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023-00047E Shop Manual

Daewoo reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.

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

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

Shop Manual

023-00047E

Serial Number 1001 and Up

May 2002

Solar 470LC-V

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Summary of Contents for Solar 470LC-V

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

Page 2: ......

Page 3: ...Product Label Instructions Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine Solar 470LC V Serial Number 1001 and Up Pub No 023 00047E Pub No 023 00047E...

Page 4: ......

Page 5: ...tructure Cab S0402040K Counterweight S0403050K Fuel Tank S0405120K Fuel Transfer Pump S0405500 Swing Bearing S0407000 Swing Reduction Gearbox S0408060 Lower Structure and Chassis Track Assembly S05051...

Page 6: ...Control Valve Kayaba Model KVMG 400 DA S0709402K Pilot Control Valve Work Lever Joystick S0709452K Travel Control Valve With Damper S0709820K Hydraulic Schematic S470LC V S0792170K Electrical System E...

Page 7: ...1SAFETY...

Page 8: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Page 43: ...series connected twelve volt batteries have a cable connecting one positive terminal on one of the 12 volt batteries to a negative terminal on the other battery Booster or charger cable connections m...

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

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

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

Page 47: ...1SPECIFICATIONS...

Page 48: ......

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

Page 50: ...ange 8 General Specifications 10 Engine Performance Curves Per DIN 6270 Standard 12 Approximate Weight of Workload Materials 14 Performance Tests 17 Excavator Performance Standards 18 Test Conditions...

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

Page 52: ...S0202090K Page 4 Specifications for Solar 470LC V COMPONENT LOCATIONS Figure 1 1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 17 16 15 14 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 ASO0010L...

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

Page 54: ...S0202090K Page 6 Specifications for Solar 470LC V...

Page 55: ...m 27 8 8 515 mm 27 11 D 4 470 mm 14 8 E 5 465 mm 17 11 F 1 460 mm 4 9 G 3 905 mm 12 10 3 705 mm 12 1 3 940 mm 12 11 H 2 990 mm 9 10 CAT Walk 3 278 mm 10 9 I 1 500 mm 4 11 CAT Walk 1 788 mm 5 10 J 1 49...

Page 56: ...h depends on the stability and support provided by ground conditions Digging too far underneath the excavator if soil conditions are wet loose or unstable can collapse ground support which could cause...

Page 57: ...420 mm 27 8 D Max Loading Height 7 760 mm 25 6 7 900 mm 25 11 8 070 mm 26 6 F Max Digging Height 10 940 mm 35 11 11 810 mm 36 4 11 230 mm 36 10 G Max Bucket Pin Height 9 560 mm 31 4 9 705 mm 31 10 9...

Page 58: ...g 22 000 lb Lower below Swing Bearing 18 195 kg 40 100 lb Digging Forces Bucket Cylinder 267 KN or 27 200 kg 59 970 lb with 3 350 mm 11 0 standard arm Arm Cylinder 216 KN or 22 100 kg 48 720 lb with 3...

Page 59: ...andard shoes 3 900 mm 12 9 Extended Working 3 340 mm 10 11 Retracted Transport Overall Shipping Height to top of cylinder hose 3 705 mm 12 1 Track Shipping Length 5 465 mm 17 11 Transport Trailer Capa...

Page 60: ...Specifications for Solar 470LC V ENGINE PERFORMANCE CURVES PER DIN 6270 STANDARD REVOLUTION rpm 1000 200 2000 1500 FUEL CONSUMPTION g ps h 170 130 110 TORQUE kg m 160 100 300 120 150 POWER OUTPUT ps...

Page 61: ...ometric Pressure 760 mmHg 20 C 68 F Cooling Fan 813 mm SUCKER 32 in Alternator 24V x 50A Air Cleaner Installed Muffler Installed Performance Standard DIN 6270 Power 316 ps 2 000 rpm 312 hp 2 000 rpm M...

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

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

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

Page 65: ...4 3 0 4 3 9 0 4 Down sec 3 0 0 3 3 0 0 3 Arm Dump sec 3 4 0 4 3 1 0 3 Crowd sec 5 1 0 4 4 6 0 4 Bucket Dump sec 3 1 0 3 3 0 0 3 Crowd sec 3 3 0 3 2 9 0 4 Swing 3 Revolutions sec 18 8 1 5 17 5 1 5 Jack...

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

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

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

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

Page 70: ...S0202090K Page 22 Specifications for Solar 470LC V...

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

Page 72: ......

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

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

Page 75: ...repairs on these types of steel are performed with the proper procedures and equipment If repairs are performed incorrectly structural weakening or other damage to the machine that is not always readi...

Page 76: ...fluid is recommended Vibration irregular or difficult movement or unusual noise from any part of the hydraulic system could be an indication of air in the system and many other types of problems As a...

Page 77: ...tion of air leaking into the circuit Refer to the appropriate Troubleshooting section for component or unit for procedures or it may be evidence of a defective pump The gear type pilot pump could be d...

Page 78: ...of flanges manifolds and piping Do not allow cleaning solvents or other fluids to mix with the oil in the system Use clean oil to flush any traces of solvent or other residue before reassembly If met...

Page 79: ...across bearing to avoid spinning bearings that are not lubricated DO NOT SPIN BEARINGS WHEN DRYING bearings may be rotated slowly by hand to facilitate drying process 3 Carefully inspect all bearing r...

Page 80: ...always carefully examine the condition of the bearings and all of its components for wear and damage Once the bearing is removed clean all parts thoroughly using a suitable cleaning solution If the be...

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

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

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

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

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

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

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

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

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

Page 90: ...ed 0 70 when Molykote white lead or similar mixtures are used as lubricants 0 75 when parkerized bolts or nuts are used 0 85 when cadmium plated bolts or nuts and zinc bolts w waxed zinc nuts are used...

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

Page 92: ...es shown below also apply to the following 1 Phosphate coated bolts used in tapped holes in steel or gray iron 2 Phosphate coated bolts used with phosphate coated prevailing torque nuts nuts with dist...

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

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

Page 95: ...e end of the torque wrench doubles the tightening force on the bolt It also halves the indicated reading on the scale or dial of the torque wrench To accurately adjust or convert indicated scale or di...

Page 96: ...on and accuracy To allow the assembly or mechanism to accept a torque wrench welding a nut or other adapter on the end of a linkage shaft or other leverage point will allow turning the shaft or assemb...

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

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

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

Page 100: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Page 118: ...S0405120K Page 2 Fuel Tank TABLE OF CONTENTS General Description 3 Parts List 4 Specifications 5 Removal 6 Installation 10 Start up Procedures 12...

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

Page 120: ...S0405120K Page 4 Fuel Tank PARTS LIST 3 7 5 6 4 23 10 9 8 19 14 35 35 33 33 20 12 11 13 26 16 1 FRONT ASS1180L Figure 1...

Page 121: ...ence Number Description 1 Fuel Tank 3 O ring 4 Cover 5 Bolt M10x1 5x25 6 Spring Washer 7 Drain Cock 8 Bolt M16x2 6x60 9 Shim 10 Shim 11 Fuel Filter 12 Cap 13 Plug 14 Level Gauge 16 O ring 19 O ring 20...

Page 122: ...representing 10 percent of total fuel supply Also look at level gauge on side of tank to estimate volume of fuel left in tank NOTE If possible work excavator until available fuel supply in tank has be...

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

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

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

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

Page 127: ...Connect as tagged fuel supply line 1 Figure 14 and fuel return line 2 to fuel tank 3 9 Install clamp 4 Figure 14 to hold fuel return line 2 to tank 3 10 Make sure fuel tank drain valve Figure 15 on bo...

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

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

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

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

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

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

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

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

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

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

Page 138: ...d to the pinion by planetary gears connected to gears on the inner ring which is fixed in the undercarriage Ball bearings turn the outer ring REBUILDING SWING BEARING 1 Remove tip of tapered pin 1 Fig...

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

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

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

Page 142: ...on 3 Theory of Operation 3 Parts List 4 Specifications 5 Special Tools and Materials 6 Special Tools 6 Troubleshooting Testing and Adjustment 8 Removal 9 Disassembly 11 Cleaning and Inspection Wear Li...

Page 143: ...gears and two step output reduction The planetary gear engages with the ring gear The pinion gear is connected with the output shaft and spline The final drive reduces swing motor rpm to increase swin...

Page 144: ...S0408060 Page 4 Swing Reduction Gearbox PARTS LIST 2 3 5 4 1 27 27 31 16 7 8 10 20 33 32 19 29 30 17 25 23 22 6 18 14 13 12 11 15 9 28 24 37 38 39 34 36 35 26 HAAA4260 Figure 1...

Page 145: ...20 No 1 Carrier 21 22 No 1 Planet Gear 23 No 1 Pin Assembly 24 Socket Bolt 25 No 1 Sun Gear 26 Spacer 27 Plug 28 Plug 29 Level Gauge Pipe 30 Level Gauge 31 Double Tab Washer 32 Pipe 33 Snap Ring 34 P...

Page 146: ...nt A 130 0 mm 5 1181 in Dia B 100 0 mm 3 9370 in Dia C 83 0 mm 3 2677 in Dimension Measurement A 10 0 mm 0 3937 in B 20 0 mm 0 7874 in C 99 0 mm 3 8976 in Dia D 123 0 mm 4 8425 in Dia E 40 0 mm 1 5748...

Page 147: ...A 18 0 mm 0 7087 in Dia B 26 0 mm 1 0236 in Dia C 40 0 mm 1 5748 in Dia D 10 0 mm 0 3937 in E 1 0 mm 0 0394 in Radius F 2 0 mm 0 0787 in Radius Dimension Measurement A 90 10 90 20 mm 3 5472 3 5512 in...

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

Page 149: ...icks in all directions to relieve pressure from accumulators 7 Set safety lever on LOCK position 8 Turn key to OFF position and remove from starter switch 9 Hang maintenance warning tag on controls 10...

Page 150: ...isconnect grease lubrication line 3 Figure 8 from reduction gearbox 5 14 Remove twenty two bolts and washers 4 Figure 8 holding swing reduction gearbox 5 to frame 15 Using a suitable lifting device sl...

Page 151: ...lled head bolts and lock washers 10 Figure 9 lock plate 11 pinion gear 12 and spacer ring 13 from drive shaft 14 NOTE Loctite is spread on the spacer ring 13 Figure 9 when it is originally installed a...

Page 152: ...S0408060 Page 12 Swing Reduction Gearbox 4 1 27 27 7 8 10 20 33 19 17 25 23 22 6 18 14 13 12 11 15 9 28 2 31 16 3 5 39 HAAA4261 Figure 10...

Page 153: ...0 away from head of bolt 16 Remove bolt 16 double tab washer 31 and No 3 thrust washer 17 securing No 2 carrier 10 to drive shaft 2 NOTE Discard double tab washer 23 Figure 10 and use a new one at rea...

Page 154: ...rocedures refer to General Maintenance Procedures section Inspect all components in the assembly Pay particular attention to oil seals lock and spring pins and fastener bolts Using new replacement par...

Page 155: ...S0408060 Page 15 Swing Reduction Gearbox...

Page 156: ...S0408060 Page 16 Swing Reduction Gearbox REASSEMBLY 4 1 27 27 7 8 10 20 33 19 17 25 23 22 6 18 14 13 12 11 15 9 28 2 31 16 3 5 39 HAAA4261 Figure 11...

Page 157: ...aded holes in end of shaft NOTE Make sure that bearing 8 Figure 11 remains seated on shoulder 6 Hand pack bearing 4 Figure 11 and grease cavity with grease Rotate drive shaft to ensure that bearing is...

Page 158: ...S0408060 Page 18 Swing Reduction Gearbox 4 1 27 27 7 8 10 20 33 19 17 25 23 22 6 18 14 13 12 11 15 9 28 2 31 16 3 5 39 HAAA4261 Figure 13...

Page 159: ...ck pin 19 Figure 13 in No 1 ring gear 9 if replacement was necessary NOTE Coat mating faces of casing and ring gear with Loctite 609 13 Attach No 1 thrust washer 6 Figure 13 No 1 planet gear 22 and ne...

Page 160: ...33 Figure 11 or an leak failure may occur 20 Install lock plate 11 Figure 15 four lock washers and drilled head bolts 10 on drive shaft 14 NOTE Apply Loctite 262 to bolt threads NOTE Tighten bolts to...

Page 161: ...an assembly on unit 4 Install twenty two bolts and washers 4 Figure 16 to secure swing reduction gearbox 5 to frame NOTE Apply Loctite 262 to bolt threads 5 Connect tube 2 Figure 16 to reduction gear...

Page 162: ...t throttle at LOW IDLE and swing upper structure slowly two full revolutions to the left and right 4 Shut down engine and check hydraulic oil level Fill hydraulic oil tank to H mark on sight gauge 5 C...

Page 163: ...1LOWER STRUCTURE AND CHASSIS...

Page 164: ......

Page 165: ...outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling l...

Page 166: ...al 10 Track Installation 11 Front Idler Roller 12 Parts List 12 Front Idler Roller Disassembly 13 Front Idler Roller Reassembly 15 Lower Roller 16 Lower Roller Removal 17 Lower Roller Disassembly 17 L...

Page 167: ...easurement WARNING Safely measuring track tension requires two people One person must be in the operator s seat running the controls to keep one side frame in the air while the other person makes dime...

Page 168: ...oximately 460 mm 18 11 in for operation over gravel rocky terrain or over sand or snow 5 Track tension adjustments are made through the grease fitting 1 Figure 3 in the middle of each side frame Addin...

Page 169: ...elines information in General Maintenance Procedures section for general recommendations and specific safety precautions before starting any lower travel frame component rebuilding procedure Component...

Page 170: ...n Master pin Lower roller axle A 85 mm 3 35 in 84 5 mm 3 33 in 84 2 mm R 3 31 in Lower roller bushing A 85 mm 3 35 in 85 5 mm 3 37 in 86 mm R 3 39 in Axle bushing clearance 0 39 mm 0 0154 in 0 51 mm 0...

Page 171: ...A 60 mm 2 36 in 59 5 mm 2 34 in 59 2 mm R 2 33 in Upper roller bushing A 60 mm 2 36 in 60 5 mm 2 38 in 61 mm R 2 40 in Axle bushing clearance 1 mm 0 039 in 1 8 mm R 0 07 in Upper roller axle B 1 mm 0...

Page 172: ...7 in 86 mm R 3 39 in Axle bushing clearance 1 mm 0 039 in 1 8 mm 0 071 in Gap between bushing and side collar Total amount for both sides B 1 mm 0 039 in 1 5 mm 0 06 in Bushing flange thickness B 8 mm...

