube 15 Cushion Ring 16 Piston 17 Slide Ring 18 Wear Ring 19 Slipper Seal 20 O ring 21 Backup Ring 22 Piston...

Page 274: ...Page 6 Cylinders SPECIAL TOOLS AND MATERIALS PISTON NUT B A D C 0 2 0 1 0 2 0 1 R R15 R20 C3 C5 35 350 ARS4730L 15 4 R 0 5 Through Hole 8 Figure 6 Material SM45C AISI 1045 Rockwell Harden from 22 27 O...

Page 275: ...OM S200N V BUCKET OPTION BOOM OP 125 0 mm 4 92 in 85 0 mm 3 35 in 12 0 mm 0 47 in 5 0 mm 0 20 in S130W V ARM S130LC V SHORT ARM S170W V BUCKET S220LC V BUCKET S220LL BUCKET BUCKET 115 0 mm 4 53 in 75...

Page 276: ...n S470LC V ARM S55W V ARM 106 0 mm 4 17 in 66 0 mm 2 60 in 12 0 mm 0 47 in 5 0 mm 0 20 in S80W II ARM 120 0 mm 4 72 in 79 0 mm 3 11 in 10 0 mm 0 39 in 5 0 mm 0 20 in S70 III ARM S80W II BOOM MEGA 130...

Page 277: ...S0705000 Page 9 Cylinders...

Page 278: ...S0705000 Page 10 Cylinders PISTON JIG C 35 A 30 R R15 20 2 B D R F 2 Through Hole 8 15 ARS4740L 4 R5 Figure 7 Material SM45C AISI 1045 Rockwell Harden from 22 27 Oil Quench...

Page 279: ...BUCKET MEGA 200 III LIFT S290LC V ARM S ARM 120 0 mm 4 72 in 13 0 mm 0 51 in 85 0 mm 3 35 in 150 0 mm 5 91 in S290LL BUCKET BOOM S300LC V ARM S ARM S330LC V BOOM BUCKET S340LC V BUCKET BOOM BUCKET OP...

Page 280: ...S0705000 Page 12 Cylinders P S Power Steering O R Out Rigger MODEL CYLINDER A 0 1 B C D MODEL CYLINDER...

Page 281: ...S0705000 Page 13 Cylinders...

Page 282: ...e 14 Cylinders STEEL BUSH JIG 20 A 20 5 A F 15 1 B 40 E ARS4750L B Figure 8 Material SM45C which is done thermal refining QT Hrc 22 28 Undefined Chamfer C R 0 5 Max Place Finally work to used DNMG Tip...

Page 283: ...4 in S70 III ARM BOOM MEGA 200 III LIFT MEGA 200 III TC H C S220LL ARM 90 0 mm 3 54 in 105 0 mm 4 13 in 40 0 mm 1 58 in 6 5 mm 0 26 in S290LC V S ARM ARM S290LL BOOM BUCKET S300LC V S ARM ARM MEGA 250...

Page 284: ...5 51 in 70 mm 2 76 in 11 mm 0 43 in K C S420LC V BOOM K C S400LC V BOOM K C S55W V BUCKET 50 0 mm 1 97 in 60 0 mm 2 36 in 30 0 mm 1 18 in S55 V ARM BOOM OP BUCKET DOZER 65 0 mm 2 56 in 75 0 mm 2 95 in...

Page 285: ...S0705000 Page 17 Cylinders...

Page 286: ...rs DUST WIPER JIG D C DIA B 40 15 3 C1 5 DIA B DIA A DIA A 20 R0 2 1 ARS4760L Figure 9 Material SM45C which is done thermal refining QT Hrc 22 28 Undefined Chamfer C R 0 5 Max Place Finally work to us...

Page 287: ...0 mm 3 31 in 5 5 mm 0 22 in 6 0 mm 0 24 in S80W III BOOM S130W V BOOM S130LC V BOOM MEGA 160 III BUCKET BUCKET 55 0 mm 2 17 in 69 0 mm 2 72 in 5 0 mm 0 20 in 6 0 mm 0 24 in S55 V ARM BOOM BOOM OP BUC...

Page 288: ...0 mm 0 24 in 7 0 mm 2 28 in S290LC V ARM 105 0 mm 4 13 in 121 0 mm 4 76 in 6 0 mm 0 24 in 7 0 mm 2 28 in S290LC V S ARM S300LC V ARM S ARM S370LC V BOOM S ARM 105 0 mm 4 13 in 121 0 mm 4 76 in 6 0 mm...

Page 289: ...0 20 in 6 0 mm 0 24 in S80W III ARM 65 0 mm 2 56 in 79 0 mm 3 11 in 5 5 mm 0 22 in 6 0 mm 0 24 in BOOM 70 0 mm 2 76 in 84 0 mm 3 31 in 5 5 mm 0 22 in 6 0 mm 0 24 in BUCKET 55 0 mm 2 17 in 69 0 mm 2 7...

Page 290: ...S0705000 Page 22 Cylinders SLIPPER SEAL JIG ARS4770L A 2 A A 14 B B 40 5 R 1 0 R1 1 0 Figure 10...

Page 291: ...OIST S290 V BOOM BUCKET S BUCKET BOOM 130 0 mm 5 12 in 28 5 mm 1 12 in S250LC V BUCKET S290LC V ARM 150 0 mm 5 91 in 28 5 mm 1 12 in S290LL BOOM HOIST BUCKET HEEL S290LC V S ARM S300LC V ARM S ARM S34...

Page 292: ...S0705000 Page 24 Cylinders S200W V BOOM 135 0 mm 5 32 in 28 5 mm 1 12 in S220LC V ARM S220N V ARM OP P S Power Steering MODEL CYLINDER A B MODEL CYLINDER 0 2 0 1 0 2 0 1...

Page 293: ...S0705000 Page 25 Cylinders...

Page 294: ...S0705000 Page 26 Cylinders SLIPPER SEAL STRAIGHTENING JIG ARS4780L 2 R1 50 25 100 A 15 A 2 5 R 2 C 1 Figure 11...

Page 295: ...BUCKET S220LL BOOM HOIST S290 V BOOM BUCKET S BUCKET BOOM 130 0 mm 5 12 in S250 V BUCKET S290LC V ARM 150 0 mm 5 91 in S300LC V ARM S ARM S340LC V BOOM BUCKET BUCKET OP S370LC V BOOM BUCKET BUCKET OP...

Page 296: ...S0705000 Page 28 Cylinders S200W V BOOM 135 0 mm 5 32 in S220LC V ARM S220N V ARM OP P S Power Steering CYLINDER A MODEL CYLINDER 0 2 0 1...

Page 297: ...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 parenth...

Page 298: ...d of cylinder wall before using a plastic or other soft faced hammer for final disassembly 5 Begin withdrawing piston rod assembly away from cylinder Attach a lifting support when final 1 3 of rod is...

Page 299: ...through end of rod 8 Remove set screw by using a socket wrench 9 Fabricate or purchase a piston nut removal wrench Dimensions are called off at beginning of this procedure This tool may also be ordere...

Page 300: ...er to evenly pull off rod cover 9 from end of piston rod Be careful not to damage rod bushing 6 and dust wiper U packing and other seals 12 Use a dull rounded tip tool to pry off O ring 11 and backup...

Page 301: ...ing 21 from cylinder head 15 During disassembly of cylinder head be careful not to damage buffer seal 5 and U packing 4 16 Disassemble retaining ring 3 and dust wiper 2 Separate retaining ring 8 and r...

Page 302: ...S0705000 Page 34 Cylinders 17 Force out pin bushing 1 from body of cylinder Figure 28...

Page 303: ...nents install the dust wiper 2 and rod bushing 6 to the rod cover 9 Insert retaining rings 3 and 8 IMPORTANT Replace any part that shows evidence of damage or excessive wear Replacement of all O rings...

Page 304: ...inning 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 du...

Page 305: ...before reassembly 10 Pre apply 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 r...

Page 306: ...S0705000 Page 38 Cylinders...

Page 307: ...ined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load...

Page 308: ...OF CONTENTS General Description 3 Theory of Operation 3 Swing Motor Anti cavitation Make up Valve 4 Relief Valve 5 Swing Brake Operation 5 Parts List 7 Specifications 8 Special Tools 9 Disassembly 10...

Page 309: ...ssure directly on the swash plate 3 to generate oil flow through the motor while force F2 pushes laterally at a right angle against the drive shaft providing the rotational energy to turn the cylinder...

Page 310: ...tage is disengaged while current flow is reduced shifting the spool in the priority valve for increased oil flow to the boom arm side of the circuit SWING MOTOR ANTI CAVITATION MAKE UP VALVE Unlike th...

Page 311: ...function and pressurization of the tank by opening momentarily so that there is no pressure developed through the valve at all Tank pressure at pressurized area A2 is set against spring pressure insid...

Page 312: ...he friction plate 11 split plate 12 and swing motor casing 301 preventing the motor drive shaft from turning When hydraulic pressure is forced to the back side of the brake piston the friction plate a...

Page 313: ...oe Plate 9 Cylinder Block 10 Spring 11 Ball Guide Shaft 12 Ball Guide 13 Set Plate 14 Piston Assembly 15 Friction Plate 16 Plate 17 Brake Piston 18 O ring 19 Spring 20 Valve Plate 21 Pin 22 Needle Bea...

Page 314: ...70 0 kg cm2 3 840 30 psi Maximum Supply Flow Rate 1 950 RPM 280 liter min 73 97 gpm Motor Shaft Speed 1 120 rpm Motor Shaft Torque 107 40 kg m 776 83 ft lb Weight 75 0 kg 165 35 lb Part No Name Dimens...

Page 315: ...SPECIAL TOOLS AND MATERIALS The special tools shown in Figure 5 can be fabricated for use in Swing Motor assembly TOOLS Reference Number Tool Dimension 24 25 12 mm L Wrench M14 28 17 mm L Wrench PF1...

Page 316: ...S0707280 Page 10 Swing Motor Return to Master Table of Contents Figure 6...

