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S0102000

Page 7

Track Excavator Safety

SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING
IN DIGGING MODE

To lift safely while in Digging Mode, the following items must be evaluated by the operator and the work site
crew.

•

Condition of ground support.

•

Excavator configuration and attachments.

•

Weight, lifting height and lifting radius.

•

Safe rigging of the load.

•

Proper handling of the suspended load.

Taglines on opposite sides of the load can be very helpful in keeping a suspended load secure, if they are
anchored safely to control points on the ground.

Always engage the "Digging Mode" control on the Instrument Panel before using the excavator for lifting
work.

DANGER!

Unsafe use of the excavator while making rated lifts could cause serious, potentially fatal
injuries or extensive damage to the 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 tagline around your hands or body.

NEVER rely on taglines or make rated lifts when wind gusts are more than 48.3 km/hr (30 mi/h).
Be prepared for any type of wind gust when working with loads that have a large surface area.

WARNING!

If you need more information or have any questions or concerns about safe operating
procedures or working the excavator correctly in a particular application or in the specific
conditions of your individual operating environment, please consult your local Daewoo
representative.

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Содержание Solar 300LC-V

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

Страница 2: ......

Страница 3: ...Product Label Instructions Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine Solar 300LC V Serial Number 1001 and Up Pub No 023 00043E Pub No 023 00043E...

Страница 4: ......

Страница 5: ...Structure Cab S0402040K Counterweight S0403050K Fuel Tank S0405110K Fuel Transfer Pump S0405500 Swing Bearing S0407000 Swing Reduction Gear S0408070K Lower Structure and Chassis Track Assembly S050500...

Страница 6: ...i S0708315K Main Control Valve Kayaba S0709401K Pilot Control Valve Work Lever Joystick S0709451K Travel Control Valve With Damper S0709820K Hydraulic Schematic S300LC V S0792160K Electrical System El...

Страница 7: ...1SAFETY...

Страница 8: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 47: ...1SPECIFICATIONS...

Страница 48: ......

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

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

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

Страница 52: ...S0202080K Page 4 Specifications for Solar 300LC V COMPONENT LOCATIONS Figure 1 1 2 3 4 5 6 11 10 9 7 8 12 13 14 15 16 17 18 19 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 35 ARO0980L...

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

Страница 54: ...S0202080K Page 6 Specifications for Solar 300LC V...

Страница 55: ...34 10 10 705 mm 35 1 10 700 mm 35 1 B 3 200 mm 10 6 C 7 420 mm 24 4 7 505 mm 24 7 7 500 mm 24 7 D 4 010 mm 13 2 E 4 930 mm 16 2 F 1 175 mm 3 10 G 3 365 mm 11 0 3 515 mm 11 6 3 930 mm 12 11 H 2 960 mm...

Страница 56: ...ends 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 inju...

Страница 57: ...22 1 7 980 mm 26 2 D Max Loading Height 7 286 mm 23 11 6 960 mm 22 10 7 475 mm 24 6 F Max Digging Height 10 345 mm 33 11 9 985 mm 32 9 10 520 mm 34 6 G Max Bucket Pin Height 8 890 mm 29 2 8 565 mm 28...

Страница 58: ...lb Lower below Swing Bearing 11 050 kg 24 360 lb Digging Forces Bucket Cylinder 177 KN or 18 100 kg 39 900 lb with either 3 100 mm 10 2 or 2 500 mm 8 2 arm Arm Cylinder 131 KN or 13 400 kg 29 500 lb...

Страница 59: ...gth standard boom and arm 10 620 mm 34 10 Overall Shipping Width standard shoes 3 200 mm 10 6 Overall Shipping Height to top of cylinder hose 3 365 mm 11 Track Shipping Length 4 930 mm 16 2 Transport...

Страница 60: ...2 Specifications for Solar 300LC V ENGINE PERFORMANCE CURVES PER DIN 6270 STANDARD REVOLUTION rpm POWER OUTPUT ps 1000 150 2000 1500 FUEL CONSUMPTION g ps h 170 90 70 TORQUE kg m 160 100 200 80 150 AR...

Страница 61: ...arometric Pressure 760 mmHg 20 C 68 F Cooling Fan 711 mm SUCKER 28 in Alternator 24V x 50A Air Cleaner Installed Muffler Installed Performance Standard DIN 6270 Power 200 ps 1 900 rpm 197 hp 1 900 rpm...

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

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

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

Страница 65: ...4 2 0 4 3 5 0 4 Down sec 2 8 0 4 2 7 0 4 Arm Dump sec 3 1 0 4 2 8 0 4 Crowd sec 4 5 0 4 3 8 0 4 Bucket Dump sec 3 1 0 4 2 6 0 4 Crowd sec 3 8 0 4 3 5 0 4 Swing 3 Revolutions sec 19 5 1 0 16 5 1 0 Jack...

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

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

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

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

Страница 70: ...S0202080K Page 22 Specifications for Solar 300LC V...

Страница 71: ...1GENERAL MAINTENANCE...

Страница 72: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 99: ...1UPPER STRUCTURE...

Страница 100: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 118: ...S0405110K Page 2 Fuel Tank TABLE OF CONTENTS General Description 3 Parts List 4 Specifications 5 Removal 6 Installation 10 Start up Procedures 12...

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

Страница 120: ...S0405110K Page 4 Fuel Tank PARTS LIST 3 7 5 6 4 10 9 23 8 12 11 1 13 16 19 20 14 34 33 ARS1660L Figure 1...

Страница 121: ...S gal Reference Number Description 1 Fuel Tank 3 O ring 4 Cover 5 Bolt M10x1 5x25 6 Spring Washer M10 7 Drain Valve 8 Bolt 9 Shim 10 Shim 11 Fuel Filter 12 Cap 2188 9004 13 Plug SP 14 Level Gauge 16...

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

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

Страница 124: ...nd fuel return line 2 from tank 3 and carefully drain remaining fuel from lines 15 Remove clamp 4 Figure 7 holding fuel return line 2 to tank 3 16 Tag and disconnect wires leading to fuel sensor 1 Fig...

Страница 125: ...Remove six bolts and washers 4 Figure 12 holding tank 3 to frame Lift tank 25 mm 1 and make sure it is balanced Make sure that there are no other electrical wires or hoses connected to tank Completely...

Страница 126: ...ged Be careful of obstacles and wind gusts 3 Install shims 5 Figure 13 as needed to prevent tank 3 from rocking or stress from mounting bolts 4 4 Tighten mounting bolts 4 Figure 13 after shims are ins...

Страница 127: ...fuel tank 2 10 Connect as tagged fuel supply line 1 Figure 18 and fuel return line 2 to fuel tank 3 11 Install clamp 4 Figure 18 to hold fuel return line 2 to tank 3 12 Make sure fuel tank drain valve...

Страница 128: ...er head 2 Unscrew and pump the hand operated primer pump Figure 21 by the fuel injection pump Pump primer until fuel is present at plug hole in fuel filter head 3 Tighten plug in fuel filter head 4 Co...

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

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

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

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

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

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

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

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

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

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

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

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

Страница 141: ...tices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely hand...

Страница 142: ...rts List 4 Specifications 5 Special Tools and Materials 6 Special Tools 6 Tool A 6 Tool B 6 Tool C 7 Tool D 7 Tool E 7 Tool F 8 Troubleshooting Testing and Adjustment 9 Removal 10 Disassembly 12 Clean...

Страница 143: ...and two step output reduction The planetary gear engages with the ring gear The pinion gear is connected with the output shaft and spline The final drive reduces swing motor RPM in order to increase...

Страница 144: ...S0408070K Page 4 Swing Reduction Gear PARTS LIST 1 5 7 8 9 10 11 12 21 20 19 18 17 2 4 6 13 14 15 16 22 24 25 27 26 28 3 1 3 2 29 23 ARS2590L Figure 1...

Страница 145: ...ring Pin 15 No 2 Planetary Gear 16 No 2 Side Plate 17 Gear Case 18 Lock Ring 19 Pinion Gear 20 Cover 21 Hex Bolt M16x40 22 Collar 23 Seal 24 Plate 25 Bearing 26 Shaft 27 Bearing 28 Lock Wire 29 Spacer...

Страница 146: ...90 mm 7 4803 in B 220 mm 8 6614 in C 350 mm 13 7795 in Dimension Measurement A 156 mm 6 1417 in B 130 mm 5 1181 in C 3 mm 0 1299 0 1378 in D 128 mm 5 0394 in E 20 mm 0 7874 in F 120 mm 4 7244 in G 268...

Страница 147: ...7559 in B 6 mm 0 2362 in C 6 mm 0 2362 in D 18 mm 0 7087 in Dimension Measurement A 60 mm 2 3622 in B 80 mm 3 1496 in C 150 mm 5 9055 in Dimension Measurement A 108 mm 4 2520 in B 138 mm 5 4331 in C...

Страница 148: ...S0408070K Page 8 Swing Reduction Gear Tool F Dimension Measurement A 128 mm 5 0394 in B 158 mm 6 2205 in C 150 mm 5 9055 in ARS2650L A B C Figure 7...

Страница 149: ...epair 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 t...

Страница 150: ...icks in all directions to relieve pressure from accumulators 7 Set safety lever on LOCK position 8 Turn key to OFF position and remove from starter switch 9 Hang maintenance warning tag on controls 10...

Страница 151: ...e 9 13 Disconnect hose 2 Figure 9 from main frame by loosening nut 3 14 Disconnect grease lubrication line 7 Figure 9 from reduction gearbox 5 15 Remove twelve bolts and washers 4 Figure 9 holding swi...

Страница 152: ...duction Gear DISASSEMBLY 1 Drain oil from port A 2 Using a pipe wrench remove oil level gauge 3 1 and pipe 3 2 PT1 4 3 Using L wrench remove socket bolts 2 and motor 1 TANK 1 A 3 2 3 1 ARS2660L Figure...

Страница 153: ...socket bolts 4 and cover 5 5 Remove sun gear No 1 6 and carrier assembly No 1 7 Remove thrust plate 10 IMPORTANT Do not remove carrier assembly No 1 7 in field because pin No 1 and carrier No 1 are ca...

Страница 154: ...rive spring pin 14 into shaft No 2 13 This will allow shaft to be pressed out of carrier No 2 8 Remove shaft No 2 13 from carrier No 2 12 Remove spring pin 14 from shaft No 2 13 Remove planetary gear...

Страница 155: ...0 Remove wire 28 and hex bolt 21 by using socket wrench Remove cover 20 and pinion 19 11 Remove lock ring 18 Put jig D on shaft 26 and press shaft assembly 22 24 25 and 26 out 9 8 ARS2730L Figure 17 2...

Страница 156: ...AND TOLERANCES For general cleaning and inspection procedures refer to General Maintenance Procedures section Inspect all components in the assembly Pay particular attention to oil seals lock and spri...

Страница 157: ...ing 25 and press bearing 25 on shaft 26 until contact is obtained 2 Install plate 24 on shaft 26 Position Jig A on collar 22 and press collar 22 on shaft 26 until contact is obtained A 25 29 26 Hydaru...

Страница 158: ...ith lock wire 28 diagonally NOTE Apply Loctite 262 to bolt threads NOTE Tighten bolt to 2 700 kg cm 195 ft lb 4 Put jig A on pinion gear and press shaft assembly with pinion into case 17 until contact...

Страница 159: ...nto shaft assembly until contact is obtained 7 Insert lock pin 9 in case 17 and install ring gear 8 on case 17 NOTE Coat mating faces of case 17 and ring gear 8 with Loctite 609 IMPORTANT When install...

Страница 160: ...carrier No 2 12 and shaft No 2 13 9 Install carrier assembly No 2 onto ring gear 8 and shaft assembly Install sun gear No 2 11 in carrier assembly No 2 10 Insert thrust plate 10 in sun gear No 2 11 I...

Страница 161: ...00 kg cm 195 ft lb 12 Secure motor 1 onto cover plate 5 with socket bolt 2 Install pipe 3 2 onto cover plate 5 Insert oil level gauge 3 1 into pipe NOTE Coat mating faces of cover plate 5 and motor 1...

Страница 162: ...ion gearbox 5 as an assembly on unit 4 Install twelve bolts and washers 4 Figure 34 to secure swing reduction gearbox 5 to frame NOTE Apply Loctite 262 to bolt threads NOTE Tighten bolt to 95 kg m 690...

Страница 163: ...rottle at LOW IDLE and swing upper structure slowly two full revolutions to the left and right 4 Shut the engine down and check the hydraulic oil level Fill hydraulic oil tank to H mark on sight gauge...

Страница 164: ...S0408070K Page 24 Swing Reduction Gear...

Страница 165: ...1LOWER STRUCTURE AND CHASSIS...

Страница 166: ......

Страница 167: ...manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately...

Страница 168: ...ont Idler Roller 12 Parts List 12 Front Idler Roller Disassembly 13 Front Idler Roller Reassembly 15 Lower Roller 16 Parts List 16 Lower Roller Removal 17 Lower Roller Disassembly 17 Lower Roller Reas...

Страница 169: ...G Safely measuring track tension requires two people One person must be in the operator s seat running the controls to keep one side frame in the air while the other person makes dimensional checks Ta...

Страница 170: ...is hard and full of rocks or gravel 4 The increased clearance recommended for muddy ground conditions is between distance D on below table The clearance should be approximately distance E on below ta...

Страница 171: ...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...

Страница 172: ...general recommendations and specific safety precautions before starting any lower travel frame component rebuilding procedure Component Reference Dimensions Reference Normal New Dimension Recommended...

Страница 173: ...1 741 42 3 mm 1 665 41 2 mm R 1 622 Master pin Lower roller axle A 75 mm 2 953 74 5 mm 2 933 74 2 mm R 2 921 Lower roller bushing A 75 5 mm 2 972 76 mm R 2 992 Axle bushing clearance 1 0 mm 0 039 1 8...

Страница 174: ...r roller axle A 55 mm 2 165 54 5 mm 2 146 54 2 mm R 2 134 Upper roller bushing A 55 5 mm 2 185 56 mm R 2 205 Axle bushing clearance 1 0 mm 0 039 1 8 mm 0 071 Flange thickness bushing B 6 5 mm 0 256 5...

Страница 175: ...ont idler bushing A 90 5 mm 3 563 91 mm R 3 583 Axle bushing clearance 1 0 mm 0 039 1 8 mm 0 071 Gap between bushing and side collar Total amount for both sides B 1 0 mm 0 039 1 5 mm 0 059 Front idler...

Страница 176: ...o clock from top position on travel reduction gearbox 4 Remove four nuts and bolts 2 Figure 13 holding shoe to link Remove enough shoes to make access to lock pin easier NOTE Support track shoes with...

