Doosan DX225LC-3 Shop Manual Download Page 365 | Manualshive

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Page 37

2.

Following reassembly of rod cover components, install the
dust wiper (11) and rod bushing (6) to the rod cover (5).
Insert retaining rings (7 and 12).

3.

Prelubricate O-rings and seals before reassembly (Figure
32).

4.

Before starting to rebuild piston assembly, heat slipper seal
for 5 minutes in an oil bath warmed to 150° - 180°C (302° -
356°F). Use special slipper seal jig (third item in list of
specialized tools at the beginning of this procedure) to
attach seal. Cool seal by pushing a retracting jig against
seal for several minutes. Apply a strip of clean,
see-through sealing tape around slipper seal to keep it free
of dust.

Figure 31

Figure 32

Figure 33

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Summary of Contents for DX225LC-3

Page 1: ...Shop Manual Doosan Infracore Construction Equipment DX225LC 3 Serial Number 1001 and Up Serial Number 50001 and Up Europe Only 950106 00364E March 2012 EXCAVATOR ...

Page 2: ...fornia to cause cancer birth defects and other reproductive harm WARNING CALIFORNIA PROPOSITION 65 WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm WASH HANDS AFTER HANDLING 05 2010 ...

Page 3: ...225LC 3 EXCAVATOR Serial Number 1001 and Up Serial Number 50001 and Up Europe Only 950106 00364E March 2012 Copyright DOOSAN 2012 DOOSAN and the DOOSAN logo are registered trademarks of DOOSAN Corporation in the United States and various other countries around the world ...

Page 4: ......

Page 5: ...bel Instructions Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine DX225LC 3 Serial Number 1001 and Up Serial Number 50001 and Up Europe Only Pub No 950106 00364E Pub No 950106 00364E ...

Page 6: ......

Page 7: ...P002404 Upper Structure Cabin SP002324 Counterweight SP002492 Fuel Tank SP002493 Fuel Transfer Pump Option SP002534 Swing Bearing SP002329 Lower Structure and Chassis Track Assembly SP002494 Engine and Drivetrain Engine Coolant Heater Option SP002328 Drive Coupling Main Pump SP002495 Hydraulics Hydraulic System Troubleshooting Testing and Adjustment SP002535 Accumulator SP002455 Center Joint Swive...

Page 8: ...002403 Remote Control Valve Work Lever Joystick SP002395 Travel Control Valve with Damper SP002381 Solenoid Valve Assembly SP002406 Breaker EPPR Valve Option SP002458 Dozer Valve SP002529 Hydraulic Schematic DX225LC 3 SP002507 Electrical System Electrical System SP002337 Electrical Schematic SP002508 Attachments Boom and Arm SP002505 Bucket SP002506 ...

Page 9: ...1Safety ...

Page 10: ......

Page 11: ...SP002322 Page 1 Track Excavator Maintenance Safety SP002322 TRACK EXCAVATOR MAINTENANCE SAFETY SP002322 Track Excavator Maintenance Safety Edition 2 ...

Page 12: ...SP002322 Track Excavator Maintenance Safety Page 2 MEMO ...

Page 13: ...aintenance Safety Table of Contents Track Excavator Maintenance Safety Safety Instructions 5 Applicable Models 5 Safety Messages 6 Safety Decals 7 General 7 Transportation 20 Operation 22 Maintenance 39 Environment and Circumstances 56 ...

Page 14: ...SP002322 Track Excavator Maintenance Safety Page 4 MEMO ...

Page 15: ...tructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX140LC 3 1001 and Up 50001 and Up DX180LC 3 1001 and Up 50001 and Up DX225LC 3 1001 and Up 50001 and Up DX255LC 3 1001 and Up 50001 and Up DX300LC 3 1...

Page 16: ...henever a Safety Alert Symbol is present no matter which signal word appears next to it SAFETY ALERT SYMBOL Be Prepared Get to Know All Operating and Safety Instructions This is a Safety Alert Symbol Wherever it appears in this manual or on safety decals on the machine you should be alert to the potential for personal injury or accidents Always observe safety precautions and follow recommended pro...

Page 17: ...that are to be used Be sure that all guards and shields are installed in their proper location Have guards and shields repaired or replaced immediately if damaged Be sure that you understand the use and maintenance of all safety features such as safety lock lever and seat belt Use them properly Never remove modify or disable any safety features Always keep them in good operating condition Always c...

Page 18: ...on While you are performing any maintenance testing or adjustments to attachments stay clear of the following areas cutting edges pinch points and crushing surfaces Never use attachment as a work platform or manlift Contact your DOOSAN distributor about auxiliary hydraulic kits for attachments installation If you are in doubt about compatibility of a particular attachment with a machine consult yo...

Page 19: ...ne and wait for coolant to cool Using gloves slowly loosen cap to relieve pressure Flying or Falling Objects On work sites where there is a potential hazard that flying or falling objects can hit operator s cabin select and use a guard to match operating conditions for additional operator protection Working in mines tunnels deep pits and loose or wet surfaces could produce hazard of falling rocks ...

Page 20: ...o not operate machine until problem has been corrected Crushing and Cutting Keep objects away from moving fan blades Fan blades can throw and cut objects Do not use a wire rope that is kinked or frayed or a wire rope with any loss of diameter Wear leather gloves when handling a wire rope When striking a loose retainer pin it can fly out and can cause a serious injury Make sure that area is clear o...

Page 21: ...opped coolant engine oil and hydraulic oil are at their highest temperatures The radiator and hydraulic tank are still under pressure Always wait for temperature to cool down Attempting to remove caps drain oil or coolant or replacing filters may lead to serious burns if done when hot Relieve all pressure in air system hydraulic oil system lubrication system fuel system and cooling system before a...

Page 22: ...mponents in a well ventilated area away from flames or sparks and wear dust mask when grinding painted parts Maintenance The machine and some attachments have components that are at high temperatures under normal operating conditions The primary source of high temperatures are the engine and exhaust system If damaged or incorrectly maintained the electrical system can be a source of arcs or sparks...

Page 23: ...rious injury Refer to Operation and Maintenance Manual for proper procedure in this manual Do not charge a frozen battery This can cause an explosion After market radios or other electric operated equipment in cabin must have a fuse in the electrical circuit Hydraulic System Check hydraulic tubes hoses and fittings for damage wear or for leaks Hydraulic lines and hoses must be properly routed and ...

Page 24: ...or starting fluids on any engine that has glow plugs or an electric grid type manifold heater These starting aids can cause an explosion and result in death or serious injury Use procedures in this manual for connecting battery and for jump starting Welding and Grinding Always clean machine and attachment set battery disconnect switch to OFF position and disconnect wiring from electronic controlle...

Page 25: ...d labels to ensure that you know how to use them It is recommended that an appropriately sized 2 27 kg 5 lb or larger multipurpose A B C fire extinguisher be mounted in cabin Check and service fire extinguisher at regular intervals and make sure that all work site crew members are adequately trained in its use Inspect fire extinguisher and service fire extinguisher regularly Follow instructions on...

Page 26: ... beyond certified value by modifying machine or by installing attachments on machine If weight limit of protective equipment is exceeded protective equipment will not be able to protect operator and this can result in death or serious injury Always observe the following This machine is equipped with a protective structure Do not remove protective structure and perform operations without it Never m...

Page 27: ...eck the ROPS cabin mounting and hardware for damage Never modify the ROPS cabin Replace the cabin and hardware if damaged See your DOOSAN distributor for parts ROPS Rollover Protective Structure complies with ISO 12117 2 2008 FG018724 Figure 16 WARNING AVOID DEATH OR SERIOUS INJURY Never modify the operator cabin by welding grinding drilling holes or adding attachments unless instructed in writing...

Page 28: ...n OPG is installed and front window needs to be cleaned loosen bolts marked with arrows Figure 18 Be sure to tighten bolts when done Never attempt to alter or modify any protective structure reinforcement system by drilling holes welding remounting or relocating fasteners Any serious impact or damage to system requires a complete inspection of the structure Reinstallation recertification and or re...

Page 29: ...ng tool It is found on left pillar of cabin This tool can be used to break the glass to exit from cabin in an emergency Grip handle firmly and use sharp point to break glass Be careful also not to slip on broken pieces of glass on ground FG015808 Figure 19 WARNING AVOID DEATH OR SERIOUS INJURY Protect your eyes when breaking the glass ...

Page 30: ...sembly Loading and Unloading To prevent machine tipping or rollover when loading or unloading machine always do the following Perform loading and unloading only on firm level ground Maintain a safe distance from edge of road or drop off Never use work equipment to load or unload machine The machine may fall or tip over Always use loading ramps of adequate strength and capacity Be sure that ramps a...

Page 31: ...ent door from suddenly opening during transportation Transporting Machine When transporting machine on a trailer or truck do the following The weight transportation height and overall length of machine may change depending on work equipment attached to it Always check the machine dimensions and work equipment s dimensions before transporting When passing over bridges or structures on private land ...

Page 32: ...avel controls move freely and work controls return to NEUTRAL when released Check that attachment is properly attached and locked Make sure that machine is equipped with a lighting system that is adequate for job conditions and lights are working properly Before moving machine check position of undercarriage The normal travel position is with idler wheels to front under cabin and drive sprockets t...

Page 33: ...k equipment near fences or near boundary obstacles Know appropriate work site hand signals and personnel that are authorized to give hand signals Follow hand signals from only one person If you need to operate on a street protect pedestrians and cars by designating a person for work site traffic duty or by erecting fences and posting No Entry signs around work site Erect barricades or fences post ...

Page 34: ...n or off machine always face machine Maintain three point contact both feet and one hand or one foot and both hands with handrails guardrails steps and track shoes to ensure that you support yourself securely Never hold onto any control levers when getting on or off machine Securely latch door If you grip handrail inside door when moving on top of track shoes and door latch is not securely engaged...

Page 35: ...ood visibility Do not stick suction pads to window glass Suction pads act as a lens and can cause fire Never bring flammable or explosive items into operator s cabin Do not leave cigarette lighters laying around operator s cabin If temperature inside operator s cabin becomes too high there is a potential hazard that lighter could explode Secure all loose items such as lunch boxes and other items t...

Page 36: ...k retractor web storage device if equipped by extending webbing and checking that it spools out and retracts correctly 5 Check webbing in areas exposed to ultraviolet UV rays from sun or extreme dust or dirt If original color of webbing in these areas is extremely faded and or webbing is packed with dirt webbing strength may be reduced NOTE Contact your DOOSAN distributor for seat belt system repl...

Page 37: ... look around work site and use mirrors and display monitor to confirm that no one is in the work area While operating or traveling in places with poor visibility it may be impossible to confirm condition of work site Inspect and remove any obstacles around the machine that could be damaged and keep other personnel out of the work area Inspect equipment and repair immediately if there are problems ...

Page 38: ...ery charger or battery booster equipment When boost starting from another machine or vehicle do not allow two machines to touch Wear safety goggles and gloves while battery connections are made 24 volt battery units consisting of two series connected 12 volt batteries have a cable connecting one positive terminal on one of the 12 volt batteries to a negative terminal on the other battery Booster o...

Page 39: ...llular telephones inside operator s cabin when driving or operating the machine When operating the machine do not extend your hands or head out of window The boom and arm linkage can allow work tool or attachment to contact undercarriage or cabin Be aware of position of work tool Do not attempt to start engine by short circuiting engine starting circuit This can result in death or serious injury o...

Page 40: ...t people in area Check that there is no one in area around machine There are restricted visibility areas behind machine so if necessary swing upper structure slowly to check that there is no one behind machine before traveling in reverse When operating in areas with poor visibility designate a flagman to direct work site traffic Keep unauthorized personnel away from turning radius or travel path o...

Page 41: ...ures in area When traveling on rough ground travel at low speed and avoid sudden changes in direction Always operate within permissible water depth Permissible water depth is up to centerline of upper track roller s When passing over bridges or structures on private land check that structure is strong enough to support weight of machine Before traveling on public roads check with appropriate autho...

Page 42: ...upport Excavator configuration and attachments Weight lifting height and swing radius Safe rigging of load Proper handling of suspended load Always watch load Bring load close to the machine before traveling any distances or swinging load Lifting capacity decreases as load is moved further from the machine Set tracks at right angles to road shoulder or drop off with sprocket at rear when performin...

Page 43: ...slopes can cause a tip over Use caution when swinging or operating work equipment on slopes Do not swing work equipment from uphill side to downhill side when bucket is loaded This could cause machine to tip or rollover In addition lower bucket as far as possible keep it pulled into front and keep swing speed as slow as possible If the machine begins to slide down on a grade immediately dump load ...

Page 44: ... towing operation Do not perform towing on steep slopes Select a place where slope is gradual If there is no place where slope is gradual perform operations to reduce angle of slope before starting towing operation When towing a machine always use a wire rope with a sufficient towing capacity Do not use a wire rope that is kinked or frayed or a wire rope with any loss of diameter Wear leather glov...

Page 45: ...ould cause the work equipment to move suddenly if the load releases and can result in death or serious injury Equipment Lowering with Engine Stopped Before lowering any equipment with the engine stopped clear the area around the equipment of all personnel and bystanders The procedure to use will vary with the type of equipment to be lowered Keep in mind most systems use a high pressure fluid or ai...

Page 46: ...ensure that passing traffic can see machine clearly Park machine so machine flags signs and fences do not obstruct traffic After front attachment has been lowered to an overnight storage position and all switches and operating controls are in OFF position safety lock lever must be moved to LOCK position This will disable all pilot control functions Always close door of operator s cabin and lock al...

Page 47: ...h battery disconnect switch Park machine where risk of theft burglary and damage is minimized Removing valuables from cabin such as cellular phone computer radio and bags See Operation and Maintenance Manual for more information Conditions Maintenance Required Cleaning Pressure wash undercarriage and track assemblies Inspect for damage or loose or missing parts Lubrication Perform all daily lubric...

Page 48: ...8 Check After Long term Parking All oil and fluid levels Tension of all belts Air pressure Air cleaner Batteries and electrical connections Lubricate all greasing points Wipe off grease from piston rods Inspect for signs of nests i e birds rodents etc ...

Page 49: ...ne of flammable materials before checking fluids Never service or adjust machine with engine running unless instructed to do so in this manual Avoid contact with leaking hydraulic fluid or diesel fuel under pressure It can penetrate skin or eyes Never fill fuel tank while engine running while smoking or when near open flame Keep body jewelry and clothing away from moving parts electrical contact h...

Page 50: ... joysticks back and forth left and right at full stroke 2 to 3 times to eliminate remaining internal pressure in hydraulic circuit Then move safety lock lever to LOCK position Check that battery relay is OFF and main power is shut off Wait for approximately one minute after turning OFF engine starter switch key and press horn switch If horn does not sound the main power is shut off Put blocks unde...

Page 51: ...Do not smoke when you service an air conditioner or if refrigerant gas is present Inhaling fumes either from a flame or gas from a cigarette that has contacted air conditioner refrigerant can cause death or serious injury Never put maintenance fluids into glass containers Drain all liquids into a suitable containers Unless instructed otherwise perform maintenance with equipment in servicing positi...

Page 52: ...others that you are performing service or maintenance on the machine Attach additional warning tags on the machine if necessary Keep warning tags in tool box while it is not used If there is no tool box then keep them in the owner manual storage pocket If any other person starts engine and operates control levers or control pedals while you are performing service or maintenance it can result in de...

Page 53: ...ery substances that can cause tripping or slipping When cleaning cabin top window which is made of polycarbonate material use tap water Avoid use of organic solvents for cleaning such as benzene toluene or methanol These solvents can cause a chemical reaction that will dissolve and damage the window Proper Tools and Clothing Only use tools that are intended for the type of service to be done Metal...

Page 54: ...ls and all lubricants in properly marked and approved containers and keep away from all unauthorized personnel Store oily rags and other flammable material in a protective container Tighten all fuel and oil caps Do not smoke while you refuel machine or while you are in a refueling area Do not smoke in battery charging areas or in areas that contain flammable material Clean all electrical connectio...

Page 55: ...em components to cool before draining cooling system Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin Vent hydraulic tank only after engine has been stopped and hydraulic tank is cool Using gloves slowly tilt hydraulic tank air breather to relieve pressure Relieve all pressure in hydraulic oil system in fuel system or in cooling system bef...

Page 56: ... the acid before any symptoms appear and therefore one is not given any immediate warning The acid may remain on the machine parts for several years after a fire If swelling redness or a stinging feeling appears and one suspects that cause may be contact with heated rubber that contains fluorides contact a medical doctor immediately If a machine or part of a machine has been exposed to fire or sev...

Page 57: ...being dangerous to the environment must be taken care of in an environmentally safe way Check List After Fire When handling a machine which has been damaged by fire or been exposed to intense heat the following instructions should be followed Use thick gloves made of rubber and wear goggles to protect your eyes Never touch burned components with your bare hands as there is a risk that you may come...

Page 58: ...vent this protect and insulate components from excessive heat Do not weld on pipes or on tubes that contain flammable fluids Do not flame cut pipes or tubes that contain flammable fluids Before welding on pipes or tubes or before flaming cut pipes or tubes clean them thoroughly with a nonflammable solvent Make sure pressure inside pipes or tubes does not cause a rupture of the component parts If h...

Page 59: ...y compartment 6 Turn battery disconnect switch to ON position 7 Close battery compartment door Warning for Counterweight and Front Attachment Removal Figure 41 ON OFF FG020630 Figure 42 FG020631 Electric Control Unit ECU FG018594 Figure 43 WARNING AVOID DEATH OR SERIOUS INJURY Removal of the machine counterweight front attachment or any other part can affect the stability of the machine This could...

Page 60: ...p when walking Never jump down from machine When getting on or off machine use steps and handrails and maintain a three point contact both feet and one hand or both hands and one foot to support yourself If job requires it wear protective clothing To prevent injury from slipping or falling when working on hood or covers never stand or walk on areas except areas equipped with nonslip pads If it is ...

Page 61: ...ollowing precautions Do not drill or punch holes in accumulator or expose it to any flames fire or external heat source Do not weld on accumulator When performing disassembly or maintenance of accumulator or when disposing of accumulator charged nitrogen gas must be properly released Contact your DOOSAN distributor for assistance Wear safety goggles and leather gloves when working on an accumulato...

Page 62: ...nsion assembly you should NEVER attempt to disassemble track adjuster or attempt to remove grease fitting or valve assembly Keep your face and body away from grease valve Refer to Operation and Maintenance Manual for proper procedure in this manual or Shop Manual Supports and Blocking for Work Equipment Do not allow weight or equipment loads to remain suspended and unsupported Lower work group to ...

Page 63: ...n rubbing against other parts and excessive heat during operation Replace hose or components if any of the following problems are found Damage or leakage from hose end fitting Wear damage cutting of hose covering or wire braiding is exposed on any hose Cover portion is swollen in any section The hose is twisted or crushed Foreign material is embedded in hose covering Hose end is deformed Connectio...

Page 64: ...ntion from a physician familiar with this injury If you accidentally drink battery electrolyte call a poison prevention center immediately and get immediate medical attention from a physician familiar with this injury When cleaning top surface of battery wipe it with a clean damp cloth Never use gasoline thinner or any other organic solvent or detergent Tighten battery caps If battery electrolyte ...

Page 65: ...nnect grounding terminal negative terminal first Conversely when connecting them begin with positive terminal and then grounding terminal Make sure that all terminals are connected securely Flammable hydrogen gas is generated when battery is charged Remove battery from machine take it to a well ventilated place and remove battery caps before charging it After charging tighten battery caps securely...

Page 66: ...g death or serious injury or property damage Deep Digging Do not perform deep digging under front of machine The ground under machine may collapse and cause machine to fall resulting in death or serious injury Working heavy loads on loose soft or uneven ground can cause side load conditions resulting in a tip over and injury Traveling without a load or a balanced load may also be hazardous Never r...

Page 67: ...and damage other equipment or property To prevent hitting objects operate machine at a slow speed when working in confined spaces indoors or in crowded areas Do not swing bucket over the top of personnel or over operator s cabin of dump truck Loose or Soft Ground Do not operate on soft ground or near edge of drop offs overhangs and deep ditches The ground can collapse because of the weight of the ...

Page 68: ...ttachment does not have to make physical contact with power lines for current to cause an electrocution Use a spotter and hand signals to stay away from power lines not clearly visible to operator On work sites where machine may operate close to electrical cables always do the following Remember that electrical voltage determines what the minimum distance is to stay away from the power line See th...

Page 69: ...s apply to ground personnel regarding exposing cables utilities and electrical lines Consider all electrical cables as live Working in Water After working in water lubricate all lubrication points on undercarriage which have been underwater so water is removed Check that no water has entered travel gearboxes and undercarriage components Working in Contaminated Environment When working within area ...

Page 70: ...ly charged to prevent freezing If distilled water is added to batteries run engine at least one hour to mix electrolyte solution 3 Keep engine in good mechanical condition for easy starting and good performance during adverse weather 4 Use engine oil with proper specifications for expected temperatures Refer to Operation and Maintenance Manual in this manual or Shop Manual for details 5 Always kee...

Page 71: ...cally to keep passages clear Avoid use of water with a high alkali content which increases scale and rust formation 2 Check level of battery electrolyte daily Keep electrolyte above plates to prevent damage to batteries Use a slightly weaker electrolyte solution in hot climates Batteries self discharge at a higher rate if left standing for long periods at high temperatures If machine is to stand f...

Page 72: ...ntering tank 3 Service air cleaner at frequent intervals check air restriction indicator daily and keep dust cup and dust valve clean Prevent dust and sand from entering engine parts and compartments as much as possible 4 Lubricate and perform services outlined on current lubrication chart on machine and Operation and Maintenance Manual Clean all lubrication fittings before applying lubricant Sand...

Page 73: ...or extreme cold Before operating at high altitudes engine fuel and air mixture may have to be adjusted according to appropriate engine manual 1 Check engine operating temperature for evidence of overheating The radiator cap must make a perfect seal to maintain coolant pressure in cooling system Perform warming up operation thoroughly If machine is not thoroughly warmed up before control levers or ...

Page 74: ...outside Asbestos Information Asbestos dust can be HAZARDOUS to your health if it is inhaled Materials containing asbestos fiber can be present on work sites Breathing air that contains asbestos fiber can ultimately cause serious or fatal lung damage or diseases such as mesothelioma lung and other cancers and asbestosis To prevent lung damage from asbestos fiber observe the following precautions Us...

Page 75: ...f any remaining residue Used motor oil or gear oil is an environmental contaminant and should only be disposed of at approved collection facilities To prevent pollution of environment always do the following Never dump waste oil in a sewer system rivers etc Always put drained oil from your machine in approved leak proof containers Never drain oil directly onto ground Obey appropriate laws and regu...

Page 76: ...tive machine using measuring procedures as described in the following standard ISO 2631 1 ISO 5349 and SAE J1166 Recommendations for Reducing Vibrations 1 Select proper machine equipment and attachments for a particular application 2 Replace any damaged seat with a genuine DOOSAN seat Keep seat properly maintained and adjusted Adjust seat and suspension for weight and size of operator Inspect and ...

Page 77: ...1Specifications ...

Page 78: ......

Page 79: ...SP002491 Page 1 Specifications for DX225LC 3 SP002491 SPECIFICATIONS FOR DX225LC 3SP002491 Specifications for DX225LC 3 Edition 1 ...

Page 80: ...SP002491 Specifications for DX225LC 3 Page 2 MEMO ...

Page 81: ...om 10 Two Piece Boom 11 Working Range 12 One Piece Boom 12 Two Piece Boom 14 General Specifications 16 Engine Performance Curves Per KS R1004 Standard 18 Approximate Weight of Workload Materials 20 Performance Tests 22 Excavator Performance Measurements 23 Test Conditions 23 Travel Speed and Travel Motor Balance Steering Deviation Tests 23 Swing Speed and Deceleration Force Test 25 Cylinder Perfor...

Page 82: ...SP002491 Specifications for DX225LC 3 Page 4 MEMO ...

Page 83: ...y before operating or servicing machine Read and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX2...

Page 84: ...SP002491 Specifications for DX225LC 3 Page 6 ...

Page 85: ... DESCRIPTION The excavator has three main component sections The Upper Structure The Lower Undercarriage and Track Frames The Excavator Front end Attachment The following illustration identifies main components and their locations See Figure 1 on page 8 ...

Page 86: ...SP002491 Specifications for DX225LC 3 Page 8 COMPONENT LOCATIONS FG019399 1 39 38 37 36 35 34 3 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 26 25 27 28 29 32 30 31 33 Figure 1 ...

Page 87: ...wing Bearing 13 Seat 14 Cabin 15 Boom Cylinder 16 Work Lever Joystick 17 Travel Lever 18 Arm Cylinder 19 Boom 20 Arm 21 Bucket Cylinder 22 Guide Link 23 Push Link 24 Bucket 25 Side Cutter 26 Tooth Point 27 Idler 28 Track Adjuster 29 Track Guard 30 Lower Roller 31 Battery 32 Center Joint 33 Upper Roller 34 Sprocket 35 Travel Motor 36 Track Link and Shoe 37 Suction Filter 38 Return Filter 39 Pumps R...

Page 88: ...Arm A 9 490 mm 31 2 9 540 mm 31 3 9 540 mm 31 4 12 355 mm 40 6 B 2 790 mm 9 2 C 6 710 mm 22 6 750 mm 22 2 6 750 mm 22 2 9 565 mm 31 5 D 3 650 mm 12 12 E 4 445 mm 14 7 F 1 055 mm 3 6 G Boom 2 870 mm 9 5 2 970 mm 9 9 3 130 mm 10 3 3 190 mm 10 6 G Hose 3 005 mm 9 10 3 130 mm 10 3 3 330 mm 10 11 3 275 mm 10 11 H 2 710 mm 8 10 I 1 400 mm 4 7 J 1 310 mm 4 4 K 2 390 mm 7 10 L 2 990 mm 9 10 M 600 mm 1 12 ...

Page 89: ...4 m 7 10 Arm 2 9 m 9 6 Arm A 9 690 mm 31 9 9 680 mm 31 9 B 2 790 mm 9 2 C 6 900 mm 22 8 6 890 mm 22 7 D 3 650 mm 12 12 E 4 445 mm 14 7 F 1 055 mm 3 6 G Boom 3 100 mm 10 2 3 080 mm 10 1 G Hose 3 100 mm 10 2 3 080 mm 10 1 H 2 710 mm 8 10 I 1 400 mm 4 7 J 1 310 mm 4 4 K 2 390 mm 7 10 L 2 990 mm 9 10 M 600 mm 1 12 N 480 mm 1 7 O 2 975 mm 9 9 ...

Page 90: ...nds on the stability and support provided by ground conditions Digging too far underneath the excavator if soil conditions are wet loose or unstable can collapse ground support which could cause death or serious injury and or equipment damage 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 0 0 1 2 3 4 5 6 7 8 9 10 11 E A F H D G L FG022236 B I K L J G C Figure 4 ...

Page 91: ...6 700 mm 21 12 6 840 mm 22 5 6 980 mm 22 11 10 845 mm 35 7 E Min Swing Radius 3 580 mm 11 9 3 560 mm 11 8 3 620 mm 11 10 4 960 mm 16 3 F Max Digging Height 9 450 mm 31 9 560 mm 31 4 9 660 mm 31 8 13 075 mm 42 11 G Max Bucket Pin Height 8 155 mm 26 9 8 295 mm 27 2 8 440 mm 27 8 12 075 mm 39 7 H Max Vertical Wall Depth 5 365 mm 17 7 5 625 mm 18 5 5 975 mm 19 7 9 710 mm 31 10 I Max Radius Vertical 6 ...

Page 92: ...SP002491 Specifications for DX225LC 3 Page 14 Two Piece Boom 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 0 0 1 2 3 4 5 6 7 8 9 10 11 E A B I K L F C J G H D G L FG022237 Figure 5 ...

Page 93: ...mm 19 7 6 460 mm 21 2 D Max Loading Height 8 010 mm 26 3 8 310 mm 27 3 E Min Swing Radius 2 790 mm 9 2 2 625 mm 8 7 F Max Digging Height 10 910 mm 35 9 11 200 mm 36 9 G Max Bucket Pin Height 9 465 mm 31 1 9 770 mm 32 1 H Max Vertical Wall Depth 4 955 mm 16 3 5 355 mm 17 7 I Max Radius Vertical 6 355 mm 20 10 6 620 mm 21 9 J Max Depth to 2 5 m Line 5 865 mm 19 3 6 350 mm 21 10 K Min Radius 2 5 m Li...

