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950106-00075E Shop Manual
Copyright 2010

DOOSAN

DOOSAN

reserves the right to improve our products in a continuing process to provide the best possible

product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.

This documentation may include attachments and optional equipment that is not available in your
machine's package. Please call your distributor for additional items that you may require.

Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.

Shop Manual

950106-00075E

Serial Number 5001 and Up

DX300LCA

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Summary of Contents for 5001

Page 1: ...recommended that consumers periodically contact their distributors for recent documentation on purchased equipment This documentation may include attachments and optional equipment that is not available in your machine s package Please call your distributor for additional items that you may require Illustrations used throughout this manual are used only as a representation of the actual piece of e...

Page 2: ......

Page 3: ...Product Label Instructions Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine DX300LCA Serial Number 5001 and Up Pub No 950106 00075E Pub No 950106 00075E ...

Page 4: ......

Page 5: ...0813 Upper Structure Cabin SP001737 Counterweight SP001748 Fuel Tank SP002027 Fuel Transfer Pump Opt SP000021 Swing Bearing SP001856 Swing Reduction Gear SP002028 Lower Structure and Chassis Track Assembly SP001741 Engine and Drive Train Drive Coupling Main Pump SP002029 Hydraulics Hydraulic System Troubleshooting Testing and Adjustment SP001751 Accumulator SP000028 Center Joint Swivel SP001620 Cy...

Page 6: ...ve SP000034 Remote Control Valve Work Lever Joystick SP000069 Travel Control Valve With Damper SP001743 Solenoid Valve Assembly SP001622 Breaker EPPR Valve Opt SP000192 Hydraulic Schematic DX300LC DX300LCA SP001752 Electrical System Electrical System SP002030 Electrical Schematic DX300 340 350LC DX300LCA SP002031 Attachments Boom and Arm SP001851 Bucket SP001852 ...

Page 7: ...1Safety ...

Page 8: ......

Page 9: ...SP002025 Page 1 Track Excavator Safety SP002025 TRACK EXCAVATOR SAFETYSP002025 Track Excavator Safety Edition 1 ...

Page 10: ...SP002025 Track Excavator Safety Page 2 MEMO ...

Page 11: ... of a DOOSAN Excavator 6 General Safety Essentials 9 Location of Safety Labels 10 Summary of Safety Precautions for Lifting in Digging Mode 10 Unauthorized Modifications 11 General Hazard Information 11 Before Starting Engine 20 Machine Operation 24 Maintenance 31 Battery 39 Towing 41 Shipping and Transportation 42 Lifting With Sling 42 ...

Page 12: ...SP002025 Track Excavator Safety Page 4 MEMO ...

Page 13: ...ow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LCA 5001 and Up ...

Page 14: ... page 1 10 4 Unauthorized Modifications on page 1 11 5 General Hazard Information on page 1 11 6 Before Starting Engine on page 1 20 7 Machine Operation on page 1 24 8 Maintenance on page 1 31 9 Battery on page 1 39 10 Towing on page 1 41 11 Shipping and Transportation on page 1 42 12 Lifting With Sling on page 1 42 DANGER Unsafe use of the excavator could lead to serious injury or death Operating...

Page 15: ...must be sure that it is safe for any others In no event should you or others engage in prohibited uses or actions as described in this manual DOOSAN delivers machines that comply with all applicable regulations and standards of the country to which it has been sent If this machine has been purchased in another country or purchased from someone in another country it may lack certain safety devices ...

Page 16: ...owed in this manual are used you must be sure that you and others can do such procedures and actions safely and without damaging the machine If you are unsure about the safety of any procedures contact a DOOSAN distributor CAUTION This word is used on safety messages and safety labels and indicates potential of a hazardous situation that if not avoided could result in minor or moderate injury It m...

Page 17: ...city ratings that are printed at the end of this safety section are based on the machine being level on a firm supporting surface with hooks and slings attached in approved configuration Loads must be balanced and supported evenly Use tag lines to keep the load steady if wind conditions and large surface area are a problem Work crew hand signals individual tasks and safe procedures should all be u...

Page 18: ...g lines on opposite sides of the load can be very helpful in keeping a suspended load secure if they are anchored safely to control points on the ground Always engage the Digging Mode control on the Instrument Panel before using the excavator for lifting work DANGER Unsafe use of the excavator while making rated lifts could cause serious potentially fatal injuries or extensive damage to the machin...

Page 19: ...ctions when operating or performing maintenance on the machine Do not operate the machine if you are not 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 judgment in emergencies and may cause accidents When working with another operator or with a person on ...

Page 20: ...n pads to the window glass Suction pads act as a lens and may cause fire Do not leave lighters laying around the operator s cabin If the temperature inside the operator s cabin becomes high there is a danger that lighter may explode Do not use cellular telephones inside the operator s compartment when driving or operating the machine There is a danger that this may lead to an unexpected accident N...

Page 21: ...ds can cause disabling or permanent injuries NOTE The equivalent continuous A weighted sound pressure level at the workstation for this machine is given in the operation manual Measurement is obtained on a dynamic machine following the procedures and cabin conditions as described in ISO 6396 NOTE The guaranteed sound power level emitted by the machinery for this machine is given in the operation m...

Page 22: ...ure brakes steering linkages etc 4 Steer brake accelerate shift gears move the attachments and load the attachments smoothly 5 Adjust the machine speed and travel path to reduce the vibration level Slow down if it is necessary when traveling through rough terrain When driving machine avoid obstacles and excessive rough terrain 6 Keep the machine on terrain where working and traveling conditions ar...

Page 23: ...y move and cause you to fall Use the points marked by arrows in the diagram when getting on or off the machine Fuel Oil and Hydraulic Fluid Fire Hazards Fuel oil and antifreeze will catch fire if it is brought close to a flame Fuel is particularly flammable and can be hazardous Always strictly observe the following Add fuel oil antifreeze and hydraulic fluid to the machine only in a well ventilate...

Page 24: ...prevent hot oil from spurting out shut down engine wait for the oil to cool then loosen the cap slowly to relieve the pressure Asbestos Dust Hazard Prevention Asbestos dust can be HAZARDOUS to your health if it is inhaled Materials containing asbestos fiber can be present on work site Breathing air that contains asbestos fiber can ultimately cause serious or fatal lung damage To prevent lung damag...

Page 25: ...inguisher be mounted in the cabin Check and service the fire extinguisher at regular intervals and make sure that all work site crew members are adequately trained in its use Provide a first aid kit in the storage compartment and keep another at the work site Check the kit periodically and make any additions if necessary Know what to do in case of injury from fire Keep emergency numbers for doctor...

Page 26: ...ould strike the operator s cabin Make sure that all other work site crew members are kept well away from the excavator and safe from possible hazards For breaker operation install a front guard and apply a laminated coating sheet to the front glass Contact your DOOSAN distributor for recommendations When carrying out demolition or cutting operation install a front guard and top guard and apply a l...

Page 27: ...ut disassembly or maintenance of the accumulator or when disposing of the accumulator the charged gas must be properly released Contact your DOOSAN distributor Wear safety goggles and protective gloves when working on an accumulator Hydraulic oil under pressure can penetrate the skin and cause serious injuries Indoor Ventilation Engine exhaust gases can cause fatal accidents and unconsciousness lo...

Page 28: ...rk site Contact each utility and identify their locations Be careful not to damage or cut any of these lines Check the condition of the riverbed and the depth and flow of the water before operating in water or crossing a river NEVER work in water that is more than the permissible water depth Any object in vicinity of boom could represent a potential hazard or cause the operator to react suddenly a...

Page 29: ...rass paper and other flammable materials accumulated in the engine compartment and around the battery They could cause a fire Remove any dirt from the window glass mirrors handrails and steps Do not leave tools or spare parts laying around in the operator s cabin The vibration of the machine when traveling or during operations may cause them to fall and damage or break the control levers or switch...

Page 30: ...e engine if there is any indication that maintenance or service work is in progress or if a warning tag is attached to controls in the cabin A machine that has not been used recently or is being operated in extremely cold temperatures could require a warm up or maintenance service before start up Check gauges and monitor displays for normal operation before starting the engine Listen for unusual n...

Page 31: ...immediately If the machine is used without repairing the problems it may lead to unexpected injury or failure Clear all personnel from directly around machine and from the area Clear all obstacles from the machine s path Beware of hazards Be sure that all windows are clean Secure the doors and the windows in the open position or in the shut position Adjust the rearview mirrors for best visibility ...

Page 32: ... before changing travel direction 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 check that there is no one behind the machine before traveling in reverse When operating in areas that may be hazardous or have poor visibility designate a person to direct work si...

Page 33: ...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 ground and cause the machine to lose its balance and this may damage the machine or structures in the area When traveling on rough ground travel at low speed and avoid sudden changes in direction Always ...

Page 34: ...y quickly lower 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 make sure that machine is always traveling directly up or down the slope Avoid changing travel direction on a slope This could result in tipping or sideslipping of the machine When possible...

Page 35: ...s or other inadequate supports when work is being done Block tracks fore and aft to prevent any movement When using the machine to prevent accidents caused by damage to the work equipment and overturning because of an excessive load do not use the machine in excess of its ability in terms of the maximum load and stability determined by the structure of the machine When working at the edge of an ex...

Page 36: ...in confined spaces indoors or in crowded areas Do not pass the bucket over the heads of workers or over the operator s cabin of dump truck Avoid High Voltage Cables Serious injury or death can result from contact or proximity to high voltage electrical lines The bucket does not have to make physical contact with power lines for current to be transmitted Use a spotter and hand signals to stay away ...

Page 37: ... Operate 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 accumulation could hide or obscure potential hazards Use care while operating or while using the machine to clear snow Warming up the engine for a short period may be necessary to avoid operating...

Page 38: ...n or runoff If parking on inclines is unavoidable block the crawler tracks to prevent movement Lower the bucket or other working attachment completely to the ground or to an overnight support saddle There should be no possibility of unintended or accidental movement When parking on public roads provide fences signs flags or lights and put up any other necessary signs to ensure that passing traffic...

Page 39: ...nger 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 nonslip soles to prevent yourself from slipping and falling on wet places Wear safety glasses and protective clothing when washing the machine with high pressure steam Take action to prevent touching high pressure water and cutting your skin or having mu...

Page 40: ...l 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 oily rags and other flammable material in a protective container Do not smoke while you refuel the machine or while you are in a refueling area Do not smoke in battery charging areas or in areas that...

Page 41: ...onents 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 hydraulic tank filter plug only after the engine has been stopped Make sure that hydraulic tank filter plug is cool before you remove it with your bare hand Remove hydraulic tank filter plug slowly to relieve pressure Relieve all ...

Page 42: ...flame 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 If heat is applied directly to rubber hoses or piping under pressure they may suddenly break so cover them with a fireproof covering Wear protective clothing Make sure there is good ventilation...

Page 43: ...ollowing 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 maintain a three point contact both feet and one hand or both hands and one foot to support yourself securely If the job requires it wear protective clothing To prevent injury from slipping or falling wh...

Page 44: ...ly out The loose retainer pin can injure personnel Make sure that 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 pin Track Tension Adjustments Require Caution Never turn out the track tension grease valve To release pressure from the crawler frame track tension assembly you should NEVER attempt to disassemble t...

Page 45: ...essurized oil has enough force to pierce the skin and cause serious injury Always use a piece of wood or cardboard to check for suspected hydraulic leaks Never use your hands or expose your fingers Do not bend high pressure lines Do not strike high pressure lines Do not install lines tubes or hoses that are bent or damaged Make sure that all clamps guards and heat shields are installed correctly t...

Page 46: ...ntaminant 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 drained from your machine in containers Never drain oil directly onto the ground Obey appropriate laws and regulations when disposing of harmful materials such as oil fuel solvent filters and batteri...

Page 47: ...antities 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 immediately When cleaning the top surface of the battery wipe it with a clean damp cloth Never use gasoline thinner or any other organic solvent or detergent Tighten the battery caps securely If the batte...

Page 48: ...wo 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 must be made between the nonseries connected positive terminals and between the negative terminal of the booster battery and the metal frame of the machine being boosted or charged Refer to the proce...

Page 49: ...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 DOOSAN distributor Never go between the towing machine and the towed machine during the towing operation It is dangerous to carry out towing on slopes so select a place where the slope is gradual If there is no place where the slope is gr...

Page 50: ...rmation 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 Specification section of Operation and Maintenance Manual for information on weight and dimensions 2 Use properly rated cables and slings for lifting 3 Position machine for a level lift 4 Lifting cable...

Page 51: ...1Specifications ...

Page 52: ......

Page 53: ...SP002026 Page 1 Specification for DX300LCA SP002026 SPECIFICATION FOR DX300LCASP002026 Specification for DX300LCA Edition 1 ...

Page 54: ...SP002026 Specification for DX300LCA Page 2 MEMO ...

Page 55: ...General Dimensions 10 Working Range 12 General Specifications 14 Engine Performance Curves Per DIN 6270 Standard 16 Approximate Weight of Workload Materials 18 Performance Tests 20 Excavator Performance Standards 21 Test Conditions 21 Travel Speed and Travel Motor Balance Steering Deviation Tests 21 Swing Speed and Deceleration Force Test 23 Cylinder Performance Tests 25 ...

Page 56: ...SP002026 Specification for DX300LCA Page 4 MEMO ...

Page 57: ...llow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LCA 5001 and Up ...

Page 58: ...SP002026 Specification for DX300LCA Page 6 ...

Page 59: ...DESCRIPTION The excavator has three main component sections The Upper Turntable The Lower Undercarriage and Track Frames The Excavator Front end Attachment The following illustration identifies main components and their locations See Figure 1 on page 8 ...

Page 60: ...SP002026 Specification for DX300LCA Page 8 COMPONENT LOCATIONS Figure 1 19 18 17 16 15 14 13 11 12 10 9 8 7 6 5 4 3 2 1 40 39 38 37 36 35 34 33 32 31 30 29 28 20 26 27 25 24 23 22 21 FG000671 ...

Page 61: ...Cleaner 13 Swing Bearing 14 Seat 15 Cabin 16 Boom Cylinder 17 Work Lever Joystick Controls 18 Arm Cylinder 19 Boom 20 Travel Lever 21 Arm 22 Bucket Cylinder 23 Guide Link 24 Bucket 25 Push Link 26 Tooth Point 27 Side Cutter 28 Idler 29 Track Adjuster 30 Track Guide 31 Battery 32 Lower Roller 33 Center Joint 34 Upper Roller 35 Sprocket 36 Travel Motor 37 Track Link and Shoe 38 Suction Filter 39 Ret...

Page 62: ...2 5 m 8 2 ft Arm 3 75 m 12 3 ft Arm A 10 620 mm 34 10 10 740 mm 35 3 10 660 mm 35 0 B 3 200 mm 10 6 C 7 420 mm 24 4 7 540 mm 24 9 7 460 mm 24 6 D 4 040 mm 13 3 E 4 940 mm 16 2 F 1 150 mm 3 9 G 3 345 mm 11 0 3 475 mm 11 5 3 475 mm 11 5 H 2 960 mm 9 9 I 1 500 mm 4 11 J 1 460 mm 4 9 K 2 600 mm 8 6 L 3 200 mm 10 6 M 600 mm 23 62 in N 500 mm 19 69 in O 3 065 mm 10 1 ...

Page 63: ...SP002026 Page 11 Specification for DX300LCA ...

Page 64: ...the stability and support provided by ground conditions Digging too far underneath the excavator if soil conditions are wet loose or unstable can collapse ground support which could cause injury and or equipment damage 0 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 C D F A E I B H G G L 0 1 2 4 3 5 6 7 8 9 10 11 FG001449 Figure 2 ...

Page 65: ...2 3 8 030 mm 26 4 D Max Loading Height 7 240 mm 23 9 6 910 mm 22 8 7 345 mm 24 1 F Max Digging Height 10 310 mm 33 10 9 950 mm 32 8 10 390 mm 34 1 G Max Bucket Pin Height 8 855 mm 29 1 8 525 mm 28 0 8 960 mm 29 5 H Max Vertical Wall 6 200 mm 20 4 5 425 mm 17 10 6 690 mm 21 11 I Max Radius Vertical 6 820 mm 22 5 6 545 mm 21 6 7 045 mm 23 1 J Max Depth to 8 ft Line 7 185 mm 23 7 6 505 mm 21 4 7 850 ...

Page 66: ...der 177 KN or 18 000 kg 39 700 lb with either 3 100 mm 10 2 or 2 500 mm 8 2 arm Arm Cylinder 131 KN or 13 400 kg 29 500 lb with 3 100 mm 10 2 standard arm Fuel Tank Capacity 500 liters 132 1 U S gal Hydraulic System Capacity 280 liters 74 U S gal Hydraulic Reservoir Capacity 160 liters 42 U S gal Bucket Heaped Capacity Range PCSA 0 80 1 75 m3 1 05 2 29 yd3 IMPORTANT Refer to the Load Weight Bucket...

Page 67: ...t to top of cylinder hose 3 345 mm 11 Track Shipping Length 4 940 mm 16 2 Transport Trailer Capacity 30 tons 33 short tons minimum load capacity Transport Loading Ramp Allowable Slope 15 angle CAUTION Refer to Transport Maximum Procedure for Safe Shipping Instructions ...

Page 68: ...ecification for DX300LCA Page 16 ENGINE PERFORMANCE CURVES PER DIN 6270 STANDARD 150 100 200 160 90 70 150 80 170 POWER OUTPUT ps TORQUE kg m FUEL CONSUMPTION g ps h REVOLUTION rpm 1000 2000 1500 FG015470 Figure 3 ...

Page 69: ...ometric Pressure 760 mmHg 20 C 68 F Cooling Fan 711 mm SUCKER 28 in Alternator 24V x 50A Air Cleaner Installed Muffler Installed Performance Standard KS R1004 Power 200 ps 1 900 rpm 197 hp 1 900 rpm Max Torque 86 kg m 1 300 rpm 620 ft lb 1 300 rpm Fuel Consumption Rated 165 g ps h 5 90 oz hp h ...

Page 70: ... 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 size 449 kg m3 756 lb yd3 Coal bituminous slack piled 801 kg m3 1 350 lb yd3 Coal bituminous r of m piled 881 kg m3 1 485 lb yd3 Coal anthracite 897 kg m3 1 512 lb yd3 Clay DRY in broken lumps 1 009 kg m3 1 701 lb yd3 Clay...

Page 71: ...ed 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 1 282 kg m3 2 160 lb yd3 Salt 929 kg m3 1 566 lb yd3 Snow light density 529 kg m3 891 lb yd3 Sand DRY loose 1 522 kg m3 2 565 lb yd3 Sand WET packed 1 922 kg m3 3 240 lb yd3 Shale broken 1 362 kg m3 2 295 lb yd3 Sulphur broken 529 kg m3 1 620 lb yd3 Material Low ...

Page 72: ...p sec 3 6 0 4 3 3 0 4 Down sec 2 7 0 3 2 5 0 3 Arm Dump sec 2 9 0 3 2 8 0 3 Crowd sec 4 1 0 4 3 8 0 4 Bucket Dump sec 2 9 0 3 2 7 0 3 Crowd sec 3 0 0 4 2 7 0 4 Swing 3 Revolutions sec 19 5 1 5 18 5 1 5 Jack up Speed 3 Turns High sec 22 8 1 0 21 7 1 5 Low sec 39 3 1 5 37 3 2 0 Travel Speed 20 m 66 ft High sec 15 5 1 0 14 3 1 0 Low sec 25 5 1 5 24 2 1 5 Travel Deviation 20 m 66 ft High mm in 150 6 1...

Page 73: ...intenance and adjustment service should be completed before testing 3 Hydraulic fluid and engine oil should be of appropriate viscosity for ambient weather conditions Warm up hydraulic oil to standard operating temperature between 45 55 C 112 135 F 4 Run all tests with the engine speed control set to maximum rpm 5 Repeat tests with Power Mode engine control settings at both Standard Mode standard ...

Page 74: ...s are parallel with the test course Operate both travel levers at the fully engaged position and measure the time it takes to cross 20 m 65 7 1 2 Compare measured results against the standard for new machines Rotate the turntable 180 Both tests should be repeated three times Average all results to obtain a final value 0 3 M 0 5 M 1 2 FG000466 Figure 4 Rate of Travel Time Standard Mode Power Mode H...

Page 75: ...n is allowed with the travel control set for high speed Swing Speed and Deceleration Force Test Swing Speed Test Extend the bucket cylinder completely and retract the arm cylinder as shown in Figure 6 to test swing speed The lowest point of the bucket will be approximately 1 5 m 3 off the ground Use paint marks at the same point on the turntable and undercarriage or select alternate measuring loca...

Page 76: ...table and undercarriage with paint at the 90 point Make several attempts to rotate the turntable exactly 90 starting from the boom straight ahead position Engage the swing lever and brake at the 90 point shown as swing stop in Figure 7 Record how far the turntable drifts past the stop point measuring the distance between paint marks Maximum distance should be less than 1200 mm 47 1 4 in both Power...

Page 77: ... tightness against the specified performance standard for new cylinders put a full load of dirt in the bucket and move the attachment cylinders so that the arm cylinder is extended 20 50 mm 1 2 and boom cylinders are retracted the same amount 20 50 mm 1 2 The top of the bucket should be approximately 2 m 6 7 off the ground Shut down engine and measure cylinder drop after 5 minutes Bucket cylinder ...

Page 78: ...SP002026 Specification for DX300LCA Page 26 ...

Page 79: ...1General Maintenance ...

Page 80: ......

Page 81: ...SP000016 Page 1 General Maintenance Procedures SP000016 GENERAL MAINTENANCE PROCEDURES SP000016 General Maintenance Procedures Edition 1 ...

Page 82: ...General Maintenance Procedures SP000016 Page 2 MEMO ...

Page 83: ...Welding Precautions and Guidelines 6 Hydraulic System General Precautions 7 Maintenance Service and Repair Procedure 9 General Precautions 9 Hydraulic System Cleanliness and Oil Leaks 10 Maintenance Precautions for Hydraulic System Service10 Oil Leakage Precautions 11 Cleaning and Inspection 12 General Guidelines 12 Bearing inspection 13 ...

Page 84: ...General Maintenance Procedures SP000016 Page 4 MEMO ...

Page 85: ...Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE ALL MODELS ALL RANGES ...

Page 86: ...types of steel are performed with the proper procedures and equipment If repairs are performed incorrectly structural weakening or other damage to the machine that is not always readily visible could be caused Always consult DOOSAN After Sales Service before welding on integral components loader arm frames car body track frames turntable attachment etc of the machine It is possible that some types...

Page 87: ...ing when welding near fuel and oil tanks batteries hydraulic piping lines or other fire hazards 2 Never weld when the engine is running Battery cables must be disconnected before the welding procedure is started 3 Never weld on a wet or damp surface The presence of moisture causes hydrogen embrittlement and structural weakening of the weld 4 If welding procedures are being performed near cylinder ...

Page 88: ...e from any part of the hydraulic system could be an indication of air in the system and many other types of problems As a general precaution and to help minimize the risk of potential long term damage allow the engine to run at no load idle speed immediately after initial start up Hydraulic fluid will circulate releasing any air that may have been trapped in the system before load demands are impo...

Page 89: ... the hydraulic circuit may be imminent or have already occurred Open the drain plugs on the main pump casings and check and compare drain oil in the pumps Look for evidence of grit or metallic particles Vibration or unusual noise during operation could be an indication of air leaking into the circuit Refer to the appropriate Troubleshooting section for component or unit for procedures or it may be...

Page 90: ... residue solvent and thoroughly clean exterior surfaces of assemblies before any part of the circuit is opened up or disassembled NOTE It s just as important to clean the cap and reservoir top before routine fluid changes or quick checks as it is before major repairs Accumulated dirt attracts moisture oil and other fluids and more dirt Keep dismantled parts covered during disassembly Use clean cap...

Page 91: ... fine dust are especially hazardous Clogging of valve spools or external piping especially pilot circuit piping can gradually diminish or very suddenly put a complete stop to normal hydraulic function You can prevent having to make these types of repairs by following recommended assembly procedures 1 Use new O rings and oil seals whenever hydraulic assemblies are rebuilt 2 Prepare joint surfaces b...

Page 92: ...ngs that are not lubricated DO NOT SPIN BEARINGS WHEN DRYING bearings may be rotated slowly by hand to facilitate drying process 3 Carefully inspect all bearing rollers cages and cups for wear chipping or nicks to determine condition Do not replace a bearing cone or cup individually without replacing mating cup or cone at the same time After inspection dip bearings in light weight oil and wrap in ...

Page 93: ...cratches wear grooves and dirt Remove any scratches and burrs with crocus cloth Remove foreign material Replace any parts that are deeply grooved or scratched which would affect their operation Bearing inspection The conditions of the bearing are vital to the smooth and efficient operation of the machinery When any component containing bearings is disassembled always carefully examine the conditio...

Page 94: ...een turning in its housing or on its shaft If available use magna flux or similar process for checking for cracks that are not visible to the naked eye The following illustrations will aid in identifying and diagnosing some of the bearing related problems NOTE The illustrations will only show tapered roller bearings but the principles of identifying diagnosing and remedying the defects are common ...

Page 95: ...rheat lubricant failure or overload Replace bearing check seals and check for proper lubrication Abrasive Step Wear Pattern on roller ends caused by fine abrasives Clean all parts and housings check all parts and housings check seals and bearings and replace if leaking rough or noisy Figure 4 Figure 5 Figure 6 ...

Page 96: ...ngs check seals and check for proper lubrication Misalignment Outer race misalignment due to foreign object Clean related parts and replace bearing Make sure races are properly seated Indentations Surface depressions on race and rollers caused by hard particles of foreign materials Clean all parts and housings check seals and replace bearings if rough or noisy Figure 7 Figure 8 Figure 9 ...

Page 97: ...s Brinelling Surface indentations in raceway caused by rollers either under impact loading or vibration while the bearing is not rotating Replace bearing if rough or noisy Cage Wear Wear around outside diameter of cage and roller pockets caused by abrasive material and inefficient lubrication Replace bearings check seals Figure 10 Figure 11 Figure 12 ...

Page 98: ...isy Cracked Inner Race Race cracked due to improper fit cocking or poor bearing seat Replace all parts and housings check seals and bearings and replace if leaking Smears Smearing of metal due to slippage caused by poor fitting lubrication overheating overloads or handling damage Replace bearings clean related parts and check for proper fit and lubrication Replace shaft if damaged Figure 13 Figure...

Page 99: ...r loss of temper on races or rollers a simple file test may be made A file drawn over a tempered part will grab and cut metal whereas a file drawn over a hard part will glide readily with no metal cutting Replace bearing if over heating damage is indicated Check seals and other related parts for damage Stain Discoloration Discoloration can range from light brown to black caused by incorrect lubric...

Page 100: ...SP000016 General Maintenance Procedures Page 20 ...

Page 101: ...SP000813 Page 1 Standard Torques SP000813 STANDARD TORQUESSP000813 Standard Torques Edition 1 ...

Page 102: ...SP000813 Standard Torques Page 2 MEMO ...

Page 103: ...or Standard Metric Fasteners 6 Torque Values for Standard U S Fasteners 7 Type 8 Phosphate Coated Hardware 9 Torque Values for Hose Clamps 10 Torque Values for Split Flanges 11 Torque Wrench Extension Tools 12 Torque Multiplication 12 Other Uses for Torque Wrench Extension Tools 13 Tightening Torque Specifications Metric 14 ...

Page 104: ...SP000813 Standard Torques Page 4 MEMO ...

Page 105: ...all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE ALL MODELS ALL RANGES ...

Page 106: ... 12 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 43 39 9 00 65 09 8 00 57 86 11 50 83 17 10 50 75 94 15 50 112 11 17 90 129 47 18 50 133 81 26 00 188 05 31 00 224 22 M16 x 1 5 6 20 44 84 6 50 47 01 9 70 70 16 8 60 62 20 12 50 90 41 11 30 81 73 17 ...

Page 107: ...sed 0 70 When Molykote white lead or similar mixtures are used as lubricants 0 75 When Parkerized bolts or nuts are used 0 85 When cadmium plated bolts or nuts and zinc bolts w waxed zinc nuts are used 0 90 When hardened surfaces are used under the nut or bolt head NOTE When reusing bolts and nuts in service use minimum torque values Type S A E Grade Description Bolt Head Marking 1 1 OR 2 WILL HAV...

Page 108: ...oot Pounds ft lb Newton Meter Nm Foot Pounds ft lb Newton Meter Nm 1 4 20 6 8 9 12 1 4 28 7 9 11 15 5 16 18 13 18 18 24 5 16 24 15 20 21 28 3 8 16 24 33 34 46 3 8 24 27 37 38 52 7 16 14 38 52 54 73 7 16 20 42 57 60 81 1 2 13 58 79 82 111 1 2 20 65 88 90 122 9 16 12 84 114 120 163 9 16 18 93 126 132 179 5 8 11 115 156 165 224 5 8 18 130 176 185 251 3 4 10 205 278 290 393 3 4 16 240 312 320 434 7 8 ...

Page 109: ...ues shown below also apply to the following 1 Phosphate coated bolts used in tapped holes in steel or gray iron 2 Phosphate coated bolts used with phosphate coated prevailing torque nuts nuts with distorted threads or plastic inserts 3 Phosphate coated bolts used with copper plated weld nuts Markings on bolt heads or nuts indicate material grade ONLY and are NOT to be used to determine required to...

Page 110: ... 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 0 68 0 72 59 63 Worm Drive Under 44 mm 1 3 4 in Open Diameter 0 2 0 3 20 30 0 5 0 6 40 50 Worm Drive Over 44 mm 1 3 4 in Open Diameter 0 5 0 6 40 50 Worm Drive All Ultra Tite 0 6 0 7 50 60 0 5 0 6 40 5...

Page 111: ...g 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 61 Split Flanges Flange Size Bolt Size Bolt Torque Kilogram Meter kg m Foot Pounds ft lb 1 2 5 16 2 1 2 5 15 18 3 4 3 8 3 0 3 7 22 27 1 3 8 3 7 4 8 27 35 1 1 4 7 16 4 8 6 2 35 45 1 1 2 1 2 6 4 8 0 4...

Page 112: ...or situations if the right extension tool is used or fabricated Torque Multiplication A wrench extension tool can be used to increase the tightening force on a high capacity nut or bolt For example doubling the distance between the bolt and the back handle end of the torque wrench doubles the tightening force on the bolt It also halves the indicated reading on the scale or dial of the torque wrenc...

Page 113: ...n a fastener For example a torque wrench and extension can be used to measure adjustment tightness of a linkage or assembly Specially fabricated extensions can be used to make very precise checks of the force required to engage or disengage a clutch mechanism release a spring applied brake assembly or take up free play in most any movable linkage Once the value of the adjustment force is establish...