Страница 177: ...aise track frame off blocking 3 With blocking removed lower track frame onto track Make sure all rollers are properly positioned on track 4 Move unit backwards while feeding track up over front idler...

Страница 178: ...S0505000 Page 12 Track Assembly FRONT IDLER ROLLER PARTS LIST Figure 18 Reference Number Description 1 Bearing 2 Plug 3 Pin 4 O ring 5 Axle 6 Group Seal 7 Idler 8 Bushing Reference Number Description...

Страница 179: ...emove plug 2 Figure 19 and drain oil from roller assembly 1 2 Separate the pin 3 Figure 20 from the bearing 1 3 Use a press to remove the bearing from the axle Separate the O ring 4 Figure 21 from the...

Страница 180: ...Detach the group seal 6 Figure 22 from the idler 7 and bearing 1 5 Use a press to separate the axle 5 Figure 23 O ring 4 and bearing 1 6 Remove bushing 8 Figure 24 with the press and special tool ST 1...

Страница 181: ...ing 1 Figure 25 and axle 5 holes and pin 3 them together 4 Install group seal 6 Figure 26 inside the idler 7 and bearing 1 NOTE Apply clean engine oil to the joint side of the group seal Apply grease...

Страница 182: ...S0505000 Page 16 Track Assembly LOWER ROLLER PARTS LIST Figure 28 Reference Number Description 1 Pin 2 O ring 3 Collar 4 Axle 5 Roller 6 Group Seal 7 Bushing 8 Plug Reference Number Description...

Страница 183: ...rame There is an alignment pin on each end of lower roller assembly NOTE To gain access to some rollers the link guard may have to be removed Remove four spring washers and bolts to remove guard NOTE...

Страница 184: ...tach collar 3 Figure 32 and O rings 2 from the axle using a press LOWER ROLLER REASSEMBLY 1 Degrease clean and dry all parts before reassembly Insert bushing 7 Figure 33 into roller 2 Apply grease to...

Страница 185: ...e inside the roller 6 Install the collar 3 Figure 36 O ring 2 and pin 1 on the remaining side 7 Fill with clean engine oil with approximately 350 cc 3 4 pint LOWER ROLLER INSTALLATION 1 Install four b...

Страница 186: ...rack Assembly UPPER ROLLER PARTS LIST Figure 38 Reference Number Description 1 Plug 2 Bolt 3 Cover 4 Bolt 5 Washer 6 Roller 7 Axle 8 Group Seal 9 Bracket 10 Bushing 11 O ring 12 Lock Washer Reference...

Страница 187: ...ck on top of track frame and apply pressure to track shoe 3 Remove mounting hardware holding upper roller assembly to track frame UPPER ROLLER DISASSEMBLY 1 Remove the plug 1 Figure 40 from the cover...

Страница 188: ...000 Page 22 Track Assembly 4 Separate the group seal 8 Figure 43 from the roller and bracket 9 5 Separate the bushing 10 Figure 44 from the roller with a press and special tool ST 1919 Figure 43 Figur...

Страница 189: ...nto the roller 6 and bushing NOTE Apply clean engine oil to the joint side of the group seal Apply grease to the group seal O ring 3 Install the axle washer 5 Figure 47 and bolt 4 4 Attach group seal...

Страница 190: ...S0505000 Page 24 Track Assembly 7 Tighten plug 1 Figure 48 Figure 48...

Страница 191: ...S0505000 Page 25 Track Assembly TRACK SPRING AND TRACK ADJUSTING CYLINDER PARTS LIST Figure 49...

Страница 192: ...mber Description 1 Piston Rod 2 Piston Ring 3 Backup Ring 4 Packing 5 Retaining Ring 6 Rod 7 O ring 8 Cylinder 9 Spring 10 Spacer 11 Flange 12 Nut 13 Valve 14 Bolt 15 Plate 16 Yoke 17 Socket Bolt 18 F...

Страница 193: ...1ENGINE AND DRIVE TRAIN...

Страница 194: ......

Страница 195: ...ned within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own pers...

Страница 196: ...ir Discharge According to Path Selection 10 Air conditioning System Circuit Diagram 12 Troubleshooting 14 Weight of R134a Gas Used In Machines 17 Refrigerant System Repairs 18 Refrigerant Safe Handlin...

Страница 197: ...air filtration system which filters out dirt and dust particles from air being circulated into operator s cab This filter should be cleaned out every 500 hours NOTE In the event that the unit is being...

Страница 198: ...e 3 and inspect for any damage 6 Use compressed air to clean filter element If filter element is very dirty use a mild soap or detergent and water to clean it NOTE If water was used to clean filter be...

Страница 199: ...nditioner REFRIGERANT CIRCULATION 1 2 3 4 5 6 HDA6046L Figure 4 Reference Number Description 1 Evaporator 2 Expansion Valve 3 Condenser 4 Condenser Fan 5 Compressor 6 Blower Fan 7 Receiver Dryer Refer...

Страница 200: ...ir surrounding the evaporator creating a cooling effect and changes from the gas to the liquid state The refrigerant once again flows into the compressor in the gaseous state and the process is repeat...

Страница 201: ...UT CONTROL PANEL OUTPUT A C CONTROL PANEL DISPLAY LOW SPEED RELAY TEMPERATURE SENSOR MID SPEED RELAY HIGH SPEED RELAY BLOWER MOTOR VENT ACTUATOR DEF ACTUATOR INTAKE ACTUATOR COMP RELAY CONDENSER FAN R...

Страница 202: ...consists of a 24 step variable selector The display uses 7 Green Red two color LEDs to display the selected temperature Blower Fan Speed Control OFF Switch LOW Switch MID Switch HI Switch Compressor C...

Страница 203: ...Green 3 28 V 0 2 8 Red Red Green Green Green Green Green 3 11 V 0 2 9 Red Red Red Green Green Green Green 2 93 V 0 2 10 Red Red Red Green Green Green Green 2 76 V 0 2 11 Red Red Red Green Green Green...

Страница 204: ...S0605060K Page 10 Air Conditioner AIR DISCHARGE ACCORDING TO PATH SELECTION Face Rear and Defroster Foot ARS1280L Figure 10 ARS1290L Figure 11...

Страница 205: ...S0605060K Page 11 Air Conditioner Face and Defroster ARS1300L Figure 12...

Страница 206: ...HRS 26P 14 9 2 7 15 9 26 16 CN5 16 2 1 4 15 4 5 6 1 2 COOL 15 CN5 AMP MIC 13P 13 6 12 11 4 5 10 9 3 7 8 2 1 15 8 M 15 1 87 9 87a 87 M 85 8 87a 7 10 30 BLOWER SPEED TEMP CONTROL RECIRCLE FRESH AIR MOD...

Страница 207: ...elay 10 Foot Defrost Control Actuator 11 Receiver Dryer Low High Pressure Cut Off Switch 12 Diode 13 Compressor 14 A C Control Panel 15 A C Unit 15 1 Blower Motor 15 2 Resister 15 3 High Speed Relay 1...

Страница 208: ...y 1 Check for traces of refrigerant oil Yes Reassemble using correct tightening torque No Go to next step 2 Using a leak detection device or soapy water check for refrigerant leakage at all major comp...

Страница 209: ...3 46 9 psi Yes Moisture in system replace receiver dryer No Contaminated system replace expansion valve Replace evaporator core assembly 5 High Pressure Over 6 18 kg cm2 85 256 psi Low Pressure 500 m...

Страница 210: ...r Conditioner 7 High Pressure Over 7 0 11 0 kg cm2 100 156 psi Low Pressure 4 0 6 0 kg cm2 57 85 psi Possible Cause Low refrigerant pressure due to poor compressor compression Inspect and replace comp...

Страница 211: ...Solar 170LC V 850 20 grams 30 0 7 oz Solar 170W III 1100 20 grams 38 0 7 oz Solar 200W III 1100 20 grams 38 0 7 oz Solar 200W V 850 20 grams 30 0 7 oz Solar 220LC III 950 20 grams 33 0 7 oz Solar 220L...

Страница 212: ...em standards require new tools equipment and parts DO NOT attempt to use equipment use in servicing the old refrigerant system WARNING Always wear protective glasses and gloves when handling refrigera...

Страница 213: ...efrigerant system with the engine running do not open the high pressure valve on the manifold gauge as the reverse flow of high pressure refrigerant will rupture the hose 10 When releasing the high pr...

Страница 214: ...R AIR LEAKAGE VACUUM SYSTEM OVER 20 MINUTES CHARGE SYSTEM APPROXIMATELY 100 g CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHARGE SYSTEM TO PROPER LEVEL Standard Capacity less Initial Charge CHECK SYSTEM FOR...

Страница 215: ...uge dials indicates 0 kg cm2 0 psi VACUUMING REFRIGERANT SYSTEM 1 Vacuuming Procedure NOTE When the A C system has been exposed to the air it must be vacuumed out Perform vacuum process for 30 minutes...

Страница 216: ...he mounting disk is in the raised position B Attach the manifold gauge center hose to the valve assembly C Turn the disc in the clockwise direction and securely mount valve onto refrigerant container...

Страница 217: ...e engine running When exchanging refrigerant containers press the manifold gauge low side valve to eliminate air from the charging hose 2 Charge the system by opening the manifold gauge low side valve...

Страница 218: ...from vehicle WARNING When charging refrigerant system with the engine running Always keep refrigerant supply container in the upright position Never open the high side pressure valve Gauge Dial Stand...

Страница 219: ...sor outlet condenser inlet receiver dryer inlet air conditioner unit inlet 2 Low pressure side Compressor inlet air conditioner unit outlet 3 Compressor Compressor shaft area bolt hole area and magnet...

Страница 220: ...S0605060K Page 26 Air Conditioner...

Страница 221: ...those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is...

Страница 222: ...S0609010K Page 2 Drive Coupling Main Pump TABLE OF CONTENTS Drive Coupling 3 Special Tools 4 Drive Coupling Installation 6 Installation Procedure 8...

Страница 223: ...it is very important to properly adjust clearance between the face of the coupling hub and end of pump drive shaft Measurement H shown in the following procedure to a specific value Figure 1 thru Fig...

Страница 224: ...d Figure 5 This distance will be referred to as Measurement H in the installation instructions that follow NOTE In manufacturing drawings Figure 4 dimension A and B equal the Measurement H The two too...

Страница 225: ...Dimension Measurement Models A 6 0 1 mm 0 2362 0 0039 in S300LC V S300LL B 7 0 1 mm 0 2756 0 0039 in S340LC V S420LC V S470LC V C 20 0 mm 0 787 in D 7 0 mm 0 275 in E 18 0 mm 0 708 in Radius F 22 0 m...

Страница 226: ...ive coupling for main pump is installed the following mounting dimensions and installation procedures must be observed NOTE If these procedures are not followed noise will occur and or the service lif...

Страница 227: ...Pin 4 2 Insert 4 3 Bolt 4 Ta 4 Flywheel 1 5 Spring Pin 8 6 Insert 4 7 Hub 1 8 Bolt 4 Ta 9 Pump shaft 1 10 Clamping screw 2 Tb 11 Element 1 Table 2 Specification for Measurement H and Torque Refer to...

Страница 228: ...ews 10 NOTE Tighten clamping screws to value Tb in the tables NOTE Coat clamping screws 10 with Loctite 262 5 Install element 11 between inserts 2 on engine flywheel 4 6 Install main pump and hub 7 by...

Страница 229: ...1HYDRAULICS...

Страница 230: ......

Страница 231: ...safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and...

Страница 232: ...rcuit 8 Swing Operating Circuit 8 Right Swing Operating Circuit 9 Left Swing Operating Circuit 9 Swing Relief Valve and Make up Valve 9 Travel Operating Circuit 9 Forward Travel Circuit 10 Reverse Tra...

Страница 233: ...and Flow Meter Kit Installation and Testing 21 Swing System Troubleshooting 23 Precautions Initial Checks 23 Swing Relief Valve Checking and Adjustment 23 Troubleshooting Swing Gearbox 25 Troubleshoot...

Страница 234: ...ncy 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...

Страница 235: ...cuit for these functions the output of both pumps can be combined allowing higher speed operation Boom up arm crowd and dumping functions can operate in any one of the two available power modes the st...

Страница 236: ...ondary boom up pilot pressure that is transmitted to the BOOM1 and BOOM2 spools of the control valve simultaneously When secondary pilot pressure reaches 7 9 kg cm2 100 130 psi boom control valve spoo...

Страница 237: ...the AM1 and AM2 spools of the control valve simultaneously When secondary pilot pressure reaches 7 9 kg cm2 100 130 psi the arm control valve spools AM1 and AM2 open Output flow from both halves of th...

Страница 238: ...ump flows to the bucket cylinder BUCKET DUMP CIRCUIT When the bucket control lever is put in the dump mode the bucket control valve spool in the left half of the control valve opens to supply oil from...

Страница 239: ...LVE AND MAKE UP VALVE Whenever the spool is shifted to the neutral mode during swing operation the possibility exists that surge pressure in the circuit caused by inertial momentum of the upper works...

Страница 240: ...achine REVERSE TRAVEL CIRCUIT When the right and left travel control levers are pushed backward output from both main pumps is directed through the PR PL TRRR and TRLR ports on the control valve throu...

Страница 241: ...t the pump drive flex coupling pull out the electrical tray under the operator s seat to inspect the self diagnostic display If the EPOS trouble code display is clear check hydraulic functions in the...

Страница 242: ...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 t...

Страница 243: ...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 sp...

Страница 244: ...uid back into the system if excessive fluid was lost To verify operation of the swing priority solenoid valve connect test equipment and begin testing with the work mode switch set to digging the stat...

Страница 245: ...Pressure must be 350 bars 5075 psi or up to 10 bars 145 psi higher Because one adjustment can affect the other check low stage main relief pressure by repeating the cylinder stall test without pressu...

Страница 246: ...tment NOTE The electrical pressure up power boost solenoid valve located alongside the swing priority solenoid and arm speed control solenoid in compartment rear of the operator s cab must be operatin...

Страница 247: ...tently overloaded and engine troubleshooting shows engine performance to be at or above rated output If reduced cylinder speed and diminished work performance provide an indication that rated maximum...

Страница 248: ...low 1 and 2 Each one of the adjustment procedures could affect the setting of the others Check and record the arm dump speed performance test before and after input power adjustment whether or not a f...

Страница 249: ...horsepower 1 4 turn on the adjusting screw is equal to approximately 17 horsepower NOTE For each full turn of adjustment on the larger diameter screw 2 the square tipped adjusting screw should be turn...

Страница 250: ...justing screw 1 Figure 16 affects the delivery rate Q of the pump Tightening the adjusting screw decreases the maximum cut flow as shown in Figure 15 while backing out the screw increases cut flow del...

