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K1009096E Shop Manual
Copyright 2005

Doosan

Doosan

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

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

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

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

Shop Manual

K1009096E

Serial Number 5001 and Up

DX420LC

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Summary of Contents for DX420LC

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

Page 2: ......

Page 3: ...Product Label Instructions Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine DX420LC Serial Number 5001 and Up Pub No K1009096E Pub No K1009096E ...

Page 4: ......

Page 5: ...P000017 Upper Structure Cabin SP000018 Counterweight SP000265 Fuel Tank SP000264 Swing Bearing SP000262 Swing Reduction Gear SP000249 Lower Structure and Chassis Track Assembly SP000263 Air Conditioner SP000025 Engine and Drive Train Drive Coupling Main Pump SP000026 Hydraulics Hydraulic System Troubleshooting Testing and Adjustment SP000273 Accumulator SP000028 Center Joint Swivel SP000181 Cylind...

Page 6: ...Travel Control Valve With Damper SP000070 Solenoid Valve Assembly SP000191 Breaker EPPR Valve Opt SP000192 Fan Motor Vane Type SP000209 Gear Pump Fan Cooling Drive SP000208 Fan Cooling Flow In Out Change Valve SP000207 Hydraulic Schematic DX420LC SP000274 Electrical System Electrical System SP000269 Electrical Schematic DX420LC SP000275 Attachments Boom and Arm SP000463 Bucket SP000072 ...

Page 7: ...1Safety ...

Page 8: ......

Page 9: ...SP000256 Page 1 Track Excavator Safety SP000256 TRACK EXCAVATOR SAFETYSP000256 Track Excavator Safety Edition 1 ...

Page 10: ...Track Excavator Safety SP000256 Page 2 MEMO ...

Page 11: ...a DOOSAN Daewoo Excavator 6 General Safety Essentials 10 Location of Safety Labels 11 Summary of Safety Precautions for Lifting in Digging Mode 12 Unauthorized Modifications 13 General Hazard Information 13 Before Starting Engine 22 Machine Operation 26 Maintenance 33 Battery 42 Towing 44 Shipping and Transportation 45 Lifting With Sling 45 ...

Page 12: ...Track Excavator Safety SP000256 Page 4 MEMO ...

Page 13: ...low all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up ...

Page 14: ...e on page 1 12 4 Unauthorized Modifications on page 1 13 5 General Hazard Information on page 1 13 6 Before Starting Engine on page 1 22 7 Machine Operation on page 1 26 8 Maintenance on page 1 33 9 Battery on page 1 42 10 Towing on page 1 44 11 Shipping and Transportation on page 1 45 12 Lifting With Sling on page 1 45 DANGER Unsafe use of the excavator could lead to serious injury or death Opera...

Page 15: ...tions 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 others In no event should you or others engage in prohibited uses or actions as described in this manual DOOSAN delivers machines that comply with all applicable regulations and standards of the country t...

Page 16: ... for personal injury or accidents Always observe safety precautions and follow recommended procedures CAUTION This word is used on safety messages and safety labels and indicates potential of a hazardous situation that if not avoided could result in minor or moderate injury It may also be used to alert against a generally unsafe practice WARNING This word is used on safety messages and safety labe...

Page 17: ...nce Therefore the safety messages in this manual and on the machine may not include all possible safety precautions If any procedures or actions not specifically recommended or allowed in this manual are used you must be sure that you and others can do such procedures and actions safely and without damaging the machine If you are unsure about the safety of some procedures contact a DOOSAN distribu...

Page 18: ...acity ratings that are printed at the end of this safety section are based on the machine being level on a firm supporting surface with hooks and slings attached in approved configuration Loads must be balanced and supported evenly Use tag lines to keep the load steady if wind conditions and large surface area are a problem Work crew hand signals individual tasks and safe procedures should all be ...

Page 19: ...ABELS Location of safety labels decals can vary from unit to unit Refer to appropriate Operation and Maintenance Manual and parts manual for your unit Always replace damaged or faded decals Figure 1 8 13 5 3 1 2 6 15 12 FG001823 14 11 9 11 10 2190 3311 16 0 7 4 ...

Page 20: ...ng 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 machine unless they ve been properly trained and understand the information in the Operation and Maintenance Manual WARNING NEVER wrap a tag line around your hands or body NEVER rely on tag lines or ma...

Page 21: ...t 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 judgement in emergencies and may cause accidents When working with another operator or with a person on work site traffic duty be sure that all personnel know the nature of the work and understand all hand ...

Page 22: ...operator s cabin To ensure safety do not use the radio or music headphones when operating the machine 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 lock lever securely in the LOCK position If you accidentally touch the work equipment levers when they a...

Page 23: ...d root mean square acceleration to which the hands arms are subjected is less than 2 5 m s2 Whole body The weighted root mean square acceleration to which the whole body is subjected is less than 0 5 m s2 Measurements are obtained on a representative machine using measuring procedures as described in the following standard ISO 2631 1 ISO 5349 and SAE J1166 Recommendations for Limiting Vibrations 1...

Page 24: ...teps or track shoes wipe it off immediately Always keep these parts clean Repair any damage and tighten any loose bolts Never jump on or off the machine In particular never get on or off a moving machine These actions may lead to serious 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 hand...

Page 25: ... 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 secured Precautions When Handling Fluids at High Temperature Immediately after operations are stopped the coolant engine oil and hydraulic oil are at high temperature and the radiator and hydraulic tank are...

Page 26: ...control levers are operated the clearance between the machine and the work equipment will change and this may lead to serious damage or personal injury If going between movable parts is necessary always position and secure the work equipment so that it cannot move Fire Extinguisher and First Aid Kit As a precaution if any injury or fire should occur always do the following Be sure that fire exting...

Page 27: ...rotective Structure or window guards Never attempt to alter or modify any type of protective structure reinforcement system by drilling holes welding remounting or relocating fasteners Any serious impact or damage to the system requires a complete integrity reevaluation Reinstallation recertification and or replacement of the system may be necessary Contact your DOOSAN distributor for available sa...

Page 28: ...ibe in Handling of Accumulator in the Operation and Maintenance Manual The accumulator is charged with high pressure nitrogen gas so it is extremely dangerous if it is handled in the wrong way Always observe the following precautions Do not drill or make any holes in the accumulator or expose it any flame fire or heat source Do not weld on the accumulator or try attaching anything to it When carry...

Page 29: ...d the operator seat in the upper right corner of the cabin This tool can be used in case of an emergency situation that requires the breaking of glass to exit from the operator s cabin Grip the handle firmly and use the sharp point to break the glass FG000178 Figure 13 WARNING Protect your eyes when breaking the glass ...

Page 30: ...not to damage or cut any of these lines Check the condition of the river bed and the depth and flow of the water before operating in water or crossing a river NEVER be in water that is in excess of the permissible water depth Any type of object in the vicinity of the boom could represent a potential hazard or cause the operator to react suddenly and cause an accident Use a spotter or signal person...

Page 31: ...are parts laying around in the operator s compartment The vibration of the machine when traveling or during operations may cause them to fall and damage or break the control levers or switches They may also get caught in the gap of the control levers and cause the work equipment to malfunction or move dangerously This may lead to unexpected accidents Check the coolant level fuel level and hydrauli...

Page 32: ... properly 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 there are no obstructions Do not let anyone near the machine when carrying out the checks Check the operating condition of the equipment and the actuation of the bucket arm boom travel and s...

Page 33: ... machine Before moving the machine check the position of undercarriage The normal travel position is with idler wheels to the front under the cabin and the drive sprockets to the rear When the undercarriage is in the reversed position the travel controls must be operated in opposite directions ...

Page 34: ...re changing the direction 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 check that there is no one behind the machine before traveling in reverse When operating in areas that may be hazardous or have poor visibility designate a person to direct work ...

Page 35: ...ope or obstacle that causes the machine to tilt 10 degrees or more to the right or left or 30 degrees or more from front to rear Do not operate the steering suddenly The work equipment may hit the ground and cause the machine to lose its balance and this may damage the machine or structures in the area When traveling on rough ground travel at low speed and avoid sudden changes in direction Always ...

Page 36: ...ass fallen leaves or wet steel plates Even slight slopes may cause the machine to slip to the side so travel at low speed and make sure that the machine is always traveling directly up or down the slope Avoid changing the direction of travel on a slope This could result in tipping or side slipping of the machine When possible operate the machine up slopes and down slopes Avoid operating the machin...

Page 37: ...work site beforehand to prevent the machine from falling and to prevent the ground stockpiles or banks from collapsing Precautions for Operation Be careful not to go close to the edge of a cliff by mistake Use the machine only for its main purpose Using it for other purposes will cause failures To ensure an ample view do as follows When working in dark areas attach working lights and front lights ...

Page 38: ...y as 4 6 m 13 20 ft from the power line Very high voltage and rainy weather could further decrease that safety margin NOTE Before starting any type of operation near power lines either above ground or buried cable type you should always contact the power utility directly and work out a safety plan with them Protecting Cabin from Falling Object Optional In a work site where falling objects or flyin...

Page 39: ...working capacity The jolting shocks and impact loads caused by bumping or bottoming the boom or attachment are more likely to cause severe stress in very cold temperatures Reducing work cycle rate and work load may be necessary When the temperature rises frozen road surfaces become soft so the machine travel becomes unstable In cold weather do not touch metal surfaces with your bare hands If you t...

Page 40: ... public roads provide fences signs flags or lights and put up any other necessary signs to ensure that passing traffic can see the machine clearly and park the machine so that the machine flags and fences do not obstruct traffic After the front attachment has been lowered to an overnight storage position and all switches and operating controls are in the OFF position the safety lock lever must be ...

Page 41: ...s 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 nonslip soles to prevent yourself from slipping and falling on wet places Wear safety glasses and protective clothing when washing the machine with high pressure steam Take action to prevent touching high pressure water and cutting your skin or havin...

Page 42: ...All fuels most lubricants and some coolant mixtures are flammable Leaking fuel or fuel that is spilled onto hot surfaces or onto electrical components can cause a fire Store all fuels and all lubricants in properly marked containers and away from all unauthorized persons Store oily rags and other flammable material in a protective container Do not smoke while you refuel the machine or while you ar...

Page 43: ...ts can cause personal injury Do not allow hot oil or hot components to contact the skin Remove the hydraulic tank filter plug only after the engine has been stopped Make sure that the hydraulic tank filter plug is cool before you remove it with your bare hand Remove the hydraulic tank filter plug slowly to relieve pressure Relieve all pressure in the hydraulic oil system in the fuel system or in t...

Page 44: ...that contain flammable fluids Do not flame cut on pipes or on tubes that contain flammable fluids Before you weld on pipes or on tubes or before you flame cut on pipes or on tubes clean the pipes or tubes thoroughly with a nonflammable solvent If heat is applied directly to rubber hoses or piping under pressure they may suddenly break so cover them with a fireproof covering Wear protective clothin...

Page 45: ...or attachment Place attachments that have been removed from the machine in a safe place so that they do not fall Put up a fence around the attachments and take other measures to prevent unauthorized persons from entering Figure 37 1 FG001446 FG000371 Figure 38 DANGER DOOSAN warns any user that the removal of the counterweight from the machine front attachment or any other part may affect the stabi...

Page 46: ... work is carried out with the inspection cover open but not locked there is danger that it may suddenly close and cause injury if there is a gust of wind Crushing Prevention and Cutting Prevention You should always have at least two people working together if the engine must be run during service One person needs to remain in the operator s seat ready to work the controls or stop the machine and s...

Page 47: ... Blocking for Work Equipment Do not allow weight or equipment loads to remain suspended Lower everything to the ground before leaving the operator s seat Do not use hollow cracked or unsteady wobbling supports Do not work under any equipment supported only by a lifting jack Action When Abnormality Is Found During Inspection If any abnormality is found during inspection always carry out repairs In ...

Page 48: ...ose your fingers Do not bend high pressure lines Do not strike high pressure lines Do not install lines tubes or hoses that are bent or damaged Make sure that all clamps guards and heat shields are installed correctly to prevent vibration rubbing against other parts and excessive heat during operation If any of the following conditions are found replace the part Damage or leakage from hose end Wea...

Page 49: ...ntaminant and may only be disposed of at approved collection facilities To prevent pollution of the environment always do the following Never dump waste oil in a sewer system rivers etc Always put oil drained from your machine in containers Never drain oil directly onto the ground Obey appropriate laws and regulations when disposing of harmful materials such as oil fuel solvent filters and batteri...

Page 50: ...ities of water and see a doctor at once If you accidentally drink battery electrolyte drink a large quantity of water or milk raw egg or vegetable oil Call a doctor or poison prevention center immediately When cleaning the top surface of the battery wipe it with a clean damp cloth Never use gasoline thinner or any other organic solvent or detergent Tighten the battery caps securely If the battery ...

Page 51: ...o series connected twelve volt batteries have a cable connecting one positive terminal on one of the 12 volt batteries to a negative terminal on the other battery Booster or charger cable connections must be made between the nonseries connected positive terminals and between the negative terminal of the booster battery and the metal frame of the machine being boosted or charged Refer to the proced...

Page 52: ...left and right hooks and secure in position If the engine on the problem machine will not start or there is a failure in the brake system always contact your DOOSAN distributor Never go between the towing machine and the towed machine during the towing operation It is dangerous to carry out towing on slopes so select a place where the slope is gradual If there is no place where the slope is gradua...

Page 53: ...formation on partial disassembly Refer to the Transportation and Shipping section of this Operation and Maintenance Manual for information on loading unloading and towing LIFTING WITH SLING 1 Refer to Specification section of Operation and Maintenance Manual for information on weight and dimensions 2 Use properly rated cables and slings for lifting 3 Position machine for a level lift 4 Lifting cab...

Page 54: ...SP000256 Track Excavator Safety Page 46 ...

Page 55: ...1Specifications ...

Page 56: ......

Page 57: ...SP000257 Page 1 Specification for DX420LC SP000257 SPECIFICATION FOR DX420LCSP000257 Specification for DX420LC Edition 1 ...

Page 58: ...Specification for DX420LC SP000257 Page 2 MEMO ...

Page 59: ...ral Dimensions DX420LC 10 Working Range 12 General Specifications 14 Engine Performance Curves Per DIN 6270 Standard 16 Approximate Weight of Workload Materials 18 Performance Tests 20 Excavator Performance Standards 21 Test Conditions 21 Travel Speed and Travel Motor Balance Steering Deviation Tests 21 Swing Speed and Deceleration Force Test 23 Cylinder Performance Tests 25 ...

Page 60: ...Specification for DX420LC SP000257 Page 4 MEMO ...

Page 61: ...llow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up ...

Page 62: ...SP000257 Specification for DX420LC Page 6 ...

Page 63: ...DESCRIPTION The excavator has three main component sections The Upper Turntable The Lower Undercarriage and Track Frames The Excavator Front end Attachment The following illustration identifies main components and their locations See Figure 1 on page 8 ...

Page 64: ...SP000257 Specification for DX420LC Page 8 COMPONENT LOCATIONS Figure 1 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 2 40 39 38 37 36 34 35 33 32 29 28 30 31 22 23 27 24 25 26 FG001806 ...

Page 65: ...Cleaner 13 Swing Bearing 14 Cabin 15 Seat 16 Work Lever Joystick Controls 17 Travel Lever 18 Boom Cylinder 19 Arm Cylinder 20 Boom 21 Arm 22 Bucket Cylinder 23 Guide Link 24 Bucket 25 Push Link 26 Side Cutter 27 Tooth Point 28 Idler 29 Track Adjuster 30 Track Guard 31 Battery 32 Lower Roller 33 Center Joint 34 Upper Roller 35 Sprocket 36 Travel Motor 37 Track Link and Shoe 38 Suction Filter 39 Ret...

Page 66: ... FT HD ARM 2 16 m3 2 83 yd3 BUCKET 1 9 m3 2 49 yd3 BUCKET 1 44 m3 1 88 yd3 BUCKET 1 51 m3 1 98 yd3 BUCKET A 11 770 mm 38 7 11 660 mm 38 3 B 3 660 mm 12 0 C 8 110 mm 26 7 8 000 mm 26 3 D 4 250 mm 13 11 E 5 200 mm 17 1 5 205 mm 17 1 F 1 265 mm 4 2 1 275 mm 4 2 G 3 680 mm 12 1 3 480 mm 11 5 3 500 mm 11 6 3 480 mm 11 5 H 2 990 mm 9 10 I 1 500 mm 4 11 J 1 490 mm 4 11 K 2 750 mm 9 0 L 3 350 mm 11 0 M 60...

Page 67: ...Specification for DX420LC Page 11 SP000257 ...

Page 68: ...ds 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 injury and or equipment damage 1 0 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 11 12 1 8 0 2 3 4 5 6 7 8 9 10 11 A B C E D FG001799 G L ...

Page 69: ...3 2 49 yd3 1 44 m3 1 88 yd3 1 51 m3 1 98 yd3 A Max digging radius 10 880 mm 35 8 11 495 mm 37 9 12 170 mm 40 0 11 540 mm 37 10 B Max digging depth 7 080 mm 23 3 7 730 mm 25 4 8 430 mm 27 8 7 770 mm 25 6 C Max digging height 10 560 mm 34 8 10 920 mm 35 10 11 350 mm 37 3 10 800 mm 35 5 D Max loading height 7 460 mm 24 6 7 795 mm 25 7 8 200 mm 26 11 7 755 mm 25 5 E Min swing radius 4 385 mm 14 5 4 38...

Page 70: ... kg 33 070 lb Including Swing Bearing Digging Forces at Power Boost Bucket Cylinder 24 200 kg 53 350 lb with 3 250 mm 10 8 arm Arm Cylinder 23 800 kg 52 470 lb with 2 600 mm 8 6 arm 19 260 kg 42 460 lb with 3 250 mm 10 8 arm 16 660 kg 36 600 lb with 3 950 mm 13 0 arm Fuel Tank Capacity 550 liters 145 U S gal Hydraulic System Capacity 420 liters 111 U S gal Hydraulic Reservoir Capacity 265 liters 7...

Page 71: ... standard shoes 3 350 mm 11 0 Overall Shipping Height to top of cylinder hose 3 480 mm 11 5 Track Shipping Length 5 200 mm 17 1 Transport Trailer Capacity 41 0 metric tons 45 2 tons minimum load capacity Transport Loading Ramp Allowable Slope 15 angle CAUTION Refer to Transport Maximum Procedure for Safe Shipping Instructions ...

Page 72: ...SP000257 Specification for DX420LC Page 16 ENGINE PERFORMANCE CURVES PER DIN 6270 STANDARD Figure 3 ...

Page 73: ...el DV11 Barometric Pressure 760 mmHg 20 C 68 F Alternator 24V x 50A Air Cleaner Installed Muffler Installed Performance Standard DIN 6270 Power 297 ps 1 800 rpm 293 hp 1 800 rpm Max Torque 140 kg m 1 300 rpm 1013 ft lb 1 300 rpm Fuel Consumption MIn Rated 160 g ps h 5 64 oz hp h ...

Page 74: ...1 600 kg m3 2 700 lb yd3 or Less High Weight or Density 2 000 kg m3 3 370 lb yd3 or Less Charcoal 401 kg m3 695 lb yd3 Coke blast furnace size 433 kg m3 729 lb yd3 Coke foundry size 449 kg m3 756 lb yd3 Coal bituminous slack piled 801 kg m3 1 350 lb yd3 Coal bituminous r of m piled 881 kg m3 1 485 lb yd3 Coal anthracite 897 kg m3 1 512 lb yd3 Clay DRY in broken lumps 1 009 kg m3 1 701 lb yd3 Clay ...

Page 75: ...ed 1 1 2 or 2 1 362 kg m3 2 295 lb yd3 Limestone crushed 1 522 kg m3 2 565 lb yd3 Limestone fine 1 602 kg m3 2 705 lb yd3 Phosphate rock 1 282 kg m3 2 160 lb yd3 Salt 929 kg m3 1 566 lb yd3 Snow light density 529 kg m3 891 lb yd3 Sand DRY loose 1 522 kg m3 2 565 lb yd3 Sand WET packed 1 922 kg m3 3 240 lb yd3 Shale broken 1 362 kg m3 2 295 lb yd3 Sulphur broken 529 kg m3 1 620 lb yd3 Material Low ...

Page 76: ... 0 4 3 8 0 4 Down sec 2 4 0 3 2 4 0 3 Arm Dump sec 3 3 0 3 3 1 0 3 Crowd sec 4 3 0 4 4 2 0 4 Bucket Dump sec 3 1 0 3 3 0 0 3 Crowd sec 3 3 0 4 3 2 0 4 Swing 3 Revolutions sec 21 0 1 5 19 6 1 5 Jack up Speed 3 Turns High sec 22 9 1 5 21 4 1 5 Low sec 39 1 2 0 36 4 2 0 Travel Speed 20 m 65 62 ft High sec 15 3 1 0 14 3 1 0 Low sec 26 1 1 5 24 3 1 5 Travel Deviation 20 m 65 62ft High mm in 150 5 91 15...

Page 77: ...intenance and adjustment service should be completed before testing 3 Hydraulic fluid and engine oil should be of appropriate viscosity for ambient weather conditions Warm up hydraulic oil to standard operating temperature between 45 55 C 112 135 F 4 Run all tests with the engine speed control set to maximum rpm 5 Repeat tests with Power Mode engine control settings at both Standard Mode standard ...

Page 78: ... are parallel with the test course Operate both travel levers at the fully engaged position and measure the time it takes to cross 20 m 65 7 1 2 Compare measured results against the standard for new machines Rotate the turntable 180 Both tests should be repeated three times Average all results to obtain a final value 0 3 M 0 5 M 1 2 FG000466 Figure 4 Rate of Travel Time Standard Mode Power Mode Hi...

Page 79: ...s allowed with the travel control set for high speed Swing Speed and Deceleration Force Test Swing Speed Test Extend the bucket cylinder completely and retract the arm cylinder as shown in Figure 6 to test swing speed The lowest point of the bucket will be approximately 1 m 3 3 off the ground Use paint marks at the same point on the turntable and undercarriage or select alternate measuring locatio...

Page 80: ... with paint at the 90 point Make several attempts to rotate the turntable exactly 90 starting from the boom straight ahead position Engage the swing lever and brake at the 90 point shown as swing stop in Figure 7 Record how far the turntable drifts past the stop point measuring the distance between paint marks Maximum distance should be less than 1000 mm 39 4 in both Power Mode and Standard Mode 1...

Page 81: ...nd Dump and crowd the bucket several times and average results for both standard and extra duty power modes Hydraulic Cylinder Natural Drop Test To check boom and arm cylinder tightness against the specified performance standard for new cylinders put a full load of dirt in the bucket and move the attachment cylinders so that the arm cylinder is extended 20 50 mm 1 2 and boom cylinders are retracte...

Page 82: ... a corresponding mark on the travel frame Use the attachment to jack up one side of the machine and operate the raised travel motor Record the number of seconds it takes the crawler shoe to make 3 full rotations during both high speed and low speed operation Operation Standard Mode Power Mode High Speed seconds 22 9 1 5 21 4 1 5 Low Speed seconds 39 1 2 0 36 4 2 0 ...

Page 83: ...1General Maintenance ...

Page 84: ......

Page 85: ...SP000016 Page 1 General Maintenance Procedures SP000016 GENERAL MAINTENANCE PROCEDURES SP000016 General Maintenance Procedures Edition 1 ...

Page 86: ...General Maintenance Procedures SP000016 Page 2 MEMO ...

Page 87: ...Welding Precautions and Guidelines 6 Hydraulic System General Precautions 7 Maintenance Service and Repair Procedure 9 General Precautions 9 Hydraulic System Cleanliness and Oil Leaks 10 Maintenance Precautions for Hydraulic System Service10 Oil Leakage Precautions 11 Cleaning and Inspection 12 General Guidelines 12 Bearing inspection 13 ...

Page 88: ...General Maintenance Procedures SP000016 Page 4 MEMO ...

Page 89: ...Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE ALL MODELS ALL RANGES ...

Page 90: ...types of steel are performed with the proper procedures and equipment If repairs are performed incorrectly structural weakening or other damage to the machine that is not always readily visible could be caused Always consult DOOSAN After Sales Service before welding on integral components loader arm frames car body track frames turntable attachment etc of the machine It is possible that some types...

Page 91: ...safety precautions 1 Use extra caution and adequate safety shielding when welding near fuel and oil tanks batteries hydraulic piping lines or other fire hazards 2 Never weld when the engine is running Battery cables must be disconnected before the welding procedure is started 3 Never weld on a wet or damp surface The presence of moisture causes hydrogen embrittlement and structural weakening of th...

Page 92: ... air in the system and many other types of problems As a general precaution and to help minimize the risk of potential long term damage allow the engine to run at no load idle speed immediately after initial start up Hydraulic fluid will circulate releasing any air that may have been trapped in the system before load demands are imposed A daily walk around prestart equipment safety inspection incl...

Page 93: ... the hydraulic circuit may be imminent or have already occurred Open the drain plugs on the main pump casings and check and compare drain oil in the pumps Look for evidence of grit or metallic particles Vibration or unusual noise during operation could be an indication of air leaking into the circuit Refer to the appropriate Troubleshooting section for component or unit for procedures or it may be...

Page 94: ... residue solvent and thoroughly clean exterior surfaces of assemblies before any part of the circuit is opened up or disassembled NOTE It s just as important to clean the cap and reservoir top before routine fluid changes or quick checks as it is before major repairs Accumulated dirt attracts moisture oil and other fluids and more dirt Keep dismantled parts covered during disassembly Use clean cap...

Page 95: ... fine dust are especially hazardous Clogging of valve spools or external piping especially pilot circuit piping can gradually diminish or very suddenly put a complete stop to normal hydraulic function You can prevent having to make these types of repairs by following recommended assembly procedures 1 Use new O rings and oil seals whenever hydraulic assemblies are rebuilt 2 Prepare joint surfaces b...

Page 96: ...are not lubricated DO NOT SPIN BEARINGS WHEN DRYING bearings may be rotated slowly by hand to facilitate drying process 3 Carefully inspect all bearing rollers cages and cups for wear chipping or nicks to determine condition Do not replace a bearing cone or cup individually without replacing mating cup or cone at the same time After inspection dip bearings in light weight oil and wrap in clean lin...

Page 97: ...wear grooves and dirt Remove any scratches and burrs with crocus cloth Remove foreign material Replace any parts that are deeply grooved or scratched which would affect their operation Bearing inspection The conditions of the bearing are vital to the smooth and efficient operation of the machinery When any component containing bearings is disassembled always carefully examine the condition of the ...

Page 98: ...een turning in its housing or on its shaft If available use magna flux or similar process for checking for cracks that are not visible to the naked eye The following illustrations will aid in identifying and diagnosing some of the bearing related problems NOTE The illustrations will only show tapered roller bearings but the principles of identifying diagnosing and remedying the defects are common ...

Page 99: ...rheat lubricant failure or overload Replace bearing check seals and check for proper lubrication Abrasive Step Wear Pattern on roller ends caused by fine abrasives Clean all parts and housings check all parts and housings check seals and bearings and replace if leaking rough or noisy Figure 4 Figure 5 Figure 6 ...

Page 100: ...ngs check seals and check for proper lubrication Misalignment Outer race misalignment due to foreign object Clean related parts and replace bearing Make sure races are properly seated Indentations Surface depressions on race and rollers caused by hard particles of foreign materials Clean all parts and housings check seals and replace bearings if rough or noisy Figure 7 Figure 8 Figure 9 ...

Page 101: ...s Brinelling Surface indentations in raceway caused by rollers either under impact loading or vibration while the bearing is not rotating Replace bearing if rough or noisy Cage Wear Wear around outside diameter of cage and roller pockets caused by abrasive material and inefficient lubrication Replace bearings check seals Figure 10 Figure 11 Figure 12 ...

Page 102: ...isy Cracked Inner Race Race cracked due to improper fit cocking or poor bearing seat Replace all parts and housings check seals and bearings and replace if leaking Smears Smearing of metal due to slippage caused by poor fitting lubrication overheating overloads or handling damage Replace bearings clean related parts and check for proper fit and lubrication Replace shaft if damaged Figure 13 Figure...

Page 103: ...r loss of temper on races or rollers a simple file test may be made A file drawn over a tempered part will grab and cut metal whereas a file drawn over a hard part will glide readily with no metal cutting Replace bearing if over heating damage is indicated Check seals and other related parts for damage Stain Discoloration Discoloration can range from light brown to black caused by incorrect lubric...

Page 104: ...SP000016 General Maintenance Procedures Page 20 ...

Page 105: ...SP000017 Page 1 Standard Torques SP000017 STANDARD TORQUESSP000017 Standard Torques Edition 1 ...

Page 106: ...Standard Torques SP000017 Page 2 MEMO ...

Page 107: ...or Standard Metric Fasteners 6 Torque Values for Standard U S Fasteners 7 Type 8 Phosphate Coated Hardware 9 Torque Values for Hose Clamps 10 Torque Values for Split Flanges 11 Torque Wrench Extension Tools 12 Torque Multiplication 12 Other Uses for Torque Wrench Extension Tools 13 Tightening Torque Specifications Metric 13 ...

Page 108: ...Standard Torques SP000017 Page 4 MEMO ...

Page 109: ...all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE ALL MODELS ALL RANGES ...

Page 110: ...2 00 86 79 17 00 122 96 20 00 144 66 M14 x 1 5 4 10 29 65 4 30 31 10 6 60 47 73 5 70 41 22 8 30 60 03 7 50 54 24 11 10 80 28 12 50 90 41 13 00 94 02 18 50 11 26 22 00 158 12 M16 x Std 5 60 40 50 6 00 43 39 9 00 65 09 8 00 57 86 11 50 83 17 10 50 75 94 15 50 112 11 17 90 129 47 18 50 133 81 26 00 188 05 31 00 224 22 M16 x 1 5 6 20 44 84 6 50 47 01 9 70 70 16 8 60 62 20 12 50 90 41 11 30 81 73 17 00...

Page 111: ...sed 0 70 When Molykote white lead or similar mixtures are used as lubricants 0 75 When Parkerized bolts or nuts are used 0 85 When cadmium plated bolts or nuts and zinc bolts w waxed zinc nuts are used 0 90 When hardened surfaces are used under the nut or bolt head NOTE When reusing bolts and nuts in service use minimum torque values Type S A E Grade Description Bolt Head Marking 1 1 OR 2 WILL HAV...

Page 112: ...oot Pounds ft lb Newton Meter Nm Foot Pounds ft lb Newton Meter Nm 1 4 20 6 8 9 12 1 4 28 7 9 11 15 5 16 18 13 18 18 24 5 16 24 15 20 21 28 3 8 16 24 33 34 46 3 8 24 27 37 38 52 7 16 14 38 52 54 73 7 16 20 42 57 60 81 1 2 13 58 79 82 111 1 2 20 65 88 90 122 9 16 12 84 114 120 163 9 16 18 93 126 132 179 5 8 11 115 156 165 224 5 8 18 130 176 185 251 3 4 10 205 278 290 393 3 4 16 240 312 320 434 7 8 ...

Page 113: ...ues shown below also apply to the following 1 Phosphate coated bolts used in tapped holes in steel or gray iron 2 Phosphate coated bolts used with phosphate coated prevailing torque nuts nuts with distorted threads or plastic inserts 3 Phosphate coated bolts used with copper plated weld nuts Markings on bolt heads or nuts indicate material grade ONLY and are NOT to be used to determine required to...

Page 114: ... boots hydraulic system etc Clamp Type And Size Torque Radiator Air Cleaner Boots Etc Hydraulic System Kilogram Meter kg m Inch Pounds in lb Kilogram Meter kg m Inch Pounds in lb T Bolt Any Diameter 0 68 0 72 59 63 Worm Drive Under 44 mm 1 3 4 in Open Diameter 0 2 0 3 20 30 0 5 0 6 40 50 Worm Drive Over 44 mm 1 3 4 in Open Diameter 0 5 0 6 40 50 Worm Drive All Ultra Tite 0 6 0 7 50 60 0 5 0 6 40 5...

Page 115: ...g bolts will damage the flanges and or bolts which may cause leakage Inside diameter of flange on end of hydraulic tube or hose fitting NOTE Values stated in chart are for Standard Pressure Series Code 61 Split Flanges Flange Size Bolt Size Bolt Torque Kilogram Meter kg m Foot Pounds ft lb 1 2 5 16 2 1 2 5 15 18 3 4 3 8 3 0 3 7 22 27 1 3 8 3 7 4 8 27 35 1 1 4 7 16 4 8 6 2 35 45 1 1 2 1 2 6 4 8 0 4...

Page 116: ...sed or fabricated Torque Multiplication A wrench extension tool can be used to increase the tightening force on a high capacity nut or bolt For example doubling the distance between the bolt and the back handle end of the torque wrench doubles the tightening force on the bolt It also halves the indicated reading on the scale or dial of the torque wrench To accurately adjust or convert indicated sc...

Page 117: ... tightness of a linkage or assembly Specially fabricated extensions can be used to make very precise checks of the force required to engage or disengage a clutch mechanism release a spring applied brake assembly or take up free play in most any movable linkage Once the value of the adjustment force is established repeated checks at regular intervals can help to monitor and maintain peak operating ...

Page 118: ...e as a general guide in selecting specific formulas that will meet the particular requirements of individual assembly installations DOOSAN does not specifically endorse a specific manufacturer or brand name but the following table of Loctite applications is included for which cross references to other makers products should also be widely available IMPORTANT Use primer T or N for all cold weather ...