Page 173: ...LINKS PARTS LIST Figure 13 Reference Number Description 1 Track Link Assembly 2 Link Track R H 3 Link Track L H 4 Link Master R H 5 Link Master L H 6 Pin 7 Spacer 8 Pin Lock 9 Bushing 10 Bushing Mast...

Page 174: ...4 Remove four nuts and bolts 2 holding shoe to link Remove enough shoes to make access to lock pin easier NOTE Support track shoes with blocking so that when master pin 4 is removed tack will not fall...

Page 175: ...h blocking removed lower track frame onto track Make sure all rollers are properly positioned on track 4 Move unit backwards while feeding track up over front idler roller Continue to pull track back...

Page 176: ...rack Assembly Return to Master Table of Contents FRONT IDLER ROLLER PARTS LIST Figure 19 Part No Part Quantity 1 Bearing 2 2 Plug 1 3 Pin 2 4 O ring 2 5 Axle 1 6 Group Seal 2 7 Idler 1 8 Bushing 2 Par...

Page 177: ...R DISASSEMBLY 1 Remove plug 2 Figure 20 and drain oil from idler 7 Figure 20 2 Separate the pin 3 Figure 21 from the bearing 1 3 Use a press to remove the bearing from the axle Separate the O ring 4 F...

Page 178: ...ble of Contents 4 Detach the group seal 6 Figure 23 from the idler 7 and bearing 1 5 Use a press to separate the axle 5 Figure 24 O ring 4 and bearing 1 6 Remove bushing 8 Figure 25 with the press and...

Page 179: ...Align the bearing 1 Figure 26 and axle 5 holes and pin 3 them together 4 Install group seal 6 Figure 27 inside the idler 7 and bearing 1 NOTE Apply clean engine oil to the joint side of the group seal...

Page 180: ...resistance and hardness High quality bushings and seals will ensure long service life if lubricant is replaced at recommended intervals NOTE An exploded view of the lower roller is shown in Figure 29...

Page 181: ...mbly from track frame There is an alignment pin on each end of lower roller assembly NOTE To gain access to some rollers the link guard may have to be removed Remove four spring washers and bolts to r...

Page 182: ...and roller 5 6 Detach collar 3 Figure 33 and O rings 2 from the axle using a press LOWER ROLLER REASSEMBLY 1 Degrease clean and dry all parts before reassembly Insert bushing 7 Figure 34 into roller 2...

Page 183: ...Slide the axle inside the roller 6 Install the collar 3 Figure 37 O ring 2 and pin 1 on the remaining side 7 Fill with clean engine oil with approximately 300 cc 10 1 fluid ounces LOWER ROLLER INSTALL...

Page 184: ...S0505120 Page 20 Track Assembly Return to Master Table of Contents UPPER ROLLER NOTE An exploded view of the upper roller is shown in Figure 39 PARTS LIST Figure 39...

Page 185: ...emove mounting hardware holding upper roller assembly to track frame UPPER ROLLER DISASSEMBLY 1 Remove the plug 1 Figure 41 from the cover and drain oil 2 Remove the bolts and cover 3 Figure 42 Detach...

Page 186: ...le of Contents 3 Separate the roller 6 Figure 43 from the axle 7 4 Separate the group seal 8 Figure 44 from the roller and bracket 9 5 Separate the bushing 10 Figure 45 from the roller with a press an...

Page 187: ...47 into the roller 6 and bushing NOTE Apply clean engine oil to the joint side of the group seal Apply grease to the group seal O ring 3 Install the axle washer 5 Figure 48 and bolt 4 4 Attach O ring...

Page 188: ...S0505120 Page 24 Track Assembly Return to Master Table of Contents 7 Tighten plug 1 Figure 49 Figure 49...

Page 189: ...ADJUSTING CYLINDER PARTS LIST 11 12 10 6 2 13 5 4 1 7 8 9 3A 3B AZS0060L Figure 50 Reference Number Description 1 Body 2 Bracket 3A Rod 3B Rod Plate 4 Spring 5 Tie Bar 6 Nut 7 Rod Packing 8 Back Up R...

Page 190: ...S0505120 Page 26 Track Assembly Return to Master Table of Contents...

Page 191: ...1ENGINE AND DRIVE TRAIN...

Page 192: ......

Page 193: ...ned within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own pers...

Page 194: ...ir Discharge According to Path Selection 10 Air conditioning System Circuit Diagram 12 Troubleshooting 14 Weight of R134a Gas Used In Machines 17 Refrigerant System Repairs 18 Refrigerant Safe Handlin...

Page 195: ...air filtration system which filters out dirt and dust particles from air being circulated into operator s cab This filter should be cleaned out every 500 hours NOTE In the event that the unit is being...

Page 196: ...e 3 and inspect for any damage 6 Use compressed air to clean filter element If filter element is very dirty use a mild soap or detergent and water to clean it NOTE If water was used to clean filter be...

Page 197: ...nditioner REFRIGERANT CIRCULATION 1 2 3 4 5 6 HDA6046L Figure 4 Reference Number Description 1 Evaporator 2 Expansion Valve 3 Condenser 4 Condenser Fan 5 Compressor 6 Blower Fan 7 Receiver Dryer Refer...

Page 198: ...ir surrounding the evaporator creating a cooling effect and changes from the gas to the liquid state The refrigerant once again flows into the compressor in the gaseous state and the process is repeat...

Page 199: ...UT CONTROL PANEL OUTPUT A C CONTROL PANEL DISPLAY LOW SPEED RELAY TEMPERATURE SENSOR MID SPEED RELAY HIGH SPEED RELAY BLOWER MOTOR VENT ACTUATOR DEF ACTUATOR INTAKE ACTUATOR COMP RELAY CONDENSER FAN R...

Page 200: ...consists of a 24 step variable selector The display uses 7 Green Red two color LEDs to display the selected temperature Blower Fan Speed Control OFF Switch LOW Switch MID Switch HI Switch Compressor C...

Page 201: ...Green 3 28 V 0 2 8 Red Red Green Green Green Green Green 3 11 V 0 2 9 Red Red Red Green Green Green Green 2 93 V 0 2 10 Red Red Red Green Green Green Green 2 76 V 0 2 11 Red Red Red Green Green Green...

Page 202: ...S0605060K Page 10 Air Conditioner AIR DISCHARGE ACCORDING TO PATH SELECTION Face Rear and Defroster Foot ARS1280L Figure 10 ARS1290L Figure 11...

Page 203: ...S0605060K Page 11 Air Conditioner Face and Defroster ARS1300L Figure 12...

Page 204: ...HRS 26P 14 9 2 7 15 9 26 16 CN5 16 2 1 4 15 4 5 6 1 2 COOL 15 CN5 AMP MIC 13P 13 6 12 11 4 5 10 9 3 7 8 2 1 15 8 M 15 1 87 9 87a 87 M 85 8 87a 7 10 30 BLOWER SPEED TEMP CONTROL RECIRCLE FRESH AIR MOD...

Page 205: ...elay 10 Foot Defrost Control Actuator 11 Receiver Dryer Low High Pressure Cut Off Switch 12 Diode 13 Compressor 14 A C Control Panel 15 A C Unit 15 1 Blower Motor 15 2 Resister 15 3 High Speed Relay 1...

Page 206: ...y 1 Check for traces of refrigerant oil Yes Reassemble using correct tightening torque No Go to next step 2 Using a leak detection device or soapy water check for refrigerant leakage at all major comp...

Page 207: ...3 46 9 psi Yes Moisture in system replace receiver dryer No Contaminated system replace expansion valve Replace evaporator core assembly 5 High Pressure Over 6 18 kg cm2 85 256 psi Low Pressure 500 m...

Page 208: ...r Conditioner 7 High Pressure Over 7 0 11 0 kg cm2 100 156 psi Low Pressure 4 0 6 0 kg cm2 57 85 psi Possible Cause Low refrigerant pressure due to poor compressor compression Inspect and replace comp...

Page 209: ...Solar 170LC V 850 20 grams 30 0 7 oz Solar 170W III 1100 20 grams 38 0 7 oz Solar 200W III 1100 20 grams 38 0 7 oz Solar 200W V 850 20 grams 30 0 7 oz Solar 220LC III 950 20 grams 33 0 7 oz Solar 220L...

Page 210: ...em standards require new tools equipment and parts DO NOT attempt to use equipment use in servicing the old refrigerant system WARNING Always wear protective glasses and gloves when handling refrigera...

Page 211: ...efrigerant system with the engine running do not open the high pressure valve on the manifold gauge as the reverse flow of high pressure refrigerant will rupture the hose 10 When releasing the high pr...

Page 212: ...R AIR LEAKAGE VACUUM SYSTEM OVER 20 MINUTES CHARGE SYSTEM APPROXIMATELY 100 g CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHARGE SYSTEM TO PROPER LEVEL Standard Capacity less Initial Charge CHECK SYSTEM FOR...

Page 213: ...uge dials indicates 0 kg cm2 0 psi VACUUMING REFRIGERANT SYSTEM 1 Vacuuming Procedure NOTE When the A C system has been exposed to the air it must be vacuumed out Perform vacuum process for 30 minutes...

Page 214: ...he mounting disk is in the raised position B Attach the manifold gauge center hose to the valve assembly C Turn the disc in the clockwise direction and securely mount valve onto refrigerant container...

Page 215: ...e engine running When exchanging refrigerant containers press the manifold gauge low side valve to eliminate air from the charging hose 2 Charge the system by opening the manifold gauge low side valve...

Page 216: ...from vehicle WARNING When charging refrigerant system with the engine running Always keep refrigerant supply container in the upright position Never open the high side pressure valve Gauge Dial Stand...

Page 217: ...sor outlet condenser inlet receiver dryer inlet air conditioner unit inlet 2 Low pressure side Compressor inlet air conditioner unit outlet 3 Compressor Compressor shaft area bolt hole area and magnet...

Page 218: ...S0605060K Page 26 Air Conditioner...

Page 219: ...those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is...

Page 220: ...S0609010K Page 2 Drive Coupling Main Pump TABLE OF CONTENTS Drive Coupling 3 Special Tools 4 Drive Coupling Installation 6 Installation Procedure 8...

Page 221: ...it is very important to properly adjust clearance between the face of the coupling hub and end of pump drive shaft Measurement H shown in the following procedure to a specific value Figure 1 thru Fig...

Page 222: ...d Figure 5 This distance will be referred to as Measurement H in the installation instructions that follow NOTE In manufacturing drawings Figure 4 dimension A and B equal the Measurement H The two too...

Page 223: ...Dimension Measurement Models A 6 0 1 mm 0 2362 0 0039 in S300LC V S300LL B 7 0 1 mm 0 2756 0 0039 in S340LC V S420LC V S470LC V C 20 0 mm 0 787 in D 7 0 mm 0 275 in E 18 0 mm 0 708 in Radius F 22 0 m...

Page 224: ...ive coupling for main pump is installed the following mounting dimensions and installation procedures must be observed NOTE If these procedures are not followed noise will occur and or the service lif...

Page 225: ...Pin 4 2 Insert 4 3 Bolt 4 Ta 4 Flywheel 1 5 Spring Pin 8 6 Insert 4 7 Hub 1 8 Bolt 4 Ta 9 Pump shaft 1 10 Clamping screw 2 Tb 11 Element 1 Table 2 Specification for Measurement H and Torque Refer to...

Page 226: ...ews 10 NOTE Tighten clamping screws to value Tb in the tables NOTE Coat clamping screws 10 with Loctite 262 5 Install element 11 between inserts 2 on engine flywheel 4 6 Install main pump and hub 7 by...

Page 227: ...1HYDRAULICS...

Page 228: ......

Page 229: ...afety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and h...

Page 230: ...uit 8 Swing Operating Circuit 8 Right Swing Operating Circuit 9 Left Swing Operating Circuit 9 Swing Relief Valve and Make up Valve 9 Travel Operating Circuit 9 Forward Travel Circuit 10 Reverse Trave...

Page 231: ...and Flow Meter Kit Installation and Testing 20 Swing System Troubleshooting 22 Precautions Initial Checks 22 Swing Relief Valve Checking and Adjustment 22 Troubleshooting Swing Gearbox 24 Troubleshoot...

Page 232: ...atures 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...

Page 233: ...cuit for these functions the output of both pumps can be combined allowing higher speed operation Boom up arm crowd and dumping functions can operate in any one of the two available power modes the st...

Page 234: ...t exceed the volume of oil coming out BOOM UP CIRCUIT When you pull the boom control lever backward the right side pilot valve generates secondary boom up pilot pressure that is transmitted to the BOO...

Page 235: ...valve generates secondary pressure that is transmitted to the ARM1 and ARM2 of the control valve simultaneously When secondary pilot pressure reaches 7 10 kg cm2 100 142 psi the arm control valve spoo...

Page 236: ...ols open so that oil from both pumps goes to the bucket cylinder BUCKET DUMP CIRCUIT When the bucket control lever is put in the dump mode the right side pilot valve generates secondary bucket dump pi...

Page 237: ...ration the possibility exists that surge pressure in the circuit caused by inertial momentum of the upper works and correspondingly reduced pressure at the opposite motor port could produce cavitation...

Page 238: ...the machine REVERSE TRAVEL CIRCUIT When the right and left travel control levers are pushed backward output from both main pumps is directed through the TRAVEL R and TRAVEL L spools on the control va...

Page 239: ...le at the pump drive flex coupling pull out the electrical tray under the operator s seat to inspect the self diagnostic display If the EPOS trouble code display is clear check hydraulic functions in...

Page 240: ...e tolerance specified in the table adjust gear pump relief pressure by loosening the lock nut and turning the set screw in clockwise to increase pressure or turning it out to decrease it NOTE Be aware...

Page 241: ...al lead Vent the lever on top of the hydraulic tank to relieve pressure and connect an in line t style adapter to the valve pressure port Install a 60 bar 1 000 psi test gauge in the adapter Restart t...

Page 242: ...ent air from the hydraulic system before installing test equipment Use the lever on the reservoir while the engine is running Pour clean replacement fluid back into the system if excessive fluid was l...

Page 243: ...Pressure must be 350 bars 5075 psi or up to 10 bars 145 psi higher Because one adjustment can affect the other check low stage main relief pressure by repeating the cylinder stall test without pressu...

Page 244: ...tment NOTE The electrical pressure up power boost solenoid valve located alongside the swing priority solenoid and arm speed control solenoid in compartment rear of the operator s cab must be operatin...

Page 245: ...tently overloaded and engine troubleshooting shows engine performance to be at or above rated output If reduced cylinder speed and diminished work performance provide an indication that rated maximum...

Page 246: ...djustment 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 Regula...

Page 247: ...square tipped adjusting screw should be turned in the opposite direction turns to avoid changing inner spring adjustment Pump input power adjustments are normally made in small increments 1 4 turn 90...

