Manual Doosan DX300LC PDF
Manual Doosan DX300LC PDF
Manual Doosan DX300LC PDF
Shop Manual
K1006409E
Serial Number 5001 and Up
Daewoo reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine's package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
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Pub.No. K1006409E
Serial Number 5001 and Up
DX300LC
Product Label
Instructions
Specifications
Specification for DX300LC.................................................................... SP000015
General Maintenance
General Maintenance Procedures ........................................................ SP000016
Standard Torques ................................................................................. SP000017
Upper Structure
Cabin .................................................................................................... SP000018
Counterweight....................................................................................... SP000019
Fuel Tank.............................................................................................. SP000020
Fuel Transfer Pump .............................................................................. SP000021
Swing Bearing....................................................................................... SP000022
Swing Reduction Gear.......................................................................... SP000023
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ............... SP000027
Accumulator.......................................................................................... SP000028
Center Joint (Swivel)............................................................................. SP000029
Table of Contents
Page I
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Cylinders............................................................................................... SP000030
Swing Motor.......................................................................................... SP000031
Travel Motor.......................................................................................... SP000032
Gear Pump ........................................................................................... SP000033
Main Control Valve ............................................................................... SP000034
Hydraulic Schematic (DX300LC) .......................................................... SP000037
Axial Piston Pump................................................................................. SP000068
Remote Control Valve (Work Lever / Joystick) ..................................... SP000069
Travel Control Valve (With Damper)..................................................... SP000070
Electrical System
Electrical System .................................................................................. SP000038
Electrical Schematic (DX300LC) .......................................................... SP000039
Attachments
Boom and Arm...................................................................................... SP000040
Bucket................................................................................................... SP000041
Table of Contents
Page II
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1Safety
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SP000014
TRACK EXCAVATOR SAFETYSP000014
Track
Excavator
Safety
Edition 1
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MEMO
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Table of Contents
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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TO THE OPERATOR OF A
DOOSAN DAEWOO EXCAVATOR
DANGER!
Unsafe use of the excavator could lead to serious injury or
death. Operating procedures, maintenance and equipment
practices or traveling or shipping methods that do not
follow the safety guidelines on the following pages could
cause serious, potentially fatal injuries or extensive
damage to the machine or nearby property.
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WARNING!
Improper operation and maintenance of this machine can
be hazardous and could result in serious injury or death.
Operator and maintenance personnel should read this
manual thoroughly before beginning operation or
maintenance.
Keep this manual in the storage compartment to the rear of
the operator's seat, and have all personnel involved in
working on the machine read the manual periodically.
Some actions involved in operation and maintenance of the
machine can cause a serious accident, if they are not done
in a manner described in this manual.
The procedures and precautions given in this manual apply
only to intended uses of the machine.
If you use your machine for any unintended uses that are
not specifically prohibited, you must be sure that it is safe
for any others. In no event should you or others engage in
prohibited uses or actions as described in this manual.
DOOSAN delivers machines that comply with all applicable
regulations and standards of the country to which it has
been shipped. If this machine has been purchased in
another country or purchased from someone in another
country, it may lack certain safety devices and
specifications that are necessary for use in your country. If
there is any question about whether your product complies
with the applicable standards and regulations of your
country, consult DOOSAN or your DOOSAN distributor
before operating the machine.
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SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and Safety
Instructions.
This is the Safety Alert Symbol. Wherever it appears in this
manual or on safety signs on the machine you should be
alert to the potential for personal injury or accidents.
Always observe safety precautions and follow
recommended procedures.
CAUTION!
This word is used on safety messages and safety labels and
indicates potential of a hazardous situation that, if not
avoided, could result in minor or moderate injury. It may
also be used to alert against a generally unsafe practice.
WARNING!
This word is used on safety messages and safety labels and
indicates potential of a hazardous situation that, if not
avoided, could result in serious injury or death. It may also
be used to alert against a highly unsafe practice.
DANGER!
This word is used on safety messages and safety labels and
indicates an imminent hazard of a situation that, if not
avoided, is very likely to cause death or extremely serious
injury. It may also be used to alert against equipment that
may explode or detonate if handled or treated carelessly.
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Safety precautions are described in SAFETY from page -11 on.
DOOSAN cannot predict every circumstance that might involve
a potential hazard in operation and maintenance. Therefore the
safety messages in this manual and on the machine may not
include all possible safety precautions. If any procedures or
actions not specifically recommended or allowed in this manual
are used, you must be sure that you and others can do such
procedures and actions safely and without damaging the
machine. If you are unsure about the safety of some procedures,
contact a DOOSAN distributor.
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GENERAL SAFETY ESSENTIALS
Accessory Applications
The excavator has been primarily designed for moving earth
with a bucket. For use as a grapple or for other object handling,
contact DOOSAN for proper installation and application. Lifting-
work applications (unless restricted or prohibited by local
regulations) are permitted in approved lift configuration, to rated
capacity only, with no side-loading. DO NOT use the machine for
activities for which it was not intended. DO NOT use the bucket
for lifting work, unless lift slings are used in the approved
configuration.
Use of an accessory hydraulic hammer (breaker), work in rough
terrain, demolition applications or other hazardous operation
may require installation of additional protective structures to
safeguard the operator.
IMPORTANT
Before using the excavator to make lifts check municipal
and regional regulations or statutes that could apply.
Governing ordinances may require that all heavy lifting be
done with single purpose equipment specifically designed
for making lifts, or other local restrictions may apply.
Making heavy lifts with a general purpose excavator that
can be used for digging, loading, grading or other work may
be expressly forbidden by a regional injunction or other
legal prohibition. Always follow all of the other instructions,
guidelines and restrictions for Safe Lifting in the Operation
and Maintenance Manuals.
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LOCATION OF SAFETY LABELS
Location of safety labels (decals) can vary from unit to unit.
Refer to appropriate Operation and Maintenance Manual, and
parts manual for your unit.
Always replace damaged or faded decals.
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SUMMARY OF SAFETY
PRECAUTIONS FOR LIFTING IN
DIGGING MODE
DANGER!
Unsafe use of the excavator while making rated lifts could
cause serious, potentially fatal injuries or extensive
damage to the machine or nearby property. Do not let
anyone operate the machine unless they've been properly
trained and understand the information in the Operation
and Maintenance Manual.
WARNING!
NEVER wrap a tag line around your hands or body.
NEVER rely on tag lines or make rated lifts when wind gusts
are more than 48.3 km/h (30 MPH). 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 DOOSAN
representative.
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UNAUTHORIZED
MODIFICATIONS
Any modification made without authorization or written approval
from DOOSAN can create a safety hazard, for which the
machine owner must be held responsible.
For safety's sake, replace all OEM parts with the correct
authorized or genuine DOOSAN part. For example, not taking
the time to replace fasteners, bolts or nuts with the correct
replacement parts could lead to a condition in which the safety
of critical assemblies is dangerously compromised.
GENERAL HAZARD
INFORMATION
Safety Rules
Only trained and authorized personnel can operate and maintain
the machine.
Follow all safety rules, precautions and instructions when
operating or performing maintenance on the machine.
Do not operate the machine if you are not feeling well, if you are
taking medication that makes you feel sleepy, if you have been
drinking, or if you are suffering from emotional problems. These
problems will interfere with your sense of judgement in
emergencies and may cause accidents.
When working with another operator or with a person on work
site traffic duty, be sure that all personnel know the nature of the
work and understand all hand signals that are to be used.
Always observe strictly any other rules related to safety.
Safety Features
Be sure that all guards and covers are installed in their proper
position. Have guards and covers repaired immediately if
damaged.
Be sure that you understand the method of use of safety
features such as safety lock lever and the seat belt, and use
them properly.
Never remove any safety features. Always keep them in good
operating condition.
Failure to use safety features according to the instructions in the
Operation and Maintenance Manual could result in serious
bodily injury.
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Inside Operator's Compartment
When entering the operator's compartment, always remove all
mud and oil from the soles of your shoes. If you operate the
travel pedal with mud or oil stuck to your shoes, your foot may
slip and this may cause a serious accident.
After using the ashtray, make sure that any matches or
cigarettes are properly extinguished, and be sure to close the
ashtray. If the ashtray is left open, there is danger of fire.
Do not stick suction pads to the window glass. Suction pads act
as a lens and may cause fire.
Do not leave lighters laying around the operator's compartment.
If the temperature inside the operator's compartment becomes
high, there is danger that the lighter may explode.
Do not use cellular telephones inside the operator's
compartment when driving or operating the machine. There is
danger that this may lead to an unexpected accident.
Never bring any dangerous objects such as flammable or
explosive items into the operator's cabin.
To ensure safety, do not use the radio or music headphones
when operating the machine. There is danger that this may lead
to a serious accident.
When operating the machine, do not put your hands or head out
of the window.
When standing up from the operator's seat, always place safety
lock lever securely in the "LOCK" position. If you accidentally
touch the work equipment levers when they are not locked, the
machine may suddenly move and cause serous injury or
damage.
When leaving the machine, lower the work equipment
completely to the ground, set safety lock lever to the "LOCK"
position and shut down engine. Use the key to lock all the
equipment. Always remove the key and take it with you.
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Breathing Masks, Ear Protection May Be
Required
Do not forget that some risks to your health may not be
immediately apparent. Exhaust gases and noise pollution may
not be visible, but these hazards can cause disabling or
permanent injuries.
NOTE: The equivalent continuous A-weighted sound
pressure level at the workstation for this machine is
73 dB(A).
Measurement is obtained on a dynamic machine
following the procedures and cabin conditions as
described in ISO 6396.
NOTE: The guaranteed sound power level emitted by the
machinery for this machine is 104 dB(A).
Measurement is obtained on a dynamic machine with
the procedures as described in 2000/14/EC.
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• Drive around obstacles and excessive rough terrain
conditions.
6. Keep the terrain on work sites where the machine is
working and traveling in good condition.
• Remove any large rocks or obstacles.
• Fill any ditches and holes.
• Provide machines for and schedule time to maintain
the terrain conditions.
7. Travel over longer distance (e.g. on public roads) at
adjusted (medium) speed.
• Always adjust the speed for preventing bouncing.
FG000355
Figure 2
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Fuel, Oil and Hydraulic Fluid Fire Hazards
Fuel, oil and antifreeze will catch fire if it is brought close to a
flame. Fuel is particularly flammable and can be hazardous.
Always strictly observe the following.
Add fuel, oil, antifreeze and hydraulic fluid to the machine only in
a well ventilated area. The machine must be parked with
controls, lights and switches turned "OFF." The engine must be
"OFF" and any flames, glowing embers, auxiliary heating units
or spark causing equipment must be doused, turned "OFF" and/
or kept well clear of the machine.
Static electricity can produce dangerous sparks at the fuel filling
nozzle. In very cold, dry weather or other conditions that could
produce a static discharge, keep the tip of the fuel nozzle in
constant contact with the neck of the fuel filling nozzle, to Figure 3
provide a ground.
Keep fuel and other fluid reservoir caps tight and do not start the
engine until caps have been secured.
To prevent hot coolant from spurting out, shut down engine, wait
for the coolant to cool, then loosen the cap slowly to relieve the
pressure.
To prevent hot oil from spurting out, shut down engine, wait for
the oil to cool, then loosen the cap slowly to relieve the pressure.
HAOA060L
Figure 5
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Asbestos Dust Hazard Prevention
Asbestos dust can be HAZARDOUS to your health if it is
inhaled. Materials containing asbestos fiber can be present on
work site. Breathing air that contains asbestos fiber can
ultimately cause serious or fatal lung damage. To prevent lung
damage from asbestos fiber, observe following precautions:
• Use a respirator that is approved for use in an
asbestos-laden atmosphere.
• Never use compressed air for cleaning. ARO1770L
• Use water for cleaning to keep down the dust. Figure 6
• Work on the machine or component with the wind at
your back whenever possible.
• Always observe any rules and regulations related to
the work site and working environment.
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If 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 to the "O" (OFF) position and
shut down engine.
• If there is time, use the fire extinguisher to extinguish
as much of the fire as possible.
• Use the handrails and steps to escape from the
machine.
The above is the basic method for escaping from the machine,
but changing the method may be necessary according to the
conditions, so carry out practice drills at the work site.
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Attachment Precautions
Option kits are available through your dealer. Contact DOOSAN
for information on available one-way (single-acting) and two-way
(double-acting) piping / valving / auxiliary control kits. Because
DOOSAN cannot anticipate, identify or test all of the
attachments that owners may wish to install on their machines,
please contact DOOSAN for authorization and approval of
attachments, and their compatibility with options kits.
Accumulator
The pilot control system is equipped with an accumulator. For a
brief period of time after the engine has been shut down, the
accumulator will store a pressure charge that may enable
hydraulic controls to be activated. Activation of any controls may
enable the selected function to operate under force of gravity.
When performing maintenance on the pilot control system, the
hydraulic pressure in the system must be released as describe
in "Handling of Accumulator" in the Operation and Maintenance
Manual.
The accumulator is charged with high-pressure nitrogen gas, so
it is extremely dangerous if it is handled in the wrong way.
Always observe the following precautions:
• Do not drill or make any holes in the accumulator or
expose it any flame, fire or heat source.
• Do not weld on the accumulator, or try attaching
anything to it.
• When carrying out disassembly or maintenance of
the accumulator, or when disposing of the
accumulator, the charged gas must be properly
released. Contact your DOOSAN distributor.
• Wear safety goggles and protective gloves when
working on an accumulator. Hydraulic oil under
pressure can penetrate the skin and cause serious
injuries.
Indoor Ventilation
Engine exhaust gases can cause fatal accidents, and
unconsciousness, loss of alertness, judgement and motor
control and serious injury.
Make sure there is adequate ventilation before starting the
engine in any enclosed area.
You should also be aware of open windows, doors or ductwork
into which exhaust may be carried, or blown by the wind,
exposing others to danger. ARO1770L
Figure 11
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Emergency Exit
This machine is equipped with a glass breaking tool. It is behind
the operator seat in the upper right corner of the cabin. This tool
can be used in case of an emergency situation that requires the
breaking of glass to exit from the operator's cabin. Grip the
handle firmly and use the sharp point to break the glass.
WARNING!
FG000178
Protect your eyes when breaking the glass. Figure 12
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BEFORE STARTING ENGINE
Check the condition of the river bed, and the depth and flow of
the water before operating in water or crossing a river. NEVER
be in water that is in excess of the permissible water depth.
Any type of object in the vicinity of the boom could represent a
potential hazard, or cause the operator to react suddenly and
cause an accident. Use a spotter or signal person working near
bridges, phone lines, work site scaffolds, or other obstructions.
FG000363
Figure 14
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areas. If the ground should collapse, the machine could fall or tip
over and this could result in serious injury or death.
Remember that the soil after heavy rain, blasting or after
earthquakes, is weakened in these areas.
Earth laid on the ground and the soil near ditches is loose. It can
collapse under the weight of vibration of your machine and
cause your machine to tip over.
Install the head guard (FOPS) if working in areas where there is
danger of falling rocks.
Engine Starting
Walk around your machine before getting in the operator's cabin.
Look for evidence of leaking fluid, loose fasteners, misaligned
assemblies or any other indications of possible equipment
hazard.
All equipment covers and machinery safety guards must be in
place, to protect against injury while the machine is being
operated.
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Look around the work site area for potential hazards, people or
properly that could be at risk while operation is in progress.
NEVER start the engine if there is any indication that
maintenance or service work is in progress, or if a warning tag is
attached to controls in the cabin.
A machine that has not been used recently, or is being operated
in extremely cold temperatures, could require a warm-up or
maintenance service before start-up.
Check gauges and monitor displays for normal operation before
starting the engine. Listen for unusual noises and remain alert
for other potentially hazardous conditions at the start of the work
cycle.
Do not short circuit the starting motor to start the engine. This is
not only dangerous, but may also damage the machine.
When starting the engine, sound the horn as an alert.
Start and operate the machine only while seated.
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• Warm up the engine and hydraulic oil before
operating machine.
• Before moving the machine, check the position of
undercarriage. The normal travel position is with idler
wheels to the front under the cabin and the drive
sprockets to the rear. When the undercarriage is in
the reversed position, the travel controls must be
operated in opposite directions.
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MACHINE OPERATION
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Travel Precautions
TRAVEL POSTURE
Never turn the starting switch to the "O" (OFF) position when
traveling. It is dangerous if the engine stops when the machine is
traveling. It will be impossible to operate the steering.
Attachment control levers should not be operated while traveling.
Do not change selected travel mode (FAST/SLOW) while
traveling.
Fold in work equipment so that the outer end of the boom is as
40 ~ 50 cm (16 ~ 20 in.)
close to the machine as possible, and is 40 - 50 cm (16 - 20 in)
above ground.
Never travel over obstacles or slopes that will cause the machine INCORRECT
to tilt severely. Travel around any slope or obstacle that causes
the machine to tilt 10 degrees or more to the right or left, or 30
degrees or more from front to rear.
Do not operate the steering suddenly. The work equipment may
hit the ground and cause the machine to lose its balance, and
this may damage the machine or structures in the area.
When traveling on rough ground, travel at low speed, and avoid
sudden changes in direction. FG000349
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Traveling on Slopes
Never jump onto a machine that is running away to stop it. There
is danger of serious injury.
Traveling on slopes could result in the machine tipping over or
slipping. 20~
30 C
m
On hills, banks or slopes, carry the bucket approximately 20 - 30
cm (8 - 12 in) above the ground. In case of an emergency,
quickly lower the bucket to the ground to help stop the machine.
Do not travel on grass, fallen leaves, or wet steel plates. Even
slight slopes may cause the machine to slip to the side, so travel
at low speed and make sure that the machine is always traveling
directly up or down the slope.
Avoid changing the direction of travel on a slope. This could
result in tipping or side slipping of the machine.
When possible, operate the machine up slopes and down Cm
30
slopes. Avoid operating the machine across the slope, when 20~
possible.
FG000365
Figure 18
Prohibited Operations
Do not dig the work face under an overhang. This may cause the
overhang to collapse and fall on top of the machine.
FG000368
Figure 19
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Do not carry out deep digging under the front of the machine.
The ground under the machine may collapse and cause the
machine to fall.
Working heavy loads over loose, soft ground or uneven, broken
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 supports when work
is being done. Block tracks fore and aft to prevent any
movement.
FG000170
Figure 20
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Avoid High Voltage Cables
Serious injury or death can result from contact or proximity to
high voltage electric lines. The bucket does not have to make
physical contact with power lines for current to be transmitted.
Use a spotter and hand signals to stay away from power lines
not clearly visible to the operator.
FG000112
Figure 24
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In a work site where falling rocks can cause damage and
possibly crush personnel, or in a mining operation, be sure to
install the falling object protective structure (Figure 25).
Be sure to install any other additional protective structures
required for work site conditions.
When the falling object protective structure is installed, and the
front window needs to be cleaned, loosen the bolts marked with
an arrow. Be sure to tighten bolts when done. 2
Operations on Slopes
When working on slopes. there is danger that the machine may
lose its balance and turn over, when swinging, or when work
equipment is operated. Always carry out these operations
carefully.
Do not swing the work equipment from the uphill side to the
downhill side when the bucket is loaded. This operation is
dangerous.
If the machine has to be used on a slope, pile the soil to make a FG000212
platform that will keep the machine as horizontal as possible.
Figure 26
In addition, lower the bucket as far as possible, keep it pulled into
the front, and keep the swing speed as low as possible.
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Parking Machine
Avoid making sudden stops, or parking the machine wherever it
happens to be at the end of the work day. Plan ahead so that the 120
excavator will be on firm, level ground away from traffic and away
from high walls, cliff edges and any area of potential water
accumulation or runoff. If parking on inclines is unavoidable,
Block
block the crawler tracks to prevent movement. Lower the bucket
or other working attachment completely to the ground, or to an
overnight support saddle. There should be no possibility of
unintended or accidental movement.
When parking on public roads, provide fences, signs, flags, or Unlock
lights, and put up any other necessary signs to ensure that
passing traffic can see the machine clearly, and park the
machine so that the machine, flags, and fences do not obstruct
traffic.
After the front attachment has been lowered to an overnight Lock
FG000666
storage position and all switches and operating controls are in
Figure 27
the "OFF" position, the safety lock lever must be set to the
"LOCKED" position. This will disable all pilot circuit control
functions.
Always close the door of the operator's compartment.
ARO1310L
Figure 28
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MAINTENANCE
Warning Tag
Alert others that service or maintenance is being performed and
tag operator's cabin controls – and other machine areas if
required – with a warning notice. OSHA mandated control lever WARNING
lockout can be made with any OSHA certified lockout device and
DO NOT OPERATE
a length of chain or cable to keep the safety lever in the fully
when performing inspection
lowered, nonactive position.
or maintenance
Warning tags, for controls are available from DOOSAN
190-00695
distributors.
ARO1320L
Figure 29
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Proper Tools
Use only tools suited to the task. Using damaged, low qualify,
faulty, or makeshift tools could cause personal injury. There is
danger that pieces from, chisels with crushed heads, or
hammers, may get into your eyes and cause blindness.
HDO1037L
Figure 31
Use of Lighting
When checking fuel, oil, battery electrolyte, or window washing
fluid, always use lighting with antiexplosion specifications. If
such lighting equipment is not used, there is danger of an
explosion.
If work is carried out in dark places without using lighting, it may
lead to injury, so always use proper lighting.
Even if the place is dark, never use a lighter or flame instead of
lighting. There is danger of fire. There is also danger that the HDO1040L
battery gas may catch fire and cause and explosion.
Figure 32
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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.
Burn Prevention
When checking the radiator coolant level, shut down engine, let
the engine and radiator cool down, then check the coolant
recovery tank. If the coolant level in the coolant recovery tank is
near the upper limit, there is enough coolant in the radiator.
Loosen the radiator cap gradually to release the internal
pressure before removing the radiator cap.
If the coolant level in the coolant recovery tank is below the lower
limit, add coolant.
Cooling system conditioner contains alkali. Alkali can cause
personal injury. Do not allow alkali to contact the skin, the eyes,
or the mouth.
Allow cooling system components 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 after the engine has
been stopped. Make sure that the hydraulic tank filter plug is
cool before you remove it with your bare hand. Remove the
hydraulic tank filter plug slowly to relieve pressure.
Relieve all pressure in the hydraulic oil system, in the fuel
system, or in the cooling system before you disconnect any
lines, fittings, or related items.
HAAE1980
Batteries give off flammable fumes that can explode.
Figure 34
Do not smoke while you are checking the battery electrolyte
levels.
Electrolyte is an acid. Electrolyte can cause personal injury. Do
not allow electrolyte to contact the skin or the eyes.
Always wear protective glasses when you work on batteries.
Welding Repairs
CAUTION!
When you connect or disconnect connectors between ECU
and Engine or connector between ECU and the machine,
always disconnect the source power to protect damage of
the ECU.
If you don't observe this procedure, the ECU would be
damaged or the engine would operate abnormally.
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When carrying out welding repairs, carry out the welding in a
properly equipped place. The welding should be performed by a
qualified worker. During welding operations, there is the danger
of, generation of gas, fire, or electric shock, so never let an
unqualified worker do welding.
The qualified welder must do the following:
• To prevent explosion of the battery, disconnect the
battery terminals and remove batteries.
• To prevent generation of gas, remove the paint from
the location of the weld.
• If hydraulic equipment, piping or places close to them
are heated, a flammable gas or mist will be generated
and there is danger of it catching fire. To avoid this,
never subject these places to heat.
• Do not weld on pipes or on tubes that contain
flammable fluids. Do not flame cut on pipes or on
tubes that contain flammable fluids. Before you weld
on pipes or on tubes or before you flame cut on pipes
or on tubes, clean the pipes or tubes thoroughly with
a nonflammable solvent.
• If heat is applied directly to rubber hoses or piping
under pressure, they may suddenly break so cover
them with a fireproof covering.
• Wear protective clothing.
• Make sure there is good ventilation.
• Remove all flammable objects and provide a fire
extinguisher.
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6. After welding, carefully reassemble the connector.
7. Connect the battery terminal cables. 1
8. Reassemble the undercover under the engine.
9. Reassemble the cover over the battery.
10. Close the cover of the battery.
FG000335
Figure 36
DANGER!
DOOSAN warns any user, that the removal of the
counterweight from the machine, front attachment or any
other part, may affect the stability of the machine. This
could cause unexpected movement, resulting in death or
serious injuries. DOOSAN is not liable for any misuse.
Never remove the counterweight or front attachment unless
the upper structure is in-line with the lower structure.
FG000371
Never rotate the upper structure once the counterweight or
Figure 37
front attachment has been removed.
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Precautions When Working on Machine
When carrying out maintenance operations on the machine,
keep the area around your feet clean and tidy to prevent you
from falling. Always do the 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 ARO1380L
machine, use the steps and handrails, and maintain a three-
Figure 39
point contact (both feet and one hand or both hands and one
foot) to support yourself securely.
If the job requires it, wear protective clothing.
To prevent injury from slipping or falling, when working on the
hood or covers, never use any part except the inspection
passage fitted with nonslip pads.
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Track Tension Adjustments Require
Caution
Never turn out the track tension grease fitting nut. To release
pressure from the crawler frame track tension assembly, you
should NEVER attempt to disassemble the track adjuster or
attempt to remove the grease fitting or valve assembly.
Keep your face and body away from the valve. Refer to the track
adjustment procedure in the Operator and Maintenance Manual
or Shop Manual.
HAOA110L
Figure 40
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Precautions with High-pressure Lines,
Tubes and Hoses X
When inspecting or replacing high-pressure piping or hoses,
check that the pressure has been released from the circuit.
Failure to release the pressure may lead to serious injury.
Always do the following:
• Wear protective glasses and leather gloves.
• Fluid leaks from hydraulic hoses or pressurized
X
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 for suspected hydraulic leaks.
Never use your hands or expose your fingers.
• Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install lines, tubes or hoses
that are bent or damaged.
• Make sure that all clamps, guards and heat shields
are installed correctly to prevent vibration, rubbing
against other parts, and excessive heat during
operation.
HDO1045I
– If any of the following conditions are found, Figure 42
replace the part.
– Damage or leakage from hose end.
– Wear, damage, cutting of covering, or exposure
of strengthening wire layer.
– Cover portion is swollen in places.
– There is twisting or crushing at movable parts of
hose.
– Foreign material is embedded in the covering.
– Hose end is deformed.
NOTE: Refer to "Hose In-service Lifetime Limit
(European Standard ISO 8331 and EN982
CEN)" in the Operation and Maintenance
Manual, for additional European
regulations.
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Waste Materials
Physical contact with used motor oil may pose a health risk.
X
Wipe oil from your hands promptly and wash off any remaining
residue.
Used motor oil is an environmental contaminant and may only
be disposed of at approved collection facilities. To prevent
pollution of the environment, always do the following:
• Never dump waste oil in a sewer system, rivers, etc.
• Always put oil drained from your machine in HAOA470L
containers. Never drain oil directly onto the ground. Figure 43
• Obey appropriate laws and regulations when
disposing of harmful materials such as oil, fuel,
solvent, filters, and batteries.
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BATTERY
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Boost Starting or Charging Engine
Batteries
If any mistake is made in the method of connecting the booster
cables, it may cause an explosion or fire. Always do the
following:
• Turn off all electrical equipment before connecting
leads to the battery. This includes electrical switches
on the battery charger or boost starting equipment.
• When boost starting from another machine or vehicle HAOA310L
do not allow the two machines to touch. Wear safety Figure 45
glasses or goggles while required battery
connections are made.
• 24 volt battery units consisting of two series
connected twelve volt batteries have a cable
connecting one positive terminal on one of the 12 volt
batteries to a negative terminal on the other battery.
Booster or charger cable connections must be made
between the nonseries connected positive terminals
and between the negative terminal of the booster
battery and the metal frame of the machine being
boosted or charged. Refer to the procedure and
illustration in "Starting Engine With a Booster Cable"
in the Operation and Maintenance Manual.
• Connect positive cable first when installing cables
and disconnect the negative cable first when
removing them. The final cable connection, at the
metal frame of the machine being charged or boost
started, should be as far away from the batteries as
possible.
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TOWING
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SHIPPING AND
TRANSPORTATION
WARNING!
Improper lifting can allow load to shift and cause injury or
damage.
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Track Excavator Safety SP000014
Page 46
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1Specifications
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SP000015
SPECIFICATION FOR DX300LCSP000015
Specification
for DX300LC
Edition 1
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MEMO
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Table of Contents
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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Specification for DX300LC SP000015
Page 6
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GENERAL DESCRIPTION
The excavator has three main component sections:
• The Upper Turntable
• The Lower Undercarriage and Track Frames
• The Excavator Front-end Attachment
The following illustration identifies main components and their
locations. (See Figure 1 on page -8.)
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COMPONENT LOCATIONS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
40
39
38
37 20
36
21
35
34 22
33 26
32
31 23
30
29
28 27
24
25
FG000671
Figure 1
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Reference Reference
Description Description
Number Number
1 Counterweight 22 Bucket Cylinder
2 Hood 23 Guide Link
3 Muffler 24 Bucket
4 Hydraulic Oil Tank 25 Push Link
5 Fuel Tank 26 Tooth Point
6 Engine 27 Side Cutter
7 Fuel Tank Fill Cap 28 Idler
8 Radiator And Oil Cooler 29 Track Adjuster
9 Control Valves 30 Track Guide
10 Swing Motor 31 Battery
11 Precleaner 32 Lower Roller
12 Air Cleaner 33 Center Joint
13 Swing Bearing 34 Upper Roller
14 Seat 35 Sprocket
15 Cabin 36 Travel Motor
16 Boom Cylinder 37 Track Link and Shoe
17 Work Lever (Joystick) Controls 38 Suction Filter
18 Arm Cylinder 39 Return Filter
19 Boom 40 Pumps
20 Travel Lever
21 Arm
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GENERAL DIMENSIONS
H A
I J B C
O G
F
N
M
K D
L E
FG000316
Figure 1
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SP000015 Specification for DX300LC
Page 11
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WORKING RANGE
WARNING!
The actual value for dimension "L" Digging Reach, depends
on the stability and support provided by ground conditions.
Digging too far underneath the excavator if soil conditions
are wet, loose or unstable can collapse ground support,
which could cause injury and/or equipment damage.
11
10
5 F
G
4
D
3
G.L 0
0 1 2 3 4 5 6 7 8 9 10 11
-1
-2
-3
H
-4 C
-5
-6
-7
-8
A
B
I
FG001449
Figure 2
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Boom Type One Piece 6.245 m (20.5 ft)
3.1 m 2.5 m 3.75 m
Arm Type
Dim. (10.17 ft) (8.2 ft) (12.3 ft)
1.27 m3 1.50 m3 1.75 m3
Bucket Type (PCSA)
(1.66 yd3) (1.96 yd3) (2.29 yd3)
10,745 mm 10,170 mm 11,270 mm
A Max. Digging Reach
(35' 3") (33' 4") (37' 0")
Max. Digging Reach 10,550 mm 9,970 mm 11,090 mm
B
(Ground) (34' 7") (32' 9") (36' 5")
7,380 mm 6,780 mm 8,030 mm
C Max. Digging Depth
(24' 3") (22' 3") (26' 4")
7,240 mm 6,910 mm 7,345 mm
D Max. Loading Height
(23' 9") (22' 8") (24' 1")
10,310 mm 9,950 mm 10,390 mm
F Max. Digging Height
(33' 10") (32' 8") (34' 1")
8,855 mm 8,525 mm 8,960 mm
G Max. Bucket Pin Height
(29' 1") (28' 0") (29' 5")
6,200 mm 5,425 mm 6,690 mm
H Max. Vertical Wall
(20' 4") (17' 10") (21' 11")
6,820 mm 6,545 mm 7,045 mm
I Max. Radius Vertical
(22' 5") (21' 6") (23' 1")
7,185 mm 6,505 mm 7,850 mm
J Max. Depth to 8 ft Line
(23' 7") (21' 4") (25' 9")
2,990 mm 2,965 mm 2,930 mm
K Min. Radius 8 ft Line
(9' 10") (9' 9") (9' 7")
625 mm 1,995 mm - 305 mm
L Min. Digging Reach
(2' 1") (6' 7") (- 1' 0")
4,055 mm 4,060 mm 4,060 mm
M Min. Swing Radius
(13' 4") (13' 4") (13' 4")
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GENERAL SPECIFICATIONS
Shipping Weight 28.9 metric tons (63,710 lb), includes 10% fuel, boom, 3,100 mm (10'
2") arm, 1,334 mm (4' 5") backhoe bucket and standard shoes
Operating Weight Add weight of full fuel tank and operator.
Shipping Weights With Optional Add 600 kg (1,320 lb) for 700 mm (28") shoes
Track Shoes Add 900 kg (1,984 lb) for 800 mm (32") shoes
Add 1,200 kg (4,408 lb) for 850 mm (34") shoes
Major Component Weights Standard Boom 2,330 kg (5,137 lb)
2,500 mm (8' 2") Arm 900 kg (1,984 lb)
3,100 mm (10' 2") Arm 1,050 kg (2,315 lb)
3,750 mm (12' 4") Arm 1,060 kg (2,337 lb)
Boom Cylinders 260 kg (573 lb) each
Arm Cylinder 340 kg (750 lb)
Bucket Cylinder 220 kg (485 lb)
Counterweight 5,300 kg (11,684 lb)
Upper Turntable 7,700 kg (16,975 lb)
Lower - below Swing Bearing 10,660 kg (23,500 lb)
Digging Forces:
Bucket Cylinder 177 KN or 18,000 kg (39,700 lb) - (with either 3,100 mm [10' 2"] or
2,500 mm [8' 2"] arm)
Arm Cylinder 131 KN or 13,400 kg (29,500 lb) with 3,100 mm (10' 2") standard arm
Fuel Tank Capacity 500 liters (132.1 U.S. gal)
Hydraulic System Capacity 280 liters (74 U.S. gal)
Hydraulic Reservoir Capacity 160 liters (42 U.S. gal)
Bucket Heaped Capacity Range PCSA 0.90 - 1.5 m3 (1.18 - 1.96 yd3)
IMPORTANT: Refer to the Load Weight, Bucket and Arm Length
Compatibility Table for information on which bucket sizes may be used
safely with which arm length, for load material weights.
Shoe Type Triple Grouser
Shoe Width and Optional Sizes 600 mm (23.5") - standard
700 mm (28") - optional
800 mm (32") - optional
850 mm (34") - optional
Ground Pressure Ratings:
Standard 600 mm (23.6") shoe - 0.56 kg/cm2 (8.0 psi)
Optional 700 mm (28.0") shoe - 0.49 kg/cm2 (7.0 psi)
Optional 800 mm (32.0") shoe - 0.43 kg/cm2 (6.1 psi)
Optional 850 mm (34.0") shoe - 0.41 kg/cm2 (5.8 psi)
Transport Dimensions
Overall Shipping Length 10,620 mm (34' 10")
(standard boom and arm)
Overall Shipping Width 3,200 mm (10' 6")
(standard shoes)
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Overall Shipping Height (to top 3,345 mm (11')
of cylinder hose)
Track Shipping Length 4,940 mm (16' 2")
Transport Trailer Capacity 30 tons (33 short tons), minimum load capacity
Transport Loading Ramp Allowable 15˚ angle CAUTION: Refer to Transport Maximum Procedure for Safe
Slope Shipping Instructions.
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ENGINE PERFORMANCE
CURVES (PER DIN 6270
STANDARD)
100
90
80
TORQUE (kg.m)
70
200
POWER OUTPUT (ps)
150
100
160
150
140
REVOLUTION (rpm)
FG001092
Figure 3
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Condition Specification
Engine Model DL08
Barometric Pressure 760 mmHg (20°C (68°F))
711 mm, SUCKER
Cooling Fan
(28 in)
Alternator 24V x 50A
Air Cleaner Installed
Muffler Installed
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APPROXIMATE WEIGHT OF
WORKLOAD MATERIALS
IMPORTANT
Weights are approximations of estimated average volume
and mass. Exposure to rain, snow or ground water; settling
or compaction due to overhead weight, chemical or
industrial processing or changes due to thermal or
chemical transformations could all increase the value of
weights listed in the table.
Medium Weight or
Low Weight or Density High Weight or Density
Density
Material 1,100 kg/m3 2,000 kg/m3
1,600 kg/m3
(1,850 lb/yd3), or Less (3,370 lb/yd3), or Less
(2,700 lb/yd3), or Less
401 kg/m3
Charcoal --------------------- ---------------------
(695 lb/yd3)
433 kg/m3
Coke, blast furnace size --------------------- ---------------------
(729 lb/yd3)
449 kg/m3
Coke, foundry size --------------------- ---------------------
(756 lb/yd3)
Coal, bituminous slack, 801 kg/m3
--------------------- ---------------------
piled (1,350 lb/yd3)
Coal, bituminous r. of m., 881 kg/m3
--------------------- ---------------------
piled (1,485 lb/yd3)
897 kg/m3
Coal, anthracite --------------------- ---------------------
(1,512 lb/yd3)
Clay, DRY, in broken 1,009 kg/m3
--------------------- ---------------------
lumps (1,701 lb/yd3)
1,746 kg/m3
Clay, DAMP, natural bed --------------------- ---------------------
(2,943 lb/yd3)
Cement, Portland, DRY 1,506 kg/m3
--------------------- ---------------------
granular (2,583 lb/yd3)
Cement, Portland, DRY 1,362 kg/m3
--------------------- ---------------------
clinkers (2,295 lb/yd3)
1,522 kg/m3
Dolomite, crushed --------------------- ---------------------
(2,565 lb/yd3)
1,202 kg/m3
Earth, loamy, DRY, loose --------------------- ---------------------
(2,025 lb/yd3)
1,522 kg/m3
Earth, DRY, packed --------------------- ---------------------
(2,565 lb/yd3)
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Medium Weight or
Low Weight or Density High Weight or Density
Density
Material 1,100 kg/m3 2,000 kg/m3
1,600 kg/m3
(1,850 lb/yd3), or Less (3,370 lb/yd3), or Less
(2,700 lb/yd3), or Less
1,762 kg/m3
Earth, WET, muddy --------------------- ---------------------
(2,970 lb/yd3)
Gypsum, calcined, 961 kg/m3
--------------------- ---------------------
(heated, powder) (1,620 lb/yd3)
Gypsum, crushed to 3 1,522 kg/m3
--------------------- ---------------------
inch size (2,565 lb/yd3)
Gravel, DRY, packed 1,810 kg/m3
--------------------- ---------------------
fragments (3,051 lb/yd3)
Gravel, WET, packed 1,922 kg/m3
--------------------- ---------------------
fragments (3,240 lb/yd3)
Limestone, graded above 1,282 kg/m3
--------------------- ---------------------
2 (2,160 lb/yd3)
Limestone, graded 1,362 kg/m3
--------------------- ---------------------
1-1/2 or 2 (2,295 lb/yd3)
1,522 kg/m3
Limestone, crushed --------------------- ---------------------
(2,565 lb/yd3)
1,602 kg/m3
Limestone, fine --------------------- ---------------------
(2,705 lb/yd3)
1,282 kg/m3
Phosphate, rock --------------------- ---------------------
(2,160 lb/yd3)
929 kg/m3
Salt --------------------- ---------------------
(1,566 lb/yd3)
529 kg/m3
Snow, light density --------------------- ---------------------
(891 lb/yd3)
1,522 kg/m3
Sand, DRY, loose --------------------- ---------------------
(2,565 lb/yd3)
1,922 kg/m3
Sand, WET, packed --------------------- ---------------------
(3,240 lb/yd3)
1,362 kg/m3
Shale, broken --------------------- ---------------------
(2,295 lb/yd3)
529 kg/m3
Sulphur, broken --------------------- ---------------------
(1,620 lb/yd3)
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PERFORMANCE TESTS
1. Main Relief Pressure
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EXCAVATOR PERFORMANCE
STANDARDS
Evaluation of equipment performance and operating condition
can be made by running the excavator through a series of
different tests, and recording results with a stop watch and tape
measure.
Compare results of performance tests against the specifications
and standards that follow, which are for equipment in new or
renewed condition.
Test Conditions
1. All tests should be performed on a flat, level, firm
supporting ground surface.
2. All recommended, applicable maintenance and adjustment
service should be completed before testing.
3. Hydraulic fluid and engine oil should be of appropriate
viscosity for ambient weather conditions. Warm up
hydraulic oil to standard operating temperature, between
45° - 55°C (112° - 135°F).
4. Run all tests with the engine speed control set to maximum
rpm.
5. Repeat tests with Power Mode engine control settings at
both Standard Mode (standard work mode) and Power
Mode (high speed mode). Travel speed tests should also
be repeated at both high and low speed.
Speed Test
Prepare the excavator for travel speed tests by extending all
hydraulic cylinders - boom, arm and bucket - to the fully
extended position, shown in Figure 4.
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0.3 M - 0.5 M (1' - 2')
FG000466
Figure 4
The lowest part of the bucket linkage should be 0.3 - 0.5 m (1' -
2') off the ground.
Mark off a 20 m (65' 7-1/2") test distance, with a 3 - 5 m (10' -
15') run-up area, and a 3 - 5 m (10' - 15', or longer) speed run-off
distance.
Travel the excavator back and forth to be sure steering is
centered and side frames are parallel with the test course.
Operate both travel levers at the fully engaged position and
measure the time it takes to cross 20 m (65' 7-1/2"). Compare
measured results against the standard for new machines:
Time
Rate of Travel
Standard Mode Power Mode
High Speed 15.1 ±1.0 sec 14.3 ±1.0 sec
Low Speed 25.5 ±1.5 sec 24.2 ±1.5 sec
3M - 5M
3M - 5M 20M
(10' - 15')
(10' - 15') (65' 7-1/2'')
FG000467
Figure 5
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Travel Deviation
To check steering deviation (travel motor balance), use a long
tape or rope, or the edge of an undeviating straight road curb or
other marker to verify side to side travel motor uniformity.
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
versa. (Figure 5)
A greater amount of deviation is allowed with the travel control
set for high speed.
1.5M
FG000468
Figure 6
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Swing Deceleration Force Test
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° reference point, perpendicular to the boom. Mark
the turntable and undercarriage with paint at the 90° point. 3
Record how far the turntable drifts past the stop point,
measuring the distance between paint marks. Maximum
distance should be less than 1200 mm (47-1/4"), in both Power
Mode and Standard Mode.
Reference
Description
Number
1 Start Swing
1
2 90˚ Swing
FG000659
3 Swing Force
Figure 7
4 Swing Stop
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Cylinder Performance Tests
NOTE: All tests are performed with standard boom, arm and
bucket configuration. The bucket should be empty.
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machine and operate the raised travel motor. Record the number
of seconds it takes the crawler shoe to make 3 full rotations,
during both high speed and low speed operation.
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1General Maintenance
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SP000016
GENERAL MAINTENANCE PROCEDURES
SP000016
General
Maintenance
Procedures
Edition 1
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MEMO
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Table of Contents
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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WELDING PRECAUTIONS AND
GUIDELINES
IMPORTANT
To avoid accidents, personal injury and the possibility of
causing damage to the machine or to components, welding
must only be performed by properly trained and qualified
personnel, who possess the correct certification (when
required) for the specific welding fabrication or specialized
repair being performed.
WARNING!
Structural elements of the machine may be built from a
variety of steels. These could contain unique alloys or may
have been heat treated to obtain particular strength
characteristics. It is extremely important that welding
repairs on these types of steel are performed with the
proper procedures and equipment. If repairs are performed
incorrectly, structural weakening or other damage to the
machine (that is not always readily visible) could be
caused. Always consult DOOSAN After Sales Service
before welding on integral components (loader arm, frames,
car body, track frames, turntable, attachment, etc.) of the
machine. It is possible that some types of structurally
critical repairs may require Magnetic Particle or Liquid
Penetrant testing, to make sure there are no hidden cracks
or damage, before the machine can be returned to service.
CAUTION!
Always perform welding procedures with the proper safety
equipment on hand. Adequate ventilation and a dry work
area are absolutely essential. Keep a fire extinguisher
nearby and always wear protective clothing and the
recommended type of eye protection.
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CAUTION!
Observe the following safety precautions:
1. Use extra caution and adequate safety shielding when
welding near fuel and oil tanks, batteries, hydraulic
piping lines or other fire hazards.
2. Never weld when the engine is running. Battery cables
must be disconnected before the welding procedure is
started.
3. Never weld on a wet or damp surface. The presence of
moisture causes hydrogen embrittlement and
structural weakening of the weld.
4. If welding procedures are being performed near
cylinder rods, operator's cabin window areas or any
other assemblies that could be damaged by weld
spatters, use adequate shielding protection in front of
the assembly.
5. During equipment setup, always attach ground cables
directly to the area or component being welded to
prevent arcing through bearings, bushings, or
spacers.
6. Always use correct welding rods for the type of weld
being performed and observe recommended
precautions and time constraints. AWS Class E7018
welding rods for low alloy to medium carbon steel
must be used within two hours after removal from a
freshly opened container. Class E11018G welding rods
for T-1 and other higher strength steel must be used
within 1/2 hour.
HYDRAULIC SYSTEM -
GENERAL PRECAUTIONS
Always maintain oil level in the system at recommended levels.
Assemblies that operate under heavy loads, at high speed, with
extremely precise dimensional tolerances between moving parts
- pistons and cylinders, or shoes and swash plates, for example -
can be severely damaged if oil supply runs dry.
Assemblies can be run dry and damaged severely in a very
short time when piping or hoses are disconnected to repair leaks
and/or replace damaged components. Hoses that are
inadvertently switched during disassembly (inlet for outlet and
vice versa), air introduced into the system or assemblies that are
low on oil due to neglect or careless maintenance, could all
produce sufficient fluid loss to cause damage.
When starting the engine (particularly after long layoff or storage
intervals), make sure that all hydraulic controls and operating
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circuits are in neutral, or "OFF." That will prevent pumps or other
components that may be temporarily oil starved from being run
under a load.
Replacement of any hydraulic system component could require
thorough cleaning, flushing, and some amount of prefilling with
fresh, clean oil if the protective seal on replacement parts has
obviously been broken or if seal integrity may have been
compromised. When protective seals are removed before
installation and reassembly, inspect all replacement parts
carefully, before they are installed. If the replacement part is
bone dry (with no trace of factory prelube) or has been
contaminated by dirt or by questionable oils, flushing and
prefilling with clean hydraulic 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 general
precaution (and to help minimize the risk of potential long-term
damage), allow the engine to run at no-load idle speed
immediately after initial start-up. Hydraulic fluid will circulate,
releasing any air that may have been trapped in the system
before load demands are imposed.
A daily walk-around prestart equipment safety inspection,
including a quick visual scan for any exterior evidence of leaking
hydraulic fluid, can help extend the service life of system
components.
IMPORTANT
Hydraulic system operating conditions (repetitive cycling,
heavy work loads, fluid circulating under high-pressure)
make it extremely critical that dust, grit or any other type of
contamination be kept out of the system. Observe fluid and
filter change maintenance interval recommendations and
always preclean any exterior surface of the system before it
is exposed to air. For example, the reservoir fill cap and
neck area, hoses that have to be disassembled, and the
covers and external surfaces of filter canisters should all be
cleaned before disassembly.
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MAINTENANCE SERVICE AND
REPAIR PROCEDURE
General Precautions
Fluid level and condition should always be checked whenever
any other type of maintenance service or repair is being
performed.
NOTE: If the unit is being used in an extreme temperature
environment (in sub-freezing climates or in high
temperature, high humidity tropical conditions),
frequent purging of moisture condensation from the
hydraulic reservoir drain tap should be a regular and
frequent part of the operating routine. In more
moderate, temperate climates, draining reservoir
sediment and moisture may not be required more
than once or twice every few months.
Inspect drained oil and used filters for signs of abnormal coloring
or visible fluid contamination at every oil change. Abrasive grit or
dust particles will cause discoloration and darkening of the fluid.
Visible accumulations of dirt or grit could be an indication that
filter elements are overloaded (and will require more frequent
replacement) or that disintegrating bearings or other component
failures in the hydraulic circuit may be imminent or have already
occurred. Open the drain plugs on the main pump casings and
check and compare drain oil in the pumps. Look for evidence of
grit or metallic particles.
Vibration or unusual noise during operation could be an
indication of air leaking into the circuit (Refer to the appropriate
Troubleshooting section for component or unit for procedures.),
or it may be evidence of a defective pump. The gear type pilot
pump could be defective, causing low pilot pressure, or a main
pump broken shoe or piston could be responsible.
NOTE: If equipped, indicated operating pressure, as shown
on the multidisplay digital gauge on the Instrument
Panel ("F-Pump" and "R-Pump") will be reduced as a
result of a mechanical problem inside the pump.
However, pressure loss could also be due to
cavitation or air leakage, or other faults in the
hydraulic system.
Check the exterior case drain oil in the main pumps. If no
metallic particles are found, make sure there is no air in the
system. Unbolt and remove the tank return drain line from the
top part of the swing motor, both travel motors and each main
pump. If there is air in any one of the drain lines, carefully prefill
the assembly before bolting together the drain line piping
connections. Run the system at low rpm.
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HYDRAULIC SYSTEM
CLEANLINESS AND OIL LEAKS
IMPORTANT
Make sure that cleaning solvents will be compatible with
rubber materials used in the hydraulic system. Many
petroleum based compounds can cause swelling,
softening, or other deterioration of system sealing
elements, such as O-rings, caps and other seals.
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Oil Leakage Precautions
Oil that is visibly seeping from joints or seals should always
serve as a "red flag" alarm.
Leaks must alert the machine operator and maintenance crew
that air, water and dirt have an open, free passageway through
which to enter the circuit. Harsh, corrosive salt air, freezing and
thawing condensation cycles and working environments that are
full of fine dust are especially hazardous. Clogging of valve
spools or external piping (especially pilot circuit piping) can
gradually diminish or very suddenly put a complete stop to
normal hydraulic function. You can prevent having to make these
types of repairs by following recommended assembly
procedures:
1. Use new O-rings and oil seals whenever hydraulic
assemblies are rebuilt.
2. Prepare joint surfaces before assembly by checking
alignment and flatness. Clean and repair corrosion or
any other damage.
3. Follow bolt torque recommendations and all other
assembly requirements.
NOTE: Grease lip seals before assembly.
Figure 1
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CLEANING AND INSPECTION
General Guidelines
All parts must be clean to permit an effective inspection. During
assembly, it is very important that no dirt or foreign material
enters unit being assembled. Even minute particles can cause
malfunction of close fitting parts such as thrust bearing, matched
parts, etc.
WARNING!