Page 119: ...C 500 F Remove HOT 210 Product Application Color Removal Required Setup 545 No filler nonclog formula for high pressure hydraulic systems Over application will not restrict or foul system components Purple Hand tools 4 Hours or 1 2 hour with Locquic T Primer 656 Solvent resistant higher viscosity tapered thread sealer White Hand tools 4 Hours or 1 2 hour with Locquic T Primer Product Application C...

Page 120: ... cold temperature applications 620 For high temperatures to 232 C 450 F Green Same as 609 above 680 For high strength bonds and tight clearance gaps to 0 00008 mm 0 002 Green Same as 609 above Product Application Color Notes 380 Black Max instant adhesive for shock and vibration resistant bonds Black May take 120 hours to reach full cure strength 454 Adhesive for porous surfaces Clear Full strengt...

Page 121: ...1Upper Structure ...

Page 122: ......

Page 123: ...SP000018 Page 1 Cabin SP000018 CABIN SP000018 Cabin Edition 1 ...

Page 124: ...Cabin SP000018 Page 2 MEMO ...

Page 125: ...SP000018 Page 3 Cabin Table of Contents Cabin Safety Precautions 5 Applicable Models 5 Removal 6 Installation 8 ...

Page 126: ...Cabin SP000018 Page 4 MEMO ...

Page 127: ...tices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 5001 and Up DX340LC 5001 and Up DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 an...

Page 128: ...Cabin interior lighting B External light wiring C Radio antenna and connections D Wiper washer connections NOTE Control console wiring harnesses and hydraulic piping lines that pass through the floor of the cabin do not need to be disassembled NOTE If unit is equipped with a cabin protective structure for forestry or hazardous working conditions it must be removed CAUTION Avoid disassembling cabin...

Page 129: ...er hose at floor plate bottom 18 Remove cover 5 Figure 4 on left side dash cover 3 and bolts 1 Figure 5 NOTE When removing cover disconnect speaker wire 19 Remove two rubber stops 2 Figure 4 used in storing the front lower glass Remove bolts 1 from the rear left and right dash covers Remove left side cover 3 20 Lift right side dash cover 4 Figure 4 and disconnect speaker wire Remove cover 21 Remov...

Page 130: ...t all electrical connections have been disconnected and all other items unbolted 29 Continue lifting with the assist crane to remove the cabin shell Lower the shell to a prepared safe blocking support INSTALLATION 1 Using a suitable lifting device attach slings to four lift points on top of cabin Figure 7 NOTE Cabin weighs approximately 290 kg 639 lb 2 Lower cabin into position on cabin floor HAOF...

Page 131: ...gure 10 after connecting speaker and antenna wires 10 Install right side dash cover 4 Figure 11 with bolts 1 Figure 10 11 Install left side dash cover 3 Figure 11 with bolts 1 Figure 10 Install two rubber stops 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 at floor plate bottom HAOF270L 2 1 3 4 Figure 9 Q...

Page 132: ...nstall cover 4 Figure 13 and connect main harness Install cover 3 Connect hour meter connector and cigar lighter connector 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 19 Install floor mat 20 Connect negative battery cable leading to frame from battery FG000667 1 2 3 Figure 12 1 6 4 5 1 7 FG000540 Figure 13 ...

Page 133: ...SP000265 Page 1 Counterweight SP000265 COUNTERWEIGHT SP000265 Counterweight Edition 1 ...

Page 134: ...Counterweight SP000265 Page 2 MEMO ...

Page 135: ...SP000265 Page 3 Counterweight Table of Contents Counterweight Safety Precautions 5 Applicable Models 5 General 6 Warning for Counterweight and Front Attachment Removal 6 Removal 8 Installation 10 ...

Page 136: ...Counterweight SP000265 Page 4 MEMO ...

Page 137: ...ll safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up ...

Page 138: ...sist crane operator and the remainder of the work crew FG000371 Figure 1 DANGER DOOSAN warns any user that the removal of the counterweight from the machine front attachment or any other part may affect the stability of the machine This could cause unexpected movement resulting in death or serious injuries DOOSAN is not liable for any misuse Never remove the counterweight or front attachment unles...

Page 139: ...emoved always go backwards up the loading ramp The counterweight end of the deck has to get on the trailer first while the cabin is still going up the ramp Figure 1 WARNING If the turntable deck has been unbalanced by removal of weight from one end only traveling the excavator swinging the turntable movement over bumps or sloping and uneven surfaces could cause loss of control and possible acciden...

Page 140: ...tors 7 Set safety lever on LOCK position 8 Turn key to O OFF position and remove from starter switch 9 Hang maintenance warning tag on controls 10 Disconnect the battery cable from the negative battery terminal 11 Remove engine compartment cover O I FG003015 WARNING WARNING DON T TOUCH WHEN PERFORMING INSPECTION OR MAINTENANCE Figure 3 WARNING If engine must be run while performing maintenance use...

Page 141: ...ning four bolts 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 Figure 4 and washers 5 have been removed lift counterweight 2 a very short distance above support frame 6 and stop Check slings and make sure counterweight is being supported evenly Figure 4 ...

Page 142: ...2 Slide washers 5 Figure 5 onto bolts 4 Apply Loctite 242 to mounting bolt threads 3 Install four bolts 4 Figure 5 with washers 5 into counterweight until washers contact support frame Fully lower counterweight onto support frame and finish tightening bolts NOTE Torque bolts 4 Figure 5 to values shown in following table 4 Remove lifting device and lifting eyes from counterweight lifting holes 3 Fi...

Page 143: ...SP000264 Page 1 Fuel Tank SP000264 FUEL TANK SP000264 Fuel Tank Edition 1 ...

Page 144: ...Fuel Tank SP000264 Page 2 MEMO ...

Page 145: ...SP000264 Page 3 Fuel Tank Table of Contents Fuel Tank Safety Precautions 5 Applicable Models 5 General Description 6 Parts List 8 Specifications 9 Removal 10 Installation 14 Start up Procedures 16 ...

Page 146: ...Fuel Tank SP000264 Page 4 MEMO ...

Page 147: ... safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up ...

Page 148: ...Tank Page 6 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 potential fire hazards ...

Page 149: ...Fuel Tank Page 7 SP000264 ...

Page 150: ...SP000264 Fuel Tank Page 8 Parts List 1 15 16 2 11 12 9 13 8 13 8 10 6 5 7 25 24 4 3 17 19 20 21 14 17 18 18 51 52 FRONT 22 23 22 23 Figure 1 ...

Page 151: ...k 2 Fuel Sender 3 O ring 4 Cover 5 Bolt 6 Spring Washer 7 Drain Cock 8 Bolt 9 Shim 10 Shim 11 Fuel Strainer Filter 12 Cap 13 Harden Spacer 14 Level Gauge 15 Spring Washer 16 Screw 17 Bolt 18 Clip 19 Housing Bracket 20 Spring Washer 21 Screw 22 Plug 23 O ring 24 Hose 25 Hose Clamp 51 O ring 52 Plug Reference Number Description ...

Page 152: ...ont attachment bucket to ground 4 Shut down engine 5 Set safety lever on RELEASED position 6 Turn starter switch to I ON position 7 Fully stroke work levers joysticks in all directions to relieve any pressure from accumulators 8 Set safety lever on LOCK position 9 Turn key to O OFF position and remove from starter switch 10 Hang maintenance warning tag on controls 11 Disconnect negative battery ca...

Page 153: ...TE Fuel tank capacity is 550 liters 145 U S gal 14 Tag and disconnect fuel supply line 26 Figure 7 and fuel return line 27 from fuel tank 1 and carefully drain remaining fuel from lines 15 Remove clamp 28 Figure 7 holding fuel return line 27 to tank 1 16 Remove components from fuel filler pump port 29 Figure 8 on side of fuel tank 1 12 FG005137 Figure 5 7 FG005130 Figure 6 28 26 27 1 FG005131 Figu...

Page 154: ...k and frame Remove four bolts 35 and 36 and fuel tank cover 37 from fuel tank Remove two bolts 38 and bracket 39 from tank Remove four bolts 40 and battery cover 41 from frame 19 Tag and disconnect wires leading to fuel sender 2 Figure 11 on side of fuel tank 1 30 31 FG005134 Figure 9 34 33 40 35 39 38 37 32 41 36 FG005133 Figure 10 2 1 FG005135 Figure 11 ...

Page 155: ... 25 mm 1 and make sure it is balanced Make sure that there are no other electrical wires or hoses connected to tank Completely remove tank after inspection NOTE The clear level gauge on the side of the tank is easily damaged Be careful of obstacles and wind gusts 22 Remove shims 10 Figure 12 NOTE If tank is to be reused note position and amount of shims used for each mounting bolt location 8 13 10...

Page 156: ...0 Figure 13 as needed to prevent tank 1 from rocking or stress from mounting bolts 8 4 Tighten mounting bolts 8 Figure 13 after shims are installed NOTE Bolt torque is 27 kg m 200 ft lb 5 Connect wires as tagged to fuel sender 2 Figure 14 on side of fuel tank 1 6 Install four bolts 40 Figure 15 and battery cover 41 on frame Install two bolts 38 and bracket 39 on fuel tank Install four bolts 35 and...

Page 157: ... Figure 18 and fuel return line 27 to fuel tank 1 10 Install clamp 28 Figure 18 to hold fuel return line 27 to tank 1 11 Make sure fuel tank drain valve 7 Figure 19 on bottom of tank is closed 12 Fill fuel tank and check for signs of leaks Correct any problems found 13 Connect negative battery cable to battery 30 31 FG005134 Figure 16 29 1 FG005132 Figure 17 28 26 27 1 FG005131 Figure 18 Figure 19...

Page 158: ...l filter 3 Loosen plug 1 Figure 21 on top of fuel filter head 4 Pump hand operated primer pump 2 Figure 21 by the fuel injection pump Pump primer until fuel is present at plug hole in fuel filter head 5 Tighten plug in fuel filter head 6 Continue to pump primer pump until a strong resistance is felt 7 Start engine and look for signs of leaks Repeat procedure if necessary Figure 20 FG004960 Figure ...

Page 159: ...SP000262 Page 1 Swing Bearing SP000262 SWING BEARING SP000262 Swing Bearing Edition 1 ...

Page 160: ...Swing Bearing SP000262 Page 2 MEMO ...

Page 161: ...ntents Swing Bearing Safety Precautions 5 Applicable Models 5 Swing Bearing Maintenance 6 Operating Recommendation 6 Measuring Swing Bearing Axial Play 6 Measuring Bearing Lateral Play 6 Swing Bearing Basic Operation 7 Disassembly 7 Assembly 9 ...

Page 162: ...Swing Bearing SP000262 Page 4 MEMO ...

Page 163: ...ll safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up ...

Page 164: ... 4 points 90 apart around the circumference of the bearing Figure 1 Record and keep all measurements Play in the bearing should increase minimally from one inspection to the next Eventually however as the bearing begins to approach the limit of its service life clearance increases become much more pronounced and the actual measured play in the bearing could exceed twice the value that was measured...

Page 165: ...motor is transferred to the pinion by planetary gears connected to gears on the inner ring which is fixed in the undercarriage Ball bearings turn the outer ring Disassembly 1 Remove tip of tapered pin 3 Figure 3 using grinder and tap lightly to remove debris 2 Remove plug 4 Figure 4 using a M10 x 1 5 bolt Figure 2 Reference Number Description 1 Outer Ring 2 Inner Ring 3 Tapered Pin 4 Plug 5 Ball 6...

Page 166: ...SP000262 Swing Bearing Page 8 3 Turn inner ring and use magnet bar C Figure 5 to remove steel balls 5 4 Turn inner ring and use wire D Figure 6 to remove retainers 6 Figure 5 Figure 6 ...

Page 167: ...ition 2 Hoist the outer race by crane horizontally and match it with the inner race coaxially Rotating the outer race insert balls 5 support 6 into the plug 4 hole one by one with a round bar 3 Top plug 4 into outer race 1 and then drive pin 3 into the pin hole Caulk the head of pin 3 with a punch Fill grease through the grease fitting Figure 7 Figure 8 Figure 9 Figure 10 ...

Page 168: ...SP000262 Swing Bearing Page 10 ...

Page 169: ...SP000249 Page 1 Swing Reduction Gear SP000249 SWING REDUCTION GEARSP000249 Swing Reduction Gear Edition 1 ...

Page 170: ...Swing Reduction Gear SP000249 Page 2 MEMO ...

Page 171: ...s 5 General Description 7 Theory of Operation 7 Parts List 8 Specifications 10 Troubleshooting Testing and Adjustment 11 Removal 12 Disassembly 13 Assembly 17 Shaft and S R Bearing Shrinkage Fitting 17 Assembly of the Carrier Subassembly 19 Assembly of Main Case 27 Test 43 Assembly of the Motor 45 Installation 51 ...

Page 172: ...Swing Reduction Gear SP000249 Page 4 MEMO ...

Page 173: ...ety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX340LC 5001 and Up DX420LC 5001 and Up ...

Page 174: ...SP000249 Swing Reduction Gear Page 6 ...

Page 175: ...sun gear and 2 step output reduction The planetary gear engages with the ring gear The pinion gear is connected with the output shaft and spline The gearbox reduces swing motor rpm to increase swing motor output torque The available maximum swing speed provides a fast turning rate for efficient rapid work cycling with more than adequate power for good acceleration ...

Page 176: ...SP000249 Swing Reduction Gear Page 8 Parts List Figure 1 ...

Page 177: ... 1 11 Planetary Gear No 1 12 Side Plate No 1 13 Pin Assembly No 1 14 Ring Gear 15 Thrust Plate 16 Case Cover 17 Lock Pin 18 Spacer 19 Collar 20 Plate 21 Lock Ring 22 Spherical Roller Bearing 23 Spherical Roller Bearing 24 Oil Seal 25 Spring Pin 26 Plug 27 Plug 28 Oil inlet 29 Bolt Socket 30 Pipe 31 Level Bar 32 Bolt Socket 33 Side Plate No 3 34 Snap Ring 35 Pinion 36 Cover 37 Bolt Socket 38 Wire R...

Page 178: ...on Gearbox Drive Type Two Stage Planetary Gear Reduction Ratio 19 565 21 968 Maximum Output Speed 57 3 rpm 59 9 rpm Maximum Output Torque 2 100 kg m 15 189 ft lb 2 360 kg m 17 070 ft lb Weight 275 kg 606 lb Pinion Gear Type Spur Gear Gear P C D 196 mm 7 72 in No of Teeth 14 Module 14 ...

Page 179: ...Repair replace broken or drive train faulty assemblies c Pressure at swing motor inlet shows Hydraulic pump or valve broken Troubleshoot hydraulic no increase but without irregular system noises from the swing motor 2 Oil leakage a From drive shaft Oil seal damaged Replace oil seal b From bolted connections or other Assembly compound joint sealer Disassemble and check assembled surfaces old and no...

Page 180: ...nt contamination from entering hydraulic system or component 12 Disconnect tube 2 from drain cock 3 and hose fitting 7 from fill hole 13 Remove twelve bolts and washers 4 Figure 3 holding swing reduction gearbox 5 to frame 14 Using a suitable lifting device sling swing motor 1 Figure 3 and remove swing motor and reduction gearbox 5 as an assembly from unit NOTE A drain cock 3 Figure 3 and tube are...

Page 181: ...ary gears and the first planetary mounting plate out of the gearbox 5 Slide sun gear off the shaft and out of the gearbox 6 Thread an eye bolt into each of the three shafts that support the planetary gears Loop lifting straps through the eye bolts and lift the gear housing assembly out of the gearbox Figure 4 IMPORTANT Use a clean dry container with at least 11 liters or 2 9 gallons capacity to ca...

Page 182: ...aft out of the housing Use this method to remove the two remaining gear shafts gears and thrust plates Use the punch to drive the spring pins out of the shafts Use new spring pins when assembling the gearbox 9 Sealant has been applied to the joint where the ring gear and the gear case meet It will be necessary to pry the ring gear from the gear case to separate the two parts 10 Use a screwdriver t...

Page 183: ...down on the shaft until the shaft with the spacer plate and roller bearing attached is pressed out of the gear case 12 Reach into the gear case and remove the roller bearing 13 Use a hammer and a screwdriver to drive the seal out of the gear case NOTE It is only necessary to disassemble the shaft when one of the shaft components is damaged bearing spacer etc and needs replacement Figure 11 Figure ...

Page 184: ...cer on top of the shaft Use a hydraulic press to press down on the spacer until the bearing is free of the shaft Slide the shaft spacer plate bearing and bearing spacer off the shaft 15 Use a nonflammable nontoxic solvent to clean all gearbox parts Dry the parts with compressed air Inspect all parts before assembly Replace any parts that show damage or obvious signs of wear Figure 14 ...

Page 185: ...1 Washing of the shaft Remove liquid like anti corrosion liquid on the shaft and then use an air gun to remove all of remaining foreign substance 2 Insert the spacer in the prepared shaft as shown in the figure below and put and heat the bearing on the specified heater Figure 15 Figure 16 ...

Page 186: ... heater reaches 90 100 C 194 212 F and put it into the shaft with both hands holding it horizontally To do so insert it slowly about 4 to 5 mm that the bearing takes its seat by itself and then push it with force that it sticks to the spacer assembled into the shaft Figure 17 Figure 18 ...

Page 187: ...assembly Washing of the Carrier Use a dipping washer to wash the carrier which was got rid of burr through a corner end finishing shaping process check again if foreign substance is removed completely and put it on the assembly die Washing of Planet Gears Check if planet gears are washed well and have any dent and put them on the assembly die Figure 19 Figure 20 ...

Page 188: ...r Page 20 Assembly of the Carrier Subassembly 1 1 Put the carrier No 1 on the assembly jig as shown in the figure below 2 Put the pin assembly No 1 on the pin hole correctly and insert it with a press Figure 21 Figure 22 Figure 23 ...

Page 189: ...rt check its state visually 4 Insert the pin assembly 1 in the 3 remaining parts with a pressure in the same way 5 Turn over the carrier in which the pin is inserted and put the thrust washer No 1 on 4 pins as shown in the figure below Figure 24 Figure 25 Figure 26 ...

Page 190: ...SP000249 Swing Reduction Gear Page 22 6 Assemble the planetary gear No 1 7 Put thrust washer No 3 as shown in the figure below Figure 27 Figure 28 Figure 29 ...

Page 191: ...ge the snap ring for φ 40 axis to each thread of the pin 1 and turn the gear to check if it rotates smooth Assembly of the Carrier Subassembly 2 1 Put the carrier No 2 on the assembly die as shown in the figure below Figure 30 Figure 31 Figure 32 ...

Page 192: ... No 2 in the planetary gear No 2 and put the thrust washer No 2 on it 3 Hold the gear with both hands and the thrust washer facing downward insert it in the carrier and arrange both gauges of the carrier and the bush Figure 33 Figure 34 Figure 35 Figure 36 ...

Page 193: ...in hole of the carrier are in the line and push it with a hand or tap it with a hammer 5 Assemble the remaining 3 parts in the same way 6 After the completion of assembling pins erect the spring pin ø10x25L above the hole ø10 of the carrier and push it inside with a hammer and then a caulking punch Figure 37 Figure 38 Figure 39 Figure 40 ...

Page 194: ...ion Gear Page 26 7 Use a caulking punch to tap three areas around the spring pin hole 8 Assemble the 3 remaining parts in the same way and turn the gear to check if it rotates smooth Figure 41 Figure 42 Figure 43 Figure 44 ...

Page 195: ...d processes Cleaning fluid PK6540 alkali Liquid density 3 5 Liquid temperature 60 70 C 140 158 F Assembly of the Shaft and the Pinion 1 Press fitting of the shaft subassembly Pun the washed casing as shown in the figure below and use a hoist to put shaft subassembly in the area to be inserted Bearing kept horizontal put the specific jig to insert it into the press table and use a press to fit it i...

Page 196: ...s fitting jig and assemble the plate with its stepped part facing downward 3 Insert the lock ring into the groove in the casing Figure 48 Figure 49 Figure 50 Figure 51 CAUTION Care should be taken not to have drive shaft drop to floor when it is pressed out of case ...

Page 197: ... put the piston on it put the press fitting jig on it and use a press to insert it 5 Put the lock plate on it engage the bolt applied Loctite 262 M16x40 torque 2 700 kgf cm and complete the procedure by tying it with wire as shown in the figure below Figure 52 Figure 53 Figure 54 Figure 55 ...

Page 198: ...SP000249 Swing Reduction Gear Page 30 Figure 56 Figure 57 Figure 58 Figure 59 ...

Page 199: ...Swing Reduction Gear Page 31 SP000249 Figure 60 Figure 61 Figure 62 ...

Page 200: ...al assembly apply grease and Loctite 609 to the seal and the outside of the oil seal TC5001300 respectively push it into the case while keeping it horizontal put the seal press fitting jig and use a press to insert it Figure 63 Figure 64 Figure 65 CAUTION Take care to prevent contamination by foreign substance or damage to the lip area and check the press fitting of the seal visually Figure 66 ...

Page 201: ...Swing Reduction Gear Page 33 SP000249 Figure 67 Figure 68 Figure 69 Figure 70 ...

Page 202: ...ner part of the prepared bearing 23024CD and assemble them again that its trade mark is visible insert it in the shaft as shown in the figure below put the bearing press fitting jig on it and use a press to insert it Figure 71 Figure 72 Figure 73 Figure 74 ...

Page 203: ...Reduction Gear Page 35 SP000249 4 Hold the pinion with both hands and turn it to check if it rotates smooth 5 Insert plugs in the PT3 8 and PT1 8 taps of the drain port Figure 75 Figure 76 Figure 77 Figure 78 ...

Page 204: ...tion Gear Page 36 Assembly of the Ring Gear 1 Press fitting of the lock pin Insert lock pins ø13 x 31 5 in 4 reamer holes of the casing and use a hammer to tap them Figure 79 Figure 80 FG000936 Figure 81 FG000937 Figure 82 ...

Page 205: ...ist to lift the prepared ring gear wipe the assembled part with a cloth put it on the hole considering its assembly direction tighten specific bolts M16 x 160 to which Loctite is not applied in the symmetrical order and be sure that the assembled parts are pressed each other completely FG000938 Figure 83 FG001353 Aim at holes Figure 84 Figure 85 ...

Page 206: ...ise lightly for it to engage with the spline of the ring gear and the shaft naturally Use a rubber hammer to tap the top of the carrier that it sticks to the bearing during the assembly 2 Insert the sun gear No 2 in the middle of the carrier No 2 as shown in the figure below and put the thrust plate on it Figure 86 FG000942 Figure 87 Figure 88 Figure 89 ...

Page 207: ...sembly No 1 on the assembling part and turn it clockwise or anticlockwise lightly for it to engage with the low toothed shaft end of the ring gear and the sun gear No 2 4 Insert the sun gear No 1 in the middle of the carrier No 1 Figure 90 Figure 91 Figure 92 Figure 93 ...

Page 208: ...SP000249 Swing Reduction Gear Page 40 5 Loosen the retaining bolt and apply liquid gasket to the assembling part Figure 94 Figure 95 FG000950 Figure 96 ...

Page 209: ... pipe on the hole of the case ø11 and use an impact wrench to tighten bolts M16x180 applied Loctite by pulling it to your breast slowly which should be repeated once more to ensure its torque after the first torque engagement is heard Use a paint marker to mark the torqued bolts Figure 97 FG000954 Figure 98 Figure 99 ...

Page 210: ...ing Reduction Gear Page 42 7 Assemble the plug with caution to prevent the inflow of foreign substance into the tap PT1 4 used for the assembly of the level pipe of the cover during the test Figure 100 Figure 101 ...

Page 211: ...the cover assembly engage the pneumatic test jig as shown in the figure below 2 Supply air when the pressure gauge indicates 2 kgf cm2 and check if the gauge indicates any change of pressure for 3 minutes 3 Finishing the test release and remove the jig Figure 102 Figure 103 Figure 104 ...

Page 212: ...n of the pneumatic test pour gear oil of 5ℓ into the reduction gear and engage the test motor 2 Start the motor up to 1400 RPM and use a noise measuring machine to carefully measure its noise level which should be below 90 dB and not include abnormal sound Figure 105 Figure 106 Figure 107 ...

Page 213: ...Swing Reduction Gear Page 45 SP000249 Assembly of the Motor Supply of Gear Oil Upon the completion of the noise test remove the test motor and pour gear oil of 2 5ℓ more Figure 108 Figure 109 Figure 110 ...

Page 214: ...o the assembling part of the cover 2 Use a hoist to lift the motor wipe its assembling part with a clean cloth check the O ring of the motor shaft and assemble it at the tap of the PT3 4 of the cover with the brake valve of the motor facing to the left Figure 111 Figure 112 Figure 113 ...

Page 215: ... Gear Page 47 SP000249 3 Engage bolts M16x40 torque 2 700 kgf cm applied Loctite using a L wrench check the standard torque using a torque wrench and mark using a paint marker FG000973 Figure 114 Figure 115 Figure 116 ...

Page 216: ...SP000249 Swing Reduction Gear Page 48 4 Engage the plug at the PT3 4 tap 5 Remove the plug engage the level pipe sealed with Teflon tape and check the oil level Figure 117 Figure 118 Figure 119 ...

Page 217: ...tion Gear Page 49 SP000249 6 Supply of Grease A Assemble the caulk in the grease inlet and put the nipple to supply grease until it flows out of the opposite hole Figure 120 FG000978 Figure 121 FG000979 Figure 122 ...

Page 218: ...pplying grease release and remove the caulk assemble the plug sealed with Teflon tape tighten it with a torque wrench and finish the procedure by wiping out grease and other foreign substance remaining on the surface FG000980 Figure 123 FG000981 Figure 124 Figure 125 ...

Page 219: ... swing motor 1 Figure 3 and position swing motor and reduction gearbox 5 as an assembly on unit 4 Install twelve bolts and washers 4 Figure 3 to secure swing reduction gearbox 5 to frame NOTE Apply Loctite 262 to bolt threads 5 Connect tube 2 to drain cock 3 and hose fitting 7 to fill hole 6 Connect hoses as tagged during removal to swing motor 1 Figure 3 7 Fill swing reduction gearbox with oil Re...

Page 220: ...SP000249 Swing Reduction Gear Page 52 ...

Page 221: ...1Lower Structure and Chassis ...

Page 222: ......

Page 223: ...SP000263 Page 1 Track Assembly SP000263 TRACK ASSEMBLY SP000263 1Track Assembly Edition 1 ...

Page 224: ...Track Assembly SP000263 Page 2 MEMO ...

Page 225: ...Removal 15 Track Installation 16 Front Idler Roller 18 Parts List 18 Front Idler Roller Disassembly 19 Front Idler Roller Reassembly 20 Lower Roller 22 Parts List 22 Lower Roller Removal 23 Lower Roller Disassembly 23 Lower Roller Reassembly 24 Lower Roller Installation 25 Upper Roller 26 Parts List 26 Upper Roller Removal 27 Upper Roller Disassembly 27 Upper Roller Reassembly 30 Track Spring and ...

Page 226: ...Track Assembly SP000263 Page 4 Track Spring Disassembly Diagram 34 Disassembly of the Track Spring Assembly 35 Assembly of the Track Spring 37 ...

Page 227: ...all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up ...

Page 228: ...afely measuring track tension requires two people One person must be in the operator s seat running the controls to keep one side frame in the air while the other person makes dimensional checks Take all necessary precautions to make sure the machine won t move or shift position during service Warm up the engine to prevent stalls travel the excavator to an area that provides level uniform ground s...

Page 229: ...d conditions are wet marshy or muddy or if the ground is hard and full of rocks or gravel 4 The increased clearance recommended for muddy ground conditions is between distance D on below table The clearance should be approximately distance E on below table for operation over gravel rocky terrain or over sand or snow A FG000223 Figure 2 Terrain Type Distance A DX420LC Normal B 380 430 mm 14 96 16 9...

Page 230: ...adjustment cylinder 2 The longer the adjustment cylinder the greater the pressure on the tension spring pushing the track idler wheel outward 6 If there is not enough slack or clearance in the tracks and the adjustment is too tight the idler wheel and adjusting cylinder can be retracted by bleeding off grease through hole in adjustment cylinder 2 Figure 3 1 3 2 FG000163 Figure 3 ...

Page 231: ...equires welding on additional material and grinding off excess Some components must be replaced before the service limit is exceeded No maintenance or renewal is possible Compare the values in the tables with dimensions and profiles shown in the adjacent figures CAUTION Refer to the Welding Precautions and Guidelines information in General Maintenance Procedures section for general recommendations...

Page 232: ...SP000263 Track Assembly Page 10 Track Shoe 1 8 7 2 9 10 11 3 6 4 5 FG004347 Figure 4 ...

Page 233: ...g and link Standard Dimension Tolerance Standard Interference Repair Limit Shaft Hole 71 0 mm 2 80 0 344 0 304 0 074 0 0 0 23 0 344 8 Interference between regular pin and link Standard Dimension Tolerance Standard Interference Repair Limit Shaft Hole 47 0 mm 1 85 0 235 0 165 0 138 0 20 0 303 0 435 9 Clearance between regular pin and bushing Standard Dimension Tolerance Standard Interference Repair...

Page 234: ...0 mm 7 87 194 mm 7 64 190 mm P 7 48 3 Width of Tread 54 6 mm 2 15 64 mm 2 52 71 mm P 2 80 4 Width of Flange 34 4 mm 1 35 5 Clearance between shaft and bushing Standard Dimension Tolerance Standard Interference Repair Limit Shaft Hole 85 mm 3 35 0 0 035 0 370 0 300 0 300 0 405 1 8 mm R 0 07 6 Interference between roller and bushing Standard Dimension Tolerance Standard Interference Repair Limit Sha...

Page 235: ...er of Tread 180 mm 7 09 171 mm 6 73 162 5 mm P 6 40 3 Width of Tread 47 5 mm 1 87 4 Width of Flange 17 5 mm 0 69 11 5 mm 0 45 5 Clearance between shaft and bushing Standard Dimension Tolerance Standard Interference Repair Limit Shaft Hole 60 mm 2 36 0 0 05 0 45 0 40 0 40 0 50 6 Interference between roller and bushing Standard Dimension Tolerance Standard Interference Repair Limit Shaft Hole 68 mm ...

Page 236: ...ad 590 mm 23 23 578 mm 22 76 3 Width of Protrusion 102 mm 4 02 4 Total Width 203 mm 7 99 5 Width of Tread 50 5 mm 1 99 56 mm 2 20 6 Clearance between shaft and bushing Standard Dimension Tolerance Standard Interference Repair Limit Shaft Hole 94 mm 3 74 0 0 035 0 515 0 415 0 461 0 256 7 Interference between roller and bushing Standard Dimension Tolerance Standard Interference Repair Limit Shaft Ho...

Page 237: ... Figure 8 holding shoe to link Remove enough shoes to make access to lock pin easier NOTE Support track shoes with blocking so that when master pin 4 Figure 8 is removed track will not fall 5 Straighten lock pin 3 Figure 8 and remove it from master pin 4 Discard lock pin 6 Remove master pin from master links 7 Move unit backward until entire track is laying on ground NOTE Do not drive unit off tra...

Page 238: ...me onto track Make sure all rollers are properly positioned on track 4 Move unit forward while feeding track up over drive sprocket Continue to pull track back until it engages front idle roller 5 Align master links and install master pin 6 Insert new lock pin in master pin Bend end of pin over so it is pointing in opposite direction of other end as shown 7 Apply track tension Refer to Track Tensi...

Page 239: ...Track Assembly Page 17 SP000263 ...

Page 240: ...SP000263 Track Assembly Page 18 FRONT IDLER ROLLER Parts List 6 3 2 7 8 3 9 8 7 5 5 4 6 1 FG004357 Figure 14 ...

Page 241: ...e the pin 6 Figure 16 from the bearing 3 3 Use a press to remove the bearing from the axle 4 Separate the O ring 8 Figure 17 from the axle Reference Number Description 1 Idler Assembly 2 Idler 3 Bearing 4 Shaft 5 Bushing 6 Pin 7 Floating Seal 8 O ring 9 Plug Reference Number Description 3 9 FG004358 Figure 15 6 3 FG004359 Figure 16 1 4 8 FG004360 Figure 17 ...

Page 242: ...20 with the press and special tool Front Idler Roller Reassembly 1 Degrease clean and dry all parts before reassembly Insert bushing 5 Figure 20 into the idler 2 2 Grease O ring 8 Figure 21 and insert it into the axle 3 Align the bearing 3 Figure 21 and axle 4 holes and pin 6 them together 2 7 3 7 3 FG004361 Figure 18 8 3 4 FG004362 Figure 19 10 5 2 FG004363 Figure 20 FG004364 6 4 3 8 8 Figure 21 ...

Page 243: ...nt side of the floating seal Apply grease to the floating seal O ring 5 Install idler 2 Figure 23 on the axle 6 Install bearing 3 Figure 23 and pin 6 to the axle NOTE Fill the idler assembly with new engine oil with approximately 450 cc 15 2 oz 7 Install plug 9 Figure 23 on the idler 2 7 3 7 3 FG004361 Figure 22 2 9 6 3 FG004365 Figure 23 ...

Page 244: ...SP000263 Track Assembly Page 22 LOWER ROLLER Parts List 1 4 8 5 4 3 2 8 5 7 7 6 2 6 FG004392 Figure 24 ...

Page 245: ... To gain access to some rollers the link guard may have to be removed Remove four spring washers and bolts to remove guard NOTE If additional track clearance is required remove upper rollers before raising track Lower Roller Disassembly 1 Remove plug from the collar and drain oil 2 Pull the pin 5 Figure 26 from the collar Reference Number Description 1 Roller 2 Collar 3 Shaft 4 Bushing 5 Pin 6 Flo...