Страница 251: ...te fittings and adapter flanges to guarantee a pressure tight seal NOTE Be sure to maintain even tightening torque on all flange fittings Use Loctite brand PST 545 or an alternate manufacturer s hydra...

Страница 252: ...book If test results do not measure up to specified values pump output tests can be repeated using different control levers Recheck front pump operation while stroking the bucket cylinder out lever a...

Страница 253: ...Investigate unusual operating noises or vibration Check for loose bolts connections SWING RELIEF VALVE CHECKING AND ADJUSTMENT Make a check of operating pressures through the swing relief valve if Th...

Страница 254: ...pressure through the port is at the recommended level the brake release valve should disengage the swing brake allowing the swing motor to rotate the excavator If pressure adjustment to the valve has...

Страница 255: ...motor drain rate Replace Repair motor Gear train defective Refer to Swing Gear Troubleshooting procedure Swing functions but only at reduced RPM Causes listed above could also produce dragging swing O...

Страница 256: ...al damaged Assembly compound joint sealer old and not sealing bolt not tight or flange warped Replace oil seal Disassemble and check mating surfaces Reapply Loctite torque bolts to specifications Exce...

Страница 257: ...valve malfunction Readjust or replace Oil leak at make up valve Clean repair Control valve spool damaged Repair or replace Dirt in control valve spool Clean or replace Actuator joystick foot pedal dam...

Страница 258: ...contamination Disassemble clean main poppet Broken or damaged spring Replace Adjusting screw loose Readjust Main poppet sticking Repair replace Clogged orifice in pilot passage to control valve Clean...

Страница 259: ...ents worn out past wear limits Replace Problem Possible Causes Remedies Secondary pressure does not increase Low primary pressure Check primary pressure Broken spring Replace spring Spool sticking Cle...

Страница 260: ...sembly Secondary pressure too high Dirt other interference between valve parts Clean repair or replace Return line pressure too high Redirect return line Secondary pressure does not hold steady Dirt o...

Страница 261: ...thin this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal r...

Страница 262: ...S0703010K Page 2 Accumulator TABLE OF CONTENTS General Description 3 Specifications 4...

Страница 263: ...and out and an elastic diaphragm to separate the two chambers The flexible diaphragm changes shape to conform to the changing pressures and volumes of the two fluids in the upper and lower chambers T...

Страница 264: ...ge pressure the flexible diaphragm begins to retract upward 4 When system oil is at highest working pressure and the accumulator fills to maximum reserve capacity the flexible diaphragm is pushed up i...

Страница 265: ...S0703010K Page 5 Accumulator Solar 470LC V S N 1001 thru 1049 Pilot Travel 10 kg cm2 140 psi 320 cc 19 53 in3 S N 1050 and Up 750 cc 45 77 in3 Model Serial Number System Charge Pressure Volume...

Страница 266: ...S0703010K Page 6 Accumulator...

Страница 267: ...d in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Rem...

Страница 268: ...S0704080K Page 2 Center Joint Swivel TABLE OF CONTENTS General Description 3 Parts List 4 Troubleshooting Testing and Adjustment 5 Inspection 5 Testing 5 Disassembly 6 Reassembly 7...

Страница 269: ...RIPTION The center joint swivel is designed to allow hydraulic oil from the upper structure to flow to components in the lower structure It is capable of allowing continuous 360 rotation of the upper...

Страница 270: ...10E 10H 10I 10J 10C 10C 10C 10B 10K 10G ARS1730L Figure 1 Reference Number Description 10A Body 10B Spindle 10C Seal 10D O ring 10E Thrust Plate 10F Retaining Ring 10G O ring 10H Cover 10I Spring Was...

Страница 271: ...of the excavator A high pressure relief valve with a setting pressure 1 5 times maximum system pressure A stop valve A manually operated in line change over valve Install the change over valve upstre...

Страница 272: ...or emergency tear down use a thin but rounded tip smooth edge scraper or spatula to remove O rings or seals to avoid causing damage to those that must be reused NOTE The backup ring shown in the asse...

Страница 273: ...fill the center swivel with clean hydraulic fluid prior to reassembly of high pressure and drain line piping Clean and pre fill piping line ends to reduce the amount of air in the system Bleed air fro...

Страница 274: ...S0704080K Page 8 Center Joint Swivel...

Страница 275: ...Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE Solar 130LC V 0001 and Up Solar 130W V 0001 and Up Solar 170LC V 1001 and Up Solar 170W V 1001 and Up Sol...

Страница 276: ...TENTS General Description 3 Theory of Operation 3 Parts List 4 Special Tools and Materials 6 Piston Nut 6 Piston Jig 10 Steel bush Jig 14 Dust Wiper Jig 18 Slipper Seal Jig 22 Slipper Seal Straighteni...

Страница 277: ...shown as oil path A or to the front of the cylinder oil path B The cylinder rod is extended as oil flow is pumped through the circuit to the back side of the piston The force F1 of the piston stroke c...

Страница 278: ...it does to lengthen it Q1 Q2 PARTS LIST The following parts list is a partial listing only for full and complete parts list information refer to the Hydraulic Equipment Component Parts List Cross sect...

Страница 279: ...t 8 Retaining Ring 9 Rod Cover 10 O ring 11 O ring 12 Backup Ring 13 Piston Rod 14 Cylinder Tube 15 Cushion Ring 16 Piston 17 Slide Ring 18 Wear Ring 19 Slipper Seal 20 O ring 21 Backup Ring 22 Piston...

Страница 280: ...Page 6 Cylinders SPECIAL TOOLS AND MATERIALS PISTON NUT B A D C 0 2 0 1 0 2 0 1 R R15 R20 C3 C5 35 350 ARS4730L 15 4 R 0 5 Through Hole 8 Figure 6 Material SM45C AISI 1045 Rockwell Harden from 22 27 O...

Страница 281: ...OM S200N V BUCKET OPTION BOOM OP 125 0 mm 4 92 in 85 0 mm 3 35 in 12 0 mm 0 47 in 5 0 mm 0 20 in S130W V ARM S130LC V SHORT ARM S170W V BUCKET S220LC V BUCKET S220LL BUCKET BUCKET 115 0 mm 4 53 in 75...

Страница 282: ...n S470LC V ARM S55W V ARM 106 0 mm 4 17 in 66 0 mm 2 60 in 12 0 mm 0 47 in 5 0 mm 0 20 in S80W II ARM 120 0 mm 4 72 in 79 0 mm 3 11 in 10 0 mm 0 39 in 5 0 mm 0 20 in S70 III ARM S80W II BOOM MEGA 130...

Страница 283: ...S0705000 Page 9 Cylinders...

Страница 284: ...S0705000 Page 10 Cylinders PISTON JIG C 35 A 30 R R15 20 2 B D R F 2 Through Hole 8 15 ARS4740L 4 R5 Figure 7 Material SM45C AISI 1045 Rockwell Harden from 22 27 Oil Quench...

Страница 285: ...BUCKET MEGA 200 III LIFT S290LC V ARM S ARM 120 0 mm 4 72 in 13 0 mm 0 51 in 85 0 mm 3 35 in 150 0 mm 5 91 in S290LL BUCKET BOOM S300LC V ARM S ARM S330LC V BOOM BUCKET S340LC V BUCKET BOOM BUCKET OP...

Страница 286: ...S0705000 Page 12 Cylinders P S Power Steering O R Out Rigger MODEL CYLINDER A 0 1 B C D MODEL CYLINDER...

Страница 287: ...S0705000 Page 13 Cylinders...

Страница 288: ...e 14 Cylinders STEEL BUSH JIG 20 A 20 5 A F 15 1 B 40 E ARS4750L B Figure 8 Material SM45C which is done thermal refining QT Hrc 22 28 Undefined Chamfer C R 0 5 Max Place Finally work to used DNMG Tip...

Страница 289: ...4 in S70 III ARM BOOM MEGA 200 III LIFT MEGA 200 III TC H C S220LL ARM 90 0 mm 3 54 in 105 0 mm 4 13 in 40 0 mm 1 58 in 6 5 mm 0 26 in S290LC V S ARM ARM S290LL BOOM BUCKET S300LC V S ARM ARM MEGA 250...

Страница 290: ...5 51 in 70 mm 2 76 in 11 mm 0 43 in K C S420LC V BOOM K C S400LC V BOOM K C S55W V BUCKET 50 0 mm 1 97 in 60 0 mm 2 36 in 30 0 mm 1 18 in S55 V ARM BOOM OP BUCKET DOZER 65 0 mm 2 56 in 75 0 mm 2 95 in...

Страница 291: ...S0705000 Page 17 Cylinders...

Страница 292: ...rs DUST WIPER JIG D C DIA B 40 15 3 C1 5 DIA B DIA A DIA A 20 R0 2 1 ARS4760L Figure 9 Material SM45C which is done thermal refining QT Hrc 22 28 Undefined Chamfer C R 0 5 Max Place Finally work to us...

Страница 293: ...0 mm 3 31 in 5 5 mm 0 22 in 6 0 mm 0 24 in S80W III BOOM S130W V BOOM S130LC V BOOM MEGA 160 III BUCKET BUCKET 55 0 mm 2 17 in 69 0 mm 2 72 in 5 0 mm 0 20 in 6 0 mm 0 24 in S55 V ARM BOOM BOOM OP BUC...

Страница 294: ...0 mm 0 24 in 7 0 mm 2 28 in S290LC V ARM 105 0 mm 4 13 in 121 0 mm 4 76 in 6 0 mm 0 24 in 7 0 mm 2 28 in S290LC V S ARM S300LC V ARM S ARM S370LC V BOOM S ARM 105 0 mm 4 13 in 121 0 mm 4 76 in 6 0 mm...

Страница 295: ...0 20 in 6 0 mm 0 24 in S80W III ARM 65 0 mm 2 56 in 79 0 mm 3 11 in 5 5 mm 0 22 in 6 0 mm 0 24 in BOOM 70 0 mm 2 76 in 84 0 mm 3 31 in 5 5 mm 0 22 in 6 0 mm 0 24 in BUCKET 55 0 mm 2 17 in 69 0 mm 2 7...

Страница 296: ...S0705000 Page 22 Cylinders SLIPPER SEAL JIG ARS4770L A 2 A A 14 B B 40 5 R 1 0 R1 1 0 Figure 10...

Страница 297: ...OIST S290 V BOOM BUCKET S BUCKET BOOM 130 0 mm 5 12 in 28 5 mm 1 12 in S250LC V BUCKET S290LC V ARM 150 0 mm 5 91 in 28 5 mm 1 12 in S290LL BOOM HOIST BUCKET HEEL S290LC V S ARM S300LC V ARM S ARM S34...

Страница 298: ...S0705000 Page 24 Cylinders S200W V BOOM 135 0 mm 5 32 in 28 5 mm 1 12 in S220LC V ARM S220N V ARM OP P S Power Steering MODEL CYLINDER A B MODEL CYLINDER 0 2 0 1 0 2 0 1...

Страница 299: ...S0705000 Page 25 Cylinders...

Страница 300: ...S0705000 Page 26 Cylinders SLIPPER SEAL STRAIGHTENING JIG ARS4780L 2 R1 50 25 100 A 15 A 2 5 R 2 C 1 Figure 11...

Страница 301: ...BUCKET S220LL BOOM HOIST S290 V BOOM BUCKET S BUCKET BOOM 130 0 mm 5 12 in S250 V BUCKET S290LC V ARM 150 0 mm 5 91 in S300LC V ARM S ARM S340LC V BOOM BUCKET BUCKET OP S370LC V BOOM BUCKET BUCKET OP...

Страница 302: ...S0705000 Page 28 Cylinders S200W V BOOM 135 0 mm 5 32 in S220LC V ARM S220N V ARM OP P S Power Steering CYLINDER A MODEL CYLINDER 0 2 0 1...

Страница 303: ...or other protective material around piston rod to avoid possibility of accidentally scratching or scoring rod surface while fasteners are being loosened and removed Component parts numbered in parenth...

Страница 304: ...d of cylinder wall before using a plastic or other soft faced hammer for final disassembly 5 Begin withdrawing piston rod assembly away from cylinder Attach a lifting support when final 1 3 of rod is...

Страница 305: ...through end of rod 8 Remove set screw by using a socket wrench 9 Fabricate or purchase a piston nut removal wrench Dimensions are called off at beginning of this procedure This tool may also be ordere...

Страница 306: ...er to evenly pull off rod cover 9 from end of piston rod Be careful not to damage rod bushing 6 and dust wiper U packing and other seals 12 Use a dull rounded tip tool to pry off O ring 11 and backup...

Страница 307: ...ing 21 from cylinder head 15 During disassembly of cylinder head be careful not to damage buffer seal 5 and U packing 4 16 Disassemble retaining ring 3 and dust wiper 2 Separate retaining ring 8 and r...

Страница 308: ...S0705000 Page 34 Cylinders 17 Force out pin bushing 1 from body of cylinder Figure 28...

Страница 309: ...nents install the dust wiper 2 and rod bushing 6 to the rod cover 9 Insert retaining rings 3 and 8 IMPORTANT Replace any part that shows evidence of damage or excessive wear Replacement of all O rings...

Страница 310: ...inning of this procedure to attach seal Cool seal by pushing a retracting jig against seal for several minutes Apply a strip of clean see through sealing tape around slipper seal to keep it free of du...

Страница 311: ...before reassembly 10 Pre apply fastener locking compound Loctite 242 or 243 or an alternate manufacturer s equivalent product to all end cover retaining bolts Wrap a protective cushion around end of r...

Страница 312: ...S0705000 Page 38 Cylinders...

Страница 313: ...shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of sa...

Страница 314: ...s 15 Special Tools 15 Pressing Tool of Inner Ring 2 and Taper Roller Bearing 4 Inner Race 15 Assembly Tool for Oil Seal 3 15 Assembly Tool for Brake Piston 13 15 Troubleshooting Testing and Adjustment...

Страница 315: ...of Spring 28 Reassembly of Balance Plate 29 Reassembly of Inner Race 29 Reassembly of O ring 29 Applying Liquid Packing 30 Reassembly of Cover 30 Tightening of Bolt Tightening of Cover 19 and Housing...

Страница 316: ...spring 6 to slide on cam plate 7 The strength of scrowave 18 and the hydraulic power which actuates bushing 16 cause the mating surfaces of balance plate 24 and cylinder block 27 to be pressed togethe...

Страница 317: ...All nine pistons in the cylinder block have equal bore diameter length and volume They are configured in a concentric layout around the drive shaft as shown in the cross sectional end view in Figure...

Страница 318: ...uses pressure c to turn into negative pressure since the motor starts to act like a pump Since the motor is now acting as a pump make up oil is needed to supply oil in c However if pressure at port B...