Page 317: ...rain port of body 1 3 Position motor with its shaft facing down 4 Match mark the mating part of body 1 and rear cover 23 NOTE Use a rubber mat or other protective covering on the workbench area to pre...

Page 318: ...ve wrench bolt 32 using M6 wrench and time delay valve assembly 31 NOTE Be careful of the remaining oil still on the inside 7 Remove wrench bolt 24 25 rear cover 23 and valve plate 20 NOTE Be careful...

Page 319: ...S0707280 Page 13 Swing Motor Return to Master Table of Contents 8 Pull out spring 19 from brake piston 17 9 Remove brake piston 17 Figure 12 using special tool Figure 8 Figure 9 Figure 10 Figure 11...

Page 320: ...grasp cylinder block 9 and pull out the interior kit NOTE Cylinder block 9 spring 10 ball guide seat 11 ball guide 12 set plate 13 piston assembly 14 friction plate 15 plate 16 and shoe plate 8 11 Re...

Page 321: ...Contents 12 Grasp shaft 5 tap the opposite end of it and remove NOTE Be careful not to damage the machined surface 13 Remove oil seal 2 using special tool NOTE Be careful not to damage the oil seal a...

Page 322: ...refully for cuts nicks brittleness or softness or any other type of damage or distortion prior to final reassembly NOTE When parts exceed the standard replace them When there is conspicuous surface da...

Page 323: ...late must always be replaced as a set If either one requires replacement replace the other Reference Number Description 1 Clearance Between Piston and Cylinder Bore 2 Spring Free Length 3 Piston Ball...

Page 324: ...ompressed air Apply clean hydraulic oil to sliding parts and reassemble them Tighten bolts plugs and tightening parts using torque wrench according to the Tightening Torque List on page 8 1 Install oi...

Page 325: ...on cylinder block 9 in order to prepare cylinder block assembly 3 4 Install shaft subassembly 2 into body subassembly 1 and install snap ring 4 5 Install shoe plate 8 on section No 4 part and install...

Page 326: ...Page 20 Swing Motor Return to Master Table of Contents 6 Install brake piston 17 with O ring 18 on body 1 and install springs 19 NOTE Be careful not to damage O ring 18 Figure 27 Figure 28 Figure 29 F...

Page 327: ...stall valve plate 20 on body 1 8 Install O ring 18 on rear cover 23 and install them on body 1 using wrench bolt 24 25 NOTE Be careful not to damage O ring 18 9 Install time delay valve assembly 31 on...

Page 328: ...in body 1 11 Install O ring 29 on plug 28 Install poppet 26 spring 27 and plug 28 NOTE Be careful not to damage O ring 18 NOTE After assembling cover port parts using clean caps plugs or tapes to pro...

Page 329: ...hop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of saf...

Page 330: ...bleshooting Testing and Adjustment 19 General Precautions 19 Troubleshooting 20 Disassembly 23 General Caution Matters 23 Reduction Gear Part 23 Hydraulic Motor Part 29 Cleaning and Inspection Wear Li...

Page 331: ...ing rotating force Relief valve Brake part Counterbalance valve part Swash tilting part 3 The reduction gear section contains a 3 level planetary gear and differential gear The symbols used for hydrau...

Page 332: ...P x A P Supply pressure A Pressure area The force F1 generates perpendicular force N1 and radial force W1 against swash plate 201 which has a tilting angle of W1 generates torque T T W1 x R1 against t...

Page 333: ...s oil flow at motor s input port to return circuit B If inertial object stops its movement relief valve brakes delivery section to forcibly stop inertial object The chamber A is always connected to po...

Page 334: ...block by splines and applies braking force NOTE When counterbalance spool is in travel mode Position 1 or 3 The pressurized oil flowing from port A or port B is depressurized at decompression valve 3...

Page 335: ...brake piston and brake will be released This state becomes same as brake release pressure is applied Socket wrench 6mm 8mm CAUTION If hydraulic motor does not rotate even after brake is released pump...

Page 336: ...eft direction Working oil in N chamber flows through orifice 1 to F chamber while working oil in chamber F passes G to AV and then is drained to tank If spool moves in direction of Right Left paths L...

Page 337: ...to P port of tilting control valve This pressure becomes save pressure As spool 531 assembled into tilting switching section is in tight contact with plug 571 through spring 533 high pressure in P po...

Page 338: ...n force against rotation force to rotate No 1 carrier C1 In other words No planetary gear P1 does not rotate but revolves Rotation force of No 1 carrier C1 is transmitted to No 2 sun gear S2 through l...

Page 339: ...S0707345K Page 11 Travel Motor with Gearbox...

Page 340: ...S0707345K Page 12 Travel Motor with Gearbox PARTS LIST Hydraulic Motor Figure 9...

Page 341: ...educing Valve 361 Washer 362 C B Spring 364 C B Cover 365 O ring 366 Socket Bolt 401 Socket Bolt 402 Socket Bolt 435 Snap Ring 451 Pin 461 Plug 464 HP Plug 472 O ring 485 O ring 491 Oil Seal 502 Pisto...

Page 342: ...S0707345K Page 14 Travel Motor with Gearbox Reduction Gear Figure 10...

Page 343: ...ing 025 Floating Bush 026 Thrust Ring 60 027 Thrust Ring 90 029 Socket Bolt 030 Socket Bolt 032 P F 1 2 Plug 033 Angular Bearing 034 Floating Seal 035 Shim 036 Spring Pin 037 Snap Ring 044 Snap Ring 0...

Page 344: ...ice 545 546 6 mm PT Plug 564 PF Plug 569 8 mm PF Plug 571 10 mm Socket Bolt 366 17 mm Socket Bolt 401 402 Socket wrench spanner 19 mm VP Plug 567 22 4 mm Relief valve 351 27 mm VP Plug 464 42 mm Relie...

Page 345: ...0 No 2 Carrier 006 Eye Bolt M16 Housing 002 Eye Bolt M20 Shaft Casing 272 Hammer Plastic hammer Also wood hammer is possible Driver Jig for assembling of floating seal Press 1 ton Angular Bearing 033...

Page 346: ...M20x100 17 4 400 461 Plug NPTF 1 16 4 90 464 VP Plug PF 1 4 27 1 100 545 Orifice NPTF 1 16 4 70 546 Orifice NPTF 1 16 4 70 564 Plug PF 1 4 6 220 567 VP Plug PF 1 4 19 370 569 Plug PF 1 4 6 370 571 Pl...

Page 347: ...ADJUSTMENT GENERAL PRECAUTIONS 1 If a defect is identified check to see if same problem has ever occurred before 2 When taking corrective action handle each part carefully Use care not to cause possi...

Page 348: ...tor damaged Check the relief valve Replace hydraulic motor Gear damaged Replace Motor Replace the reduction gear Replace the reduction gear Oil flow path in valve casing and shaft casing cracked Relea...

Page 349: ...r mating plate seized or deformed Replace non conforming parts Replace the brake piston casing Yes Yes No Operation of brake piston Damage to spring Friction plate separate plate swings lightly No No...

Page 350: ...ring damaged and sealing force eteriorated Tighten to the specified torque Replace Plug loosened E Temperature of casing is high Atmospheric temperature 60 C or higher Reduction gearbox generates heat...

Page 351: ...on assembly cross section diagram 4 The piping side of motor should be called Rear while output side Front REDUCTION GEAR PART 1 Choose a good place for disassembly work NOTE Choose a clean place Plac...

Page 352: ...044 disassemble side plate 018 No 1 planetary gear 012 and needle cage 021 NOTE If any flaking is found on surface of inner race 024 remove race from No 1 carrier and replace it with a new one At same...

Page 353: ...ssembly A Remove spring pin 036 and remove No 2 pin 016 from No 2 carrier NOTE Check for following before disassembly and if there is abnormality disassemble it 1 Check surface of planetary gear teeth...

Page 354: ...t bolt 029 attach two M8 eyebolts then use a crane to disassemble ring gear 001 Remove O ring 082 from housing 002 NOTE Use a hex wrench and pipe to disassemble it It has been coated with LOCTITE for...

Page 355: ...Remove nut ring 047 from shaft casing 272 NOTE After disconnecting nut ring from set screw blow set screw assembly part to remove foreign materials and then disassemble nut ring by using jig for disa...

Page 356: ...NOTE Be careful not to damage O ring surface and seat 16 Remove floating seal 034 from shaft casing 272 Do not damage it NOTE Be careful not to damage O ring surface and seat 17 Remove angular bearing...

Page 357: ...MOTOR PART Disassembly of Main Body of Motor Section 1 Place output side of hydraulic motor facing down and fix it 2 Remove relief valve 35 decompression valve 351 and adjustment cover 352 from valve...

Page 358: ...traint and tighten them to subassemble valve casing and brake piston 4 Remove socket bolts 401 402 tightened with valve casing 303 5 Remove socket bolts and valve plate 131 together with valve casing...

Page 359: ...Motor with Gearbox 7 Remove cylinder block and piston assembly NOTE Be sure to place motor in level position 8 Remove swash plate 201 9 Remove pivot ball 504 and tilting piston assembly Figure 39 Figu...

Page 360: ...aring 102 if it does not need to be replaced 11 Remove oil seal 491 from shaft casing 272 NOTE Never reuse oil seal 491 Replace it with a new one when assembling Disassembly of Valve Casing Subassembl...

Page 361: ...NOTE Do not disassemble tilting switching system if it functions properly Do not disassemble needle bearing 103 if it is OK Disassembly of Cylinder Block Assembly 1 Remove cylinder block assembly wit...

Page 362: ...N WEAR LIMITS AND TOLERANCES For general cleaning and inspection procedures refer to General Maintenance Procedures section MAINTENANCE STANDARD Change parts with standard of following table If parts...

Page 363: ...mm Even if one each of recommended value of replacement is not reached replace Cylinder spline 49 06 mm 48 46 mm Over pin diameter 4 5 of spline inside of cylinder and spherical bushing 35 25 mm 35 7...