Care should be exercised to avoid inhalation of vapors,
exposure to skin and creating fire hazards when using
solvent type cleaners.
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any seal lip will seriously impair its efficiency. Apply a thin
coat of Loctite #120 to outer diameter, of metal casing, on
oil seals to assure an oil tight fit into retainer. Use extreme
care not to get Loctite on lips of oil seals. If this happens,
that portion of the seal will become brittle and allow
leakage.
When replacing lip type seals, make sure spring loaded
side is towards oil to be sealed.
5. If available, use magna-flux or similar process for checking
for cracks that are not visible to the eye. Examine teeth on
all gears carefully for wear, pitting, chipping, nicks, cracks
or scores. Replace all gears showing cracks or spots
where case hardening has worn through. Small nicks may
be removed with suitable hone. Inspect shafts and quills to
make certain they have not been sprung, bent, or splines
twisted, and that shafts are true.
NOTE: Spline wear is not considered detrimental
except where it affects tightness of splined
parts.
Inspect thrust washers for distortion, scores, burs, and
wear. Replace thrust washer if defective or worn.
6. Inspect bores and bearing surfaces of cast parts and
machined surfaces for scratches, wear, grooves and dirt.
Remove any scratches and burrs with crocus cloth.
Remove foreign material. Replace any parts that are
deeply grooved or scratched which would affect their
operation.
Bearing inspection
The conditions of the bearing are vital to the smooth and
efficient operation of the machinery. When any component
containing bearings is disassembled, 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 bearing is excessively dirty soak
the bearing assembly in a light solution and move the bearing
around until all lubricants and or foreign materials are dissolved
and the parts are thoroughly clean.
When drying bearings, moisture free compressed air can be
used. Be careful not to direct the air in a direction which will force
the bearing to dry spin while not being properly lubricated.
After the bearings have been cleaned and dried, carefully
inspect all bearing rollers, cages and cups for wear, chipping or
nicks. If the bearing cannot be removed and is to be inspected in
place, check foe roughness of rotation, scoring, pitting, cracked
or chipped races. If any of these defects are found replace the
whole bearing assembly. NEVER replace the bearing alone
without replacing the mating cup or the cone at the same time.
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After inspection lightly coat the bearing and related parts with oil
and wrap in a clean lintless cloth or paper and protect them from
moisture and other foreign materials until installation.
It is also important to inspect the bearing housing and/or shaft
for grooved, galled or burred conditions that indicate that the
bearing has been turning in its housing or on its shaft.
If available, use magna-flux or similar process for checking for
cracks that are not visible to the naked eye.
The following illustrations will aid in identifying and diagnosing
some of the bearing related problems.
NOTE: The illustrations will only show tapered roller
bearings, but the principles of identifying, diagnosing
and remedying the defects are common to all styles
and types of bearings.
Normal Bearing
Smooth even surfaces with no discoloration or marks.
Figure 2
Bent Cage
Cage damage due to improper handling or tool usage.
Figure 3
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Replace bearing.
Figure 4
Galling
Metal smears on roller ends due to overheat, lubricant failure or
overload.
Replace bearing - check seals and check for proper lubrication.
Figure 5
Figure 6
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Etching
Bearing surfaces appear gray or grayish black in color with
related etching away of material usually at roller spacing.
Replace bearings - check seals and check for proper lubrication.
Figure 7
Misalignment
Outer race misalignment due to foreign object.
Clean related parts and replace bearing. Make sure races are
properly seated.
Figure 8
Indentations
Surface depressions on race and rollers caused by hard
particles of foreign materials.
Clean all parts and housings, check seals and replace bearings
if rough or noisy.
Figure 9
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Fatigue Spalling
Flaking of surface metal resulting from fatigue.
Replace bearing - clean all related parts.
Figure 10
Brinelling
Surface indentations in raceway caused by rollers either under
impact loading or vibration while the bearing is not rotating.
Replace bearing if rough or noisy.
Figure 11
Cage Wear
Wear around outside diameter of cage and roller pockets caused
by abrasive material and inefficient lubrication.
Replace bearings - check seals.
Figure 12
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Abrasive Roller Wear
Pattern on races and rollers caused by fine abrasives.
Clean all parts and housings, check seals and bearings and
replace if leaking, rough or noisy.
Figure 13
Figure 14
Smears
Smearing of metal due to slippage caused by poor fitting,
lubrication, overheating, overloads or handling damage.
Replace bearings, clean related parts and check for proper fit
and lubrication.
Replace shaft if damaged.
Figure 15
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Frettage
Corrosion set up by small relative movement of parts with no
lubrication.
Replace bearing. Clean all related parts. Check seals and check
for proper lubrication.
Figure 16
Heat Discoloration
Heat discoloration can range from faint yellow to dark blue
resulting from overload or incorrect lubrication.
Excessive heat can cause softening of races or rollers.
To check for loss of temper on races or rollers, a simple file test
may be made. A file drawn over a tempered part will grab and
cut metal, whereas a file drawn over a hard part will glide readily
with no metal cutting.
Replace bearing if over heating damage is indicated. Check
seals and other related parts for damage.
Figure 17
Stain Discoloration
Discoloration can range from light brown to black caused by
incorrect lubrication or moisture.
if the stain can be removed by light polishing or if no evidence of
overheating is visible, the bearing can be reused.
Check seals and other related parts for damage.
Figure 18
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General Maintenance Procedures SP000016
Page 20
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SP000017
STANDARD TORQUESSP000017
Standard
Torques
Edition 1
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MEMO
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Table of Contents
Standard Torques
Safety Precautions................................................ 5
Applicable Models................................................. 5
Torque Values for Standard Metric Fasteners....... 6
Torque Values for Standard U.S. Fasteners .......... 7
Type 8 Phosphate Coated Hardware.................... 9
Torque Values for Hose Clamps ......................... 10
Torque Values for Split Flanges .......................... 11
Torque Wrench Extension Tools ......................... 12
Torque Multiplication...................................................... 12
Other Uses for Torque Wrench Extension Tools ............ 13
Tightening Torque Specifications (Metric) ..................... 13
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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TORQUE VALUES FOR
STANDARD METRIC
FASTENERS
NOTE: The units for the torque values are kg•m (ft lb).
Grade
Dia. x Pitc
h (mm)
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
(4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M5 x Std.
(1.08) (1.15) (1.80) (1.59) (2.24) (2.02) (3.11) (3.47) (3.61) (5.42) (6.50)
0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.90 1.25 1.50
M6 x Std.
(2.02) (2.16) (3.25) (2.89) (3.97) (3.39) (5.56) (6.14) (6.50) (9.04) (10.84)
0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35
M7 x Std.
(3.11) (3.32) (5.06) (4.55) (6.00) (5.64) (8.67) (9.40) (10.12) (14.10) (16.99)
0.70 0.75 1.10 1.00 1.40 1.25 1.90 2.10 2.20 3.10 3.80
M8 x Std.
(5.06) (5.42) (7.95) (7.23) (10.12) (9.04) (13.74) (15.18) (15.91) (22.42) (27.48)
0.73 0.80 1.20 1.00 1.50 1.35 2.10 2.30 2.40 3.35 4.10
M8 x 1
(5.28) (5.78) (8.67) (7.23) (10.84) (9.76) (15.18) (16.63) (17.35) (24.23) (29.65)
1.35 1.40 2.20 1.90 2.70 2.35 3.70 4.20 4.40 6.20 7.20
M10 x Std.
(9.76) (10.12) (15.91) (13.74) (19.52) (19.99) (26.76) (30.37) (31.18) (44.84) (52.07)
1.50 1.60 2.50 2.10 3.10 2.80 4.30 4.90 5.00 7.00 8.40
M10 x 1
(10.84) (11.57) (18.08) (15.18) (22.42) (20.25) (31.10) (35.44) (36.16) (50.63) (60.75)
2.40 2.50 3.70 3.30 4.70 4.20 6.30 7.20 7.50 10.50 12.50
M12 x Std.
(17.35) (18.08) (26.76) (23.86) (33.99) (30.37) (45.56) (52.07) (54.24) (75.94) (90.41)
2.55 2.70 4.00 3.50 5.00 4.50 6.80 7.70 8.00 11.20 13.40
M12 x 1.5
(18.44) (19.52) (28.93) (25.31) (36.16) (32.54) (49.18) (55.69) (57.86) (81.00) (96.92)
3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00
M14 x Std.
(26.76) (28.20) (13.23) (37.61) (54.24) (50.63) (72.33) (83.17) (86.79) (122.96) (144.66)
4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M14 x 1.5
(29.65) (31.10) (47.73) (41.22) (60.03) (54.24) (80.28) (90.41) (94.02) (11.26) (158.12)
5.60 6.00 9.00 8.00 11.50 10.50 15.50 17.90 18.50 26.00 31.00
M16 x Std.
(40.50) (43.39) (65.09) (57.86) (83.17) (75.94) (112.11) (129.47) (133.81) (188.05) (224.22)
6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 35.50
M16 x 1.5
(44.84) (47.01) (70.16) (62.20) (90.41) (81.73) (122.96) (141.04) (144.66) (202.52) (256.77)
7.80 8.30 12.50 11.00 16.00 14.50 21.00 27.50 28.50 41.00 43.00
M18 x Std.
(56.41) (60.03) (90.41) (79.56) (115.72) (104.87) (151.89) (198.90) (206.14) (296.55) (311.01)
9.10 9.50 14.40 12.50 18.50 16.70 24.50 27.50 28.50 41.00 49.00
M18 x 1.5
(65.82) (68.71) (104.15) (90.41) (133.81) (120.79) (177.20) (198.90) (206.14) (296.55) (354.41)
11.50 12.00 18.00 16.00 22.00 19.00 31.50 35.00 36.00 51.00 60.00
M20 x Std.
(83.17) (86.79) (130.19) (115.72) (159.12) (137.42) (227.83) (253.15) (260.38) (368.88) (433.98)
12.80 13.50 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00
M20 x 1.5
(92.58) (97.64) (148.27) (130.19) (180.82) (162.74) (253.15) (285.70) (296.55) (419.51) (491.84)
15.50 16.00 24.50 21.00 30.00 26.00 42.00 46.00 49.00 67.00 75.00
M22 x Std.
(112.11) (115.72) (177.20) (151.89) (216.99) (188.05) (303.78) (332.71) (354.41) (484.61) (542.47)
17.00 18.50 28.00 24.00 34.00 29.00 47.00 52.00 56.00 75.00 85.00
M22 x 1.5
(122.96) (133.81) (202.52) (173.59) (245.92) (209.75) (339.95) (44.76) (405.04) (542.47) (614.80)
20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00
M24 x Std.
(148.27) (155.50) (238.68) (195.29) (289.32) (245.92) (397.81) (419.51) (455.67) (593.10) (655.43)
23.00 35.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.00
M24 x 1.5
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)
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TORQUE VALUES FOR
STANDARD U.S. FASTENERS
S.A.E. Bolt Head
Type Description
Grade Marking
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The following General Torque Values must be used in all cases
where SPECIAL TORQUE VALUES are not given.
NOTE: Torque values listed throughout this manual are lubricated (wet) threads; values should be
increased 1/3 for nonlubricated (dry) threads.
Heat Treated Material Grade 5 and Grade 8
Grade 5 Grade 8
Thread Size (3 Radial Dashes On Head) (6 Radial Dashes On Head)
Foot Pounds Newton Meter Foot Pounds Newton Meter
(ft lb) (Nm) (ft lb) (Nm)
1/4" - 20 6 8 9 12
1/4" - 28 7 9 11 15
5/16" - 18 13 18 18 24
5/16" - 24 15 20 21 28
3/8" - 16 24 33 34 46
3/8" - 24 27 37 38 52
7/16" - 14 38 52 54 73
7/16" - 20 42 57 60 81
1/2" - 13 58 79 82 111
1/2" - 20 65 88 90 122
9/16" - 12 84 114 120 163
9/16" - 18 93 126 132 179
5/8" - 11 115 156 165 224
5/8" - 18 130 176 185 251
3/4" - 10 205 278 290 393
3/4" - 16 240 312 320 434
7/8" - 9 305 414 455 617
7/8" - 14 334 454 515 698
1" - 8 455 617 695 942
1" - 14 510 691 785 1064
1 1/8" - 7 610 827 990 1342
1 1/8" - 12 685 929 1110 1505
1 1/4" - 7 860 1166 1400 1898
1 1/4" - 12 955 1295 1550 2102
1 3/8" - 6 1130 1532 1830 2481
1 3/8" - 12 1290 1749 2085 2827
1 1/2" - 6 1400 2034 2430 3295
1 1/2" - 12 1690 2291 2730 3701
1 3/4" - 5 2370 3213 3810 5166
2" - 4 1/2 3550 4813 5760 7810
NOTE: If any bolts and nuts are found loose or at
values less than what the chart states, it is
recommended that the loose bolt and/or nut be
replaced with a new one.
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TYPE 8 PHOSPHATE COATED
HARDWARE
This chart provides tightening torque for general purpose
applications using original equipment standard hardware as
listed in the Parts Manual for the machine involved. DO NOT
SUBSTITUTE. In most cases, original equipment standard
hardware is defined as Type 8, coarse thread bolts and nuts and
thru hardened flat washers (Rockwell "C" 38 - 45), all phosphate
coated and assembled without supplemental lubrication (as
received) condition.
The torques shown below also apply to the following:
1. Phosphate coated bolts used in tapped holes in steel or
gray iron.
2. Phosphate coated bolts used with phosphate coated
prevailing torque nuts (nuts with distorted threads or plastic
inserts).
3. Phosphate coated bolts used with copper plated weld nuts.
Markings on bolt heads or nuts indicate material grade ONLY
and are NOT to be used to determine required torque.
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TORQUE VALUES FOR HOSE
CLAMPS
The following chart provides the tightening torques for hose
clamps used in all rubber applications (radiator, air cleaner,
operating lever boots, hydraulic system, etc.).
Torque
Radiator, Air Cleaner, Boots, Etc. Hydraulic System
Clamp Type And Size
Kilogram Meter Inch Pounds Kilogram Meter Inch Pounds
(kg•m) (in lb) (kg•m) (in lb)
"T" Bolt (Any Diameter) 0.68 - 0.72 59 - 63 ------- ------
Worm Drive - Under
44 mm (1-3/4 in) Open 0.2 - 0.3 20 - 30 0.5 - 0.6 40 - 50
Diameter
Worm Drive - Over 44 mm
0.5 - 0.6 40 - 50 ------- ------
(1-3/4 in) Open Diameter
Worm Drive - All "Ultra-
0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50
Tite"
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TORQUE VALUES FOR SPLIT
FLANGES
The following chart provides the tightening torques for split
flange connections used in hydraulic systems. Split flanges and
fitting shoulders should fit squarely. Install all bolts, finger tight
and then torque evenly.
NOTE: Over torquing bolts will damage the flanges and/or
bolts, which may cause leakage.
Bolt Torque
Flange Bolt
Kilogram Meter Foot Pounds
Size (*) Size
(kg•m) (ft lb)
1/2" 5/16" 2.1 - 2.5 15 - 18
3/4" 3/8" 3.0 - 3.7 22 - 27
1" 3/8" 3.7 - 4.8 27 - 35
1 - 1/4" 7/16" 4.8 - 6.2 35 - 45
1 - 1/2" 1/2" 6.4 - 8.0 46 - 58
2" 1/2" 7.6 - 9.0 55 - 65
2 - 1/2" 1/2" 10.9 - 12.6 79 - 91
3" 5/8" 19.1 - 20.7 138 - 150
3 - 1/2" 5/8" 16.2 - 18.4 117 - 133
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TORQUE WRENCH EXTENSION
TOOLS
Very large diameter, high grade fasteners (nuts, bolts, cap
screws, etc.) require a great deal of turning force to achieve
recommended tightening torque values.
Common problems that could occur as a result are:
• Recommended torque exceeds the measuring
capacity of the torque wrench.
• Specialized sockets do not fit the adapter on the front
end (nose) of the torque wrench.
• Generating adequate force on the back end (handle)
of the wrench is difficult or impossible.
• Restricted access or an obstruction may make use of
the torque wrench impossible.
• A unique application requires fabrication of an
adapter or other special extension.
Most standard torque wrenches can be adapted to suit any one
of the proceeding needs or situations, if the right extension tool
is used or fabricated.
Torque Multiplication
A wrench extension tool can be used to increase the tightening
force on a high capacity nut or bolt.
For example, doubling the distance between the bolt and the
back (handle) end of the torque wrench doubles the tightening
force on the bolt. It also halves the indicated reading on the
scale or dial of the torque wrench. To accurately adjust or
convert indicated scale or dial readings, use the following
formula:
I = A x T / A + B where:
I = Indicated force shown on the torque wrench scale or dial.
T = Tightening force applied to the nut or bolt (actual Torque). Figure 1
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extension and torque wrench. Readings may
also be inaccurate:
• If the extension itself absorbs some of the tightening
force and starts to bend or bow out.
• If an extension has to be fabricated that is not
perfectly straight (for example, an extension made to
go around an obstruction, to allow access to a difficult
to tighten fastener), the materials and methods used
must be solid enough to transmit full tightening
torque.
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CAUTION!
Disassembly, overhaul and replacement of components on
the machine, installation of new or replacement parts and/
or other service-related maintenance may require the use of
thread or flange sealing assembly compound.
Use the information on this page as a general guide in
selecting specific formulas that will meet the particular
requirements of individual assembly installations. Daewoo
does not specifically endorse a specific manufacturer or
brand name but the following table of "Loctite" applications
is included for which cross-references to other makers'
products should also be widely available.
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of
fastener adhesives, with Thread locker sealers 222, 242/243,
262, 271, 272, or 277.
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I. "Loctite" Fastener Adhesives
Breakaway Cure
Product Application Color Removal Strength (in lb) of
Sealer Alone
Low strength for 6 mm (1/4") or
222 Purple Hand tools 45
smaller fasteners.
Medium strength for 6 mm (1/4") and
242 or 243 Blue Hand tools 80
larger fasteners.
Heat/260°C (500°F)
High strength for high grade fasteners Remove HOT
262 Red 160
subject to shock, stress and vibration.
(NO solvent)
Extra high strength for fine thread Heat/260°C (500°F)
271 Red 160
fasteners up to 25 mm (1") diameter. Remove HOT
High temperature/high strength for
Heat/316°C (600°F)
272 hostile environments to 232°C Red 180
Remove HOT
(450°F).
Extra high strength for coarse thread
Heat/260°C (500°F)
277 fasteners 25 mm (1") diameter and Red 210
Remove HOT
larger.
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IV. "Loctite" retaining compounds
V. "Loctite" Adhesives
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1Upper Structure
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SP000018
CABIN SP000018
Cabin
Edition 1
Cabin SP000018
Page 1
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MEMO
SP000018 Cabin
Page 2
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Table of Contents
Cabin
Safety Precautions................................................ 5
Applicable Models................................................. 5
Removal................................................................ 6
Installation ............................................................ 8
Cabin SP000018
Page 3
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MEMO
SP000018 Cabin
Page 4
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
SP000018 Cabin
Page 5
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REMOVAL
CAUTION!
Avoid disassembling cabin if there are strong wind gusts,
which could catch large surface area of cabin shell and
push it sideways during lift.
FG003015
If engine must be run while performing maintenance, Figure 1
use extreme care. Always have one person in the
cabin at all times. Never leave the cabin with the
engine running.
Cabin SP000018
Page 6
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12. Remove floor mat.
1
13. Remove operator's seat (1, Figure 2).
5
NOTE: Be careful not to damage seat covering. 4
14. Remove duct covers (2, 3 and 4, Figure 2). When removing 6
cover (2) disconnect hour meter connector and cigar lighter
7
connector. Disconnect main harness connector before
removing cover (4).
1
15. Remove pocket (5, Figure 2) before removing side panel
(6, Figure 2). FG000540
Figure 2
2 FG000667
Figure 3
18. Remove cover (5, Figure 4) on left side dash cover (3) and
bolts (1, Figure 5).
NOTE: When removing cover, disconnect speaker wire.
2 1 2
19. Remove two rubber stops (2, Figure 4) used in storing the
front lower glass. Remove bolts (1) from the rear left and 3
ARS1530L
Figure 4
ARS1540L
Figure 5
SP000018 Cabin
Page 7
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24. Remove four mounting nuts from four corners of cabin floor
(2, Figure 6). 1
25. Remove four hex bolts (3, Figure 6) from door side of cabin
floor.
26. Remove two hex bolts (1, Figure 6) from right side of cabin 2
floor and one bolt (4) from front of cabin floor.
4
Quantity Description
4 16 mm hex nuts at each corner of the
cabin.
4 10 mm x 1.5 hex bolts at the door side
of the cabin.
3 10 mm x 1.5 mm hex head bolts, 2 on 3
the right side of the cabin and 1 under HAOF270L
the front window. Figure 6
FG000541
Figure 7
INSTALLATION
1. Using a suitable lifting device, attach slings to four lift
points on top of cabin (Figure 7).
NOTE: Cabin weighs approximately 290 kg (639 lb).
2. Lower cabin into position on cabin floor.
FG000541
Figure 8
Cabin SP000018
Page 8
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3. Install four mounting nuts on four corners of cabin floor (2,
Figure 9). 1
NOTE: Mounting nut torque 20.2 kg•m (146 ft lb)
4. Install four hex bolts (3, Figure 9) in door side of cabin floor.
2
5. Install two hex bolts (1, Figure 9) in right side of cabin floor
and one bolt (4) in front of cabin floor.
4
Quantity Description
4 16 mm hex nuts at each corner of the
cabin.
4 10 mm x 1.5 hex bolts at the door side
of the cabin. 3
3 10 mm x 1.5 mm hex head bolts, 2 on HAOF270L
the right side of the cabin and 1 under Figure 9
the front window.
ARS1540L
Figure 10
10. Install right side dash cover (4, Figure 11) with bolts (1,
Figure 10).
11. Install left side dash cover (3, Figure 11) with bolts (1,
2 1
Figure 10). Install two rubber stops (2, Figure 11). 2
12. Install cover (5, Figure 11) on left side dash cover (3). 3
ARS1530L
Figure 11
SP000018 Cabin
Page 9
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14. Install air duct (3, 2 and 1, Figure 12) at right side of cabin.
NOTE: Connect wire connector of duct (2, Figure 12). 3
2 FG000667
Figure 12
15. Install side panel (6, Figure 13) and pocket (5).
1
16. Install cover (4, Figure 13) and connect main harness.
Install cover (3). Connect hour meter connector and cigar 5
lighter connector of cover (2). 4
6
17. Install cover (2, Figure 13).
7
18. Install operator's seat (1, Figure 13).
NOTE: Be careful not to damage seat covering. 1
19. Install floor mat.
FG000540
20. Connect negative (-) battery cable leading to frame from
Figure 13
battery.
Cabin SP000018
Page 10
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SP000019
COUNTERWEIGHT SP000019
Counterweight
Edition 1
Counterweight SP000019
Page 1
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MEMO
SP000019 Counterweight
Page 2
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Table of Contents
Counterweight
Safety Precautions................................................ 5
Applicable Models................................................. 5
General ................................................................. 6
Warning for Counterweight and Front Attachment
Removal .......................................................................... 6
Removal................................................................ 8
Installation .......................................................... 10
Counterweight SP000019
Page 3
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MEMO
SP000019 Counterweight
Page 4
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
SP000019 Counterweight
Page 5
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GENERAL
DANGER!
DOOSAN warns any user, that the removal of the
counterweight from the machine, front attachment or any
other part, may affect the stability of the machine. This
could cause unexpected movement, resulting in death or
serious injuries. DOOSAN is not liable for any misuse.
Never remove the counterweight or front attachment unless
the upper structure is in-line with the lower structure.
FG000371
Never rotate the upper structure once the counterweight or
Figure 1
front attachment has been removed.
WARNING!
The weight of counterweight is given in the following table.
Use only rated and approved slings and hardware when
removal or installation lifts are being made. Lifting slings,
shackles and all other hardware must be rigged safely. An
assist crane that is rated above weight capacity is required.
Counterweight SP000019
Page 6
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WARNING!
If the turntable deck has been unbalanced by removal of
weight from one end only, traveling the excavator, swinging
the turntable, movement over bumps or sloping and uneven
surfaces could cause loss of control and possible
accidents or injuries.
90 ~ 110
15 FG000325
Figure 1
15
FG000326
Figure 2
SP000019 Counterweight
Page 7
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REMOVAL
1. Park on firm and level ground. O I
2. Lower front attachment (bucket) to the ground.
3. Shut down engine.
4. Set safety lever on "RELEASED" position.
5. Turn starter switch to "I" (ON) position.
WARNING
FG003015
If engine must be run while performing maintenance, Figure 3
use extreme care. Always have one person in the
cabin at all times. Never leave the cabin with the
engine running.
Counterweight SP000019
Page 8
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12. Remove two caps (1, Figure 4) from counterweight (2).
3
13. Install two lifting eyes in lifting holes (3, Figure 4). 1
4 FG000469
Figure 4
SP000019 Counterweight
Page 9
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INSTALLATION
1. Using suitable lifting device capable of handling a heavy
3
load, raise counterweight (2, Figure 5) into position just
1
above support frame (6) leaving counterweight suspended.
Verify that counterweight is level and even. 3
NOTE: Leave counterweight (2, Figure 5) suspended
3 mm (0.125") above support frame (6) until all
four mounting bolts (4) are started in
2
counterweight mounting holes.
2. Slide washers (5, Figure 5) onto bolts (4). Apply Loctite
#242 to mounting bolt threads.
3. Install four bolts (4, Figure 5) with washers (5) into
counterweight until washers contact support frame. Fully
lower counterweight onto support frame and finish
tightening bolts.
NOTE: Torque bolts (4, Figure 5) to values shown in
following table.
Counterweight SP000019
Page 10
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SP000020
FUEL TANK SP000020
Fuel Tank
Edition 1
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MEMO
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Table of Contents
Fuel Tank
Safety Precautions................................................ 5
Applicable Models................................................. 5
General Description.............................................. 6
Parts List ......................................................................... 6
Specifications .................................................................. 7
Removal................................................................ 8
Installation .......................................................... 13
Start-up Procedures ........................................... 15
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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GENERAL DESCRIPTION
WARNING!
Engine fuel is highly flammable and potentially explosive.
To prevent possible injury and/or damage to equipment,
extinguish or move to a safe distance all potential fire
hazards.
Parts List
11
10
17
18
16 1
12 51
52
15
14
15
14
9
13 2
7 3
8
5 13
4 6
7 FG000470
Figure 1
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Reference Reference
Description Description
Number Number
1 Fuel Tank 10 Fuel Strainer
2 O-ring 11 Cap
3 Cover 12 Level Gauge
4 Bolt 13 Spacer
5 Spring Washer 14 Bolt
6 Drain Valve 15 Clip
7 Bolt 16 Fuel Sender
8 Shim 17 Bolt
9 Shim 18 Spring Washer
Specifications
Fuel tank capacity is 500 liters (132 U.S. gal).
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REMOVAL
1. Look at fuel level display (Figure 2) on instrument panel in
operator's cabin to see what it displays. The display is
divided into ten separated segments, each representing 10 Green
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 been run down as far as Red
possible.
E F
FG000608
Figure 2
FG000471
Figure 3
WARNING! WARNING
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12. Clean area around fuel tank fill cap (11, Figure 5). Open
11
fuel cap.
FG003871
Figure 5
FG003872
Figure 6
14. Tag and disconnect fuel supply line (21, Figure 7) and fuel
return line (19) from fuel tank (1) and carefully drain 1
remaining fuel from lines.
15. Remove clamp (20, Figure 7) holding fuel return line (19) to
tank (1).
19
20
21 FG003873
Figure 7
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16. If equipped, remove components from fuel filler pump port
(22, Figure 8) on side of fuel tank (1).
1
22
FG003874
Figure 8
17. Remove five bolts (23, Figure 9) and cover (24) from fuel
23
tank.
24
FG003875
Figure 9
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18. Remove six bolts (25 and 26, Figure 10) and stay (27) from
fuel tank and frame.
Remove four bolts (28 and 29) and fuel tank cover (30) 27
26
from fuel tank.
28
Remove two bolts (31) and bracket (32) from tank.
Remove four bolts (33) and battery cover (34) from frame. 31
32 29
33
30
25
34
FG003876
Figure 10
19. Tag and disconnect wires leading to fuel sender (16, Figure
11) on side of fuel tank (1).
1
16
FG003877
Figure 11
20. Remove four bolts (35 and 36, Figure 12) and cover (37)
from fuel tank and support.
37
36
35 FG003878
Figure 12
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21. Install two 12 mm eyebolts in threaded holes (38 and 39,
Figure 13). Using a suitable lifting device, sling eyebolts.
1
22. Remove six bolts (7) and spacers (13, Figure 13) holding 38
tank (1) to frame. Lift tank 25 mm (1") and make sure it is 39
balanced. Make sure that there are no other electrical
wires or hoses connected to tank. Completely remove tank
after inspection.
NOTE: The clear level gauge on the side of the tank is
easily damaged. Be careful of obstacles and
wind gusts.
23. Remove shims (9, Figure 13).
NOTE: If tank is to be reused note position and amount
of shims used for each mounting bolt location. 9
13
7 FG003879
Figure 13
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INSTALLATION
1. Install two 12 mm eyebolts in threaded holes (38 and 39,
Figure 14). Using a suitable lifting device, sling eyebolts.
1
2. Set fuel tank (1, Figure 14) into position. Install six bolts (7) 38
and spacers (13) finger tight, to secure tank to frame. 39
NOTE: The clear level gauge on the side of the tank is
easily damaged. Be careful of obstacles and
wind gusts.
3. Install shims (9, Figure 14) as needed to prevent tank (1)
from rocking or stress from mounting bolts (7).
4. Tighten mounting bolts (7, Figure 14) after shims are
installed.
NOTE: Bolt torque is 27 kg•m (200 ft lb). 9
13
7 FG003879
Figure 14
5. Install four bolts (35 and 36, Figure 15) and cover (37) on
fuel tank and support.
37
36
35 FG003878
Figure 15
FG003877
Figure 16
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7. Install four bolts (33, Figure 17) and battery cover (34) on
frame.
Install two bolts (31) and bracket (32) on fuel tank. 27
26
Install four bolts (28 and 29) and fuel tank cover (30) on 28
fuel tank.
Install six bolts (25 and 26) and stay (27) on fuel tank and 31
32 29
frame. 33
30
25
34
FG003876
Figure 17
8. Install five bolts (23, Figure 18) and cover (24) on fuel tank.
23
24
FG003875
Figure 18
22
FG003874
Figure 19
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10. Connect as tagged, fuel supply line (21, Figure 20) and
fuel return line (19) to fuel tank (1). 1
11. Install clamp (20, Figure 20) to hold fuel return line (19) to
tank (1).
19
20
21 FG003873
Figure 20
12. Make sure fuel tank drain valve (6, Figure 21) on bottom of
tank is closed.
13. Fill fuel tank and check for signs of leaks. Correct any
problems found.
14. Connect negative (-) battery cable to battery.
FG003872
Figure 21
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START-UP PROCEDURES
If engine does not start, the fuel system may need priming.
Prime the fuel system using the following procedure:
1. Stop Engine.
2. Open left side door and then there is fuel filter.
FG000413
Figure 22
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SP000021
FUEL TRANSFER PUMPSP000021
Fuel Transfer
Pump
Edition 1
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MEMO
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Table of Contents
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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GENERAL DESCRIPTION
Theory of Operation
Fuel
4
1 2
6 5 3
Fuel Tank
IN OUT
DONG JIN
2-2 2-1
FG003881
Figure 1
Reference Reference
Description Description
Number Number
1 Motor 3 Inlet Hose
2 Pump 4 Outlet Hose
2-1 Pump Cover 5 Check Valve
2-2 Rotor and Vane 6 Strainer Cap
Hose
Switch FG001143
Figure 2
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TROUBLESHOOTING
On some pumps the ON-OFF switch is installed separately at a
Switch Cover
remote location.
Connector "B"
A thermal limiter, built into the motor, will automatically shut off
power if motor is overheating to protect it from being damaged.
NOTE: OPEN TEMP: 150 ±5°C (302 ±41°F). After circuit is Connector "A"
automatically shut off due to overheating the pump IV
will stop running. When temperature drops below
143˚C (289˚F) the circuit will reactivate allowing the III
V
pump to restart.
FG003882
Figure 3 WITH TOGGLE SWITCH
III
V
FG001145
Figure 4 WITHOUT TOGGLE SWITCH
FG000670
Figure 5 WITHOUT TOGGLE SWITCH
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Insert vane, with the circled edge of vane facing in the
counterclockwise direction. (Detail A)
IN OUT
Insert a new O-ring during reassembly of pump cover.
FG003883
Figure 6
REPLACEMENT OF REAR
COVER
Brush assembly 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 rear cover, widen the space of the brush and
insert it to the armature. Then fit the hole of screw in the Figure 7
housing.
Be careful when installing the screw. The cover screw may be
attracted by the motor magnet.
REPLACEMENT OF ARMATURE
Rear Cover
Pump Side
You can replace only the armature in case motor was damaged Side
by a short circuit.
Remove the switch cover and rear cover, than remove the
armature from the housing.
Remove the pump cover and remove the rotor and vane.
Insert a new armature into the housing. Commutator
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SP000022
SWING BEARING SP000022
Swing Bearing
Edition 1
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MEMO
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Table of Contents
Swing Bearing
Safety Precautions................................................ 5
Applicable Models................................................. 5
Swing Bearing Maintenance................................. 6
Operating Recommendation ........................................... 6
Measuring Swing Bearing Axial Play............................... 6
Measuring Bearing Lateral Play ...................................... 6
Swing Bearing Basic Operation....................................... 7
Rebuilding Swing Bearing ............................................... 7
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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SWING BEARING
MAINTENANCE
Operating Recommendation
The service life of the swing bearing may be extended if a
conscious, daily effort is made to equalize usage over both ends
of the excavator. If the excavator is used in the same operating
configuration day in and day out (for example, with the travel
motors always under the counterweight, or with the attachment
over one side of the machine more than the other), the bearing's
service life could be reduced. Taking a few minutes in the middle
of each work shift to reposition the excavator, to work the
opposite end of the bearing, will provide a payoff in terms of
more even, gradual rate of wear and extended service life.
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Swing Bearing Basic Operation
The swing bearing, which connects the upper structure with the
lower structure, consists of a inner ring, outer ring and ball
bearings. During swing movement, power from the swing motor
is transferred to the pinion by planetary gears connected to
gears on the inner ring, which is fixed in the undercarriage. Ball
bearings turn the outer ring.
Reference
Description
Number
1 Outer Ring
2 Inner Ring
3 Tapered Pin
4 Plug
5 Ball
6 Retainer
7 Seal A
Figure 2
Figure 3
Figure 4
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3. Lift outer ring and check that inner ring can move freely.
See Figure 5, if not, replace seal (7, Figure 6).
Figure 5
4. Turn inner ring and use magnet bar (C, Figure 6) to remove
steel balls (5).
Figure 6
Figure 7
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SP000023
SWING REDUCTION GEARSP000023
Swing
Reduction Gear
Edition 1
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MEMO
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Table of Contents
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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Swing Reduction Gear SP000023
Page 6
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GENERAL DESCRIPTION
Theory of Operation
The swing motor final drive is a two-stage planetary gearbox
with two planet gears, two sun gears and two-stage output
reduction. The planetary gear engages the ring gear. The pinion
gear is connected to the output shaft and spline.
The final drive reduces swing motor rpm in order to increase
swing motor output torque. The available maximum swing speed
provides a fast turning rate for efficient, rapid work cycling with
more than adequate power for good acceleration.
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Parts List
39 29
38 A
31
30 17
14
27
37 2 26
10
27
15 18
33
32
22
11
9
12
20
13
21
4
19
7 28
3
25
8
35
5
23 34
6
24
36
A FG000852
Figure 1
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Reference Reference
Description Description
Number Number
1 Shaft 21 Lock Ring
2 Gear Case 22 Spherical Roller Bearing
3 No. 2 Carrier 23 Spherical Roller Bearing
4 No. 2 Sun Gear 24 Oil Seal
5 No. 2 Planetary Gear 25 Spring Pin
6 No. 2 Thrust Plate 26 Plug
7 No. 2 Shaft 27 Plug
8 No. 2 Bushing 28 Pinion
9 No. 1 Carrier 29 Socket Head Bolt
10 No. 1 Sun Gear 30 Pipe
11 No. 1 Planetary Gear 31 Level Gauge
12 No. 1 Thrust Plate 32 No. 3 Thrust Plate
13 No. 1 Shaft 33 Retaining Ring
14 Ring Gear 34 Socket Head Bolt
15 Thrust Plate 35 Cover
17 Lock Pin 36 Wire
18 Spacer 37 Retaining Ring
19 Collar 38 Case Cover
20 Plate 39 Socket Head Bolt
Specifications
Swing Reduction Gearbox Specification
Drive Type Two-stage Planetary Gear
Reduction Ratio 21.968
Maximum Output Speed 59 rpm
1,875 kg•m
Maximum Output Torque
(13,560 ft lb)
340 kg
Weight
(750 lb)
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TROUBLESHOOTING, TESTING
AND ADJUSTMENT
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REMOVAL
1. Park on firm and level ground. O I
2. Lower front attachment (bucket) to ground.
3. Shut down engine.
4. Set safety lever on "RELEASED" position.
5. Turn starter switch to "I" (ON) position.
WARNING
FG003015
If engine must be running while performing Figure 2
maintenance, always use extreme caution. Always
have one person in cab at all times. Never leave cab
with engine running.
3
FG004063
Figure 3
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DISASSEMBLY
IMPORTANT
Select a clean place.
Spread a rubber mat or cloth on top of the overhaul
workbench to prevent parts from being damaged.
CAUTION!
The motor should be separated without damage or any
foreign substance.
Figure 4
Figure 5
CAUTION!
Care should be taken not to damage mounting surface
of cover. Carefully remove all gasket material from
mounting surfaces.
Figure 6
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Figure 7
Figure 8
CAUTION!
Care should be taken not to damage teeth of No. 1 sun
gear.
Figure 9
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Figure 10
Figure 11
Figure 12
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6. Remove washer and No. 2 sun gear.
CAUTION!
Care should be taken not to damage teeth of No. 2 sun
gear.
Figure 13
Figure 14
CAUTION!
Care should be taken not to damage teeth of No. 2
carrier and ring gear.
Figure 15
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Figure 16
CAUTION!
Care should be taken not to damage mounting
surfaces of ring gear and case. Carefully remove all
gasket material from mounting surfaces.
Figure 17
Figure 18
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9. Use a rollover machine to turn assembly over, loosen lock
wire, bolts and cover.
Figure 19
Figure 20
Figure 21
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Figure 22
Figure 23
Figure 24
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12. Using snap ring pliers, remove lock ring and disassemble
plate.
Figure 25
Figure 26
13. Use a rollover machine to turn case over and place a jig on
drive shaft. Use a press to remove drive shaft from case.
CAUTION!
Care should be taken not to have drive shaft drop to
floor when it is pressed out of case.
Figure 27
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Figure 28
Figure 29
15. Put drive shaft in press, and remove bearing and spacer.
Figure 30
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Figure 31
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REASSEMBLY
Cleaning Carrier
Put carrier, to whose corners grinding was made to remove all
foreign substances like burr, on steam washer if there remain
any foreign substance and put it on assembly die.
FG000877
Figure 32
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2. Align No. 1shaft with hole and press it into place.
FG000878
Figure 33
FG000879
Figure 34
FG000880
Figure 35
FG000881
Figure 36
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5. Turn over carrier. Install a No. 1 thrust washer onto each of
the four shafts.
FG000882
Figure 37
FG000883
Figure 38
FG000884
Figure 39
FG000885
Figure 40
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8. Install retaining rings on No. 1 shafts. Make sure that
retaining rings are fully seated in grooves. Make sure that
gears properly rotate.
FG000886
Figure 41
FG000887
Figure 42
FG000888
Figure 43
FG000889
Figure 44
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3. Turn over gear assembly and insert it into No. 2 carrier.
Align bushing hole with carrier holes.
NOTE: Thrust washer must be on bottom side of gear.
FG000890
Figure 45
FG000891
Figure 46
4. Align spring pin hole in No. 2 shaft with spring pin hole of
No. 2 carrier. Insert shaft into carrier and No. 2 bushing.
NOTE: Shaft may need to be gently tapped with a soft-
faced hammer. They should
be placed on
straight line.
FG001354
Figure 47
FG000893
Figure 48
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5. Install three remaining No. 2 gears in same manner.
FG000894
Figure 49
6. After all four shafts are installed, align spring pin with
carrier hole and drive it into position using a hammer.
FG000895
Figure 50
FG000896
Figure 51
FG000897
Figure 52
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FG000898
Figure 53
FG000899
Figure 54
FG000900
Figure 55
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FG000901
Figure 56
FG000902
Figure 57
FG000903
Figure 58
FG000904
Figure 59
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FG000905
Figure 60
FG000906
Figure 61
FG000907
Figure 62
FG000908
Figure 63
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FG000909
Figure 64
FG000910
Figure 65
FG000911
Figure 66
FG000912
Figure 67
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FG000913
Figure 68
FG000914
Figure 69
FG000915
Figure 70
FG000916
Figure 71
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FG000917
Figure 72
FG000918
Figure 73
FG000919
Figure 74
FG000920
Figure 75
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CAUTION!
Make sure that there is no foreign substances on lip
area. Use care not to damage seal when inserting it.
Chack for proper installation after pressing seal into
position.
FG000921
Figure 76
FG000922
Figure 77
FG000923
Figure 78
FG000924
Figure 79
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FG000925
Figure 80
FG000926
Figure 81
FG000927
Figure 82
2 3 0 2 4 C M 3 3C 3
FG000928
Figure 83
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FG000929
Figure 84
FG000930
Figure 85
FG000931
Figure 86
FG000932
Figure 87
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6. Insstall plugs into PT1/2 and PT1/8 drain ports.
FG000933
Figure 88
FG000934
Figure 89
FG000935
Figure 90
FG000936
Figure 91
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FG000937
Figure 92
FG000938
Figure 93
3. Lift ring gear with hoist, wipe its mating surface clean with
Aim at holes.
cloth, match and align holes after checking its assembling
direction, and press assembled parts firmly by tightening
special bolts (M16x160) on which no Loctite has been
applied.
NOTE: The specail bolts will be removed during Step 6,
on page 41.
FG001353
Figure 94
FG000940
Figure 95
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Assembly of Carrier.
1. Using a suitable lifting device, lower No. 2 carrier assembly
into ring gear, making sure that planetary gears are
engaged. Continue to lower carrier and engaging it onto
splines of pinion shaft. Make sure that carrier is resting on
bearing.
NOTE: Make sure that carrier and drive shaft can
rotate.
FG000941
Figure 96
FG000942
Figure 97
FG000943
Figure 98
FG000944
Figure 99
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FG000945
Figure 100
FG000946
Figure 101
FG000947
Figure 102
FG000948
Figure 103
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6. Remove press-in bolts that were installed to hold ring gear
in position.
7. Apply liquid gasket on ring gear.
FG000949
Figure 104
FG000950
Figure 105
FG000951
Figure 106
FG001352
Figure 107
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FG000953
Figure 108
FG000954
Figure 109
FG000955
Figure 110
FG000956
Figure 111
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FG000957
Figure 112
FG000958
Figure 113
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Assembly of Motor
FG000968
Figure 114
FG000970
Figure 115
Assembly of Motor
1. Apply liquid gasket to cover assembly.
FG000983
Figure 116
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2. Lift motor with hoist. Install retaining ring on shaft spline.
Align mounting holes and intall motor on case cover.
NOTE: Gear oil fill plug should point towards fill tube. Gear Oil Inlet
PT3/8
FG001350
Figure 117
Should be
placed on a
straight line.
FG001351
Figure 118
FG000973
Figure 119
FG000974
Figure 120
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4. Tighten bolts to specified torque. Mark them with paint
marker.
FG000975
Figure 121
FG000976
Figure 122
FG000977
Figure 123
Supply of Grease
1. Install grease fitting in grease inlet and add grease through
grease until it starts to be discharged from the opposite
hole.
FG000978
Figure 124
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FG000979
Figure 125
FG000980
Figure 126
FG000981
Figure 127
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FG000982
Figure 128
INSTALLATION
1. Coat pinion gear with grease. Refer to operation manual for
specifications. 1
2. Make sure two alignment pins (6, Figure 129) are installed
4
in flange of swing reduction gearbox (5).
3. Using a suitable lifting device, sling swing motor (1, Figure
129) and position swing motor and reduction gearbox (5)
as an assembly on unit. 6
5
4. Install twelve bolts and washers (4, Figure 129) to secure
swing reduction gearbox (5) to frame.
NOTE: Apply Loctite #262 to bolt threads.
2
NOTE: Tighten bolt to 95 kg•m (690 ft lb).
5. Connect hose (2, Figure 129) to reduction gearbox (5).
6. Connect grease lubrication line (7, Figure 129) to reduction 7
gearbox (5).
7. Connect hoses as tagged during removal to swing motor 8
(1, Figure 129).
3
8. Fill swing reduction gearbox with oil. Refer to operation FG004063
manual for specifications. Figure 129
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START-UP PROCEDURES
IMPORTANT
If air is not vented from system, it will cause damage to
swing motor and bearings.
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Swing Reduction Gear SP000023
Page 50
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1Lower Structure and
Chassis
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SP000024
TRACK ASSEMBLY SP000024
Track
Assembly
Edition 1
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Table of Contents
Track Assembly
Safety Precautions................................................ 5
Applicable Models................................................. 5
General Description.............................................. 6
Track Tension ........................................................ 6
Cleaning and Inspection (Wear Limits and
Tolerances) ........................................................... 9
Track Shoe..................................................................... 10
Lower Roller .................................................................. 12
Upper Roller .................................................................. 13
Front Idler ...................................................................... 14
Track Shoes and Links........................................ 15
Track Removal ............................................................... 15
Track Installation............................................................ 16
Front Idler Roller ................................................. 18
Parts List ....................................................................... 18
Front Idler Roller Disassembly ...................................... 19
Front Idler Roller Reassembly ....................................... 20
Lower Roller........................................................ 22
Parts List ....................................................................... 22
Lower Roller Removal ................................................... 23
Lower Roller Disassembly ............................................. 23
Lower Roller Reassembly.............................................. 24
Lower Roller Installation ................................................ 25
Upper Roller ....................................................... 26
Parts List ....................................................................... 26
Upper Roller Removal ................................................... 27
Upper Roller Disassembly ............................................. 27
Upper Roller Reassembly ............................................. 29
Track Spring and Track Adjusting Cylinder ......... 30
Parts List ....................................................................... 30
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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GENERAL DESCRIPTION
The track assembly is composed of the following major
components:
1. Track
2. Front Idler Roller
3. Upper Roller
4. Lower Roller
5. Track Spring and Track Adjustment Cylinder
TRACK TENSION
WARNING!
Safely measuring track tension requires two people. One
person must be in the operator's seat, running the controls
to keep one side frame in the air, while the other person
makes dimensional checks. Take all necessary precautions
to make sure the machine won't move or shift position
during service. Warm up the engine to prevent stalls, travel
the excavator to an area that provides level, uniform ground
support and/or use support blocks when necessary.
The track adjusting mechanism is under very high-
pressure. NEVER release pressure too suddenly. The
grease cylinder valve should never be backed off more than
1 complete turn from the fully tightened down position.
Bleed off pressure slowly and keep your body away from
the valve at all times.
Track shoe link pins and bushings wear with normal usage,
reducing track tension. Periodic adjustment is necessary to
compensate for wear and it may also be required by working
conditions.
1. Track tension is checked by jacking up one side of the
excavator. See Figure 1. Place blocking under frame while
taking measurement.
90 ~ 110
FG000345
Figure 1
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2. Measuring the distance (A, Figure 2) between the bottom
of the side frame and the top of the lowest crawler shoe.
Recommended tension for operation over most types of
terrain is distance "B" on below table.
NOTE: This measurement can be thrown off if there is
too much mud or dirt or other material in the
track assembly. Clean off the tracks before A
checking clearance.
3. Too little sag in the crawler track (less than clearance
distance "C" on below table) can cause excessive
FG000223
component wear. The recommended adjustment can also
be too tight causing accelerated stress and wear if ground Figure 2
conditions are wet, marshy or muddy, or if the ground is
hard and full of rocks or gravel.
4. The increased clearance recommended for muddy ground
conditions is between distance "D" on below table. The
clearance should be approximately distance "E" on below
table for operation over gravel, rocky terrain, or over sand
or snow.
Distance "A"
Terrain Type
DX300LC DX340LC
Normal "B" 320 - 340 mm 330 - 360 mm
(12.60 - 13.39 in) (13.0 - 14.17 in)
Minimum "C" 320 mm 330 mm
(12.60 in) (13.0 in)
Muddy "D" 340 - 370 mm 360 - 410 mm
(13.39 - 14.57 in) (14.17 - 16.14 in)
Gravel, Rocky, Sand or 370 mm 410 mm
Snow "E" (14.57 in) (16.14 in)
WARNING!
The track adjusting mechanism is under very high-
pressure. NEVER release pressure too suddenly. The
grease cylinder valve should never be backed off more than
1 complete turn from the fully tightened down position.
Bleed off pressure slowly and keep your body away from
the valve at all times.
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5. Track tension adjustments are made through the grease
fitting (1, Figure 3) in the middle of each side frame. Adding
grease increases the length of an adjustment cylinder (2). 2
The longer the adjustment cylinder, the greater the
pressure on the tension spring pushing the track idler
wheel outward.
6. If there is not enough slack or clearance in the tracks and
the adjustment is too tight, the idler wheel and adjusting
cylinder can be retracted by bleeding off grease through 1
hole in adjustment cylinder (2, Figure 3). 3
FG000163
Figure 3
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CLEANING AND INSPECTION
(WEAR LIMITS AND
TOLERANCES)
CAUTION!
Refer to the "Welding Precautions and Guidelines"
information in "General Maintenance Procedures" section
for general recommendations and specific safety
precautions, before starting any lower travel frame
component rebuilding procedure.