Page 114: ...y compound Use the information on this page as a general guide in selecting specific formulas that will meet the particular requirements of individual assembly installations DOOSAN does not specifically endorse a specific manufacturer or brand name but the following table of Loctite applications is included for which cross references to other makers products should also be widely available IMPORTA...

Page 115: ...C 500 F Remove HOT 210 Product Application Color Removal Required Setup 545 No filler nonclog formula for high pressure hydraulic systems Over application will not restrict or foul system components Purple Hand tools 4 Hours or 1 2 hour with Locquic T Primer 656 Solvent resistant higher viscosity tapered thread sealer White Hand tools 4 Hours or 1 2 hour with Locquic T Primer Product Application C...

Page 116: ... 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 Application Color Notes 380 Black Max instant adhesive for shock and vibration resistant bonds Black May take 120 hours to reach full cure strength 454 Adhesive for porous surfaces Clear Full strengt...

Page 117: ...1Upper Structure ...

Page 118: ......

Page 119: ...SP001737 Page 1 Cabin SP001737 CABIN SP001737 Cabin Edition 1 ...

Page 120: ...SP001737 Cabin Page 2 MEMO ...

Page 121: ...SP001737 Page 3 Cabin Table of Contents Cabin Safety Precautions 5 Applicable Models 5 Removal 6 Installation 10 ...

Page 122: ...SP001737 Cabin Page 4 MEMO ...

Page 123: ...e front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up DX420LC 5327 and Up DX480LC 5221 a...

Page 124: ...in interior lighting B External light wiring C Radio antenna and connections D Wiper washer connections NOTE Control console wiring harnesses and hydraulic piping lines that pass through the floor of the cabin do not need to be disassembled NOTE If unit is equipped with a cabin protective structure for forestry or hazardous working conditions it must be removed CAUTION Avoid disassembling cabin if...

Page 125: ... 7 Figure 2 and switch panel 8 Figure 2 15 After removing rear mat 1 Figure 3 remove rear center cover 2 Figure 3 cassette cover 3 Figure 3 and rear side covers 4 and 5 Figure 3 16 Remove fuse box bracket 1 Figure 4 from left side wall without disassembly harness connector 17 Disconnect cabin ground cable located near fuse box bracket 18 Remove cassette bracket 2 Figure 4 and disconnet antenna and...

Page 126: ...r ducts 1 2 3 4 and 5 Figure 6 right side of cabin step by step from the front duct 23 Disconnect washer hose located at floor plate bottom 24 Disconnect cabin wiring connectors from main harness 25 Remove four mounting nuts from four corners of cabin floor 1 Figure 7 26 Remove four M12 hex bolts 2 Figure 7 and two M10 hex bolts 3 Figure 7 Figure 5 Figure 6 Figure 7 ...

Page 127: ...8 NOTE Cabin weights approximately 315 kg 700 lb 28 Lift cab from 25 50 mm 1 2 above deck height Check that all electrical connections have been disconnected and all other items unbolted 29 Continue lifting with the assist crane to remove the cab shell Lower the shell to a prepared safe blocking support Figure 8 ...

Page 128: ...OTE Mounting nut torque 21 kg m 205 N m 150 lbf ft 4 Install four M12 hex bolts 2 Figure 10 and two M10 hex bolts 3 Figure 10 NOTE Mounting nut torque M12 11 kg m 108 N m 80 lbf ft M10 6 5 kg m 64 N m 47 lbf ft 5 Once cab is mounted to floor unhook lifting device 6 Connect cabin wiring connectors to main harness 7 Connect washer hose located at floor plate bottom 8 Install air ducts 1 2 3 4 and 5 ...

Page 129: ... Figure 13 12 Install cassette bracket 2 Figure 13 and connet antenna and speaker wire 13 Connect cabin gound cable located near fuse box bracket 14 Install fuse box bracket 1 Figure 13 to left side wall of the cab 15 Install rear side covers 4 and 5 Figure 14 cassette cover 3 Figure 14 and rear center cover 2 Figure 14 last install rear mat 1 Figure 14 Figure 12 Figure 13 Figure 14 ...

Page 130: ...de covers 5 and 6 Figure 15 when install cover 4 Figure 15 connect hour meter connector 17 Install seat 2 Figure 15 NOTE Be careful not to damage seat covering 18 Install floor mat 1 Figure 15 19 Connect negative battery cable leading to frame from battery Figure 15 ...

Page 131: ...SP001748 Page 1 Counterweight SP001748 COUNTERWEIGHT SP001748 Counterweight Edition 1 ...

Page 132: ...SP001748 Counterweight Page 2 MEMO ...

Page 133: ...SP001748 Page 3 Counterweight Table of Contents Counterweight Safety Precautions 5 Applicable Models 5 General 6 Warning for Counterweight and Front Attachment Removal6 Removal 8 Installation 9 ...

Page 134: ...SP001748 Counterweight Page 4 MEMO ...

Page 135: ...recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up ...

Page 136: ... crane operator and the remainder of the work crew FG000371 Figure 1 DANGER DOOSAN warns any user that the removal of the counterweight from the machine front attachment or any other part may affect the stability of the machine This could cause unexpected movement resulting in death or serious injuries DOOSAN is not liable for any misuse Never remove the counterweight or front attachment unless th...

Page 137: ...emoved always go backwards up the loading ramp The counterweight end of the deck has to get on the trailer first while the cabin is still going up the ramp Figure 1 WARNING If the turntable deck has been unbalanced by removal of weight from one end only traveling the excavator swinging the turntable movement over bumps or sloping and uneven surfaces could cause loss of control and possible acciden...

Page 138: ...device capable of handling a heavy load partially support counterweight 1 Figure 4 before loosening four bolts 2 Stop lifting with assist crane as soon as lifting slings are taut 13 Remove four bolts 2 Figure 4 and washers 3 from counterweight 1 NOTE Heat bolts if necessary to free them 14 When bolts 2 Figure 4 and washers 3 have been removed lift counterweight 1 a very short distance above suppor...

Page 139: ...weight mounting holes 2 Slide washers 3 Figure 5 onto bolts 2 Apply Loctite 242 to mounting bolt threads 3 Install four bolts 2 Figure 5 with washers 3 into counterweight until washers contact support frame Fully lower counterweight onto support frame and finish tightening bolts NOTE Torque bolts 2 Figure 5 to values shown in following table 4 Remove lifting device and lifting eyes from counterwei...

Page 140: ...SP001748 Counterweight Page 10 ...

Page 141: ...SP002027 Page 1 Fuel Tank SP002027 FUEL TANK SP002027 Fuel Tank Edition 1 ...

Page 142: ...SP002027 Fuel Tank Page 2 MEMO ...

Page 143: ...SP002027 Page 3 Fuel Tank Table of Contents Fuel Tank Safety Precautions 5 Applicable Models 5 General Description 6 Parts List 6 Specifications 7 Removal 8 Installation 12 Start up Procedures 15 ...

Page 144: ...SP002027 Fuel Tank Page 4 MEMO ...

Page 145: ... safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LCA 5001 and Up ...

Page 146: ...NING 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 potential fire hazards 9 4 7 5 7 13 3 6 8 13 2 18 17 16 1 10 FG000470 11 12 14 14 15 15 51 52 Figure 1 ...

Page 147: ...liters 132 U S gal Reference Number Description 1 Fuel Tank 2 O ring 3 Cover 4 Bolt 5 Spring Washer 6 Drain Valve 7 Bolt 8 Shim 9 Shim 10 Fuel Strainer 11 Cap 12 Level Gauge 13 Spacer 14 Bolt 15 Clip 16 Fuel Sender 17 Bolt 18 Spring Washer Reference Number Description ...

Page 148: ...ront attachment bucket to ground 4 Shut down engine 5 Set safety lever on RELEASED position 6 Turn starter switch to I ON position 7 Fully stroke work levers joysticks in all directions to relieve any pressure from accumulators 8 Set safety lever on LOCK position 9 Turn key to O OFF position and remove from starter switch 10 Hang maintenance warning tag on controls 11 Disconnect negative battery c...

Page 149: ...drain valve 6 Figure 6 at bottom of tank and drain NOTE Fuel tank capacity is 500 liters 132 U S gal 14 Tag and disconnect fuel supply line 21 Figure 7 and fuel return line 19 from fuel tank 1 and carefully drain remaining fuel from lines 15 Remove clamp 20 Figure 7 holding fuel return line 19 to tank 1 FG003871 11 Figure 5 FG003872 6 Figure 6 20 21 19 1 FG003873 Figure 7 ...

Page 150: ...cover 24 from fuel tank 18 Remove six bolts 25 and 26 Figure 10 and stay 27 from fuel tank and frame Remove four bolts 28 and 29 and fuel tank cover 30 from fuel tank Remove two bolts 31 and bracket 32 from tank Remove four bolts 33 and battery cover 34 from frame 1 22 FG003874 Figure 8 23 24 FG003875 Figure 9 FG003876 25 26 27 31 32 29 28 30 33 34 Figure 10 ...

Page 151: ...nd spacers 13 Figure 13 holding tank 1 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 inspection NOTE The clear level gauge on the side of the tank is easily damaged Be careful of obstacles and wind gusts 23 Remove shims 9 Figure 13 NOTE If tank is to be reused note position and amou...

Page 152: ... the tank is easily damaged Be careful of obstacles and wind gusts 3 Install shims 9 Figure 14 as needed to prevent tank 1 from rocking or stress from mounting bolts 7 4 Tighten mounting bolts 7 Figure 14 after shims are installed NOTE Bolt torque is 27 kg m 200 ft lb 5 Install four bolts 35 and 36 Figure 15 and cover 37 on fuel tank and support 6 Connect wires as tagged to fuel sender 16 Figure 1...

Page 153: ...28 and 29 and fuel tank cover 30 on fuel tank Install six bolts 25 and 26 and stay 27 on fuel tank and frame 8 Install five bolts 23 Figure 18 and cover 24 on fuel tank 9 If equipped connect components to fuel filler pump port 22 Figure 19 on side of fuel tank 1 FG003876 25 26 27 31 32 29 28 30 33 34 Figure 17 23 24 FG003875 Figure 18 1 22 FG003874 Figure 19 ...

Page 154: ... 1 11 Install clamp 20 Figure 20 to hold fuel return line 19 to tank 1 12 Make sure fuel tank drain valve 6 Figure 21 on bottom of tank is closed 13 Fill fuel tank and check for signs of leaks Correct any problems found 14 Connect negative battery cable to battery 20 21 19 1 FG003873 Figure 20 Figure 21 FG003872 6 ...

Page 155: ...l filter 3 Loosen plug 1 Figure 23 on top of fuel filter head 4 Pump hand operated primer pump 2 Figure 23 by the fuel injection pump Pump primer until fuel is present at plug hole in fuel filter head 5 Tighten plug in fuel filter head 6 Continue to pump primer pump until a strong resistance is felt 7 Start engine and look for signs of leaks Repeat procedure if necessary FG015484 Figure 22 Figure ...

Page 156: ...SP002027 Fuel Tank Page 16 ...

Page 157: ...SP000021 Page 1 Fuel Transfer Pump Opt SP000021 FUEL TRANSFER PUMP OPT SP000021 Fuel Transfer Pump Opt Edition 1 ...

Page 158: ...SP000021 Fuel Transfer Pump Opt Page 2 MEMO ...

Page 159: ...p Opt Table of Contents Fuel Transfer Pump Opt Safety Precautions 5 Applicable Models 5 General Description 6 Theory of Operation 6 Troubleshooting 7 Replacement of Rotor and Vane 7 Replacement of Rear Cover 8 Replacement of Armature 8 ...

Page 160: ...SP000021 Fuel Transfer Pump Opt Page 4 MEMO ...

Page 161: ...ed in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up DX420LC 5327 and Up DX480L...

Page 162: ...ts of a motor pump switch and hose assembly FG003881 IN OUT 1 2 4 2 2 2 1 6 5 3 Fuel Fuel Tank 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 Valve 6 Strainer Cap Reference Number Description FG001143 Pump Hose Switch Figure 2 ...

Page 163: ... 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 is not present the switch is bad Be sure to check resistance through the motor REPLACEMENT OF ROTOR AND VANE If dirt or other foreign materials enter the pump during operation it can become lodged between the rotor and or vanes and generate he...

Page 164: ... screw in the housing Be careful when installing the screw The cover screw may be attracted by the motor magnet REPLACEMENT OF ARMATURE You can replace only the armature in case motor was damaged by a short circuit Remove the switch cover and rear cover 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 Repl...

Page 165: ...SP001856 Page 1 Swing Bearing SP001856 SWING BEARING SP001856 Swing Bearing Edition 1 ...

Page 166: ...SP001856 Swing Bearing Page 2 MEMO ...

Page 167: ...ntents Swing Bearing Safety Precautions 5 Applicable Models 5 Swing Bearing Maintenance 6 Operating Recommendation 6 Measuring Swing Bearing Axial Play 6 Measuring Bearing Lateral Play 6 Swing Bearing Basic Operation 7 Disassembly 7 Assembly 9 ...

Page 168: ...SP001856 Swing Bearing Page 4 MEMO ...

Page 169: ...n the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up DX420LC 5327 and Up DX480LC 52...

Page 170: ... 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 however as the bearing begins to approach the limit of its service life clearance increases become much more pronounced and the actual measured play in the bearing could exceed twice the value that was measured...

Page 171: ...motor is transferred to the pinion by planetary gears connected to gears on the inner ring which is fixed in the undercarriage Ball bearings turn the outer ring Disassembly 1 Remove tip of tapered pin 3 Figure 3 using grinder and tap lightly to remove debris 2 Remove plug 4 Figure 4 using a M10 x 1 5 bolt Figure 2 Reference Number Description 1 Outer Ring 2 Inner Ring 3 Tapered Pin 4 Plug 5 Ball 6...

Page 172: ... and check that inner ring can move freely See Figure 5 if not replace seal 7 Figure 6 4 Turn inner ring and use magnet bar C Figure 6 to remove steel balls 5 5 Turn inner ring and use wire D Figure 7 to remove retainers 6 Figure 5 Figure 6 Figure 7 ...

Page 173: ...ition 2 Hoist the outer race by crane horizontally and match it with the inner race coaxially Rotating the outer race insert balls 5 support 6 into the plug 4 hole one by one with a round bar 3 Top plug 4 into outer race 1 and then drive pin 3 into the pin hole Caulk the head of pin 3 with a punch Fill grease through the grease fitting Figure 8 Figure 9 Figure 10 Figure 11 ...

Page 174: ...SP001856 Swing Bearing Page 10 ...

Page 175: ...SP002028 Page 1 Swing Reduction Gear SP002028 SWING REDUCTION GEARSP002028 Swing Reduction Gear Edition 1 ...

Page 176: ...SP002028 Swing Reduction Gear Page 2 MEMO ...

Page 177: ...heory of Operation 7 Parts List 8 Specifications 9 Troubleshooting Testing and Adjustment 10 Removal 11 Disassembly 12 Cleaning and Inspection Wear Limits and Tolerances 21 Reassembly 22 Shaft and S R Bearing Heat fit 22 Assembly of Carrier Subassemblies 22 Assembly of Main Case 28 Assembly of Motor 44 Installation 48 Start up Procedures 49 ...

Page 178: ...SP002028 Swing Reduction Gear Page 4 MEMO ...

Page 179: ...w all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LCA 5001 and Up ...

Page 180: ...SP002028 Swing Reduction Gear Page 6 ...

Page 181: ...ears and two stage output reduction The planetary gear engages the ring gear The pinion gear is connected to the output shaft and spline The final drive reduces swing motor rpm in order to increase swing motor output torque The available maximum swing speed provides a fast turning rate for efficient rapid work cycling with more than adequate power for good acceleration ...

Page 182: ...SP002028 Swing Reduction Gear Page 8 Parts List 39 31 30 29 38 10 15 9 32 11 13 4 33 37 27 27 26 12 22 18 19 21 14 17 2 1 3 6 7 8 5 25 23 24 20 28 35 34 36 A A FG000852 Figure 1 ...

Page 183: ...rical Roller Bearing 23 Spherical Roller Bearing 24 Oil Seal 25 Spring Pin 26 Plug 27 Plug 28 Pinion 29 Socket Head Bolt 30 Pipe 31 Level Gauge 32 No 3 Thrust Plate 33 Retaining Ring 34 Socket Head Bolt 35 Cover 36 Wire 37 Retaining Ring 38 Case Cover 39 Socket Head Bolt Reference Number Description Swing Reduction Gearbox Specification Drive Type Two stage Planetary Gear Reduction Ratio 21 968 Ma...

Page 184: ...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 system noises from the swing motor 2 Oil leakage a From drive shaft Oil seal damaged Replace oil seal b From bolted connections or other Assembly compound joint sealer Disassemble and check assembled surfaces old and no...

Page 185: ...mponent 12 Remove drain plug 3 Figure 3 from reducer 8 and drain oil from reduction gearbox 5 Figure 3 13 Reassemble drain plug 3 to reducer 8 and disconnect hose 2 Figure 3 from reduction gearbox 5 14 Disconnect grease lubrication line 7 Figure 3 from reduction gearbox 5 15 Remove twelve bolts and washers 4 Figure 3 holding swing reduction gearbox 5 to frame 16 Using a suitable lifting device sli...

Page 186: ...se IMPORTANT Select a clean place Spread a rubber mat or cloth on top of the overhaul workbench to prevent parts from being damaged Figure 4 CAUTION The motor should be separated without damage or any foreign substance Figure 5 Figure 6 CAUTION Care should be taken not to damage mounting surface of cover Carefully remove all gasket material from mounting surfaces ...

Page 187: ...SP002028 Page 13 Swing Reduction Gear 4 Remove No 1 sun gear from No 1 carrier Figure 7 Figure 8 Figure 9 CAUTION Care should be taken not to damage teeth of No 1 sun gear ...

Page 188: ...SP002028 Swing Reduction Gear Page 14 5 Remove No 1 carrier Figure 10 Figure 11 Figure 12 ...

Page 189: ...nd No 2 sun gear 7 Install eye bolts in No 2 carrier and remove it from ring gear Figure 13 CAUTION Care should be taken not to damage teeth of No 2 sun gear Figure 14 Figure 15 CAUTION Care should be taken not to damage teeth of No 2 carrier and ring gear ...

Page 190: ...r Page 16 8 Install eye bolts in ring gear and remove it Figure 16 Figure 17 CAUTION Care should be taken not to damage mounting surfaces of ring gear and case Carefully remove all gasket material from mounting surfaces Figure 18 ...

Page 191: ...SP002028 Page 17 Swing Reduction Gear 9 Use a rollover machine to turn assembly over loosen lock wire bolts and cover Figure 19 Figure 20 Figure 21 ...

Page 192: ...SP002028 Swing Reduction Gear Page 18 10 Remove pinion gear 11 Using a gear puller to remove collar Figure 22 Figure 23 Figure 24 ...

Page 193: ...k ring and disassemble plate 13 Use a rollover machine to turn case over and place a jig on drive shaft Use a press to remove drive shaft from case Figure 25 Figure 26 Figure 27 CAUTION Care should be taken not to have drive shaft drop to floor when it is pressed out of case ...

Page 194: ...SP002028 Swing Reduction Gear Page 20 14 Remove bearing from case 15 Put drive shaft in press and remove bearing and spacer Figure 28 Figure 29 Figure 30 ...

Page 195: ...SP002028 Page 21 Swing Reduction Gear CLEANING AND INSPECTION WEAR LIMITS AND TOLERANCES For general cleaning and inspection procedures refer to General Maintenance Procedures section Figure 31 ...

Page 196: ...nsert it slowly first by 4 5 mm 0 16 0 29 in for bearing to seat itself and then push it hard that it contacts to spacer assembled in shaft completely 4 After bearing assembly is completed leave it air cool for 1 2 hours Assembly of Carrier Subassemblies Cleaning Carrier Put carrier to whose corners grinding was made to remove all foreign substances like burr on steam washer if there remain any fo...

Page 197: ...ign No 1shaft with hole and press it into place 3 Make sure that shaft is fully pressed into position 4 Install remaining three No 1 shafts into carrier in same manner FG000878 Figure 33 FG000879 Figure 34 FG000880 Figure 35 FG000881 Figure 36 ...

Page 198: ...ver carrier Install a No 1 thrust washer onto each of the four shafts 6 Install four No 1 planetary gears 7 Position a No 3 thrust washer on each gear as shown in Figure 40 FG000882 Figure 37 FG000883 Figure 38 FG000884 Figure 39 FG000885 Figure 40 ...

Page 199: ...ooves Make sure that gears properly rotate Assembly of No 2 Carrier 1 Put No 2 carrier on assembly jig as shown in Figure 43 NOTE Lifting eye hole should be facing up 2 Insert No 2 bushing into No 2 planetary gear and position a No 2 thrust washer on it FG000886 Figure 41 FG000887 Figure 42 FG000888 Figure 43 2 1 FG000889 Figure 44 ...

Page 200: ...hrust washer must be on bottom side of gear 4 Align spring pin hole in No 2 shaft with spring pin hole of No 2 carrier Insert shaft into carrier and No 2 bushing NOTE Shaft may need to be gently tapped with a soft faced hammer FG000890 Figure 45 FG000891 Figure 46 FG001354 They should be placed on straight line Figure 47 FG000893 Figure 48 ...

Page 201: ...gears in same manner 6 After all four shafts are installed align spring pin with carrier hole and drive it into position using a hammer 7 Using a hammer and punch calking spring pin into position FG000894 Figure 49 FG000895 Figure 50 FG000896 Figure 51 FG000897 Figure 52 ...

Page 202: ...ts to remove any foreign substances Cleaning fluid PK6540 alkali Liquid density 3 5 Liquid temperature 60 70 C 140 158 F Assembly of Shaft and Pinion 1 Insertion of shaft subassembly A Set gear case as shown in Figure 55 B Using a suitable lifting device lower shaft subassembly into case C Using special jig keep bearing level and press it into case FG000898 Figure 53 FG000899 Figure 54 FG000900 Fi...

Page 203: ...e 29 Swing Reduction Gear 2 Remove bearing insertion jig and assemble plate with its step part so it is facing down as shown in Figure 59 FG000901 Figure 56 FG000902 Figure 57 FG000903 Figure 58 FG000904 Figure 59 ...

Page 204: ... sure lock ring is inserted completely into groove 4 Insert collar on shaft making sure it is properly seated Install pinion gear and special jig on shaft and press collar and pinion gear into place on shaft and case FG000905 Figure 60 FG000906 Figure 61 FG000907 Figure 62 FG000908 Figure 63 ...

Page 205: ...eduction Gear 5 Install lock plate and drilled head bolts on end of shaft NOTE Coat bolts with Loctite 262 NOTE Torque bolts to 2 700 kg cm 195 ft lb FG000909 Figure 64 FG000910 Figure 65 FG000911 Figure 66 FG000912 Figure 67 ...

Page 206: ...SP002028 Swing Reduction Gear Page 32 6 Use lock wire to hold drilled head bolts in final position FG000913 Figure 68 FG000914 Figure 69 FG000915 Figure 70 FG000916 Figure 71 ...

Page 207: ...o foreign substance left on seal assembly apply grease to and around lip of oil seal TC5001300 as in Figure 75 and Loctite 609 to its external part 3 Using seal installation jig press seal into case keeping it level during installation Make sure that seall is fully seated FG000917 Figure 72 FG000918 Figure 73 FG000919 Figure 74 FG000920 Figure 75 ...

Page 208: ...21 Figure 76 CAUTION Make sure that there is no foreign substances on lip area Use care not to damage seal when inserting it Chack for proper installation after pressing seal into position FG000922 Figure 77 FG000923 Figure 78 FG000924 Figure 79 ...

Page 209: ... installation jig position bearing on end of shaft with bearing trade mark on inner race facing up Press bearing firmly into place making sure it is properly seated FG000925 Figure 80 FG000926 Figure 81 FG000927 Figure 82 23024CM33C3 FG000928 Figure 83 ...

Page 210: ...SP002028 Swing Reduction Gear Page 36 5 Rotate pinion by hand and check if it turns properly FG000929 Figure 84 FG000930 Figure 85 FG000931 Figure 86 FG000932 Figure 87 ...

Page 211: ...and PT1 8 drain ports Assembly of Ring Gear 1 Insertion of lock pin Insert four lock pins in four reamed holes of case flange Tap them into place by gently hitting them with a soft face hammer FG000933 Figure 88 FG000934 Figure 89 FG000935 Figure 90 Figure 91 FG000936 ...

Page 212: ... mating surface clean with cloth match and align holes after checking its assembling direction and press assembled parts firmly by tightening special bolts M16x160 on which no Loctite has been applied NOTE The specail bolts will be removed during Step 6 on page 41 FG000937 Figure 92 FG000938 Figure 93 FG001353 Aim at holes Figure 94 FG000940 Figure 95 ...

Page 213: ...planetary gears are engaged Continue to lower carrier and engaging it onto splines of pinion shaft Make sure that carrier is resting on bearing NOTE Make sure that carrier and drive shaft can rotate 2 Install No 2 sun gear in No 2 carrier 3 Postion thrust plate on No 2 sun gear FG000941 Figure 96 FG000942 Figure 97 FG000943 Figure 98 FG000944 Figure 99 ...

Page 214: ...Gear Page 40 4 Position No 1 carrier assembly into ring gear making sure it engages No 2 sun gear 5 Install No 1 sun gear in middle of No 1 carrier FG000945 Figure 100 FG000946 Figure 101 FG000947 Figure 102 FG000948 Figure 103 ...

Page 215: ...sket on ring gear 8 Align mounting holes and postion case cover on ring gear 9 Coat socket head bolts with Loctite and install NOTE Torque bolts to 2 700 kg cm 195 ft lb FG000949 Figure 104 FG000950 Figure 105 FG000951 Figure 106 FG001352 Service tap of the ring gear Penetrating hole of the ring gear Should be matched Figure 107 ...

Page 216: ...SP002028 Swing Reduction Gear Page 42 FG000953 Figure 108 FG000954 Figure 109 FG000955 Figure 110 FG000956 Figure 111 ...

Page 217: ...SP002028 Page 43 Swing Reduction Gear FG000957 Figure 112 FG000958 Figure 113 ...

Page 218: ...sembly of Motor Add Gear Oil 1 Fill case with 7 0 liters 1 8 U S gal of gear oil EP80W 90 2 Install level pipe in plug hole Assembly of Motor 1 Apply liquid gasket to cover assembly FG000968 Figure 114 FG000970 Figure 115 FG000983 Figure 116 ...

Page 219: ...ft spline Align mounting holes and intall motor on case cover NOTE Gear oil fill plug should point towards fill tube 3 Apply Loctite on bolts Install bolts FG001350 Gear Oil Inlet PT3 8 Figure 117 FG001351 Should be placed on a straight line Figure 118 FG000973 Figure 119 FG000974 Figure 120 ...

Page 220: ...fied torque Mark them with paint marker Supply of Grease 1 Install grease fitting in grease inlet and add grease through grease until it starts to be discharged from the opposite hole FG000975 Figure 121 FG000976 Figure 122 FG000977 Figure 123 FG000978 Figure 124 ...

Page 221: ...ng Reduction Gear 2 Remove grease fitting and install a plastic plug in hole to prvent contamination A grease hose will be connected during installtion on machine FG000979 Figure 125 FG000980 Figure 126 FG000981 Figure 127 ...

Page 222: ...arbox 5 as an assembly on unit 4 Install twelve bolts and washers 4 Figure 129 to secure swing reduction gearbox 5 to frame NOTE Apply Loctite 262 to bolt threads NOTE Tighten bolt to 95 kg m 690 ft lb 5 Connect hose 2 Figure 129 to reduction gearbox 5 6 Connect grease lubrication line 7 Figure 129 to reduction gearbox 5 7 Connect hoses as tagged during removal to swing motor 1 Figure 129 8 Fill s...

Page 223: ...set throttle at LOW IDLE and swing upper structure slowly two full revolutions to left and right 4 Shut engine down and check hydraulic oil level Fill hydraulic oil tank to H mark on sight gauge 5 Check for oil leaks and clean all fill and venting locations ARO1689P Figure 130 IMPORTANT If air is not vented from system it will cause damage to swing motor and bearings ...

Page 224: ...SP002028 Swing Reduction Gear Page 50 ...

Page 225: ...1Lower Structure and Chassis ...

Page 226: ......

Page 227: ...SP001741 Page 1 Track Assembly SP001741 TRACK ASSEMBLY SP001741 Track Assembly Edition 1 ...

Page 228: ...SP001741 Track Assembly Page 2 MEMO ...

Page 229: ...hoes and Links 15 Track Removal 15 Track Installation 16 Front Idler Roller 18 Parts List 18 Front Idler Roller Disassembly 19 Front Idler Roller Reassembly 21 Lower Roller 22 Parts List 22 Lower Roller Removal 23 Lower Roller Disassembly 23 Lower Roller Reassembly 24 Lower Roller Installation 25 Upper Roller 26 Parts List 26 Upper Roller Removal 27 Upper Roller Disassembly 27 Upper Roller Reassem...

Page 230: ...SP001741 Track Assembly Page 4 MEMO ...

Page 231: ...safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up ...

Page 232: ...Track Assembly Page 6 GENERAL DESCRIPTION The track assembly is composed of the following major components 1 Track 2 Front Idler Roller 3 Upper Roller 4 Lower Roller 5 Track Spring and Track Adjustment Cylinder ...

Page 233: ... can cause excessive component wear The recommended adjustment can also be too tight causing accelerated stress and wear if ground conditions are wet marshy or muddy or if the ground is hard and full of rocks or gravel WARNING Safely measuring track tension requires two people One person must be in the operator s seat running the controls to keep one side frame in the air while the other person ma...

Page 234: ...r clearance in the tracks and the adjustment is too tight the idler wheel and adjusting cylinder can be retracted by bleeding off grease through hole in adjustment cylinder 2 Figure 3 Terrain Type Distance A DX300LC DX300LCA DX340LC DX350LC Normal B 320 340 mm 12 60 13 39 in 330 360 mm 13 0 14 17 in Minimum C 320 mm 12 60 in 330 mm 13 0 in Muddy D 340 370 mm 13 39 14 57 in 360 410 mm 14 17 16 14 i...

Page 235: ...equires welding on additional material and grinding off excess Some components must be replaced before the service limit is exceeded No maintenance or renewal is possible Compare the values in the tables with dimensions and profiles shown in the adjacent figures CAUTION Refer to the Welding Precautions and Guidelines information in General Maintenance Procedures section for general recommendations...