Page 364: ...45K Page 36 Travel Motor with Gearbox 2 Thickness of shoe t 3 Vibration of vertical direction of piston and shoe 4 Height difference of spherical bushing and pressure plate H h Figure 52 Figure 53 Fig...

Page 365: ...Z 25 Ring gear for level 1 and 2 Overpin 299 33 6 75 299 93 mm Replace Z 76 No 3 sun gear Base tangent length 54 92 4 pcs 54 62 mm Replace Z 25 No 3 planetary gear Base tangent length 54 93 4 pcs 54 6...

Page 366: ...sary to use a hammer etc use a plastic hammer to gently tap work piece into position 4 Numbers in behind part name indicate part indication No on assembly cross section diagram HYDRAULIC MOTOR PART Re...

Page 367: ...disassembly Assembly of Valve Casing Subassembly 1 Assemble seat 541 steel ball 543 stopper 542 and plug 569 NOTE Be careful of assembly direction of seat and stopper NOTE Tightening torque for plug...

Page 368: ...1 NOTE Tightening torque for plug 571 750kgf cm 5 Install orifice 703 into brake piston NOTE Tightening torque 35kgf cm 6 Attach brake spring 705 to brake piston 702 and insert M10x135 socket bolts in...

Page 369: ...lock 111 NOTE Align cylinder with spline of spherical bushing 2 Insert piston 121 and shoe 122 assembly into plate 123 and assemble it on cylinder block 3 Assemble plug 461 and orifices 545 and 546 on...

Page 370: ...jig for oil seal 491 to assemble oil seal 491 to shaft casing 272 5 Fit drive shaft subassembly and assemble snap ring 435 NOTE Use key for outer race of roller bearing 102 and gently tap it with a ha...

Page 371: ...Coat rear side of swash plate 201 with and then assemble it to shaft casing 272 NOTE Check swash plate for smooth movement 8 Turn shaft casing 272 so it is in a horizontal position and then assemble c...

Page 372: ...friction plate 742 onto shaft casing 272 and cylinder 111 respectively 11 Assemble O rings 707 708 into shaft casing 272 NOTE When reassembling replace O ring with a new one 12 Position valve plate 13...

Page 373: ...embling valve casing to shaft casing Tightening torque for socket bolts 401 and 401 4400 kgf cm 13 Assemble plug relief valve 35 and decompression valve 351 into valve casing subassembly to specified...

Page 374: ...NOTE When reusing housing use M16 tap to completely remove adhesive such as Teflon from M16 thread 2 Assemble O ring of floating seal 034 to seat and then to housing 002 NOTE Lightly coat O ring with...

Page 375: ...ith bearing inserted insert nut ring 047 with shim 035 into shaft casing Use assembly jig to tighten it to specified torque NOTE Tighten nut ring to shaft casing to maximum torque 5000 kgf cm and then...

Page 376: ...Guide groove should face up 9 Install needle cage 023 inside No 3 planetary gear 014 and assemble side plate 020 on both sides then insert gear assembly into shaft casing NOTE Align pin hole of shaft...

Page 377: ...coat O ring with grease When reassembling use a new O ring 12 Install socket bolts 029 to secure housing 002 and ring gear 001 together NOTE Tightening torque is 3000 kgf cm NOTE Use LOCTITE 636 on bo...

Page 378: ...into No 2 carrier NOTE Align carrier pin with center of planetary gear D Insert spring pin 036 into pin hole of No 2 carrier and caulk it at two places with a punch so that it may not be fallen out 14...

Page 379: ...carrier 005 in No 2 sun gear 010 and secure into position with clip 045 C Position thrust ring 026 on No 2 sun gear 010 NOTE Pay attention to assembly direction of thrust ring Guide groove should face...

Page 380: ...ines and engage No 1 planetary gears 18 Using ring gear 001 as a measuring surface measure distance from it to top side of No 1 sun gear The dimension A the value after subtracting thickness of jig 19...

Page 381: ...tall washer 053 and thrust ring 026 which have been selected using above formula on side cove r 004 NOTE Be sure to caulk thrust ring with guide groove facing up 22 Install new O ring 081 on ring gear...

Page 382: ...Test Equipment Is Available If any built in part has been replaced be sure to carry out performance test after conducting test operation in accordance with following conditions 1 Conditions for test o...

Page 383: ...s If on site performance test is unavoidable as test equipment is not available Attach and pipe TM motor to equipment with shoes not attached conduct test operation and then carry out performance test...

Page 384: ...ntry of foreign material into oil may cause premature wear on sliding parts resulting in stick or seizure To prevent such defects be sure to install a filter of 10 m or less within circuit GEAR OIL Ki...

Page 385: ...sition check port PF 1 2 vertically See external dimension diagram and add oil until oil it is present at level port approximately 5 5 liter GENERAL CAUTION MATTERS 1 Check whether there are loose bol...

Page 386: ...S0707345K Page 58 Travel Motor with Gearbox...

Page 387: ...s outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling...

Page 388: ...the Intermediate Wheel 27 Remove Auxiliary Drive 30 Inspection 33 Re fitting the Rotary Group 38 Pump Assembly 40 Hydraulic Component Measurement D 43 Measuring Device Hydraulic Component 452 269 43...

Page 389: ...S0708355K Page 3 Main Pump Rexroth SECTIONAL VIEW A8VO140LA1KH1 63 AUS0010L Figure 1...

Page 390: ...S0708355K Page 4 Main Pump Rexroth AUS0020L Figure 2...

Page 391: ...EPAIR GUIDELINES NOTE Observe the following cautions when carrying out repairs on hydraulic units 1 Close off all openings of hydraulic unit 2 Replace all seals Use only original spare parts ASS1140L...

Page 392: ...sealing and sliding surfaces for wear NOTE Rework of sliding surfaces using crocus cloth or other similar materials can damage the surface 4 Fill hydraulic unit with hydraulic oil before putting into...

Page 393: ...0708355K Page 7 Main Pump Rexroth SEAL KITS AND SUB ASSEMBLIES 1 Seal kit for drive shaft 2 Peripheral seal kit 3 Rotary group 1 ready to install ASS0070L Figure 8 ASS0080L Figure 9 ASS0090L Figure 10...

Page 394: ...nent order rotary groups 1 and 2 separately NOTE Adjustment is necessary NOTE Pay attention to direction of rotation 6 Rotary group 1 mechanical section ready to install 7 Rotary group 2 mechanical se...

Page 395: ...S0708355K Page 9 Main Pump Rexroth 8 Control pre adjusted 9 Gear pump complete 10 Intermediate gear AUS0440L Figure 15 AUS0450L Figure 16 AUS0460L Figure 17...

Page 396: ...S0708355K Page 10 Main Pump Rexroth 11 Auxiliary drive 12 Valve plate with valves 13 Pipe complete with fittings AUS0470L Figure 18 ASS0180L Figure 19 AUS0480L Figure 20...

Page 397: ...S0708355K Page 11 Main Pump Rexroth SEALING THE DRIVE SHAFT 1 Protect drive shaft e g with tape 2 Remove retaining ring 3 Press off cover ring ASS0210L Figure 21 AUS0030L Figure 22 AUS0040L Figure 23...

Page 398: ...1 cover ring 2 drive shaft 3 housing 4 O ring 5 and shim 6 5 Remove old shaft seal 6 Press in shaft seal 7 If the shaft is deeply scored insert the shim provided in front of the shaft seal AUS0050L Fi...

Page 399: ...Grease O ring as well as the seal and dust lips of the drive shaft 9 Install cover ring 10 Install retaining ring tapping home until it springs into place carry out visually check to ensure that the...

Page 400: ...S0708355K Page 14 Main Pump Rexroth GEAR PUMP SEALING Remove gear pump Visually check 1 O ring AUS0120L Figure 31 AUS0130L 1 Figure 32...

Page 401: ...S0708355K Page 15 Main Pump Rexroth 2 Sealing surface of the housing 2 AUS0140L Figure 33...

Page 402: ...S0708355K Page 16 Main Pump Rexroth REMOVE THE CONTROL HOUSING 1 Place pump into a disassembly assembly device with a crane and secure it into position AUS0150L Figure 34 AUS0160L Figure 35...

Page 403: ...emove screws holding port plate 3 Using a suitable lifting device remove port plate NOTE Mark installation position NOTE Be careful control lenses can fall out 4 Remove paper seal clean sealing surfac...

Page 404: ...isassembly of regulator measure distance X of adjustment screw and record value Number Description 1 Setting Screw Qmax 2 Setting Screw Hydraulic Stroke Limitation 3 Setting Screw Power Characteristic...

Page 405: ...S0708355K Page 19 Main Pump Rexroth CONTROL MODULE CONTROL MODULE LR Remove and disassemble control module LR AUS0190L Figure 40 ASS0350L Figure 41...

Page 406: ...S0708355K Page 20 Main Pump Rexroth Remove and disassemble control module AUS0200L Figure 42 AUS0210L Figure 43...

Page 407: ...S0708355K Page 21 Main Pump Rexroth REMOVING THE CONTROLLER 1 Remove cover NOTE Do not change the setting of adjustment screw 1 Figure 44 AUS0220L 1 Figure 44 ASS0390L Figure 45...

Page 408: ...s NOTE Install control lens torque support 3 Remove locking screw and replace with a new one NOTE Loosen adhesive with a gentle flame approximately 120 C 4 Remove swivel pin ASS0400L Figure 46 Figure...

Page 409: ...S0708355K Page 23 Main Pump Rexroth VALVE PLATE WITH VALVES 1 Pressure relief valve 2 Electro proportional pressure reducing valve EPPR ASS0440L 1 2 Figure 50...

Page 410: ...Page 24 Main Pump Rexroth REMOVE THE ROTARY GROUPS 1 Remove cylinder Take out the drive shaft without cylinder 2 Remove cup springs 1 and spring cup 2 AUS0230L Figure 51 ASS0470L Figure 52 ASS0480L F...