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Track Shoe
8 10
7
2
9 11
1
3
6
4 5 FG003910
Figure 4
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Limit for Use
Recommended Limit for
No. Check Item Standard Dimension (Repair - P or
Maintenance
Replace - R)
216 mm
1 Link Pitch
(8.504")
Bushing Outside 66.5 mm 62.5 mm 59 mm [R]
2
Diameter (2.618") (2.461") (2.323")
116 mm 108 mm 103 mm [P]
3 Link Height
(4.567") (4.252") (4.055")
22 mm
4 Length at Tip
(0.866")
16 mm
5 Length at Tip
(0.630")
30 mm 24 mm 20 mm
6 Height
(1.181") (0.945") (0.787")
Standard Tolerance Standard Repair
Interference between Dimension Shaft Hole Interference Limit
7
bushing and link 66.5 mm +0.464 +0.074
0.35 - 0.464
(2.618") +0.424 0.0
Standard Tolerance Standard Repair
Interference between Dimension Shaft Hole Interference Limit
8
regular pin and link 44.6 mm +0.235 -0.188
0.273 - 0.485
(1.756") +0.085 -0.25
Standard Tolerance Standard Repair
Clearance between Dimension Shaft Hole Interference Limit
9
regular pin and bushing 44.6 mm +0.235 +0.915
0.18 - 0.83
(1.756") +0.085 +0.415
Standard Tolerance Standard Repair
Interference between Dimension Shaft Hole Interference Limit
10
master pin and bushing 44.6 mm -0.205 -0.188
0.0 - 0.045
(1.756") -0.235 -0.25
Standard Tolerance Standard Repair
Clearance between Dimension Shaft Hole Interference Limit
11
master pin and bushing 44.6 mm -0.205 +0.915
0.62 - 1.15
(1.756") -0.235 +0.415
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Lower Roller
3 4
2
6
1
FG000508
Figure 5
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Upper Roller
4 3
2
6
1
5
FG000509
Figure 6
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Front Idler
4
3 5
1
2
FG000510
Figure 7
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TRACK SHOES AND LINKS
Track Removal
1. Position machine on a smooth level surface with adequate
room for forward and reverse travel.
2. Relieve track tension. Refer to "Track Tension" in this
section for procedure. 4
3. Move machine until master link (1, Figure 8) is positioned 3
at approximately 10 o'clock from top position on front idle 1
roller.
2
4. Remove four nuts and bolts (2, Figure 8) holding shoe to
link. Remove enough shoes to make access to lock pin
easier.
NOTE: Support track shoes with blocking so that when FG0039
master pin (4, Figure 8) is removed track will not Figure 8
fall.
5. Straighten lock pin (3, Figure 8) and remove it from master
pin (4). Discard lock pin.
6. Remove master pin from master links.
7. Move unit backward until entire track is laying on ground.
NOTE: Do not drive unit off track.
FG003911
Figure 9
90 ~ 110
FG000345
Figure 10
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Track Installation
1. Lay rebuilt or new track into position under track frame.
End of track should be positioned under drive sprocket.
2. With upper structure at 90˚ to track frame. Use bucket and 90 ~ 110
boom to raise track frame off blocking.
3. With blocking removed, lower track frame onto track. Make
sure all rollers are properly positioned on track.
FG000345
Figure 11
FG003912
Figure 12
FG0039
Figure 13
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SP000024 Track Assembly
Page 17
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FRONT IDLER ROLLER
Parts List
1 9
2 8
7
4
5
6 7
8
9
3
FG003913
Figure 14
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Reference Reference
Description Description
Number Number
1 Idler Assembly 6 Pin
2 Idler 7 Floating Seal
3 Bearing 8 O-ring
4 Shaft 9 Plug
5 Bushing
FG003914
Figure 15
2. Separate the pin (6, Figure 16) from the bearing (3).
3
FG003915
Figure 16
FG001482
Figure 17
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4. Detach the floating seal (7, Figure 18) from the idler (2)
3
and bearing (3).
7
2
3 FG001483
Figure 18
5. Use a press to separate the axle (4, Figure 19), O-ring (8)
and bearing (3).
8
FG001484
Figure 19
6. Remove bushing (5, Figure 20) with the press and special
tool (10, ST-1909).
10
5 2
FG001485
Figure 20
8
FG001486
Figure 21
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4. Install floating seal (7, Figure 22) inside the idler (2) and
3
bearing (3).
NOTE: Apply clean engine oil to the joint side of the 7
floating seal. Apply grease to the floating seal 2
O-ring.
3 FG001483
Figure 22
FG001488
Figure 23
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LOWER ROLLER
Parts List
2 8
5 6
7
7
8
2 FG000483
Figure 24
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Reference Reference
Description Description
Number Number
1 Roller 5 Pin
2 Collar 6 Floating Seal
3 Shaft 7 O-ring
4 Bushing 8 Plug
FG001489
Figure 26
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3. Separate the collar (2, Figure 27) from the axle, using
press.
2
FG001490
Figure 27
2
7 6 FG001493
Figure 28
FG001491
Figure 29
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2. Apply grease to the O-rings (7, Figure 29) and insert into
axle. 5
3. Align collar (2, Figure 30) and axle (3) pin holes and pin (5)
the collar. 3 7 2
FG001492
Figure 30
4. Insert floating seals (6, Figure 31) into the roller (1) and
1
collar (2).
6
NOTE: Apply clean engine oil to the joint side of the
2
floating seal. Apply grease to the floating seal
O-ring.
5. Slide the axle inside the roller.
2
7 6 FG001493
Figure 31
6. Install the collar (2, Figure 32), O-ring (7), and pin (5) on
the remaining side. 5
2 FG001487
Figure 32
FG000345
Figure 33
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UPPER ROLLER
Parts List
3
8
6
Track Frame
4
1
5
11
14
12
7
10
15
13
FG001141
Figure 34
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Reference Reference
Description Description
Number Number
1 Roller 9 Plug
2 Shaft 10 Cover
3 Thrust Ring 11 Washer
4 Bushing 12 Bolt
5 Bushing 13 Blot
6 Floating Seal 14 Spring Washer
7 O-ring 15 Spring Washer
8 O-ring
FG000524
Figure 35
9
FG001494
Figure 36
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2. Remove the bolts (13, Figure 37) and cover (10). Detach
bolts (12) and washer (11).
11
12
10
13
FG001495
Figure 37
3. Separate the roller (1, Figure 38) from the axle (2).
2
1
FG001497
Figure 38
4. Separate the floating seal (6, Figure 39) from the roller.
1
5. Separate the O-ring (8) and thrust ring (3) from the axle.
6
8
3
FG003916
Figure 39
FG001502
Figure 40
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Upper Roller Reassembly
1. Degrease, clean and dry all parts before reassembly. Insert
bushing (4 and 5, Figure 41) into the roller (1). 4
1
5
FG003917
Figure 41
2. Insert floating seal (6, Figure 42) into the roller (1) and
1
bushing.
NOTE: Apply clean engine oil to the joint side of the
floating seal. Apply grease to the floating seal 2
O-ring.
6
3. Install the axle (2), O-ring (8) and thrust ring (3). 8
3
FG003916
Figure 42
9 FG001501
Figure 43
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TRACK SPRING AND TRACK
ADJUSTING CYLINDER
Parts List
9 11
8
7 3
10
1
12
13
14
2
FG003918
Figure 44
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Reference Reference
Description Description
Number Number
1 Cylinder 8 Lock Plate
2 Piston Rod 9 Bolt
3 Yoke 10 Spring Pin
4 Spacer 11 Spring Washer
5 Shaft 12 Packing
6 Spring 13 Backup Ring
7 Lock Nut 14 Dust Seal
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Track Assembly SP000024
Page 32
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SP000025
AIR CONDITIONER SP000025
Air Conditioner
Edition 1
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Table of Contents
Air Conditioner
Safety Precautions................................................ 5
Applicable Models................................................. 5
Air Conditioner System ......................................... 6
Outline ............................................................................. 6
Internal and external filters .............................................. 7
Air-Conditioning System Layout ...................................... 9
Air Conditioner/heater Circuit Diagram.......................... 10
Air Conditioner/heater Unit ............................................ 11
Ambient Temperature Sensor........................................ 16
Sun Sensor.................................................................... 17
Control Panel................................................................. 17
Compressor................................................................... 25
Receiver Driver.............................................................. 25
Troubleshooting .................................................. 26
Weight of R134a Gas Used In Machines............ 29
Refrigerant System Repairs ............................... 30
Refrigerant Safe Handling Procedures.......................... 30
Repair and Replacement Procedure ............................. 31
Refrigerant Recovery .................................................... 33
Vacuuming Refrigerant System..................................... 33
Leakage Check ............................................................. 34
Refrigerant Charging ..................................................... 35
Inspecting System For Leakage .................................... 37
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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AIR CONDITIONER SYSTEM
Outline
A
C
FG000784
Figure 1
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(Please refer to the Operation Manual for detailed whole
automatic control.
Vent mode selects the direction of discharged air.
Outlets by vent modes
Modes
Outlets A A+B B B+C C
FG000422
Figure 2
Donaldson.
FG000440
Figure 3
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2. Turn marked knobs (1, Figure 4) at the rear side of the
cabin to open the cover.
FG000441
Figure 4
FG000342
Figure 5
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Air-Conditioning System Layout
10
11
2
5
6
5
7
4
1
8
9 FG003919
Figure 6
Reference Reference
Description Description
Number Number
1 Air Conditioner/heater Unit 7 Liquid Hose (1)
2 Condenser 8 Liquid Hose (2)
3 Compressor 9 Ambient Temperature Sensor
4 Receiver Dryer 10 Sun Sensor
5 Discharge Hose 11 Control Panel
6 Suction Hose
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Air Conditioner/Heater Circuit Diagram
0.5RW
FUSIBLE LINK
LAMP SWITCH
A/C THERMO (LOW) 105B CN9-8 0.5LB CN10-5 105A CN11-4 0.85LW 47C
DIODE 4
1.25B CN11-1 99 - +
M
107B CN8-12 0.5LW CN10-1 107A 0.85B 0.85B
BLOWER
99 CN9-10 1.25B
20 19 18 17 16 15 14 13 12 11 10
4 3 18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
FG000781
Figure 7
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Air Conditioner/Heater Unit
Cold Box
Internal Air Inlet
Outlet
Vent Rear
Outlet
Vent
Front
Outlet
Foot
DEF Outlet
Outlet
External Air
VENT
COOL
DOOR
DOOR -INTAKE
-MIX
DEF Internal Air
WARM
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Door Open by Vent Modes
Mode
Door
Vent Bi-level Foot Def/foot Def
Vent 100 60 0 0 0
Foot 0 40 100 80 60
Def 0 0 0 20 40
Main Components
Internal
Internal Air Sensor
Air Filter
Actuator Water Temp Evaporator
-Wind Direction Sensor FG001360
Control
Figure 9
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FG001361
Figure 10
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Actuator - Internal/external air exchange
CN10-20 CN10-2
FG001055
Figure 11
DRAIN
(CN10-1)
SOURCE GATE
(CN11-1) (CN10-6)
FG001056
Figure 12
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Relay - Blower
Power is supplied to the blower motor when the system is turned
on.
Specifications
Rated voltage 24V
Rated current 20A
Figure 13
Relay - A/C
Power is supplied to the magnetic clutch of the compressor.
Specifications
L S1 (+)
Rated voltage 24V
Rated current 10A
B S2
(-)
FG001058
Figure 14
Duct Sensor
It is inserted in the core of the evaporator to prevent freezing of
the evaporator.
The sensor consist of negative characteristic thermistor that
resistant value increases and decreases when the temperature
rises and falls, respectively.
Temp (°C) Ω)
Resistance (KΩ
0 11.36 ±0.1
2 10.39 ±0.2
2.5 10.17 ±0.2 Figure 15
3 9.95 ±0.2
3.5 9.73 ±0.2
4 9.52 ±0.2
5 9.12 ±0.2
10 7.36 ±0.15
25 4.02 ±0.08
30 3.33 ±0.07
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Water Temp Sensor
It senses the temperature of coolant water in the heater core.
Temp (°C) Ω)
Resistance (KΩ
-10 55.8 ±1.7
0 32.9 ±0.9
15 15.76 ±0.5
25 10.0 ±0.3
35 6.5 ±0.2
Figure 16
Temp (°C) Ω)
Resistance (KΩ
-15 218.2 ±7.5
0 97.83 ±0.9
15 47.12 ±0.7
25 30.0 ±0.36
35 19.60 ±0.3
Figure 17
Temp (°C) Ω)
Resistance (KΩ
-10 163 ±4.9
0 96.9 ±2.9
10 59.4 ±1.8
20 37.4 ±1.1
25 30 ±0.9
30 24.2 ±0.7 FG001064
Figure 18
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Sun Sensor
Built beside the socket of spare power, it senses the quantity of
the sun radiation to optimize discharge temperature and air flow
as set by driver.
83.7
OUTPUT VOLTAGE(mV)
76.2
67.7
58.8
46.6
36.0
21.4
Control Panel
A/C OUTSIDE
AUTO A/C
AUTO MAX
TEMP
OFF
SEL MODE
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
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Terminal Terms
Control Logic
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Categories Inputs System Operation
Sensor Set Temp 1. In case of sensor failure, following defaults are applied:
compensation
Internal air temp sensor Internal air temp sensor: 25°C Ambient air temperature
sensor: 25°C, Duct sensor: -2°C.
Ambient air temp sensor
Temp control actuator:
Water temp sensor
- Set Temp 17 - 24.5°C: Max cooling, Set Temp 25 - 32°C:
Max heating.
Wind direction mode actuator
- VENT: VENT fix, modes other than VENT: Fixed to DEF
* Sun sensor is not compensated.
Max cooling/ Set Temp 1. Set Temp 32°C: Max heating
heating
Auto Setting 2. Set Temp 17°C: Max cooling
control
Temp Control
FULL COOL FULL HOT
Actuator
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Categories Inputs System Operation
Starting Auto mode 1. Prevention of discharge of hot air before discharge temp
Control of drops enough in hot summer weather.
Duct sensor
Cooling
2. Start conditions (AND condition)
(1) A/C ON (AUTO or manual)
(2) Temperature sensed by the duct sensor is above 30°C
(3) Air flow: Auto mode
3. One time control in the cycle of engine OFF → engine run
4. Initial cooling control is executed when the Auto switch is On
in the manual status.
(A/C Off and manual control of air flow) in 5 seconds after
engine run.
5. Initial cooling control should be before max cooling.
6. Release condition (OR condition)
(1) A/C OFF
(2) Air flow: Manual control
(3) Release is possible with the OFF switch but not allowed
within 12 seconds
(after Start On) while the system is off using the OFF switch
and during the time of initial cooling control.
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Categories Inputs System Operation
1. Start condition (AND condition)
(1) When wind direction mode is one of the following modes
in the Auto or manual control mode
- BI-LEVEL, FOOT or FOOT/DEF
(2) The Water temp sensor is stable and the water temp <
73°C
(3) Air flow: Auto mode
(4) Set temp > Internal air temp + 3°C
* Air flow falls gradually up to 12 seconds when operation
released.
Water temp sensor 2. One time control in the cycle of engine OFF → engine start
Starting Internal air temp sensor 3. Initial heating control should be before max heating.
control of
heater (1) Auto mode 4. Air flow is controlled only when the wind direction is in the
Set Temp manual mode and BI-LEVEL, FOOT, or FOOT/DEF is set.
5. Control through the water temp sensor for start
6. Heater starting control (2) starts in case of fault of the water
temp sensor during controlling.
7. Operation release (OR condition)
(1) Only air flow is released if it is selected manually.
(2) When handling the wind direction mode switch, only wind
direction is released but the air flow control is performed
only for the remaining period of the starting control of heater.
(3) When Max Cooling (17°C) is selected.
(4) Water temp sensor > 73°C
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Categories Inputs System Operation
Initial heating Water temp sensor 1. Entry condition (AND condition)
control (2)
External temperature (1) Auto Mode
sensor
(2) External air temp < 5°C and difference between external
Internal air temp sensor and internal air temp 5°C
Auto mode (3) Failure of water temp sensor
2. Only one time of engine OFF → engine run
3. Starting control of heater is before max heating.
4. Operation release (OR condition)
(1) Air flow: Manual selection
(2) When handling the wind direction mode switch, only wind
direction is released but the air flow control is performed
only for the remaining period of the starting control of heater.
(3) Difference between internal and external air temp>15°C
(4) When Max Cooling (17°C) is selected.
5. Exceptional case
Starting control of heater is performed only once during the
remaining period if the entry condition is satisfied within the
starting control period that is the accumulation of initial start
times.
(Inclusive of Auto mode ON case within the period of
starting control of heater.)
* Air flow should be reduced slowly for up to 12 seconds in
case of exceptional entry case.
Duct sensor 1. Function: Magnetic clutch of compressor is turned ON/OFF
depending on temp of the duct sensor to prevent the
freezing of the evaporator with A/C being ON.
2. Control pattern
Compressor
control External temperature 1. Function: Prevention of compressor in winter.
sensor
2. Control pattern
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Self Diagnosis
How to start self diagnosis
Starter Switch ON
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Error codes
Code Description
E0 Normal
E1 Internal Air Temp Sensor Short
E2 Internal Air Temp Sensor Open
E3 Ambient Air Temp Sensor Short
E4 Ambient Air Temp Sensor Open
E5 Duct Sensor Short
E6 Duct Sensor Open
E7 Sun Sensor Short
E8 Sun Sensor Open
E9 Water Temp Sensor Short
E10 Water Temp Sensor Open
E11 D.P.S OPEN
E12 Position Error of Wind Direction
Actuator.
E13 Position Error of Temp Control
Actuator.
0.5 0.5
FG001067
Figure 22
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Compressor
Categories Specifications Relief Valve
Output 155.3 cc/rev
(9.48 in∏)
Oil Level 120 cc (ND-OIL8)
(7.32 in∏ (ND-OIL8))
Refrigerant R134a
Rated Voltage 24V
Open: 35 - 42.2 kg/cm2G
(500 - 600 psi)
Relief Valve FG001365
Close: 28.1 kg/cm2G Figure 23
(400 psi)
Receiver Dryer
The receiver dryer reserves refrigerant enough to ensure High/Low Pressure Switch
smooth freezing cycle responding immediately to the change of
level in the freezing cycle.
As liquid refrigerant from the condenser may contain refrigerant
gas with bubbles whose presence in the expansion valve
decreases the freezing power excessively, it separates liquid
and gas and sends liquid only to the expansion valve.
Water in refrigerant shall be eliminated with dryer and through
filter.
FG001366
Figure 24
kgf/cm2G
kgf/cm2G
kgf/cm2G
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TROUBLESHOOTING
Refrigerant Pressure Check
1. Open all doors and windows.
2. Install manifold gauge set.
3. Start engine and maintain engine speed at 1,800 - 2,000
rpm.
LO HI
HDA6074L
Figure 26
4. Check high / low-pressure of refrigerant.
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High-pressure: Approximately 20 - 25 kg/cm2 (285 - 356 psi)
3
Low-pressure: Approximately 2.5 - 3.5 kg/cm2 (36 - 50 psi)
Possible Cause: Air in system.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long period of time, replace the receiver dryer.
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High-pressure: Over 7.0 - 11.0 kg/cm2 (100 - 156 psi)
7
Low-pressure: 4.0 - 6.0 kg/cm2 (57 - 85 psi)
Inspect and replace compressor if necessary.
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WEIGHT OF R134a GAS USED IN
MACHINES
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REFRIGERANT SYSTEM
REPAIRS
WARNING!
Always wear protective glasses and gloves when handling
refrigerant. If refrigerant comes in contact with the skin or
eyes, immediately flush with clean, running water and
consult a physician.
Select a clean and well ventilated area to work.
The refrigerant container is under high-pressure and
should be stored below 40˚C (104˚F). Be careful not to drop
the container from a high location.
The contents are under high-pressure and should not be
used with compressed air or near an open flame.
UNION NUT
TORQUE WRENCH
CORRECT WRONG
WRONG
WRONG
CORRECT
O - RING POSITION
HDA6066L
Figure 27
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3. Do not over tighten connections when working on
refrigerant system.
4. The new refrigerant system standards require new tools,
equipment and parts. DO NOT attempt to use equipment
use in servicing the old refrigerant system.
5. The new refrigerant oil (PAG type) has a high moisture
absorption characteristic. When the refrigerant system
vacuum seal has been broken, immediately plug up all
openings to prevent moisture from entering into the
system.
6. When joining unions which use O-ring seals, lightly coat O-
rings with refrigerant oil. Be careful not to drip oil on the
threads of the nut.
7. Be certain the O-rings are seated properly on the
refrigerant line lip. Always use new O-rings when
reassembling parts. Do not reuse old O-rings.
8. Use a vacuum pump to evacuate refrigerant system of air.
9. When charging the refrigerant system with the engine
running, do not open the high-pressure valve on the
manifold gauge as the reverse flow of high-pressure
refrigerant will rupture the hose.
10. When releasing the high-pressure hose after completing
the charging process, quickly disconnect the hose to
minimize refrigerant released to the air.
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INSTALL REPAIR TOOL
RECOVER REFRIGERANT
RUN SYSTEM
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Refrigerant Recovery
Reference
Description 2 3
Number
1 4
1 To Compressor
2 Low-pressure Side
3 High-pressure Side
4 From Receiver
5 Refrigerant Recovery Tank
3. When the manifold gauge dial falls below 3.5 kg/cm2 (50
psi), slowly open the low-pressure valve.
4. Open both the high and low-pressure valves slowly until
the manifold gauge dials indicates 0 kg/cm2 (0 psi).
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2. Check system for vacuum leak.
Allow system to sit for 10 minutes and check whether the
system is holding the pressure. If the pressure has
dropped, it must be repaired before proceeding to the next
step.
3. Vacuuming Procedure
If the system is holding the pressure and it has not
changed for 10 minutes, vacuum out the system for an
additional 20 minutes.
HDA6069L
A. Turn on the vacuum pump and slowly open both
Figure 31
valves.
B. Allow vacuum pump to run for additional 20 minutes
until the low-pressure gauge dial reads approximately
750 mmHg.
C. Close both valves and stop the vacuum pump.
4. Installation of Refrigerant Container
Reference 1
Description
Number
1 Handle
2 Hose Connection
2
3 Mounting Disk
3
A. Before mounting valve on the container, make sure
the handle is in the counterclockwise most position,
with the puncture pin retracted and the mounting disk HDA6070L
is in the raised position. Figure 32
B. Attach the manifold gauge center hose to the valve
assembly.
C. Turn the disk in the clockwise direction and securely
mount valve onto refrigerant container.
D. Turn the valve handle in the clockwise direction and
puncture the container seal with the pin.
E. Once the can has been punctured, turn the handle in
the counterclockwise direction so the refrigerant can
flow into the manifold gauge center hose. At this time,
do not open the low and high-pressure valves of the
manifold gauge.
F. Press the manifold gauge low side valve to eliminate
the trapped air in the hose.
Leakage Check
NOTE: Perform the leakage check after completing
vacuuming process.
1. After attaching the manifold gauge, open the high side
valve.
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2. Charge system until the low side gauge dial indicates a
pressure of 1 kg/cm2 (14 psi) and close the high side valve.
3. Using a refrigerant leak detector or soapy water check
each joint for leakage.
1
Reference
Description
Number
1 Refrigerant Leak Detection Device
WARNING!
For accurate refrigerant leak detection, perform leak
detection procedure in a well ventilated area.
Refrigerant Charging
1. Perform the vacuuming procedure, vacuum holding and
leaking tests as described in the proceeding headings.
NOTE: First charge the refrigerant system with 100g
(3.5 ounces) of refrigerant with the engine off.
Then using the manifold gauges as a guide fully
charge the system with the engine running.
When exchanging refrigerant containers, press
the manifold gauge low side valve to eliminate
air from the charging hose.
Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low-pressure Side
3 High-pressure Side
4 From Receiver
5 Refrigerant Supply Container
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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.
WARNING!
• When outside temperature is low, warm the
refrigerant supply container with warm
water not exceeding 40˚C (104˚F). Do not
allow water to come in contact with the
charging adapter valve handle.
• When outside temperature is high, cool off
refrigerant supply container and condenser
to aid the refrigerant charging process.
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Inspecting System For Leakage
After completing charging procedures, clean all joints and
connections with a clean dry cloth. Using a refrigerant leak
detecting device or soapy water, inspect system for leaks
2
starting from the high-pressure side.
1
NOTE: When the refrigerant circulation has been stopped
the high-pressure will start to decrease and the low-
pressure will start to increase until they are
equalized. Starting the inspection from the high side 3
will result in a accurate test.
Reference 4
Description HDA6073L
Number Figure 35
1 Pressure
2 High-pressure
3 Low-pressure
4 Compressor Stop
Inspection Procedure
1. High-pressure Side
Compressor outlet → condenser inlet → receiver dryer
inlet → air conditioner unit inlet.
2. Low-pressure side
Compressor inlet → air conditioner unit outlet.
3. Compressor
Compressor shaft area, bolt hole area and magnetic clutch
area.
4. Receiver dryer
Pressure switch and plug area.
5. Connection valve area
Inspect all valve areas.
Verify all valves are capped to prevent leaking.
Check for foreign material inside of valve cap.
6. Interior of air-conditioning unit.
After stopping engine, insert detector probe into drain
hose. (Leave inserted for 10 seconds minimum.)
NOTE: When inspecting leakage from the air-
conditioning unit, perform the inspection in a
well ventilated area.
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Air Conditioner SP000025
Page 38
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1Engine and Drive Train
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SP000026
DRIVE COUPLING (MAIN PUMP)SP000026
1Drive Coupling
(Main Pump)
Edition 1
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MEMO
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Table of Contents
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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DRIVE COUPLING
Figure 1 thru Figure 2, show typical drive coupling installations.
FG000656
Figure 1
FG000657
Figure 2
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INSTALLATION OF DRIVE
COUPLING
Always follow the following installation procedure when installing
the drive coupling in the main pump.
NOTE: Noncompliance with the procedure may cause noise
or shortening of life of the drive coupling or the main
pump.
Installation Procedure
1. Assemble the flange of the coupling (1, Figure 3) in the
engine flywheel with bolts (2, Figure 3). 1
NOTE: Apply lock tight to bolts (2).
NOTE: Set the flange that the label saying "2 mounted
long side" faces the pump. 2
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Drive Coupling (Main Pump) SP000026
Page 8
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1Hydraulics
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SP000027
HYDRAULIC SYSTEM TROUBLESHOOTING,
TESTING AND ADJUSTMENTSP000027
Hydraulic System
Troubleshooting,
Testing and
Adjustment
Edition 1
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MEMO
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Table of Contents
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Control Valve Pressure and Current Adjustments ......... 19
Pressure Up Valve .............................................. 21
Checks and Adjustments............................................... 21
Pump Input Power Control.................................. 23
Pump Regulator Adjustment ......................................... 23
Flow Meter and Flow Meter Kit Installation and
Testing ................................................................ 27
Swing System Troubleshooting........................... 29
Precautions/Initial Checks ............................................. 29
Swing Relief Valve Checking and Adjustment ............... 29
Troubleshooting – Swing Gearbox ...................... 32
Troubleshooting – Hydraulic Problems ............... 33
Troubleshooting – Control Valve ......................... 34
Troubleshooting – Travel Control Valve ............... 36
Troubleshooting – Joystick Control Valve............ 36
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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HYDRAULIC SYSTEM -
GENERAL NOTES
Center Joint
Travel Motor
Travel Motor
FG001322
Figure 1
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Electronic management of hydraulic control valves assists in
optimizing the application speed and overall operator control of
hydraulic actuators and functions.
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HYDRAULIC SCHEMATIC
The hydraulic schematic(s) is available in the "Hydraulic and
Electrical Schematic Shop Manual." This manual is a collection
of diagrams and schematics for a number of models.
General Notes
When referring to the schematic, refer to the following items:
• As shown in the schematic, the main pump assembly
is driven by the engine. Mechanical energy is
converted to hydraulic power, generating the required
hydraulic flow which drives the system. Two main
pumps (a right side pump and a left side pump) make
up the main pump assembly.
• Hydraulic output from the right side pump is
transmitted to the right side of the control valve.
Output from the left side pump is transmitted to the
valve spools on the left side of the control valve.
Hydraulic output from the pilot pump is used to
control the pump and to operate pilot and solenoid
valves.
• The right half of the hydraulic control valve, supplied
by the right pump in the pump assembly, operates
valve spools for right travel, swing, boom up and arm
functions. The amount of oil flow to the actuators at
the output end of each of those circuits is regulated
through the movement of each individual valve spool.
• The left half of the hydraulic control valve, fed by the
left pump in the pump assembly, has control spools
for left travel, bucket, boom and arm operation.
• Two-stage operation is a feature of boom and arm
function. All of these circuits can be operated using
the output of only one half of the hydraulic pump
assembly (one pump or the other), or – since both
halves of the control valve have a spool and available
circuit 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 standard or general duty mode, the high speed/
rapid cycling mode.
• Whenever the right travel or left travel control spools
are shifted, output from the main pump assembly
flows through the center joint to one or both of the
axial piston motors driving the side frame crawler
tracks. A pilot valve connected to the swash plate of
each travel motor changes motor capacity (and
output) in direct proportion to the position of the travel
switch selected by the operator.
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• The hydraulic reservoir return line and the pilot circuit
both have 10 micron full flow filters. The disposable
elements in these two canister type filters trap and
remove impurities from the oil in the system. An 80
mesh, 177 micron reservoir intake strainer also helps
maintain system cleanliness and should be cleaned
each time hydraulic fluid is drained and replaced. An
oil cooler in the hydraulic system helps maintain the
operating temperature of the system at approximately
50°C (122°F).
• The arm cylinder operating circuit includes
anticavitation valves which protect the hydraulic
system from vacuum that could result from external
shocks or other unusual conditions. Boom, Arm, and
Bucket cylinder circuit are also protected by overload
relief valves. Whenever high-pressure is generated
as a result of a shock or overload, excess pressure is
dumped to the reservoir return circuit through the
relief valve.
A selection valve in the travel circuit can be used to provide
constant high torque/low speed travel, or variable speed/variable
torque output for travel. To prevent sliding during simultaneous
travel and boom/arm/bucket operation, select the high torque/
low speed travel position.
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OPERATION OF WORKING
COMPONENTS
Boom Up Circuit
When you pull the boom control lever backward, the right side
pilot valve generates secondary boom up pilot pressure that is BOOM
CYLINDER
transmitted to the BOOM1 and BOOM2 spools of the control
valve simultaneously. When secondary pilot pressure reaches 7
- 9 kg/cm2 (100 - 130 psi), boom control valve spools open and BMD BM1 PILOT VALVE BM2
PUMP(L) PUMP(R)
ARS1560L
Figure 2
PUMP(L)
ARS1570L
Figure 3
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Arm Operating Circuit
The arm operating circuit includes both the right and left
hydraulic main pumps, the right and left halves of the control
valve, a slow return orifice, and the arm cylinder. The circuit can
be operated in the two-stage speed control mode which works
through both halves of the control valve and doubles the volume
of oil flowing to the cylinder.
Overload relief valves set at 360 kg/cm2 (5,112 psi) have been
installed at the AM 1 and AMD 1 ports on the right side of the
control valve to protect the circuit and system components from
possible damage caused by shocks and/or overload pressure.
Additional protection - to prevent cavitation of the cylinder - is
provided by a makeup valve and reservoir return circuit, which
ensures that the volume of oil going to the cylinder will not
exceed the volume of oil coming out.
to the AM1 and AM2 spools of the control valve simultaneously. REGENERATION VALVE
When secondary pilot pressure reaches 7 - 9 kg/cm2 (100 - 130 AM2 PILOT VALVE AMD1 AM1
psi), the arm control valve spools AM1 and AM2 open. Output
flow from both halves of the pump assembly is directed to the PL TL PR
arm cylinder.
When working in the arm crowd mode, under certain conditions, CONTROL
VALVE(L)
CONTROL
VALVE(R)
oil in the arm cylinder could suddenly be forced out by the weight
of the arm and bucket. Insufficient oil flow to the cylinder could PUMP(L) PUMP(R)
lead to cavitation in the cylinder and/or surging or irregular ARS1580L
movement. This is prevented by a regeneration valve attached to
Figure 4
the control valve which maintains the balance between oil
flowing into the cylinder and oil flowing out.
CONTROL CONTROL
VALVE(L) VALVE(R)
PUMP(L) PUMP(R)
ARS1590L
Figure 5
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Bucket Operating Circuit
The bucket operating circuit includes the left main pump, the left
half of the control valve and the bucket cylinder. 360 kg/cm2
(5,112 psi) overload relief valves at BKT and BKTD 1 ports of
the control valve protect the circuit and its components from
being damaged.
TL PL
CONTROL
VALVE(L)
PUMP(L)
ARS1600L
Figure 6
VALVE(L)
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Right Swing Operating Circuit
When the swing control lever is pushed to the right swing
position, pilot pressure from the left side pilot valve is directed to
CONTROL
the right side pump regulator and right half of the control valve. VALVE(L)
Output flow from the right pump is then directed through the PR
and SWR ports of the control valve to the swing motor. SWD SW PILOT VALVE
TL PR
CONTROL
VALVE(R)
PUMP(R) ARS1620L
Figure 8
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Forward Travel Circuit
When the right and left travel control levers are pushed forward, TRAVEL
MOTOR(L)
TRAVEL
MOTOR(R)
output from both of the main pumps is directed through the PR,
PL, TRRF, and TRLF ports on the control valve, through the CENTER JOINT
upper works center joint, to the travel motors on each side of the
machine.
TRL TRLD PILOT VALVE TRRD TRR
PL TL PR
CONTROL CONTROL
VALVE(L) VALVE(R)
PUMP(L) PUMP(R)
ARS1630L
Figure 10
PL TL PR
CONTROL CONTROL
VALVE(L) VALVE(R)
PUMP(L) PUMP(R)
ARS1640L
Figure 11
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PROCEDURAL
TROUBLESHOOTING BASELINE
RECOMMENDATIONS
Triage Summary
An excavator that fails to deliver designed performance should
be checked for the following:
• Hydraulic flow, first, and.
• Hydraulic pressure, afterwards, in a specified order of
priority through different points of the system.
To verify adequate available hydraulic flow, before any other
tests are performed through the circuit:
Check engine operation -
• at 1,950 rpm with no load.
• at 1,950 rpm stall load.
If engine rpm drops excessively with a load or fails to surpass
rated speed (1,900 rpm), performance problems may be due to
inadequate hydraulic flow caused by lagging rotational speed.
NOTE: Verify actual flow on the excavator against rated
performance, with a flow meter.
If engine tests meet specifications and adequate torque and
horsepower are available at the pump drive flex coupling, pull
out the electrical tray under the operator's seat to inspect the
self-diagnostic display.
If the EPOS trouble code display is clear, check hydraulic
functions in the following sequence:
• Pilot pressure.
• Negacon, negative control pressure.
• Main relief pressure (front and rear pump)
• Swing pressure.
• Port relief pressure (individual control functions;
boom, arm, bucket, swing, and travel)
• Power boost circuit.
• Standard performance tests; cylinder speed,
hydraulic motor (travel and swing) speed, cylinder oil
tightness "permissible drift" test.
NOTE: System specification performance tests of
individual activator function are
determined by flow rate through the
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component or circuit, not the control
pressure or system pressure available to
the actuator. Poor flow through the
individual circuit may indicate that the
component is worn beyond tolerance
limits, while all other hydraulic functions
are adequate.
IMPORTANT
It is suggested that the troubleshooter maintain the testing
sequence of the preceding list. Checks and adjustments
nearer the middle or the end of the list may depend on
adequate functioning of systems tested nearer the top of
the list.
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PILOT PRESSURE
WARNING!
This procedure should be done with two people. To reduce
the chance of accident or unintended start-up, one person
should remain at the operator's control stand while checks
and adjustments are made.
IMPORTANT
Top off the hydraulic fluid reservoir if there is any
measurable loss of hydraulic oil during test gauge and
adapter fitting installation.
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POWER MODE VALVE
WARNING!
This procedure should be done with two people. To reduce
the chance of accident or unintended start-up, one person
should remain at the operator's control stand while checks
and adjustments are made.
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SWING PRIORITY VALVE
Mode Engine RPM Current Pressure
150 ±20 mA
Mid-range value corresponding 0.83 bar
Power Mode High Idle: 2,000 rpm to engine rpm for both current (12 psi)
and hydraulic pressure
readings.
15.8 bar
Standard Mode High Idle: 1,900 rpm 400 mA
(229 psi)
WARNING!
This procedure should be done with two people. To reduce
the chance of accident or unintended start-up, one person
should remain at the operator's control stand while checks
and adjustments are made.
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Valve Function / Work Mode Signal Voltage Hydraulic Pressure
Swing Priority / Trenching 20 - 30 V 20 - 40 bar (290 - 580 psi)
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PRESSURE UP VALVE
WARNING!
This procedure should be done with two people. To reduce
the chance of accident or unintended start-up, one person
should remain at the operator's control stand while checks
and adjustments are made.
IMPORTANT
Pressure adjustments and checks cannot be made if pilot
pressure is outside the specified range. Refer to the pilot
pump adjustment procedure if required, then proceed with
any necessary adjustments to main relief pressure settings.
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Main Pressure and Pilot Pressure and
Power Mode Operation
Tolerance Tolerance
20 - 40 bar 30 bar +10 bar
Power Mode Neutral, No Operation
(290 - 580 psi) (435 psi +145 psi)
330 bar +5 bar 30 bar +10 bar
Power Mode Cylinder Stall
(4,785 psi +75 psi) (435 psi +145 psi)
Power Mode W/ 350 bar +10 bar 30 bar +10 bar
Cylinder Stall
Pressure Up 5,075 psi +145 psi (435 psi +145 psi)
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PUMP INPUT POWER CONTROL
WARNING!
This procedure should be done with two people. To reduce
the chance of accident or unintended start-up, one person
should remain at the operator's control stand while checks
and adjustments are made.
IMPORTANT
Before starting this procedure or going onto make any
changes of adjustment settings:
• Verify engine output to the rated speed –
2,050 ±50 rpm.
• Permanently mark setscrew positions at the
current regulator control setting.
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adjustment, the pump which supplies output to the track frame
toward which the excavator is veering is weak.
D
B
F
A
G
E
C
D
1
E 2
F
A G
B
C
FG000654
Figure 12
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the output of the other. It is not necessary to adjust
both regulators at the same time, but after checking
or adjusting one of them, the remaining unit should
also be checked.
Start the engine and turn the engine speed dial to maximum.
When normal operating temperature is reached, loosen the
largest diameter lock nut around the adjustment screw (2) for the
outer regulator spring. Tightening the screw shifts the P/Q
(Pressure/Flow) control curve to the right, and increases
compensating control pressure.
On the other hand, if the persistent cause of performance
problems is engine overloading, decreasing the adjustment by
turning the larger diameter adjusting screw (2) out will decrease
pump input horsepower. 1/4 turn on the adjusting screw is equal
to approximately 17 horsepower.
Figure 13
IMPORTANT
Because changing the position of adjusting screw (2) also
affects the setting of the adjustment for the inner spring,
the smaller diameter adjusting screw (1), turn in the inner
screw 198° (slightly more than 1/2 turn, 180°) before screw
(2) is backed out 1/4 turn (90°).
Figure 14
The adjusting 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 delivery rate.
Balance both pumps for equal output.
Q
P
HDA3008L
Figure 15
FG000655
Figure 16
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FLOW METER AND FLOW
METER KIT INSTALLATION AND
TESTING
Checking regulator and pump output, to assess the output
balance between the front and rear pumps and to verify
operating adjustment of each regulator, will require installation of
a flow meter.
The After Sales Service department of the nearest local
DOOSAN dealer can assist you with these tests or, if you prefer
carrying out your own testing, they should be able to help in
putting together a hose and fitting kit (or the required dimensions
and specifications for hoses and fittings) to allow you to install a
flow meter downstream from the main pump assembly.
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power mode selector at Power Mode and the work mode
selector at digging mode:
• Unloaded maximum engine speed baseline test (all
controls in neutral).
• Front pump test – operate "travel right" lever. Record
values at all specified pressures.
• Rear pump test – operate "travel left" lever. Record
values at all specified pressures.
Record the values for each of the three tests (neutral, travel right
and travel left) at the following pump pressure levels, with travel
speed control set at "high speed."
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SWING SYSTEM
TROUBLESHOOTING
Precautions/Initial Checks
1. Stop work. Release all weight or any type of load safely
before proceeding. Avoid risking injury or adding to
damage.
2. Shut down engine and disengage control functions until
initial tests are ready to be made.
WARNING
Prevent possible injury and/or loss of operating control.
Stop work and park the excavator at the first indication of:
1. Equipment breakdown.
2. Inadequate control response.
3. Erratic performance.
Stop the machine, put the boom and arm in the inoperative
(overnight park) position and begin by making the fastest,
simplest checks first:
• Check oil level.
• Check for overheating, oil leaks, external oil cooler
clogging or broken fan belt. Consult service record for
prior repair/service work.
• Drain some tank oil into a clean, clear container. Look
for metal shavings/grit, cloudiness/water or foam/air
bubbles in the oil.
NOTE: Dispose of drained fluids according to
local regulations.
• Check for wobble through the engine/pump flex
coupling. Run engine with the pump input hydraulic
power control nut turned to the lowest power to check
the engine.
• Investigate unusual operating noises or vibration.
Check for loose bolts, connections.
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• Swings but continues to coast.
• There is drifting on a slope.
1. Check operation by connecting:
A. Two 600 bar (8,700 psi) pressure gauges to the inlet
and outlet measuring ports on top of the swing motor.
Pressure should be between 270 and 280 bar (3,916
psi and 4,060 psi), with both swing locks engaged.
With swing locks released, during full acceleration
and deceleration, pressure should approach 250 bar
(3,625 psi) in each direction.
B. Connect a 60 bar (870 psi) pressure gauge at the
"SH" port of the hydraulic brake.
Pressure should always stay at or above 13 bar (190
psi) when operating swing, boom or arm.
C. Connect a 10 bar (145 psi) gauge at the motor
makeup valve.
Pressure should stay consistently above 2.5 bar (36
psi). If pressure falls below the recommended
minimum level, forceful acceleration of the swing
motor could lead to cavitation of the circuit and
stalling, slowed rotation, noise and possible damage.
2. If main inlet and outlet pressures were off in the preceding
tests in Step 1, adjust swing relief valve pressure.
Following adjustment, repeat the operating pressure tests
(with gauges connected to the inlet and outlet test ports on
top of the swing motor) and check pressures with the swing
locks engaged and released.
If pressure adjustment fails to restore adequate
performance, proceed to the Troubleshooting – Swing
table.
3. If pressure tests were at recommended levels through the
main inlet and outlet ports, and through the "SH" port of the
swing brake, the causes of poor swing performance could
include a faulty swing motor, drive train overloading or
gearbox defect, or a problem in the brake assembly or
swing control valve. Proceed to the troubleshooting
information in the next procedure.
If pressure through the "SH" port was tested below the
minimum 13 bar (190 psi) level, check the shuttle valve in
the rear compartment behind cabin. When 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 been restored but the brake
still fails to release, the brake piston or friction plate may be
frozen, requiring disassembly of the motor and parts
repair/replacement.
4. If pressure tested at the motor makeup valve falls below
recommended minimum level, and consequent problems
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with cavitation, stalling and surging are observed, check
the restriction valve. If pressure adjustment to the valve
has been restored but if problems with cavitation
continues, disassemble the upper swing motor housing
and clean or replace assembly components as required.
NOTE:If all tested pressures are at or above
recommended levels, and there are no
mechanical problems in the drive train or in the
motor/brake assembly, the problem will require
further hydraulic troubleshooting. It's also
possible that a defective joystick, an intermittent
short in an electrical control circuit or a problem
in the e-EPOS circuit is causing diminished
swing performance. Pull out the e-EPOS
indicator panel from underneath the operator's
seat and perform the self-diagnostic test. If the
display panel reads code "0.2," it is reporting
that the swing priority proportional valve is not
functioning, except in the minimum "fail-safe"
mode. Refer to the Electrical section of this
book for more information.
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TROUBLESHOOTING – SWING
GEARBOX
Problem Possible Cause Remedy
Swing motor fails to operate and:
Three pressure tests at Swing relief valve defective Brake Adjust pressure to recommended range
motor, brake or makeup release valve defective Motor in affected valve.
valve show low reading(s). makeup valve defective.
OR
Disassemble and clean valve assembly.
Replace all valve components that show
damage.
All three pressure checks Exchange front and rear pump inlet If swing and left travel are restored but
are OK but left travel also and outlet hoses to test pump right travel stops working, replace or
fails to run. function. repair P1 pump.
All three pressure tests are Brake assembly or motor friction Check for binding. Disassemble and
OK, but machine fails to plate failing to release. repair.
swing at all. Pilot (control) pressure low or swing Disassemble / Repair pilot pressure
control valve stuck. swing spool (305) and / or swing control
valve.
Swing motor defective. Test motor drain rate. Replace / Repair
motor.
Gear train defective. Refer to "Swing Gear Troubleshooting"
procedure.
Swing functions but only at Causes listed above could also Check above list; then replace oil, test
reduced rpm. produce dragging swing, OR hot or motor drain rate and check for "03"
wrong oil OR worn-out parts. reading (e-EPOS self-test).
Left travel speed is also Low output at P1 pump or external Clean and repair piping or repair or
reduced. pilot piping leaks/is clogged. replace pump P1.
Swing control movement is Inlet / outlet piping reversed. Reset controls or reverse piping.
reversed.
Machine swings but Swing control valve spool not Replace return spring; clean/ repair
continues coasting on past centered. valve piston and spool.
stopping point. Pilot pressure may be outside Disassemble, clean or replace pilot relief
range. valve or pilot valve.
Swing relief valve may be faulty. Repair/Replace swing relief valve.
Swing movement is in one Check to see that pilot pressure is If pilot pressure is unequal, clean or
direction only. the same right and left. repair piping or repair/replace valve.
Swing control valve spool may be Repair/Replace the swing control valve.
stuck.
Swing relief valve may be faulty. Repair/Replace the swing relief valve.
No rotation and:
Pressure at swing motor Swing brake not releasing. Check brake engagement and
inlet increases. disengagement; check release pressure.
Internal damage to gearbox drive Replace broken gears and drive train
train. assemblies.
Overload. Reduce load weight.
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Problem Possible Cause Remedy
Pressure at swing motor Swing motor drive shaft damage. Replace swing motor.
inlet shows no increase, Internal damage to gearbox drive Repair/Replace broken or faulty
and the swing motor is train. assemblies.
making irregular noises.
Pressure at swing motor Hydraulic pump or valve problem. Troubleshoot hydraulic system.
inlet shown no increase, but
without irregular noises
from the swing motor.
Oil Leakage:
From drive shaft From Oil seal damaged Assembly Replace oil seal Disassemble and check
bolted connections or other compound (joint sealer) old and not mating surfaces. Reapply Loctite; torque
assembled surfaces. sealing, bolt not tight or flange bolts to specifications.
warped.
Excess heat:
Gearbox casing becomes Low oil level. Replace oil; refill to specified level.
excessively hot, with or Bearings or gears worn but not Repair or replace gearbox.
without irregular noise (s), completely inoperative.
during operation.
TROUBLESHOOTING –
HYDRAULIC PROBLEMS
Problem Possible Cause Remedy
Attachment cylinders, swing Main pump(s) malfunction. Repair or replace.
and travel motors are all Low oil level in hydraulic system. Refill.
inoperable. Loud noises are
Main pump inlet (oil supply) piping Repair or replace.
heard from main pump
or hose damaged.
assembly.
Attachment cylinders, swing Pilot pump malfunction. Repair or replace.
and travel motors are all Pilot cutoff solenoid stuck. Repair or replace.
inoperable. No usual or loud
Pilot cutoff switch faulty. Repair or replace.
noises can be heard.
Engine/pump flex coupling Replace flex coupling.
damaged.
Sluggish performance of all Main pump(s) damaged or worn. Repair or replace.
hydraulic functions – Main relief valve pressure off. Readjust pressure.
attachment, swing and
Low oil level in hydraulic system. Refill.
travel.
Hydraulic reservoir intake strainer Clean.
clogged.
Pump inlet (supply side) piping or Tighten connection.
hose allowing air into hydraulic
system.
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Problem Possible Cause Remedy
Oil temperature abnormally Oil cooler clogged or air circulation Clean.
high. to cooler blocked.
Cooling fan belt tension too loose. Readjust belt tension.
Relief valve set too low. Readjust valve.
Relief valve in constant use. Reduce or slow work load or cycling rate.
Hydraulic oil severely neglected or Replace oil.
incorrect for application.
One circuit in hydraulic Overload relief valve malfunction. Readjust or replace.
system inoperable. Oil leak at makeup valve. Clean, repair.
Control valve spool damaged. Repair or replace.
Dirt in control valve spool. Clean or replace.
Actuator (joystick, foot pedal) Repair or replace.
damaged or worn.
Internal seal leak in cylinder. Repair or replace.
Cylinder rod damaged. Repair or replace.
Pilot valve or piping malfunction. Repair or replace.
Mechanical linkage frozen, loose or Repair or replace.
damaged.
Travel motors inoperable. Center joint damaged. Repair or replace.
Parking brake not releasing. Repair or replace.
Travel motor worn or damaged. Repair or replace.
Travel motor pilot piping damaged. Repair or replace.
Travel motors operate very Track tension poorly adjusted Low Readjust tension Refill.
slowly. oil in idlers or rollers.
Travel brake dragging. Repair.
Track frame out of alignment, Repair.
deformed or twisted.
Swing motor inoperable. Swing brake not releasing. Repair or replace.
Relief valve malfunction. Repair or replace.
Pilot piping damaged. Repair or replace.
Swing motor operates Swing gear, bearing or mounting Repair or replace.
unevenly. loose or worn.
Lubricant worn away, inadequate. Grease.
Swing relief valve may be faulty. Repair/Replace the swing relief valve.
TROUBLESHOOTING –
CONTROL VALVE
Check control valve problems only after other hydraulic circuit
operational tests have been made. Refer to the "Troubleshooting
Baseline Recommendations" procedure. Pump flow, pilot
pressure, Negacon pressure, main relief pressure, and port
relief pressure should all be checked before starting to work on
the control valve. Make sure the hydraulic system is topped up to
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the required level and free of oil leaks or air in the system that
could cause cavitation problems.
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TROUBLESHOOTING – TRAVEL
CONTROL VALVE
Problem Possible Cause Remedy
Secondary pressure does Low primary pressure. Check primary pressure.
not increase. Broken spring. Replace spring.
Spool sticking. Clean, repair or replace.
Excess spool to casing clearance. Replace spool casing.
Worn or loose universal joint Repair or replace U-joint subassembly.
(handle) subassembly.