Страница 319: ...a resistance against spring 49 which forces open poppet 48 so that oil can pass through oil passages g and h from port B thus opening make up check 36 and allowing oil to flow into passage c During t...

Страница 320: ...mber of check 64 on side A the side A check 64 pushes the side B check 64 to the left until it contacts seat 62 on side A This action closes the bypass passage while reducing speed of the upper struct...

Страница 321: ...ver the swing controls are engaged to swing in one direction or the other IMPORTANT Along with the swing brake a 2 position positive swing lock has also been provided It should be secured whenever the...

Страница 322: ...spring 16 Figure 4 locks up the friction plate 11 split plate 12 and swing motor casing 301 preventing the motor drive shaft from turning When hydraulic pressure is forced to the back side of the bra...

Страница 323: ...rated When pressurized oil flowing into port SH is stopped as in condition 2 spool 73 is pushed to the right side end by spring 77 and closes port PG and PB Pressurized oil from port PB flows out to p...

Страница 324: ...S0707270K Page 12 Swing Motor Toshiba MFC200 PARTS LIST Figure 6...

Страница 325: ...ston 14 O ring 15 Spring 16 Bush 17 Teflon Ring 18 Scrowave 19 Cover 20 O ring 21 Cap 22 Parallel Pin 23 Piston 24 Balance Plate 25 Needle Bearing 26 Snap Ring 27 Cylinder 28 Housing 29 Plug 30 Bypass...

Страница 326: ...77 kg cm 565 psi 100 Release Pressure Allowable Pressure 49 97 kg cm 710 psi Rotating Direction B Port Inflow Clockwise A Port Inflow Counterclockwise Allowable Viscosity Range 10 1000 mm2 s Allowable...

Страница 327: ...g Motor Toshiba MFC200 SPECIAL TOOLS AND MATERIALS SPECIAL TOOLS Pressing Tool of Inner Ring 2 and Taper Roller Bearing 4 Inner Race Assembly Tool for Oil Seal 3 Assembly Tool for Brake Piston 13 Figu...

Страница 328: ...internal damaged Open inlet and outlet port of motor apply pilot pressure of 3 9 4 9 Mpa to brake release port and then check the turning of output shaft with torque of about 30 40 Nm over one revolu...

Страница 329: ...k fluid in tank and motor case Bleed air fully Fastening parts loose Check pipe laying parts fastening part bolts motor fastening bolts and each motor fastening part bolts Fasten suitable tightening t...

Страница 330: ...valves or timer This could result in them being deformed and or malfunctioning No INSPECTION PARTS CORRECTION a Wear of sliding part of balance plate 24 Repair or replace parts b Damage of sliding pa...

Страница 331: ...nent to cool to 40 C or below Working on this component when it is at higher temperatures can result in burns When disconnecting hoses from component always work after allowing pressurized air and oil...

Страница 332: ...ex hole size 17 mm and cover 19 from housing 4 Remove snap ring 26 inner race of needle bearing 25 and balance plate 24 5 Remove piston 23 from balance plate 24 NOTE Be careful not to scratch the slid...

Страница 333: ...8 Remove springs 15 from piston 13 NOTE Match mark springs 15 with piston 13 9 Piston 13 will not come out of housing 28 due to sliding resistance of O rings 12 and 14 Remove it using tap holes M6 in...

Страница 334: ...4 and oil seal 3 will remain in housing 28 3 Keep the sliding surface A of cylinder 27 covered until installation This will protect it from damage 4 Mark or number piston holes of cylinder 27 and pist...

Страница 335: ...ng bearing puller 2 Remove collar 5 from cylinder 27 Remove cam plate 7 return plate 8 and piston assembly 9 from cylinder 27 3 Remove cam plate 7 from sliding surface of piston assembly 9 by sliding...

Страница 336: ...each part for damage when disassembling If it is damaged repair it with fine grade oil stone or crocus cloth as necessary Then thoroughly clean it with a suitable cleaning oil and dry it with moistur...

Страница 337: ...f return plate 8 3 Install piston assembly 9 and return plate 8 into cylinder 27 NOTE Install piston assembly 9 into holes of cylinder 27 in the original position NOTE When reassembling apply hydrauli...

Страница 338: ...to it and press fit inner ring 2 using special tool Install snap ring 1 NOTE Use extreme care not to get Loctite on the rollers of taper roller bearing 4 NOTE Clean off remaining Loctite between inner...

Страница 339: ...king spring 6 is inserted in the spot facing of return plate 8 NOTE When installing cylinder assembly as the spline of cylinder 27 is out from the under part of housing 28 put a support of 30 50 mm un...

Страница 340: ...and 14 REASSEMBLY OF BRAKE PISTON 1 Apply hydraulic oil to the circumferential sliding surface of piton 13 and install it to housing 28 NOTE Since there is an interference between piston 13 and O rin...

Страница 341: ...reassembling direction which was marked before disassembling of balance plate 24 and cover 19 NOTE Fully apply grease to piston 23 and pin 22 for stopping turning of balance plate of cover 19 and inst...

Страница 342: ...ing 28 lift cover 19 by hand and install it to housing 28 slowly NOTE Align and install cover 19 to housing 28 according to the installation position marked before disassembling NOTE The clearance bet...

Страница 343: ...RMING OF REASSEMBLY 1 Open inlet and outlet port of motor apply pilot pressure of 3 9 4 9 Mpa to brake release port and then check the turning of output shaft with torque of about 30 40 Nm over one re...

Страница 344: ...case with hydraulic oil If motor is operated without hydraulic oil it can result in internal parts being damage After fully filling motor with oil operate it at a no load condition and low speed for...

Страница 345: ...ctices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely han...

Страница 346: ...Troubleshooting Testing and Adjustment 23 Hydraulic Motor 23 General Caution Matters 23 Inspection method of abnormality of hydraulic motor 23 Cause and remedy of trouble 23 Travel Reduction Gear 25 G...

Страница 347: ...aring 18 of Housing 1 Part 44 Selection Method of Shim 15 Thickness 45 Reassembling of Floating Seal 19 46 Reassembling of Housing 1 and Shaft Casing 25 46 Reassembling of Stopper 27 46 Reassembling o...

Страница 348: ...erating rotating force Cross over relief valve Negative brake Counter balance valve Swash tilting assembly 3 Reduction gear consists of two speed differential gear represented by the following graphic...

Страница 349: ...F1 P x A P Supply pressure A Pressure area The force F1 generates perpendicular force N1 and radial force W1 against swash plate 201 which has a tilting angle of W1 generates torque T T W1 x R1 again...

Страница 350: ...A poppet A is opened and hydraulic oil flows from chamber A to port B 3 Operation of negative brake Pressurized oil entering through counter balance spool 361 in valve casing forces brake piston 702 t...

Страница 351: ...t Oil in chamber N flows through orifice I to chamber Dv drains from port Bv to tank and spool moves to left then oil flows to K to Dv and to Bv Passages of Cv H and P are constructed so that pressure...

Страница 352: ...le creating more torque A External pilot pressure Pi 0 Large tilt angle If pilot pressure does not act on tilting valve the position of swash plate 201 is set at a large tilting angle Swash plate 201...

Страница 353: ...a small tilt angle Reduction Gear 1 Operation Reduction gear consists of a compound planetary gear assembly The compound gear assembly changes the high speed low torque input from the hydraulic motor...

Страница 354: ...ts planetary motion and revolution of gear P1 rotates carrier C1 Rotation of carrier C raises differential motion among gears R1 R2 P1 and P2 and rotates ring gear R1 This ring gear R1 rotates housing...

Страница 355: ...S0707315K Page 11 Travel Motor with Gearbox...

Страница 356: ...368 367 350 369 366 381 464 485 567 506 572 571 531 533 534 541 543 542 567 568 568 350 464 381 361 364 363 362 369 367 368 365 384 485 383 382 485 567 461 546 401 509 507 568 568 567 567 402 568 384...

Страница 357: ...ket Bolt 368 Hex Socket Bolt 369 O ring 381 Plunger C B Valve 382 Stopper Check 383 Backup Ring 384 Spring Check 401 Hex Socket Bolt 402 Hex Socket Bolt 435 Lock Ring 451 Valve Plate Pin 452 Support P...

Страница 358: ...S0707315K Page 14 Travel Motor with Gearbox Reduction Gear 19 1 18 27 31 30 29 30 7 8 22 17 6 11 20 16 17 30 29 30 23 24 14 10 10 32 3 32 12 9 4 13 5 21 15 2 28 20 ARS3970L Figure 12...

Страница 359: ...al 20 Needle Roller 21 Snap Ring 22 Hex Socket Head Bolt 23 Hex Bolt 24 Plug 27 Stopper 28 Spacer 29 Collar 30 Thrust Washer 31 Hex Head Bolt 32 O ring Reference Number Description Travel Motor Specif...

Страница 360: ...S0707315K Page 16 Travel Motor with Gearbox SPECIAL TOOLS AND MATERIALS SPECIAL TOOLS JIG 1 JIG 2 JIG 3 JIG 4 JIG 5 JIG 6 ARS3990L Figure 13...

Страница 361: ...S0707315K Page 17 Travel Motor with Gearbox JIG 7 JIG 8 JIG 9 JIG 10 JIG 11 JIG 12 ARS4000L Figure 14...

Страница 362: ...S0707315K Page 18 Travel Motor with Gearbox JIG 13 JIG 14 JIG 15 JIG 17 JIG 18 ARS4010L JIG 19 20 JIG 16 Figure 15...

Страница 363: ...G 19 Cluster Gear 6 JIG 20 Carrier 9 Tools Applicable Parts Section Name Standard Remark Tool Hex L wrench Nominal dimension 4mm Plug 24 Hex wrench Nominal dimension 17mm Bolt 22 Socket wrench Nominal...

Страница 364: ...S0707315K Page 20 Travel Motor with Gearbox Etc Air pressure 6 kg cm2 85 psi Oil bath Heating temperature over 120 C Vacuum cleaner...

Страница 365: ...spanner 19 mm Hp Plug 567 27 mm Hp Plug 464 36 mm Relief Valve 350 Snap ring pliers For hole or shaft Stop Ring 107 108 Plastic hammer Also wood hammer is possible Steel bar 7x7x200 Needle Bearing 10...

Страница 366: ...mm 750 567 HP Plug PF 1 4 19 mm 370 545 546 Orifice screw NPTF 1 16 4 mm 70 368 Hex socket bolt M12x30L 10 mm 1 000 367 Hex socket bolt M10x30L 8 mm 670 401 Hex socket bolt M16x50L 14 mm 2 400 402 Hex...

Страница 367: ...roblem Possible Cause Remedy Travelling device fails to operate Motor pressure does not increase Oil is bypassed at relief valve 350 Replace or repair relief valve Check spring damaged Replace check s...

Страница 368: ...parts Brake operation is difficult Brake torque low Friction and separation plate worn Replace worn parts Brake spring damaged Replace brake spring Brake does not operate Parts in brake stuck Replace...

Страница 369: ...use Remedy Temperature of reduction gear housing is high Over 60 C of ambient temperature Gear oil is insufficient Lubricating poor due to insufficient gear oil Fill gear oil in rated quantity Bearing...

Страница 370: ...nd output side indicates front side 6 Before applying Loctite completely remove oil from mating surfaces using Loctite 587 and uniting them 7 When tightening bolts apply Loctite 262 to bolt threads an...

Страница 371: ...and shaft 11 5 Remove calking mark of carrier 9 and pull pin 12 using a pulling tap M6x1 6 Tap and drop shaft 11 under jig 3 by using copper hammer 7 Pull cluster gear 6 and remove thrust washer 30 t...

Страница 372: ...B17 11 Remove coupling gear subassembly from shaft casing using bolts 3 ea M10x1 5x70 and pulling tap of coupling gear 5 12 Put it with coupling gear subassembly facing ground by using eye bolts 2 ea...

Страница 373: ...f ring gear No 1 3 facing ground 16 Pull out floating seal 19 from housing by using drive and separate O ring and seal 17 Pull out floating seal 19 from shaft casing by using drive and separate O ring...

Страница 374: ...05 NOTE Spring 10ea Hole 11ea 6 Remove brake piston 702 from shaft casing 272 7 Remove piston ring 708 278 and 707 252 from brake piston 702 8 Turn disassembling and reassembling jig 90 and set it wit...

Страница 375: ...e drive shaft subassembly NOTE Lightly tap and remove cylindrical roller and outer race of bearing 102 by using copper bar and plastic hammer 16 Remove oil seal 491 17 Remove fixing pin 709 from separ...

Страница 376: ...rical bush 122 from cylinder block 111 Disassembly of Valve Casing 1 Remove drain HP plug 464 with O ring 485 2 Remove O ring 472 from valve casing 3 Remove swash spool 531 swash spring 533 and O ring...

Страница 377: ...ol 361 10 Remove HP plug 567 with O ring 568 NOTE 5 places 11 Remove seat 541 ball 543 stopper 542 and HP plug 567 with O ring 568 12 Remove needle bearing 103 NOTE Use plastic hammer and copper bar 1...

Страница 378: ...AR LIMITS AND TOLERANCES For general cleaning and inspection procedures refer to General Maintenance Procedures section MAINTENANCE STANDARD Change parts with standard of the following table If parts...

Страница 379: ...spline 49 06 48 46 Over pin diameter 4 5 of spline inside of cylinder and spherical bush 35 25 35 75 Replace Thickness of separate plate 3 3 3 Thickness of friction plate 2 3 2 1 Free length of brake...

Страница 380: ...h Gearbox 1 Clearance between piston and cylinder bore D d 2 Thickness of shoe t 3 Vibration of vertical direction of piston and shoe 4 Height difference of spherical bush and pressure plate H h Figur...

Страница 381: ...Ring gear No 2 Coupling gear 0 200 0 608 1 30 Coupling Sun gear spline 0 1 0 2 0 5 OPD Ring gear No 1 386 106 368 514 Ring gear No 2 337 482 337 678 Base tangent length Cluster gear No 1 63 259 63 344...

Страница 382: ...n heater to heat fit of cylindrical roller bearing and adjust temperature to about 100 C NOTE Be careful not to damage oil seal contacting part of drive shaft 2 Install stopper ring 107 by using plier...

Страница 383: ...der and direction of seat and stopper NOTE Tightening torque 370 kg cm 27 ft lb 5 Install HP plug 567 with O ring 568 NOTE Five places NOTE Tightening torque 370 kg cm 27 ft lb 6 Tighten orifice screw...

Страница 384: ...12 1 000 kg cm 72 ft lb M10 670 kg cm 48 ft lb 10 After tighten plug 571 with O ring 572 to proper torque insert swash spool 531 swash spring 533 and O ring 509 NOTE Tightening torque 750 kg cm 54 ft...