Page 94: ...At Power Boost ISO Bucket Cylinder 149 KN or 15 200 kg 33 500 lb with Mono Boom Articulated Boom GP Bucket 98 KN or 10 000 kg 22 050 lb with SLR GP Bucket Arm Cylinder 106 KN or 10 800 kg 23 800 lb with 2 900 mm 9 6 Standard Arm Fuel Tank Capacity 400 liters 106 U S gal Hydraulic System Capacity 240 liters 63 U S gal Hydraulic Reservoir Capacity 200 liters 52 8 U S gal Bucket Heaped Capacity Range...

Page 95: ...tandard shoes 2 990 mm 9 10 Overall Shipping Height to top of cylinder hose 3 005 mm 9 10 Track Shipping Length 4 445 mm 14 7 Transport Trailer Capacity 22 tons 24 short tons minimum load capacity Transport Loading Ramp Allowable Slope When Transporting 15 angle NOTE Refer to Operation and Maintenance Manual for Recommended Transportation Instructions ...

Page 96: ...pecifications for DX225LC 3 Page 18 ENGINE PERFORMANCE CURVES PER KS R1004 STANDARD FG022719 Power Output ps Torque kg m Fuel Consumption g ps h Revolution rpm 1000 2000 1500 160 60 150 100 150 140 70 80 Figure 6 ...

Page 97: ...c Pressure 760 mmHg 20 C 68 F Cooling Fan ø704 mm 28 11 Blade Sucker Alternator 24V x 60A Air Cleaner Installed Muffler DPF Installed Performance Standard KS R1004 Power 169 ps 1 800 rpm 167 hp 1 800 rpm Max Torque 77 kg m 1 400 rpm 557 ft lb 1 400 rpm Fuel Consumption Rated 155 g ps h 5 55 oz hp h ...

Page 98: ...s Density 2 100 kg m3 3 500 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 DAMP natural bed 1 746 kg m3 2 943 lb yd3 Ceme...

Page 99: ...estone 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 Sulfur broken 529 kg m3 891 lb yd3 Material Density 1 200 kg m3 2 000 lb yd3 or less Density ...

Page 100: ...wn sec 2 5 0 3 2 4 0 3 Arm Crowd sec 4 2 0 4 3 8 0 4 Dump sec 2 6 0 3 2 4 0 3 Bucket Crowd sec 4 5 0 4 3 7 0 4 Dump sec 2 6 0 3 2 3 0 3 Swing 3 Revolutions sec 18 4 1 5 16 2 1 5 Dozer Low sec 1 9 0 4 1 8 0 4 High sec 1 9 0 4 1 8 0 4 Jack up Speed 3 Turns Low sec 36 7 2 0 33 0 2 0 High sec 20 0 1 5 18 0 1 5 Travel Speed 20 m 66 ft Low sec 26 7 1 5 24 0 1 5 High sec 14 5 1 0 13 0 1 0 Travel Deviatio...

Page 101: ...ll recommended applicable maintenance and adjustment service should be completed before testing 3 Hydraulic fluid and engine oil should be of appropriate viscosity for ambient weather 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 control settings at both Standard Mode standard w...

Page 102: ...d forth to be sure steering is centered and side frames 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 upper structure 180 Both tests should be repeated three times Average all results to obtain a final value 0 3 m 0 5 m 1 2 FG01...

Page 103: ...ter amount of deviation 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 9 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 upper structure and undercarriage or sel...

Page 104: ...e and undercarriage with paint at the 90 point Make several attempts to rotate the upper structure 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 10 Record how far the upper structure drifts past the stop point measuring the distance between paint marks Maximum distance should be less than 1200 mm 47 1 4 in b...

Page 105: ... Dump and crowd the bucket several times and average results for both Standard Mode and Power Mode Hydraulic Cylinder Natural Drop Test To check boom and arm cylinder 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 arm cylinder is extended 20 50 mm 1 2 and boom cylinders are retracted the same am...

Page 106: ...SP002491 Specifications for DX225LC 3 Page 28 ...

Page 107: ...1General Maintenance ...

Page 108: ......

Page 109: ...SP002454 General Maintenance Instructions Page 1 SP002454 GENERAL MAINTENANCE INSTRUCTIONS SP002454 General Maintenance Instructions Edition 2 ...

Page 110: ...SP002454 General Maintenance Instructions Page 2 MEMO ...

Page 111: ...Welding Precautions and Instructions 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 Instructions 12 Bearing Inspection 13 ...

Page 112: ...SP002454 General Maintenance Instructions Page 4 MEMO ...

Page 113: ... necessary before operating or servicing machine Read and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER ...

Page 114: ...is extremely important that welding repairs on these types of steel are performed with the proper procedures and equipment If repairs are performed incorrectly structural weakening or other damage to the machine that is not always readily visible could result Always consult DOOSAN After Sales Service before welding on integral components loader arm frames car body track frames upper structure atta...

Page 115: ...rom fuel and oil tanks batteries hydraulic piping lines or other fire hazards when welding 2 Never weld when the engine is running Battery cables must be disconnected before the welding procedure is started 3 Never weld on a wet or damp surface The presence of moisture causes hydrogen embrittlement and structural weakening of the weld 4 If welding procedures are being performed near cylinder rods ...

Page 116: ...any part of the hydraulic system could be an indication of air in the system and many other types of problems As a general precaution and to help lessen the risk of potential long term damage allow the engine to run at no load idle speed immediately after initial start up Hydraulic fluid will circulate releasing any air that may have been trapped in the system before load demands are imposed Befor...

Page 117: ...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 118: ...ue solvent and thoroughly clean exterior surfaces of assemblies before any part of the circuit is opened or disassembled NOTE It s just as important to clean the cap and reservoir top before routine fluid changes or quick checks as it is before major repairs Accumulated dirt attracts moisture oil and other fluids and more dirt Keep dismantled parts covered during disassembly Use clean caps plugs o...

Page 119: ... of fine dust are especially hazardous Clogging of valve spools or external piping especially pilot circuit piping can gradually diminish or suddenly put a stop to normal hydraulic function You can prevent having to make these types of repairs by the following recommended assembly procedures 1 Use new O rings and oil seals whenever hydraulic assemblies are rebuilt 2 Prepare joint surfaces before a...

Page 120: ...ing bearings that are not lubricated DO NOT SPIN BEARINGS WHEN DRYING bearings may be rotated slowly by hand to facilitate drying process 3 Carefully inspect all bearing rollers cages and cups for wear chipping or nicks to determine condition Do not replace a bearing cone or cup individually without replacing mating cup or cone at the same time After inspection dip bearings in lightweight oil and ...

Page 121: ...cast parts and machined surfaces for scratches wear grooves and dirt Remove any scratches and burrs with crocus cloth Remove foreign material Replace any parts that are deeply grooved or scratched which would affect their operation Bearing Inspection The conditions of the bearing are vital to the smooth and efficient operation of the machinery When any component containing bearings is disassembled...

Page 122: ...has been turning in its housing or on its shaft If available use magna flux or similar process for checking for cracks that are not visible The following illustrations will aid in identifying and diagnosing some of the bearing related problems NOTE The illustrations will only show tapered roller bearings but the principles of identifying diagnosing and remedying the defects are common to all style...

Page 123: ...overheat 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 124: ...gs check seals and check for proper lubrication Misalignment Outer race misalignment because of 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 125: ...ts 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 126: ...er Race Race cracked because of improper installation cocking or poor bearing seat Replace all parts and housings check seals and bearings and replace if leaking Smears Smearing of metal because of slippage caused by poor installation lubrication overheating overloads or handling damage Replace bearings clean related parts and check for proper installation and lubrication Replace shaft if damaged ...

Page 127: ...or loss of temper on races or rollers a simple file test may be made A file drawn over a tempered part will grab and cut metal whereas a file drawn over a hard part will glide readily with no metal cutting Replace bearing if overheating damage is indicated Check seals and other related parts for damage Stain Discoloration Discoloration can range from light brown to black caused by incorrect lubric...

Page 128: ...SP002454 General Maintenance Instructions Page 20 ...

Page 129: ...SP002404 Page 1 Standard Torques SP002404 STANDARD TORQUESSP002404 Standard Torques Edition 2 ...

Page 130: ...SP002404 Standard Torques Page 2 MEMO ...

Page 131: ... Fasteners 6 Torque Values for Standard U S Fasteners 7 Type 8 Phosphate Coated Hardware 9 Torque Values for Hose Clamps 10 ORFS Swivel Nut Recommended Torque 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 132: ...SP002404 Standard Torques Page 4 MEMO ...

Page 133: ...ry before operating or servicing machine Read and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE AL...

Page 134: ... 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 135: ... used 0 70 When Molykote white lead or similar mixtures are used as lubricants 0 75 When Parkerized bolts or nuts are used 0 85 When cadmium plated bolts or nuts and zinc bolts w waxed zinc nuts are used 0 9 When hardened surfaces are used under the nut or bolt head NOTE When reusing bolts and nuts in service use minimum torque values Type SAE Grade Description Bolt Head Marking 1 1 or 2 WILL HAVE...

Page 136: ...s 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 9 305 414...

Page 137: ...s 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 torq...

Page 138: ...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 Diam eter 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 50 Dash Size Hose I D Thread Size Torque kg m Recommended 4 1 4 9 16 2 4 2 6...

Page 139: ...g bolts will damage the flanges and or bolts which can 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 140: ...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 141: ...a fastener For example a torque wrench and extension can be used to measure adjustment tightness of a linkage or assembly Specially fabricated extensions can be used to make very precise checks of the force required to engage or disengage a clutch mechanism release a spring applied brake assembly or take up free play in most any movable linkage Once the value of the adjustment force is established...

Page 142: ...compound Use the information on this page as a general guide in selecting specific formulas that will meet the particular requirements of individual assembly installations DOOSAN does not specifically approve a specific manufacturer or brand name but the following table of Loctite applications is included for which cross references to other manufacturer s products should also be widely available I...

Page 143: ...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 144: ... 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 145: ...1Upper Structure ...

Page 146: ......

Page 147: ...SP002324 Page 1 Cabin SP002324 CABIN SP002324 Cabin Edition 3 ...

Page 148: ...SP002324 Cabin Page 2 MEMO ...

Page 149: ...SP002324 Page 3 Cabin Table of Contents Cabin Safety Instructions 5 Applicable Models 5 Cabin Identification 6 Rollover Protective Structure ROPS 6 Removal 8 Installation 12 ...

Page 150: ...SP002324 Cabin Page 4 MEMO ...

Page 151: ...he manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX140LC 3 1001 and Up 50001 and Up DX180LC 3 1001 and Up 50001 and Up DX225LC 3 1001 and Up 50001 and Up DX255LC 3 1001 and Up 50001 and Up DX300LC 3 1001 and Up 500...

Page 152: ... equipment will not be able to protect operator and operator may suffer death or serious injury Always observe the following This machine is equipped with a protective structure Do not remove protective structure and perform operations without it Never modify the operator s cabin by welding grinding drilling holes or adding attachments unless instructed by DOOSAN Changes to the cabin can cause los...

Page 153: ...ROPS cabin mounting and hardware for damage Never modify the ROPS cabin Replace the cabin and hardware if damaged See your DOOSAN dealer for parts ROPS Rollover Protective Structure complies with ISO 12117 2 2008 WARNING AVOID DEATH OR SERIOUS INJURY Never modify the operator cabin by welding grinding drilling holes or adding attachments unless instructed in writing by DOOSAN Changes to the cabin ...

Page 154: ...re cabin shell for removal by disconnecting wiring connectors for A Cabin 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 cabin is equipped with additional protective guards over cabin openings they mus...

Page 155: ...erator s cabin 17 Disconnect monitor and sun sensor connectors 18 Disconnect washer hose from floor plate 19 Remove glove box pad 1 Figure 5 and two bolts under pad 20 Remove three caps 2 Figure 5 from top of rear cover Remove three bolts securing rear cover in place 21 Remove two bolts 3 Figure 5 from bottom of rubber mounts in rear cover 22 Remove rear cover FG018676 1 2 Figure 2 1 1 FG018677 2 ...

Page 156: ...igure 8 from door side of cabin floor 28 Remove four bolts 1 Figure 8 on right hand side of floor in operator s cabin 29 Remove two bolts 4 Figure 8 at front of floor in operator s cabin and bolt 5 Figure 8 at rear of floor in operator s cabin 4 5 7 6 FG015888 Figure 6 8 9 10 FG015889 Figure 7 3 3 4 2 1 1 5 FG015890 Figure 8 Quantity Description 4 16 mm nuts at each corner of cabin 4 12 mm x 1 75 ...

Page 157: ... 12 NOTE Cabin weighs approximately 485 kg 1 069 lb 33 Lift cabin approximately 25 50 mm 1 2 above deck Check that all electrical connections have been disconnected and all other items unbolted 34 Continue lifting with crane to remove cabin shell Lower shell and rest on support NOTE Lift operator s cabin slowly to prevent damaging controls covers and other components FG018678 1 Figure 9 2 FG021955...

Page 158: ... in operator s cabin 6 Install two bolts 4 Figure 15 on front of floor in operator s cabin and one bolt 5 on rear of floor in operator s cabin 7 Once cabin is mounted to floor unhook lifting device 8 Connect cabin ground cable 9 Connect cabin light wiring connector 10 Install stereo assembly with bolts 2 Figure 15 after connecting speaker and antenna wires FG015892 Figure 13 FG021964 Figure 14 3 3...

Page 159: ...16 12 Install ROPS bolt 2 Figure 17 NOTE Mounting nut torque 13 kg m 94 ft lb 13 Install air ducts 1 thru 5 Figure 18 Install atmospheric air duct 6 14 Install brackets 7 thru 9 Figure 19 on body of operator s cabin Figure 16 FG018678 1 2 FG021955 Figure 17 1 3 4 6 5 2 FG015893 Figure 18 7 8 9 FG015895 Figure 19 ...

Page 160: ...hose at floor plate bottom 18 Install air ducts 1 thru 4 Figure 21 on right hand side of cabin 19 Connect monitor sun sensor connector and washer hose 20 Install duct covers 1 and 2 Figure 22 21 Install safety lever Apply Loctite on screws when installing lever 22 Install mats on steps and floor 23 Connect negative battery cable leading to frame from battery FG015896 1 3 2 Figure 20 FG015897 3 4 5...

Page 161: ...SP002492 Page 1 Counterweight SP002492 COUNTERWEIGHT SP002492 Counterweight Edition 1 ...

Page 162: ...SP002492 Counterweight Page 2 MEMO ...

Page 163: ...SP002492 Page 3 Counterweight Table of Contents Counterweight Safety Instructions 5 Applicable Models 5 General 6 Warning for Counterweight and Front Attachment Removal 6 Removal 8 Installation 9 ...

Page 164: ...SP002492 Counterweight Page 4 MEMO ...

Page 165: ...e operating or servicing machine Read and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX225LC 3 ...

Page 166: ... other part can affect the stability of the machine This could cause tipping or rollover resulting in death or serious injuries Never remove counterweight or front attachment unless the upper structure is in line with the lower structure Never rotate the upper structure once the counterweight or front attachment has been removed WARNING AVOID DEATH OR SERIOUS INJURY The weight of counterweight is ...

Page 167: ...e counterweight should be removed only when the front attachment is taken off the machine When loading an excavator either track or wheeled type on a trailer for transport after the front attachment has been removed always go backwards up the loading ramp with the counterweight uphill Figure 3 WARNING AVOID DEATH OR SERIOUS INJURY If the upper structure deck has been unbalanced by removal of weigh...

Page 168: ...s 2 Figure 5 and washers 3 from counterweight 1 NOTE Heat bolts if necessary to free them 14 When bolts 2 Figure 5 and washers 3 have been removed lift counterweight 1 a very short distance above support frame 4 and stop Check slings and make sure counterweight is being supported evenly FG018470 DO NOT OPERATE when performing inspection WARNING 190 00695A or maintenance ON OFF O I Figure 4 WARNING...

Page 169: ...ounterweight mounting holes 2 Slide washers 3 Figure 6 onto bolts 2 Apply Loctite 242 to mounting bolt threads 3 Install four bolts 2 Figure 6 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 6 to values shown in the following table 4 Remove lifting device from counterweight lif...

Page 170: ...SP002492 Counterweight Page 10 ...

Page 171: ...SP002493 Page 1 Fuel Tank SP002493 FUEL TANK SP002493 Fuel Tank Edition 1 ...

Page 172: ...SP002493 Fuel Tank Page 2 MEMO ...

Page 173: ...SP002493 Page 3 Fuel Tank Table of Contents Fuel Tank Safety Instructions 5 Applicable Models 5 General Description 6 Parts List 6 Specifications 7 Removal 8 Installation 12 Start up Procedures 15 ...

Page 174: ...SP002493 Fuel Tank Page 4 MEMO ...

Page 175: ...operating or servicing machine Read and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX225LC 3 10...

Page 176: ...ID DEATH OR SERIOUS INJURY Diesel fuel is highly flammable and can be potentially explosive To prevent fires or explosion keep arcs sparks or other ignition sources away from diesel fuel or fuel containers FG022488 9 7 13 3 2 1 4 5 12 17 8 7 13 14 16 15 6 10 11 Figure 1 ...

Page 177: ...rs 106 U S gal Reference Number Description 1 Fuel Tank 2 O ring 3 Fuel Tank Cover 4 Bolt 5 Washer 6 Drain Valve 7 Bolt 8 Shim 9 Shim 10 Fuel Strainer 11 Cap 12 Level Gauge 13 Spacer 14 Fuel Sensor 15 Bolt 16 Spring Washer 17 Fuel Float Switch Reference Number Description ...

Page 178: ...r work tool to ground 4 Stop engine 5 Set safety lever to RELEASED UNLOCK 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 to LOCK position 9 Turn key to O OFF position and remove from starter switch 10 Attach maintenance warning tag on controls 11 Turn battery disconnect switch to OF...

Page 179: ...ll cap 11 Figure 5 Open fuel cap 13 Open drain valve Figure 6 right side door and drain NOTE Fuel tank capacity is 400 liters 106 U S gal 14 Remove five bolts 23 Figure 7 and cover 24 from fuel tank FG022489 11 Figure 5 FG020064 Figure 6 23 24 FG022490 Figure 7 ...

Page 180: ... bolts 33 and storage box 34 from frame 16 Remove four bolts 35 and 36 Figure 9 and cover 37 from fuel tank and support 17 Tag and disconnect fuel supply line 21 Figure 10 and fuel return line 19 from fuel tank 1 and carefully drain remaining fuel from lines 18 Remove clamp 20 Figure 10 holding fuel return line 19 to tank 1 Figure 8 26 28 27 30 29 31 32 34 25 33 FG022491 36 FG003878 37 35 Figure 9...

Page 181: ...22 Remove six bolts 7 and spacers 13 Figure 13 holding tank 1 to frame Lift tank 25 mm 1 and make sure it is balanced Make sure 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...

Page 182: ...ly 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 Connect wires as tagged to sensor 14 and fuel float switch 17 Figure 15 on side of fuel tank 1 6 If equipped connect components to fuel filler pum...

Page 183: ...5 and 36 Figure 18 and cover 37 on fuel tank and support 10 Install four bolts 33 Figure 19 and storage box 34 on frame Install two bolts 31 and bracket 32 on fuel tank Install four bolts 28 and 29 and fuel tank cover 30 on fuel tank Install ten bolts 25 and 26 and handrail 27 on fuel tank and frame Figure 17 1 19 20 21 FG022492 36 FG003878 37 35 Figure 18 Figure 19 26 28 27 30 29 31 32 34 25 33 F...

Page 184: ...lve Figure 20 right side door is closed 12 Fill fuel tank and check for signs of leaks Correct any problems found 13 Turn disconnect switch to ON position 14 Install five bolts 23 Figure 21 and cover 24 on fuel tank Figure 20 FG020064 Figure 21 23 24 FG022490 ...

Page 185: ...fuel 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 Figure 22 FG022496 Figu...

Page 186: ...SP002493 Fuel Tank Page 16 ...

Page 187: ...SP002534 Page 1 Fuel Transfer Pump Option SP002534 FUEL TRANSFER PUMP OPTION SP002534 Fuel Transfer Pump Option Edition 1 ...

Page 188: ...SP002534 Fuel Transfer Pump Option Page 2 MEMO ...

Page 189: ...tion Table of Contents Fuel Transfer Pump Option Safety Instructions 5 Applicable Models 5 General Description 6 Theory of Operation 6 Troubleshooting 8 Replacement of Rotor and Vane 8 Replacement of Rear Cover 9 Replacement of Armature 9 ...

Page 190: ...SP002534 Fuel Transfer Pump Option Page 4 MEMO ...

Page 191: ... before operating or servicing machine Read and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX22...

Page 192: ...PTION Theory of Operation FG003881 IN DONG JIN 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 ...

Page 193: ...34 Page 7 Fuel Transfer Pump Option The fuel pump consists of a motor pump switch and hose assembly Pump Hose FG024596 Figure 2 FG024597 START STOP SENSOR POWER PUMP CONTROL UNIT FOR FUEL FILLER PUMP Figure 3 ...

Page 194: ...d and must be replaced On units equipped with a toggle switch check the resistance through the toggle switch while the switch is in the ON position If continuity 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 genera...

Page 195: ...hole of 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 switch cover and rear cover then remove armature from the housing Remove pump cover and remove rotor and vane Insert a new armature into the housing Refer to Replacement o...

Page 196: ...SP002534 Fuel Transfer Pump Option Page 10 ...

Page 197: ...SP002329 Page 1 Swing Bearing SP002329 SWING BEARING SP002329 Swing Bearing Edition 2 ...

Page 198: ...SP002329 Swing Bearing Page 2 MEMO ...

Page 199: ...tents Swing Bearing Safety Instructions 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 200: ...SP002329 Swing Bearing Page 4 MEMO ...

Page 201: ...in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX140LC 3 1001 and Up 50001 and Up DX180LC 3 1001 and Up 50001 and Up DX225LC 3 1001 and Up 50001 and Up DX255LC 3 1001 and Up 50001 and Up DX300LC 3 1001 and Up...

Page 202: ...d 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 when the machine was ne...

Page 203: ...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 P 1 5 bolt Figure 2 Reference Number Description 1 Outer Ring 2 Inner Ring 3 Tapered Pin 4 Plug 5 Ball...

Page 204: ... 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 205: ...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 pinhole Caulk the head of pin 3 with a punch Fill grease through the grease fitting Figure 8 Figure 9 Figure 10 Figure 11 ...

Page 206: ...SP002329 Swing Bearing Page 10 ...

Page 207: ...1Lower Structure and Chassis ...

Page 208: ......

Page 209: ...SP002494 Page 1 Track Assembly SP002494 TRACK ASSEMBLY SP002494 Track Assembly Edition 1 ...

Page 210: ...SP002494 Track Assembly Page 2 MEMO ...

Page 211: ...Shoes and Links 15 Track Removal 15 Track Installation 16 Front Idler Roller 17 Parts List 17 Front Idler Roller Disassembly 18 Front Idler Roller Reassembly 20 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 Reasse...

Page 212: ...SP002494 Track Assembly Page 4 MEMO ...

Page 213: ...e operating or servicing machine Read and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX225LC 3 ...

Page 214: ...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 215: ... component wear The recommended adjustment can also be too tight causing accelerated stress and wear if ground conditions are wet marshy or muddy WARNING AVOID DEATH OR SERIOUS INJURY Measuring track tension requires two people One person must be in the operator s seat operating the controls while the other person makes dimensional checks Block frame to make sure the machine won t move or shift po...

Page 216: ...he 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 Recommended Distance A Normal B 290 310 mm 11 40 12 20 in Muddy Sandy or Snowy C 310 340 mm 12 20 13 40 in WARNING AVOID DEATH OR SERIOUS INJURY The track adjusting mechanism is under very high pressure NEVER release grease pressure t...

Page 217: ...s 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 AVOID INJURY Refer to the Welding Precautions and Guidelines information in General Maintenance Procedures section for general recommen...

Page 218: ...SP002494 Track Assembly Page 10 Track Shoe 8 9 10 11 2 7 2 7 FG023178 1 3 6 4 5 Figure 4 ...

Page 219: ...en regular pin and link Standard Dimension Regular Pin Tolerance Standard Dimension Link Tolerance Standard Interference Repair Limit 38 mm 1 496 0 222 0 165 37 8 mm 1 488 0 062 0 0 0 300 0 422 9 Clearance between regular pin and bushing Standard Dimension Regular Pin Tolerance Standard Dimension Bushing Tolerance Standard Clearance Repair Limit 38 mm 1 496 0 222 0 162 38 85 mm 1 530 0 500 0 0 0 6...

Page 220: ...9 mm 1 929 55 mm 2 165 145 mm P 5 709 4 Width of Flange 29 5 mm 1 161 5 Clearance between shaft and bushing Standard Dimension Shaft Tolerance Standard Dimension Bushing Tolerance Standard Clearance Repair Limit Shaft Hole 65 mm 2 559 0 0 03 65 4 mm 2 575 0 05 0 0 40 0 48 63 3 mm R 2 492 6 Interference between roller and bushing Standard Dimension Roller Tolerance Standard Dimension Bushing Tolera...

Page 221: ...30 mm P 5 276 3 Width of Tread 51 5 mm 2 028 56 5 mm 2 224 4 Width of Flange 17 mm 0 669 5 Clearance between shaft and bushing Standard Dimension Shaft Tolerance Standard Dimension Bushing Tolerance Standard Clearance Repair Limit 54 5 mm 2 146 0 0 03 54 8 mm 2 157 0 07 0 03 0 33 0 40 6 Interference between roller and bushing Standard Dimension Roller Tolerance Standard Dimension Bushing Tolerance...

Page 222: ...53 65 mm 2 559 4 Total Width 160 mm 6 299 150 mm 5 906 140 mm 5 512 5 Width of Tread 37 5 mm 1 476 43 mm 1 693 6 Clearance between shaft and bushing Standard Dimension Shaft Tolerance Standard Dimension Bushing Tolerance Standard Clearance Repair Limit 75 mm 2 953 0 06 0 09 75 mm 2 953 0 415 0 37 0 430 0 505 76 mm R 2 992 7 Interference between idler and bushing Standard Dimension Idler Tolerance ...

Page 223: ...Use socket wrench 27 mm 6 Remove four nuts and bolts 1 and 2 Figure 9 holding shoe to link Remove enough shoes to make access to master pin 7 Remove master pin from master link by hammer or press Remove pin after detaching shoe FG019247 Figure 8 Figure 9 1 2 4 FG004355 Figure 10 1 FG004356 WARNING AVOID DEATH OR SERIOUS INJURY The track adjusting mechanism is under very high pressure NEVER release...

Page 224: ...upper structure at 90 to track frame Use bucket and boom to raise track frame off blocking 3 With blocking removed lower track frame onto track Make sure all rollers are properly positioned on track 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 Install four nuts and bolts t...

Page 225: ...ly FRONT IDLER ROLLER Parts List 1 FG022507 8 6 5 7 3 4 2 9 9 5 7 8 3 6 Figure 15 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 226: ...a suitable container 2 Separate the pin 6 Figure 17 from the bearing 3 3 Use a press to remove bearing from the axle 4 Separate the O ring 8 Figure 18 from the axle 4 Detach the floating seal 7 Figure 19 from the idler 2 and bearing 3 9 FG022246 Figure 16 FG022247 6 3 Figure 17 3 FG022507 4 8 Figure 18 3 7 2 7 3 FG022508 Figure 19 ...

Page 227: ...ge 19 Track Assembly 5 Use a press to separate the axle 4 Figure 20 O ring 8 and bearing 3 6 Remove bushing 5 Figure 21 with the press and special tool 10 ST 1909 FG022509 4 3 8 Figure 20 FG022510 10 5 2 Figure 21 ...

Page 228: ...tall floating seal 7 Figure 23 inside the idler 2 and bearing 3 NOTE Apply clean gear oil ISO VG 220EP to the joint side of the floating seal Apply grease to the floating seal O ring 5 Install idler 2 Figure 24 on the axle 6 Install bearing 3 Figure 24 and pin 6 to the axle NOTE Fill the idler assembly with new gear oil ISO VG 220EP with approximately 320 cc 10 8 oz 7 Install plug 9 Figure 24 on t...

Page 229: ...SP002494 Page 21 Track Assembly ...

Page 230: ...bly Page 22 LOWER ROLLER Parts List 8 2 6 4 1 8 2 7 3 7 6 4 5 5 FG022255 Figure 25 Reference Number Description 1 Roller 2 Collar 3 Shaft 4 Bushing 5 Pin 6 Floating Seal 7 O ring 8 Plug 9 Bolt Reference Number Description ...