Page 411: ...25 Main Pump Rexroth 3 Note disassembly position 1 2 and 3 Figure 54 4 Press out rotary group with an appropriate device 1 2 3 Rotary Group 1 AUS0240L Rotary Group 2 Figure 54 AUS0250L 2 2 2 2 2 1 1 1...

Page 412: ...ied through torque NOTE 1 Fixing screw Retaining device 2 Removal of screws is only possible if drive shaft is warmed up to a temperature of approximately 120 C for 1 2 hour in an oil bath or heat air...

Page 413: ...7 Main Pump Rexroth REMOVE THE INTERMEDIATE WHEEL 1 Press bolt Figure 57 into gear wheel Fixed pressing fit NOTE Can only be disassembled with a hydraulic press 2 Remove bearing AUS0270L Figure 57 AUS...

Page 414: ...S0708355K Page 28 Main Pump Rexroth Install sleeve NOTE Press out bolt with a hydraulic press 3 Remove gear wheel through side drive opening AUS0290L Figure 59 ASS0540L Figure 60...

Page 415: ...S0708355K Page 29 Main Pump Rexroth 4 Remove bearing with extraction device ASS0550L Figure 61...

Page 416: ...S0708355K Page 30 Main Pump Rexroth REMOVE AUXILIARY DRIVE 1 Remove screws and auxiliary drive 2 Press off bearing cap AUS0300L Figure 62 ASS0570L Figure 63 ASS0580L Figure 64...

Page 417: ...leakage visually check O ring housing and groove 4 Install extractor device 5 Pull out output pinion 6 Install bearing extractor device 7 Completely mount device and pull out bearing ASS0590L Figure 6...

Page 418: ...S0708355K Page 32 Main Pump Rexroth 8 Pull out pinion bearing ASS0640L Figure 69...

Page 419: ...exroth INSPECTION 1 Check to see that bearing bore is free of scores and that there is no evidence of wear 2 Visually check To ensure that bearing seats are free of scores AUS0310L Figure 70 ASS0650L...

Page 420: ...with retaining plate installed 5 Drive shafts Check to ensure that cups are free of scores and that there is no pitting 1 Figure 75 Check to see that there is no evidence of corrosion and wear steps 2...

Page 421: ...dence of wear 9 Check cylinder block control lens Bores 1 Figure 79 are free of scores no evidence of wear Faces 2 Figure 79 are even that there are no cracks no scores Side guides 3 Figure 79 show no...

Page 422: ...scores Seal 2 Figure 81 12 Complete rotary group NOTE Adjustment of the hydraulic component is necessary Mechanical component drive shaft is adjusted with the bearing 1 Figure 82 Hydraulic component...

Page 423: ...S0708355K Page 37 Main Pump Rexroth 13 Rotary group All of the components Adjustment Figure 83 For adjustment values and torque values see service information AUS0320L Figure 83...

Page 424: ...rews 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 3 Insert spring plate 1 Figure 86 and...

Page 425: ...ll parts are assembled in correct order and orientation 5 Insert pistons into cylinder Using a soft surface as a support to prevent sliding surfaces from being damaged Pre assemble both rotary groups...

Page 426: ...1 Warm up housing to approximately 80 C 2 Insert the pre assembled rotary group 1 taking into account gear tooth marks 3 Insert pre assembled rotary group 2 being sure to align gear tooth marks ASS083...

Page 427: ...S0708355K Page 41 Main Pump Rexroth 4 Gear tooth marks must align with each other ASS0860L Figure 92...

Page 428: ...he 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 dimen...

Page 429: ...vice Centering Device 1 Intermediate Ring 4 Shim 5 S H C S 6 Intermediate Plate 7 1x 2x 2x 2x 2x 80 9452269 9452019 9452014 9083277 9083105 107 9452269 9452022 9452014 9083277 9083105 140 9452269 9452...

Page 430: ...g position is used The numbers on the top of the measuring device Figure 94 refer to the piston diameter 1 Install intermediate ring or plates onto the housing A Size 80 107 Figure 97 Size Mounting Po...

Page 431: ...until the stop is reached Set dial gauge to zero A Size 80 107 Figure 99 B Size 140 200 Figure 100 MEASURING PROCEDURE 1 Turn down by 4 turns on the dial gauge Check 2 mm clearance set dial gauge to Z...

Page 432: ...h B Size 140 200 Figure 102 2 Turn down using the hand wheel until resistance is met Read the measured value NOTE Do not use excessive force A Size 80 107 Figure 103 B Size 140 200 Figure 104 ASS0960L...

Page 433: ...in into correct position and orientation Take hardening time and tightening torque into account NOTE Tightening Torques M6 8 5 Nm 0 87 kg m 6 27 ft lb M8 14 Nm 1 43 kg m 10 33 ft lb M10 35 Nm 3 57 kg...

Page 434: ...ng torques into account 3 Install control housing 4 Install control lens in their correct position using grease to hold them in place AUS0360L Figure 107 AUS0370L Figure 108 Direction of rotation coun...

Page 435: ...S0708355K Page 49 Main Pump Rexroth 5 Install seal and controller AUS0380L Figure 110 AUS0390L Figure 111...

Page 436: ...re 112 into housing 2 Install and align intermediate wheel 2 Figure 112 through side drive opening 3 Cool down bolt 3 Figure 112 with nitrogen and install it 4 Press in bearing 4 Figure 112 5 Press be...

Page 437: ...S0708355K Page 51 Main Pump Rexroth INSTALLATION OF GEAR PUMP Install front cover AUS0410L Figure 114 AUS0420L Figure 115...

Page 438: ...S0708355K Page 52 Main Pump Rexroth INSTALLATION OF COVER AUXILIARY DRIVE AUS0430L Figure 116...

Page 439: ...2 socked head cap screws DIN 931 hexagon bolt or DIN 933 hexagon bolts with threads up to the head Thread Tensile Strength Class 8 8 10 9 12 9 Tightening Torque M A In Nm M 3 1 1 1 6 1 9 M 4 3 1 4 5 5...

Page 440: ...Nm Thread Tightening Torque M A In Nm M8 x 1 5 G 1 8 A 10 M10 x 1 10 G 1 4 A 30 M12 x 1 5 20 G 3 8 A 35 M14 x 1 5 30 G 1 2 A 60 M16 x 1 5 35 G 3 4 A 90 M18 x 1 5 40 G 1 A 140 M20 x 1 5 50 G 1 1 4 A 24...

Page 441: ...n Pump Rexroth SEAL LOCK SEALING NUTS TO N 02 100 Thread Tightening Torque M A In Nm M6 10 M6 x 0 5 11 M8 22 M8 x 1 24 M10 40 M10 x 1 44 M12 69 M12 x 1 5 72 M14 110 M14 x 1 5 120 M16 170 M16 x 1 5 180...

Page 442: ...S0708355K Page 56 Main Pump Rexroth...

Page 443: ...outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling...

Page 444: ...rallel Orifice for Arm 20 Relief Valve 21 Combined Operation 22 Bucket Combined Operation 24 Antidrift Valve 25 Main Relief Valve 26 Overload Relief Valve 69 Total Six Places 27 Low Pressure Relief Va...

Page 445: ...2 Disassembly 43 General Instructions for Disassembly 43 Disassembly of Main Spool Part 43 Disassembly of Arm 1 Para Spool Turn 44 Disassembly of Arm Regeneration Release Valve Part 45 Disassembly of...

Page 446: ...rift Valve Assembly 52 Reassembly Procedure of Control Valve Body 53 Reassembly of Relief Valve 53 Reassembly of Load Check Valve 53 Reassembly of Antidrift Valve 54 Reassembly of Spare Section Part 5...

Page 447: ...ports T1 T2 and T3 Oil supplied to port P1 flows through neutral passage R1 to low pressure relief valve orifice Rc1 then to tank passage Ta and returns to ports T1 T2 and T3 The pressures of low pre...

Page 448: ...S0709401K Page 6 Main Control Valve Kayaba Figure 1...

Page 449: ...S0709401K Page 7 Main Control Valve Kayaba Figure 2...

Page 450: ...d land Rc3 into tank passage Ta 2 The same oil supplied to port PP then flows through orifice Lc5 into port PA and it also flows through passages L4 7 and R4 to bucket spool land Rc4 and then flows in...

Page 451: ...S0709401K Page 9 Main Control Valve Kayaba...

Page 452: ...allel passage R3 and passage S6 1 are equal so poppet S6 2 does not open 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 Lc...

Page 453: ...S0709401K Page 11 Main Control Valve Kayaba Figure 4...

Page 454: ...A3 B3 to spool and is returned to tank passage Ta Bucket Spool Shifting 1 Oil flow control in bucket section portion of valve is different from other sections because it has a regeneration function th...

Page 455: ...passage R1 is closed Oil supplied to port P2 flows through parallel passage R3 load check valve S7 2 passage S7 1 spool and into port A7 Oil flows through port B7 and one portion of the oil returns th...

Page 456: ...ting 1 Neutral This valve also works with anti drift valves that are installed on the bottom side of each boom cylinder When in neutral poppet AD1 Figure 7 is closed by port A8 pressure that is sent t...

Page 457: ...t P2 flows through parallel passage R3 and load check valve S8 2 to spool and flows into port A8 When boom 2 spool is shifted by increasing pressure of boom 2 section 4 pilot port Pb4 neutral passage...

Page 458: ...h parallel passage R3 and load check valve S8 2 to spool and flows into port B8 When spool AD3 of antidrift valve is shifted by increasing pressure of port P2 poppet AD1 is opened by decreasing of pre...

Page 459: ...ting 1 Neutral This valve also works with an anti drift valve that is installed on rod side of the arm cylinder When in neutral poppet AD1 Figure 10 is closed by port A5 pressure that is sent through...

Page 460: ...spool into port B5 When arm 2 spool is shifted by increasing pressure of arm 2 section 9 pilot port pb9 oil supplied to port P2 flows through neutral passage R1 load check valve S9 1 passage S9 2 and...