Secondary pressure too Dirt, other interference between Clean, repair or replace.
high. valve parts.
Return line pressure too high. Redirect return line.
Secondary pressure does Dirt, other interference between Clean, repair or replace.
not hold steady. valve parts, or worn spool sticking
intermittently.
Interference or binding on spool Clean, repair or replace.
return spring.
Interference, restriction or unsteady Repair or reroute tank return line.
pressure in tank return line.
Air bubbles in piping (temporary) or Vent air, or repair leak.
air leak.
NOTE: Look for evidence of leaking oil.
TROUBLESHOOTING –
JOYSTICK CONTROL VALVE
Problem Possible Cause Remedy
Secondary pressure does Low primary pressure. Check primary pressure.
not increase. Broken spring. Replace spring.
Spool sticking. Clean, repair or replace.
Excess spool to casing clearance. Replace spool casing.
Worn or loose handle subassembly. Repair or replace handle subassembly.
Secondary pressure too Dirt, other interference between Clean, repair or replace.
high. valve parts.
Return line pressure too high. Redirect return line.
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Problem Possible Cause Remedy
Secondary pressure does Dirt, other interference between Clean, repair or replace.
not hold steady. valve parts, or worn spool sticking
intermittently.
Interference or binding on spool Clean, repair or replace.
return spring.
Unsteady pressure in tank return Redirect return line.
line.
Air bubbles in piping (temporary) or Vent air, or repair leak.
air leak.
NOTE: Look for evidence of leaking oil to help locate damaged seals or gaskets that could be the cause of
air leaks.
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Hydraulic System Troubleshooting, Testing and SP000027
Adjustment
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SP000028
ACCUMULATOR SP000028
Accumulator
Edition 1
Accumulator SP000028
Page 1
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MEMO
SP000028 Accumulator
Page 2
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Table of Contents
Accumulator
Safety Precautions................................................ 5
Applicable Models................................................. 5
General Description.............................................. 6
Specifications .................................................................. 8
Accumulator SP000028
Page 3
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MEMO
SP000028 Accumulator
Page 4
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
SP000028 Accumulator
Page 5
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GENERAL DESCRIPTION
The accumulator is a gas-charged storage device designed to
hold a reserve quantity of hydraulic fluid under pressure. 1
Accumulators are used in hydraulic circuits in much the same
way that condensers (or capacitors) are used to collect, store 2
and maintain electrical charge in a circuit.
In a hydraulic circuit, minor variations or lags in pump output that
might otherwise cause unsteady or irregular operation are made
up from the supply of pressurized oil in the accumulator.
Reference 3
Description
Number
1 Screw Plug
2 Steel Pressure Vessel
3 Diaphragm 4
4 Fluid Valve
ARS1790L
Accumulator SP000028
Page 6
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of the diaphragm eventually seals off the lower
oil passage. Just after the needle on the gauge
reaches its highest point (when there is 0 bar (0
psi) resistance from hydraulic system pressure)
pressure on the gauge will drop sharply to zero,
as the accumulator is completely emptied of oil
and the diaphragm button closes.
Record the highest gauge reading and compare to the "P1"
rated precharge pressure on the accumulator
manufacturer's data label. Repeat this test at least once a
year to verify proper functioning of the accumulator.
3. As hydraulic system pressure overcomes accumulator
precharge pressure, the flexible diaphragm begins to
retract upward.
4. When system oil is at highest working pressure and the
accumulator fills to maximum reserve capacity, the flexible
diaphragm is pushed up into the top of the upper chamber.
The highest working pressure is sometimes referred to as
the "P3" pressure and can also be referenced on the
manufacturer's data label on the exterior of the
accumulator.
5. If system oil pressure begins to fall off or is momentarily
checked or interrupted, the energy stored on the other side
of the diaphragm, in the form of compressed gas, pushes
oil back out of the lower chamber, maintaining oil pressure
of the circuit.
6. With minimal system pressure, an equilibrium point may be
reached in which accumulator precharge pressure and
hydraulic system oil pressure achieve a rough balance. In
this condition a minimal amount of oil is stored in the
accumulator.
SP000028 Accumulator
Page 7
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Specifications
Model Serial Number System Charge Pressure Volume
10 kg/cm2 320 cc
DX300LC S/N 5001 and Up Pilot / Travel
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX340LC S/N 5001 and Up Pilot / Travel
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX420LC S/N 5001 and Up Pilot / Travel
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX480LC S/N 5001 and Up Pilot / Travel
(140 psi) (19.53 in3)
Accumulator SP000028
Page 8
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SP000029
CENTER JOINT (SWIVEL)SP000029
1Center Joint
(Swivel)
Edition 1
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MEMO
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Table of Contents
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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GENERAL DESCRIPTION
The center joint (swivel) is designed to allow hydraulic oil from
the upper structure to flow to components in the lower structure.
It is capable of allowing continuous 360˚ rotation of the upper
structure in relationship to the lower structure.
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Parts List
11
1
18
17 12
8
4
9
16 6
15
5
10 7
14
13 FG000536
Figure 1
Reference Reference
Description Description
Number Number
1 Body 10 O-ring
2 Spindle 11 Plug
3 Cover 12 Plug
4 Spacer 13 Bolt
5 Shim 14 Spring Washer
6 Wear Ring 15 Bolt
7 Slipper Ring 16 Spring Washer
8 O-ring 17 Bolt
9 O-ring 18 Spring Washer
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TROUBLESHOOTING, TESTING
AND ADJUSTMENT
Inspection
The center joint should be checked for evidence of external oil
leakage every 2,000 operating hours. Leaking or defective O-
rings are an indication that dirt and other contaminants could be
getting inside the assembly, which will promote accelerated,
abnormal wear and may cause early failure of the assembly.
If internal seals or other sliding surface components are worn
and there is internal fluid leakage, complete overhaul and repair
or replacement of the center joint may be required.
Testing
Pressure
Gauge
To check pressure through the center joint, make up a test kit
from the following equipment list:
• 700 bar (10,000 psi) pressure gauge.
Swivel Joint
• Adapters, connectors, piping and flange block-off Body (Outer)
pressure (as the stop valve is closed manually) for a leak down Figure 2
test.
NOTE: The same type of kit can also be made up for the
drain port (return line) side of the center joint. Use
appropriate piping, connectors, test gauges, etc., and
follow the same block diagram general layout (Figure
2).
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DISASSEMBLY
Refer to the assembly drawing of the swivel joint for component
references (Figure 1).
IMPORTANT
Do not unbolt the center joint from the lower car body until
an adequate number of piping block-off plates are available,
for disconnected piping lines. Be sure that system pressure
has been vented - including the hydraulic accumulator and
tank reserve pressure - before disassembly is started.
1. Clean off the exterior of the swivel joint after it has been
removed.
2. Scribe or otherwise mark a line across the cover and the
body of the center joint, to allow reassembly in the same
configuration.
3. Unbolt the four 12 mm fasteners holding the cover. Use a
vise or V-block to hold the assembly in place.
4. Remove the cover, withdraw the O-ring and remove the
retaining ring holding the thrust plate, taking care to
support the spindle assembly, so that it will not separate
and fall out when retaining ring is removed.
5. If the spindle assembly doesn't separate easily when the
thrust plate and retaining ring are removed, use a wooden
block and hammer to drive it out of the housing.
6. O-rings and seals should be replaced whenever the
assembly is being overhauled or rebuilt. For repair
procedures or emergency tear down, use a thin but
rounded tip, smoothedge 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 assembly
drawing (above the swivel joint spindle lower
seals) should not be overlooked. It is tucked
behind the top slip ring, doubled up inside the
same groove in the body of the spindle.
7. Before reassembling the center swivel, visually inspect ball
bearing surfaces for visible signs of wear, damage or
discoloration and replace any worn component.
Check clearance between the spindle and thrust plate.
Replace any component that shows more than 0.5 mm
(0.020") of visible wear.
Clearance between the spindle and body of the center
swivel must be tight. Replace or repair either component if
there is more than 0.1 mm (0.0039") of measurable wear.
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REASSEMBLY
1. Prelubricate O-rings with hydraulic oil, white grease or
petroleum jelly.
CAUTION!
Apply a very light film of white grease or petroleum jelly to
the lower rim of the stem and inner surface of the center
swivel body. Apply slow, even-handed pressure, using both
hands, to slowly push the stem into the body. Seals may be
damaged if the stem is pushed in too quickly.
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SP000030
CYLINDERS SP000030
Cylinders
Edition 1
Cylinders SP000030
Page 1
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MEMO
SP000030 Cylinders
Page 2
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Table of Contents
Cylinders
Safety Precautions................................................ 5
Applicable Models................................................. 5
General Description.............................................. 6
Theory of Operation ........................................................ 6
Parts List ......................................................................... 7
Special Tools and Materials .................................. 9
Piston Nut........................................................................ 9
Piston Jig....................................................................... 10
Steel Bushing Jig........................................................... 12
Dust Wiper Jig ............................................................... 14
Slipper Seal Jig ............................................................. 16
Slipper Seal Straightening Jig ....................................... 17
Disassembly ....................................................... 18
Reassembly ........................................................ 23
Cylinders SP000030
Page 3
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MEMO
SP000030 Cylinders
Page 4
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
SP000030 Cylinders
Page 5
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GENERAL DESCRIPTION
Two essentially similar types of hydraulic cylinders are used on
the excavator. The cylinder that is used to operate the excavator
boom or bucket is equipped with a rod stopper, which acts as a
cushion only when the cylinder rod is fully retracted (and the
bucket is pulled close to the arm). This type of cylinder is shown
in the lower drawing.
Arm cylinders have a cushion or stopper for operation in both
directions. This type of cylinder is shown in the upper drawing.
Theory of Operation
1 Piston
2 Oil Path A 1
3 Oil Path B D
F1 = P x πD2
4
F2 = P x π(D2-R2) Figure 2
4
Cylinders SP000030
Page 6
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Because the volume of oil needed to lengthen the cylinder rod
(Q1) is greater than the volume of oil required to retract the
cylinder rod, it takes more time to extend a cylinder than it does
to retract it. 1
Q1 = S x π(D2)
4
Q2 = S x π(D2-R2)
4
Q1 > Q2 FG001459
Figure 3
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 section in Figure 4 shows an arm cylinder.
Cross section in Figure 5 shows a boom cylinder.
The bucket and boom cylinders are identical and differ only in
the attached pipes.
20 19 18 21,22 23 24 26
54 4 11,12 9,10 8 6 27 7 5 15 13,14 1 3 16 17
25 2 54
SP000030 Cylinders
Page 7
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38, 39, 40
4 41 11, 12 9, 10 8 6 7 15 13, 14 5 3 1
16 17 20 19 18 21,22 23
24 2 41
FG000613
Figure 5
Reference Reference
Description Description
Number Number
1 Tube Assembly 16 Cushion Ring
2 Bushing 17 Piston
3 Rod Assembly 18 Slipper Seal
4 Bushing 19 Wear Ring
5 Rod Cover 20 Ring
6 DD-Bushing 21 O-ring
7 Retaining Ring 22 Backup Ring
8 Buffer Seal 23 Piston Nut
9 U-Packing 24 Set Screw
10 Backup Ring 25 Socket Head Bolt
11 Dust Wiper 26 Pipe Band Assembly
12 Retaining Ring 38 Spring Washer
13 O-ring 39 Hex Bolt
14 Backup Ring 40 Pipe Assembly
15 O-ring
Cylinders SP000030
Page 8
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SPECIAL TOOLS AND
MATERIALS
Piston Nut
( )
15
-0.1
-0.2
C
(C3~C5)
D +0.1
+0.2
A
35
B
∅8 Through Hole
5
0.
R
R(R15 ~ R20)
4-
350
ARS4730L
Figure 6
Material SM45C (AISI 1045)
Rockwell Harden from 22 - 27
Oil Quench
SP000030 Cylinders
Page 9
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Piston Jig
( )
15
2-∅"B"
)
F/2
∅8 Through Hole
R(
"
"D
∅
"A"
∅"
C"
R(R15~20) 35
R5
4-
30
ARS4740L
Figure 7
Material SM45C (AISI 1045)
Rockwell Harden from 22 - 27
Oil Quench
Cylinders SP000030
Page 10
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SP000030 Cylinders
Page 11
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Steel Bushing Jig
(5)
"A" - 20
"B" + 40
∅"B"
∅"A"
(∅20)
15 F E
ARS4750L
Figure 8
Material: SM45C which is done thermal refining <QT> Hrc 22 - 28
Undefined Chamfer C/R = 0.5 Max.
1 Place: Finally work to used DNMG Tip <Nose R0.4>
Cylinders SP000030
Page 12
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MODEL
MODEL CYLINDER øA-0.05 øB ( ±0.1) E F+0.05 Part
-0.15 0 (CYLINDER)
90.0 mm 105.0 mm 40.0 mm 7.0 mm
BOOM
(3.54 in) (4.13 in) (1.58 in) (0.28 in)
90.0 mm 105.0 mm 40.0 mm 6.5 mm
DX300LC ARM S/ARM
(3.54 in) (4.13 in) (1.58 in) (0.26 in)
90.0 mm 105.0 mm 40.0 mm 7.0 mm
BUCKET S/BUCKET
(3.54 in) (4.13 in) (1.58 in) (0.28 in)
SP000030 Cylinders
Page 13
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Dust Wiper Jig
1.5
3-C
R0.2
1
DIA. (B+40)
DIA. (A-20)
DIA. A
DIA. B
15 C D
ARS4760L
Figure 9
Material: SM45C which is done thermal refining <QT> Hrc 22 - 28
Undefined Chamfer C/R = 0.5 Max.
Cylinders SP000030
Page 14
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MODEL CYLINDER øA-0.2
-0.3 øB -0.2
-0.3 C 0-0.1 D MODEL (CYLINDER)
95.0 mm 109.0 mm 6.0 mm 7.0 mm
BOOM
(3.74 in) (4.29 in) (0.24 in) (2.28 in)
105.0 mm 121.0 mm 6.0 mm 7.0 mm
DX300LC ARM S/ARM
(4.13 in) (4.76 in) (0.24 in) (2.28 in)
90.0 mm 104.0 mm 6.0 mm 7.0 mm
BUCKET S/BUCKET
(3.54 in) (4.10 in) (0.24 in) (2.28 in)
SP000030 Cylinders
Page 15
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Slipper Seal Jig
0
R1
R1
∅(A+2)
∅A
∅(A-14)
10°
B
(B+40)
ARS4770L
Figure 10
Cylinders SP000030
Page 16
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Slipper Seal Straightening Jig
1
2-C
R
2-5
∅(A+15)
∅A
1
2-R
100
25
50
ARS4780L
Figure 11
SP000030 Cylinders
Page 17
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DISASSEMBLY
CAUTION!
Vent air from the hydraulic system before disconnecting
cylinder piping connections. Use the lever on the reservoir,
while the engine is running. Discharge the hydraulic
accumulator and vent residual tank pressure after the
engine is shut off. Pour clean replacement fluid back into
the system if excessive fluid is lost.
Figure 12
Figure 13
Figure 14
Cylinders SP000030
Page 18
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4. Tap two bolts into cover of cylinder head, 180° apart.
Tighten them in a staggered, even sequence, to back off
piston rod end cover from edge of cylinder wall. Look for
adequate clearance between cover and end of cylinder
wall before using a plastic or other soft-faced hammer for
final disassembly.
Figure 15
Figure 16
Figure 17
Figure 18
SP000030 Cylinders
Page 19
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8. Remove set screw using socket wrench.
HAOF340L
Figure 19
Figure 20
Figure 21
11. Use a plastic hammer to evenly pull off rod cover (9) from
end of piston rod. Be careful not to damage rod bushing (6)
and dust wiper, U-packing and other seals.
Figure 22
Cylinders SP000030
Page 20
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12. Use a dull, rounded tip tool to pry off O-ring (11) and
backup ring (12).
HAOF37OL
Figure 23
Figure 24
14. Remove O-ring (20) and backup ring (21) from cylinder
head.
HAOF38OS
Figure 25
HAOF39OL
Figure 26
SP000030 Cylinders
Page 21
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16. Disassemble retaining ring (3) and dust wiper (2). Separate
retaining ring (8) and rod bushing (6).
Figure 27
Figure 28
Cylinders SP000030
Page 22
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REASSEMBLY
IMPORTANT
Replace any part that shows evidence of damage or
excessive wear. Replacement of all O-rings and flexible
seals is strongly recommended. Before starting the cylinder
reassembly procedure, all parts should be thoroughly
cleaned and dried, and/or prelubricated with clean
hydraulic fluid. Prepare the work area beforehand to
maintain cleanliness during the reassembly procedure.
Figure 29
Figure 30
SP000030 Cylinders
Page 23
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3. Prelubricate O-rings and seals before reassembly (Figure
31).
Figure 31
Figure 32
Figure 33
Figure 34
Cylinders SP000030
Page 24
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7. Use specially fabricate or factory sourced tool to tighten
piston nut (22).
Figure 35
8. Assemble wear ring (18), slide ring (17) and set screw (23)
to piston assembly.
Reference
Description
Number
1 Set Screw
Figure 36
Figure 37
Figure 38
SP000030 Cylinders
Page 25
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Cylinders SP000030
Page 26
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SP000031
SWING MOTOR SP000031
Swing Motor
Edition 1
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MEMO
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Table of Contents
Swing Motor
Safety Precautions................................................ 5
Applicable Models................................................. 5
General Description.............................................. 6
Theory of Operation ........................................................ 6
Makeup Check Valve ....................................................... 9
Operation of Time Delay Valve ........................................ 9
Operation of Swing Reactionless Valve........................... 9
Parts List ....................................................................... 10
Specifications ................................................................ 11
Torques.......................................................................... 11
Tools and Materials............................................. 12
Tools .............................................................................. 12
Troubleshooting, Testing and Adjustment ........... 13
General Precautions...................................................... 13
How to Check Faults of Hydraulic Motor ....................... 13
Troubleshooting ............................................................. 13
Disassembly ....................................................... 15
General Cautions .......................................................... 15
Disassembly .................................................................. 15
Cleaning and Inspection (Wear Limits and
Tolerances) ......................................................... 23
Reassembly ........................................................ 24
General Cautions .......................................................... 24
Assembly ....................................................................... 24
Assembly of Cylinder Block Assembly Subassembly .... 27
Assembly of Rear Cover Assembly Subassembly......... 31
Air Pressure Test ........................................................... 37
Oil Leakage Check ........................................................ 37
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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GENERAL DESCRIPTION
Theory of Operation
Structure
The hydraulic motor consists of the following five parts:
• Rotary part generating rotary power.
• Relief valve.
• Parking brake.
• Makeup check valve.
• Time delay valve.
• Swing reactionless valve.
Circuit Diagram
SH PG
Dr GA
Mu
Am GB
FG001323
Figure 1
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Generation of Rotary Power
High-pressure oil from hydraulic pump flows into the cylinder (9)
through the valve casing (1) and the valve plate (22). The motor
is designed to only let high-pressure oil to flow into one side with
relationship to Y-Y axis (the centerline of top and bottom dead
centers of piston (13)).
As shown in the Figure 2, the high-pressure oil acts on the
piston to generate F1 = P*A (P: supply pressure, A: hydraulic
area). F1 is divided into a N1 thrust component and a W1 radial
component in relationship to the swash plate with slope of •·. W1
generates a torque T = W1*R1 in relationship to Y-Y, the
centerline of top and bottom dead centers of the piston. This
torque generates the rotary power through a resultant force
(¢≤W1*R1) occurring at (4-5) hydraulic pistons by the high-
pressure oil. Rotary power and torque, is transferred through the
pistons and cylinder (9) via spline to the drive shaft.
Y Cylinder A Piston
W1 W1
R1 N1
f1 P
F1
O
Drive Shaft
Y
High pressure Low pressure
ARS4530L
Figure 2
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Operation of Relief Valve
The relief valve performs two functions:
1. It maintains uniform pressure when hydraulic motor starts
and bypasses surplus oil at the inlet of the motor to the
outlet in relationship with acceleration of the inertia weight.
2. Device is forced to stop by the generation of brake
pressure at the discharge side when the inertia weight is
stopped.
High-pressure oil flowing in to port P increases pressure in the
shockless spool through a poppet orifice, which acts to keep a
set pressure when it is higher than the spring force.
It maintains a set pressure when the hydraulic motor starts and
forces the swing motor to stop by generating brake pressure at
the discharge side when the inertia weight stops. FG001324
Figure 3
Operation of Parking Brake
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Makeup Check Valve
A makeup check valve is installed to compensate for the lack of
supply line oil to prevent cavitation due to the lack of oil being
supplied when the motor turns faster than the expected oil flow
rate to the inlet of the swing motor.
When an excavator suddenly stops swinging, and supply oil
stops flowing to the inlet port of the swing motor, the swing motor
will try to turn a little further due to inertia force. When this
happens, the makeup check valve opens and supplies oil to the
inlet port while the pressure in the inlet port is lower then the oil
waiting in the makeup check valve port.
FG001324
Figure 5
FG001327
Figure 7
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Parts List
21
9Ab
36 23
37 9A
19 9Aa
28 30 9 : 9A ~ 9D
31 9B
32
29
9Cb
33A 24
33B 25
33C 9D
27
33E 9C
33D 26
20
33 8
9Ca
17
18
6
5
16
38 1
34A
34B
34
15
35
14
15
4
14
3
15
39
14
7
FG000762
Figure 8
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Specifications
Items Units
260 l/min
Oil Flow
(69 gpm)
Set Pressure of Relief V/V 275 kg/cm2
(Cracking) (3,900 psi)
194.5 cc/rev
Motor Displacement
(11.87 in∏/rev)
85.1 kg•m
Motor Output Torque
(620 ft lb)
Motor Speed rpm
88.2 kg•m
Brake Torque
(640 ft lb)
Spool Cracking 8 kg/cm∑
Brake Pressure (114 psi)
Switching
Delay Period 6.5 ±1.5 sec
Weight kg
Torques
No. Tools Measures B Torque
33 Relief Valve M33 36 mm 1700 - 1900 kg•cm
(123 - 137 ft lb)
36 Plug PT 1/4 36 mm 691 kg•cm
(50 ft lb)
37 Plug PF 1/4 5 mm 691 kg•cm
(50 ft lb)
40 Plug PF 1/2 6 mm 2,090 kg•cm
(150 ft lb)
41 Plug PF 1 6 mm 4,843 kg•cm
(350 ft lb)
47 Plug 6 mm
27 Hex Socket M18X65L 14 mm 2,000 kg•cm
Head Bolt (145 ft lb)
36 Hex Socket M6X75L 5 mm 163 kg•cm
Head Bolt (12 ft lb)
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TOOLS AND MATERIALS
Tools
Tools B Length Tools to Be Used
Hex L Wrench 5 mm Plug (37), hex socket head bolt (36)
6 mm Plugs (40, 41, and 47)
14 mm Hex socket head bolt (27)
Socket Wrench 36 mm Plug (39), relief valve assembly (33)
Spanner
Retaining Ring Pliers (For Orifice Ring stop (4)
And Axis)
Bar Hammer Needle bearing (22), Pin (8, 23 and 43)
Torque Wrench Measure:
Oil Seal Assembly Jig Oil seal (2)
Bearing Induction Heating Device Roller bearing (3)
B B
ARS3980L
Figure 9
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TROUBLESHOOTING, TESTING
AND ADJUSTMENT
General Precautions
1. Observe any abnormalities and any possible causes that
have noting to do with the motor before starting work.
2. Make sure that no foreign substance is involved when
disassembling the machine, which is the most frequent
cause of its wear.
3. Treat carefully and pay attention to avoid any damage
against it that is machined precisely.
Troubleshooting
Problem Possible Cause Remedy
Abnormal operation of driving devices.
Motor pressure does not Oil bypassing in relief valve (33) Replace or repair relief valve.
increase. Check spring broken. Replace check spring.
Crack in channel in valve casing. Replace valve casing.
Abnormal wear on check surface. Replace check.
Pressure increases but Friction and/or separation plates Replace friction and/or separation plates.
hydraulic motor does not stuck.
rotate. Slideway stuck. Replace stuck slideway.
Number of rotations is below specification.
Insufficient rotation. Lack of incoming oil. Check hydraulic circuits up to motor.
Too high oil temperature. Low oil temperature.
Too much leakage. Replace or repair faulty parts.
Low-pressure. Low set pressure in relief valve. Adjust pressure.
Brake released but weak Sticking or abnormal wear of Replace or repair slideway.
driving force. slideways.
Hard to control brake.
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Problem Possible Cause Remedy
Low brake torque. Wear of friction and/or separation Replace worn parts.
plates.
Damage of brake spring. Replace brake spring.
No brake operation. Sticking of inner brake parts. Replace parts.
Oil leakage.
Leakage from oil seal (2). Oil seal or shaft slidway damaged. Replace damaged parts and remove any
foreign substance.
High-pressure in case. Check the drain line.
Leakage from assembled O-ring damaged. Replace the O-ring.
parts. Volt or plug loosened. Tighten up to specified torque.
Main ways stuck.
Piston and shoe. Overload rotation of motor. Check the operation of the relief valve.
Shoe and swash plate. Increase of temperature. Check circuits.
Piston and cylinder.
Insufficient intensity of illumination Repair or replacement of faulty parts.
Cylinder and valve plate. on slideway.
Replace oil.
Front plate and spherical
Improper oil or lubrication.
bushing.
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DISASSEMBLY
General Cautions
1. Prepare for a clean place for disassembly. Place a rubber
sheet on place to prevent any damage to parts.
2. Wash out dust and foreign substance in motor and
deceleration assembly.
3. Take care not to damage connecting parts and ways of O-
ring, oil seal, seal surface, gear, pin, and surface of
bearings.
4. Numbers in parentheses indicate those on sectional plans
of motor.
Disassembly
1. Remove hex socket head bolt and disassemble time delay
valve assembly, beginning with rear cover (19).
FG000682
Figure 10
FG000683
Figure 11
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2. Remove rear cover from body (1) by removing hex socket
head bolt (23) of its assembly with impact.
FG000685
Figure 12
FG000686
Figure 13
FG000687
Figure 14
FG000688
Figure 15
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4. Remove cylinder block assembly, friction plate (14), and
plate (15) from body (1).
NOTE: Pay attention to order of plates and friction
plates.
FG000689
Figure 16
FG000690
Figure 17
FG000691
Figure 18
FG000692
Figure 19
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7. Remove retaining ring (4) from body (1) using retaining
ring pliers.
8. Turn body over, and separate shaft assembly using steel
bar.
FG000693
Figure 20
FG000694
Figure 21
FG000695
Figure 22
FG000696
Figure 23
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FG000697
Figure 24
10. Remove friction plate (12), plate (15), ball guide (11), and
spring (10) from cylinder block.
FG000698
Figure 25
FG000699
Figure 26
FG000700
Figure 27
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11. Separate valve plate (22) from rear cover (19).
FG000701
Figure 28
FG000703
Figure 29
FG000704
Figure 30
FG000705
Figure 31
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13. Remove two relief valve assemblies (33) from rear cover
(19).
FG000706
Figure 32
FG000707
Figure 33
14. Remove check valve assemblies from rear cover (19) with
L wrench, and disassemble it in order of plug (26), spring
(23), and poppet (24).
FG000708
Figure 34
FG000709
Figure 35
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15. Remove plug (29) from rear cover (19) with L wrench and
disassemble it in order of backup ring (50), O-ring (49), O-
ring (48), spring, and anti-inversion valve assembly (28).
FG000710
Figure 36
FG000711
Figure 37
FG000712
Figure 38
16. Remove plugs (36 and 37) from rear cover (19) with L
wrench
FG000713
Figure 39
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CLEANING AND INSPECTION
(WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to
"General Maintenance Procedures" section.
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REASSEMBLY
General Cautions
1. Wash and clean each part. Then dry them with
compressed air. The friction plate, however, should not be
washed with treated oil.
2. Each connecting parts should be tightened according to its
assigned torque.
3. Only use a plastic soft-faced hammer.
Assembly
1. Put roll bearing (3) and bushing (39) on a heater and apply
3
heat to their inner race (inlet temperature: 290˚C for 2 39
minutes).
FG000715
Figure 41
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2. Assemble heated roll bearing (3) and bushing (39). Use
retaining ring pliers to assemble install retaining ring (7).
FG000716
Figure 42
FG000717
Figure 43
FG000718
Figure 44
FG000719
Figure 45
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FG000720
Figure 46
FG000717
Figure 47
FG000721
Figure 48
FG000722
Figure 49
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FG000723
Figure 50
7. Coat shoe plate (8) with grease, and assemble it into body.
FG000724
Figure 51
FG000725
Figure 52
FG000726
Figure 53
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FG000727
Figure 54
FG000728
Figure 55
FG000729
Figure 56
10. Assemble friction plate (14) and plate (15) into cylinder
block (9)
FG000759
Figure 57
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FG000730
Figure 58
FG000731
Figure 59
FG000696
Figure 60
FG000732
Figure 61
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12. Assemble cylinder block into body (1).
FG000733
Figure 62
FG000734
Figure 63
FG000704
Figure 64
FG000687
Figure 65
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15. Insert brake piston assembly in body and secure it using
jig.
FG000735
Figure 66
FG000736
Figure 67
FG000737
Figure 68
FG000738
Figure 69
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FG000739
Figure 70
FG000740
Figure 71
FG000741
Figure 72
FG000742
Figure 73
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FG000743
Figure 74
4. Insert poppet (24), spring (25), and plug (26) in rear cover
(19). Tighten plug with L wrench. (Left and right
symmetrically.)
FG000708
Figure 75
FG000744
Figure 76
FG000745
Figure 77
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FG000711
Figure 78
FG000710
Figure 79
FG000746
Figure 80
FG000747
Figure 81
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FG000748
Figure 82
FG000706
Figure 83
FG000749
Figure 84
FG000701
Figure 85
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FG000750
Figure 86
10. Position rear cover assembly on body (1) and tighten hex
socket head bolt (23).
FG000751
Figure 87
FG000752
Figure 88
11. Install time delay valve assembly onto rear cover (19) with
hex socket head bolts (35).
FG000682
Figure 89
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FG000753
Figure 90
FG000754
Figure 91
FG000755
Figure 92
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FG000756
Figure 93
FG000757
Figure 94
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SP000032
TRAVEL MOTOR SP000032
Travel Motor
Edition 1
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MEMO
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Table of Contents
Travel Motor
Safety Precautions................................................ 5
Applicable Models................................................. 5
General Description.............................................. 7
Structure.......................................................................... 7
Operation Basics ............................................................. 8
Parts List ....................................................................... 13
Specifications ................................................................ 16
Connection Torque ........................................................ 16
Special Tools and Materials ................................ 18
Troubleshooting, Testing and Adjustment ........... 19
General Precautions...................................................... 19
How to Check Faults of Hydraulic Motor ....................... 19
Troubleshooting ............................................................. 19
Disassembly ....................................................... 22
General Cautions .......................................................... 22
Disassembly .................................................................. 22
Disassembly of Valve Casing Subassembly .................. 26
Disassembly of Cylinder Subassembly ......................... 28
Cleaning and Inspection (Wear Limits and
Tolerances) ......................................................... 30
Maintenance Standard .................................................. 30
Reassembly ........................................................ 34
General Cautions .......................................................... 34
Reassembly of Drive Shaft Subassembly ..................... 34
Assembly of Valve Casing Subassembly....................... 35
Assembly of Cylinder Subassembly .............................. 39
Assembly of Motor Body ............................................... 41
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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Travel Motor SP000032
Page 6
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GENERAL DESCRIPTION
Structure
The hydraulic motor consists of five parts:
• Rotary part generating rotary power.
• Cross-over relief valve.
• Negative brake.
• Counterbalance valve.
• Tilting switching part.
Am Dr
A
B
Bm N Pi Pi Dr
Counter balance valve part Relief valve part Swash tilting part Negative brake part Rotary part
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Operation Basics
Y Cylinder A Piston
W1 W1
R1 N1
f1 P
F1
O
Drive Shaft
Y
High pressure Low pressure
ARS4530L
Figure 2
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Operation of Relief Valve
The relief valve performs two functions:
1. It maintains uniform pressure when the hydraulic motor
starts and bypasses surplus oil at the inlet of the motor to
the outlet in relationship with acceleration of the inertia
weight.
2. Device is forced to stop by the generation of brake
pressure at the discharge side when the inertia weight
stops. Chamber A is connected to port A of the motor.
Hydraulic oil flows from chamber A to port B because,
when the pressure in the port A increases, poppet A is
opened; when it is above the spring setting pressure,
Poppet A opens and hydraulic flows from chamber A to
port B.
Port A Port B
Chamber A
Poppet A
FG001330
Figure 3
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Operation of Negative Brake
Pressurized oil entering through counterbalance spool in valve
casing (303), forces brake piston (702) to release the brake.
When hydraulic oil pressure, is not present, the brake is spring
applied by ten springs (705).
Brake force is generated by frictional force between separator
plate (741) (which is fixed by pin pressed into shaft casing) and
friction plate (742) (which is connected to shaft casing, brake
piston (702) and spline of cylinder block (111)).
When no oil pressure is applied to the brake piston, the brake
spring presses the brake piston and oil brake cavity flows to the
drain of the motor through an orifice. And the brake piston
presses the separator and friction plates located between it and
the shaft casing together, due to the force from 10 brake springs
(705). This frictional force activates the brake that slows the
drive shaft (101) connected to the cylinder block (111).
101
FG003957
Figure 4
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Counterbalance Valve
The port Av is connected to hydraulic pump. Port Bv is
connected to hydraulic oil tank. The oil supplied from the
hydraulic pump tries to turn the hydraulic motor by opening the
check valve poppet, allowing oil to flow from; Av → Cv → C' → L
→ Am of the hydraulic motor.
Even though oil tries to turn the motor, the motor cannot turn due
to the negative brake. Pressurized oil from pump rises, and it is
transmitted through passage G and orifice 1' to spring chamber
M. As pressure in chamber M exceeds spring force keeping the
spool centered in neutral, the spool is then moved to the right.
Oil in the chamber N (at the opposite end of the spool), flows to
the chamber Dv through orifice 1, and is discharged to the
hydraulic oil tank through port Bv. The spool continues to move
to the right and oil starts to flow from K → Dv → Bv. Once the
spool is moved far enough to the right, passage H is opened.
With passage H opened, oil now flows from Cv → H → port P.
The spool will be moved slowly because oil in the chamber N is
discharged through orifice 1.
When the pump decreases flow to port Av, the spring of the
chamber N moves the spool back to the left. Oil in the chamber
M flows to the chamber Cv through orifice 1' and is discharged
to the port Av.
The spool returns to the neutral position when the hydraulic oil
pressure in chamber M and port Av, equals the hydraulic oil tank
pressure in chamber N.
Am P Bm
L K
C
H
M
N
G
1'
Cv Dv 1
Av Bv
FG003922
Figure 5
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Operation of Swash Plate Control
Capacity of traveling motor varies with the change of swash
plate (201) tilting angle. The tilt angle is controlled by tilting
valve.
NOTE: The smaller the tilt angle is, the faster the motor will
rotate, while creating less torque.
NOTE: The larger the tilt angle is, the slower the motor will
rotate, while creating more torque.
1. External pilot pressure: Pi = 0 (Large tilt angle)
If pilot pressure does not act on tilting valve, the position of
swash plate (201) is set at a large tilting angle. Swash plate
(201) has a movable round surface to tilt on. High-pressure
oil flows through port Sa and Sb of tilting valve and
passages, and forces swash piston (501) to move until
swash piston (502) is stopped by stopper (503), and the
position of swash plate (201) is in large tilting.
505
507
506
Sa Sb
External pilot pressure
Pi = 0
514 501
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2. External pilot pressure: Pi ≥ 20 kg/cm2 (284 psi) (Small tilt
angle)
If pilot pressure acts on tilting valve, the force acting to
spool (531) is greater than the swash spring (533). This
forces the swash spool (531) to move to the left. High-
pressure oil flows through port Sa and Sb of tilting valve
and passages, and acts on swash piston (502) until swash
piston (501) is stopped by stopper (514). The position of
swash plate (201) is now at a small tilt angle.
505
507
506
514 501
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Parts List
272
545
709
507
506 435
491
452
107 201
102
106
101
741
122
103 509 121
512
514
501
116
502
742 503
114 504
513
111
131
707
708
461 368
472
705
451 367
303 369 366
362
364 382
383
485
702 381 384
350
464
508 485
505 361
567 568
363 568 567
568
364
508 567 402
381 461 509
384 505
368 533
485 485 541
531
369 383 464 543
382 568 506
567 542
572 507
568 571
365 567
546
367
401
350 FG003961
Figure 8
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Reference Reference
Description Description
Number Number
101 Shaft 461 Plug
102 Roller Bearing 464 HP Plug
103 Needle Bearing 472 O-ring
106 Spacer - Bearing 485 O-ring
107 Retaining Ring 491 Oil Seal
111 Cylinder Block 501 Swash Piston
114 Spring Cylinder 502 Swash Piston
116 Spacer 503 Stopper (Left)
121 Piston and Shoe Assembly 504 O-ring
122 Bushing and Push Plate 505 Swash Rod
Assembly 506 Lock Screw
131 Valve Plate 507 Hex Nut
201 Swash Assembly 508 O-ring
272 Shaft Casing 509 O-ring
281 Name Plate 512 Backup Ring
303 Valve Casing 513 Backup Ring
350 Relief Valve Assembly 514 Stopper (S)
361 Spool - Counterbalance Valve 531 Swash Spool
362 Spring - Counterbalance Valve 533 Swash Spring
363 Orifice Screw 541 Seat
364 Damping Check Assembly 542 Stopper
365 Cap - Counterbalance Valve 543 Ball
(Left)
545 Orifice Screw
366 Cap - Counterbalance Valve
546 Orifice Screw
(Right)
567 HP Plug
367 Hex Socket Head Bolt
568 O-ring
368 Hex Socket Head Bolt
571 Plug
369 O-ring
572 O-ring
381 Plunger- Counterbalance Valve
702 Brake Piston
382 Stopper - Check
705 Brake Spring
383 Backup Ring
707 Piston Ring
384 Spring - Check
708 Piston Ring
401 Hex Socket Head Bolt
709 Brake Pin
402 Hex Socket Head Bolt
741 Separator Plate
435 Lock Ring
742 Friction Plate
451 Valve Plate Pin
452 Support Pin
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Specifications
Items Specification
Input Flow 260 l/min
(69 gpm)
Set Pressure of Relief V/V 330 kg/cm2
(Cracking) (4,700 psi)
Motor Displacement 173/101 cc/rev
(10.56 - 6.16 in3)
Motor Output Torque 90.9/53.1 kg•m
(657 - 384 ft lb)
Theoretical Output Speed 1503/2574 rpm
Theoretical Brake Torque 40 kg•m
(290 ft lb)
Brake Release Pressure 9 kg/cm2
(128 psi)
Allowable Drain Pressure Normal: 2 kg/cm2
(28.4 psi)
Surge: 10 kg/cm2
(142 psi)
Weight 154 kg
(340 lb)
Connection Torque
No. Tools Measures B Torque\
1,700 - 1,900 kg•cm
350 Relief valve HEX 46 46
(123 - 137 ft lb)
70 - 110 kg•cm
461 Plug NPTF 1/16 4
(5 - 8 ft lb)
1,100 kg•cm
464 HP Plug PF 1/2 27
(80 ft lb)
2,400 kg•cm
507 Hex Nut M16 24
(175 ft lb)
750 kg•cm
571 Plug PF 3/8 8
(55 ft lb)
370 kg•cm
567 HP Plug PF 1/4 19
(27 ft lb)
70 kg•cm
545, 546 Orifice Screw NPTF 1/16 4
(5 ft lb)
1,000 kg•cm
368 Hex Socket Head Bolt M12X30L 10
(72 ft lb)
670 kg•cm
367 Hex Socket Head Bolt M10X30L 8
(48 ft lb)
2,400 kg•cm
401 Hex Socket Head Bolt M16X50L 14
(175 ft lb)
2,400 kg•cm
402 Hex Socket Head Bolt M16X120L 14
(175 ft lb)
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SP000032 Travel Motor
Page 17
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SPECIAL TOOLS AND
MATERIALS
Tools B Length Tools to Be Used
Hex L wrench 4 mm Plug (461), orifice screws (545 and 546)
8 mm Hex socket head bolt (367), lock screw (506), plug
(571)
10 mm Hex socket head bolt (368)
46 mm Relief Valve (350)
Socket wrench spanner 19 mm HP plug (567)
24 mm Hex nut (507)
27 mm HP plug (464)
Retaining ring pliers (for orifice and axis) Ring stop (107), lock ring (435)
Bar hammer Needle bearing (103), Pin (451, 452 and 709)
Torque wrench Measure: 500 and 3000
Oil seal assembly Jig Oil seal (491)
Bearing induction heating device Roller bearing (102)
B B
ARS3980L
Figure 9
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TROUBLESHOOTING, TESTING
AND ADJUSTMENT
General Precautions
1. Observe any abnormalities and any possible causes that
have noting to do with the motor before starting work.
2. Make sure that no foreign substance is involved when
disassembling the machine, which is the most frequent
cause of its wear.
3. Treat carefully and pay attention to avoid any damage
against it that is machined precisely.
Troubleshooting
Problem Possible Cause Remedy
Abnormal operation of driving devices.
Motor pressure does not Oil bypassing in relief valve (350). Replace or repair relief valve.
increase. Check spring broken. Replace check spring.
Valve spring of counterbalance Replace the valve spring of
valve broken. counterbalance valve.
Crack in channel in valve casing. Replace valve casing.
Abnormal wear on check surface. Replace check.
Excessive clearance between valve Replace valve casing and/or
casing and counterbalance spool. counterbalance spool.
Coupling of deceleration assembly Disassemble deceleration assembly and
damaged. replace the coupling.
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Problem Possible Cause Remedy
Pressure increases but Orifice screw (363) blocked. Wash or replace orifice screw.
hydraulic motor does not Piston ring (707 and 708) Replace piston ring.
rotate. damaged.
Friction and/or separation plates Replace friction and/or separation plates.
stuck.
Slideway stuck. Replace stuck slideway.
Orifice screw in counterbalance Wash or replace orifice screw.
spool blocked.
Gear of deceleration assembly Disassemble deceleration assembly and
damaged. replace the gear.
Number of rotation is below specification.
Insufficient rotation. Lack of incoming oil. Check hydraulic circuits up to motor.
Too high oil temperature. Decrease oil temperature.
Too much leakage. Replace or repair faulty parts.
Each way worn or broken that tilting Replace or repair faulty parts.
angle not switched (small to large
- Wash or replace orifice.
angle).
- Replace faulty parts.
- Orifice at small tilting side blocked.
- Leakage at small tilting chamber
(excessive clearance in shaft
casing, swash piston, or stopper L).
Driving power is below specification.
Low-pressure. Low set pressure in relief valve. Adjust pressure.
Brake released but weak Sticking or abnormal wear of Replace or repair slideway.
driving force. slideways.
Hard to control brake.
Low brake torque. Wear of friction and/or separation Replace worn parts.
plates.
Damage of brake spring. Replace brake spring.
No brake operation. Sticking of inner brake parts. Replace parts.
Tilting angle not switched.
Tilting angle is not switched. Orifice at the tilting channel of shaft Wash or replace orifice.
casing blocked.
Tilting angle adjustment spool (531) Replace faulty parts.
and case stuck.
Leakage due to excessive
clearance among shaft casing,
swash piston, and stopper.
Outer diameter of swash piston and
spheral face stuck.
High-pressure select valve in valve
casing not operating.
Oil leakage.
Leakage from oil seal (491). Oil seal or shaft slidway damaged. Replace damaged parts and remove any
foreign substance.
High-pressure in case. Check drain line.
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Problem Possible Cause Remedy
Leakage from assembled O-ring damaged. Replace O-ring.
parts. Volt or plug loosed. Tighten with specified torque.
Main ways stuck.
Piston and shoe. Overload rotation of motor. Check the operation of relief valve.
Shoe and swash plate. Increase of temperature. Check circuits.
Piston and cylinder.
Insufficient intensity of illumination Repair or replacement of faulty parts.
Cylinder and valve plate. on slideway.
Replace oil.
Front plate and spherical
Improper oil or lubrication.
bushing.
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DISASSEMBLY
General Cautions
1. Prepare for a clean place for disassembly. Place a rubber
sheet on place to prevent any damage to parts.
2. Wash out dust and foreign substance in motor and
deceleration assembly.
3. Take care not to damage connecting parts and ways of O-
ring, oil seal, seal surface, gear, pin, and surface of
bearings.
4. Numbers in parentheses indicate those on sectional plans
of motor.
5. Mark piping part of motor as rear and its discharge part as
front.
6. To reassemble, use liquid gasket and make sure to remove
any oil before appling sealer.
7. Bolt should be tightened after Loctite #262 is applied on
threads using torque wrench according to specified torque.
Disassembly
1. Secure motor on jig with four bolts (M16x60L).
NOTE: Secure motor so that drain plug (464) points
down when disassembly/reassembly jig rotates
90°.
FG001096
Figure 10
2. Remove drain plug (464) and drain oil from motor case.
NOTE: Check if processed chips or metal substance
are in drained oil.
FG001098
Figure 11
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FG001099
Figure 12
FG001100
Figure 13
4. Remove hex socket head bolts (401 and 402) holding valve
casing.
FG001101
Figure 14
FG001102
Figure 15
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FG001103
Figure 16
FG001104
Figure 17
FG001105
Figure 18
FG001106
Figure 19
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7. Rotate disassembly/reassembly jig 90° so motor is
horizontal. Remove cylinder and piston subassembly.
Figure 20
FG001108
Figure 21
FG001109
Figure 22
FG001110
Figure 23
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11. Disassemble swash plate piston (501) and stopper (S)
(514).
FG001111
Figure 24
FG001112
Figure 25
FG001115
Figure 27
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FG001114
Figure 28
FG001116
Figure 29
FG001117
Figure 30
FG001118
Figure 31
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FG001119
Figure 32
FG001120
Figure 33
FG001121
Figure 34
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2. Remove friction plate (742) and separation plate (741).
FG001122
Figure 35
FG001123
Figure 36
FG001124
Figure 37
FG001125
Figure 38
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CLEANING AND INSPECTION
(WEAR 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 have
damages of external appearance, change without the following
table.
Recommend
Standard
Parts name and inspection item ed value of Remedy
dimension
replacement
Clearance between piston and cylinder bore 0.035 0.06
Vertical direction vibration of piston and
0.05 0.3 Replace
shoe
Shoe thickness 5.5 5.3
Height difference between spherical bush
13.5 13 Replace with set
and pressure plate
Free length of cylinder spring 47.9 47.3 Replace
Drive spline 43.91 43.31 Even if one each of
Over pin diameter (4.5) recommended value of
of drive shaft Cylinder spline 49.06 48.46 replacement is not
reached, replace.
Over pin diameter (4.5) of spline inside of
35.25 35.75
cylinder and spherical bush
Thickness of separate plate 3.3 3
Thickness of friction plate 2.3 2.1
Free length of brake spring 46.6 45.97 Replace
Base tangent length of cylinder outside (7
49.97 49.37
each)
Over pin diameter (4.5) of inside gear of
145.77 146.37
friction plate
Swash plate/
0.8S 3.2S Lap each
shoe
Cylinder 1.6S 3.2S
Lap
valve plate 0.8S 3.2S
Roughness of sliding
surface Swash plate/
swash plate 6.3sS 12.5S
support Joint lapping
Pressure plate/
1.6S 6.3S
spherical bush
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Recommend
Standard
Parts name and inspection item ed value of Remedy
dimension
replacement
If there are flaking on
Roller bearing/needle bearing
sliding surface, replace.
When disassembling,
O-ring/Oil seal
replace as a rule.
If there are crushing
Kinds of bolt
parts, replace.
If there are signs of
Piston ring sticking or deforming,
replace.
Figure 39
2. Thickness of shoe: t
Figure 40
Figure 41
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4. Height difference of spherical bush and pressure plate: H-h
Figure 42
Parts Inspection and Inspection Standard of Reduction
Gear
1. This reduction gear has few parts and designing life of
each part is about the same. And so a state of single part
can be supplied, but when changing there are many parts
to change simultaneously for structure and function.
2. Inspection and inspection standard: It is a rule to change
damaged parts unconditionally.
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Inspection item Standard Standard of replacement Remark
Carrier Clearance between 0.3 - 0.7 1.2
assembly cluster gear and
thrust washer
Smoothing turn and
noise of cluster gear
Floating Seal Damage of sliding surface
seal O-ring Damage
Thrust bearing 5.0 Below 4.7
5.5 Below 5.2
6.0 Below 5.7
Gear oil Refer to Change after first 250 hours of
Operation operation and every 1,000 hours
Manual thereafter.
- But, change unconditionally when
disassembling.
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REASSEMBLY
General Cautions
1. Wash and clean each part. Then dry them with
compressed air. The friction plate, however, should not be
washed with treated oil.
2. Each connecting parts should be tightened according to its
assigned torque.
3. Only use a plastic soft-faced hammer.
FG001126
Figure 43
FG001127
Figure 44
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FG001128
Figure 45
FG001129
Figure 46
FG001130
Figure 47
FG001131
Figure 48
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3. Assemble needle bearing (103).
FG001132
Figure 49
FG001133
Figure 50
FG001134
Figure 51
FG001135
Figure 52
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6. Install orifice screws (363) both ends of counterbalance
spool (361).
NOTE: Connection torque: 70 kg•cm (5 ft lb).
FG001173
Figure 53
FG001118
Figure 54
FG001117
Figure 55
FG001120
Figure 56
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FG001119
Figure 57
FG001136
Figure 58
FG001137
Figure 59
FG001114
Figure 60
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10. Install swash rod (505) with O-ring (508).
FG001138
Figure 61
FG001139
Figure 62
FG001140
Figure 63
FG001147
Figure 64
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FG001148
Figure 65
FG001149
Figure 66
FG001150
Figure 67
FG001151
Figure 68
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FG001152
Figure 69
4. Insert oil seal (491) in shaft casing (272) using jig. Make
sure it is properly seated.
FG001153
Figure 70
FG001154
Figure 71
FG001155
Figure 72
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2. Insert pins (452 and 709) using hammer or a round bar.
NOTE: Two pins (452: Adjust their height to be 10 mm
(0.39 in) above swash plate support surface.
NOTE: Four pins (709): Adjust their height to be 19 mm
(0.75 in) above machined shaft casing surface.