Page 231: ...gnment pin on each end of lower roller assembly NOTE To gain access to some rollers the link guard may have to be removed Remove four spring washers and bolts to remove guard NOTE If additional track clearance is required remove upper rollers before raising track Lower Roller Disassembly 1 Remove plug 8 Figure 27 from the collar and drain oil 2 Pull the pin 5 Figure 27 from the collar 3 Separate t...

Page 232: ...29 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 30 into roller 2 Apply grease to the O rings 7 Figure 31 and insert into axle 3 Align collar 2 Figure 31 and axle 3 pinholes and pin 5 the collar 1 6 6 7 2 2 FG022515 Figure 29 FG022516 4 Figure 30 FG022517 5 2 7 3 Figure 31 ...

Page 233: ...llar 2 Figure 33 O ring 7 and pin 5 on the remaining side 7 Fill with clean gear oil ISO VG 220EP with approximately 280 cc 9 5 oz 8 Install plug 8 Figure 33 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 washers and bolts to remove guard Figure 32 1...

Page 234: ...SP002494 Track Assembly Page 26 UPPER ROLLER Parts List FG022519 Track Frame 12 14 8 11 9 13 7 10 6 4 3 2 5 1 Figure 35 ...

Page 235: ...Shaft 3 Thrust Ring 4 Bushing 5 Bushing 6 Floating Seal 7 O ring 8 Plug 9 Cover 10 Washer 11 Bolt 12 Blot 13 Spring Washer 14 Spring Washer Reference Number Description FG022520 Figure 36 WARNING AVOID DEATH OR SERIOUS INJURY The track adjusting mechanism is under very high pressure NEVER release grease pressure too fast The track tension grease valve should never be loosened more than one 1 compl...

Page 236: ...gure 39 from the axle 2 4 Separate the floating seal 6 Figure 40 from the roller 5 Separate the thrust ring 3 from the axle 6 Separate the bushing 4 and 5 Figure 41 from the roller with a press and special tool ST 1919 10 11 9 12 FG022268 Figure 38 1 2 FG022522 Figure 39 1 2 6 3 FG022270 Figure 40 FG022523 4 5 ST 1919 Figure 41 ...

Page 237: ...ly clean engine oil to the joint side of the floating seal Apply grease to the floating seal O ring 3 Install the axle 2 and thrust ring 3 4 Install washer 10 Figure 44 and bolt 11 5 Insert the O ring 7 Figure 44 to the cover 9 Attach cover 9 and bolt 12 to the roller 6 Fill with gear oil ISO VG 220EP with 200 cc 6 8 oz 7 Tighten plug 8 Figure 44 4 1 5 FG022271 Figure 42 1 2 6 3 FG022270 Figure 43...

Page 238: ...SP002494 Track Assembly Page 30 TRACK SPRING AND TRACK ADJUSTING CYLINDER Parts List FG022524 9 11 8 7 3 4 5 6 12 15 14 1 2 13 16 Idler 10 Figure 45 ...

Page 239: ...eference Number Description 1 Cylinder Body 2 Piston Rod 3 Bracket 4 Spacer 5 Shaft 6 Spring 7 Nut 8 Plate 9 Bolt 10 Spring Pin 11 Washer 12 U Packing 13 Plate 14 Dust Seal 15 Piston Ring 16 Retaining Ring Reference Number Description ...

Page 240: ...SP002494 Track Assembly Page 32 ...

Page 241: ...1Engine and Drivetrain ...

Page 242: ......

Page 243: ...SP002328 Page 1 Engine Coolant Heater Option SP002328 ENGINE COOLANT HEATER OPTION SP002328 Engine Coolant Heater Option Edition 2 ...

Page 244: ...SP002328 Engine Coolant Heater Option Page 2 MEMO ...

Page 245: ...tructions 5 Applicable Models 5 Disassembly and Assembly 6 Changing the Circulating Pump 6 Changing the Temperature Limiter 8 Changing the Temperature Sensor 9 Changing the Combustion Air Fan 11 Changing the Burner Flame Monitor and Glow Plug 13 Changing the Burner Head 15 Changing the Heat Exchanger 17 ...

Page 246: ...SP002328 Engine Coolant Heater Option Page 4 MEMO ...

Page 247: ...ctions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX140LC 3 1001 and Up 50001 and Up DX180LC 3 1001 and Up 50001 and Up DX225LC 3 1001 and Up 50001 and Up DX255LC 3 1001 and Up 50001 and Up DX300LC 3 1001...

Page 248: ...Remove clip 3 Figure 1 and circulating pump 2 Figure 1 5 Complete the work on stripped down components Installation 1 Apply acid free grease to the sealing ring 1 Figure 1 2 Place the circulating pump 2 Figure 1 in the assembly position and attach with the clip 3 Figure 1 and screws 4 Figure 1 3 Tighten the screws 4 Figure 1 to 3 Nm 10 4 Connect the electrical connections 5 Install the heater ...

Page 249: ...0 S heater the control unit can also be arranged on the combustion air fan without having any effect on changing the circulating pump 1 2 3 4 FG018670 Figure 1 Changing the Circulating Pump Reference Number Description 1 Sealing Ring 2 Circulating Pump 3 Clip 4 Screw 2 Reference Number Description ...

Page 250: ...ne Installation 1 Insert the new temperature limiter 3 Figure 2 into the heat exchanger 4 Figure 2 and press in the retaining spring NOTE You must be able to hear and feel the spring clip into the groove Only then is the temperature limiter in the correct installation position If you do not hear and feel the spring clip in Clean the contact surface of the temperature limiter on the heat exchanger ...

Page 251: ...ring 5 Figure 2 4 Complete the work on stripped down components Installation 1 Apply acid free grease Vaseline to the round sealing ring 5 Figure 2 2 Install the temperature sensor 6 Figure 2 with the round sealing ring 5 Figure 2 and screw it into the heat exchanger 4 Figure 2 Tighten to 1 5 Nm 10 3 Connect the electrical connections 4 Install the heater WARNING AVOID DEATH OR SERIOUS INJURY Leak...

Page 252: ...anged on the combustion air fan without having any effect on changing the temperature sensor 6 5 1 2 3 4 FG018671 Figure 2 Changing the Temperature Limiter and Temperature Sensor Reference Number Description 1 Protective Cap 2 Clip 3 Temperature Limiter 4 Heat Exchanger 5 Round Sealing Ring 6 Temperature Sensor Reference Number Description ...

Page 253: ...flange mounted control unit 5 Complete the work on stripped down components Installation NOTE Insert the shaped seal 3 Figure 3 correctly and grease it e g with Vaseline Take care not to squash it 1 Install the new shaped sealing ring 3 Figure 3 onto the combustion air fan 1 Figure 3 Bring the fan into the assembly position and secure it with screws 2 Figure 3 2 Tighten the screws 2 Figure 3 to 3 ...

Page 254: ...Thermo 90 ST heater is shown 2 3 4 5 1 FG018672 Control Unit 1 Thermo 90 S Figure 3 Changing the Combustion Air Fan Reference Number Description 1 Combustion Air Fan 2 Screw 2 3 Shaped Sealing Ring 4 Burner Head 5 Control Unit Reference Number Description ...

Page 255: ... 2 Carefully insert the flame monitor 7 Figure 5 and glow plug 6 Figure 5 into the burner up to the stop and push the grommets 11 and 12 Figure 5 into the slots in the housing of the burner pipe 3 Figure 5 3 Insert the burner 1 Figure 5 and grommet 13 Figure 5 into the burner head 3 Figure 5 4 Push the insulation 9 Figure 5 onto the bar 8 Figure 5 and bring the bar into the assembly position NOTE ...

Page 256: ... Thermo 90 S heater 6 7 8 9 13 1 3 5 4 2 10 11 12 FG018674 Figure 5 Changing the Burner Flame Monitor and Glow Plug Reference Number Description 1 Burner 2 Swirl Orifice 3 Burner Head 4 Washer 5 Screw 6 Glow Plug 7 Flame Monitor 8 Bar 9 Insulation 10 Nut 2 11 Grommet 12 Grommet 13 Grommet Reference Number Description ...

Page 257: ...the heat exchanger 3 Figure 6 6 Complete the work on stripped down components Installation NOTE The burner head and exhaust outlet port can also be aligned during installation in the machine 1 Guide the burner head 1 Figure 6 into the heat exchanger 3 Figure 6 align it if necessary and secure with the V clamping collar 2 Figure 6 2 If necessary tighten the mounting screw of the V clamping collar t...

Page 258: ...NOTE A Thermo 90 ST heater is shown The figure can also be used for the Thermo 90 S heater 1 2 3 FG018675 Figure 6 Changing the Burner Head Reference Number Description 1 Burner Head 2 V clamping Collar 3 Heat Exchanger Reference Number Description ...

Page 259: ... plug 7 Remove burner head 8 Remove plug and connector housing 9 Complete the work on stripped down components Installation 1 Clip the connector housing onto the heat exchanger and insert the plug into the connector housing 2 Install the burner head 3 Install the burner flame monitor and glow plug 4 Attach the combustion air fan 5 Install the temperature sensor 6 Install the temperature limiter 7 ...

Page 260: ...SP002328 Engine Coolant Heater Option Page 18 ...

Page 261: ...SP002495 Page 1 Drive Coupling Main Pump SP002495 DRIVE COUPLING MAIN PUMP SP002495 Drive Coupling Main Pump Edition 1 ...

Page 262: ...SP002495 Drive Coupling Main Pump Page 2 MEMO ...

Page 263: ... Page 3 Drive Coupling Main Pump Table of Contents Drive Coupling Main Pump Safety Instructions 5 Applicable Models 5 Drive Coupling 6 Special Tools 7 Installation of Drive Coupling 8 Installation Procedure 10 ...

Page 264: ...SP002495 Drive Coupling Main Pump Page 4 MEMO ...

Page 265: ...before operating or servicing machine Read and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX225...

Page 266: ...very important to set specified clearance between the end of the pump driveshaft the Dimension H described below and the coupling hub surface when installing the main pump in the engine The Figure 1 shows installation of a typical drive coupling FG019390 Figure 1 ...

Page 267: ...the drive coupling hub 4 Figure 2 NOTE Dimensions A and B are the same as Measure H in Figure 3 Two tools in the figure below are designed for various models while only their one end may be used in some special models HAAA8020 Figure 2 C Relief Relief KNURL HAAA8360 A B D E F G H Figure 3 Model A B C D E F G H DX225LC 3 10 5 0 1mm 5 0 0 1mm 20 0mm 7 0 mm Radius 12 0 mm Radius 14 0 mm Radius 25 0 m...

Page 268: ...ain Pump Page 8 INSTALLATION OF DRIVE COUPLING Follow the installation dimensions and procedures whenever installing the drive coupling in the main pump 4 1 5 11 8 5 10 7 3 2 9 H HAAA8040 Figure 4 Installation of Drive Coupling ...

Page 269: ...ening torques of bolts and screws Parts and Torques References Parts Q ty Torque 1 Spring Pin 4 2 Insert 4 3 Bolt 4 Ta 4 Flywheel 1 5 Spring Pin 8 6 Insert 4 7 Hub 1 8 Bolt 4 Ta 9 Pump Shaft 1 10 Fixing Nut 2 Tb 11 Element 1 MODEL Coupling Part Reference Measure H Torque of Ta Torque of Tb DX225LC 3 2414 9041 10 0 11 0 mm 21 23 kg m 10 12 kg m ...

Page 270: ... the screws using the torque Tb value specified in the table NOTE Apply Loctite 262 to fixing screws 10 5 Install element 11 in between the engine flywheel 4 and the insert 6 Install the main pump and hub 7 by gently pushing them with element 11 7 Bolt down the flywheel cover and the pump housing on the flywheel housing 4 1 5 11 8 5 107 3 2 9 HAAA8040 1 H Figure 5 IMPORTANT Apply the adhesive to b...

Page 271: ...1Hydraulics ...

Page 272: ......

Page 273: ...2535 Page 1 Hydraulic System Troubleshooting Testing and Adjustment SP002535 HYDRAULIC SYSTEM TROUBLESHOOTING TESTING AND ADJUSTMENTSP002535 Hydraulic System Troubleshooting Testing and Adjustment Edition 1 ...

Page 274: ...SP002535 Hydraulic System Troubleshooting Testing and Adjustment Page 2 MEMO ...

Page 275: ...wd 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 ...

Page 276: ...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 277: ...s are necessary before operating or servicing machine Read and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NU...

Page 278: ... 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 279: ...ing 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 supplied 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 280: ... of the 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 because of a shock or overload excess pressure is dumped to...

Page 281: ...tes 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...

Page 282: ...he 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 Insu...

Page 283: ...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 284: ... 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 structure works and correspondingly reduced pressure at the opposite motor port could produce cavitation in the circuit To keep that from happening a 270 kg cm2 3 840 psi relief valve is installed in the swing ...

Page 285: ...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 286: ...fails to surpass rated speed 1 900 rpm performance problems may be because of inadequate hydraulic flow caused by lagging rotational speed NOTE Verify actual flow on the excavator against rated performance with a flow meter If engine tests meet specifications and adequate torque and horsepower are available at the pump drive flex coupling pull out the electrical tray under the operator s seat to i...

Page 287: ... or system pressure available to the actuator Poor flow through the individual circuit may indicate that component is worn beyond tolerance limits while all other hydraulic functions are adequate IMPORTANT It is suggested that troubleshooter maintain the testing sequence of the preceding list Checks and adjustments nearer the middle or the end of the list may depend on adequate functioning of syst...

Page 288: ...adjust gear pump relief pressure by loosening the locknut 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 numbers stamped on your assembly ma...

Page 289: ...estart 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 meter and hydraulic pressure gauge readings and make sure both conform to the values in the table below NOTE If reco...

Page 290: ...ning the outside widest diameter locknut on the relief valve Turn the adjusting screw clockwise to increase pressure or counterclockwise to decrease it Pressure must be 370 kg cm2 5 263 psi or up to 10 kg cm2 142 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 relief pressure by t...

Page 291: ...n must be operating 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 kg cm2 285 570 psi 40 10 kg cm2 569 142 psi Power Mode Cylinder Stall 330 5 kg cm2 4 693 71 psi 40 10 kg cm2 569 142 psi Power Mode W Pressure Up Cylinder Stall 350 10 kg cm2 4 978 142 psi 40 10 kg...

Page 292: ...rmed If the engine is being constantly 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 pum...

Page 293: ...ith the Negacon negative control adjustment screw 3 directly below 1 and 2 Each one 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 ot...

Page 294: ...n of adjustment on the larger diameter 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 ...

Page 295: ...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 fit...

Page 296: ...l left at the following pump pressure levels with travel speed 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 meet 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 actu...

Page 297: ...external oil cooler clogging or broken fan belt Consult service record for prior repair service work Drain some tank oil into a clean clear container Look for metal shavings grit cloudiness water or foam air bubbles in the oil 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 298: ...or could lead to cavitation of the circuit and stalling slowed rotation noise 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...

Page 299: ...tation continues disassemble the upper swing motor housing and clean 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 drivetrain 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 electr...

Page 300: ...y at 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 O...

Page 301: ...il 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 ...

Page 302: ...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 303: ...l 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 r...

Page 304: ...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 inter...

Page 305: ...sembly Secondary pressure too high Dirt other interference between valve parts Clean repair or replace Return line pressure too high Redirect return line Secondary pressure does not hold steady Dirt 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 ret...

Page 306: ...SP002535 Hydraulic System Troubleshooting Testing and Adjustment Page 34 ...

Page 307: ...SP002455 Page 1 Accumulator SP002455 ACCUMULATOR SP002455 Accumulator Edition 1 ...

Page 308: ...SP002455 Accumulator Page 2 MEMO ...

Page 309: ...SP002455 Page 3 Accumulator Table of Contents Accumulator Safety Instructions 5 Applicable Models 5 General Description 6 Specifications 8 ...

Page 310: ...SP002455 Accumulator Page 4 MEMO ...

Page 311: ...n the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX140LC 3 1001 and Up 50001 and Up DX180LC 3 1001 and Up 50001 and Up DX225LC 3 1001 and Up 50001 and Up DX255LC 3 1001 and Up 50001 and Up DX300LC 3 1001 and Up ...

Page 312: ...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 313: ...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 314: ...50001 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX300LC 3 S N 1001 and Up S N 50001 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX340LC 3 S N 1001 and Up S N 10001 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX350LC 3 S N 1001 and Up S N 10001 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX380LC 3 S N 10001 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX420LC 3 S N 10001 and Up...

Page 315: ...SP002456 Page 1 Center Joint Swivel SP002456 CENTER JOINT SWIVEL SP002456 1Center Joint Swivel Edition 2 ...

Page 316: ...SP002456 Center Joint Swivel Page 2 MEMO ...

Page 317: ...r Joint Swivel Table of Contents Center Joint Swivel Safety Instructions 5 Applicable Models 5 General Description 7 Parts List 8 Troubleshooting Testing and Adjustment 9 Inspection 9 Testing 9 Disassembly 10 Reassembly 13 ...

Page 318: ...SP002456 Center Joint Swivel Page 4 MEMO ...

Page 319: ...and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX140LC 3 1001 and Up 50001 and Up DX180LC 3 1001 and Up 50001 and Up DX225LC...

Page 320: ...SP002456 Center Joint Swivel Page 6 ...

Page 321: ...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 322: ...igure 1 Reference Number Description 1 Hub 2 Shaft 3 Cover 4 Spacer 5 Shim 6 Shim 7 Wear Ring 8 Slipper Seal 9 O ring 1AP105 10 O ring 1BP90 11 Retaining Ring 12 PT Plug PT1 4 13 Bolt M12 14 Spring Washer 15 O ring 1AG100 Reference Number Description ...

Page 323: ...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 324: ... spacer at the back of the retaining ring IMPORTANT Do not unbolt the center joint from the lower frame until an adequate number of piping block off plates are available for disconnected piping lines Be sure that system pressure has been relieved including the hydraulic accumulator and tank reserve pressure before disassembly is started WARNING AVOID DEATH OR SERIOUS INJURY Due to its weight use a...

Page 325: ... to drive it out of the housing 8 Separate the hub into 8 each slipper seals 1 each O ring 1BP80 and 1 each dust seal LBH80 3 4 FG013230 Figure 4 IMPORTANT Care should be taken not to make a scratch or damage the surface of the shaft when disassembling the Hub of the Shaft assembly FG021966 Figure 5 IMPORTANT Care should be taken not to damage the inside of the hub because it is likely to be damag...

Page 326: ...ng surfaces for visible signs of wear damage or discoloration and replace any worn component Check clearance between the shaft and shim and 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 FG01323...

Page 327: ... very light film of white grease or petroleum jelly to the lower rim of the stem and inner surface of the center swivel body Apply slow evenhanded pressure using both hands to slowly push the stem into the body Seals may be damaged if the stem is pushed in too quickly PT 1 4 6 mm wrench Engagement torque 3 4 kg m CAUTION AVOID INJURY After assembling the slipper seal a manual test should be perfor...

Page 328: ...Clean and prefill piping line ends to reduce the amount of air in the system Bleed air from the hydraulic system and check hydraulic tank fluid level before returning the excavator to service IMPORTANT For any slipper seal which is protruded press it with finger to seat it in its position Care should be taken when using a driver or a metal tool which can cause damage the seal FG013243 1 2 Figure 9...

Page 329: ...SP002497 Page 1 Cylinders SP002497 CYLINDERS SP002497 Cylinders Edition 1 ...

Page 330: ...SP002497 Cylinders Page 2 MEMO ...

Page 331: ...uctions 5 Applicable Models 5 General Description 6 Theory of Operation 6 Parts List 8 Special Tools and Materials 14 Piston Nut 14 Piston Jig 16 Steel Bushing Jig 19 Dust Wiper Jig 22 Slipper Seal Jig 25 Slipper Seal Straightening Jig 28 Disassembly 31 Reassembly 36 ...

Page 332: ...SP002497 Cylinders Page 4 MEMO ...

Page 333: ...operating or servicing machine Read and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX225LC 3 10...

Page 334: ... 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 335: ...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 336: ... Cross section in Figure 4 shows an arm cylinder Cross section in Figure 5 shows a boom cylinder LH Cross section in Figure 6 shows a boom cylinder RH The bucket and boom cylinders are identical and differ only in the attached pipes 21 22 20 20 4 3 17 18 19 19 28 15 16 10 11 12 9 8 5 39 41 40 13 14 7 6 38 1 36 37 35 34 33 31 30 29 42 44 43 2 32 26 23 25 24 27 FG022281 Figure 4 ...

Page 337: ...g 15 O ring 16 Cushion Ring 17 Piston 18 Slipper Seal 19 Wear Ring 20 Dust Ring 21 O ring 22 Backup Ring 23 Piston Nut 24 Steel Ball 25 Set Screw 26 Cushion Plunger 27 Stop Ring 28 Socket Bolt 29 Check Valve 30 Spring 31 Spring Support 32 O ring 33 Plug 34 Pipe Band Ass y B 35 Pipe Band 36 Spring Washer 37 Hex Bolt 38 Pipe Ass y R 39 O ring 40 Spring Washer 41 Socket Bolt 42 U bolt 43 Spring Washe...

Page 338: ...SP002497 Cylinders Page 10 10 22 21 20 4 3 17 18 19 19 9 25 16 15 11 12 8 5 13 14 34 30 38 39 7 6 1 2 40 28 29 35 33 32 31 27 26 37 36 23 24 FG024695 Figure 5 ...

Page 339: ... 13 O ring 14 Backup Ring 15 O ring 16 Cushion Ring 17 Piston 18 Slipper Seal 19 Wear Ring 20 Dust Ring 21 O ring 22 Backup Ring 23 Piston Nut 24 Set Screw 25 Socket Bolt 26 Pipe Band Ass y 27 Pipe Band 28 Spring Washer 29 Bolt 30 H Pipe Ass y L H 31 O ring 32 Spring Washer 33 Socket Bolt 34 R Pipe Ass y L H 35 O ring 36 Spring Washer 37 Socket Bolt 38 Pipe Clamp 39 Spring Washer 40 Bolt Reference...

Page 340: ...SP002497 Cylinders Page 12 34 29 28 26 30 38 39 1 2 40 35 27 33 32 31 10 22 21 20 4 3 17 18 19 19 9 25 16 15 11 12 8 5 13 14 7 6 37 36 23 24 FG024696 Figure 6 ...

Page 341: ... 13 O ring 14 Backup Ring 15 O ring 16 Cushion Ring 17 Piston 18 Slipper Seal 19 Wear Ring 20 Dust Ring 21 O ring 22 Backup Ring 23 Piston Nut 24 Set Screw 25 Socket Bolt 26 Pipe Band Ass y 27 Pipe Band 28 Spring Washer 29 Bolt 30 H Pipe Ass y R H 31 O ring 32 Spring Washer 33 Socket Bolt 34 R Pipe Ass y R H 35 O ring 36 Spring Washer 37 Socket Bolt 38 Pipe Clamp 39 Spring Washer 40 Bolt Reference...

Page 342: ...SP002497 Cylinders Page 14 SPECIAL TOOLS AND MATERIALS Piston Nut FG018703 35 350 A Figure 7 Material SM45C AISI 1045 Rockwell Hardened from 22 27 Oil Quench ...

Page 343: ...00 DX225LC 3 Boom Hex 80 Arm Hex 110 Bucket Hex 80 Arti Hex 110 DX255LC 3 Boom Hex 90 Arm Hex 110 Bucket Hex 90 Arti Hex 110 DX300LC 3 Boom Hex 110 Arm Hex 110 Bucket Hex 100 DX340LC 3 DX350LC 3 Boom Hex 110 Arm Hex 130 Bucket Hex 110 DX380LC 3 Boom Hex 110 Arm Hex 130 Bucket Hex 110 DX420LC 3 Boom Hex 130 Arm Hex 130 Bucket Hex 120 DX490LC 3 DX530LC 3 Boom Hex 130 Arm Hex 140 Bucket Hex 130 ...

Page 344: ...SP002497 Cylinders Page 16 Piston Jig C 35 A 30 R R15 20 2 B D R F 2 Through Hole 8 15 ARS4740L 4 R5 Figure 8 Material SM45C AISI 1045 Rockwell Hardened from 22 27 Oil Quench ...

Page 345: ...4 in 13 0 mm 0 51 in 75 0 mm 2 95 in 125 0 mm 4 92 in Bucket 80 0 mm 3 15 in 11 0 mm 0 43 in 58 0 mm 2 28 in 110 0 mm 4 33 in Arti 120 0 mm 4 72 in 13 0 mm 0 51 in 80 0 mm 3 15 in 160 0 mm 6 30 in DX225LC 3 Boom 90 0 mm 3 54 in 13 0 mm 0 51 in 75 0 mm 2 95 in 125 0 mm 4 92 in Arm 110 0 mm 4 33 in 13 0 mm 0 51 in 85 0 mm 3 35 in 140 0 mm 5 51 in Bucket 90 0 mm 3 54 in 13 0 mm 0 51 in 67 0 mm 2 64 i...

Page 346: ...1 in 13 0 mm 0 51 in 105 0 mm 4 13 in 170 0 mm 6 70 in Arm 130 0 mm 5 12 in 13 0 mm 0 51 in 110 0 mm 4 33 in 160 0 mm 6 30 in Bucket 130 0 mm 5 12 in 13 0 mm 0 51 in 110 0 mm 4 33 in 160 0 mm 6 30 in DX490LC 3 DX530LC 3 Boom 135 0 mm 5 31 in 13 0 mm 0 51 in 105 0 mm 4 13 in 170 0 mm 6 70 in Arm 150 0 mm 5 91 in 13 0 mm 0 51 in 110 0 mm 4 33 in 190 0 mm 7 50 in Bucket 135 0 mm 5 31 in 13 0 mm 0 51 ...

Page 347: ... 19 Cylinders Steel Bushing Jig 20 A 20 5 A F 15 1 B 40 E ARS4750L B 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 348: ... 80 in 86 0 mm 3 39 in 40 0 mm 1 57 in 6 0 mm 0 24 in Arm 71 0 mm 2 80 in 86 0 mm 3 39 in 40 0 mm 1 57 in 6 0 mm 0 24 in Bucket 71 0 mm 2 80 in 86 0 mm 3 39 in 40 0 mm 1 57 in 5 5 mm 0 22 in Arti 90 0 mm 3 54 in 105 0 mm 4 13 in 40 0 mm 1 57 in 7 0 mm 0 28 in DX225LC 3 Boom 80 0 mm 3 15 in 95 0 mm 3 74 in 40 0 mm 1 57 in 6 5 mm 0 26 in Arm 80 0 mm 3 15 in 95 0 mm 3 74 in 40 0 mm 1 57 in 6 5 mm 0 2...

Page 349: ...30 in 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 DX420LC 3 Boom 110 0 mm 4 33 in 130 0 mm 5 12 in 50 0 mm 1 97 in 11 0 mm 0 43 in HEAD SIDE 120 0 mm 4 72 in 140 0 mm 5 51 in 50 0 mm 1 97 in 11 0 mm 0 43 in ROD SIDE Arm 110 0 mm 4 33 in 130 0 mm 5 12 in 50 0 mm 1 97 in 11 0 mm 0 43 in Bucket 110 0 mm 4 33 in 130 0 mm 5 12 in 50 0 mm 1 97 in 11 0 mm 0 43 in DX490LC 3 DX5...

Page 350: ... 22 Dust Wiper Jig D C DIA B 40 15 3 C1 5 DIA B DIA A DIA A 20 R0 2 1 ARS4760L Figure 10 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 351: ... in DX190W 3 Boom 85 0 mm 3 35 in 99 0 mm 3 90 in 6 0 mm 0 24 in 7 0 mm 0 28 in Arm 90 0 mm 3 54 in 104 0 mm 4 09 in 6 0 mm 0 24 in 7 0 mm 0 28 in Bucket 75 0 mm 2 95 in 89 0 mm 3 50 in 6 0 mm 0 24 in 7 0 mm 0 28 in Arti 95 0 mm 3 74 in 109 0 mm 4 29 in 6 0 mm 0 24 in 7 0 mm 0 28 in DX225LC 3 Boom 85 0 mm 3 35 in 99 0 mm 3 90 in 6 0 mm 0 24 in 7 0 mm 0 28 in Arm 100 0 mm 3 94 in 114 0 mm 4 49 in 6...