Page 461: ...passage Ta The other portion of the oil flows through fixed orifice b regeneration check c and fixed orifice i in arm 1 spool and joins in bridge passage S5 1 From there if load pressure of port B is...

Page 462: ...9 1 spool and passage 8 and joins at port A5 Return oil from port B5 returns through spool to tank passage Ta Parallel Orifice for Arm The orifice that is installed in parallel passage for arm 1 contr...

Page 463: ...valve The highest pressure of pump P1 and P2 is controlled by reaction 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...

Page 464: ...el Pump 2 50 Section 6 Travel 50 If there is no travel straight circuit machine will travel in zig zag manner PT closed The oil passage is closed at the signal land Lc4 Lc7 Rc3 and Rc5 PA closed The o...

Page 465: ...S0709401K Page 23 Main Control Valve Kayaba Figure 16...

Page 466: ...piston S7 6 piston S7 5 and plug S7 4 are pressed and poppet assembly S7 2 is seated on valve housing This causes oil flowing from parallel passage R3 to open poppet S7 3 in poppet assembly and flow i...

Page 467: ...m port A5 is cut off by seat S1 and seat S2 2 Cut off condition of passage of port A5 Figure 19 and spring chamber A If port pc1 is pressurized piston 2 is moved and spool 3 reacts B Spool 3 activates...

Page 468: ...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 3 As pilot poppet F ope...

Page 469: ...ure 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 3 As p...

Page 470: ...der port HP to eliminate cavitation LOW PRESSURE RELIEF VALVE 70 TOTAL TWO PLACES Generation of Signal Pressure Oil supplied from pump port P1 P2 flows through neutral passage L1 R1 low pressure relie...

Page 471: ...orifice Lc1 Rc1 goes to back chamber of poppet and poppet operates by the difference of pressurized area between passage and back chamber By operation of this poppet oil flows from passage through plu...

Page 472: ...Main Control Valve Kayaba PARTS LIST 75 69 37 69 92 77 81 75 52 74 76 L L B B A A C D E F G H I C D E F G H I K K 71 74 78 72 37 69 90 72 75 37 90 69 43 72 75 89 88 73 37 72 92 68 52 76 J J X VIEW X A...

Page 473: ...Page 31 Main Control Valve Kayaba Figure 33 8 15 16 17 5 70 13 7 8 12 8 8 8 8 8 70 2 3 4 5 6 7 1 63 SECTION A1 A1 61 62 33 32 72 57 SECTION A A SECTION B B SECTION L L SECTION K K X 41 Y 42 X 41 Y 42...

Page 474: ...0 7 6 5 103 104 36 SECTION C C SECTION D D SECTION E E SECTION G G SECTION H H SECTION J J SECTION I I DETAIL F1 F1 SECTION F F 34 35 53 55 54 51 35 36 36 72 72 47 49 50 45 36 44 91 105 67 38 39 35 3...

Page 475: ...5 Spring 36 O ring 37 Flange 38 Poppet 39 Spring 40 Spacer Assembly 41 O ring 42 O ring 43 Flange 44 Poppet 45 Spring 46 Plug 47 O ring 48 Spring 49 Poppet 50 Steel Ball 51 Poppet 52 Flange 53 Spacer...

Page 476: ...er Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End 5 Plug 6 Poppet 7 Spring 8 O ring 9 Backup Ring Reference Number Descr...

Page 477: ...sembly 14 Arm1 Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description 1 Spool 2 Sp...

Page 478: ...Regeneration Release Valve Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description...

Page 479: ...7 Main Control Valve Kayaba Spacer Assembly 40 Plug Assembly 60 Reference Number Description 1 Spacer 2 O ring 3 Backup Ring 4 O ring Reference Number Description 1 Plug 2 O ring 3 O ring 4 O ring Fig...

Page 480: ...mbly 67 Figure 47 Reference Number Description 1 Body 2 Poppet 3 Plug 4 Piston 5 Spool 6 Sleeve 7 Spring 8 Spring 9 O ring 10 O ring 11 Backup Ring 12 Backup Ring 13 O ring 14 Plug Assembly 15 Plug As...

Page 481: ...ing 6 O ring Reference Number Description 1 Plug 2 O ring 3 O ring 4 Backup Ring Control Valve Specification Rated Flow 270 liter min 50 liter min at Neutral Max Pressure 34 3 MPa Allowable Back Press...

Page 482: ...cap crisscrossed Remove center and retighten cap Valve temperature uneven Warm up entire system Dirt in valve Clean valve flushing Lack of pilot pressure Check pilot valve and pilot relief pressure F...

Page 483: ...Remedy Pressure does not rise Stuck main poppet sleeve or pilot poppet opened or dirt in seat part Replace relief valve Relief pressure unstable Seat parts of pilot poppet damaged Piston or main poppe...

Page 484: ...ighten lock nut 7 after pressure has been adjusted 6 Recheck pressure setting by raising pressure once more Over Load Relief Valve 1 Shift control valve spool and read pressure gauge from stroke end o...

Page 485: ...own as assembly part number further part number Disassembly of Main Spool Part 1 Remove socket head bolt 74 two places per each section width across flats 8 mm and cap 8 ten places 2 Remove plug assem...

Page 486: ...pool end 22 width across flats 5 mm spring seat 20 and spring 21 from spool 19 IMPORTANT Work with spool gripped in vise with wood see Figure 50 not to scratch outside diameter of spool Because Loctit...

Page 487: ...on C C 7 Remove spring 33 and poppet 32 from valve housing 8 Remove plug 72 width across flats 8 mm section L L 9 Remove spacer 57 spring 33 and poppet 32 from valve housing 10 Remove plug 92 width ac...

Page 488: ...emove plug assembly 67 14 width across flats 38 mm and O ring B Remove piston 67 4 spool 67 5 and spring 67 7 C Remove plug 67 3 width across flats 38 mm and O ring D Remove sleeve 67 6 and poppet 67...

Page 489: ...ts 36 mm and O ring 5 Remove plug assembly 71 width across flats 6 mm and O ring 6 Remove plug assembly 72 width across flats 8 mm and O ring Disassembly of Valve Housing Combined Bolt 1 Remove socket...

Page 490: ...t 4 and plug 1 and replace O ring 3 If oil is leaking from nut 7 remove nut 7 and plug 8 and replace O ring 3 Disassembly of Overload Relief Valve This relief valve should be replaced as an assembly W...

Page 491: ...75 mm and O ring 2 If oil is leaking from adjusting kit 3 remove adjusting kit 3 and replace O ring 4 Disassembly of Low Pressure Relief Valve This unit has press fit portion D so that it should be re...

Page 492: ...ion inspect it using relief valve maintenance procedure 6 Replace all O rings and backup rings with new ones 7 After disassembling cap or plug check whether there are paint chips around body hole or p...

Page 493: ...e inlet At this time be careful not to touch applying part to spring seat PROCEDURE OF SUBASSEMBLY Reassembly of Spool Assembly Main Spool 1 Apply Loctite to threaded portion of spool 2 6 14 17 and in...

Page 494: ...4 Install spring 67 7 and piston 67 4 in plug 67 3 5 Tighten plug assembly 67 14 with O ring installed on plug 67 3 Tightening torque 14 99 16 01 kg m 108 116 ft lb 6 Install O ring 67 13 on plug 67...

Page 495: ...47 ft lb 4 Install poppet 51 and spring 35 in common section I I Insert spacer 53 with O ring 54 and backup ring 55 Tightening torque 3 98 4 49 kg m 29 32 ft lb 5 Install O ring 36 on spare section se...

Page 496: ...O ring 89 on cap 88 two places and fasten it in place with socket head bolt 76 Tightening torque 5 91 6 53 kg m 43 47 ft lb 2 Install O ring and backup ring on plug assembly 87 two places Install plu...

Page 497: ...t lb 3 Tighten orifice plug 63 Tightening torque 1 43 1 84 kg m 10 33 13 28 ft lb 4 Install O ring on plug assembly 92 and install Tightening torque 20 90 23 15 kg m 151 167 ft lb 5 Install O ring on...

Page 498: ...S0709401K Page 56 Main Control Valve Kayaba Figure 54...

Page 499: ...t pressure by referring to Over Load Relief Valve on page 42 NOTE The torque values are based on use of lubricated threads Reassembly of Low Pressure Relief Valve Check if there is dirt and paint chip...

Page 500: ...RT UP PROCEDURES 1 Before operating machine make sure that oil passages and hydraulic oil are clean 2 Hydraulic oil of which annealing point is 82 113 C should be used in the hydraulic system 3 Relief...

Page 501: ...d safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capabl...

Page 502: ...OF CONTENTS General Description 3 Theory of Operation 3 Structure 3 Function 3 Parts List 4 Specifications 5 Torques 5 Performance 6 Removal 6 Disassembly 9 Cleaning and Inspection Wear Limits and Tol...

Page 503: ...eutral mode the spool is thrust upward by return spring and the force of balancing spring which determines the secondary discharge pressure is not transmitted to the spool The input port is closed and...

Page 504: ...S0709451K Page 4 Pilot Control Valve Work Lever Joystick PARTS LIST 30 29 26 23 24 13 22 21 17 31 15 16 36 32 33 34 35 1 2 3 5 4 6 7 9 10 8 28 27 25 14 19 18 12 11 20 ARS2260L Figure 1...

Page 505: ...ing Pin 30 Handle Assembly 31 Bushing 32 Terminal 33 Seal Wire 34 Housing 35 Holder Rear 36 Clip Band Reference Number Description Pilot Control Valve Specification Type Pilot Control 2 Stage Joystick...

Page 506: ...joysticks in all directions to relieve pressure from accumulators 7 Set safety lever on LOCK position 8 Turn key to OFF position and remove from starter switch 9 Hang maintenance warning tag on contr...

Page 507: ...2 and pull remote control valve LH 1 out 15 Tag and disconnect hoses from remote control valve LH 1 Figure 5 Plug and cap hoses and ports to prevent contamination from entering hydraulic system or co...