Page 246: ... Detach collar 2 Figure 28 and O rings 7 from the axle using press Lower Roller Reassembly 1 Degrease clean and dry all parts before reassembly Insert bushing 4 Figure 29 into roller 2 Apply grease to the O rings 7 Figure 30 and insert into axle 3 Align collar 2 Figure 30 and axle 3 pin holes and pin 5 the collar 2 Figure 27 1 6 2 2 6 7 FG004393 Figure 28 4 FG004396 Figure 29 5 3 7 2 FG004397 Figu...

Page 247: ... 2 Figure 32 O ring 7 Figure 31 and pin 5 on the remaining side 7 Fill with new engine oil with approximately 450cc 15 2 oz 8 Install plug 8 Figure 32 on the collar Lower Roller Installation 1 Install four bolts to hold lower roller assembly to track frame NOTE To gain access to some rollers a link guard may have to be removed Remove four spring washers and bolts to remove guard 1 6 2 2 6 7 FG0043...

Page 248: ...SP000263 Track Assembly Page 26 UPPER ROLLER Parts List 13 9 14 10 12 11 5 1 2 3 8 6 4 7 Figure 34 ...

Page 249: ...sure to track shoe 3 Remove mounting hardware holding upper roller assembly to track frame Upper Roller Disassembly 1 Remove the plug 9 Figure 36 from the cover and drain oil Reference Number Description 1 Roller 2 Shaft 3 Thrust Ring 4 Bushing 5 Bushing 6 Floating Seal 7 O ring 8 O ring 9 Plug 10 Cover 11 Washer 12 Bolt 13 Blot 14 O ring Reference Number Description FG005127 Figure 35 9 FG004400 ...

Page 250: ... 12 and washer 11 3 Separate the roller 1 Figure 38 from the axle 2 4 Separate the floating seal 6 Figure 39 from the roller and coller 1 5 Separate the O ring 8 and thrust ring 3 from the axle 2 13 10 14 12 11 FG004404 Figure 37 2 1 FG004406 Figure 38 1 6 FG004409 Figure 39 3 8 2 FG004411 Figure 40 ...

Page 251: ...Track Assembly Page 29 SP000263 6 Separate the bushing 4 and 5 Figure 41 from the roller with a press FG001502 4 5 ST 1919 Figure 41 ...

Page 252: ... and coller NOTE Apply clean engine oil to the joint side of the floating seal Apply grease to the floating seal O ring 3 Install the axle washer 11 Figure 44 and bolt 12 4 Insert the O ring 8 Figure 44 to the cover Attach cover 10 and bolt 13 to the roller 5 Fill with new engine oil with 600cc 20 3 oz 6 Tighten plug 9 Figure 44 1 5 FG004419 4 Figure 42 1 6 FG004409 Figure 43 13 9 10 14 12 11 FG00...

Page 253: ...Track Assembly Page 31 SP000263 ...

Page 254: ...SP000263 Track Assembly Page 32 TRACK SPRING AND TRACK ADJUSTING CYLINDER 11 12 10 6 2 13 5 4 1 7 8 9 3 FRONT 14 15 FG004444 Figure 45 ...

Page 255: ...Track Spring Assembly Diagram Reference Number Description 1 Body 2 Bracket 3 Rod 4 Spring 5 Tie Bar 6 Nut 7 Rod Packing 8 Backup Ring 9 Dust Seal 10 Plate 11 Bolt 12 Spring Washer 13 Stopper 14 Spring Pin 15 Body Assembly Reference Number Description Figure 46 ...

Page 256: ...k Spring Disassembly Diagram Figure 47 Reference Number Description 1 Bolt 2 Lock Plate 3 Lock Nut 4 Bracket 5 Spring 6 Sotpper 7 Tie Bar 8 Spring Pin 9 Body 10 Rod Packing 11 Back up Rinf 12 Dust Seal 13 Rod Reference Number Description ...

Page 257: ... seal 12 the back up ring 11 and the rod packing 10 which should be replaced with new ones because they cannot be reused CAUTION The track spring assembly is assembled with strong force that more care should be taken for its disassembly Figure 48 CAUTION When supplying air the operator should stand beside not behind the rod for it may be sprung forth suddenly with a blasting sound Figure 49 ...

Page 258: ...3 release the load of the press to separate the bracket 4 the spring 5 the stopper 6 and the body assemblies 7 8 9 CAUTION Remember that spring has a very high elasticity that it might be sprung forth during assembly or disassembly CAUTION The lock nut 3 can be removed easily by means of heating as it is attached with a special adhesive Figure 50 CAUTION When using a spanner nuts should be tighten...

Page 259: ...eating them as they are attached with a special adhesive 8 Check and remove rust or damage in the body 9 Assembly of the Track Spring CAUTION Take care not to damage the inside of the body and screw threads after the disassembly of the tie bar Figure 51 CAUTION Take care not to damage the inside of the body and screw threads after the disassembly of the tie bar Figure 52 ...

Page 260: ... stopper 6 in the body assembly which shall be seated in the press 6 Apply pressure to the press slowly 7 Continue pressure until the clearance between the bottom of the bracket and the end of the body is 965 mm 8 Apply the adhesive Loctite 277 threadlocker to the lock nut and bolt it on the lock plate CAUTION When applying pressure make sure that the tie bar is set to the hole of the bracket prop...

Page 261: ... evenly 11 Insert the back up ring 3 and press outward 12 Bend the rod packing and insert it into the back up ring Figure 54 CAUTION Remember that spring has a very high elasticity that it might be sprung forth during assembly or disassembly CAUTION If the range is poor eccentric driving and or earlier wear of the idler may occur CAUTION Safety precaution should be followed as the track spring ass...

Page 262: ...in the body and carefully push the rod completely 15 Use a 27 mm spanner to install the grease valve and supply grease 16 Release the grease valve a little push the rod with full force to remove air completely and tighten it again CAUTION If air is not removed completely air explosion due to load may damage the rod packing ...

Page 263: ...SP000025 Page 1 Air Conditioner SP000025 AIR CONDITIONER SP000025 Air Conditioner Edition 1 ...

Page 264: ...Air Conditioner SP000025 Page 2 MEMO ...

Page 265: ...elay Blower 15 Relay A C 15 Duct Sensor 15 Water Temp Sensor 16 Internal Air Temp Sensor 16 Ambient Air Temperature Sensor 16 Sun Sensor 17 Control Panel 17 Compressor 25 Receiver Dryer 25 Troubleshooting 26 Weight of R134a Gas Used In Machines 28 Refrigerant System Repairs 29 Refrigerant Safe Handling Procedures 29 Repair and Replacement Procedure 30 Refrigerant Recovery 32 Vacuuming Refrigerant ...

Page 266: ...Air Conditioner SP000025 Page 4 MEMO ...

Page 267: ... practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 5001 and Up DX340LC 5001 and Up DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 50...

Page 268: ...CONDITIONER SYSTEM Outline Solid type heater and air conditioner are installed in the cover behind the driver s seat Temperature of the driver s room is adjusted automatically to the temperature set by operator FG000784 A A C B C Figure 1 ...

Page 269: ... 500 hours If machine operates in an excessively contaminated environment filters should be cleaned more frequently and if necessary replaced with new ones How to check Indoor air filter 1 Press both levers on the left and right side at the top of the filter installed at the rear of the driver s seat How to check outdoor air filter 1 Open the front door at the left side of machine and loosen four ...

Page 270: ...e rear side of the cabin to open the cover 3 Remove the filter attached to the cover and clean the contaminated filter using compressed air 4 Close the cover replace the knobs and secure the cover to the support with butterfly bolts FG000441 1 Figure 4 FG000342 Figure 5 ...

Page 271: ... 8 8 9 4 5 5 6 7 2 3 Figure 6 Reference Number Description 1 Air Conditioner heater Unit 2 Condenser 3 Compressor 4 Receiver Dryer 5 Discharge Hose 6 Suction Hose 7 Liquid Hose 1 8 Liquid Hose 2 9 Ambient Temperature Sensor 10 Sun Sensor 11 Control Panel Reference Number Description ...

Page 272: ...L 0 85YG 1 SENSOR CN10 AMP 20P 2 CN10 17 1 INCAR CN11 KET 4P WATER SENSOR CN10 19 CN8 2 0 5OrB CN9 2 CN9 4 1 25BL 0 5YW CN9 1 0 5LgW CN9 3 CN9 18 0 5LgB 0 5YR CN9 10 1 25B ACTUATOR CN10 15 MIX F BACK GND CN10 4 CN10 9 DUCT SENSOR WARM P1 Vref MIX COOL P2 CN10 7 CN10 3 M Temp Control 0 85LW CN10 1 CN10 2 CN10 20 CN10 12 CN11 1 CN10 11 CN10 13 CN9 16 CN9 14 0 5YB 0 5OrW CN9 15 CN9 12 0 5OrR 0 5GrY C...

Page 273: ...ter Unit Air Flow Diagram VENT DEF FOOT Heater Core Evaporator Fan Internal Air External Air Vent Rear Outlet Cold Box Outlet External Air Inlet Internal Air Inlet Vent Front Outlet DEF Outlet Foot Outlet DOOR INTAKE DOOR MIX COOL WARM FG001359 Figure 8 ...

Page 274: ...F VENT Actuator Temp control Change of discharged air temperature by controlling the position of temp control door Door Mode Vent Bi level Foot Def foot Def Vent 100 60 0 0 0 Foot 0 40 100 80 60 Def 0 0 0 20 40 FG001360 Actuator Temp Control A C Relay Duct Sensor Blower Relay Air Flow Control Module Blower Motor Actuator Internal external Air Exchanger Internal Air Sensor Internal Air Filter Evapo...

Page 275: ...or Temp control FG001361 Figure 10 Wind Direction Mode Output Terminal Voltage Vent c CN10 10 b CN10 4 0 5 0 2V Bi level 1 3 0 2V Foot 2 45 0 2V Foot def 3 5 0 2V Def 4 5 0 2V Set Temp Output Terminal Voltage Max cooling c CN10 9 b CN10 4 Below 0 4V Max heating Above 4 5V ...

Page 276: ...ir flow is set manually CN10 20 CN10 2 FG001055 Figure 11 Sel mode Output Terminal Output Internal Air P1 P2 Moving of exchange door by selecting external air External Air P1 P2 Moving of exchange door by selecting internal air DRAIN CN10 1 SOURCE CN11 1 GATE CN10 6 FG001056 Figure 12 Air flow Output Terminal Output 1st CN11 2 CN10 1 10 0 5V 2nd 12 5 0 5V 3rd 15 0 5V 4th 17 5 0 5V 5th 20 0 0 5V 6t...

Page 277: ...e evaporator The sensor consist of negative characteristic thermistor that resistant value increases and decreases when the temperature rises and falls respectively Figure 13 Specifications Rated voltage 24V Rated current 20A FG001058 L S1 S2 B Figure 14 Specifications Rated voltage 24V Rated current 10A Figure 15 Temp C Resistance KΩ Ω Ω Ω 0 11 36 0 1 2 10 39 0 2 2 5 10 17 0 2 3 9 95 0 2 3 5 9 73...

Page 278: ...nt Air Temperature Sensor Built at the bottom of the cockpit it senses the temperature of external air Figure 16 Temp C Resistance KΩ Ω Ω Ω 10 55 8 1 7 0 32 9 0 9 15 15 76 0 5 25 10 0 0 3 35 6 5 0 2 Figure 17 Temp C Resistance KΩ Ω Ω Ω 15 218 2 7 5 0 97 83 0 9 15 47 12 0 7 25 30 0 0 36 35 19 60 0 3 FG001064 Figure 18 Temp C Resistance KΩ Ω Ω Ω 10 163 4 9 0 96 9 2 9 10 59 4 1 8 20 37 4 1 1 25 30 0 ...

Page 279: ...ol Panel Appearance and Terminal Arrangement Refer to Air Conditioner and Heater of operation manual Terminal Terms 83 7 76 2 67 7 58 8 46 6 36 0 21 4 1 0 2 0 3 0 4 0 5 0 6 0 7 0 LUX x10 000 OUTPUT VOLTAGE mV FG001062 Figure 19 AUTO AUTO OFF TEMP A C A C MAX OUTSIDE SEL MODE FG001063 18 8 CN8 AMP 070 12P CN9 15 17 16 12 14 13 9 11 10 12 11 10 AMP 070 18P 6 5 7 4 1 3 2 5 4 6 7 8 9 1 2 3 Figure 20 ...

Page 280: ... 4 Ambient air temp sensor 5 Power KEY ON 5 Internal air temp sensor 6 Back up 6 7 7 8 A C output LOW 8 9 9 10 Earth 10 D P S CHECK 11 Light 11 Air flow module gate 12 External internal air Ex 12 Blower motor feedback 13 External internal air In 14 Wind direction control VENT 15 Wind direction control DEF 16 Wind direction control Power 5V 17 Wind direction control feedback 18 Temp control cool ...

Page 281: ...ir temp sensor Ambient air temp sensor Water temp sensor 1 In case of sensor failure following defaults are applied Internal air temp sensor 25 C Ambient air temperature sensor 25 C Duct sensor 2 C Temp control actuator Set Temp 17 24 5 C Max cooling Set Temp 25 32 C Max heating Wind direction mode actuator VENT VENT fix modes other than VENT Fixed to DEF Sun sensor is not compensated Max cooling ...

Page 282: ... the cycle of engine OFF engine run 4 Initial cooling control is executed when the Auto switch is On in the manual status A C Off and manual control of air flow in 5 seconds after engine run 5 Initial cooling control should be before max cooling 6 Release condition OR condition 1 A C OFF 2 Air flow Manual control 3 Release is possible with the OFF switch but not allowed within 12 seconds after Sta...

Page 283: ...OFF engine start 3 Initial heating control should be before max heating 4 Air flow is controlled only when the wind direction is in the manual mode and BI LEVEL FOOT or FOOT DEF is set 5 Control through the water temp sensor for start 6 Heater starting control 2 starts in case of fault of the water temp sensor during controlling 7 Operation release OR condition 1 Only air flow is released if it is...

Page 284: ...er 3 Difference between internal and external air temp 15 C 4 When Max Cooling 17 C is selected 5 Exceptional case Starting control of heater is performed only once during the remaining period if the entry condition is satisfied within the starting control period that is the accumulation of initial start times Inclusive of Auto mode ON case within the period of starting control of heater Air flow ...

Page 285: ...cle of 0 5 sec ON and 0 5 sec OFF In case of two or more errors codes concerned blink twice at a time For normal E0 lights for error the first error code is indicated For 2 or more error error codes are indicated upstreams downstreams if the temp control switch is set to up down For normal condition only EO lights Press the SEL switch more than 3 times in 5 secs while pressing the A C switch Retur...

Page 286: ... Display of ambient temp may be released in the same way for its entry way It returns automatically to default mode 5 seconds after entering the ambient air temp display mode Code Description E0 Normal E1 Internal Air Temp Sensor Short E2 Internal Air Temp Sensor Open E3 Ambient Air Temp Sensor Short E4 Ambient Air Temp Sensor Open E5 Duct Sensor Short E6 Duct Sensor Open E7 Sun Sensor Short E8 Su...

Page 287: ...rigerant from the condenser may contain refrigerant gas with bubbles whose presence in the expansion valve decreases the freezing power excessively it separates liquid and gas and sends liquid only to the expansion valve Water in refrigerant shall be eliminated with dryer and through filter Volume of refrigerant by model FG001365 Relief Valve Figure 23 Categories Specifications Output 155 3 cc rev...

Page 288: ... device or soapy water check for refrigerant leakage at all major components and joints Yes Repair leaking component No Recharge system to correct pressure 2 High pressure Over 23 kg cm2 327 psi Low pressure Approximately 2 5 3 0 kg cm2 36 43 psi Possible Cause Overcharge Frost on condenser Step Inspection Item Remedy 1 Check for condenser pin damage or contamination Yes Clean repair or replace co...

Page 289: ...ible Cause Moisture in system has iced up the expansion valve NOTE When the absorbed moisture freezes the pressure readings may look normal Careful readings should be made to determine whether pressure is in normal range 1 Recover any remaining refrigerant 2 Vacuum out system 3 Recharge system NOTE If the system has been exposed to the air for a long period of time replace the receiver dryer 6 Hig...

Page 290: ...ner Page 28 WEIGHT OF R134a GAS USED IN MACHINES Model Weight of Gas DX300LC 800 20 grams 28 0 7 oz DX340LC 800 20 grams 28 0 7 oz DX420LC 800 20 grams 28 0 7 oz DX480LC 800 20 grams 28 0 7 oz DX520LC 800 20 grams 28 0 7 oz ...

Page 291: ...harge the system WARNING Always wear protective glasses and gloves when handling refrigerant If refrigerant comes in contact with the skin or eyes immediately flush with clean running water and consult a physician Select a clean and well ventilated area to work The refrigerant container is under high pressure and should be stored below 40 C 104 F Be careful not to drop the container from a high lo...

Page 292: ...g parts Do not reuse old O rings 8 Use a vacuum pump to evacuate refrigerant system of air 9 When charging the refrigerant system with the engine running do not open the high pressure valve on the manifold gauge as the reverse flow of high pressure refrigerant will rupture the hose 10 When releasing the high pressure hose after completing the charging process quickly disconnect the hose to minimiz...

Page 293: ...OR AIR LEAKAGE VACUUM SYSTEM OVER 20 MINUTES CHARGE SYSTEM APPROXIMATELY 100 g CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHARGE SYSTEM TO PROPER LEVEL Standard Capacity less Initial Charge CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHECK FOR PROPER REFRIGERANT LEVEL RUN SYSTEM RECOVER REFRIGERANT IN CHARGING HOSE REMOVE REPAIR TOOLS REPAIR HDA6067L Figure 28 ...

Page 294: ...auge dials indicates 0 kg cm2 0 psi Vacuuming Refrigerant System 1 Vacuuming Procedure NOTE When the A C system has been exposed to the air it must be vacuumed out Perform vacuum process for 30 minutes for complete moisture and air evacuation A Attach the manifold gauges and vacuum pump to the refrigerant system as shown B Turn on the vacuum pump and open both valves C When the low pressure gauge ...

Page 295: ...unting valve on the container make sure the handle is in the counterclockwise most position with the puncture pin retracted and the mounting disk is in the raised position B Attach the manifold gauge center hose to the valve assembly C Turn the disk in the clockwise direction and securely mount valve onto refrigerant container D Turn the valve handle in the clockwise direction and puncture the con...

Page 296: ... leaking tests as described in the proceeding headings NOTE First charge the refrigerant system with 100g 3 5 ounces of refrigerant with the engine off Then using the manifold gauges as a guide fully charge the system with the engine running When exchanging refrigerant containers press the manifold gauge low side valve to eliminate air from the charging hose 2 Charge the system by opening the mani...

Page 297: ... off engine and close refrigerant supply container adapter valve Disconnect manifold gauge hoses from vehicle WARNING When charging refrigerant system with the engine running Always keep refrigerant supply container in the upright position Never open the high side pressure valve Gauge Dial Standard Reading High Side Gauge 13 20 kg cm2 185 285 psi Low Side Gauge 1 5 3 5 kg cm2 22 50 psi WARNING Whe...

Page 298: ...ssor outlet condenser inlet receiver dryer inlet air conditioner unit inlet 2 Low pressure side Compressor inlet air conditioner unit outlet 3 Compressor Compressor shaft area bolt hole area and magnetic clutch area 4 Receiver dryer Pressure switch and plug area 5 Connection valve area Inspect all valve areas Verify all valves are capped to prevent leaking Check for foreign material inside of valv...

Page 299: ...1Engine and Drive Train ...

Page 300: ......

Page 301: ...SP000026 Page 1 Drive Coupling Main Pump SP000026 DRIVE COUPLING MAIN PUMP SP000026 1Drive Coupling Main Pump Edition 1 ...

Page 302: ...Drive Coupling Main Pump SP000026 Page 2 MEMO ...

Page 303: ...SP000026 Page 3 Drive Coupling Main Pump Table of Contents Drive Coupling Main Pump Safety Precautions 5 Applicable Models 5 Drive Coupling 6 Installation of Drive Coupling 7 Installation Procedure 7 ...

Page 304: ...Drive Coupling Main Pump SP000026 Page 4 MEMO ...

Page 305: ... shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 5001 and Up DX340LC 5001 and Up DX420LC 5001 and Up DX480LC 5001 and Up DX520...

Page 306: ...SP000026 Drive Coupling Main Pump Page 6 DRIVE COUPLING Figure 1 thru Figure 2 show typical drive coupling installations FG000656 Figure 1 FG000657 Figure 2 ...

Page 307: ...n pump Installation Procedure 1 Assemble the flange of the coupling 1 Figure 3 in the engine flywheel with bolts 2 Figure 3 NOTE Apply lock tight to bolts 2 NOTE Set the flange that the label saying 2 mounted long side faces the pump 2 Assemble it until it is put to the end of pump axle of the clamping hub 3 Figure 3 3 Tighten the socket bolt 4 Figure 3 NOTE Tightening torque 21 4kg m 4 Assemble t...

Page 308: ...SP000026 Drive Coupling Main Pump Page 8 ...

Page 309: ...1Hydraulics ...

Page 310: ......

Page 311: ...0273 Page 1 Hydraulic System Troubleshooting Testing and Adjustment SP000273 HYDRAULIC SYSTEM TROUBLESHOOTING TESTING AND ADJUSTMENTSP000273 Hydraulic System Troubleshooting Testing and Adjustment Edition 1 ...

Page 312: ...Hydraulic System Troubleshooting Testing and Adjustment SP000273 Page 2 MEMO ...

Page 313: ...Circuit 12 Arm Dump Circuit 12 Bucket Operating Circuit 13 Bucket Crowd Circuit 13 Bucket Dump Circuit 13 Swing Operating Circuit 13 Right Swing Operating Circuit 14 Left Swing Operating Circuit 14 Swing Relief Valve and Makeup Valve 14 Travel Operating Circuit 14 Forward Travel Circuit 15 Reverse Travel Circuit 15 Procedural Troubleshooting Baseline Recommendations 16 Initial Checks and Tests to ...

Page 314: ...ntrol 24 Pump Regulator Adjustment 24 Flow Meter and Flow Meter Kit Installation and Testing 27 Swing System Troubleshooting 29 Precautions Initial Checks 29 Swing Relief Valve Checking and Adjustment 29 Troubleshooting Swing Gearbox 32 Troubleshooting Hydraulic Problems 33 Troubleshooting Control Valve 34 Troubleshooting Travel Control Valve 36 Troubleshooting Joystick Control Valve 36 ...

Page 315: ...nges CAUTION Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up ...

Page 316: ... to maximize output efficiency The system features an electronically controlled output optimization system which allows the operator to choose between two distinctly different power modes high output rapid cycling maximum speed power mode and a standard power mode for most types of general operation 20 5 14 16 14 20 4 19 11 20 16 14 2 1 9 12 7 13 21 15 17 12 8 13 6 1 21 15 17 10 18 16 14 20 3 16 C...

Page 317: ...m Troubleshooting Testing and Adjustment Page 7 SP000273 Electronic management of hydraulic control valves assists in optimizing the application speed and overall operator control of hydraulic actuators and functions ...

Page 318: ...el swing boom up and arm functions The amount of oil flow to the actuators at the output end of each of those circuits is regulated through the movement of each individual valve spool The left half of the hydraulic control valve fed by the left pump in the pump assembly has control spools for left travel bucket boom and arm operation Two stage operation is a feature of boom and arm function All of...

Page 319: ...system at approximately 50 C 122 F The arm cylinder operating circuit includes anticavitation valves which protect the hydraulic system from vacuum that could result from external shocks or other unusual conditions Boom Arm and Bucket cylinder circuit are also protected by overload relief valves Whenever high pressure is generated as a result of a shock or overload excess pressure is dumped to the...

Page 320: ...damage as a result of overloads or shocks to the boom Additional protection to prevent cavitation of the cylinder is provided by a make up valve and reservoir return circuit which ensures that the volume of oil going to the cylinder will not 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...

Page 321: ...ht and left halves of the control valve a slow return orifice and the arm cylinder The circuit can be operated in the two stage speed control mode which works through both halves of the control valve and doubles the volume of oil flowing to the cylinder Overload relief valves set at 360 kg cm2 5 112 psi have been installed at the AM 1 and AMD 1 ports on the right side of the control valve to prote...

Page 322: ...weight of the arm and bucket Insufficient oil flow to the cylinder could lead to cavitation in the cylinder and or surging or irregular movement This is prevented by a regeneration valve attached to the control valve which maintains the balance between oil flowing into the cylinder and oil flowing out Arm Dump Circuit When the arm control lever is put in dump mode the left side pilot valve generat...

Page 323: ...ft main pump flows to the bucket cylinder Bucket Dump Circuit When the bucket control lever is put in the dump mode the bucket control valve spool in the left half of the control valve opens to supply oil from the left main pump to the cylinder Swing Operating Circuit The swing operating circuit consists of the right main pump in the pump assembly the right half of the control valve and the swing ...

Page 324: ...r Swing Relief Valve and Makeup Valve Whenever the spool is shifted to the neutral mode during swing operation the possibility exists that surge pressure in the circuit caused by inertial momentum of the upper works and correspondingly reduced pressure at the opposite motor port could produce cavitation in the circuit To keep that from happening a 285 kg cm2 4 052 psi relief valve is installed in ...

Page 325: ...f 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 PR PL TRRR and TRLR ports on the control valve through the upper works center joint to the travel motors TRAVEL MOTOR L TRAVEL MOTOR R CENTER JOINT TRAVEL L TRAVEL R L TRAVEL FORWARD PILOT R TRAVEL FORWARD PILOT PUMP L PUMP R ATS0830L Figure 10 ...

Page 326: ...may be due to inadequate hydraulic flow caused by lagging rotational speed NOTE Verify actual flow on the excavator against rated performance with a flow meter If engine tests meet specifications and adequate torque and horsepower are available at the pump drive flex coupling pull out the electrical tray under the operator s seat to inspect the self diagnostic display If the EPOS trouble code disp...

Page 327: ... the individual circuit may indicate that the component is worn beyond tolerance limits while all other hydraulic functions are adequate IMPORTANT It is suggested that the troubleshooter maintain the testing sequence of the preceding list Checks and adjustments nearer the middle or the end of the list may depend on adequate functioning of systems tested nearer the top of the list ...

Page 328: ...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 that serial number changes and variation in the joystick assemblies used on different excavators could produce slight change in actual performance characteristics Comparison of part numbers to serial...

Page 329: ...to the extra leads on the harness and reconnect the valve electrical 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 the engine and increase engine rpm by turning the speed control to the maximum speed setting Warm up the engine and hydraulic system un...

Page 330: ...73 Hydraulic System Troubleshooting Testing and Adjustment Page 20 Mode Engine RPM Current Pressure Power Mode High Idle 1 880 RPM 200 20 mA 2bar 29 psi Standard Mode High Idle 1 770 RPM 350 mA 7 bar 102 psi ...

Page 331: ...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 lost Operate the swing motor in both directions Measure signal current and hydraulic pressure through the valve and record the highest and lowest values as the swing motor rotate clockwise and counterclockwise several times Rese...

Page 332: ...valve adjustment by loosening the outside widest diameter lock nut on the relief valve Turn the adjusting screw clockwise to increase pressure or counterclockwise to decrease it Pressure must be 350 bars 5075 psi or up to 10 bars 145 psi higher Because one adjustment can affect the other check low stage main relief pressure by repeating the cylinder stall test without pressure up Readjust standard...

Page 333: ...rator s cabin must be operating correctly or pressure tests and further adjustments cannot be made Power Mode Operation Main Pressure and Tolerance Pilot Pressure and Tolerance Mode Neutral No Operation 20 40 bar 290 580 psi 30 bar 10 bar 435 psi 145 psi Mode Cylinder Stall 320 bar 5 bar 4 641 psi 75 psi 30 bar 10 bar 435 psi 145 psi Mode W Pressure Up Cylinder Stall 350 bar 10 bar 5 075 psi 145 p...

Page 334: ...re is normally performed If the engine is being consistently overloaded and engine troubleshooting shows engine performance to be at or above rated output If reduced cylinder speed and diminished work performance provide an indication that rated maximum pump flow may not be available and all other troubleshooting gives no indication of other flaws or hydraulic system defects If pump output is out ...

Page 335: ...i Q Pd Q adjustment screws 1 2 and 3 Each one of the adjustment procedures could affect the setting of the others Check and record the arm dump speed performance test before and after input power adjustment whether or not a flow meter is used NOTE Regulator adjustments affect total cumulative horsepower since each regulator compensates for the output of the other It is not necessary to adjust both...

Page 336: ... 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 or less each time Turning the screw 3 clockwise shift Pd Q curves right and increase input horse power 1 2 turn on the screw 3 is equal to approximately 33 kg cm2 of Pd The adjusting screw 1 Figure 12 affects the delivery rate Q of the pum...

Page 337: ...e output line Install the input flange of the flow meter on the pump end of the output line Cap off the unused input end of the pump discharge line with a blocking flange Bolt up a pre measured length of hydraulic hose between the output end of the flow meter assembly and the top of the reservoir Use appropriate fittings and adapter flanges to guarantee a pressure tight seal NOTE Be sure to mainta...

Page 338: ...wing pump pressure levels with travel speed control set at high speed Compare recorded values with output shown in the P Q curve in the specifications section of this book If test results do not measure up to specified values pump output tests can be repeated using different control levers Recheck front pump operation while stroking the bucket cylinder out lever and the rear pump by actuating the ...

Page 339: ...prior repair service work Drain some tank oil into a clean clear container Look for metal shavings grit cloudiness water or foam air bubbles in the oil Check for wobble through the engine pump flex coupling Run engine with the pump input hydraulic power control nut turned to the lowest power to check the engine Investigate unusual operating noises or vibration Check for loose bolts connections Swi...

Page 340: ... to the inlet and outlet test ports on top of the swing motor and check pressures with the swing locks engaged and released If pressure adjustment fails to restore adequate performance proceed to the Troubleshooting Swing table 3 If pressure tests were at recommended levels through the main inlet and outlet ports and through the SH port of the swing brake the causes of poor swing performance could...

Page 341: ...e assembly the problem will require further hydraulic troubleshooting It s also possible that a defective joystick an intermittent short in an electrical control circuit or a problem in the e EPOS circuit is causing diminished swing performance Pull out the e EPOS indicator panel from underneath the operator s seat and perform the self diagnostic test If the display panel reads code 0 2 it is repo...

Page 342: ... reduced rpm Causes listed above could also produce dragging swing OR hot or wrong oil OR worn out parts Check above list then replace oil test motor drain rate and check for 03 reading e EPOS self test Left travel speed is also reduced Low output at P1 pump or external pilot piping leaks is clogged Clean and repair piping or repair or replace pump P1 Swing control movement is reversed Inlet outle...

Page 343: ...l level Replace oil refill to specified level Bearings or gears worn but not completely inoperative Repair or replace gearbox Problem Possible Cause Remedy Problem Possible Cause Remedy Attachment cylinders swing and travel motors are all inoperable Loud noises are heard from main pump assembly Main pump s malfunction Repair or replace Low oil level in hydraulic system Refill Main pump inlet oil s...

Page 344: ...rol valve spool damaged Repair or replace Dirt in control valve spool Clean or replace Actuator joystick foot pedal damaged or worn Repair or replace Internal seal leak in cylinder Repair or replace Cylinder rod damaged Repair or replace Pilot valve or piping malfunction Repair or replace Mechanical linkage frozen loose or damaged Repair or replace Travel motors inoperable Center joint damaged Rep...

Page 345: ...m up operation Rod check valve damaged or clogged Clean replace Poppet sticking Clean replace Broken or damaged spring Replace Slow operation or response Excessive clearance between spool or casing Check pilot pressure and or replace spool or casing Sticking spool Clean replace Broken or damaged spring Replace Main or port relief valve damaged Check pressure replace Swing priority not operating co...

Page 346: ...hold steady Dirt other interference between valve parts or worn spool sticking intermittently Clean repair or replace Interference or binding on spool return spring Clean repair or replace Interference restriction or unsteady pressure in tank return line Repair or reroute tank return line Air bubbles in piping temporary or air leak Vent air or repair leak NOTE Look for evidence of leaking oil Prob...

Page 347: ...intermittently Clean repair or replace Interference or binding on spool return spring Clean repair or replace Unsteady pressure in tank return line Redirect return line Air bubbles in piping temporary or air leak Vent air or repair leak NOTE Look for evidence of leaking oil to help locate damaged seals or gaskets that could be the cause of air leaks Problem Possible Cause Remedy ...

Page 348: ...SP000273 Hydraulic System Troubleshooting Testing and Adjustment Page 38 ...

Page 349: ...SP000028 Page 1 Accumulator SP000028 ACCUMULATOR SP000028 Accumulator Edition 1 ...

Page 350: ...Accumulator SP000028 Page 2 MEMO ...

Page 351: ...SP000028 Page 3 Accumulator Table of Contents Accumulator Safety Precautions 5 Applicable Models 5 General Description 6 Specifications 8 ...

Page 352: ...Accumulator SP000028 Page 4 MEMO ...

Page 353: ...ractices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 5001 and Up DX340LC 5001 and Up DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001...

Page 354: ...llows 1 With no gas charge in the upper chamber 0 bar 0 psi empty and no oil in the bottom 0 bar 0 psi dry the elastic diaphragm hangs loosely 2 When the prepressure charge of gas usually nitrogen is introduced through the port at the top of the accumulator the diaphragm expands to maximum size The valve button in the center of the diaphragm pushes into the fluid opening in the bottom chamber seal...