Page 236: ...SP001741 Track Assembly Page 10 Track Shoe 8 7 2 10 11 9 FG003910 1 3 6 4 5 Figure 4 ...

Page 237: ...mm 2 618 0 46 0 41 0 074 0 0 0 336 0 46 8 Interference between regular pin and link Standard Dimension Tolerance Standard Interference Repair Limit Shaft Hole 44 6 mm 1 756 0 235 0 085 0 188 0 25 0 273 0 485 9 Clearance between regular pin and bushing Standard Dimension Tolerance Standard Interference Repair Limit Shaft Hole 44 6 mm 1 756 0 235 0 085 1 35 0 85 0 615 1 265 10 Interference between m...

Page 238: ...008 166 mm 6 535 164 mm P 6 457 3 Width of Tread 50 5 mm 1 988 56 5 mm 2 224 59 5 mm P 2 343 4 Width of Flange 24 mm 0 945 5 Clearance between shaft and bushing Standard Dimension Tolerance Standard Interference Repair Limit Shaft Hole 75 mm 2 953 0 06 0 09 0 390 0 344 0 404 0 48 1 5 mm R 0 059 6 Interference between roller and bushing Standard Dimension Tolerance Standard Interference Repair Limi...

Page 239: ...ad 142 mm 5 591 135 mm 5 315 130 mm P 5 118 3 Width of Tread 45 mm 1 772 52 mm 2 047 54 mm P 2 126 4 Width of Flange 18 5 mm 0 728 5 Clearance between shaft and bushing Standard Dimension Tolerance Standard Interference Repair Limit Shaft Hole 55 mm 2 165 0 01 0 03 0 37 0 33 0 34 0 40 6 Interference between roller and bushing Standard Dimension Tolerance Standard Interference Repair Limit Shaft Ho...

Page 240: ...2 520 568 mm P 22 362 3 Width of Protrusion 102 mm 4 016 4 Total Width 190 mm 7 480 5 Width of Tread 44 mm 1 732 47 mm 1 850 49 mm 1 929 6 Clearance between shaft and bushing Standard Dimension Tolerance Standard Interference Repair Limit Shaft Hole 90 mm 3 543 0 072 0 107 0 34 0 30 0 372 0 447 1 0 mm R 0 039 7 Interference between roller and bushing Standard Dimension Tolerance Standard Interfere...

Page 241: ... Figure 8 holding shoe to link Remove enough shoes to make access to lock pin easier NOTE Support track shoes with blocking so that when master pin 4 Figure 8 is removed track will not fall 5 Straighten lock pin 3 Figure 8 and remove it from master pin 4 Discard lock pin 6 Remove master pin from master links 7 Move unit backward until entire track is laying on ground NOTE Do not drive unit off tra...

Page 242: ...me onto track Make sure all rollers are properly positioned on track 4 Move unit forward while feeding track up over drive sprocket Continue to pull track back until it engages front idle roller 5 Align master links and install master pin 6 Insert new lock pin in master pin Bend end of pin over so it is pointing in opposite direction of other end as shown 7 Apply track tension Refer to Track Tensi...

Page 243: ...SP001741 Page 17 Track Assembly ...

Page 244: ...18 FRONT IDLER ROLLER Parts List 8 6 5 7 3 FG003913 4 2 1 9 9 4 7 8 3 6 Figure 14 Reference Number Description 1 Idler Assembly 2 Idler 3 Bearing 4 Shaft 5 Bushing 6 Pin 7 Floating Seal 8 O ring 9 Plug Reference Number Description ...

Page 245: ...itable container 2 Separate the pin 6 Figure 16 from the bearing 3 3 Use a press to remove the bearing from the axle 4 Separate the O ring 8 Figure 17 from the axle 4 Detach the floating seal 7 Figure 18 from the idler 2 and bearing 3 FG003914 9 Figure 15 FG003915 6 3 Figure 16 3 FG001482 4 8 Figure 17 FG001483 3 3 7 7 2 Figure 18 ...

Page 246: ...ack Assembly Page 20 5 Use a press to separate the axle 4 Figure 19 O ring 8 and bearing 3 6 Remove bushing 5 Figure 20 with the press and special tool 10 ST 1909 FG001484 4 3 8 Figure 19 FG001485 10 5 2 Figure 20 ...

Page 247: ...ether 4 Install floating seal 7 Figure 22 inside the idler 2 and bearing 3 NOTE Apply clean engine oil to the joint side of the floating seal Apply grease to the floating seal O ring 5 Install idler 2 Figure 23 on the axle 6 Install bearing 3 Figure 23 and pin 6 to the axle NOTE Fill the idler assembly with new engine oil with approximately 420 cc 14 2 oz 7 Install plug 9 Figure 28 on the bearing ...

Page 248: ...SP001741 Track Assembly Page 22 LOWER ROLLER Parts List 5 2 7 3 7 6 4 1 4 6 2 8 FG000483 5 8 Figure 24 ...

Page 249: ... 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 If additional track clearance is required remove upper rollers before raising track Lower Roller Disassembly 1 Remove plug 8 Figure 26 from the collar and drain oil 2 Pull the pin 5 Figure 26 from the collar Reference Number Description 1 Roller...

Page 250: ...e axle 5 Separate floating seals 6 Figure 28 from the collar and roller 1 6 Detach collar 2 Figure 28 and O rings 7 from the axle using press Lower Roller Reassembly 1 Degrease clean and dry all parts before reassembly Insert bushing 4 Figure 29 into roller 2 FG001490 Figure 27 2 6 1 2 6 7 FG001493 Figure 28 FG001491 4 Figure 29 ...

Page 251: ...5 Slide the axle inside the roller 6 Install the collar 2 Figure 32 O ring 7 and pin 5 on the remaining side 7 Fill with clean engine oil with approximately 480 0 cc 16 2 oz 8 Install plug 8 Figure 32 on the collar Lower Roller Installation 1 Install four bolts to hold lower roller assembly to track frame NOTE To gain access to some rollers a link guard may have to be removed Remove four spring wa...

Page 252: ...SP001741 Track Assembly Page 26 UPPER ROLLER Parts List 13 15 9 10 7 12 14 11 5 1 4 6 8 3 2 FG001141 Track Frame Figure 34 ...

Page 253: ...k shoe 3 Remove mounting hardware holding upper roller assembly to track frame Upper Roller Disassembly 1 Remove the plug 9 Figure 36 from the cover and drain oil Reference Number Description 1 Roller 2 Shaft 3 Thrust Ring 4 Bushing 5 Bushing 6 Floating Seal 7 O ring 8 O ring 9 Plug 10 Cover 11 Washer 12 Bolt 13 Blot 14 Spring Washer 15 Spring Washer Reference Number Description FG000524 Figure 35...

Page 254: ...38 from the axle 2 4 Separate the floating seal 6 Figure 39 from the roller 5 Separate the O ring 8 and thrust ring 3 from the axle 6 Separate the bushing 4 and 5 Figure 40 from the roller with a press and special tool ST 1919 13 10 12 11 FG001495 Figure 37 2 1 FG001497 Figure 38 1 6 3 8 2 FG003916 Figure 39 FG001502 4 5 ST 1919 Figure 40 ...

Page 255: ...Apply clean engine oil to the joint side of the floating seal Apply grease to the floating seal O ring 3 Install the axle 2 O ring 8 and thrust ring 3 4 Install washer 11 Figure 43 and bolt 12 5 Insert the O ring 7 Figure 43 to the cover 10 Attach cover 10 and bolt 13 to the roller 6 Fill with engine oil with 200cc 7 Tighten plug 9 Figure 43 5 1 FG003917 4 Figure 41 1 6 3 8 2 FG003916 Figure 42 13...

Page 256: ...arts List 8 7 3 5 4 6 1 10 2 12 13 9 11 14 FG003918 Figure 44 Reference Number Description 1 Cylinder 2 Piston Rod 3 Yoke 4 Spacer 5 Shaft 6 Spring 7 Lock Nut 8 Lock Plate 9 Bolt 10 Spring Pin 11 Spring Washer 12 Packing 13 Backup Ring 14 Dust Seal Reference Number Description ...

Page 257: ...1Engine and Drive Train ...

Page 258: ......

Page 259: ...SP002029 Page 1 Drive Coupling Main Pump SP002029 DRIVE COUPLING MAIN PUMP SP002029 1Drive Coupling Main Pump Edition 1 ...

Page 260: ...SP002029 Drive Coupling Main Pump Page 2 MEMO ...

Page 261: ...29 Page 3 Drive Coupling Main Pump Table of Contents Drive Coupling Main Pump Safety Precautions 5 Applicable Models 5 Drive Coupling 6 Special Tools 7 Drive Coupling Installation 8 Installation Procedure 10 ...

Page 262: ...SP002029 Drive Coupling Main Pump Page 4 MEMO ...

Page 263: ...low all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LCA 5001 and Up ...

Page 264: ...he engine 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 Figure 2 show typical drive coupling installations ARS1710L Figure 1 ARS1720L Figure 2 ...

Page 265: ... 4 dimension A and B equal the Measurement H The two tools shown are designed to be used on various models of equipment Only one end of the tool is used for a specific model of equipment Figure 3 KNURL RELIEF RELIEF A B C D E F G H HAAA8350 Figure 4 Dimensional Details for Figure 4 Dimension Measurement Models A 6 0 1 mm 0 2362 0 0039 in DX300LC DX300LCA S300LC V B 7 0 1 mm 0 2756 0 0039 in C 20 0...

Page 266: ...main pump is installed the following mounting dimensions and installation procedures must be observed NOTE If these procedures are not followed noise will occur and or the service life of drive coupling or main pump will be reduced 4 1 5 11 8 5 10 7 3 2 9 H HAAA8040 Figure 5 DRIVE COUPLING INSTALLATION ...

Page 267: ... 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 Figure 5 Model Coupling Part Number Measurement H Torque Value for Ta Torque Value for Tb DX300LC 414 00040A 5 5 6 5 mm 0 216 0 256 in 44 49 kg m 318 354 ft lb 20 22 kg m 145 159 ft lb DX300LCA S300LC V S34...

Page 268: ... 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 pushing it softly into element 11 7 Attach flywheel cover pump housing to flywheel housing with bolts 4 1 5 11 8 5 107 3 2 9 HAAA8040 1 H Figure 6 CAUTION 1 Bolts 3 and 8 are coated against loosening wi...

Page 269: ...1Hydraulics ...

Page 270: ......

Page 271: ...1751 Page 1 Hydraulic System Troubleshooting Testing and Adjustment SP001751 HYDRAULIC SYSTEM TROUBLESHOOTING TESTING AND ADJUSTMENTSP001751 Hydraulic System Troubleshooting Testing and Adjustment Edition 1 ...

Page 272: ...SP001751 Hydraulic System Troubleshooting Testing and Adjustment Page 2 MEMO ...

Page 273: ...d Circuit 10 Arm Dump Circuit 10 Bucket Operating Circuit 11 Bucket Crowd Circuit 11 Bucket Dump Circuit 11 Swing Operating Circuit 11 Right Swing Operating Circuit 12 Left Swing Operating Circuit 12 Swing Relief Valve and Makeup Valve 12 Travel Operating Circuit 12 Forward Travel Circuit 13 Reverse Travel Circuit 13 Procedural Troubleshooting Baseline Recommendations 14 Initial Checks and Tests t...

Page 274: ...20 Flow Meter and Flow Meter Kit Installation and Testing 23 Swing System Troubleshooting 25 Precautions Initial Checks 25 Swing Relief Valve Checking and Adjustment 26 Troubleshooting Swing Gearbox 28 Troubleshooting Hydraulic Problems 29 Troubleshooting Control Valve 31 Troubleshooting Travel Control Valve 32 Troubleshooting Joystick Control Valve 33 ...

Page 275: ...ON Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up...

Page 276: ... features an electronically controlled output optimization system which allows the operator to choose between two distinctly different power modes high output rapid cycling maximum speed power mode and a standard power mode for most types of general operation Electronic management of hydraulic control valves assists in optimizing the application speed and overall operator control of hydraulic actu...

Page 277: ...el swing boom up and arm functions The amount of oil flow to the actuators at the output end of each of those circuits is regulated through the movement of each individual valve spool The left half of the hydraulic control valve fed by the left pump in the pump assembly has control spools for left travel bucket boom and arm operation Two stage operation is a feature of boom and arm function All of...

Page 278: ...system at approximately 50 C 122 F The arm cylinder operating circuit includes anticavitation valves which protect the hydraulic system from vacuum that could result from external shocks or other unusual conditions Boom Arm and Bucket cylinder circuit are also protected by overload relief valves Whenever high pressure is generated as a result of a shock or overload excess pressure is dumped to the...

Page 279: ... secondary boom up pilot pressure that is transmitted to the BOOM1 and BOOM2 spools of the control valve simultaneously When secondary pilot pressure reaches 7 9 kg cm2 100 130 psi boom control valve spools open and oil from both pumps goes to the boom cylinder Boom Down Circuit When the boom control lever is pushed forward the right side pilot valve generates secondary boom down pilot pressure th...

Page 280: ... the AM1 and AM2 spools of the control valve simultaneously When secondary pilot pressure reaches 7 9 kg cm2 100 130 psi the arm control valve spools AM1 and AM2 open Output flow from both halves of the pump assembly is directed to the arm cylinder When working in the arm crowd mode under certain conditions oil in the arm cylinder could suddenly be forced out by the weight of the arm and bucket In...

Page 281: ...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 the left main pump to the cylinder Swing Operating Circuit The swing operating circuit consists of the right main pump in the pump assembly the right half of the control valve and the swing motor To ...

Page 282: ...Valve and Makeup 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 and correspondingly reduced pressure at the opposite motor port could produce cavitation in the circuit To keep that from happening a 285 kg cm2 4 052 psi relief valve is installed in the swing motor...

Page 283: ...machine 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 through the upper works center joint to the travel motors PUMP L PUMP R TL PR CONTROL VALVE L CONTROL VALVE R TRRD TRL PL CENTER JOINT TRAVEL MOTOR R TRAVEL MOTOR L TRR ARS1630L TRLD PILOT VALVE Figure 10...

Page 284: ...ails to surpass rated speed 1 900 rpm performance problems may be due to inadequate hydraulic flow caused by lagging rotational speed NOTE Verify actual flow on the excavator against rated performance with a flow meter If engine tests meet specifications and adequate torque and horsepower are available at the pump drive flex coupling pull out the electrical tray under the operator s seat to inspec...

Page 285: ...system pressure available to the actuator Poor flow through the individual circuit may indicate that the component is worn beyond tolerance limits while all other hydraulic functions are adequate IMPORTANT It is suggested that the troubleshooter maintain the testing sequence of the preceding list Checks and adjustments nearer the middle or the end of the list may depend on adequate functioning of ...

Page 286: ...tolerance 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 serial number changes and variation in the joystick assemblies used on different excavators could produce slight change in actual performance characteristics Comparison of part numbers to serial n...

Page 287: ...nect 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 the speed control to the maximum speed setting Warm up the engine and hydraulic system until hydraulic oil temperature is at least 45 C 113 F Select Power Mode on the Instrument Panel Check current readings in milliamps on the VOM met...

Page 288: ...valve adjustment by loosening the outside widest diameter lock nut on the relief valve Turn the adjusting screw clockwise to increase pressure or counterclockwise to decrease 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 pressure up Readjust standard...

Page 289: ...perating correctly or pressure tests and further adjustments cannot be made Power Mode Operation Main Pressure and Tolerance Pilot Pressure and Tolerance Power Mode Neutral No Operation 20 40 bar 290 580 psi 30 bar 10 bar 435 psi 145 psi Power Mode Cylinder Stall 330 bar 5 bar 4 785 psi 75 psi 30 bar 10 bar 435 psi 145 psi Power Mode W Pressure Up Cylinder Stall 350 bar 10 bar 5 075 psi 145 psi 30...

Page 290: ...stently 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 pump flow may not be available and all other troubleshooting gives no indication of other flaws or hydraulic system defects If pump output is out of balance and one pump is failing to keep up with th...

Page 291: ...of the adjustment 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 Regulator adjustments affect total cumulative horsepower since each regulator compensates for the output of the other It is not necessary to adjust both regulators at the same time but after checkin...

Page 292: ...meter screw 2 the square tipped adjusting screw should be turned in the opposite direction 2 2 turns to avoid changing inner spring adjustment Pump input power adjustments are normally made in small increments 1 4 turn 90 or less each time Turning the square tipped smaller diameter screw 1 clockwise moves the flow curve up increasing flow and then input horsepower The adjusting screw 1 Figure 12 a...

Page 293: ...of the flow meter on the pump end of the output line Cap off the unused input end of the pump discharge line with a blocking flange Connect a premeasured length of hydraulic hose between the output end of the flow meter assembly and the top of the reservoir Use appropriate fittings and adapter flanges to guarantee a pressure tight seal NOTE Be sure to maintain even tightening torque on all flange ...

Page 294: ...peed control set at high speed Compare recorded values with output shown in the P Q curve in the specifications section of this 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 and the rear pump by actuating the swing control lever NOTE When testing b...

Page 295: ...nal oil cooler clogging or broken fan belt Consult service record for prior repair service work Drain some tank oil into a clean clear container Look for metal shavings grit cloudiness water or foam air bubbles in the oil NOTE Dispose of drained fluids according to local regulations Check for wobble through the engine pump flex coupling Run engine with the pump input hydraulic power control nut tu...

Page 296: ...e and possible damage 2 If main inlet and outlet pressures were off in the preceding tests in Step 1 adjust swing relief valve pressure Following adjustment repeat the operating pressure tests with gauges connected to the inlet and outlet test ports on top of the swing motor and check pressures with the swing locks engaged and released If pressure adjustment fails to restore adequate performance p...

Page 297: ...ean or replace assembly components as required NOTE If all tested pressures are at or above recommended levels and there are no mechanical problems in the drive train or in the motor brake assembly the problem will require further hydraulic troubleshooting It s also possible that a defective joystick an intermittent short in an electrical control circuit or a problem in the e EPOS circuit is causi...

Page 298: ... reduced rpm Causes listed above could also produce dragging swing OR hot or wrong oil OR worn out parts Check above list then replace oil test motor drain rate and check for 03 reading e EPOS self test Left travel speed is also reduced Low output at P1 pump or external pilot piping leaks is clogged Clean and repair piping or repair or replace pump P1 Swing control movement is reversed Inlet outle...

Page 299: ...l level Replace oil refill to specified level Bearings or gears worn but not completely inoperative Repair or replace gearbox Problem Possible Cause Remedy Problem Possible Cause Remedy Attachment cylinders swing and travel motors are all inoperable Loud noises are heard from main pump assembly Main pump s malfunction Repair or replace Low oil level in hydraulic system Refill Main pump inlet oil s...

Page 300: ...e Cylinder rod damaged Repair or replace Pilot valve or piping malfunction Repair or replace Mechanical linkage frozen loose or damaged Repair or replace Travel motors inoperable Center joint damaged Repair or replace Parking brake not releasing Repair or replace Travel motor worn or damaged Repair or replace Travel motor pilot piping damaged Repair or replace Travel motors operate very slowly Tra...

Page 301: ... Replace spool or casing Spool does not return to neutral sticking spool Check secondary pilot pressure Spool does not return to neutral because of dirt or other contaminants Clean Broken or damaged spring Replace Main relief or port relief not operating properly See above Impurities in pilot circuit Clean Cylinder drops before start at boom up operation Rod check valve damaged or clogged Clean re...

Page 302: ... Excess spool to casing clearance Replace spool casing Worn or loose universal joint handle subassembly Repair or replace U joint subassembly 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 other interference between valve parts or worn spool sticking inte...

Page 303: ...embly 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 other interference between valve parts or worn spool sticking intermittently Clean repair or replace Interference or binding on spool return spring Clean repair or replace Unsteady pressure in tank retu...

Page 304: ...SP001751 Hydraulic System Troubleshooting Testing and Adjustment Page 34 ...

Page 305: ...SP000028 Page 1 Accumulator SP000028 ACCUMULATOR SP000028 Accumulator Edition 1 ...

Page 306: ...SP000028 Accumulator Page 2 MEMO ...

Page 307: ...SP000028 Page 3 Accumulator Table of Contents Accumulator Safety Precautions 5 Applicable Models 5 General Description 6 Specifications 8 ...

Page 308: ...SP000028 Accumulator Page 4 MEMO ...

Page 309: ... the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up DX420LC 5327 and Up DX480LC 522...

Page 310: ...the upper and lower chambers There are six possible positions the diaphragm can be in and they are as follows 1 With no gas charge in the upper chamber 0 bar 0 psi empty and no oil in the bottom 0 bar 0 psi dry the elastic diaphragm hangs loosely 2 When the prepressure charge of gas usually nitrogen is introduced through the port at the top of the accumulator the diaphragm expands to maximum size ...

Page 311: ...cumulator 3 As hydraulic system pressure overcomes accumulator precharge pressure the flexible diaphragm begins to retract upward 4 When system oil is at highest working pressure and the accumulator fills to maximum reserve capacity the flexible diaphragm is pushed up into the top of the upper chamber The highest working pressure is sometimes referred to as the P3 pressure and can also be referenc...

Page 312: ...01 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX340LC S N 5980 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX350LC S N 5980 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX420LC S N 5327 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX480LC S N 5221 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX520LC S N 5117 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 ...

Page 313: ...SP001620 Page 1 Center Joint Swivel SP001620 CENTER JOINT SWIVEL SP001620 1Center Joint Swivel Edition 1 ...

Page 314: ...SP001620 Center Joint Swivel Page 2 MEMO ...

Page 315: ...er Joint Swivel Table of Contents Center Joint Swivel Safety Precautions 5 Applicable Models 5 General Description 7 Parts List 8 Troubleshooting Testing and Adjustment 9 Inspection 9 Testing 9 Disassembly 10 Reassembly 13 ...

Page 316: ...SP001620 Center Joint Swivel Page 4 MEMO ...

Page 317: ...d safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX225LC 5433 and Up DX225LCA 5167 and Up DX300LC 7440 and Up DX300LCA 5001 and ...

Page 318: ...CRIPTION The center joint swivel is designed to allow hydraulic oil from the upper structure to flow to components in the lower structure It is capable of allowing continuous 360 rotation of the upper structure in relationship to the lower structure ...

Page 319: ...ure 1 Reference Number Description 1 Hub 2 Shaft 3 Cover 4 Spacer 5 Shim 6 Shim 7 Wear Ring 8 Sliper Seal 9 O Ring 1AP105 10 O Ring 1BP90 11 Retaining Ring 12 PT Plug PT1 4 13 HEX Bolt M12 14 Spring Washer 15 O Ring 1AG100 Reference Number Description ...

Page 320: ...ns 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 changeover valve Install the changeover valve upstream from one of the stem high pressure ports Connect the pressure gauge downstream from one of the body ports Install the stop valve between the changeover valve and the stem of the center joint Other ...

Page 321: ...the spacer at the back of the retaing ring IMPORTANT Do not unbolt the center joint from the lower car body until an adequate number of piping block off plates are available for disconnected piping lines Be sure that system pressure has been vented including the hydraulic accumulator and tank reserve pressure before disassembly is started CAUTION It is recommended to use a hoist or a similar devic...

Page 322: ...and hammer to drive it out of the housing 8 Separate the Hub into 8ea sliper seals 1ea O ring 1BP80 and 1ea Dust seal LBH80 3 4 FG013230 Figure 4 CAUTION Care should be taken not to make a flaw on the surface of the Shaft when disassembling the Hub of the Shaft assembly FG013231 Figure 5 CAUTION Care should be taken not to damage the inside of the Hub becasuse it is likely to be damaged when disas...

Page 323: ...g surfaces for visible signs of wear damage or discoloration and replace any worn component Check clearance between the shaft and shim spacer Replace any component that shows more than 0 5 mm o o20 of visible wear Clearance between the spindle and body of the center swivel must be tight Replace or repair either component if there is more than 0 1 mm 0 0039 of measurable wear 1 2 3 4 G FG013237 Fig...

Page 324: ...ace of the center swivel body Apply slow even handed pressure using both hands to slowly push the stem into the body Seals may be damaged if the stem is pushed in too quickly 1 2 3 4 G FG013240 Figure 8 PT 1 4 6mm wrench Engagement torque 3 4 kg m CAUTION After assembling the sliper seal a manual test should be performed to ensure that every part is assembled for its position properly CAUTION For ...

Page 325: ...ith clean hydraulic fluid before reassembly of high pressure and drain line piping Clean and prefill piping line ends to reduce the amount of air in the system Bleed air from the hydraulic system and verify hydraulic tank fluid level before returning the excavator to service FG013243 1 2 Figure 9 CAUTION Applying active oil to the surface of the shaft enables the assembly without any damage to the...

Page 326: ...SP001620 Center Joint Swivel Page 14 ...

Page 327: ...SP000030 Page 1 Cylinders SP000030 CYLINDERS SP000030 Cylinders Edition 1 ...

Page 328: ...SP000030 Cylinders Page 2 MEMO ...

Page 329: ...autions 5 Applicable Models 5 General Description 6 Theory of Operation 6 Parts List 8 Special Tools and Materials 10 Piston Nut 10 Piston Jig 12 Steel Bushing Jig 14 Dust Wiper Jig 16 Slipper Seal Jig 18 Slipper Seal Straightening Jig 20 Disassembly 22 Reassembly 27 ...

Page 330: ...SP000030 Cylinders Page 4 MEMO ...

Page 331: ...actices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up DX420LC 5327...

Page 332: ... 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 can be expressed by the formula below where P circuit oil pressure and the inside diameter of the cylinder is expressed by D Figure 1 P Pressure π 3 14 D Cylinder Inside Diameter When the cylinder rod is retracted oil fl...

Page 333: ...me of oil needed to lengthen the cylinder rod Q1 is greater than the volume of oil required to retract the cylinder rod it takes more time to extend a cylinder than it does to retract it Q1 Q2 1 FG001459 Figure 3 Q1 S x π D2 4 Q2 S x π D2 R2 4 ...

Page 334: ...ist Cross section in Figure 4 shows an arm cylinder Cross section in Figure 5 shows a boom cylinder The bucket and boom cylinders are identical and differ only in the attached pipes 35 4 5 11 12 9 10 27 8 6 7 15 13 14 3 1 16 28 29 30 31 35 25 2 26 18 17 20 19 21 22 23 24 FG005226 Figure 4 1 2 3 4 17 18 19 20 21 22 23 24 16 5 6 7 8 15 35 35 32 33 34 13 14 11 12 9 10 FG005227 Figure 5 ...

Page 335: ...Dust Wiper 12 Retaining Ring 13 O ring 14 Backup Ring 15 O ring 16 Cushion Ring 17 Piston 18 Slipper Seal 19 Wear Ring 20 Ring 21 O ring 22 Backup Ring 23 Piston Nut 24 Set Screw 25 Socket Head Bolt 26 Pipe Band Assembly 27 Hex Socket Bolt 28 Check Valve 29 Spring 30 Spring Support 31 Hex Socket Plug 32 Spring Washer 33 Hex Bolt 34 Pipe Assembly 35 Grease Nipple Reference Number Description ...

Page 336: ...Cylinders Page 10 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 Oil Quench ...

Page 337: ...m 0 20 in S BUCKET DX340LC DX350LC BOOM 145 0 mm 5 71 in 105 0 mm 4 13 in 12 0 mm 0 47 in 5 0 mm 0 20 in OPT BOOM ARM 147 0 mm 5 79 in 107 0 mm 4 21 in 12 0 mm 0 47 in 5 0 mm 0 20 in OPT ARM BUCKET 145 0 mm 5 71 in 105 0 mm 4 13 in 12 0 mm 0 47 in 5 0 mm 0 20 in OPT BUCKET DX420LC BOOM 147 0 mm 5 79 in 107 0 mm 4 21 in 12 0 mm 0 47 in 5 0 mm 0 20 in ARM 147 0 mm 5 79 in 107 0 mm 4 21 in 12 0 mm 0 ...

Page 338: ...SP000030 Cylinders Page 12 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 339: ...mm 5 51 in S BUCKET DX340LC DX350LC BOOM 120 0 mm 4 72 in 13 0 mm 0 51 in 85 0 mm 3 35 in 150 0 mm 5 91 in OPT BOOM ARM 130 0 mm 5 12 in 13 0 mm 0 513 in 93 0 mm 3 66 in 165 0 mm 6 50 in OPT ARM BUCKET 120 0 mm 4 72 in 13 0 mm 0 51 in 85 0 mm 3 35 in 150 0 mm 5 91 in OPT BUCKET DX420LC BOOM 130 0 mm 5 12 in 13 0 mm 0 51 in 93 0 mm 3 66 in 165 0 mm 6 50 in ARM 130 0 mm 5 12 in 13 0 mm 0 513 in 93 0...

Page 340: ...nders Page 14 Steel Bushing 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 Nose R0 4 1 ...

Page 341: ...in S BUCKET DX340LC DX350LC BOOM 100 0 mm 3 94 in 115 0 mm 4 53 in 45 0 mm 1 77 in 7 5 mm 0 30 in OPT BOOM ARM 100 0 mm 3 94 in 115 0 mm 4 53 in 45 0 mm 1 77 in 7 5 mm 0 30 in OPT ARM BUCKET 100 0 mm 3 94 in 115 0 mm 4 53 in 45 0 mm 1 77 in 7 5 mm 0 30 in OPT BUCKET DX420LC BOOM 110 0 mm 4 33 in 130 0 mm 5 12 in 70 0 mm 2 76 in 11 0 mm 0 43 in ARM 110 0 mm 4 33 in 130 0 mm 5 12 in 70 0 mm 2 76 in ...

Page 342: ... 16 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 used DNMG Tip Nose R0 4 1 ...

Page 343: ...S BUCKET DX340LC DX350LC BOOM 100 0 mm 3 94 in 114 0 mm 4 49 in 6 0 mm 0 24 in 7 0 mm 2 28 in OPT BOOM ARM 115 0 mm 4 53 in 131 0 mm 5 16 in 6 0 mm 0 24 in 7 0 mm 2 28 in OPT ARM BUCKET 100 0 mm 3 94 in 114 0 mm 4 49 in 6 0 mm 0 24 in 7 0 mm 2 28 in OPT BUCKET DX420LC BOOM 115 0 mm 4 53 in 131 0 mm 5 16 in 6 0 mm 0 24 in 7 0 mm 2 28 in ARM 120 0 mm 4 72 in 136 0 mm 5 35 in 6 0 mm 0 24 in 7 0 mm 2 ...

Page 344: ...SP000030 Cylinders Page 18 Slipper Seal Jig ARS4770L A 2 A A 14 B B 40 5 R 1 0 R1 1 0 Figure 10 ...