Page 508: ...e four bolts 3 Figure 7 and cover 2 and pull remote control valve RH 1 out 20 Tag and disconnect hoses from remote control valve RH 1 Figure 7 Plug and cap hoses and ports to prevent contamination fro...

Page 509: ...ilot Control Valve Work Lever Joystick DISASSEMBLY 1 Lift up the boot 28 and pull the switch cord through the hole in the case 1 2 Loosen nut 27 from hex nut 25 and remove handle assembly 30 Figure 8...

Page 510: ...age 10 Pilot Control Valve Work Lever Joystick 3 Remove hex nut 25 and swash plate 24 4 Remove joint 23 from case 1 5 Remove plate 21 6 Press spring 10 and remove plug 18 Figure 11 Figure 12 Figure 13...

Page 511: ...reduction valve 6 7 8 9 11 and spring 10 8 Remove plug 3 and four plugs 2 9 Remove stopper 11 from pressure reduction valve 6 7 8 9 11 10 Remove spool 6 spring seat 9 spring 8 and shim 7 IMPORTANT Mar...

Page 512: ...S0709451K Page 12 Pilot Control Valve Work Lever Joystick 11 Remove push rod 14 and plug 18 12 Remove O ring 19 from plug 18 13 Remove seal 20 from plug 18 Figure 19 Figure 20 Figure 21...

Page 513: ...ck CLEANING AND INSPECTION WEAR LIMITS AND TOLERANCES For general cleaning and inspection procedures refer to General Maintenance Procedures section Clean all parts and dry them with compressed air Ke...

Page 514: ...3 slowly NOTE Tightening torque 350 kg cm 25 3 ft lb Tighten four plugs 2 NOTE Use Loctite 592 pipe sealant on plugs NOTE Tightening torque 150 kg cm 10 9 ft lb 2 Install shim 7 spring 8 spring seat...

Page 515: ...lve Work Lever Joystick 4 Install spring 10 in case 1 and pressure reducing valve assembly 6 7 8 9 11 5 Install seal 20 on plug 18 6 Install O ring 19 on plug 18 7 Install push rod 14 on plug 18 Figur...

Page 516: ...Valve Work Lever Joystick 8 Install spring 13 on stopper 12 9 Position stopper 12 and spring 13 on pressure reducing valve 10 Install plug 18 in case 1 11 Install plate 21 and tighten joint 23 Figure...

Page 517: ...nstall hex nut 25 and tighten swash plate 24 NOTE Tightening torque 1 240 kg cm 89 7 ft lb 14 Pull cord and tube out through hole of hex nut 25 15 Align the direction of handle 30 and tighten hex nut...

Page 518: ...S0709451K Page 18 Pilot Control Valve Work Lever Joystick 16 Grease joint 23 swash plate 24 and push rod 14 17 Install boot 28 Figure 37 Figure 38...

Page 519: ...ews two bolts and washers 7 and 8 Figure 40 and cover 4 4 Install a screw three bolts and washers 6 Figure 40 and cover 3 Push cap 5 into cover 3 5 Install four bolts and washers 2 Figure 40 and cover...

Page 520: ...Push cap 5 into cover 3 10 Install four bolts and washers 2 Figure 42 and cover 1 START UP PROCEDURES 1 Start engine and set throttle at LOW IDLE 2 Set safety lever on UNLOCK position 3 Slowly cycle b...

Page 521: ...is manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimatel...

Page 522: ...ry of Operation 3 Pressure Reducing Valve 3 Operating Theory of Damper Mechanism 5 Parts List 6 Specification 7 Torque 7 Troubleshooting Testing and Adjustment 8 Removal 9 Disassembly 11 Cleaning and...

Page 523: ...port T through inner hole of spool 2 Half Operation Condition 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 prima...

Page 524: ...tted through inner hole of spool to operating 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...

Page 525: ...amber of upper part of low pressure at this time ball check valve becomes closing condition because high pressure operates to vibration prevention chamber of lower part 2 Operation When Operating Leve...

Page 526: ...20K Page 6 Travel Control Valve With Damper PARTS LIST 32 24 23 22 16 21 13 12 11 9 5 4 3 10 8 6 7 19 20 17 18 14 15 3 36 25 26 19 20 30 29 28 33 37 1 35 34 2 ARS1850L Figure 5 P T 1 2 3 4 ARS1860L Fi...

Page 527: ...Deal 25 Cover 26 Wrench Bolt 27 Cam 28 Bushing 29 Camshaft 30 Set Screw 31 Set Screw 32 Hex Nut 33 Bellows 34 Space 35 O ring 36 O ring 37 Wrench Bolt Reference Number Description Travel Control Valve...

Page 528: ...mary pressure Defective secondary pressure select spring Replace with new spring Gap between spool and casing is abnormally large Replace spool casing assembly Defective operating parts and components...

Page 529: ...y to OFF position and remove from starter switch 9 Hang maintenance warning tag on controls 10 Disconnect negative battery cable leading to frame from battery 11 Remove cabin under cover by loosening...

Page 530: ...ve With Damper 13 Remove rubber boots 1 Figure 9 14 Remove four bolts and washers 2 Figure 9 pedal brackets 3 with levers 15 Remove four bolts and washers 2 Figure 10 and pedal valve 1 1 2 1 ARS2951L...

Page 531: ...ainer in which disassembled parts can be stored 3 All precision parts must be handled with great care and all parts must be reassembled to their original position 4 All parts must be carefully reassem...

Page 532: ...9820K Page 12 Travel Control Valve With Damper 3 Remove cam shaft 29 and bushing 28 from cam 27 4 Remove cam 27 from cover 25 5 Remove wrench bolt 26 by using tool Figure 13 Figure 14 Figure 15 Figure...

Page 533: ...With Damper 6 Remove cover 25 from body 1 and 2 7 Remove plug assembly 21 24 with push rod assembly 14 20 8 Remove snap ring 13 9 Remove rod guide 11 IMPORTANT Be careful not to spring rod guide 11 F...

Page 534: ...820K Page 14 Travel Control Valve With Damper 10 Remove spool assembly 5 9 11 Remove spring 10 12 Remove stopper 9 spring 6 and spring seat 7 from spool assembly 5 9 Figure 21 Figure 22 Figure 23 Figu...

Page 535: ...trol Valve With Damper 13 Remove plug assembly 21 24 from push rod assembly 14 20 14 Remove seal 23 and 24 from plug 21 15 Remove O ring 22 from plug 21 16 Remove seal 16 from push rod 14 Figure 25 Fi...

Page 536: ...el Control Valve With Damper 17 Remove snap ring 20 from push rod 14 18 Remove plate 19 from push rod 14 19 Remove spring 18 from push rod 14 20 Remove steel ball 17 from push rod 14 Figure 29 Figure...

Page 537: ...d may cause poor equipment performance Be sure to use clean uncontaminated solvent when cleaning precision parts 2 Clean parts thoroughly by gently turning the solvent Dry and clean each part with a c...

Page 538: ...approved lubricant to aid in smooth assembly 6 Tighten all bolts to the specified torque rating as outlined in the torque table 7 Seal all opens ports to prevent foreign material from entering the va...

Page 539: ...nstall rod seal 23 and dust seal 24 on both sides of plug by using tool 4 Install O ring 22 on outside diameter of plug 21 and check plug whether it is abnormal 5 Install spring seat 7 spring 6 and sp...

Page 540: ...spring 18 plate 19 and spring pin 15 on push rod 14 8 Install snap ring 20 on push rod assembly 14 19 9 Install seal 16 on push rod 14 10 After installing spool assembly 5 9 on body 1 and 2 insert rod...

Page 541: ...rod assembly 14 20 on body 1 and 2 12 Install cover 25 on the upside of body 1 and 2 13 Tighten wrench bolt 26 NOTE Tightening torque 88 kg cm 6 37 ft lb 14 Put cam 27 on cover 25 and install cam shaf...

Page 542: ...by using wrench NOTE Tightening torque 88 kg cm 6 37 ft lb 16 One side holds L wrench and the other side holds spanner and tighten set screw 31 and hex nut 32 attached to cam 27 not to loose NOTE Tig...

Page 543: ...and washers 2 2 Install pedal brackets 3 and levers 4 Figure 50 on pedal valve and install four bolts and washers 2 3 Install rubber boots 1 Figure 50 4 Connect hoses as tagged during removal to peda...

Page 544: ...mper START UP PROCEDURES 1 Start engine and set throttle at LOW IDLE 2 Set safety lever on UNLOCK position 3 Slowly push and pull both travel lever about five times without a load to vent air from pil...

Page 545: ...fe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of...

Page 546: ...S0792190K Page 2 Hydraulic Schematic S340LC V TABLE OF CONTENTS General Description 3 Solar 340LC V 4...

Page 547: ...340LC V GENERAL DESCRIPTION Schematic s presented in this section are laid out on facing pages An overlapping edge has been taken into consideration so that a photocopy can be made and pasted together...

Page 548: ...S0792190K Page 4 Hydraulic Schematic S340LC V SOLAR 340LC V Figure 2...

Page 549: ...S0792190K Page 5 Hydraulic Schematic S340LC V...

Page 550: ...S0792190K Page 6 Hydraulic Schematic S340LC V...

Page 551: ...1ELECTRICAL SYSTEM...

Page 552: ......

Page 553: ...ained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own pe...

Page 554: ...el 15 Monitoring System Schematic 16 Operation 18 Instruments 18 Warning and Indicator Lights 20 Initial Operation 22 Mode Select Switch 23 Graphic Information Area Display 24 Overview 24 Main Menus f...

Page 555: ...verheat Protection System 60 Power Boost Mode 61 Operation 61 Power Boost Control Circuit Diagram 62 Automatic Travel Speed Control 63 Automatic Travel Speed Control Circuit Diagram 64 Engine Control...

Page 556: ...t Engine throttle controller defective or not connected Repair connection or replace component Blown fuse Replace fuse Check connections and circuit components for shorts or other damage Wiring harnes...

Page 557: ...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 f...