Page 352: ...0 mm 2 28 in 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 DX420LC 3 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 28 in Bucket 110 0 mm 4 33 in 126 0 mm 4 96 in 6 0 mm 0 24 in 7 0 mm 2 28 in DX490LC 3 DX530LC 3 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 130 0...

Page 353: ...SP002497 Page 25 Cylinders Slipper Seal Jig ARS4770L A 2 A A 14 B B 40 5 R 1 0 R1 1 0 Figure 11 ...

Page 354: ...Boom 120 0 mm 4 72 in 28 5 mm 1 12 in Arm 125 0 mm 4 92 in 28 5 mm 1 12 in Bucket 110 0 mm 4 33 in 28 5 mm 1 12 in Arti 160 0 mm 6 30 in 34 5 mm 1 36 in DX225LC 3 Boom 125 0 mm 4 92 in 28 5 mm 1 12 in Arm 140 0 mm 5 51 in 28 5 mm 1 12 in Bucket 120 0 mm 4 72 in 28 5 mm 1 12 in Arti 150 0 mm 5 91 in 28 5 mm 1 12 in DX255LC 3 Boom 130 0 mm 5 12 in 28 5 mm 1 12 in Arm 140 0 mm 5 51 in 28 5 mm 1 12 in...

Page 355: ...91 in 34 5 mm 1 36 in DX420LC 3 Boom 170 0 mm 6 69 in 34 5 mm 1 36 in Arm 180 0 mm 7 09 in 41 5 mm 1 63 in Bucket 160 0 mm 6 30 in 34 5 mm 1 36 in DX490LC 3 DX530LC 3 Boom 170 0 mm 6 69 in 34 5 mm 1 36 in Arm 190 0 mm 7 48 in 41 5 mm 1 63 in Bucket 170 0 mm 6 69 in 34 5 mm 1 36 in Model Cylinder øA B Model Cylinder 0 2 0 1 0 2 0 1 ...

Page 356: ...SP002497 Cylinders Page 28 Slipper Seal Straightening Jig ARS4780L 2 R1 50 25 100 A 15 A 2 5 R 2 C 1 Figure 12 ...

Page 357: ...mm 4 72 in Arti 150 0 mm 5 91 in DX140W 3 Boom 110 0 mm 4 33 in Arm 115 0 mm 4 53 in Bucket 95 0 mm 3 74 in Arti 140 0 mm 5 51 in DX190W 3 Boom 120 0 mm 4 72 in Arm 125 0 mm 4 92 in Bucket 110 0 mm 4 33 in Arti 160 0 mm 6 30 in DX255LC 3 Boom 130 0 mm 5 12 in Arm 140 0 mm 5 51 in Bucket 125 0 mm 4 92 in Arti 160 0 mm 6 30 in DX300LC 3 Boom 140 0 mm 5 51 in Arm 150 0 mm 5 91 in Bucket 135 0 mm 5 31...

Page 358: ...30 in Arm 170 0 mm 6 69 in Bucket 150 0 mm 5 91 in DX420LC 3 Boom 170 0 mm 6 69 in Arm 180 0 mm 7 09 in Bucket 160 0 mm 6 30 in DX490LC 3 DX530LC 3 Boom 170 0 mm 6 69 in Arm 190 0 mm 7 48 in Bucket 170 0 mm 6 69 in Model Cylinder øA Model Cylinder 0 2 0 1 ...

Page 359: ...r 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 IMPORTANT Vent air from the hydraulic system before disconnecting cylinder piping connections Use the lever on the reservoir while the engine is running Discharge the hydraulic acc...

Page 360: ...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 19 from end of rod 7 Immobilize piston rod by inserting a wooden or other ...

Page 361: ...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 16 taking care not to damage cushion ring 11 Use a plastic hammer to evenly pull off rod cover 5 from end of piston rod Be careful not to damage rod bushing 6 and dust wiper U packing and other seals HAOF340L Figure 20 Figure 21 Fi...

Page 362: ... appropriate width tip to facilitate removal of slipper seal 18 wear ring 19 and slide ring 20 from piston 17 14 Remove O ring 21 and backup ring 22 from cylinder head 15 During disassembly of cylinder head be careful not to damage buffer seal 8 and U packing 9 HAOF37OL Figure 24 Figure 25 HAOF38OS Figure 26 HAOF39OL Figure 27 ...

Page 363: ...SP002497 Page 35 Cylinders 16 Disassemble retaining ring 12 and dust wiper 11 Separate retaining ring 7 and rod bushing 6 17 Force out pin bushing 2 4 from body of cylinder Figure 28 Figure 29 ...

Page 364: ...lace damaged or excessively worn parts Clean parts and lubricate with clean hydraulic oil Make sure work area is clean Replace any part that shows evidence of damage or excessive wear Replacement of all O rings and flexible seals is strongly recommended Before starting the cylinder reassembly procedure all parts should be thoroughly cleaned and dried and or prelubricated with clean hydraulic fluid...

Page 365: ... Before starting to rebuild piston assembly heat slipper seal for 5 minutes in an oil bath warmed to 150 180 C 302 356 F Use special slipper seal jig third item in list of specialized tools at the beginning of this procedure to attach seal Cool seal by pushing a retracting jig against seal for several minutes Apply a strip of clean see through sealing tape around slipper seal to keep it free of du...

Page 366: ... piston rod Push rod cover by tightening piston nut 23 6 Assemble cushion ring 16 and attach piston assembly to piston rod 7 Use specially fabricated or factory sourced tool to tighten piston nut 23 8 Assemble wear ring 19 slide ring 20 and set screw 24 to piston assembly Figure 34 Figure 35 Figure 36 Figure 37 Reference Number Description 1 Set Screw ...

Page 367: ...ing 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 38 Figure 39 ...

Page 368: ...SP002497 Cylinders Page 40 ...

Page 369: ...SP002498 Page 1 Swing Device SP002498 SWING DEVICE SP002498 Swing Device Edition 1 ...

Page 370: ...SP002498 Swing Device Page 2 MEMO ...

Page 371: ... Direction of Rotation 18 External Load at the End of Shaft 19 Hydraulic Oil and Temperature Range 19 Filter 20 Installation and Piping 20 Oil Filling and Air Breather 21 Instructions before Starting to Operate 21 Troubleshooting 22 General Pre caustions 22 Examination of Hydraulic Motor 22 Troubleshooting 23 Disassembly and Reassembly 26 Disassemble Swing Motor 28 Reassemble Swing Motor 32 Disass...

Page 372: ...SP002498 Swing Device Page 4 MEMO ...

Page 373: ...ine Read and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX180LC 3 1001 and Up 50001 and Up DX19...

Page 374: ...28 CH B RG 1600 245 Design code Max theoretical output torque Reduction gear type If or not there is an auxiliary device B Mechanical brake installed Type of valve cover Capacity 72 72 0 cc rev 86 86 0 cc rev 128 127 9 cc rev 132 131 8 cc rev Typeofmotor ...

Page 375: ...Nomal min 1 1 250 Maximum min 1 1 700 Theoretical Output Torque kg cm 56 0 56 0 55 0 Brake Torque kg m 63 Brake Release Pressure kg cm2 23 Weight kgf 62 Swing Reduction Gearbox No 1 Sun Gear Module 3 No of teeth 23 No 1 Planetary Gear Module 3 No of teeth 29 No 2 Sun Gear Module 3 No of teeth 22 No 2 Planetary Gear Module 3 No of teeth 29 Ring Gear Module 3 No of teeth 82 Reduction Ratio 21 58 1 W...

Page 376: ...RINCIPLE OF OPERATION Structure Structural Diagram Motor FG022304 101 107 108 102 103 104 110 109 105 112 213 113 201 202 203 206 205 207 208 209 303 305 307 308 309 310 306 311 210 211 210 212 301 312 400 314 406 302 214 Figure 1 Motor Structure ...

Page 377: ...ring 113 Pin Spring 201 Driveshaft 202 Shoe Plate 203 Shoe 204 Piston 205 Cylinder Block 206 Thrust Ball 207 Retainer Plate 208 Collar 209 Roller 210 Washer 211 Spring 212 Ring Snap 213 Valve Plate 301 Casing S1 302 Oil Seal 303 Roller Bearing 305 Separation Plate 306 Friction Plate 307 O ring 308 O ring 309 Brake Piston 310 Brake Spring 311 PT Plug 312 PT Plug 400 Brake V V 406 Bolt Reference Num...

Page 378: ...Page 10 Structural Diagram Reduction Gear FG022340 501 502 503 507 506 511 512 505 801 802 504 510 511 701 707 508 509 706 703 706 705 704 606 603 605 604 606 601 708 602 607 608 702 700 600 Figure 2 Reduction Gear Structure ...

Page 379: ...rust Washer 509 Hex Bolt 510 PT Plug 511 PT Plug 512 Pin 601 No 1 Carrier 602 No 1 Sun Gear 603 No 1 Planetary Gear 604 Inner Ring 605 Needle Bearing 606 No 1 Thrust Washer 607 Thrust Plate 608 Flat Head Screw 701 No 2 Carrier 702 No 2 Sun Gear 703 No 2 PL Gear 704 No 2 Pin 705 Bushing 706 No 2 Whrust Washer 707 Spring Pin 708 Thrust Washer 801 Ring Gear 802 Socket Bolt Reference Number Descriptio...

Page 380: ...SP002498 Swing Device Page 12 Structural Diagram Swing Device FG022341 313 312 Figure 3 Swing Device Structure Reference Number Description 311 Level Gauge 312 Socket Bolt Reference Number Description ...

Page 381: ...ution low pressure oil is discharged as the pistons ride to toward a higher position on the shoe plate A small amount of supply oil flows through the center of each piston to lubricate the piston ball joint and the piston shoe face The motor is internally lubricated from leakage inside the motor To reverse rotation system oil flow is changed from inlet port to outlet port and vice versa Theoretica...

Page 382: ...y the pressure area A2 by pressure Pg of room g in the plunger 301 Here Pg is the pressure of room g applied pressure by passing oil through orifice m If Pg arrives at the pressure which is determined by spring 321 pushing the piston 302 the piston moves to left side When piston 302 moves to left side room h operates as damping room which is designed at the side of adjustment plug 401 and piston 3...

Page 383: ...ge 15 Swing Device Spring 321 Piston 302 h m HYD Area A1 Pressure Ps Adjust Plug 401 HYD Area A2 Pressure Pg Plunger 301 n g P Port 1 2 3 4 P T Ps P1 FG018897 Figure 6 Relief Valve Operation Diagram of KRD22EK10C ...

Page 384: ...dy tends to shift to the opposite direction Because of the brake pressure the swing device stops first and tends to reverse Although the oil pressure of B port tries to shift the poppet to left side the operating will be delayed by the orifice of the A port In this case a bypass is generated between A port and B port and pressure oil in B port flows into A port through the bypass 2 Figure 7 And th...

Page 385: ...he separation plate 305 and the brake piston 309 when the friction plate is pressed against the casing through the separation plate and the brake piston This friction force constraints the driving shaft engaging the brake Meanwhile the brake piston moves and the friction plate is separated from the casing to release the brake as oil pressure force overcomes the spring force by applying a releasing...

Page 386: ...the inside of the motor is dirty with intruded dust Direction of Rotation The relation between the oil flow and the revolutionary direction of the shaft is self explanatory as shown in Figure 9 and Table The direction of rotation differs by the direction of the slope of casing Be careful for the direction of swing which is differentiated by the shape of casing and direction of flange Counterclockw...

Page 387: ... is between 10 and 1000 cSt but 10 to 200 cSt is recommended for the optimum efficiency The temperature range is limited to 25 C to 100 C for the sake of the oil seal and the O ring For the operation temperature at most 60 C is recommended taking into consideration the degradation of active oil and seals 1000 750 500 400 300 200 150 100 75 50 40 30 25 20 15 10 30 20 10 0 10 20 30 40 50 60 70 80 90...

Page 388: ...liness level of class 8 of NAS Also install a 10μ filter in the hydraulic circuit and 2 4 mg 100cc or below millipore filter pollution rating is recommended Installation and Piping 1 When the motor is installed its shaft should face downward 2 The deviation of offset center from driven parts should be equal to or less than 0 05 mm or less 3 The tightening torque of the bolts used in mounting the m...

Page 389: ... otherwise it will be likely be causes of imperfect working or a damage of the motor Instructions before Starting to Operate 1 Check if the direction of revolution is correct or not 2 Check whether or not there is any leakage of oil from the motor 3 Check if the equipment vibrates abnormally or not operates or when the revolution direction is changed 4 Check if the oil temperature rises rapidly in...

Page 390: ...surfaces Once seals have been disassembled they should be replaced even if damage is not observed Examination of Hydraulic Motor It is extremely difficult to trace trouble in the hydraulic circuits Inspect the following items and investigation whether or not the fault is caused by the motor 1 Inspection the oil in casing Remove the drain plug and inspect the hydraulic oil in the casing If a large ...

Page 391: ...isassembly or cleaning 3 Replace for damaged seat part The pressure of the circuit is not increasing 1 Overloaded 2 Sticking of moving parts 3 The brake dose not release 4 Stick of brake piston 5 Stick of friction plate 1 Remove load 2 Check repair the piston shoe cylinder block valve plate etc 3 1 Check repair circuit 2 Check for the break valve 4 Disassemble and check 5 Disassemble and check Rep...

Page 392: ...nd circuit up to the motor 2 Reduce the oil temperature 3 Replace it Symptom Possible Cause Corrective Action Brake torque is not sufficient 1 Friction plates are worn 2 Brake piston is sticking 3 Brake releasing pressure is not working 4 Spline of friction plates are damaged 1 Disassemble and check Replace the part if excessively worn 2 Disassemble and check 3 1 Check repair the circuit 2 Check f...

Page 393: ...ively high pressure in the casing 4 The shaft is rusty 1 Replace the oil seal 2 Replace the driving shaft or defective centering of the driving shaft 3 Repair clogged pipeline 4 Disassemble and correct it Symptom Possible Cause Corrective Action Oil leak from joint surface 1 O ring is missing 2 O ring is dammaged 3 Seal face is defective 4 The bolt is loose or not tightened 1 Insert O ring 2 Repla...

Page 394: ...g 370 20 111 M33 Relief Valve 1 800 100 107 Name Size 2 face Width Application Part Tool Hexagon Bolt M6 10 Brake Valve Hexagon Wrench Socket Wrench Hexagon Socket Bolt M20 17 Valve Casing Hexagon Wrench Plug M22 10 RO Plug Hexagon Wrench Plug M30 17 RO Plug Hexagon Wrench Plug PF 1 4 19 VP Plug Hexagon Wrench Socket Wrench Relief Valve M33 36 Relief Valve Hexagon Wrench Socket Wrench Specificatio...

Page 395: ...SP002498 Page 27 Swing Device M10 effectiveness screw length 20 40 2 x o9 100 250 o11 o9 o169 o240 M10 M10 FG022440 Figure 13 Tools for Break Piston Disassembly ...

Page 396: ...e rope around motor Lift up the motor with a crane and clean the motor with cleaning oil After cleaning dry with compressed air 2 Draw the oil out of the casing 301 3 Point the end of the driveshaft downward and fix it on a disassembly table for easy disassembling Before disassembling make a match mark on motor casing 301 and valve casing 101 4 Remove brake valve 400 5 Remove relief valve 107 from...

Page 397: ... 101 8 Remove hex socket bolts 109 110 and disassemble valve casing 101 from casing 301 When loosening bolts the valve casing will be raised by brake springs 310 Remove valve plate 213 from the valve casing 101 9 Remove brake springs 310 from the brake piston 309 101 102 104 103 FG022405 Figure 17 105 FG022406 Figure 18 109 101 310 FG022407 Figure 19 309 310 FG022408 Figure 20 ...

Page 398: ...inder block be careful not to pull out roller 209 Be careful not to damage the sliding parts of the cylinder block thrust ball and shoe washer 210 2 ea spring 211 retaining ring 212 are not disassemble at the disassembled cylinder block 12 Pull out friction plate 306 2 ea and separation plate 305 3 ea from casing 301 13 Remove shoe plate 202 from casing 301 When removing the shoe plate 202 be care...

Page 399: ...be disassembled 15 Do next step only if required 1 Remove roller bearing 303 from casing 301 Do not reuse the disassembling bearing 2 Take out oil seal 302 from the casing 301 with a jig Do not reuse the disassembling oil seal 302 3 Take out valve plate 213 from the valve casing 101 201 301 FG022413 Figure 25 303 301 FG022414 Figure 26 FG022415 Rod PRESS Casing Oil Seal Figure 27 213 101 FG022416 ...

Page 400: ...luid and dry with compressed air 3 Apply clean hydraulic oil on the sliding surfaces and bearings 4 Replace O rings and oil seals which is a principle 5 Tighten screws bolts and plugs at specified torque using a torque wrench 1 Place casing 301 on the work table with the valve casing side downward 2 This procedure applies when oil seal was disassembled from the casing Insert oil seal 302 at the ca...

Page 401: ...to casing 301 When assembling the shoe plate 202 be careful not to damage the sliding parts of the shoe plate 202 6 Insert roller 209 to cylinder block 205 Make sure that cylinder block is assembled with all component washer 210 spring 211 ring snap 212 Be careful not to damage the sliding surface of the cylinder block Insert roller to each hole one by one 303 301 FG022414 Figure 32 201 301 FG0224...

Page 402: ...ligning with the spline 10 Place casing 301 downward and assemble separation plate 305 3 ea and friction plate 306 2 ea in sequence Assemble the parts of the friction plate cut off with four gears at the same phase up and down Assemble the parts of the separation plate cut off with four jaws at the same phase 206 205 FG022421 208 Figure 36 207 203 204 205 FG022422 Figure 37 205 201 FG022410 Figure...

Page 403: ...semble brake springs 310 into brake piston 309 Confirm the springs are fitted to the brake piston completely 14 This procedure applies when ball bearing 108 was disassembled from the valve casing Assemble of ball bearing 108 Insert it to valve casing 101 while tapping it lightly Tap evenly on the outer diameter of the outer race with a brass drift until it completely stops Do not use a steel punch...

Page 404: ...nting direction of the valve casing Reference to the drawing Be careful not to drop the valve plate or let the brake springs pop out Tighten the bolts evenly 17 Install plunger 104 and spring 103 to valve casing 101 and tighten RO plug 102 with O ring 106 Confirm the smooth movement of the plunger before installing the plug 18 Install swing reactionless valve ass y 105 to valve casing 101 Confirm ...

Page 405: ... inspection and repair of the reduction gear 2009 8 10 Numerals given in parentheses following the parts names indicate the part number shown by the drawing in the instruction and maintenance manual 1 Wind the wire rope around reduction gear outside Lift it up with a crane and clean the reduction gear with cleaning oil After cleaning dry with compressed air 2 Remove the PT plug 510 and drain out g...

Page 406: ...arrier subassembly 4 Remove No 1 carrier subassembly 5 Remove No 2 sun gear 702 from No 2 carrier subassembly 6 Remove bolt 509 in No 2 carrier 602 No 1 Carrier FG022430 Figure 51 No 1 Carrier sub assembly FG022431 Figure 52 702 FG022441 Figure 53 509 FG022451 Figure 54 ...

Page 407: ...embly from ring gear 8 Remove bolt 314 in ring gear 9 Remove ring gear 801 from casing 501 10 Remove pins 512 from casing 501 No 2 Carrier No 2 Carrier Sub assembly FG022452 Figure 55 314 FG022453 Figure 56 801 501 FG022454 Figure 57 512 501 FG022455 Figure 58 ...

Page 408: ...er machine to turn case over and place a jig on driveshaft Use a press to remove pinion shaft from case 501 13 Remove bearing 504 from case 501 14 Remove pinion shaft 502 from casing 507 501 FG022456 Figure 59 FG022457 JIG 501 Figure 60 FG022458 50 Figure 61 502 FG022459 Figure 62 ...

Page 409: ... Every part should be cleaned enough with cleaning oil and dried with compressed air before starting assembly 3 Sliding parts and bearings should be applied clean hydraulic oil before their assembly 4 Seal parts of the O ring and the oil seal should be replaced according to the standards 5 Use a torque wrench to tighten or engage bolts and plugs in accordance with Tightening Torque of Bolts on pag...

Page 410: ... Apply grease thinly on the outer circumference of the oil seal 505 and insert it into casing 501 by using pressing jig 502 501 FG022462 Figure 65 IMPORTANT Prior to assembling the pinion shaft etc Apply grease slightly on the lip surface to prevent any scratch when installing 507 506 FG022463 Figure 66 501 FG022464 Figure 67 505 501 FG022465 Figure 68 IMPORTANT Do not reuse oil seal ...

Page 411: ...emble pins 512 with casing 501 8 Apply sealant evenly to ring gear assembly of casing 9 Lift ring gear 801 with hoist wipe its mating surface clean with cloth Match and align holes and attach to casing 501 504 FG022466 Figure 69 512 501 FG022455 Figure 70 FG022467 Figure 71 801 FG022468 Figure 72 ...

Page 412: ... no 2 pin 704 into carrier and No 2 bushing NOTE Pin No 2 may need to be gently tapped with a soft faced hammer After all four No 2 are installed align spring pin 707 with carrier hole and drive it into position using a hammer 13 Using a suitable lifting device lower No 2 carrier subassembly into ring gear making sure that planetary gears are engaged Continue to lower carrier and engaging it onto ...

Page 413: ... head of the hexagon bolt 509 15 Install No 2 sun gear 702 in No 2 carrier 16 Assemble the following parts on the carrier No 1 17 Assemble the following parts 509 FG022451 Figure 77 702 FG022441 Figure 78 502 606 604 605 603 606 FG022471 Figure 79 Reference Number Description 502 Thrust Washer 603 Planet Gear 604 Innerring 605 Needle Bearing 606 Thrust Washer No 1 608 607 FG022472 Figure 80 Refere...

Page 414: ...pline of the No 2 sun gear 702 and the ring gear 801 19 Install No 1 sun gear 602 in No 1 carrier 20 Use a hoist to lift the prepared motor wipe out the assembly and install the retaining ring 214 on the shaft 201 21 Apply sealant evenly to ring gear assembly of motor No 1 Carrier sub assembly FG022431 Figure 81 602 FG022473 Figure 82 201 214 FG022474 Figure 83 FG022475 Figure 84 ...

Page 415: ... gear should be alligned Assemble the motor by turning it clockwise or counterclockwise gently so that splines of the shaft shall be engaged with the No 1 sun gear 23 Apply Loctite to 16 socket bolts 314 24 Insert bolt into holes and tighten with an impact wrench FG022497 Level Gauge Port Figure 85 314 FG022498 Figure 86 314 FG022499 Figure 87 ...

Page 416: ...25 Install the level gauge pipe sealed with teflon tape with a pipe wrench 26 Fill with the correct hydraulic oil and check the oil level with stick level gauge Assembly is done FG022500 Level Gauge Pipe Figure 88 FG022501 Figure 89 ...

Page 417: ...iteria mm Corrective Action Clearance between the piston and cylinder block 0 025 0 055 Replace the piston or cylinder block Clearance between the piston and shoe compressed part δ 0 05 0 2 Replace the piston or shoe assembly Shoe thickness t 4 5 4 3 Replace the piston or shoe assembly Assembled height of the retainer plate and spherical bushing H h 10 8 10 3 Replace the retainer and spherical bus...

Page 418: ...SP002498 Swing Device Page 50 ...

Page 419: ...SP002499 Page 1 Travel Device SP002499 TRAVEL DEVICE SP002499 Travel Device Edition 1 ...

Page 420: ...SP002499 Travel Device Page 2 MEMO ...

Page 421: ...tions 6 Indication of Type 7 Basic Structure and Diagram 8 Operation Principles 9 Cautions for Operation 16 External Specifications Diagrams 22 Basic Structure and Diagrams 23 TM40VD Maintenance Instructions 26 Precautions 26 Tools List for Disassembly and Reassembly 27 Disassembly Instructions 30 Reassembly 41 Testing 56 List of Seals 58 ...

Page 422: ...SP002499 Travel Device Page 4 MEMO ...

Page 423: ...e operating or servicing machine Read and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX225LC 3 ...

Page 424: ...ly in the crawler 4 Stand against big external load due to a heavy duty bearing in it 5 Two speed high and low switching available for high speed low torque and low speed high torque rotations SPECIFICATIONS Specifications above are for typical performance Performance of parts are illustrated in the External Specifications Diagrams Item Units TM40VD Rated Output Torque kg m max 4650 Max Speed r p ...

Page 425: ...age 7 Travel Device INDICATION OF TYPE TM 40 VD A 92 169 1 Design number Discharge capacity cc rev 2 speed 1 speed Reduction ratio of reducer Classification of motor Size number Type hydraulic motor with reducer ...

Page 426: ...SP002499 Travel Device Page 8 Basic Structure and Diagram Basic Structure of TM Motor Figure 1 ...

Page 427: ... the input side rotates the planetary gear P on its on axis to be engaged and revolve with the fixed ring R This revolution is transferred to the carrier K to create torque The rotation of the carrier K will have planetary gears P1 P2 revolved At this time setting of a proper difference between teeth of P1 R and P1 P2 creates the rotation difference at the gear D for gears P1 and P2 are coaxial to...

Page 428: ... motor by controlling inertia rotation of the TM motor due to the inertia of its body when shutting down the motor 2 It acts like a check valve preventing the cavitation of the hydraulic valve 3 It acts like a surge cut valve controlling the brake pressure of the hydraulic valve and a anticavitation valve preventing the cavitation C Function of High and Low Speed Shifting It switches the tilting d...

Page 429: ...ure oil in the lateral side of cylinder block 104 press down piston 105 4 or 5 ea generating the force F kgf P kg cm2 x A cm2 This force acts to swash plate 103 and then is divided into F1 and F3 as the plate is fixed to the axis of driveshaft 102 at the degree of a F3 the vertical force of such divided ones generates torques T F3 x ri for Y1 Y2 each the sum of which is the rotation power T F3 x r...

Page 430: ...eturn sides of the hydraulic motor right and left actions of spool 223 and valve 227 reverse to generate reverse rotation When Stopping Brake Applies If oil supply from port A stops during travel the hydraulic force is released and spool 223 that was moved to the left side tries to move to the right side neutral position trough stopper 225 by the force of spring 228 This hydraulic oil in chamber b...

Page 431: ...the brake force of the motor is released If oil is above 45 kg cm2 it is reduced by the reducing valve to set the pressure of cylinder chamber a at 45 kg cm2 When Stopping If the pressure in cylinder chamber a is below 9 5 kg cm2 after oil supply from the brake valve stops piston 112 tries to return by the force of spring 113 This force of spring 113 presses down piston 112 to cause mating plate 1...

Page 432: ...cm2 valve 263 moves to the left side by the force of spring 266 to stop hydraulic fluid of supply port B but to release hydraulic fluid of chamber C into the motor case So the Max tilting angle of swash plate 103 becomes 1 and the piston stroke capacity of the hydraulic motor becomes minimum to enable low speed rotation θ Case of Motor Spindle Spring FG007063 Figure 10 ...

Page 433: ... right side and pressure oil of supply port B flows into chamber C through valve 263 Oil in chamber C presses piston 161 that swash plate 103 touches side b of the holder flange and keeps the status At this time the minimum tilting degree of swash plate 103 becomes 2 and the piston stroke capacity of the hydraulic motor becomes minimum to enable high speed rotation θ Case of Motor Spindle Spring F...

Page 434: ...ts piping ports of brake valve and motor drain plugged and capped 3 Do not remove cover or plug from ports before connecting pipeline as they are intended to prevent dust or weld scale from entering them 4 Make sure to fill the motor case with hydraulic oil before starting the motor 5 Recommended quantity of oil for the case 1 2 liter 6 Determine the pipeline diameter so that back pressure at the ...

Page 435: ... Change oil according to the following intervals though its frequency depends on operation conditions The following is the recommended interval of changing hydraulic oil A Interval 1000 hours or 1 year B Replacement criteria NOTE For further details please contact us since above criteria varies greatly by the type of oil and manufacturer Grade Viscosity 40 C 32 CST 46 CST ISO VG VG 32 VG 46 Manufa...

Page 436: ...use fix the problem and fill it 3 Quantity of Lubricating Oil to be Changed 3 3 liters 4 Order of Lubricating Oil Change Gear oil to be changed or refilled must be of the same kind Do not mix with a different type or grade of oil A Make sure that filling and the drain ports should be at right angles with the level surface B To drain oil remove both plugs at two ports and drain it C Refill gear oil...