Page 248: ...d of the flow meter assembly and the top of the reservoir Use appropriate fittings and adapter flanges to guarantee a pressure tight seal NOTE Be sure to maintain even tightening torque on all flange...

Page 249: ...sts can be repeated using different control levers Recheck front pump operation while stroking the bucket cylinder out lever and the rear pump by actuating the swing control lever NOTE When testing bu...

Page 250: ...the lowest power to check the engine Investigate unusual operating noises or vibration Check for loose bolts connections SWING RELIEF VALVE CHECKING AND ADJUSTMENT Make a check of operating pressures...

Page 251: ...xt procedure If pressure through the SH port was tested below the minimum 4 bar 58 psi level check the shuttle valve in the rear compartment behind cabin When pressure through the port is at the recom...

Page 252: ...r Pilot control pressure low or swing control valve stuck Disassemble Repair pilot pressure swing spool 305 and or swing control valve Swing motor defective Test motor drain rate Replace Repair motor...

Page 253: ...e swing motor Hydraulic pump or valve problem Troubleshoot hydraulic system Oil Leakage From drive shaft From bolted connections or other assembled surfaces Oil seal damaged Assembly compound joint se...

Page 254: ...alve malfunction Readjust or replace Oil leak at make up valve Clean repair Control valve spool damaged Repair or replace Dirt in control valve spool Clean or replace Actuator joystick foot pedal dama...

Page 255: ...contamination Disassemble clean main poppet Broken or damaged spring Replace Adjusting screw loose Readjust Main poppet sticking Repair replace Clogged orifice in pilot passage to control valve Clean...

Page 256: ...ents worn out past wear limits Replace Problem Possible Causes Remedies Secondary pressure does not increase Low primary pressure Check primary pressure Broken spring Replace spring Spool sticking Cle...

Page 257: ...embly Secondary pressure too high Dirt other interference between valve parts Clean repair or replace Return line pressure too high Redirect return line Secondary pressure does not hold steady Dirt ot...

Page 258: ...S0702190K Page 30 Hydraulic System Troubleshooting Testing and Adjustment...

Page 259: ...thin this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal r...

Page 260: ...S0703010K Page 2 Accumulator TABLE OF CONTENTS General Description 3 Specifications 4...

Page 261: ...and out and an elastic diaphragm to separate the two chambers The flexible diaphragm changes shape to conform to the changing pressures and volumes of the two fluids in the upper and lower chambers T...

Page 262: ...ge pressure the flexible diaphragm begins to retract upward 4 When system oil is at highest working pressure and the accumulator fills to maximum reserve capacity the flexible diaphragm is pushed up i...

Page 263: ...S0703010K Page 5 Accumulator Solar 470LC V S N 1001 thru 1049 Pilot Travel 10 kg cm2 140 psi 320 cc 19 53 in3 S N 1050 and Up 750 cc 45 77 in3 Model Serial Number System Charge Pressure Volume...

Page 264: ...S0703010K Page 6 Accumulator...

Page 265: ...ices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handl...

Page 266: ...S0704090K Page 2 Center Joint Swivel TABLE OF CONTENTS General Description 3 Parts List 4 Troubleshooting Testing and Adjustment 5 Inspection 5 Testing 5 Disassembly 6 Reassembly 7...

Page 267: ...RIPTION The center joint swivel is designed to allow hydraulic oil from the upper structure to flow to components in the lower structure It is capable of allowing continuous 360 rotation of the upper...

Page 268: ...PARTS LIST Figure 1 Reference Number Description 10A Center Joint Body 10B Spindle 10C O ring 10D Slipper Seal 10E O ring 10F Cover 10G Hex Bolt 10H Spring Washer 10I Plug 10J Plug 25 Spring Washer 3...

Page 269: ...s of the excavator A high pressure relief valve with a setting pressure 1 5 times maximum system pressure A stop valve A manually operated in line change over valve Install the change over valve upstr...

Page 270: ...gs or seals to avoid causing damage to those that must be reused NOTE The O ring 10E shown in the assembly drawing above the swivel joint stem lower seals should not be overlooked It is tucked behind...

Page 271: ...er swivel with clean hydraulic fluid prior to reassembly of high pressure and drain line piping Clean and pre fill piping line ends to reduce the amount of air in the system Bleed air from the hydraul...

Page 272: ...S0704090K Page 8 Center Joint Swivel...

Page 273: ...Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE Solar 130LC V 0001 and Up Solar 130W V 0001 and Up Solar 170LC V 1001 and Up Solar 170W V 1001 and Up Sol...

Page 274: ...TENTS General Description 3 Theory of Operation 3 Parts List 4 Special Tools and Materials 6 Piston Nut 6 Piston Jig 10 Steel bush Jig 14 Dust Wiper Jig 18 Slipper Seal Jig 22 Slipper Seal Straighteni...

Page 275: ...shown as oil path A or to the front of the cylinder oil path B The cylinder rod is extended as oil flow is pumped through the circuit to the back side of the piston The force F1 of the piston stroke c...

Page 276: ...it does to lengthen it Q1 Q2 PARTS LIST The following parts list is a partial listing only for full and complete parts list information refer to the Hydraulic Equipment Component Parts List Cross sect...

Page 277: ...t 8 Retaining Ring 9 Rod Cover 10 O ring 11 O ring 12 Backup Ring 13 Piston Rod 14 Cylinder Tube 15 Cushion Ring 16 Piston 17 Slide Ring 18 Wear Ring 19 Slipper Seal 20 O ring 21 Backup Ring 22 Piston...

Page 278: ...Page 6 Cylinders SPECIAL TOOLS AND MATERIALS PISTON NUT B A D C 0 2 0 1 0 2 0 1 R R15 R20 C3 C5 35 350 ARS4730L 15 4 R 0 5 Through Hole 8 Figure 6 Material SM45C AISI 1045 Rockwell Harden from 22 27 O...

Page 279: ...OM S200N V BUCKET OPTION BOOM OP 125 0 mm 4 92 in 85 0 mm 3 35 in 12 0 mm 0 47 in 5 0 mm 0 20 in S130W V ARM S130LC V SHORT ARM S170W V BUCKET S220LC V BUCKET S220LL BUCKET BUCKET 115 0 mm 4 53 in 75...

Page 280: ...n S470LC V ARM S55W V ARM 106 0 mm 4 17 in 66 0 mm 2 60 in 12 0 mm 0 47 in 5 0 mm 0 20 in S80W II ARM 120 0 mm 4 72 in 79 0 mm 3 11 in 10 0 mm 0 39 in 5 0 mm 0 20 in S70 III ARM S80W II BOOM MEGA 130...

Page 281: ...S0705000 Page 9 Cylinders...

Page 282: ...S0705000 Page 10 Cylinders PISTON JIG C 35 A 30 R R15 20 2 B D R F 2 Through Hole 8 15 ARS4740L 4 R5 Figure 7 Material SM45C AISI 1045 Rockwell Harden from 22 27 Oil Quench...

Page 283: ...BUCKET MEGA 200 III LIFT S290LC V ARM S ARM 120 0 mm 4 72 in 13 0 mm 0 51 in 85 0 mm 3 35 in 150 0 mm 5 91 in S290LL BUCKET BOOM S300LC V ARM S ARM S330LC V BOOM BUCKET S340LC V BUCKET BOOM BUCKET OP...

Page 284: ...S0705000 Page 12 Cylinders P S Power Steering O R Out Rigger MODEL CYLINDER A 0 1 B C D MODEL CYLINDER...

Page 285: ...S0705000 Page 13 Cylinders...

Page 286: ...e 14 Cylinders STEEL BUSH JIG 20 A 20 5 A F 15 1 B 40 E ARS4750L B Figure 8 Material SM45C which is done thermal refining QT Hrc 22 28 Undefined Chamfer C R 0 5 Max Place Finally work to used DNMG Tip...

Page 287: ...4 in S70 III ARM BOOM MEGA 200 III LIFT MEGA 200 III TC H C S220LL ARM 90 0 mm 3 54 in 105 0 mm 4 13 in 40 0 mm 1 58 in 6 5 mm 0 26 in S290LC V S ARM ARM S290LL BOOM BUCKET S300LC V S ARM ARM MEGA 250...

Page 288: ...5 51 in 70 mm 2 76 in 11 mm 0 43 in K C S420LC V BOOM K C S400LC V BOOM K C S55W V BUCKET 50 0 mm 1 97 in 60 0 mm 2 36 in 30 0 mm 1 18 in S55 V ARM BOOM OP BUCKET DOZER 65 0 mm 2 56 in 75 0 mm 2 95 in...

Page 289: ...S0705000 Page 17 Cylinders...

Page 290: ...rs DUST WIPER JIG D C DIA B 40 15 3 C1 5 DIA B DIA A DIA A 20 R0 2 1 ARS4760L Figure 9 Material SM45C which is done thermal refining QT Hrc 22 28 Undefined Chamfer C R 0 5 Max Place Finally work to us...

Page 291: ...0 mm 3 31 in 5 5 mm 0 22 in 6 0 mm 0 24 in S80W III BOOM S130W V BOOM S130LC V BOOM MEGA 160 III BUCKET BUCKET 55 0 mm 2 17 in 69 0 mm 2 72 in 5 0 mm 0 20 in 6 0 mm 0 24 in S55 V ARM BOOM BOOM OP BUC...

Page 292: ...0 mm 0 24 in 7 0 mm 2 28 in S290LC V ARM 105 0 mm 4 13 in 121 0 mm 4 76 in 6 0 mm 0 24 in 7 0 mm 2 28 in S290LC V S ARM S300LC V ARM S ARM S370LC V BOOM S ARM 105 0 mm 4 13 in 121 0 mm 4 76 in 6 0 mm...

Page 293: ...0 20 in 6 0 mm 0 24 in S80W III ARM 65 0 mm 2 56 in 79 0 mm 3 11 in 5 5 mm 0 22 in 6 0 mm 0 24 in BOOM 70 0 mm 2 76 in 84 0 mm 3 31 in 5 5 mm 0 22 in 6 0 mm 0 24 in BUCKET 55 0 mm 2 17 in 69 0 mm 2 7...

Page 294: ...S0705000 Page 22 Cylinders SLIPPER SEAL JIG ARS4770L A 2 A A 14 B B 40 5 R 1 0 R1 1 0 Figure 10...

Page 295: ...OIST S290 V BOOM BUCKET S BUCKET BOOM 130 0 mm 5 12 in 28 5 mm 1 12 in S250LC V BUCKET S290LC V ARM 150 0 mm 5 91 in 28 5 mm 1 12 in S290LL BOOM HOIST BUCKET HEEL S290LC V S ARM S300LC V ARM S ARM S34...

Page 296: ...S0705000 Page 24 Cylinders S200W V BOOM 135 0 mm 5 32 in 28 5 mm 1 12 in S220LC V ARM S220N V ARM OP P S Power Steering MODEL CYLINDER A B MODEL CYLINDER 0 2 0 1 0 2 0 1...

Page 297: ...S0705000 Page 25 Cylinders...

Page 298: ...S0705000 Page 26 Cylinders SLIPPER SEAL STRAIGHTENING JIG ARS4780L 2 R1 50 25 100 A 15 A 2 5 R 2 C 1 Figure 11...

Page 299: ...BUCKET S220LL BOOM HOIST S290 V BOOM BUCKET S BUCKET BOOM 130 0 mm 5 12 in S250 V BUCKET S290LC V ARM 150 0 mm 5 91 in S300LC V ARM S ARM S340LC V BOOM BUCKET BUCKET OP S370LC V BOOM BUCKET BUCKET OP...

Page 300: ...S0705000 Page 28 Cylinders S200W V BOOM 135 0 mm 5 32 in S220LC V ARM S220N V ARM OP P S Power Steering CYLINDER A MODEL CYLINDER 0 2 0 1...

Page 301: ...or other protective material around piston rod to avoid possibility of accidentally scratching or scoring rod surface while fasteners are being loosened and removed Component parts numbered in parenth...

Page 302: ...d of cylinder wall before using a plastic or other soft faced hammer for final disassembly 5 Begin withdrawing piston rod assembly away from cylinder Attach a lifting support when final 1 3 of rod is...

Page 303: ...through end of rod 8 Remove set screw by using a socket wrench 9 Fabricate or purchase a piston nut removal wrench Dimensions are called off at beginning of this procedure This tool may also be ordere...

Page 304: ...er to evenly pull off rod cover 9 from end of piston rod Be careful not to damage rod bushing 6 and dust wiper U packing and other seals 12 Use a dull rounded tip tool to pry off O ring 11 and backup...

Page 305: ...ing 21 from cylinder head 15 During disassembly of cylinder head be careful not to damage buffer seal 5 and U packing 4 16 Disassemble retaining ring 3 and dust wiper 2 Separate retaining ring 8 and r...

Page 306: ...S0705000 Page 34 Cylinders 17 Force out pin bushing 1 from body of cylinder Figure 28...

Page 307: ...nents install the dust wiper 2 and rod bushing 6 to the rod cover 9 Insert retaining rings 3 and 8 IMPORTANT Replace any part that shows evidence of damage or excessive wear Replacement of all O rings...

Page 308: ...inning of this procedure to attach seal Cool seal by pushing a retracting jig against seal for several minutes Apply a strip of clean see through sealing tape around slipper seal to keep it free of du...

Page 309: ...before reassembly 10 Pre apply fastener locking compound Loctite 242 or 243 or an alternate manufacturer s equivalent product to all end cover retaining bolts Wrap a protective cushion around end of r...

Page 310: ...S0705000 Page 38 Cylinders...

Page 311: ...ontained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own...

Page 312: ...l Description 3 Theory of Operation 3 Swing Motor Anti cavitation Make up Valve 4 Relief Valve 5 Swing Brake Operation 6 Parts List 8 Specifications 10 Special Tools 11 Disassembly 12 Cleaning and Ins...

Page 313: ...the swash plate 3 to generate oil flow through the motor while force F2 pushes laterally at a right angle against the drive shaft providing the rotational energy to turn the cylinder block around the...

Page 314: ...d while current flow is reduced shifting the spool in the priority valve for increased oil flow to the boom arm side of the circuit SWING MOTOR ANTI CAVITATION MAKE UP VALVE Unlike those designs for h...

Page 315: ...urization of the tank by opening momentarily so that there is no pressure developed through the valve at all Tank pressure at pressurized area A2 is set against spring pressure inside the valve openin...

Page 316: ...742 split plate 743 and swing motor casing 301 preventing the motor drive shaft from turning When hydraulic pressure is forced to the back side of the brake piston the friction plate and swing motor c...

Page 317: ...S0707260 Page 7 Swing Motor...

Page 318: ...LIST 303 468 487 51 116 111 121 122 123 124 117 113 101 401 472 712 707 131 451 464 485 993 432 106 443 304 471 437 106 432 491 301 438 106 114 118 743 743 742 742 743 706 702 433 351 444 469 488 355...