Страница 385: ...er torque NOTE After winding seal tape and applying Loctite to plug install it NOTE Tightening torque 70 110 kg cm 5 8 ft lb 2 Press pin 709 for securing separate plate 741 using hammer and round bar...

Страница 386: ...plate moves smoothly 8 Install swash piston 502 and stopper 503 9 Turn disassembling and reassembling jig 90 so shaft is changed from a horizontal position to a vertical position NOTE Be careful not t...

Страница 387: ...and size 546 2ea 1 5 546 1ea 0 8 NOTE Tightening torque 70 kg cm 5 ft lb 16 After inserting valve plate 131 to valve casing tighten it to shaft casing by means of hex socket bolts 401 and 402 NOTE 1 A...

Страница 388: ...ture to 100 5 C 2 Fully submerge housing 1 into oil bath by using two eye bolts of M10 and crane Be careful not to contact bottom of housing 1 to bottom of oil bath NOTE Prevent uneven heat 3 Take out...

Страница 389: ...4 and measure F by using jig 2 or jig 11 6 Calculate T3 T3 F D 7 Calculate T T T1 T3 0 1 T2 8 Select shim 15 thickness Ts with value T from below table Method is to decide most approximate value Part...

Страница 390: ...Do not damage seal surface when using jig 14 NOTE Pay attention to intruding of foreign materials Pay attention to damaging of O ring Reassembling of Housing 1 and Shaft Casing 25 1 After attaching tw...

Страница 391: ...of end surface of pin 13 hole of coupling gear 5 with 180 space by using punch and prevent pin 13 from dropping NOTE Refer to Figure 77 3 After lightly applying Loctite 262 to threads of hex socket bo...

Страница 392: ...rrier 9 by using hammer and jig 9 Using a punch close end surface of pin 12 hole of carrier 9 with two points 180 apart Figure 77 to prevent pin 12 from coming out 6 Install the remaining two cluster...

Страница 393: ...of ring gear No 1 3 and set down into position aligning tooth of cluster No 1 spur gear and ring gear No 1 Insert jig 15 to M10x1 5 four bolts 23 and temporarily fasten 6 Turn the whole reduction gear...

Страница 394: ...s fit thrust plate 14 to be stuck to cover 2 by using hammer 7 Fill gear oil with specific quantity NOTE Specific quantity 4 3 liters 8 Loosen M10x1 5 bolts 23 temporarily fastened at Reassembly of Ho...

Страница 395: ...wo pipes Fill fully hydraulic oil in motor casing before piping Pipe to lower drain pressure under 2 kg cm2 28 psi 4 If sand or metal powder are mixed in hydraulic oil sliding surfaces will wear exces...

Страница 396: ...position oil drain port to low side then drain oil If level plug is loosened the oil will drain faster Oil Filling Set LEVEL mark on cover horizontally then fill 4 3 liters of oil GENERAL CAUTION MATT...

Страница 397: ...es outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handlin...

Страница 398: ...ting 11 Cautions During Starting Operation 11 Troubleshooting 11 General Cautions 11 Check Pump Proper for Abnormalities 11 Overload of Prime Mover 12 Extreme Decrease of Pump Delivery Flow and Non in...

Страница 399: ...r Function Diagram 32 Negative Flow Control 33 Total Horsepower Control 34 Variable Horsepower Control 36 Adjustment of Maximum and Minimum Flows 37 Adjustment of Maximum Flow 37 Adjustment of Minimum...

Страница 400: ...IGNATION K 5 V 1 4 0 D T 1 C 9 R 9 N 0 1 Regulator type For more details see the instruction manual for the regulator Shaft rotation viewed from shaft end Design series number R Clockwise L Counterclo...

Страница 401: ...ese are the speeds when the suction pressure is 0 kg cm2 0 psi Item Specification Size 140 Displacement 140 cm3 rev Pressure Rated 34 3 MPa 350 kg cm2 Max 37 7 MPa 385 kg cm2 Speed Max 1 2 500 min 1 M...

Страница 402: ...ed by bearings 123 and 124 at both ends The shoe is caulked to the piston to form a spherical coupling It has a pocket to relieve thrust force generated by loading pressure and to take hydraulic balan...

Страница 403: ...mover engine it rotates the cylinder block via a splined coupling If the swash plate is tilted as in Figure 2 the pistons arranged in the cylinder block make a reciprocating motion with respect to the...

Страница 404: ...ir respective sizes shown in Tightening Torques on page 26 All types Item Caution Applied Type Rotating direction and delivery direction For the variable pump these indications depend on the command m...

Страница 405: ...de pumps Tilting to both side circuit It is ideal to provide a filter of 10 in the booster line as shown in a of the following figure but there are also a number of experiences to provide filters of 1...

Страница 406: ...ngs etc It is desirable to use oil at a temperature lower than 65 C as low as possible considering deterioration of working oil seals and so on All types Working oil other than mineral oil When any wo...

Страница 407: ...disassembling and follow the right disassembling procedures 4 Even when any section is to be disassembled not to make dust or let it enter into the pump 5 Since the parts are finely finished handle t...

Страница 408: ...of Pump Delivery Flow and Non increase of Delivery Pressure Cause Countermeasure Remark Is not the speed pressure higher than their specified values Set them as specified Is not the torque setting of...

Страница 409: ...e suction pipe Increased suction resistance Damage in the caulking suction of the shoe Replace the piston shoe plate etc Cranking of the cylinder Replace the cylinder Wrong installation of the pump Co...

Страница 410: ...ke 214 532 732 789 535 806 953 886 717 406 261 111 774 824 127 710 123 251 490 212 211 153 156 728 467 157 983 981 313 312 124 114 466 725 885 314 141 401 Valve plate for c clockwise rotation Valve pl...

Страница 411: ...upport 261 Seal Cover F 262 Seal Cover R 271 Pump Casing 312 Valve Block 313 Valve Plate R 314 Valve Plate L 325 Valve Casing 401 Hexagon Socket Head Bolt 406 Hexagon Socket Head Bolt 466 VP Plug 468...

Страница 412: ...e Necessary Tool Marked with O Part Name Pump Type Name B K5V80 K5V140 Hexagon socket head bolt PT plug PT thread PO plug PF thread Hexagon socket head setscrew Allen wrench 2 M4 2 5 M5 3 M6 4 O O M5...

Страница 413: ...anner 19 O O M12 M12 VP 1 4 22 VP 3 8 24 O M16 M16 27 O M18 M18 VP 1 2 30 O M20 M20 36 O VP 3 4 41 VP 1 50 VP 11 4 55 VP 11 2 Adjustable angle wrench O O Medium size 1 set Screwdriver O O Minus type s...

Страница 414: ...her pump 1 Select place suitable to disassembling 2 Remove dust rust etc from pump surfaces with cleaning oil 3 Remove drain port plug 468 and let oil out of pump casing 4 Remove hexagon socket head b...

Страница 415: ...head bolts 406 and seal cover F 261 9 Remove hexagon socket head bolts 408 and seal cover R 262 NOTE In case there is a gear pump remove it first IMPORTANT Before laying this surface down spread rubb...

Страница 416: ...plate support from pump casing 11 Remove shoe plate 211 and swash plate 212 from pump casing 271 12 Lightly tap ends of drive shafts 111 and 113 with plastic hammer to remove shafts from swash plate s...

Страница 417: ...valve block 312 IMPORTANT When removing tilting pin use a protector to prevent pin head from being damaged Since Loctite is applied to mounting areas of tilting pin and servo piston do not damage ser...

Страница 418: ...ont pump with those of the rear pump 1 Install swash plate support 251 on pump casing 271 by lightly tapping it with a hammer 2 Place pump casing with its regulator mounting surface down Install tilti...

Страница 419: ...pherical bushing 156 and cylinder spring 157 6 Fit spline phases of retainer and cylinder 7 Then insert piston cylinder subassembly into pump casing IMPORTANT Do not tap drive shaft with hammer Assemb...

Страница 420: ...468 IMPORTANT Do not mistake suction delivery directions of valve plate IMPORTANT Assemble the rear pump side first to make the procedure easier Do not mistake direction of valve block Clockwise rota...

Страница 421: ...piston and cylinder bore D d 0 028 0 056 0 043 0 070 Replace piston or cylinder Play between piston and shoe caulking section 0 0 1 0 3 0 0 1 0 3 Replace assembly of piston and shoe Thickness of shoe...

Страница 422: ...B 10 M 14 1 600 kg cm B 12 M 16 2 400 kg cm B 14 M 18 3 400 kg cm B 14 M 20 4 400 kg cm B 17 PT plug Material S45C Wind a seal tape 11 2 to 2 turns round the plug PT 1 16 70 kg cm B 4 Do PT 1 8 105 k...

Страница 423: ...ol C Negative flow control With 2 stage max flow control D Positive flow control With flow cut function ARS0200L Kind of horsepower control 1 Constant horsepower control 2 Total cumulative horsepower...

Страница 424: ...S0708315K Page 28 Main Pump Kawasaki CONSTRUCTION OF REGULATOR Figure 22...

Страница 425: ...625 Outer Spring 626 Inner Spring 627 Adjusting Ring C 628 Adjusting Screw C 629 Cover C 630 Lock Nut 631 PF Sleeve 641 Pilot Cover 643 Pilot Piston 644 Spring Seat 645 Adjusting Ring Q 646 Pilot Spri...

Страница 426: ...2 Total horsepower control P2 Companion pump pressure According to the rise of delivery pressure of a pump the tilting angle of the pump is automatically controlled and torque control is achieved comp...

Страница 427: ...During normal operation 10 200 cSt Miscellaneous With proportional pressure reducing valve In case of type KR3 9 Code Control Type Control Curve Function and Features M Manual flow control With the m...

Страница 428: ...XPLANATIONS The regulator for Kawasaki in line axial piston pump K3V Series consists of the following control functions 1 Negative flow control 2 Total cumulative horsepower control 3 Variable horsepo...

Страница 429: ...rge diameter section of the servo position The delivery pressure P1 that is constantly admitted to the small diameter section of the servo piston moves the servo piston to the right due to the area di...

Страница 430: ...1 Functional explanation Since this regulator is of the simultaneous total horsepower type it controls the tilting angles displacement volumes of the two pumps to the same values as represented by th...

Страница 431: ...erential function As mentioned above flow control and horsepower control tilting angle commands are transmitted to the feedback lever and spool via the large hole sections C and F of levers 1 and 2 Ho...

Страница 432: ...trol section of each pump regulator through the pump s internal path to shift it to the same set horsepower level This function permits arbitrary setting of the Pump output power thereby providing the...

Страница 433: ...the hexagon nut 809 and by tightening or loosening the set screw 954 The maximum flow only is adjusted without changing other control characteristics Adjustment of Minimum Flow Adjust it by loosening...

Страница 434: ...compensating rod 623 are stuck with each other Disassemble and clean the regulator 4 The Pin 898 is stuck Disassemble and clean the regulator Item Specification Speed 2200 min 1 Adjustment of Maximum...

Страница 435: ...ck Disassemble and clean the regulator 4 The piston QMC stopper 647 and piston 648 are stuck with each other Disassemble and clean the regulator 5 The spool COV 637 is stuck Disassemble and clean the...

Страница 436: ...embly is necessary for an unavoidable reason read through this manual to the end before starting disassembly 2 The numbers in parentheses after part names represent those in the Construction of Regula...

Страница 437: ...C 624 from compensating section Then draw out adjusting ring Q 645 pilot spring 646 and spring seat 644 from pilot section CAUTION 1 Choose a clean place 2 Spread rubber mat or cloth on top of work be...

Страница 438: ...ing 814 spring seat 653 return spring 654 and sleeve 651 8 Remove locking ring 858 fulcrum plug 614 and adjusting plug 615 IMPORTANT Sleeve 651 is attached with snap ring 836 When removing snap ring 8...

Страница 439: ...75 12 Draw out pilot piston 643 and spool 652 13 Draw out piston case 622 compensating piston 621 and compensating rod 623 NOTE Since component parts are small do not lose them IMPORTANT Work will be...

Страница 440: ...as O rings with new ones as a rule 1 Put compensating rod 623 into compensating hole of casing 601 2 Press fit pin in lever 1 612 into groove of compensating rod and fit lever 1 to pin press fitted in...

Страница 441: ...nserted into pin hole of lever 2 Then attach locking ring 858 8 Insert adjusting plug 615 and install locking ring 9 Install return spring 654 and spring seat 653 into spool hole Install snap ring 814...

Страница 442: ...ert spring seat 644 pilot spring 646 and adjusting ring Q 645 into pilot hole 13 Install spring seat 624 inner spring 626 and outer spring 625 into compensating hole 14 Install cover C 629 with adjust...

Страница 443: ...14 1 600 kg cm 10 M 16 2 400 kg cm 12 M 18 3 400 kg cm 14 M 20 4 400 kg cm 17 PT filling plug Material S45C Wind a seal tape 1 1 2 to 2 turns round the plug PT 1 16 70 kg cm 4 Do PT 1 8 105 kg cm 5 P...

Страница 444: ...S0708315K Page 48 Main Pump Kawasaki...

Страница 445: ...outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling...

Страница 446: ...rallel Orifice for Arm 20 Relief Valve 21 Combined Operation 22 Bucket Combined Operation 24 Antidrift Valve 25 Main Relief Valve 26 Overload Relief Valve 69 Total Six Places 27 Low Pressure Relief Va...

Страница 447: ...2 Disassembly 43 General Instructions for Disassembly 43 Disassembly of Main Spool Part 43 Disassembly of Arm 1 Para Spool Turn 44 Disassembly of Arm Regeneration Release Valve Part 45 Disassembly of...

Страница 448: ...rift Valve Assembly 52 Reassembly Procedure of Control Valve Body 53 Reassembly of Relief Valve 53 Reassembly of Load Check Valve 53 Reassembly of Antidrift Valve 54 Reassembly of Spare Section Part 5...

Страница 449: ...ports T1 T2 and T3 Oil supplied to port P1 flows through neutral passage R1 to low pressure relief valve orifice Rc1 then to tank passage Ta and returns to ports T1 T2 and T3 The pressures of low pre...

Страница 450: ...S0709401K Page 6 Main Control Valve Kayaba Figure 1...

Страница 451: ...S0709401K Page 7 Main Control Valve Kayaba Figure 2...

Страница 452: ...d land Rc3 into tank passage Ta 2 The same oil supplied to port PP then flows through orifice Lc5 into port PA and it also flows through passages L4 7 and R4 to bucket spool land Rc4 and then flows in...

Страница 453: ...S0709401K Page 9 Main Control Valve Kayaba...

Страница 454: ...allel passage R3 and passage S6 1 are equal so poppet S6 2 does not open Return oil flows through port A6 B6 to spool and returns to tank passage Ta 3 When shifting either spool section 1 or 6 land Lc...