Page 437: ...f bolts are loosen 3 If there is any noise 4 If temperature in the case increases abnormally External standard temperature of the case during continuous operation Max 80 C 5 If gear oil is changed at proper intervals See Lubricating Oil on page 18 6 Allowed quantity of drain for the hydraulic motor Idle Number of rotation 25 rpm Pressure 50 kg cm2 at 4 liter min ...

Page 438: ... valve and repair other damaged parts Hydraulic motor is damaged Replace the motor and check hydraulic oil and change if necessary Reducer is damaged Replace the reducer Overload Remove load Contacting Area Scratch Remove any scratches with whetstone or paper Loosened bolt Tighten and torque again Casing Loosened plug Tighten Damage due to stone etc Replace reducer Leakage Floating Seal Worn slidi...

Page 439: ...r the pump Difference between the right and the left motor drains Replace the hydraulic motor Happens at high pressure Difference between the right and the left discharges Replace the pump and the regulator Difference between the right and the left motor drains Replace the motor Different movement between the right and the left brake valves Replace the brake valves rear flanges Reduction of either...

Page 440: ...SP002499 Travel Device Page 22 External Specifications Diagrams Figure 14 ...

Page 441: ...SP002499 Page 23 Travel Device Basic Structure and Diagrams Assembly Cross Section Figure 15 ...

Page 442: ...Washer F 110 Pin Spring 111 Needle Bearing 112 Floating Bushing 113 Shaft Bearing 114 Sun Gear 115 Retaining Ring 117 Planetary Gear R 118 Needle Bearing 121 Drive Gear 122 Pin Spring 123 Cover 124 Socket Bolt 125 A Ball Bearing 126 O ring 128 RO Plug 129 Seal Ring 130 O ring 131 Thrust Washer R 132 Thrust Washer M 133 Thrust Plate R 134 Carrier No 1 136 Shim Plate C Control Part Assembly C 1 Rear...

Page 443: ...iston 2 speed 262 Shoe 2 speed 267 Pivot 275 O ring M Hydraulic Motor Assembly M 1 Cylinder Block and Piston Kit M 2 Piston Assembly M 3 Piston 2 speed Kit 401 Plunger 402 Piston Seal 403 Body 404 Back up Ring 405 O ring 406 O ring 407 Spring Retainer 408 Spring 409 Piston 412 Adjust Plug 413 Locknut Reference Number Description ...

Page 444: ...ed in accordance with instructions stated in this manual 2 Use tools stated in these instructions for the disassembly and reassembly of the machine 3 Use parts we produce or recommend for expendables and parts to be replaced CAUTION AVOID INJURY Please read these instructions carefully before the disassembly and reassembly ...

Page 445: ...A 1 5 Extension Bar JISB 4637 150 mm 1 6 Hammer 12 1 7 Plastic Hammer L 300 1 8 Driver 150 mm 1 9 Retaining Ring Pliers For shaft For hole 1 10 Hanger Weight Over 300 kgf 1 Eyebolt M16 2 Eyebolt M10 2 Eyebolt PF1 2 2 Wire 1 11 Press Press Capacity Above 200 kgf 1 12 Compressed Air 3 5 kg cm2 nozzle 1 13 Vessel General Vessel W450 x D300 x H120 2 14 Heating Vessel Heating Capacity Over 100 C 1 Volu...

Page 446: ...1 2 1 7 1 3 1 8 1 4 1 9 1 5 1 10 1 Main Bearing Press Fitting Tool FG007070 Coupling Gear Hanger FG007071 Aluminum Rod FG007072 Pressing Tool 1 FG007073 Thrust Plate R Adjustment Tool FG007074 Gap Measuring Tool FG007075 Hanger 1 FG007076 Sun Gear Positioning Tool FG007077 Hanger 2 FG007078 Tapered Steel Rod FG007079 ...

Page 447: ...99 Page 29 Travel Device No Names and Typical Sizes Q ty No Names and Typical Sizes Q ty 11 1 13 1 12 1 14 1 Steel Rod FG007080 Cocking Tool FG007081 Insert Tool FG007082 Shaft Insertion Guiding Tool FG007083 ...

Page 448: ...use the disassembling procedures described below 2 Numerals in brackets following the part name denote the part numbers used in the operation manual 3 Prior to disassembly install the TM motor on a inversion working bench 4 Fit the TM motor on the turn over working die to start its disassembly Disassembling the Reduction Gear Part 1 Remove plugs 128 3 ea and drain the reduction gear oil NOTE Fit t...

Page 449: ... 107 carrier 134 thrust washer 131 spring pin 122 5 Dissembling the carrier no 1 assembly A Drive spring pins 122 into shaft bearing R 107 NOTE Please don t remove if repair is not necessary Do not reuse the spring pin 122 B Remove shaft bearing R 107 planetary gears R 117 thrust washer R 131 needle bearings 118 and thrust washer R 131 Figure 17 Figure 18 Figure 19 Figure 20 ...

Page 450: ...gear 114 Do not remove it if not necessary 7 Remove carrier no 2 assembly NOTE Remove it using a crane after M10 eyebolts are installed 8 Drive spring pins 110 into shaft bearing F 113 NOTE Do not reuse the spring pin 110 9 Remove shaft bearing 113 4 ea Figure 21 Figure 22 Figure 23 Figure 24 ...

Page 451: ... NOTE Each part consists of the 1 st 11 Take off lock shim plate 136 by hammering on chisel or on similar tool placed at parting surface 12 Remove the hub 105 from the spindle 101 NOTE Remove it using a crane after M16 eyebolts are installed at the hub 105 13 Remove the distance piece 106 from the spindle 101 Figure 25 Figure 26 Figure 27 Figure 28 ...

Page 452: ...ratch using aluminum rod or hammer Disassembling Hydraulic Motor Part 1 Remove the relief valve 2 ea from rear flange 1 NOTE Hexagon socket 32 Torque wrench 2 Remove hex socket head bolts 43 from the rear flange 1 NOTE Hexagon wrench 14 3 Remove the rear flange 1 form the spindle 101 4 Remove the spring 213 10 ea form the rear flange 1 NOTE Remove rear flange 1 carefully after taken using hands Be...

Page 453: ...ve the timing plate 9 from the rear flange 1 NOTE When removing the timing plate user can have difficulty of the removal due to the close adhesion of rear flange 1 and oil Remove it after fitting a rod through the hole which is used when a casting is detached Be careful to not scratch the surfaces if using a sharp tool or leakage can occur B Remove the parallel pin 41 from the rear flange 1 Figure...

Page 454: ...ange 1 C Remove the spool 23 from the rear flange 1 NOTE Be careful not to damage the outer surface of the spool 23 and the sliding surface of the rear flange 1 Since the rear flange 1 and the spool 23 are of the selective fitting type replace them together as a kit even if only one of the two parts is damaged 9 Disassembling the check valve A Remove two plugs 26 from the rear flange 1 NOTE Users ...

Page 455: ...table Hexagon wrench 10 B Remove the spool 65 spring 66 from rear flange 1 11 Disassembling the parking brake A Remove the piston 212 by injecting compressed air from the parking brake access hole in the spindle 101 NOTE Use the protection cover on the upperpart of spindle 101 when using compressed air Otherwise part damage and injury might happen because the piston 212 is rushed out of the spindl...

Page 456: ...04 with both hands and remove it from the shaft 202 NOTE Before removal hold the cylinder block 204 with both hands and turn it two to three times in a clockwise and a counterclockwise direction alternately to detach the shoe 206 from the swash plate 203 D Remove the mating plates 216 and friction plates 215 from the cylinder block 204 NOTE Be careful that if an attempt is made to remove the cylin...

Page 457: ... assembly piston 205 shoe 206 from the removed cylinder block 204 B Remove piston 205 shoe 206 from the removed retainer plate 207 C Remove thrust ball 208 from the removed cylinder block 204 D Remove spring 214 9 ea from the removed cylinder block 204 Figure 48 Figure 49 Figure 50 Figure 51 ...

Page 458: ...7 Remove parallel pin 242 pivot 267 from the spindle 101 18 Remove ball bearing 249 from the spindle 101 NOTE When piston 261 or shoe 262 is damaged if exchange is necessary they have to be exchanged together because the seperation is impossible Use the protection cover on the upperpart f spindle when users put the pressed air into suddenly Otherwise part damage and accident might go on because th...

Page 459: ...all parts throughly in a suitable solvent Dry throughly with compressed air Do not use the cloths 6 When reassembling oil motor components of TM motor be sure to coat the sliding parts of the motor and valve with fresh hydraulic oil NAS class 9 or above 7 Use a torque wrench to tighten bolts and plugs to the torque specified as follows Reassembly Procedure Reassemble the Hydraulic Motor Part 1 Ins...

Page 460: ...le 101 NOTE Assemble after applying grease on oil seal lip 232 4 Install pivot 267 2 ea into the spindle 101 5 Install swash plate 303 to the spindle 101 NOTE The swash plate 203 and the 2 speed stopper of the spindle will conflict Install the swash plate 203 after rotating And then install it as the regular position Figure 57 Figure 58 Figure 59 Figure 60 ...

Page 461: ...207 NOTE After mounting immerse the entire them in a working fluid D Mount the piston assembly in the cylinder block 204 7 Install cylinder block 204 assembly to the shaft 202 NOTE After fitting splines of both cylinder block 204 and shaft 202 assemble them After installing the cylinder 204 confirm whether it revolves or not by turning using both hands Motor is malfunction when it isn t revolve Fi...

Page 462: ...ll two O rings 235 239 and two backup ring 247 248 in then O ring grooves of the piston 212 NOTE Apply a thin coat of grease to the O rings 235 239 D Mount a piston 212 in the spindle 101 NOTE If the piston 212 does not fit into the spindle 101 because of the resistance of the O ring tap the edge of the piston 212 lightly and equally with a plastic hammer Be careful not to damage the O ring and ba...

Page 463: ...lug to the required torque Tightening torque 26 4 0 kg m NOTE Adapter for hexagon wrench 14 Torque wrench 2 Reassemble the spool A Install spool 23 into the rear flange 1 NOTE Before installing the spool 23 apply hydraulic oil to the spool Be careful not to damage the spool s surface and the inner of rear flange 1 B Install O ring 36 on the plug 24 C Install spring 28 and a stopper c 3 into the pl...

Page 464: ...ear flange 1 NOTE Be careful not to damage the hole s liner of the rear flange 1 and the spool 65 outer It brings on low efficiency of the TM motor because of the leakage increase after reassembling The shaft center should align with the hole center because of little gap It is in order to protect the damage and smooth assembling of the rear flange 1 and the spool 65 C Insert a plug 63 into the rea...

Page 465: ...necessary B Install orifice 71 filter 79 into the rear flange 1 Caulk it after assembling certainly NOTE Do not disassemble and assemble if not necessary 5 Insert a ball bearing 250 timing plate 209 parallel pin 41 1 ea and spring 213 12 ea into the rear flange 1 NOTE Be careful not to seperate the spring 213 and the timing plate 209 should not separate from the rear flange 1 Apply hydraulic oil t...

Page 466: ...dle 101 fix the spring 13 with applied grease so it does not drop B Tighten the socket bolt 43 into the spindle 101 to the required torque Tightening torque 5 9 1 0 kg m 14 adapter torque wrench for wrench 7 Tighten the relief valve into the rear flange 1 to the required torque Tightening torque 25 5 kg m 32 socket torque for wrench Figure 78 Figure 79 Figure 80 Figure 81 ...

Page 467: ...de face upward 2 Install floating seal 102 on the spindle 101 NOTE Apply grease to the floating seal 102 Hub Assembly 1 Install angular bearing 125 into the hub 105 NOTE Be careful of the insert direction Figure 82 Floating Seal Spindle Floating Seal FG018821 Figure 83 Press Jig Hammer A Ball Bearing Hub FG018819 Figure 84 ...

Page 468: ... the sealing 129 in the hub 105 NOTE Apply a thin layer of grease to the O ring 130 3 Install floating seal 102 on the hub 102 NOTE Apply grease to the floating seal 105 4 Install distance piece 106 into the spindle Figure 85 Figure 86 Figure 87 Figure 88 ...

Page 469: ...bearing 125 into its full depth 7 While pressing flange of spindle 101 install Shimplate 136 into groove 8 Assemble thrust washer F 109 planetary gears F 108 needle bearings 111 floating bushing 112 into carrier no 2 103 9 Install shaft bearing 113 into the carrier no 2 103 Figure 89 Figure 90 Figure 91 Figure 92 ...

Page 470: ...l spring pin 110 into the carrier no 2 103 11 Place carrier no 2 assembly into hub 105 12 Attach the retaining ring 115 on the sun gear 114 NOTE Snap ring pliers Snap ring C 75 S 13 Install sun gear 114 Figure 93 Figure 94 Figure 95 Figure 96 ...

Page 471: ...ry gears R 117 needle bearings 118 shaft bearing R 107 into carrier no 1 134 15 Install the spring pin 122 into the carrier no 1 134 16 Place carrier no 1 assembly into hub 105 17 Install drive gear 121 in the carrier no 1 assembly Figure 97 Figure 98 Figure 99 Figure 100 ...

Page 472: ...3 NOTE Apply grease to the thrust plate 133 19 Install thrust washer M 132 in the cover 123 20 Apply sealant to the cover 123 after intalling with the hub 107 NOTE Sealant silicon rubber 780 RTV 21 Mount the cover 123 on the hub 105 Figure 101 Figure 102 Figure 103 Figure 104 ...

Page 473: ...O ring 38 Tightening torque 10 2 kg m 10 adapter torquer wrench for hexagon wrench Checking Facts After Assembly 1 Air test of reduction gear Disassemble plug 32 of reduction gear part When compressed air 0 3 kg cm2 is applyed through the plug hole under water for 2 minutes there must be no observable air bubble Gear oil 3 3 liter 2 Air Test Of Hydraulic Motor With one port opened and the other po...

Page 474: ...ad pressure 1 minute clockwise counterclockwise rotation B Conditions for performance tests 1 Working fluid ISO VG 46 wear resistant type 2 Lubricating oil Gear oil 3 Temperatures Ambient temperature Room temperature Working fluid temperature 50 5 degrees C Casing temperature of reducer section 40 to 80 degrees C 4 Drainage pressure 0 8 kg cm2 or less C Efficiency tests for the first speed D Secon...

Page 475: ...ng a testing apparatus Install the TM motor in the vehicle and provide piplines without attaching the shoe carry out running in operation followed by performance tests A Conditions for running in operation 1 10 r p m no load pressure one minute clockwise counterclockwise rotation 2 20 r p m no load pressure one minute clockwise counterclockwise rotation B Conditions for running in operation 1 Temp...

Page 476: ...102 4 O ring 1BP18 5 46 38 5 Oil Seal TCN48 x 70 x 12 1 232 6 O ring 1BP180 1 235 7 O ring 1BP210 1 239 8 Backup Ring 1BP180 1 247 9 Backup Ring 1BP210 1 248 10 O ring 1BP16 6 405 12 Backup Ring T2 P16 4 404 13 O ring 1BP29 2 406 14 Piston Seal SPGO 7 5 10 5 1 5 2 402 15 O ring 1BP32 2 36 16 O ring 1BP22A 2 37 17 O ring 1BP11 2 74 18 O ring JIS1516W P82 2 130 ...

Page 477: ...SP002502 Page 1 Main Pump SP002502 MAIN PUMP SP002502 Main Pump Edition 1 ...

Page 478: ...SP002502 Main Pump Page 2 MEMO ...

Page 479: ... Applicable Models 5 Pump Maintenance 6 Component Locations 6 Parts List 8 Tools 10 Tightening Torque 11 Disassembly 12 Reassembly 15 Pump Body Maintenance Standards 18 Change Standards of Worn Parts 18 Fix Standards of Cylinder Block Valve Plate and Swash Plate Shoe Plate 19 ...

Page 480: ...SP002502 Main Pump Page 4 MEMO ...

Page 481: ...operating or servicing machine Read and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX225LC 3 10...

Page 482: ...90 401 211 153 158 156 157 725 710 313 468 806 953 886 717 406 261 111 774 710 127 824 548 732 789 535 532 214 702 531 724 792 534 VIEW A 543 541 725 79 545 544 312 885 124 314 466 728 981 983 141 13 14 41 271 710 954 901 717 985 986 808 151 152 11 530 113 4 212 214 30 541 544 545 42 Figure 1 ...

Page 483: ...6 Flexible Bushing 157 Cylinder Spring 158 Spacer 211 Shoe Plate 250 Support Kit 251 Support 261 Seal Cover 271 Pump Casing 312 Valve Block 401 Socket Bolt 406 Socket Bolt 466 Plug 468 Plug 490 Expander 530 Tilted Pin Assembly 532 Piston 534 Stopper 535 Stopper 702 O ring 710 O ring 717 O ring 724 O ring 725 O ring 723 O ring 732 O ring 774 Oil Seal 789 Backup Ring 792 Backup Ring 806 Nut 808 Nut ...

Page 484: ...953 824 124 127 123 532 702 792 534 A 157 114 717 251 250 717 728 466 271 886 401 111 774 261 710 406 806 211 158 156 153 30 11 A B 490 124 725 468 885 B 312 490 954 901 717 724 710 113 885 808 886 886 79 542 42 725 41 13 14 710 985 986 FG001842 Figure 2 ...

Page 485: ...rical Bushing 157 Cylinder Spring 211 Shoe Plate 250 Support Kit 251 Support 261 Seal Cover F 271 Pump Casing 312 Block Valve 401 Socket Bolt 406 Socket Bolt 466 Plug 467 Plug 468 Plug 490 Plug 530 Tilting Pin Assembly 532 Piston 534 Stopper L 535 Stopper S 702 O ring 710 O ring 717 O ring 724 O ring 725 O ring 727 O ring 728 O ring 732 O ring 774 Oil Seal 789 Backup Ring 792 Backup Ring 806 Nut 8...

Page 486: ...Screws Hex Wrench 4 O O M5 BP 1 16 M8 5 O O M6 BP 1 8 M10 6 O O M8 BP 1 4 PF 1 4 M12 M14 8 O O M10 BP 3 8 PF 3 8 M16 M18 10 M12 BP 1 2 PF 1 2 M20 14 O M16 M18 BP 3 4 PF 3 4 17 O M20 M22 BP 1 PF 1 1 1 4 1 1 2 Socket Wrench 19 O O M12 VP 1 4 22 O VP 3 8 24 O O M16 27 O M18 VP 1 2 30 O M20 36 O M5 VP 3 4 Monkey Wrench O O 1 mid size Driver O O 2 type mid size Hammer O O 1 plastic Flyer O O TSR 160 fo...

Page 487: ...7 B 4 Hex Wrench M6 1 2 5 M8 3 6 M10 5 8 8 M12 10 10 M14 16 12 M16 24 14 M18 34 14 M20 44 17 PT Plugs Quality S45C Wrap thread tape 1 5 2 times PT 1 16 0 9 4 Hex Wrench PT 1 8 1 05 5 PT 1 4 1 75 6 PT 3 8 3 5 8 PT 1 2 5 0 10 PF Plugs Quality S45C PF 1 4 3 0 6 Hex Wrench PF 1 2 10 10 PF 3 4 15 14 PF 1 19 17 PF 1 1 4 27 17 PF 1 1 2 28 17 ...

Page 488: ...ulic oil in the pump casing 5 Remove socket bolts 412 413 to disassemble the regulator and PTO 3 Loosen socket bolts 401 retaining swash plate support 251 pump casing 271 and valve block 312 IMPORTANT 1 The place should be clean 2 Put a rubber sheet of cloth on the floor to prevent any damage to parts Figure 3 IMPORTANT Drain the oil from both the front and the rear pumps IMPORTANT 1 Refer to the ...

Page 489: ...1 from pump casing 271 by gently knocking the connecting flange part of swash plate at the shaft of pump casing with plastic hammer Figure 4 IMPORTANT 1 Always put a rubber sheet or similar protection on the working die to prevent any damage to the regulator connection part facing downward 2 When removing pump casing and valve block remove the gear 1 too Figure 5 IMPORTANT Take care not to damage ...

Page 490: ... pump casing 271 and needle bearing 124 and spool line coupling 114 from valve block 312 Figure 8 Figure 9 Figure 10 IMPORTANT Sometimes this procedure may not be necessary IMPORTANT 1 Use a proper tool when removing tilting pin to prevent any damage to its head 2 Take care not to damage servo piston for the inserting area of tilting pin and servo piston is applied Loctite 3 Do not remove needle b...

Page 491: ...mix parts of the front and the rear pumps 1 Install swash plate support 251 in pump casing 271 by gently knocking it with plastic hammer 3 Put the pump casing with its regulator connection part facing downward insert the tilting bushing of swash plate in tilting pin 531 and set swash plate 212 on its support 251 properly Figure 11 IMPORTANT 1 Insert removed servo piston tilting pin stopper L and s...

Page 492: ...der block and flexible bushing 5 Install valve plate 313 in valve block 312 by arranging pin 885 Figure 13 IMPORTANT 1 Do not strike driveshaft with hammer or a hard object 2 Use a plastic hammer to gently knock the rim of bearing to insert it and use a steel rod to insert it up to the end firmly Figure 14 IMPORTANT 1 Apply a thin grease coating to the oil seal of seal cover F 2 Take care not to d...

Page 493: ... plug 468 to complete the reassembly procedure Figure 17 IMPORTANT 1 Start to reassemble from the rear pump which facilitates the reassembly 2 Take care not to set valve block in the wrong direction the ball regulator should be at the top and the suction flange at the right side when observed from the front side 3 Insert gear 1 in valve block and connect it to spool line of the driveshaft Figure 1...

Page 494: ...Gap between Piston and Cylinder Bore ØD Ød See Figure 1 0 028 0 056 0 039 0 067 Change piston or cylinder block Gap between Piston and Shoe Pressing Part and See Figure 2 0 0 1 0 3 0 0 1 0 3 Change piston and shoe assembly Thickness of Shoe t See Figure 2 3 9 3 7 4 9 4 7 Change piston and shoe assembly Free Field of Cylinder Spring L See Figure 3 31 3 30 2 41 1 40 3 Change cylinder spring Height o...

Page 495: ...ee Field of Cylinder Spring L Fig 2 Gap between Piston and Shoe Pressing Part Thickness of Shoe T Spherical Bushing Assembly H h Figure 19 Valve Plate Sliding Part Swash Plate Shoe Plate Part Adjustment Needed Surface Intensity of Illumination 0 8a 3 2z Intensity of Illumination Each Face of Cylinder Block Sliding Part Standard Surface Intensity of Illumination Adjusted Value Below 0 1a 0 4z Loppi...

Page 496: ...SP002502 Main Pump Page 20 ...

Page 497: ...SP002503 Page 1 PTO Server SP002503 PTO SERVER SP002503 PTO Server Edition 1 ...

Page 498: ...SP002503 PTO Server Page 2 MEMO ...

Page 499: ...SP002503 Page 3 PTO Server Table of Contents PTO Server Safety Instructions 5 Applicable Models 5 Pump Maintenance 6 Disassembly 7 Reassembly 9 Maintenance Standards of Pump Body 10 ...

Page 500: ...SP002503 PTO Server Page 4 MEMO ...

Page 501: ...operating or servicing machine Read and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX225LC 3 10...

Page 502: ...e disassembly and reassembly of the PTO server 2 Tightening Torque Tools B Parts List Hex Wrench 10 Hex Bolt M10 Flange Socket Bolt 10 Flyer TRR150 TRR200 Retaining Ring RR 20 Retaining Ring RR 72 Parts Size Torque Values kgf m Socket Bolt Material SOM435 Flange socket Bolt M10 M10 5 8 3 4 ...

Page 503: ... of cloth on the floor to prevent any damage to parts 2 Remove dust or rust on the surface of the pump using lubricating oil 3 Remove oil plug 468 to drain hydraulic oil in the pump casing NOTE Drain the oil from both the front and the rear pumps 4 Remove the flange socket bolts and then the gear pump 5 Remove hex socket bolt 414 and then the PTO server 6 Remove retaining ring 827 and disassemble ...

Page 504: ...SP002503 PTO Server Page 8 7 Remove retaining ring 825 and disassemble the gear 3 118 and the ball bearing NOTE Do not remove ball bearing 125 from the gear 3 118 Figure 3 ...

Page 505: ...pared by hand 2 Wash each part sufficiently with lubricating oil and dry them with compressed air before their reassembly 3 Always apply clean lubricating oil to sliding parts and bearing before their reassembly 4 Make it a rule to replace O rings and oil seals 5 Tighten fixing bolts and plugs with proper torque wrenches and with torques specified in the Maintenance Standards ...

Page 506: ...F PUMP BODY 1 Standards to Replace Worn Parts Replace gears 2 117 and 3 118 whose teeth have pitting the size of 1 ft is the same and below 1 mm or is more than 5 of the area Any parts whose appearance is severly damaged should be replaced also Figure 4 ...

Page 507: ... PUMP GEAR PUMP FG007126 Figure 5 Reference Parts 886 Pin 827 Retaining Ring 826 Retaining Ring 825 Retaining Ring 728 O ring 712 O ring 710 O ring 466 VP Plug 414 Socket Bolt 326 Gear Case 128 Bearing Spacer 126 Roller Bearing 125 Ball Bearing 118 Gear 3 117 Gear 2 115 Idle Shaft Reference Parts ...

Page 508: ...SP002503 PTO Server Page 12 ...

Page 509: ...SP002500 Page 1 Gear Pump SP002500 GEAR PUMP SP002500 Gear Pump Edition 1 ...

Page 510: ...SP002500 Gear Pump Page 2 MEMO ...

Page 511: ...SP002500 Page 3 Gear Pump Table of Contents Gear Pump Safety Instructions 5 Applicable Models 5 Single Gear Pump 6 Disassembly 6 Reassembly 8 ...

Page 512: ...SP002500 Gear Pump Page 4 MEMO ...

Page 513: ...operating or servicing machine Read and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX225LC 3 10...

Page 514: ... exterior of pump 2 Remove clamp bolts 3 Cover sharp edges of driveshaft 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 515: ...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 516: ... 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 517: ...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 518: ...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 519: ...11 Tighten bolts with washer in a crisscross pattern to a torque value of 45 Nm 12 Check that pump rotates freely when driveshaft is turned by hand If not a pressure plate seal may be pinched FG001085 Figure 20 FG000851 Figure 21 ...

Page 520: ...SP002500 Gear Pump Page 12 ...

Page 521: ...SP002403 Page 1 Main Control Valve SP002403 MAIN CONTROL VALVESP002403 Main Control Valve Edition 1 ...

Page 522: ...SP002403 Main Control Valve Page 2 MEMO ...

Page 523: ... Parts List 38 Specifications 43 Troubleshooting Testing and Adjustment 44 Troubleshooting 44 Adjustment of Valves 45 Removal 47 Disassembly 48 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 69 ...

Page 524: ...SP002403 Main Control Valve Page 4 MEMO ...

Page 525: ...Read and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX225LC 3 1001 and Up 50001 and Up DX255LC ...

Page 526: ...orts 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 into the neutral passage the negativ...

Page 527: ...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 528: ...SP002403 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 529: ...SP002403 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 530: ...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 531: ...SP002403 Page 11 Main Control Valve ...

Page 532: ...assage 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 pressure at port PT rises Option Spool Shift When shifting option spool by increasing pressure of option Section 2 pilot port Pb2...

Page 533: ...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 534: ... 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 535: ...SP002403 Page 15 Main Control Valve FG001300 Switched Position Neutral Position BUCKET Section 7 SWING Section 3 Figure 6 ...

Page 536: ...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 537: ...alve also works with antidrift 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 538: ...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 539: ... 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 540: ... valve also works with an antidrift 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 541: ...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 542: ...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 543: ...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 544: ...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 545: ...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 546: ... in ports 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 If the load pressure of...

Page 547: ...SP002403 Page 27 Main Control Valve 5 1 2 FG001310 TRAVEL Section 1 TRAVEL Section 1 STRAIGHT TRAVEL Section ST Figure 17 ...

Page 548: ...n 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 flows...

Page 549: ...SP002403 Page 29 Main Control Valve FG001311 Switched Position Neutral Position BUCKET Section 7 SWING Section 3 Figure 18 ...

Page 550: ...ed 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 flux flowing into A3 B3 is...

Page 551: ...SP002403 Page 31 Main Control Valve FG001312 Switched Position Neutral Position BUCKET Section 7 SWING Section 3 Figure 19 ...

Page 552: ...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 B The...