FG001156
Figure 73
FG001157
Figure 74
FG001158
Figure 75
FG001159
Figure 76
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5. Assemble swash plate supports (201) into swash plates.
NOTE: Apply grease to slideway of swash plate.
NOTE: Check for smooth movement of swash plate.
FG001160
Figure 77
FG001161
Figure 78
FG001162
Figure 79
FG001163
Figure 80
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8. Assemble cylinder subassembly.
NOTE: Align holes of separation plate with pins.
FG001164
Figure 81
FG001165
Figure 82
10. Install piston rings 252 (707) and 278 (708) onto brake
piston (702).
FG001166
Figure 83
FG001167
Figure 84
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12. Install brake spring (705).
NOTE: Qty: Ten springs and eleven holes.
NOTE: The top brake piston shall not be assembled.
FG001168
Figure 85
FG001169
Figure 86
FG001171
Figure 88
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16. Remove four bolts (M20x50L) holding motor and remove it
from jig.
FG001172
Figure 89
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SP000033
GEAR PUMP SP000033
Gear Pump
Edition 1
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MEMO
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Table of Contents
Gear Pump
Safety Precautions................................................ 5
Applicable Models................................................. 5
Single Gear Pump ................................................ 6
Disassembly .................................................................... 6
Reassembly..................................................................... 8
Double Gear Pump ............................................. 12
Disassembly .................................................................. 12
Reassembly................................................................... 14
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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SINGLE GEAR PUMP
Disassembly
1. Clean exterior of pump.
FG001072
Figure 1
FG001074
Figure 2
FG001073
Figure 3
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4. Remove mounting flange taking care to keep flange as
straight as possible during removal.
If mounting flange is stuck, tap around edge with rubber
mallet in order to break it away from body.
NOTE: Make sure that while removing mounting flange,
shaft and other components remain in position.
FG001075
Figure 4
FG000834
Figure 5
FG000835
Figure 6
FG001076
Figure 7
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8. Remove driving gear and driven gear, keeping gears as
straight as possible.
FG001077
Figure 8
FG001078
Figure 9
Reassembly
1. Clean all components with care.
FG001078
Figure 10
FG000839
Figure 11
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3. Install retaining ring in groove.
FG000840
Figure 12
FG001079
Figure 13
FG001080
Figure 14
Inlet Side
FG001401
Figure 15
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7. Insert pressure plate assembly into body while keeping it
straight.
NOTE: Seal side should face to rear cover, opposite
side of gears.
NOTE: Pay attention to installation direction of seal.
FG001081
Figure 16
FG001082
Figure 17
FG001083
Figure 18
FG001084
Figure 19
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11. Tighten bolts with washer in a crisscross pattern to a
torque value of 45 Nm.
FG001085
Figure 20
12. Check that pump rotates freely when drive shaft is turned
by hand. If not a pressure plate seal may be pinched.
FG000851
Figure 21
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DOUBLE GEAR PUMP
Disassembly
1. Clean exterior of pump.
FG000830
Figure 22
FG000831
Figure 23
FG000832
Figure 24
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4. Remove mounting flange taking care to keep flange as
straight as possible during removal.
If mounting flange is stuck, tap around edge with rubber
mallet in order to break it away from body.
NOTE: Make sure that while removing mounting flange,
shaft and other components remain in position.
FG000833
Figure 25
FG000834
Figure 26
FG000835
Figure 27
FG000836
Figure 28
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8. Remove intermediate cover and through shaft.
FG000837
Figure 29
FG000838
Figure 30
Reassembly
1. Clean all components with care.
FG000838
Figure 31
FG000839
Figure 32
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3. Install retaining ring in groove.
FG000840
Figure 33
FG000841
Figure 34
FG000842
Figure 35
Inlet Side
FG001401
Figure 36
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7. Insert pressure plate assembly into body while keeping
plate straight.
NOTE: Seal side should face to rear cover, opposite
side of gears.
NOTE: Pay attention to direction of seal.
FG000844
Figure 37
FG000845
Figure 38
FG000846
Figure 39
FG000847
Figure 40
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11. Install remaining section using preceding procedure.
FG000848
Figure 41
FG000849
Figure 42
FG000850
Figure 43
14. Check that pump rotates freely when drive shaft is turned
by hand. If not a pressure plate seal may be pinched.
FG000851
Figure 44
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Gear Pump SP000033
Page 18
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SP000034
MAIN CONTROL VALVESP000034
Main Control
Valve
Edition 1
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MEMO
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Table of Contents
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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Main Control Valve SP000034
Page 6
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GENERAL DESCRIPTION
Theory of Operation
Neutral Passage
The oil supplied from the port (P1) enters into the tank passage
(Ta) through the orifice (Lc 1) of negative relief from the neutral
passage (L1) and returns to ports (T1, T2 and T3).
The oil supplied from the port (P2) passes the tank passage (Ta)
through orifice (Rc 1) of negative relief from the neutral passage
(R1) and returns to port (T1, T2 and T3).
The pressure of chambers (L2 and R2) flowing over the negative
relief, flows into pump from ports (ps1 and ps2), to control the
volume of pump P1 and P2.
In addition, when excessive oil flows excessive into the neutral
passage, the negative relief operates to prevent the abnormally
high-pressure on ports (ps1 and ps2).
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Negative Control Negative Control
Relief Valve (L) Relief Valve (R)
ARM 1 ARM 2
[Section 5] [Section 9]
BOOM 2 BOOM 1
[Section 4] [Section 8]
SWING BUCKET
[Section 3] [Section 7]
TRAVEL
OPTION [Section 6]
[Section 2]
TRAVEL STRAIGHT
[Section 1] TRAVEL
[Section ST]
P1 Side P2 Side
FG001295
Figure 1
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ARM 1
[Section 5]
BOOM 2
[Section 4]
SWING
[Section 3]
OPTION
[Section 2] Z
TRAVEL
[Section 1]
SECTION "L-L"
"Z" Detail FG001296
Figure 2
ARM 2
[Section 9]
BOOM 1
[Section 8]
6
BUCKET
[Section 7]
TRAVEL
[Section 6]
STRAIGHT
TRAVEL
[Section ST]
Ta
3
2
Ta
SECTION "R-R"
FG001297
Figure 3
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Signal Passage
Oil supplied to port (PP) flows through orifice (Lc3) to port (PT)
and simultaneously flows through land (Lc4), passage (5), and
land (Rc3) into tank passage (Ta).
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 into drain
passage (DR).
The oil passing through orifice (Lc6) flows through land (Lc7) to
tank passage (Ta) or flows through passage (4) to travel spool
land (Rc5) and then flows into tank passage (Ta).
OPTION
[Section 2]
TRAVEL
[Section 6]
TRAVEL
[Section 1]
STRAIGHT
TRAVEL
[Section ST]
FG001298
Figure 4
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Single Operation
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Switched Position
OPTION
[Section 2]
Neutral Position
Switched Position
TRAVEL
[Section 6]
Neutral Position
TRAVEL
[Section 1]
Switched Position
STRAIGHT
TRAVEL
[Section ST]
FG001299
Figure 5
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Swing Spool Shift
When shifting swing spool by increasing pressure of swing
(Section 3) pilot port (Pb3 (Pa3)), neutral port (L1) is closed. Oil
supplied to port (P1) flows through parallel passage (L3), load
check valve (S3-2), passage (S3-1) and spool, it then flows to
port (B3 (A3)).
Return oil flows through port (A3 (B3)) to spool and is returned
to tank passage (Ta).
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Switched Position
SWING
[Section 3]
Neutral Position
BUCKET
[Section 7]
FG001300
Figure 6
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2. Regeneration
When bucket spool is shifted by increasing pressure of
bucket (Section 7) pilot port (Pb7), neutral 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 through spool to tank passage (Ta), and the other
portion of oil flows through inside of spool, and pushes up
load check, and then is combined at port (A7).
Switched Position
SWING
[Section 3]
Neutral Position
BUCKET
[Section 7]
FG001301
Figure 7
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Boom Spool Shift
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) is closed by port (A8)
pressure that is sent through passage (AD2), spool (AD3)
to spring chamber (AD4).
BOOM 2
[Section 4]
BOOM 1
[Section 8]
FG001302
Figure 8
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2. Boom up (2-pump confluence)
When boom 1 spool is shifted by increasing pressure of
boom 1 (Section 8) pilot port (Pa8), neutral passage (R1) is
closed. Oil supplied to port (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 (L1) is
closed. Oil supplied to port (P1) flows through parallel
passage (L3), load check valve (S4-2), spool, and to
passage (6) and joins at port (A8). Return oil flows from
port (B8) to spool and returns to tank passage (Ta).
BOOM 2
[Section 4]
BOOM 1
[Section 8]
FG001303
Figure 9
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3. (Boom down (regeneration)
When boom 1 (Section 8) spool is shifted by increasing
pressure of boom 1 pilot port (Pb8), neutral passage (R1)
is closed. Oil supplied to port (P2) flows through 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 pressure of spring chamber (AD4), and
return oil from port (A8) flows to tank passage. Some
return oil opens poppet (S8-3) in boom 1 spool, flows
through passage (S8-2), joins at port (B7), and then
prevents cavitation of cylinder rod side.
BOOM 2
[Section 4]
BOOM 1
[Section 8]
FG001304
Figure 10
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Arm Spool Shift
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) is closed by port (A5)
pressure that is sent through passage (AD2), spool (AD3)
and to spring chamber (AD4).
ARM1
[Section 5]
ARM 2
[Section 9]
FG001305
Figure 11
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2. Arm in
A. 2-pump confluence
When arm 1 spool is shifted by increasing pressure of
arm 1 (Section 5) pilot port (Pb5), oil supplied to port
(P1) flows through neutral passage (L1), load check
valve (S5-2), passage (S5-1) and 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 spool to passage
(8) and joins at port (B5).
The return oil from port (B5) flows through
regeneration check valve in spool, and then flows to
port B to regenerate, and some oil returns through
variable regeneration release valve to tank (Ta).
(Refer to section 2-2)
ARM1
[Section 5]
ARM 2
[Section 9]
FG001306
Figure 12
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B. Variable regeneration
When crowding arm, after return oil from port (A5)
flows through notch (a), one portion of the oil returns
through fixed orifice (d), passage (e) and variable
orifice (f) and to tank 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 increased, it
flows through regeneration release valve piston (g)
and pushes regeneration release spool (h), as a
result area of variable orifice (f) is increased, and oil
returning to tank (Ta) is increased, and some oil to
regenerate in port (B5) is decreased.
ARM1
[Section 5]
i a b c
g h d e f
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3. Arm out (2-pump confluence)
When arm 1 spool is shifted by increasing pressure of arm
1 (Section 5) pilot port (Pa5), oil supplied to port (P1) flows
through neutral passage (L1), load check valve (S5-2),
passage (S5-1) and spool and into port (A5).
Oil supplied to port (P2) flows through neutral passage
(R1), load check valve (S9-2), passage (S9-1), spool and
passage (8) and joins at port (A5). Return oil from port (B5)
returns through spool to tank passage (Ta).
ARM1
[Section 5]
ARM2
[Section 9
FG001308
Figure 14
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Parallel Orifice for Arm
The orifice, that is installed in parallel passage for arm 1,
controls arm speed when operating in a combined operation. Oil
supplied from parallel passage (L3) of arm 1 (Section 5) pushes
open poppet (S5-3). It then flows through orifice (Lc8) of variable
orifice spool, and then is connected to passage (L5). From here,
flow of orifice (Lc8) can be varied by increasing or decreasing
pressure against pilot poppet (Pc3).
Normal Position
DR2 Passage
FG001309
Figure 15
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Relief Valve
1. Main relief valve
Oil supplied to port (P1) flows through poppet (LP). Oil
supplied to port (P2) flows through poppet (RP) and
passage (3). They join at the main relief valve. The highest
pressure of pump (P1 and P2) is controlled by reaction of
main relief valve.
2. Overload relief valve
The overload relief valve, that is installed in each cylinder
port of boom 1, arm 1 and bucket, prevents pressure of
actuator from increasing extremely high from outside
forces. This relief valve, when pressure of cylinder port is
negative, has a function to prevent cavitation by drawing oil
from tank.
FG000631
Figure 16
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Compound Operation
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TRAVEL
[Section 1]
TRAVEL
[Section 1]
2
1 STRAIGHT
TRAVEL
[Section ST]
FG001310
Figure 17
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Bucket Compound Operation
A priority control valve is installed in bucket (Section 7). This
valve controls oil flow entering into bucket when operating during
a combined operation with travel, boom 1, and arm 2 sections,
on P2 side.
If pressure at port (Pi) is increased when operating bucket,
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 into passage (S7-1).
As a result, passage diameter is smaller during combined
operation, than passage diameter during a single operation. This
smaller passage reduces flow of oil to port (A7, B7). Remaining
oil flows through parallel passage (R3) and primarily flows to
section being operated at P2 side during a combine operating
procedure.
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Switched Position
SWING
[Section 3]
Neutral Position
BUCKET
[Section 7]
FG001311
Figure 18
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Swing Compound Operation
The valve's swing Section (Section 3) is equipped with the
control valve that adjusts the flux that flows into the swing when
combined operating with the Section (travel, boom 2, arm 1) of
P1.
If port (Pi) is pressurized when operating swing function, piston
(S3-6) is pushed to have the poppet assembly (S3-2) to be
pressed under the seat part of the valve housing through the
piston (S3-5) and plug (S3-4). In this way, the oil in the parallel
passage (L3) is flowing into the passage (S3-1) by pushing up
the poppet (S3-3) inside the poppet assembly.
As a result, the passage at the time of compound operation is
tightened more than when single operation that the flux flowing
into A3 (B3) is reduced, and the surplus flux is advanced to the
section that P1 is simultaneously operated through the parallel
passage (L3).
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Switched Position
SWING
[Section 3]
Neutral Position
BUCKET
[Section 7]
FG001312
Figure 19
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Antidrift Valve
The antidrift valve is installed on the cylinder port on the arm
load (boom bore) for the natural antidrift of the arm (boom)
cylinder. (For typical example, arm (A5) is shown.)
1. Neutral condition (maintaining port (A5))
1 a b
A. The holding pressure of port (A5) is sent through
passages (a, b, and c), and into spring chamber (d) of A5
poppet (1). At this time pressurized oil flow, from port
(A5) is cut off by seats (S1 and S2). pc1
S1 d c S2
DR
To Main Spool
FG001313
Figure 20
2. Oil passage cut off condition of the port (A5) and the spring
chamber. 1 a 4 b 3 2
A. If port pc1 is pressurized, piston (2) is moved and A5
spool (3) reacts.
B. Spool (3) activates poppet (4). pc1
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Main Relief Valve
1. The main relief valve is between neutral oil passage (HP, E
"LP"
Figure 23) and low-pressure oil passage (LP). Pressurized
oil flows into neutral oil passage (HP) through orifice in the
main poppet (C) to fill internal cavity (D). Due to the B
difference in areas between (A and B), on which hydraulic A "HP"
pressure acts, main poppet (C) seats on sleeve (E).
C D
FG000639
Figure 23
"HP"
F
FG000640
Figure 24
"HP"
C D
FG000641
Figure 25
4. Pressure up operation
I
If pressure is applied to pilot port "PH," piston (H) moves to "LP"
the pressure setting position of plug (I) so that the force of
spring increases, thus increasing pressure in the neutral oil
passage (HP).
"HP"
H
FG000642
Figure 26
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Overload Relief Valve
K
"LP"
Operation B
1. The overload relief valve is between cylinder port (HP) and
low-pressure oil passage (LP). Pressurized oil at cylinder
A "HP"
port (HP), flows through an orifice in piston (C), to fill
internal cavity (G). Due to the difference in area between
(A and B) on which the hydraulic pressure acts, main
poppet (D) seats on sleeve (K).
C D G FG000644
Figure 27
"HP"
FG000645
Figure 28
"HP"
FG000646
Figure 29
"HP"
F
FG000647
Figure 30
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Absorption Operation
An anti void unit is installed in cylinder port (HP) to prevent "LP"
the development of cavitation. If pressure at cylinder port
(HP) becomes lower than that of oil passage (LP), sleeve
(K) moves so that oil is supplied from the low-pressure oil
passage (LP) to cylinder port (HP) to eliminate cavitation. "HP"
FG000648
Figure 31
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Low-pressure Relief Valve
1. Signal pressure
Ta Poppet
Oil supplied from pump port (P1 (P2)) flows through neutral
passage (L1 (R1)), low-pressure relief valve passage (L2
(R2)), and orifice (Lc1 (Rc1)) to tank passage (Ta). Lc1 [Rc1]
Now, pressure generated at passage (L2 (R2)) by orifice
(Lc1 (Rc1)) moves to low-pressure relief signal port (Ps1
(Ps2)). L2 [R2]
ps1
If main spool of upper reaches of L2 (R2)) operates, signal [ps2] L1
pressure of Ps1 (Ps2) decreases because oil flowing to L2 [R1]
(R2) decreases. FG001319
Figure 32
2. Operation of relief
Ta Poppet
If excessive oil flows into passage (L2 (R2)), pressure
generated at passage (L2 (R2)) by orifice (Lc1 (Rc1)) goes
to back chamber of poppet, and poppet operates by the Lc1 [Rc1]
difference of pressurized area between passage and back
chamber.
By operation of this poppet, oil flows from passage through L2 [R2]
plug and drill hole to tank passage (Ta). By this action, ps1
generation of excessive pressure in low-pressure relief [ps2] L1
[R1]
signal port is prevented. FG001320
Figure 33
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SP000034 Main Control Valve
Page 37
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Parts List
72
57 72
33
32
32
33
72
81
71 69
77
69
81 72
92
77
93
69
72
89
88
75 69
89
60
75 88 72 72
62
61
68
VIEW A
Figure 34
FG003962
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Reference Reference
Description Description
Number Number
32 Poppet 72 Plug Assembly
33 Spring 75 Socket Bolt (M10 x40L)
57 Spacer 77 Socket Bolt (M16 x130L)
60 Plug Assembly 81 Washer
61 Plug 88 Cap
62 O-ring 89 O-ring
68 Main Relief Valve 92 Plug Assembly
69 Overload Relief Valve 93 Plug Assembly
71 Plug Assembly
74
7
91
62 70
70
63 A
16
ARM 1
15
72 14
BOOM 2
7
SWING
74 12
8 OPTION 74
7
TRAVEL
4
17
3
2
7 5
12
74
13 105
1 B
ARM 2
5 BOOM 1
BUCKET
6
65 TRAVEL
66 66
STRAIGHT
TRAVEL
72
65
66
50 65
65
65
65
VIEW A SECTION B
FG003963
Figure 35
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Reference Reference
Description Description
Number Number
1 Housing Valve 16 Swing Spool Assembly
2 Arm Spool Assembly 2 17 Option Spool Assembly
3 Boom Spool Assembly 1 50 Plug
4 Bucket Spool Assembly 62 O-ring
5 Travel Spool Assembly 63 Orifice Plug
6 T/S Spool Assembly 65 O-ring
7 O-ring 66 O-ring
8 Cap 70 Foot Relief Valve
12 Cap 72 Plug Assembly
13 Housing Valve 74 Socket Bolt (M10x28L)
14 Arm Spool Assembly 1 91 Plug
15 Boom Spool Assembly 2 105 Plug Assembly
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42
20
76 21
20
67 19 22
41
40
39 19A
38
23
34
35 18
36
37
75 A
78
101 49
48
47
46
36
94A 37
75
97
100
95 103
104
102 99
94 98
96 31
30
31
27
26
25
24
34
35
36
37 24A
75
36 42
94A
38
44
45 39
101 40
36 41
43
67
51 34
92 73 35
35 54 76
36 55
53
37 VIEW A
52
75 75
Figure 36
FG003964
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Reference Reference
Description Description
Number Number
18 Cap 47 O-ring
19A SP Valve 48 Spring
19 Spool 49 Poppet
20 Spring Seat 51 Poppet
21 Spring 52 Flange
22 End Spool 53 Spacer
23 O-ring 54 O-ring
24A Arm Regen Assembly 55 Backup-ring
24 Plug 67 Anti-drift Valve Assembly
25 O-ring 73 Socket Bolt (M10x55L)
26 Spring 75 Socket Bolt (M10x40L)
27 Spool 76 Socket Bolt (M10x70L)
30 O-ring 78 Socket Bolt (M6x20L)
31 Backup Ring 92 Plug Assembly
34 Poppet 94A Boom Priority Valve
35 Spring 94 Plug
36 O-ring 95 Piston
37 Flange 96 Body
38 Poppet 97 Piston
39 Spring 98 Spring
40 Spacer Assembly 99 Sleeve
41 O-ring 100 Poppet Assembly
42 O-ring 102 O-ring
43 Flange 103 Backup-ring
44 Poppet 104 O-ring
45 Spring 101 Socket Bolt (M10x90L)
46 Plug
Specifications
Rated flux: 270 L/min
However, 50L/min. in neutral
Rated pressure: 34.3MPa
Permitted pressure: Max. pressure of 1.5MPa or less
Used pressure of 0.5MPa or less
Permitted use of oil temperature: Normally -20 - 80°C
Highest 100°C
(Use of the rubber for thread.)
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TROUBLESHOOTING, TESTING
AND ADJUSTMENT
Troubleshooting
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Relief Valve
Adjustment of Valves
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(Figure 38 on page 54) must be more than 4.0 mm
(0.16 in). Tighten lock nut (7).
B. Loosen lock nut (4) and turn adjusting plug (6)
clockwise to raise relief pressure of preceding step.
Turn adjusting plug (6) counterclockwise to lower
relief pressure. One turn varies pressure by
approximately 28.4 MPa [9,290 kg/cm2 (4,120 psi)].
Tighten lock nut (4) after pressure has been adjusted.
5. Low-pressure adjustment (second stage)
A. Loosen lock nut (7) and turn adjusting plug (8)
counterclockwise to lower relief pressure at state of 4.
One turn varies pressure by approximately 21.3 MPa
[217 kg/cm2 (3,090 psi)]. Tighten lock nut (7) after
pressure has been adjusted.
6. Recheck pressure setting by raising pressure once more.
CAUTION!
If pressure of main relief valve is higher than the specified
pressure for it, change main relief valve assembly setting
without adjusting overload relief valve.
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DISASSEMBLY
Caution in Disassembly
1. Shut down engine when pressure of actuator is not
indicated.
It is dangerous to disassemble control valve while it is
under pressure. High-pressure oil can squirt out or
components can spring out. When partially disassembling
control valve that is on machine, be careful to follow the
following caution.
CAUTION!
When disassembling assembly, when pressure is not
fully released, or bucket is not lowered to ground, is
very dangerous. A poppet in an antidrift valve may
spring out and drop the bucket at the same time.
Always lower bucket to ground and fully release
pressure before disassembling.
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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 assembly (72, width across flats: 8 mm) and
plug (91, width across flats: 22 mm) according to necessity.
3. Remove O-ring (7, one place per each section) from valve
housing (1 and 13).
4. Remove all spool subassemblies from valve housing
CAUTION!
When removing spool, be careful not to damage it.
Attach label to each spool in order to install it in the
correct position when reassembling.
5. Remove socket head bolt (74, two places per each section,
width across flats: 8 mm) and cap (12, ten places).
6. Remove O-ring (7, one place per each section) from valve
housing (1 and 13).
7. Disassembly of spool.
70~100
Work with spool gripped in vise with wood (see Figure
37) so as not to scratch outside diameter of spool.
Because Loctite is applied to threaded portion of
spool end, heat outside surface of spool with
industrial drier to release Loctite.
Heat spool until spool end is easily loosened, and FG001316
remove immediately after heating it to 200° - 250°C
Figure 37
(392° - 482°F).°
If it is over heated, change spring to new one.
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Disassembly of Arm 1 Para-turn Spool Part
1. Remove socket head bolt (78, width across flats: 5 mm)
and cap (18).
2. Remove O-ring (23) from cap (18).
3. Remove spool (19) from valve housing under subassembly
conditions.
4. Disassembly of spool.
CAUTION!
Work with spool gripped in vise with wood (see Figure
37), so as not to scratch outside diameter of spool.
Because Loctite is applied to threaded portion of
spool end, heat outside surface of spool with
industrial drier to release Loctite.
Heat spool until spool end is easily loosened, and
remove immediately after heating it to 200° - 250°C
(392° - 482˚F).
If it is over heated, replace spring with a new one.
CAUTION!
When removing a plug, when pressure is not fully released,
or bucket is not lowered to ground, is very dangerous. A
part in the valve may spring out and drop the bucket at the
same time. Always lower bucket to ground and fully release
pressure before disassembling.
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Disassembly of Load Check Valve Part
CAUTION!
Removing a plug, when pressure is not fully released, or
bucket is not lowered to ground, is very dangerous. A part
in the valve may spring out and drop the bucket at the same
time. Always lower bucket to ground and fully release
pressure before disassembling.
CAUTION!
Be careful, there is not a poppet and spring in travel
straight valve section (Section H-H).
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18. Grip body (96) in vise. Remove plug (94), piston (95) and
O-ring (102).
CAUTION!
Removing antidrift valve seat, when pressure is not fully
released, or bucket is not lowered to ground, is very
dangerous. A part in the valve may spring out and drop the
bucket at the same time. Always lower bucket to ground and
fully release pressure before disassembling.
CAUTION!
Removing inner parts of antidrift valve, when pressure
is not fully released, or bucket is not lowered to
ground, is very dangerous. A part in the valve may
spring out and drop the bucket at the same time.
Always lower bucket to ground and fully release
pressure before disassembling.
Slowly loosen plug assembly (67-14) and plug (67-3),
check if there is a resistance by remaining pressure
and remove.
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E. Pull spring seat (67-16) and spring (67-8) out of
inside hole.
F. Remove plug assembly (67-15) if necessary.
NOTE: Do not remove steel ball (67-14) because
it is pressed in body.
CAUTION!
Removing relief valve, when pressure is not fully released,
or bucket is not lowered to ground, is very dangerous. A
part in the valve may spring out and drop the bucket at the
same time. Always lower bucket to ground and fully release
pressure before disassembling.
Do not loosen adjusting plug for pressure setting or lock
nut.
Adjusting plug for pressure setting is dangerous because
pressure setting will be changed which may result in a
dangerous situation.
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Disassembly of Valve Housing Bolt
CAUTION!
Do not disassemble combined bolt (77) if it is
unnecessary.
If it is necessary to disassemble it, work by placing it
horizontally on a work bench.
Prepare spare O-ring (65 and 66).
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Disassembly of Main Relief Valve
A
Piston JIS O-ring Type
Figure 38
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Disassembly of Overload Relief Valve
Width across flat 31.75 Width across flat 17 Width across flat 6
(Cap) (Lock Nut) (Adjuster)
FG001318
Figure 39
CAUTION!
When disassembling adjuster kit, be careful not to let
parts spring out or lose poppet because of spring
force.
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Instruction of Disassembly and Assembly of Low-pressure
Relief Valve
2 D 1
4 2
"O-ring" P/N: 95113-02100 "O-ring" P/N: 21001-00213
FG001321
Figure 40
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CLEANING AND INSPECTION
(WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to
"General Maintenance Procedures" section.
Cleaning
Clean all parts thoroughly using a suitable cleaning fluid and dry
them with moisture free compressed air. Put them on a clean
paper or a vinyl for inspection.
Inspection
Inspect all parts for scratches, notches and other defects.
1. Inspect load check seat surface of valve housing for
scratches, scores, dirt, notches and corrosion. Remove
small scratches with oilstone.
2. Inspect exterior surface of spool for scratches and notches.
Remove small scratches with oilstone.
3. Sliding parts should be moved lightly and foreign materials
should be removed in all grooves and passages.
4. Replace any springs that are damaged, heavy deformed or
worn.
5. If relief valve malfunction, inspect it using relief valve
maintenance procedure.
6. Replace all O-rings and backup rings with new.
7. After disassembling cap or plug, check whether there are
paint chips around body hole or plug. If paint chips
penetrate into valve, they can cause malfunction or valve to
leak.
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REASSEMBLY
Caution on Assembly
CAUTION!
When working with Loctite, work in a place that is well
ventilated.
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Sequence of Subassembly
CAUTION!
Check number of each part, installation position and tools
needed before reassembling.
CAUTION!
Be careful not to get Loctite into spool by over
applying it.
Be careful that spool operation does become
deteriorated by over torquing spool end.
When reassembling it and A56, be careful because
there are two different types of springs.
CAUTION!
Be careful not to get Loctite into spool by over
applying it.
Be careful that spool operation does become
deteriorated by over torquing spool end.
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Antidrift Valve Assembly
1. Install O-ring (67-9 and 67-10) and backup ring (67-11 and
67-12) in groove of sleeve (67-6).
CAUTION!
Be careful of installation position of O-ring and backup
ring.
If they are reversed, the O-ring will be damaged and
drift speed of actuator can be increased.
CAUTION!
It Is better to apply grease to seat surface when
installing spring and spring seat onto seat of poppet.
CAUTION!
When reassembling safety valve, securely tighten plug that
is installed in body.
Do not loosen adjusting plug for pressure setting or lock
nut.
Adjusting plug for pressure setting is dangerous because
pressure setting will be changed which may result in a
dangerous situation.
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Assembly of Relief Valve
1. Install main relief valve (68). Tightening torque: Tightening
torque: 7.95 - 8.97 kg•m (58 - 65 ft lb).
2. Install overload relief valve (69, six places) in each section.
Tightening torque: 7.95 - 8.97 kg•m (58 - 65 ft lb).
3. Install spring seat (67-16) on small diameter of poppet.
Then insert spring (67-8) and them with sleeve to body (67-
1). Tightening torque: 11 - 12 kg•m (76 - 83 ft lb).
CAUTION!
Be careful of installation position of O-ring and backup
ring.
If they are reversed, the O-ring will be damaged and an
oil leak can occur.
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B. Insert backup ring (103), O-ring (104), spring (98)
and poppet assembly (100) in sleeve (99), and install
it to body (96).
C. Install O-ring (36) in valve housing and fasten body
using socket head bolt (101). Tightening torque: 5.91
- 6.53 kg•m (43 - 47 ft lb)
9. Insert poppet (32) and spring (33) in arm 1 para turn part
(Section C-C). Install plug assembly (72) with O-ring.
Tightening torque: 7.44 - 8.06 kg•m (54 - 58 ft lb).
10. Insert poppet (32), spring (33), and spacer (57) in arm 2
para turn part (Section L-L). Install plug assembly (72) with
O-ring. Tightening torque: 7.44 - 8.06 kg•m (54 - 58 ft lb).
CAUTION!
Be careful of installation position of O-ring and backup
ring.
If they are reversed, the O-ring will be damaged and an
oil leak can occur.
Check installing of O-ring (40-4) on spacer assembly
and be careful of installation direction.
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Assembly of Arm 1 Para-turn Spool
1. Install spool subassembly (19) into valve housing.
CAUTION!
After inserting spool, check to see if it slides easily.
CAUTION!
Align spool with hole and insert it slowly.
After inserting spool, check to see if it slides easily.
If spool is inserted when it is in a poor operating
condition with a scratch, it can cause a malfunction of
the spool.
CAUTION!
When tightening plug to cap, be careful not to over
tighten. If it is over tighten, threads of cap can be
damaged.
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Assembly of Other Plugs
1. Install O-ring on plug assembly (60) and install. Tightening
torque: 11 - 12 kg•m (76 - 83 ft lb)
2. Install O-ring (62) on plug assembly (61) and install.
Tightening torque: 4 - 4.5 kg•m (29 - 32 ft lb)
3. Tighten orifice plug (63). Tightening torque: 1.4 - 1.8 kg•m
(10 - 13 ft lb).
4. Install O-ring on plug assembly (92) and install. Tightening
torque: 21 - 23 kg•m (151 - 167 ft lb).
5. Install O-ring on plug assembly (71) and install. Tightening
torque: 1.4 - 1.8 kg•m (10 - 13 ft lb).
6. Install O-ring on plug assembly (72) and install. Tightening
torque: 7.5 - 8 kg•m (54 - 58 ft lb)
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Maintenance of Relief Valves
A
Piston JIS O-ring Type
Figure 41
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Reassembly of Overload Relief Valve (69, Total of 6 Places)
Width across flat 31.75 Width across flat 17 Width across flat 6
(Cap) (Lock Nut) (Adjuster)
FG001318
Figure 42
CAUTION!
In the event of disassembling the adjustment kit, be
careful for popping out of parts by the spring or the
loss of the poppet.
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Reassembly of Low-pressure Relief Valve (70, Total of 2
Places)
2 D 1
4 2
"O-ring" P/N: 95113-02100 "O-ring" P/N: 21001-00213
FG001321
Figure 43
CAUTION!
The sources of all tightening torque is coating with the
operation oil.
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INSTALLATION
1. Be careful not to apply stress on control valve when
attaching piping and hoses. Unnecessary stress may
cause spools to bind and the control valve from functioning
properly.
2. Tighten the assembling bolts alternately and evenly to the
specified torque.
3. If welding procedures are being performed near the control
valve, the valve could damaged by weld spatter and heat.
Use adequate shielding to protect valve.
4. Valve ports should be covered with caps, plugs or tape to
protect them from dust and other foreign materials, until
pipe laying work is started.
START-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 (180° -
235˚F) should be used in the hydraulic system.
3. Relief valve pressure should not be raised above specified
pressure setting.
4. The difference between main relief valve setting pressure
and overload relief valve setting pressure should not be
over 2.0 MPa [20.39 kg/cm2 (290 psi)].
5. Before operating machine, the hydraulic system should be
fully warmed up. If machine is operated with cold hydraulic
oil and valve, be careful of the following, to prevent spool
sticking due to heat shock.
NOTE: Do not operate main relief valve or overload
relief valve suddenly and continuously. Cycle oil
through all actuators and warmed up cold
hydraulic oil in the lines and components
uniformly.
NOTE: Slight or compound work should not be
suddenly operated at cold weather because
heat is developed partly at all the orifices.
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SP000037
HYDRAULIC SCHEMATIC (DX300LC)SP000037
1Hydraulic
Schematic
(DX300LC)
Edition 1
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MEMO
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Table of Contents
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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Hydraulic Schematic (DX300LC) SP000037
Page 6
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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 to make a
complete schematic.
1. PUMP
2. PILOT FILTER
C/V PA 3. SOLENOID VALVE (CUT OFF)
4. ACCUMULATOR
SH
Dr Pi Pi N Am Am N Pi Pi Dr OPTION APPLIED PART 5. SOLENOID VALVE (PACKAGE)
6. JOYSTICK VALVE(L)
ONE-WAY ; JOYSTICK BOTTON 24 25 26 7. JOYSTICK VALVE(R)
B FORWARD
A FORWARD
Au
Dr
PG 8. PEDAL VALVE
ONE-WAY ; JOYSTICK BOTTON or PEDAL 24 25 29 30 26 9. SHUTTLE VALVE
S 10. CONTROL VALVE
q2 min.
q2 min.
ONE/TWO-WAY 24 25 26 27 28 29 30 26
T 11. BOOM CYLINDER
BACKWARD B
BACKWARD A
q1
q1
max.
max.
ROTATING ; JOYSTICK SWITCH 31 32 33 34 D 12. ARM CYLINDER
GB GA 13. BUCKET CYLINDER
1 2 Pi Dr 4 3
14 ROTATING ; PEDAL 31 32 34 35 14. SWING DEVICE
Dr Bm Bm Dr 15. TRAVEL DEVICE
B RIGHT Mu LEFT A
15 TRAVEL MOTOR (L) 16 TRAVEL MOTOR (R) 15 QUICK COUPLER 36 16. CENTER JOINT
17. RESTRICTION VALVE
18. RESTRICTION VALVE
19. OIL COOLER
20. FULL FLOW FILTER
21. AIR BREATHER
22. HYDRAULIC TANK
a A B
DR2 DR3 DR4 Valve;control
23. LOCK VALVE
V2 T E 24. PROPORTIONAL VALVE
34
DR1
23
25. HIGH PRESS. RETURN FILTER
11 11 10 12
Pi1 of Pump C2 P 26. ONE/TWO-WAY SELECT V/V 1
Pi2 of Pump from #32
ps2
T2 T1 T3
ps1 27. ONE/TWO-WAY SELECT V/V 2
O 28. STOP VALVE
Pi1 E
P 29. OPT. PEDAL VALVE 1
T 30. SHUTTLE VALVE for OPT.
C2 C2 pc1 T 31. PTO
E E 36
32. ADDITIONAL GEAR PUMP
A5 b
33. SOL. V/V for ROTATING
34. ROTATING VALVE
Pi1 Pi1 pb9 ARM2 ARM1 B5
2 2 4 2
35. OPT. PEDAL VALVE 2
T T P 36. QUICK CLAMP VALVE
V2 V2 pb5
pa9 39. SOL. VLAVE E3C
1 1 3 1
23 23
pc2
pa5
A8 T
pc3
8
B8
B4 T P
35 T P T P
29
13 pb8 BOOM1 BOOM2 pb4
pa4 L.H
pa8 B3
B7
A3
A7
BKT SWING OPT. PEDAL 1
L.TRAVEL R.TRAVEL
OPT. PEDAL 1
pb3
27 2 1 2 1 4 3 2 1
pb7 CW CCW FORWARD FORWARD
pa7
pa3 28 BACKWARD BACKWARD
B6 A2 T
OPT R.H
A6 pb2
TR(L) 26
P4
pb6 33
pa2
B1
pa6 P1
A1
TR(R) from JOYSTICK(L) SWITCH
pb1
25
pa1
VALVE(LEFT) VALVE(RIGHT) 6 7
pr PA PT T P T P
P2 P3 PH PP P1
PH of Sol. v/v 2 2
19k
SWING MOTOR SH 19k 1 3 1 3
4 4
SWING ARM BOOM BUCKET
1 3 2 4 2 4 1 3
19 LEFT DUMP DOWN CROWD
17 UP DUMP
RIGHT CROWD
24
A1 A2 A3 A4 A5 A6 A7 A8 30
18 9
A9 A10
ps1
B1 S1 B2 B3 B5 B6 B7 B8 B9 S2 B10
Pi1
Hammer Operating
B4
21 A1 A2 PH pc3 pa3 pb3 pb5 pb8 pa7 pa8 pb7 pb2
Psv a4
Safety Cut-off
Swing Priority
pa2
Pressure up
from PRESS. SWITCH ON #30
high speed
4 SOL. V/V P3 pa5
500k
a2 500k Travel 5
a1
20 (FRONT) SENSOR SENSOR (REAR) pc1 pc2 Pi
P2 HO TR2 PH SP
1
10u T
P1 ACC
22 G1 Opt. Pedal
P Hammer Select
177u Operating A B
Pi1 Pi2
ps1 ps2 A
T T
2 P1
P4 P5 P3
40k 3
ENGINE SHUTTLE VALVE S1
B1
a3
1. PUMP
2. PILOT FILTER
C/V PA 3. SOLENOID VALVE (CUT OFF)
4. ACCUMULATOR
SH
Dr Pi Pi N Am Am N Pi Pi Dr OPTION APPLIED PART 5. SOLENOID VALVE (PACKAGE)
6. JOYSTICK VALVE(L)
ONE-WAY ; JOYSTICK BOTTON 24 25 26 7. JOYSTICK VALVE(R)
B FORWARD
A FORWARD
Au
Dr
PG 8. PEDAL VALVE
ONE-WAY ; JOYSTICK BOTTON or PEDAL 24 25 29 30 26 9. SHUTTLE VALVE
S 10. CONTROL VALVE
q2 min.
q2 min.
ONE/TWO-WAY 24 25 26 27 28 29 30 26
T 11. BOOM CYLINDER
BACKWARD B
BACKWARD A
q1
q1
max.
max.
pa4 L.H
pa8 B3
B7
A3
A7
BKT SWING OPT. PEDAL 1
L.TRAVEL R.TRAVEL
OPT. PEDAL 1
pb3 27 2 1 2 1 4 3 2 1
pb7 CW CCW FORWARD FORWARD
pa7
pa3 28 BACKWARD BACKWARD
B6 A2 T
OPT R.H
A6 pb2
TR(L) 26
P4
pb6 33
pa2
B1
pa6 P1
A1
TR(R) from JOYSTICK(L) SWITCH
pb1
25
pa1
VALVE(LEFT) VALVE(RIGHT) 6 7
pr PA PT T P T P
P2 P3 PH PP P1
PH of Sol. v/v 2 2
19k
SWING MOTOR SH 19k 1 3 1 3
4 4
SWING ARM BOOM BUCKET
1 3 2 4 2 4 1 3
19 LEFT DUMP DOWN CROWD
17 UP DUMP
RIGHT CROWD
24
A1 A2 A3 A4 A5 A6 A7 A8 30
18 9
A9 A10
ps1
B1 S1 B2 B3 B5 B6 B7 B8 B9 S2 B10
Pi1
Hammer Operating
B4
21 A1 A2 PH pc3 pa3 pb3 pb5 pb8 pa7 pa8 pb7 pb2
Psv a4
Safety Cut-off
Swing Priority
pa2
Pressure up
a1 a2
20 (FRONT) SENSOR SENSOR (REAR) pc1 pc2 Pi
P2 HO TR2 PH SP
1
10u T
P1 ACC
22 G1 Opt. Pedal
P Hammer Select
177u Operating A B
Pi1 Pi2
ps1 ps2 A
T T
2 P1
P4 P5 P3
40k 3
ENGINE SHUTTLE VALVE S1
B1
a3
FG001424
Figure 1
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DX300LC
Dr Pi Pi N Am Am N Pi Pi Dr
B FORWARD
A FORWARD
Au
Dr
q2 min.
q2 min.
BACKWARD B
BACKWARD A
q1
q1
max.
max.
GB GA
1 2 Pi Dr 4 3
Dr Bm Bm Dr
B RIGHT Mu LEFT A
15 TRAVEL MOTOR (L) 16 TRAVEL MOTOR (R) 15
C2 C2 pc1
E E
A5
pa4
pa8 B3
B7
A3
A7
BKT SWING
pb3
pb7
pa3
pa7
pi4
Pi B2
B6 A2
OPT
A6 pb2
TR(L)
P4
pb6
pa2
B1
pa6
A1
TR(R)
pb1
25
pa1
VALVE(LEFT) VALVE(RIGHT)
P2 P3 pr PH PA PP PT P1
PH of Sol. v/v
19k
SWING MOTOR SH 19k
17 19
24
18
ps1
Pi1
21 A1 A2
Psv a4
Safety Cut-off
from PRESS. SWITCH ON #30
4
500k 500k
a1 a2
20 (FRONT) SENSOR SENSOR (REAR) P2
1
10u T
P1 ACC
22 G1
P
177u Pi1 Pi2
ps1 ps2 A
2 P1
P4
40k 3
ENGINE
B1
a3
Dr1 B3 Dr3 A3
31
32 to #34 P
Figure 2
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1. PUMP
2. PILOT FILTER
C/V PA 3. SOLENOID VALVE (CUT OFF)
4. ACCUMULATOR
SH
OPTION APPLIED PART 5. SOLENOID VALVE(PACKAGE)
6. JOYSTICK VALVE(L)
ONE-WAY ; JOYSTICK BOTTON 24 25 26 7. JOYSTICK VALVE(R)
Au
Dr
PG 8. PEDAL VALVE
ONE-WAY ; JOYSTICK BOTTON or PEDAL 24 25 29 30 26 9. SHUTTLE VALVE
ONE/TWO-WAY 24 25 26 27 28 29 30 26 S 10. CONTROL VALVE
T 11. BOOM CYLINDER
ROTATING ; JOYSTICK SWITCH 31 32 33 34 D 12. ARM CYLINDER
GB GA 13. BUCKET CYLINDER
14 ROTATING ; PEDAL 31 32 34 35 14. SWING DEVICE
15. TRAVEL DEVICE
B RIGHT Mu LEFT A
QUICK COUPLER 36 16. CENTER JOINT
17. RESTRICTION VALVE
18. RESTRICTION VALVE
19. OIL COOLER
20. FULL FLOW FILTER
21. AIR BREATHER
22. HYDRAULIC TANK
a A B
Valve;control
23. LOCK VALVE
V2 T E 24. PROPORTIONAL VALVE
34
23
25. HIGH PRESS. RETURN FILTER
12 P 26. ONE/TWO-WAY SELECT V/V 1
C2 from #32
27. ONE/TWO-WAY SELECT V/V 2
O 28. STOP VALVE
Pi1 E
P 29. OPT. PEDAL VALVE 1
T 30. SHUTTLE VALVE for OPT.
pc1 T 31. PTO
36
32. ADDITIONAL GEAR PUMP
A5 b
33. SOL. V/V for ROTATING
34. ROTATING VALVE
B5
2 2 4 2
35. OPT. PEDAL VALVE 2
P 36. QUICK CLAMP VALVE
pb5
39. SOL. VLAVE E3C
1 1 3 1
pa5
T
pc3
8
B4 T P
35 T P T P
29
pb4
pa4 L.H
B3
A2 T
R.H
pb2
P4
26
33
pa2
B1
P1
A1
from JOYSTICK(L) SWITCH
pb1
25
pa1
6 7
T P T P
2 2
1 3 1 3
4 4
SWING ARM BOOM BUCKET
1 3 2 4 2 4 1 3
LEFT DUMP DOWN CROWD
RIGHT CROWD UP DUMP
A1 A2 A3 A4 A5 A6 A7 A8 30
9
A9 A10
B1 S1 B2 B3 B5 B6 B7 B8 B9 S2 B10
Hammer Operating
B4
PH pc3 pa3 pb3 pb5 pb8 pa7 pa8 pb7 pb2
Safety Cut-off
Swing Priority
pa2
Pressure up
high speed
pc1 pc2 Pi
P2 HO TR2 PH SP
T
P1 ACC
G1 Opt. Pedal
P Hammer Select
Operating A B
A
T T
P1
P4 P5 P3
3 SHUTTLE VALVE S1
DX300LC
FG001415
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Hydraulic Schematic (DX300LC) SP000037
Page 10
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SP000068
AXIAL PISTON PUMPSP000068
Axial Piston
Pump
Edition 1
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MEMO
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Table of Contents
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Adjustment of Maximum and Minimum Flows.......... 37
Preparation for Disassembly ......................................... 39
Regulator Disassembly ................................................. 40
Regulator Reassembly .................................................. 43
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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AXIAL PISTON PUMP
General Description
Regulator type:
For more details, see
the instruction manual
for the regulator.
- : DT
P : DTD
S : Single pump
DT : Tandem type double-pump
Size
K5V series
ARS0120L
Figure 1
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Theory of Operation
Construction
This pump assembly consists of two pumps connected by a
spline inside 1st gear (116). The two pumps can be driven
simultaneously as the rotation of the prime mover (engine) is
transferred by the drive shaft (F) (111) on the front side. The
suction and discharge ports are integrated at the connecting
part of the two pumps; i.e. in valve block (312): The suction port
serves both the front pump and the rear pump.
Function
The pumps may be classified roughly into the rotary group
performing a rotary motion and working as the major part of the
whole pump function: the swash plate group that varies the
delivery rates: and the valve cover group that changes over oil
suction and discharge.
1. Rotary Group
The rotary group consists of a drive shaft (F) (111),
cylinder block (141), piston shoes (151, 152), set plate
(153), spherical bushing (156) and cylinder spring (157).
The drive shaft is supported by bearings (123 and 124) at
both ends. The shoe is caulked to the piston to form a
spherical coupling. It has a pocket to relieve thrust force
generated by loading pressure and to take hydraulic
balance so that it slides lightly over the shoe plate (211).
The subgroup is composed of a piston and shoe pressed
against the shoe plate by the action of the cylinder spring
via a retainer and a spherical bush.
Similarly, the cylinder block is pressed against valve plate
(313) by the action of the cylinder spring.
2. Swash Plate Group
The swash plate group consists of swash plate (212), shoe
plate (211), swash plate support (251), tilting bushing
(214), tilting pin (531) and servo piston (532).
The swash plate is a cylindrical part formed on the
opposite side of the sliding surface of the shoe and is
supported by the swash support.
The servo piston moves to the right and left as hydraulic
oil, controlled by the regulator is transmitted to each
hydraulic chamber on both ends of the servo piston. The
swash plate slides over the swash plate support via the Figure 2 SWASH PLATE GROUP
spherical part of the tilting pin to change the tilting angle
(α).
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3. Valve Block Group
The valve block group consists of valve block (312), valve
plate (313) and valve plate pin (885). The valve plate has
two melon-shaped ports, that are mated to the valve block.
These feed and collect oil to and from the cylinder block.
The oil changed over by the valve plate is connected to an
external pipeline by way of valve block.
When the drive shaft is driven by the prime 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 Figure 3 VALVE BLOCK GROUP
to the cylinder block, while they revolve with the cylinder
block. If you pay attention to a single piston, it performs a
motion away from the valve plate (oil sucking process)
within 180 degrees, and makes a motion towards the valve
plate (or oil discharging process) in the rest of 180
degrees. When the swash plate has no tilt angle (zero
degrees), the piston does not stroke and neither
discharges or draws oil.
Parts List
535 789 732 532 214 548 531 724 702 792 534 717 901 954 808 151 152 211 113
806
953
886 4
717
406
261
127
824
111
774
710
123
251
490 401 212 211 153 156 157 468 313 467 116 124 466 885 314 981 141 271 401
728 710 726 312 725 983 FG000611
Figure 4
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Reference Reference
Description Description
Number Number
04 Gear Pump 490 Plug
111 Drive Shaft (F) 531 Tilting Pin
113 Drive Shaft (R) 532 Servo Piston
116 1st Gear 534 Stopper (L)
123 Roller Bearing 535 Stopper (S)
124 Needle Bearing 548 Feed Back Pin
127 Bearing Spacer 702 O-ring
141 Cylinder Block 710 O-ring
151 Piston 717 O-ring
152 Shoe 719 O-ring
153 Set Plate 724 O-ring
156 Spherical Bushing 725 O-ring
157 Cylinder Spring 728 O-ring
211 Shoe Plate 732 O-ring
212 Swash Plate 774 Oil Seal
214 Tilting Bushing 789 Backup Ring
251 Swash Plate Support 792 Backup Ring
261 Seal Cover (F) 806 Nut
271 Pump Casing 808 Nut
312 Valve Block 824 Retaining Ring
313 Valve Plate (R) 885 Valve Plate Pin
314 Valve Plate (L) 886 Spring Pin
401 Hex Socket Head Bolt 901 Eyebolt
406 Hex Socket Head Bolt 953 Set Screw
466 VP Plug 954 Set Screw
467 Plug 981 Name Plate
468 RO Plug 983 Pin
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Torques
PF 11/4 2700 17
PF 11/2 2800 17
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Special Tools and Materials
Tools
The tools necessary to disassemble / reassemble the K3V pump
are shown in the following list. The sizes of the bolts and plugs
depend on the pump type.