Page 345: ... 140 0 mm 5 51 in 28 5 mm 1 12 in S BUCKET DX340LC DX350LC BOOM 150 0 mm 5 91 in 28 5 mm 1 12 in OPT BOOM ARM 170 0 mm 6 69 in 34 5 mm 1 36 in OPT ARM BUCKET 150 0 mm 5 91 in 28 5 mm 1 12 in OPT BUCKET DX420LC BOOM 165 0 mm 6 50 in 34 5 mm 1 36 in OPT BOOM ARM 180 0 mm 7 09 in 41 5 mm 1 63 in OPT ARM BUCKET 160 0 mm 6 30 in 34 5 mm 1 36 in OPT BUCKET 0 2 0 1 0 2 0 1 ...

Page 346: ...SP000030 Cylinders Page 20 Slipper Seal Straightening Jig ARS4780L 2 R1 50 25 100 A 15 A 2 5 R 2 C 1 Figure 11 ...

Page 347: ...m 5 51 in ARM 150 0 mm 5 91 in S ARM BUCKET 140 0 mm 5 51 in S BUCKET DX340LC DX350LC BOOM 150 0 mm 5 91 in OPT BOOM ARM 170 0 mm 6 69 in OPT ARM BUCKET 150 0 mm 5 91 in OPT BUCKET DX420LC BOOM 165 0 mm 6 50 in OPT BOOM ARM 180 0 mm 7 09 in OPT ARM BUCKET 160 0 mm 6 30 in OPT BUCKET 0 2 0 1 ...

Page 348: ... or other protective material around piston rod to avoid possibility of accidentally scratching or scoring rod surface while fasteners are being loosened and removed Component parts numbered in parentheses are keyed to Figure 4 CAUTION Vent air from the hydraulic system before disconnecting cylinder piping connections Use the lever on the reservoir while the engine is running Discharge the hydraul...

Page 349: ...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 still inside barrel of cylinder Prepare support blocks for piston rod before it has been completely withdrawn 6 Lower piston rod to support blocks and detach wear ring outer surface 18 from end of rod 7 Immobilize piston rod by inserting a wooden or other ...

Page 350: ...r local DOOSAN Parts distributor Remove nut from end of piston 10 Use second piston tool described at beginning of this procedure to separate piston Detach cushion ring 15 taking care not to damage cushion ring 11 Use a plastic hammer 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 HAOF340L Figure 19 Figure 20 Fi...

Page 351: ... appropriate width tip to facilitate removal of slipper seal 19 wear ring 18 and slide ring 17 from piston 16 14 Remove O ring 20 and backup ring 21 from cylinder head 15 During disassembly of cylinder head be careful not to damage buffer seal 5 and U packing 4 HAOF37OL Figure 23 Figure 24 HAOF38OS Figure 25 HAOF39OL Figure 26 ...

Page 352: ...SP000030 Cylinders Page 26 16 Disassemble retaining ring 3 and dust wiper 2 Separate retaining ring 8 and rod bushing 6 17 Force out pin bushing 1 from body of cylinder Figure 27 Figure 28 ...

Page 353: ...onents 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 and flexible seals is strongly recommended Before starting the cylinder reassembly procedure all parts should be thoroughly cleaned and dried and or prelubricated with clean hydraulic fluid Prepare ...

Page 354: ...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 dust 5 Immobilize piston rod on solid support blocks Assemble O ring 20 and backup ring 21 Prepare to attach rod cover assembly to piston rod Push rod cover by tightening piston nut 22 6 Assemble cushio...

Page 355: ...er before reassembly Preapply fastener locking compound Loctite 242 or 243 or an alternate manufacturer s equivalent product to all end cover retaining bolts Wrap a protective cushion around end of rod while tightening fasteners to prevent possible damage to polished surface of rod should a wrench slip during retightening Figure 35 Figure 36 Reference Number Description 1 Set Screw Figure 37 Figur...

Page 356: ...SP000030 Cylinders Page 30 ...

Page 357: ...SP000031 Page 1 Swing Motor SP000031 SWING MOTOR SP000031 Swing Motor Edition 1 ...

Page 358: ...SP000031 Swing Motor Page 2 MEMO ...

Page 359: ...ns 12 Torques 12 Tools and Materials 13 Tools 13 Troubleshooting Testing and Adjustment 14 General Precautions 14 How to Check Faults of Hydraulic Motor 14 Troubleshooting 14 Disassembly 16 General Cautions 16 Disassembly 16 Cleaning and Inspection Wear Limits and Tolerances 23 Reassembly 24 General Cautions 24 Assembly 24 Assembly of Cylinder Block Assembly Subassembly 27 Assembly of Rear Cover A...

Page 360: ...SP000031 Swing Motor Page 4 MEMO ...

Page 361: ...ecommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7740 and Up DX300LCA 5001 and Up ...

Page 362: ...Operation Structure The hydraulic motor consists of the following five parts Rotary part generating rotary power Relief valve Parking brake Makeup check valve Time delay valve Swing reactionless valve Circuit Diagram GB Am Dr GA PG SH B Mu A FG001323 Figure 1 ...

Page 363: ...e F1 P A P supply pressure A hydraulic area F1 is divided into a N1 thrust component and a W1 radial component in relationship to the swash plate with slope of W1 generates a torque T W1 R1 in relationship to Y Y the centerline of top and bottom dead centers of the piston This torque generates the rotary power through a resultant force ΣW1 R1 occurring at 4 5 hydraulic pistons by the high pressure...

Page 364: ...ff Pilot oil moves the swing spool and flows to port SH of time delay valve in swing motor through shuttle valve in case when the swing control lever is in the swing position This pressure moves the spool to the left against the spring force causing the port PG oil of the time delay valve to move to the parking piston The oil moves the parking piston pressing the friction plate upwards to release ...

Page 365: ...lve casing The high pressure oil flows into the port Sb as the spool assembled in the tilting switching part sticks to the plug by spring This high pressure oil applies pressure on the chamber A through the valve casing and the channel A of the shaft casing from the port Sb Oil in the chamber B comes to flow into the drain line through the channel B Ê Sa The tilting piston moves to the right side ...

Page 366: ...ing Motor Page 10 Parts List 34 36 37 19 23 20 33 24 25 27 26 28 30 31 32 29 17 18 16 38 21 9Ab 15 15 14 14 15 14 9Aa 9D 9Cb 8 5 9Ca 35 1 39 2 7 3 4 6 9 9A 9D 33A 33B 33C 33D 33E 34B 9A 9C 9B 34A FG000762 Figure 8 ...

Page 367: ...iston KT 14 Friction Plate 15 Plate 16 Brake Piston 17 O ring 18 Spring 19 Cover 20 Needle Bearing 21 Parallel Pin 23 Socket Bolt M20x2 5 24 Poppet 25 Spring 26 Plug 27 O ring 28 Reductionless Valve Assembly 29 Plug 30 O ring 31 O ring 32 Back up Ring 33 Relief Valve Assembly 33A O ring 33B Back up Ring 33C O ring 33D O ring 33E Back up Ring 34 Time Delay Valve Assembly 34A O ring 34B O ring 35 So...

Page 368: ... 640 ft lb Brake Switching Spool Cracking Pressure 8 kg cm 114 psi Delay Period 6 5 1 5 sec Weight 60 kg No Tools Measures B Torque 33 Relief Valve M33 36 mm 1700 1900 kg cm 123 137 ft lb 36 Plug PT 1 4 36 mm 691 kg cm 50 ft lb 37 Plug PF 1 4 5 mm 691 kg cm 50 ft lb 40 Plug PF 1 2 6 mm 2 090 kg cm 150 ft lb 41 Plug PF 1 6 mm 4 843 kg cm 350 ft lb 47 Plug 6 mm 27 Hex Socket Head Bolt M18X65L 14 mm ...

Page 369: ... mm Plugs 40 41 and 47 14 mm Hex socket head bolt 27 Socket Wrench Spanner 36 mm Plug 39 relief valve assembly 33 Retaining Ring Pliers For Orifice And Axis Ring stop 4 Bar Hammer Needle bearing 22 Pin 8 23 and 43 Torque Wrench Measure Oil Seal Assembly Jig Oil seal 2 Bearing Induction Heating Device Roller bearing 3 B B ARS3980L Figure 9 ...

Page 370: ...e up to the hydraulic motor before disassembling the motor Troubleshooting Problem Possible Cause Remedy Abnormal operation of driving devices Motor pressure does not increase Oil bypassing in relief valve 33 Replace or repair relief valve Check spring broken Replace check spring Crack in channel in valve casing Replace valve casing Abnormal wear on check surface Replace check Pressure increases b...

Page 371: ...essure in case Check the drain line Leakage from assembled parts O ring damaged Replace the O ring Volt or plug loosened Tighten up to specified torque Main ways stuck Piston and shoe Overload rotation of motor Increase of temperature Insufficient intensity of illumination on slideway Improper oil or lubrication Check the operation of the relief valve Check circuits Repair or replacement of faulty...

Page 372: ...reign substance in motor and deceleration assembly 3 Take care not to damage connecting parts and ways of O ring oil seal seal surface gear pin and surface of bearings 4 Numbers in parentheses indicate those on sectional plans of motor Disassembly 1 Remove hex socket head bolt and disassemble time delay valve assembly beginning with rear cover 19 FG000682 Figure 10 FG000683 Figure 11 ...

Page 373: ...or 2 Remove rear cover from body 1 by removing hex socket head bolt 23 of its assembly with impact 3 Remove brake piston assembly from body 1 using jig FG000685 Figure 12 FG000686 Figure 13 FG000687 Figure 14 FG000688 Figure 15 ...

Page 374: ...embly friction plate 14 and plate 15 from body 1 NOTE Pay attention to order of plates and friction plates 5 Remove O ring 38 from body 1 6 Remove shoe plate 8 from body 1 using jig FG000689 Figure 16 FG000690 Figure 17 FG000691 Figure 18 FG000692 Figure 19 ...

Page 375: ...ing ring 4 from body 1 using retaining ring pliers 8 Turn body over and separate shaft assembly using steel bar 9 Separate piston assembly 13 from cylinder block assembly FG000693 Figure 20 FG000694 Figure 21 FG000695 Figure 22 FG000696 Figure 23 ...

Page 376: ...SP000031 Swing Motor Page 20 10 Remove friction plate 12 plate 15 ball guide 11 and spring 10 from cylinder block FG000697 Figure 24 FG000698 Figure 25 FG000699 Figure 26 FG000700 Figure 27 ...

Page 377: ...SP000031 Page 21 Swing Motor 11 Separate valve plate 22 from rear cover 19 12 Remove O ring 17 from rear cover 19 FG000701 Figure 28 FG000703 Figure 29 FG000704 Figure 30 FG000705 Figure 31 ...

Page 378: ...ief valve assemblies 33 from rear cover 19 14 Remove check valve assemblies from rear cover 19 with L wrench and disassemble it in order of plug 26 spring 23 and poppet 24 FG000706 Figure 32 FG000707 Figure 33 FG000708 Figure 34 FG000709 Figure 35 ...

Page 379: ...9 O ring 48 spring and anti inversion valve assembly 28 16 Remove plugs 36 and 37 from rear cover 19 with L wrench CLEANING AND INSPECTION WEAR LIMITS AND TOLERANCES For general cleaning and inspection procedures refer to General Maintenance Procedures section FG000710 Figure 36 FG000711 Figure 37 FG000712 Figure 38 FG000713 Figure 39 ...

Page 380: ...e washed with treated oil 2 Each connecting parts should be tightened according to its assigned torque 3 Only use a plastic soft faced hammer Assembly 1 Put roll bearing 3 and bushing 39 on a heater and apply heat to their inner race inlet temperature 290 C for 2 minutes 39 3 FG001328 Bushing X 1ea SUJ Roll Bearing X 1ea NUP2209 Figure 40 FG000715 Figure 41 ...

Page 381: ...and bushing 39 Use retaining ring pliers to assemble install retaining ring 7 3 Put body 1 on assembly jig and secure it so it cannot move 4 Assemble oil seal 2 in body 1 using bar hammer FG000716 Figure 42 FG000717 Figure 43 FG000718 Figure 44 FG000719 Figure 45 ...

Page 382: ...031 Swing Motor Page 26 5 Install shaft in body 1 using bar hammer 6 Secure shaft with retaining ring 4 using retaining ring pliers FG000720 Figure 46 FG000717 Figure 47 FG000721 Figure 48 FG000722 Figure 49 ...

Page 383: ...t shoe plate 8 with grease and assemble it into body Assembly of Cylinder Block Assembly Subassembly 8 Insert nine sets of springs 1 thru 9 in cylinder block 9 FG000723 Figure 50 FG000724 Figure 51 FG000725 Figure 52 FG000726 Figure 53 ...

Page 384: ...1 Swing Motor Page 28 9 Insert ball guide 1 B 11 in cylinder block 9 10 Assemble friction plate 14 and plate 15 into cylinder block 9 FG000727 Figure 54 FG000728 Figure 55 FG000729 Figure 56 FG000759 Figure 57 ...

Page 385: ...wing Motor 11 Insert piston assembly 1 C 13 in set plate 1 B 12 and assemble it into cylinder block 9 NOTE Coat piston with clean hydraulic oil FG000730 Figure 58 FG000731 Figure 59 FG000696 Figure 60 FG000732 Figure 61 ...

Page 386: ...1 Swing Motor Page 30 12 Assemble cylinder block into body 1 13 Insert O ring 38 in body 1 14 Assemble O ring 17 into brake piston 16 FG000733 Figure 62 FG000734 Figure 63 FG000704 Figure 64 FG000687 Figure 65 ...

Page 387: ... it using jig 16 Insert eighteen springs 18 into brake piston 16 Assembly of Rear Cover Assembly Subassembly 1 Insert pins 6 and 21 in rear cover 19 with bar hammer and assemble needle bearing 20 using jig FG000735 Figure 66 FG000736 Figure 67 FG000737 Figure 68 FG000738 Figure 69 ...

Page 388: ...SP000031 Swing Motor Page 32 2 Assemble O ring 17 into rear cover 19 3 Assemble check valve Install O ring 27 using jig FG000739 Figure 70 FG000740 Figure 71 FG000741 Figure 72 FG000742 Figure 73 ...

Page 389: ... Tighten plug with L wrench Left and right symmetrically 5 Assemble anti inversion valve Assemble body spring seat spring poppet poppet seat stopper and spring Then assemble O ring 31 backup ring 32 and O ring 30 FG000743 Figure 74 FG000708 Figure 75 FG000744 Figure 76 FG000745 Figure 77 ...

Page 390: ...on valve set Assemble anti inversion valve set and plug assembly 29 into rear cover 19 and tighten them with L wrench 7 Assemble plug assembly 36 into rear cover 19 with L wrench FG000711 Figure 78 FG000710 Figure 79 FG000746 Figure 80 FG000747 Figure 81 ...

Page 391: ... two relief valve assemblies into rear cover 19 with torque wrench Left and right symmetrically 9 Coat valve plate 1 A 22 with grease and attach it to rear cover 19 FG000748 Figure 82 FG000706 Figure 83 FG000749 Figure 84 FG000701 Figure 85 ...

Page 392: ...osition rear cover assembly on body 1 and tighten hex socket head bolt 23 11 Install time delay valve assembly onto rear cover 19 with hex socket head bolts 35 FG000750 Figure 86 FG000751 Figure 87 FG000752 Figure 88 FG000682 Figure 89 ...

Page 393: ...ly air pressure into assembled motor dip it in treated oil for one minute and check any leakage from it Oil Leakage Check Wash motor with Color Check No 1 spray No 3 and check for any oil leakage FG000753 Figure 90 FG000754 Figure 91 FG000755 Figure 92 ...

Page 394: ...SP000031 Swing Motor Page 38 FG000756 Figure 93 FG000757 Figure 94 ...

Page 395: ...SP000032 Page 1 Travel Motor SP000032 TRAVEL MOTOR SP000032 Travel Motor Edition 1 ...

Page 396: ...SP000032 Travel Motor Page 2 MEMO ...

Page 397: ...nt 18 General Precautions 18 How to Check Faults of Hydraulic Motor 18 Troubleshooting 18 Disassembly 20 General Cautions 20 Disassembly 20 Disassembly of Valve Casing Subassembly 24 Disassembly of Cylinder Subassembly 26 Cleaning and Inspection Wear Limits and Tolerances 28 Maintenance Standard 28 Reassembly 32 General Cautions 32 Reassembly of Drive Shaft Subassembly 32 Assembly of Valve Casing ...

Page 398: ...SP000032 Travel Motor Page 4 MEMO ...

Page 399: ...ecommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up ...

Page 400: ...SP000032 Travel Motor Page 6 ...

Page 401: ...f five parts Rotary part generating rotary power Cross over relief valve Negative brake Counterbalance valve Tilting switching part Bm A B Am Pi N Pi Dr Dr FG001329 Counter balance valve part Relief valve part Swash tilting part Negative brake part Rotary part Hydraulic motor part Figure 1 ...

Page 402: ...F1 is divided into a N1 thrust component and a W1 radial component in relationship to swash plate 201 with slope of β W1 generates a torque T W1 R1 in relationship to Y Y the connection line of top and bottom dead centers of piston This torque generates rotary power through resultant force W1 R1 occurring at 4 5 ea hydraulic pistons by the high pressure oil The drive shaft turns and rotary power i...

Page 403: ...ion of the inertia weight 2 Device is forced to stop by the generation of brake pressure at the discharge side when the inertia weight stops Chamber A is connected to port A of the motor Hydraulic oil flows from chamber A to port B because when the pressure in the port A increases poppet A is opened when it is above the spring setting pressure Poppet A opens and hydraulic flows from chamber A to p...

Page 404: ...g and friction plate 742 which is connected to shaft casing brake piston 702 and spline of cylinder block 111 When no oil pressure is applied to the brake piston the brake spring presses the brake piston and oil brake cavity flows to the drain of the motor through an orifice And the brake piston presses the separator and friction plates located between it and the shaft casing together due to the f...

Page 405: ...hamber N at the opposite end of the spool flows to the chamber Dv through orifice 1 and is discharged to the hydraulic oil tank through port Bv The spool continues to move to the right and oil starts to flow from K Dv Bv Once the spool is moved far enough to the right passage H is opened With passage H opened oil now flows from Cv H port P The spool will be moved slowly because oil in the chamber ...

Page 406: ...ting more torque 1 External pilot pressure Pi 0 Large tilt angle If pilot pressure does not act on tilting valve the position of swash plate 201 is set at a large tilting angle Swash plate 201 has a movable round surface to tilt on High pressure oil flows through port Sa and Sb of tilting valve and passages and forces swash piston 501 to move until swash piston 502 is stopped by stopper 503 and th...

Page 407: ...533 This forces the swash spool 531 to move to the left High pressure oil flows through port Sa and Sb of tilting valve and passages and acts on swash piston 502 until swash piston 501 is stopped by stopper 514 The position of swash plate 201 is now at a small tilt angle Pi 20 kgf cm _ External pilot pressure FG004056 514 503 501 502 546 533 531 572 571 506 505 507 116 114 121 201 Sa Sb Figure 7 ...

Page 408: ...81 464 485 567 506 572 571 531 505 533 541 543 542 567 568 568 350 464 381 363 361 364 369 367 368 365 384 485 383 382 485 461 567 461 546 401 509 507 568 568 508 567 567 402 568 384 485 383 382 362 364 705 451 303 708 707 702 505 508 111 131 114 503 504 513 102 107 106 741 742 101 709 435 545 491 272 FG003961 Figure 8 ...

Page 409: ...x Socket Head Bolt 368 Hex Socket Head Bolt 369 O ring 381 Plunger Counterbalance Valve 382 Stopper Check 383 Backup Ring 384 Spring Check 401 Hex Socket Head Bolt 402 Hex Socket Head Bolt 435 Lock Ring 451 Valve Plate Pin 452 Support Pin 461 Plug 464 HP Plug 472 O ring 485 O ring 491 Oil Seal 501 Swash Piston 502 Swash Piston 503 Stopper Left 504 O ring 505 Swash Rod 506 Lock Screw 507 Hex Nut 50...

Page 410: ...m2 28 4 psi Surge 10 kg cm2 142 psi Weight 154 kg 340 lb No Tools Measures B Torque 350 Relief valve HEX 46 46 1 700 1 900 kg cm 123 137 ft lb 461 Plug NPTF 1 16 4 70 110 kg cm 5 8 ft lb 464 HP Plug PF 1 2 27 1 100 kg cm 80 ft lb 507 Hex Nut M16 24 2 400 kg cm 175 ft lb 571 Plug PF 3 8 8 750 kg cm 55 ft lb 567 HP Plug PF 1 4 19 370 kg cm 27 ft lb 545 546 Orifice Screw NPTF 1 16 4 70 kg cm 5 ft lb ...

Page 411: ...71 10 mm Hex socket head bolt 368 46 mm Relief Valve 350 Socket wrench spanner 19 mm HP plug 567 24 mm Hex nut 507 27 mm HP plug 464 Retaining ring pliers for orifice and axis Ring stop 107 lock ring 435 Bar hammer Needle bearing 103 Pin 451 452 and 709 Torque wrench Measure 500 and 3000 Oil seal assembly Jig Oil seal 491 Bearing induction heating device Roller bearing 102 B B ARS3980L Figure 9 ...

Page 412: ... Cause Remedy Abnormal operation of driving devices Motor pressure does not increase Oil bypassing in relief valve 350 Replace or repair relief valve Check spring broken Replace check spring Valve spring of counterbalance valve broken Replace the valve spring of counterbalance valve Crack in channel in valve casing Replace valve casing Abnormal wear on check surface Replace check Excessive clearan...

Page 413: ...icking of inner brake parts Replace parts Tilting angle not switched Tilting angle is not switched Orifice at the tilting channel of shaft casing blocked Wash or replace orifice Tilting angle adjustment spool 531 and case stuck Replace faulty parts Leakage due to excessive clearance among shaft casing swash piston and stopper Outer diameter of swash piston and spheral face stuck High pressure sele...

Page 414: ...nal plans of motor 5 Mark piping part of motor as rear and its discharge part as front 6 To reassemble use liquid gasket and make sure to remove any oil before appling sealer 7 Bolt should be tightened after Loctite 262 is applied on threads using torque wrench according to specified torque Disassembly 1 Secure motor on jig with four bolts M16x60L NOTE Secure motor so that drain plug 464 points do...

Page 415: ...p Remove lock ring 435 using retaining ring pliers 4 Remove hex socket head bolts 401 and 402 holding valve casing 5 Remove valve casing subassembly and valve plate 131 NOTE If valve plate is excessively worn replace it with new one FG001099 Figure 12 FG001100 Figure 13 FG001101 Figure 14 FG001102 Figure 15 ...

Page 416: ...age 22 6 Remove brake spring 705 and brake piston by connecting two M16 bolts to piston 702 and pulling them upwards NOTE There are ten brake springs FG001103 Figure 16 FG001104 Figure 17 FG001105 Figure 18 FG001106 Figure 19 ...

Page 417: ...ontal Remove cylinder and piston subassembly 8 Disassemble stopper L 503 and swash plate piston 502 NOTE Swash plate piston M5 bolt used 9 Remove swash plate 201 10 Insert M12 bolts in support 201 and disassemble support Figure 20 FG001108 Figure 21 FG001109 Figure 22 FG001110 Figure 23 ...

Page 418: ...ing NOTE Take care not to damage roller bearing 102 Disassembly of Valve Casing Subassembly NOTE Take care not to damage needle bearing 103 1 Remove tilting rod 505 automatic switching spring 533 and automatic switching spool 531 NOTE Do not touch hex nut 507 and lock screw 506 If tilting spool or spring is damaged replace it with a new one FG001111 Figure 24 FG001112 Figure 25 FG001113 Figure 26 ...

Page 419: ...nd 366 and disassemble counterbalance valve 361 NOTE Pay attention to direction of left and right sides of plunger when disassembling counterbalance valve NOTE If spool or spring is damaged replace it with a new one FG001114 Figure 28 FG001116 Figure 29 FG001117 Figure 30 FG001118 Figure 31 ...

Page 420: ...SP000032 Travel Motor Page 26 Disassembly of Cylinder Subassembly 1 Remove push plate 122 and piston 121 FG001119 Figure 32 FG001120 Figure 33 FG001121 Figure 34 ...

Page 421: ...00032 Page 27 Travel Motor 2 Remove friction plate 742 and separation plate 741 3 Remove bush plate 122 spacer 116 and spring 114 FG001122 Figure 35 FG001123 Figure 36 FG001124 Figure 37 FG001125 Figure 38 ...

Page 422: ...plate 13 5 13 Replace with set Free length of cylinder spring 47 9 47 3 Replace Over pin diameter 4 5 of drive shaft Drive spline 43 91 43 31 Even if one each of recommended value of replacement is not reached replace Cylinder spline 49 06 48 46 Over pin diameter 4 5 of spline inside of cylinder and spherical bush 35 25 35 75 Replace Thickness of separate plate 3 3 3 Thickness of friction plate 2 ...

Page 423: ...cal direction of piston and shoe δ O ring Oil seal When disassembling replace as a rule Kinds of bolt If there are crushing parts replace Piston ring If there are signs of sticking or deforming replace Parts name and inspection item Standard dimension Recommend ed value of replacement Remedy Figure 39 Figure 40 Figure 41 ...

Page 424: ...arts unconditionally Figure 42 Inspection item Standard Standard of replacement Remark Backlash Sun gear Cluster gear 0 160 0 320 1 00 Cluster gear Ring gear No 1 0 200 0 395 1 00 Cluster gear Ring gear No 2 0 200 0 395 1 00 Ring gear No 2 Coupling gear 0 200 0 608 1 30 Coupling Sun gear spline 0 1 0 2 0 5 OPD Ring gear No 1 386 106 368 514 Ring gear No 2 337 482 337 678 Base tangent length Cluste...

Page 425: ...luster gear Floating seal Seal Damage of sliding surface O ring Damage Thrust bearing 5 0 Below 4 7 5 5 Below 5 2 6 0 Below 5 7 Gear oil Refer to Operation Manual Change after first 250 hours of operation and every 1 000 hours thereafter But change unconditionally when disassembling Inspection item Standard Standard of replacement Remark ...

Page 426: ...cording to its assigned torque 3 Only use a plastic soft faced hammer Reassembly of Drive Shaft Subassembly 1 Assemble bearing spacer 106 into drive shaft and insert cylindrical roller bearing 102 by heating it NOTE For heat installation of cylindrical roller bearing use an induction heater Heat bearing to 100 C NOTE Take care not to damage oil seal slideway of drive shaft FG001126 Figure 43 FG001...

Page 427: ...ect 5 plugs 461 to valve casing 303 according to a specified torque NOTE Wrap sealing tape around plug or spread Loctite before starting assembly NOTE Connection Torque 70 110 kg cm 5 8 ft lb 2 Insert pin 451 NOTE Use hammer to adjust pin that its height is 5 mm 0 20 in above valve plate surface 3 Assemble needle bearing 103 FG001129 Figure 46 FG001130 Figure 47 FG001131 Figure 48 FG001132 Figure ...

Page 428: ... sheet and stopper NOTE Connection torque 370 kg cm 27 ft lb 5 Assemble HP plug 567 to which O ring 568 is attached NOTE Five places NOTE Connection torque 370 kg cm 27 ft lb 6 Install orifice screws 363 both ends of counterbalance spool 361 NOTE Connection torque 70 kg cm 5 ft lb FG001133 Figure 50 FG001134 Figure 51 FG001135 Figure 52 FG001173 Figure 53 ...

Page 429: ...SP000032 Page 35 Travel Motor 7 Insert counterbalance spool 361 and damper check 364 in valve casing FG001118 Figure 54 FG001117 Figure 55 FG001120 Figure 56 FG001119 Figure 57 ...

Page 430: ...nection points of Caps R and L NOTE Connection torque M12 1 000 kg cm 72 ft lb 368 M10 670 kg cm 48 ft lb 367 9 Insert automatic switching spool 531 spring 533 and O ring 509 NOTE Connection torque 750 kg cm 54 ft lb 10 Install swash rod 505 with O ring 508 FG001136 Figure 58 FG001137 Figure 59 FG001114 Figure 60 FG001138 Figure 61 ...

Page 431: ...g 485 NOTE Connection torque 1 100 kg cm 80 ft lb Assembly of Cylinder Subassembly 1 Assemble cylinder spring 114 spacer 116 and bush plate 112 into cylinder 111 NOTE Match positions of cylinder and spool line of spherical bushing FG001139 Figure 62 FG001140 Figure 63 FG001147 Figure 64 FG001148 Figure 65 ...

Page 432: ...age 38 2 Assemble friction plate 742 and separation plate 741 into cylinder 3 Insert piston shoe 121 in push plate 122 and assemble it into cylinder FG001149 Figure 66 FG001150 Figure 67 FG001151 Figure 68 FG001152 Figure 69 ...

Page 433: ...ing tape around plug or spread Loctite before starting assembly NOTE Connection torque 70 110 kg cm 5 8 ft lb 2 Insert pins 452 and 709 using hammer or a round bar NOTE Two pins 452 Adjust their height to be 10 mm 0 39 in above swash plate support surface NOTE Four pins 709 Adjust their height to be 19 mm 0 75 in above machined shaft casing surface FG001153 Figure 70 FG001154 Figure 71 FG001155 Fi...

Page 434: ...wash plates 201 NOTE Pay attention to insertion direction of swash plate supports 5 Assemble swash plate supports 201 into swash plates NOTE Apply grease to slideway of swash plate NOTE Check for smooth movement of swash plate FG001157 Figure 74 FG001158 Figure 75 FG001159 Figure 76 FG001160 Figure 77 ...

Page 435: ...otate disassembly reassembly jig 90 to change shaft direction from vertical to horizontal NOTE Take care that swash plate does not fall apart from its support 8 Assemble cylinder subassembly NOTE Align holes of separation plate with pins FG001161 Figure 78 FG001162 Figure 79 FG001163 Figure 80 FG001164 Figure 81 ...

Page 436: ...n rings 252 707 and 278 708 onto brake piston 702 11 Install brake piston into shaft casing NOTE Pay attention to direction of assembling brake piston 12 Install brake spring 705 NOTE Qty Ten springs and eleven holes NOTE The top brake piston shall not be assembled FG001165 Figure 82 FG001166 Figure 83 FG001167 Figure 84 FG001168 Figure 85 ...

Page 437: ...revent it from falling out B Use a suitable lifting device to assemble it into valve plate shaft casing C Assembly should be done so that holes in valve plate face entrance of valve casing D Apply grease to tilting spool in tilting spring to prevent it from falling out of spring E Connection torque 2 400 kg cm 175 ft lb 15 Install relief valve 350 according to a specified torque NOTE Connection to...