Page 553: ...lve setting pilot poppet F opens Pressurized oil flows through pilot poppet F into low pressure oil passage LP passing through hole G 3 As pilot poppet F opens pressure in internal cavity D lowers to move main poppet C so 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 554: ...elief 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 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 pressure on bac...

Page 555: ...installed in cylinder port HP to prevent the development of cavitation If pressure at cylinder port HP becomes lower than that of oil passage LP sleeve K moves so oil is supplied from the low pressure oil passage LP to cylinder port HP to eliminate cavitation Figure 31 HP LP FG000648 ...

Page 556: ...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 this acti...

Page 557: ...SP002403 Page 37 Main Control Valve ...

Page 558: ...SP002403 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 559: ... 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 x 40L 77 Socket Bolt M16 x 130L 81 Washer 88 Cap 89 O ring 92 Plug Assembly 93 Plug Assembly Reference Number Description ...

Page 560: ... 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 561: ...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 M10 x 28L 91 Plug 105 Plug Assembly Reference Number Description ...

Page 562: ...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 563: ...sembly 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 Antidrift Valve Assembly 73 Socket Bolt M10 x 55L 75 Socket Bolt M10 x 40L 76 Socket Bolt M10 x 70L 78 Soc...

Page 564: ...stent 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 leaki...

Page 565: ...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 Reset pressure and tighten locking screw with regular Torque Oil leakage Damage to relief valve seat part Replace re...

Page 566: ...2 3 090 psi Tighten locknut 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 locknut 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 Tighten...

Page 567: ...oved hoses for reassembling 2 Install eyebolts M10 x 1 5 2 used to control valve 1 Figure 37 3 Remove bolts 2 Figure 37 4 used and spacers 4 used from control valve 1 Figure 37 Control valve weight 193 kg 426 lbs 4 Hoist and remove control valve from the bracket WARNING AVOID DEATH OR SERIOUS INJURY Release any pressure in the hydraulic oil tank before doing any work 2 1 FG020165 Figure 37 ...

Page 568: ... disassembly 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 WARNING...

Page 569: ... spool 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 IMPORTANT When removing spool be careful not to damage it Attach label to each spool to install it...

Page 570: ...ve 27 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 IMPORTANT Work with spool gripped in vise with wood see Figure 38 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 loos...

Page 571: ...plug 92 width across flats 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 b...

Page 572: ...mm and O ring B Remove piston 67 4 spool 67 5 and spring 67 7 C Slowly remove plug 67 3 width across flats 38 mm and O ring 67 13 D Remove 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 WARNING AVOID DEATH OR SERIOUS INJ...

Page 573: ...idth across flats 27 mm and O ring Section J J 2 Remove plug 61 width across flats 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 WARNING AVOID DEATH OR SERIOUS INJURY ...

Page 574: ...2 mm and O ring 2 If 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 IMPORTANT Do not disassemble combined bolt 77 If it is necessary to disassemble it place it horizontally on a workbench Prepare spare O ring 65 and 66 FG001317 A O ring P N 95111 01400 O ring P N 21001 00098 O ring P N 95111 01100 Pis...

Page 575: ... 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 Figur...

Page 576: ...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 41 ...

Page 577: ...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 578: ...e of screw portion can cause a malfunction of spool 2 Be careful that each spool 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 alk...

Page 579: ...ly Loctite to threaded portion of spool 19 and install spring seat 20 spring 21 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 IMPORTANT Check number of each part installation position and tools needed before reassembling IMPORTANT Be careful not to get Loctite into spool by over applying i...

Page 580: ...orque 15 16 kg m 108 116 ft lb 6 Install O ring 67 13 on plug 67 3 Install it in body 67 1 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 IMPORTANT Be careful of installation position of O ring and backup ring If they are reversed the O ring will be dama...

Page 581: ...htening 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 ...

Page 582: ...ection 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 Rege...

Page 583: ...ghtening 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 G G Ti...

Page 584: ...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 585: ...n 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 1 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 586: ...alues are based on use of lubricated threads NOTE If relief valve was disassembled adjust pressure by referring to Overload Relief Valve on page 1 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 43 IMPORTANT When disassembling the adjustment kit parts can fall out because o...

Page 587: ...tall 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 44 IMPORTANT Torque values should be measured when using lubricated threads ...

Page 588: ...ply stress on control valve when attaching piping and hoses Unnecessary stress can cause spools to bind and the control valve from functioning properly 2 Tighten the assembling bolts alternately and evenly to the specified torque 3 If welding procedures are being performed near the control valve the valve could damaged by weld spatter and heat Use adequate shielding to protect valve 4 Valve ports ...

Page 589: ... valve setting pressure should not be over 2 0 MPa 20 39 kg cm2 290 psi 5 Before operating machine the hydraulic system should be fully warmed up If machine is operated with cold hydraulic oil and valve be careful of the following to prevent spool sticking because of heat shock NOTE Do not operate main relief valve or overload relief valve suddenly and continuously Cycle oil through all actuators ...

Page 590: ...SP002403 Main Control Valve Page 70 ...

Page 591: ...SP002395 Page 1 Remote Control Valve Work Lever Joystick SP002395 REMOTE CONTROL VALVE WORK LEVER JOYSTICK SP002395 Remote Control Valve Work Lever Joystick Edition 2 ...

Page 592: ...SP002395 Remote Control Valve Work Lever Joystick Page 2 MEMO ...

Page 593: ...able of Contents Remote Control Valve Work Lever Joystick Safety Instructions 5 Applicable Models 5 General Description 7 Theory of Operation 7 Parts List 8 Specifications 10 Torques 10 Tools and Materials 10 Disassembly 11 Reassembly 14 Start up Procedures 22 ...

Page 594: ...SP002395 Remote Control Valve Work Lever Joystick Page 4 MEMO ...

Page 595: ...igns decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX140LC 3 1001 and Up 50001 and Up DX140W 3 1001 and Up 50001 and Up DX170W 3 1001 and Up DX180LC 3 1001 ...

Page 596: ...SP002395 Remote Control Valve Work Lever Joystick Page 6 ...

Page 597: ...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 598: ...ote Control Valve Work Lever Joystick Page 8 Parts List 22 20 28 24 23 21 19 30 2 3 18 35 16 17 12 8 10 11 7 6 5 4 9 9 1 A 24 28 29 A 26 33 18 36 16 17 12 8 15 11 14 13 5 4 34 25 25 R H L H 38 37 FG019389 Figure 1 ...

Page 599: ...10 Stopper 11 Spring 12 Push Rod 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 Joystick LH Joystick RH 26 Handle Bar 28 Bellows 29 Bushing 30 Spring Pin 33 Spool Kit 1 3 34 Spool Kit 2 4 35 Plug Kit 1 3 36 Plug Kit 2 4 37 Handle Kit RH 38 Handle Kit LH Reference Number Description ...

Page 600: ...ressure Operating Torque Secondary Pressure kgf cm 2 Operating Torque kgf cm Secondary Pressure kgf cm 2 Operating Torque kgf cm Push Rod Strike mm Push Rod Stroke mm 2 4 1 3 FG019380 No Tool Standard Remark 2 Plug PT 1 8 370 kg cm 27 ft lb 22 Swash Plate 27 mm 1 660 kg cm 120 ft lb 23 Hex Nut 22 mm 1 660 kg cm 120 ft lb 24 Nut 22 mm 1 660 kg cm 120 ft lb No Tool Standard Remark 2 L Wrench PT1 8 p...

Page 601: ...iers M 13 mm hex socket and ratchet hex wrench set 2 Remove armrest M8 bolt 3 each Remove armrest cover M5 screw 1 each 3 Remove rubber pad then unscrew M6 screws and disassemble S W cover 4 Unscrew socket bolt 1 each and M6 screws Then disassemble upper cover FG019384 Figure 3 FG019385 Figure 4 FG019386 Figure5 FG019387 Figure 6 ...

Page 602: ...move bracket M5 screw 2 each Disassemble joystick Socket bolt 4 each 6 Remove lead wire from bushing 29 7 Remove lever assembly from case 1 8 Remove hex nut 23 and swash plate 22 from case 1 FG019388 Figure 7 FG013494 Figure 8 FG013495 Figure 9 FG013496 Figure 10 ...

Page 603: ...emove joint assembly 21 from case 1 10 Install lead wire terminal into connector terminal pressing them together 11 Assemble connector assembly and connect it to lead wire terminal and properly route wiring FG013497 Figure 11 FG013118 Figure 12 FG013519 Figure 13 ...

Page 604: ...SP002395 Remote Control Valve Work Lever Joystick Page 14 REASSEMBLY 1 Install four plugs 2 into case 1 FG013520 Figure 14 FG013504 Figure 15 FG013507 Figure 16 ...

Page 605: ... 3 into case 1 using jig 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 FG013506 Figure 17 FG013508 Figure 18 FG013509 Figure 19 FG013503 Figure 20 ...

Page 606: ... 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 12 into plug 16 in proper order FG013499 Figure 21 FG013502 Figure 22 FG013511 Figure 23 FG013512 Figure 24 ...

Page 607: ...oppers 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 9 Install joint assembly 21 into case 1 FG013499 Figure 25 FG013501 Figure 26 FG013498 Figure 27 FG013497 Figure 28 ...

Page 608: ...e 18 10 Install boot and swash plate 22 and hex nut 23 into case 1 11 Insert bar and tighten it with a wrench to check balance of joint assembly 12 Install bushing 29 into case 1 FG013513 Figure 29 FG013514 Figure 30 FG013515 Figure 31 FG013516 Figure 32 ...

Page 609: ...k Lever Joystick 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 FG013495 Figure 33 FG013494 Figure 34 FG013118 Figure 35 ...

Page 610: ...mbly 30 and connect it to lead wire terminal and properly route wiring 17 Assemble joystick Socket bolt 4 each Assemble bracket M5 screw 2 each 18 Assemble upper cover Then add socket bolt 1 each and M6 screws FG013519 Figure 36 FG013520 Figure 37 FG019388 Figure 38 FG019387 Figure 39 ...

Page 611: ...ontrol Valve Work Lever Joystick 19 Assemble S W cover then add M6 screws And add the rubber pad 20 Assemble armrest M8 bolt 3 each Assemble armrest cover M5 screw 1 each FG019386 Figure 40 FG019385 Figure 41 FG019384 Figure 42 ...

Page 612: ...OCEDURES 1 Start engine and set throttle at LOW IDLE 2 Set safety lever to 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 FG019382 Figure 43 FG019383 Figure 44 ...

Page 613: ...SP002381 Page 1 Travel Control Valve with Damper SP002381 TRAVEL CONTROL VALVE WITH DAMPER SP002381 Travel Control Valve with Damper Edition 2 ...

Page 614: ...SP002381 Travel Control Valve with Damper Page 2 MEMO ...

Page 615: ...able Models 5 General Description 6 Theory of Operation 6 Pressure Reducing Valve 7 Operating Theory of Damper Mechanism 8 Causes of Faults and Measures 9 Parts List 10 Specification 12 Torques 12 Removal 13 Disassembly 16 Cleaning and Inspection Wear Limits and Tolerances 18 Reassembly 19 Installation 24 Start up Procedures 27 ...

Page 616: ...SP002381 Travel Control Valve with Damper Page 4 MEMO ...

Page 617: ...ructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX140LC 3 1001 and Up 50001 and Up DX180LC 3 1001 and Up 50001 and Up DX225LC 3 1001 and Up 50001 and Up DX255LC 3 1001 and Up 50001 and Up DX300LC 3 10...

Page 618: ...peration 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 619: ...nsmitted through hole acts on bottom part of spool balance is maintained by hydraulic force acting upward and then this pressure is transmitted to traveling spool of control valve In short primary pressure is transmitted to operating port as secondary pressure equivalent to control spring force compressed by spool 3 Full Operating Condition If pedal is moved to a maximum the bottom part of push ro...

Page 620: ...e orifice to the low pressure upper chamber The ball check valve then closes due to the high pressure in the lower part of the vibration prevention chamber 2 Operation When Operating Lever In Neutral Condition The spring acting on the push rod raises the piston and the oil pressure in the upper vibration prevention chamber prevents the push rod from quickly returning to neutral and damping is achi...

Page 621: ...mary 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 direct...

Page 622: ...SP002381 Travel Control Valve with Damper Page 10 Parts List Figure 3 ...

Page 623: ...g 11 Spring Pin 12 O ring 13 Push Rod 14 Spring Pin 15 Seal 16 Steel Ball 17 Spring 18 Plate 19 Retaining Ring 20 Plug 21 O ring 22 Rod Seal 23 Dust Seal 24 Cover 25 Hex Socket Head Bolt 26 Cam 27 Bushing 28 Camshaft 29 Set Screw 30 Set Screw 31 Hex Nut 32 Bellows 33 Piston 34 O ring 35 O ring 36 Expand 37 Spool Kit 38 Plug Kit 39 Cam Kit Reference Number Description ...

Page 624: ...g cm 25 1 5 40 0 1 0 5 4 3 0 5 5 46 4 91 8 112 6 160 FG024460 Figure 4 Travel Control Valve Specification Type Pilot Control With Damper Pressure Stroke 25 kg cm2 4 3 mm Stroke 356 psi 0 1692 in Stroke Weight 7 8 kg 17 lb No Bolt Size Tool Tightening Torque 26 M6 PT1 8 88 kg cm 6 ft lb 30 M8 27 mm 100 kg cm 7 ft lb 32 M10 22 mm 440 kg cm 32 ft lb 37 M10 22 mm 440 kg cm 32 ft lb ...

Page 625: ...maintenance warning tag on controls 10 Turn battery disconnect switch to OFF position 11 Remove cabin under cover by loosening bolts 12 Tag and disconnect hoses from pedal valve 1 Figure 6 Plug and cap hoses and ports to prevent contamination from entering hydraulic system or component FG018470 DO NOT OPERATE when performing inspection WARNING 190 00695A or maintenance ON OFF O I Figure 5 WARNING ...

Page 626: ...emove hoses 1 from travel control valve 2 Attach identification tags to the removed hoses for reassembling 17 mm 22 mm 15 Remove floor mat 1 from the cabin 16 Remove bolts 1 and washer Remove footrest 2 from floor plate 3 17 mm 1 2 3 FG020150 Figure 7 FG020145 2 1 1 Figure 8 Figure 9 FG020151 1 FG020147 1 1 2 3 Figure 10 ...

Page 627: ...ket 4 17 mm Remove socket bolts 1 and washer 2 Remove travel pedal bracket 3 from travel control valve 4 8 mm Remove socket bolts 1 and washer 2 Remove travel control valve 3 from floor plate 4 8 mm Move travel control valve 3 from floor plate 4 3 4 1 2 FG020146 Figure 11 FG020148 3 1 2 4 Figure 12 FG020149 3 4 1 2 Figure 13 ...

Page 628: ...amper Page 16 DISASSEMBLY 1 Remove bellows 32 2 Remove set screw 29 from cam 26 3 Remove camshaft 28 from cam 26 4 Remove hex nut 31 and set screw 30 from cam 27 FG013535 Figure 14 FG013536 Figure 15 FG013537 Figure 16 FG013538 Figure 17 ...

Page 629: ...l Valve with Damper 5 Remove hex socket head bolt 25 and cover 24 from each body 1 and 2 6 Remove push rod assembly from body 2 7 Remove body 2 from body 1 FG013539 Figure 18 FG013540 Figure 19 FG013541 Figure 20 FG013542 Figure 21 ...

Page 630: ...mbly and spring 10 from body 1 9 Remove plug 3 and 4 and O rings 12 and 34 CLEANING AND INSPECTION WEAR LIMITS AND TOLERANCES For general cleaning and inspection procedures refer to General Maintenance Procedures section FG013543 Figure 22 FG013544 Figure 23 FG013545 Figure 24 ...

Page 631: ...Insert spring 10 into body 1 2 Assemble in proper order damper spool 8 shim 7 spring 6 spring seat 5 and stopper 9 3 Install damper spool assembly into body 1 4 Assemble body 2 onto body 1 FG013544 Figure 25 FG013546 Figure 26 FG013547 Figure 27 FG013542 Figure 28 ...

Page 632: ...le rod seal 22 dust seal 23 and O ring 21 into plug 20 6 Assemble seal 15 piston 33 steel ball 16 plate 18 spring 17 and retaining ring 19 into push rod 13 7 Assemble push rod and plug FG013548 Figure 29 FG013549 Figure 30 FG013550 Figure 31 FG013551 Figure 32 ...

Page 633: ...amper 8 Install push rod assembly into body 2 9 Install bushing 27 in cover 24 using jig 10 Assemble cover 24 onto each body 1 and 2 and install hex socket head bolt 25 using torque wrench FG013552 Figure 33 FG013553 Figure 34 FG013554 Figure 35 ...

Page 634: ...t screws 30 and hex nut 31 into cam 26 and tighten it 12 Position cam 26 on cover 24 and insert camshaft 29 using hammer 13 Install set screw 29 in cam 26 and tighten it using torque wrench FG013555 Figure 36 FG013556 Figure 37 FG013557 Figure 38 FG013558 Figure 39 ...

Page 635: ...SP002381 Page 23 Travel Control Valve with Damper 14 Check cam balance 15 Install bellows FG013559 Figure 40 FG013560 Figure 41 FG013561 Figure 42 ...

Page 636: ... four bolts and washers 2 2 Install pedal brackets 3 Figure 44 on pedal valve and install four bolts and washers 2 3 Install plastic pedals 1 4 Connect hoses as tagged during removal to pedal valve 1 Figure 45 5 Install cabin under cover by tightening bolts 1 2 FG003016 Figure 43 FG019381 3 2 3 1 2 Figure 44 Figure 45 1 2 FG003016 ...

Page 637: ...asher 2 8 mm Install travel pedal bracket 3 to travel control valve 4 Install socket bolts 1 and washer 2 8 mm 7 Install travel pedal 3 to travel pedal bracket 4 Install bolts 1 and washer 2 17 mm 8 Install footrest 2 to floor plate 3 Install bolts 1 and washer 17 mm FG020149 3 4 1 2 Figure 46 FG020148 3 1 2 4 Figure 47 3 4 1 2 FG020146 Figure 48 FG020147 1 1 2 3 Figure 49 ...

Page 638: ...to the cabin 10 Detach identification tags from the removed hoses for reassembling Install hoses 1 to travel control valve 2 17 mm 22 mm 11 Install cover 2 to frame 3 Install hex bolts 1 and washer 19 mm FG020151 1 Figure 50 FG020145 2 1 1 Figure 51 1 2 3 FG020150 Figure 52 ...

Page 639: ...mper START UP PROCEDURES 1 Start engine and set throttle at LOW IDLE 2 Set safety lever to UNLOCK position 3 Slowly push and pull both travel levers about five times without a load to vent air from pilot lines Figure 53 FG019382 Figure 54 HAOB903L ...

Page 640: ...SP002381 Travel Control Valve with Damper Page 28 ...

Page 641: ...SP002406 Page 1 Solenoid Valve Assembly SP002406 SOLENOID VALVE ASSEMBLYSP002406 1Solenoid Valve Assembly Edition 2 ...

Page 642: ...SP002406 Solenoid Valve Assembly Page 2 MEMO ...

Page 643: ...Assembly Safety Instructions 5 Applicable Models 5 5 Solenoid Valve 6 Parts List 6 Functions of 5 Solenoid Valve Assembly 7 Assembly Diagram and Tools Required 8 Cautions During Disassembly and Reassembly 9 Solenoid Valve Diagram 10 Check Points and Solutions for Problems 11 ...

Page 644: ...SP002406 Solenoid Valve Assembly Page 4 MEMO ...

Page 645: ...ions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX140LC 3 1001 and Up 50001 and Up DX180LC 3 1001 and Up 50001 and Up DX225LC 3 1001 and Up 50001 and Up DX255LC 3 1001 and Up 50001 and Up DX300LC 3 1001 a...

Page 646: ...ed in the 5 solenoid valve FG020607 4 5 1 2 2 1 3 Figure 1 Reference Number Description Sizes Quantity Remarks 1 Block Body 78 x 82 x 263 1 FB EXDS01657 2 Solenoid Valve SQ S3A 00 5 C1 C5 2 1 Coil Deutsch Type VDD24VDC 5 C1 C5 3 Check Valve FD DCP 0 A 1 C6 4 Plug PF 1 4 3 P3 P4 H0 5 Plug PF 1 8 6 ...

Page 647: ...pressure supply solenoid valve to operate each work system C2 Breaker Pressure Sup ply Supplies pilot pressure for the pedal valve assembly and shuttle valve C3 High Low Travel Speed Sets low and high travel speed Shifts speed between both depending on the state of the solenoid valve or a signal detected in the e EPOS controller C4 Main Pressure Power Boost Increase Temporarily increases the press...

Page 648: ...es should be used FG020608 4 5 1 3 2 2 2 2 1 Figure 2 Reference Number Description Sizes Torques kg cm Tools 2 Solenoid Valve UNF7 8 14 350 25 Torque Wrench 1 Hex 2 1 Coil Locknut UNF1 2 20 60 2 Torque Wrench 19 mm Hex 2 2 Coil 3 Check Valve UNF7 8 14 350 25 Torque Wrench 1 Hex 4 PF 1 4 Plug PF 1 4 250 25 Torque Wrench 19 mm Hex 5 PF 1 8 Plug PF 1 8 100 25 Torque Wrench 5 mm Socket ...

Page 649: ...nd 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 reassembly p...

Page 650: ...SP002406 Solenoid Valve Assembly Page 10 Solenoid Valve Diagram FG020609 1 2 3 4 5 Figure 3 Reference Number Description 1 Coil Locknut 2 Coil 3 Connector 4 Tube and Retainer 5 Case ...

Page 651: ...k 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 Pilot pump C...

Page 652: ...SP002406 Solenoid Valve Assembly Page 12 ...

Page 653: ...SP002458 Page 1 Breaker EPPR Valve Option SP002458 BREAKER EPPR VALVE OPTION SP002458 2Breaker EPPR Valve Option Edition 2 ...

Page 654: ...SP002458 Breaker EPPR Valve Option Page 2 MEMO ...

Page 655: ... Option Table of Contents Breaker EPPR Valve Option Safety Instructions 5 Applicable Models 5 Structure 6 Parts List 6 Functions and Operation 7 Cautions for Operation 7 Maintenance Instructions 8 Maintenance 8 Disassembly 9 Assembly 10 ...

Page 656: ...SP002458 Breaker EPPR Valve Option Page 4 MEMO ...

Page 657: ...tions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX140LC 3 1001 and Up 50001 and Up DX180LC 3 1001 and Up 50001 and Up DX225LC 3 1001 and Up 50001 and Up DX255LC 3 1001 and Up 50001 and Up DX300LC 3 1001 ...

Page 658: ...002458 Breaker EPPR Valve Option Page 6 STRUCTURE Parts List Figure 4 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 659: ...o A decreases CAUTIONS FOR OPERATION 1 Wiring of the solenoid The solenoid has no polarity 2 Input electricity Do not supply electric current more than 0 7A to the solenoid coil 3 Adjustment screw It was adjusted to the standard The pressure of the port A increases when turning the adjustment screw clockwise 4 Symptoms and Solutions of Problems Symptoms Causes Solutions Pressure does not increase ...

Page 660: ...le 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 kg 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 Wrench Sleeve M 10 200 20 Hex bar wrench NPTF plug 1 ...

Page 661: ...ke 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 5 FG003691 Figure 6 FG003692 Figure 7 ...

Page 662: ...advance Every part should be cleaned thoroughly with cleaning oil and dried with compressed air before starting assembly Sliding parts and bearings should be applied clean active oil before their assembly Make it a rule to replace O rings and oil seals Use a torque wrench to tighten or engage bolts and plugs according to reference torques as described in Maintenance Guide 1 Assemble the sleeve Tak...

Page 663: ...SP002458 Page 11 Breaker EPPR Valve Option 2 Assemble the spool the spring and the pin Make sure that the spring and the pin do not fall off FG003695 Figure 10 FG003696 Figure 11 ...

Page 664: ...SP002458 Breaker EPPR Valve Option 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 12 FG003698 Figure 13 ...

Page 665: ...SP002529 Page 1 Dozer Valve SP002529 DOZER VALVE SP002529 3Dozer Valve Edition 1 ...

Page 666: ...SP002529 Dozer Valve Page 2 MEMO ...

Page 667: ...le of Contents Dozer Valve Safety Instructions 5 Applicable Models 5 Structure Diagram 6 Performance Specification 7 Hydraulic Pressure Circuit Diagram 7 Parts List 8 Disassembly and Assembly ToolS 9 Disassembly 9 Assembly Method 11 ...

Page 668: ...SP002529 Dozer Valve Page 4 MEMO ...

Page 669: ...d and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX140LC 3 1001 and Up 50001 and Up DX180LC 3 1...

Page 670: ...SP002529 Dozer Valve Page 6 STRUCTURE DIAGRAM IV 3 I 9 I 5 I 8 I 7 I 6 14 16 20 1 24 4 2 17 II 10 II 13 II 11 II 12 15 18 19 22 21 23 FG023116 Figure 1 ...

Page 671: ... SPECIFICATION HYDRAULIC PRESSURE CIRCUIT DIAGRAM FG023115 Push ROD Stroke mm Secondary Pressure Operating Torque 2 Secondary Pressure kg cm Operating Torque kg cm 0 2 4 6 28 3 0 16 6 2 4 1 5 6 5 0 5 Figure 2 P T 1 2 FG011415 Symbol Figure 3 ...

Page 672: ...9 Stopper 2 set AJV12D106 X II Plug Kit JA6J8011 O II 10 Plug 2 J96H2007 X II 11 Rod Seal DYR 10 N B R 2 RSY 10 X II 12 O ring P14 N B R 2 po 014 X II 13 Push Rod 2 J96H2008 X 14 Cover 1 J96H2009 O 15 Wrench Bolt M6 x 35L SCM440 2 WBM0635 O 16 Guide 1 J96H2010 O 17 Pin 1 J96H2011 O 18 Socket Bolt M5 x 15L 2 J96H2012 O 19 Nut M5 SCM440 2 HNM05 O 20 Lever 1 JA2C1001 O 21 Spring Pin ø3 x 18L 1 SP0318...

Page 673: ...eparate the boot 22 2 Remove the pin 17 and separate the lever 20 3 Loosen the fixated wrench bolt 15 and separate the cover 14 Part No Tool Specification Remarks 15 Torque Wrench L35 mm 150 kg cm2 17 L Wrench 10 mm 18 L Wrench 15 mm 19 Wrench 8 mm Figure 4 Figure 5 Figure 6 ...

Page 674: ... Valve Page 10 4 Separate the plug kit II from the body 1 5 Separate the spool kit I from the body 1 6 Separate the spring 4 from the body 1 7 Separate the plug 2 from the body 1 Figure 7 Figure 8 Figure 9 Figure 10 ...

Page 675: ...e plug 2 to the body 1 2 Assemble the spring 4 to the body 1 3 Assemble the spool kit I Assemble spring seat I 5 spring I 8 spring seat I 5 stopper I 9 to spool I 6 in this order 4 Assemble the spool kit I to the body 1 Figure 11 Figure 12 Figure 13 Figure 14 ...

Page 676: ... Dozer Valve Page 12 5 Assemble the plug kit II Assemble the rod seal II 11 O ring II 12 and push rod II 13 to the plug II 10 in this order 6 Assemble the plug kit II to the body 1 Figure 15 Figure 16 Figure 17 ...

Page 677: ...age 13 Dozer Valve 7 Assemble the cover 14 to the body 1 8 After assembling the lever 20 and guide 16 then install it on the body 1 and attach the assembly with the pin 17 Figure 18 Figure 19 Figure 20 Figure 21 ...

Page 678: ...SP002529 Dozer Valve Page 14 9 Adjust the gap between the guide 16 and push rod II 13 10 Assemble the boot 22 Figure 22 Figure 23 ...

Page 679: ...SP002507 Page 1 Hydraulic Schematic DX225LC 3 SP002507 HYDRAULIC SCHEMATIC DX225LC 3 SP002507 4Hydraulic Schematic DX225LC 3 Edition 1 ...

Page 680: ...SP002507 Hydraulic Schematic DX225LC 3 Page 2 MEMO ...

Page 681: ...SP002507 Page 3 Hydraulic Schematic DX225LC 3 Table of Contents Hydraulic Schematic DX225LC 3 Safety Instructions 5 Applicable Models 5 DX225LC 3 7 ...

Page 682: ...SP002507 Hydraulic Schematic DX225LC 3 Page 4 MEMO ...

Page 683: ...ry before operating or servicing machine Read and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX...