Страница 455: ...S0709401K Page 11 Main Control Valve Kayaba Figure 4...

Страница 456: ...A3 B3 to spool and is returned to tank passage Ta Bucket Spool Shifting 1 Oil flow control in bucket section portion of valve is different from other sections because it has a regeneration function th...

Страница 457: ...passage R1 is closed Oil supplied to port P2 flows through parallel passage R3 load check valve S7 2 passage S7 1 spool and into port A7 Oil flows through port B7 and one portion of the oil returns th...

Страница 458: ...ting 1 Neutral This valve also works with anti drift valves that are installed on the bottom side of each boom cylinder When in neutral poppet AD1 Figure 7 is closed by port A8 pressure that is sent t...

Страница 459: ...t P2 flows through parallel passage R3 and load check valve S8 2 to spool and flows into port A8 When boom 2 spool is shifted by increasing pressure of boom 2 section 4 pilot port Pb4 neutral passage...

Страница 460: ...h parallel passage R3 and load check valve S8 2 to spool and flows into port B8 When spool AD3 of antidrift valve is shifted by increasing pressure of port P2 poppet AD1 is opened by decreasing of pre...

Страница 461: ...ting 1 Neutral This valve also works with an anti drift valve that is installed on rod side of the arm cylinder When in neutral poppet AD1 Figure 10 is closed by port A5 pressure that is sent through...

Страница 462: ...spool into port B5 When arm 2 spool is shifted by increasing pressure of arm 2 section 9 pilot port pb9 oil supplied to port P2 flows through neutral passage R1 load check valve S9 1 passage S9 2 and...

Страница 463: ...passage Ta The other portion of the oil flows through fixed orifice b regeneration check c and fixed orifice i in arm 1 spool and joins in bridge passage S5 1 From there if load pressure of port B is...

Страница 464: ...9 1 spool and passage 8 and joins at port A5 Return oil from port B5 returns through spool to tank passage Ta Parallel Orifice for Arm The orifice that is installed in parallel passage for arm 1 contr...

Страница 465: ...valve The highest pressure of pump P1 and P2 is controlled by reaction of main relief valve 2 Over Load Relief Valve The over load relief valve that is installed in each cylinder port of boom 1 arm 1...

Страница 466: ...el Pump 2 50 Section 6 Travel 50 If there is no travel straight circuit machine will travel in zig zag manner PT closed The oil passage is closed at the signal land Lc4 Lc7 Rc3 and Rc5 PA closed The o...

Страница 467: ...S0709401K Page 23 Main Control Valve Kayaba Figure 16...

Страница 468: ...piston S7 6 piston S7 5 and plug S7 4 are pressed and poppet assembly S7 2 is seated on valve housing This causes oil flowing from parallel passage R3 to open poppet S7 3 in poppet assembly and flow i...

Страница 469: ...m port A5 is cut off by seat S1 and seat S2 2 Cut off condition of passage of port A5 Figure 19 and spring chamber A If port pc1 is pressurized piston 2 is moved and spool 3 reacts B Spool 3 activates...

Страница 470: ...oil passage HP rises and exceeds relief valve setting pilot poppet F opens Pressurized oil flows through pilot poppet F into low pressure oil passage LP passing through hole G 3 As pilot poppet F ope...

Страница 471: ...ure in cylinder port HP rises and exceeds the relief valve setting pilot poppet E opens Pressurized oil then flows through pilot poppet E into low pressure oil passage LP passing through hole H 3 As p...

Страница 472: ...der port HP to eliminate cavitation LOW PRESSURE RELIEF VALVE 70 TOTAL TWO PLACES Generation of Signal Pressure Oil supplied from pump port P1 P2 flows through neutral passage L1 R1 low pressure relie...

Страница 473: ...orifice Lc1 Rc1 goes to back chamber of poppet and poppet operates by the difference of pressurized area between passage and back chamber By operation of this poppet oil flows from passage through plu...

Страница 474: ...Main Control Valve Kayaba PARTS LIST 75 69 37 69 92 77 81 75 52 74 76 L L B B A A C D E F G H I C D E F G H I K K 71 74 78 72 37 69 90 72 75 37 90 69 43 72 75 89 88 73 37 72 92 68 52 76 J J X VIEW X A...

Страница 475: ...Page 31 Main Control Valve Kayaba Figure 33 8 15 16 17 5 70 13 7 8 12 8 8 8 8 8 70 2 3 4 5 6 7 1 63 SECTION A1 A1 61 62 33 32 72 57 SECTION A A SECTION B B SECTION L L SECTION K K X 41 Y 42 X 41 Y 42...

Страница 476: ...0 7 6 5 103 104 36 SECTION C C SECTION D D SECTION E E SECTION G G SECTION H H SECTION J J SECTION I I DETAIL F1 F1 SECTION F F 34 35 53 55 54 51 35 36 36 72 72 47 49 50 45 36 44 91 105 67 38 39 35 3...

Страница 477: ...5 Spring 36 O ring 37 Flange 38 Poppet 39 Spring 40 Spacer Assembly 41 O ring 42 O ring 43 Flange 44 Poppet 45 Spring 46 Plug 47 O ring 48 Spring 49 Poppet 50 Steel Ball 51 Poppet 52 Flange 53 Spacer...

Страница 478: ...er Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End 5 Plug 6 Poppet 7 Spring 8 O ring 9 Backup Ring Reference Number Descr...

Страница 479: ...sembly 14 Arm1 Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description 1 Spool 2 Sp...

Страница 480: ...Regeneration Release Valve Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description...

Страница 481: ...7 Main Control Valve Kayaba Spacer Assembly 40 Plug Assembly 60 Reference Number Description 1 Spacer 2 O ring 3 Backup Ring 4 O ring Reference Number Description 1 Plug 2 O ring 3 O ring 4 O ring Fig...

Страница 482: ...mbly 67 Figure 47 Reference Number Description 1 Body 2 Poppet 3 Plug 4 Piston 5 Spool 6 Sleeve 7 Spring 8 Spring 9 O ring 10 O ring 11 Backup Ring 12 Backup Ring 13 O ring 14 Plug Assembly 15 Plug As...

Страница 483: ...ing 6 O ring Reference Number Description 1 Plug 2 O ring 3 O ring 4 Backup Ring Control Valve Specification Rated Flow 270 liter min 50 liter min at Neutral Max Pressure 34 3 MPa Allowable Back Press...

Страница 484: ...cap crisscrossed Remove center and retighten cap Valve temperature uneven Warm up entire system Dirt in valve Clean valve flushing Lack of pilot pressure Check pilot valve and pilot relief pressure F...

Страница 485: ...Remedy Pressure does not rise Stuck main poppet sleeve or pilot poppet opened or dirt in seat part Replace relief valve Relief pressure unstable Seat parts of pilot poppet damaged Piston or main poppe...

Страница 486: ...ighten lock nut 7 after pressure has been adjusted 6 Recheck pressure setting by raising pressure once more Over Load Relief Valve 1 Shift control valve spool and read pressure gauge from stroke end o...

Страница 487: ...own as assembly part number further part number Disassembly of Main Spool Part 1 Remove socket head bolt 74 two places per each section width across flats 8 mm and cap 8 ten places 2 Remove plug assem...

Страница 488: ...pool end 22 width across flats 5 mm spring seat 20 and spring 21 from spool 19 IMPORTANT Work with spool gripped in vise with wood see Figure 50 not to scratch outside diameter of spool Because Loctit...

Страница 489: ...on C C 7 Remove spring 33 and poppet 32 from valve housing 8 Remove plug 72 width across flats 8 mm section L L 9 Remove spacer 57 spring 33 and poppet 32 from valve housing 10 Remove plug 92 width ac...

Страница 490: ...emove plug assembly 67 14 width across flats 38 mm and O ring B Remove piston 67 4 spool 67 5 and spring 67 7 C Remove plug 67 3 width across flats 38 mm and O ring D Remove sleeve 67 6 and poppet 67...

Страница 491: ...ts 36 mm and O ring 5 Remove plug assembly 71 width across flats 6 mm and O ring 6 Remove plug assembly 72 width across flats 8 mm and O ring Disassembly of Valve Housing Combined Bolt 1 Remove socket...

Страница 492: ...t 4 and plug 1 and replace O ring 3 If oil is leaking from nut 7 remove nut 7 and plug 8 and replace O ring 3 Disassembly of Overload Relief Valve This relief valve should be replaced as an assembly W...

Страница 493: ...75 mm and O ring 2 If oil is leaking from adjusting kit 3 remove adjusting kit 3 and replace O ring 4 Disassembly of Low Pressure Relief Valve This unit has press fit portion D so that it should be re...

Страница 494: ...ion inspect it using relief valve maintenance procedure 6 Replace all O rings and backup rings with new ones 7 After disassembling cap or plug check whether there are paint chips around body hole or p...

Страница 495: ...e inlet At this time be careful not to touch applying part to spring seat PROCEDURE OF SUBASSEMBLY Reassembly of Spool Assembly Main Spool 1 Apply Loctite to threaded portion of spool 2 6 14 17 and in...

Страница 496: ...4 Install spring 67 7 and piston 67 4 in plug 67 3 5 Tighten plug assembly 67 14 with O ring installed on plug 67 3 Tightening torque 14 99 16 01 kg m 108 116 ft lb 6 Install O ring 67 13 on plug 67...

Страница 497: ...47 ft lb 4 Install poppet 51 and spring 35 in common section I I Insert spacer 53 with O ring 54 and backup ring 55 Tightening torque 3 98 4 49 kg m 29 32 ft lb 5 Install O ring 36 on spare section se...

Страница 498: ...O ring 89 on cap 88 two places and fasten it in place with socket head bolt 76 Tightening torque 5 91 6 53 kg m 43 47 ft lb 2 Install O ring and backup ring on plug assembly 87 two places Install plu...

Страница 499: ...t lb 3 Tighten orifice plug 63 Tightening torque 1 43 1 84 kg m 10 33 13 28 ft lb 4 Install O ring on plug assembly 92 and install Tightening torque 20 90 23 15 kg m 151 167 ft lb 5 Install O ring on...

Страница 500: ...S0709401K Page 56 Main Control Valve Kayaba Figure 54...

Страница 501: ...t pressure by referring to Over Load Relief Valve on page 42 NOTE The torque values are based on use of lubricated threads Reassembly of Low Pressure Relief Valve Check if there is dirt and paint chip...

Страница 502: ...RT UP PROCEDURES 1 Before operating machine make sure that oil passages and hydraulic oil are clean 2 Hydraulic oil of which annealing point is 82 113 C should be used in the hydraulic system 3 Relief...

Страница 503: ...d safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capabl...

Страница 504: ...OF CONTENTS General Description 3 Theory of Operation 3 Structure 3 Function 3 Parts List 4 Specifications 5 Torques 5 Performance 6 Removal 6 Disassembly 9 Cleaning and Inspection Wear Limits and Tol...

Страница 505: ...eutral mode the spool is thrust upward by return spring and the force of balancing spring which determines the secondary discharge pressure is not transmitted to the spool The input port is closed and...

Страница 506: ...S0709451K Page 4 Pilot Control Valve Work Lever Joystick PARTS LIST 30 29 26 23 24 13 22 21 17 31 15 16 36 32 33 34 35 1 2 3 5 4 6 7 9 10 8 28 27 25 14 19 18 12 11 20 ARS2260L Figure 1...

Страница 507: ...ing Pin 30 Handle Assembly 31 Bushing 32 Terminal 33 Seal Wire 34 Housing 35 Holder Rear 36 Clip Band Reference Number Description Pilot Control Valve Specification Type Pilot Control 2 Stage Joystick...

Страница 508: ...joysticks in all directions to relieve pressure from accumulators 7 Set safety lever on LOCK position 8 Turn key to OFF position and remove from starter switch 9 Hang maintenance warning tag on contr...

Страница 509: ...2 and pull remote control valve LH 1 out 15 Tag and disconnect hoses from remote control valve LH 1 Figure 5 Plug and cap hoses and ports to prevent contamination from entering hydraulic system or co...

Страница 510: ...e four bolts 3 Figure 7 and cover 2 and pull remote control valve RH 1 out 20 Tag and disconnect hoses from remote control valve RH 1 Figure 7 Plug and cap hoses and ports to prevent contamination fro...

Страница 511: ...ilot Control Valve Work Lever Joystick DISASSEMBLY 1 Lift up the boot 28 and pull the switch cord through the hole in the case 1 2 Loosen nut 27 from hex nut 25 and remove handle assembly 30 Figure 8...

Страница 512: ...age 10 Pilot Control Valve Work Lever Joystick 3 Remove hex nut 25 and swash plate 24 4 Remove joint 23 from case 1 5 Remove plate 21 6 Press spring 10 and remove plug 18 Figure 11 Figure 12 Figure 13...

Страница 513: ...reduction valve 6 7 8 9 11 and spring 10 8 Remove plug 3 and four plugs 2 9 Remove stopper 11 from pressure reduction valve 6 7 8 9 11 10 Remove spool 6 spring seat 9 spring 8 and shim 7 IMPORTANT Mar...

Страница 514: ...S0709451K Page 12 Pilot Control Valve Work Lever Joystick 11 Remove push rod 14 and plug 18 12 Remove O ring 19 from plug 18 13 Remove seal 20 from plug 18 Figure 19 Figure 20 Figure 21...

Страница 515: ...ck CLEANING AND INSPECTION WEAR LIMITS AND TOLERANCES For general cleaning and inspection procedures refer to General Maintenance Procedures section Clean all parts and dry them with compressed air Ke...

Страница 516: ...3 slowly NOTE Tightening torque 350 kg cm 25 3 ft lb Tighten four plugs 2 NOTE Use Loctite 592 pipe sealant on plugs NOTE Tightening torque 150 kg cm 10 9 ft lb 2 Install shim 7 spring 8 spring seat...

Страница 517: ...lve Work Lever Joystick 4 Install spring 10 in case 1 and pressure reducing valve assembly 6 7 8 9 11 5 Install seal 20 on plug 18 6 Install O ring 19 on plug 18 7 Install push rod 14 on plug 18 Figur...

Страница 518: ...Valve Work Lever Joystick 8 Install spring 13 on stopper 12 9 Position stopper 12 and spring 13 on pressure reducing valve 10 Install plug 18 in case 1 11 Install plate 21 and tighten joint 23 Figure...

Страница 519: ...nstall hex nut 25 and tighten swash plate 24 NOTE Tightening torque 1 240 kg cm 89 7 ft lb 14 Pull cord and tube out through hole of hex nut 25 15 Align the direction of handle 30 and tighten hex nut...

Страница 520: ...S0709451K Page 18 Pilot Control Valve Work Lever Joystick 16 Grease joint 23 swash plate 24 and push rod 14 17 Install boot 28 Figure 37 Figure 38...