Page 319: ...ly 121 Piston 122 Shoe 123 Retainer 124 Shoe Plate 131 Valve Plate 301 Casing 303 Valve Casing 304 Front Cover 351 Plunger 355 Spring 401 Socket Bolt 432 Snap Ring 433 Snap Ring 437 Snap Ring 438 Snap...

Page 320: ...81 in3 rev 2 x 128 0 cc rev 2 x 7 81 in3 rev Crossover Relief Valve Setting 280 kg cm2 3 980 psi 280 kg cm2 3 980 psi 280 kg cm2 3 980 psi Maximum Supply Flow Rate 2000 rpm 227 lpm 60 gpm 210 lpm 55...

Page 321: ...S0707260 Page 11 Swing Motor SPECIAL TOOLS Figure 5...

Page 322: ...hands and clothing promptly and don t allow used oil containers to accumulate 3 After oil has been drained completely motor should be positioned so that exposed end of drive shaft faces downwards IMP...

Page 323: ...e casing 303 5 Disassemble brake valve 31 from side of casing 6 Remove relief valve assemblies 51 from upper valve casing 303 7 Remove RO plug 469 from upper valve casing 303 That will allow subsequen...

Page 324: ...r cover is removed 9 Remove all twenty brake springs NOTE If brake springs are to be reused and not replaced check and record spring free height If a test stand is available check height of all twenty...

Page 325: ...ded incrementally by maintaining previous wear pattern relationships by avoiding new ones 12 Pull out friction plates 742 and separator plates 743 from area behind cylinder block 13 Remove lock ring 4...

Page 326: ...of casing 16 Disassembly of motor has now been completed unless there is any reason to suppose that drive shaft bearing has become excessively worn If it is necessary replace bearing by pulling away s...

Page 327: ...parated during removal Apply force 2 Figure 21 and use a plug 1 to hammer through drive shaft opening in cover B If upper bearing is going to be replaced whether as a general precaution as part of nor...

Page 328: ...ssemble relief valves pull out plug 201 Figure 4 disassemble bushing 343 spring 322 and spring seat 331 from rod 303 Position valve housing facing down and separate piston 302 rod 303 spring 321 sprin...

Page 329: ...ded unless motor has had minimal use Inspect O rings and oil seals very carefully for cuts nicks brittleness or softness or any other type of damage or distortion before final reassembly NOTE When par...

Page 330: ...bly if any must be reused Item Standard Value mm In Replacement Limit mm In Remedy Clearance between cylinder bore and piston D d 0 028 mm 0 0011 in 0 058 mm 0 0023 in Replace piston or cylinder Clear...

Page 331: ...re not disassembled go onto next phase of assembly Bearing reassembly begins with replacement of stop ring 432 Figure 4 and its accompanying Parts List and spacer 106 on drive shaft 101 Make sure that...

Page 332: ...oil seal Be careful that you install seal inside cover with correct side facing in 5 Before replacing O ring 471 in lower casing 301 grease O ring and or inside of groove very lightly to facilitate as...

Page 333: ...g grease on assembled side can help keep individual components in place 9 Carefully examine cylinder block for any evidence of damage around rotating parts Put push rods 116 and front spacer 117 back...

Page 334: ...3 and two friction plates 742 which should be positioned as shown in drawing below with clearance towards side of casing with brake valve 1 Figure 38 13 Very lightly grease larger O rings 706 and 707...

Page 335: ...re 43 of the valve plate turned away from mounting flanges 1 on side of valve plate Lightly grease O ring to help keep it in place during assembly 18 Bolt up two halves of motor casing 301 and 303 Fig...

Page 336: ...by putting rod spring stop and piston back together then turning plunger side of valve up to reassemble valve body and all components of piston spring seat spring bushing retainer O ring and plug 21...

Page 337: ...S0707260 Page 27 Swing Motor 22 Replace the VP plugs 464 468 and O rings 485 487 on each of the three plugs Reinstall the brake cutoff valve 31 Figure 49...

Page 338: ...S0707260 Page 28 Swing Motor...

Page 339: ...op practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safe...

Page 340: ...tional View 23 Seal Kits and Component Groups 24 Sealing Drive Shaft 27 Sealing Control Parts 28 Sealing Relief Valve 28 Disassembly Port Plate 29 Exchanging Rotary Group 34 Travel Motor Speed Reducti...

Page 341: ...section at the end Travel motor consists of the hydraulic motor and reduction gearbox Hydraulic motor consists of the rotary part cross relief valve negative brake counter balance valve and tilting pa...

Page 342: ...er flowing into the side of the cylinder block 104 exerts force on each piston 4 or S pieces and generates force F p kg cm x A cm2 The force F is exerted on the swash plate 103 as the swash plate 103...

Page 343: ...D at the return side of the motor and part B at the tank are connected together by a hole in the spool and the motor turns as the return oil from motor flows into the tank By the movement of spool 126...

Page 344: ...lic motor stops because all passages are closed completely Like this the spool s returning speed controls the return oil from motor gradually according to the spool s shape and stops the hydraulic mot...

Page 345: ...ses above 11 kg cm2 it over comes the spring force and the piston 112 moves By the movement of the piston the force exerted by the piston 112 on the separator plate 116 and the friction plate 115 is r...

Page 346: ...112 returns by the spring 113 force If the piston 112 is pushed by the spring force the separator plate 116 and the friction plate 115 are pushed to the spindle of the reduction device The friction f...

Page 347: ...ed from port A If the pressure is lower than 10 kg cm2 the valve 163 is pushed to the left by the spring I66 force the pressure oil from the supply port B is blocked and the oil of the chamber C flows...

Page 348: ...alve 163 is pushed to the right bv the spring 166 force the pressure oil from the supply port B goes through valve 163 into the chamber C So the piston 161 is fixed because the swash plate 103 is push...

Page 349: ...gear If the carrier combined to the input shaft rotates the planetary gears Pl P2 turn If the gear ratios between R and P1 Pl and P2 are properly different the co axial gears P1 and P2 transmit torque...

Page 350: ...S0707365 Page 12 Travel Motor With Gearbox A6V160HD PARTS LIST Travel Motor Figure 12 HTS6331...

Page 351: ...Reference Number Description Qty 6315 Travel Motor 2 1 Rotary Group 1 2 Control 1 5 Housing 1 9 Retaining Ring 1 10 Shaft Seal Ring 1 11 Backup Plate 1 12 O ring 1 13 Rocking Screw 1 17 Threaded Pin 2...

Page 352: ...S0707365 Page 14 Travel Motor With Gearbox A6V160HD Travel Motor Rotary Group Figure 13 HTS6321...

Page 353: ...1 1a Cylinder 1 1b Control Lens 1 1c Center Pin 1 1d Piston 7 1e Steel Sealing Ring 14 1f Adjustment Shim 1 1g Pressure Spring 1 1h Retaining Plate 1 1i Screw 14 2 Drive Shaft 1 3 Shim 1 6 Backup Pla...

Page 354: ...S0707365 Page 16 Travel Motor With Gearbox A6V160HD Travel Motor Control HTS6331 Figure 14...

Page 355: ...on 1 4 Control Bush 1 5 Control Piston 1 6 Pressure Spring 1 7 Rocking Screw 1 8 Throttle Screw 1 9 Throttle Screw 1 13 Rocking Screw 1 14 Valve Screw 1 15 Bush 1 20 Socket Head Screw 2 21 Socket Head...

Page 356: ...S0707365 Page 18 Travel Motor With Gearbox A6V160HD Travel Motor Speed Reduction Gearbox Assembly 3033 Figure 15...

Page 357: ...11 Screw Uni 5931 4 12 3rd Red Gear Assembly 1 13 Bushing 4 14 Sun Gear 1 15 Bearing Assembly 1 16 Gasket Lifetime 1 17 Hub 1 18 Spacer 1 19 Brake Shaft 1 20 O ring 1 21 Disc 7 22 Ring Steel 6 23 Rin...

Page 358: ...V Brake Release Valve and Relief Valves Incorporated 2 Beginning of Regulation At Max Displacement 3 2 hole Flange 4 Drive Shaft 45 mm Diameter 5 Vitron Seals 6 Alternating Direction of Rotation 7 Ser...

Page 359: ...s and head support surface dimensions in accordance with DIN 912 DIN 931 and DIN 933 These values are also valid only for light or unoiled untreated surface and for use only with torque indicating wre...

Page 360: ...200 300 Tightening torques for seal lock nuts Metric ISO Standard Thread The values for tightening torques shown in the table are valid only for seal lock nuts of the strength class 8 8 and with metri...

Page 361: ...S0707365 Page 23 Travel Motor With Gearbox A6V160HD TRAVEL MOTOR DISASSEMBLY SECTIONAL VIEW HTS063S Figure 16...

Page 362: ...out repair work at hydraulic aggregates 1 Close all points of the hydraulic aggregates 2 Replace all seals NOTE Use only original spare parts 3 Check all seal and sliding surfaces for w ear NOTE Rewor...

Page 363: ...Motor With Gearbox A6V160HD 4 Full up hydraulic aggregates with hydraulic oil before start up 5 Seal kit for drive shaft 6 External seal kit 7 Housing Figure 21 HTS005S Figure 22 HTS006S Figure 23 HT...

Page 364: ...Complete rotary group 9 Port plate with control piston and counter balance valve 10 Relief valve Make up check valve 11 Replace seal nut NOTE First measure and record setting height Figure 25 HTS009S...

Page 365: ...With Gearbox A6V160HD 12 When tightening counter hold setting screw then check setting height SEALING DRIVE SHAFT 1 Protecting the drive shaft 2 Remove retaining ring and shim Figure 29 HTS013S HTS014...

Page 366: ...pliers 5 Press in shaft seal and shim with bush to stop NOTE Pay attention to pressing depth Mark for pressing depth Assemble retaining ring SEALING CONTROL PARTS 1 H Z Controller NOTE Inspect O ring...

Page 367: ...S0707365 Page 29 Travel Motor With Gearbox A6V160HD 2 Inspect O ring DISASSEMBLY PORT PLATE 1 Note dimension X 2 Remove Qmin screw Figure 36 HTS021S Figure 37 HTS023S...

Page 368: ...iston rings to hang out the cylinder boring Swivel rotary group to zero position with screw Q max 5 Port plate A Mark position B Loosen screws C Remove 6 Check O ring NOTE Coat new O ring with some gr...

Page 369: ...S0707365 Page 31 Travel Motor With Gearbox A6V160HD 7 Braking valve 8 Throttle pin 9 Valve 10 Pressure control valve HTS027S Figure 41 HTS028S Figure 42 HTS029S Figure 43 HTS030S Figure 44...

Page 370: ...S0707365 Page 32 Travel Motor With Gearbox A6V160HD 11 Pressure relief valve 12 Positioning piston 13 H Z control 14 Check valve HTS031S Figure 45 HTS032S Figure 46 HTS033S Figure 47 HTS034S Figure 48...

Page 371: ...S0707365 Page 33 Travel Motor With Gearbox A6V160HD 15 Screw in threaded pin into center pin 16 Fix the cylinder with disc and locknut HTS035S Figure 49 HTS036S Figure 50 HTS037S Figure 51...

Page 372: ...n the drive shaft EXCHANGING ROTARY GROUP 1 Complete rotary group NOTE Setting of hydraulic part necessary 2 Rotary group Mechanical part Adjust drive shaft with bearing Hydraulic part Adjustment nece...

Page 373: ...aining plate NOTE screws are glued Use Torx tools 6 Free of corrosion erosion or fretting No damage to splines or keyways 7 Pistons No scoring and no pitting 8 Center pin No scoring and no pitting HTS...

Page 374: ...ontrol lens Bores free of scoring no evidence of wear Faces smooth and even free of cracks and scoring 11 Control housing Sliding surface and side guides free of scoring and no wear 12 Visual check Be...

Page 375: ...REDUCTION GEARBOX DISASSEMBLY 1 Drain gear oil and remove travel motor and O ring 2 Remove motor flange 8 socket bolts M16 x 35 Figure 64 3 Remove O ring from motor flange Figure 65 4 Remove O ring f...

Page 376: ...60HD 5 Attach disc B Figure 67 to spring retainer fasten pusher A to hub and install screw rod C 6 Remove retaining ring from hub groove using pliers Figure 68 7 Remove jig and retaining ring Figure 6...

Page 377: ...60HD 8 Remove spring retainer Figure 70 9 Pull spring from groove Figure 71 10 Blow air into brake port hole and remove brake piston using pliers Figure 72 11 Remove brake shaft Figure 73 Figure 70 30...

Page 378: ...D 12 Remove disc Figure 74 13 Remove O ring and backup ring Figure 75 14 Turn reduction gear assembly over and remove 2 plugs M22 x 1 5 Figure 76 15 Remove 16 socket bolts M14 x 40 Figure 77 Figure 74...

Page 379: ...6V160HD 16 Remove end cover using puller Figure 78 17 Remove O ring from end cover groove Figure 79 18 Remove first sun gear Figure 80 19 Remove first planetary gear assembly Figure 81 Figure 78 3048...

Page 380: ...Remove second sun gear Figure 82 21 Remove second planetary gear assembly Figure 83 22 Remove third sun gear Figure 84 23 Remove bolts 4 M 30 x 150 from third planetary gear assembly Figure 85 Figure...

Page 381: ...6V160HD 24 Remove bolts Figure 86 25 Separate hub from reduction gear housing using press and stopper Figure 87 NOTE Do not remove main ball bearing 26 Remove third shift assembly from hub Figure 88 F...

Page 382: ...07365 Page 44 Travel Motor With Gearbox A6V160HD 27 Remove bushing from hub using a jig Figure 89 28 Remove bearing inner race and spacer from hub using puller Figure 90 H H Figure 89 3059 Figure 90 3...

Page 383: ...S0707365 Page 45 Travel Motor With Gearbox A6V160HD 29 Remove gasket Figure 91 Figure 91 3061...

Page 384: ...pection procedures refer to General Maintenance Procedures section Gearbox Inspection 1 If a gear is damaged replace the damaged gear and the interlocking gear next to it If one planetary gear is dama...

Page 385: ...tor With Gearbox A6V160HD TRAVEL MOTOR SPEED REDUCTION GEARBOX REASSEMBLY 1 Install seal to jig Figure 92 2 Install jig to housing Figure 93 3 Clean seal surface Figure 94 HTS3062S Figure 92 3062 Figu...

Page 386: ...ly lubricant to seal surface Figure 96 6 Support ball bearing housing with spacers 1 and 2 Figure 97 and install bearing into housing Install spacer between balls noting diameter shown in illustration...

Page 387: ...nstall hub to housing Figure 99 9 Press hub into housing using a press and a stopper Figure 100 10 Install four bushings using a press Figure 101 11 Assemble planetary gear assembly Figure 102 Figure...