Necessary Tool
Tool Name and Size (Marked with O) Part Name
Pump Type
Hex
Hex
PT Plug PO Plug Socket
Name B K5V80 K5V140 Socket
(PT thread) (PF thread) Head
Head Bolt
Setscrew
Allen wrench 2 M4
2.5 M5
3 M6
4 O O M5 BP-1/16 M8
5 O O M6 BP-1/8 M10
6 O O M8 BP-1/4 PO-1/4 M12 M14
8 O M10 BP-3/8 PO-3/8 M16 M18
10 M12 BP-1/2 PO-1/2 M20
12 M14
14 O M16 M18 BP-3/4 PO-3/4
PO-1,
17 O M20 M22 BP-1
11/4, 11/2
19 M24 M27
21
22 M30 PO-2
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Necessary Tool (O)
Tool Name and Size Part Name
Pump Type
Hex headed VP plug (PF
Name B K5V80 K5V140 Hex nut
bolt thread)
Double ring 19 O O M12 M12 VP-1/4
spanner, Socket 22
wrench, Double
24 O M16 M16
(single) open
end spanner. 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
O O Medium size, 1 set
wrench
Screwdriver O O Minus type screwdriver, medium size, 2 set
Hammer O O Plastic hammer, 1 set
Retaining Ring
O O For retaining ring, TSR-160
Pliers
Steel bar of key material approx.
Steel bar O O
10x8x200
Torque wrench O O Capable of tightening with the specified torques
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Troubleshooting, Testing and Adjustment
General Cautions
This section describes the countermeasures to be taken if any
abnormality is detected during the operation of the Kawasaki
swash plate type axial piston pump.
The general cautions are as follows:
1. Consider the condition before starting work.
2. Judge the nature of the abnormality, before starting work.
Especially, judge if it is a problem in the circuit or caused by
the regulator or attached valves and determine that
something is truly wrong with the pump or not.
3. Read and understand the maintenance manual before
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 them carefully to
prevent damage.
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If the failure is a problem in control, do not unnecessarily
overhaul the pump, but measure pressures at various
areas to investigate the abnormal position.
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Disassembly
For disassembling the pump, read this section thoroughly and
disassemble it in the following sequence. The figures in
parentheses after part names show the items in Figure 17
construction of pump.
This maintenance manual describes the disassembling
procedures for both the single pump and tandem type double-
pump. Disassemble the pump, referring to the contents for its
appropriate type.
In addition, for the double-pump, take care not to exchange parts
from one pump with the same ones of the other pump.
1. Select place suitable to disassembling.
IMPORTANT
Select a clean place.
Spread a rubber mat or cloth on top of the overhaul
workbench to prevent parts from being damaged.
IMPORTANT
For tandem type pump, remove plugs from both front
and rear pumps.
IMPORTANT
If a gear pump is attached to rear face of pump,
remove it before proceeding.
HDM3016P
Figure 5
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6. Place horizontally on workbench with its regulator-
fitting surface down, and separate pump casing (271) from
valve block (312).
IMPORTANT
Before laying this surface down, spread rubber mat on
workbench to prevent this surface from being
damaged.
HDM3017L
Figure 1
IMPORTANT
Do not damage sliding surfaces of cylinder, spherical
bushing, shoes, swash plate, etc.
Figure 2
8. Remove hex socket head bolts (406) and seal cover (F)
(261).
IMPORTANT
Install bolt into pulling-out tapped hole of seal cover
(F), and cover can be removed easily.
Since oil seal is attached on seal cover (F), do not
damage it when removing cover.
HDM3019L
[In case fitting a gear pump, first, remove gear pump]
Figure 3
Figure 4
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10. Remove shoe plate (211) and swash plate (212) from
pump casing (271).
HDM3021L
Figure 5
11. Lightly tapping shaft ends of drive shafts (111 and 113)
with plastic hammer, remove drive shafts from swash plate
supports.
Figure 6
12. Remove valve plates (313 and 314) from valve block (312).
IMPORTANT
These may be removed in work 6.
IMPORTANT Figure 7
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Cleaning and Inspection (Wear Limits and
Tolerances)
For general cleaning and inspection procedures, refer to
"General Maintenance Procedures" section.
H
h
t
Play between Piston & Shoe : Combined Height of Set Plate &
Thickness of Shoe : t Spherical Bush : H-h FG001294
Figure 8
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Reassembly
For reassembling reverse the disassembling procedures, paying
attention to the following items.
• Do not fail to repair parts damaged during
disassembling, and prepare replacement parts in
advance.
• Clean each part fully with cleaning oil and dry it with
compressed air.
• Do not fail to apply clean oil to sliding sections,
bearings, etc. before assembling them.
• Replace seal parts, such as O-rings, oil seals, etc.
• For fitting bolts, plug, etc., tighten them with torques
shown in “Torques” on page 10.
• For double-pump, take care not to exchange parts of
the front pump with those of the rear pump.
1. Fit swash plate support (251) to pump casing (271),
tapping it lightly with a hammer.
IMPORTANT
After servo piston, tilting pin, stopper (L) and stopper
(S) are removed, Install them on pump casing in
advance for reassembling.
When tightening servo piston and tilting pin, use a
protector to prevent tilting pin head and feedback pin
from being damaged. In addition, apply Loctite
(medium strength) to their threaded sections. Figure 9
IMPORTANT
Confirm with fingers of both hands that swash plate
can be moved smoothly.
Apply grease to sliding sections of swash plate and
swash plate support, so drive shaft can be easily
installed.
Figure 10
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3. On swash plate support (251), secure drive shaft (111), set
bearing (123), bearing spacer (127) and retaining ring
(824).
IMPORTANT
Do not tap drive shaft with hammer.
Assemble them into support, lightly tapping outer race
of bearing with plastic hammer. Fully seat them, using
steel bar.
Figure 11
IMPORTANT
Lightly apply grease to oil seal in seal cover (F).
Assemble oil seal, taking full care not to damage it.
Figure 12
Figure 13
IMPORTANT
Do not mistake suction / delivery directions of valve
plate.
Figure 14
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7. Position valve block (312) in pump casing (271) and tighten
hex socket head bolts (401).
IMPORTANT
Assemble the rear pump side first, to make the
procedure easier.
Do not mistake direction of valve block.
Clockwise rotation (viewed from input shaft side) -
Install block with regulator up and with delivery flange
left, viewed from front side. Figure 15
Counterclockwise rotation (viewed from input shaft
side) - Install block with regulator up and with delivery
flange right, viewed from front side.
IMPORTANT
Do not mistake regulator of front pump for that of rear
pump.
Figure 16
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534
548 792
531 702
532
271
A
732
789
535 728
886 468
251
953
808
113 717
824 490
127
123
710 774
261 401
719
406 B
114
124 806
313 953
141
886 824
127
151 153 156 123
152
211 719
214 157
212
401
724
251
A 111
719
808
954 314
5
710 490 901
312
885
124
886
B
725 FG000609
885 886 466
Figure 17
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Start-up Procedures
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REGULATOR FOR AXIAL
PISTON PUMP
General Description
KR3 S - 9 N 01
Regulator Design Series Number
Size
6 : K5V63
8 : K5V80
G : K3V112
S : K5V140
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Parts List
Figure 19
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Reference Reference
Description Description
Number Number
412 Hex Socket Head Screw 652 Spool
413 Hex Socket Head Screw 653 Spring Seat
436 Hex Socket Head Screw 654 Return Spring
438 Hex Socket Head Screw 655 Set Spring
496 Plug 656 Block Cover
531 Tilting Pin 708 O-ring
548 Feedback Pin 722 O-ring
601 Casing 724 O-ring
611 Feedback Lever 725 O-ring
612 Lever (1) 728 O-ring
613 Lever (2) 730 O-ring
614 Fulcrum Plug 732 O-ring
615 Adjusting Plug 733 O-ring
621 Compensating Piston 734 O-ring
622 Piston Case 735 O-ring
623 Compensating Rod 755 O-ring
624 Spring Seat (C) 756 O-ring
625 Outer Spring 763 O-ring
626 Inner Spring 801 Nut
627 Adjusting Ring (C) 814 Retaining Ring
628 Adjusting Screw (C) 836 Retaining Ring
629 Cover (C) 858 Locking Ring
630 Lock Nut 874 Pin
631 PF Sleeve 875 Pin
641 Pilot Cover 887 Pin
643 Pilot Piston 897 Pin
644 Spring Seat 898 Pin
645 Adjusting Ring (Q) 924 Adjusting Screw
646 Pilot Spring 925 Adjusting Screw (QI)
651 Sleeve
Outline
The regulator for the K3V Series Kawasaki in-line type axial
piston pump has various models to satisfy various kinds of
specifications required. Therefore, the customer can select the
appropriate model to its intended application.
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Horsepower Control
Horsepower
control If the pressure rises above the set value,
5 High-pressure
pressure the pump outlet flow is automatically
cutoff
cutoff decreased by the pressure cutoff control.
Total
horsepower
6 control
pressure
cutoff
Flow Control
Lever stroke
Pilot pressure
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Code Control Type Control Curve Function and Features
Specifications
• Working oil: Wear resistant hydraulic oil, ISO VG 32,
46 and 68
• Temperature range: -20 °C - +95°C
• Viscosity range: 10 - 1000 cSt (During normal
operation: 10 - 200 cSt)
• Miscellaneous: With proportional pressure reducing
valve (In case of type KR3*-9***)
Functional Explanations
The regulator for Kawasaki in-line axial piston pump K3V Series
consists of the following control functions.
1. Negative flow control
2. Total cumulative horsepower control
3. Variable horsepower control
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Regulator Function Diagram
Figure 20
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The groove (A) in the pilot piston is attached with pin
(875) that is fixed to lever 2 (613). Therefore, when
the pilot piston moves, lever 2 rotates around the
fulcrum of point B (fixed by the fulcrum plug (614) and
pin (875). Since the large-hole section (C, Figure 20)
of lever 2 contains a protruding pin (897) fixed to the
feedback lever (611), the pin (897) moves to the right
as lever 2 rotates. Since the opposing-flat section (D)
of the feedback lever is attached with the pin (548)
fixed by the tilting pin (531) that swings the swash
plate, the feedback lever rotates around the fulcrum
of point D, as the pin (897) moves. Since the
feedback lever is connected with the spool (652) via
the pin (874), the spool moves to the right.
The movement of the spool causes the delivery
pressure P1 to connect to port C liter through the
spool and to be admitted to the large-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 difference, resulting in
decrease of the tilting angle.
When the servo piston moves to the right, point D
also moves to the right. The spool is fitted with the
return spring (654) and is tensioned to the left at all
times, and so the pin (897) is pressed against the
large-hole section (C) of lever2. Therefore, as point D
moves, the feedback lever rotates around the fulcrum
of point C, and the spool is shifted to the left. This
causes the opening between the sleeve (651) and
spool (652) to close slowly, and the servo piston
comes to a complete stop when it closes completely.
B. Flow Increasing Function
As the pilot pressure Pi decreases, the pilot piston
(643) moves to the left by the action of the pilot spring
(646) and causes lever 2 (613) to rotate around the
fulcrum of point B. Since the pin (897) is pressed
against the large-hole section (C) of lever 2 by the
action of the return spring (654) via the spool (652),
pin (874), and feedback lever (611), the feedback
lever rotates around the fulcrum of point D as lever 2
rotates, and shifts the spool to the left. Port C liter
opens a way to the tank port as the spool moves. This
deprives the large-diameter section of the servo
piston of pressure, and shifts the servo piston to the
left by the discharge pressure P1 in the small-
diameter section, resulting in an increase in the flow
rate.
As the servo piston moves, point D also moves to the
left, the feedback lever rotates around the fulcrum of
point C, and the spool moves to the right till the
opening between the spool and sleeve is closed.
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2. Adjustment of flow control characteristic
The flow control characteristic can be adjusted with the
adjusting screw.
Adjust it by loosening the hex nut (801) and by tightening
(or loosening) the hex socket head screw (924).
Tightening the screw shifts the control chart to the right as
shown in the Figure 22.
NOTE: Adjusting values are shown in the attached
Table. See “Summary of Regulator Adjustment
Values” on page 38.
Figure 22
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section of the servo piston via Port C liter, causes the
servo piston move to the right, reduces the pump
delivery flow rate, and prevents the prime mover from
being overloaded.
The movement of the servo piston is transmitted to
the feedback lever via point D. Then the feedback
lever rotates around the fulcrum of point F and the
spool is shifted to the left. The spool moves till the
opening between the spool and sleeve (651) is
closed.
B. Flow Reset Function
As the self pump delivery pressure P1 or the
companion pump delivery pressure P2 decreases,
the compensating rod (623) is pushed back by the
action of the springs (625 and 626) to rotate Lever 1
around point E. Rotating of Lever 1 causes the
feedback lever to rotate around the fulcrum of point D
and then the spool to move to the left. As a result,
Port C liter opens a way to the tank port. This causes
the servo piston to move to the left and the pump's
delivery rate to increase.
The movement of the servo piston is transmitted to
the spool by the action of the feedback mechanism to
move it till the opening between the spool and sleeve
is closed.
2. Low tilting angle (low flow) command preferential function
As mentioned above, flow control and horsepower control
tilting angle commands are transmitted to the feedback
lever and spool via the large-hole sections (C and F) of
levers 1 and 2. However, since sections C and F have the
pins (∅4) protruding from the large hole (∅8), only the
lever lessening the tilting angle contacts the pin (897); the
hole (∅8) in the lever of a larger tilting angle command is
freed without contacting the pin (897). Such a mechanical
selection method permits preference of the lower tilting
angle command of the flow control and horsepower
control.
3. Adjustment of Input horsepower
Since the regulator is of total cumulative horsepower type,
adjust the adjusting screws of both the front and rear
pumps, when changing the horsepower set values. The
pressure change values by adjustment are based on two
pumps pressurized at the same time, and the values will be
doubled when only one pump is loaded.
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A. Adjustment of outer springs
Adjust it by loosening the hex nut (630) and by
tightening (or loosening) the adjusting screw C (628).
Tightening the screw shifts the control chart to the
right and increases the input horsepower as shown in
the Figure 24. Since turning the adjusting screw C by
N turns changes the setting of the inner spring, return
the adjusting screw CI (925) by NxA turns at first.
Figure 24
Figure 25
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Tightening Torque
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Special Tools and Materials
Tools
Name Description
4,5,6
Allen Wrench (Dimension B mm)
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Maximum Flow Is Not Available
1. Check that the pilot pressure Pi is normal.
2. The pilot piston (643) is stuck:
• Disassemble and clean the regulator.
3. The spool (652) is stuck:
• 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 regulator.
NOTE: Replace faulty parts that are deeply scored.
(1 and 2) are only for cases of the pilot control.
(4) is only for cases of the two-stage max. flow
control.
(5) is only for cases of the cutoff control.
Figure 27
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Adjustment of Minimum Flow
Adjust it by loosening the hex nut (909) and by tightening (or
loosening) the hex socket head set screw (953). Similarly to the
adjustment of the maximum flow, other characteristics are not
chanced. However, remember that, if tightened too much, the
required horsepower during the maximum delivery pressure (or
during relieving) may increase.
Figure 28
Item Specification
Speed 1900 min-1
Adjustment of Maximum Flow Tightening amount of adjusting screw +1/4 Turn
(954).
Flow change amount. -5.9 l/min
Adjustment of Minimum Flow Tightening amount of adjusting screw +1/4 Turn
(953).
Flow change amount. +4.7 l/min
Adjustment of Input Adjustment of outer Tightening amount of adjusting screw +1/4 Turn
Horsepower spring. (C) (628).
Compensating control starting +19 kg/cm2
pressure change amount.
Input torque change amount. +6.9 kg•m
A 1.9
Adjustment of inner Tightening amount of adjusting screw +1/4 Turn
spring. (QI) (925).
Flow Change Amount +11 l/min
Input torque change amount. +5.8 kg•m
Adjustment of flow control characteristic. Tightening amount of adjusting screw +1/4 Turn
(924).
Flow control starting pressure change +1.8 kg/cm2
amount.
Flow change amount. +15.4 l/min
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Preparation for Disassembly
1. Since the regulator consists of small precision finished
parts, disassembly and assembly are rather complicated.
For this reason, replacement of a regulator assembly is
recommended, unless there is a special reason, but in
case disassembly is necessary for an unavoidable reason,
read through this manual to the end before starting
disassembly.
2. The numbers in parentheses after part names represent
those in the “Parts List” on page 26.
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Regulator Disassembly
1. Choose a place for disassembly.
CAUTION!
1. Choose a clean place.
2. Spread rubber mat or cloth, on top of workbench to
prevent parts from being damaged.
IMPORTANT
Do not lose O-ring.
Figure 29
IMPORTANT
Cover (C) is attached with adjusting screw (C), (QI)
(628, 925), adjusting ring (C) (627), lock nut (630), hex
nut (801) and adjusting screw (924). Do not loosen
these screws and nuts. If they are loosened, adjusted
pressure flow setting will vary.
Figure 30
IMPORTANT
Adjusting ring (Q) (645) can easily be drawn out with
M4 bolt.
Figure 31
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7. Remove hex socket head screws (436, 438) and pilot cover
(641). After removing pilot cover, remove set spring (655)
from pilot section.
Figure 32
IMPORTANT
Sleeve (651) is attached with retaining ring (836).
When removing retaining ring (814), return spring
(654) may pop out. Take care not to lose it.
Figure 33
Figure 34
IMPORTANT
Fulcrum plug (614) and adjusting plug (615) can be
easily taken out with M6 bolt.
Figure 35
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10. Remove lever (2) (613). Do not draw out pin (875).
IMPORTANT
Work will be promoted by using pincers.
Figure 36
11. Draw out pin (874) and remove feedback lever (611).
Figure 37
IMPORTANT
Push out pin (874) (4 mm (0.16 in) in dia.) from above
with slender steel bar so that it may not interfere with
lever (1) (612).
12. Remove lever (1) (612). Do not draw out pin (875).
13. Draw out pilot piston (643) and spool (652).
14. Draw out piston case (622), compensating piston (621) Figure 38
and compensating rod (623).
NOTE: Since component parts are small, do not lose
them.
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Regulator Reassembly
For assembly, reverse disassembly procedures, but pay
attention to the following.
• Always repair parts that were scored at disassembly.
Get replacement parts ready beforehand.
• Mixing of foreign material will cause malfunction.
Therefore, wash parts well with cleaning oil, let them
dry with jet air and handle them in clean place.
• Always tighten bolts, plugs, etc. to their specified
torques.
• Do not fail to coat sliding surfaces with clean
hydraulic oil before assembly.
• Replace seals such as O-rings with new ones as a
rule.
1. Put compensating rod (623) into compensating hole of
casing (601).
2. Press fit pin in lever (1) (612) into groove of compensating
rod and fit lever (1) to pin press fitted in casing.
3. Install spool (652) and sleeve (651) into hole in spool of
casing.
IMPORTANT
Confirm that spool and sleeve slide smoothly in casing
without binding.
Pay attention to orientation of spool.
Figure 39
4. Install feedback lever (611), matching its pin hole with pin
hole in spool. Then insert pin (874).
IMPORTANT
Insert pin in feedback lever a little to ease operation.
Do not mistake direction of feedback lever.
IMPORTANT
Confirm that pilot piston slides smoothly without
binding.
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6. Press fit pin in lever (2) (613) into groove of pilot piston.
Then attach lever (2).
Figure 41
IMPORTANT
Do not mistake inserting holes for fulcrum plug and
adjusting plug.
Now move feedback lever to confirm that it has no Figure 42
large play and is free from binding.
9. Install return spring (654) and spring seat (653) into spool
hole. Install retaining ring (814).
Figure 43
Figure 44
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12. Insert 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.
IMPORTANT
When fitting spring seat, do not mistake direction of
spring seat.
Figure 45
14. Install cover (C) (629) with adjusting screws (628 and 925),
adjusting ring (C) (627), lock nut (630), hex nut (801) and
adjusting screw (924). Secure them with hex socket head
screws (438).
Figure 46
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Axial Piston Pump SP000068
Page 46
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SP000069
REMOTE CONTROL VALVE (WORK LEVER /
JOYSTICK) SP000069
Remote Control
Valve (Work
Lever / Joystick)
Edition 1
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MEMO
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Table of Contents
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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Remote Control Valve (Work Lever / Joystick) SP000069
Page 6
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GENERAL DESCRIPTION
Theory of Operation
Structure
The remote control valve contains four push rods, spring
holders, spools and return springs, which are in the valve casing.
The valve works as a pressure reduction valve.
The housing has six ports, which include input port P, tank port
T, and four secondary pressure ports.
The electric horn button is installed in the valve handle.
Gear pump pressure is used for operating control spools.
Function
1. Neutral Position
When the lever is in neutral mode, the spool is pushed
upward by return spring. The force of balancing spring,
which determines the secondary discharge pressure, is not
transmitted to the spool. The input port is closed and the
pressure of the output port is the same as the pressure of
the tank port T.
2. Control Switch
Pressing of the push rod starts to press the balance spring,
whose force is transferred to the spool to connect the P
and T ports, transferring the pilot pressure. Output
pressure acts on the bottom of the spool and press the
spool upwards until it is balanced with the force of the
balance spring.
In short, the second pressure (output pressure) changes in
proportion to the pressing force of the balance spring.
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Parts List
28
24
18
25A
16 23
17
36
12 18
22 16
32 11 17
25 15 35
8 20 12
14
11
13 10
34 8
5 7
21
30
6
4 33
5
19
27 9
4
26 1
9
3 4
2 1
29
37 : 24 ~ 28
3
Figure 1 FG003938
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Reference Reference
Description Description
Number Number
1 Case 21 Joint Assembly
2 Plug 22 Swash Plate
3 Bushing 23 Nut
4 Spool 24 Nut
5 Shim Handle Assembly (L)
25
6 Spring Handle Assembly (R)
7 Spring Seat 25A Cap
8 Stopper 26 Handle Bar
9 Spring 27 Spring Pin
10 Stopper 28 Bellows
11 Spring 29 Bushing
12 Push Rod 30 Connector Assembly
13 Spring 32 Switch Assembly
14 Spring Seat 33 Spool Kit 1, 3
15 Stopper 34 Spool Kit 2, 4
16 Plug 35 Plug Kit 1, 3
17 O-ring 36 Plug Kit 2, 4
18 Rod Seal Handle Kit (Left)
37
Handle Kit (Right)
19 Plate
20 Boot
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Specifications
Performance
PRESSURE (kgf/cm2)
(20)
TORQUE (kgf.cm)
TORQUE (kgf.cm)
Operating Torque
15.9 3 15.4 3
5.5 2 5.5 2
Secondary Pressure
Secondary Pressure
(6.2) (5)
FG003944
Figure 2
Torques
No. Tool Standard Remark
500 kg•cm
3 Plug PF 3/8
(36 ft lb)
1,660 kg•cm
19 Swash Plate 27 mm
(120 ft lb)
1,660 kg•cm
20 Hex Nut 22 mm
(120 ft lb)
1,660 kg•cm
22 Nut 22 mm
(120 ft lb)
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DISASSEMBLY
1. Remove lead wire from bushing (29).
FG000804
Figure 3
FG000805
Figure 4
3. Remove hex nut (23) and swash plate (22) from case.
FG000806
Figure 5
FG000807
Figure 6
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5. Remove plate (19) from case (1).
FG000808
Figure 7
FG000809
Figure 8
FG000810
Figure 9
FG000811
Figure 10
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7. Remove four spool kit assemblies from case (1).
FG000812
Figure 11
FG000813
Figure 12
FG000814
Figure 13
FG000815
Figure 14
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FG000816
Figure 15
FG000817
Figure 16
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CLEANING AND INSPECTION
(WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to
"General Maintenance Procedures" section.
REASSEMBLY
1. Install four plugs (4) into case (1).
FG000815
Figure 17
FG000817
Figure 18
FG000814
Figure 19
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FG000816
Figure 20
FG000818
Figure 21
FG000819
Figure 22
FG000812
Figure 23
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4. Install spring (9) into case (1).
FG000820
Figure 24
5. Install spool kit assembly into case (1). (The same way is
used for four parts.)
FG000821
Figure 25
6. Assemble plug kit insert rod seal (18), O-ring (17), and
push rod (2) into plug (16) in proper order.
FG000822
Figure 26
FG000810
Figure 27
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7. Assemble four springs (11) and stoppers (10) and insert
assembled set in case (1) to form a plug kit assembly.
NOTE: Pay attention to measurement specifications of
stoppers (1 and 3, 2 and 4).
FG000809
Figure 28
FG000811
Figure 29
FG000823
Figure 30
FG000808
Figure 31
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9. Install joint assembly (21) into case (1).
FG000807
Figure 32
10. Install wash plate (22) and hex nut (23) into case (1).
FG000806
Figure 33
FG000824
Figure 34
12. Install boot (20) and bushing (29) into case (1).
FG000825
Figure 35
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13. Install lever assembly into case (1).
FG000805
Figure 36
14. Put lead wire in bushing (29), tie it, and arrange boot.
FG000826
Figure 37
FG000827
Figure 38
FG001097
Figure 39
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16. Assemble connector assembly (30), and connect it to lead
wire terminal, and properly route wiring.
FG000828
Figure 40
FG000829
Figure 41
START-UP PROCEDURES
1. Start engine and set throttle at "LOW IDLE."
2. Set safety lever on "UNLOCK" position.
HAOB290L
Figure 42
ARO0470L
Figure 43
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Remote Control Valve (Work Lever / Joystick) SP000069
Page 22
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SP000070
TRAVEL CONTROL VALVE (WITH DAMPER)
SP000070
Travel Control
Valve (With
Damper)
Edition 1
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MEMO
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Table of Contents
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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Travel Control Valve (With Damper) SP000070
Page 6
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GENERAL DESCRIPTION
Theory of Operation
The damper valve is divided into two areas of operation. There is
the pressure reducing valve (a) and the damper mechanism (b).
The following hydraulic circuit is an example of a remotely
located control valve.
5
6
4
2
ARS1810L
Figure 1
Reference Reference
Description Description
Number Number
1 Remote Control Valve 4 Control Valve
2 Pilot Pump 5 Hydraulic Motor
3 Main Pump 6 Hydraulic Cylinder
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Deceleration Valve
1. In neutral position, the damper spool is pushed to the
neutral position by return spring which is seated on the
spring seat (and washer. As a result of the damper spool's
switching function, the output port is connected to port T
and the pressure at the output port and port T is the same.
2. When the cam of the remote control valve is operated and
moved from the neutral position to the clockwise direction,
the push rod and damper spool of port 1 is moved down
within the constraints of washer 1, spring seat, secondary
pressure select spring, washer 2 and washer 3. As a result
port P and port 1 are connected and oil pressure from the
pilot pump flows through port 1, generating pressure.
When the pressure of port 1 reaches the selected pressure
of the secondary pressure select spring, the oil pressure
and the spring set pressure will equalize and the output
pressure of port 1 is maintained at a constant rate.
The damper spool in port 2 is in the neutral position, oil
returning from the control valve is discharged through port
T. In cases where the controls are operated to the
maximum position, the push rod makes direct contact with
the damper spool forcing port P to make a direct path with
the discharge port, permitting the pressure to equalize at
these ports.
40 160
SECONDARY PRESSURE (kg/cm2)
112.6
25±1.5
Operating Torque 91.8
46.4
7.5±1
Secondary Pressure
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Dampening Parts of the Control Section
1. In the neutral position, the push rod is pushed up to its
neutral position by the return spring and damper spring.
2. When the cam is moved in the clockwise direction from the
neutral position, the push rod and damper spool of port 1
are moved in a downward direction. At this time, the
pressurized oil in the damper spool is discharged through
the orifice and the dampening pressure is generated.
Meanwhile, the push rod in port 2 moves up with the
damper spring and the damper spool between them. At the
same time, the oil from the oil tank passes through the
check ball (3 positions) consisting of a spring and steel
ball, and flows out through port T in the upper portion of the
casing to tank.
3. When the operating levers are moved to the extreme
opposite position: When the cam is moved to the
counterclockwise position from the clockwise most
position, the push rod and piston in port 2 is moved in the
downward direction. As in the case described above, the
oil in the damping piston chamber is discharged through
the orifice and the dampening pressure is generated in this
chamber, providing dampening force. In port 1, the push
rod is moved up by the action of the return spring and
damper spring. At the same time, the oil from the oil tank
passes through the check ball (3 positions) consisting of a
spring and steel ball, and flows out through port T in the
upper portion of the casing to tank
The damping operation is effective in both operations, when the
levers are moved from the neutral position to the maximum travel
position and when the levers are moved from the maximum
travel position to the neutral position as well.
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A. When moving lever from the neutral position
Moving the lever from the neutral position to the right 1
forces oil in the right damper spool to discharged
through the orifice, generating pressure that creates
a dampening force.
2
Moving the lever in the opposite direction, causes the
left damper spool to assume the function of the right
spool. 3
HB4M033L-1
Figure 3
HB4M032L-1
Figure 4
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CAUSES OF FAULTS AND
MEASURES
At times it may be difficult to pinpoint the source of the problem.
The following table lists some of the possible problems, possible
causes and remedies. Refer to this table for possible causes and
remedies to assist in correcting the sometimes difficult
problems.
The table only lists some general problems, possible causes and
their remedies. In many cases the problem is not caused by the
failure of a single part but, may be the result of a combination of
problems from related parts and their components. Possible
problems other than the ones list are not being specified but that
is not to say that these are the only possible problems that can
occur. The technician must diagnose the problem, considering
all possible causes and repair the source of the malfunction.
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Parts List
27 31 30 29 28 33
32 25,26
24
23
3
22
16 14,15
21 36
38 17
13 18
12 19
11 20
9
6
5
7
4 10
3 8
37 1 35 34 2
P T
1 2 3 4
FG003925
Figure 5
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Reference Reference
Description Description
Number Number
1 Body (1) 20 Retaining Ring
2 Body (2) 21 Plug
3 Plug 22 O-ring
4 Plug 23 Rod Seal
5 Spring Seat 24 Dust Seal
6 Damper Spring 25 Cover
7 Spring Seat 26 Hex Socket Head Bolt
8 Damper Spool 27 Cam
9 Stopper 28 Bushing
10 Return Spring 29 Camshaft
11 Rod Guide 30 Set Screw
12 O-ring 31 Set Screw
13 Retaining Ring 32 Hex Nut
14 Push Rod 33 Bellows
15 Spring Pin 34 Spacer
16 Seal 35 O-ring
17 Steel Ball 36 O-ring
18 Damper Spring 37 Hex Socket Head Bolt
19 Cam Plate 38 Piston
Specifications
Travel Control Valve Specification
Pilot Control
Type
(With Damper)
Torques
Part Reference
Bolt Size Tool Tightening Torque
Number
88 kg•cm
26 M6 5 mm L-Wrench
(6 ft lb)
100 kg•cm
30 M8 4 mm L-Wrench
(7 ft lb)
440 kg•cm
32 M10 17 mm Spanner
(32 ft lb)
440 kg•cm
37 M10 8 mm L-Wrench
(32 ft lb)
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REMOVAL
1. Park on firm and level ground. O I
2. Lower front attachment (bucket) to ground.
3. Shut down engine.
4. Set safety lever on "RELEASED" position.
5. Turn starter switch to "I" (ON) position.
WARNING
WARNING!
PERFORMING INSPECTION
OR MAINTENANCE
FG003015
If engine must be running while performing Figure 6
maintenance, always use extreme caution. Always
have one person in the cab at all times. Never leave the
cab with engine running.
FG003016
Figure 7
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DISASSEMBLY
1. Remove bellows (33).
ARS1870P
Figure 8
FG000985
Figure 9
3. Remove cam shaft (29) and cover (25) from cam (27).
FG000986
Figure 10
4. Remove hex nut (32) and swash plate (31) from cam.
FG000987
Figure 11
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5. Remove hex socket head bolt (26) and cover (25) from
each body (1 and 2).
FG000988
Figure 12
FG000989
Figure 13
FG000990
Figure 14
FG000991
Figure 15
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8. Remove rod guide (11) from each body (1 and 2).
FG000992
Figure 16
FG000993
Figure 17
FG000994
Figure 18
FG000995
Figure 19
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10. Remove hex socket head bolt (37) from each body (1 and
2). Disassemble each body (1 and 2) and spacer (34).
Remove plugs (3 and 4) and O rings (35 and 36).
FG000996
Figure 20
FG000997
Figure 21
FG000998
Figure 22
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ASSEMBLY
1. Assemble plugs (3 and 4) and O rings (35 and 36) into
each body (1 and 2) and spacer (34). Install hex socket
head bolt (37) using torque wrench.
FG000996
Figure 23
FG000997
Figure 24
FG000998
Figure 25
FG000995
Figure 26
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3. Assemble in proper order, damper spool (8), shim (7),
spring (6), spring seat (5), and stopper (9).
FG000999
Figure 27
FG001000
Figure 28
FG000994
Figure 29
FG000992
Figure 30
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FG000993
Figure 31
FG000991
Figure 32
7. Assemble rod seal (23), dust seal (24), and O-ring (22) into
plug (21).
FG001001
Figure 33
FG001002
Figure 34
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8. Assemble seal (16), piston (38), steel ball (17), plate (19),
spring (18), and retaining ring (20) into push rod (14).
FG001003
Figure 35
FG001004
Figure 36
FG001005
Figure 37
10. Install push rod assembly into each body (1 and 2).
FG000990
Figure 38
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11. Install bushing (28) in cover (25) using jig.
FG001006
Figure 39
12. Assemble cover (28) onto each body (1 and 2) and install
hex socket head bolt (26) using torque wrench.
FG001007
Figure 40
FG000989
Figure 41
13. Install set screws (31) and hex nut (32) into cam (27) and
tighten it.
FG000987
Figure 42
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14. Position cam (27) on cover (25), and insert cam shaft (29)
using hammer.
FG000986
Figure 43
15. Install set screw (30) in cam (27) and tighten it using torque
wrench.
FG000985
Figure 44
FG001009
Figure 45
ARS2250P
Figure 46
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INSTALLATION
1. Position pedal valve (1, Figure 47) on cabin floor plate and
install four bolts and washers (2). 2
FG003016
Figure 47
2. Install pedal brackets (3) and levers (4, Figure 48) on pedal
valve and install four bolts and washers (2).
3. Install rubber boots (1, Figure 48). 1
3
3
2
2
ARS2951L
Figure 48
FG003016
Figure 49
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START-UP PROCEDURES
1. Start engine and set throttle at "LOW IDLE."
2. Set safety lever on "UNLOCK" position.
HAOB290L
Figure 50
3. Slowly push and pull both travel lever about five times
without a load to vent air from pilot lines.
HAOB903L
Figure 51
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1Electrical System
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SP000038
ELECTRICAL SYSTEMSP000038
Electrical
System
Edition 1
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MEMO
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Table of Contents
Electrical System
Safety Precautions................................................ 7
Applicable Models................................................. 7
Introduction ........................................................... 9
Electrical Supply System .................................... 10
Engine Starting Circuit........................................ 12
Start Operation .............................................................. 12
After Start ...................................................................... 14
Engine Preheating System ................................. 16
Engine Stop ........................................................ 18
Charging System ................................................ 20
Monitoring System.............................................. 21
Instrument Panel ........................................................... 22
Monitoring System Schematic....................................... 24
Operation ............................................................ 26
Instruments.................................................................... 26
Warning and Indicator Lights .............................. 28
Indication of Warning Lights .......................................... 28
Indication of Multifunction Gauge and
Letter Information Area.................................................. 29
Initial Operation................................................... 31
Mode Selector Switch ......................................... 31
Graphic Information Area Display....................... 32
Overview ....................................................................... 32
Main Menus for the Graphic Display Area ..................... 33
Menu Selector Buttons .................................................. 33
Main Menu .......................................................... 34
Language ...................................................................... 34
Set Clock ....................................................................... 35
Filter/Oil Info .................................................................. 35
Adjust Display................................................................ 36
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Set Password ................................................................ 37
Special Menu ...................................................... 38
Entering/Accessing and Exiting/Escaping Menus ......... 38
Special Menu Selections ............................................... 39
Electronic Hydraulic Control System (e-EPOS).. 56
Control System Schematic ............................................ 56
Power Mode Control ........................................... 58
Operation....................................................................... 60
Power Mode Control - Circuit Diagram ............... 64
Work Mode Control............................................. 66
Operation....................................................................... 67
Work Mode Control - Circuit Diagram................. 68
Engine Control System ....................................... 69
Engine Control Dial............................................. 70
Engine Control Circuit Diagram .......................... 72
Automatic Deceleration Control
(Auto Idle Control)............................................... 74
Engine Overheat Protection System................... 76
Power Boost Mode.............................................. 78
Operation....................................................................... 78
Power Boost Control - Circuit Diagram.......................... 80
Automatic Travel Speed Control.......................... 82
Automatic Travel Speed Control - Circuit Diagram ........ 84
Self-diagnostic Function ..................................... 85
e-EPOS Controller......................................................... 85
Air Conditioner System ....................................... 87
Outline ........................................................................... 87
Internal and External Filters .......................................... 88
Air-Conditioning System Layout .................................... 90
Air Conditioner/heater Circuit Diagram.......................... 91
Air Conditioner/heater Unit ............................................ 92
Ambient Air Temperature Sensor .................................. 97
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Sun Sensor.................................................................... 98
Control Panel................................................................. 98
Compressor................................................................. 105
Receiver Dryer ............................................................ 105
Wiper System ................................................... 106
Wiper Circuit................................................................ 106
Wiper operation ........................................................... 107
Lighting System ................................................ 110
Lighting System Circuit Diagram ................................. 110
Kind of Light ................................................................ 111
Operation..................................................................... 111
Overload Warning Device ................................. 112
Overload Warning Device Circuit Diagram .................. 112
Audio Controller ................................................ 113
Audio Controller Circuit Diagram ................................. 113
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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MEMO
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INTRODUCTION
The electrical system for this equipment is DC 24 volts. The
rated voltage for all electric components is 24 volts with the
exception of the stereo and the air-conditioning control actuator.
The system contains two 12 volt batteries connected in series
and a three phase AC generator with a rectifier. The electric
wiring used in the system is easily identifiable by the insulator
color. The color symbols used in the electrical system are listed
in the following chart.
Symbol Color
W White
G Green
Or Orange
B Black
L Blue
Lg Light green
R Red
Gr Gray
P Pink
Y Yellow
Br Brown
V Violet
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ELECTRICAL SUPPLY SYSTEM
MEMO
The electric power circuit supplies electric current to each
electric component. It consists of a battery, battery relay, starter
switch, circuit breaker, fusible link and fuse box.
The negative terminal of the battery is grounded to the vehicle
body.
Even when the starter switch (5) is in the "OFF" position, electric
current is supplied to the following components through battery
(1) → fusible link (3) → fuse box (6).
1. Terminal "1" of DC-DC converter (for memory backup of
stereo)
2. Terminal "B" of starter switch
3. Hour meter
4. Engine controller
5. Fuel feeder pump switch
6. Terminal "6" of wiper motor
7. Terminal "13" of wiper controller
8. Terminal "CN6-11" of instrument panel
9. Terminal "CN9-6" of air conditioner panel
10. Cabin light
When the starter switch (5) is in the "ON or START" positions,
the current flows from the battery (1) → fusible link (3) → fuse
box (6) → "B" terminal of starter switch (5) → "BR" terminal of
starter switch (5) → "BR" terminal of battery relay (2) which
activates the coil of the battery relay and the electric supply
system is energized.
When the battery relay's contacts are connected, all electric
devices can be operated.
While the engine is not running, the electric power for all electric
devices are supplied by the battery. Once the engine is started
the power is supplied from the alternator (7).
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ACC C
B
R2
5
BR
0.5G
R1
6
3
8
4 2
B A
BR
E
- + - +
12V 150AH 12V 150AH
R(I) B(B+) P(R)
STARTER SWITCH CONNECTION
1
PST TML B BR R1 R2 C ACC
OFF SG
ON 7
START
R
F
E
FG001476
Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM
Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode
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ENGINE STARTING CIRCUIT
MEMO
Start Operation
When the starter switch is turned to the "START" position, the
"S" and "E" terminals of the starter controller (7) are connected.
At this time the contacts in the starter relay (8) are closed by the
current flow from the battery (1) → fusible link (3) → fuse box (6)
→ "B" terminal of starter switch (5) → "C" terminal of starter
switch (5) → "30" terminal of starter relay (12) - "87a" terminal →
"C" terminal of starter relay (8) - "D" terminal → "S" terminal of
starter controller (7) - "E" terminal → ground.
When the contact point "B" and "PP" of starter relay (8) are
connected, the pinion gear of the starter (9) is pushed forward
and makes contact with the ring gear of the flywheel and the
internal contacts of the starter are connected. The current flows
from the battery (1) → "A" terminal of the battery relay (2) → "B"
terminal of the battery relay (2, Figure 3) → "B" terminal of the
starter (9). The starter motor is rotated and the engine is started.
If the instrument panel has the password function activated ,
input number should match the set number, otherwise the start
circuit closes and the engine does not start.
NOTE: If the security system is "LOCKED," a four-digit
password will be required to start the engine. If the 02/05 [MO] 11:30
system is "UNLOCKED," no password will be
required and this display screen will not appear.
ENTER
In the event the security system is locked, current PASSWORD
E F
flows from battery (1) → fusible link (3) → fuse box
(6) → "B" terminal of starter switch (5) → "ACC"
terminal of starter switch (5) → "86" terminal of C H C H
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7 8 9
N S D PP C
P C B B
B E
11
A
87a
30
87
85 86 ACC
C
B 5
R2 BR
12
R1
3
CN1-15
6
4
B A
CN2-1
BR
13 E
11
R(I) B(B+) P(R) 2
STARTER SWITCH CONNECTION
PST TML B BR R1 R2 C ACC
OFF SG
- + - +
ON 10
START R
F 1
E
FG003926
Figure 3 STARTER CIRCUIT (1) - WHILE STARTING
Reference Reference
Description Description
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
3 Fusible Link 10 Alternator
4 Circuit Breaker 11 Diode
5 Starter Switch 12 Starter Relay 2
6 Fuse Box 13 e-EPOS Controller
7 Starter Controller
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After Start MEMO
Once the engine has been started, the belt driven alternator (10)
generates a current.
The output generated by the alternator (10) is a square wave
pulse voltage through the "P" terminal and the frequency of the
pulse voltage is proportional to the rotation of the alternator.
The starter controller (7) monitors the frequency of the output
current. Once the frequency is equivalent to 500 rpm, it is
sensed and the connection between "S" and "E" terminals and
the connection between "B" and "PP" terminals are opened. As
a result the rotation of the starter (9) is stopped. Once the
engine is running, the starter (9) will not operate even if the
starter switch (5) is moved to the start position, preventing
possible damage to the starter.
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Operation of the Start Circuit (2) - Immediately After Start
7 8 9
N S D PP C
P C B B
B E
11
A
87a
30
87
85 86 ACC
C
B 5
R2 BR
12
R1
3
CN1-15
6
4
B A
CN2-1
BR
13 E
11
R(I) B(B+)
STARTER SWITCH CONNECTION
P(R) 2
PST TML B BR R1 R2 C ACC
OFF SG
- + - +
ON 10
START R
F 1
E
FG003927
Figure 4 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START
Reference Reference
Description Description
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
3 Fusible Link 10 Alternator
4 Circuit Breaker 11 Diode
5 Starter Switch 12 Starter Relay 2
6 Fuse Box 13 e-EPOS Controller
7 Starter Controller
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ENGINE PREHEATING SYSTEM
MEMO
An air heater (8) is installed in the intake manifold of the engine.
When the starter switch (5) is turned "ON," the current flows
from the battery (1) → fusible link (3) → fuse box (6) → "B"
terminal of starter switch (5) → "BR" terminalof starter switch (5)
→ "1-39" terminal of engine controller (12), causing current to
flow though "1-16" terminal of engine controller (12) → "C and
D" terminals of preheat relay (7) → "1-04" terminals of engine
controller (12) → ground.
This current flow causes the coil in preheat relay (7) to be
activated, closing contacts.
When the contacts of the preheat relay (7) are closed, the
heating coils of the air heating device (8) are heated by current
flowing from the battery (1) → battery relay (2) → preheat relay
(7) → air heater (8) → ground.
The duration of the heating cycle depends on the temperature of
engine coolant. The preheat indicator light in the instrument
panel (9) will turn "ON" during preheating cycle.
The preheat relay (7) is controlled by the engine controller (12)
and operates only at temperatures of 10˚C (50˚F) and below.
The longer the preheating period, the lower the temperature of
coolant is.
6
9 4
CN6-1,2 2
ACC C B A
PREHEAT CN7-4,5,6
L5 B 5
R2 BR
R1 BR E
10
CN4-4,5,6
CN2-1
- + - +
11 C B 1
- +
7 200A
STARTER SWITCH CONNECTION
1-33,34,35 8 TML
1-39 PST B BR R1 R2 C ACC
(1) (2)
1-16 D OFF
H + -
1-04 ON
START
12
FG001478
Figure 5 ENGINE PREHEAT CIRCUIT
Reference Reference
Description Description
Number Number
1 Battery 7 Preheat Relay
2 Battery Relay 8 Air Heater
3 Fusible Link 9 Preheat Indicator Light
4 Circuit Breaker 10 Diode
5 Starter Switch 11 e-EPOS Controller
6 Fuse Box 12 Engine Controller
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ENGINE STOP MEMO
When starter switch (5) is turned "ON" the engine controller (8)
is activated. The engine controller monitors and controls the
engine including the injector solenoid (9). It controls the fuel
deliver rate and the injection timing for each cylinder.
NOTE: There is an individual injector solenoid (9) for each of
the six cylinders. Only one soleniod is shown in
Figure 7.
When starter switch (5) is turned "OFF," the engine controller
stops suppling power to the injector solenoid (9). This stops fuel
from being injexted into the engine cylinder, thus stopping the
engine.
In the event that the engine can be shut down using the starter
switch (5), an emergency stop switch (10) is provided to shut O I
down engine. To activate the emergancy stop switch, move it to
the "I" (EMERGENCY STOP) position.
The emergency stop switch (10) is in its "O" (OFF) position
during normal operation. The switch must be moved and held in
the "I" (EMERGENCY STOP) position until the engine stops.
When released it will automatically move back to the "O" (OFF)
position.
FG001344
Figure 6 ENGINE EMERGENCY STOP
SWITCH
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STARTER SWITCH CONNECTION
PST TML B BR R1 R2 C ACC
OFF
ON
START
8
6
0.5G
3
ACC C
10 B 5
R2
1-19 2 3 BR
4 2
R1 B A
1-45
1-39 BR
E
7
9
- + - +
1
FG001473
Figure 7 ENGINE STOP CIRCUIT
Reference Reference
Description Description
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 7 Diode
3 Fusible Link 8 Engine Controller
4 Circuit Breaker 9 Injector Solenoid
5 Starter Switch 10 Emergency Stop Switch
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CHARGING SYSTEM MEMO
When the starter switch (5) is turned to the "ON" position, an
initial excited current flows to the field coil of the alternator (7)
through the battery relay (2) and circuit breaker (4). When the
engine is started from this condition the alternator (7) starts
charging. The current flows from the "B(B+)" terminal of
alternator (7) → circuit breaker (4) → battery relay (2) → battery
(1).
The alternator also supplies electric current to other electrical
components. When the alternator (7) starts to operate, a current
flows from the "R(I)" terminal of alternator → diode (8) → battery
relay (2) coil securing a path for the charging current to the
battery (1). Thus preventing the possibility of a high voltage build
up and possible damage to the electric system.
ACC C
B
R2
5
BR
0.5G
R1
6
3
8
4 2
B A
BR
E
- + - +
R(I) B(B+) P(R) 12V 150AH 12V 150AH
STARTER SWITCH CONNECTION
1
PST TML B BR R1 R2 C ACC
OFF SG
ON 7
START
R
F
E
FG001474
Figure 8 CHARGING CIRCUIT
Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode
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MONITORING SYSTEM
1
+ 2
-
5 7
8
4 R
CHECK
3 9
E F
C H C H
10
E/G SPEED 1700 RPM
6
POWER
AUTO
1 2 3 4
ESC
11
5 6 7 8
13
12
FG000547
Figure 9
Reference Reference
Description Description
Number Number
1 Instrument Panel 8 Warning Buzzer
2 Battery Pump Discharge Pressure
9
3 Light Switch Sensor
4 Return Filter Switch Hydraulic Oil Temperature
10
Sensor
5 Pilot Filter Switch
11 Fuel Sensor
6 e-EPOS Controller
12 Air Cleaner Indicator
7 Alternator
13 Engine Controller
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Instrument Panel MEMO
7 8 9 10 11 12
5 CHECK
1
3
E F
4
2
C H C H
19
6 5 4 3 2 1 8 7 6 5 4 3 2 1
13
12 11 10 9 8 7 16 15 14 13 12 11 10 9
POWER
AUTO
1 2 3 4 (CN7) (CN6)
ESC
20
14 5 6 7 8
16 18
FG000548
Figure 10
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Gauges Warning Lights Mode Selector Switches
1. Fuel Gauge 7. Charge Warning Light 13. Power Mode Selector Switch
and Indicator
2. Engine Coolant Temperature 8. Engine Oil Pressure Warning
Gauge Light 14. Work Mode Selector Switch
and Indicator
3. Hydraulic Oil Temperature 9. Coolant Temperature
Gauge Warning Light 15. Auto Idle Switch and
Indicator
4. Multifunction Gauge and 10. Engine Check Warning Light
Letter Information Area 16. Flow Adjusting Switch
11. Preheat Indicator Light
5. Digital Clock 17. Up Button Switch
12. Work Light Indicator Light
6. Hour Meter 18. Down Button Switch
19. Display Selector Switch
20. Selector Button Switch
When the engine starter switch is turned to the "I" (ON) position,
all gauge bands, switch/button indicator lights and indicator/
warning lights will turn "ON" and the alarm buzzer will sound
about two seconds.
During this functional check, a LOGO will appear on the multi
function gauge in the graphic information area
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Monitoring System Schematic MEMO
19
CN6-1
3
CN6-3
ILL.