Страница 521: ...ews two bolts and washers 7 and 8 Figure 40 and cover 4 4 Install a screw three bolts and washers 6 Figure 40 and cover 3 Push cap 5 into cover 3 5 Install four bolts and washers 2 Figure 40 and cover...

Страница 522: ...Push cap 5 into cover 3 10 Install four bolts and washers 2 Figure 42 and cover 1 START UP PROCEDURES 1 Start engine and set throttle at LOW IDLE 2 Set safety lever on UNLOCK position 3 Slowly cycle b...

Страница 523: ...is manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimatel...

Страница 524: ...ry of Operation 3 Pressure Reducing Valve 3 Operating Theory of Damper Mechanism 5 Parts List 6 Specification 7 Torque 7 Troubleshooting Testing and Adjustment 8 Removal 9 Disassembly 11 Cleaning and...

Страница 525: ...port T through inner hole of spool 2 Half Operation Condition If pedal is moved push rod moves down and they transmit this force through spring seat and control spring to spool If spool is moved prima...

Страница 526: ...tted through inner hole of spool to operating port secondary pressure transmitted through spool overcomes control spring force and pushes spool up but spool is restricted by push rod and does not move...

Страница 527: ...amber of upper part of low pressure at this time ball check valve becomes closing condition because high pressure operates to vibration prevention chamber of lower part 2 Operation When Operating Leve...

Страница 528: ...20K Page 6 Travel Control Valve With Damper PARTS LIST 32 24 23 22 16 21 13 12 11 9 5 4 3 10 8 6 7 19 20 17 18 14 15 3 36 25 26 19 20 30 29 28 33 37 1 35 34 2 ARS1850L Figure 5 P T 1 2 3 4 ARS1860L Fi...

Страница 529: ...Deal 25 Cover 26 Wrench Bolt 27 Cam 28 Bushing 29 Camshaft 30 Set Screw 31 Set Screw 32 Hex Nut 33 Bellows 34 Space 35 O ring 36 O ring 37 Wrench Bolt Reference Number Description Travel Control Valve...

Страница 530: ...mary pressure Defective secondary pressure select spring Replace with new spring Gap between spool and casing is abnormally large Replace spool casing assembly Defective operating parts and components...

Страница 531: ...y to OFF position and remove from starter switch 9 Hang maintenance warning tag on controls 10 Disconnect negative battery cable leading to frame from battery 11 Remove cabin under cover by loosening...

Страница 532: ...ve With Damper 13 Remove rubber boots 1 Figure 9 14 Remove four bolts and washers 2 Figure 9 pedal brackets 3 with levers 15 Remove four bolts and washers 2 Figure 10 and pedal valve 1 1 2 1 ARS2951L...

Страница 533: ...ainer in which disassembled parts can be stored 3 All precision parts must be handled with great care and all parts must be reassembled to their original position 4 All parts must be carefully reassem...

Страница 534: ...9820K Page 12 Travel Control Valve With Damper 3 Remove cam shaft 29 and bushing 28 from cam 27 4 Remove cam 27 from cover 25 5 Remove wrench bolt 26 by using tool Figure 13 Figure 14 Figure 15 Figure...

Страница 535: ...With Damper 6 Remove cover 25 from body 1 and 2 7 Remove plug assembly 21 24 with push rod assembly 14 20 8 Remove snap ring 13 9 Remove rod guide 11 IMPORTANT Be careful not to spring rod guide 11 F...

Страница 536: ...820K Page 14 Travel Control Valve With Damper 10 Remove spool assembly 5 9 11 Remove spring 10 12 Remove stopper 9 spring 6 and spring seat 7 from spool assembly 5 9 Figure 21 Figure 22 Figure 23 Figu...

Страница 537: ...trol Valve With Damper 13 Remove plug assembly 21 24 from push rod assembly 14 20 14 Remove seal 23 and 24 from plug 21 15 Remove O ring 22 from plug 21 16 Remove seal 16 from push rod 14 Figure 25 Fi...

Страница 538: ...el Control Valve With Damper 17 Remove snap ring 20 from push rod 14 18 Remove plate 19 from push rod 14 19 Remove spring 18 from push rod 14 20 Remove steel ball 17 from push rod 14 Figure 29 Figure...

Страница 539: ...d may cause poor equipment performance Be sure to use clean uncontaminated solvent when cleaning precision parts 2 Clean parts thoroughly by gently turning the solvent Dry and clean each part with a c...

Страница 540: ...approved lubricant to aid in smooth assembly 6 Tighten all bolts to the specified torque rating as outlined in the torque table 7 Seal all opens ports to prevent foreign material from entering the va...

Страница 541: ...nstall rod seal 23 and dust seal 24 on both sides of plug by using tool 4 Install O ring 22 on outside diameter of plug 21 and check plug whether it is abnormal 5 Install spring seat 7 spring 6 and sp...

Страница 542: ...spring 18 plate 19 and spring pin 15 on push rod 14 8 Install snap ring 20 on push rod assembly 14 19 9 Install seal 16 on push rod 14 10 After installing spool assembly 5 9 on body 1 and 2 insert rod...

Страница 543: ...rod assembly 14 20 on body 1 and 2 12 Install cover 25 on the upside of body 1 and 2 13 Tighten wrench bolt 26 NOTE Tightening torque 88 kg cm 6 37 ft lb 14 Put cam 27 on cover 25 and install cam shaf...

Страница 544: ...by using wrench NOTE Tightening torque 88 kg cm 6 37 ft lb 16 One side holds L wrench and the other side holds spanner and tighten set screw 31 and hex nut 32 attached to cam 27 not to loose NOTE Tig...

Страница 545: ...and washers 2 2 Install pedal brackets 3 and levers 4 Figure 50 on pedal valve and install four bolts and washers 2 3 Install rubber boots 1 Figure 50 4 Connect hoses as tagged during removal to peda...

Страница 546: ...mper START UP PROCEDURES 1 Start engine and set throttle at LOW IDLE 2 Set safety lever on UNLOCK position 3 Slowly push and pull both travel lever about five times without a load to vent air from pil...

Страница 547: ...fe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of...

Страница 548: ...S0792160K Page 2 Hydraulic Schematic S300LC V TABLE OF CONTENTS General Description 3 Solar 300LC V 4...

Страница 549: ...300LC V GENERAL DESCRIPTION Schematic s presented in this section are laid out on facing pages An overlapping edge has been taken into consideration so that a photocopy can be made and pasted together...

Страница 550: ...B1 Dr1 A1 a4 Psv A2 500k A3 REAR 40k SENSOR Dr3 a3 Pi2 ps2 VALVE LEFT Pi2 of Pump VALVE RIGHT pa1 pb1 P1 SWING MOTOR SH PH of Sol v v PT PP PA PH pr P3 P2 pa3 TR R OPT P4 pa2 B1 A1 pb2 B2 A2 SWING BOO...

Страница 551: ...4 3 P T 4 BOOM 2 1 T P 3 4 1 2 3 1 2 3 4 3 2 1 4 pb8 pb3 SOL V V P2 B2 pa3 B1 S1 pa8 pb5 pa5 B3 B4 B5 pb7 pa7 pc2 B7 B8 B6 A2 A1 A3 A4 A5 A7 A8 A6 9 pc1 Pi VALVE RIGHT pa1 pb1 pa3 TR R OPT P4 pa2 B1...

Страница 552: ...S0792160K Page 6 Hydraulic Schematic S300LC V...

Страница 553: ...1ELECTRICAL SYSTEM...

Страница 554: ......

Страница 555: ...ained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own pe...

Страница 556: ...el 15 Monitoring System Schematic 16 Operation 18 Instruments 18 Warning and Indicator Lights 20 Initial Operation 22 Mode Select Switch 23 Graphic Information Area Display 24 Overview 24 Main Menus f...

Страница 557: ...verheat Protection System 60 Power Boost Mode 61 Operation 61 Power Boost Control Circuit Diagram 62 Automatic Travel Speed Control 63 Automatic Travel Speed Control Circuit Diagram 64 Engine Control...

Страница 558: ...t Engine throttle controller defective or not connected Repair connection or replace component Blown fuse Replace fuse Check connections and circuit components for shorts or other damage Wiring harnes...

Страница 559: ...and a three phase AC generator with a rectifier The electric wiring used in the system is easily identifiable by the insulator color The color symbols used in the electrical system are listed in the f...

Страница 560: ...ne stop motor When the starter switch 5 is in the preheat on and start positions the current flows from the battery 1 fusible link 3 fuse 6 starter switch 5 B terminal starter switch 5 BR terminal bat...

Страница 561: ...er relay 8 are connected the pinion gear of the starter 9 is pushed forward and makes contact with the ring gear of the flywheel and the internal contacts of the starter are connected The current flow...

Страница 562: ...and PP terminals are opened As a result the rotation of the starter 9 is stopped Once the engine is running the starter 9 will not operate even if the starter switch 5 is moved to the start position p...

Страница 563: ...e preheat time is approximately 19 seconds A built in timer in the instrument panel will activate an indicator light approximately 19 seconds after the preheat process has been selected Even after the...

Страница 564: ...is in the ON position the engine stop motor rotates 180 and comes to a stop due to the cam switch When the start switch is in the OFF position the engine stop motor moves 180 from the running mode pos...

Страница 565: ...elay 5 A terminal of engine stop motor 6 E terminal of engine stop motor 6 ground The engine stop motor opens pushes the fuel shut off lever of the fuel injection pump and the system is in the running...

Страница 566: ...e shut off lever of the fuel injection pump linked to the engine stop motor by a cable is moved to the close pull position and the engine is stopped The engine stop motor moves 180 from the running mo...

Страница 567: ...ctrical components When the alternator 7 starts to operate a current flows from the R I terminal of alternator diode 8 battery relay 2 coil securing a path for the charging current to the battery 1 Th...

Страница 568: ...plays information selected by the operator ARS0090L Figure 9 Reference Number Description 1 Instrument Panel 2 Battery 3 Engine Speed Sensor 4 Return Filter Switch 5 Pilot Filter Switch 6 e EPOS Contr...

Страница 569: ...ion area 3 and 4 Figure 10 Gauges Warning Lights Mode Select Switches 1 Engine Coolant Temp Gauge 2 Fuel Gauge 3 Multi function Gauge and Graphic Information Area 4 Digital Clock 5 Service Hour Meter...

Страница 570: ...ER LOAD L3 WATER TEMP L4 PREHEAT L5 WORK LAMP L1 BATTERY CHARGE L2 ENG OIL PRESS 8 7 ILLUMINATION EL 5 20 6 SIG 19 SIG L4 L1 L2 L3 6 17 L6 L5 11 1 9 10 2 22 CN2 13 CN2 14 CN2 11 CN2 12 CN2 1 RS 422 CN...

Страница 571: ...ssure Sensor 7 Engine Coolant Temperature Sensor 8 Fuel Gauge 9 Engine Speed Sensor 10 Hydraulic Oil Temp Sensor 11 Engine Oil Pressure Switch 12 Air Cleaner Indicator 13 Return Filter Switch 14 Pilot...

Страница 572: ...F 128 ohms Fuel Level CN4 7 CN4 8 1 10 LCD Blinking over 5K ohms FULL under 525 ohms Tachometer CN4 16 CN4 17 N 146 f 60 S300LC V N 146 f 60 S300LL N 152 f 60 S340LC V N 152 f 60 S420LC V N 152 f 60...

Страница 573: ...4 2 V 0 00816 x P 1 0 V Sensor output voltage V P Displayed pressure Bar Main pump discharge pressure rear pump CN4 3 CN4 4 Function Display Sensor Specification Input Terminal Input Specification FRO...

Страница 574: ...ssure CN2 11 Lights up when engine oil pressure switch is turned ON Oil pressure drops below 0 7 kg cm2 10 psi After starting engine if engine oil pressure is insufficient after 8 seconds a warning bu...

Страница 575: ...Area Air Cleaner CN2 12 Lights up when air cleaner is clogged Symbol is blinking Return Filter CN2 13 Lights up when return filter pressure increases over 1 5 kg cm2 21 psi Symbol is blinking Pilot F...

Страница 576: ...Initial Operation When battery voltage is input to CN7 9 starter switch is turned from OFF to ON position All LCD LED and warning lights are turned on and turned off after about 2 seconds Warning buzz...

Страница 577: ...put Pump Discharge Volume Control Valve Current mA Swing Priority Solenoid Valve 7 Segment Display Power Mode Power Mode ON Variable Output 9 x Standard Mode OFF 0 7 x Work Mode Trenching Mode ON ON x...

Страница 578: ...ided into two menus One is main menu for user and the other is special menu for specialist These menus can be moved from normal display mode by the combination of select buttons Selection Buttons Grap...

Страница 579: ...f machine operation MENU SELECTION BUTTONS 1 Up Arrow Button 1 on Figure 12 Move the cursor to up left and previous screen 2 Down Arrow Button 2 on Figure 12 Move the cursor to down right and next scr...

Страница 580: ...ter oil information to the operator Refer to the Operation and Maintenance Manual for details LANGUAGE SETTING This mode is used for setting desired language TIME SETTING This mode is used for setting...

Страница 581: ...reset the operating hour and then the operating hours until the next service interval can be easily checked Menu Display Order and Icon Explanation ARO0400L Hrs 0232 Reset 1 Fuel Filter Figure 16 1 2...

Страница 582: ...ESSING AND EXITING ESCAPING MENUS Entering Accessing Menus When normal mode screen is displayed if the enter button 3 and escape button ESC 4 are pressed simultaneously for more than 3 seconds normal...

Страница 583: ...once again SPECIAL MENU SELECTIONS Sub menu Selection Method Various sub menus can be selected by pressing Up 1 on Figure 18 and Down 2 on Figure 18 button Move the cursor to desired menu and a select...

Страница 584: ...Max 9 E G Oil Press 3 Work Travel Solenoid 10 Air Cleaner 4 Hi Speed Solenoid 11 Return Filter 5 Auto Travel 12 Pilot Filter 6 Work Lamp 13 OWD Select 7 Pressure Py 5 Output State 1 Relief Press Up 4...

Страница 585: ...hine Status Information 1 EPPR Valve Current 2 Dial Voltage 3 TPS Voltage Output voltage of potentiometer built into engine control motor EPPR CURRENT ARS0870L mA 598 Figure 24 DIAL VOLTAGE ARS0880L m...

Страница 586: ...on OFF and the other statuses of on off type sensors MACHINE INFO ARS1780L Input State Output State Hyd Oil Temp 4 Figure 27 1 Alternator OFF 2 Power Max ON 3 Work Travel Sel OFF 4 Hi Speed Sel OFF 5...