Page 388: ...assemblies using press Figure 103 13 Tighten gear box of planetary gear assembly to 150 Nm 110 7 ft lb Figure 104 14 Assemble third shift sun gear Figure 105 15 Assemble the second shift reduction as...

Page 389: ...r carrier into hub Figure 108 18 Apply loctite to planetary gear carrier fastening bolts 19 Install and tighten bolts Figure 109 NOTE In next step the O ring and backup rings are different Be careful...

Page 390: ...te 243 to bolts and torque to 10 Nm 7 38 ft lb Figure 111 22 Tighten plugs to 6 8 Nm 4 42 5 90 ft lb Figure 112 23 Turn housing over and install second shift sun gear Figure 113 24 Install first shift...

Page 391: ...Gearbox A6V160HD 25 Install first shift sun gear Figure 115 26 Install O ring 1 Figure 116 and backup ring 2 into hub groove NOTE The O ring and backup rings are different Be careful not to switch th...

Page 392: ...Figure 117 28 Install brake disc assembly starting with a copper disc seven pieces and alternating with steel discs six pieces Figure 118 and Figure 119 29 Install jig to hub and insert spring retain...

Page 393: ...using retaining ring pliers Figure 121 31 Install O ring to hub groove Figure 122 32 Place brake piston inside hub being careful not to damage seal Figure 123 33 Insert springs into brake piston hole...

Page 394: ...6 Travel Motor With Gearbox A6V160HD 34 Install retainer disc Figure 125 35 Install O ring to motor flange groove Figure 126 36 Tighten motor flange to hub Figure 127 Figure 125 3095 Figure 126 3096 F...

Page 395: ...With Gearbox A6V160HD TRAVEL MOTOR REASSEMBLY ROTARY GROUP ASSEMBLY 1 Rotary group completely assembled ready for assembly 2 Place assembly sleeve 3 Warm up housing to 80 C 176 F Figure 128 HTS051S F...

Page 396: ...sing to seat position 5 Fix zero position of cylinder with Qmax screw 6 Disassemble cylinder fixing screw 7 Insert O ring ROTARY GROUP ADJUSTMENT SEE SERVE INFORMATION 1 Determine cylinder swivel rang...

Page 397: ...0707365 Page 59 Travel Motor With Gearbox A6V160HD 2 Disc 3 Place centering disc 4 Mount measuring device 5 Check dimension X HTS056S Figure 134 HTS057S Figure 135 HTS058S Figure 136 HTS059S Figure 13...

Page 398: ...order 3 Mount port plate 4 Assemble port plate NOTE Take care of assembly design Tighten fixing screws with torque 5 Set Qmin screw to dimension 6 Assemble plug 7 Remove assembly sleeve 8 Assemble sh...

Page 399: ...the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remembe...

Page 400: ...25 Remove the Intermediate Wheel 28 Remove Auxiliary Drive 30 Inspection 33 Re fitting the Rotary Group 38 Pump Assembly 40 Hydraulic Component Measurement D 43 Measuring Device Hydraulic Component 4...

Page 401: ...S0708325K Page 3 Main Pump Rexroth...

Page 402: ...S0708325K Page 4 Main Pump Rexroth SECTIONAL VIEW A8VO200LA1KH1 63 ASS0010L Figure 1...

Page 403: ...S0708325K Page 5 Main Pump Rexroth ASS0020L Figure 2...

Page 404: ...EPAIR GUIDELINES NOTE Observe the following cautions when carrying out repairs on hydraulic units 1 Close off all openings of hydraulic unit 2 Replace all seals Use only original spare parts ASS1140L...

Page 405: ...sealing and sliding surfaces for wear NOTE Rework of sliding surfaces using crocus cloth or other similar materials can damage the surface 4 Fill hydraulic unit with hydraulic oil before putting into...

Page 406: ...0708325K Page 8 Main Pump Rexroth SEAL KITS AND SUB ASSEMBLIES 1 Seal kit for drive shaft 2 Peripheral seal kit 3 Rotary group 1 ready to install ASS0070L Figure 8 ASS0080L Figure 9 ASS0090L Figure 10...

Page 407: ...mponent order rotary groups 1 and 2 separately NOTE Adjustment is necessary Pay attention to direction of rotation 6 Rotary group 1 mechanical section ready to install 7 Rotary group 2 mechanical sect...

Page 408: ...S0708325K Page 10 Main Pump Rexroth 8 Control pre adjusted 9 Gear pump complete 10 Intermediate gear ASS0140L Figure 15 ASS0150L Figure 16 ASS0160L Figure 17...

Page 409: ...S0708325K Page 11 Main Pump Rexroth 11 Auxiliary drive 12 Valve plate with valves 13 Pipe complete with fittings ASS0170L Figure 18 ASS0180L Figure 19 ASS0190L Figure 20...

Page 410: ...S0708325K Page 12 Main Pump Rexroth SEALING THE DRIVE SHAFT 1 Protect drive shaft e g with tape 2 Remove retaining ring and shim ASS0200L Figure 21 ASS0210L Figure 22 ASS0220L Figure 23...

Page 411: ...et metal screw s into holes fitted with rubber Pull out seal with pliers 4 Press in shaft seal ring and shim with bushing to stop NOTE Take note of press in depth Install mark for press in depth of sa...

Page 412: ...S0708325K Page 14 Main Pump Rexroth GEAR PUMP SEALING Remove gear pump Visually check 1 O ring 1 Figure 27 ASS0250L Figure 26 1 ASS0260L Figure 27...

Page 413: ...S0708325K Page 15 Main Pump Rexroth 2 Sealing surface of housing 2 Figure 27 2 ASS0270L Figure 28...

Page 414: ...S0708325K Page 16 Main Pump Rexroth REMOVE THE CONTROL HOUSING ASS0280L Figure 29...

Page 415: ...mbly assembly device with a crane and secure it into position 2 Remove screws holding port plate 3 Using a suitable lifting device remove port plate NOTE Mark installation position NOTE Be careful con...

Page 416: ...4 Remove paper seal and clean sealing surface Number Description 1 Setting Screw Qmax 2 Setting Screw Hydraulic Stroke Limitation 3 Setting Screw Power Characteristic Begin of Regulation ASS0310L Figu...

Page 417: ...S0708325K Page 19 Main Pump Rexroth NOTE Before carrying out setting or disassembly of regulator measure distance X of adjustment screw and record value X ASS0330L Figure 34...

Page 418: ...S0708325K Page 20 Main Pump Rexroth CONTROL MODULE CONTROL MODULE LR Remove and disassemble control module LR ASS0340L Figure 35 ASS0350L Figure 36...

Page 419: ...S0708325K Page 21 Main Pump Rexroth CONTROL MODULE H Remove and disassemble control module H ASS0360L Figure 37 ASS0370L Figure 38...

Page 420: ...S0708325K Page 22 Main Pump Rexroth REMOVING THE CONTROLLER 1 Remove cover NOTE Do not change the setting of adjustment screw 1 Figure 39 1 ASS0380L Figure 39 ASS0390L Figure 40...

Page 421: ...s NOTE Install control lens torque support 3 Remove locking screw and replace with a new one NOTE Loosen adhesive with a gentle flame approximately 120 C 4 Remove swivel pin ASS0400L Figure 41 Figure...

Page 422: ...S0708325K Page 24 Main Pump Rexroth VALVE PLATE WITH VALVES 1 Pressure relief valve 2 Electro proportional pressure reducing valve EPPR ASS0440L 1 2 Figure 45...

Page 423: ...mp Rexroth REMOVE THE ROTARY GROUPS 1 Keep cylinder with device Remove it completely along with drive shaft 2 Remove cylinder Take out the drive shaft without cylinder ASS0450L Figure 46 ASS0460L Figu...

Page 424: ...cup springs 1 and spring cup 2 4 Note disassembly position 1 2 and 3 Figure 50 5 Press out rotary group with an appropriate device ASS0480L Figure 49 1 2 3 Rotary Group 1 ASS0490L Rotary Group 2 Figu...

Page 425: ...ied through torque NOTE 1 Fixing screw Retaining device 2 Removal of screws is only possible if drive shaft is warmed up to a temperature of approximately 120 C for 1 2 hour in an oil bath or heat air...

Page 426: ...EMOVE THE INTERMEDIATE WHEEL 1 Press bolt Figure 53 into gear wheel Fixed pressing fit NOTE Can only be disassembled with a hydraulic press 2 Install sleeve NOTE Press out bolt with a hydraulic press...

Page 427: ...S0708325K Page 29 Main Pump Rexroth 3 Remove gear wheel through side drive opening 4 Remove bearing with extraction device ASS0540L Figure 55 ASS0550L Figure 56...

Page 428: ...S0708325K Page 30 Main Pump Rexroth REMOVE AUXILIARY DRIVE 1 Remove screws and auxiliary drive 2 Press off bearing cap ASS0560L Figure 57 ASS0570L Figure 58 ASS0580L Figure 59...

Page 429: ...3 In the event of oil leakage visually check O ring housing and groove 4 Install extractor device 5 Pull out output pinion 6 Install bearing extractor device ASS0590L Figure 60 ASS0600L Figure 61 ASS...

Page 430: ...S0708325K Page 32 Main Pump Rexroth 7 Completely mount device and pull out bearing 8 Pull out pinion bearing ASS0630L Figure 64 ASS0640L Figure 65...

Page 431: ...free of scores and that there is no evidence of wear 2 Visually check To ensure that bearing seats are free of scores 3 Visually check Check to see that bearing bores are free of scores and that ther...

Page 432: ...that there is no pitting 1 Figure 70 Check to see that there is no evidence of corrosion and wear steps 2 Figure 70 6 Piston Check to ensure that they are free of scores and that there is no pitting 7...

Page 433: ...ores no evidence of wear Faces 2 Figure 74 are even that there are no cracks no scores Side guides 3 Figure 74 show no evidence of wear free of scores 10 Check Control land 1 Figure 75 internal contro...

Page 434: ...mplete rotary group NOTE Adjustment of the hydraulic component is necessary Mechanical component drive shaft is adjusted with the bearing 1 Figure 77 Hydraulic component 2 Figure 77 Adjustment is nece...

Page 435: ...S0708325K Page 37 Main Pump Rexroth 13 Rotary group All of the components Adjustment Figure 78 For adjustment values and torque values see service information ASS0770L Figure 78...

Page 436: ...rews 2 Assemble retaining plate with pistons and center pin in position Use screws that have a Precoat coating NOTE For tightening torques see service information 3 Insert spring plate 1 Figure 81 and...

Page 437: ...ll parts are assembled in correct order and orientation 5 Insert pistons into cylinder Using a soft surface as a support to prevent sliding surfaces from being damaged Pre assemble both rotary groups...

Page 438: ...UMP ASSEMBLY 1 Warm up housing to approximately 80 C 2 Insert pre assembled rotary group 2 being sure to align gear tooth marks 3 Insert rotary group 1 Align the marked gear teeth ASS0830L Figure 84 A...

Page 439: ...S0708325K Page 41 Main Pump Rexroth 4 Gear tooth marks must align with each other ASS0860L Figure 87...

Page 440: ...to dimension A The tapered roller bearings are adjusted to the stipulated breakaway torque Assembly Guideline Retaining force After rotary group has been installed into housing it has to be pressed in...

Page 441: ...After assembling complete unit the breakaway torque of the rotary group has to be checked with a torque wrench HYDRAULIC COMPONENT MEASUREMENT D MEASURING DEVICE HYDRAULIC COMPONENT 452 269 Size Meas...

Page 442: ...g position is used The numbers on the top of the measuring device Figure 89 refer to the piston diameter 1 Install intermediate ring or plates onto the housing A Size 80 107 Figure 92 Size Mounting Po...

Page 443: ...l until the stop is reached Set dial gauge to zero A Size 80 107 Figure 94 B Size 140 200 Figure 95 MEASURING PROCEDURE 1 Turn down by 4 turns on the dial gauge Check 2 mm clearance set dial gauge to...

Page 444: ...roth B Size 140 200 Figure 97 2 Turn down using the hand wheel until resistance is met Read the measured value NOTE Do not use excessive force A Size 82 107 Figure 98 B Size 140 200 Figure 99 ASS0960L...

Page 445: ...in into correct position and orientation Take hardening time and tightening torque into account NOTE Tightening Torques M6 8 5 Nm 0 87 kg m 6 27 ft lb M8 14 Nm 1 43 kg m 10 33 ft lb M10 35 Nm 3 57 kg...

Page 446: ...ng torques into account 3 Install control housing 4 Install control lens in their correct position using grease to hold them in place ASS1010L Figure 102 ASS1020L Figure 103 Direction of rotation coun...

Page 447: ...S0708325K Page 49 Main Pump Rexroth 5 Install seal and controller ASS1040L Figure 105 ASS1050L Figure 106...

Page 448: ...re 107 into housing 2 Install and align intermediate wheel 2 Figure 107 through side drive opening 3 Cool down bolt 3 Figure 107 with nitrogen and install it 4 Press in bearing 4 Figure 107 5 Press be...

Page 449: ...8325K Page 51 Main Pump Rexroth INSTALLATION OF GEAR PUMP 1 Assemble shaft seal disc and safety ring Press in with assemble sleeve NOTE Take care of press in depth ASS1080L Figure 109 ASS1090L Figure...

Page 450: ...S0708325K Page 52 Main Pump Rexroth INSTALLATION OF COVER AUXILIARY DRIVE ASS1100L Figure 111...

Page 451: ...2 socked head cap screws DIN 931 hexagon bolt or DIN 933 hexagon bolts with threads up to the head Thread Tensile Strength Class 8 8 10 9 12 9 Tightening Torque M A In Nm M 3 1 1 1 6 1 9 M 4 3 1 4 5 5...

Page 452: ...Nm Thread Tightening Torque M A In Nm M8 x 1 5 G 1 8 A 10 M10 x 1 10 G 1 4 A 30 M12 x 1 5 20 G 3 8 A 35 M14 x 1 5 30 G 1 2 A 60 M16 x 1 5 35 G 3 4 A 90 M18 x 1 5 40 G 1 A 140 M20 x 1 5 50 G 1 1 4 A 24...

Page 453: ...n Pump Rexroth SEAL LOCK SEALING NUTS TO N 02 100 Thread Tightening Torque M A In Nm M6 10 M6 x 0 5 11 M8 22 M8 x 1 24 M10 40 M10 x 1 44 M12 69 M12 x 1 5 72 M14 110 M14 x 1 5 120 M16 170 M16 x 1 5 180...

Page 454: ...S0708325K Page 56 Main Pump Rexroth...

Page 455: ...ctices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely han...