Page 438: ...SP000032 Travel Motor Page 44 ...

Page 439: ...SP000068 Page 1 Axial Piston Pump SP000068 AXIAL PISTON PUMPSP000068 Axial Piston Pump Edition 1 ...

Page 440: ...SP000068 Axial Piston Pump Page 2 MEMO ...

Page 441: ...pection Wear Limits and Tolerances 18 Worn Part Replacement Criteria 18 Correction Criteria for Cylinder Valve Plate and Swash Plate Shoe Plate 19 Reassembly 20 Start up Procedures 24 Oil filling and Air Venting 24 Cautions During Starting Operation 24 Regulator for Axial Piston Pump 25 General Description 25 Model Number Designation 25 Parts List 26 Outline 27 Specifications 29 Functional Explana...

Page 442: ...SP000068 Axial Piston Pump Page 4 Maximum Flow Is Not Available 37 Adjustment of Maximum and Minimum Flows 37 Preparation for Disassembly 39 Regulator Disassembly 40 Regulator Reassembly 43 ...

Page 443: ...y recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up ...

Page 444: ...ignation K 5 V 1 4 0 D T 1 C 9 R 9 N 0 1 Regulator type For more details see the instruction manual for the regulator Shaft rotation viewed from shaft end Design series number R Clockwise L Counterclockwise DT P DTD S Single pump DT Tandem type double pump Size K5V series ARS0120L Figure 1 ...

Page 445: ...ported by bearings 123 and 124 at both ends The shoe is caulked to the piston to form a spherical coupling It has a pocket to relieve thrust force generated by loading pressure and to take hydraulic balance so that it slides lightly over the shoe plate 211 The subgroup is composed of a piston and shoe pressed against the shoe plate by the action of the cylinder spring via a retainer and a spherica...

Page 446: ...d in the cylinder block make a reciprocating motion with respect to the cylinder block while they revolve with the cylinder block If you pay attention to a single piston it performs a motion away from the valve plate oil sucking process within 180 degrees and makes a motion towards the valve plate or oil discharging process in the rest of 180 degrees When the swash plate has no tilt angle zero deg...

Page 447: ...t 261 Seal Cover F 271 Pump Casing 312 Valve Block 313 Valve Plate R 314 Valve Plate L 401 Hex Socket Head Bolt 406 Hex Socket Head Bolt 466 VP Plug 467 Plug 468 RO Plug 490 Plug 531 Tilting Pin 532 Servo Piston 534 Stopper L 535 Stopper S 548 Feed Back Pin 702 O ring 710 O ring 717 O ring 719 O ring 724 O ring 725 O ring 728 O ring 732 O ring 774 Oil Seal 789 Backup Ring 792 Backup Ring 806 Nut 8...

Page 448: ...n wrench M6 120 5 M8 300 6 M10 580 8 M12 1000 10 M14 1600 12 M16 2400 14 M18 3400 14 M20 4400 17 PT plug Material S45C Wind a seal tape 11 2 2 turns round the plug PT 1 16 70 4 Do PT 1 8 105 5 PT 1 4 175 6 PT 3 8 350 8 PT 1 2 500 10 PF plug Material S45C PF 1 4 300 6 Do PF 1 2 1000 10 PF 3 4 1500 14 PF 1 1900 17 PF 11 4 2700 17 PF 11 2 2800 17 ...

Page 449: ...Tool Name and Size Necessary Tool Marked with O Part Name Pump Type Name B K5V80 K5V140 Hex Socket Head Bolt PT Plug PT thread PO Plug PF thread Hex Socket Head Setscrew Allen wrench 2 M4 2 5 M5 3 M6 4 O O M5 BP 1 16 M8 5 O O M6 BP 1 8 M10 6 O O M8 BP 1 4 PO 1 4 M12 M14 8 O M10 BP 3 8 PO 3 8 M16 M18 10 M12 BP 1 2 PO 1 2 M20 12 M14 14 O M16 M18 BP 3 4 PO 3 4 17 O M20 M22 BP 1 PO 1 11 4 11 2 19 M24 ...

Page 450: ... O O M12 M12 VP 1 4 22 24 O M16 M16 27 O M18 M18 VP 1 2 30 O M20 M20 36 O VP 3 4 41 VP 1 50 VP 11 4 55 VP 11 2 Adjustable angle wrench O O Medium size 1 set Screwdriver O O Minus type screwdriver medium size 2 set Hammer O O Plastic hammer 1 set Retaining Ring Pliers O O For retaining ring TSR 160 Steel bar O O Steel bar of key material approx 10x8x200 Torque wrench O O Capable of tightening with ...

Page 451: ...It is very difficult to find the cause of the failure Investigate the following items and the abnormal point will be revealed 1 Check filter and drain oil Check filters for excessive amount of abnormal impurities Since the shoes and cylinder may give off worn metal particles a small quantity may be detected there However if a excessive amount of metal particles is found in the filters it should be...

Page 452: ...nual of the regulator Seizure or damage of a part inside the pump Replace the damaged part Check the filters and drain oil Failure of the associated pump Replace the damaged part Remove the associated pump and check the shaft coupling Failure of the accessory valve Check the accessory valves Especially check the poppets seats and springs See the instruction manual of the accessory valves Wrong ins...

Page 453: ...rom one pump with the same ones of the other pump 1 Select place suitable to disassembling 2 Remove dust rust etc from pump surface with cleaning oil or equivalent 3 Remove drain port plug 468 and drain oil from pump casing 4 Remove hex socket head bolts 412 and 413 and regulator 5 Remove hex socket head bolts 401 which secure swash plate support 251 pump casing 271 and valve block 312 IMPORTANT S...

Page 454: ...ar pump first remove gear pump 9 Lightly tapping fitting flange section of swash plate support 251 on its pump casing side separate swash plate support from pump casing HDM3017L Figure 6 IMPORTANT Before laying this surface down spread rubber mat on workbench to prevent this surface from being damaged Figure 7 IMPORTANT Do not damage sliding surfaces of cylinder spherical bushing shoes swash plate...

Page 455: ... pin 531 from pump casing 271 Remove needle bearing 124 and splined coupling 114 from valve block 312 HDM3021L Figure 10 Figure 11 Figure 12 IMPORTANT These may be removed in work 6 IMPORTANT When removing tilting pin use a protector to prevent pin head from being damaged Since Loctite is applied to mounting areas of tilting pin and servo piston do not damage servo piston Do not remove needle bear...

Page 456: ...me and Inspection Item Standard Dimension Recommended Replacement Value Countermeasures Pump Type K3V63 K5V80 K5V140 Clearance between piston and cylinder bore D d 0 028 0 056 0 043 0 070 Replace piston or cylinder Play between piston and shoe caulking section δ 0 0 1 0 3 0 0 1 0 3 Replace assembly of piston and shoe Thickness of shoe t 3 9 3 7 4 9 4 7 Replace assembly of piston and shoe Free heig...

Page 457: ...r Bore D d Free Height of Cylinder Spring L Play between Piston Shoe Thickness of Shoe t Combined Height of Set Plate Spherical Bush H h Figure 13 Surface roughness for valve plate sliding face swash plate shoe plate area and cylinder sliding face Surface roughness necessary to be corrected 3 Z Standard surface roughness Corrected value 0 4 Z or lower Lapping ...

Page 458: ...e rear pump 1 Fit swash plate support 251 to pump casing 271 tapping it lightly with a hammer 2 Place pump casing with its regulator fitting surface down fit tilting bushing of swash plate to tilting pin 531 and fit swash plate 212 to swash plate support 251 correctly Figure 14 IMPORTANT After servo piston tilting pin stopper L and stopper S are removed Install them on pump casing in advance for r...

Page 459: ...ylinder spring 157 Align spline of retainer and cylinder Insert piston cylinder subassembly into pump casing 6 Position valve plate 313 to valve block 312 entering pin into pin hole Figure 16 IMPORTANT Do not tap drive shaft with hammer Assemble them into support lightly tapping outer race of bearing with plastic hammer Fully seat them using steel bar Figure 17 IMPORTANT Lightly apply grease to oi...

Page 460: ...igure 20 IMPORTANT Assemble the rear pump side first to make the procedure easier Do not mistake direction of valve block Clockwise rotation viewed from input shaft side Install block with regulator up and with delivery flange left viewed from front side Counterclockwise rotation viewed from input shaft side Install block with regulator up and with delivery flange right viewed from front side Figu...

Page 461: ...406 261 710 774 123 127 824 113 953 808 401 251 490 886 717 535 789 732 271 548 531 728 468 532 702 792 534 211 153 156 141 313 157 151 152 124 114 719 214 212 719 885 886 725 466 808 954 490 312 710 901 886 885 5 123 127 824 953 806 886 251 401 FG000609 Figure 22 ...

Page 462: ...rom the circuit 5 Check the pump and pipings for oil leaks and abnormal vibrations 6 When the pump is attached to a gear box check that the box is full of oil to its proper level Item Caution Applied Type Oil filling Fill the pump casing with oil Inside the pump there are high speed sliding and moving parts such as bearings pistons shoes retainer etc If not filled with oil these parts may suffer s...

Page 463: ...ive flow control With 2 stage max flow control D Positive flow control With flow cut function FG003923 Kind of horsepower control 1 Constant horsepower control 2 Total cumulative horsepower control 4 High pressure cut off control 5 Constant horsepower control High pressure cut off control 6 Total cumulative horsepower control High pressure cut off control 7 Total cumulative horsepower control Vari...

Page 464: ...SP000068 Axial Piston Pump Page 26 Parts List Figure 24 ...

Page 465: ...m Plug 615 Adjusting Plug 621 Compensating Piston 622 Piston Case 623 Compensating Rod 624 Spring Seat C 625 Outer Spring 626 Inner Spring 627 Adjusting Ring C 628 Adjusting Screw C 629 Cover C 630 Lock Nut 631 PF Sleeve 641 Pilot Cover 643 Pilot Piston 644 Spring Seat 645 Adjusting Ring Q 646 Pilot Spring 651 Sleeve 652 Spool 653 Spring Seat 654 Return Spring 655 Set Spring 656 Block Cover 708 O ...

Page 466: ...ntrol can be achieved by decreasing the horsepower of a pump depending upon the pressure of its companion pump 4 High pressure cutoff Pressure cutoff If the pressure rises above the set value the pump outlet flow is automatically decreased by the pressure cutoff control 5 Horsepower control pressure cutoff 6 Total horsepower control pressure cutoff 9 Variable horsepower control Variable horsepower...

Page 467: ...tion 10 200 cSt Miscellaneous With proportional pressure reducing valve In case of type KR3 9 Functional Explanations The regulator for Kawasaki in line axial piston pump K3V Series consists of the following control functions 1 Negative flow control 2 Total cumulative horsepower control 3 Variable horsepower control N Negative flow control Negative flow control can be carried out by using the pilo...

Page 468: ... flow Q decreases as the pilot pressure Pi rises With this mechanism when the pilot pressure corresponding to the flow required for the work is commanded the pump discharges the required flow only so it does not consume unnecessary power 1 Functional Explanation A Flow reducing Function As the pilot pressure Pi rises the pilot piston 643 moves to the right to a position where the force of the pilo...

Page 469: ...ight The spool is fitted with the return spring 654 and is tensioned to the left at all times and so the pin 897 is pressed against the large hole section C of lever2 Therefore as point D moves the feedback lever rotates around the fulcrum of point C and the spool is shifted to the left This causes the opening between the sleeve 651 and spool 652 to close slowly and the servo piston comes to a com...

Page 470: ...ition of the two pumps when horsepower control is under way 1 Functional explanation Since this regulator is of the simultaneous total horsepower type it controls the tilting angles displacement volumes of the two pumps to the same values as represented by the following equation T in P1 x q 2π P2 x q 2π P1 P2 x q 2π The horsepower control function is the same as the flow control function and is su...

Page 471: ...move to the left and the pump s delivery rate to increase The movement of the servo piston is transmitted to the spool by the action of the feedback mechanism to move it till the opening between the spool and sleeve is closed 2 Low tilting angle low flow command preferential function As mentioned above flow control and horsepower control tilting angle commands are transmitted to the feedback lever...

Page 472: ...sure reducing valve attached to the pump Only one proportional pressure reducing valve is provided However the secondary pressure Pf power shift pressure is admitted to the horsepower control section of each pump regulator through the pump s internal path to shift it to the same set horsepower level This function permits arbitrary setting of the Pump output power thereby providing the optimum powe...

Page 473: ... 14 1 600 kg cm 10 M 16 2 400 kg cm 12 M 18 3 400 kg cm 14 M 20 4 400 kg cm 17 PT filling plug Material S45C Wind a seal tape 1 1 2 2 turns round the plug PT 1 16 70 kg cm 4 Do PT 1 8 105 kg cm 5 PT 1 4 175 kg cm 6 PT 3 8 350 kg cm 8 PT 1 2 500 kg cm 10 PO plug Material S35C PF 1 4 300 kg cm 6 Do PF 1 2 1 000 kg cm 10 PF 3 4 1 500 kg cm 14 PF 1 1 900 kg cm 17 PF 1 1 4 2 700 kg cm 17 PF 1 1 2 2 800...

Page 474: ... 1 and 2 are only for cases of the variable horsepower contr28 ol 1 Check that the power shift command current I is normal 2 The power shift pressure is low Check the amplifier dither Replace the proportional pressure reducing valve 3 The compensating piston 621 and compensating rod 623 are stuck with each other Disassemble and clean the regulator 4 The Pin 898 is stuck Disassemble and clean the r...

Page 475: ...ty parts that are deeply scored 1 and 2 are only for cases of the pilot control 4 is only for cases of the two stage max flow control 5 is only for cases of the cutoff control Adjustment of Maximum and Minimum Flows The regulator can adjust the maximum and minimum flows with the adjusting screws NOTE Their respective adjustment values are shown in the attached Table See Summary of Regulator Adjust...

Page 476: ...g amount of adjusting screw 954 1 4 Turn Flow change amount 5 9 l min Adjustment of Minimum Flow Tightening amount of adjusting screw 953 1 4 Turn Flow change amount 4 7 l min Adjustment of Input Horsepower Adjustment of outer spring Tightening amount of adjusting screw C 628 1 4 Turn Compensating control starting pressure change amount 19 kg cm2 Input torque change amount 6 9 kg m A 1 9 Adjustmen...

Page 477: ...sembly are rather complicated For this reason replacement of a regulator assembly is recommended unless there is a special reason but in case disassembly is necessary for an unavoidable reason read through this manual to the end before starting disassembly 2 The numbers in parentheses after part names represent those in the Parts List on page 26 ...

Page 478: ...624 from compensating section Then draw out adjusting ring Q 645 pilot spring 646 and spring seat 644 from pilot section CAUTION 1 Choose a clean place 2 Spread rubber mat or cloth on top of workbench to prevent parts from being damaged Figure 34 IMPORTANT Do not lose O ring Figure 35 IMPORTANT Cover C is attached with adjusting screw C QI 628 925 adjusting ring C 627 lock nut 630 hex nut 801 and ...

Page 479: ...14 spring seat 653 return spring 654 and sleeve 651 9 Remove locking ring 858 fulcrum plug 614 and adjusting plug 615 Figure 37 Figure 38 IMPORTANT Sleeve 651 is attached with retaining ring 836 When removing retaining ring 814 return spring 654 may pop out Take care not to lose it Figure 39 Figure 40 IMPORTANT Fulcrum plug 614 and adjusting plug 615 can be easily taken out with M6 bolt ...

Page 480: ...13 Draw out pilot piston 643 and spool 652 14 Draw out piston case 622 compensating piston 621 and compensating rod 623 NOTE Since component parts are small do not lose them Figure 41 IMPORTANT Work will be promoted by using pincers Figure 42 Figure 43 IMPORTANT Push out pin 874 4 mm 0 16 in in dia from above with slender steel bar so that it may not interfere with lever 1 612 ...

Page 481: ...as O rings with new ones as a rule 1 Put compensating rod 623 into compensating hole of casing 601 2 Press fit pin in lever 1 612 into groove of compensating rod and fit lever 1 to pin press fitted in casing 3 Install spool 652 and sleeve 651 into hole in spool of casing 4 Install feedback lever 611 matching its pin hole with pin hole in spool Then insert pin 874 5 Insert pilot piston 643 into pil...

Page 482: ... ring 9 Install return spring 654 and spring seat 653 into spool hole Install retaining ring 814 10 Install set spring 655 in spool hole Slide compensating piston 621 and piston case 622 into compensating hole 11 Install pilot cover 641 and secure it in place with hex socket head screws 436 and 438 Figure 46 Figure 47 IMPORTANT Do not mistake inserting holes for fulcrum plug and adjusting plug Now...

Page 483: ...g seat 624 inner spring 626 and outer spring 625 into compensating hole 14 Install cover C 629 with adjusting screws 628 and 925 adjusting ring C 627 lock nut 630 hex nut 801 and adjusting screw 924 Secure them with hex socket head screws 438 Figure 50 IMPORTANT When fitting spring seat do not mistake direction of spring seat Figure 51 ...

Page 484: ...SP000068 Axial Piston Pump Page 46 ...

Page 485: ...SP000033 Page 1 Gear Pump SP000033 GEAR PUMP SP000033 Gear Pump Edition 1 ...

Page 486: ...SP000033 Gear Pump Page 2 MEMO ...

Page 487: ...SP000033 Page 3 Gear Pump Table of Contents Gear Pump Safety Precautions 5 Applicable Models 5 Single Gear Pump 6 Disassembly 6 Reassembly 8 Double Gear Pump 12 Disassembly 12 Reassembly 14 ...

Page 488: ...SP000033 Gear Pump Page 4 MEMO ...

Page 489: ...commendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up ...

Page 490: ... exterior of pump 2 Remove clamp bolts 3 Cover sharp edges of drive shaft with adhesive tape and coat shaft end extension with clean grease to avoid any damage to lip of shaft seal when removing mounting flange FG001072 Figure 1 FG001074 Figure 2 FG001073 Figure 3 ...

Page 491: ...eak it away from body NOTE Make sure that while removing mounting flange shaft and other components remain in position 5 Remove retaining ring if replacement is necessary 6 Remove shaft seal taking care not to damage surface of shaft hole if replacement is necessary 7 Pull drive gear up to facilitate removal of front plate FG001075 Figure 4 FG000834 Figure 5 FG000835 Figure 6 FG001076 Figure 7 ...

Page 492: ... gear keeping gears as straight as possible 9 Remove rear plate and end cover Reassembly 1 Clean all components with care 2 Using a suitable driver install shaft seal in mounting flange FG001077 Figure 8 FG001078 Figure 9 FG001078 Figure 10 FG000839 Figure 11 ...

Page 493: ...old O rings in body 5 Install rear section body on rear cover 6 Install seals in pressure plate s groove Then install backup ring in groove with seals Coat seals with grease NOTE The front and rear pressure plates and seals and backup rings are the same FG000840 Figure 12 FG001079 Figure 13 FG001080 Figure 14 FG001401 Outlet Side Inlet Side Figure 15 ...

Page 494: ...should face to rear cover opposite side of gears NOTE Pay attention to installation direction of seal 8 Install drive gear and driven gear 9 Insert pressure plate into body in proper direction 10 Locate mounting flange in right position FG001081 Figure 16 FG001082 Figure 17 FG001083 Figure 18 FG001084 Figure 19 ...

Page 495: ...1 Tighten bolts with washer in a crisscross pattern to a torque value of 45 Nm 12 Check that pump rotates freely when drive shaft is turned by hand If not a pressure plate seal may be pinched FG001085 Figure 20 FG000851 Figure 21 ...

Page 496: ...exterior of pump 2 Remove clamp bolts 3 Cover sharp edges of drive shaft with adhesive tape and coat shaft end extension with clean grease to avoid any damage to lip of shaft seal when removing mounting flange FG000830 Figure 22 FG000831 Figure 23 FG000832 Figure 24 ...

Page 497: ...t while removing mounting flange shaft and other components remain in position 5 Remove retaining ring if replacement is necessary 6 Remove shaft seal taking care not to damage surface of shaft hole if replacement is necessary 7 Pull drive gear up to facilitate removal front plate Remove drive gear driven gear rear plate keeping gears as straight as possible FG000833 Figure 25 FG000834 Figure 26 F...

Page 498: ...hrough shaft 9 Remove all remaining components in same manner as first section Reassembly 1 Clean all components with care 2 Using a suitable driver install shaft seal in mounting flange FG000837 Figure 29 FG000838 Figure 30 FG000838 Figure 31 FG000839 Figure 32 ...

Page 499: ...old O rings in body 5 Install rear section body on rear cover 6 Install seals in pressure plate s groove Then install backup ring in groove with seals Coat seals with grease NOTE The front and rear pressure plates and seals and backup rings are the same FG000840 Figure 33 FG000841 Figure 34 FG000842 Figure 35 FG001401 Outlet Side Inlet Side Figure 36 ...

Page 500: ...ould face to rear cover opposite side of gears NOTE Pay attention to direction of seal 8 Install drive gear and driven gear 9 Insert pressure plate into body in proper direction 10 Install intermediate cover one rear section and through shaft FG000844 Figure 37 FG000845 Figure 38 FG000846 Figure 39 FG000847 Figure 40 ...

Page 501: ...ting flange in right position 13 Tighten bolts with washer in a crisscross pattern to a torque value of 45 Nm 14 Check that pump rotates freely when drive shaft is turned by hand If not a pressure plate seal may be pinched FG000848 Figure 41 FG000849 Figure 42 FG000850 Figure 43 FG000851 Figure 44 ...

Page 502: ...SP000033 Gear Pump Page 18 ...

Page 503: ...SP000034 Page 1 Main Control Valve SP000034 MAIN CONTROL VALVESP000034 Main Control Valve Edition 1 ...

Page 504: ...SP000034 Main Control Valve Page 2 MEMO ...

Page 505: ...ion 6 Parts List 38 Specifications 43 Troubleshooting Testing and Adjustment 44 Troubleshooting 44 Adjustment of Valves 45 Disassembly 47 Cleaning and Inspection Wear Limits and Tolerances 57 Cleaning 57 Inspection 57 Reassembly 58 Caution on Assembly 58 Sequence of Subassembly 59 Maintenance of Relief Valves 65 Installation 68 Start up Procedures 68 ...

Page 506: ...SP000034 Main Control Valve Page 4 MEMO ...

Page 507: ...dations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up ...

Page 508: ...T1 T2 and T3 The oil supplied from the port P2 passes the tank passage Ta through orifice Rc 1 of negative relief from the neutral passage R1 and returns to port T1 T2 and T3 The pressure of chambers L2 and R2 flowing over the negative relief flows into pump from ports ps1 and ps2 to control the volume of pump P1 and P2 In addition when excessive oil flows excessive into the neutral passage the ne...

Page 509: ...ontrol Relief Valve L Negative Control Relief Valve R ARM 1 Section 5 ARM 2 Section 9 BOOM 2 Section 4 BOOM 1 Section 8 SWING Section 3 BUCKET Section 7 OPTION Section 2 TRAVEL Section 1 TRAVEL Section 6 STRAIGHT TRAVEL Section ST P1 Side P2 Side Figure 1 ...

Page 510: ...SP000034 Main Control Valve Page 8 Z SECTION L L FG001296 ARM 1 Section 5 BOOM 2 Section 4 SWING Section 3 OPTION Section 2 TRAVEL Section 1 Z Detail Figure 2 ...

Page 511: ...SP000034 Page 9 Main Control Valve SECTION R R 8 7 6 5 4 3 2 1 Ta Ta FG001297 ARM 2 Section 9 BOOM 1 Section 8 BUCKET Section 7 TRAVEL Section 6 STRAIGHT TRAVEL Section ST Figure 3 ...

Page 512: ...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 into drain passage DR The oil passing through orifice Lc6 flows through land Lc7 to tank passage Ta or flows through passage 4 to travel spool land Rc5 and then flows into tank passage Ta 5 FG001298 OPTION Section 2 TRAVEL Section 6 TRAVEL Section 1 STRAIGHT TR...

Page 513: ...SP000034 Page 11 Main Control Valve ...

Page 514: ... 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 When shifting either spool Section 1 or 6 land Lc4 or Rc3 is closed Oil supplied from port PP does not flow into tank passage so that pressure at port PT rises Option Spool Shift When shifting option spool by increasing pressure of option Section 2 pilot p...

Page 515: ...Page 13 Main Control Valve FG001299 Switched Position Switched Position Switched Position Neutral Position Neutral Position TRAVEL Section 6 STRAIGHT TRAVEL Section ST OPTION Section 2 TRAVEL Section 1 Figure 5 ...

Page 516: ... A3 B3 to spool and is returned to tank passage Ta Bucket Spool Shift Oil flow control in bucket section portion of valve is different from other sections because it has a regeneration function that works against pilot port pressure 1 Dump When bucket spool is shifted by increasing pressure of bucket Section 7 pilot port Pa7 neutral passage R1 is closed Oil supplied to port P2 flows through parall...

Page 517: ...SP000034 Page 15 Main Control Valve FG001300 Switched Position Neutral Position BUCKET Section 7 SWING Section 3 Figure 6 ...

Page 518: ...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 through spool to tank passage Ta and the other portion of oil flows through inside of spool and pushes up load check and then is combined at port A7 FG001301 Switched Position Neutral Position BUCKET Section 7 SWING Section 3 Figure 7 ...

Page 519: ...lve also works with anti drift valves that are installed on the bottom side of each boom cylinder When in neutral poppet AD1 is closed by port A8 pressure that is sent through passage AD2 spool AD3 to spring chamber AD4 FG001302 BOOM 2 Section 4 BOOM 1 Section 8 Figure 8 ...

Page 520: ...assage 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 L1 is closed Oil supplied to port P1 flows through parallel passage L3 load check valve S4 2 spool and to passage 6 and joins at port A8 Return oil flows from port B8 to spool and returns to tank passage Ta FG001303 BOOM 2 Sectio...

Page 521: ... 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 pressure of spring chamber AD4 and return oil from port A8 flows to tank passage Some return oil opens poppet S8 3 in boom 1 spool flows through passage S8 2 joins at port B7 and then prevents cavitation of cylinder rod side FG001304...

Page 522: ... valve also works with an anti drift valve that is installed on rod side of the arm cylinder When in neutral poppet AD1 is closed by port A5 pressure that is sent through passage AD2 spool AD3 and to spring chamber AD4 FG001305 ARM1 Section 5 ARM 2 Section 9 Figure 11 ...

Page 523: ...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 spool to passage 8 and joins at port B5 The return oil from port B5 flows through regeneration check valve in spool and then flows to port B to regenerate and some oil returns through variable regeneration release valve to tank ...

Page 524: ...h 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 increased it flows through regeneration release valve piston g and pushes regeneration release spool h as a result area of variable orifice f is increased and oil returning to tank Ta is increased and some oil to regenerate in port B5 is decreased FG00...

Page 525: ...plied to port P1 flows through neutral passage L1 load check valve S5 2 passage S5 1 and spool and into port A5 Oil supplied to port P2 flows through neutral passage R1 load check valve S9 2 passage S9 1 spool and passage 8 and joins at port A5 Return oil from port B5 returns through spool to tank passage Ta FG001308 ARM1 Section 5 ARM2 Section 9 Figure 14 ...

Page 526: ...ed operation Oil supplied from parallel passage L3 of arm 1 Section 5 pushes open poppet S5 3 It then flows through orifice Lc8 of variable orifice spool and then is connected to passage L5 From here flow of orifice Lc8 can be varied by increasing or decreasing pressure against pilot poppet Pc3 FG001309 pc3 Pressurized Position Normal Position DR2 Passage Figure 15 ...

Page 527: ...ghest pressure of pump P1 and P2 is controlled by reaction of main relief valve 2 Overload relief valve The overload relief valve that is installed in each cylinder port of boom 1 arm 1 and bucket prevents pressure of actuator from increasing extremely high from outside forces This relief valve when pressure of cylinder port is negative has a function to prevent cavitation by drawing oil from tank...

Page 528: ...rts PT and PA When the straight travel spool is shifted the oil supplied from port P1 flows to travel section1 from neutral passage L1 while oil supplied to port P2 flows into travel section 6 after passing through passage 2 straight travel spool head and neutral passage R1 flowing into the parallel passage L3 after passing the straight travel spool head and passage 1 In the event that load pressu...

Page 529: ...SP000034 Page 27 Main Control Valve 5 1 2 FG001310 TRAVEL Section 1 TRAVEL Section 1 STRAIGHT TRAVEL Section ST Figure 17 ...

Page 530: ...ton 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 into passage S7 1 As a result passage diameter is smaller during combined operation than passage diameter during a single operation This smaller passage reduces flow of oil to port A7 B7 Remaining oil flo...

Page 531: ...SP000034 Page 29 Main Control Valve FG001311 Switched Position Neutral Position BUCKET Section 7 SWING Section 3 Figure 18 ...

Page 532: ... to have the poppet assembly S3 2 to be pressed under the seat part of the valve housing through the piston S3 5 and plug S3 4 In this way the oil in the parallel passage L3 is flowing into the passage S3 1 by pushing up the poppet S3 3 inside the poppet assembly As a result the passage at the time of compound operation is tightened more than when single operation that the flux flowing into A3 B3 ...

Page 533: ...SP000034 Page 31 Main Control Valve FG001312 Switched Position Neutral Position BUCKET Section 7 SWING Section 3 Figure 19 ...

Page 534: ... the port A5 and the spring chamber A If port pc1 is pressurized piston 2 is moved and spool 3 reacts B Spool 3 activates poppet 4 C Then by moving poppet 4 port A5 and spring chamber d is cut off by part T1 3 Main poppet operation condition A When the piston 2 starts the spring chamber d passes from the passage c to the passage e and connect the oil passage by the part T2 to the drain chamber DR ...

Page 535: ...etting 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 opens pressure in internal cavity D lowers to move main poppet C so that pressurized oil flows into neutral oil passage HP and directly into low pressure oil passage LP 4 Pressure up operation If pressure is applied to pilot port PH piston H moves to ...

Page 536: ... 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 pilot poppet E opens pressurized oil flows through orifice I so that pressure on back of piston C lowers to move piston C As a result piston C seats on pilot poppet E 4 Pressurized oil in passage HP flows through orifice F in piston C so that pressure o...

Page 537: ...lled in cylinder port HP to prevent the development of cavitation If pressure at cylinder port HP becomes lower than that of oil passage LP sleeve K moves so that oil is supplied from the low pressure oil passage LP to cylinder port HP to eliminate cavitation Figure 31 HP LP FG000648 ...