CN6-2 +
CN6-12 -
L1
L2 CN6-11
2
17
L3 4
L4 R2 B 16
B
CN6-9
L5
CN6-10 BR
L6 14
E
1-35
CN3-7
1-34 1
2
CN3-8 8
1-33
3
1-53
4 CN3-9
1-52
20
1-51
5 CN3-10 7
6
1-29 (Preheat)
14
CN5-2
R(I) CN2-14
13
FG001472
Figure 11
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Reference Reference
Description Description
Number Number
1 Instrument Panel 11 Pilot Filter Switch
2 Pilot Buzzer 12 Return Filter Switch
3 Light Switch 13 Alternator
4 Starter Switch 14 e-EPOS Controller
5 Front Pump Pressure Sensor 15 Battery
6 Rear Pump Pressure Sensor 16 Battery Relay
7 Hydraulic Oil Temperature 17 Circuit Breaker
Sensor 18 Fusible Link
8 Fuel Sensor 19 Fuse Box
9 Pedal Pressure Switch (Optional) 20 Check Connector
10 Air Cleaner Indicator 21 Engine Controller
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OPERATION MEMO
Instruments
Sensor Specification
Function Display
Input Terminal Input Specification
Blue
Coolant ECU-CAN
61°C 102°C
Temperature Communication
41°C 107°C
C H
White Red
FG000550
Blue
48 l/min → 615 mA
210 244
150 190
230 70 l/min → 583 mA
130 (Output
170 90 l/min → 555 mA
Terminal)
Flow 110
90 130 l/min → 495 mA
Adjusting CN1-19
70 (Default Set)
CN1-20
48 210 l/min → 376 mA
(None)
FG000553 244 l/min → 260 mA
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Sensor Specification
Function Display
Input Terminal Input Specification
N = 162 f / 60
ECU-CAN N = Engine speed (rpm)
Tachometer E/G SPEED 1700 RPM Communication
f = Frequency of engine
speed sensor (Hz)
FG000049
FG000050
Main pump
discharge CN3-1
pressure FRONT PUMP 320 BAR
CN3-2
(front pump)
V = 0.00816 x P + 1.0
FG000051
V: Sensor output voltage (V)
P: Displayed pressure (Bar)
Main pump
discharge CN3-3
pressure REAR PUMP 313 BAR
CN3-4
(rear pump)
FG000052
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WARNING AND INDICATORMEMO
LIGHTS
It lights in case of no
charge [voltage of
Normally, it lights
"R(I)" terminal is
when starting engine
Charge CN2 - 14 below 12 ±1V] or
and is out after engine
overcharge [voltage
starts.
of "R(I)" terminal is
HAOA610L above 33(V)].
FG000045
Preheating period
depends on coolant
It lights during temperature.
preheating ("CN5-2"
terminal voltage is No preheating at
Preheating CN5-2 below 2V) and turns above 10°C
"OFF" after 10 sec preheating at
completion of 5°C
HAOA639L
preheating.
20 sec preheating at
below 0°C
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Input
Description Symbol Operation Remarks
Terminal
HB4O2003
Input
Description Symbol Operation Remarks
Terminal
FG000056
FG000057
FG000053
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MEMO
When pilot filter
pressure is above
Pilot Filter CN2-18
about 1 kg/cm∑ (14
psi)
FG000055
FG000554
FG001470
FG001471
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INITIAL OPERATION
Item Input (Terminal) Output (Operation and initial setting mode)
Initial When "CN6-1,2" is applied • LCD, all of LED and warning lights are turned
Operation battery voltage (starter switch "ON" and turned "OFF" after about 2 seconds.
shifts from "OFF" to "ON"
• Warning buzzer is activated and turned "OFF"
after about 2 seconds.
• Power mode: Standard mode.
• Work Mode: Digging mode.
• Auto Idle: High Output (Activation).
• Display: Indicating coolant temperature, Fuel
level, Hydraulic oil temperature, Engine speed.
• Clock: Current time display.
e-EPOS Output
Output Check
(Operation Electromagnetic
Operation Mode Proportional Pressure Swing Priority 7-Segment
mode display
LED) Reducing Valve (E.P.P.R Solenoid Valve Display
Valve) Current (mA)
No-load: 150 ±20mA
Power Mode ON Load: Variable output - 9x
Power (Max. current: 400 ±20mA)
Mode No-load: 400 ±20mA
Standard Mode OFF Load: Variable output - 7x
(Max. current: 600 ±60mA)
Work Trenching Mode OFF - ON x2
Mode Digging Mode ON - OFF x0
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GRAPHIC INFORMATION AREA
MEMO
DISPLAY
Overview
Many kinds of condition of machine are displayed on the letter
information display department. The information display
department is divided 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
selector buttons.
CHECK
5
E F
C H C H
POWER 4
AUTO
1 2 3 4
ESC
3
5 6 7 8
2
FG000557
Figure 12
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Main Menus for the Graphic Display Area
1. Main menu: Language setting, Time setting, Filter/Oil
information, Brightness adjustment, Password
2. Special menu: Information of machine status, failure
information, Information of machine operation.
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MAIN MENU MEMO
When the "ESC" button is pressed for more than 3 seconds, the
main menu screen is displayed. MAIN MENU
Main menu offers sub-menus (language setting, time setting, or 1. Language
filter/oil information, brightness adjustment, password) to the 2. Set Clock
operator.
3. Filter / Oil Info
Refer to the "Operation and Maintenance Manual" for details.
4. Adjust Display
5. Set Password
: UP : DOWN : SELECT
FG000072
Figure 13
Language
MAIN MENU
Put the cursor on Language in the main menu and put the Enter
1. Language
Button ( , 3 on Figure 12) and the language select view
appears. 2. Set Clock
The default language is Korean, but it will memorize and use the
3. Filter / Oil Info
newly set language. 4. Adjust Display
Use the Up Arrow Button ( , 1 on Figure 12) or Down Arrow
5. Set Password
Button ( , 2 on Figure 12) to move cursor to a language to be : UP : DOWN : SELECT
selected on the Language Select display and press the Enter FG000072
Button ( , 3 on Figure 12) and the selected language is Figure 14
indicated in the right bottom of the screen.
: UP : DOWN : SELECT
FG000783
Figure 15
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Set Clock
MAIN MENU
It is used to adjust time of the digital clock.
1. Language
Pressing the Enter Button ( , 3 on Figure 12) in the Main 2. Set Clock
Menu after putting cursor on Set Clock brings Set Clock display.
3. Filter / Oil Info
Without pressing a button more than 20 seconds, the default 4. Adjust Display
view appears.
5. Set Password
Please refer to the Operation Manual for detailed information on
Time Setting. : UP : DOWN : SELECT
FG000075
Figure 16
SET CLOCK
06:05
2004 06/29
: + : : MOVE
FG000076
Figure 17
Filter/Oil Info
MAIN MENU
This mode displays total operating hours of filters and oils.
1. Language
After changing the filter and oil, reset the operating hour and 2. Set Clock
then the operating hours until the next service interval can be
easily checked. 3. Filter / Oil Info
4. Adjust Display
5. Set Password
: UP : DOWN : SELECT
FG000077
Figure 18
1. Fuel Filter
Hrs : 0025
: UP : DOWN : RESET
FG000078
Figure 19
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Menu Display Order and Icon Explanation MEMO
1. Fuel Filter 2. Air Cleaner 3. Engine Oil Filter 4. Hyd. Oil Filter
Adjust Display
MAIN MENU
Pressing the Enter Button ( , 3 on Figure 12) in the main
1. Language
menu after putting cursor on Adjust Display brings Adjust
Display. 2. Set Clock
Screen brightness can be adjusted using the Up Arrow Button
3. Filter / Oil Info
( , 1 on Figure 12) or the Down Arrow Button ( , 2 on Figure 4. Adjust Display
12). 5. Set Password
The default brightness is set to 50%. : UP : DOWN : SELECT
FG000080
Figure 21
Adjust Display
50%
+
LCD TEST
LCD TEST
LCD TEST
: + :
FG000081
Figure 22
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Set Password
MAIN MENU
This menu is used to apply (lock), release, or change password.
1. Language
Please refer to the Operation Manual for detailed information on 2. Set Clock
Password Setting.
3. Filter / Oil Info
4. Adjust Display
5. Set Password
: UP : DOWN : SELECT
FG000227
Figure 23
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SPECIAL MENU MEMO
In this menu, many types of operating conditions and functions
can be accessed and displayed, including the e-EPOS
controller. This menu is mainly used for machine testing and
failure diagnostics.
The special menu offers three sub-menus:
1. Machine status.
2. Failure information.
3. Information on machine operation.
Entering/Accessing Menus
1 4
When normal mode screen is displayed, if the enter button ( ,
3) and escape button (ESC, 4) are pressed simultaneously for
POWER
more than 3 seconds, normal mode screen (Figure 25) will be AUTO
changed to special menu screen (Figure 26). 1 2 3 4
ESC
5 6 7 8
2 3
FG001402
Figure 24
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Special Menu Screen
NOTE: Displayed language on the special menu screen SPECIAL MENU
consists of Korean and English. 1. Machine Info
If any language except for Korean is selected during
language selection mode of main menu, only English 2. Failure Info
will be displayed on special menu screen.
3. Operating Hrs
: UP : DOWN : SELECT
FG000558
Figure 26
Exiting/Escaping Menus
1. If escape button (ESC, 4 on Figure 24) is pressed for more
than 1 second, the special menu screen will be returned to
the normal mode screen.
2. If this special menu is "ON" without any activity, for more
than 20 seconds, it will turn to the normal mode screen.
3. After the turning starter switch to the "OFF" position, turn it
back to the "ON" position, and the normal mode screen
displayed once again.
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Analog Inputs Description
Submenu Selections
: UP : DOWN Page:3/3
FG003928
Figure 29
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Digital Inputs Descriptions
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Menu Select
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Digital Outputs Descriptions
Menu Select
DIGITAL OUTPUT STATE
1. Relief Press. Up S/V :
2. High Speed S/V :
3. Swing Priority S/V :
4. Reverse Fan S/V : N.A
5. Starter Relay :
6. Afterheat Relay : N.A
: UP : DOWN Page:1/1
FG003930
Figure 31
Failure Information
1. Entering Sub-menus: When a cursor is located in "Failure SPECIAL MENU
Info" of special menu screen press enter button ( , 3 on 1. Machine Info
Figure 24) and "Failure Info" screen is displayed.
2. Exiting Sub-menus: If escape button (ESC, 4 on Figure 24) 2. Failure Info
is pressed for more than 1 second, this information screen
will be returned to previous screen. 3. Operating Hrs
: UP : DOWN : SELECT
FG000563
Figure 32
* Real-time Failure:
Current status of failure is displayed. FA I L U R E I N F O
* Failure Log:
Memorized record of past failure is displayed.
1. Realtime Fail
* Delete Fail Log: 2. Failure Log
This mode is used to delete all of the
memorized record of past failure.
3. Delete Fail Log
: UP : DOWN : SELECT
FG000564
Figure 33
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A. Current failure information
Current status of failure is displayed (Failure code, R E A LT I M E FA I L
failure contents). 1/2 CODE : V204-05
When a number of failures are produced, failure 2/2 CODE : E011-04
information can be checked using "UP" ( , 1 on
Relief Pressure Up S/V
Figure 24) or "DOWN" ( , 2 on Figure 24) button.
Current below normal (CURRENT
* 1/2: A serial number of current failure/ total quantity BELOW NORMAL or open circuit)
of failure.
: UP : DOWN
* Vxxx-xx: Vxxx is a unique code and xx is a FMI FG000565
(Failure Mode Identifier) number. Figure 34
- V: Machine related failure code
- E: Engine related failure code
Refer to the failure information code for unique codes
and FMI numbers.
This example shows one of two failures.
B. Past failure information
Memorized record of past failure is displayed (Failure FA I L U R E L O G
code, failure contents). 1/2 CODE : V204-05
When a number of failures are produced, failure 2/2 CODE : E011-04
information can be checked using "UP" ( , 1 on Period:00254Hr 29m Number:08
Figure 24) or "DOWN" ( , 2 on Figure 24) button. Relief Pressure Up S/V
Current below normal (CURRENT
NOTE: " Number: xxx ": "xxx" means that the BELOW NORMAL or open circuit)
totally counted number of the same failure.
: UP : DOWN
" Period:xxxxxHrxxm ": It indicates the FG000566
period for which machine has operated Figure 35
until a failure takes place. (For more than
two occurrences of the same failure, until
the first occurrence time.)
C. Failure record deletion
This mode is used to delete the memorized record of DELETE FAIL LOG
past failure. If this mode is selected, all records will be
deleted.
All Fail Log will be
When "YES" ( , 3 on Figure 24) button is pressed,
the memorized record will be deleted. DELETED.
At 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. : Yes ESC: No
FG000567
Figure 36
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Input your password with one of No. 1 - 8 switches.
When "NO" (ESC, 4 on Figure 24) button is pressed, DELETE FAIL LOG
the screen will recover to previous menu without
deletion.
ENTER PASSWD
: Yes ESC: No
FG000568
Figure 37
DELETED! ! !
: Yes ESC: No
FG000569
Figure 38
: Yes ESC: No
FG000570
Figure 39
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Failure Information Code at Machine Side
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Measuring Correct Value
Code Failure Component Remarks
Points Active Passive
CN3-1 It has to be
V220 Front Pump Press. Sensor V = IV - measured in
CN3-2
engine stop
CN3-3 state.
V221 Rear Pump Press. Sensor V = IV -
CN3-4
R = 2.45 ±0.25
kΩ (25°C
CN3-9
V222 Hyd. Oil Temperature Sensor - (77°F))
CN3-10
R = 320 ±32 Ω
(80°C (176°F))
V223 Water Temperature Sensor - - N.A.
V224 Engine Speed Sensor - - N.A.
Empty: 5 ±0.25
CN3-7 kΩ
V225 Fuel Level Sensor -
CN3-8 Full: 320 ±32
Ω
It has to be
CN2-14 measured in
V226 Alternator Potential V = 2 ±1V -
engine stop
CN1-8
state.
R = 1.0 ±0.3
CN3-16 kΩ
V227 Dial -
CN3-7 R = 4.0 ±1.5
kΩ
V228 Tps (Wheel) - - N.A.
V229 Parking Brake Press. Sensor - - N.A.
V230 E/g Control Motor Sensor - - N.A.
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Failure Information Code at Engine Side
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Measuring Current Valve
Code Failure Component Remarks
Points Active Passive
2-23
E043 E/G speed (Camshaft) - -
2-30
Synchronizing
error between
crank shaft
E044 Engine speed sensor - -
speed sensor
and cam shaft
speed sensor.
Data storing
E045 EEPROM - - error when
engine stop.
E046 Recovery - -
When the
pressure
sensor of
E047 Monitoring of PRV - - common rail or
high-pressure
pump has a
defect.
1-13
E048 Power supply V = V_volt -
1-15
E049 Booster voltage C1 - -
Booster voltage C2 (#6, 2
E051 and 4)
- -
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Measuring Current Valve
Code Failure Component Remarks
Points Active Passive
Fuel metering
Fuel HI pressure pump
unit error of
E083 (E/G: Current controlled - - -
high-pressure
Highside power stage 1)
pump.
Power supply
System start-up test for error
E091 shutoff path
- - -
Engine
controller error.
Injector error
Speed signal
Monitoring of misfire cylinder error of cam
E092 1
- - - shaft speed
sensor or
crank shaft
speed sensor.
Monitoring of misfire cylinder
E093 2
- - -
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FMIs (Failure Mode Identifier)
FMI 0 Above normal range (DATA VALID but ABOVE NORMAL OPERATIONAL RANGE)
FMI 1 Below normal range (DATA VALID but BELOW NORMAL OPERATIONAL RANGE)
FMI 2 Incorrect signal (DATA ERRATIC, INTERMITTENT OR INCORRECT)
FMI 3 Voltage above normal (VOLTAGE ABOVE NORMAL OR SHORTED TO HIGH SOURCE)
FMI 4 Voltage below normal (VOLTAGE BELOW NORMAL OR SHORTED TO LOW SOURCE)
FMI 5 Current below normal (CURRENT BELOW NORMAL OR OPEN CIRCUIT)
FMI 6 Current above normal (CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT)
FMI 8 Abnormal signal (ABNORMAL FREQUENCY OR PULSE WIDTH OR PERIOD)
FMI 11 Failure mode not identifiable (ROOT CAUSE NOT KNOWN - Malfunction)
FMI 31 NOT AVAILABLE OR CONDITION EXISTS
Reset Hours
: UP : DOWN : SELECT
FG000572
Figure 41
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C. Operating Hours Screen
D. Exiting Sub-menus: If escape button (ESC, 4 on
OPERATING HOURS
Figure 24) is pressed for more than 1 second, this 1. Power : 00042 Hr
information screen will be returned to previous 2. Trenching : 00003 Hr
screen. 3. Auto idle : 00005 Hr
4. Travel speed
I speed : 00007 Hr
II speed : 00001 Hr
: UP : DOWN : SELECT
FG000573
Figure 42
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Menu Selection of Operation Hour Information
1. Power Mode 2. Trenching Mode 3. Auto Idle 4. Travel Speed 1st, 2nd
OPERATING HOURS
6. Coolant Temp. [ C]
40 : 00003 Hr
41 - 60 : 00005 Hr
61 - 85 : 00000 Hr
86 - 95 : 00000 Hr
96 - 105 : 00007 Hr
106 : 00001 Hr
: UP : DOWN Page:3/3
FG000575
Figure 44
: UP : DOWN : Yes
FG000578
Figure 45
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B. Reset screen of operation hour
C. Exiting Sub-menus: If escape button (ESC, 4 on OPERATING HOURS
Figure 24) is pressed for more than 1 second, this
information screen will be returned to previous
screen.
All Operating
Hours will be
NOTE: When "YES" ( , 3 on Figure 24) button is
DELETED.
pressed, operation hours will reset.
At this time, resetting signal will be displayed
and the screen will move to previous menu after : Yes ESC: No
resetting. FG000579
NOTE: When "NO" (ESC, 4) button is pressed, the Figure 46
screen will recover to previous menu without
resetting.
ENTER PASSWD
: Yes ESC: No
FG000576
Figure 47
DELETED!!!
: Yes ESC: No
FG000577
Figure 48
: Yes ESC: No
FG001086
Figure 49
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SP000038 Electrical System
Page 55
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ELECTRONIC HYDRAULIC
CONTROL SYSTEM (e-EPOS)
16
6 6
7 7 11 12 14
8
8
13
15
E/G
4 4 5
3
9 10
Work Mode
Auto Idle
Machine Info
2
CHECK
E F
C H C H
23 1
POWER
2
AUTO
3 4
ESC
5 6 7 8
R UP
WE
PO
1
17 21 19 18 22 20
FG000795
Figure 50
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Reference Reference
Description Description
Number Number
1 Instrument Panel 11 Solenoid Valve (Boost)
2 e-EPOS Controller 12 Solenoid Valve (Swing Priority)
3 Engine Controller (ECU) 13 Solenoid Valve (High Speed)
4 Main Pump 14 Solenoid Valve (Breaker)
5 Aux Pump 15 Travel Motor
6 Control Valve 16 Main Relief Valve
7 Pressure Switch 17 Engine Control Dial
8 Pump Pressure Sensor Breaker/Boost/Shear Selector
18
Electromagnetic Proportional Switch
9 Pressure Reducing Valve 19 Auto Travel Selector Switch
(Attachment) 20 Boost Switch (Right Work Lever)
Electromagnetic Proportional 21 Sensor
10 Pressure Reducing Valve (Mode
22 Aux Mode Switch
Control)
23 Aux Mode Resistor
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POWER MODE CONTROL
6 6
E/G
5
4 4
3
10
2
1
POWER
AUTO
1 2 3 4
ESC
17 5 6 7 8
23 22
FG000796
Figure 51
Reference Reference
Description Description
Number Number
Instrument Panel (Power Mode 10 Electromagnetic Proportional
1
Selector Switch) Pressure Reducing Valve (Mode
2 e-EPOS Controller Control)
3 Engine Controller (ECU) 17 Engine Control Dial
4 Main Pump 22 Aux Mode Switch
5 Aux Pump 23 Aux Mode Resistor
6 Control Valve
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The power mode switch permits the selection of the appropriate
engine power depending on the working condition. One of the
two, Power Mode or Standard Mode, setting can be selected.
When the engine starter switch is turned "ON," the power mode
is automatically defaulted to standard mode. The desired mode
can be selected by pressing the selector button on the
instrument panel. When the power mode is selected, the
indicator light will turn "ON" to display the selected mode.
The quantity of oil discharged by the pump and the engine
speed are determined by the mode selected by the operator.
The pump output in each mode is determined by the mode
selection and is listed in the following table
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Operation
1. Power Mode
This mode should be selected for high speed work. In this
mode the engine output is most efficiently utilized due to
the discharged oil volume being controlled based on the
equivalent horsepower curve at various loaded pressures.
The e-EPOS controller compares the target engine speed
with the actual engine speed and controls the signal to the
E.P.P.R. (Electromagnetic Proportional Pressure
Reducing) valve which in turn varies the pump output
quantity.
If the load increases, the engine speed will fall below the
rated speed. When this occurs, the controller senses this ARO0260L
decrease and immediately reduces the pump discharge Figure 52
volume to maintain the engine speed at the rated level.
On the other hand, if the load is decreased the controller
increases the discharge volume of the pump to maintain
the engine speed at the rated level.
By repeating these control operations, the engine speed is
maintained at the rated speed so that maximum power can
be generated.
In Power Mode, the e-EPOS controller receives engine
speed signals from the engine control dial and the engine
controller (ECU) and converts it to an operating signal
current and is then transferred to the pump's E.P.P.R valve.
At this time the E.P.P.R. valve converts the electric signal to
the corresponding control pressure and sends it to the two
pumps, adjusting the pump discharge volume to the
desired level.
B D
FG000580
Figure 53
Reference Reference
Description Description
Number Number
A Engine Horsepower (hp) D Pump Discharge Pressure (kg/
B Engine Speed (rpm) cm2)
C Pump Discharge Volume (lpm)
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2. Standard Mode
Standard Mode is used for general work. When this mode
is selected it will reduce noise and fuel consumption 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 C
B D
FG000581
Figure 54
Reference Reference
Description Description
Number Number
A Engine Horsepower (hp) D Pump Discharge Pressure (kg/
B Engine Speed (rpm) cm2)
C Pump Discharge Volume (lpm)
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SP000038 Electrical System
Page 63
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POWER MODE CONTROL -
CIRCUIT DIAGRAM
1
15A
CN6-1
CN6-2
26
4 26 15A 26 10A
CN6-9
25
CN6-10
CN1-1
CN7-4 CN4-4 CN1-2
CN7-5 CN4-5 CAN
CN7-6 CN4-6
CN1-8 24
CN1-9 11
3
23
1-35
1-34 22
1-33 CN1-10 1 10
5
P/V-(A)
1-53 2
1-52 CN1-21 3
VEHICLE 6
1-51 4
CONN
(CONN.1) 1-03
1-09
17
+(5V) CN3-15 1
1-14 CW LOW
SIG CN3-16 2
1-15
GND CN3-17 3
HIGH
1-01
1-07
1-12
15A 26
1-13
1-39 BR B 10A 26
28
AMP 070 16P AMP 040 12P AMP 040 20P AMP 070 18P AMP MIC 21P
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
18 35 6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 17
12 11 10 9 8 7 16 15 14 13 12 11 10 9
36 53
7 11 54 71
(CN7) (CN6)
1 6 72 89
FG000582
Figure 55
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Reference Reference
Description Description
Number Number
1 Instrument Panel 23 Aux Mode Resistor
3 Engine Controller 24 Battery
4 e-EPOS Controller 25 Battery Relay
10 E.P.P.R. Valve (Electromagnetic 26 Fuse
Proportional Pressure Reducing) 27 Fusible Link
17 Engine Control Dial 28 Starter Switch
22 Aux Mode Switch
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WORK MODE CONTROL
6 6
12
E/G
5
3 4 4
2
1
POWER
AUTO
1 2 3 4
ESC
17 5 6 7 8
FG000797
Figure 56
Reference Reference
Description Description
Number Number
Instrument Panel (Trenching 5 Aux Pump
1
Mode Selector Switch) 6 Control Valve
2 e-EPOS Controller 12 Solenoid Valve
3 Engine Controller 17 Engine Control Dial
4 Main Pump
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Operation
1. Digging Mode
This mode is used for general digging work, loading work
and ground leveling work requiring quick stops. The current
to the solenoid valve for swing priority is shut off.
2. Trenching Mode
This mode is used for heavy duty ditch digging work or for
loading work requiring big swing angles. The voltage is
assigned to the swing priority control valve activating the
swing control valve restricting the flow of oil to the boom
and the arm.
ARO0270L
Figure 57
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WORK MODE CONTROL -
CIRCUIT DIAGRAM
15A
CN6-1
CN6-2
26
4 26 15A
CN6-9 25
CN6-10
CN1-1
CN7-4 CN4-4 CN1-2
CN7-5 CN4-5 CAN
CN7-6 CN4-6
24
12
(C5)
CN1-13
CN1-8
CN1-9
AMP 070 16P AMP 040 12P AMP 040 20P AMP 070 18P AMP MIC 21P
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
AMP 040 28P
6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
(CN7) (CN6)
FG000583
Figure 58
Reference Reference
Description Description
Number Number
1 Instrument Panel 24 Battery
2 e-EPOS Controller 25 Battery Relay
12 Solenoid Valve (Swing Priority) 26 Fuse
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ENGINE CONTROL SYSTEM
FG000584
Figure 59
Reference Reference
Description Description
Number Number
3 Engine Controller 17 Engine Control Dial
4 e-EPOS Controller
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ENGINE CONTROL DIAL
CCW ( 10 ) ( 10 ) CW
MECHANICAL MECHANICAL
STOP STOP
(V)
5
4.0V
4
3 2.5V
2
2 1.0V
1
0 SETUP
1ST 2nd 7th 12th 13th
CCW CW
STOP STOP
FG000866
Figure 60
Reference Reference
Description Description
Number Number
1 Knob 2 Potentiometer (Variable Resistor)
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The engine control dial has a built in potentiometer. When the
control knob is moved the output voltage (through "2 and 3"
terminals) will vary from the 5 V supplied from the e-EPOS
controller as shown in the graph.
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ENGINE CONTROL CIRCUIT
DIAGRAM
1
15A
CN6-1
CN6-2
26
4 26 15A
CN6-9 25
CN6-10
CN1-1
CN7-4 CN4-4 CN1-2
CN7-5 CN4-5 CAN
CN7-6 CN4-6
CN1-8 24
CN1-9 28
3
1-35
1-34
1-33
1-53
1-52
VEHICLE 1-51
29
CONN Py
CN2-15
(CONN.1) 1-03
17
1-09
Px +(5V) CN3-15 1
1-14 CN2-16 CW LOW
SIG CN3-16 2
1-15
GND CN3-17 3
1-01
30 HIGH
1-07
26 15A
1-12
1-13
BR B 10A
1-39
27 26
AMP 070 16P AMP 040 12P AMP 040 20P AMP 070 18P AMP MIC 21P
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
18 35 6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 17
12 11 10 9 8 7 16 15 14 13 12 11 10 9
36 53
7 11 54 71
(CN7) (CN6)
1 6 72 89
FG000585
Figure 61
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Reference Reference
Description Description
Number Number
1 Instrument Panel 26 Fuse
3 Engine Controller 27 Starter Switch
4 e-EPOS Controller 28 Fusible Link
17 Engine Control Dial 29 Pressure Switch (Py)
24 Battery 30 Pressure Switch (Px)
25 Battery Relay
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AUTOMATIC DECELERATION
CONTROL (AUTO IDLE
CONTROL)
E/G
4
3
1
POWER
AUTO
1 2 3 4
ESC
5 6 7 8
5 5
FG000798
Figure 62
Reference Reference
Description Description
Number Number
1 Instrument Panel (Auto Idle Switch) 4 Engine Control Dial
2 e-EPOS Controller 5 Pressure Switch
3 Engine Controller
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If the machine is idling without the controls being operated or is
waiting for a dump truck the engine speed is automatically
lowered. Once the controls are operated and work is being
started the machine will be restored to the previous settings. As
a result, noise and fuel consumption will be reduced. This
function can be selected or cancelled through the Auto Idle
Selector Switch on the instrument panel.
The initial setting at start-up is with this switch in the select
position. Approximately 4 seconds after this function is selected,
if all work levers are in the neutral position, the e-EPOS
controller compares the automatic reduction signal with the
signal set by engine control dial. The lower of the two signals is
selected, the e-EPOS controller sends a signal to the engine
controller to control the engine speed.
The neutral status of the machine is detected by the two
pressure switches in the control valve. When the work levers are
in the neutral position, the switch is in the "OFF" position.
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ENGINE OVERHEAT
PROTECTION SYSTEM
6 6
E/G
4 4 5
3
31
7
(Pump control signal)
2
1
(E/G overheating signal)
CHECK
E F
POWER
AUTO
1 2 3 4
ESC
5 6 7 8
FG000802
Figure 63
Reference Reference
Description Description
Number Number
1 Instrument Panel 6 Control Valve
2 e-EPOS Controller 10 E.P.P.R. Valve (Electromagnetic
3 Engine Controller Proportional Pressure Reducing
Valve)
4 Main Pump
31 Warning Buzzer
5 Aux Pump
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When the engine coolant temperature increases to over 107°C
(225°F), the engine controller detects it from the sensor
mounted in the coolant line and will send a signal to the e-EPOS
controller. The e-EPOS controller sends a overheat signal to the
instrument panel turning "ON" the warning light and buzzer
simultaneously.
Also, the e-EPOS controller returns an overheat signal to the
engine controller and changes power mode to standard mode.
The engine speed is then set to a low speed by the engine
controller.
When coolant temperature falls below 95°C (203°F), normal
operation will resume.
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POWER BOOST MODE
Operation
16
6 6
11
E/G
4 4 5
3
2 1
CHECK
E F
C H C H
UP
WER POWER
PO AUTO
1 2 3 4
20
ESC
5 6 7 8
18
FG000800
Figure 64
Reference Reference
Description Description
Number Number
1 Instrument Panel 11 Solenoid Valve (Boost)
2 e-EPOS Controller 16 Main Relief Valve
3 Engine Controller Breaker/Boost/Shear Selector
18
4 Main Pump Switch
5 Aux Pump Power Boost Switch (Top of Right
20
Work Lever)
6 Control Valve
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The Power Boost function is used to temporarily increase the
main relief pressure to enhance excavation ability. When the
breaker/boost/shear selector switch is set to "BOOST" and the
power boost button on the center of the right-hand work lever
(joystick) is pressed during work, the e-EPOS controller will
activate the power boost solenoid valve and increase the relief
valve pressure from 330 - 350 kg/cm2 (4,700 - 5,000 psi). The
excavation ability is increased by approximately 6%.
When the power boost function is in activated, a power boost
symbol appears on the information display department of
instrument panel.
NOTE: Do not use this switch for more than 10 seconds.
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Power Boost Control - Circuit Diagram
1
15A
CN6-1
CN6-2
26
2 26 15A 26 20A
CN6-9 25
CN6-10
CN1-1 18
CN7-4 CN4-4 CN1-2
CN7-5 CN4-5 CAN
CN7-6 CN4-6 PST SHEAR PRESS BREAKER
UP
TML 1 0 2
9
24
11 10
3
(C4) 14
CN1-11
13
11
6
CN2-2 (POWER MAX)
16
15
CN1-8 12
CN1-9
6 3
(Center)
(POWER MAX / BREAKER)
20
AMP 070 16P AMP 040 12P AMP 040 20P AMP 070 18P AMP MIC 21P
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
AMP 040 28P
6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
(CN7) (CN6)
FG000586
Figure 65
Reference Reference
Description Description
Number Number
1 Instrument Panel 20 Power Boost Switch (Top of Right
2 e-EPOS Controller Work Lever)
11 Solenoid Valve (Pressure Up) 24 Battery
18 Breaker/Boost/Shear Selector 25 Battery Relay
Switch 26 Fuse
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SP000038 Electrical System
Page 81
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AUTOMATIC TRAVEL SPEED
CONTROL
6 6
13
E/G 8
15
4 4 5
3
17 2 19
FG000799
Figure 66
Reference Reference
Description Description
Number Number
2 e-EPOS Controller 8 Pump Pressure Sensor
3 Engine Controller 13 Solenoid Valve (High speed)
4 Main Pump 15 Travel Motor
5 Aux Pump 17 Engine Control Dial
6 Control Valve Selector Switch For Automatic
19
7 Pressure Switch (Py Port) Travel
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If the automatic travel speed control switch is set to the "OFF"
position, the travel motor will run in the I-speed (low speed)
range. If the selector switch is set to the "I" position, the travel
motor will run in the II-speed (high speed) range. If the selector
switch is set to the "II" position, the e-EPOS controller will
monitor the main pump discharge pressure and automatically
select the "ON" - "OFF" status of the II - speed travel solenoid
valve based on the travel load. The travel speed is changed
between the I-speed and the II-speed mode.
The travel load is monitored by the two pressure sensors in the
discharge lines of the front (upper) and rear (lower) pumps.
When the travel load is high (pressure over 300 kg/cm2 (4,300
psi) the solenoid valve is turned "OFF" and I-speed (low) is
selected. In the case when the travel load is low (pressure under
160 kg/cm2 (2,280 psi), the solenoid valve will be turned "ON"
and the II-speed will be selected. But, if the engine speed control
switch dial is set below approximately 1400 rpm, the travel
speed will be set to I-speed mode.
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Automatic Travel Speed Control - Circuit
Diagram
15A
26
2 26 15A 26 15A
25
8 CN1-1
+ CN1-2
SIG CN3-1
CN3-2
- 13
(C3) 24
+ CN1-12
SIG CN3-3
CN3-4
- 19
9 3
0
2
CN2-4 I
II
0
I 5
CN2-5 6 II
7 8
17
CN1-8 +(5V) CN3-15 1
CW LOW
CN1-9 SIG CN3-16 2
GND CN3-17 3
HIGH
AMP 070 16P AMP 040 12P AMP 040 20P AMP 070 18P AMP MIC 21P
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
AMP 040 28P
6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
(CN7) (CN6)
FG000587
Figure 67
Reference Reference
Description Description
Number Number
2 e-EPOS Controller Selector Switch For Automatic
19
8 Pressure Sensor (Front Pump) Travel
9 Pressure Sensor (Rear Pump) 24 Battery
13 Solenoid Valve (High speed) 25 Battery Relay
17 Engine Control Dial 26 Fuse
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SELF-DIAGNOSTIC FUNCTION
e-EPOS Controller
The system operation status and malfunction codes can be
checked through the display on top of the e-EPOS controller box
the rear cover behind the operator's seat.
1 2
4 3
FG000588
Figure 68
Reference Reference
Description Description
Number Number
1 Upper Digit Power Monitor (Stays "ON" While
4
2 Lower Digit Power Is In Normal Range,)
Engine Speed Monitor LED
3 (Flash Interval Increases With
Engine Speed.)
1. Power Monitor
This LED is turned "OFF" when the input voltage to the
e-EPOS controller is below 18.5 ±1 V or above 32.5 ±1 V.
Stays "ON" while in normal range.
2. Engine Speed Monitor
This LED light flashes according to the engine speed. The
flashing interval is proportional to the engine speed.
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3. Normal Operation Display Readout
Display Readout
Mode Selection Operation Status
Upper Digit Lower Digit
Normal Operation
Power Mode
Power Mode
HAOH340L
Power Mode
Normal Operation
Standard Mode
Standard Mode
HAOH350L
Normal Operation
Digging
Digging Mode
HAOH370L
Work Mode
Normal Operation
Trenching
Trenching Mode
HAOH380L
4. Communication Monitor
What are shown in the 7-SEGMENT LED are same as
those in the Error Codes.
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AIR CONDITIONER SYSTEM
Outline
A
C
FG000784
Figure 69
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(Please refer to the Operation Manual for detailed full automatic
control.
Vent mode selects the direction of discharged air.
Outlets by vent modes
Modes
FG000422
Figure 70
Donaldson.
FG000440
Figure 71
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2. Turn marked knobs (1, Figure 72) at the rear side of the
cabin to open the cover.
FG000441
Figure 72
FG000342
Figure 73
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Air-Conditioning System Layout
10
11
2
5
6
5
7
4
1
8
9 FG001464
Figure 74
Reference Reference
Description Description
Number Number
1 Air Conditioner/heater Unit 7 Liquid Hose (1)
2 Condenser 8 Liquid Hose (2)
3 Compressor 9 Ambient Temperature Sensor
4 Receiver Dryer 10 Sun Sensor
5 Discharge Hose 11 Control Panel
6 Suction Hose
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Air Conditioner/heater Circuit Diagram
0.5RW
FUSIBLE LINK
LAMP SWITCH
A/C THERMO (LOW) 105B CN9-8 0.5LB CN10-5 105A CN11-4 0.85LW 47C
DIODE 4
1.25B CN11-1 99 - +
M
107B CN8-12 0.5LW CN10-1 107A 0.85B 0.85B
BLOWER
99 CN9-10 1.25B
20 19 18 17 16 15 14 13 12 11 10
4 3 18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
FG001463
Figure 75
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Air Conditioner/heater Unit
Cold Box
Internal Air Inlet
Outlet
Vent Rear
Outlet
Vent
Front
Outlet
Foot
DEF Outlet
Outlet
External Air
VENT
COOL
DOOR
DOOR -INTAKE
-MIX
DEF Internal Air
WARM
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Door Open by Vent Modes
Mode
Door
Vent Bi-level Foot Def/foot Def
Vent 100 60 0 0 0
Foot 0 40 100 80 60
Def 0 0 0 20 40
Main Components
Internal
Internal Air Sensor
Air Filter
Actuator Water Temp Evaporator
-Wind Direction Sensor FG001360
Control
Figure 77
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Actuator - Wind Direction Control
Change of discharged air flow according to selected wind
direction mode
Change of wind direction: Direction changes in the order of
VENT→ BI-LEVEL → FOOT → FOOT/DEF → VENT.
FG001361
Figure 78
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Actuator - Internal/external Air Exchange
CN10-20 CN10-2
FG001055
Figure 79
DRAIN
(CN10-1)
SOURCE GATE
(CN11-1) (CN10-6)
FG001056
Figure 80
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The air flow is based on manual set.
Relay - Blower: Power is supplied to the blower motor when the
system is turned "ON."
Specifications
Rated voltage 24V
Rated current 20A
Figure 81
Specifications
Rated voltage 24V L S1 (+)
Rated current 10A
B S2
(-)
FG001058
Figure 82
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Water Temperature Sensor: It senses the temperature of
coolant water in the heater core.
Figure 84
Figure 85
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Sun Sensor
Built beside the socket of spare power, it senses the quantity of
the sun radiation to optimize discharge temperature and air flow
as set by operator.
83.7
OUTPUT VOLTAGE(mV)
76.2
67.7
58.8
46.6
36.0
21.4
Control Panel
A/C OUTSIDE
AUTO A/C
AUTO MAX
TEMP
OFF
SEL MODE
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
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Terminal Terms
Control Logic
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Categories Inputs System Operation
Sensor Set temperature 1. In case of sensor failure, following defaults are applied:
compensatio
Internal air temperature Internal air temperature sensor: 25°C, Ambient air
n
sensor temperature sensor: 25°C, Duct sensor: -2°C
Ambient air temperature Temperature control actuator:
sensor
- Set Temperature 17 - 24.5°C: Max cooling, Set
Water temperature sensor Temperature 25 - 32°C: Max heating
Wind direction mode actuator
- VENT: VENT fix, modes other than VENT: Fixed to DEF
* Sun sensor is not compensated.
Max cooling/ Auto Setting 1. Set Temperature 32°C: Max heating
heating
2. Set Temperature 17°C: Max cooling
control
Temp Control
FULL COOL FULL HOT
Actuator
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Categories Inputs System Operation
1. Start condition (AND condition)
(1) When wind direction mode is one of the following modes
in the Auto or manual control mode
- BI-LEVEL, FOOT or FOOT/DEF
(2) The Water temperature sensor is stable and the water
temperature < 73°C
(3) Air flow: Auto mode
(4) Set temperature > Internal air temperature + 3°C
* Air flow falls gradually up to 12 seconds when operation
released.
Water temperature sensor 2. One time control in the cycle of engine OFF → engine run
Starting Internal air temperature 3. Initial heating control should be before max heating.
control of sensor
4. Air flow is controlled only when the wind direction is in the
heating (1) Auto mode manual mode and BI-LEVEL, FOOT, or FOOT/DEF is set.
Set Temperature 5. Control through the water temperature sensor for start.
6. Starting control of heating (2) starts in case of fault of the
water temperature sensor during controlling.
7. Operation release (OR condition)
(1) Only air flow is released if it is selected manually.
(2) When handling the wind direction mode switch, only
wind direction is released but the air flow control is
performed only for the remaining period of the starting
control of heater.
(3) When Max Cooling (17°C) is selected.
(4) Water temperature sensor > 73°C.
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Categories Inputs System Operation
Starting Water temperature sensor 1. Entry condition (AND condition)
control of
Ambient air temperature (1) Auto Mode
heating (2)
sensor
(2) Ambient air temperature < 5°C and difference between
Internal air temperature ambient and internal air temperature ??5°C
sensor
(3) Failure of water temperature sensor
Auto mode
2. Only one time of engine OFF → engine run
3. Starting control of heating is before max heating.
4. Operation release (OR condition)
(1) Air flow: Manual selection
(2) When handling the wind direction mode switch, only
wind direction is released but the air flow control is
performed only for the remaining period of the starting
control of heater.
(3) Difference between internal and ambient air
temperature>15°C
(4) When Max Cooling (17°C) is selected.
5. Exceptional case
Starting control of heating is performed only once during
the remaining period if the entry condition is satisfied within
the starting control period that is the accumulation of initial
start times.
(Inclusive of Auto mode "ON" case within the period of
starting control of heater.)
* Air flow should be reduced slowly for up to 12 seconds in
case of exceptional entry case.
Duct sensor 1. Function: Magnetic clutch of compressor is turned "ON/
OFF" depending on temperature of the duct sensor to
prevent the freezing of the evaporator with A/C being "ON."
2. Control pattern.
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Self Diagnosis
How to start self diagnosis
Starter Switch ON
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Error codes
Code Description
E0 Normal
E1 Internal air temperature sensor short
E2 Internal air temperature sensor open
E3 Ambient air temperature sensor short
E4 Ambient air temperature sensor open
E5 Duct sensor short
E6 Duct sensor open
E7 Sun sensor short
E8 Sun sensor open
E9 Water temperature sensor short
E10 Water temperature sensor open
E11 D.P.S open
E12 Position error of wind direction actuator
E13 Position error of temperature control actuator
0.5 0.5
FG001067
Figure 90
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Compressor
Categories Specifications Relief Valve
Output 155.3 cc/rev
Oil Level 120 cc (ND-OIL8)
Refrigerant R134a
Rated Voltage 24V
Open: 35 - 42.2 kg/cm2G
Relief Valve
Close: 28.1 kg/cm2G
Receiver Dryer
The receiver dryer reserves refrigerant enough to ensure High/Low Pressure Switch
smooth freezing cycle responding immediately to the change of
level in the freezing cycle.
As liquid refrigerant from the condenser may contain refrigerant
gas with bubbles whose presence in the expansion valve
decreases the freezing power excessively, it separates liquid
and gas and sends liquid only to the expansion valve.
Water in refrigerant shall be eliminated with dryer and through
filter.
FG001366
Figure 92
FG001462
Figure 93
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WIPER SYSTEM
Wiper Circuit
5 6 7
- 2 3 5 (Continuous mode) 3
+
M
8 (Intermittent 1 mode) 4
4 4
10 (Intermittent 2 mode) 5
5 6 11 (Washer mode) 6
1 7 8
12 - + 1
P
1
6 9 13 2
9 2 8
AMP MIC 13P
CN12 CN13 KET 8P
3
AMP MIC 13P 1
1 2 3 4 5 6 4 3 2 1 4 5 6
1 2
7 8 9 10 11 12 13 9 8 7 6 5
FG000589
Figure 94
Reference Reference
Description Description
Number Number
1 Battery 6 Wiper Controller
2 Battery Relay 7 Wiper Switch Panel
3 Fusible Link 8 Window Washer
4 Fuse Box 9 Wiper Cutoff Switch
5 Wiper Motor 10 Light Switch
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Wiper operation
Continuous operation
- Operation of wiper motor
Pressing the successive operation switch on the wiper switch
panel (7) changes the voltage of the "5" terminal of the wiper
controller (6) from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and
also current flows via the "3" terminal of the wiper controller (6)
→ the "2" and "4" terminals of the wiper motor (5) → the "4"
terminal of the wiper controller (6) to run the wiper motor (5)
continuously.
- Stop of wiper motor
Pressing again the successive operation switch on the wiper
switch panel (7) changes the voltage of the "5" terminal of the
wiper controller (6) from LOW (0+0.5V) to HIGH (about
5.5 ±0.5V). As the "5" and "6" terminals of the wiper motor are
connected still that power is supplied to the "6" terminal of the
wiper controller (6),
However, the controller (6) runs the wiper motor continuously
and then rotates the motor reversely by " letting current flow via
the "4" terminal of the wiper controller (6) → the "2" and "4"
terminals of the wiper motor (5) → the "3" terminal of he wiper
controller (6) when the "1" and "6" terminals of he wiper motor
(5) are connected and thus power voltage is supplied to the "7"
terminal of the wiper controller (6).
The Wiper motor (5) stops reverse revolution when the contact
of a cam switch connected to the "6" terminal of the wiper motor
(5) moves to an insulation area of the cam plate to disconnect
the "5" and "6" terminals of the wiper motor (5).
When the wiper motor (5) stops, arm and blade connected to it
move to the stop positions of the right pole in the cabin.
Intermittent operation
- Intermittent 1st (3-second)
Pressing once the Intermittent switch in the switch panel (7)
changes voltage of the "8" terminal in the wiper controller (6)
from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and current flows
through the "3" terminal in the wiper controller (6) → the "2" and
"4" terminals in the wiper motor (5) → the "4" terminal in the
wiper controller (6) to start the cycle that wiper stops 3 seconds
after every operation.
- Intermittent 2nd (6-second)
Pressing twice the Intermittent switch in the switch panel (7)
changes voltage of the "10" terminal in the wiper controller (6)
from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and current flows
through the "3" terminal in the wiper controller (6) → the "2" and
"4" terminals in the wiper motor (5) → the "4" terminal in the
wiper controller (6) to start the cycle that wiper stops 6 seconds
after every operation.
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- Stopping the intermittent action
Pressing three times the Intermittent switch in the switch panel
(7) while the wiper is operating stops the action of the wiper
motor.
NOTE: The wiper system does not work when the wiper
cutoff switch (9) is "ON."
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SP000038 Electrical System
Page 109
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LIGHTING SYSTEM
7
13 87a
30
87
*15 85 86
*16
*9 6
87a
30 87a
*14 87
87
30
85 86
85 86
12
*8
87a
87
30 *5
0 0
85 86 3 I 2 2 I 3
II II
0
I 5 5
0
I
4
6 II II 6
7 8 8 7
20A
15A
10 30A
CN6-1 15A
CN6-2 15A
CN6-9 11
L6 CN6-10 3
CN2-6
CN7-4 CN4-4
2
CN7-5 CN4-5 CAN
CN7-6 CN4-6 CN1-1
CN1-2
CN1-8
1
CN1-9
FG000590
Figure 95
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Reference Reference
Description Description
Number Number
1 Battery 9 Front Cabin Light /
2 Battery Relay Rear Work Light Relay
3 Fuse Box 10 Instrument Panel
4 Light Switch 11 e-EPOS Controller
5 Cabin Light Switch 12 Headlight (2 ea.)
6 Headlight Relay (Work Light 13 Work Light (2 ea.)
Indicate Light) 14 Front Cabin Light (4 ea.)
7 Work Light Relay 15 Rear Cabin Light (2 ea.)
8 Front Cabin Light Relay 16 Rear Work Light (1 ea.)
Kind of Light
The lighting system is consists of headlights, work lights, cabin
lights (optional), relays and switches.
Operation
Connected Terminal
Switch Position Activated Relay Lit Light
of switch
1 "2-3" Terminal - Illumination Light of Switch
"2-3" Terminal - Illumination Light of Switch
Headlight Relay Headlight (2 Ea.)
Light Switch
2 Work Light (2 Ea.)
"5-6" Terminal
Work Relay Indicator Light of Work Light
(L6)
Front Cabin Light (2 Ea.) or
1 "2-3" Terminal Front Cabin Light Relay
Front Cabin Light (4 Ea.)
Cabin Light Front Cabin Light (2 Ea.) or
"2-3" Terminal Front Cabin Light Relay
Switch Front Cabin Light (4 Ea.)
2
Rear Cabin Light Relay / Rear Cabin Light (2 Ea.) and
"5-6" Terminal
Rear Work Light Relay Rear Work Light (1 Ea.)
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OVERLOAD WARNING DEVICE
4 1
5
ARS1260L
Figure 96
Reference Reference
Description Description
Number Number
1 Battery 4 e-EPOS Controller
2 Battery Relay 5 OWD Selector Switch
3 Fuse Box 6 Pressure Sensor
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AUDIO CONTROLLER
ANTENNA
7 8 10
MODULE
2 15
3 Vcc(+5V) 9
11 3 16 (LH) (RH)
15A 1 MICOM
4 13
+ - + -
5 Vcc(+5V)
7
3 14
10A 1 DC/DC 17
CONVERTER 1 2 5 2
6 10
10A 87a 3
30 11
87 4
86 85
4
9 10 11 12 13 14 15 16 17 18
1 2 3 4
1 1 2 3 4 5 6 7 8
FG000591
Figure 97
Reference Reference
Description Description
Number Number
1 Battery 7 Audio Control Panel
2 Battery Relay 8 Stereo
3 Fuse Box 9 Speaker
4 Fusible Link 10 Antenna Module
5 Converter 11 Light Switch
6 Stereo Relay
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Operations Via Audio Control Panel
Connected Terminal of
Switch Measured values Operations
switch
PWR 4.36 ±0.2V Stereo ON, OFF
1.24 ±0.2V Volume up
"3-4"
0+0.2V Volume down
SCAN 2.49 ±0.2V Frequency selection
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SP000039
ELECTRICAL SCHEMATIC (DX300LC)SP000039
1Electrical
Schematic
(DX300LC)
Edition 1
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MEMO
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Table of Contents
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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Electrical Schematic (DX300LC) SP000039
Page 6
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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 to make a
complete schematic.