Page 456: ...ifting Figure 8 16 Arm Spool Shifting 17 Neutral cut Spool Shifting Figure 11 19 Parallel Throttle for Arm Figure 11 19 Relief Valve 20 Combined Operation 22 Travel Combined Operation Figure 13 22 Swi...

Page 457: ...elief Valve 41 Main Relief Valve 41 Over Load Relief Valve 42 Disassembly 43 General Instructions for Disassembly 43 Disassembly of Main Spool 3 11 43 Disassembly of Subspool 24 44 Disassembly of Subs...

Page 458: ...heck Valve 51 Reassembly of Swing Load Check 51 Reassembly of Other Check Valve 52 Reassembly of Flange 52 Reassembly of Boom and Arm Anti Drift Valve 52 Reassembly of Relief Valve 52 Reassembly of Su...

Page 459: ...S0709402K Page 5 Control Valve Kayaba Model KVMG 400 DA...

Page 460: ...d returns to ports T1 and T3 2 Oil supplied to port P2 flows through neutral passage R1 to low pressure relief valve throttle Rc1 to tank passage Ta and returns to ports T1 and T3 3 The pressures of l...

Page 461: ...S0709402K Page 7 Control Valve Kayaba Model KVMG 400 DA Figure 1...

Page 462: ...and Lc4 and passage 5 to land Rc3 and into tank passage Ta 2 The same oil supplied from port PP after passing through orifice Lc5 flows partly to port PA and passes partly through passages L4 8 and R4...

Page 463: ...S0709402K Page 9 Control Valve Kayaba Model KVMG 400 DA Figure 2...

Page 464: ...tank passage Ta 2 When shifting travel spool by increasing pressure of travel section 6 pilot port Pb6 Pa6 oil supplied to port P2 flows through neutral passage R1 and spool to passage S6 1 and flows...

Page 465: ...S0709402K Page 11 Control Valve Kayaba Model KVMG 400 DA Figure 3...

Page 466: ...hifting swing spool by increasing pressure of swing section 2 pilot port Pb2 Pa2 neutral port L1 is closed Oil supplied to port P1 flows through parallel passage L3 load check valve S2 1 and spool to...

Page 467: ...utral Figure 5 This valve also works with anti drift valves that are installed on the bottom side of each boom cylinder When in neutral poppet AD1 is closed by pressure from port A7 that is sent throu...

Page 468: ...lows through parallel passage R3 and load check valve S7 1 to spool and flows into port A7 When boom 2 section 3 spool is shifted by increasing pressure of boom 2 pilot port Pa3 also neutral passage L...

Page 469: ...llel passage R3 and load check valve S7 1 to spool and flows into port B7 When spool AD3 of anti drift valve is shifted by increasing pressure of port Pc2 also poppet AD1 is opened by decreasing of pr...

Page 470: ...sage 11 and poppet S4 3 it then joins with passage S4 2 Return oil returns through port A4 B4 and spool to tank passage Ta Bucket Spool Shifting Figure 8 1 When bucket spool is shifted by increasing p...

Page 471: ...rom port P1 flows through neutral passage L1 load check valve S5 1 passage S5 2 and spool into port B5 When arm 2 spool is shifted by increasing pressure of arm 2 section 9 pilot port pb9 also oil sup...

Page 472: ...nd return oil from port B5 returned through spool passage S5 3 and arm variable regeneration throttle Lc8 to tank passage Ta Some of return oil open poppet S5 4 in boom 1 spool flows through passage S...

Page 473: ...h passage 11 and poppet S4 3 Figure 8 it then joins with spare section 4 passage S4 2 Figure 8 Parallel Throttle for Arm Figure 11 1 The throttle that is installed in the parallel circuit for arm of t...

Page 474: ...e The highest pressure of pump P1 and P2 is controlled by actuating of main relief valve 2 Over load relief valve The over load relief valve that is installed in each cylinder port of boom 1 arm 1 and...

Page 475: ...S0709402K Page 21 Control Valve Kayaba Model KVMG 400 DA...

Page 476: ...ol is shifted and the pressures of ports PT and PA increase When travel straight spool is shifted oil supplied from port P1 flows through neutral passage L1 to travel section 1 and simultaneously flow...

Page 477: ...S0709402K Page 23 Control Valve Kayaba Model KVMG 400 DA Figure 13...

Page 478: ...with the swing and another implement poppet S2 1 is fixed by increasing port pc6 pressure poppet S2 3 is opened and pressure supplied to port L3 is increased through throttle S2 4 Accordingly even in...

Page 479: ...ompletely closed by spring strength or pressure differential due to difference of poppet sizes When arm dumping boom up Figure 16 oil supplied from pump opens poppet AD1 it allows oil to flow to cylin...

Page 480: ...utral oil passage HP rises and exceeds relief valve setting pilot poppet F opens Pressurized oil flows through pilot poppet F into low pressure oil passage LP passing through hole G 3 As pilot poppet...

Page 481: ...in cylinder port HP rises and exceeds the relief valve setting pilot poppet E opens Pressurized oil then flows through pilot poppet E into low pressure oil passage LP passing through hole H 3 As pilo...

Page 482: ...oes not pass 2 When spool is in neutral Oil in neutral oil passage HP flows through signal orifice A into low pressure oil passage LP The pressure of the signal port 4Ps 5Ps increases by the negacon s...

Page 483: ...S0709402K Page 29 Control Valve Kayaba Model KVMG 400 DA PARTS LIST Figure 30...

Page 484: ...S0709402K Page 30 Control Valve Kayaba Model KVMG 400 DA Figure 31...

Page 485: ...S0709402K Page 31 Control Valve Kayaba Model KVMG 400 DA Figure 32...

Page 486: ...lug 28 Poppet 29 Spring 30 Poppet 31 Poppet 32 Poppet 33 Spring 34 Flange 35 O ring 36 Poppet Assembly 37 Spring 38 Sleeve 39 Piston 40 O ring 41 Backup Ring 42 Body 43 Piston 44 Flange 45 O ring 46 P...

Page 487: ...el Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spring 5 Spool End Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spring 5 Spool End 6 Poppet 7 Spring 8 Plug 9 O ring 1...

Page 488: ...Service Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spring 5 Spool End Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spring 5 Spool End 6 Poppet 7 Spring 8 Plug 9 O r...

Page 489: ...wing Spool Assembly 3 Arm 2 Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spring 5 Spool End Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spring 5 Spool End Reference...

Page 490: ...se Valve Spool Assembly 24 Poppet Assembly 36 Reference Number Description 1 Spool 2 Sleeve 3 Sleeve 4 Piston 5 O ring 6 Backup Ring 7 O ring 8 Backup Ring Reference Number Description 1 Spool 2 Spool...

Page 491: ...trol Valve Kayaba Model KVMG 400 DA Plug Assembly 51 Plug Assembly 58 Reference Number Description 1 Plug 2 O ring 3 O ring 4 O ring Reference Number Description 1 Plug 2 O ring 3 O ring 4 Backup Ring...

Page 492: ...Relief Valve Assembly 48 Item Specification Serial No 1001 thru 1050 1051 and Up Relief Valve Pressure Hi 34 3 0 5 MPa Low 31 4 0 5 MPa Hi 34 3 0 5 MPa Low 31 4 0 3 MPa Flow 250 liter min 150 liter mi...

Page 493: ...ng 7 O ring Item Specification Relief Valve Pressure 35 3 0 5 MPa Flow 20 liter min Reference Number Description 1 Plug 2 Spring 3 Poppet 4 Sleeve 5 O ring 6 O ring Component Name Specification Rated...

Page 494: ...Spring or cap crisscrossed Remove and center cap Valve temperature uneven Warm up entire system Dirt in valve Clean valve Lack of pilot pressure Check pilot valve and pilot relief pressure Fails to b...

Page 495: ...n 15 mm 0 59 in Tighten lock nut 5 Problem Possible Cause Remedy Pressure does not rise Pressure does not rise Replace relief valve Pressure unstable Pressure unstable Relief pressure is incorrect Sea...

Page 496: ...proximately 21 3 MPa Tighten lock nut 5 after pressure has been adjusted B Recheck the setting pressure by raising pressure Over Load Relief Valve 1 Shift the control valve spool and read the pressure...

Page 497: ...across flats 10 mm and long cap 12 and 73 Remove O ring 14 from valve housing 2 Remove all spool subassemblies from valve housing 3 Remove socket head bolts 63 and short cap 13 and 74 Remove O ring fr...

Page 498: ...2 Remove spring 33 and poppet 46 3 Grip body assembly 47 width across flats 8 mm in vise taking care not to scratch O ring 35 and 70 surface 4 Remove plug 47 5 and O ring 47 10 5 Remove spring 47 4 sp...

Page 499: ...port P1 Remove socket head bolt 63 width across flats 10 mm and flange 34 Remove poppet 32 spring 33 and O ring 35 3 Remove the remaining load check Remove socket head bolt 63 width across flats 10 mm...

Page 500: ...57 DISASSEMBLY OF RELIEF VALVE 1 Remove eight overload relief valves 49 8 places width across flats 32 mm 2 Remove main relief valve 48 width across flats 41 mm 3 Remove two negacon relief valves 50 w...

Page 501: ...LIEF VALVE 1 This relief valve should be replaced as an assembly When replacing it loosen cap 8 width across flats 41 and O ring 1 Figure 52 If oil leaks from nut 3 remove nut 3 and plug 4 and replace...

Page 502: ...31 75 mm and O ring 2 If oil leaks from nut 3 remove adjusting kit and replace O ring 4 NOTE When disassembling adjusting kit be careful not to allow components to spring out by force of spring or to...

Page 503: ...cores dirt notches and corrosion Remove small scratches with oilstone 2 Inspect exterior surface of spool for scratches and notches Remove small scratches with oilstone 3 Inspect all grooves and passa...

Page 504: ...nd 5 5 and tighten spool end Torque is 2 45 2 65 kg m 18 19 ft lb 3 Assemble poppet 8 6 and spring 8 7 in middle hole of spool 8 Apply Loctite to thread of spool and assemble plug 8 8 Torque is 2 45 2...

Page 505: ...mble poppet 52 and spring 53 and fasten plug 54 with O ring 55 Torque is 10 50 11 52 kg m 76 83 ft lb 2 Assemble travel load check for P1 port Assemble poppet 32 spring 33 and O ring 35 and fasten fla...

Page 506: ...2 Assemble flange for boom two Install O ring 57 on valve housing and fasten flange 56 with socket head bolt 64 The good surface of flange should be facing the O ring side Torque is 5 91 6 53 kg m 43...

Page 507: ...orque is 10 50 11 52 kg m 76 83 ft lb Reassembly of Other Plugs 1 Tighten plug assembly 60 with O ring Torque is 3 16 4 28 kg m 23 31 ft lb 2 Tighten plug assembly 61 with O ring Torque is 11 83 13 05...

Page 508: ...en cap 8 Width across flats 41 Torque is 9 48 11 01 kg m 69 80 ft lb When adjusting the position of port Pi adjust it before adjusting pressure and tightening plug 2 Width across flats 41 mm After adj...

Page 509: ...S0709402K Page 55 Control Valve Kayaba Model KVMG 400 DA Figure 57 S N 1051 and Up...

Page 510: ...1 Torque is 7 95 8 97 kg m 58 65 ft lb If adjusting kit is disassembled clean around threads and adjust pressure by referring to Over Load Relief Valve on page 42 NOTE The torque values are based on...

Page 511: ...ine make sure that oil passages and hydraulic oil are clean 2 Hydraulic oil of which annealing point is 82 113 C should be used in the hydraulic system 3 Relief valve pressure should not be raised abo...

Page 512: ...S0709402K Page 58 Control Valve Kayaba Model KVMG 400 DA...

Page 513: ...d safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capabl...

Page 514: ...OF CONTENTS General Description 3 Theory of Operation 3 Structure 3 Function 3 Parts List 4 Specifications 5 Torques 5 Performance 6 Removal 7 Disassembly 9 Cleaning and Inspection Wear Limits and Tol...

Page 515: ...eutral mode the spool is thrust upward by return spring and the force of balancing spring which determines the secondary discharge pressure is not transmitted to the spool The input port is closed and...

Page 516: ...S0709452K Page 4 Pilot Control Valve Work Lever Joystick PARTS LIST 1 2 3 5 4 6 7 9 10 8 11 30 29 28 27 12 13 14 15 16 17 19 18 20 21 22 23 25 24 26 ASS1240L Figure 1...

Page 517: ...22 Nut 23 Boot 24 Spring Pin 25 Handle Assembly 26 Bushing 27 Terminal 28 Seal Wire 29 Housing 30 Rear Holder Reference Number Description Component Name Specification Type Pilot Control Pressure Str...

Page 518: ...ve Work Lever Joystick Performance Complex Single PUSH ROD STROKE mm 1 1 0 3 Operating Torque PRESSURE kgf cm 0 5 1 28 1 5 2 40 TORQUE kgf cm 9 6 2 5 SECONDARY PRESSURE 2 4 6 5 0 5 6 7 6 8 2 18 4 3 25...

Page 519: ...OFF position and remove from starter switch 9 Hang maintenance warning tag on controls 10 Disconnect negative battery cable leading to frame from battery 11 Remove left and right control stand case 1...

Page 520: ...Page 8 Pilot Control Valve Work Lever Joystick 15 Tag and disconnect hoses from joystick valve 1 Figure 5 16 Remove six fittings 3 Figure 5 and O rings 2 Figure 5 T 3 2 P 4 3 T 1 P 4 2 1 2 3 1 ATS0890...

Page 521: ...l Valve Work Lever Joystick DISASSEMBLY 1 Lift up boot 23 and pull switch cord through hole in case 1 2 Loosen nut 22 from hex nut 20 and remove handle assembly 25 3 Remove hex nut 20 and swash plate...

Page 522: ...9452K Page 10 Pilot Control Valve Work Lever Joystick 4 Remove boot 17 5 Remove joint assembly 18 from case 1 6 Remove plate 16 7 Press spring 10 and remove plug 12 Figure 9 Figure 10 Figure 11 Figure...

Page 523: ...ressure reduction valve 6 7 8 9 11 and spring 10 9 Remove plug 3 10 Remove stopper 11 from pressure reduction valve 6 7 8 9 11 11 Remove spool 6 spring seat 9 spring 8 and shim 7 IMPORTANT Mark valve...

Page 524: ...S0709452K Page 12 Pilot Control Valve Work Lever Joystick 12 Remove push rod 15 and plug 12 13 Remove O ring 13 from plug 12 14 Remove seal 14 from plug 12 Figure 17 Figure 18 Figure 19...

Page 525: ...ck CLEANING AND INSPECTION WEAR LIMITS AND TOLERANCES For general cleaning and inspection procedures refer to General Maintenance Procedures section Clean all parts and dry them with compressed air Ke...