Page 684: ...SP002507 Hydraulic Schematic DX225LC 3 Page 6 ...

Page 685: ... 2 FORWARD 1 P 2 1 T 43 OPT PEDAL 2 2 UP 47 1 DOWN 1 2 pa5 P T T PI 50 pa9 51 A 48 from C V P3 10 T Pa P C1 49 P pb9 pb5 E Pi1 T V2 E A B Pb C2 46 51 pa2 T A 36 One way from 5 BS from SELECTION ON DISPLAY MONITOR pb2 10 B 34 TWO WAY P T A 23 ps1 10 A1 55 B1 P T1 P B T2 P 1 2 T 54 Pb1 Pa1 300kg cm2 56 B A B A Two Pump pb9 ROTATING OPTION ONE WAY TWO WAY 33 34 33 36 37 36 37 APPLIED PART STRAIGHT TR...

Page 686: ......

Page 687: ...1Electrical System ...

Page 688: ......

Page 689: ...SP002337 Page 1 Electrical System 8 SP002337 ELECTRICAL SYSTEMSP002337 Electrical System Edition 2 ...

Page 690: ...SP002337 Electrical System Page 2 MEMO ...

Page 691: ...nel 22 Functional Check 22 Monitoring System Schematic 24 Operation 26 Instruments 26 Warning and Indicator Lights 28 Indication of Warning Lights 28 Indication of Multifunction Gauge 30 Initial Operation 31 Graphic Information Area Display 32 Overview 32 Main Menus for the Graphic Display Area 32 Menu Selector Buttons 32 User Menu 33 User Menu Access and Escape Methods 33 Special Menu 65 Entering...

Page 692: ...ircuit Diagram 110 Automatic Travel Speed Control 112 Automatic Travel Speed Control Circuit Diagram 114 Self diagnostic Function 115 e EPOS Controller 115 Air Conditioner System 117 Outline 117 Internal and External Filters 118 Air Conditioning System Layout 120 Air Conditioner heater Circuit Diagram 121 Air Conditioner heater Unit 122 Ambient Air Temperature Sensor 127 Sun Sensor 128 Control Pan...

Page 693: ...heck 145 Refrigerant Charging 145 Inspecting System For Leakage 147 Wiper System 148 Wiper Circuit 148 Wiper operation 149 Lighting System 152 Lighting System Circuit Diagram 152 Kind of Light 153 Operation 153 Overload Warning Device 154 Overload Warning Device Circuit Diagram 154 Audio Controller 155 Audio Controller Circuit Diagram 155 ...

Page 694: ...SP002337 Electrical System Page 6 ...

Page 695: ...nd Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX140LC 3 1001 and Up 50001 and Up DX180LC 3 1001 and Up 50001 and Up DX225LC ...

Page 696: ... series and a three phase AC generator with a rectifier The electrical wiring used in the system is easily identifiable by the insulator color The color symbols used in the electrical system are listed in the following chart Electrical 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 Whit...

Page 697: ...SP002337 Page 9 Electrical System ...

Page 698: ...ntroller 6 Terminal 6 of wiper motor 7 Terminal 13 of wiper controller 8 Terminal CN7 5 CN7 6 of instrument panel controller 9 Terminal CN9 6 of air conditioner panel 10 Cabin light 11 Terminal 11 of diesel heater timer 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 switc...

Page 699: ...A R2 ACC R1 B BR C 0 5G 8 START ON OFF STARTER SWITCH CONNECTION TML PST B BR R1 R2 C ACC 7 8 4 1 2 6 5 3 FG018839 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 700: ...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 the input number should match the set number otherwise the start circuit closes and the engine does not start NOTE If the security system is LOCKED a four digit password will be required to s...

Page 701: ...witch 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 STARTER SWITCH CONNECTION FG018841 4 BR B PST START PREHEAT OFF ON TML ACC C R2 R1 R F E E SG 10 11 1 E BR B A B R1 6 5 ACC B BR C P N 7 E S 2 3 R I B B P R 12 85 87 87a 86 30 13 CN2 96 CN1 58 R2 A B S 8 85 87 87a 86 30 5 ...

Page 702: ...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 703: ...ible 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 STARTER SWITCH CONNECTION FG018841 4 BR B PST START PREHEAT OFF ON TML ACC C R2 R1 R F E E SG 10 11 1 E BR B A B R1 6 5 ACC B BR C P N 7 E S 2 3 R I B B P R 12 85 87 87a 86 30 13 CN2 96 CN1 58 R2 A B S 8 8...

Page 704: ...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 fuse 13 preheat relay 7 air heater 8 ground The duration of the heating cycle depends on the temperature of engine coolant The pre...

Page 705: ...83 12 CN2 93 11 1 74 CN1 77 78 59 1 69 1 46 47 10 D A 1 2 C B 200A 10 7 13 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 13 Preheat Relay Fuse Reference Number Description ...

Page 706: ...FF the engine controller stops suppling power to the injector solenoid 9 This stops fuel from being injected into the engine cylinder thus stopping the engine If the engine cannot be shut down using the starter switch 5 an emergency stop switch 10 is provided to stop engine To activate the emergency stop switch move it to the I EMERGENCY STOP position The emergency stop switch 10 is in its O OFF p...

Page 707: ... A 0 5G PREHEAT ON OFF PST TML BR B R2 R1 ACC C 8 9 1 69 1 11 2 3 10 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 708: ...lectrical components When the alternator 7 starts to operate a current flows from the R I terminal of alternator diode 8 battery relay 2 coil securing a path for the charging current to the battery 1 Thus preventing the possibility of a high voltage build up and possible damage to the electrical system STARTER SWITCH CONNECTION FG018844 TML START OFF PREHEAT ON PST B R1 BR R2 C ACC R F E E SG 8 7 ...

Page 709: ...operator 1 2 8 3 4 5 7 9 10 11 12 13 14 6 FG018845 E H H F C C rpm AM Min Max s DIG ISO USB Figure 9 Reference Number Description 1 Instrument Panel 2 Battery 3 Light Switch 4 Return Filter Switch 5 Pilot Filter Switch 6 e EPOS Controller 7 Alternator 8 Warning Buzzer 9 Pump Discharge Pressure Sensor 10 Hydraulic Oil Temperature Sensor 11 Fuel Sensor 12 Air Cleaner Indicator 13 Engine Controller 1...

Page 710: ... graphic information area 3 and 4 Figure 10 FG018710 1 2 5 7 8 9 10 14 12 13 E H H F C C rpm AM Min Max 3 4 6 11 s DIG ISO USB Figure 10 Reference Number Description 1 Fuel Gauge 2 Engine Coolant Temperature Gauge 3 Hydraulic Oil Temperature Gauge 4 Multifunction Gauge and Graphic Information Area 5 ECO Gauge 6 Digital Clock 7 Display Warning Symbols 8 Warning Light 9 Function Buttons 10 Mode Sele...

Page 711: ...SP002337 Page 23 Electrical System ...

Page 712: ... R2 3 4 BR E 16 17 19 A B 20 1 10 1 47 1 46 1 15 1 33 1 14 1 32 14 1 64 2 92 1 46 5 6 3 1 2 4 1 61 1 62 1 81 CAN A SIG 1 78 1 59 1 36 1 18 1 77 SIG 1 19 1 37 1 58 21 12 1 2 3 4 2 3 4 1 3 4 1 2 1 2 3 4 2 3 4 7 3 7 4 7 20 7 10 7 17 7 7 7 9 7 19 7 8 7 18 7 5 6 1 7 2 7 6 6 13 6 12 22 22 2 7 1 GND TxD RxD Figure 11 ...

Page 713: ...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 714: ...1 32 1 10 LCD Red Zone Blinking over 5K ohms FULL under 525 ohms Hydraulic Oil Temperature CN1 15 CN1 33 30 C 86 F 1 397 ohms 60 C 140 F 881 ohms 80 C 176 F 881 ohms 95 C 203 F 190 ohms 96 C 205 F 177 ohms 98 C 208 F 177 ohms When reading increase FG018847 H C Red 110 C 105 C 104 C 98 C White 85 C 60 C 34 C E F Red FG018848 White 1 10 Full FG018849 H C Red 98 C 96 C 95 C 80 C 60 C White 30 C ...

Page 715: ...workload Green Normal operation Amber Idling operation Red Heavy loading operation Gray ECO symbol off ECO gauge The average fuel efficiency for 1 minute Green Fuel efficiency is good Amber Fuel efficiency is normal Red Fuel efficiency is not good Function Display Sensor Specification Input Terminal Input Specification 1750 RPM FG018850 FG018851 Min Max Green Amber Red Gray Red Amber Green ...

Page 716: ...eference 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 CN2 93 This symbol appears during preheating CN...

Page 717: ... when the operator inhibits regeneration DPF ECU CAN Communic ation This symbol appears in case manual regeneration is needed Steady symbol Required manual regeneration Blinking symbol Required manual regeneration urgently Engine Stop ECU CAN Communic ation This symbol appears in case of failure in DPF regeneration If manual regeneration is not performed despite requirement alarm for manual regene...

Page 718: ... cleaner is clogged Return Filter CN1 64 When return filter pressure is above about 1 50 kg cm 21 psi Pilot Filter CN1 46 When pilot filter pressure is above about 1 kg cm 14 psi Overload Warning CN1 20 CN1 38 Warning buzzer also starts when boom pressure sensor output voltage is about 2 7V while overload warning switch is ON It flashes in case of 2 71V and above and lights continuously in case of...

Page 719: ...r sensor output voltage is about 1 5V below FG000554 FG001470 FG001471 FG010520 Item Input Terminal Output Operation and Initial Setting Mode Initial Operation When CN7 2 is applied battery voltage starter switch shifts from OFF to ON LCD all of LED and warning lights are turned ON and turned OFF after about 2 seconds Warning buzzer is activated and turned OFF after about 2 seconds Power mode When...

Page 720: ...tch Main Menus for the Graphic Display Area 1 User menu Language setting Time setting Filter Oil information Brightness adjustment Password 2 Special menu Information of machine status fault information Information of machine operation Menu Selector Buttons 1 Jog Switch 1 on Figure 12 Move cursor and set menu 2 Escape Button ESC 2 on Figure 12 Move a screen to previous menu or main menu FG018855 1...

Page 721: ...u Turn the jog switch and move the cursor to see a reversed display on the desired menu Then click on the jog switch to select the menu Vehicle State Vehicle Configuration Entertainment GP Configuration Press the ESC button to return to the previous screen FG018478 E H H F C C rpm PM Min Max PM Vehicle State Vehicle Configuration GP Configuration Entertainment User Menu Main Menu Monitor Normal In...

Page 722: ...Turn the jog switch to locate the cursor to reset the operation hour or change the replacement period Click on the jog switch once to display the selection screen on clear at the right bottom Then click on the jog switch to display a screen to select the operation hour reset Turn the jog switch to locate it at YES Then click on the jog switch to reset the operation hour Turn the jog switch to loca...

Page 723: ...h to allow the pop up window to disappear without the replacement period being changed Filter Oil Period Setup Table Unit time hr Figure 19 FG018485 TIME CHANGE 50h 500h 450h REMAIN 10 CLEAR TIME CHANGE 74h 1600h 1526h REMAIN 5 CLEAR TIME CHANGE 74h 500h 426h REMAIN 15 CLEAR TIME CHANGE 74h 1000h 926h REMAIN 7 CLEAR Fuel Filter Filter Oil Information Air Cleaner Engine Oil Filter Return Filter Res...

Page 724: ...eded this pop up window will be created Press the ESC button or the jog switch to allow the pop up window to disappear FG024693 Filter Oil Name Icon Fuel Filter Air Cleaner ENG Oil Filter Return Filter Pilot Filter ENG Oil HYD Oil Coolant Water DPF Filter Figure 21 Figure 22 E H H F C C rpm PM FG018516 Min Max Pilot Filter The use time arrives s DIG ISO USB Figure 23 E H H F C C rpm PM FG018515 Mi...

Page 725: ...ve the cursor to see an reversed display on the desired menu Then click the jog switch to select the menu Attachment Select Attachment Setting Camera Setting Jog Shuttle for Dial Press the ESC button to return to the previous screen Figure 25 PM FG018482 Monitoring Filter Oil Information Vehicle Information Vehicle State s DIG ISO USB Figure 26 FG024557 Vehicle Information Vehicle Name Engine Atta...

Page 726: ...mpleted the Select Complete pop up window is displayed for 3 seconds and the checkbox of the selected list is updated The cursor can only be moved from the selectable lists The selectable list items at the attachment setting are set as Enable in the use or non use of attachments in the attachment setting B Attachment Setting The attachment setting screen is used to set up the use or non use of att...

Page 727: ...he ESC button to locate the cursor at breaker two way at the top When the cursor is placed at breaker two way at the top press the ESC button to return to the previous screen How to Set Up Attachments Attachment setting items include attachment use max E G limit max flow ATT min flow ATT and user setting max flow Operate the jog switch clockwise counterclockwise to locate the cursor Then click on ...

Page 728: ...en using attachments Operate the jog switch to move the cursor to the max E G limit Then click on the jog switch to convert into the editing mode At the editing mode operate the jog switch clockwise counterclockwise to determine the desired max engine limit Then click the jog switch to complete setup At the editing mode press the ESC button to disable the editing mode and the saving of the setup v...

Page 729: ...t setup method The change value by stage in the jog switch operation is 10 lpm When setting up all above items the setup limits are outlined as follows If these limits are exceeded a pop up window is displayed for 3 seconds saying You can set value in limit range C Camera Setting The camera setting screen is designed to set up various cameras ON OFF and normal mirror From the vehicle configuration...

Page 730: ...Turn the jog switch to locate the cursor at normal mirror Then click on the jog switch to set up normal mirror D Jog Shuttle for Dial The jog shuttle for dial screen provides a method whereby to use the gauge panel s jog switch and control the engine rpm replacing the engine control dial From the vehicle configuration select the jog shuttle for dial to access it Figure 40 PM FG018500 Camera Settin...

Page 731: ... mode to set up the rpm dial When the cursor is placed at the editing mode operate the jog switch clockwise counterclockwise thus setting up the engine rpm When the cursor is at the editing mode press the ESC button to disable the editing mode When the cursor is not at the editing mode press the ESC button to return to the previous screen Before keying off the gauge panel or disabling the using jo...

Page 732: ... limited this pop up window will be created The pop up window will automatically disappear in 3 seconds Press the ESC button or the jog switch to remove pop up window FG018507 PM Entertainment Video MP3 s DIG ISO USB Figure 48 Figure 49 FG018514 PM Entertainment s DIG ISO USB Video MP3 The entertainment use is restricted FG018508 PM Entertainment Video MP3 Be careful playing entertainment menu on ...

Page 733: ...hen initially accessing the video player the USB storage system file tree is displayed on the screen operate the jog switch clockwise counterclockwise to select and play a video If there is a video file that played last it will automatically be replayed Figure 51 FG018507 PM Entertainment Video MP3 s DIG ISO USB FG018510 PM Entertainment DMB Video MP3 USB Storage is not installed s DIG ISO USB Fig...

Page 734: ...er Play Pause Replay the Previous File Video Progress Bar Replay the Next File Video Files List Adjust Video Brightness If no operation continues for more than 5 seconds the video will automatically be converted into the whole screen On the whole screen click on the jog switch or the ESC button to remove whole screen Figure 55 FG020115 This file is not available Title Formats that can be supported...

Page 735: ...ck on the jog switch to replay the previous file Locate the cursor at the video progress bar and click on the jog switch to convert into the fast forward rewinding mode On the fast forward rewinding mode operate the jog switch clockwise counterclockwise to conduct fast forward rewinding Fast forward rewinding can be conducted at an interval of 30 seconds per click during which the jog switch is tu...

Page 736: ...htness symbol and click on the jog switch to create the video brightness setup window With the video brightness setup window being created operate the jog switch clockwise counterclockwise to set brightness After completing the setup click on the jog switch to return to the previous screen Figure 62 FG020121 Title Figure 63 FG018557 3 Video 1 avi Video 2 avi Video 3 avi Hard Disk MOVIE Video 4 avi...

Page 737: ...initially accessing the MP3 player the file tree screen of USB storage system is displayed Operate the jog switch clockwise counterclockwise to select and play an MP3 file If there is an MP3 file played last the file will automatically be played PM FG018524 Entertainment Video MP3 s DIG ISO USB Figure 66 AM FG018523 Video MP3 Entertainment USB Storage is not installed s DIG ISO USB Figure 67 Figur...

Page 738: ...vious File MP3 Progress Bar Replay the Next File MP3 Files List Background MP3 Play Play Pause Locate the cursor at the play pause symbol and click on the jog switch to execute the MP3 play pause functions With play being on click the jog switch to display the pause symbol at the center of the screen causing the MP3 to pause With pause being on click on the jog switch to cause the pause symbol at ...

Page 739: ...is turned On the fast forward rewinding mode press the ESC button to disable the fast forward rewinding mode Replay the Next File Locate the cursor at the replay the previous file symbol and click on the jog switch to replay the next file MP3 Files List Locate the cursor at the MP3 files list symbol and click on the jog switch to move to the file list screen Select a file and replay the MP3 Figure...

Page 740: ...e Number Setting Unit Setting Language Setting Notification Setting Entertainment Use Setting Press the ESC button to return to previous screen A Password Setting The owner and user password can be set Only the owner password is selected for password setting when the product is delivered first Machine start up and function use can be managed using the password setting function Figure 77 FG020130 S...

Page 741: ... Input Password Turn your jog switch and select a number 0 9 from the below section and press the Enter on the jog switch to input the number If the incorrect password is entered it can be deleted using the button at the right bottom of the screen 3 Composition Owner password setting is composed of password change start up limitation setting functional item setting user password setting and user p...

Page 742: ...ever the owner and user password can be used at the same time when using Engine Start up The Permission items can be set only when the Use items are selected and used to assign the use right to the user Once the permission is set the user has the same right with the owner User s equipment setting will take precedence over that of the owner No item is selected when first shipped Engine Start up The...

Page 743: ...inute after password input and key off at the time of engine start up password input is not required 5 min If the engine is restarted within five minutes after password input and key off at the time of engine start up password input is not required d User Password Setting Setting Use User Password The user password is used If the User Password item is not selected only the owner password can be us...

Page 744: ...Enter Password screen appears input the password to enter the setting window using the jog switch or keypad See Password input on page 53 The factory setting password is 1111 3 Composition User password setting is composed of password change start up limitation setting functional item setting a Password Change To change the user password select Password Change and change the password using the jog...

Page 745: ...e Owner Password Setting on page 53 Engine Start up The password input function can be set for equipment start up Attachment Setting The password input function can be set for attachment setting Entertainment Use Setting The password input function can be set for entertainment video MP3 use setting Figure 92 FG020179 Password Setting User Password Change Engine Startup Lock has not been set Item S...

Page 746: ...ight to the user the user cannot select the use of the Engine Start up function but can set the password re input time B Brightness Setting On the GP configuration screen when the cursor is placed on the brightness setting click on the jog switch to display the screen brightness setting and camera brightness setting screen Brightness can be set up in two ways day night If you want to change the sc...

Page 747: ...amera brightness setting to display the camera screen brightness adjustment screen Turn the jog switch to adjust the brightness of 0 100 at an interval of 10 The camera screen brightness at the machine release time is set as 60 Press the ESC button to return to the previous screen Figure 97 E H H F C C rpm Min Max FG018532 60 Screen Brightness Setting Figure 98 PM FG018531 Brightness Setting Scree...

Page 748: ...hen click on the jog switch to select the style The selected style screen is displayed as the normal display screen The screen when manufactured is set as 1 style Figure 100 PM FG022140 GP Configuration Password Setting Brightness Setting Default Screen Setting Default Power Mode Setting Time Setting s DIG ISO USB Figure 101 FG018536 PM Default Screen Setting 1 Style 2 Style s DIG ISO USB FG018537...

Page 749: ...n the jog switch to change numbers of each item If the setup is completed click on the jog switch to store the setup details Press the ESC button to return to the previous screen Figure 103 PM FG022141 GP Configuration Password Setting Brightness Setting Default Screen Setting Default Power Mode Setting Time Setting s DIG ISO USB ON OFF ON PWR P PWR P STD S ECO E ECO E STD S PWR P PWR P Figure 104...

Page 750: ...n the pop up window G Unit Setting On the GP configuration screen when the cursor is placed on the unit setting click the jog switch to access the unit setting Figure 107 PM FG022145 GP Configuration Brightness Setting Default Screen Setting Default Power Mode Setting Time Setting Service Phone Number Setting s DIG ISO USB Figure 108 FG018539 2 3 4 5 6 7 8 0 9 1 Service Phone Number Setting Curren...

Page 751: ...ch to adopt the selected language Press the ESC button to return to the previous screen I Notification Setting On the GP configuration screen when the cursor is placed on the notification setting click on the jog switch to access the notification setting Figure 111 FG018546 Unit Setting Temperature Pressure Flux Speed Figure 112 FG022147 Default Power Mode Setting Time Setting Service Phone Number...

Page 752: ...n when the cursor is placed on the entertainment use setting click on the jog switch to access the entertainment use setting Depending on the entertainment use setting details the use of video and MP3 is limited The setup when manufactured is set as not limited Figure 115 FG018545 Enable Enable Disable Notification Setting Warning Alarm Pop up Status Change Notification Pop up Maintenance Notifica...

Page 753: ...guration Entering Accessing and Exiting Escaping Menus Entering Accessing Menus When normal mode screen is displayed if jog switch 1 Figure 118 power mode selector button 2 Figure 118 and multimedia button are pressed simultaneously for more than 3 seconds normal mode screen Figure 119 will be changed to special menu screen Figure 120 Normal Mode Screen NOTE Normal mode screen display fuel gauge e...

Page 754: ...ving the cursor to see an reversed display on the desired menu Then click on the jog switch to select the menu Press the ESC button to return to the previous screen Entering Submenus When cursor is located on Machine Info of special menu screen press Enter 3 on Figure 118 button and the Machine Info will be displayed Monitoring 1 Entering Submenus When cursor is located on Monitoring of special me...

Page 755: ...uel Level Fuel residual quantity radio of fuel tank 12 Hydraulic Oil Temperature C Hydraulic oil temperature 13 Power Shift P V 1 mA Current in pump proportional valve 14 Coolant Fan Control P V mA Current in coolant fan control proportional valve 15 Flow Control P V mA Current in flow control proportional valve 16 Two way P V Open mA Current in two way open flow control proportional valve 17 Two ...

Page 756: ... is set to the I position or the II position 11 Pilot Cut Off Switch Lights up when the pilot cutoff switch is ON 12 Air Cleaner Indicator Lights up when the air cleaner indicator contact is ON 13 Pilot Filter Lights up when the pilot filter pressure switch is ON 14 Return Filter Lights up when the return filter pressure switch is ON 15 OWD Select Switch Lights up when the overload warning selecto...

Page 757: ...SP002337 Page 69 Electrical System Submenu Selections ON FG018866 OFF OFF OFF OFF OFF OFF ON OFF ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF Figure 124 ...

Page 758: ... 7 Fuel Temperature C Fuel Temperature 8 Engine Oil Temperature C Engine Oil Temperature 9 Coolant Water Temperature C Coolant Coolant Temperature Gauge 10 DOC Intake Temperature C DOC Intake Temperature 11 DOC Outlet Temperature C DOC Outlet Temperature 12 DPF Outlet Temperature C DPF Outlet Temperature 13 DPF Pressure bar DPF Pressure 14 Fan Speed rpm Fan Speed 15 Intake Manifold Temperature C I...

Page 759: ...ure Rear Pump Pressure Boom Cylinder Pressure Px Pressure Py Pressure Alternator Voltage Battery Voltage FG018863 You can select up to 6 items Figure 127 User Selection Signal Front Pump Pressure Rear Pump Pressure Boom Cylinder Pre Pilot Gear Pump P Alternator Voltage Battery Voltage Accelerator Pedal FG018864 Front Pump Pressure Air Cleaner Indicator Preheat Elec Breaker Operating 289 bar OFF OF...

Page 760: ...be returned to previous screen Graph Data Monitoring Real time monitoring of the selected data FG018867 Graph Graph Data Monitoring Graph Data Setting s DIG ISO USB Figure 130 Graph Front Pump Pressure Rear Pump Pressure Battery Voltage FG018868 331 bar 500 0 0 s 16 s t Figure 131 FG018870 Graph Graph Data Monitoring Graph Data Setting s DIG ISO USB Figure 132 Graph Data Setting Front Pump Pressur...

Page 761: ...de failure contents When several fault are produced failure information can be checked using the jog switch 1 Figure 118 1 2 A serial number of current failure Vxxxxxx Vxxxxxx is a unique code V Machine related fault code E Engine related fault code FMI is Failure Mode Identifier number FG018872 Graph Data Setting Engine Dial Voltage Flow Con Flow Con Fuel Level Hydraulic Power Shift Flow Control ...

Page 762: ... are produced failure information can be checked using the jog switch 1 Figure 118 NOTE Count xxx xxx means that totally counted number of the same fault Occurrence Time It indicates the period for which machine has operated until a fault takes place For more than two occurrences of the same fault until first occurrence time Failure Log Information NO Code FMI Count Occurrence Time FG018876 Descri...

Page 763: ...00214 Flow Control P V E Rotating CW CN2 103 CN2 104 R 18 2 Ω 25 C 77 F V000215 Flow Control P V F Rotating CCW CN2 105 CN2 113 R 18 2 Ω 25 C 77 F V000216 Flow Control P V G CN2 115 CN2 120 R 13 5 2 Ω 25 C 77 F V000217 Press Control1 P V H CN2 112 CN2 111 R 9 5 2 Ω 25 C 77 F V000218 Press Control 2 P V I CN2 110 CN2 109 R 9 5 2 Ω 25 C 77 F V000219 Fan Control P V J CN2 116 CN2 121 R 22 5 2 Ω 25 C ...

Page 764: ... 36 V 1 V V000239 OWD Press Sensor CN1 20 CN1 38 V 1 V V000240 Px Front Press Sensor CN1 22 CN1 40 V 1 V V000241 Py Travel Press Sensor CN1 23 CN1 41 V 1 V V000242 Parking Brake Press Sensor CN1 24 CN1 42 V 1 V V000243 Boom Up Press Sensor CN5 4 CN5 14 V 1 V V000244 Boom Down Press Sensor CN5 2 CN5 12 V 1 V V000245 Bucket CR Press Sensor CN5 3 CN5 13 V 1 V V000246 Bucket Dump Press Sensor CN5 1 CN...

Page 765: ... R 2 5 0 3 kΩ V000255 Machine Speed Sensor CN2 91 CN2 84 V000256 Fuel Sensor CN1 14 CN1 32 Empty 5 0 2 kΩ Full 320 32 Ω V000257 Alternator Potential CN1 2 V 2 1 V It has to be measured in engine stop state V000258 Dial CN1 16 CN1 34 R 1 0 0 3 kΩ R 4 0 1 5 kΩ V000259 Angle Sensor A CN5 10 CN5 20 V 0 5 V excess V 4 5 V less than V000260 Angle Sensor B CN5 9 CN5 19 V 0 5 V excess V 4 5 V less than V0...

Page 766: ...ent temperature 23 5 C Supply voltage 5 0 25 V Boost pressure is default value setting Boost pressure correction is stopped E000108 Barometric Pressure Sensor in ECU ECU internal Torque limit 10 EGR valve 0 Signal range 4877 8 mV 178 4 mV E000110 Coolant Temperature 2 39 2 59 20 C R 2 5 kΩ 5 100 C R 0 186kΩ 2 Default value of coolant temperature at engine start 20 C during engine running 90 C Torq...

Page 767: ... exhaust emissions 6 cylinder Activate Q limit for regeneration stop E000736 Solenoid Power Stage 3 Cylinder 3 2 50 2 74 E000737 Solenoid Power Stage 4 Cylinder 6 2 26 2 02 E000738 Solenoid Power Stage 5 Cylinder 2 2 51 2 75 E000739 Solenoid Power Stage 6 Cylinder 4 2 27 2 03 E000977 Auto Fan Clutch PWM Out 1 74 1 87 Coil R 25Ω 10 at 20 C No torque limit E001207 Engine ECU Temperature No torque li...