WIPER
CONTROLLER WIPER AUDIO
6-LAMP ASS'Y (OPT) ROTATING BEACON (OPT) LOWER WIPER (OPT) (543-00106 )
SWITCH PANEL
(543-00095)
CONTROL PANEL
(543-00096)
STARTER SWITCH CONNECTION WORKING LAMP 50B
(534-00064 )x2 87a - 155B 2 5 (CONT) 0.5LR 3
30 0.85LW 3 155A 159A 159B
+
TML 129B 0.85RG 129C 2RY TELESCOPIC BEACON M
B BR R1 R2 C ACC 1.25RG 0.85RG 51B 8 (INT-1) 4 CONT. POWER
PST 0.85RG 2RG 51A 87 33C LOWER WIPER RELAY 160A 0.5LY 160B
(RR) 0.85Or 0.85LR 156A 4 0.85LB 4 156B
OFF 0.85B 0.85B (RH) (2544-9033) 161A 10 (INT-2) 0.5LG 5 161B INT SEEK ANTENNA
0.85B 0.5B 85 86 0.5RG ROTATING
0.85B WASHER VOL.
ON (REAR) BEACON SWITCH L 36B 0.85R 36A 87a 0.85G 37B 1 0 162A 11 (WASHER) 0.5L 6 162B
REAR WORKING LAMP 87a 0.85RG 129D 55C 30 38B 2 38A
1.25RG (549-00101/K1002406D3) 87
START (534-00085 ) 30 125E 1.25RL 51C 88B 3 I WINDOW WASHER MODULE
87 (RL) 0.85RG ROTATING BEACON 124B 157B 1 0.85WL 7 157A CAR STEREO
129A 0.85B 1 0 (K1000789) (K1002641 )
WORKING LAMP RELAY 86 88E 0.5B 7 8 54L
+
(534-00062) 2 0.85RG STOP RUN B 88H 0.85Br 85 5 (541-00010 )
86 128B (LH) 0.85B (2544-9033 )
158B 0.85WB 6 158A 35C 12 0.85RB - + 0.85L 1 34E
0.5B 85 0.5RG 1.25B CABIN LAMP 33B 0.85Or 33A 3 I 0.5WR P SPEAKER
127B 0.85RG M 190A 63C 6 35A 34C 2 121B 121A 15
(534-00085 )x2 LOWER WIPER SW 0.5WG (2541-9020 )x2
0.85B 0.5B 7 8 0.5WR Vcc(+5V)
NOTE. (FR) 0.85B 52D S 37A 0.85G (549-00101/K1002406D5) 0.85WR 0.5RB 0.5L
HEAD LAMP 87a -
3 123B 0.5W 123A 16 (LH) (RH)
30 1.25R WIPER MOTOR 35B 34D 54D MICOM
1. DIODE PART NO. CABIN LAMP RELAY 2 (534-00085 )x2 53B 54K E 0.85B 0.85BR 0.85BR 0.5WR 1
DIODE 5
127C 0.85RG 0.85RW 1.25RW 53A 87 (538-00011)
(2544-9033 ) 34B 1 0.85L 0.85L 4 169A 0.5BL 169B 13
DIODE 1 . : 548-00003A CABIN LAMP SWITCH (RH) 2 1
(FMR) 0.85B 0.85B 0.5B 85 86 0.5RG
0.5RW 54C + - + -
DIODE 2 ~ 9 : 2548-1027 (549-00103/K1002406D13 ) LAMP SWITCH (549-00103/K1002406D11) LOWER WIPER MOTOR 130B 13 0.5WR 2
190B CN14 MOLEX 4P Vcc(+5V) 117B 118B 119B 120B
2B 125B 55B (538-00012 ) 0.85B 0.85Lg 9 138A 99 2 8
0 0 0.85B 0.5B 7
DA1~DA3, DA6 : K1000815 87a 2 2 52B LOWER WIPER CUT SW 117A 0.5GrR
(FRONT) 30 125D 2RL 0.5WR 126A 3 I 0.5RL 53C 0.85WR 54A 3 I 0.85R 138B AMP MIC 13P
0.85RW HEAD LAMP RELAY (549-00077) CN12 CN13 KET 8P 118A 17 0.5BY
DA4, DA5 : K1000814 127D 0.85RG 87 II II WIPER CUT SW 17B 14
2RG 127A (LH) (2544-9033 ) 0.5BR
125C 0.85B 0 (549-00086 ) 119A 2 0.5GrL
(FML) 85 86 126B 0 0.85BR 0.85L 16C 5
0.85B 0.5B 5 52C
I 5 0.5RL I 0.5R 120A 10 0.5BW
0.5WR 0.5WR
0.5RG 128A 6 II 0.5RG 0.5RG 55A 6 II FUEL PUMP (OPT) 87a 0.5LW 3 65C
16B 30 11 0.5B
127E 0.85RG 7 8 0.5WR 0.5B 7 8 54G 0.5WR 0.85L
0.5B CIGAR LIGHTER 87 65A 0.85LW 4 65B
CABIN LAMP RELAY 1 FUEL PUMP FUEL PUMP SW
(FL) 0.85B 54F (545-00001) 99
(2544-9033 ) SEAT HEATER (OPT) 1.25R
(401-00238) (549-00093 )
0.5BR 0.5BR 88C 86 85 0.5B 0.85B
2B 2RL 1.25B 64B 1.25WL 64A 1 2 63B 1.25WR
CABIN LAMP P 99
2RY
(534-00085 )x2 1 0
2 143B 1.25RB 1.25B DC/DC 3 17A 0.85BR
1.25B 3 0.85WR 15B 1 STEREO RELAY
144B 1.25R 144A I CONVERTER 1
2 16A 0.85L (2544-9033 )
8 54Q (2531-1003 )
0.5B 7
SEAT AIR SUSPENSION (OPT) 1.25RB 1.25RB
62B STARTER CONTROLLER STARTER RELAY
SEAT HEATER
1.25R (2543-9015 ) (2544-1022)
0.85WR
AIR SUSPENSION
0.85BR
0.5RW
(545-000 )
0.85L
SEAT HEATER SWITCH (401-00 ) 1.25W N
TERMINAL NO LCD GAUGE PANEL 2RY 14C S 0.85BW D PP 3Y
CN2 (549-00101/K1002406D1) 143C 2 132A 0.85R
(539-00076 ) 1.25B 1.25RB DC/DC 14B 14A 5A
P 0.85RG 0.85LR 1
CONVERTER 2 132B +
131B 3 12V POWER 0.85BL C B 3W
DIODE 3
(2531-1003 ) 18B
KET 118 9P DIAGNOSTIC CONN. 14P 99 SOCKET 12C 4C
CN6-3 3 54B 0.5WR 0.5WR 0.5WR - E B P
4 3 2 1 ILL. (527-00006) 0.85B
CN6-1 1 28B 0.85R 0.85R 0.85BL
0.5R 0.85B 13B 12B
1.25WG
9 8 7 6 5 3 2 1 CN6-2 2 28C 0.5R 2RL 2RL
PILOT BUZZER 0.5RW 0.85LR STARTER RELAY 2
(CN13) 7 6 5 4
(2516-1116 ) (2544-9033 )
11 10 9 8 L1 1.25RB 87a 0.85BL
+
14 13 12
0.5R 28G TRAVEL/SWING ALARM ASS'Y (OPT) FUEL HEATER (OPT) 0.85BY 30
MOLEX 4P L2 CN6-12 12 29B 0.5WB 29A - 87 12A
11B
L3 + 31B 0.85RY 0.85RY 0.5LR 86 85 0.5GB
CN6-11 11 130D 0.5RW ALARM BUZZER 87a
1.25WR
1 2 3 4 (CN15) - 0.85B 30 20C 2RG 0.5RG 13C
0.85WR
89A
0.85RG
0.85BR
0.85RY
(516-00011 )
1.25R
0
0.85R
1.25W
0.85LR
L4 2.5R 59A 87
0.85L
2RG
2RL
2RY
(CN14) 3 2 87a 30B 1 0
0.5P I 0.5W 2 0.5GB
CN6-9 9 99 0.5B 30 59B 85 86 0.5RY
L5 II 32B 0.85RG 39A 3 I 125A 50A 20A 28A 52A 63A 124A 179A 62A 131A 34A 88A 15A 3Y
ECU CONNECTOR CN6-10 10 99 0.5B
104C 31A 87 0.5B 20B 3W STARTER
0 39B 0.5B 7 8
L6 9 10 11 12 13 14 1 2 3 4 5 6 7 8 6A 1.25WR (65.26201-7049)
I 5 0.5W 0.5W 85 86 0.5RG
122B 122A 6 54K 5B C 24V 6KW
0.85B 0.85V II 32C 32A FUEL HEATER 30A 20A 20A 15A 15A 15A 10A 10A 10A 10A 10A 10A 10A 10A
1.25WR
30C FUEL HEATER 1.25WR 2WR
0.85LR
0.85BY
12 17 18 35
36 53
OVER LOAD WARNING (OPT) 4bar
7 8 0.5WR RELAY
(2544-9033 )
SWITCH
4G
17 18 2E
4D
15
2B
16
11A
54M ALARM RELAY (549-00101/K1002406D2) 15R 98A B
7 11 54 71 SWING PRESS SW (2544-9033 )
ALARM SWITCH 5W 5W ACC C
1 6 72 89 (549-00010 ) 0.5B 2.5B FUSE BOX 2 FUSE BOX 1
OVER LOAD (549-00103/K1002406D14) 5W 5W 13A
ONLY SWING (OPT) FUEL HEATER (K1001263A) (K1001263A)
WARNING SWITCH B
(549-00102/K1002406D4) 4F 2D 4E 10A 6B BR 0.85Br
ECU CON.1 (89-PIN) 1 0 0.5RG 15 16 2WR 17 18 2C 2WR R2
2 140B 0.5BrY 57B 0.85RY 7A
VEHICLE CONN. A
0.5B 3 I 0.5RW 0.5RW HORN 1 10A 10A 10A 10A 10A 10A 10A 10A 30A 20A 20A 15A 15A 15A
H.F 0.85B HORN RELAY R1
8 0.5WR 0.5WR (516-00014 ) (2544-9033 )
0.5B 7 54P 0.5WR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 STARTER SWITCH
WARNING LAMP 87a 60B
1.25RB
0.85RY
(K1001654 )
0.5RW
0.5WR
0 30 56B 0.85RB 56A 66A 30A 93A 166A 40A 130A 83A 42A 133A 143A 21A 19A
0.5GB
0.5BG
L1 : CHARGE 28D 0.85R CN5-4 140A 141A 3 2 21B 57C 0.85RY 57A 87
+ I 0.5RL 0.85RY 60R
L2 : ENG OIL PRESS HORN 2 FUSIBLE LINK
0.85WR
0.85RB
0.85LB
0.85RG
0.85RL
II
0.85Y
0.5GBr
0.5RW
1.25BrR
PRESSURE SENSOR L.F
2RW
139B 0.85BrW CN3-5 139A 51D CN2-6 0.85B 85 86 56C 0.5RB (2527-1023A)
1.25RB
0.5G 58A
1.25RL
L3 : W/T OVER HEAT SIG 0.5RG (516-00015 ) 0.5Br
(OWD)
2LR
145A 0.85W CN3-6 145B 0
L4 : E/G WARNING - 141B CN2-4 0.5BrB (MANUAL) 0.5BrB 5 21L
(2547-9045 ) I 0.5RL 0.85LB 2WR 2WR 2WR 2R
L5 : PREHEAT 22B CN2-5 0.5BrW (AUTO) 0.5BrW 22A 6 II
CONTROLLER 0.85RG 0.85RG 0.85Br 2A 1B
L6 : WORK LAMP 28E 0.85R 8 54H
+ (543-00108 ) 0.5B 7 0.5WR 7B 0.5G
ECU CON.3 (16-PIN) ECU CON.2 ( PIN) 0.5G 0.5GBr 0.85RY
PRESSURE SENSOR(A) 74B 0.85GR CN3-1 74A 3W
CYLINDER CONN. ENGINE CONN. LCD DISPLAY PANEL SIG 0.85Y 2RW
(FRONT PUMP) HIGH SPEED SWITCH
WATER TEMPERATURE 75A 0.85W CN3-2 75B DIODE 2 BATTERY RELAY
(2547-9045 ) - 10B CN2-1 0.5BG KEY SW 'START' (549-00103/K1002406D12) 0.5BG 0.5BG 0.5BG CIRCUIT BREAKER
FUEL LEVEL (2544-9024 ) 2R
(2527-9004 )
DIODE ARRAY 89B CN1-15 0.5GB START RELAY 0.5GB 0.5GB 0.5GB 8A 1A
28F 0.85R B
+ Py A
GRAPHIC DISPLAY PRESSURE SENSOR(B) 1.25BrR 8W 8W 8W
76B 0.85GY CN3-3 76A 104A CN2-15 0.85P 104B 0.85B AUTO IDLE (1)
(REAR PUMP) SIG
5 6 7 8 3 4 / TRAVEL SW 0.5RW 0.5RW 0.5RW 4B 3B 3A
(2547-9045 ) 77A 0.85WL CN3-4 77B 19bar
- (2549-9112 ) 1.25BrW
21C CN1-1 0.85RL 0.5WR 0.5WR 1.25BrW 8C BR
CN7-4 4 80A 0.5Y 0.5Y CN4-4 80B 21D CN1-2 0.85RL 1.25RL 1.25RL 1.25RL 1.25RL
1 2 3 4 1 2
E
CN7-5 5 81A 0.5YB 0.5YB CN4-5 81B 9D CN2-14 0.5RW ALT 'I' 0.5RW 0.5RW 0.5RW 9D 3 1 6C 0.5WR 1.25B
CAN A 8B
DA1 ~ DA3 DA4 ~ DA6 CN7-6 6 82A SHIELD SHIELD CN4-6 82B NC 0.85RL 0.5B 2 HOUR
40B 60R
COM 0.85Y
CN1-8 0.85B SOL-VALVE ASS'Y 0.85YG 41A NO HOUR METER
99 OFF
(426-00262 ) 10W (2528-9040 ) DIODE 1 60B 60R
99 CN1-9 0.85B 0.5B E DR B+ 0.5WR
CN7 CN6 0.85YG 41B PILOT CUT-OFF SWITCH
(C1)
AMP 040 12P+16P 41C (549-00089 ) ON 83B
3 PILOT 9B
DA4-1
CUT OFF
1
0.85B 99 ROOM LAMP
ECU - + - +
(539-000 )
0.85YL 0.85YL 61C (C2) QUICK CLAMP(OPT) (534-00079 )
2RW 0.5RW 0.5RW 12V 150AH 12V 150AH
4 61B 15R
ENGINE CYLINDER INJECTOR DA4-2 BREAKER 0.5Br 0.5Br
2
0.85B 99 (고정) 1 BATTERY
AMP 040 12P
1.25BrR
0.5WR AIRCON UNIT
0.85BG
0.85RL
0.5GBr
0.85W
CN4
0.5Br
FUEL HIGH PRESSURE 21E
2RW
0.5G
3-04 0.85RL 0.85RL (920-00127 ) 0.85W 18A 4A 9A
CN1
(C4)
PUMP 2-05 CYL. 3 0.5RW P(R) B(B+) R(I)
3-12 5 21H RELIEF SOL-VALVE 1.25LR CN11-2 42C 153B 98B
(0 445 020 011) DA1-1 LED 1~12 130C
PRESS UP CN9-6 C B
23C CN1-11 0.85GrW 23B 1 0.85GrW 23A 0.85B 0.5LR CN10-8 42D
3 2-09 54E CN9-11 0.5WR - +
3-03 0.85RL 0.85RL 21G
OIL PRESSURE P& (C5) CN10-18 46B
200A
4 2-33 CYL. 2 ILL 42B CN9-5 1.25LR
SENSOR 3-06 7 21K SWING
t곁 DA1-3 0.5BW SG
AMP 070 18P
15L 15B
BOOST PRESSURE P& 4 2-28
60B CN2-2 0.5BrW (POWER MAX) 0.5BrW 168B CN8-10 0.5LG CN10-16 168A 0.85BG F
SENSOR 3-10 E
(LDF 6T)
t곁 1 2-21
71B CN2-10 0.5GY (BREAKER) 0.5GY
BREAKER SHEAR SELECT SW A/C THERMO (LOW) 105B CN9-8 0.5LB CN10-5 105A 100A 100B
3-15 CYL. 6 PREHEAT RELAY
(0 281 002 576) 0.5RG CN4-3 137A GND 150E CN2-8 0.5RL (1-WAY) 0.5RL (K1006572/K1002406D21) AIR HEATER
2 2-29 106B CN8-11 0.5LY CN10-6 106A (544-00007 ) E ALTERNATOR 50A
V 0.5GW CN4-2 136A RxD 151C CN2-9 0.5RY (2-WAY) 0.5RY
0.5B FET 99
(2502-9009 )
3-05 PST SHEAR PRESS BREAKER 1.25B COMPRESSOR 8B
FUEL 0.5GL 135A TxD UP CN11-1 99 - +
1 CN4-1 M (2208-6013B )
TEMPERATURE 2-34 3-14 CYL. 4 AUXI MODE RESISTOR TML 1 0 2
SENSOR
t곁 RS-232
(545-00011 ) 1WAY-2WAY S/V (OPT) 99 107B CN8-12 0.5LW CN10-1 107A
2 2-17 9 BLOWER MAGNET ALTERNATOR 80A(OPTION)
(0 281 002 209) V 0.85BrB 94A 93B 0.85RL 54J 0.85LW 47C CLUTCH
1.25BrR
(CONN.3) 0.5WR CN11-4 (502-00003A)
0.85BG
0.85RY
0.5GBr
0.5WR
0.85W
SHEAR 10
0.5Br
152A
2RW
0.5G
SELECT 152D 0.85RB 152C 1 0.85RY 151A 108A CN9-13 0.5GrG CN10-2 108B FRE (P1) 47A 47B
COOLANT 1 2-36 VEHICLE 5 1
3 INTAKE
t곁 101A CN1-10 0.85Or 101B 1 109A CN9-12 0.5GrY CN10-20 109B REC (P2) ACTUATOR
TEMPERATURE CONN 5
7 0.85BrR 133G M
2 DA2-3 151B 14
DIODE 4
2-18 0.85LgR (B) DA2-1
SENSOR V CHECK
94B 2
P/V-(A) 3 0.85BrR 133H
(0 281 002 209) CONN 95A 95B 13
80C 1-35 CAN B H 0.5Y 110A CN9-15 0.5OrR CN10-12 110B DEF (P1)
0.5GL 135B 0.85RL 150A 0.85B 0.85B
1 102B CN1-21 0.85OrB 102A 3 152B 11
81C 1-34 CAN B L 0.5YB 6 0.85LgW (426-00263 ) 111A CN9-14 0.5OrW CN10-13 111B VENT (P2)
0.5GW 136B 4 6 M
1-33 2 0.85B 96B 96A DA2-2 6 MODE
82C SHIELD PUMP 43A CN9-16 0.5YB CN10-11 43B Vref MODE
0.85RL
5 0.85BrR
0.5GBr
(K1001702 ) 1
0.5Br
DUCT
2RW
1 0.5B 99 (R)
1 2-25 13 (426-00263 ) (ROTATING-CW) SENSOR
INCREMENT SPEED SENSOR 163A 163B 2 3 164A 68A CN2-18 0.85BG 68B 0.85B PILOT FILTER SW
N
AMP 070 16P
1-09 0.85B 2B 72B 0.85YR CN3-7 72A 148C 148B 1 5 71C 4 0.85GY 142A CN8-3 0.5Lg 2 - + 1 20 19 18 17 16 15 14 13 12 11 10
(CLOSE) (C) 4 3 18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
AMP 040 20P
27B 0.85LgW CN3-10 27A GND 92B CN3-17 0.5GB 92A 3 (R)
(k1003296) 8 (SHEAR-OPEN) AMP 12P + 18P
HIGH DA6-4 149D 180F 180C
0.85BrW (1)
4 3 0.85B JOYSTICK LEVER SWITCH A/C CONTROL PANEL
5
19B 1-01 0.85RW (543-00107 ) DA3-1
(420-00468 ) 0.5WR
0 1 70F 1 70C
19C 1-07 0.85RW 2RW (ON JOYSTICK R.H) 179B 2 0.85GB
0.85RY
3 180A 180G 180D 2-PUMP S/V
19D 1-12 0.85RW 0.5GBr 0.5GBr 0.5GBr I 0.85BrW 0.85BrW (2)
19E 2RW 2RW 2RW 2RW 2RW 0.5WR 54R 8 7 0.5B 6
1-13 0.85RW DA3-2
7C 1-39 0.5Br (KEY SW) 0.5Br 0.5Br 0.5Br 70G 2
0.85GB 70D
2-PUMP SWITCH
153A 1-16 0.85W (AIR HEATER RELAY) 0.85W 0.85W 0.85W (549-00101/K1002406DXX) 180H 0.85BrW 180E
(3)
154B 1-04 0.85BG (AIR HEATER RELAY) 0.85BG 0.85BG 0.85BG 7
DA3-3
0.85GB 0.85GB 0.85GB 70H 3 0.85GB 70E
(CONN.2) (CONN.1)
WIPER
CONTROLLER WIPER AUDIO
6-LAMP ASS'Y (OPT) ROTATING BEACON (OPT) LOWER WIPER (OPT) (543-00106 )
SWITCH PANEL
(543-00095)
CONTROL PANEL
(543-00096)
STARTER SWITCH CONNECTION WORKING LAMP 50B
(534-00064 )x2 87a - 155B 2 5 (CONT) 0.5LR 3
30 0.85LW 3 155A 159A 159B
+
AIR SUSPENSION
0.85BR
0.5RW
(545-000 )
0.85L
(2531-1003 ) 18B
KET 118 9P DIAGNOSTIC CONN. 14P 99 SOCKET 12C 4C
CN6-3 3 54B 0.5WR 0.5WR 0.5WR - E B P
4 3 2 1 ILL. (527-00006) 0.85B
CN6-1 1 28B 0.85R 0.85R 0.85BL
0.5R 0.85B 13B 12B
1.25WG
89A
0.85RG
0.85BR
0.85RY
(516-00011 )
1.25R
0
0.85R
1.25W
0.85LR
L4 2.5R 59A 87
0.85L
2RG
2RL
2RY
0.85BY
12 17 18 35
36 53
OVER LOAD WARNING (OPT) 4bar
7 8 0.5WR RELAY
(2544-9033 )
SWITCH
4G
17 18 2E
4D
15
2B
16
11A
54M ALARM RELAY (549-00101/K1002406D2) 15R 98A B
7 11 54 71 SWING PRESS SW (2544-9033 )
ALARM SWITCH 5W 5W ACC C
1 6 72 89 (549-00010 ) 0.5B 2.5B FUSE BOX 2 FUSE BOX 1
OVER LOAD (549-00103/K1002406D14) 5W 5W 13A
ONLY SWING (OPT) FUEL HEATER (K1001263A) (K1001263A)
WARNING SWITCH B
(549-00102/K1002406D4) 4F 2D 4E 10A 6B BR 0.85Br
ECU CON.1 (89-PIN) 1 0 0.5RG 15 16 2WR 17 18 2C 2WR R2
2 140B 0.5BrY 57B 0.85RY 7A
VEHICLE CONN. A
0.5B 3 I 0.5RW 0.5RW HORN 1 10A 10A 10A 10A 10A 10A 10A 10A 30A 20A 20A 15A 15A 15A
H.F 0.85B HORN RELAY R1
7 8 0.5WR 0.5WR 0.5WR (516-00014 ) (2544-9033 )
0.5B 54P
1 2 3 4 5 6 7 8 9 10 11 12 13 14 STARTER SWITCH
WARNING LAMP 87a 60B
1.25RB
0.85RY
(K1001654 )
0.5RW
0.5WR
0 30 56B 0.85RB 56A 66A 30A 93A 166A 40A 130A 83A 42A 133A 143A 21A 19A
0.5GB
0.5BG
L1 : CHARGE 28D 0.85R CN5-4 140A 141A 3 2 21B 57C 0.85RY 57A 87
+ I 0.5RL 0.85RY 60R
L2 : ENG OIL PRESS HORN 2 FUSIBLE LINK
0.85WR
0.85RB
0.85LB
0.85RG
0.85RL
II
0.85Y
0.5GBr
0.5RW
1.25BrR
139B 0.85BrW CN3-5 139A 51D CN2-6 0.85B 85 86 56C 0.5RB (2527-1023A)
1.25RB
0.5G 58A
1.25RL
0.5GBr
0.85W
CN4
(C4)
PUMP 2-05 CYL. 3 0.5RW P(R) B(B+) R(I)
3-12 5 21H RELIEF SOL-VALVE 1.25LR CN11-2 42C 153B 98B
(0 445 020 011) DA1-1 LED 1~12 130C
PRESS UP CN9-6 C B
23C CN1-11 0.85GrW 23B 1 0.85GrW 23A 0.85B 0.5LR CN10-8 42D
3 2-09 54E CN9-11 0.5WR - +
3-03 0.85RL 0.85RL 21G
OIL PRESSURE P& (C5) CN10-18 46B
200A
15L 15B
BOOST PRESSURE P& 4 2-28
60B CN2-2 0.5BrW (POWER MAX) 0.5BrW 168B CN8-10 0.5LG CN10-16 168A 0.85BG F
SENSOR 3-10 E
(LDF 6T)
t곁 1 2-21
71B CN2-10 0.5GY (BREAKER) 0.5GY
BREAKER SHEAR SELECT SW A/C THERMO (LOW) 105B CN9-8 0.5LB CN10-5 105A 100A 100B
3-15 CYL. 6 PREHEAT RELAY
(0 281 002 576) 0.5RG CN4-3 137A GND 150E CN2-8 0.5RL (1-WAY) 0.5RL (K1006572/K1002406D21) AIR HEATER
106B CN8-11 0.5LY CN10-6 106A
V
2 2-29
0.5GW CN4-2 136A RxD 151C CN2-9 0.5RY (2-WAY) 0.5RY FG001415
0.5B
PST SHEAR PRESS BREAKER
FET
(544-00007 )
COMPRESSOR 8B
E
99
ALTERNATOR 50A
(2502-9009 )
FUEL 3-05 UP 1.25B CN11-1 99 - +
0.5GL CN4-1 135A TxD M (2208-6013B )
TEMPERATURE 1 2-34 3-14 CYL. 4 AUXI MODE RESISTOR TML 1 0 2
SENSOR
t곁 RS-232 (545-00011 ) 1WAY-2WAY S/V (OPT) 99 107B CN8-12 0.5LW CN10-1 107A
2 2-17 9 BLOWER MAGNET ALTERNATOR 80A(OPTION)
(0 281 002 209) V 0.85BrB 94A 93B 0.85RL 54J 0.85LW 47C CLUTCH
1.25BrR
0.5WR
0.85W
SHEAR 10
0.5Br
152A
2RW
0.5G
SELECT 152D 0.85RB 152C 1 0.85RY 151A 108A CN9-13 0.5GrG CN10-2 108B FRE (P1) 47A 47B
COOLANT 1 2-36 VEHICLE 5 1
3 INTAKE
t곁 101A CN1-10 0.85Or 101B 1 109A CN9-12 0.5GrY CN10-20 109B REC (P2) ACTUATOR
TEMPERATURE CONN 5
7 0.85BrR 133G M
2 DA2-3 151B 14
DIODE 4
12 0.85OrR 147A 2 133C AMP 040 28P AMP 070 16P AMP 040 12P AMP 040 20P
0.85W
5 0.85BrR
0.5GBr
(K1001702 ) 1
0.5Br
DUCT
2RW
1 0.5B 99 (R)
1 2-25 13 (426-00263 ) (ROTATING-CW) SENSOR
INCREMENT SPEED SENSOR 163A 163B 2 3 164A 68A CN2-18 0.85BG 68B 0.85B PILOT FILTER SW
N
AMP 070 16P
1-09 0.85B 2B 72B 0.85YR CN3-7 72A 148C 148B 1 5 71C 4 0.85GY 142A CN8-3 0.5Lg 2 - + 1 20 19 18 17 16 15 14 13 12 11 10
(CLOSE) (C) 4 3 18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
AMP 040 20P
27B 0.85LgW CN3-10 27A GND 92B CN3-17 0.5GB 92A 3 (R)
(k1003296) 8 (SHEAR-OPEN) AMP 12P + 18P
HIGH DA6-4 149D 180F 180C
0.85BrW (1)
4 3 0.85B JOYSTICK LEVER SWITCH A/C CONTROL PANEL
5
19B 1-01 0.85RW (543-00107 ) DA3-1
(420-00468 ) 0.5WR
0 1 70F 1 70C
19C 1-07 0.85RW 2RW (ON JOYSTICK R.H) 179B 2 0.85GB
0.85RY
3 180A 180G 180D 2-PUMP S/V
19D 1-12 0.85RW 0.5GBr 0.5GBr 0.5GBr I 0.85BrW 0.85BrW (2)
19E 2RW 2RW 2RW 2RW 2RW 0.5WR 54R 8 7 0.5B 6
1-13 0.85RW DA3-2
7C 1-39 0.5Br (KEY SW) 0.5Br 0.5Br 0.5Br 70G 2
0.85GB 70D
2-PUMP SWITCH
153A 1-16 0.85W (AIR HEATER RELAY) 0.85W 0.85W 0.85W (549-00101/K1002406DXX) 180H 0.85BrW 180E
(3)
154B 1-04 0.85BG (AIR HEATER RELAY) 0.85BG 0.85BG 0.85BG 7
DA3-3
0.85GB 0.85GB 0.85GB 70H 3 0.85GB 70E
(CONN.2) (CONN.1)
FG001435
Figure 1
[email protected]
DX300LC
0 5G
3-04 0.85RL 0.85RL (C4)
CN1
27B 0.85LgW CN3-10 27A GND 92B CN3-17 0.5GB 92A 3 (R)
(k1003296) 8 (SHEAR-OPEN)
HIGH DA6-4 149D
4 3 0.85B JOYSTICK LEVER SWITCH
19B 1-01 0.85RW (420-00468 )
19C 1-07 0.85RW 2RW (ON JOYSTICK R.H)
19D 1-12 0.85RW 0.5GBr 0.5GBr 0.5GBr
19E 1-13 0.85RW 2RW 2RW 2RW 2RW 2RW
7C 1-39 0.5Br (KEY SW) 0.5Br 0.5Br 0.5Br
153A 1-16 0.85W (AIR HEATER RELAY) 0.85W 0.85W 0.85W
154B 1-04 0.85BG (AIR HEATER RELAY) 0.85BG 0.85BG 0.85BG
0.85GB 0.85GB
(CONN.2) (CONN.1)
Figure 2
[email protected]
WIPER
CONTROLLER WIPER AUDIO
N (OPT) LOWER WIPER (OPT) (543-00106 )
SWITCH PANEL
(543-00095)
CONTROL PANEL
(543-00096)
- 155B 2 0.85LW 3 155A 159A 5 (CONT) 0.5LR 3 159B
+
M
160A 8 (INT-1) 0.5LY 4 160B CONT. POWER
LOWER WIPER RELAY 0.85LR 156A 4 0.85LB 4 156B
(2544-9033) 161A 10 (INT-2) 0.5LG 5 161B INT SEEK ANTENNA
ROTATING
L 36B 0.85R 36A 87a 0.85G 37B 1 0 11 (WASHER) 6 WASHER VOL.
BEACON SWITCH 30 38B 2 38A 162A 0.5L 162B
00101/K1002406D3) 87 88B 3 I 1 WINDOW WASHER MODULE
124B 157B 0.85WL 7 157A
(K1000789) CAR STEREO
1 0 (K1002641 )
86 88E 0.5B 7 8 54L
+
2 0.85RG STOP RUN B 88H 0.85Br 85 5 (541-00010 )
158B 0.85WB 6 158A 35C 12 0.85RB - + 0.85L 1 34E
3 I 0.5WR P SPEAKER
M 190A 63C 6 35A 34C 2 121B 0.5WG 121A 15
7 8 0.5WR LOWER WIPER SW Vcc(+5V) (2541-9020 )x2
S 37A 0.85G (549-00101/K1002406D5) 0.85WR 0.5RB 0.5L
-
3 123B 0.5W 123A 16 (LH) (RH)
WIPER MOTOR 35B 34D 54D MICOM
54K E 0.85B 0.85BR 0.85BR 0.5WR 1
(538-00011) DIODE 5
34B 1 0.85L 0.85L 4 169A 0.5BL 169B 13
2 1
54C + - + -
0103/K1002406D11) 130B 13 0.5RW 0.5WR 2
LOWER WIPER MOTOR 190B CN14 MOLEX 4P Vcc(+5V) 117B 118B 119B 120B
(538-00012 ) 0.85B 0.85Lg 9 138A 99 2 0.85B 0.5B 8
2 52B 117A 7 0.5GrR
0.85R LOWER WIPER CUT SW 138B AMP MIC 13P
(549-00077) WIPER CUT SW CN12 CN13 KET 8P 118A 17 0.5BY
0.5BR 17B 14
(549-00086 ) 119A 2 0.5GrL
0.85BR 0.85L 16C 5
5 52C 0.5R
0.5WR 120A 10 0.5BW
0.5WR
FUEL PUMP (OPT) 87a 0.5LW 3 65C
11 0.5B
8 54G 0.5WR 0.85L 16B 30
FUEL PUMP FUEL PUMP SW CIGAR LIGHTER 87 65A 0.85LW 4 65B
(401-00238) (549-00093 ) (545-00001) 99
0.5BR 0.5BR 88C 86 85 0.5B 0.85B
1.25B 64B 1.25WL 64A 1 2 63B 1.25WR
P 99
1.25B DC/DC 3 17A 0.85BR
0.85WR 15B 1 STEREO RELAY
CONVERTER 1 (2544-9033 )
2 16A 0.85L
(2531-1003 )
T) 1.25RB 1.25RB
62B STARTER CONTROLLER STARTER RELAY
1.25R (2543-9015 ) (2544-1022)
0.85WR
0.85BR
0.5RW
0.85L
1.25W N
2RY 14C S 0.85BW D PP 3Y
43C 1.25RB 2 132A 0.85R
0.85RG 0.85LR 1 DC/DC 14B 14A 5A
CONVERTER 2 132B +
131B 3 12V POWER 0.85BL C B 3W
DIODE 3
(2531-1003 ) 18B
0.5WR 99 SOCKET 12C 4C
- E B P
(527-00006) 0.85B
0.85R 12B 0.85BL
0.85B 13B
1.25WG
2RL
0.5RW 0.85LR STARTER RELAY 2
(2544-9033 )
1.25RB 87a 0.85BL
FUEL HEATER (OPT) 0.85BY 30
87 12A
11B
0.5LR 86 85 0.5GB
87a
1.25WR
0.85WR
89A
0.85RG
0.85BR
0.85RY
1.25R
0.85R
1.25W
0.85LR
2.5R 59A 87
0.85L
2RG
2RL
2RY
1 0
2 0.5GB
59B 85 86 0.5RY 39A 3 I 125A 50A 20A 28A 52A 63A 124A 179A 62A 131A 34A 88A 15A 3Y
0.5B 20B 3W STARTER
39B 0.5B 7 8
9 10 11 12 13 14 1 2 3 4 5 6 7 8 6A 1.25WR (65.26201-7049)
54K 5B C 24V 6KW
FUEL HEATER 30A 20A 20A 15A 15A 15A 10A 10A 10A 10A 10A 10A 10A 10A
1.25WR
FUEL HEATER 1.25WR 2WR
0.85LR
0.85BY
RELAY SWITCH 17 18 2E 15 16
(2544-9033 ) 4G 4D 2B 11A
(549-00101/K1002406D2) 15R 98A B
5W 5W ACC C
2.5B FUSE BOX 2 FUSE BOX 1
5W 5W 13A
FUEL HEATER (K1001263A) (K1001263A) B
4F 2D 4E 10A 6B BR 0.85Br
15 16 2WR 17 18 2C 2WR R2
57B 0.85RY 7A A
HORN 1 HORN RELAY 10A 10A 10A 10A 10A 10A 10A 10A 30A 20A 20A 15A 15A 15A
H.F 0.85B R1
(516-00014 ) (2544-9033 )
1 2 3 4 5 6 7 8 9 10 11 12 13 14 STARTER SWITCH
87a 1.25RB
60B
0.85RY
0.5RW (K1001654 )
0.5WR
30 56B 0.85RB 56A 66A 30A 93A 166A 40A 130A 83A 42A 133A 143A 21A 19A
0.5GB
0.5BG
57C 0.85RY 0.85RY 57A 87
HORN 2 60R FUSIBLE LINK
0.85WR
0.85RB
0.85LB
0.85RG
0.85RL
0.85Y
0.5GBr
0.5RW
1.25BrR
L.F
2RW
1.25RL
ROOM LAMP - + - +
QUICK CLAMP(OPT) (534-00079 )
2RW 0.5RW 0.5RW 12V 150AH 12V 150AH
15R
0.5Br 0.5Br
(고정) 1 BATTERY
2 0.85LB 0.85W 0.85W AVX 8W (2506-6008 )x2
0.5Br 0.85Br (풀림) 3 0.85BG 0.85BG
66B AVX 1.25WG
84B 84A
84C 0.85RY AVX 2RW
QUICK CLAMP SW
1.25BrR
0.5GBr
0.85W
DIODE 6 (549-00092 )
0.5Br
2RW
0.5G
0.5WR
0.85W
10
0.5Br
152A
2RW
0.5G
C 1 0.85RY 151A 108A CN9-13 0.5GrG CN10-2 108B FRE (P1) 47A 47B
5 1
3 INTAKE
0.85BrR 133G 109A CN9-12 0.5GrY CN10-20 109B REC (P2) ACTUATOR
A2-3 151B M
DIODE 4
DA2-1 14
0.85BrR 133H
13
0.85RL 150A 110A CN9-15 0.5OrR CN10-12 110B DEF (P1) 0.85B 0.85B
152B 11
111A CN9-14 0.5OrW CN10-13 111B VENT (P2)
6 M
-2 6 MODE
43A CN9-16 0.5YB CN10-11 43B Vref MODE
0.85RL
JOYSTICK LEVER SWITCH 112A CN9-1 0.5LgW CN10-19 112B WARM (P1)
(420-00469 ) AMP MIC 13P AMP 070 18P AMP MIC 21P
0.85B 3 113A CN9-18 0.5LgB CN10-3 113B COOL (P2)
M 1 2 3 4 5 6
0.5B 99 6 3 58B 0.5G 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
114A CN9-3 0.5YR CN10-7 114B Vref MIX MIX
(HORN) (C)
115A CN9-4 0.5YW CN10-9 115B MIX F/BACK ACTUATOR 7 8 9 10 11 12 13 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
B 1 0.85OrB 0.85OrB 146A 4 1 133B 0.85BrR
167C CN9-2 1.25BL CN10-4 167A GND (CN12) WIPER CONT. (CN2) (CN1)
(ROTATING-CCW) (L)
DA5-1
0.85BG
0.85RY
0.85OrR 147A 2 133C AMP 040 28P AMP 070 16P AMP 040 12P AMP 040 20P
0.85W
5 0.85BrR
0.5GBr
0.5Br
DUCT
2RW
DX300LC
FG001434
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Electrical Schematic (DX300LC) SP000039
Page 10
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1Attachments
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SP000040
BOOM AND ARM SP000040
Edition 1
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MEMO
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Table of Contents
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MEMO
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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FRONT ATTACHMENT PIN
SPECIFICATIONS
The table below has a complete listing of dimensional
specifications for all mounting pins used on the front attachment.
NOTE: Some mounting pins must be drilled and tapped for
lubrication fittings and piping, or may have other
required specifications. Consult DOOSAN After Sales
Service for information on wear tolerances and
replacement limits for mounting pins.
F
E
G
C
D
K
H
B I
FG004069
Figure 1
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Criteria
Mark Measuring Part Standard Tolerance Standard Clearan Remedy
Size Pin Hole Clearance ce Limit
105 mm -0.10 +0.18
A Boom Foot 0.13 ~ 0.33 1.5
(4.134") -0.15 +0.03
90 mm -0.10 +0.18
B Boom Cylinder Head 0.13 ~ 0.33 1.5
(3.543") -0.15 +0.03
90 mm -0.10 +0.18
C Boom Center 0.13 ~ 0.33 1.5
(3.543") -0.15 +0.03
100 mm -0.10 +0.18
D Boom End 0.13 ~ 0.33 1.5
(3.937") -0.15 +0.03
90 mm -0.10 +0.18
E Arm Cylinder Head 0.13 ~ 0.33 1.5
(3.543") -0.15 +0.03
90 mm -0.10 +0.18
F Arm Cylinder Rod 0.13 ~ 0.33 1.5 Replace
(3.543") -0.15 +0.03
80 mm -0.10 +0.18
G Bucket Cylinder Head 0.13 ~ 0.33 1.5
(3.150") -0.15 +0.03
90 mm -0.06 +0.18
H Arm Link 0.09 ~ 0.27 2.0
(3.543") -0.11 +0.03
90 mm -0.10 +0.18
I Arm End 0.13 ~ 0.33 2.0
(3.543") -0.15 +0.03
90 mm -0.10 +0.18
J Bucket Cylinder Rod 0.13 ~ 0.33 2.0
(3.543") -0.15 +0.03
90 mm -0.10 +0.18
K Push Link to Bucket 0.13 ~ 0.33 2.0
(3.543") -0.15 +0.03
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FRONT ATTACHMENT -
REMOVAL AND INSTALLATION
DANGER!
DOOSAN warns any user, that the removal of the
counterweight from the machine, front attachment or any
other part, may affect the stability of the machine. This
could cause unexpected movement, resulting in death or
serious injuries. DOOSAN is not liable for any misuse.
Never remove the counterweight or front attachment unless
the upper structure is in-line with the lower structure.
Never rotate the upper structure once the counterweight or
front attachment has been removed.
FG000371
IMPORTANT Figure 2
WARNING!
This procedure is only intended for routine removal or
replacement of the attachment, while working under
normal, safe operating conditions. In the event of a major
structural collapse of some part of the attachment, an
accident or complete loss of attachment hydraulic function,
DO NOT proceed with attachment disassembly unless you
are completely sure of what you are doing. Please call your
local DOOSAN distributor or DOOSAN After Sales Service
for assistance. DO NOT allow personnel to stand
underneath a weakened or only partially supported
attachment section. Keep clear of hydraulic lines that may
have fluid escaping at high-pressure - it can cause severe
or even fatal injuries.
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Park the excavator away from obstructions and all traffic on
clear, flat, level ground. Extend the arm cylinder and crowd the
arm into the boom. Partially retract the boom cylinder so that the
boom is stretched out in front of the excavator, as low to the
ground as possible, with the arm crowded under the boom.
The tip of the arm point should be lowered to secure blocking
that will safely support the weight of the arm. Place the blocking
directly in front of the excavator and make sure that it will not be
unbalanced with an initial weight load that is all to one end,
under the arm point.
Shut off the engine and release hydraulic system pressure -
move any of the control levers with the engine off to release
pressure built up in the accumulator. Manually vent residual
hydraulic pressure in the tank by moving the lever near the cap,
on top of the reservoir.
WARNING!
Secure the swing lock and tag and lock out controls in the
operator's cabin to keep anyone from moving or
inadvertently starting the engine. Restrict access to the
work site while sections of the attachment are in the air, or
while they are being supported by the assist crane. The safe
lifting capacity of the assist crane or hoist that is used must
exceed the weight of the heaviest section of the attachment,
the boom (approximately 2,000 kg [4,400 lb], not including
the weight of accessories or fixtures).
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CAUTION!
To make sure that the polished surfaces of cylinder rod
ends will not suffer accidental damage during disassembly
or removal procedures, wrap exposed rod surfaces
(especially those of boom cylinders) with a protective
covering material. Immediately following disassembly and
removal, cylinder rods should always be fully retracted.
This eases handling problems and also avoids possible
damage.
Remove retainers on the end of the mounting pin for the arm
cylinder rod end. Use the assist crane to relieve the weight load
and withdraw the pin. Lower the arm down to the blocking
support for any continued disassembly procedures.
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Boom Removal Procedure
NOTE: Boom removal may be simplified if the shell of the
operator's cabin is taken off the turntable deck first.
Refer to the Operator's Cabin Removal procedure
before continuing, if both components are to be
removed from the excavator.
After the bucket, arm and arm cylinder have been removed,
lower the end of the boom to a stable, secure blocking support.
Attach the assist crane sling to the body of either boom cylinder,
break the mounting pin connection to the boom by tapping
through the pin from the same side of the boom and repeat for
the opposite cylinder.
Release hydraulic pressure and disconnect line couplings as
previously outlined in the Arm Removal Procedure, observing
the same precautions.
Disconnect wiring for work light assemblies and any other
accessory lines or connections. Locate the sling of the assist
crane near the center of gravity, optimum lift point for the boom,
and use the crane to take pressure off the boom foot pin. Drive
out the pin after disassembling retainers and carefully lift away
the boom.
WARNING!
Traveling the excavator, swinging the turntable or
movement over bumps or sloping, uneven surfaces could
all produce loss of control and possible accidents or
injuries, if the turntable deck has been unbalanced by
removal of weight from one end only.
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INSTALLATION
WARNING!
Before assembling the front attachment, make sure that the
individual boom, arm and bucket sections are all
compatible and can be used safely for work intended. Refer
to the General Safety Pages, Lift Ratings, Working Range
Diagrams and Weights of Materials sections in the
Operation and Maintenance Manual. Consult your dealer or
DOOSAN After Sales Service for more information if you
have any questions or require more information.
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START-UP PROCEDURES
Once the boom has been serviced, it should be lubricated as
outlined in the initial start-up procedures of the operation
manual. Refer to the appropriate operation and maintenance
manual for unit.
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Boom and Arm SP000040
Page 14
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SP000041
BUCKET SP000041
1Bucket
Edition 1
Bucket SP000041
Page 1
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MEMO
SP000041 Bucket
Page 2
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Table of Contents
Bucket
Safety Precautions................................................ 5
Applicable Models................................................. 5
Bucket Tooth Inspection and Replacement........... 6
Bucket O-ring Replacement.................................. 7
Bucket Shimming Procedures .............................. 9
New Bucket Installation ................................................... 9
Bucket Attachment, Removal and Reversal........ 11
Detaching the Bucket .................................................... 11
Attaching the Bucket...................................................... 11
Reversing the Bucket..................................................... 12
Bucket SP000041
Page 3
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MEMO
SP000041 Bucket
Page 4
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SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
SP000041 Bucket
Page 5
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BUCKET TOOTH INSPECTION
AND REPLACEMENT
There are several different types of attachment methods for
replaceable bucket teeth. Some of the most common types are
shown in the following drawings.
Bucket teeth are usually replaced in sets but it may sometimes
be necessary to replace individual teeth.
Look for the following indications of wear or damage:
• Lock pins protrude unevenly on one side.
• Lock pins have been worn down so far that they no
longer make full contact through the length of the pin
hole.
• Lock washers or pins show obvious damage or
weakness.
• Wear 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.
HAOC680L
Figure 1
3. Once the worn tooth has been removed, use a putty knife 3
to scrape the adapter as clean as possible.
4. Slide the new tooth into position and insert the lock washer. 2 1 FG000346
Figure 2
5. Insert the locking pin into the tooth and with a hammer,
drive the pin in until the lock washer seats in the locking
groove.
Bucket SP000041
Page 6
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BUCKET O-RING
REPLACEMENT
WARNING!
Due to possibility of flying metal objects, always wear
safety helmet, protective gloves and eye protection when
changing pins.
ARO1350L
Figure 3
2. Roll the old O-ring (1, Figure 4) onto the boss (2) around
the bucket pin (3). Remove the bucket pin and move the
1 4
arm or bucket link (4) out of the way. 2
ARO1390L
Figure 4
ARO1391L
Figure 5
SP000041 Bucket
Page 7
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5. Roll the new O-ring (1, Figure 6) into the O-ring groove.
ARO1392L
Figure 6
Bucket SP000041
Page 8
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BUCKET SHIMMING
PROCEDURES
WARNING!
When performing this adjustment, put the hydraulic
cativation control lever in the LOCKED position and stop
the engine.
Improperly adjusted clearance could cause galing on the
contact surfaces of the bucket and arm, resulting in
excessive noise and damaged O-ring.
3
1 2 8 7
5 10
9 4 6
FG000415
Figure 7
Reference Reference
Description Description
Number Number
1 No Gap 6 Stopper
2 Arm Boss 7 Bolt
3 Bucket Clearance 8 Hard Washer
4 Shim 9 Flange
5 Pin 10 Bucket Boss
SP000041 Bucket
Page 9
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Shimming Procedures for Installed Bucket
The clearance of the bucket linkage on this machine can be
adjusted by shimming. If the gap between the bucket and the
arm becomes excessive, adjust bucket clearance to 1.0 mm.
The thickness of the shims are 1.0 mm (0.04 inch)
1. Position the machine on a level surface and lower the
bucket to the ground.
2. Slowly operate the swing control lever until arm boss (2)
and the bucket boss (10) are in full face contact at no gap
(1).
3. Place the hydraulic activation control lever in the LOCKED
position and stop the engine.
4. Measure bucket clearance (3), determine the number of
shim that need to be removed from shims (4) by using the
following calculation;
Subtract 1mm from bucket clearance (3).
5. Remove the appropriate number of shim at location (9) in
order to meet the above thickness. To remove the shim,
detach stopper (6) and bolts (7) from bucket.
6. After correcting the number of shim, install stopper (6) and
tighten bolts (7).
NOTE: Bolt torque: 27 kg•m (195 ft lb)
7. After installation, make sure that bucket clearance (3) is
still correct.
Bucket SP000041
Page 10
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BUCKET ATTACHMENT,
REMOVAL AND REVERSAL
CAUTION!
Use care pulling out the pin to avoid damaging the dust
seals on either end of the arm.
When the pin has been withdrawn, move the operating joystick
slightly to take weight off the remaining link pin. Disassemble 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.
SP000041 Bucket
Page 11
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When the link pin has been installed, withdraw the temporary
support rod from the bucket pin holes, lower and raise the arm
and boom and install the bucket pin.
WARNING!
When making linkage alignments, never insert fingers into
pin holes. The attachment or bucket could shift position
and cause a severe injury. Match holes by visually lining
them up. Use the sharp-tipped, soft point of a pencil or a FG000607
similar tool to check for high spots or irregularities. Figure 9
WARNING!
Bucket curl and dump levers must be used in opposite
directions, after the bucket has been reversed.
Bucket SP000041
Page 12