Page 526: ...Control Valve Work Lever Joystick REASSEMBLY 1 Tighten plug 3 slowly NOTE Torque 350 kg cm 25 ft lb 2 Install shim 7 spring 8 spring seat 9 and spool 6 3 Press spring 10 and install stopper 11 Figure...

Page 527: ...lve Work Lever Joystick 4 Install spring 10 in case 1 and pressure reducing valve assembly 6 7 8 9 11 5 Install seal 14 on plug 12 6 Install O ring 13 on plug 12 7 Install push rod 15 on plug 12 Figur...

Page 528: ...52K Page 16 Pilot Control Valve Work Lever Joystick 8 Install plug 12 in case 1 9 Install plate 16 10 Tighten joint assembly 18 11 Install swash plate 19 on joint 18 Figure 27 Figure 28 Figure 29 Figu...

Page 529: ...nut 20 and tighten swash plate 19 13 Grease joint 18 swash plate 19 and push rod 15 14 Install boot 17 NOTE Apply grease onto fitting surface swash plate and push rod 15 Align direction of handle 25 a...

Page 530: ...S0709452K Page 18 Pilot Control Valve Work Lever Joystick 16 Push switch cord through hole in case 1 17 Install boot 23 Figure 35 Figure 36...

Page 531: ...ure 37 3 Install plate and four socket bolts top secure joystick 5 Figure 38 valve to control stand bracket 4 Install left and right control stand case 1 and 2 Figure 38 START UP PROCEDURES 1 Start en...

Page 532: ...K Page 20 Pilot Control Valve Work Lever Joystick 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 5 minutes ARO0470L F...

Page 533: ...is manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimatel...

Page 534: ...ry of Operation 3 Pressure Reducing Valve 3 Operating Theory of Damper Mechanism 5 Parts List 6 Specification 7 Torque 7 Troubleshooting Testing and Adjustment 8 Removal 9 Disassembly 11 Cleaning and...

Page 535: ...port T through inner hole of spool 2 Half Operation Condition If pedal is moved push rod moves down and they transmit this force through spring seat and control spring to spool If spool is moved prima...

Page 536: ...tted through inner hole of spool to operating port secondary pressure transmitted through spool overcomes control spring force and pushes spool up but spool is restricted by push rod and does not move...

Page 537: ...amber of upper part of low pressure at this time ball check valve becomes closing condition because high pressure operates to vibration prevention chamber of lower part 2 Operation When Operating Leve...

Page 538: ...20K Page 6 Travel Control Valve With Damper PARTS LIST 32 24 23 22 16 21 13 12 11 9 5 4 3 10 8 6 7 19 20 17 18 14 15 3 36 25 26 19 20 30 29 28 33 37 1 35 34 2 ARS1850L Figure 5 P T 1 2 3 4 ARS1860L Fi...

Page 539: ...Deal 25 Cover 26 Wrench Bolt 27 Cam 28 Bushing 29 Camshaft 30 Set Screw 31 Set Screw 32 Hex Nut 33 Bellows 34 Space 35 O ring 36 O ring 37 Wrench Bolt Reference Number Description Travel Control Valve...

Page 540: ...mary pressure Defective secondary pressure select spring Replace with new spring Gap between spool and casing is abnormally large Replace spool casing assembly Defective operating parts and components...

Page 541: ...y to OFF position and remove from starter switch 9 Hang maintenance warning tag on controls 10 Disconnect negative battery cable leading to frame from battery 11 Remove cabin under cover by loosening...

Page 542: ...ve With Damper 13 Remove rubber boots 1 Figure 9 14 Remove four bolts and washers 2 Figure 9 pedal brackets 3 with levers 15 Remove four bolts and washers 2 Figure 10 and pedal valve 1 1 2 1 ARS2951L...

Page 543: ...ainer in which disassembled parts can be stored 3 All precision parts must be handled with great care and all parts must be reassembled to their original position 4 All parts must be carefully reassem...

Page 544: ...9820K Page 12 Travel Control Valve With Damper 3 Remove cam shaft 29 and bushing 28 from cam 27 4 Remove cam 27 from cover 25 5 Remove wrench bolt 26 by using tool Figure 13 Figure 14 Figure 15 Figure...

Page 545: ...With Damper 6 Remove cover 25 from body 1 and 2 7 Remove plug assembly 21 24 with push rod assembly 14 20 8 Remove snap ring 13 9 Remove rod guide 11 IMPORTANT Be careful not to spring rod guide 11 F...

Page 546: ...820K Page 14 Travel Control Valve With Damper 10 Remove spool assembly 5 9 11 Remove spring 10 12 Remove stopper 9 spring 6 and spring seat 7 from spool assembly 5 9 Figure 21 Figure 22 Figure 23 Figu...

Page 547: ...trol Valve With Damper 13 Remove plug assembly 21 24 from push rod assembly 14 20 14 Remove seal 23 and 24 from plug 21 15 Remove O ring 22 from plug 21 16 Remove seal 16 from push rod 14 Figure 25 Fi...

Page 548: ...el Control Valve With Damper 17 Remove snap ring 20 from push rod 14 18 Remove plate 19 from push rod 14 19 Remove spring 18 from push rod 14 20 Remove steel ball 17 from push rod 14 Figure 29 Figure...

Page 549: ...d may cause poor equipment performance Be sure to use clean uncontaminated solvent when cleaning precision parts 2 Clean parts thoroughly by gently turning the solvent Dry and clean each part with a c...

Page 550: ...approved lubricant to aid in smooth assembly 6 Tighten all bolts to the specified torque rating as outlined in the torque table 7 Seal all opens ports to prevent foreign material from entering the va...

Page 551: ...nstall rod seal 23 and dust seal 24 on both sides of plug by using tool 4 Install O ring 22 on outside diameter of plug 21 and check plug whether it is abnormal 5 Install spring seat 7 spring 6 and sp...

Page 552: ...spring 18 plate 19 and spring pin 15 on push rod 14 8 Install snap ring 20 on push rod assembly 14 19 9 Install seal 16 on push rod 14 10 After installing spool assembly 5 9 on body 1 and 2 insert rod...

Page 553: ...rod assembly 14 20 on body 1 and 2 12 Install cover 25 on the upside of body 1 and 2 13 Tighten wrench bolt 26 NOTE Tightening torque 88 kg cm 6 37 ft lb 14 Put cam 27 on cover 25 and install cam shaf...

Page 554: ...by using wrench NOTE Tightening torque 88 kg cm 6 37 ft lb 16 One side holds L wrench and the other side holds spanner and tighten set screw 31 and hex nut 32 attached to cam 27 not to loose NOTE Tig...

Page 555: ...and washers 2 2 Install pedal brackets 3 and levers 4 Figure 50 on pedal valve and install four bolts and washers 2 3 Install rubber boots 1 Figure 50 4 Connect hoses as tagged during removal to peda...

Page 556: ...mper START UP PROCEDURES 1 Start engine and set throttle at LOW IDLE 2 Set safety lever on UNLOCK position 3 Slowly push and pull both travel lever about five times without a load to vent air from pil...

Page 557: ...fe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of...

Page 558: ...S0792170K Page 2 Hydraulic Schematic S470LC V TABLE OF CONTENTS General Description 3 Solar 470LC V 4...

Page 559: ...470LC V GENERAL DESCRIPTION Schematic s presented in this section are laid out on facing pages An overlapping edge has been taken into consideration so that a photocopy can be made and pasted together...

Page 560: ...S0792170K Page 4 Hydraulic Schematic S470LC V SOLAR 470LC V Figure 2...

Page 561: ...S0792170K Page 5 Hydraulic Schematic S470LC V...

Page 562: ...S0792170K Page 6 Hydraulic Schematic S470LC V...

Page 563: ...1ELECTRICAL SYSTEM...

Page 564: ......

Page 565: ...ained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own pe...

Page 566: ...el 15 Monitoring System Schematic 16 Operation 18 Instruments 18 Warning and Indicator Lights 20 Initial Operation 22 Mode Select Switch 23 Graphic Information Area Display 24 Overview 24 Main Menus f...

Page 567: ...verheat Protection System 60 Power Boost Mode 61 Operation 61 Power Boost Control Circuit Diagram 62 Automatic Travel Speed Control 63 Automatic Travel Speed Control Circuit Diagram 64 Engine Control...

Page 568: ...t Engine throttle controller defective or not connected Repair connection or replace component Blown fuse Replace fuse Check connections and circuit components for shorts or other damage Wiring harnes...

Page 569: ...and a three phase AC generator with a rectifier The electric wiring used in the system is easily identifiable by the insulator color The color symbols used in the electrical system are listed in the f...

Page 570: ...ne stop motor When the starter switch 5 is in the preheat on and start positions the current flows from the battery 1 fusible link 3 fuse 6 starter switch 5 B terminal starter switch 5 BR terminal bat...

Page 571: ...er relay 8 are connected the pinion gear of the starter 9 is pushed forward and makes contact with the ring gear of the flywheel and the internal contacts of the starter are connected The current flow...

Page 572: ...and PP terminals are opened As a result the rotation of the starter 9 is stopped Once the engine is running the starter 9 will not operate even if the starter switch 5 is moved to the start position p...

Page 573: ...e preheat time is approximately 19 seconds A built in timer in the instrument panel will activate an indicator light approximately 19 seconds after the preheat process has been selected Even after the...

Page 574: ...is in the ON position the engine stop motor rotates 180 and comes to a stop due to the cam switch When the start switch is in the OFF position the engine stop motor moves 180 from the running mode pos...

Page 575: ...elay 5 A terminal of engine stop motor 6 E terminal of engine stop motor 6 ground The engine stop motor opens pushes the fuel shut off lever of the fuel injection pump and the system is in the running...

Page 576: ...e shut off lever of the fuel injection pump linked to the engine stop motor by a cable is moved to the close pull position and the engine is stopped The engine stop motor moves 180 from the running mo...

Page 577: ...ctrical components When the alternator 7 starts to operate a current flows from the R I terminal of alternator diode 8 battery relay 2 coil securing a path for the charging current to the battery 1 Th...

Page 578: ...plays information selected by the operator ARS0090L Figure 9 Reference Number Description 1 Instrument Panel 2 Battery 3 Engine Speed Sensor 4 Return Filter Switch 5 Pilot Filter Switch 6 e EPOS Contr...

Page 579: ...ion area 3 and 4 Figure 10 Gauges Warning Lights Mode Select Switches 1 Engine Coolant Temp Gauge 2 Fuel Gauge 3 Multi function Gauge and Graphic Information Area 4 Digital Clock 5 Service Hour Meter...

Page 580: ...ER LOAD L3 WATER TEMP L4 PREHEAT L5 WORK LAMP L1 BATTERY CHARGE L2 ENG OIL PRESS 8 7 ILLUMINATION EL 5 20 6 SIG 19 SIG L4 L1 L2 L3 6 17 L6 L5 11 1 9 10 2 22 CN2 13 CN2 14 CN2 11 CN2 12 CN2 1 RS 422 CN...

Page 581: ...ssure Sensor 7 Engine Coolant Temperature Sensor 8 Fuel Gauge 9 Engine Speed Sensor 10 Hydraulic Oil Temp Sensor 11 Engine Oil Pressure Switch 12 Air Cleaner Indicator 13 Return Filter Switch 14 Pilot...

Page 582: ...F 128 ohms Fuel Level CN4 7 CN4 8 1 10 LCD Blinking over 5K ohms FULL under 525 ohms Tachometer CN4 16 CN4 17 N 146 f 60 S300LC V N 146 f 60 S300LL N 152 f 60 S340LC V N 152 f 60 S420LC V N 152 f 60...

Page 583: ...4 2 V 0 00816 x P 1 0 V Sensor output voltage V P Displayed pressure Bar Main pump discharge pressure rear pump CN4 3 CN4 4 Function Display Sensor Specification Input Terminal Input Specification FRO...

Page 584: ...ssure CN2 11 Lights up when engine oil pressure switch is turned ON Oil pressure drops below 0 7 kg cm2 10 psi After starting engine if engine oil pressure is insufficient after 8 seconds a warning bu...

Page 585: ...Area Air Cleaner CN2 12 Lights up when air cleaner is clogged Symbol is blinking Return Filter CN2 13 Lights up when return filter pressure increases over 1 5 kg cm2 21 psi Symbol is blinking Pilot F...

Page 586: ...Initial Operation When battery voltage is input to CN7 9 starter switch is turned from OFF to ON position All LCD LED and warning lights are turned on and turned off after about 2 seconds Warning buzz...

Page 587: ...put Pump Discharge Volume Control Valve Current mA Swing Priority Solenoid Valve 7 Segment Display Power Mode Power Mode ON Variable Output 9 x Standard Mode OFF 0 7 x Work Mode Trenching Mode ON ON x...

Page 588: ...ided into two menus One is main menu for user and the other is special menu for specialist These menus can be moved from normal display mode by the combination of select buttons Selection Buttons Grap...

Page 589: ...f machine operation MENU SELECTION BUTTONS 1 Up Arrow Button 1 on Figure 12 Move the cursor to up left and previous screen 2 Down Arrow Button 2 on Figure 12 Move the cursor to down right and next scr...

Page 590: ...ter oil information to the operator Refer to the Operation and Maintenance Manual for details LANGUAGE SETTING This mode is used for setting desired language TIME SETTING This mode is used for setting...

Page 591: ...reset the operating hour and then the operating hours until the next service interval can be easily checked Menu Display Order and Icon Explanation ARO0400L Hrs 0232 Reset 1 Fuel Filter Figure 16 1 2...

Page 592: ...ESSING AND EXITING ESCAPING MENUS Entering Accessing Menus When normal mode screen is displayed if the enter button 3 and escape button ESC 4 are pressed simultaneously for more than 3 seconds normal...

Page 593: ...once again SPECIAL MENU SELECTIONS Sub menu Selection Method Various sub menus can be selected by pressing Up 1 on Figure 18 and Down 2 on Figure 18 button Move the cursor to desired menu and a select...

Page 594: ...Max 9 E G Oil Press 3 Work Travel Solenoid 10 Air Cleaner 4 Hi Speed Solenoid 11 Return Filter 5 Auto Travel 12 Pilot Filter 6 Work Lamp 13 OWD Select 7 Pressure Py 5 Output State 1 Relief Press Up 4...

Page 595: ...hine Status Information 1 EPPR Valve Current 2 Dial Voltage 3 TPS Voltage Output voltage of potentiometer built into engine control motor EPPR CURRENT ARS0870L mA 598 Figure 24 DIAL VOLTAGE ARS0880L m...

Page 596: ...on OFF and the other statuses of on off type sensors MACHINE INFO ARS1780L Input State Output State Hyd Oil Temp 4 Figure 27 1 Alternator OFF 2 Power Max ON 3 Work Travel Sel OFF 4 Hi Speed Sel OFF 5...