Page 355: ... begins to retract upward 4 When system oil is at highest working pressure and the accumulator fills to maximum reserve capacity the flexible diaphragm is pushed up into the top of the upper chamber The highest working pressure is sometimes referred to as the P3 pressure and can also be referenced on the manufacturer s data label on the exterior of the accumulator 5 If system oil pressure begins t...

Page 356: ...1 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX340LC S N 5001 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX420LC S N 5001 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX480LC S N 5001 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX520LC S N 5001 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 ...

Page 357: ...SP000181 Page 1 Center Joint Swivel SP000181 CENTER JOINT SWIVEL SP000181 1Center Joint Swivel Edition 1 ...

Page 358: ...Center Joint Swivel SP000181 Page 2 MEMO ...

Page 359: ...SP000181 Page 3 Center Joint Swivel Table of Contents Center Joint Swivel Safety Precautions 5 Applicable Models 5 General Description 6 Center Joint Disassembly Diagram 7 Disassembly 8 Reassembly 11 ...

Page 360: ...Center Joint Swivel SP000181 Page 4 MEMO ...

Page 361: ...nd safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX340LC 5001 and Up DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and U...

Page 362: ...CRIPTION The center joint swivel is designed to allow hydraulic oil from the upper structure to flow to components in the lower structure It is capable of allowing continuous 360 rotation of the upper structure in relationship to the lower structure ...

Page 363: ... SP000181 Center Joint Disassembly Diagram Figure 1 Reference Number Description 1 Body 2 Shaft 3 Cover 4 Spacer 5 Shim 6 Wear Ring 7 Slipper Seal 8 O ring 1AP 120 9 O ring 1BP 100 10 O ring 1BG 120 Reference Number Description ...

Page 364: ... 17 mm spanner to disassemble the spacer and the shim CAUTION It is recommended to use a hoist or a similar device for it is heavy CAUTION Remove active oil and wash it out before starting disassembly CAUTION It should be disassembled after its active oil is cool enough after it is removed from the system for its active oil is very hot Figure 2 Figure 3 CAUTION Care should be taken not to make a f...

Page 365: ...uds on the spindle drain port as shown in the figure 6 Separate the body into 6 slipper seals 1 wear ring and 1 O ring 7 Remove the PT and PF plugs sealing the shaft Internal sealing PF 3 4 12 mm wrench External sealing PT3 8 8 mm Wrench Figure 4 Figure 5 CAUTION Care should be taken not to damage the inside of the body because it is likely to be damaged when disassembling the slipper seal It may ...

Page 366: ...e at every pieces disassembled and wash them out 9 Replace disassembled O rings and slipper seals with new ones for they cannot be reused CAUTION The inside of the body should be air washed and rust proof treated after washing it as its material is subject to rust ...

Page 367: ...0 O ring the outside of the body CAUTION Apply active oil to every functional moving part before assembly to reduce any assembly friction as much as possible Figure 7 Internal sealing PF3 4 12 mm wrench External sealing PT3 8 8 mm wrench Engagement torque 15 1 09 Kg m Engagement torque 4 5 9 5 kg m Figure 8 CAUTION After assembling the sliper seal a manual test should be performed to ensure that e...

Page 368: ...ts on the top of the shaft 8 Use a torque wrench to tighten spacer bolts at 5 6 kg m CAUTION For any sliper seal which is protruded press it with finger to seat it in its position Care should be taken when using a driver or a metal tool which may cause damage to it CAUTION Applying active oil to the surface of the shaft enables the assembly without any damage to the sliper seal Figure 9 CAUTION Ta...

Page 369: ... in the figure 10 Engage the cover bolt M 12 at torque of 10 12 5 kg m 11 Return the O ring 1 AP 120 assembled to the outside of the body to its original position Figure 11 CAUTION After the completion of the assembly a start up and a rotation torque tests should be performed for the sliper seal to seat in its place properly ...

Page 370: ...SP000181 Center Joint Swivel Page 14 ...

Page 371: ...SP000030 Page 1 Cylinders SP000030 CYLINDERS SP000030 Cylinders Edition 1 ...

Page 372: ...Cylinders SP000030 Page 2 MEMO ...

Page 373: ...autions 5 Applicable Models 5 General Description 6 Theory of Operation 6 Parts List 8 Special Tools and Materials 10 Piston Nut 10 Piston Jig 12 Steel Bushing Jig 14 Dust Wiper Jig 16 Slipper Seal Jig 18 Slipper Seal Straightening Jig 20 Disassembly 22 Reassembly 27 ...

Page 374: ...Cylinders SP000030 Page 4 MEMO ...

Page 375: ...ons and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 5001 and Up DX340LC 5001 and Up DX420LC 5001 and Up ...

Page 376: ... or to the front of the cylinder oil path B The cylinder rod is extended as oil flow is pumped through the circuit to the back side of the piston The force F1 of the piston stroke can be expressed by the formula below where P circuit oil pressure and the inside diameter of the cylinder is expressed by D Figure 1 P Pressure π 3 14 D Cylinder Inside Diameter When the cylinder rod is retracted oil fl...

Page 377: ...me of oil needed to lengthen the cylinder rod Q1 is greater than the volume of oil required to retract the cylinder rod it takes more time to extend a cylinder than it does to retract it Q1 Q2 1 FG001459 Figure 3 Q1 S x π D2 4 Q2 S x π D2 R2 4 ...

Page 378: ...ist Cross section in Figure 4 shows an arm cylinder Cross section in Figure 5 shows a boom cylinder The bucket and boom cylinders are identical and differ only in the attached pipes 35 4 5 11 12 9 10 27 8 6 7 15 13 14 3 1 16 28 29 30 31 35 25 2 26 18 17 20 19 21 22 23 24 FG005226 Figure 4 1 2 3 4 17 18 19 20 21 22 23 24 16 5 6 7 8 15 35 35 32 33 34 13 14 11 12 9 10 FG005227 Figure 5 ...

Page 379: ...Dust Wiper 12 Retaining Ring 13 O ring 14 Backup Ring 15 O ring 16 Cushion Ring 17 Piston 18 Slipper Seal 19 Wear Ring 20 Ring 21 O ring 22 Backup Ring 23 Piston Nut 24 Set Screw 25 Socket Head Bolt 26 Pipe Band Assembly 27 Hex Socket Bolt 28 Check Valve 29 Spring 30 Spring Support 31 Hex Socket Plug 32 Spring Washer 33 Hex Bolt 34 Pipe Assembly 35 Grease Nipple Reference Number Description ...

Page 380: ...Cylinders Page 10 SPECIAL TOOLS AND MATERIALS Piston Nut B A D C 0 2 0 1 0 2 0 1 R R15 R20 C3 C5 35 350 ARS4730L 15 4 R 0 5 Through Hole 8 Figure 6 Material SM45C AISI 1045 Rockwell Harden from 22 27 Oil Quench ...

Page 381: ... 0 20 in S BUCKET DX340LC BOOM 145 0 mm 5 71 in 105 0 mm 4 13 in 12 0 mm 0 47 in 5 0 mm 0 20 in OPT BOOM ARM 147 0 mm 5 79 in 107 0 mm 4 21 in 12 0 mm 0 47 in 5 0 mm 0 20 in OPT ARM BUCKET 145 0 mm 5 71 in 105 0 mm 4 13 in 12 0 mm 0 47 in 5 0 mm 0 20 in OPT BUCKET DX420LC BOOM 147 0 mm 5 79 in 107 0 mm 4 21 in 12 0 mm 0 47 in 5 0 mm 0 20 in ARM 147 0 mm 5 79 in 107 0 mm 4 21 in 12 0 mm 0 47 in 5 0...

Page 382: ...SP000030 Cylinders Page 12 Piston Jig C 35 A 30 R R15 20 2 B D R F 2 Through Hole 8 15 ARS4740L 4 R5 Figure 7 Material SM45C AISI 1045 Rockwell Harden from 22 27 Oil Quench ...

Page 383: ...m 5 51 in S BUCKET DX340LC BOOM 120 0 mm 4 72 in 13 0 mm 0 51 in 85 0 mm 3 35 in 150 0 mm 5 91 in OPT BOOM ARM 130 0 mm 5 12 in 13 0 mm 0 513 in 93 0 mm 3 66 in 165 0 mm 6 50 in OPT ARM BUCKET 120 0 mm 4 72 in 13 0 mm 0 51 in 85 0 mm 3 35 in 150 0 mm 5 91 in OPT BUCKET DX420LC BOOM 130 0 mm 5 12 in 13 0 mm 0 51 in 93 0 mm 3 66 in 165 0 mm 6 50 in ARM 130 0 mm 5 12 in 13 0 mm 0 513 in 93 0 mm 3 66 ...

Page 384: ...nders Page 14 Steel Bushing Jig 20 A 20 5 A F 15 1 B 40 E ARS4750L B Figure 8 Material SM45C which is done thermal refining QT Hrc 22 28 Undefined Chamfer C R 0 5 Max Place Finally work to used DNMG Tip Nose R0 4 1 ...

Page 385: ...in S BUCKET DX340LC BOOM 100 0 mm 3 94 in 115 0 mm 4 53 in 45 0 mm 1 77 in 7 5 mm 0 30 in OPT BOOM ARM 100 0 mm 3 94 in 115 0 mm 4 53 in 45 0 mm 1 77 in 7 5 mm 0 30 in OPT ARM BUCKET 100 0 mm 3 94 in 115 0 mm 4 53 in 45 0 mm 1 77 in 7 5 mm 0 30 in OPT BUCKET DX420LC BOOM 110 0 mm 4 33 in 130 0 mm 5 12 in 70 0 mm 2 76 in 11 0 mm 0 43 in ARM 110 0 mm 4 33 in 130 0 mm 5 12 in 70 0 mm 2 76 in 11 0 mm ...

Page 386: ... 16 Dust Wiper Jig D C DIA B 40 15 3 C1 5 DIA B DIA A DIA A 20 R0 2 1 ARS4760L Figure 9 Material SM45C which is done thermal refining QT Hrc 22 28 Undefined Chamfer C R 0 5 Max Place Finally work to used DNMG Tip Nose R0 4 1 ...

Page 387: ... BUCKET DX340LC BOOM 100 0 mm 3 94 in 114 0 mm 4 49 in 6 0 mm 0 24 in 7 0 mm 2 28 in OPT BOOM ARM 115 0 mm 4 53 in 131 0 mm 5 16 in 6 0 mm 0 24 in 7 0 mm 2 28 in OPT ARM BUCKET 100 0 mm 3 94 in 114 0 mm 4 49 in 6 0 mm 0 24 in 7 0 mm 2 28 in OPT BUCKET DX420LC BOOM 115 0 mm 4 53 in 131 0 mm 5 16 in 6 0 mm 0 24 in 7 0 mm 2 28 in ARM 120 0 mm 4 72 in 136 0 mm 5 35 in 6 0 mm 0 24 in 7 0 mm 2 28 in BUC...

Page 388: ...SP000030 Cylinders Page 18 Slipper Seal Jig ARS4770L A 2 A A 14 B B 40 5 R 1 0 R1 1 0 Figure 10 ...

Page 389: ...140 0 mm 5 51 in 28 5 mm 1 12 in S BUCKET DX340LC BOOM 150 0 mm 5 91 in 28 5 mm 1 12 in OPT BOOM ARM 170 0 mm 6 69 in 34 5 mm 1 36 in OPT ARM BUCKET 150 0 mm 5 91 in 28 5 mm 1 12 in OPT BUCKET DX420LC BOOM 165 0 mm 6 50 in 34 5 mm 1 36 in OPT BOOM ARM 180 0 mm 7 09 in 41 5 mm 1 63 in OPT ARM BUCKET 160 0 mm 6 30 in 34 5 mm 1 36 in OPT BUCKET 0 2 0 1 0 2 0 1 ...

Page 390: ...SP000030 Cylinders Page 20 Slipper Seal Straightening Jig ARS4780L 2 R1 50 25 100 A 15 A 2 5 R 2 C 1 Figure 11 ...

Page 391: ... 5 51 in ARM 150 0 mm 5 91 in S ARM BUCKET 140 0 mm 5 51 in S BUCKET DX340LC BOOM 150 0 mm 5 91 in OPT BOOM ARM 170 0 mm 6 69 in OPT ARM BUCKET 150 0 mm 5 91 in OPT BUCKET DX420LC BOOM 165 0 mm 6 50 in OPT BOOM ARM 180 0 mm 7 09 in OPT ARM BUCKET 160 0 mm 6 30 in OPT BUCKET 0 2 0 1 ...

Page 392: ... or other protective material around piston rod to avoid possibility of accidentally scratching or scoring rod surface while fasteners are being loosened and removed Component parts numbered in parentheses are keyed to Figure 4 CAUTION Vent air from the hydraulic system before disconnecting cylinder piping connections Use the lever on the reservoir while the engine is running Discharge the hydraul...

Page 393: ...faced hammer for final disassembly 5 Begin withdrawing piston rod assembly away from cylinder Attach a lifting support when final 1 3 of rod is still inside barrel of cylinder Prepare support blocks for piston rod before it has been completely withdrawn 6 Lower piston rod to support blocks and detach wear ring outer surface 19 from end of rod 7 Immobilize piston rod by inserting a wooden or other ...

Page 394: ...r local DOOSAN Parts distributor Remove nut from end of piston 10 Use second piston tool described at beginning of this procedure to separate piston Detach cushion ring 16 taking care not to damage cushion ring 11 Use a plastic hammer to evenly pull off rod cover 5 from end of piston rod Be careful not to damage rod bushing 6 and dust wiper U packing and other seals HAOF340L Figure 19 Figure 20 Fi...

Page 395: ... appropriate width tip to facilitate removal of slipper seal 18 wear ring 19 and slide ring 20 from piston 17 14 Remove O ring 21 and backup ring 22 from cylinder head 15 During disassembly of cylinder head be careful not to damage buffer seal 8 and U packing 9 HAOF37OL Figure 23 Figure 24 HAOF38OS Figure 25 HAOF39OL Figure 26 ...

Page 396: ...SP000030 Cylinders Page 26 16 Disassemble retaining ring 12 and dust wiper 11 Separate retaining ring 7 and rod bushing 6 17 Force out pin bushing 2 4 from body of cylinder Figure 27 Figure 28 ...

Page 397: ...nts install the dust wiper 11 and rod bushing 6 to the rod cover 5 Insert retaining rings 7 and 12 IMPORTANT Replace any part that shows evidence of damage or excessive wear Replacement of all O rings and flexible seals is strongly recommended Before starting the cylinder reassembly procedure all parts should be thoroughly cleaned and dried and or prelubricated with clean hydraulic fluid Prepare t...

Page 398: ...inning of this procedure to attach seal Cool seal by pushing a retracting jig against seal for several minutes Apply a strip of clean see through sealing tape around slipper seal to keep it free of dust 5 Immobilize piston rod on solid support blocks Assemble O ring 21 and backup ring 22 Prepare to attach rod cover assembly to piston rod Push rod cover by tightening piston nut 23 6 Assemble cushio...

Page 399: ...er before reassembly Preapply fastener locking compound Loctite 242 or 243 or an alternate manufacturer s equivalent product to all end cover retaining bolts Wrap a protective cushion around end of rod while tightening fasteners to prevent possible damage to polished surface of rod should a wrench slip during retightening Figure 35 Figure 36 Reference Number Description 1 Set Screw Figure 37 Figur...

Page 400: ...SP000030 Cylinders Page 30 ...

Page 401: ...SP000261 Page 1 Swing Motor SP000261 SWING MOTOR SP000261 Swing Motor Edition 1 ...

Page 402: ...Swing Motor SP000261 Page 2 MEMO ...

Page 403: ... General Precautions 14 How to Check Faults of Hydraulic Motor 14 Troubleshooting 14 Disassembly 16 General Cautions 16 Disassembly of drive shaft subassembly 16 Disassembly of the cylinder block subassembly 19 Disassembly of the rear cover subassembly 20 Cleaning and Inspection Wear Limits and Tolerances 23 Reassembly 23 General Cautions 23 Reassembly of drive shaft subassembly 23 Assembly of Cyl...

Page 404: ...Swing Motor SP000261 Page 4 MEMO ...

Page 405: ...ecommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX340LC 5001 and Up DX420LC 5001 and Up ...

Page 406: ...61 Swing Motor Page 6 GENERAL DESCRIPTION Parts List 31 24 22 18 19 17 39 21 15 15 16 16 15 15 16 16 14 8 5 32 1 40 2 7 3 4 6 25 23 33 30 26 27 29 28 34 38 36 37 35 20 9 10 42 41 43 11 12 13 FG005164 Figure 1 ...

Page 407: ...ly 15 Friction Plate 16 Plate 17 Brake Piston 18 O ring 19 Spring 20 Valve Plate 21 Pin 22 Needle Bearing 23 Rear Cover 24 Socket Bolt 25 Socket Bolt 26 Poppet 27 Spring 28 Plug 29 O ring 30 Relief Valve Assembly 31 Time Delay Valve 32 Socket Bolt 33 Plug 34 Swing Reactionless Valve 35 Plug 36 O ring 37 Backup Ring 38 O ring 39 O ring 40 Bushing 41 Rotary Kit 42 Cylinder Block Kit 43 Retainer Kit ...

Page 408: ...m 777 ft lb Motor Speed 1 316 rpm Brake Torque 107 kg m 774 ft lb Brake Switching Spool Cracking Pressure 13 kg cm2 185 psi Delay Period 6 5 1 5 sec Weight kg No Tools Measures B Torque 30 Relief Valve M33 36 mm 1700 1900 kg cm 123 137 ft lb 33 Plug PT 1 4 6 mm 2 090 kg cm 150 ft lb 32 Wrench Bolt PF 1 4 5 mm 691 kg cm 50 ft lb 24 Wrench Bolt M14 12 mm 2 090 kg cm 150 ft lb 25 Wrench Bolt M14 12 m...

Page 409: ...ory of Operation Structure The hydraulic motor consists of the following five parts Rotary part generating rotary power Relief valve Parking brake Makeup check valve Time delay valve Swing reactionless valve Circuit Diagram Figure 2 ...

Page 410: ...te F1 P A P supply pressure A hydraulic area F1 is divided into a N1 thrust component and a W1 radial component in relationship to the swash plate with slope of W1 generates a torque T W1 R1 in relationship to Y Y the centerline of top and bottom dead centers of the piston This torque generates the rotary power through a resultant force W1 R1 occurring at 4 5 hydraulic pistons by the high pressure...

Page 411: ...g Brake Off Pilot oil moves the swing spool and flows to port SH of time delay valve in swing motor through shuttle valve in case when the swing control lever is in the swing position This pressure moves the spool to the left against the spring force causing the port PG oil of the time delay valve to move to the parking piston The oil moves the parking piston pressing the friction plate upwards to...

Page 412: ...on built in the valve casing The high pressure oil flows into the port Sb as the spool assembled in the tilting switching part sticks to the plug by spring This high pressure oil applies pressure on the chamber A through the valve casing and the channel A of the shaft casing from the port Sb Oil in the chamber B comes to flow into the drain line through the channel B Sa The tilting piston moves to...

Page 413: ... 6 mm Plug 33 12 mm Wrench bolt 24 25 17 mm Plug 28 Socket Wrench Spanner 36 mm Relief valve assembly 33 Snap Ring Pliers For Orifice And Axis Snap Ringp 4 Bar Hammer Needle bearing 22 Pin 6 21 Torque Wrench Measure Oil Seal Assembly Jig Oil seal 2 Bearing Induction Heating Device Roller bearing 3 B B ARS3980L Figure 9 ...

Page 414: ... to the hydraulic motor before disassembling the motor Troubleshooting Problem Possible Cause Remedy Abnormal operation of driving devices Motor pressure does not increase Oil bypassing in relief valve 30 Replace or repair relief valve Check spring broken Replace check spring Oil channel inside the rear cover cracked Replace rear cover Abnormal wear on check surface Replace check Pressure increase...

Page 415: ...essure in case Check the drain line Leakage from assembled parts O ring damaged Replace the O ring Volt or plug loosened Tighten up to specified torque Main ways stuck Piston and shoe Overload rotation of motor Increase of temperature Insufficient intensity of illumination on slideway Improper oil or lubrication Check the operation of the relief valve Check circuits Repair or replacement of faulty...

Page 416: ...n substance in motor and deceleration assembly 3 Take care not to damage connecting parts and ways of O ring oil seal seal surface gear pin and surface of bearings 4 Numbers in parentheses indicate those on sectional plans of motor Disassembly of drive shaft subassembly 1 Remove the wrench bolt 32 and take away the time delay valve assembly 31 from the body 1 FG000682 Figure 10 Figure 11 ...

Page 417: ...mbly from the body 1 3 Disassemble the spring 19 to remove the break piston 17 and disassemble it from the body 1 using a jig 4 Remove cylinder block assembly friction plate 15 and plate 16 from body 1 NOTE Pay attention to order of plates and friction plates Figure 12 FG000687 Figure 13 FG000688 Figure 14 FG000689 Figure 15 ...

Page 418: ...otor Page 18 5 Remove shoe plate 8 from body 1 6 Remove snap ring 4 from body 1 using snap ring pliers jig 7 Turn body over and separate shaft 5 assembly using steel bar Figure 16 Figure 17 FG000693 Figure 18 Figure 19 ...

Page 419: ...block subassembly 8 Separate piston assembly 14 and the set plate 13 from cylinder block assembly 9 Remove friction plate 15 plate 16 ball guide 12 ball guide seat 11 and spring 10 from cylinder block 9 FG000696 Figure 20 FG000697 Figure 21 FG000698 Figure 22 ...

Page 420: ...SP000261 Swing Motor Page 20 Disassembly of the rear cover subassembly 10 Separate valve plate 20 from rear cover 23 FG000699 Figure 23 FG000700 Figure 24 FG000701 Figure 25 ...

Page 421: ...alve assemblies 30 from rear cover 23 with torque wrench 12 Remove check valve assemblies from rear cover 23 with L wrench and disassemble it in order of plug 28 spring 27 and poppet 26 Figure 26 FG000706 Figure 27 FG000707 Figure 28 FG000708 Figure 29 ...

Page 422: ... 13 Remove plug 35 from rear cover 23 with L wrench and disassemble it in order of backup ring 37 O ring 36 O ring 38 and anti inversion valve assembly 34 FG000709 Figure 30 FG000710 Figure 31 FG000711 Figure 32 FG000712 Figure 33 ...

Page 423: ...y them with compressed air The friction plate however should not be washed with treated oil 2 Each connecting parts should be tightened according to its assigned torque 3 Only use a plastic soft faced hammer Reassembly of drive shaft subassembly 1 Put roll bearing 3 on a heater and apply heat to their inner race inlet temperature 290 C for 2 minutes 39 3 FG001328 Bushing X 1ea SUJ Roll Bearing X 1...

Page 424: ...Page 24 2 Assemble heated roll bearing 3 into the shaft 5 Use a pliers jig to assemble install stop ring 7 3 Assemble oil seal 2 in body 1 using bar hammer FG000716 Figure 36 FG000717 Figure 37 FG000719 Figure 38 Figure 39 ...

Page 425: ...Swing Motor Page 25 SP000261 4 Install shaft in body 1 using bar hammer 5 Secure shaft with snap ring 4 using snap ring pliers FG000717 Figure 40 Figure 41 FG000722 Figure 42 Figure 43 ...

Page 426: ...26 6 Coat shoe plate 8 with grease and assemble it into body Assembly of Cylinder Block Assembly Subassembly 7 Insert nine sets of springs 10 in cylinder block 9 FG000724 Figure 44 Figure 45 FG000726 Figure 46 FG000727 Figure 47 ...

Page 427: ...Swing Motor Page 27 SP000261 8 Insert ball guide seat 11 and ball guide 12 in cylinder block 9 FG000728 Figure 48 FG000729 Figure 49 FG000759 Figure 50 FG000730 Figure 51 ...

Page 428: ...mbly 14 in set plate 13 and assemble it into cylinder block 9 NOTE Coat piston with clean hydraulic oil 10 Assemble cylinder block into body 1 11 Assemble friction plate 15 and plate 16 into body 1 FG000731 Figure 52 FG000696 Figure 53 FG000732 Figure 54 Figure 55 ...

Page 429: ...61 12 Assemble O ring 18 into brake piston 17 13 Insert brake piston assembly in body and secure it using jig 14 Insert eighteen springs 19 into brake piston 17 Figure 56 FG000704 Figure 57 FG000687 Figure 58 FG000736 Figure 59 ...

Page 430: ...ly 1 Insert pins 6 and 21 in rear cover 23 with bar hammer and assemble needle bearing 22 using jig 2 Insert poppet 26 spring 27 and plug 28 in rear cover 23 Tighten plug with L wrench Left and right symmetrically Figure 60 FG000738 Figure 61 Figure 62 FG000708 Figure 63 ...

Page 431: ... Assemble anti inversion valve Assemble body spring seat spring poppet poppet seat stopper and spring Then assemble O ring 36 backup ring 37 and O ring 38 using jig Figure 64 FG000745 Figure 65 FG000711 Figure 66 FG000710 Figure 67 ...

Page 432: ...plug assembly 35 into rear cover 23 and tighten them with L wrench 5 Assemble two relief valve assemblies 30 into rear cover 23 with torque wrench Left and right symmetrically 6 Coat valve plate 20 with grease and attach it to rear cover 23 FG000746 Figure 68 FG000706 Figure 69 Figure 70 FG000701 Figure 71 ...

Page 433: ...Put the rear cover ass y on the body 1 and tighten its wrench bolts 24 25 with impact and then torch wrench 8 Install time delay valve assembly onto rear cover 23 with wrench bolts 32 Figure 72 Figure 73 FG000682 Figure 74 Figure 75 ...

Page 434: ...ssure into assembled motor dip it in treated oil for one minute and check any leakage from it Oil Leakage Check Wash motor with Color Check No 1 spray No 3 and check for any oil leakage FG000754 Figure 76 FG005165 Figure 77 FG005166 Figure 78 FG005169 Figure 79 ...

Page 435: ...Swing Motor Page 35 SP000261 Installation of test bench Install the motor test bench to test each function Figure 80 ...

Page 436: ...SP000261 Swing Motor Page 36 ...

Page 437: ...SP000266 Page 1 Travel Motor With Gearbox SP000266 TRAVEL MOTOR WITH GEARBOX SP000266 Travel Motor With Gearbox Edition 1 ...

Page 438: ...Travel Motor With Gearbox SP000266 Page 2 MEMO ...

Page 439: ...embly 16 Reassembly 20 Maintenance Standard 23 Troubleshooting 25 Reduction Gear M3V270 160A RG7 5 27 Specifications 27 Structure and Operation 28 Disassembly and Assembly 30 Disassembling Reduction Unit 31 Assembling 36 Maintenance 43 Inspection After Assembling 45 Brake Valve RBV 24DL4 46 Specification 46 Structure and Operation 47 Disassembling and Reassembling 53 Disassembling Procedure 53 Rea...

Page 440: ...Travel Motor With Gearbox SP000266 Page 4 MEMO ...

Page 441: ...llow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up ...

Page 442: ...SP000266 Travel Motor With Gearbox Page 6 TRAVEL MOTOR M3V270 160A Specifications Outline Dimensions Figure 1 ...

Page 443: ... rev Minor Capacity 160 60 cc rev 9 80 in3 rev Rated Pressure 355 kg cm2 5 049 psi Maximum Pressure 420 kg cm2 5 974 psi Braking Torque Over 65 7 kg m 644 Nm Brake Release Pressure Below 15 7 kg cm2 233psi Allowable Drain Pressure Normal 2 kg cm2 28 5 psi Surge 10 Weight 130 kg 287 lb wet Including Brake Valve 11 ...

Page 444: ...SP000266 Travel Motor With Gearbox Page 8 Structure and Function Structure Figure 2 ...

Page 445: ...18 C type Retaining Ring 19 Round R Retaining Ring 20 Control Piston 22 Pivot 23 Piston Seal 24 M6 Restrictor 0 6 25 M6 Restrictor 0 8 26 Oil Seal 27 Spring for Check Valve 28 Spring for Cylinder Block 29 Brake Spring 30 Bearing HR32209J 31 Bearing HR32207C 32 C SK Head Cap Screw M18x50 33 Shim 34 Parallel Pin 8x12 35 O ring 1B P6 36 O ring 1B P8 37 O ring 1B P9 38 O ring 1B S10 39 O ring 215 57 x...

Page 446: ...e cylinder block rotates Bearings are provided on the end surface of piston assembly 14 to reduce the sliding resistance and the ends of piston assembly 14 are pushed toward shoe plate 11 by cylinder spring 28 through spring seat 13 spherical coupling 12 and shoe retainer 4 2 Negative Brake Five separator plates 7 and four friction plates 5 are alternately set on the spline of cylinder block 3 and...

Page 447: ... in the hole of socket 40 1 C Connecting piston 40 4 that fitted in the hole of the valve 40 2 and functions also as an oil passage D Piston 40 7 that is inserted in the pilot body 40 6 E Shim 40 8 that adjust the spring force Figure 3 Structure of Overload Valve 2259 3 20776 Reference Number Description 40 1 Socket 40 2 Valve 40 3 Valve Seat 40 4 Connecting Piston 40 5 Plug 40 6 Pilot Bod 40 7 Pi...

Page 448: ...ied to five pieces of pistons r5 F35 should be added This drive torque is transmitted via cylinder block 3 to driving shaft 9 Negative Brake Negative brake is released when high pleasure oil selected by the brake valve 42 Figure 6 that is connected directly to the rear cover 2 Is applied to the brake piston 6 Otherwise the braking torque is always applied This braking torque is generated by fricti...

Page 449: ...ivoting motion of the shoe plate 11 is limited by stopper 1 1 that holds its position With the shoe plate in the near vertical position the piston stroke become shorter and motor capacity becomes smaller this causes the motor to rotate faster around 1 5 times from the same volume of oil while producing less torque When there is no hydraulic pressure in the high speed pilot line PA spool 41 2 is pu...

Page 450: ...hile stopping For these purposes the developed pressure is kept comparatively low using an orifice for a short period This orifice then allows the line pressure to rise to its normal value While the pressure is low a smooth meshing of reduction gears crawler and sprocket etc can be accomplished while the initial shock is absorbed When starting Port A pressure increases This pressure is applied to ...

Page 451: ...d exhaust oil to B port side After the piston reached to the plug the valve acts the same as at starting Disassembly and Assembly Tools and Jigs Description Specification etc Hex Key Width Across Flat 5 6 10 14 Spanner Width Across Flat 19 27 32 35 Snap Ring Prier For Shaft 45 Snap Ring Prier For Bore 32 80 Plastic Hammer Screw Driver Minus Medium Size 2 Pieces Torque Wrench 0 38 5 kg m 0 300 ft l...

Page 452: ...ore applying Loctite completely remove oil from mating surfaces using Loctite 587 and uniting them 7 When tightening bolts apply Loctite 262 to bolt threads and tighten to rated torque using a torque wrench Apply when assembling reduction gear only 8 Use only a plastic hammer 9 After cleaning each part blow dry with moisture free air But do not clean friction plates with cleaning oil Disassembling...

Page 453: ... block 3 using a rounded point bar 5 8 mm through oil hole of rear cover 2 Be careful not to scratch any of these parts while pulling out rear cover 2 E Remove valve plate 8 without pulling out cylinder block 3 NOTE Match mark valve plate 8 and rear cover 2 so that valve plate 8 will not be reversed during reassembly F Using removed cap screws fasten two metal mounts so they push in on cylinder bl...

Page 454: ...t reuse damaged ones NOTE It is impossible to disassemble piston and shoe because they are calked together M Remove shoe plate 11 N Do not detach control piston 20 unless necessary If it must be detached hold control piston and using compressed air through the hole shown to force it out O Remove shaft 9 P Remove retaining ring 19 and oil seal 26 Q If bearings need to be replaced remove inner races...

Page 455: ...NOTE Do not remove oil seal 26 for the purpose of inspection If removed install a new oil seal 3 Disassembly of overload valve A Remove overload valve 40 Figure 14 as an assembly utilizing hexagonal flats on socket 40 1 B Normally the overload valve 40 should be replaced one service part If disassembly is necessary remove plug 40 5 from socket 40 1 and remove internal components NOTE Valve seat 40...

Page 456: ... position with retaining ring 19 Figure 16 3 Place outer race of bearing 30 on case 1 this is a loose fit and press the inner race on shaft 9 this is a tight fit NOTE It is easier to install inner race if it is heated to 100 C Never over heat 4 Coat contact surface to oil seal 26 with grease to prevent damage and install shaft 9 into case 1 5 Install control piston 20 into case 1 6 Using match mar...

Page 457: ... piston 6 into case 1 using inserting jig after NOTE Two kinds of D rings are used on brake piston 6 The larger one 16 is first inserted into the groove then the smaller one 15 is installed It is impossible to see how the smaller ring goes into the groove Therefore never push it forcibly into the groove Otherwise it may be scraped off by the edge of case 1 12 Lay down rear cover 2 Figure 19 to mou...

Page 458: ...SP000266 Travel Motor With Gearbox Page 22 Figure 19 Mounting Rear Cover ...

Page 459: ...he surfaces of both cylinder block and valve plate to remedy their roughness Lap with 1200 powder Measure the surface hardness with a hardness taster Shoe plate Over HS78 HS74 Replace 2 Clearance between piston and cylinder block Measure outer dia of piston and bore of cylinder block at least 3 places in the longitudinal direction with micrometer and obtain max outer dia d max min outer dia d min ...

Page 460: ...er races at the same time NOTE Also the bearing shims 33 must be re adjusted when replaced shaft 9 and or bearings 30 31 Contact dealers for jigs and tools required 6 Bearings Replace bearings 30 31 before hour meter of host machine indicates 10 000 hours 7 Splines Replace if the wear of splines exceeds the allowable value If the wear of splines is less than 0 3 mm the spline is reusable 8 Overloa...