Page 558: ...ne stop motor When the starter switch 5 is in the preheat on and start positions the current flows from the battery 1 fusible link 3 fuse 6 starter switch 5 B terminal starter switch 5 BR terminal bat...

Page 559: ...er relay 8 are connected 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 flow...

Page 560: ...and PP terminals are opened 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 p...

Page 561: ...e preheat time is approximately 19 seconds A built in timer in the instrument panel will activate an indicator light approximately 19 seconds after the preheat process has been selected Even after the...

Page 562: ...is in the ON position the engine stop motor rotates 180 and comes to a stop due to the cam switch When the start switch is in the OFF position the engine stop motor moves 180 from the running mode pos...

Page 563: ...elay 5 A terminal of engine stop motor 6 E terminal of engine stop motor 6 ground The engine stop motor opens pushes the fuel shut off lever of the fuel injection pump and the system is in the running...

Page 564: ...e shut off lever of the fuel injection pump linked to the engine stop motor by a cable is moved to the close pull position and the engine is stopped The engine stop motor moves 180 from the running mo...

Page 565: ...ctrical 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 Th...

Page 566: ...plays information selected by the operator ARS0090L Figure 9 Reference Number Description 1 Instrument Panel 2 Battery 3 Engine Speed Sensor 4 Return Filter Switch 5 Pilot Filter Switch 6 e EPOS Contr...

Page 567: ...ion area 3 and 4 Figure 10 Gauges Warning Lights Mode Select Switches 1 Engine Coolant Temp Gauge 2 Fuel Gauge 3 Multi function Gauge and Graphic Information Area 4 Digital Clock 5 Service Hour Meter...

Page 568: ...ER LOAD L3 WATER TEMP L4 PREHEAT L5 WORK LAMP L1 BATTERY CHARGE L2 ENG OIL PRESS 8 7 ILLUMINATION EL 5 20 6 SIG 19 SIG L4 L1 L2 L3 6 17 L6 L5 11 1 9 10 2 22 CN2 13 CN2 14 CN2 11 CN2 12 CN2 1 RS 422 CN...

Page 569: ...ssure Sensor 7 Engine Coolant Temperature Sensor 8 Fuel Gauge 9 Engine Speed Sensor 10 Hydraulic Oil Temp Sensor 11 Engine Oil Pressure Switch 12 Air Cleaner Indicator 13 Return Filter Switch 14 Pilot...

Page 570: ...F 128 ohms Fuel Level CN4 7 CN4 8 1 10 LCD Blinking over 5K ohms FULL under 525 ohms Tachometer CN4 16 CN4 17 N 146 f 60 S300LC V N 146 f 60 S300LL N 152 f 60 S340LC V N 152 f 60 S420LC V N 152 f 60...

Page 571: ...4 2 V 0 00816 x P 1 0 V Sensor output voltage V P Displayed pressure Bar Main pump discharge pressure rear pump CN4 3 CN4 4 Function Display Sensor Specification Input Terminal Input Specification FRO...

Page 572: ...ssure CN2 11 Lights up when engine oil pressure switch is turned ON Oil pressure drops below 0 7 kg cm2 10 psi After starting engine if engine oil pressure is insufficient after 8 seconds a warning bu...

Page 573: ...Area Air Cleaner CN2 12 Lights up when air cleaner is clogged Symbol is blinking Return Filter CN2 13 Lights up when return filter pressure increases over 1 5 kg cm2 21 psi Symbol is blinking Pilot F...

Page 574: ...Initial Operation When battery voltage is input to CN7 9 starter switch is turned from OFF to ON position All LCD LED and warning lights are turned on and turned off after about 2 seconds Warning buzz...

Page 575: ...put Pump Discharge Volume Control Valve Current mA Swing Priority Solenoid Valve 7 Segment Display Power Mode Power Mode ON Variable Output 9 x Standard Mode OFF 0 7 x Work Mode Trenching Mode ON ON x...

Page 576: ...ided 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 select buttons Selection Buttons Grap...

Page 577: ...f machine operation MENU SELECTION BUTTONS 1 Up Arrow Button 1 on Figure 12 Move the cursor to up left and previous screen 2 Down Arrow Button 2 on Figure 12 Move the cursor to down right and next scr...

Page 578: ...ter oil information to the operator Refer to the Operation and Maintenance Manual for details LANGUAGE SETTING This mode is used for setting desired language TIME SETTING This mode is used for setting...

Page 579: ...reset the operating hour and then the operating hours until the next service interval can be easily checked Menu Display Order and Icon Explanation ARO0400L Hrs 0232 Reset 1 Fuel Filter Figure 16 1 2...

Page 580: ...ESSING AND EXITING ESCAPING MENUS Entering Accessing Menus When normal mode screen is displayed if the enter button 3 and escape button ESC 4 are pressed simultaneously for more than 3 seconds normal...

Page 581: ...once again SPECIAL MENU SELECTIONS Sub menu Selection Method Various sub menus can be selected by pressing Up 1 on Figure 18 and Down 2 on Figure 18 button Move the cursor to desired menu and a select...

Page 582: ...Max 9 E G Oil Press 3 Work Travel Solenoid 10 Air Cleaner 4 Hi Speed Solenoid 11 Return Filter 5 Auto Travel 12 Pilot Filter 6 Work Lamp 13 OWD Select 7 Pressure Py 5 Output State 1 Relief Press Up 4...

Page 583: ...hine Status Information 1 EPPR Valve Current 2 Dial Voltage 3 TPS Voltage Output voltage of potentiometer built into engine control motor EPPR CURRENT ARS0870L mA 598 Figure 24 DIAL VOLTAGE ARS0880L m...

Page 584: ...on OFF and the other statuses of on off type sensors MACHINE INFO ARS1780L Input State Output State Hyd Oil Temp 4 Figure 27 1 Alternator OFF 2 Power Max ON 3 Work Travel Sel OFF 4 Hi Speed Sel OFF 5...

Page 585: ...on Remarks 1 6 BAR Lit CN 3 4 CN 3 5 Over 1 510 Below 30 C Below 86 F 1 6 2 6 BAR Lit 745 1 510 31 50 C 87 122 F 1 6 3 6 BAR Lit 332 745 51 75 C 123 167 F 1 6 4 6 BAR Lit 244 332 76 85 C 168 185 F 1 6...

Page 586: ...cursor is located in Failure Info of special menu screen press enter button 3 on Figure 18 and Failure Info screen is displayed 2 Exiting Sub menus If escape button ESC 4 on Figure 18 is pressed for...

Page 587: ...ure information Memorized record of past failure is displayed Failure code failure contents When a number of failures are produced failure information can be checked by using PRV 1 on Figure 18 or NXT...

Page 588: ...t this time deletion signal will be displayed and the screen will move to previous menu after deletion This screen will be displayed during 3 seconds When NO ESC 4 on Figure 18 button is pressed the s...

Page 589: ...82 Communication Err Communication error between e EPOS controller and instrument panel Note Automatic reset when problem is corrected 01 EPPR v v short Short Circuit Cut off output current 0 mA Afte...

Page 590: ...put voltage Over 4 6 0 2 V Cut off EPPR v v current 0 mA 24 TPS Voltage Err L Output voltage Over 0 4 0 2 V Cut off EPPR v v current 0 mA 25 Fpump Sensor Err H Output voltage Over 4 6 0 2 V 26 Fpump S...

Page 591: ...ion A Entering Sub menus When a cursor is located in Operating Info of special menu screen Figure 37 press enter button 3 on Figure 18 and Operating Info screen will be displayed Figure 38 B Informati...

Page 592: ...itch Py control valve ON status High speed High speed s v and travel pressure switch Py control valve ON status Hydraulic Oil Temperature Distribution C F Temperature of hydraulic oil is classified 6...

Page 593: ...urned to previous screen NOTE When YES 3 on Figure 18 button is pressed operation hours will reset At this time resetting signal will be displayed and the screen will move to previous menu after reset...

Page 594: ...19 Mode select signal Machine information Auto idle signal Sensors 18 Engine speed sensor signal Engine throttle control signal Drive signal Potentiometer signal Coolant water temp signal Throttle co...

Page 595: ...8 Pump Pressure Sensor 9 Engine Speed Sensor 10 Electro magnetic Proportional Pressure Reducing Valve E P P R Valve 11 Solenoid Valve Pressure Up 12 Solenoid Valve Swing Priority 13 Solenoid Valve Hi...

Page 596: ...e indicator lamp will turn ON to display the selected mode Wheel type Power mode switch signal 1 Potentiometer signal Pump control signal g 15 Low Throttle signal Hi 16 Engine throttle control signal...

Page 597: ...low the rated speed When this occurs the controller senses this decrease and immediately reduces the pump discharge volume to maintain the engine speed at the rated level On the other hand if the load...

Page 598: ...ption in comparison with Power Mode The current to the E P P R valve is shut off and pump discharge volume is controlled by pump regulator A B C D HDA6020L Figure 46 Reference Number Description A Eng...

Page 599: ...S0802220K Page 47 Electrical System Reference Number Description A Engine Horsepower hp B Engine Speed rpm C Pump Discharge Volume lpm D Pump Discharge Pressure kg cm2 Reference Number Description...

Page 600: ...1 9 9 10 8 11 CN3 9 10 11 12 14 15 13 17 16 CN1 6 5 7 8 6 4 3 2 1 20 18 19 11 CN7 14 16 15 13 12 CN3 11 CN3 10 CN3 9 CN3 12 CN3 8 CN1 7 CN1 5 CN4 11 CN4 10 CN4 13 CN4 12 LOW 1 1 5 2 3 1 4 CN2 3 12 2 2...

Page 601: ...stem Reference Number Description 1 Battery 2 Battery Relay 3 Fuse 4 e EPOS Controller 5 Instrument Panel 6 Engine Speed Sensor 7 Engine Throttle Controller 8 Engine Control Motor 9 Engine Control Dia...

Page 602: ...oid adjusts the assignment of hydraulic oil flow to each device on the equipment Wheel Engine throttle control signal Trenching mode switch signal 15 Throttle signal Hi Lo Potentiometer signal Drive s...