Page 597: ...on Remarks 1 6 BAR Lit CN 3 4 CN 3 5 Over 1 510 Below 30 C Below 86 F 1 6 2 6 BAR Lit 745 1 510 31 50 C 87 122 F 1 6 3 6 BAR Lit 332 745 51 75 C 123 167 F 1 6 4 6 BAR Lit 244 332 76 85 C 168 185 F 1 6...

Page 598: ...cursor is located in Failure Info of special menu screen press enter button 3 on Figure 18 and Failure Info screen is displayed 2 Exiting Sub menus If escape button ESC 4 on Figure 18 is pressed for...

Page 599: ...ure information Memorized record of past failure is displayed Failure code failure contents When a number of failures are produced failure information can be checked by using PRV 1 on Figure 18 or NXT...

Page 600: ...t this time deletion signal will be displayed and the screen will move to previous menu after deletion This screen will be displayed during 3 seconds When NO ESC 4 on Figure 18 button is pressed the s...

Page 601: ...82 Communication Err Communication error between e EPOS controller and instrument panel Note Automatic reset when problem is corrected 01 EPPR v v short Short Circuit Cut off output current 0 mA Afte...

Page 602: ...put voltage Over 4 6 0 2 V Cut off EPPR v v current 0 mA 24 TPS Voltage Err L Output voltage Over 0 4 0 2 V Cut off EPPR v v current 0 mA 25 Fpump Sensor Err H Output voltage Over 4 6 0 2 V 26 Fpump S...

Page 603: ...ion A Entering Sub menus When a cursor is located in Operating Info of special menu screen Figure 37 press enter button 3 on Figure 18 and Operating Info screen will be displayed Figure 38 B Informati...

Page 604: ...itch Py control valve ON status High speed High speed s v and travel pressure switch Py control valve ON status Hydraulic Oil Temperature Distribution C F Temperature of hydraulic oil is classified 6...

Page 605: ...urned to previous screen NOTE When YES 3 on Figure 18 button is pressed operation hours will reset At this time resetting signal will be displayed and the screen will move to previous menu after reset...

Page 606: ...19 Mode select signal Machine information Auto idle signal Sensors 18 Engine speed sensor signal Engine throttle control signal Drive signal Potentiometer signal Coolant water temp signal Throttle co...

Page 607: ...8 Pump Pressure Sensor 9 Engine Speed Sensor 10 Electro magnetic Proportional Pressure Reducing Valve E P P R Valve 11 Solenoid Valve Pressure Up 12 Solenoid Valve Swing Priority 13 Solenoid Valve Hi...

Page 608: ...e indicator lamp will turn ON to display the selected mode Wheel type Power mode switch signal 1 Potentiometer signal Pump control signal g 15 Low Throttle signal Hi 16 Engine throttle control signal...

Page 609: ...low the rated speed When this occurs the controller senses this decrease and immediately reduces the pump discharge volume to maintain the engine speed at the rated level On the other hand if the load...

Page 610: ...ption in comparison with Power Mode The current to the E P P R valve is shut off and pump discharge volume is controlled by pump regulator A B C D HDA6020L Figure 46 Reference Number Description A Eng...

Page 611: ...S0802220K Page 47 Electrical System Reference Number Description A Engine Horsepower hp B Engine Speed rpm C Pump Discharge Volume lpm D Pump Discharge Pressure kg cm2 Reference Number Description...

Page 612: ...1 9 9 10 8 11 CN3 9 10 11 12 14 15 13 17 16 CN1 6 5 7 8 6 4 3 2 1 20 18 19 11 CN7 14 16 15 13 12 CN3 11 CN3 10 CN3 9 CN3 12 CN3 8 CN1 7 CN1 5 CN4 11 CN4 10 CN4 13 CN4 12 LOW 1 1 5 2 3 1 4 CN2 3 12 2 2...

Page 613: ...stem Reference Number Description 1 Battery 2 Battery Relay 3 Fuse 4 e EPOS Controller 5 Instrument Panel 6 Engine Speed Sensor 7 Engine Throttle Controller 8 Engine Control Motor 9 Engine Control Dia...

Page 614: ...oid adjusts the assignment of hydraulic oil flow to each device on the equipment Wheel Engine throttle control signal Trenching mode switch signal 15 Throttle signal Hi Lo Potentiometer signal Drive s...

Page 615: ...ck stops The current to the solenoid valve for swing priority is shut off 2 Trenching Mode This mode is used for heavy duty ditch digging work or for loading work requiring big swing angles The voltag...

Page 616: ...15 16 7 6 2 1 4 5 2 1 11 3 13 2 12 1 9 8 10 14 6 5 4 7 CN7 1 13 3 2 CN3 CN4 CN2 3 20 19 1 5 2 10A CN7 TxD RxD 10 9 5 2 20A 3 TxD RxD RxD TxD CN3 8 CN3 11 CN3 12 CN3 10 CN3 9 CN1 9 CN1 14 RS 422 CN1 1...

Page 617: ...ter feed back signals are the same the engine controller shuts off the current to the control motor The engine control motor cable is a solid type and is connected to the engine fuel injection control...

Page 618: ...S0802220K Page 54 Electrical System...

Page 619: ...r switch should be turned off and the cause of abnormal load should be repaired and the starter switch can be turned on again The engine control dial can once again be used to control the engine speed...

Page 620: ...umber Description 1 Knob 2 Potentiometer Variable Resistor 2 1 1 1 VIEW POTENTIOMETER BOTTOM 1st STEP 10 10 7th STEP 13th STEP CCW MECHANICAL STOP CW MECHANICAL STOP 2 3 2 3 1 2 3 4 2 5V 1 0V 4 0V 1ST...

Page 621: ...ical System The engine control dial has a built in potentiometer When the control knob is moved the output voltage through terminals 2 and 3 will vary from the 5 V supplied from the throttle controlle...

Page 622: ...55 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse 4 e EPOS Controller 5 Instrument Panel 6 Engine Speed Sensor 7 Engine Throttle Controller 8 Engine Control Motor 9 Engine Control Dial...

Page 623: ...ers are in the neutral position the e EPOS controller sends an automatic reduction signal to the throttle controller When the engine throttle controller receives this signal it is compared with the si...

Page 624: ...throttle controller will signal the engine control motor to decrease the engine speed When the coolant is overheated the warning buzzer will sound standard mode is selected and low engine speed will...

Page 625: ...activate the power boost solenoid valve and increase the relief valve pressure from 330 350 kg cm2 4 700 5 000 psi The excavation ability is increased by approximately 6 NOTE Do not use this switch fo...

Page 626: ...CN3 11 12 13 14 17 CN1 6 7 8 6 3 4 1 2 20 11 16 CN7 CN1 1 CN4 1 3 10 7 8 9 CN1 CN3 11 CN3 12 CN3 8 CN3 10 CN3 9 RxD RxD RS 422 TxD TxD 5 6 1 CN2 3 7 6 CN1 13 CN1 9 CN1 2 CN1 8 4 1 3 20A 2 ARS1150L Fig...

Page 627: ...monitored by the two pressure sensors in the discharge lines of the front upper and rear lower pumps When the travel load is high pressure over 300 kg cm2 4 300 psi the solenoid valve is turned OFF an...

Page 628: ...2 17 14 4 9 10 15 16 1 LOW CN4 10 CN4 11 8 CN3 CN4 CN2 6 CN2 5 0 II 3 10 I 6 AUTO MANUAL 9 2 CN1 12 SIG 6 SIG 5 CN4 2 CN4 4 CN4 3 CN4 1 10A CN1 8 CN1 9 CN1 1 CN1 2 4 3 20A 2 1 ARS1170L Figure 61 Refe...

Page 629: ...stopper position and the cable slack is acceptable 3 A If the lever is not in the minimum position and touching the stopper move the 3 cable to one hole lower on the lever If the cable slack is exces...

Page 630: ...le VR1 Refer to throttle controller name plate 3 Figure 64 Standard Mode VR2 Refer to throttle controller name plate 3 Figure 64 Reference Number Description 1 VR1 Automatic Deceleration Adjusting Var...

Page 631: ...age 67 Electrical System Figure 65 Reference Number Description 1 Engine Fuel Control Lever Area 2 Control Motor Cable Bracket 3 Engine Speed Control Cable 4 To Engine Control Motor Reference Number D...

Page 632: ...in normal range 2 Engine Speed Monitor This LED light flashes according to the engine speed The flashing interval is proportional to the engine speed 3 Communication Monitor These LED lamps flash whe...

Page 633: ...re information codes a part of failure information Refer to the failure information part of letter information display for details Mode Selection Display Readout Operation Status Upper Digit Lower Dig...

Page 634: ...ssibility of motor damage or burn out exists 4 After the malfunction is corrected turn the starter switch from OFF to the ON position and normal operation will resume Throttle Controller Input Signal...

Page 635: ...ly 5 seconds Continuous Operation II Position When the wiper switch 4 is turned I position the current flows from the fuse 3 B terminal of wiper motor 7 L terminal of wiper motor 7 No 5 terminal of wi...

Page 636: ...er 6 No 4 terminal of wiper timer 6 S terminal of wiper motor 7 B terminal of wiper motor 7 and the wiper motor is stopped at the auto stop position WINDOW WASHER OPERATION When the window washer swit...

Page 637: ...S0802220K Page 73 Electrical System...

Page 638: ...2 CN3 10 CN3 9 CN3 12 CN3 11 CN3 8 CN7 1 L5 CN7 9 11 10A 15 RH 14 LH LH RH RH 16 LH 17 FL FR FMR 18 FL FR FML 30 86 87 85 7 87a 3 10 II 6 I 4 0 86 30 85 87a 87 8 13 1 7 10 9 2 10A 5 I 5 0 9 10A 20A 1...

Page 639: ...a 15 Work Light 2 ea 16 Additional Work Light 2 ea 17 Front Cabin Light 2 ea 18 Front Cabin Light 4 ea 19 Rear Cabin Light 2 ea Reference Number Description Switch Position Connected Terminal of switc...

Page 640: ...AD WARNING DEVICE OVERLOAD WARNING DEVICE CIRCUIT DIAGRAM 5 6 4 2 1 3 ARS1260L Figure 69 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse Box 4 e EPOS Controller 5 OWD Select Switch 6 Pre...

Page 641: ...safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable...

Page 642: ...S0892170K Page 2 Electrical Schematic S470LC V TABLE OF CONTENTS General Description 3 Solar 470LC V 4...

Page 643: ...470LC V GENERAL DESCRIPTION Schematic s presented in this section are laid out on facing pages An overlapping edge has been taken into consideration so that a photocopy can be made and pasted together...

Page 644: ...S0892170K Page 4 Electrical Schematic S470LC V SOLAR 470LC V Figure 2...

Page 645: ...S0892170K Page 5 Electrical Schematic S470LC V ELECTRICAL DIAGRAM DAEWOO HEAVY INDUSTRIES LTD NO 599 00039 Model Solar 470LC V Name HAAD4180...

Page 646: ...S0892170K Page 6 Electrical Schematic S470LC V...

Page 647: ...1ATTACHMENTS...

Page 648: ......

Page 649: ...nt of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that u...

Page 650: ...CONTENTS Front Attachment Pin Specifications 3 Front Attachment Removal and Installation 4 Arm Removal Procedure 4 Boom Removal Procedure 6 Installation 7 Arm Installation Procedure 7 Boom Installati...

Page 651: ...on on wear tolerances and replacement limits for mounting pins Mounting Pin Diameter mm Inches Length mm Inches A 125 0 mm 4 92 in 1 140 0 mm 44 88 in B 120 0 mm 4 72 in 1 119 0 mm 44 06 in C 120 0 mm...

Page 652: ...with the lower structure Never rotate the upper structure once the counterweight or front attachment has been removed IMPORTANT Always break down the front attachment by removing outermost sections f...

Page 653: ...ly if necessary Place a sling under the arm cylinder the cylinder used to extend and retract the attachment arm pinned to the top of the boom Lift the sling so that the weight load on the rod end of t...

Page 654: ...aulic pressure and disconnect line couplings as previously outlined in the Arm Removal Procedure observing the same precautions Disconnect wiring for work light assemblies and any other accessory line...

Page 655: ...sling from around the rod end arm cylinder pin withdraw the pin and lift the body of the arm cylinder to re pin the mounting connection BOOM INSTALLATION PROCEDURE Before reassembling the attachment m...

Page 656: ...and Arm START UP PROCEDURES Once the boom has been serviced it should be lubricated as outlined in the initial start up procedures of the operation manual Refer to the appropriate operation and mainte...

Page 657: ...s section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsib...

Page 658: ...Tooth Inspection and Replacement 3 Type 1 3 Type 2 4 Bucket O ring Replacement 6 Bucket Shimming Procedures 8 New Bucket Installation 8 Bucket Attachment Removal and Reversal 9 Detaching the Bucket 9...

Page 659: ...points on the working surfaces of tooth points pits cracks chips or craters are larger than 8 mm to 10 mm 1 3 to 1 2 across 1 On a routine basis inspect the bucket teeth to make sure that tooth wear o...

Page 660: ...ng steel ball causes the boss to go inside WARNING Due to the possibility of flying metal objects always wear safety helmet protective gloves and eye protection when changing bucket teeth Curl the buc...

Page 661: ...wear down to a point that bucket adapter is exposed See Figure 4 2 To replace a tooth use a hammer 1 Figure 5 and punch 2 to drive locking pin assembly out of tooth and tooth adapter 3 Once the worn...

Page 662: ...he way 3 Remove the old O ring and temporarily install the new O ring 1 Figure 8 onto the bucket boss 2 Make sure that the O ring groove on both the bucket link 4 and boss have been cleaned 4 Realign...

Page 663: ...S0904005K Page 7 Bucket 5 Roll the new O ring 1 Figure 9 into the O ring groove ARO1392L 1 Figure 9...

Page 664: ...rance should be 1 mm 0 04 in between side face of boss and inside edge of ear bushing Y Figure 10 Too tight a fit less than 1 mm 0 04 in can cause excessive wear while too much clearance may produce e...

Page 665: ...semble the link pin end retainers and pull out the pin Lift the arm away from the bucket so that the bucket can be carried away or another end attachment can be put on the excavator ATTACHING THE BUCK...

Page 666: ...simplified if some type of rotating or swiveling support can be used on the ground underneath the bucket Follow instructions for Bucket Attachment to replace pins WARNING When making linkage alignment...

Page 667: ...EET ADDRESS TELEPHONE CITY FAX STATE PROVINCE COUNTRY NAME MACHINE MODEL SERIAL NUMBER MANUAL NUMBER SHOP MANUAL SECTION NUMBER PROPOSED DESCRIPTION OF CORRECTION AND OR SUGGESTION Use additional pape...

Page 668: ......

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