Page 461: ...alve Repair or replace relief valve Pressure increases Negative brake is not released Clogged choke of release pressure passage Check clogged passage Wash or replace it Stuck friction plate or stuck separator plate provided in negative brake Replace friction and separator plate Stuck brake piston of negative brake Repair outer dia of brake piston or replace it Seizure of sliding portion Check repa...

Page 462: ...fuses to work Brake refuses to work Malfunction of negative brake Worn friction plate Broken spring Check repair or replace brake piston friction plate spring etc Oil leakage Oil leakage Loose cap screw or plug O ring is torn off Oil leaks inside gear case Fasten it with given torque Replace O ring Replace oil seal Would not shift from high to low Would not shift from high to low Stick of spool of...

Page 463: ...ions Specifications Figure 21 Item M3V270 160A RG7 5 Motor Displacement 273 5 160 6 cc rev 16 69 9 80 in3 rev Rated Pressure 355 kg cm2 5 049 psi Gear Ratio 50 324 Number of Stages 2 Oil Capacity 11 0 liters 2 9 U S gal Oil Specification Gear Oil SAE 90 API GL 4 Weight w accessory valves 430 kg wet 950 lb ...

Page 464: ...SP000266 Travel Motor With Gearbox Page 28 Structure and Operation Structure Figure 22 ...

Page 465: ...sun gear 5 This movement is transferred to carrier k and deliver the torque This mechanism is called a planetary gear mechanism Reference Number Description 1 Cover 2 Carrier 1 3 Carrier Pin 1 4 Needle Bearing 5 Thrust Washer 1 6 Planetary Gear 1 7 Spring Pin 4x32 8 Thrust Plate 9 Sun Gear 1 10 Sun Gear 2 11 Carrier 2 12 Carrier Pin 2 13 Needle Bearing 14 Planetary Gear 2 15 Spring Pin 8x56 16 Thr...

Page 466: ...frame gear d drivers ring gear a and then ring gear a rotates to drive sprocket Disassembly and Assembly Tools Prepare following tools and instruments before disassembling or assembling Figure 24 Description Remarks Torque Wrench 0 0 5 kg m 0 4 9 Nm Hex Socket Wrench Width across flats 8mm and 14mm Work Stand Micro Depth Gauge 0 25 mm 0 0 98 in Pin For knocking in spring pins 3 5x7 5 7x70 Eye Bolt...

Page 467: ...TE Numeral in after the part name corresponds to the number on Structure on page 1 28 Setting Reduction Unit on Work stand for Disassembling 1 Remove three M10 cap screws 24 at three places from cover 1 almost equally apart from each other Install three eye bolts and lift unit and place it on work stand with cover 1 facing up CAUTION While oil is still hot inside of the unit may be pressurized Tak...

Page 468: ...er 1 is adhered to ring gear 17 Remove cover 1 by lightly hammering slantwise upward using a wooden bar aiming at projection of cover 1 Removing Carrier 1 Assembly 1 Remove thrust plate 8 2 Remove sun gear 1 9 3 Screw three M10 eye bolts into carrier 1 2 and lift up and remove carrier 1 assembly 2 3 4 5 6 7 Figure 26 Figure 27 Figure 28 ...

Page 469: ...ve carrier 2 assembly 11 12 13 14 15 16 Removing Housing Assembly 1 Remove support ring 22 Figure 22 2 Take off lock washers 21 by hammering on chisel or on similar tool placed at parting surface 3 Screw three eye bolts into ring gear 17 and remove housing assembly including ring gear 17 housing 18 bearing 17 and floating seal 23 Figure 29 Figure 30 Figure 31 ...

Page 470: ... lightly on there heads This will help to remove ring gear 17 from housing 18 NOTE Be careful not to damage sliding surface of floating seal 23 or its O ring NOTE Bearings 19 have been tightly press fitted in housing 18 Don t remove the bearings 19 unless otherwise their exchange is needed If case bearings were removed do not re use them New bearings should be used and properly adjusted with shims...

Page 471: ...he same combination as before 1 Drive spring pins 7 into carrier pins 1 3 2 Remove carrier pins 1 3 from carrier 1 2 3 Remove thrust washers 1 7 planetary gears 1 6 and needle bearings 4 4 Drive out spring pins 7 from carrier pins 1 3 for reassembling NOTE When carrier pin 1 3 or planetary gear 1 6 is replaced all three pins or three gears should be replaced Figure 35 Figure 36 Figure 37 ...

Page 472: ...ars should be replaced Assembling General Notes 1 Clean every part with kerosene and dry them with compressed air Surfaces to be coated with Loctite must be degreased with solvent 2 Check every part for any abnormalities 3 Each cap screw should be coated with Loctite 242 applied on its threads 4 Apply gear oil lightly on each part before assembling 5 Be careful not to pinch your hand between parts...

Page 473: ...Assembling Carrier 1 Assembly 1 Install planetary gears 1 6 needle bearings 4 and thrust washers 1 5 into carrier 1 2 2 Install carrier pins 1 3 into carrier 1 2 Align holes for spring pins 7 wish those in carrier 1 2 3 Install spring pins 7 into carrier 1 2 and carrier pins 1 3 Figure 41 Figure 42 Figure 43 ...

Page 474: ...SP000266 Travel Motor With Gearbox Page 38 Installing Floating Seal 1 Install floating seal 23 on motor case Figure 44 Figure 45 ...

Page 475: ... tighten them with torque wrench to 41kg m 4 Install floating seal 23 on housing 18 NOTE Clean the groove for floating seals 23 to eliminate oil dust paint or other foreign material NOTE Apply gear oil lightly on sliding surfaces of floating seals 27 before assembling Keep O rings and mounting surfaces dry and free of oil NOTE Make sure floating seal 23 O are not twisted and that floating seal is ...

Page 476: ...n calculate and use there mean average value 5 When thickness of shim 20 to be used is placed as S Figure 49 the clearance X can be calculated as follows X B C A D S 6 Select a shim 20 so that clearance X comes to 0 08 interference 0 02 clearance on this unit Pressing Motor Into Assembly 1 Place motor on work stand with shaft pointing up and place the selected shim 20 Refer to Step 6 above on bear...

Page 477: ...lation Carrier 2 Assembly 1 Position three planetary gears 2 14 as shown and place carrier 2 assembly into ring gear 17 and engage splines to those of motor 2 Position sun gear 2 10 on center NOTE Positioning carrier 2 assembly as above is important to obtain better lubrication Figure 52 Figure 53 Figure 54 ...

Page 478: ... can be added before installing cover 1 if you can measure proper volume of oil 1 Apply Loctite 515 on mating surfaces of cover 1 and ring gear 17 Install cover 1 on ring gear 17 2 Apply Loctite 242 on threads of 18 M10x25 cap screws 24 and tighten them with to a torque of 8 kg m Filling Gear Oil 1 Fill gear oil SAE 90 API class GL 4 10 5 litters from two PT3 4 ports for taper screw plugs 26 2 Wra...

Page 479: ...oot of tooth by using a die check Bearings 1 Rotate by hand to see if there are something unusual such as noise or uneven rotation Floating seal 1 Check for flaws or scoring on sliding surfaces or on O rings Maintenance Standards 1 The followings are general maintenance standards However it is important to determine which parts should be replaced depending on the characteristics shown before disas...

Page 480: ...6 of pitching no cracks at root Change a set for plane opinion C Thrust clearance of angular bearings 0 08 0 02 Adjust shim See Determining Shim Thickness For Angular Bearings on page 40 D Thickness of thrust washer 1 7 0 2 wear 0 1 Replace E Thickness of thrust washer 2 4 0 2 wear 0 1 Replace Item Description Size Fastening Torque 24 Socket Head Cap Screw M10 x 25 8 kg m 78 5 Nm with Loctite 242 ...

Page 481: ... at its lowest position and check if lubrication oil comes out when loosening the level plug If not oil is present at the level plug add oil Rotating Inspection Place the unit on a test stand and rotate it with no load and check if there are any abnormal noises or oil leaks NOTE This inspection can be done while mounted on the track frame before attaching track ...

Page 482: ...SP000266 Travel Motor With Gearbox Page 46 BRAKE VALVE RBV 24DL4 Specification Outline Dimensions Figure 59 Number Description 13 O ring 14 Socket Head Cap Screw 15 Plug 16 O ring 17 O ring 18 O ring ...

Page 483: ... 355 kg cm2 5 049 psi Spool changeover pressure 7 8 13 kg cm2 111 185 psi Cracking pressure of check valve 0 3 kg cm2 4 27 psi Figure 60 Reference Number Description 1 Body 2 Spool Assembly 3 Spring Seat 4 Spring 5 O ring 6 O ring 7 Cover 8 Restricto 9 Spring 10 Plug 11 O ring 12 Socket Head Cap Screw Reference Number Description ...

Page 484: ...pplying passage to hydraulic motor and at the same time functions to block oil displacement Therefore this valve serves as not only as a make up suction valve but also as a holding valve for hydraulic motor Relief Valve Built in the Hydraulic Motor When the oil is pressurized in either the oil supply or oil discharge passage of hydraulic motor to a pressure that is higher this valve s pressure set...

Page 485: ... hydraulic motor Since a passage to parking brake is also connected to tank line brake cylinder pressure is equal to that of tank pressure and brake is applied by springs This prevents mechanical rotation of motor If an external force torque is exerted on motor shaft it will not rotate If brake should be released for some reason pressure will rise at either port MA or MB Due to normal oil leakage ...

Page 486: ...ases the negative brake is released At the same time the oil pressure of pilot chamber increases to move the spool to the left overcoming spring force This allows return line from MB to VB to open and start to rotate motor When the starting inertia load is too large to start rotation acceleration pressure reaches the pressure setting of relief valve and high pressure oil is relieved while the moto...

Page 487: ...the passage from MA to VA is closed Due to inertia force from the upper structure load the hydraulic motor will be forced to continue to rotate Now the motor functions as a pump and starts to flow oil out of port MB but the passage is blocked and so the port MB port increases Now the relief valve opens to relieve this pressure and rotational speed starts to decelerate and final stops the motor Neg...

Page 488: ...re the passage from MA to VA becomes smaller and the pressure on MA side rises due to increased resistance in the passage This resistance causes a hydraulic braking effect on the motor When motor is rotating slower than volume of oil being supplied pilot chamber pressure on port VB increases and spool moves to the right to enlarge passage from MA to VA This reduces the braking effect and rotationa...

Page 489: ...ly remove oil from mating surfaces using Loctite 587 and uniting them 7 When tightening bolts apply Loctite 262 to bolt threads and tighten to rated torque using a torque wrench Apply when assembling reduction gear only 8 Use only a plastic hammer 9 After cleaning each part blow dry with moisture free air But do not clean friction plates with cleaning oil Tools Disassembling Procedure 1 Remove val...

Page 490: ...Restrictor No pitting scratches or other damage should be found on seat surface The hole should not be clogged 6 O ring O rings must be replaced with the new ones each time valve is disassembled 7 If damage is found on body or spool replace valve as a complete assembly Instructions on Reassembling 1 Perform the reassembling work on clean place 2 Be careful to install the parts at the same position...

Page 491: ... 8 and spring 9 with cover 7 2 Put the O rings 5 and 6 in body 1 3 Install spool 2 spring seat 3 and spring 4 with the body 1 in this order Pay attention to installation direction of spool 4 Mount cover 7 on body 1 with hex head cap screw 12 5 Position O rings 16 and 17 on gasket surface ...

Page 492: ...es normal but motor rotates weakly Negative brake is not fully released Clogged pilot line for negative brake Inspect the passage for negative brake built in hydraulic motor Have no brake effect when the control lever returned to neutral Brake works on counter lever operation Malfunction of spool Stick between spool and body Stick of check valve or that by small particle Clogged restrictor Repair ...

Page 493: ...SP000186 Page 1 Main Pump SP000186 MAIN PUMP SP000186 Main Pump Edition 1 ...

Page 494: ...Main Pump SP000186 Page 2 MEMO ...

Page 495: ... H 23 Removing the Controller 24 Valve Plate With Valves 26 Remove the Rotary Groups 27 Remove the Intermediate Wheel 30 Remove Auxiliary Drive 32 Inspection 35 Re fitting the Rotary Group 40 Pump Assembly 42 Hydraulic Component Measurement D 45 Measuring Device Hydraulic Component 452 269 45 Mounting Position 46 Measuring Procedure 48 Installation of Control Housing 49 Assembly of Intermediate Wh...

Page 496: ...Main Pump SP000186 Page 4 Bolts To N 08 001 55 Plugs with Internal Hexagon and Profile Seal Ring to N 02 009 56 Seal lock Sealing Nuts to N 02 100 57 ...

Page 497: ...ons and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up ...

Page 498: ...SP000186 Main Pump Page 6 ECTIONAL VIEW A8VO200LA1KH1 63 ASS0010L Figure 1 ...

Page 499: ...Main Pump Page 7 SP000186 ASS0020L Figure 2 ...

Page 500: ...lic units 1 Close off all openings of hydraulic unit 2 Replace all seals Use only original spare parts 3 Check all sealing and sliding surfaces for wear NOTE Rework of sliding surfaces using crocus cloth or other similar materials can damage the surface ASS1140L Figure 3 ASS0030L Figure 4 ASS0040L Figure 5 ASS0050L Figure 6 ...

Page 501: ...Main Pump Page 9 SP000186 4 Fill hydraulic unit with hydraulic oil before putting into operation ASS0060L Figure 7 ...

Page 502: ...SP000186 Main Pump Page 10 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 503: ...nent 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 section ready to install ASS0100L Figure 11 ASS0110L Figure 12 ASS0120L Figure 13 ASS0130L Figure 14 ...

Page 504: ...SP000186 Main Pump Page 12 8 Control pre adjusted 9 Gear pump complete 10 Intermediate gear ASS0140L Figure 15 ASS0150L Figure 16 ASS0160L Figure 17 ...

Page 505: ...Main Pump Page 13 SP000186 11 Auxiliary drive 12 Valve plate with valves 13 Pipe complete with fittings ASS0170L Figure 18 ASS0180L Figure 19 ASS0190L Figure 20 ...

Page 506: ...SP000186 Main Pump Page 14 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 507: ...etal 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 safety ring ASS0230L Figure 24 ASS0240L Figure 25 ...

Page 508: ...SP000186 Main Pump Page 16 GEAR PUMP SEALING Remove gear pump Visually check 1 O ring 1 Figure 27 ASS0250L Figure 26 1 ASS0260L Figure 27 ...

Page 509: ...Main Pump Page 17 SP000186 2 Sealing surface of housing 2 Figure 28 2 ASS0270L Figure 28 ...

Page 510: ...SP000186 Main Pump Page 18 REMOVE THE CONTROL HOUSING ASS0280L Figure 29 ...

Page 511: ...y 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 control lenses can fall out ASS0290L Figure 30 ASS0300L Figure 31 ...

Page 512: ...move paper seal and clean sealing surface ASS0310L Figure 32 2 3 2 3 1 1 ASS0320L Figure 33 Number Description 1 Setting Screw Qmax 2 Setting Screw Hydraulic Stroke Limitation 3 Setting Screw Power Characteristic Begin of Regulation ...

Page 513: ...Main Pump Page 21 SP000186 NOTE Before carrying out setting or disassembly of regulator measure distance X of adjustment screw and record value X ASS0330L Figure 34 ...

Page 514: ...SP000186 Main Pump Page 22 CONTROL MODULE Control Module LR Remove and disassemble control module LR ASS0340L Figure 35 ASS0350L Figure 36 ...

Page 515: ...Main Pump Page 23 SP000186 Control Module H Remove and disassemble control module H ASS0360L Figure 37 ASS0370L Figure 38 ...

Page 516: ...SP000186 Main Pump Page 24 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 517: ...OTE 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 ASS0410L Figure 42 ASS0420L Figure 43 ASS0430L Figure 44 ...

Page 518: ...SP000186 Main Pump Page 26 VALVE PLATE WITH VALVES 1 Pressure relief valve 2 Electro proportional pressure reducing valve EPPR ASS0440L 1 2 Figure 45 ...

Page 519: ...P000186 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 Figure 47 ASS0470L Figure 48 ...

Page 520: ...prings 1 and spring cup 2 I 4 Note disassembly position 1 2 and 3 Figure 50 I 5 Press out rotary group with an appropriate device ASS0480L Figure 49 1 2 3 Rotary Group 1 ASS0490L Rotary Group 2 Figure 50 2 2 2 2 2 1 1 1 1 1 ASS0500L Figure 51 ...

Page 521: ...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 furnace 3 Remove screw quickly A A Drive shaft 2 Drive shaft 1 Fixing screws are glued Adjustment of measurement D 1 Holding device 1 Holding device Adjustment of measurement D Fixing screws are glued AS...

Page 522: ...THE INTERMEDIATE WHEEL I 1 Press bolt Figure 53 into gear wheel Fixed pressing fit NOTE Can only be disassembled with a hydraulic press I 2 Install sleeve NOTE Press out bolt with a hydraulic press ASS0520L Figure 53 ASS0530L Figure 54 ...

Page 523: ...Main Pump Page 31 SP000186 I 3 Remove gear wheel through side drive opening I 4 Remove bearing with extraction device ASS0540L Figure 55 ASS0550L Figure 56 ...

Page 524: ...SP000186 Main Pump Page 32 REMOVE AUXILIARY DRIVE 1 Remove screws and auxiliary drive 2 Press off bearing cap ASS0560L Figure 57 ASS0570L Figure 58 ASS0580L Figure 59 ...

Page 525: ...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 ASS0610L Figure 62 ASS0620L Figure 63 ...

Page 526: ...SP000186 Main Pump Page 34 7 Completely mount device and pull out bearing 8 Pull out pinion bearing ASS0630L Figure 64 ASS0640L Figure 65 ...

Page 527: ...nce 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 there is no evidence of wear 4 Axial piston play Checked with retaining plate installed ASS0650L Figure 66 ASS0660L Figure 67 ASS0670L Figure 68 ASS0680L Figure 69 ...

Page 528: ...rosion and wear steps 2 Figure 70 6 Piston Check to ensure that they are free of scores and that there is no pitting 7 Central pin Check to ensure that it is free of scores and that there is no pitting 8 Retaining plate Check to ensure that it is free of scores and that there is no evidence of wear ASS0690L Figure 70 ASS0700L Figure 71 ASS071L Figure 72 ASS0720L Figure 73 ...

Page 529: ...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 control drilling 2 Figure 75 and pin cups 3 Figure 75 11 Check That sliding surfaces 1 Figure 76 are free of scores Seal 2 Figure 76 ASS0730L Figure 74 ASS0740L Figure 75 ASS0750L Figure 76 ...

Page 530: ...ete 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 necessary Figure 77 1 1 2 ASS0760L Figure 77 ...

Page 531: ...Main Pump Page 39 SP000186 13 Rotary group All of the components Adjustment Figure 78 For adjustment values and torque values see service information ASS0770L Figure 78 ...

Page 532: ... 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 cup springs 2 Figure 81 into their correct position and orientation using grease to hold them into place ASS0780L Figure 79 ASS0790L Figure 80 ASS0800L Figure 81 ...

Page 533: ...arts 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 in this manor ASS0810L Figure 82 ASS0820L Figure 83 ...

Page 534: ...proximately 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 4 Gear tooth marks must align with each other ASS0830L Figure 84 ASS0840L Figure 85 ASS0850L Figure 86 ASS0860L Figure 87 ...

Page 535: ...imension 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 until the end stop is reached Allow housing to cool down from its assembly temperature approximately 80 C to room temperature Stop A D D Stop A ASS0870L Figure 88 ...

Page 536: ...rried out using spring plates of differing thickness so that the correct clearance is achieved between the rotary group which is installed in housing and center pin and spring plates NOTE Dimension D 0 4 0 1 mm After assembling complete unit the breakaway torque of the rotary group has to be checked with a torque wrench ...

Page 537: ... 107 ASS0880L Figure 89 Size Measuring Device Centering Device 1 Intermediate Ring 4 Shim 5 S H C S 6 Intermediate Plate 7 1x 2x 2x 2x 2x 80 9452269 9452019 9452014 9083277 9083105 107 9452269 9452022 9452014 9083277 9083105 140 9452269 9452026 9452015 9083279 9083134 2775186 200 9452269 9452025 9452015 9083279 9083134 2775187 ...

Page 538: ...osition 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 ASS0900L Figure 90 ASS0890L Figure 91 Size Mounting Position 80 22 107 25 140 28 200 28 ASS0910L Figure 92 ...

Page 539: ... B Only Size 140 200 Figure 93 2 Zero adjustment measuring device Turn using the hand wheel until the stop is reached Set dial gauge to zero A Size 80 107 Figure 94 B Size 140 200 Figure 95 ASS0920L Figure 93 Figure 94 Figure 95 ...

Page 540: ...gauge to Zero NOTE Clearance Size 28 160 0 4 mm 0 1 A Size 82 107 Figure 96 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 ASS0950L Figure 96 ASS0960L Figure 97 Figure 98 Figure 99 ...

Page 541: ...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 m 25 81 ft lb M12 69 Nm 7 04 kg m 50 89 ft lb ASS0990L Figure 100 ASS1000L Figure 101 ...

Page 542: ...orques 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 counterclockwise Direction of rotation clockwise Pressure side Pressure side Suction side ASS1030L Figure 104 ...

Page 543: ...Main Pump Page 51 SP000186 5 Install seal and controller ASS1040L Figure 105 ASS1050L Figure 106 ...

Page 544: ...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 bearing into housing New Assembly Position ASS1060L 1 3 1 2 Figure 107 ASS1070L Figure 108 ...

Page 545: ...Main Pump Page 53 SP000186 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 110 ...

Page 546: ...SP000186 Main Pump Page 54 INSTALLATION OF COVER AUXILIARY DRIVE ASS1100L Figure 111 ...

Page 547: ...ocked head cap screws DIN 931 hexagon bolt or DIN 933 hexagon bolts with threads up to the head ASS1110L Figure 112 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 3 M 5 6 1 8 9 10 4 M 6 10 4 15 5 18 M 8 25 37 43 M 10 51 75 87 M 12 87 130 150 M 14 140 205 240 M 16 215 310 370 M 18 300 430 510 M 20 430 620 720 M 22 480 830 970 M 24 740 1060 1240...

Page 548: ...ightening Torque M A In 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 240 M22 x 1 5 60 G 1 1 2 A 300 M26 x 1 5 70 M27 x 2 90 M30 x 1 5 100 M33 x 2 140 M42 x 2 240 M48 x 2 300 ...

Page 549: ...57 SP000186 Seal lock Sealing Nuts to N 02 100 ASS1130L Figure 114 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 550: ...SP000186 Main Pump Page 58 ...

Page 551: ...SP000187 Page 1 Control Valve KVMG 400 DA SP000187 CONTROL VALVE KVMG 400 DA SP000187 1 Control Valve KVMG 400 DA Edition 1 ...

Page 552: ...Control Valve KVMG 400 DA SP000187 Page 2 MEMO ...

Page 553: ...t 40 General 40 Relief Valve 41 Hydraulic System 41 Adjustment of Relief Valve 41 Disassembly 43 General Instructions for Disassembly 43 Disassembly of Main Spool 3 11 44 Disassembly of Subspool 24 45 Disassembly of Subspool 20 45 Disassembly of Anti Drift Valve of Boom and Arm 45 Disassembly of Swing Load Check 46 Disassembly of Load Check 46 Disassembly of Other Check Valves 47 Disassembly Of Fl...

Page 554: ...alve KVMG 400 DA SP000187 Page 4 Cleaning and Inspection Wear Limits and Tolerances 51 Cleaning 51 Inspection 51 Reassembly 52 Subassembly 52 Reassembly of Control Valve 54 Installation 60 Start up Procedures 60 ...

Page 555: ...mmendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up ...

Page 556: ...rns to ports T1 and T3 2 Oil supplied to port P2 flows through neutral passage R1 to low pressure relief valve throttle Rc1 to tank passage Ta and returns to ports T1 and T3 3 The pressures of low pressure relief valve chambers L2 and R2 reach through ports Ps1 and Ps2 to pumps and control displacement of pumps P1 and P2 4 If too much oil flows into neutral passages low pressure relief valves are ...

Page 557: ...Control Valve KVMG 400 DA Page 7 SP000187 Figure 1 ...

Page 558: ...4 and passage 5 to land Rc3 and into tank passage Ta 2 The same oil supplied from port PP after passing through orifice Lc5 flows partly to port PA and passes partly through passages L4 8 and R4 to boom spool 1 land Rc4 and flows into tank passage Ta 3 The oil passing through orifice Lc6 flows partly from land Lc7 to tank passage Ta and passes partly through passage 4 to travel spool land Rc5 and ...

Page 559: ...Control Valve KVMG 400 DA Page 9 SP000187 Figure 2 ...

Page 560: ...passage Ta 2 When shifting travel spool by increasing pressure of travel section 6 pilot port Pb6 Pa6 oil supplied to port P2 flows through neutral passage R1 and spool to passage S6 1 and flows to port B6 A6 At this time poppet S6 2 is not opened because parallel passage R3 pressure equals passage pressure S6 1 Return oil flows through port A6 b6 to spool and returns to tank passage Ta 3 When shi...

Page 561: ...Control Valve KVMG 400 DA Page 11 SP000187 Figure 3 ...

Page 562: ...g swing spool by increasing pressure of swing section 2 pilot port Pb2 Pa2 neutral port L1 is closed Oil supplied to port P1 flows through parallel passage L3 load check valve S2 1 and spool to port B2 A2 Return oil flows through port A2 B2 to spool and returns to tank passage Ta Figure 4 ...

Page 563: ...Figure 5 This valve also works with anti drift valves that are installed on the bottom side of each boom cylinder When in neutral poppet AD1 is closed by pressure from port A7 that is sent through passage AD2 spool AD3 and passage AD4 to poppet AD1 Figure 5 Neutral Condition ...

Page 564: ...hrough parallel passage R3 and load check valve S7 1 to spool and flows into port A7 When boom 2 section 3 spool is shifted by increasing pressure of boom 2 pilot port Pa3 also neutral passage L1 is closed Oil supplied to port P1 flows through parallel passage L3 load check valve S3 1 and spool to passage 6 and it then joins at port A7 Return oil flows through port B7 to spool and returns to tank ...

Page 565: ...assage R3 and load check valve S7 1 to spool and flows into port B7 When spool AD3 of anti drift valve is shifted by increasing pressure of port Pc2 also poppet AD1 is opened by decreasing of pressure in spring chamber AD5 and return oil from port B7 returns to tank passage Some return oil opens poppet S7 3 in boom 1 spool flows through passage S7 2 it then joins with port B7 and prevents cavitati...

Page 566: ...1 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 pressure of bucket section 8 pilot port Pb8 Pa8 neutral passage R1 is closed Oil supplied to port P2 flows through parallel passage R3 load check valve S8 1 passage S8 2 and spool into port B8 A8 When neutra...

Page 567: ...rt P1 flows through neutral passage L1 load check valve S5 1 passage S5 2 and spool into port B5 When arm 2 spool is shifted by increasing pressure of arm 2 section 9 pilot port pb9 also oil supplied from port P2 flows through neutral passage R1 load check valve S9 1 passage S9 2 spool and passage 10 it then joins with port B5 Return oil returns through port A5 and spool to tank passage Ta Figure ...

Page 568: ...d return oil from port B5 returned through spool passage S5 3 and arm variable regeneration throttle Lc8 to tank passage Ta Some of return oil open poppet S5 4 in boom 1 spool flows through passage S5 2 it then joins with port A5 increases cylinder speed and then prevents cavitation on cylinder bottom side 3 Variable regeneration when crowding Figure 10 When crowding arm spool S5 6 is stroked acco...

Page 569: ...Control Valve KVMG 400 DA Page 19 SP000187 Figure 10 ...

Page 570: ...age 11 and poppet S4 3 Figure 8 it then joins with spare section 4 passage S4 2 Figure 8 Parallel Throttle for Arm Figure 11 1 The throttle that is installed in the parallel circuit for arm of this valve one in each of arm 1 section 5 and the arm 2 section 9 prevents the arm speed from increasing during combined operation 2 The parallel circuit of arm 2 section 9 after narrowing at the throttle Rc...

Page 571: ...highest pressure of pump P1 and P2 is controlled by actuating of main relief valve 2 Over load relief valve The over load relief valve that is installed in each cylinder port of boom 1 arm 1 and bucket prevent the actuator pressure from increasing to extremely high pressures by external forces This relief valve when pressure of cylinder port is a negative pressure also has the function to prevent ...

Page 572: ...shifted and the pressures of ports PT and PA increase When travel straight spool is shifted oil supplied from port P1 flows through neutral passage L1 to travel section 1 and simultaneously flows through passage 2 travel straight spool and passage R1 into travel section 6 Oil supplied to port P2 flows through travel straight spool and passage 1 into parallel passage L3 If the section load pressure...

Page 573: ...Control Valve KVMG 400 DA Page 23 SP000187 Figure 13 ...

Page 574: ...he swing and another implement poppet S2 1 is fixed by increasing port pc6 pressure poppet S2 3 is opened and pressure supplied to port L3 is increased through throttle S2 4 Accordingly even in the case that the swing load pressure is low the simultaneous operation character with the other implement can be secured Figure 14 ...

Page 575: ...er AD5 Poppet AD1 is completely 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 cylinder port When crowding arm boom down Figure 17 spool AD3 is shifted by increasing pressure of port pc1 pc2 and oil in spring chamber AD5 is allowed to flow through passage AD6 to...

Page 576: ...oil passage HP rises and exceeds relief valve setting pilot poppet F opens Pressurized oil flows through pilot poppet F into low pressure oil passage LP passing through hole G 3 As pilot poppet F opens pressure in internal cavity D lowers to move main poppet C so that pressurized oil flows into neutral oil passage HP and directly into low pressure oil passage LP 4 Pressure up operation When pressu...

Page 577: ...linder 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 pilot poppet E opens pressurized oil flows through orifice I so that pressure on back of piston C lowers to move piston C As a result piston C seats on pilot poppet E 4 Pressurized oil in passage HP flows throu...

Page 578: ...it is installed in cylinder port HP to prevent the development of cavitation If pressure at cylinder port HP becomes lower than that of oil passage LP sleeve K moves so that oil is supplied from the low pressure oil passage LP to cylinder port HP to eliminate cavitation Figure 26 ...

Page 579: ...signal port 4Ps 5Ps increases by the negacon signal orifice A 3 Low pressure relief valve operation When the excessive quantities of oil in the neutral oil passage HP flow pressure in neutral oil passage HP exceeds spring setting pressure C This causes poppet B to open Oil then flows from neutral oil passage HP into low pressure oil passage LP so excessive pressure is prevented in neutral oil pass...

Page 580: ...SP000187 Control Valve KVMG 400 DA Page 30 Parts List Figure 30 ...

Page 581: ...Control Valve KVMG 400 DA Page 31 SP000187 Figure 31 ...

Page 582: ...SP000187 Control Valve KVMG 400 DA Page 32 Figure 32 ...

Page 583: ...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 Poppet 47 Body Assembly 48 Relief Valve Assembly 49 Relief Valve Assembly 50 Relief Valve Assembly 51 Plug Assembly 52 Poppet 53 Spring 54 Plug 55 O ring 56 Flange 57 O ring 58 Plug Assembly 59 Plug Assemb...

Page 584: ...ure 33 Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spring 5 Spool End Figure 34 Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spring 5 Spool End 6 Poppet 7 Spring 8 Plug 9 O ring 10 Backup Ring Figure 35 Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spring 5 Spool End ...

Page 585: ...e Figure 36 Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spring 5 Spool End Figure 37 Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spring 5 Spool End 6 Poppet 7 Spring 8 Plug 9 O ring 10 Backup Ring Figure 38 Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spring 5 Spool End ...

Page 586: ...erence Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spring 5 Spool End Figure 40 Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spring 5 Spool End Figure 41 Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spring 5 Spool End Figure 42 Reference Number Description 1 Spool 2 Sleeve 3 Sleeve 4 Piston 5 O ring 6 Backup Ring 7 O ring 8 Backup Ring ...

Page 587: ...Plug Assembly 58 Figure 43 Reference Number Description 1 Spool 2 Spool End Figure 44 Reference Number Description 1 Poppet 2 Poppet 3 Spring 4 Plug Figure 45 Reference Number Description 1 Plug 2 O ring 3 O ring 4 O ring Figure 46 Reference Number Description 1 Plug 2 O ring 3 O ring 4 Backup Ring ...

Page 588: ... 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 min Figure 48 Reference Number Description 1 O ring 2 O ring 3 O ring 4 Backup Ring 5 O ring 6 Backup Ring 7 O ring Item Specification Relief Valve Pressure 35 3 0 5 MPa Flow 20 liter min ...

Page 589: ...nce Number Description 1 Plug 2 Spring 3 Poppet 4 Sleeve 5 O ring 6 O ring Component Name Specification Rated Flow 400 liter min 500 liter min at Neutral Max Pressure 31 9 MPa Allowable Back Pressure Peak Pressure Below 1 5 MPa Normal Pressure Below 0 5 MPa Allowable Working Temperature Range 20 90 C ...

Page 590: ...g or cap crisscrossed Remove and center cap Valve temperature uneven Warm up entire system Dirt in valve Clean valve Lack of pilot pressure Check pilot valve and pilot relief pressure Fails to bear load Leaky cylinder Check seal parts of cylinder Leaky spool Check spool Leaky overload relief valve Clean valve housing and relief valve seat parts Leaky anti drift valve Remove anti drift valve and cl...