Page 538: ... Ps1 Ps2 decreases because oil flowing to L2 R2 decreases 2 Operation of relief If excessive oil flows into passage L2 R2 pressure generated at passage L2 R2 by 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 plug and drill hole to tank passage Ta By ...

Page 539: ...SP000034 Page 37 Main Control Valve ...

Page 540: ...SP000034 Main Control Valve Page 38 Parts List 72 72 72 69 71 72 92 77 81 57 33 33 32 32 69 69 69 72 72 89 89 93 88 88 75 75 62 61 72 60 68 77 81 VIEW A A FG003962 Figure 34 ...

Page 541: ...t 33 Spring 57 Spacer 60 Plug Assembly 61 Plug 62 O ring 68 Main Relief Valve 69 Overload Relief Valve 71 Plug Assembly 72 Plug Assembly 75 Socket Bolt M10 x40L 77 Socket Bolt M16 x130L 81 Washer 88 Cap 89 O ring 92 Plug Assembly 93 Plug Assembly Reference Number Description ...

Page 542: ... 40 7 70 70 7 74 74 62 91 8 8 72 63 16 15 14 7 12 105 5 17 74 1 13 50 VIEW A A B SECTION B 4 3 2 7 12 74 72 5 6 65 65 65 65 65 65 66 66 66 ARM 2 BOOM 1 STRAIGHT TRAVEL TRAVEL BUCKET ARM 1 BOOM 2 SWING OPTION TRAVEL FG003963 Figure 35 ...

Page 543: ... 5 Travel Spool Assembly 6 T S Spool Assembly 7 O ring 8 Cap 12 Cap 13 Housing Valve 14 Arm Spool Assembly 1 15 Boom Spool Assembly 2 16 Swing Spool Assembly 17 Option Spool Assembly 50 Plug 62 O ring 63 Orifice Plug 65 O ring 66 O ring 70 Foot Relief Valve 72 Plug Assembly 74 Socket Bolt M10x28L 91 Plug 105 Plug Assembly Reference Number Description ...

Page 544: ...35 36 36 46 47 48 49 37 37 75 75 94A 94 102 95 98 97 99 96 104 103 100 101 42 19A 23 18 22 20 20 19 21 78 34 35 36 37 75 94A 101 36 36 43 73 92 45 44 51 35 36 37 75 24 24A 25 26 27 30 31 31 38 34 35 54 55 53 52 75 39 40 41 67 76 42 VIEW A A FG003964 Figure 36 ...

Page 545: ...ssembly 24 Plug 25 O ring 26 Spring 27 Spool 30 O ring 31 Backup Ring 34 Poppet 35 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 51 Poppet 52 Flange 53 Spacer 54 O ring 55 Backup ring 67 Anti drift Valve Assembly 73 Socket Bolt M10x55L 75 Socket Bolt M10x40L 76 Socket Bolt M10x70L 78 Socket ...

Page 546: ...ent Warm up entire circuit The valve is clogged by dust Remove flushing dust The pilot pressure is insufficient Check pilot valve and pilot relief pressure Load is not maintained Oil is leaking from cylinder Check chamber part of cylinder Oil is bypassed from spool Check groove of spool Oil is leaking from overload relief valve Wash valve housing seat part and relief valve seat part Oil is leaking...

Page 547: ... pilot poppet are stuck open and valve seat part has dust Replace relief valve Unstable relief pressure The seat part of pilot poppet has groove Piston or main poppet gets stuck Abnormal relief pressure Abrasion of seat part by dust Locking screw and adjustment equipment are loosened Re set pressure and tighten locking screw with regular Torque Oil leakage Damage to relief valve seat part Replace ...

Page 548: ...2 3 090 psi Tighten lock nut 7 after pressure has been adjusted 6 Recheck pressure setting by raising pressure once more Overload Relief Valve 1 Shift control valve spool and read pressure gauge from stroke end of cylinder 2 Loosen lock nut 3 and turn adjusting plug clockwise to raise pressure Item number 69 six places One turn varies pressure by approximately 21 2 MPa 216 kg cm2 3 075 psi 3 Tight...

Page 549: ...ssembly and protect it from dirt and foreign materials 4 Match mark the disassembled parts to make sure of proper reassembling position 5 Replace all sealing parts such as O rings and backup rings with a new ones 6 Do not replace spools they are matched with valve housing and sleeve NOTE The further part numbers of an assembly part are shown as assembly part number further part number CAUTION When...

Page 550: ...assembly 2 6 and 14 17 NOTE There is a poppet spring and plug in spool assembly Do not disassemble unless absolutely necessary If disassembly is necessary heat spool outside surface to release Loctite in screw portion and remove plug When reassembling replace O ring and backup ring to new ones CAUTION When removing spool be careful not to damage it Attach label to each spool in order to install it...

Page 551: ...2 3 Remove sleeve 27 2 from valve housing 4 Remove piston 27 3 O ring 30 and backup ring 31 from sleeve 27 2 CAUTION Work with spool gripped in vise with wood see Figure 37 so as not to scratch outside diameter of spool Because Loctite is applied to threaded portion of spool end heat outside surface of spool with industrial drier to release Loctite Heat spool until spool end is easily loosened and...

Page 552: ... 36 mm Section G G 11 Remove socket head bolt 73 four places width across flats 8 mm and flange 43 12 Remove spring 45 poppet 44 and O ring 36 from valve housing 13 Remove plug 46 width across flats 27 mm and O ring 47 14 Remove spring 48 and poppet 49 from valve housing 15 Remove socket head bolt 101 four places width across flats 8 mm from body 96 one places 16 Remove body 96 from valve housing ...

Page 553: ...ve sleeve 67 6 and poppet 67 2 from body Remove O ring 67 9 and 10 and backup ring 67 11 and 12 from outside diameter of sleeve E Pull spring seat 67 16 and spring 67 8 out of inside hole F Remove plug assembly 67 15 if necessary NOTE Do not remove steel ball 67 14 because it is pressed in body CAUTION Removing antidrift valve seat when pressure is not fully released or bucket is not lowered to gr...

Page 554: ... 22 mm and O ring 62 Section K K 3 Remove orifice plug 63 width across flats 5 mm Section A1 A1 4 Remove plug assembly 92 width across flats 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 CAUTION Removing relief valve when pressure is not fully released or bucket is not lowered to ground is very dangerous A...

Page 555: ...ght places width across flats 14 mm and washer 81 eight places 2 Remove O ring 65 and 66 from valve housing mating surface CAUTION Do not disassemble combined bolt 77 if it is unnecessary If it is necessary to disassemble it work by placing it horizontally on a work bench Prepare spare O ring 65 and 66 ...

Page 556: ...f oil is leaking from nut 4 remove nut 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 FG001317 A O ring P N 95111 01400 O ring P N 21001 00098 O ring P N 95111 01100 Piston JIS O ring Type Width across flat 32 Width across flat 27 Width across flat 30 Width across flat 27 Width across flat 36 Plug Plug Plug Hex Nut Hex Nut Figure 38 ...

Page 557: ...8 and replace O ring 3 NOTE This relief valve should be replaced as an assembly When replacing it Remove cap 1 width across flats 32 mm and O ring 2 If oil is leaking from adjusting kit 3 remove adjusting kit 3 and replace O ring 4 FG001318 2 1 4 3 O ring P N 21001 00098 O ring P N 95113 01000 Poppet Spring Width across flat 31 75 Width across flat 17 Width across flat 6 Cap Lock Nut Adjuster Figu...

Page 558: ...e 56 Instruction of Disassembly and Assembly of Low pressure Relief Valve 1 This unit has press fit portion D and it should be replaced as a complete assembly FG001321 2 4 2 D 1 O ring P N 95113 02100 O ring P N 21001 00213 Figure 40 ...

Page 559: ...using for scratches scores dirt notches and corrosion Remove small scratches with oilstone 2 Inspect exterior surface of spool for scratches and notches Remove small scratches with oilstone 3 Sliding parts should be moved lightly and foreign materials should be removed in all grooves and passages 4 Replace any springs that are damaged heavy deformed or worn 5 If relief valve malfunction inspect it...

Page 560: ...l spring and spool end should be reassembled like before disassembling Method of Painting the Adhesives screw part and arm screw part of parts requiring the adhesiveness NOTE Male and female screw threads of parts which need to adhere 1 Cleaning removal of grease Remove grease with steam acetate etc or clean with an alkali cleanser 2 Dry Dry Loctite surface with moisture free air or naturally If i...

Page 561: ...1 and spool end 22 2 After gripping spool in vise with wood that is used when disassembling it tighten spool end Tightening torque 1 94 2 24 kg m 14 16 ft lb CAUTION Check number of each part installation position and tools needed before reassembling CAUTION Be careful not to get Loctite into spool by over applying it Be careful that spool operation does become deteriorated by over torquing spool ...

Page 562: ...Tightening torque 15 16 kg m 108 116 ft lb 7 Tighten plug assembly 67 15 with O ring in body 67 1 Tightening torque 1 4 1 8 kg m 10 13 ft lb Assembly Sequence of Main Body of the Control Valve CAUTION Be careful of installation position of O ring and backup ring If they are reversed the O ring will be damaged and drift speed of actuator can be increased CAUTION It Is better to apply grease to seat...

Page 563: ...g torque 6 6 5 kg m 43 47 ft lb 3 Install O ring 36 on travel straight section Section H H Mount flange 37 and install socket head bolt 75 Tightening torque 5 91 6 53 kg m 43 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 option section Section G G Install poppet...

Page 564: ...n Section E E 2 Insert poppet 38 and spring 39 Install spacer assembly 40 with O ring and backup ring 3 Install antidrift valve assembly 67 two places and socket head bolt Tightening torque 3 98 4 49 kg m 29 32 ft lb Assembly of Option Section Part 1 Install O ring 89 on cap 88 two places and fasten it in place with socket head bolt 75 Tightening torque 5 91 6 53 kg m 43 47 ft lb Assembly of Arm R...

Page 565: ...t 74 Tightening torque 3 98 4 49 kg m 29 32 ft lb 5 Install O ring on plug assembly 72 and tighten it to two sides of cap of travel straight section Section H H Tightening torque 3 98 4 49 kg m 29 32 ft lb 6 Install O ring 62 on plug assembly 91 and install it on long cap of spare section Section G G Install O ring 62 on plug assembly 105 Install plug assembly on short cap of spare section Section...

Page 566: ...d install Tightening torque 4 4 5 kg m 29 32 ft lb 3 Tighten orifice plug 63 Tightening torque 1 4 1 8 kg m 10 13 ft lb 4 Install O ring on plug assembly 92 and install Tightening torque 21 23 kg m 151 167 ft lb 5 Install O ring on plug assembly 71 and install Tightening torque 1 4 1 8 kg m 10 13 ft lb 6 Install O ring on plug assembly 72 and install Tightening torque 7 5 8 kg m 54 58 ft lb ...

Page 567: ...en tighten plug 1 width across flats 32 mm Tightening torque 7 95 8 97 kg m 58 65 ft lb NOTE The torque values are based on use of lubricated threads NOTE If relief valve was disassembled adjust pressure by referring to Main Relief Valve on page 45 FG001317 A O ring P N 95111 01400 O ring P N 21001 00098 O ring P N 95111 01100 Piston JIS O ring Type Width across flat 32 Width across flat 27 Width ...

Page 568: ...97 kg m 58 65 ft lb NOTE The torque values are based on use of lubricated threads NOTE If relief valve was disassembled adjust pressure by referring to Overload Relief Valve on page 46 FG001318 2 1 4 3 O ring P N 21001 00098 O ring P N 95113 01000 Poppet Spring Width across flat 31 75 Width across flat 17 Width across flat 6 Cap Lock Nut Adjuster Figure 42 CAUTION In the event of disassembling the...

Page 569: ...l new O ring 4 on sleeve 2 Clean installation portion of relief valve and valve housing Tighten plug 1 width across flats 32 mm of relief valve Torque 11 12 kg m 76 83 ft lb NOTE The torque values are based on use of lubricated threads FG001321 2 4 2 D 1 O ring P N 95113 02100 O ring P N 21001 00213 Figure 43 CAUTION The sources of all tightening torque is coating with the operation oil ...

Page 570: ... hydraulic oil are clean 2 Hydraulic oil of which annealing point is 82 113 C 180 235 F should be used in the hydraulic system 3 Relief valve pressure should not be raised above specified pressure setting 4 The difference between main relief valve setting pressure and overload relief valve setting pressure should not be over 2 0 MPa 20 39 kg cm2 290 psi 5 Before operating machine the hydraulic sys...

Page 571: ...SP000069 Page 1 Remote Control Valve Work Lever Joystick SP000069 REMOTE CONTROL VALVE WORK LEVER JOYSTICK SP000069 Remote Control Valve Work Lever Joystick Edition 1 ...

Page 572: ...SP000069 Remote Control Valve Work Lever Joystick Page 2 MEMO ...

Page 573: ...trol Valve Work Lever Joystick Safety Precautions 5 Applicable Models 5 General Description 7 Theory of Operation 7 Parts List 8 Specifications 10 Torques 10 Tools and Materials 10 Disassembly 11 Cleaning and Inspection Wear Limits and Tolerances 15 Reassembly 15 Start up Procedures 22 ...

Page 574: ...SP000069 Remote Control Valve Work Lever Joystick Page 4 MEMO ...

Page 575: ...ndations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC...

Page 576: ...SP000069 Remote Control Valve Work Lever Joystick Page 6 ...

Page 577: ...en the lever is in neutral mode the spool is pushed upward by return spring The force of balancing spring which determines the secondary discharge pressure is not transmitted to the spool The input port is closed and the pressure of the output port is the same as the pressure of the tank port T 2 Control Switch Pressing of the push rod starts to press the balance spring whose force is transferred ...

Page 578: ...e Control Valve Work Lever Joystick Page 8 Parts List 22 20 28 24 23 21 19 2 3 18 35 16 17 12 8 10 11 7 6 5 4 9 9 1 1 2 3 4 A 37 24 28 29 25 25A A 27 26 32 30 33 18 36 16 17 12 8 15 11 14 13 5 4 34 FG003938 Figure 1 ...

Page 579: ...d 13 Spring 14 Spring Seat 15 Stopper 16 Plug 17 O ring 18 Rod Seal 19 Plate 20 Boot 21 Joint Assembly 22 Swash Plate 23 Nut 24 Nut 25 Handle Assembly L Handle Assembly R 25A Cap 26 Handle Bar 27 Spring Pin 28 Bellows 29 Bushing 30 Connector Assembly 32 Switch Assembly 33 Spool Kit 1 3 34 Spool Kit 2 4 35 Plug Kit 1 3 36 Plug Kit 2 4 37 Handle Kit Left Handle Kit Right Reference Number Description...

Page 580: ... Secondary Pressure Secondary Pressure Operating Torque Operating Torque 5 5 2 15 9 3 20 5 5 2 15 4 3 19 6 5 6 2 Figure 2 No Tool Standard Remark 3 Plug PF 3 8 500 kg cm 36 ft lb 19 Swash Plate 27 mm 1 660 kg cm 120 ft lb 20 Hex Nut 22 mm 1 660 kg cm 120 ft lb 22 Nut 22 mm 1 660 kg cm 120 ft lb No Tool Standard Remark 3 L Wrench 8 mm 19 Spanner 27 mm 20 Spanner 22 mm 22 Spanner 22 mm ...

Page 581: ... Joystick DISASSEMBLY 1 Remove lead wire from bushing 29 2 Remove lever assembly from case 1 3 Remove hex nut 23 and swash plate 22 from case 4 Remove joint assembly 21 from case FG000804 Figure 3 FG000805 Figure 4 FG000806 Figure 5 FG000807 Figure 6 ...

Page 582: ...mote Control Valve Work Lever Joystick Page 12 5 Remove plate 19 from case 1 6 Remove plug kit assembly stopper 10 and spring 11 from case 1 FG000808 Figure 7 FG000809 Figure 8 FG000810 Figure 9 FG000811 Figure 10 ...

Page 583: ...Remote Control Valve Work Lever Joystick 7 Remove four spool kit assemblies from case 1 8 The bushing 3 and plug cannot be removed from case 1 FG000812 Figure 11 FG000813 Figure 12 FG000814 Figure 13 FG000815 Figure 14 ...

Page 584: ...SP000069 Remote Control Valve Work Lever Joystick Page 14 FG000816 Figure 15 FG000817 Figure 16 ...

Page 585: ...SPECTION WEAR LIMITS AND TOLERANCES For general cleaning and inspection procedures refer to General Maintenance Procedures section REASSEMBLY 1 Install four plugs 2 into case 1 2 Install bushing 3 into case 1 using jig FG000815 Figure 17 FG000817 Figure 18 FG000814 Figure 19 ...

Page 586: ... 16 3 Take care when assembling spool kit assemblies 1 and 3 2 and 4 They should be assembled in same way The assembly order is spool 4 shim 5 spring 6 spring seat 7 and stopper 8 FG000816 Figure 20 FG000818 Figure 21 FG000819 Figure 22 FG000812 Figure 23 ...

Page 587: ...l spring 9 into case 1 5 Install spool kit assembly into case 1 The same way is used for four parts 6 Assemble plug kit insert rod seal 18 O ring 17 and push rod 2 into plug 16 in proper order FG000820 Figure 24 FG000821 Figure 25 FG000822 Figure 26 FG000810 Figure 27 ...

Page 588: ... springs 11 and stoppers 10 and insert assembled set in case 1 to form a plug kit assembly NOTE Pay attention to measurement specifications of stoppers 1 and 3 2 and 4 8 Install plate 19 into case 1 FG000809 Figure 28 FG000811 Figure 29 FG000823 Figure 30 FG000808 Figure 31 ...

Page 589: ...assembly 21 into case 1 10 Install wash plate 22 and hex nut 23 into case 1 11 Insert bar and tighten it with a spanner to check balance of joint assembly 12 Install boot 20 and bushing 29 into case 1 FG000807 Figure 32 FG000806 Figure 33 FG000824 Figure 34 FG000825 Figure 35 ...

Page 590: ...age 20 13 Install lever assembly into case 1 14 Put lead wire in bushing 29 tie it and arrange boot 15 Install lead wire terminal into connector terminal pressing them together FG000805 Figure 36 FG000826 Figure 37 FG000827 Figure 38 FG001097 Figure 39 ...

Page 591: ...SP000069 Page 21 Remote Control Valve Work Lever Joystick 16 Assemble connector assembly 30 and connect it to lead wire terminal and properly route wiring FG000828 Figure 40 FG000829 Figure 41 ...

Page 592: ...OCEDURES 1 Start engine and set throttle at LOW IDLE 2 Set safety lever on UNLOCK position 3 Slowly cycle boom arm bucket cylinders and swing motor about five times without a load to vent air from pilot lines Do this for five minutes Figure 42 HAOB290L ARO0470L Figure 43 ...

Page 593: ...SP001743 Page 1 Travel Control Valve With Damper SP001743 TRAVEL CONTROL VALVE WITH DAMPER SP001743 Travel Control Valve With Damper Edition 1 ...

Page 594: ...SP001743 Travel Control Valve With Damper Page 2 MEMO ...

Page 595: ...4 Track Shoes and Links 15 Track Removal 15 Track Installation 16 Front Idler Roller 18 Parts List 18 Front Idler Roller Disassembly 19 Front Idler Roller Reassembly 21 Lower Roller 22 Parts List 22 Lower Roller Removal 23 Lower Roller Disassembly 23 Lower Roller Reassembly 24 Lower Roller Installation 25 Upper Roller 26 Parts List 26 Upper Roller Removal 27 Upper Roller Disassembly 27 Upper Rolle...

Page 596: ...SP001743 Travel Control Valve With Damper Page 4 MEMO ...

Page 597: ...utlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up DX420LC 5327 and Up D...

Page 598: ...ion There is the pressure reducing valve a and the damper mechanism b The following hydraulic circuit is an example of a remotely located control valve 1 2 3 5 4 ARS1810L 6 Figure 1 Reference Number Description 1 Remote Control Valve 2 Pilot Pump 3 Main Pump 4 Control Valve 5 Hydraulic Motor 6 Hydraulic Cylinder Reference Number Description ...

Page 599: ...port 1 are connected and oil pressure from the pilot pump flows through port 1 generating pressure When the pressure of port 1 reaches the selected pressure of the secondary pressure select spring the oil pressure and the spring set pressure will equalize and the output pressure of port 1 is maintained at a constant rate The damper spool in port 2 is in the neutral position oil returning from the ...

Page 600: ...on of the casing to tank 3 When the operating levers are moved to the extreme opposite position When the cam is moved to the counterclockwise position from the clockwise most position the push rod and piston in port 2 is moved in the downward direction As in the case described above the oil in the damping piston chamber is discharged through the orifice and the dampening pressure is generated in t...

Page 601: ...e Moving the lever in the opposite direction causes the left damper spool to assume the function of the right spool Thus a dampening force is generated at both ways B Operation of forward and reverse lever control Oil outside the damper spool runs out through the channel from the top of the casing to the port T And oil in the damper spool is discharged through orifice generating pressure that crea...

Page 602: ...SP001743 Travel Control Valve With Damper Page 10 ...

Page 603: ...t primary pressure Defective secondary pressure select spring Replace with new spring Gap between damper spool and casing is abnormally large Replace damper 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 d...

Page 604: ...SP001743 Travel Control Valve With Damper Page 12 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 27 31 30 29 28 33 37 1 35 34 2 P T 1 2 3 4 FG003925 38 Figure 5 ...

Page 605: ... Seal 24 Dust Seal 25 Cover 26 Hex Socket Head Bolt 27 Cam 28 Bushing 29 Camshaft 30 Set Screw 31 Set Screw 32 Hex Nut 33 Bellows 34 Spacer 35 O ring 36 O ring 37 Hex Socket Head Bolt 38 Piston Reference Number Description Travel Control Valve Specification Type Pilot Control With Damper Pressure Stroke 25 kg cm2 4 8 mm Stroke 356 psi 0 1890 in Stroke Weight 7 8 kg 17 lb Part Reference Number Bolt...

Page 606: ... switch 9 Hang a maintenance warning tag on controls 10 Disconnect negative battery cable leading to frame from battery 11 Remove cabin under cover by loosening bolts 12 Tag and disconnect hoses from pedal valve 1 Figure 7 Plug and cap hoses and ports to prevent contamination from entering hydraulic system or component O I FG014348 DO NOT OPERATE when performing inspection WARNING 190 00695A or ma...

Page 607: ...h Damper DISASSEMBLY 1 Remove bellows 33 2 Remove set screw 30 from cam 27 3 Remove cam shaft 29 and cover 25 from cam 27 4 Remove hex nut 32 and swash plate 31 from cam ARS1870P Figure 8 FG000985 Figure 9 FG000986 Figure 10 FG000987 Figure 11 ...

Page 608: ...Damper Page 16 5 Remove hex socket head bolt 26 and cover 25 from each body 1 and 2 6 Remove push rod assembly from each body 1 and 2 7 Remove retaining ring 13 FG000988 Figure 12 FG000989 Figure 13 FG000990 Figure 14 FG000991 Figure 15 ...

Page 609: ...ravel Control Valve With Damper 8 Remove rod guide 11 from each body 1 and 2 9 Remove damper spool assembly and spring 10 from each body 1 and 2 FG000992 Figure 16 FG000993 Figure 17 FG000994 Figure 18 FG000995 Figure 19 ...

Page 610: ...y 1 and 2 Disassemble each body 1 and 2 and spacer 34 Remove plugs 3 and 4 and O rings 35 and 36 CLEANING AND INSPECTION WEAR LIMITS AND TOLERANCES For general cleaning and inspection procedures refer to General Maintenance Procedures section FG000996 Figure 20 FG000997 Figure 21 FG000998 Figure 22 ...

Page 611: ...BLY 1 Assemble plugs 3 and 4 and O rings 35 and 36 into each body 1 and 2 and spacer 34 Install hex socket head bolt 37 using torque wrench 2 Insert spring 10 into each body 1 and 2 FG000996 Figure 23 FG000997 Figure 24 FG000998 Figure 25 FG000995 Figure 26 ...

Page 612: ...spool 8 shim 7 spring 6 spring seat 5 and stopper 9 4 Install damper spool assembly into each body 1 and 2 5 Install O ring 12 on rod guide 11 Coat guide assembly with grease and slide it into each body 1 and 2 FG000999 Figure 27 FG001000 Figure 28 FG000994 Figure 29 FG000992 Figure 30 ...

Page 613: ...ntrol Valve With Damper 6 Install retaining ring 13 Make sure that it is properly seated 7 Assemble rod seal 23 dust seal 24 and O ring 22 into plug 21 FG000993 Figure 31 FG000991 Figure 32 FG001001 Figure 33 FG001002 Figure 34 ...

Page 614: ...ssemble seal 16 piston 38 steel ball 17 plate 19 spring 18 and retaining ring 20 into push rod 14 9 Assemble push rod and plug 10 Install push rod assembly into each body 1 and 2 FG001003 Figure 35 FG001004 Figure 36 FG001005 Figure 37 FG000990 Figure 38 ...

Page 615: ...g 28 in cover 25 using jig 12 Assemble cover 28 onto each body 1 and 2 and install hex socket head bolt 26 using torque wrench 13 Install set screws 31 and hex nut 32 into cam 27 and tighten it FG001006 Figure 39 FG001007 Figure 40 FG000989 Figure 41 FG000987 Figure 42 ...

Page 616: ...14 Position cam 27 on cover 25 and insert cam shaft 29 using hammer 15 Install set screw 30 in cam 27 and tighten it using torque wrench 16 Check cam balance 17 Install bellows FG000986 Figure 43 FG000985 Figure 44 FG001009 Figure 45 ARS2250P Figure 46 ...

Page 617: ...and washers 2 2 Install pedal brackets 3 and levers 4 Figure 48 on pedal valve and install four bolts and washers 2 3 Install rubber boots 1 Figure 48 4 Connect hoses as tagged during removal to pedal valve 1 Figure 49 5 Install cabin under cover by tightening bolts 1 2 FG003016 Figure 47 Figure 48 ARS2951L 3 2 2 3 1 1 Figure 49 1 2 FG003016 ...

Page 618: ...e 26 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 pilot lines Figure 50 HAOB290L Figure 51 HAOB903L ...

Page 619: ...SP001622 Page 1 Solenoid Valve Assembly SP001622 SOLENOID VALVE ASSEMBLYSP001622 1Solenoid Valve Assembly Edition 1 ...

Page 620: ...SP001622 Solenoid Valve Assembly Page 2 MEMO ...

Page 621: ...tions of 5 Solenoid Valve Assembly 7 Assembly Diagram and Tools Required 10 Cautions During Disassembly and Reassembly 11 Solenoid Valve Diagram 12 Check Points and Solutions for Problems 13 2 Solenoid Valve 14 Parts List 14 Assembly Diagram and Tools Required 15 Cautions During Disassembly and Reassembly 16 Solenoid Valve Diagram 17 Troubleshooting Guide 17 ...

Page 622: ...SP001622 Solenoid Valve Assembly Page 4 MEMO ...

Page 623: ...ices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX420LC 5327 and Up DX480LC 5221 an...

Page 624: ...n the 5 solenoid valve FG013248 1 5 4 3 2 2 1 2 2 Figure 1 Reference Number Description Sizes Quantity Remarks 1 Block Body 79x82x272 5 1 1 A0098 07 0 2 Solenoid Valve QF S3A 0421 5 C1 C2 C3 C4 C5 2 1 Coil VDL24VDC 5 C1 C2 C3 C4 C5 3 Check Valve FD DCP 0 A 1 C6 4 Plug PF 1 4 3 P3 P4 H0 5 Plug PT 1 8 6 ...

Page 625: ...n the left side of the operator s seat allows the electrical power from the pilot cutoff switch to activate the pilot cutoff solenoid valve The pilot cutoff solenoid valve then supplies pressurized oil to each of the other solenoid valves Reference Number Function Operations Remarks C1 Pilot Cut off Provides pressurized oil coming from the pilot pump for the pilot pressure supply solenoid valve to...

Page 626: ...e main pump and automatically turns the high travel speed control ON or OFF depending on if the travel load is high or low to switch the travel speed to speed I or II The travel load is detected by two pressure sensors located on the discharge line of the front and rear pumps If the load is high pressure about 300 kg cm2 the solenoid valve turns OFF for travel at low speed If the load is low press...

Page 627: ...The breaker shear switch activates the solenoid valve when the front option attachment is changed from shear to breaker When the switch is set to breaker pilot pressure is supplied to shear valve shifting the spool inside with the pressurized oil from the main pump supplied to breaker ...

Page 628: ...e Number Description Sizes Torques kg cm Tools 2 Solenoid Valve UNF7 8 14 200 25 kg cm 170 20 in lb Hex torque wrench 1 socket 2 1 Coil Locknut UNF1 2 20 60 2 kg cm 50 2 in lb Hex torque wrench 19 mm socket 3 Check Valve UNF7 8 14 400 2 kg cm 350 2 in lb Hex torque wrench 1 socket 4 PT 1 4 Plug UNF1 4 19 250 25 kg cm 220 20 in lb Hex torque wrench 19 mm socket 5 PT 1 8 Plug Bolt UNF1 8 28 280 kg c...

Page 629: ...y and reassembly of the solenoid valve A Remove coil locknut 2 1 from tube and retainer B Remove coil 2 2 by hand C Remove solenoid valve 2 D Check disassembled components for damage and reassemble them in the reverse order of the disassembly E Do not use excessive torque when assembling he solenoid valve and coil 5 Do not allow any contamination to enter the valve during disassembly and reassembl...

Page 630: ...SP001622 Solenoid Valve Assembly Page 12 Solenoid Valve Diagram Figure 3 ...

Page 631: ... and check the pilot pressure discharged from the pilot pump when operating the pilot cut off valve C1 Refer to Causes and How to Check of the solenoid valve above Pilot relief valve Check if the relief valve installed in the pilot line operates properly Check if pressure is bypassing because of the presence of foreign substance Remove foreign substance reas semble and replace the relief valve Pil...

Page 632: ...14 2 SOLENOID VALVE Parts List Figure 4 shows components used in the 2 solenoid valve 1 3 2 2 2 FG013249 Figure 4 Reference Number Description Size Quantity Remarks 1 Block Body 57x73x105 1 1 A1097 07 0 2 Solenoid Valve QF S3A 0421 2 C1 C2 ...

Page 633: ...s described in the table below Observe the specified torque values using the right tool 1 3 2 2 2 FG013249 Figure 5 Reference Number Description Sizes Torques kg cm Tools 2 Solenoid Valve UNF7 8 14 200 25 kg cm 170 20 in lb Torque wrench 1 hex socket 2 1 Coil Locknut UNF1 2 20 200 25 kg cm 170 20 in lb Torque wrench 19 mm hex socket ...