Page 768: ...mperature 1 16 1 18 25 C R 220 1 Ω 1 9Ω 100 C R 276 4 Ω 1 9Ω Torque limit level 2 E004767 Diesel Oxidation Catalyst Differential Pressure 1 90 1 55 0 kPa 0 bar V 0 5 V 2 100 kPa 1 bar V 4 5 V 2 40 135 C Supply voltage 5 5 V Torque level 1 E005456 MU Hydrocarbon Doser Intake Fuel Temperature 1 42 1 33 20 C R 2 416 kΩ 3 4 100 C R 0 182 kΩ 2 0 Display Code E005465 Pressure Control Regulator Display c...

Page 769: ...eater 1 83 E520611 Time Out Error of CAN Receive Frame Vehicle Cutoff Switch CAN signal No torque limit E520612 Accelerator Pedal CAN Max Error CAN signal Torque level 2 E520613 Vehicle Cutoff Switch Error CAN signal No torque limit E520614 Time Out Error of CAN Receive Frame VGT CAN signal Torque limit 1 E520615 Performance Limit Activation Internal fault Torque limit level 3 E520616 ECU Power St...

Page 770: ... 100 C R 0 178 kΩ 2 28 No torque limit E520637 Actuator Relay 0 Error Internal fault No torque limit E520638 Actuator Relay 1 Error Internal fault No torque limit E520639 Actuator Relay 2 Error Internal fault No torque limit E520640 Actuator Relay 3 Error Internal fault No torque limit E520601 ECU Hardware Chip CY320 Error Internal fault No torque limit E520641 Monitoring of Complete ROM Test Inte...

Page 771: ...torque limit E520653 Forced Regeneration Inhibit Switch 1 58 No torque limit E520654 MSC Errors of R2S2 1 70 No torque limit E520655 MU Shut Off Valve 1 20 1 45 R 3 3Ω 5 at 20 C Display code GP Display Code GP Display Description Measuring Point Correct Value Remarks Active Passive FMI 0 Above normal range DATA VALID but ABOVE NORMAL OPERATIONAL RANGE FMI 1 Below normal range DATA VALID but BELOW ...

Page 772: ...n will be displayed Figure 140 2 Operating Hours Screen 3 Exiting Submenus If escape button ESC 4 on Figure 118 is pressed for more than 1 second this information screen will be returned to previous screen FG018877 Service Menu Monitoring Graph Failure Information Operationg Hour Information Vehicle Configuration s DIG ISO USB Figure 139 FG018878 Operationg Hour Power Mode Standard Mode Economy Mo...

Page 773: ... speed are displayed 1st High speed s v OFF status 2nd High speed s v and travel pressure sensor Py control valve over 15 5 bar 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 169 186 F 86 95 C 187 203 F Over 96 C 204 F The resistance delivered fro...

Page 774: ...SP002337 Electrical System Page 86 Example of Machine Operation Info Screen Operationg Hour Operationg Hour FG018879 Operationg Hour Figure 141 ...

Page 775: ...revious screen Option Setting 1 Entering Submenus When a cursor is located in Option Setting of special menu screen Figure 144 press jog switch 1 on Figure 118 and Option Setting screen will be displayed Figure 145 FG018880 Service Menu Monitoring Graph Failure Information Operationg Hour Information Vehicle Configuration s DIG ISO USB Figure 142 FG018881 Vehicle Configuration Option Setting Progr...

Page 776: ...1 on Figure 118 and Program Update Screen will be displayed Figure 148 NOTE When USB memory is installed in jack assy program update can be updated FG018881 Vehicle Configuration Option Setting Program Update Vehicle Serial Number Vehicle Information Delete Vehicle Information s DIG ISO USB Figure 145 FG018884 Breaker Two Way Not Attached Not Available Option Setting Attachment Option DMB Option T...

Page 777: ...hicle Information Delete Screen will be displayed Figure 152 NOTE When press jog switch 1 on Figure 118 in the selected menu the menu will be initialized Delete Failure Log Reset Operation Hour GP Setting Reset FG018887 Vehicle Configuration Option Setting Program Update Vehicle Serial Number Vehicle Information Delete Vehicle Information s DIG ISO USB Figure 149 FG018888 Vehicle Serial Number Ent...

Page 778: ...tch 1 on Figure 118 and Version Information Screen will be displayed Figure 154 FG018891 Vehicle Configuration Option Setting Program Update Vehicle Serial Number Vehicle Information Delete Vehicle Information s DIG ISO USB Figure 153 FG018893 V0510 2010 06 24 V0101 2010 05 24 V0101 2011 05 19 Version Information EPOS S W Version GP S W Version GP OS Version Figure 154 ...

Page 779: ...SP002337 Page 91 Electrical System ...

Page 780: ...tem Page 92 ELECTRONIC HYDRAULIC CONTROL SYSTEM e EPOS Control System Schematic E G E G speed order FG018898 5 4 4 3 8 8 7 7 15 6 6 11 13 12 14 10 9 2 16 17 20 18 21 19 22 1 E H H F C C rpm AM Min Max s DIG ISO USB Figure 155 ...

Page 781: ...Proportional Pressure Reducing Valve Attachment 10 Electromagnetic Proportional Pressure Reducing Valve Mode Control 11 Solenoid Valve Boost 12 Solenoid Valve High speed 13 Solenoid Valve Breaker 14 Travel Motor 15 Main Relief Valve 16 Engine Control Dial 17 Jog Switch Control Panel 18 Auto Travel Selector Switch 19 Boost Switch Right Work Lever 20 Sensor 21 Aux Mode Switch 22 Aux Mode Resistor Re...

Page 782: ... 156 Reference Number Description 1 Instrument Panel Power Mode Selector Switch 2 e EPOS Controller 3 Engine Controller ECU 4 Main Pump 5 Aux Pump 6 Control Valve 10 Electromagnetic Proportional Pressure Reducing Valve Mode Control 17 Engine Control Dial 22 Aux Mode Switch 23 Aux Mode Resistor 32 Jog Switch Control Panel Reference Number Description ...

Page 783: ... standard mode The desired mode can be selected by pressing the jog switch on the jog switch control panel When the power mode is selected the indicator light will turn ON to display the selected mode The quantity of oil discharged by the pump and the engine speed are determined by the mode selected by the operator The pump output in each mode is determined by the mode selection and is listed in t...

Page 784: ...nd 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 maximum power can be generated In Power Mode the e EPOS controller receives engine speed signals from the engine control dial and the engine controller ECU and converts it to ...

Page 785: ...Mode The EPOS controller compares the target engine speed with the actual engine speed and controls the signal to the EPPR valve which in turn varies the pump output quantity and it is the same method with power volume B D C A FG018902 Power Plus Mode Power Mode Standard Mode Economy Mode Figure 160 Reference Number Description A Engine Horsepower hp B Engine Speed rpm C Pump Discharge Volume lpm ...

Page 786: ...2 1 9 5 8 14 15 7 6 20 19 7 1 GND TxD RxD GND 5V GND SIG 1 2 3 4 5 6 7 8 11 10 9 15 16 17 14 13 12 21 24 23 22 19 20 18 39 40 41 42 43 34 35 36 37 38 33 29 30 31 32 28 27 26 25 52 58 62 60 61 59 56 57 54 55 53 45 48 49 50 51 46 47 44 71 77 81 80 79 78 76 75 74 73 72 64 70 69 68 67 66 65 63 114 115 116 117 118 121 120 119 88 82 83 84 85 86 87 89 93 92 91 90 97 96 95 94 101 100 99 98 105 104 103 102...

Page 787: ... Controller 10 EPPR Valve Electromagnetic Proportional Pressure Reducing 17 Engine Control Dial 22 Aux Mode Switch 23 Aux Mode Resistor 24 Battery 25 Battery Relay 26 Fuse 27 Fusible Link 28 Starter Switch 32 Jog Switch Control Panel 33 Engine Emergency Stop Switch 34 Circuit Breaker Reference Number Description ...

Page 788: ... controller converts this output voltage of dial to digital signal and sends it to the engine controller by CAN line According to the dial command the quantity of fuel injection is adjusted FG000584 Drive Signal Command Signal 3 4 17 Figure 162 Reference Number Description 3 Engine Controller 4 e EPOS Controller 17 Engine Control Dial Reference Number Description ...

Page 789: ...2 and 3 terminals will vary from the 5 V supplied from the e EPOS controller as shown in the graph FG018941 Mechanical 13th Step 1st Step Stop CW Mechanical Stop CCW 7th Step 1 2 3 13th 2nd CCW Stop Stop 0 1st 7th 12th CW Step 1 0V 4 0V Output Voltage V 2 1 3 4 5 2 5V 1 2 Figure 163 Reference Number Description 1 Knob 2 Hall Effect Sensor Reference Number Description ...

Page 790: ...1 68 67 66 65 72 71 70 69 57 73 75 74 76 84 80 78 79 77 83 82 81 88 87 86 85 92 91 90 89 96 95 94 93 EPOS CN1 EPOS CN2 GAUGE CN7 GAUGE CN6 AMP 040 36P 16 10 11 12 13 14 15 9 8 4 3 2 1 7 5 6 18 11 12 13 16 17 10 4 3 2 1 9 5 8 14 15 7 6 20 19 5 1 6 1 35 RS1 2 1 1 76 15A 26 36 7 4 7 3 6 13 6 12 7 2 7 5 7 6 7 1 GND TxD RxD GND 5V SIG 1 2 3 4 5 6 7 8 11 10 9 15 16 17 14 13 12 21 24 23 22 19 20 18 39 40...

Page 791: ...oller 10 EPPR Valve Electromagnetic Proportional Pressure Reducing 17 Engine Control Dial 24 Battery 25 Battery Relay 26 Fuse 27 Fusible Link 28 Starter Switch 32 Jog Switch Control Panel 33 Engine Emergency Stop Switch 34 Circuit Breaker 35 Solenoid Valve Pressure Up 36 Power Boost Switch Reference Number Description ...

Page 792: ...ELERATION CONTROL AUTOIDLECONTROL E G FG018916 2 4 1 3 5 5 Figure 165 Reference Number Description 1 Jog Switch Control Panel Auto Idle Switch 2 e EPOS Controller 3 Engine Controller 4 Engine Control Dial 5 Pressure Sensor Reference Number Description ...

Page 793: ...tch 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 engi...

Page 794: ...ol signal FG018917 6 6 4 4 5 7 31 2 3 1 E H H F C C rpm AM Min Max s DIG ISO USB Figure 166 Reference Number Description 1 Instrument Panel 2 e EPOS Controller 3 Engine Controller 4 Main Pump 5 Aux Pump 6 Control Valve 10 EPPR Valve Electromagnetic Proportional Pressure Reducing Valve 31 Warning Buzzer Reference Number Description ...

Page 795: ...e 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 wi...

Page 796: ...C rpm AM Min Max s DIG ISO USB Figure 167 Reference Number Description 1 Instrument Panel 2 e EPOS Controller 3 Engine Controller 4 Main Pump 5 Aux Pump 6 Control Valve 11 Solenoid Valve Boost 16 Main Relief Valve 18 Jog Switch Control Panel 20 Power Boost Switch Top of Right Work Lever Reference Number Description ...

Page 797: ...ight hand work lever joystick is pressed during work the e EPOS controller will activate the power boost solenoid valve and increase the relief valve pressure from 350 to 370 kg cm2 4 980 5 260 psi for 7 seconds The excavation ability is increased by approximately 6 When the power boost function is in activated a power boost symbol appears on the information display department of instrument panel ...

Page 798: ...2 61 68 67 66 65 72 71 70 69 57 73 75 74 76 84 80 78 79 77 83 82 81 88 87 86 85 92 91 90 89 96 95 94 93 EPOS CN1 EPOS CN2 GAUGE CN7 GAUGE CN6 AMP 040 36P 16 10 11 12 13 14 15 9 8 4 3 2 1 7 5 6 18 11 12 13 16 17 10 4 3 2 1 9 5 8 14 15 7 6 20 19 5 1 6 1 35 RS1 2 1 1 76 15A 26 36 7 4 7 3 6 13 6 12 7 2 7 5 7 6 7 1 GND TxD RxD GND 5V SIG 1 2 3 4 5 6 7 8 11 10 9 15 16 17 14 13 12 21 24 23 22 19 20 18 39...

Page 799: ... 3 Engine Controller 4 e EPOS Controller 17 Engine Control Dial 24 Battery 25 Battery Relay 26 Fuse 27 Fusible Link 28 Starter Switch 32 Jog Switch Control Panel 34 Circuit Breaker 35 Solenoid Valve Pressure Up 36 Power Boost Switch Top of Right Work Lever Reference Number Description ...

Page 800: ...9 3 Figure 169 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 801: ...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 802: ... 9 15 16 17 14 13 12 21 24 23 22 19 20 18 39 40 41 42 43 34 35 36 37 38 33 29 30 31 32 28 27 26 25 52 58 62 60 61 59 56 57 54 55 53 45 48 49 50 51 46 47 44 71 77 81 80 79 78 76 75 74 73 72 64 70 69 68 67 66 65 63 114 115 116 117 118 121 120 119 88 82 83 84 85 86 87 89 93 92 91 90 97 96 95 94 101 100 99 98 105 104 103 102 109 108 107 106 113 112 111 110 Figure 170 Reference Number Description 2 e E...

Page 803: ...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 171 Reference Number Description 1 Upper Digit 2 Lower Digit 3 Engine Speed Monitor LED Flash Interval Increases With Engine Speed...

Page 804: ...Power Mode P P Normal Operation Power Mode S Normal Operation Standard Mode E Normal Operation Economy Mode Work Mode Digging Normal Operation Digging Mode Lift Normal Operation Lift Mode HAOH340L HAOH340L FG018940 FG018938 FG018940 HAOH350L FG018940 FG018940 HAOH370L FG018940 FG018939 Error Code Indication Code Fault Location V201 01 Communication error in instrument panel V202 02 Communication e...

Page 805: ...nstalled in the cover behind the operator s seat Temperature of the operator s cabin is adjusted automatically to the temperature set by operator Please refer to the Operation and Maintenance Manual for detailed full automatic control Vent mode selects the direction of discharged air FG019033 A A C B Figure 172 ...

Page 806: ...ely 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 cover Modes Outlets A A...

Page 807: ...s at the rear side of the cabin to open the cover 3 Remove filter attached to the cover and clean the contaminated filter using compressed air 4 Close the cover replace the knobs and secure the cover to the support with butterfly bolts FG016044 Figure 175 ...

Page 808: ...6 8 8 9 4 5 5 6 7 2 3 Figure 176 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 809: ...L 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 g CN9 3 CN9 18 0 5LgB g 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 5G...

Page 810: ...al System Page 122 Air Conditioner heater Unit Airflow Diagram VENT DEF FOOT Heater Core Evaporator Fan Internal Air External Air DOOR MIX COOL WARM FG016942 DOOR INTAKE External Air Inlet Internal Air Inlet Figure 178 ...

Page 811: ...pen by Vent Modes Main Components Door Mode Vent Bi level Foot Def foot Def Vent 100 60 0 0 0 Foot 0 40 100 80 60 Def 0 0 0 20 40 FG016943 Blower Motor Actuator Internal external Air Exchanger Internal Air Sensor Internal Air Filter Figure 179 ...

Page 812: ...ure Control Change of discharged air temperature by controlling the position of temperature control door Actuator Airflow Direction Control Actuator Temperature Control FG001361 N P2 c b e P2 P1 c b e Figure 180 Airflow 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 ...

Page 813: ... on manual set CN10 20 CN10 2 FG001055 P2 P1 c e N P2 P1 Figure 181 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 182 Airflow 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 814: ...or 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 183 Specifications Rated voltage 24V Rated current 20A FG001058 L S1 S2 B Figure 184 Specifications Rated voltage 24V Rated current 10A Figure 185 Temperature C Resistance KΩ 0 11 36 0 1 2 10 39 0 2 2 5 10 1...

Page 815: ...ure Ambient Air Temperature Sensor Built at the bottom of the cockpit it senses the temperature of external air Figure 186 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 187 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 188 Temperature C Resistance KΩ 10 163 4 9 0 96 9 2 9 10 59 4 1 8 20 37...

Page 816: ...or 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 189 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 190 ...

Page 817: ...k 4 Ambient air temperature sensor 5 Power KEY ON 5 Internal air temperature sensor 6 Backup 6 7 7 8 A C output LOW 8 9 9 10 Ground 10 D P S CHECK 11 Illumination 11 Airflow module gate 12 Intake Recirculate Recirculate 12 Blower motor feedback 13 Intake Recirculate Intake 14 Airflow direction control VENT 15 Airflow direction control DEF 16 Airflow direction control Power 5V 17 Airflow direction ...

Page 818: ...r temperature sensor Ambient air temperature sensor Coolant temperature gauge sensor 1 In case of sensor fault the following defaults are applied Internal air temperature sensor 25 C Ambient air temperature sensor 25 C Duct sensor 2 C Temperature control actuator Set Temperature 17 24 5 C Max cooling Set Temperature 25 32 C Max heating Airflow direction mode actuator VENT VENT fix modes other than...

Page 819: ...ol 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 airflow in 5 seconds after engine run 5 Initial cooling control should be before max cooling 6 Release condition OR condition A A C OFF B Airflow Manual control C Release is possible with the OFF switch but not allowed within 12 seconds after ...

Page 820: ...le of engine OFF engine run 3 Initial heating control should be before max heating 4 Airflow is controlled only when the airflow direction is in the manual mode and BI LEVEL FOOT or FOOT DEF is set 5 Control through the coolant temperature gauge sensor for start 6 Starting control of heating 2 starts in case of fault of the coolant temperature gauge sensor during controlling 7 Operation release OR...

Page 821: ... control of heater C Difference between internal and ambient air temperature 15 C D When Max Cooling 17 C is selected 5 Exceptional case Starting control of heating is performed only once during the remaining period if the entry condition is satisfied within the starting control period that is the accumulation of initial start times Inclusive of Auto mode ON case within the period of starting cont...

Page 822: ...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 823: ...erature 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 open E7 Sun ...

Page 824: ...ponding immediately to the change of level in the freezing cycle As liquid refrigerant from the condenser may contain refrigerant gas with bubbles whose presence in the expansion valve decreases the freezing power excessively it separates liquid and gas and sends liquid only to the expansion valve Water in refrigerant shall be eliminated with dryer and through filter FG001365 Relief Valve Figure 1...

Page 825: ...tion 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 replac...

Page 826: ...ssible 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 time replace the receiver dryer 6 High pressu...

Page 827: ...X180LC 3 800 20 grams 28 0 7 oz DX225LC 3 800 20 grams 28 0 7 oz DX255LC 3 800 20 grams 28 0 7 oz DX300LC 3 800 20 grams 28 0 7 oz DX340LC 3 800 20 grams 28 0 7 oz DX350LC 3 800 20 grams 28 0 7 oz DX380LC 3 800 20 grams 28 0 7 oz DX420LC 3 800 20 grams 28 0 7 oz DX490LC 3 800 20 grams 28 0 7 oz DX530LC 3 800 20 grams 28 0 7 oz ...

Page 828: ...gles and gloves when handling refrigerant If refrigerant comes in contact with the skin or eyes immediately flush with clean running water and consult a physician Select a clean and well ventilated area to work The refrigerant container is under high pressure and should be stored below 40 C 104 F Be careful not to drop the container from a high location The contents are under high pressure and sho...

Page 829: ...the refrigerant line lip Always use new O rings when reassembling parts Do not reuse old O rings 8 Use a vacuum pump to evacuate refrigerant system of air 9 When charging the refrigerant system with the engine running do not open the high pressure valve on the manifold gauge as the reverse flow of high pressure refrigerant will rupture the hose 10 When releasing the high pressure hose after comple...

Page 830: ...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 198 ...

Page 831: ...ge 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 sh...

Page 832: ... mounting 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 ...

Page 833: ... 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 manifold gauge low si...

Page 834: ...d close refrigerant supply container adapter valve Disconnect manifold gauge hoses from machine WARNING AVOID DEATH OR SERIOUS INJURY When charging refrigerant system with the engine running Always keep refrigerant supply container in the upright position Never open the high side pressure valve 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...

Page 835: ...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 836: ...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 206 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 837: ...he 5 and 6 terminals of the wiper motor are connected still that power is supplied to the 6 terminal of the wiper controller 6 However the controller 6 runs the wiper motor continuously and then rotates the motor reversely by letting current flow by the 4 terminal of the wiper controller 6 the 2 and 4 terminals of the wiper motor 5 the 3 terminal of he wiper controller 6 when the 1 and 6 terminals...

Page 838: ... operation Intermittent 2nd 6 second Pressing twice the Intermittent switch in the switch panel 7 changes voltage of the 10 terminal in the wiper controller 6 from HIGH about 5 5 0 5 V to LOW 0 0 5 V and current flows through the 3 terminal in the wiper controller 6 the 2 and 4 terminals in the wiper motor 5 the 4 terminal in the wiper controller 6 to start the cycle that wiper stops 6 seconds aft...

Page 839: ...SP002337 Page 151 Electrical System ...

Page 840: ...ircuit Diagram 6 4 6 5 6 12 6 11 6 9 6 10 L6 1 78 1 77 1 59 1 5 1 4 1 74 1 3 1 1 CAN 30A 15A 15A 20A 15A 30 3 85 86 II I 0 II I 7 6 30 87 0 2 2 8 5 8 5 II 3 I 7 6 I II 0 0 30 86 87a 85 87 87 85 87 85 86 30 86 87a 16 14 9 8 10 11 3 2 1 4 15 13 7 6 12 5 FG018942 Figure 207 ...

Page 841: ...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 842: ...rning Device Circuit Diagram FG018950 1 1 6 SIG 0 7 I 1 10 5 9 1 38 1 20 1 45 1 5 1 3 1 4 3 5 4 20A 10A 1 2 Figure 208 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 843: ...6 17 1 10 14 7 8 2 3 5 4 6 1 Handsfree Unit 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 Figure 209 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse Box 4 Fusible Link 5 Hands free Unit 7 Audio Control Panel 8 Stereo 9 Speaker 10 Antenna Module 11 Light Switch Reference Number Description Switch Connected Terminal of switch Measured values Operations...

Page 844: ...SP002337 Electrical System Page 156 ...

Page 845: ...SP002508 Page 1 Electrical Schematic SP002508 ELECTRICAL SCHEMATICSP002508 1Electrical Schematic Edition 1 ...

Page 846: ...SP002508 Electrical Schematic Page 2 MEMO ...

Page 847: ...SP002508 Page 3 Electrical Schematic Table of Contents Electrical Schematic Safety Instructions 5 Applicable Models 5 DX140LC 3 DX180LC 3 DX225LC 3 DX255LC 3 7 ...

Page 848: ...SP002508 Electrical Schematic Page 4 MEMO ...

Page 849: ...and the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX140LC 3 1001 and Up 50001 and Up DX180LC 3 1001 and Up 50...

Page 850: ...SP002508 Electrical Schematic Page 6 ...

Page 851: ...0 85RG RR K1055454 x2 RL 1 25B 0 5RG 0 85B REAR CABIN LAMP 0 85RG 1 25RL 0 85B REAR 0 85RG 1 25RG 7 6 XXXXXXX 0 5B 1 25RW LH 0 85B 0 85B 0 85RW HEAD LAMP K1055454 x2 RH 0 85RW 0 85RG LH 0 85B RH 0 85B 301005 00132 x2 WORKING LAMP 2RG 0 85RG 87a K1053326 0 5RG 0 5B HEAD LAMP RELAY 87 85 1 25RY 86 30 301202 00042 WORKING LAMP RELAY 85 86 0 5RG 87 2RY 30 549 00103 K1056625 LAMP SWITCH 0 5WR 8 7 0 5B ...

Page 852: ......

Page 853: ...1Attachments ...

Page 854: ......

Page 855: ...SP002505 Page 1 Boom and Arm SP002505 BOOM AND ARM SP002505 Boom and Arm Edition 1 ...

Page 856: ...SP002505 Boom and Arm Page 2 MEMO ...

Page 857: ...uctions 5 Applicable Models 5 Front Attachment Pin Specifications 6 DX225LC 3 7 Front Attachment Removal and Installation 8 Arm Removal Procedure 8 Boom Removal Procedure 10 Installation 11 Arm Installation Procedure 11 Boom Installation Procedure 11 Start up Procedures 12 ...

Page 858: ...SP002505 Boom and Arm Page 4 MEMO ...

Page 859: ... operating or servicing machine Read and understand the Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX225LC 3 1...

Page 860: ...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 FG018705 E D F G J K I H A B C Figure 1 ...

Page 861: ... End 90 mm 3 543 0 10 0 15 0 18 0 03 0 13 0 33 1 5 E Arm Cylinder Head 80 mm 3 150 0 06 0 11 0 18 0 03 0 09 0 29 1 5 F Arm Cylinder Rod 80 mm 3 150 0 06 0 11 0 18 0 03 0 09 0 29 1 5 G Bucket Cylinder Head 80 mm 3 150 0 06 0 11 0 18 0 03 0 09 0 29 1 5 H Arm Link 71 mm 2 795 0 06 0 11 0 18 0 03 0 09 0 29 2 0 I Arm End 80 mm 3 150 0 06 0 11 0 18 0 03 0 09 0 29 2 0 J Bucket Cylinder Rod 80 mm 3 150 0 ...

Page 862: ...ted movement and result in death or serious injury Never remove counterweight or front attachment unless the upper structure is in line with the lower structure Never rotate the upper structure once the counterweight or front attachment has been removed IMPORTANT Always break down the front attachment by removing outermost sections first the bucket before the arm the arm before the boom Reinstalla...

Page 863: ...clean plug in the end of each one Use any reasonable precautions necessary to avoid introducing dirt or other contaminants into the hydraulic system Wipe down coupling points before disconnecting hydraulic lines and use evaporative type solvent spray cleaner Tag and mark hoses for reassembly if necessary Place a sling under the arm cylinder the cylinder used to extend and retract the attachment ar...

Page 864: ...ame 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 counterweight should be removed whe...

Page 865: ...ylinder Remove sling from around the rod end arm cylinder pin withdraw the pin and lift the body of the arm cylinder to repin the mounting connection Boom Installation 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...

Page 866: ... Page 12 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 867: ...SP002506 Page 1 Bucket SP002506 BUCKET SP002506 1Bucket Edition 1 ...

Page 868: ...SP002506 Bucket Page 2 MEMO ...

Page 869: ...Bucket Table of Contents Bucket Safety Instructions 5 Applicable Models 5 Bucket Tooth Inspection and Replacement 6 Bucket O ring Replacement 7 Attachments 9 Bucket Replacement and Reversal 9 Replacement 10 Reversal 11 ...

Page 870: ...SP002506 Bucket Page 4 MEMO ...

Page 871: ... Operation and Maintenance Manual and signs decals on machine Follow warnings and instructions in the manuals when making repairs adjustments or servicing Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause death or serious injury MODEL SERIAL NUMBER RANGE DX140LC 3 1001 and Up 50001 and Up DX180LC 3 1001 and Up 50001 and...

Page 872: ...ing 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 bucket adapter is exposed See Figure 2 2 To replace a tooth 1 Figure 3 use a hammer and punch to drive the locking p...

Page 873: ...move old O ring and temporarily install the new O ring 1 Figure 6 onto the bucket boss 2 Make sure that O ring groove on both the bucket link 4 and boss have been cleaned 4 Realign the arm or link with the bucket pinhole and insert the bucket pin 3 Figure 5 WARNING AVOID DEATH OR SERIOUS INJURY Prevent injury from flying metal objects Always wear safety helmet protective gloves and eye protection ...

Page 874: ...SP002506 Bucket Page 8 5 Roll the new O ring 1 Figure 7 into the O ring groove FG019075 1 Figure 7 ...

Page 875: ...ves and other protective equipment When the bucket is removed place it in a stable condition If pins are hit with a strong force there is a hazard that pin may fly out and injure people in the surrounding area Make sure that there is no one in the surrounding area before starting the operation When removing the pins do not stand behind the bucket In addition be extremely careful not to put your fo...

Page 876: ... 5 Install the stopper bolts and nuts for each pins 6 Lubricate with grease thoroughly until the grease comes out from the end face 5 A 6 B FG020108 Figure 8 IMPORTANT When removing the pins place the bucket so it is in light contact with the ground If the bucket is lowered strongly to the ground the resistance will be increased and it will be difficult to remove pins After removing the pins make ...

Page 877: ...face Figure 11 5 A 6 B FG020108 IMPORTANT When removing the pins place the bucket so it is in light contact with the ground If the bucket is lowered strongly to the ground the resistance will be increased and it will be difficult to remove pins After removing the pins make sure that mud or sand does not get on them Dust seals are fitted at both ends of the bushings be careful not to damage them Fi...

Page 878: ...SP002506 Bucket Page 12 ...

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