Page 591: ...ief pressure is incorrect Seat parts worn due to dirt Lock nut and adjuster deformed Reset pressure and tighten lock nut in rated torque Oil leaks Relief valve seat parts damaged Replace relief valve Every parts stuck due to dirt O ring worn Replace adjuster or O ring Problem Possible Cause Remedy Hydraulic system is poor or none of the controls function Hydraulic pump failed Check pressure or rep...

Page 592: ...sted 5 Low pressure adjustment A Loosen lock nut 5 and turn adjusting plug 6 counterclockwise to lower relief pressure at step 4 One turn varies pressure by approximately 21 3 MPa Tighten lock nut 5 after pressure has been adjusted B Recheck the setting pressure by raising pressure Over Load Relief Valve 1 Shift the control valve spool and read the pressure gauge from the stroke end of the cylinde...

Page 593: ...assembly and protect it from dirt and foreign materials 4 Match mark the disassembled parts to ensure proper reassembling position 5 Replace all sealing parts such as O rings and backup rings with a new ones 6 Do not replace spools they are matched with valve housing and sleeve NOTE The further part numbers of an assembly part are shown as assembly part number further part number CAUTION When disa...

Page 594: ... 4 Remove plug 5 8 groove width 3 mm O ring 5 9 and backup ring 5 10 6 Remove spool end 8 5 width across flats 22 mm of spool 8 spring seat 8 2 and spring 8 3 4 Remove plug 8 8 groove width 3 mm spring 8 7 and poppet 8 6 7 Disassembly of spool WARNING When removing spool be careful not to damage it Attach label to each spool in order to install it in the correct position when reassembling Figure 5...

Page 595: ...emove socket head bolt 63 and body assembly 47 and O ring 35 and 70 2 Remove spring 33 and poppet 46 3 Grip body assembly 47 width across flats 8 mm in vise taking care not to scratch O ring 35 and 70 surface 4 Remove plug 47 5 and O ring 47 10 5 Remove spring 47 4 spool 47 2 and O ring 47 3 6 Remove plug assembly 47 7 width across flats 6 mm and O ring WARNING Removing antidrift valve seat when p...

Page 596: ...move poppet 36 1 spring 36 3 and poppet 36 2 Disassembly of Load Check 1 Remove travel semi parallel check from port P2 Remove plug 54 width across flats 27 mm Remove O ring 54 from plug Remove spring 53 and poppet 52 2 Remove travel load check from port P1 Remove socket head bolt 63 width across flats 10 mm and flange 34 Remove poppet 32 spring 33 and O ring 35 3 Remove the remaining load check R...

Page 597: ...3 Remove spring 29 and poppet 28 4 Remove semi parallel check valve from arm two Remove plug 61 width across flats 10 mm and O ring Remove spring 29 and poppet 30 Disassembly Of Flange 1 Remove flange from spare port Remove socket head bolt 77 width across flats 10 mm and flange 76 and O ring 78 2 Remove flange from boom two Remove socket head bolt 64 width across flats 8 mm and flange 56 and O ri...

Page 598: ...ngs NOTE Valve housings 1 and 2 should not be disassembled because O rings and housings can be deformed and mating surfaces can be crisscrossed when reassembling them Steel ball 75 should not be disassembled since it is a press fit Reference Number Size Quantity 60 6 mm 5 61 10 mm 17 62 12 mm 6 58 24 mm 1 52 27 mm 59 8 mm ...

Page 599: ...sembly of Main Relief Valve 1 This relief valve should be replaced as an assembly When replacing it loosen cap 8 width across flats 41 and O ring 1 Figure 51 If oil leaks from nut 3 remove nut 3 and plug 4 and replace O ring and backup ring Figure 51 ...

Page 600: ...mm and O ring 2 If oil leaks from nut 3 remove adjusting kit and replace O ring 4 NOTE When disassembling adjusting kit be careful not to allow components to spring out by force of spring or to lose the poppet Disassembly of Low Pressure Relief Valve 1 This relief valve is a press fit at area D making it a non serviceable item that should be replaced as a whole assembly Figure 52 Figure 53 ...

Page 601: ...dirt notches and corrosion Remove small scratches with oilstone 2 Inspect exterior surface of spool for scratches and notches Remove small scratches with oilstone 3 Inspect all grooves and passages of sliding parts for foreign materials 4 Replace any springs that are damaged heavy deformed or worn 5 If relief valve malfunctions inspect it by using relief valve procedure see page 6 Replace all O ri...

Page 602: ...hich O ring 5 9 and backup ring 5 10 are inserted Torque is 2 45 2 65 kg m 18 19 ft lb Assemble spring seat 5 2 spring 5 3 4 and spool end 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 65 kg m 18 19 ft lb Apply Loctite to thread of spool Grip spool...

Page 603: ... 5 Tighten plug 47 9 with O ring to body 47 1 Torques 1 43 1 73 kg m 10 23 ft lb Tighten plug 47 8 with O ring in body 47 1 Torque is 2 86 3 06 kg m 21 22 ft lb 6 Tighten plug 47 7 with O ring and filter in body 47 1 Torque is 2 86 3 06 kg m 21 22 ft lb Swing Load Check 1 Insert poppet 36 2 and spring 36 3 in poppet 36 1 and tighten plug 36 4 Torque is 3 98 4 38 kg m 29 32 ft lb IMPORTANT Be caref...

Page 604: ...g 33 and O ring and fasten flange 34 with socket head bolts 63 Torque is 10 50 11 52 kg m 76 83 ft lb Reassembly of Swing Load Check 1 Install O ring 40 and backup ring 41 on sleeve 38 2 Install piston 39 spring 37 and poppet assembly 36 in sleeve 38 3 Install sleeve assembly in body Install O ring 35 on body 4 Install piston 43 and O ring 45 in body 42 5 Install body assembly in sleeve 38 6 Faste...

Page 605: ...e 1 Assemble flange for spare port Install O ring 78 on flange 76 and fasten flange with socket head bolts 77 Torque is 10 50 11 52 kg m 76 83 ft lb 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 47 ft lb Reassembly of Boom and Arm Anti Drift Valv...

Page 606: ... spring 22 3 Tighten plug 23 with O ring 72 Torque is 9 48 11 01 kg m 69 80 ft lb Reassembly of Main Spool 3 11 1 Install O ring on valve housing 1 2 2 Fasten short cap 74 with socket head bolt 63 for travel straight spool 7 Fasten short cap 13 with socket head bolt 63 for the other travel straight spools Torque is 10 50 11 52 kg m 76 83 ft lb 3 Install spools 3 11 in valve holes they were removed...

Page 607: ...7 44 8 06 kg m 54 58 ft lb 4 Tighten plug assembly 58 with O ring and backup ring Torque is 7 95 8 97 kg m 58 65 ft lb 5 Tighten plug assembly 51 with O ring Torque is 10 50 11 52 kg m 76 83 ft lb 6 Tighten plug assembly 59 with O ring Torque is 7 44 8 06 kg m 54 58 ft lb IMPORTANT After reassembly is completed recheck tightening torque of all components If they are not properly tightened an oil l...

Page 608: ...n 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 adjusting plug 2 move cap 7 Width across flats 54 mm Torque is 7 95 8 97 kg m 58 65 ft lb If plugs are disassembled Adjust pressure by referring to Main Relief Valve on page 1 41 NOTE The torque values ar...

Page 609: ...ue 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 1 42 NOTE The torque values are based on the threads being lubricated Reassembly of Low Pressure Relief Valve Check whether there is dirt or paint chips around plug 1 width across flats 46 mm and reassemble it with new O rings 3 and 4 NOTE The to...

Page 610: ...ke 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 above specified pressure setting 4 The difference between main relief valve setting pressure and over load relief valve setting pressure should not be over 2 0 MPa 5 Before operating machine the hydraulic syst...

Page 611: ...SP000189 Page 1 Remote Control Valve Work Lever Joystick SP000189 REMOTE CONTROL VALVE WORK LEVER JOYSTICK SP000189 Remote Control Valve Work Lever Joystick Edition 1 ...

Page 612: ...Remote Control Valve Work Lever Joystick SP000189 Page 2 MEMO ...

Page 613: ...te Control Valve Work Lever Joystick Safety Precautions 5 Applicable Models 5 General Description 7 Function 7 Parts List 8 Specifications 10 Torques 10 Tools and Materials 10 Disassembly 11 Cleaning and Inspection Wear Limits and Tolerances 15 Reassembly 15 Start up Procedures 21 ...

Page 614: ...Remote Control Valve Work Lever Joystick SP000189 Page 4 MEMO ...

Page 615: ...ety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and ...

Page 616: ...SP000189 Remote Control Valve Work Lever Joystick Page 6 ...

Page 617: ...er is in neutral mode the spool is pushed upward by return spring The force of balancing spring which determines the secondary discharge pressure is not transmitted to the spool The input port is closed and the pressure of the output port is the same as the pressure of the tank port T 2 Control Switch Pressing of the push rod starts to press the balance spring whose force is transferred to the spo...

Page 618: ...9 Remote Control Valve Work Lever Joystick Page 8 Parts List 22 20 28 24 23 21 19 2 3 18 35 16 17 12 8 7 6 5 4 9 9 1 1 2 3 4 A 37 24 28 29 25 25A A 27 26 32 30 33 18 35 16 17 12 8 7 6 5 4 33 FG004596 Figure 1 ...

Page 619: ...pper 9 Spring 12 Push Rod 16 Plug 17 O ring 18 Rod Seal 19 Plate 20 Boot 21 Joint Assembly 22 Swash Plate 23 Nut 24 Nut 25 Handle Assembly L Handle Assembly R 25A Cap 26 Handle Bar 27 Spring Pin 28 Bellows 29 Bushing 30 Connector Assembly 32 Switch Assembly 33 Spool Kit 1 3 35 Plug Kit 1 3 37 Handle Kit Left Handle Kit Right Reference Number Description ...

Page 620: ... TOOLS AND MATERIALS Figure 2 No Tool Standard Remark 3 Plug PF 3 8 500 kg cm 36 ft lb 19 Swash Plate 27 mm 1 660 kg cm 120 ft lb 20 Hex Nut 22 mm 1 660 kg cm 120 ft lb 22 Nut 22 mm 1 660 kg cm 120 ft lb No Tool Standard Remark 3 L Wrench 8 mm 19 Spanner 27 mm 20 Spanner 22 mm 22 Spanner 22 mm ...

Page 621: ... SP000189 DISASSEMBLY 1 Remove lead wire from bushing 29 2 Remove lever assembly from case 1 3 Remove hex nut 23 and swash plate 22 from case 4 Remove joint assembly 21 from case FG000804 Figure 3 FG000805 Figure 4 FG000806 Figure 5 FG000807 Figure 6 ...

Page 622: ...l Valve Work Lever Joystick Page 12 5 Remove plate 19 from case 1 6 Remove plug kit assembly from case 1 7 Remove four spool kit assemblies from case 1 FG000808 Figure 7 FG000810 Figure 8 FG000811 Figure 9 FG000812 Figure 10 ...

Page 623: ...Remote Control Valve Work Lever Joystick Page 13 SP000189 8 The bushing 3 and plug cannot be removed from case 1 FG000813 Figure 11 FG000814 Figure 12 FG000815 Figure 13 FG000816 Figure 14 ...

Page 624: ...SP000189 Remote Control Valve Work Lever Joystick Page 14 FG000817 Figure 15 ...

Page 625: ...SPECTION WEAR LIMITS AND TOLERANCES For general cleaning and inspection procedures refer to General Maintenance Procedures section REASSEMBLY 1 Install four plugs 2 into case 1 2 Install bushing 3 into case 1 using jig FG000815 Figure 16 FG000817 Figure 17 FG000814 Figure 18 ...

Page 626: ... 16 3 Take care when assembling spool kit assemblies 1 and 3 2 and 4 They should be assembled in same way The assembly order is spool 4 shim 5 spring 6 spring seat 7 and stopper 8 FG000816 Figure 19 FG000818 Figure 20 FG000819 Figure 21 FG000812 Figure 22 ...

Page 627: ... spring 9 into case 1 5 Install spool kit assembly into case 1 The same way is used for four parts 6 Assemble plug kit insert rod seal 18 O ring 17 and push rod 12 into plug 16 in proper order FG000820 Figure 23 FG000821 Figure 24 FG000822 Figure 25 FG000810 Figure 26 ...

Page 628: ...Valve Work Lever Joystick Page 18 7 Assemble plug kit 35 and insert assembled set in case 1 to form a plug kit assembly 8 Install plate 19 into case 1 FG000811 Figure 27 FG000811 Figure 28 FG000823 Figure 29 FG000808 Figure 30 ...

Page 629: ...assembly 21 into case 1 10 Install wash plate 22 and hex nut 23 into case 1 11 Insert bar and tighten it with a spanner to check balance of joint assembly 12 Install boot 20 and bushing 29 into case 1 FG000807 Figure 31 FG000806 Figure 32 FG000824 Figure 33 FG000825 Figure 34 ...

Page 630: ...age 20 13 Install lever assembly into case 1 14 Put lead wire in bushing 29 tie it and arrange boot 15 Install lead wire terminal into connector terminal pressing them together FG000805 Figure 35 FG000826 Figure 36 FG000827 Figure 37 FG001097 Figure 38 ...

Page 631: ...erly route wiring START UP PROCEDURES 1 Start engine and set throttle at LOW IDLE 2 Set safety lever on UNLOCK position 3 Slowly cycle boom arm bucket cylinders and swing motor about five times without a load to vent air from pilot lines Do this for five minutes FG000828 Figure 39 FG000829 Figure 40 HAOB290L Figure 41 ARO0470L Figure 42 ...

Page 632: ...SP000189 Remote Control Valve Work Lever Joystick Page 22 ...

Page 633: ...SP000070 Page 1 Travel Control Valve with Damper SP000070 TRAVEL CONTROL VALVE WITH DAMPER SP000070 Travel Control Valve with Damper Edition 1 ...

Page 634: ...Travel Control Valve with Damper SP000070 Page 2 MEMO ...

Page 635: ...cable Models 5 General Description 7 Theory of Operation 7 Deceleration Valve 8 Dampening Parts of the Control Section 9 Causes of Faults and Measures 11 Parts List 12 Specifications 13 Torques 13 Removal 14 Disassembly 15 Cleaning and Inspection Wear Limits and Tolerances 18 Assembly 19 Installation 25 Start up Procedures 26 ...

Page 636: ...Travel Control Valve with Damper SP000070 Page 4 MEMO ...

Page 637: ...safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 5001 and Up DX340LC 5001 and Up DX420LC 5001 and Up DX480LC 5001 and Up D...

Page 638: ...SP000070 Travel Control Valve with Damper Page 6 ...

Page 639: ...ion There is the pressure reducing valve a and the damper mechanism b The following hydraulic circuit is an example of a remotely located control valve 1 2 3 5 4 ARS1810L 6 Figure 1 Reference Number Description 1 Remote Control Valve 2 Pilot Pump 3 Main Pump 4 Control Valve 5 Hydraulic Motor 6 Hydraulic Cylinder Reference Number Description ...

Page 640: ...port 1 are connected and oil pressure from the pilot pump flows through port 1 generating pressure When the pressure of port 1 reaches the selected pressure of the secondary pressure select spring the oil pressure and the spring set pressure will equalize and the output pressure of port 1 is maintained at a constant rate The damper spool in port 2 is in the neutral position oil returning from the ...

Page 641: ...on of the casing to tank 3 When the operating levers are moved to the extreme opposite position When the cam is moved to the counterclockwise position from the clockwise most position the push rod and piston in port 2 is moved in the downward direction As in the case described above the oil in the damping piston chamber is discharged through the orifice and the dampening pressure is generated in t...

Page 642: ...Moving the lever in the opposite direction causes the left damper spool to assume the function of the right spool Thus a dampening force is generated at both ways B Operation of forward and reverse lever control Oil outside the damper spool runs out through the channel from the top of the casing to the port T And oil in the damper spool is discharged through orifice generating pressure that create...

Page 643: ...t primary pressure Defective secondary pressure select spring Replace with new spring Gap between damper spool and casing is abnormally large Replace damper spool casing assembly Defective operating parts and components Disassemble reassemble and replace defective parts Unstable secondary pressure Jamming of interconnected parts Repair replace cause of jamming Unstable tank line pressure Install d...

Page 644: ...SP000070 Travel Control Valve with Damper Page 12 Parts List 32 24 23 22 16 21 13 12 11 9 5 4 3 10 8 6 7 19 20 17 18 14 15 3 36 25 26 27 31 30 29 28 33 37 1 35 34 2 P T 1 2 3 4 FG003925 38 Figure 5 ...

Page 645: ... Seal 24 Dust Seal 25 Cover 26 Hex Socket Head Bolt 27 Cam 28 Bushing 29 Camshaft 30 Set Screw 31 Set Screw 32 Hex Nut 33 Bellows 34 Spacer 35 O ring 36 O ring 37 Hex Socket Head Bolt 38 Piston Reference Number Description Travel Control Valve Specification Type Pilot Control With Damper Pressure Stroke 25 kg cm2 4 8 mm Stroke 356 psi 0 1890 in Stroke Weight 7 8 kg 17 lb Part Reference Number Bolt...

Page 646: ...ter switch 9 Hang a maintenance warning tag on controls 10 Disconnect negative battery cable leading to frame from battery 11 Remove cabin under cover by loosening bolts 12 Tag and disconnect hoses from pedal valve 1 Figure 7 Plug and cap hoses and ports to prevent contamination from entering hydraulic system or component O I FG003015 WARNING WARNING DON T TOUCH WHEN PERFORMING INSPECTION OR MAINT...

Page 647: ...SP000070 DISASSEMBLY 1 Remove bellows 33 2 Remove set screw 30 from cam 27 3 Remove cam shaft 29 and cover 25 from cam 27 4 Remove hex nut 32 and swash plate 31 from cam ARS1870P Figure 8 FG000985 Figure 9 FG000986 Figure 10 FG000987 Figure 11 ...

Page 648: ...Damper Page 16 5 Remove hex socket head bolt 26 and cover 25 from each body 1 and 2 6 Remove push rod assembly from each body 1 and 2 7 Remove retaining ring 13 FG000988 Figure 12 FG000989 Figure 13 FG000990 Figure 14 FG000991 Figure 15 ...

Page 649: ...ve with Damper Page 17 SP000070 8 Remove rod guide 11 from each body 1 and 2 9 Remove damper spool assembly and spring 10 from each body 1 and 2 FG000992 Figure 16 FG000993 Figure 17 FG000994 Figure 18 FG000995 Figure 19 ...

Page 650: ...y 1 and 2 Disassemble each body 1 and 2 and spacer 34 Remove plugs 3 and 4 and O rings 35 and 36 CLEANING AND INSPECTION WEAR LIMITS AND TOLERANCES For general cleaning and inspection procedures refer to General Maintenance Procedures section FG000996 Figure 20 FG000997 Figure 21 FG000998 Figure 22 ...

Page 651: ...BLY 1 Assemble plugs 3 and 4 and O rings 35 and 36 into each body 1 and 2 and spacer 34 Install hex socket head bolt 37 using torque wrench 2 Insert spring 10 into each body 1 and 2 FG000996 Figure 23 FG000997 Figure 24 FG000998 Figure 25 FG000995 Figure 26 ...

Page 652: ...spool 8 shim 7 spring 6 spring seat 5 and stopper 9 4 Install damper spool assembly into each body 1 and 2 5 Install O ring 12 on rod guide 11 Coat guide assembly with grease and slide it into each body 1 and 2 FG000999 Figure 27 FG001000 Figure 28 FG000994 Figure 29 FG000992 Figure 30 ...

Page 653: ...Damper Page 21 SP000070 6 Install retaining ring 13 Make sure that it is properly seated 7 Assemble rod seal 23 dust seal 24 and O ring 22 into plug 21 FG000993 Figure 31 FG000991 Figure 32 FG001001 Figure 33 FG001002 Figure 34 ...

Page 654: ...ssemble seal 16 piston 38 steel ball 17 plate 19 spring 18 and retaining ring 20 into push rod 14 9 Assemble push rod and plug 10 Install push rod assembly into each body 1 and 2 FG001003 Figure 35 FG001004 Figure 36 FG001005 Figure 37 FG000990 Figure 38 ...

Page 655: ...g 28 in cover 25 using jig 12 Assemble cover 28 onto each body 1 and 2 and install hex socket head bolt 26 using torque wrench 13 Install set screws 31 and hex nut 32 into cam 27 and tighten it FG001006 Figure 39 FG001007 Figure 40 FG000989 Figure 41 FG000987 Figure 42 ...

Page 656: ...14 Position cam 27 on cover 25 and insert cam shaft 29 using hammer 15 Install set screw 30 in cam 27 and tighten it using torque wrench 16 Check cam balance 17 Install bellows FG000986 Figure 43 FG000985 Figure 44 FG001009 Figure 45 ARS2250P Figure 46 ...

Page 657: ...and washers 2 2 Install pedal brackets 3 and levers 4 Figure 48 on pedal valve and install four bolts and washers 2 3 Install rubber boots 1 Figure 48 4 Connect hoses as tagged during removal to pedal valve 1 Figure 49 5 Install cabin under cover by tightening bolts 1 2 FG003016 Figure 47 Figure 48 ARS2951L 3 2 2 3 1 1 Figure 49 1 2 FG003016 ...

Page 658: ...e 26 START UP PROCEDURES 1 Start engine and set throttle at LOW IDLE 2 Set safety lever on UNLOCK position 3 Slowly push and pull both travel lever about five times without a load to vent air from pilot lines Figure 50 HAOB290L Figure 51 HAOB903L ...

Page 659: ...SP000191 Page 1 Solenoid Valve Assembly SP000191 SOLENOID VALVE ASSEMBLYSP000191 1Solenoid Valve Assembly Edition 1 ...

Page 660: ...Solenoid Valve Assembly SP000191 Page 2 MEMO ...

Page 661: ...alve Assembly Safety Precautions 5 Applicable Models 5 Parts List 6 Functions of 5 Solenoid Valve Assembly Package 7 Functions of Solenoid Valve Assembly Package 7 Assembly Diagram and Tools Required 9 Solenoid Valve Diagram 11 Check Points and Solutions for Problems 12 ...

Page 662: ...Solenoid Valve Assembly SP000191 Page 4 MEMO ...

Page 663: ...mendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up ...

Page 664: ...ame as in the parts list below Figure 1 Reference Number Description Sizes Quantity Remarks 1 Block Body 95x120x240 1 1 A1079 05 0 2 Solenoid valve TF S34 00 VDL24VDC 6 C1 C2 C3 C4 C5 3 Check Valve FD DCP 0 A 1 C6 4 Pilot Shift Valve FD PSS1 0005 1 C7 5 Plug PF 1 4 3 P5 P6 H0 6 Plug PT 1 4 1 7 Plug PT 1 8 14 ...

Page 665: ...t and the electrical signal of the limit switch starts the pilot cut off valve to supply pressure and oil to each pilot pressure supply solenoid valve Reference Number Function Operations Remarks C1 Pilot cut off Provides pressure and oil coming from the pilot pump for the pilot pressure supply solenoid valve to drive each work system C2 Breaker operation Supplies pilot pressure for the breaker va...

Page 666: ... the front and rear pumps If the load is high pressure about 300 kgf cm2 the solenoid valve turns Off for the travel at low If the load is low pressure about 160 kgf cm2 the solenoid valve turns On for the travel at high If the engine control dial is set equal and below 1400 RPM however the solenoid valve always turns On for the travel at low though the automatic travel switch is set to the automa...

Page 667: ...ents Screw Sizes Torques kg cm Tools 2 Solenoid valve UNF7 8 14 200 25 Hex torque wrench 1 socket 2 1 Coil Lock Nut UNF1 2 20 60 2 Hex torque wrench 19 mm socket 3 Check Valve UNF7 8 14 400 2 4 Pilot Shift Valve UNF7 8 14 200 25 Hex torque wrench 1 socket 5 PT 1 4 Plug PF 1 4 19 250 25 Torque wrench 19 mm socket 6 PT 1 8 Plug Bolt PT 1 4 19 500 Torque wrench 6 mm wrench socket 7 PT 1 8 Plug Bolt P...

Page 668: ...ction Take care not to damage the valve tube and the retainer when disassembling the coil lock nut If the valve tube or the retainer is damaged bent or deformed the solenoid valve may not operate B Grip the coil 2 2 with a hand and pull it out C Remove the solenoid valve 2 by turning it in the Disassembly Direction D Check disassembled components and reassemble them in the reverse order of the dis...

Page 669: ...Solenoid Valve Assembly Page 11 SP000191 Solenoid Valve Diagram Figure 3 ...

Page 670: ...generate Pilot pressure Remove the plug of the P5 port set up a pressure gage and check the pilot pressure discharged from the pilot pump when operating the cut off C1 valve Refer to Causes and How to Check of the solenoid valve above Pilot relief valve Check if the relief valve installed in the pilot line operates properly Check if pressure is bypassed due to the presence of foreign substance Rem...

Page 671: ...d Valve Assembly Page 13 SP000191 Checking of Pilot Pressure for Defects Port where pressure gage set up Screw size Remark P1 P3 P4 P5 P6 TR2 PH HO SP PF1 4 O ring BOSS Operate the solenoid valve concerned ON ...

Page 672: ...SP000191 Solenoid Valve Assembly Page 14 ...

Page 673: ...SP000192 Page 1 Breaker EPPR Valve Opt SP000192 BREAKER EPPR VALVE OPT SP000192 2Breaker EPPR Valve Opt Edition 1 ...

Page 674: ...Breaker EPPR Valve Opt SP000192 Page 2 MEMO ...

Page 675: ...Table of Contents Breaker EPPR Valve Opt Safety Precautions 5 Applicable Models 5 Structure 6 Numbers and Names of Parts 6 Functions and Operation 7 Cautions for Operation 7 Maintenance Instructions 8 Maintenance 8 Disassembly 9 Assembly 10 ...

Page 676: ...Breaker EPPR Valve Opt SP000192 Page 4 MEMO ...

Page 677: ...shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 5001 and Up DX340LC 5001 and Up DX420LC 5001 and Up DX480LC 5001 and Up DX520L...

Page 678: ... Breaker EPPR Valve Opt Page 6 STRUCTURE Numbers and Names of Parts Figure 4 Reference Number Description 1 Solenoid 2 Valve casing 3 Sleeve 4 Spool 5 Pin 6 Spring 7 O ring 8 O ring Reference Number Description ...

Page 679: ...ses CAUTIONS FOR OPERATION 1 Wiring of the solenoid The solenoid has no polarity 2 Input electricity Do not supply electric current more than 0 7A to the solenoid coil 3 Adjustment screw It was adjusted to the standard The pressure of the port A increases when turning the adjustment screw clockwise 4 Symptoms and Solutions of Problems Symptoms Causes Solutions Pressure does not increase nor change...

Page 680: ...1 Tools Used for Disassembly and Assembly Table 2 shows tools necessary for disassembly and assembly As bolts and plugs to be used depend on types they should be checked accordingly in advance Bolt Sizes Names Used Torques kgf cm M 35 Hex bolt 450 50 M 10 Hex bolt 200 20 NPTF 1 16 Plug 90 For Sizes Used Torques Used Tools Solenoid M 35 450 50 Spanner Sleeve M 10 200 20 Hex bar spanner NPTF plug 1 ...

Page 681: ...table and take care not to damage parts 2 Remove dust and rust of the proportional pressure reducing valve with cleansing oil 3 Disassemble the solenoid Take care not to damage O rings of the solenoid 4 Disassemble the spool the spring and the pin 5 Disassemble the sleeve Take care not to damage O rings of the sleeve Figure 5 Figure 6 Figure 7 ...

Page 682: ...vance Every part should be cleaned enough with cleaning oil and dried with compressed air before starting assembly Sliding parts and bearings should be applied clean active oil before their assembly Basically parts of the O ring and the oil seal should be replaced Use a torque wrench to tighten or engage bolts and plugs in accordance with reference torques as described in Maintenance Guide 1 Assem...

Page 683: ...Breaker EPPR Valve Opt Page 11 SP000192 2 Assemble the spool the spring and the pin The spring and the pin should not be fell off 3 Assemble the solenoid correctly Figure 10 Figure 11 Figure 12 ...

Page 684: ...SP000192 Breaker EPPR Valve Opt Page 12 Take care not to damage O rings of the solenoid Figure 13 ...

Page 685: ...SP000209 Page 1 Fan Motor Vane Type SP000209 FAN MOTOR VANE TYPE SP000209 Fan Motor Vane Type Edition 1 ...

Page 686: ...Fan Motor Vane Type SP000209 Page 2 MEMO ...

Page 687: ...9 Performance Data 9 Loads on Shaft 10 Mounting Flange and Coupling 11 Mounting Flange 11 Misalignment 11 Loads on Shaft 11 Splined Shafts 11 Shafts 12 Taper Shafts 12 Pipe Connection 12 Pipe 12 Flange Connections 13 External Drain 13 Cleanliness and Seals 14 Fluid Cleanliness 14 Seals S1 Nbr Nitrile Base Polymere 14 Seals S4 Epr Ethylene Propylene Polymere 14 Seals S5 Fpm Fluorocarbon 14 Maintena...

Page 688: ...000209 Page 4 Priming 19 Cold Starting 19 Changing Porting Position 19 Cartridge Replacement 20 End Cap Replacement 20 Shaft Replacement 20 Shaft Seal Replacement 20 Seal Driver 21 Couping Dimensions 21 Taper Keyed Shafts 21 ...

Page 689: ...ndations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up ...

Page 690: ...ly 3 Spring Vane 4 Pin Vane Holdout 5 Vane 6 Cam Ring 012 7 Port Plate Pressure 8 O ring 9 Housing 10 Ball Bearing 11 Key 12 Shaft 13 Retaining Ring 14 Retaining Ring 15 Shaft Seal 16 Sq Section seal 17 Dowel Pin 18 Sq Section seal 19 Needle Bearing 20 Screw 21 Ball 22 Adaptor Valve 23 Screw Reference Number Description ...

Page 691: ...tridge camring rotor vanes springs and pins the end cap cap and needle bearing the shaft assembly shaft ball bearing retaining ring and key The design of the motors allows to change the cartridge to renew the motor or to change the displacement to suit altered requirements for speed or torque Applications The motors are designed primarily for coaxial drives which do not impose axial or side loadin...

Page 692: ...s Radial grooves and holes through the vanes equalize hydraulic forces on the vanes at all times Fluid enters and leaves the motor cartridge through openings in the side plates at the ramps Each motor port connects the two diametrically opposed ramps The rotor is separated axially from the sideplate surfaces by the film of oil The front sideplate is clamped against the cam ring by the pressure mai...

Page 693: ...ar ft lb 100 PSI kW bar HP 100 PSI l min gpm Nm ft lb kW HP 012 12 0 0 73 0 191 0 971 0 020 0 185 12 2 3 22 14 6 3 86 17 1 4 52 42 8 31 6 4 5 6 0 018 18 0 1 10 0 286 1 457 0 030 0 277 18 2 4 81 20 6 5 44 23 1 6 10 69 1 51 0 7 2 9 7 028 28 0 1 71 0 445 2 266 0 047 0 432 28 2 7 45 30 6 8 08 33 1 8 75 112 8 83 2 11 8 15 8 036 36 0 2 20 0 573 2 914 0 060 0 555 36 2 9 56 38 6 10 2 41 1 10 9 147 9 109 1...

Page 694: ...n Motor Vane Type Page 10 Loads on Shaft Loads on Shaft Max axial load Fa max 6000 N Max radial load Fr max 5500 N Lifetime Under Load Theoretical lifetime hour L10H Figure 3 Figure 4 L10h Hour 16 666 x L10 N RPM ...

Page 695: ...les must be less than 0 1 Loads on Shaft The motor can bear higher axial and radial loads thanks to an oversized ball bearing the maximum loads are given page 11 The lifetime in millions of revolutions of this bearing under load can be determined with the curve page 10 and can be calculated in hours with the formula Splined Shafts The mating female spline should be free to float and find its own c...

Page 696: ...d radial loads This shaft is 125 1000 taper with M16x150 threaded end to install a bolt and a pin PIPE CONNECTION Pipe All fluid lines either pipe tubing or hose must be of adequate size and strength to assure free flow to and from the motor An undersized inlet line will restrict the fluid flow to the motor and prevent proper operation by creating turbulences and aeration If rigid pipe or tubing i...

Page 697: ...827 MPa and metric screws must in conformity with class 8 8 The mounting torque 28 to 40 Nm 21 to 30 ft lb External Drain The externally drained motors must have a drain line connected to the center housing drain connection of sufficient size to prevent back pressure in excess of 3 5 bar 50 PSI returning direct to the reservoir below the surface of the oil as far away as possible from the suction ...

Page 698: ...plications mineral oil temperature less than 90 C 194 F Color identification code none Operating temperature 40 C to 107 C 40 to 225 F Seals S4 Epr Ethylene Propylene Polymere Use this seal type with fire resistant fluids Color identification code purple seal or white stripe on black seal Operating temperature 54 C to 121 C 65 to 250 F Special instruction seals to this specification are to be lubr...

Page 699: ...and bolts are tight For the motor part numbers refer to section drawing page 6 Disassembly 1 Drain all the fluid from the motor and thoroughly clean the external surface Prepare a clean lint free surface on which to place the internal parts for inspection and repair Remove the four housing screws 20 and carefully remove the end cap 1 2 By using two 10 24 UNC 2B screws remove the cartridge from the...

Page 700: ...me screws remove the pressure plate 7 4 Remove the retaining ring 13 by using the tool 5 Remove the shaft 12 from the housing Figure 9 CAUTION the cartridge and the pressure plate may go out from the housing together sticked by oil Figure 10 Figure 11 ...