Page 603: ...ck stops The current to the solenoid valve for swing priority is shut off 2 Trenching Mode This mode is used for heavy duty ditch digging work or for loading work requiring big swing angles The voltag...

Page 604: ...15 16 7 6 2 1 4 5 2 1 11 3 13 2 12 1 9 8 10 14 6 5 4 7 CN7 1 13 3 2 CN3 CN4 CN2 3 20 19 1 5 2 10A CN7 TxD RxD 10 9 5 2 20A 3 TxD RxD RxD TxD CN3 8 CN3 11 CN3 12 CN3 10 CN3 9 CN1 9 CN1 14 RS 422 CN1 1...

Page 605: ...ter feed back signals are the same the engine controller shuts off the current to the control motor The engine control motor cable is a solid type and is connected to the engine fuel injection control...

Page 606: ...S0802220K Page 54 Electrical System...

Page 607: ...r switch should be turned off and the cause of abnormal load should be repaired and the starter switch can be turned on again The engine control dial can once again be used to control the engine speed...

Page 608: ...umber Description 1 Knob 2 Potentiometer Variable Resistor 2 1 1 1 VIEW POTENTIOMETER BOTTOM 1st STEP 10 10 7th STEP 13th STEP CCW MECHANICAL STOP CW MECHANICAL STOP 2 3 2 3 1 2 3 4 2 5V 1 0V 4 0V 1ST...

Page 609: ...ical System The engine control dial has a built in potentiometer When the control knob is moved the output voltage through terminals 2 and 3 will vary from the 5 V supplied from the throttle controlle...

Page 610: ...55 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse 4 e EPOS Controller 5 Instrument Panel 6 Engine Speed Sensor 7 Engine Throttle Controller 8 Engine Control Motor 9 Engine Control Dial...

Page 611: ...ers are in the neutral position the e EPOS controller sends an automatic reduction signal to the throttle controller When the engine throttle controller receives this signal it is compared with the si...

Page 612: ...throttle controller will signal the engine control motor to decrease the engine speed When the coolant is overheated the warning buzzer will sound standard mode is selected and low engine speed will...

Page 613: ...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 NOTE Do not use this switch fo...

Page 614: ...CN3 11 12 13 14 17 CN1 6 7 8 6 3 4 1 2 20 11 16 CN7 CN1 1 CN4 1 3 10 7 8 9 CN1 CN3 11 CN3 12 CN3 8 CN3 10 CN3 9 RxD RxD RS 422 TxD TxD 5 6 1 CN2 3 7 6 CN1 13 CN1 9 CN1 2 CN1 8 4 1 3 20A 2 ARS1150L Fig...

Page 615: ...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 an...

Page 616: ...2 17 14 4 9 10 15 16 1 LOW CN4 10 CN4 11 8 CN3 CN4 CN2 6 CN2 5 0 II 3 10 I 6 AUTO MANUAL 9 2 CN1 12 SIG 6 SIG 5 CN4 2 CN4 4 CN4 3 CN4 1 10A CN1 8 CN1 9 CN1 1 CN1 2 4 3 20A 2 1 ARS1170L Figure 61 Refe...

Page 617: ...stopper position and the cable slack is acceptable 3 A If the lever is not in the minimum position and touching the stopper move the 3 cable to one hole lower on the lever If the cable slack is exces...

Page 618: ...le VR1 Refer to throttle controller name plate 3 Figure 64 Standard Mode VR2 Refer to throttle controller name plate 3 Figure 64 Reference Number Description 1 VR1 Automatic Deceleration Adjusting Var...

Page 619: ...age 67 Electrical System Figure 65 Reference Number Description 1 Engine Fuel Control Lever Area 2 Control Motor Cable Bracket 3 Engine Speed Control Cable 4 To Engine Control Motor Reference Number D...

Page 620: ...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 Communication Monitor These LED lamps flash whe...

Page 621: ...re information codes a part of failure information Refer to the failure information part of letter information display for details Mode Selection Display Readout Operation Status Upper Digit Lower Dig...

Page 622: ...ssibility of motor damage or burn out exists 4 After the malfunction is corrected turn the starter switch from OFF to the ON position and normal operation will resume Throttle Controller Input Signal...

Page 623: ...ly 5 seconds Continuous Operation II Position When the wiper switch 4 is turned I position the current flows from the fuse 3 B terminal of wiper motor 7 L terminal of wiper motor 7 No 5 terminal of wi...

Page 624: ...er 6 No 4 terminal of wiper timer 6 S terminal of wiper motor 7 B terminal of wiper motor 7 and the wiper motor is stopped at the auto stop position WINDOW WASHER OPERATION When the window washer swit...

Page 625: ...S0802220K Page 73 Electrical System...

Page 626: ...2 CN3 10 CN3 9 CN3 12 CN3 11 CN3 8 CN7 1 L5 CN7 9 11 10A 15 RH 14 LH LH RH RH 16 LH 17 FL FR FMR 18 FL FR FML 30 86 87 85 7 87a 3 10 II 6 I 4 0 86 30 85 87a 87 8 13 1 7 10 9 2 10A 5 I 5 0 9 10A 20A 1...

Page 627: ...a 15 Work Light 2 ea 16 Additional Work Light 2 ea 17 Front Cabin Light 2 ea 18 Front Cabin Light 4 ea 19 Rear Cabin Light 2 ea Reference Number Description Switch Position Connected Terminal of switc...

Page 628: ...AD WARNING DEVICE OVERLOAD WARNING DEVICE CIRCUIT DIAGRAM 5 6 4 2 1 3 ARS1260L Figure 69 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse Box 4 e EPOS Controller 5 OWD Select Switch 6 Pre...

Page 629: ...safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable...

Page 630: ...S0892190K Page 2 Electrical Schematic S340LC V TABLE OF CONTENTS General Description 3 Solar 340LC V 4...

Page 631: ...340LC V GENERAL DESCRIPTION Schematic s presented in this section are laid out on facing pages An overlapping edge has been taken into consideration so that a photocopy can be made and pasted together...

Page 632: ...S0892190K Page 4 Electrical Schematic S340LC V SOLAR 340LC V Figure 2...

Page 633: ...S0892190K Page 5 Electrical Schematic S340LC V ELECTRICAL DIAGRAM DAEWOO HEAVY INDUSTRIES LTD NO Model Solar 340 370LC V Name 599 00042 HAAD4200...

Page 634: ...S0892190K Page 6 Electrical Schematic S340LC V...

Page 635: ...1ATTACHMENTS...

Page 636: ......

Page 637: ...nt of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that u...

Page 638: ...CONTENTS Front Attachment Pin Specifications 3 Front Attachment Removal and Installation 4 Arm Removal Procedure 4 Boom Removal Procedure 6 Installation 7 Arm Installation Procedure 7 Boom Installati...

Page 639: ...ion on wear tolerances and replacement limits for mounting pins Mounting Pin Diameter mm Inches Length mm Inches A 110 0 mm 4 33 in 1 047 0 mm 41 22 in B 100 0 mm 3 94 in 918 0 mm 36 14 in C 100 0 mm...

Page 640: ...with the lower structure Never rotate the upper structure once the counterweight or front attachment has been removed IMPORTANT Always break down the front attachment by removing outermost sections f...

Page 641: ...ly if necessary Place a sling under the arm cylinder the cylinder used to extend and retract the attachment arm pinned to the top of the boom Lift the sling so that the weight load on the rod end of t...

Page 642: ...aulic 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 line...

Page 643: ...sling from around the rod end arm cylinder pin withdraw the pin and lift the body of the arm cylinder to re pin the mounting connection BOOM INSTALLATION PROCEDURE Before reassembling the attachment m...

Page 644: ...and Arm START UP PROCEDURES Once the boom has been serviced it should be lubricated as outlined in the initial start up procedures of the operation manual Refer to the appropriate operation and mainte...

Page 645: ...s section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsib...

Page 646: ...Tooth Inspection and Replacement 3 Type 1 3 Type 2 4 Bucket O ring Replacement 6 Bucket Shimming Procedures 8 New Bucket Installation 8 Bucket Attachment Removal and Reversal 9 Detaching the Bucket 9...

Page 647: ...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 1 On a routine basis inspect the bucket teeth to make sure that tooth wear o...

Page 648: ...ng steel ball causes the boss to go inside WARNING Due to the possibility of flying metal objects always wear safety helmet protective gloves and eye protection when changing bucket teeth Curl the buc...

Page 649: ...wear down to a point that bucket adapter is exposed See Figure 4 2 To replace a tooth use a hammer 1 Figure 5 and punch 2 to drive locking pin assembly out of tooth and tooth adapter 3 Once the worn...

Page 650: ...he way 3 Remove the old O ring and temporarily install the new O ring 1 Figure 8 onto the bucket boss 2 Make sure that the O ring groove on both the bucket link 4 and boss have been cleaned 4 Realign...

Page 651: ...S0904005K Page 7 Bucket 5 Roll the new O ring 1 Figure 9 into the O ring groove ARO1392L 1 Figure 9...

Page 652: ...rance should be 1 mm 0 04 in between side face of boss and inside edge of ear bushing Y Figure 10 Too tight a fit less than 1 mm 0 04 in can cause excessive wear while too much clearance may produce e...

Page 653: ...semble the link pin end retainers and pull out the pin Lift the arm away from the bucket so that the bucket can be carried away or another end attachment can be put on the excavator ATTACHING THE BUCK...

Page 654: ...simplified if some type of rotating or swiveling support can be used on the ground underneath the bucket Follow instructions for Bucket Attachment to replace pins WARNING When making linkage alignment...

Page 655: ...EET ADDRESS TELEPHONE CITY FAX STATE PROVINCE COUNTRY NAME MACHINE MODEL SERIAL NUMBER MANUAL NUMBER SHOP MANUAL SECTION NUMBER PROPOSED DESCRIPTION OF CORRECTION AND OR SUGGESTION Use additional pape...

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