Page 634: ...ly and reassembly of solenoid valve A Remove coil locknut 2 1 from tube and retainer B Remove coil 3 by hand C Remove tube and retainer 2 D Check disassembled components for damage and reassemble them in the reverse order of the disassembly E Do not use excessive torque when assembling he solenoid valve and coil 5 Do not allow any contamination to enter the valve during disassembly and reassembly ...

Page 635: ...d assemble components Tube or retainer of solenoid valve dam aged Disassemble the solenoid valve and check if there is any deformation bending or reduction in the tube or the retainer Replace sole noid valve Coil broken short or burned Disassemble the solenoid valve and check the coil resistance Spec 26 7Ω 20 C Disconnection Short Low or excessive resistance Disassemble the solenoid valve and chec...

Page 636: ...SP001622 Solenoid Valve Assembly Page 18 ...

Page 637: ...SP000192 Page 1 Breaker EPPR Valve Opt SP000192 BREAKER EPPR VALVE OPT SP000192 1Breaker EPPR Valve Opt Edition 1 ...

Page 638: ...SP000192 Breaker EPPR Valve Opt Page 2 MEMO ...

Page 639: ...Table of Contents Breaker EPPR Valve Opt Safety Precautions 5 Applicable Models 5 Structure 6 Numbers and Names of Parts 6 Functions and Operation 7 Cautions for Operation 7 Maintenance Instructions 8 Maintenance 8 Disassembly 9 Assembly 10 ...

Page 640: ...SP000192 Breaker EPPR Valve Opt Page 4 MEMO ...

Page 641: ...ed in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up DX420LC 5327 and Up DX480L...

Page 642: ... Breaker EPPR Valve Opt Page 6 STRUCTURE Numbers and Names of Parts Figure 7 Reference Number Description 1 Solenoid 2 Valve casing 3 Sleeve 4 Spool 5 Pin 6 Spring 7 O ring 8 O ring Reference Number Description ...

Page 643: ...ses CAUTIONS FOR OPERATION 1 Wiring of the solenoid The solenoid has no polarity 2 Input electricity Do not supply electric current more than 0 7A to the solenoid coil 3 Adjustment screw It was adjusted to the standard The pressure of the port A increases when turning the adjustment screw clockwise 4 Symptoms and Solutions of Problems Symptoms Causes Solutions Pressure does not increase nor change...

Page 644: ...1 Tools Used for Disassembly and Assembly Table 2 shows tools necessary for disassembly and assembly As bolts and plugs to be used depend on types they should be checked accordingly in advance Bolt Sizes Names Used Torques kgf cm M 35 Hex bolt 450 50 M 10 Hex bolt 200 20 NPTF 1 16 Plug 90 For Sizes Used Torques Used Tools Solenoid M 35 450 50 Spanner Sleeve M 10 200 20 Hex bar spanner NPTF plug 1 ...

Page 645: ... care not to damage parts 2 Remove dust and rust of the proportional pressure reducing valve with cleansing oil 3 Disassemble the solenoid Take care not to damage O rings of the solenoid 4 Disassemble the spool the spring and the pin 5 Disassemble the sleeve Take care not to damage O rings of the sleeve FG003690 Figure 8 FG003691 Figure 9 FG003692 Figure 10 ...

Page 646: ...y part should be cleaned enough with cleaning oil and dried with compressed air before starting assembly Sliding parts and bearings should be applied clean active oil before their assembly Basically parts of the O ring and the oil seal should be replaced Use a torque wrench to tighten or engage bolts and plugs in accordance with reference torques as described in Maintenance Guide 1 Assemble the sl...

Page 647: ...SP000192 Page 11 Breaker EPPR Valve Opt 2 Assemble the spool the spring and the pin The spring and the pin should not be fell off FG003695 Figure 13 FG003696 Figure 14 ...

Page 648: ...SP000192 Breaker EPPR Valve Opt Page 12 3 Assemble the solenoid correctly Take care not to damage O rings of the solenoid FG003697 PART No SERIAL No 426 00266 Figure 15 FG003698 Figure 16 ...

Page 649: ...SP001752 Page 1 Hydraulic Schematic DX300LC DX300LCA SP001752 HYDRAULIC SCHEMATIC DX300LC DX300LCA SP001752 2Hydraulic Schematic DX300LC DX300LCA Edition 1 ...

Page 650: ...SP001752 Hydraulic Schematic DX300LC DX300LCA Page 2 MEMO ...

Page 651: ...SP001752 Page 3 Hydraulic Schematic DX300LC DX300LCA Table of Contents Hydraulic Schematic DX300LC DX300LCA Safety Precautions 5 Applicable Models 5 DX300LC DX300LCA 7 ...

Page 652: ...SP001752 Hydraulic Schematic DX300LC DX300LCA Page 4 MEMO ...

Page 653: ...all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up ...

Page 654: ...SP001752 Hydraulic Schematic DX300LC DX300LCA Page 6 ...

Page 655: ...EDAL VALVE 22 HYDRAULIC TANK 21 AIR BREATHER 20 FULL FLOW FILTER 19 OIL COOLER 24 26 27 28 29 30 Valve control P 80kg cm2 a A 35 41 42 43 44 45 31 32 33 34 46 24 29 30 34 B D S T APPLIED PART 1 PUMP PACKAGE CUT OFF 25 25 25 QUICK COUPLER 36 ps1 Pi1 to 34 P from 32 DUMP RIGHT A1 9 LEFT A4 A3 A2 A8 A5 A6 A7 DUMP CROWD DOWN UP CROWD pa3 B1 pc2 pc1 Pi B4 pb5 pb3 pa5 B3 S1 B2 pb7 pb8 pa7 pa8 B6 B5 B8 B...

Page 656: ......

Page 657: ...1Electrical System ...

Page 658: ......

Page 659: ...SP002030 Page 1 Electrical System SP002030 ELECTRICAL SYSTEMSP002030 Electrical System Edition 1 ...

Page 660: ...SP002030 Electrical System Page 2 MEMO ...

Page 661: ...nd Indicator Lights 26 Initial Operation 29 Mode Selector Switch 29 Graphic Information Area Display 30 Main Menu 32 Special Menu 36 Electronic Hydraulic Control System e EPOS 54 Power Mode Control 56 Power Mode Control Circuit Diagram 61 Engine Control System 62 Engine Control Motor 63 Engine Control Dial 64 Engine Control Circuit Diagram 65 Automatic Deceleration Control Auto Idle Control 66 Eng...

Page 662: ... 4 Self diagnostic Function 75 Air Conditioner System 77 Troubleshooting 97 Weight of R134a Gas Used In Machines 99 Refrigerant System Repairs 100 Wiper System 108 Lighting System 110 Overload Warning Device 112 Audio Controller 113 ...

Page 663: ...SP002030 Electrical System Page 5 MEMO ...

Page 664: ... all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LCA 5001 and Up ...

Page 665: ...series and a three phase AC generator with a rectifier The electric wiring used in the system is easily identifiable by the insulator color The color symbols used in the electrical system are listed in the following chart Electric Wire Color NOTE RW Red wire with White stripe R Base Color W Stripe Color NOTE 0 85G Nominal sectional area of wire core less insulator 0 85 mm2 Symbol Color W White G G...

Page 666: ... Engine controller 5 Fuel feeder pump switch 6 Terminal 6 of wiper motor 7 Terminal 13 of wiper controller 8 Terminal CN6 11 of instrument panel 9 Terminal CN9 6 of air conditioner panel 10 Cabin light When the starter switch 5 is in the ON or START positions the current flows from the battery 1 fusible link 3 fuse box 6 B terminal of starter switch 5 BR terminal of starter switch 5 BR terminal of...

Page 667: ...F F E REG I L FIELD GRD 7 12V 100AH R I P R B 8 B B E BR 4 B 12V 100AH 1 2 A 6 R2 ACC R1 B BR C 5 0 5G 3 FG007233 Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Starter Switch 6 Fuse Box 7 Alternator 8 Diode Reference Number Description ...

Page 668: ...terminal of the battery relay 2 B terminal of the battery relay 2 Figure 3 B terminal of the starter 9 The starter motor is rotated and the engine is started If the instrument panel has the password function activated input number should match the set number otherwise the start circuit closes and the engine does not start NOTE If the security system is LOCKED a four digit password will be required...

Page 669: ... 30 87a 87 P N B C BR R2 R1 ACC B 5 E S 11 D C B PP 7 8 2 10 1 BR E B A 3 A B C 9 FG007234 Figure 3 STARTER CIRCUIT 1 WHILE STARTING Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Starter Switch 6 Fuse Box 7 Starter Controller 8 Starter Relay 9 Starter 10 Alternator 11 Diode 12 Starter Relay 2 13 e EPOS Controller Reference Number Description ...

Page 670: ...nal to the rotation of the alternator The starter controller 7 monitors the frequency of the output current Once the frequency is equivalent to 500 rpm it is sensed and the connection between S and E terminals and the connection between B 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 sw...

Page 671: ...a P 30 B E N S C B D PP E B BR A B A C 12 13 10 6 11 4 5 7 11 8 1 2 3 9 F E GRD P R R I I L REG F B B B FIELD Figure 4 OPERATION OF START CIRCUIT 2 IMMEDIATELY AFTER START Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Starter Switch 6 Fuse Box 7 Starter Controller 8 Starter Relay 9 Starter 10 Alternator 11 Diode 12 Starter Relay 2 13 e EPOS Controller Re...

Page 672: ...troller 12 ground This current flow causes the coil in preheat relay 7 to be activated closing contacts When the contacts of the preheat relay 7 are closed the heating coils of the air heating device 8 are heated by current flowing from the battery 1 battery relay 2 preheat relay 7 air heater 8 ground The duration of the heating cycle depends on the temperature of engine coolant The preheat indica...

Page 673: ...ON 200A B TML PST B BR R1 1 R1 R2 ACC B C BR 5 E 10 BR B ACC R2 C A 4 3 FG007137 Figure 5 ENGINE PREHEAT CIRCUIT Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Starter Switch 6 Fuse Box 7 Preheat Relay 8 Air Heater 9 Preheat Indicator Light 10 Diode 11 e EPOS Controller 12 Engine Controller Reference Number Description ...

Page 674: ...ine controller stops suppling power to the injector solenoid 9 This stops fuel from being injexted into the engine cylinder thus stopping the engine In the event that the engine can be shut down using the starter switch 5 an emergency stop switch 10 is provided to shut down engine To activate the emergancy stop switch move it to the I EMERGENCY STOP position The emergency stop switch 10 is in its ...

Page 675: ... BR STARTER SWITCH CONNECTION 6 START ON TML OFF PST B ACC R1 R2 C Figure 7 ENGINE STOP CIRCUIT Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Starter Switch 6 Fuse Box 7 Diode 8 Engine Controller 9 Injector Solenoid 10 Emergency Stop Switch Reference Number Description ...

Page 676: ...ponents When the alternator 7 starts to operate a current flows from the R I terminal of alternator diode 8 battery relay 2 coil securing a path for the charging current to the battery 1 Thus preventing the possibility of a high voltage build up and possible damage to the electric system TRIO DIODE 0 5 uF 8 START ON OFF STARTER SWITCH CONNECTION TML PST B BR R1 R2 C ACC F F E REG I L FIELD GRD 7 1...

Page 677: ...4 ESC 8 E G SPEED 02 05 MO 11 30 1700 RPM CHECK CHECK CHECK CHECK POWER AUTO 5 1 2 14 13 3 4 6 7 8 9 10 11 12 FG015509 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 Controller 7 Alternator 8 Warning Buzzer 9 Pnmp Discharge Pressure Sensor 10 Engine Coolant Temperature Sensor 11 Fuel Sensor 12 Air Clean...

Page 678: ... H C POWER 1 5 2 3 6 7 AUTO 4 ESC 8 E G SPEED 02 05 MO 11 30 1700 RPM CHECK 5 1 2 14 16 13 15 19 17 3 4 18 20 7 8 9 10 11 12 FG015472 6 CN7 CONNECTOR AND TERMINAL NO 12 6 5 11 4 10 14 8 7 15 16 2 1 8 7 3 9 12 5 4 3 2 1 10 11 9 6 13 CN6 AMP 040 28P 1 Figure 10 ...

Page 679: ...Switches 1 Fuel Gauge 2 Engine Coolant Temperature Gauge 3 Hydraulic Oil Temperature Gauge 4 Multifunction Gauge and Letter Information Area 5 Digital Clock 6 Hour Meter 7 Charge Warning Light 8 Engine Oil Pressure Warning Light 9 Coolant Temperature Warning Light 10 Engine Check Warning Light 11 Preheat Indicator Light 12 Work Light Indicator Light 13 Power Mode Selector Switch and Indicator 14 E...

Page 680: ... 4 CN6 5 CN6 6 CN6 7 CN6 9 CN6 3 CN6 1 CN6 2 CN6 12 CN6 11 13 21 22 6 5 20 14 18 7 8 11 10 12 9 15 1 4 2 3 19 17 16 CN7 4 CN7 5 CN7 6 CN4 1 CN2 17 CN2 18 CN2 14 CN4 4 CN3 3 CN3 4 CN4 6 CN4 5 CN4 2 CN4 3 CN3 2 CN3 1 CN5 3 CN3 7 CN3 8 CN3 9 CN3 10 CN5 7 CN2 1 1 35 1 34 1 53 1 33 1 52 1 51 R I CAN A TxD RxD GND 4 2 1 3 6 5 14 SIG SIG R2 B B E BR A CN7 9 CN7 10 1 62 1 65 Figure 11 ...

Page 681: ...mp Pressure Sensor 7 Hydraulic Oil Temperature Sensor 8 Fuel Sensor 9 Pedal Pressure Switch Optional 10 Air Cleaner Indicator 11 Pilot Filter Switch 12 Return Filter Switch 13 Alternator 14 e EPOS Controller 15 Battery 16 Battery Relay 17 Circuit Breaker 18 Fusible Link 19 Fuse Box 20 Check Connector 21 Engine Controller 22 Rearview Camera Reference Number Description ...

Page 682: ...e CN3 9 CN3 10 40 C 104 F 1 397 ohms 50 C 122 F 1 139 ohms 60 C 140 F 881 ohms 94 C 201 F 190 ohms 96 C 205 F 177 ohms When reading increase Flow Adjusting Output Terminal CN1 19 CN1 20 48 l min 615 mA 70 l min 583 mA 90 l min 555 mA 130 l min 495 mA Default Set 210 l min 376 mA 244 l min 260 mA C H FG000550 Blue White Red 107 C 102 C 41 C 61 C E F FG000552 Blue Red Full 1 10 C H FG000551 Blue Whi...

Page 683: ... VDC Main pump discharge pressure front pump CN3 1 CN3 2 V 0 00816 x P 1 0 V Sensor output voltage V P Displayed pressure Bar Main pump discharge pressure rear pump CN3 3 CN3 4 Function Display Sensor Specification Input Terminal Input Specification E G SPEED 1700 RPM FG000049 BATTERY 28 0 VOLT FG000050 FRONT PUMP 320 BAR FG000051 REAR PUMP 313 BAR FG000052 ...

Page 684: ... reference After starting engine if engine oil pressure is insufficient after 8 seconds a warning buzzer will sound Engine Check ECU CAN Communic ation This symbol appears in case of failure in engine system Coolant Temperature ECU CAN Communic ation This symbol appears when engine coolant temperature sensor resistant is below about 128 ohms Preheating CN5 2 This symbol appears during preheating C...

Page 685: ...tion Remarks HB4O2003 Description Symbol Input Terminal Operation Remarks Hydraulic Oil Temperature CN3 9 CN3 10 When hydraulic oil temperature is above about 96 C Fuel Exhausted CN3 7 CN3 8 When fuel is almost exhausted Air Cleaner CN2 17 When air cleaner is clogged Return Filter CN5 3 When return filter pressure is above about 1 50 kg cm 21 psi FG000056 FG000057 FG000053 FG000054 ...

Page 686: ...ssure sensor output voltage is about 2 7V while overload warning switch is ON It flickers in case of 2 71V and above and lights continuously in case of 2 8V and above and warning buzzer also starts Boost CN2 2 It lights when boost is selected Breaker CN2 10 It lights when breaker is selected Shear CN2 9 It lights when shear is selected FG000055 FG000253 FG000554 FG001470 FG001471 ...

Page 687: ... activated and turned OFF after about 2 seconds Power mode Standard mode Auto Idle High Output Activation Display Indicating coolant temperature Fuel level Hydraulic oil temperature Engine speed Clock Current time display Operation Mode OutputCheck Operation mode display e EPOS Output Electromagnetic Proportional Pressure Reducing Valve E P P R Valve Current mA Swing Priority Solenoid Valve 7 Segm...

Page 688: ...ne is main menu for user and the other is special menu for specialist These menus can be moved from normal display mode by the combination of selector buttons C H E F H C 1 5 2 3 6 7 4 8 POWER AUTO ESC FG015511 E G SPEED 02 05 MO 11 30 1700 RPM 5 1 2 3 4 CHECK CHECK CHECK CHECK Figure 12 Selector Buttons Graphic Display Area 1 Up Arrow Button 2 Down Arrow Button 3 Enter Button 4 Escape Button 5 Le...

Page 689: ...ion Menu Selector 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 screen 3 Enter Button 3 on Figure 12 Move the menu to selected mode When setting the menu this button is used to function as the selector button 4 Escape Button ESC 4 on Figure 12 Move a screen to previous menu or main m...

Page 690: ...on 2 on Figure 12 to move cursor to a language to be selected on the Language Select display and press the Enter Button 3 on Figure 12 and the selected language is indicated in the right bottom of the screen At this point pressing the Enter Button 3 on Figure 12 or the Escape Button ESC 4 on Figure 12 more than 1 second brings the main menu with changed language and then pressing the ESC button ag...

Page 691: ...Oil Info This mode displays total operating hours of filters and oils After changing the filter and oil reset the operating hour and then the operating hours until the next service interval can be easily checked MAIN MENU 1 Language 4 Adjust Display 5 Set Password 2 Set Clock 3 Filter Oil Info UP DOWN SELECT FG000075 Figure 16 SET CLOCK MOVE FG000076 06 05 2004 06 29 Figure 17 MAIN MENU 1 Language...

Page 692: ...d using the Up Arrow Button 1 on Figure 12 or the Down Arrow Button 2 on Figure 12 The default brightness is set to 50 1 Fuel Filter 2 Air Cleaner 3 Engine Oil Filter 4 Hyd Oil Filter 5 Pilot Filter 6 Engine Oil 7 Hydraulic Oil 8 Coolant Water FG001358 Figure 20 MAIN MENU 1 Language 4 Adjust Display 5 Set Password 2 Set Clock 3 Filter Oil Info UP DOWN SELECT FG000080 Figure 21 Adjust Display FG000...

Page 693: ... menu is used to apply lock release or change password Please refer to the Operation Manual for detailed information on Password Setting MAIN MENU 1 Language 4 Adjust Display 5 Set Password 2 Set Clock 3 Filter Oil Info UP DOWN SELECT FG000227 Figure 23 ...

Page 694: ...aping 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 mode screen Figure 24 will be changed to special menu screen Figure 24 Normal Mode Screen NOTE Normal mode screen can display many kinds of display mode by selecting for example engine speed RPM battery voltage VOLT front ...

Page 695: ...Submenu Selection Method Various sub menus can be selected by pressing Up 1 on Figure 24 and Down 2 on Figure 24 button Move the cursor to desired menu and a selected menu will be inverse displayed When the selected menu is inverse displayed press the Enter 3 on Figure 24 button for menu selection Information of Machine Status 1 Entering Sub menus When cursor is located on Machine Info of special ...

Page 696: ...ature C Temperature of air incoming to intake manifold 11 E G Oil Pressure BAR Engine oil pressure 12 Fuel Temperature C Fuel temperature 13 E G Oil Temperature C Engine oil temperature 14 Load At Current Speed Current load ratio of equipment FG003928 ANALOG INPUT STATE UP DOWN Page 1 3 UP DOWN Page 2 3 UP DOWN Page 3 3 1 Pump P V 000mA 2 Cooling Fan P V 000mA 3 Flow Control P V 000mA 4 Dial N A 5...

Page 697: ...rn filter pressure switch is ON 10 Pilot Filter Clogged Lights up when the pilot filter pressure switch is ON 11 OWD Warning SW Lights up when the overload warning selector switch is ON 12 Brake Oil Press SW N A only for wheel type equipment 13 Pedal Press SW Lights up when the pedal pressure switch is ON 14 One Way Sel SW Lights up when the selector switch is turned to breaker 15 Two way Sel SW L...

Page 698: ...ressure SW Py 6 Pressure SW Px 19 Quick Coupler 20 F R Lever 21 Preheat Select 22 Reverse Fan SW 23 Pilot Cutoff SW N A 7 E G Oil Press SW 8 Air Cleaner Clogged 9 Return Filter Clogged 10 Pilot Filter Clogged 11 OWD Warning SW 12 Brake Oil Press SW N A 13 Pedal Press SW 14 One Way Sel SW 15 Two Way Sel SW 16 Power Max SW 17 Breaker SW 18 Preheat Select DIGITAL INPUT STATE DIGITAL INPUT STATE DIGIT...

Page 699: ... all of the memorized record of past failure Digital Outputs Items Mark Remark 1 Relief Press Up S V ON OFF Lights up when the relief press up solenoid valve is ON 2 High Speed S V Lights up when the high speed solenoid valve is ON 3 Swing Priority S V Lights up when the swing priority solenoid valve is ON 4 Reverse Fan S V N A 5 Starter Relay When the starter relay is ON 6 After Heat Relay N A UP...

Page 700: ...means that the totally counted number of the same failure Period xxxxxHrxxm It indicates the period for which machine has operated until a failure takes place For more than two occurrences of the same failure until the first occurrence time C Failure record deletion This mode is used to delete the memorized record of past failure If this mode is selected all records will be deleted When YES 3 on F...

Page 701: ...reen will move to Failure Info screen It has been shown 3 seconds upon deleting Fail Log The screen shown on the left will appear 3 seconds in case of wrong password input and then Enter Password screen appears again It has been shown 3 seconds in case of password failure ESC No FG000568 Yes ENTER PASSWD DELETE FAIL LOG Figure 37 ESC No FG000569 Yes DELETED DELETE FAIL LOG Figure 38 ESC No FG00057...

Page 702: ...9 CN1 20 R 14 2 Ω 25 C 77 F Flow control proportional pressure reducing valve V213 Relief Pressure Up S V CN1 1 CN1 11 V V_volt Note 4 R 26 2 2 Ω 25 C 77 F Breaker boost shear selector switch has to be selected as a boost function and the boost switch on the right hand joystick is ON status V214 High Speed S V CN1 1 CN1 12 V V_volt R 26 2 2 Ω 25 C 77 F Voltage is only measured when the pressure sw...

Page 703: ...equipment V222 Hyd Oil Temperature Sensor CN3 9 CN3 10 R 2 45 0 25 kΩ 25 C 77 F R 320 32 Ω 80 C 176 F V223 Water Temperature Sensor N A V224 Engine Speed Sensor N A V225 Fuel Level Sensor CN3 7 CN3 8 Empty 5 0 25 kΩ Full 320 32 Ω V226 Alternator Potential CN2 14 CN1 8 V 2 1V It has to be measured in engine stop state V227 Dial CN3 16 CN3 17 R 1 0 0 3 kΩ R 4 0 1 5 kΩ V228 Tps Wheel N A V229 Parking...

Page 704: ...186 5 Ω 100 C 212 F E018 E G oil pressure sensor 2 27 2 32 V 2 318 80mV at 23 C 73 F and absolute pressure 3bar It has to be measured in engine running state E021 Battery voltage 1 03 1 06 V V_volt Note 4 E022 Fuel pressure sensor 2 14 2 12 V 1 833 28mV at 23 C 73 F and absolute pressure 300bar It has to be measured in engine running state E032 Fuel pressure monitoring MPROP 3 09 3 10 R 2 60 3 15 ...

Page 705: ...pply 1 03 1 06 V V_volt E049 Main Relay SCB ECU Engine ECU fail E051 Main Relay ECU Engine ECU fail E058 Solenoid power stage 1 3 04 3 13 R 0 31 0 42 Ω 20 C 68 F E059 Solenoid power stage 2 3 11 3 06 E061 Solenoid power stage 3 3 05 3 12 E062 Solenoid power stage 4 3 03 3 14 E063 Solenoid power stage 5 3 01 3 16 E064 Solenoid power stage 6 3 02 3 15 E065 Fuel HI pressure pump E G Current controlle...

Page 706: ...fterheat function is operating status E083 Preheat light E G Lowside Power stage 2 1 13 1 56 E091 CAN A Line 1 53 1 52 R 60 5 Ω 20 C 68 F It is a composite resistance of CAN line This value has to be measured by connected condition of CAN line E097 Monitoring of misfire cylinder 1 Injector error Speed signal error of cam shaft speed sensor or crank shaft speed sensor E098 Monitoring of misfire cyl...

Page 707: ...ALID but BELOW NORMAL OPERATIONAL RANGE FMI 2 Incorrect signal DATA ERRATIC INTERMITTENT OR INCORRECT FMI 3 Voltage above normal VOLTAGE ABOVE NORMAL OR SHORTED TO HIGH SOURCE FMI 4 Voltage below normal VOLTAGE BELOW NORMAL OR SHORTED TO LOW SOURCE FMI 5 Current below normal CURRENT BELOW NORMAL OR OPEN CIRCUIT FMI 6 Current above normal CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT FMI 8 Abnormal sign...

Page 708: ...N2 14 is HI Travel Speed 1st 2nd Operation hours used low speed and high speed are displayed 1st High speed s v OFF status 2nd 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 steps And operation hours of each step are displayed Under 30 C 87 F 31 50 C 88 123 F 51 75 C 124 168 F 76 85 C 169 ...

Page 709: ...ution FG013856 Figure 43 FG000575 OPERATING HOURS UP DOWN Page 1 3 UP DOWN Page 2 3 UP DOWN Page 3 3 1 Power 2 Trenching 3 Auto idle 4 Travel speed I Speed II Speed 00042 Hr 00003 Hr 00005 Hr 00007 Hr 00001 Hr 5 Hyd Oil Temp C 30 31 50 51 75 86 95 96 00003 Hr 00005 Hr 00008 Hr 76 85 00000 Hr 00007 Hr 00001 Hr 6 Coolant Temp C 40 41 60 61 85 86 95 96 105 106 00003 Hr 00005 Hr 00000 Hr 00000 Hr 0000...

Page 710: ...t At this time resetting signal will be displayed and the screen will move to previous menu after resetting NOTE When NO ESC 4 button is pressed the screen will recover to previous menu without resetting Machine Operation Info Screen 1 If you press the YES 3 on Figure 24 button password entrance screen appears 2 When right password is input machine operation periods will be deleted and Reset Compl...

Page 711: ...SP002030 Page 53 Electrical System 3 If you press the NO ESC 4 button the previous screen appears without resetting operation periods ESC No FG001086 Yes PASSWORD ERR OPERATING HOURS Figure 49 ...

Page 712: ...e speed sensor signal Engine throttle control signal Drive signal Potentiometer signal Coolant water temp signal Throttle command Lo Hi P M N Switch signal Throttle signal Pump control signal P Main Relief v v FG015513 C H E F H C 1 5 2 3 6 7 4 ESC 8 E G SPEED 02 05 MO 11 30 1700 RPM CHECK CHECK CHECK CHECK POWER AUTO 6 6 4 7 8 9 10 11 12 13 14 19 16 17 18 15 5 2 1 3 Figure 50 ...

Page 713: ... 8 Pump Pressure Sensor 9 Engine Speed Sensor 10 Electromagnetic Proportional Pressure Reducing Valve E P P R Valve 11 Solenoid Valve Pressure Up 12 Solenoid Valve Swing Priority 13 Solenoid Valve High Speed 14 Travel Motor 15 Engine Throttle Control 16 Engine Control Dial 17 e EPOS Controller 18 Auto Travel Selector Switch 19 Boost Switch Right Work Lever Reference Number Description ...

Page 714: ...wer mode switch signal Potentiometer signal P Pump control signal Low Throttle signal Hi Engine throttle control signal Throttle Position signal Engine speed sensor signal Drive signal M N P FG015515 Figure 51 Reference Number Description 1 Instrument Panel Power Mode SelectIon Switch 2 Engine Control Motor 3 Engine 4 Main Hydraulic Pump 5 Control Pump 6 Control Valve 9 Engine Speed Sensor 10 Elec...

Page 715: ...ly defaulted to standard mode The desired mode can be selected by pressing the select button on the instrument panel When the power mode is selected the indicator lamp will turn ON to display the selected mode The quantity of oil discharged by the pump and the engine speed are determined by the mode selected by the operator The pump output in each mode is determined by the mode selection and is li...

Page 716: ... the rated level On the other hand if the load is decreased the controller increases the discharge volume of the pump to maintain the engine speed at the rated level By repeating these control operations the engine speed is maintained at the rated speed so that maximum power can be generated In Power Mode the e EPOS controller receives engine speed signals from the engine control dial and the engi...

Page 717: ...y Mode Economy mode is used for light loading work When this mode is selected it will reduce noise and fuel consumption in comparison with standard mode Engine torque curve is changed by ECU The e EPOS controller compares the target engine speed with the actual engine speed and controls the signal to the E P P R valve which in turn varies the pump output quantity and it is the same method with pow...

Page 718: ...lectrical System Page 60 B D C A FG013633 Figure 56 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 719: ...16 8 6 5 4 7 8 1 2 CN2 AMP 070 18P 11 1 14 16 15 6 5 18 17 7 8 19 8 10 9 10 2 1 21 20 9 13 12 4 11 3 9 13 12 11 10 5 1 2 3 4 CN1 14 11 13 12 3 4 2 1 16 17 15 6 5 AMP MIC 21P GND CN3 17 B BR 15A 10A 5V SIG CN3 16 CN3 15 4 3 HIGH CW LOW 2 1 CAN 2 1 CN1 10 3 CN1 21 CN4 6 CN1 8 CN1 9 P V A 5 15A CN4 5 CN4 4 CN1 1 CN1 2 15A 10A 1 3 4 26 26 26 25 24 11 23 22 10 17 26 26 28 FG000582 Figure 57 Reference N...

Page 720: ...k 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 lever The engine speed is controlled by the movement of the fuel injection lever which is directly linked with the rotation of the control motor e EPOS CONTROLLER 5V RETRACT M 10A 2 1 3 SIG 7 6 8 5V 5 5 4 5 9 HI...