Page 701: ...n hydraulic fluid to lubricate all the internal parts including seals 2 Install the shaft in the housing Install the remaining ring by using the tool 3 Install seal 16 on the pressure plate spigot 7 Install seal 8 in the housing 9 Figure 12 Figure 13 Figure 14 ...

Page 702: ...l pins facing the corresponding hole on the pressure plate Be sure the cartridge is well seated on the pressure plate by pushing with fingers on the vanes and the cam ring they should not be lower than the cam ring surface 6 Install seal 18 on the end cap spigot 7 Insert the end cap in the housing the locating hole facing the dowel pin on the cam ring As the cap is well inserted less than 1 mm 0 0...

Page 703: ...ime properly in the first minute or pressure can not be obtained it should be shut down and condition corrected Cold Starting The motor should be started at low pressure and low speed until the fluid warms up before running at high pressure or speed Changing Porting Position There are four possible positions of flanges with reference to drain hole and mounting flange Put a container under the moto...

Page 704: ...ce shaft up Remove the retaining ring 13 and extract the shaft 12 from the housing by pulling it straightly not to scare the shaft seal lips 15 Visually inspect the shaft seal if the lips are damaged replace the seal Grease the seal and the shaft seal area Manually insert the shaft into the housing and install the retaining ring Reassemble the motor Shaft Seal Replacement Disassemble the motor Rem...

Page 705: ...s between length 2 and shoulder Grease length 2 installing shaft seal onto tool to prevent to the seal from being damaged Material XC42 or equivalent COUPING DIMENSIONS Taper Keyed Shafts Figure 20 Figure 21 Shaft Code DIA 25 27 25 40 0 995 1 000 W 6 36 6 41 0 250 0 252 B 28 70 28 95 1 130 1 140 C 53 5 54 5 2 106 2 146 L 34 8 35 2 1 370 1 386 ...

Page 706: ... PORT TAPER 125 1000 SAE BB J 744 with M16 j SHAFT CODE1 3 2 0 13 0 13 KEY ED 34 7 40 9 0 13 0 2 0 2 0 0 05 54 0 M18 1 5 DEEP 13 5max 0 9 0 9 22 2 1 5 4 0 25 Ø85 9 8 M10 P1 5 19 DEEP D 90 15 1 8 2 5 4 3 Ø29 Ø19 7 D INDUSTRIAL APPLICATION DISPLACEMENT C W C C W INLET OUTLET A B A B WORKING PURESSURE 28 MPa max 0 35 MPa max DRAIN BACK PRESSURE MAX PURESSURE Int MPa max 32 45 0 max 2500 DISPLACEMENT ...

Page 707: ...SP000208 Page 1 Gear Pump Fan Cooling Drive SP000208 GEAR PUMP FAN COOLING DRIVE SP000208 Gear Pump Fan Cooling Drive Edition 1 ...

Page 708: ...Gear Pump Fan Cooling Drive SP000208 Page 2 MEMO ...

Page 709: ...ing Drive Table of Contents Gear Pump Fan Cooling Drive Safety Precautions 5 Applicable Models 5 Disassembling Single Gear Pump 6 Reassembling Single Gear Pump 9 Disassembling Double Gear Pump Opt 12 Reassembling Double Gear Pump Opt 15 ...

Page 710: ...Gear Pump Fan Cooling Drive SP000208 Page 4 MEMO ...

Page 711: ...ommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up ...

Page 712: ... the pump externally with care 2 Loosen and remove the clamp bolts 3 Coat the sharp edges of the drive shaft with adhesive tape and smear a clean grease on the shaft end extension to avoid any damaging lip of the shaft seal when removing the mounting flange Figure 1 Figure 2 Figure 3 ...

Page 713: ...th rubber mallet in order to break away from the body NOTE Ensure that while removing mounting flange shaft and other components remain position 5 Remove snap ring with proper tool only when it is needed to replace shaft seal 6 Remove the shaft seal taking care not to give any damage on the surface of shaft hole only when it is needed to replace shaft seal Figure 4 Figure 5 Figure 6 Figure 7 ...

Page 714: ...208 Gear Pump Fan Cooling Drive Page 8 7 Ease the drive gear up to facilitate removal the front plate 8 Remove driving gear driven gear keeping gears as straight as possible And rear plate Figure 8 Figure 9 ...

Page 715: ...SEMBLING SINGLE GEAR PUMP 1 Clean all components externally with care 2 Insert the shaft seal carefully and fit it inside of mounting flange with proper tool 3 Fit the snap ring in pre arranged position with proper tool Figure 10 Figure 11 Figure 12 ...

Page 716: ...n locate back up ring on the groove pre arranged on the seals Smear clean grease on the seals The front and rear pressure plates and seals and back up rings are same 6 Insert the complete pressure plate into body while keeping the plate straight NOTE Seal side should face to the inside opposite side of gears NOTE Pay attention to the direction of seal 7 Locate drive gear and driven gear Figure 13 ...

Page 717: ...e mounting flange in right position Tap around mounting flange with rubber mallet 10 Tighten the bolts with washer in a crisscross pattern to torque value of 140 Nm 11 Check that the pump rotate freely when the drive shaft is turned by hand If not a pressure plate seal may be pinched Figure 17 Figure 18 Figure 19 Figure 20 ...

Page 718: ...n the pump externally with care 2 Loosen and remove the clamp bolts 3 Coat the sharp edges of the drive shaft with adhesive tape and smear a clean grease on the shaft end extension to avoid any damaging lip of the shaft seal when removing the mounting flange Figure 21 Figure 22 Figure 23 ...

Page 719: ...ving mounting flange shaft and other components remain position 5 Remove snap ring with proper tool only when it is needed to replace shaft seal 6 Remove the shaft seal taking care not to give any damage on the surface of shaft hole only when it is needed to replace shaft seal 7 Ease the drive gear up to facilitate removal the front plate And remove drive gear driven gear rear plate keeping gears ...

Page 720: ...SP000208 Gear Pump Fan Cooling Drive Page 14 8 Remove first section and through shaft 9 Remove all remaining components with same way of removal first section Figure 28 Figure 29 ...

Page 721: ...care 2 Insert the shaft seal carefully and fit it inside of mounting flange with proper tool Fit the snap ring in pre arranged position with proper tool 3 Fit the o ring on the pre arranged groove of rear body Smear clean grease on the o rings to avoid drifting away of o ring from the body Figure 30 Figure 31 Figure 32 ...

Page 722: ...nt and rear pressure plates and seals and back up rings are same 5 Insert the complete pressure plate in to body while keeping the plate straight NOTE Seal side should face to the rear cover opposite side of gears NOTE Pay attention to the direction of seal 6 Locate driving gear and driven gear while keeping the gears straight 7 Locate pressure plate with care for the direction Figure 33 Figure 34...

Page 723: ...9 Repeat same process from 5 to 7 after inserting through shaft 10 Locate mounting flange while taking care not to give any damage on the shaft seal by edge of shaft And tap around the mounting flange with rubber mallet 11 Tighten the bolts with washer in a crisscross pattern to torque value of 140 Nm Figure 37 Figure 38 Figure 39 Figure 40 ...

Page 724: ...SP000208 Gear Pump Fan Cooling Drive Page 18 12 Check that the pump rotate freely when the drive shaft is turned by hand If not a pressure plate seal may be pinched Figure 41 ...

Page 725: ...SP000207 Page 1 Fan Cooling Flow In Out Change Valve SP000207 FAN COOLING FLOW IN OUT CHANGE VALVE SP000207 Fan Cooling Flow In Out Change Valve Edition 1 ...

Page 726: ...Fan Cooling Flow In Out Change Valve SP000207 Page 2 MEMO ...

Page 727: ...SP000207 Page 3 Fan Cooling Flow In Out Change Valve Table of Contents Fan Cooling Flow In Out Change Valve Safety Precautions 5 Applicable Models 5 Cooling Fan a Change of Direction Valve 6 ...

Page 728: ...Fan Cooling Flow In Out Change Valve SP000207 Page 4 MEMO ...

Page 729: ...y recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up...

Page 730: ...NG FAN A CHANGE OF DIRECTION VALVE Figure 1 Reference Number Description 10 Relief Valve 20 Seal Kit 30 Coil 40 Nut 50 O ring 60 Solenoid Valve 70 Seal Kit 80 Check Valve Make up 90 Check Valve 100 Seal Kit 110 Socket Bolt 120 Body Reference Number Description ...

Page 731: ...SP000274 Page 1 Hydraulic Schematic DX420LC SP000274 HYDRAULIC SCHEMATIC DX420LC SP000274 1Hydraulic Schematic DX420LC Edition 1 ...

Page 732: ...Hydraulic Schematic DX420LC SP000274 Page 2 MEMO ...

Page 733: ...SP000274 Page 3 Hydraulic Schematic DX420LC Table of Contents Hydraulic Schematic DX420LC Safety Precautions 5 Applicable Models 5 General Description 7 DX420LC 8 ...

Page 734: ...Hydraulic Schematic DX420LC SP000274 Page 4 MEMO ...

Page 735: ...ollow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up ...

Page 736: ...SP000274 Hydraulic Schematic DX420LC Page 6 ...

Page 737: ... PT P1 TR R pb1 pa1 pa2 A1 B1 pb2 P4 pc3 SWING pa3 B2 A3 pb3 BOOM2 pa4 B3 B4 pb4 B5 ARM1 pa5 pb5 A5 pc1 P1 33 T 28 26 T 36 q2 TRAVEL MOTOR L 11 11 max 15 Dr q1 10 Pi2 of Pump Bm min BACKWARD A 2 1 Dr Pi B FORWARD Dr Dr Pi Pi N Am Dr T2 ps2 DR2 DR3 DR1 T1 T3 TRAVEL MOTOR R BACKWARD B 16 3 4 Bm A FORWARD max min q2 q1 Pi1 of Pump ps1 15 Am N Pi Pi Dr Dr C2 23 T V2 Pi1 E E Mu GB B RIGHT Au Dr LEFT A ...

Page 738: ...L FP RIGHT 19k PT P1 P1 pr1 pb1 pa1 pb2 pc6 TRAVEL B1 A1 DR3 pa2 B2 SWING A2 BOOM2 pa3 to X1 A1 of pump BOOM LOCK 11 Pi1 of Arm Lock v v 26 Pi1 V2 T C2 E 11 Pi1 T V2 26 pa8 pc2 A7 DR2 DR2 BUCKET A8 pb8 B8 E C2 opt B9 ARM2 pa9 A9 pb9 pa10 BC 360k 20L 250k 20L 360k 20L A3 B3 pa4 OPTION A4 pb4 B4 REGEN ARM LOCK BC pb5 pa5 ARM1 A5 pc1 B5 pa11 DR1 DR1 to X1 A2 of pump FOOT RELIEF through A of EPPR valv...

Page 739: ...WO WAY SELECT V V 1 28 HIGH PRESS RETURN FILTER 27 PROPORTIONAL VALVE 26 LOCK VALVE 22 HYDRAULIC TANK 21 AIR BREATHER P T O 12 ARM CYLINDER 19 OIL COOLER 16 CENTER JOINT 15 TRAVEL DEVICE 14 SWING DEVICE 13 BUCKET CYLINDER D 11 BOOM CYLINDER 10 CONTROL VALVE 9 CONNECTOR 8 PEDAL VALVE 5 SOLENOID VALVE 4 ACCUMULATOR 3 S T 2 PILOT FILTER 1 PUMP 220kg cm 2 R H L H 28 2 3 1 0 5 2 4 0 5 3 1 T P A 24 FAN ...

Page 740: ...SP000274 Hydraulic Schematic DX420LC Page 10 ...

Page 741: ...1Electrical System ...

Page 742: ......

Page 743: ...SP000269 Page 1 Electrical System SP000269 ELECTRICAL SYSTEMSP000269 Electrical System Edition 1 ...

Page 744: ...Electrical System SP000269 Page 2 MEMO ...

Page 745: ... 20 Monitoring System 21 Instrument Panel 22 Monitoring System Schematic 24 Operation 26 Instruments 26 Warning and Indicator Lights 28 Indication of Warning Lights 28 Indication of Multifunction Gauge and Letter Information Area29 Initial Operation 31 Mode Selector Switch 31 Graphic Information Area Display 32 Overview 32 Main Menus for the Graphic Display Area 33 Menu Selector Buttons 33 Menu Se...

Page 746: ...it Diagram 68 Engine Control System 69 Engine Control Dial 70 Engine Control Circuit Diagram 72 Automatic Deceleration Control Auto Idle Control 74 Engine Overheat Protection System 76 Power Boost Mode 78 Operation 78 Power Boost Control Circuit Diagram 80 Automatic Travel Speed Control 82 Automatic Travel Speed Control Circuit Diagram 84 Self diagnostic Function 85 e EPOS Controller 85 Air Condit...

Page 747: ... Panel 98 Compressor 105 Receiver Dryer 105 Control of Cooling Fan 106 Control of Cooling Fan Speed 106 Control of Reverse Rotation of Cooling Fan 106 Cooling Fan Control Circuit 107 Wiper System 108 Wiper Circuit 108 Wiper operation 109 Lighting System 112 Lighting System Circuit Diagram 112 Kind of Light 113 Operation 113 Audio Controller 114 Audio Controller Circuit Diagram 114 ...

Page 748: ...Electrical System SP000269 Page 6 MEMO ...

Page 749: ... all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up ...

Page 750: ...SP000269 Electrical System Page 8 ...

Page 751: ...series and a three phase AC generator with a rectifier The electric wiring used in the system is easily identifiable by the insulator color The color symbols used in the electrical system are listed in the following chart Electric Wire Color NOTE RW Red wire with White stripe R Base Color W Stripe Color NOTE 0 85G Nominal sectional area of wire core less insulator 0 85 mm2 Symbol Color W White G G...

Page 752: ...r 4 Engine controller 5 Fuel feeder pump switch 6 Terminal 6 of wiper motor 7 Terminal 13 of wiper controller 8 Terminal CN6 11 of instrument panel 9 Terminal CN9 6 of air conditioner panel 10 Cabin light When the starter switch 5 is in the ON or START positions the current flows from the battery 1 fusible link 3 fuse box 6 B terminal of starter switch 5 BR terminal of starter switch 5 BR terminal...

Page 753: ...CC R2 C R1 E F E R P R SG 8 B B E 7 6 B R1 R2 ACC 5 BR C 8 3 0 5G B 4 BR 1 12V 150AH A 2 FG001476 Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Starter Switch 6 Fuse Box 7 Alternator 8 Diode Reference Number Description ...

Page 754: ...y 8 D terminal S terminal of starter controller 7 E terminal ground When the contact point B and PP of starter 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 flows from the battery 1 A terminal of the battery relay 2 B terminal of the battery relay 2 Fig...

Page 755: ...a B R2 ACC 6 86 30 R1 B 5 BR C 11 P N E S 7 D C 8 B PP 3 A 30 50 9 FG004533 Figure 2 STARTER CIRCUIT 1 WHILE STARTING Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Starter Switch 6 Fuse Box 7 Starter Controller 8 Starter Relay 9 Starter 10 Alternator 11 Diode 12 Starter Relay 2 13 e EPOS Controller Reference Number Description ...

Page 756: ...nal to the rotation of the alternator The starter controller 7 monitors the frequency of the output current Once the frequency is equivalent to 500 rpm it is sensed and the connection between S and E terminals and the connection between B and PP terminals are opened As a result the rotation of the starter 9 is stopped Once the engine is running the starter 9 will not operate even if the starter sw...

Page 757: ... B 11 P R 4 R1 B C 5 BR 87 87a P 30 B E N S 7 C 11 B D 8 PP 1 E B BR 2 A 3 30 A 50 9 FG004666 Figure 3 OPERATION OF START CIRCUIT 2 IMMEDIATELY AFTER START Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Starter Switch 6 Fuse Box 7 Starter Controller 8 Starter Relay 9 Starter 10 Alternator 11 Diode 12 Starter Relay 2 13 e EPOS Controller Reference Number D...

Page 758: ...troller 12 ground This current flow causes the coil in preheat relay 7 to be activated closing contacts When the contacts of the preheat relay 7 are closed the heating coils of the air heating device 8 are heated by current flowing from the battery 1 battery relay 2 preheat relay 7 air heater 8 ground The duration of the heating cycle depends on the temperature of engine coolant The preheat indica...

Page 759: ...ECTION 200A 8 B TML PST B BR R1 1 R1 R2 ACC B C BR 5 E 10 BR B ACC R2 C A 4 3 FG001478 Figure 4 ENGINE PREHEAT CIRCUIT Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Starter Switch 6 Fuse Box 7 Preheat Relay 8 Air Heater 9 Preheat Indicator Light 10 Diode 11 e EPOS Controller 12 Engine Controller Reference Number Description ...

Page 760: ...ine controller stops suppling power to the injector solenoid 9 This stops fuel from being injexted into the engine cylinder thus stopping the engine In the event that the engine can be shut down using the starter switch 5 an emergency stop switch 10 is provided to shut down engine To activate the emergancy stop switch move it to the I EMERGENCY STOP position The emergency stop switch 10 is in its ...

Page 761: ...ER SWITCH CONNECTION 6 START ON TML OFF PST B ACC R1 R2 C FG001473 Figure 6 ENGINE STOP CIRCUIT Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Starter Switch 6 Fuse Box 7 Diode 8 Engine Controller 9 Injector Solenoid 10 Emergency Stop Switch Reference Number Description ...

Page 762: ...r electrical components When the alternator 7 starts to operate a current flows from the R I terminal of alternator diode 8 battery relay 2 coil securing a path for the charging current to the battery 1 Thus preventing the possibility of a high voltage build up and possible damage to the electric system 2 STARTER SWITCH CONNECTION START TML OFF PST ON R1 R2 B BR 6 E F R E C ACC R I B R2 ACC R1 E P...

Page 763: ...E B R C H E F H C POWER 1 5 2 3 6 7 AUTO 4 ESC 8 E G SPEED 02 05 MO 11 30 1700 RPM CHECK 1 2 8 3 4 5 7 9 10 11 12 13 6 FG000547 Figure 8 Reference Number Description 1 Instrument Panel 2 Battery 3 Light Switch 4 Return Filter Switch 5 Pilot Filter Switch 6 e EPOS Controller 7 Alternator 8 Warning Buzzer 9 Pump Discharge Pressure Sensor 10 Hydraulic Oil Temperature Sensor 11 Fuel Sensor 12 Air Clea...

Page 764: ...F H C POWER 1 5 2 3 6 7 AUTO 4 ESC 8 FG000548 E G SPEED 02 05 MO 11 30 1700 RPM CHECK 7 8 9 10 11 12 5 1 2 15 13 14 3 6 4 17 19 20 16 18 CN7 CONNECTOR AND TERMINAL NO 12 6 5 11 4 10 14 8 7 15 16 2 1 8 7 3 9 12 5 4 3 2 1 10 11 9 6 13 CN6 AMP 040 28P 1 Figure 9 ...

Page 765: ...hes 1 Fuel Gauge 2 Engine Coolant Temperature Gauge 3 Hydraulic Oil Temperature Gauge 4 Multifunction Gauge and Letter Information Area 5 Digital Clock 6 Hour Meter 7 Charge Warning Light 8 Engine Oil Pressure Warning Light 9 Coolant Temperature Warning Light 10 Engine Check Warning Light 11 Preheat Indicator Light 12 Work Light Indicator Light 13 Power Mode Selector Switch and Indicator 14 Work M...

Page 766: ... HEAT WATER TEMPERATURE LCD DISPLAY PANEL L6 WORK LAMP GRAPHIC DISPLAY FUEL LEVEL CN7 4 CN7 5 CN7 6 6 CN6 10 CN6 9 5 20 4 2 1 3 6 5 14 R I CN4 1 CN2 14 CN5 2 CN3 8 CN3 7 CN3 10 CN3 9 CAN A 14 CN4 4 CN3 3 CN3 4 CN4 6 CN4 5 CN4 2 CN4 3 CN2 1 CN3 2 CN3 1 CN5 3 CN2 17 CN2 18 CN5 7 E BR 18 7 8 11 10 12 9 15 A L1 L3 L2 L4 1 ILL CN6 3 CN6 1 CN6 2 CN6 12 CN6 11 4 2 3 R2 B 19 17 16 FG001472 TxD RxD GND Fig...

Page 767: ...6 Rear Pump Pressure Sensor 7 Hydraulic Oil Temperature Sensor 8 Fuel Sensor 9 Pedal Pressure Switch Optional 10 Air Cleaner Indicator 11 Pilot Filter Switch 12 Return Filter Switch 13 Alternator 14 e EPOS Controller 15 Battery 16 Battery Relay 17 Circuit Breaker 18 Fusible Link 19 Fuse Box 20 Check Connector 21 Engine Controller Reference Number Description ...

Page 768: ...e CN3 9 CN3 10 40 C 104 F 1 397 ohms 50 C 122 F 1 139 ohms 60 C 140 F 881 ohms 94 C 201 F 190 ohms 96 C 205 F 177 ohms When reading increase Flow Adjusting Output Terminal CN1 19 CN1 20 50 l min 615 mA 50 l min 519 mA 50 l min 482 mA 100 l min 409 mA Default Set 220 l min 335 mA 308 l min 300 mA C H FG000550 Blue White Red 107 C 102 C 41 C 61 C E F FG000552 Blue Red Full 1 10 C H FG000551 Blue Whi...

Page 769: ... VDC Main pump discharge pressure front pump CN3 1 CN3 2 V 0 00816 x P 1 0 V Sensor output voltage V P Displayed pressure Bar Main pump discharge pressure rear pump CN3 3 CN3 4 Function Display Sensor Specification Input Terminal Input Specification E G SPEED 1700 RPM FG000049 BATTERY 28 0 VOLT FG000050 FRONT PUMP 320 BAR FG000051 REAR PUMP 313 BAR FG000052 ...

Page 770: ...ow the reference After starting engine if engine oil pressure is insufficient after 8 seconds a warning buzzer will sound Engine Check ECU CAN Communic ation It lights in case of failure in engine system Coolant Temperature ECU CAN Communic ation It lights when engine coolant temperature sensor resistant is below about 128 ohms Preheating CN5 2 It lights during preheating CN5 2 terminal voltage is...

Page 771: ...nal Operation Remarks HB4O2003 Description Symbol Input Terminal Operation Remarks Hydraulic Oil Temperature CN3 9 CN3 10 When hydraulic oil temperature is above about 96 C Fuel Exhausted CN3 7 CN3 8 When fuel is almost exhausted Air Cleaner CN2 17 When air cleaner is clogged Return Filter CN5 3 When return filter pressure is above about 1 50 kg cm 21 psi FG000056 FG000057 FG000053 FG000054 ...

Page 772: ...ssure sensor output voltage is about 2 7V while overload warning switch is ON It flickers in case of 2 71V and above and lights continuously in case of 2 8V and above and warning buzzer also starts Boost CN2 2 It lights when boost is selected Breaker CN2 10 It lights when breaker is selected Shear CN2 9 It lights when shear is selected FG000055 FG000253 FG000554 FG001470 FG001471 ...

Page 773: ...is activated and turned OFF after about 2 seconds Power mode Standard mode Work Mode Digging mode Auto Idle High Output Activation Display Indicating coolant temperature Fuel level Hydraulic oil temperature Engine speed Clock Current time display Operation Mode OutputCheck Operation mode display LED e EPOS Output Electromagnetic Proportional Pressure Reducing Valve E P P R Valve Current mA Swing P...

Page 774: ...o menus One is main menu for user and the other is special menu for specialist These menus can be moved from normal display mode by the combination of selector buttons C H E F H C POWER 1 5 2 3 6 7 AUTO 4 ESC 8 FG000557 E G SPEED 02 05 MO 11 30 1700 RPM CHECK 5 1 4 3 2 Figure 11 Selector Buttons Graphic Display Area 1 Up Arrow Button 2 Down Arrow Button 3 Enter Button 4 Escape Button 5 Letter Info...

Page 775: ...menu this button is used to function as the selector button 4 Escape Button ESC 4 on Figure 11 Move a screen to previous menu or main menu 1 Main menu Language setting Time setting Filter Oil information Brightness adjustment Password 2 Special menu Information of machine status failure information Information of machine operation Menu Selector Buttons 1 Up Arrow Button 1 on Figure 11 Move the cur...

Page 776: ...on 2 on Figure 11 to move cursor to a language to be selected on the Language Select display and press the Enter Button 3 on Figure 11 and the selected language is indicated in the right bottom of the screen At this point pressing the Enter Button 3 on Figure 11 or the Escape Button ESC 4 on Figure 11 more than 1 second brings the main menu with changed language and then pressing the ESC button ag...

Page 777: ...Oil Info This mode displays total operating hours of filters and oils After changing the filter and oil reset the operating hour and then the operating hours until the next service interval can be easily checked MAIN MENU 1 Language 4 Adjust Display 5 Set Password 2 Set Clock 3 Filter Oil Info UP DOWN SELECT FG000075 Figure 15 SET CLOCK MOVE FG000076 06 05 2004 06 29 Figure 16 MAIN MENU 1 Language...

Page 778: ...ed using the Up Arrow Button 1 on Figure 11 or the Down Arrow Button 2 on Figure 11 The default brightness is set to 50 1 Fuel Filter 2 Air Cleaner 3 Engine Oil Filter 4 Return Filter 5 Pilot Filter 6 Engine Oil 7 Pilot Filter 8 Coolant Water FG004977 Figure 19 MAIN MENU 1 Language 4 Adjust Display 5 Set Password 2 Set Clock 3 Filter Oil Info UP DOWN SELECT FG000080 Figure 20 Adjust Display FG0000...

Page 779: ... menu is used to apply lock release or change password Please refer to the Operation Manual for detailed information on Password Setting MAIN MENU 1 Language 4 Adjust Display 5 Set Password 2 Set Clock 3 Filter Oil Info UP DOWN SELECT FG000227 Figure 22 ...

Page 780: ...scaping Menus Entering Accessing Menus When normal mode screen is displayed if the enter button 3 and escape button ESC 4 are pressed simultaneously for more than 3 seconds normal mode screen Figure 24 will be changed to special menu screen Figure 25 Normal Mode Screen NOTE Normal mode screen can display many kinds of display mode by selecting for example engine speed RPM battery voltage VOLT fron...

Page 781: ...Submenu Selection Method Various sub menus can be selected by pressing Up 1 on Figure 23 and Down 2 on Figure 23 button Move the cursor to desired menu and a selected menu will be inverse displayed When the selected menu is inverse displayed press the Enter 3 on Figure 23 button for menu selection Information of Machine Status 1 Entering Sub menus When cursor is located on Machine Info of special ...

Page 782: ... Intake Manifold Temperature C Temperature of air incoming to intake manifold 11 E G Oil Pressure BAR Engine oil pressure 12 Fuel Temperature C Fuel temperature 13 E G Oil Temperature C Engine oil temperature 14 Load At Cur Spd Current load ratio of equipment FG003928 ANALOG INPUT STATE UP DOWN Page 1 3 UP DOWN Page 2 3 UP DOWN Page 3 3 1 Pump P V 000mA 2 Cooling Fan P V 000mA 3 Flow Control P V 0...

Page 783: ...Lights up when the return filter pressure switch is ON 10 Pilot Filter Clogged Lights up when the pilot filter pressure switch is ON 11 OWD Warning SW Lights up when the overload warning selector switch is ON 12 Brake Oil Press SW N A only for wheel type equipment 13 Pedal Press SW N A only for wheel type equipment 14 One Way Sel SW Lights up when the selector switch is turned to breaker 15 Two wa...

Page 784: ... Py 6 Pressure SW Px 19 Quick Coupler 20 F R Lever 21 Preheat Select 22 Reverse Fan SW 23 Pilot Cutoff SW N A N A N A 7 E G Oil Press SW 8 Air Cleaner Clogged 9 Return Filter Clogged 10 Pilot Filter Clogged 11 OWD Warning SW 12 Brake Oil Press SW N A N A N A N A 13 Pedal Press SW 14 One Way Sel SW 15 Two Way Sel SW 16 Power Max SW 17 Breaker SW 18 Preheat Select DIGITAL INPUT STATE DIGITAL INPUT S...

Page 785: ...record of past failure Digital Outputs Items Mark Remark 1 Relief Press Up S V ON OFF Lights up when the relief press up solenoid valve is ON 2 High Speed S V Lights up when the high speed solenoid valve is ON 3 Swing Priority S V Lights up when the swing priority solenoid valve is ON 4 Reverse Fan S V Lights up when the reverse fan solenoid valve is ON 5 Starter Relay When the starter relay is ON...

Page 786: ...xxxxxHrxxm It indicates the period for which machine has operated until a failure takes place For more than two occurrences of the same failure until the first occurrence time C Failure record deletion This mode is used to delete the memorized record of past failure If this mode is selected all records will be deleted When YES 3 on Figure 23 button is pressed the memorized record will be deleted A...

Page 787: ...reen will move to Failure Info screen It has been shown 3 seconds upon deleting Fail Log The screen shown on the left will appear 3 seconds in case of wrong password input and then Enter Password screen appears again It has been shown 3 seconds in case of password failure ESC No FG000568 Yes ENTER PASSWD DELETE FAIL LOG Figure 36 ESC No FG000569 Yes DELETED DELETE FAIL LOG Figure 37 ESC No FG00057...

Page 788: ...P V CN1 19 CN1 20 R 14 2 Ω 25 C 77 F Flow control proportional pressure reducing valve V213 Relief Pressure Up S V CN1 1 CN1 11 V V_volt Note 4 R 26 2 2 Ω 25 C 77 F Breaker boost shear selector switch has to be selected as a boost function and the boost switch on the right hand joystick is ON status V214 High Speed S V CN1 1 CN1 12 V V_volt R 26 2 2 Ω 25 C 77 F Voltage is only measured when the pr...

Page 789: ...ess Sensor CN3 1 CN3 2 V 1V It has to be measured in engine stop state V221 Rear Pump Press Sensor CN3 3 CN3 4 V 1V V222 Hyd Oil Temperature Sensor CN3 9 CN3 10 R 2 45 0 25 kΩ 25 C 77 F R 320 32 Ω 80 C 176 F V223 Water Temperature Sensor N A V224 Engine Speed Sensor N A V225 Fuel Level Sensor CN3 7 CN3 8 Empty 5 0 25 kΩ Full 320 32 Ω V226 Alternator Potential CN2 14 CN1 8 V 2 1V It has to be measu...

Page 790: ...R 186 5 Ω 100 C 212 F E018 E G oil pressure sensor 2 33 2 09 V 2 318 80mV at 23 C 73 F and absolute pressure 3bar It has to be measured in engine running state E021 Battery voltage 1 13 1 15 V V_volt Note 4 E022 Fuel pressure sensor 2 27 2 20 V 1 833 28mV at 23 C 73 F and absolute pressure 300bar It has to be measured in engine running state E032 Fuel pressure monitoring MPROP 2 7 2 5 R 2 60 3 15 ...

Page 791: ...r voltage C1 E051 Booster voltage C2 6 2 and 4 E058 Solenoid power stage 1 3 13 3 09 R 0 31 0 42 Ω 20 C 68 F E059 Solenoid power stage 2 3 03 3 06 E061 Solenoid power stage 3 3 04 3 12 E062 Solenoid power stage 4 3 05 3 14 E063 Solenoid power stage 5 3 11 3 16 E064 Solenoid power stage 6 3 10 3 15 E066 Preheat light E G Lowside Power stage 2 1 29 1 30 E072 Preheat relay E G Highside Power stage 1 ...

Page 792: ... controlled Highside power stage 1 Fuel metering unit error of high pressure pump E091 System start up test for shutoff path Power supply error Engine controller error E092 Monitoring of misfire cylinder 1 Injector error Speed signal error of cam shaft speed sensor or crank shaft speed sensor E093 Monitoring of misfire cylinder 2 E094 Monitoring of misfire cylinder 3 E095 Monitoring of misfire cyl...

Page 793: ...ALID but BELOW NORMAL OPERATIONAL RANGE FMI 2 Incorrect signal DATA ERRATIC INTERMITTENT OR INCORRECT FMI 3 Voltage above normal VOLTAGE ABOVE NORMAL OR SHORTED TO HIGH SOURCE FMI 4 Voltage below normal VOLTAGE BELOW NORMAL OR SHORTED TO LOW SOURCE FMI 5 Current below normal CURRENT BELOW NORMAL OR OPEN CIRCUIT FMI 6 Current above normal CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT FMI 8 Abnormal sign...

Page 794: ...ment panel ON status and Alternator signal CN2 14 is HI Travel Speed 1st 2nd Operation hours used low speed and high speed are displayed 1st High speed s v OFF status 2nd High speed s v and travel pressure switch Py control valve ON status Hydraulic Oil Temperature Distribution C F Temperature of hydraulic oil is classified 6 steps And operation hours of each step are displayed Under 30 C 87 F 31 ...

Page 795: ... Hydraulic Oil Temperature Distribution 6 Coolant Temperature Distribution FG000574 Figure 42 FG000575 OPERATING HOURS UP DOWN Page 1 3 UP DOWN Page 2 3 UP DOWN Page 3 3 1 Power 2 Trenching 3 Auto idle 4 Travel speed I Speed II Speed 00042 Hr 00003 Hr 00005 Hr 00007 Hr 00001 Hr 5 Hyd Oil Temp C 30 31 50 51 75 86 95 96 00003 Hr 00005 Hr 00008 Hr 76 85 00000 Hr 00007 Hr 00001 Hr 6 Coolant Temp C 40 ...