Страница 587: ...on Remarks 1 6 BAR Lit CN 3 4 CN 3 5 Over 1 510 Below 30 C Below 86 F 1 6 2 6 BAR Lit 745 1 510 31 50 C 87 122 F 1 6 3 6 BAR Lit 332 745 51 75 C 123 167 F 1 6 4 6 BAR Lit 244 332 76 85 C 168 185 F 1 6...

Страница 588: ...cursor is located in Failure Info of special menu screen press enter button 3 on Figure 18 and Failure Info screen is displayed 2 Exiting Sub menus If escape button ESC 4 on Figure 18 is pressed for...

Страница 589: ...ure information Memorized record of past failure is displayed Failure code failure contents When a number of failures are produced failure information can be checked by using PRV 1 on Figure 18 or NXT...

Страница 590: ...t this time deletion signal will be displayed and the screen will move to previous menu after deletion This screen will be displayed during 3 seconds When NO ESC 4 on Figure 18 button is pressed the s...

Страница 591: ...82 Communication Err Communication error between e EPOS controller and instrument panel Note Automatic reset when problem is corrected 01 EPPR v v short Short Circuit Cut off output current 0 mA Afte...

Страница 592: ...put voltage Over 4 6 0 2 V Cut off EPPR v v current 0 mA 24 TPS Voltage Err L Output voltage Over 0 4 0 2 V Cut off EPPR v v current 0 mA 25 Fpump Sensor Err H Output voltage Over 4 6 0 2 V 26 Fpump S...

Страница 593: ...ion A Entering Sub menus When a cursor is located in Operating Info of special menu screen Figure 37 press enter button 3 on Figure 18 and Operating Info screen will be displayed Figure 38 B Informati...

Страница 594: ...itch Py control valve ON status High speed High speed s v and travel pressure switch Py control valve ON status Hydraulic Oil Temperature Distribution C F Temperature of hydraulic oil is classified 6...

Страница 595: ...urned to previous screen NOTE When YES 3 on Figure 18 button is pressed operation hours will reset At this time resetting signal will be displayed and the screen will move to previous menu after reset...

Страница 596: ...19 Mode select signal Machine information Auto idle signal Sensors 18 Engine speed sensor signal Engine throttle control signal Drive signal Potentiometer signal Coolant water temp signal Throttle co...

Страница 597: ...8 Pump Pressure Sensor 9 Engine Speed Sensor 10 Electro magnetic Proportional Pressure Reducing Valve E P P R Valve 11 Solenoid Valve Pressure Up 12 Solenoid Valve Swing Priority 13 Solenoid Valve Hi...

Страница 598: ...e indicator lamp will turn ON to display the selected mode Wheel type Power mode switch signal 1 Potentiometer signal Pump control signal g 15 Low Throttle signal Hi 16 Engine throttle control signal...

Страница 599: ...low the rated speed When this occurs the controller senses this decrease and immediately reduces the pump discharge volume to maintain the engine speed at the rated level On the other hand if the load...

Страница 600: ...ption in comparison with Power Mode The current to the E P P R valve is shut off and pump discharge volume is controlled by pump regulator A B C D HDA6020L Figure 46 Reference Number Description A Eng...

Страница 601: ...S0802220K Page 47 Electrical System Reference Number Description A Engine Horsepower hp B Engine Speed rpm C Pump Discharge Volume lpm D Pump Discharge Pressure kg cm2 Reference Number Description...

Страница 602: ...1 9 9 10 8 11 CN3 9 10 11 12 14 15 13 17 16 CN1 6 5 7 8 6 4 3 2 1 20 18 19 11 CN7 14 16 15 13 12 CN3 11 CN3 10 CN3 9 CN3 12 CN3 8 CN1 7 CN1 5 CN4 11 CN4 10 CN4 13 CN4 12 LOW 1 1 5 2 3 1 4 CN2 3 12 2 2...

Страница 603: ...stem Reference Number Description 1 Battery 2 Battery Relay 3 Fuse 4 e EPOS Controller 5 Instrument Panel 6 Engine Speed Sensor 7 Engine Throttle Controller 8 Engine Control Motor 9 Engine Control Dia...

Страница 604: ...oid adjusts the assignment of hydraulic oil flow to each device on the equipment Wheel Engine throttle control signal Trenching mode switch signal 15 Throttle signal Hi Lo Potentiometer signal Drive s...

Страница 605: ...ck stops The current to the solenoid valve for swing priority is shut off 2 Trenching Mode This mode is used for heavy duty ditch digging work or for loading work requiring big swing angles The voltag...

Страница 606: ...15 16 7 6 2 1 4 5 2 1 11 3 13 2 12 1 9 8 10 14 6 5 4 7 CN7 1 13 3 2 CN3 CN4 CN2 3 20 19 1 5 2 10A CN7 TxD RxD 10 9 5 2 20A 3 TxD RxD RxD TxD CN3 8 CN3 11 CN3 12 CN3 10 CN3 9 CN1 9 CN1 14 RS 422 CN1 1...

Страница 607: ...ter feed back signals are the same the engine controller shuts off the current to the control motor The engine control motor cable is a solid type and is connected to the engine fuel injection control...

Страница 608: ...S0802220K Page 54 Electrical System...

Страница 609: ...r switch should be turned off and the cause of abnormal load should be repaired and the starter switch can be turned on again The engine control dial can once again be used to control the engine speed...

Страница 610: ...umber Description 1 Knob 2 Potentiometer Variable Resistor 2 1 1 1 VIEW POTENTIOMETER BOTTOM 1st STEP 10 10 7th STEP 13th STEP CCW MECHANICAL STOP CW MECHANICAL STOP 2 3 2 3 1 2 3 4 2 5V 1 0V 4 0V 1ST...

Страница 611: ...ical System The engine control dial has a built in potentiometer When the control knob is moved the output voltage through terminals 2 and 3 will vary from the 5 V supplied from the throttle controlle...

Страница 612: ...55 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse 4 e EPOS Controller 5 Instrument Panel 6 Engine Speed Sensor 7 Engine Throttle Controller 8 Engine Control Motor 9 Engine Control Dial...

Страница 613: ...ers are in the neutral position the e EPOS controller sends an automatic reduction signal to the throttle controller When the engine throttle controller receives this signal it is compared with the si...

Страница 614: ...throttle controller will signal the engine control motor to decrease the engine speed When the coolant is overheated the warning buzzer will sound standard mode is selected and low engine speed will...

Страница 615: ...activate the power boost solenoid valve and increase the relief valve pressure from 330 350 kg cm2 4 700 5 000 psi The excavation ability is increased by approximately 6 NOTE Do not use this switch fo...

Страница 616: ...CN3 11 12 13 14 17 CN1 6 7 8 6 3 4 1 2 20 11 16 CN7 CN1 1 CN4 1 3 10 7 8 9 CN1 CN3 11 CN3 12 CN3 8 CN3 10 CN3 9 RxD RxD RS 422 TxD TxD 5 6 1 CN2 3 7 6 CN1 13 CN1 9 CN1 2 CN1 8 4 1 3 20A 2 ARS1150L Fig...

Страница 617: ...monitored by the two pressure sensors in the discharge lines of the front upper and rear lower pumps When the travel load is high pressure over 300 kg cm2 4 300 psi the solenoid valve is turned OFF an...

Страница 618: ...2 17 14 4 9 10 15 16 1 LOW CN4 10 CN4 11 8 CN3 CN4 CN2 6 CN2 5 0 II 3 10 I 6 AUTO MANUAL 9 2 CN1 12 SIG 6 SIG 5 CN4 2 CN4 4 CN4 3 CN4 1 10A CN1 8 CN1 9 CN1 1 CN1 2 4 3 20A 2 1 ARS1170L Figure 61 Refe...

Страница 619: ...stopper position and the cable slack is acceptable 3 A If the lever is not in the minimum position and touching the stopper move the 3 cable to one hole lower on the lever If the cable slack is exces...

Страница 620: ...le VR1 Refer to throttle controller name plate 3 Figure 64 Standard Mode VR2 Refer to throttle controller name plate 3 Figure 64 Reference Number Description 1 VR1 Automatic Deceleration Adjusting Var...

Страница 621: ...age 67 Electrical System Figure 65 Reference Number Description 1 Engine Fuel Control Lever Area 2 Control Motor Cable Bracket 3 Engine Speed Control Cable 4 To Engine Control Motor Reference Number D...

Страница 622: ...in normal range 2 Engine Speed Monitor This LED light flashes according to the engine speed The flashing interval is proportional to the engine speed 3 Communication Monitor These LED lamps flash whe...

Страница 623: ...re information codes a part of failure information Refer to the failure information part of letter information display for details Mode Selection Display Readout Operation Status Upper Digit Lower Dig...

Страница 624: ...ssibility of motor damage or burn out exists 4 After the malfunction is corrected turn the starter switch from OFF to the ON position and normal operation will resume Throttle Controller Input Signal...

Страница 625: ...ly 5 seconds Continuous Operation II Position When the wiper switch 4 is turned I position the current flows from the fuse 3 B terminal of wiper motor 7 L terminal of wiper motor 7 No 5 terminal of wi...

Страница 626: ...er 6 No 4 terminal of wiper timer 6 S terminal of wiper motor 7 B terminal of wiper motor 7 and the wiper motor is stopped at the auto stop position WINDOW WASHER OPERATION When the window washer swit...

Страница 627: ...S0802220K Page 73 Electrical System...

Страница 628: ...2 CN3 10 CN3 9 CN3 12 CN3 11 CN3 8 CN7 1 L5 CN7 9 11 10A 15 RH 14 LH LH RH RH 16 LH 17 FL FR FMR 18 FL FR FML 30 86 87 85 7 87a 3 10 II 6 I 4 0 86 30 85 87a 87 8 13 1 7 10 9 2 10A 5 I 5 0 9 10A 20A 1...

Страница 629: ...a 15 Work Light 2 ea 16 Additional Work Light 2 ea 17 Front Cabin Light 2 ea 18 Front Cabin Light 4 ea 19 Rear Cabin Light 2 ea Reference Number Description Switch Position Connected Terminal of switc...

Страница 630: ...AD WARNING DEVICE OVERLOAD WARNING DEVICE CIRCUIT DIAGRAM 5 6 4 2 1 3 ARS1260L Figure 69 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse Box 4 e EPOS Controller 5 OWD Select Switch 6 Pre...

Страница 631: ...safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable...

Страница 632: ...S0892160K Page 2 Electrical Schematic S300LC V TABLE OF CONTENTS General Description 3 Solar 300LC V 4...

Страница 633: ...300LC V GENERAL DESCRIPTION Schematic s presented in this section are laid out on facing pages An overlapping edge has been taken into consideration so that a photocopy can be made and pasted together...

Страница 634: ...S0892160K Page 4 Electrical Schematic S300LC V SOLAR 300LC V Figure 2...

Страница 635: ...S0892160K Page 5 Electrical Schematic S300LC V ELECTRICAL DIAGRAM DAEWOO HEAVY INDUSTRIES LTD NO 599 00035 Model Solar 300LC V Name HAAD4190...

Страница 636: ...S0892160K Page 6 Electrical Schematic S300LC V...

Страница 637: ...1ATTACHMENTS...

Страница 638: ......

Страница 639: ...nt of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that u...

Страница 640: ...CONTENTS Front Attachment Pin Specifications 3 Front Attachment Removal and Installation 4 Arm Removal Procedure 4 Boom Removal Procedure 6 Installation 7 Arm Installation Procedure 7 Boom Installati...

Страница 641: ...ns Consult Daewoo After Sales Service for information on wear tolerances and replacement limits for mounting pins Mounting Pin Diameter mm Inches Length mm Inches A 105 mm 4 134 1001 mm 39 409 B 90 mm...

Страница 642: ...with the lower structure Never rotate the upper structure once the counterweight or front attachment has been removed IMPORTANT Always break down the front attachment by removing outermost sections f...

Страница 643: ...ly if necessary Place a sling under the arm cylinder the cylinder used to extend and retract the attachment arm pinned to the top of the boom Lift the sling so that the weight load on the rod end of t...

Страница 644: ...aulic pressure and disconnect line couplings as previously outlined in the Arm Removal Procedure observing the same precautions Disconnect wiring for work light assemblies and any other accessory line...

Страница 645: ...sling from around the rod end arm cylinder pin withdraw the pin and lift the body of the arm cylinder to re pin the mounting connection BOOM INSTALLATION PROCEDURE Before reassembling the attachment m...

Страница 646: ...and Arm START UP PROCEDURES Once the boom has been serviced it should be lubricated as outlined in the initial start up procedures of the operation manual Refer to the appropriate operation and mainte...

Страница 647: ...s section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsib...

Страница 648: ...Tooth Inspection and Replacement 3 Type 1 3 Type 2 4 Bucket O ring Replacement 6 Bucket Shimming Procedures 8 New Bucket Installation 8 Bucket Attachment Removal and Reversal 9 Detaching the Bucket 9...

Страница 649: ...points on the working surfaces of tooth points pits cracks chips or craters are larger than 8 mm to 10 mm 1 3 to 1 2 across 1 On a routine basis inspect the bucket teeth to make sure that tooth wear o...

Страница 650: ...ng steel ball causes the boss to go inside WARNING Due to the possibility of flying metal objects always wear safety helmet protective gloves and eye protection when changing bucket teeth Curl the buc...

Страница 651: ...wear down to a point that bucket adapter is exposed See Figure 4 2 To replace a tooth use a hammer 1 Figure 5 and punch 2 to drive locking pin assembly out of tooth and tooth adapter 3 Once the worn...

Страница 652: ...he way 3 Remove the old O ring and temporarily install the new O ring 1 Figure 8 onto the bucket boss 2 Make sure that the O ring groove on both the bucket link 4 and boss have been cleaned 4 Realign...

Страница 653: ...S0904005K Page 7 Bucket 5 Roll the new O ring 1 Figure 9 into the O ring groove ARO1392L 1 Figure 9...

Страница 654: ...rance should be 1 mm 0 04 in between side face of boss and inside edge of ear bushing Y Figure 10 Too tight a fit less than 1 mm 0 04 in can cause excessive wear while too much clearance may produce e...

Страница 655: ...semble the link pin end retainers and pull out the pin Lift the arm away from the bucket so that the bucket can be carried away or another end attachment can be put on the excavator ATTACHING THE BUCK...

Страница 656: ...simplified if some type of rotating or swiveling support can be used on the ground underneath the bucket Follow instructions for Bucket Attachment to replace pins WARNING When making linkage alignment...

Страница 657: ...EET ADDRESS TELEPHONE CITY FAX STATE PROVINCE COUNTRY NAME MACHINE MODEL SERIAL NUMBER MANUAL NUMBER SHOP MANUAL SECTION NUMBER PROPOSED DESCRIPTION OF CORRECTION AND OR SUGGESTION Use additional pape...

Страница 658: ......

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