Page 721: ...d 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 P5 Y P3 L P4 G P1 Gr P2 P GREEN YELLOW PINK BLUE GRAY DECEL EXTEND RETRACT ACCEL CIRCUIT DIAGRAM M P2 P3 P1 Vp 5 0V Vs P5 P4 ARS1100L 2 1 3 Figure 59 Reference Number Description 1 Motor Assembly 2 Cable 3 Spring ...

Page 722: ...ill vary from the 5 V supplied from the e EPOS controller as shown in the graph 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 2nd 7th 12th 13th CW STOP CCW STOP 5 SETUP V 0 FG000866 Figure 60 Reference Number Description 1 Knob 2 Potentiometer Variable Resistor Reference Number Description ...

Page 723: ...3 4 7 8 9 10 12 11 Figure 61 Reference Number Description 1 Instrument Panel 3 Engine Controller 4 e EPOS Controller 17 Engine Control Dial 24 Battery 25 Battery Relay 26 Fuse 27 Starter Switch 28 Fusible Link 29 Pressure Switch Py 30 Pressure Switch Px Reference Number Description ...

Page 724: ...Signal C H E F H C 1 5 2 3 6 7 4 ESC 8 E G SPEED 02 05 MO 11 30 1700 RPM CHECK CHECK CHECK CHECK POWER AUTO 1 2 16 15 17 3 7 7 FG015517 Figure 62 Reference Number Description 1 Instrument Panel Auto Idle Switch 2 Engine Control Motor 3 Engine 7 Pressure Switch 15 Engine Throttle Controller 16 Engine Control Dial 17 e EPOS Controller Reference Number Description ...

Page 725: ... on the instrument panel The initial setting at start up is with this switch in the select position Approximately 4 seconds after this function is selected if all work levers are in the neutral position the e EPOS controller compares the automatic reduction signal with the signal set by engine control dial The lower of the two signals is selected the e EPOS controller sends a signal to the engine ...

Page 726: ...1 C H E F H C 1 5 2 3 6 7 4 ESC 8 E G SPEED 02 05 MO 11 30 1700 RPM CHECK CHECK CHECK CHECK POWER AUTO FG015519 Figure 63 Reference Number Description 1 Instrument Panel 2 Engine Control Motor 3 Engine 4 Main Pump 5 Contro Pump 10 E P P R Valve Electromagnetic Proportional Pressure Reducing Valve 15 Engine Throttle Controller 17 e EPOS Controller 21 Warning Buzzer Reference Number Description ...

Page 727: ... e EPOS controller The e EPOS controller sends a overheat signal to the instrument panel turning ON the warning light and buzzer simultaneously Also the e EPOS controller returns an overheat signal to the engine controller and changes power mode to standard mode The engine speed is then set to a low speed by the engine controller When coolant temperature falls below 95 C 203 F normal operation wil...

Page 728: ...excavation ability is increased by approximately 6 When the power boost function is in activated a power boost symbol appears on the information display department of instrument panel NOTE Do not use this switch for more than 10 seconds PO WER UP E G FG015520 6 6 16 4 4 5 2 20 18 1 11 3 C H E F H C 1 5 2 3 6 7 4 ESC 8 E G SPEED 02 05 MO 11 30 1700 RPM CHECK CHECK CHECK CHECK POWER AUTO Figure 64 R...

Page 729: ...1 CN1 1 CN1 2 15A 15A CN2 CN1 Center 6 12 3 14 6 16 13 PRESS PST SHEAR TML 3 1 0 10 BREAKER 2 20A FG000586 1 2 26 26 11 18 26 25 24 20 Figure 65 Reference Number Description 1 Instrument Panel 2 e EPOS Controller 11 Solenoid Valve Pressure Up 18 Breaker Boost Shear Selector Switch 20 Power Boost Switch Top of Right Work Lever 24 Battery 25 Battery Relay 26 Fuse Reference Number Description ...

Page 730: ...9 3 Figure 66 Reference Number Description 2 e EPOS Controller 3 Engine Controller 4 Main Pump 5 Aux Pump 6 Control Valve 7 Pressure Switch Py Port 8 Pump Pressure Sensor 13 Solenoid Valve High speed 15 Travel Motor 17 Engine Control Dial 19 Selector Switch For Automatic Travel Reference Number Description ...

Page 731: ...I speed travel solenoid valve based on the travel load The travel speed is changed between the I speed and the II speed mode The travel load is monitored by the two pressure sensors in the discharge lines of the front upper and rear lower pumps When the travel load is high pressure over 300 kg cm2 4 300 psi the solenoid valve is turned OFF and I speed low is selected In the case when the travel lo...

Page 732: ...1 3 CN3 17 GND HIGH AMP 070 18P CN3 16 SIG 5V CN3 15 2 1 LOW AMP MIC 21P 8 5 2 CN2 5 CN2 4 7 6 I 0 0 I 3 CN1 12 C3 CN1 1 CN1 2 15A 15A 15A 8 9 2 26 26 26 25 24 19 17 13 FG000587 Figure 67 Reference Number Description 2 e EPOS Controller 8 Pressure Sensor Front Pump 9 Pressure Sensor Rear Pump 13 Solenoid Valve High speed 17 Engine Control Dial 19 Selector Switch For Automatic Travel 24 Battery 25 ...

Page 733: ...n the input voltage to the e EPOS controller is below 18 5 1 V or above 32 5 1 V Stays ON while in normal range 2 Engine Speed Monitor This LED light flashes according to the engine speed The flashing interval is proportional to the engine speed 1 2 4 3 FG000588 Figure 68 Reference Number Description 1 Upper Digit 2 Lower Digit 3 Engine Speed Monitor LED Flash Interval Increases With Engine Speed ...

Page 734: ...splay Readout Operation Status Upper Digit Lower Digit Power Mode Power Mode Normal Operation Power Mode Standard Mode Normal Operation Standard Mode Economy Mode Normal Operation Economy Mode HAOH340L HAOH370L HAOH350L HAOH370L FG013637 HAOH370L Error Code Indication Code Fault Location V201 01 Communication error in instrument panel V202 02 Communication error in engine controller ...

Page 735: ...heater and air conditioner are installed in the cover behind the operator s seat Temperature of the operator s room is adjusted automatically to the temperature set by operator Please refer to the Operation Manual for detailed full automatic control FG013857 A A C B C Figure 69 ...

Page 736: ...n excessively contaminated environment filters should be cleaned more frequently and if necessary replaced with new ones How to Check Internal Air Filter 1 Press both levers on the left and right side at the top of the filter installed at the rear of the operator s seat How to Check External Air Filter 1 Open the door at the left side of machine and loosen four marked bolts to remove the cover 1 F...

Page 737: ...he rear side of the cabin to open the cover 3 Remove the filter attached to the cover and clean the contaminated filter using compressed air 4 Close the cover replace the knobs and secure the cover to the support with butterfly bolts FG000441 1 Figure 72 FG000342 Figure 73 ...

Page 738: ... 9 8 6 6 10 FG007144 Figure 74 Reference Number Description 1 Air Conditioner heater Unit 2 Condenser 3 Compressor 4 Receiver Dryer 5 Discharge Hose 6 Suction Hose 7 Liquid Hose 1 8 Liquid Hose 2 9 Ambient Temperature Sensor 10 Sun Sensor 11 Control Panel Reference Number Description ...

Page 739: ...BL 0 85YG 1 SENSOR CN10 AMP 20P 2 CN10 17 1 INCAR CN11 KET 4P WATER SENSOR CN10 19 CN8 2 0 5OrB CN9 2 CN9 4 1 25BL 0 5YW CN9 1 0 5LgW CN9 3 CN9 18 0 5LgB 0 5YR CN9 10 1 25B ACTUATOR CN10 15 MIX F BACK GND CN10 4 CN10 9 DUCT SENSOR WARM P1 Vref MIX COOL P2 CN10 7 CN10 3 M Temp Control 0 85LW CN10 1 CN10 2 CN10 20 CN10 12 CN11 1 CN10 11 CN10 13 CN9 16 CN9 14 0 5YB 0 5OrW CN9 15 CN9 12 0 5OrR 0 5GrY ...

Page 740: ... 82 Air Conditioner heater Unit Air Flow Diagram FG001359 Vent Rear Outlet Cold Box Outlet External Air Inlet Internal Air Inlet Foot Outlet DEF Outlet Vent Front Outlet Heater Core Evaporator Fan Internal Air External Air Figure 76 ...

Page 741: ... Def Vent 100 60 0 0 0 Foot 0 40 100 80 60 Def 0 0 0 20 40 FG007754 Actuator Temp Control A C Relay Duct Sensor Blower Relay Air Flow Control Module Blower Motor Actuator Internal external Air Exchanger Internal Air Sensor Internal Air Filter Evaporator Water Temp Sensor Actuator Wind Direction Control Figure 77 ...

Page 742: ...re Control Change of discharged air temperature by controlling the position of temperature control door Actuator Wind Direction Control Actuator Temperature Control FG001361 N P2 c b e P2 P1 c b e Figure 78 Wind Direction Mode Output Terminal Voltage Vent c CN10 10 b CN10 4 0 5 0 2V Bi level 1 3 0 2V Foot 2 45 0 2V Foot def 3 5 0 2V Def 4 5 0 2V Set Temperature Output Terminal Voltage Max cooling ...

Page 743: ...d on manual set CN10 20 CN10 2 FG001055 P2 P1 c e N P2 P1 Figure 79 Mode Output Terminal Output Intake P1 P2 Moving of exchange door by selecting intake Recirculate P1 P2 Moving of exchange door by selecting recirculate DRAIN CN10 1 SOURCE CN11 1 GATE CN10 6 FG001056 Figure 80 Air flow Output Terminal Output 1st CN11 2 CN10 1 10 0 5V 2nd 12 5 0 5V 3rd 15 0 5V 4th 17 5 0 5V 5th 20 0 0 5V 6th 22 0 0...

Page 744: ...sor consist of negative characteristic thermistor that resistant value increases and decreases when the temperature rises and falls respectively 30 86 87 85 87 86 85 30 FG001057 FG001057 Figure 81 Specifications Rated voltage 24V Rated current 20A FG001058 L S1 S2 B Figure 82 Specifications Rated voltage 24V Rated current 10A Figure 83 Temperature C Resistance KΩ 0 11 36 0 1 2 10 39 0 2 2 5 10 17 ...

Page 745: ... Ambient Air Temperature Sensor Built at the bottom of the cockpit it senses the temperature of external air Figure 84 Temperature C Resistance KΩ 10 55 8 1 7 0 32 9 0 9 15 15 76 0 5 25 10 0 0 3 35 6 5 0 2 Figure 85 Temperature C Resistance KΩ 15 218 2 7 5 0 97 83 0 9 15 47 12 0 7 25 30 0 0 36 35 19 60 0 3 FG001064 Figure 86 Temperature C Resistance KΩ 10 163 4 9 0 96 9 2 9 10 59 4 1 8 20 37 4 1 1...

Page 746: ...tor Control Panel Appearance and Terminal Arrangement Refer to Air Conditioner and Heater of operation manual 83 7 76 2 67 7 58 8 46 6 36 0 21 4 1 0 2 0 3 0 4 0 5 0 6 0 7 0 LUX x10 000 OUTPUT VOLTAGE mV FG001062 Figure 87 AUTO AUTO OFF TEMP A C A C MAX OUTSIDE SEL MODE FG001063 18 8 CN8 AMP 070 12P CN9 15 17 16 12 14 13 9 11 10 12 11 10 AMP 070 18P 6 5 7 4 1 3 2 5 4 6 7 8 9 1 2 3 Figure 88 ...

Page 747: ...edback 13 Intake Recirculate Intake 14 Wind direction control VENT 15 Wind direction control DEF 16 Wind direction control Power 5V 17 Wind direction control feedback 18 Temperature control cool Categories Inputs System Operation AUTO Set temperature Internal air temperature sensor Ambient air temperature sensor Water temperature sensor Sun sensor 1 Automatically adjust room temperature as set and...

Page 748: ...ischarge of hot air before discharge temperature drops enough in hot summer weather 2 Start conditions AND condition 1 A C on AUTO or manual 2 Temperature sensed by the duct sensor is above 30 C 3 Air flow Auto mode 3 One time control in the cycle of engine OFF engine run 4 Initial cooling control is executed when the Auto switch is ON in the manual status A C OFF and manual control of air flow in...

Page 749: ...ycle of engine OFF engine run 3 Initial heating control should be before max heating 4 Air flow is controlled only when the wind direction is in the manual mode and BI LEVEL FOOT or FOOT DEF is set 5 Control through the water temperature sensor for start 6 Starting control of heating 2 starts in case of fault of the water temperature sensor during controlling 7 Operation release OR condition 1 Onl...

Page 750: ...When handling the wind direction mode switch only wind direction is released but the air flow control is performed only for the remaining period of the starting control of heater 3 Difference between internal and ambient air temperature 15 C 4 When Max Cooling 17 C is selected 5 Exceptional case Starting control of heating is performed only once during the remaining period if the entry condition i...

Page 751: ...r is turned ON OFF depending on temperature of the duct sensor to prevent the freezing of the evaporator with A C being ON 2 Control pattern External temperature sensor 1 Function Prevention of compressor in winter 2 Control pattern Only for Auto mode Categories Inputs System Operation 2 0 0 5 C 3 5 0 5 C ...

Page 752: ...ycle of 0 5 sec ON and 0 5 sec OFF In case of two or more errors codes concerned blink twice at a time For normal E0 lights for error the first error code is indicated For 2 or more error error codes are indicated upstreams downstreams if the temp control switch is set to up down For normal condition only EO lights Press the SEL switch more than 3 times in 5 secs while pressing the A C switch Retu...

Page 753: ...ient temperature may be released in the same way for its entry way It returns automatically to default mode 5 seconds after entering the ambient air temperature display mode Code Description E0 Normal E1 Internal air temperature sensor short E2 Internal air temperature sensor open E3 Ambient air temperature sensor short E4 Ambient air temperature sensor open E5 Duct sensor short E6 Duct sensor ope...

Page 754: ...tain refrigerant gas with bubbles whose presence in the expansion valve decreases the freezing power excessively it separates liquid and gas and sends liquid only to the expansion valve Water in refrigerant shall be eliminated with dryer and through filter Volume of refrigerant by model FG001365 Relief Valve Figure 91 Categories Specifications Output 155 3 cc rev Oil Level 120 cc ND OIL8 Refrigera...

Page 755: ...n device or soapy water check for refrigerant leakage at all major components and joints Yes Repair leaking component No Recharge system to correct pressure 2 High pressure Over 23 kg cm2 327 psi Low pressure Approximately 2 5 3 0 kg cm2 36 43 psi Possible Cause Overcharge Frost on condenser Step Inspection Item Remedy 1 Check for condenser pin damage or contamination Yes Clean repair or replace c...

Page 756: ...sible Cause Moisture in system has iced up the expansion valve NOTE When the absorbed moisture freezes the pressure readings may look normal Careful readings should be made to determine whether pressure is in normal range 1 Recover any remaining refrigerant 2 Vacuum out system 3 Recharge system NOTE If the system has been exposed to the air for a long period of time replace the receiver dryer 6 Hi...

Page 757: ...S Model Weight of Gas DX225LC 800 20 grams 28 0 7 oz DX225NLC 800 20 grams 28 0 7 oz DX300LC 800 20 grams 28 0 7 oz DX300LCA 800 20 grams 28 0 7 oz DX340LC 800 20 grams 28 0 7 oz DX420LC 800 20 grams 28 0 7 oz DX480LC 800 20 grams 28 0 7 oz DX520LC 800 20 grams 28 0 7 oz ...

Page 758: ...charge the system WARNING Always wear protective glasses and gloves when handling refrigerant If refrigerant comes in contact with the skin or eyes immediately flush with clean running water and consult a physician Select a clean and well ventilated area to work The refrigerant container is under high pressure and should be stored below 40 C 104 F Be careful not to drop the container from a high l...

Page 759: ...ng parts Do not reuse old O rings 8 Use a vacuum pump to evacuate refrigerant system of air 9 When charging the refrigerant system with the engine running do not open the high pressure valve on the manifold gauge as the reverse flow of high pressure refrigerant will rupture the hose 10 When releasing the high pressure hose after completing the charging process quickly disconnect the hose to minimi...

Page 760: ...FOR 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 REFRIGERANT LEAKAGE CHECK FOR PROPER REFRIGERANT LEVEL RUN SYSTEM RECOVER REFRIGERANT IN CHARGING HOSE REMOVE REPAIR TOOLS REPAIR HDA6067L Figure 96 ...

Page 761: ...gauge 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 for complete moisture and air evacuation A Attach the manifold gauges and vacuum pump to the refrigerant system as shown B Turn on the vacuum pump and open both valves C When the low pressure gauge...

Page 762: ...ounting valve on the container make sure the handle is in the counterclockwise most position with the puncture pin retracted and the mounting disk is in the raised position B Attach the manifold gauge center hose to the valve assembly C Turn the disk in the clockwise direction and securely mount valve onto refrigerant container D Turn the valve handle in the clockwise direction and puncture the co...

Page 763: ... leaking tests as described in the proceeding headings NOTE First charge the refrigerant system with 100g 3 5 ounces of refrigerant with the engine off Then using the manifold gauges as a guide fully charge the system with the engine running When exchanging refrigerant containers press the manifold gauge low side valve to eliminate air from the charging hose 2 Charge the system by opening the mani...

Page 764: ...ut off engine and close refrigerant supply container adapter valve Disconnect manifold gauge hoses 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 Standard Reading High Side Gauge 13 20 kg cm2 185 285 psi Low Side Gauge 1 5 3 5 kg cm2 22 50 psi WARNING W...

Page 765: ...essor outlet condenser inlet receiver dryer inlet air conditioner unit inlet 2 Low pressure side Compressor inlet air conditioner unit outlet 3 Compressor Compressor shaft area bolt hole area and magnetic clutch area 4 Receiver dryer Pressure switch and plug area 5 Connection valve area Inspect all valve areas Verify all valves are capped to prevent leaking Check for foreign material inside of val...

Page 766: ...KET 8P Continuous mode Intermittent 2 mode Intermittent 1 mode Washer mode 5 1 6 7 11 12 4 2 M 3 10 8 5 4 P 6 1 3 5 4 5 6 7 8 9 4 10 2 3 1 FG000589 Figure 104 Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Fuse Box 5 Wiper Motor 6 Wiper Controller 7 Wiper Switch Panel 8 Window Washer 9 Wiper Cutoff Switch 10 Light Switch Reference Number Description ...

Page 767: ...stops reverse revolution when the contact of a cam switch connected to the 6 terminal of the wiper motor 5 moves to an insulation area of the cam plate to disconnect the 5 and 6 terminals of the wiper motor 5 When the wiper motor 5 stops arm and blade connected to it move to the stop positions of the right pole in the cabin Intermittent operation Intermittent 1st 3 second Pressing once the Intermi...

Page 768: ... Diagram CN7 6 CN7 4 CN7 5 CN6 10 CN6 9 CN6 1 CN6 2 L6 CN4 5 CN4 4 CN4 6 CN1 9 CN1 8 CN2 6 CN1 2 CN1 1 CAN 30A 15A 20A 30 3 86 II I 7 6 30 87 87a 0 2 2 8 5 8 5 II 3 7 6 I 0 30 86 87a 85 87 87a 87 85 87 85 86 30 86 87a 16 14 9 8 10 11 3 2 1 4 15 13 7 6 12 5 FG000590 Figure 105 ...

Page 769: ...Work Light 2 ea 14 Front Cabin Light 4 ea 15 Rear Cabin Light 2 ea 16 Rear Work Light 1 ea Reference Number Description Switch Position Connected Terminal of switch Activated Relay Lit Light Light Switch 1 2 3 Terminal Illumination Light of Switch 2 2 3 Terminal Illumination Light of Switch 5 6 Terminal Headlight Relay Headlight 2 Ea Work Relay Work Light 2 Ea Symbol Light of Work Light Cabin Ligh...

Page 770: ...ircuit Diagram 5 6 4 2 1 3 ARS1260L CN2 15 CN1 1 10A 20A CN1 2 CN1 8 CN1 9 CN1 3 CN1 4 CN1 CN2 CN3 CN4 7 1 10 5 9 O I SIG Figure 106 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse Box 4 e EPOS Controller 5 OWD Selector Switch 6 Pressure Sensor Reference Number Description ...

Page 771: ...Vcc 5V 13 MICOM 2 15 RH LH ANTENNA MODULE 7 8 5 6 4 3 1 2 11 9 10 12 16 13 14 15 18 17 STEREO 1 2 3 4 Audio Control Panel 3 4 2 1 5 11 7 8 10 9 6 FG000591 Figure 107 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse Box 4 Fusible Link 5 Converter 6 Stereo Relay 7 Audio Control Panel 8 Stereo 9 Speaker 10 Antenna Module 11 Light Switch Reference Number Description ...

Page 772: ... System Page 114 Operations Via Audio Control Panel Switch Connected Terminal of switch Measured values Operations PWR 3 4 4 36 0 2V Stereo ON OFF 1 24 0 2V Volume up 0 0 2V Volume down SCAN 2 49 0 2V Frequency selection ...

Page 773: ...SP002031 Page 1 Electrical Schematic DX300LCA SP002031 ELECTRICAL SCHEMATIC DX300LCASP002031 1Electrical Schematic DX300LCA Edition 1 ...

Page 774: ...SP002031 Electrical Schematic DX300LCA Page 2 MEMO ...

Page 775: ...SP002031 Page 3 Electrical Schematic DX300LCA Table of Contents Electrical Schematic DX300LCA Safety Precautions 5 Applicable Models 5 DX300LCA 7 ...

Page 776: ...SP002031 Electrical Schematic DX300LCA Page 4 MEMO ...

Page 777: ...Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LCA 5001 and Up ...

Page 778: ...SP002031 Electrical Schematic DX300LCA Page 6 ...

Page 779: ...16 15 2WR 6 10A 0 85LB 0 5BG 0 85RG 10A 0 85RG 0 85LB 2 1 10A 0 85RB 0 85RL 5 10A 4 3 10A 10A 0 85WR 8 7 10A 10A 0 5RW 30A 9 1 25RL 2LR 18 14 15A 15A 15A 15A 20A 30A FUSE BOX 2 17 5W 5W 10 9 2RL 2RY 0 85R 13 12 11 1 25WR 1 25R 10A 1 25WR 1 0 85RG 1 25W LAMP SWITCH ROTATING BEACON OPT 0 5B 0 85R 0 5WR 1 25R 2RY 87 0 85RG 2RG TRAVEL SWING ALARM ASS Y OPT 0 5WR 0 5RG 0 85R LH 2RL 0 85B 0 85RW 0 5B 7 ...

Page 780: ......

Page 781: ...1Attachments ...

Page 782: ......

Page 783: ...SP001851 Page 1 Boom and Arm SP001851 BOOM AND ARM SP001851 Boom and Arm Edition 1 ...

Page 784: ...SP001851 Boom and Arm Page 2 MEMO ...

Page 785: ...els 5 Front Attachment Pin Specifications 6 DX300LC 7 DX340LC DX350LC 8 DX420LC 9 DX480LC DX520LC 10 Front Attachment Removal and Installation 11 Arm Removal Procedure 11 Boom Removal Procedure 13 Installation 14 Arm Installation Procedure 14 Boom Installation Procedure 14 Start up Procedures 15 ...

Page 786: ...SP001851 Boom and Arm Page 4 MEMO ...

Page 787: ... the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up DX420LC 5327 and Up DX480LC 522...

Page 788: ...ns for all mounting pins used on the front attachment NOTE Some mounting pins must be drilled and tapped for lubrication fittings and piping or may have other required specifications Consult DOOSAN After Sales Service for information on wear tolerances and replacement limits for mounting pins F G H I J K A B C D E FG004069 Figure 1 ...

Page 789: ... 0 03 0 13 0 33 1 5 D Boom End 100 mm 3 937 0 10 0 15 0 18 0 03 0 13 0 33 1 5 E Arm Cylinder Head 90 mm 3 543 0 10 0 15 0 18 0 03 0 13 0 33 1 5 F Arm Cylinder Rod 90 mm 3 543 0 10 0 15 0 18 0 03 0 13 0 33 1 5 G Bucket Cylinder Head 80 mm 3 150 0 10 0 15 0 18 0 03 0 13 0 33 1 5 H Arm Link 80 mm 3 150 0 06 0 11 0 18 0 03 0 09 0 29 2 0 I Arm End 90 mm 3 543 0 10 0 15 0 18 0 03 0 13 0 33 2 0 J Bucket ...

Page 790: ... 03 0 13 0 33 1 5 D Boom End 110 mm 4 331 0 10 0 15 0 18 0 03 0 13 0 33 1 5 E Arm Cylinder Head 100 mm 3 937 0 10 0 15 0 18 0 03 0 13 0 33 1 5 F Arm Cylinder Rod 100 mm 3 937 0 10 0 15 0 18 0 03 0 13 0 33 1 5 G Bucket Cylinder Head 100 mm 3 937 0 10 0 15 0 18 0 03 0 13 0 33 1 5 H Arm Link 90 mm 3 543 0 10 0 15 0 18 0 03 0 13 0 33 2 0 I Arm End 100 mm 3 937 0 10 0 15 0 18 0 03 0 13 0 33 2 0 J Bucke...

Page 791: ... 13 0 33 1 5 D Boom End 120 mm 4 724 0 10 0 15 0 18 0 03 0 13 0 33 1 5 E Arm Cylinder Head 110 mm 4 331 0 10 0 15 0 18 0 03 0 13 0 33 1 5 F Arm Cylinder Rod 110 mm 4 331 0 10 0 15 0 18 0 03 0 13 0 33 1 5 G Bucket Cylinder Head 110 mm 4 331 0 10 0 15 0 18 0 03 0 13 0 33 1 5 H Arm Link 100 mm 3 937 0 10 0 15 0 18 0 03 0 13 0 33 2 0 I Arm End 110 mm 4 331 0 10 0 15 0 18 0 03 0 13 0 33 2 0 J Bucket Cy...

Page 792: ... 03 0 13 0 33 1 5 D Boom End 125 mm 4 921 0 10 0 15 0 18 0 03 0 13 0 33 1 5 E Arm Cylinder Head 120 mm 4 724 0 10 0 15 0 18 0 03 0 13 0 33 1 5 F Arm Cylinder Rod 120 mm 4 724 0 10 0 15 0 18 0 03 0 13 0 33 1 5 G Bucket Cylinder Head 100 mm 3 937 0 10 0 15 0 18 0 03 0 13 0 33 2 0 H Arm Link 100 mm 3 937 0 10 0 15 0 18 0 03 0 13 0 33 2 0 I Arm End 120 mm 4 724 0 10 0 15 0 18 0 03 0 13 0 33 2 0 J Buck...

Page 793: ...r structure is in line 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 first the bucket before the arm the arm before the boom Reinstallation of the attachment should begin with the boom and end with the bucket WARNING This procedure is only intended...

Page 794: ...ings and put a clean plug in the end of each one Use any and all reasonable precautions necessary to avoid introducing dirt or other contaminants into the hydraulic system Wipe down coupling points before disconnecting hydraulic lines and use evaporative type solvent spray cleaner Tag and mark hoses for reassembly if necessary Place a sling under the arm cylinder the cylinder used to extend and re...

Page 795: ...Removal Procedure observing the same precautions Disconnect wiring for work light assemblies and any other accessory lines or connections Locate the sling of the assist crane near the center of gravity optimum lift point for the boom and use the crane to take pressure off the boom foot pin Drive out the pin after disassembling retainers and carefully lift away the boom To maintain stability the co...

Page 796: ... 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 make sure to inspect all bushings and pivot points of each section To avoid damaging the seats bushings should never be hammered or chiseled out of their seats Installation is otherwise a reversal of ...

Page 797: ... 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 maintenance manual for unit ...

Page 798: ...SP001851 Boom and Arm Page 16 ...

Page 799: ...SP001852 Page 1 Bucket SP001852 BUCKET SP001852 1Bucket Edition 1 ...

Page 800: ...SP001852 Bucket Page 2 MEMO ...

Page 801: ...ons 5 Applicable Models 5 Bucket Tooth Inspection and Replacement 6 Bucket O ring Replacement 7 Bucket Shimming Procedures 9 New Bucket Installation 9 Bucket Attachment Removal and Reversal 11 Detaching the Bucket 11 Attaching the Bucket 11 Reversing the Bucket 12 ...

Page 802: ...SP001852 Bucket Page 4 MEMO ...

Page 803: ...tices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up DX420LC 5327 a...

Page 804: ... 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 or breakage has not developed Do not allow the replaceable bucket teeth to wear down to the point that the bucket adapter is exposed See Figure 1 2 To replace a tooth 1 Figure 3 use a hammer and punch to drive the locking ...

Page 805: ...the way 3 Remove the old O ring and temporarily install the new O ring 1 Figure 6 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 the arm or link with the bucket pin hole and insert the bucket pin 3 Figure 5 WARNING Due to possibility of flying metal objects always wear safety helmet protective gloves and eye protection when ch...

Page 806: ...SP001852 Bucket Page 8 5 Roll the new O ring 1 Figure 7 into the O ring groove ARO1392L 1 Figure 7 ...

Page 807: ...osition and stop the engine Improperly adjusted clearance could cause galing on the contact surfaces of the bucket and arm resulting in excessive noise and damaged O ring Figure 8 Reference Number Description 1 No Gap 2 Arm Boss 3 Bucket Clearance 4 Shim 5 Pin 6 Stopper 7 Bolt 8 Hard Washer 9 Flange 10 Bucket Boss Reference Number Description FG000415 1 5 10 9 4 6 2 8 7 3 ...

Page 808: ...t boss 10 are in full face contact at no gap 1 3 Place the hydraulic activation control lever in the LOCKED position and stop the engine 4 Measure bucket clearance 3 determine the number of shim that need to be removed from shims 4 by using the following calculation Subtract 1mm from bucket clearance 3 5 Remove the appropriate number of shim at location 9 in order to meet the above thickness To re...

Page 809: ... reassembling the bucket linkage Look for cracks or any other evidence of physical damage and replace any seal or O ring that is not in like new condition Prelube linkage pins before reassembly Use an old cylinder rod a long breaker bar or a similar relatively thin diameter support bar for making the first temporary pin connection between the bucket and arm If the support bar is straight the arm c...

Page 810: ...he bucket 180 to change bucket configuration This procedure is greatly simplified if some type of rotating or swiveling support can be used on the ground underneath the bucket Follow instructions for Bucket Attachment to replace pins WARNING Bucket curl and dump levers must be used in opposite directions after the bucket has been reversed ...

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