Page 796: ...e screen will recover to previous menu without resetting Machine Operation Info Screen 1 If you press the YES 3 on Figure 23 button password entrance screen appears 2 When right password is input machine operation periods will be deleted and Reset Completed screen will appear 3 seconds 3 If you press the NO ESC 4 button the previous screen appears without resetting operation periods ESC No FG00057...

Page 797: ...Electrical System Page 55 SP000269 ...

Page 798: ...TEM e EPOS Control System Schematic Work Mode Auto Idle Machine Info E G E G speed order FG000795 PO WE R UP C H E F H C POWER 1 5 2 3 6 7 AUTO 4 ESC 8 E G SPEED 02 05 MO 11 30 1700 RPM CHECK 5 4 4 3 8 8 7 7 16 6 6 11 12 14 13 15 10 9 2 17 21 19 18 22 20 23 1 Figure 49 ...

Page 799: ...Reducing Valve Attachment 10 Electromagnetic Proportional Pressure Reducing Valve Mode Control 11 Solenoid Valve Boost 12 Solenoid Valve Swing Priority 13 Solenoid Valve High Speed 14 Solenoid Valve Breaker 15 Travel Motor 16 Main Relief Valve 17 Engine Control Dial 18 Breaker Boost Shear Selector Switch 19 Auto Travel Selector Switch 20 Boost Switch Right Work Lever 21 Sensor 22 Aux Mode Switch 2...

Page 800: ...Figure 50 Reference Number Description 1 Instrument Panel Power Mode Selector Switch 2 e EPOS Controller 3 Engine Controller ECU 4 Main Pump 5 Aux Pump 6 Control Valve 10 Electromagnetic Proportional Pressure Reducing Valve Mode Control 17 Engine Control Dial 22 Aux Mode Switch 23 Aux Mode Resistor Reference Number Description ...

Page 801: ...ly defaulted to standard mode The desired mode can be selected by pressing the selector button on the instrument panel When the power mode is selected the indicator light will turn ON to display the selected mode The quantity of oil discharged by the pump and the engine speed are determined by the mode selected by the operator The pump output in each mode is determined by the mode selection and is...

Page 802: ...s 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 is decreased the controller increases the discharge volume of the pump to maintain the engine speed at the rated level By repeating these control operations the engine speed is maintained at the rated speed so that maximum power can be generated In Power M...

Page 803: ... System Page 61 SP000269 B D C A FG000580 Figure 52 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 804: ...ressure Reducing Valve controlling the discharge volume of pump due to fault in control system the machine can be operated in the aux mode Upon turning ON the aux mode switch the E P P R Valve controlling the discharge volume of pump comes into contact with the aux mode resistor to let current of a certain value flow At this time the discharge volume of pump follow the control by the pump regulato...

Page 805: ...Electrical System Page 63 SP000269 ...

Page 806: ...1 07 1 01 1 51 1 15 1 14 1 03 1 09 CONN 1 CONN 1 52 1 53 1 34 1 33 1 35 CN7 6 CN6 10 CN6 9 CN7 4 CN7 5 CN6 1 CN6 2 6 14 AMP 040 28P 18 7 15 6 7 3 9 10 11 12 16 8 6 5 4 7 8 1 2 CN2 AMP 070 18P 11 1 14 16 15 6 5 18 17 7 8 19 8 10 9 10 2 1 21 20 9 13 12 4 11 3 9 13 12 11 10 5 1 2 3 4 CN1 14 11 13 12 3 4 2 1 16 17 15 6 5 AMP MIC 21P GND CN3 17 B BR 15A 10A 5V SIG CN3 16 CN3 15 4 3 HIGH CW LOW 2 1 CAN ...

Page 807: ...ent Panel 3 Engine Controller 4 e EPOS Controller 10 E P P R Valve Electromagnetic Proportional Pressure Reducing 17 Engine Control Dial 22 Aux Mode Switch 23 Aux Mode Resistor 24 Battery 25 Battery Relay 26 Fuse 27 Fusible Link 28 Starter Switch Reference Number Description ...

Page 808: ... digging mode Depending on the trenching mode selected the control valve solenoid adjusts the assignment of hydraulic oil flow to each device on the equipment POWER 1 5 2 3 6 7 AUTO 4 ESC 8 2 17 1 5 4 4 6 6 12 3 FG000797 E G Figure 55 Reference Number Description 1 Instrument Panel Trenching Mode Selector Switch 2 e EPOS Controller 3 Engine Controller 4 Main Pump 5 Aux Pump 6 Control Valve 12 Sole...

Page 809: ...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 voltage is assigned to the swing priority control valve activating the swing control valve restricting the flow of oil to the boom and the arm ARO0270L Figure 56 ...

Page 810: ... CN4 5 CN6 1 CN6 2 10 11 12 CN6 15 14 9 13 12 11 10 CN7 9 7 8 16 4 9 10 11 16 13 14 15 12 6 5 CN2 18 17 14 18 19 16 17 15 21 20 CN1 6 7 8 5 1 2 3 4 3 1 2 AMP 040 28P 1 2 3 6 5 4 AMP 070 18P 7 8 4 7 8 6 5 AMP MIC 21P 10 9 13 11 12 3 2 1 C5 CN1 13 CN1 9 CN1 8 CN1 2 CN1 1 15A 15A 1 26 4 26 25 24 12 FG000583 Figure 57 Reference Number Description 1 Instrument Panel 2 e EPOS Controller 12 Solenoid Valv...

Page 811: ... controller converts this output voltage of dial to digital signal and sends it to the engine controller by CAN line According to the dial command the quantity of fuel injection is adjusted FG004980 Drive Signal Command Signal 3 4 17 Figure 58 Reference Number Description 3 Engine Controller 4 e EPOS Controller 17 Engine Control Dial Reference Number Description ...

Page 812: ...EW POTENTIOMETER BOTTOM 1st STEP 10 10 7th STEP 13th STEP CCW MECHANICAL STOP CW MECHANICAL STOP 2 3 2 3 1 2 3 4 2 5V 1 0V 4 0V 1ST 2nd 7th 12th 13th CW STOP CCW STOP 5 SETUP V 0 FG000866 Figure 59 Reference Number Description 1 Knob 2 Potentiometer Variable Resistor ...

Page 813: ...e 71 SP000269 The engine control dial has a built in potentiometer When the control knob is moved the output voltage through 2 and 3 terminals will vary from the 5 V supplied from the e EPOS controller as shown in the graph ...

Page 814: ...1 8 7 4 5 6 8 16 12 11 10 9 3 7 6 15 CN7 AMP 070 18P 8 7 17 18 5 6 15 16 14 1 11 3 11 4 12 13 9 20 21 1 2 10 9 10 8 19 CN2 4 3 2 1 5 10 11 12 13 9 CN6 AMP MIC 21P 5 6 15 17 16 1 2 4 3 12 13 11 14 CN1 CONN 1 1 07 1 12 1 13 1 39 1 09 1 03 1 14 1 15 1 01 1 34 1 33 1 53 1 52 CONN 1 51 VEHICLE 1 35 CN7 5 CN7 4 CN6 10 CN7 6 CN6 2 CN6 1 CN6 9 B BR 10A 15A 5V CN3 15 CN3 16 SIG CN3 17 GND 3 HIGH CW LOW 2 1...

Page 815: ...e Number Description 1 Instrument Panel 3 Engine Controller 4 e EPOS Controller 17 Engine Control Dial 24 Battery 25 Battery Relay 26 Fuse 27 Starter Switch 28 Fusible Link 29 Pressure Switch Py 30 Pressure Switch Px Reference Number Description ...

Page 816: ...TROL AUTO IDLE CONTROL POWER 1 5 2 3 6 7 AUTO 4 ESC 8 E G FG000798 2 4 1 3 5 5 Figure 61 Reference Number Description 1 Instrument Panel Auto Idle Switch 2 e EPOS Controller 3 Engine Controller 4 Engine Control Dial 5 Pressure Switch Reference Number Description ...

Page 817: ... on the instrument panel The initial setting at start up is with this switch in the select position Approximately 4 seconds after this function is selected if all work levers are in the neutral position the e EPOS controller compares the automatic reduction signal with the signal set by engine control dial The lower of the two signals is selected the e EPOS controller sends a signal to the engine ...

Page 818: ... E G E G overheating signal E G overheating signal Pump control signal FG000802 6 6 4 4 5 7 31 2 1 3 Figure 62 Reference Number Description 1 Instrument Panel 2 e EPOS Controller 3 Engine Controller 4 Main Pump 5 Aux Pump 6 Control Valve 7 E P P R Valve Electromagnetic Proportional Pressure Reducing Valve 31 Warning Buzzer Reference Number Description ...

Page 819: ... e EPOS controller The e EPOS controller sends a overheat signal to the instrument panel turning ON the warning light and buzzer simultaneously Also the e EPOS controller returns an overheat signal to the engine controller and changes power mode to standard mode The engine speed is then set to a low speed by the engine controller When coolant temperature falls below 95 C 203 F normal operation wil...

Page 820: ...PO WER UP E G FG000800 6 6 16 4 4 5 2 20 18 1 11 3 Figure 63 Reference Number Description 1 Instrument Panel 2 e EPOS Controller 3 Engine Controller 4 Main Pump 5 Aux Pump 6 Control Valve 11 Solenoid Valve Boost 16 Main Relief Valve 18 Breaker Boost Shear Selector Switch 20 Power Boost Switch Top of Right Work Lever Reference Number Description ...

Page 821: ...er boost button on the center of the right hand work lever joystick is pressed during work the e EPOS controller will activate the power boost solenoid valve and increase the relief valve pressure from 330 350 kg cm2 4 700 5 000 psi The excavation ability is increased by approximately 6 When the power boost function is in activated a power boost symbol appears on the information display department...

Page 822: ... 2 CN6 1 CN1 1 CN1 2 15A 15A AMP 040 28P 7 2 1 4 3 5 6 8 15 16 8 7 10 9 12 11 CN7 4 3 2 1 5 6 10 11 12 13 9 14 CN6 19 8 4 9 10 3 2 1 12 13 20 21 11 10 9 CN2 1 AMP MIC 21P 5 6 7 2 4 3 CN1 15 17 16 18 12 13 14 11 Center 6 12 3 14 11 6 15 16 13 PRESS PST SHEAR TML 3 1 0 10 9 UP BREAKER 2 20A FG000586 1 2 26 26 11 18 26 25 24 20 Figure 64 Reference Number Description 1 Instrument Panel 2 e EPOS Contro...

Page 823: ...Electrical System Page 81 SP000269 ...

Page 824: ...9 3 Figure 65 Reference Number Description 2 e EPOS Controller 3 Engine Controller 4 Main Pump 5 Aux Pump 6 Control Valve 7 Pressure Switch Py Port 8 Pump Pressure Sensor 13 Solenoid Valve High speed 15 Travel Motor 17 Engine Control Dial 19 Selector Switch For Automatic Travel Reference Number Description ...

Page 825: ...I speed travel solenoid valve based on the travel load The travel speed is changed between the I speed and the II speed mode The travel load is monitored by the two pressure sensors in the discharge lines of the front upper and rear lower pumps When the travel load is high pressure over 300 kg cm2 4 300 psi the solenoid valve is turned OFF and I speed low is selected In the case when the travel lo...

Page 826: ... 7 12 13 11 10 9 15 14 16 CN2 4 3 2 1 5 7 6 1 8 10 11 12 13 9 14 15 CN6 16 7 CN1 15 17 16 19 18 13 14 20 21 12 11 3 CN3 17 GND HIGH AMP 070 18P CN3 16 SIG 5V CN3 15 CW 2 1 LOW AMP MIC 21P 8 5 2 CN2 5 CN2 4 7 6 II I II 0 0 I 3 CN1 12 C3 CN1 1 CN1 2 15A 15A 15A 8 9 2 26 26 26 25 24 19 17 13 FG000587 Figure 66 Reference Number Description 2 e EPOS Controller 8 Pressure Sensor Front Pump 9 Pressure Se...

Page 827: ...n the input voltage to the e EPOS controller is below 18 5 1 V or above 32 5 1 V Stays ON while in normal range 2 Engine Speed Monitor This LED light flashes according to the engine speed The flashing interval is proportional to the engine speed 1 2 4 3 FG000588 Figure 67 Reference Number Description 1 Upper Digit 2 Lower Digit 3 Engine Speed Monitor LED Flash Interval Increases With Engine Speed ...

Page 828: ...Operation Status Upper Digit Lower Digit Power Mode Power Mode Normal Operation Power Mode Standard Mode Normal Operation Standard Mode Work Mode Digging Normal Operation Digging Mode Trenching Normal Operation Trenching Mode HAOH340L HAOH350L HAOH370L HAOH380L Error Code Indication Code Fault Location V201 01 Communication error in instrument panel V202 02 Communication error in engine controller...

Page 829: ... CONDITIONER SYSTEM Outline Solid type heater and air conditioner are installed in the cover behind the driver s seat Temperature of the driver s room is adjusted automatically to the temperature set by operator FG000784 A A C B C Figure 68 ...

Page 830: ... 500 hours If machine operates in an excessively contaminated environment filters should be cleaned more frequently and if necessary replaced with new ones How to check Indoor air filter 1 Press both levers on the left and right side at the top of the filter installed at the rear of the driver s seat How to check outdoor air filter 1 Open the front door at the left side of machine and loosen four ...

Page 831: ...he rear side of the cabin to open the cover 3 Remove the filter attached to the cover and clean the contaminated filter using compressed air 4 Close the cover replace the knobs and secure the cover to the support with butterfly bolts FG000441 1 Figure 71 FG000342 Figure 72 ...

Page 832: ...6 8 8 9 4 5 5 6 7 2 3 Figure 73 Reference Number Description 1 Air Conditioner heater Unit 2 Condenser 3 Compressor 4 Receiver Dryer 5 Discharge Hose 6 Suction Hose 7 Liquid Hose 1 8 Liquid Hose 2 9 Ambient Temperature Sensor 10 Sun Sensor 11 Control Panel Reference Number Description ...

Page 833: ...BL 0 85YG 1 SENSOR CN10 AMP 20P 2 CN10 17 1 INCAR CN11 KET 4P WATER SENSOR CN10 19 CN8 2 0 5OrB CN9 2 CN9 4 1 25BL 0 5YW CN9 1 0 5LgW CN9 3 CN9 18 0 5LgB 0 5YR CN9 10 1 25B ACTUATOR CN10 15 MIX F BACK GND CN10 4 CN10 9 DUCT SENSOR WARM P1 Vref MIX COOL P2 CN10 7 CN10 3 M Temp Control 0 85LW CN10 1 CN10 2 CN10 20 CN10 12 CN11 1 CN10 11 CN10 13 CN9 16 CN9 14 0 5YB 0 5OrW CN9 15 CN9 12 0 5OrR 0 5GrY ...

Page 834: ...ater Unit Air Flow Diagram VENT DEF FOOT Heater Core Evaporator Fan Internal Air External Air Vent Rear Outlet Cold Box Outlet External Air Inlet Internal Air Inlet Vent Front Outlet DEF Outlet Foot Outlet DOOR INTAKE DOOR MIX COOL WARM FG001359 Figure 75 ...

Page 835: ...F VENT Actuator Temp control Change of discharged air temperature by controlling the position of temp control door Door Mode Vent Bi level Foot Def foot Def Vent 100 60 0 0 0 Foot 0 40 100 80 60 Def 0 0 0 20 40 FG001360 Actuator Temp Control A C Relay Duct Sensor Blower Relay Air Flow Control Module Blower Motor Actuator Internal external Air Exchanger Internal Air Sensor Internal Air Filter Evapo...

Page 836: ...tor Temp control FG001361 Figure 77 Wind Direction Mode Output Terminal Voltage Vent c CN10 10 b CN10 4 0 5 0 2V Bi level 1 3 0 2V Foot 2 45 0 2V Foot def 3 5 0 2V Def 4 5 0 2V Set Temp Output Terminal Voltage Max cooling c CN10 9 b CN10 4 Below 0 4V Max heating Above 4 5V ...

Page 837: ...air flow is set manually CN10 20 CN10 2 FG001055 Figure 78 Sel mode Output Terminal Output Internal Air P1 P2 Moving of exchange door by selecting external air External Air P1 P2 Moving of exchange door by selecting internal air DRAIN CN10 1 SOURCE CN11 1 GATE CN10 6 FG001056 Figure 79 Air flow Output Terminal Output 1st CN11 2 CN10 1 10 0 5V 2nd 12 5 0 5V 3rd 15 0 5V 4th 17 5 0 5V 5th 20 0 0 5V 6...

Page 838: ...he evaporator The sensor consist of negative characteristic thermistor that resistant value increases and decreases when the temperature rises and falls respectively Figure 80 Specifications Rated voltage 24V Rated current 20A FG001058 L S1 S2 B Figure 81 Specifications Rated voltage 24V Rated current 10A Figure 82 Temp C Resistance KΩ Ω Ω Ω 0 11 36 0 1 2 10 39 0 2 2 5 10 17 0 2 3 9 95 0 2 3 5 9 7...

Page 839: ...ent Air Temperature Sensor Built at the bottom of the cockpit it senses the temperature of external air Figure 83 Temp C Resistance KΩ Ω Ω Ω 10 55 8 1 7 0 32 9 0 9 15 15 76 0 5 25 10 0 0 3 35 6 5 0 2 Figure 84 Temp C Resistance KΩ Ω Ω Ω 15 218 2 7 5 0 97 83 0 9 15 47 12 0 7 25 30 0 0 36 35 19 60 0 3 FG001064 Figure 85 Temp C Resistance KΩ Ω Ω Ω 10 163 4 9 0 96 9 2 9 10 59 4 1 8 20 37 4 1 1 25 30 0...

Page 840: ...er Control Panel Appearance and Terminal Arrangement Refer to Air Conditioner and Heater of operation manual 83 7 76 2 67 7 58 8 46 6 36 0 21 4 1 0 2 0 3 0 4 0 5 0 6 0 7 0 LUX x10 000 OUTPUT VOLTAGE mV FG001062 Figure 86 AUTO AUTO OFF TEMP A C A C MAX OUTSIDE SEL MODE FG001063 18 8 CN8 AMP 070 12P CN9 15 17 16 12 14 13 9 11 10 12 11 10 AMP 070 18P 6 5 7 4 1 3 2 5 4 6 7 8 9 1 2 3 Figure 87 ...

Page 841: ...edback 13 Intake Recirculate Intake 14 Wind direction control VENT 15 Wind direction control DEF 16 Wind direction control Power 5V 17 Wind direction control feedback 18 Temperature control cool Categories Inputs System Operation AUTO Set temperature Internal air temperature sensor Ambient air temperature sensor Water temperature sensor Sun sensor 1 Automatically adjust room temperature as set and...

Page 842: ...discharge of hot air before discharge temperature drops enough in hot summer weather 2 Start conditions AND condition 1 A C on AUTO or manual 2 Temperature sensed by the duct sensor is above 30 C 3 Air flow Auto mode 3 One time control in the cycle of engine OFF engine run 4 Initial cooling control is executed when the Auto switch is ON in the manual status A C OFF and manual control of air flow i...

Page 843: ...ycle of engine OFF engine run 3 Initial heating control should be before max heating 4 Air flow is controlled only when the wind direction is in the manual mode and BI LEVEL FOOT or FOOT DEF is set 5 Control through the water temperature sensor for start 6 Starting control of heating 2 starts in case of fault of the water temperature sensor during controlling 7 Operation release OR condition 1 Onl...

Page 844: ... heater 3 Difference between internal and ambient air temperature 15 C 4 When Max Cooling 17 C is selected 5 Exceptional case Starting control of heating is performed only once during the remaining period if the entry condition is satisfied within the starting control period that is the accumulation of initial start times Inclusive of Auto mode ON case within the period of starting control of heat...

Page 845: ...ycle of 0 5 sec ON and 0 5 sec OFF In case of two or more errors codes concerned blink twice at a time For normal E0 lights for error the first error code is indicated For 2 or more error error codes are indicated upstreams downstreams if the temp control switch is set to up down For normal condition only EO lights Press the SEL switch more than 3 times in 5 secs while pressing the A C switch Retu...

Page 846: ...E Display of ambient temp may be released in the same way for its entry way It returns automatically to default mode 5 seconds after entering the ambient air temp display mode Code Description E0 Normal E1 Internal Air Temp Sensor Short E2 Internal Air Temp Sensor Open E3 Ambient Air Temp Sensor Short E4 Ambient Air Temp Sensor Open E5 Duct Sensor Short E6 Duct Sensor Open E7 Sun Sensor Short E8 S...

Page 847: ...efrigerant from the condenser may contain refrigerant gas with bubbles whose presence in the expansion valve decreases the freezing power excessively it separates liquid and gas and sends liquid only to the expansion valve Water in refrigerant shall be eliminated with dryer and through filter Volume of refrigerant by model FG001365 Relief Valve Figure 90 Categories Specifications Output 155 3 cc r...

Page 848: ... the engine controller and controlling current of the cooling fan speed control valve Control of Reverse Rotation of Cooling Fan It is possible to clean radiator oil cooler and air conditioner condenser by reversing the rotation of the cooling fan It may be done in the following order 1 Start the engine 2 Turn the work interrupt switch OFF 3 Turn the cooling fan reverse rotation switch ON The cool...

Page 849: ...cription 4 Start Switch 7 Hydraulic Oil Temperature Sensor 14 e EPOS Controller 15 Battery 16 Battery Relay 17 Circuit Braker 19 Fuse Box 21 Engine Controller 22 Coolant Temperature Sensor 23 Cooling Fan Speed Control Valve 24 Work interrupt switch 25 Cooling Fan Reverse Rotation Switch 26 Cooling Fan Reverse Rotation Solenoid Reference Number Description ...

Page 850: ...15A 10A 2 8 CN13 KET 8P Continuous mode Intermittent 2 mode Intermittent 1 mode Washer mode 5 1 6 7 11 12 4 2 M 3 10 8 5 4 P 6 1 3 5 4 5 6 7 8 9 4 10 2 3 1 FG000589 Figure 94 Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Fuse Box 5 Wiper Motor 6 Wiper Controller 7 Wiper Switch Panel 8 Window Washer 9 Wiper Cutoff Switch 10 Light Switch Reference Number Description ...

Page 851: ...motor 5 are connected and thus power voltage is supplied to the 7 terminal of the wiper controller 6 The Wiper motor 5 stops reverse revolution when the contact of a cam switch connected to the 6 terminal of the wiper motor 5 moves to an insulation area of the cam plate to disconnect the 5 and 6 terminals of the wiper motor 5 When the wiper motor 5 stops arm and blade connected to it move to the s...

Page 852: ...Stopping the intermittent action Pressing three times the Intermittent switch in the switch panel 7 while the wiper is operating stops the action of the wiper motor NOTE The wiper system does not work when the wiper cutoff switch 9 is ON ...

Page 853: ...Electrical System Page 111 SP000269 ...

Page 854: ... 6 CN7 4 CN7 5 CN6 10 CN6 9 CN6 1 CN6 2 L6 CN4 5 CN4 4 CN4 6 CN1 9 CN1 8 CN2 6 CN1 2 CN1 1 CAN 30A 15A 15A 20A 15A 30 3 85 86 II I 0 II I 7 6 30 87 87a 0 2 2 8 5 8 5 II 3 I 7 6 I II 0 0 30 86 87a 85 87 87a 87 85 87 85 86 30 86 87a 16 14 9 8 10 11 3 2 1 4 15 13 7 6 12 5 FG000590 Figure 95 ...

Page 855: ...rk Light 2 ea 14 Front Cabin Light 4 ea 15 Rear Cabin Light 2 ea 16 Rear Work Light 1 ea Reference Number Description Switch Position ConnectedTerminal of switch Activated Relay Lit Light Light Switch 1 2 3 Terminal Illumination Light of Switch 2 2 3 Terminal Illumination Light of Switch 5 6 Terminal Headlight Relay Headlight 2 Ea Work Relay Work Light 2 Ea Indicator Light of Work Light L6 Cabin L...

Page 856: ... Vcc 5V 13 MICOM 2 15 RH LH ANTENNA MODULE 7 8 5 6 4 3 1 2 11 9 10 12 16 13 14 15 18 17 STEREO 1 2 3 4 Audio Control Panel 3 4 2 1 5 11 7 8 10 9 6 FG000591 Figure 96 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse Box 4 Fusible Link 5 Converter 6 Stereo Relay 7 Audio Control Panel 8 Stereo 9 Speaker 10 Antenna Module 11 Light Switch Reference Number Description ...

Page 857: ...age 115 SP000269 Operations Via Audio Control Panel Switch Connected Terminal of switch Measured values Operations PWR 3 4 4 36 0 2V Stereo ON OFF 1 24 0 2V Volume up 0 0 2V Volume down SCAN 2 49 0 2V Frequency selection ...

Page 858: ...SP000269 Electrical System Page 116 ...

Page 859: ...SP000275 Page 1 Electrical Schematic DX420LC SP000275 ELECTRICAL SCHEMATIC DX420LC SP000275 1Electrical Schematic DX420LC Edition 1 ...

Page 860: ...Electrical Schematic DX420LC SP000275 Page 2 MEMO ...

Page 861: ...SP000275 Page 3 Electrical Schematic DX420LC Table of Contents Electrical Schematic DX420LC Safety Precautions 5 Applicable Models 5 General Description 7 DX420LC 8 ...

Page 862: ...Electrical Schematic DX420LC SP000275 Page 4 MEMO ...

Page 863: ...Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up ...

Page 864: ...SP000275 Electrical Schematic DX420LC Page 6 ...

Page 865: ...6 5 1 3 0 5LW 0 85BrR 0 85BrL PEDAL SWITCH OPTION DIODE 9 6 2 DA6 1 5 1 1 0 85OrY DA6 2 0 85GY 0 85YL 426 00263 86 30 85 87a 87 0 85G 2544 9033 LOWER WIPER RELAY 0 85BR 0 85BR 0 85G 0 85Br 1 NC PREHEAT LAMP 0 85RY 0 85RY 0 5RG RxD TxD GND 1A 1B 2A 3A 4B 3B 8C 8A 7B 8B 9B 7A 10A 11A 6B 13A 89A 13C 11B 12A 14A 5A 4C 12C 14B 15B 14C 99 18B 131B 99 16A 17A 132A 99 88C 16B 65A 2C 2B 4D 4E 62B 132B 15A ...

Page 866: ... 85BrW 0 5WR 8 0 5WB 0 5RW 0 5WR OVER LOAD WARNING OPT CN6 12 CN6 11 CN6 3 11 12 3 OVER LOAD 549 00102 K1002406D4 WARNING SWITCH 2516 1116 PILOT BUZZER L1 539 00076B LCD GAUGE PANEL L3 L2 FRONT DIAGNOSTIC CONN 14P TERMINAL NO 3 2 1 7 6 5 4 548 00003A 2548 1027 DIODE 1 DIODE 2 8 0 5R 0 5R 0 5B 0 5B 1 CN6 1 CN6 2 CN6 10 CN6 9 2 10 9 CN2 87a 87 85 0 85RG 0 85B FL CABIN LAMP 534 00085 x2 2B 0 85B 0 85...

Page 867: ...3 4 7 8 AMP 070 12P 14 2 7 10 3 5 4 9 11 12 8 16 15 1 6 13 12 9 10 11 CN5 13 CN2 AMP 070 16P 1 2 8 7 14 16 15 18 17 5 4 6 1 2 3 9 10 11 12 CN11 4 M VENT P2 CN10 3 COOL P2 Vref MIX GND MIX F BACK CN10 9 CN10 7 CN10 4 CN10 15 Vref MODE WARM P1 MODE F BACK CN10 11 CN10 10 CN10 19 ACTUATOR M MIX MODE ACTUATOR BLOWER REC P2 FRE P1 DEF P1 CN10 2 CN10 20 CN10 12 CN10 13 CN10 6 CN10 5 CN11 1 CN10 1 M FET ...

Page 868: ...SP000275 Electrical Schematic DX420LC Page 10 ...

Page 869: ...1Attachments ...

Page 870: ......

Page 871: ...SP000463 Page 1 Boom and Arm SP000463 BOOM AND ARM SP000463 Boom and Arm Edition 1 ...

Page 872: ...Boom and Arm SP000463 Page 2 MEMO ...

Page 873: ...y Precautions 5 Applicable Models 5 Front Attachment Pin Specifications 6 Front Attachment Removal and Installation 8 Arm Removal Procedure 8 Boom Removal Procedure 10 Installation 11 Arm Installation Procedure 11 Boom Installation Procedure 11 Start up Procedures 11 ...

Page 874: ...Boom and Arm SP000463 Page 4 MEMO ...

Page 875: ...ll safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up ...

Page 876: ...ns for all mounting pins used on the front attachment NOTE Some mounting pins must be drilled and tapped for lubrication fittings and piping or may have other required specifications Consult DOOSAN After Sales Service for information on wear tolerances and replacement limits for mounting pins F G H I J K A B C D E FG004069 Figure 1 ...

Page 877: ...0 33 1 5 D Boom End 120 mm 4 724 0 10 0 15 0 18 0 03 0 13 0 33 1 5 E Arm Cylinder Head 110 mm 4 331 0 10 0 15 0 18 0 03 0 13 0 33 1 5 F Arm Cylinder Rod 110 mm 4 331 0 10 0 15 0 18 0 03 0 13 0 33 1 5 G Bucket Cylinder Head 110 mm 4 331 0 10 0 15 0 18 0 03 0 13 0 33 1 5 H Arm Link 100 mm 3 937 0 06 0 11 0 18 0 03 0 09 0 27 2 0 I Arm End 110 mm 4 331 0 10 0 15 0 18 0 03 0 13 0 33 2 0 J Bucket Cylind...

Page 878: ... structure is in line with the lower structure Never rotate the upper structure once the counterweight or front attachment has been removed IMPORTANT Always break down the front attachment by removing outermost sections first the bucket before the arm the arm before the boom Reinstallation of the attachment should begin with the boom and end with the bucket WARNING This procedure is only intended ...

Page 879: ...before disconnecting hydraulic lines and use evaporative type solvent spray cleaner Tag and mark hoses for reassembly if necessary Place a sling under the arm cylinder the cylinder used to extend and retract the attachment arm pinned to the top of the boom Lift the sling so that the weight load on the rod end of the arm cylinder pinned to the ears on the inner end of the arm is released Prepare bl...

Page 880: ...o the boom by tapping through the pin from the same side of the boom and repeat for the opposite cylinder Release hydraulic pressure and disconnect line couplings as previously outlined in the Arm Removal Procedure observing the same precautions Disconnect wiring for work light assemblies and any other accessory lines or connections Locate the sling of the assist crane near the center of gravity o...

Page 881: ...e pin the mounting connection Boom Installation Procedure Before reassembling the attachment make sure to inspect all bushings and pivot points of each section To avoid damaging the seats bushings should never be hammered or chiseled out of their seats Installation is otherwise a reversal of the removal procedures START UP PROCEDURES Once the boom has been serviced it should be lubricated as outli...

Page 882: ...SP000463 Boom and Arm Page 12 ...

Page 883: ...SP000072 Page 1 Bucket SP000072 BUCKET SP000072 1Bucket Edition 1 ...

Page 884: ...Bucket SP000072 Page 2 MEMO ...

Page 885: ...ons 5 Applicable Models 5 Bucket Tooth Inspection and Replacement 6 Bucket O ring Replacement 7 Bucket Shimming Procedures 9 New Bucket Installation 9 Bucket Attachment Removal and Reversal 11 Detaching the Bucket 11 Attaching the Bucket 11 Reversing the Bucket 12 ...

Page 886: ...Bucket SP000072 Page 4 MEMO ...

Page 887: ...ns and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX300LC 5001 and Up DX340LC 5001 and Up DX420LC 5001 and Up ...

Page 888: ...he 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 or breakage has not developed Do not allow the replaceable bucket teeth to wear down to the point that the bucket adapter is exposed See Figure 1 2 To replace a tooth 1 Figure 2 use a hammer and punch to drive th...

Page 889: ...the way 3 Remove the old O ring and temporarily install the new O ring 1 Figure 5 onto the bucket boss 2 Make sure that the O ring groove on both the bucket link 4 and boss have been cleaned 4 Realign the arm or link with the bucket pin hole and insert the bucket pin 3 Figure 4 WARNING Due to possibility of flying metal objects always wear safety helmet protective gloves and eye protection when ch...

Page 890: ...SP000072 Bucket Page 8 5 Roll the new O ring 1 Figure 6 into the O ring groove ARO1392L 1 Figure 6 ...

Page 891: ...osition and stop the engine Improperly adjusted clearance could cause galing on the contact surfaces of the bucket and arm resulting in excessive noise and damaged O ring Figure 7 Reference Number Description 1 No Gap 2 Arm Boss 3 Bucket Clearance 4 Shim 5 Pin 6 Stopper 7 Bolt 8 Hard Washer 9 Flange 10 Bucket Boss Reference Number Description FG000415 1 5 10 9 4 6 2 8 7 3 ...

Page 892: ...t boss 10 are in full face contact at no gap 1 3 Place the hydraulic activation control lever in the LOCKED position and stop the engine 4 Measure bucket clearance 3 determine the number of shim that need to be removed from shims 4 by using the following calculation Subtract 1mm from bucket clearance 3 5 Remove the appropriate number of shim at location 9 in order to meet the above thickness To re...

Page 893: ...ble 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 Bucket Carefully inspect all parts before reassembling the bucket linkage Look for cracks or any other evidence of physical damage and replace any seal or O ring that is not in like new condition Prelube lin...

Page 894: ...lified 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 Figure 9 FG000607 WARNING When making linkage alignments never insert fingers into pin holes The attachment or bucket could shift position and cause a severe injury Match holes by visually lining them up Use the sharp tipped soft point of a ...

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